35

sPECIFICATIONS
20
25 and 25 COM.
5200-5800 rpm
4500-5500 rpm .
4500
-
5500
rpm ... . ... w .. . j p. rt. Number 386891
Full throttle operating range P. N b
388880
Wheel Part Number 388880 .. hee a 5300
POWER HEAD
Tank test ... ... .. . .... . ........... Wheel art um er . . . . . . 5200 rpm
4650 _rpm I 2 cvcle alternate tiring ... .. 2 cyl., 2 cycle, alternate tmng
Engine type ........ . . . .... . ...... 2 cyl., 2 cycle, .. 76 io x 57 15 mm stroke .. 76,20 mm bore x 57,15 mm strok3
Bore and stroke .. .. ........... 76,20 mm bore x 57,1 .. : .......... . .. . . . 521 cm3 ....... . . .. .. ........ 521 em
Piston displacement ...... . ............. :
Piston and ri ngs available standard and 76 mm overs1ze
Thickness of ring 2 286 2 273 2 286- 2 273 mm .... . . . ....... 2,286 -2,273 mm
: ?;... Upper....... . ................ .. .. ... .. . ' 88. 1,562 mm .. . .... . . . . . :: 1,588-1:562 mm .... .. .. . ... .. 1,588- 1,562 mm
1 5 - mm... . . . .....
... . ..... . ' '
size
31 775
_
31 788
mm ....... . ....
31
,775 _ 31 ,788 mm .. . ......... 31,775-31,788 mm
29,985-29,997 mm ...... . ..... 29,985.29,997 mm ... . .... .. .. 2294,998959-2295,909079 mm
enter JOurna . . . : . ' ' 24 999 _ 25 009 mm . . . . . . . . . . . . . , mm
Bottom journal .. .......... . ...... 24,999
25

009
mm
30

043 30
'030 mm 30 043-30 030 mm
30 043 30 030 mm -
Connecting rod crank pin ... .
6

2

1
' _ 76 19'mm min ... 76,21 mm max.- 76,19 mm min.
+Standard bore s1ze ..... . ....... 76,21 mm max. - 76,19 mm m1n ... 7 , mm max. ,
+To determine correct bore size for oversize piston, merely add oversize dimension for standard bore size .
.:: 'X ,
,1 '7 kJo ot)
: 7 1(!), t 0;03 J
FUEL SYSTEM
Carburetion .......... . . . . . ....... Single barrel, float feed, fixed ..
high speed, adjustable low-
speed, manual choke
L 6 ::J6 o' )
j "(/ l1t:. I '1
. . Single barrel, float feed, fixed .. ... Single float feed, .fixed
high speed, adjustable low high speed, adjustable lo -
speed (under motor cover), speed (under motor cover),
manual choke manual choke
Float level setting . .... . ....... . Between steps on gauge no. 324891 . Between steps on gauge no. 324891 . Between steps on gauge no. 324891
F I oat drop setti ng ............... 28 - 41 mm from carburetor body .. 28 41 mm from carburetor body . . 28 - 41 mm from carburetor body
lnletneedleseat .... . . . .......... .. ...... . .... 1,65-1,57mm............. 1,65-1,57mm .......... . ... . . 1,65-1,57mm
Initial low speed needle sett ing ... .. .. . ............ 3/ 4 turn open .. . .. .. . . ..... . . 1-1 / 2 turn open .. . ............. 1-1 / 4 turn open
Idle speed . . . . . . . . . . . . . .. . ...... 650 rpm maximum ......... ... . 650 rpm maximum .... . .. . . . ... 650 rpm maximum
Maximum neutral rpm .... . .. . . . ........ 2000- 3500 rpm . . . . . . . . . . . . . 2000- 3500 rpm . . .. . . . .... . ... 2000- 3500 rpm
LOWER UNIT
Cooling system . . . . . . . . . . . . . . Combination positive displace- . .
ment and centrifugal pump
Thermostatically and
pressure controlled
Propeller gear ratio . . . . . . . . . . . . . . . . . . . . . 12:21
Propeller supplied with motor .... .. 3 blade, 9-1/ 4" dia. x 11" pitch.
Propeller options ..... . .... ........... 3 blade, 9" dia. x 9" pitch . . .
MISCELLANEOUS
3 blade, 9" dia . x 10" pitch
3 blade, 9-1 / 4" dia. x
9" pitch SST
3 blade, 9-1 / 4" dia. x
12" pitch SST
3 blade, 9-1 / 4" dia. x
12" pitch
....
Combination positive displace- . . . . Combination positive displace-
ment and centrifugal pump ment and centrifugal pump
Thermostatically and Thermostati cal ly and
pressure control led pressure controlled
.... . 12:21 ................. 14:27
3 blade, 9-1 / 4" dia. x 11 " pitch . ... . . . ... 3 blade, 10" dia. x 13"
pitci:J alum.
. 3 blade, 9" dia. x 9" pitch . .. ........ 3 blade, 11" dia. x 9"
pitch alum.
3 blade, 1 0-1/2" dia. x 11"
pitch alum.
3 blade, 10-1/ 4" dia. x
. 13" pitch SST
3 blade, 10-1/ 2" dia. x
11" pitch SST
3 blade, 11" dia. x
9" pitch SST
3 blade, 9" dia. x 10::pitch
3 blade, 9-1 / 4" dia. x
9" pitch SST
3 blade, 9-1 / 4" dia. x
12" pitch SST
3 blade, 9-1 / 4" dia. x
12" pitch
Speed control ....... .. . . .......... . .. . On steering handle .. On steering handle (Manual start)
Remote control available
(E lectric start)
On steering handle (Manual start)
Remote control available
(Electric start)
Forward, rfeutral and reverse
Gear shift control . . . . . . . .. . .. Forward, neutral and reverse ...... Forward, neutral and reverse .
- Weight (without fuel tank, fuel tank weight 5 kg net.)
Standard length
Manual start
Electric start . ..
Long shaft
Manual start ... . . . .... . ........ . ....... ... ... .
Elect ric start ...... ...... . .. ..... .. . ..... .... .
Fuel capacity . . . . . . . . . . . . . . . . . . . . ... . .... . . . . .
ENGLISH

I
45,8 kg ... . . . . .. .. .
47,2 kg .. . . . . .. . ... . . .... .. . 51,7 kg
51,4 kg." " " " "" . " " 53,1 kg
46,7 kg .
48,5 kg . . . . . . . . . . . . 53,5 kg
52,7 kg. . . ........... . 54,9' kg
22,7 litres .... . . . . . . .... .
22,7 litres ... .. . . .. . ..... . .. .. 22,7 litres
1-7A
\
\
SPECIFICATIONS (CONT.)
20
25 and 25 COM. 35
ELECTRICAL SYSTEM
Generation
Electric start . .... .. . ... . . . ... .. ....... . .. .. . .... . .... 5 amp f lywheel alternator . . . . ... 5 amp f lywheel alternat or
Manual start . . ... ... .. .
. ... 60 watts AC at 12V . .. 60 watts AC at 12V ..... . . . . . .. . 60 watts AC at 12V
Starter amperage draw whi le cranking
....... 100ampsmax .. . .. .. . . . . ...... 100 ampsmax .
IGNITION SYSTEM
:gnition -f . ........... Magneto breakerless C. D.. . . . . . . . Magneto breakerless C. D. . . . . . . . . Magneto breakerless C. D.

: : : : :: : : : :: : : :: : : : : : L . ... .. : : :: :
+Alter nate spark plugs . . . . . . . . . . . . . . Champion L78V, OL78V ... .. ... Champion L78V, QL78V ........ Champion L78V, QL78V
or AC-VOFFK or AC-VOF FK or AC-VOFFK
Spark plug gap .. . . . . . . . . . . 1 ,0 mm . 1 ,0 mm . . . 1 ,0 mm
Spark plug torque . . . 2,4 2,8 kg-m (24- 27 N-m) . . 2.4 - 2,8 kg-m (24 - 27 N-m) . . 2,4- 2,8 kg-m (24 - 27 N-m)
Ignition co il ... . . . Part No. 582106.. ... Part No. 582106 .. . ..... . . Part No. 582106
(Coil Test page 4)
+Alternate spark plugs should be used when operat ing at high RPM for extended periods of t ime.
IGNITION COMPONENT TESTS
Ground Test Output
Meter Setting Reading Meter Setting Reading Meter Setting Reading
Charge coil High ohms scale 575 75 0 High ohms
00
H. 500 230
Sensor coil Low ohms scale 4o 10 n Low ohms
00
S,5 0.3
Power pack -- -- -- -- H. 500 180
CLEARANCE CHART
POWER HEAD
Piston ring gap . ... .. . . . ... . . . . . . ... .. . .. . . .. . . . .. .... . .. . . . .. . . . . . .. . .. .. . . . ... . . .. . ......... . .. . 0.43-0, 18mm
Piston ring groove clearance, lower . . ........ . .. .. . . .. . .. . . .. . . . .. ......... . 0,102-0,038 mm
Cylinder and piston. . .. . .. . . ....... .
Crankshaft end play . . . . . . . . . ........... . .
LOWER UNIT
Propeller shaft i n front gear bushing . ... . ... . ....... . . . ... . . . . . . . . . . . .. . . . .. . .. . . . ....... . ... .
Rear reverse gear to rear bushing . . . . . . . ..... . . . .... . .
Reverse gear bushing to propeller shaft .. . .. . .. . . . .. . . . ..... . ..... . .. . . . . . . .. .. .. . . .. . ... . .... .
TORQUE CHART
POWER HEAD
. . .. .. . .. 0,165-0,089mm
. . .. ... . . . . 0.28 - 0,08 mm
0,051 -0,025 mm
0,051 -0, 013 mm
0,038 - 0,013 mm
Flywheel nut ...... . .... . . .. . .. . . 13- 14 kgm (135 - 140 N-m) . . ... 13 - 14 kgm (135. 140 N-m) . . . .. 13 - 14 kg-m (135 - 140 N-m)
Connecting rod screw ... . .... . . .. ... . 4,0- 4,2 kg-m (40- 42 N-m) . .... . 4,0-4,2 kg-m (40- 42 N-m) . ...... 4,0 4,2 kg-m (40- 42 N-m)
Cylinder head screws .. ... .. . . . . .. . . . 2,5- 2,8 kgm (24- 27 N-m) .. . ... 2,5-2,8 kgm (24. 27 N-m) . .. . .. 2,5 - 2,8 kg- m (24- 27 N-m)
Crankcase to cylinder screws-
upper, center, and lower . . . .. . ...... 1,9-2,2 kgm (19 - 22 Nm) ...... 1,9-2,2 kgm (19 -22 N-m) .. . ... 1,9-2,2 kgm (19 -22 Nm)
Powerhead to exhaust housing screws .. . ... . ................... . ...... . . . ... . ........ . . . .. . ..... .. 2.2 - 2,5 kgm (22 - 24 Nm)
Electric starter through bolts ..... . . . . . . ..... . . ...... ... . .. . ....... 0.7-1,0 kgm (7 ,0 - 9,5 Nm) ..... 0.7 - 1,0 kg m (7,0 9,5 Nm)
Electric starter pinion nut ... .. . . .. . ... . . .... . ..... . .... .. . . . ...... 2,8- 3.4 kg m (27 - 34 Nm) .. . ... 2,8 - 3.4 kgm (27- 34 Nm)
Spark plug . ..... . . . ... .. . ...... . .. 2.4- 2,8 kgm (24- 27 Nm) ..... . 2,4 - 2,8 kgm (24- 27 Nm) . ..... 2,4- 2,8 kgm (24 - 27 Nm)
Manual starterassemblyscrew .. . . .. . . . 1) - 1.4 kg-m(11- 14N- m) .. . ... 1,1 - 1.4kg-m(11 - 14N-m) .. .... 1,1 - 1,4kgm(1 1 - 14Nm)
Power pack mounting screws .... . . . @)55- 0,69 kgm (5 7 Nm) ...... 0,55 - 0,69 kgm (5-7 Nm). . . 0,55 - 0,69 kgm (5 7 Nm)
Ignit ion co il mounting screws . . . . . 0;55. - 0,69 kgm (5-7 Nm) . . . . 0,55- 0,69 kgm (5-7 Nm) . . . 0,55 - 0,69 kgm (5 7 Nm)
. .
LOWER UNIT
Upper mounts .... . . . .. . ......... . 0.7 . 1,0 kgm (7 ,0 - 9,0 N-m) . . ... 0.7 - 1,0 kgm (7 ,0- 9,0 N-m) .... . 0.7 1,0 kgm (7 ,0 9,0 Nm)
Pilot shaft to steering . . ............. . . 1.4. 1,6 k-m (14 - 16 N-m) ...... 1.4 - 1,6 kg-m (14- 16 N-m) ...... 1.4 1,6 kgm (14 - 16 N m)
* Pull at propeller shaft for tilt up ........ .. ... .. ... 13,6- 18,1 kg . ............... . 13,6- 18,1 kg ..... . . . .. . .. 13,6 18,1 kg
* Pull at propeller shaft to
overcome reverse lock ........ . ... _: :. ' \:\' _. . . . . . . . . 68 - 113 kg . . . . . . . . . . . . . . . . . . 68 - 113 kg .. . . 68 113 kg
* Standard length lower unit.
1-78
I :
LUBRICATION CHART - 20, 25 AND 25 COM., 35
FREQUENCY (PERIOD OF OPERATION
LUBRICATION POINT LUBRICANT FRESH WATER SALT WATERt
1. Throttle and Shaft Linkage, 60 days 30 days
Rear Motor Cover Latch,
0
Starter Neutral Lockout
(Manual Start). See
Figu re 1-21.
2. Throttle Shaft Bushings and
0
-
60 days 30 days
Gears, Steering Handl e and
Bracket. See Figure 1-24.
3. Vertical Throttle Shaft and
0
60 days 30 days
Gears. See Figure 1-22.
4. Carburetor, Choke Linkage,
0
60 days 30 days
and Cam. See Figure 1-25.
5. Clamp Screws and Reverse
0
60 days 30 days
Lock. See Figures 1-23
and 1-26.
6. Shift Lever Shaft and

60 days 30 days
Swivel Bracket. See
Figures 1-27 and 1-28.
7. Gearcase, Capacity -
Change after first 20 hours of operation. Check every 50 hours of operation thereafter.
35 - 361 ml

Add lubricant if necessary .
20/25 - 246 ml
See Figures 1-29 and 1-30. Drain and refill every 100 hours of operation or once each season, whichever occurs first .
8. Electric Starter Pinion

As required As required
Hel i x. See Figure 1-25.
t Some areas may require more frequent lubrication.
TYPES OF LUBRICANT
Contact your DEALER for OMC Lubri cants.
OMC
OMC HI -V IS
LUBRIPLATE
TR IPLEGUARD
GEARCASE
777
GREASE
LUBRICANT
\:1
....
l ~ -
'
~
, .
......
~
"""
......
~ J ! . -
"""' '
yrease
-
""
~
~
d ~ -
-
...:. r:.. .....:
v
~
TUBE
GREASE GUN
0

