6gdd67n9p 1996 Johnson Evinrude ED 9 9 Thru 30 2-Cylinder Service Manual 507122 PDF

In.
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:

Alerts you to the possibility of danger and
In. Safety Warning identifies information that will help pre-
vent injuries.
Identifies information that will help pre-

vent damage to machinery.
Appears next to information that controls

Important correct assembly and operation of the
product.
This Service Manual is written for qualified, factory-

trained service technicians familiar with the use of CIVIC
Service Tools.
This Service Manual tells you how to correctly maintain

and service the outboard and its systems. When cor-
rectly serviced, the outboard will be reliable and safe to
operate.
When avIC 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
Safety Section
32CJeng 1
INDEX
Topic Service Manual Title Page
Air Bleed Orifices Carburetor Orifice Plug Chart 1-49
Alcohol in gasoline Fuel Requirements 1-22
Anodes Anodes - Testing and Replacement 1-34
Battery Cable Extensions Battery Cable Extension 8-5
Battery Charging See OMC Accessory Service Manual •
Battery Recommendations Battery Specifications 8-4
Battery Testing See OMC Accessory Service Manual •
Break-In Procedure Break-In Procedure 1-27
Compression Check Tune-up Procedure 1-32
Core Plug Carburetor Cleaning and Inspection 2-16
Double Firing Indexing Flywheel, Erratic Ignition 3-22
Engine Weight Engine Specifications Section 1
Exhaust Housing Parallelism Cleaning and Inspection 5-4
Flywheel Nut Torque Flywheel Servicing 3-8
Fogging Engine Off-Season Storage 1-28
Fuel Filter In-line Fuel Filter Servicing 2-7
Fuel Oil Mixture Fuel/Oil Ratios 1-20
Fuel Primer Primer System Servicing 2-10
Fuel Pump Pressure Fuel Pump Servicing 2-8
Full Throttle Operating Range Engine Specifications Section 1
Full Throttle Timing Synchronization and Linkage Adjustments Section 1
Galvanic Corrosion Anodes - Testing and Replacement 1-34
Gear Ratio Engine Specifications Section 1
Gearcase Capacity Engine Specifications Section 1
Heli-Coillnserts Heli-Coillnserts and Installers 1-52
High Altitude Operation Weather, Altitude, and Engine Performance 1-26
High Performance Oil Ratios Fuel/Oil Ratios 1-20
Idle RPM Engine Specifications Section 1
Ignition Timing Synchronization and Linkage Adjustments Section 1
Jet Chart Carburetor Orifice Plug Chart 1-49
Key Switch Check Key Switch Tests 8-14
Lubrication Chart Lubrication Chart Section 1
Maximum Spark Advance Synchronization and Linkage Adjustments Section 1
Models Covered Models Covered Page 4
Motor Mounts Exhaust Housing Servicing Section 5
2 32C /e n g
Topic Service Manual Title Page
Octane Requirements Fuel Requirements 1-22
Off-Season Storage Off-Season Storage 1-28
Operating Temperature Engine Temperature Check 4-5
Orifice Chart Carburetor Orifice Plug Chart 1-49
Orifice Plugs - Factory Installed See OMC Parts Catalog •
Overheating Engine Temperature Check 4-5
Preseason Service Preseason Service 1-31
Pressure Test - Gearcase Gearcase Servicing - Assembly Section 6
Propeller Selection Propeller Selection 1-24
Pyrometer Engine Temperature Check 4-5
RPM Limit Engine Specifications Section 1
Sending Unit - Temperature Temperature Switch Test 4-7
Severe Service Oil Ratios Fuel/Oil Ratios 1-20
Shift Cable Installation Rigging Information 1-45
Spark Plugs Spark Plug Information 3-7
Spark Test Ignition Output Test 3-24
Starter Rope Length Starter Servicing Section 7
Storage Mixture Off-Season Storage 1-28
Submerged Engines Submerged Engines 1-35
Summerize Preseason Service 1-31
Sync & Link Synchronization and Linkage Adjustments Section 1
Temperature Switch Temperature Switch Test 4-7
Test Wheel RPM Engine Specifications Section 1
Thermomelt Sticks Engine Temperature Check 4-5
Thermostat Powerhead Servicing - Assembly Section 4
Throttle Cable Installation Rigging Information 1-45
Timing Synchronization and Linkage Adjustments Section 1
Tune-up Procedures Tune-up Procedure 1-32
Vacuum Test - Gearcase Gearcase Servicing - Assembly Section 6
Voltage Drop Test Starter System Voltage Drop Test 8-12
Warning Horn Signals System Check Engine Monitor 8-34
Warning Horn Tests Circuit Verification, Instrument Harness 8-38
Water Pump Water Pump Servicing Section 6
Wi nterization Off-Season Storage 1-28
32C/enQ 3
Outboard Models Covered in This Service Manual
9.9 Models
E10RED E10RLED J10RED J10RLED
E10EED E10ELED J10EED J10ELED
E10RELED E10SELED J10RELED J10SELED
10 Models
10RPB
10RPLB
15 Models
E15RED E15EED 15RPG J15RED J15EED
E15RLED E15ELED 15RPLG J15RLED J15ELED
E15RELED 15KCN J15RELED
E15BAED 15KCLN J15BAED
15RSC
15RSLC
20 Models
E20CRED E20SRED J20CRED J20SRED
E20CRLED E20SRLED J20CRLED J20SRLED
E20SEED J20SEED
E20SELED J20SELED
25 Models
E25RED E25RLED 25RWED J25RED J25RLED
E25RAED E25RALED 25RWLED J25RAED J25RALED
E25TEED E25TELED 25RSLO J25TEED J25TELED
E25EED E25ELED 25RPO J25EED J25ELED
E25BAED E25BALED 25RPLO J25BAED J25BALED
E25JRED E25RDED 25FPO J25JRED J25RDED
28 Models
E28ESLED J28ESLED
30 Models
E30RED E30EED J30RED J30EED
E30RLED E30ELED J30RLED J30ELED
E30BAED E30TEED J30BAED J30TEED
E30BALED E30TELED J30BALED J30TELED
35 Models
E35RED J35RED
E35RLED J35RLED
4 32e/eng
General Information
Table of Contents
In. General Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . .. 1- 2

Service Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1- 3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1- 4
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1- 7
Engine Specifications
9.9/15 ....................................... 1- 8
10/15 Comm .............................. . .... 1-10
20 thru 30 .. ..... .................... . .. . . . ... 1-12
Gearcase Lubrication - All Models ................... 1-15
Steering System Lubrication - Remote Electric Models .. 1-15
Lubrication Chart
9.9 thru 15 ...... . . . ..... . .. .. ................. 1-16
20 thru 30 .............................. . ..... 1-18
Fuel/Oil Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-20
Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-22
New Engine Pre-Delivery Checks . . . . . . . . . . . . . . . . . . .. 1-23
Propeller Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-24
Weather, Altitude, and Engine Performance. . . . . . . . . . .. 1-26
Break-In Procedure ............................... 1-27
Off-Season Storage ............................... 1-28
Preseason Service ................................ 1-31
Tune-Up Procedure ............................... 1-32
Anodes - Testing and Replacement. . . . . . . . . . . . . . . . .. 1-34
Submerged Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-35
Synchronization and Linkage Adjustments,
9.9 thru 15 .................................... 1-37
20 ............ . ..... . ........... . ........... 1-40
25, 28, 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42
20-Hour Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-44
Rigging Information .............................. 1-45
Carburetor Orifice Plug Chart ....................... 1-49
Drill Size Conversion Chart ......................... 1-51
Heli-Coillnserts and Installers . . . . . . . . . . . . . . . . . . . . .. 1-52
32 C/enQ 1-1
& General Safety Warnings
Before working on any part of the outboard, read the section
called Safety at the end of this manual.
When replacement parts are required, use genuine OMC parts or

parts with equivalent characteristics including type, strength,
and material. Failure to do so may result in product malfunction
and possible injury to the operator and/or passengers.
To prevent possible eye injury, always wear SAFETY GLASSES

while servicing the unit.
Always read and follow safety related precautions found on

containers of hazardous substances like parts cleaners, primers,
sealants, and sealant removers.
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 rotat-
ing flywheel.
Replace any locking type fastener (locknut or patch screw) if its

locking feature becomes weak. Definite resistance to tightening
must be felt or locking fastener is not suitable for continued use.
Replace only with authorized replacement part or equivalent.
1-2 32e/eng
Service Specifications
Standard Torque Chart _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Size In. Lbs. Ft. Lbs. N'm
No.6 7-10 • 0,8-1,2
No.8 15-22 • 1,6-2,4
No. 10 25-35 2-3 2,8-4,0
No. 12 35-40 3-4 4,0-4,6
1/4 in. 60-80 5-7 7-9
5/16 in. 120-140 10-12 14-16
3/8 in. 220-240 18-20 24-27
7/16 in. 340-360 28-30 38-40
PCE00 23
INotel These values only apply when a special torque for a

specific fastener is not listed in the Special Torque Chart found at
the beginning of each section .
INotel When tightening two or more screws on the same part, do

not tighten screws completely, or one at a time. To avoid
distortion, first tighten all screws in sequence to one-third of
torque value, then tighten to two-thirds of torque value, then
tighten to full value.
Sealants and Lubricants Required _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
OVIC Ultra-HPF™ Gearcase Lube

OVIC Triple-Guard@Grease
Evinrude @Outboard Lubricant
Johnson @Outboard Lubricant
OVIC 2+4@Fuel Conditioner
OVIC Carbon Guard ™Fuel Additive
OVIC Storage Fogging Oil
OVIC Starter Pinion Lube
OVIC Engine Tuner
OVIC Electrical Grease
32C/eng 1-3
Introduction
This manual covers service information on 13.2 cu. in. (216 cm 3 )
and 32 cu. in. (521 cm 3 ) models. Some of the information might
apply to previous models.
Use this manual together with the proper Parts Catalog for part
numbers and 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 ( ).
Good Service Practice
Service required for OMCengines is generally one ofthree kinds :
• Normal care and maintenance - which includes putting

a new engine into operation, storing engines, lubrica-
tion, and care under special operating conditions such as
salt water and cold weather. This includes engine servic-
ing 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
t ime.
Repair time can also be minimized by the use of special tools.

OMC 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.
f'N=J Do not operate engine out of water, even 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 32C/en g
Arrangement of Service Manual
This Service Manual includes the specific information you will

need to service Evinrude and Johnson engines. All general
procedures are covered in abbreviated form, mostly by reference
to procedural illustrations. The specific procedures which apply
to this engine are covered in fully-illustrated, detailed, step-by-
step instructions.
Each of the manual sections contains detailed instructions for

disassembly, inspection, assembly, testing, and operating adjust-
ments of the various engine systems. These procedures will help
you service a specific system or completely overhaul the out-
board.
Product Reference and Illustrations
Outboard Marine Corporation reserves the right to make changes

at any time, without notice, in specifications and models and also
to discontinue models. The right is also reserved to change any
specifications or parts, at any time, without incurring any obliga-
tion to equip same on models manufactured prior to date of such
change. Specifications used are based on the latest product
information available at the time of publication.
The continuing accuracy of this manual cannot be guaranteed.
All photographs and illustrations used in this manual may not

depict actual models or equipment, but are intended as represen-
tative views for reference only.
Certain features or systems discussed in this manual might not be

found on all models in all marketing areas.
32C/eng 1-5
Service Policy
When servicing an outboard which is within its normal warranty

period, make repairs using only genuine OMC replacement com-
ponents or parts.
If OMC genuine replacement components or parts are not used,

OMC might refuse subsequent warranty claims involving that
engine.
~ When replacement parts are required, use genuine OMC

ill parts or parts with equivalent characteristics, including
type, strength, and material. Failure to do so may result in
product malfunction and possible injury to the operator and/or
passengers.
When reference is made to a brand name product or specific tool,

an equivalent product may be used in place of the referenced
product. Substitute products used must have equivalent charac-
teristics, including type, strength, and material. You must deter-
mine if incorrect substitution could result in product malfunction
and possible injury to the operator and/or passengers.
Whether within or following the warranty period, OMC has a

constant interest in its products. It is OMC's policy to provide
dealers with service information so they can give the professional
service demanded by today's consumer. The OMC Training
Centers, frequent mailings of Service Bulletins and Advisories,
OMC Special Tools, and this Service Manual represent some of
OMC's efforts to assist dealers in giving consumers the best
service possible.
The Service Manual covers all phases of servicing outboards.

However, new situations sometimes arise in servicing an engine.
If a service question does not appear to be answered in this
manual, you are invited to write to the Service Department for
additional help. Always be sure to give complete information,
including engine model number and serial number.
Be sure that you are familiar with OMC warranty policies.
Special Service Tools
OMC has specially designed tools to simplify some of the

disassembly and assembly operations. These tools are illustrated
in this Service Manual, in many cases in actual use. Refer to the
OMC Special Tool Guide for a description and ordering instruc-
tions for these tools. Individual purchasers of Service Manuals
must order Special Tools through an authorized dealer.
Outboard Engine Nomenclature
Sometimes the words "right" and "left" are very confusing when
referring to the sides of an outboard. Therefore, the sides are
referred to as STARBOARD or PORT. STARBOARD means on the
right hand while facing FORWARD; PORT means left hand.
& Safetv Related 1-6 32C/eng

1 DR2065
2 DR2066
3
L..:::.....J.- - - - - - - - - = D R = 4 2 = 0 3 : - l
Symbols
Throughout this service manual, symbols are used to interpret
electrical troubleshooting results or to assign values in drawings.
Electrical
[!] This symbol indicates continuity or very low resistance.

~ This symbol indicates no continuity or very high resistance. 4 DR4204
Use an ohmmeter calibrated on high ohms scale, or a continuity

light, to test continuity.
r:;J When "00" shows on the meter face, no continuity, or very high
~ resistance, is indicated. The symbol is referred to as infinity.
f41 When "'I" follows a val~e on the meter face, the procedure is
~ measuring voltage.
f51 When "0" follows a value on the meter face, the procedure is 5
~ measuring resistance. 0 is the symbol for ohm, the unit of DR4205
measurement for resistance.
Values
I.;l When "s," precedes a value on the meter face, it indicates

~ your reading should be less than, or equal to, the value shown .
~ When "~" precedes a value on the meter face, it indicates
~ your reading should be greater than, or equal to, the value
shown.
6
DR4206
7
DR4207
32C/eng 1-7
9.9/15
Operation _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ __ _ __
Full Throttle Operating Range 9.9 - 5000 to 6000 RPM

15 - 5500 to 6500 RPM
Power 9.9 - 9.9 HP (7,4 kw)

15 - 15 HP (11,2 kw)
Power Rated @ 9.9 - 5500 RPM

15 - 6000 RPM
Idle RPM in Gear 700 ± 25
Test Propeller OMC PI N 340177
Minimum Test RPM 9.9 - 4900

15 - 5700
SEL - 3500
Weight R - 72 Ibs. (33 kg)

RL - 77 Ibs. (35 kg)
E - 75 Ibs. (34,4 kg)
EL, REL - 80 Ibs. (36,4 kg)
9.9 SEL - 88 Ibs. (40 kg)
Powerhead _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _...
Type In-line 2-Cylinder
Displacement 15.6 cu. in. (255 cm 3 )
Bore 2.375 in. (60,33 mm)
Stroke 1.760 in . (44,70 mm)
Standard Bore * 2.3745-2.3750 in. (60,31-60,33 mm)
Crankshaft Dimensions:
Top Journal 0.8757-0.8762 in. (22,24-22,26 mm)
Center Journal 0.8120-0.8125 in. (20,63-20,64 mm)
Bottom Journal 0.7870-0.7874 in. (19,98-19,99 mm)
Rod Crankpin 0.8120-0.8125 in. (20,63-20,64 mm)
Piston Ring End Gap, Both 0.005-0.015 in. (0,13-0,38 mm)
Piston Ring Groove Side Clearance, Lower 0.004 in. (0,10 mm) maximum
*To bore oversize, add piston oversize dimension to standard bore.
1-8 32Cl eng

Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .
Gear Ratio 12:29 (0.414)
Lubricant OMC Ultra-HPF Gearcase Lube
Capacity 9 fl. oz. (260 ml)
Shift Rod Height (Neutral) See Page 6-20
Ignition System ...............................................................
Type Magneto Powered Capacitor Discharge
Power Pack RPM Limit None
Ignition Coil OMC PI N 583740
Spark Plug, Champion
Models Recommended Extended Idle
OL82C OL86C
9.9/15
0.030 in. (0,8 mm) 0.030 in. (0,8 mm)
Electrical System ............................................................. .
Battery, Minimum Recommendation 12-Volt, 360 CCA (465 MCA) with 90 Minutes Reserve
Capacity (50 Ampere-Hours)
Alternator 5-Amp, Non-Regulated
Tachometer Setting 5
Engine Fuse (20 Amp) OMC PI N 514021
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Fuell Oil Ratios See Page 1-20
Fuel Requirements See Page 1-22
Carburetion One Single-Throat Carburetor, Float Feed
Calibration Adjustable Low Speed, Fixed High Speed
Initial Low-Speed Setting * 3 Turns
Starting Enrichment Manual Choke

REL - Electric Primer
Float Level Setting OMC Float Gauge, PI N 324891
Float Drop Setting 1-1% in . (25-35 mm)
* Refer to Section 2, Carburetor Mixture Adjustment, 9.9/15

32Cle ng 1-9
10/15 Comm.
Operation _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Full Throttle Operating Range 10 - 5000 to 6000 RPM

15 - 5500 to 6500 RPM
Power 10 - 9.9 HP (7,4 kw)

15 - 15 HP (11,2 kw)
Power Rated @ 10 - 5500 RPM

15 - 6000 RPM

15 KC - 1000 ± 100
Test Propeller OMC PIN 340177

15 KC - OMC PIN 386537
Minimum Test RPM 10 - 4900

15 - 5700
Weight RP, RS, KC - 72 Ibs. (33 kg)

RPL, RSL, KCL - 77 Ibs. (35 kg)
Powerhead _ _ _ _- -_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _...
Bore 2.375 in. (60,33 mm)
Stroke 1.760 in. (44,70 mm)
Standard Bore * 2.3745-2.3750 in . (60,31-60,33 mm)
Top Journal 0.8757-0.8762 in. (22,24-22,26 mm)
Center Journal 0.8120-0.8125 in. (20,63-20,64 mm)
Rod Crankpin 0.8120-0.8125 in. (20,63-20,64 mm)
* To bore oversize, add piston oversize dimension to standard bore.
1-10 32C enQ

Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .
Gear Ratio 12:29 (0.4141
Lubricant CIVIC Ultra-HPF Gearcase Lube
Capacity 9 fl. oz. (260 mil
Shift Rod Height (Neutrall See Page 6-20
Ignition System ...............................................................

,
Power Pack RPM Limit None
Ignition Coil CIVIC PI N 583740
OL82C OL86C
9.9/15
0.030 in. (0,8 mml 0.030 in. (0,8 mml
Fuel System ..................................................................
Fuell Oil Ratios See Page 1-20
Calibration Adjustable Low Speed, Fixed High Speed
Initial Low-Speed Setting * 3 Turns
Starting Enrichment Manual Choke
Float Level Setting CIVIC Float Gauge, PI N 324891
Float Drop Setting 1-1% in. (25-35 mml
* Refer to Section 2, Carburetor Mixture Adjustment, 9.9/15
32C/eng 1-11
20 thru 30
Operation _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Full Throttle Operating Range 20, 25, 25 Comm., 28 - 4500 to 5500 RPM
30 - 5200 to 5800 RPM
Power 20 - 20 HP (14,9 kw)
25 - 25 HP (18,7 kw)
28 - 28 HP (20,0 kw)
30 - 30 HP (22,4 kw)
Power Rated @ 20, 25, 28 - 5000 RPM
30 - 5500 RPM
Test Propeller 20 - OMC PIN 386891
25, 30 - OMC PI N 434505 *
25 Comm. - OMC PIN 396561
28 - OMC PIN 398948
Minimum Test RPM 20 - 4550
25,28 - 4800
25 Comm. - 4800
30 - 5400
Weight R - 114 Ibs. (51,8 kg) Long Shaft - Add 2 Ibs. (0,9 kg)
TE - 120 Ibs. (54,5 kg) Long Shaft - Add 2 Ibs. (0,9 kg)
E - 118 Ibs. (53,6 kg) Long Shaft - Add 2 Ibs. (0,9 kg)
*Test Propeller PIN 394145 can be used if trim tab is removed.
Powerhead _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ _ _ __ ...
Bore 3.000 in. (76,20 mm)
Stroke 2.250 in. (57,15 mm)
Standard Bore* 2.9995-3.0005 in. (76,19-76,21 mm)
Top Journal 1.2510-1.2515 in. (31,78-31,79 mm)
Center Journal 1.1833-1 .1838 in. (30,06-30,07 mm)
Rod Crankpin 1.1823-1 .1828 in. (30,03-30,04 mm)
Piston Diameter, Standard See Section 4
*To bore oversize, add piston oversize dimension to standard bore.
1-12 32Cle nQ
Gearcase .....................................................................
Gear Ratio 13 :28 (0.461

25 Comm., 28 - 12:21 (0.571
Lubricant OMC Ultra-HPF Gearcase Lube
Capacity 11 flo oz. (330 mil
25 Comm., 28 - 8 flo oz. (245 mil
Shift Rod Height See Page 6-32
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

Power Pack RPM Limit 20-30 Rec. - 6100
25 Comm. - 5700
Ignition Coil OMC PI N 582508
OL82C@
20, 25, 28, 30
0.030 in. (0,8 mml •
OL82C @
25 Comm.
0.030 in. (0,8 mml •
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ._
Battery, Minimum Recommendation 12-Volt, 360 CCA (465 MCAI with 90 Minutes Reserve
Capacity (50 Ampere-Hoursl
Alternator 4-Amp, Non-Regulated
AC Model 60 Watts
Tachometer Setting 5
Engine Fuse (20 Ampl OMC PI N 514021
32C/eng 1-13
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .
Fuel/Oil Ratios See Page 1-20

Calibration Adjustable Low Speed, Fixed Intermediate and High Speed
Initial Low-Speed Setting * 20 - 3 Turns
25-30 - 2112 Turns
Starting Enrichment R, TE - Manual Primer

E - Electric Primer
Float Level Setting OMC Float Gauge, PI N 324891
Float Drop Setting 1%-1% in. (28-41 mm)
20 - 1-1% in. (25-35 mm)
* Refer to Section 2, Carburetor Mixture Adjustment
E
o
u
..:
~
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....
Qi
1-14 32C/eng
<1\
o
Gearcase lubrication - All Models
11 To avoid accidental starting of engine while servicing, twist

and remove all spark plug leads.
Remove oil drain/fill plug and oil level plug from gearcase. With
motor in normal operating position, allow oil to drain completely.
[JJ[IJ Important Do not remove shift cradle screw @.
[JJ [IJ To refill, place a tube or pressure can nozzle of OMC

Ultra-HPF gearcase lubricant in drain/fill hole ®
20-30
INote I If OMC Ultra-HPF gearcase lubricant is not available, OMC
Hi-Vis gearcase lube can be used as an alternate.
• With motor in normal operating position, fill until lubri-

cant appears at oil level hole @.
• Install oil level plug before removing lubricant tube or

pressure can nozzle from oil drain/fill hole. Drain/fill plug
can be installed securely without oil loss.
• Tighten plugs to a torque of 84-86 in . Ibs. (9-10 N·m)
Steering System lubrication - Remote Electric

Models
rn &. The installer was instructed to grease the steering cable
ram during installation. Once the engine is put into use, periodic
cleaning and regreasing with OMC Triple-Guard grease is re-
quired . In fresh water usage, lubricate every 60 days; salt water
usage, lubricate every 30 days.
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Lubrication Chart - 9.9 thru 15
FREQUENCY t
TYPE (PERIOD OF OPERATION)
OF
FIGURE LUBRICATION POINT LUBRICANT FRESH WATER SALT WATER t
~
Cam Follower, Carburetor,
"
60 days 30 days
and Throttle Linkage
~
~
Spark Advance Linkage
" 60 days 30 days
"e
Choke, Shift Lever Shaft and
60 days 30 days
Detent
Gearcase Capacity: Change after first 20 operating hours.
0 9 tl. oz. (226 ml) Check level every 50 operating hours.

Change every 100 operating hours or once
each season, whichever comes first.
~
Swivel Bracket, Clamp Screws,
~
Tilt/Run Lever Shaft, Tilt Shaft
Electric Starter Pinion Shaft

"e 60 days
60 days
30 days
30 days
t Some areas may require more frequent lubrication.
OMC OMC Ultra-HPF™ OMC Starter

Triple-Guard® Gearcase Pinion Lube
Grease Lube PART # 337016
.-111/1,-
__ . __
........
. .....
ULnu -HP.f. __
OII~~!!~
DR4848
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1-16 32Cle ng
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1-17
32C/eng
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Lubrication Chart - 20 thru 30
FREQUENCY t
TYPE (PERIOD OF OPERATION)
OF
FIGURE LUBRICATION POINT LUBRICANT FRESH WATER SALTWATER t
[!] Throttle Shaft and Linkage,
""
60 days 30 days
Rear Motor Cover Latch
~ Shift Lever Shaft 60 days 30 days
~ Vertical Throttle Shaft

e 60 days 30 days
~
"
Carburetor Linkage, Cam and
60 days 30 days
Shifter Starter Lockout
~
~
Clamp Screws and Tilt Tube
Swivel Bracket, and Tilt Lock " 60 days 30 days
"e
60 days 30 days
(Port and Starboard)
Gearcase Capacity: Change after first 20 operating hours.

[!J~ 20, 25, S25RP, 30: 11 flo oz. (325 ml) Check level every 50 operating hours.
25RS, 25RW, A25RP, 28: Change every 100 operating hours or once
8 flo oz. (245 ml) each season, whichever comes first.
~ Electric Starter Pinion Helix

e As required As requi red
~ Tilt Lever Shaft and Reverse Lock
t Some areas may require more frequent lubrication. " 60 days 30 days
OMC OMC U/tra-HPF™ OMC Starter

Trip/e-Guard@ Gearcase Pinion Lube
Grease Lube PART # 337016
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1-18 32C/eng
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/o'j;,. ........- - - - -
~
33673 33672
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32CJeng 1-19 o
Fuel/Oil Ratios
Lubricant
Only the following lubricants should be used:
• Evinrude TC-W3 Outboard Lubricant

• Johnson TC-W3 Outboard Lubricant
These lubricants are formulated by OMC to give best engine

performance while:
• Controlling piston and combustion chamber deposits

• Providing superior lubrication
• Ensuring maximum spark plug life
If Evinrude or Johnson Outboard Lubricant is not available,

another NMMA certified TC-W3 oil may be used. Look for the
certification information on the container label.
INote IFailure to follow this minimum lubricant recommendation

could void your engine warranty.
INotel
Running or storing an engine on a leaner than recom-
mended fuel/oil mixture may result in powerhead damage.
INotelAvoid the use of the following as they could damage your

engine and/or shorten spark plug life:
• Automotive oils
• Premix fuel of unknown oil quantity
• Premix fuel richer than the recommended ratio
• Premix fuel leaner than the recommended ratio
Some additives in EvinrudelJohnson Outboard Lubricant are

subject to evaporation. Always cover partially filled containers to
prevent deterioration of lubricant.
Normal Service
All recreational and commercial engines require a 50: 1 fuel /oil

mixture.
High Performance
Any recreational engine, when used for high performance, re-

quires a 25: 1 fuel/oil mixture.
Severe Service
The fuel/oil ratio for recreational models is 50:1 (2% oil) when
used in commercial, rental, or extended severe service.
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1-20 32C/eng
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Fuel/Oil Mixing Instructions
INote I To be used if engine's AccuMix automatic oiling system is

not desired.
11 Gasoline is extremely flammable and highly explosive under

certain conditions. Always stop engine and do not smoke or
allow open flames or spark near the boat when refueling or
changing fuel tanks. Always mix in well ventilated area.
IT] Portable tank - Above and below 32° F (00 Cl, add one gallon
1
(4 litres) of fuel. Pour in required amount of oil. Add remaining OR3848
fuel. Install filler cap and tip tank gently to distribute oil.
m rn 11 Permanently Installed Tank - Above 32° F (0° Cl,

pour oil slowly with the fuel as tank is filled. Below 32° F (0° Cl,
add one gallon (4 litres) of fuel to a separate container. Pour in
required amount of oil. Install filler cap and tip container gently to
distribute oil. Slowly pour oil/fuel mixture into tank with fuel as
tank is filled. To prevent static spark, use a large metal filter
funnel as shown in figure. The fuel nozzle must contact the metal
funnel when filling the tank.
GASlllNE
3
~ OR 3986
Oil Requirements
3 Gallons 6 Gallons 18 Gallons

(11,4 Litres) (22,7 Litres) (68,1 Litres)
100: 1 4 fl. oz. 8 fl. oz. 24 fl. oz.

(1% Lubricant) (118 ml) (236 ml) (708 ml )
50:1 8 fl. oz. 16 fl. oz. 48 fl. oz.

(2% Lubricant) (236 ml) (473 ml) (1419 ml)
25:1 16 fl. oz. 32 fl. oz. 96 fl. oz.

(4% Lubricant) (473 ml) (946 ml) (2838 m l)
PCE0025
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Fuel Requirements
Minimum Octane
Models Recommendation (R+M)/2 "RON"

"AKI"
9.9 - 30 See fuel classifications below. 67 69
Preferred Fuel: Any regular unleaded, regular leaded, or premium unleaded gasoline having t he
recommended octane rating, and not extended with alcohol is the preferred fuel.
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'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.
&. Fuel leakage can contribute to a fire or explosion.

INote I OIVIC 2+4@fuel conditioner and OIVIC 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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New Engine Pre-Delivery Checks
OMC OWNER IDENTIFICATION CARD
The careful preparation of an engine before delivery will ensure Owner's
Name
owner satisfaction. Address
City State _ Zip _ _

1. Upon uncrating a new engine, inspect it. If you find: Date of Purchase
• Shipping damage - contact the carrier that delivered it MODEL# SERIAL-
• Parts or connections are loose - repair as required

• Parts are missing - contact OMC .... _.....
2. Check gearcase lubricant level. Fill to oil level hole. I DEALER RECORD CARD
I
OWnfH"sName
AOc*ess
3. Install test wheel and put engine into test tank. City StOlte Zip
Sec:ondOwner NCW'I'Ie
& 4. Momentarily, pressurize fuel system. Check for leaks! ~ess
Cj,y
Repair any leaks before continuing. Oale01 Pt.cl\ase
"'''
IgYtIOl"lKey No.
Z.
Boat Mlgr. ""'No

5. Start engine and check cooling system operation. Be sure Boal ModeI 6oa1Leng1h
Imporqnt: The Fed..-., ao.t SIi'.ty Ac:t re(JJires registration lisls to be mafllaned
engine warms to operating temperature at idle. 00 product sales by manutacll.rer and DE ALER This i5 a standard ca rd on which
a dealer can keep his records.
&
Name
6. Check shift operation. Check start-in-gear prevention on S Address
engines so equipped. 0
L
0
City ISlate
& 7. Check electrical and ignition systems for stray spark T

0
Owner's Phone
IZIp "4
sources. Purchase Date
o Ple asure
Type 01 Use
Dcom"" DGollt
Dealer Name
8. Check all adjustments. See Synchronization and Linkage S

0 Address
Adjustments, this section. L

0 City Is tal8
B
y Zip + 4 I
Dealer Code
9. With the engine at all trim angles, turn boat's steering wheel
fully right and left. Be sure there is no interference of the steering I. A.~""""
E~oo I~d.1 • I'M;..
connector, remote control cables, and electrical cables at the .
boat's motor well. I
Boat MIg T MOd81
Hull No ILength
10. Correct any problems found.
T,aller V IN
11. Clean entire engine.
12. Review Operator's Manual information, including owner's @

responsibilities and engine requirements. DR 5700
13. Complete the paperwork: ®

• Owner's identification card
• Dealer's customer record
• Registration
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32C/e ng & Safety Related 1-23
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Propeller Selection
Selecting the correct propeller for each engine and boat combina-
tion will ensure good engine service life and good boat perfor-
mance. A propeller must be carefully selected to match the
engine/boat combination, the application, and the anticipated
load in the boat.
~ Selection of the wrong propeller could reduce engine

~ service life, affect boat performance, or cause serious
damage to the powerhead.
OMC propellers available for these engines are listed in the OMC
SysteMatched Parts and Accessories Dealer Catalog.
Procedure
The propeller selection process is very important to the engine's

service life and to boat performance. Proceed carefully and
thoroughly while considering the following points:
• During the engine break-in period, run the engine at

wide-open throttle for only brief periods of time to verify
full-throttle RPM.
• You must use an accurate tachometer to determine the

engine's full-throttle RPM as you test various propellers.
• Select a propeller that suits the customer's application

and allows the engine to run near the midpoint of the
full-throttle operating range when the boat has a normal
load in it. Refer to Engine Specifications, this section .
• To compensate for changes in boat loading, the engine's

full-throttle RPM must be verified periodically.
• Occasionally, one propeller will not cover a wide range

of boat applications - water skiing to high speed perfor-
mance boating . In such cases, it might be necessary to
have a propeller for each situation.
rv~ ~ operating
~ If the propeller blades have too much pitch, the engine is
below its normal range at full throttle ® ,
power is being lost, and powerhead damage could occur. If the
propeller blades have too little pitch, the engine is operating
above its normal range at full throttle @ and damage from
overspeeding could occur.
'r Twist and remove all spark plug leads to avoid accidental
i l l starting while changing propellers.
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& Safety Related 1-24 32C/eng
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100%
®
90%
80%
@ 70%
60%
50%
40%
30%
~® . -@-
@Q ~@~
1
DR1261
@ Percentage of available horsepower (kw)
@ Engine RPM
© Horsepower (kw) curve

@ Full throttle operating range
® Rating RPM for horsepower (kw)
® Engine is overloading at W .O.T.

@ Engine is overspeeding at W.O.T.
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Rated Power
Hot Weatherl
-------
High Altitude
I~
~ I~
~ I~
o RPM a:
~~----------------------------~-----
DR4013
Weather, Altitude, and Engine Performance
The horsepower ratings of all engines are those that would be

obtained under standard conditions. However, changes in weath-
er and altitude will affect the performance of any outboard. Some
factors that will decrease the output of an engine are:
• Low barometric pressure

• High temperature
• High humidity
• High altitude
r:jl Performance can decrease noticeably when an engine is run

~ on a hot, humid day. Sometimes the weather or altitude alone
can cause the engine RPM to drop below the recommended
operating range. In such a case, a lower pitch propeller can be
used to bring RPM back into the operating range. In any case, top
boat speed will not be as high as on a cool, dry day.
r.::-=J A loss of engine performance can occur if an engine has not

~ been properly modified for high altitude operation. If you
service high altitude engines, consider ordering Information and
Decal Kit, PIN 393533, from your distributor.
To avoid permanent powerhead damage, be sure that an engine

modified for high altitude operation is properly identified and
recalibrated when operated at lower altitude.
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1-26 32C/e ng
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Break-In Procedure
Standard Fuel Tank - Use a 25:1 fuel/oil mixture for the first 12 gallons of fuel.
Optional AccuMix®Tank - Use a 50: 1 fuel /oil mixture in addition to the AccuMix system for the first 12
gallons of fuel.
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
INotel DO NOT operate motor out of water. Water pump can be damaged or engine can overheat.
INotel DO NOT operate engine at a constant throttle setting. Change engine RPM often.
First 20 Minutes _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Operate engine in gear at fast idle ONLY. DO NOT exceed 1500 RPM.
• Verify water pump operation by looking for a steady stream of water at the water pump
indicator.
Next 40 Minutes _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• DO NOT operate engine above 1/2 throttle (no more than 3500 RPM).
• DO NOT hold a constant throttle setting. Change engine speed every 15 minutes.
• Verify water pump operation.
INotel 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.
Next Nine Hours _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Avoid continuous full-throttle operation .
• Verify water pump operation.
• Bring boat onto plane and operate engine below 3f4 throttle. DO NOT EXCEED 4500 RPM.
• Every 30 minutes, operate engine at full throttle for approximately one minute.
• DO NOT exceed recommended maximum engine RPM. Refer to Specifications, this Section .
INotel Retorque cylinder head screws after engine break-in period. Retorque after engine has been run
and cylinder heads have cooled to the touch.
lNotel After 10 hours of break-in, check oil level in the AccuMix reservoir to verify that oil is being
consumed to ensure proper lubrication of engine. Add oil to refill AccuMix reservoir before switching
from 50:1 fuel/oil mixture to clear fuel.
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32C/ena 1-27 o
Off-Season Storage
Use the following procedure to properly prepare Johnson and
Evinrude outboards for extended periods of nonuse. These steps
are intended to protect the engine during storage and simplify the
preseason servicing procedure.
1. Stabilize the engine's fuel supply with OMC 2+4fuel condition-

er, following directions on the bottle.
INote I Use a flushing attachment if you operate the engine on a

trailer or dolly to prevent engine or water pump damage.
&. When using a flushing attachment, always remove engine's

propeller before starting engine to prevent accidental contact
with moving propeller.
2. Run the engine at approximately 1500 RPM for five minutes to

ensure that the entire fuel supply system and the engine's
carburetors are full of stabilized fuel.
3. Prepare an engine "storage mixture" in a shop V6 six gallon

tank PIN 397767. The mixture should include:
• Five gallons of fuel

• Two quarts of OMC Storage Fogging Oil
• One pint of Evinrude or Johnson Outboard Lubricant
• 21/2 oz. of OMC 2+4 fuel conditioner
4. Connect the tank containing the "storage mixture" to the

engine. Leave the oil supply hose connected to the engine. Run
the engine on the "storage mixture" at approximately 1500 RPM
for five minutes.
5. Stop engine and remove all spark plugs. Spray a liberal amount
of OMC 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.
&. 7. Prevent accidental starting during storage; leave spark

plug leads off all of the spark plugs.
8. If engine is equipped with a portable fuel tank, disconnect fuel

hose from engine and tank.
&. Avoid fire or explosion hazard; store all portable fuel tanks in
a well ventilated area, away from any open flames.
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&. 9. If the engine is removed from boat, examine all hardware
you loosened or removed from the motor and its steering,
throttle , and shift systems. Replace damaged or missing parts
with genuine OMC parts or equivalent. These fasteners are made
of special materials to resist weakening and rusting. Do not
substitute these fasteners with nuts and bolts which look the
same. Using the wrong nuts and bolts may result in sudden
unexpected loss of engine control.
&. 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. Refer to
Section 8 for battery maintenance information .
12. If equipped, service the boat fuel filter following instructions

on canister.
13. Remove propeller and check for damage. A slightly bent

propeller blade can hardly be noticed but will affect the perfor-
mance of the engine. Clean and lubricate the propeller shaft with
OMC 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.
&. Make sure electrical and fuel system fasteners and clamps
are tight and in good condition. Failure to do so may cause
electrical sparks and fuel leakage under the engine cover. Fire and
explosion could occur.
16. Replace engine cover. Use touch-up paint where needed.
17. Coat all outside painted surfaces of engine with automotive

wax.
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NOTES
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1-30 32Clenq
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Preseason Service
1. Check gearcase lubrication. If leakage is evident, gearcase seals

may need attention. Check lubricant level in power trim/tilt
reservo ir. See lubrication, this section.
& 2. Apply a light coating of avIC Electrical Grease to the ribbed

portion of the spark plug ceramics and the opening of the spark
plug covers. Connect spark plug leads. Make sure spark plug
boots are not cracked or torn.
& 3. Check water level in battery, then charge. While the battery
is charging , the acid solution inside the battery gives off hydro-
gen gas which can explode if ignited by a spark or open flame. If
hydrogen gas is not able to leave the battery (vents are clogged),
the battery itself may explode. Therefore, when charging batter-
ies, make sure that battery is vented to atmosphere and lots of
fresh air is in the area. Make sure no sparks or flames are present.
Do not short across battery terminals to check battery condition.
Install and connect battery.
& 4. When engine is reattached to the boat's transom, make

sure the steering, shift, and throttle systems are attached to the
engine using the factory-specified hardware stored with the
engine earlier. Follow the manufacturer's installation instruc-
tions! If control systems are attached to the engine using the
wrong fasteners or assembled carelessly, sudden unexpected
loss of engine control may result.
5. Test engine warning system. Refer to Section 8.
& 6. Check fuel system for leaks.
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Tune-Up Procedure
1. Visually inspect engine for leaks, missing or loose parts, or
other 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 condi-

tion.
• 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: '
• scored cylinder walls

• damaged pistons
• stuck piston rings
• worn piston rings
IF the engine shows a variation greater than 15 PSI (100 kPa),

check for:
• damaged head gasket

• damaged pistons
• broken or stuck piston rings
• scored cylinder walls.
IF the engine has equal compression and runs normally, continue

the tune-up procedure.
~ 3. Clean and regap or replace spark plugs. Make certain

ill ceramic portion of plug is not cracked. Replace if cracked to
prevent sparks.
'" 4. Inspect and test ignition components. See Section 3.

i l l Replace deteriorated or damaged parts such as wires,
boots, etc., which may emit sparks.
'" 5. Replace in-line fuel filter. Replace deteriorated or dam-

i l l aged fuel system parts such as hoses or gaskets which may
result in fuel leaks. Inspect carburetor and primer system.
6. Synchronize the engine. See Synchronization and Linkage

Adjustments, this section.
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7. Inspect propeller shaft seals for evidence of leakage. Replace if
necessary.
8. Drain and refill gearcase. Lubricate all components of engine.

See Lubrication, this section.
9. Check propeller condition. Replace if damaged.
10. Retorque all screws and nuts to specifications.
11 . Run engine in test tank with correct test propeller. Check

cooling system operation .
12. To remove carbon deposits from combustion chambers and

pistons, inject 0IVk: Engine Tuner. Let tunner soak in engine
between three and sixteen hours. After soaking, run engine at fast
idle (1500 RPM) for at least 15 minutes at normal operating
temperature .
INotel During engine operation, carbon can build up on internal

powerhead components, eventually causing piston rings to
"stick." Adding 0IVk: Carbon Guard ™ fuel additive to every tank of
fuel is your best protection against such buildup and the resulting
mechanical problems. If Carbon Guard is not used consistently in
the fuel, 0IVk: Engine Tuner should be applied every 50 operating
hours.
13. Check engine operation by verifying minimum test propeller

RPM. Refer to Engine Specifications, this Section.
&. 14. Momentarily pressurize fuel system and check for leaks.
15. If engine is to be stored, refer to Off-Season Storage , this

section .
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32 Cl e ng & Safety Related 1-33
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Anodes - Testing and Replacement
Erosion or disintegration in salt or brackish water indicates the
anodes are performing their function. The anodes should be
inspected at intervals and replaced when necessary, or corrosion
of the engine will increase.
~ If any anode has been reduced to 0/3 its original size (V3
~ eroded) it must be replaced!
'1l f21 Test for proper installation of the anode. Calibrate an

~ ~ ohmmeter on high ohms scale. Connect one meter lead to a
powerhead ground and the other lead to the anode. Be sure the
surface of the anode is clean to make good contact. The ohm-
meter should show a low reading. If not, remove the anode and
clean the area where the anode is installed. The mounting screws
and the anode itself should also be cleaned. Install and retest.
INote\ Do not paint or coat the anodes or their mounting surfaces.
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1-34 32C/e ng
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Submerged Engines
Engine Dropped Overboard (Not Running)
If engine is recovered from water immediately, it must be serv-

iced within three hours. See Prolonged Submersion.
c:J If engine cannot be started or serviced immediately, it

~ should be resubmerged in fresh water to avoid exposure to
the atmosphere. Make arrangements to have it serviced with the
least possible delay.
Once the outboard is exposed to air, both fresh and salt water will
start etching the highly polished bearing surfaces of the crank-
shaft, connecting rods, and bearings. The engine must be serv-
iced within three hours of recovery to avoid costly repairs.
Proceed as follows:
1. Remove engine cover and rinse powerhead with fresh water.
2. Twist and remove spark plug leads and remove spark plugs.
~ To remove or attach leads, pull off or push on with a slight

~ counterclockwise twist.
3. Disconnect fuel line from engine. Drain and clean all fuel lines
and fuel tank.
4. Place engine in horizontal position (spark plug openings down)

and work out all of the water by slowly rotating flywheel approxi-
mately 20 times, or until there are no signs of water.
5. Drain carburetors - place engine in upright position and

remove carburetors for disassembly and draining.
6. Starters, electrical connectors, and all electrical equipment

should be completely disassembled, cleaned, flushed with fresh
water, treated with a water displacing electrical spray, and
thoroughly dried before assembly.
7. Inject outboard lubricant into spark plug holes.
8. Reassemble parts you removed and disconnected. Start engine

(follow starting instructions) and run '/2 hour using the "break-in"
fuel/oil mixture.
Run the engine on a "break-in" fuel/oil mixture for approximately

three hours after servicing. See Break-in Procedure in this sec-
tion.
9. If engine fails to start, remove spark plugs again to see if water

is present on electrodes. Blowout any water from electrodes and
reinstall, or replace with new plugs. Repeat starting procedure.
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32C/enQ 1-35 o
~ If engine shows evidence that sand or silt may have entered
~ it (sand or silt under the engine cover or a slight grinding or
scraping when flywheel is rotated), do not attempt to start the
engine. It must be disassembled and cleaned.
Engine Dropped Overboard (Running)
Follow the same procedure as Engine Dropped Overboard (Not

Running) . However, if there is any binding when flywheel is
rotated, it may indicate a bent connecting rod and no attempt
should be made to start the engine. POWERHEAD MUST BE
DISASSEMBLED AND SERVICED IMMEDIATELY.
Engine Dropped Overboard (In Salt Water)
Follow same procedures as Engine Dropped Overboard (Not

Running) and (Running) . Even if engine can be started, it must be
serviced (disassembled and cleaned and electrical components
cleaned or replaced where necessary) as salt water can cause
excessive corrosion of electrical components and internal parts.
Prolonged Submersion (Fresh or Salt Water)
If engine has been dropped overboard and not recovered immedi-

ately, the engine must be serviced within three hours after
recovery. Follow same procedures as Engine Dropped Overboard
(Not Running) and (Running) . When prolonged submersion oc-
curs in salt water, even if engine can be started, the engine must
be disassembled and cleaned and electrical components cleaned
or replaced where necessary.
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1-36 32C/eng
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Synchronization and Linkage Adjustments -
9.9 thru 15
INote I It is important that this step-by-step procedure be followed
in sequence and be performed exactly as written to ensure
consistent engine idling and smooth operation throughout the
RPM range.
INote I If equipped, remove both remote control cables from the

engine before performing these adjustments.
Preliminary Adjustments _ _ _ _ _ _ _ _ _ _ _ _ _ __
OJ 1. Tiller models - Turn the idle adjusting knob counterclock-

wise to the full SLOW position.
rn • Remove
lever.
the pin retaining the connector to the throttle
rn • Turn the connector clockwise until it seats. Turn counter-

clockwise no more than one-half turn to align it with the
throttle lever. Install the retaining pin.
rn • The throttle cable bracket must be flush with the inside

edge of the threaded cable. To adjust, remove screw and
turn bracket. Install screw.
rn []] 2. All Models - Close the throttle completely so the idle

speed screw is against the stop. The center of the cam follower
roller should be halfway between pick-up mark and end of the
throttle cam. To adjust, advance the throttle to wide open position
and adjust idle speed screw. Turn the screw in to move the cam
closer to the roller and out to move cam away from the roller.
Close the throttle completely and check the cam to roller align-
ment. Repeat procedure if necessary.
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32C1enQ 1-37 o
Cam Follower Pickup Point _ _ _ _ _ _ _ _ _ _ _ _...._
[]] 1. Connect a throttle shaft amplifier @' such as the one

shown, to the carburetor throttle shaft.
[]] 2. Advance the throttle until the tip of amplifier begins to

move. At this point, the center of the roller ® should align with
single mark © on cam.
rn 3. To adjust, use OMC Ballhex Screwdriver, PIN 327622.

