1974 ——— We a4) outboard motor INTRODUCTION z GENERAL ERVICE INFORMATION UEL manual *« IGNITION SYSTEM 15 up fet models rowan 15R74 15RL74 ELECTRICAL 15E74 15EL74 MANUAL. STARTER ONOOaAWDND =A\ SAFETY WARNING PROPER SERVICE AND REPAIR IS IMPORTANT FOR THE SAFE, RELIABLE OPERATION OF ALL MECHANICAL PRODUCTS. THE SERVICE PROCEDURES WE RECOMMEND AND DESCRIBE IN THIS SERVICE MANUAL ARE EFFECTIVE METHODS FOR PERFORMING SERVICE OPERATIONS. SOME OF THESE SERVICE OPERATIONS REQUIRE THE USE OF TOOLS SPECIALLY DESIGNED FOR THE PURPOSE. THESE SPECIAL TOOLS SHOULD BE USED WHEN AND AS RECOMMENDED. ITIS IMPORTANT TO NOTE THAT SOME WARNINGS AGAINST THE USE OF SPECIFIC SERVICE METHODS THAT CAN DAMAGE THE ENGINE OR RENDER IT UNSAFE ARE STATED IN THIS SERVICE MANUAL. HOWEVER, PLEASE REMEMBER THAT THESE WARNINGS ARE NOT ALL INCLUSIVE. SINCE JOHNSON OUTBOARDS COULD NOT POSSIBLY KNOW, EVALUATE AND ADVISE THE SERVICE TRADE OF ALL POSSIBLE WAYS IN WHICH SERVICE MIGHT BE DONE OR OF THE POSSIBLE HAZARDOUS CONSEQUENCES OF EACH WAY, WE HAVE NOT UNDERTAKEN ANY SUCH BROAD EVALUATION. ACCORDINGLY, ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT RECOM- MENDED BY JOHNSON OUTBOARDS MUST FIRST THOR- OUGHLY SATISFY HIMSELF THAT NEITHER HIS NOR THE ENGINE’S SAFETY WILL BE JEOPARDIZED BY THE SERVICE METHODS SELECTED. SAFETY The purpose of the safety symbols is to attract your attention to possible dangers. The symbols, and the explanations with them, d e your careful attention and understanding. Safety warnings do not by themselves eliminate any dange! The instructions or warnings they give are not substitutes for proper accident prevention measures. A\ SAFETY WARNING FAILURE TO OBEY A SAFETY WARNING MAY RESULT IN INJURY TO YOU OR TO OTHERS. NOTE Advises you of information specially useful in the servicing and overhaul of your motor.SECTION 1 | | | SECTION 3 } } i \ SECTION 4 ~ SECTION 5 PAGE INTRODUCTION Arrangement of Manual, Parts Catalog... - Service Policy... +. Special Service Tools . ‘Outboard Motor Nomenelature + GENERAL SERVICE INFORMATION Specifications ..... Coil Test Specifications» Clearance Charts... +5 Torque Chart... 22.22 Lubrication Chart | Gearease Lubrication. | Lubrication Points... + + ‘Tune-Up Procedure . - ‘Trouble Check Chart’ | Submenged Motors . FUEL SYSTEM Deseription. . . ‘Theory of Operation - . Carburetor Removal.» Carburetor Disassembly. : Cleaning, Inspection, and Repair... +... 0s. Carburetor Reassembly ..... ++ ss Carburetor Installation . |. | Carburetor Adjustments Fuel Pump and Filter « Testing Fuel Pump. . « Fuel Pump and Filter Removal « Cleaning, Inspection, and Repair. « Fuel Pump and Filter Reassombly Fuel Tank... Cleaning, Inspection, and Repair . IGNITION SYSTEM Deseription. ‘Theory of Operation ‘Troubleshooting. Armature Plate Removal... Armature Plate Disassembly |. || Cleaning, Inspection, and Repair. « Testing Coils, Condensers, and Breaker Points 4 Armature Plate Reassembly 4 Reassembly of Armature Plate to Motor .. 11110 Breaker Point Adjustment . 4 POWER HEAD Description. pe ene pes ee 5-2 Theory of Oparation 52 Checking Motor Temperature. 5-3TABLE OF CONTENTS (CONT) SECTION 6 SECTION 7 SECTION 8 PAGE Power Head Removal .... +++ 8 Power Head Disassembly... 155 Cleaning, Inspection, and Repair. |! | 2 $10 Heassembly ol ower Head.........s. 2... B18 Installation of Power Heads... 22... scc.. | S18 DEOMI cine wees Fa canna ene ves vatnte SAB Power Head Reference Views... 11.1.1... | S-19, 5-20, 5-21, 5-22 LOWER UNIT Descripticn. 6 Heine won aoe we BE Gearcase Rem Pil 68 Exhaust Housing and Pivot Tube Removal. <<... 6-4 Exhaust Housing and Pivot Tube Installation: <1 6-7 Steering Handle and Gear Removal . 2 68 Steering Handle Disassembly... - D690 Cleaning, Inspection, and Repair... - 5 69 Steering Handle Assembly : + 68 Stooring Handle and Gear Installation ve... ..1 | 6-0 Gearcase Disassembly ..-..+.e0e00sc0000 GIL Cleaning, tnspection, and Repair. < + + 614 Gearease Assembly '...... +402. 1 e448 Gearease Pressure Test | 6-18 Gearcase installation... 1... 6-18 Adjustments . eoneees Till 619 Shift Lever Adjustments |. 1) 6-19 Propeller Selection . ... 1+ 6-20 Selecting the Correct Propeller . 6-20 ELECTRICAL SYSTEM Description. ...2.4sesseeees ery Battery Specifications: +. 21. Dome Starter System vs... ssscsecsee ne) Starter Removal |... ies 3&8 Starter Disassembly. 0000020 220I0IIIID m4 Cleaning, Inspection, and Repair oma Starter Reassembly’. . .. Dons Starter Installation. «21220 + 16 Alternator Stator Test’ | 6 Rectifier Diode Test... 2222121 1 Wiring Diegram. DLDDITITID’ Bna'of Section 8 MANUAL STARTER Description.......s4+4. Starter Removal |... Rope Replacement . +: | Starter Installation. Starter Disassembly. Cleaning, inspection, and Repair... Starter Reassembly Starter Adjustments aSECTION 1 INTRODUCTION TABLE OF CONTENTS ARRANGEMENT OF MANUAL . . « 1a PARTS CATALOG ...... shea pert (tea SERVICE POLICY : ae SPECIAL SERVICE TOOLS « 12 OUTBOARD MOTOR NOMENC! 12a INTRODUCTION Johnson outboard motors are designed and built for dependable high performance. To assure continued peak operation, it is important that every Johnson owner be able to receive skilled and thorough ser- vice for his motor. Customer satisfaction and prof- itable service operation depend on service "know- how" and training. Read this manual carefully so that you are familiar with the service procedures - then keep it readily avaliable as a reference book in your service de- partment. Always remember, each service job is a chance for you to maintain motor performance that will keep your customer happy to be a Johnson owner. ARRANGEMENT OF MANUAL This Service Manual includes the specific informa- tion you will need to service the motor. All general procedures are covered in abbreviated form, mostly dy reference to procedural illustrations. The spe cific procedures which apply only, or primarily, to these motors are covered in fully-illustrated, de- tailed, step-by-step instructions ‘The General Service Information section will help you diagnose a malfunctioning motor. It includes specifications, tune-up procedures, and a Trouble Check Chart.’ Clearances and torque values are also included for quick reference during servicing oper- ations. Each of the following sections, Fuel System, Ignition System, Power Head, Lower Unit, Electrical System, and Manual Starter,’ gives detailed instruc Uuus for disasseinbly, iispeclion, reassembly, aid operating adjustments’ of the components. ‘These procedures will help you service a specific system, or completely overhaul the motor. PARTS CATALOG ‘The Johnson Parts Catalog contains exploded views illustrating the correct sequence of all parts as well as complete listing of the parts for replacement. This catalog can be of considerable help as a ref- erence during disassembly and reassembly. SERVICE POLICY Whether within or following the warranty period, Johnson Outboards has a constant interest in its produets, It is Johnson's policy to assist dealers in building up their service knowledge and facilities so that they can give prompt, efficient service. The Johnson Service School, frequent Service Bulletins, and this Service Manual represent tangible efforts to give Johnson owners the best and most prompt service possible, This Service Manual covers all phases of Eervieing the motor However, now stfuations some. times arise in servicing a motor. Ifa service ques- 1-2 tion 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 motor model number and se~ rial number. Write to: Johnson Outboards, Plant 3 ‘01 Pershing Road ‘Waukegan, Ilinois 60085 Attention: Service Department Be sure that you are familiar with the Johnson warranty. If you have any questions, write the ‘Jhnson Service Department. SPECIAL SERVICE TOOLS Jenson has specially-designed tools to simplify ‘some of the disassembly and reassembly operations. ‘Those tools are illustrated in this Service Manual, in many cases in actual use. Refer to the Johnson Srectal Service Tool Catalog for a description and ofdering instructions for these tools. Individual pur~ chasers of Service Manuals must order Special Tools, ‘through an authorized dealer. OUTBOARD MOTOR NOMENCLATURE Scmetimes the words “right” and "left" are very ‘confusing when referring to the sides of an outboard motor. Therefore, the sides are referred to as STARBOARD or PORT sides. STARBOARD means on the right hand while facing the bow (FRONT) of the boat; PORT moana left hand. Soc Figures 1-1 and 1-2. Service required for the Johnson outboard is gen= erally one of three kinds... . 1, NORMAL CARE AND MAINTENANCE, which in. cludes putting anew motor into operation, storing motors, lubrication, and care under special op- erating’ conditions Such as salt water and cold ‘weather. 2. OPERATING MALFUNCTIONS due to improper motor mounting, propeller condition or size, boat condition, or the malfunction of some part of the motor. This includes motor tune-up procedures to keep the motor in prime operating condition. 3. COMPLETE DISASSEMBLY and overhaul, such as inspecting a motor that has been submerged or rebuilding trade-in units. It ts important to you as the service man to deter~ mine before disassembly just what the trouble is, and how to correct it quickly and with minimum ex” pense to the owner. This section of the manual is Besigned ta help you diagnoae motor malfunctions and correct them.1. Low speed adjusting knob 2: Chake nob 5: Starter handle 4, shite lever 5. Start button (electric start) 8. Clamp screws 7. Tut lover 8: Stem brackets 8, Thrust rod (Lilt adjustment) 10. Shallow water drive bracket 11; Off tevel plug 12 Water intake, port and starboard 13. Oil drain/All ola 14: Water discharge, port and starboard 15. Exhaust relict 46, Fuel pump and filter Figure 1-1. startoard (Manual Start) 1 18, 19) a 22, 23, 25. 26. 21. 28, 29. 30. 31. 32, Flywheel Armature plate assembly Electric starter Ignition coils Lateh, motor cover Idle speed adjusting knob Propeller and converging ring Gearease Battery cable (electric start) Swivel bracket Model and serial number plate Safety chain link Steering handle and twist grip Stop button Air silencer Re-wind starter Figure 1-2. Purt side (Electric Start)SECTION 2 GENERAL SERVICE INFORMATION TABLE OF CONTENTS SPECIFICATIONS COIL, TEST SPECIFICATIONS - CLEARANCE CHART GEARCASE LUBRICATION « LUBRICATION POINTS TUNE-UP PROCEDURE - ‘TROUBLE CHECK CHART SUBMERGED MOTORSSPECIFICATIONS. ‘Model Numbers 15R74 Standard length (15° transom) 1SRL74--5" longer (20" transom) 1SE74 ~ Standard length (15" transom) 15EL74-5" longer (20" transom) Horsepower (B.I.A. certified 15 hp at 6000 rpm Full throttle operating range 5500 to 6500 rpm ‘Tank test with test wheel 6200 rpm Part Number 386537 Engine type 2 cyl., 2 cycle, alternate firing Bore and stroke 2.188" bore x 1.160" stroke Piston displacement 13.20 cuble inches vuston ring sets (2 per set) standard art Number 396279 030" oversize Part Number 386280 Diameter of ring 2.1875 in. (standard) Width of ring Upper ~ .0700 - .0895 in. Lower ~ .0615 - .0625 in. Lbs. compression recommended when compressed Upper = .25 - 2.0 tbs. Lower ~ 2.5 - 5.0 Ibs. | Piston less rings | standard | Part