0
0
LUBRICATION PICTURE SYMBOLS
1-17
ENGL.ISH
1-21
1-22
1-23
1-26
1-27
1-17
1-30
CARBURETOR REMOVAL -
9.9/ 10 AND 14 COM./ 15
Use Parts Catalog as reference (Carburetor
Section).
a. Remove low speed knob.
b. 9.9/ 15 - Remove air silencer cover. Remove
air silencer base from carburetor (2 screws).
c. Remove choke knob detent. Disengage choke
shaft f rom choke lever, and remove choke
knob and shaft from lower motor cover.
d. Remove manual starter .
e. Remove cam follower shoulder screw and
washer, and disengage lever from link and
starter lockout pawl spring. Observe position
of link in cam follower lever.
f. Remove nuts, carburetor, gasket and link as
an assembly, from intake manifold. Observe
position of link on lever.
NOTE ...
Link must be installed in throttle lever before re-
i nstalling carburetor on manifold, as manual
starter lockout bracket prevents installation after
carburetor is mounted on manifold.
g. Remove fuel hose t ie strap and disconnect
fuel hose from carburetor.
LEAF PLATE REMOVAL
a. Remove six intake mani f old screws and re-
move manifold. Remove leaf plate and gas-
ket from crankcase.
REMOVAL. OF CARBURETOR -
20, 25, 2!5 COM. AND 35
J. Disconnect carburetor to fuel pump hose at
fuel pump.
b. Remove screw retaining choke lever to
carburetor . Remove wave washer and spacer.
Disengage choke lever from choke knob, and
pull out of retainer in air silencer.
c. Remove pin from end of throttle control rod.
d. On Non-Commercial Models Remove
locknut, three screws, and air silencer . See
Figure 2-21 . Remove gaskets.
e. Disconnect throttle arm to cam follower link.
See Figure 2-22.
f. Remove electric starter if model is so
equipped.
g. Remove carburetor to manifold nuts and
remove carburetor.
REMOVAL OF LEAF PLATE ASSEMBLY
a. Disconnect oil recirculation hose. See Figure
2-22A. Remove seven hex head screws and
one slotted flat head screw. See Figure 2-
22A. Remove intake manifold and gasket.
ENG L.ISH
b. Remove one slotted flat head screw and re-
move leaf plate assembly and gasket.
REMOVAL OF CARBURETOR -
40 COM.
a. Disconnect fuel line at carburetor. Remove
choke link from choke lever . See Figure 2-
228 .
UliiliU NOTE
If choke link screw is removed, manual choke
must be readjusted so choke opens and closes
fully.
NOTE
Remove throttle cam link by pulling out of
throttle arm bushing. If throttle arm adjustment
screw is loosened and throttle arm removed,
throttle cam adjustment must be made. See
Figure 2-228.
2-13
b. Remove two nuts and lockwashers attaching
carburetor to intake manifold. Remove
carburetor and gasket from intake manifold.
c. Remove eleven screws attaching intake
manifold to powerhead. See Figure 2-23.
Remove intake manifold from powerhead.
d. Remove oil recirculation hose and screw
attaching leaf plate to crankcase and remove
leaf valve assembly, and gasket . See Figure
2-23.
1. Throttle Control Rod
2. Pin
2-20
1. Screw
2. Locknut
3. Air Silencer
2-21
1. Link
2-22
1. Hose
2-22A
1. Choke Link
2. Adjustment Screw
3. Cotter Pin
4. Link
2-228
1. Intake Manifold
2. Leaf Plate to Crankcase Screw
2 -23
2-20
2-22A
2-21 2-228
2-22
2-23
2-13
CARBURIETOR DISASSEMBLY
a. 2 . thru 35 - Remove packing nut and
adJustable needle valves with adjusting knob.
b. 4 thru V-6 - Remove fixed jets with Tool No.
317002.
c. Remove float chamber and gasket. Remove
hinge pin to permit removal of float and float
arm assembly.
CLEANING, INSPECTION, AND
REPAIR
GENERAL 11\ISTRUCTIONS
Clean all parts, except float and float valve, in
solvent and blow dry with no more than 138 kPa
of shop air. Do NOT dry parts with a cloth as lint
3Y cause trouble in the reassembled car-
ouretor. Be sure all particles of gaskets are re-
moved from gasket surfaces. Flush all passages
in the carburetor body with solvent and remove
any gummy deposits with OMC Engine Cleaner .
Certain solvents will not remove this gum which
accumulates, particularly in the f loat chamber
and on needle valves.
litffi!;"li l NOTE
Do not use OMC Engine Cleaner (OMC Engine
Tuner) on rubber or similar parts.
FLOAT AND NEEDLE VALVE
a. Inspect float and arm for wear or damage. If
the cork float has become oil-soaked, discard
it and install a new one. Check float arm
wear in the hinge pin and needle valve con-
tact areas. l=leplace if necessary.
b. Inspect the inlet needle valve for grooves,
nicks, or scratches. If any are found, replace
float valve assembly. See Figure 2-30. DO
NOT attempt to alter the shape of the needle
valve.
c. Check the float with a magnifying glass; if
the seat is nicked, scratched, or worn out-of -
round, it will not give satisfactory service.
See Figure 2-31. The valve seat and valve
are a matched set; if either is worn, both
parts must be replaced. Use a new sealing
washer when reinstalling the needle seat .
NEEDLE VALVES
a. Inspect the tapered end of t he needle valves
for grooves, nicks, or scratches; replace if
necessary. See Figure 2-32.
b. DO NOT attempt to aher the shape of the low
speed valve .
ENG LISH
CARBURETOR BODY
a. Clean out all the jets and passages, and the
venturi making sure no gum or varnish
deposits remain. Dry after cleaning with com-
pressed air. Keep clean for final reassembly.
b. Check all gasket surfaces for nicks,
scratches. or distortion. Slight irregularities
can be corrected with the use of a surface
plate and emery cloth.
c. Check throttle and choke shafts for exces-
sive play. Check operation of choke and
throttle valves to be sure they correctly shut
off air flow, yet move freely without binding.
Replace carburetor if valves or shafts are
excessively worn or damaged.
DNOTE
The threaded edges of the choke and throttle
valve attaching screws are staked during car-
buretor assembly to prevent loss during op-
eration. Disassembly of these valves is possible,
but replacement of the carburetor body i s
recommended.
CORE PLUGS
a.
b.
c.
If necessary, remove core plug to clean out
slow speed orifice holes. If leakage occurs at
a core plug area, a smart tap with a hammer
and flat end punch in the center of the core
plug will normally correct this condition.
If leakage persists, drill a 3 mm hole through
the center of t he core plug to a depth of not
more than 1 ,5 mm below its surface. With a
punch, carefully pry out t he core plug.
Inspect and clean the casting contact area. If
nicks, scratches, or an out-of-round condi-
tion exist, the casting will have to be
replaced. If casting opening is normal, apply
a bead of OMC Adhesive "M" to the outer
edge of a new core plug. Place the new core
plug in the casting opening, convex side up.
Flatten to a tight fit with a flat end punch and
hammer. Check f or l eakage.
LEAD SHOTS
If leakage occurs at a lead shot area, follow these
corrective measures:
a. If leakage is slight, a smart tap with a ham-
mer in the center of the lead shot will nor-
mally correct this condition.
b. If 1 eakage sti II exists, remove the lead shot
with an appropriate sharp tool.
c. Clean and inspect casting opening. If the
casting opening is normal, install a new lead
shot in casting opening and flatten out w1th
it, I ight hammer taps. Check for leakage.
ffi Safety Related
2-16
6332.4
2-30
@'-=-==)
63324
2-32
63324
2-31
2-1 6
LEAF VALVES
a. Inspect the leaf plate assembly and dis-
assemble if necessary. The leaf valves must
be free from all varnish and gum, and the
leaves must be perfectly flat and without dis-
tortion so that they form a perfect seal with
the leaf plate base.
b. DO NOT attempt to bend or repair a dam-
aged leaf; replace the complete assembly if
damaged. DO NOT under any circumstances
bend or flex the leaves by hand.
c. Replace the leaf stop if any leaves are
broken.
FUEL RECIRCULATING VALVE
When servicing the leaf valve assembly, remove
the recirculation valve leaf and clean the hole in
the plate and the leaf with OMC Engine Cleaner.
TESTING ELECTRIC CHOKE -
50/60(70(75
For effici ent operation, the plunger should be
free from corrosion so that it can move freely in
the solenoid housing. It is not necessary to lubri-
cate the solenoid plunger since the oil film will
only attract dust and cause sluggish plunger
movement. Choke solenoid should test 2,0 0,5
ohms between purple/ white stripe lead and black
ground lead. See Figure 2-33.
PRIMER SYSTEM - V-4 AND V-6
For efficient operation, the solenoid plunger
should be free from dirt and corrosion so that it
can move freely in the housing.
Primer solenoid should test 5.5 1.5 ohms
between purple/white stripe lead and black
ground lead. See Figure 2-33.
To disassemble primer solenoid remove cover
screws. See Figure 2-34. Lift off cover and
gasket. Remove seal. filter, plunger and spring.
Clean or replace filter . When reassembling use
new gasket and seal.
Replace any cracked or deteriorated primer
hoses. Clean nipples in bypass covers with
Special Tool Part No. 326623. See Figure 2-35. If
damaged replace bypass covers.
CARBURETOR REASSEMBLY
GENERAL INSTRUCTIONS
Reassemble the carburetor, paying particular
attention to the following procedure. Keep all
dust, dirt, and lint out of the carburetor during
reassembly. Be sure that parts are clean and free
from gum, varnish and corrosion when reas-
ENCiL. ISH
r..._ sembling them. Replace all gaskets and sealing
DO NOT attempt to use original
gaskets and washers, as leaks may develop
after the engine is back in use.
CARBURETOR BODY
a. 2 thru 35 - Install low speed needle valve.
Install orifice plugs. Replace float valve seat
and gasket, float valve, float, and hinge pin.
b. To check position of float, turn carburetor
body upside down, so that weight of the float
closes float needle. Top of float should be be-
tween steps on gauge no. 324891. See Fig-
ure 2-36.
c. Check for correct float drop dimension. See
Figure 2-37. With carburetor body in normal
running position, the float must drop open to
dimension shown.
d. Using a new gasket, install the float cham-
ber to the carburetor body.
e. V -4 and V -6 - Invert carburetor and place a
small drop of Loctite Part No. 290 sealant to
base of idle tube where idle tube comes out
of casting. See Figure 2-38. Allow sealant to
wick around tube but not run down tube or
run down into idle air bleed orifices. Allow to
dry.
2-17
1. Purple/ white Lead
2. Lo Ohms Scale
2-33
1. Cover
2. Gasket
3. Seal
4. Filler
5. Plunger
6. Spring
7. Solenoid Body
8. Plunger Valve
2-34
1. Gauge Number 324891
2. Top of Float Should be Between These
Two Steps
2-36
1 . Base of Carburetor Body
2. Bend Float Lever Tang to
Achieve Proper .Dimension
3 . 2 thru 15 28-33 mm
20 thru 75 28-41 mm
V -4 thru V -6 22-28 mm
2-37
.&. Safety Related
2-36
803 1 39
2-33
2
803406
2-37
803305
2-34
8 0 3 4 0 7
803395
2-35
2-38
2-17
INSTALLATION OF CARBURETOR
AND LEAF VALVES - 2 THRU 40
l'{\vr;: l NOTE
DO NOT use gasket sealer on leaf plate, mani-
fold or carburetor gaskets.
a. 2 thru 4 - Place new gaskets between the
leaf plate, intake manifold, and crankcase,
and attach to crankcase with four screws.
b. Using a new gasket, place carburetor in posi -
tion on manifold studs and fasten in place
with nuts.
c. Adjust throttle cam.
d. 2 - Install support bracket and air silencer.
e. Install integral fuel ta nk with two retainers.
f. Connect fuel hose to carburetor and install
rewind starter.
a. 4.5 thru 15 - Using new gaskets, install leaf
valve assembly and intake manifold on crank-
case. Install recirculation hoses.
b. Reconnect fuel line to carburetor using a
new nylon hose strap.
c. Using a new gasket, place carburetor in posi -
tion on manifold studs and fasten in place
w ith nuts.
d. Install cam follower and l ink.
e. Install manual starter.
f . Install choke, knob, pin, and cotter pin.
g. Install air silencer base and cover.
h. Push slow speed knob in place.
a. 20 thru 40 Com. - Using new gaskets,
install leaf valve assembly and intake mani-
fold on crankcase. Connect throttle control
rod. Install recircu lat ion hoses.
b. Reconnect fuel line to carburetor using a
new nylon hose strap.
c. Place a new carburetor gasket on intake
manifold . Route fuel hose to fuel pump, and
install carburetor. Connect cam follower link.
Connect fuel hose to fuel pump using a new
nylon hose strap.
d. Install electric starter if model is so equipped.
See Section 7 .
e. Inst all air silencer with four screws and one
locknut.
f. Push choke knob into place through retainer
in air si l encer . Engage choke lever in choke
knob and install choke lever w ith shoulder
screw, wave washer, and spacer.
INSTALLATION OF INTAKE
MANIFOLD AND CARBURETORS -
50 THRU V-6
ENG !fiSH
E:] NOTE
DO NOT use gasket sealer on leaf plate, manifold
or carburetor gaskets.
a. If removed and disassembled, attach the leaf
segment, shims, and leaf stops to the leaf
plates, then examine each leaf carefully.
Shims go on the long side of the leaf pl ates
(115 and 140 only). Each leaf must lie flat
against the plate with no edges turned up or
away from the plate. Replace any leaf valve
assembly which shows any indication of dis-
tortion or damage of leaf stop.
b. Attach the leaf plate assemblies to the in-
take manifold. Tighten screws to specified
torque to avoid distortion of the leaf plates.
c. Apply OMC Screw Lock to intake mani fold
screws. Using a new gasket install intake
manifold and leaf assembly to powerhead.
d. Connect recircul ation hoses using new tie
straps.
e. Place new gaskets in position on studs on
manifold. Connect fuel hoses between car-
buretors using nylon tie st raps. Place car-
buretors on studs and fasten in place with
nuts and lockwashers.
f . If necessary, install electric starter .
g. Connect choke and throttle linkages. See
Figures 2-39, 2-40, 2- 24 or 2- 26. Adjust link-
ages as descr ibed in Engine Synchronization
and Adjustment, before installing air silencer .
Throttle valves must close fully.
h. If removed, install fuel pumps with new
gaskets.
1. 50 thru 75- Install choke solenoid and adjust
as described in Choke Solenoid Adjustment -
50 Thru 75 Models.
J. V-4 and V-6 models- Install primer solenoid.
INSTALLATION OF AIR
SILENCER - 50 THRU V-6
a. Connect air silencer to manifold hose.
b. Install new gaskets and install air silencer
base using OMC Screw Lock on new screws.
Torque screws to specifications. See Section
1. Check that gasket surface on air silencer
cover is not damaged or deformed. Install
with new gasket.
1. Linkage Retainers (2)
2. Choke Solenoid Spring
3 . Fastener
5 . Throttle Link
6 . Throttle Shaft
Levers
. 4 . Choke Links
7 . Screw
2-39
. ~
1. Link Retainer
2. Choke Solenoid Link
2 -40
2-18
2-39
2-40
2-18
CARBURETOR ADJUSTMENT
THROTTLE CAM ADJUSTMENT - 2 THRU
15
a. Proper setting of the throttle pickup on the
throttle cam is important for obtaining good
overall running qualities together with the
best possible fuel economy.
b. Advance speed control until center of roller is
between marks on cam.
c. At this point the throttle should just begin to
open. Sometimes though, it is difficult to tell
when the carburetor's throttle shaft first
begins to move. You can make a simple tool
to exaggerate this movement from an
alligator clip and a piece of stiff wire. See
Figures 2-41 and 2-42
i. Attach cl ip to end of throttle shaft opposite
the cam follower linkage. The wire is bent
upwards 90.
e. Back out the cam follower "'adjustment screw
with Special Tool Ballhex Driver Part No.
327622 until the throttle valve is closed com-
pletely. Then advance the screw until the
throttle shaft just begins to rotate.
f. Install starter.
LOW-SPEED NEEDLE - 2 THRU 40
a. Start engine.
rntm NOTE
~
Allow motor to reach normal operating tem-
perature by running in a tank with test propeller
in gear. at one-half throttle or slightly more
before proceeding to next step.
b. With motor at operating temperature. run at
slow speed (700 - 750 rpm) with test pro-
peller in tank or on boat. Adjust low-speed
knob until motor runs fastest and smoothest
performance is obtained. Allow 15 seconds
for motor to respond to adjustment.
c. Position low speed knob with pointer down,
and replace on needle valve shaft without
disturbing position of needle.
d. Adjust idle adjustment knob to allow motor to
run at 650 rpm in gear. For neutral speed ad-
justment.
ENGLISH
THROTTLE CAM ADJUSTMENT - 20
THRU 40
Advance throttle until marks on throttle cam are
aligned with contact point of cam follower roller-
on 20 and 25, at second mark to 6,34 mm past,
on 35 and 40, between two marks. See Figure 2-
43.
THROTTLE CONTROL ROD ADJUSTMENT -
20 THRU 35
To adjust throttle control rod, shift lever must be
in forward gear. Throttle lever must touch stop
on cylinder. Push throttle control rod to full open,
and adjust collar to touch nylon pivot block and
tighten screw. See Figure 2-44.
THROTTLE AND CHOKE LINKAGE - 50
THRU V-4
a. Loosen carburetor throttle lever fastener
screws to allow spring on throttle shafts to
close throttle valves. Tighten screws. See
Figure 2-45.
b. Loosen upper and lower choke lever retain-
ing screws, and close choke valves, Tighten
screws. See Figure 2-45. (50 thru 75
models.)
1. Stiff Wire and Alligator Clip
2-41
1 . Cam Follower
2. Mark on Cam
3. Throttle Cam
4. Cam Adjusting Screw
2-42
1. Cam Adjustment Screw
2. Cam Marks
3. Cam Follower Roller
2-43
1 . Collar
2. Nylon Pivot Block
2-44
1 ) Upper Choke Lever Screw
2 . Upper Throttle Lever Screw
3. Lower Choke Lever Screw
4 . Lower Throttle Lever Screw
5. Yoke
2-45
2 -44
2-4 7
2-42
2-45
2-43
2-19 .
SECTION 3
IGNITION SYSTEM
.& SAFETY WARNING
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.
To prevent possible fire and explo-
sion under the motor cover, make
sure electrical wires are routed and
clamped in original position; away
from rotating parts which could cut
or abrade wire insulation.
GENERAL INFORMATION
SPARK PLUG
The spark plugs should be removed and
examined. If the electrodes are worn, or plug has
a cracked insulator or shows other signs of
damage, spark plug should be replaced. See
Specifications. Section 1 .
SPARK TEST
a. Remove the high tension lead from each
spark plug. To prevent damage to the spring
terminal on the high tens ion lead, twist and
pull on the cover . See Figure 3-1.
b. Adjust the air gap of the spark tester to spec-
ifications - Table 1 and connect the
tester leads to the high tension leads. Secure
the other end of the spark tester to a clean
engine ground.
li NOTE
To prevent possible arcing of high voltage,
position the t ester leads at least 51 mm from any
metal surface.
& SAFETY WARNING
To avoid possible shock hazards, do not
handle ignition coil or tester leads
during this test.
c. Crank the engine and observe the results at
the spark tester .
If a spark jumps at all gaps alternately, the igni-
tion system is OK. Check the spark plugs. and
other engine systems.
If there is no spark, or only a spark at just one
gap, continue the troubleshooting procedure.
ENG L.ISH
Table 1
Model
Ignition System Spark Tester Gap
2 & 4
Magneto 6 mm
40 (Com.)
Low Tension 11 mm
4.5 - V-4
C.D. 12 mm
V-6
C.D. 1 1 mm
FLYWHEEL REMOVAL
&a. To prevent accidental starting of motor,
disconnect the four wire cable connector
between the armature plate and power
pack or disconnect spark plug leads.

b. Remove the flywheel nut using a strap
wrench or other suitable tool to hold the fly-
wheel. See Figure 3-2.
c. To remove flywheel install the foll owing com-
ponents from universal puller: (3) three
screws Part No. 307641, (3) three washers
Part No. 307639, Puller Body Part No.
307636 and Pressing Screw Part No.
307637. Install puller on flywheel with
shoulder screws completely installed in fly-
wheel, tighten center pressing screw while
holding puller body with large screwdriver or
handle Part No. 307638. See Figure 3-2.


The flywheel may not "pop" from the taper with
only the force of the puller. In such a case, after
applying tension with the pressing screw, pry up
on the flywheel rim with a large screwdriver. and
at the same time rap the pressing screw with a
large brass hammer.
& SAFETY WARNING
Wear protective safety glasses before
striking metal object with hammer to
prevent accidental injury to eyes.
1. Spring
2. Cover
3. Hook
4. Wire
5. Spark Plug
3-1
& Safety Related