Back out cam follower adjusting screw until the cam and cam
follower do not touch. Turn in screw until amplifier begins to
move and check to 'v erify the mark on the cam aligns with the
center of the cam follower. Repeat procedure if necessary. If air
silencer is on, remove plug to adjust screw. Reinstall plug after
procedure.
Wide Open Throttle Adjustment _ _ _ _ _ _ _ _ _ _ __
[!Q]1. Adjust throttle stop screw until the tip protrudes 1/4 in.
(8 mm) through the throttle lever.
[!!] rrn 2. Open throttle to wide open position and verify that
the throttle shaft pin @ is vertical. If adjustment is required, turn
the cam screw in to open the throttle valve and out to close it
using OMC Ballhex Screwdriver, PIN 327622.
Maximum Spark Advance _ _ _ _ _ _ _ _ _ _ _ _ _ __
No maximum spark advance adjustment is necessary. Correct

primary lead position is all that is required to maintain proper
ignition timing. Orangelblue lead must go to the top ignition coil.
Idle Speed _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
1. The boat must be in the water, under normal operating

conditions, with the correct propeller installed. The boat's move-
ment must be unrestrained. The boat must not be tied to a dock or
trailer.
INote I Before
proceeding with this procedure, be sure the low-
speed needle is properly adjusted. Refer to Carburetor Adjust-
ment, Section 2.
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1-38 32C/enQ
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r;Jl 2. Tiller models - turn the idle speed knob fully counterclock-
~ wise to the full SLOW position .
3. Start the engine and allow it to reach normal operating

temperature.
4. When speed is reduced, engine must idle at 700 ± 25 RPM in

FORWARD gear. Stop the engine
1141 5. Adjust the idle speed screw to change idle speed.

r:;;;l 6. Tiller Models - Remove throttle cable bracket screw.
~ Adjust the throttle cable bracket to provide a slight preload
against the idle speed screw when the Twist-Grip is held at the full
SLOW position.
7. Run engine in gear at, or near, full throttle for one minute.
Quickly reduce speed to SLOW (700-S00 RPM) and shift into
NEUTRAL. Engine should continue to run smoothly.
S. If engine stalls or backfires, the idle mixture is too lean . Refer to

Carburetor Adjustment, Section 2.
Shift Lever Detent Adjustment _ _ _ _ _ _ _ _ _ _ _ __
1. Rotate propeller shaft and move the shift lever to NEUTRAL

position.
1.J6l 2. The lower detent spring should be fully engaged in notch

~ of the shift lever detent.
3. To adjust, loosen the detent retaining screw. Move the lower

detent spring to fully engage notch. Tighten the screw securely.
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32C/eng 1-39 o
Synchronization and Linkage Adjustments - 20
~ It is important that this step-by-step procedure be followed
~ in sequence and be performed exactly as written to ensure
RPM range.
~ If equipped, remove both remote control cables from the

~ engine before performing these adjustments.
Cam Follower Pickup Point _ _ _ _ _ _ _ _ _ _ _ _ __
Gl 1. Tiller models -turn the idle adjusting knob counterclock-

~ wise to the full SLOW position.
f21 2. Remote models - back out the throttle arm stop screw until
t=J throttle arm touches screw's mounting bracket.
rJl 3. 'Connect a throttle shaft amplifier @, like the one shown, to
~ the carburetor throttle shaft.
~ 4. Advance the throttle by moving the throttle control lever

~ until tip of the amplifier begins to move. At this point, the cam
follower ® should contact the cam between the two marks ©.
f51 5. To adjust, loosen the screw @ retaining the adjustment lever

~ to the throttle shaft. Slide the adjustment lever up or down to
make the adjustment.
~ Run the engine with the proper test wheel. Do not run the
~ engine with a propeller or a flushing adapter for the
adjustment.
1. Connect a timing light to the top cylinder. Start the engine and
allow it to reach normal operating temperature.
2. Run the engine at full throttle in FORWARD. The engine timing

mark must align with appropriate mark on the flywheel grid.
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1-40 32C/eng <1\
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• Electric start models - Timing mark ® must align with
appropriate mark on the ELEC CD flywheel grid .
• Rope start models - Timing mark ® must align with

appropriate mark on the CD flywheel grid.
Maximum Spark Advance
20 34° ± 1° BTDC
Isl rJl '" 3. To .adjust, stop the engine. to. preve~t contact with
~ ~ i l l rotatmg parts. Loosen the timing adjustment screw
nut @ . Turn the adjustment screw ® in or out, as necessary, to
correct the timing. One turn clockwise retards timing about 1°;
one turn counterclockwise advances timing about 1°.
4. Tighten the nut and recheck the timing adjustment.

Idle Speed _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

trailer.
f1l 2. Tiller models - turn the idle adjusting knob counterclock-

L!J wise to the full SLOW position.
temperature.

FORWARD.
Ial 5. Tiller models - move the throttle cable bracket CD to change

~ idle speed. Verify cam follower pickup point after making the
adjustment.
f21 6. Remote models - adjust the throttle arm stop screw to

~ change idle speed.
Quickly reduce speed to SLOW (700-S00 RPM) and shift to
NEUTRAL. Engine should continue to run smoothly.
S. If engine stalls or backfires, the idle mixture is too lean. Refer to

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Synchronization and Linkage Adjustments -
25,28,30
INote I It is important that this step-by-step procedure be followed
in sequence and be performed exactly as written to ensure
RPM range.
INote I If equipped, remove both

remote control cables from the
engine before performing these adjustments.
Cam Follower Pickup Point _ _ _ _ _ _ _ _ _ _ _ _ __
OJ 1. Tiller models - turn the idle adjusting knob counterclock-

wise to full SLOW position.
W 2. Remote models - back out throttle arm stop screw until

throttle arm touches screw's mounting bracket.
rn 3. Connect a throttle shaft amplifier @, like the one shown, to

the carburetor throttle shaft.
rn 4. Advance the throttle by moving the throttle control lever

until tip of the amplifier begins to move. At this point, the cam
follower ® should contact the cam between the two marks @.
[ ] ] 5. To adjust, loosen the screw @ retaining the adjustment

lever to the throttle shaft. Slide the adjustment lever up or down
to make the adjustment.
Throttle Control Rod _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
[[] INote I Offset on pivot block ® must face toward the control
rod collar ®.
[ [ ] 1. While rotating the propeller shaft, move the shift lever to
FORWARD. Loosen the control rod collar ® screw.
[ [ ] 2. Advance the throttle lever ® until it contacts the stop on

the cylinder block.
3. Move the throttle control rod forward until the carburetor

throttle plate is horizontal.
rn 4. Move the control rod collar ® backward until it touches

the pivot block. Tighten the collar screw securely.
[]] 5. Check your adjustment. The carburetor throttle plate must
be exactly horizontal when the throttle lever ® is fully advanced.
If necessary, repeat Steps 1 thru 4.
INote I Ru n the eng i ne with the proper test wheel. Do not ru n the
engine with a propeller or a flushing adapter for the adjustment.
1. Connect a timing light to the top cylinder. Start the engine and
allow it to reach normal operating temperature.
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2. Run the engine at full throttle in FORWARD. The engine timing o
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mark must align with appropriate mark on the flywheel grid. ..:
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1-42 32Cl eng
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rn • Electric start models - Timing mark CD must align with
appropriate mark on the ELEC CD flywheel grid.
[[] • Rope st art models - Timing mark Q) must align with

appropriate mark on the CD flywheel grid.
Maximum Spark Advance
25, 28, 30 30° ± 1° BTDC
PCE0026
rn [[] &:. 3. To adjust, stop the engine to prevent contact

with rotating parts. Loosen the timing adjustment screw nut @.
Turn the adjustment screw © in or out, as necessary, to correct
the timing. One turn clockwise retards timing about 1°; one turn
counterclockwise advances timing about 1°.
4. Tighten the nut and recheck the timing adjustment.

Idle Speed _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

trailer.
IT] 2. Tiller models - turn the idle speed knob counterclockwise

to the full SLOW position.

temperature.

FORWARD gear.
[]J 5. Tiller models - move the throttle cable bracket @ to

change idle speed. Verify cam follower pickup point after making
adjustment.
W 6. Remote models - adjust the throttle arm stop screw to

change idle speed.
Quickly reduce speed to SLOW (700-800 RPMI and shift into
NEUTRAL. Engine should continue to run smoothly. 9
26424
8. If engine stalls or backfires, the idle mixture is too lean. Refer to
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20-Hour Check
~ Outboard Marine Corporation encourages all Johnson and

~ Evinrude owners to return their new engines to an author-
ized dealer for a mechanical check.
This check should be performed after approximately 20 operating

hours. The cost of this check should be figured at local dealer
labor rates and paid for by the engine owner.
The 20-hour check should include:
1. Drain and fill gearcase with recommended lubricant.

Pressure and vacuum test gearcase if signs of water are
present.
2. If equipped, check power trim reservoir for proper fluid

level.
3. On mechanically steered engines, lubricate cable ram

with OMC Triple-Guard grease.
4. On power steering engines:
• Lubricate cable ram with OMC Triple-Guard grease.

• Check pump reservoir for proper fluid level.
• Check entire system for signs of external fluid leaks.
• Check pump drive belt tension.
5. Check torque on cylinder head screws and spark plugs.
6. Check all linkage adjustments.
7. Check engine mounting hardware for tightness.
8. Lubricate all grease fittings with OMC Triple-Guard

grease.
9. Check entire boat and engine fuel system for signs of

deterioration, damage, or leaks.
10. Check all engine systems for signs of deterioration or

problems.
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1-44 32C/e n~
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Rigging Information
& To prevent accidental starting of engine, verify that battery

cables are disconnected at battery.
Control Cable Identification - 9.9 thru 30
[JJ 1. Put the control handle into NEUTRAL position. The throt-
tle cable casing guide @ will retract completely and the shift cable
casing guide ® will go to the midpoint of its travel.
1
[JJ 2. As you move the control handle into FORWARD, the shift
cable casing guide ® must retract. As you move the control
handle to wide open throttle (W.O.T.) the throttle cable casing
guide @ extends completely.
3. As you move the control handle from NEUTRAL to REVERSE,

the shift cable casing guide ® extends. As you move the control
handle to W.O.T. the throttle cable casing guide @ extends.
4. Identify each control cable for proper installation later.
& Control cable identification and function must be correct

before continuing with installation.
Throttle Cable - 9.9/15
1. Remove the rubber grommet from front of lower engine cover.

Remove cable retainer. Apply a liberal amount of OMC Trip le-
Guard grease to both anchor block pockets.
rn
grease.
2. Extend throttle cable and lubricate with OMC Triple-Guard
3. Move the remote control handle to NEUTRAL. Verify that the

fast idle lever is down in the RUN position.
W& 4. Attach cable casing guide to throttle lever using clevis

pin and cotter pin supplied with engine. Secure cable by spread-
ing cotter pin ends.
5. Hold throttle lever tight against idle stop screw.
rn 6. Pull firmly on throttle cable to remove backlash and install

trunnion nut in anchor pocket.
7. Install cable retainer and torque screw to 60-84 in . Ibs. (7-9

N·m).
8. Check cable adjustment:
• If throttle cable adjustment is too loose, idle speed will

be high and/or inconsistent.
• If throttle cable adjustment is too tight, control effort will

be high when shifting in and out of gear.
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Shift Cable - 9.9/15
[]] 1. Extend shift cable and lubricate with OMC Triple-Guard

grease.
&. Before connecting shift cable: on remote controls that have

NEUTRAL lock features; verify that control handle is locking, and
that it is locking in NEUTRAL.
2. Move the remote control handle to NEUTRAL.
3. Verify that the fast idle lever is down in the RUN position.
4. Shift the gearcase into NEUTRAL.
[]J &. 5. Connect shift cable to shift lever using clevis pin and
cotter pin supplied with engine. Secure cable by spreading cotter
pin ends.
[IJ 6. Adjust cable trunnion nut to locate in anchor pocket.
W 7. Install the anchor pocket cover and torque the screw to

60-84 in. Ibs. (7-9 N·m).
8. Slip rubber grommet onto control cables and press grommet

into groove in lower engine cover.
&. 9. Inspect installation to ensure that the control cables are

attached to the proper engine levers by lifting the fast idle lever,
if equipped, to the START position. If correctly attached, the
throttle cable and engine throttle lever will move.
Shift Cable - 20 thru 30
1. Place engine's shift lever in NEUTRAL position. (Propeller shaft

will turn freely when in NEUTRAL position.)
2. Check that remote control handle is in NEUTRAL and the fast

idle lever is in RUN position (latched) .
3. Place shift cable through anchor bracket.
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rv~ i'"l l 4.lever.
Install shift cable casing guide on shoulder bolt of shift
Install the flat washer and locking nut supplied
with engine. Do not substitute locknut. Tighten locknut securely.
5. Adjust the length of the shift cable by turning the knurled

adjusting nut on the shift cable until the cable trunnion fits into
the trunnion anchor pocket in trunnion anchor block.
rt '" 6. Secure shift cable in anchor bracket by installing screw

l=.J i l l and locknut. Tighten screw securely.
Throttle Cable - 20 thru 30
I] 1. Install the trunnion tension retainer onto the cable bracket.

~ 2. Place throttle cable trunnion into bracket.
r;;"] 3. Attach spring clip guide by sliding onto side of guide and
~ turning until holes in spring clip snap over both pins on guide.
f61 4. ~ttach. casing guide to engine throttle arm and secure with
~ spring clip.
Trunnion Adjustment - 20 thru 30
I.A. The trunnions on both remote control cables must be

ill adjusted properly or operator may lose control of direction
and engine speed.
The remote control cable trunnion provides an adjustment for

both the shift cable and the throttle cable. Adjust by turning the
trunnion nut.
1. Adjust the shift trunnion so that when the remote control

handle is in NEUTRAL, the engine's shift lever is in NEUTRAL.
2. Adjust the throttle trunnion so that when the remote control

handle is at extreme slow speed position, the engine's throttle
arm is at extreme slow speed position.
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Electrical Cables - 9.9 thru 30
& Disconnect battery cables from battery before servlcmg

electrical systems. Failure to do so could result in injury from
ignition sources (sparks) or from contact with moving parts if
accidental cranking or starting occurs.
Provide sufficient slack at motor end to permit steering and tilting

of motor without binding cables.
IJJ 1. 20 thru 30 - Route electrical cable along starboard side to

rear of junction box.
2. Install protective plug ® (supplied with engine) on power

trim /tilt 3-pin connector.
W 3. Before installing connections, check the seal ® is in place.

Clean off any dirt from connectors. Apply a light coat of OMC
Electrical Grease to the seal. Push connectors together until
latched .
rn 4. Secure connectors in junction box by latching connector

in slot of junction box.
Install junction box cover and secure with screw.
rn []] & 5. Route the positive (red) battery cable © to the

starter solenoid. Secure the cable to the starter solenoid. Cover
terminal with rubber boot.
rn []] & 6. Secure the negative battery cable @ to the

powerhead ground terminal.
W 7. Install battery cables and electrical cable into grommet.
[ ] ] 8. Install clamp and secure with two screws.
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Carburetor Orifice Plug Chart
It is occasionally necessary to replace carburetor orifices to improve engine running characteristics.
Check current parts catalogs for orifice part numbers.
INotel Check current parts catalogs and service bulletins before making any orifice changes.
The following charts list available orifices, orifice sizes, and part numbers. The identification number is
stamped on most orifices.
Orifices (8-32 Thread Size)
ID No. Part No. Size ID No. Part No. Size
0 333342 0.000 43 325828 0.043
14 331952 0.014 44 325827 0.044
16 333243 0.016 45 323151 0.045
20 324005 0.020 46 327342 0.046
22 331934 0.022 47 328560 0.047
23 326188 0.023 48 326500 0.048
24 328549 0.024 49 333741 0.049
25 323003 0.025 50 323708 0.050
26 324652 0.026 53 328531 0.053
27 317474 0.027 54 334014 0.054
28 322936 0.028 55 326928 0.055
29 322776 0.029 56 333982 0.056
30 317473 0.030 57 325869 0.057
31 318823 0.031 58 328280 0.058
32 320016 0.032 59 327739 0.059
33 320015 0.033 60 327092 0.060
34 324025 0.034 61 324977 0.061
35 318832 0.035 62 326856 0.062
36 323703 0.036 64 325837 0.064
37 324698 0.037 66 328526 0.066
38 323149 0.038 67 327689 0.067
39 334568 0.039 68 327740 0.068
40 327745 0.040 70 328562 0.070
41 328535 0.041 73 328536 0.073
42 325829 0.042
Orifices (%-20 Thread Size - D Type)
ID No. Part No. Size ID No. Part No. Size
0 338548 0.000 570 322907 0.057
290 330142 0.029 580 328543 0.058
320 333184 0.032 590 319831 0.059
340 330141 0.034 600 332204 0.060
350 333183 0.035 610 319907 0.061
370 328537 0.037 620 331433 0.062
380 328525 0.038 630 328544 0.063
390 328538 0.039 640 328545 0.064
400 328524 0.040 650 327541 0.065
410 333182 0.041 670 319534 0.067
420 322249 0.042 680 333211 0.068
430 328539 0.043 690 327558 0.069
440 328540 0.044 700 327769 0.070
450 323280 0.045 710 327559 0.071
460 328541 0.046 720 328546 0.072
470 328542 0.047 730 327487 0.073
490 324020 0.049 740 333669 0.074
500 326526 0.050 750 327560 0.075
510 331567 0.051 760 329411 0.076
520 321108 0.052 770 333438 0.077
530 321297 0.053 780 319002 0.078
540 321407 0.054 790 329414 0.079
550 320921 0.055 800 333298 0.080 E
0
56D 318684 0.056 810 330917 0.081 u
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Orifices (1/4-20 Thread Size - C Type)
10 No. Part No. Size 10 No. Part No. Size
23C 336709 0.023 56C 325019 0.056

25C 333458 0.025 57C 317021 0.057
26C 333459 0.026 58C 321731 0.058
27C 333460 0.027 58.5C 324389 0.0585
29C 333461 0.029 59C 317330 0.059
30C 333312 0.030 60C 321449 0.060
31C 333462 0.031 61C 320661 0.061
34C 333463 0.034 62C 317607 0.062
36C 333464 0.036 63C 321559 0.063
38C 323150 0.038 64C 324776 0.064
41C 328550 0.041 65C 322810 0.065
43C 328551 0.043 66C 328554 0.066
45C 322664 0.045 67C 317183 0.067
46C 328547 0.046 68C 328555 0.068
47C 328552 0.047 69C 319776 0.069
48C 323903 0.048 70C 322996 0.070
49C 322221 0.049 71C 328556 0.071
50C 324906 0.050 72C 317488 0.072
51C 323938 0.051 73C 328559 0.073
52C 328548 0.052 74C 328557 0.074
53C 328553 0.053 75C 328558 0.075
54C 317646 0.054 76C 320502 0.076
55C 329911 0.055
Orifices (5/16 -24 Thread Size)
10 No. Part No. Size 10 No. Part No. Size
26 333185 0.026 46 328532 0.046

29 328529 0.029 48 328533 0.048
32 328530 0.032 49 328527 0.049
33 328124 0.033 52 328528 0.052
34 328574 0.034 53 328534 0.053
35 326064 0.035 54 322293 0.054
36 323637 0.036 56 326858 0.056
37 329069 0.037 58 320820 0.058
38 322752 0.038 66 326634 0.066
39 329954 0.039 68 326524 0.068
40 321742 0.040 70 326635 0.070
42 326522 0.042
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Drill Size Conversion Chart
SHOWING MILLIMETER SIZES, FRACTIONAL AND
DECI MAL INCH SIZES AND NUMBER DRILL SIZES
Milli· Dec. Frac· Num· Mill i· Dec . Frac· Num· Milli· Dec. Frac· Num· Milli· Dec. Frac· Num· Milli· Dec. Frac·
Meter Equiv. ti onal ber Meter Eq uiv . tional ber Meter Equiv. tional ber Meter Equ iv. tional ber Meter Equiv. tional
.1 .0039 1.75 .0689 .1570 22 6.8 .2677 10.72 .4219 27 /64

.15 .0059 .0700 50 4.0 .1575 6.9 .2716 11 .0 .4330
2 .0079 1.8 .0709 .1590 21 .2720 I 11.11 .4375 7/ 16
.2 5 .0098 1.85 .0728 .1610 20 7.0 .2756 11.5 .4528
.3 .0118 ... .0730 49 4.1 .1614 .2 770 J 11 .5 1 .4531 29 /64
.0135 80 1.9 .0748 4.2 .1654 7.1 .2795 11.91 .4687 15/32
.35 .0138 .... .0760 48 .1660 19 .28 11 K 12 .0 .4724
.0415 79 1.9 5 .0767 4.25 .1673 7.14 .2812 9/32 .. 12 .30 .4843 31/64
.39 .0156 1/64 1.98 .0781 5/64 4.3 .1693 7.2 :2835 12.5 .492 1
.4 .0157 ·. .D785 47 .1695 18 7.25 .2854 12.7 .5000 1/2
.0160 78 2.0 .0787 4.37 .1719 11 /64 7.3 .2874 13.0 .5 118
.45 .0177 205 .0807 .1730 17 ... .2900 L 13 .1 0 .5156 33/64
. , .. .0180 77 ... .08 10 46 4.4 .1732 7.4 .2913 13.49 .5312 17 /32
.5 .0 197 ... , .0820 45 .1770 16 .29 50 M 13 .5 .5315
.0200 76 2.1 .0827 4.5 .1771 7.5 .2953 13 .89 .5469 35/64
.0210 75 2.15 .0846 .1800 15 7.54 .2968 19/64 .... 14.0 .5512
.55 .0217 .086 0 44 4.6 .1811 7.6 .2992 14 .29 .5624 9/16
.,' . .0225 74 2.2 .0866 .1820 14 .3020 N 14 .5 .5709
.6 .0236 2.25 .0855 4.7 .1850 13 7.7 .3031 14 .68 .578 1 37 /64
... .0240 73 .0890 43 4.75 .1870 7.75 .3051 15 .0 .5906
.0250 72 2.3 .0905 4.76 .1875 3/16 7.8 .30 71 15 .08 .5937 19/32
.65 .0256 2.35 .0925 4.8 .189 0 12 7.9 .3110 15.48 .6094 39/64
.. " .0260 71 ... .0935 42 .1910 11 7.94 .3125 5/i6 15 .5 .6 102
.0280 70 2.38 .0937 3/32 ... 4.9 .1929 8.0 .3 150 15 .88 .6250 5/8
.7 .0276 2.4 .0945 .1935 10 .3160 0 16 .0 .6299
.0292 69 .0960 41 .1960 9 8.1 .3189 16.27 .6406 41 /64
.75 .0295 2.45 .0964 5.0 .1968 8.2 .3228 16.5 .6496
.0310 68 .0980 40 .1990 8 .. . . .3230 P 16 .67 .6562 21 /32
.79 .0312 1/32 2.5 .0984 5.1 .2008 8.25 .3248 17 .0 .6693
.8 .0315 .... .0995 39 .20 10 7 8.3 .3268 17 .U6 .6719 43/64
.. . . .0320 67 .10 15 38 5.16 .203 1 13/64 8.33 .328 1 21 /64 .. 17 .46 .6875 11/16
... . .03 30 66 2.6 .1024 .2040 6 8.4 .3307 17 .5 .6890
.85 .0335 .1040 37 5.2 .2047 .3320 Q 17.86 .7031 45/64
... .0350 65 2.7 .1063 .2055 5 8.5 .3346 18.0 .7087
.9 .0354 , ... .1065 36 5.25 .2067 8.6 .3386 18 .26 .7187 23/32
.0360 64 2.75 .1082 5.3 .2086 .. . . .3390 R 18 .5 .7283
... .0370 63 2.78 .1094 7/64 .2090 4 8.7 .3425 18 .65 .7344 47 /64
.95 .0374 .1100 35 5.4 .2 126 8.73 .3437 11 /32 .. 19 .0 .7480
" .. .0380 62 2.8 .1102 .2 130 3 8.75 .3445 19 .05 .7500 3/4
.0390 61 .1110 34 5.5 .2 165 8.8 .3465 19.45 .7656 49/64
1.0 .0394 ... .11 30 33 5.56 .2 187 7/32 .3480 S 19 .5 .7677
.0400 60 2.9 .1141 5.6 .22 05 8.9 .3504 19 .84 .7812 25/32
.... .0410 59 .11 60 32 .22 10 2 9.0 .3543 20.0 .7874
1.05 .0413 3.0 .11 81 5.7 .2244 .... .3580 T 20.24 .7969 51 /64
.. . . .0420 58 .12 00 31 5.7 5 .2263 9.1 .3583 20 .5 .8071
... . .0430 57 3.1 .1220 . . .. .2280 1 9.13 .3594 23/64 20.64 .8 125 13/ 16
1.1 .0433 3.18 .1250 1/8 .... 5.8 .22 83 9.2 .3622 21.0 .8268
1.15 .0452 3.2 .1260 5.9 .2323 9.25 .3641 21.04 .8218 53 /64
.. .0465 56 3.25 .1279 .2340 A 9.3 .3661 21.43 .8437 27132
1.19 .0469 3/64 ... ·. .1285 30 5.95 .2344 15/64 .... .3680 U 21.5 .8465
1.2 .0472 3.3 .1299 6.0 .2362 9.4 .370 1 21.83 .8594 55 /64
1.25 .0492 3.4 .1338 .2380 B 9.5 .3740 22.0 .866 1
1.3 .0512 · .. .1360 29 6.1 .2 401 9.53 .3750 3/8 .... 22.23 .8750 7/8
. ... .0520 55 3.5 .1378 .2 420 C .3 770 V 22.5 .8858
1.35 .0513 ' ... .1405 28 6.2 .2441 9.6 .3780 22.62 .8906 57 /64
... . .0550 54 3.57 .1406 9/64 6.25 .2460 0 9.7 .38 19 23.0 .9055
1.4 .0551 3.6 .1417 6.3 .2480 9.75 .3838 23.02 .9062 29 /32
1.45 .0570 · .. .1440 27 6.35 .2 500 1/4 E 9.8 .3858 23.42 .9219 59 /64
1.5 .0591 3.7 .1457 6.4 .2520 .3860 W 23.5 .9252
... .0595 53 .1470 26 6.5 .2559 9.9 .3839 23.81 .9375 15/ 16
1.55 .0610 3.75 .1476 .2570 F 9.92 .3906 25/64 24.0 .9449
1.~9 .0625 1116 .1495 25 6.6 .2598 10.0 .3937 24 .2 1 .953 1 61 /64
1.6 .0629 3.8 .1496 .26 10 G .39 70 X 24.5 .9646
.0635 52 .1520 24 6.7 .2638 .4040 y 24.61 .9687 31/32
1.65 .0649 3.9 .1535 6.75 .2657 16/64 10 .32 .4062 13/32 25.0 .9843
1.7 .0669 .1540 23 6.75 .2657 .4130 Z 25 .03 .9 844 63 /64
.. , . .0610 51 3.97 .1562 5/32 .2660 H 10 .5 .4134 25.4 1.0000 1
32C 1-51
o
Heli-Coillnserts and Installers
OJ Use these Heli-Coil inserts on all models to repair damaged

threads. The installation kit consists of drill, tap, and insertion
tools.
INotel The 14 mm spark plug inserts are specially made for use
in aluminum cylinder heads. Do not use substitutes.
Installation Instructions
1
1. Drill to adequate depth using drill size supplied with kit. C03603
2. Use Heli-Coil tap supplied with pack. Check thread size on

shank to make certain proper size is used.
3. Screw insert onto mandrel until tang is fully engaged in driving

contour .
4. Screw insert into tapped hole. Top of insert must be one-

quarter to one-half turn below top surface.
5. The tang must be removed to allow full passage of screw into

the insert.
The tang may be broken off cleanly at the notch in the bottom coil
with a punch or rod having a diameter that just fits into the
assembled insert. Make sure that the punch or rod has a square
end (no chamfer). Place punch or rod into assembled insert until it
rests on tang. Holding tool squarely, strike it sharply with a
hammer.
PIN Name of Part PIN Name of Part
391436 Heli-Coillnstaller Kit, 8-32 391448 Heli-Coillnserts, 8-32

391438 He Ii-Coil Installer Kit, 10-24 391447 Heli-Coillnserts, 10-24
391439 He Ii-Coil Installer Kit, 1/4-20 391446 Heli-Coillnserts, 1/4-20
391440 Heli-Coillnstaller Kit, 5/16 -18 391445 Heli-Coill nserts, 5/ 16 -18
391441 Heli-Coillnstaller Kit, 3/8 -16 391444 Heli-Coill nserts, 3/8-16
391450 He Ii-Coil Installer Kit, 1/2-13 391449 Heli-Coill nserts, 1/2-13
984963 He Ii-Coil Insta Iler Kit, 3/4-16 913412 He Ii-Co il Inserts, 3/4-16
391437 Heli-Coillnstaller Kit, 14 mm 437948 Heli-Coillnserts, M5 x 0.8
437276 Heli-Coillnstaller Kit, M5 x 0.8 437949 Heli-Coillnserts, M6 x 1.0
437277 Heli-Coillnstaller Kit, M6 x 1.0 437280 Heli-Coillnserts, M8 x 1.25
437278 Heli-Coillnstaller Kit, M8 x 1.25 437950 Heli-Coillnserts, M 10 x 1.50
437279 He Ii-Co il Installer Kit, M 10 x 1.50 391443 Heli-Coillnserts, 14 mm (318 in. Reach)
391442 He/i-Coi/lnserts, 14 mm (112 in. Reach)
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1-52 32Cl e nQ
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Fuel System
Table of Contents
In. General Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 2

Service Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 3
Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 5
Description of Fuel System ......................... 2- 6
In-Line Fuel Filter Servicing - Commercial Models . . . . . . 2- 7
Fuel Pump Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 8
Primer System Servicing . ......................... 2-10
Electric Primer ......... . ................ .... ... 2-11
Manual Primer ............... .. ........ . ....... 2-12
Carburetor Cleaning and Inspection - All Models ....... 2-16
Carburetor Servicing, 9.9/15 . ....................... 2-19
Carburetor Mixture Adjustment, 9.9/15 ............... 2-23
Intake Manifold Servicing, 9.9/15 .................... 2-24
Carburetor Servicing, 20. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Carburetor Mixture Adjustment, 20 . . . . . . . . . . . . . . . . . . 2-31
Carburetor Servicing, 25 - 30 . . . . . . . . . . . . . . . . . . . . . . . 2-32
Carburetor Mixture Adjustment, 25 - 30. . . . . . . . . . . . . . . 2-36
Intake Manifold Servicing, 20 - 30. . . . . . . . . . . . . . . . . . . . 2-37
Fuel System Trouble Check Chart . . . . . . . . . . . . . . . . . . . END
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Before working on any part of the fuel system, read the section

ing 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

must be felt when reusing a locking fastener. If replacement is
indicated, use only authorized replacement or equivalent.
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2-2 32C/eng
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Special Torque Chart _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Description In. Lbs. N'm Adhesive
Leaf Valve Screws 25-35 2,8-4,0 avIC Screw Lock
Intake Manifold Screws 60-84 7-9 •

Cover and Bowl Screws -
9.9 - 20
8-10 0,8-1,2 •
Cover and Bowl Screws -
25 - 30
25-35 2,8-4,0 •
PCE0034
avIC Special Tools Required
Orifice Plug Screwdriver, PI N 317002

Float Gauge, PI N 324891
Fuel Nipple Cleaning Tool, PI N 326623
Pressure Test Adapter, PI N 389945
Fuel Line Vacuum Tester, PI N 390954
Tie Strap Installation Tool, PI N 323716
Hose Clamp Wrench, PIN 325043
Ballhex Screwdriver, PI N 327622
Service Aids Required
Stevens Gearcase Vacuum Gauge, V-34

Stevens Gearcase Pressure Gauge, S-34
Automotive Fuel Pump Testing Gauge
Isopropyl Alcohol
Monoject 412 Syringe, or equivalent
Clear Tubing, 1/8 in. I.D. x 12 in. (3 mm I.D. x 305 mm) long
Brass or Copper Tubing, 3132 in. x 4 in. (2 mm x 102 mm) long
Ohmmeter
Machinist's Straightedge
Inch Pound Torque Wrench
Lubricants and Sealants Required
avIC Cleaning Solvent

Johnson or Evinrude Outboard Lubricant
avIC Locquic Primer
avIC Screw Lock
avIC Nut Lock
Gasoila Sealer
avIC Gel-Seal /I ™
Isopropyl Alcohol
avIC 2+4@Fuel Conditioner
avIC Carbon Guard ™ Fuel Additive E
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NOTES
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2 -4 32C
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Fuel Requirements
Minimum Octane
Models Recommendation (R+M)/2 "AKI" "RON"
9.9 - 30 See fuel classifications below. 67 69
PCE0020
Preferred Fuel: Any regular unleaded, regular leaded, or premium unleaded gasoline having the
recommended octane rating, and not extended with alcohol.
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.
& Fuel leakage can contribute to a fire or explosion.

INote I 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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Description of Fuel System
m 1. The fuel pump is of the diaphragm-displacement type and

is operated by changes in crankcase pressure. Alternately, suc-
tion and pressure in the crankcase are transmitted to the pump
diaphragm.
rn 2. The carburetor meters and distributes the fuel consumed.

It controls engine speed and power output by varying the intake
charge density. To react correctly to a wide range of operating
conditions, the carburetor has multiple fuel mixing circuits.
rn rn rn Mixture enrichment for cold starting is controlled

by either a choke ®, a manual primer ®, or a fuel primer solenoid
©.
30393
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2-6 32Cleng
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In-Line Fuel Filter Servicing - Commercial Models
'sl 1. Unscrew in-line filter cover @. It is not necessary to remove

~ fuel hoses to service filter.
'sl 2. Clean filter canister ® and shake filter element to remove

~ collected particles.
'sl 3. Clean all parts of the filter assembly and fuel connectors
~ with a mild aerosol solvent, and blow dry. Do not dry parts
with a cloth as lint might stick to the parts and clog the passages
or prevent the fuel pump valves from seating. Dissolve any
gummy deposits with OMC Cleaning Solvent.
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32C/eng 2-7 o
Fuel Pump Servicing
Before replacing a suspect fuel pump, remove and clean the fuel
filter and install a new filter element. Also, remove the fuel hose
from the fuel tank and blow through all passages and hoses with
low-pressure compressed air to be sure they are open. This might
be the cause of inadequate fuel delivery. If this procedure does
not correct the trouble, test the fuel pump.
INote I Toprevent excessive fuel spillage, disconnect hose con-

nector 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.
[]] rn To service filter, loosen screw and remove cover @. Do

not lose small a-ring ® from around center post or large a -ring ©
from outer edge of cover.
rn • Wash filte r element @ with clean solvent and a brush .
• Install filter with lip facing fuel pump body. 2

rn • Make sure the large a-ring © is seated in its groove in
the cover and the small a -ring ® is in place around
DR3000
center post.
rn • Install cover @' Position inlet nipple between screw

heads .
• Tighten the cover screw securely.
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Function Test
Conduct this test with the motor in a test tank or on the boat.
Before testing, loosen fuel tank gas cap momentarily to release

any pressure that may have built up. Fuel tank must not be more
than 30 in. (76 cm) below fuel pump.
W 1. Remove carburetor to fuel pump hose. Connect a fuel

pressure gauge (obtain locally) between the carburetor and fuel
pump.
63328
2. Start motor and observe gauge. Pump pressures should read
as follows:
Pressure
RPM PSI kPa
600 1 7
2500-3000 1.5 10
4500 2.5 17
PCEoon
3. If fuel pump does not meet these specifications, replace it.
• When installing a new fuel pump, apply OMC Nut Loekto

threads of screws. Install screws and torque to 24-36 in.
Ibs. (2,8-4,0 N·m).
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Primer System Servicing
Function Test
1. Start engine and allow it to reach normal operating tempera-

ture. Set engine speed at 2000 RPM.
2. While engine is running:
IT] • Electric start models - Push key in. Engine should run
richly and drop 1000 RPM .
• Manual start models - Stroke primer knob. Engine

should run richly and drop 1000 RPM.
rn 3. Remove primer hose from any primer fitting that you

suspect is clogged. Connect a 1/8 in. I.D. clear vinyl hose between
the fitting and a syringe filled with isopropyl alcohol.
4. Press lightly on the syringe plunger.
• If fluid moves through the fitting, it is okay.
[]] • If fluid does not move through the fitting, clean it with
OMC Cleaning Tool, PIN 326623.
5. Manual start models - Be sure to check for obstructions in

primer hose tee.
3
803395
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2-10 32Cl e ng
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Electric Primer
rn 1. 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.
2. To test solenoid valve and seat:
[[] • Lightly pressurize inlet fitting with alcohol and syringe.
[]] • With lever in run position @' no fluid should enter inlet
fitting.
[]] • With lever in prime position @ , fluid should come out

both outlet fittings.
[l] 3. To inspect or replace internal components, remove the

four solenoid cover screws.
[ ] ] 4. When assembling solenoid, back out screws in their holes

to engage original threads - then, tighten securely.
C0A1138
Installation /(- . -fe\

I'~
,
1. Attach purple/white leads and three hoses. Secure large hose
with tie strap.
2. Install solenoid and bracket. Position ground lead under the

inside bracket screw. ~-@
& 3. Check for leaks by connecting fuel tank hose to motor and
squeezing primer bulb until definite pressure is felt in the bulb.
6
DR1417
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Manual Primer
If the primer is difficult to operate or suspected of not working:
1. Remove primer hose from nipple in carburetor. Install hose end

into a suitable container to catch fuel.
2. Squeeze fuel tank primer bulb to fill carburetor bowls with fuel.
3. Operate primer pump twice.
• Fuel should squirt from the hoses into the container,

indicating primer is functioning.
4. Inspect primer nipple to ensure nipple is free of obstructions.
5. If primer pump fails to pump fuel from hoses, a restricted or

kinked hose or inoperative primer pump may be the cause.
6. Operate primer pump and watch for fuel squirting from hose.
• If fuel squirts from hose, primer pump is okay; if not,

proceed to next step.
rn 7. Remove hose at small nipple on top side of primer pump.

Inspect hose for kinks or obstructions to flow. Operate primer
pump; fuel should squirt from small nipple @ .
• If primer pump fails to pump, inspect inlet hose between

primer pump and carburetor for kinks and obstructions.
• If hose is open and not kinked, remove and disassemble

primer pump assembly.
• If the primer pump was not working in the above test or

is externally leaking, replace the a-rings.
INotel The three smaller a-rings are made with a special materi-
al; use only the proper a-rings.
A built-in check valve on the primer housing (under the small

nipple) should allow fuel to come out in one direction and close in
the other direction.
[]J The fuel inlet check valve ® allows fuel into the end of the
plunger and out through the hole in the side of the plunger @.
Replace if damaged or does not function.
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2-12 32C/eng
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,-,
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1
II
-- I I
I I
I i
I I
--'I I
'i I
'-'
9
DR2578
/
@
10
DR2579
[ ] ] Plunger @ Shown in Warm-Up Position
[1Q] Plunger @ Shown in Off Position.

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2-13
32C/eng
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Disassembly
[II]
1. Remove primer pump housing retaining ring from primer
pump.
[g] 2. Remove primer plunger from housing. Discard O-rings.
Inspection
1. Inspect brass plunger shaft for any burrs or scratches. Remove

small scratches by polishing the plunger with crocus cloth. If the
plunger has deep scratches, replace the plunger.
[1l]2. Inspect plunger where cross hole intersects inside hole.

Any burrs around cross hole will accelerate wear of O-rings.
Remove any protruding burrs and polish with crocus cloth.
The check valve under the small nipple on the primer pump
housing allows fuel flow out of the pump housing and prevents
flow into the housing.
~ [![] 3. To inspect for proper check valve function, use a

squeeze bottle containing alcohol (such as isopropyl rubbing
29283
alcohol). Connect a clear plastic hose between small nipple and
bottle to observe flow of alcohol. Squeeze the bottle lightly to
force alcohol through the hose. Visually check for flow of alcohol
into the housing. It is permissible for a few drops to be present.
This indicates the check valve is blocking the flow and functioning
correctly. If a steady stream of alcohol flows through the small
nipple, the check valve is inoperative and the primer pump
housing must be replaced.
13
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2-14 32Cl e ng
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18
29281 29280
I1ID 4. Install a hose over the large nipple of the primer pump
housing and connect other end of hose to the alcohol squeeze
bottle. Place your thumb over end of the plunger housing.
Squeeze the alcohol bottle to fill the plunger housing. Alcohol
should flow freely out of the small nipple, indicating no obstruc-
tions. If no flow is indicated, replace primer pump housing .
Assembly
GIl 1. Position the spring and washer on the plunger shaft.
[1!J 2. Install two new a-rings @ and quad ring ® onto plunger
shaft.
[1ID 3. Install a new a-ring onto the end cap and position the end
cap on the plunger shaft.
12014. Insert plunger shaft and end cap into primer pump
housing. Reinstall retainer clip.
~ 5. To bench test the primer pump after assembly, connect a

5 in. piece of hose to the large nipple and place the other end of
hose in a container of alcohol. Place a hose on the small nipple
and place other end of hose to drain into a container. Hold primer
pump in horizontal position as it would be installed on the engine.
Move plunger back and forth ten times. Primer should pump
approximately 10 cc of alcohol in ten strokes. If pump fails to
pump alcohol, disassemble and check for missing, cut, or split
a-rings or damaged check valves.
&. 6. After installing, check for leaks by connecting fuel tank

hose to motor and squeezing primer bulb until definite pressure
is felt in the bulb.
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Carburetor Cleaning and Inspection - All Models
Cleaning
INote I Never clean a carburetor by submerging or soaking it in a

hot tank or carburetor cleaner. Do not expose plastic or rubber
parts to any carburetor cleaner.
1. Before inspection, all carburetor components must be perfectly

clean:
• Carburetor must be completely disassembled.
• Clean parts with OMC Carburetor and Choke Cleaner.
[I] • Use a clean bristle brush to remove gum or varnish

deposits.
• 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
1. Inspect the inlet needle and float valve seat :
rn • Check the inlet needle tip for grooves, nicks, scratches, or

distortion.
rn • Check the float valve seat for nicks, scratches, or distor-

tion.
• Check the float for signs of oil or gasoline saturation .
INote I The inlet needle and float valve seat must be replaced as a 3
63324
set.
Needle Valves
[ ] ] Inspect the tapered end of the needle valve for nicks,

scratches, grooves, or signs of distortion .
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2-16 32C/eng
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Carburetor Body
W 1. Check all drillings and passages with a syringe filled with

isopropyl alcohol.
2. Visually inspect all gasket surfaces for nicks or irregularities.
3. Check for excessive throttle shaft play. Check for throttle valve
misalignment.
4. If necessary, remove the calibration pocket core plug to inspect

the pocket for damage or restrictions:
[[] • Drive a small punch not more than 1/8 in . (3 mm)

through plug and pry out.
• Install a new core plug with the convex side up. Seat the
plug using a flat end punch and plastic mallet. Apply
Gasoila sealer to the rim of the core plug after it is
seated.
5. If necessary, remove the lead shot to inspect passage for

restrictions or leaks:
rn • Gently pry up on lead shot with a sharp edged tool.

[]J • Install a new lead shot. Flatten shot with flat end punch
and plastic mallet. Check for leakage.
[ [ ] 6. Check for leaks between emulsion pickup tube and carbu-

retor body:
• Invert carburetor body and fill idle circuit with isopropyl

alcohol.
• Check for leaks at point (8).
• If a leak occurs, blow dry and apply a drop of OMC Ultra

Lock at point (8) .
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NOTES
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2-18 32C/enQ
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Carburetor Servicing, 9.9/15
Removal
In. 1. Avoid accidental start-up while servicing engine; twist

2. Move the manual starter as described in Section 7.
[JJ 3. Loosen two retaining screws and remove air silencer.
rn 4. Remove the choke lever.
rn 5. Remove the cam follower a-ring.

rn 6. Loosen two mounting nuts and remove carburetor.
[ ] ] 7. Cut tie strap securing fuel hose to carburetor.
32C/eng it Safety Related 2-19

9.9/15
o
@~ ~
® .~ 9
®---~ :
f~-"-@
©
6
DR4975
W Disassembly
1. Remove the low-speed needle ® and spring ® from the

carburetor body cover.
2. Remove the six cover screws. Lift the cover and gasket off the
carburetor body.
3. Remove the seven float chamber screws. Remove the float

chamber and gasket.
4. Remove the hinge pin © , float @ , and float valve ®.
5. Remove the valve seat ® and gasket @ .
6. Remove the high-speed orifice ® .
7. If necessary, remove the air vent CD .
8. Refer to Carburetor Cleaning and Inspection.

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2-20 32Cleng <1\
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m Assembly
INote I Before proceeding, be sure that all parts are perfectly
clean. Be sure that all replacement parts match original ones in o 9.9 8 I5 H.P.
168 ~ GI:
2 THRU G H P.
size and shape. Replace all gaskets, O-rings, and sealing washers
each time you assemble a carburetor.
1. If removed, press the air vent CD in the carburetor body.
2. Install the high-speed orifice @.

93328
3. Install the gasket © and valve seat ®.
4. Install the hinge pin ©, float @, and float valve @.
5. 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.
rn • Turn carburetor body upside down and hold so gasket

surface is horizontal. The weight of the float will close
the float valve needle. Rest OMC Float Gauge, PI N
324891, on gasket surface and slide gauge up, next to 8
803406
float. Top of float should be between notches on gauge.
rn Use notch that is indicated "9.9 & 15 HP." Be certain gauge is

not holding down the float.
• If float level is not between the notches of gauge, lightly

bend metal float arm to adjust level. Be careful not to
force float needle valve into seat.
6. Check for correct float drop dimension. This dimension affects

the full opening of the inlet needle and is critical to correct
operation of the carburetor. With carburetor body in normal
running position, the float must drop open to dimension shown.
To adjust, bend tab on float arm where tab contacts float seat.
[]J Q) Base of carburetor body.

® Bend float lever tab to achieve proper dimension
CD 1 in. to 13/s in. (25-35 mm).
7. Place the lower gasket into the float chamber. Install the float
chamber and bowl gasket. Tighten the screws to a torque of
8-10 in. Ibs. (0,8-1,2 N·m), following sequence embossed on
float chamber.
8. Install the carburetor body cover and gasket. Tighten the

screws to a torque of 8-10 in. Ibs. (0,8-1,2 N·m), following
sequence embossed on cover.
9. Install the low-speed needle and spring. Turn needle carefully

until it lightly contacts the seat; then back it off 3 turns.
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Installation
[]J 1. Attach the fuel supply hose, and secure with a tie strap.
2. Position a new gasket on the intake manifold.
ITQ] 3. Install the carburetor. Tighten two retaining nuts securely.
I1TI 4. Install cam follower on post. Position O-ring on the post to

secure cam follower.
ern 5. Install the choke lever.

6. Install the air silencer cover and tighten screws securely.
7. Install manual starter as described in Section 7.
8. If the slow speed needle adjustment has been disturbed, refer

to Carburetor Mixture Adjustment, 9.9/15.
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Carburetor Mixture Adjustment, 9.9/15
1. Start the engine and run it in FORWARD at one-half throttle.
Allow the engine to reach normal operating temperature.
[IJ 2. Tiller models - as you face the steering handle, turn the
idle speed adjustment knob counterclockwise to full SLOW speed
position.
rn 3. Run the engine at slow speed (700-800 RPM) and adjust

the low-speed needle until the highest consistent RPM is attained.
Allow 15 seconds after each adjustment for the engine to re-
spond.
4. After the final adjustment is completed, turn the low-speed

needle counterclockwise one-eighth turn to prevent a lean condi -
tion, particularly in NEUTRAL.
5. Reduce engine speed and turn the idle speed adjustment to

allow the engine to run at a minimum of 650 RPM in FORWARD.
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.
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Intake Manifold Servicing, 9.9/15
Removal
1. Remove the powerhead as described in Section 4.
[IJ 2. Loosen and remove six intake manifold screws.
/]] 3. Remove intake manifold, leaf plate, and two gaskets.