Number 386012 030" oversize Part Number 386013 Crankshaft size ‘Top journal 8125 - .8120 Center journal 8125 - .8120 Bottom journal +8125 - .8120 Connecting rod 1.08350 - 1.06300 in. crak pin Carburetion Single barrel, float feed, fixed Iulght speed adjustable low= speed, manual choke High speed orifice Part Number 319781 plug Identification Number 60 Check with #.060" dia. arin Float level setting Flush with rim of casting 065 - .062 ‘Use #52 drill as gage Inlet needle seat Cooling system Vari-volume (combination positive displacement and ‘centrifugal pump) ‘Thermostatically controlled Propeller gear 12:28 ratio Propeller supplied 3 blade, 9-1/2" dla. x 10" piteh ‘with motor Propeller 3 blade, 9-3/4" dia, x 7” piten options 2 blade weedless 10" dia. x 10" piteb ‘Speed control (On steering handle Remote control available Gear shift control Forward, neutral and reverse Weight (without Model 15R74 - 65 lbs. fuel tank) ‘Model 15RL7A ~ 66 Ibs. Model 15E74 - 73 lbs. Model 15EL74 - 74 Tbs. (Fuel tank weight 11 pounds net) Fuel capacity 6 gallons Electrical system 5 amp flywheel alternator (Electric start F ‘models only) Starter Manual - Self-winding Electric - 12 volt, and rope Starter amperage draw while ‘cranking 55 AMPS Max. Ignition Low tension magneto Spark plug Champion ULAJ, Mmm Spark plug gap 030 inch, Spark plug torque 17-1/2 - 20-1/2 foot-pounda ‘Breaker point Gap .020 inch Condenser Part Number 580422 Capacity 25 - 29 Mfd. Cou Part No. 581407 COIL TEST SPECIFICATIONS With Stevens Tester Model No. M.A.-75 or M.A.-80 with M.A.-14 Adapter in Series with High Tension Lead Switen Index Adjustment B 25 ‘Mere-O-Tronie ‘Operating | Primary Resistance | Secondary Continuity Amperage| Min. Max. ‘Min, Max. 17 0.8- 1.2 60-70 Graham Tester Model ‘Maximum | Maximum | Coit | Minimum | Gap Secondary | Primary | Index | Coil Test | Index 20,000 ohms | 14.0 ohms | 50 4 45 COIL OHMMETER TEST Primary (Low Ohms) | Secondary (High Ohms) 1354.3 13,500 + 1500, “Horsepower established at sea level. Allow % reduction per 1000" above sea level.CLEARANCE CHART upper and lower 145 ~ 170 Inch-pounds (12 ~ 14 Foot-pounds) POWER HEAD LOWER UNIT Piston ring gap 015 Max. - .008 Min. Propeller shaft 0087 Max. - .0002 Min. {in front gear Piston ring groove bushing clearance, lower Piston pin to piston loose end Cylinder and piston Crankshaft end Controlled by lower journal play Dearing TORQUE CHART POWER HEAD LOWER UNIT Flywheel nut 45 - 50 Foot-pounds Upper mounts 60 ~ 60 Tnch-pounds 5 ~ 7 Foot-pounds) Connecting rod 48 - 60 Inch-pounds " : serew (4 - 5 Foot-pounds) Pilot shaft to 60 - 80 meh-pounds Cylinder head 145 - 170 Inch-pounds: steering (6 - 7 Foot-pounds) screws: (12 - 14 Foot-pounds). bracket screws Crankease to eyl- Ship Clutch 485 Foot-pounds Min. inder serews ~ sits ca *Pull at propeller Re-check torque on cylinder head serews and spark plugs after motor has been run, has reached operating temperature, and motor has eooled comfortable to touch. Electric tartar Shaft for it up 30 = 40 Ibs. through bots 30 - 40 Ineh-pounds Rlectric starter eee pind oat 150 - 170 tnch-pounds oe Spark plug 17-1/2 - 20-1/2 Foot- come reverse pounds lock 100 - 200 1s. Manual starter 18 - 20 Foot-pounds assembly screw 'STARDARD SCREWS Tneh-Pounds ——_‘Foot-Pounds When tightesing two or more screws on the [nae port, DO NOT tighten ccews. comme z10 Plotely, ong ata time. ‘To avoid distortion of fare) the net, teat gts all cvs gatian bs 25-35 23 onevihird of specified. torque, then to two- No.12 S50 i tedsas ot areciied tortor Wee ora! eo yar to-00 a completely site" xo-i40 ola ae" 220-240 15-2 Standard length lower unit. naveLUBRICATION CHART FREQUENCY (PERIOD OF OPERATION) FRESH WATER ld. Gearcast 26 = Seo Figure | OMC Sea-Lube* Gearcase Lube Capacity 13,9 ozs. after. tion or ‘occurs 5. Electric Starter Pinion | Lubriplate 777 ‘Shaft Helix - See Figure | (OMC #317619) | 60 days 21 6. Swivel Bracket and OMC Sea~Lube* | 60 days Motor Cover Latch Lever | Anti-Corrosion Shaft - See Figure 2-8 | Lube usnicanion rons | Lumens —— Thur Reverse Lone Leer | OMe geartne* | 6 ve soars Jase Cay Stew" | OME genta Fan ame Sera | A en se 2S ite i bo bine i en a sae ete i ta Meme Linn, ee 2 a , sue Laver Deen Ca, somaye | cote ale BEE || so cays Carburetor Linkage and ANTI. ‘SEALUBE* Sprpretos Taare an Cm nail ne Check level after first 10 hours of operation ‘and every 50 hours of operation there- Drain and refill every 100 hours of opera- Same as Fresh Water ‘Add lubricant if necessary. Same as Fresh ‘once each geason, whichever Water first. 30 days, 30 days Some areas may require more frequent lubrication. GEARCASE LUBRICATION Remove upper and lower plug and gasket assemblies from starboard side of gearcase. With propeller shaft in a normal running position, allow oil to drain completely. NOTE: Do not remove pivot pin. See Figure 2 Refill with OMC Sea-Lube* Gearcase Lube. With propeller shaft still in a normal running position, 411. until lubricant appears at upper hole. See Figure 2 Install upper plug before removing lubricant fier hose from lower hole. Lower plug ean then be in- stalled without oil loss. If filler type can is not available, install lower plug. Slowly nll gearease wrougn upper nole, allowing trapped air to escape. Install plug. 24 NOTE: If OMC Sea-Lube* Gearcase Lube is not available, use Dexron® transmission fluid (available from General Motors). CJ RECOMMENDED GASOLINE: Use lead free, low- lead, or leaded gasolines that have a minimum oc- tano’rating of 91 (Research Number). [FR]NOTE: When operating in any other country than the United