& Safety Warning

This Service Manual will alert you to certain procedures

that must be done very carefully. If you ignore this
information, you could ...

e Injure yourself or people around you

elnjure the boat operator, boat passengers, or
people around the boat
e Damage the outboard or its systems

Understand the following symbols before proceeding:

Alerts you to the possibility of danger and

& Safety Warning identifies information that will help pre-
vent injuries.

Identifies information that will help pre-

vent damage to machinery.

Appears next to information that controls

Important correct assembly and operation of the
product.

This Service Manual is written for qualified, factory-

trained service technicians familiar with the use of OMC
Service Tools.

This Service Manual tells you how to correctly maintain

and service the outboard and its systems. When cor-
rectly 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
Safety

4C 1
 INDEX
Topic Service Manual Title Page
Air Bleed Orifices Carburetor Orifice Plug Chart 1-47
Alcohol in gasoline Fuel Requirements 1-24
Anodes Anodes - Testing and Replacement 1-35
Battery Cable Extensions Battery Cable Extensions 8-3
Battery Charging Battery Specifications 8-4
Battery Recommendations Battery Specifications 8-4
Battery Testing Battery Specifications 8-4
Break-In Procedure Break-In Procedure 1-29
Compression Check Tune-up Procedure 1-33
Core Plug Carburetor Servicing 2-16
Double Firing Indexing Flywheel 3-32
Engine Weight Engine Specifications Section 1
Exhaust Housing Parallelism Cleaning and Inspection 5-5
Flywheel Nut Torque Flywheel Servicing 3-8
Fogging Engine Off-Season Storage 1-30
Fuel Filter In-Line Fuel Filter 2-7
Fuel Oil Mixture Fuel/Oil Ratios 1-22
Fuel Pump Pressure Fuel Pump Servicing 2-10
Full Throttle Operating Range Engine Specifications Section 1
Full Throttle Timing Synchronization and Linkage Adjustments Section 1
Galvanic Corrosion Anodes - Testing and Replacement 1-35
Gear Ratio Engine Specifications Section 1
Gearcase Capacity Engine Specifications Section 1
Heli-Coi/lnserts Heli-Coi/lnserts and Installers 1-49
High Altitude Operation Weather, Altitude, and Engine Performance 1-28
High Performance Oil Ratios Fuel/Oil Ratios 1-22
Idle RPM Engine Specifications Section 1
Ignition Timing Synchronization and Linkage Adjustments Section 1
t-
Jet Chart Carburetor Orifice Plug Chart 1-47
Lubrication Chart Lubrication Chart Section 1
Maximum Spark Advance Synchronization and Linkage Adjustments Section 1

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2 4C1eng
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 Topic Service Manual Title Page
Models Covered Models Covered Page 4
Motor Mounts Exhaust Housing Servicing Section 5
Octane Requirements Fuel Requirements 1-24
Off-Season Storage Off-Season Storage 1-30
Operating Temperature Engine Temperature Check 4-5
Orifice Chart Carburetor Orifice Plug Chart 1-47
Orifice Plugs - Factory Installed See OMC Parts Catalog •
Overheating Engine Temperature Check 4-5
Preseason Service Preseason Service 1-32
Pressure Test - Gearcase Gearcase Servicing - Assembly Section 6
Propeller Selection Propeller Selection 1-26
RPM Limit Engine Specifications Section 1
Severe Service Oil Ratios Fuel/Oil Ratios 1-22
Spark Plugs Spark Plug Information 3-6
Spark Test Ignition Output Test Section 3
Starter Rope Length Starter Servicing Section 7
Storage Mixture Off-Season Storage 1-30
Submerged Engines Submerged Engines 1-36
Summerize Preseason Service 1-32
Sync & Link Synchronization and Linkage Adjustments Section 1
Test Wheel RPM Engine Specifications Section 1
Thermomelt Sticks Engine Temperature Check 4-5
Thermostat Powerhead Servicing - Assembly Section 4
Timing Synchronization and Linkage Adjustments Section 1
Tune-up Procedures Tune-up Procedure 1-33
Vacuum Test - Gearcase Gearcase Servicing - Assembly Section 6
Water Pump Water Pump Servicing Section 6
Winterization Off-Season Storage 1-30

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4C1eng 3 E
 Outboard Models Covered in This Service Manual

2, 2.3, 3.3 Models

E2ROED J2ROED
E2RED J2RED
E2RSA J2RSA
E3ROED J3ROED
E3RSA J3RSA

3 Models
E3RED J3RED

4 Models
E4BRED E4BRLED J4BRED J4BRLED
E4RED E4RLED J4RED J4RLED
E4RDHED E4RDHLED J4RDHED J4RDHLED

5 Models
E5DRED E5DRLED J5DRED J5DRLED

6 Models
E6DRED E6DRLED J6DRED J6DRLED
E6RED E6RLED J6RED J6RLED
E6SLED J6SLED

8 Models
E8RED E8RLED 8RCH J8RED J8RLED
E8SRLED 8RCLH J8SRLED

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4C1eng
 General Information
Table of Contents

General Safety Warnings ........ . ...... . .......... 1- 2

Service Specifications ........ .. .. . ............... . 1- 3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 4
Symbols .. . . .. ......... .. . . .................... 1- 7
Engine Specifications
2, 2.3, 3.3 ..................................... 1- 8
3,4 ............................... . .. . . ..... 1-10
4 Deluxe . .................................. . . 1-12
5 thru 8 ............. .... ..................... 1-14
Gearcase Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Lubrication Chart
2 thru 4 ... . ... . .... ' .' ........................ 1-18
4 Deluxe thru 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-20
Fuel/Oil Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-22
Fuel Requirements ............. . . . ............... 1-24
New Engine Pre-Delivery Checks .................... 1-25
Propeller Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
Weather, Altitude, and Engine Performance ............ 1-28
Break-In Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
Off-Season Storage............................... 1-30
Preseason Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-32
Tune-Up Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-33
Anodes - Testing and Replacement. . . . . . . . . . . . . . . . . . . 1-35
Submerged Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
Synchronization and Linkage Adjustments
3,4 ...................... ......... ... ... .... 1-38
4 Deluxe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-40
5 thru 8 ...................................... 1-42
20-Hour Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-45
Drill Size Conversion Chart. . . . . . . . . . . . . . . . . . . . . . . . . 1-46
Carburetor Orifice Plug Chart. . . . . . . . . . . . . . . . . . . . . .. 1-47
Heli-Coillnserts and Installers ..... . ............. . .. 1-49

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4C1eng 1-1 E
 & 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 rotat-
ing flywheel.

Replace any locking type fastener (locknut or patch screw) if its

locking feature becomes weak. Definite resistance to tightening
must be felt or locking fastener is not suitable for continued use.
Replace only with authorized replacement part or equivalent.

1-2 4C/eng
 Service Specifications

Standard Torque Chart _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

Size In. lbs. Ft. lbs. N'm

No.6 7-10 • 0,8-1,2

No.8 15-22 • 1,6-2,4

No. 10 25-35 2-3 2,8-4,0

No.12 35-40 3-4 4,0-4,6

1/4 in. 60-80 5-7 7-9

5/16 in. 120-140 10-12 14-16

3/8 in. 220-240 18-20 24-27

7/ 16 in. 340-360 28-30 38-40

PCE0023

INotel 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.

I Note I 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 @Outboard Lubricant
Johnson @Outboard Lubricant
OMC 2+4@Fuel Conditioner
OMC Carbon Guard ™ Fuel Additive
OMC Storage Fogging Oil
OMC Engine Tuner
OMC Electrical Grease

4C /eng 1-3
Introduction
This manual covers service information on 2 thru 8 models. Some
of the information might apply to previous models.

Use this manual together with the proper Parts Catalog for part
numbers and exploded views which are a valuable aid to service.

This manual presents the English values and dimensions first and
metric values and dimensions second, inside parentheses ( ).

Good Service Practice

Service required for OMCengines is generally one ofthree 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 condi-
tion.

• 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.

OMC 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.

~ 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!

1-4 4C/eng
Arrangement of Service Manual

This Service Manual includes the specific information you will

need to service Evinrude and Johnson engines. All general
procedures are covered in abbreviated form, mostly be reference
to procedural illustrations. The specific procedures which apply
to this engine are covered in fully-illustrated, detailed, step-by-
step instructions.

Each of the manual sections contains detailed instructions for

disassembly, inspection, assembly, testing, and operating adjust-
ments of the various engine systems. These procedures will help
you service a specific system or completely overhaul the out-
board.

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 obliga-
tion 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 represen-
tative views for reference only.

Certain features of systems discussed in this manual might not be

found on all models in all marketing areas.

4C/eng 1-5
Service Policy

When servicing an outboard which is within its normal warranty

period, make repairs using only genuine OMC replacement com-
ponents or parts.

If OMC genuine replacement components or parts are not used,

OMC might refuse subsequent warranty claims involving that
engine.

~ When replacement parts are required, use genuine OMC

ill 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, OMC has a

constant interest in its products. It is OMC's policy to provide
dealers with service information so they can give the professional
service demanded by today's consumer. The OMC Training
Centers, frequent mailings of Service Bulletins and Advisories,
OMC Special Tools, and this Service Manual represent some of
OMC'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
additional help. Always be sure to give complete information,
including engine model number and serial number.

Be sure that you are familiar with OMC warranty policies.

Special Service Tools

OMC 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
OMC Special Tool Guide for a description and ordering instruc-
tions 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 while in the boat and facing forward; PORT means on the
left.

& Safety Related 1-6 4C/eng

1 2 3
DR2065 DR2066 DR4203

Symbols

Throughout this service manual, symbols are used to interpret

electrical troubleshooting results or to assign values in drawings.

Electrical

[!] This symbol indicates continuity or very low resistance.

4
~ 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.

rJl When "00" shows on the meter face, no continuity, or very high
~ resistance, is indicated. The symbol is referred to as infinity.
~ When "v" follows a value on the meter face, the procedure is
measuring voltage.

Is1 When "0" follows a value on the meter face, the procedure is 5
~ measuring resistance. 0 is the symbol for ohm, the unit of DR4205

measurement for resistance.

Values

f61 When "s" precedes a value on the meter face, it indicates

~ your reading should be less than, or equal to, the value shown.
o When "?" precedes a value on the meter face, it indicates
your reading should be greater than, or equal to, the value
shown. 6
DR4206

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4C/eng 1-7 ~
 Engine Specifications
2, 2.3, 3.3
Operation _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

Full Throttle Operating Range 2 - 4000 to 5000 RPM

2.3 - 4200 to 5200 RPM
3.3 - 4500 to 5500 RPM

Power 2 - 2 HP (1,5 kw)

2.3 - 2.3 HP (1,7 kw)
3.3 - 3.3 HP (2,5 kw)

Power Rate 2 - 4500 RPM

2.3 - 4700 RPM
3.3 - 5000 RPM

Idle RPM in Gear 1200 ± 100

Test Propeller 2, 2.3 - OMC Standard Propeller PIN 115208

3.3 - OMC PIN 115306

Minimum Test RPM 2 - 4500

2.3 - 4800
3.3 - 5000

Weight 29.7 Ibs. (13,5 kg)

Powerhead _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ___

Type Single Cylinder

Displacement 4.75 cu. in. 07,8 cm 3 )

Bore 1.8898 (48 mm)

Stroke 1.6929 (43 mm)

Standard Bore 1.8890 - 1.8906 in . (48.00 - 48.02 mm)

Crankshaft Dimensions

Top Journal 0.7875 - 0.7878 in . (20,002 - 20,010 mm)

Bottom Journal 0.5906 - 0.5910 in. (15,001 - 15,011 mm)

Rod Crankpin 0.6299 - 0.6301 in. (16,00 - 16,005 mm)

Piston Diameter, Standard 1.8868 - 1.8873 in. (47,9247 - 47,9374 mm)

Piston Ring End Gap 0.0059 - 0.0138 in. (0,15 - 0,35 mm)

Piston Ring Groove Side Clearance 0.0026 in. (0,066 mm) maximum

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1-8 4C/eng E
Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .

Gear Ratio 13:24 (0.54)

Lubricant ave Ultra-HPF Gearcase Lube

Capacity 3 fl. oz. (90 ml)

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

Type Magneto Powered Capacitor Discharge

Spark Plug, Champion

Model Recommended

2,2.3,3.3 L87YC or QL87YC @

0.030 in. (0,8 mm)

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

Fuel/Oil Ratios See Page 1-22

Fuel Requirement See Page 1-24

Carburetion One Single-Throat Carburetor, Float Feed

Calibration Adjustable, Low Speed

Starting Enrichment Manual Choke

Float Level Setting See Section 2

4C/eng 1-9
 Engine Specifications
3,4
Operation _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

Full Throttle Operating Range 4500 to 5500 RPM

Power 3 - 3 HP j2,2 kw)

4 - 4 HP j3 kw)

Power Rated @ 5000 RPM

Idle RPM in Gear 750 ± 50

Test Propeller OMC PIN 317738

Minimum Test RPM 4400

Weight R - 33 Ibs. 05,0 kg)

RL - 35 Ibs. j16,0 kg)
Powerhead _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ___

Type In-line 2-Cylinder

Displacement 5.28 cu . in . j87 cm 3 )

Bore 1.565 in. j39,7 mm)

Stroke 1.374 in. j34,9 mm)

Standard Bore * 1.5643-1.5650 in. j39,74-39,75 mm)

Crankshaft Dimensions

Top Journal 0.7515-0.7520 in. (19,08-19,10 mm)

Center Journal 0.6685-0.6690 in. (16,98-16,99 mm)

Bottom Journal 0.6691-0.6695 in. (17,00-17,01 mm)

Rod Crankpin 0.6695-0.6700 in. (17,01-17,02 mm)

Piston Diameter, Standard 1.5625-1.5631 in. (39,69-39,70 mm)

Piston Ring End Gap, Both 0.005-0.015 in. (0,13-0,38 mm)

Piston Ring Groove Side Clearance, Both 0.004 in . (0,10 mm) maximum

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

1-10 4C/eng
Gearcase ................................................................... .

Gear Ratio 12:25 (0.48)

Lubricant ONIC Ultra-HPF Gearcase Lube

Capacity 2.7 fl. oz. (80 ml)

Shift Rod Height None

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

Type Magneto Powered Capacitor Discharge

Spark Plug, Champion

Recommended Extended Idle

QL86C L90C

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

Fuel System ..................................................................

Fuel/Oil Ratios See Page 1-22

Fuel Requirement See Page 1-24

Carburetion One Single-Throat Carburetor, Float Feed

Calibration Adjustable Low Speed, Fixed High Speed

Initial Low-Speed Setting 1 Turn

Starting Enrichment Manual Choke

Float Level Setting ONIC Float Gauge, PI N 324891

Float Drop Setting 1% - 11/2 in. (28-38 mm)

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4C /e ng 1-11 E
 Engine Specifications
4 Deluxe
Operation _ _ _ _ _ _ _ _ _ _ _ _ _ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

Full Throttle Operating Range 4500 to 5500 RPM

Power 4 HP (3 kw)

Power Rated @ 5000 RPM

Idle RPM in Gear 625 ± 25

Test Propeller OMC PIN 390123

Minimum Test RPM 5100

Weight RDH - 50 Ibs. (23 kg)

RDHL - 53 Ibs. (24 kg)
Powerhead _ _ _ _ _ _ _ _ _ _ _ _. . . . . . . ._ . ._ _....................... .

Type In-line 2-Cylinder

Displacement 5.28 cu. in . (87 cm 3 )

Bore 1.565 in. (39,7 mm)

Stroke 1.375 in. (34,93 mm)

Standard Bore * 1.5643-1.5650 in. (39,73339,751 mm)

Crankshaft Dimensions

Top Journal 0.7515-0.7520 in. (19,08-19,10 mm)

Center Journal 0.6685-0.6690 in. (16,98-16,99 mm)

Bottom Journal 0.6691-0.6695 in. (17,00-17,01 mm)

Rod Crankpin 0.6695-0.6700 in. (17,01-17,02 mm)

Piston Diameter, Standard 1.5625-1.5631 in. (39,69-39,70 mm)

Piston Ring End Gap, Both 0.005-0.015 in. (0,13-0,38 mm)

Piston Ring Groove Side Clearance, Both 0.004 in. (0,10 mm) maximum

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

1-12 4C1eng
Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .

Gear Ratio 13:29 (0.451

Lubricant OMC Ultra-HPF Gearcase Lube

Capacity 11 flo oz. (325 mil

Shift Rod Height None

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

Type Magneto Powered Capacitor Discharge

Power Pack RPM Limit None

Spark Plug, Champion

Recommended Extended Idle

QL86C L90C

INote I All spark plugs are to be gapped at 0.030 in. (0,8 mml

Fuel System ................................................................. .

Fuel/Oil Ratios See Page 1-22

Fuel Requirement See Page 1-24

Carburetion One Single-Throat Carburetor, Float Feed

Calibration Adjustable Low Speed, Fixed High Speed

Initial Low-Speed Setting 1 Turn

Starting Enrichment Manual Choke

Float Level Setting OMC Float Gauge, PI N 324891

Float Drop Setting 11/8 - 11/2 in. (28-38 mml

4C /eng 1-13
 Engine Specifications
5 thru 8
Operation _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

Full Throttle Operating Range 5, 6 - 4500 to 5500 RPM

8 - 5000 to 6000 RPM

Power 5 - 5 HP (3,7 kw)

6 - 6 HP (4,5 kw)
8 - 8 HP (6 kw)

Power Rated @ 5, 6 - 5000 RPM

8 - 5500 RPM

Idle RPM in Gear 700 ± 25

6SL, 8SRL - 900 ± 25

Test Propeller ONK: PIN 390239

Minimum Test RPM 5 - 4500

6 - 4800
8 - 5300
8SRL - 4850

Weight R, BA - 56 Ibs. (25,4 kg)

RL, BAL - 58.5 Ibs. (26,5 kg)
6SL - 61.3 Ibs. (27,4 kg)
8SRL - 64 Ibs. (29 kg)

Powerhead _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ___

Type In-Line 2-Cylinder

Displacement 10 cu. in. (164 cm 3 )

Bore 1.9375 in. (49,21 mm)

Stroke 1.700 in . (43,18 mm)

Standard Bore * 1.9373-1.9380 in. (49,21 49.23 mm)

Crankshaft Dimensions:

Top Journal 0.8762-0.8767 in. (22,26-22,27 mm)

Center Journal 0.8120-0.8125 in. (20,62-20,64 mm)
Bottom Journal 0.6691-0.6695 in. (17,00-17,01 mm)
Rod Crankpin 0.6695-0.6700 in. (17,01-17,02 mm)

Piston Diameter, Standard 1.9345-1.9355 in. (49,14-49,16 mm)

Piston Ring End Gap, Both 0.005-0.015 in. (0,13-0,38 mm)

Piston Ring Groove Side Clearance, Both 0.004 in . (0,10 mm) maximum

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

1-14 4C/eng
Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

Gear Ratio 13:29 (0.448)

Lubricant OMC Ultra-HPF Gearcase Lube

Capacity 11 fl. oz. (325 ml)

Shift Rod Height None

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

Type Magneto Powered Capacitor Discharge

Power Pack RPM Limit None

Spark Plug, Champion

Recommended Extended Idle

QL86C L92YC*

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

* All models except 8RC

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

Battery, Minimum Recommendation 12-Volt, 360 CCA (465 MCA) with

90 Minutes of Reserve Capacity (50 Ampere-Hours)

Alternator 4 Amp, Non-Regulated

AC Model 60 Watts

Tachometer Setting 5

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

Fuel/Oil Ratios See Page 1-22

Fuel Requirement See Page 1-24

Carburetion One Single-Throat Carburetor, Float Feed

Calibration Adjustable Low Speed, Fixed High Speed

Initial Low-Speed Setting 3 Turns

Starting Enrichment Manual Choke

Float Level Setting OMC Float Gauge, PI N 324891

Float Drop Setting 1 - 13/8 (25-35 mm)

4C/eng 1-15
NOTES

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1-16 4C/eng s::
Gearcase Lubrication

'" To avoid accidental starting of engine while servicing, twist

~ and remove all spark plug leads.

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

rv f2l Tomended
~~
refill, place a tube or pressure can nozzle of recom-
lubricant in drain/fill hole.

26109

Gearcase Lubrication

If OMC Ultra-HPF Gearcase

Lube is not available, OMC
2 Thru 8 Except 4 Deluxe
Hi-Vis gearcase lube can be
used as an alternate.

4 Deluxe If OMC Ultra-HPF Gearcase

Lube is not available, OMC
Premium Blend gearcase lube 25350

can be used as an alternate.

PCE0085

• 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.

• Tighten plugs to torque specified in chart.

2,2.3,3.3 30-40 in. Ibs.

(3,8-4,5 N·m)

3-4 40-50 in. Ibs.

(4,5-5,6 N·m)

4 Deluxe - 8 84-86 in. Ibs.

(9-10 N·m)

PCE0053

4C1eng & Safety Related 1-17

Lubrication Chart - 2 thru 4

Frequency

Figure Lubrication Point Lubricant Fresh Water Salt Water *

[TI Clamp Screws, Steering Han-
die Pivot, Friction Knob Screw
- 2, 2.3, 3.3
e 60 Days 30 Days

~
Clamp Screws, Carrying Han-
die - 3, 4 e 60 Days 30 Days

0~
Gearcase
3 oz. (90 mil - 2, 2.3, 3.3 €) Change after first 20 operating hours.
Check level every 50 operating hours.
2.70 oz. (80 mil - 3, 4 Change every 100 operating hours or
once each season, whichever comes
first.

~
Fuel Shut-Off (Integral Tank
Model) and Choke Shaft -3, 4 e 60 Days 30 Days

~ Shift Lever Fitting - 3, 4

e 60 Days 30 Days

0 Steering Handle Pivot - 3, 4

e 60 Days 30 Days

~
Carburetor Linkage and Throt-
tie Linkage - 3, 4 e 60 Days 30 Days

~ Tilt Lock Pin - 2, 2.3, 3.3

e 60 Days 30 Days

~
Angle Adjustment Bolt - 2, 2.3,
3.3 e 60 Days 30 Days

* Some areas may require more frequent lubrication.

PCE0058

OMC OMC U/tra-HPF""

Trip/e-Guard@ Gearcase
Grease Lube

DR4849

1-18 4C/eng
10

4C/eng 1-19
Lubrication Chart - 4 Deluxe thru 8
Frequency

Figure Lubrication Point Lubricant Fresh Water Salt Water *

OJ Clamp Screws and Tilt/Run Lever 60 Days 30 Days

rn
- 5, 6, and 8

Fuel Shut-Off Linkage (Integral

Tank), Cam Roller, Choke and
Throttle Linkage -
4 Deluxe
"" 60 Days 30 Days

W Swivel Bracket - Upper and 60 Days 30 Days

rn
Lower

Trail Lock Linkage " 60 Days 30 Days

[]]
Gearcase - 10-11 flo oz.
(290-325 ml)
"e Change after first 20 operating hours. Check
level every 50 operating hours. Change
every 100 operating hours or once each
season, whichever comes first.

II]

""
Tilt Linkage - 5, 6, and 8 60 Days 30 Days

[[J Carburetor Linkage - 60 Days 30 Days

4 Deluxe

[]] Throttle and Choke Linkage - 60 Days 30 Days

W
5,6, and 8

Carburetor Linkage - " 60 Days 30 Days

[!Q]
5,6, and 8

Clamp Screws, Tilt/Run Lever,

and Steering Handle -
4 Deluxe
"" 60 Days 60 Days

[IT] Motor Cover Rear Latch - 60 Days 60 Days

4 Deluxe

* Some areas may require more frequent lubrication. " PCE0055

OMC OMC Ultra-HPF™

Triple-Guard@ Gearcase
Grease Lube

It-.'-
..
~
__ iii _ _ .....

•••• •••

DR4849

1-20 4C/eng
4Cleng 1-21
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.

INote I Failure to follow this minimum lubricant recommendation

could void your engine warranty.

INote I Running or storing an engine on a leaner than recom-

mended fuel/oil mixture may result in powerhead damage.

INotelAvoid the use of the following as they could damage your

engine and/or shorten spark plug life:

• Automotive oils
• Premix fuel of unknown oil quantity
• Premix fuel richer than the recommended ratio
• Premix fuel leaner than the recommended ratio

Some additives in EvinrudelJohnson Outboard Lubricant are

subject to evaporation. Always cover partially filled containers to
prevent deterioration of lubricant.

Normal Service
All recreational and commercial engines require a 50: 1 fuel/oil
mixture.

High Performance
Any recreational engine, when used for high performance, re-
quires a 50: 1 fuel/oil mixture.

Severe Service
The fuel/oil ratio for recreational models is 25:1 (4% oil) when
used in commercial, rental, or extended severe service.

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1-22 4C/eng
E
Fuel/Oil Mixing Instructions

11 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.

[I] 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.

W rn 11 Permanently Installed Tank - Above 32° F (00 Cl, 1

pour oil slowly with the fuel as tank is filled. Below 32° F (0° C),
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 6 Gallons 18 Gallons

(11,4 Litres) (22,7 Litres) (68,1 Litres)

100: 1 4 fl. oz. 8 fl. oz. 24 fl. oz.

(1% Lubricant) (118 ml) (236 ml) (708 ml)

50:1 8 fl. oz. 16 fl. oz. 48 fl. oz.

(2% Lubricant) (236 ml) (473 ml) (1419 ml)

25:1 16 fl. oz. 32 fl. oz. 96 fl. oz.

(4% Lubricant) (473 ml) (946 ml) (2838 ml)
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4C/eng & Safety Related 1-23

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 Fuel Requirements

Minimum Octane

Models Recommendation (R+M)/2 "AKI" "RON"

2-8 See fuel classifications below. 67 69

PCE0020

Preferred Fuel: Any regular unleaded, regular leaded, or premium unleaded gasoline having the
recommended octane rating, and not extended with alcohol.

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'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.

/1 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.

& Safety Related 1-24 4C/eng

New Engine Pre-Delivery Checks
The careful preparation of an engine before delivery will ensure
owner satisfaction.
OMC OWNER IDENTIFICATION CARD
Owner's
N. me
1. Upon uncrating a new engine, inspect it. If you find:
_ aa
• Shipping damage - contact the carrier that delivered it
City Stote _ Zip _ _
• Parts or connections are loose - repair as required Date 01 Purchase
• Parts are missing - contact OMC MODEL- SERIAL_

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

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

....
I
--
DEALER RECORD CARD
I
O¥n.',Ntme

/1 4. Momentarily, pressurize fuel system. Check for leaks! Adctlll

Coty ""', z.
Repair any leaks before continuing. SecnOwnet Name

AcldrUI

5. Start engine and check cooling system operation . Be sure Coty

"'. '"
Olleo!lVchaH ipionKey No.
engine warms to operating temperature at idle.

/1 6. Check shift operation. Check start-in-gear prevention on

...,-
8oItMl\J'.

Imporgnt: The Fedwal IoIt "'ety

"'No.
Botll.-,glh

Act r8Cf.*e5 registration itsls to be mmtaned

on proOJcl sales by m8rUactU'9I' and DEALER This is a standard card on which

engines so equipped. a dealer can keep tis records.

Name

/1 7. Check electrical and ignition systems for stray spark S

0
AdOre..

sources. L
0
City St
1 '"
T
0
Ownet"s Phone Il ip ....

8. Check all adjustments. See Synchronization and linkage Purchase Date Type 01 UN

Adjustments, this section. o Pleasure Dc""",, OGoVI

Deller Name
S
0 Address
9. With the engine at all trim angles, turn boat's steering wheel L
0
fully right and left. Be sure there is no interference of the steering City Ist8te

connector, remote control cables, and electrical cables at the

B
10..,
'-,-,
V lIP· .. Code

boat's motor well.

,. R'."'''~. . !~ .
10. Correct any problems found . 1
BoalMlg
1"-
11 . Clean enti re engine. Hull No. I Length

TI&ilef \lIN

12. Review Operator's Manual information, including owner's

responsibilities and engine requirements.

13. Complete the paperwork: ®

@
• Owner's identification card
DR5700
• Dealer's customer record
• Registration

4C/eng Safety Related 1-25

Propeller Selection

Selecting the correct propeller for each engine and boat combina-
tion will ensure good engine service life and good boat perfor-
mance. A propeller must be carefully selected to match the
engine/boat combination, the application, and the anticipated
load in the boat.

c:J Selection of t he wrong propeller could reduce engine

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

OMC propellers available for these engines are listed in the OMC
SysteMatched Parts and Accessories Dealer Catalog.

Procedure

The propeller selection process is very important to the engine's

service life and to boat performance. Proceed carefully and
thoroughly while considering the following points:

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

wide-open throttle for only 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 perfor-
mance boating . In such cases, it might be necessary to
have a propeller for each situation.

r:jl fN=llf 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.

'" Twist and remove all spark plug leads to avoid accidental
~ starting while changing propellers.

& Safety Related 1-26 4C/eng

 1
DR1211

® Percentage of available horsepower (kw)

® Engine RPM
© Horsepower (kw) curve
@ Full throttle operating range

® Rating RPM for horsepower (kw)

® Engine is overloading at W.O.T.

@ Engine is overspeeding at W.O.T.

4C/eng 1-27
 Rated Power

Hot Weatherl
-------
High Altitude

I~
I~
RPM 1*
ex::

1
DR4013

Weather, Altitude, and Engine Performance

The horsepower ratings of all engines are those that would be
obtained under standard conditions. However, changes in weath-
er 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

f11 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 any case, top boat speed will not be as high as
on a cool, dry day.

fN=l A loss of engine performance can occur if an engine has not

~ been properly modified for high altitude operation. If you
service high altitude engines, consider ordering Information and
Decal Kit, PIN 393533, from your distributor.

To avoid permanent powerhead damage, be sure that an engine

modified for high altitude operation is properly identified and
recalibrated when operated at lower altitude.

1-28 4C1eng
Break-In Procedure
Standard Fuel Tank - Use a 25: 1 fuel/oil mixture for the first 5 hours of operation.

Optional AccuMix@Tank - Use a 50: 1 fuel/oil mixture in addition to the AccuMix system for the first 5
hours of operation.

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

INotel DO NOT operate motor out of water. Water pump can be damaged or engine can overheat.

INotel DO NOT operate engine at a constant throttle setting. Change engine RPM often.

First 10 Minutes
• Operate engine in gear at fast idle ONLY.
• Verify water pump operation; look for a steady stream of water from the water pump indicator.

Next 50 Minutes
• Operate engine up to 1/2 throttle (no more than 3500 RPM).
• Verify water pump operation; look for a steady stream of water from the water pump indicator.
• Change engine speed every 15 minutes; DO NOT hold a constant throttle setting.

I Note I If your boat is easy to plane, use full throttle to quickly plane the boat. Once on plane, reduce the
throttle to 1/2 . BE SURE your boat remains on plane at this throttle setting.

Second Hour
• Use full throttle to plane your boat, then reduce the throttle to 314. BE SURE your boat remains
on plane at this throttle setting.
• Verify water pump operation; look for a steady stream of water from the water pump indicator.
• At intervals, apply full throttle for periods of one to two minutes, returning to 314 throttle for a
cooling period.
• Change engine speed every 15 minutes.

Next Three Hours

• Avoid continuous full-throttle operation.
• Verify water pump operation; look for a steady stream of water from the water pump indicator.
• Change engine speed every 15 minutes.

INotel Retorque cylinder head screws after engine break-in period. Retorque after engine has been run
and cylinder heads have cooled to the touch.

INotel After 10 hours of break-in, check oil level in the AccuMix reservoir to verify that oil is being
consumed to ensure proper lubrication of engine. Add oil to refill AccuMix reservoir before switching
from 50: 1 fuel/oil mixture to clear fuel. E
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4C/e ng 1-29 E
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 OMC 2+4fuel condition-

er, following directions on the bottle.

INotel Use a flushing attachment if you operate the engine on a

trailer or dolly to prevent engine or water pump damage.

&. 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, PIN 397767. The mixture should include:

• Five gallons of fuel

• Two quarts of OMC Storage Fogging Oil
• One pint of Evinrude or Johnson Outboard Lubricant
• 2'/2 oz. of OMC 2+4 fuel conditioner

4. Connect the tank containing the "storage mixture" to the

engine. Run the engine on the "storage mixture" at approxi-
mately 1500 RPM for five minutes.

5. Stop engine and remove all spark plugs. Spray a liberal amount
of OMC 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 eng ine is equipped with a portable fuel tank, disconnect fuel

hose from engine and tank.

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

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& Safety Related 1-30 4C/eng
ii
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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 systems. Replace damaged or missing parts
with genuine OMC 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.

&. 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
of problems. Follow equipment manufacturer's maintenance and
lubrication recommendations when servicing the steering sys-
tem.

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. Refer to
Section 8 for battery maintenance information.

12. If equipped, service the boat fuel filter following instructions

on canister.

13. Remove propeller and check for damage. A slightly bent

propeller blade can hardly be noticed but will affect the perfor-
mance of the engine. Clean and lubricate the propeller shaft with
OMC 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.

&. 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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4Cleng & Safety Related 1-31 E
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.

& 2. Apply a light coating of ONIC 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.

& 3. Check water level in battery, then charge. While the battery
is charging, the acid solution inside the battery gives off hydro-
gen 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 batter-
ies, 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.

& 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 instruc-
tions! If control systems are attached to the engine using the
wrong fasteners or assembled carelessly, sudden unexpected
loss of engine control may result.

& 5. Check fuel system for leaks.

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& Safety Related 1-32 4C/eng
E
Tune-Up Procedure
1. Visually inspect engine for leaks, missing or loose parts, or
other obvious defects.

2. Compression check - Proper compression is essential to 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 condi-

tion.

• 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 cylinder 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:

• damage 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.

I.A 3. Clean and regap or replace spark plugs. Make certain

ill ceramic portion of plug is not cracked. Replace if cracked to
prevent sparks.

'" 4. Inspect and test ignition components. See Section 3.

i l l Replace deteriorated or damaged parts such as wires,
boots, etc., which may emit sparks.

'" 5. Replace in-line fuel filter. Replace deteriorated or dam-

i l l aged fuel system parts such as hoses or gaskets which may
result in fuel leaks. Inspect carburetor and choke or primer.

6. Synchronize the engine. See Synchronization and Linkage

Adjustments, this section. E
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4C/eng & Safety Related 1-33 E
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 condit ion. 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
temperature.

INote I 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 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.

& 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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& Safety Related 1-34 4C/eng

ii
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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.

fN=J If any anode has been reduced to 0/3 its original size (113
~ eroded), it must be replaced!

'1l ~ ~ Test for proper installation of the anode. Calibrate an

L!.J ~ ~ 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
ohmmeter 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.

INotel Do not paint or coat the anodes or their mounting surfaces.