3-1
l . -----.,
3-2
FLYWHEEL INSTALLATION
a. Clean the crankshaft and flywheel tapers
with OIVIC Cleaning Solvent Part No. 390905
and blow dry with compressed air. These sur-
faces must be clean and dry to allow proper
locking of the tapers.
b. Install the flywheel and tighten the nut to the
torque specified in Table 2.
Table 2
Flywheel Nut Torque
Model kg.m N.m
2 3,0 - 3,5 30 - 34
4 & 4.5 4,1 - 5,5 40 - 54
6/6 COM. & 7.5 5,5 - 6,1 54 - 60
9.9/10 & 6,1 -7,1. 60 - 70
14 COM./15
20, 25,25 COM., 13,8- 14, 3 1 35 - 140
35 & 40 COM.
50, 55, 55 COM. , 11 ,2 -
11 ' 7
110 - 11 5
60
70, 75, V-4 13,8- 14,3 1 35 - 140
V-6 19,3 - 20,4 190 - 200
ENGLISH
3-2
I
I
TROUBLESHOOTING THE C.D.
SYSTEM - 4.5 THRU V-6
!he magneto capacitor discharge ignition system
IS easy to t roubleshoot. Remember these tips to
obtain fast, accurate test results:
a. Visual Inspection - Check wiring for broken,
pmched, or loose leads. Connectors should
be securely fastened and free from moisture
or water accumulation.
b. Test Equipment Condition - Be sure testers
are in working order. Many hours can be
wasted by replacing working components
needlessly.
c. Follow Procedure - Troubleshooting can seem
difficult if you vary your technique for each
problem. Many times items in the system are
overlooked because you "thought" you tested
them. By following the same procedure each
time you troubleshoot, all items in the igni -
tion system are sure to be tested.
d. Test the Complete System - There may be
occasions when more than one component is
defective. If this condition is undetected,
repeated ignition system failure may occur,
or damage to replacement parts could result.
Test everything.
TEST EQUIPMENT REQUIRED
a. Spark tester. See General Information.
b. Stevens or Electro-Specialties C.D. Volt-
meter Tester. See Figure 3-35.
c. Ohmmeter - Capable of indicating low ohms
(RX1) and high ohms (RX1 ,000).
d. Jumper Wires (4 required) . Jumper leads can
be made as shown in Figure 3-36.
e. C.D. adapter available from Stevens or
Electro Specialties.
CONNECTOR PLUGS
Two water-proof connectors, male and female
plug-in type, are utilized in the ignition system.
Each connector is secured by a retainer. The re-
tainer must be removed to unplug the connector.
E NGLISH
CONNECTOR TERMINAL
REMOVAL
I::'J&:w: l NoTE
Use the recommended lubricant for terminal re-
moval. Substitutes may cause high resistance
connections, short circuits between terminals, or
have adverse effects on the connector material.
a. Apply isopropyl alcohol into t he connector
cavity at both ends to lubricate the terminal
and connector .
b. Place the connector against the edge of a flat
surface and allow clearance for the terminal
to be removed.
c. Select - the proper removal tool for the ter-
minal in the connector. See Figure 3-37.
d. Insert the removal tool onto the terminal and
push the terminal from the connector . See
Figure 3-38.
e. Pin and socket terminals may be replaced if
damaged. Crimp new terminals onto the wire
using OMC Crimping Pliers (Special Tool No.
322696). See Figure 3-37 for crimping loca-
tion. If crimping pliers are not available, the
terminals can be installed onto the wire
using needle nose pliers, and then must be
soldered to the wire to insure good electrical
contact and security. No soldering is re-
quired when using the OMC Crimping Pliers.
1 . Stevens CD-77 Tester
2. Electro-Specialties Model PRV-1
3. Stevens Adapter
4. Electro Specialties Adapter
3-35
1. No. 16 Wire, 200 mm Long
2. Pin (OMC Part No. 511469)
3. Socket (OMC Part No. 581656)
4. Tubing (OMC Part No. 51 0628) 25 mm Long
3-36
1. Insert Tool (OMC Part No. 322697)
2. Pin Remover (OMC Part No. 322698)
3. Socket Remover (OMC Part No. 322699)
4. Pin Terminal
5. Socket Terminal
6. Crimp Termi nal Here
3-37
3-17
'
0 3156
8 300 ,
3-35
' i
~
0 I
CD
73 158
3-37
3-36
3-17
- '
-------------- ~
CONNECTOR TERMINAL
INSTALLATION
a. Connect both halves of the connector
toget her.
U;l#31U N 0 TE
Do not use grease or oil. Clean out any grease or
oil that may be present in cavities.
b. Apply isopropyl alcohol into the connector
cavity.
&sAFETY WARNING
To avoid personal inj ury, securely hold
insert tool against shoulder of t ermi nal
while installing t erminal s into con-
nector cavity.
c. Position the i nsert tool against the shoulder
of the terminal. See Figure 3-39.
d. Support the connector against a flat surface
and push the terminal into the connector
until the shoulder on the insert tool is at the
end of the connector . See Figure 3-40.
e. Reinstall wire retainer on connector .
.GNITION COIL TESTS
A wide variety of ignition testers are available
from various manufacturers. In addition, some
automotive testers having the proper specifica-
ti ons can be used.
Detailed instructions for the use of any tester are
provided with the unit; therefore, only general in-
f ormation is given here. See Coil Specifications,
Section 1.
IGNITION COIL MUST BE REMOVED FROM
POWERHEAD FOR POWER AND LEAKAGE
TESTING.
& SAFETY WARNING
To avoid possible shock hazards and to
prevent leal<age, perform all tests to the
coil on a wooden or insulated bench
top.
ENGL. I S H
POWER PACK REPLACEMENT -
ALL MODELS
REMOVAL
a. Separate the connector between the power
pack and ignition coils, and the connector be-
tween the armature plate and power pack.
See Figure 3-41.
NOTE
Remember the routing of the power pack leads
and the location of clamps for proper lead posi-
tioning during installation.
b. Unscrew the power pack mount screws and
ground wire screw to remove the power
pack.
INSTALLATION
bii!l NOTE
Unless otherwise specified, when installing lock-
washers on electrical connectors, place the
washer on the engine side of the connector to
provide a good ground.
a. Install the power pack ground wire and posi-
tion the wire so there wi II be no pu II (stretch)
when the power pack is installed. Excessive
pull on the ground wire could result in igni-
tion failure.
b. Mount the power pack and tighten the
screws to 0,55 - 0,69 kg.m.
3-18
1. Insert Tool
2. Shoulder on Termina l
3. Joined Connectors
3-39
1. Shoulder on Tool
3-40
1. Four Wire Connector - Charge Coi ls and
Sensor Coils to Power Pack
2. Three Wire Connector - Power Pack to
Ignition Coi ls and Stop Switch
3 -41
93397
3-39
3-40
3-41
3-18
4.5 THRU 60 - C.D. IGNITION
SYSTEMS
CONNECTOR PLUGS
A four wire conductor connects the charge coil
and sensor coil leads to the power pack. The
three wire connector connects the power pack
leads to the ignition coils. See Figure 3-41.
STOP BUTTON ELIMINATION TEST
a. Separate the three wire connector between
the power pack and ignition coils. See Fig -
ure 3-41.
b. Insert a jumper wir e between the " B"
terminals of the three wire connector . See
Figure 3-43.
c. Insert a jumper wire between the "C"
terminals of the three wi re connector.
& SAFETY WARNING
To avoid possible shocl< hazards, do not
handle ignition coil or tester leads dur-
ing the test.
d. Crank eng i ne and observe the results at the
spark test er. On electric starting models,
crank the engine by hand using an emer -
gency starter rope .
e. If a spark jumps alternately at both gaps, the
problem is in the stop button circuit Refer to
the stop button circuit test . If ther e is no
spark, or a spark at only one gap, remove the
jumper wires.
NOTE
Carefully align the connector halves during as-
sembly to insure proper terminal contact.
f . Reconnect the three wire connector and con-
tinue troubleshooting procedure.
STOP BUTTON CIRCUIT TEST - MANUAL
START MODELS
a. Separate the three wire connector between
t he power pack and ignition coils.
b. Calibrate the ohmmeter to high ohms scale.
Connect the meter red lead(+) to the "A" ter-
minal in the ignition coil end of the con-
nector, and the meter black lead (-)to a clean
engine ground. See Figure 3-42.
3-19
c. The meter should indicate open circuit (oo) . If
there is any needle movement, replace the
stop switch and lead assembly.
d. Push the stop button. The meter should indi-
cate a closed circuit (0).
KEY SWITCH STOP CIRCUIT TEST
ELECTRIC START MODELS
a. Perform steps a. and b. in STOP BUTION
CIRCUIT TEST and separate the 4-wire con-
nector.
b . Turn the key switch to "ON."
c. The meter should indicate an open circuit
(oo). If there is any needle movement, re-
move the blackjyellow stripe wire from the
key switch " M" terminal with the ohmmeter
still connected as shown in Figure 3-42.
d. If the meter indicates an open circuit (oo)
with the wire removed from the key switch,
replace the switch. If a closed circuit (o) is
indicated, repair or replace the black/ yellow
stripe lead between the key switch and igni-
tion coil end of the three wire connector.
1. High Ohm Scale
2 . Red Meter Lead
3 . Black Meter Lead
4 . Stop Button or Key Switch
5. Key Switch "M" Terminal
6. Terminal "A"
3-42
1. Jumper Wires
2. Stop Button or Key Switch
3. Terminal " B"
4. Terminal "C"
3 -43
6
8 1 3034
3-42
813030
3-43
3-19
r - ~ --
- #'it
OHMMETER TESTS
Ohmmeter tests are necessary to determine if
the sensor coil or charge coil have failed in a
manner which could cause ignition failure.
Ui;j\t l NOTE
Resistance readings should be checked when the
motor has completely cooled to ambient air tem-
peratl!re. The higher temperature, caused by
runnmg the motor, will increase the resistance
reading and may result in unnecessary parts
replacement.
Sensor Coil Test (Ohmmeter)
a. Separate the four wire connector between
the armature plate and power pack See Fig-
ure 3-41.
b. Insert a jumper wire to terminal "B" in the
armature plate end of the connector. See Fig-
ure 3-44.
c. Insert a jumper wire to terminal "C" in the
armature plate end of the connector. See Fig-
ure 3-44.
d. To test the resistance, connect an ohmmeter
(calibrated on low ohm scale) between the
two jumper wires. The sensor coil resistance
is good if the meter indicates 40 1 0 ohms
(4 thru 60}, 45 10 ohms (55 rope model)
Replace the sensor coil if the resistance
reading is not within this range. See Figure
3-44.
e. To test for shorts to ground, calibrate the
ohmmeter to high ohm scale. Connect the
black meter lead (-) to the armature plate
(ground). Attach the red meter lead (+)to the
" C" terminal jumper wire in the connector .
See Figure 3-45. Any needle movement
indicates the sensor coil or leads are shorted
to ground. A shorted sensor must be re-
placed, or the grounded lead repaired to
remove the shorted condition.
f . Remove the jumper wires from the connector
and continue the troubleshooting procedure.
Charge Coil Test (Ohmmeter)
a. Insert a jumper wire to terminal "A" in the
armature plate end of the connector. See
Figure 3-46.
b. Insert a jumper wire to terminal "D" in the
armature plate end of the connector. See Fig -
ure 3-46.
ENGL. ISH
c. To test the resistance, connect an ohmmeter
(calibrated to high ohm scale) between the
two jumper wires. The charge coil resistance
is good if the needle indicates 575 75 ohms
(manual start) or 475 75 ohms (electric
start). See Figure 3-46.
d. To test for shorts to ground, calibrate the
ohmmeter to high ohm scale. Connect the
black meter lead (-) to the armature plate
(ground). Attach the red meter lead (+)to the
"A" terminal jumper wire in the connector.
See Figure 3-47. Any needle movement indi-
cates the charge coil or leads are shorted to
ground. A shorted charge coil must be re-
placed, or the grounded lead repaired to re-
move the shorted condition.
e. Do not remove the jumper wires from the
connector, and continue the troubleshooting
procedure.
1. Jumper Wires
2. Low Ohm Scale
3. Terminal "B"
4. Terminal "C"
3-44
1. High Ohm Scale
2. Black Meter Lead
3. Red Meter Lead
4. Jumper Wire
5. Armature Plate
6. Terminal "B"
7. Terminal "C"
3-45
1. Jumper Wires
2. High Ohm Scale
3. Terminal "A"
4. Terminal "B"
5. Terminal "C"
6. Terminal "D"
3-46
1. High Ohm Scale
2. Black Meter Lead
3. Armature Plate
4. Red Meter Lead
5. Jumper Wire
6. Terminal "A"
7. Terminal "B"
8. Terminal "C"
9. Terminal "D"
3-47
3-20
3-44
v
(g;))
3-45
8340 1
4
83402
83399
3-46
3
83400
3-47
3-20
IGNITION SYSTEM TESTS
USING C.D. VOLTMETER
TESTER
ltil\%1'\i l N 0 TE
Before conducting these tests be sure to do the
Spark Test and the Ohmmeter Tests.
CHARGE COIL TESTS
Set meter switches to Negative and 500. First,
check for shorts to ground. Disconnect four wire
connector. Insert red meter lead into cavity "A."
Attach black meter lead to armature plate. See
Figure 3-48. Crank engine and observe meter
reading. Remove lead from cavity "A" and insert
'"1to cavity "D." Crank engine and observe meter.
Any reading on either test means charge coil is
shorted to ground. Locate short and repair, or
replace charge coil.
To check charge coil output, remove black lead
from armature plate and insert probe into cavity
"A" of connector. See Figure 3-48. Crank engine
and observe meter reading.
a. If meter ,reads 230 or higher, go to Power
Pack Output Test.
b. If meter reads below 230 replace charge coil.
SENSOR COIL TESTS
Set meter switches to "S" and 5. First, check for
shorts to ground. Disconnect four wire con-
nector. Insert red meter lead into cavity "C."
Attach black meter lead to armature plate. See
Figure 3-49. Crank engine and observe meter
reading. Remove lead from cavity "C" and insert
into cavity "B." Crank engine and observe meter.
Any reading on either test means sensor coil is
shorted to ground. Locate short and repair, or
replace sensor coil.
To check sensor coil output, remove black lead
from armature plate and insert probe into cavity
"C" of connector. See Figure 3-49. CrC!nk engine
and observe meter reading.
a. If meter reads 0.3 or higher, go to Power
Pack Output Test.
b. If meter reads below 0.3, replace sensor coil.
ENCiLISH
1 , Term ina! " D"
2. Red Meter Lead
3. Black Meter Lead
4. Terminal "A"
5. Test for Short to Ground
3-48
1 , Term in a I "C"
2. Red Meter Lead
3. Black Meter Lead
4. Terminal "B"
5. Test for Short to Ground
3 -49
3-21
83403
3-48
2 - - ; r - t - - - - - '
\
I
3
83404
3-49
3-21
.. ___________ , ______ = - - - - - - - - - - - - - - - - - - ~ ~ - - - - - - - - - - ~ ~ =
I i
I
POWER PACK OUTPUT
Set meter switches to Negative and 500. Dis-
connect three wire connector between power
pack and ignition coils.
Insert jumper leads between "B" terminals of
connectors and between "C" terminals. See
Figure 3-50. Connect meter black lead to engine
ground. Connect meter red lead to metal part of
jumper lead coming from power pack cavity "B."
Crank engine, observe meter reading. Connect
meter red lead to metal part of jumper lead cavity
"C." Crank engine, observe meter reading.
a. If meter reads 180 or higher, check ignition
coil, or coils.
b. If meter does not read 180 or higher on one
output, remove jumper lead from that cavity
of connector from power pack. Insert meter
red lead into that cavity. Crank engine: If
meter reads 180 or higher, ignition coil is de-
fective. If meter does not read 180 or higher,
power pack is defective.
c. If meter does not read on both outputs,
power pack is defective.
d. The power pack can be substituted with a
known good pack. Be sure the power pack
ground Lead is securely connected to the
powerhead.
IGNITION COIL TESTS
OHMMETER TEST
Resistance tests may be performed while the
ignition coil is still mounted to the powerhead.
a. Remove the high tension lead from the
ignition coil.
b. Separate the three wire connector between
the power pack and ignition coils.
c. Insert a jumper wire into the "B" terminal on
the ignition coil end of the three wire con-
nector. See Figure 3-51.
d. Calibrate an ohmmeter to low ohm scale,
then connect the black meter lead (-) to a
clean engine ground, and the red meter lead
(+) to the "B" terminal jumper wire. See
Figure 3-51.
e. Resistance of the primary winding should be
0,1 0,05 ohms.
ENGL. ISH 3-22
f. Calibrate the ohmmeter to high ohm scale,
then connect the meter red lead (+) to the
"B" terminal jumper wire. Connect the meter
black lead(-) to the high tension terminal of
the coil. See Figure 3-52.
g. Resistance of the secondary winding should
be 275 50 ohms. Replace the ignition coil if
the reading is other than specified.
h. To test No. 2 ignition coil, repeat the above
procedure using terminal "C" in the three
wire connector.
i. Test resistance of high tension leads on low
ohms scale. Resistance should be near zero.
1 . Term in a I "B"
2. Terminal "C"
3. Red Meter Lead
4. Black Meter Lead
3-50
1. Jumper Wire
2. Low Ohm Scale
3 . Black Meter Lead
4. Red Meter Lead
5. Terminal "C"
6 . Terminal "B"
7 . Terminal "A"
8. Primary Resistance Test
~ 9 . Secondary Resistance Test
10. High Ohm Scale
3-51 and 3-52
j _
~
_ 5 0 ~
=-4
813039
3-50
2
8
813032
9 813033
3-51 3-52
I
3-22
:ll
!l
. I
IGNITION TIMING
It is possible for the ignition system to produce a
good spark and yet the engine will not start . If
the engine "pops" or "backfires" dur i ng starting
attempts, the ignition timing could be 180
degrees off. Check the following:
a. Sensor Wire Positioning - On the four wire
connector between the armature plate and
power pack be sure the white/ black stripe
wire is located in the " 8" terminal of both
connector halves.
b. Ignition Coil Wire Positioning - Check t he
three wire connector to be sure the No. 1
(TOP) ignition coil orange wire is in terminal
"8 " of connector, and that it mates with the
orange/blue stripe wire from the power pack.
4.5 thru 15 - No timing adjustments are nec-
essary. Correct wire positioning in the three and
four wi re connectors is all that is required to
maintain proper ignition timing.
IGNITION TIMING ADJUSTMENT -
20 THRU 60
a. Connect a timing light to the No. 1 cylinder.
Start and run the engine at full throttle.
b. The timing mark must align with the mark on
the flywheel grid. See Table 3 and Figure 3-
53.
c. Loosen the timing stop adjustment screw
locknut, and turn the screw in or out as
necessary to correct the timing. See Figure
3-54.
d. Tighten the locknut, and re-check the timing
adustment.
Table 3
Model Timing
20 & 25, 34 1
25 COM.
35 30
1 0
'-
50, 55, 19
1 0
55 COM.
60 21
1 0
IGNITION COIL REPLACEMENT
REMOVAL
a. Separate the three wire connector between
the power pack and ignition coils.
b. Twist and pull on the cover to remove the
high tension lead from the spark plug.
ENGl. I SH
3-25
c. Release the ignition coil wires from the sup-
port clamps, and remove the coil mounting
screws.
d. Remove the ignition coil terminal from the
three wire connector .
INSTALLATION
a. Reconnect the three wire connector, and se-
cure with retainer.
I <it I NOTE
Carefully align the connector halves during
assembly to provide proper terminal contact.
b. Insert the ignition coil terminal into the three
w_ire connector. Secure with retainer.
c. Clean and prime screw threads with OMC
Locquic Primer Part No. 384884. Apply OMC
Screw Lock Part No. 384848 to mounting
screws. Mount the ignition coil to the engine
with the lockwasher between the ignition coi l
and ground wire connector. Torque screws to
7-9 N.m. See Figure 3-55. Install the stop
button or key switch ground wire with the
lockwasher between the ignition coil and the
ground wire connector.
d. Secure the high tension lead to the spark
plug.
I :I NOTE
To insure proper ignition timing check the No. 1.
(TOP) ignition coil orange lead to be sure it is i'7
the "8" terminal of the connector, and that 1t
connects to the orange I blue stripe wire from the
power pack.
A. 20, 25, 35 - Manual Start
B. 20, 25, 35 - Electric Start
C. 50, 55, 60
3-53
1. Locknut
2. Adjustment Screw
3. Stop
3-54
1. Engine
2. Lockwasher
3. Electrical Connector
4. Washer or "J" Clamp
3-55
3-53
B 13037
3-55
3-25
ARMATURE PLATE REMOVAL
a. 55 models - Remove manual starter .
b. Remove the flywheel . (Refer to Flywheel
Removal .)
c. Remove the armature plate leads from the
support clamps. On electric starting models
remove three armature plate leads from the
terminal board.
d. Loosen the screws attaching the armature
plate to the retainer plate, and lift the arma-
ture plate from the powerhead. See Figure 3-
56, view A (manual start) and view B (electric
start) .
e. The retainer plate and support plate may be
removed (if necessary for servicing) by dis-
connecting the throttle lever to armature
plate link, then removing the screws from the
support plate. See Figure 3-57.
ARMATURE PLATE
INSTALLATION
a. If removed for servicing, install the retainer
plate on the crankcase. Next. position the
support plate over the retainer plate and
align the holes between the plate and crank-
case. Install the screws and torque to specifi-
cations in Section 1. Reconnect the throttle
lever to armature plate link. See Figure 3-57.
b. Apply OMC Moly Lube to the crankcase boss
(pilot for armature plate) . See Figure 3-58.
Lubricate the armature plate bearing with a
light coat of OMC outboard lubricant .
d. Insert needle nose pliers into the slots pro-
vided, and hold the armature plate bearing
compressed while guiding the armature plate
into position. See Figure 3-58.
e. Position the armature plate with the center of
the charge coil in line with the stop on the
retainer plate, and tighten the screws to the
torque specified in Section 1. See Figure 3-
56, view A. On electric starting models,
position the cut-outs in the armature plate
assembly as shown in Figure 3-56, view B.
ENGL..ISH
[]NOTE
To provide adequate movement of the armature
plate and to prevent damage to the wires, route
the armature plate lead so the dots on the sleeve
are located inside the forward support clamp.
f. Secure the armature plate lead in the support
clamps so that the lead has sufficient slack at
full advance. On electric starting models,
route the stator assembly lead behind the
starboard bracket, and connect the three
wires to the terminal board. Match the wire
colors from the stator lead with those from
the rectifier .
g. Install the flywheel. (Refer to Flywheel
Installation).
h. Install the manual starter assembly.
View A - Manual Start
1. Armature Plate Link
View 8 - Electric Start
1. Armature Plate Cut-Outs
3-56
1. Crankcase Boss
2. Throttle Cam
3-58
3-26
VIEW A
I
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.ij
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VIEW B
i
3-60
73023
3-59
3-61
3-27
II
CHARGE COIL OR SENSOR COIL
REPLACEMENT (STATOR
ASSEMBLY REPLACEMENT)
REMOVAL
ilia. To prevent accidental st arting of motor dis-
connect charge coil connection (4 wire
connector).
b. Remove the flywheel. (Refer to Flywheel
Removal. )
c. Remove the armature plate as described in
Armature Plate Removal.
d. If replacing the charge coil, terminals " A"
and "D" must be removed from the arma-
ture plate end of the four wire connector. To
replace the sensor coil, remove terminals "B"
and "C" from the armature plate end of the
four wire connector. On electric starting
models, remove all four terminals from the
connector .
e. Remove the cover from the bottom of the
armature plate. See Figure 3-59.
f. Next, remove the clamp on top of the arma-
ture plate retaining the leads. See Figure 3-
60.
g. With the screws secur ing the charge coil or
sensor coil removed, pull the coi l and lead
assembly from the insulation sleeve and
armature plate. On electr ic starting models,
remove t he screws from the stator assembly
and pull the stator from the insulati on sleeve
and armature plate.
INSTALLATION
a. Lubricate the insulation sleeve with iso-
propyl alcohol, and insert the coil leads
through the armature plat e and sleeve to the
four wire connector.
b. Install the terminals into the connector .
c. Position the charge coi l or sensor coil on the
armature plate, and insert the mount screws
just finger tight. On electric starting models,
position the stator assembly on the armature
plate and install the mounting screws to the
torque specified in Section 1, then proceed to
step e.
ill Safety Related
ENGL. ISH 3-27
d. Correct locating of the coi l assembly is
governed by machined mounting surfaces on
the armature plate. The outside edge of the
charge coil and sensor coil must be flush
with the machined surfaces on the armature
plate to prevent contact with the flywheel
magnet and provide maximum output from
the coils. See Figure 3-60, view A. A l ig n-
ment of the charge coil and sensor coil will
be simplified when using the OMC Coil
Locating Ring (Speci al Tool No. 317001) ma-
chined to fit over the armature plate bosses.
See Figure 3-61 . With the Coil Locating Ring
in position over the armature plate bosses,
push the ring toward the coil while pulling
the coil toward the ring, and tighten the coil
mounting screws to the torque specified in
Section 1 .
e. Instal l the clamp on top of the armature plate
to position the charge coil and sensor coil
leads. See Figure 3-60, view A or B.
f. Slide the insulation sleeve to the armature
plate to protect the coil leads, and install the
cover on the bottom of the armature plate.
Line up the notch in the plate with the notch
on the cover during installation. See Figure
3-59.
g. Install the armature plate. Refer to Armature
Plate Installati on procedures.
h . Reconnect charge coil connection.
1. Notch in Cover
3-59
VI EW A - MANUAL START
1. Outside Edge of Charge Coil
2. Machined Boss
3. Clamp
VIEW B - ELECTRIC START
1. Armature Plate
2. Clamp
3. Stator Assembly Mount Screws
3-60
KEY SWITCH ELIMINATION TEST
a. Separate t he four wire connector that
connects the power pack to the ignition coils
and key switch. See Figure 3-66.
b. Insert a jumper wire between the "A" ter-
minals of the four wire connector . See Figure
3- 66.
c. Insert a jumper wire between the "8" ter-
minals of the four wire connector. See Figure
3-66.
d. Insert a jumper wire between the "C" ter-
minals of the four wire connector. See Figure
3-66.
& SAFETY WARNING
To avoid possible shock hazards, do not
handle ignition coil or tester leads
during this test.
e. Crank engine and observe the results at the
spark tester.
f . If a spark jumps alternately at all gaps, the
problem is in the key switch circuit. Refer to
the key switch stop circuit test . If there is no
spark, or a spark at only one gap, remove the
jumper wires.
r;::'01 NOTE
~
Carefully align the connector halves during as-
sembly to insure proper terminal contact.
g. Reconnect the four wire connector and con-
tinue troubleshooting procedure.
ENGLISH
3-29
KEY SWITCH STOP CIRCUIT TEST
a. Separate the four wire connector between
the power pack and ignition coils.
b. Calibrate the ohmmeter to high ohms scale.
Connect the meter red lead (+) to the "D" ter-
minal in the ignition coil end of the con-
nector, and the meter black lead(-) to a clean
engine ground. See Figure 3-67.
c. Turn the key switch to "ON."
d. The meter should indicate an open circuit
(DO}. If there is any needle movement, re-
move the black/ yellow stripe wire from the
key switch "M" terminal with the ohmmeter
still connected as shown in Figure 3-67.
e. If the meter indicates an open circuit (oo)
with the wire removed from the key switch,
replace the switch. If a closed circuit (o) is
indicated, repair or replace the black/ yellow
stripe lead between the key switch and igni-
tion coil end of the four wire connector.
f . Turn key switch to "OFF" position. Meter
should indicate a closed circuit.
g. If meter does not indicate closed circuit,
check key switch, key switch ground lead and
black/ yellow stripe lead for open circuit .
Repair circuit.
h. If engine does not stop when key switch is
turned to "OFF" position, and stop circuit
checks out ok, replace power pack.
1. Terminal "A"
2. Terminal "8"
3. Terminal "C"
4. Spark Gap Checker
3-66
1. Ohmmeter
2. High Ohms Scale
3. Red Meter Lead
4. Terminal "D"
5. Black Meter Lead
6. Key Switch
3-67
4
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I - I
L - ~ - - - J
3-66
3-67
3-29
81304 1
OHMMETER TESTS
Ohmmeter tests are necessary to determine if
t he sensor coil or charge coil have failed in a
manner which could cause ignition failure.
lrsi\r l NOTE
Resistance readings should be checked when the
motor has completely cooled to ambient air tem-
perature. The higher temperature, caused by
running the motor, will increase the resistance
reading and may result in unnecessary parts
replacement.
Sensor Coil Test (Ohmmeter)
a. Separate the four wire connector between
the t imer base and power pack. See Figures
3-62, 3-63 and 3-64.
b. Insert a jumper wire in "A" terminal of the
t imer base end. See Figure 3-68.
c. Insert a jumper wire in terminal " B" in the
timer base end of the connector . See Figure
3-68.
d. Insert a jumper into "C" terminal.
e. Insert a jumper into "D" terminal.
f . To t est t he resistance, connect an ohmmeter
(calibrated on low ohm scale) between the
"A" and " D" terminal jumper wires, then the
"B" and "D" t erminals, and then the " C" and
"D" termi nals. The sensor coil resistance is
good if the meter indicates 17 5 ohms.
Replace the sensor coil if the resistance
readi ng is not withi n this range. See Figure
3-68.
g. To t est for shorts to ground, calibrate the
ohmmeter to high ohm scale. Connect the
black meter lead (-) to the timer base
(ground). Attach the red meter lead (+)to the
" A" terminal, then "B," then "C," then "D,"
jumper wire in the connector . See Figure 3-
69. Any needle movement indicates the
sensor coil or leads are shorted to ground. A
shorted sensor must be replaced, or the
grounded lead repaired to remove the shorted
condition.
h. Remove the jumper wires from the connector
and continue the troubleshooting procedure.
Charge Coil Test (Ohmmeter)
a. Separate two wire connector (CHARGE COIL).
b. Insert a jumper wire to terminal "A" in the
stator end of the 2 wire connector. See
Figure 3-70.
c. Insert a jumper wire to terminal "B" in the
stator end of the connector. See Figure 3-70.
ENG L.I S H
3-30
d. To test the resistance, connect an ohmmeter
(calibrated to high ohm scale) between the
two jumper wires. The charge coil resistance
should be 550 75 ohms.
e. To test for shorts to ground,calibrate the
ohmmeter t o high ohm scale. Connect the
black meter lead (-) to the timer base
(ground) . Attach the red meter lead (+) to the
" A" terminal jumper wire in the connector .
See Figure 3-71 . Observe the meter . Then
move red lead t o "B" terminal. Any needle
movement indicates the charge coil or leads
are shorted to ground. A shorted charge coil
must be replaced, or the grounded lead
repaired to remove the shorted condition.
f. Do not remove the jumper wires from the
connector, and continue the troubleshooting
procedure.
1. Jumper Wires
2. Low Ohm Scale