Discard gaskets.
Inspection
rn 1. Inspect the leaf plate assemblies for damage:
• The leaf valves and plate must not be distorted.
• The leaf valve tips ® must not be cracked or chipped.

• The leaf stops ® must not be distorted or loose.
• The check valve disk © must be intact and free to move
inside the valve. The check valve screen must be clean.
rn • Use a machinist's straightedge to check the flatness of

the leaf plate. The gasket surfaces must be flat,
± 0.003 in. (0,08 mm).
• Test leaf plate screw tightness. If loose, .retighten using

OMC Screw Lock.
2. Inspect the intake manifold:
• All gasket surfaces must be smooth and free of nicks.
[]] • Use a machinist's straightedge to check for flatness in all

directions. The gasket surface must be flat, ± 0.003 in.
(0,08 mm).
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2-24 32C/eng
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Disassembly
INotel Do not disassemble leaf plate assemblies unless leaf plate

seats, leaf valves, or leaf stops are damaged or corroded.
[ ] ] 1. Remove two screws per leaf valve and remove the leaf
valves as required.
2. When disassembling leaf plate assemblies, do not lift or bend

leaf valves. Remove the leaf stop screws and remove the stops,
shims, and leaf valves.
12320
3. When disassembled, keep the stops, shims, and leaf valves
separated by assembly.
Assembly
I Note I All intake manifold components must be perfectly clean

before assembly. Do not use a strong carburetor cleaner or hot
. soaking tank.
rn 1. Place leaf valves on leaf plate. If new valves do not seat on

the leaf plate, turn the leaf valves over. 7 12321
INotel Used leaf valves must not be turned over for reuse. Leaf
valve may break when returned to service, causing serious
powerhead damage.
2. If any leaf valves are standing open, apply light pressure using
a pencil eraser. If leaf valve closes with light pressure, valve is
acceptable. If not, inspect leaf plate for high spots or burrs.
I Note I Do not lap leaf plate. If plate is too smooth, the leaf valves
may stick closed after off-season storage.
3. Apply OMC Locquic Primer to mounting screws and allow to air

dry.
[ ] ] 4. Apply OMC Screw Lock to mounting screws. Wipe off

excess adhesive.
5. Assemble leaf valve shim (if required) and leaf stop. Install
screws finger tight.
[ ] ] 6. Center the leaf valves on the plate using index marks @.
[ ] ] 7. Tighten screws securely.
Installation
1. Position leaf plate assembly and new gaskets on powerhead.

Install gaskets dry. Use no sealer.
llQ) 2. Install intake manifold using six retaining screws. Torque

screws to 60-80 in. Ibs. (7-9 N·m).
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NOTES
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2-26 32C/enq
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Carburetor Servicing, 20
Removal
&. Avoid accidental starting of engine while servicing; twist

IT] 1. Remove cam follower link.
W 2. Remove the carburetor mounting nuts and remove the

carburetor.
[ ] ] 3. Remove tie straps and large primer hose from carburetor

nipple.
rn 4. Remove tie straps, fuel pump hose from carburetor nipple,

and small primer hose from carburetor nipple.
[ ] ] 5. Remove carburetor to manifold gasket.
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6
DR4975
[]J Disassembly
1. Remove the low-speed needle ® and spring ® from the

carburetor body cover.
2. Remove the six cover screws. Lift the cover and gasket off the
carburetor body.
3. Remove the seven float chamber screws. Remove the float

chamber and gasket.
4. Remove the hinge pin ©, float @ , and float valve ® .
5. Remove the valve seat ® and gasket @.
6. Remove the high-speed orifice ® .
7. If necessary, removed the air vent CD.

8. Refer to Carburetor Cleaning and Inspection.
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2-28 32Cl enQ
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[ ] ] Assembly
INotel Before proceeding, be sure that all parts are perfectly

clean. Be sure that all replacement parts match original ones in 0
size and shape. Replace all gaskets, O-rings, and sealing washers
each time you assemble a carburetor.
1. If removed, press the air vent CD in the carburetor body.
2. Install the high-speed orifice @.
3. Install the gasket @ and valve seat ®.

4. Install the hinge pin @, float @ , and float valve @.
5. 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.
m• Turn carburetor body upside down and hold so gasket

the float valve needle. Rest OMC Float Gauge, PIN
324891, on gasket surface and slide gauge up, next to 8 803406
float. Top of float should be between notches on gauge.
m Use notch that is indicated "9.9 & 15 HP." Be certain gauge is

not holding down the float .


To adjust, bend tab on float arm where tab contacts float seat.
[]] Cd) Base of carburetor body

® Bend float lever tab to achieve proper dimension
CD 1 in. to Pis in. (25-35 mm)
7. Place the lower gasket into the float chamber. Install the float
chamber and bowl gasket. Tighten the screws to a torque of 8-10
in. Ibs. (0,8-1,2 N·m), following sequence embossed on float
chamber.
8. Install the carburetor body cover and gasket. Tighten the

screws to a torque of 8-10 in. Ibs. (0,8-1,2 N·m), following
sequence embossed on cover.
9. Install the low-speed needle and spring. Turn needle carefully

until it lightly contacts the seat; then back it off 3 turns.
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Installation
[ ] ] 1. Place a new gasket on manifold studs. Do not use sealer

on the gasket.
I1Q] 2. Attach hose from fuel pump to carburetor nipple and

small primer hose to carburetor nipple. Secure with tie straps.
[I!J 3. Attach large primer hose to carburetor nipple. Secure with

tie strap.
em 4. Install the carburetor. Tighten two mounting nuts se-

curely.
[]]] 5. Attach cam follower link.
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Carburetor Mixture Adjustment, 20
1. Start the engine and run it in FORWARD at one-half throttle.

Allow the engine to reach normal operating temperature .
OJ 2. Tiller models - as you face the steering handle, turn the

idle speed adjustment knob counterclockwise to full SLOW speed
position.
II] 3. Run the engine at slow speed (700-800 RPM), and adjust
t he low-speed needle until the highest consistent RPM is attained.
Allow 15 seconds after each adjustment for the engine to re-
spond.
4. After the final adjustment is completed, turn the low-speed

needle counterclockwise one-eighth turn to prevent a lean condi-
tion, particularly in NEUTRAL.
5. Reduce engine speed, and turn the idle speed adjustment to

allow the engine to run at a minimum of 650 RPM in FORWARD.
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 '/16 turn. Allow 15 seconds after each
adjustment for the engine to respond . Repeat Step 6 to verify that
t he 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.
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Carburetor Servicing, 25 - 30
Removal
1. Remove electric starter bracket (if equipped) and set it aside.
OJ 2. Remove primer hose from nipple.

rn 3. Push throttle link out of cam follower.
rn 4. Remove carburetor mounting nuts.
5. Remove carburetor from manifold.
rn 6. Remove and discard tie strap. Disconnect hose from fuel

nipples.
Disassembly
[]J 1. Remove manual primer fuel nipple and high speed orifice
® from float chamber using OMC Orifice Driver, PI N 317002.
[]J 2. Remove intermediate air bleed orifice @ .
[]J 3. Remove retaining screws and float chamber @.
[]J 4. Remove float and inlet valve assembly @ .
[]J 5. Remove nozzle well gasket @.
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2-32 32C/ enQ
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m 6. Remove components of slow speed needle ®.
W 7. Remove four screws and carburetor body cover @.
[ ] ] 8. Remove carburetor body gasket @.
9. Refer to Cleaning and Inspection - All Models.
When installing new parts from a carburetor rebuild kit, inspect

gaskets and compare to original gaskets to ensure all holes are
correctly punched. Also, inspect new gaskets for any loose fibers
or particles of gasket material.
Assembly
[ ] ] 1. Install a new high speed nozzle gasket @.
[ ] ] 2. Install the float and inlet valve assembly @.
[ ] ] 3. Install the intermediate air bleed orifice @.
[ ] ] 4. Install the high speed orifice @, gasket, and manual

primer fuel nipple.
[ ] ] 5. Install slow speed needle and spring ® . Turn carefully

until it lightly contacts seat .
• Back needle out for initial setting - 2112 turns.

DR4808
[ [ ] 6. Install the carburetor body cover and gasket. Tighten the

screws in an "X" pattern to a torque of 15-22 in. Ibs.
(1,6-2,4 N·m).
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32C/eng 2-33 Qi
25 - 30 <1\
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7. Check for correct positioning of float level. Float level controls
the height of fuel in the float chamber and is critical with regard to
carburetor calibration and function.
W • Turn carburetor body upside down and hold so gasket

the float valve needle. Rest OMC Float Gauge,
PI N 324891, on gasket surface, and slide gauge up next
to float. Top of float should be between notches @ on
float gauge. Be certain gauge is not holding down the
float .


@ 0
To adjust, bend tab on float arm where tab contacts float seat. _,L..-__ ~
[ ] ] @ Base of carburetor body

© Bend float lever tab to achieve proper dimension 7
803406
@ 1% in. to 1% in. (28-41 mm)
9. Install float chamber and a new gasket.
10. Apply OMC Locquic Primer and OMC Screw Lock to the
threads of four float chamber screws. Install the screws and
torque in an "x" pattern to 25-35 in. Ibs. (2,8-4,0 N·m).
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Installation
[]J 1. Install the fuel inlet hose and manual primer hose to the
carburetor. Secure the hoses using new tie straps. Install with
OMC Tie Strap Installation Tool, PI N 323716.
rn 2. Position a new carburetor base gasket on the intake

manifold studs. Do not use sealer on the gasket.
[1Q] 3. Secure the carburetor to the intake manifold.
[I!] 4. Connect the throttle link to the cam follower.
~ 5. Secure the primer hose to the carburetor using a new tie

strap.
6. If the slow speed needle adjustment has been disturbed, refer

to Carburetor Mixture Adjustment, 25 - 30.
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25 - 30 Qi
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Carburetor Mixture Adjust ment, 25 - 30
INote I The slow speed mixture in this carburetor is controlled by
an adjustable needle
[]] 1. Make a reference mark ® on the carburetor body before

you disturb the needle adjustment.
rn 2. Tiller models - as you face the steering handle, turn idle

speed adjustment knob counterclockwise to full SLOW speed
position.
3. Start the engine and run it in gear, at slow speed (700-800

RPM), for three minutes. Allow it to reach normal operating
temperature.
• If the adjustment is too lean, the engine will sneeze and

backfire. Go to Step 4.
• If the adjustment is too rich, the engine will be rough and

unsteady. Go to Step 5.
[IJ 4. If the adjustment is too lean, note your reference mark ®

and turn the needle '/8 revolution counterclockwise. Wait 15
seconds after each adjustment and repeat this procedure until
you reach the highest consistent RPM.
[IJ 5. If the adjustment is too rich, note your reference mark ®

and turn the needle '/8 revolution clockwise. Wait 15 seconds after
each adjustment and repeat this procedure until you reach the
highest consistent RPM .
6. To test your adjustment, run engine near full throttle for three
minutes. Return the engine to idle, in gear. The engine should
maintain a smooth idle RPM.
• If your test results vary, repeat Steps 3 thru 5.
Important If the engine does not respond properly to

these adjustments, check the following:
• Engine temperature
• Linkage adjustments
• External recirculation system
• Sufficient exhaust back pressure
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2-36 32C/eng
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Intake Manifold Servicing, 20 - 30
Removal
1. Follow steps listed in Carburetor Removal , this section.
rn 2. Remove pin @ from end of throttle control rod ® .

rn
@.
3. Remove tie strap © and disconnect oil recirculation hose
4. Remove screws attaching intake manifold to powerhead.

Remove intake manifold and gasket.
rn 5. Remove flat head Phillips screw ® and carefully remove

leaf plate assembly and gasket.
Inspection
INotelDo not lift or bend leaf valves by hand. This may damage
them so that they may not seal properly or may break after the
engine is returned to service.
1. Inspect the leaf plate assemblies for damage:
• The leaf valves and plate must not be distorted.
• The leaf valve tips must not be cracked or chipped.
• The leaf stops must not be distorted or loose.
C!] • Use a machinist's straightedge to check the flatness of

the leaf plate. The gasket surfaces must be flat,
± 0.003 in. (0,08 mm).
2. Inspect the intake manifold:
• All gasket surfaces must be smooth and free of nicks.
[[] • Use a machinist's straightedge to check for flatness in all

directions. The gasket surfaces must be flat, ± 0.003 in.
(0,08 mm).
4
12684
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Disassembly
I
I Note Do not disassemble leaf plate assemblies unless leaf plate
seats, leaf valves, or leaf stops are damaged or corroded.
I]] 1. Remove one screw and nut per leaf valve and remove the
leaf plate assemblies as required.
2. When disassembled, keep the stops and leaf valves separated

by assembly.
Assembly
INote I All
intake manifold components must be perfectly clean
before assembly. Do not use a strong carburetor cleaner or hot
soaking tank.
rn 1. Place leaf valves on leaf plate. If new valves do not seat on

the leaf plate, turn the leaf valves over.
INotel Used leaf valves must not be turned over for reuse. Leaf
valve may break when returned to service, causing serious
powerhead damage.
12687
2. If any leaf valves are standing open, apply light pressure using
a pencil eraser. If leaf valve closes with light pressure, valve is
acceptable. If not, inspect leaf plate for high spots or burrs.
INotel Do not lap leaf plate. If plate is too smooth, the leaf valves
may stick closed after off-season storage.
rn 3. Viewed from the back (leaf stop) side, the alignment

notches ® must face as shown. The port notch will face one
o'clock and the starboard notch will face 11 o'clock. Failure to
follow this procedure will cause premature leaf valve failure.
DR1465
rn
@.
4. Center the leaf valves on the plate using the index marks
I]] 5. Center the leaf stops, and tighten the leaf valve screws to a
torque of 25-35 in. Ibs. (3-4 N·m).
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2-38 32Cl eng
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Installation
[ ] ] 1. Position the leaf plate with a new gasket on crankcase.

Apply OMC Gel-Seal /Ito the threads of the flat head Phillips head
screw ® and install loosely. Align the leaf plate and gasket with
crankcase ant tighten screw securely.
INote I Install all intake manifold gaskets dry; use no sealer.
[!Q] 2. Install the intake manifold using a new gasket between

manifold and leaf plate. Install throttle rod in pivot pin on throttle
lever.
[!Q] 3. Align the gasket with the manifold and install manifold
screws. Tighten screws evenly and securely. Install wire retainer
CD in throttle rod Q).
[TI] 4. Install the oil recirculation hose on the intake manifold and
secure with tie strap.
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FUEL SYSTEM TROUBLE CHECK CHART
ENGINE WILL NOT START

STARTS, WILL NOT IDLE
• •• ••• • • ••• •
WILL NOT IDLE SLOWLY
• • • •••• • ••••••• •••••••••
SPITS AT IDLE, LEAN
•• • •• • • • • • • • •• • • • •• •• •• •• • •
ENGINE RICH AT IDLE
•• • •••
EXCESSIVE OIL USE
•
• • • • •
STALLS ON ACCELERATION
•••••
SURGES AT HIGH SPEED
• ••••• •• • •••• ••••••
RUNS RICH AT HIGH SPEED
• •••••• • •• •• • • • •• • •
LOSS OF W.O .T RPM
• •
CARBURETOR FUEL SPITBACK
• •••••• • • • • • • • • • • • • •• •
REFER TO
REFER TO REFER TO REFER TO REFER TO REFER TO
32C OWNER MANUAL PAGES 2-24,
PAGE 2-10 SECTION 1 PAGES 2-19, 2-27, 2,32
** REFER TO ACCESSORIES SERVICE MANUAL
Ignition System
Table of Contents
&. General Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 2

About This Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 5
Flywheel Holding Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 6
Spark Plug Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 7
Flywheel Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 8
Ignition Coil Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Principles of Operation ........................... . 3-12
RPM Limiting Power Pack ........ . . . ............... 3-14
General Information - CD II Ignition ....... . .......... 3-14
Troubleshooting Test Equipment ............ . ....... 3-15
Amphenol Connector Servicing ... . ................. 3-17
Ignition Plate Servicing - 9.9/15 ........ . ..... . ..... 3-18
Ignition Plate Servicing - 20 thru 30 .. . .............. 3-19
Ignition Component Replacement . . . . . . . . . . . . . . . . . . . 3-20
Ignition Coil Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Indexing Flywheel, Erratic Ignition. . . . . . . . . . . . . . . . . . . 3-22
S.L.D.W. Warning System .......................... 3-22
Blocking Diode Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Ignition Output Tests - CD II . . . . . . . . . . . . . . . . . . . . . . . 3-24
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Before working on any part of the ignition system, read the
section called Safety at the end of this manual.

ing flywheel.
Perform all ignition coil tests on a wooden or insulated bench top

to prevent leakage or shock hazards.
To avoid possible shock hazards, do not handle ignition coil or

tester leads during output test.
Do not touch high voltage ignition coils or spark plug wires when
engine is being started or when running. Shock can cause
serious personal injury under certain conditions.
To prevent possible fire and explosion under the engine cover,

make sure electrical wires are routed and clamped in original
position away from rotating parts which could cut or abrade wire
insulation.
If necessary to remove the spark plugs, be sure to keep the spark

tester away from open spark plug holes.

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Component Specifications _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Ignition Coil Charge Coil Sensor Coil Ignition Modulel

Power Pack
Primary Secondary Min. Output Voltage

Models
Ohms Ohms Ohms Ohms
Cranking Running
9.9/15R 0.1 ± 0.05 275 ± 50 900 ± 100 40 ± 10 175 200
9.9/15E,
REL,SE 0.1 ± 0.05 275 ± 50 760 ± 80 40 ± 10 175 200
20-30 0.1 ± 0.05 275 ± 50 900 ± 100 40 ± 10 175 200
PCE0074
DESCRIPTION IN. LBS. FT. LBS. N'm ADHESIVE
Ignition Coil Screws 48-96 • 5,4-10,8 •

Ignition Support Plate Screws 48-60 • 5-7 OMC Nut Lock
Ignition to Retainer Plate Screws 25-35 • 2,8-4,0 OMC Nut Lock
Spark Plug 216-240 18-21 24-27 •

Flywheel Nut: 9.9/15 • 45-50 60-70 OMC Gasket
Sealing Compound
Flywheel Nut : 20-30 • 100-105 135-140 OMC Gasket

Sealing Compound
Sensor Coil Screws 15-22 • 1,6-2,4 •

Charge Coil Screws 15-22 • 1,6-2,4 •
Power Pack Screws 60-84 • 7-9 •
Stator Assembly Screws - 9.9/15 25-35 • 2,8-4,0 OMC Nut Lock
PCE00 50
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32Cle nQ 3-3 o
avJC Special Tools Required _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Universal Puller Kit, PI N 378103

Socket Removal Tool, PI N 322699
Pin Removal Tool, PI N 322698
Insert Tool, PI N 322697
Crimping Pliers, PI N 322696
Locating Ring, PIN 334994
Sealants and Lubricants Required _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
CIVIC Gasket Sealing Compound

CIVIC Moly Lube
CIVIC Black Neoprene Dip
CIVIC Cleaning Solvent
CIVIC Nut Lock
CIVIC Triple-Guard@ Grease
CIVIC Electrical Grease
Evinrude@ or Johnson@ Outboard Lubricant
Isopropyl Alcohol
CIVIC Ultra Lock
Stevens Flywheel Strap Wrench No. 5-17, or equivalent

Snap-On Holding Fixture No. A-144, or equivalent
Spark Tester
Peak-reading Voltmeter
Stevens Terminal Extenders No. TS-77, or equivalent
Stevens Load Adaptor No. PL-88, or equivalent
Ohmmeter
Jumper Wire
Ignition Analyzer
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3-4 32Cl eng
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About This Section
The information in this section of the Service Manual has been
organized into a format that will allow the technician to make
maximum use of his troubleshooting time. To be most effective,
the technician should read and understand these statements
before proceeding.
1. To save time, routine service information has been covered in

the first pages of this section. It includes:
• A brief review of the principles of operation for OMC's

CD II ignition system, Page 3-12.
• A listing of available troubleshooting test equipment,

Page 3-15.
• A brief review of spark plug information, Page 3-7.
• Servicing flywheels, flywheel and crankshaft tapers,

Page 3-8.
• Flywheel Nut Torque Chart, Page 3-9.
• A review of all testing procedures for ignition coils, Page

3-10.
• An Ignition Coil Specification chart, Page 3-10.
2. If you are working on an engine where the ignition problem

makes the engine very hard to start or impossible to start, begin
your testing with Ignition Output Tests, Page 3-24.
3. If you are working on an engine where the ignition problem

creates an intermittent high speed miss or inconsistent running
qualities above cranking RPM, refer to Indexing Flywheel, Erratic
Ignition , Page 3-21.
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32C/enQ 3-5 o
...........- - - - - - - - - - - - - - - - - 15" (38 em) • I
4"
I .. (10 em) ., 3"
15fa in. (41 mm) -(7,5em)~
Dia. Bolt Circle
I
2V16 in. (52 mm)
Dia. Bolt Circle
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9.9/15 & 4 Deluxe & 1112" :::r
20 thru 30 (38 mm) CD
5 thru 8 t CD
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11f2" (38 mm) Dia.
15116" (33 mm) Dia.
3/S" (9,5 mm) Dia. Holes (3)
1200 Apart
5/S" (16 mm) Dia. Holes (3)

1200 Apart
Material: W' (6,3 mm)

Cold Roll Steel
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Scale: Half Size
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CJ SelfFixer.Com Online Manuals _

Spark Plug Information
The spark plugs should be removed and examined. A spark plug
should be replaced if the electrodes are badly worn, if it has a
cracked insulator, or is badly fouled. Before installing the spark
plug cover, apply a light coating of OMC Electrical Grease to the
ribbed portion of the spark plug ceramic and to the opening of the
spark plug cover. This will help prevent corrosion of the spring
terminal and the spark plug which can cause high tension arcing.
9.9 Ol82C Ol86C
15 Ol82C •
10 Comm. Ol82C Ol86C
15 Comm. Ol82C •
20, 25, 28, 30 Ol82C •
25 Comm. Ol82C •
INotel All spark plugs are to be gapped at 0.030 in. (0,8 mm).
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32C/ena 3-7 o
Flywheel Servicing
~ In order to produce the voltage necessary to run an ignition
~ system, the flywheel magnets must be of a particular
strength. Weak flywheel magnets can cause low ignition voltage,
which could affect motor performance. Weak flywheel magnets
can also cause low readings on ignition test equipment, such as
the peak-reading voltmeter, which may cause unnecessary re-
placement of ignition components.
Flywheels rarely go bad and would only be replaced as a last

resort in solving an ignition problem.
Removal
'" 1. To avoid accidental starting of engine while servicing,

~ twist and remove all spark plug leads.
r:jl f21 2. Remove the flywheel nut. Use a flywheel

holding tool as
~ ~ drawn on Page 3-6 and three PIN 307641 screws from OMC
Universal Puller Set, PIN 378103, or other suitable tool to hold
the flywheel.
rJl 3. Apply OMC Moly Lube to threads of pressing screw and

~ center hole of crankshaft.
f4l 4. Assemble the followin.g ~omponents from OMC Universal

~ Puller Set, PIN 378103:
® Body, PIN 307636

® Pressing Screw, PIN 307637
© Handle, PIN 307638
9.9/15
@ 3 Screws, PIN 307641

® 3 Washers, PIN 307639
20 thru 30
@ 3 Screws, PIN 307642

® 3 Washers, PIN 307640
5. 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.
6. Remove the flywheel.
/.
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Installation 9.9/15
1. Install the flywheel key:
• 9.9/15 - Install the key with its outer edge parallel to

taper of crankshaft.
• 20 thru 30 - Install the key with its outer edge parallel to

centerline of crankshaft and single upset mark facing
down.
2. Clean the crankshaft and flywheel tapers with OMC Cleaning DR2115
Solvent and let dry. These surfaces must be clean and dry to
allow proper locking of the tapers. 20-30
f71 3.Align the flywheel keyway and install flywheel. Coat the
~ threads of the flywheel nut with OMC Gasket Sealing Com-
pound. Install the nut and torque to the correct value. See chart
below.
Flywheel Nut Torque Chart

6
MODEL FT. LBS. N·m ADHESIVE
45-50 60-70
OMC
9.9/15
Gasket
20-30 100-105 135-140
Sealing
Compound
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32C/enQ 3-9 o
Ignition Coil Tests
A wide variety of ignition testers are available from various 0 . 10 1
1
manufacturers. In addition, some automotive testers having the
proper specifications can be used . Q) (Q
ra
Detailed instructions for the use of any tester are provided with
the unit; therefore, only general information is given here. Refer
to the manual of the ignition tester you are using for coil
specifications. Specifications will vary among testers.
1
Ignition coil must be removed from powerhead for power and DR4093
leakage testing.
l' To avoid possible shock hazards and to prevent leakage, 2750

1 1
i l l perform all tests to the coil on a wooden or insulated bench Q) (Q
top.
Specifications
Primary Secondary Operating Analyzer

Resistance Resistance Amps (Max) Polarity
2
Merc-O-Tronic DR4094
Magneto C.D. 1.li amps

Coil 0.1 ± 0.05 n 275 ± 50 n Normal
PIN 582508 Stevens
1.1 amps
PCE0043 .
Ohmmeter Test
Resistance tests can be performed while the ignition coil is still

mounted to the powerhead.
DR4081
1. Twist and remove the spark plug and primary leads from the
ignition coil.
rv black
~
2. Calibrate ohmmeter on appropriate scale. Connect meter
lead to clean engine ground. If the coil is not mounted on
the engine, connect meter black lead to ground tab on the coil.
Connect meter red lead to coil primary terminal.
• Meter must show 0.1 ± 0.05 ohm.
f2l 3. Calibrate ohmmeter on appropriate scale. Connect meter

~ red lead to coil primary terminal. Connect meter black lead to
coil spark plug terminal. .
• Meter must show 275 ± 50 ohms.
f31 4. Test spark plug leads for continuity. Calibrate ohmmeter on

~ low ohms scale. Attach one ohmmeter lead to each spring
terminal. While wiggling both spark plug covers and entire length
of the spark plug lead, the resistance should remain near zero.
Replace spark plug lead if your test results vary.
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Safety Related 3-10 32C/eng <1\
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Power Test
/~
~ Do not exceed the coil's maximum specified amperage
~ when testing it.
f4l 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
'L
I
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©
@
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 Specifica-
tions.
Surface Leakage Test
~ Do not exceed the coil's maximum specified amperage

~ when testing it.
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.
lsi 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. Flashover will be apparent wherever insulation
has broken down. Replace any coil or spark plug lead that shows
leakage.
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32C/eng 3-11 o
Principles of Operation
Flywheel
f1l The flywheel contains permanent magnets ® which energize

~ the charge coil, sensor coil, and alternator stator. Once the
flywheel exceeds a minimum cranking RPM, the flywheel's mag-
netic lines of force pass through the ignition plate components to
produce 'Jo\tage in those circuits.
The flywheel must be in good condition and correctly located to

ensure proper ignition timing and sufficient charge coil output.
Charge Coil
f21 The charge coil ® consists of many windings of wire wrapped

t=J around a metal lamination. Once the flywheel exceeds a
minimum cranking RPM, the flywheel's magnetic lines of force
pass through the charge coil windings to produce approximately
300 volts of alternating current.
This voltage is supplied to the power pack to operate the system.
Sensor Coil
f2l The sensor coil © consists of many windings of wire wrapped

t=J around a metal lamination. Once the flywheel exceeds a
minimum cranking RPM, the flywheel's magnetic lines of force
cutting through the sensor coil windings produce approximately
3 volts.
This voltage is supplied to the power pack to control small

electronic switches (SCRs) which, in turn, direct power pack
output to the correct ignition coil primary.
Power Pack
Ial The power pack has several basic functions. It stores and
~ distributes the voltage received from the charge coil. The
power pack uses electronic switches (SCRs), activated by sensor
coil output, to select the correct ignition coil primary winding for
firing.
20 thru 30 - The power pack has an RPM counting and RPM

limiting circuit to protect the engine from damage due to severe
overspeeding.
20 thru 30 - The power pack incorporates the S.L.O. W. ™ warning

system, which limits engine speed to approximately 2000 RPM if
engine temperature exceeds 1800 F (82 0 C). Once the S.L.O. W.
warning system has been activated, the engine must cool to 1550
F (680 C) and the engine must be slowed to an idle before normal
operation can be resumed.
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3-12 32C/eng
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Stop Circuit
~ f51 The
stop button @, key switch @, and emergency stop
~ ~ switch ® are 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.
~ The steering handl~ contains a combination stop switch/

~ emergency stop device.
• When the clip and lanyard assembly is removed, the

emergency stop device is in the STOP position.
• When the clip and lanyard assembly is installed, the

emergency stop device is in the RUN position.
• To stop the engine when the clip and lanyard assembly is

in place, press the stop button inward until the engine
stops.
Ignition Coil
f61 rJl The ignition coil consists of two windings of wire wrapped
~ ~ around a compacted ferrite core . The coil has primary and
secondary terminal connections and a ground plate.
Through mutual induction, the ignition coil transforms the igni-

tion module output to as much as 40,000 volts to fire the spark
plugs.
• There is one ignition coil per cylinder.
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32C/e ng 3-13 o
RPM Limiting Power Pack
Some power packs have a built-in RPM limiting device. Certain
models are equipped with a limiting power pack to guard against
possible powerhead failures caused by improper propeller selec-
tion (underpropping), excessive wear on propeller blades, im-
proper motor installation, propeller ventilation, or unusually light
boat loading.
Be sure to use the correct power pack when servicing the models
listed below to control the engine's operating RPM range and
protect it from possible powerhead damage due to overspeeding.
Model RPM Limit
20-30 6100
25RW 5700
General Information - CD II Ignition

Troubleshooting the Ignition System
The magneto powered capacitor discharge ignition system is

easy to troubleshoot. Remember these tips to obtain fast, accu-
rate test resu Its:
1. Visual Inspection - Check wiring for broken, pinched, or loose

leads. Connectors should be securely fastened and free from
moisture or water accumulation.
2. Test Equipment Condition - Be sure testers are in working

order. Many hours can be wasted by replacing working compo-
nents needlessly.
3. Follow Procedure - Troubleshooting can seem difficult if you

vary your technique for each problem. Many times items in the
system are overlooked because you "thought" you tested them.
By following the same procedure each time you troubleshoot, all
items in the ignition system will be tested.
4. Test the Complete System - There may be occasions when

more than one component is defective. If this condition is unde-
tected, repeat ignition system failure may occur, or damage to
replacement parts could result. Test everything.
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3-14 32C/e nQ
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3
2804 16489
Troubleshooting Test Equipment
r.::=J The following equipment is available from various manu-

~ facturers to support your ignition and electrical system
troubleshooting. Manufacturer ordering addresses are on the
rear inside cover of this manual.
[!] Spark testers:

• Stevens No. S21, S13C, or S48 4
• Merc-O- Tronic No. 55-4S or 55-6S
~ Peak-reading voltmeters:
• Merc-O- Tronic No. 781
• Stevens No. CO-77
• Electro-Specialties No. PRV-1
~ Ohmmeter capable of reading low and high ranges :

• Merc-O-Tronic No. 700 VOA
• Stevens No. AT-101
~ Component temperature can affect resistance values at a

~ rate of 10 ohms per 1° F. All resistance values listed in this
manual are correct at (70° For 21 ° C).
~ Ignition module load adapter:

• Stevens No. PL-88
~ Ignition coil terminal extenders:

• Stevens No. TS-77
6
~ Jumper wire for Amphenol connectors. Can be made with :
73158
® No. 16 wire, 8 in . (200 mm)

® Pin, OMC PIN 511469
© Socket, OMC PIN 581656
@ Shrink tube, OMC PIN 510628
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NOTES
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42201
Amphenol Connector Servicing
INote I The Ampheno/@pin and socket terminals are not the same ®
size as Deutsch@ pin and socket terminals. You cannot inter-
change them.
I
Terminal Removal
1. To remove a terminal from the plug or receptacle, lubricate both
ends of the cavity with isopropyl alcohol.
OJ Pick the proper tool for the service being performed: DR6201
® OMC Pin Remover, PI N 322698

® OMC Socket Remover, PI N 322699
© OMC Crimping Pliers, PI N 322696
@ ®
II] [}]
@ OMC Insert Tool, PIN 322697
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 m 3. Pin and socket terminals may be replaced if dam-

aged. Strip % in. (6 mm) insulation from wire and crimp new
42226
terminal onto wire at point ® with crimping pliers.
Terminal Installation
4. Connect the plug and receptacle before installing terminal.
Apply isopropyl alcohol to connectors, align arrows, and p~sh
together.
5. Apply isopropyl alcohol to the terminal cavity.
[]J []] & 6. Place connectors against solid surface. To avoid

injury, hold tip of tool @ securely against shoulder of terminal ®
while inserting terminal. Push terminal into connector until step
@ of insert tool touches connector body.
rn 7. Check your work. Separate the connectors and check to

see that terminals are inserted the proper distance.
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Ignition Plate Servicing - 9.9/15
Removal
& 1. To avoid accidental starting of engine while servicing,

twist and remove all spark plug leads.
2. If equipped, remove the manual starter. See Section 7.
3. Remove the flywheel. Refer to Flywheel Servicing.
[IJ 4. Loosen the six screws attaching the ignition plate to the
retainer plate. Lift the ignition plate from the powerhead.
rn 5. Remove the four support plate screws @ . Lift the retainer

and support plate from the powerhead.
Installation
rn 1. Place the retainer plate, then the support plate on the

powerhead. Align support plate with four screw holes in
powerhead. Apply OMC Nut Lock to threads of the four support
plate screws @. Install the screws and tighten them to a torque of
48-60 in. Ibs. (5-7 N·m).
rn 2. Apply OMC Moly Lube to the crankcase boss.
W 3. Lubricate the ignition plate bearing groove ® with OMC

Moly Lube.
[ [ ] 4. Apply OMC Nut Lock to the threads of the ignition plate

screws. Insert needle-nose pliers into slots in the ignition plate
bearing and compress bearing while guiding the ignition plate
into position.
5. Align the ignition plate with the retainer plate. Tighten the
screws to a torque of 25-35 in. Ibs. (2,8-4,0 N·m).
6. Connect and adjust spark advance link. Refer to Synchroniza-

tion and Linkage Adjustment, Section 1.
7. Check for sufficient slack on ignition component leads during

full advance movement of the ignition plate.
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Ignition Plate Servicing - 20 thru 30
Removal
/1 1. To avoid accidental starting of engine while servicing,

2. If equipped, remove the manual starter. See Section 7.
3. Remove the flywheel. Refer to Flywheel Servicing.
[]] 4. Loosen the screws attaching the ignition plate to the

retainer plate. Lift the ignition plate from the powerhead.
m 5. Remove the thrust washer from the ignition plate.
[[] 6. Remove the four screws retaining the pilot ring.
[!] 7. Remove the pilot ring and stepped washer.
[IQ]
8. Remove the spacer ring from the crankcase bosses.
Remove the retainer.
Installation
[IQ] 1. Place retainer plate on powerhead . Place the spacer ring

on the crankcase bosses.
[!] 2. Lubricate the top side and underside of stepped washer,

with OMC Moly Lube, where it contacts the retainer and pilot ring.
Position the stepped washer and pilot ring on the retainer.
[[] 3. Install the four screws to retain the pilot ring. Torque to
48-60 in. Ibs. (5-7 N·m).
m 4. Lubricate the thrust washer with OMC Moly Lube and

place in ignition plate.
[]] 5. Apply OMC Nut Lock to ignition plate screws. Lower

ignition plate onto retainer and torque screws to 25-40 in. Ibs.
(2,8-4,0 N·m) .
6. Check for sufficient slack on ignition component leads during

full advance movement of the ignition plate.
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Ignition Component Replacement

[JJ 2. Remove the screws retaining the ignition component that

is being replaced.
rn 3. Remove the wire clamp @ from the ignition plate.

rn 4. Loosen the ignition plate screws. Lift the ignition plate
from the powerhead.
rn 5. Remove the plate @ from the bottom of the ignition plate.

6. Remove the leads from the spiral wrap and from the ignition
component.
7. Apply OMC Ultra Lock to the threads of the component

retaining screws. Loosely install the new ignition component on
the ignition plate.
rn rn 8. Route leads and install clamp @ , plate @ , and spiral

wrap.
INote I All component leads must be routed through clamp @ and

plate @ in a single layer, not twisted or crossed over another lead.
9. Apply OMC Nut Lockto the threads of the ignition plate screws.
Install the ignition plate on the retainer plate. Torque retaining
screws to 25-35 in. Ibs. (2,8-4,0 N·m).
10. Check for sufficient slack on ignition component leads. Route

component leads through wire clamps.
[]] 11. Position OMCLocating Ring, PIN 334994, over machined

bosses on the ignition plate. Push the locating ring in toward the
component to be installed. Hold the ring in place and pull the
component out toward the ring. Tighten screws to 15-22 in. Ibs.
(1,6-2,4 N·m).
[]] 12. Repeat Step 11 for each component.
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& Safetv Related 3-20 32C/eng
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9.9/15 20-30
6 /~®
DR5055 DR5741
© Fiber Washer
@ Flat Washer
® Ignition Coil Ground Strap
® Star Washer
@ J-clamp
® Stop Switch Ground Lead
Ignition Coil Replacement
Removal
1. Twist and remove cover to remove the spark plug and primary leads from the ignition coils.
[ ] ] [ [ ] 2. Notice the fastener and washer orientation before removing any screws.
3. Remove the screws, coil, and washers.
Installation
[ ] ] [ [ ] 1. Assemble the correct sequence of washers and locate the ignition coil on the powerhead.
Install and tighten the retaining screws to a torque of 48-96 in. Ibs. (5,4-10,8 N·m).
2. Apply a light coating of CIVIC Electrical Grease to the ribbed portion of the spark plug ceramics and to
the openings of each of the spark plug lead covers. Install the spark plug leads.
3. Apply a light coating of CIVIC Electrical Grease to the opening of each primary lead cover and install
tne covers. Observe proper wire routing and ignition timing. Orange/blue primary lead must be
connected to the No.1 ignition coil.
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32C/eng 3-21 o
Indexing Flywheel, Erratic Ignition
Internal power pack problems could cause a pack to fire errati-
cally or continuously. To troubleshoot this situation, you must
determine that each cylinder is firing at the correct time and no
more than once per revolution.
1. Disconnect the spark plug leads and remove both spark plugs.
IT] 2. Place the eraser end of a pencil in the No.1 spark plug
hole. Slowly turn the flywheel by hand clockwise, until the
greatest length of the pencil is outside the spark plug hole. This
indicates the No.1 piston is near top dead center.
[IJ 3. Mark on the flywheel rim, directly across from the timing
pointer or starter pivot screw. Label this mark "No.1".
4. Repeat Steps 2 and 3 for the No.2 cylinder. Label this mark
"No. 2".
5. Install the spark plugs and spark plug leads. Start the engine in
a test tank and run the engine at the RPM where the problem
exists.
6. Carefully hook an induction timing light to each cylinder,

alternately. The timing light should indicate that cylinder's num-
ber only, and the number should only appear near the timing
pointer or starter pivot screw .
• If another cylinder's number appears, or the correct

number appears more than once per revolution, verify
ignition coil primary lead routing or replace power pack.
S.L.O. W. Warning System

The 20 thru 30 HP ignition system incorporates the S.L.O. W. ™
warning system, which gradually limits engine speed to approxi-
mately 2000 RPM when engine temperature exceeds 1800 F
(82 0 C). To resume normal operation after the S.L.o. W. ™ warning
system has been activated, the engine must cool to 1550 F (680 C)
and the engine must be brought to an idle.
The S.L.O. W. ™ warning system depends on input from the

temperature switch tan lead.
Functional Tests
1. Disconnect temperature switch tan lead.
2. Install correct test propeller. Start engine in test tank and run at
3500 RPM.
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3-22 32Cl enQ
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101/2 in.
~ (26,7 cm)
1
DRC625 1
3. Attach engine harness tan lead to a clean engine ground.
• If engine slows to approximately 2000 RPM, test temper-

ature switch. Refer to Temperature Switch Test, Section
4.
• If engine does not slow to approximately 2000 RPM,

check wiring or replace power pack.
INotel On remote electric start models, if the engine goes into

5.L.D. W. repeatedly or ifthe engine goes into 5.L.0. W. without an 2
operator warning signal, check the engine harness blocking L....---IL-.._ _ _ _ _ _ _ _-==~
diode. Refer to Blocking Diode Test.
Blocking Diode Test
OJ The diode is located in the engine harness tan wire circuit at

position @.
1. Disconnect engine harness 6-pin Deutsch connector that con-

tains the tan wire.
2. Disconnect temperature switch tan lead.
rn 3. Calibrate ohmmeter on appropriate scale. Using jumper

wires, connect meter between engine harness tan lead and
engine harness 6-pin connector terminal "6". Note reading.
4. Reverse meter connections or press "polarity" button. Note

reading.
• A very high reading (00 ) in one direction and a low

reading in the other direction indicates diode is good.
5. Replace engine harness blocking diode if your test results vary.
6. Complete all circuits disconnected during this test.
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32C/enQ 3-23 o
IGNITION OUTPUT TESTS - CD II
~ All cranking output tests must be performed with spark
ill plugs installed and torqued in the cylinder head. If neces-
sary to remove the spark plugs, be sure to keep the spark tester
away from open spark plug holes.
R The following series of steps will systematically isolate a

~ problem area in the ignition system. To reduce your trou -
bleshooting time and to avoid incomplete results, perform these
steps in the order written.
STEP 1 - TOTAL OUTPUT TEST
[!] 1. Twist and remove the leads from both spark plugs.
r:;l 2. Adjust the gap on the spark tester to 112 in. (12 mm).
~ Connect tester leads to the spark plug leads. Secure tester clip
to a clean engine ground.
~ To prevent possible arcing of high voltage, route tester

~ leads at least 2 in. (51 mm) from any metal surface.
'" To avoid possible shock hazard, do not handle ignition coils

ill or spark tester during cranking tests.
3. If equipped, install the emergency stop switch clip and lanyard

assembly. Crank the engine. Spark should jump each tester gap
alternately.
• If tester shows good output on both cylinders, go to

STEP 6 - RUNNING OUTPUT TEST.
• If tester shows good output on one cyli nder, go to STEP 5

- POWER PACK OUTPUT TEST.
• If tester shows no output, go to STEP 2 - STOP CIRCUIT

TEST.
~ It is possible for the ignition system to have a problem but

~ still produce good output. If the engine "pops" or "back-
fires" during starting, the ignition may be out of time. Check the
following:
• Coil primary wire routing
• Spark plug lead routing
• Flywheel condition and location
• Synchronization and linkage adjustments
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DR4185
STEP 2 - STOP CIRCUIT TEST
Elimination Test
& To avoid possible shock hazard, do not handle ignition coils or spark tester during cranking tests.
1. Disconnect 5-pin Amphenol connector between ignition plate and power pack.
~ 2. Insert jumper wires between the "A", "B", "C", and "0" terminals of the 5-pin connector.
3. Crank engine and observe results at spark tester.
• If spark now jumps alternately at each gap, the problem is in the stop circuit. Go to Ohmmeter
Test - Stop Button or Ohmmeter Test - Key Switch.
• If there is no spark at one gap, go to STEP 5 - POWER PACK OUTPUT TEST.
• If there is no spark at both gaps, go to STEP 3 - CHARGE COIL TEST.
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OR4186
Ohm m eter Test - Stop Button
INotel All ohmmeter tests must be performed with the engine NOT running.
~ 1. Most steering handles contain a combination stop button/emergency stop device.

• When the clip and lanyard assembly is removed, the emergency stop device is in the STOP
position.
• When the clip and lanyard assembly is installed, the emergency stop device is in the RUN
position .
• To stop the engine when the clip and lanyard assembly is in place, press the stop button until
the engine stops.
2. Install the clip and lanyard.
f51 3. Calibrate an ohmmeter on appropriate scale. Connect meter leads between ignition plate end of
~ connector, terminal "E", and a clean engine ground.
• The meter must show a high reading .
4. Momentarily, press inward on the stop button.
• The meter must show a low reading.
5. Remove the clip and lanyard.
• The meter must show a low reading.
& To avoid sudden loss of control, replace the stop button assembly if your test results vary.
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& Safety Related 3-26 32Cle ng
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0116224
Ohmmeter Test - Key Switch
1. Install emergency stop switch clip and lanyard assembly.
1sl 2. Calibrate ohmmeter on appropriate scale. Connect meter leads between ignition plate end of
~ connector, terminal "E", and a clean engine ground.
• Key OFF, meter must show a low reading
• Key ON, meter must show a high reading
3. If Step 2, Key ON reading is a low one, disconnect harness black/yellow leads from key switch "M"
terminal.
• If meter now shows a high reading, test key switch. Refer to Electrical Section.
• If meter shows a low reading, go to Step 4.
4. Separate emergency stop switch lead from harness black/yellow lead at key switch.
• If meter now shows a high reading, test emergency stop switch.
• If meter shows a low reading, test wiring harness.
5. If engine fails to shut off, test for open black/yellow lead, damaged key switch, or damaged power
pacK.

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7 8
DR4619 DR4620
STEP 3 - CHARGE COIL TEST
Ground Test
[2] 1. Disconnect 5-pin Amphenol connector between ignition plate and power pack.
2. Set peak-reading voltmeter to:
• 9.9/15 - "NEG" and "500".
• 20 thru 30 - "POS" and "500".
rJl 3. Alternately, connect voltmeter between ignition plate connector terminals "A", "0", and a clean
~ engine ground. Crank engine and observe meter at each connection.
• Any reading on either test indicates charge coil or leads are grounded.
• Locate and repair ground, or replace charge coil.
4. If no reading is indicated in Step 3, go to Output Test.
Output Test

• 9.9/15 - "NEG" and "500".
• 20 thru 30 - "POS" and "500".
f81 2. Attach voltmeter black lead to ignition plate connector, terminal "A". Attach meter red lead to
EI terminal "0".
3. Crank engine and observe meter.
• If meter shows 230 volts or higher, go to STEP 4 - SENSOR COIL TEST.
• If meter shows less than 230 volts, check condition of wiring and connectors. E
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• If wiring and connector condition is good, go to Ohmmeter Test. ..:
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3-28 32C/e nQ
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9 10
DR4620 DR4619
Ohmmeter Test
~ 1. Insert jumper wires in ignition plate connector, terminals "A" and "0".
~ 2. Calibrate ohmmeter on appropriate scale. Connect between jumpers. Meter must show:
9.9/15E, SEL, REL 760 ± 80
9.9/15R, 20-30 900 ± 100
r,Ql 3. To test .for a grounded condition, connect ohmmeter alternately between each jumper and a
~ clean engine ground .
• Any needle movement indicates charge coil or leads are grounded .