4C/eng 1-35
Submerged Engines

Engine Dropped Overboard (Not Running)

If engine is recovered from water immediately, it must be serv-

iced within three hours. See Prolonged Submersion.

~ If 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 crank-
shaft, connecting rods, and bearings. The engine must be serv-
iced within three hours of recover to avoid costly repairs. Proceed
as follows:

1. Remove engine cover and rinse powerhead with fresh water.

2. Disconnect spark plug leads and remove spark plugs.

~ 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.

4. Place engine in horizontal position (spark plug openings down)

and work out all of the water by slowly rotating flywheel approxi-
mately 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. Starter, 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. Start engine

(follow starting instructions) and run 1/2 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, 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.

1-36 4C/en g
'N'='J If 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. If 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 immedi-

ately, the engine must be serviced within three hours after
recovery. Follow same procedures as Engine Dropped Overboard
(Not Running) and (Running). When prolonged submersion oc-
curs in salt water, even if engine can be started, the engine must
be disassembled and cleaned and electrical components cleaned
or replaced where necessary.

4C1eng 1-37
Synchronization and Linkage Adjustments -
3,4
~ It is important that this step-by-step procedure be followed
~ in sequence and be performed exactly as written to ensure
consistent engine idling and smooth operation throughout the
RPM range.
Cam Follower Pickup Point _ _ _ _ _ _ _ _ _ _ _ __

rvL!J to1. Connect the throttle shaft amplifier, such as the one shown,
the carburetor throttle shaft.

r.;J 2. Advance the throttle until the tip of amplifier begins to

L!J move. At this point, center of the roller should align with single
mark on cam.

f313. Back out cam follower adjustment screw with OMC Ballhex
~ Driver, PIN 327622, until the throttle valve is closed com-
pletely. Then advance the screw until the throttle shaft just begins
to rotate. .

4. Repeat Step 2 to verify adjustment.

1-38 4C/eng
Carburetor Adjustment _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

1. Start engine and run in FORWARD gear at one-half throttle or

slightly more. Allow engine to reach normal operating tempera-
ture before making low-speed mixture adjustments. The boat's
movement must be unrestrained, not tied to a dock or trailer.

~ r.v ~ 2. Stop the engine to prevent contact with rotating

i l l L!.J ~ parts. Loosen the two throttle cable nuts and idle
speed adjustment screw to allow the ignition plate to contact stop
in powerhead.

Isl 3. Start the engine and turn idle speed adjustment screw to
~ allow engine to operate at 700-800 RPM. Adjust the low-speed
needle until the highest consistent RPM is attained. Allow 15
seconds after each adjustment for engine to respond.

4. After final adjustment is completed, turn low-speed needle

counterclockwise one-eighth turn to prevent engine from being
too lean at slow speeds, particularly in NEUTRAL.

~ 5. Reduce engine speed and turn idle speed adjustment to

~ allow engine to run at a minimum of 750 RPM in FORWARD
gear.

6. Run engine in gear at or near full throttle for one minute.

Promptly reduce speed to SLOW (700-800 RPM) and shift into
NEUTRAL. Engine should continue to run smoothly.

7. If engine stalls or pops, the mixture is probably too lean. Turn

the needle counterclockwise one-sixteenth turn. Allow 15 sec-
onds after each adjustment for engine to respond. Observe
engine running quality. If satisfactory, repeat Step 6 to verify that
mixture adjustment is correct.

8. If engine does not respond to adjustments, check engine for

other problems. Make sure gasoline is of good quality and mixed
with the proper amount of oil.
Throttle Cable Adjustment _ _ _ _ _ _ _ _ _ _ _ _ __

1. Rotate twist grip to idle position.

r.v 2. With the ignition plate against idle speed adjustment screw,
L!.J
remove slack between end of throttle casing and ignition
plate, in the throttle cable by adjusting the two nuts.

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4C/eng & Safety Related 1-39
ii
E
Synchronization and Linkage Adjustments -
4 Deluxe
INote I It is importantthatthis step-by-step procedure be followed
in sequence and be performed exactly as written to ensure
consistent engine idling and smooth operation throughout the
RPM range.
Cam Follower Pickup Point _ _ _ _ _ _ _ _ _ _ _ _ __

rn 1. Connect a throttle shaft amplifier @, such as the one

shown, to the carburetor throttle shaft.

rn 2. Advance the throttle until the tip of amplifier begins to

move. At this point, center of the roller should align with single
mark on cam.

rn 3. Back out cam follower adjustment screw with OMC

Ballhex Driver, PIN 327622 @, until the throttle valve is closed
completely. Then advance the screw until the throttle shaft just
begins to rotate.

4. Repeat Step 2 to verify adjustment.

DR2145
Maximum Spark Advance Adjustment _ _ _ _ _ _ _ _ __

No maximum spark advance adjustment is necessary. Correct

wire positioning in the connectors is all that is required to
maintain proper ignition timing.

1-40 4C/eng
Carburetor Adjustment _ _ _ _ _ _ _ _ _ _ _ _ _ __

1. Start engine and run in FORWARD gear at one-half throttle or

slightly more. Allow engine to reach normal operating tempera-
ture before making low-speed mixture adjustments. The boat's
movement must be unrestrained, not tied to a dock or trailer.

2. Run engine at slow speed (700-800 RPM) and adjust the

low-speed needle until the highest consistent RPM is attained.
Allow 15 seconds after each adjustment for engine to respond.

3. After final adjustment is completed, turn low-speed needle

counterclockwise one-eighth turn to prevent engine from being
too lean at slow speeds, particularly in NEUTRAL.

4. Reduce engine speed and turn idle speed adjustment to allow

engine to run at a minimum of 625 RPM in FORWARD gear.

5. Run engine in gear at or near full throttle for one minute.

Promptly reduce speed to SLOW (700-800 RPM) and shift into
NEUTRAL. Engine should continue to run smoothly.

6. If engine stalls or pops, the mixture is probably too lean. Turn

the needle counterclockwise one-sixteenth turn. Allow 15 sec-
onds after each adjustment for engine to respond. Observe
engine running quality. If satisfactory, repeat Step 5 to verify that
mixture adjustment is correct.

7. If engine does not respond to adjustments, check engine for

other problems. Make sure gasoline is of good quality and mixed
with the proper amount of oil.

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4C/eng 1-41 E
Synchronization and Linkage Adjustment -
5 thru 8
~ It is important that this step-by-step procedure be followed
~ in sequence and be performed exactly as written to ensure
consistent engine idling and smooth operation throughout the
RPM range.
Throttle Cable Adjustment _ _ _ _ _ _ _ _ _ _ _ _ __

rv~ adjustment
1. As you face the steering handle, turn the idle speed
knob counterclockwise to minimum speed posi-
tion. Turn twist grip throttle clockwise to the lowest throttle
setting.

2. Verify the throttle cam is against its idle stop.

~ 3. Remove the screw retaining the throttle cable bracket to the

~ powerhead.

f314. Adjust the throttle cable bracket to align with its mounting
~hole.

5. Before fastening throttle cable bracket to motor, turn the

bracket one revolution toward throttle lever to lightly preload the
throttle toward the closed position.

6. Install the throttle bracket screw.

Maximum Spark Advance Adjustment

No maximum spark advance adjustment is necessary. Correct

wire positioning in the connectors is all that is required to
maintain proper ignition timing.

1-42 4C/eng
Carburetor Adjustment _ _ _ _ _ _ _ _ _ _ _ _ _ __

r:7::J The motor must be mounted on the boat and in the water,
~ or in a test tank, with appropriate propeller or test prop
installed to make this adjustment.

1. Make the following initial adjustments:

• Using a ball hex screwdriver, back out the throttle cam

follower screw until follower does not touch the cam. If
necessary, advance the throttle to access the throttle
cam screw. Return to the lowest throttle setting and
verify the follower does not touch the cam.

• Turn the low-speed needle in (clockwise) until it seats

lightly; then back it out (counterclockwise) 3 turns.

• Turn the cracking screw in until the spring is fully but

lightly compressed.

2. Start the engine and allow it to reach normal operating

temperature.

f613. With the engine running in forward gear, adjust the throttle
~ cracking screw to achieve 700 RPM (900 RPM on Sail models).

~ 4. Adjust the low-speed needle until the highest consistent

~ RPM is attained. Allow 15 seconds between each adjustment
for the engine to respond.

f515. After the final adjustment, turn the low-speed needle Va turn
~ counterclockwise to prevent a lean condition at idle. Readjust
the throttle cracking screw to 700 RPM (900 RPM on Sail models).

I:A.
r:;J 6. Stop the engine. Remove the air silencer. Connect a
~ ill throttle shaft amplifier @ to the carburetor throttle shaft.

r:;, 7.
Using OMC Ball Hex Driver, PIN 327622, turn the throttle
~ cam follower screw clockwise until the tip of the amplifier
begins to move. Then back off the screw Va turn. Remove amplifier
and install air silencer.

8. Start the engine and allow it to reach normal operating

temperature. Shift the motor into forward gear. Rapidly advance
throttle to wide open position. Ifthe engine stalls or backfires, the
idle mixture is too lean. Turn the low-speed needle '/a of a turn
counterclockwise. If necessary, repeat this procedure.
Wide Open Throttle Stop _ _ _ _ _ _ _ _ _ _ _ __

Iol I:A. 1. Stop the engine to avoid accidental contact with

L!J ill rotating parts. Rotate the throttle to the wide open
position.

2. Check the position of the throttle shaft roll pin. The roll pin
should be exactly vertical. Return the throttle to the idle position.

3. Using OMC Ball Hex Driver, PIN 327622, adjust the throttle
cam until the roll pin in the throttle shaft is in the vertical position.

4C/eng & Safety Related 1-43

NOTES

1-44 4C1eng
20-Hour Check

~ Outboard Marine Corporation encourages all Johnson and

~ Evinrude owners to return their new engines to an author-
ized dealer for 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. Check torque on cylinder head screws and spark plugs.

3. Check all linkage adjustments.

4. Check engine mounting hardware for tightness.

5. Lubricate all grease fittings with OMC Triple-Guard grease.

6. Check entire boat and engine fuel system for signs of deteriora-
tion, damage, or leaks.

7. Check all engine systems for signs of deterioration or prob-

lems.

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4C/eng 1-45 E
 Drill Size Conversion Cha rt
SHOWING MILLIMETER SIZES,; FRACTIONAL AND
DECIMAL INCH SIZES AND NUMBER DRILL SIZES

Milli- Dec_ Frac- Num- Milli- Dec. Frac- Num - Milli- Dec. Frac- Num- Milli- Dec_ Frac- Num- MiIIi· Dec. Frac-
Meter Equiv. tional her Meter Equiv. tional her Meter Equiv. tional her Meter Equiv. tional her Meter Equiv. tional
.1 .0039 1.75 .0689 .... .1570 22 6.8 .2677 10.72 .4219 27/64
.15 .0059 .0700 50 4.0 .1575 6.9 .2716 11.0 .4330
.2 .0079 1.8 .0709 ·. .1590 21 ., .. .2720 I 11.11 .4375 7/ 16
.25 .0098 1.85 .0728 ... .1610 20 7.0 .2756 11.5 .4528
.3 .0118 ., .. .0730 49 4.1 .1614 . ... .2770 J 11.51 .4531 29/64
.. .0135 80 1.9 .0748 4.2 .1654 7.1 .2795 11 .91 .4687 15/32
.35 .0138 .... .0760 48 .... .1660 19 . ... .2811 K 12.0 .4724
.... .0415 79 1.95 .0767 4.25 .1673 7.14 .2812 9/32 12 .30 .4843 31/64
.39 .0156 1/64 .. o. 1.98 .0781 5/64 . ... 4.3 .1693 7.2 :2835 12.5 .4921
.4 .0157 .... .Q785 47 · ' .. .1695 18 7.25 .2854 12.7 .5000 1/2
.... .0160 78 2.0 .0787 4.37 .1719 11 /64 . ... 7.3 .2874 13.0 .5118
.45 .0177 2.05 .0807 .... .1730 17 .., . .2900 L 13.10 .5156 33/64
, ... .0180 77 , ... .0810 46 4.4 .1732 7.4 .2913 13.49 .5312 17/32
.5 .0197 .... .0820 45 .1770 16 .... .2950 M 13 .5 .5315
.... .0200 76 2.1 .0827 4.5 .1771 7.5 .2953 13.89 .5469 35(64
.... .0210 75 2.15 .0846 ·. .1800 15 7.54 .2968 19/64 . , .. 14.0 .5512
.55 .0217 .... .0860 44 4.6 .1811 7.6 .2992 14 .29 .5624 9/16
", . .0225 74 2.2 .0866 ., .. .1820 14 . .. .3020 N 14.5 .5709
.6 .0236 2.25 .0855 4.7 .1850 13 7.7 .3031 14.68 .5781 37/64
.. " .0240 73 , . .. .0890 43 4.75 .1870 7.75 .3051 15.0 .5906
.... .0250 72 2.3 .0905 ~.76 .1875 3/16 7.8 .3071 15.08 .5937 19/32
.65 .0256 2.35 .0925 4.8 .1890 12 7.9 .3110 15.48 .6094 39/64
.... .0260 71 . .. .0935 42 .., . .1910 11 7.94 .3125 5116 " .. 15.5 .6102
... .0280 70 2.38 .0937 3/32 . . .. 4.9 .1929 8.0 .3150 15.88 .6250 5(8
.7 .0276 2.4 .0945 .... .1935 10 . .. .3160 0 16.0 .6299
... .0292 69 .. .. .0960 41 , ... .1960 9 8.1 .3189 16.27 .6406 41 /64
.75 .0295 2.45 .0964 5.0 .1968 8.2 .3228 16.5 .6496
.... .0310 68 .. " .0980 40 .. .. .1990 8 , ... .3230 P 16.67 .6562 21 /32
.79 .0312 1/32 .. . . 2.5 .0984 5.1 .2008 8.25 .3248 17.0 .6693
.8 .0315 .0995 39 .... .2010 7 8.3 .3268 17 .06 .6719 43/64
.. . . .0320 67 ... . .1015 38 5.16 .2031 13/64 .. . 8.33 .3281 21 /64 , ... 17 .46 .6875 11 / 16
... .0330 66 2.6 .1024 . ... .2040 6 8.4 .3307 17.5 .6890
.85 .0335 .. " .1040 37 5.2 .2047 .. . . .3320 Q 17.86 .7031 45/64
.. . .0350 65 2.7 .1063 ·. .2055 5 8.5 .3346 18.0 .7087
.9 .0354 '" . .1 065 36 5.25 .2067 8.6 .3386 18.26 .7187 23/32
.... .0360 64 2.75 .1082 5.3 .2086 · ... .3390 R 18.5 .7283
.... .0370 63 2.78 .1094 7/64 .... ·.., .2090 4 8.7 .3425 18.65 .7344 47 /64
.95 .0374 ... . .1100 35 5.4 .2126 8.73 .3437 11/32 .... 19 .0 .7480
... . .0380 62 2.8 .1102 ... .2130 3 8.75 .3445 19 .05 .7500 3/4
.... .0390 61 .1110 34 5.5 .2165 8.8 .3465 19.45 .7656 49/64
1.0 .0394 ... . .1130 33 5.56 .2187 7/32 ... . , .. . .3480 S 19.5 .7677
.... .0400 60 2.9 .1141 5.6 .2205 8.9 .3504 19.84 .7812 25/32
.... .0410 59 .., . .1 160 32 · ... .2210 2 9.0 .3543 20 .0 .7874
1.05 .0413 3.0 .1181 5.7 .2244 ., " .3580 T 20 .24 .7969 51 /64
.... .0420 58 .... .1200 31 5.75 .2263 9.1 .3583 20.5 .8071
.... .0430 57 3.1 .1220 .." .2280 1 9.13 .3594 23/64 ., . . 20.64 .8125 13/ 16
1.1 .0433 3.18 .1250 1/8 ... 5.8 .2283 9.2 .3622 21.0 .8268
1.1 5 .0452 3.2 .1260 5.9 .2323 9.25 .3641 21.04 .8218 53/64
.., . .0465 56 3.25 .1279 .2340 A 9.3 .3661 21.43 .8437 27 /32
1.19 .0469 3/64 . .. . . -, .1285 30 5.95 .2344 15/64 ... · ... .3680 U 21.5 .8465
1.2 .0472 3.3 .1299 6.0 .2362 9.4 .3701 21.83 .8594 55 /64
1.25 .049 2 3.4 .1338 .. , . .2380 B 9.5 .3740 no .8661
1.3 .0512 ... . .1360 29 6.1 .2401 9.53 .3750 3/8 .... 22.23 .8750 7/8
.. . . .0520 55 3.5 .1378 . .. . .2420 C . .. . .3770 V 22.5 .8858
1.35 .0513 .. " .1405 28 6.2 .2441 9.6 .3780 22.62 .8906 57 /64
.. .. .0550 54 3.57 .1406 9/64 ... 6.25 .2460 0 9.7 .3819 23.0 .9055
1.4 .0551 3.6 .1417 6.3 .2480 9.75 .3838 23 .02 .9062 29/32
1.45 .0570 .... .1440 27 6.35 .2500 1/4 E 9.8 .3858 23.42 .9219 59 /64
1.5 .0591 3.7 .1457 6.4 .2520 .. . . .3860 W 23.5 .925 2
.. .0595 53 . .. . .1470 26 6.5 .2559 9.9 .3839 23 .81 .9375 15/16
1.55 .0610 3.75 .1476 .. . . .2570 F 9.92 .3906 25/64 .... 24.0 .9449
1.59 .0625 1/ 16 .. . .. . . .1495 25 6.6 .2 598 10.0 .3937 24.21 .9531 61 /64
1.6 .0629 3.8 .1496 .2610 G .3970 X 24.5 .9646
... . .0635 52 . .. .1520 24 6.7 .2638 · ... .4040 y 24 .61 .9687 31/32
1.65 .0649 3.9 .1535 6.75 .2657 16/64 .. " 10.32 .4062 13/32 .. " 25 .0 .9843 E
o
1.7 .0669 ., .. .1540 23 6.75 .2657 ... .4130 Z 25 .03 .9844 63/64 u
.. .. .0670 51 3.97 .1562 5/32 ... . ... .2660 H 10.5 .4134 25.4 1.0000 1 oj
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1-46 4C .s:::
Carburetor Orifice Plug Chart
It is occasionally necessary to replace carburetor orifices to improve engine running characteristics.
Check current parts catalogs for orifice part numbers.

INotel Check current parts catalogs and service bulletins before making any orifice changes.
The following charts list available orifices, orifice sizes, and part numbers. The identification number is
stamped on most orifices.
Orifices (8-32 Thread Size)
10 No. Part No. Size 10 No. Part No. Size
0 333342 0.000 43 325828 0.043
14 331952 0.014 44 325827 0.044
16 333243 0.016 45 323151 0.045
20 324005 0.020 46 327342 0.046
22 331934 0.022 47 328560 0.047
23 326188 0.023 48 326500 0.048
24 328549 0.024 49 333741 0.049
25 323003 0.025 50 323708 0.050
26 324652 0.026 53 328531 0.053
27 317474 0.027 54 334014 0.054
28 322936 0.028 55 326928 0.055
29 322776 0.029 56 333982 0.056
30 317473 0.030 57 325869 0.057
31 318823 0.031 58 328280 0.058
32 320016 0.032 59 327739 0.059
33 320015 0.033 60 327092 0.060
34 324025 0.034 61 324977 0.061
35 318832 0.035 62 326856 0.062
36 323703 0.036 64 325837 0.064
37 324698 0.037 66 328526 0.066
38 323149 0.038 67 327689 0.067
39 334568 0.039 68 327740 0.068
40 327745 0.040 70 328562 0.070
41 328535 0.041 73 328536 0.073
42 325829 0.042
Orifices (1/4-20 Thread Size - 0 Type)
10 No. Part No. Size 10 No. Part No. Size
0 338548 0.000 570 322907 0.057
290 330142 0.029 580 328543 0.058
320 333184 0.032 590 319831 0.059
340 330141 0.034 600 332204 0.060
350 333183 0.035 610 319907 0.061
370 328537 0.037 620 331433 0.062
380 328525 0.038 630 328544 0.063
390 328538 0.039 640 328545 0.064
400 328524 0.040 650 327541 0.065
410 333182 0.041 670 319534 0.067
420 322249 0.042 680 333211 0.068
430 328539 0.043 690 327558 0.069
440 328540 0.044 700 327769 0.070
450 323280 0.045 710 327559 0.071
460 328541 0.046 720 328546 0.072
470 328542 0.047 730 327487 0.073
490 324020 0.049 740 333669 0.074
500 326526 0.050 750 327560 0.075
510 331567 0.051 760 329411 0.076
520 321108 0.052 770 333438 0.077
530 321297 0.053 780 319002 0.078
540 321407 0.054 790 329414 0.079 E
550 320921 0.055 800 333298 0.080 0
u..:
560 318684 0.056 810 330917 0.081 '"
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4C/eng 1-47 E
 Orifices (%-20 Thread Size - C Type)

10 No. Part No. Size 10 No. Part No. Size

23C 336709 0.023 56C 325019 0.056

25C 333458 0.025 57C 317021 0.057
26C 333459 0.026 58C 321731 0.058
27C 333460 0.027 58.5C 324389 0.0585
29C 333461 0.029 59C 317330 0.059
30C 333312 0.030 60C 321449 0.060
31C 333462 0.031 61C 320661 0.061
34C 333463 0.034 62C 317607 0.062
36C 333464 0.036 63C 321559 0.063
38C 323150 0.038 64C 324776 0.064
41C 328550 0.041 65C 322810 0.065
43C 328551 0.043 66C 328554 0.066
45C 322664 0.045 67C 317183 0.067
46C 328547 0.046 68C 328555 0.068
47C 328552 0.047 69C 319776 0.069
48C 323903 0.048 70C 322996 0.070
49C 322221 0.049 71C 328556 0.071
50C 324906 0.050 72C 317488 0.072
51C 323938 0.051 73C 328559 0.073
52C 328548 0.052 74C 328557 0.074
53C 328553 0.053 75C 328558 0.075
54C 317646 0.054 76C 320502 0.076
55C 329911 0.055
Orifices (5/16-24 Thread Size)

10 No. Part No. Size 10 No. Part No. Size

26 333185 0.026 46 328532 0.046

29 328529 0.029 48 328533 0.048
32 328530 0.032 49 328527 0.049
33 328124 0.033 52 328528 0.052
34 328574 0.034 53 328534 0.053
35 326064 0.035 54 322293 0.054
36 323637 0.036 56 326858 0.056
37 329069 0.037 58 320820 0.058
38 322752 0.038 66 326634 0.066
39 329954 0.039 68 326524 0.068
40 321742 0.040 70 326635 0.070
42 326522 0.042

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1-48 4C/eng E
Heli-Coillnserts and Installers
OJ Use these Heli-Coil inserts on all models to repair damaged
threads. The installation kit consists of drill, tap, and insertion
tools.

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

Installation Instructions

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 one-

quarter 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 Name of Part PIN Name of Part

391436 He Ii-Coil Installer Kit, 8-32 391448 Heli-Coillnserts, 8-32

391438 Heli-Coillnstaller Kit, 10-24 391447 He Ii-Coil Inserts, 10-24
391439 Heli-Coillnstaller Kit, 114-20 391446 He Ii-Coil Inserts, 114-20
391440 Heli-Coillnstaller Kit, 5/16 -18 391445 Heli-Coillnserts, 5116-18
391441 Heli-Coillnstaller Kit, 3/s-16 391444 He Ii-Coil Inserts, %-16
391450 Heli-Coillnstaller Kit, 1/2-13 391449 He Ii-Co il Inserts, 1/2-13
984963 Heli-Coillnstaller Kit, 314-16 913412 Heli-Coillnserts, 314-16
391437 Heli-Coillnstaller Kit, 14 mm 437948 Heli-Coillnserts, M5 x 0.8
437276 Heli-Coillnstaller Kit, M5 x 0.8 437949 Heli-Coillnserts, M6 x 1.0
437277 Heli-Coillnstaller Kit, M6 x 1.0 437280 He Ii-Coil Inserts, M8 x 1.25
437278 Heli-Coillnstaller Kit, M8 x 1.25 437950 Heli-Coillnserts, M10 x 1.50
437279 Heli-Coillnstaller Kit, M10 x 1.50 391443 He Ii-Coil Inserts, 14 mm (3!s in. Reach)
391442 Heli-Coillnserts, 14 mm (112 in. Reach)

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4Cle ng 1-49 E
 Fuel System
Table of Contents

& General Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 2

Service Specifications ............................. 2- 3
Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 5
Description of Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . 2- 6
In-Line Fuel Filter Servicing . . . . . . . . . . . . . . . . . . . . . . . . 2- 7
Shut-Off Valve - 3, 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 7
In-Line Fuel Filter/Shut-Off Valve - 2, 2.3, 3.3 . . . . . . . . . . 2- 7
Fuel Tank Servicing - 2, 2.3, 3.3. . . . . . . . . . . . . . . . . . . . . 2- 8
Integral Fuel Tank Servicing - 3. . . . . . . . . . . . . . . . . . . . . 2- .9
Fuel Pump Servicing .............................. 2-10
Carburetor Cleaning and Inspection - All Models ....... 2-12
Carburetor Servicing - 2, 2.3, 3.3 .................... 2-14
Carburetor Adjustment - 2,2.3,3.3 .................. 2-17
Carburetor Servicing - 3 thru 4 Deluxe . .............. 2-18
Carburetor Servicing - 5 thru 8 . . . . . . . . . . . . . . . . . . . . . 2-25
Intake Manifold Servicing - 3 thru 8 . . . . . . . . . . . . . . . . . 2-29
Fuel System Trouble Check Chart . . . . . . . . . . . . . . . . . . . END

4C/eng 2-1
 & 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 rotat-
ing 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 4C/eng
 Service Specifications
Special Torque Chart _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

Description In. Lbs. N·m Adhesive

Leaf Va Ive Screws 25-35 2,8-4,0 OMC Screw Lock

Intake Manifold Screws - 3, 4 96-120 10,8-13,6 •

Intake Manifold Screws - 4 Deluxe thru 8 60-84 7-9 •
Cover & Bowl Screws - 5 thru 8 8-10 0,8-1,2 •
PCE0079

OMC Special Tools Required _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

Orifice Plug Screwdriver, PIN 317002

Float Gauge, PIN 324891
Pressure Test Adapter, PIN 389945
Tie Strap Installation Tool, PIN 323716
Hose Clamp Wrench, PIN 325043
Ball Hex Screwdriver, PIN 327622

Stevens Gearcase Vacuum Gauge, V-34

Stevens Gearcase Pressure Gauge, S-34
Automotive Fuel Pump Testing Gauge
Isopropyl Alcohol
Monoject 412 Syringe, or equivalent
Inch Pound Torque Wrench

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

OMC 2+4® Fuel Conditioner

OMC Cleaning Solvent
OMC Engine Tuner
OMC Locquic Primer
OMC Nut Lock
OMC Ultra Lock
Gasoila Sealer
OMC Screw Lock
OMC Carbon Guard'" Fuel Additive
OMC Carburetor and Choke Cleaner

4C/eng 2-3
NOTES

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2-4 4C/eng
 Fuel Requirements

Minimum Octane

Models Recommendation (R+M)/2 "AKI" "RON"

2-8 See fuel classifications below. 67 69

PCE0020

Preferred Fuel: Any regular unleaded, regular leaded, or premium unleaded gasoline having the
recommended octane rating, and not extended with alcohol.

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 Fuelor 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.

4C/eng & Safety Related 2-5

Description of Fuel System
2,2.3,3.3 .

rv 1. The fuel system consists of a fuel tank mounted on the

~ powerhead, a fuel filter and shut-off valve assembly, and a
carburetor. Fuel flows, gravity-fed, from the fuel tank to the
carburetor.

3 Thru 8

~ 1. The fuel pump is of the diaphragm-displacement type and is

~ operated by changes in crankcase pressure. Alternately, suc-
tion and pressure in the crankcase are transmitted to the pump
diaphragm.

rJl 2. The carburetor meters and distributes the fuel to be con-

~ sumed. It controls engine speed and power output by varying
the intake charge density. To react correctly to a wide range of
operating conditions, the carburetor has multiple fuel mixing
circuits.

~ 3. Mixture enrichment for cold starting is controlled by a choke

@.

2-6 4C/eng
In-Line Fuel Filter Servicing

(";l Replace the filter during the 20-Hour Check. Thereafter,

l!Jchange the filter seasonally or every 100 hours.

Shut-Off Valve - 3, 4
r&1 Disconnect linkage to shut-off valve. Remove gum and varnish
~ deposits by washing in OMC Cleaning Solvent.

In-Line Fuel Filter/Shut-Off Valve - 2, 2.3, 3.3

f711. Loosen clamp securing filter and valve, and remove from
~tank.

2. Clean all parts of the filter/valve assembly with a mild aerosol

solvent, and blow dry. Do not dry parts with a cloth as lint might
stick to the parts and clog the screen. Dissolve any gummy
deposits with OMC Cleaning Solvent.

3. In-line fuel filter/shut-off valve is serviced as a complete

assembly only.

4C/eng 2-7
Fuel Tank Servicing - 2, 2.3, 3.3
"'" Drain and flush the fuel tank at least once a year and at every
i l l tune-up or major repair. Drain tank at an outdoor location,
away from all possible sources of ignition.

Removal

GJ 1. Shut off fuel supply at fuel shut-off valve @ .

f21 2. Remove upper engine cover by unsnapping the hold-down
~ levers.

1al 3. Start removing the lower engine covers by removing the

~ four side screws.

~~ 4. Finish removing the lower engine covers by removing

L!J EI the six screws from the front and bottom. .

~ 5. Disconnect fuel hose at carburetor.

0 6. Remove two screws attaching the fuel tank to powerhead.

~ 7. ~en:'0ve shut-off valve from fuel tank. Lift the fuel tank and
I.!J dram It.

Cleaning and Inspection

1. Inspect fuel tank and shut-off valve for leakage. If leakage

occurs, replace component.

2. Remove fuel filter from the shut-off valve and clean it. Replace
assembly if clogged.

3. Inspect cap for damage or leakage. Replace, if necessary.

4. Flush tank with clear gasoline or solvent.

& Safety Related 2-8 4C/eng

Installation

1. Assemble the shut-off valve to the fuel tank.

2. Install fuel tank on powerhead. Tighten screws to a torque of

60-84 in. Ibs. (7-9 N·m).

3. Connect the fuel hose to the carburetor with a tie strap using
OMC Tie Strap Installation Tool, PIN 323716.

[!] 4. Make certain water indicator hose @ is in position.

f1l 5. Make certain shut-off valve is at OFF position. Place star-
~ board engine cover on powerhead and align the shut-off valve
in position. Tighten two screws to hold cover.

6. Install the port engine cover and all attaching screws.

Integral Fuel Tank Servicing - 3

Removal

1. Remove the lower engine covers.

"" 2. Avoid accidental starting of engine while servicing; twist

~ and remove spark plug leads.

'" 3. Disconnect fuel hose at the carburetor. Fuel will flow from
~ the hose when disconnected. Plug the hose with a smooth
object.

19l 4.
Remove the three screws holding the fuel tank to the
~ mounting brackets. Lift off the fuel tank.

Cleaning and Inspection

1. Inspect filler cap and gasket for wear, damage, or leakage.

Replace, if necessary.

2. Disconnect fuel filter and inspect for clogging. Replace, if dirty.

3. Inspect fuel tank. If it leaks, replace tank.

4. If tank is in good condition, flush it with clear gasoline or

solvent.

Installation

1. Place the fuel tank on the two mounting brackets and secure
with the three screws.

2. Connect the fuel hose to the carburetor with a tie strap using
OMC Tie Strap Installation Tool, PIN 323716.

3. Connect the spark plug leads to the spark plugs. Install the E
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4Cleng & Safety Related 2-9

ii
E
Fuel Pump Servicing

Before replacing a suspect fuel pump, remove and clean the fuel
filter and install a new filter element. 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 pump.

[!] To service filter, loosen the screw and remove the cover @.

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

W • Install filter with its lip facing the gasket ©
• Install the cover and tighten its screw securely.

Function Test

Conduct this test with the motor in a test tank or on the boat.
41145
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 cm) below fuel pump.

W 1. Remove carburetor to fuel pump hose. Connect a fuel

pressure gauge (obtain locally) between the carburetor and fuel
pump.

2. Start motor and observe gauge. Pump pressures should read

as follows:

63328
Pressure
RPM PSI kPa
600 1 7

2500-3000 1.5 10

4500 2.5 17

PCE0072

3. If fuel pump does not meet these specifications, replace it .

• When installing a newfuel pump, apply OMC Nut Lock to

threads of screws. Install screws and torque to 24-36 in.
Ibs. (2,8-4,0 N·m).

2-10 4C/eng
 NOTES

4Cleng 2-11
Carburetor Cleaning and Inspection - All Models
Cleaning

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.

Inspection DR3584

1. Inspect the inlet needle and float valve seat:

W • Check the inlet needle tip for grooves, nicks, scratches, or

distortion.

W • Check float valve seat for nicks, scratches, or distortion.

• Check float for signs of oil or gasoline saturation.

INote I Inlet needle and float valve seat must be replaced as a set.
rn 2. 2,2.3,3.3 - Inspect tapered jet needle for nicks, scratches,
grooves, or signs of distortion.

rn 3. 3 thru 8 - Inspect tapered end of needle valve for nicks,

scratches, grooves, or signs of distortion.
DR3595

63324
2-12 4C/eng
[ ] ] 4. Check all carburetor body drillings and passages with a
syringe filled with isopropyl alcohol.

5. Visually inspect all gasket surfaces for nicks or irregularities.

6. Check for excessive throttle shaft play. Check for throttle valve
misalignment.

7. If necessary, remove the calibration pocket core plug to inspect

the pocket for damage or restrictions:

W • Drive a small punch not more than 1/a in. (3 mm) through
plug and pry out.

• Install a new core plug with its convex side up. Securely
flatten plug with a flat end punch and plastic mallet.
Apply Gasoila sealer to the rim of plug.

8. If necessary, remove the lead shot to inspect passage for

restrictions or leaks:

rn • Gently pry up on lead shot with a sharp-edged tool.

[!] • Install a new lead shot. Flatten shot with flat end punch
and plastic mallet. Check for leakage.

[]J 9. Check for leaks between emulsion pickup tube and carbu-
retor 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 @.

4C/eng 2-13
Carburetor Servicing - 2, 2.3, 3.3
Removal

& 1. Avoid accidental starting of engine while servicing; twist

and remove spark plug leads.

IT] 2. Shut off fuel supply at fuel shut-off valve @ .

