Documente Academic
Documente Profesional
Documente Cultură
&
Safety Warning
This Service Manual will alert you to certain procedures that must be done very carefully.
If you ignore this information, you could . . .
Injure yourself or people around you
Injure the boat operator, boat passengers, or people around the boat
Damage the outboard or its systems
Understand the following symbols before proceeding:
&
Safety Warning
Important
Appears next to information that controls correct assembly and operation of the product.
This Service Manual is written for qualified, factory-trained service technicians familia r
w ith the use of OMC Service Tools.
This Service Manual tells you how to correctly maintain and service the outboard and its
systems. When correctly serviced, the outboard will be reliable and safe to operate.
When OMC Service Tools are called for, use them. Where mentioned, the tools are required
to perform the service procedure.
If you use procedures or service tools that are not recommended in this manual, YOU
ALONE must decide if your actions might injure people or damage the outboard.
Index
General Information
Fuel System
Ignition System
Powerhead
Midsection
Gearcase
Manual Starter
Electrical System
Power Trim/Tilt
Safety
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INDEX
Topic
Page
Alcohol in Gasoline
Fuel Requirements
1-16
Anodes
1-28
Anti-Siphon Valve
2-12
Battery Charging
Battery Recommendations
Battery Testing
Break-In Procedure
Break-In Procedu re
1-21
Carburetor Adjustment
2-22
Compression Check
Tune-up Procedure
1-26
Engine Weight
Engine Specifications
1-8
5-4
Flywheel Servicing
3-7
Fogging Engine
Off-Season Storage
1-22
Fuel Filter
2-7
Fuel/Oil Ratios
1-14
Fuel Primer
2-10
2-9
2-9
Engine Specifications
1-8
1-31
Galvanic Corrosion
1-28
Gear Ratio
Engine Specifications
1-9
Gearcase Capacity
Engine Specifications
1-9
Heli-Coillnserts
1-43
1-20
Idle RPM
Engine Specifications
1-8
Ignition Timing
1-31
Ignition Specs
Service Specifications
3-3
Ignition Troubleshooting
Output Tests
3-22
Lubrication Chart
Lubrication Chart
1-12
Ma intenance Va lve
2-35
1-31
Models Covered
Models Covered
Page 4
Motor Mounts
5-11
Octane Requirements
Fuel Requirements
1-16
Off-Season Storage
Off-Season Storage
1-22
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Topic
Page
Operating Temperature
4-5
Overheating
4-5
Preseason Service
Preseason Service
1-25
6-13
Propeller Selection
Propeller Selection
1-18
2-25
Pyrometer
4-5
RPM Lim it
Engine Specifications
1-8
4-7
Rigging Information
1-38
Spark Plugs
3-8
Starter Servicing
7-5
Storage Mixture
Off-Season Storage
1-22
Submerged Engines
Submerged Engines
1-29
1-31
Tachometer Test
8-24
Temperature Switch
4-7
Engine Specifications
1-8
Thermomelt Stiks
4-5
Thermostat
4-19
Rigging Information
1-38
Timing
1-31
Trim Tab
6-20
Tune-up Procedures
Tune-up Procedure
1-28
6-13
Oil Tank
2-25
8-6
CD
Water Pump
6-5
Winterization
Off-Season Storage
1-22
CD
Mirage/eng
35 Models
J35EL3EE
J35PL3EE
J35TEL3EE
J35R3EE
J35RL3EE
Mirage/eng
General Information
Table of Contents
General Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . ..
Service Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Engine Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Gearcase Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering System Lubrication - Remote Electric Models ..
Lubrication Chart ...... . .... . ................... .
Fuel/Oil Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Fuel Requirements .. .. .... . .......... . ...... . ....
New Engine Pre-Delivery Checks ....................
Propeller Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Weather, Altitude, and Engine Performance ............
Break-In Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Off-Season Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Preseason Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Tune-Up Procedure ............. .. ................
Anodes - Testing and Replacement . . . . . . . . . . . . . . . . ..
Submerged Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Synchronization and linkage Adjustments ............
20-Hour Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Rigging Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Drill Size Conversion Chart. . . . . . . . . . . . . . . . . . . . . . . ..
Heli-Coillnserts and Installers . . . . . . . . . . . . . . . . . . . . ..
1- 2
1- 3
1- 4
1- 7
1- 8
1-11
1-11
1-12
1-14
1-16
1-17
1-18
1-20
1-21
1-22
1-25
1-26
1-28
1-29
1-31
1-37
1-38
1-42
1-43
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1-1
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1-2
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Service Specifications
Standard Torque Chart _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Size
In. Lbs.
Ft. Lbs.
Nm
Size
In. Lbs.
Ft. Lbs.
N m
M3
15-22
1,6-2,4
No. 6
7-10
24-36
2,7-4,0
No.8
15-22
0,8-1,2
M4
M5
36-60
3-5
4,0-6,8
No.10
25-35
2-3
2,8-4,0
M6
84-106
7-9
9,5-12,0
No. 12
35-40
3-4
4,0-4,6
M6
(Taptite)
108-132
9-11
12,2-14,9
in .
60-80
5-7
7-9
in .
120-140
10-12
14-16
M8
180-204
15-17
20,3-23,0
220-240
18-20
24-27
M10
312-336
26-28
35,2-38,0
340-360
28-30
38-40
1/ 4
5/ 16
3/s in.
7/ 16
in .
1,6-2,4
INote I These
INotel
Mi rage/en g
1-3
Introduction
This manual covers service information on 30.5 cu . in . (500 ccl
and 34.5 cu. in. (565 ccl 3-cylinder models.
Use this manual together with the proper Parts Catalog for part
numbers and for exploded views which are a valuable aid to
service.
This manual presents the English values and dimensions first and
the metric values and dimensions second, inside parentheses ( I.
Good Service Practice
Service required for ONIC engines is generally one of three kinds:
Normal care and maintenance - which includes putting
a new engine into operation, storing engines, lubrication, and care under special operating conditions such as
salt water and cold weather. This includes engine servicing procedures to keep the engine in prime operating
condition.
Operating malfunctions - due to improper engine
mounting, propeller condition or size, boat condition, or
the malfunction of some part of the engine.
Complete disassembly and overhaul - such as major
service or rebuilding a unit.
It is important to you as the service person to determine, before
disassembly, just what the trouble is and how to correct it quickly,
with minimum expense to the owner.
When repairing a component, the most reliable way to ensure a
good job is to do a complete overhaul on that component, rather
than just replacing the bad part. Wear not readily apparent on
other parts could cause a malfunction soon after the repair job.
Repair kits and overhaul kits contain all the parts needed to
ensure a complete repair, to eliminate guesswork, and to save
time .
Repair time can also be minimized by the use of special tools.
ONIC special tools speed repair work so it can be done within flat
rate time . In some cases, the use of substitute tools can damage
the part.
momentarily. If
operated in test tank, use proper test wheel. Failure to do so can
result in damage to water pump and engine overheating!
1-4
Mi rage eng
Mirage/eng
1-5
Service Policy
When servicing an outboard which is within its normal warranty
period, make repairs using only genuine ()fIIIC replacement components or parts.
If ()fIIIC genuine replacement components or parts are not used,
()fIIIC might refuse subsequent warranty claims involving that
engine.
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DR2066
DR2065
DR4203
Symbols
Throughout this service manual, symbols are used to interpret
electrical troubleshooting results or to assign values in drawings.
Electrical
[JJ
DR4204
rn
When
shows on the meter face, no continuity, or very
high resistance, is indicated . The symbol is referred to as infinity.
rn
When "v" follows a value on the meter face, the procedure
is measuring voltage.
rn
When "fl" follows a value on the meter face, the procedure
is measuring resistance. fl is the symbol for ohm, the unit of
"00"
DR4205
rn
When
precedes a value on the meter face, it indicates
your reading should be less than, or equal to, the value shown.
rn
When
precedes a value on the meter face, it indicates
your reading should be greater than, or equal to, the value shown.
"s;"
"'2:."
DR4206
M irage/eng
1-7
DR4207
Engine Specifications
25 and 35
Operation _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Power
25 - 25 HP (18,7 kw)
35 - 35 HP (26,1 kw)
Power Rated @
5500 RPM
Test Propeller
OMC PI N 434505
25 - 4200
35 - 5000
Weight:
Powerhead _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Type
Displacement
Bore
Stroke
Standard Bore *
Crankshaft Dimensions:
Top Journal
Center Journals
Bottom Journal
Rod Crankpin
1.4979
1.3748
1.1810
1.1823
1.4984
1.3752
1.1815
1.1828
in.
in.
in.
in.
(38,05
(34,92
(30,00
(30,03
38,06
34,93
30,01
30,04
mm)
mm)
mm)
mm)
1-8
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Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .
Gear Ratio
13:28 (0.46)
Lubricant
Capacity
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Type
Firing Order
1-2-3
Ignition Features
6200
Ignition Coil
OMC PI N 584826
Spark Plug, Champion
INotel
Recommended
Extended Idle
OL86C or L86C
OL87YC or L87YC
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ._
Alternator
Tachometer Setting
OMC PI N 514021
AC Model
71 Watts AC
Warning Signals
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1-9
FueISystem ............................................................... .
Fuel/Oil Ratios
Fuel Requirements
Carburetion
Calibration
Starting Enrichment
2.1 qts. (2 II
1-10
MirageJeng
Gearcase Lubrication
fA
[I]
Remove oil drain/fill plug and oil level plug from gearcase.
With motor in normal operating position, allow oil to drain
completely.
Important
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Lubrication Chart
Frequency
Figure
Lubrication Point
Lubricant
IT]
Gearcase
rn
Steering
rn
Electric Start
[]]
W
1Il
Carburetor Linkage
Manual tilt models - Swivel
Bracket, Tilt Support, Shallow
Water Drive Bracket
[!]
[!]
[!Q]
e
e
e
e
e
e
e
e
e
Fresh Water
Salt Water
30 Days
As Required
60 Days
30 Days
60 Days
30 Days
60 Days
30 Days
60 Days
30 Days
60 Days
30 Days
60 Days
30 Days
60 Days
30 Days
OMC Ultra-HpprM
OMC Starter
Triple-Guard
Grease
Gearcase
Lube
Pinion Lube
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DR4847
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DR38761
Mi rage/eng
1- 13
Fuel/Oil Ratios
Lubricant
INotel
Running or storing an engine on a leaner than recommended fuel/oil mixture may result in powerhead damage.
INote I Avoid the use of the following as they could damage your
engine and/or shorten spark plug life:
Automotive
Premix fuel
Premix fuel
Premix fuel
oils
of unknown oil quantity
richer than the recommended ratio
leaner than the recommended ratio
INotel
High Performance
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IT]
Portable tank - Above and below 32 F (00 Cl, add one gallon
(4 litres) of fuel. Pour in required amount of oil. Add remaining
fuel. Install filler cap and tip tank gently to distribute oil.
[[]
rn &. Permanently Installed Tank - Above 32 F
pour oil slowly with the fuel as tank is filled . Below 32 F
(00 Cl,
(00 Cl,
DR3986
Oil Requirements
3 Gallons
(11,4 Litres)
6 Gallons
(22,7 Litres)
18 Gallons
(68,1 Litres)
100: 1
(1% Lubricant)
4 fl. oz.
(118 ml)
8 fl. oz.
(236 ml)
24 fl. oz.
(708 ml)
50 :1
(2% Lubricant)
8 fl. oz.
(236 ml)
16 fl. oz.
(473 ml)
48 fl . oz.
(1419 mil
25:1
16 fl. oz.
(473 ml)
32 fl . oz.
(946 ml)
96 fl. oz.
(2838 ml)
(4% Lubricant)
PCE0025
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Fuel Requirements
Minimum Octane
Models
Recommendations
(R+M)/2 "AKI"
"RON"
All
87
90
Preferred Fuel: Any regular unleaded, regular leaded, or premium unleaded gasoline having the
recommended octane rating.
Acceptable Fuel: Any of the above gasolines with up to the following percentage alcohol by volume:
10% ETHANOL or
5% METHANOL with 5% cosolvents
Unacceptable Fuel: Do not use any gasoline having more than 10% ETHANOL or more than 5%
METHANOL even if it contains cosolvents or corrosion inhibitor, regardless of octane rating .
OMC products have been designed to operate using the Preferred Fuel or Acceptable Fuel; however, be
aware of the following:
The boat fuel system may be different regarding use of alcohol fuels. Refer to boat owner' s
manual.
Alcohol attracts and holds moisture which may cause corrosion of metallic parts of the fuel
system.
Alcohol extended fuels can cause engine performance problems.
All parts of the fuel system should be inspected frequently and replaced if signs of
deterioration or fuel leakage are found. Inspect at least annually.
&.
INotel OMC 2+4 fuel conditioner and OMC Carbon Guard fuel additive are the only gasoline additives
recommended by Outboard Marine Corporation. Use of other gasoline additives can result in poor
performance or engine damage.
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M ir age eng
Owner's
Name
Address
State_ ZIp _
City
1. Upon
Date of Purchase
SERIAL -
MODEL#
........
....
Owner'sHame
Address
C~y
State
Z.
City
Stile
Z.
DateofPu'cnase
1911iOrl Key No
SecoodOwner Name
Address
......
Boat MtI1.
""'''''' _
_ __
BoatLength
IlTIpOI'tIInt: The F..,.I aoet Safety Act reQi.lres registration lists to be mal'llained
&
Name
S
0
Addfess
City
ISl81e
Ow ner's Phone
jZIp. 4
0
Purchase Date
&
Type of Use
Pleasure
Addre ss
Ci ty
B
Zip" 4
Slate
_reater
Code
'ng;Mj Mod.,.
Registration
Oeom", 0 00"
DealerNarne
S
0
D
&
Boat Mig
!-lull No.
ISM'" .
Model
Length
Trailer V IN
@
DR 5700
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1-17
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Propeller Selection
Selecting the correct propeller for each engine and boat combination will ensure good engine service life and good boat performance. A propeller must be carefully selected to match the
engine/boat combination, the application, and the anticipated
load in the boat.
INotel Selection of the wrong propeller could reduce engine
OJ I Note I If
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1-18
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Miraye eng
100%
90%
80%
70%
60%
50%
40%
30%
@Q
-@@~
1
DR1261
Engine RPM
Horsepower (kwj curve
@ Full-throttle operating range
Mirage/eng
1-19
Rated Power
Hot Weather/
------High Altitude
I
I
I
I~
I~
I~
....
Cl)
RPM
1m
a:
DR4013
1-20
Mirage/eng
Break-In Procedure
During the first 10 hours of break-in operation you must use a 50:1 fuel /oil ratio in your fuel tank in
addition to the operation of the oil mixing unit. After the 10-hour break-in period, check to see that the
oil level in the oil tank has changed, indicating that oil has been used before using unl')1ixed gasoline in
the fuel system.