3. Terminal " A"
4. Terminal "B"
5. Terminal "C"
6. Terminal "D"
7. Stator
8. Timer Base
3-68
1. High Ohm Scale
2. Black Meter Lead
3. Red Meter Lead
4. Jumper Wire
5. Timer Base
6. Terminal "A"
7. Terminal "B"
8. Terminal " C"
9. Terminal "D"
3-69
1. Jumper Wires
2. High Ohm Scale
3. Terminal "A"
4. Terminal " B"
3-70
1. High Ohm Scale
2. Black Meter Lead
3. Timer Base
4. Red Meter Lead
5. Jumper Wire
6. Terminal "A"
7. Terminal "B"
3-71
I '
I '
'
3-68
3-69
83275
3-70
3-71
3-30
83277
83278
I
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\1
!
i
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II
IGNITION SYSTEM TESTS
USING C.D. VOLTMETER
TESTER
I i!i l NOTE
Before conducting these tests be sure to do the
Key Switch Elimination Test and the Ohmmeter
Tests.
CHARGE COIL OUTPUT
a. Set meter switches to negative and 500.
b. Disconnect two wire connector between
st ator and power pack.
c. To test for shorts to ground, set meter
swi t ches t o (-) 500 scale. Connect the black
meter lead (- ) to the timer base (ground) .
Attach the red meter lead (+) to the " A"
t erminal jumper wire in t he connector . See
Figure 3-73. Observe the meter . Then move
red lead to " B" terminal.
d. Any needle movement indicates the charge
coil or leads are shorted to ground. A shorted
cha.rge coil must be replaced, or the
grounded lead repa i red to remove the shorted
condition.
e. Insert meter black lead probe into cavity " A "
of connector from stator . Insert meter red
lead probe into cavity " B" of connector. See
Figure 3-72.
f . Crank engine and observe reading.
g. If meter reading is 220 or higher, go to
Sensor Coi l Output Test .
h. If low or no reading, check resistance of
charge coi l. If resistance does not meet
specifications, replace charge coil.
SENSOR COIL OUTPUT TEST
a. Set meter switches to "S" and 5. Separate
four w ire connector between timer base and
power pack. To test for shorts to ground,
connect t he black meter lead (-) to the timer
base (ground) . Attach the red meter lead (+)
to the "A" terminal. then "B," then "C," then
" D," jumper w i re in the connector . See
Figure 3-74. Any needle movement indicates
t he sensor coi I or leads are shorted to
ground. A shorted sensor must be replaced,
or the grounded lead repaired to remove the
shorted condition.
b. To test sensor coil output, insert meter black
lead probe into cavity "D" of four wire con-
nector from timer base.
ENG L. ISH 3-31
c. Insert meter red lead probe into cavity " A" of
four wire connector from timer base. See
Figure 3-74.
d. Crank engine and observe meter reading.
e. Move meter red lead from cavity " A" to
cavity " B" of the connector .
f . Crank engine and observe meter reading .
g. Move meter red lead from cavity " B" to
cavity "C" of the connector .
h. Crank engine and observe meter reading .
i . Meter should read 0.4 or higher . If it does
not, sensor coil may be bad. Engine rpm may
be too low or sensor magnet may be weak.
1. C.D. Voltmeter Tester
2. Meter Red Lead
3. Meter Black Lead
4. Stator
5. Terminal " A"
6. Terminal "B"
3-72
1. C.D. Voltmeter Tester
2. Meter Red Lead
3. Met er Black Lead
4 . Stator
5. Terminal "A"
6. Terminal "B"
7. Short to Ground Test
3-73
1. CD Voltmeter Tester
2. Black Meter Lead
3. Red Meter Lead
4. Terminal "A"
5. Terminal "B"
6. Terminal "C"
7. Terminal "D"
8. Jumper Wire
9. Timer Base
1 0. Short to Ground Test
3-74
81 304 2
3-72
93433
3-74
3-31
93432
3-73
I
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II
POWER PACK OUTPUT
a. Set meter switches to negative and 500.
b. Disconnect four wire connector between
power pack and ignition coi ls.
c. Insert jumper leads between "A" terminals of
connectors. See Figure 3-75.
d. Insert jumper leads between "B" terminals of
connectors.
e. Insert j umper leads between "C" terminals of
connectors. Connect meter black lead to en-
gine ground.
f . Connect meter red lead to metal part of
jumper lead coming from power pack cavity
"A." Crank engine and observe meter
reading.
g. Connect meter red lead to metal part of
jumper l ead coming from power pack cavity
" B." Crank engine and observe meter
reading.
h. Connect meter red lead to metal part of
jumper lead cavity " C." Crank engine and ob-
serve meter reading.
1. If meter reads 230 or higher, check ignition
coil or coils.
J.
If meter does not read 230 or higher on one
output, remove jumper lead from that cavity
of connector from power pack. Insert meter
red lead into that cavity. Crank engine. If
meter reads 230 or higher, ignition coil is
defective. If meter does not read 230 or
higher, power pack is defective.
IGNITION COIL TESTS
OHMMETER TEST
Resistance tests may be performed while the
ignition coil is still mounted to the powerhead.
a. Remove the high tension lead from the
ignition coil.
b. Separate the four wire connector between
the power pack and ignition coils.
c. Insert a jumper wire into the "A" terminal on
the ignition coil end of the connector. See
Figure 3-76.
d. Calibr ate an ohmmeter to low ohm scale,
then connect the black meter lead (-) to a
clean engine ground, and the red meter lead
(+) to the "A" termi nal jumper w ire. See
Figur e 3-76.
ENG L.. I SH
e. Resistance of the primary wind ing should be
0 , 1 0 ,05 ohms.
f. Calibrate the ohmmeter to high ohm scale,
then connect the meter red lead (+) to the
" B" terminal jumper wire. Connect the meter
black lead(-) to the the high tension terminal
of the coil. See Figure 3-77.
g. Resistance of the secondary winding should
be 275 50 ohms. Replace the ignition coil if
the reading is other than specified.
h. To test all ignition coils, repeat the above
procedure using terminals "B" and " C" in
the four wire connector.
i . Test resistance of high tension leads on low
ohms scale. Resistance should be near zero.
See Figure 3-75A.
1. Terminal " A "
2. Terminal " B"
3 . Terminal "C"
4 . Terminal " D"
5 . Red Meter Lead
6 . Jumper Lead
7. Black Meter Lead
3 -75
1. Jumper Wire
2 . Low Ohm Scale
3 . Bl ack Meter Lead
4. Red Meter Lead
5 . Terminal "A" No. 1
6 . Terminal " B" No. 2
7 . Terminal "C" No. 3
8 . Engine Ground
3 -76
1. High Ohm Scale
2 . Red Meter Lead
3. Bl ack Meter Lead
4. Terminal "A" No. 1
5 . Terminal "B" No. 2
6. Terminal "C" No. 3
3-77
3-32
EEJ
@
- 500
8 1 3044
3-75
813301
3-75A
8 1 3 046
8 1 3045
3-76
3-77
3-32
SECTION 4
POWER HEAD
& SAFETY WARNING
To prevent possible damage to eyes
and irritation of skin, always wear
eye protection and rubber gloves or
other non-porous hand protection
while working with Gel Seal and
Gasket Remover Compounds.
To prevent possible fire and ex-
plosion, after reassembly of any
motor, always:
Check fuel system for leaks.
Make sure electrical leads are
routed and clamped securely in
original position away from
rotating parts which may
damage insulation and make
electrical sparks.
To prevent sudden movement of the
boat when starting the motor and
possible man-overboard situations,
after reassembly of motors
equipped with a start-in-gear-pro-
tection system, test the
shift/throttle interlock systems for
proper operation before returning
the motor to the field.
CLEAI\IING, INSPECTION, AND
REPAIR - ALL MODELS
CYLINDER BLOCK AND CRANKCASE
Check cylinder walls for excessive wear and
check cylinder ports for carbon accumulation.
Cylinder walls wear in various degrees, depend-
ing on lubrication and conditions under which
the motor is operated. Major portion of wear is in
the port area and the area covered by ring travel.
Check cylinder for size and wall straightness by
using an inside micrometer. Replace cylinder
block, or rebore block for oversize pistons if wear
is in excess of 0,05 mm. See the chart below for
maximum tolerance.
Model Maximum Tolerance
2 thru 6 0,05 mm
9.9 thru 60 0,08 mm
70!75 0,76 mm
V-4/V-6 0,10 mm
ENCL.ISH
4-1
Oversize pistons and ring sets are available.
Carbon accumulation in the exhaust ports
restricts the flow of exhaust gases and has con-
siderable effect on performance of the motor.
Carefully scrape carbon from cylinder heads and
exhaust ports with scraper or other blunt instru-
ment. Exhaust ports and all exhaust passages
must be free from carbon deposits to insure
maximum performance. Avoid getting carbon in
water jackets.
If equipped, check recirculation orifice in crank-
case. Clean as required. Also, clean nipples in
by-pass covers with Nipple Cleaning Tool Part
No. 326623.
55 Model - Be sure compress ion relief holes in
cylinders are clear.
With continued operation of the motor, the cyl-
inder walls will take on a glaze which reduces
the effectiveness of the seal between the piston
rings and the cylinder walls. The result will be
reduced compression and a decrease in perform-
ance of the motor. Before reinstalling the pistons,
break the glaze by using a f ine cylinder hone to
refinish cylinder walls. Use low rpm on drill with
rapid up and down movement to obta in a good
cross-hatch pattern for good oil retention . Use
hone with medium stone (220 grit). Blow out all
oil passages and drains. See Figure 4- 1.
:
I I
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4-1
4-1
GASKET SURFACES
Remove all traces of dried cement, using OMC
Gel Seal and Gasket Remover Part No. 390928.
In using Gel Seal and Gasket Remover, spray the
area to be cleaned and let stand for 5-10 min-
utes before cleaning off the remover. Care should
be taken to prevent overspray of Gel Seal and
Gasket Remover on painted surfaces as the paint
may be removed.
& Wear eye protection and rubber gloves or other
non-porous hand protection while working with
Gel Seal and Gasket Remover.
Check all gasket faces for flatness. Under certain
conditions, gasket faces may warp or spring,
particularly where thin sections or flanges are
employed and are subject to temperature
changes.
To check for flatness, lay a sheet of No. 120
emery cloth on a surface plate or piece of plate
glass. Place the part to be surfaced on the emery
cloth and move slowly .. back and forth several
times i n a figure 8 motion, exerting evenly dis-
tributed, light pressure. Lift part from surface
plate to observe results. See Figure 4-2.
If the surface is actually warped or sprung, high
spots making contact with the surface plate will
take on. a dull polish, while the low areas will
have retained their original state. To insure
flatness over the entire surface, continue sur-
facing until the entire gasket surface has been
polished to a dull luster . Finish surfacing with
No. 180 emery cloth.
r;&;l
l.ii!!ll N 0 T E
DO NOT scratch cylinder head gasket surface of
cylinder. Use surface plate to surface this area.
& Safety Related
ENGLI S H
4-2
4-2
4-2
A
4 -77A
4-778
4-77
4-25
THE USE OF GEL SEAL -
4 THRU V-6
Utili NOTE
On motors that use neoprene "spaghetti" seal.
Do not use OMC Gel Seal in place of OMC Ad-
hesive M.
SURFACE PREPARATION:
1. Remove all traces of old Gel Seal (crankcase
sealer) by using OMC Gel Seal and Gasket
Remover Part No. 390928. In using Gel Seal
and Gasket Remover, spray the area to be
cleaned and let stand for 5-10 minutes
before cleaning off the remover .
~
a=:! NOTE
Care should be taken to prevent over-spray of
Gel Seal and Gasket Remover on painted
surfaces as the paint m a ~ be removed.
& Wear eye protection and rubber gloves or other
non-porous hand protection while working with
Gel Seal and Gasket Remover.
2. Use OMC Cleaning Solvent Part No. 390905
to remove all traces of Gel Seal and Gasket
Remover. See Figure 4-8. Use a black light to
check for any remaining Gel Seal. The black
light should be used i n a darkened room.
Hold black light at an angle to the power-
head being inspected.
APPLYING GEL SEAL:
Iii) NOTE
Be sure your hands are clean and free of oil or
grease before applying Gel Seal.
1. Apply a small amount of OMC Needle
Bearing Grease Part No. 378642 to the
crankcase and cylinder block labynnth seals
to prevent engine "lock-up" from excess Gel
Seal. Again use Cleaning Solvent to remove
any oil or grease on flanges from assembly.
Oil or grease on flanges will cause leaks.
2. Squeeze out a ball of Gel Seal, 5 mm on
1
4
0
-
40 models, 6 mm on 50-60 models and
mm on 70 - V-6 models, and dab it along one
flange of the crankcase.
3. Dab the Gel Seal over one crankcase fla
1
nge
from end to end, being sure to apply sea ant
inside all bolt holes. Avoid getting closer than
6 mm to the labyrinth seals. Repeat for the
other crankcase . flange.
& Safety Related
4-4
4. On 50 - V-6 models, add additional dabs of
Gel Seal to areas of crankcase flanges where
they narrow down. See Figure 4-9.
If the motor is to be run the same day, the
surface opposite the one Gel Seal is applied to
should be sprayed with OMC locquic Primer Part
No. 384884. Wait several hours before running
to allow Gel Seal to cure. If Locquic Primer is not
used, the assembly should sit overnight before
being run.
If excess Gel Seal has caused the motor to "lock-
up," it may be loosened by turning the flywheel
with a wrench. The motor may then be started
and run with no detrimental effects.
Since Gel Seal begins curing as soon as it is
confined (especially on those motors where
Locquic Primer has been used), the assembly
should be completed and all screws torqued
promptly after assembly.
lit;i(J;![i l NOTE
If Gel Seal is allowed to set up before drawing
down and torquing screws, Gel Seal may act as a
shim. This may cause bearing misalignment,
improper bearing location, and tight armature
plate bearings.
1. Add Additional Dabs of Gel Seal
4-9
co 3162
4-8
50/ 55/ 60
co 1 548
4-9
4-4
I I
-- l_.- - ----
CHECKING MOTOR
TEMPERATURE - ALL MODELS
The Markal Thermomelt Stik, a heat sensitive
stick similar to a crayon which melts on contact
w ith a surface at a specific temperature, is used
to measure powerhead temperature.
The motor is best checked when operating on a
boat . If this is not possible, run the motor in a
test tank for at least five minutes at a maximum
speed of 3000 rpm. Mark the cylinder water
jacket wit h the St ik. The mark will appear dull
and chalky. When the surface temperature
reaches the temperature rating of the Stik, the
mark will melt becoming liquid and glossy in
appearance. On some painted surfaces on which
the Stik will not leave a mark, it will be neces-
sary to hold the Stik against the surface. See
Figure 4-10.
2 thru 4.!5 - Using a 73 C Thermomelt Stik,
mark the side of the cylinder .
Uimwl NorE
DO NOT use the Stik on the cylinder head The
center of the cylinder head on the motor will nor-
ma//y run slightly hotter than 73 C.
The mark wi_ll appear dull and chalky. If the mark
melts and appears glossy, the powerhead is over-
heating. Check for a worn water pump or a
clogged or leaky cooling system.
6 thru V-6 - Two Thermomelt Stiks are necessary
to check motor - a 52 C Stik and a 73 C Stik.
With the engine at operating temperature, the
52 C mark should melt and the 73 C mark
should not melt .
If the 52 C mark does not melt after a rea-
sonable length of time, the thermostat is stuck
open and the motor is running too cold. If the
73 C mark also melts, the cooling system is not
functioning properly allowing the motor to over -
heat. Check for a worn pump assembly, leaky
water system, or restrictions in the cooling
system.
TESTING TEMPERATURE
SWITCHES - REMOTE CONTROL
MODELS
Temperature switches, installed in each cylinder
head, are i n series with a "HOT" warning horn
in the remote control box. Should an irregularity
develop in the cooling system and cause ab-
normal water jacket temperatures, the switches
close the warning circuit.
ENGl..ISH
4-5
A switch may be checked by submerging it in hot
oil. Use a test light to check the contacts and a
thermometer to check oil temperature. The
contacts should close at a temperature of 99 C
3 and open at 79 C 4 See Figure 4-11.
To remove switches for testing, pull back
insulating sleeves and open knife terminal con-
nections. Remove cylinder head cover(s) and
switch(es). See Figure 4-12. On installation,
clean gasket surface thoroughly Apply OMC
Gasket Sealing Compound lightly to gasket
surface(s). Also apply the same sealing com-
pound to top surface of heat switch grommet and
again after cover has been installed. Install
cyli nder head cover using a new gasket. Re-
connect temperature switch leads and slide
insulating sleeves over connections.
REMOVAL OF UPPER
CRANKCASE SEAL - 2 THRU 15
The presence of oil under the flywheel indicates
a leaking upper crankcase seal. The upper main
bearing seal can be replaced without disas-
sembly of crankcase. Remove flywheel. Use Seal
Remover Special Tool No. 319060 to remove and
install the seal. See Figure 4-13.
Use tip " A" on 4 and 4.5 models, tip " B" on 6, 6
Com. and 7.5 models, and tip "C" on 2, 9.9, 10
and 14 Com. and 15 models.
To remove seal, install tip into remover/ installer
body. Thread remover/ installer body with tip into
seal to engage metal case.
While holding remover/ installer body, turn
pressing screw and remove seal.
To install, apply OMC Gasket Sealing Compound
to metal casing of a new seal. Position seal on
powerhead with lip facing down.
Using a mallet and remover/ installer body, install
seal in powerhead.
A. Removal of Seal
B. Install New Seal-Lip of Seal Facing Down
1. Pressing Screw
2. Removal/Installer Body
3. Tip
4-13
I
4-10
4-12
536 2 I
4-11
4-5
REMOVAL OF POWERHEAD - 20,
25, 25 COM. AND 35
NOTE
If only replacing upper main bearing seal, per -
form steps (f) through (j). Use Seal Remover Too(
Part No. 387780 to remove seal, and Installer
Tool Part No. 321539 to install seal. See Figure
4-77.
a. Disengage throttle arm spring from throttle
arm. Remove pin from end of throttle control
rod, and remove two screws and clamp
retaining vertical throttle shaft. Lift vertical
throHie shaft from throttle gear. See Figure
4-77A.
b. Remove three screws, manual starter, starter
lockout lever, and spring.
c. Remove screw retaining choke lever to car-
buretor. Remove wave washer and spacer.
Disengage choke lever from choke knob and
pull knob out of retainer in air silencer.
d. Remove three air silencer screws and lock-
nut and remove air silencer. Disconnect
throttle arm to cam follower link. See Figure
4-778.
e. Disconnect carburetor to fuel pump hose at
fuel pump. Disconnect overboard water hose.
f. Remove two carburet_or nuts. Remove car-
buretor . Discard gaskets.
g. Remove flywheel nut using a suitable tool to
"'' hold flywheel. Remove f lywheel using OMC
puller tool No. 378103.
h. Loosen five armature plate screws. Remove
port and starboard starter mounting brackets
(manual start) or starboard bracket (electric
start ).
i. Disconnect 4-wire connector from armature
plate. Remove coils from cylinder head. Ob-
serve location of coil ground leads for correct
reassembly.
J. Lift armature plate from powerhead.
k. Remove four screws and armature plate sup-
port and retainer plates.
I. Remove shifter lock lever and bracket from
powerhead.
m. Remove two screws, fuel pump, and gasket.
n. Remove hose from intake manifold. Remove
screws and nuts retaining intake manifold.
Remove intake manifold and gasket, and re-
move one screw and leaf valve assembly.
ENGLISH 4-25
o. Remove four screws retaining powerhead to
exhaust housing.
p. Using a 1/ 2 inch offset box wrench (Special
Tool No. 322700), remove port and starboard
nuts retaining powerhead to exhaust
housing.
q. Remove cotter pin and disconnect shift link.
See Figure 4-77C.
r. Lift powerhead from exhaust housing, and
place on work bench.
A
1. Seal Remover Part No. 387780
2. Seal Installer Part No. 321539
B
1. Sea l Remover Part No. 387780
c
1. Seal Installer Part No. 321539
4-77
1. Throttle Control Rod
2. Pi n
3. Spring
4. Clamp
4-77A
1. Link
4-778
POWERHEAD DISASSEMBLY -
20, 25, 25 COM. AND 35
li!)NOTE
To simplify reassembly and wiring installation,
lay out the various screws and clamps in order of
their proper location.
a. Remove screws and inner exhaust tube. Re-
move and discard gasket.
b. Remove water tube guide from inner ex-
haust tube by pressing in on tab while
pulling guide from exhaust tube. Remove and
discard rubber grommet in exhaust tube. See
Figure 4-78.
c. Remove three screws and lower main
bearing seal housing. Remove and discard 0-
ring on seal housing and inside of crank-
shaft. See Figure 4-79. Seal inside of seal
housing can be removed by driving it out
with a punch and hammer.
NOTE
If only replacing lower main bearing seal, coat
outside metal case of new seal with OMC Gasket
Sealing Compound and press into housing using
OMC installer tool no. 321515 and an arbor
press. Press seal into housing with lip facing up.
See Figums 4-79 and 4-80. Press until tool is
seated on face of seal housing.
d. Remove screws, cylinder head, and gasket.
e. Remove screws and cylinder head cover. Re-
move and discard gasket . Remove thermostat
and seal. Discard seal. See Figure 4-81.
f. Remove screws and exhaust cover. Remove
inner e><haust cover, and discard inner and
outer gaskets.
g. Remove screws and intake bypass cover .
Discard gasket.
h. Using a punch and hammer, remove taper
pin, punching from back to front of crank-
case. See Figure 4-82.
E N G LI SH 4-26
1. Inner Exhaust Tube
2. Grommet
3. Tab
4. Guide
4-78
1. 0-Ring
2. Seal Lip Faces Up
3. Internal 0-ring
4. Lower Main Bearing
4-79
1. Tool No. 321515
4 -80
1. Thermostat
2. Seal
3. Gasket
4. Cylinder Head Cover
4-81
4-79
63249
4-80
4-26
POWERHEAD DISASSEMBLY - 20,
25, 25 COM. AND 35 (Continued)
1. Remove crankcase screws. See Figure 4-83.
J. Tap crankshaft with soft mallet to break seal
between crankcase and cylinder. See Figure
4-84. Remove crankcase from cyl inder block.
k. Remove rod caps and bearing retainers.
Pistons, connecting rods, bearings, and caps are
matched parts and seat with the operation of the
motor. Because of this it is essential to maintain
their original positions at reassembly.
Mark each connecting rod and cap, piston, and
bear ing component to assure correct mating
when they are reassembled. Also mark the
cylinder from which piston assemblies are
removed.
I. Remove lower half of center main bearing,
needles and ret ainer .
m. Lift crankshaft from cylinder block. See Fig-
ure 485. Reinstall matched caps on con-
nect ing rods and remove pistons and rods
from cy linders.
n. The top main bearing slides off. If necessary
to remove the bottom main bearing, remove
Truarc ring and use an appropriate bearing
puller . See Figure 4-86. Remove remaining
center main bearing components. Remove 0-
ring from inside of crankshaft lower main
bearing journal. See Figure 4-79.
o. Remove the rings from the pistons by prying
the ends loose enough to grip them with
pliers and then breaking them away from the
piston. DO NOT try to save the rings. Install a
complet e set of new rings on every power-
head service job.
p. If necessary to remove piston from con-
necting rod, remove wrist pin retaining rings.
Use piston cradle (Special Tool No. 326573)
and wrist pin pressing pin (Special Tool No.
321434). With piston skirt flush with cradle,
press out pin using an arbor press.
REASSEMBLY OF POWER-
HEAD - 20, 25, 25 COM.
AND 35
Proceed slowly. Make no forced assemblies
unless press fits are called for , and make no
"dry" assemblies. Be sure all parts to be as-
sembled are clean and free from dirt and grit .
Perfectly good cylinder walls, pistons, and rings
can be ruined in a few minutes of operation
unless all forms of grit are removed before
assembly. Work in clean surroundings and with
reasonably clean hands. Coat all bearing
surfaces, cylinder walls, etc., with clean oil
before assembly. Where the use of oil is
specified, we recommend 50/ 1 Outboard
Lubricant.
[J NOTE
Always use new gaskets throughout when re-
assembling the powerhead. Coat gaskets with
OMC Gasket Sealing Compound No. 317201. Do
not use sealer if so stated on gasket.
Make sure water deflectors are in place. See
Figure 4-87.
1. Upper Main Bearing Locator Hole
2. Seal
3. Bearing
4. Bearing
5. Bearing
4-85
1 . Locator Pin
2. Locator Hole
3. Seal
4. Upper Main Needle Bearing
5. Needle Bearing
6. Ball Bearing
7. Retaining Ring
4-86
4-27
63203
4-83
4-85
. I I I
PISTONS, WRIST PINS, AND CONNECTING
RODS
a. The relative positions of pistons and con-
necting rods must be considered when as-
sembling pistons to rod. Pistons must be in-
stalled in cylinders with intake side of
deflector toward intake port. See Figure 4-87.
Oil hole in connecting rod must be toward
top of motor.
b. Apply a coat of oil to wrist pin, making sure
surface is clean. Place a drop or two of oil in
each pin hole in the piston.
c. Insert wrist pin through hole in piston. Oil
wrist pin bearing in connecting rod. Place
connecting rod in position, then proceed to
install the wrist pin using Piston Cradle
Special Tool Part No. 326573 and Wrist Pin
Pressing Pin Part No. 321434.
d. Replace retaining rings using Special Tools
Part No. 318600 and 318599. See Figure 4-
87A. Make certain rings come to rest
securely in the groove provided for this
purpose.
e. Check piston with micrometer to determine
whether piston has been distorted during as-
sembly. Replace the piston if variation in
diameter at the bottom of the piston skirt is
greater than 0,08 mm.
PISTON RI NGS
Install the piston ri ngs on each piston. Spread each
ring with a ring expander just enough to slip it over
the head of the piston and down into place. Be sure
the rings fit freely in the piston r i ng grooves. The ring
grooves are pinned to secure the position of the
rings, primarily to prevent ends of the rings from
catching on the edges of the ports in the cylinders,
but also to assure staggering of the ring gaps.
ENGLISH
PISTON AND CONNECTING ROD
INSTALLATION
Coat pistons and cylinder bores with oil and install
piston and connecting rod assemblie!?. being sure to
match each assembly with the cylinder it was
removed from. The intake side oft he piston deflect or
must be placed toward the intake port. The piston
rings must be compressed before the pistons can be
replaced in the cylinders. Makecertainthatthe rings
are correctly positioned in their grooves with respect
to the groove pins. Damaged pistons and broken
piston rings may result from imperfect alignment of
the ring gap and the piston dowel pins.
The use of automotive type ring compressing tools
should be avoided, as these frequently cause
damaged pistons and broken piston rings through
imperfect alignment of the ring gap and piston dowel
pin. The use of Special Tool No. 326591 is
recommended. See Figure 4-88. Using one hand to
push the piston into the cylinder, use the free hand to
guide the connecting rod into place.
1. Intake Side of Deflector
2. Intake Side of Cylinder
3. Exhaust Side of Cylinder
4. Exhaust Side of Deflector
5. Water Deflectors
4-87
1. Start Retaining Ring in Tapered End of Cone
2. Cone Part No. 318600
3. Driver Part No. 318599
4-87A
1. Special Tool No. 326591
4-88
4-28
6321 a
4-87
"t
63217
4-88
22183
4-87A
4-28
I
I'
;,
CRANKSHAFT
a. Oil crankshaft bearing surfaces. Replace main
bearings and upper main oil seal on crankshaft.
b. Remove rod caps from connecting rods. Place
one retainer half and bearings on each rod. See
Figure 4-89.
c. Place center bearing shell with locator in block.
Be sure raised portion seats into hole in block.
See Figure 4-89. Be sure pointed end of bearing
shell is on intake side of engine.
d. Place crankshaft in position on cylinder block,
upper main bearing dowel pin with dowel pin
hole in cylinder block and center main bearing
dowel pin hole with dowel pin in cylinder block.
See Figure 4-90.
e. Place other retainer halves and bearings on
crankpins.
f. Install connecting rod caps, but do nottorquethe
screws at this time.
min NOTE
1.:!!.1
One side of connecting rod and cap has raised dots,
and the corners are also chamfered for alignment of
rod and cap. Connecting rod caps are not inter-
changeable with those of other rods, nor can they be
turned end for end.
Draw a pencil over the chamfered corners on both
sides of rod to make certain that cap and rod are
aligned at this point. If misaligned, the chamfered
corners can be felt with the pencil point. See Figure
4-91. If misaligned, tap lightly with a punch and
hammer.
g. Tighten connecting rod screws to torque
specified in Section 1, using a torque wrench.
Rods and bearings should float on crankpins.
h. Install crankcase half of center main bearing
rollers and shell, matching dovetail ends. See
Figure 4-92.
ENGL.ISH
1. Center Main Bearing Locator
2. Rollers and Retainer
3. Upper Main Bearing Locator Hole
4-89
1. Upper Main Bearing Locator Hole
2. Seal
3. Bearing
4. Bearing
5. Bearing
4-90
1. Chamfered Corners
4-91
1. Exhaust Side of Engine
4-92
4-29
I
4 -91
83255
4-89
4-92
4-90
-4-29
CRANKCASE AND CYLINDER
& a. Refer to The Use of Gel Seal at the be-
ginning of this section.
b. Position crackcase on cylinder block, and in-
stall screws finger tight. Replace crankcase
taper pin, driving in carefully with a ham-
mer .
c. Tighten all crankcase screws to torque speci -
fied in Section 1.
d. Place a new 0-ring in groove on lower main
bearing seal housing. Install seal housing
with screws dipped in OMC Gasket Sealing
Compound. Torque screws to specifications
given i n Section 1. Place a new 0-ring inside
crankshaft. See Figure 4-93.
e. Check for binding between the crankshaft
and the bearings or connecting rods by
rotating the crankshaft with the flywheel.
f. Install cylinder head, .using a new gasket
coated lightly with OMC Gasket Sealing
Compound. Do not use sealer if so stated on
the gasket. Tighten cylinder head bolts to
specified torque, following the sequence
shown in Figure 4-93A.
IIRI NOTE
Re-torque cylinder head screws after motor test
has been completed and motor has cooled com-
fortable to touch.
g. Reinstall thermostat. Install cylinder head
cover, using a new gasket.
h. Install inner and outer exhaust covers using
new gaskets. Tighten all screws to specified
torque.
i.. Apply OMC Adhesive "M" t o outside of water
tube grommet. Install grommet in inner ex-
haust tube. Be sure none of the sealant is
inside the grommet . Insert water tube guide
into inner exhaust housing.
j . Make sure the gasket surfaces of the power-
head are clean. Apply OMC Gasket Sealing
Compound to powerhead and inner exhaust
tube surfaces. Place a new gasket on the
powerhead and install the inner exhaust
tube.
k. Attach oil recirculation hoses to crankcase.
Longer hose connects by-pass cover to fitting
on intake manifold. See Figure 4-938.
& Safety Related
ENGLISH 4-30
1. 0-Ring In Crankshaft Groove
4-93
1. Longer Hose
4-938
'
'
8
p
1
'
4-93
,...