• Locate and repair ground, or replace charge coil.
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11 12
DR4621 DR4622
STEP 4 - SENSOR COIL TEST
Ground Test
[!!J 1. Disconnect 5-pin Amphenol connector between ignition plate and power pack.
• 9.9/15 - "NEG" and "50", or "SEN" and "50" on Stevens CD-77 meter.
• 20 thru 30 - "pas" and "50", or "SEN" and "50" on Stevens CD-77 meter.
r;1l 3. Alternately, connect voltmeter between ignition plate connector terminals "8", "C", and a clean
~ engine ground. Crank engine and observe meter at each connection .
• Any reading indicates sensor coil or leads are grounded.
• Locate and repair ground, or replace sensor coil.
4. If no reading is indicated in Step 3, go to Output Test.
Output Test

• 9.9/15 - "NEG" and "50", or "SEN" and "50" on Stevens CD-77 meter.
• 20 thru 30 - "pas" and "50", or "SEN" and "50" on Stevens CD-77 meter.
r:J2l 2. Attach voltmeter black lead to ignition plate connector, terminal "C". Attach meter red lead to
~ terminal "B".
3. Crank engine and observe meter.

• If meter shows 1.5 volts or higher, go to STEP 5 - POWER PACK TEST.
• If meter shows less than 1.5 volts, check condition of wiring and connectors. E
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• If wiring and connector condition is good, go to Ohmmeter Test. ..:
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13
DR4622 DR4621
Ohmmeter Test
INotel A ll ohmmeter tests must be performed with the engine NOT running.
1. Calib rate ohmmeter on appropriate scale.
~ 2. Insert jumper wires in ignition plate connector, terminals "8" and "C".
3. Calibrate ohmmeter on appropriate scale. Connect between jumpers.
• Meter must show 40 ± 10 ohms.
1141 4. To test .for a grounded condition, connect ohmmeter alternately between each jumper and a
clean engine ground.
• Any needle movement indicates sensor coil or leads are grounded.

• Locate and repair ground, or replace sensor coil.
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32C /e ng 3-31
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DR4052
STEP 5 - POWER PACK OUTPUT TEST
& To prevent accidental starting of engine while testing, twist and remove both spark plug leads.
1. Twist and remove primary leads from ignition coils.
1151 2. Connect No.1 ignition coil primary lead to Stevens Instrument load adapter No. PL-88 red lead.
Connect adapter black lead to a clean engine ground.
~ If Stevens Instrument 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.
r:J5l 3. C.onnect peak-reading voltmeter red lead to adapter red lead and meter black lead to a clean
~ engme ground.
4. Adjust voltmeter to settings listed in following chart. Crank engine and observe meter. Meter must
show at least:
Models Voltmeter Output
9.9/15 "NEG", 500 175
20 thru 30 "POS", 500 175
5. Repeat Step 4 for No.2 ignition coil primary lead.
• If both primary leads have good output, test ignition coils. Refer to Ignition Coil Tests, Page
3-10.
• If one primary lead has no output, replace power pack.
• If both primary leads have no output, go to STEP 3 - CHARGE COIL TEST. If charge coil tests E
good, replace the power pack. o
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>200V
16
DR4053
STEP 6 - RUNNING OUTPUT TEST

1. Twist and remove primary leads from ignition coils.
f161 2. ~se .a. clock~ise. twist to install Stevens Instrument No. TS-77 terminal extenders, or equivalent,
~ on Ignition coli pnmary posts.
1.J6l 3. Install primary leads on terminal extenders. Observe proper wire routing. Orange/blue primary
~ lead must be connected to the No.1 ignition coil.
INotel Route all tester leads so they do not interfere with moving engine parts.
f161 4. Connect ~eak-reading voltmeter red lead to No. 1 terminal extender. Connect meter black lead to
~ a clean engme ground.
5. Adjust voltmeter to setting listed in following chart. Start engine and run it under load at RPM where
ignition problem exists. Meter must show at least:
Models Voltmeter Output
9.9/15 "NEG", 500 200
20 thru 30 "POS", 500 200
6. Repeat Step 5 for No.2 ignition coil.

• If either cylinder shows less than specified output, test charge coil. Refer to STEP 3 - CHARGE
COIL TEST .
• \~ charge coil tests good, replace the power pack.
7. Remove terminal extenders. Install ignition coil primary leads. Observe proper wire routing.
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Powerhead
Table of Contents
& General Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 2

Engine Temperature Check. . . . . . . . . . . . . . . . . . . . . . . . . 4- 5
Removal of Upper Crankcase Seal - 9.9/15 . . . . . . . . . . . . 4- 6
Temperature Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 7
Retaining Ring Pliers ...... .. .. . . . . . . . . . . . . . . . . . . . 4- 8
Taper Pin Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 9
Powerhead Service - 9.9/15 . ...... . ........... .. ... 4-10
Removal ....... . ............................. 4-10
Disassembly .................................. 4-13
Cleaning ....... . ............................. 4-16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Assembly ......... . ........................... 4-19
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Neutral Start Switch Adjustment - 9.9/15 TE ...... . ... 4-24
Shift Lever and Linkage Service - 9.9/15. . . . . . . . . . . . . . 4-26
Powerhead Service - 20 thru 30 .... .. ............... 4-34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Installation ..... . ....................... . ...... 4-50
Shift Lever Adjustment, 20 thru 30 ......... . . . . . ..... 4-52
Neutral Start Switch Adjustment, 20 thru 30 TE . . . . . . . . 4-52
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Before working on any part of the powerhead, read the section

ing flywheel.
To prevent possible fire or explosion under the engine cover after

servicing:
• Check entire fuel system for leaks.
• Make sure all electrical and ignition leads are routed and
clamped in their original positions away from rotating
engine parts which could cut or abrade wire insulation.
To avoid accidental starting of engine while servicing, take

adequate precautions to disarm the ignition system:
• Connect engine wiring harness to a boat wiring harness

with key switch in OFF position.
• Twist and remove all spark plug leads from spark plugs.
• Disconnect the battery cables at the battery.

To prevent sudden movement when starting engine and possible

"man overboard" situations, test the "start-in-gear prevention"
feature before returning engine to customer.
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Description 9.9/15 20 thru 30
Connecting Cap Screws 60-70 in. Ibs. CD 30-32 ft. Ibs. CD @

(7-7,5 N·m) (40-43 N·m)
Lower Crankcase Head Screws 60-84 in . Ibs. ® 60-84 in . Ibs. ®

(7-9 N·m) (7-9 N·m)
Cylinder Head Screws 216-240 in. Ibs. 216-240 in. Ibs.

(25-27 N·m) (25-27 N·m
Powerhead Retaining Screws 60-84 in. Ibs. ® 192-216 in. Ibs.

(7-9 N·m) (22-24 N·m)
Main Bearing Screws 144-168 in. Ibs. ® 168-192 in . Ibs. ®

(16-19 N·m) (19-22 N·m)
Inner Exhaust Tube Screws 60-84 in. Ibs. 96-120 in. Ibs.
(7-9 N·m) (11-14 N·m)
Cylinder Head Cover Screws 60-84 in. Ibs. ® 60-84 in. Ibs.
(7-9 N·m) (7-9 N·m)
Exhaust Cover Screws 95-130 in . Ibs. 48-84 in. Ibs.

(11 -14N·m) (5-9 N·m)
Bypass Cover Screws 60-84 in . Ibs. 60-84 in. Ibs.

(7-9 N·m) (7-9 N·m)
Intake Manifold Screws and Nuts 60-84 in . Ibs. 60-84 in. Ibs.
(7-9 N·m) (7-9 N·m)
PCE 0081
CD Apply Johnson or Evinrude Outboard Lubricant to threads.

® Apply OMC Gel-Seal" to threads.
® Apply OMC Gasket Sealing Compound to threads of screws.
@ To ensure maximum bearing life, use OMC Rod Cap Alignment Fixture, PI N 396749.
Service Aids Required _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Inside Micrometer or Telescoping Gauge

Cylinder Hone (fine)
Emery Cloth (No. 120 and No. 180)
Micrometer
Feeler Gauge
Markal Thermomelt Stiks or Pyrometer
Isopropyl Alcohol
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OMC Special Tools Required _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
9.9/15 Models
Piston Cradle, PIN 326573

Pressing Pin Driver and Cone, PIN 392511
Ring Compressor (Standard), PIN 339754
Ring Compressor (Oversize), PIN 339755
Upper Main Bearing Seal Remover and Installer, PIN 391060*
Crankcase Head Seal Installer, PIN 330251 or 433391
20 thru 30 Models
Upper Main Bearing Seal Remover, PIN 387780*

Upper Main Bearing Seal Installer, PIN 321539*
Box Wrench, PIN 322700
Crankcase Head Seal Installer, PIN 333520
Grommet Installer, PIN 304148
Rod Screw Torque Socket, PIN 331638
Piston Cradle, PIN 326573
Wrist Pin Pressing Pin, PIN 326356
Wrist Pin Retaining Ring Driver, PIN 318599
Wrist Pin Retaining Ring Cone, PIN 318600
Ring Compressor (Standard), PIN 326591
Ring Compressor (Oversize), PIN 330223
Rod Cap Alignment Fixture, PIN 396749
Wrist Pin Bearing Tool, PIN 336660
Crankshaft BearinglSleeve Installer, PIN 339749
* Used to replace seal without disassembling powerhead.

Sealants and Lubricants Required
Johnson@ or Evinrude@ Outboard Lubricant

OMC Gel-Seal and Gasket Remover
OMC Cleaning Solvent
OMC Gel-Seal" ™
OMC Needle Bearing Assembly Grease
OMC Locquic Primer
OMC Gasket Cleaning Compound
Permatex No. 2
OMC Moly Lube
OMC Adhesive M ™
OMC Black Neoprene Dip
OMC Triple-Guard@ Grease
OMC Screw Lock
STP Oil Treatment
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Engine Temperature Check
The Markal Thermomelt Stik is a heat sensitive marker that melts
on contact with a surface of a specific temperature. One source
for Thermomelt Stiks is Stevens Instrument Company.
rv Atbe least
~
two Thermomelt Stiks or a digital pyrometer should
used to accurately determine the engine's operating tem-
peratures.
The Thermomelt Stik mark will appear dull and chalky when the 1
surface marked is below the Stik's rated temperature. When the L...-~------------:--:-::-::-'
surface exceeds the Stik's rated temperature, the mark will
appear liquid and glossy.
f21 To achieve accurate and consistent readings, engine tempera-

~ ture must be gauged at the top of cylinder head.
~ For the following engine operating temperatures and RPM

~ figures to be correct, the inlet water temperature must be
70 0 ± 100 F (21 0 ± 30 C).
Pyrometer Procedure
1. Install correct test propeller and place engine in a test tank.
'r To avoid accidental starting of engine while changing pro-

i l l pellers, twist and remove all spark plug leads.
2. Start engine and run at 3000 RPM for at least five minutes.
r:J 3. Reduce engine speed to 900 PM. At 900 RPM a digital

l!J pyrometer should indicate 1400 ± 150 F (600 ± r C) when
held on both cylinder heads .
• If engine temperature is not within this range, trouble-

shoot cooling system to determine problem.
f3l 4. Increase engine speed to 5000 RPM . At 5000 RPM, the digital
~ pyrometer must not indicate more than 160 F (71 C) .
0 0
• If engine temperature exceeds 1600 F (71 0 C), trouble-

shoot cooling system to determine problem .
~ If 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.
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Thermomelt Stik Procedure
1. Install correct test propeller and place engine in a test tank.
"" To avoid accidental starting of engine while changing pro-

i l l pellers, twist and remove all spark plug leads.
2. Start engine and run at 3000 RPM for at least five minutes.
f4l 3. Reduce engine speed to 900 RPM and mark the cylinder
~ head with a 1250 F (52 0 e) and a 1630 F (73 0 e) Thermomelt
Stik.
4. At 900 RPM , the 1250 F (52 0 e) mark should remain liquid and
glossy. The 1630 F (73 0 e) mark should remain dull and chalky.
• If the 1250 F (52 0 e) mark does not remain liquid and

glossy, troubleshoot the cooling system for causes of
overcooling .
• If the 1630 F (730 e) mark becomes liquid and glossy,

troubleshoot the cooling system for causes of overheat-
ing.
f4l 5. When the engine speed is increased to 5000 RPM, the

~ 1630 F (73 0 e) mark should remain dull and chalky.
• If the mark becomes liquid and glossy, troubleshoot the

cooling system for causes of overheating.
Removal of Upper Crankcase Seal - 9.9/15

The presence of oil under the flywheel could indicate a leaking
upper crankcase seal. The upper crankcase seal can be replaced
without disassembly of crankcase. Remove the flywheel as de-
scribed in Section 3. Use OMC Seal Remover, PIN 391060, to
remove and install the seal.
rv To remove seal, install tip "e"

into remover/installer body.
~ Thread remover/installer body ® with tip ® into seal to
engage metal case .
rvWhile holding remover/installer body, turn pressing screw

~ and remove seal.
©
To install a new seal, apply OMC Gasket Sealing Compound to the

outside diameter of the metal casing. Position seal on powerhead
with lip facing down.
'2l Remove the pressing screw and tip from the remover/in staller.
~ Using a mallet and remover/installer body @ , install seal in
powerhead.
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Temperature Switch Test
Purpose
A heat sensitive switch is installed in the cylinder head to monitor

engine temperature. The switch is connected in series with the
warning system. If the switch senses temperature in excess of a
predetermined limit, contacts close and cause the System Check
gauge " WATER TEMP" light to turn on and the warning horn to
sound for ten seconds. If boat is not equipped with a System
Check gauge, the warning horn will sound a continuous tone.
INote ITo ensure that the temperature sensing system can alert
the operator during an overheating condition, test the warning
system as described in Section 8, System Check Engine Monitor.
Testing
rn 1. Separate the connector

switch f rom the cylinder head.
and remove the temperature
2. Using a continuity light or ohmmeter, make positive connec-

tions to the switch - one lead to the switch lead and one lead to
the metal portion of the switch.
W 3. Place the switch and an accurate industrial thermometer

in warm automotive crankcase oil.
4. Slowly increase the oil temperature using an external heat

source.
& To avoid possible fire or explosion:
• Use a suitable container for the oil.

• Use an oil that has a flashpoint above 300° F (150° C),
such as OMC Cobra 4-Cyc/e Motor Oil.
• Do not use open flame as a heat source.
5. The switch must react to the changing temperature as fol-

lows:
Wire Switch Switch

Color Closed Open
203 ± 6° F 170 ± 15° F

Tan
(95 ± 3° C) (77 ± r C)
4
824063
180 ± 6° F 155 ± 15° F
Tan/Red
(82 ± 3° C) (68 ± 6° C)
6. Replace the switch if your test results vary.
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32Cleng & Safety Related 4-7
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Retaining Ring Pliers
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I-LU""':a..
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4-8 32C
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r 13 mmII/2")
:c 0'.1. K <c=pt< < fa ,

? -- -1
7 mm(9/32") . HOLE FOR STORAGE SCALE: FULL SIZl:
I .. 292 mm(11 1/2") ... I

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1"'- 241 mm(9 1/2") .. I 13 mm(1/2") ~

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L2B mmlll/B")
Cold Roll Steel & Safety Warning
Heat Treatment: Striking a steel punch with a steel hammer may produce chips
Carburize 0,3-0,5 mm (0 .015-0.020 in.) deep. which can cause serious damage to eyes. Safety glasses must
Quench and harden to 58-62 R "C" case. be worn to prevent injury.
CJ SelfFixer.Com Online Manuals _

Powerhead Service - 9.9/15
Removal
~ 1. To avoid accidental starting of engine while servicing,

ill twist and remove all spark plug leads.
~ 2. On electric start models, disconnect the battery cables
ill from the battery. Remove the battery cables from the
engine.
rv 3.engme cover.the two screws and nuts from the top rear of lower
~
R~move
~ 4. Remove the water indicator hose and remove the screw

~ from the lower rear of the lower engine cover.
f31 5. R.emove the two screws from the top front of the lower
~ eng me cover.
141 6. R~move the screw and nut from the lower front of the lower
~ engme cover.
7. Remove the lower covers.
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8. Remove electrical components as described in Section 8.
9. Remove the fuel components as described in Section 2.
10. Remove the ignition components as described in Section 3.
11. Remove the shift lever and linkage as described in this

Section .
12. If equipped with a steering handle, remove the handle and

components as described in Section 5.
f51 13. Remove the six retaining screws, powerhead to the ex-
~ haust housing .
f61 14. The powerhead can now be removed. Lift the powerhead
~ from the exhaust housing.
fJl 15. Remove the exhaust and water tube assembly ® from the
~ powerhead. Remove and discard the gasket.
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Disassembly
~ To simplify reassembly, layout the various screws and

~ clamps in the order of their proper location.
rv the
~
1. Remove the three screws retaining the crankcase head to
powerhead. Using a mallet and a punch, drive the seals
from the crankcase head. Discard the O-ring and seals.
~ 2. Remove the exhaust cover screws. If necessary, tap the

~ exhaust cover edge with a rawhide mallet. Remove the inner
and outer exhaust covers; carefully separate the pieces.
~ Check the inner exhaust cover for pitting and flatness. If

~ pitting exists or the cover is warped, discard it and replace
with a new cover during reassembly.
~ f413. Remove the thermostat assembly and temperature

~ ~ switch (if equipped).
4. Remove the cylinder head screws.
1s15. Remove cylinder head. With number punches, mark the top
~ piston dome "No.1" and the bottom piston dome "No. 2".
1sl6. Remove the intake bypass cover from the cylinder block.
~ Clean the gasket surfaces.
rJl7. Remove the six intake manifold screws, intake manifold, leaf
~ plate assembly, and gaskets.
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101 8. Using a tool as drawn on Page 4-9, or equivalent, push
!!J crankcase taper pin toward intake manifold surface. Do not
use any tool smaller than taper pin bore to remove the pin.
19l 9. R~move the four crankcase flange screws and six main
~ beanng screws.
10. Turn the powerhead so the intake manifold surface faces up.
~ 11. Using a rawhide mallet, lightly tap upward on the

~ crankshaft until the halves just begin to separate. Lift up and
remove the crankcase.
f11l ~ Pistons, connecting rods, needle bearings, and liners

~ ~ are wearing parts and seat with the operation of the
engine. Because of this, it is essential to maintain their original
positions at reassembly. Using an indelible ink marker, mark each
component when they are removed to ensure correct mating, and
keep the needles of each cylinder together.
f'N=J Loosely install the cylinder head to prevent the pistons

~ from falling out when the crankshaft is removed.
r:t2l 12. Use a 5/3 2 in. Allen wrench to remove connecting rod
~ screws. Remove rod caps and bearing retainers.
G3l 13. Lift the crankshaft out of the cylinder block. Replace the
~ connecting rod caps on the rods. Orient them exactly as they
were before you removed them. Install the screws finger tight.
14. Disassemble the crankshaft as follows:
• Remove the flywheel key using diagonal-cutting pliers to

pry it out of the crankshaft.
• Slide the upper seal and main bearing off the crankshaft.
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• Remove the retaining ring from groove of the center
main bearing. Separate the bearing and remove the 23
loose needle bearings .
• Remove the lower main bearing only if it needs to be

replaced. Using external retaining ring pliers, remove
the lower bearing retaining ring. Using an appropriate
bearing separator, support the bearing, place separator
flats against the bearing and press off the crankshaft.
15. Rotate the powerhead so the cylinder head faces up. Remove
the cylinder head and gently push up on the connecting rods to
15 COB1127
remove No.1 and No. 2 piston assemblies. Protect the condition
ofthe piston by packing papertowels between the connecting rod
and piston. Do not allow the connecting rod to contact the inside
of the piston skirt during handling.
16. Remove the piston rings using an appropriate ring expander.

DO NOT try to save the rings. Install a complete set of new rings
on every powerhead service job.
f161 17. Using a tool as drawn on Page 4-8, or OMCRetaining Ring

~ Pliers, PIN 325937, remove the wrist pin retaining rings.
Discard the rings.
COB1129
11]1 18. The fit between the wrist pin to bosses of the piston is
~ loose on both sides. Push the wrist pin through to free the
piston from the connecting rod. If necessary, use OMC Piston
Cradle, PIN 326573, and OMC Wrist Pin Pressing Pin,
PIN 392511. With the piston skirt flush with the cradle, press out
the wrist pin using an arbor press. Be careful not to lose any of the
22 needle bearings or the two wrist pin washers. If any of the
bearings are worn or lost, replace all the bearings on reassembly.
COB1130
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Cleaning
~ Before inspecting or assembling powerhead, all internal

~ components must be perfectly clean and free of contami-
nants.
1. Remove any carbon accumulation from exhaust port areas.
2. Remove any carbon accumulation from cylinder head combus-

tion chambers.
3. If cylinder walls are glazed from extended use, use a medium

grit hone to resurface walls. Use slow RPM to achieve a strong
"crosshatch" pattern for best oil retention and ring sealing.
~ To avoid piston or cylinder block damage, restore the

~ chamfer to all port edges using a ball hone or other suitable
tool.
'" To avoid personal injury, wear eye protection and rubber

~ gloves when using OMC Gel Seal and Gasket Remover.
r:;-;;J 4. Use OMC Gel Seal and Gasket Remover to remove all
~ traces of gaskets, adhesives, and OMC Gel-Seal" from the
cylinder block and crankcase.
5. Carefully remove any carbon accumulation from the tops and

ring grooves of the piston. A ring groove cleaning tool can be
made by breaking an old ring and grinding an angle on its end. Do
not damage ring grooves while cleaning.
6. Thoroughly wash entire cylinder block and crankcase with

warm, soapy water to remove all traces of contaminants.
'" To avoid personal injury, wear eye protection and set

~ compressed air pressure at less than 25 PSI (172 kPa).
7. Air dry cylinder block and crankcase. Blowout all holes and
passageways with compressed air.
8. Cover the cylinder walls with a liberal amount of Johnson or

Evinrude Outboard Lubricant to protect them from corrosion.
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Inspection
1. Before any inspection process can begin, all internal compo-

nents must be clean and free of excess oil. Refer to Cleaning, this
Section.
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 or bearing surfaces,
and broken components.
119l 3. Check for cylinder head warpage using a piece of bar stock
~ or machinist's straightedge and a feeler gauge set.
• Cylinder head warpage must not exceed 0.004 in.

(0,10 mm), end to end. Resurface or replace head if
warpage exceeds this dimension.
4. Use a micrometer to measure the diameter of each crankpin

and main bearing journal. The lower main bearing jQurnal would
only be measured ifthe bearing was removed for another reason.
Refer to Engine Specifications, Section 1, for dimensions. .
1201 5. Use a telescoping gauge or inside reading micrometer 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.
f21l 6. 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

0.003 in. (0,08 mm).
21
7. The dimensional difference between the two areas is the DRll19
cylinder taper.
• The cylinder taper must not exceed 0.002 in. (0,05 mm)
8. 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 oversize by more than 0.002 in.

(0,05 mm).
~ If any cylinder is outside these tolerances, it must be bored

~ oversize. One oversize piston is available for this engine
(0.020 in., 0,508 mm). To determine oversize bore, add 0.020 in.
(0,508 mm) to the standard bore. Refer to Engine Specifications,
Section 1. It is permissible to have one or more oversize pistons in
an engine.
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0
\22\ 9. Measure the piston in two locations, 90 apart from each
other, '/s in. (3 mm) above the bottom of the piston skirt.
10. The difference between the two measurements is the out-of-

roundness and must be no more than 0.002 in. (0,05 mm).
1231 11. 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. o
----~- .
• The ring gap must be within 0.005-0.015 in. 22
(0,13-0,38 mm).
1241 12. Use a feeler gauge to check groove side clearance on the
lower square rings. Install each square ring on its piston.
With the ring seated in its groove, make several checks around the
piston.
• The side clearance must not exceed 0.004 in.

(0,10 mm).
\251 13. Use a machinist's straightedge to check clearance on the

upper tapered rings. Install each ring on its piston. When
checked with the straightedge, there should be enough ring
clearance to allow the straightedge to touch the piston on both
sides of the ring groove. Make several checks around the piston.
• If straightedge does not touch piston, remove the ring

and clean ring groove.
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1 DR2661
Assembly
fN=J Proceed slowly. Make no forced assemblies unless a press-

~ ing operation is called for. All internal components must be
perfectly clean and lightly coated with Johnson or Evinrude
Outboard Lubricant.
r:;l r:;] 1. Using components from OMC Wrist Pin Retaining Ring
l3J
L.!J Installer and Pressing Pin, PIN 392511, seat a new retain-
ing ring in groove of the piston . When installed, gap @ of the ring
should be positioned opposite groove ® in the piston.
131 2. Using the piston cradle and wrist pin driver, oil and start the
~ wrist pin into the piston wrist pin boss opposite where the
retaining ring is installed. Do not allow the wrist pin to enter the
piston cavity.
f41 is13. Slide one of the wrist pin washers © down the wrist pin .
~ ~ Position the top end of the connecting rod over the wrist
pin. Apply OMC Needle Bearing Assembly Grease to the 22
needle bearings and install the bearings into the connecting rod.
r;J 4. Slide the connecting rod with the needle bearings and
~ washer up and off the wrist pin, being careful not to disturb the
bearings. Place the connecting rod and the two wrist pin washers
© in position in the piston cavity, aligned with the wrist pin boss.
r:;] 5. Finish installing the w rist pin through the connecting rod
l2.J and the piston until the wrist pin contacts the installed retain-
ing ring. Check to be sure none of the needle bearings have been
disturbed and pushed out of the connecting rod. Install a second
new retaining ring.
~ Due to a slight decrease in wrist pin inside diameter, it

~ might be necessary to remove 0.015 in. (0,38 mm) from
the guide end of OMCWrist Pin Driver, PIN 392511 , before using.
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6. Install piston rings on each piston. Tapered ring must be
installed in top groove. Spread each ring with a ring expander just
enough to slip it over the head of the piston and down into place.
7. Coat t he piston and cylinder bore with oil.
101 8. Place the piston in OMC Ring Compressor, PIN 339754,

l!J (PIN 339755 for oversize pistons). Make certain that the rings
are correctly positioned in their grooves with respect to the dowel
pins. Damaged pistons and broken rings may result from imper-
fect alignment of the ring gap and the dowel pins.
~ The piston rings must be correctly located on their dowel

~ pins to prevent permanent powerhead damage.
19l 9. Start the piston into bore of the cylinder with deflector @ of
~ the piston (sharp edge) toward intake port side ® of the
cylinder block.
~ Loosely install the cylinder head to prevent the pistons

~ from falling out.
f101 10. If removed, oil and press a new lower main bearing onto
~ the crankshaft. When pressing on the bearing, support the
crankshaft between the two lower counterweights and press
againstthe lettered side ofthe bearing. Install the retaining ring in
groove of the crankshaft with sharp edge of the ring facing away
from bearing.
f111 11. Oil the upper main bearing surface of the crankshaft.
~ Slide the upper main bearing onto the crankshaft with
lettered side facing the flywheel end of the crankshaft.
r:;:;J 12. Install the center main bearing. Apply OMC Needle
~ Bearing Assembly Grease to the 23 needle bearings. Place
the bearings around the center main journal of the crankshaft.
Place the sleeves around the bearings with retaining ring end of
the sleeves facing flywheel end of the crankshaft. Secure the
sleeves together with the retaining ring .
COBl142
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12
f13l13. Remove the rod caps from connecting rods. Place one
~ retainer half © and bearings on each rod.
114114. Place crankshaft in position on cylinder block. Align

center main bearing dowel pin hole with dowel pin in
cylinder block. Roll the upper main bearing pin @ into groove of
the cylinder block. Position the rods on the crankpins at this time.
~ 15. Place other retainer halves and bearings on crankpins.

16. Oil threads of rod cap screws and install both rod caps finger 32454
tight.
~ INotel Be sure alignment dot ® on rod cap matches dot ® on

rod.
r:J1l17. Install both rod caps finger tight exactly positioned as

~ they were originally, and then using your fingernail or pencil
lead, determine if the caps are aligned properly by scraping it
across the joint between the cap and the rod. If your rod caps are
not correctly aligned, lightly tap them into position with an
aluminum rod and a mallet. 16
53628
~ Replace connecting rod assembly if satisfactory cap and
E.:J rod alignment cannot be achieved.
[!!] 18. Tighten the screws in stages to a final torque of 60-70 in.
Ibs. (7,0-7,5 N·m).
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19. Thoroughly clean and degrease the crankcase mating flange
of the cylinder block with OMC Cleaning Solvent and let air dry.
20. Apply Locquic Primer to the mating flange of the crankcase

and let air dry.
[1ID 21. Apply Gel-Seal I! t o the cylinder block flange. The

application must cover the flange evenly and consistently without
being excessive. The application must not come within % in .
(6,4 mm) of the labyrinth seals or bearings.
INote I Gel-Seal I! has a shelf life of at least one year when stored
at room temperature. Test the Gel-Seal II or replace it if the age of
the tube can not be determined. Using old Gel-Seall/could cause
crankcase air leaks.
22. Lower the crankcase into place.
120 I 23. Lightly coat threads of the six main bearing screws with
OMC Gel-Seall!. Install the screws finger tight.
I11J 24. When the crankcase is seated, install and firmly seat the
crankcase taper pin.
COA6229
25. Using a soft face mallet, lightly tap bottom of the crankshaft to
seat the lower main bearing .
1221 26. Apply OMC Gasket Sealing Compound to meta I case of a

new upper main bearing seal. Install seal using OMC Seal
Installer PIN 391060 with lip of seal facing in.
12311241 27. Apply OMC Gasket Sealing Compound to metal

cases of two new crankcase head seals. Place the small diameter
seal @ on OMC Crankcase Head Seal Installer, PIN 330251 or
433391, with lip ofthe seal facing large diameter ofthe tool. Install
the seal until tool contacts the head. Use the opposite side of the
tool to install the large diameter seal @' Lip of this sea l must face
away from large diameter of the tool. When installed, both seal
lips will face toward each other. Apply approximately 3 cc of OMC
Moly Lube between the seals.
28. Oil and place a new O-ring on the crankcase head . Install the
crankcase head. Apply OMC Gasket Sealing Compound to
threads of crankcase head screws. Install the screws finger tight.
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29. Tighten the six main bearing screws in stages to a final torque
of 144-168 in. Ibs. (16-19 N·m). Begin with the center screws and
work outward in a spiral pattern. Tighten the smaller crankcase
screws to a torque of 60-84 in. Ibs. (7-9 N·m).
30. Tighten the crankcase head screws to 60-84 in. Ibs. (7-9 N·m).
/251 31 . Apply Permatex No.2 to the two ribs in the cylinder head
next to thermostat water passage.
1261 32. Lightly coat both sides of a new cylinder head gasket 32388
with OMC Gasket Sealing Compound. Install the gasket and
cylinder head. Tighten the cylinder head screws in stages to the
final torque of 216-240 in. Ibs. (24-27 N·m), following the se-
quence shown.
33. Install the thermostat assembly (and temperature switch, if

equipped) in the cylinder head.
/271 34. Install thermostat cover and O-ring. Torque screws to

60-84 in. Ibs. (7-9 N·m).
12s1 35. Apply OMC Gasket Sealing Compound to both sides of

two new exhaust cover gaskets. Install the inner and outer
exhaust covers. Tighten the screws to a torque of 95-130 in.lbs.
(11-14 N·m), starting with the center screws.
1291 36. Apply OMC Gasket Sealing Compound to both sides of a

new bypass cover gasket. Install the bypass cover. Install and
tighten the screws to a torque of 60-84 in. Ibs. (7-9 N·m), starting
with the center screws.
130137. Install the intake manifold and leaf valve assembly using
new gaskets. Do not use sealer on these gaskets. Tighten the 30
--~-------------------3=23~83
38. Install the carburetion, ignition, and electrical components to

the powerhead.
/1 To prevent possible fire and explosion under the engine

cover, make sure ignition and electrical wires are routed and
clamped in original position; away from rotating parts which
could cut or abrade wire insulation.
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Installation
INotel Remove the gearcase as described in Section 6. This will

aid in guiding the water tube into the water pump grommet.
1. Install new powerhead to exhaust housing gasket. Install dry,

use no sealer.
IT] 2. Install both grommets ® and water tubes in inner exhaust

tube @. Center water tube in grommets. Do not allow water tubes
to touch inner exhaust tube. Position inner exhaust tube on
powerhead. Tighten the screws to a torque of 60-84 in . Ibs.
(7-9 N·m).
W 3. Apply a liberal amount of Permatex No.2 sealer to the

machined diameter of the lower crankcase head © .
4. Carefully lower the powerhead into the exhaust housing as

follows:
W • Install the long water tube against the exhaust tube.

rn • Guide the long water tube into the water tube opening @
in the exha ust housing.
W • Guide the small water tube ® into the opening ® in the

rn rear of the exhaust housing.
W • Apply OMC Gasket Sealing Compound to the six

powerhead retaining screws and install the screws.
Tighten the six powerhead retaining screws to a torque
of 60-84 in. Ibs. (7-9 N·m).
& 5. Adjust the neutral start switch.

I Note I To avoid permanent powerhead damage, instruct operator
to repeat the original engine break-in procedure as described in
Section 1 before putting engine back into normal service.
Neutral Start Switch Adjustment - 9.9/15 TE
INotel Disconnect the battery cables at the battery.
IT] 1. To test, shift motor into NEUTRAL. Disconnect the starter

motor red wire @ at the motor.
IT] 2. Attach a continuity light or ohmmeter between the starter

wire and the neutral start switch wire ® at the electrical box, and
press start button.
3. The continu ity light or ohmmeter should show continuity.
& 4. Shift motor into FORWARD and REVERSE and press start
button. No continuity should be indicated in either position.
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W 5. To adjust, loosen the neutral start button screw CD. With
the motor in NEUTRAL, center the button Q) in the switch recess
@. Tighten the neutral start button screw. Repeat Step 4.
6. Connect the starter motor red wire to the starter motor. Tighten
the nut securely. Apply OMC Black Neoprene Dip to the connec-
tion . Reconnect the battery cables.
Removal
rn
handle.
1. Remove screw and wave washer CD retaining the shift
rn 2. Remove adjustment screw and nut from neutral start

button and remove button .
rn 3. Remove screw tOOl retaining neutral start switch.
IT] 4. Disconnect the red wires @ and ® from the starter motor
and electrical box connection.
5. Pull wires out of grommet.
Installation
IT] 1. Reinstall switch wires through grommet. Connect the red

wires to the starter motor and electrical box. Apply OMC Black
Neoprene Dip to the connections.
rn 2. Install switch to shift bracket and tighten screw

curely.
tOOl se-
rn rn 3. Install start button on shift handle and secure with

screw and nut.
rn 4. Install shift handle on bracket and secure with wave

washer and screw.
INote I Testneutral start switch in FORWARD and REVERSE.

Adjust as required.
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Shift Lever and Linkage Service - 9.9/15
Removal
1. Remove the lower engine covers as described in Powerhead

Servicing , this section.
[!] 2. Remove the clip and drive pin from the shift handle.
~ 3. Remove the screw retaining the shift handle.
~ 4. Remove the lockout rod.
~ 5. Remove the choke lever and grommet.
~ 6. Remove the pin, shift rod, and grommet.
~ 7. Remove the screw and detent springs.
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f]l 8. Bend lock tab back and remove screw. Remove lock tab from
~ shift arm.
I!J 9. Remove shift arm and spacer.

19l 10. Remove the cotter pin, pin and shift lever. Remove the two
~ shift arm bushings.
Installation
19l 1. Install the two shift arm bushings. Install the shift lever, pin,
~ and clip.
[!] 2. Install the shift arm and spacer.

fJl 3. Position lock tab on shift arm and install screw securely.
~ Bend tab onto screw.
1!1 4. Place detent springs in position and secure with screw.
~ 5. Install shift rod and retain with pin. Install grommet.
~ 6. Attach choke lever to each linkage and install grommet.
@] 7. Install the lockout rod.

~ 8. Install shift handle and secure with screw.
[!] 9. Install the drive pin and clip in shift handle.
10. Install lower engine covers.
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· Remote Electric Start Models
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Remote Electric Start Models
42340
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Tiller Electric Start Models
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Tiller Electric Start Models
38659
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Manual Start Models
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Manual Start Models
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Powerhead Service - 20 thru 30
Removal
"" 1. To avoid accidental starting of engine while servicing,

i l l twist and remove all spark plug leads. On electric start
models, disconnect the battery cables at the battery.
2. Remove the manual starter as described in Section 7.
rv ®3. .Disengage
~
the spring ® from pin of the throttle control lever
Remove the washer © .
f21 4. Remove four screws from the pivot bearing clamps @ .

~ Remove the clamps from the throttle control lever.
r:;) 5. Remove the pin® from end of the throttle control rod ® .
~ Lift the armature plate link @ from the throttle control lever.
Move the throttle control lever aside.
~ 6. Remove the fuel pump cover @ ' Retain inside O-ring .

15l 7. Remove the overboard water indicator hose CD from f itting
~ on exhaust cover. Remove the hose from J-clamp.
1sl 8. Remove the two primer hoses Q) from the carburetor and
~ one primer hose ® from the intake manifold.
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r:;] 9. Tiller models - Separate the 5-pin Amphenol connector.
l2J Remove the stop switch wire from terminal liE". Remove stop
switch ground wire from ignition coil.
f81 10. Remove the shift lever. Insert a paper clip into plunger and
~ remove the pin ® and washer from the actuator cam link.
Disengage the link from the shift actuator cam.
11. Remove the ground lead from the powerhead.
Ig1 r;Ql 12.

Using OMC Special 112 in. Box Wrench, PIN 322700,
~ ~ remove port © and starboard @il powerhead retaining
nuts with washers.
r:t1l 13. Remove the four screws ® retaining the powerhead to

~ the exhaust housing.
r;:;-l 14. The powerhead now can be removed. It may be neces-

~ sary to rock the powerhead sideways to break the gasket
loose.
f13l 15. Remove the inner exhaust tube @ from the powerhead
~ and discard the gasket ®.
16. Place the powerhead in a suitable holding fixture and remove

all carburetor, ignition, and electrical components from the
powerhead. To simplify reassembly and wiring installation, lay
out the various screws and clamps in order of their proper
location.
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Disassembly
~ To simplify reassembly and wiring installation, layout the

~ various screws and clamps in the order of their proper
location.
f141 1. To remove the water tube grommet, depress tab of the

~ grommet. Push the grommet out of the inner exhaust hous-
ing.
f151 2. Use OMC Grommet Insta"er, PIN 304148, to install a new

~ grommet. Apply OMC Gasket Sealing Compound to outside
diameter of the grommet. Align tab of the grommet with hole in
the housing and install grommet.
1.J6l 3. Using diagonal or end cutters, gently pry out and remove
~ the flywheel key.
f17l f181 4. Remove the three lower crankcase head screws and
~ ~ pull it free evenly on a" sides. Discard both crankcase
head O-rings and the three screws.
5. Using a punch and a mallet, drive the seal from the lower
crankcase head. Remove a" traces of sealer from the crankcase
head.
16
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f1916. Remove all the screws from the cylinder head water cover,
~ tap it around the edge with a soft mallet to break the seal, and
then remove it. Remove the thermostat @' seal @' and spring © .
Then, remove the cylinder head.
12017. With number punches, mark the top piston dome "No.1"
and the bottom piston do;;ne "No. 2".
f21l 8. Remove the inner and outer exhaust covers; carefully

~ separate the pieces and clean the gasket surfaces.
~ Check the inner exhaust cover for pitting and flatness. If

~ pitting exists or the cover is warped, discard it and replace
with a new cover during reassembly.
1221 9. Remove the intake bypass cover and clean the gasket
surfaces.
1231 10. Remove the seven hex head screws and one flat head
screw, and remove the intake manifold.
1241 11. Remove one Phillips head screw and remove the leaf
plate.
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125 112. Using a tool as drawn on Page 4-9, or equivalent, push the
taper pin toward the intake manifold surface. Do not use any
tool smaller than the taper pin bore to remove the pin.
1261 13. Remove the six main bearing screws and eight flange
screws.
1271 14. Turn the powerhead with the intake facing up and then
tap lightly upward on the crankshaft until the crankcase
halves begin to separate.
15. Lift the crankcase from the cylinder block.

•
12sliNotei Pist?ns, connecti~g rods, rod bearin~s, and bear~ng
retainers are weanng parts and seat With the operation
of the engine. Because of this, it is essential to maintain their
original positions at reassembly. Using an indelible ink marker,
mark each connecting rod, cap, and bearing component when
they are removed to ensure correct mating, and keep the needles
of each cylinder together.
INotel Loosely install cylinder head to prevent pistons from falling

out.
1291 16. Remove the rod cap screws using OMC Torque Socket,
PIN 331638. Remove the cap's needle bearings and cages.
1301 17. Lift the crankshaft out of the cylinder block. Replace the
rod caps on the rods. Orient them exactly as they were before
you removed them. Install the screws finger tight.
f31l 18. Rotate the powerhead so that the cyl i nder head faces up.
~ Remove the cylinder head and gently push up on the con-
necting rods to remove No.1 and No.2 piston assemblies. Protect
the condition of the piston by packing paper towels between the
connecting rod and piston. Do not allow the connecting rod to
contact the inside of the piston skirt during handling .
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I I
~ ~
132119. Remove the upper crankshaft seal ® and bearing @.

Discard the seal and clean and inspect the bearing.
133120. Remove O-ring from crankshaft sleeve and inspect.

Replace if necessary.
134121. Inspect crankshaft sleeve and replace if necessary. To

remove, use OMC Slide Hammer, PIN 432128, and OMC
Large Puller Jaws, PIN 432129.
c.) _....
22. Remove the lower main bearing only if it needs to be
35
22153
replaced. Using external retaining ring pliers, remove the lower
bearing retaining ring. Using an appropriate bearing separator,
support the bearing, place separator flats against the bearing and
press off the crankshaft.
r:;;;;l23. Remove the rings from the pistons using piston ring
~ expanders. DO NOT try to save the rings. Install a complete
set of new rings on every powerhead service job.
136124. Using a tool as drawn on Page 4-8, or OMCRetaining Ring

Pliers, PIN 325937, remove the wrist pin retaining rings.
Discard the rings.
1371138125. The fit between the wrist pin to bosses of the piston
is loose on both sides. Push the wrist pin through to free
the piston from the connecting rod. If necessary, use OMC Piston
Cradle, PIN 326573, and OMC Wrist Pin Pressing Pin,
PIN 326356. With the piston skirt flush with the cradle, press out
the wrist pin using an arbor press. Be careful not to lose any of the
28 needle bearings or the two wrist pin washers. If any of the
bearings are worn or lost, replace all the bearings on reassembly.
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Cleaning
~ Before inspecting or assembling powerhead, all internal

~ components must be perfectly clean and free of contami-
nants.
1. Remove any carbon accumulation from exhaust port areas.
2. Remove any carbon accumulation from cylinder head combus-

tion chambers.
3. If cylinder walls are glazed from extended use, use a medium

grit hone to resurface walls. Use slow RPM to achieve a strong
"crosshatch" pattern for best oil retention and ring sealing .
~ To avoid piston or cylinder block damage, restore the

~ chamfer to all port edges using a ball hone or other suitable
tool.
'" To avoid personal injury, wear eye protection and rubber

~ gloves when using OMC Gel Seal and Gasket Remover.
~ 4. Use OMC Gel Seal and Gasket Remover to remove all

~ traces of gaskets, adhesives, and OMC Gel-Seal" from the
cylinder block and crankcase.
5. Carefully remove any carbon accumulation from the tops and

ring grooves of the piston. A ring groove cleaning tool can be
made by breaking an old ring and grinding an angle on its end. Do
not damage ring grooves while cleaning.
6. Thoroughly wash entire cylinder block and crankcase with

warm, soapy water to remove all traces of contaminants.
'" To avoid personal injury, wear eye protection and set

~ compressed air pressure at less than 25 PSI (172 kPa).
7. Air dry cylinder block and crankcase. Blowout all holes and
passageways with compressed air.
8. Cover the cylinder walls with a liberal amount of Johnson or

Evinrude Outboard Lubricant to protect them from corrosion.
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Inspection
1. Before any inspection process can begin, all internal compo-

nents must be clean and free of excess oil. Refer to Cleaning, this
Section.
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 or bearing surfaces,
and broken components.
1401 3. Check for cylinder head warpage using a piece of bar stock
40
10346
or machinist's straightedge and a feeler gauge set.
• Cylinder head warpage must not exceed 0.004 in .

(0,10 mm) end to end. Resurface or replace head if
warpage exceeds this dimension.
4. Use a micrometer to measure the diameter of each crankpin

and main bearing journal. The lower main bearing journal would
only be measured if the bearing was removed for another reason.
Refer to Engine Specifications, Section 1, for dimensions.
1411 5. Use a telescoping gauge or inside reading micrometer 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.
1421 6. 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

0.003 in. (0,08 mm).
7. The dimensional difference between the two areas is cylinder

taper.
• The cylinder taper must not exceed 0.002 in. (0,05 mm)
8. 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 oversize by more than 0.003 in.

(0,08 mm).
~ If any cylinder is outside these tolerances, it must be bored

~ oversize. One oversize piston is available for this engine
(0.030 in.,0,762 mm). To determine oversize bore, add 0.030 in.
(0,762 mm) to the standard bore. Refer to Engine Specifications,
Section 1. It is permissible to have one or more oversize pistons in
an engine.
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43
1431 9. Measure the piston diameter in at least two places to verify

piston condition. Make your measurements 1/8 to 114 in. (3,2 to
6,4 mm) above the bottom edge of the piston skirt.
~ These engines have pistons of several different manufac-

~ turers. Use the chart below to visually identify the piston
you are measuring and select the appropriate dimensions.
• The major diameter ® of the piston is measured 90° from

the wrist pin hole centerline. See the chart.
• The minor diameter @ of the piston is measured in line

with the wrist pin hole centerline. The minor diameter
must be smaller than the major diameter by the cam
dimension. See the chart.
@- @-
, A
@ @
Major Standard + 0.030 in. Standard + 0.030 in.
Diameter 2.9956 in. 3.0266 in. 2.9969 in. 3.0269 in.
(76,11 mm) (76,88 mm) (76,12 mm) (76,96 mm)
Cam 0.006 ± 0.001 in. 0.002 ± 0.0005 in.