If the oil mixing unit is disconnected, you must use a 25: 1 fuel/oil ratio in the fuel tank for the first 10
hours.
To help ensure long engine life and prevent serious engine damage, using additional oil in the fuel is
mandatory during the first few hours of operation of:
a new engine
a used engine with a new powerhead
a used engine with a newly rebuilt powerhead
INote I DO NOT operate motor out of water. Water pump can be damaged or engine can overheat.
INote I DO NOT operate engine at a constant throttle setting. Change engine RPM often.
INote I Verify water pump operation by looking for a steady stream of water at the water pump
indicator.
First 10 Minutes _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
idle
ONLY.
Minutes
Operate engine
Next 50
_ _ _in
_gear
_ _at
_fast
__
__
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
INote I With
easy planing boats, use full throttle to quickly accelerate boat onto plane. Immediately
reduce throttle to one-half as soon as boat is on plane. BE SURE boat remains on plane at this throttle
setting.
Second Hour _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _. .
Use full throttle to accelerate boat onto plane, then reduce throttle setting to three-quarters.
BE SURE boat remains on plane at this throttle setting.
At intervals, apply full throttle for periods of one to two minutes, returning to three-quarters
throttle for a cooling period.
Change engine speed every 15 minutes.
INote I Verify
water pump operation by looking for a steady stream of water at the water pump
indicator.
Next Eight Hours . ._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _. ._ _ __
Avoid continuous full-throttle operation for extended periods.
Change engine speed every 15 minutes.
DO NOT exceed recommended maximum engine RPM. Refer to Specifications, this section.
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INote I Retorque cylinder head screws after engine break-in period . Retorque after engine has been run
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1-21
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Off-Season Storage
Use the following procedure to properly prepare Johnson and
Evinrude outboards for extended periods of non-use. These steps
are intended to protect the engine during storage and simplify the
preseason servicing procedure.
1. Stabilize the engine's fuel supply with OIVIC 2+4fuel conditioner, following directions on the bottle.
I Note
&.
INotel
5. Stop engine and remove all spark plugs. Spray a liberal amount
of OIVIC Storage Fogging Oil into the spark plug holes.
6. Turn flywheel in a clockwise direction to distribute the fogging
oil throughout the cylinders. Install and torque the spark plugs.
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Safety Related
1-22
Mirage/eng
&
&
10. Inspect the entire boat steering system for damage due
to corrosion, aging, lack of maintenance, or abuse. Inspect
mechanical steering cables for deterioration or cracks. Inspect
hydraulic steering models for fluid leaks or other external signs
or problems. Follow equipment manufacturer's maintenance
and lubrication recommendations when servicing the steering
system.
11. Remove battery and check its condition, water level, and
charge . Store in a cool, dry place, out of direct sunlight. Check the
water level and charge periodically during storage.
12. If equipped, service the boat fuel filter following instructions
on canister. Clean and inspect the oil tank.
13. Remove propeller and check for damage. A slightly bent
propeller blade can hardly be noticed but will affect the performance of the engine. Clean and lubricate the propeller shaft with
OIVIC Triple-Guard grease.
14. Drain and refill gearcase . Lubricate engine. See Lubrication,
this section .
15. Check engine carefully. Make sure screws and nuts are tight.
Replace damaged or worn parts.
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NOTES
1-24
Mirage eng
Preseason Service
1. Check gearcase lubrication. If leakage is evident, gearcase seals
may need attention . Check lubricant level in power trim /tilt
reservoir. See Lubrication, this section.
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Tune-Up Procedure
1. Visually inspect engine for leaks, missing or loose parts, or the
obvious defects.
2. Compression check - Proper compression is essential for good
engine performance . An engine with uneven compression cannot
be properly tuned.
Operate the engine until it reaches normal operating
temperature. Stop engine.
Remove and inspect all spark plugs. Check their condition.
Install thread-type compression tester in spark plug hole.
With throttle in wide-open position, crank engine with
starter through at least four compression strokes.
Variation between cylinders should not exceed 15 PSI
(100 kPa) .
IF the engine has equal compression, is hard to start, AND
operates poorly, check for:
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INotel
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INotellf any anode has been reduced to 213 its original size (%
eroded), it must be replaced! To increase the duration of the
anodic protection, the sta rboard stern bracket (on some models)
is drilled to accept an additional anode.
m rn
INote I Do
faces.
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1-28
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Mirage eng
Submerged Engines
Engine Dropped Overboard (Not Running)
If engine is recovered from water immediately, it must be serviced within three hours. See Prolonged Submersion.
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1-29
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M irage eng
1
DRC6805
INote I You must perform this step-by-step procedure exactly as written to ensure consistent engine
idling and smooth operation throughout the RPM range.
Preli~inaryAdju~~ents~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
INote I Some preliminary adjustments must be made to ensure that the linkage is in the correct position
before starting.
&
IT]
2. Set the idle stop screw @ length at % in. (19 mm), measuring from the throttle arm to the idle
stop screw boss. Lock the screw in place.
IT]
3. Tiller Models Only: Remove the pivot screw securing the throttle cable bracket to the support
arm.
IT]
4. Tiller Models Only: Turn the idle speed adjustment knob counterclockwise to the full SLOW
position. Verify that the knob and the throttle twist grip are in the full SLOW position. Verify that the
throttle arm is touching the idle stop screw @.
IJJ
5. Tiller Models Only: Rotate the throttle cable bracket to align it with the mounting screw hole.
Rotate the bracket one revolution toward the cable end to preload the cable. Install the bracket and pivot
screw, placing the flat washer between the bracket and the cable support arm.
6.
Re~ote
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Safety Related
1-31
INote I If the timing pointer bracket has been disturbed, check the
timing pointer alignment.
1. Remove the three spark plugs from the cylinder head .
IT]
1-32
Mirage eng
W [[]
[!Q]
\Notel
[I1]
1. Separate the temperature switch white/black lead connector. Use a jumper to connect the ignition module side of the lead
to a clean engine ground. This will disable the QuikStart's
cold-start feature, preventing an inaccurate timing reading .
2. Connect the spark plug leads.
Idle Timing
25,35
4 ATOC
:;j
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Qi
Mirage eng
1-33
ii
OJ & 4. Stop the engine. To adjust, loosen the idle stop screw
locknut. Rotate the idle stop screw to achieve 4 ATDC idle timing,
then tighten locknut.
1. Make sure the throttle arm is against the stop screw. Use a
sharp grease pencil to make a mark @ on the crankcase, inline
with the 4 ATDC mark on the timer base grid.
rn
rn
3. Close the throttle, then open the throttle until the mark @
lines up with the zero on the timing grid. Verify that the cam
follower is just touching the cam.
Maximum Spark Advance _ _ _ _ _ _ _ _ _ _ _ _ _ __
20 BTDC
E
35
22 BTDC
:;j
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PCE0026
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ii
Safety Related
1-34
Mirage eng
[[J
Wide-Open Throttle _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
rn
2. Attach the drain hose to the air silencer. Install the air
silencer on the engine.
rn
2. Move the shift lever back and forth to verify the neutral
detent position .
[IQ]
ITIJ
:;j
><
Qi
Mirage/eng
1-35
ii
[I]
5. Move the shift lever rearward to the limit of free play. Mark
this position with a line @ on the neutral detent cam.
rn
6. Find the middle between the two marks made on the
neutral detent cam . Place a mark at this position .
rn
1-36
Mirage eng
20-Hour Check
ave
Triple-Guard
Mirage/eng
1-37
Rigging Information
Remote Control
&
[JJ
1. Put the control handle into NEUTRAL position. The throttle cable casing guide will retract completely and the shift cable
casing guide @ will go to the midpoint of its travel.
I,
'''h''~
([0)
[JJ
& Control
Shift Cable
rn
grease.
2. Verify that the fast idle lever is down in the RUN position.
3. Move the remote control handle to NEUTRAL.
&
rn
4. Move the remote control handle to full throttle in FORWARD.
W
&
Safety Related
1-38
Mirage,eng
11 . Temporarily remove the shift cable from the shift lever pin and
verify that the gearcase is in its NEUTRAL detent.
I Note I If there are not enough threads on the shift cable to allow
the adjustment in Step 7, or if the gearcase detent does not
correspond with remote control NEUTRAL in Step 10, refer to
Section 6 for shift rod height adjustment.
[]] &.
INotelwhen installing OMC Accessory Controls, except for prewired surface mount, the shift cable must be adjusted and
installed when the control and engine are in NEUTRAL.
Throttle Cable
rn &.
rn
7. Install the anchor pocket cover and torque screw to 60-84
in. Ibs. (7-9 Nm).
8. Check cable adjustment; if throttle cable adjustment is too
loose, idle speed might be high and inconsistent. If throttle cable
adjustment is too tight, control effort might be high through the
shifting range.
&.
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Mi rage/eng
it
Safety Related
1-39
ii
42079A
Electrical Cable
&.
IJJ
1. Route instrument harness into lower engine cover. Position harness so it will not interfere with the upper engine cover
when installed. Route harness to a position where the connectors
can be attached at the junction box.
[I]
rn
rn
rn &.
&.
:;j
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&
ii
Safety Related
1-40
M irage eng
NOTES
o
u
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<II
:::::
i:i.
M irage/eng
1-41
FracMilli - Dec.
Meter Equ iv . tional
.1
.15
.2
.25
.3
...
.35
...
.39
.4
.. .
.45
. ..
.5
.. .
...
.55
...
.6
.. .
.. .
.65
.. .
...
.7
...
.75
...
.79
.8
...
...
.85
.. .
.9
.. .
.. .
.95
.. .
.. .
1.0
...
.. .
1.05
. ..
.. .
1.1
1.15
.. .
1.19
1. 2
1.25
1.3
.. .
1.35
. ..
1.4
1.45
1.5
. . .
1.55
1.59
1.6
.. .
1.65
1.7
.. .
.0039
.0059
.0079
.0098
.0118
.0 135
.0138
.0415
.0156
.0157
.0160
.0 177
.Q180
.0197
.0200
.0210
.0217
.0225
.0236
.0240
.0250
.0256
.0260
.0280
.0276
.0292
.0295
.0310
.0312
.0315
.0320
.0330
.0335
.0350
.0354
.0360
.0370
.0374
.0380
.0390
.0394
.0400
.0410
.0413
.0420
.0430
.0433
.0452
.0465
.0469
.0472
.0492
.0512
.0520
.0513
.0550
.0551
.0570
.0591
.0595
.0610
.0625
.0629
.0635
.0649
.0669
.0670
1.75
.. .
1.8
1.85
.. .
1.9
80
.. .
79
'/ 64
...
1.95
1.98
.. .
78
2.0
2.05
77
...
...
76
75
2.1
2.15
74
2.2
2.25
73
72
...
.. .
2.3
2.35
...
71
70
2.38
2.4
.. .
69
2.45
'/ 32
68
...
. ..
2.5
.. .
.. .
67
66
2.6
65
2.7
64
63
2.75
2.78
. ..
. ..
...
62
61
2.8
.. .
.. .
2.9
60
59
.. .
3.0
...
58
57
3/64
56
3.1
3.18
3.2
3.25
...
...
3.3
3.4
.. .
55
54
3.5
., .
3.57
3.6
. ..
3.7
...
53
3.75
'/ '6
..
. ..
3.8
52
...
3.9
.. .
51
3.97
.0689
.0700
.0709
.0728
.0730
.0748
.0760
.0767
.0781
.0785
.0787
.0807
.0810
.0820
.0827
.0846
.0860
.0866
.0855
.0890
.0905
.0925
.0935
.0937
.0945
.0960
.0964
.0980
.0984
.0995
.1015
.1024
.1040
.1063
.1065
.1082
.1094
.1100
.1102
.1110
.1130
.1141
.1160
.1181
.1200
.1220
.1250
.1260
.1279
.1285
.1299
.1 338
.1360
.1378
.1405
.1406
.1417
.1440
.1457
.1470
.1476
. 1495
.1496
.1520
.1535
.1540
.1562
Num- Milli- Dec. Frac- Num- Milli- Dec. FracMeter Equiv . tional
Meter Equiv. tiona I ber
ber
...
50
4.0
.. .
...
49
5/64
4.1
4.2
48
.. .
. ..
4.25
4.3
47
.. .
4.37
., .
46
45
4.4
. ..
4.5
...
44
43
42
3132
...
41
4.6
...
4.7
4.75
4.76
4.8
...
4.9
.. .
. ..
5.0
40
...
5.1
39
38
37
36
7/ 64
.. .
.. .
5.16
. ..
5.2
...
5.25
5.3
...
35
5.4
34
33
5.5
5.56
5.6
32
. ..
31
5.7
5.75
...
.. .
'/ 0
. ..
5.8
5.9
. ..
30
5.95
6.0
...
29
6.1
...
28
9/ 64
. ..
27
26
6.2
6.25
6.3
6.35
6.4
6.5
...
25
6.6
...
24
5/3 2
23
6.7
6.75
6.75
...
. ..
.1 570
.1575
.1590
.1610
.1614
.1654
.1660
.1673
.1693
.1695
.1719 " /64
.1730
.1732
.1770
.1771
.1800
.1811
.1820
.1850
.1870
.1875 3/ '6
.1890
.1910
.1929
.1935
.1960
.1968
.1990
.2008
.2010
.2031 '3/ 64
.2040
.2047
.2055
.2067
.2086
.2090
.2126
.2130
.2165
.2187 7/32
.2205
.2210
.2244
.2263
.2280
.2283
.2323
.2340
.2344 15/64
.2362
.2380
.2401
.2420
.2441
.2460
.2480
.2500 '14
.2520
.2559
.2570
.2598
.2610
.2638
.2657 '7/64
.2657
.2660
22
6.8
6.9
21
20
...
7.0
.. .
7.1
19
. ..
.. .
7.14
7.2
7.25
7.3
17
. ..
18
7.4
16
. ..
15
7.5
7.54
7.6
14
13
.. .
7.7
7.75
7.8
7.9
7.94
8.0
. ..
12
11
10
9
...
...
8.1
8.2
8.25
8.3
8.33
8.4
.. .
6
. ..
8.5
8.6
.. .
4
8.7
8.73
8.75
8.8
.. .
...
8.9
9.0
.. .
9.1
9.13
9.2
9.25
9.3
...
...
9.4
9.5
9.53
...
9.6
9.7
9.75
9.8
D
E
. ..
F
9.9
9.92
10.0
..
.. .
.
.. .
10.32
10.5
.. .
.2677
.2716
.2720
.2756
.2770
.2795
.2811
.2812
.2835
.2854
.2874
.2900
.2913
.2950
.2953
.2968
.2992
.3020
.3031
.3051
.3071
.3110
.3125
.3150
.3160
.3189
.3228
.3230
.3248
.3268
.3281
.3307
.3320
.3346
.3386
.3390
.3425
.3437
.3445
.3465
.3480
.3504
.3543
.3580
.3583
.3594
.3622
.3641
.3661
.3680
.3701
.3740
.3750
.3770
.3780
.3819
.3838
.3858
.3860
.3839
.3906
.3937
.3970
.4040
.4062
.4130
.4134
J
K
9/ 32
...