3. Remove the engine covers as described in Fuel Tank Servicing .

4. Remove the knobs from throttle and choke levers.

5. Remove two screws and lift air silencer from carburetor.

W 6. Disconnect the fuel hose ® from the carburetor.

W 7. Loosen clamp screw © and remove carburetor assembly.

Disassembly

W 1. Remove the screw @ and discard gasket @.

rn 2. Remove two float chamber screws ®. Turn carburetor

assembly upside down and lift float chamber @ from carburetor
body.

[]] 3. Remove float ® from carburetor body. Remove and

discard float chamber gasket.

[]] 4. Remove main jet Q) and needle jet ® .

[]] 5. Remove slow speed adjustment screw © and spring @Y .

& Safety Related 2-14 4C/eng

W 6. Remove float pin and float hinge. Remove float valve.

rn 7. Remove valve seat CD.

8. Remove throttle lever.

rn 9. Remove carburetor body cap.

rn 10. Compress spring
throttle valve .
® and unhook throttle cable @ from

[!Q] 11. Remove jet needle @ and retainer ® from throttle valve.
12. Refer to Carburetor Cleaning and Inspection.

Assembly

INotel 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.

[!Q]1. If clip ® is removed from jet needle @, refer to Carburetor

Adjustment to determine correct slot.

[!Q] 2. Assemble the jet needle in throttle valve.

[!Q] 3. Place retainer ® in throttle valve, over the clip. Align

retainer slot with the slot in the throttle valve.

rn 4. Place spring ® over throttle cable @. Compress spring

and slide anchor (f) of throttle cable through slot into pocket in
bottom of throttle valve.

rn 5. Position throttle valve so that slot slides over alignment

pin, and slide throttle valve assembly into carburetor body.
Tighten cover.

rn 6. Install throttle lever @. Place throttle lever in front of

holder. Position the support tab on the hole of holder @, and
tighten screw.

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25373 :::::
4Cle ng 2-15
2, 2.3, 3.3
IT!] 7. Install valve seat.

[g] 8. Place float valve @ into valve seat, and install float hinge
® and pin.

~ 9. Install needle jet © and main jet @ .

[}l]10. Install slow speed adjustment screw ® with spring on
carburetor body.
14
11. Install a new float chamber gasket. DRC3548

[1!] 12. Check for correct positioning of float hinge. Float level
controls the height of fuel in the float chamber and is critical to
carburetor calibration and function. Top of float hinge should be
0.090 in. (2,3 mm), measured from the top of the gasket.

[j1] 13. Install float.

[lID 14. Install float chamber on carburetor body.

15. Using a new gasket, install drain screw on float chamber.

Installation

&. Replace any fuel hose or fuel hose clamp if deteriorated or

damaged.

1. Install new O-ring into carburetor throat.

[lru2. Slide carburetor onto crankcase and tighten the clamp

screw ® .

3. Connect the fuel hose to carburetor with a tie strap using OMC
Tie Strap Installation Tool, PIN 323716.

4. Install air silencer on carburetor.

5. Install knobs on throttle and choke levers.

6. If removed, connect the stop switch wires.

7. Install eng ine covers as described in Fuel Tank Servicing.

& Safety Related 2-16 4C/eng

Carburetor Adjustment - 2, 2.3, 3.3
Idle Speed Adjustment
For accurate results, test run the engine in the water on the
customer's boat.

& 1. Start engine and run it at half throttle until it reaches

operating temperature before making adjustment. Inspect engine
for gasoline leaks.

[JJ 2. Run engine at slow speed, and adjust the slow speed
adjustment screw @ until the engine runs in the range of
1100-1300 RPM. Allow 15 seconds for the engine to respond to
adjustment. CD
Throttle Jet Needle Adjustment

rn The carburetor is equipped with a throttle valve that uses a

tapered jet needle to vary the fuel flow as the carburetor is
opened. Normally, the clip is in the third groove ®. Relocating the
clip to the first or second groove of the jet neeCJle will lean the
mixture.

The first indication of too rich a mixture is a decrease in RPM as

the carburetor is opened beyond 0/3 throttle. So, maximum RPM
will occur at less than wide open throttle.

If the mixture is too rich, change the clip position on jet needle as
follows:

1. Remove carburetor as described in Carburetor Removal.

2. Disassemble throttle valve assembly. Refer to Carburetor

Disassembly. [IJ---------==:-==-I DR3595

3. Relocate the clip one groove closer to the flat end of the jet
needle. CD Leaner
Q) Richer
4. Reassemble the carburetor. Refer to Carburetor Assembly.

5. Install carburetor as described in Carburetor Installation.

4C/eng & Safety Related 2-17

2, 2.3, 3.3
Carburetor Servicing - 3 thru 4 Deluxe
Removal - 3, 4

&. 1. Avoid accidental starting of engine while servicing; twist

and remove spark plug leads.

OJ 2. Remove choke knob and stop button retainer nut.

rn 3. Remove two top fore and aft lower cover retaining screws.

WW 4. Remove bottom fore and aft lower cover retaining

screws. Remove aft cover.

[]J 5. Remove tie strap and fuel hose from connection in lower
cover. Remove cover.

m 6. Remove two air silencer screws and air silencer.

[ [ ] 7. Disconnect choke linkage.

& Safety Related 2-18 4C/eng

rn 8. Remove roll pin for fuel shut-off valve, and remove
shut-off valve.

W 9. Remove fuel hose(s) from carburetor.

[!QJ 10. Remove screw, cam follower, and link.

[I1] 11. Remove two nuts, carburetor, and gasket.

~ 12. If necessary, remove intake manifold screws, manifold

®, leaf plate ®, and gaskets.
13. Refer to Disassembly.

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4C/eng 2-19
3 - 4 Deluxe
Installation - 3, 4

1Note 1 The air gap between the ignition module and flywheel
must be verified after torquing the intake manifold screws. Refer
to Section 3, Ignition Component Replacement - 3, 4.

\ Note I Do not use sealer on intake manifold or carburetor gaskets.

& Replace any fuel hoses or fuel clamps if deteriorated or

damaged.

1. Attach the leaf plate and intake manifold using new gaskets. 10119

Torque screws to 96-120 in. Ibs. (10,8-13,6 N·m).

2. Using a new gasket, place the carburetor in position and secure

with nuts. Connect the fuel hose(s) to the carburetor with a tie
strap using OMCTie Strap Installation Tool, PIN 323716.

3. Install cam follower and link.

4. Install fuel shut-off valve.

[1l] \Note\ Make sure both O-rings are in place while installing
the fuel shut-off valve. 25985

1141 5. Engage choke assembly and choke shaft.

6. Install control panel.

7. Install choke and stop switch nut.

& 8. Coat screw threads with OMC Screw Lock, and install
carrying handle. Torque screws to 60-84 in. Ibs. (7-9 N·m).

9. Refer to Synchronization and Linkage Adjustments, Section 1.

& Safety Related 2-20 4C/eng

Removal - 4 Deluxe
& Avoid accidental starting of engine while servicing; twist
and remove spark plug leads.

1. Remove low speed adjustment knob by pulling it straight out.

0] 2. Remove retaining ring on choke knob. Pull knob out

through hole in lower engine cover.

rn 3. Remove screw @ cam follower ® and link.

4. Disconnect the fuel hose at the carburetor.

rn 5. Remove two nuts, carburetor, and gasket.

rn 6. If necessary, remove intake manifold screws, and remove

leaf assembly @ and gaskets ® from the powerhead.

7. Refer to Disassembly.

Installation - 4 Deluxe

INote I Do not use sealer on intake manifold or carburetor gaskets.

& Replace any fuel hoses or fuel hose clamps if deteriorated or
damaged.

rn 1. Attach the leaf plate @ and intake manifold © using new

gaskets ® Tighten screws to a torque of 60-84 in. Ibs. (7-9 N·m).

rn 2. Using a new gasket, place the carburetor in position and

secure in place with nuts. Connect the fuel hose to the carburetor
with a tie strap using OMC Tie Strap Installation Tool,
PIN 323716.

rn 3. Install cam follower and link.

rn 4. Install choke knob and retaining ring.
5. Install low speed adjustment knob.

6. Refer to Synchronization and Linkage Adjustments, Section 1.

4C/eng & Safety Related 2-21

3 - 4 Deluxe
[JJ Disassembly - 3 t hru 4 Deluxe

1. Remove four screws @ , and separate float chamber ® from

carburetor body @. Remove and discard float chamber gasket @.

2. Remove low-speed packing nut @ , then remove needle valve

®. Carefully, remove packing @ from carburetor to avoid damag-
ing threads in carburetor body.

3. Remove roll pin @ , and remove fuel shut-off valve Q) (if

equipped). Remove O-rings Q) .

4. Remove fuel pump bladder ® by unscrewing fuel pump nipple

© (if equipped).
5. Remove hinge pin ~ , float @, float valve @, and spring clip ® .
Unscrew valve seat and gasket @ .

6. Remove high-speed orifice plug @ .

7. Remove high-speed nozzle @ .

8. Refer to Carburetor Cleaning and Inspection.

[JJ Assembly - 3 thru 4 Deluxe 802004

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 nozzle @ into carburetor body and

t ighten. Install orifice @ in high-speed nozzle.

2. Replace float valve seat and gasket @ , float valve @, float @,

spring clip ®, and hinge pin ~ in carburetor body @.

3. Check for correct positioning of float level. Float level controls

the height of fuel in the float chamber and is critical with regard to
carburetor calibration and function.

m• Turn carburetor body upside down and hold so gasket

surface is horizontal. The weight of the float will close
the float valve needle. Rest OMC Float Gauge,
PIN 324891 (f) , on gasket surface and slide gauge up,
next to float. Top of float should be between notches @
on gauge.

m Use notch that is indicated "2 thru 6 HP." Be certain gauge is

not holding down the float.
93327

• 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.

2-22 4C/eng
W 4. 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.

5. Replace fuel pump bladder® and nipple © (if equipped).

6. Place two new O-rings(.i) on fuel shut-off valve CD (if equipped).

Install O-rings on shut-off valve with a light film of oil. Install
assembly in the bowl with a twisting motion as you push it in.
This will prevent damage to O-rings. Install roll pin ® . 3 813000

® Base of carburetor body

7. Install a new float chamber gasket@.
@ Bend float lever tab to
8. Install the float chamber ® to the carburetor body ©. Install achieve proper dimen-
float chamber screws ®. Tighten screws in an "x" pattern to a sion.
torque of 15-22 in. Ibs. (1,6-2,4 N·m). ® 1118 to 1112 in. (28-38 mm)

9. Install cam follower linkage.

10. Install new packing washers @ in carburetor body. Install

needle valve packing nut ®, but do not tighten against the
packing .

11 . Carefully, install needle valve ® , turning clockwise, carefully,

until it is seated lightly. Turn the needle counterclockwise one
turn .

12. Tighten the packing nut® against the packing until the needle
can just be turned with finger pressure. The needle valve will be
adjusted after the carburetor has been installed on the engine.

4C/eng 2-23
3 - 4 Deluxe
NOTES

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2-24 4C/eng ~
.s:::
Carburetor Servicing - 5 thru 8
Removal

& Avoid accidental starting of engine while servicing; twist

and remove spark plug leads.

1. Remove starter. Refer to Section 7.

m 2. Remove two screws retaining air silencer. Remove air

silencer.

[]J 3. Remove the bell crank retaining screw.

rn 4. Remove fuel hose.

W 5. Remove two nuts retaining the carburetor. Disconnect fuel

hoses and remove carburetor.

6. If necessary, remove the cam follower and linkage.

7. If necessary, remove the intake manifold by removing four

retaining screws. Discard gaskets.

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4C/eng & Safety Related 2-25
5-8
 @
@ \
\ ~
~

6
DR4795

[]] Disassembly

1. Remove the low-speed needle ® and spring ® from the

carburetor body cover.

2. Remove the six cover screws. Lift the cover and gasket off the
carburetor body.

3. Remove the seven float chamber screws. Remove the float

chamber and gasket.

4. Remove the hinge pin ©, float @, and float valve @.

5. Remove the valve seat ® and gasket @.

6. Remove the high-speed orifice @ .

7. If necessary, remove the air vent Q) .

8. Refer to Carburetor Cleaning and Inspection.

2-26 4C/eng
[]] Assembly

INotel 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 0
each time you assemble a carburetor.

1. If removed, press the air vent CD in the carburetor body.

2. Install the high-speed orifice @.

3. Install the gasket © and valve seat ®.

4. Install the hinge pin ©, float @ , and float valve @ .
5. Check for correct positioning of float level. The float level
controls the height of fuel in the float chamber and is critical with
regard to carburetor calibration and function.

rn • Turn carburetor body upside down and hold so gasket

surface is horizontal. The weight of the float will close
the float valve needle. Rest OMC Float Gauge,
PIN 324891, on gasket surface and slide gauge up, next
to float. Top of float should be between notches on 8
803406
gauge.

rn 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.

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.

[ [ ] Q) Base of carburetor body

® Bend float lever tab to achieve proper dimension
© 1 in...to 13/s in. (25-35 mm)
7. Place the lower gasket into the float chamber. Install the float
chamber and bowl gasket. Tighten the screws to a torque of 8-10
in. Ibs. (0,8-1,2 N·m), following sequence embossed on float
chamber.

8. Install the carburetor body cover and gasket. Tighten the

screws to a torque of 8-10 in. Ibs. (0,8-1 ,2 N·m), following
sequence embossed on cover.

9. Install the low-speed needle and spring. Turn needle carefully

until it lightly contacts the seat; then back it off 3 turns.

4C/e ng 2-27
Installation

INote I Do not use sealer on intake manifold or carburetor gaskets.

&. Replace any fuel hoses or fuel hose clamps if deteriorated or
damaged.

1. If removed, install the intake manifold and leaf plate assembly.

Install new gaskets dry; use no sealer. Torque screws to 60-84 in.
Ibs. (7-9 N·m).

[!Q]2. Install the carburetor using a new gasket. Tighten nuts

securely.

[TIl 3. Connect fuel hose to carburetor.

[}II 4. Install the bell crank retaining screw.

[ll] 5. Install air silencer using two retaining screws.

6. Refer to Synchronization and Linkage Adjustment, Section 1.

& Safety Related 2-28 4C/eng

Intake Manifold Servicing - 3 thru 8
Removal

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

2. Remove the screws securing intake manifold to crankcase.

5 thru 8 - Remove two screws securing leaf plate to crankcase.
Inspection

INotel Do not lift or bend leaf valves by hand. This may damage
them so that they may not seal properly or may break after the
engine is returned to service.

1. Inspect the leaf plate assemblies for damage:

• The leaf valves and plate must not be distorted.

• The leaf valve tips must not be cracked or chipped .

• The leaf stops must not be distorted or loose.

rn • the
Use a machinist's straightedge to check the flatness of
leaf plate. The gasket surfaces must be flat,
± 0.003 in. (0,08 mm).

rn 2. 5 thru 8 - Inspect the check valve.

3. Inspect the intake manifold:

• All gasket surfaces must be smooth and free of nicks.

• Use a machinist's straightedge to check for flatness in all

directions. The gasket surfaces must be flat, ± 0.003 in.
(0,08 mm).
Disassembly

I Note I Do not disassemble leaf plate assemblies unless leaf plate

seats, leaf valves, or leaf stops are damaged or corroded.

rn 1. Remove the screws and leaf valve.

2. When disassembled, keep the stops and leaf valves separated
by assembly.

38810

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4Cleng 2-29 E
Assembly

I Note I All intake manifold components must be perfectly clean

before assembly. Do not use a strong carburetor cleaner or hot
soaking tank.

[[] 1. Place leaf valves on leaf plate. If new valves do not seat on
the leaf plate, turn the leaf valves over.

I Note I Used leaf valves must not be turned over for reuse. Leaf
valve may break when returned to service, causing serious
powerhead damage.

2. If any leaf valves are standing open, apply light pressure using
a pencil eraser. If leaf valve closes with light pressure, valve is
acceptable. If not, inspect leaf plate for high spots or burrs.

I Note I Do not lap leaf plate. If plate is too smooth, the leaf valves
may stick closed after off-season storage.

3. Apply OMC Locquic Primer to mounting screws and allow to air

dry.

4. Apply OMC Screw Lock to mounting screws. Wipe off excess

adhesive.

5. Assemble leaf valve shim (if required) and leaf stop. Install
screws finger tight.

[]] [ [ ] 6. Center the leaf valves on the plate using index marks.

7. Tighten screws to 25-35 in. Ibs. (2,8-4 N·m).

Installation

[]] 1. Position leaf plate assembly and new gaskets on

powerhead. Install gaskets dry. Use ho sealer. Install intake
manifold using retaining screws. 5 thru 8- Apply OMC Gel-Seal II
to the two center screws securing the leaf plate to the crankcase.
Torque intake manifold screws to:

• 3,4- 96-120 in. Ibs. (10,8-13,6 N·m)

• 4 Deluxe thru 8- 60-84 in. Ibs. (7-9 N·m)

INotel 3, 4 - The air gap between the ignition module and

flywheel must be verified after torquing the intake manifold
screws. Refer to Section 3, Ignition Component Replacement -
3,4.

2-30 4C/eng
ENGINE
STARn
WILL" NI
SPITS ~

ENGINE
EXCES~

STALLS
SURGE:
RUNS F
LOSS Q
CARBU!

4C

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 FUEL SVSTE

REFER TO REFER TO REFER TO REFER

SECTION 1 PAGES
OWNER MANUAL
*
* REFER TO ACCESSORIES SERVICE MANUAL
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M TROUBLE CHECK CHART

TO REFER TO
:1l-12 THRU 2-28 PAGE 2-29
 Ignition System
Table of Contents

&. General Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 2

Service Specifications ....... . ......... .. .. . . . ... . . 3- 3
About This Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 5
Spark Plug Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 6
Flywheel Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 8
Ignition Coil Tests .. . .. . . .. ..... . . . .......... . .... 3-10
Troubleshooting Test Equipment .... . ............... 3-13
Amphenol Connectors, Servicing Information .......... 3-14
CD II Ignition System - 4 Deluxe thru 8
Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Ignition Plate Servicing .......................... 3-18
Ignition Component Replacement .................. 3-19
Ignition Coil Replacement. . . . . . . . . . . . . . . . . . . . . . . . 3-20
Ignition Output Tests - CD II . . . . . . . . . . . . . . . . . . . . . . 3-22
Indexing Flywheel - Erratic Ignition - 3 thru 8 . . . . . . . . . 3-32
CD Ignition System - 3, 4
Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Ignition Plate Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Ignition Component Replacement. . . . . . . . . . . . . . . . . . 3-36
Ignition Output Tests ............................ 3-37
Indexing Flywheel - Erratic Ignition. . . . . . . . . . . . . . . . . 3-32
CD Ignition Output Tests - 2, 2.3, 3.3 . . . . . . . . . . . . . . . . . 3-44

4C/eng 3-1
 & 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 rotat-
ing 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.

3-2 4C/eng
 Service Specifications

Component Specifications _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

Ignition Coil Charge Coil Sensor Coil Ignition Modulel

Power Pack

Min. Output Voltage

Primary Secondary
Ohms Ohms
Ohms Ohms Cranking Running

2,2.3,3.3 0.1 ± 0.05 275 ± 50 610 ± 60 50 ± 10 180 220

3,4 0.1 ± 0.05 275 ± 50 NA 100 ± 15 125 150

4 Deluxe 0.1 ± 0.05 275 ± 50 900 ± 100 40 ± 10 175 200

6 thru 8 0.1 ± 0.05 275 ± 50 900 ± 100 40 ± 10 175 200

PCE0042

DESCRIPTION IN. LBS. FT. LBS. N'm ADHESIVE

Spark Plug - All 216-240 18-21 24-27 •

Ignition Module
Screws - 3, 4 30-40 • 3,4-4,5 OMC Ultra Lock

Charge Coil
Screws - 3, 4 30-40 • 3,4-4,5 OMC Ultra Lock

Flywheel Nut - OMC Gasket Sealing

3, 4, 4 Deluxe • 30-40 40-54 Compound

Ignition Coil
Screws - 3 thru 8 48-96 • 5,4-10,8 •
Ignition Support
Plate Screws - 3 thru 8 48-60 • 5-7 OMC Nut Lock

Ignition Plate to Retainer

Plate Screws - 3 thru 8 25-35 • 2,8-4,0 OMC Nut Lock

Charge Coil
Screws - 4 Deluxe thru 8 15-22 • 1,6-2,4 •
Sensor Coil
Screws - 4 Deluxe thru 8 15-22 • 1,6-2,4 •
Power Pack
Screws - 4 Deluxe thru 8 60-84 • 7-9 • E
o
Flywheel Nut - OMC Gasket Sealing o
~
6 thru 8 • 40-50 54-70 Compound )(

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PCE0041 ~
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4C/eng 3-3 E
Special ~rqueChart -2,2.3 , 3 .3 ~~~~~~~~~~~~~~~~~~~~~~~~.

DESCRIPTION IN. LBS. FT. LBS. N'm ADHESIVE

Spark Plug 216-240 18-21 24-27 •

Flywheel Nut • 29-33 40-45 OMC Gasket Sealing
Compound

Ignition Coil Screws 62-89 • 7-10 •

Armature Plate Screws 27-44 • 3-5 OMC Screw Lock

OMC Special Tools Required ~~~~~~~~~~~~~~~~~~~~~~~~~~_

Universal Puller Kit, PI N 378103 - All

Socket Removal Tool, PI N 322699 - All
Pin Removal Tool, PI N 322698 - All
Insert Tool, PI N 322697 - All
Crimping Pliers, PIN 322696 - All
Flywheel Holder, PI N 115315 - 2, 2.3, 3.3
Puller Screw, PIN 115308 - 2, 2.3, 3.3
Flywheel Holder, PIN 333827 - 3, 4
Locating Ring, PIN 334994 - 4 Deluxe thru 8
Piston Stop, PIN 384887 - 5 thru 8

Sealants and Lubricants Required ~~~~~~~~~~~~~~~~~~~~~~~~_

OMC Gasket Sealing Compound

OMC Moly Lube
OMC Black Neoprene Dip
OMC Cleaning Solvent
OMC Nut Lock
OMC Ultra Lock
OMC Triple-Guard@Grease
OMC Electrical Grease
Evinrude@ or Johnson @Outboard Lubricant
Isopropyl Alcohol
Scotch-Grip Rubber Adhesive 1300

Stevens Flywheel Strap Wrench No. S-17, or equivalent

Snap-On Holding Fixtu re No. A-144, or equivalent
Spark Tester
Peak-reading Voltmeter
Stevens Terminal Extenders No. TS-77, or equivalent
Stevens Load Adaptor No. PL-88, or equivalent
Ohmmeter
Jumper Wire
Ignition Analyzer

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3-4 4C/eng E
About This Section
The information in this section of the Service Manual has been
organized 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. It includes:

• A brief review of the principles of operation for OMC's

CD II ignition system, Page 3-16.

• A listing of available troubleshooting test equipment,

Page 3-13.

• A brief review of spark plug information, Page 3-6.

• Servicing flywheels, flywheel and crankshaft tapers,

Page 3-8.

• Flywheel Nut Torque Chart, Page 3-9.

• A review of all testing procedures for ignition coils, Page

3-10.

• An Ignition Coil Specification 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, select
the appropriate area in the section (by model) and begin your
testing with Ignition Out put Tests.

3. If you are working on an engine where the ignition problem

creates an intermittent high speed miss or inconsistent running
qualities above cranking RPM, refer to Indexing Flywheel, Erratic
Ignition, Page 3-27.

4C/eng 3-5
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 cover, apply a light coating of OVIC Electrical Grease to the
ribbed portion ofthe spark plug ceramic and to the opening ofthe
spark plug cover. This will help prevent corrosion of the spring
terminal and the spark plug, which can cause high tension arcing.

Spark Plug, Champion

Models Recommended Extended Idle

2,2.3,3.3 L87YC •
3,4 OL86C L90C

4 Deluxe OL86C L90C

5-8 OL86C L92YC*

* All models except 8RC

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

3-6 4C/eng
 NOTES

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• 4C1eng 3-7 E
Flyw heel Servicing
~ 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 re-
placement of ignition components.

Flywheels rarely go bad and would only be replaced as a last 10260

resort in solving an ignition problem .

Removal

'" 1. To avoid accidental starting of engine, twist and remove

i l l all spark plug leads.

[!] 2. 2, 2.3, 3.3 - Remove the starter pulley from flywheel.

f2l 3. 2, 2.3, 3.3 - Remove the flywheel nut using OMC Flywheel
~ Holder, PIN 115315.

rJl 4. 3,4 - Remove the flywheel nut using OMC Flywheel Holder,
~ PIN 333827.

f41 5. 4 Deluxe - Remove the flywheel nut using a strap wrench to

~ hold the flywheel.

f51 6. 5 thru 8 - Install OMC Piston Stop, PIN 384887, in No.1

~ spark plug hole. Lock the tool in place with ring. Slowly rotate
the crankshaft counterclockwise until piston contacts the piston
stop. Remove the flywheel nut.

1sl 7. All Models - Apply OMC Moly Lube to threads of pressing

~ screw and center hole of crankshaft.

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& Safety Related 3-8 4C/eng

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1]1 8. From OMC Universal Puller Set, PIN 378103, assemble the
~ following components:

@ Body, PIN 307636

® Pressing Screw, PIN 307637
© Handle, PIN 307638
@ Screws (3), PIN 307641 - 3 thru 8
• Screws (3), PIN 115308 - 2, 2.3, 3.3
® Washers (3), PIN 307639 - 3 thru 8
• Washers (3), PIN 307646 - 2, 2.3, 3.3

f71 9. Install the puller @ on flywheel with body flat side up. Seat
~ the shoulder screws completely. Hold puller with its handle ©
and tighten pressing screw ® until flywheel releases.

10. Remove the flywheel.

Installation

1. Install the flywheel key as follows:

!al2, 2.3, 3.3 - Install the flywheel key ® with its outer edge
~ parallel to centerline of crankshaft.
8
19l3 thru 8 - 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 OMC Cleaning

Solvent and let dry. These surfaces must be clean and dry to
allow proper locking of the tapers.

3. Align the flywheel keyway and install flywheel. Coat the

threads of the flywheel nut with OMC Gasket Sealing Compound.
Install the nut and torque to the correct value. See chart below.

Flywheel Nut Torque Chart 9

DR2116

MODELS FT. LBS. N·m ADHESIVE

2,2.3,3.3 29-33 40-45

OMC Gasket
3, 4, 4 Deluxe 30-40 40-54 Sealing
Compound
5-8 40-50 54-70

PCE0040

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4C/eng 3-9 E
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 the manual of the ignition tester you are using for coil
specifications. Specifications will vary among testers.
1
Ignition coil must be removed from powerhead for power and DR4037

leakage testing .

&. To 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 Analyzer
Models Resistance Resistance Amps (Max.) Polarity

Merc-O- Tronic
1.5 amps
2-8 0.1 ± 0.05 n 275 ± 50 n Normal
Stevens DR4038
1.1 amps

PCE0043
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.

[JJ 2. Calibrate ohmmeter on appropriate scale. Connect meter

black lead to clean engine ground. If the coil is not mounted on DR4081

the engine, connect meter black lead to ground tab on the coil.
Connect meter red lead to coil primary terminal.

• Meter must show 0.1 ± 0.05 ohm.

rn 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 275 ± 50 ohms.

rn 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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Power Test

INotel Do not exceed the coil's maximum specified amperage

when testing it.

rn The ignition coil is tested with "normal" polarity connec-

tions. 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 Specifica-
tions.

Surface Leakage Test

I Note I Do not exceed the coil's maximum specified amperage

when testing it.

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.

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

4C/eng 3-11
NOTES

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3-12 4C/eng :::
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 1 1942
2
16489

Troubleshooting Test Equipment

~ 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.

[!] 5park testers:

• Stevens No. 521, 513C, or 548
• Merc-O- Tronic No. 55-45 or 55-65 4
~ Peak-reading voltmeters:
• Merc-O- Tronic No. 781
• Stevens No. CD-77
• Electro-Specialties No. PRV-1

[!J Ohmmeter capable of reading low and high ranges:

• Merc-O- Tronic No. 700 VOA
• Stevens No. AT-101

~ Component temperature can affect resistance values at a 5

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

~ Ignition module load adapter:

• Stevens No. PL-88

~ Ignition coil terminal extenders :

fJ ©
\
• Stevens No. T5-77

~ Jumper wire for Amphenol connectors. Can be made with:

@-!/
® No. 16 wire, 8 in. (200 mm) 6
® Pin, OMC PIN 511469 73158

© 50cket, OMC PIN 581656

@ Shrink tube, OMC PIN 510628

4C/eng 3-13
Amphenol Connectors, Servicing Information

Terminal Removal

fN=J Use the recommended lubricant for terminal removal.

~ Substitutes may cause high resistance connections, short
circuits among terminals, or damage to the connector material.

1. To remove a terminal from the plug or receptacle, apply

isopropyl alcohol to the cavity at both ends to lubricate the
terminal.

~ 2. Select the proper removal tool for the terminal:

@ PIN 322698, OMC Pin Removal Tool
® PIN 322699, OMC Socket Removal Tool
f213. Place the plug or receptacle against the edge of a flat surface
~ and allow clearance for the terminal to be removed.

f214. Insert the removal tool into the terminal and push the
~ terminal out of the connector.

'3l5. Pin © and socket @ terminals may be replaced if damaged.

~ Crimp new terminals onto the wire at point @.

f416. Use OMC Crimping Pliers, PIN 322696, when attaching

~ Amphenol terminals.

/ c
@

4
30387

3-14 4C/eng
Terminal Installation

1. Connect the plug and receptacle before installing the terminal.

Apply isopropyl alcohol to the plug and receptacle. Align arrows
and carefully insert the plug into the receptacle.

2. Apply isopropyl alcohol to the terminal cavity.

[]J &. Use only OMC Insert Tool, PIN 322697, to install termi-
nals. To avoid injury, securely hold insert tool against shoulder of
terminal while inserting terminals.

[ ] ] 3. Position the insert tool ® against the shoulder @ of the

terminal.

[ [ ] 4. Rest the connector against a solid surface. With the insert

tool firmly against its shoulder, insert the leading tip of the
terminal into its cavity. Push the terminal until step ® ofthe insert
tool reaches the connector body, seating the terminal.

[]] 5. Check your work. Separate the connector and look at the
terminal you just inserted. If it is properly seated, apply isopropyl
alcohol to both connector halves and reconnect them. If the
terminal did not seat, remove it and repeat the procedure.

II] 6. Secure the connector with wire retainer.

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4C/eng & Safety Related 3-15
30392

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Principles of Operation - CD II

Flywheel

r;] The flywheel contains permanent magnets @ which energize

L!J the charge coil, sensor coil, and alternator stator. Once the
flywheel exceeds a minimum cranking RPM, the flywheel's mag-
netic lines of force pass through the ignition plate components to
produce voltage in those circuits.

The flywheel must be in good condition and correctly located to

ensure proper ignition timing and sufficient charge coil output.

Charge Coil

f21 The charge coil @ consists of many windings of wire wrapped

~ around a metal lamination. Once the flywheel exceeds a
minimum cranking RPM, the flywheel's magnetic lines of force
pass through the charge coil windings to produce approximately
300 volts of alternating current.

This voltage is supplied to the power pack to operate the system.

Sensor Coil

f21 The sensor coil © consists of many windings of wire wrapped

~ around a metal lamination. Once the flywheel exceeds a
minimum cranking RPM, either by manual or electric starter, the
flywheel's magnetic lines of force cutting through the sensor coil
windings produce approximately 3 volts.

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3-16 4C/eng
E
Power Pack

~ The power pack @ has three major functions:

• To receive its operating voltage from the charge coil and
convert it into direct current for storage.

• To store this direct current in a capacitor.

• To use a series of electronic switches (SCRs), activated

by sensor coil output, to select the correct ignition coil
primary winding for firing. The power pack has one SCR
for each ignition coil it controls.

Stop Circuit

'4l The stop button/emergency stop switch ® is connected to the

~ power pack through the engine wiring harness. When acti-
vated, the switch directs the power pack output to ground,
stopping the ignition system.

'4l The steering handle contains a combination stop switch/

~ emergency stop switch device.

• When the clip and lanyard assembly is removed, the

emergency stop switch is in the STOP position.

• When the clip and lanyard assembly is installed, the

emergency stop switch is in the RUN position.

• To STOP the engine when the clip and lanyard assembly

is in place, press inward on the stop button until the
engine stops.

Ignition Coil

f51 Theignition coil ® consists of windings of wire wrapped

~ around a compacted ferrite core. The coil has primary and
secondary terminal connections and a ground plate.

Through mutual induction, the ignition coil transforms the igni-

tion module output to as much as 40,000 volts to fire the spark
plugs.

• There is one ignition coil per cylinder.

4C/eng 3-17
Ignition Plate Servicing - CD II
Removal

l' 1. To avoid accidental starting of engine while servicing,

i l l twist and remove all spark plug leads.
2. Remove the manual starter. See Section 7.

3. Remove the flywheel. Refer to Flywheel Servicing .

f11 4. Loosen the five screws attaching the ignition plate to the
~ retainer plate. Lift the ignition plate from the powerhead.

f21 5. Remove the four support plate screws ® . Lift the retainer
~ and support plates fror,n the powerhead.

Installation

~ 1. Place the retainer plate, then the support plate on the

~ powerhead. Align support plate with four screw holes in
powerhead. Apply OMC Nut Lock to threads of the four support
plate screws® . Install and tighten the screws to a torque of 48-60
in. Ibs. (5-7 N·m).

@] 2. Apply OMC Moly Lube to crankcase boss.

~ 3. Lubricate the ignition plate bearing groove ® with outboard
~ lubricant.

r;l 4. Apply OMC Nut Lock to the threads of the five ignition plate
~ screws. Insert needle-nose pliers into slots in the ignition plate
bearing and compress bearing while guiding the ignition plate
into position.

5. Align the ignition plate with the retainer plate. Tighten the five
screws to a torque of 25-35 in. Ibs. (2,8-4,0 N·m).

6. Connect and adjust spark advance link. Refer to Synchroniza-

tion and Linkage Adjustments, Section 1.

7. Check for sufficient slack on ignition component leads during

full advance movement of the ignition plate.
L

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it Safety Related 3-18 4C/eng

~
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E
Ignition Component Replacement - CD II
'" 1. To avoid accidental starting of engine while servicing,
i l l twist and remove all spark plug leads.
'6l2. Remove the screws retaining the ignition component that is
~ being replaced.

03. Remove the wire clamp © from the ignition plate.

rv from
~
4. Loosen the five ignition plate screws. Lift the ignition plate
the powerhead.

~ 5. Remove the plate @ from bottom of the ignition plate.

6. Remove the leads from the spiral wrap and from the ignition
component.

7. Loosely install the new ignition component on the ignition

plate.

f711sl8. Route leads and install clamp ©, plate @, and spiral

~~wrap.