" 11 ,.,..--- ...... ,
'
'
5
4 I
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3 - ~
I
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6
....... ___ ,._ ... /
4-93A
A
~ ~ D t
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~
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/"
,LJ
4-938
4-30
63226
9
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..
.:
0
10
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P'
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53629
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INSTALLATION OF POWERHEAD
20, 25, 25 COM. AND 35
a. Coat driveshaft splines with OMC Moly Lube.
Do not coat top surface of driveshaft as lubri-
cant here may prevent seating of driveshaft
in crankshaf t.
b. Apply OMC Gasket Sealing Compound to ex-
haust housing surface. Apply liquid hand
soap to top of water t ube. Assemble power-
head to exhaust housing making sure water
tube enters inner exhaust tube guide. Rotate
powerhead slightly back and forth to align
crankshaft and driveshaft splines.
c. Apply OMC Nut Lock to port and starboard
powerhead to exhaust housing studs. Install
nuts. Torque to Specifications in Section 1.
d. Install four exhaust housing to powerhead
screws with OMC Screw Lock. Torque
screws to Specifications in Section 1 .
e. Install leaf plate assembly using a new gas-
ket . Tighten flat head screw to Specifications
in Section 1.
f . Install intake manifold using a new gasket.
Flat head screw goes into port hole. Torque
screws to Specifications in Section 1. Con-
nect oil recirculation hose.
g. Install shifter lock lever with screw and bush-
ings, and install spring. Install fuel pump.
h. Apply OMC Nut Lock to threads and install
armature retainer and support plates aligning
holes as shown in Figure 4-94. Torque
screws to Specifications in Section 1.
1. Using new gaskets install carburetor, choke
bracket, and choke shaft while engaging
choke lever in slot in choke shaft .
j . Connect carburetor to fuel pump hose and
secure with hose strap. Install starter mount-
ing brackets.
k. If flywheel key has been removed, reas-
semble to crankshaft with outer edge parallel
to centerline crankshaft.
l!tii1 NOTE
Be sure that the single upset mark on the side of
the key is facing down.
1. Apply OMC Moly Lube around crankcase
boss (armature plate pilot). Oil groove of
plast ic armature plate bearing with OMC out-
board lubricant. Install ring over edge of re-
tainer plate. Position support plate on crank-
case. Place retainer plate over support plate
aligning holes with crankcase. Attach plate.
Torque screws to specifications given in Sec-
tion 1. Install armature plate over crank-
shaft. Using a needle nose pliers in slots in
armature plate bearing, compress ring, and
locate armature plate over Delrin ring. Align
holes in armature plate and support plate.
Tighten screws and torque to specifications
given in Section 1. Install ignition coils by
locating upper coil to upper cylinder . Upper
coil is identified by a band marked No. 1,
around coil lead. Reconnect all leads, con-
nectors, and linkages. Coil ground leads and
star washers are located below lamination in
upper screw hole. Clamp armature plate
wires.
m. Connect throttle arm to throttle cam follower
link. Install vertical throttle shaft and con-
nect throttle link to vertical throttle shaft arm
with pin. Offset on pivot must face forward.
Adjust throttle control rod and throttle cam
synchronization. Install manual starter with 3
screws, and install starter lockout cable, or
electric starter.
n. Coat air silencer screws with OMC Screw
Lock. Install air silencer with three screws
and a locknut . Use OMC Adhesive "M" on
gaskets to hold them in place during as-
sembly. Two rods placed in threaded holes in
carburetor will align bracket and gaskets. Re-
move one and install screw. Remove
remaining rod and install other screw. Lubri-
cate linkages. Test engine in test tank with
appropriate test wheel (see Section 1 ), or on
a boat . Adjust carburetor. Check idle, slow
speed, and full throttle performance. Check
engine temperature. Check starting inner
lock system to be sure engine cranks in
neutral only.
BREAK-IN - 20, 25, 25 COM.
AND 35
Be sure that when the engine is returned to ser-
vice after an overhaul, the owner is advised to
follow break-in procedures. See Break-In Section ..
1. On Reassembly, Locate This Screw First
4 -94
& Safety Related
4-94
4-31
GEARCASE PRESSURE AND
VACUUM TESTS - ALL MODELS
To t est all gearcases for correct sealing, proceed
as follows:
NOTE
All gearcases must be completely empty of gear -
case lube before performing pressure or vacuum
tests.
a. Remove drain plug and screw in a pressure
test gauge. See Figure 5- 1. Stevens Experi -
mental pressure test gauge illustrated.
b . Pump pressure up to 3-6 psi (21-42 kPa). If
pressure gauge indicates leakage, submerge
gearcase in water to determine source of
leakage as evidenced by bubbles. If gearcase
pressure gauge does not indicate leakage, in-
crease pressure to 16- 1'8 psi (11 0-124 kPa) .
If pressure does not hold, submerge gear-
case in water and check for source of leak-
age. Make necessary repairs and repeat test.
c . Screw in vacuum tester . Pump out to 76-127
mm of mercury and see if vacuum holds.
Then pump out to 381 mm of mercury and
check. If gearcase fails to hold on either test.
put oil around suspected seal. If leak then
stops or oil is drawn in, that seal is defec-
tive. When gearcase checks out OK, refill
with lubricant. See Section 1 Lubrication
Chart.
FILLING GEARCASE
a. 2 models - lay motor on side with fill hole
facing up.
4 thru V-6 - gearcase must be in an upright
position.
b. Remove oil level and oil fill/drain plugs.
c. Fill gearcase with OMC HI-VIS Gearcase
Lube until lubricant appears at oil level hole.
See Figure 5-2. Insert and tighten oil level
plug first . Invert gearcase and remove oil fill
hose. Install fill/drain plug and tighten.
d. Inspect gearcase oil level after motor test.
1. Gearcase Pressure Test
5-1