L
M
19/ 64
. ..
N
5/ ,6
. ..
0
P
2 '/ 64
.. .
Q
R
" 132
. ..
S
T
23/ 64
...
3/ 0
. ..
V
W
25/64
...
X
Y
' 3/32
. ..
10.72 .4219
11 .0
.4330
11.11
.4375
11 .5
.4528
11 .51
.4531
11.91
.4687
.4724
12.0
12.30 .4843
.4921
12.5
12.7
.5000
13.0
.5118
13.10 .5156
13.49 .5312
13.5
.5315
13.89 .5469
14.0
.5512
14.29 .5624
14.5
.5709
14.68 .5781
15.0
.5906
15.08 .5937
15.48 .6094
15.5
.6102
15.88 .6250
16.0
.6299
16.27 .6406
.6496
16.5
16.67 .6562
17.0
.6693
17.06 .6719
17.46 .6875
17.5
.6890
17.86 .7031
18.0
.7087
18.26 .7187
18.5
.7283
18.65 .7344
19.0
.7480
19.05 .7500
19.45 .7656
19.5
.7677
19.84 .7812
20.0
.7874
20.24 .7969
20.5
.8071
20.64 .8125
21 .0
.8268
21 .04 .8218
21.43 .8437
21 .5
.8465
21.83 .8594
.8661
22.0
22.23 .8750
22.5
.8858
22.62 .8906
23.0
.9055
23.02 .9062
23.42 .9219
23.5
.9252
23.81
.9375
24.0
.9449
24.21
.9531
24.5
.9646
24.61
.9687
25.0
.9843
25.03 .9844
25.4
1.0000
27/64
7/' 6
29/ 64
'5/32
3 '/64
'12
33/64
17/32
35/64
9/ ' 6
37/64
' 9132
39/ 64
5fs
4 '/64
2'/ 32
43/ 64
" / '6
45/64
23/ 32
47/6,
%
49/64
25/32
5 '/ 64
'3/' 6
53/ 64
27/32
55/64
7/0
57/64
29/32
59/64
'5/' 6
6'/64
3 '/32
63/6,
DR2949E NG
1-42
Mirage /eng
:;j
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ii
IJJ
INotel
\ \>
1
Installation Instructions
-,1
'j
C03603
PIN
391436
391438
391439
391440
391441
391450
984963
391437
437276
437277
437278
437279
Mirage/eng
Name of Part
Heli-Coillnstaller
Heli-Coillnstaller
Heli-Coillnstaller
Heli-Coillnstaller
Heli-Coillnstaller
Heli-Coillnstaller
Heli-Coillnstaller
Heli-Coillnstaller
Heli-Coillnstaller
He Ii-Coil Installer
Heli-Coillnstaller
Heli-Coillnstaller
Kit,
Kit,
Kit,
Kit,
Kit,
Kit,
Kit,
Kit,
Kit,
Kit,
Kit,
Kit,
8-32
10-24
%-20
5/ 16 -18
%-16
1/2-13
3/4-16
14 mm
M5 x 0.8
M6 x 1.0
M8 x 1.25
M10 x 1.50
1-43
PIN
Name of Part
391448
391447
391446
391445
391444
391449
913412
437948
437949
437280
437950
391443
391442
Heli-Coillnserts, 8-32
Heli-Coillnserts, 10-24
Heli-Coillnserts, %-20
Heli-Coillnserts,5/ 16 -18
Heli-Coillnserts, 3/ 8 -16
Heli-Coillnserts, 1/2- 13
Heli-Coillnserts, 3/4-16
Heli-Coillnserts, M5 x 0.8
Heli-Coillnserts, M6 x 1.0
Heli-Coillnserts , M8 x 1.25
Heli-Coillnserts , M10 x 1.50
Heli-Coillnserts, 14 mm (% in . Reach)
Heli-Coillnserts, 14 mm (1/2 in . Reach)
Fuel System
Table of Contents
General Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description of Fuel System. . . . . . . . . . . . . . . . . . . . . . . . .
In-Line Fuel Filter Servicing . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Primer System Servicing ...... . .............
Boat Fuel System Recommendations .................
Carburetor Servicing .... ...... ................... .
Carburetor Mixture Adjustment. . . . . . . . . . . . . . . . . . . . .
Intake Manifold Servicing. . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Tank and Mixing Unit Servicing . . . . . . . . . . . . . . . . . .
Low Oil Light Test - Tiller Model. . . . . . . . . . . . . . . . . . . .
Maintenance Valve Servicing . . . . . . . . . . . . . . . . . . . . . . .
Fuel System Trouble Check Chart . . . . . . . . . . . . . . . . . . .
2- 2
2- 3
2- 5
2- 6
2- 7
2- 8
2-10
2-12
2-15
2-22
2-23
2-25
2-35
2-36
END
:;j
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Qj
M irage/eng
2-1
c.
E
&
Before working on any part of the fuel system, read the section
called Safety at the end of this manual.
The engine cover is a machinery guard. Use caution when
conducting tests on running engines. Do not wear jewelry or
loose clothing. Keep hair, hands, and clothing away from rotating flywheel.
To avoid accidental starting of engine while servicing, twist and
remove all spark plug leads.
Check nonmetallic fuel system parts for signs of deterioration,
cuts, cracking, or abrasion. Always replace with specified parts.
Do not attempt to run engine with any fuel system component
disconnected or removed. Fuel leakage could contribute to a fire
or explosion.
After completing any service procedure, momentarily pressurize
fuel system and check for leaks! Fuel leakage could contribute to
a fire or explosion.
When using shop air for cleaning or drying parts:
Be sure air supply is regulated to not more than 25 PSI
(172 kPa).
Be sure you use appropriate eye protection to avoid
personal injury.
Replace any locking fastener (locknut or patch screw) if its
locking feature becomes weak. Definite resistance to tightening
must be felt when reusing a locking fastener. If replacement is
indicated, use only authorized replacement or equivalent.
2-2
M irage en
Service Specifications
Special Torque Chart _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
In. Lbs.
N'm
Adhesive
25-35
2,8-4,0
60-84
7-9
17-19
1,9-2,1
24-36
3-4
Primer Solenoid
Screws
Powerhead
84-106
10-12
216-240
25-27
180-204
21-23
180-204
21-23
60-84
7-9
Description
to
Carburetor to Intake
Mounting Screws
Manifold
:;j
><
Qi
ii
Mirage /eng
2-3
PIN
Tool Panel
317002
324891
326623
390954
323716
325043
322698
322697
E
E
E
E
E
E
Description
2-4
Mirage/eng
Fuel Requirements
Minimum Octane
Models
Recommendation
(R+M)/2 "AKI"
"RON"
All
87
69
PCE0020
Preferred Fuel: Any regular unleaded, regular leaded, or premium unleaded gasoline having the
recommended octane rating.
Acceptable Fuel: Any of the above gasolines with up to the following percentage by volume:
10% ETHANOL or
5% METHANOL with 5% cosolvents
Unacceptable Fuel: Do not use any gasoline having more than 10% ETHANOL or more than 5%
METHANOL, even if it contains cosolvents or corrosion inhibitor, regardless of octane rating.
OMC products have been designed to operate using the Preferred Fuel or Acceptable Fuel; however, be
aware of the following:
The boat's fuel system may be different regarding use of alcohol fuels. Refer to boat owner's
manual.
Alcohol attracts and holds moisture which may cause corrosion of metallic parts of the fuel
system.
Alcohol extended fuels can cause engine performance problems.
All parts of the fuel system should be inspected frequently and replaced if signs of
deterioration or fuel leakage are found. Inspect at least annually.
&
conditioner and OMC Carbon Guard fuel additive are the only gasoline additives
recommended by Outboard Marine Corporation. Use of other gasoline additives can result in poor
performance or engine damage.
:;j
><
Qi
Mirage/eng
&
ii
Safety Related
2-5
IJJ
INote I The
2. The carburetors meter the fuel to their individual cylinders. They control engine speed and power output by varying the
intake charge density. To react correctly to a wide range of
operating conditions, the carburetors have multiple fuel mixing
circuits.
rn
[!] Mixture enrichment for cold starting is controlled by
either a choke @ or a fuel primer solenoid @.
4
30393
2-6
Mirage eng
INotel
rn
1. Loosen both clamps and move them away from the fuel
filter.
rn
&. 2. Remove both the inlet@ and outlet fuel hoses from
the filter. Catch any fuel that may leak from the hoses or filter.
Discard the filter.
rn
3. Install a new fuel filter and connect both hoses @ and to
the filter.
rn &. 4. Move the clamps into position to secure the filter.
&.
Mirage/eng
&
Safety Related
2-7
&.
To prevent excessive fuel spillage, disconnect hose connector at motor before disassembly. After servicing, check for leaks
by connecting fuel hose to motor and squeezing primer bulb
until definite resistance is felt in bulb.
2
DR3000
&
Safety Related
2-8
M ir age em;}
Function Test
Mirage eng
2-9
1. Start engine and allow it to reach normal operating temperature. Set engine speed at 2000 RPM.
[IJ
rn OMC
If fluid does not move through the fitting, clean it with
Fuel Nipple Cleaning Tool, PI N 326623.
40684
23655
2-10
MIrage eng
rn
5. To test the solenoid windings, calibrate an ohmmeter on
low ohms scale and connect between the purple/white and black
leads .
Meter should indicate 5.5 1.5 ohms.
6. To test solenoid valve and seat:
[[]
[]]
[]]
rn
7. To inspect or replace internal components, remove the
four solenoid cover screws.
[ [ ] 8. When assembling solenoid, back out screws in their holes
to engage original threads - then, tighten securely.
Installation
COAl138
-@
&.
6
DR3814
30239
DR1417
Mirage/eng
&
Safety Related
2-11
INote I A permanently installed fuel system with excessive restrictions could exceed the fuel pump's pumping capacity and cause
poor engine performance or serious powerhead damage.
To evaluate the restrictiveness of a permanently installed fuel
system, refer to Fuel Pump Servicing, this section.
Recommendations
IT]
2-12
1
DR5980
Mirage/eng
5/ 16
3/8
3/8
in . 1.0. hose
in. 1.0. hose
in. 0.0. copper
:;j
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Mirage/eng
2-13
ii
NOTES
2-14
Mirage eng
Carburetor Servicing
Removal
In.
OJ
:;j
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Qi
Mirage/eng
&
ii
Safety Related
2-15
~"'~ --r--Ft=-t ~
Q
@~
____
~o e ___
#>
(J
(J) ~
1
DR5958
OJ
Disassembly
and gasket
and
2-16
Mirage eng
rn deposits.
Use a clean bristle brush to remove gum or varnish
Blow dry with shop air of not more than 25 PSI (172 kPa) .
When drying passages, direct the flow of shop air
opposite to the direction of fuel flow.
Float Valve Assembly
rn
rn
DR3584
INotel
set.
4
DR5981
Needle Valves
M irage/eng
2-17
Carburetor Body
[IJ
W 4. Check for leaks between emulsion pickup tube and carburetor body:
2
7626
2-18
Mirage eng
3
DR5958
rn
Assembly
INote I Before
4. Check for correct positioning of the float level. The float level
controls the height of fuel in the float chamber and is critical with
regard to carburetor calibration and function.
5. Install the adapter with a new gasket CD onto the carburetor
and secure with two screws. Tighten the screws securely.
Mirage/eng
2-19
OJ Turn
2 THRU 6 H .P.
OJ
DA5982
7. Install the float bowl and bowl gasket. Tighten the screws to a
torque of 17-19 in . Ibs. (1,9-2,1 Nm), following sequence embossed on float chamber.
2
DA5983
2-20
Mirage/eng
Installation
1. Attach the fuel supply hose, and secure with a tie strap
rn
4. Snap the throttle linkage CD into the throttle arm. Check for
a secure attachment.
W
[ [ ] 6. Attach the drain hose to the nipple on the bottom of the air
silencer. Attach the air silencer to the powerhead and secure by
twisting the silencer lock.
:;j
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Mirage/eng
2-21
ii
INotel
[JJ
6. Run the engine in gear near full throttle for one minute. Quickly
reduce speed to SLOW (700-800 RPM) and shift into NEUTRAL.
The engine should continue to run smoothly.
7. If the engine stalls or pops, the mixture is too lean . Turn the
needle counterclockwise 1/ 16 turn. Allow 15 seconds after each
adjustment for the engine to respond. Repeat Step 6 to verify that
the mixture adjustment is correct.
8. If the engine does not respond to adjustments, check it for other
problems. Make sure gasoline is of good quality and mixed with
the proper amount of oil.
2-22
Mirage/eng
1. Remove the two screws per leaf plate assembly, and remove
the leaf plate assemblies as required.
INotel Do not disassemble leaf plate assemblies. Leaf plate
assemblies are not serviced in detail.
rn
40412
surface
must
be
flat,
Mirage/eng
2-23
Assembly
1. Apply OMC Locquic Primer and OMC Ultra Lock to the leaf plate
assembly to manifold screws.
IT]
rn
2-24
Mirage eng
Installation
1. Apply OMC Locquic Primer and OMC Ultra Lock to the eight
intake manifold mounting screws.
rn
2. Remove the retainer from the oil level sender 3-pin
Amphenol connector @. Disconnect the sender leads from the
engine wiring harness.
Mirage/eng
2-25
IT]
&
rn &
6. Cut the tie strap securing the fuel outlet hose to the
mixing unit. Remove the hose from the mixing unit nipple. Catch
any fuel that might leak out.
40555
rn
1. Separate the oil tank from the mixing unit by cutting the
tie strap . Pull the hose off the oil tank nipple. Plug the nipple to
prevent loss of oil.
2. Cut the tie strap and remove the short fuel hose from the inlet
nipple .
[IJ
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&
Safety Related
2-26
ii
Mirage e ng
39990
39992
rn
7. Remove the three screws securing the fitting retainer CD
to the oil inlet housing . Remove the retainer.
[IQ]
ill]
[J1]
[J1] IJ1]
and
a-ring seal @.
INote I Do not attempt to pull the outlet valve out of the housing.
This could damage the seat.
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Mirage/eng
2-27
ii
IT]
12. Remove the two screws securing the fuel outlet fitting
retainer to the oil mixing unit cover. Remove the retainer, fitting,
and O-ring. Discard the O-ring.
13. Pinch the piston seal and roll it off the piston. Discard the
piston seal.
rn
14. Remove six screws @ securing the mixing unit bracket to
the mixing unit. Note the position of the bracket, then remove it.
rn []J
W []] 2.
:;j
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2-28
ii
Mirage,eng
Assembly
rn
1. Position the small spring on the end of the short stub of
the piston and diaphragm assembly @. Place the large spring CD
inside of the diaphragm .
