Product Information

Table of Contents

Table of Contents

1. General Information

• How to Use This Manual
  • Manual Format
  • The Illustrations
  • References
  • Warnings, Cautions and Notes
  • Symbols
• Identification Numbers
  • Hull Identification Number (H.I.N.)
  • Primary I.D. Number
  • Engine Serial Number
• Safety While Working
  • Fire Prevention
  • Ventilation
  • Self-Protection
  • Oils, Greases and Sealing Fluids
  • Good Working Practices
  • Disassembly and Assembly
• Special Tools
  • Special Tools for Tune-Up
  • Special Tools for Power Unit Service
  • Special Tools for Drive Unit Service
• Sealing Agents and Lubricants

2. Specifications

• General Specifications
• Maintenance Specifications
• Torque Specifications
• General Torque Specification

3. General Service

• Periodic Maintenance
  • Maintenance Interval Chart
• Trolling Speed Adjustment
• Fuel System Inspection
  • Fuel Filter
  • Check Valve
  • Fuel Filler
• Oil Injection System Inspection
  • Oil Filter
  • Check Valve
• Throttle Lever Adjustment
• Choke Cable Adjustment
• Reverse System Inspection and Adjustment
• Steering System Inspection and Adjustment
  • Pivot Shaft Bearing
  • Steering Cable
• Impeller Inspection
  • Rubber Coupling
• Electrical System Inspection
  • Electrical Wire
  • Starter Switch/Stop Switch
  • Battery
  • Spark Plug
  • Compression Pressure Inspection
• Hull and Hood Inspection
  • Seal Rubber
  • Bilge Strainer
  • Drain Plug
• Greasing Points

4. Fuel System

• Fuel System Diagram
• Fuel System
  • Preparation for Removal
  • Exploded Diagram
  • Fuel System Inspection
  • Fuel System Installation
• Carburetor
  • Preparation for Removal
  • Exploded Diagram
  • Clean and Inspection
  • Assembly
  • Installation and Adjustment
• Oil Injection System Diagram
• Oil Injection System
  • Exploded Diagram
  • Oil Injection System Inspection
  • Oil Injection System Installation

5. Power Unit

• Engine Unit
  • Preparation for Removal
  • Removal and Disconnection
  • Exploded Diagram
• Inspection and Repair
  • Cylinder Head
  • Cylinder Block
  • Piston
  • Piston Rings
  • Piston Pin and Bearing
  • Crankshaft
  • Crankcase
  • Reed Valve
  • Crank Main Bearing
• Assembly and Installation
  • Piston
  • Small End Bearings and Piston
  • Crankcase and Cylinder Assembly
  • Cylinder Head
  • Intake Manifold
  • Magneto Base and Starter Motor
  • Flywheel and Cover
  • Thermo Sensor
  • Muffler Stay
  • Muffler
• Installation
• Intermediate Shaft and Housing
  • Exploded Diagram
  • Removal Point
  • Inspection
  • Installation

6. Jet Pump Unit

• Jet Pump Unit
  • Preparation for Removal
  • Removal and Disconnection
  • Exploded Diagram
  • Inspection
  • Assembly
  • Installation
• Bilge System
  • Preparation for Removal
  • Exploded Diagram
  • Inspection
  • Installation

7. Electrical System

• Electrical Components
• Wiring Diagram
• Battery
• Ignition System
  • Spark Plug
  • Ignition Coil
  • Flywheel Magneto
  • CDI Unit
• Starter System
  • Starter Motor
  • Starter Relay
• Charging System
  • Stator Coil
  • Rectifier/Regulator
• Lighting System
  • Headlight
  • Taillight
• Auxiliary System
  • Bilge Pump
  • Speedometer
  • Tachometer
  • Trim System
  • Fuel Gauge

8. Hull and Hood

• Hull
  • Inspection
  • Repair
• Hood
  • Inspection
  • Repair

9. Troubleshooting

• Troubleshooting Procedures
  • Engine Will Not Start
  • Engine Lacks Power
  • Engine Overheats
  • Engine Misfires
  • Engine Knocks
  • Poor Performance
  • Electrical Problems
  • Jet Pump Problems

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