Dimension (0,15 ± 0,03 mm) (0,05 ± 0,01 mm)
Vendor Zollner Art, Rightway

PCE0073
144 110. Ifthe grinding on the sides ofthe piston is worn smooth in
a pattern simila r to the illustration, replace the piston.
1451 11. Place each ring, separately, in its respective bore. Use a
piston to square the ring in the cylinder. Use a feeler gauge to
measu re the ring end gap.
• The ring gap must be within 0.007-0.017 in. (0,17-0,43 E

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1529 3125 21227
146112. Use a feeler gauge to check groove side clearance on the

lower square rings. Install each square ring on its piston.
With the ring fully seated in its groove, make several checks
around the piston .
• The side clearance must not exceed 0.004 in. (0,10 mm).
147113. Use a machinist's straightedge to check clearance on the

upper Pressure-Back™ rings. Install each Pressure-Back ring
on its piston. When checked with the straightedge, there should
be enough ring clearance to allow the straightedge to touch the 3521
piston on both sides of the ring groove. Make several checks
around the piston .
• If the straightedge does not touch the piston, remove the

ring and clean the ring groove.
Assembly
rr:i=J Proceed slowly. Make no forced assemblies unless a press-

~ ing operation is called for. All internal components must be
perfectly clean and lightly coated with Johnson or Evinrude
Outboard Lubricant. 24911
r:jl1. Lightly lubricate the three water deflectors with STP Oil
L'.J Treatment. Install the two long ® and one short ® water
deflectors until they are flush, or nearly flush, with the gasket
surface.
~ DO NOT shorten the water deflectors. The water deflectors

~ might be slightly above the gasket surface in a normal
installation.
~ 2. Determine which part of the piston faces up by holding the

~ piston next to the cylinder block. When installed, the sharp
4
24910
edge @ of the piston deflector will face the intake ports.
rJl3. Apply OMC Needle Bearing Assembly Grease to the 28 wrist

~ pin bearings. Install the bearings in the wrist pin bore. Align
the bearings in the bore using OMC Wrist Pin Bearing Tool, PIN
336660.
f411sl4. Place the two wrist pin thrust washers on the tool with
~ ~ flat side of the washers facing out.
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5. The connecting rod has no specific orientation. Support the
piston in OMC Piston Cradle, PIN 326573. Oil the wrist pin bore
and wrist pin.
1sl 6. Install the wrist pin through the piston and connecting rod,
~ pushing the tool out through the piston.
r:;J 101 7. Using OMC Cone, PIN 318600, and Driver, PIN 318599,
~ ~ install new wrist pin retaining rings in each wrist pin hole.
Gap ® of the retaining ring faces down, away from notch ® in
piston.
8. Repeat Steps 2 thru 7 for each piston.
9. Install piston rings on each piston. Tapered ring must be

installed in top groove. Spread each ring with a ring expander just
enough to slip it over the head of the piston and down into place.
Igl 10. Clean the seal bore ofthe crankcase head and install a new
~ seal using OMC Installer, PIN 333520. Apply OMC Gasket
Sealing Compound to the metal casing of the seal and press the
seal into the crankcase head until the tool is seated. The sharp
edge of the seal's metal case must face the tool during installa-
tion. Lightly coat the seal lips with OMC Triple-Guard grease. 7
~ 11. To install a new lower main bearing: Oil the end of the
~ crankshaft. Use OMC Crankshaft BearinglSleeve Installer,
PIN 339749, and place bearing onto crankshaft with lettered side
facing the tool. Install bearing until it seats in the crankshaft.
f11l 12. To install a new crankshaft sleeve: Oil the end of the
~ crankshaft. Place the sleeve in OMC Crankshaft Bearingl
Sleeve, PIN 339749, and drive the sleeve onto the crankshaft until
the installer contacts the lower main bearing .
• If the installer sticks on the sleeve after installation,

thread OMC Slide Hammer, PIN 391008, onto installer
and pull off.
~ Inspect sleeve surface after installing . Sleeve must not be

~ used if surface is damaged.
G2l 13. Lubricate a new driveshaft a-ring and lightly lubricate

~ crankshaft splines with OMC Moly Lube. Install a-ring in
sleeve.
r:j3l 14. Using retaining ring pliers, install lower main bearing
~ retaining ring with sharp edge of ring facing out.
15. Oil the upper main bearing and replace it with the lettering
facing the flywheel end of the crankshaft.
16. Oil the two roller assemblies and place them around the
center journal of the crankshaft.
17. Install the center main bearing sleeve with its ring end facing
the lower end of the crankshaft. Secure sleeves together with
retaining ring . E
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12 13
33272 33271 33270
18. Coat pistons, rings, cylinders, and OMC Ring Compressor,

PIN 326591 (PIN 330223 for oversize), with outboard lubricant.
1141 19. Center connecting rod in piston and locate piston rings on
their dowel pins. Slide one piston assembly into the respec-
tive cylinder bore while guiding the connecting rod through the
block.
~ The piston rings must be correctly located on their dowel

~ pins to prevent permanent powerhead damage.
rr::J=lt Loosely install cylinder head to prevent pistons from falling

~out.
f15l 20. Remove the connecting rod caps from the connecting
~ rods.
~ 21. Place one-half of crankpin bea ring on each rod.

f17l 22. Place the crankshaft in position. Align top and
~ main bearings with pins in the cylinder block.
center \ I
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~ 23. Install the remaining bearing half on each crankpin.
24. Oil threads of rod cap screws and install both rod caps finger
tight.
~ INotel Be sure alignment dot on rod cap matches dot on rod .

~ Torquing the rod cap screws without OMC Rod Cap Align-
~ ment Fixture, PIN 396749, or using an incorrect procedure,
could cause permanent damage to the connecting rod and
crankshaft. To maintain accurate torque values, keep extension
length to a minimum.
1201 25. Torque the rod cap screws using OMCRod Cap Alignment
Fixture, PIN 396749. Align the flat marked "set" on the rod
engagement stop with the arrow on the frame. Move the adjust-
ment knob to setting ®. Rotate adjustment knob 1800 to lock
position.
~ 1221 26. Secure retaining jaw "c" and forcing jaw "D" to the
~ frame.
1231 27. Tighten the rod cap screws to a torque of 25-30 in. Ibs.
(2-3 N·m).
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28. 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:
• Position frame onto the connecting rod so the contact

area ® of the jaw is centered in the side of the rod ©.
• Tighten forcing screw until jaws contact connecting rod.
• Slide frame down until adjustment stop contacts the

connecting rod. The groove lines on the jaws must be
centered on the rod/crankpin diameter.
INotel The abov~ proc.e~ure must be followed to assure frame is

squarely In position.
1261 29. Tighten the forcing screw to a torque of 23 in. Ibs.

(2,5 N·m).
30. Loosen both rod cap screws % turn.
1271 31. Apply a preliminary torque of 40-60 in. Ibs. (5-7 N·m) to
both rod cap screws.
32. Apply a final torque of 30-32 ft. Ibs. (40-43 N·m) in two
alternate increments to both rod cap screws.
33. Loosen forcing screw and remove the frame. Repeat Steps 27
thru 32 for remaining connecting rod.
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34. Thoroughly clean and degrease the crankcase mating flange
of the cylinder block with OMC Cleaning Solvent and let air dry.
35. Apply Locquic Primer to the mating flange of the crankcase

and let air dry.
1281 36. Apply Gel-Seal /Ito the cylinder block flange. The applica-
tion must cover the flange evenly and consistently without
being excessive. The application must not come within 1/4 in.
(6,4 mm) of the labyrinth seals or bearings.
~ Gel-Seal/l has a shelf life of at least one year when stored at

~ room temperature. Test the Gel-Seal /I or replace it if the
age ofthe tube can not be determined. Using old Gel-Seal II could
cause crankcase air leaks.
37. Lower the crankcase into place.
38. Lightly coat threads of the six main bearing screws with OMC
Gel-Seal II. Install the screws finger tight.
39. When the crankcase is seated, install and firmly seat the
crankcase taper pin.
40. Install crankcase flange screws finger tight.
1291 41. Using a soft face mallet, lightly tap bottom of the
crankshaft to seat the lower main bearing. Check for binding
between the crankshaft and the bearings on the connecting rods
by rotating the crankshaft with the flywheel.
1301 42. Lightly coat the machined mating surface of the crank-
case head with OMC Gasket Sealing Compound. Lubricate a
new crankcase head O-ring with OMC Triple-Guard grease and
install it. Install the lower crankcase head. Lightly coat the threads
of three new crankcase head screws with OMC Gasket Sealing
Compound and install them finger tight.
1311 43. Starting with the center screws, tighten the six main
bearing screws to a torque of 168-192 in . Ibs. (19-22 N·m).
Starting with the center screws, tighten the remaining eight
44. Tighten the three lower crankcase head screws to a torque of

60-84 in. Ibs. (7-9 N·m).
45. Apply OMC Gasket Sealing Compound to outside metal

casing of a new upper main bearing seal. Using OMC Seal
Installer, PIN 321539, install the seal with its lip facing down.
1321 46. Lightly coat both sides of a new cylinder head gasket with
OMC Gasket Sealing Compound. Install the gasket and cylin-
der head. Tighten the screws in the sequence shown to a torque
of 216-240 in. Ibs. (24-27 N·m).
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1331 47. Place the thermostat ® and the seal ® in the cavity
provided in the cylinder head. Set the spring © on top of the
thermostat.
134\ 48. Apply OMC Gasket Sealing Compound to both sides of a

new cylinder head water cover gasket; install the gasket and
cover. Starting with the center screws and working outward,
tighten the screws to a torque of 60-84 in. Ibs. (7-9 N·m).
135\ 49. Install the inner and outer exhaust covers. Coat both sides
of two new gaskets with OMC Gasket Sealing Compound.
Install the screws. Starting with the center screws and working
outward, tighten them to a torque of 48-84 in. Ibs. (5-9 N·m) .
50. Apply a bead of OMC Adhesive M to both sides of a new

bypass cover gasket. Install the gasket and bypass cover. Tighten
the screws to a torque of 60-84 in. Ibs. (7-9 N·m).
1361 51 . Slide a new leaf plate gasket over the crankcase studs,
then install the leaf plate. Do not use sealer on the gasket.
Apply OMC Gel-Seal lito the threads of the flat head screw, then
install and tighten the screw.
137/ 52. Install a new intake manifold gasket over the crankcase
studs, then install the manifold. Do not use sealer on the
gasket. Install and tighten the screws to a torque of 60-84 in. Ibs.
(7-9 N·m).
53. Install a new powerhead gasket. Install dry, use no sealer.
54. Install the inner exhaust housing. Tighten the screws to a

torque of 96-120 in. Ibs. (11 -14 N·m).
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Installation
rv head
~
1. Lightly coat a new a-ring and outside bore of the crankcase
with OMC Triple-Guard grease. Install the a-ring in
groove of the crankcase head.
2. Coat crankshaft splines with OMC Moly Lube. Do not allow

lubricant to pack at end of splines. Lubricant here may prevent
seating of driveshaft in crankshaft. Be sure a -ring is in crankshaft
sleeve.
f21 3. Check to be sure the water tube washer ® is positioned on

~ the water tube. Lightly apply OMC Triple-Guard grease to
upper outside diameter of the water tube.
4. Assemble the powerhead to the exhaust housing, making sure

the water tube enters the inner exhaust housing. Rotate the
powerhead slightly back and forth to align the crankshaft and the
driveshaft splines.
f31 5. Install and tighten the four powerhead retaining screws to a

~ torque of 192-216 in . Ibs. (22-24 N·m).
6. Apply OMC Nut Lock to the threads of the port and starboard
exhaust housing studs. Place the washer on the studs. Install and
tighten the two powerhead retaining nuts.
141 7. Install the ground lead to the powerhead. Apply OMC Black
~ Neoprene Dip to ground screw connections.
8. Install the carburetor, ignition, and electrical components to the

powerhead.
'" To prevent possible fire or explosion, make sure all electrical

ill and ignition wiring is routed and clamped in its original
position.
f51 9. Rand TE Models - Install the neutral start plunger and
~ spring through the component bracket. Using a pin @, secure
the plunger as shown.
f61 '" 10. After checking the ignition plate routing , install the
~ ill component bracket, neutral start plunger, lockout lever,
pivot screw ©, and flat washer @, as shown. Tighten the pivot
screw to a torque of 60-84 in . Ibs. (7-9 N·m) and remove the pin
securing the plunger.
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r:;l 11. Rotate the propeller shaft and shift the engine into RE-
l2J VERSE. Place the actuator cam link ® into the shift actuator
cam ®. Secure the link with the washer and pin.
19l 12. Seat shift lever socket on the lever. Snap socket onto the
~ stud. Secure the socket with washer and cotter pin.
191 13. Connect the overboard water indicator hose @ to the fitting
~ on the exhaust cover. Secure the hose in the J-clamp.
f1Ol 14. Connect the fuel hose to the fuel pump with a new tie
~ strap.
OIl 15. Install the throttle control lever.

r:J2l 16. Slide the throttle control rod ® through the nylon block
~ on the throttle control lever. Insert the pin CD in the end of the
rod. Offset on nylon block must face forward.
r:J2l 17. Place the nylon bushing on the stud ofthe throttle control
~ lever. Engage the armature plate link Q) on the stud. Place the
washer over the stud and engage the spring @.
~ 18. Install the starter lockout cable bracket (6).

19. Install the manual starter as described in Section 7.
'" 20. Adjust the shift lever and neutral start switch as de-
i l l scribed on Page 4-52.
~ To avoid permanent powerhead damage, instruct operator
~ to repeat the original engine break-in procedure as de-
scribed in Section 1 before putting engine back into normal
service.
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Shift Lever Adjustment, 20 thru 30
1. Rotate the propeller shaft and move the shift lever to NEU-
TRAL
[!] 2. Loosen both shift lever screws @.

r:;l 3. Move the shift actuator cam ® back and forth until the
L3J neutral shift lockout lever © centers in the notch of shift
actuator cam.
4. Tighten the shift lever screws to a torque of 60-84 in. Ibs.

(7-9 N·m).
Neutral Start Switch Adjustment, 20 thru 30 TE

Correct neutral start adjustment is possible only when the shift
handle coincides with the shift position of the gearcase.
1. Disconnect the battery cables at the battery.
2. Remove the yellow/red lead from the neutral start switch.
f31 3. With the shift handle in NEUTRAL, adjust the distance

~ between the bottom of the neutral start switch and the top of
the plunger to V16 in. (1,6 mm):
• Loosen the two neutral start switch screws.

• Insert a 1/16 in. (1,6 mm) drill bit between the bottom of
the switch and the top of the plunger.
• Move the switch until the switch and plunger contact the
drill bit.
• Tighten the switch screws securely.
141 4. To test for proper operation of the neutral start switch,

~ connect a continuity light or an ohmmeter (set to low ohms
scale) between the neutral start switch yellow/red lead terminal
and ground.
• With the motor in NEUTRAL, the light or ohmmeter

should show continuity.
• While rotating the propeller shaft, shift the motor into

FORWARD, then ' REVERSE. The light or ohmmeter
should not show continuity in either FORWARD or
REVERSE.
5. If adjustment is necessary, rotate the propeller shaft and shift

motor into NEUTRAL. Loosen the neutral start screws and move
the switch until satisfactory adjustment is made. Tighten the
screws and repeat Step 4.
• If a satisfactory adjustment cannot be made, replace the

switch.
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NOTES
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Manual Start Models
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Manual Start Models
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32Cle nQ 4-55 o
Remote Electric Models
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Remote Electric Models
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Tiller Electric Models
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Tiller Electric Models
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Midsection
Table of Contents
General Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 2

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 4
Twist-Grip Throttle Service - 9.9/15 ................. 5- 5
Steering Handle Service - 9.9/15 . ................... 5- 8
Twist-Grip Throttle Service - 20 thru 30 ............ . . 5-11
Steering Handle Service - 20 thru 30 ................. 5-14
Exhaust Housing Service - 9.9/15 .................. . 5-16
Midsection Adjustments - 9.9/15 . ................... 5-18
Exhaust Housing Service - 20 thru 30 ... . .. . ......... 5-19
Swivel Bracket Service - 9.9/15 . .................... 5-22
Swivel Bracket Service - 20 thru 30. . . . . . . . . . . . . . . . . . 5-24
Midsection Adjustments - 20 thru 30 . . . . . . . . . . . . . . . . 5-26
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32C/e nQ 5-1 o
Before working on any part of the midsection; read the section
To avoid accidental starting of engine while servicing, take

adequate precautions to disarm the ignition system:
• Connect the engine's wiring harness to the boat's wir-

ing harness with the key switch in OFF position.
• Twist and remove all spark plug leads from the spark
plugs.
• Disconnect the battery cables at the battery.
To prevent possible fire or explosion under the engine cover after

servicing:
• Check entire fuel system for leaks.
• Make sure all electrical and ignition leads are routed and
clamped in their original positions away from rotating
engine parts.

To prevent possible injury, test the engine's entire shift system

and start-in-gear prevention before returning engine to the
customer.
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5-2 32C/eng
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DESCRIPTION 9.9/15 20-30 ADHESIVE
Upper Mount to 60-84 in. Ibs. CIVIC Nut Lock

Exhaust Housing (7-9 N·m) •
Upper Mount to 18-20 ft. Ibs. CIVIC Nut Lock
Steering Bracket (24-27 N·m) •
Lower Mount 60-84 in . Ibs. CIVIC Nut Lock
Bracket Screws (7-9 N·m) •
Idle Relief Muffler 48-60 in. Ibs. CIVIC Nut Lock
Screws (5-7 N·m) •
Steering Bracket to 18-20 ft. Ibs. CIVIC Ultra Lock
Pivot Shaft Screws (24-27 N·m) •
Lower Side Mount 144-168 in. Ibs . CIVIC Gasket Sealing Compound
Nuts • (16-19 N·m)
Upper Side Mount 144-168 in. Ibs . CIVIC Gasket Sealing Compound
Nuts • (16-19 N·m)
Tilt Tube Nut* 50-54 ft. Ibs. 50-54 ft. Ibs.

(68-73 N·m) (68-73 N·m) •
* Back off nut 1J4 turn after torquing .
OMC Special Tools Required

Twist-Grip Throttle Remover, PIN 390767
Socket Removal Tool, PI N 322699
Insert Tool, PI N 322697
Sealants and Lubricants Required _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
CIVIC Locquic Primer

OMC Ultra Lock
OMC Nut Lock
CIVIC Moly Lube
OMC Gasket Sealing Compound
OMC Trip/e-Guard@Grease
OMC Adhesive M ™
Isopropyl Alcohol
Loctite Depend 330 Adhesive
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32C/ena 5-3 o
Cleaning and Inspection
1. Inspect clamp screw assembly. Replace swivel plate and
retainer if bent or loose. To install a new swivel plate remove
screw and old plate. Apply OMC Locquic Primer to the threads of
the screw and allow it to dry four to five minutes. Then apply
OMC Ultra Lock to threads. Install a new swivel plate with screw
and tighten securely.
2. Clean all parts with parts cleaning solvent and dry with
compressed air. All nut and screw threads coated with OMC
Screw Lock or OMC Nut Lock must be thoroughly cleaned before
reassembly. When using a thread locking product, be sure to
prime the threads with OMC Locquic Primer.
3. Discard all oil seals, O-rings, and gaskets.
4. Examine the rubber motor mounts and replace if deteriorated

or damaged.
5. Before checking the exhaust housing for distortion, thoroughly

clean the top and bottom mating surfaces and remove all sealer
and corrosion.
r,l 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 .
• On split gearcase models - also check parallelism of the

upper gearcase housing. See Section 6.
~ A bent exhaust housing will cause upper driveshaft splines

~ to wear excessively, and will also damage crankshaft
splines. .
7. Inspect water tube for obstructions or kinks which may restrict

water flow.
8. Inspect shift components for wear. Replace if deteriorated or

damaged.
9. 20 thru 30 - If necessary to replace the powerhead retaining

studs, install new studs to the following heights:
~ • Starboard Stud - 7/8 in. (21 mm)
~ • Port Stud - 1V32 in . (26 mm)
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5-4 32C/eng
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1 32290
2
1-...--I-------------;:C:::"OA=-=2=674-:-'
Twist-Grip Throttle Service - 9.9/15
Disassembly
r:;l 1. Using OMC Twist-Grip Throttle Remover, PIN 390767, de-

t]j press the grip detents. Tighten screw ® and remove the grip
by pulling grip and turning the idle adjustment knob ® clockwise.
~ 2. Remove the helix halves @, rollers @, and guides @.

I] 3. Pull the throttle pin out of the cable.
04. Remove throttle end cap from inner handle.
f5l 5. Remove stop switch cover screws and cover/stop switch

~ assembly.
~ 6. Remove the throttle control plate. 5

~ 7. Remove the throttle cable from the steering handle.
f71 8. Remove stop switch assembly with throttle cable from
~ cover.
9. Remove the throttle cable seal from the inner handle.
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32294 <1\
32C/ena 5-5 o
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.
Assembly
8 32295
1. Install the throttle cable seal in inner handle.
101 2. Snap the stop switch assembly with the throttle cable into
l!J the cover. Be sure the protective sleeve covers the stop switch
wires and throttle cable.
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5-6 32Cle ng
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In! 3. Place the throttle cable into the inner handle and align the
~ cover with the handle. Install the throttle control plate on outer
handle.
r;Ql 4. Place the throttle end cap into inner handle. The tab on the
~ cap goes into the recess of the inner handle.
1111 5. Push the throttle cable pin through the end of the throttle
~ cable.
f121 6. Lubricate end of the pin, guides, rollers, helix grooves, and
12
24293
~ inner handle guide slot with OMC Moly Lube. Place the
guides over the roller pin and into the slots of the inner handle.
Place the rollers on the ends of the roller pin.
f121 r:J3l 7. Assemble the helix halves on the handle and slide the
~ ~ grip over the helix. Be sure the twist-grip's speed indica-
tor line is positioned with the speed range symbol on the handle.
Snap the grip into place.
f13l 8. Turn the idle speed adjustment knob counterclockwise to

~ the minimum slow speed position.
1141 9. Install stop switch cover onto handle.
14
32292
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32C/en o 5-7 o
Steering Handle Service - 9.9/15
Removal

2. Remove the lower motor covers, manual starter, and air
silencer.
[!] 3. Remove the throttle cable pin @ from the throttle lever.
r:;l 4. Remove the shoulder screw and washer ® retaining the
L.!J throttle cable anchor to the powerhead. Remove the cable end
connector and throttle cable anchor from the cable.
~ 5. Remove the stop button ground lead from the ignition coil.
fJ1 6. Cut tie strap and separate the 5-pin Amphenol connector.
~ Remove the stop button black wire from the plug using OMC
Socket Removal Tool, PIN 322699.
f41 7. Remove the steering handle screw, nut and sleeve. Lift the
~ handle from the steering bracket.
f51 8. Pull the throttle cable and stop button leads through the
~ grommet in the lower motor cover. Use isopropyl alcohol on
the sleeve to ease removal.
9. Refer to Page 5-5 for Twist-Grip throttle disassembly instruc-

tions.
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Installation
1. Insert the stop button wires and throttle cable through the
lower motor cover grommet. Use isopropyl alcohol on the sleeve
-®
to ease assembly.
1cl 2. Apply OMC Triple-Guard grease to the steering handle

~ sleeve and place the sleeve into the steering bracket. Replace
sleeve if necessary.
3. Attach the steering handle to the bracket. Tighten the nut just
tight enough so the steering handle will maintain any position.
'" Re~lace the steering handle locknut if it has lost its locking
i l l action.
~ 4. Secure the stop button ground lead behind the ignition coil
~ on the lower screw, with star washer next to block.
f71 5. Use OMC Pin Insert Tool, PIN 322697, to install the stop
~ button black wire into the 5-pin Amphenol plug.
f8l 6. Connect the Amphenol connector. Secure the connector to

~ the ignition coil post with a tie strap.
19l 7. Threadthe throttle cable anchor onto the cable housing

~ until anchor is flush with end of threads ®
~ 8. Thread the cable end connector @ on the cable until seated.

rv~. Positi.on the throttle cable connector into throttle lever and
~ Insert pin ®.
rv10. Position throttle cable anchor on powerhead and secure

~ with shoulder screw and washer @.
f101 1.1. Hook cable retainer around throttle cable and install air
~ silencer.
12. Install manual starter and lower motor covers.
13. To adjust the throttle cable, refer to Synchronization and

Linkage Adjustment, Section 1.
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NOTES
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5-10 32Cleng
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COA2674
Twist-Grip Throttle Service - 20 thru 30
Disassembly
rv press
~
1. Using OMC Twist-Grip Throttle Remover, PIN 390767, de-
the grip detents. Tighten screw ® and remove the grip
by pulling grip and turning the idle adjustment knob ® clockwise.
~ 2. Remove the helix halves @ , rollers @ , and guides @.

~ 3. Pull the throttle pin out of the cable.
@] 4. Remove throttle end cap from inner handle.
1sl 5. Remove stop switch cover screws and cover/stop switch
~ assembly.
~ 6. Remove the throttle control plate. 5

24288
rJl 7. Remove the throttle cable retainer clip ®. Pry the throttle
~ cable trunnion @ out of the steering handle and remove the
cable.
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24286 <1\
32C/e ng 5-11 o
10
Isl 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.
19l 9. Remove the plastic inner handle from the metal outer
~ handle by driving the outer handle off with a mallet and a
punch. Inner handle is bonded to the outer handle. After remov-
ing, chip away remnants of inner handle.
10. Remove the throttle cable seal from the inner handle.
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.

24282
Assembly
1. Install the throttle cable seal in inner handle.
r,Ql 2. If removed, apply Loctite Depend 300 adhesive to inner

~ handle at areas shown.
r:J11 3. Install the metal outer handle over the plastic inner handle
~ and drive the outer handle into place.
Isl 4. Secure tab of the inner handle into recess of the outer
~ handle with the steel pin . 13
24299
r:J2l1131 5. Install the handle end of the throttle cable. Snap the
~ throttle cable trunnion into the recess in the handle.
Install the retainer clip.
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5-12 32C/eng
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~ 6. Install the throttle control plate on outer handle.
I.i5l 7. Place the throttle end cap into inner handle. The tab on the
~ cap goes into the recess of the inner handle.
G6l 8. Push the throttle cable pin through the end of the throttle
~ cable.
r:J7l 9. Lubricate end ofthe pin, guides, rollers, helix grooves, and
~ inner handle guide slot with OMC Moly Lube. Place the
guides over the roller pin and into the slots of the inner handle.
Place the rollers on the ends of the roller pin.
r:J7l r:J8l 10. Assemble the helix halves on the handle and slide
~ ~ the grip over the helix. Be sure the twist-grip's speed
indicator line is positioned with the speed range symbol on the
handle. Snap the grip into place.
r:J8l 11. Turn the idle speed adjustment knob counterclockwise to

~ the minimum slow speed position.
f19l12o1 12 . Slide the protective sleeve over the stop switch leads
~ and throttle cable. Slide grommet over the protective
sleeve until V2 in. (12 mm) of the sleeve is exposed. Place
grommet in position and install stop switch bracket.
20
24288
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5-13
32C/e ng
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24197
Steering Handle Service - 20 thru 30

Removal

i l l twist and remove all spark plug leads.
rv throttle
~
2. Remove the shoulder screw ® and spacer from end of the
cable.
rt 3. Remove cotter pin @, connector, and two washers from

~ throttle arm.
4. Remove bracket and connector from throttle cable.
131 ~ 5. Separate the 1-pin Amphenol connector. Remove the

~ ~ stop button lead from the plug using OMC Socket Removal
Tool, PIN 322699.
lsi 6. .Remove .the stop button ground lead from bottom ignition
~ cOil mounting screw.
7. Remove protective sleeve from stop button leads and throttle

cable.
f61 8. Remove the steering handle screw. Pull the throttle cable
~ and stop button leads through the grommet in the lower
engine cover.
9. Refer to Page 5-11 for Twist-Grip throttle disassembly instruc-

tions.
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& Safety Related 5-14 32Cle n g
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Installation
1. Insert the stop button leads and the throttle cable through the
lower engine cover grommet.
2. Apply OMC Triple-Guard grease to the two steering handle

bushings. Place the bushings into the steering bracket. Attach the
steering handle to the steering bracket.
1sl 3. ~igh~en the nu~ ~o the steering handle can be pivoted and
~ maintain any position.
4. Slide the protective sleeve over the stop button leads.
f51 5. Secure stop button ground lead to bottom ignition coil

~ mounting screw. Tighten screw to a torque of 48-96 in. Ibs.
(5,4-10,8 N·m).
f71 6. Using OMC Insert Tool, PI N 322697, install the stop button
~ lead into the plug. Connect the 1-pin Amphenol connector.
Secure connector with wire retainer.
'8l7. Thread the connector onto the cable housing 1314 in .

~ (44 mm) from end of the cable sleeve. Secure connector in 8
24193
place with nut.
~ 8. Thread the bracket onto the cable until seated.

f21 9. Position the connector on the throttle arm . Secure the
~ connector to the throttle arm using two washers and a cotter
pin.
f1l 10. Secure the bracket to the lower engine cover using shoul-
~ der screw and spacer.
11. To adjust the throttle cable, refer to Synchronization and

Linkage Adjustment, Section 1.
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5-15
32C /e ng
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Exhaust Housing Service - 9.9/15
Removal and Disassembly
1. Remove the lower engine covers as described in Section 4.
2. Remove carburetor as described in Section 2.

4
4. Remove the gearcase as described in Section 6.
[!] 5. Remove the exhaust housing baffle.

f21 6. Remove the cotter pin. Remove the shift arm pin ® to
t=I disengage the shift rod from the shift arm, and remove the
rod.
f31 7. Remove the five screws and lift the lower engine cover
~ support off the exhaust housing.
f41 8. Remove the two lower mount bracket ® screws. Remove

~ the port and starboard lower mount brackets with two lateral
mounts.
f51 9. Remove the two idle relief muffler screws. Remove the
~ muffler and discard gasket.
f61 10. Remove the two upper mount to steering bracket screw
~ caps © and discard O-rings. Remove the two upper mount
screws. Separate the exhaust housing from the swivel bracket
assembly.
f71 11. Remove the upper thrust mount and plate from the swivel
~ bracket assembly.
12. Remove the four screws (two port and two starboard) retain-
ing the two upper mounts to the exhaust housing. Remove the
two upper mounts.
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5-16 32C/eng
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[]] 13. Remove the lower thrust mount @ and shift rod grommet
@.
14. Refer to Cleaning and Inspection at the beginning of this

section .
Assembly and Installation
[ ] ] 1. Install the lower thrust mount @, and shift rod grommet @

to the exhaust housing.
[ ] ] 2. Apply GE RTVadhesive and install the two upper mounts.

Apply OMC Nut Lock to the four upper mount retaining screws
and torque to 60-84 in. Ibs. (7-9 N·m).
rn 3. Place the upper thrust mount and plate in position on the

swivel bracket assembly.
[ ] ] 4. Clean all sealant from the threads on the two upper mount
to steering bracket screws. Apply OMC Nut Lock to threads of
screws. Position the swivel bracket assembly on the exhaust
housing . Install the two upper mount screws and tighten to a
torque of 18-20 ft. Ibs. (24-27 N·m). Install caps with new O-rings
and torque screws to 60-84 in. Ibs. (7-9 N·m).
[IQ] 5. Place the lateral mounts ® in the lower mount brackets.

Apply OMC Nut Lock to threads of lower mount bracket screws.
Install t he lower mount brackets. Tighten screws to a torque of
60-84 in. Ibs. (7-9 N·m).
[I!] 6. Position a new idle relief muffler gasket. Install the muffler
to the exhaust housing . Apply OMC Nut Lock to the muffler's
retaining screw threads. Tighten the screws to a torque of
48-60 in. Ibs. (5-7 N·m).
rn 7. Position the lower engine cover support on the exhaust

housing and torque the five screws to 60-84 in. Ibs. (7-9 N·m).
rn 8. Lubricate the upper shift rod with OMC Triple-Guard

grease. Install the shift rod into the shift arm ® with pin and a
new cotter pin .
9. Install the powerhead as described in Section 4.
IT] 10. Place exhaust housing baffle in position .
11. Install the gearcase as described in Section 6.
12. Install the carburetor as described in Section 2.
13. Install the lower engine covers as described in Section 4.
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5-17
32 C/e n~
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Midsection Adjustments - 9.9/15
Tilt Friction Adjustment (Tiller Handle Models)
rn Use 9/16 in. wrench to tighten the tilt shaft nut only enough to
control the return of the gearcase from TILT to RUN position.
Steering Friction Adjustment
& rn Adjust steering friction with motor mounted to boat by

loosening or tightening screw with screwdriver. Steering friction
should be adjusted so that a slight drag is felt when turning.
Minimum friction is required when remote steering is used. Do
not overtighten. The steering friction screw is not intended to
allow "hands off" steering.
Idle Speed Adjustment
rn The idle speed adjusting knob is located on the steering

handle. Turning the knob clockwise increases idle speed, turning
it 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.
Throttle Friction Adjustment
rn Some models are equipped with a throttle friction adjust-

ment knob located on the steering handle. Tighten the knob to
reduce the effort required to hold a throttle setting. Turn the knob:
• clockwise to increase friction
• counterclockwise to decrease friction
& Tighten knob only enough to hold throttle at a constant

engine speed. Overtightening will prevent quick throttle change
in case of emergency.
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Exhaust Housing Service 20 thru 30
2. Remove the gearcase as described in Section 6.
r:jl 3.
Remote Models - Remove the two screws @ with lock
~ washers retaining the shift lever @ . Pull the shift lever out of
the lower engine cover.
~ 4. Remove the actuator cam grommet © from the lower

~ engine cover. Raise the grommet toward top of the actuator
cam @ . To remove the actuator cam, pull base of it over the
grease fitting ® in the adjustment lever and shaft.
r]l ~ 5. Remove the four screws holding the lower engine cover
~ ~ to the exhaust housing. Lift the cover off the exhaust
housing. Ifthe washers on the exhaust housing are loose, remove
them at this time.
f511sl 6. Bend locking tab on the clip ® and remove the screw @
~ ~ and the clip retaining the shift lever to the bellcrank.
Remove the shift shaft retainer @ with a small screwdriver. Hold
the shift rod lever and the upper shift rod while removing the
adjustment lever and shaft.
~ 7. Remove two lower mount to exhaust housing screws from

~ front of the lower mount housings.
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17264 Qi
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32C/eng
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1sl 8. Remove the three screws retaining the idle relief muffler.
~ Remove the muffler. Discard the muffler gasket and seals from
the screws.
Inl r:;-;J 9. Remove the two remaining lower mount housing

~ ~ screws from the port lower mount housing. Separate and
remove the port and starboard lower mount housing. Slide the
mount housing bumper ® from between the lower front mount
and the exhaust housing.
r;v 10. Remove the nuts and washers from the two upper side
~ mounts @.
f121 11. Remove the nut © and the washer from the upper front
~ mount. Separate the exhaust housing from the swivel brack-
et assembly.
f13l 12. Remove the two screws retaining the lower motor cover
~ bracket @ to the exhaust housing and remove the bracket.
Remove and discard the exhaust housing to lower engine cover
seal @.
r;v f101 13. Remove the upper side mount.s ® and the lower front
~ ~ mount ® from the exhaust housmg.
r,(il 14. Remove the nuts from inside of the exhaust housing that
~ retain both lower side mounts @ to the exhaust housing.
15. Refer to Cleaning and Inspection at the beginning of this

section.
Assembly and Installation
~ If not otherwise specified, apply OMC Gasket Sealing

~ Compound to threads of all screws.
r,(il 1. Apply OMC Gasket Sealing Compound to the threads of

~ lower side mounts. Install the two lower side mounts @ .
Tighten the nuts to a torque of 144-168 in. Ibs. (16-19 N·m).
r;Ql r;v 2. Install the lower front mou~t ® and the upper side
~ ~ mounts ® to the exhaust housmg.
G3l 3.
Install the lower motor cover bracket @ to the exhaust
~ housing. Apply OMC Adhesive M to the seal surface of the
exhaust housing. Position a new exhaust housing to lower engine
cover seal @.
f111 f121 4. Apply OMC Gasket Sealing Compound to threads of

~ ~ the upper side mounts. Place front of the exhaust hous-
ing over the upper front mount. Push lower part of the exhaust
housing toward the swivel bracket. Align the two upper side
mounts ® in the steering brackets. Install the washers and nuts
on the upper front mount ® and the two upper side mounts.
Tighten the nuts to a torque of 144-168 in. Ibs. (16-19 N·m) .
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32Cl e nQ
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Igl r:tQl 5. Slide the mount housing bumper ® into place between
EJ ~ the lower front mount and the exhaust housing. Position
the port and starboard lower mount housings. Clean the threads
of the four lower mount housing screws and apply OMC Screw
Lock to threads of the screws. Install the two side lower mount
screws, then install the two front screws. Tighten all four screws
to a torque of 144-168 in. Ibs. (16-19 N·m).
101 6. Apply OMC Gasket Sealing Compound to a new idle relief

l!J muffler gasket. Place new seals on the screws. Position the
gasket and install the muffler.
\141 7. Slide the adjusting lever and shaft through the exhaust
housing with flat side up. As the adjusting lever and shaft
comes through the exhaust housing, install the shift rod lever CD.
Snap the shift shaft retainer Q) into place. Place a new shift rod
lever clip ® over the shift rod lever. Install and tighten the screw
to a torque of 60-84 in. Ibs. {7-9 N·m).Bend the locking tab of the
clip against the head of the screw.
f151 8. If removed, apply OMC Adhesive M to the four washers

~ and place the washers as shown in figure. Place the lower
engine cover on the exhaust housing. Install and tighten the
116\ 9. Slide the actuator cam© through the lower engine cover.
Place the bottom of the cam over the grease fitting of the
adjustment lever and shaft. Position the actuator cam grommet in
place in the lower engine cover.
~ to the adjust-
f17l 10. Remote Models - Secure the shift lever
~ ment lever and shaft with two screws and lock washers.
11. Install the gearcase as described in Section 6.
12. Install the powerhead as described in Section 4.
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32480
Swivel Bracket Service - 9.9/15

Disassembly
rv~ Lift
1. Loosen the swivel bracket adjustment screw @ with spring.
the pivot tube and steering bracket from the swivel
bracket. Remove the upper thrust washer @ .
~ 2. Remove the lower thrust washer ©, O-ring @ , and lower

~ bushing ® from the swivel bracket.
32482
1Jl 3. Remove the liner ® and friction block @ from the swivel
~ bracket.
f4l 4. If necessary, disassemble the pivot tube from the steering

~ bracket by removing the three screws @ .
r.;l r,;] 5. If necessary, service the components of the stern brack-

~ ~ ets. If the tilt bolt is removed, tighten the bolt to a torque of o
60-84 in. Ibs. (7-9 N·m) when assembled. -====,."... 01 ~
10
32471
32478
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5-22 32C/e nQ
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Assembly
o
[[J []] 1. If any of the swivel bracket components were re -

moved, refer to the two reference pictures for correct reassembly. -
W 2. If removed, install the steering bracket to the pivot tube ~
with the three screws @. Tighten the screws to a torque of
18-20 ft. Ibs. (24-27 N·m).
W []] 3. Assemble the friction block and liner. Lubricate and

\
I ~ 00
place the liner and friction block in the swivel bracket.

32473
CD 4. Install the upper thrust washer ® on the swivel bracket.

[IJ 5. Apply OMC Triple-Guard grease to the lower bushing.
Install the lower bushing @, O-ring @, and lower thrust washer
©.
6. Apply OMC Triple-Guard grease to the pivot tube. Install the
pivot tube and steering bracket into the swivel bracket.
7. Thread the swivel bracket adjustment screw with spring into

the swivel bracket to retain the steering bracket.
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5-23
32Cfe n~
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Swivel Bracket Service - 20 thru 30
Disassembly
[I] rn 1. Loosen the swivel bracket adjustment screw @ . Lift

the pilot shaft and steering bracket from the swivel bracket.
Remove upper thrust washer @ .
rn 2. Remove the lower thrust washer @ , O-ring @ , and lower

bushing ® from the swivel bracket.
rn 3. Remove the liner ® and friction block @ from the swivel

bracket.
[ [ ] 4. Remove the upper front mount ® from the steering

bracket. Disassemble the pilot shaft from the steering bracket by
removing the four screws 0) .
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5-24 32C/eng
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Assembly
~ Lubricate the tilt tube and tiller handle components with

~ OMC Triple-Guard grease.
Icl r:;J 1. If any of the swivel bracket components were removed,

~ ~ refer to the two reference pictures for correct reassembly.
1sl 2. Clean the threads of the four pilot shaft to steering bracket
~ screws thoroughly. Apply OMC Screw Lock to the threads.
Apply OMC Ultra Lock to top mating flange of the pilot shaft.
Assemble the pilot shaft to the steering bracket and tighten the
1sl 3. Install the upper front mount ® to the steering bracket with
~ nut and washer. Tighten the nut to a torque of 144-168 in.lbs.
(16-19 N·m).
f41 f81 4. Assemble the friction block and liner as shown in figure
~ ~ 4. Lubricate and place the liner and friction block in the
swivel bracket.
f21 5. Install the upper thrust washer. Slide the pilot shaft into the
~ swivel bracket.
r:;-J 6. Lubricate and slide the lower bushing @ , O-ring @ , and

~ lower thrust washer © on the pilot shaft and seat in the swivel
bracket.
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32C/e ng 5-25 o
Midsection Adjustments - 20 thru 30
Steering Friction Adjustment.
I.jl "" Adjust steering friction with motor mounted to boat by

~ i l l loosening or tightening screw with a screwdriver, as
shown. Steering friction should be adjusted so that a slight drag is
felt when turning. Minimum friction is required when remote
steering is used. The steering friction screw is not intended to
allow "hands off" steering.
Idle Speed Adjustment
~ The idle speed knob is located on the steering handle. Turning

~ clockwise on the knob increases idle speed, turning counter-
clockwise 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.
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Gearcase
Table of Contents

Water Pump Servicing - 9.9/15 ......... . .... ' ....... 6- 6
Water Pump Servicing - 20, 25, 30. . . . . . . . . . . . . . . . . . . 6- 8
Water Pump Servicing - 25 Comm., 28 ......... . ..... 6-10
Service Chart - 9.9/15 ... . ....................... . 6-12
Gearcase Servicing - 9.9/15 . ... . .......... . ... . .... 6-13
Removal ................. ......... ...... ... .. 6-13
Disassembly ...... . .. .... .. ..... .............. 6-13
Cleaning and Inspection ......................... 6-17
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Installation .................................... 6-22
Service Chart - 20, 25, 30 . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Gearcase Servicing - 20, 25, 30 • . . . . . . . . . . . . . . . . . . . . 6-24
Removal .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Disassembly .................................. 6-25
Cleaning and Inspection ......................... 6-28
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Installation .... ....... .... .... ..... . ..... ...... 6-34
Trim Tab Adjustment - 20, 25, 30. . . . . . . . . . . . . . . . . . . . 6-36
Service Chart - 25 Comm., 28 . . . . . . . . . . . . . . . . . . . . . . 6-37
Gearcase Servicing - 25 Comm., 28. . . . . . . . . . . . . . . . . . 6-38
Removal ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Installation .................................... 6-47
Servicing the 7112 in. Gearcase Extension - 25 Comm.. . . . 6-48
Checking Propeller Hub Slippage - 9.9 - 30 . . . . . . . . . . . . 6-49
Jet Drive Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
Removal and Disassembly. . . . . . . . . . . . . . . . . . . . . . . . 6-50
Bearing Housing Servicing . . . . . . . . . . . . . . . . . . . . . . . 6-52
Water Pump Servicing ........................... 6-55
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 6-57
Installation .......... .... .................. .... 6-58
Jet Drive Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60
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32C/eno 6-1 o
.& General Safety Warnings
Before working on any part of the gearcase, read the section


(172 kPa) .

personal injury.

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6-2 32C/en9
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Special Torque Chart _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
DESCRIPTION 9.9/15 20,25,30 25 COMM., 28 ADHESIVE
60-80 in. Ibs. 60-80 in. Ibs. 60-80 in . Ibs. OMC Gasket
Water Pump screws
(7-9 N·m) (7-9 N·m) (7-9 N·m) Sealing Compound
Oil level & 84-86 in. Ibs. 84-86 in. Ibs. 84-86 in. Ibs.
Fill/drain plug (9-10 N·m) (9-10 N·m) (9-10 N·m) •
Gearcase Retaining 96-120 in. Ibs. 192-216 in. Ibs. 192-216 in. Ibs.
Screws (11 -14 N·m) CD (22-25 N·m) ® (22-25 N·m) ® •
Propeller Shaft Bearing 60-80 in. Ibs. 60-80 in. Ibs. OMC Gasket
Housing Screws (7-9 N·m) (7-9 N·m) • Sealing Compound
Lower Gearcase to 60-80 in. Ibs.

Upper Gearcase Screws • • (7-9 N·m) •
48-84 in. Ibs. 48-84 in. Ibs. 48-84 in. Ibs.
Pivot Pin OMC Nut Lock
(5-9 N·m) (5-9 N·m) (5-9 N·m)
Gearcase Retaining 192-216 in . lbs. 45-50 in. Ibs.

Nut • (22-25 N·m) (61-68 N·m)
OMC Nut Lock
CD OMC Nut Lock

® OMC Gasket Sealing Compound
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32C/enQ 6-3 o
Sealants and Lubricants Required
OMC Adhesive M ™
OMC Gasket Sealing Compound
OMC Ultra-HPF™ Gearcase Lube
OMC Moly Lube
OMC Nut Lock
OMC Triple-Guard@ Grease
RTV Silicone Rubber Adhesive Sealant
Scotch Grip Rubber Adhesive 1300
OMC Marine Wheel Bearing Grease
Service Aids Required
Magnetic Tool
Emery Cloth
Gearcase Pressure Tester
Gearcase Vacuum Tester
OMC Special Too's Required
9.9/15 Models
Gearcase Bearing Housing Puller, PIN 386631

Shift Rod Bushing Remover, PIN 327693
Bearing Remover, PIN 319880
Propeller Housing Bearing Installer, PIN 339751
Propeller Housing Seal Installer, PIN 342663
Forward Gear Bearing Cup Installer, PIN 319929
Upper Driveshaft Bearing Installer, PIN 319931
Driveshaft Seal Installer, PIN 326554
Shift Rod Bushing Installer, PIN 304515
Yoke Locator, PIN 319991
Universal Pinion Bearing Remover and Installer, PIN 391257
Upper Pinion Bearing Spacer, PIN 339753
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6-4 32Cleng
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25 Comm., 28 Models

Driveshaft Bearing Remover, PI N 326570
Bearing Remover, PI N 326571
Shift Rod Bushing Installer, PI N 304515
Upper Driveshaft Bearing Installer, PI N 326564
Upper Driveshaft Seal Installer, PI N 330655
Pinion Bearing Installer, PI N 326565
Gearcase Head Seal Installer, PI N 326691
Gearcase Alignment Tool, PI N 390880
Driveshaft Bushing Remover and Installer, PIN 330334
Driveshaft Seal Installer, PI N 330335
20, 25, 30 Models
Retaining Ring Pliers, PIN 331045

Universal Pinion Bearing Remover and Installer, PIN 391257
Lower Pinion Bearing Spacer, PIN 330067
Upper Pinion Bearing Spacer, PI N 330068
Propeller Housing Rear Bearing Installer, PIN 335820
Propeller Housing Forward Bearing Installer, PIN 321428
Propeller Housing Seal Installer, PI N 335821
Forward Gear Bearing Cup Installer, PI N 319929
Shift Rod Bushing Installer, PIN 304515
Driveshaft Bearing Installer, PI N 322923
Driveshaft Seal Installer, PI N 326552
Shift Detent Sleeve, PI N 328081
Guide Pin, PI N 383175
Plate, PI N 318122
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32C/enQ 6-5 o
Water Pump Servicing - 9.9/15
Disassembly
1. Remove gearcase from exhaust housing as described in Gear-

case Servicing, this Section.
[!J 2. Remove the four impeller housing screws.

