TABLE OF CONTENTS 3 POWERHEAD

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Paula Booker
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1 TABLE OF CONTENTS 1 SAFETY POWERHEAD SERVICE -- REDESIGNED MODEL (See Listing on Page) CLEANING, WAXING, &. POLISHING CONTROLLING CORROSION PROPELLERS FUEL SYSTEM LOADING 1-9 HORSEPOWER 1-10 CLEANING &. INSPECTING 3-66 FLOTATION 1-10 Thermostat Service 3-66 EMERGENCY EQUIPMENT 1-12 Reed Block Service 3-66 COMPASS 1-14 Crankshaft Service 3-68 ANCHORS 1-16 Connecting Rod Service 3-70 MISCELLANEOUS EQUIPMENT 1-17 Piston Service 3-72 BOATING ACCIDENT REPORTS 1-18 Honing Procedures 3-74 NAVIGATION 1-18 Cylinder Block Service 3-75 Check valves TUNING ~TRODUCTIDN ~1 4 FUEL TUNE-UP SEQUENCE 2-2 COMPRESSION CHECK SPARK PLUG INSPECTION 2-3 GENERAL CARBURETION IGNITION SYSTEM 2-4 INFOR MA TION 4-1 TIMING AND SYNCHRONIZING 2-5 TROUBLESHOOTING 4-4 CARBURETOR ADJUSTMENT 2-7 "Sour" Fuel 4-4 FUEL PUMPS 2-9 Lpaded Gasoline &. Gasohol 4-5 CRANKING MOTOR Removing Fuel From the System 4-5 AND SOLENOID 2-10 Fuel Pump Test 4-7 INTERNAL WIRING HARNESS 2-11 Fuel Line Test 4-9 WATER PUMP CHECK 2-12 Rough Engine Idle 4-10 PROPELLER 2-13 Excessive Fuel Consumption 4-10 LOWER UNIT 2-15 Engine Surge 4-11 BOAT TESTING 2-16 Anti-Syphon Valve POWERHEAD ENRICHENER SYSTEM SYSTEM W/ACCELERATOR PUMP &. 115HP CARBURETOR IDENTIFICATION 4-13 Chapter Organization 3-3 POWERHEAD SERVICE -- ORIGINAL REFERENCED "A" - SIDE BOWL DESIGN (See Listing on Page) 3-5 AND BACK DRAG & Cisassembling Adj ustm ents 4-23

2 4 FUEL (Continued) REFERENCED ''B'' W/INTEGRAL FUEL PUMP &. Adjustments REFERENCED "C" - CENTER SQUARE BOWL &. Operating Adjustments REFERENCED "D" SERIES WME CENTER SQUARE BOWL &. Adjustments FUEL PUMP Theory of Operation Pum p Pressure Check OIL INJECTION -- AUTO BLEND Preparation for Use Auto Blend OIL INJECTION -- ADV ANCED Filling System Purging System System 51GNmON SPARK PLUG EVALtJATION POLARITY CHECK WIRING HARNESS TYPE I - DISTRIBUTOR MAGNETO WITH POINTS &. Operation Cleanin &. Inspecting Assemb ft ing TYPEII-THUNDERBOLT DISTRIB UTOR LIGHTNING ENERGIZER - POINTLESS AKA ALTERNA TOR DRIVER IGNITION (ADI) T roub leshooting TYPE III - THUNDERBOLT DISTRIBUTOR C.D. POINTLESS TYPE IV - THUNDERBOLT FL YWHEEL - C.D. - POINTLESS.5-40 &. Operation TYPE V - THUNDERBOLT FLYWHEEL - C.D. COIL PER CYLINDER &. Operation & & TIMING AND SYNCHRONIZING &. PREPARATION 6-1 MODEL and 1968 to Serial No MODEL.500S No and Up Mid 1968 MODEL.500M No and Up Mid 1968 MODEL.500E No and Up Mid 1968 to MODEL 650S No to Mid 1968 and 1969 MODEL 6.50E No to Mid 1968 and MODEL MODEL to No

3 MODEL.500 No and Up 1977 to 1979 MODEL.50HP Since 1979 MODEL 45HP 1986 to 1989 MODEL 40HP Since 1990 MODEL and 1966 MODEL 6.50E 1968 to No MODEL 6.50S 1968 to No MODEL and 1971 MODEL to 1972 MODEL MODEL to 1975 MODEL MO DEL to 1979 MODEL 70HP 1979 to 1983 MODEL 60HP 1984 to 1990 MO DEL.50HP 1986 to 1990 MODEL and 1975 To No STA TOR SERVICE CHOKE CIRCUIT AND ENRICHENER SYSTEM CRANKING MOTOR CIRCUIT & Operation - Pinion Gear with Rubber Cushion - Pinion Gear with Snap Ring or Nut - Pinion Gear with Top Spring CRANKING MOTOR REPAIR Dis ass em bling Testing Parts a Bosch a Delco Remy MODEL and 1979 MODEL and 1977 No and Above MODEL 80HP 1979 to 1983 MODEL 75HP 1984 to 86 MODEL 90HP Since 1987 MODEL 70HP, & 80HP 1987 to 1989 MODEL 75HP Since 1990 MODEL 50HP Since 1991 MODEL 60HP Since MODEL 100HP Since 1988 ALSO MODEL 115HP Since ELECTRICAL BATTERIES GA UGES AND HORNS Temperature Gauges Warning Lights Fuel Gauges Tachometer Horns ELECTRICAL SYSTEM General Information CHARGING CIRCUIT SERVICE Rectifier Rectifier REMOTE CONTROLS 8-1 STEERING SYSTEMS 8-1 DIRECTIONAL INDICA TOR 8-2 ROTARY STEERING SERVICE STANDA RD RIDE GUIDE KIT CUSTOM RIDE GUIDE KIT MERCONTROL PANEL EARLY MODEL 8-11 MERCONTROL BOX LATE MODEL COMMANDER CONTROL BOX & & 8-26 CABLE ADJUSTMENTS POWER TRIM/TILT 9-1 Chapter Organizadon 9-2 MECHANICAL TILT PIN 9-2

