Johnson 737 Part Catalog

Service
Manual
40 THRU 55
t:~!1
[ EVlnRUDE
DUTBDARDS
1992 OUTBOARD MARINE CORPORATION. PRINTED IN USA
it Safety Warning
This Service Manual will alert you to certain procedures

that must be done very carefully. If you ignore this
information, you could ...
e Injure yourself or people around you

elnjure the boat operator, boat passengers, or
people around the boat
e Damage the outboard or its systems
Understand the following symbols before proceeding:

Alerts you to the possibility of danger and
it 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 OMC
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 OMC Service Tools are called for, use them.

Where mentioned, the tools are required to perform the
service procedu reo
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
Remote Control
Power Trim
Safety
45C 1
INDEX
Topic Service Manual Title Page
Air Bleed Orifices Carburetor Orifice Plug Chart 1-47
Alcohol in Gasoline Fuel Requirements 1-22
Anodes Anodes - Testing and Replacement 1-34
Anti-Siphon Valve Testing VRO~ System 2-24
Battery Cable Extensions Battery Cable Extensions 8-4
Battery Charging Battery Specifications 8-4
Battery Recommendations Battery Specifications 8-4
Battery Testing Battery Specifications 8-4
Break-In Procedure Break-In Procedure 1-27
Compression Check Tune-up Procedure 1-32
Core Plug Carburetor Servicing 2-37
Double Firing Indexing Flywheel, Erratic Ignition 3-23
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 Line Diameter Boat Fuel System Recommendations 2-22
Fuel Oil Mixture Fuel/Oil Ratios 1-20
Fuel Primer Primer System Servicing 2-16
Fuel Pump Pressure Fuel Pump Servicing 2-14
Fuel System Vacuum Test . VRO~ Com ponent Servici ng 2-29
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 1-50
High Altitude Operation Weather, Altitude and Engine Performance 1-26
High Performance Oil Ratios Fuel/Oil Ratios 1-20
Hydrostatic Seal Rings Cleaning and Inspection 6-5
Idle RPM Engine Specifications Section 1
Ignition Timing Synchronization and Linkage Adjustments Section 1
Jet Chart Carburetor Orifice Plug Chart 1-47
Key Switch Check Key Switch Check 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 45c/eng
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 1-47
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
Pulse Limiter Fitting VRO~ Component Servicing 2-29
Pyrometer Engine Temperature Check 4-5
RPM Limit Engine Specifications Section 1
Sending Unit - Temperature Temperature Switch Test 4-7
Sending Unit - TNT Unit Trim Sending Unit Adjustment Section 10
Severe Service Oil Ratios Fuel/Oil Ratios 1-20
Shift Cable Installation Installation of Cables Section 9
Shift Rod Heights Service Specifications 6-3
Spark Plugs Spark Plug Information 3-7
Spark Test Ignition Output Test Section 3
Starter Rope Length Starter Servicing Section 7
Storage Mixture Off-Season Storage 1-28
Submerged Engines Submerged Engines 1-35
Summarize 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 Stiks Engine Temperature Check 4-5
Thermostat Powerhead Servicing 4-11
Throttle Cable Installation Installation of Cables Section 9
Timing Synchronization and Linkage Adjustments Section 1
Trim Tab Trim Tab Adjustment 6-42
Tune-up Procedures Tune-up Procedure 1-32
Vacuum Test - Gearcase Gearcase Servicing - Assembly Section 6
Vacuum Test - Fuel VRO~Component Servicing 2-29
Verifying Fuel/Oil Ratio VRO~ Component Servicing 2-29
Voltage Drop Test Starter System Voltage Drop Test 8-12
Warning Horn Signals Description of Remote Control 9-4
Warning Horn Tests Warning Horn Test 1-30
Water Pump Water Pump Servicing 6-6
Winterization Off-Season Storage 1-28
45c1e ng 3
Outboard Models Covered in This Service Manual
25 Models
E25DRLET J25DRLET
E25DELET J25DELET
E25DTLET J25DTLET
E25DRET J25DRET
.E25DEET J25DEET
40 Models
E40RET 40RSW J40RET
E40RLET 40RSLW J40RLET
E40BAET 40RSYW J40BAET
E40BALET J40BALET
E40EET J40EET
E40ELET J40ELET
E40TEET J40TEET
E40TELET J40TELET
E40TLET J40TLET
E40TTLET J40TTLET
45 Models
45RSO
45RSLO
45RSYO
45RCET
45RCLET
48 Models
E48ESLET J48ESLET
50 Models
E50BEET J50BEET
E50BELET J50BELET
E50TELET J50TELET
E50TLET J50TLET
E50JET J50JET
55 Models
55RWLET
55RSK
55RSLK
55RSYK
4 45c/eng
General Information
Table of Contents
General Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . .. 1- 2

Service Specifications ........................... . . 1- 3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1- 4
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1- 7
Engine Specifications
40, 48, 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 8
40 Comm ............... . ....... .. ...... ..... . 1-10
45 and 55 Comm ......................... . ..... 1-12
Gearcase Lubrication - All Models . . . . . . . . . . . . . . . . . .. 1-15
Steering System Lubrication - Remote Electric Models ... 1-15
Lubrication Chart
40,48, 50 ............................... ... ... 1-16
45 and 55 Comm ............................... 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
Warning Horn Test ............. . ................. 1-30
Preseason Service . ............ . .. . ............... 1-31
Tune-Up Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-32
Anodes - Testing and Replacement. . . . . . . . . . . . . . . . . .. 1-34
Submerged Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-35
Synchronization and Linkage Adjustments
40,48, 50 ..................................... 1-37
45 and 55 Comm. ... . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-42
20-Hour Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-46
Carburetor Orifice Plug Chart . . ......... . ........... 1-47
Drill Size Conversion Chart. . . . . . . . . . . . . . . . . . . . . . . .. 1-49
Heli-Coillnserts and Installers . . . . . . . . . . . . . . . . . . . . .. 1-50
45C/eng 1-1
it 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 substance 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 45C/eng
Service Specifications
Standard Torque Chart _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Size In. Lbs. Ft. Lbs. Nm
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
V4 in. 60-80 5-7 7-9
5116 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
PCE0023
R 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.
~ 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 _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
OMC Hi-Vis@ Gearcase Lubricant

OMC Triple-Guard@ Grease
Evinrude@ Outboard Lubricant
Johnson@ Outboard Lubricant
OMC 2 + 4@ Fuel Conditioner
OMC Carbon Guard Fuel Additive
OMC Storage Fogging Oil
OMC Starter Pinion Lube
OMC Engine Tuner
45C/eng 1-3
Introduction
This manual covers service information on 45 cu . in. (737 cm 3 )
models. Some of the information might apply to previous mod-
els.
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 va lues and dimensions second, inside parentheses O.
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, lubrication,
and care under special operating conditions such as salt
water and cold weather. This includes engine servicing
procedures to keep the engine in prime operating condi-
tion.
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 itquickly,
with minimum expense to the owner.
When repairing a component, the most reliable way to ensure a

good job is to do a complete overhaul on that component, rather
than just replacing the bad part. Wear not readily apparent on
other parts could cause a malfunction soon after the repair job.
Repair kits and overhaul kits contain all the parts needed to
ensure a complete repair, to eliminate guesswork, and to save
time.
Repair time can also be minimized by the use of special tools.

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.
r::-=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 45C1eng
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.
45C/eng 1-5
Service Policy
When servicing an outboard which is within its normal warranty

period or covered by the OMC 1+2@ Extended Protection Plan,
make repairs using only genuine OMC replacement components
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

i l l 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 while in the boat and facing forward; PORT means on the
left.
& Safety Related 1-6 45C/eng

1 2 3 DR2065 DR2066 L......---'-- - - - - - - - - D = = R = 4 2 = - ' 0
3
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.

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

light, to test continuity.
f31 When " 00" shows on the meter face, no continuity, or very high
~ resistance, is indicated. The symbol is referred to as infinity.
f41 When "y" follows a value on the meter face, the procedure is
L!J measuring voltage.
Isl When "0" follows a value on the meter face, the procedure is
t.=.I measuring resistance. 0 is the symbol for ohm, the unit of DR4205
measurement for resistance.
Values
f61 When "-:::;," precedes a value on the meter face, it indicates

~ your reading should be less than, or equal to, the value shown.
rJl When "'2:." 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
45C/eng 1-7
250,40,48,50
Operation _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Full Throttle Operating Range 4500 to 5500 RPM
Power 250 - 25 HP (18,4 kw)

40 - 40 HP (29,8 kw)
48 - 48 HP (35,8 kw)
50- 50 HP (37,0 kw)
Power Rated @ 5000 RPM
Idle RPM in Gear 750 25
Test Propeller 250 - OMC PIN 433638

40 thru 50 - OMC PIN 432968
Minimum Test RPM 250 - 5000

40 - 4900
48,50 - 5200
Weight R, E, TE - 180 Ibs. (81,1 kg)

RL, EL, TL, TEL - 185 Ibs. (84,0 kg)
Powerhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .
Type In-line 2-Cylinder
Displacement 45 cu. in. (737 cm 3 )
Bore 3.1875 in . (80,96 mm)
Stroke 2.820 in. (71,63 mm)
Standard Bore * 3.1870-3.1880 in. (80,95-80,98 mm)
Crankshaft Dimensions:
Top Journal 1.4974-1.4979 in. (38,03-38,04 mm)
Center Journal 1.3748-1.3752 in . (34,92-34,93 mm)
Bottom Journal 1.1810-1.1815 in. (30,00-30,01 mm)
Rod Crankpin 1.1823-1.1828 in. (30,03-30,04 mm)
Piston Diameter, Standard See Section 4
Piston Ring End Gap, Both 0.007-0.017 in. (0,18-0,43 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 4 5C
Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .
Gear Ratio 12:29 (0.414)
Lubricant OMC Hi-Vis Gearcase Lubricant
Capacity 16.4 fl. oz. (485 m I)
Shift Rod Height R, E, TE - 1615116 %2 in. (430,3 0,8 mm)

RL, EL, TL, TEL - 21 15116 1/32 in . (557,3 0,8 mm)
Shift Cable Stroke See Page 6-3

Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ._
Type Magneto Powered Capacitor Discharge
ModulelPower Pack RPM Limit 6700

250R, 40R, 48 - 6100
Ignition Coil OMC PIN 583740

Spark Plug, Champion
Sustained
Model Recommended Alternate High Speed Alternate
25D,40, OL78C@ 0L16V @ L16V @

NA
48, 50 0.030 in. (0,8 mm) FIXED GAP FIXED GAP
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .
Battery, Minimum Recommendation 360 CCA @ 0 F (72 Ampere-hours @ -18 C)

and 115 Minutes Reserve @ 80 F (2r C)
Alternator 12-Amp, Fully Regulated
250; 48 - 4-Amp, Non-Regulated
Tachometer Setting 12-Amp - 6

4-Amp - 5
AC Model 60 Watts
Engine Fuse (20-Amp) 12-Amp - OMC PIN 514021
4-Amp - OMC PIN 510884
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
FuellOil Ratios See Page 1-20
Fuel Requirements See Page 1-22

Carburetion Two Single-Throat Carburetors, Float Feed
Calibration Adjustable Low Speed, Fixed Intermediate and High Speed
Starting Enrichment T, E, TE - Electric Primer
R - Manual Primer
Float Level Setting OMC Float Gauge, PIN 324891
Float Drop Setting 1%-15fe in. (28-41 mm)
45C/eng 1-9
40 Comm.
Operation _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Power 40 HP (29,8 kw)
Test Propeller OMC PIN 432968
Minimum Test RPM 5200
Weight RS - 180 Ibs. (81,1 kg)

RSL-185Ibs. (84 kg)
RSY - 188 Ibs. (86 kg)
Powerhead _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ___
Bore 3.1875 in. (80,96 mm)
Stroke 2.820 in. (71,63 mm)
Top Journal 1.4986-1.4991 in. (38,06-38,08 mm)
Center Journal 1.3745-1.3749 in. (34,91-34,92 mm)
1-1 45C1eng
Gearcase ................................................................... .
Gear Ratio 12:29 (0.414)
Capacity 16.4 fl. oz. (485 ml)
Shift Rod Height RS - 1615/16 1/32 in. (430,3 0,8 mm)

RSL - 21 15/16 1/ 32 in . (557,3 0,8 mm)
RSY - 247/ 16 1/ 32 in. (620,8 0,8 mm)
Shift Cable Stroke See Page 6-3
Ignition System ................_ .............................................
Power Pack RPM Limit 5800
Sustained
QL16V @ L16V @ QL78C @

40 Comm. NA
Fixed Gap Fixed Gap 0.030 in. (0,8 mm)
Electrical System _ .........................................................._
AC Model 60 Watts
FueISystem . ._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _..
Calibration Adjustable Low Speed, Fixed Intermediate and High Speed
Starting Enrichment Manual Primer
Float Drop Setting 1%-1% in. (28-41 mm)
45C/e ng 1-11
45 and 55 Comm.
Operation _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Power 45 - 45 HP (33,6 kw)

55 - 55 HP (41,0 kw)
Test Propeller OMC PIN 382861

Minimum Test RPM 5200
Weight R - 184 Ibs. (83,4 kg)

L - 191 Ibs. (86,6 kg)
V - 202 Ibs. (91,6 kg)
Powerhead _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ___
Bore 3.1875 in. (80,96 mm)
Stroke 2.820 in. (71,63 mm)
Top Journal 1.4986-1.4991 in. (38,06-38,08 mm)
Center Journal 1.3745-1.3749 in . (34,91-34,92 mm)
1-12 45C/eng
Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .
Gear Ratio 12:32 (0.375)
Capacity 22 fl. oz. (650 ml)
Shift Rod Height R - 1529/32 1/32 in. (404 0,8 mm)

L - 20 29/32 1132 in. (531 0,8 mm)
y - 23 13/32 1/32 in. (594 0,8 mm)
Ignition System ...............................................................
Power Pack RPM Limit 5800
Sustained
45, QL16V @ L16V@ QL78V @ L78V@

55 Fixed Gap Fixed Gap Fixed Gap Fixed Gap
Electrical System ............................................................. .
AC Model 60 Watts
Fuel System ..................................................................
Calibration 45 - Fixed Low and High Speeds

55 - Adjustable Low Speed, Fixed Intermediate and High
Speed
Starting Enrichment Manual Primer
Float Drop Setting 1%-1% in. (28-41 mm)
45C/eng 1-13
NOTES
1-14 45Cleng
Gearcase Lubrication - All Models
'" To avoid accidental starting of engine while servicing, twist

ill 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.
To refill, place a tube or pressure can nozzle of OMC Hi-Vis

gearcase lubricant in drain/fill hole.
fN=J If OMC Hi-Vis gearcase lubricant is not available, OMC

~ Premium Blend 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 then be installed securely without oil loss.
Tighten plugs to a torque of 60-84 in. Ibs. (7-9 Nm).
Steering System Lubrication - Remote Electric

Models
f11 '" The installer was instructed to grease the steering cable
~ i l l ram during installation. Once the engine is put into use,
periodic cleaning and regreasing with OMC Triple-Guard grease is
required. In fresh water usage, lubricate every 60 days; salt water
usage, lubricate every 30 days.
45C/eng & Safety Related 1-15

Lubrication Chart - 40, 48, 50
FREQUENCY
FIGURE LUBRICATION POINT LUBRICANT

FRESH WATER SALT WATER*
Change after first 20 operating hours.
[!] Gearcase
16.4 fl. oz. (485 mil
0
Check level every 50 operating hours.
Change every 100 operating hours
or once each season, whichever comes first.
~
Power TrimfTilt Reservoir
Capacity - 11.7 fl. oz. (345 mil e As Required
~ Starter Pinion Gear Shaft Helix (9 60 days 30 days
0 Trailering Lock (Port and
~
Starboard) Swivel Bracket
Tilt Tube, Upper Tilt Cylinder Rod

"e 60 days
60 days
30 days
30 days
~
Shift and Throttle
""
60 days 30 days
Shaft Fittings
0 Carburetor Linkage, Roller 60 days 30 days
~
Control Shaft Bushings and
"
60 days 30 days
Control Lever Bearing
* Some areas may require more frequent lubrications.
OMC OMC Hi-Vis@ OMCPower

OMC Starter
Triple-Guard@ Gearcase TrimlTilt and Power
Pinion Lube
Grease Lube Steering Fluid
HI-VIS
RAIlCASI
LUB.
~,
DR4247PCE0078
1-16 45C/eng
45CJeng 1-17
Lubrication Chart - 45 and 55 Comm.
FREQUENCY
FIGURE LUBRICATION POINT LUBRICANT
FRESH WATER SALTWATER t
Change after first 20 operating hours.
[1] Gearcase
22 fl. oz. (650 mL) e Check level every 50 operating hours.
Change every 100 operating hours
or once each season, whichever comes first.
[g]
@]
Swivel Bracket, Tilt Lever and Tilt
Lever Shaft
Tilt Bolt Bushings

60 days
60 days
30 days
30 days
~
~
Cover Latches Front and Rear
Control Shaft Bushings and

Control Lever Bearing
60 days
60 days
30 days
30 days
[]
[I]
Carburetor Linkage, Cam Follower
Trailering Lock
60 days
60 days
30 days
30 days
rID
Shift Shaft Fitting and Lever,
Tiller Steering Joint
t Some areas may require more frequent lubrications.

60 days 30 days
OMC OMC Hi-Vis@

Trip/e-Guard@ Gearcase
Grease Lube
HI'VIS
GIARCASE
LUBI
~
DR4Z63
1-18 45C
45C/eng 1-19
Fuel/Oil Ratios
Lubricant
Only the following lubricants should be used :
Evinrude Outboard Lubricant

Evinrude XP Outboard Lubricant
Johnson Outboard Lubricant
Johnson GT Outboard Lubricant
OMC 2-Cycle Motor Oil
They are formulated to give best engine performance with least

combustion chamber deposits, least piston varnish, maximum
spark plug life, maximum corrosion protection, and best lubrica-
tion.
If Evinrude or Johnson Outboard Lubricant or OMC 2-Cycle Motor

Oil is not available, another NMMA certified TC-W 3 oil may be
used. Look for the certification information on the container label.
~ Running or storing an engine on a leaner than recom-

~ mended fuel/oil mixture may result in powerhead damage.
~ Avoid 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
Oil and gasoline leaner than the recommended ratio
Some additives in EvinrudelJohnson Outboard Lubricant and

OMC 2-Cycle Motor Oil are subject to evaporation. Always cover
partially filled containers to prevent deterioration of lubricant.
Normal Service
All recreational engines not equipped with a VRO~

system require a 50:1 fuel/oil mixture.
All commercial engines not equipped with a VRO~ sys-

tem require 50:1 fuel oil mixture.
r:=J Any recreational or commercial engine equipped with

~ VRO~ system must use a 50: 1 fuel/oil ratio in the fuel tank if
the VRO~ featu re IS NOT USED.
If the VRO~ system ,is not used, follow this procedure.
Install protective cap, PIN 315391, over the oil inlet

fitting to protect the VRO~ pump. Secure with clamp,
PIN 322654.
Disconnect the VRO~ wiring harness. Seal engine har-

ness Amphenol connector with cover, PIN 335655.
1-20 45C/eng
High Performance
Any recreational engine, when used for high performance, re-
quires a 50: 1 fuel/oil mixture in the fuel tank along with the VRO
system. If the VROl system is not used, a 25: 1 fuel/oil mixture is
required in the fuel tank.
~ Models equipped with the optional AccuMix system will

~ require a 50:1 fuel oil mixture in the fuel tank in addition to
the lubrication supplied by the AccuMix system, when used in
high performance applications.
Severe Service
The fuel/oil ratio for recreational models is 50:1 (2% oil) when
used in commercial, rental, or extended severe service .
Fuel/Oil Mixing Instructions
~ To be used if engine's VRol or AccuMix automatic oiling

~ system is not desired.
'" Gasoline is extremely flammable and highly explosive un- 1

i l l der 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.
rvL!J into
Portable tank - Pour approximately 1 gallon (4 liters) gasoline
tank and add required lubricant. Replace filler cap se-
curely. Thoroughly mix by shaking tank. Add balance of gasoline.
f2l '" Built-in tanks - To prevent static spark, use a large metal"
~ i l l filter funnel as shown in figure. The fuel nozzle must
contact the metal funnel when filling the tank.
Two methods for refueling built-in tanks:
Mix the lubricant slowly with the fuel as the tank is filled .
Using a separate container, mix all the necessary lubri-

cant with 1 gallon (4 liters) of fuel and pour this mixture
slowly with fuel as tank is filled.
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) (1419ml)
25:1 16 flo oz. 32 fl. oz. 96 fl. oz.

(4% Lubricant) (473 ml) (946 ml) (2838 ml)
45C/e ng & Safety Related 1-21

PCE0025
Fuel Requirements
Minimum Octane
Models Recommendations (R+M)/2 "RON"

"AKI"
40RS,45,55 See fuel classifications below 67 69
40, 48,50 See fuel classifications below 87 90
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 alcohol by volume:
10% ETHANOL or
5% METHANOL with 5% cosolvents
R The use of premium grade fuels is specifically encouraged. Most national brand premium fuels
~ contain detergent and dispersant ingredients advertised to reduce intake valve and fuel injector
deposits. These ingredients also remove and prevent carbon buildup on pistons and rings. These
ingredients can extend engine life while maintaining a high level of performance.
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.

r::=J OMC 2+4@ fuel conditioner and OMC Carbon Guard " I 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.

New Engine Pre-Delivery Checks
Engine IModel
The careful preparation of an engine before delivery will ensure Reg ist ration I
owner satisfaction. Sold To
Name
1. Upon uncrating a new engine, inspect it. If you find: Address
Shipping damage - contact the carrier that delivered it City

Parts or connections are loose - repair as required
Purchase Dat I! Type of Use
Parts are missing - contact OMC OPJ easure OCommt OGovt
Sold By
Dealer Name
2. Check gearcase lubricant level. Fill to oil level hole.
Address
3. Install test wheel and put engine into test tank. City I Sta te I Z;p
Please T ype o r Print _ ~ ID ea ler Code

'" 4. Momentarily, pressurize the fuel system. Check for leaks!
~:~;r~=~::~a::~e:V:a9n~~~ I,o
'cc,-;-;C,h"'"--p:-.o7d
:-: u-,-",- -----'
i l l Repair any leaks before continuing.
Customer 's S ignature
5. Start engine and check cooling system operation. Be sure

engine warms to operating temperature at idle.
'" 6. C~eck shift operation. Check start-in-gear prevention on

i l l engines so equipped.
CAB5 2 4 8
'" 7. Check electrical and ignition systems for stray spark

i l l sources. DEALER RECORD CARD
8. Check all adjustments. See Synchronization and Linkage Owner's Name
Adjustments, this section. AdOres s
City State I"

Second Owner Name
9. With the engine at all trim angles, turn boat's steering wheel Address
fully right and left. Be sure there is no interference of the steering CtlV State ,"
Dale ot PUlchase Ignihon Ker No.
connector, remote control cables, and electrical cables at the SoaI Mrgr Hull No
boat's motor well. BoalModel BoalLellglh
Importanl: The Federal Boal Salety Act reqUires registration lists to be maintained on
product sales by manufacturer and OEALER . This i~ a standard card on which a
B
10. Correct any problems found. dealer can keep his records .
11. Clean entire engine.

12. Review Operator's Manual information, including owner's
responsibilities and engine requirements. OMC OWNER IDENTIFICATION CARD
Owner's
Name
13. Complete the paperwork: Address
Registration @ City State _ Zip _ _
Dealer's customer record Date of Purchase
Owner's identification card MODEL.. SERIAL..
45C/eng Safety Related 1-23

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
~ Ifthe propeller blades have too much pitch, the engine is
below its normal range at full th rottle ,
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.
1- Twist and remove all spark plug leads to avoid accidental

i l l starting while changing propellers.
& Safety Related 1-24 45Cleng

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.
45Cleng 1-25
Rated Power
Hot Weatherl
-------
High Altitude
....
Q)
~
o RPM
CL
~----------------------------~-----
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
rv~ 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.
1-26 45C/eng
Break-In Procedure
During the first 12 gallons of fuel you must use a 50:1 fuel/oil ratio in your fuel tank in addition to the
operation of the VRO~ Oil Injection System or AccuMix. After the 12 gallons offuel, check to see that the
oil level in the VRO~tank has changed, indicating that oil has been used before using unmixed gasoline
in the fuel system.
If the VRO~ system is disconnected or the engine is not equipped with a VRO~ or AccuMix system, you
must use a 25: 1 fuel/oil ratio in the fuel tank 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 10 Minutes _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Operate engine in gear at fast idle ONLY.

Verify water pump operation by looking for a steady stream of water at the water pump
indicator.
Next 50 Minutes _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _...
DO NOT operate engine above half throttle (no more than 3500 RPM).
DO NOT hold a constant throttle setting. Change engine speed every 15 minutes.
~ With easy planing boats, use full throttle to quickly accelerate boat onto plane. Immediately
~ reduce throttle to one-half as soon as boat is on plane. BE SURE boat remains on plane at this
throttle setting.
Second Hour _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _..
Use full throttle to accelerate boat onto plane, then reduce throttle setting to three-quarters.
BE SURE boat remains on plane at this throttle setting.
At intervals, apply full throttle for periods of one to two minutes, returning to three-quarters
throttle for a cooling period.
Change engine speed every 15 minutes.
INotel Verify water pump operation by looking for a steady stream of water at the water pump indicator.
Next Eight Hours _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ___
Avoid continuous full-throttle operation for extended periods.

Change engine speed every 15 minutes.
DO NOT exceed recommended maximum engine RPM. Refer to Specifications, this Section.
~ Retorque cylinder head screws after engine break-in period. Retorque after engine has been run
~ and cylinder heads have cooled to the touch.
45C/eng 1-27
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 + 4 fuel

conditioner. Add one ounce of OMC 2 + 4 fuel conditioner for
every gallon of gasoline.
~ 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

ill propeller before starting engine to prevent accidental con-
tact 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 eng ine "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 Johnson or Evinrude Outboard Lubricant
One pint OMC 2+4 fuel conditioner
4. Connect the tank containing the "storage mixture" to the

engine. Leave the oil supply hose line connected to the engine.
Run the engine on the "storage mixture" at approximately 1500
RPM for five minutes.
r.::=J Do not disconnect fuel hose or run VRO~ equipped engines

~ out offuel. Disconnecting fuel hose while engine is running
could cause excessive oil consumption and eventual hard start-
ing .
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

i l l 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 hazards; store all portable fuel tanks
i l l in a well ventilated area, away from any open flames.

~ 9. If the engine is removed from boat, carefully store the
ill special locknuts and lockbolts used to attach the remote
steering, shift, and throttle systems with the engine. 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
ill 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
of 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. Clean and inspect VRO oil reservoir and VRO pickup
filter. Replace filter if it is damaged or contaminated.
13. Remove propeller and check for damage. A slightly bent

propeller blade can hardly be noticed but will affect the
performance of the engine. Clean and lubricate the propeller shaft
with 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
i l l 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.
45C & Safety Related 1-29

Warning Horn Test
~ To avoid possible powerhead damage, be sure the warning
~ horn is in operating condition. It is advisable to check the
horn at the start of each boating season and periodically during
the season.
[TI 1. Disconnect bullet connector at temperature switch.

2. Connect engine harness half of bullet connector to a clean
engine ground.
3. With the key switch in the ON position, the horn should sound.
If the horn does not sound, but other electrical components
function correctly, the horn or wiring may be damaged. Repair or
replace as required.
Refer to Temperature Switch Test, Section 4.
1-30 45Cleng
Preseason Service
1. Check gearcase lubrication. If leakage is evident, gearcase seals

may need attention. Check lubricant level in power trim/tilt
reservoir. See Lubrication, this seCtion.
~ 2. Apply a light coating of OMC Triple-Guard grease to the

ill 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

ill battery is charging, the acid solution inside the battery gives
off hydrogen 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 charg-
ing batteries, 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

ill sure the steering, shift, and throttle systems are attached
to the engine using the special locknuts, lockbolts, and any other
special fasteners stored with the engine earlier. Follow the
manufacturer's installation instructions! 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 horn. See Warning Horn Test, this section.
6. For models with VRO~: If oil line has been disconnected, the oil
line must be purged and the system primed before any attempt is
made to start the engine. Refer to Section 2, OMC VRO~.
~ Any time that the VRO oil supply line has been discon-
~ nected from the engine, you must run a 50: 1 fuel/oil
mixture in the fuel tank for a period of time sufficient to verify oil
consumption. Once oil consumption has been verified, you can
switch back to clear fuel in the tank.
it 7. Check fuel system for leaks.

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.

ill 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 .

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

pistons, inject OMC Engine Tunerfol\owing directions on can. DO
NOT allow tuner to soak in engine more than one hour.
~ During engine operation, carbon can build up on internal

~ powerhead components, eventually causing piston rings to
" stick." Adding OMC Carbon Guard '" fuel additive to every tank
of fuel is your best protection against such buildup and the
resulting mechanical problems. If OMC Carbon Guard is not used
consistently in the fuel , OMC 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.
45CJeng & Safety Related 1-33

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.
fN=J If any anode has been reduced to 0/3 its original size (113
~ eroded), it must be replaced! To increase the duration ofthe
anode protection, the starboard stern bracket (on some models) is
drilled to accept an additional anode.
r.jl ~ 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.
\Note\ Do not paint or coat the anodes or their mounting surfaces.
1-34 45C/eng
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.
r:::-=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.
~tTo 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. Drain and clean VRO oil reservoir. Purge all
contaminated oil from supply lines.
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 1/2 hour using the "break-in"
fuel/oil mixture.
Run the engine on a "break-in " fuel/oil mixture for approximately

three hours after seJvicing. See Break-in Procedure in this Sec-
tion .
~ For models with VRO~ : If oil line has become discon-

~ nected, the oil line must be purged and the system primed
before any attempt is made to start the engine. Refer to Section 2,
OMCVRO~.
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.
45C/ong 1-35
~ If engine shqws 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.
1-36 45C/eng
1
DR4551
Synchronization and Linkage Adjustments - 40, 48, and 50

~ You must perform this step-by-step procedure exactly as written to ensure consistent engine
~ idling and smooth operation throughout the RPM range.
Preliminary Adjustments _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
1. Remove throttle cable from throttle lever .

2. Adjust throttle control rod to length listed in chart, measured to center of the socket.
25D; 40R, BA; 48 7 13/16 in. (198 mm)
* 40E, TE, TL, TTL

50BE, TE, TL,JE
7% in. (193 mm)
* 12-Amp Charging System

3. Adjust spark control rod to length listed in chart, measured between the centers ofthe two sockets.
Remove the forward socket for adjustment.
25D; 40R, BA; 48 2V16 in. (53 mm)
* 40E, TE, TL, TTL

50BE, TE, TL,JE
2% in. (67 mm)
* 12-Amp Charging System

INotellf adjustment is required, use a gentle prying motion to remove the control rod sockets.
4. Adjust idle speed screw @ until the dimension is 112 in. (12 mm) .
Tighten idle speed screw locknut.
45C/eng 1-37
2
DR4552
Throttle Plate Synchronization _ _ _ _ _ _ _ _ _ _ __ II
f211. Loosen cam follower adjustment screw and move cam

~ follower away from throttle cam.
rJl2. Loosen carburetor lever adjustment screw @ on upper

~ carburetor.
3. Rotate both throttle shafts slightly and allow them to snap shut.
f414. Press up gently on the adjusting tab and tighten the

5
~ adjustment screw @.
5. Verify that both throttle shafts begin to rotate at exactly the

same time.
Cam Pickup Point _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
1. Move the throttle cam and cam follower toward each other.
f512. Tighten the cam follower adjustment screw when the

~ cam and cam follower are just touching at the pickup mark .
The carburetor throttle plates must be closed .
The pickup mark must point at the center of the cam

follower.
~ 3. While holding the idle speed screw against its stop, adjust
~ the screw to obtain a 0.010 in. (0,35 mm) gap @ between the
throttle cam and cam follower.
Wide Open Throttle Stop _ _ _ _ _ _ _ _ _ _ _ _ __
1sl1 .. With the eng~~e not running, advance the throttle lever to
~ wide open position.
r7J 2. The carburetor throttle shaft pins must be exactly vertical

~ at wide open throttle.
f613. Loosen the locknut and adjust the W.O.T. stop screw @ to
~ adjust pin orientation to exactly vertical.
o 4. Tighten the locknut and recheck pins orientation .
1-38 45C/eng
Maximum Spark Advance _ _ _ _ _ _ _ _ _ _ _ _ _ __
I"N'=J Run the engine with t he correct test propeller. Do not run
~ the engine with a regular propeller or a flushing adapter for
this adjustment.
1. Connect a timing light to the top cylinder's spark plug lead.