~ 3. Remove the impeller housing and impeller by sliding them
~ up and off the driveshaft. Then remove the impeller drive pin
@ and impeller plate @ .
4. Remove and discard the water tube grommet, O-ring, and seal
in the impeller housing.
5. Inspect the impeller, housing, and plate for excessive wear.
6. Clean the impeller plate and gearcase.
Assembly
r:;J 1. Apply OMC Gasket Sealing Compound to the metal casing

~ of a new driveshaft seal @ . Install the seal in the impeller
housing with lip of seal facing into the housing.
14l 2. Apply OMC Adhesive M to the impeller housing O-ring @

~ and install it on the housing.
r;;"] 3. Apply Adhesive M to outside surface of the water tube

~ grommet. Install the grommet in the impeller housing with
bosses of grommet ® seated in housing. Coat the inside surface
of grommet with OMC Triple-Guard grease. 3
4
16315
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6-6 32C/eng
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I,;l 4. Lightly coat the exterior of the impeller cup with OMC
~ Gasket Sealing Compound. Position the impeller cup in the
impeller housing as shown.
rJl 5. Lightly coat the impeller cup with oil. With a counterclock-
~ wise rotation install the impeller.
6. Apply a thin bead of OMC Adhesive Mto the machined surface,

on the top of the gearcase that contacts the impeller plate. Slide
the plate down over the driveshaft and position it.
16313
7. Apply OMC Needle Bearing Assembly Grease to the impeller
drive pin and position in on the flat of the driveshaft.
8. Apply a thin bead of OMC Adhesive M to the impeller housing

mounting surface.
9. Slide the impeller housing into position while rotating the

driveshaft to engage the impeller with the drive pin.
1ol 10. Apply OMC Nut Lock to the threads of the four impeller
l!J housing screws. Install the two short screws positioned aft
7
and the two long screws forward. Tighten the screws to a torque
of 60-80 in. Ibs. (7-9 N·m)
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32C/eno 6-7 o
Water Pump Servicing - 20, 25, 30
Disassembly
1. Remove gearcase assembly as described in Gearcase Servic-

ing, this Section.
IT] 2. Remove the six impeller housing screws and washers.
3. Pull up on the driveshaft and remove the driveshaft with the

water pump assembly from the gearcase. Remove the water 21219
pump assembly from the driveshaft.
rn 4. Remove the impeller plate and gasket. Discard the gasket.
5. Scrape all gasket material from the plate and gearcase.
6. Remove the water pump grommet, all O-rings, and the shift rod
bushing from the impeller housing.
7. Inspect all components for excessive wear.
Assembly
rn 1. Oil and install the shift rod bushing ® into the impeller
housing.
rn 2. Apply OMC Triple-Guard grease to the two impeller

housing O-rings. Install the small, thick shift rod O-ring @. Place
the large O-ring © into the impeller housing.
[]J 3. Lightly coat the exterior of the impeller cup with OMC
Gasket Sealing Compound. Align tabs @ of the impeller cup with
location holes ® of the impeller housing and install the impeller
cup into the impeller housing.
[ ] ] 4. Lightly coat the impeller cup with oil and with a counter-
clockwise rotation, install the impeller ® into the impeller cup.
Sharp edge of cam slot is leading edge during rotation.
[ ] ] 5. Apply Scotch-Grip Rubber Adhesive 1300 to outside of

water tube grommet @. Install grommet and locate grommet
bosses into holes of impeller housing.
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[ ] ] 6. Apply OMC Adhesive Mto groove ofthe impeller housing. o
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6-8 32C/eng
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1sl 7. Lightly oil pinion splines of the driveshaft. Slide the
~ driveshaft through the impeller housing and impeller until
drive pin flat of the driveshaft is below the impeller.
1sl 8. Align drive cam flat with groove of the impeller. Install the
~ impeller drive cam .
• Sharp edge CD of the cam is leading. edge ' during

driveshaft rotation Q). Slide the impeller housing down
the driveshaft. Engage the impeller with the cam.
~ Verify that the impeller engages the impeller cam properly.

~ Serious powerhead damage will result if impeller cam is
displaced.
9. Lightly coat both sides of a new impeller plate gasket with OMC
Gasket Sealing Compound. Place gasket on the gearcase.
10. Place the impeller plate over the gasket.
11. Slide the driveshaft down into the gearcase and engage the
pinion.
f1Ol 12. Turn the driveshaft until holes of the impeller housing are
~ aligned with holes of the gearcase. Place the washers on the
six impeller housing screws. Apply OMC Gasket Sealing Com-
pound to the threads of the screws. Install and tighten the screws
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6-9
32C/eng
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Water Pump Servicing - 25 Comm., 28
Disassembly
1. Remove gearcase as described in Gearcase Servicing, this

Section.
rv Slide
~
2. Remove the four impeller housing screws with washers.
the impeller housing and impeller up and off the
driveshaft. Remove the impeller drive pin @.
3. Pry under the impeller plate to loosen it. Slide the plate up and
off the driveshaft. Scrape all gasket material from the plate,
gearcase, and impeller housing.
4. Remove and discard the impeller housing seal and water tube
grommet.
5. Inspect the impeller, plate, and housing for excessive wear.
Assembly
f21 1. Apply OMC Gasket Sealing Compound to the metal casing

2
COA3433
~ of a new driveshaft seal. Install the seal using OMC Upper
Driveshaft Seal Installer, PIN 330655. Install the seal ® into the
impeller housing with lip of seal facing away from the tool. Coat
the lip of the seal with OMC Trip/e-Guard grease.
2. Lightly coat the exterior of the impeller cup with OMC Gasket
Sealing Compound. Install impeller housing liner. The liner locks
in place in the impeller housing with two square tabs.
1al 3. Oil the blades of the impeller. In a counterclockwise direc-

~ tion, twist the impeller into the impeller housing. 3
COA3434
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6-10 32C/ena
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I4J 4. Oi~, then install the water tube grommet into the impeller
~ housing.
f51 5. Lightly coat both sides of a new impeller plate lower gasket
~ with OMC Gasket Sealing Compound. Position gasket on the
gearcase.
f61 6. Slide the impeller plate © down the driveshaft and position
~ it. Lightly coat both sides of a new impeller plate upper gasket
with OMC Gasket Sealing Compound. Position upper gasket @ on
the impeller plate.
f61 7. Apply OMC Triple-Guard grease to the impeller drive pin ®

~ and place the pin in the slot of the driveshaft.
8. Slide the impeller housing down the driveshaft, engage the

impeller pin, and orient the housing. Apply OMC Gasket Sealing
Compound to threads of the impeller housing screws. Install the
impeller screws and washers. Tighten the screws to a torque of
60-80 in . Ibs. (7-9 N·m).
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32C/enQ 6-11 o
Service Chart - 9.9/15
CD OMC Triple-Guard Grease CD fi\

~
60-84 in. Ibs.
(7-9 N·m)
® OMC Gasket Sealing Compound ', ~4 ®
®~~
® OMC Adhesive M O/"-V /
o OMC Moly Lube f.i\~./i] I
® OMC Nut Lock 0 /" .J
CD®~ fi\ 60-84 in. lb•.
®.....--~ (7-9 N·m)
CIVIC Ultra-HPF Gearcase Lubricant:
9 fl. oz. (260 ml) @
Go ®
®\~~\k
~'\ ~
CDa®
~
~
84-86 in. Ibs.
~~
VO (9-10 N·m)
f2\
~
60-84 in. Ibs.
(7-9 N·m)
\ '1'
JC}~ '-V
~CDlt~d(jf
® ,,/
CD
48-84 in. Ibs.

(5-9 N·m)
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6-12 32C/eng
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Gearcase Servicing - 9.9/15
Removal
'" 1. To avoid accidental starting of engine while servicing,

[!] 2. Remove six screws attaching gearcase to exhaust housing.

f2l 3. Separate gearcase and exhaust housing to expose the shift
~ rod connector. Remove the upper connector screw.
4. Remove gearcase and place in a suitable holding fixture.
Disassembly
1. Remove propeller from gearcase.
f31 2. Remove the oil level plug ® and oil fill/drain plug ® to drain
~ gearcase.
@] 3. Remove the four impeller housing screws.

4. Remove the impeller housing and impeller from the driveshaft.
~ 5. Remove the impeller drive pin © and impeller plate @ .

6. Remove driveshaft from gearcase.
7. Remove two screws, propeller shaft bearing housing to gear-

case.
f6l 8. Using OMC Gearcase Bearing Housing Puller, PIN 386631,

~ and a propeller nut, remove the propeller shaft bearing hous-
ing .
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~ 9. Remove the propeller shaft and reverse gear components.
10. Using a magnetic tool, locate and remove the two shifter
detent balls and one detent spring from the gearcase.
~ 11. Remove pivot pin from gearcase. Discard the O-ring.

~ 12. Unscrew the shift rod and remove it from the gearcase. 32577
r:JOl 13. Using a pair of long-nose pliers, remove the clutch dog
~ from the gearcase.
r;:;-] 14. Use long-nose pliers to remove the forward gear and
L..!..!J
shifter lever assembly. Use no force. Tilting the shifter lever
slightly will allow you to remove it from the gearcase. Remove the
forward gear roller bearing.
1121 bearmg.
15. ~emove the pinion, two thrust washers, and thrust
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~ 16. Remove the shift rod bushing as follows:
• Position OMC Shift Rod Bushing Remover, PIN 327693,
@ under the shift rod bushing.
• Thread the adapter ® of the Universal Slide Hammer,

PIN 391008, in the slide hammer. Place the adapter
through the shift rod bushing © and thread into the
remover tool @.
• Remove the handle from the remover tool. Then remove

the bushing from the gearcase.
• Once the bushing has been removed from the gearcase,

examine the bushing for damage. If damaged, replace
the bushing on reassembly. Remove and discard the
a-ring from the bushing.
1141 17. Using OMC Puller Bridge, PIN 432127, and OMC Small
Puller Jaws, PIN 432131, remove the two driveshaft seals.
Discard the seals.
~ Inspect bearings for damage while in place. If bearing is

~ damaged, remove and discard. Ifthe bearing is removed for
any reason, it must be replaced.
f151 18. Using OMC Puller Bridge, PIN 432127, and OMC Small
~ Puller Jaws, PIN 432131, remove the bearing and sleeve
from the gearcase. Discard the bearing.
r:p;1 19. Using OMCSlide Hammer, PIN 432128, and OMC Bear-
~ ing Puller, PIN 432130, remove the forward bearing cup from
the gearcase.
16
32548
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~ Inspect bearings for damage while in place. If bearing is
~ damaged, remove and discard. If the bearing is removed for
any reason, it must be replaced.
f.i7l 20. Using OMC Bearing Remover, PIN 319880, and a mallet,
~ remove the two pinion bearings. Discard the bearings.
1,8l 21. Remove the propeller shaft bearing housing O-ring.

~ Discard the O-ring.
r,gl 22. Using OMC Puller Bridge, PIN 432127, and OMC $mall
~ Puller Jaws, PIN 432131, remove the propeller shaft seal.
Discard the seal.
1201 23. Using OMC Bearing Remover, PIN 319880, and a mallet,
remove the smaller propeller shaft bearing located in the aft
end of the bearing housing. Discard the bearing.
1211 24. Using OMCPulier Bridge, PIN 432127, and OMCBearing

Puller, PIN 432130, remove the larger propeller shaft bearing
located in the front of the bearing housing. Discard the bearing.
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6-16 32C/eng
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"" Replace damaged components. Shift system failure could

i l l cause loss of control over direction of engine thrust.
1. Discard all seals O-rings, gaskets, and clutch dog spring.
I:A 2. Clean all gearcase components in solvent and dry with

ill compressed air. To avoid personal injury, wear eye protec-
tion and regulate air pressure to not more than 25 PSI (172 kPa).
After cleaning, coat all internal components with OMC Ultra-HPF
gearcase lube to prevent rusting.
3. Perform the following inspections:
• Gearcase housing - all gasket surfaces must be free of

gasket material. All threaded holes must be free of
corrosion and sealer.
• Gearcase anode - if anode has been reduced to two-

thirds of its original size, it must be replaced. Refer to
Section 1 for testing procedure.
• Driveshaft - check splines for chips, wear, and cracks.

Bearing and gear surfaces must not show signs of metal
transfer, corrosion, or discoloration. Severe spline wear
might indicate an exhaust housing or gearcase has been
distorted by impact damage.
• Water intake screen - must be clear. If screen can't be

cleaned, it must be replaced.
• All internal components - must be visually inspected for

signs of wear, distortion, chipping, metal transfer, pit-
ting, galling, and discoloration due to improper lubrica -
tion .
• Water pump - check impeller for wear, crumbling, and

hub bonding. Check liner and wear plate for scoring and
d istortion.
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Assembly
INote I Makeno dry assemblies. Lubricate bearings, shafts, and

gear with OMC Ultra -HPF gearcase lube.
[JJ 1. Oil the small bearing and install in the propeller shaft
bearing housing using OMC Bearing Installer, PI N 339751 . Press
against the lettered side of the bearing when installing.
rn 2. Oil the large bearing and install in the propeller shaft

bearing housing using OMC Bearing Installer, PI N 339751. Press
against the lettered side of the bearing when installing.
rn 3. Use OMC Sea l Installer, PI N 342663, to install a new seal

in the rear of the bearing housing. Apply oil to the casing of the
seal before installing. Install the seal with the exposed lip facing
away from the bearing housing. Press the seal into the housing
until the tool seats. Apply OMC Triple-Guard grease to the seal lips
after installing.
4. Apply OMC Triple-Guard grease to a new bearing housing

a -ring . Place the a -ring in the bearing housing groove.
rn 5. To install the forward bearing cup into the gearcase,

remove the gearcase from the holding fixture, and place the nose
of it on a wooden block. Drive in the bearing cup with a mallet and
OMC Bearing Cup Installer, PIN 319929, attached to OMC Drive
Handle, PI N 311880.
[ [ ] 6. Install the pinion bearings using the following compo-

nents of OMC Universal Pinion Bearing Remover and Installer,
PIN 391257, and one additional tool spacer :
® PI N 326582 Rod
® PI N 326583 Plate
© PI N 326578 Removerl lnstaller
@ 1/4-20 x '/2 in. Screw
® 1/4-20 x 11/4 in. Screw
® 1 in. Flat Washer
@ PI N 326585 Spacer, Short
® PIN 339753 Spacer, Long
m • toAssemble the tools using the short spacer, PI N 326585,
install the lower pinion bearing. Press against the
bearing's lettered side until washer ® contacts short
spacer @.
32551
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6-18 32C/eng
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DR2061
• Assemble the tools using the long spacer, PIN 339753,

to install the upper pinion bearing. Press against the
bearing's lettered side until washer ® contacts long
spacer @.
Isl fN=J To ensure accurate bearing location, washer ® must be

~ ~ flat and screw @ must be tight.
1cl 7. Using OMC Bearing Installer, PIN 319931, and an arbor
l§ press, install the driveshaft bearing into the bearing sleeve
with the lettered side against the tool.
r7J 8. Oil the bearing sleeve and install with the bearing into the
~ gearcase using OMC Bearing Installer, PIN 319931. Keep the
lettered side of the bearing against the tool.
f811gl 9. Using OMC Seal Installer, PIN 326554, install two new
~ ~ driveshaft seals back to back as follows:
• Apply OMC Gasket Sealing Compound to the metal

casing of the seals before installing.
• Install the inner seal Q) with lip of the seal facing toward
the gearcase. Install the outer seal ® with lip of the seal
facing away from the gearcase.
• Apply OMC Triple-Guard grease to the seal lips after
installing.
10. Coat the shift rod a-ring with OMC Triple-Guard grease and
install in shift rod bushing.
1,01 11. Place a new washer © and bushing @ on OMC Shift Rod
~ Bushing Installer, PIN 304515. Apply OMC Gasket Sealing
Compound to the outside diameter of the shift rod bushing. Using
a mallet, drive the bushing into the gearcase.
12. Oil and place the forward bearing cone and roller assembly in
the forward bearing cup.
G11 13. To install the forward gear ® and the shifter lever @ and
~ yoke ® assembly, begin by threading OMC Yoke Locator,
PIN 319991, through the shift rod bushing and threading it into
the shifter yoke. Remove the cradle @ from the yoke. Then, while
pulling on the yoke locator, guide the assembly into the gearcase.
The forward gear should come to rest against the forward
bearing, and the shift lever should be located in the slot at the
bottom of the gearcase. E
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I ,@
@
32544 32558
G2' 14. Position one pinion thrust washer ® on the pinion. Oil
~ and install the thrust bearing @. Install the other thrust
washer © on the pinion.
113( 15. Install the pinion in the gearcase.

fN=J If the pinion binds upon assembly, angle the forward gear
~ to allow engagement. If binding is still present, the forward
bearing cup is not properly seated.
1141 16. Pull shift rod up and install cradle on yoke.
r;;;l 17. Oil a new a-ring and install on the pivot pin. Apply OMC
~ Nut Lock to the threads of the pivot pin . Use the yoke locator
to locate the pivot pin hole in the yoke. Install and tighten the
pivot pin to a torque of 48-84 in. Ibs. (5-9 N·m).
r:J6l 18. Coat the threaded area of the shift rod with OMC
~ Triple-Guard grease. Slide the shift rod down through the
shift rod bushing and thread it into the yoke until seated. Then
back out shift rod until slotted face of connector faces the
driveshaft.
r:tJl 19. Using long-nose pliers, place the clutch dog in the cradle
~ with grooved side facing the forward gear.
\ 181 1Notel Groove on the clutch dog must face the forward gear.
20. Apply OMC Needle Bearing Assembly Grease to the propeller

shaft spring and two detent balls. Install the spring and balls in
the propeller shaft. Align the two detent balls with the two
grooves in internal splines of the clutch dog .
21 . Aid installation of loose detent ball with a flat blade screwdriv- 17

er. Push the propeller shaft into the clutch dog, forward gear and
the forward bearing.
22. Hold propeller shaft in place and move shift rod up to

NEUTRAL position.
~ 23. Slide the reverse gear onto the propeller shaft.

24. Lightly apply OMC Gasket Sealing Compound to the aft
E
support flange of the propeller shaft bearing housing. Install the o
u
bearing housing into the gearcase. ..:
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32556 Qi
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6-20 32C/eng
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25. Apply OMC Gasket Sealing Compound to the threads of the
bearing housing screws. Install the screws and tighten to a torque
of 60-80 in. Ibs. (7-9 N·m) .
120 126. Install the driveshaft. Rotate the driveshaft to allow the
splines in the pinion to engage the splines on the driveshaft.
~ 27. Pressure and vacuum test the gearcase as follows:

INotel Pressure and vacuum test gearcase before filling.
• Remove the oil level plug and screw in a pressure test
gauge.
• Hold down firmly on the driveshaft and pump pressure

up to 3-6 PSI (21-42 kPa). If pressure gauge indicates
leakage, submerge the gearcase in water to determine
source of leakage as evidenced by bubbles. If the gear-
case pressure gauge does not indicate leakage, hold the
driveshaft down and increase pressure to 16-18 PSI
(110-124 kPa). If pressu re does not hold, su bmerge the
gearcase in water and check for source of leakage. Make
necessary repairs and repeat test.
• Screw in vacuum tester. Pump out to 3-5 in. of mercury

and see if vacuum holds. Then pump out to 15 in. of
mercury and check. If the gearcase fails to hold on either
test, put oil around suspected seal. If leak then stops or
oil is drawn in, that seal is defective. When the gearcase
checks out OK, refill with OMC Ultra-HPF gearcase lubri-
cant.
1221 28. Fill the gearcase with 8-9 flo oz. (230-260 ml) lubricant as
follows:
• Secure the gearcase in an upright position.
• Remove the oil level and the oil fill /drain plugs. Replace
the seals.
• Fill the gearcase with OMC Ultra-HPFgearcase 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 the fill/drain plugs to a torque of 84-86 in. Ibs.
(9-10 N·m).
• Inspect the gearcase oil level after a motor test has been
performed.
29. Inspect water pump as described in Water Pump Servicing,

this Section.
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Installation
1. On models with a gearcase extension kit, make sure the

driveshaft tube extension, water tube extension, and gearcase
exhaust seals are in place.
[JJ 2. Coat the driveshaft splines with OMC Moly Lube. Do not
coat top surface of the driveshaft as lubricant here may prevent
seating of the driveshaft in the crankshaft.
3. Pull up on the shift rod and engage REVERSE gear. Move the
shift lever on the motor to REVERSE position.
W 4. Lightly apply OMC Triple-Guard grease to lower outside

diameter of the water tube. Carefully install the gearcase making
sure the driveshaft splines engage the crankshaft, the water tube
enters the impeller housing grommet, and the upper shift rod
enters the shift rod connector.
&. 5. Align the groove in the lower shift rod with the screw hole
in the connector. Apply OMC Gasket Sealing Compound to shift
rod connector screw. Install and tighten the screw with washer
INotel When installing a gearcaseto a gearcase extension, do not

tighten the retaining screws until the gearcase and the extension
have been placed i.n proper position with the exhaust housing and
powerhead assembly.
rn 6. Apply OMC Nut Lock to the threads of the gearcase and

extension retaining screws. Install and tighten the screws to a
torque of 96-120 in . Ibs. (11-14 N·m).
W 7. Install the propeller as follows:
• Apply OMC Triple-Guard grease to entire length of the

propeller shaft.
• Install the thrust bushing @ onto the propeller shaft with

shoulder of the bushing facing aft and fish line trap
groove facing forward.
• Install the propeller. Propeller should seat onto the thrust

bushing.
• Install the spacer @, engaging the propeller shaft

splines.
• Install and tighten the propeller nut © to a torque of

120 in . Ibs. (14 N·m). Continue to tighten the nut to align
next cotter pin hole.
• Install and secure the cotter pin @.
8. Adjust the shift detent as described in Section 4.
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Service Chart - 20, 25, 30
®
CD OMC Triple-Guard Grease o 0- CD

® OMC Gasket Sealing Compound
CD---\~I- -0
®~~I
® OMC Adhesive M
60-84 0lb
m. s.
0 0MC Moly Lube ~O (7-9 N·m)
® OMC Nut Lock

®--~
~CD
®
$ ~~3
OMC Ultra-HPF
Gearcase Lubricant:
11 fl. oz. (330 ml)
o .
0_~
~~0
o CD
0~~ ..
f1\~~®::u
" ~\...!.J~o~
f1' 0" ....
~ ~
T
1
~9 ~
1 1 ....... 0 LJ
\...!.J "
~ ~-~-~-=--===-~
I I
t CD 0,_
~@@(jrttJ
A~l :' 0I ~-!
192-216 m. Ibs.
192-216 in_ Ibo.
(22-25 N·m)
/ (k ~ oj CJ(@)Q't1);:)(22-25 N·m) ~ 84-86 in.lbs.
~t \t _ ~~!lD !) I II~ (9-10 Nml

c
CD 60-84 m. Ibs. ~ ~ I
® ®2 (7-9Nml ~ >-~~~~
I edit,,;>
. CD
~l if~®
84-86 in. Ibs. ~ 5
(9-10 N·m) E
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48-84 in. Ibs. ~
(5-9 N·m) DR3652 ~
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32C/eng 6-23 o
Gearcase Servicing - 20, 25, 30
Removal

2. Remove the trim tab. Remove the propeller from the gearcase.
Inspect the condition of the propeller hub.
[!] 3. Drain the gearcase by first removing the oil level plug @ ,
then the oil fill/drain plug ® .
W 4. Remove both water intake screens.
INotel Remove any paint from the upper shift rod before disas-
sembling the shift rod connectors.
rn 5. Disengage the shift rod using two open-end wrenches.
W 6. Remove and discard the upper plastic keeper © . Remove

the upper connector.
[ ] ] 7. Remove the nut @ and the four gearcase to exhaust

housing screws ® .
8. Remove the gearcase from the exhaust housing and place in a

suitable holding fixture.
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& Safety Related 6-24 32C/e ng
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Disassembly
[ ] ] 1. Remove the six impeller housing screws and washers.
2. Pull up on the driveshaft and remove the driveshaft with the

water pump assembly from the gearcase. Disassemble the water
pump assembly from the driveshaft.
[ [ ] 3. Remove the impeller plate and gasket. Discard the gasket.
[ ] ] 4. Remove the two propeller shaft bearing housing screws.
[ [ ] 5. Assemble the following components from OMC Universal

Puller, PI N 378103. Remove the propeller shaft bearing housing
from the gearcase.
® PIN 307636 Body

© PIN 307637 Pressing Screw
® 2 Screws, %-20 x 6 in. (obtain locally)
CD PIN 307639 Flat Washers
Q) PIN 307638 Handle
[1Q] In.
6. Remove the retaining ring using OMC Retaining Ring
Pliers, PIN 331045. The retaining ring is under extreme pressure
during removal and installation . Wear safety glasses and proceed
with care to avoid unsnapping the ring from the pliers. After the
retaining ring is removed far enough from the gearcase to clear
the housing, release the pliers while retaining ring is still around
the propeller shaft.
7. Remove the retainer plate from gearcase.
[I1]8. Unthread the lower shift rod from the shifter yoke and
remove the shift rod from the gearcase. Remove and discard
lower plastic keeper.
21624
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21623
~ 9. Remove the shift yoke with long-nose pliers.

f1il 1O.. Remove the shifter lever pivot pin. Discard the pivot pin
~ O-nng.
f14l 11. Remove the propeller shaft and reverse gear components
r:J5l 12.Using a magnetic tool, locate and remove the two shifter
~ detent balls and one detent spring from the gearcase.
r:J6l 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.
r;Jl 14. Remove the forward bearing, forward gear, pinion, pinion
~ thrust bearing, and two pinion thrust washers.
9593
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1.J8l 15. Use OMC Bearing Puller PI N 432130 attached to OMC
~ Slide Hammer PIN 432128 to remove the forward bearing
cup. Secure the puller jaws into grooves behind the cup with jaws
facing port and starboard . Use OMC Wrench PI N 334359 ® to
hold the puller while tightening the jaws.
~ 16. Use OMC Puller Bridge PI N 432127 and OMC Small

~ Puller PIN 432131 to remove the driveshaft seals from the
gearcase.
IN=J Inspect bearings in place. If a bearing is removed for any

~ reason, it must be replaced.
1201 17. Remove the upper driveshaft bearing ® and bearing

sleeve © from the gearcase using the same two tools.
Discard the bearing.
f21l 18. To remove the pinion bearings, assemble the following

~ components from OMC Universal Pinion Bearing Remover
and Installer PIN 391257:
@ PI N 326582 Rod
® PI N 326583 Pilot Plate
® PI N 326577 Remover and Installer
© %-20 x 112 in. Hex Head Screw
® %-20 x 1% in. Hex Head Screw
CD 1 in . 0.0. Flat Washer
Place the tool in the gearcase. Using a mallet, drive the pinion
bearings into the gearcase propeller shaft cavity. Discard the
bearings.
22
1 1 19. Remove the shift rod bushing as follows:
• Position OMCShift Rod Bushing Remover PI N 327693 Q)

under the shift rod bushing.
• Thread the adapter ® of the universal slide hammer in

the slide hammer. Place the adapter through the shift rod
bushing CD and thread into the remover tool Q).
• Remove the handle from the remover tool. Then remove

the bushing from the gearcase. -@
• Once the bushing has been removed from the gearcase,
examine the bushing for damage. If damaged, replace
the bushing. Remove and discard the a-rings and wash- 21 ~®
er from the bushing.
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20. Remove and discard the propeller shaft bearing housing
O-ring.
~ Inspect bearings in place. If a bearing is removed for any

~ reason, it must be replaced.
1231 21. Using OMC Puller Bridge, PIN 432127, and OMC Small
Puller, PIN 432131, remove and discard the bearings and
two seals from the propeller shaft bearing housing.
Cleaning and Inspection 21795
'" Replace damaged components. Shift system failure could

~ cause loss of control over direction of engine thrust.
1. Discard all seals, O-rings, gaskets, and clutch dog spring.
'" 2. Clean all gearcase components in solvent and dry with

~ compressed air. To avoid personal injury, wear eye protec-
gearcase lube to prevent rusting.
3. Perform the following inspections.





ting, galling, and discoloration due to improper lubrica-
tion.

distortion.
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21793 DR2061
Assembly
fN"=J Make no dry assemblies. Lubricate bearings, shafts, and

~ gears with OMC Ultra-HPF gearcase lube.
1241 1. Oil and install a new bearing in aft end of the bearing
housing using OMC Bearing Installer, PIN 335820. Press
against the lettered side of the bearing to prevent damage to the
bearing when installing. Press the bearing into the housing until
the tool is seated on the housing. 27
----------------------~~
1251 2. Oi l and install a new bearing in the forward end of the
bearing housing using OMC Bearing Installer, PI N 321428.
Press against the lettered side of the bearing until the tool is
seated on the bearing housing.
12611271 3. Install new seals back to back in aft end ofthe bearing
housing using OMC Seal Installer, PIN 335821. Apply
OMC Gasket Sealing Compound to the metal casing of the seals
before installing. Install the inner seal ® with lip facing into the
bearing housing and install the outer seal @ with lip facing away
from the bearing housing. Apply OMC Triple-Guard grease to the
seal lips after installing.
4. Lightly apply OMC Triple-Guard grease to a new bearing

housing O-ring. Place the O-ring in groove of the bearing housing.
1281 5. Oi l and install the forward bearing cup © into the gear-
case. Use OMC Drive Handle, PI N 311880, and OMC Bearing
Cup Installer, PIN 319929. Support nose of gearcase on the floor
and seat t he cup firmly in the gearcase.
6. Coat the shift rod O-ring with OMC Triple -Guard grease and
1291 7. Apply OMC Gasket Sealing Compound to the outside

diameter of the bushing. Install the bushing and washer @
using OMC Shift Rod Bushing Installer, PIN 304515.
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@~~
.
30 :-©@ DR2088
31
1301 8. Install the pinion bearings using the following components

of OMC Universal Pinion Bearing Remover and Installer
PI N 391257 and two tool spacers:
® PIN 326582 Rod

® PIN 326583 Plate
© PIN 326577 Removerllnstaller
@ %-20 x 1/2 in. Screw
® %-20 x 1% in. Screw
® 1 in. Flat Washer 33
@ PIN 330067 Spacer, Short DR2061
® PIN 330068 Spacer, Long
• Assemble the tools using short spacer PI N 330067 to
install the lower pinion bearing. Press against the bear-
ing's lettered side until washer ® contacts short spacer
@.
• Assemble the tools using long spacer PI N 330068 to
install the upper pinion bearing. Press against the bear-
ing's lettered side until washer ® contacts long spacer
®.
1301 ~ To ensure accurate bearing location, washer ® must DR2062
~ be flat and screw @ must be tight.
rJil1321 9. Oil and install a new driveshaft bearing Q) in the

~ bearing sleeve ® using OMC Bearing Installer
PIN 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.
\33\ \34\ using

10. Install new seals back to back in the driveshaft bore
OMC Seal Installer, PIN 326552. Apply OMC Gas-
COA3216
ket Sealing Compound to the metal casing of the seals before

installing. Install the inner seal with flush lip © facing into the
gearcase, then the outer seal with extended lip @j) facing out of the
gearcase. Apply OMC Triple-Guard grease to the seal lips after
installing.
1351 11. Coat the forward bearing with oil and place it in the
bearing cup. E
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®
~<Z2?d QZ4
.<Imi:!B:II!rDl(II!]!mD
C/""
36 803051
1361 12. Assemble the small pinion thrust washer with the inside
chamfered diameter ® onto the pinion, chamfered side
facing pinion. Oil and install the thrust bearing @. Install the large
thrust washer with chamfered outside edge ® facing up.
1371 13. Using a right angled rod, install the pinion assembly in
the gearcase.
1381 14. Place the forward gear into the gearcase.
1391 15. Install the shifter cradle on clutch dog. Grooved end of
clutch dog must face forward gear end of the propeller shaft.
~ Apply OMC Needle Bearing Assembly Grease to clutch dog

~ and shifter cradle to hold in place while assembling.
140 116: Install the shift.er cradle and clutch dog in the gearcase
uSing long-nose pliers.
1411 17. Apply OMC Triple-Guard grease to a new pivot pin a-ring.
Install the a-ring on the pivot pin. Apply OMC Nut Lock to
threads of the pin. Align hole of the shifter lever with hole in the
gearcase. Install and tighten the pivot pin to a torque of 48-84 in.
Ibs. (5-9 N·m) .
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32C/eng 6-31 20, 25, 30 Qi
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42 43
26727 26728 COB3058
"" Wear safety glasses for eye protection. Detent balls can pop
~ out with great force.
r.;;;l 18. Slide OMC Shift Detent Sleeve PI N 328081 over the
~ propeller shaft. Align slot in the tool with hole in the propeller
shaft.
\431 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.
\44\ 20. Install the propeller shaft and detent tool in gearcase:
• Propeller shaft must engage forward bearing.
• Tool ramps must engage clutch dog ramps.
• Hold tool firmly against clutch dog.
• Gently tap propeller shaft with a rawhide mallet to seat
detent assembly.
21. Remove detent tool.
145\ 22. Slide the reverse gear down the propeller shaft and into COA3229
the gearcase.
\45\ 23. Coat the reverse gear bushing with oil. Slide the bushing
down the propeller shaft, seating the bushing into the re-
verse gear.
\461 24. Holding the shifter yoke @ with long-nose pliers, install
the yoke at a tilted position, locating top ® of yoke into upper
gearcase cavity.
\471 25. Engage the shifter yoke hook onto the shifting lever clevis
pin in bottom of the gearcase cavity. 47
COA3230
1481 26. Install a new plastic keeper and the lower shift rod nut.
Apply OMC Triple-Guard grease to threads of lower shift rod
and install 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.
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COA3238 COA3239 COA3240
1491 27. Slide the retainer plate down the propeller shaft and into
the gearcase with tab facing down .
1501 &28. Using OMCRetaining Ring Pliers, PI N 331045, install

the retaining ring into groove in gearcase with sharp outside edge
facing aft. The retaining ring is under extreme pressure during
installation . Wear safety glasses and proceed with care to avoid
unsnapping the ring from the pliers. Look inside the gearcase and
make sure that the ring is seated in groove.
ffiTI 29.Thread one OMC Guide Pin, PI N 383175 @, into the COA3309
retainer plate.
1521 30. Stick the reverse gear thrust washer @ to the back side of
the propeller shaft bearing housing with OMC Needle Bearing
Assembly Grease.
1531 31. Lightly apply OMC Gasket Sealing Compound to the aft
support f lange of the bearing housing. Align the propeller shaft
bearing housing on the guide pin with the word "UP" toward the
top.
1541 32. Using a brass punch and a mallet, seat the bearing
housing in the gearcase.
1551 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 N·m).
35. Coat the lower driveshaft splines with OMC Ultra-HPF gear-
case lubricant. Install the driveshaft into the gearcase with the 54
water pump key end down. Be careful not to damage the seals ----------'-"-~~~
with the splines. Turn the driveshaft to engage the pinion gear.
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1561 36. Pressure and vacuum test the gearcase as follows:
INote I Pressure and vacuum test gearcase before filling.
gauge.

source of leakage as evidenced by bubbles. If the gear-
case pressure does not indicate leakage, increase pres-
56 26729
sure to 16-18 PSI (110-124 kPa).lf pressure does not hold,
submerge the gearcase in water and check for source of
leakage. Make necessary repairs and repeat the test.
• Screw in a vacuum test. Pump out 3-5 in. (76-127 mm) of

mercury and see if vacuum holds. Then pump out 15 in.
(381 mm) of mercury and check. If the gearcase fails to
hold on either test, put lubrication around suspected
seal. If the leak stops or lubricant is drawn in, that seal is
defective. When the gearcase checks out properly, fill the
gearcase with OMC Ultra-HPF gearcase lubricant.
57
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 OMC Ultra-HPF gearcase lube until

plug first. Install the fill/drain plug. Tighten the oil level
and fill/drain plugs to a torque of 84-86 in . Ibs. 58
(9-10 N·m). 32895
• 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
1571 1. Check outside diameter of the water tube for dents and
burrs. Remove dents and burrs. Check to be sure the water tube
washer ® is positioned on the water tube. Lightly apply OMC
Triple-Guard grease to upper and lower outside diameter of the
water tube. Install the straight end of water tube through the
guide and into inner exhaust tube.
1581 2. Apply OMC Triple-Guard grease to two new driveshaft

spacer O-rings. Install O-rings ® on the driveshaft spacer. Posi-
tion spacer in exhaust housing with tabs facing rear of the
housing.
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3. Coat the driveshaft splines with OMC 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 OMC Triple-Guard grease.
4. Temporarily install the upper shift rod connector on the

gearcase lower shift rod.
5. Install the gearcase onto the exhaust housing. Guide the water
tube into the water tube grommet and see that the driveshaft
engages the crankshaft. Rotate the flywheel, if necessary.
~ 6. Apply OMC Gasket Sealing Compound to the threads of

~ the gearcase and extension retaining screws and threads of
the gearcase stud . Place lock washers on the screws and the stud.
Install and tighten the screws @ and one nut ® to a torque of
192-216 in. Ibs. (22-25 N·m).
~ When installing a gearcase to a gearcase extension, do not

~ tighten the retaining screws until the gearcase and the
extension have been placed in proper position with the exhaust
housing and powerhead assembly.
!60! 7. Slide the upper connector half onto the upper shift rod and
install the plastic keeper 0.
rsv 8.lower
~
Move the shift lever until the upper shift rod engages the
shift rod connector. While holding the lower shift rod
connector, tighten the upper shift rod connector securely.
\621 9. Install the port and starboard water intake screens with
water intake holes facing rear of gearcase. Tighten the two
screen retaining screws securely.
!631 10. Install the propeller as follows:

propeller shaft.
• Install the large thrust bushing @ onto the propeller

shaft with fish line groove facing gearcase.
• Install the propeller. Propeller should seat onto the thrust

bushing.
• Install the spacer ®, engaging the propeller shaft

splines.
• Install the propeller nut CD to a torque of 120 in . Ibs.

(14 N·m). Continue to tighten the nut to align next cotter
pin hole.
• Install and secure the cotter pin Q).
". Adjust the shift lever and neutral start switch (rope and TE
models) as described in Section 4.
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Trim Tab Adjustment - 20, 25, 30
& Improper trim tab adjustment can cause difficult steering.
A propeller will generate steering torque when the propeller shaft

is not running parallel to the water's surface. The trim tab is
adjustable to compensate for this steering torque.
Important A single trim tab adjustment will relieve steer-

ing 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:
• 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. Ifthe boat pulled to the left, move the
rear of the trim tab slightly to the left.
• Tighten the trim tab screw to a torque of 60-84 in. Ibs.

(7-9 N·m).
• 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.
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Service Chart - 25 Comm., 28
CD OMC Triple-Guard Grease f4\ @

® OMC Gasket Sealing
. Compound \.!J.~O~ I (,)\
® 60-84 in. Ibs.
® OMC Adhesive M 3 ~ i /0 (7-9 N·m)
ffl:/ f
o 3
OMC Moly Lube
60-84 in. Ibo. f.>\
(7-9 N·m) 0 .......... ®I ~ OJ
® OMC Nut Lock ® if' ~ .. ®~-CD

® RTV Silicone Rubber ~~
OMC Ultra-HPF nD
U f2\
>6J
Gearcase Lubricant:
8 fl. oz. (245 ml)
45-50 ft. Ibs.

(61-68 N·m)
®------!! -
~- ~--'2'
~~ '61
f2\ ~~ @
'61 El
(9-10 N·m) V
84-86 in. Ibs.
c>
o rJ!J~
CD
84-86 in. Ibs. ~~~~

(9-10 N·m) " - ~ t:J O'j
48-84 in. IbS.® ~ ~~ &"

(5-9 N·m) ---""<If'tV '" "
· ~1 (,)\2 60-84 in. Ibs. E
~ '61 (7-9 N·m) o
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C02520 <1\
32C/eno 6-37 o
Gearcase Servicing - 25 Comm., 28
'" To avoid accidental starting of engine while servicing, twist

ill and remove all spark plug leads.
Removal
~ 1. Remove the exhaust housing cover plate and gasket to

~ expose the shift rod connector.
~ 2. Shift the motor to FORWARD gear position. Remove the

~ lower shift rod connector screw ®.
~ 3. Remove the four gearcase retaining screws ® and one

~ retaining nut @ with lock washer.
4. Remove the gearcase and mount in a suitable holding fixture.
r.;] 5. The impeller housing spacer may come out with the
~ gearcase or stay in the exhaust housing. Locate the spacer and
discard the a-rings. Use new a-rings on reassembly.
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Disassembly
1. Remove the propeller or test wheel from the gearcase. Inspect

the condition of the propeller hub.
f61 2. Drain the gearcase by removing first the oil level plug @ ,
~ then the oil fill/drain plug CD.
3. Remove the copper water tube from either the water pump or
t he exhaust housing.
f71 4. Remove the four impeller housing screws with washers .

~ Slide the impeller housing and impeller up and off the
driveshaft. Remove the impeller drive pin Q) .
f81 5. Pry under the impeller plate to loosen it. Slide the plate up
~ and off the driveshaft. Scrape all gasket material from the
plate, gearcase, and impeller housing.
6. Slide the driveshaft out of the gearcase.
~ 7. Remove the shift lever pivot pin and discard the O-ring.
r,Ql 8. Remove the six screws attaching the lower gearcase to the
~ upper gearcase.
I11l 9. Usi ng a soft face mallet, tap the skeg on its side. Remove
~ the lower gearcase. Discard the rubber seal between the two
gearcase halves.
@] 10. Remove the cradle ® .

11. Remove the propeller shaft assembly.
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32C/eng 6-39 25 COMM, 28 Qi
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",,",::, ::::
15
COA3419 COA3420
f131 12. Remove the pinion, thrust washers, and thrust bearing
13. Inspect the upper end of the shift rod for burrs. Remove the
burrs using 400 grit wet or dry sandpaper. Slide the shift rod out
of the gearcase.
f141 14. Remove all components from the propeller shaft except
~ the clutch dog. Inspect the components for excessive wear.
r;5l 15. Slide the clutch dog ® forward and off the propeller shaft.
16
9595
~ Be careful not to lose the two detent balls ® and the spring
@.
~ 16. Mount the gearcase head in a suitable bearing separator.

r:;:;] 17. Using OMC Puller Bridge PIN 432127 and OMC Small
L..!2J Puller PIN432131, remove the two gearcase head seals.
18. Remove the gearcase head O-ring. Discard the O-ring.
f18l 19. Remove the driveshaft seals using OMC Puller Bridge
~ PIN 432127 and OMCSmal1 Puller PIN 432131.
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6-40 32C/eng
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/191 20. Use OMC Shift Rod Bushing Remover, PIN 304514, to
remove the shift rod bushing. Using a mallet, drive the
bushing from the gearcase.
~ Inspect the driveshaft bearing and pinion bearing for dam-

~ age while in place. If bearing is damaged, remove and
discard the bearing from the gearcase.
1201 21. Remove driveshaft bearing using OMCBearing Remover,

PIN 326570. Discard the bearing.
f21l 2? . Install .OMC Bearing Remover, PIN 326571, into the

~ pinion bearing.
1221 23. Using OMC Bearing Remover, PIN 326570, and a mallet,
drive the pinion bearing and remover from the gearcase.
COA6008
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32C/eng 6-41 5Qi
25 COMM, 28 <1\
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'" Replace damaged components. Shift system failure could

ill cause loss of control over direction of engine thrust.
1. Discard all seals, O-rings, gaskets, and clutch dog spring.
~ 2. Clean all gearcase components in solvent and dry with

ill compressed air. To avoid personal injury, wear eye protec-
gearcase lube to prevent rusting .
3. Perform the following inspections.





ting, galling, and discoloration due to improper lubrica-
tion.

distortion.
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©
~
23 COA3432 COA6226
Assembly
~ Make no dry assemblies. Lubricate bearings, shafts, and

~ gears with OMC Ultra-HPF gearcase lube.
1. Coat the shift rod a-ring with OMC Triple-Guard grease and
r:;:;] 2. Apply OMC Gasket Sealing Compound to the outside

~ diameter of the bushing. Install the bushing and washer @ 26
using OMC Shift Rod Bushing Installer, PIN 304515. COA6125
12413. Oil, then install a new upper driveshaft bearing in the

gearcase using OMC Upper Driveshaft Bearing Installer,
PIN 326564. Press the bearing into the gearcase against the
lettered side of the bearing and until the tool is seated on the
gearcase.
12514. Install two new upper driveshaft seals back to back in the
gearcase using OMC Upper Driveshaft Seal Installer,
PIN 330655, attached to OMC Drive Handle, PIN 378737. Apply
OMC Gasket Sealing Compound to the metal casing of the seals
before installing. Install the inner seal @ with lip facing toward the 27
DR2061
gearcase and the outer seal © with lip facing away from the
gearcase. Apply OMC Triple-Guard grease to the seal lips after
installing.
12615. Oil, then install a new pinion bearing in the gearcase using
OMC Pinion Bearing Installer, PIN 326565. Press against the
lettered side of the bearing until the tool is seated on the
gearcase.
127112816.using
Install new seals back to back in the gearcase head
OMC Seal Installer, PIN 326691. Apply OMC Gas-
ket Sealing Compound to the metal casing of the seals before
installing. Install the inner seal @ with lip facing in the gearcase DR2062
head and the outer seal ® with lip facing away from the bearing
housing. Apply OMC Triple-Guard grease to the seal lips after
installing.
7. Apply OMC Triple-Guard grease to a new gearcase head a-ring.