States, Canada or Australi any gasoline may be used which will satisfac~ torily operate an automotive engine. LUBRICANT: Use a reputable Outboard 50:1 lubri~ cant which is BIA certified for service TC-W (two cyele-water cooled). It is formulated to give best engine performance wilh least combustion chamber daposits, least piston varnish, maximum spark plug life, and best lubrication. See inside back cover UW our OUTBOARD LUBRICANT is not available, anotier BIA certified 1U-w lubricant (ou) may é ‘used.Figure 2-5. Shift Lever Detent Cam, Carburetor Linkage ‘and Choke Figure 2-4, Idle Speed Adjust ment, Magneto Linkage, and Manval Starter Drag Spring ame a Figure 2-3, Tit Reverse Lock ‘Lever Shatt, Clamp Screw ‘Threads, and Throttle Sat Gears LUBRICATION POINTS nL Leven bo Nor Pivor PIN Figure 2-6. Gearease ROTATE SHAFT Figuze 2-1. Starboard (Manual Start) Figure 2-1. Electric Starter Pinion Shaft Helix sre 2-2, Port Side (Electric Start) 25 ‘igure 2-8. Swivel Bracket and ‘Motor Cover Latch Lever ShaftNOTE: Avoid the use of the following, as they jwill contribute to deterioration of your engine and shorten spark plug life: AVOID USE OF: ¢ Automotive oils ‘¢ Premix fuel of unknown ofl quality ¢ Premix fuel richer than 50:1 ratio FUEL MIXING INSTRUCTIONS Always use fresh gasoline, A SAFETY WARNING GASOLINE IS HIGHLY FLAMMABLE - ALWAYS ‘MIX IN WELL VENTILATED AREA. Abow. Portable Tank - Pour lubricant into tank, add fuel. Replace filler cap securely. To mix fuel, tip tank on side as shown and back to upright position. Built-in Tank - Use large filter funnel. Pour lubri~ ant slowly with the fuel a tank is filed, ‘Portable Tank - Pour approximately ono gallon gaso- Line into tank, add required lubricant. Replace filler cap securely. Thoroughly mix by shaking tank. Add balance of gasoline. Built-in Tank - In’ separate container mix all lubri cant needed with one gallon or more of gasoline Use large filter funnel. Pour this mixture slowly with fuel as tank is filled. OG PORTABLE TANK eutan TANK FUEL MIXTURE 1 part Lubricant to 50 parts Gasoline OR: (6 Gal. ‘Tank) 1 pint lubricant to 6 gallons (8 Impe- al) of gasoline (3 Gal. Tank) 1/2 pint lubricant to 9 gallons (2-1/2 Imperial) of gasoline TUNE-UP PROCEDURE When an owner brings a motor to you for a tune-up, or for some minor operating malfunction, the follow. ing procedure should be used as a guide to determine the cause of the malfunction. Write down the owner's comments. Keep an accurate card file on your ser- vice shop operation. Each service operation should bbe on record as to the: (OWNER'S NAME MODEL NO. SERIAL NO. NATURE OF COMPLAINT NATURE OF WORK PERFORMED COST TO THE OWNER WAS WORK PERFORMED UNDER WARRANTY After writing down the owner's comments, check the ‘motor visually and begin a systematic tune-up pro- cedure. Consult the Trouble Check Chart to find ‘the causes of any malfunction which may be dis- covered when tuning up the motor. SAFETY WARNING ELECTRIC START MODELS - DISCONNECT BATTERY CABLES AND COVER RED POSI- TIVE LEAD WITH INSULATING BOOT, BE- FORE MANUALLY CRANKING ENGINE OR ATTEMPTING ANY REPAIRS ON ENGINE EXCEPT WHERE OTHERWISE SPECIFIED. Remove intake and exhaust by-pass covers, and eylinder head. Slowly rotate flywheel and visu- ally inspect pistons, rings, and cylinders for ‘wear, freeness, and carbon deposits. f= Piston ring and cylinder wall condition should bbe determined before continuing tune-up. Gum and varnish deposits on rings or pistons may be removed with an application of OMC Ac- cessory Engine Cleaner. If scuffing is evi- dent power head must be removed. If pistons and rings are considered to be in satis factory condition for continued service, remove car- ‘bon, surface and reinstall covers, using new gaskets. 2, “Clean earbou from cylinder head and top of pis- tons. Do not alter piston deflector. Surface cyl- inder head and by-pass covers and reinstall, us- ing new gaskets. Tighten cylinder head screws to specified torque Inspect spark plugs. Clean and re-gap or re- place as necessary. Inspect and test points, condenser, coils, and ignition wires. Check for spark on each eylinder. See Section 4 for test procedures. Inspect upper main bearing seal for evidence of oil leakage. If necessary, replace. See Section 5. Inspect carburetor and choke. See Section 3. Inspect fuel pump and lines. Replace filter ele- ment and gasket. See Section 3. Synchronize carburetor and magneto. See Sec- tion 4. ‘Check propeller for condition and correet pitch. See Section 6. Drain and refill gearcase and thoroughly lubri- cate all components of the motor. See Pages 2-4 and 2-5. Tighten all screws and nuts, etc., to specified torque. See Page 2-3. Tank-test and adjust carburetor low-speed needle; check cooling system operation. Use a tachometer and test wheel for accurate xpm tests. Retighten cylinder screws to specified torque after motor has cooled comfortable to touch. See Page 2-3. Fog motor for storage, using OMC Accessory Rust Preventative Oil and fuel containing OMC 2+4 Fuel Conditioner. Use OMC Gasket Sealing Compound 4317201 on all screws, nuts, bolts, and pressed in seals in gear housing. 14 TT fuel Guk Is uot dratued for storage, aud OMG 2+4 Fuel Conditioner to stabilize the gasoline. 