Mark the flywheel timing grid at 19 BTDC.
2. Start the engine and allow it to reach normal operating

temperature.
3. Run the engine at no less than 5000 RPM in FORWARD. The

engine's timing pointer must align with 19 1 BTDC on
flywheel's timing grid.
f81 '" 4. Stop the engine to prevent contact with rotating

~ i l l parts. Adjust the length of the spark control rod @, as
necessary, by removing the forward socket from spark lever CD.
f815. Rotate the socket in a clockwise direction to advance timing

~ or in a counterclockwise direction to retard timing. Two
revolutions equal approximately one degree of timing.
f816. Install the spark control rod @ on the spark lever CD, and
~ verify maximum spark advance following Steps 1 thru 3.
Idle Speed _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
1. The boat and engine must be in the water under normal

operating conditions with the correct propeller installed. The
boat's movement must be unrestrained. The boat must not be
tied to a dock or trailer.

temperature.
3. Check idle RPM in FORWARD gear with an accurate tachome-

ter.
[!] '" 4. Stop the engine to prevent contact with rotating

i l l parts. Loosen locknut and adjust the idle speed screw to
achieve 750 25 RPM when the idle speed screwQ) is against its
stop. Tighten locknut.
[!] 5. If adjustment of idle speed screw Q)

is required to achieve
750 25 RPM, you must reset the 0.010 in. (0,35 mm)
throttle cam follower gap. Adjust the throttle rod socket to
achieve a 0.010 in . (0,35 mm) gap.
45C/eng & Safety Relat ed 1-39

Throttle Cable Installation _ _ _ _ _ _ _ _ _ _ _ _ __
Tiller Models
i.iQl 1. .T~rn idle speed adjustm~~t knob fully counterclockwise to

~ minimum slow speed position.
'11l 2. Attach throttle cable to throttle lever upper hole using pin
~ and cotter clip. Cotter clip must be installed parallel to raised
rib on lever.
3. Hold throttle twist grip in full SLOW position. With idle speed
screw on its stop, pull firmly on cable to remove backlash. Rotate
cable bracket to align with mounting screw hole.
f121 4. Turn cable bracket two revolutions toward cable end to

~ preload linkage. Place flat washer between cable bracket and
intake manifold. Install bracket screw and torque to 36 in. Ibs.
(4 Nm).
5. Install cable retainer plate and tighten screw securely.
6. To check throttle cable bracket adjustment, rotate throttle twist

grip several times and verify that the idle speed screw touches
stop when twist grip is in full SLOW position.
Remote Models
1. Refer to Cable Installation , Section 9.
R If the gearcase has been serviced, verify the powerhead

~ NEUTRAL detent adjustment. Refer to Installation ,
Section 6.
1-40 45C/eng
NOTES
45Cle ng 1-41
31270
Synchronization and Linkage Adjustments

45 and 55 Comm.
~ 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.
Throttle Cable Adjustment _ _ _ _ _ _ _ _ _ _ _ __
[':;11. As you face the steering handle, turn the idle speed
L!J adjustment knob counterclockwise to minimum slow speed
position.
'2l2. Be sure throttle cable bracket is secured to the powerhead

~ using the forward bracket hole.
rJl14l3. Back out the idle speed screw and wide open stop
~~ screw.
r;;l [';l 4. Turn the twist grip to full open and to full closed
~ ~ positions. Check the clearance between the roller and
end of the cam slot. The roller should be approximately 1f4 in.
(6 mm) away from both ends of slot.
1Jl5. If adjustment is necessary, loosen jam nut and rotate thumb

l!J wheel to obtain correct adjustment. Tighten jam nut after
correct adjustment is obtained.
Throttle Valve Synchronization _ _ _ _ _ _ _ _ _ _ _ __
~ With the engine idling in NEUTRAL, if loosening the carbu-

~ retor lever adjustment screws results in a better idle,
improper synchronization of the throttle valves is indicated.
At idle, the throttle valves in all carburetors must be completely

closed. If the carburetor linkage is misadjusted so one carburetor
throttle plate is slightly open, erratic and poor quality idling will
result.
f811. Turn throttle handle to idle position. Loosen the throttle cam
~ follower screw. Push the throttle cam roller away from the
throttle cam. The throttle cam roller must not touch the throttle
cam.
1-42 45C/eng
2. Loosen the upper carburetor lever adjusting screw.
Igl 3. Partially rotate the throttle shaft open and allow it to quickly
~ snap to the closed position to be certain the throttle valve is
closed in the throttle bore. Press lightly on tab of the adjusting
link to remove backlash. Tighten the adjusting screw. Move lower
throttle shaft and check that both throttle shafts start to rotate at
the same time.
Cam Follower Pickup Point
r,Ql 1. Connect a throttle shaft amplifier @, such as the one

~ shown, to the top carburetor throttle plate.
f11l 2. While advancing the throttle cam, the lower embossed

~ mark on the cam should align with the center of the
throttle cam follower as tip of the amplifier begins to move.
f12l 3. To adjust, align the lower embossed mark on the throttle

~ cam with center of the cam follower (follower screw should
still be loose). Allow the throttle spring to close the throttle
valves. While pressing on the cam follower lever, hold the cam
follower against lower mark on the throttle cam and tighten the
screw. Recheck that the throttle valves begin to rotate as the
embossed mark aligns with center of the cam follower.
Cam Follower Pickup Timing
1. Connect a timing light to No.1 cylinder spark plug lead.
2. Advance the throttle by moving the throttle control lever until

tip of the amplifier begins to move. Remove the amplifier but do
not move the throttle control lever.
3. Start the engine and observe spark advance with a timing light.
The proper pickup timing is indicated in chart.
Pickup Timing
45
55
f11l '" 4. Stop the engine to prevent contact with rotating

~ ill parts. To adjust the pickup timing, loosen the jam nut.
Rotate the top of the thumb wheel toward the crankcase to
increase the pickup timing degrees and away from the crankcase
to decrease the pickup timing degrees.
5. Tighten the jam nut and repeat Steps 1 thru 4.

Maximum Spark Advance 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's spark plug lead.

Mark the flywheel timing grid at 19 BTDC.

temperature. Run the engine at no less than 5000 RPM in
FORWARD with timer base fully advanced.
3. The engine's timing pointer must align with 19 1 BTDC on

flywheel's timing grid.
Maximum Spark Advance
45, 55
I
~ ~ 4. Stop the engine to prevent contact with rotating
~ ill parts. Adjust the length of the spark control rod , as
necessary, by removing the forward socket from spark lever @ .
Gil 5. Rotate the socket in a clockwise direction to advance

~ timing or in a counterclockwise direction to retard timing'.
Two revolutions equal approximately one degree of timing.
Gil 6. Install the spark control rod

on the spark lever @ and
~ verify maximum spark advance following Steps 1 thru 3.
Wide Open Throttle Stop Adjustment _ _ _ _ _ _ _ _ __
1. With the engine not running, advance the throttle control to

wide open position.
14 1
1 2. Pins in the carburetor shafts must be exactly vertical.
f15l 3. To adjust, loosen the wide open stop screw nut. Turn the
~ stop screw @ until pins are vertical. Tighten the nut.
Shift Lever Detent Adjustment _ _ _ _ _ _ _ _ _ _ __
1. Move the shift lever to NEUTRAL position.
rw 2. The lower detent spring should be fully engaged in

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

detent spring to fully engage notch. Tighten the screw securely.
& Safety Related 1-44 45C/e ng

Engine Idle Speed Adjustment _ _ _ _ _ _ _ _ _ _ __
1. The boat and engine must be in the water under normal

operating conditions with the correct propeller installed. The
boat's movement must be unrestrained. The boat must not be
tied to a dock or trailer.

temperature.
3. Check idle RPM in FORWARD gear with an accurate tachome-

ter.
r:J7l l'4. Stop the engine to prevent contact with rotating

~ i l l parts. Adjust the idle speed screw to obtain recom-
mended RPM .
Turn screw counterclockwise to lower idle speed .
Turn screw clockwise to raise idle speed.
it 5. Start engine and recheck idle speed. Stop the engine.

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, flush, and fill gearcase with recommended lubri-

cant. 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.
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.
1-46 45C/eng
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)
10 No. Part No. Size 10 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 (1/4-20 Thread Size - 0 Type)
0 338548 0.000 57D 322907 0.057
29D 330142 0.029 58D 328543 0.058
32D 333184 0.032 59D 319831 0.059
34D 330141 0.034 60D 332204 0.060
35D 333183 0.035 61D 319907 0.061
37D 328537 0.037 62D 331433 0.062
38D 328525 0.038 63D 328544 0.063
39D 328538 0.039 64D 328545 0.064
40D 328524 0.040 65D 327541 0.065
41D 333182 0.041 67D 319534 0.067
42D 322249 0.042 68D 333211 0.068
43D 328539 0.043 69D 327558 0.069
44D 328540 0.044 70D 327769 0.070
45D 323280 0.045 71D 327559 0.071
46D 328541 0.046 72D 328546 0.072
47D 328542 0.047 73D 327487 0.073
49D 324020 0.049 74D 333669 0.074
50D 326526 0.050 75D 327560 0.07.5
51D 331567 0.051 76D 329411 0.076
52D 321108 0.052 77D 333438 0.077
53D 321297 0.053 78D 319002 0.078
54D 321407 0.054 79D 329414 0.079
55D 320921 0.055 80D 333298 0.080
56D 318684 0.056 81D 330917 0.081
45Cleng 1-47
Orifices (114-20 Thread Size - C Type)
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 (5116-24 Thread 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
1-48 45C/eng
Drill Size Conversion Chart
SHOWING MILLIMETER SIZES, FRACTIONAL AND
DECIMAL INCH SIZES AND NUMBER DRILL SIZES
Milli Dec. Frac Num Milli Dec. Frac Num Milli Dec. Frac Num Milli Dec. Frac Num Milli Dec. Frac
Meter Equiv. tional ber Meter Equiv. tional ber Meter Equiv. tional ber Meter Equiv. tional ber Meter Equiv. tional
.1 .0039 1.75 .0689 .1570 22 6.8 .2677 10.72 .421 9 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 711 6
.25 .0098 1.85 .0728 .1610 20 7.0 .2756 11 .5 .4528
.3 .0118 . .. . .0730 49 4.1 .1614 . .. . .2770 J 11 .51 .4 531 29/64
... , .0135 80 1.9 .0748 4.2 .1654 7.1 .2795 11 .91 .4687 15/32
.35 .0138 . .. . .0760 48 .1660 19 .,' . .2811 K 12.0 .4724
.... .0415 79 1.95 .0767 4.25 .1673 7.14 .2812 9/32 . .. . 12.30 .4843 31/64
.39 .0156 1/64 o 1.98 .0781 5/64 4.3 .1693 7.2 :2835 12 .5 .4921
.4 .0157 . .0785 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 .5118
.45 .0177 2.05 .0807 . ... .1730 17 . ... .2900 L 13 .10 .5156 33/64
.... .0180 77 . ... .0810 46 4.4 .1732 7.4 .2913 13 .49 .531 2 17 /32
.5 .0197 .... .0820 45 . .. , .1770 16 . . .. .2950 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 .... .0860 44 4.6 .1811 7.6 .2992 14 .29 .5624 911 6
.... .02 25 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 .5781 37164
... . .0240 73 . ... .0890 43 4.75 .1870 7.75 .3051 15.0 .5906
.. .0250 72 2.3 .0905 4.76 .1875 311 6 .. 7.8 .3071 15.08 .5937 19/32
.65 .0256 2.35 .0925 4.8 .1890 12 7.9 .3110 15.48 .6094 . 39/64
.... .0260 71 .. " .0935 42 .. .1910 11 7.94 .3125 5;;6 .. ,- 15.5 .6102
... .0280 70 2.38 .0937 3/32 . .. 4.9 .1929 8.0 .3150 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 .. .2010 7 8.3 .3268 17 .06 .6719 43/64
.0320 67 .... .1015 38 5.16 .2031 13/64 ... . 8.33 .3281 21 /64 .... 17.46 .6875 11 11 6
.. . . .0330 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 .71 87 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 .2126 8.73 .3437 11 /32 .. . . 19 .0 .7480
. . .. .0380 62 2.8 .1102 . .. .2130 3 8.75 .3445 19 .05 .7500 3/4
' ... .0390 61 .... .1110 34 5.5 .2165 8.8 .3465 19.45 .7656 49/64
1.0 .0394 .. . . .1130 33 5.56 .2187 7/32 . . .. . ... .3480 S 19 .5 .7677
. .. . .0400 60 2.9 .1141 5.6 .2205 8.9 .3504 19 .84 .7812 25/32
... .0410 59 .. " .1160 32 .... .2210 2 9.0 .3543 20 .0 .7874
1.05 .0413 3.0 .1181 5.7 .2244 .3580 T 20 .24 .7 969 51 /64
.... .0420 58 '"
.1200 31 5.75 .2263 9.1 .3583 20 .5 .8071
. .. .0430 57 3.1 .1220 '"
.2280 1 9.13 .3594 23/64 . . .. 20.64 .81 25 13116
1.1 .0433 3.18 .1250 1/8 .... 5.8 .2283 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 27 /32
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 .3701 21.83 .8594 55 /64
1.25 .0492 3.4 .1338 . ... .2380 B 9.5 .3740 22 .0 .8661
1.3 .0512 .. . .1360 29 6.1 .2401 9.53 .3750 3/8 .. . . 22.23 .8750 7/8
.. .. .0520 55 3.5 .1378 '" . .2420 C .... .3770 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 .3819 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 .2500 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
1.59 .0625 1/ 16 .... . ... .1495 25 6.6 .2598 10.0 .3937 24.21 .9531 61 /64
1.6 .0629 3.8 .1496 .. .. .2610 G ... .3970 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 .9844 63 /64
. . .. .0670 51 3.97 .1562 5/32 .2660 H 10 .5 .4134 25.4 1.0000 1
45C 1-49
Heli-Coillnserts and Installers
r:;l Use these Heli-Coil inserts on all models to repair damaged
L!J threads. The installation kit consists of drill, tap, and insertion
tools.
R The 14 mm spark plug inserts are specially made for use in

~ aluminum cylinder heads. Do not use substitutes.
PIN Name of Part

1
C03603
391436 Heli-Coillnstaller Kit, 8-32

391438 Heli-Coillnstaller Kit, 10-24
391439 Heli-Coillnstaller Kit, %-20
391440 Heli-Coillnstaller Kit, 5/16 -18
391441 Heli-Coillnstaller Kit, 3/8-16
391450 Heli-Coillnstaller Kit, 1/2 -13
391437 Heli-Coillnstaller Kit, 14 mm
391448 Heli-Coillnserts, 8-32
391446 Heli-Coillnserts, %-20
391445 Heli-Coillnserts, 5/16 -18
391444 Heli-Coillnserts, 3/8 -16
391443 Heli-Coillnserts, 14 mm (3!8 in. Reach)
391442 Heli-Coillnserts, 14 mm (1/2 in. Reach)
PCE0027
Installation Instructions
1. Drill to adequate depth using drill size supplied with kit.
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.
1-50 45C/eng
Fuel System
Table of Contents
General Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 2

Service Specifications ............................. 2- 3
Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 5
Description of Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . 2- 6
In-Line Fuel Filter Servicing . . . . . . . . . . . . . . . . . . . . . . . . 2- 7
Fuel Tank Servicing .................. . ............ 2- 8
Fuel Pump Servicing ................. . . . .. . .. . .... 2-14
Function Test .................................. 2-15
Primer System Servicing ..................... . . . .. 2-16
Electric Primer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Manual Primer ................................. 2-18
Boat Fuel System Recommendations. . . . . . . . . . . . . . . . . 2-22
Testing VRO~ System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
VRO~ Oil Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Installation Recommendations . . . . . . . . . . . . . . . . . . . . 2-27
VRO~ Component Servicing . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Oil Supply Hose and Pickup Assembly . . . . . . . . . . . . . . 2-29
Pulse Limiter Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Pump ... . .................................... 2-30
Pump Trouble Check Chart. . . . . . . . . . . . . . . . . . . . . . . 2-32
VRO~ Warning Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Carburetor Servicing - All Models. . . . . . . . . . . . . . . . . . . . 2-37
Carburetor Mixture Adjustment - All Models . . . . . . . . . . . 2-42
Intake Manifold Servicing - All Models. . . . . . . . . . . . . . . . 2-44
Fuel System Trouble Check Chart . . . . . . . . . . . . . . . . . . . END
45C1eng 2-1
it. General Safety Warnings
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.
2-2 45C/eng
Special Torque Chart
Description In. Lbs. Nm Adhesive
Leaf Valve Screws 25-35 2,8-4,0 OMC Screw Lock
Intake Manifold Screws 60-84 7-9

Bowl Screws 25-35 2,8-4,0
OMC Special Tools Required
Orifice Plug Screwdriver, PIN 317002

Float Gauge, PIN 324891
Fuel Nipple Cleaning Tool, PIN 326623
Pressure Test Adapter, PIN 389945
Fuel Line Vacuum Tester, PIN 390954
Tie Strap Installation Tool, PIN 323716
Hose Clamp Wrench, PIN 325043
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/e in. I.D. x 12 in. (3 mm I.D x 305 mm) long
Brass or Copper Tubing, 3/32 in. x 4 in. (2 mm x 102 mm) long
Ohmmeter
T-25 Torx Driver or Ve in. (3 mm) Hex Wrench
Machinist's Straightedge
Inch Pound Torque Wrench
Lubricants and Sealants Required
OMC Cleaning Solvent

OMC Pipe Sealant with Teflon
Johnson or Evinrude Outboard Lubricant
OMC Locquic Primer
OMC Screw Lock
Isopropyl Alcohol
Gasoila Sealer
OMC Ultra Lock
OMC Nut Lock
OMC 2 + 4@ Fuel Conditioner
OMC Carbon Guard Fuel Additive
45C/eng 2-3
NOTES
2-4 45C/eng
Fuel Requirements
Minimum Octane
Models Recommendations (R+M)/2 "RON"

"AKI"
40RS,45,55 See fuel classifications below 67 69
40,48,50 See fuel classifications below 87 90
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
~ The use of premium grade fuels is specifically encouraged. Most national brand premium fuels
~ contain detergent and dispersant ingredients advertised to reduce intake valve and fuel injector
deposits. These ingredients also remove and prevent carbon buildup on pistons and rings. These
ingredients can extend engine life while maintaining a high level of performance.
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.
~ OMC 2+4@ fuel conditioner and OMC Carbon Guard T" 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.

Description of Fuel System
[":;1 1. The fuel pump is of the diaphragm-displacement type and is
L.!J operated by changes in crankcase pressure. Alternately, suc-
tion and pressure in the crankcase are transmitted to the pump
diaphragm.
f2l 2. The carburetors meter and distribute the fuel consumed.

~ They control engine speed and power output by varying the
intake charge density. To react correctly to a wide range of
operating conditions, the carburetors have multiple fuel mixing
circuits.
1al 3. The VRO~ unit is a combination mechanical fuel and oil

~ pump, powered by crankcase pressure and vacuum pulses,
which responds to various engine power settings by injecting the
proper amount of oil into the fuel system.
The VRO~ pump incorporates a circuit that warns the operator

of a "no oil" situation.
~ 1sl 4. Mixture enrichment for cold starting is controlled by

~ ~ either a manual primer @ (rope models ) or a fuel primer
solenoid (TE, TTL and remote control models).
2
5
30393
2-6 45C/eng
In-Line Fuel Filter Servicing
Commercial Models
1sl1. Unscrew in-line filter cover@. It is not necessary to remove

~ fuel hoses to service filter.
1sl2. Clean filter canister and shake filter element to remove

~ collected particles.
1sl3. 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.
Recreational Models
~ Replace the filter during the 20-Hour Check. Thereafter,

l2J change the filter seasonally or every 100 hours.
45C/eng 2-7
Fuel Tank Servicing
r:JI l' Drain and flush the tank at least once a year, and at every
~ ~ tune-up or major repair. Drain tank at an outdoor loca-
tion, away from all possible sources of ignition. A drain screw
is provided in the fuel tank upper housing. Shake the tank before
draining to mix sediments. Clean the tank by flushing with clear
gasoline or solvent. Primer pump, screens, etc., may be inspected
and cleaned as described below. Refill the tank with the correct
fuel mixture.
Cleaning and Inspection
If the tank or hose appears to be leaking fuel or fumes, pressure

test tank and hose assembly before doing any disassembly.
Clean the fuel tank and inspect for rust or leakage. Replace tank if
badly rusted or if it has developed leaks in the metal body.
I:A Never apply patching materials to an outboard fuel tank,

ill even though these materials are sold as being suitable for
fuel tank repair. Generally, these materials are sold for repairing
automotive fuel tanks and are not suitable for portable marine
tanks, which are subjected to much higher pressure and vacuum
conditions. Never use a patched or repaired fuel tank. If the repair
fails, the tank will leak fuel which could ignite.

Housing and Fuel Gauge - Commercial
f21 The fuel level indicator is mounted to the upper housing and
~ fuel line assembly. The entire assembly may be removed by
removing the four attaching screws. Lift the assembly from the
tank carefully to avoid damaging the indicator float CD or the
screen Q) at the end of the fuel line.
'2l Check for free movement of the indicator on the indicator pin.
~ Remove the pin from the indicator support by compressing the
free end and pulling it out. Inspect the indicator to make sure
that the float arm is not bent and that the float CD is not
damaged or oil-soaked .
'2l Remove the two screws attaching the indicator support CD to

~ the upper housing. Lift the indicator lens out of the upper
housing, and clean it with solvent or lacquer thinner to remove
any foreign matter which may be clouding the lens. Inspect the
lens seal @ for cracks or shrinkage which may allow leakage.
When reassembling support to housing, tighten screws to a torque
of 15-20 in . Ibs. (1,6 -2,2 Nm).
rJl The release valves @ must seat tightly to prevent gasoline

~ or fumes from leaking out, but must open a clear passage for
air to enter the tank and for fuel to be drawn out when the fuel
hose is connected . Dirt may keep the release valves from seating
properly. The release valves are best cleaned by removing the core
plugs and disassembling. Replace valve seats (O-rings) @ to
ensure a tight seal. Install small ends of springs on valves @, T
and secure the assembly in the housing using new core plugs
staked in place.
rJl The air inlet disc valve must seat tightly to prevent fumes
~ from escaping the tank when the fuel hose is connected, but
must allow air to enter the tank. The disc valve spring retainer
is staked to the upper housing and may be removed by filing
off the burrs if replacement is necessary. Restake with a small
punch . Reassemble upper housing (f) to fuel tank using a new
gasket. Tighten screws to a torque of 25 -35 in. Ibs (2,8-4,0 Nm).
Ji... Failure to follow reassembly procedure correctly could

ill result in fuel leakage. Ignition of this leakage could result
in fire or explosion.

131 ----~
72112
45C &safety Related 2-9

Testing
'" Omitting the tank pressure test may result in returning a @

i l l fuel system to service which could leak liquid or vaporized
fuel, resulting in fire or explosion.
Whenever a fuel tank or line has been serviced or has had parts
\
disassembled, the unit must be tested to ensure that the repaired
or reassembled portion will not leak or emit fumes. Simply
adding fuel to the tank and checking for leakage is not an
adequate test, as leakage or fumes may occur only when the 1
tank's contents have been pressurized. As examples, pressuriza- 15827
tion can occur when the tank is left in sunlight, or when the fuel is
agitated, as might occur during transport.
rv~ ~ Tank
~ Tools needed are an air pressure gauge and OMC Fuel
Pressure Test Adapter, PIN 389945 @. A compressed
air supply is also needed.
~ Do not smoke during test or perform test in area where

ill there are sparks or open flames. Once air pressure is applied
to tank, gasoline traces may be expelled as a vapor or mist.
Gasoline in these forms is extremely flammable and highly
explosive.
1. Remove fuel cap and disengage from tank. Empty fuel tank
completely.
IN=llf any fuel remains in the tank during testing, it could

~ conceal the presence of leakage.
2. Attach pressure test adapter to fuel tank.
IJl f41 3. Apply compressed air to valve stem on adapter in short

~~ bursts until 10 PSI (69 kPa) is achieved.
fN=J Short bursts of air will minimize the danger of overpressur-

~ izing. Overpressurizing can permanently damage tank.

4. Point end of fuel hose into a container below top of tank.
Depress the ball in the fuel connector until any remaining fuel is
expelled.
5. Add air to bring pressure back to 10 PSI (69 kPa).
6. Submerge fuel tank in water, one portion at a time, in the same

manner you would check a tire for air leaks. Any air bubbles
indicate a leak point which must be repaired or replaced.
1sl 7. Disconnect hose from tank. With fuel connector housing

~ submerged, check for leakage from fuel nipple and fuel
valve pin @. Depress vent valve pin to check air vent disc valve
for leakage.
f61 8. After testing, release tank pressure through valve stem

~ before removing cap.
f61 R
Do not attempt to remove screw from center of Test
~ ~ Adapter, PIN 389945.
45C1eng 2-11
NOTES
2-12 45C/eng
Connector Housing
Igllf O-ring in fuel connector becomes damaged, air may enter

~ the fuel line, resulting in motor surging and/or stalling.
r,Qllnstaliation of the O-ring in the fuel hose connector requires

~ the use of two instruments, one to hold the plunger down
and one to remove the O-ring. Both instruments are illustrated
and can be made easily of 16 gauge lA6 in. (1,59 mm) diameter
steel wire. A piece of discarded remote control wire may be used.
Form a small hook @ on the bottom end of the longer tool of
about 1/16 in. (1,59 mm) radius. After cutting the wires to length,
1484
be sure the ends are rounded off to prevent scratching or
damaging the O-ring seat on the plunger.
Igl To remove the O-ring from the connector, proceed as

~follows: ====0
1. Grip the connector gently in a vise between two wooden
blocks.
~r=====O
~ 2. Push the plunger down with the straight instrument @. ~
19l3. Insert the hooked instrument @ between the O-ring and its 10 @
1494
~ seat with the hook in a flat or horizontal position.
4. Twist the hook around to grasp the O-ring, then pull out.
Discard O-ring.
To install new O-ring in the connector, proceed as follows:
1. Place a drop or two of oil on the O-ring.
2. Place the O-ring on face of the connector.
3. Push the plunger down with the straight instrument.
4. Pinch the O-ring together and gently push into position with
fingers.
When reassembling the fuel hose, check for cracks in the primer
bulb or in the hose. The primer bulb must be attached so that fuel
flow is from the shorter to the longer hose length. Fuel flow
through the primer bulb is indicated by an arrow.
I:A Check for leaks by connecting fuel tank hose to motor and
ill squeezing primer bulb until definite pressure is felt in the
bulb.
@O-Ring
Hose (2) 72112
Clamp (6)
@ Primer Bulb
Inlet Valve
CD Outlet Valve
Q) Connector Housing Assembly (2)

Fuel Pump Servicing
r:;'] Before replacing a suspect fuel pump, remove and clean the
L..!J 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.
~ To prevent excessive fuel spillage, disconnect hose connec-

~ tor at motor before disassembly.
~ After servicing, check for leaks by connecting fuel hose to

ill motor and squeezing primer bulb until definite resistance is
felt in bulb.
f21 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.
Wash filter element @ with clean solvent and a brush.
Install filter with lip facing the fuel pump body. DR3000
Make sure the large a-ring is seated in its groove in

the cover and the small a-ring @ is in place around
center post.
Install cover @. Position inlet nipple between screw

heads.
Tighten the cover screw securely.
& Safety Related 2-14 45C/e ng

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 24 in. (61 em) below fuel pump.
r:;l 1. Remove carburetor to fuel pump hose. Connect a fuel

~ pressure gauge (obtain locally) between the carburetor and
fuel pump. 3
633328
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
PCE0072
3. If fuel pump does not meet these specifications, replace it .
When installing a new fuel pump, apply OMC Nut Lockto

threads of screws. Install screws and torque to 24-36 in.
Ibs. (2,8-4,0 Nm).
45C/eng 2-15
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:
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.
121 3.
Remove primer hose from any primer fitting that you
~ suspect is clogged. Connect a 1/S 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
2-16 45C/eng
Electric Primer
f41 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.
rJl 3. To inspect or replace internal components, remove the four

~ solenoid cover screws.
lsi 4. When assembling solenoid, back out screws in their holes to

~ engage original threads - then, tighten securely.
Installation
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.
J:A 3. Check for leaks by connecting fuel tank hose to motor and
ill squeezing primer bulb until definite pressure is felt in the
bulb.
DR1417

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.
Isl 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.
rr;t:l The three smaller a-rings are made with a special material;
~ 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.
f81 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.
2-18 45C
lal ------------------------------------~ DR2578
191 __________________~----------------------------------------D-R~25~79~
~ Plunger @ Shown in Warm -Up Position
@] Plunger @ Shown in Off Position
45C 2-19
Disassembly
110k Remove primer pump housing retainerfrom primer pump.

[!!] 2. Remove primer plunger from housing. Discard O-rings.
Inspection
r.;:;, lnspect 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.
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.
f13l To verify check valve function, connect a clear plastic hose

~ between the small nipple and a syringe filled with isopropyl
29283
alcohol. Squeeze the syringe lightly to force alcohol through the
hose. Visually check for alcohol flow into the housing. It is
permissible for a few drops to enter. 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 .
1141 Install a hose between the large nipple of the primer pump
housing and the syringe. Place your thumb over the end of
the plunger housing. Squeeze the syringe to fill the plunger
housing. Alcohol should flow freely out of the small nipple,
indicating no obstructions. If no flow is indicated, replace the
primer pump housing .
2-20 45Cle ng
Assembly
~ 1. Position the spring and washer on the plunger shaft.

f16l2. Install two new a-rings and quad-ring@ onto plunger
~ shaft.
f1713. Install a new a-ring on the end cap, and position the end
~ cap on the plunger shaft.
f1814. Insert the plunger shaft and end cap into the primer pump
15
29281
~ housing. Reinstall retainer clip.
\19\5.5 To bench test the primer pump after assembly, connect a

in. (127 mm) piece of hose to the large nipple and place the
other end of hose in a container of alcohol. Connect a hose to 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.
16
29280
'" 6. After installing, check for leaks by connecting fuel tank
ill hose to motor and squeezing primer bulb until firm.
18

Boat Fuel System Recommendations
Purpose
This information is provided to assist you in evaluating a boat's

permanently installed fuel system. Large outboards require a
boat fuel system that has a high fuel flow rate and a low pressure
drop across the entire system.
It is very important that all boat fuel system components are of

the correct capacity and that they are properly installed. ABYC's
Standard H-24 and ICOMIA's Standard No. 17 are accepted as
industry standards and should be referred to for additional
information.
~ A permanently installed fuel system with excessive restric-

~ tions could exceed the VRO~ unit's pumping capacity and
cause poor engine performance or serious powerhead damage.
To evaluate the restrictiveness of a permanently installed fuel

system, refer to Testing Fuel System, this section.
Recommendations
1. Fuel Tank Pickup Tube - a minimum inside diameter of 3/s in.

(9,5 mm) is required for V6 and larger engines. 3/S in. (9,5 mm) is
preferred for V4 and smaller engines, while a minimum of 5/16 in.
(7,9 mm) is required. Two separate pickup tubes are required for
a dual engine installation.
rv~ 2.No.Pickup Tube Filter - to be constructed from stainless steel

304 wire cloth, 30 mesh, with wire diameter of
0.010-0.012 in. (0,25-0,30 mm). A cylindrical screen equal to
pickup tube outside diameter and 1 in. (25,4 mm) long will
provide adequate surface area. The screen should be horizontal 813309
and slightly above the tank bottom.
2-22 45C/eng
3. Anti-Siphon Valve - safety standards require permanently
installed fuel systems to have anti-siphon protection. This protec-
tion can be afforded in two ways:
All fuel distribution lines must be secured above the

highest fuel level when the boat is in its normal, un-
loaded, static floating position.
Each fuel pickup tube must have an anti-siphon valve

installed.
Anti-siphon valves used must have a pressure drop of no more

than 2.5 in. of mercury (Hg) at a flow rate of 20 gallons per hour.
The following OMC valves meet this requirement:
PIN 173273 for 5/16 in. 1.0. hose

PIN 173274 for 3/S in. 1.0. hose
PIN 173275 for 3/S in. 0.0. copper
4. Fuel Distribution Lines - a minimum inside diameter of 3/S in.

(9,5 mm) is required for V6 and larger engines. 3/S in. (9,5 mm) is
preferred for V4 and smaller engines, while a minimum of 5/16 in.
(7,9 mm) is required. Distribution lines must be USCG Type "A1"
or "81". Vinyl hose must not be used in a permanently installed
fuel distribution system.
5. Fuel Distribution Fittings - all fittings must have a minimum

inside diameter of 1/4 in. (6,4 mm), while 9/3 2 in. (7,1 mm) is
preferred.
6. Fuel Filter - fuel filters must have a pressure drop of no more

than 0.4 in. of mercury (Hg) at a flow rate of 20 gallons per hour.
The filter should have a minimum filtered area of 200 square
inches (1290 cm 2).
OMC Fuel Filter Kit, PIN 174176, meets these requirements.