Place the a-ring on the gearcase head.
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32 C/e ng 6-43 Qi
25 COMM, 28 <1\
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(222"
<C!mIC:IJ:!
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22~2 ===::::32kZZl
2l ..
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29
40587
1291 8. Position the small pinion thrust washer with the inside
chamfered diameter © on the pinion, chamfered side facing
pinion. Oil and install the thrust bearing @ . Install the large thrust
washer with chamfered outside edge @ facing up.
9. Install pinion in gearcase.
1301 10. Grease the end of shift rod and slide it through the shift
rod bushing. Place the cradle @ on the shifter lever @ .
f31l1321 11. Place the spring ® and two detent balls @ in the hole 83298
~ in the propeller shaft. While holding the detent balls and
spring in the hole, slide the clutch dog onto the propeller shaft
splines with the chamfered and grooved lugs ® toward the
forward gear and aligned as shown.
INotel The grooves on the clutch dog must face the forward gear.
1331 12. Oil, theninstall the forward gear CD, thrust bearing Q) ,
thrust washer @, and roller bearing © on the propeller shaft.
The lettering on the roller bearing goes forward.
1341 13. Oil, then install the reverse gear @ , bushing @ , and
gearcase head @ .
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1351 14. Place a bead of OMC Adhesive M on the upper gearcase
in the location shown.
1361 15. Position the propeller shaft assembly in the upper

gearcase as shown. The gearcase head has a hole in it that must
engage a pin in the upper gearcase.
INote I Allow approximately 1/32

in. (0,8 mm) clearance between
the forward bearing and the thrust washer.
1371 16. Seat the forward gear and thrust bearing firmly against
the gearcase using OMC Gearcase Alignment Tool, PIN 390880.
Leave the tool in position until the lower gearcase has been
installed.
17. From a bulk spool of gearcase seal, cut a new seal to the
length of 127/8 in. (32 em).
1381 18. Apply OMC Adhesive M to the machined surfaces of the

upper and lower gearcases and to the exposed area of the
gearcase head a-ring. Lay the seal in the groove of the lower
gearcase. Cut the ends of the seal to fit exactly in the groove.
Apply RTV adhesive to the ends of the seal for a length of 1/2 in.
(12 mm) ®.
19. Position the lower gearcase on the upper gearcase. Apply

OMC Gasket Sealing Compound to the threads of the gearcase
retaining screws. Install the two front and two rear screws, then
loosely tighten the screws evenly to draw the gearcases together.
Push rearward on the lower gearcase with steady pressure as the
retaining screws are tightened. Install the remaining screws and
gradually tighten them, alternating from side to side and working
toward the rear. Tighten the screws to a torque of 60-80 in. Ibs.
(7-9 N·m). Remove the alignment tool.
1391 20. Apply OMC Triple-Guard grease to a new pivot pin

a-ring . Install the a-ring on the pivot pin. Apply OMC Nut Lock to
the threads of the pin. Install the pivot pin. You may have to move
the shift rod in or out to locate the hole in the shifter lever. Tighten
the pivot pin to a torque of 48-84 in. Ibs. (5-9 N·m).
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32C/eng 6-45 Qi
25 COMM 28 <1\
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\40\ 21. Carefully slide the driveshaft into position. Rotate the
driveshaft until it engages the pinion.
@!] 22. Pressure and vacuum test the gearcase as follows:

INotel Pressure and vacuum test gearcase before filling.
gauge.

source of leakage as indicated by bubbles. If the gear-
case pressure does not indicate leakage, hold the drive-
shaft down and increase pressure to 16-18 PSI (110-124
kPa). If pressure does not hold, submerge the gearcase in
water and check for source of leakage. Make necessary
repairs and repeat the test.
• Screw in a vacuum tester. Pump out 3-5 in . (76-127 mm)

of mercury and see if vacuum holds. Then pump out 15
in. (381 mm) of mercury and check. If the gearcase fails
to hold on either test, put lubricant around suspected
seal. If the leak then stops or lubricant is drawn in, the
seal is defective. When the gearcase checks out properly,
fill the gearcase with OMC Ultra-HPF gearcase lubricant.
23. Fill the gearcase with lubricant as follows:
• Be sure the gearcase is in an upright position .
• Remove the oil level and oil fill/drain plugs. Replace the
seals if damaged.
• Fill the gearcase with OMC Ultra-HPFgearcase lube until

plug first. Install the fill/drain plug. Tighten the oil level
and fill/drain plugs to a torque of 84-86 in. Ibs.
(9-10 N·m).
• Inspect the gearcase oil level after the motor test has
been performed.
24. Install the water pump as described in Water Pump Servicing,

this Section.
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6-46 32 C/e ng
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Installation
1. Coat the driveshaft splines with OMC Moly Lube grease. Do not
coat top surface of the driveshaft as lubricant here may prevent
seating of the driveshaft in the crankshaft.
2. Check to make sure the gearcase and the shift lever on the
engine are in the FORWARD position.
1421 3. Oil, then place two new a-rings ® on the impeller housing
spacer @. Slide the spacer down the driveshaft and into
position on the impeller housing. Position tabs of the spacer to
face rear of the gearcase.
4. If removed, lubricate both ends of the water tube with OMC

Triple-Guard grease and install the straight end in the inner
exhaust housing guide. Bring the gearcase into position. Be sure
to engage the crankshaft splines with the driveshaft splines; be
sure the water tube enters the water tube grommet; and be sure
the lower shift rod engages the shift rod connector.
5. Apply OMC Gasket Sealing Compound to threads of the

gearcase and extension retaining screws. Install and tighten the
screws to a torque of 192-216 in. Ibs. (22-25 N·m). Apply OMC
Loequie Primer then OMC Nut Loekto threads of the gearcase and
extension stud. Install the nut and tighten to a torque of 45-50 ft.
Ibs. (61-68 N·m). ®
~ When installing a gearcase onto a gearcase extension, do
~ not tighten the retaining screws until the gearcase and the
extension have been placed in proper position with the exhaust
housing and powerhead assembly.
1431 l' 6. Align the groove in the lower shift rod with the screw
i l l hole in the connector. Install the screw with washer
and tighten to a torque of 120-144 in. Ibs. (14-16 N·m). 44 @
C02384
7. Apply OMC Adhesive Mto a new exhaust housing cover plate

gasket. Install the gasket and the cover plate.
44
1 1 8. Install the propeller as follows:

propeller shaft.
• Install and tighten the propeller nut @ to a torque of

120 in. Ibs. (14 N·m). Continue to tighten the nut to align
the cotter pin hole.
• Install and secure the cotter pin @ .
9. Adjust the shift lever as described in Section 4.
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Servicing the 7 112 in. (19 cm) Gearcase Extension-
25 Comm.
f1l 1. Using a flat blade screwdriver, pry up on the upper

L!.J driveshaft seal. Remove and discard the seal.
f21 2. Using OMC Driveshaft Bushing Remover/lnstaller
~ PIN 330334, remove the bushing and lower driveshaft seal
from the extension. With a mallet, drive the bushing and the seal
out of the extension. Discard both parts.
rJl f41 3. Insert the pin ® of the tool through the drive portion of
~ ~ the tool. Apply OMC Triple-Guard grease to a new bushing
® and place the bushing on the tool. From the gearcase end ofthe
extension, drive the bushing into position until the pin contacts
the extension.
f51 4. Attach OMC Driveshaft Seal Installer PIN 330335 to the

~ OMC Drive Handle PIN 378737. Apply OMC Gasket Sealing
Compound to outside case of two new' driveshaft seals. Position
one seal onto the installer with lip facing the tool. Install the seal
into top of the extension until seal is seated. Position the remain-
ing seal into the installer with lip facing the tool. Install the seal
into bottom of the extension until seal is seated.
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Checking Propeller Hub Slippage - 9.9 - 30
The propeller torque fixture is used to detect slippage between

the propeller and hub.
1. There are two sets of holes for mounting the propeller stops to
the base and bushing assembly. The inner hole pattern is used for
current outboard models through the 30 models. Install the
propeller stops in the inner hole pattern.
OJ 2. Splined shafts, 9.9-15, 28SPL, 25RW - Install stub arbor

into bushing in base. Place propeller on stub arbor and insert
spline adapter .
• 20-30 Thru Hub - Install torque shaft into bushing in

base. Place propeller on torque shaft.
m 3. All models - Install correct socket on torque wrench.

Select the torque value for the model being checked from the
torque column on chart. The propeller hub should not slip when
the wrench is held at the specified torque.
Models Adapter Minimum Torque

2
COA6200
9.9-15, 28SPL, 25RW 327633 100 ft. Ibs. (135 N·m)
20-30 Thru Hub 327630 150 ft. Ibs. (200 N·m)
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6-49
32C/eng
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Jet Drive Servicing
&. 1. To avoid accidental starting of engine while servicing,

2. Remove retaining clip, washer, and spring from lower end of

shift rod.
IT] 3. Pull shift rod out of reverse gate cam.
W 4. Remove six screws retaining the intake housing to the jet

housing. Remove the intake housing.
rn 5. Bend tab-lock washer ears, and remove impeller nut.

Remove tab-lock washer and discard.
rn 6. Note the number and placement of impeller shims. Refer

to Impeller Clearance Adjustment. Remove impeller adjustment
shims from driveshaft.
[[] 7. Remove the impeller from the driveshaft. Retain the

impeller key ® and impeller sleeve @.
[]] 8. As soon as the impeller is free of the driveshaft, check to

see if any shims were above impeller. If so, note their number and
placement for reassembly, then remove them.
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rn []] 9. Remove the adapter to jet housing screw. Remove
the four hex-head screws and lock washers through the opening
in the housing and the two slotted head screws. Remove bearing
housing, driveshaft, water pump, and jet housing as an assembly.
[ [ ] 10. If servicing the adaptor or exhaust housing, remove

screws retaining the adaptor and remove it from the exhaust
housing.
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27110
Bearing Housing Servicing
'7. Remove water pump assembly from bearing housing.
2. Separate jet housing from bearing housing and driveshaft.
[IJ &. 3. Remove retaining ring with snap-ring pliers. Wear

safety glasses and proceed with care to avoid unsnapping the
ring from the pliers.
[IJ 4. Remove O-rings from housing and discard.
rn 5. Warm bearing housing with a propane torch to aid in

removal of upper seal carrier.
INote I Do not apply too much heat as seals or carrier may be

damaged.
&. 6. Allow bearing housing to cool until it is warm to the touch.
W 7. Place bearing housing assembly in a press. Press from the

impeller end of the driveshaft until the seal carrier is free from the
housing. Continue to press bearings and driveshaft from bearing 5
housing.
rn 8. To replace the bearing housing seal, remove inner seal

retaining ring with a knife blade or thin-blade screwdriver. Lift
tang of retaining ring, and raise retaining ring in a circular motion
until it has been removed .
[ ] ] 9. Using a punch, drive out the inner seal and discard.
10. Remove the outer seal retaining ring using the same proce-
dure as described in Step 8.
6
00 11. Drive out the outer seal and discard.
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7 8
27122
[]] 12. To assemble inner and outer seals to bearing housing,

install outer seal retaining ring into its groove in the bearing
housing.
[]] 13. Apply OMC Gasket Sealing Compound to metal casing of

seal before installation. Apply OMC Triple-Guard grease to seal
lips before installing inner seal. Install outer seal into bearing
housing with lip facing outward. Press seal in until it makes
contact with retaining ring.
[]] [1QJ 14. Install inner seal with lip facing outward. Tap seal 27119
into bearing housing using a socket slightly smaller than the
outside diameter of the seal. When the seal is seated, install the
inner retaining ring.
[l!] 15. Remove the seal carrier assembly and spacer from the
driveshaft. If seals are damaged, the carrier and seals are serviced
as an assembly.
[g] fA.
16. Remove the retaining ring with retaining ring pliers.
Wear safety glasses and proceed with care to avoid unsnapping
the ring from the pliers.
11
[}]] INote I 17. Inspect driveshaft bearing in place.lfthat bearing 27120
is removed for any reason, it must be discarded. To remove, press

bearing off driveshaft from impeller end of shaft. Discard bearing.
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25JR Qi
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It
©@
14
[!!]18. Remove thrust washer @ and collar ® from driveshaft.

Remove retainer ring © if required.
C!:§]19. If removed, install retaining ring in groove of the

driveshaft. Install collar ® with step of it facing down, and install
thrust washer @ with bow side of it facing up.
[1§] 20. To assemble bearing to driveshaft, place bearing on the

press with lettered side of it facing down. Apply a light coat of
OMC Marine Wheel Bearing Grease to the bearing and driveshaft 17
pressing surfaces. Press bearing onto shaft until bearing makes '----'-- - - - - - - - - - = : - = - '
contact with retaining ring.
ITZl &. 21. Using retaining ring pliers, install snap ring with
sharp edge of it facing away from bearing. Make sure the
retaining ring is seated in its groove in the driveshaft. Wear safety
glasses and proceed with care to avoid unsnapping the ring from
the pliers.
[1!] 22. Place spacer @ and seal carrier assembly ® onto the
driveshaft. Apply OMC Triple-Guard grease to two new O-rings
and install on seal carrier.
18
[!ID23. Fill bearing housing cavity with OMC Marine Wheel
Bearing Grease.
120 I 24. Heat the bearing housing slightly with a propane torch.
Press the driveshaft and bearing assembly into the bearing
housing until seated.
&. 25. Allow the bearing housing to cool until it is warm to the
touch.
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~ 26. Apply OMC Marine Wheel Bearing Grease to lip of seals
in the seal carrier assembly. Press spacer and seal carrier assem-
bly into bearing housing using finger pressure.
\22\ &
27 . Using retaining ring pliers, install snap ring with
beveled side of retaining ring facing outward. Make sure the
retaining ring is seated in its groove. Wear safety glasses and
proceed with care to avoid unsnapping the ring from the pliers.
28. After assembly is complete, rotate driveshaft in bearing

housing. The assembly should turn freely.
29. Coat three new O-rings with OMC Adhesive M sealant and
install in grooves in the bearing housing.
\23\ 30. Place bearing housing assembly into jet housing and
secure using two slotted head screws.
Water Pump Servicing
[I] 1. Apply OMC Gasket Sealing Compound to metal casing of

a new impeller housing seal. Install the seal flush with the
housing, and lip of it facing up. Apply OMC Triple-Guard grease to
lip of seal.
rn 2. Lightly coat the exterior of the impeller cup with OMC

Gasket Sealing Compound. Align tabs of the impeller cup with
location holes ofthe impeller housing and install the impeller cup
into the impeller housing.
rn 3. Lightly coat the impeller cup with oil and with a counter-
clockwise rotation, install the impeller into the impeller cup.
Sharp edge of cam slot is leading edge during rotation .
W 4. Apply Scotch-Grip Rubber Adhesive 1300 to outside of

water tube grommet. Install grommet and locate grommet bosses
into holes of impeller housing.
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W 5. Apply OMC Gasket Sealing Compound to both impeller
plate gaskets. Both gaskets are identical. Align one gasket on top
of the bearing housing.
[ ] ] 6. Position the impeller plate. The side marked "UP" must

face up.
[ [ ] 7. Position the second impeller plate gasket.
[]] rn 8. Apply OMC Needle Bearing Assembly Grease to the

cam's flat area of the driveshaft. Position the cam on the
driveshaft. Sharp edge ® of the cam is leading edge during
driveshaft rotation ®.
[!Q] 9. Slide the impeller housing down the driveshaft. Engage

the impeller with the cam.
INote I Verify that the impeller engages the impeller cam properly.
Serious powerhead damage will result if impeller cam is dis-
placed.
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10. Apply OMC Gasket Sealing Compound to threads of the @
impeller housing screws. Install and torque the screws to
60-84 in. Ibs. (7-9 N·m).
[ill 11. Apply OMC Triple-Guard grease to O-rings on both

impeller housing spacers. Position spacers as shown. Tabs in
longer spacer must face to rear of the jet housing.
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6-56 32C / en~
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&. Replace damaged components. Shift system failure will

cause loss of control over direction of engine thrust.
1. Discard all seals, O-rings, and gaskets.
&. 2. Clean all jet drive components in solvent and dry with
compressed air. To avoid personal injury, wear eye protection
and regulate air pressure to not more than 25 PSI (172 kPa).
3. Perform the following inspections:
• Jet drive housing - All surfaces must be free of corro-

sion and sealer. All threaded holes must be free of
OJ • Drive impeller - Check impeller for nicks and burrs. File

edges to remove any nicks and to keep surface sharp.
rn • Intake housing liner - Inspect for wear or damage. If

impeller clearance adjustment is not obtainable, the liner
will require replacement. Refer to Impeller Clearance
Adjustment. Remove four screws retaining liner to hous-
ing and replace liner.
• Driveshaft - Check threads and splines for chips, wear,

and cracks. Bearing and gear surfaces must not show
signs of metal transfer, corrosion, or discoloration. Se-
vere spline wear indicates the exhaust housing or jet
drive housing has been distorted, possibly by impact
damage.
• All internal components - Inspect for signs of wear,

distortion, chipping, metal transfer, pitting, galling, and
discoloration due to improper lubrication.
• Water pump - Check impeller for wear, crumbling, and

distortion.
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32C/eng .& Safety Related 6-57

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Installation
OJ 1. Apply OMC Gasket Sealing Compound to threads of the

spacer to exhaust housing screws. Install and tighten the screws
and nut to a torque of 192-216 in . Ibs. (22-25 N·m) .
rn 2. If removed, install water tube extension on water tube.
rn 3. Apply OMC Moly Lube to splines of driveshaft. Do not

coat top surface of driveshaft as lubricant here may prevent
seating of driveshaft in crankshaft.
4. Slide jet housing into place, making sure driveshaft engages

crankshaft and water tube extension enters water pump.
rn 5. Apply OMC Gasket Sealing Compound to threads of

spacer to jet housing screw. Install screw and torque it to
10-12 ft. Ibs. (14-16 N·m).
[[] 6. Apply OMC Nut Lockto the four bearing housing to spacer
screws. Install screws and torque them to 60-84 in. Ibs.
(7-9 N·m).
7. Install key, bushing, shims, a new tab-lock washer, and nut on

driveshaft. Be sure shims are placed in original position. Refer to
Impeller Clearance Adjustment.
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6-58 32C/e nQ
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rn 8. When proper clearance adjustment is achieved, tighten
Impeller nut to 16-18 ft. Ibs. (22-24 N·m).
rn 9. Using a new tab-lock washer, bend tabs around driveshaft

nut to secure the assembly.
[ ] ] 10. Assemble intake housing to jet housing. Apply OMC

Gasket Sealing Compound to threads of six retaining screws, and
install them finger tight only. Check for any rubbing or binding
between casing liner and impeller. If clearance is greater on one
side, verify that intake housing is centered. Tighten screws in a
crisscross pattern to 60-84 in. Ibs. (7-9 N·m).
11. Recheck impeller clearance after shimming adjustment has

been performed.
[]J 12. Remove vent hose to expose grease fitting. Using OMC
Marine Wheel Bearing Grease and a grease gun, add enough
grease to fill the vent hose. Replace hose on fitting.
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Jet Drive Adjustments
Impeller Clearance Adjustment
If a loss of performance combined with a higher than normal

wide-open-throttle RPM is noted (or the RPM limiter actuates),
check for wear between the impeller's edge and the water intake
casing liner.
INotel Accelerated impeller wear can occur when operating in

waterways which have bottoms composed I'argely of sand, silt,
and gravel.
OJ 1. To check clearance between the impeller and intake casing

liner, place a feeler gauge through the intake grille and measure
the clearance ® between impeller's edge ® and liner @ .
Impeller Clearance
0.020 in. (0,5 mm) Minimum to 0.030 in. (0,8 mm) Maximum
PCE0084
[]] 2. If clearance is more than 0.030 in., transfer appropriate

number of shims @ from below to above the impeller. This will
move the impeller down and decrease clearance .
• Moving one shim' will reduce clearance approximately

0.004 in. (0,1 mm).
& To avoid accidental starting of engine while servicing, twist

W 3. Remove six screws retaining the intake housing to the jet

housing. Remove the intake housing.
/]] 4. Bend tab-lock washer ears @ and remove impeller nut @ .

Remove tab-lock washer and discard.
/]] 5. Remove shims ®, impeller, key, and impeller sleeve from

driveshaft.
rn 6. Use a flat file and remove any nicks or burrs from edge of
impeller.
rn 7. Transfer one or more shims from bottom to top of

impeller.
INotel Lubricate impeller driveshaft hole, impeller sleeve, and

key with OMC Trip/e-Guard grease prior to assembling parts.
8. Place impeller back onto driveshaft, aligning impeller key and

sleeve in impeller.
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ill rn 9. Assemble remaining shims, new tab-lock washer,
and impeller nut onto driveshaft. Tighten impeller nut to 16-18 ft.
Ibs. (22-24 N·m). Use a new tab-lock washer each time, and bend
tabs around driveshaft nut to secure.
rn 10. Assemble intake housing to main housing. Apply OMC

Gasket Sealing Compound to threads of six retaining screws and
install them finger tight only.
11. Check for any rubbing or binding between the casing liner and
impeller. If clearance is greater on one side, verify that the intake
housing is centered. Tighten screws in a crisscross pattern to
10-12 ft. Ibs. (14-16 N·m).
12. Repeat Step 1 to verify adjustment.
Gate Adjustment
1. Move remote control handle to NEUTRAL detent.
[[] 2. Hold reverse gate up and check for proper clearance

between reverse gate and water flow passage :
• 9/16 in. (23,9 mm)
[]] 3. If adjustment is required:
• Loosen cam screw @.
• Rotate cam eccentric nut CD while holding reverse gate

up, until proper clearance is achieved. Tighten cam
screw @ and recheck adjustment.
4. Move remote control handle to FORWARD detent.
[]] 5. When the roller is in FORWARD position Q), apply hand

pressure to move the reverse gate up, toward NEUTRAL. If
properly adjusted, reverse gate should not move toward NEU-
TRAL.
6. If gate can be moved toward NEUTRAL, readjust eccentric to

hold reverse gate in FORWARD position.
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Shift Rod Adjustment
&. The shift rod must be adjusted correctly or water pressure

from forward boat travel could move the gate into REVERSE,
causing the boat to stop abruptly. Occupants could be thrown
about or ejected.
[IQ] 1. With shift rod removed from shift cam, pull up on shift
cam ® until roller is at the far end of the FORWARD detent range
@.
[!!] 2. Move shift handle to FORWARD position . Push lower end

10
of shift rod through shift cam.
[j]] 3. Move shift handle to NEUTRAL. The cam roller should

snap into NEUTRAL detent © when you pull up on the reverse
gate with moderate pressure.
[1]] 4. If you cannot achieve NEUTRAL detent, loosen locknut

and lengthen shift rod slightly and recheck your adjustment.
Important It is very important that the reverse gate re-

mains locked in the FORWARD detent range when shift handle is
in FORWARD. When properly adjusted, the reverse gate cannot
be pulled out of the FORWARD detent range by hand.
[!!] 7. Tighten locknut and secure shift rod to shift cam with
spring, washer, and retaining clip.
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Manual Starter
Table of Contents

Service Specifications ............................. 7- 3
Starter Servicing - 9.9/15 ......................... 7- 4
Removal ..................................... 7- 4
Disassembly ........... . ...................... 7- 4
Cleaning and Inspection ......................... 7- 5
Assembly .......... '................... . ....... 7- 5
Installation .................................... 7- 6
Starter Servicing - 20 thru 30 ...................... 7- 7
Removal ................... . ................. 7- 7
Disassembly .................................. 7- 8
Cleaning and Inspection ......................... 7- 8
Assembly ................. . ........... . ....... 7- 9
Installation .................................... 7-11
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32Cl enQ 7-1 o
Before working on any part of the manual starter, read the
Wear safety glasses while servicing the manual starter.


(172 kPa)

personal injury.

To prevent sudden movement when starting engine and possible

" man overboard" situations, test the " start-in-gear prevention"
system before returning engine to customer.
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7-2 32C/eng
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MODEL DESCRIPTION IN. LBS. FT. LBS. N·m
9.9/15 Starter Retaining Screw 60-84 5-7 7-9
20-30 Starter Retaining Screws 48-72 • 5,4-8
9.9-30 Starter Spindle Screw and Nut 120-145 10-12 14-16
PCE0070
Starter Rope Length _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _. .
9.9/15 59 in. (150 cm)
20-30 73 1/2 in. (186,6 cm)
PCE0068
OMC Special Tools Required _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Starter Spring Winder and Installer, PIN 392093

Starter Rope Thread Tool, PIN 378774
Sealants and Lubricant Required _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~
OMC Trip/e-Guard@ Grease

Lubrip/ate 77
OMC Screw Lock
OMC Nut Lock
Johnson@ or Evinrude@ Outboard Lubricant
OMC Locquic Primer
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32C/enQ 7-3 o
Starter Servicing - 9.9/15
Removal
"'" 1. Avoid accidental starting of engine while servicing; twist

i l l and remove all spark plug leads.
rv2. Loosen starter lockout cam screw @ several revolutions.
~ Remove the three starter retaining screws.
4
~ 3. Remove link from lockout cam. Lift starter from powerhead.
Disassembly
[] 1. To service lockout assembly, remove the retaining pin.
~ 2. Remove the plunger, spring, tappet, and cam from the .

I
I
~ housing, and the screw from the cam.
"'" Wear safety glasses while disassembling and assembling

i l l manual starters because of rewind spring tension.
f51 3. Pull the starter rope out far enough to tie a slipknot in the
~ rope. Pry the starter rope anchor out of the handle. Remove
the handle, release the slipknot, and let pulley slowly wind up
rope until the rewind spring is completely unwound.
f61 4. Remove the retaining ring, and lift the pawl and links as an
~ assembly.
'7l "'" 5. Hold the spindle nut under the housing, and remove
~ i l l the spindle screw, nut and spindle. Hold pulley in place
to prevent starter spring from coming loose.
~ 6. Hold the pulley in the starter housing while turning the

ill starter over, right side up. Hold fingers clear of the pulley,
and jar the starter housing against a bench to dislodge the
rewind spring and pulley.
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1. Wash metal components in solvent and dry with compressed

air.
2. Inspect the rewind spring for cracked or broken end loops.
3. Examine the pawl for wear, and inspect the links.
4. Remove starter rope from pulley. Inspect rope and replace if

frayed. Cut new rope 59 in. (150 cm) long. Fuse 112 in. (12 mm) of
both ends and pull through towel to make threading rope through
holes easier.
5. Examine the pulley and the starter housing. Look for sharp
edges and rough surfaces that could fray the starter rope. File and
polish to remove.
6. Examine starter lockout parts. Replace any worn or damaged

parts.
Assembly
~ Wear safety glasses while disassembling and assembling

i l l manual starters because of rewind spring tension.
1al 1. Place shield into starter housing. Lubricate starter housing,
~ shield, spring, and pulley bearing surfaces with OMC Trip/e-
Guard grease.
19l 2. Insert spring through starter housing. Hook spring end ®

~ into pulley hub slot © as pulley is placed in position in the
starter housing .
r,Ql 3. Hold pulley in place and turn pulley slightly to check that
~ spring is hooked to pulley. Secure pulley with screw,
lubricated spindle, and locknut. Torque locknut to 120-140 in. Ibs.
(14-16 N·m).
r:-:;, 4. With starter upside down, carefully turn pulley counter-

L.!.!J clockwise until spring is completely drawn into starter hous-
ing. Continue turning pulley carefully until spring is wound tight.
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1121 5. Let spring slowly unwind, turning pulley 1/2 to 11/2 revolu-
tions until rope anchor @ is opposite rope guide @ . Insert a
Phillips screwdriver or long punch © through pulley and starter
housing to hold pulley in position against spring tension.
1131 6. Thread rope through handle and anchor retainer @ . Heat

rope and press end flat. Pull knot tight and assemble knot
into anchor ® , and anchor into handle as shown.
1141 7. Thread rope through rope guide, and through pulley rim
and rope channel, to anchor point with a sharp, hooked pin.
Heat rope and press end flat. Knot rope and pull tight into anchor
point.
1151 8. Remove tool holding pulley, and let spring slowly wind
rope onto pulley. Reinstall starter pawl components as an
assembly. Install E-ring with sharp edge up.
9. Check the operation of the pawl. The pawl should extend when
the starter rope is pulled and retract when the starter rope
rewinds.
r,&1 10. Reinstall scre~ into .c~m. . Reinstall plunger, spring,

~ tappet, and cam With retaining pin.
Installation
r:j7l 11. Position starter on motor. Connect starter lockout link to

~ cam. Turn cam screw IN carefully until screw head contacts
cam. Do not overtighten .
1181 12. Reinstall starter screws. Torque screws to 60-84 in. Ibs.
(7-9 N·m).
1- 13. Check operation of starter and starter lockout. Starter

~ should crank motor in NEUTRAL gear. Starter MUST NOT
crank motor in FORWARD or REVERSE gear.
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Starter Servicing - 20 thru 30
Removal

rv starter
~
2. Remove the three starter housing retaining screws. Lift
housing from motor.
r::;J 3. Using a screwdriver, apply pressure to one side of the

L?J starter lockout locking tab as shown. While applying pressure,
pull on cable until tab is clear of starting housing.
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32C/eng & Safetv Related 7-7
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Disassembly
& Wear safety glasses while disassembling and assembling

manual starters because of rewind spring tension.
[IJ 1. Pull the starter rope out far enough to tie a slip knot in the
rope. Pry the starter rope anchor ® out of the handle @. Remove
the handle, release the slip knot, and ease the pulley back until the
rewind spring if fully unwound.
rn 2. Remove the spindle screw nut @.

[[] 3. Remove the spindle screw @, spindle washer @, spindle
®, two spring washers @, and friction ring @ .
[[] 4. Remove the two retaining rings Q) and lift both pawls,
links, and friction plate as an assembly. Remove the spindle
bushing Q) and shim @.
5. Hold the pulley in the starter housing while turning the starter
over, legs down. Hold fingers clear ofthe pulley and jar the starter
housing against a bench to dislodge the rewind spring and pulley.
Cleaning and Inspection 4

COA1341
1. Wash metal components in solvent and dry with compressed

air.
2. Inspect the rewind spring for broken end loops and weak
tension.
3. Examine the pawls for wear.
4. Inspect the friction plate, spindle, and links.
5. Inspect starter rope. Replace rope if frayed. Cut nut rope to 73 1/2
in. (186,6 cm) in length. Fuse ends of rope to a length of 1/2 in. (12 0646
mm).
6. Examine the pulley and the starter housing. Look for sharp
edges and rough surfaces that could fray the starter rope. File and
polish to remove.
7. Inspect the starter spring shield for wear.
8. Examine starter lockout parts. Replace any worn or damaged

parts.
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Assembly
& Wear safety glasses while disassembling and assembling

manual starters because of rewind spring tension.
[I] 1. Using OMC Starter Spring Winder and Installer

PI N 392093, clamp spring winder base CD in a vise. Insert adapter
release plate @j) into spring winder base.
[ ] ] 2. Apply OMC Triple-Guard grease or Lubriplate 777 to the

rewind spring. Place inner loop of rewind spring ® in the spring
winder base. Insert the pin @ of the crank and pin assembly ®
into the inner loop of the rewind spring. Secure the crank and pin
assembly to the starter winder base with the crank retainer screw.
[ ] ] 3. Rotate the crank and pin assembly in the direction shown

on the tool. Wind the spring into the starter winder base until end
of rewind spring @ contacts the starter winder base.
[lID4. Remove the crank retainer screw and the crank and pin
assembly from the starter winder base.
5. Remove the adapter release plate with the rewind spring from
2684
the starter winder base.
III] 6. Install the rewind spring into the starter housing. Locate
the outer loop ® of the rewind spring on the pin ® in the starter
housing . Press down through the holes of the adapter release
plate to transfer the rewind spring into the starter housing.
~ 7. Place the starter spring shield with holes onto the pulley.
12
0648
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IJ]] 8. Bend the inside loop ® of the rewind spring in toward the
center of the starter housing. Engage the pin ® of the pulley with
the inner loop of the rewind spring and install the pulley in the
starter housing.
1141 9. Lightly apply OMC Triple-Guard grease or Lubriplate 777

to the spindle bushing © and pawl pins on the pulley. Install the
bushing © and the shim @ into the starter pulley. Next install the
friction plate @ , links, and pawls. Secure the pawls with the
retaining clips.
[H] 10. Light apply OMC Triple-Guard grease or Lubriplate 777to

the spindle. Install the spindle ® , friction ring @, and two spring
washers @.
INote I The flat section of the friction ring @ and spindle ® must
be a(igned.
11. Clean threads of the spindle retaining screw and nut to

remove adhesive. Install the spindle retaining screw and washer
into the starter housing. Tighten screw to a torque of 120-145 in.
Ibs. (14-16 N·m). Spray threads of spindle retaining screw that
protrude through the starter housing with OMC Locquic Primer.
Apply OMC Nut Lock to the threads of the nut. Hold the spindle
screw and torque the nut to 120-145 in. Ibs. (14-16 N·m).
[1ID 12. Tie a knot in one end of the starter rope. With the starter
housing upside down on a bench, wind the pulley counterclock-
wise until the rewind spring is tight. Back off the spring about 1/2 to
1 turn. Thread the starter rope through the hole in the pulley,
behind roll pin in pulley, and out through the starter housing.
ern 13. Apply OMC Triple-Guard grease or Lubriplate 777 to the

handle end of the starter rope. Using OMC Starter Rope Thread-
ing Tool PIN 378774, thread the starter rope through the handle.
Press the starter rope into the channel of the rope anchor, with
end of starter rope butting firmly against end of channel. Press
the anchor into the handle. Tug on end of starter rope to seat the
knot against the pulley. Allow the starter rope to wind slowly onto
the pulley.
14. Check the operation of the pawls when the starter rope is
pulled out. The pawls should extend when the starter rope is
pulled and retract when the starter rope recoils.
COA1347
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7-10 32ClenQ
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Installation
1. Inspect the starter mount. If the mounts are damaged or worn,

rep}ace as follows:
IT] • Remove the mount using a crescent wrench.
rn • Apply OMC Locquic Primer and OMC Screw Lock to

threads of new mount .
• Tighten mount securely.
IT] 2. Install caps on starter mounts.
3. Install the starter lockout cable into the starter housing .
W 4. Position the starter assembly onto the motor. Install the

three starter housing retaining screws. The short screw Q) is
installed on the port side of the starter housing. Tighten screws to
a torque of 48-72 in . Ibs. (5,4-8 N·m).
11 5. Check operation of the starter lockout. Manual starter

must not function when shift handle is in FORWARD or REVERSE
position .
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Electrical System
Table of Contents
&General Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 2

Battery Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 4
Battery Cable Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 5
Starter Circuit Check, 9.9/15TE. . . . . . . . . . . . . . . . . . . . . . 8- 6
Starter Circuit Check, 20-30TE . . . . . . . . . . . . . . . . . . . . . . 8- 8
Starter Circuit Check, 20-30 Remote .................. 8-10
Starter System Voltage Drop Test ................... 8-12
Key Switch Tests ................................ 8-14
Start Switch Ohmmeter Test, 20-30TE ................ 8-15
Solenoid Tests .................................. 8-16
No Load Current Draw, Electric Starter ............... 8-16
Electric Starter Service, 9.9/15 . ..................... 8-17
Electric Starter Service, 20-30 ....................... 8-19
Description of Charging System. . . . . . . . . . . . . . . . . . . . . 8-23
Charging System Check Chart . . . . . . . . . . . . . . . . . . . . . . 8-24
Running Test, Alternator Output - All Models. . . . . . . . . . . 8-25
Stator Resistance Tests, 9.9/15 . ..................... 8-26
Stator Resistance Tests, 20-30 . . . . . . . . . . . . . . . . . . . . . . 8-27
Rectifier Ohmmeter Tests, 9.9-30 . . . . . . . . . . . . . . . . . . . . 8-28
AC Lighting Coil Resistance Tests, 20-30 . . . . . . . . . . . . . . 8-29
Electrical Components Service, 9.9/15 ................ 8-30
Tachometer Circuit Tests, 9.9-30. . . . . . . . . . . . . . . . . . . . . 8-32
System Check Engine Monitor. . . . . . . . . . . . . . . . . . . . . . 8-34
I I
SYSTEM Adapter Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
~e::
"3
Dash Connections, Instr~n:'ent Harness . . . . . . . . . . . . . . .
Deutsch Connector Servlcmg . . . . . . . . . . . . . . . . . . . . . . .
8-35
8-36
8-37
CHECK Circuit Verification, Instrument Harness. . . . . . . . . . . . . . . 8-38
Circuit Verification, OMC Tester, PIN 437274 ........... 8-39
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32Cle no 8-1 o
Before working on any part of the electrical system, read the


loose clothing.
Before working on or removing any electrical parts, disconnect

the battery cables at the battery to prevent electrical sparks.
Before returning the outboard motor to the owner, make sure:
• all electrical connections are tight,
• insulator boots and sleeves are in place, and
• electrical wires are routed and clamped in their original

positions.
Do not use jumper cables and a booster battery to start engine.

Do not charge a battery in the boat with an external charger.
Fumes vented during either operation can lead to an explosion.

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8-2 32C/eng
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Description In. Lbs. Ft. Lbs. N'm Adhesive
Flywheel Nut: 9.9/15 • 45-50 60-70 OMC

Gasket Sealing
Compound
Flywheel Nut: 20-30 • 100-105 135-140 OMC

Gasket Sealing
Compound
Starter Motor to Cylinder Block Screws:

9.9/15
• 10-12 14-16 •
Starter Motor Bracket to Cylinder Block
Screws: 20-30
60-84 5-7 7-9 •
Stator to Ignition Plate Screws: 9.9/15 25-35 • 2,8-4,0 OMC Nut Lock
Stator to Ignition Plate Screws: 20-30 15-22 • 1,8-2,4 •
Rectifier Screws: 9.9-30 48-96 • 5,4-10,8 •
Stator Resistance Chart _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Model 4 Amp SAmp
9.9/15 • See Page 8-26
20-30 0.55 ± 0.05 Ohm •

Electric Starter No Load Current Specifications _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Amps
Model Voltage (Maximum) RPM
9.9/15 12 - 12.4 7 7000 - 9200
20-30 12 - 12.4 30 6500 - 7500
PCE0059
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32Cl e nQ 8-3 o
Battery Specifications
OJ For each motor provide one battery that is:

• 12-volt, heavy-duty, designated "marine"
• Vented/refillable or maintenance-free
• Rated 360 CCA (465 MCA) with 90 minutes reserve
(50 amp-hrs)
Deep-cycle batteries are suitable IF they meet or exceed the

minimum CCA requirements.
Installing and Connecting Batteries and Cables
Place the battery so it is easily accessible for frequent checking

and recharging and in a hold-down system. Install positive cable
to positive post and negative cable to negative post.
W When connecting to the battery, begin by placing a large-

surface star washer ® over the threaded battery post, then stack
cables from accessories, then cables from the motor. Finish the
connection with a hex nut, tightened firmly with a wrench.
INotel DO NOT use wing nuts on battery connections even ifthey

were supplied with the battery. Wing nuts can loosen and cause
errant warning horn signals or electrical system damage.
rn Apply ONIC Electrical Grease to connections.
& The battery terminal connections must always be insulated.

If the battery mounting system does not cover the connections,
install protective covers. This will help prevent shorting or arcing
at the battery terminals.
Refer to ONIC Accessory Service Manual, PIN 507129, for

3 DR5104
battery testing and maintenance procedures.
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Battery Cable Extension
The following are MINIMUM specifications for stranded copper cable without splices. Cable measure-
ments given are from the motor to the battery. The maximum length is 20 feet, regardless of cable
diameter.
INotel These specifications do not apply to aluminum battery cables. OMC does not recommend the
use of aluminum battery cables.
Minimum Recommended Gauge
Total Extended Length
1 - 10 ft. 11 - 15 ft. 16 - 20 ft.

Model (0,3 - 3 m) (3,4 - 4,6 m) (4,9 - 6,1 m)
9.9/15 10 gao 8 gao 6 gao
20 - 30 6 ga o 4 gao 3 gao
PCE0061
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8-5
32C/eng
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Starter Circuit Check, 9.9/ 1STE
In. Avoid accidental starting while testing; disconnect the starter cable at point CD.
INote I Engine must be in NEUTRAL throughout test procedure and battery must be fully charged.
Step Procedure Results
D Check voltage between @ and Connect voltmeter red lead to @ . a. If meter shows 12 volts, go to
@. Connect meter black lead to @ . Step fJ.
b. If meter shows 0 volts, test
battery.
D Check voltage between @ and Connect meter black lead to @ . a. If meter shows 12 volts, go to
©. Step IJ.
negative battery cable.
II Check voltage between @ and Connect meter red lead to @ . a. If meter shows 12 volts, go to
©. Step II.
b. If meter shows 0 volts, t est
positive battery cable.
II Check voltage between @ and Connect meter black lead to ® a. If meter shows 12 volts, go to
®. (powerhead). Step II.
b. If meter shows 0 volts, clean
and retighten rectifier screw
@.
II Check voltage between ® and Connect meter red lead to ®. a. If meter shows 12 volts, go t o
®. Push start button @ . Step g.
b. If meter shows 0 v olts, check
start switch, wires, and con -
nector @ .
II Check operation of starter. Connect start switch output lead a. If starter runs, check condit ion
® to starter terminal CW. Push of pinion CD.
start button @.
b. If starter does not run, service
starter.
PCE007 1
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Starter Circuit Check, 20-30TE
& Avoid accidental starting while testing; disconnect the starter cable at point CD.
INote I Engine must be in NEUTRAL throughout test procedure and battery must be fully charged.
Step Procedure Results
D Check voltage to cable at CD. Connect voltmeter @ between a. If meter shows 12 volts, test
cable at CD and ground. Press starter.
start button @.
b. If meter shows 0 volts, go to
Step fJ.
D Check voltage at ®. Connect voltmeter @ between ® a. If meter shows 12 volts, go to

and ground. Step II.
battery and cables.
II Check voltage at @. Connect voltmeter @ between @ a. If meter shows 12 volts, go to

and ground. Press start button Step II.
@.
start button and wiring .
II Check voltage at @ . Disconnect yellow/red lead @ a. If meter shows 12 volts, test

from neutral start switch @. Con- neutral start switch @ and
nect voltmeter @ between lead proceed to Step g.
@ and ground. Press start button
b. If meter shows 0 volts, replace
@.
solenoid or lead.
II Check voltage at @. Reconnect yellow/red lead @ . a. If meter shows 0 volts, replace

Connect voltmeter @ between @ solenoid.
and ground. Press start button
b. If meter shows 12 volts, re-
@.
place starter cable.
PCEO071
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Starter Circuit Check, 20-30 Remote
INote I Battery must be fully charged.
Step Procedure Result
D Check voltage between ground Remove black lead from ground a. If no reading, go to Step EJ.
and CD. at CD. Connect voltmeter be-
b. If meter reads battery voltage,
&. Steps II thru m- Remove
starter to solenoid cable from
tween CD and common engine
ground. Turn key to START posi-
reconnect black lead to ground
and go to Step m.
tion. Voltmeter should show bat-
(1) to prevent starter engage-
tery voltage.
ment while making checks.
II Check voltage between ground Connect meter at ®. Turn key to a. If meter reads battery voltage,
and ®. START position. lead is open between CD and
INote I Steps EJ thru m-Turn key ®.
OFF before connecting and b. If no reading, go to Step II.
disconnecting meter. Turn key
to START position after con-
necting.
and ®. START position. solenoid is faulty.
b. If no reading, go to Step II.
II Check voltage between ground Connect meter at @. Turn key to a. If meter reads battery voltage,
and @. START position. lead is open between ® and
@ or neutral start switch ® is
open or improperly adjusted.
b. If no reading, go to Step B.
and ®. OFF position. check key switch.
b. If no reading at ®, check for
open lead or open fuse be-
tween ® and ®.
c. Connect meter at ®. If no read-
ing, check for open lead be-
tween ® and battery" +" ter-
minal. If meter reads battery
voltage, go to Step II.
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II Check voltage between ground Connect voltmeter at (}). Turn a. If no reading, solenoid is
and (}). key to START position. faulty.
b. If solenoid clicks and meter
reads battery voltage, go to
Step II.
II Check voltage between ground Reconnect starter to solenoid ca- a. If meter reads battery voltage
and ®. ble at (}). Connect meter at ®. and starter motor does not
Turn key to START position. turn, check starter motor.
b. If no reading, check for broken
cable or poor connection.
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DR4029
2
DR4030
Starter System Voltage Drop Test

By making a systematic check of the starter system, any compo-
nent or electrical connection having excessive resistance can be
located.
& Avoid accidental starting of engine while servicing; twist

Clean and retighten, or replace, any connection, cable, or compo-

nent having greater than specified voltage drop.
[JJ 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 In Step 2, connect the voltmeter leads only while the

engine is cranking, or damage to the voltmeter can occur.
rn 2. Connect voltmeter negative lead to the starter side of the

starter solenoid terminal. While cranking engine, connect voltme-
ter 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.
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& Safety Related 8-12 32C /eng
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3
DR4031 DR4032
rn 3. Connect voltmeter positive lead to starter solenoid, starter

lead terminal. Connect voltmeter negative lead to starter motor
terminal. Turn key switch to START. Voltage reading should not
exceed 0.2 volt.
m 4. Connect voltmeter positive lead to battery negative lead

common powerhead ground screw. Connect voltmeter negative
lead to battery negative post. Turn key switch to START. Voltage
reading should not exceed 0.3 volt.
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m 824005 DRC5887
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DRC5888
@.- \ ,?" @ .::.~. <':~"
4 5 6
DRC5889 DRC5890 DRC5891
Key Switch Tests
@
Ohmmeter or Continuity Light
OJ 1. Disconnect battery leads and leads at the key switch.

!I1 2. With key switch in "OFF" position, connect a continuity
light or meter leads between key switch "BATT" and "A" termi-
nals. Light or meter should not show continuity.
rn 3. Turn key switch to "ON" position. Light or meter should

show continuity.
7
DRC5892
rn 4. Turn key switch to "START" position. Light or meter

should still show continuity.
W 5. With key held in "START" position, transfer lead from "A"

terminal to "S" terminal. Light or meter should still show continu -
ity.
@
.-
\
,?""
,
[ ] ] 6. Transfer leads to "M" terminals . Light or meter should not

show continuity in "START" or "ON" positions.
8
DRC5893
[ ] ] 7. Turn key switch to "OFF" position. Light or meter should
show continuity.
[ ] ] 8. Transfer leads to "B" and "e" terminals. Turn key switch to

"ON" position and push in key. Light or meter should show
continuity when key is pushed in.
1
~
[ ] ] 9. Turn key switch to "START" position and push in key. Light
or meter should show continuity when key is pushed. ~
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High Voltage
I1QJ In some conditions, the key switch may be shorting (some

leakagel to the other terminals in the key switch, but will not show
up with a test light or an ohmmeter. This condition may be found
by using a condenser tester (leakage testl where a voltage of
approximately 500 volts is applied to the key switch terminals.
With all leads disconnected and the key switch in the "OFF"
position, connect the black lead ® of the tester to one of the "M"
terminals of the key switch.
1. Attach the red lead ® of the test to the "B" terminal and apply
leakage test.
2. Repeat test by moving the red lead to each of the terminals and
applying the leakage test. The meter will indicate if leakage is
present.
3. When applying test to other "M" terminal, turn key to the "ON"
position .
Start Switch Ohmmeter Test, 20-30TE
Disconnect the two switch leads from the starter solenoid.
Calibrate ohmmeter on appropriate scale. Connect one meter

lead to switch yellow/red lead, the other meter lead to switch red
lead. Depress switch. Meter should show:
• Low reading when the switch is depressed .
• High reading when the switch is released.
Replace the start switch if your test results vary.
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Solenoid Tests
INote \ All engine wiring must be disconnected from the solenoid

before proceeding with this test.
[IJ 1. Calibrate ohmmeter on appropriate scale. Connect one

lead to terminal ® and the other lead to terminal ®.
• The ohmmeter should show a high reading.
• If the ohmmeter reading is a low reading, replace the

solenoid.
OJ 2. Attach a positive battery jumper to terminal © and a

negative battery jumper to terminal @ . The solenoid should close
with an audible click.
• The ohmmeter should show a low reading.
• If the ohmmeter reading is a high reading, replace the

solenoid.
3. After installing the solenoid, coat all wires and terminals,

except the battery" +" connection, with OMC Black Neoprene Dip.
No Load Current Draw, Electric Starter
INote \ Securely fasten

starter in a vise or other suitable fixture
before proceeding with this check.
1. Locate a battery rated at 350 cold cranking amps or higher that

is in good condition and fully charged, to perform this test.
m ~. Connect a 0-50 amp ammeter in series with a heavy

jumper between the battery "+" terminal and the starter "+"
terminal.
3. Attach or hold a vibration tachometer, such as a Frahm Reed

tachometer, to the starter while performing the test.
m 4. Complete the circuit with a heavy jumper between the

battery "-" terminal and the starter frame.
5. Monitor the starter RPM and current draw and refer to the chart
below for the correct specifications.
No load Current Specifications
Amps
Model Voltage (Maximum) RPM
9.9/15 12 - 12.4 7 7000 - 9200
20 - 30 12-12.4 30 6500 - 7500
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Electric Starter Service, 9.9/15
Removal
INote I Disconnect the battery cables at the battery.

[]J 1. Remove the two retaining screws.
OJ 2. Disconnect the starter lead at the terminal ® on the

bottom of the starter.
[]J 3. Remove rectifier from the starter bracket
Disassembly
Remove the following:
W 1. Two thru-bolts ®.
W 2. Drive end cap © and the armature from the frame and
magnet assembly @.
W 3. Brush end cap CD from the frame and magnet assembly.
rn rn 4. Pinion nut Q), spacer @' spring CD, pinion @l, and
washer ® from the armature @.
5. Refer to Cleaning and Inspection, Page 8-20.
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Assembly
1. Lubricate the armature shaft bearing surface with one drop of

SAE No. 10 oil. Lubricate the armature shaft on and above the
pinion helix with O\IIC Starter Pinion Lube, PIN 337016.
[]] 2. Assemble the brush end cap ® with brushes and springs
to the armature shaft. Place a new gasket ® on the brush end cap.
ill & 3. Align the brush end cap mark © with the mark @ on
the frame and magnet assembly. Assemble the brush end cap to
the frame and magnet assembly. Observe caution when insert-
ing armature into frame and magnet assembly as the permanent
magnets in the frame exert extreme pulling force on the arma-
ture which could result in pinched fingers.
4. Place the washer on the armature shaft. Place a new gasket on

the drive end cap.
[IJ 5. Align the drive end cap mark with the mark on the frame
and magnet assembly. Assemble the drive end cap to the frame
and magnet assembly.
& 6. Put a drop of oil on the two thru -bolts and install the
thru-bolts. Tighten the thru-bolts to a torque of 30-40 in. Ibs.
(3,4-4,6 N·m). Apply OMC Black Neoprene Dip to the seams
between the end caps and frame and magnet assembly.
[]] 7. Assemble the pinion, spring, spacer, and nut to the

armature shaft. Tighten the nut to a torque of 150-170 in. Ibs.
(17-19 N·m).
8. Refer to No Load Current Draw, Electric Starter to check starter

operation .
Installation
[]] 1. Install the starter on the bypass cover. The electric starter
motor must be held firmly against the bracket while bolting it to
the bypass cover. Tighten screws to a torque of 10-12 ft. Ibs.
(14-16 N·m).
[ ] ] 2. Install the starter lead to the starter. Tighten the nut ®

securely. Apply OMC Black Neoprene Dip to connection.
INote I Then, tightening the terminal nut, make sure the starter
lead and terminal does not turn into a position where the lead and
terminal could contact the starter or lower engine cover.
[ ] ] 3. Attach rectifer and two black wires to starter bracket.
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&. Safety Related 8-18 32C/eng
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Electric Starter Service, 20-30
Removal
INote I Disconnect the battery cables at the battery.