1. Oil Level Plug
{,\___ ./ - - ~ \ : _
'-.!.;------=:.:..___-- -7- ~
--
...
635 12
5-2
5-1
5-8
GEARCASE REMOVAL - 35
It is possible to remove the lower gearcase as-
sembly without removing the powerhead from
the motor. However, if disassembly of the ex-
haust housing is required, it is necessary first to
remove the powerhead. See Section 4 for
instructions.
The gearcase assembly may be removed from the
exhaust housing as follows:
,& a. Remove upper motor cover . To prevent acci-
dental starting of motor, disconnect the
charge coil connector.
b. Remove both port and starboard water intake
screens. See Figure 5-141. With two
wrenches, hold lower shift rod and turn
upper shift rod connector . See Figure 5-142.
Remove plastic keeper on shift rod. The
upper connector cannot be removed at this
time. The connector will fall off when the
gearcase is removed from the exhaust
housing. See Figure 5-143.
c. Remove screws and nut attaching gearcase
to exhaust housing. See Figure 5-141.
d. Remove gearcase assembly from exhaust
housing, taking care to avoid damaging drive-
shaft, which extends upward to the power-
head ..
e. Place gearcase in a suitable stand for disas-
sembly.
GEABCASE DISASSEMBLY - 35
a. Remove oil level and drain plugs, and drain
gearcase.
b. Remove cotter key, nut, spacer, propeller, and
thrust bushing.
c. Remove pump housi ng screws, driveshaft,
and water pump assembly from gearcase.
Remove impeller plate. See Figure 5-145.
Driveshaft sleeve, seals and bearing are
visible.
d. Remove two propeller shaft bearing head
screws using a 5/16 inch deep thinwall
socket. Using puller tool No. 378103 and two
long 1/ 4-20 screws, pull housing from gear-
case. See Figures 5-146 and 5-147.
.& Safety Related
ENGL.ISH
5-47
1. Water Intake Screws -
Two Each Port and Starboard
2. Nut and Lockwasher
3. Screws - Two Each Port and Starboard
5-141
1. Upper Shift Rod Connector
2. Lower Shift Rod Connector
5-142
1. Keeper
2. Upper Connector
5 - 143
1. Water Tube
2. Driveshaft
3. Grommet
4. Water Pump Screws
5. Water Pump
5-144
1. Impeller Housing
2. Impeller
3. Impeller Pin
4. Impeller Plate
5. Scraper - Bushing
5-145
1. Puller Tool No. 378103
2. Long Screws 1/ 4"-20
5-146
1. 0 -Ring
5-147
813101
5-47
GEAR CASE DISASSEMBLY - 35
(Cont.)
e. Using retammg ring pliers No. 303859,
remove retaining ring. See Figure 5-148. Re-
move retainer plate. See Figure 5-149.
& SAFETY WARNING
Retaining rings are under extreme pres-
sures during removal and installation.
Wear safety glasses and proceed with
care to avoid unsnapping ring from
pliers.
f. Unscrew lower shift rod from yoke. Using a
needle nose pliers, remove yoke from gear-
case. See Figure 5-150.
g. Remove pivot pin with a Phillips screwdriver.
See Figure 5-1 51. Pull propeller shaft, thrust
washers, clutch dog, cradle, and reverse gear
from gearcase. See Figure 5-152.
h. Remove shifting lever from gearcase. See
Figure 5-153. Remove pinion gear, thrust
bearing, forward gear, a.rd bearing from
gearcase. See Figure 5-154.
E N G ~ J S H
5-48
1. Retaining Ring Pliers No. 303859
2. Retaining Ring
5-148
1. Forward Bearing
2. Forward Gear
3. Thrust Washer
4. Thrust Bearing
5. Pinion Gear
6. Lower Thrust Washer
7. Upper Thrust Washer
5- 154
~
'
'
5-151
813103
5-48
1
~ . ~ . ~
I
i
5-153
5-154
GEARCASE DISASSEMBLY - 35
(Cont.)
1. If dr iveshaft upper bearing seals and bearing
are worn, use a Two Jaw Puller No. 391010
or Seal Remover Part No. 391259. Pull drive-
shaft seals from gearcase. See Figure 5-155.
To remove driveshaft bearing, drive out using
OMC Special Tool Part No. 326570. See Fig-
ure 5-156. Remove bearing sleeve usi ng
Sli de Hammer Special Tool Part No. 391008
and Two Jaw Puller Part No. 391010. Invert
gearcase and driveshaft bearings will fall out .
J. If pinion bearing is worn, assemble com-
ponents from Pinion Remover/ Installer
Special Tool Part No. 391257. See Figure 5-
157. Drive bearing out of gearcase.
k. If shi ft rod bushing and 0-ring are worn, use
Sli de Hammer with adapter (Special Tool No.
391 008) and a 1/4-20 or 1/ 4-28 nut with
corners ground to clear casting. Remove shift
rod washer, 0-ri ng and bushing. See Figure
5-158. .,
I. If forward roller bearing and cup are worn or
pitted, use OMC Special Tool No. 391010,
and Slide Hammer No. 391008 to remove
forward bearing cup. See Figure 5-159.
Space is provided in gearcase to allow jaws
of t ool to engage cup.
m. If bearing housing seals and bearings are
worn, use OMC Special Tool No. 321259 to
r emove gearcase bear i ng housing seals (pro-
peller end). See Figure 5-1 60. Using OMC
Specia l Tool No. 391008 and Two Jaw Puller
391010, remove front bearing.
ENG L.I SH 5-49
1. Two Jaw Puller No. 391010
5-155
1. 1/ 4-20 x 1/ 2 Screw
2. Washer No. 326587
3. Plate No. 326583
4. Gearcase
5. Rod No. 326582
6. Remover/I nstaller No. 326577
7. Screw 1/ 4-20 x 1-1/ 4"
5- 157
1. Sl ide Hammer No. 391 008
2. Adapter
3. Bushing
4. 0-Ring
5. Washer
6. Rounded 1/ 4 Inch Nut
5-158
1. Two Jaw Puller No. 391010 with
Slide Hammer No. 391 008
5-759
1. Puller No. 321259
5-760
5-155
2005
5-156
6 1 3 11 7
5-157
5-49
I
l.
,.l , I
I
~ ~ . ..:. t '
'
I
' I
5-158
5-159
co 3 4 5 2
5-160
GEARCASE REASSEMBLY - 35
U!i!li;];f NOTE
Use OMC Gasket Sealing Compound Part No.
317201 in bores or around met a/ case of all
pressed in seals in gearcase bearing housing and
i mpeller housing.
Make no dry assemblies. Lubricate bearings, 0-
rings, shafts and gears with OMC HI-VIS Gear-
case Lube. Use OMC Needle Bearing Grease to
hold detent spring and balls in propeller shaft.
a. If removed, install new rear bearing in pro-
peller shaft bearing housing using installer
tool No. 321429 and an arbor press. See Fig-
ure 5- 161. Press until tool is seated on hous-
ing. Install new oil seals, one lip in, one lip
out, using Seal Installer Part No. 326546.
Use OMC Triple-Guard Grease between
seals. See Figure 5-162. Install new front
bearing using installer tool No. 321428 and
an ar bor press. See Figure 5-163.
b. If removed, install propeller shaft front bear-
ing cup using installer .\ool No. 319929 and
drive handle No. 311880. See Figure 5-164.
c. If removed, install shift rod bushing, 0-ring,
and washer using installer tool No. 304515.
See Figure 5-165. Use OMC Gasket Sealing
Compound on bushing.
d. If removed, install new pinion bearing using
Remover- Inst aller Part No. 391257. Assem-
ble as shown in Figure 5-164. Apply a little
needle bearing grease to end of tool and slide
bearing on tool lettered side up. Insert tool in
gearcase, and drive bearing in until plate is
seated on face of gearcase. See Figure 5-
166.
~ I
ENGL.JSH
5-50
1. Bearing Installer No. 321429
5-161
1. Seal Installer No. 326546
5-162
1. Bearing Installer No. 321428
5-163
1. Bearing Cup Installer No. 319929
2. Drive Handle No. 311880
5 - 164
1. Bushing Installer No. 304515
2. Bushing
3. 0-Ring
5-165
1. Screw 1/ 4-20 x 1/ 2"
2. Washer No. 326587
3. Spacer No. 326585
4. Plate No. 326583
5. Gearcase
6. Rod No. 326582
7. Remover-Installer No. 326577
8. Screw 1/ 4-20 x 1-1/ 4"
5-166
t
l
5 - 161
2002
5-162
5-163
803455
6 3 272
5 - 164
5-165
8 1 3 117
5 - 166
5-50
GEARCASE REASSEMBLY - 35
(Cont.)
e. Using Installer Part No. 322923 and an arbor
press, press a new driveshaft bearing into
the housing. Press u nti I the bearing is flush.
See Figure 5- 167. Press housing in gear-
case using the same tool. See Figure 5-168.
Press housing in until seated. See Figure 5-
169. Install seals back to back. Drive both
seals i n with installer tool No. 326552. See
Figure 5-170. Apply OMC Triple-Guard
Grease between lips of seals. If removed,
apply OMC Gasket Sealing Compound to
threads of gearcase stud, and thread into
gearcase until seated . Use two nuts
tightened together to turn in stud. Install
bushing on stud. See Figure 5-169.
f . Oil and install forward bearing in cup. Swab
inside of gearcase with gearcase oil.
g. Oil and install pinion, lower thrust washer,
thrust bearing, and upper thrust washer in
gearcase. Chamfer in lower thrust washer
must face pinion. See Figure 5-170A.
ENGLISH
5-51
1. Driveshaft Bearing
2. Bearing Housing
3. Bearing Installer No. 322923
5-167
1. Bearing Installer No. 322923
2. Plate No. 318122
3. Screw 1/2-13
5-168
1. Plate Flush With Gearcase
2. Gearcase Stud
5-169
1. Seal Installer No. 32652
2
2. Installing Inner Seal
3. Installing Outer Seal
5-170
1 . Chamfered Edges of Thrust
2. Thrust Washer
5-170A
5-167
5-170
5 -168
803051
5-170A
5-169
5-51
GEARCASE REASSEMBLY - 35
{Cont.}
h. Install forward gear and thrust washer.
i. Assemble cradle to clutch dog with OMC
Needle Bearing Grease. Place shift lever on
cradle as shown in Figure 5-171. Note that
groove on dog is facing forward.
j. Rotate clutch dog so that upon installation
dog will be OUT OF engagement with for-
ward gear. See Figure 5-1 72. Insert as-
sembly into gearcase keeping all parts to-
gether as shown in Figure 5-171. Install pivot
pin. See Figure 5-173.
k. Assemble detent balls and spring on prop
shaft. Sl ide Special Tool No. 321519 onto
propeller shaft. Align holes in sleeve with
detent balls and slide sleeve over balls until
balls are visible thru holes in sleeve. See
Figure 5-174.
I. Position shaft and sleeve .f!ssembly in gear-
case so that slots in sleeve match up with
clutch dog. DO NOT disturb clutch dog posi-
tion. If splines do not match up, rotate shaft
180. When splines match up and sleeve
seats on clutch dog, push propeller shaft into
place. Remove sleeve. If correctly done clutch
dog will be retained on shaft by detent balls.
Check for detent balls that may have popped
out of position. Slide the thrust washer, and
reverse gear down the propeller shaft.
ENGLISH
1. Engaged
2. Out of Engagement
5-172
5-52
5-171
CD
5-172
5 - 173
5-52
_/<""\
r '1
83132
GEARCASE REASSEMBLY - 35
(Cont.)
m. Position the yoke in gearcase and engage the
shifting lever clevis pin. See Figure 5-175.
Thread lower shift rod into yoke until rod bot-
toms in yoke.
n. Slide reverse gear bushing onto propeller
shaft. Use sleeve, OMC Special Tool No.
321519 to press bushing into gear. See Fig-
ure 5-176.
o. Posi t ion retainer plate in gearcase.
&sAFETY WARNING
Retaini ng rings are under extreme pres-
sures during removal and installation.
Wear safety glasses and proceed with
care to avoid unsnapping ring from
pliers.
p. Using retaining ring pliers OMC Special Tool
No. 303859, install retaining ring in
gearcase.
q. Oil and place a new 0-ring in groove on pro-
peller shaft bearing head. See Figure 5-177.
Apply OMC Needle Bearing Grease to thrust
washer, and place thrust washer in propeller
shaft bearing head. See Figure 5-177.
Install propeller shaft bearing housing with
" UP" mark up. See Figure 5-178.
r . Apply OMC Gasket Sealing Compound to
screws and tighten to torque specified in
Section 1.
s. Install water pump. See Water Pump Service.
t. Install oil level and drain and refill plugs in
gearcase. If removed, slide gearcase stud
bushing over stud. See F1gure 5-179.
u. Perform gearcase and vacuum pressure tests.
ENGLISH
5-53
1. Yoke
2. Hook Engages Shifting
Lever Clevis Pin
5-175
1
. OMC Special Tool No. 321519
2. Bushing
5-176
1. Thrust Washer
2. 0-Ring
3. Bearing Head
5-177
1. Stud
2. Bushing
3. Water Tube
5-179
6328 0
5-775
5-178
5-179
5-176
5-177
5-53
GEARCASE INSTALLATION - 35
a. If powerhead was removed, remove inner
exhaust tube f rom powerhead. Clean
surfaces of powerhead and inner exhaust
t ube and outer exhaust housing. Apply OMC
Gasket Sealing Compound to these surfaces.
Place a new gasket on powerhead and re-
install i nner exhaust tube.
b. Lubricate upper outside diameter of water
tube. Insert water t ube into exhaust tube
guide. Coat driveshaft splines with OMC
Moly Lube. Do not coat top surface of shaft
as lubri cant here may prevent seating of
driveshaft in crankshaft . Lubricate lower end
of shift rod and water t ube.
c. Install upper shift rod connector into lower
shift rod. Inspect upper shift rod for burrs.
Remove with file or sandpaper. Apply motor
oil to shift rod to minimize damage to shift
rod 0-rings in pump housing.
NOTE.
Damage to shift rod 0-rings could allow exhaust
gasses to enter cooling system resulting m
engine overheat causing permanent damage.
d. Bring gearcase into position beneath ex-
haust housing. Guide shift rod into position.
Carefully guide water tube into the water
pump grommet (See Figure 5- 144) whil e
aligning the driveshaft and crankshaft splines
by rocking the f lywheel.
e. Attach gearcase to exhaust housing with
screws, nut and lockwasher dipped in OMC
Gasket Sealing Compound No. 317201 and
tighten to torque specified in Section 1.
f. Move shift lever to forward gear. Slide con-
nector onto shift rod and install keeper into
shift rod groove. See Figures 5-142 and 5-
143. Move shift lever back to neutral and
tighten connector. Do not turn lower shift rod
while tightening upper shift rod connector .
See Figure 5-141.
g. Coat propeller shaft splines with OMC Gasket
Sealing Compound. Place thrust bushing in
propel ler and then slide assembly onto
propeller shaft. Install thrust washer on shaft
spline. Install and tighten propeller nut finger
t ight and then tighten to align next cotter pin
hole. Install cotter pin (use new pin if nec-
essary). bending ends over nut. Fill gearcase
wi t h OMC HI-VIS Gearcase Lube.
FUNCTI ON TEST OF GEARCASE
a. Run motor in test tank and check cooling
system operation as indicated by spray from
idle relief holes.
ffi Saf ety Related
ENCiL.I S H
b. Shift to forward, then reverse, propell er
should turn.
I n neut ral positi on. propeller should not
turn.
ADJUSTMENTS
SHIFT HANDLE ADJUSTMENT -
20, 25, 35
If removed or replaced, check shift handle
register with REVERSE, NEUTRAL, FORWARD,
on lower motor cover.
a. Place gearshift in neutral. Propeller should
turn freely. The roller on the shift lever
should be centered on the neutral detent on
t he shifter lock lever. When shifted into for-
ward gear, you should feel a slight shifter
dog drag when turning propeller shaft back
and forth. This indicates full engagement be-
t ween clutch dog and forward gear.
b. If out of adjustment , shift gearcase linkage
into neutral. Propeller shaft should turn
freely. Loosen shift lever clamp screw and
adjustment screw.
c. Move shift lever into neutral detent on shifter
lock. Tighten both screws. Shift into forward
gear and feel for slight shifter dog drag. If
you do not feel the drag, then readjust shift
lever slightly toward reverse position and
tighten screws. Recheck for drag. This drag
in forward gear assures that the shifter dog
and gear are in full engagement.
STEERI NG FRICTION ADJUSTMENT
Adjust steeri ng friction with motor mounted to
boat by simply loosening or tightening screw
with screwdriver as shown. Steering friction
should be adjusted so that a slight drag is felt
when turning. This will allow smooth steering.
Minimum friction is required when remote steer-
ing is used. See Figure 5-182 or 5-183.
& SAFETY WARNING
The steering friction screw is not
intended to allow "hands off " steering .
IDLE SPEED ADJUSTMENT
If disturbed, adjust idle speed knob. Turning
clockwise on the knob increases idle speed.
turning counterclockwise decreases idle speed.
Make certain that throttle is in slow position and
the motor is at normal operating temperature
before making the idle speed adjustment. s ~ e
Figure 5-184. Motor should idle at 650 rpm m
gear.
5-54
20 & 25
21056
5-182
35 61361
5-183
5-184
5-54
REMOVAL OF MOTOR
FROM SWIVEL BRACKET -
20, 25, 35
a. Place motor on a suitable stand.
b. Remove f ront upper mount nut. See Figure 5-
185.
c. Remove lower side mount screws. Loosen
lower thr ust mount screws. See Figure 5-
186.
d. Remove lower mount covers. See Figure 5-
187.
e. Remove port and starboard upper side mount
nuts. See Figure 5- 188.
f . Using a hoist, l ift motor from swivel bracket .
See Fi gure 5- 189. Place motor in a con-
venient place resting on the lower motor
cover and on tip of ant i-ventilation plate.
1. Upper Thrust Mount Nut and Flat Washer
5-185
1. Remove Lower Side Mount Cover Scr ews
2. Loosen Lower Thrust Mount Screws
3. Lower Mount Covers
5- 186
1. Lower Thrust Mount
2. Lower Side Mount - Port and Starboard
3. Port Side Cover
4. Screw and Washer
5. Starboard Side Cover
6. Screws Pass Thru These Holes
7. Bumper
5 - 187
1. Lower Motor Cover
2. Anti-Ventilat ion Plate
3. Pivot Shaft
4. Swivel Bracket
5. Stern Bracket
6. Steering Ha ndle - Rope Start
5-189
II ; ' Hi 'll
JA tl kl!i .. 4
/'''
I