[!Q]
8
39935
[I1]
3. Install the mixing unit bracket and secure with six screws
@. Tighten all eight screws @ and to 5-7 in. Ibs. (0,6-0,8 Nm).
4. Carefully install the oil piston seal into the groove in the oil
piston.
10
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Qi
Mirage/eng
2-29
ii
39995
rn W
rn
[}J
2-30
M irage eng
40012
rn
I1Q] 11. Install the oil CD and fuel Q) inlet fittings. Secure the
fittings with retainer and three screws CD. Tighten the screws to
5-7 in. Ibs. (0,6-0,8 Nm).
[I!J
~ and
large a -ring
[11]
40003
40005
40006
Mirage/eng
2-31
40685
OJ
rn W
&
16. Attach the short fuel inlet hose to the fuel inlet nipple and
secure with a tie strap.
W&
17. Attach the oil outlet hose @to the oil tank nipple and
secure with a tie strap @.
Installation
[]] &
to
2. Apply OMC Locquic Primer and OMC Nut Lock to the oil
mixing unit and lower oil tank mounting bracket screw. Mount the
mixing unit and tank on the engine and secure with mounting
bracket screw @. Tighten the screw to 180-204 in. Ibs. (20,3-23,0
Nm) .
Safety Related
2-32
Mirage/eng
[]] &.
CD
rn
4. Route the oil tank sending unit lead behind the upper oil
tank bracket (h).
rn
5. Apply OMC Locquic Primer and OMC Ultra Lock to the
upper oil tank mounting bracket screw. Secure the tank to the
upper bracket with the screw
Ibs. (24,4-27,1 Nm).
[!Q]
6. Connect the oil tank sending unit lead to the engine wiring
harness and secure with retainer @.
[!Q] [!Il
iW
40544
[TI]
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Mirage/eng
&
Safety Related
2-33
40563
ii
[I]
.~
40564
2
40565
2. Place the sending unit into the oil tank. Let the sending
unit rest on the bottom of the tank.
[]J []J
ITJ 4. Route the oil tank sending unit lead @ behind the upper oil
tank bracket @.
2-34
Mirage/eng
6. Connect the oil tank sending unit lead to the engine wiring
harness and secure with retainer Q).
[1Q]
receptacle~.
:;j
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ii
Mirage/eng
2-35
40596
rn
INote I The old valve core housing must be pulled straight out of
the intake manifold, or the manifold will be damaged.
Installation
rn
2. Thread the valve repair tool half of the way onto the end of
the valve core housing .
[ [ ] 3. Place a small socket over the end of the valve core tool and
drive the valve core housing straight into the intake manifold
until it seats. Remove the valve core tool.
rn
:;j
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ii
2-36
Mirage/eng
500/565cc 25, 3
FUEL SYSTEf
FUEL TANK
AND FILTER
REFER TO
OWNER
MANUAL
REFER TO
PAGES
2-5 THRU 13
REFER TO
PAGE 2-10
REFER TO
SECTION 1
RE
PA
CARBURETOR
FER TO
GE 2-15 THRU 22
REFER TO
PAGE 2-23
Ignition System
Table of Contents
General Safety Warnings ......................... .
Service Specifications ............................ .
About This Section .............................. .
Flywheel Holding Tool ........................... .
Flywheel Servicing .............................. .
Spark Plug Information ........................... .
RPM Limiting Ignition Module ..................... .
General Information - CD Ignition .................. .
Ignition Coil Tests ............................... .
Principles of Operation ........................... .
Ignition Component Servicing ..................... .
Amphenol Connector Servicing .................... .
Packard Connector Servicing ...................... .
Troubleshooting Test Equipment ................... .
QuikStart Electronic Starting ...................... .
SL 0. W Warning System ......................... .
Troubleshooting Sequence Chart ................... .
Output Tests ................................... .
M irage/eng
3-1
3- 2
3- 3
3- 5
3- 6
3- 7
3- 8
3- 9
3- 9
3-10
3-11
3-14
3-16
3-17
3-18
3-19
3-20
3-21
3-22
&
3-2
Mirag e'eng
Service Specifications
Component Specifications
Power Coil
Ignition Coil
Ignition Module
Min . Output Voltage
Primary
Ohms
Secondary
Ohms
Ohms
Ohms
Cranking
Running
0.28 0.05
2300 300
57 5
30
800 80
220
100
240
PCE0074D
In. Lbs.
Description
Spark Plug
Flywheel Nut
84-106
84-106
Stator Screws
Sensor Screws
Encoder Screws
Ft. Lbs.
Nm
Adhesive
18-20
24-27
100-105
136-142
9-12
9-12
9-12
2,7-4,1
2,7-4,1
84-106
24-36
24-36
PCE0050
Mirage/eng
3-3
PIN
Tool Panel
378103
B
E
E
E
E
322699
322698
322697
322696
342228
342226
342225
771311
F
F
Description
3-4
M irag e/eng
M irage/eng
3-5
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Flywheel Servicing
INote I In
&
IT]
INote I Use
Body, PI N 307636
Pressing Screw, PI N 307637
Handle, PIN 307638
@ 3 Screws, PI N 309492
3 Washers, PIN 307639
6. Install the puller on flywheel with body flat side up. Seat the
shoulder screws completely. Hold puller by its handle, and
tighten pressing screw until flywheel releases.
7. Remove the flywheel.
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Mirage/eng
&
Safety Related
3-7
ii
Installation
IT]
INote I After replacing any major ignition component, verify correct maximum spark advance using the procedure outlined in
Section 1.
Encoder Servicing
rn
INotel
Recommended
Extended Idle
OL86C or L86C
OL87YC or L87YC
3-8
Mirage/eng
6200
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ii
Mirage/eng
3-9
1
DRC6004
& To
Secondary
Operating
Resistance
Resistance
Amps (Max)
Analyzer
Polarity
Merc-O- Tronic
Coil
DRC6003
1.5 amps
Magneto C.D.
0.28 0.05
2300 300
Normal
Stevens
PIN 584826
1.1 amps
PCE 0043
Ohmmeter Test
Resistance tests can be performed while the ignition coil is still
mounted to the powerhead.
1. Twist and remove the spark plug and primary leads from the
ignition coil.
DR4081
IT]
rn
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Safety Related
3-10
M irag e/eng
rn
The ignition coil is tested with "normal" polarity connections. Connect tester red lead to the primary terminal @ of the coil
and the tester black lead to the ground tab @. Connect the high
tension lead of the tester to the coil spark plug lead @.
A steady spark, in the tester at or before maximum specified
amperage, indicates a good coil. Refer to Ignition Coil Specifications.
Surface Leakage Test
The ignition coil and spark plug lead should be tested for leakage
and insulation failures using the ignition tester. Leakage is caused
by moisture, cracks, or holes in the coil housing or spark plug
leads.
~~
__________________~~
40852
[ ] ] With the tester's small black and red leads still connected,
remove the tester's high tension lead from the coil. Turn on the
tester and probe entire surface of the coil, spark plug lead, and
spark plug cover. Flash over will be apparent wherever insulation
has broken down. Replace any coil or spark plug lead that shows
leakage.
Principles of Operation
6
40787
Flywheel
[ ] ] The flywheel contains the permanent magnets necessary to
energize the charge coil and power coil. Once the flywheel
exceeds a minimum cranking RPM, the flywheel's magnetic lines
of force passing through the charge coil and power coil windings
produce voltage in those circuits. The charge coil and power coil
magnets are located around the flywheel's inner rim.
[ ] ] An encoder @ is mounted on the inside of the flywheel. The
encoder determines crankshaft position and ignition timing.
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Mirage/eng
3-11
ii
Stator Assembly
S.L.D. W.
TAl
warning system
Ignition Module
rn
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3-12
ii
Mirage eng
Once the S.L.O. W. warning system has activated, the engine must
cool to allow the temperature switch to open or outboard lubricant must be added to the oil tank. The engine must be operated
below 1500 RPM before normal operation can be resumed.
The ignition module also incorporates QuikStart electronic starting, which automatically advances the ignition timing when the
engine temperature is less than 1050 F (41 0 el, and for approximately 7 seconds each time the engine is started, to ensure
reliable starts.
Key Switch
[ ] ] A combination key switch @ and emergency stop switch is
connected to the power pack through the engine wiring harness.
When activated, these switches direct the power pack output to
ground, stopping the ignition system.
Ignition Coil
:;j
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Mirage/eng
3-13
ii
1. Remove flywheel.
IT]
[I]
QNK; Ball
rn
[]] 7. Remove the tan/black no-oil sender lead from the ignition
module 2-pin Amphenol connector using QNK; Pin Removal Tool,
PIN 322698. Remove and disconnect the ignition module 4-pin
Amphenol connector @.
[ ] ] 8. Remove three screws retaining the ignition module.
Remove ignition module ground screw CD, then remove the
module.
:;j
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3-14
ii
Mirage eng
[IQ]
[!1]
[1!]
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Mirage/eng
3-15
ii
42201
INote I The Ampheno/@pin and socket terminals are not the same
size as Deutsch @ pin and socket terminals . You cannot interchange them.
Terminal Removal
rn
OJ 2. Place the plug or receptacle against the edge of a flat
surface with clearance behind connector for terminal to be
pushed out. Push terminal from connector with tool @ or @.
rn rn
3. Pin and socket terminals may be replaced if damaged. Strip 1/4 in. (6 mm) insulation from wire and crimp new
terminal onto wire at point with crimping pliers.
Terminal Installation
[[] m &
&
Safety Related
3-16
Mirage/en g
rn
rn
W 3. Insert a tool , such as the one shown,
connector above the terminal to push the tab down.
W
into the
Terminal Installation
rn
1. The tab on the terminal must extend enough to lock the
terminal in place inside the connector. If the tab isn 't extended,
2
DRC5940
, in . (25 mm )
mmD jl
.090 in . 12.3 mml
mID&,
DRC594 1
4
40324
o
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)(
Qj
~
Mirage/eng
3-17
40332
ii
2804
1942
16489
facturers to support your ignition and electrical system troubleshooting. Manufacturer ordering addresses are on the rear inside
cover of this manual.
OJ
rn
Spark testers:
Stevens No. S21, S13C, or S48
Merc-O- Tronic No. 55-4S or 55-6S
Peak-reading voltmeters:
Merc-O-Tronic No. 781
Stevens No. CD-77
Electro-Specialties No. PRV-1
Ohmmeter capable of reading low and high ranges:
Merc-O- Tronic No. 700 VOA
Stevens No. AT-101
[I]
73158
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3-18
40269
Mirage/eng
ii
Functional Test
1. Install correct test propeller and start engine in test tank. Engine
temperature must be above 1050 F (41 0 C) before proceeding . Stop
the engine.
INotel All engine linkage adjustments must be correct and idle
RPM must be normal before proceeding. Refer to Synchronization and Linkage Adjustments, Section 1.
m
2. Disconnect temperature switch 2-pin
tor.
Amphenol connec-
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Mi rage/eng
3-19
ii
CL for an
[II
No Oil Sender
1. Install correct test propeller. Start engine in test tank and run at
3500 RPM .
rn
2. Using a jumper wire, connect the tan/yellow lead to the
black lead in the 3-pin Ampheno/ connector.
After four seconds, if engine slows to approximately
2500 RPM, check oil level in the oil tank.
After four seconds, if engine does not slow to approximately 2500 RPM, check wiring or replace ignition module.
3-20
M irag e eng
Go To
Step 4
y
Visually Check
Sensor &
Encoder
PCE0004-DR 601 8
Substitute
Sensor,
Check Encoder
Substitute
Ignition
Module
Go To
Step 2
Go To
Step 3
Visually Check
Sensor &
Encoder
No Spark On
Any Cylinder
Substitute
Ignition
Module
Test
Ignition Coil,
Page 3-10
No Spark On
Two Cylinders
Check
Timing
No Spark On
One Cylinder
Go To
Step 6
Check Other
Systems
Good Spark,
Motor Doesn't
Run
Total Output
Test,
Step 1
Good Spark,
High Speed
Misfire
Good Spark,
Motor Runs
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Output Tests
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2. Adjust the gap on the spark tester to 3/8 in. (9 mml. Connect
tester leads to the spark plug leads. Secure tester clip to a clean
engine ground.
\Notel
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&
ii
Safety Related
3-22
Mirage eng
3
DR6490
&
To avoid possible shock hazard, do not handle ignition coil or spark tester during cranking tests.
rn
1. Disconnect the 4-pin Amphenol connector between start button and ignition module.
2. Connect jumper wires between terminals "A", "C", and "0" of the 4-pin connector.
3. Pull the engine over and observe results at spark tester :
If spark now jumps sequentially at each gap, the problem is in the stop circuit. Go to Ohmmeter
Test - Stop Button.
If there is still no spark, go to STEP 3 - POWER COIL TEST.
Elimination Test - Tiller Electric
rn rn
1. Disconnect 4-pin Amphenol connector between start button and key switch , and ignition
module.
2. Connect jumper wires between terminals "A", "C", and "0" of the 4-pin connector.
3. Crank the engine over and observe results at spark tester:
If spark now jumps sequentially at each gap, the problem is in the stop circuit. Go to Ohmmeter
Test - Stop Button and Ohmmeter Test - Key Switch .
If there is still no spark, go to STEP 3 - POWER COIL TEST.
Mirage/eng
&.
Safety Related
3-23
DR6492
[f]
1. Disconnect 4-pin Amphenol connector between key switch and ignition module.
2. Connect jumper wires between terminals "A", "C", and "0" of the 4-pin connector.
3. Crank the engine over and observe results at spark tester:
If spark now jumps sequentially at each gap, the problem is in the stop circuit. Go to Ohmmeter
Test - Key Switch .
If there is no spark, go to STEP 3 - POWER COIL TEST.
:;j
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3-24
ii
Mirage/en g
3
Ohmmeter Test - Stop Button
INotel All ohmmeter tests must be performed with the engine NOT running.
rn
fA
To avoid sudden loss of control, replace the stop button assembly if your test results vary.
:;j
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Mi r age/eng
&
ii
Safety Related
3-25
00
'@
DR6225
INote I All ohmmeter tests must be performed with the engine NOT running.
1. Insta ll the emergency stop switch clip.
2. Disconnect the 4-pin Amphenol connector between the ignition module and key switch.
IT]
3. Calibrate ohmmeter on appropriate scale . Co nnect meter leads between key switch end of 4-pin
connector, terminal "8", and a clean engine ground .
Key OFF, meter must show a low reading.
Key ON, meter must show a high reading.
4. If Step 3 key ON reading is a low one, disconnect harness black/yellow lead from key switch "M"
terminal.
If meter now shows a high reading, replace key switch.
If meter shows a low reading, go to Step 5.
5. Disconnect the key switch 6-pin connector @.
If meter now shows a high reading, repair or replace key switch harness.
