Content

Introduction

• Models covered in this manual
• Model designation
• Abbreviations used in this manual
• Product reference and illustrations
• Symbols

Service specifications and special tools

• Technical data
• Standard torque specifications
• Special tools
• Shop aids

Installation and predelivery

• Boat rigging
• Outboard installation
• Outboard rigging
• Fuel and oil
• Running checks
• Propeller selection

Maintenance

• Inspection and maintenance schedule
• Anti-corrosion protection
• Cooling system
• Fuel system
• Battery
• Lubrication
• Spark plugs
• Valve clearance
• Idle speed
• Ignition timing
• Storage
• Pre-season service
• Submerged engines

Electrical

• Caution system
• Battery charging system
• Electric starter system

Ignition system

• Service chart
• Operation
• Troubleshooting
• Ignition tests
• Component servicing

Fuel system

• Carburetor operation
• Carburetor service
• Fuel pump
• Intake manifold service
• Throttle control

Powerhead

• Specifications
• Test procedures
• Removal and installation
• Oil pump
• Cylinder head
• Crankshaft, pistons and camshaft
• Thermostat service
• Cooling system diagram
• Engine lubrication diagram

Midsection

• Service chart
• Side cover
• Driveshaft housing and oil pan
• Stern bracket
• Steering handle

Gearcase

• Service chart
• Propeller
• Lubricant
• Leak test
• Removal and installation
• Water pump
• Disassembly
• Cleaning and inspection
• Assembly
• Shimming adjustments

Manual starter

• Service chart
• Removal
• Disassembly
• Inspection
• Assembly
• Installation
• Neutral start interlock (NSI)

Wire / hose routing

• Wiring diagrams
• Wire routing
• Fuel / water hose routing

Safety

• Marine products and the safety of people who use them
• Marine products and the safety of people who fix them

Index