Maintenance • Troubleshooting • Repair

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CHAPTER ONE GENERAL INFORMATION TOOLS, FASTENERS AND SAFETY EQUIPMENT General tools Mechanic’s tips Tools for painting and refinishing Corrosion Fastener materials Fastener types Safety equipment TROUBLESHOOTING Electrical components Preliminary inspection Starting difficulty Electric starting system Fuel system Ignition system Warning system Charging system Power head Cooling system Gearcase Trim tilt system Electronic fuel injection EFI system Specifications LUBRICATION, MAINTENANCE AND TUNE-UP Before each use After each use Routine maintenance Fuel requirements Lubricants Power head maintenance Gearcase maintenance Midsection maintenance Tune up Storage preparation and recommissioning Submersion Corrosion prevention Oil change Air filter Lube Valve clearance adjustment measurement Timing Specifications LAY-UP, COOLING SYSTEM SERVICE AND FITTING OUT SYNCHRONIZATION AND ADJUSTMENTS Engine timing Synchronizing Required equipment Mariner 2 Mariner 3.5 Mariner 4 and water-cooled 5 Mariner 5 air-cooled Mariner 8A and 8B Mariner 8 hp 1985-1987 Mariner 9.9 and 15 magneto ignition Mariner 9.9 and 15 CDI except 1987-on 9.9 and 1989 15 Mariner 8 1988-on, 9.9 1987-on and 15 1989 Mariner 20, 25 and W25 magneto ignition Mariner 20, 25, W25, 30 and W30 CDI except 1985-on 20 Mariner 20 and 25 hp 1985-on with WMC carburetor Mariner 28 Mariner 40A, 40B and W40 magneto ignition Mariner 40B and W40 CDI, single carburetor Mariner 40B and W40 CDI, dual carburetors Mariner 48 CDI Mariner 45 hp 1986-on and 50 hp through 1985 with alternator-driven CDI Mariner 60 hp with CDI 1976-1983 Mariner 70 hp, 1984-on 60 hp and 1986-on 40 hp with alternator-driven CDI 1987-on Mariner 75 and 90 Mariner 90, 115 and 140 hp with distributor CDI Mariner 1988-on 100 and 1989 115 with flywheel CD ignition Mariner V135, V150, V150 Magnum, V150 Magnum II, V175 serial no. 6618751 and above and V200 serial no. 6655032 and below hp Mariner V200 serial no. 6655033 and above Mercury 3.5 and 3.6 hp Mercury 40 and 2-cylinder 4 hp with Thunderbolt breakerless ignition Mercury 45, 4.5 and 4 1986-1987 Merc model 40, 75, and 110 with Phase-maker ignition Merc 4 and 5 hp 1988-on Merc model 75 and 7.5 hp through serial No. 5226934; Merc model 110 and 9.8 hp through serial No. 5206549 Mercury 7.5 hp above serial No. 5226934; Mercury 9.8 hp above serial No. 5206549 Mercury 6, 8, 9.9 and 15 hp Mercury 18 and 25 hp 1979-1984 Mercury 18, 20 and 25 hp with WMC carburetor Mercury 200 with Phase-maker ignition Merc model 200 and 20 hp with Thunderbolt breakerless ignition Merc model 402, 35 and 40 hp 2.5 and 3.3 hp models 4 and 5 hp models 6, 8, 9.9 and 15 hp models 20-25 hp and 20 Jet models 30 and 40 hp 50-60 hp and 45 Jet models Johnson Evinrude 2 hp, Colt and Junior breaker point ignition 1973-1978 Johnson Evinrude 4 breaker point ignition Johnson Evinrude 2.5, 3 hp, 4 Standard, Excel 4, Ultra 4, 4 Deluxe, 4.5 and 7.5 CD 2 and CD2UL ignition 1976-1977 Johnson Evinrude 6 1978-1985 Johnson Evinrude 5, 6, and 9 CD 2 ignition 1986-1990 Johnson Evinrude 6 and 8 CD 2 and CD2UL ignition Johnson Evinrude 9.5 breaker point ignition Johnson Evinrude 9.9 and 15 breaker point ignition Johnson Evinrude 9.9 and 15 CD 2 and CD2UL ignition Johnson Evinrude 18, 20 and 25 breaker point ignition Johnson Evinrude 20, 25, 28 and 30 CD 2 and CD2UL ignition Johnson Evinrude 35 all ignitions Johnson Evinrude 40 breaker point ignition 1985-1988 Johnson Evinrude 40 hp tiller models CD 2 models 1985-1988 Johnson Evinrude 40 hp remote control models CD 2 ignition 1989-1990 Johson Evinrude 40 hp modles CD2UL ignition Pilot screw adjustment Linkage, throttle position sensor, carburetor synchronization and idle speed adjustments Ignition timing check Throttle cable adjustment Shift cable adjustment Valve adjustment