If meter shows a low reading, go to Step 6.
6. Disconnect the engine harness to instrument harness 6-pin connector that contains the
black/yellow lead.
If meter now shows a high reading, repair or replace instrument harness.
If meter shows a low reading, repair or replace engine harness.
7. If the engine fails to shut off, test for open black/yellow lead, black/white lead , damaged key switch, or
damaged ignition module.
8. Complete all circuits disconnected during this test.
:;j
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ii
3-26
M irage eng
"pas"
and "500".
3. Connect the meter black lead to a clean engine ground. Alternately connect meter red lead
between the orange and orange/black stator leads. Crank engine and observe meter at each
connection:
Any reading indicates power coil is grounded.
Locate and repair ground, or replace stator assembly.
2. Attach meter black lead to orange/black stator lead . Attach meter red lead to the orange stator
lead.
3. Crank engine and observe meter :
If meter shows 30 volts or higher, go to STEP 4 - CHARGE COil TEST.
If meter shows less than 30 volts, check condition of wiring and connectors.
If wiring and connector condition is good, go to Ohmmeter Test.
Ohmmeter Test
INote I All ohmmeter tests must be performed with engine NOT running.
1. Calibrate ohmmeter on appropriate scale.
2. Connect meter between the orange and orange/black stator leads. Meter must show:
Rope and Electric Start
57 5 Ohms
3. To test for a grounded condition, connect ohmmeter black lead to a clean engine ground. Alternately
connect ohmmeter red lead between the orange and orange/black stator leads:
Any needle movement indicates power coil or leads are grounded.
Locate and repair ground, or replace stator assembly.
4. Complete all circuits disconnected during this test.
:;j
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ii
Mirage/eng
3-27
[IJ
3. Connect the meter black lead to a clean eng ine ground. Alternately connect meter red lead
between the brown and brown/yellow stator leads. Crank engine and observe meter at each
connection:
Any reading indicates charge coil is grounded .
Locate and repair ground, or replace stator assembly.
4. If no reading is indicated in Step 3, go to Output Test.
Output Test
1. Set peak-reading voltmeter to "POS" and "500".
2. Attach meter black lead to brown/yellow stator lead . Attach meter red lead to the brown stator
lead.
Ohmmeter Test
INotel
2. Connect meter between the brown and brown/yellow stator leads. Meter must show:
800 80 Ohms
3. To test for a grounded condition, connect ohmmeter black lead to a clean engine ground. Alternately
connect ohmmeter red lead between the brown and brown/yellow stator leads:
Any needle movement indicates charge coil or leads are grounded.
Locate and repair ground, or replace stator assembly.
E
:;j
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3-28
ii
M irage/eng
DRC6002
In.
1. Prevent accidental starting of engine while testing; twist and remove all spark plug leads.
rn
3. Connect primary lead to Stevens PL-88 load adapter red lead. Connect adapter black lead to a
clean engine ground.
/Notellf Stevens No. PL-88 is not available, you can make an adapter using a 10-ohm, 10-watt resistor,
Radio Shack No. 271-132, or equivalent.
4. Set peak-reading voltmeter to "POS" and "500".
rn
5. Connect meter red lead to adapter red lead, and meter black lead to a clean engine ground.
:;j
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Mirage/eng
&
Safety Related
3-29
ii
DRC6001
IT]
2. Use a clockwise twist to install a Stevens No. TS-77 terminal extender, or equivalent, to ignition
coil primary post.
IT]
INote I Route aII tester leads so they do not interfere with movi ng eng i ne pa rts .
4. Set peak-reading voltmeter to " POS" and " 500" .
IT]
5. Connect meter red lead to terminal extender. Connect meter black lead to a clean engine
ground .
6. Start engine and run under load at RPM where ignition problem exists :
Meter must show 240 volts or higher.
If test shows low output, go to STEP 4 - CHARGE COIL TEST.
If test shows no output, go to STEP 5 - IGNITION MODULE TEST.
7. Remove terminal extender. Install ignition coil primary lead.
3-30
M irage eng
Powerhead
Table of Contents
In.
444444-
2
3
5
6
7
8
4- 8
4-10
4-12
4-16
4-17
4-19
4-27
4-31
4-33
4-36
E
o
u
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Mirage/eng
4- 1
ii
i1
&
4-2
M irag e eng
Service Specifications
Special Torque Chart
Description
CD
CD
In. Lbs.
Ft. Lbs.
N'm
Adhesive
180-204
15-17
20-23
170-190
19-21
Outboard Lubricant
216-240
18-20
24-27
60-84
5-7
7-9
216-240
18-20
24-27
To ensure maximum bearing life, use OMC Rod Cap Alignment Fixture, PIN 396749, with OVIC
Connecting Rod Alignment Jaw Kit, PIN 437273.
Apply OMC
Ultra Lock to the threads. Apply OMC Gel-Seal/l'M underside of washer face.
:;j
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M iragel eng
4-3
ii
PIN
Tool Panel
342223
396749
437273
342218
342220
342219
342221
342217
342222
342225
342226
342658
396748
432128
432130
342657
391008
322697
342664
771311
G
H
H
I
I
H
H
F
F
G
B
A
A
G
A
E
H
Description
Service Aids _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
OVIC
OVIC
OVIC
OIVIC
Cleaning Solvent
Gasket Sealing Compound
Gel Seal and Gasket Remover
Gel-Seal /I
Johnson or Evinrude TC-W3@ Outboard Lubricant
OVIC Moly Lube
OVIC Needle Bearing Assembly Grease
OVIC Locquic Primer
RTV Silicone Rubber Adhesive
OVIC Triple-Guard@ Grease
Wakefield Heat Sink Compound
OVIC Ultra Lock
OVIC Nut Lock
OIVIC Black Neoprene Dip
:;j
><
Qi
4-4
ii
MirageJeng
IT]
The Thermomelt Stik mark will appear dull and chalky when the
surface marked is below the Stik's rated temperature. When the
surface exceeds the Stik's rated temperature, the mark will
appear liquid and glossy.
[IJ
To achieve accurate and consistent readings, engine temperature must be gauged at the top of the thermostat pocket.
Pyrometer Procedure
OR6825
&
Twist and remove spark plug leads before changing propellers to avoid accidental starting of engine.
1. Install correct test propeller and place engine in a test tank.
2. Start engine and run at 3000 RPM for at least five minutes.
[IJ
3. Reduce engine speed and run engine at 900 RPM for five
minutes. At 900 RPM the digital pyrometer or OMC Temperature
Gun should indicate 1400 15 0 F (60 0 r C) when checking the
cylinder head.
39169
If engine temperature is not within this range, troubleshoot cooling system to determine problem .
[IJ
INotel When using the digital pyrometer, you get low or inaccurate readings during these tests, coat the probe location with a
liberal amount of Wakefield Heat Sink Compound, OMC
PIN 322170.
:;j
><
Qi
Mirage/eng
&.
Safety Related
4-5
ii
DR 2523
&. Twist and remove spark plug leads before changing propellers to avoid accidental starting of engine.
1. Install correct test propeller and place engine in a test tank.
2. Start engine and run at 3000 RPM for at least five minutes.
[ ] ] 3. Reduce engine speed and run engine at 900 RPM for five
minutes. Mark the cylinder head with 1250 F (52 0 C) and a 1630 F
(73 0 C) Thermomelt Stik.
4. At 900 RPM, the 1250 F (52 0 C) mark should be liquid and glossy.
The 1630 F (73 0 C) mark should remain dull and chalky.
If the 1250 F (52 0 C) mark does not remain liquid and
glossy, troubleshoot the cooling system for causes of
over cooling .
If the 1630 F (73 0 C) mark becomes liquid and glossy,
troubleshoot the cooling system for causes of overheating.
[ ] ] 5. When the engine speed is increased to 5000 RPM, the 1630
F (73 0 C) mark should remain dull and chalky.
If the mark becomes liquid and glossy, troubleshoot the
cooling system for causes of overheating.
E
:;j
><
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&
Safety Related
4-6
ii
MIrage eng
Testing
Wire
Color
Switch
Closed
Switch
Open
Tan/Blue
240 6 F
(114 4 C)
207 15 F
(97 r C)
White/Black
105 3 F
(41 2 C)
90 3 F
(32 2 C)
Mirage/eng
&
Safety Related
4-7
Powerhead Servicing
Removal - Tiller Models
&.
W
clip
:;j
><
Qi
Safety Related
4-8
ii
M irage eng
rn
10. Tiller Electric Models: Remove the two neutral start
switch wires (yellow/red) from the connector. Make sure to
identify the pin locations (2 and 6) for installation during reassembly.
ITQ]
11. Remove the throttle cable ball socket from the ball on
the throttle lever using OIVIC Ball Socket Remover, PI N 342226.
Remove the clip securing shift rod CD to shift lever. Remove shift
rod from lever.
I1Q]
!II]
15. Remove the screw @j) securing the shift lever to the
engine.
:;j
><
Qi
M irage eng
4-9
ii
[JJ
rn
III &
\Notel Threading the lifting eye screws in too far into the flywheel
39201
rn
19. Remove the seven screws securing the powerhead to
the exhaust housing.
W
&
IIJ
Safety Related
4-10
Mirage:en g
rn
&. 4. Remove the port side lower motor cover enough to cut
the tie strap securing the fuel hose to the fuel connector. Remove
the fuel hose. Use caution as there might be fuel under pressure
in the hose. Catch any fuel in the hose in a suitable container.
[1Q]
I1II 6. Remove the two screws securing the electrical connector cover to the engine. Remove the cover.
[]l]
G1]
:;j
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Qi
Mirage!eng
&
Safety Related
4-11
ii
39201
39203
[IJ fA
INote I Threading the lifting eye screws in too far into the flywheel
will damage components mounted to the underside of the flywheel.
securing
the powerhead to
hose
and three
39273
rn
CD,
:;j
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Qi
Safety Related
4-12
ii
M ir age:en g
[!Q]
[!!]
9. Separate crankcase and cylinder block. It may be necessary to tap on crankshaft with a rawhide or rubber mallet to
. loosen.
[Jl]
:;j
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Miragel en g
4-13
ii
39286
IT]
rn
rn
13. Use one hand to support the piston . Remove the rod cap
screws with your other hand. Remove the piston . Do not allow the
rod to contact the cylinder wall.
39303
[[J
W
W
4-14
39307
M irage en y
fi
o
19. Inspect housing and replace if necessary.
[ ] ] 20. Remove the upper crankshaft bearing and seal assembly.
Remove and discard the a-ring from the assembly.
rn
21 . Support the bearing assembly. Use a punch to remove
the seal. Discard the seal.
[1Q]
[!IJ
[1l]
[11]
:;j
><
Qi
Mirage/eng
4-15
ii
[II
rn
29. Using a tool as drawn on Page 4-6, remove all wrist pin
retaining rings. Discard retaining rings.
rn
30. The wrist pin fit is loose on both sides. Push the wrist pin
through to free the piston from the connecting rod. If necessary,
use OMC Wrist Pin Remover, PI N 342657, to remove the wrist pin.
31. Be careful not to lose any of the 24 needle bearings or the two
wrist pin washers. If any of the bearings are worn or lost, replace
all 24 bearings during reassembly.
[ ] ] 32. Remove the neutral detent retaining ring using a small
screwdriver. Remove the detent ball and spring.
5
40273
Cleaning
INote I Before
40314
INote I To
In
:;j
><
Qi
Safety Related
4-16
ii
Mi rage eny
[I]
&
To avoid person injury, wear eye protection and set compressed air pressure at less than 25 PSI (172 kPa).
1. Before any inspection process can begin, all internal components must be clean and free of excess oil.
2. Make a visual inspection of all internal components. Check for
unusual wear patterns, scuffing or deterioration of aluminum
parts, heat-related discoloration of bearings and bearing surfaces, and broken components.
[]J
[IQ]
:;j
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Qi
Mirage/eng
&
Safety Related
4-17
ii
[f]
ave
6. Use
Cylinder Bore Gauge, PI N 771310, to inspect
each cylinder bore for an out-of-round, oversize, or tapered
condition. Be sure the gauge or micrometer is perfectly square in
the bore when measuring .
rn
7. Measure each cylinder in at least two areas as shown.
Each area should be measured twice. The difference between the
two measurements in each area is the cylinder out-of-round
dimension.
The cylinder must not be out-of-round by more than
0.004 in. (0,10 mml.
rn
8. The dimension
cylinder taper.
39 321
The cylinder taper must not exceed 0.002 in. (0,05 mml.
rn
9. The difference between your measurements and standard
bore dimension is cylinder oversize. Refer to Engine Specifications, Section 1, for dimensions.
The cylinder must not be oversized by more than 0.003
in . (0,08 mml.
L...---L._ _ _ _ _ _ _ _---=~
11. Make the following inspections for new ring sets. Place
each ring, separately, in its respective bore. Use a piston to
square the ring in the cylinder. Use a feeler gauge to measure the
ring end gap.
The ring end gap must be within 0.005 - 0.020 in. (0,130,51 mml.
4-18
Mirage/eng
[ ] ] 13. Inspect center main bearing and split sleeves for excess
wear, nicks, or scratches. Replace if necessary.
[ [ ] 14. Inspect crankshaft rod bearings for excess wear, nicks, or
scratches. Replace if necessary.
Assembly
INotel
Co
2438 1
[ ] ] 1. Install the neutral detent ball and spring into the pocket in
the crankcase. Use OMC Retaining Ring Installer, PI N 342658, to
install the retaining ring.
[ [ ] 2. Oil the end of the crankshaft. Place a new lower main
bearing onto the crankshaft with the lettered side of the bearing
facing away from the crankshaft. Use OMC Crankshaft Bearingl
Sleeve Installer, PIN 342222, to press the bearing onto the
crankshaft until it seats.
[!Q]
:;j
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Qi
ii
Mirage/eng
4-19
1
[JJ
[I]
5. Using external retaining ring pliers, install bearing retain ing ring with sharp edge facing away from bearing .
6. Lubricate the two center main bearings and split sleeves with
outboard lubricant and install them in their original positions. The
split sleeve ring grooves must face away from flywheel when
installed .
rn
39317
INote I It
[l]
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4-20
ii
8
40342
39320
rn
13. Install the upper bearing and seal assembly onto the
crankshaft.
[IQ]
[!!]
[1l]
16. Place the two wrist pin thrust washers on the tool.
INote I The piston and wrist pin have a loosel loose fit.
No tool is
required to install the wrist pin. DO NOT install a wrist pin that will
not easily go into place in the piston. Remove any burrs or carbon
deposits from around the wrist pin bore that could cause difficulty
installing the wrist pin.
2 4902
[1l]
17. Position the piston with the word "UP" on the piston
dome facing up. Oil the wrist pin bore and wrist pin. Install the
connecting rod with the alignment marks or OMC part number
facing up. Install the wrist pin through the piston and connecting
rod, pushing the alignment tool out through the piston.