IT] 1. Disconnect all the leads from the starter solenoid.
IT] 2. Remove the vertical throttle shaft clamp screws and

clamp @'
IT] []] 3. Remove the screws and washers retaining the starter
bracket ® to the side of the powerhead . Note that the ground lead
attaches to the lower screw and has a lock washer.
rn 4. Remove the locknut and washer retaining the starter

bracket to the front of the powerhead. Lift the starter bracket from
the powerhead.
5. Remove the red lead from the starter motor.
Disassembly
W 1. Gently pry bottom of protective cap from groove on

spacer and remove cap.
[ ] ] 2. Pull cup down on armature shaft to expose retaining ring.

Remove ring using OMC Retaining Ring Pliers, PI N 325937.
Remove cup.
[ ] ] 3. Remove spring and spacer.
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9
[ ] ] 4. Remove pinion and base.
[[] INote I Before disassembly, scribe marks on frame and end

caps for reference during reassembly.
[ ] ] 5. Remove the two thru bolts and separate components.
1. Inspect the brushes; replace if one-half worn, damaged, or

cracked. Replace brush springs, if weak.
2. Clean commutator with 300 grade emery cloth. If commutator

surface is unevenly worn or pitted, turn on a lathe. Remove any
trace of oil or metal dust from commutator.
[!Q] !TIl
3. Check the armature on a growler for shorted turns.
Check armature for grounding by using a test light or meter.
Inspect armature insulation for indications of overheating or
damaged windings. Clean off any deposits of carbon or foreign
matter which may contribute to later failure of the windings.
[!II 4. Check permanent magnets. Magnets should attract steel

or iron objects held inside the frame . Weak magnets will cause
excessive RPM on No Load Current Draw, Electric Starter test.
5. Do not clean drive assembly while the starter and drive are
installed . The cleaning agent could drain into the starter, washing
dirt from the drive into the bearings and commutator. After
disassembling, clean each part with a grease solvent and inspect.
6. If the pinion does not properly engage the flywheel , the pinion
and screw shaft assembly may be worn , distorted, or dirty.
Locate the cause and correct before completing assem bly.
Assembly
1. Lubricate the armature shaft bearing surface with one drop of

SAE No.1 0 oil. Lubricate pinion helix on armature shaft with OMC
Starter Pinion Lube, PIN 337016.
[ ] ] 2. Install washer ® on drive end of armature shaft.
[ ] ] 3. Assemble drive end cap ® to drive end of armature shaft. E

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DR5446 30716
4. Assemble armature to frame and magnet assembly, aligning

marks on drive cap end and frame.
[TIJ 5. Install insulated brush and terminal set in commutator

end cap with long lead in slot. Position the insulators and nut as
shown in figure.
INote I Reversing these brushes will cause starter motor to run

backwards.
[}!]6. Install brush holder, brush springs, and ground brushes.

Screws secure ground brush leads and holder. Insert insulated
brushes in holder.
[!§] 7. Assemble end cap to frame and field, aligning notch and
rib. A suitable tool for holding brushes in place can be made from
a putty knife.
& 8. Put a drop of oil on thru-bolts before assembling starter

motor. Install thru-bolts. Torque thru-bolts to 95-100 in. Ibs.
(11-12 N·m). Seal with CIVIC Black Neoprene Dip.
[lID 9. Install pinion base and pinion on armature shaft.
[IZJ 10. Install spacer and spring on armature shaft.
11. Install cup on armature shaft. Press cup down on spring and
install retaining ring in groove on armature shaft.
[}ID INote I Pull cup up over retaining ring and verify ring seats in
shaft groove and cup groove to allow full bendix travel.
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ern 12.lf cup won't pull up over ring, use a screwdriver or similar
tool to compress ring and pry cup up over ring .
/20/ 13. Install protective cap over armature shaft and spacer.
14. Refer to No Load Current Draw, Electric Starter to check

starter operation.
Installation
1. Position the starter bracket on the powerhead. Secure the

starter bracket using the two screws with washers and the locknut
with washer. Be sure to install the ground lead and lock washers
on the lower screw. Tighten the screws and locknut to
60-84 in . Ibs. (7-9 N·m).
2. Attach the vertical throttle shaft to the powerhead with the

clamp and two screws.
3. Secure all the solenoid leads to the solenoid. Apply ave Black
Neoprene Dip to all connections except the battery 0+" cable and
terminal.
4. Reconnect the battery cables at the battery.
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8-22 32C/enq
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Description of Charging System
The outboard charging system consists of a battery, a flywheel,
an alternator stator, and a rectifier.
The engine's battery can affect the charging system operation.
The battery should be of heavy-duty marine construction, should
be the correct capacity for the application, and should be in good
condition with a normal charge.
II] The engine's flywheel contains the permanently charged
magnets which provide the energy to power the stator windings.
The magnets must be at their original design strength for full 1
alternator output.
rn rn The alternator stator consists of many windings of wire
wrapped around metal laminations. The stator is attached to the
ignition plate. The flywheel's magnetic lines of force cutting
through the stator windings produce alternating current. The
stator or its leads could be damaged which could result in
reduced or no alternator output.
rn The rectifier consists of a series of diodes, built into a metal
case, which changes the stator's alternating current to the direct
current used to charge the battery. One, several, or all of the
rectifier diodes might become damaged, resulting in a system
grounded condition, a no charge condition, or an incorrect
charging rate.
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Charging System Check Chart
Where to Look Cause Procedure Reference
Battery 1. Battery defective or worn out 1. Check condition and QVK:

charge Accessory
2. Low electrolyte level 2. Add water and recharge Service
3. Terminal connections loose 3. Clean and tighten Manual
or corroded
4. Excessive electrical load 4. Evaluate accessory loads
Wiring 1. Connections loose or

corroded
1. Clean and tighten •
2. Stator leads shorted or 2. Perform ohmmeter tests 2. Pages
grounded 8-26,
8-27
3. Circuit wiring grounded 3. Perform ohmmeter tests 3. Pages
8-26,
8-27
Alternator stator 1. Damaged stator windings 1. Perform ohmmeter tests 1. Pages

8-26,
8-27
2. Weak flywheel magnets 2. Perform running output 2. Page
tests 8-25
3. Damaged stator leads 3. Perform ohmmeter tests 3. Pages
8-26,
8-27
Rectifier 1. Damaged wiring or diodes 1. Perform rectifier ohmmeter 1. Page

test 8-30
PCE0089
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8-24 32C/eng
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Running Test, Alternator Output - All Models
4AMP
INote I Disconnect battery cables before proceeding with this
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.
II o
Illlfltlf I
1000 2000 3000 4000 5000 6000
& Guard against any red wire, its terminals, or the ammeter 1
coming in contact with engine ground while the engine is DRl153
running. Contact may cause arcing.
5 AMP
[]] rn 3. The engine's battery should not be fully charged
!Itlfttllill
when beginning this test. Connect the battery cables and run the
engine in a test tank. Refer to the output curves to determine the
correct output-to-RPM ratio for your engine .
• If there is no output or the output is not correct, refer to o 500 1500 2500 3500 4500 5500
the stator and rectifier ohmmeter tests in this section.
2
DR4809
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Stator Resistance Tests, 9.9/15
check.
1. Disconnect all stator leads.
[IJ2. Calibrate ohmmeter on appropriate scale. Connect the

ohmmeter between the two stator yellow/gray leads:
• Ohmmeter should show a low reading.
• If ohmmeter shows a high reading, repair lead between

the two yellow/gray connectors, or replace stator.
II] 3. Connect ohmmeter between the yellow and yellow/gray

stator leads:
• Ohmmeter should show 0.80-0.90 fl.
4. Connect ohmmeter between the yellow and yellow/blue stator

leads:
• Ohmmeter should show 0.80-0.90 fl.

2
DR4817
5. Connect ohmmeter between yellow/blue and one yellow/gray

lead:
• Ohmmeter should show 1.5-1.7 fl .
W 6. Check stator for a grounded condition: Disconnect both

ohmmeter leads. Calibrate ohmmeter on appropriate scale. Con-
nect one ohmmeter lead to a clean engine ground.
W 7. Connect the other ohmmeter lead to stator yellow/blue

3
lead:
DR4818
• Ohmmeter should show a high reading.
• If ohmmeter shows a low reading, stator is grounded.
W 8. Repeat Step 7 on stator yellow and yellow/gray leads:
• Results should be similar.
9. If a stator lead is grounded, repair it or replace the stator

assembly.
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8-26 32Cleng
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4 DR4155 DR4156
Stator Resistance Tests, 20-30

check.
rn 1. Disconnect all stator leads from terminal board.

rn 2. Calibrate ohmmeter on appropriate scale. Connect the
ohmmeter black lead ® to the stator yellow/blue lead.
rn
lead .
3. Connect the ohmmeter red lead ® to the stator yellow
• Ohmmeter should show 0.55 ± 0.05 n.

rn
lead.
4. Move the ohmmeter red lead ® to the stator yellow/gray
• Ohmmeter should show 0.55 ± 0.05 n.

[ ] ] 5. Check for a grounded condition: Disconnect both ohm-
meter leads. Calibrate ohmmeter on appropriate scale. Connect
one ohmmeter lead to a clean engine ground.
[ ] ] 6. Connect the other ohmmeter lead to stator yellow/blue

lead.
• Ohmmeter should show a high reading.
• If ohmmeter shows a low reading, stator is grounded.
[ [ ] 7. Repeat Step 6 on stator yellow and yellow/gray leads.
8. If a stator lead is grounded, repair it or replace the stator

assembly.
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32ClenQ 8-27 o
Rectifier Ohmmeter Tests, 9.9-30
check.
IT] 1. Disconnect all rectifier leads from terminal board.
IT] 2. Calibrate ohmmeter on appropriate scale. Connect one

lead ® to a clean engine ground. Connect the other lead ® to the
rectifier yellow/gray lead. Note the reading. Reverse the ohm-
meter connections or press the "reverse polarity" button and
note the reading.
• A high reading in one direction and a low reading in the

other direction indicates the diode is OK.
• Two high readings or two low readings indicates the

diode is damaged .
IT] 3. Repeat Step 2 using the rectifier yellow lead.
IT] 4. Repeat Step 2 using the rectifier yellow/blue lead.
rn 5. Move ohmmeter lead ® from engine ground to rectifier

red lead.
rn 6. Repeat Step 2 with ohmmeter leads connected to rectifier

red and yellow/gray leads.
• A high reading in one direction and a low reading in the

other direction indicates the diode is OK.
• Two high readings or two low readings indicates the

diode is damaged.
rn 7. Repeat Step 6 using rectifier red and yellow leads.

rn 8. Repeat Step 6 using rectifier red and yellow/blue leads.

9. Replace the rectifier if your test results vary.
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8-28 32C/enq
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AC lighting Coil Resistance Tests, 20-30
~@
rn / ~- ~
©
1. Calibrate an ohmmeter on appropriate scale. Connect it
between yellow/gray © and yellow @ leads. C .
• Meter must show 0.86 ± 0.05 n.
W 2. Connect meter between yellow/gray © and yellow/blue ®
leads.
• Meter must show 1.21 ± 0.02 n. 3

[ [ ] 3. Calibrate ohmmeter on appropriate scale. Connect one
lead to a clean engine ground ® . Probe each of the connector
pins with the other ohmmeter jumper wire.
• The ohmmeter should show a high reading.
• If the ohmmeter reading is low, repair the grounded coil

lead or replace the stator assembly. Refer to Section 3 for
ignition plate servicing.
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Electrical Components Service, 9.9/15
Removal
OJ 1. Disconnect the black and purple/white wires and remove

the primer.
rn 2. Remove the black ® and yellow/red ® wires from the top

posts. Remove the red cables and remove the solenoid with
bracket.
[ ] ] 3. Disconnect the yellow/blue, yellow/gray, and yellow wires.

Remove the red wire and two screws retaining the rectifier and
black cables. Remove the rectifier.
[IJ 4. Remove the fuse and disconnect the gray and tan wires.
[]J5. Remove the two screws retaining the electrical bracket.

Remove the bracket.
Installation
[]J 1. Install bracket (with coil) on powerhead. Torque screws to

48-96 in . Ibs. (5,4-10,8 N·m).
rn 2. Install the fuse and connect the gray and tan wires.
[ ] ] 3. Install the rectifier with the red wire and black cables and
torque screws to 48-96 in. Ibs. (5,4-10,8 N·m). Connect the
yellow/blue, yellow/gray, and yellow wires.
rn 4. Install bracket with solenoid and tighten screws securely.

Attach the red cables (starter cable to top large post). Attach black
and yellow/red wires to top posts.
IJJ 5. Install primer and connect black and purple/white wires.
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NOTES
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Tachometer Circuit Tests, 9.9-30
Perform the following tests if the tachometer does not operate.
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 .
1. Set your peak-reading voltmeter to "POS" and "50". Check voltage at the battery. Use this reading as
your reference for battery voltage.
2. Use peak-reading voltmeter to check for battery voltage between the tachometer purple lead ® and
black lead ® at the dash with the engine NOT running and the key switch ON.
• If the voltmeter shows battery voltage, go to Step 3.
• If the voltmeter shows less than battery voltage, check the purple, purple/red, and black
circuits, engine fuse, key switch, and the battery connections.
3. With the engine NOT running and the key switch ON, check for battery voltage between the
instrument harness gray lead © and black lead ® at the dash.
• If voltmeter shows a volt, go to Step 4.

• If voltmeter shows any voltage, replace the rectifier.
4. With the engine running at 1000 RPM, check for voltage between the instrument harness gray lead ©
and black lead ® at the dash.
• If voltmeter shows a volt, go to Step 5.

• If voltmeter shows 8 volts or higher, replace the tachometer.
5. With the engine running at 1000 RPM, check for voltage at the engine terminal board gray connect ion
@.
• If voltmeter shows a volt, replace or repair the rectifier.

• If voltmeter shows 8 volts or higher, check the instrument harness and engine harness gray
circuit for an open.
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NO~!OIL
WATERgiTEMP
CHECK ill
ENGINE
LOWL[!lOIL
DR5206
ji;!I
CHECK
System Check Engine Monitor
The CIVIC System Check™ engine monitor warns the operator of conditions that could damage the
engine. The monitoring system consists of a dash -mounted gauge with four light emitting diodes
(LEOs), a warning horn, sensors on the engine and oil tank, and related wiring. The system is
compatible with the OMC Modular Wiring System.
OJ rn Gauges of two sizes and types are available - a 2 in : gauge with four LEDs or a 3 in . gauge
and analog tachometer combination. Both gauges have been added to each style of OMC instruments.
The system logic is provided by a microprocessor in the gauge. The microprocessor is connected to
sensors mounted on the engine and oil tank. These sensors support individual circuits that will activate
the warning horn and the appropriate LED on the gauge as follows:
• NO OIL light indicates an oil delivery problem such as an empty oil tank, kinked oil hose, or
damaged components in the VRO pump. On four-stroke models, NO OIL light indicates low oil
pressure in the crankcase.
• WATER TEMP light indicates an engine overheat.
• CHECK ENGINE light indicates a fuel restriction such as a kinked fuel hose or blocked fuel filter.
• LOW OIL light indicates the oil level in the oil tank is down to the "reserve" level (about % full).
INotel Not all conditions are monitored on all models. Refer to Specifications, Section 1.
Operation
The System Check gauge and horn will self-test when the key switch is turned ON. All LEOs light at
once, then turn off in sequence. The warning horn sounds for 112 second.
When a monitored problem occurs during engine operation, the warning horn sounds for 10 seconds,
and the appropriate LED lights up for at least 30 seconds. The LED turns off when the key switch is shut
off or when the problem goes away. If there is more than one problem, more than one LED will light up.
The monitoring system also has a diagnostic mode. When the key switch is ON and the motor is not
running, the monitor is in a diagnostic mode immediately after the self-test. You can test the four
warning circuits by connecting sender leads to engine ground and observing the gauge. The warning
horn will not sound while in the diagnostic mode. Make it a habit to test the warning system of each
new engine before you deliver it to its owner. Refer to Circuit Verification, Instrument Harness, t his
section.
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Adapter Kits
For the purpose of wiring identification, the conventional

RED, molded, 10-pin connector will be referred to as "1995".
@~
If the engine end of the harness has three BLACK Deutsch
connectors, the wiring is considered "1996".
1996 Engine to 1995 Wiring - System Check Installation
rn Use PIN 176345 Adapter Kit - Equips the boat with System
3 © 42805
Check engine monitor.
Kit includes:
@ Harness to adapt engine and trim connections
® Harness to supply System Check signals to the dash
© 1996 oil tank pickup assembly
@ Warning horn
INote I Installation also requires a 2 or 3 in. System Check gauge

or an Audible Adapter, PIN 176458.
4
42804
1996 Engine to 1995 Wiring - Non-System Check Installation
rn Use PIN 176349 Adapter Kit - System Check engine moni-

tor not used in this installation.
Kit includes: CD
® Harness to adapt engine and trim connections
® Harness to adapt oil tank connection
o ©
®
1991 thru 1995 Engine to 1996 Wiring - System Check
Installation
5
42803
[ ] ] Use PIN 176346 Adapter Kit - Equips the engine with

System Check engine monitor.
Kit includes:
© Harness to adapt engine and trim connections
® Harness to adapt oil tank connection
CD Wiring to adapt NO OIL, LOW OIL, temperature switch, and
vacuum switch senders
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Dash Connections, Instrument Harness
3-pin connector ® - Connect to trim switch located in the handle

@
of the remote control or to trim switch mounted on the boat dash.
On models without power trim, protect the open connector by
installing 3-pin plug, PIN 586072 (not supplied).
6-pin connector ® - Connect to a prewired remote control or to a

dash-mounted key switch .
@
Black, purple, white/tan wires © - Connect to the trim gauge.
On models without power trim, leave the protective insulation on
whiteltan and purple leads.
8-pin connector @ - Connect to a 2 in. System Check gauge or to

a 3 in. System Check tachometer. If neither gauge is available,
install an Audible Adapter, PIN 176458. ©
2-pin connector ® - Must connect to the warning horn in all
installations.
Black, purple, gray wires ® - Connect to a conventional tachom-

eter when a System Check tachometer is not used. Leave protec-
tive insulation on the purple and gray wires if you do not use @
them.
®
DRC6279
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Deutsch Connector Servicing
INotel The Deutsch@ pin and socket terminals are not the same
size as Amphenol@ pin and socket terminals . You cannot inter-
change them.
Disconnect
Press latch - pull connectors apart.

1
Connect
OJ Check that seal ® is in place. Clean off old grease/dirt from

connectors. Apply light coat of OMC Electrical Grease to seal.
Push connectors together until latched.
Terminal Removal
m Use hook-end of OMC Connector Service Tool, PIN 342667,

to pull out wedge ® from receptacle, or use other end of tool to
pry out wedge © from plug. Use needle-nose pliers to remove
wedge from 3-pin receptacle.
rn Release terminal latch @ or @ ; gently pull on wire.

Terminal Installation
Push terminal through seal until it clicks into place. Twist and tug
wire if no click is heard .
rn Fill connector with OMC Electrical Grease to

below ledge ® or end of plug @ .
1132 in . (0,8 mm)
INote I No other grease is recommended. Incorrect grease appli~

cation can cause electrical or warning system problems.
rn Push wedge in until latched. Wedge in 2-pin receptacle is not

symmetrical; position latch shoulders next to terminals.
Crimping New Terminal Onto Wire
Strip insulation back 3/16 in. (5 mm).
[ ] ] Use OMC Crimping Pliers, PI N 322696. Place terminal in

"18" notch of crimper for 18 gao wire. Position end of wire strands
® in terminal past wire crimp area CD, and position end of
insulation Q) past insulation crimp area @ .
® ®
Capture all wire strands in crimp - leave no loose strands. Crimp
wire securely. Do not solder. Crimp insulation in "14-16" notch of
crimper. --#irr~-
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Circuit Verification, Instrument Harness
To make sure the OMC System Check™ engine monitor can alert
the operator during a LOW OIL, NO OIL, FUEL RESTRICTION, or
engine OVERHEAT condition, it is very important to verify the
condition of the sensors and associated wiring. Test the engine
monitor regularly and anytime you suspect an alert situation has /
been missed.
INote I The instrument harness must be connected to the engine

befDT,e performing the following tests. Verify the condition of all
wiring and connectors before proceeding. 42811
INote I The warning horn will not sound while in the diagnostic
mode.
NO~!OIL
IT] INote I Use jumper wires made with the appropriate termi- WATER Gl TEMP
nals to test the warning circuits.
CHECK ill ENGINE
LOW~OIL
System Check Gauge
1. Turn the key switch to ON position, engine not running .

DR5206
• The gauge warning lights for NO OIL, WATER TEMP,

CHECK ENGINE, and LOW OIL must all light at once, then
turn off in sequence, and the warning horn must sound
for 1/2 second.
rn 2. If the gauge lights do not turn on, turn the key switch OFF.
Disconnect the gauge 8-pin connector and turn the key switch ON.
Test for battery voltage between instrument harness purple wire,
terminal "1", and black wire, terminal "2".
• If battery voltage is present, replace the gauge.
• If no battery voltage, check condition of the instrument

harness, key switch, and engine 20-amp fuse.
3. If the lights worked, but the warning horn did not sound for 1/2
second, turn the key switch OFF. Disconnect the warning horn
2-pin connector. Substitute a known good warning horn. Turn the
key switch ON.
• Ifthe substitute horn beeps, the original horn is defective

and must be replaced.
[]] • If the substitute horn does not beep, check for battery
4
42761
voltage at the instrument harness 2-pin connector, termi -
nal "2", purple wire ® with the key switch ON. Also,
check the tan/blue wire ® for an open between the
instrument harness 8-pin connector and 2-pin connector.
• If battery voltage is present at the purple wire and the 1

tan/blue wire is not open, replace System Check gauge. ~
@ ~
4. Turn the key switch OFF and reconnect all circuits disconnected
during these tests.
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WATER TEMP Circuit
1. Separate the connector between the engine harness and the

temperature switch.
[ ] ] 2. Using a jumper wire, connect the engine harness tan lead

to a clean engine ground.
3. Turn the key switch to ON position. After the normal self-test

sequence, the gauge WATER TEMP light should stay on .
• If WATER TEMP light is not on, troubleshoot tan circuit

for an open in the engine harness or the instrument
harness.
4. On V engines, test both temperature switch tan circuits.
5. To test the temperature switch itself, refer to Temperature

Switch, Section 4.
6. Turn the key switch OFF and reconnect all circuits disconnected
during these tests.
Circuit Verification, OMC Tester, PIN 437274

Verify the condition ofthe boat modular wiring system using OMC
Tester, PIN 437274.
Power to the tester is supplied by:
• 110 VAC adapter supplied with the tester.
OR
• Internal batteries (two rechargeable 6-volt batteries). To

recharge batteries, move tester power switch to OFF position
and plug in A.C. adapter.
OJ The circuitry in the tester is protected from an overload

condition by a circuit breaker.
[IJ Verify condition of terminals in connectors of both the

instrument harness and tester harness. Then, connect the tester
harness to engine end of the instrument harness.
OJ Turn the tester ON for all tests.

Important These tests must be performed in sequence
and as a complete procedure to ensure that the entire system is
verified.
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Key Switch Function
W 1. With the engine key switch in OFF position, the tester

IGNITION light should be off.
• If the IGNITION light is on, troubleshoot the black/yellow

and black/white circuits for an open, and check the key TAlC
..
TAe
switch.
K.:i
OVEI
W 2. Turn the engine key switch to ON position, the tester
SWITCHED B+ and IGNITION lights should turn on.
• If the SWITCHED B+ light does not turn on, troubleshoot

the red/purple and purple circuits for an open, and check
the key switch.
• If the IGNITION light does not turn on, troubleshoot for a

short between the black/yellow and black/white circuits,
and check the key switch.
rn 3. Rotate the propeller shaft and move control handle to

FORWARD gear position. The tester START light should not turn
on when the key switch is in START position. Rotate the propeller
shaft and move control handle to REVERSE gear position. The
tester START light should not turn on when the key switch is in
START position.
• If the START light turns on when the control handle is in

FORWARD or REVERSE, troubleshoot the neutral start
switch and yellow/red circuit. Check the key switch and
remote control for adjustment.
rn 4. Move remote control handle to NEUTRAL position. Turn

the engine key switch to START position . The tester START light
should turn on.
• If the START light does not turn on, troubleshoot the

yellow/red circuit for an open. Check the key switch,
neutral start switch, and remote control adjustment.
rn 5. With the engine key switch in START position, push key in

to activate the primer circuit. The tester PRIME light should turn
on.
• If the PRIME light does not turn on, troubleshoot the

purple/white and purple/red circuits for an open, and
check the key switch.
System Check Gauge Function
1. To test the gauge self-test feature, turn the engine key switch to
ON position.
2. The gauge warning lights for NO OIL, WATER TEMP, CHECK

ENGINE, and LOW OIL must all light at once, then turn off in
sequence, and the warning horn must sound for 112 second.
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• If the gauge lights do not turn on or if the warning horn l
does not sound for 112 second, test the gauge and wiring
as described in Circuit Verification, Instrument Harness,
this section.
3. To test the instrument harness temperature warning circuit,

I
turn the engine key switch to ON position. TRIM
TACH SNOR
m 4. Move tester TACH ON/OFF switch to ON position.
[ ] ] 5. Press the tester OVERHEAT button. The gauge WATER

TEMP light should turn on for 30 seconds, and the warning horn
should sound for 10 seconds.
• If the WATER TEMP light does not stay on for 30 seconds,

troubleshoot the instrument harness tan circuit for an
open.
Tachometer Function
1. Turn the engine key switch to ON position.
rn 2. Move tester TACH ON/OFF switch to ON position.
3. The tachometer should read approximately 3200 RPM.
• If the tachometer does not indicate this reading, check

the instrument harness gray, black, and purple circuits
for an open.
• If the gray, black, and purple circuits are OK, replace

tachometer.
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Safety Section
Table of Contents
Part A Marine Products and the Safety of

People Who Use Them . . . . . . . . . . . . . . . . . . . . . S- 2
Outboard Shift System and Persons Safety. . . . . . . . . . . . S- 3
Outboard Speed Control System and Persons Safety . . . . S- 4
Outboard Steering System and Persons Safety. . . . . . . . . S- 5
Outboard Fuel, Electrical System and Persons Safety .... S- 7
Outboard Mounting System and Persons Safety ........ S-10
Outboard Hydraulic Tilt/Trim Shock Absorpti9n
System and Persons Safety ................. S-12
Outboard Emergency Stop System and
Persons S~fety . . . . . . . . . . . . . . . . . . . . . . . . . . . S-13
Part B Marine Products and the Safety of

People Who Fix Them ..................... S-16
Handling Lead/Acid Batteries ....................... S-19
Gasoline! Handle With Care ........................ S-20
Hazardous Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-21
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People Who Use Them
Enjoyable boating is the Goal of people who design and build marine products. To reach this Goal, manu-
facturers are careful to make sure ....
• Product User is Informed .. . ..
• Products are Safe and Reliable . . . . .
It's up to You, the people who .....
• 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, E
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Outboard Shift System and Persons Safety
The outboard Shift System

starts here at the
remote control lever .....
and ends here .. .. .

at the propeller.
What's Most Important?

When control lever is in
"Forward," "Neutral" or
"Reverse" position,
Shift linkage must

\J>.--- _ match control
lever position.
What Could Happen?
elf . .... elf . . . ..
Forward
or .Reverse
Reverse
..... propeller still powered (turning)

unknown to operator, or motor will . .... boat will move Opposite
Start in Gear, boat will move suddenly. to direction wanted by operator.
How Can Loss of Shift Control be Minimized?
• Read, Understand, and Follow manufacturers Instructions.
when
Rigging • Follow warnings marked" &" closely.
or after e Assemble Parts Carefully.

Servicing
•• Make Adjustments Carefully.
Test Your Work. Don't Guess. Make Sure Propeller Does Just What the
Operator Wants and Nothing Else.
e Do Not Shift Gears When Motor is Stopped. Adjustments Can be Lost
and Parts Weakened. E
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Outboard Speed Control System and
Persons Safety
The outboard Speed Control System
starts here at the remote control
lever .. . .. (single lever remote control)
and ends
here on the
powerhead.
powerhead speed must slow

down enough to allow operator
to shift into Neutral
Operator must be able to Stop propeller.
What Could Happen?
If Operator can't slow down the motor Or shift into Neutral gear (stop propeller), Operator could panic
and lose control of boat.
How Can Loss of Speed Control be Minimized?
• Follow warnings marked /I & /I closely.
•••
Assemble Parts Carefully
when Make Adjustment Carefully
Rigging Test Your Work. Don't Guess. Make Sure Motor Changes Speed
or after Smoothly, Quickly.
Servicing
• Make Sure Full Throttle Can be Obtained so Operator Won't Overload
Parts.
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Outboard Steering System and
Persons Safety
The outboard steering system starts here

at the steering wheel .....
. . . . . and ends .....
here at the Trim Tab

What' s Most Important? on the outboard motor .....
The Steering System .....
• must not come apart
• must not jam
• must not be sloppy or loose
What Could Happen?
• If steering system comes apart, boat might turn suddenly and circle ..... persons thrown into water
could be hit.
---
• If steering jams, operator may not be able to
avoid obstacles. Operator could panic.
• If steering is loose, boat may weave while

operator tries to steer a straight cou rse. With some
rigs (at high speed) loose steering could lead to loss of boat control.
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How Can Loss of Steering Control be Minimized?
• Use a steering system recommended by the motor manufacturer which meets

Marine Industry Safety Standards (ABYC).
When • Read, Understand, and Follow manufacturers Instructions.
Rigging
or after •
•
Follow warnings marked"
Assemble Parts Carefully
&"
closely.
Servicing
• Make Adjustments Carefully
• Keep Parts Moving Freely ..... Lubricate Parts as Shown in Manuals
• Use the bolts, nuts, and washers supplied with steering attachment kits
... . they' re a Special Locking Type That Won't Loosen, Rust, or Weaken.
• When Transom Mounted steering systems (see picture) are used, check to uncover possible Trouble!
During this procedure, steering parts
• Must Not Bind
• Must Not Touch Other boat, motor

or accessory Parts in Transom Area.
Why? A hard blow to the motor's
/ " , - - gearcase can result in damage
" I to steering parts here
- - ')'"
transom
~
mounted ~ . . . . . .~~ stop
steerer to
• Be aware that Ra ising or Lowering motor

on transom can change a set up which was
O.K . earlier. If moved up or down even
1/2 inch, run test again to make sure
steering parts are free and clear.
• Check for Damaged parts . . . . . Blows to the Motor like this
or this can put Heavy Loads on steering parts. Look for . . . ..

• Cracked parts, including steering parts, swivel brackets
and transom brackets
• Bent parts
• Loose nuts and bolts
• Replace damaged parts. I f weakened, parts could fail later .. . .

on the water . - . . when least expected. E
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Outboard Fuel, Electrical System and
Persons Safety
The Fuel System The Electrical System begins

starts here at here ..... at the battery .....
the fuel tank .....
. . . . . and ends here ..... ~_ _- \

at the carburetor
..... and ends here on the powerhead.
What's Important?
• Fuel Leakage must be eliminated.
• Stray electric sparks must be avoided.
What Could Happen?
Gasoline can ignite and burn easily. Gasoline vapors can ignite and explode.
• 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.
How Can Fire and Explosion Be Minimized?
• Follow warnings marked 1/ & 1/ closely.
• Do not substitute fuel or electrical system parts with other parts which may look the same.
Some electrical 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.
Always fill the tank Outside the boat.

• When Mixing and Refueling .... .
Always Mix gas and oil Outside .... .
Fumes are hard to control .....
. . . . . they collect and Hide in the
bottom of the boat.
To avoid those
Static Electric
Sparks .....
Ground (touch) the

spout against the tank
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• 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
I~I
• When Storing:
Whenever possible,
... remove Hose from
motor And from tank .
. . . . . and store arou nd

I f tank cap has an ears of tank.
air vent valve, make
This way gasoline is
sure it's closed.
trapped in tank and not
in the hose where it
might leak onto the floor
if hose deteriorates.
If stored indoors, do not put in
room having an appliance with
Pilot Light or where electrical
appliances or switches (which
may spark) will be used.
• When Running:
Carburetor air intake

silencer will catch and
hold fuel which may
u Flood into motor if
carburetor float sticks.
So make sure Silencer and all its Gaskets are on motor And Drain Hose is in place.
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• If electrical parts are replaced or even removed from the motor, check the following:
Wire and High Voltage Lead Routing

• as shown in service manual
• away from moving parts which could cut wires or wire insulation
• away from motor cover latches which can catch and cut insulation from High Voltage
spark plug leads.
Sleeves, Boots, Shields Wire Clamps - Tie Straps

• in position (to avoid • position as shown in manuals
shock hazard) • use only coated clamps
not torn or cracked
Screws, Nuts, Washers

........~..... tighten firmly, They keep clamps in
position and ends of wires from sparking
• where lockwashers are called for .....
use them .
............... Spark Plug Boots

• not torn or cracked
• fully pushed onto spark plug
~. ._ . . Spark Plugs
• avoid rough handling that could
crack Ceramic part of plug.
(Sparks may jump across
outside of plug.)
• I n transom area .....
All Connections
• clean
• Tight Electrical Cable
(Prevents sparks)
• Not rubbing
on sharp objects .... .
• enough slack to allow full
turning without pull loads
on cable (Prevents Sparks)
• Secure in approved
battery box or bat-
tery tray.
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S-9 0
Outboard Mounting System and
Persons Safety
The Mounting System includes
-~ _ _ _--
. . motor parts
"""" bolts, nuts, washers, and

~-.:..------
~__~_- boat's transom
What's Important?
Motor must stay in position on boat's transom
What Could Happen?
• Motor may
on transom
... . . Boat may turn and be
hard to steer.
• Motor may
T . . . I ... L . . . T on transom . .. Boat may turn
and be hard
to steer.
• If motor hits
.... Motor could break or boat's
something solid .. ...
transom could break away.
Motor may be lost overboard.

Boat may S
How Can Loss of Mounting Be Minimized?
• Read, Understand, and Follow manufacturers mounting Instructions.
• Follow warnings marked" & "closely . . ...

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• If Boat Plate shows ..... U.S. COAST GUARD
CAPAC IT Y IN FORMAT
ON I .
..... use
MAXHP ... .. ... ~ Only • • • • •
MAX PE RSONS
MAX WEIGHT
Or Smaller!
• When Rigging or
Fixing any boat ....
if transom looks
Weak, tell the
owner .....
If transom is Curved, Mount on Flat Su r-face only .

motor may come . . . . . Use Shims to make surface flat.
Loose .....
Flat
• Use Bolts, Nuts, and Washers sent with Motor ••_ - - -...-...~
They're usually Special ... . . won't Rust ... or
Weaken.
• I f owner tells you

"1 hit something
rea lIy hard ..... .
. .... High speed blow
to lower unit ... or, . ... . "1 was backing up ... think motor may have
hit the tree ... or something"
A2~
{/.Iv fJJ~ v
~t~i) VD~tJrf.fq
I' ~
I
~, 1< ", 'f> , /~
slow, heavy squash

to motor .....
. . . . . look for Damaged Parts and

Loosened Nuts and Bolts in both
the Steering and Mounting Systems.
Replace damaged parts.
If weakened, parts could fail later . . . . . on the water

. . . . . when not expected. E
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5-11 o
Outboard Hydraulic Tilt/Trim Shock
Absorption System and Persons Safety
What's Important?
• Shock Absorption system must always be ready to Absorb some Blows to the lower parts of the
motor.
• Motor must not Trim "In"
What Can Happen?
• Without Shock protection,

a Blow like this ......... and Motor could break ... or
Transom could break away ..... Motor may be lost overboard,
..... and Boat may . .... S
i
n
k
• At high boat speeds,

Sudden trimming "in"
too far and boat may dive under
water or spin around.
How Can Possible Conditions

Be Minimized?
• Read, Understand, and Follow

manufacturers Instructions.
• Follow warnings marked" & "closely.

• Test your work whenever Possible. Trimming "In" too Far can
• If oil Leaks seen in area, determine happen when Angle Adjusting Rod
Source. Keep reservoir filled. isn't in the Right hole ... Or
• If motor is Hydraulic Tilt/Trim Model, is Not in Any H~. (Lost)
Always return Rod to Hole Position determined earlier by Boat Operator .. . E

and make sure Angle Adjusting Rod Retainer is in locked position. o
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Outboard Emergency Stop System and
Persons Safety
the Emergency Stop system begins

here at the Buckle . ... .
. . . here in the ignition

system on the power head .. . .
\",~""",~,~=-
The Emergency System . . . ..
• must STOP the engine when the emergency stop switch's cap is pulled from switch.
What Could Happen?
• If switch fails . . . ..
. . . . engine will keep running when cap is pulled from switch.
• If lanyard is caught ....
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• If lanyard is cut or frayed ... ~
,~
... lanyard or cap may break when pu lied .. ..
and engine will continue running.
~-- ............
/
/ "- \
,...
/
,'"\ ~~
~
~'--~ ~'
-
~~ )'.
• If engine does NOT stop when lanyard is pulled,
an operator thrown from boat could be hit as
boat circles area ... . or boat may not turn but
'- ~~
,,~~
-... ~
~
/
leave area as a runaway .. .. operator may drown and boat WI LL run into something.
How can failure of the Emergency Stop system be minimized?
• Follow warnings marked & closely.
• Assemble parts carefully
• Inspect lanyard for cuts or fraying, rubber cap for wear.

When Replace with original parts. Do not substitute.
Rigging or
after • Locate control box and other items in area to keep
Servicing lanyard from being caught.
• ALWAYS TEST EMERGENCY STOP SYSTEM . PULL

LANYARD . ENGINE MUST STOP. IF IT DOESN'T,
REPAIR BEFORE NEXT USE. E
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S - 14 o
People Who Use Them
Summing Up
Now You know some things that can take the Joy out of enjoyable boating.
No doubt about it ..... It Takes Time!
~ Reading and Understanding Instructions,
~ Re-Reading Warnings Marked" & ",

~ Putting Parts Together Right.
~ Making Adjustments Right,
~ Testing Your Work,
and making sure
~ Worn or Damaged Parts are Replaced,
~ Replaced Parts are Like Originals ..... in Every Way,
~ Customer is Told of Things Which Need Attention .....
But, Do You Really Want the Alternative?
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Part B Marine Products and the Safety of
People*Who Fix Them
Part A talked about Safe boating and how You, the mechanic, can help keep it Safe for the boater. But
What About You? Mechanics Can be Hurt While .... .
~ Rigging Boats ~ Fixing Things

~ Trouble Shooting Problems ~ Testing Their Work
Some items you'll know . .... others you may not.
Handling Motors
When Lifting Motors
•
Stand Clear!
Center of gravitV-.......;.....
It might hit
you as it swings.
• If motor does not have fixed lift
bracket and you use Universal Puller
(378103) and Lifting Eye (321537) . . . ..
. . . . . use only the special

hardened screws and washers
from the set.
... Regular screws aren't

• Motor may also Drop suddenly
strong enough. Screws
if Hoist or Motor Stand are in
may Break and motor
Poor shape . ... or Too small
-- for the job may drop suddenly.
• Make sure Shop Aids have Extra Capacity .... . . .. .. and keep them in Good Repair!
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5-16 o
Running Motor with Motor Cover Removed
• 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 . . .. .
. . . . . can be Caught by the

spinning Flywheel.
Handling High Voltage
[Rf
·'1
Parts like spark plugs
and coils can shock
i=TIi~""'---- you .... may cause
-----....!..--J....-....L-ll_ _ _~~Id.:::~~ you to recoil into
the flywheel
• 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.
Motors Starting at the Wrong Time
• When you do things that turn the Flywheel like

~ End-of-the-season
Fogging (oiling)
of motor
~ Removing propeller
with a powered tool
~ Electrical system checks

~ Removing or replacing the flywheel
~ Or? ? ?
o Always .....
Turn Key Switch "Off"
Shift to
•
Neutral
Twist and remove ALL
spark plug leads shaft ..... is motor
really in Neutral?
E
NO SPARK NO START NO SURPRISES o
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5-17 o
Running Motors Too Fast (Overspeeding)
"Too Fast" means faster than motor

normally runs on the Boat .....
• Running Too Fast can happen
•
when .....
. . . . . using a
Flushing Kit ..... . .......... Turn on water Before
starting motor and Keep
motor Speed below
2000 RPM ..... with no load,
motor will run Too Fast very
easily ..... and wear Ear
Protectors .
• running motor with the Wrong
Test Wheel .....
This may happen if

motor runs
Too Fast .....
Running Motors: Exhaust Fumes
Exhaust Gases of running Motors contain Carbon Monoxide ... . . you can't See it .... .
you can't Smell it ..... you can't Taste it ... but It's There whenever a motor Runs ... .
And It's Deadly!
When you smell the Other gases in the Exhaust, You are inhaling Carbon Monoxide. Run
motors only in Well Ventilated areas.
Eyes need Help
~Sprayed
Cleaners,
~Grinding Paints
~ChiSeling
(Steel on Steel)
(Tip: Use Plastic or Brass type Hammers.
They don't chip off as easily as steel hammer.)
---
~ Protect Eyes .....
~ACid ~ Ends of Cables Wear Safety Glasses E
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5-18 o
Handling Lead/Acid Batteries
~~~/ - Strong
~ If spilled or splashed on
~ / ,Acid
'1"---!--~~ So Iutio n Any part of Body .....
(Sulfuric Acid)
Wash with lots

of Water .....
Wash ... . .. And contact
a Doctor, Fast!
Charging Lead Acid Batteries
(1) Attach and remove these cables with

charger UNPLUGGED from 110 volt
wall socket. (Prevents shocks if the
charger is defective.)
(2) Observe correct polarity when connecting

these charger Leads.
(3) Always charge in a well ventilated area.

Charging causes acid solution to give off
Hydrogen gas thru the Vents in the Caps
..... Make sure Vents are open. If '~~..............~~~
clogged, pressure inside may build .. .•
battery may EXPLODE.
Battery Gas is Explosive!

While Charging or Discharging,
remember . . ...
Never remove charger cables from

No Smoking
battery posts . . . it's a sure way to
No Flames make lots of sparks ... surrounded by
No Sparks Battery Gas.
Don't check battery charge

by placing metal objects After Charging
across posts
( 1) Shut Off charger
You're sure to
make Sparks and (2) Pull charger Plug out of 110V outlet
serious Burns are possible.
. .. Then, (3) Take charger Cables off battery Posts
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5-19 o
Gasoline! Handle With Care
Gasoline vapor and air mixtures 1 Part L; }., ".
explode easily and violently Gasoline -
when mixed as shown ...... . .. .
20 Parts By
When you smell ANY odor of gasoline,
explosion is possible t Air r--
Volume
Gasoline fumes are heavy

and will sink to the lowest
point in the boat or room .....
and will Stay there ..... Waiting
•
!GAS
FUME S
I
4
If the air around

you is quiet .....
the pilot light in
the heater may
ignite the heavy fumes .....
before you r nose
What Can You Do? ever smells the fumes
Store in sturdy, approved

sealed Gas Can
..... and .....
Keep Outside
• 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 In and Around repair area which can Ignite gasoline fumes ..... Control
them if fumes are smelled.
~ Matches, Cigarettes, Blow Torches, Welders
~ Electric Motors (with unsealed cases)
~ Electric Generators (with unsealed cases)
~ Light Switches
~ Appliance Pilot Lights (furnace, dryer, water heaters)
~ Loose Wires on Running Motors
~????????
How Many of These are in Your Area? E

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S-20 o
Hazardous Products
Know How
items in the
Shop can
--
hurt people .....
- --
~--
..;;;;!
rUEL --
ADDITIVE
--
DANGER
--
"""-
-
..-
• Read ~ "How and Where to Use,"
~ "How to give First Aid." Have "recommended"

first aid materials on hand - should an emergency arise,
~ "How to Dispose of Can."
It's All on the back of the Can or Bottle label.
And remember .....

little children are very curious and will try to taste everything, so . ....
Keep Containers Away

From Children
..... mummmmmmmm
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5-21 III
o
WATER FLOW DIAGRAM
9.9/15
DR4698
WATER FLOW
DIAGRAM
20-30
DRC6181
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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:
Hansen Marine Products Merc-O-Tronic Instruments Corporation

P. O. Box 1106 215 Branch Street
Lake Villa IL 60046 Almont MI 48003
(708) 356-9552 (810) 798-8555
Meyer Engineering Company OTC

1139 N. Lewis Avenue 655 Eisenhower Drive
Winthrop Harbor IL 60096 Owatonna MN 55060
(708) 746-1500 1-800-533-0492 or 1-800-533-5338
Stevens Instrument Company

P. O. Box 193
Waukegan IL 60079
(708) 336-9375
Do not order this equipment from Outboard Marine Corporation. Contact the above
manufacturers for pricing and ordering information.
Order OMC Service Tools from OMC SysteMatched Parts & Accessories TM .
ire 9/95
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In.

This Service Manual will alert you to certain procedures

• Injure yourself or people around you

Understand the following symbols before proceeding:

Identifies information that will help pre-

Appears next to information that controls

This Service Manual is written for qualified, factory-

This Service Manual tells you how to correctly maintain

If you use procedures or service tools that are not

In. General Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . .. 1- 2

When replacement parts are required, use genuine OMC parts or

To prevent possible eye injury, always wear SAFETY GLASSES

Always read and follow safety related precautions found on

The engine cover is a machinery guard. Use caution when

Replace any locking type fastener (locknut or patch screw) if its

Size In. Lbs. Ft. Lbs. N'm

No.6 7-10 • 0,8-1,2

No.8 15-22 • 1,6-2,4

No. 10 25-35 2-3 2,8-4,0

No. 12 35-40 3-4 4,0-4,6

1/4 in. 60-80 5-7 7-9

5/16 in. 120-140 10-12 14-16

3/8 in. 220-240 18-20 24-27

7/16 in. 340-360 28-30 38-40

INotel These values only apply when a special torque for a

INotel When tightening two or more screws on the same part, do

Sealants and Lubricants Required _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

OVIC Ultra-HPF™ Gearcase Lube

Good Service Practice

Service required for OMCengines is generally one ofthree kinds :

• Normal care and maintenance - which includes putting

• Operating malfunctions - due to improper engine

• Complete disassembly and overhaul - such as major

It is important to you as the service person to determine, before

When repairing a component, the most reliable way to ensure a

Repair time can also be minimized by the use of special tools.

f'N=J Do not operate engine out of water, even momentarily. If

This Service Manual includes the specific information you will

Each of the manual sections contains detailed instructions for

Product Reference and Illustrations

Outboard Marine Corporation reserves the right to make changes

The continuing accuracy of this manual cannot be guaranteed.

All photographs and illustrations used in this manual may not

Certain features or systems discussed in this manual might not be

When servicing an outboard which is within its normal warranty

If OMC genuine replacement components or parts are not used,

~ When replacement parts are required, use genuine OMC

When reference is made to a brand name product or specific tool,

Whether within or following the warranty period, OMC has a

The Service Manual covers all phases of servicing outboards.

Be sure that you are familiar with OMC warranty policies.

Special Service Tools

OMC has specially designed tools to simplify some of the

Outboard Engine Nomenclature

& Safetv Related 1-6 32C/eng

[!] This symbol indicates continuity or very low resistance.

Use an ohmmeter calibrated on high ohms scale, or a continuity

I.;l When "s," precedes a value on the meter face, it indicates

Full Throttle Operating Range 9.9 - 5000 to 6000 RPM

Power 9.9 - 9.9 HP (7,4 kw)

Power Rated @ 9.9 - 5500 RPM

Idle RPM in Gear 700 ± 25

Test Propeller OMC PI N 340177