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
• Engine side covers
• Anti-corrosion protection
• Battery and battery connections
• Carburetors
• Engine oil and filter
• Fuel system
• Gearcase
• Idle speed
• Ignition timing
• Overboard water pressure indicator
• Lubrication points
• Spark plugs
• Valve clearance

Engine control

• Components
• Operation
• Troubleshooting
• Ignition tests
• Caution systems
• Removal and installation

Electrical

• Battery charging system
• Electric starter system
• Starter motor

Fuel system

• Fuel lines
• Carburetors
• Throttle control
• Fuel pump
• Operation

Powerhead

• Test procedures
• Removal and installation
• Timing chain and tensioner
• Cylinder head
• Piston, cylinder, and crankshaft
• Thermostat
• Operation

Midsection

• Cleaning and inspection
• Steering handle
• Tilt assist cylinder
• Exhaust housing and oil pan
• Stern brackets, steering arm, and swivel bracket

Gearcase

• Components
• Propeller
• Trim tab adjustment
• Lubricant
• Leak test
• Removal and installation
• Water pump
• Bearing and seal removal
• Bearing and seal installation
• Shimming and gear backlash checks

Power trim and tilt

• System wiring
• Service procedures
• Power trim and tilt unit
• PTT motor
• Operation

Wire and hose routing

• 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

Diagrams