14
Mi rag e 'eng
4-21
402 79
DR3481
[IJ
INotel Use one the following ring compressor tools for inserting
the pistons into the block:
500
500
565
565
cc
cc
cc
cc
22. Coat pistons, rings, cylinder walls, and ring compressor with
outboard lubricant.
rn
23. Center connecting rod in piston and locate piston rings
on dowel pins. Slide No.1 piston assembly into top cylinder while
guiding connecting rod through cylinder block. Make sure the
word "UP" on the piston dome, is facing toward the flywheel.
24. Repeat Steps 22 and 23 for remaining pistons.
5
DRC5942
:;j
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Qi
4-22
ii
Mlray e eng
I Note Be sure alignment dot on rod cap matches dot on rod and
that both dots face flywheel.
INotel Torquing the screws without OMC Rod Cap Alignment
Fixture, PI N 396749, and OMC Connecting Rod Alignment Jaw
Kit, PI N 437273, or using an incorrect procedure could cause
permanent damage to the connecting rod and crankshaft. To
maintain accurate torque values, keep torque wrench extension
length to a minimum.
[ [ ] 32. Torque the rod cap screws using OMC Rod Cap Aligning
Fixture, PI N 396749, OMC Connecting Rod Alignment Jaw Kit,
PI N 437273, and OMC Rod Screw Torque Socket, PI N 342664.
Align the flat marked "set" on the rod engagem ent stop with the
arrow on the frame. Move the adjustment knob to setting @.
Rotate adjustment knob 180 0 to lock position.
Mirage/eng
4-23
21591
IT]
frame.
rn
34. Tighten the rod cap screws to a torque of 25-30 in. Ibs.
(2-3 Nm) .
35. Apply a light coat of outboard lubricant to the corners of the
connecting rod and rod cap. Place frame on connecting rod using
the following procedure:
rn
[I]
40. Loosen forcing screw and remove the frame . Repeat Steps 36
thru 39 for remaining connecting rods.
4-24
Mirayc eng
40350
[IQ]
INotel OMC Gel-Seal II sealant has a shelf life of at least one year
when stored at room temperature. Test the CIVIC Gel-Seal II
sealant or replace it if the age of the tube cannot be determined.
Using old OMC Gel-Seal /I sealant could cause crankcase air
leaks.
III]
[J]]
[1!]
Mirage/eng
4-25
1
40376
rn
rn
rn
51. Install the throttle/spark lever to the crankcase and
secure with two flat washers and shoulder bolt. Tighten the bolt
to 60-84 in. Ibs. (7-9 Nm).
INote I The larger of the two flat washers must be placed between
the throttle/spark lever and the crankcase.
39278
:;j
><
Qi
ii
4-26
Mirage re ng
m
rn 55. Install one crankcase oiling
recirculating hoses CD to the powerhead.
hose
and three
rn
1. Coat both sides of a new powerhead base gasket with OMC
Gasket Sealing Compound and install it on the exhaust housing.
rn
2. Coat the driveshaft splines Q) with OMC MolV Lube. Do not
apply lubricant to the end of the driveshaft as lubricant here may
prevent seating of driveshaft in crankshaft.
[1QJ &.
INote I Threading the lifting eye screws in too far into the flywheel
will damage components mounted to the underside of the flywheel.
[I!]
[JII
IJl]
M irage/eng
&
Safety Related
4-27
IT]
9. Attach the steering arm to the tiller arm . Secure with two
screws and washers. Tighten the screws to 216-240 in. Ibs. (24-27
Nm) . Thread two locknuts onto the threaded end s to the two
tiller arm screws and tighten to 216-240 in. Ibs. (24-27 Nm).
10. Place the shift and electrical cables in the lower motor
cover grommet and secure in place in the lower motor cover.
[]] In
:;j
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Qi
&
Safety Related
4-28
ii
Mirage eng
&
Mirage1eng
&
Safety Related
4-29
[I]
19. Secure the tiller arm electrical cables (and battery cables
if equipped) to the starboard lower motor cover with a J -clamp
and screw. Tighten the screw to 84-106 in. Ibs. (9-12 Nm).
W&
20. Attach the fuel line to the fitting in the port lower
motor cover. Secure with a tie strap.
rn
21. Install the port lower motor cover and secure with six
screws. Tighten the screws to 84-106 in. Ibs. (9-12 Nm).
rn
22. Position choke cable in the bracket and secure with clip
[ [ ] 23. Attach the drain hose to the nipple on the bottom of the
air silencer. Attach the air silencer to the powerhead and secure
by twisting the silencer lock.
:;j
><
Qi
Safety Related
4-30
Mirage:eng
ii
[]J
[]J
rn
fA 3. Attach OMC lifting Eye, PI N 396748, to the flywheel
and tighten the screws only enough to ensure thread engagement.
INote I Threading the lifting eye screws in too far into the flywheel
will damage components mounted to the underside of the flywheel.
[ [ ] 4. Using a hoist, carefully lower the powerhead onto the
exhaust housing. Secure with seven screws coated with OMC
Gasket Sealing Compound. Tighten the screws to 180-204 in. Ibs.
(20-23 Nm). Remove the lifting eye.
[ ] ] 5. Attach shift arm @ to shift lever shaft and secure with
screw and washer. Tighten the screw to 84-106 in.lbs. (9-12 Nm) .
I1Q]
[!j]
39200
Mirage/eng
&
Safety Related
4-31
8. Place the main engine cables into the motor cover grommet
and install in the starboard lower motor cover. Route the cables
along the side of the cover back to the electrical bracket.
IT]
9. Connect all connectors and secure to the electrical bracket. Connect all ground wires to the ground stud. Secure with nut
tightened to 60-84 in. Ibs. (7-9 Nm) and coat the connection with
OMC Black Neoprene.
10. Install the electrical connector cover and secure with two
screws. Tighten the screws 24-36 in. Ibs. (3-4 Nm).
rn
11. Secure the main engine cable to the starboard lower
motor cover with a J-clamp and screw. Tighten the screw to
84-106 in. Ibs. (9-12 Nm).
[ ] ] 13. Install the port lower motor cover and secure with six
screws. Tighten the screws to 84-106 in. Ibs. (9-12 Nm).
[ ] ] 14. Connect the trim/ti't three bullet connectors and route
out of the way.
15. Attach the drain hose to the nipple on the bottom of the
air silencer. Attach the air silencer to the powerhead and secure
by twisting the silencer lock.
:;j
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Safety Related
4-32
ii
Thermostat Servicing
Disassembly
rn
2. Unscrew the thermostat cover @ from the thermostat
housing @. Remove the relief spring , diaphragm and cup @,
11
40387
[!Q]
12
I1II
[J1] ~
M irage/eng
4-33
40388
IT]
rn
4. Install a new thermostat housing O-ring and cover
O-ring @ onto the thermostat assembly.
W
:;j
><
Qi
4-34
ii
Mi raye en g
NOTES
o
u
:;j
><
Qj
<II
M irage/eng
4-35
:::::
i:i.
Rope Models
:;j
><
Qi
ii
Mirage/eng
Rope Models
Mirage/eng
4-37
DP0097
:;j
><
Qi
ii
Mirage/eng
:;j
><
Qi
ii
Mirage/eng
Remote Models
DP0102
:;j
><
Qi
ii
Mirage/eng
Remote Models
M irage/eng
4-41
Midsection
Table of Contents
&
...
...
...
...
...
...
...
...
.......
.......
.......
.......
.......
.......
.......
.......
.
.
.
.
.
.
.
.
.......
.......
.......
.......
.......
.......
.......
.......
5- 2
5- 3
5- 4
5- 5
5- 7
5-11
5-14
5-21
E
o
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~
M ira ge/eng
5- 1
i::i.
In
5-2
M irage eng
Service Specifications
Special Torque Chart _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Description
Torque
Adhesive
Upper Mount
Lower Mount
PIN
Tool Panel
390767
322699
322697
342226
342225
K
E
E
F
E
Description
Twist-Grip Remover
Socket Removal Tool
Insert Tool
Ball Socket Remover
Ball Socket Installer
orJIC
orJIC
orJIC
orJIC
orJIC
orJIC
orJIC
Locquic Primer
Ultra Lock
Nut Lock
Moly Lube
Gasket Sealing Compound
Triple-Guard@Grease
Black Neoprene Dip
Isopropyl Alcohol
Loctite Depend 300 Adhesive
Mirage.eng
5-3
OJ
6. Check the exhaust housing for distortion. Place the housing on a surface plate. Using a dial indicator, check flatness by
measuring the run-out on the top edge of the housing. The
maximum allowable run-out is 0.009 in. (0,228 mm). If you do not
have access to a dial indicator and surface plate, seek the services
of a machine shop. DO NOT attempt to straighten a distorted
housing; replace it.
INote I A
5-4
M ir ag e eng
11
m
2. Remove the throttle cable ball socket @ from the ball on
the throttle arm using OMC Ball Socket Remover, PI N 342226.
rn
3. Remove the shoulder screw and spacer securing
throttle cable to bracket.
W
[[J
[]
[I]
10. Remove the steering handle screw. Pull the throttle cable
and stop button leads through the grommet in the lower engine
cover.
39083
:;j
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Mirage/eng
&
Safety Related
5-5
ii
Installation
rn
[!]
4. Using OMC Insert Tool, PIN 322697, install the stop button
lead into the plug. Connect the 1-pin Amphenol connector @.
Secure connector in the bracket.
13f4in.
(44mm)-
:J;.;
'=
:;j
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Qi
5-6
Ml ra y e.en g
ii
9
Twist-Grip Throttle Service
Disassembly
rn
1. Using OMC Twist-Grip Throttle Remover, PIN 390767,
depress the grip detents. Tighten screw and remove the grip by
pulling grip and turning the idle adjustment knob
~,
CD
[!Q]
[!1]
clockwise.
[J1]
[lID
12
24288
:;j
><
14
Mirage/eng
5-7
Qi
24286
ii
'~II-
112 In.
(12 mm)
3
[ ] ] 8. Using a punch and mallet, drive the steel pin that retains
the inner handle from the steering handle.
INotel Do not remove the inner handle except to replace it.
Inspection
1. Inspect the throttle cable for kinks and wear. Replace if
necessary.
2. Inspect the steering handle components for wear, cracks, or
damage. Replace parts if necessary.
3. Refer to Ignition System, Section 3, to test stop switch.
.---.a....4.~'-------5
24282
Assembly
1. Install the throttle cable seal in inner handle.
rn
2. If removed, apply Loctite Depend 300 adhesive to inner
handle at areas shown.
3. Install the metal outer handle over the plastic inner handle
and drive the outer handle into place.
[[] W
:;j
><
Qi
5-8
Mirage1eng
ii
8. Push the throttle cable pin through the end of the throttle
cable.
24293
~ [!!]
[!!]
[11] [j]]
12
24291
:;j
><
13
Mirage/eng
5-9
Qi
24288
ii
NOTES
5-10
Mirage eng
rn
3. Move the shift lever to allow access to the shift rod and
bellcrank. Remove the bellcrank clip @.
rn
4. Slide the shift rod off the bellcrank pin @. Make a note
of which way the offset in the shift rod faces for reassembly
(offset to the rear). Remove the shift rod from the exhaust
housing.
rn
5. Remove the screw securing the shift lever to the
bellcrank. Remove the shift lever from the bellcrank.
W
from the
CD from
the exhaust
6
38882
:;j
><
Qi
Mirage eng
5-11
ii
rn
10. Remove the upper and lower motor mounts by prying
them out of the pockets in the exhaust housing with a screwdriver.
rn
12. Remove the upper and lower motor cover seals by
pulling them out of their grooves and off the exhaust housing.
13. Refer to Cleaning and Inspection at the beginning of this
section.
Assembly and Installation
1. Install the upper and lower motor cover seals into their
grooves. No adhesive is required.
[ ] ] 2. Install the two lower motor cover mounts onto their roll
pins. Push them into position until they seat.
5-12
Mirage/eng
[IJ
[1Q]
[!1J
:;j
><
Qi
Mirage/eng
5-13
ii
rn
rn
m
&
clip@.
:;j
><
Qi
&
Safety Related
5-14
ii
Mirage /eng
[1Q]
[II]
[1l]
11. Tilt the swivel bracket into the UP position and lock it in
place. Remove the port and starboard tilt lock pins and locknuts
~.
:;j
><
Qi
M irage/eng
5-15
38939
ii
38940
IT]
13. Carefully remove the tilt tube @ and two thrust washers
from the swivel and stern brackets.
14. Remove the two tilt tube bushings @ from the swivel
bracket.
Assembly
W []] []]
5-16
M irage'eng
5
38941
6
38942
Mirage/eng
5-17
/
0.62 in .
(15,7 mm)
--39044
38944
[]] 6. Install a second locknut on the other end of the tilt tube .
Hold the starboard locknut with a wrench. Tighten the port
locknut to 50-54 ft. Ibs. (68-73 Nm), then back the nut off 1fs to %
turn .
:;j
><
Qi
5-18
ii
Mirage eng
I1Q]
[!1]
[!!I
38960
M irage/eng
5-19
[JJ
14. Apply OMC Nut Lock to the threaded ends of the two
mounting bolts @. Install the two bolts, four flat washers, and two
locknuts in the lower motor mount bracket. Tighten the bolts and
locknuts to 180-204 in . Ibs. (20-23 Nm).
15. Install the exhaust housing as described in this section.
5-20
Mirage eng
Midsection Adjustments
Steering Friction Adjustment
W&
rn
The idle speed knob is located on the steering handle.
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. Motor should idle
at recommended RPM in gear.
Mirage/eng
&
Safety Related
5-21
Gearcase
Table of Contents
General Safety Warnings ......................... .
Service Specifications ............................ .
Water Pump Servicing ........................... .
Service Chart .................................. .
Gearcase Servicing .............................. .
Removal .................................... .
Disassembly ................................. .
Cleaning and Inspection ........................ .
Assembly .................................... .
Installation ................................... .
Trim Tab Adjustment ............................ .
Gearcase Extension Servicing ..................... .
Removal .................................... .
Disassembly ........................... . ..... .
Assembly .................................... .
Installation ............ . ...................... .
6666666-
2
3
5
7
8
8
9
6-12
6-13
6-19
6-20
6-21
6-21
6-22
6-22
6-22
o
u
:;j
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<II
Mirage/eng
6-1
:::::
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6-2
Mirage /eng
ii
Service Specifications
Special Torque Chart
Torque
Adhesive
48-84 in . Ibs.
(5-9 Nm)
Description
PIN
331045
391257
330067
330068
327693
335820
321428
335821
319929
304515
322923
326552
328081
383175
318122
Mirage/eng
Tool Panel
B
C
C
C
N
P
o
P
o
N
o
o
N
Q
Description
6-3
Adhesive M
Gasket Sealing Compound
Ultra-HPF'MGearcase Lube
Moly Lube
Nut Lock
Triple-Guard@Grease
Needle Bearing Assembly Grease
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6-4
Mirage /eng
ii
[I]
rn
1. ail and install the shift rod bushing into the impeller
housing.