7. Fuel System Priming - OMC Electric Fuel Primer Kit,
PIN 174651, is available for built-in fuel systems. The kit mounts
near the fuel supply and, when activated, fills the fuel distribution
lines and engine fuel system for quicker starting.
OMC Manual Filter Primer Assembly, PIN 398540, is available for

engines below 120 HP.
45C/e ng 2-23
Testing VRO~ System
Purpose
The following procedure is designed to help you isolate a defec-

tive component in the boat or engine fuel system .
The problem might cause a loss of engine performance or, if left

unrepaired, might cause serious powerhead damage.
After you have isolated the component, refer to Servicing, this

section, for specific repair procedures.
Testing Procedure
'" Avoid accidental starting of engine while changing propel-

i l l lers; twist and remove all spark plug leads.
~ Some checks require that the engine be run at full throttle
~ under load. Install the correct test propeller and run the
engine in a suitable test tank.
1. Start engine and allow it to reach normal operating tempera-

ture.
fN=J Push fuel hose off fuel fittings - don't pull. If pushing won't
~ separate hose and fitting, carefully cut the hose along its
side and peel it back to avoid damaging the fittings.
r:jl 2. Install OMC Vacuum Gauge, PIN 390954 @, or equivalent,

~ and 8 in . (20,3 cm) of clear vinyl hose at the fuel inlet fitting
on the lower engine cover. Secure all connections with tie straps
to eliminate air leakage.
~ Do not use fuel primer bulb, manual fuel primer pump, or

~ electric fuel primer pump to restart engine. Fuel system
pressure could cause immediate damage to vacuum gauge.
3. Start engine and run at full throttle for at least two minutes.
Monitor clear vinyl hose for signs of air or vapor bubbles and note
reading on vacuum gauge.
4. The vacuum gauge reading must not exceed 4 in. of mercury

(Hg) at any time. There should be no air or vapor bubbles visible
in the clear hose.
If reading is 1 to 4 in. Hg and no bubbles are present, go

to Step 8.
If reading is 1 to 4 in. Hg and bubbles are present, go to

Step 7.
If reading exceeds 4 in. Hg, go to Step 5.
& Safety Related 2-24 45Cl eng

5. If your reading exceeds 4 in. Hg, you must test each boat fuel
system component for excessive restriction before continuing.
Refer to Boat Fuel System Recommendations, this section, for
component descriptions.
~ 6. If you suspect the anti-siphon valve, perform these tests:

Remove anti-siphon valve from fuel tank, and install
adaptors and clear hose as shown.
Fill clear hose with water until "X" dimension is 20 in.

(500 mm). Water must not run through valve.
@ Transparent Hose
Increase water level until "X" dimension is 25 in. Adaptors
(630 mm). Water must begin to run through valve before Tank End
reaching 25 in. (630 mm). @ Anti-Siphon Valve
Engine End
Replace the anti -siphon valve if your test results vary.
7. If your reading is less than 4 in. Hg and air bubbles are visible
in the clear hose, check entire boat fuel system for air leaks.
Remember, an air leak into a fuel supply system might not create
a visible fuel leak.
8. If your reading is less than 4 in. Hg and no bubbles are visible,

move the clear hose to the output side of the in-line fuel filter.
Start engine and run it at full throttle.
If bubbles appear, test in-line fuel filter.
If no bubbles appear, go to Step 9.
9. If no bubbles appeared in Step 8, remove the clear hose and

install a 0-15 PSI (0-103 kPa) fuel pressure gauge between VRO~
pump and carburetors.
10. Start engine and run it at 800 RPM, in gear. After fuel
pressure stabilizes, the pressure gauge must not indicate less
than 3 PSI (21 kPa) when held level with VRO hose fitting.
If pressure is less than 3 PSI (21 kPa), test pulse limiter

and crankcase fitting. Refer to VRO~ Component Servic-
ing, this section.
If pulse limiter and crankcase fitting are good and

pressure is less than 3 PSI (21 kPa), replace VRO~
pump.
45C/eng 2-25
VRO~ Oil Supply System
Optional Equipment
1. VRO~ equipped outboards are shipped with a 1.8 gallon

(6,8 litre) oil reservoir. There is an optional 3.0 gallon (11,4 litre)
reservoir available for dual engine installations or extended
range.
OMC PIN 175531 reservoir has a 3.0 gallon (11,4 litre)

capacity.
2. Dual engine oil pickup kits allow you to supply oil to two
engines from one oil reservoir. The kits include all components to
add a second oil pickup to your existing reservoir.
OMC PIN 175515 is compatible with the 3.0 gallon res-

ervoir.
3. An oil level gauge and sending unit kit is available to allow

continuous monitoring of oil level in the reservoir.
OMC PIN 174198 is compatible with all reservoirs.
4. A remote oil fill kit is available to allow filling of an inaccessible

reservoir through a deck mounted fitting.
OMC PIN 174133 is compatible with all reservoirs .
2-26 45C/eng
Installation Recommendations
IN=J Carefully, follow the installation instructions packaged with

~ the VRO oil reservoir. Incorrect installation might restrict
the oil supply to the engine and cause serious powerhead
damage.
If the VRol system is not used, follow this procedure:

Install protective cap, PIN 315391, over the oil inlet
fitting to protect the VRol pump. Secure with clamp,
PIN 322654.
Disconnect the VRol wiring harness. Seal engine har-

ness Amphenol connector with cover, PIN 335655.
1. Determine if the standard oil reservoir has sufficient capacity

for the application. If it doesn't, consider a 3.0 gallon reservoir.
Refer to Optional Equipment, this section.
2. Choose a reservoir location that allows easy access and is

within installation recommendations. The reservoir has 15 ft.
(4,5 m) of oil hose and 17 ft. (5,3 m) of wiring harness.
3. The reservoir hose can be extended to a maximum of 25 ft.

(7,6 m). If the installation is extended, the oil hose between the
primer bulb and engine must be one continuous section with no
fittings or connections. Do not add on to the existing hose.
The wiring harness can be extended by soldering on additional

16-gauge wire to each lead. Protect the connections with shrink
tube and electrical tape. Observe proper wire color for identifica-
tion. .
4. When making connections in the oil supply system, use only

the clamp supplied with the system.
Do not use tie straps. They do not provide adequate

clamping action.
Do not use a metal worm clamp on vinyl hose. It can

damage the hose and cause leakage.
5. Test the "low oil" warning circuit before filling the oil reservoir:
Make all electrical connections and connect the engine's

battery.
Turn the key switch ON.
With the reservoir empty, the warning horn should

sound for '/2 second every 40 seconds.
With the reservoir more than 1/4 full, the signal should
stop.
45C/eng 2-27
6. Test the "no oil" warning circuit:
Connect a shop tank with 50: 1 fuel/oil mix to the fuel inlet
fitting.
Remove the protective cap from the oil inlet fitting.
Start the engine and run it at 1000 RPM, in gear.
After the residual oil is exhausted from the oil line, the
"no oil" circuit should activate the warning horn.
The signal should be an urgent 1/2 second on, 1/2 second

off.
~ The "low oil" and "no oil" warning circuits alert the
~ operator to possible problems with the VRO~ system . You
must be sure they are functional before continuing . If they are not
functional, serious powerhead damage might occur.
7. Complete the installation by connecting the oil supply hose to

the engine's oil inlet fitting.
Before attaching hose, squeeze oil primer bulb to purge

all air from oil line. Allow a small amount of oil to flow
from the hose to remove any contaminants that might be
in the line.
Install the oil hose on the oil inlet fitting. Use only the
ratchet clamp supplied with the kit to secure the line.
Tighten with pliers.
To complete priming, squeeze oil primer bulb until oil is

visible at the sight tube@ located in the oil hose near the
VRO~ pump.
During the break-in period, the engine's fuel tank must

have a 50: 1 fuel/oil mixture in addition to VRO~ opera-
tion.
~ Prime the VRO~ oil system before priming fuel system. If

~ fuel system is primed first, the oil system must be primed
with the engine idling. Prime until oil is visible at the sight tube.
Warning horn will sound until oil reaches the VRO~ pump.
8. Store the protective cap removed from the oil inlet fitting on the
yellow cap holder attached to the VRO fuel hose.
9. The oil level must be marked on the side of the reservoir before
putting the engine into service.
After the break-in period, the operator must verify that

oil has been used before switching to clear fuel in the
boat's fuel tank.
10. Follow Engine Break-In Procedure outlined in Section 1.
2-28 45C/eng
VRO~ Component Servicing
r::=J Anytime the VRO oil supply line has been disconnected
~ from the engine, you must run a 50:1 fuell oil mixture in the
fuel tank for a period of time sufficient to verify oil consumption.
Once oil consumption has been verified, you can switch back to
clear fuel in the tank.
Oil Supply Hose and Pickup Assembly
If you suspect the oil supply to the VRO~ pump is being restricted,
check two areas.
1. Remove the pickup assembly and inspect for clogged or

contaminated filter:
Remove the four No. 25 Torx screws, and remove the

pickup assembly from the reservoir.
Carefully, remove the pickup filter and flush with a mild

solvent to remove any contamination.
Install the filter, being careful not to move the pickup

assembly on its support rods.
2. With the pickup assembly out of the reservoir, vacuum test the
system to check for air leaks:
Carefully, remove the oil hose from pickup assembly and

from engine oil inlet fitting.
Use low pressure air to purge hose of oil.
Use cap holder, PIN 329661 @, to plug pickup end of

hose.
~ Attach a vacuum tester to the engine end of oil line and

~ draw a 7 in . Hg vacuum. The oil system is good if it can
maintain a 7 in. Hg vacuum for at least five minutes.
t
@] Before installing pickup assembly, check pickup height @:
!
1.8 gallon pickup - 6.9 0.06 in. (174 1,5 mm)
3.0 gallon pickup - 8.8 0.06 in . (224 1,5 mm)
COB5657A
45Cleng 2-29
Pulse Limiter Fitting
rv~ check
The pulse limiter fitting for the VRO pulse hose has an integral
valve. The check valve is not serviced separately, but it
must be clear to allow normal pump operation.
~ A clogged check valve will limit fuel and oil supply, causing
~ serious powerhead damage.
1. Remove the pulse limiter fitting from the pulse hose.
f2l
2. Backflush the valve with a mild aerosol solvent to remove
~ any carbon deposits.
R If you find excessive carbon deposits, check the engine for

~ causes of backfiring:
Linkage adjustments incorrect

Engine temperature incorrect
Crankcase air leaks
Carburetor problems
Extended use of flushing attachment
3. Position the fitting in the pulse hose with blue nipple facing the
VRO~ pump.
4. Secure the pulse hose with ratchet clamps.
Pump
For function tests of the VRO~ pump, refer to Testing Fuel

System, this section.
To verify oil consumption and proper fuel/oil ratios :
~ 1. Avoid accidental starting of engine while changing pro-

ill pellers; twist and remove all spark plug leads. Then, install
the proper test propeller, and put the engine in a suitable test
tank.

temperature. Stop the engine.
r::=J Push fuel hose off fuel fittings - don't pull. If pushing won't
3. Carefully remove the oil supply hose from the pump's oil inlet
fitting.

DR1438
f11 4. Install and secure a 10 in. (25 cm) length of 1/4 in. (6,35 mm)
~ I.D. clear vinyl hose. A few inches from the loose end, measure
carefully, and mark the hose every V2 in. (12,7 mm) for three
inches (76 mm) @ .
5. Fill the hose with Evinrude or Johnson Outboard Lubricant, and

run the engine to eliminate air from the base of the hose. Shut off
the engine, and add or eliminate oil until its level is even with the
highest mark.
6. Start the engine, and monitor the pump cycles by using a fuel
pressure gauge or by putting light finger pressure on the outlet
hose .
At 800 RPM, the oil level in your hose should drop 1 in.
(25,4 mm) in approximately five pulses .
At full throttle, the oil level in your hose should drop 1 in .

(25,4 mm) in approximately three pulses.
7. If your results vary, check the pulse limiter fitting before

replacing the pump.
8. If you remove the pump, carefully cut the hose to avoid

damaging the fitting. When installing, use a ratchet clamp on the
oil supply hose. Torque the screws, pump-to-bracket, to 18-24 in.
Ibs. (2-3 Nm). Refer to Hose Routing Chart, this section.
INotel Whe~ i~stalling the oil supply hose, be sure .connections

are airtight. Poor connections can cause senous power-
head damage.
45C!ong 2-31
Install gearcase pressure tester to VRO~ pulse hose fitting. Pump to 15 PSI. Pump holds pressure?
I I
Hold pump in normal running position. Cover fuel outlet; rapidly Slowly pump gearcase tester. Inspect for escaping air.
remove pressure hose from pulse fitting. Pump should not click. Does pump click several times with each stroke of tester?
Did pump click? I i
c
"
3
PUMP DIA-I I Wait 5 seconds. Uncover fuel outlet. STOP HERE. Air motor housing is ~
Pump should click. Did pump cracked or leaking. Repair leak or IN-
click? STALL MOTOR HOUSING KIT.
:;t
o
c
N C"
I
W CD
-
N
(")
Shaft seal is leaking. REPLACE INTERME- Locate external leak. REPLACE ::::T
DIATE HOUSING. AIR MOTOR HOUSING OR IN-
CD
n
TERMEDIATE HOUSING. ~
(")
Install gearcase vacuum tester to VRO~ pump pulse fitting . Install gearcase vacuum tester to VRO~ pump pulse fitting. ::::T
Q)
Pump to 15 in. Hg. Pump to 15 in. Hg. -r
Hold pump in normal running position. Hold pump in normal running position.
....
Cover fuel outlet. Cover fuel outlet.
Rapidly remove vacuum hose from pulse fitting . Rapidly remove vacuum hose from pulse fitting.
Wait 5 seconds. Wait 5 seconds.
Uncover fuel outlet. Pump should click. Did pump click? Uncover fuel outlet. Pump should click. Did pump click?
I i i ,
REPLACE INTERMEDIATE HOUSING REPLACE INTERMEDIATE HOUSING

PCEOO82
fj,
~:0
co
Disassembly
All screws addressed in this procedure are No. 15 Torx.
if' The air motor cover is under spring pressure. Use caution
i l l when removing screws and releasing that pressure.
r;J With a No. 15 Torx screwdriver, remove the 8 Torx screws
L.!J holding
the air motor cover. To control the spring pressure,
place VRO~ pump on your bench with the air motor cover facing
upward. Hold down on cover while removing screws.
Set cover, screws, O-ring, and two springs aside .
.~ Remove the 6 Torx screws attaching the inlet housing to the

~ intermediate housing and separate these parts. As you lift the
inlet housing, the oil piston will be drawn out of the oil pump.
'3l Hold the intermediate housing and air motor piston in one
~ hand, and use the other to unscrew t he fuel piston - pull
gently with a counterclockwise motion .
... .. -
. --
-
~ Remove the fuel piston and the air motor piston from the A
t.:!.I intermediate housing.

Isl Remove the stem from the piston. Discard the stem and the
~ steel washers. Set the flapper valve and nylon washer/retainer
aside.
Clean all parts with OMC Cleaning Solvent and inspect for wear
and damage. Replace any suspect parts.
45C & Safety Related 2-33

6
Assembly
When assembling the fuel piston, always install a new washer

and stem in addition to other new parts required. Be sure to
lightly tighten stem with fingers; never with pliers.
Isl Lubricate stem with Evinrude or Johnson Outboard Lubricant

~ and slide it into hole in center of intermediate housing.
71 Install a new washer on air motor piston screw. Then, thread

~ air motor piston onto stem with clockwise rotation. Push
poppet valve @ in (toward the stem) to hold the screw in place
while turning. Tighten 1/4 turn past point of contact.
Isl Posit~on outer lip offuel piston in its groove in the intermediate
~ housmg.
Igl
Align oil piston with oil pump bore and install inlet housing.
~ Install 6 Torx screws and tighten 1/a turn past point of contact.
'1Ol ~osition
?uter lip .of air motor piston in its groove in the
~ mtermedlate housing.
24579
2-34 45C/eng
[!!] Place vacuum passage O-ring into cavity.
G2' Apply OMC Triple-Guard grease to one end of the poppet
~ spring, and install greased end onto the air motor dia-
phragm's poppet valve. (The grease will help stabilize the spring
while assembling.)
[!!] Install the air motor spring onto the air motor diaphragm.
1141 While installing the air motor cover, verify that the center
boss aligns with the poppet spring.
r:j5l lnstall the 8 Torx screws and tighten 1/8 turn past point of
~ contact.
45C/eng 2-35
VRO~ Warning Signals
~ Push fuel hose off fuel fittings - don't pull. If pushing won't
"Low Oil" Signal
A complete procedure for testing the VRO~ "low oil" circuit can
be found in VRO~ Installation Recommendations,this section.
"No Oil" Signal
1. Connect a shop tank with 50: 1 fuel/oil mixture to the fuel inlet
fitting.
2. Carefully, cut the oil supply hose from the pump oil inlet fitting.
3. Start the engine and run it at 1000 RPM, in gear.
4. After the residual oil is exhausted from the pump, the "no oil"
circuit should activate the warning horn .
The horn should sound 1/2 second on, 1/2 second off.
5. If the horn does not sound within ten minutes, check for battery
voltage at purple lead, VRO~ connector terminal "0", when
engine is running, and check the tachometer circuit. Refer to
Rectifier IRegulator Tests, Section 8.
6. If battery voltage is present at the pump, the tachometer circuit

is okay, and the warning horn circuit is okay - replace the VRO~
pump.
~ When testing is complete, be sure all oil hose connections

~ are airtight to avoid possible powerhead damage.
~ The "low oil" and "no oil" signals alert the operator to
~ possible VRO~ system problems. To prevent possible seri-
ous powerhead damage, you must be sure these signals are
working.
2-36 45C/eng
9494
Carburetor Servicing - All Models

fN=l Push fuel hose off fuel fittings - don't pull. If pushing won't
rv f211.cover
~~
Remove air silencer cover screws. Discard air silencer
gasket.
rJl ~ 2. Remove air silencer base screws and gasket; discard all.
~ ~ Use new screws and gasket upon reassembly.
3. Disconnect the drain hose and set the air silencer aside.
4. Cut fuel hose tie straps at carburetors and disconnect fuel

hoses.
~ ~ 5. Disconnect linkage from throttle levers.

6. Remove carburetor nuts, lock washers, and carburetors.
7. Remove primer hoses from carburetor nipples.
8. Remove carburetor flange gaskets and discard.
45C/eng 2-37
Disassembly
40,45,48
f811gl 1. Remove drain plug and high speed orifice @ from float
~ ~ chamber using OMC Orifice Driver, PIN 317002.
~ ~ 2. Remove intermediate air bleed orifice .

~ ~ 3. Remove retaining screws and float chamber .
~ ~ 4. Remove float and inlet valve assembly @.
~ ~ 5. Remove nozzle well gasket .
~ ~ 6. Remove components of slow speed needle .
~ 7. Remove four screws and carburetor body cover @.
[!] 8. Remove carburetor body gasket .
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.
~ 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 a mild aerosol solvent.
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.
2-38 45C/eng
Float Valve Assembly
1. Inspect the inlet needle and float valve seat:
Check inlet needle tip for grooves, nicks, scratches, or

distortion.
Check float valve seat for nicks, scratches, or distortion .
Check float for signs of oil or gasoline saturation.

11
INotellnl et needle and float valve seat must be replaced as a set.
Carburetor Body
f12l 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 l/e in. (3 mm)

through plug and pry out.
Install the plug convex side up. Securely flatten plug with
a flat end punch and plastic mallet. Apply Gasoila sealer
to the edge of plug .
5. If necessary, remove the lead shot to inspect passage for

restrictions or leaks.
Gently pry up on lead shot with a sharp edged tool.
Install a new lead shot. Flatten shot with flat end punch
and plastic mallet. Check for leakage.
45C/eng 2-39
r:J6l 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 .
If a leak occurs, blow dry and apply a drop of OMC Ultra

Lock at point .
Assembly
16
9489
40,45, 48
[m~ 1. Install a new high speed nozzle gasket .
@] 1181 2. Install the float and inlet valve assembly .

@]1181 3.lnstall the intermediate air bleed orifice @.
f171 f18l 4. Install the high speed orifice , gasket, and drain
~~ plug.
@] 5. 40, 45, 48 - Install components of slow spe~d needle :

Place one O-ring on threaded end of adapter sleeve.
Lubricate other O-ring with outboard lubricant and place
in groove on needle head.
Install adapter sleeve and torque to 30-35 in . Ibs.
(3-4 Nm).
Install needle and spring. Turn in carefully until it lightly
contacts seat.
Back out needle for initial setting - 2 turns for 40 or 2V2
tu rns for 45, 48.
17 ----------------~D~R=27~78
r,sJ
6. 50, 55 - Install slow speed needle and spring @ . Turn
~ carefully until it lightly contacts seat. 50, 55 ,
Back needle out for initial setting - 2V2 turns. (0)0
r:;-;J 7. 50, 55 - Install the carburetor body cover and gasket.
'-\,/~
L!!J Tighten the screws in an "X" pattern to a torque of 15-22 in.
Ibs. (1,6-2,4 Nm).
~ ~, a

~ C
!~ ~
~ @. --~
DR4598
2-40 45C/eng
8. Check for correct positioning of float level. Float level controls
the height of fuel in the float chamber and is very critical with
regard to carburetor calibration and function .
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,
PIN 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.
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.
9. 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.

K
To adjust, bend tab on float arm where tab contacts float seat.
CD Base of Carburetor Body

Q) Bend Float Lever Tang to achieve proper dimension 20
803406
1% in. to 1% in. (28-41 mm)
10. Install float chamber and a new gasket.
11. 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 Nm).
Installation
INotel Do not use sealer on carburetor gaskets.

& Replace any fuel hoses if deteriorated or damaged.
1. Install new carburetor flange gaskets.
2. Install primer hoses to carburetor nipples.
3. Install carburetors on manifold studs, and secure with lock

washers and nuts.
4. Install fuel hoses on carburetors, and secure, using a new

clamp and OMCTie Strap Installation Tool, PIN 323718.
5. Snap throttle linkage into place. To adjust linkage, refer to

Synchronization and Linkage Adjustments, Section 1, before
installing air silencer.

f211 6. Install .pul~e equalization hose between carburetors and
~ secure with tie strap.
7. Connect drain hose to air silencer base.
8. Install a new air silencer base to carburetor gasket and secure

air silencer using new screws.
9. Install air silencer cover using a new gasket.
10. Install air silencer screws and secure the air silencer cover.
11. If the slow speed needle adjustment has been disturbed, refer
to Carburetor Mixture Adjustment - All Models.
Carburetor Mixture Adjustment - All Models
~ The slow speed mixture in this carburetor is controlled by a

~ factory adjusted needle. This procedure should only be
used if the factory seal is gone or if the needle adjustment has
been disturbed.
\22\ 1. Make a reference mark on the adapter sleeve before you

disturb the needle adjustment.
123\ 2. Tiller models - as you face the steering handle, turn the idle
speed adjustment knob counterclockwise to complete slow
speed position.
3. Start the engine and run it in gear at idle speed 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.
1221 4. If the adjustment is too lean, note your reference mark

and turn the needle V12 revolution counterclockwise. Wait 15
seconds after each adjustment and repeat this procedure until
you reach the highest consistent RPM.
2-42 45C/e ng
1221 5. If the adjustment is too rich, note your reference mark @
and turn the needle 1/12 revolution clockwise. Wait 15 seconds
after each adjustment and repeat this procedure until you reach
the highest consistent RPM.
6. Repeat Steps 3 thru 5 for each carburetor.
7. To test your adjustment, run the 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 followi ng:
Engine temperature
Linkage adjustments
External recirculation system
Sufficient exhaust back pressure
Pulse equalization hose
45C/eng 2-43
Intake M anifold Servicing - All M odels
Removal
1. Follow steps listed in Carburetor Removal, this section .
2. Remove manifold screws and remove manifold.
Disassembly
1. Remove the two screws per leaf plate assembly, and remove
the leaf plate assemblies as required.
~ Do not disassemble leaf plate assemblies unless leaf plate

~ seats, leaf valves, or leaf stops are damaged or corroded.
~ Check parts availability before servicing leaf plate assem-

~ blies. Assemblies on some models are not serviced in
detail.
2. When disassembling leaf plate assemblies, do not lift or bend

leaf valves. Remove the leaf stop screws, and remove the stops
and leaf valves.
2
3. When disassembled, keep the stops and leaf valves separated
by assembly.
Inspection
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.
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.
'2l f3l . Use a machinist's straightedge to check for flatness in all

~~ directions. The mounting surface must be flat,
0.004 in. (0,10 mm).
fN=J All intake manifold components must be perfectly clean

~ before assembly. Do not use a strong carburetor cleaner or
hot soaking tank.
2-44 45C/eng
Assembly
1411. Place leaf valves on leaf plate. If new valves do not seat on
~ the leaf plate, turn the leaf valves over.
r::=J 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.
4
1254
~ Do not lap leaf plates. 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.
1sl4. Apply OMC Screw Lock to mounting screws. Wipe off

~ excess adhesive.
5. Assemble leaf valve shim (if required) and leaf stop. Install two
screws near center of leaf stop. Do not tighten. 2683
f616. Hold leaf valve assembly in a horizontal position. This will

~ usually align leaf valves over ports in leaf plate. Tighten the
two screws evenly.
07. Use a sharp pencil to mark the edges of leaf valves.
1sl8. Use a pencil eraser to gently open the leaf valves to check
~ the alignment of the valve over the port. Valves should be
spaced evenly over port. If not, loosen mounting screws and
reposition leaf valve.
9. After leaf valve is positioned properly, install remaining screws.

Tighten all screws evenly to a torque of 25-35 in . Ibs. (3-4 Nm).
10. Apply OMC Locquic Primerand OMC Nut Lockto the leaf plate
assembly to manifold screws.
11. Using new gaskets installed dry, position each leaf plate
assembly and torque the screws to 25-35 in. Ibs. (3-4 Nm).
Installation
1. Using new gaskets installed dry, install the intake manifold.

Torque the screws evenly to 60-84 in. Ibs. (7-9 Nm) .
2. Refer to Synchronization and Linkage Adjustments, Section 1,

for adjustment information.
45C/eng 2-45
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 PAGE REFER TO REFER TO REFER TO REFER TO

REFER TO
OWNER MANUAL 2-8 PAGE 2-16 PAGE 2-24 SECTION 1 PAGE 2-37 PAGE 2-44
45C
Ignition System
Table of Contents
& General Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Specifications .............................
3- 2
3- 3
About This Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 6
Spark Plug Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 7
Flywheel Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 8
Ignition Coil Tests ................................ 3-10
Principles of Operation - CD II ....................... 3-12
RPM Limiting Power Pack .......................... 3-14
General Information - CD II Ignition .................. 3-14
Troubleshooting Test Equipment .................... 3-15
Amphenol Connectors, Servicing Information .......... 3-16
Ignition Plate Servicing - UFI, CD II - 4 Amp ............ 3-18
Ignition Component Replacement - UFI, CD II - 4 Amp .... 3-19
Stator Servicing - CD II - 12 Amp . . . . . . . . . . . . . . . . . . . . 3-20
Timer Base Servicing - CD II - 12 Amp . . . . . . . . . . . . . . .. 3-20
Ignition Coil Replacement - All Models ................ 3-22
Indexing Flywheel, Erratic Ignition - All Models. . . . . . . . . 3-23
Function Tests, S.L.O. W. - UFI ...................... 3-24
Ignition Output Tests - UFI . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Ignition Output Tests - CD II . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Function Tests, S.L.O. W. - CD II ..................... 3-42
45C/eng 3-1
& General Safety Warnings
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.

3-2 45C/eng
Special Torque Chart _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
MODEL DESCRIPTION IN. LBS. FT. LBS. Nm ADHESIVE
All Ignition Coil Screws 48-96 5,4-10,8

All Spark Plug 216-240 18-21 24-27
All Flywheel Nut 100-105 135-140 OMC Gasket
Sealing Compound
UFI Ignition Module Screws 30-40 3,4-4,5 OMC Ultra Lock
UFI Charge Coil Screws 30-40 3,4-4,5 OMC Ultra Lock
UFI, CD II Ignition Support Plate

Screws
48-60 5-7 OMC Nut Lock
UFI, CD II Ignition to Retainer Plate

Screws
25-35 2,8-4,0 OMC Nut Lock
CD II Sensor Coil Screws 15-22 1,6-2,4

CD II Charge Coil Screws 15-22 1,6-2,4
CD II Power Pack Screws 60-84 7-9
CD II
12 Amp Adapter Screws 48-60 5-7
CD II
12 Amp Timer Base Tab Screws 25-35 2,8-4,0 OMC Nut Lock
CD II
12 Amp Stator Screws 120-144 14-16 OMC Nut Lock
45C/eng 3-3
UFI
Ignition Coil Charge Coil Ignition Module
Model Primary Secondary Minimum Output Voltage

Ohms Ohms Ohms
Cranking Running
All 0.1 0.05 275 50 900 100 175 200
PCE0074
CD II
Ignition Coil Sensor Coil Charge Coil Power Pack
Primary Secondary Minimum Output Minimum Output Min. Output Voltage

Ohms Ohms
Ohms Ohms Voltage Cranking Voltage Cranking Cranking Running
0.1 0.05 275 50 40 10 1.5 900 100 230 175 200
PCE0074C
CD II - 12 Amp System
Ignition Coil Sensor Coil Charge Coil Power Pack Power Coil
Min. Output Voltage
Primary Secondary Ohms Minimum Output Minimum Output Ohms
Ohms
Ohms Ohms Voltage Cranking Voltage Cranking Cranking Running
0.1 0.05 275 50 15 2 0.5 850 100 230 230 250 400 40
PCE0074B
3-4 45C/eng
Universal Pullar Kit, PIN 378103
Socket Removal Tool, PIN 322699
Pin Removal Tool, PIN 322698
Insert Tool, PIN 322697
Crimping Pliers, PIN 322696
Locating Ring, PIN 334994
Sealants and Lubricants Required
OMC Gasket Sealing Compound

OMC Moly Lube
OMC Black Neoprene Dip
OMC Nut Lock
Evinrude@ or Johnson@ Outboard Lubricant
Isopropyl Alcohol
OMC Ultra Lock
Specialized Test Equipment _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Stevens Flywheel Strap Wrench No. S-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
45C/eng 3-5
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, select
the appropriate area in the section (by model) and begin your
testing with Ignition Output Tests.
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 - All Models, Page 3-23.
3-6 45C/eng
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 Triple-Guard 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.
Sustained
40 OL78C @ 0L16V @
NA NA
48, 50 0.030 in. (0,8 mm) FIXED GAP
OL16V @ L16V @ OL78V @ L78V@

45, 55
FIXED GAP FIXED GAP FIXED GAP FIXED GAP
45C 3-7
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 equipmenti 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, twist and remove

L..ll all spark plug leads.
rv f21 2. Remove the flywheel nut using a strap wrench or other
~ ~ suitable tool to hold the flywheel.
fJ1 3. Apply OMC Moly Lube to threads of pressing screw and

~ center hole of crankshaft.
~ 4. Assemble the following components from OMC Universal

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

Pressing Screw, PIN 307637
Handle, PIN 307638
@ Screws (3), PIN 309492
Washers (3), 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.
& Safety Related 3-8 45C1eng

Installation
'5l 1. Install the flywheel key with its outer edge parallel to
EJ centerline of crankshaft and single upset mark facing down.
2. Clean the crankshaft and flywheel tapers with OMC Cleaning
Solvent and let dry. These surfaces must be clean and dry to
allow proper locking of the tapers.
1sl 3. Align the flywheel keyway and in.stall 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
5 DR2116
below.
Flywheel Nut Torque Chart
MODEL FT. LBS. N'm ADHESIVE
OMC
Gasket
40-55 100-105 135-140
Sealing
Compound
45C/eng 3-9
Ignition Coil Tests
A wide variety of ignition testers are available from various
manufacturers. In addition, some automotive testers having the
proper specifications can be used.
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 DR4037
leakage testing.
~ To avoid possible shock hazards and to prevent leakage,

ill perform all tests to the coil on a wooden or insulated bench
top.
Specifications
Primary Secondary Operating Analyzer

Resistance Resistance Amps (Max) Polarity
Mere-O- Tronie
2
DR4038
Magneto C.D. 1.5 amps
Coil 0.10.05 n 27550 n Normal
PIN 583740 Stevens
1.1 amps
Ohmmeter Test
Resistance tests can be performed while the ignition coil is still

mounted to the powerhead.
1. Twist and remove the spark plug and primary leads from the
DR4081
ignition coil.
rv black
~
2. Calibrate ohmmeter on appropriate scale. Connect meter
lead to a 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.
~ 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.

Power Test
INoteI when
Do not e~ce~d the coil's maximum
testmg It.
specified amperage
f41 The ignition coil is tested with "normal" polarity connections.