10. n. 12, 13.CHECK CHART ‘TROUBLE POSSIBLE CAUSE 1, MOTOR WILL NOT START FUEL SYSTEM - See Section 3 Fuel line improperly comected Engine not primed Speed control not advanced (throttle closed) Engine flooded Old fuel Clogged fuel filter hake not closing completely Choke spring broken or disconnected ‘uel system faulty B. IGNITION SYSTEM - See Section 4 Spark plug leads crossed or reversed Linkage improperly adjusted Sheared flywheel key Ignition system faulty C. STARTER - See Section 7 and 8 Starter cireult faulty Neutral start switch (faulty or adjustment) NEUTRAL START Gear shift not in neutral Manual start lockout adjustment 2. LOSS OF POWER - (Assuming Ignition OK) - POWER HEAD - See Section 5 Carburetor and magneto not synchronized ‘Throttle control lever bent (won't advance) Air leak at manifold gaskets ~ warped manifold (backfires) Broken leaf valves (backfires) ‘Worn main bearing seals Excessive carbon on pistons and eylinder head, Stuck piston rings, or scored cylinder or piston Recirculating system plugged (check valve See Section 3) B, CARBURETOR - See Section 3 Poor fuel mix ~ too much lubricant Carburetor adjustment - (too lean ~ backfires) (too rich ~ excessive fuel) ‘Choke not opening Air leak at low speed needle Inlet needle and seat worn or sticky Incorrect carburetor float setting Dirt in high speed orifice FUEL PUMP AND TANK - See Section 3 Faulty fuel hose ~ kinked uel tank or pump filter plugged Fuel filter restricted Fuel and vent valves not opening. Valves not operating, Diaphragm leaking or damaged Fuel system hoses plugged "O" ring damaged in fuel line connector D, EXHAUST GAS ENTERING CARBURETOR - See Section 6 Exhaust cover screws leaking Cover plate gasket damaged Damaged exhaust housing seal Cracked exhaust housing E. OVERHEATING POWER HEAD - See Section 5 Exhaust cover gasket leaking Inner exhaust cover leaking Power head gasket improperly installed or damaged Head gasket leaking (warped head) (water in cylinders) Pump housing "0" ring 24‘TROUBLE CHECK CHART (CONT) ‘TROUBLE POSSIBLE CAUSE . LOWER UN.T - See Section 6 ‘Water Intakes obstructed ‘Pump housing air bleed restricted Water passages obstructed Punip plate not sealing (bottom) Pump impeller damaged Pump housing or plate worn Pump housing seal worn (driveshaft grooved) ‘Water tube grommet damaged G. EXHAUST GASES ENTEHUNG CUULING SYSTEM See Section 6 Pump impeller plate not sealing (bottom) Damaged water tube grommet or "O" rings Pump housing seal damaged (5" adapter seals) Exhuast tube to water tube grommet Seal between gearease and exhaust housing ‘MOTOR MISFIRES (Assuming ‘A. SPARK PLUGS - See Section 4 Fuel System & Carburetor OK) Cover or imer terminal damaged (spark plug terminal point out of H.T. lead) boot Faulty spark plug leads Loose - low torque Incorrect spark plug Defective (cracked insulator) B. LOW TENSION IGNITION - See Section 4 Incorrectly adjusted points Loose wiring. Damaged ccil leads Condenser damaged (loose) Fibre breaker block worn Points dirty or pitted Sheared flywheel key Cam on armature plate improperly adjusted Driver coil leads loose 4. VOOR PERFORMANCE ON BOAT | A. INCORRECT PROPELLER Incorrect tilt angle Incorrect {uel mixture - too much lubricant - (smoking) Propeller hub slipping Bent or wom propeller - converging ring missing Bent gear housing or exaust housing Altitude horsepower loss Catamaran (single engine) ~ venturi effect Exhaust leaks Overheating CAVITATION Protruding hull attachments Keel too lorg Bent propeller (vibration) ‘Transom too high ©. BOAT Improper load distribution Marine growth on bottom ‘Added weight (water absorption) Hook in bottom w 28 sors‘TROUBLE CHECK CHART (CONT) ‘TROUBLE POSSIBLE CAUSE STARTER MOTOR WILL NOT ‘A. STARTING CIRCUIT - See Section 7 OPERATE Loose or corroded battery connections ‘Neutral start switch inoperative (loose) ‘Tarottle advanced too far Poor or broken battery connections, ‘Weak or shorted battery Defective starter switch Jammed starter drive Damaged starter drive parts ‘Wor biusiies Broken brush spring Barned commutator Shorted or open windings - armature EXCESSIVE STARTER CURRENT DRAW - See Section 7 Worn or dry armature shaft bearings Excessive friction in engine Brushes not seating | Dirty or corroded commutator Shorted armature Bearing heads buckled SUBMERGED MOTORS Ifa motor is lost overboard while running, it should always be disassembled before any attempt is made to start it. Often internal parts are sprung and running under these conditions can result in perm: nent damage. A motor lost overboard in salt water should always be disassembled and cleaned before starting is at- tempted. Some materials used in modern engines are subject to very rapid corrosion in the presence fof calt wator and ehould be inopeoted to detormins if replacements are required. ‘A motor lost overboard in fresh water can usually be safely started if recovered within twelve hours providing no sand or silt Is present. Remove the 28 ‘spark plugs, the carburetor orifice screw, and drain all fuel lines and tank. Crank the engine with the ‘manual starter rope until all water present has been expelled. Squirt outboard lubricant into spark plug holes. Reassemble and start. If sand has entered the engine, no attempt at starting should be made. Disassemble and clean the power- head. If it is impossible to have the engine serviced im- ‘mediately after it has been retrieved after extended submersion, it is advisable to submerge the power- hhead in lean fresh water to prevent Oxidation until it can be taken apart.SECTION 3 FUEL SYSTEM TABLE OF CONTENTS PAGE DESCRIPTION 32 THEORY OF OPERATION « 3-2 CARBURETOR REMOVAL 3-3 3-5 3-6 3-8 3-9 30 3-9 3-9 3-10 3-10 FUEL PUMP AND FILTER REASSEMBLY | 3-10 FORUEANE! isesilentine nen 3-10 CLEANING, INSPECTION, AND REPAIR 3-1 ps 3-1DESCRIPTION FUEL FLOW ‘The fuel system consists of fuel tank, fuel pump, and carburetor. The fuel tank is non-pressurized, suc- tion operated. A