~ All component leads must be routed through clamp © and

~ plate @ in a single layer, not twisted or crossed over
another lead.

9. Apply OMC Nut Lock to the threads of the five ignition plate
screws. Install the ignition plate on the retainer plate. Torque five
retaining screws to 25-35 in. Ibs. (2,8-4,0 N·m).

10. Check for sufficient slack on ignition component leads. Route

component leads through wire clamps.

1nl11. Position OMC Locating Ring, PIN 334994, over machined

~ bosses on the ignition plate. Push the locating ring in toward
the component to be installed. Hold the ring in place and pull the
component out toward the ring. Tighten screws to a torque of
15-22 in. Ibs. (1,6-2,4 N·m).

~ 12. Repeat Step 11 for each component.

4C1eng & Safety Related 3-19

Ignition Coil Replacement - CD II

Removal

1. Twist and remove cover to remove the spark plug lead and
primary leads from the ignition coil.

2. Notice the fastener and washer orientation before removing

any screws.
1
3. Remove the coil mounting screws and remove the coil and C02960

washers.

Installation

111 f'2l 1. Assemble the correct sequence of washers and locate

~ ~ the ignition coil on the powerhead. Install and tighten the
retaining screws to a torque of 48-96 in. Ibs. (5,4-10,8 N·m).

2. Apply a light coating of OMC Triple-Guard grease to the ribbed

portion of the spark plug ceramics and to the openings of each of
the spark plug lead covers. Install the spark plug leads.
3. Apply a light coating of OMC Triple-Guard grease to the
opening of each primary lead cover and install the covers.
Observe the proper wire routing and ignition timing. The orange/
blue primary lead must be connected to the No.1 ignition coil.

[!] 4 Deluxe
® Fiber Washer
@ Flat Washer
© Ignition Coil Ground Strap
@ Star Washer
DR3630

[3J 5 thru 8
® Flat Washer
@ Ignition Coil Ground Strap
© Star Washer
@ Fiber Washer

3-20 4CJeng
 NOTES

4C/eng 3-21
 IGNITION OUTPUT TESTS - CD II
~ All cranking output tests must be performed with spark
ill plugs installed and torqued in the cylinder head. If neces-
sary to remove the spark plugs, be sure to keep the spark tester
away from open spark plug holes.

R The following series of steps will systematically isolate a

~ problem area in the ignition system. To reduce your trou-
bleshooting time and to avoid incomplete results, perform these
steps in the order written.

STEP 1 - TOTAL OUTPUT TEST

!II 1. Twist and remove the leads from both spark plugs.
r:;] 2. Adjust the gap on the spark tester to V2 in. (12 mm).
~ Connect tester leads to the spark plug leads. Secure tester clip
to a clean engine ground.

~ To prevent possible arcing of high voltage, route tester

~ leads at least 2 in. (51 mm) from any metal surface.
32204

'" To avoid possible shock hazard, do not handle ignition coils

i l l or spark tester during cranking tests.
3. If equipped, install the emergency stop switch clip and lanyard
assembly. Crank the engine. Spark should jump each tester gap
alternately.

• If tester shows good output on both cylinders, go to

STEP 6 - RUNNING OUTPUT TEST.

• If tester shows good output on one cylinder, go to STEP 5

- POWER PACK OUTPUT TEST.

• If tester shows no output, go to STEP 2 - STOP CIRCUIT

TEST.

~ It is possible for the ignition system to have a problem but

~ still produce good output. If the engine "pops" or "back-
fires" during starting, the ignition may be out of time. Check the
following:

• Coil primary wire routing

• Spark plug lead routing

• Flywheel condition and location

• Synchronization and linkage adjustments

& Safety Related 3-22 4C/eng

 DR4185

STEP 2 - STOP CIRCUIT TEST

Elimination Test

it To avoid possible shock hazard, do not handle ignition coils or spark tester during cranking tests.
1. Disconnect 5-pin Amphenol connector between ignition plate and power pack.

~ 2. Insert jumper wires between the "A", "B", "C", and "0" terminals of the 5-pin connector.
3. Crank engine and observe results at spark tester.

• If spark now jumps alternately at each gap, the problem is in the stop circuit. Go to Ohmmeter
Test - Stop Button or Ohmmeter Test - Key Switch.

• If there is no spark at one gap, go to STEP 5 - POWER PACK OUTPUT TEST.

• If there is no spark at both gaps, go to STEP 3 - CHARGE COIL TEST.

4C/eng & Safety Related 3-23

4 Deluxe - 8
Ohmmeter Test - Stop But ton

INotel All ohmmeter tests must be performed with the engine NOT running.
~ 1. Most steering handles contain a combination stop button/emergency stop device.
• When the clip and lanyard assembly is removed, the emergency stop switch is in the STOP
position.

• When the clip and lanyard assembly is installed, the emergency stop switch 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.

2. Install the clip and lanyard.

1sl 3. Calibrate an ohmmeter on appropriate scale. Connect meter leads between ignition plate end of
E.I connector, terminal "E", 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 .

&. 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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Safety Related 3-24 4C1eng
E
 6
DR4618

Ohmmeter Test - Key Switch

INotel All ohmmeter tests must be performed with the engine NOT running.

1. Install emergency stop switch clip and lanyard assembly.

1sl 2. Calibrate ohmmeter on appropriate scale. Connect meter leads between ignition plate end of
~ connector, terminal "E", and a clean engine ground.

• Key OFF, meter must show a low reading.

• Key ON, meter must show a high reading.

3. If Step 2, Key ON reading is a low one, disconnect harness black/yellow leads from key switch "M"
terminal.

• If meter now shows a high reading, test key switch. Refer to Electrical Section.

• If meter shows a low reading, go to Step 4.

4. Separate emergency stop switch lead from harness black/yellow lead at key switch.

• If meter now shows a high reading, test emergency stop switch.

• If meter shows a low reading, test wiring harness.

5. If engine fails to shut off, test for open black/yellow lead, damaged key switch, or damaged power
pack.

6. Complete all circuits disconnected during this test.

4Cleng 3-25 4 Deluxe - 8

 7 DR4619 DR4620

STEP 3 - CHARGE COIL TEST

Ground Test

~ 1. Disconnect 5-pin Ampheno/ connector between ignition plate and power pack.
2. Set peak-reading voltmeter to "NEG" and "500".

rJl 3. Alternately, connect voltmeter between ignition plate connector terminals "A", "0", and a clean
~ engine ground. Crank engine and observe meter at each connection.

• Any reading on either test indicates charge coil or leads are grounded.
• Locate and repair ground, or replace charge coil.

4. If no reading is indicated in Step 3, go to Output Test.

Output Test

1. Set peak-reading voltmeter to "NEG" and "500".

1al 2. Attach voltmeter black lead to ignition plate connector, terminal "A". Attach meter red lead to
~ terminal "0".

3. Crank engine and observe meter.

• If meter shows 230 volts or higher, go to STEP 4 - SENSOR COIL TEST.

• If meter shows less than 230 volts, check condition of wiring and connectors.
• If wiring and connector condition is good, go to Ohmmeter Test.
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3-26 4C/eng E
 9 10
DR4619

Ohmmeter Test

INotel All ohmmeter tests must be performed with the engine NOT running.

[!] 1. Insert jumper wires in ignition plate connector, terminals "A" and "0".
~ 2. Calibrate ohmmeter on appropriate scale. Connect between jumpers.
• Meter must show 900 ± 100 ohms.

r,Ql 3. To test .for a grounded condition, connect ohmmeter alternately between each jumper and a
~ clean eng me ground.

• Any needle movement indicates charge coil or leads are grounded.

• Locate and repair ground, or replace charge coil.

4. Complete all circuits disconnected during this test.

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4C1eng 3-27 4 Deluxe - 8
11
OR4621 OMa22

STEP 4 - SENSOR COIL TEST

Ground Test

[!!] 1. Disconnect 5-pin Amphenol connector between ignition plate and power pack.
2. Set peak-reading voltmeter to "NEG" and /15/1, "SEN" and "5" on Stevens CD-77 meter.

f11l 3. Alternately, connect voltmeter between ignition plate connector terminals "B", "C" , and a clean
~ engine ground. Crank engine and observe meter at each connection.

• Any reading indicates sensor coil or leads are grounded.

• Locate and repair ground, or replace sensor coil.

4. If no reading is indicated in Step 3, go to Output Test.

Output Test

1. Set peak-reading voltmeter to "NEG" and "5", " SEN" and "5" on Stevens CD-77 meter.

r:;:;l12 2. Attach voltmeter black lead to ignition plate connector, terminal/lC". Attach meter red lead to
~ terminal "B".

3. Crank engine and observe meter.

• If meter shows 1.5 volts or higher, go to STEP 5 - POWER PACK TEST.

• If meter shows less than 1.5 volts, check condition of wiring and connectors.
• If wiring and connector condition is good, go to Ohmmeter Test.
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3-28 4C/eng E
13
DR4622 DR4621

Ohmmeter Test

INotel All ohmmeter tests must be performed with the engine NOT running.

1. Calibrate ohmmeter on appropriate scale.

@] 2. Insert jumper wires in ignition plate connector, terminals "8" and "C".
3. Calibrate ohmmeter on appropriate scale. Connect between jumpers.

• Meter must show 40 ± 10 ohms.

1141 4. To test .for a grounded condition, connect ohmmeter alternately between each jumper and a
clean engme ground.

• Any needle movement indicates sensor coil or leads are grounded.

• Locate and repair ground, or replace sensor coil.

5. Complete all circuits disconnected during this test.

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4C/eng 3-29
4 Deluxe - 8
 >175V

15 DR4256

STEP 5 - POWER PACK OUTPUT TEST

.& To prevent accidental starting of engine while testing, twist and remove both spark plug leads.

1. Twist and remove primary leads from ignition coils.

r:J5l 2. Connect No.1 ignition coil primary lead to Stevens Instrument load adapter No. PL-88 red lead.
~ Connect adapter black lead to a clean engine ground.

~ If Stevens Instrument 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.

3. Set peak-reading voltmeter to "NEG " and "500".

~ 4. Connect voltmeter red lead to adapter red lead and meter black lead to a clean engine ground.
5. Crank engine and observe meter.

• Meter must show 175 volts or higher.

6. Repeat Steps 4 and 5 for No.2 ignition coil primary lead.

• If both primary leads have good output, test ignition coils. Refer to Ignition Coil Tests, Page
3-10.

• If one primary lead has no output, replace power pack.

• If both primary leads have no output, go to STEP 3 - CHARGE COIL TEST. If charge coil tests
good, replace the power pack.

& Safety Related 3-30 4C1eng

 >200V

DR4257

STEP 6 - RUNNING OUTPUT TEST

1. Twist and remove primary leads from ignition coils.

r,&l2. ~se .a. clock~ise. twist to install Stevens Instrument No. TS-77 terminal extenders, or equivalent,
~ on Ignition coli primary posts.

r,&l3. Install primary leads on terminal extenders. Observe proper wire routing. Orange/blue primary
~ lead must be connected to the No.1 ignition coil.

INotel Route all tester leads so they do not interfere with moving engine parts.
4. Set peak-reading voltmeter to "NEG" and "500".

r,&l5. C.onnect voltmeter red lead to No.1 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 200 volts or higher.

7. Repeat Steps 5 and 6 for cylinder No.2.

8. If either cylinder shows less than 200 volts, test charge coil. Refer to STEP 3 - CHARGE COIL TEST .

• If charge coil tests good, replace the power pack.

9. Remove terminal extenders. Install ignition coil primary leads. Observe proper wire routing.
Orange/blue primary lead must be connected to the No.1 ignition coil. E
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4C/eng 3-31
4 Deluxe - 8
Indexing Flywheel - Erratic Ignition - 3 thru 8
Internal ignition module problems could cause a module to fire
erratically or continuously. To troubleshoot this situation, you
must determine that each cylinder is firing at the correct time and
no more than once per revolution.

1. Disconnect the spark plug leads and remove all spark plugs.

rn 2. Place the eraser end of a pencil in the No.1 spark plug

hole. Slowly turn the flywheel by hand in a clockwise direction
until the greatest length of the pencil is outside the spark plug
hole. This indicates the No.1 piston is near top dead center.

WW 3. Make a reference mark on the starter housing. Make

a mark on the flywheel rim directly beneath the starter housing
reference mark. Label this mark "No. 1".

4. Repeat Step 2 using No.2 spark plug hole.

rn 5. Mark the flywheel rim directly beneath the same reference

mark on the starter housing. Label this mark "No.2".

6. Install the spark plugs and spark plug leads. Start the engine in
a test tank and run the engine at the RPM where the problem
exists.

7. Carefully hook an induction timing light to each cylinder,

alternately. The timing light should indicate that cylinder's num-
ber only, and the number should only appear near the mark on
the starter housing .

• If another cylinder's number appears, or the correct

number appears more than once per revolution, verify
ignition coil primary lead routing or replace the ignition
module.

3-32 4C/eng
Principles of Operation - 3, 4
Flywheel

[JJ The flywheel contains permanent magnets ® which ener-

gize the sensor coil and ignition module. Once the flywheel
exceeds a minimum cranking RPM, the flywheel's magnetic lines
of force pass through the ignition plate components to produce
voltage in those circuits.

The flywheel must be in good condition and correctly located to

ensure proper ignition timing and sufficient ignition module
output.

Sensor Coil

[JJ The sensor coil ® consists of many windings of wire

wrapped around a metal lamination. Once the flywheel exceeds a
minimum cranking RPM, the flywheel's magnetic lines of force
cutting through the sensor coil windings produce approximately
4 volts. This voltage is supplied to the ignition module.

Ignition Module

II] The ignition module © has four basic functions:

• The ignition module has an internal charge coil that

produces approximately 200 volts of alternating current.

• The ignition module converts charge coil alternating

current to direct current.

• The ignition module stores the direct current in a capaci-

tor.

• The ignition module directs the capacitor output to the

ignition coil primary windings through a series of elec-
tronic switches (SCR's). The SCR's select the correct
ignition coil primary winding by sensing the polarity of
the sensor coil output.

Stop Circuit

rn The stop button is connected to the ignition module through

the engine wiring. When activated, the switch directs the ignition
module output to ground, stopping the ignition system .

Ignition Coil

[JJ The ignition coil @consistsoftwowindingsofwirewrapped

around a compacted ferrite core. The coil has primary and
secondary terminal connections and a ground plate.

Through mutual induction, the ignition coil transforms the igni-

tion module output to as much as 40,000 volts to fire the spark
plugs.
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4C/eng 3-33 E
Ignition Plate Servicing - 3, 4
Removal

& 1. To avoid accidental starting of engine while servicing,

twist and remove spark plug leads.

2. Remove the manual starter as described in Section 7.

3. Remove flywheel. Refer to Flywheel Servicing.

[JJ rn 4. Loosen three screws attaching ignition plate to

retainer plate and disconnect spring. Lift the ignition plate from
the powerhead. Remove throttle cable from ignition plate.

rn W 5. The retainer plate @ and support plate @ may be

removed for service by removing screws from support plate and
removing spring © from retainer plate.

Installation

rn W 1. If removed for service, install the retainer plate on the

crankcase and attach spring. Position support plate on crankcase.
Apply OMC Nut Lock to threads of retaining screws. Torque all
three screws to 48-60 in. Ibs. (5,4-7 N·m).

& Safety Related 3-34 4C/eng

[ ] ] 2. Lubricate the ignition plate bearing groove @ with a light
coating of outboard lubricant. Place bearing on support plate.

[ ] ] 3. Apply OMC Moly Lube to crankcase boss ® (pilot for

ignition plate).

[[] 4. Install throttle cable in ignition plate.

[ ] ] 5. Compress the bearing by hand and guide the ignition

plate into place.

INote I The gap in the bearing must be centered around the

5
DR2618
throttle cable connection.

[ ] ] 6. Position the ignition plate on the retainer plate. Apply

OMC Screw Lock to threads of retaining screws. Install screws
and torque to 25-35 in. Ibs. (2,8-4,0 N·m). Install spring.

7. Install the flywheel as described in Flywheel Servicing.

8. Install the manual starter as described in Section 7.

4C/e ng 3-35
Ignition Component Replacement - 3, 4
Ignition Coil ® ©I@@
1. Twist and remove cover to remove the spark plug lead and "'/~
r----
/
~H@-
primary leads from the ignition coils.

2. Notice the fastener and washer orientation before removing

any screws.

3. Remove the coil mounting screws and remove the coil and
washers.

OJ 4. Assemble the correct sequence of washers and locate the

ignition coil on the powerhead. Install and tighten the retaining
screws to a torque of 48-96 in. Ibs. (5,4-10,8 N·m).

5. Apply a light coating of OMC Triple-Guard grease to the ribbed

portion of the spark plug ceramics and to the openings of each of
the spark plug lead covers. Install the spark plug leads.

6. Apply a light coating of OMC Triple-Guard grease to the

opening of each primary lead cover and install the covers.
Observe proper wire routing and ignition timing. Orange/blue DR3636
primary lead must be connected to the No.1 ignition coil.

Ignition Module ® Fiber Washer

® Flat Washer
1. Separate the ignition module connector. © Ignition Coil Ground Strap
@ Star Washer
2. Remove the ignition module mounting screws and remove the
ignition module.

3. Clean the ignition module mounting bosses to provide a clean

engine ground.

4. Lightly coat threads of ignition retaining screws with OMC

Gasket Sealing Compound. Install the ignition module screws,
finger tight.

rn 5. Set the air gap between the ignition module and flywheel
using a nonmetallic gauge that is 0.013-0.017 in. (0,33-0,43 mm)
thick (such as the card supplied with every new ignition module).

6. Torque the retaining screws to 60-84 in. Ibs. (7-9 N·m).

2
DR3721

3-36 4C/eng
 IGNITION OUTPUT TESTS - 3, 4
I:A All cranking output tests must be performed with spark
ill plugs installed and torqued in the cylinder ·head. If neces-
sary to remove the spark plugs, be sure to keep the spark tester
away from spark plug holes.

~ The following series of steps will systematically isolate a

~ problem area in the ignition system. To reduce your trou-
bleshooting time and to avoid incomplete results, perform these
steps in the order written.

STEP 1 - TOTAL OUTPUT TEST

1. Remove the spark plug leads from both spark plugs. To prevent
damage to the spring terminal on the spark plug lead, twist and
pull the cover.

rv~ Connect
2. Adjust the spark gap on the spark tester to in. (0,9 mm).
3/8
the tester leads to the spark plug leads. Secure tester
clip to a clean engine ground.

~ To prevent possible arcing of high voltage, position the

~ tester leads at least 2 in. (51 mm) from any metal surface.

"" To avoid possible shock hazard, do not handle ignition coils

i l l or spark tester during cranking tests.
3. Crank the engine. Spark should jump each gap alternately.

• If tester indicates good ignition, refer to STEP 5 - IGNI-

TION MODULE RUNNING TEST.

• If there is no spark or poor spark, proceed to STEP 2 -

STOP CIRCUIT TEST.

~ It is possible for the ignition system to have a problem but

~ still produce good output. If the engine "pops" or "back-
fires" during starting, the ignition may be out of time. Check the
following:

• Coil primary wire routing

• Spark plug lead routing

• Flywheel condition and location

• Synchronization and linkage adjustments

4C1eng & Safety Related 3-37

 STEP 2 - STOP CIRCUIT TEST

Elimination Test

rn 1. Disconnect 6-pin Packard connector from ignition module.

rn 2. Insert a thin wire, such as a paper clip, about 1/4 in. (6 mm)
into slot next to black/yellow lead, terminal "E". Gently pull the
lead and slide its terminal out of the connector body.

/1 To avoid possible shock hazard, do not handle ignition coils

or spark tester during cranking tests.

3. Connect Packard connector to ignition module. Do not allow

term inal of black/yellow lead to touch powerhead. Crank engine
and observe results at spark tester .

• If spark now jumps alternately at each gap, the problem

is in the stop circuit. Go to Ohmmeter Test.

• If there is no spark at one or both gaps, go to STEP 3 -

SENSOR COIL TEST.

rn 4. To install lead back into connector, extend tab on the

terminal to lock inside the connector body. Insert the terminal into
the connector body until tab locks into place.

& Safety Related 3-38 4C/eng

Ohmmeter Test

~tA.II ohmmeter tests must be made with engine NOT run-

~nmg .

~ 1. Disconnect 6-pin Packard connector from ignition module.

Isl 2. Attach 6-pin Packard test adapter from OMC Ignition Test Kit,
~ PIN 434017, to engine harness connector.

~ Engine harness lead colors and test adapter lead colors do

~ not match. When testing a particular engine harness lead,
be sure to use appropriate test adapter lead according to connec-
tor terminal location.

f71 3. Calibrate an ohmmeter on appropriate scale. Connect meter

~ leads between black/yellow lead, terminal liE" 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.

"" To avoid sudden loss of control, replace the stop button

i l l assembly if your test results vary.
5. Complete all circuits disconnected during this test.

4C/eng & Safety Related 3-39

 STEP 3 - SENSOR COIL TEST

Ground Test

1. Disconnect 6-pin Packard connector from ignition module.

2. Attach 6-pin Packard test adapter from OMC Ignition Test Kit,
PIN 434017, to engine harness connector.

r:::J Engine harness lead colors and test adapter lead colors do
~ not match. When testing a particular engine harness lead,
be sure to use appropriate test adapter lead according to connec-
tor terminal location .

3. Set peak-reading voltmeter to "POS" and "5", "SEN" and "5"

on Stevens CD-77 meter.

f81 4. Alternately connect meter between bluelwhite lead termi-

~ nal "C", white lead terminal "0", and a clean engine ground.
Crank engine and observe meter at each connection.

• Any reading indicates sensor coil or leads

grounded.
are 9 27388
• Locate and repair ground, or replace sensor coil.

5. If no reading is indicated in Step 4, go to Output Test.

Output Test

1. Set peak-reading voltmeter to "POS" and "5", "SEN" and "5"

on Stevens CD-77 meter.

19l 2. Attach meter black lead to one sensor lead. Attach meter red
~ lead to remaining sensor lead .

3. Crank engine and observe meter.

• If meter shows 4 volts or higher, go to STEP 4 -IGNITION

MODULE CRANKING TEST.
• If meter shows less than 4 volts, check condition of
wiring and connectors.
• If wiring and connector condition is good, go to Ohm-
meter Test.

3-40 4C/eng
Ohmmeter Test

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

~ 2. Attach ohmmeter leads between the two sensor leads.

• Meter must show 100 ± 15 ohms.

r:J1l 3. To test f.or a grounded condition, connect ohmmeter alternately between each sensor lead and a
~ clean engme ground .

• Meter must show a high reading.

• If meter shows a low reading, locate and repair ground, or replace sensor coil.

4. Complete all circuits disconnected during this test.

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4C/e ng 3-41
3,4 '
 STEP 4 - IGNITION MODULE CRANKING TEST
&. To prevent accidental starting of the engine, twist and
remove the spark plug leads from the spark plugs. Attach to
spark tester.

1. Set peak-reading voltmeter to "NEG" and "500". Twist and pull

the primary leads off the ignition coil.

2. Install terminal extenders on the primary terminals by twisting

in a clockwise direction.

3. Attach the primary leads to the terminal extenders.

\12\ 4. To test the ignition module output to the No. 1 (top)

ignition coil, connect the meter black lead to a clean engine
ground. Connect the meter red lead to metal part of extender on
No. 1 ignition coil. Crank the engine and observe the meter
reading.

• Meter should indicate 125 volts or higher.

1121 5.lf meter reads less than 125 volts, remove the primary lead
from the terminal extender. Connect the meter red lead to spring
clip in boot of the primary lead. Crank the engine and observe the
meter reading.

• If meter reads 125 volts or higher, test the ignition coil as

described on Page 3-10.

• If the meter reads below 125 volts, check condition of

spring clip and primary wire.

• If a problem with the wire or spring clip is found, correct

the problem and retest the ignition module output.

• If the condition of the wire and spring clip is acceptable,

replace the ignition module.

6. Test the ignition module output to the No. 2 ignition coil as

described above.

7. To remove terminal extender from ignition coil, turn extender in

a clockwise direction and pull off.

8. Install ignition module primary leads on ignition coil primary

terminals. Observe proper wire routing and ignition timing:
orange/blue lead must go to the No.1 ignition coil.

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& Safety Related 3-42 4Cleng
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E
 STEP 5 - IGNITION MODULE RUNNING TEST
INotel Make all running tests at the engine RPM where the
intermittent or high speed ignition problem exists. The correct
RPM can have an effect on identifying the problem.

1. Set peak-reading voltmeter to "NEG" and "500". Twist and pull

the primary leads off the ignition coil. Turning in a clockwise
direction, attach terminal extenders to the primary terminals of
the coil. Reconnect primary leads to terminal extenders. Observe
wire routing: orange/blue lead to the No.1 (top) cylinder.

I Note I Route all tester leads so they do not interfere with moving
engine parts.

2. Connect meter black lead to a clean engine ground. Start

engine and run at RPM where problem exists.

[31] 3. Hold the meter red lead against metal part ofthe No. 1 coil
extender. Do not hold metal part of meter lead when engine is
operating. Stop the engine.

• Meter should indicate a continuous reading of 150 volts

or higher.

INote I The voltage reading must be steady at a constant engine

RPM.

4. If meter reads less than 150 volts, remove the No.1 ignition coil
primary lead. Connect the meter red lead to spring clip in boot of
primary lead. Remove No.2 spark plug lead from spark plug and
connect to a spark tester. Crank engine and observe meter.

• If meter reads 125 volts or higher, test the ignition coil as

described on Page 3-10.

• If meter reads less than 125 volts, replace the ignition

module.

5. Test the ignition module output to No. 2 ignition coil as

described above.

6. Turn the extender in a clockwise direction to remove it.

7. Install ignition module primary leads on ignition coil terminals.

Observe proper wire routing: orange/blue lead to the No. 1
ignition coil.

4C/eng 3-43
 CD IGNITION OUTPUT TESTS - 2, 2.3, 3.3
In All cranking output tests must be performed with spark plug
installed and torqued in the cylinder head. If necessary to remove
the spark plug, be sure to keep the spark tester away from spark
plug hole.

INotel The following series of steps will systematically isolate a

problem area in the ignition system. To reduce your troubleshoot-
ing time and to avoid incomplete results, perform these steps in
the order written.

STEP 1 - TOTAL OUTPUT TEST

1. Remove the spark plug lead from spark plug. To prevent
damage to the spring terminal on the spark plug lead, twist and
pu II the cover.

[]J 2. Adjust the spark gap on the spark tester to 3/8 in. (0,9 mm).
Connect the tester lead to the spark plug lead. Secure tester clip to
a clean engine ground.

I Note I To prevent possible arcing of high voltage, position the

tester lead at least 2 in. (51 mm) from any metal surface.

In To avoid possible shock hazard, do not handle ignition coil or

spark tester during cranking tests.

3. Crank the engine. Spark should jump consistently .

• If tester indicates good ignition, refer to STEP 6 - POWER

PACK RUNNING TEST .

• If there is no spark or poor spark, proceed to STEP 2 -

STOP CIRCUIT TEST.

I Note 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 flywheel
condition and location.

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& Safety Related 3-44 4C/eng
ii
E
 STEP 2 - STOP CIRCUIT TEST
Elimination Test

& To avoid possible shock hazard, do not handle ignition coil or

spark tester during cranking tests.

rn 1. Disconnect black lead connector between stop button and

power pack. Crank engine and observe results at spark tester.

• If spark now jumps consistently, the problem is in the

stop circuit. Go to Ohmmeter Test.

• If there is no spark, go to STEP 3 - SENSOR COIL TEST.

Ohmmeter Test

INote I All ohmmeter tests must be made with engine NOT

running.

rn 1. Calibrate an ohmmeter on appropriate scale. Connect

meter leads between stop button lead terminal, and a clean
engine ground.

• The meter must show a high reading.

2. Momentarily press inward on the stop button.

• The meter must show a low reading .

& To avoid sudden loss of control, replace the stop button if

your test results vary.

3. Complete all circuits disconnected during this test.

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4Cleng & Safety Related 3-45
2, 2.3, 3.3
ii
 STEP 3 - SENSOR COIL TEST

Output Test

1. Set peak-reading voltmeter to "POS" and "5", "SEN" and "5"

on Stevens CD-77 meter.

2. Seperate the blue lead between sensor coil and power pack.

m 3. Attach meter black lead to a clean engine ground. Attach

meter red lead to sensor coil blue lead terminal.

4. Crank engine and observe meter.

• If meter shows 1 volt or higher, go to STEP 4 - CHARGE

COIL TEST.
• If meter shows less than 1 volt, check condition of wiring
and connectors.
• If wiring and connector condition is good, go to Ohm-
meter Test.

Ohmmeter Test

INotel All ohmmeter tests must be performed with engine NOT

running .

1. Calibrate an ohmmeter on appropriate scale.

[[] 2. Attach ohmmeter leads between sensor coil blue lead

terminal, and a clean engine ground.

• Meter must show 50 ± 10 ohms.

3. Complete all circuits disconnected during this test.

3-46 4C/eng
 STEP 4 - CHARGE COIL TEST

Ground Test

1. Set peak-reading voltmeter to "pas" and "500".

2. Seperate both the brown lead and brown/yeillow lead between

charge coil and power pack.

W 3. Alternately connect meter between charge coil brown lead

terminal, charge coil brown/yellow lead terminal, and a clean
engine ground. Crank engine and observe meter at each connec-
tion.

• Any reading indicates charge coil or leads are

grounded.
• Locate and repair ground, or replace charge coil.

4. If no reading is indicated in Step 3, go to Output Test.

Output Test

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

[ [ ] 2. Attach meter black lead to one charge coil lead. Attach

meter red lead to remaining charge coil lead.

3. Crank engine and observe meter.

• If meter shows 180 volts or higher, go to STEP 5 - POWER

PACK CRANKING TEST.
• If meter shows less than 180 volts, check condition of
w iring and connectors.
• If wiring and connector condition is good, go to Ohm-
meter Test.

Ohmmeter Test

INote I All ohmmeter tests must be performed with engine NOT

running.

1. Calibrate an ohmmeter on appropriate scale.

\]] 2. Attach ohmmeter leads between the two charge coil

leads.

• Meter must show 610 ± 60 ohms.

[ ] ] 3. To test for a grounded condition, connect ohmmeter

alternately between each charge coil lead and a clean engine
ground.

• Meter must show a high reading.

• If meter shows a low reading, locate and repair ground,
or replace charge coil. .

4. Complete all circuits disconnected during this test. E

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4Cleng 3-47
2, 2.3, 3.3
 STEP 5 - POWER PACK CRANKING TEST

/1 To prevent accidental starting of the engine, twist and

remove the spark plug lead from the spark plug. Attach to spark
tester.

1. Set peak-reading voltmeter to "POS" and "500". Twist and pull

the primary lead off the ignition coil.

2. Install terminal extender on the primary terminal by twisting in

a clockwise direction.

3. Attach the primary lead to the terminal extender.

[1Q] 4. To test the power pack output, connect the meter black
lead to a clean engine ground. Connect the meter red lead to
metal part of extender on ignition coil. Crank the engine and
observe the meter reading.

• Meter should indicate 180 volts or higher.

[I!] 5. If meter reads less than 180 volts, remove the primary lead
from the terminal extender. Connect ignition coil primary lead to
Stevens Instrument load adapter No. PL-88, red lead. Connect
adapter black lead to a clean engine ground. Crank the engine and
observe the meter reading.

• If meter reads 180 volts or higher, test the ignition coil as

described on Page 3-10.

• If the meter reads below 180 volts, check condition of

spring clip and primary wire.

• If a problem with the wire or spring clip is found, correct

the problem and retest the power pack output.

• If the condition of the wire and spring clip is acceptable,

replace the power pack.

6. To remove terminal extender from ignition coil, turn extender in

a clockwise direction and pull off.

7. Install power pack primary lead on ignition coil primary

terminal.

& Safety Related 3-48 4C/eng

 STEP 6 - POWER PACK RUNNING TEST

INotel Make all running tests at the engine RPM where the
intermittent or high speed ignition problem exists. The correct
RPM can have an effect on identifying the problem .

1. Set peak-reading voltmeter to "POS" and "500". Twist and pull

the primary lead off the ignition coil. Turning in a clockwise
direction, attach terminal extender to the primary terminal of the
coil. Reconnect primary lead to terminal extender.

INotel Route all tester leads so they do not interfere with moving
engine parts.

2. Connect meter black lead to a clean engine ground. Start

engine and run at RPM where problem exists.

[g] 3. Hold the meter red lead against metal part of the cQil
extender. Do not hold metal part of meter lead when engine is
operating. Observe meter reading . Stop the engine.

• Meter should indicate a continuous reading of 220 volts

or higher.

INote I The voltage reading must be steady at a constant engine

RPM.

r::!ID 4. If meter reads less than 220 volts, remove the ignition coil
primary lead. Connect ignition coil primary lead to Stevens
Instrument load adapter, No. PL-88, red lead. Connect adapter
black lead to a clean engine ground. Crank engine and observe
meter.

• If meter reads 180 volts or higher, test the ignition coil as

described on Page 3-10.

• If meter reads less than 180 volts, replace the ignition

module.

5. Turn the extender in a clockwise direction to remove it.

6. Install the primary lead on ignition coil terminal.

4C/e ng 3-49
2, 2.3, 3.3
NOTES

3-50 4C/eng
 Powerhead
Table of Contents

General Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 2

Service Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 3
Engine Temperature Check - All Models. . . . . . . . . . . . . . . 4- 5
Overheat Inspection - All Models . . . . . . . . . . . . . . . . . . . . 4- 6
Retaining Ring Pliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 7
Taper Pin Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 8
Cleaning - All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 9
Inspection - All Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Removal of Upper Crankcase Seal - 3 thru 8 ........... 4-12
Powerhead Servicing - 2, 2.3, 3.3 .................... 4-13
Removal ... . . . .... .. . .. ...... .. .............. 4-13
Disassembly ....... . .......................... 4-14
Assembly .......... . . . ..... ... ................ 4-15
Installation ................................... . 4-17
Powerhead Servicing - 3 thru 4 Deluxe. . . . . . . . . . . . . . . . 4-20
Removal - 3, 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Removal - 4 Deluxe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Disassembly - 3 thru 4 Deluxe. . . . . . . . . . . . . . . . . . . . . 4-21
Assembly - 3 thru 4 Deluxe. . . . . . . . . . . . . . . . . . . . . . . 4-23
Installation - 3, 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Installation - 4 Deluxe. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Powerhead Servicing - 5 thru 8 . . . . . . . . . . . . . . . . . . . . . 4-34
Removal .......... .. . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

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4C/eng 4-1 E
 & General Safety Warnings
Before working on any part of the powerhead, 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 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 at 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

"man overboard" situations, test the "start-at-limited-throttle"
feature before returning engine to customer.