~ Connect tester red lead to the primary terminal of the coil
and the tester black lead to the ground tab @. Connect the high
tension lead of the tester to the coil spark plug lead @.
A steady spark in the tester, at or before maximum specified

amperage, indicates a good coil. Refer to Ignition Coil Specifica-
tions.
Surface Leakage Test
r;=Jt
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.
f51 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. Leakage will be apparent wherever insulation
has broken down. Replace any coil or spark plug lead that shows
leakage.
45Cleng 3-11
Principles of Operation - CD II
Flywheel
rv The flywheel contains permanent magnets necessary to ener-

~ gize the sensor and charge coils. Once the flywheel exceeds a
minimum cranking RPM, the flywheel's magnetic lines of force
passing through the sensor and charge coil windings produce
voltage in those circuits.
When the flywheel is in good condition and correctly located, it

controls ignition timing and charge coil output.
All models - The sensor magnets are in a ring around the

flywheel hub and the charge coil magnets are in the
flywheel rim.
Charge Coil (Stator and Charge Coil Assembly)
f21 rJl The charge coil consists of many windings of wire

l=.J ~ wrapped around a metal lamination. Once the flywheel
exceeds a minimum cranking RPM, the flywheel's magnetic lines
of force cutting through the charge coil windings produce be-
tween 200 and 300 volts of alternating current (VAC). This voltage
is supplied to the power pack to operate the ignition system.
Sensor Coil (Timer Base and Sensor Coil Assembly)
f21 f3l The sensor coil consists of many windings of wire

l=.J ~ wrapped 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 approx-
imately 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 Coil - CD II - 12 Amp
rJl The power coil is located on the stator assembly. It consists

~ of many windings of wire wrapped around a metal lamination.
Once the flywheel exceeds a minimum cranking RPM, the fly-
wheel's magnetic lines of force cut through the coil windings to
produce voltage. The voltage is supplied to the power pack to
operate the S.L.o. W. warning system.
3-12 45C/eng
Power Pack
[";l 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.
The power pack has an RPM counting and RPM limiting circuit to
protect the engine from damage due to severe overspeeding.
The power pack incorporates the S.L.D. W. warning system,

which limits engine speed to approximately 2500 RPM if engine
temperature exceeds 2030 F (95 0 C). Once the S.L.D. W. warning
system has been activated, t he engine must cool to 1620 F (72 0 C)
and the engine must be stopped before normal operation can be
resumed.
Stop Circuit
f511s1 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.
f51 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
rJl Theignition 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.
7
There is one ignition coil per cylinder. 20473
45C/eng 3-13
RPM Limiting Power Pack
This power pack has a built-in RPM limiting device. Certain
models are equipped with a RPM limiting power pack to guard
against possible powerhead failures caused by improper propel-
ler selection (underpropping), excessive wear on propeller
blades, improper 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 powerhead damage due to overspeeding.
Model RPM Limit
40, 50 Recreational 6700
25DR,40R,48 6100
40RS,45,55 5800
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 when the problem was in the tester.
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 .
3-14 45C/eng
1 2 ~3~__________~
1942 2804 16489
Troubleshooting Test Equipment

fN=1 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
Merc-O- Tronic No. 55-4S or 55-6S
~ Peak-reading voltmeters:
Merc-O- Tronic No. 781
Stevens No. CD-77
Electro-Specialties No. PRV-1
~ Ohmmeter capable of reading low and high ranges :

Merc-O-Tronic No. 700 VOA
Stevens No. AT-101
~ 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 room temperature (70 F or 21 C).
~ Ignition module load adapter:

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

Stevens No. TS-77
~ Jumper wire for Amphenol connectors - can be made with:

@ No. 16 wire, 8 in. (200 mm) 6
@XJMC PIN 511469, Pin 73158
~MC PI N 581656, Socket

@XJMC PIN 510628, Shrink tube
45C1eng 3-15
Amphenol Connectors, Servicing Information
Terminal Removal
R Use the recommended lubricant for terminal removal.

~ Substitutes may cause high resistance connections, short
circuits among terminals, or damage to the connector material.
1. To remove a terminal from the plug or receptacle, apply

isopropyl alcohol to the cavity at both ends to lubricate the
terminal.
[!] 2. Select the proper removal tool for the terminal :

@ OMC Pin Removal Tool, PIN 322698
@ OMC Socket Removal Tool, PIN 322699
~ 3. Place the plug or receptacle against the edge of a flat surface

t=l and allow clearance for the terminal to be removed.
~ 4. Insert the removal tool into the terminal and push the
t=l terminal out of the connector.
f31 5. Pin and socket @ terminals may be replaced if damaged.
~ Crimp new terminals onto the wire at point @ .
f41 6. Use OMC Crimping Pliers, PIN 322696, when attaching

~ Amphenol terminals.
4
30387
3-16 45Cle ng
Terminal Installation
1. Connect the plug and receptacle before installing the terminal.

Apply isopropyl alcohol to the plug and receptacle. Align arrows
and carefully insert the plug into the receptacle.
2. Apply isopropyl alcohol to the terminal cavity.
f51 ~, Use only OMC Insert Tool, PIN 322697, to install termi-
~ ~ nals. To avoid injury, securely hold insert tool against
shoulder of terminal while inserting terminals.
f61 3. P~sition the insert tool @ against the shoulder of the

~ termmal.
rJl 4. Rest the connector against a solid surface. With the insert
~ tool firmly against its shoulder , insert the leading tip of the
terminal into its cavity. Push the terminal until step CD of the insert
tool reaches the connector body, seating the terminal.
f8l 5. Check your work. Separate the connector and look at the
~ terminal you just inserted. If it is properly seated, apply
isopropyl alcohol to both connector halves and reconnect them. If
the terminal did not seat, remove it and repeat the procedure.
~ 6. Secure the connector with wire retainer.
9
30392
Ignition Plate Servicing - UFI CD II - 4 Amp
Removal
'" 1. To avoid accidental starting of engine while servicing,

i l l 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.
rv 4.retainer
~
Loosen the five screws attaching the ignition plate to the
plate. Lift the ignition plate from the powerhead.
f21 5. Remove the four support plate screws @. Lift the retainer
~ and support plate from the powerhead.
Installation
f21 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 and tighten the screws to a torque of 48-60
in. Ibs. (5-7 Nm).
~ 2. Apply OMC Moly Lube to crankcase boss.

r.il 3. Lubricate the ignition plate bearing groove @ with OMC
~ Moly Lube.
151 4. Apply OMC Nut Lock to the threads of the five 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 five
screws to a torque of 25-35 in. Ibs. (2,8-4,0 Nm).
6. Connect and adjust spark advance link. Refer to Synchroniza-

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

full advance movement of the ignition plate.
it Safety Related 3-18 45Cieng

Ignition Component Replacement -
UFI, CD II - 4 Amp
f612. Remove the screws retaining the ignition component that is
~ being replaced.
1713. UFI- If the charge coil or ignition module is being replaced,

~ separate the bullet connectors underneath the ignition mod-
ule.
[!] 4. Remove the wire clamp from the ignition plate.

'115. Loosen the five ignition plate screws. Lift the ignition plate
~ from the powerhead.
[!] 6. Remove the plate @ from bottom of the ignition plate.

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

retaining screws. Loosely install the new ignition component on
the ignition plate. Connect bullet connectors if necessary.
Is' 19l9.
Route leads and install clamp , plate @, and spiral
~~wrap.
~ All component leads must be routed through clamp and

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

component leads through wire clamps.
r,Ql12. Position OMC Locating 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 torque speci-
fied in chart on Page 3-3.
~ 13. Repeat Step 12 for each component.
45Cleng it Safety Related 3-19

Stator Servicing - CD II - 12 Amp
Removal
"" To avoid accidental starting of engine while servicing, twist

1. Remove the flywheel. Refer to Flywheel Servicing, Page 3-8.
2. Disconnect stator yellow and yellow/gray leads at terminal

board .
3. Separate the stator 5-pin Amphenol connector. Remove the

black/yellow stop circuit lead from terminal liE".
~ 4. Remove stator retaining screws @ .

Installation
121 1.
Remove any varnish around retaining screw holes on
~ both sides of stator. The stator must have metal to metal
contact with the crankcase head and its retaining screws.
2. Position the stator on adapter and route the leads.
3. Apply OMC Nut Lock to mounting screws. Install screws and

torque them to 120-144 in. Ibs. (14-16 Nm).
4. Attach stator yellow and yellow/gray leads to terminal board.

Coat final connection with OMC Black Neoprene Dip.
5. Install black/yellow stop circuit lead in 5-pin Amphenol connec-

tor, terminal liE".
6. Install the flywheel. Refer to Flywheel Servicing , Page 3-8.
Timer Base Servicing - CD II - 12 Amp
Removal
'" To avoid accidental starting of engine while servicing, twist

1. Remove the stator. Refer to Stator Servicing.
2. Separate the timer base 3-pin Amphenol connector.

!al3. Remove the three timer base retaining clips. Remove timer
~ base from adapter.
4. Remove timer base retainer.
f415. Remove the three adapter mounting plate screws . Re-

~ move plate from powerhead.
Installation
1. Inspect bushing in the timer base and inspect powerhead timer

base boss. Both surfaces must be free of dirt, metal chips, and
scratches.
f512. Align adapter with threaded holes in powerhead. Slotted

~ area of adapter must face starboard side.
f413. Install adapter mounting screws. Torque screws to 48-60 in.

~ Ibs. (5,5-7 Nm).
f614. Apply OMC Moly Lube grease around powerhead boss and
~ timer base bushing @, and into retainer groove .
05. Lubricate timer base retainer with outboard lubricant.
1ol6. Install retainer in timer base groove with retainer tabs

l!J positioned to right of lever. Squeeze tabs and insert timer base
into adapter.
~ 7. Position the three retainer clamps @ on adapter.

!al8. Apply OMC Nut Lock to the three retainer clamp screws.
~ Install screws and torque them to 25-35 in. Ibs. (2,8-4 Nm).
9. Connect the timer base 3-pin Amphenol connector.
45C/eng 3-21
Ignition Coil Replacement - All Models
Removal
1. Twist and remove cover to remove the spark plug and primary
leads from the ignition coils.
rv any
~
2. Notice the fastener and washer orientation before removing
screws.
3. Remove the screws, coil, and washers.
Installation
r.;l 1. Assemble the correct sequence of washers and locate the

L.!J ignition coil on the powerhead. Install and tighten the retain-
ing screws to a torque of 48-96 in. Ibs. (5,4-10,8 Nm).
2. Apply a light coating of OMC Triple-Guard 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 OMC Triple-Guard grease to the

opening of each primary lead cover and install the covers.
Observe proper wire routing and ignition timing. Orange/blue
primary lead must be connected to the No.1 ignition coil.
1
DR2619
@ Flat Washer
@ Ignition Coil Ground Strap
Starwasher
3-22 45C/eng
Indexing Flywheel, Erratic Ignition - All Models
Internal ignition module problems could cause a module to fire
erratically 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 all spark plugs.
r.;l 2. Place the eraser end of a pencil in the No.2 spark plug hole.
L.!J Slowly turn the flywheel by hand clockwise, until the greatest
length of the pencil is outside the spark plug hole. This indicates
the No.2 piston is near top dead center.
'21 3. Mark on the flywheel rim directly across from the timing
~ pointer. Label this mark "No. 2".
4. 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.
5. 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.
If another cylinder's number appears or the correct

number appears more than once per revolution, verify
ignition coil primary lead routing or replace ignition
module.
45C/eng 3-23
Function Tests, S.L.O. W. - UFI
This ignition system incorporates the S.L.O. W. warning system
TAl
which will gradually limit engine speed to approximately 2000

RPM when engine temperature exceeds 2030 F (95 0 C). To resume
normal operation after the S.L.O. W. warning system has been
TAl
activated, the engine must cool to 1620 F (72 0 C) and the engine
must be slowed to an idle.
The S.L.O. W warning system depends on input from the

TAl
temperature switch tan lead. On remote electric start models, the

S.L.O. W. warning system is isolated from other warning horn
TAl
signals by a blocking diode in the engine wiring harness.

o
Temperature Switch
1. Disconnect temperature switch tan lead.
2. Install correct test propeller. Start engine in test tank and run at
3500 RPM.
3. Attach engine harness tan lead to a clean engine ground.

1
If engine slows to approximately 2000 RPM, test temper- DR2344
ature switch. Refer to Temperature Switch Test, Section

4.
If engine does not slow to approximately 2000 RPM,
check wiring or replace ignition module. Refer to Ignition
Plate Servicing.
Blocking Diode - Remote Electric Models
If the S.L.D. W. warning system is activated when warning horn

TAl
receives a no oil or low oil signal, test engine harness blocking

diode.
1. Disconnect engine harness red connector.
rv engine
~
3. Calibrate ohmmeter on appropriate scale. Connect between
harness tan lead and engine harness tan pin @. 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.
3-24 45C/e ng
IGNITION OUTPUT TESTS - UFI
I.A 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.
~ 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

f1l 1. Twist and remove the spark plug leads from both spark
~ plugs.
r:;"] 2. Adjust the gap on the spark tester to 1/2 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

i l l 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 5 - RUNNING OUTPUT TEST.
If tester shows good output on one cylinder, go to STEP 3

- IGNITION PLATE 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

STEP 2 - STOP CIRCUIT TEST
Elimination Test
fJI 1. Remove component bracket cover and disconnect stop

~ circuit 1-pin Amphenol connector.
"'" To avoid possible shock hazard, do not handle ignition coils

2. Crank engine and observe results at spark tester . 131 DR2621
_ _ _ _ _ ---1
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 or both gaps, go to STEP 3 -

IGNITION PLATE OUTPUT TEST.
& Safety Related 3-26 45C

Ohmmeter Test - Stop Button
~ All ohmmeter tests must be performed with the engine

~ NOT running.
f411. Most steering ha~dles 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.
f5l3. Calibrate an ohmmeter on appropriate scale. Connect meter

~ leads between stop button 1-pin Amphenol connector and a
clean engine ground.
DR4097
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.
"" To avoid sudden loss of control, replace the stop button

i l l assembly if your test results vary.

Ohmmeter Test - Key Switch
~ All ohmmeter tests must be performed with the engine

~ NOT running.
1. Install emergency stop switch clip and lanyard assembly.
'6l 2. Calibrate ohmmeter on appropriate scale. Connect meter

~ leads between engine harness black/yellow lead and a clean
engine ground.
DR4097
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 ignition module.
3-28 45C/eng
7
DR4256
STEP 3 - IGNITION PLATE 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.
~ 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.
3. Set peak-reading voltmeter to "POS" and "500".
0 4. Connect voltmeter red lead to adapter red lead and meter black lead to a clean engine ground .
5. Crank engine and observe meter.
Meter must show 175 volts or higher.
6. Repeat Steps 2 thru 5 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 ignition module. Refer to Ignition Component
Replacement, Page 3-19.
If both primary leads have no output, go to STEP 4 - CHARGE COIL TEST.

STEP 4 - CHARGE COil TEST
'" To prevent accidental starting of engine while testing, twist

ill and remove both spark plug leads.
1. Remove manual starter and flywheel. Refer to Flywheel Servic-

ing, Page 3-B.
~ 2. Remove the two ignition module mounting screws.

19l 3. Disconnect the brown and brown/yellow lead bullet connec-
~ tors.
4. Calibrate ohmmeter on appropriate scale. Connect to charge

coil brown and brown/yellow leads .
Meter must show 900 100 ohms.
5. Check for a grounded condition - calibrate ohmmeter on

appropriate scale and connect its black lead to a clean engine
ground. Alternately connect ohmmeter red lead to charge coil
brown and brown/yellow leads .
Meter must show a high reading.
6. Replace charge coil if your test results vary.
7. If charge coil tests good, replace ignition module. Refer to

Ignition Component Replacement, Page 3-19.
B. Install flywheel. Refer to Flywheel Servicing, Page 3-B.
9. Complete all circuits disconnected during this test. Observe

proper ignition coil primary lead routing. Orange/blue primary
lead must be connected to the No.1 ignition coil.

DR4257
STEP 5 - RUNNING OUTPUT TEST
r;Ql 2. ~se .a. clock~ise. twist to install Stevens Instrument No. TS-77 terminal extenders, or equivalent,
~ on Ignition cOIl pnmary posts.
r;Ql 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.
r;Ql 5. C.onnect voltmeter red lead to No. 1 terminal extender. Connect meter black lead to a clean
~ engme ground.
6. Start engine and run under load at RPM where ignition problem exists .
Meter must show 200 volts or higher.
7. Repeat Steps 5 and 6 for cylinder No.2.
8. If either cylinder shows less than 200 volts, test charge coil. Refer to STEP 4 - CHARGE COIL TEST .
If charge coil tests good, replace the ignition module.
9. Remove terminal extenders. Install ignition coil primary leads. Observe proper wire routing.
Orange/blue primary lead must be connected to the No. 1 ignition coil.
3-31
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.
f21 2. Adjust the gap on the spark tester to 1/2 in. (12 mm).
~ Connect tester leads to the spark plug leads. Secure tester clip
to a clean engine ground.
R 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

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 cylinder:
Rope or 4 Amp , go to STEP 5 - POWER PACK OUTPUT

TEST
12 Amp , go to STEP 4 - SENSOR COIL TEST
If tester shows no output, go to STEP 2 - STOP CIRCUIT

TEST.
r.::=J 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

3 DR4185
STEP 2 - STOP CIRCUIT TEST
Elimination Test
it 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.
45C/eng & Safety Related 3-33 CD II

DR4186
Ohmmeter 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, terminaIIE", and a clean engine ground.
The meter must show a high reading.
4. Momentarily, press inward on the stop button.
5. Remove the clip and lanyard.
it To avoid sudden loss of control, replace the stop button assembly if your test results vary.
it Safety Related 3-34 45C/eng

--
DR4186
Ohmmeter Test - Key Switch
1. Install emergency stop switch clip and lanyard assembly.
1612. 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.
45C /ong 3-35

CD II
STEP 3 - CHARGE COIL TEST
Ground Test
12] 1. Disconnect 5-pin Amphenol connector.
rJl 3. Alternately, connect voltmeter between charge coil terminals and a clean engine ground. Refer to
~ chart for terminal locations. Crank engine and observe meter reading at each connection.
Any reading on either test indicates charge coil or leads are grounded.
Locate and repair ground, or replace charge coil.
Rope or 4 Amp 12 Amp
"A", "0"
PCE0068
4. If no reading is indicated in Step 3, go to Output Test.
Output Test
1sl 2. Attach voltmeter black lead to charge coil terminal " A". Attach meter red lead to the other charge
~ coil terminal.
3. Crank engine and observe meter reading.
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.
If w iring and connector condition is good, go to Ohmmeter Test.
3-36 45C/eng
Ohmmeter Test
~ 1. Insert jumper wires in charge coil terminals listed in chart:
Rope or 4 Amp 12Amp
IIA" , "D" IIAIf, liB"
PCE0068
~ 2. Calibrate ohmmeter on appropriate scale. Connect between jumpers. Meter must show :
900 100 Ohms 850 100 Ohms
PCE0068
f101 3. To test !or 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.
4. Complete all circuits disconnected during these tests.
45C/eng 3-37
CD II
STEP 4 - SENSOR COIL TEST
Ground Test
[!!J 1. Disconnect Amphenol connector:

Rope or 4 Amp, the 5-pin connector
12 Amp, the 3-pin connector
2. Set peak-reading voltmeter to:
Rope or 4 Amp, "POS" AND "5", or "SEN" and "5" on Stevens CD-77 meter.
12 Amp, "POS" and "5", or "SEN" and "5" on Stevens CD-77 Meter.
f111 3. Alternately, connect voltmeter between sensor coil terminals and a clean engine ground. Refer
~ to following chart for terminal location. Crank engine and observe meter reading at each
connection.
Any reading indicates sensor coil or leads are grounded.

Locate and repair ground, or replace sensor coil.
IIB","C" IIA", "8", "C"
PCE0068
4. If no reading is indicated in Step 3, go to Output Test.
Output Test
1. Set peak-reading voltmeter to "POS" and "5", or "SEN" and "5" on Stevens CD-77 meter.
r:J2l 2. Attach voltmeter black lead to ignition plate connector, terminal "C". Attach meter red lead per
~ following chart.
3-38 45C/eng
3. Crank engine and observe meter reading.
1.50 Volts 0.5 Volt

lIB" IIA", liB"
PCE0068
If meter shows higher voltage, go to STEP 5 - POWER PACK TEST.

If meter shows lower voltage, check condition of wiring and connectors.
If wiring and connector condition is good, go to Ohmmeter Test.
Ohmmeter Test
1. Calibrate ohmmeter on appropriate scale.
@] 2. Insert jumper wires in sensor coil terminals listed in chart.
Rope or 4 Amp 12Amp
"B","C" "A", "B"

"C","8"
PCE0068
3. Connect ohmmeter between jumpers. Meter reading must be:
40 10 Ohms 15 2 Ohms
PCE0068
1141 4. To test .for a grounded condition, connect ohmmeter alternately between each jumper and a
clean engme ground.
Any needle movement indicates sensor coil or leads are grounded.
Locate and repair ground, or replace sensor coil.
5. Complete all circuits disconnected during these tests.
45C/eng 3-39
CD II
15
DR4258
STEP 5 - POWER PACK OUTPUT TEST
& To prevent accidental starting of engine while testing, twist and remove both spark plug leads.
1.j5l 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.
1151 3. C.onnect peak-reading voltmeter red lead to adapter red lead and meter black lead to a clean
engine ground.
4. Adjust voltmeter to settings listed in following chart. Crank engine and observe meter. Meter must
show at least:
Models Voltmeter Output

40RS,45,55 "NEG," 500 175
40RE, BA "POS," 500 175
12 Amp "POS," 500 230
5. Repeat Steps 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
good, replace the power pack.

DR4257
STEP 6 - RUNNING OUTPUT TEST

f16l 2. ~se .a. clock~ise. twist to install Stevens Instrument No. TS-77 terminal extenders, or equivalent,
~ on Ignition cOil primary posts.
f16l 3.lnstall 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.
f16l 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

40RS,45,55 "NEG," 500 200
40RE,BA "POS," 500 200
12 Amp "POS," 500 250
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.
If charge coil tests good, replace the power pack.
7. Remove terminal extenders. Install ignition coil primary leads. Observe proper wire routing.
Orange/blue primary lead must be connected to the No.1 ignition coil.
45C1eng 3-41
CD II
] [4000 [
(D Qj
Rxl00
(D Qj Rxl00
DR4137 DR4138
Function Tests, S.L.O. W. - CD II
This ignition system incorporates the 5.L.0. W. warning system, which gradually limits engine speed to
approximately 2500 RPM when engine temperature exceeds 2030 F (95 0 C).
To resume normal operation after the 5.L.0. W. system has activated, allow the engine to cool to 1620 F
(72 0 C) and turn it off.
The 5.L.0. W. system depends on input from the temperature switch tan lead. On electric start models,
the 5.L.0. W. system is isolated from other warning horn signals by a blocking diode in the engine
wiring harness.
Temperature Switch
2. Install correct test propeller. Start engine in test tank and run at 3500 RPM.
3. Attach the engine harness tan lead to a clean engine ground.

Engine must slow to approximately 2500 RPM.
4. Stop the engine.
If engine speed reduced in Step 3, test the temperature switch. Refer to Temperature Switch
Test, Section 4.
If engine speed did not reduce in Step 3, continue with this procedure.
5. Separate 5-pin Amphenol connector between the stator assembly and power pack.
111 6. Calibrate ohmmeter on appropriate scale. Alternately attach meter leads between terminal"C",
~ "0", and a clean engine ground.
Meter must show a high reading.
~ 7. Attach ohmmeter leads to terminals "C" and "D".

If meter shows 400 40 ohms, replace power pack.
If your test results vary, replace stator.
INotel Do not run the engine with power coil leads disconnected.
3-42 45C/eng
Powerhead
Table of Contents

Service Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 3
Engine Temperature Check. . . . . . . . . . . . . . . . . . . . . . . . . 4- 5
Temperature Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 7
Retaining Ring Pliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 8
Taper Pin Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 9
Powerhead Servicing ............................. 4-11
Removal ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Disassembly .................................. 4-12
Cleaning ..................................... 4-16
Inspection .................................... 4-17
Assembly .... . ................................ 4-19
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
45C 4-1
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.
4-2 45C1eng
Special Torque Chart
Description In. Lbs. Ft. Lbs. Nm Adhesives
Flywheel Nut 100-105 108-115 OMC Gasket Sealing Compound
Cylinder Head Screws 216-240 18-20 25-27

Connecting Rod Screws * 30-32 40-43 Outboard Lubricant
Main Bearing Screws 216-240 18-20 25-27

Spark Plug 216-240 18-20 25-27
Crankcase Head Screws 60-84 7-9 OMC Gasket Sealing Compound
Powerhead Mounting Screws 216-240 25-27 OMC Gasket Sealing Compound
Exhaust Cover Screws 48-84 5-9 OMC Gasket Sealing Compound
Intake Manifold Screws 60-84 7-9

Idle Stop Bumper Screw 84-120 9,5-13,5
Pipe Plug - Exhaust Cover 60-84 7-9
* To ensure maximum bearing life, use OMC Rod Cap Alignment Fixture, PIN 396749.
45C/eng 4-3
Sealants and Lubricants Required _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Johnson@ or Evinrude@ Outboard Lubricant

OMC Gel-Seal"
OMC Gel Seal and Gasket Remover
OMC Needle Bearing Assembly Grease
OMC Locquic Primer
OMC Moly Lube
OMC Adhesive M
OMC Nut Lock
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
Machinist's Straightedge
Powerhead Holding Fixture, OTC No. OEM 4157, or equivalent
Rubber Gloves
OMC Special Tools Required _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Rod Screw Torquing Socket, PIN 331638

Pressing Pin, PIN 326356
Piston Cradle, PIN 326573
Retaining Ring Driver, PIN 318599
Retaining Ring Cone, PIN 318600
Upper Crankcase Seal Installer, PIN 334500
Lower Crankcase Seal Installer, PIN 339752
Ring Compressor, PIN 326592
Ring Compressor, Oversize, PIN 330222
Rod Cap Alignment Fixture, PIN 396749
Wrist Pin Bearing Tool, PIN 336660
4-4 45C/eng
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.
1
The Thermomelt Stik mark will appear dull and chalky when the
surface marked is below the Stik's rated temperature . When the
surface exceeds the Stik's rated temperature, the mark will
appear liquid and glossy.
rt 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
700 100 F (21 0 30 C).
Pyrometer Procedure

1. Install correct test propeller and place engine in a test tank.
2. Start the engine and run it at 3000 RPM for at least 5 minutes.
1313. Reduce engine speed and run it at 900 RPM for 5 minutes. At
~ 900 RPM , a digital pyrometer should indicate 1400 150 F (600
rC) when held on cylinder head .
If engine temperature is not within this range, trouble-

shoot cooling system to determine problem.
1314. Increase engine speed to 5000 RPM. At 5000 RPM, the digital
~ pyrometer must not indicate more than 1200 F (50 0 C) .
If engine temperature exceeds 1200 F (50 0 C), trouble-

shoot cooling system to determine problem.
~ If your test readings are low or inconsistent, coat the probe

~ location with a liberal amount of Wakefield Heat Sink
Compound, OMC PIN 322170.
45C/eng it Safety Related 4-5

Markal Thermomelt Stik Procedure

1. Install correct test propeller and place engine in a test tank.
2. Start engine and run it at 3000 RPM for at least 5 minutes.
03.MarkReduce engine speed and run it at 900 RPM for 5 minutes.

0 0 0
the cylinder head with a 125 F (52 C) and a 163 F (73 C)0
Thermomelt Stik.
4. At 900 RPM, the 1250 F (52 0 C) mark should appear liquid and
glossy. The 1630 F (73 0 C) mark should remain dull and chalky.
0 0
If the 125 F (52 C) mark does not appear liquid and
glossy, troubleshoot the cooling system for causes of
overcooling.
If the 1630 F (730 C) mark becomes liquid and glossy,

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

should appear dull and chalky.
If either mark appears liquid and glossy, troubleshoot

the cooling system for causes of overheating.

Temperature Switch Test
Purpose
A heat sensitive switch is installed in the cylinder head to monitor

engine temperature. This switch is connected in series with the
warning horn. If the switch senses temperature in excess of a
predetermined limit, contacts close and cause the warning horn
to sound a continuous tone when the key switch is in the ON
position.
f'N=J To ensure that the temperature sensing system can alert

~ the operator during an overheating condition, it is very
important that the warning horn be tested on a regular basis. See
Warning Horn Test, Section 1.
Testing
151 1. Disconnect the bullet connector(s) and remove the tempera-

~ ture switch from the cylinder head.
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.
1sl 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. 6

Use oil that has a flashpoint above 300 F (150 C), such 824063
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 follows:
Wire Switch Switch

Color Closed Open
203 6" F 170 15 F

Tan
(95 3 C) (77 7 C)
6. Replace the switch if your test results vary.

Retaining Ring Pliers
u
ZU)
-U
c)I
UN
....J~~
0(0 .....
O,c.b
I-c.o N
..... NN
"'Nc.o
U .....
- 0 .
.. I- Z 0
W:J Z
I-Wr:~
OU)Cl
Z:JUW
4-8 45C
.
'"~
'""
113 mm(1/2"j
cu . .-L f --]
v<~/ / . J
7 mm(9/32") - HOLE FOR STORAGE SCALE: FULL SIZE
I ... 292 mm(11 1/2") .. I

-t
Q)
"C
I.... 241 mm(9 1/2") .. I 13 mm(1/2") ~ (t)
~
"'C
_.
~ ::::s
c.o I .... 127 mm(5") ~ I
-t
0
0
r 10mm(3/S"j
T
16 mm(5/8")
51 mm(2")
( T ~J
L 2S mm(11/S"j
& Safety Warning
Cold Roll Steel
Heat treatment: Striking a steel punch with a steel hammer may produce chips
Carbonize 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.
NOTES
4-10 45C/eng
Powerhead Servicing
Removal
1- 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 four lower engine cover screws:
[!] @ Front
~ Lower
~ Rear
Separate the two lower engine covers.
~ 3. Remove the shift rod screw @.

~ 4. Remove the nut from rear stud of the powerhead .
[!] 5. Remove the eight exhaust housing to powerhead screws.
f71 6. Using OMC Lifting Eye, PIN 321537, pieces of OMC Univer-
~ sal Puller Set, PIN 378103, and a suitable hoist, lift the
powerhead from the exhaust housing.
7. Place the powerhead assembly on a suitable work stand, OTe

No. OEM 4157, or equivalent.
8. Remove the carburetion, ignition, and electrical components

from the powerhead.
45Cieng & Safety Related 4-11

22339
, 22338
3
Disassembly
'111. Remove the ten screws attaching the intake manifold.

~ Remove the manifold and discard the gasket.
~ 2. Remove the starboard lower engine cover mount bracket.

r:;J 3. 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.
~ 4. Remove the four lower crankcase head screws.

f515. Remove both lower crankcase head seals using OMC Puller
~ Bridge, PIN 432127, and OMC Small Puller, PIN 432131. Dis-
card both seals and O-ring.
1sl6. Remove the twelve exhaust cover screws. Remove the cover
~ and discard the gasket.
[~h. Remove the eight crankcase flange screws.
4-12 45Cle n9
22352
[!] 8. Remove the six main bearing screws.

1nl9. Using a soft face mallet, tap upward on the crankshaft to
l!Jseparate the crankcase and cylinder block. Lift straight up and
remove the crankcase.
11Ol10. Using an indelible marker, identify each connecting rod

~ cap by cylinder. Cylinder number one is closest to the
flywheel.
~ Identify all internal components so that if reused they can

~ be installed in their original positions.
r,v 11. Usi ng OMC Torque Socket, PIN

331638, loosen in stages
~ and remove the connecting rod screws. Remove caps and set
the bearings aside.
@] 12. Lift the crankshaft from the cylinder block.

r:J3113. Rein~tall th.e rod caps on their original rods. Install the
~ screws fmger tight.
22349
45C/e ng 4-13
o
14 22348
14. Remove the upper main bearing from the crankshaft.

r:;-;]
~ Discard the seal and O-ring.
1141 15. Remove the retaining clip from the center main bearing .
Separate the sleeves and remove the roller assemblies.
115l 16. Inspect the lower main bearing in place. If it is removed

~ for any reason, it must be replaced . To replace the bearing,
remove the retaining ring. Press the bearing off using a bearing
separator and a press. 17
~~-------------------=~
~ 17. Remove the thermostat cover. Discard the O-ring.