[[J
2. Apply OIVIC Triple-Guard grease to the two impeller housing a-rings. Install the small, thick shift rod a-ring @. Place the
large a-ring into the impeller housing .
4. Lightly coat the impeller cup with oil. Install the impeller
into the impeller cup with a counterclockwise rotation. Sharp
edge of cam slot in the impeller is leading edge during rotation.
CD
Mirage/eng
6-5
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21062
ii
1
38644
IJJ
8. Align drive cam flat with groove of the impeller. Install the
impeller drive cam.
rn driveshaft
Sharp edge of the cam is leading edge during
rotation @. Slide the impeller housing down
38630
INote I Verify that the impeller engages the impeller cam properly.
Serious powerhead damage will result if impeller cam is displaced.
12. Turn the driveshaft until holes ofthe impeller housing are
aligned with holes of the gearcase. Place the washers on the six
impeller housing screws. Apply avIC Gasket Sealing Compound
to the threads of the screws. Install and tighten the screws to
60-84 in . Ibs. (7-9 Nm).
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6-6
Mirageieng
ii
Service Chart
CD
/
~
~~
('J1JII(j .-
CD
/
192-216in.lbs.~/~
2 /i
~I----====f"
~
(!!j
(22-25 Nom)
, w~
I
I
'~(g~
...,.~
0'
if,
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DRC5745
Mirage/eng
6-7
C.
Gearcase Servicing
Removal
In.
2. Mark the trim tab position for reference, then remove the trim
tab. Remove the propeller from the gearcase. Inspect the condi tion of t he propeller hub.
[]J
[]J
INotel Remove any paint from the upper shift rod before disassembling the shift rod connectors.
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Safety Related
6-8
ii
Mirage.' eng
Disassembly
[IJ
rn
PI N 307636 Body
PI N 307637 Pressing Screw
Q) 2 Screws, %-20 X 6 in. (obtain locally)
PIN 307639 Flat Washers
PI N 307638 Handle
CD
I1Q]
In.
7. Remove the retainer plate and reverse gear thrust washer from
gearcase.
[1IJ
8. Unthread the lower shift rod from the shifter yoke and
remove the shift rod from the gearcase. Remove and discard
lower plastic keeper ~, then remove the nut @.
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Mirage/eng
&
Safety Related
6-9
ii
IT]
rn
10. Remove the shifter lever pivot pin. Discard the pivot pin
O-ring.
rn
11. Remove the propeller shaft and reverse gear components from the gearcase.
INotel
Shifter detent balls and spring will pop out of the clutch
dog when the propeller shaft is removed.
[]J
13. Use long-nose pliers to remove the clutch dog and shifter
lever assembly. Use no force . Tilting the shifter lever slightly will
allow you to remove it from the gearcase.
6-10
Mirage eng
[I]
[ ] ] 16. Use OMC Puller Bridge, PIN 432127, and OMC Small
Puller, PI N 432131, to remove the driveshaft seals from the
gearcase.
2 1789
and bearing
sleeve from the gearcase using the same two tools. Discard the
bearing.
ITQ]
CD
Place the tool in the gearcase. Using a mallet, drive the pinion
bearings into the gearcase propeller shaft cavity. Discard the
bearings.
[I!]
@~~CD
~.-@
10
~-
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Mirage/eng
6-11
Qi
DR1505
ii
IJJ 21.
21795
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Safety Related
6-12
Mira ge e ng
DR2061
Assembly
INotel
rn
rn
2. Oil and install a new bearing in the forward end of the
bearing housing using OMC Bearing Installer, PIN 321428. Press
against the lettered side of the bearing until the tool is seated on
the bearing housing.
rn
[]J
6. Coat the shift rod a-ring with OMC Triple-Guard grease and
install in shift rod bushing.
[ ] ] 7. Apply OMC Gasket Sealing Compound to the outside
diameter of the bushing. Install the bushing and washer @ using
OMC Shift Rod Bushing Installer, PI N 304515.
7
COA3319
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Mirage/eng
6-13
ii
@.:
@ .
@ ..
DR2088
IT]
8. Install the pinion bearings using the following components of OMC Universal Pinion Bearing Remover and Installer,
PIN 391257, and two tool spacers:
4
DR2061
IT]
IT]
@.
IT]
must
DR2062
rn
rn 9. Oil and install a new driveshaft bearing CD in the
bearing sleeve Q) using OMC Bearing Installer, PI N 322923. Press
against the lettered side of the bearing until the tool is seated on
the bearing sleeve. Using the same tool attached to OMC Plate,
PIN 318122, press the bearing sleeve assembly into the gearcase
until the plate contacts the gearcase. Press against the lettered
side of the bearing when installing it into the gearcase.
W []]
COA3216
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6-14
ii
Mirage eng
7 8 9
DR5939
COA3290
L . . . - - - - L - - - - - - --
----;:C""OS;:::"30==
57=-'
rn
12. Assemble the small pinion thrust washer ~ with the
inside chamfered diameter facing the pinion, onto the pinion . Oil
and install the thrust bearing @. Install the large thrust washer @
with chamfered outside edge facing up.
[ ] ] 13. Using a right angled rod , install the pinion assembly in
the gearcase.
[ ] ] 14. Place the forward gear into the gearcase.
[IQJ
[!!]
16. Install the shifter cradle and clutch dog in the gearcase
using long-nose pliers.
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Mirage/eng
6-15
ii
1
26727
26728
11 Wear safety glasses for eye protection. Detent balls can pop
out with great force.
OJ
19. Insert one detent ball, then the spring, then the other
detent ball. Push down on the ball and slide the tool back until you
feel the ball slip into the detent.
22. Slide the reverse gear down the propeller shaft and into
the gearcase.
23. Coat the reverse gear bushing with oil. Slide the bushing
down the propeller shaft, seating the bushing into the reverse
gear.
25. Engage the shifter yoke hook onto the shifting lever
clevis pin in bottom of the gearcase cavity.
&
Safety Related
6-16
M ir age/eng
[ ] ] 26. Install a new plastic keeper and the lower shift rod nut
@ onto the lower shift rod @. Apply OMC Triple-Guard grease to
threads of lower shift rod. Install the shift rod into gearcase
through the water intake opening and engage the shifter yoke.
Thread the shift rod into the shifter yoke until the rod bottoms in
the yoke.
[ ] ] 27. Slide the retainer plate down the propeller shaft and into
the gearcase with tab facing down.
rn &
I1Q]
COA3240
into the
[11]
30. Stick the reverse gear thrust washer to the back side of
the propeller shaft bearing housing with OMC Needle Bearing
Assembly Grease.
COA3309
[]1]
COA3241
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Mirage /eng
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Safety Related
6-17
ii
[I]
rn
33. Place new O-rings on the bearing housing retaining
screws. Apply OMC Gasket Sealing Compound to the O-rings and
threads of the screws.
34. Install one screw in the bearing housing. Remove the guide
pin and install the second screw. Tighten the screws to a torque of
60-84 in. Ibs. (7-9 Nm).
6-18
Mirage/eng
37. Fill the gearcase with 9-11 fl. oz. (264-330 ml) lubricant as
follows:
Secure the gearcase in an upright position.
Remove the oil level and oil fill /drain plugs. Replace the
seals if damaged.
Fill the gearcase with OIVIC Ultra-HPF gearcase lube until
lubricant appears at the oil level hole. Insert the oil level
plug first. Install the fill /drain plug. Tighten the oil level
and fill/drain plugs to 84-86 in. Ibs. (9-10 Nm).
Inspect the gearcase oil level after the motor test has
been performed.
38. Install water pump assembly as described in Water Pump
Servicing, this section.
Installation
1. Coat the driveshaft splines with OIVIC Moly Lube. Do not coat
top surface of the driveshaft as the lubricant here may prevent
seating of the driveshaft in the crankshaft. Coat upper shift rod
with OIVIC Triple-Guard grease.
2. Temporarily install the upper shift rod connector on the
gearcase lower shift rod. Installation of the gearcase will not
allow the upper shift rod connector to be installed at a later time.
3. Install the gearcase onto the exhaust housing. See that the
driveshaft engages the crankshaft. Rotate the flywheel, if necessary.
I}]
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M irage/eng
6-19
IT]
6. Move the shift lever until the upper shift rod engages the
lower shift rod connector. While holding the lower shift rod
connector, tighten the upper shift rod connector securely.
&.
Important A single trim tab adjustment will relieve steering effort under only one set of speed, motor angle, and load
conditions. No single adjustment can relieve steering effort under
all speed, motor angle, and load conditions.
If the boat pulls to the left or right when its load is evenly
distributed, adjust the trim tab as follows:
&
Safety Related
6-20
Mirag e/eng
With the motor shut OFF, loosen the trim tab screw@. If
the boat pulled to the right, move the rear of the trim tab
slightly to the right. If the boat pulled to the left, move the
rear of the trim tab slightly to the left .
Tighten the trim tab screw to 60-84 in. Ibs. (7-9 Nm) .
Test the boat and, if needed, repeat the procedure until
steering effort is as equal as possible.
High motor installations - The trim tab might be above the water
when the motor is trimmed out. Steering effort might increase.
Steering effort will be reduced if you trim the motor in and
submerge the trim tab.
Dual motors - Move both trim tabs equally and in the same
direction.
&
[]
rn
4. Remove and discard the upper plastic keeper . Remove
the upper connector @.
[]J
Mirage/eng
&
Safety Related
6-21
38648
from
the spacer.
Assembly
rn
1. Install the spacer @ onto the extension. No sealer is
required.
[ ] ] [ ] ] 2. Apply CIVIC Adhesive M to the groove on the underside of the grommet . Install the grommet on top of the spacer
@.
Installation
IT]
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6-22
Mirage/e n g
OJ
rn
5. Apply OMC Gasket Sealing Compound to two of the long
gearcase extension screws. Install these screws into the two
middle screw holes of the gearcase before the gearcase is
installed. Their length will not allow access past the anti-ventilation plate once the gearcase is installed. Install the gearcase onto
the extension. See that the driveshaft engages the crankshaft.
Rotate the flywheel, if necessary.
[IQ]
7. Slide the upper connector half CD onto the upper shift rod
lI!1
8. Move the shift lever until the upper shift rod engages the
lower shift rod connector. While holding the lower shift rod
connector, tighten the upper shift rod connector securely.
[1!]
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Mirage/eng
6-23
ii
Manual Starter
Table of Contents
General Safety Warnings ....... . ......... . .........
Service Specifications ..............................
Starter Servicing .................................
Removal ......................................
Rope Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly ...................................
Cleaning and Inspection ............... . ..........
Assembly ......................................
Installation ....................................
7-2
7-3
7-4
7-4
7-4
7-5
7-5
7-6
7-7
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Mirage/eng
7-1
/1
7-2
M irage/eng
Service Specifications
Special Torque Chart _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Description
In. Lbs.
Ft. Lbs.
N'm
60-84
5-7
7-9
120-145
10-12
14-16
PCE0070
PIN
Tool Panel
342682
Description
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Mirage/eng
7-3
ii
-L
III
..
46664
Starter Servicing
m Important
Use
PIN 342682, is required.
of
Starter
Spring
Installer
Kit,
Removal
&
W
W
from engine
4. Remove
powerhead.
link from
lockout cam.
Rope Replacement
46681
[[] 1. Pull rope out completely and retain pulley in position with
stop tool (Kit, PI N 342682).
2. Remove rope from pulley channel, untie knot and remove rope
from starter assembly.
[]] 3. Remove rope from anchor and replace with new rope.
Cut new rope 59 in. (150 cm) long. Fuse 1/2 in. (12 mm) of both
ends.
6
37454
5. Hold rope taut and pull stop tool out. Allow rope to slowly wind
into starter.
&
Safety Related
7-4
Mirage/eng
Disassembly
& Wear
[!Q] &
&
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Mirage/eng
&
Safety Related
7-5
ii
Assembly
& Wear
IT]
rn
4. Pull lightly on spring to eliminate slack and turn pulley
counterclockwise with handle (Kit, PI N 342682) until spring hook
engages pulley hub slot.
5. Turn pulley counterclockwise to pull spring all the way into
housing .
6. Allow pulley to slowly unwind until tension is relieved.
8. Route rope through housing into pulley. Tie knot in rope and
place in channel.
[ ] ] 9. Hold rope taut and pull stop tool out. Allow rope to slowly
wind into starter.
Safety Related
7-6
M irage/eng
!!
10. Remove nut and pulley retainer from mandrel and remove
starter assembly.
[1J
[]J
12. Install pawl, linkage, and retaining ring (sharp edge up).
[!Q]
cam.
[II]
11 4.
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Mirage/eng
&
Safety Related
7-7
ii
Electrical System
Table of Contents
In.
8- 2
8- 3
8- 4
8- 6
8- 7
8- 8
8- 8
8- 9
8-16
8-17
8-18
8-19
8-20
8-23
8-24
8-26
Mirage/eng
8-1
In.
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8-2
Mirage!eng
ii
Service Specifications
Special Torque Chart _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
In. Lbs.
Ft. Lbs.
Nm
Adhesive
100-105
136-142
OMC Gasket
Sealing Compound
84-106
9-12
Rectifier/Regulator to Cylinder
Block Screws
60-84
7-9
15-17
20-23
Description
Flywheel Nut
Voltage
Amps
(Maximum)
RPM
12 - 12.4
30
6500 - 7500
12 Amp
0.45 - 0.54
OMC
OMC
OMC
OMC
OMC
OMC
OMC
OMC
Electrical Grease
Black Neoprene Dip
Starter Pinion Lube
Locquic Primer
Triple-Guard@Grease
Screw Lock
Nut Lock
Wheel Bearing Grease
PIN
Tool Panel
342667
322696
F
E
Mirage/eng
Description
Connector Tool
Crimping Pliers
8-3
Step
II Check voltage
and
Procedure
between ground
CD.
In
iii -
Steps
thru
Remove
starter to solenoid cable from
to prevent starter engagement while making checks.
0.
Result
0. Turn
key to
iii.
between ground
and@.
between ground
and@.
II.
II Check voltage
II.
II Check voltage
fJ.
key
OFF before connecting and
disconnecting meter. Turn key
to START position after connecting.
a. If no reading, go to Step
Ell.
IJ.
PCE0054
Safety Related
8-4
Mirage eng
between ground
and (]).
a. If no reading, solenoid is
faulty.
b. If solenoid clicks and meter
reads battery voltage, go to
Step
II.
II Check voltage
and@.
between ground
DR C6 169
M irage eng
8-5
&
Clean and retighten, or replace, any connection, cable, or component having greater than specified voltage drop.
[}] 1. Connect voltmeter positive 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 volt.