diaphragm-displacement type fuel pump on the motor draws fuel from the tank and furnishes it to the carburetor through a fuel filter. CARBURETOR ‘The carburetor is a single-barrel, float feed type. ‘The high-speed jet is fixed and only the low-speed jet is adjustable, The carburetor has a manual choke. ‘Throttle linkage is synchronized with the magneto by 2 cam on the magneto armature plate. See Figure THEORY OF OPERATION ‘The carburetor is a metering device for mixing fuel and air. At idle speed, an engine requires a mixture ‘of about & parts air to 1 part fuel. High speed mix- ture is about 12:1. ‘A small chamber holds the fuel. A float valve ad- mits fuel from the fuel tank to replace fuel as it is ‘consumed by the engine. Metering jets in the car- buretor throat extend down into the fuel chamber. ‘The upstroke of the piston in the cylinder creates a ‘suction that draws air through the throat. A restric tion in the throat, called venturi, has the effect of reducing alr pressure at this point by controlling air velocity. ‘The differential in throat and chamber alr pressures causes the fuel to be pushed out of the metering jets and into the air stream. Here it mixes with the air Wo form 4 combusible miatuse for exploding in the engine cylinders. In order to mix the fuel and air in just the right proportions for all engine speeds, the low speed jet has an adjustable needle valve to compensate for changing atmospheric conditions. The high speed jet may have a fixed high speed orifice or an adjust- able needle valve. ‘To regulate engine speeds, a throttle valve controls the volume of fuel-air mixture drawn into the engine. ‘To compensate for the extra amount of fuel required to start a cold engine, a choke valve is placed ahead of the metering jets and venturi. ‘When the valve is closed, a very rich fuel mixture is drawn into the engine. As the engine starts and ‘warms up, the choke is opened to restore the normal ratio required, ‘The carburetor throat is frequently called the "bar- rel." Carburetors with single, double, or four bar- rela have individual metering jets, needle valves, throttle and choke plates for each barrel. ‘The two barrel carburetor is fed by a single float and cham- Bor while the four barrel model has a separate Naat valve and chamber for each barrel. 3-2 Inouceo {OW PRESSURE ATMOSPHERIC AIR PRESSURE. 9 ILE AND. stow seE0 ‘onirices aaerte AIR INTAKE 10 stow sPeE0 ‘cRANKCASE te ee ‘CHOKE VALVE oh seeeD nozzie FLOAT CHANGER ‘veNTUAL RING HIGH SPEED NEEDLE HiGH SPEED ORIFICE SLOW SPEED ‘ORIFICES [AIR INTAKE THsoTTLe VALVE 10 so sree cmancase necour 7 ~ CHOKE VALVE rioar gh speED NOZZLE vvenTUni ANG seE-eD NEEDLE Wa SPEED ORIFICE Figure $-1. Carburetor PrincipleLear VALVE — RecincULATING Lear VALVE & SOREEN PLATE Figure 3-2. Leaf Valve Assembly LEAF VALVES ‘The leaf valves time the injection of the fuel mixture into the erankcase by opening only when the pressure in the crankcase has dropped to a predetermined point on the compression stroke. See Figure 3-2. CHOKE ‘Tne carburetor is fitted with a manual choke to re- duce the ratio of air to fuel for cold starts. A choke valve in the air inlet of the barrel is mounted to a ‘choke shaft. When the choke knob is pushed in, the valve is held open, allowing air to pass freely through the inlet. When the choke knob is pulled out, the valve is closed, restricting the flow of air to the’carburetor. See Figure 3-1, FUEL PUMP ‘The fuel pump is of the diaphragm-~ Line oF solvent. See Owner's Manual for correct ftel mixture. DESCRIPTION ‘The fuel tank is of simple but rugged constructicn, with a capacity of 6 gallons of fuel mixture. It in- cludes the bulb primer (for priming the fuel pump), fuel Ievel yage, fuel hose and connectors, a bracket arrangement to hold the fuel line when not in use, and a carrying grip. The fuel tank upper housing, which provides the connection to the fuel hose, contains two release valves and a disc valve which prevent any escape of gasoline or fumes, minimizing the danger of explosion or fire. CLEANING, INSPECTION, AND REPAIR ‘The fuel level indicator is mounted to the upper housing and fuel line assembly. The entire assembly may be removed by removing the four attaching screws, Lift the assembly from the tank carefully to avoid damaging the indicator float or the screen at the end of the fuel line. See Figure 3-28. Check for free movement. of the indicator on the indicator pin. Remove the pin from the indicator Support by compressing the free end and pulling it ut. Inspect the indicator to make sure that the float arm is not bent and that the float is not damaged or oil-soaked. Remove the two screws attaching the indicator sup- port to the upper housing. Lift the indicator lens ut of the upper housing, and clean it with solvent or Tacquer inner Ww remove any foreigu uialter whi ‘may be clouding the lens. rec sous pos oa sn oS ~ moicaror ees —~ seman if °——§ screw \ sencen \ roxr Pv Figure 2-28. Fuel Tank Level Indicator Inspect the lens seal for cracks or shrinkage which may allow leakage. The release valves must seat tightly to prevent gasoline or fumes from leaking ‘out, but must open a clear passage for air to enter the’ tank and for fuel to be drawn out when the fuel hose is connected. Dirt may keep the release valves {rom seating properly. The release valves are best cleaned by removing the core plugs and disassem- bling. Replace valve seats ("O" rings) to assure a tight seal. See Figure 3-29. ‘The air inlet dise valve must seat tightly to prevent fumes from escaping the tank when the fuel hose is connected, but must