4 9 POWER TRIM/TILT (Continued) SYSTEM "A" - MODELS WITH TWO TRIM/TIL T CYLINDERS &: Operation Special Instructions Bleeding Trim Switch Service Service System "A" Hydraulic Pump Service Electric Motor Service SYSTEM "B" - MODELS WITH TWO TRIM CYLINDERS AND ONE TILT CYLINDER &: Operation Bleeding Flushing &: Manual Release Valve Oil Reservoir Cover Trim Cylinders Tilt Cylinder Motor &: Pump Cleaning &: Inspecting &: Pump &: Motor Tilt Cylinder Trim Cylinders Reservoir Cover Manual Release Valve System 10 LOWER UNIT DESCRIPTION CHAPTER COVERAGE TROUBLESHOOTING REMOVAL - ALL UNITS Propeller WATER PUMP SERVICE and High Pressure Type Pump High Volume Type Pump SERVICING CAM~SHIFT TYPE I UNITS MATCHED WITH EARLY 3-CYLINDER POWERHEADS TO ABOUT Bearing Carrier and Propeller Shaft Driveshaft &: Bearing Forward Gear &: Bearing D isassemb ling Bear ing Carrier Propeller Shaft Driveshaft Lower Driveshaft Bearing Shift Shaft Bear ing Carrier Forward Gear &: Bear ing Forward Bearing Race Driveshaft Shimming &: Backlash Pinion Gear Depth Forward Gear Backlash &: Bear ing Carrier Reverse Gear Backlash SERVICING CAM-SHIFT TYPE II UNITS MATCHED WITH LATE 3- and 4-CYLINDER POWERHEADS SINCE ABOUT and Bearing Carrier Propeller Shaft Shift Shaft Pinion Gear Driveshaft Forward Gear P inion Gear Bear ing Race Forward Bearing Race Driveshaft Bearing and Driveshaft Bearing Pinion Gear Bearing Race Forward Gear Bearing Race Shift Shaft Forward Gear Driveshaft Pinion Gear Propeller Shaft Bear ing Carrier Pinion Gear Depth Forward Gear Backlash WATER PUMP ASSEMBLING AND INSTALLA TION High Pressure Type Pump Shimming (Certain Units) High Volume Type Pump CLEANING AND INSPECTING ALL UNITS LOWER UNIT INSTALLA non Filling Lower Unit Exhaust Tube Propeller 10-64

5 11 HAND REWIND STARTER TYPE "A" (See Introduction) and Cleaning and Inspecting and PROPELLER SERVICE POWER TRIM/TILT INSIDE THE BOAT LO\\'ER UNIT WINTER STORAGE Units With Oil Injection Battery Storage Type 1'8" (See Introduction) and Cleaning and Inspecting and 12 MAINTENANCE OUTBOARD SERIAL NUMBERS 12-2 LUBRICATION - COMPLETE UNIT 12-2 PRE-SEASON PREPARATION 12-3 Units With Oil Injection 12-4 All Units 12-5 FIBERGLASS HULLS BELOW WATERLINE SERVICE SUBMERGED ENGINE SERVICE Salt Water Submersion Fresh Water Submersion APPENDIX METRIC CONVERSION CHART A-I ENGINE SPECIFICATIONS AND TUNE-UP ADJ. A-2 thru A-12 REED STOP OPENING A-13 CARBURETORJETS~E/ ELEVATION CHART A-14 LOWER UNIT BACKLASH TABLE A-16 LOWER UNIT OIL CAPACITY AND GEAR CHART A-17 PISTON & CYLINDER SPECIFICA TIONS A-18 WIRE IDENTIFICATION DWGS. Igni tion Systems A-19 thru A-39 Power Trim/Til t A-40 Remote Controls A-43 Console Wiring A-47

TABLE OF CONTENTS 3 MAINTENANCE

TABLE OF CONTENTS 3 MAINTENANCE TABLE OF CONTENTS 1 SAFETY " FUEL 1-1 CLEANING, WAXING, &: POLISHING 1-1 CONTROLLING CORROSION 1-1 PROPELLERS 1-2 FUEL SYSTEM 1-7 LOADING 1-9 HORSEPOWER 1-10 FLOTATION 1-10 EMERGENCYEQUWMENT 1-12 COMPASS