5-185
5-188
63230
5-189
5-55
803 302
, I
I i
i
DI SASSEMBLY OF STERN
AND SWI VEL BRACKETS -
20, 25, 35
a. Figure 5-190 shows the tilt and reverse lock
components that are replaceable if
necessary.
b. Upper front rubber mount can be replaced if
necessary by removing nut and washer. See
Figure 5-191 .
c. If necessary steering bracket can be re-
moved from pivot shaft by removing four
screws. See Figure 5-1 91 .
d. Pivot shaft can be removed from pivot
bracket . See Figure 5-192.
STEERING HANDLE AND THROTILE
GEARS (ROPE START)
a. Remove handle grip screw, handle grip, fric-
tion block, spring, and throttle control plate.
b. Remove the three screw holding the steer-
ing handle halves
c. To remove long shaft and gear from port side
hal f of handle, remove groove pin and
washer. Pull shaft out.
d. To remove throttle control gear, loosen screw
holding pinion gear to short throttle shaft and
gear assembly, and withdraw shaft . Lift
thrott le control gear from bushing in steer -
ing bracket. Bushing can be pressed out if
servicing is required.
REASSEMBLY OF STERN
AND SVVIVEL BRACKETS -
20, 25, 35
a. If pivot shaft has been removed, lubricate
t hrust washer and liner with OMC Triple-
Guard Grease. Place thrust washer and liner
on pivot shaft.
b. If removed, place co-pilot plate and spacer in
swivel bracket . Slide pivot shaft into swivel
bracket. Lubricat e pivot shaft bushing, 0-ring,
and lower thrust washer with OMC Triple-
Guard Grease and install on pivot shaft.
c. If disassembled, reassemble stern brackets.
Assemble stern brackets to swivel bracket
with t ilt t ube and nuts.
d. Coat t he steering bracket screw threads with
OMC Screw Lock. Assemble steering bracket
to pivot shaft and tighten the four screws to
torque specified in Section 1. Install upper
thrust mount, if removed, and tighten nut
and washer securely. See Figure 5-193.
e. Lubricat e and position throttle gear bushing
in steering bracket and install throttle con-
trol gear.
ENGL. I S H
f . Lubricate and install the two throttle shaft
bushings in steering bracket. Install the short
gear and shaft. Position the throttle control
pinion on the short shaft meshed with the
control gear, as shown in Figure 5-193, and
tighten the screw.
g. Lubricate and insert the bushing in the steer-
ing handle half. Install the long shaft and
gear, and insert groove pin.
h. Assemble the handle halves to the steering
bracket , positioning the spacer between the
two flat washers. See Figure 5-194. Be sure
that the throttle gears are properly meshed.
See Figure 5-194. Tighten the two screws
securely, and torque to specifications in Sec-
tion 1.
i. Place the throttle control plate (SLOW SHIFT
START FAST) on the steering handle. Lubri-
cale the spring and friction block with OMC
Triple-Guard Grease and slide onto throttle
shaft. Place grip spring washer on shaft.
Place handle grip on shaft and insert screw
and t ighten. Advance throttle to fast posi-
tion. Throttle and pinion gears should rotate
freely from slow to fast.
1. Clamp Screws, Buttons and Retainers
2. Stern Brackets
3. Shallow Water Drive Bracket
4. Swivel Bracket
5. Reverse Lock Springs
6. Tilt Tube
7. 35 Model Shown
5-190
1. Steering Bracket to Pivot Shaft Screws
2. Nut and Flat Washer
3. Steering Bracket
4. Upper Thrust Mount
5-191
1. Thrust Washer
2. Liner
3. Pivot Shaft
4. Swivel Bracket
5. Thrust Washer
6. 0-Ring
7. Bushing
5-792
1. Screw
2. Control Gear
3. Pinion
4. Upper Thrust Mount
5. Nut and Washer
6. Screws
5-193
1. Washers
5-194
5-56
63254
5 - 190
5-193
I"<
53253
5 - 191
5-192
5-56
INSTALLATION OF MOTOR TO
SWIVEL BRACKET - 20, 25, 35
a. Clamp stern and swivel brackets to a motor
stand. Using a hoist, position motor on swivel
bracket. See Figure 5-189.
b. Place port and starboard side lower mount
housings in position on exhaust housing and
pivot shaft . Insert the two lower side mount
cover screws, but do not tighten. Be sure
scr ews pass t hru holes in pivot shaft, see
Figure 5-186.
c. Make sure upper side mount and thrust
mount st uds are correct ly located in slots in
steeri ng bracket . Install washers and nuts.
Tight en al l hardware to torque specified in
Section 1. See Figure 5-188.
d. Lubr icate all l ube points with OMC Triple-
Guard Grease as described in Section 1.
REMOVAL OF EXHAUST
HOUSING
a. Remove wire from end of throttle control rod.
Unhook armature plate link to vertical throttle
ar m spri ng. Remove t wo screws and clamps.
b. Remove vertical throttle shaft . See Section 2.
c. Remove locknut, three screws, and remove
ai r si lencer. Disengage choke shaft from car-
buretor choke lever . See Section 2.
d. Cut hose str ap at fuel connector and dis-
connect fuel hose.
e. Remove port side powerhead to exhaust
housi ng stud nut. See Section 4.
f . If necessary, remove hardware attaching
st arboard electrical components bracket
(electric start model), and swi ng aside. Re-
move starboard powerhead to exhaust
housing stud nut. See Section 4.
g. Remove four screws retaining powerhead to
exhaust housing. Disconnect ground wire be-
t ween power head and lower motor cover .
Disconnect cooling indicator hose. Lift power-
head from exhaust housing.
h. Remove four rubber mount screws, shift
lever, and lower motor cover. See Figure 5-
195. Avoid loss of washers.
ENGLI SH 5-57
i . Remove two screws and exhaust housing
cover plate to expose shift rod connector. Re-
move lower screw. Remove four screws, one
nut and lockwasher. Carefully remove
gearcase.
J. Remove upper thrust mount nut and flat
washer . See Figure 5-197. Remove upper
port and starboard side mount nuts, and f lat
washers. See Figure 5-198.
k. Remove two lower side mount cover screws.
Loosen two lower thrust mount screws. See
Figure 5- 198. Remove lower mount covers.
Remove exhaust housing from swivel
bracket. See Figure 5- 197.
1. Lower Motor Cover Support
2. Screws
3. Screw
4. Shift Rod Lever
5. Seal
6. Exhaust Housing
7. Steering Bracket
8. Shift Lever and Shaft
5-196
1. Exhaust Housing
2. Upper Side Mount (Port and Starboard)
3. Lower Thrust Mount
4. Lower Side Mount (Port and Starboard)
5. Screw - Thrust Mount
6. 35 Model Shown
5-197
I
5- 195
8 1 3 1 77
5-197
co 1 699
5-198
5-196
5-57
INSTAILlATION OF EXHAUST
HOUSING - 20, 25, 35
a.
b.
c.
d.
e.
f.
g.
If removed, install a new exhaust housing to
lower motor cover seal, using OMC Ad-
hesive "M." Lubricate shift lever shaft and
install thru exhaust housing and upper shift
rod lever. Shaft has a f lat spot for retaining
screw. Tighten screw to torque given in
Sect ion 1. Install lower motor cover front
bracket and torque screws to specifications in
Section 1.
If removed, install upper and lower rubber
mounts, and lower thrust mount. See Figure
5-197. Apply OMC Gasket Sealing Compound
to threads.
Place exhaust housing in swivel bracket.
Install nuts and flat washers loosely. See
Figures 5-195 and 5- 196.
Position lower mount covers on pivot shaft
and exhaust housing. Insert the two lower
side mount cover screws thru the port side
cover, pivot shaft, and thread into starboard
cover. Tighten all screws and nuts to torque
specified in Section 1. See Figure 5-198.
Install gearcase with screws dipped in OMC
Gasket Sealing Compound, making sure
lower shift rod enters connector . Apply same
to threads of stud and install lockwasher and
nut. Torque to specifications in Section 1. In-
stall cover with screws dipped in OMC
Gasket Sealing Compound.
Remove inner exhaust tube from power-
head. Clean surfaces of powerhead and inner
exhaust tube to remove old cement and
gasket material. Apply OMC Gasket Sealing
Compound to these surfaces. Position a new
gasket on powerhead and reinstall inner ex-
haust tube.
Oil and install a new 0-ring in crankshaft.
Coat driveshaft splines with OMC Moly Lube.
Do not coat top surface of shaft as lubricant
here may prevent seating of driveshaft in
crankshaft.
h. Install powerhead on exhaust housing while
rotating slightly back and forth to engage
driveshaft and crankshaft splmes. Be sure
water tube enters water tube guide.
I.
j .
Install exhaust housing to powerhead screws
and nuts. Torque to specifications in Section
1 .
Install vertical throttle shaft, aligning nylon
pin with slot in control gear . Attach clamp
with two screws, secure throttle control rod
with wire, and connect throttle shaft arm to
armature plate link with spring.
ENGLISH
k. Coat threads of air silencer screws with OMC
Screw Lock. Engage choke shaft with car-
buretor choke lever. Using two pins in air
silencer thread holes in carburetor as a
guide, install air silencer . Hold air silencer
against carburetor, remove pin and thread
screw into carburetor. Remove other pin, and
thread screw into carburetor. Attach re-
maining screw and locknut.
REMOVAL OF EXHAUST
HOUSING, STEERING AND
STERN BRACKETS - 40 COM.
a.
b.
c.
d.
e.
f .
g.
h.
Remove powerhead as described in Section
4.
Remove four nuts and lockwashers attach-
ing lower motor cover to exhaust housing.
Remove lower motor cover, powerhead plate,
and gaskets.
Remove gearcase, and gearcase extension if
used.
Remove screws and nuts attaching lower
mount housing to exhaust tube assembly.
See Figure 5-198. Remove both lower mount
housings.
Remove nuts and washers from upper side
mounts. Remove nut attaching exhaust tube
assembly to upper front mount. Loosen steer-
ing friction adjustment screw. Lift exhaust
housing from steering bracket. See Figure 5-
121.
Remove and discard any rubber mounts
which are cracked or otherwise deteriorated.
To remove throttle control, loosen screw at-
taching throttle control pinion to shaft . Re-
move throttle control pinion, shaft, and gear.
Press throttle control bushing from bracket, if
worn.
Lift steering bracket from swivel bracket as-
sembly. Stern bracket assembly may be d1s- .
assembled by removing nut from tilting shaft
bolt and removing stern bracket strap.
SEE GENERAL CLEANING,
INSPECTION, AND REPAIR
5-58
REMOVAL OF STARTER FROM
POWERHEAD - 20/25/35,
25 COM. AND 40 COM.
On Non-Commercial Models - A locking lever
linked to the gearshift lockout lever prevents
manual starter engagement while the motor is in
gear. See Figure 6-43 .
.&a. 40 Commercial - Twist high tension lead
counterclockwise and pull off from spark
plug.
b. Remove three screws and lift starter from
powerhead.
&a. 20/25/35 and 25 Commercial - Disconnect
electrical connector between armature
plate and power pack to avoid accidentally
starting motor.
b. Remove starter housing screws.
c. Use a screwdriver to disengage cable con-
nector from starter hou.sing. See Figure 6-
43A.
d. To remove lockout lever from motor, remove
two bottom fuel pump screws and move fuel
pump aside.
e. Remove screw on cable bracket. See Figure
6-43A.
f. Disconnect cable from lockout lever and lift
off cable assembly.
& Safety Related
ENGLISH
1 . Upper Lockout Lever
2. Lower Lockout Lever
3. Adjustment Screw
4. Locknut
5. Spring
6-43
6-11
6-43A
~
\
6- i i
DISASSEMBLY OF STARTER -
20/ 25/ 35, 25 COM. AND 40 COM.
& SAFETY WARNING
We recommend wearing safety glasses
whil e disassembling and reassembling
manual st arters because of tension re-
tained in rewind spring.
a. Pull the starter rope out far enough to tie a
slip knot in the rope. Pry t he rope anchor out
of t he handle. Remove the handle, release
the knot, and ease the starter pulley back
until t he starter drum is fully unwound.
b. Remove retaining ring and lift off pawl with
links and spring as an assembly.
c. Remove nut. screw, and washer from
spindle. Hold pulley in housing while turning
starter over, legs down. Hold fingers clear of
pulley and jar housing against bench top to
dislodge spr ing and pulley.
CLEANING, INSPECTION, AND
REPAIR
a. Wash metal components in solvent and dry
with compressed air .
b . Inspect spring for broken end loops and weak
tension.
c. Examine pawl for wear.
d. Inspect f r iction spring, spindle, and links.
e. Inspect rope and discard if frayed. Be sure to
replace with starter rope cut to a length of
174 em.
f . Examine pulley and housing. Look for sharp
edges and rough surfaces that cou ld fray
rope. File and polish to remove.
q. Examine starter interlock parts. Replace any
worn or damaged parts.
REASSEMBLY OF STARTER
a. Clamp Spring Winder base (Special Tool Part
No. 392093) in a vise. When rewinding 25
and 40 model spring, insert adapter release
plat e into base. See Figure 6-43B.
b. Place inner loop of spring inside cup. Locate
crank and pin assembly into winder base
installing crank retainer screw. See Figure 6-
43C.
c. Rotate crank and pin assembly in direction of
arrow shown on handle. Wind spring into
base until loose loop end contacts base. See
Figure 6-430.
d. Remove crank retainer screw and crank as-
sembly. See Figure
e. Remove adapter releas-e: 'plate from base.
Install spring into starter housing, locating
pin into spring loop. See Figure 6-44.
f. Press down through holes of base to transfer
spring into starter housing.
g. Bend inside loop end of spring in toward
center of housing to align with pin in pulley.
Lubricate spring with Lubriplate 777. Install
pulley being sure to engage pin with inside
spring loop. See Figure 6-45.
h. Apply a light coat of Lubriplate 777 to spindle
and install in housing with spindle screw,
washer, and nut .
i. With housing upside down on bench, wind
pulley counterclockwise until spring is tight.
Back off about 1/ 2 to 1 turn and align hole in
pulley with hole in housing. Lock pulley by
inserting a nail , small pin or drill thru holes
in pulley and housing. See Figure 6-46.
j. Cut new rope to a length of 174 em. Using a
match or cigarette lighter, fuse nylon strands
at each end for about 13 mm. Rope ends
must be stiff to hold in pulley and rope
anchor. Ti e knot in end of rope and thread
through pulley and housing. See Figure 6-47.
k. Apply Lubriplate 777 to handle end of rope.
Using Starter Rope Threading Tool (Special
Tool No. 378774), thread rope through
handle. Press rope into channel in rope
anchor, with end of rope butting firmly
against end of channel. Press anchor into
handle.
I. Tug on end of rope to seat the knot against
the pulley. Remove locking pin and allow
rope to wind slowly onto the pulley.
m. Apply a light coat of Lubriplate 777 to pawl
pin, and install pawl with spring and links.
Secure pawl with retaining ring.
n. Check operation of pawl when rope is pulled
out. Pawl should extend when rope is pulled
and retract when rope recoils.
o. Pull starter rope out a few times, then check
timing. When the starter is properly timed, an
arrow on the housing will align within the
limits of a box marked on the pulley.
NOTE
A new rope, being stiff, may cause timing marks
to misalign slightly. This condition normally cor-
rects itself after using starter a few t imes.
6-12
1. Adapter Release Plate
6-438
1. Loop Over Pin In Housing
6-44
1. Pin 2 . Inside Loop
6-45
1. Locking Pin 2. Retaining Ring
6-46
1. Punch 4. Grommet
2. Rope Knot 5. Retaining Ring
3 . Seat Rope Knot Here
6-47
..