allow air to enter tme tank. The disc’ valve spring retainer is staked to the upper housing and may be removed by filing off the burrs if replacement is necessary. Restake with a small punch. a Sete ay ise. vaLvE = | snes Pen ee ale nevaINER SCREEN Figure 3-29. Fuel Tank Upper Housing and Valve 3aHOSE AND PRIMER BULB ASSEMBLY CLAMPS. To disassemble hose clamps, grip clamp with pliers, Bend overlapping hook backward (in direction of ar- row) to release clamp. See Figure 3-30. Figure 3-30. Removing Hose Clamp To assemble hose clamps, grip clamp firmly with pliers. Apply slight pressure to hook on top side with screw driver. Squeeze clamp with pliers until hooks interlock. See Figure 3-31. if "O" ring in connector housing is damaged, it will be necessary to replace connector hhousing as air will enter fuel line and car- buretor. Motor will run out of fuel. When reassembling the fuel hose, check for cracks in the primer bulb or in the hose. The primer bulb must be attached so that fuel flow is from the shorter to the longer hose length. Fuel flow through the primer bulb is indicated by an arrow. See Figure 8-32. ‘CONNECTING HOUSING ‘ASSEMBLY. Figure 3-32, Primer Bulb and Hose AssemblySECTION 4 IGNITION SYSTEM TABLE OF CONTENTS DESCRIPTION .... TESTING COILS, CONDENSERS, AND BREAKER FOLNTS. ARMATURE PLATE REASSEMBLY REASSEMBLY OF ARMATURE PLAT 4410 ait ome SPECIAL TOOLS REQUIRED FLYWHEEL PULLER PART NUMBER 378103 COIL LOCATING RING PART NUMBER 317001 ‘TIMING FIXTURE PART NUMBER 386636 wrsve 44DESCRIPTION ‘MAGNETO ‘The Ignition system consists of a low tension fly- wheel type magneto connected to the spark plugs through individual ignition colls and high tension leads. The magneto is a self-contained electrical generating unit consisting of an armature plate with fone driver coll and lamination assembly, two con- densers, and two breaker assemblies. The electric start model includes two alternator coils. Two per- manent magnets are cast into the flywheel on manual ‘Start moaeis and Tour on electric start moaels to complete the assembly. See Figures 4-1 thru 4-4 Armature Plate - Electric Start waaner Figure 4-3. Flywheel Magnets - Rope Start Figure 4-4. Flywheel Magnets - Electric Start THEORY OF OPERATION As the flywheel rotates, magnet #1 passes by the driver coll inducing current flow from the driver coll through #1 points (closed) across the armature plate up through points #2 (closed) and then to the other side of the driver coll. The cam now opens points #1, and the voltage rises rapidly across the primary of ignition coil #1. The condenser in the primary absorbs the current which would otherwise are across the opening points (#1). The ignition coil elg a transformer steps up te voltage into me secondary, firing cylinder ¥1. See Figure 4-5.Tan ‘The second magnet, 180° away and of opposite po larity, passes the driver coil, inducing current flow from the driver coll through points #2 (closed) acress the armature plate up through points #1 (closed) and then to the other side of the driver coil. The cam now opens points #2, and the voltage rises rapidly across the primary of ignition coll #2. ‘The conden ser in the primary absorbs the current which would otherwise arc across the opening points (#2). The ignition coll steps up the voltage and fires cylincer 42, See Figure 4-6, aawer DRIVER cont Figure 4-5. Low Tension Ignition System - oa ‘Ignition Cofl #1 wagner 2 DRIVER COIL PriMany Figure 4-6. Low ‘Tension igmuon system - ‘Ignition Coll #2 43 Each ignition coil actually consists of two coils. See Figure 4-7. One, called the primary, consists of a relatively few tums of heavy gage copper wire. The other, called the secondary, cousists of many turns of fine gage wire. The coils are separated by insu- lation and mounted on the center leg of a "D" shaped Taminated iron core. Figure 4-1. Ignition Cott One end of both the primary and secondary coils is grounded. The other end of the primary coil con- nects to the insulated stationary breaker point. ‘The other end of the secondary eoil connects to the spark plug. The movable breaker point 1s grounded to the armature plate. ‘The condenser, which acts like a storage tank, con~ sists of thin sheets of metal foil separated by insula~ tion, rolled to save space and enclosed in a metal ease. One sheet of foil 1s grounded to the case, the other is connected through an insulated wire to the insulated stationary breaker point. See Figure 4-8. Figure 4-8. CondenserSPARK PLUGS Spark plugs having the proper heat range are very Important for peak operation of the motor. This motor is designed to operate with Champion ULAJ spark plugs. Spark plugs are classified according to the temperatures at which they are designed to operate, HOT or COLD. See Figure 4-9. Figure 4-9. HOT and COLD Plugs Selection of the correct spark plug depends on the type of service to which itis subjected. Unless the spark plug is properly suited to the motor, trouble may arise which might be interpreted as earburetor aitficulty. Very low trolling speeds will fend ta foul plugs due to the oll not burning from the core. “How ever, at full throttle with a hotter plug, the operating temperature may be too high, resulting in pre ignition. An extreme temperature range will be difficult to control with one plug. Spark plugs furnished with the motor are selected for average service. Spark plug recommended is Champion ULAJ. TROUBLESHOOTING Rive Ol — 77 GAP Figure 4-10. Ignition Spark Test Remove spark plug leads from spark plugs by grasp- ing rubber boot and twisting counterclockwise while pulling lead off