4-2 4C/eng
 Service Specifications
Special Torque Chart _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

DESCRIPTION 2,2.3,3.3 3 - 4 Deluxe 5-8

Connecting Cap Screws • 60-70 in. Ibs. CD

(7-7,5 N·m)
60-70 in. Ibs. CD
(7-7,5 N·m)

Crankcase Head Screws 60-84 in. Ibs.

(7-9 N·m)
® •
Cylinder Head Screws 60-84 in. Ibs. 60-84 in. Ibs. 144-168 in. Ibs.
(7-9 N·m) (7-9 N·m) (16-19 N·m)

Powerhead Retaining Screws 60-84 in. Ibs. ® 60-84 in. Ibs. 60-84 in. Ibs.
(7-9 N·m) (7-9 N·m) (7-9 N·m)

Main Bearing Screws 90-120 in. Ibs. @ 60-84 in. Ibs. @ 144-168 in. Ibs. @
(10-14 N·m) (7-9 N·m) (16-19 N·m)

Inner Exhaust Tube Screws • 60-84 in. Ibs.

(7-9 N·m)
60-84 in. Ibs.
(7-9 N·m)

Exhaust Cover Screws • 60-84 in. Ibs.

(7-9 N·m)
60-84 in . Ibs.
(7-9 N·m)

Intake Manifold Screws and Nuts • 60-84 in. Ibs.

(7-9 N·m)
60-84 in. Ibs.
(7-9 N·m)

PCE0048
CD ApplyJohnson@ or Evinrude@ Outboard Lubricant to threads
@ Apply OMC Gel-Seal" sealant to threads of screws
® OMC Gasket Sealing Compound

4C/en g 4-3
OMC Special Tools Required _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

2, 2.3, 3.3 Models

Crankshaft Bearing Puller, PIN 115316

Crankshaft Bearing Installer, PIN 115309

3 thru 4 Deluxe Models

Piston Cradle, PIN 326572
Wrist Pin Pressing Pin, PIN 326624
Wrist Pin Bearing Remover and Installer, PIN 327637
Ring Compressor, PIN 327017
Upper Main Bearing Seal Remover and Installer, PIN 391060 *
5 thru 8 Models
Piston Cradle, PIN 326573
Wrist Pin Bearing Remover and Installer, PIN 327645
Ring Compressor, PIN 326589
Pressing Pin, PIN 333141
Lock Ring Compressor, PIN 333142
Upper Main Bearing Seal Remover and Installer, PIN 391060 *
* Used to replace seal without disassembling powerhead.
Sealants and Lubricant Required _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

Johnson® or Evinrude® Outboard Lubricant

OMC Gel Seal and Gasket Remover
OMC Cleaning Solvent
OMC Gel-Seal" rOf
OMC Needle Bearing Assembly Grease
OMC Locquic Primer
OMC Gasket Sealing Compound
Permatex No. 2
OMC Moly Lube
OMC Adhesive M rOf
OMC Black Neoprene Dip
OMC Triple-Guard® Grease
OMC Screw Lock

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

Inside Micrometer or Telescoping Gauge

Cylinder Hone (fine)
Emery Cloth (No. 120 and No. 180)
Micrometer
Feeler Gauge
Markal Thermomelt Stiks or Pyrometer
Isopropyl Alcohol
Vee Block
Dial Indicator (2)

4-4 4C/eng
Engine Temperature Check - All Models
The Markal Thermomelt Stik is a heat-sensitive marker that melts
on contact with a surface of a specific temperature. One source
for Thermomelt Stiks is Stevens Instrument Company.

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.

IT] To achieve accurate and consistent readings, engine temper-

ature must be checked on the lower starboard cylinder head
screw for 2, 2.3,3.3, and on the cylinder water jacket for 3 thru 8.

INote I For the following engine operating temperatures and RPM

figures to be correct, the inlet water temperature must be 70 0 ±
100 F (21 0 ± 30 C) .

Therm omelt Stik Procedure

& Twist and remove spark plug leads before changing propel-
lers 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 to 900 RPM for five minutes. Mark the
engine with a 1000 F (380 C) and a 1630 F (73 0 C) Thermomelt Stik at
locations shown in figures.

4. At 900 RPM, the 1000 F (380 C) mark should become liquid and
glossy. The 1630 F (73 0 C) mark should remain dull and chalky.

• If the 1000 F (380 C) mark does not become liquid and

glossy, troubleshoot the cooling system for causes of
overcooling.

• If the 1630 F (73 0 C) mark becomes liquid and glossy,

troubleshoot the cooling system for causes of overheat-
ing .

IT] 5. When engine speed is increased to 5000 RPM, the 1630 F

0
(73 C) mark should remain dull and chalky.

• If the mark becomes liquid and glossy, troubleshoot the

cooling system for causes of overheating.

4C/eng & Safety Related 4-5

Overheat Inspection - All Models
If the engine has overheated, the following items should be
checked for damage.

1. Check the water cover and exhaust cover gaskets for leakage.

2. Remove the cylinder head.

3. Inspect the pistons, rings and cylinders for damage.

4. Inspect the cylinder block and cylinder head for warpage. 28070

12' 5. Check the water passages for damage or missing water

~ deflectors (3 - 4 Deluxe models).

~ Water deflectors MUST be in correct position in the water

~ passages. Loose deflectors may lodge in the water pas-
sages or allow leakage that would interfere with proper water
circulation.

6. Replace the cylinder head and gasket.

7. 5-8 models - inspect the thermostat for proper operation.

8. Check all of the powerhead screws for proper torque.

4-6 4C/eng
 +:.
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f£ CAT. No. 226 - 6 1/2 HCS
EDP No. 16226-11
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DR2523

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& Safety Warning
Cold Roll Steel
Heat Treatment : Striking a steel punch with a steel hammer may produce chips
Carburize 0,3-0,5 mm (0.015-0.020 in .) deep. which can cause serious damage to eyes. Safety glasses must
h Quench and harden to 58-62 R "C" case. be worn to prevent injury.

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Cleaning - All Models
~ Before inspecting or assembling powe r-head, all internal
~ components must be perfectly clean and free of contami-
nants.

1. Remove any carbon accumulation from exhaust port areas.

2. Remove any carbon accumulation from cylinder head combus-

tion chambers.

3. If cylinder walls are glazed from extended use, use a medium

grit hone to resurface walls. Use slow RPM to achieve a strong
"crosshatch" pattern for best oil retention and ring sealing.

r::-::J To avoid piston or cylinder block damage, restore the

~ chamfer to all port edges using a ball hone or other suitable
tool.

'" To avoid personal injury, wear eye protection and rubber

i l l gloves when using OMC Gel Seal and Gasket Remover.
r.jl 4. Use OMC Gel Seal and Gasket Remover to remove all traces
1
10134
~ of gaskets, adhesives, and OMC Gel-Seal" sealant from t he
cylinder block and crankcase.

~ 5. Carefully remove any carbon accumulation from the tops

~ and ring grooves of the pistons. 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.

'" To avoid personal injury, wear eye protection and set 852008
i l l compressed air pressure at less than 25 PSI (172 kPa).
7. Air dry cylinder block and crankcase. Blowout all holes and
passageways with compressed air.

8. Cover the cylinder walls with a liberal amount of Johnson or

Evinrude Outboard Lubricant to protect them from corrosion .

9. Refer to Inspection, this Section.

4CJeng & Safety Related 4-9

Inspection - All Models
1. Before any inspection process can begin, all internal compo-
nents must be clean and free of excess oil. Refer to Cleaning, this
Section.

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 or bearing surfaces,
and broken components.

• 3 thru 8 - The metering rods must be in place in the

crankcase. Place the long rod in the upper hole and the
short rod in the lower hole.

f213. 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 0.004 in. (0,10

mm) end to end. Resurface or replace head if warpage
exceeds this dimension.

4. Use a micrometer to measure the diameter of each crankpin 10132

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.

f315. Use a telescoping gauge or inside-reading micrometer 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.

f416. 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
3
10157
dimension.

• The cylinder must not be out-of-round by more than

0.003 in. (0,08 mm).

7. The dimensional difference between the two areas is the

cylinder taper.

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

8. The difference between your measurements and standard bore

dimension is cylinder oversize. Refer to Engine Specifications,
DR1119
Section 1, for dimensions.

• The cylinder must not be oversize by more than 0.002 in.

(0.05 mm).

fN=J 3 thru 8 - If any cylinder is outside these tolerances, it must

~ be bored. One oversize piston is available for this engine
(0.030 in., 0,762 mm). To determine oversize bore add 0.030 in.
(0,762 mm) to tt)e standard bore. See Engine Specification,
Section 1. It is permissible to have one or more oversize pistons in
an engine.

4-10 4C/eng
 ) ) ~~

0
51
IIIIIIIIIiI ~
t
-

-
C03082

f519. Take piston diameter measurement 1/8 in. (3 mm) above the
3142 3144

~ bottom edge of the piston.

1sl10. Take at least two measurements. The first measurement

~ should be in line with the wrist pin bore.

f711.1. The second measurement should be 90 0 away from the

~ first.

12. The difference between the two measurements is the out-of-

roundness and must be no more than 0.002 in. (0,05 mm).

13. Refer to Engine Specifications, Section 1 for piston dimen-

sions.

1al14. 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.

• 2,2.3,3.3 - The ring end gap must be within 0.006-0.014

in. (0,15-0,35 mm).
• 3 thru 8 - The ring end gap must be within 0.005-0.015 in.
(0,13-0,38 mm).
1529

19l15. Use a feeler gauge to check groove side clearance of the

t=.J piston rings. Install each ring on its piston. With the ring fully
seated in its groove, make several checks around the piston.

• 2,2.3,3.3 - The side clearance must not exceed 0.0026 in.

(0,065 mm).
• 3 thru 8 - The side clearance must not exceed 0.004 in.
(0,10 mm).

f10116. 2, 2.3, 3.3 - Measu re the con necti ng rod deflection at the
~ small end of the rod to determine the amount of wear of the
crankpin and connecting rod bearing. DR3552

• The connecting rod deflection is 0.022 in. to 0.056 in.

(0,6-1,5 mm). Replace crankshaft assembly if deflection
exceeds tolerance.

G1l17. 2,2.3,3.3 - Use a "Vee" block and two dial indicators to

~ check crankshaft off-center at ®. Rotate crankshaft on block.
Movement of indicators must not exceed 0.001 in. (0,05 mm). E
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DR3553 ii
4C/eng 4-11 E
Removal of Upper Crankcase Seal - 3 thru 8
The presence of oil under the flywheel could indicate a leaking
upper crankcase seal. The upper crankcase seal can be replaced
without disassembly of crankcase. Remove the flywheel as de-
scribed in Section 3. Use OMC Seal Remover, PIN 391060, to
remove and install the seal.

• Use tip "A" on 3 thru 4 Deluxe models .

• Use tip "8" on 5 thru 8 models.

rn To remove seal, install tip into remover/installer body.

Thread remover/installer body ® with tip into seal to engage
@
metal case.

OJ While holding remover/installer body, turn pressing screw

© and remove seal.
To install a new seal, apply OMC Gasket Sealing Compoundto the
outside diameter of the metal casing. Position seal on powerhead
with lip facing down.

rn Remove the pressing screw and tip from the remover/

installer. Using a mallet and remover/installer body @, install seal
in powerhead.

4-12 4C/eng
Powerhead Servicing - 2, 2.3, 3.3

Removal

1. Remove the engine covers as described in Section 2.

&. 2. To avoid accidental starting of engine while servicing,

twist and remove spark plug leads.

3. Remove the fuel tank and carburetor as described in Section 2.

4. Remove the manual starter as described in Section 7.

5. Remove the flywheel and ignition components as described in

Section 3.

m 6. Remove the six screws ® attaching powerhead to exhaust

housing . Remove the powerhead.

7. Discard the gasket.

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4C/eng & Safety Related 4-13
2, 2.3, 3.3
ii
 25432

Disassembly

~ To simplify reassembly and wiring installation, layout the

~ various screws and clamps in the order of their proper
location.

1. Remove the cylinder head and gasket. Discard the gasket.

[!] 2. Remove the lower crankcase head.

(!] 3. Remove the six main bearing screws.
4. Using a rawhide mallet, lightly tap upward on the crankshaft
until the halves just begin to separate. Lift up and remove the
crankcase.

[!] 5. Remove two screws, leaf stop and leaf valve.

6. Remove upper and lower crankshaft seals.

r4J 7. Remove the crankshaft assembly, upper and lower retainers

~ from the cyli nder block.

8. Remove piston ring using an appropriate ring expander.

r.;l 9. Using needle-nose pliers or a tool as drawn on Page 4-7,

~ remove the wrist pin retaining rings. Discard the rings.
16l 10. To remove the wrist pin and bearing, use a suitable tool to
~ drive the wrist pin out of the piston.

11 . Inspect wrist pin besring. If worn, replace wrist pin and 6

bearing. 25428

rJl 12. If necessary, remove the upper and lower ball bearings
~ using OMC Crankshaft Bearing Puller, PIN 115316. When
removing, place the locating pin of bearing diagonally on the
puller to prevent pin damage.

13. Refer to Cleaning and Inspection at beginning of this section.

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25427 ii
4-14 4C/eng E
Assembly

fN=J Proceed slowly. Make no forced assemblies unless a press-

~ ing operation is called for. All internal components must be
perfectly clean and lightly coated with Johnson or Evinrude
Outboard Lubricant.

INotel Use new gaskets and seals during assembly.

1sl1gl 1. If removed, install new upper and lower ball bearings
~ ~ using OMC Bearing Installer, PIN 115309. When pressing
on the bearings, support the crankshaft between the two counter-
weights and press against lettered side of the bearing.

2. Apply a coat of oil to wrist pin and wrist pin hole in piston.

r;Q1 3. Insert wrist pin through either side of piston . Oil wrist pin
~ bearing and place into connecting rod. Position the connect-
ing rod into piston with the arrow mark on piston top pointing to
bottom of the crankshaft. Install wrist pin using a suitable tool.
Install new wrist pin retaining rings.

r:;:;l 4. Install piston ring on piston. Spread ring with a ring

L!!J expander just enough to slip it over the head of the piston
and down into place.

5. Coat the piston and cylinder bore with oil.

6. Place the piston in cylinder block. Make certain that the ring is
correctly positioned in its groove with respect to the dowel pin.
Damaged piston and broken ring may result from imperfect
alignment of the ring gap and the dowel pin.

~ The piston ring must be correctly located on its dowel pin to

~ prevent permanent powerhead damage.

7. Use a suitable tool to compress the piston ring and install the
piston into bore of the cylinder.

r.;:;J 8. Check piston ring for spring tension through exhaust port
~ by pressing it with a screwdriver. If piston ring fails to return
to its position, it is likely that the ring was broken during
installation and must be replaced.

11

4C/eng 4-15
2, 2.3, 3.3
 0.236 - 0.244
(6-6,3 mm)
in'l
I ---
-1
15
25475 DR3556

r:;::;l9. Install the crankshaft assembly on cylinder block and

L.!!J rotate bearings so that the locating pins are positioned in
notches of the cylinder block.

[!!] 10. Install upper and lower retainer on cylinder block.

r:J3l11. Install new upper and lower crankshaft seals with the lip
~ of each seal facing the crankcase.

r:;;] 12. Apply OMC Screw Lock to threads of leaf valve screws.
~ Install the leaf valve and stop. Tighten the screws to a torque
of 27-35 in. Ibs. (3-4 N·m).

r:j5l13. C~ec.k leaf v.a~ve .opening. Replace leaf stop if opening is

~ not wlthm specifications.

14. Thoroughly clean and degrease the crankcase mating flange

of the cylinder block with OMC Cleaning Solvent and let air dry.

116115. Apply OMC Locquic Primer to the mating flange of the

crankcase and let air dry.

f17116. Apply OMC Gel-Seal" sealant to the cylinder block

~ flange. The application must cover the flange evenly and
consistently without being excessive. The application must not
come within 1f4 in. (6 mm) of the bearings.

~ OMC Gel-Seal" sealant has a shelf life of at least one year

~ when stored at room temperature. Test the OMC Gel-Seal"
sealant or replace it if the age of the tube cannot be determined.
Using old OMC Gel-Seal II sealant could cause crankcase air
leaks.

118117. Lower the crankcase into place and align the guide
bushing. Lightly coat threads of the six main bearing screws
with OMC Gel-Seal" sealant. Tighten the screws to a torque of
90-120 in. Ibs. (10-14 N·m).

119118. Install the crankcase head. Lightly coat threads of the two
crankcase head screws with OMC Gasket Sealing Com-
pound. Torque screws to 60-84 in. Ibs. (7-9 N·m).

4-16 4C/eng
19. Apply OMC Gasket Sealing Compound to both sides of a new
cylinder head gasket. Install the cylinder head and torque the
screws to 60-84 in. Ibs. (7-9 N·m).

Installation

1. Apply OMC Moly Lube to the square end of crankshaft.

2. Apply OMC Gasket Sealing Compound on both sides of a new

powerhead gasket.

3. Place the gasket on the exhaust housing and set the powerhead
in place.

~ 4. Apply OMC Gasket Sealing Compound to the powerhead

~ retaining screws. Install the screws and torque to 60-84 in.
Ibs. (7-9 N·m).

5. Install the ignition components as described in Section·3.

6. Install the rew1nd starter. Tighten the screws to a torque of

60-84 in. Ibs. (7-9 N·m).

7. Install fuel tank and carburetor as described in Section 2.

8. Install engine covers.

~ To avoid permanent powerhead damage, instruct operator

~ to repeat the original engine break-in procedure, as de-
scribed in Section 1, before putting engine back into normal
service.

4C1eng 4-17
2, 2.3, 3.3
2, 2.3, 3.3

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i:i.
4C/eng ~
 2, 2.3, 3.3

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4C/eng E
Powerhead Servicing - 3 thru 4 Deluxe
Removal - 3, 4

'" 1. To avoid accidental starting of engine while servicing,

i l l twist and remove spark plug leads.
2. Remove fuel tank, if integral model.

3. Remove ignition components as described in Section 3.

4. Remove fuel components as described in Section 2.

5J 5. Remove shield from midsection.

~ 6. Remove the six screws attaching the powerhead to the
~ exhaust housing @. Lift the powerhead from the exhaust
housing.

Removal - 4 Deluxe

'" 1. To avoid accidental starting of engine while servicing,

i l l twist and remove spark plug leads.
2. Remove fuel tank.

3. Remove ignition components as described in Section 3.

4. Remove low speed knob and choke knob.

5. Remove manual starter as described in Section 7.

f31 6. Remove the six screws attaching the powerhead to the

~ exhaust housing @. Lift the powerhead from the exhaust
housing.

f4l 7. Remove the screws attaching the inner exhaust housing to

~ the powerhead©. Water tube is held in place by a retainer@.
Discard gasket.

it Safety Related 4-20 4C1eng

Disassembly - 3 thru 4 Deluxe

~ To simplify reassembly and wiring installation, layout the

~ various screws and clamps in the order of their proper
location.

1. Remove carburetor, leaf valve assembly and intake manifold .

Discard gaskets.

2. Remove the cylinder head and gasket. Discard the gasket.

3. With an indelible ink marker, mark the top piston dome, "No.
1", and the bottom piston dome, "No. 2".

4. Remove exhaust cover. Discard gasket.

[!] 5. Remove the lower crankcase head.

~ 6. Remove seal and remove snap ring from crankcase.
r:;l7. Using a tool as drawn on page 4-8, or equivalent, push the
~ crankcase taper pin toward intake manifold surface. Do not
use any tool smaller than taper pin bore to remove the pin.

~ 8. Remove the six main crankcase to cylinder block screws and

~ four flange screws.

~ Loosely install the cylinder head to prevent the pistons

~ from falling out when the crankshaft is removed.

1sl 9. Turn the powerhead so that the intake manifold surface 3

~ faces up. Using a rawhide mallet, lightly tap upward on the
crankshaft until the halves just begin to separate. Lift up and "'---.........- - - - - - - - - - = = = - '
remove the crankcase.

10. Remove center main bearing liner. Collect and retain the 30
needle bearings.

~ Pistons, connecting rods, and needle bearings are wearing

~ parts and seat with the operation of the engine. Because of
this, it is essential to maintain their original positions at reassem-
bly. Using an indelible ink marker, mark each component when
removed to ensure correct mating and keep the needles of each
cylinder together.
26073

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26072
ii
::::
4C/eng 4-21
3 - 4 Deluxe
~~--------~~------~2=~~9
m 26043
8
f61 f71 ~ 1. Mark and remove the connecting rod caps and bear-
~~ mgs. @
12. Lift the crankshaft out of the cylinder block. Replace the
connecting rod caps on the rods. Orient them exactly as they were
I ©
rj
before you removed them. Install the screws finger tight.

~ 13. Remove seal ring from crankshaft.

14. Rotate the powerhead so that the cylinder head faces up.
O•
9 @@
.
. ••

\ ~-
,$",

Remove the cylinder head and gently push up on the connecting

rods to remove No.1 and No.2 piston assemblies. Do not allow
the connecting rod to contact the cylinder wall or inside of the
piston skirt during handling.

19l 15. Remove upper crankshaft seal @ and upper main bearing
~ ® from crankshaft.

~ 16. Remove the lower crankshaft seal ©.

19l 17. The lower crankshaft bearing @ should be removed only
~ for replacement.

18. Inspect crankshaft seallsleeve assembly. If necessary to

replace, grind the sleeve, being careful not to damage the
crankshaft.

r,Ql 19. Remove the piston rings using an appropriate ring

~ expander.

r,v 20. Using needle-nose pliers, remove the wrist pin retaining
~ rings. Discard the rings.

r:w2l 21. Place the piston with "L" side ® facing up, into OMC
~ Piston Cradle, PIN 326572. Push the wrist pin through the
piston using OMC Wrist Pin Pressing Pin, PIN 326624.

~ Pressing pin must enter the "L" (loose) side of piston. 21

~ needle bearings and two washers are loose and must be
retained.

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4-22 4C/eng E
r;3l 22. Inspect wrist pin, needle bearings, and washers. If worn,
~ replace all these components. o
23. Refer to Cleaning and Inspection at beginning of this section.

Assembly - 3 thru 4 Deluxe o

~ Proceed slowly. Make no forced assemblies unless a press-
~ ing operation is called for. All internal components must be
perfectly clean and lightly coated with Johnson or Evinrude 13
26461
Outboard Lubricant.

INotel Use new gaskets, seals, and O-rings during assembly.

1141 1Notel Make sure water deflector ® is in place.

1. Apply a coat of oil to wrist pin and wrist pin hole in piston.

r:t5l f161 2. Insert wrist pin through "L" side @ of piston. Install
~ ~ wrist pin to inside edge of piston using OMC Wrist Pin
26070
Pressing Pin, PIN 326624, and OMC Piston Cradle, PIN 326572.

INotel Pressing pin must enter "L" (loose) side of piston.

r:;:;J 3. Install 21 needle bearings in rod end with OMC Needle

~ Bearing Assembly Grease. Place one washer on the wrist pin.
Press wrist pin through rod, allowing clearance to place second
washer on wrist pin. Finish installing wrist pin.

17
4C/eng 4-23
.
3 - 4 Deluxe
18
26041

r:w8l4. Install piston rings on piston. Spread each ring with a ring
~ expander just enough to slip it over the head of the piston
and down into place.

5. Coat the piston and cylinder bore with oil.

~ 6. Place the piston in OMC Ring Compressor, PIN 327017.

L.!!l Make certain that the rings are correctly positioned in their
grooves with respect to the dowel pins. Damaged pistons and
broken rings will result from imperfect alignment of the ring gap
and the dowel pins.
21
29073

~ The piston rings must be correctly located on their dowel

~ pins to prevent permanent powerhead damage.

r,gl7. Start the piston into bore of the cylinder with deflector @ of
~ the piston (sharp edge) toward intake port side ® of the
cylinder block. After pistons are installed, loosely install the
cylinder head to prevent the pistons from falling out.

\20\ ~ Connecting rod cap cannot be turned end for end. To

~ assist correct assembly, small embossments © are
provided on matching side of rod and cap. 22
\21\8. If removed, lubricate inside of a new crankshaft seal/sleeve
with isopropyl alcohol. Support the crankshaft between the
two lower counterweights. Press on crankshaft.

\22\9. If removed, press on a new lower main bearing ®. Support

the crankshaft between the two lower counterweights. Install
the retaining ring with flat side facing out.

\22\10. Oil and replace the upper main bearing @ with lettering
facing down. Apply OMC Gasket Sealing Compound to
outside diameter of a new main bearing seal @. Place the seal 23
onto the crankshaft with lip facing down. 10146

\23\11. Place a new seal ring on crankshaft.

12. Place main bearing liner with hole in cylinder block.

13. Apply a coat of OMC Needle Bearing Assembly Grease to

main bearing liner 30 needle bearings. Place 14 needles in E
o
cylinder block half. o
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4-24 4C/eng
E
124114. Oil the crankshaft and install it carefully in cylinder block
to avoid disturbing needle bearings. Be certain to align upper
main bearing dowel with crankcase recess.

125115. Move the pistons up so that the connecting rod bearings

are against the crankpin. Place one bearing half between
crankpin and rod and one on top of crankpin. Orient and place the
connecting rod cap on the needle bearings. Oil threads of the rod
cap screws. Install and tighten the screws in stages to a final
torque of 60-70 in. Ibs. (7-7,5 N·m).

16. Place remainder of the 30 needles on center journal of the

crankshaft. Place bearing liner on needles aligning dovetails.

r:;;l17. Thoroughly, clean and degrease the crankcase mating

~ flange of the cylinder block with OMC Cleaning Solvent and
let air dry.

127118. Apply OMC Locquic Primer to the mating flange of the

crankcase and let air dry.

r:;;;l19. Apply OMC Gel-Seal" sealant to the cylinder block

~ flange. The application must cover the flange evenly and
consistently without being excessive. The application must not
come within 1/4 in. (6,4 mm) of the labyrinth seals or bearings.

IN tel OMC Gel-Seal" sealant has a shelf life of at least one year
o when stored at room temperature. Test the OMC Gel-Seal"
sealant or replace it if the age ofthe tube cannot be determined.
Using old OMC Gel-Seal 1/ sealant could cause crankcase air
leaks.

20. Lower the crankcase into place. Lightly coat threads of the
main bearing screws with OMC Gel-Seal" sealant. Install the six 26
main bearing screws finger tight. ~....;;..a._ _ _ _ _ _ _ _ _---::-=~
26063

21 . When the crankcase is seated, install and firmly seat the

crankcase taper pin.

22. Using a soft face mallet, lightly tap bottom ofthe crankshaftto
seat the lower main bearing.

4C/eng 4-25 3 - 4 Deluxe

\29123. Tighten the six main bearing screws in stages to a final
torque of 60-84 in. Ibs. (7-9 N·m). Begin with center screws
and work outward in a spiral pattern. Tighten the four flange
screws to a torque of 60-84 in. Ibs. (7-9 N·m).

\301 ra:il 24.

Install the lower bearing retaining ring ® with
~ BEVELED EDGE OUT. The gap of retaining ring must be
centered around the oil hole @ in the front of the crankcase.

\301 ra:il 25 . Apply OMC Gasket Sealing Compound to the outside

~ diameter of a new lower crankshaft seal ©. Install the
seal with lip facing down toward gearcase, until seal bottoms on
the retaining ring.

26. Check for binding between the crankshaft and the bearings or
connecting rods by rotating the crankshaft with the flywheel.

r:;:;J 27. Apply OMC Gasket Sealing Compound to both sides of a

~ new cylinder head gasket. Place the gasket on the cylinder
head with tab @facing up and numbered side of gasket facing the
cylinder block. Install the cylinder head and torque the screws in
stages to 60-84 in. Ibs. (7-9 N·m), following sequence shown.

28. Apply OMC Gasket Sealing Compound to new exhaust cover

gasket. Install the exhaust cover. Tighten the screws to a torque of
25-35 in. Ibs. (3-4 N·m), starting with the center screws.

29. Install the intake manifold and leaf plate assembly using a
new gasket. Do not apply sealer to the gasket. Tighten the screws
to a torque of 60-84 in. Ibs. (7-9 N·m).

133130. Position the lower crankcase head. Install and tighten the
screws to a torque of 25-35 in. Ibs. (3-4 N·m), using an "x"
pattern.
31
31 . 4 Deluxe - Install the water tube and grommet in the inner DR17B1

exhaust tube. Lubricate the grommet before installing.

@
32. 4 Deluxe - Install the inner exhaust tube to the powerhead
using a new gasket. Do not apply sealer to gasket. Install and
tighten the screws to a torque of 60-84 in. Ibs. (7-9 N·m), starting
with the center screws.

DR2211

4-26 4C/eng
Installation - 3, 4

1. Apply OMC Moly Lube to driveshaft splines.

2. Place a new gasket on the exhaust housing and set the

powerhead in place.

r.iAl3. Apply OMC Gasket Sealing Compound to the powerhead

~ retaining screws. Install the screws and torque to 60-84 in.
Ibs. (7-9 N·m).

4. Install the ignition components as described in Section 3.

5. Install the rewind starter. Apply OMC Serew Loekto the threads
of the retaining screws and torque to 60-84 in . Ibs. (7-9 N·m).

6. Install carburetor and air silencer as described in Section 2.

7. Install engine covers.

~ To avoid permanent powerhead damage, instruct operator

~ to repeat the original engine break-in procedure, as de-
scribed in Section 1, before putting engine back into normal
service.
Installation - 4 Deluxe

1. Remove gearcase from exhaust housing.

2. Lubricate end of water tube. Assemble the powerhead to the

exhaust housing. Tighten the screws to a torque of 60-84 in. Ibs.
(7-9 N·m), starting with center screws.

3. Coat driveshaft splines with OMC Moly Lube. Do not coat top
surface of shaft as lubricant here may prevent seating of
driveshaft in crankshaft.

4. Install the gearcase on the exhaust housing, make sure the

water tube enters grommet of the water pump. Apply OMC
Gasket Sealing Compound to the threads of the gearcase screws.
Install the screws and tighten to a torque of 60-84 in. Ibs. (7-9
N·m).

5. Install ignition system components as described in Section 3.

6. Install fuel system components as described in Section 2.

~ To avoid permanent powerhead damage, instruct operator

~ to repeat the original engine break-in procedure, as de-
scribed in Section 1, before putting engine back into normal
service.

-
4Cleng 4-27
3 - 4 Deluxe
3,4

26035

26034

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4-28 4C/eng ~
 3,4

26033

26036

4C/eng 4-29
3,4

26030

26031

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4-30 4C/eng E
 3,4

26029

26032

4C1eng 4-31
4 Deluxe

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4C/eng
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 4 Deluxe

4C/eng
 26262

Powerhead Servicing - 5 thru 8

Removal

'" 1. To avoid accidental starting of engine while servicing,

i l l twist and remove spark plugs leads.
2. Remove fuel system components as described in Section 2.

3. Remove manual starter as described in Section 7.

4. Remove ignition components as described in Section 3.

5] 5. Disconnect throttle cable and linkage.

~ '3l 6. Remove two inner screws connecting lower cover
~~ halves. Disconnect choke linkage.

~ 7. Remove outer screw connecting cover halves.

~ 8. Remove two front plate to lower cover screws.
9. Remove tie strap from fuel inlet connection and remove hose.

~ 10. Remove six screws retaining powerhead.

fJ1 11. Remove three screws attaching inner exhaust housing to
~ exhaust housing. Remove inner exhaust housing.

'sl 12. Check condition of upper water tube grommet and remove
~ adapter plate.

f91 13. Remove screws attaching inner exhaust housing to power-

l!.I head. Discard gasket.
& Safety Related 4-34 4C/eng
 26272

Disassembly

INote I To simplify reassembly and wiring installation, layout the

various screws and clamps in the order of their proper location.

[1Q] 1. Use a punch to remove lower crankshaft seal. If necessary,

replace crankshaft to driveshaft seal.

[II] [j]J 2. Remove leaf valve assembly and intake manifold.

Discard the gaskets.

3. Remove the thermostat cap and thermostat components from

the cylinder head.

4. Remove the cylinder head and gasket. Discard the gasket.

5. With an indelible ink marker, mark the top piston dome, "No.
1", and the bottom piston dome, "No. 2".

6. Remove the exhaust cover screws. If necessary, tap the exhaust

cover edge with a rawhide mallet.

7. Remove the inner exhaust cover. 14

28279

[1l] 8. Remove crankshaft retaining ring and bearing retaining

ring.

1141 9. Using a punch with a diameter larger than the taper pin,
push the crankcase taper pin toward intake manifold surface. Do
not use any tool smaller than taper pin bore to remove the pin.

IJ]] 10. Remove the crankcase to cylinder block screws.

INote I Loosely install the cylinder head to prevent the pistons

from falling out when the crankshaft is removed.

UID 11. Turn the powerhead so that the intake manifold surface
faces up. Using a rawhide mallet, lightly tap upward on the
crankshaft until the halves just begin to separate. Lift up and
remove the crankcase.

12. Remove center main bearing liner. Collect and retain the 30
needle bearings.

4Cfeng 4-35
.
5-8
INote I Pistons, connecting rods, and needle bearings are wearing
parts and seat with the operation of the engine. Because of this, it
is essential to maintain their original positions at reassembly.
Using an indelible ink marker, mark each component when
removed to ensure correct mating and keep the needles of each
cylinder together.

[11] 13. Mark and remove the connecting rod caps and bearings.

14. Lift the crankshaft out of the cylinder block. Replace the
conneGting rod caps on the rod. Orient them exactly as they were
before you removed them. Install the screws finger tight.

15. Rotate the powerhead so that the cylinder head faces up.
Remove the cylinder head and gently push up on the connecting
rods to remove No.1 and No.2 piston assemblies. Do not allow
the connecting rod to contact the cylinder wall or inside of the
piston skirt during handling.

16. Remove upper crankshaft seal, upper main bearing, seal ring,
and center main bearing from the crankshaft. Discard seal ring.

17. The lower crankshaft bearing should be removed only for

replacement.

[!ID 18. Inspect crankshaft seallsleeve assembly. If necessary to

replace, grind the sleeve, being careful not to damage the
crankshaft.

UID 19. Remove the piston rings using an appropriate ring

expander.

1201 20. Using a tool as drawn on Page 4-7 or OMC Retaining Ring
Pliers PI N 325937, remove the wrist pin retaining rings. Discard
the rings.

Il1l 21 .
Remove the wrist pin using OMC' Pressing Pin,
PIN 333141, and OMC Piston Cradle, PIN 326573.

/1 To avoid personal injury, use insulated gloves when handling

pistons that have been heated.