~ 18. Remove the thermostat components for inspection .
118119. Inspect the thermostat seat. Replace the seat if necessary.
20.45,55 Comm. - Remove the 14 screws that retain the cylinder
head water jacket cover. Remove the cover and discard the
gasket.
1191 21. Remove the ten cylinder head screws. Remove the
cylinder head and discard the gasket.
1201 22. Remove the temperature switch for inspection.
4-14 45C/eng
r:;:;l23. Carefully remove the pistons from the cylinder block.
~ Protect the condition of the piston by packing paper towels
between the connecting rod and piston. Do not allow the connect-
ing rod to touch the inside of the piston or the cylinder wall.
122124. Using an appropriate ring expander, remove piston rings

from both pistons.
r:;.:;l25. Using a tool as drawn on Page 4-8 or OMC Retaining Ring

~ Pliers, PIN 325937, remove all wrist pin retaining rings.
Discard retaining rings.
1241125126. The fit between the wrist pin and bosses ofthe 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 ofthe
28 needle bearings or the two wrist pin washers. If any of the
bearings are worn or lost, replace all the bearings on reassembly.
9235
23 9180
24
9237
o
o
22664
45C/eng 4-15
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.
fN=J 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

i l l gloves when using OMC Gel Seal and Gasket Remover.
r;] 4. Use OMC Gel Seal and Gasket Remover to remove all traces
L!J of gaskets, adhesives, and Gel Seal II from the cylinder block
and crankcase.
5. Carefully remove any carbon accumulation from the tops and

ring grooves of the pistons. 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

i l l 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.
& Safety Related 4-16 4SC/eng

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. 2
~~------------------~9~=5~
f213. 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 journal would
only be measured ifthe bearing was removed for another reason.
Refer to Engine Specifications, Section 1, for dimensions.
rJl5. 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.
f416. Measure each cylinder in at least two areas as shown. Each

L!J 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 4

0.003 in. (0,08 mm). "'-----'---------=::=-I
DRll19
7. The dimensional difference between the two areas is the

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 oversized by more than

0.003 in. (0,08 mm).
45C/eng 4-17
~ If any cylinder is outside these tolerances, it must be bored
~ oversize. A 0.030 in. (0,762 mm) oversize piston is avail-
able for this engine. 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.
1sl 9.
Use a micrometer to measure the piston major diameter
~ in. (3,2 mm) above the bottom edge of the piston skirt. The
1/8
micrometer should be in line with the upper piston ring dowel pin
@. 1101
The major diameter should be no smaller than 3.1831 in.

(80,85 mm) for a standard piston and 3.2131 in.
(81,61 mm) for an oversize piston.
10. Measure the piston in several more locations 1/8 in. (3,2 mm)
above the bottom edge of the piston skirt. No measurement
should be larger than the major diameter and no measurement
should be more than 0.004 in. (0,10 mm) smaller than the major
diameter.
If the grooves on the sides of the piston are worn smooth 6

in an area similar to that shown, replace the piston.
'71 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.
The ring gap must be within 0.007-0.017 in.

(0,17-0,43 mm).
f'8l 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 fully seated in its groove, make several checks around the
piston.
The side clearance must not exceed 0.004 in.

(0,10 mm).
19'1 13. 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
piston on both sides of the ring groove.
If the straightedge does not touch piston, remove the

ring and clean ring groove.
5572
4-18 45C/eng
1 2
22535 24908
Assembly
r::=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.
INotel Use new gaskets, seals, and O-rings during assembly.

rv~ of1. Apply OMC Gasket Sealing Compound to outside diameter
a new upper crankshaft seal. Install the seal with lip facing 24907
bearing using OMC Seal Installer, PIN 334500. Coat the lip of the
seal with OMC Triple-Guard grease.
~ 2. Apply OMC Gasket Sealing Compound to outside diameter

t=I of two new lower crankshaft seals. Install both seals with lip
facing up using OMC Seal Installer, PIN 339752, 40, 48, 50
models (PIN 334998, 45, 55 models). Liberally apply OMC Moly
Lube between the seals.
rJl 3.Apply OMC Needle Bearing Grease to the 28 wrist pin

~ bearings. Install the bearings in the wrist pin bore. Align the 5
bearings in the bore using OMC Wrist Pin Bearing Tool, PIN
336660.
r4J f51
4. Place the two wrist pin thrust washers on the tool with
~ ~ flat side of the washers facing out.
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.
f6l rJl
6. Install the wrist pin through the piston and connecting
~ ~ rod, pushing the tool out through the piston.
45C/ong 4-19
8
DR1641
Iollnl 7. Using OMC Cone, PIN 318600, and Driver, PI N 318599,

l!J l!J 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 3 thru 7 for each piston.
r,Ql9. Install piston rings on each piston. Spread each ring with a
~ ring expander just enough to slip it over the head of the
piston and down into place.
10. Coat pistons, rings, cylinders, and OMCRing Compressor, PIN

326592 (PIN 330222 for oversize), with outboard lubricant.
r:t1l11. Center connecting rod in position and locate piston rings

~ on their dowel pins. With the word "UP" on dome of piston
facing flywheel end of crankshaft, slide piston into its respective
cylinder bore while guiding the connecting rod through the block.
fN=J The piston rings must be correctly located on their dowel

~ pins or permanent powerhead damage will occur.
112112. Lightly coat both sides of a new cylinder head gasket with
OMC Gasket Sealing Compound. Install gasket with tab
facing port side of cylinder block.
r:j3l13. Install cylinder head. Following sequence shown, torque

~ all screws in stages to 216-240 in. Ibs. (25-27 Nm).
I
4-
\
\
\
DR2814
4-20 45C/e ng
DR1676
r:;:;,14. 40, 48, 50 - Apply OMC Gasket Sealing Compound to

~ outside diameter oftemperature switch and install in cylinder
head. Install sending unit cover.
15.45 WML - Apply OMC Triple-Guard grease to pressure relief

grommet and install in cylinder head.
~ 16. 45 WML - Install thermostat relief valve and spring in

~ cylinder head. The tapered side of relief valve @ must face
the rubber grommet.
17.45 WML - Apply OMC Gasket Sealing Compoundto both sides

of a new cylinder head water cover gasket; install the gasket and
cover. Tighten the screws to a torque of 60-84 in. Ibs. (7-9 Nm).
116118. Place the thermostat and thermostat spring in the cylin-

der head. Place a new O-ring on the thermostat cover. Apply
OMC Gasket Sealing Compound to threads of the cover. Install
and tighten the cover.
r:J7l19. 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
against the lettered side ofthe bearing. Install the retaining ring in
groove of the crankshaft with sharp edge of the ring facing away
from bearing.
r:;-;;] 20. Oil the upper main bearing surface of the crankshaft.
~ Slide the upper main bearing onto the crankshaft with seal
facing the flywheel end of crankshaft.
~ 21. Lightly coat the center main journal of the crankshaft

L.!!J surface
with outboard lubricant. Install both halves of the
center main bearings.
120122. Place the sleeves around the bearings with retaining ring
end of the sleeves facing bottom of the crankshaft. Secure
the sleeves together with the retaining ring.
20
22678
45C/eng 4-21
21 22618
22
121\23. lightly coat a new O-ring with OMC Triple-Guard grease.

122\24. Install O-ring onto upper main bearing.
123125. Rotate cylinder block so crankcase flange faces up.
Remove rod caps and keep them identified by cylinder
number. Lubricate the crankpin bearing assemblies and connect-
ing rods with outboard lubricant. Place one half of the bearing
assemblies in each connecting rod.
1241 ~6. Gently lower the crankshaft and main bearing assembly
mto place.
Align upper O-ring in its groove.

Align main bearings with locating pin.
Carefully pull each connecting rod into place.
125127. Install the remaining bearing halves in each crankpin.

126128. Oil threads of rod cap screws with outboard lubricant and
install both rod cap screws finger tight.
12711 Note l Be sure alignment dot on rod cap matches dot on rod.
4-22 45C/eng
128129. Following its instructions, install OMC Rod Cap Align-
ment Fixture, PIN 396749. Torque the rod screws in stages to
30-32 ft. Ibs. (40-43 Nm).
IN=J Torquing the screws without OMC Rod Cap Alignment

~ Fixture, PIN 396749, or using an incorrect procedure, could
cause permanent damage to the connecting rod and crankshaft.
To maintain accurate torque values, keep socket extension length
to a minimum.
Thoroughly clean and degrease the crankcase mating flange of

the cylinder block with OMC Cleaning Solvent and let air dry.
129130. Apply OMC Locquic Primer to the mating flange of the

crankcase and let air dry.
\30\ ~1. Apply Gel-Seal /Ito the cylinder block flan~e. The a~plica-
tlOri must cover the flange evenly and consistently Without
being excessive. The application must not come within 1f4 in. (6,4
mm) of the labyrinth seals or bearings.
~ Gel-Seal /I has a shelf life of at least one year when stored at

~ room temperature. Discard your Gel-Seal /I if its age cannot
be determined. Using old Gel-Seal II could cause crankcase air
leaks.
ra:il32. Position the crankcase on the cylinder block. Align mount-

~ ing holes and upper main bearing a-ring in groove. Install 6
main bearing screws finger tight.
132133. When the cra~kcase is seated, install and firmly seat the
crankcase taper pm.
133\34. Use a softface mallet and lightly tap bottom of crankshaft

to seat the lower main bearing.
22620
35. Lightly coat anew lower crankcase head a -ring with OMC
Triple-Guard grease. Install a-ring onto lower crankcase head.
134136. Lightly coat the flange of the lower crankcase head with
OMC Gasket Sealing Compound.
45C/ong 4-23
r:;;;l37. Install the lower crankcase head. Apply OMC Gasket
~ Sealing Compound to threads of the retaining screws. Install
screws finger tight.
38. Starting at the center, torque all main bearing screws in stages
to 18-20 ft. Ibs. (25-27 Nm).
136139. Temporarily install the flywheel and key to rotate crank-

shaft and check for binding.
137140. Install the eight flange screws and torque screws to

60-84 in. Ibs. (7-9 Nm).
138141. Torque the lower crankcase head screws to 60-84 in.lbs.

(7-9 Nm).
139142. Lightly coat both sides of a new exhaust cover gasket with
OMC Gasket Sealing Compound. Install the gasket and ex-
haust cover.
140143. Starting at the center and expanding outward, torque all

screws in stages to 60-84 in. ibs. (7-9 Nm).
141144. Install the intake manifold and leaf valve assembly using
new gasket. Do not use sealer on gasket. Tighten the screws
to a torque of 60-84 in. Ibs. (7-9 Nm).
4-24 45C/eng
142145. Install starboard lower engine cover mount bracket and
torque screws to 60-84 in. Ibs. (7-9 Nm).
46. Install the complete ignition, electrical, and fuel systems.
If'. To prevent possible fire or explosion, make sure all electrical

ill and ignition wiring is routed and clamped in its original
position.
Installation
1. Position a new powerhead gasket. Do not use sealer on the

42
gasket.
[':;12. Coat driveshaft splines with OMC Moly Lube. Do not coat
~ top surface of driveshaft as lubricant here may prevent seating
of driveshaft in crankshaft.
3. Lower the powerhead assembly into place.
r:;l4. Apply OMC Gasket Sealing Compound to threads of the

~ eight powerhead retaining screws. Install and torque the
screws to 18-20 ft. Ibs. (25-27 Nm).
f315. Install the exhaust housing to powerhead nut. Tighten the

~ nut to 18-20 ft. Ibs. (25-27 Nm).
f4l If'.
6. Engage the shift rod in the shift rod link. Install and
~ ill tighten the shift rod retaining screw.
7. Perform all linkage adjustments and verify full advance ignition

timing before returning engine to customer. Refer to Synchroni-
zation and Linkage Adjustments, Section 1.
~ 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.

Remote Models With Power Trim/Tilt
45C/e ng
Remote Models With Power Trim/Tilt
45C/eng 4-27
Remote Models Without Power Trim/Tilt
45C/eng
Remote Models Without Power Trim/Tilt
45C/e ng 4-29
Tiller Electric Models With Power Trim/Tilt
45C/eng
Tiller Electric Models With Power Trim/Tilt
45Cleng 4-31
Tiller Electric Models Without Power Trim/Tilt
45C/eng
Tiller Electric Models Without Power Trim/Tilt
45C/eng 4-33
Manual Start Models
45C/eng
Manual Start Models
45C/eng 4-35
Midsection
Table of Contents

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 4
Steering Handle Servicing . . . . . . . . . . . . . . . . . . . . . . . . . 5- 5
Exhaust Housing Servicing - 40, 48, 50 .... . ........... 5-10
Stern Bracket Servicing - 40, 48, 50 ........ ... ... . ... 5-12
Midsection Adjustments - 40, 48, 50 . . ... . . . .......... 5-14
Touch-Trim Servicing ............ .. .... . .. . ....... 5-15
Exhaust Housing Servicing - 45, 55 . . . . . . . . . . . . . . . . . . 5-18
Stern Bracket Servicing - 45, 55 . . . . . . . . . . . . . . . . . . . . . 5-20
Midsection Adjustments - 45, 55 . . . . . . . . . . . . . . . . . . . . 5-25
45C/eng 5-1
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.
The Touch Trim unit must only be serviced as a complete

assembly. No detail parts are available. To avoid personal injury,
do not attempt to service or disassemble any part of the
hydraulic unit. The internal components and fluid are under
extreme pressure.
5-2 45C/eng
Special Torque Chart _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Description 40,48,50 45,55 Adhesive
Lower side mou nt to 18-20 ft. Ibs.

exhaust housing screws (25-27 Nm)
Lower thrust mount to 60-84 in. Ibs.
exhaust housing screws (7-9 Nm)
Lower mount to lower 18-20 ft. Ibs.
mount bracket screws (25-27 Nm) OMC Nut Lock
Upper mount to 18-20 ft. Ibs. 18-20 ft. Ibs.

adapter screws (25-27 Nm) (25-27 Nm) OMC Nut Lock
Upper mount to 24-26 ft. Ibs. 24-26 ft. Ibs. OMC Nut Lock -
steering arm screws ,(32-35 Nm) (32-35 Nm) 40, 48, 50 Models
Lower side 16-18 ft. Ibs.

mount cover screws (22-25 Nm)
40-45 ft. Ibs. 50-54 ft. Ibs.
Tilt Tube Nut*
(54-60 Nm) (68-73 Nm)
* Back off nut 1f4 turn after torquing.
Tilt Tube Puller, PIN 392998

Twist Grip Remover, PIN 390767
Sealants and Lubricants Requi red
OMC Locquic Primer

OMC Ultra Lock
OMC Moly Lube
OMC Nut Lock
Locktite Depend 300 Adhesive
45C/eng 5-3
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 an OMCtnread locking product, be sure
to prime the adhesion surfaces with OMC Locquic Primer.
3. Discard all oil seals, a-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.
/]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.
~ 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.
1
DR2223
5-4 45C/eng
Steering Handle Servicing
Removal
l' 1. To avoid accidental starting of engine while servicing,

rv 2. Remove the throttle cable retaining clip and throttle cable
~ anchor screw and washer @. Loosen throttle cable retainer
screw@.
~ 3. Manual Start Models - Remove electrical bracket cover

~ screws. Remove cover.
f314. Separate the 1-pin Amphenol connector. Remove the stop

~ button wire from the plug using OMC Socket Removal Tool,
PIN 322699.
~ 5. Disconnect the stop button ground terminal.

6. Remove throttle cable and wires in protective sleeve from
grommet in lower engine cover.
f517. Remove screws securing warning horn assembly to steering

~ handle.
Isl TE and TTL Models - Separate the 3-pin Amphenol connector

~ from the warning horn.
o 8. Remove screw securing steering handle. Remove handle.
7
45C/e ng it Safety Related 5-5
31194
Disassembly
[';11. Using OMC Twist Grip Remover, PIN 390767, depress the
l!J grip detents. Tighten screw@, and remove the grip by pulling
it while turning the idle adjusting knob clockwise.
[!] 2. Remove the helix halves , roller @, and guides @.

~ 3. Pull the throttle pin out of the cable.
[!1] 4. Remove throttle end cap from inner handle.
[g] 5. Remove the throttle control plate.
f.i316. Remove stop switch cover screws. Remove switch assem-
~ bly from handle.
\14\7. Remove the throttle cable retainer clip CD. Pry the throttle
cable trunnion Q) out of the steering handle and remove the
cable.
5-6 45C/eng
f1518. Using a punch and mallet, drive out the steel pin that
~ retains the inner handle in the steering handle.
11619.handle
Remove the plastic inner handle from the metal outer
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. Remove protective sleeves and inspect the throttle cable and

terminal wires for kinks and wear. Replace if necessary.
2. Inspect the steering handle components for wear, cracks, or

damage. Replace parts if necessary. Put protective sleeves on
throttle cable and terminal wires.
3. Refer to Ignition System, Section 3, to test stop switch.
Assembly
1. Install the throttle cable seal into inner handle.

~ _1/2"
r:J7l2. If removed, apply Loctite Depend 300 adhesive to inner (12 mml
~ handle at areas shown.
r;8l3. Install the metal outer handle over the plastic inner handle
~ and drive the outer handle into place.
f1514. Secure tab of the inner handle into recess of the outer
~ handle with the steel pin.
1.j9l5. Install the handle end of the throttle cable. Snap the
~ throttle cable trunnion into the recess in the handle. Install
the retainer clip.
24680
45C/eng 5-7
1201 6. Install the stop switch cover and secure with screws.
~ 7. Install the throttle control plate on the outer handle.
1221S. Place the throttle end cap into inner handle. The tab on the
cap goes into the recess of the inner handle.
1231 9. Push the throttle cable pin through the end of the throttle
cable.
\241 10. Lubricate end of 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:;;J 11. Assemble the helix halves on the handle and slide the
~ grip over the helix. Be sure the speed indicator is positioned
with the speed range. Snap the grip into place.
1251 12. Turn the idle speed adjusting knob counterclockwise to

the minimum slow speed position.
5-S 45C/eng
26
Installation
12611. Attach steering handle to bracket. Tighten screw securely.
12712. TE and TTL Models - Attach warning horn assembly to

steering handle. Tighten screws securely.
3. Place throttle cable and wires into grommet in lower engine

cover.
12814. TE and TTL Models - Secure warning horn 3-pin Amphenol

connector.
1291 5. Attach stop button ground terminal to engine.
13016. Using OMC Pin Insert Tool, PIN 322697, insert stop button
wire into plug and place connector in clamp.
f31l7. Manual Start Models - Attach electrical bracket cover.

~ Tighten screws securely.
13218. Place throttle cable in position and tighten bracket retainer

screw@. Attach anchor to bracket@, tighten screw securely,
and attach cable end to pin. Secure with clip @.
9. Refer to Synchronization and Linkage Adjustments, Section 1,

to adjust throttle cable.
45C/eng 5-9
Exhaust Housing Servicing - 40, 48, 50
Removal
1. Remove the powerhead as described in Section 4.
2. Remove the gearcase as described in Section 6.
[!] 3. Remove the three lower mount cover screws.

~ 4. Separate the lower mount covers from the swivel bracket.
~ 1al5. Check the. condition of the lower front mount @ and the
~ ~ two lower side mounts @.
~ 6. Remove the three upper mount to inner exhaust housing

~ screws.
7. Lift the exhaust housing assembly from the swivel bracket.
Disassembly
1sl1. Remove the four inner exhaust housing to exhaust housing

~ screws.
1sl2. Using a soft face mallet, tap on side of the inner exhaust
~ housing to break the seal between the inner and outer housing
loose. Lift the adapter from the exhaust housing.
03. Remove the four screws retaining the exhaust relief baffle.
5-10 45Cieng
[!] 4. Remove the exhaust relief plate. Discard the gasket.
Assembly
1sl1. Apply OMC Gasket Sealing Compound to a new exhaust

~ relief gasket. Position the gasket and plate.
1712. Install the exhaust relief baffle. Apply OMC HT 400 to
~ threads of the retaining screws. Install and tighten the screws
to 60-84 in. Ibs. (7-9 Nm) .
3. Check the condition of the following components. Replace if
necessary.
Lower inner exhaust housing seal
Exhaust relief grommet, lower engine cover seal
Lower crankcase head grommet
Shift rod grommet
f.i314.
Apply OM.C Gel-Seal" to the top flange of the outer
~ exhaust housing.
5. Install the inner exhaust housing into the outer exhaust
housing.
'sl6.Apply OMC Gasket Sealing Compound to threads of the four
~ inner exhaust housing retaining screws. Install and tighten the
screws to 60-84 in. Ibs. (7-9 Nm).
Installation
1. Bring the outer exhaust housing in position with the swivel

bracket.
f412. Apply OMC Nut Lock to threads of the upper mount to inner
~ exhaust housing screws. Install the screws and place ground
lead under the center screw. Tighten the screws to 18-20 ft. Ibs.
(25-27 Nm).
~ 3. Position the lower front mount.

11414. Install the lower side mount covers. Install and tighten the
screws in stages to 16-18 ft. Ibs. (22-25 Nm) following
sequence shown.
17528
45C/eng 5-11
Stern Bracket Servicing - 40, 48, 50
Disassembly
'111. Remove the bumpers from the upper mount retaining

~ screws. Remove the screws, upper mount and ground lead
from the bracket.
2. R, TE Models - Loosen the friction adjustment screw.
f213. Pull the steering arm out of the swivel bracket. Remove the
~ upper seal, liner and thrust washer.
R, TE Models - Remove the liner set screw before

removing the liner.
@] 4. Remove the lower seal.

f41 5.
To separate the swivel bracket from the stern bracket,
~ remove one tilt tube nut.
~ 6. Remove the tie bar to separate the two stern brackets. 17541
f617. Check the condition of the anode. Replace the anode if it has
~ been reduced to two-thirds its original size.
6
17551
5-12 45C/eng
17540
Assembly
rJl1. Assemble the tie bar to the stern brackets. If equipped, place
~ the ground lead and star washer between the port stern
bracket and tie bar.
2. Lubricate the swivel bracket bushings with OMC Triple-Guard

grease. Place the bushings in the swivel bracket.
rSJ 19l3. Position the swivel bracket between the stern brackets.
~ ~ Place a thrust washer between each of the stern brackets
and the swivel bracket.
4. Install the tilt tube. Tighten the tilt tube nuts to 40-45 ft. Ibs.
(54-60 Nm), then back off one nut 1f4 turn.
'1Q15. Apply OMC Nut Lock to threads of the upper mount to

~ steering arm screws. Install the mount and tighten the
screws to 24-26 ft. Ibs. (32-35 Nm). Be sure to place the ground
lead under the port screw.
G1l6. Apply a liberal amount of OMC Adhesive M to heads of the

~ upper mount screws.
1
12 17. Place the bumpers on the upper mount screws.
45C/eng 5-13
Midsection Adjustment - 40, 48, 50
Steering Friction Adjustment
rv The steering friction adjustment is preset at the factory.

~ Readjust after 20 hours operation, and when necessary.
~ The steering friction should be adjusted so motor torque

i l l does not swing motor. Do not overtighten for "hands off"
steering, which could result in loss of control.
With motor mounted on boat, adjust steering friction by turning

screw.
Idle Speed Adjustment
[:;l The idle speed adjusting knob is located on steering handle.

~ Turning knob clockwise increases idle speed; turning counter-
clockwise decreases idle speed.
Minimum Trim Angle Adjustment
Ial The stern bracket has three . positions for adjusting motor's
~ minimum trim angle. The motor is shipped with tilt pin in
second hole. This will be the best position for most boats. On
some boats it may be advisable to limit the amount of trim "IN"
that can be used. This may be due to a large transom angle, the
boat loading, or other reasons. If it is necessary to limit the trim
angle, then:
Place motor in full tilt position and engage trailering lock.
Remove locknut @.
Move tilt pin to next hole. Install and tighten locknut to a

torque of 20-25 ft. Ibs. (27-34 Nm).
~ Replace any locking type fastener if its locking feature

ill becomes weak. Definite resistance to turning must be felt or
fastener is not suitable for continued use. Replace only with
authorized replacement part or equivalent.

Touch- Trim Servicing
~ The Touch-Trim unit must be serviced as a complete
ill assembly. No detail parts are available. To avoid personal
injury, do not attempt to disassemble any part of hydraulic unit.
The internal components and fluid are under high pressure.
Cable Replacement
1. Raise motor to full tilt position and engage tilt support. Lower
motor until tilt support rests on stern brackets.
f1l2. Remove Touch-Trim cable from holder and gently pry cable
~ end from lever ball.
~ 3. Remove cable nut @.

~ '" If valve body starts to unscrew from cylinder assem-
~ i l l bly - STOP! Do not continue servicing. Carefully screw
valve body back into cylinder. Remove cylinder and cable as an
assembly and replace.
~ 4. Pull cable up and disconnect ball from slide valve socket.

5. Remove cable from clamp and from cable block on stern
bracket. Retain cable nut.
6. Slide cable nut down new cable.
7. Loop cable down from lever, up past clamp, across and in front
of cylinder, and down port side to valve .

8. Apply OMC Triple-Guard grease to cable retainer cavity and
cable ball end.
fJl9. Apply a light coating of Permatex No.2 to external threads

~ @ of slide valve body.
fJl10. Attach cable ball end to slide valve. Push down on cable
~ retainer and attach cable nut to valve body. Torque nut to
36-48 in. Ibs. (4-5 Nm).
011. Secure cable with cable clamp.
'5l12. For initial adjustment, thread ball connector onto cable

~ until cable retainer CAN JUST BE PULLED INTO ALIGNMENT
WITH ANCHOR BLOCK ON STERN BRACKET, with ball connector
pushed against ball.
13. Snap cable end onto lever ball. Snap cable retainer into
anchor block.
14. Cycle lever from RUN to TILT 10 times before adjusting cable.
Adjustment
1. The cable must be adjusted so lever and cable will always let
valve close completely before lever reaches RUN position.
2. The lever reserve motion is amount of lever movement that

remains after valve is closed.
5-16 45C/eng
f61 3. To measure lever reserve motion - Tilt motor up. Move
~ lever to position @, and then slowly move lever toward RUN
POSITION @ as motor is slowly tilted down. Valve will first slow
I
tilting movement, then stop movement completely. Leave lever in /
/
t
this CLOSED VALVE POSITION .
4. To check if valve is completely closed, leave lever in that I
position and push down hard on gearcase. Motor should hold its
position. f-~-
f6l f715. Hold a scale next to end of lever and move lever from
~ ~ CLOSED VALVE POSITION to RUN POSITION @ . Mea-
6 @ DR4604
sure this distance, the lever reserve motion, which should be
~;.~~~
about l/S in. (3 mm).
6. To adjust, gently pry cable retainer out of anchor block and l J]

~ '- / (3 mm)
cable end off lever ball.
7. Turn cable end onto cable (clockwise) to REDUCE the lever

reserve motion, and off (counterclockwise) to INCREASE the lever
reserve motion. Each half turn of the cable end changes the lever
reserve motion by about l/S in . (3 mm). Reconnect cable end to
lever ball, and snap cable retainer into anchor block.
Isl a. Rerneasure lever reserve motion and readjust until reserve DR2840
~ motion is l/S in. (3 mm). If there is insufficient reserve motion,

the valve will leak and the motor will not lock in either up or down
position. If there is excessive reserve motion, the valve will not
open enough, and it will be difficult to move the motor.
9. If you run out of threads and cannot remove excess lever

reserve motion, cable liner is worn and cable must be replaced.
45C/e ng 5-17
Exhaust Housing Servicing - 45, 55
Removal
If equipped with power trim and tilt, refer to Section 10 for

removal instructions.
1. Remove the powerhead as described in Section 4.
2. Remove the gearcase as described in Section 6.
rv 3. Remove the port and the starboard lower mount bracket

~ covers.
~ 4. Remove the port and starboard lower mount to lower mount

~ bracket screws.
rJl 5. Remove the upper mount to exhaust housing adapter

~ screws .
~ 6. Lift the exhaust housing and adapter assembly from the

~ swivel bracket.
Disassembly
fs1 1. Remove the two lower rubber mounts @ and the thrust
~ mount from the exhaust housing.
Isl f71 2. Remove the inner exhaust housing to adapter screws.

~ ~ Lift the inner exhaust housing from the adapter.
5-18 45C/eng
1sl3. Mark the position of the wAter tube for correct reassembly.
~ Remove the water tube cover screws. Separate the water
tube cover, grommets @ and water tube from the adapter.
1sl4. Remove the inner exhaust housing from the adapter.

~ Discard the adapter to exhaust housing gasket.
Assembly
1nl 1. Apply OMC Gasket Sealing Compound to both sides of a

l!J new adapter to exhaust housing gasket @. Place the gasket on
the adapter.
2. Secure the inner exhaust housing to the adapter.
\10\3. Slide one water tube grommet @ and the water tube cover
down the water tube. Place second water tube grommet @
in bore of the adapter. Align the water tube and secure the cover
to the adapter.
4. Slide the inner exhaust housing and the adapter into the outer
exhaust housing. Secure the adapter to the outer exhaust hous-
ing.
.....
f515. Install the two lower side mounts to the exhaust housing.
~ ~
~ Tighten the screws to a torque of 18-20 ft. Ibs. (25-27 Nm).
Install the thrust mount to the housing and tighteh the screws
to a torque of 60-84 in. Ibs. (7-9 Nm) .
f516. Check condition of the shift rod seal and replace if

~ necessary.
@~....
t
Installation
f11l 1. Position the exhaust housing in the swivel bracket assem-

10
~ bly. Apply OMC Nut Lock to threads of the upper mount
screws. Position the ground lead CD under the center screw.
Tighten the screws to a torque of 18-20 ft. Ibs. (25-27 Nm).
~ 2. Apply OMC Nut Lockto threads of the lower mount to lower

~ mount bracket screws. Install and tighten the screws to a
r:jl 3. Install the port and the starboard lower mount bracket
~ screws.
4. Install the gearcase as described in Section 6.
5. Install the powerhead as described in Section 4.
45C/eng 5-19
COA2952
Stern Bracket Servicing - 45, 55
Disassembly
r:jl ~ 1. Remove the bumpers from the upper mount retaining

~ ~ screws. Remove the screws, upper mount , and ground
lead from the bracket.
f312. Using OMC Retaining Ring Pliers No.4, PIN 307429, re-
~ move the retaining ring from the pivot shaft.
[";l [';13. The pivot shaft is splined to the lower mount bracket and
~ ~ secured with locking adhesive. Heat the pivot shaft splined
end with a torch. A"ow the heated area to cool, then remove the
lower mount bracket and the lower thrust washer @ from the
pivot shaft.
1sl4. Slide the pivot shaft and the upper thrust washer out and
~ off the swivel bracket.
f711al5. Using a screwdriver, pry the upper and the lower seals
~ ~ from the swivel bracket. On remote start models, remove COA2958
the pivot shaft bushing from the swivel bracket.
f9l11Ol r.t1l6.T~ Mode~s -

Loosen the steering. fricti.o~ scr~w
~ ~ ~ while pushing outward on the steering friction pin @.
When the pin is flush with the inside surface of the casting,
remove the steering friction thrust ring @. Tighten the steering
friction screw until the pin can be removed. Then, remove the
steering friction screws.
1121~. Remove the two setscrews from the swivel bracket.
5-20 45C/eng
C0A2960

C0A2962
1141 r,st. Dri~e the steering friction bushing up and out of the
~ sWivel bracket.
Remove the thrust rod CD from the stern brackets.

Remove the tilt shaft screw Q) and nut from the stern
brackets and swivel bracket. Remove the port and
starboard stop link screws and nuts from the stern
brackets. Remove the two stern bracket flange screws
(b). Separate the stern brackets from the swivel brack-
et.
'16l G717. Remote Start Models - remove the thrust rod CD from
~ ~ the stern brackets. Remove the starboard tilt tube nut.
Pull the tilt tube from the swivel bracket assembly. If necessary,
use OMC Tilt Tube Puller, PIN 392998. Remove the port and
starboard stop link screws and nuts from the stern brackets.
Remove the two stern bracket flange screws (b). Separate the
stern brackets from the swivel bracket.
45C/eng 5-21
C0A2977
G8l r,gl1201 8. Place the tilt/run lever in the RUN position. Loos-
~~ en the bellcrank setscrew @. Remove the tilt/run
lever @, port stop link @, and bushing @ from the swivel bracket.
Remove the starboard stop link retaining screw and nut from
the swivel bracket.
f21l12219.
~
Remove the cotter pins from the reverse lock pins.
Remove the reverse lock pins. Remove the reverse lock
assembly from the swivel bracket.
10. Refer to Cleaning and Inspection at the beginning of this

section.
Assembly
\23\1. Place the reverse lock springs in the swivel bracket.

Insert the reverse lock pins @ in the swivel bracket and part
way through the reverse lock springs. Place the reverse lock
assembly between the springs. Push the pins through the springs
and the reverse lock assembly.
\241\2112.theInstall the washers on the reverse lock pins. Install

link spring CD on the port pin. Install the two cotter
pins in the reverse lock pins.
r,gl f.i8l3.
Install the bushing @, the port stop link @, and the
~ ~ tilt/run lever @ in the swivel bracket. The tilt/run lever
should be in the RUN position. Install the wave washer and the
bellcrank on the tilt/run shaft. Tighten the setscrew.
12014. Install the starboard stop link on the swivel bracket.