'1
6-438 6-44
6-43
6-47
6-12
REASSEMBLY OF STARTER
TO POWERHEAD - 20/25/35 AND
25 COM.
a. 20/ 25/ 35
housing.
Snap lockout cable into starter
b. Align starter with powerhead, and attach
with three housing screws.
To install lockout cable to powerhead:
a. Hook end of cable into lockout lever .
b. Connect cable bracket to powerhead with
screw. See Figure 6-48.
c. Reinstall fuel pump.
~ d . If equipped, check operation of starter
interlock. Manual starter must not function
when throttle is advanced beyond the
"START" position.
~ Safety Related
1. Cable Bracket Screw
6-48
6-13
6-48
I ! .
SECTION 7
ELECTRICAL SYSTEM
SAFETY WARNING
To prevent sparks which may result in
fire and explosion, make sure all elec-
trical connections are tight, insulator
boots and sleeves are in place and elec-
trical wires are routed and clamped in
the original position before returning
motor to owner.
STARTER SYSTEM TROUBLE
ISOLATION CHART
PROBLEM: STARTER DOES NOT CRANK ENGINE
a. If checking starter system on a boat. place
remote control lever in neutral.
b. Inspect battery condition. Battery must be
fully charged.
c. Inspect cables and leads for worn insulation.
Check connections. They must be clean,
tight. and free of corrosion .
d. Check 20 amp fuse in lead between solenoid
and key switch.
STARTER SYSTEM VOLTAGE
DROP TEST
a. By making a systematic check from the
positive battery terminal, through the starting
circui t and back to the negative battery
terminal, any component or electrical con-
nection having excessive resistance, thus
causing high voltage drop and subsequent
hard starting, can be located below.
b. Disconnect four wire connector between
armature plate and power pack so that
engine can be cranked without firing.
Connect voltmeter and turn ignition switch to
START to crank engine. See Figure 7-1 .
..., NOTE
~
By placing voltmeter leads against battery,
solenoid. and starter motor terminals rather than
against connecting cable ends, each connection
can be tested for high resistance along w1th
component.
c. Clean and retighten, or replace, any connec-
tion, cable, or component having greater than
specif ied voltage drop.
ENGL.ISH
7-1
STARTER SYSTEM
VOLTAGE DROP TEST
(See Figure 7 -1.)
a. Connect voltmeter pos1t1ve lead to battery
positive post. Connect voltmeter negative
lead to starter solenoid positive terminal.
Turn key switch to start to crank engine.
Voltage reading should not exceed 0.3 volts.
b. Connect voltmeter (only while engine is
cranking) positive lead to starter solenoid
positive terminal. Connect voltmeter nega-
tive lead to starter solenoid starter lead
terminal. Turn key switch to start engine.
Voltage reading should not exceed 0.2 volts.
c. Connect voltmeter positive lead to starter
solenoid, starter lead terminal. Connect volt-
meter negative lead to starter motor terminal.
Turn key switch to start engine. Voltage
reading should not exceed 0.2 volts.
d. Connect voltmeter positive lead to battery
negative lead common powerhead ground
screw. Connect voltmeter negative lead to
battery negative post. Turn key switch to start
engine. Voltage reading should not exceed
0.3 volts.
1. Common Engine Ground
2. Starter Motor
3. Solenoid Switch
4. 12 Volt Battery
5. 0.3 Volts Maximum
6. 0.2 Volts Maximum
7-1
a.
b.
c.
d.
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7-1
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7-1
a
STEP
Check voltage between ground and
point(}.
..6sAFETY WARNING
Steps 1 thru 6 - Remove starter
to solenoid cable from check
point 0 to prevent starter
engagement whi le making
checks.
Check voltage between ground and
point0.
0NOTE
In STEPS 2 thru 6 turn key to
"off" position before discon-
necting and connecting meter.
Turn key to "start" position
after making connection where
required.
EJ Check voltage between ground -and
point@.
II Check voltage between ground ond
point 0.
IJ Check voltage between ground and
point 0. Check voltage be-
tween ground and point 0 .
1':1 Check val tage between ground and
point0.
fJ Check voltage between ground and
point 0
ENGLISH
1. Place Voltmeter Lead
to Each Check point
2. Common Engine Ground
3. Common Engine Ground
PROCEDURE
Remove white lead from safety switch
at check point 0. Connect volt-
meter between point 0 and com-
mon engine ground. Turn key switch
to start position. Voltmeter should
show 12 volts (battery voltage).
Connect meter at 0 . Turn key
switch to "start" position.
Connect meter at 0 . Turn key
switch to "start" position.
Connect meter at 0 . Turn key
switch to "stort" position.
Connect meter at 0. Turn key
switch to "off" position.
Connect voltmeter at point 0.
Turn key to "start" position.
Reconnect starter to solenoid cab I e
at check point 0. Connect
meter at point 0. Turn key to
"start" position.
4. Starter Motor
5. Solenoid Switch
RESULT
a. If meter does not read any val tage, pro-
ceed to STEP 2.
b. If meter reads 12 volts (battery voltage)
reconnect white lead to safety switch
and proceed to STEP 6.
a. If meter reads 12 volts (battery voltage),
lead is open between 0& 0.
b. If no reading, proceed to STEP 3.
a. If meter reads 12 volts (battery voltage),
solenoid switch is faulty.
b. If no reading, proceed to STEP 4.
a. If meter reads 12 volts (battery voltage),
I ead is open between VJ & 0.
b. If no reading, proceed to STEP 5.
a. If meter reads 12 val ts (battery voltage),
check key switch.
b. If no reading at 0 check for open
I ead or fuse between 0 and 0
c . Connect meter at point@. If no
reading ot 0, check for open lead
between 0 and battery positive
terminal. If reading at 0 1 proceed
to STEP?.
a. If no reading, solenoid is faulty.
b. If meter reads 12 val ts (battery val tage
- click should be heard in solenoid),
proceed to STEP 7 .
a. If meter reads 12 val ts (battery vol
a nd starter motor does not turn, check
starter motor.
b. If no reading, check for broken cable
or poor connection.
8. Fuse
9. Ignition Switch
6. Common Engine Ground
10. Yellow/Red
11 . Safety Switch
7. 12 Volt Battery
7-1A
7-2
I+
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---
83107
7-1A
7-2
KEY SWITCH CHECK
(With Test Light or Ohmmeter)
(See Figure 7-1 B.)
a. Disconnect battery leads.
b. With key switch in " OFF" position, connect a
continuity light or meter leads between key
swi t ch " BATT" and "A" terminals. Light or
meter should not show continuity.
c. Turn key switch to "ON" position. Light or
met er should show continuity.
d. Tur n key switch t o "START" position. Light or
meter should still show continuity.
e. Wit h key held in "START" position, transfer
lead f rom "A" terminal to "S" terminal. Light
or met er shoul d still show continuity.
f . Transfer leads to "M" terminals. Light or
met er should not show continuity in
" START" or " ON" positions.
J. Turn key switch to " OFF" position. Light or
meter should show continuity.
h. Transf er leads t o "B" and "C" terminals.
Turn key switch to "ON" position and push in
key. Light or meter should show continuity
when key is pushed in.
i. Turn key switch to "START" position and
push in key. Light or meter should show con-
t inuity when key is pushed in.
KEY SWITCH CHECK
(With Leakage Test er)
In some conditions, the key switch may be
shorti ng (some leakage) to the other terminals in
t he key switch, but will not show up with a test
I ight or an ohmmeter. This condition may be
f ound by using a condenser tester (leakage test)
w here a voltage of approximately 500 volts is ap-
pli ed t o t he key switch terminals.
'3 . With all leads disconnected and the key
switch in the off position, connect the black
lead of t he tester to one of the "M" ter-
minals of the key switch. See Figure 7-1C.
b. Attach t he red lead of the tester to the "B"
terminal CD and apply leakage test .
c. Repeat t est by moving the red lead to each of
the termi nals and applying the leakage test.
The met er will indicate if leakage is present .
d . When app ly ing test to other "M"
turn key to the on position.
REMOVAL OF STARTER
Due t o the constr uction of the starter motor ,
maintenance operations are generally limited to
periodic checking for looseness of mounting.
Unless it is certai n that the starter motor re-
quires attention, do not remove it for overhaul. A
t horough check should be made of the battery.
cables, starting solenoid, and switch.
EN G L.I SH
7-3
25 AND 35
Uliiill NOTE
Disconnect battery cables at battery.
a. Remove vertical throttle shaft clamp screws
and clamp. See Figure 7-3.
b. Remove the upper and lower screws
retammg the starter bracket to the power-
head. See Figure 7-3. Observe that the
ground lead attaches to the lower screw.
c. Disconnect all leads from the solenoid. See
Figure 7-3.
d. Remove one locknut and three screws
attaching air silencer to powerhead. Remove
air silencer .
e. Remove starter bracket front screw and place
starter and bracket assembly on a bench for
disassembly. See Figure 7-3.
50 THRU V-6
N 0 TE
Disconnect battery cables at battery.
a. Disconnect lead f rom starter motor .
b. Remove air silencer as described in Section
2.
c. Remove three starter mounting screws. See
Figure 7-2.
1. Battery
2. Off
3. On
4. Start
5. Choke Start
7-18
a. Leakage Tester
b. Black Lead
c. Red Lead
d . Red Lead with Key in "ON" Position
7-1C
1. Starter Mounting Screws
7-2
1. Screws
2. Clamp
3. Vertical Throttle Shaft
4. Starter Bracket Screws
5. Starter Pinion Gear
6. Ground Lead
7. Solenoid Leads
8. Starter Solenoid
7-3
7-1 c
~
S M
M 8
0 7-2
7- 18
7-3
7-3
ALTERNATOR STATOR TEST -
25 THRU 60
~ J i \ \ ! ~ 1 NOTE
Set ohmmeter on Low Ohms scale.
a. Connect black ohmmeter lead to the yellow
I ead of stator .
Connect red ohmmeter lead to the yellow/ grey
lead of the stator. See Figures 7-17 and 7-17A.
Ohmmeter should read 0,35 0,1 ohm.
b. Disconnect ohmmeter red lead from the
stator yellow/grey lead. (Leave ohmmeter
black lead connected to yellow lead.)
Connect the ohmmeter's red lead to the stator's
yellow with blue st ripe lead. Ohmmeter should
read 0,2 0, 1 ohm. See Figures 7-17 and 7-17 A.
Disconnect red ohmmeter lead from the
stator's yellow with blue stripe lead (leaving
the ohmmeter 's black lead connected to the
yellow I ead of stator).
Set ohmmeter scale to Hi Ohms.
Connect the ohmmeter's red lead to ground.
Ohmmeter should show open circuit (infinity) . If
ohmmeter shows any reading, stator is shorting
to ground. See Figu re 7-17B.
RECTIFIER DIODE TEST - 25
THRU 60
a. Connect one lead of ohmmeter to rectifier
case (ground) and other lead to yellow/ grey
stripe lead of rectifier. Note reading. See
Figures 7-18 and 7 -18A. Reverse ohmmeter
leads or press polarity button. Note readmg.
Reading on one check and no reading
(infinity) on the other check - diode is good;
both readings zero, diode is shorted.
OHMMETER LEADS MUST BE REVERSED FOR
EACH TEST OR PRESS POLARITY BUTION
b. Repeat above test using yellow rectifier lead.
C.
Reading on one check and no readmg (In-
finity) on the ot her check - d1ode IS good;
both readings high, diode is open; both read-
ings zero, diode is shorted.
Repeat above test using yellow/blue stripe
lead. Reading on one check and no readmg
(infinity) on the other check - diode is good;
both readings high, diode is open; both read-
ings zero, diode is shorted.
ENG L.I SH 7-8
d. Repeat test procedure with ohmmeter be-
tween red lead of rectifier and yellow/ grey
stripe lead of rectifier. Reading on one check
and no reading (infinity) on the other check -
diode is good; both readings high, diode is
open; both readings zero, diode is shorted.
e. Repeat test between red and yellow lead of
rectifier. Reading on one check and no read-
ing (infinity) on the other check - diode is
good; both readings high, diode is open; both
readings zero, diode is shorted.
f. Repeat test between red and yellow/ blue
stripe lead of rectifier. Reading on one check
and no reading (infinity) on the other check -
diode is good; both readings high, diode is
open; both readings zero, diode is shorted.
1. Ohmmeter
2. Steps <D and @
3. Step @ Hi Ohms
4. Red
5. Yellow
6. Yellow/ Grey
7. Yellow/ Blue
8. 5 Amp Stator
9. Terminal Block
10. Black
7-17
Lo Ohms Scale
Scale
1 . Ohmmeter Red Lead
2. Stator Yellow Lead
3. Stator Yellow/ Grey Lead
4. Ohmmeter Black Lead
5. Stator Yellow/Blue Lead
7-17A
1. Ohmmeter Black Lead
2. Stator Yellow/ Grey Lead
3. Ground
4. Ohmmeter Red Lead
7-178
1. Rectifier Yellow/ Grey Lead
2. Meter Black Lead
3. Meter Red Lead
4. Ground
7-18 and 7-18A
83082
8 1 311 1
7- 17A 7-18
8 1 3 1 1 2
7-178
7-TBA
CONTROL CABLES
INSTALLATION ON MOTOR
a.
b.
c.
d.
Identify the throttle cable from the shift cable
at the engine end of cables by lifting fast idle
lever. The throttle cable will move.
Lubricate the shift and throttle cable ends
with OMC Triple-Guard Grease.
& SAFETY WARNING
To prevent accidental starting of engine
always remove ignition key from start
switch. Accidental starting of engine
could cause possible injury to the in-
staller and/ or bystanders.
Remove rubber grommet from front of lower
motor cover. Open cable retainers. See
Figure 8-6 or 8-7.
Move control lever on remote control box to
neutral position. Move fast idle lever down to
"run" position.
-
& SAFETY WARNING
Before connecting shift control cable to
engine. insme that the remote control is
in neutral and the engine shift lever is in
neutral. Failure to make this adjust-
ment can result in the engine starting in
gear and/ or the control "locking" in
gear. Operator may become confused
and temporarily lose control of boat.
e. Place shift lever on engine in neutral posi-
tion (propeller shaft will turn freely when in
neutral). Note amount of free play in shift
lever, and position lever in center of this
travel.
Determine mid-point of shift cable backlash
by first pushing cable and trunnion nut
toward each other. and then pulling them
apart.
Position backlash at mid-point. Then place
trunnion adjustment nut of shift cable into
trunnion pocket of anchor block which aligns
with the shift lever . See Figure 8-20.
Turn the trunnion adjustment nut until hole
in cable is in line with pin on shift lever.
Attach cable to pin using washer and lock-
nut supplied with engine.
f. Move throttle lever on engine so that idle
stop screw is against its stop.
g. Grasp throttle cable and trunnion nut. Pull
firmly on cable while pushing on trunnion
nut to remove backlash from cable and
remote control.
ENGLI SH
Ul1 NOTE
Unless backlash is removed (as in step "g"
above) before adjusting and connecting throttle
cable. engine may not return to a consistent idle
speed.
h. Position throttle cable in notch in anchor
block. Turn trunnion adjustment nut until
hole in cable is in line with pin on throttle
lever. Attach cable to pin using washer and
locknut supplied with engine. See Figure 8-
21.
& The throttle cable must be adjusted just tight
enough to insure that the engine throttle lever
returns to its idle stop. If this cable is too loose.
the engine idle speed will be high and incon-
sistent. causing difficulty shifting out of gear.
If it is too tight. the control will feel stiff through
the shifting range, and the warm-up lever will
tend to move up when shifting to neutral.
&i. Slip rubber grommet onto control cables.
and press grommet into groove in lower
motor cover. Snap cable retainers shut. See
Figure 8-6 or 8-7.
8-7
J. Test operation. See Function Testing of
Controls.
>
'?,
1. Locknut and Washer
2. Shift Control Cable
3. Anchor Block
4. Shift Trunnion Adjustment Nut
8-20
1. Locknut and Washer
2. Throttle Cable
3. Throttle Trunnion Adjustment Nut
4. Throttle Lever
8-21
.ffi Safety Related
8-20
8-7
/
COMBINATION THERMOSTAT
AND PRESSURE RELIEF
25 GEARCASE
\
\
\
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~ I ~ ~
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~ ~ ~ ! I
I - II
20/25 COMMERCIAL/25-35
WATER FLOW DIAGRAM
20/25/35
35 GEARCASE
93
SENSOR COIL
(A) BROWN
---
WIRING DIAGRAM C.D. 2
4.5 THRU 55 MANUAL START
CHARGE COIL
SHORTING SWITCH ASSY.
2
1 : ~ : : {
---------J - - - - - - - - - - - - - - - - - - - - - - - - ~
lANGE/BLUE
lANGE
.ACK/YELLOW
8 1 3276
BLACI} --
POWER PACK CD 2
__________ __.
L----,---
SENSOf
(B) ORANGE/ BLUE

(A) BLACK/YELLOW
35 ELECTRIC START
CONTROL BOX
CABLE CONNECTOR
VACANT
YELLOW/ RED 16 GA.
RED/ PURPLE
STRI PE
VACANT--- ,
PURPLE
VACANT
VACANT
RED/ PURPLE
STRIPE
BLACK/ YELLOW
PURPLE
RED
MOTOR CABLE
CONNECTOR
MOLDED
A R R O W ~
YELLOW/ RED 16 GA.
VACANT
63110