1Note I The pistonmust be heated to 200 0 - 4000 F (93 0 - 2040 C).

The heat source must be applied evenly, not concentrated in a
small area on the piston.

22. Inspect wrist pin bearing in connecting rod. If worn, replace

wrist pin and bearing. To remove bearing, use OMC Wrist Pin
Bearing Remover and Installer PIN 327645.

23. Refer to Cleaning and Inspection at the beginning of this

section.

& Safety Related 4-36 4Cleng

Assembly

R Proceed slowly. Make no forced assemblies unless a press-

~ ing operation is called for. All internal components must be
perfectly clean and lightly coated with Johnson or Evinrude
Outboard Lubricant.

INotel Use new gaskets, seals, and O-rings during assembly.

1. If removed, install wrist pin bearing using OMC Bearing 22

Installer and Remover, PIN 327645. ~=.I----------...,.,~

1221~ When installing wrist pin bearing, the oil hole ® must
~ align with the hole in rod end @.

r:;:;J r.;:;, 2. Using OMC Cone, PIN 333142, and Driver,

~ ~ PIN 333141, install one snap ring in groove of piston.
When installed, gap © of the ring should be positioned opposite
groove @ in the piston.

"" To avoid personal injury, use insulated gloves when han-

i l l dling pistons that have been heated.
12513. Heat the piston to 2000 - 400 0 F (93 0 - 2040 C). Using OMC
Piston Cradle, PIN 326573, and OMC Pressing Pin,
PIN 333141, oil the wrist pin and start it into the piston opposite
the installed retaining ring. Do not allow the wrist pin to enter the
piston cavity.

R Before attempting to install wrist pin in piston, heat piston

~ at wrist pin area to 200 0 - 400
0
F (93 0 - 2040 C). The heat
source must be applied evenly, not concentrated on a small area
of the piston.

4. Position the connecting rod in the piston and finish installing

the wrist pin.

5. Install the remaining retaining ring as described in Step 2.

6. Check piston with micrometer to determine if piston has been

distorted during assembly. Measure the piston at two places, 90 0
from each other, Va to V4 in. (3 mm to 6 mm) above bottom edge of
the skirt.

If the difference between the two measurements is greater than

0.002 in. (0,05 mm), the piston is out of round or worn and must
be replaced.

4C/eng & Safety Related 4-37

126\ 7. Install piston rings on each piston. Spread each ring with
ring expander just enough to slip it over the head of the piston
and down into place.

8. Coat the pistons and cylinder bores with oil.

127\ 9. Place the piston in OMC Ring Compressor, PI N 326589.

Make certain that the rings are correctly positioned in their
grooves with respect to the dowel pins. Damaged pistons and
broken rings may result from imperfect alignment of the ring gap
and the dowel pins.
26 10143
\Note\ The piston rings must be correctly located on their dowel
pins to prevent permanent powerhead damage.

\27\ 10. Startthe piston into bore ofthe cylinder with deflector ®
of the piston (sharp edge) toward intake port side ® of the
cylinder block.

INotel 11. Loosely install the cylinder head to preventthe pistons

from falling out.

\281\Note\ Connecting rod cap cannot be turned end for end. To

assist correct assembly, small embossments © are provided on
matching side of rod and cap.

1291 12. If removed, lubricate inside of a new crankshaft seall

sleeve with isopropyl alcohol. Support the crankshaft between
the two lower counterweights. Press on crankshaft.

1301 13.lf removed, press on new lower main bearing ® . Support

the crankshaft between the two lower counterweights. Install the
retaining ring with flat side facing out.

130\ 14. Oil and install the upper main bearing @ with lettering
facing down. Apply OMC Gasket Sealing Compound to outside 28
diameter of a new main bearing seal @ . Place the seal onto the
crankshaft with lip facing down.

130\ 15. Oil and install a new seal ring @ into the groove in the
center of the crankshaft.

[!!] 16. Install the center main bearing. Apply OMC Needle
Bearing Assembly Grease to the 23 needle bearings. Place the
bearing around the center main journal of the crankshaft. Place
the sleeves around the bearings with retaining ring end of the
sleeves facing flywheel end of the crankshaft. Secure the sleeves
together with the retaining ring.

17. Oil the crankshaft and place into cylinder block. Orient seal
ring gap facing up. Be certain to align upper main bearing dowel
with crankcase recess. Align center main bearing dowel pin hole
with dowel pin in cylinder block. Position the rods on the crank
pins at this time.

4-38
18. Move the pistons up so that the connecting rod bearings are
against the crankpin. Place one bearing half between crankpin
and rod and one on top of crankpin . Orient and place the
connecting rod cap on the needle bearings. Oil threads of the rod
cap . screws. Install and tighten the screws in stages to a final
torque of 60-70 in. Ibs. (7-7,5 N·m).

1321 19. Thoroughly clean and degrease the crankcase mating

flange of the cylinder block with ONIC Cleaning Solvent and let air
dry.

1331 20. Apply CWIC Locquic Primer to the mating flange of the
crankcase and let air dry.

/341 21. Apply CWIC Gel-Seal I! sealant to the cylinder block

flange. The application must cover the flange evenly and consist-
ently without being excessive. The application must not come
within % in. (6 mm) of the labyrinth seals or bearings.

1Note 1 ONIC Gel-Seal I! sealant has a shelf life of at least one year
when stored at room temperature. Test the CWIC Gel-Seal I!
sealant or replace it if the age of the tube can not be determined.
Using old ONIC Gel-Seal /I sealant could cause crankcase air
leaks.

22 . Lower the crankcase into place. Lightly coat threads of the two
center and two bottom main bearing screws with CWIC Gel-Seal I!
sealant. Install the six main bearing screws finger tight.

23. When the crankcase is seated, install and firmly seat the
crankcase taper pin.

24. Using a soft face mallet, lightly tap bottom ofthe crankshaft to
seat the lower main bearing.

25. Tighten the six main bearing screws in stages to a final torque
of 144-168 in. Ibs. (16-19 N·m). Begin with center screws and work
outward in a spiral pattern.

26. Install and tighten the flange screws to a torque of 60-84 in.
Ibs. (7-9 N·m).

13511361 27. Installthe lower bearing retaining ring with BEV-

ELED EDGE OUT. The gap of retaining ring must be centered
around the oil hole ® in the front of the crankcase.

4Cle ng 4-39
1361 28. Apply avIC Gasket Sealing Compound to the outside
diameter of a new lower crankshaft seal @. Install the seal with lip
facing up towards flywheel, until seal bottoms on the retaining
ring.

29. Check for binding between the crankshaft and the bearings or
connecting rods by rotating the crankshaft with the flywheel.

137130. Apply avIC Gasket Sealing Compound to both sides of a

new cylinder head gasket. Install the cylinder head and torque the
screws in stages to 144-168 in. Ibs. (16-18 N·m), following
sequence shown.
36
DR179 1

1381 31 . Apply avIC Gasket Sealing Compound to a new thermo-

stat cover gasket. Install the thermostat using a new seal.

32. Apply ONIC Gasket Sealing Compound to new exhaust cover

gasket(s). Install the inner and outer exhaust cover. Tighten the
screws to a torque of 60-84 in. lbs. (7-9 N·m), starting with the
center screws.

33. Install the intake manifold and leaf plate assembly using a
new gasket. Do not apply sealer to the gasket. Tighten the screws
to a torque of 60-84 in. Ibs. (7-9 N·m).

34. Install the water tube and grommet in the inner exhaust tube.
Lubricate the grommet before installing.

35. Install the inner exhaust tube to the powerhead using a new
gasket. It is not necessary to apply sealer to this gasket. Install and
tighten the screws to a torque of 60-84 in. Ibs. (7-9 N·m), starting
with the center screws.

Installation

1. Coat driveshaft spl ines with avIC Moly Lube. Do not coat top
surface of shaft as lubricant here may prevent seating of
driveshaft in crankshaft.

2. Place a new gasket on the exhaust housing, and lower

powerhead into place.

1391 3. Install powerhead retaining screws and torque to 60-80 in.

Ibs. (7-9 N·m).

1401 4. Install three inner exhaust housing to exhaust housing

screws.

5. Insta ll throttle cable and linkage.

6. Install ignition system components as described in Section 3.

7. Install fuel system components as described in Section 2.

1Note 1To avoid permanent powerhead damage, instruct operator

to repeat the original engine break-in procedure, as described in
Section 1, before putting engine back into normal service. E
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4-40 4Cleng E
 NOTES

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4C/eng 4-41 E
Manual Start Models

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4C/eng
E
 Manual Start Models

32072
4C/eng 4-43
Sail Models

4-44 4C/eng
 Sail Models

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4C/eng 4-45 E
 Midsection
Table of Contents

General Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 2

Service Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 3
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 5
Exhaust Housing Servicing - 2, 2.3, 3.3. . . . . . . . . . . . . . . . 5- 6
Removal and Disassembly. . . . . . . . . . . . . . . . . . . . . . . . 5- 6
Assembly and Installation. . . . . . . . . . . . . . . . . . . . . . . . 5- 6
Midsection Adjustments - 2, 2.3, 3.3. . . . . . . . . .. . . . . . . . 5- 7
Exhaust Housing Servicing - 3, 4 . . . . . . . . . . . . . . . . . . . . 5- 8
Removal and Disassembly. . . . . . . . . . . . . . . . . . . . . . . . 5- 8
Assembly and Installation. . . . . . . . . . . . . . . . . . . . . . . . 5- 8
Midsection Adjustments - 3, 4 . . . . . . . . . . . . . . . . . . . . . . 5- 9
Exhaust Housing Servicing - 4 Deluxe thru 8 ........... 5-10
Removal ..................................... 5-10
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Assembly ..................................... 5-11
Installation .................................... 5-11
Midsection Adjustments - 4 Deluxe thru 8 ............. 5-11
Steering Handle Servicing - 3, 4 ..................... 5-13
Steering Handle Servicing - 4 Deluxe thru 8 ............ 5-14

4C/eng 5-1
 & General Safety Warnings
Before working on any part of the misection, 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 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.

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-at-limited throttle protection feature before returning
engine to the customer.

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5-2 4C/eng E
 Service Specifications
Standard Torque Chart _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

Size In. Lbs. Ft. Lbs. N·m

No.6 7-10 • 0,8-1,2

No.8 15-22 • 1,6-2,4

No. 10 25-35 2-3 2,8-4,0

No. 12 35-40 3-4 4,0-4: 6

1/4 in. 60-80 5-7 7-9

SA6 in. 120-140 10-12 14-16

3/8 in. 220-240 18-20 24-27

7A6 in. 340-360 28-30 38-40

PCE0023

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

OMC Gasket Sealing Compound

OMC Triple-Guard@ Grease
OMC Moly Lube

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4C/eng 5-3 E
NOTES

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C.
5-4 4C/eng E
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
Screw Lock or OMC Nut Lock must be thoroughly cleaned before
reassembly. When using an OMCthread locking product, be sure
to prime the adhesive surfaces with OMC Locquic Primer.

3. Discard all oil seals, O-rings, and gaskets.

4. Examine the rubber mounts and replace if deteriorated or

damaged.

5. Inspect components for nicks on the machined surfaces.

Remove nicks and resurface faces on a surface plate. Start with
No. 120 emery cloth and finish with No. 180 emery cloth.

f11 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.

~ A distorted exhaust housing will cause the upper driveshaft

~ splines to wear excessively and will damage the crankshaft
splines. 1
----------------------~D~==57~1
7. Inspect water tube for obstructions or kinks which may restrict
water flow.

8. Inspect shift components for wear. Replace if deteriorated or

damaged.

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4C/eng 5-5 E
Exhaust Housing Servicing - 2, 2.3, 3.3

Removal and Disassembly

rv be1. Theremoved
~
entire powerhead, exhaust housing, and gearcase may
from the swivel bracket as an assembly by
removing four screws @.

2. Remove the powerhead as described in Section 4.

3. Remove the gearcase as described in Section 6.

~ 4. Re~ove the water tube ® and grommet © from the exhaust

~ housing.

1al5. Remove the two split bushings @ by spreading them

~ enough to clear the exhaust housing.

6. Remove the adjustment screw, spring, washer, wedge, and

O-ring from housing clamp.

7. Refer to Cleaning and Inspection at the beginning of this

section.

Assembly and Installation

1. Apply OMC Gasket Sealing Compound on adjustment screw.

f412. Install O-ring ®, wedge ®, washer @, spring ®, and

~ adjustment screw CD to split bushing.

3. Apply OMC Triple-Guard grease on split bushings and install

two split bushings on exhaust housing.

4. Install water tube and grommet.

5. Install the exhaust housing on the swivel bracket with the

housing clamp.

6. Apply OMC Gasket Sealing Compound to threads of retaining

screws. Install the screws and tighten to a torque of 60-84 in. Ibs.
(7-9 N·m).

7. Install the powerhead as described in Section 4.

8. Install the gearcase as described in Section 6.

5-6 4C/eng
Midsection Adjustments - 2, 2.3, 3.3

Tilt Adjustment

Isl Pull tilt knob out and tilt engine all the way up. Push knob back
~ in and let engine down to make contact with tilt pin.

Tilting Friction

f61 Tighten the tilt shaft nut ® only enough to hold the motor in
~ any position of tilt.

r::=J DO NOT overtighten, as doing so will increase the pressure

~ required to tilt the motor when an obstruction is hit. Failure
to tilt when hitting an obstruction can cause serious damage to
the motor.

Steering Friction

f61 Adjust the steering friction with motor mounted to boat by

~ loosening or tightening the adjustment screw ®. Adjust the
steering until a slight drag is felt when turning.

'" The steering friction should be adjusted so that stable boat

i l l operation is maintained with a minimum of operator effort.
Do not overtighten to allow "hands off" steering which could
result in loss of control.

4C/eng & Safety Related 5-7

Exhaust Housing Servicing - 3, 4

Removal and Disassembly

rv be1. Theremoved
~
entire powerhead, exhaust housing, and gearcase may
from the swivel bracket as an assembly by
removing four screws @.

2. Remove the powerhead as described in Section 4.

3. Remove the gearcase as described in Section 6.

~ 4. Remove the water tube and grommet @ from the exhaust

~ housing by pulling them out.

~ 5. Remove the cotter pin and lift out the shift rod ©.
~ 6. Remove the setscrew @ to separate the shift lever and the
~ bellcrank.

~ 7. Remove exhaust relief tube and grommet @.

r:;J 8. Remove the two rubber vibration dampeners ® by stretch-
l!J ing them over bottom ofthe exhaust housing. The plastic pivot
bushings @ can be removed by spreading them enough to clear
the housing.

9. Refer to Cleaning and Inspection at the beginning of this

section.

Assembly and Installation

~ 1. Install the plastic pivot bushing @.

~ 2. Install the vibration dampeners by stretching them over
~ bottom of the housing.

~ 3. Place.the shift rod © in the bellcrank hole and secure with

~ cotter Pin.

~ 4. Install the shift lever in the housing. Slide the washer and
~ bellcrank into the shaft and install the setscrew @.

~ 5. Install the exhaust relief tube and grommet @, and water

~ tube and grommet @. 813235

5-8 4C/eng
~ 6. Place the steering friction plate in the bracket.
7. Install the exhaust housing on the swivel bracket with the upper
and lower swivel bracket retainers.

8. Apply OMC Gasket Sealing Compound to threads of the

retaining screws. Install the screws and tighten to a torque of
60-84 in. Ibs. (7-9 N·m).

Midsection Adjustments - 3, 4
Throttle Friction

f61 The throttle friction adjustment knob is located on the steering

~ handle. Turning the knob clockwise increases friction on the
throttle rod assembly.

Tilt Friction

rJl
Tighten the tilt shaft nut only enough to control the return of
~ the gearcase from TILT to RUN position.

~ DO NOT overtighten, as doing so will increase the pressure

~ required to tilt the motor if an obstruction is hit. Failure to
tilt when hitting an obstruction can cause serious damage to the
motor.

Steering Friction

Isl Adjust steering friction with motor mounted to boat by loosen-

~ ing or tightening screw. Steering friction should be adjusted
so that a slight drag is felt when turning.

'i'- The steering friction adjustment should not be over-

i l l tightened to allow "hands off" steering.

4C/eng & Safety Related 5-9

 1 :.

1
803055

Exhaust Housing Servicing - 4 Deluxe thru 8

Removal
1. Remove the powerhead as described in Section 4.

2. Remove the gearcase as described in Section 6.

[!] 3. Remove the two screws securing the lower mount housings.
r:;, 4. Remove the lower mount housings @, thrust mount ® ,and
~ the two lower side mounts ©.
rJl5. Lift and twist the exhaust housing to free the upper mounts
~ from the swivel bracket assembly.

Disassembly
r;J 1. Remove the two screws (5) retaining the exhaust housing
~ cover. Remove the cover ana discard the O-ring.

~ 2. Remove the setscrew ® from the shift shaft gear ®. Remove

~ the shift lever from the shift shaft gear. Discard the O-ring
from the shift lever.

1!13. Lift out the shift rod pinion ®.

r.il4. Remove the four screws @ retaining the lower engine cover
L!.J to the exhaust housing.
5. Refer to Cleaning and Inspection at the beginning of this
section.

5-10 4C/eng
Assembly

1. Install the lower engine cover to the exhaust housing.

1sl1sl2. Place a new a-ring on the shift lever. Install the shift rod
~ ~ pinion with dot ® toward the port side. Install the shift
shaft gear with flat directly on top. Insert the shift lever and
engage shift shaft gear. Install and tighten the setscrew securely.

f413. Pack the gear cavity with OMC Triple-Guard grease. Place a
~ new a-ring on the exhaust housing cover. Install the cover and
tighten the two screws @ securely.

Installation

1311. Lubricate the upper mount blocks with liquid soap and place
~them in position in the exhaust housing.

@J 2. Slide the exhaust housing into the swivel bracket.

~ 3. Place the two lower side mounts © into the two lower
~ mount housings. Put the port housing in place, insert the
thrust mount ® and position the starboard housing. Secure the
lower mounts with screws.

Midsection Adjustments - 4 Deluxe thru 8

Throttle Friction

f7l The throttle friction adjustment knob is located on the steering

~ handle. Turning the knob clockwise increases friction on the
throttle rod assembly.

Tilt Friction

Isl Tighten the tilt shaft nut only enough to control the return of
~ the gearcase from TILT to RUN position.

~ DO NOT overtighten, as doing so will increase the pressure

~ required to tilt the motor if an obstruction is hit. Failure to
tilt when hitting an obstruction can cause serious damage to the
motor.

4C/eng 5-11
Steering Friction

Inl Adjust steering friction with motor mounted to boat by loosen-

l!J ing or tightening screw. Steering friction should be adjusted
so that a slight drag is felt when turning.

~ The steering friction adjustment should not be over-

ill tightened to allow "hands off" steering.
Idle Speed

~ The idle speed adjusting knob is located on the steering

~ handle. Turning clockwise increases idle speed, turning
counterclockwise decreases idle speed. Make certain that throttle
grip is in slow position and the motor is at normal operating
temperature before making the adjustment.

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& Safety Related 5-12 4C/eng
ii
E
Steering Handle Servicing - 3, 4

Removal

& 1. To avoid accidental starting of engine while servicing,

twist and remove all spark plug leads.

OJ W 2. Advance sensor coil to allow slack in the throttle

cable. Disconnect cable from throttle rod assembly.

[ ] ] 3. Remove steering handle retaining nut and washers. Re-

move handle.

rn 4. Check throttle cable parts and replace if necessary.

Disassembly

rn 1. Remove rod retainer and throttle friction screw.

rn 2. Remove grip retaining screw. Grip has spring tension, be

careful when disassembling. 25993

[ ] ] 3. Inspect all parts and replace if necessary.

Assembly

rn 1. Install grip on throttle rod assembly and secure with

reta i n i ng screw.

rn 2. Attach rod retainer and throttle friction screw.

6
25992
Installation

[ ] ] 1. Route throttle cable into handle and secure with washers

and retaining nut.
o
OJ W 2. Advance sensor coil and attach throttle cable to
throttle rod assembly.

3. Refer to Synchronization and Linkage Adjustments, Section 1.

7
4C/e ng & Safety Related 5-13
25990
Steering Handle Servicing - 4 Deluxe thru 8

Removal

l' 1. To avoid accidental starting of engine while servicing,

Lll twist and remove all spark plug leads.
f1l2. 4 Deluxe - Remove the screw that retains the throttle cable
~ connector @ to the lower engine cover .

• 5, 6 and 8 - Remove the screw that retains the throttle

cable connector ® to the powerhead .

• Remove throttle arm screw and remove throttle end

from arm.

@J 3. Remove the stop button ground lead from the powerhead.

f414. Separate the 5-pin Amphenol connector. Remove black!
~ yellow wire from plug.

f1l5. 4 Deluxe - Spread the throttle lever and remove the throttle
~ cable pivot pin @.

6. Thread the pivot connector off the throttle cable .

f517. Remove the steering handle screw. Lift the handle from the
~ steering bracket. Pull the throttle cable and stop button wires
through the grommet in the lower engine cover.

Disassembly

1sl1. Using OMC Twist-Grip Remover, PIN 390767, depress the

~ grip detents. Tighten screw ®. Remove the grip by pulling it
26140
and turning the idle adjustment knob ® clockwise.

02. Remove the helix halves @, rollers ®, and guides CD.

• 0 0 •

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& Safety Related 5-14
C0A2674
4C/e ng
ii
E
[!] 3. Remove throttle friction control and handle cover.
[!] 4. Pull throttle pin out of the cable.
r.;;;l5. Remove the throttle cable/stop switch clamp screw and
~ washer and turn the clamp to the side. Remove throttle cable.
r:J1l6. Remove the stop switch retainer screw. Remove the stop 8
~ switch from the steering handle. L.....;~_ _ _ _ _ _ _ _ _---==~

Cleaning and Inspection

1. Inspect the throttle cable for kinks and wear. Replace if

necessary.

2. Inspect the steering handle components for wear, cracks, and

·other damage. Replace damaged parts.

3. Refer to Section 3, Ignition System, to test the stop button.

Assembly

IT!] 1. Install the stop switch into the handle. Secure with screw.
~ 2. Place the throttle cable in position and secure with clamp.
rgl3. Push the throttle cable pin through the end of the throttle
~cable.

1121 4. Place throttle friction control in position on handle.

12
26188
4C/eng 5-15
r:j3l5. Lubricate end of the pin, guides, roller, helix grooves, and
~ inner handle guide slot with OMC Moly Lube. Place the
guides over the roller pin and place the pin into slots of the inner
handle. Place the rollers ® on ends of the roller pin .

r;;] 6. Assemble the helix halves on the handle, place idle

~ adjustment knob in end of handle, and slide the grip over the
helix. Be sure the speed indicator is positioned with the speed
range and not 1800 out. Snap the grip into place.

G517. Be sure handle screw retainer is in proper position and 13

~ place cover on handle.

Installation

1. Insert the stop button wires and the throttle cable through the
grommet in the lower engine cover.

2. Attach the steering handle to the steering bracket.

3. Secure the stop button ground lead to the powerhead.

4. Install black/yellow wire into plug.

1161 ~ 5. Thread the throttle cable connector onto the cable.

6. To adjust the throttle cable:

• Set the idle adjustment knob to the minimum idle speed.

• Attach the throttle cable to the throttle arm.

• Turn the throttle grip to the FAST position as far as grip

will turn.

• Have the ignition plate in full advance position. Turn the

cable connector until attachment hole in connector is
aligned with mounting location . Turn the connector one
or two additional turns to preload the cable .

• Secure the cable connector. Check to see that the twist

grip will advance the ignition plate to maximum advance
stop.

• Check to see that the cam follower is off the cam when
the twist grip is set at idle position . If full throttle or
minimum idle is not attainable, turn the cable connector
one turn at a time until setting is correct.

• Be sure all fasteners are tight.

5-16 4C/eng
 Gearcase
Table of Contents

&. General Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 2

Service Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 3
Cleaning and Inspection - All Models. . . . . . . . . . . . . . . . . 6- 4
Service Chart - 2, 2.3, 3.3 . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 5
Gearcase Servicing - 2, 2.3, 3.3. . . . . . . . . . . . . . . . . . . . . . 6- 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 6
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 8
Installation ....... ............................. 6-10
Service Chart - 3, 4 ............................... 6-12
Gearcase Servicing - 3, 4 .......................... 6-13
Removal .................... ................. 6-13
Disassembly .................................. 6-13
Assembly ..................................... 6-16
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Service Chart - 4 Deluxe thru 8. . . . . . . . . . . . . . . . . . . . . . 6-20
Gearcase Servicing - 4 Deluxe thru 8 . . . . . . . . . . . . . . . . . 6-21
Removal ............................... .. .... 6-21
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Installation ................... .. .......... . .... 6-30
Checking Propeller Hub lippage - 4 Deluxe thru 8 . . . . . . 6-31

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4C/eng 6-1 E
 & 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.

6-2 4C/eng
 Service Specifications
Special Torque Chart _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

DESCRIPTION 2,2.3,3.3 3,4 4 Deluxe - 8 ADHESIVE

Water pump screws 62-89 in: Ibs. 25-35 in. Ibs. 60-84 in. Ibs. OMC Gasket Sealing
(7-12 N·m) (3-4 N·m) (7-9 N·m) Compound

Oil level & filiidrain

plugs
31-40 in. Ibs.
(3,5-4,5 N·m)
40-50 in. Ibs.
(4,5-5,6 N·m)
84-86 in. Ibs.
(9-10 N·m)
•
Gearcase retaining 89-115 in. Ibs. 60-84 in. Ibs. OMC Nut Lock
screws (10-13 N·m) (7-9 N·m) +
Gearcase head
screws
• 60-84 in. Ibs.
(7-9 N·m)
60-84 in. Ibs .
(7-9 N·m)
OMC Gasket Sealing
Compound

PCE0048
+ FRONT: 120-144 in. Ibs. (14-16 N·m)
REAR: 60-84 in Ibs. (7-9 N·m)
OMC Special Tools Required _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

2,2.3,3.3

Driveshaft Bearing Puller Kit, PIN 115307

Gearcase Bearing & Seal Installer, PIN 115310
Gearcase Head Bearing and Seal Installer, PIN 115311
Backing Plate, PIN 115312
Front Bearing Collar, PIN 115313
Lower Bearing Collar, PIN 115314

3,4

Propeller Shaft Bearing Remover/lnstaller, PIN 392091

Gearcase Head Seal Installer, PIN 327572
Driveshaft Bearing Remover/lnstaller, PIN 392092
Driveshaft Seal Installer, PIN 327431

4 Deluxe - 8

Shifter Clutch Dog Spring Depressor, PIN 390766

Pinion Bearing Remover, PIN 319880
Gearcase Head Seal Installer, PIN 326548
Gearcase Cover Seal Installer, PIN 326547
Pinion Bearing Installer, PIN 319878
Forward Bearing Cup Installer, PIN 326025

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4C/eng 6-3 E
Cleaning and Inspection - All Models

&. Replace damaged components. Shift system failure will

cause loss of control over direction of engine thrust.

1. Discard all seals, O-rings, gaskets, and the 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. 8289

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. Upper driveshaft oil circulation
hole must be clear.

IJJ • Gearcase anodes - if anodes have eroded to two-thirds

rn their original size, they must be replaced. Refer to
Section 1 for testing procedure.
25457
• Driveshaft - check threads and splines for chips, wear,
and cracks. Bearing and gear surfaces must not show
signs of metal transfer, corrosion, or discoloration. Se-
vere spline wear indicates the exhaust housing or gear-
case has been distorted, possibly by impact damage.

• Water intake screen - must be clear. If screen can't be

cleaned, it must be replaced.

• All internal components - must be inspected for signs of

wear, distortion, chipping, metal transfer, pitting, gall-
ing, 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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& Safety Related 6-4 4C/eng

ii
E
Service Chart - 2, 2.3, 3.3

CD OMC Triple-Guard Grease

® OMC Moly Lube
® OMC Gasket Sealing Compound
8) Scotch-Grip Rubber Adhesive 1300
® OMC Nut Lock

OMC Ultra-HPF
Gearcase Lubricant:
3 fl. oz. (90 ml)

.®
CD
@--®
I Clf
CD @7CD\®,3
~
<$ ,/
/' 0
~~
J ~ ~1 6G-84in,lbs.
"" ~ /" /(7-9 N'm)

I ~-~-:-
~ ~
~~ ~.
· J
30-40 in. Ibs.
(3,5-4,5 N·m)
I ;l-® ~ ~~
\ \
V 60-84 in. Ibs.
(7-9 N·m)
82-115 in. Ibs.
(10-13 N·m)
G)

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DR3547
~
ii
4C/eng 6-5 E
Gearcase Servicing - 2, 2.3, 3.3
Removal

'" 1. To avoid accidental starting of engine while servicing,

i l l twist and remove spark plug lead .
. ~ Gearcase does not have to be removed from exhaust
~. housing to repair water pump.

2. Remove cotter pin, propeller, and drive pin from the gearcase.

rvl.!J 3exhaust
.. Remove the two screws @ attaching the gearcase to the
housing.

4. Withdraw the gearcase carefully to avoid damaging the drive-

shaft and water tube.

5. Pull tube and upper driveshaft from gearcase.

6. Drain the gearcase by removing the oil level plug and oil
fill/drain plug.

Disassembly

~ Before disassembling the gearcase, refer to Cleaning and

~ Inspection at the beginning of this section.

[~] 1. Remove the two screws ® and washers.

2. Lift impeller cover from propeller shaft.

f3l3. Lift the impeller from the cavity of the gearcase head. If the
~ water pump components are worn extensively, rebuild the
water pump using a water pump repair kit.

4~ Remove impeller drive pin from propeller shaft.

f415. Slide the gearcase head off the propeller shaft. If necessary,
I.!.I rotate the gearcase head and tap the ears with a mallet.
. Discard the gearcase head O-ring.

6. Remove pinion retainer from end of driveshaft.

E

~17. Pull driveshaft out of gearcase and remove pinion.

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& Safety Related 6-6 4C/eng
ii
E
1sl8. Remove the forward gear and propeller shaft assembly and o
~ thrust washer.

rJl9. Remove the gearcase head bearing © using OMC Puller

~ Bridge, PIN 432127, OMC Two-Jaw Puller, PIN 432130, and
OMC Backi ng Plate, PIN 115312.

rJl10. Remove and discard the gearcase head seal using the
o
~ same special tools.

[!] 11. Remove the water tube grommet @ and discard.

19l12. Remove and discard the driveshaft seal using OMC Puller
~ Bridge, PIN 432127, OMC Two-Jaw Puller, PIN 432130, and
OMC Backing Plate, PIN 115312.

1101 ~3. ~se No.3 retaining ring pliers to remove bearing retain-
mg rmg.

19l14. Remove upper driveshaft bearing. Use OMC Puller Bridge,

~ PIN 432127, OMC Two-Jaw Puller, PIN 432130, and OMC
Backing Plate, PIN 115312.

[!TI 15. Lift driveshaft bearing spacer @ .

r,v f.i2116. Remove lower driveshaft bearing using OMCBearing
~ ~ Puller Kit, PIN 115307.

113l114117. Remove the forward bearing using the same special

~ tool.

4C1eng 6-7 2, 2.3, 3.3

 o

25537

Assembly

Before beginning assembly procedures, refer to Cleaning and

Inspecton, Page 6-4.

r:J5l 1. To install a new forward bearing, assemble OMC Collar,

~ PIN 115313, to OMCBearing and Seal Installer, PIN 115310.
Place the lettered side of the bearing to the collar. Support the
nose of gearcase on a block of wood on the floor. Using a mallet,
drive the forward bearing in until it is seated.

f161 2. To install a new lower driveshaft bearing, assemble OMC

~ Collar, PIN 115314, to OMC Bearing and Seal Installer,
PIN 115310. Place the lettered side of the bearing to the collar.
Drive the bearing in until the installer contacts the top of gear-
case.

~ 3. Install the bearing spacer.

G8l 4. Install a new upper driveshaft bearing using OMC Bearing
~ and Seal Installer, PIN 115310. Press against the lettered
side of the bearing until the tool is seated on gearcase.

f17l 5. Using No.3 retaining ring pliers, install bearing retaining

~ ring with sharp side of ring facing out.

f191 6. Install a new driveshaft seal in gearcase using OMC

~ Bearing and Seal Installer, PIN 115310. Apply OMC Gasket
Sealing Compound to the casing ofthe seal. Use a mallet to install
the seal with the garter spring facing downward. o
7. Apply Scotch-Grip Rubber Adhesive 1300 to the outer surface
of water tube grommet. Install water tube grommet.

1201 8. Install a new seal in gearcase head using OMCBearing and 25532

Seal Installer, PIN 115311. Apply OMC Gasket Sealing Com-

pound to outside of surface of the seal. Use a mallet to install the
seal with lettered side facing the tool. Apply OMC Triple-Guard
grease to the lips after installing.

1201 9. Install a new bearing in gearcase head using OMC Bearing

and Seal Installer, PIN 115311. Press against the lettered
side of the bearing until the tool is seated on gearcase head.

10. Place a washer on forward gear and propeller shaft assembly.

Install the assembly into gearcase.
6-8 4C/eng
11 . Position the pinion into gearcase.

12. Install the driveshaft. Rotate the driveshaft to engage the

pinion.

121\ 13 .. Install the pinion retaining ring with sharp side of ring
facmg out.

14. Lightly apply OMC Triple-Guard grease to a new gearcase

head O-ring. Install the O-ring in groove of the gearcase head.

15. Install the gearcase head on propeller shaft until it seats on

21
gearcase.

16. Install the impeller pin the propeller shaft.

122 \17. Lightly oil the impeller blades and install the impeller in
the gearcase head while turning in a clockwise direction,
making sure the blades seat.

18. Position the impeller cover.

19. Apply OMC Gasket Sealing Compoundto pump cover screws.

Tighten screws to a torque of 60-84 in. Ibs. (7-9 N·m). 22
25451

20. Pressure test the gearcase as follows:

• Remove the oil level plug. Attach a pressure tester to the

gearcase using OMC Pressure Gauge Adapter,
PIN 115330.

• Pump pressure up to 3-6 PSI (21-42 kPa). If pressure

gauge indicates leakage, submerge the gearcase in wa-
ter to determine source of leakage as evidenced by
bubbles. If the gearcase pressure gauge does not indi-
cate leakage, increase pressure to 16-18 PSI (110-124
kPa). If pressure does not hold, submerge the gearcase in 25350

water and check for source of leakage. Make necessary

repairs and repeat test.

123\ 21. Fill the gearcase with 3 flo oz. (90 ml) lubricant as follows:

• The gearcase must be in an upright position.

• Remove the oil level and the oil fill/drain plugs. Replace
the seals if damaged.