Trim tab adjustment Trim position sender adjustment Dashpot Yamaha 2 3 4 56 89.9 1525 30 40 50 7090115 130150 175 200 220 225 Specifications INLINE ENGINES V4 V6 V8 GM GENERAL MOTORS CHEVY CHEVROLET FORD MERCRUISER 60 80 90 470 485 488 170MR 190MR VOLVO PUSHROD VOLT OVERHEAD CAM 3.0 LITER 4 FOUR 4.3 5.0 5.7 5.8 7.4 8.2 LITER CYLINDER ENGINES Engine serial numbers Special tools Replacement parts Engine removal Engine installation Disassembly checklist Rocker arm cover Intake and exhaust manifolds Front cover and seal Rocker arm assemblies Camshaft Oil pan Oil pump Cylinder head Valves and valve seats Piston connecting rod assembly Crankshaft Flywheel Cylinder block Core plugs ELECTRICAL AND IGNITION SYSTEM Battery Starting system Charging system Ignition system Warning system components Phelon magneto braker point ignition Kiekhaefer 4-cylinder Kiekhaefer 6-cylinder Thunderbolt breakerless battery ignition Lighting energizer breakerless ignition Thunderbolt Phase-maker CD ignition Thunderbolt CD breakerless ignition Lightning energizer ignition Optimax ESA module switches OIS2000 ignition system CD1 CD2 CD3 CD4 CD6 CD8 CD 1 2 3 4 6 8 CD2USL ignition Delco HEI Delco EST Prestolite integral BID ignition DT 2 7.5 8 15 20 80 140 225 Yamaha microcomputer ignition system YMIS FUEL SYSTEM Fuel system service Fuel tank Fuel hose Fuel filter Primer bulb Mechanical fuel pump Silencer cover Intake manifold Dashpot Electrothermal valve Carburetor Throttle body Vapor separator tank Secondary vapor separator tank Low-pressure electric fuel pump Fuel pump relay Fuel pump driver Fuel cooler Fuel pressure regulator Fuel rail and injectors Idle air control motor Air temperature sensor Air pressure sensor Throttle position sensor 2-48 hp carburetors Throttle plunger carburetor Mariner 2A 2B Mikuni BV 18-14 carburetor Mariner 3.5 hp Throttle plunger carburetor Mariner 15A, 15B, W15 Downdraft carburetor Mariner 8 8A Integral fuel pump carburetor Center bowl carburetor Mariner 40 hp 48 hp Integral fuel pump carburetor with primer system Model 100 and model 115 Concept 2 + 2 Dual-float center bowl carburetor Side bowl and back drag carburetor WME carburetor Electronic fuel injection EFI Enrichener valve and choke solenoid systems Anti-siphon devices Water-separating fuel filter Fuel tank Fuel line and primer bulb Throttle plunger carburetor Integral fuel pump carburetor Integral fuel pump carburetor with primer system 8-25 hp models WMA carburetor MerCarb center bowl carburetor WME carburetor WMH carburetor MerCarb center bowl carburetor Thermal air valve Enrichment valve and choke solenoid systems Anti-siphon devices Merc model 39, 40, 60, 75 and 110 1970 Merc model 40, 75 and 110 with Thunderbolt ignition Merc model 110 with Phase-maker ignition Merc model 200 with Thunderbolt ignition Phase-maker ignition Merc model 350 Merc model 400 Merc model 500 Merc model 650 with lighting energizer ignition Merc model 650 Merc model 650 800 850 with Thunderbolt breakerless ignition Merc model 950 and 1100 Standard ignition Merc model 950SS 1100SS Thunderbolt breaker point ignition Merc model 500SS 650SS 950SS 1100SS 1967 Thunderbolt breakerless ignition Merc model 1000SS 1250SS Thunderbolt breakerless ignition Merc model 1150 1350 Integral fuel pump carburetor Integral fuel pump carburetor Centerbowl carburetor Sidebowl carburetor 3.5 and 3.6 hp carburetor Integral fuel pump carburetor with primer system Integral fuel pump carburetor Sight bowl fuel filter WMC series carburetor TR and SV carburetor Minlon carburetors FICHT FUEL INJECTION FFI Governor Specifications THROTTLE BODY FUEL INSPECTION TBI Gasoline Fuel injection components operation Depressurizing the fuel system diagnosis Troubleshooting Fuel injection pump Vapor separator tank and fuel injection pump Fuel lift pump Fuel injection pump relay System relay Fuel pressure regulator Throttle