plug. Attach leads to spark gap tester with gap set to 7/10". Crank engine with key switch or rope start, See Figures 4-10, 4-11. Spark strong and steady firing each cylinder sepa- rately, ignition system 1s good. Check spark plugs. No spark, check system with Stevens 8-80 or Mere (O-Tronic’M-80 neon test light. Figure 4-12. Ignition Coll #1 Cireuit Test Disconnect blue primary lead of #1 ignition coll. Connect the blue lead of neon tester to the blue primary lead, coming out from the armature plate and black lead to ground. Se: neon test light switch to position #1. (Remove Spark plugs for easier cranking.) Crank engine with key switch or rope start, See Figure 4-12,ob Light steady and bright - output good - check for faulty #1 ignition coil Dim light ~ check for open #1 condenser. No Light - check resistance reading of driver ecil; check both sets of breaker points for correct gap and condition of points (burned, ete). Reconnect blue primary lead of #1 ignition coil. Dis connect the #2 ignition coil blue/white stripe lead coming out from the armature plate. Connect the blue lead of neon tester to the blue/white stripe lead trom armature plate and black lead to ground. See Figure 4-13. Figure 4-13. Ignition Coil #2 Circuit Test Set meon test light switch to position #1. (Remove spark plugs for easier cranking.) Crank engine with key switeh or rope start. Light steady and bright - output good - check for faulty #2 ignition coil. Dim light - check for open #2 condenser. No light - check resistance reading of driver cail; check potn sets of breaker points for vorrect yap anil condition of points (burned, etc.). ARMATURE PLATE REMOVAL a. Twist leads off spark plugs counterclockwise. b. Remove flywheel nut. Using Flywheel Puller (Special Tool #378103), pull flywheel from erank- shaft. See Figures 4-14 and 4-148, Figure 4-148, Removing Flywheel ¢. Disconnect armature plate leads and Packard connectors. To accomplish this, lift up on the Packard connector locking tabs and slide connectors apart. See Figure 4-15. Remove ground wire from Figure 4-15. Disconnecting Packard Connectorsunder by pass cover screw. See Figure 4-16. move coils from cylinder head. Re- INOTE: Avoid loss of star lockwashers under Jeoll ground lead serews. d. Disconnect stop switch connectors. Uren waster COIL GROUNO Disconnect ALTERNATOR LEADS. Figure 4-168. Electric Start Alternator ‘Leads and Ground €. On electric start models, disconnect yellow, yellow/grey, and ycllow/blue stripe leads at termi- nal board. See Figure 4-16A. {. Remove five screws attaching armature plate to retainer plate, (see Figure 4-17) and lift armature plate wut cable assuiubly uff power lead. See Fig- ure 4-17A, Retainer plate and support plate can be 4-6 Figure 4-17A. Removing Armature Plate ‘and Assembly Figure 4-19. Support Plate Screws (Four) removed (if necessary) by removing four screws, cotter pin and nylon washer, connecting retainer plate to vertical control shaft. See Figure 4-18,ARMATURE PLATE DISASSEMBLY All components may be removed from the armature plate by removing the attaching screws. Remove driver coll for visual inspection and test. See Sec tion ' for alternator coil tests. CLEANING, INSPECTION, AND REPAIR SPARK PLUGS Inspect plugs for cracked porcelain and worn elec trodes. ‘Clean te electrodes with 4 polul file. DO NOT sandblast spark plugs. Adjust gap to the speci- fied .030 inch. In re-gapping, adjust only the ground side electrode, as attempting to bend the center elec~ trode will crack the insulator. See Figure 4-19. Figure 4-19. Checking Spark Plug Gap Poor motor performance and premature spark plug failure may result from improper spark plug in- stallation. Before installing the plug, be sure the plug seat in the cylinder head is clean and free from obstructions. See Figure 4-20. Screw the plug in by hand, then tighten to the specified 17-1/2 to 20-1/2 foot-pounds. If threads are stripped in cylinder head, Heli-Coil inserts are available. Caution should be taken when installing the Heli-Coil inserts. Tools for insetts are available from your parts distributor. Figure 4-20, Cleaning Spark Plug Seat a1 CLEANING BREAKER POINTS a, After extensive service, the breaker points may become worn, dirty, or out of adjustmont. Inspect the breaker ‘assemblies for corrosion or unusual wear. Questionable breaker points should be re- placed. Breaker points are serviced as an assembly. See Figure 4-21. Check action of the spring and free movement of the breaker arm. DO NOT change breaker arm spring tension. aneaKeR Figure 4-21. Breaker Point Installation b. Dirt, foreign particles, and oll are very detri- mental ly contact performance. The oils and acids from a person's hand, even though clean, can affect contact resistance. Oil deposits on the points will cause them to burn out after a very short period of, operation. If points need cleaning, use alcohol or trichlorethylene. NEVER FILE POINTS---replace them. ¢. To remove any traces of dirt from contacts, in= sert a strip of bias tape and work it up and down be- tween the points. Repeat entire cleaning procedure for second set of points. 4, Check points for good electrical contact, using ignition analyzer as described under "Breaker Point Testing.” Check and adjust breaker point setting as necessary as deseribed under "Breaker Point Adjust ment." TESTING COILS, CONDENSERS, AND BREAKER POINTS To determine accurately the condition of components, of the ignition system, an ignition tester should be used. Without the use’of test equipment, coils, con- Gensers, oF point aagomblico may bo replaced need lessly.