• Fill the gearcase with OMC Ultra-HPF gearcase lubricant

until lubricant appears at the oil level hole. Insert the oil
level plug first. Invert the gearcase and remove the oil fill
hose. Install the fill/drain plug. Tighten the oil level and
the fill/drain plugs to a torque of 30-40 in. Ibs. (3,5-4,5
N·m).

• Inspect the gearcase oil level after a motor test has been
performed. E
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4C/eng 6-9
2, 2.3, 3.3
Installation

1. Insert tube into exhaust housing and push tube into lower
crankshaft seal.

1241 2. Apply OMC Moly Lube on both ends of the transmission

I
shaft @ . Insert shaft into tube and push shaft onto end of
crankshaft.

3. Apply oil in the water tube grommet.

\251 4. Coat the driveshaft splines with OMC Moly Lube.

5. Install the gearcase using care to align water tube in grommet
and driveshaft splines with the transmission shaft. Turn propeller
shaft clockwise to engage driveshaft into transmission shaft.

~ Always turn the flywheel or propeller shaft in a clockwise

~ direction only to avoid water pump impeller damage.

6. Apply OMC Nut Lock to the threads of gearcase mounting

screws. Install the screws and tighten screws to a torque of 89-115
in. Ibs. (10-13 N·m).

7. Apply OMC Triple-Guard grease to the propeller shaft and a

new drive pin.

8. Install propeller onto drive pin and secure with a new cotter pin.

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6-10 4C/eng E
 NOTES

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i:i.
4C/eng 6-11 ~
Service Chart - 3, 4

CD OMC Triple-Guard Grease

® OMC Gasket Sealing Compound
® OMC Moly Lube
o OMC Nut Lock

OMC Ultra-HPF
Gearcase Lubricant:
2.7 flo oz. (80 ml)

60-84 in. Ibs.

(7-9 N·m)

C02519
6-12 4C/eng
Gearcase Servicing - 3, 4
Removal

t.:.. 1. Remove the lower engine cover. To avoid accidental

ill starting of engine while servicing, twist and remove spark
plug leads.

2. Remove the propeller and attaching hardware.

r:;l3. Drain the gearcase by removing the oil level @ and oil
L.!J fill/drain ® plugs. Remove the oil level plug first.
r:;, 4.
Remove the two screws attaching the gearcase to the
~ exhaust housing. Withdraw the gearcase carefully from the
exhaust housing and mount the gearcase in a suitable fixture.

Disassembly

~ Before disassembling the gearcase, refer to Cleaning and

~ Inspection at the beginning of this section.

@] 1. Remove the three water pump attaching screws.

~ 2. Separate the water pump housing from the water pump
~ plate. The water pump housing must be carefully pried away
from the plate. Remove the impeller drive pin.

f513. Pry up on the impeller plate with a screwdriver as shown,

~then slide it up and off the driveshaft. Discard the impeller
plate gasket.

f614. Slide the water intake screen out of the cavity in the
~ gearcase and inspect it for blockage or other damage.

4CJeng it Safety Related 6-13

[!J 5. Slide the driveshaft up and out of the gearcase.
~ 6. Remove the two gearcase head screws.
r.;;J 7. Using a soft mallet, alternately tap each of the ears of the
~ gearcase head either clockwise or counterclockwise until the
gearcase head is in the position shown. Then tap the ears from
behind, alternately, to disengage the gearcase head O-ring.

r;11 8. Remove the propeller shaft components. Remove the

~ gearcase head. Discard the gearcase head O-ring.

~ 9. Remove the pinion, thrust bearing, and thrust washer.

r.;:;] 10. Insert a punch into the drive pin hole in the propeller
~ shaft. While holding the forward gear still, rotate the propel-
ler shaft in a counterclockwise direction. Gently pull outward on
the propeller shaft and remove.

114\11 . Gently remove the clutch spring from the forward gear.
Clean all propeller shaft components. Inspect the clutch
spring for distortion. The coils of the spring must touch one
another. Replace the clutch spring, if necessary.

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22282 ii
6-14 4C1eng E
 17
22436

r:J5l 12. Remove and discard both gearcase head seals. Use OMC
~ Puller Bridge, PIN 432127, and OMC Small Puller,
PIN 432131.

f16l 13. Remove and discard the gearcase head bearing . Use OMC
~ Bearing Removerllnstaller, PIN 392091

f171 14. Remove and discard both driveshaft seals. Use OMC
~ Puller Bridge, PIN 432127, and OMC Small Puller,
PIN 432131.

r:j8l 15. To remove the upper ® and lower ® driveshaft bearings,

~ assemble the components of the OMC Driveshaft Bearing
Remover and Installer, PIN 392092 (Guide Plate @, Small Disc @
with flat side toward bearing, and Rod @ ), within the gearcase.
Attach OMC Slide Hammer, PIN 391008, to the rod and remove
both bearings at the same time.

f191 16. To remove the forward gearcase bearing, assemble OMC

~ Puller Bridge, PIN 432127, and OMC Bearing Puller,
PIN 432130. Make sure that the jaws of the puller are oriented
vertically and then extract the forward bearing.

1201 17. To remove the shift rod bushing ®, use components of

OMC Driveshaft Bearing Remover and Installer, PIN 392092
(Guide Plate © and Rod ®). Thread the top ofthe rod into the shift
rod bushing. Attach OMC Slide Hammer, PIN 391008, to the rod @
and remove the bushing. Discard both the bushing and O-ring.

f21l 18. Using OMC Bearing Remover and Installer, PIN 392091,
~ oil and drive a new gearcase head bearing into the gearcase
I
head. The lettered side of the bearing must go toward the tool to
prevent damage to the bearing.

813223

4C/eng 6-15
 ~©

813227
23
813228

Assembly

Before beginning assembly procedures, refer to Cleaning and

Inspection, Page 6-4.

\22\ 1. Oil and install a new O-ring into a new shift rod bushing.
Assemble the Bushing Installer @ to the Rod © (components of
OMC Driveshaft Bearing Remover and Installer, PIN 393092).
Place the bushing ® onto the Bushing and Installer with O-ring
down. Apply OMC Adhesive M sealant to the outside of the
bushing . Using a mallet, drive the bushing into the gearcase until
seated.

\23\ 2. To install a new lower driveshaft bearing, assemble

components of OMC Driveshaft Bearing Remover and Installer,
PIN 393092 (Rod ©, Guide Plate ®, Pin ®, and Small Disc @ with
concave side toward bearing), as shown. Place the lettered side of
the bearing toward the small disc. Using a mallet, drive in the
lower bearing until the pin comes in contact with the guide plate.

\24\ 3. To install a new upper driveshaft bearing , assemble

components of OMC Driveshaft Bearing Remover and Installer,
PIN 393092 (Rod © , Guide Plate ® , and Large Disc ® with 26 DR2061
concave side toward bearing), as shown. Place the lettered side of
the bearing toward the large disc. Using a mallet, drive the upper
bearing in until it is seated firmly.

\25\ 4. Using OMCPropelier Shaft Bearing Remover and Installer,

PIN 392091, and a soft mallet, drive in a new forward gearcase
bearing as far as it will go. Support the nose of the gearcase on a
block of wood on the floor while driving in the bearing . Make
certain that the lettered side of the bearing is facing the tool to
prevent damage to the bearing.

\26\\27\ 5. Install two new seals back-to-back in the gearcase

head using OMC Seal Installer, PIN 327572 . Apply OMC Gasket
Sealing Compound to the metal casing of the seals. Install the
inside seal @ with the lip facing inward and the outside seal ®
with the lip facing outward. Apply OMC Triple-Guard grease to the
lips after installing.

\26\127\ 6. Install two new driveshaft seals back-to-back using

OMC Upper Driveshaft Seal Installer, PI N 327431. Apply OMC
E
Gasket Sealing Compound to the metal casing of the seals. Install o
o
the inner seal @ with the lip facing in and the outside seal ® with :;j
><
the lip facing out. Liberally apply OMC Triple-Guard grease ~
Qi
between seals. ~
ii
6-16 4C/eng E
 30
22293

r:;;l7. Place the pinion thrust washer in the gearcase with

~ chamfered side facing top of the gearcase. Position the thrust
bearing then the pinion .

1291 8. Lubricate, ~h.en install the driveshaft. Rotate the shaft to

engage the pmlon.

1301 9. ~osition the water intake screen in the gearcase with tabs
facmg up.

r::;:;l1 0. Apply OMC Gasket Sealing Compound to both sides of a

32
l!!J new impeller place gasket. Position the gasket and impeller
plate on the gearcase.

r.;::;l11. Apply OMC Needle Bearing Assembly Grease to the

~ impeller drive pin CD. Place the pin on flat of the driveshaft.

\33\ 12. Oil and install a new water pump grommet.

134113. Lightly coat the exterior of the impeller cup with OMC
Gasket Sealing Compound. Place the impeller cup in the
impeller housing. Lightly oil the impeller blades and install the 33
impeller in the housing in a counterclockwise direction.

13411 4. Lightly apply OMC Triple-Guard grease to a new impeller

housing a-ring. Place the a-ring in groove in bottom of the
housing.

135 115. Slide the water pump housing down over the driveshaft
and engage the water pump impeller drive pin and then
rotate the housing until the screw holes line up. Only rotate the
water pump housing in a counterclockwise direction to prevent
the impeller blades from being turned backwards. Once the screw
holes line up, seat the water pump in position. Coat the three
screws with OMC Gasket Sealing Compound, install them, and
tighten the screws to a torque of 25-35 in. Ibs. (2,8-4,0 N·m).

4C1eng 6-17
36 22285
37
""-------------2=22=8'=-'

136116. To assemble the propeller shaft components, place the

spring between the gear and the shaft. The tang end of the
spring faces the gear. Assemble by turning the gear counterclock-
wise while pushing together.

137117. Place the forward gear thrust bearing ® and thrust

washer ® on the propeller shaft. Chamfered edge of the
washer must face away from the gear.

138118. Install the propeller shaft assembly.

~ 19. Wrap a single layer of cellophane tape around the

~ propeller shaft over the groove in the shaft. This will prevent
the seals in the gearcase head from becoming damaged in the
groove.

140120. Lightly apply OMC Triple-Guard grease to a new gearcase

head a-ring. Install the a-ring in groove of the housing.

141121. Coat the a-ring and two gearcase head attaching screws
with OMC Gasket Sealing Compound. Slide the gearcase
head over the propeller shaft and then fully seat it in its correct
position.

142122. Install and tighten the gearcase head retaining screws to

a torque of 60-84 in. Ibs. (7-9 N·m).

Installation
1. Coat the driveshaft splines with OMC Moly Lube. Do not coat
top surface of the driveshaft as lubricant here may prevent
seating of the driveshaft in the crankshaft.
2. Install the gearcase while guiding the water tube into the water
pump grommet and the shift rod into the shift rod bushing.
14313. Apply OMC Nut Lock to threads of the gearcase and
extension (if removed) screws. Tighten screws to a torque of
60-84 in. Ibs. (7-9 N·m).
~ When installing a gearcase to a gearcase extension, do not
~ tighten the retaining screws until the gearcase and the
extension have been placed in proper position with the exhaust
housing and powerhead assembly.

6-18 4C/eng
\44\4. Pressure and vacuum test the gearcase as follows:

INotel Pressure and vacuum test gearcase before filling.

• Remove the oil fill/drain plug and screw in a pressure test
gauge.

• Pump pressure up to 3-6 PSI (21-42 kPa). If pressure

gauge indicates leakage, submerge the gearcase in wa-
ter to determine source of leakage as evidenced by
bubbles. If the gearcase pressure gauge does not indi-
cate leakage, increase pressu re to 16-18 PSI (110-124
kPa). If pressure does not hold, submerge the gearcase in
water and check for source of leakage. Make necessary
repairs and repeat test.
• Screw in vacuum tester. Pump outto 3-5 in. (76-127 mm)
of mercury and see if vacuum holds. Then pump out to
15 in. (381 mm) of mercury and check. If the gearcase
fails to hold on either test, put oil around suspected seal.
If leak then stops or oil is drawn in, that seal is defective.
When the gearcase checks out OK, refill with the proper
lubricant.
5. Fill the gearcase with 2.7 fl. oz. (80 ml) lubricant as follows:
• The gearcase must be in an upright position.
• Remove the oil level and the oil fill/drain plugs. Replace
the seals if damaged.
• Fill the gearcase with OMC Ultra-HPF gearcase lube until
lubricant appears at the oil level hole. Insert the oil level
plug first. Invert the gearcase and remove the oil fill
hose. Install the fill/drain plug. Tighten the oil level and
the fill/drain plugs to a torque of 40-50 in. Ibs. (4,5-5,6
N·m).
• Inspect the gearcase oil level after a motor test has been
performed.
14516. Apply OMC Triple-Guard grease to the entire length of the
propeller shaft. Install hub @ and secure with drive pin ®.
Install shock absorber © and the propeller. Install and secure the
cotter pin @ .

45
C02697

4C/eng 6-19
Service Chart - 4 Deluxe thru 8

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. (325 ml)

~ ~--
~ ---- -
~ 84-86 in. Ibs.
(9-10 N·m)
DR4585

6-20 4C!eng
Gearcase Servicing - 4 Deluxe thru 8
Removal

l' 1. To avoid accidental starting of engine while servicing,

i l l twist and remove all spark plug leads.
rv~ fill/drain
2. Drain the gearcase by removing the oil level plug ® and oil
plug @.

~ 3. Remove the propeller and attaching hardware.

4. Rotate the propeller shaft and place the shift lever into
FORWARD gear.

~ 5. Remove three gearcase retaining screws @ .

~ 6. Remove gearcase and mount in a suitable holding fixture.

4C1eng it Safety Related 6-21

4 Deluxe - 8
Disassembly

~ 1. Remove four water pump screws.

r:;] 2. Slide water pump housing up and off driveshaft. Remove
~ impeller drive key ®, two gaskets ®, and water pump plate ©.
'8l 3. Remove three gearcase cover screws @ and remove the
~ cover. Discard the gearcase cover gasket.

4. Slide the shift rod and driveshaft straight up and out of the
gearcase.

~ 5. Remove the two gearcase head screws.

6. Tap lightly on the ears of the gearcase head using a wooden
dowel and mallet until the gearcase head has rotated 10° or 15° in
either direction.
GO' 7. Remove the propeller shaft assembly from the gearcase.
~ The thrust washer and/or detent balls might remain in the
gearcase. Check inside the gearcase for any of these components
and remove them.

6-22 4C/eng
 ®
t
- --
-------- - m",,,,,mm,,,
o
~,~-

11
31938 26330

f111 '" 8. Wear safety glasses. Slide the gearcase head ®,

~ i l l reverse gear ®, and thrust washers © off the propeller
shaft. Remove the plunger ®, spring CD, and four detent balls Q) .

~ 9. Remove seal saver and O-ring from gearcase head.

r:j3l 1~. ,Remove
~ pInion.
the forward gear by rotating the gear under the

13
•
1141 11 . Tilt the gearcase and remove the shift cam.
~ 12. Remove the pinion, two thrust washers, and thrust
bearing.

f161 13. Inspect the forward bearing race in place. If necessary,

~ remove the race using OMC Small Puller Assembly,
PIN 432131, and OMC Slide Hammer, PIN 432128.

4C/eng & Safety Related 6-23 4 Deluxe - 8 .

-
r:J7l 14. Inspect the driveshaft bearing in place. If necessary,
~ remove the bearing and sleeve using the slide hammer and
OMCTwo-Jaw Puller, PIN 391012. The jaws of the puller must be
reversed so the jaw tips are facing inward. Use a stiff rubber band
to keep the jaws together.

f181 15. Inspect the pinion bearings in place. If necessary, remove

~ the bearings using OMC Bearing Remover, PIN 319880.
Place a shop cloth inside the gearcase to catch the bearings and
tool. If pinion bearings are removed for any reason, they must be
replaced.

1191 16. Temporarily install the gearcase head into the gearcase
with the two screws, finger tight. Using OMC Small Puller
Assembly, PIN 432131, remove propeller shaft seal.

r:::-=J When installing the puller on the seals, be sure the jaws
~ catch the seals and not the bushing in the gearcase head.
1201 17. Remove the driveshaft seals from the gearcase cover
using OMC Puller Bridge, PIN 432127, and OMC Small
Puller, PIN 432131 .

1211 18.Remove the shift rod bushing from the gearcase cover by
prying it out with the shift rod. Remove and discard O-ring.

21
COA3377
6-24 4C1eng
Assembly

Before beginning assembly procedures, refer to Cleaning and

Inspection, Page 6-4.

12211. Using a socket, install new gearcase head seal. Apply OMC
Gasket Sealing Compound to the metal case of the seal. The
seal should be installed with the letters facing outward. Tap seal
in until seated. Apply OMC Triple-Guard grease to the seal lips.

r:;:;J 2. Apply OMC Gasket Sealing Compound to the outside

~ diameter of two new gearcase cover seals. Install the seals
back-to-back on OMC Seal Installer, PIN 326547. Then press
them into the gearcase cover until they are flush. Apply OMC
Triple-Guard grease to the seal lips.

12313. Coat a new shift rod O-ring with OMC Triple-Guard grease
and install it in the gearcase cover.

12414. Apply a thin bead of OMC Adhesive M to a new shift rod

bushing, install it in the gearcase cover, and allow the
adhesive to dry.

12515. Install the upper driveshaft using OMC Pinion Installation

Tool, PIN 326575, from OMC Universal Pinion Bearing Re-
mover and Installer, PIN 391257. Tap the bearing and sleeve
assembly until it seats in the gearcase.

4C/eng 6-25
.
4 Deluxe - 8
\26\6. Install the upper pinion bearing using OMC Pinion Bearing
Installer, PIN 319878 @, a 6V2-16 x 3/8 in. bolt @, and a wide
washer @.

• Assemble the tools with lettered side of the bearing

facing the installer. Draw the upper pinion bearing @
into the gearcase until tool contacts gearcase. Disassem-
ble tool components .

• Assemble the tools with the lower pinion bearing facing

installer tool. Draw the lower pinion bearing ® into the
gearcase until tool contacts gearcase.

r:;:;] 7. If removed, position a new forward bearing race in the

~ gearcase. Using OMCBearing Cup Installer, PIN 326025, and
a mallet, drive the bearing race into its bore until it is seated.

r.;;J 8. The forward gear and bearing cone are serviced as an

~ assembly. If either is worn or damaged, replace the assem-
bly.

\29 19. Install the shift cam with the side labeled "UP" toward the
flywheel.

10. Install the shift rod and rotate to engage rod with shift cam.

\30111 . Coat both sides of a new gearcase cover gasket with OMC
Adhesive M. Install the gasket and cover. Apply OMC Nut
Lock to the cover screws and tighten the screws to a torque of
60-80 in . Ibs. (7-9 N·m).

6-26 4C/eng
@!] 12. Position one pinion thrust washer ® on the pinion. Oil
and install the thrust bearing @. Install the other thrust washer ®
on the pinion.

1321 13. Place the gearcase in the position shown and install
pinion.

1331 14. Install the forward gear by positioning it in the gearcase.

Insert the propeller shaft into the forward gear. Pull up sharply on
the shaft and you will feel the forward gear snap into position.
Remove the propeller shaft.
31
134115. Position the reverse gear and one thrust washer on the
803051

propeller shaft.

16. Install the spring and plunger into the propeller shaft.

17. Apply OMC Needle Bearing Assembly Grease to two of the

detent balls.

& To avoid personal injury, wear safety glasses while perform-

ing Steps 18 through 21.

18. Depress the plunger until the reverse gear detent notches are
in place.

1351 19. Place the second thrust washer on the forward gear side
of the propeller shaft flange. Position the detent balls in the
propeller shaft. Hold the plunger in and slide the reverse gear in
position . This will trap the detent balls and hold the plunger in
position.

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ii
4C/eng Safety Related 6-27
4 Deluxe - 8
20. While holding the reverse gear in position, fill the forward
gear detent notches with ONK: Needle Bearing Assembly Grease
and install the detent balls.

1361 1371 21. Hold the reverse gear in position and install the
propeller shaft assembly into the gearcase. The detent balls must
be positioned between the driving lugs ® of the forward gear.

22. Rotate the propeller shaft to ensure the reverse gear is fully
engaged with the pinion.

13s1 23. Apply OVIC Gasket Sealing Compound to the th reads of

the retaining screws and around a-ring flange of the gearcase
head. Apply ONK: Triple-Guard grease to a new gearcase head
a-ring. Install the a-ring. Apply OVIC Triple-Guard grease to the
seal lips. Install the gearcase head and tighten the screws to a
torque of 60-84 in. Ibs. (7-9 N·m).

1391 24. Install seal saver on propeller shaft with lip facing out.
Press it securely in place.

I
140 25. Apply ONK: Triple-Guard grease to the driveshaft seal
lips. Install the driveshaft and rotate to engage pinion splines.

@II 26. Install the water pump plate ® and the gasket © . Coat
16904A

both sides of the plate gaskets with ONK: Gasket Sealing Com-
pound.

[ill 27. Coat the impeller drive key @ with ONK: Needle Bearing
Assembly Grease and put it in position on the flat on the
driveshaft.

39

6-28 4C/eng
r;;J 28. If you have disassembled the impeller housing compo-
~ nents, reassemble them at this time. Oil the tips of the
impeller. Screw impeller into the cup in a counterclockwise
direction. Lightly coat the exterior of the impeller cup with OMC
Gasket Sealing Compound. Install the cup and impeller. Slide the
water pump assembly down over the driveshaft and position it.
Apply OMC Gasket Sealing Compound to threads of the four
impeller housing screws. Install and tighten the four screws to a
torque of 60-84 in. Ibs. (7-9 N·m).

142129. Pressure and vacuum test the gearcase as follows:

INotel Pressure and vacuum test gearcase before filling.

• Remove the oil level plug and screw in a pressure test

gauge.

• Pump pressure up to 3-6 PSI (21-42 kPa). If pressure

gauge indicates leakage, submerge the gearcase in wa-
ter to determine source of leakage as evidenced by
bubbles. If the gearcase pressure gauge does not indi-
cate leakage, increase pressure to 16-18 PSI (110-124
kPa). If pressure does not hold, submerge the gearcase in
water and check for source of leakage. Make necessary
repairs and repeat test.

• Screw in vacuum tester. Pump outto 3-5 in. (76-127 mm)

of mercury and see if vacuum holds. Then pump out to
15 in. (381 mm) of mercury and check. If the gearcase
fails to hold on either test, put oil around suspected seal.
If leak then stops or oil is drawn in, that seal is defective.
Replace defective components, test, and fill gearcase.

143130. Fill the gearcase with 10-11 flo oz. (290-325 ml) lubricant as
follows:

• Secure the gearcase in an upright position.

• Remove the oil level and the oil fill/drain plugs. Replace
the seals if damaged.

• Fill the gearcase with OMC Ultra-HPF gearcase lube until

lubricant appears at the oil level hole. Insert the oil level
plug first. Invert the gearcase and remove the oil fill
hose. Install the fill/drain plug. Tighten the oil level and
the fill/drain plugs to a torque of 84-86 in. Ibs. (9-10 N·m).

• Inspect the gearcase oil level after a motor test has been
performed.

4C/eng 6-29
Installation
'" 1. To avoid accidental starting of engine while servicing,
i l l twist and remove spark plug leads.
2. Place the shift lever into FORWARD gear.

r:;-l 3. Lubricate the driveshaft splines with OMC Moly Lube. Do

L!J not coat the top surface of the driveshaft as lubricant here may
prevent seating of the driveshaft in the crankshaft.

4. Lightly apply OMC Triple-Guard grease to lower outside diame-

1
16600
ter of the water tube. Slide the gearcase into position on the
exhaust housing being careful to guide the water tube into the
water pump grommet. Rotate the flywheel clockwise to align
crankshaft splines with driveshaft.

r:;J 5. Apply OMC Nut Lock to threads of the gearcase and

~ extension screws. Install the gearcase retaining screws @ .
Tighten the front screw to a torque of 120-144 in. Ibs. (14-16 N·m)
and the two rear screws to a torque of 60-84 in. Ibs. (7-9 N·m).

R When installing a gearcase to a gearcase extension, do not

~ tighten the retaining screws until the gearcase and the
extension have been placed in proper position with the exhaust
housing and powerhead assembly. .

[!] 6. Install the propeller as follows:

• Apply OMC Triple-Guard grease to entire length of the
propeller shaft.

• Install the propeller and thrust washer @.

• Secure the propeller with drive pin ©.

C02386
• Install the propeller nut @ and secure with cotter pin @.

& Safety Related 6-30 4C1eng

Checking Propeller Hub Slippage -
4 Deluxe thru 8

The propeller torque fixture is used to detect slippage between

the propeller and hub.

1. There are two sets of holes for mounting the propeller stops to
the base and bushing assembly. The inner hole pattern is used for
current outboard models through the 40 Commercial models.
Install the propeller stops in the inner hole pattern.

OJ 2. Drive pin shaft, 4 Deluxe thru 8 - Install the correct torque

shaft into bushing in base. Place propeller on torque shaft. Align
drive pin hole in propeller hub with hole in torque shaft. Install
correct lock pin.

rn 3. All models -Install correct socket on torque wrench. Select

the torque value for the model being checked from the torque
column on chart. The propeller hub should not slip when the
wrench is held at the specified torque.

Models Adapter Minimum Torque 2

COA6200

4 Deluxe thru 8 327631 40 ft. Ibs. (54 N·m)

PCE0086

4C/eng 6-31
 Manual Starter
Table of Contents

/1 General Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 2

Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 3
Manual Starter Servicing - 2, 2.3, 3.3 ................. 7- 4
Removal ..................................... 7- 4
Disassembly .................................. 7- 4
Cleaning and Inspection ......................... 7- 5
Assembly ..................................... 7- 5
Installation .................................... 7- 6
Manual Starter Servicing - 3, 4 ..................... . 7- 7
Removal ..................................... 7- 7
Starter Rope Replacement ....................... 7- 7
Disassembly ....................... . .......... 7- 8
Cleaning and Inspection ......... . ............... 7- 8
Assembly .................................. . .. 7- 9
Installation .................................... 7- 9
Manual Starter Servicing - 4 Deluxe . . ........ . ....... 7-10
Start er Rope Replacement ....................... 7-10
Removal ..................................... 7-12
Disassembly .................................. 7-12
Cleaning and Inspection ......................... 7-12
Assembly ..................................... 7-12
Installation .................................... 7-13
Manual Starter Servicing - 5 thru 8 ... .. ............. 7-14
Removal ..................................... 7-14
Starter Rope Replacement ....................... 7-14
Disassembly .................................. 7-15
Cleaning and Inspection ......................... 7-15
Assembly ................ . ............. . ...... 7-16
Installation .................................... 7-16
Interlock and Shifter Bracket Servicing - 5 thru 8 ...... . . 7-17

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:::::
ii
4C/eng 7-1 E
 it 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-at-limited-throttle"
feature before returning engine to customer.

7-2 4C/eng
 Service Specifications
Sealants and Lubricants Required _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

OMC Triple-Guard@ Grease

Lubriplate 777
OMC Nut Lock
OMC Screw Lock
OMC Locquic Primer
Johnson@ or Evinrude@ Outboard Lubricant
Starter Rope Length _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

2,2.3,3.3 53 in. (135 em)

3-8 59112 in. (151 em)

4C/e ng 7-3
 ~ 4 _
30001

Manual Starter Servicing - 2, 2.3, 3.3

Removal
1. Remove port and starboard engine covers. See Section 2.

'" 2. To avoid accidental starting of engine while servicing,

i l l twist and remove spark plug lead.

[!] 3. Remove two screws ® retaining fuel tank. 4 30029

~ 4. Remove two mounting screws. Lift starter from powerhead. ®@

Disassembly A.1 @
~)
f311. Pull out starter rope and tie slipknot to relieve spring tension
~ while removing handle. Remove two screws and washer
retaining motor, cover panel ®. Untie knot in end of rope and
Y '1
remove handle. CD ®
2. Pull starter rope out to limit. Hold pulley firmly so it will not 25390
rewind and release slipknot. Carefully allow pulley to slowly
rotate until it is fully unwound.

f4\ 3. Remove retaining ring @, thrust washer @' and friction plate
~®.

1sl4. Remove return spring ®, spring cover @' friction spring @,

~ and ratchet CD.

r;! 5. Rotate pulley back and forth until spring disengages from
~ bottom of pulley. Carefully lift the pulley straight off the starter
housing so that the spring remains in the housing.
30028

6. Untie the knot and remove starter rope.

7. Jar the housing, bottom side down, on the bench to dislodge

spring.

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& Safety Related 7-4 4C/eng
ii
E
Cleaning and Inspection

1. Wash metal components in solvent and dry with compressed

air.

2. Inspect spring for worn or broken end loops.

3. Inspect all components for wear.

4. Inspect rope and discard if frayed. Replace with rope cut to a

length of 53 in. (135 em).
7
30027
5. Examine pulley and housing for sharp edges and rough
surfaces that could fray rope. File and polish to remove.

Assembly

1. Lubricate spring, spring cavity, and spindle with OMC Triple-

Guard grease or Lubriplate 777.

rJl2. Hook end of spring into pulley. Coil spring counterclockwise

~ inside starter housing.

1al3. If a new rope is used, fuse both ends. Tie a knot at one end of
~ the rope and pass rope through hole in pulley. Push knot and
end of rope into recess.

~ 4. Wind rope counterclockwise on pulley.

5. Apply a thin coat of OMC Triple-Guard or Lubriplate 777 to
outer surface of spring.

19l6. Install pulley into starter housing. The inner spring hook Q)
~ must catch into slot ® of the pulley.
9
30028

4Cl eng 7-5

.
2, 2.3, 3.3
~ 7. Place ratchet on pulley.
~ 8. Place cover and friction spring on spindle.
f111 9. Hook end of return spring in slot of friction plate. Insert the
~ other end of return spring into hole on pulley. Install return
spring and friction plate together over spindle.

f11110. Place thrust washer on spindle. Install retaining ring with

~ sharp side facing out.

11. Place rope in notch and turn pulley three turns counterclock-
wise from its relaxed position.

r:;:;J 12. Feed rope through eyelet on starter housing. When there
~ is still approximately 12 in. (30 cm) of rope outside the starter
housing, tie a slipknot in the rope to hold in place. Install motor
cover panel onto starter housing.

r:jJl13. Install handle onto rope. Tie a knot in end of rope. Insert
~ knotted end of rope into handle.
30029
14. Release slipknot and ease starter pulley back.

Installation

11411. Lift the fuel tank up and attach starter housing to power-
head. Tighten screws to a torque of 60-84 in. Ibs. (7-9 N·m).

11412. Install fuel tank mounting screws and torque screws to

60-84 in. Ibs. (7-9 N·m).

3. Connect spark plug lead.

12
4. Install port and starboard engine covers. See Section 2. 30024

53074

7-6 -30001
4C/eng
 35436

Manual Starter Servicing - 3, 4

Removal

"'" 1. To avoid accidental starting while servicing engine, twist

i l l and remove spark plug leads.

[!] 2. Remove three starter housing screws.

Starter Rope Replacement

f211. Pull out starter rope and tie slip knot to hold against spring
t=J tension while removing handle. Pry anchor out of handle and
remove anchor. Untie knot in rope and remove handle.

rJl2. Cut a new rope 59112 in. (151 em) long. Fuse both ends and
~ knot one end of rope.

"'" 3. ~o ayoid injury or damage do not release pulley when

i l l sprmg IS wound.

~ 4. Pull starter rope out to end of rope. Hold pulley from turning
~ and release slip knot. Pull rope out of pulley.

1sl5. Check spring pre-wind by turning pulley counterclockwise

~ against spring until tight. Let spring slowly unwind 1/4 to 11/4
revolutions until rope anchor ® in pulley, and rope eyelet ® in
starter housing, are aligned.

~ f216. Thread new starter rope through pulley and through

~ t=J starter housing eyelet. Pull rope until tight in pulley. Tie slip
knot in rope to hold against spring tension.

f61 rJl7. Thread rope through handle. Tie a knot in end of rope.
~ ~ Insert knotted end of rope into anchor, and pull anchor into 35439

handle.

8. Release slip knot and let spring slowly wind rope onto pulley.

4C1eng & Safety Related 7-7

Disassembly

I.A. Wear safety glasses to protect your eyes while disassem-

ill bling and reassembling a manual starter. Coiled spring can
cause injury if released.

1. Remove rope. See Starter Rope Replacement .

& 2. Let pulley slowly unwind until all tension is off the spring.

~ 3. Remove the retaining ring @. Remove starter pawl @ ,

~ friction spring, and links © as an assembly.

l' 1sl 4. Remove the starter spindle screw @. Hold pulley in the
i l l ~ housing and carefully lift out spindle ®.
l' Igl 5. Keep fingers away from uncoiling spring. Turn housing
i l l ~ over and jar on bench to dislodge pulley and spring.

Cleaning and Inspection

1. Wash metal components in solvent and dry with compressed

air.

2. Inspect spring for worn or broken end loops.

3. Inspect all components for wear.

4. Inspect rope and discard if frayed. Cut new rope 59'/2 in. (151
cm) long .

5. Examine pulley and housing for sharp edges and rough

surfaces that could fray rope. File and polish to remove any sharp
edges.
35440

& Safety Related 7-8 4C/eng

Assembly

1. Lubricate spring cavity and spring, pulley, and spindle, with

OMC Triple-Guard grease or Lubriplate 777.

r;Q12. Insert spring through housing and position spring and

~ pulley so spring hook ® engages slot @ on pulley as shown.

f11l3. Clean threads of spindle retaining screw to remove adhe-

~ sive. Spray threads with OMC Locquic Primer, let dry, and
apply OMC Nut Lock. Position and hold spindle slot over starter
housing rib. Tighten screw to a torque of 60-84 in. Ibs. (7-9 N·m).

'" f1214. Wind pulley counterclockwise until outside loop of

i l l ~ spring ® is pulled into starter housing pocket 0). To
avoid injury or damage do not release pulley when spring is
wound. Continue winding pulley until spring is tight.

5. Install rope. See Starter Rope Replacement.

f1316. Install starter pawl Q), friction spring, and friction spring
~ links ® as an assembly. Install retaining ring © with sharp
side facing out.

7. Check operation of pawl. The pawl should extend when the

starter rope is pulled and retract when the rope rewinds.

Installation

1. Attach starter housing to powerhead. Tighten the three screws

to a torque of 60-84 in. Ibs. (7-9 N·m).