Install and tighten the screw and the nut to a torque of
144-168 in. Ibs. (16-19 Nm).
5-22 45C/eng
5. Assemble the port and the starboard stern brackets onto the
swivel bracket. TE Models - Install the tilt shaft bolt through the
following components:
Tang washer, bushing, port stern bracket,

thrust washer, swivel bracket, thrust washer,
starboard stern bracket, bushing, washer
1251 Position the tang on the port washer Q) toward rear of the
stern bracket. Install the nut loosely on the tilt shaft bolt.
Remote Start Models - Place thrust washers between stern and

swivel brackets. Insert the tilt tube and nut assembly from port
side of the stern bracket. Tighten the starboard tilt tube nut to a
torque of 24-26 ft. Ibs. (32-35 Nm). Back off nut 1/8 to 1J4 turn after
applying torque.
1261 ~ 6. Apply OMC Nut Lock to threads of the two flange

ill screws @. Install the two screws through the starboard
stern bracket flange into the port stern bracket flange. Tighten the
screws to a torque of 144-168 in. Ibs. (14-16 Nm). TE Models -
Tighten the nut on the tilt shaft bolt to a torque of 14-16 ft.
Ibs. (19-22 Nm).
7. Install the thrust rod in the stern brackets.
12711201 8. Install the 7/8 in. head screw through the port stop link
, wave washer 8 , and port stern bracket. Install and
tighten the nutto a torque of 144-168 in.lbs. {16-19 Nm).lnstall
the 3/4 in. head screw through the starboard stop link and stern
bracket. Install and tighten the nut to a torque of 144-168 in.lbs.
(16-19 Nm).
12811291 9. TE Models - Install the large setscrew in the swivel

bracket, one thread from being flush with the casting. If
these screws are not patchlock screws, apply OMC Ultra Lock to
threads of screws before installing .
Place the steering friction bushing in the swivel bracket

with groove in line with the setscrews .
Apply OMC Triple-Guard grease to the steering friction

pin . Install the pin in the swivel bracket flush with
inside surface. The pin should point up.
45CJeng & Safety Related 5-23

Install the steering friction thrust ring @, bevel side up in
the swivel bracket. Thread the steering friction screw in
the swivel bracket. Turn the screw until the steering
friction pin makes contact with top of the thrust ring. Do
not tighten the screw.
10. Install new upper and lower seals in the swivel bracket with
lips of seals facing away from the bracket. On remote start
models, place pivot shaft bushing in the swivel bracket before
installing the top seal.
\331 11. Slide the upper thrust washer @ on the pivot shaft. Slide
the pivot shaft through the swivel bracket.
\341\35\ 12. Thoroughly clean splines of the pivot shaft and the
lower mount bracket. Spray the splines with OMC Loc-
quic Primer. Apply OMC Nut Lock evenly to all pivot shaft spline
teeth. Place the lower thrust washer in the lower mount
bracket. Slide the lower mount bracket on the splines of the pivot
shaft while aligning front of the mount bracket with the steering
arm. Install the retaining ring on the pivot shaft with sharp edge
of ring facing out.
13. Lubricate the swivel bracket through the fou r lubrication

fittings with OMC Triple-Guard grease.
\361 14. Slide the steering arm seal @ onto the steering arm with
the word "TOP" facing up.
\361 15. Position the upper rubber mount, the upper mount
washers @ , and the retaining washers on the steering arm
with the word "UP" on the mount facing up. Be sure to place the
ground lead @ between the mount (starboard side) and the
steering arm. Install and tighten the mount retaining screws to a
137 1 16 . Place the mount screw bumpers on head of the screws.
5-24 45C/eng
Midsection Adjustment - 45, 55
Steering Friction Adjustment
rv Adjust the steering friction with motor mounted to boat by

~ loosening or tightening the adjustment handle. Adjust the
steering friction until a slight drag is felt when turning.
'" The steering friction should be adjusted so that stable boat

i l l operation is maintained with a minimum of operator effort.
Do not overtighten to allow for "hands off" steering which could
result in loss of control.
Idle Speed Adjustment
~ The idle speed adjusting knob is located on the steering

~ handle. Turning clockwise on the knob increases idle speed,
turning counterclockwise decreases idle speed. Make certain that
throttle grip is in SLOW position and the motor is at normal
operating temperature before making the idle speed adjustment.

Gearcase
Table of Contents

Propeller Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 4
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 5
Water Pump Servicing ............................ 6- 6
Service Chart - 40, 48, 50 . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 8
Gearcase Servicing - 40, 48, 50. . . . . . . . . . . . . . . . . . . . . . 6- 9
Removal ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Service Chart - 45, 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Gearcase Servicing - 45, 55. . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Removal . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6~42
Jet Drive Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Removal and Disassembly. . . . . . . . . . . . . . . . . . . . . . . . 6-43
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
Assembly ....................... . ......... . ... 6-51
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
Jet Drive Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
45C/e ng 6-1
Before working on any part of the gearcase, read the section
Avoid accidental starting of engine while servicing; twist and


(172 kPa).

personal injury.

6-2 45C/eng
Special Torque Chart _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
DESCRIPTION 40,48,50 45, 55 ADHESIVE
60-84 in. Ibs. 60-84 in. Ibs.

Water pump screws OMC Gasket Sealing Compound
(7-9 Nm) (7-9 Nm)
Oil level & 60-84 in. lbs. 60-84 in. Ibs.

fill/drain plugs (7-9 Nm) (7-9 Nm)
Gearcase retaining 18-20 ft. Ibs. 18-20 ft. Ibs.
screws 3/8 in. (24-27 Nm) (24-27 Nm) CD
Gearcase retaining 28-30 ft. Ibs. 28-30 ft. I bs.
screw 7/16 in. (38-40 Nm) (38-40 Nm) CD
Propeller shaft 120-144 in.lbs. 120-144 in. Ibs.
bearing housing screws (14-16 Nm) (14-16 Nm) CD
Upper driveshaft 14-16 ft. I bs. 96-120 in.lbs.
bearing housing screws (19-22 Nm) (11-14 Nm)
60-84 in . Ibs. 60-84 in. Ibs.

Shift rod cover screws OMC Gasket Sealing Compound
(7-9 Nm) (7-9 Nm)
40-45 ft. Ibs. 40-45 ft. Ibs.

Pinion nut Outboard Lubricant
(54-60 Nm) (54-60 Nm)
Pinion bearing 48-80 in. Ibs. 48-80 in. Ibs.

OMC Nut Lock
retaining screw (5-9 Nm) (5-9 Nm)
Anode to propeller 108-132 in . lbs.

housing screws (12-15 Nm)
216-240 in . Ibs. 216-240 in. Ibs.
Trim Tab Screw
(24-27 Nm) (24-27 Nm)
CD 40, 48, 50 - OMC Nut Lock
45, 55 - OMC Gasket Sealing Compound
Shift Rod Heights _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
MODEL STANDARD LONG EXTRA LONG
16 15/ 16 1/ 32 in. 21 15/ 16 1/ 32 in. 247/ 16 1/32 in.

40,48,50
(430,3 0,8 mm) (557,3 0,8 mm) (620,8 0,8 mm)
45, 55 1529/ 32 1/ 32 in. 20 2 %2 1/ 32 in. 23 13/ 32 1/32 in .

(404 0,8 mm) (531 0,8 mm) (594 0,8 mm)
~
45C/eng 6-3

OMC Adhesive M TIl
OMC Moly Lube
OMC Nut Lock
OMC Hi-Vis@ Gearcase Lubricant
OMC Needle Bearing Assembly Grease
Service Aids Required
Stevens Gearcase Pressure Tester, 5-34

Stevens Gearcase Vacuum Tester, V-34
Propeller Installation
111 2. Coat the propeller shaft splines sparingly with OMC Triple-
~ Guard grease.
3. Place the thrust bushing @ in the propeller and then slide the
assembly onto the propeller shaft.
4. Install the thrust washer on splines of the propeller shaft.
5. Install and tighten the propeller nut to a torque of 120 in.lbs.

(14 Nm). Install a new cotter pin @ or continue to tighten the nut
to align the nearest cotter pin hole. The propeller shaft should
turn freely (engine in NEUTRAL) after the propeller is installed.
6. Install a new cotter pin @, bending ends over the nut.

DR2477

1'- 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-
tion and regulate air pressure to not more than 25 PSI (172 kPa).
After cleaning, coat all internal components with OMC Hi-Vis
gearcase lubricant 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. Upper driveshaft oil circulation
hole must be clear.
Hydrostatic seal rings - must be undamaged and in

good condition to help prevent propeller ventilation.
Gearcase anodes - if anodes have been reduced to

two-thirds their original size, they must be replaced.
Refer to Section 1 for testing procedure.
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 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
distortion.

Water Pump Servicing
If the gearcase has been in service for any length of time, it is a
good policy to install a water pump repair kit. To install the repair
kit, proceed as follows:
Removal
rv the
~
1. Remove the four screws retaining the impeller housing @ to
gearcase.
r2J 2. Slide the water pump assembly off the driveshaft. Remove
~ the impeller drive cam @, impeller plate , and gasket @.
Discard the gasket.
6-6 45C/eng
Disassembly/Assembly
f31 1. Start by removing all the parts from the housing . Inspect the
~ housing for cracks or melting, and install a new top plate @.
The top plate locks into place in the housing with a square index
tab.
~ 2. The liner now slides in and mates with the plate at the
~ point where the liner is split.
5
~ 3. Place the water tube grommet in the impeller housing.
15462
1cl 4. Apply a thin bead of OMC Adhesive M sealant to groove of

~ the impeller housing grommet. Place the grommet in position
on the impeller housing.
r:;J 5. Lightly coat the liner with oil. With a counterclockwise

~ rotation, install the impeller into the liner with slot for impeller
cam facing out.
rJl 6. Run a thin bead of OMC Adhesive M sealant in the seal

~ groove, and install the specially shaped O-ring seal. 6
15463
Installation
1. Apply OMC Gasket Sealing Compound to both sides of a new

impeller plate gasket. Position the gasket and impeller plate on
the gearcase. Do not use the impeller plate gasket on a Jet model.
Apply OMC Gasket Sealing Compound to the impeller plate
before installing.
101 2. Apply OMC Needle Bearing Assembly Grease to flat area of

L!J the driveshaft. Install the drive cam . The sharp edge @ of the 7
cam is the leading edge during driveshaft rotation @.
~~------------------~1=~~59
3. Slide the water pump assembly down the driveshaft. Align the
impeller housing with the gearcase. Rotate the driveshaft to
engage the impeller cam with the impeller, and slide the water
pump assembly down over the impeller. Be sure the impeller cam
does not fall out of position.
~ Verify that the impeller engages the impeller cam properly.

~ Serious powerhead damage will result if impeller cam is
displaced.
4. Apply OMC Gasket Sealing Compound to the threads of the 4

impeller screws. Position the water tube bracket. Install the C02995
screws and tighten them to a torque of 60-84 in. Ibs. (7-9 Nm).
45C/eng 6-7
Service Chart - 40, 48, 50
CD OMC Triple-Guard Grease ~~~

OMC Gasket Sealing Compound 60-84 in. Ibs. ~
OMC Adhesive M Sealant (7-9 Nm) ,,--,,- - - -
o OMC Moly Lube

o

@ OMC Nut Lock attn
OMC Hi-Vis Gearcase Lubricant:
16.4 fl. oz. (485 ml)
48-60 in. Ibs.

(5-7 Nm)
~/
40-45 ft. Ibs.
(54-60 Nm)
o
~-J
~A-
~-j
/
, a
()Ocf~
60-84 in. Ibs.
,~j~7-9N.m)
-, CD
108-132 in. Ibs. ~(j(J m~
(12~15_N.m
o
'"
en(JJ@- e() (]) :-

@ _120-144in'lbS'
\ (14-16 Nm)
216-240in.lbs .
(0
24 27
N~ ~ I
O ! 9 i3
J;'~
6 '
'- - - - - ~
'\
60-84 in. Ibs.
(7-9 Nm)
i:-/
/ -
~
.t'
--~~-
'-
CD ~I
CD
+ A 60-84
(7-9 Nm)
in. Ibo. --~-8:-:::.
(5-9 Nm)
DR3653
6-8 45C/eng
Gearcase Servicing - 40, 48, 50
Removal

OJ 2. Remove the shift rod screw @.

f213. Using a 5/8 in. thin wall socket, remove the countersunk
~ screw@.
[!] 4. Remove the four gearcase screws @.

5. Remove the gearcase from the exhaust housing, being careful
not to bend the shift rod.
~ In preparation for gearcase disassembly, remove the water

~ pump as described in Water Pump Servicing.

40,48,50

Disassembly
1. Remove the propeller and mounting hardware. Inspect the

propeller for a spun hub.
1412. Drain the gearcase by first removing the oil level plug @,
~ then the oil fill/drain plug @. Inspect the lubricant for water
which will give it a milky appearance, or overheating, which will
give the lubricant a black color and burned odor.
~ 3. Remove the two anode retaining screws.

1sl4. R~move the two propeller shaft bearing housing screws and
~ retainers.
rJl5. Using OMC Universal Puller Kit PIN 378103, two 114-20 x
~ 8 in. screws and two washers, pull the propeller shaft bearing
housing from the gearcase. Discard the O-ring.
'al6. Separate the reverse gear thrust washer from the bearing
~ housmg.
~ 7. Remove the reverse gear and thrust washer.
6-10 45C/eng
~ 8. Remove the shift lever pivot screw. Discard the seal.
~ 9. Remove the two shift rod housing screws.

\12\10. Pull up on the shift rod and remove the shift rod assembly
from the gearcase.
113' 11 .. Disassemble the shift rod housing. Discard the two

~O- nngs.
\14\12. Remove the propeller shaft assembly and shift cradle

from the gearcase.
13 o
45C/eng 6-11
40,48,50
15
15477
o 15478 15479
1151 13. Pry the clutch dog retainer spring out of the clutch dog
groove. Discard the spring.
~ 14. Remove the clutch dog retainer.

52] 15. Remove the clutch dog from the propeller shaft.
f.i8l '" 16. Wear safety glasses to avoid personal injury when
~ ~ servicing the detent. Remove the shifter shaft, three
detent balls, and detent spring from the propeller shaft. 18
G!] 17. Remove the three driveshaft bearing housing screws.
1201 18. Using OMC Driveshaft Holding Socket PIN 334995 and
an 11/16 in. wrench, remove the pinion nut from the
driveshaft.
f'21l 19. Pull up on the driveshaft to remove the assembly from the
~ gearcase. The driveshaft to pinion taper is a locking taper. If
necessary, use OMCPulier PIN 387206 @ and OMCBacking Plate
PIN 325867 @ to break the lock. Install the tools as shown by
clamping them around the driveshaft with the tool's set screw
aligned with the impeller drive cam slot. Tighten the set screw
into the slot. Alternately tighten the two vertical screws against
the backing plate inserted between the puller and the gearcase
until the driveshaft pops loose from the pinion.

1221 20. Remove the forward gear, thrust bearing, and thrust
washer.
1231 21. Inspect the water screen for blockage. Remove the
screens by removing both water screen screws.
22. Inspect the pinion bearing for damage without removing it. If
bearing is damaged, remove and discard the pinion bearing from
the gearcase. If the bearing is removed for any reason, it must be
replaced.
Remove the bearing retaining screw from the gearcase.

Discard the seal from the screw.
Assemble the following components of OMC Pinion

Bearing Remover and Installer PIN 391257 and OMC
Pinion Service Kit PIN 433033.
@ PIN 326582 Rod (from PIN 391257)

PIN326575 Removerllnstaller (from PIN 391257)
PIN334987 Guide Plate (from PIN 433033)
@ %-20 x 1% in. Hex Head Screw
1 in. 0.0. Flat Washer
%-20 x 112 in. Hex Head Screw
Position the tool in the gearcase. Using a mallet, drive

the bearing into the propeller shaft cavity.
1271 23. Ifthe forward gear bearings need to be replaced, assem-

ble components of OMC Forward Bearing Service Kit
PIN 433034 as follows:
Insert the rod assembly @ into the gearcase with puller

plate behind both forward bearings.
Assemble step plate @, large washer CD, thrust washer

Q), and nut onto the rod.
Using a 15/16 in. wrench, draw the bearings out of the

gearcase.
45CJeng 6-13
40,48,50
Propeller Shaft Bearing Housing Servicing
Inspect the bearings in place. If a bearing is removed for any

reason, it must be replaced.
1291.f311 use
~
1.ToOMCBearing
remove the two seals, front and rear bearings,
Puller PI N 432130 attached to either
OMC Slide Hammer PIN 432128 or OMC Puller Bridge
PIN 432127 . Thoroughly clean the housing in solvent.
2. Install new bearings in the bearing housing using OMCBearing 15500

Installer PIN 334997 .
Oil and place a new forward bearing on the tool with

lettered side of the bearing facing the tool. Install the
bearing until the tool contacts the housing.
1331 Oil and place a new rear bearing on the tool wit h lettered
side of the bearing facing the tool. Install the bearing
until the tool contacts the housing.
r::;;l r:;;l 3. Install new seals back to back in the rear of the
~ ~ bearing housing using OMCSeallnstalier PI N 910585 or 15501
326556. Apply OMC Gasket Sealing Compound to the metal
casing of the seals before installing. Install the inner seal with
lip facing toward 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.
1361 4. Lightly apply OMC Triple-Guard grease to a new bearing

housing O-ring . Install the O-ring in groove of t he housing.
34
DR2061
DR2062
6-14 45C/eng

DR2061
Driveshaft Bearing Housing Service

The driveshaft bearing is not serviceable. Replace the bearing
housing if the bearing is worn or damaged. Also, inspect the
driveshaft bearing surface if the bearing is damaged.
137\ 1. Using a punch and mallet, drive the two seals out of the
housing. Discard the seals.
@
2. Remove the a-ring from the bearing housing and discard.
3. Clean the bearing housing in solvent to remove sealer from the
seal bore and the a-ring groove. DR2062
\38\\39\ 4. Install new seals back to back in the housing using

OMC Seal Installer PI N 335823. Apply OMC Gasket
Sealing Compound to the metal casings of the seals before
installing. Install the inner seal with flush lip facing toward the
bearing housing, then the outer seal @ with extended lip facing
away from the bearing housing. Apply OMC Triple-Guard grease
to the seal lips after installing.
140\ 5. Lightly apply OMC Trip/e-Guardgrease to a new a -ring and
install in its groove in the bearing housing.
Driveshaft Shimming Using Tool, PIN 393185 and Service Kit,

PIN 433032
The driveshaft pinion is precisely meshed with the forward and
reverse gears by using a shim or shims between the driveshaft
bearing housing and upper thrust washer. When installing a new
thrust bearing or washers, bearing housing, pinion, or driveshaft,
it is necessary to properly shim the assembly to restore factory
clearance.
Gauge bars are precision made and should be handled carefully.
The length of each bar is stamped near the part number. This
dimension is 0.030 in. (0,762 mm) shorter than the actual
shimmed length of the driveshaft.
INotel Degrease pinion and driveshaft tapers prior to assembly.

141\ 1. Assemble the driveshaft bearing housing , thrust bear-
ing , two thrust washers @, and pinion onto the driveshaft.
Tighten the pinion nut to a torque of 40-45 ft. Ibs. (54-61 Nm).
45C/e ng 6-15
40,48,50
1421 2. Slide the Collar PIN 334985 from OMC Driveshaft Shim
Kit PIN 433032 onto the driveshaft with large end touching
the bearing housing. .
42 13. Insert the assembled driveshaft into the tool base.

1
1431 4. Tighten preload screw against the driveshaft until groove

on the spring-loaded plunger is flush with end of threads.
Tighten lock ring on preload screw.
5. Rotate the driveshaft several revolutions to seat bearings.
1441 6. Position Shim Gauge PIN 334984 from OMC Driveshaft

Shim Kit PIN 433032 against guide pins of the tool base.
1451 7. Check the squareness of the bearing housing mounting

surface by holding the gauge bar against the pinion while
rotating just the bearing housing and measuring the clearance
between the gauge bar and bearing housing with feeler gauges.
Make measurements between each pair of screw holes. Replace
the bearing housing and repeat check if variance exceeds 0.004
in. (0,10 mm).
1461 8 . Check the squareness of the pinion to the driveshaft by

holding the gauge bar against the bearing housing, between
the screw holes, while rotating just the driveshaft and pinion
assembly and measuring the clearance between the gauge bar
and the pinion. Replace the gear set or the driveshaft, as neces-
sary, and repeat the check if variance exceeds 0.002 in.
(0,050 mm).
9. Subtract the average clearance measurement obtained in Step

8 from 0.030 in. (0,762 mm) to determine the correct shim
thickness required. Select fewest number of shims to achieve 44
correct thickness. "'--------------=-==='
10. Remove the driveshaft from the tool base. Remove the collar
and bearing housing from the driveshaft and add the required
amount of sh ims.
11. Check shimm ing by reassembling the driveshaft with shims

and placing it back into the tool base. The measurement between
the gauge bar and pinion should be 0.030 in. (0,762 mm).
12. Remove the nut and pinion from the driveshaft.
6-16 45C/eng
Assembly
r::=J Before beginning assembly procedures, all gearcase com-

~ ponents must be thoroughly cleaned and in serviceable
condition. Refer to Cleaning and Inspection, Page 6-5.
rv PIN
~
1. Assemble the following components of OMC Special Tool
391257 and OMC Pinion Service Kit PIN 433033.
@ %-20 X 1/2 in. Hex Head Screw

@ PIN 334986 Spacer (from PIN 433033)
@ PIN 326582 Rod (from PIN 391257)
PIN 326575 Installer (from PIN 391257)
%-20 x 1% in. Hex Head Screw
@ PIN 334987 Guide Plate (from PIN 433033)
2. Place the bearing on the installer tool with the lettered side of
the bearing facing the tool. Use OMC Needle Bearing Assembly
Grease to hold the bearing onto the tool.
f213. Insert the tool with the bearing into the gearcase. Drive the
~ bearing in the gearcase until the washer on the tool contacts
the spacer.
rJl4. R~move ~h.e tool. Position a new seal on the pinion

~ bearing retaining screw. Apply OMC Nut Lockto threads of the
screw. Install the screw and tighten to a torque of 48-80 in. Ibs.
(5-9 Nm).
5. Using OMC Forward Bearing Service Kit PIN 433034 and OMC
Drive Handle PIN 311880, install two new forward gear bearings
in the gearcase as follows:
Place the gearcase in a vertical position on the floor. 3

Support nose of the gearcase with wood.
Place drive handle through the step plate. Assemble the

bearing installer to the drive handle to install the short
bearing.
Place the short bearing on the installer tool with lettered

side of the bearing facing the tool.
Insert the tool with the bearing into the gearcase. Drive
the bearing in the gearcase until installer tool contacts
the gearcase. 4
To install the long bearing, reverse the installer tool on
the drive handle.
45C/eng 6-17
40,48,50
6 7 8L......;~-----------:-=186~36
DR2790 15467
Place the long bearing on the installer tool with lettered

side of the bearing facing the tool.
Insert the tool with the bearing into the gearcase. Drive
the bearing in the gearcase until installer tool contacts
the gearcase.
'7l6. Install the clutch dog on the propeller shaft with end marked
l.!...J PROP END to the rear, and shifter hole of the clutch dog and
propeller shaft slot aligned. 9
L......;~----------1~86~35
101 I:A. 7. Wear safety glasses to avoid personal injury when
~ ill servicing the detent. Insert two detent balls in detent
hole of the shifter shaft.
19l8. Insert the third ball and then the detent spring through hole
EJ in end of shifter shaft.
r,Ql9. While holding the detent balls in shifter shaft, carefully

~ align holes in shifter shaft and clutch dog with slot in the
propeller shaft. Insert the shifter shaft into the propeller shaft
until the detent balls slip into grooves in the propeller shaft. 10
~~-----------:-=186=34~
@ 9/3 2 in. (7,1 mm) diameter

@ 2% in. (75 mm)
20

12
15515
r,v f12110. With holes in the clutch dog and shifter shaft lined
~ ~ up, insert wedge end of the tool with flat side facing end
of detent spring. When the tool is flush with the clutch dog, press
the retaining pin through the clutch dog, pushing out the tool.
r:J3l11. Secure the pin with a new retainer spring. Position three
~ coils over each end of the pin, making certain no coils of the
spring overlap.
114112. Install the forward gear thrust washer with chamfered

edge facing into the gearcase.
1,5l13. Apply OMC Needle Bearing Assembly Grease to the

~ forward gear thrust bearing. Place the bearing on shoulder of
the gear and install the gear.
'16l14. Place one of the thrust washers @ onto the driveshaft

~ with chamfered edge facing down. Install the thrust bearing
. Place the remaining thrust washer @ onto the driveshaft with
chamfered edge facing up. Lightly coat the shim(s) with OMC
Needle Bearing Assembly grease and place them into the bear-
ing housing. Slide bearing housing onto driveshaft. 16
INotel Position items @, , and exactly in order shown. --------------=~
'17115. Lightly apply OMC Gasket Se.a1ing Compound to ~he
~ gearcase area that contacts mounting flange of the bearing
housing. Do not coat inside bearing housing bore surface of the
gearcase.
45C/e ng 6-19
40,48 50
1181 16. Install the pinion and driveshaft as follows:
Degrease tapers of the pinion and driveshaft. Install the

pinion and driveshaft into the gearcase. Push the
driveshaft bearing housing in position.
Lightly coat the threads of the pinion nut with outboard

lubricant.
While holding the pinion nut with an 11A6 in. wrench, and
the driveshaft with an OMC Driveshaft Holding Socket
Pin PIN 334995, tighten the nut to a torque of 40-45 ft.
Ibs. (54-60 Nm). Pad handle of the wrench to prevent
damage to the gearcase.
~ Incorrect torque of the pinion nut will reduce pinion life. Do
~ not reuse damaged pinion nuts.
~ 17. Apply OMC Gasket Sealing Compound to threads of the

L!!J housing retaining screws. Install and tighten the screws to a
1201 18. Apply OMC Triple-Guard grease to two new shift housing
a-rings. Install the large a -ring on the housing. Slide the
bushing then the small a-ring onto the shift rod. Apply OMC
Adhesive M to threads of the bushing. Assemble the housing,
a-ring, and bushing. Tighten the bushing to 48-60 in. Ibs.
(5-7 Nm).
f21l 19. Thread the shift lever and connector assembly onto the
~ shift rod nine turns.
20 18220
15470
6-20 45C/eng
I
I
...I - I,
f \
I I
I
1221 20. Install shift cradle on shift shaft with part number facing
straight up. Use OMC Needle Bearing Assembly Grease to
keep the cradle from rotating on the shift shaft.
1231 21. Tilt nose of gearcase down and install propeller shaft until
rear edge of shift cradle is flush with front edge of forward
gear @.
1231 22. Slide shift lever and rod into gearcase. Shift lever tangs
must engage shift cradle slots.
~ Verify that the shift lever has engaged the cradle before DR2815
~ proceeding.
23. Install a new seal on the shift lever screw. Apply OMC Nut
Lock to threads of the screw.
1241 24. Move the shift rod to align hole in the shift lever with hole
in gearcase. Install and tighten the screw to a torque of
48-80 in. Ibs. (5-9 Nm).
r:;;;l 25. Push the shift housing in position . Apply OMC Gasket
~ Sealing Compound to threads of the retaining screws. Install
and tighten the screws to a torque of 60-84 in. Ibs. (7-9 Nm).
1261 26. Using OMC Needle Bearing Assembly grease, place the
reverse gear thrust bearing on shoulder of the reverse gear.
Install the gear in the gearcase.
45C/eng 6-21
40,48,50
r:;:;J 27. Carefully apply OMC Gasket Sealing Compound to the
~ O-ring flange and aft support flange of the propeller shaft
bearing housing.
r:;;l 28. Apply OMC Needle Bearing Assembly Grease to the

t3!J reverse gear thrust washer. Place the thrust washer in the
propeller shaft bearing housing.
29. Install the propeller shaft bearing housing in the gearcase with
screw holes in a vertical position and drain slot facing down.
r:;;;l 30. Apply OMC Nut Lock to threads of the propeller housing
~ retainer screws. Install the retainers and tighten the screws to
a torque of 120-144 in. Ibs. (14-16 Nm).
1301 31 . Before installing lubricant, pressure test and vacuum test

the gearcase as follows:
Remove the oil level plug, and screw in a pressure test

gauge.
Pump up pressure to 3-6 PSI (21-42 kPa). If pressure

gauge indicates leakage, submerge the gearcase in wa-
ter to determine source of leakage as evidenced by
bubbles. If the gearcase pressure gauge does not indi -
cate leakage, 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 test.
Screw in vacuum tester. Pump outto 3-5 in. (76-127 mm)

of mercury and see if vacuum holds. Then, pump out to
15 in. (381 mm) 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 OK, refill with the proper
lubricant.
6-22 45C/eng
32. Fill the gearcase with 16.4 fl. oz. (485 ml) lubricant as
follows:
The gearcase must be in an upright position.
- Remove the oil level and the oil fill/drain plugs. Replace
the seals if damaged.
- Fill the gearcase with OMC Hi-Vis gearcase lube until

lubricant appears at the oil level hole. Insert the oil level
plug first. Install the fill/drain plug. The fill/drain plug has
a magnet. Tighten the oil level and the fill/drain plugs to 18231
a torque of 60-84 in. Ibs. (7-9 Nm) .
- Inspect the gearcase oil level after the motor test has
been performed .
33. Adjust the shift rod as follows:
'~
31l1321 - case
Check from the shift rod hole to surface of the gear-
using OMC Universal Shift Rod Height Gauge
PIN 389997 with the shift rod in the NEUTRAL posi -
tion. Rotate the shift rod full turns up or down, as
necessary, to obtain the correct adjustment. Check the 18284
shift rod height with the rod offset to the front.
Shift Rod Heights
Standard Shaft 1615/ 16 in . V32 in.

(430,3 0,8 mm)
Long Shaft 21 15/ 16 in . 1/ 32 in.

(557,3 0,8 mm)
15433
Extra Long Shaft 247/ 16 in. %2 in.
(620,8 0,8 mm)
1331 34. Install the anode. Tighten the screws to a torque of

108-132 in.lbs. (12-15 Nm). Do not use sealer on threads of
the anode screws.
35. Install the water pump as described in Water Pump Servicing
45C/eng 6-23 40,48,50

Installation
1. Coat the driveshaft splines with OMC Moly Lube. Do not coat
the top surface of the driveshaft as lubricant here may prevent
seating of the driveshaft in the crankshaft.
2. Slide the gearcase into place making sure that the driveshaft
engages the crankshaft and the water tube of the inner exhaust
housing enters the water pump.
r:jl ~ 3. Apply OMC Nut Lock to threads of the retaining screws.

~ ~ Install and tighten all the screws to the following torques:
Gearcase Retaining Screws
3/8 in. screw @ 18-20 ft. Ibs.

(24-27 Nm)
7/ 16 in. screw 28-30 ft. Ibs.

(38-40 Nm)
rJl '"
4. Engage the shift rod in the shift rod link. Install and
~ ~ tighten shift rod retaining screw @.
f4l 5. Verify NEUTRAL detent adjustment. Loosen the two power-

~ head detent screws.
f51 6. Rotate the propeller shaft and verify that the gearcase is in
~ NEUTRAL detent.
7. Verify that the powerhead shift linkage is in the NEUTRAL

detent position.
'" 8. Tighten the two powerhead detent screws to a torque of

ill 60-84 in. Ibs. (7-9 Nm).
it Safety Related 6-24

18868
45C/eng
NOTES
45C/eng 6-25
Service Chart - 45, 55
CD OMC Triple-Guard Grease ~-

.. --@
v
~
01
..
OMC Adhesive M Sealant e:
I
@ OMC Moly Lube I ~-"f-------f2\

~ i,
~ 60-84 in. Ibs.
OMC Nut Lock (7-9 N'm)
8
OMC Hi-Vis Gearcase Lubricant: ~
22 fl. oz. (650 ml) eL,
o~
0~
Q 1
f2' ~ '~f2' 96-120in.lbs.
~~:.,~ (11-14N'm)
~ (.;\
% in. screws:
216-240 in. Ibs.
o -..
@
>----\!J
(24-27 Nm) @

Y,6 in. screws: o
28-30 ft. Ibs.
(38-40 Nm)
~
92-120 in . Ibs. 2
(11-14 N'm)
48-80 in. Ibs.

(5,5-9,0 N'm) DR 3654
6-26 45C/e ng
Gearcase Servicing - 45, 55
Removal
"" 1. To avoid accidental starting of engine while servicing,

ill twist and remove all spark plug leads.
~ 2. Remove the shift lever retaining pin. Push the shift lever
~ toward the powerhead to disengage the shift lever from the
shift rod.
f313. Mark the trim tab and the gearcase before removing the trim
t.=..I tab so tab is put back in the same position. Remove the trim
tab retaining screw and the trim tab from the gearcase.
f314. Using a 5/8 in. thin wall socket, remove the countersunk
t.=..I screw @ with the lock washer.
~ 5. Remove the screw from inside trim tab cavity.

1sl6. Remove the four gearcase retaining screws with lock wash-
@
EJ ers.
COA3140
7. Remove the gearcase assembly from the exhaust housing,

being careful not to bend the shift rod. Secure the gearcase in a
suitable holding fixture.
R In preparation for gearcase disassembly, remove the water

~ pump as described in Water Pump Servicing.