position TP sensor Manifold absolute pressure MAP sensor Fuel injectors and fuel metering body Throttle body Idle air control IAC valve Engine coolant temperature ECT sensor Engine control module ECM Antisiphon devices MULTIPORT FUEL INJECTION MPI Fuel injection system operation Depressurizing the fuel system Throttle body Plenium Fuel injectors and fuel rails 350 Magnum 454 Magnum 502 Magnum 7.4LX Electric fuel pump vapor separator tank Fuel lift pump Fuel pressure regulator Fuel injection pump relay System relay Throttle position TP sensor Manifold absolute pressure MAP sensor Idle air control IAC valve Engine coolant temperature ECT sensor Engine control module ECM Intake air temperature IAT sensor Antisiphon devices Fuel lines OIL INJECTION SYSTEM AutoBlend II Constant-ratio oil injection Injection system service Variable-ratio oil injection Warning horn system Injection system service Variable-ratio oil injection Warning horn system Injection system service Accumix R oil injection system VRO2 OMC Economixer OMC VRO system HULL MAINTENANCE Synthetic paint systems Maintaining wood Maintaining aluminum Maintaining steel Maintaining fiberglass OUTBOARD MOTORS Shop manual Four-stroke fundamentals Two-stroke fundamentals Daily care Proper fuel selection Proper engine oil selection 4-strokes Proper engine oil selection 2-strokes Premixing fuel 2-strokes Consistent premixing Oil injection system 2-strokes Other lubricants Engine flushing Shear pin replacement Lubrication Anticorrosion maintenance Tune-up Troubleshooting Propellers Accidental immersion Lay-up and storage Recommissioning MERC THRUSTER ELECTRIC OUTBOARDS Lubrication Periodic maintenance Battery Propeller Electrical troubleshooting Electrical component testing Electrical component testing rotary switch models Lower unit Control housing STERN DRIVE AND INBOARD ENGINES Shop manual Basic engine systems Fuel requirements gasoline Proper engine oil selection Pre-operational checks Starting check list Post-operational checks Periodic maintenance Gasoline engine tune-up Compression test gasoline engines Ingition service Carburetor service gasoline engines Diesel engine tune-up Cooling system flushing Engine troubleshooting Winter lay-up storage POWER HEAD Flywheel cover Timing belt and tensioner Crankshaft pulley Valve cover Camshaft, timing chain and camshaft pulley Cylinder head removal and installation Water pressure relief valve Thermostat Exhaust water jacket cover Cylinder head Power head Oil pump Crankshaft pulley Power head Cylinder block components Bearing selection Engine break-in procedures Specifications MIDSECTION Lower motor mount Tilt tube Clamp bracket Tilt lock lever Oil pump Upper motor mount Swivel tube Swivel housing Power head adapter Exhaust silencer Exhaust tube Oil pressure relief valve Oil pan and oil pickup tube Drive shaft housing Specifications INTERMEDIATE HOUSING AND TRANSOM SHIELD BRACKET Intermediate housing DP-C1 D1 and DPX models Transom shield DP-C1 D1 and DPX models Transom bracket SX and DP-S models GEARCASE Gearcase operation Gearcase identification Propeller Gearcase removal and installation Water pump Gearcase Inspection MANUAL STARTER Removal, disassembly, assembly and installation POWER TRIM AND TILT Power trim system Fluid filling Air bleeding Midsection One-ram integral power trim system Three-ram integral power trim system One-ram oildyne power trim system SelecTrim Tilt HYDRAULIC TRIM REMOTE CONTROL Cable removal and installation Remote control disassembly and assembly STERN DRIVE AND INBOARD DRIVE UNITS Shop manual Standard installation V-drive installation Stern drive installation Inboard final drive maintainance Mercruiser stern drive early model I Mercruiser stern drive late model I Mercruiser stern drive model II Mercruiser stern drive model II-TR, 215, III Mercruiser stern drive Alpha One except Generation II Mercruiser