This manual can be used by anyone from a first time owner/amateur to a professional technician. It provides easy to read type and all the information needed to perform procedures correctly. Keeping this shop manual handy and using it often will help in performing routine, preventive maintenance, saving time and money by preventing premature failure and unnecessary repairs.
Safety first / Basic hand tools / Test equipment / Service hints / Special tips / Mechanic's techniques
CHAPTER THREE / TROUBLESHOOTING
Operating requirements / Starting system / Choke solenoid or fuel primer valve circuits / Alternator charging system / Ignition system / Magneto ignition system / Battery breaker point ignition system / Prestolite magneto capacitor discharge ignition / Thunderbolt capacitor discharge ignition / Breakerless ignition module (BIM) system / Sem walbro capacitor discharge ignition / Capacitor discharge module (CDM) ignition / Ignition switch / Fuel system / Power head
CHAPTER FOUR / LUBRICATION, MAINTENANCE AND TUNE-UP
Lubrication / Storage / Complete submersion / Anticorrosion maintenance / Engine flushing / Tune-up / Compression check / Cylinder head bolt torque / Spark plugs / Gearcase and water pump check / Fuel system service / Breaker point ignition system service / Battery and starter motor check (electric start models) / Wiring harness check / Engine synchronization and adjustment / Performance test (on boat)
CHAPTER FIVE / ENGINE SYCHRONIZATION AND LINKAGE ADJUSTMENTS
Engine timing and synchronization / 4, 5, 7.5, 9.9 and 15 hp models / 25 hp 2-cylinder and 35 hp models / 25 hp 3-cylinder models / 40, 50 and 60 hp models / 70-150 hp models (including L-drive)
CHAPTER SIX / FUEL SYSTEM
Fuel pump / Carburetors / Carburetor removal/installation / Carburetor disassembly, reassembly and adjustment / Carburetor cleaning and inspection / Core plugs and lead shot / Reed valve assembly / Choke solenoid / Primer valve / Integral fuel tank / Portable fuel tank / Fuel hose and primer bulb / Fuel recirculation system
CHAPTER SEVEN / IGNITION AND ELECTRICAL SYSTEMS
Battery / Alternator charging system / Electric starting system / Starter motor system / Ignition systems / Breaker point magneto ignition / Battery breaker point ignition / Prestolite magneto CD ignition / Thunderbolt capacitor discharge ignition / Breakerless ignition module (BIM) / Sem-walbro ignition system / Capacitor discharge module (CDM) ignition (40-120 hp models)
CHAPTER EIGHT / POWER HEAD
Force model numbering system / Fasteners and torque specifications / Power head removal/installation / Power head disassembly / Power head cleaning/inspection / Piston and connecting rod / Connecting rod and crankshaft / Cylinder block and crankcase assembly