45, 55
9437
Disassembly
1. Remove the propeller and mounting hardware. Inspect the

propeller for a spun hub.
71 2. Drain the gearcase by first removing the oil level plug @,

~ then the oil filiidrain plug @. Inspect the lubricant for water
which will give it a milky appearance, or overheating, which will
give the lubricant a black color and burned odor.
1sl 3. Remove the four propeller shaft bearing housing screws 9438
~ with O-rings using a 5/ 16 in. thin wall socket.
19l 4. Using two OMC 5/ 16 -18 x 8 in. screws, PIN 316982 or OMC
~ Propeller Shaft Bearing Housing Puller, PIN 330278, and pull-
er body from OMC Universal Puller Kit, PIN 378103, pull the
propeller shaft bearing housing from gearcase.
r:tOl "" 5. Remove the two retaining rings using OMCRetain-

~ ~ ing Ring Pliers PIN 331045. Retaining rings are under
extreme pressure during removal and installation. To prevent
personal injury, wear safety glasses and proceed with care to
avoid unsnapping the ring from the pliers. After the retaining
rings are removed far enough from the gearcase to clear the
housing, release the tension on the pliers while retaining ring is
still around the propeller shaft.
[!!J 6. Remove the retainer plate @ from the gearcase.

f121 7. Remove the larger thrust washer @, thrust bearing and
~ reverse gear @ from the gearcase. Remove the reverse gear
smaller thrust washer located in front of the gear.
~ 8. Remove the four screws from the driveshaft seal housing

.

9. Remove the pinion and driveshaft from the gearcase as
follows:
Pull up on the shift rod to engage FORWARD gear

position.
Using OMCDriveshaft Holding Socket, PIN 316612, and

an 11/16 in. open-end wrench, back the pinion nut off the
driveshaft. Pad the handle of the wrench to prevent
damage to the gearcase.
The driveshaft to pinion taper is a locking taper. If

necessary, use OMC Puller PIN 387206 CD and OMC
Backing Plate PIN 325867 Q) to break the lock. Install the
tools, as shown, by clamping them around the driveshaft
with the tool's set screw aligned with the impeller drive
cam slot. Tighten the set screw into the slot. Alternately
tighten the two vertical screws against the backing plate
inserted between the puller and the gearcase until the
driveshaft pops loose from the pinion.
Remove the driveshaft with the driveshaft bearing hous-

ing @, shim(s) CD, thrust washer ~ , and thrust bearing
from the gearcase. Reach inside the gearcase and re-
move the pinion. It may be necessary to pull up on the
shift rod to gain enough clearance to remove the pinion.
r:;:;] 10. Push down on the shift rod and unthread the shift rod
~ from the shifter detent. Remove the four screws, shift rod,
and cover assembly from the gearcase. Discard the cover gasket.
Remove and discard the O-ring from inside of the cover.
1181 11. Remove the fillidrain plug. Remove the propeller shaft
assembly from the gearcase.
45C/eng 6-29
45, 55
f191 12. To remove the bearing housing and forward gear from the
~ propeller shaft, pry the clutch dog reta iner spring out of the
clutch dog groove and push out the clutch dog pin. Discard the
retainer spring .
1201 13. Separate the bearing housing from the propeller shaft.
Remove the thrust washer, thrust bearing, and forward gear
from the housing.
21 1 14. Disassemble the bearing housing as follows:

1
Push out the shift lever pin @, disengage the shifter

shaft and cradle from the shift lever @, and
remove the shift lever.
Rotate the shifter detent 1800 to depress the detent

ball and spring. Ball and spring can pop out with great
force. Wear safety glasses for eye protection and
proceed with care. Pull the shifter detent from the
bearing housing being prepared to catch the ball and
spring.
COA3584
15. The forward gear bearing and bearing housing are serviced as
an assembly. If either are worn or damaged, replace the assem -
bly.
21
COA3587
COA3588

16. Inspect the pinion bearing for damage without removing it. If
the bearing is removed for any reason, it must be replaced.
Remove the bearing retaining screw from the gearcase.

Discard the O-ring from the screw.
Assemble the following components of OMC Pinion

Bearing Remover and Installer, PI N 391257, in the gear-
case.
PIN 326586 Flange Nut

@ PIN 391260 Plate
PI N 326582 Rod
CD PIN 326580 Remover
Use a 1 in. wrench to hold the remover in place. Using a

3/4 in. wrench, turn the flange nut clockwise and draw the
bearing up and out of the gearcase.
1251 17. Inspect the water intake screen for blockage and remove I-@
it by depressing the tabs on either side of the screen and
pushing upward. ~CD
24
45C/eng 6-31
45, 55
Propeller Shaft Bearing Housing Service
/26/ 1. Remove both seals using OMC Puller Bridge PIN 432127
and OMC Large Puller Jaws PIN 432129. Position plate on
top of housing to support bridge and tighten jaws securely
behind lower seal.
~ Inspect the bearings in place. If a bearing is removed for

~ any reason , it must be replaced.
1271 2. Remove rear bearing using OMCPulier Bridge PIN 432127

and OMC Large Puller Jaws PIN 432129. Rest puller plate on
top of housing to support bridge and tighten jaws securely
behind bearing.
1281 3. Remove front bearing using OMC Puller Bridge

PIN 432127 and OMCBearing Puller PIN 432130. Rest puller
plate on top of housing to support bridge and tighten jaws
securely behind bearing.
4. Clean housing and bearings in solvent and dry thoroughly. If

bearings were not replaced, rotate needles with your fingers to
check for freedom of movement. Inspect a-ring groove and sand
off any sharp edges that would cut a-ring and prevent its sealing.
5. Thoroughly clean the four bearing housing retaining screws in

solvent. Discard the retaining screw a-rings.
6. Inspect the bearing housing anode. Replace anode if it has

been reduced to two-thirds its original size (one-third eroded).
6-32 45C/eng
-@
COA3580
31
DR2061
32 DR2062
\29\\30\7. Oil, then install new bearings in the bearing housing

using OMC Bearing Installer, PIN 326562 @. Press
against the lettered side of the bearing to prevent damage to the
bearings when installing.
rJil\32\8. Use OMC Seal Installer PIN 326551 to install two new
~ seals back to back in the rear of the bearing housing.
Apply OMC Gasket Sealing Compound to the meta I casi ngs of the
seals before installing. Install the inner seal with lip facing
toward the bearing housing, then the outer seal with lip facing
r:;;l9. Lightly apply OMC Triple-Guard grease to a new bearing

~ housing O-ring. Install the O-ring in its groove in the housing.
Install new O-rings on the retaining screws.
Driveshaft Bearing Housing Service
~ If the needle bearing in the housing is worn, the bearing

~ and housing must be replaced as an assembly.
\34\1. Remove the two driveshaft bearing housing seals using

OMC Puller Bridge PIN 432127 and OMC Large Puller Jaws
PIN 432129. Discard the seals.
\35\2. Remove the O-ring from the bearing housing and discard.
3. Clean the bearing housing in solvent to remove sealer from the

seal bore and the O-ring groove.
rJil\32\4. Install new seals back to back in the bearing housing

~ using OMC Seal Installer PIN 326549. Apply OMC Gas-
ket Sealing Compound to the metal casings of the seals before COA3581
installing. Install the inner seal with flush lip facing toward the
bearing housing, then the outer seal with extended lip facing
\35\5. Lightly apply OMC Triple-Guard grease to a new O-ring and

install in its groove in the bearing housing.
45Cleng 6-33 45, 55

Driveshaft Shimming Using Tool PIN 393185 .
The driveshaft pinion is precisely meshed with the forward and

reverse gears by the use of a shim or shims between the
driveshaft bearing housing and thrust washer. When installing a
new thrust bearing or washer, bearing housing, pinion, or
driveshaft, it is necessary to gauge and select the proper shims to
restore factory clearance.
Gauge bars are precision made and should be handled carefully.

The length of each gauge is stamped near the part number, and
37 COA3593
this dimension can be used to measure the gauge to confirm
accuracy. This dimension is 0.020 in. (0,508 mm) shorter than
the actual shimmed length of the driveshaft.
INot 1 Before assembling the pinion to the driveshaft, degrease

e tapers on both parts.
13711. Lightly coat the threads of the pinion nut with outboard
lubricant. Install the pinion . Tighten the pinion nut to a
13712. Assemble the driveshaft bearing housing @, thrust washer 38

COA3594
@, and thrust bearing onto the driveshaft. Use OMC
Driveshaft Seal Protector PIN 316614 whenever installing or
removing the bearing housing.
13813. Slide the Collar PIN 328361 @ onto the driveshaft with
large end in contact with the bearing housing.
6-34 45Cleng
r:;;l r:;;;;l 4. Insert the assembled driveshaft into the tool base
~ ~ and tighten preload screw CD against the driveshaft until
groove Q) on the spring-loaded plunger is flush with end of
threads. Tighten locking ring on preload screw.
5. Rotate the driveshaft several revolutions to seat bearing.
14016. Position Shim Gauge PIN 328366 against guide pins of

the tool base.
7. Check the squareness ofthe bearing housing mounting surface

by holding the gauge bar against the pinion while rotating just the
bearing housing and measuring the clearance between the gauge
bar and bearing housing with feeler gauges. Make measurements
between each pair of screw holes. Replace the bearing housing
and repeat check if variance exceeds 0.004 in. (0,10 mm) .
.r;:;l 8. Check the squareness of the pinion to the driveshaft by

~ holding the gauge bar against the bearing housing (between
the screw holes) while rotating just the driveshaft and pinion
assembly and measuring the clearance between the gauge bar
and the pinion. Replace the pinion or the driveshaft, as necessary,
and repeat the check if variance exceeds 0.002 in. (0,050 mm).
9. Subtract the average clearance measurement obtained in

Step 8 from 0.020 in. (0,508 mm) to determine the correct shim
thickness required. Select fewest number of shims to achieve
correct thickness.
10. Remove the driveshaft from the tool base. Remove the collar
and bearing housing from the driveshaft and add the required
amount of shims.
~ Use extreme care when removing bearing housing to avoid

~ damaging the seals. Use OMC Driveshaft Seal Protector,
PIN 316614.
11. Check shimming by reassembling the driveshaft with shims

and placing it back into the tool base. The measurement between
the gauge bar and pinion should be 0.020 in. (0,508 mm).
12. Remove the nut and pinion from the driveshaft.
45C/e ng 6-35
45, 55
Assembly
@
R Before beginning assembly procedures, all gearcase com-
~ ponents must be thoroughly cleaned and in serviceable
@~ ~
condition. Refer to Cleaning and Inspection, Page 6-5.
14211. Assemble the following components of OMC Pinion Bear- @

ing Remover and Installer, PIN 391257, as shown:
@ 114-20 x 112 in. Hex Head Screw

PIN 326584 Spacer 42
813305
@ PI N 326582 Rod
PIN 326575 Installer
114-20 x 1114 in. Hex Head Screw
PIN 391260 Plate
2. Place the bearing on the installer tool with the lettered side of
the bearing facing the tool. Use OMC Needle Bearing Assembly
Grease to hold the bearing onto the tool.
3. Insert the tool with the bearing into the gearcase. Drive the 43
bearing into the gearcase until the washer on the tool contacts the "'"""---'-----------==:=-1
spacer.
1431 4. Remove the tool. Position a new a-ring CD on the pinion

bearing screw. Apply OMC Nut Lockto threads of the screw.
Install the screw into the gearcase. Tighten the screw to a torque
of 48-80 in . Ibs. (5,5-9,0 Nm).
5. To install the water intake screen, drop it into the water intake
cavity, and push it down as far as it will go with a screwdriver or
other suitable tool.
1441 1451 '" 6. To prevent personal injury, wear safety glasses.

~ Insert the spring and ball, coated with OMC Needle
Bearing Assembly Grease, into the housing. Press the ball down
with a small pin punch until it is below the detent cross hole. Push
the shifter detent over the ball, withdraw the punch , and force the
shifter detent in until it slides over the detent ball.
14611471 7.shifter
Place the shift lever in the housing, engaging the
detent, and press the shifter detent all the way in.
Next, hold the cradle on the shifter shaft with OMC Needle
Bearing Assembly Grease, hook the cradle over the shift lever,
and install the shift lever pin .
\481 8. Place the thrust bearing Q) on the shoulder of the forward

gear. Place the thrust washer on the bearing housing. Use
OMC Needle Bearing Assembly Grease to hold the bearing and
washer in place. Install the forward gear into the housing.

1491 9. Align hole in the clutch dog with slot in the propeller shaft.
Install the clutch dog on the shaft with grooved end of the
clutch dog facing forward end of the shaft.
1501 10. Insert the shifter shaft into the propeller shaft aligning
holes in the shifter shaft, propeller shaft, and clutch dog.
When holes are aligned, insert the clutch dog pin into the clutch
dog and shifter shaft. Secure pin with a new retainer spring. Make
certain no coils of the spring overlap.
11. Push the shifter detent down into the REVERSE position .
f51l 12. Locate the propeller shaft assembly and align the forward
~ bearing housing with the shifter detent toward the top. Be
sure the thrust bearing and thrust washer are properly positioned.
Insert the propeller shaft assembly into the gearcase as far as
possible, being sure to align the shift housing pin with hole in
forward end of gearcase housing.
1521 13. Lubricate a new shift rod cover a -ring with OMC Triple-
Guard grease. Install the a-ring into the shift rod cover.
Grease the threaded end of the shift rod and insert it through the
cover bushing. Turn the shift rod while pushing it through the
bushing to avoid damaging the a-ring.
1531 14. Apply OMC Gasket Sealing Compound to both sides of a

new shift cover gasket ~ . Position the gasket on the gear-
case. Thread the shift rod into the shifter detent about four turns.
15. Move shift rod from side-to-side while pushing on the propel-
ler shaft to ensure proper alignment of the bearing housing
locator pin into the locator pin hole in the gearcase. Gently tap the
end of the propeller shaft with a plastic or rawhide mallet to fully
seat the bearing housing.
52
6-37
45C/eng
45, 55
1541 16. Apply OMC Gasket Sealing Compound to the threads of
the shift rod cover screws. Install the screws. Tighten the
screws to a torque of 60-84 in. Ibs. (7-9 Nm).
1541 17. On standard shaft models - Place the gearcase cover seal
@ on the shift rod cover. On long shaft models - Install the
shift rod seal as follows:
Lightly apply OMC Triple-Guard grease to the shift rod

starting about 3 in . (7,6 cm) above the shift rod cover.
COA3168
Slide the shift rod seal down the shift rod and onto the
shift rod cover. Using a new tie strap, secure the seal to
the cover.
1571 18. Position the driveshaft thrust bearing , washer @ , and

shim(s) onto the driveshaft.
INotel Position items , @ , and exactly in order shown.
15811591 19. Lightly apply OMC Gasket Sealinfl, Compound to the

gearcase area that contacts mountmg flange of the
bearing housing. Do not coat inside bearing housing bore surface
of the gearcase. Using a driveshaft OMC Seal Protector,
PIN 316614, slide the driveshaft bearing housing onto the
driveshaft.
20. Install the pinion and the driveshaft as follows :
Pull up on the shift rod to engage the FORWARD gear

position.
Degrease tapers of the pinion and the driveshaft. Install

the pinion and the driveshaft into the gearcase.
Lightly coat the threads of the pinion nut with outboard

lubricant. Using OMC Pinion Nut Holder PIN 320675,
start the pinion nut onto the driveshaft.
While holding the pinion nut with an 11/ 16 in. open-end

wrench and the driveshaft with an OMC Driveshaft
Holding Socket PIN 316612, tighten the pinion nut to a
torque of 40-45 ft. Ibs. (54-60 Nm). Pad handle of the
wrench to prevent damage to the gearcase.
~ Incorrect torque of the pinion nut will reduce pinion life. Do

~ not reuse damaged pinion nuts.
6-38 45C/en g
COA3597
r;;] 21 . Align the embossed word "FRONT" toward the shift rod
~ and push the driveshaft bearing housing in position. Apply
OMC Gasket Sealing Compound to the threads of the housing
retaining screws. Install the screws and tighten the screws a little
at a time to press the bearing housing down evenly. Tighten the
screws to a torque of 96-120 in . Ibs. (11-14 Nm).
22. Place the small thrust washer in recess of the
r~:;lr~:;-]
~~ reverse gear. Oil and install first the thrust bearing @
and then the larger thrust washer on the hub of the reverse
gear. Slide the reverse gear onto the propeller shaft until it
engages the pinion.
1641 23. Slide the bearing housing retainer plate into position over
the propeller shaft.
16sl ~' 24. Using OMC Retaining Ring Pliers, PI N 331045, in-
illstall the two retaining rings. Retaining rings are 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 retaining rings
are seated in the grooves in the gearcase.
1661 25. Thread two OMC Guide Pins, PI N 383175, into the
retainer plate to align holes in the plate with holes in the
propeller shaft bearing housing. Do not thread guide pins more
than two turns into the retainer plate.
26. Carefully apply OMC Gasket Sealing Compound to the a-ring
flange and aft support flange of the bearing housing. Do not allow
sealer to contact either forward thrust surface or bearings in the
housing . Align the bearing housing on the guide pins with the
word "UP" toward the top. Press the bearing housing into the
gearcase and tap the housing in with a soft face mallet to seat the
a-ring .
27. Apply OMC Gasket Sealing Compound to the threads and
seals of the four propeller housing retaining screws. Install two of
the screws into the bearing housing finger tight. Remove the
guide pins and install the remaining two screws. Then tighten all
four screws to a torque of 120-140 in. Ibs. (14-16 Nm).
28. Before installing lubricant, pressure test and vacuum test the
gearcase as follows :
Remove t he oil level plug, and screw in a pressure test
gauge.

45, 55
Pump pressure up to 3-6 PSI (21-42 kPa). If pressure
gauge indicates leakage, submerge the gearcase in wa-
ter to determine source of leakage as evidenced by
bubbles. If the gearcase pressure gauge does not indi-
cate leakage, increase pressure to 16-18 PSI
(110-124 kPa). If pressu re does not hold, submerge the
gearcase in water and check for source of leakage. Make
necessary repairs and repeat the test.
Install a vacuum tester. Pump out to 3-5 in. (76-127 mm)

of mercury and see if vacuum holds. Then pump out to
15 in. (381 mm) of mercury and check. If the gearcase
fails to hold on either test, put lubricant around sus-
pected seal. If leak then stops or lubricant is drawn in,
that seal is defective. When the gearcase checks out
properly, fill the gearcase with the proper lubricant.
29. Fill the gearcase with 20-22 flo oz. (600-650 ml) lubricant as
follows:
Secure gearcase in an upright position.
Remove the oil level and the oil fill/drain plugs. Replace
the seals if damaged.
Fill the gearcase with OMC Hi-Vis gearcase lube until

lubricant appears at the oil level hole. Insert the oil level
plug first. Install the fill/drain plug. Tighten the oil level
and the fill/drain plugs to a torque of 60-84 in. Ibs.
(7-9 Nm).
Inspect the gearcase oil level after the motor test has
been performed.
30. Adjust the shift rod as follows:

COA3668
Check from the shift rod hole to surface of the gear-

case using OMC Universal Shift Rod Height Gauge,
PIN 389997, with the shift rod in the NEUTRAL posi-
tion. Rotate the shift rod full turns up or down as
necessary to obtain the correct adjustment. Check the
shift rod height with the rod offset to the rear.
68 COA3553
6-40 45C/eng
Shift Rod Heights
1529,62 in. '1.32 in.

Standard Shaft (404 mm 0,8 mm)
2029,62 in. '1.32 in.

Long Shaft
(531 mm 0,8 mm)
23'31.32 in. '1.32 in.

Extra Long Shaft
(594 mm 0,8 mm)
31. Install the water pump as described in Water Pump Servicing.
Installation
1. 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.
2. Slide the gearcase into place making sure that the driveshaft
engages the crankshaft and the water tube enters the water
pump.
3. Apply OMC Gasket Sealing Compound to threads of the

retaining screws. Install and tighten all the screws to the follow-
ing torques:
Gearcase Retaining Screws
216-240 in. Ibs., 18-20 ft. Ibs.

3/8 in. screws
(24-27 Nm)
336-360 in. Ibs., 28-30 ft. Ibs.

7116 in. screws
(38-40 Nm)
4. Install the trim tab and align it with marks. Tighten the retaining
screw to a torque of 216-240 in. Ibs. (24-27 Nm).
& 5. Engage the shift rod in the shift rod link and install pin.

45, 55
Trim Tab Adjustment - All Models
The boat may be slightly easier to steer in one direction or the
other due to steering forces or other reasons. To check this, run
the boat in a straight line with a balanced load in an area where
current and wind will not be a factor.
R A single trim tab adjustment will only relieve steering effort

~ under one set of speed, trim, and loading conditions. No
single setting can relieve steering effort under all speed, trim, and
loading conditions.
1. Turn the steering wheel in both directions to determine the

direction that requires the least amount of steering effort.
[!] 2. Loosen the trim tab. If the .boat

pulls to port, move the rear of the trim tab to port.
pulls to starboard, move the rear of the trim tab to

starboard .
3. Reference numbers, 0 thru 6, are embossed on the trim tab for

ease of adjustment. Align the reference number with the recessed
screw or the embossed line.
4. Retighten trim tab screw and recheck steering effort in both

directions. Repeat procedure until steering effort is equal in both
directions.
5. After final adjustment, tighten the trim tab screw to a torque of

216-240 in. Ibs. (24-27 Nm).
6-42 45C/eng
27160
Jet Drive Servicing

Removal and Disassembly

rv 2.reverse
~
Remove nut , flat washer , and shift cable end from
gate cam.
rv 3.removing
~
Remove cable by rotating shift cable to vertical position and
the adjusting nut and cable from the shift cable
anchor.
~ 4. Remove six screws retaining the intake housing to the jet

~ housing. Remove the intake housing.
~ 5. Bend tab-lock washer ears @ and remove impeller nut @.

~ Remove tab-lock washer and discard .
~ 6. Note the number and placement of impeller shims. Refer to

~ Impeller Clearance Adjustment. Remove impeller adjustment
shims from driveshaft.
1sl7. Remove the impeller from the driveshaft. Retain the impel-
~ ler key @ and impeller sleeve @.
'1618. 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.

fJ11s19. Remove the adapter to jet housing screw. Remove four
~ ~ screws and lock washers through the opening in the
housing. Remove bearing housing, driveshaft, water pump, and
jet housing as an assembly.
19l10. If servicing the adaptor or exhaust housing, remove screws

L!J retaining the adaptor and remove it from the exhaust housing.
Remove Gate - Cam Models
~ 1. Remove cam screw @' eccentric nut @' and bushings @.

r,v 2. Remove cam roller nut, and remove cam assembly from
~ reverse gate arm.
11213. Move roller to position shown, and remove roller from

cam.
r;:;J 4. Remove screws @ retaining reverse gate shafts. With a

~ drift and hammer, lightly tap shafts from housing. If forward
stop is to be replaced, remove screw , and remove stop and
spring.
5. Remove reverse gate from housing, and inspect shaft bush-

ings. Replace if worn or damaged.
6-44 45C/eng
Remove Gate - Linkage Models
1141 1. Remove cotter pin , washer @' and bushing retaining

the linkage to the reverse gate.
2. Remove screw CD retaining linkage to the jet housing.
~ 3. Remove two screws Q) retaining the gate shafts.

f161 4. Push sha!t~ out of gate, and note position of holes in shafts
~ for the retammg screws.
f171 5. Remove the gate and wave washer on port side. Remove
~ the bushings from the reverse gate.
45C/eng 6-45
Bearing Housing Assembly Servicing
1. Remove water pump assembly from jet housing.
f1l2. Remove four bearing housing retaining screws, and remove

~ bearing housing assembly from jet housing.
~ '" 3. Remove retaining ring with snap-ring pliers. Wear

~ i l l safety glasses and proceed with care to avoid
unsnapping the ring from the pliers.
~ 4. Remove O-rings from housing and discard .

1a15. Warm bearing housing with a propane torch to aid in
~ removal of upper seal carrier.
R 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

i l l touch.
r;l7. 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 housing.
8. If seals are damaged, the carrier and seals are serviced as an

assembly. Apply OMC Triple-Guard grease to seal lips before
reinstalling the carrier and seal assembly.
r;'] 9. 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.
~ 10. Using a punch, drive out the inner seal and discard.
11. Remove the outer seal retaining ring using the same proce-
dure as described in Step 9.
012. Drive out the outer seal and discard.

& Safety Related 6-46 45Cl eng
8 27122
9
10113. To assemble inner and outer seals to bearing housing,
~ install outer seal retaining ring into its groove in the bearing
housing.
1nl14. 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 .
r,Ql r,v 15. Install inner seal with lip facing outward. Tap seal into 27119
~ ~ bearing housing using a socket slightly smaller than the
outside diameter of the seal. When the seal is seated, install the
inner retaining ring.
112116. Remove the seal carrier assembly and spacer from the
driveshaft.
r:J3l ""17. Remove the retaining ring with retaining ring pliers.
~ ill Wear safety glasses and proceed with care to avoid
f141 ~ 18. Inspect driveshaft bearing in place. If that bearing 12

~ ~ is removed for any reason, it must be discarded. To
remove, press bearing off driveshaft from impeller end of shaft.
Discard bearing.

r:J5l19. Remove thrust washer and collar from driveshaft.
~ Remove retainer ring if required.
r;;] 20. To assemble bearing to driveshaft, make sure bearing

~ retaining ring @ is in position on the driveshaft. Apply a light
coat of OMC Marine Wheel Bearing Grease to the bearing and
driveshaft pressing surfaces. Press bearing onto shift until
bearing makes contact with retaining ring.
r:J7l i'"l l sure

~
21. Using ret~i~ing ~ing pliers, ins~all. snap ring .. Make
the retaining ring IS seated In ItS groove In the
18
L..:..~_ _ _ _ _ _ _ _ _-=~
driveshaft. Wear safety glasses and proceed with care to avoid ...------------.....=.:..=-,
118122. Place spacer and upper seal carrier assembly @ onto

the driveshaft. Apply OMC Triple-Guard grease to two new
O-rings and install on upper seal carrier.
r,gl23. ~ill bearing housing cavity with OMC Marine Wheel

~ Beanng Grease.
120124. Heat the bearing housing slightly with a propane torch. 19

Press the driveshaft and bearing assembly into the bearing '--..;;....J._ _ _ _ _ _ _ _--=:~~
housing until seated.
'" 25. Allow the bearing housing to cool until it is warm to the
ill touch.
f21l26: Pre.ss spacer and bearing carrier into bearing housing

~ uSing finger pressure.

1221 '" 27. Using retaining ring pliers, install snap ring with
i l l 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.
123130. Install bearing housing assembly into jet housing and

retain with four screws and lock washers. Torque screws to
60-84 in. Ibs. (7-9 Nm).

'" Replace damaged components. Shift system failure will

ill cause loss of control over direction of engine thrust.
1. Discard all seals, O-rings, and gaskets.
J:.... 2. Clean all jet drive 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).
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
corrosion and sealer.
Drive impeller - Check impeller for nicks and burrs. File

edges to remove any nicks and to keep surface sharp.
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

hub bonding . Check liner and wear plate for scoring and
distort ion.
& Safety Related 6-50 45 C/eng

Assembly - Gate Cam Models
1.jl1. If the reverse gate was removed during disassembly, install

~ reverse gate @, bushings ,and shafts to jet housing.
Position shafts so holes align with holes where retaining screws
make contact.
2. Torque screws @ to 60-84 in. Ibs. (7-9 Nm). After installation,

check to make sure the reverse gate moves freely.
~ 3. Place roller into cam in position shown. The roller will not
~ assemble in any other position.
rJl4.Place cam roller on reverse gate stud, and torque nut to

~ 60-84 in. Ibs. (7-9 Nm).
~ 5. Install bushing , eccentric nut @, and cam screw .

~ Before tightening cam screw, adjust reverse gate. Refer to
~ Gate Adjustment.
Assembly - Gate Linkage Models
f511. Position gate to housing with wave washer CD, bushings Q),
~ and shafts to jet housing .
2. Torque screws @ to 60-84 in. Ibs. (7-9 Nm). After installation,

check to make sure reverse gate moves freely.
~ Before tightening linkage screw, adjust reverse gate. Refer

~ to Gate Adjustment.
f613. Make sure bushing is in lower hole of reverse gate arm.

~ Attach linkage to gate arm with washer ~ and cotter pj n .
Attach linkage to jet housing with screw @, and torque screw to 27127
60-84 in. Ibs. (7-9 Nm).
Both Models
1. Apply OMC Adhesive M sealant to the spacer and jet drive

housing mating surfaces. Place the spacer on the jet drive
housing.
45C/eng 6-51
2. Install water pump assembly to jet housing. Refer to Water
Pump Servicing. Do not use the impeller plate gasket on a Jet
model. Apply OMC Gasket Sealing Compound to the impeller
plate before installing.
3. Coat driveshaft splines with OMC Moly Lube. Do not coat top
surface of driveshaft as lubricant here may prevent seating of
driveshaft in crankshaft.
Installation
1. Slide jet housing into place, making sure driveshaft engages

crankshaft, water tube enters water pump, and lower inner
exhaust housing does not slip out of position.
r:jl f21 2. Apply OMC Gasket Sealing Compound to threads of jet

~ ~ housing retaining screws and rear exhaust housing screw.
Install two 5A6-16 x 2 1/2 in. screws in forward holes @ and two
5/16 -16 x 3 in. screws in rear holes@. Install adapter to jet housing
screw. Torque all screws to 10-12 ft. Ibs. (14-16 Nm).
3. Install key, bushing, shims, tab-washer, and nut on driveshaft. 5

Be sure shims are placed in original position. Refer to Impeller L.----"------------=:;-:--:-l
Clearance Adjustment.
1a14. When proper clearance adjustment is achieved, torque

~ impeller nut to 16-18 ft. Ibs. (22-24 Nm).
~ 5. Using a new tab-lock washer, bend tabs around driveshaft

~ nut to secure the assembly.
f516. 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 27161A
side, verify that intake housing is centered. Torque screws in a
crisscross pattern to 60-84 in. Ibs. (7-9 Nm).
7. Recheck impeller clearance after shimming adjustment has

been performed.
Isl8. 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.
6-52 45C/eng
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.
~ Accelerated impeller wear can occur when operating in

~ waterways which have bottoms composed largely of sand,
silt, and gravel.
f111. 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
0
Impeller Clearance
0.020 in. (0,5 mm) Minimum to 0.030 in. (0,8 mm) Maximum
PCE0084
1sl2. 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

i l l and remove all spark plug leads.
f213. Remove six screws retaining the intake housing to the jet
t=I housing. Remove the intake housing.
f314. Bend tab-lock washer ears and remove impeller nut CD.
~ Remove tab-lock washer and discard.
f315. Remove shims Q), impeller, key, and impeller sleeve from
~ driveshaft.
~ 6. Use a flat file and remove any nicks or burrs from edge of
~ impeller.
~ 7. Transfer one or more shims from bottom to top of impeller.

~ 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.
45Cleng & Safety Related . 6-53

Isl f71 9. Assemble remaining shims, new tab-lock washer, and
~ ~ impeller nut onto driveshaft. Torque impeller nut to 16-18
ft. Ibs. (22-24 Nm). Use a new tab-lock washer each time, and
bend tabs around driveshaft nut to secure.
f'3l 10. Assemble intake housing to main 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 the casing liner and
impeller. If clearance is greater on one side, verify that the intake
housing is centered. Torque screws in a crisscross pattern to
10-12 ft. Ibs. (14-16 Nm).
11. Repeat Step 1 to verify adjustment.
Gate and Shift Cable Adjustment - Cam Models
Gate Adjustment
1. Move remote control handle to NEUTRAL detent.
Isl 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 @ while holding reverse gate

up, until proper clearance is achieved. Tighten cam
screw @ and recheck adjustment.
4. Move remote control handle to FORWARD detent.
19'1 5. When the roller is in FORWARD position , 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.
6-54 45C/eng
Shift Cable Adjustment
r,Ql When the shift cable is properly installed, the reverse gate
~ CANNOT be moved into the NEUTRAL position @ by hand.
~ The shift cable adjustment must be correct, or water

ill pressure from the boat's forward motion of boat could
engage the reverse gate and activate REVERSE unexpectedly.
Boat would stop abruptly. Occupants could be thrown about or
ejected.
r,Ql 1. Install shift cable with remote control and reverse cam in
~ NEUTRAL position. Adjust shift cable trunnion to achieve this
setting.
2. After adjustment is made, install shift cable to its anchor and

turn 900 to lock the cable trunnion into place.
~ 3. Place shift cable end onto reverse gate cam stud .