INotel
rn
2. Connect voltmeter negative lead to the starter side of the
starter solenoid terminal. While cranking engine, connect voltmeter positive lead to starter solenoid opposite terminal. Voltage
reading should not exceed 0.2 volt. Remove voltmeter positive
lead from starter solenoid and stop cranking engine.
DR4030
&
Safety Related
8-6
Mirage eng
8-7
Solenoid Tests
INotel
II]
II]
3. After installing the solenoid, coat all wires and terminals with
INotel
rn
rn
5. Monitor the starter RPM and current draw and refer to the chart
below for the correct specifications.
No Load Current Draw Specifications
Voltage
Amps
(Maximum)
RPM
12 - 12.4
30
6500 - 7500
E
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8-8
ii
Mirage/eng
INotel
rn
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on
[!]
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rn
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Mirage/eng
8-9
ii
40092
Disassembly
W
W
rn
3. Check the end cap and brush holder cap orientation marks
for reassembly reference. If there are no marks, make some.
Remove the two thru bolts @.
8-10
M ir age eng
o
9
40111
40112
rn
7. Remove retaining ring securing starter Bendix components to shaft using modified needle-nose pliers found in the
Powerhead section.
10
ITQ]
2. Clean the commutator with 300-grade emery cloth. If commutator surface is unevenly worn or pitted, turn it on a lathe. Remove
any trace of oil or metal dust from commutator.
[IT]
M irage/eng
8-11
_ _L -_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
~~
5. If the pinion does not properly engage the flywheel, the pinion
and shaft may be worn, distorted, or dirty.
6. Inspect and replace end cap thrust washer if distorted or worn
excessively.
[]J
6. Install the plastic cover onto the armature shaft. Push the
cover until it snaps into place.
ave
Screw
7
8-12
40124
M ir age eng
8
401 2 7
INote I Incorrect
40 128
[lID
11. Align marks Q) and and place brush holder cap firmly
on armature and slide putty knife out, making sure the brushes
are retained properly.
ITIJ
12. Apply OMC Locquic Primer and OMC Screw Lock to the
threaded portion, and install the two thru bolts. Tighten to 50-60
in . Ibs. (5,6-9 Nm).
lm [11]
13
4 01 2 0
M irage/eng
8-13
Installation
1. Apply ONIC Locquic Primer and OMC Nut Lock to the threads of
the two starter mounting screws.
IT]
rn
rn
7. Connect positive battery cable to large solenoid terminal. Tighten nut securely. Position protective cover over the
connection.
8-14
M irage eng
NOTES
Mirage/eng
8-15
[I]
1
=::-'
0...-___'_ _ _ _ _ _ _ _ _ _
rn
rn
The rectifier/regulator changes the stator's alternating current to the direct current used to charge the engine's battery and
support the boat's electrical system. The unit also provides full
wave regulation of the charging system. An additional circuit,
represented by the gray lead, provides a tachometer signal for the
Quartach @and 7K tachometers.
8-16
Mirage/eng
Where to Look
Battery
Procedure
Cause
1. Battery defective or worn out
2. Low electrolyte level
3. Terminal connections loose
or corroded
4. Excessive electrical load
Wiring
Alternator stator
Rectifier
Reference
OMC
Accessories
Service
Manual
1. Connections loose or
corroded
2. Stator leads shorted or
grounded
3. Circuit wiring grounded
1. Inoperative rectifier/regulator
2. Page
8-19
3. Page
8-19
1. Page
8-19
2. Page
8-18
3. Page
8-19
1. Page
8-20
PCE0089
Mirage/eng
8-17
12 AMP
14
12
10
",
/
/
-""'"
1000
2000
3000
4000
5000
6000
1
DRC5871
INote I Disconnect
check.
1. Disconnect the rectifier red lead.
2. Wire a 0-40 amp ammeter in series with the rectifier red lead
and the wiring harness red lead .
&.
[IJ
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Safety Related
8-18
Mi r age 'eng
ii
3
DR5882
DR5883
IT]
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Mirage/eng
8-19
ii
Rectifier/Regulator Tests
Variable Load Tests
To test the operation of the rectifier/regulator, you must be able to
run the engine continuously at approximately 4500 RPM, such as
in a test tank or on a marine dynamometer.
The test consists of monitoring the system's response to a
partially discharged battery. Two methods for performing this
test are described below.
Variable Load High Rate Discharge Method
INote I The
IJJ
IJJ 4.
11 Excessive
rn
rn
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Safety Related
8-20
MlfayC e n g
ii
Stator
Rectifier/Regulator Assembly
Red Wire
@ Ammeter (0-40)
Jumper Wire
Starter Solenoid
@ Red Battery Cable
Carbon Pile
---
I
+
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DRC6337
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i:i.
8-21
INotel
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8-22
ii
Mirage eng
1
DR5882
DR5883
[JJ
n.
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Mirag e eng
8-23
ii
INote I The tachometer circuit is driven by the stator output. Before proceeding, check condition of the
stator following Stator Resistance Tests, this section.
Important
Verify that all engine and boat wiring and connectors are in good condition.
and
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ii
8-24
Mirage/eng
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DRC6296
M irage/eng
8-25
Qi
III
:::::
ii
Rectifier/Regulator Service
Removal
[IJ
@.
rn
, purple ,
rn
4. Remove the two screws retaining the rectifier/regulator
to the cylinder block.
Installation
:;j
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8-26
ii
Mirage eng
Safety Section
Table of Contents
Part A Marine Products and the Safety of
People Who Use Them . . . . . . . . . . . . . . . . . . . . .
Outboard Shift System and Persons Safety. . . . . . . . . . . .
Outboard Speed Control System and Persons Safety ....
Outboard Steering System and Persons Safety. . . . . . . . .
Outboard Fuel, Electrical System and Persons Safety . . . .
Outboard Mounting System and Persons Safety. . . . . . . .
Outboard Hydraulic Tilt/Trim Shock Absorption
System and Persons Safety . . . . . . . . . . . . . . . . .
Outboard Emergency Stop System and
Persons Safety . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part B Marine Products and the Safety of
People Who Fix Them. . . . . . . . . . . . . . . . . . . . . .
Handling Lead/Acid Batteries .......................
Gasoline! Handle With Care ........................
Hazardous Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S-1
S- 2
S- 3
S- 4
S- 5
S- 7
S-10
S-12
S-13
S-16
S-19
S-20
S-21
Rig Boats
Fix Machinery
Maintain Equipment
.... to Keep the products safe and reliable.
This section talks about safe boating and how You can help make it safe. Some items you may know .....
but others you may not.
First!
A word about parts ..... Plain parts ..... Special parts . .... AU. parts!
DO NOT SUBSTITUTE PARTS
"They look the same, but . .... are they the same?
Same Size?
Same Strength?
Same Material?
Same Type?
Don't Substitute unless You Know they are the Same in ~ characteristics.
Second!
Special Locking bolts and nuts are often used to hold steering, shift, and throttle remote control
cables to the motor .
When you take any motor off a boat, Keep Track of Special Nuts and Bolts. Don't mix with other
parts.
When motor is returned to boat, Use Only the Special Nuts and Bolts to hold remote Steering,
Shift, and Throttle cables to the motor.
S-2
If .....
Forward
or
Reverse
Reverse
when
Rigging
or after
Servicing
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i:i.
S-3
and ends
here on the
powerhead.
when
Rigging
or after
Servicing
&"
closely.
S-4
I f steering system comes apart, boat might tu rn suddenly and circle ..... persons thrown into water
could be hit.
5-5
When
Rigging
or after
Servicing
&"
When Transom Mounted steering systems (see picture) are used, check to uncover possible Trouble!
During this procedure, steering parts
transom
mounted
steerer
"
"
'. '
- - /"
~
stop
~...---~
to
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5 -6
ii
When not boating, fuel leaking in car trunk or van, or a place where portable tank is stored
(basement, cottage) could be ignited by any open flame or spark (furnace pilot light, etc.).
When boating, fuel leaking under the motor cover could be ignited by a damaged or deteriorated
electrical part or loose wire connection making stray sparks.
Do not substitute fuel or electrical system parts with other parts which may look the same.
Someelectrical parts, like starter motors, are of special design to prevent stray sparks outside
their cases.
Replace wires, sleeves, boots which are cracked or torn or look in poor condition.
&"
closely.
And remember
~I
'?
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S-7
ii
After Repair on any part of the fuel system, pressure test engine portion of fuel system as shown:
(See Section 2 for testing the fuel tank portion.)
Squeeze
till bulb feels
hard
~::::::iiiiiiiii~~~\ /
I~~I
When Storing:
Whenever possible,
... remove Hose from
motor And from tank .
. . . . . and store arou nd
ears of tank.
When Running:
So make sure Silencer and all its Gaskets are on motor And Drain Hose is in place.
Air silencer mounting Screws are special lock screws. Use only the special Screws.
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5-8
ii
If electrical parts are replaced or even removed from the motor, check the following:
Wire and High Voltage Lead Routing
Spark Plugs
40764
All Connections
clean
Tight
(Prevents sparks)
Electrical Cable
S-9
Not rubbing
on sharp objects .....
enough slack to allow full
turning without pull loads
on cable (Prevents Sparks)
Secure in approved
battery box or battery tray.
Battery terminals insulated.
No strain on cables.
E
0
..:
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Qi
III
:::::
ii
~-...:.----
What's Important?
Motor must stay in position on boat's transom
SL . . . I .. . 0 . . . E
on transom
Motor may
Motor may
and be hard
to steer.
... .or boat's transom could break away.
_-_:_-_-_-~_-_-_-_~-_--_-~"~~+---jl--m-in;l
&
"closely .. . ..
S -1 0
50
..... use
[]
Only .....
~------'
~)-
Or Smaller!
When Rigging or
Fixing any boat ....
if transom looks
Weak, tell the
owner .... .
If transom is Curved,
motor may come
Loose .....
/ /
Flat
.&_---..
-..~
~~~
-: . "":" . : -::.:...
- - ::- .- -.-
~v~~
,c ~J v~~~~
r~
~ ",
~
.r.--__
~/I~
i/
,',
1../
slow, heavy squash
to motor .....
~~
l
\1 weakened, parts could fail later . . . . . on the water
. . . . . when not expected.
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S-11
ii
Shock Absorption system must always be ready to Absorb some Blows to the lower parts of the
motor.
Without Shock protection,a Blow like this could cause serious damage to the motor and injury to boat
occupants from the motor or its parts entering the boat ... . or Transom could break away .... Motor
may be lost overboard,
.... and Boat may .. .. S
n
&"
closely.
Trimming "I n" too Far can
happen when Angle Adjusting Rod
isn 't in the Right hole ... Or
is Not in Any H~ . (Lost)
S- 12
,----,.",,~~~
What's Most Important?
The Emergency System .....
must STOP the engine when the emergency stop switch's cap is pulled from switch .
Ifswitchfails .. .. .
S-13
~--- ...........
/'"
1/
t"
\
"-
"-... ~ ,~
~- ~
pUlled~
,.-.
~-
When
Rigging or
after
Servicing
&
closely.
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S- 14
ii
Summing Up
Now You know some things that can take the Joy out of enjoyable boating .
No doubt about it ... . . It Takes Time!
& ",
S-15
~ Fixing Things
Rigging Boats
~ Trouble Shooting Problems
Handling Motors
When Lifting Motors
Some motors have a fixed lift bracket bolted to the powerhead. Because motor will want to
"'"
Center of gravity-.........;;.,.
If motor does not have fixed lift bracket and you use Universal Puller
(378103) and Lifting Eye (321537) or
Lifting Eye and Adapter Assembly
(396748) .... use only the special hardened screws and washers from the
set.
. .... use only the special
hardened screws and washers
from the set.
. .. Regular screws aren't
strong enough. Screws
may Break and motor
may drop suddenly.
Make sure Shop Aids have Extra Capacity .. . . ... ... and keep them in Good Repair!
S- 16
Motor Cover is a Guard. When you remove Cover/Guard to work on motor remember .....
Loose Clothing (open shirt sleeves, neckties) ..... Long hair .... .
Jewelry (rings, watches, bracelets) . . .. . Hands and arms .... .
Two People working together on a Live Motor must Look Out for each other.
Never, Ever, hit the Key to Start Motor Before signaling your Partner. He may
be leaning over the motor with hands on flywheel .. . . or a "hot" electrical part ..... or
near the propeller.
~ Off-Season Storage
Fogging (oiling)
of motor
~ Removing propeller
with a powered tool
Always .... .
Turn Key Switch "Off"
NO SPARK
Shift to
Neutral
Twist and remove ALL
spark plug leads
NO START
S-17
,~ -.
~Sprayed
'~~
:~ ' .\~IJ-\
,
'
Cleaners,
Paints
~Grinding
" .
\
'(
~Acid
~Chiseling
(Steel on Steel)
(Tip: Use Plastic or Brass type Hammers.
They don't chip off as easily as steel hammer.)
C-~
~ Ends of Cables
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S-18
ii
~ If spilled or splashed on
Any part of Body .....
No Smoking
No Flames
No Sparks
After Charging
( 1) Shut Off charger
You're sure to
make Sparks and
serious Burns are possible.
S-19
1 Part
Gasoline
20 Parts
Air
By
Volume
!GAS
FUMES
Always store gasoline outside in a safety can (flame arrester and pressure relief valve in pour spout).
Fill portable tanks outside of boat. Spillage will collect in bottom of boat.
Use fuel for Fuel ..... Not for a cleaner, degreaser
If Fumes are Smelled in shop, basement or garage, Immediately .. . ..
~ Put Out open flames, cigarettes, sparking devices
~ Wipe up spill or leak.
~ Get towels, rags Outside Fast
~ Open doors or windows
~ Check Lowest area for fumes.
Know Items I n and Around repair area which can Ignite gasoline fumes ..... Control
them if fumes are smelled.
~
~
~
~
~????????
E
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S-20
ii
Hazardous Products
~_~
----- -K::
I'-
rUEL
:::..---
-------::::::
--
ADDITIVE
AD~ESIVE
DANGER
---- -
--::::
Know How
items in the
Shop can
hurt people . ... .
...."
Read
~
~
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S-21
ii
-o
l
- H8@ +
I
DRC7060
FUEL
_-OIL
-
1
1
~
1
1
-----.1
-+-
PULSE
+
I
I
t
~"""'_~--4-...r1- 1
t
I
I
DRC7396
BA
DRC7057
- -e::g)
DRC7059
BA
It
....~ o +
DRC7058
Special Equipment
Ordering Information
Some tools and equipment demonstrated in this manual are only available directly from the
manufacturer. Use the following addresses when ordering:
OTC
28635 MOUND ROAD
WARREN MI 48092
1-800-533-0492 or 1-800-533-5338
Do not order this equipment from Outboard Marine Corporation. Contact the above
manufacturers for pricing and ordering information.
irc 5/97
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ii