stern drive Alpha One Generation II, Bravo One and Bravo Two OMC stern drive Omc Cobra stern drive Volvo stern drive Yamaha stern drive Jacuzzi jet drive maintenance Winter lay-up or storage Propellers MERCRUISER DRIVE SYSTEM MerCruiser Model O MerCruiser Model I MerCrusier Model II non-transom mounted MerCruiser Model II transom-mounted models MerCruiser II-TR, II-TRS and 215-H MerCruiser 215-E ELECTRICAL SYSTEM Battery systems Battery chargers Power inverters Bonding Lighting Shore power Auxiliary power plants Repairing and splicing wiring Making a wiring diagram Power plant lay-up Battery lay-up Fuel pump relay Electronic fuel injection EFI system relay Oil pressure sender Oil pressure switch Coolant temperature sender Coolant temperature sensor Engine overheat switch Manifold air pressure sensor Intake air temperature IAT sensor Throttle position sensor TPS Idle air control motor IAC Idle speed control solenoid ISC Knock sensor KS Knock sensor module Knock sensor amplifier Engine control unit ECU Engine control assembly ECA MARINE ELECTRONICS Typical radio installation Other receiving equipment Noise interference in electronic equipment Preventive maintenance Soldering Repairing and splicing wire Replacing a transmission line Coaxial cable connectors Emergency antenna VHF Using a multimeter Engine instruments Navigational instruments GALLEY Cooking fuels Alcohol kerosene systems LPG systems Stoves Optimus Primus alcohol and kerosene stoves Homestrand Kenyon alcohol stoves Homestrand kerosene stoves Propane marine stoves Converting to bulk LPG Ice box Refrigerators Norcold model MRFT 614 Norcold model DE-250 Norcold model DE-250A Norcold model DE-250C Norcold model DE-251A Norcold model DE-400 FRESH WATER SYSTEMS Simple water systems Pressurized water systems Water tanks Sanitizing water systems Purifying potable water Automatic water pumps Par pumps Jabsco pumps Water faucets Water heater Troubleshooting Lay-up HEADS Toilets Typical systems Thetford portables Thetford Electra Magic Thetford Aqua-Magic Galaxy, Starlite Thetford Aqua-Magic IV Monogram Handiheaad II Monogram Monomatic II Sealand Mansfield vacu-flush Sealand Mansfield 911-912-M28 Raritan crown head Raritan compact, PH, PHE< PHII and PHEII Ball-head Holding tanks Waste treatment systems Recirculating systems ELECTRIC MOTORS Lubrication Periodic maintenance Battery Propeller 1975-1981 12 volt bow mount model 1982-on 12 volt bow mount model 1975-1976 12 volt transom mount model 1982-on 12 volt transom mount model 1975-1981 12 24 volt vow mount model 1982-on 12 24 volt bow mount model 1975-1976 12 24 volt transom mount model 1980-1981 12 24 volt hand control model 1982-on 12 24 volt hand control model SEA DRIVES Selectrim 1.6 Sea Drive Selectrim tilt 2.0, 3.0 and 4.0 Sea Drives JET DRIVES Maintenance Water pump Jet drive Bearing housing Intake housing liner GEAR HOUSING Service precautions Model I drive Model II drive Model II-TR and II-TRS gear housing Model I-MR drive Alpha One drive Bravo One and Bravo Two drive Bravo Three DRIVE SHAFT HOUSING Service precautions Model I drive Model II Model II-TR and II-TRS drive Alpha One and Alpha One Generation II drive Bravo One, Bravo Two and Bravo Three drive BELL HOUSING , GIMBAL BEARING AND GIMBAL RING I-drive bell housing II-TRS bell housing Gimbal bearing Gimbal ring CORROSION PROTECTION SYSTEMS Corrosion Sacrificial anodes Continuity devices Galvanic isolator MerCathode system Corrosion protection set FORK AND MOUNTING COLLAR Intermediate housing and steering fork Mounting collar transom shield TRAILERS AND TOWING Trailer weight Hitches Sway controls Lighting Trailer inspection Trailer frame Tires and wheels Wheel bearings Bearing protectors Trailer brakes Electric brakes Hydraulic brakes Tow vehicle COLOR WIRING DIAGRAMS schematics SPECIFICATIONS torque Clymer not a free download downloadable pdf or html