4C/eng & Safety Related 7-9

Manual Starter Servicing - 4 Deluxe
Starter Rope Replacement

if'. 1. To avoid accidental starting of engine while servicing,

i l l twist and remove spark plug leads.
r:jl
2. Pull starter rope out and tie a slipknot in front of the lower
~ motor cover. Pry out cap ® and untie starter rope knot.
Remove starter handle.

f21 3. Release slipknot while holding pulley. Let starter spring

~ slowly unwind .

f3l 4. Unwind starter rope from pulley. Turn pulley counterclock-

~ wise until knot is visible in window. If knot does not pass
w indow, turn pulley clockwise until knot is visible in the window.
Put a piece of the rope in the mesh point of the pulley-gear and
t he idler-gear ® to hold the spring from unwinding. Pull old rope
out of pulley.

~ 5. Mark the side of the pulley next to the rope hole © as a

~ reference.

f51 6. Wind pulley two revolutions clockwise by turning the pulley

~ by hand. Place the end of the rope in the gear mesh point.

it Safety Related 7-10 4C/eng

 6
53074

f617. Cut new rope 59112 in. (151 cm) long. Fuse 112 in. (12 mm) at
~ each end with heat. Tie starter rope knot @ in one end.

rJl8. Push other end of rope through hole in side of pulley with a
~ small pick and pull rope out through pulley. Seat knot firmly in
pulley cavity.

1sl9. Wind rope around pulley clockwise, using a small wire hook
~ ® to thread rope past rope guard at bottom and idler at top.
Wind rope as many turns as possible, ending with rope extending
out the front of pulley above rope guard.

19l10. Pull enough rope off pulley to thread rope through lower
t=J motor cover eyelet, and tie slip knot in rope.
r;Ql11 . Push rope end through handle and tie starter rope knot
~ ©. Pull knot into handle and insert cap @. Pull out slipknot
and let spring rewind rope.

'11112. To check spring pretension, pull starter rope out fully, and
~ pull out spring end ® until spring is tight. Spring pull-out
must be 8 to 18 in. (20-46 cm). Wind starter rope an additional
turn around pulley if spring pUll-out is more than 18 in. (46 cm),
and remove a turn if pull-out is less than 8 in. (20 cm).

32155

4C/eng 7-11
4 Deluxe
Removal

'" 1. To avoid accidental starting of engine while servicing,

i l l twist and remove all spark plug leads.
r:jl 2. Pull the starter rope out far enough to tie a slip knot in the
~ rope behind starter handle. Untie knot in end of rope and
remove the handle and rubber bumper.

3. Release the slip knot while holding the pulley, and allow the
starter spring to slowly unwind.

'2l 4. Grasp the end ofthe starter spring and pull spring out as far
~ as it will go. This w ill relieve spring tension.

fil 5. Remove the port ignition coil from the powerhead. Remove
~ the starter assembly adjustment screw @ .

f31 6. While holding the starter assembly together, remove shoul-

~ der screw @. Remove the starter assembly from the power-
head.

Disassembly

f41 1. L.ift off the idler gear arm @ , idler gear @ , and idler gear arm
~ spring @.

r.;l 2. Lift the pulley ® out of the cup and stop assembly @ .
~ Unhook spring ® and spring retainer CD from pin in pulley.
Note position of spring loop. Remove rope from pulley. Remove
washer Q) from cup and stop assembly.

Cleaning and Inspection

1. Wash all parts, except rope, in solvent and dry with com-
pressed air.
2. Remove any traces of corrosion. Prevent further corrosion by
wiping metal parts with an oil dampened cloth.
3. Inspect starter spring end loops. Replace spring if weak,
corroded, or cracked.

4. Inspect rope. Replace rope if frayed. Cut new rope to 59112 in.
(151 cm) in length. Fuse ends of rope.
5. Inspect pulley and bushing in cup and stop assembly. Replace
if cracked or chipped.

Assembly
1. Lightly coat inside of cup and stop assembly and idle gear arm
with OMC Triple-Guard grease or Lubriplate 777. If removed,
insert bushing in idler gear arm.

~ 2. Place washer Q) in cup and stop assembly.

& Safety Related 7-12 4C/eng

~ 3. Position spring retainer CD on pulley as shown.
714. Lubricate spring with OMC Triple-Guard grease or
~ Lubriplate 777. Hook end loop of spring to pulley roll pin.

1815. Install cup and stop assembly with washer over pulley. Be
~ sure spring is positioned through tabs as shown.

6. Temporarily insert shoulder screw through cup and stop

assembly. Install a nut on the shoulder screw to secure assembly.

7. While pressing down on pulley, turn pulley clockwise and wind

6
COAl178
spring into cup and stop assembly until outside loop of spring
engages outside face of assembly.

8. Slowly release pulley, relieving spring tension. Hold starter

assembly together and remove shoulder screws.

~ 9. Position idler gear arm spring ® in idler gear arm @ . Place

~ idler gear @ on idler gear arm.

10. Clean threads of shoulder screw to remove adhesive. Spray

threads with OMC Locquic Primer.

19l11. Insert shoulder screw through idler gear arm. Install idler
~ gear arm assembly over pulley. Be sure stop ® of idler gear
arm is positioned between the two tabs © of the cup and stop
assembly.

Installation

1- 1. To avoid accidental starting of engine while servicing,

i l l twist and remove all spark plug leads.
2. Apply OMC Screw Lock to the threads of the shoulder screw.
Position the starter on the powerhead. Install the shoulder screw
and the adjustment screw. Tighten but do not torque these
screws at this time.

3. Install the starter rope, see Starter Rope Replacement.

4. The idler gear arm is limited by two stops. The upper stop
controls the depth of engagement between the flywheel and idler
gear teeth. A slot in the cup and stop assembly bracket provides
the adjustment. Hold the idler gear arm stop against the cup stop;
fully engage the idler gear teeth in the flywheel.

rJl5. Tighten the shoulder screw @ to a torque of 120-144 in. Ibs.

~ (14-16 N·m). Securely tighten the adjustment screw ®.

6. Install the port ignition coil to the powerhead.

4C/eng & Safety Related 7-13

4 Deluxe
Manual Starter Servicing - 5 thru 8

Removal

'" 1. To avoid accidental starting of engine while servicing,

i l l twist and remove spark plug leads.
rv starter
~
2. Remove the three starter housing retaining screws and lift
off powerhead.

f213. Push on side of locking tab ® and pull on lockout cable to

~ disconnect cable. Remove the plunger and spring from the
cable.

Starter Rope Replacement

'3l f414. Pull starter rope out to end of rope. Turn pulley until rope
~ ~ anchor ® in pulley and rope guide © in housing align.
Insert tool @ through pulley and starter housing to hold pulley
against spring tension.

1sl5. Pry anchor out of handle and remove anchor. Untie knot in
~ end of rope and remove handle. Pull old rope out through
pulley.

6. Cut a new rope 59112 in. (151 cm) long. Fuse both ends of rope.

I.A. 1cl7. Check spring pre-wind by removing tool from pulley

ill ~ and turning pulley counterclockwise until tight. To avoid
injury or damage do not release pulley when spring is wound. Let
spring slowly unwind % to 1% revolutions until rope anchor ® in
pulley and rope guide © in starter housing are aligned. Reinsert
tool to hold pulley.

r.;l hl8. Thread rope through handle. Tie a knot in end of rope.
~ ~ Insert knotted end of rope into anchor, and pull anchor into
handle.

f819. Using a sharp, hooked pin @, thread rope through rope

~ guide ®, down through pulley rim @, and up through rope
channel to anchor point @. Knot rope and pull knot into anchor
point.
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10. Remove tool and let spring slowly wind rope onto pulley. o
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& Safety Related 7-14

DR5097
4Cleng
ii
E
Disassembly

~ Wear safety glasses to protect your eyes while disasserr.·

ill bling and reassembling a manual starter. The starter spring
can cause injury if released.

1. Remove rope, See Starter Rope Replacement.

19l 2. Let pulley slowly unwind until all tension is off the spring.
~ Remove the E-ring CD, and lift pawl and links Q) off as an
assembly.

~ ~ 3. Remove the starter spindle screw and locknut @.

ill ~ Hold the pulley down in housing and lift out spindle (1).
Carefully lift out pulley, leaving spring in housing.

~ Do not remove spring with spring turned up. Do not lift

ill spring out of housing by hand or with pliers. Spring is under
tension and will cause injury if accidentally released.

1- f11l 4. Ke~p fingers aw~y from uncoiling spring. Tu.rn starter

i l l ~ housmg over and Jar on bench to remove sprmg.
Cleaning and Inspection

1. Wash metal components 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. Inspect starter rope. Replace if frayed. Cut new rope 59112 in.
(151 cm) long. Fuse 112 in. (12 mm) at each end of the rope.

5. Examine the pulley and the starter housing. Look for sharp
edges and rough surfaces that could fray starter rope. Smooth all
rough edges.

6. Examine starter lockout parts. Replace any worn or damaged

parts.

4C/eng & Safety Related 7-15

 31978

Assembly

f.i2l 1. Place shield ® into starter housing. Lubricate starter

~ housing, shield, spring, and pulley ® bearing surfaces with ,
OMC Trip/e-Guard grease.

f1il2. Insert spring through starter housing @ . Hook spring end

~ @ into pulley hub slot ® as pulley is placed in position in the
starter housing.

1141 f1513. Check to see that spring is attached to pulley. Secure 31975
~ pulley with screw ®,lubricated spindle @, and locknut
@. Torque locknut to 120-140 in. Ibs. (14-16 N·m).

'" r,&14. Carefully turn pulley counterclockwise until spring is

illl~ completely drawn into starter housing pocket CD. Con-
tinue winding until spring is tight. To avoid injury or damage do
not release pulley when spring is wound.

5. Install rope. See Starter Rope Replacement

r:j7l 6. Reinstall. pawl components as an assembly. Install E-ring

~ with sharp side out.

Installation

1181 1. Install starter assembly on motor with spacers and screws.

Torque screws to 60-84 in. Ibs. (7-9 N·m). Install spring Q)
and lockout plunger ® on cable. Push cable into starter housing
with locking tabs © on the sides.

'r 2. Check operation of starter and starter lockout. Starter

ill should crank motor when in NEUTRAL. Starter MUST NOT
crank motor in FORWARD or REVERSE.

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& Safety Related 7-16 4C/eng

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Interlock and Shifter Bracket Servicing - 5 thru 8

Removal

1. Remove the powerhead as described in Section 4.

IT] 2. Remove spring clip from bracket.

[IJ 3. Remove shift rod from bracket.

m 4. Remove two screws retaining bracket. Remove bracket.

W 5. Inspect components and replace if necessary.

[ [ ] 6. Remove clip rings retaining shift lever. Remove pins and

lever.

Installation

1. Install shift lever, pins, and clip rings.

2. Place bracket components in proper position and secure with

screws.

3. Place shift rod in bracket and secure with spring clip.

4. Install powerhead as described in Section 4.

4C/eng 7-17
 Electrical System
Table of Contents

fA General Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 2

Service Specifications ...... . ...................... 8- 3
Battery Cable Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 3
Battery Specifications . . ..... . ..................... 8- 4
Description of Charging System. . . . . . . . . . . . . . . . . . . . . 8- 7
Charging System Check Chart . . . . . . . . . . . . . . . . . . . . . . 8- 8
Running Test, Alternator Output. . . . . . . . . . . . . . . . . . . . . 8- 9
Stator Resistance Check ...... .. ......... .. ........ 8-10
Rectifier Ohmmeter Tests .......................... 8-11
AC Lighting Coil Resistance Check ................... 8-12

4C/eng 8-1
 & 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 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 the original

position.

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.

8-2 4C1eng
 Service Specifications
Stator Resistance Chart _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

Model 4Amp

5-8 0.55 ± 0.05 Ohm

PCE0068

Battery Cable Extension

The following are minimum specifications for stranded copper cable without splices. Cable measure-
ments given are from the motor to the battery. The maximum length is 20 ft. (6,1 m), regardless of cable
diameter.

~ These specifications do not apply to aluminum battery cables. OMC does not recommend the
~ use of aluminum battery cables.

Minimum Recommended Gauge

Total Extended Length

1 - 10 ft. 11 - 15 ft. 16 . 20 ft.

Model (0,3 . 3 m) (3,4·4,6 m) (4,9·6,1 m)

5-8 10 Ga. 8 Ga. 6 Ga .

PCE006 1

4C/eng 8-3
Battery Specifications
r;:;J Batteries must be heavy-duty, marine construction and
~ either vented/refillable, maintenance-free, or deep-cycle
with a eeA or MeA rating.

For best performance, OMC recommends you use a 12-volt

battery with a minimum rating of 360 eeA (465 MCA) with 90
minutes of reserve capacity (50 ampere-hours).

~ Use bolts and nuts to secure battery cables to the battery.

~ DO NOT use wing nuts even if they were supplied with the
battery. Wing nuts will work lose. Loose battery cables can cause
damage to the electrical system.

Battery Testing

~ Battery electrolyte is an acidic solution and should be

ill handled with care. If electrolyte contacts any part of the
body, immediately flush the exposed area with liberal amounts
of water and seek medical aid as soon as possible.

1. Visual Inspection

The first step in determining the condition of a battery should be a

visual inspection. Look for conditions such as damage to the case,
loose terminals and evidence of electrolyte seepage. These signs
may indicate improper care, installation, or application of the
battery.

Look for excessive corrosion on the battery terminals and cables.

Check the battery cables for worn or frayed insulation. Replace
cables, if necessary.

Check the electrolyte level in each cell. If electrolyte level is below

the plates, it is possible the battery is permanently damaged. Also 1
842018
look for dirt, oil, or other contaminants floating in the electrolyte.

ill 2. Hydrometer
~ Disconnect positive battery cable whenever charging bat-
~tery.

This test can only be used when there is sufficient electrolyte

above the battery plates to fill the hydrometer tube. Do not,
however, take readings immediately after refilling the cells with
water. The battery must be charged, then checked with a hydrom-
eter.

View the hydrometer with your eye on the same level with the
liquid surface. The float of the hydrometer must be free. Make
correction for the temperature.

Specific gravity will vary 4 points (0.004) with every 10° F (6° e)
temperature change. For each 10° F (6° e) below 80° F (27° e),
subtract 4 points from hydrometer reading. For each 10° F (6° e)
above 80° F (2]0 e), add 4 points to hydrometer reading.

& Safety Related 8-4 4C/eng

After correcting to 80° F (2]0 C)' interpret readings as follows:

• All cell readings uniform and above 1.225 specific gravity

indicates battery is serviceable, but may require charg-
ing.

• All cell readings uniform and below 1.225 specific gravi-

ty, charge fully and retest.

• Variation of more than 30 points (0.030) specific gravity

between any two cells, indicates battery condition is
questionable. Recharge and retest before replacing bat-
tery.

3. Capacity Test

Satisfactory capacity tests can be made only when the battery

electrolyte equals or exceeds 1.225 specific gravity at 80° F (2]0
C).

~ 4. Terminal Voltage Test

"'" Use extreme caution during any load testing. Improper
i l l procedures could overheat battery and cause electrolyte
gassing. This might cause an explosive atmosphere.

a. Variable Load High Rate Discharge Tester (Recom-

mended)

Connect tester to battery terminal posts. Discharge at a rate of

three times battery ampere hour rating for 15 seconds. If the
voltage is 9.6 volts or higher at the end of 15 seconds, the battery
has good output capacity.

b. Fixed Resistance Tester

This equipment has built-in load for high-rate discharge testing.

Follow equipment manufacturer's instructions regarding test per-
iod and meter readings.

c. Engine Load for Resistance

Twist and remove the spark plug leads. Connect a voltmeter

across the battery. Crank engine for 15 seconds. If voltage is 9.6
volts or higher at the end of 15 seconds, the battery has good
output capacity.

4C/e ng it Safety Related 8-5

Battery Charging

Boost charge 12-volt batteries at 50 amperes for 20 minutes (1000

ampere minutes). If the charger will not give this rate, charge for
an equal number of ampere minutes at best rate available. DO
NOT boost battery more than this amount for the "light load
test."

If batteries are to be fully charged by means of a quick charger,

the charge rate must be "tapered" (reduced to a safe limit) when
the electrolyte temperature reaches 125°F (52°C), or when gassing
becomes excessive. Failure to do so may harm the battery.

If the battery is to be slow charged, adjust electrolyte to proper

level by adding water, then charge the battery at 5 amperes until
fully charged . Full charge of the battery is indicated when all cell
gravities do not increase when checked at three intervals of one
hour and all cells are gassing freely. Plenty of time must be
allowed for slow charging. Charge periods of 24 hours or more
might be required.

Battery Care

Keep the battery charged at all times. Check the state of charge by
making specific gravity readings with a battery hydrometer. It is
suggested that specific gravity readings and checking for replace-
ment of water be made every two weeks. If the battery has been
standing for 30 days, recharge the battery before placing it into
service to ensure reliable starting. Charge battery to the specific
gravity recommended by the battery manufacturer.

Check the specific gravity of the battery electrolyte with a battery

hydrometer, preferably one that has a built-in thermometer and
correction chart. No other method should be used to determine
the charge condition of a battery. Note also that a hydrometer
reading is not accurate if water has been recently added, because
the water has not had a chance to mix with the electrolyte.

The proper water level should be maintained at all times. If water

is added in freezing weather, the battery should be charged to full
charge at once. Only distilled water, or water approved for battery
use, should be added to the battery to replace water lost through
evaporation. Never add acid except when acid has been lost by
spilling.

Install the battery near the motor. Mount the battery in a

ventilated case and attach the case to the boat. A loose battery
can shift in the boat damaging itself or other equipment. Tighten
hold-down nuts evenly until the battery is secure. If hold-down
nuts are too tight, distortion and damage to the battery case will
result. Connect battery cables, making sure clamps are tight on
battery posts to ensure good contact. Apply a coat of Q\IIC
Electrical Grease to exposed areas of battery posts and clamp
connectors to retard corrosion.

INote I Correct battery polarity

is extremely important. The bat-
tery MUST be connected so its negative post (-) is connected to E
o
ground. If the positive post (+) is connected to ground, the o
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rectifier diodes will be damaged. ><
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8-6 4C/eng E
Description of Charging System

The outboard charging system consists of a battery, a flywheel,

an alternator stator, and a rectifier.

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.

The engine's flywheel contains the permanently charged mag-

nets which provide the energy to power the stator windings. The
magnets must be at their original design strength for full alterna-
tor output.

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.

The rectifier consists of a series of diodes, built into a metal case,

which changes the stator's alternating current to the direct
current used to charge the battery. One, several, or all of the
rectifier diodes might become damaged , resulting in a system
grounded condition, a no charge condition, or an incorrect
charging rate.

4C/eng 8-7
Charging System Check Chart

Where to Look Cause Procedure

Battery 1. Battery defective or worn out 1. Check condition and charge

2. Low electrolyte level 2. Add water and recharge
3. Terminal connections loose or 3. Clean and tighten
corroded
4. Excessive electrical load 4. Evaluate accessory loads

Wiring 1. Connections loose or corroded 1. Clean and tighten

2. Stator leads shorted or grounded 2. Perform ohmmeter tests
3. Circuit wiring grounded 3. Perform ohmmeter tests

Alternator stator 1. Damaged stator windings 1. Perform ohmmeter tests

2. Weak flywheel magnets 2. Perform running output tests
3. Damaged stator leads 3. Perform ohmmeter tests

Rectifier 1. Damaged wiring or diodes 1. Perform rectifier ohmmeter tests

PCE0080

8-8 4C/eng
Running Test, Alternator Output

lllli.l.tlr I
~ Disconnect battery cables before proceeding with this
~ check.

1. Remove the rectifier red lead from the terminal board.

o 1000 2000 3000 4000 5000 6000
2. Wire a 0-40 amp ammeter in series with the rectifier red lead
and the wiring harness red lead.
1
'" Guard against any red wire, its terminals, or the ammeter DR1153

i l l coming in contact with engine ground while the engine is

running. Contact could cause arcing.

3. The engine's battery should not be fully charged when begin-

ning 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.

4C/eng & Safety Related 8-9

 DR4156

Stator Resistance Check

~ Disconnect battery cables before proceeding with this

~ check.

~ 1. Disconnect all stator leads from terminal board.

f21 2. Calibrate ohmmeter on appropriate scale. Connect the
~ ohmmeter black lead ® to the stator yellow/blue lead.

~ 3. Connect the ohmmeter red lead ® to the stator yellow lead.

• Ohmmeter should show 0.55 ± 0.05 !1.

f21 4. Move the ohmmeter red lead ® to the stator yellow/gray

~ Iead .
• Ohmmeter should show 0.55 ± 0.05 !1.

rJl 5. Check for a grounded condition: Disconnect both ohm-

~ meter leads. Calibrate ohmmeter on appropriate scale. Con-
nect one ohmmeter lead to a clean engine ground.

@] 6. Connect the other ohmmeter lead to stator yellow/blue lead.

• Ohmmeter should show a high reading.

• If ohmmeter shows a low reading, stator is grounded.

~ 7. Repeat Step 6 on stator yellow and yellow/gray leads.

• Results should be similar.

8. If a stator lead is grounded, repair it or replace the stator

assembly.

8-10 4C1eng
Rectifier Ohmmeter Tests
INotel Disconnect battery cables before proceeding with this
check.

W 1. Disconnect all rectifier leads from terminal board.

W 2. Calibrate ohmmeter on appropriate scale. Connect one

lead @ to a clean engine ground. Connect the other lead ® to the
rectifier yellow/gray lead. Note the reading. Reverse the ohm-
meter connections or press the "reverse polarity" button and
note the reading.

• A high reading in one direction and a low reading in the

other direction indicates the diode is OK.

• Two high readings or two low readings indicates the

diode is damaged.

W 3. Repeat Step 2 using the rectifier yellow lead.

• Results should be similar.

rn 4. Repeat Step 2 using the rectifier yellow/blue lead.

• Results should be similar.

[ [ ] 5. Move ohmmeter lead @ from engine ground to rectifier

red lead.

[ [ ] 6. Repeat Step 2 with ohmmeter leads connected to rectifier

red and yellow/gray leads.

• A high reading in one direction and a low reading in the

other direction indicates the diode is OK.

• Two high readings or two low readings indicates the

diode is damaged.

[ [ ] 7. Repeat Step 6 using rectifier red and yellow leads.

• Results should be similar.

[ [ ] 8. Repeat Step 6 using rectifier red and yellow/blue leads.

• Results should be similar.

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4C/eng 8-11 E
AC Lighting Coil Resistance Check

[ ] ] 1. Calibrate an ohmmeter on appropriate scale. Connect it

-@
between yellow/grey ® and yellow ® leads.

• Meter must show 0.86 ± 0.05 n.

ITJ 2. Connect meter between yellow/grey ® and yellow/blue ©
leads.

• Meter must show 1.21 ± 0.02 n.

DR41 S9

[ [ ] 3. 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.

DR4161

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8-12 4Cleng
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 Safety Section
Table of Contents

Part A Marine Products and the Safety of

People Who Use Them . . . . . . . . . . . . . . . . . . . . . S- 2
Outboard Shift System and Persons Safety. . . . . . . . . . . . S- 3
Outboard Speed Control System and Persons Safety . . . . S- 4
Outboard Steering System and Persons Safety. . . . . . . . . S- 5
Outboard Fuel, Electrical System and Persons Safety . . . . S- 7
Outboard Mounting System and Persons Safety ....... . S-10
Outboard Hydraulic Tilt/Trim Shock Absorption
System and Persons Safety ..... . . . ... . ..... S-12
Outboard Emergency Stop System and
Persons Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . S-13

Part B Marine Products and the Safety of

People* Who Fix Them ... .. ................ S-16
Handling Lead/Acid Batteries ....... . .... .. ......... S-19
Gasoline! Handle With Care . . .... ... ... . ........... S-20
Hazardous Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-21

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4C 5-1 E
 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, manu-
facturers 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.
E
• When motor is returned to boat, Use Only the Special Nuts and Bolts to hold remote Steering, o
o
Shift, and Throttle cables to the motor. :;j
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S-2 E
 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,

0.---- Shift linkage must

match control
lever position.

What Could Happen?

• If ..... .If .....

Forward
or .Reverse
Reverse

..... propeller still powered (turning)

unknown to operator, or motor will ..... boat will move Opposite
Start in Gear, boat will move suddenly. to direction wanted by operator.

How Can Loss of Shift Control be Minimized?

• Read, Understand, and Follow manufacturers Instructions.

when
Rigging • Follow warnings marked" & " closely.
or after
Servicing •• 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.

S-3
 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" & "closely.

• Assemble Parts Carefully

when • Make Adjustment Carefully
Rigging • Test Your Work. Don't Guess. Make Sure Motor Changes Speed
or after Smoothly, Quickly.
Servicing • Make Sure Full Throttle Can be Obtained so Operator Won't Overload
Parts. E
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5 -4 E
 Outboard Steering System and
Persons Safety

The outboard steering system starts here

at the steering wheel .....

. . . . . and ends .....

here at the Trim Tab

What's Most Important? on the outboard motor .....

The Steering System .....

• must not come apart

• must not jam

• must not be sloppy or loose

What Could Happen?

• If steering system comes apart, boat might turn 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?

• Use a steering system recommended by the motor manufacturer which meets

Marine Industry Safety Standards (ABYC).
When • Read, Understand, and Follow manufacturers Instructions.
Rigging
or after • Follow warnings marked" &"
closely.
Servicing • 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

• Must Not Bind

• Must Not Touch Other boat, motor

or accessory Parts in Transom Area.
Why? A hard blow to the motor's
" I
- - gearcase can result in damage

- - "I
" I to steering parts here
transom - -'"
~
mounted ~...- ...- - stop
steerer 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 ....

E
on the water. - .. when least expected. o
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S -6 E
 Outboard Fuel, Electrical System and
Persons Safety

The Fuel System The Electrical System begins

starts here at here ..... at the battery .....
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 "&" closely.

• 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.

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 H ide in the
bottom of the boat.

To avoid those
Static Electric
Sparks .....

Ground (touch) the

spout against the tank E
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it has to be Metal to Ground the spout to the tank. ~
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$-7 E
• 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
~:=iiiiiiiiiE~~ \ I

I~I

• When Storing:

Whenever possible,
... remove Hose from
motor And from tank .

. . . . . and store arou nd

I f tank cap has an ears of tank.
air vent valve, make
This way gasoline is
sure it's closed.
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:

I Carburetor air intake

silencer will catch and
hold fuel which may

)_U Flood into motor if

carburetor float sticks.

So make sure Silencer and all its Gaskets are on motor And Drain Hose is in place.

Air silencer mounting Screws are special lock screws. Use only the special Screws.

S-8
• 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 Wire Clamps - Tie Straps

• in position (to avoid • position as shown in manuals
shock hazard) • use only coated clamps
not torn or cracked

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.)

• I n transom area .....

All Connections
• clean
• Tight Electrical Cable
(Prevents sparks)
• Not rubbing
on sharp objects .. . ..
• enough slack to allow full
turning without pull loads
on cable (Prevents Sparks)

~~__"";;'ioIIII!!____
~~~ Batteries
• Secure in approved E
battery box or bat- o
o
tery tray. :;j
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• Battery terminals in- ~
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sulated.
~
• No strain on cables. ii
S-9 E
 Outboard Mounting System and
Persons Safety

The Mounting System includes

--"-;!"_ _ _--- motor parts

""", bolts, nuts, washers, and

Ij/f!--~---~
_ _ _ _- #- boat's transom
.....

What's Important?

Motor must stay in position on boat's transom

What Could Happen?

• Motor may SL . . . I ... 0 ... E

on transom
..... Boat may turn and be
hard to steer.

• Motor may
T . . . I ... L ... T on transom ... Boat may turn
and be hard
to steer.
• If motor hits .... Motor could break or boat's
something solid ..... p transom could break away.

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" & "closely .....

S-10
 50
• If Boat Plate shows ..... U .S. COAST GUARD
CAPAC ITY INFORMATI.ON

MAXHP ....
MAX PERSONS
§
... . . use
Only ..... ~r-
~~
MAX WEIGHT

Or Smaller!

• When Rigging or
Fixing any boat ... .
if transom looks
Weak, tell the
owner .....

Mount on Flat Surface only .

motor may come . . . . . Use Shims to make surface flat .
Loose .. ...

Flat

• Use Bolts, Nuts, and Washers sent with Motor _ - - - -....__

They're usually Special ..... won't Rust ... or
Weaken.

• I f owner tells you

"I hit something
really hard .. . .. .
~~
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-
--
-.
-
.

--- -.--...--- . - - .- .
. . . . . High speed blow
to lower unit . .. or,

slow, heavy squash

to motor .... .

. . . . . look for Damaged Parts and

Loosened Nuts and Bolts in both
the Steering and Mounting Systems.
Replace damaged parts.

If weakened, parts could fail later . . . . . on the water

E
. . . . . when not expected. o
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S-11 E
 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"

~-~------------~- too far Suddenly

What Can Happen?

• Without Shock protection,

a Blow like this ......... and Motor could break ... or
Transom could break away ..... Motor may be lost overboard,
..... and Boat may .. ... S
i
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? ~
r Make sure Manual Release
. L / Valve is closed tight.
(45-55 in. Ibs.)

• Read, Understand, and Follow I f left Open .. . motor

manufacturers Instructions. has No shock protection

• Follow warnings marked" &" closely.

• Test your work whenever Possible. Trimming "In" too Far can
• If oil Leaks seen in area, determine happen when Angle Adjusting Rod
Source. Keep reservoir filled. isn't in the Right hole ... Or
• If motor is Hydraulic Tilt/Trim Model, is Not in Any H~. (Lost)
E
Always return Rod to Hole Position determined earlier by Boat Operator ... o
o
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and make sure Angle Adjusting Rod Retainer is in locked position. ><
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S-12 E
 Outboard Emergency Stop System and
Persons Safety

the Emergency Stop system begins

here at the Buck Ie .....

. . . 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?

• If switch fails .....

. . . . engine will keep running when cap is pulled from switch.

• If lanyard is caught ....

. .. engine will keep running.

S-13
 • If lanyard is cut or frayed ... ~

,~

... lanyard or cap may break when pulled ....

and engine will continue running.

• If engine does NOT stop when lanyard is pulled,

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 Instructions.

• Follow warnings marked & closely.

• Assemble parts carefully

• Inspect lanyard for cuts or fraying, rubber cap for wear.

When Replace with original parts. Do not substitute.
Rigging or
after • Locate control box and other items in area to keep
Servicing lanyard from being caught.

• ALWAYS TEST EMERGENCY STOP SYSTEM. PULL

LANYARD . ENGINE MUST STOP. IF IT DOESN'T,
REPAIR BEFORE NEXT USE.

S-14
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,

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?

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i:i
S-15 :::
.:::
 Part B Marine Products an d 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 .....

~ Rigging Boats ~ Fixing Things

~ 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
"'-... hang like this when
~ lifted off the floor .... .

Center of gravitv-...._ Stand Clear!

It might hit
you as it swings.
• I f motor does not have fixed lift
bracket and you use Universal Puller
(378103) and Lifting Eye (321537) .. . ..

. . . . . use only the special

hardened screws and washers
from the set.

. . . Regular screws aren't

• Motor may also Drop suddenly
if Hoist or Motor Stand are in strong enough. Screws
Poor shape .... or Too small may Break and motor
-- for the job may drop suddenly.
300lbs

• Make sure Shop Aids have Extra Capacity . ... . .. .. . and keep them in Good Repair!
- E
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* Mechanics, Technicians, backyard do-it-yourselfers. ~
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S-16 E
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
r=fIl't.....- - - - you .... may cause
------''-L--L--1JL_ _-.l!~5a_=~=_ 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 .....
O Turn Key Switch "Off"

Shift to

•
Neutral
Twist and remove ALL
spark plug leads

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NO SPARK NO START NO SURPRISES oj
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:::::
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S -17 E
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 below
2000 RPM . .. . . with no load,
motor will run Too Fast very
easily ..... and wear Ear
Protectors .
• running motor with the Wrong
Test Wheel .....

This may happen if

motor runs
Too Fast .... .

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 '" \

'---·'\V'.
, II #' '
Yl
~Sprayed
.
./
.------ Cleaners,
~Grinding Paints

~ChiSeling
(Steel on Steel)
(Tip: Use Plastic or Brass type Hammers.
They don't chip off as easily as steel hammer.)

Protect Eyes ..... E

~Acid ~ Ends of Cables Wear Safety Glasses o
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5-18 ii
E
 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 'P~. . . . . . ._ _ _~~::----
clogged, pressure inside may build ...•
battery may EXPLODE.

Battery Gas is Explosive!

While Charging or Discharging,
remember . ... .

No Smoking Never remove charger cables from

battery posts ... it's a sure way to
No Flames
make lots of sparks ... surrounded by
No Sparks
Battery Gas.

Don't check battery charge

by placing metal objects · After Charging
across posts
(1) Shut Off charger
You ' re sure to
make Sparks and (2) Pull charger Plug out of 110V outlet
serious Burns are possible.
. . . Then, (3) Take charger Cables off battery Posts E
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::::
5 - 19 i:i
:::
.:::
 Gasoline! Handle With Care
Gasoline vapor and air mixtures 1 Part
explode easily and violently Gasoline - - - . -
when mixed as shown ..... . . .. .

20 Parts By
When you smell ANY odor of gasoline, Air Volume
explosion is possible

Gasoline fumes are heavy

and will sink to the lowest
point in the boat or room .. . ..
and will Stay there . .. . . Waiting
•
!GAS
FUME S
I

If the air around

you is quiet. ....
the pilot light in
the heater may
ignite the heavy fumes ... . .
before you r nose
What Can You Do? ever smells the fumes

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 (furnace, dryer, water heaters)
~ Loose Wires on Running Motors
~????????

E
How Many of These are in Your Area? o
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ii
S-20 E
 Hazardous Products

Know How
items in the
Shop can

--
._-_ hurt people . . . . .

'- - -
--
rUEL -
-
-----AD~ESIVE
--.:::::::
--
--
-
ADDITIVE

DANGER
...... ----

• Read ~ "How and Where to Use,"

~ "How to give First Aid." Have "recommended"

first aid materials on hand - shou Id 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

S -21
 WATER FLOW DIAGRAM

2-3.3

DR5088
 WATER FLOW DIAGRAM

3,4

DR5110
 WATER FLOW DIAGRAM

4 DELUXE

DR5105
 WATER FLOW DIAGRAM

5-8

DR5106
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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:

Hansen Marine Products Merc-O-Tronic Instruments Corporation

P. O. Box 1106 215 Branch Street
Lake Villa IL 60046 Almont MI 48003
(708) 356-9552 (810) 798-8555

Meyer Engineering Company OTC

1139 N. Lewis Avenue 655 Eisenhower Drive
Winthrop Harbor IL 60096 Owatonna MN 55060
(708) 746-1500 1-800-533-0492 or 1-800-533-5338

Stevens Instrument Company

P. O. Box 193
Waukegan IL 60079
(708) 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 SysteMatched Parts & Accessories TM.

irc 9/95