4. Install washer and nut to reverse gate cam stud, and hand
tighten nut.
r:J1l 6. When roller is in FORWARD position , apply hand

~ pressure to try and move reverse gate up, toward NEUTRAL
position.
Important It is more important that FORWARD locking

position be met, giving less importance to roller position in
NEUTRAL. If properly adjusted, reverse gate should not move
toward NEUTRAL.
7. Ifthe gate can be moved toward NEUTRAL, readjust shift cable

to hold gate in FORWARD position. Remove shift cable from
reverse gate cam stud and shift cable anchor.
r:J2l 8. Rotate trunnion to shorten cable and further seat roller into
~ FORWARD position .
9. Install cable. Make sure reverse gate CANNOT be moved into

the NEUTRAL position.
r,Ql 10. Install washer and nut to reverse gate cam stud .
~ Tighten nut, then loosen 1fa to 1/4 turn.
~ With running engine in NEUTRAL and warm-up lever

~ raised, engine will run rough due to exhaust restriction
from the reverse gate being in NEUTRAL.
45Cle ng & Safety Related 6-55

Gate and Shift Cable Adjustment - Linkage Models
Gate Adjust ment
~ Before installing and adjusting the shift cable, the length of

~ the shift link must be verified and adjusted, if incorrect. All
checking, adjusting, and operating is done with the shift link
installed in the lower hole of the reverse gate arm (when there are
two holes).
@] The shift link length is correct when:

the shift link @ is installed in the lower hole of the
reverse gate arm @,
AND the shift link is parallel with the horizontal center-
line of the unit,
AND the reverse gate @ is firmly against its pad .
All three of the above conditions must exist. If any do not, adjust
the shift link length:
1141 1. Remove the cotter pin @ from the reverse gate arm @.
2. Turn shift link IN or OUT until the three conditions listed above
are met. Repeat this procedure until the gate is accurately
adjusted.
3. Insert shift link into lower hole of reverse gate arm.
4. Install washer and secure with a new cotter pin .
r::-=J Do not be concerned if, after proper shift link adjustment,

~ the reverse gate does not close fully when the unit is shifted
into REVERSE. Water pressure from normal operation will close it
fully.
6-56 45C/eng
Shift Cable Adjustment
115l 1. Insert the shift cable vertically into anchor and turn it 90
~ to lock the cable trunnion into place. Temporarily, attach
cable end to shift lever @ while you adjust linkage.
J':.... The shift cable adjustment must be correct, or water

ill pressure from the boat's forward motion could engage the
reverse gate and activate REVERSE unexpectedly. Boat would
stop abruptly and occupants could be thrown about or ejected.
f161 3. Be sure reverse gate is firmly against reverse gate pad .

~ The reverse gate is properly adjusted when it is firmly against
pad .
4. If cable adjustment is required, remove shift cable from both

shift lever and cable anchor. Adjust cable trunnion until reverse
gate is firmly against pad.
f171 '" 4. Replace the shift cable into its anchor and turn 90
~ i l l to lock the cable trunnion into place. Replace the shift
cable end onto the shift lever @, and secure with washer and
locknut. Use only the locknut supplied to secure the cable to the
shift lever.
5. Install washer and locknut to reverse gate cam stud and tighten
nut, then loosen Va to 1/4 turn.
~ With engine running in NEUTRAL and warm-up lever

~ raised, engine will run rough due to exhaust restriction
from the reverse gate being in NEUTRAL.

Manual Starter
Table of Contents
& General Safety Warnings . ...... . . . . . . . . . . . . . . . .

Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . .
.
.
7 -2
7-3
Manual Starter Servicing. . . . . . . . . . . . . . . . . . . . . . . . 7-4
Removal . . ... . . . . .. . . .. . ... . ... . . ........ . 7-4
Disassembly .. . ........ . ...... . . . . . . . . . . . . . 7-4
Cleaning and Inspection . . . . . . . . . . . . . .. . . ..... . 7-5
Assembly . . .. . . . . . . . . . . . . . . .. . .... . .. . .. . . 7-6
Installation . . . . . . . . . . . . . .. .. . ... . .. . ...... . 7 -8
45C 7- 1
Before working on any part of the manual starter, read the
Wear safety glasses while servicing the manual starter.
Avoid accidental starting of engine while servicing; twist and


(172 kPa).

personal injury.

Prevent overboard falls from sudden boat movement when the

engine starts. Be sure the "start-in-gear prevention" feature
works as intended before you return the engine to your custom-
er.
7-2 45C/eng
Starter Spring Winder and Installer PIN 392093

Starter Rope Threading Tool PIN 378774
OMC Trip/e -Guard Grease

or
Lubrip/ate 777
OMC Nut Lock
Johnson or Evinrude Outboard Lubricant
OMC Locquic Primer
Starter Rope Length
96112 in. 245 em

PCE0068
45C 7-3
Manual Starter Servicing
Removal

rv~ 2. Remove the screw retaining the starter lockout cable clamp
@ to the starter housing. Remove starter lockout slide from
the starter housing.
rv~ 3. Remove the three starter housing retaining screws

lock washers and washers.
with
rt 4. Remove the two screws @ retaining the starter handle

~ bracket to the motor. Lift starter housing from motor.
Disassembly
'" 1. Wear safety glasses while disassembling and assembling

ill manual starters because of rewind spring tension.
~ 2. 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 knot, and ease the starter pulley
back until the rewind spring is fully unwound. If necessary,
remove the starter handle bracket from the starter housing.

COA1371
r.;l 3. Remove the shoulder screw retaining the starter lockout

~ lever @, lockout lever spring @, and washer to the starter
housing.
~ 4. Remove the nut @ from the starter pawl retaining screw.

1sl 5. Remove the starter pawl retaining screw , washer , and
~ starter pawl plate @ with plate return spring from the
starter assembly.
f71 6. Remove the starter housing spring CD and the starter pawl Q)
l.!J with spring washer from the starter assembly.
f81 7. Using a screwdriver, pry open the pulley lock ring CD, and
~ remove ring from the starter.
~ 8. Remove the friction plate ~ and friction plate spring washer

@.
9. 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.
Remove the pulley bushing from the pulley.
11Ql 10. Remove the rope guide shoulder screw @ and guide
~ from the starter housing.
Cleaning and Inspect ion
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 starter pawl for wear.
4. Inspect the starter components for wear. Replace as necessary.
5. Inspect starter rope. Replace rope if frayed. Cut new rope 96112
in. (245 cm) in length. Fuse ends of rope to a length of '/2 in . (12
mm).
10
COA1366
45C/eng 7-5
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. Examine the starter and starter lockout parts. Replace any worn
or damaged parts.
Assembly
"'" Wear safety glasses while disassembling and assembling

ill manual starters because of rewind spring tension.
IT!] 1. Place the starter spring shield @ into the starter housing.
r:w2l2. Using OMC Starter Spring Winder and Installer
~ PIN 392093, clamp spring winder base in a vise. Insert
release plate into spring winder base.
r.J3l 3. Apply OMC Triple-Guard grease or Lubriplate 777 to the

~ rewind spring. Install the rewind spring into the spring
winder base with open loop of spring facing inward. Insert the pin
of the crank and pin assembly into the loop of the rewind spring.
Secure the crank and pin assembly to the starter winder base with
the crank retainer screw.
4. Rotate the crank and pin assembly in the direction shown on

the tool. Wind the spring into the starter winder base until end of
spring contacts the starter winder base.
11415.Remove the crank retainer screyv and the crank and pin
assembly from the starter winder base. Remove the starter
winder base from the vise.
'15l 6. Install the rewind spring into the starter housing. Locate 16
COA1364
~ the outer loop CD of the rewind spring on the pin @ in the
starter housing. Press down through the holes in the spring
winder base to transfer the rewind spring into the starter housing.
rw 7. Apply OMC Triple-Guard grease or Lubriplate 777 to the

~ pulley bushing . Install the pulley bushing in the pulley.
Place the pulley shim @ on the pulley.

r:;:;J 8. Bend the inside loop @ of the rewind spring in toward the
~ center of the starter housing . Engage the slot @ of the pulley
with the inner loop of the rewind spring, and install the pulley in
the starter housing.
r:;;;J r;;;l 9. Place the friction plate sp ring washer and the
L.!!J ~ friction plate @ on the pulley hub. Secure the friction
plate and friction plate spring washer with the pulley lock ring @ .
r:J9l 10. Be sure the starter pawl bushing is installed in the pulley.
~ Apply OMC Triple-Guard grease or Lubriplate 777 to boss of
the starter pawl. Place spring washer on the boss of the starter
pawl. Place the starter pawl in the pulley.
1191 11. ~osition the starter housing spring @ in the starter

housmg.
1201 12. Install the starter pawl plate return spring on the starter
pawl plate CD. Press the other end of spri ng on the boss of the
pulley. Position the starter pawl plate on the pulley.
'21'l 13. Clean threads of the starter pawl plate retaining screw
~ and nut to remove adhesive. Install the starter pawl plate
375
retaining screw Q) and washer into the starter housing. Tighten
screw to a torque of 120-144 in . Ibs. (14-16 Nm). Spray threads of
starter pawl plate retaining screw that protrude through the
starter housing and threads of the nut with OMC Loequie Primer.
Apply OMC Nut Loekto the threads of the nut. Install and tighten
the nut securely.
14. Using the shoulder screw, install the rope guide to the starter
housing. Tighten the shoulder screw securely.
1221 15.lf removed, install the starter handle bracket to the starter
housing. Be sure to place the washers between the rubber
mounts of the starter handle bracket and the starter housing.
Tighten the shoulder screws securely.
45C/eng 7-7
16. If necessary, tie a knot in one end ofthe starter rope. With the
starter housing upside down on a bench, wind the pulley counter-
clockwise until the rewind spring is tight. Back off the rewind
---.. . --1--
spring until the rope cavity of the pulley is aligned with the rope
guide. Thread the starter rope through the pulley, rope guide, and
outlet in the starter handle bracket. Seat the knotted end of the
starter rope in the pulley. Tie a slip knot in the starter rope to hold
rope in position.
123117. Apply OMC Triple-Guard grease or Lubriplate 777 to the

handle end of the starter rope. Using OMC Starter Rope
Threading 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.
18. Check operation of the starter pawl when the starter rope is
pulled out. The starter pawl should extend when the starter rope
is pulled and retract when the starter rope recoils.
lever~, lockout lever spring @,

124119. Install the starter lockout
and washer @ to starter housing using the shoulder screw.
Tighten the shoulder screw securely.
Installation
12511. Position the starter assembly onto the motor. Place the
lifting ring on the rear screw mounting boss. Install the five
starter housing retaining screws. Be sure to place washers
between the starter housing rubber mounts and the motor.
Tighten the three starter housing screws to a torque of 120-144
in. Ibs. (14-16 Nm).
12612. Tighten the two starter handle bracket screws @ to a

torque of 60-84 in. Ibs. (7-9 Nm).
3. Apply OMC Triple-Guard grease or Lubriplate 777 to the starter

lockout slide area of the starter housing. Place the starter lockout
slide in the channel of the starter housing. Loosely secure the
starter lockout cable to the starter housing with cable clamp and
screw.
12714. Shift the motor to NEUTRAL position. Adjust starter

lockout cable so that starter lockout slide is centered on the
lockout lever . Tighten the cable clamp screw securely.
'" 5. Check operation of the starter lockout. Manual starter

i l l must not function when shift handle is in FORWARD or
REVERSE position.

Electrical System
Table of Contents

Service Specifications ............................. 8- 3
Battery Cable Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 4
Battery Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 4
Starter Circuit Check - TEL, TTL. . . . . . . . . . . . . . . . . . . . . 8- 8
Starter Circuit Check - Remote ...................... 8-10
Starter System Voltage Drop Test . . . . . . . . . . . . . . . . . . . 8-12
Key Switch Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Start Switch Ohmmeter Check - TEL, TTL ............. 8-15
Neutral Start Switch Test ..... . .................... 8-15
Solenoid Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
No Load Current Draw, Electric Starter ............... 8-16
Electric Starter Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Description of Charging System - All Models. . . . . . . . . . . 8-20
Charging System Check Chart - All Models . . . . . . . . . . . . 8-21
Running Test, Alternator Output - All Models. . . . . . . . . . . 8-22
Stator Resistance Check - 4 Amp Models. . . . . . . . . . . . . . 8-23
Rectifier Ohmmeter Tests - 4 Amp Models. . . . . . . . . . . . . 8-24
Stator Resistance Check - 12 Amp Models. . . . . . . . . . . . . 8-25
Rectifier/Regulator Tests - 12 Amp Models ............. 8-26
Rectifier/Regulator Replacement . . . . . . . . . . . . . . . . . . . . 8-30
AC Lighting Coil Resistance Check. . . . . . . . . . . . . . . . . . . 8-30
45C/eng 8-1
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 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 the original

position.
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.

8-2 45C/eng
Starter No Load Current Specifications _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Amps
Model Voltage (Maximum) RPM
40-50 12 - 12.4 32 5700-8000
PCE0059
Stator Resistance Chart - All Models _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Model 4Amp
40-50 0.55 0.05 Ohm
PCE0068
45C/eng 8-3
Battery Cable Extensions
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 ft. (6,1 m), regardless of cable
diameter.
~ 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)
20 - 50 6 ga o 4 gao 3 ga o
PCE0061
Battery Specifications
~ All batteries should be of heavy duty, marine construction
~ and a vented, refillable type. Maintenance-free or sealed
batteries are acceptable for use ONLY with engines that are
equipped with a fully regulated charging system. Refer to Specifi-
cations, Section 1.
~ Deep-cycle batteries must not be used as the engine's

~ cranking battery.
A battery that is not fully charged or is less than recommended

capacity may not crank the engine fast enough to produce
ignition component output.
For best performance, OMC recommends you use a 12-volt

battery with a m inimum rating of 360 cold cranking amps (CCA)
at 0 F (72 amp. hrs. at -18 C) and 115 minutes reserve capacity at
80 F (2]0 C).
Battery Testing
J:....
Battery electrolyte is an acidic solution and should be
ill handled with care. If electrolyte contacts any part of the
body, immediately flush the exposed area with liberal amounts
of water and seek medical aid as soon as possible.

1. Visual Inspection
The first step in determining the condition of a battery should be a

visual inspection. Look for conditions such as damage to the case,
loose terminal, evidence of electrolyte seepage, etc. These signs
may indicate improper care, installation, or application of the
battery.
Look for excessive corrosion on the battery terminals and cables.

Check the battery cables for worn or frayed insulation. Replace
cables, if necessary. 842018
Check the electrolyte level in each cell. If electrolyte level is below

the plates, it is possible the battery is permanently damaged. Also
look for dirt, oil, or other contaminants floating in the electrolyte.
~ 2. Hydrometer
~ Disconnect the positive battery cable whenever charging
~ the battery.
This test can only be used when there is sufficient electrolyte

above the battery plates to fill the hydrometer tube. Do not,
however, take readings immediately after refilling the cells with
water. The battery must be charged, then check with a hydrome-
ter.
View the hydrometer with your eye on the same level with the
liquid surface. The float of the hydrometer must be free. Make
correction for the temperature.
Specific gravity will vary 4 points (0.004) with every 10F (6C)
temperature change. For each 1QF (6C) below 80F (2JOC),
subtract 4 points from hydrometer reading . For each 1QF (6C)
above 80F (2JOC), add 4 points to hydrometer reading.
After correcting to 80F (2JOC), interpret readings as follows:
All cell readings uniform and above 1.225 specific gravity

indicates battery is serviceable, but may require charg-
ing.
All cell readings uniform and below 1.225 specific gravi -

ty, charge fully and retest.
Variation of more than 30 points (0.030) specific gravity

between any two cells, indicates battery condition is
questionable. Recharge and retest before replacing bat-
tery.
45C/e ng 8-5
3. Capacity Test
Satisfactory capacity tests can be made only when the battery

electrolyte equals or exceeds 1.225 specific gravity at 80 F (2r
C).
~ 4. Terminal Voltage Test
~ Use extreme caution during any load testing. Improper

ill procedures could overheat battery and cause electrolyte 2 12009
gassing. This might cause an explosive atmosphere.
a. Variable Load High Rate Discharge Tester (Recom-

mended)
Connect tester to battery terminal posts. Discharge at a rate of

three times battery ampere hour rating for 15 seconds. If the
voltage is 9.6 volts or higher at the end of 15 seconds, the battery
has good output capacity.
b. Fixed Resistance Tester
This equipment has built-in load for high-rate discharge testing.

Follow equipment manufacturer's instructions regarding test per-
iod and meter readings.
c. Engine Load for Resistance
Twist and remove the spark plug leads. Connect a voltmeter

across the battery. Crank engine for 15 seconds. If voltage is 9.6
volts or higher at the end of 15 seconds, the battery has good
output capacity.

Battery Charging
Boost charge 12-volt batteries at 50 amperes for 20 minutes (1000

ampere minutes). If the charger will not give this rate, charge
for an equal number of ampere minutes .at best rate available.
DO NOT boost battery more than this amount for the "light load
test."
If batteries are to be fully charged by means of a quick charger,

the charge rate must be " tapered" (reduced to a safe limit) when
the electrolyte temperature reaches 125 0 F (52 0 C), or when
gassing becomes excessive. Failure to do so may harm the battery.
If the battery is to be slow charged, adjust electrolyte to proper level

by adding water, then charge the battery at 5 amperes until fully
charged . Full charge of the battery is indicated when all cell gravities
do not increase when checked at three intervals of one hour and all
cells are gassing freely. Plenty of time must be allowed for slow
charging. Charge periods of 24 hours or more might be required .
Battery Care
Keep the battery charged at all times . Check the state of charge
by making specific gravity readings with a battery hydrometer. It
is suggested that specific gravity readings and checking for
replacement of water be made every two weeks . If the battery
has been standing for 30 days, recharge the battery before placing
it into service to ensure reliable starting . Charge battery to the
specific gravity recommended by the battery manufacturer.
Check the specific gravity of the battery electrolyte with a battery

hydrometer, preferably one that has a built-in thermometer and
correction chart . No other method should be used to determine the
charge condition of a battery. Note also that a hydrometer reading is
not accurate if water has been recently added because the water
has not had a chance to mix with the electrolyte.
The proper water level should be maintained at all times. If water

is added in freezing weather, the battery should be charged to
full charge at once. Only pure distilled water or water approved
for battery use should be added to the battery to replace water
lost through evaporation . Never add acid except when acid has
been lost by spilling .
Install the battery near the motor. Mount the battery in a ventilated
case and attach the case to the boat. A loose battery may shift
in the boat damaging itself or other equipment. Tighten hold-down
nuts evenly until the battery is secure. If hold -down nuts are too
tight, distortion and damage to the battery case will result.
Connect battery cables, making sure clamps are tight on battery
posts to ensure good contact. Apply a coat of petroleum jelly to
exposed areas of the battery posts and clamp connectors to retard
corrosion .
INote I Correct battery polarity is extremely important. The battery

MUST be connected so its negative post (-) is connected
to ground. If the positive post (+) is connected to ground, the
rectifier diodes will be damaged.
45C 8-7
Starter Circuit Check - TEL, TTL
If' Avoid accidental starting while testing; disconnect the starter cable at point CD before proceed-
L..ll ing with this check.
INotel Engine must be in NEUTRAL throughout test procedure. Battery must be fully charged.
Step Procedure Result
II Check voltage between

CD and ground.
Connect voltmeter between
and ground.
CD If meter shows 12V, test starter.
Press start button .

If meter showS OV, go to Step D.
and ground .
and ground.
If meter shows 12V, test cable to
starter.
If meter shows OV, go to Step II.
EI Check voltage between
and ground.
and ground.
If meter shows OV, check battery
cable and battery.
If meter shows 12V, go to Step II.
@ and ground.
Connect voltmeter between @
and ground.
If meter shows 12V, go to Step II.
If meter reads OV, go to Step II.
Turn key switch ON.

and ground.
and ground.
If meter shows 12V, replace start
button and/or wire.
Turn key switch ON.
If meter shows OV, go to Step g.
and ground.
and ground.
If meter shows 12V, go to Key
Switch Check , this section. Check
wire to terminal strip.
If meter shows OV, go to Step ID.
BoCheck voltage between
and ground.
Connect voltmeter between (j)
and ground.
If meter shows 12V, replace fuse,
holder, or wire to key switch.
.If meter shows OV, replace w ire from
solenoid terminal to fuse 0.
II. Check voltage between

and ground .
Disconnect black ground wires
from . Connect voltmeter be-
If meter shows 12V, repair/replace
black wire between and ground .
tween solenoid terminal and
If meter shows OV, disconnect all
ground. leads from solenoid, and test sole-
Turn key switch ON . noid . Go to Solenoid Check , this
Push start switch . section.
PCE0054

@
/ (=
CD
I I@
' ':"

~
+
@ 1

@ Start Button
@ Key Switch
Fuse
I
@ Red
Yellow/Red
Purple

@ Red/Purple
Black
\@
DR4602
45C/eng 8-9
Starter Circuit Check Chart - Remote Control Models
INotel Battery must be fully charged.
Step Procedure Result
check voltage between ground Remove black lead from ground a. If no reading , go to Step fJ.
II and CD at CD Connect voltmeter be-
tween CD and common engine
b. If meter reads battery voltage,
~ Steps" thru g - Remove
ground. Turn key to START posi-
reconnect black lead to ground
ill starter to solenoid cable from
tion. Voltmeter should show bat-
and go to Step g.
(J) to prevent starter engage-
tery voltage.
ment while making checks.
I!I Check voltage between ground Connect meter at Turn key to a. If meter reads battery voltage,
liiI and START position. lead is open between CD and
INotel Steps fJ thru g -
Turn key
OFF before connecting and b. If no reading, go to Step EJ.
disconnecting meter. Turn key
to START position after con-
necting.
II Check voltage between ground Connect meter at Turn key to a. If meter reads battery voltage,
liI and START position. solenoid is faulty.
b. If no reading, go to Step II.
Check voltage between ground Connect meter at @. Turn key to a. If meter reads battery voltage,
II and @. START position. lead is open between and
@ or neutral start switch is
open or improperly adjusted .
b. If no reading, go to Step II.
... Check voltage between ground Connect meter at @. Turn key to a. If meter reads battery voltage,
U 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.
PCE0054
Safety Related 8-10 45C/eng

B 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 D.
!II Check voltage between ground Reconnect starter to solenoid a. If meter reads battery volt-
II and @ . cable at (}). Connect meter at age and starter motor does
@ . Turn key to START posi- not turn, check starter mo-
tion. tor.
b. If no reading, check for bro-
ken cable or poor connec-
tion.
PCE0054
,+
I
I I
I I
IL... _ _ _ _ _ _ .J
~-------------------- __________________________________________________ ~83~30~13U

45C/eng 8-11
6 ~7~______~~~____~
DR4029 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

illand remove all spark plug leads.
Clean and retighten, or replace, any connection, cable, or compo-

nent having greater than specified voltage drop.
'sl 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.
~ In Step 2, connect the voltmeter leads only while the engine

~ is cranking, or damage to the voltmeter can occur.
71 2. Connect voltmeter negative lead to the starter side of the

~ starter solenoid terminal. While cranking engine, connect
voltmeter positive lead to starter solenoid opposite terminal.
Voltage reading should not exceed 0.2 volt. Remove voltmeter
positive lead f rom starter solenoid and stop cranking engine.

8 9
DR4031 DR4032
f8l 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.
19l 4. Connect voltmeter positive lead to battery negative lead

~ common powerhead ground screw. Connect voltmeter nega-
tive lead to battery negative post. Turn key switch to START.
Voltage reading should not exceed 0.3 volt.
45C/eng 8-13
~
@ @
rfOl 824005 824005
12
824005
@~
I '
\
.?"
@'
.
. \
.?"
14 15
824005 824005 824005
Key Switch Check

Ohmmeter or Continuity Light
~ 1. Disconnect battery leads and leads at the key switch.

f11l 2. With key switch in "OFF" position, connect a continuity
~ light or meter leads between key switch "SATT" and "A"
terminals. Light or meter should not show continuity.
r.J2l 3. Turn key s~itch to "ON" position. Light or meter should 16

~ show continuity. 824005
r:J3l 4. Turn key switch to "START" position. Light or meter should

~ still show continuity .
@
r:J4l 5. With key held in "START" position, transfer lead from "A"
~ terminal to "S" terminal. Light or meter should still show
I '
. .?'"
continuity. . \
f151 6. Transfer leads to "M" terminals. Light or meter should not

~ show continuity in "START" or "ON" positions.
17
116l 7. Turn key s~itch to "OFF" position. Light or meter should 824005
~ show continuity.
r:r71 8. Transfer leads to "S" and "C" terminals. Turn key switch to
~ "ON" position and push in key. Light or meter should show
continuity when key is pushed in .
f18l 9. Turn key switch to "START" position and push in key. Light
~ or meter should show continuity when key is pushed in.
18
824005
8-14 45C/eng
High Voltage
r,gl ln some conditions, the key switch may be shorting (allowing

~ some leakage) 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 test) 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" 19
terminals of the key switch. 824006
1. Attach the red lead @ of the tester to the "8" terminal and
apply leakage test.
2. Repeat test by moving the red leadto 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 Check - TEL, TTL

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 results vary.
Neutral Start Switch Test
R All engine wiring must be disconnected from the switch

~ before proceeding with this check.
1. Disassemble the remote control. Refer to Section 9 for disas-

sembly and assembly procedures.
1201 2. Calibrate ohmmeter on appropriate scale. Connect one

meter lead to each switch terminal. Meter should show:
High reading when the plunger is relaxed .

Low reading when the plunger is depressed.
3. Replace the neutral start switch if your test results vary.

Reassemble the remote control.
'" 4. Test ALL functions of the remote control after reassem-

~ bly. An undetected problem in the remote control could
cause sudden and unexpected loss of throttle or shift control.

Solenoid Check
~ All engine wiring must be disconnected from the solenoid

~ before proceeding with this test.
1211 1. Calibrate ohmmeter on appropriate scale. Connect one

lead to terminal and other lead to terminal @.
Ohmmeter should show a high reading .
If ohmmeter shows a low reading, replace the solenoid.
~ 2. Attach a positive battery jumper to terminal and a

~ negative battery jumper to terminal @. The solenoid should
close with an audible click.
Ohmmeter should show a low reading.
If ohmmeter shows 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
~ Securely fasten starter in a vise or other suitable fixture

~ before proceeding with this check.
1. Locate a battery rated 350 cold cranking amps or higher that is

in good condition and fully charged.
1221 2. 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.
1221 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
40 - 50 12 - 12.4 32 5700 - 8000
PCE0059
8-16 45C/eng
Electric Starter Servicing
Removal
\Note\ Disconnect the battery cables at the battery.
1. Disconnect the starter motor lead at the motor.
2. Remove the carburetor air silencer assembly for improved

access.
rv 3.starter
~
Remove the three screws @ and lock washers retaining the
to the powerhead.
Disassembly
r:;J 1. Observe alignment marks @ on the commutator end cap

l3J and drive end cap for correct reassembly. Remove two thru-
bolts from starter motor.
rJl 2. Tap the commutator end cap and carefully remove it to

~ prevent the loss of four springs under the two ground brushes
and insulated brushes.
rJl 3. Tap the drive end cap @ to loosen it and pull armature @
~ from the frame . You will find that the permanent magnets in
the frame will resist the removal of the armature.
rJl f41 4. If necessary to remove pinion @, use a strap wrench to

~ ~ hold armature. Remove locknut , spacer CD, anti -drift
spring Q), pinion @, drive end cap @, and thrust washer from
armature @. Discard locknut as it loses its locking feature, once
removed.
EJ-
3 ~----
45C/eng 8-17
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
t race of oil or metal dust from the commutator.
Isl r&' 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.
rJl 4. Check permanent magnets. Magnets should strongly attract

~ any steel or iron object held inside the frame. Weak magnets
will cause excessive RPM on No Load Current Draw, Electric
Starter test.
5. Do not clean the starter drive assembly while the starter motor
and drive are installed on the powerhead. The cleaning agent 101
U
~
could drain into the starter motor, washing dirt from the drive into ~!---~ C02505
t he starter bearings and commutator. After disassembling the
drive, clean each part with a grease solvent and inspect for wear
or distortion.
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 of binding and correct before completing
assembly.
833094
8-18 45C/eng
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.
~ 2. If removed, install retaining ring and washer on drive end

~ of armature shaft @.
3. Assemble drive end cap , pinion @ , anti-drift spring @, and

spacer to drive end of armature shaft. Install a new locknut.
Using a strap wrench to prevent damage to armature, tighten nut
to a torque of 240-300 in. Ibs., 20-25 ft. Ibs. (27-34 Nm).
4. Assemble armature to frame and magnet assembly, aligning

marks on drive cap end and frame.
1nl 5. Install insulated brush and terminal set @ in commutator

~ end cap with long lead in slot. Position the insulators @' flat
washer Q), lock washer Q), and nut as shown in figure.
r:=J
N
Reversing these brushes will cause motor to run back-
~ wards.
r,Q1 6. Install brush holder (0, brush springs, and ground brushes
~ Igl. Screws secure ground brush leads and holder. Insert
insulated brushes @ in holder.
r,v 7. Assemble commutator 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

i l l motor. Install thru-bolts. Tighten thru-bolts to a torque of
95-110 in. Ibs. (11-12 Nm). Seal with OMC Black Neoprene Dip
around end caps.
9. Refer to No Load Current Draw, Electric Starter to check starter

operation.
Installation
1. Apply OMC Nut Lock to threads of the three starter motor

screws. Place the starter motor in position against the power-
head. Install the screws with lock washers. Tighten the front
screw first. Tighten all screws to a torque of 14-16 ft. Ibs. (19-22
Nm).
2.Reconnect the starter motor lead to the starter motor. Apply

OMC Black Neoprene Dip to the connection.
3. Using new air silencer base screws, install the air silencer base
and cover on the carburetors.
4. Reconnect the battery cables to the battery.

Description of Charging System - All Models
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.
The engine's flywheel contains the permanently charged mag-

nets which provide the energy to power the stator windings. The
magnets must be at their original design strength for full alterna-
tor output.
The alternator stator consists of many windings of wire wrapped

around metal laminations. The stator is attached to the ignition
plate (4 amp models) or mounting plate (12 amp models). 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.
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.
The rectifier/regulator found on 12 amp models performs the

above functions and provides full wave regulation of the charging
system. An additional circuit, represented by the gray lead,
provides a tachometer signal for the OMC Quartach@and 7K
tachometers. The rectifier/regulator equipped models are com-
patible with maintenance-free batteries.
8-20 45C/eng
Charging System Check Chart - All Models
Where to Look Cause Procedure Reference
Battery 1. Battery defective or worn out 1. Check condition and All Steps -
charge See Pages
2. Low electrolyte level 2. Add water and recharge 8-4
3. Terminal connections loose 3. Clean and tighten thru
or corroded 8-7
4. Excessive electrical load 4. Evaluate accessory loads
Wiring 1. Connections loose or 1. Clean and tighten 1. Pg. 8-6

corroded thru 8-22
2. Stator leads shorted or 2. Perform ohmmeter tests 2. Pg. 8-23
grounded or 8-25
3. Circuit wiring grounded 3. Perform ohmmeter tests 3. Pg . 8-23
or 8-25
Alternator stator 1. Damaged stator windings 1. Perform ohmmeter tests 1. Pg. 8-23
or 8-25
2. Weak flywheel magnets 2. Perform running output 2. Pg. 8-23
tests or 8-25
3. Damaged stator leads 3. Perform ohmmeter tests 3. Pg. 8-23
or 8-25
Rectifier 1. Damaged wiring or diodes 1. Perform rectifier ohmmeter 1. Pg. 8-24

tests
Rectifier/regu lator 1. Inoperative rectifier/regulator 1. Perform variable load tests 1. Pg . 8-26

PCE0089
45C/eng 8-21
Running Test, Alternator Output - All Models 4AMP
~ Disconnect battery cables before proceeding with this
~ check.
1. Remove the rectifier red lead or rectifier/regulator red lead from

the terminal board . '
2. Wire a 0-40 amp ammeter in series with the rectifier red lead or
rectifier/regulator red lead and the wiring harness red lead.
!ID.ft(rl
o 1000 2000 3000 4000 5000 6000
1
"" Guard against any red wire, its terminals, or the ammeter DR1153
12_
i l l coming in contact with engine ground while the engine is 12 AMP
running. Contact could cause arcing.
t,l f21 3. The engine's battery should not be fully charged when 10
~ ~ beginning this test. Connect the battery cables and run the 8
6
engine in a test tank. Refer to the output curve to determine the
4
correct output-to-rpm ratio. 2
OL.....at--+--+--I--I-+-+--+--I--I-+--'
On non-regulated systems: If there is no output or the o 500 1500 2500 3500 4500 5500
output is not correct, refer to the stator and rectifier
ohmmeter tests in this section. 2 DR4167
On regulated systems: If there is no output or the output
is not correct, refer to the stator ohmmeter and rectifier/
regu lator running tests in this section.

'!--_ _ _ _ ~Il
l'!--_ _ _ _~@
~
LWJ
DR4155 DR41 56
Stator Resistance Check - 4 Amp Models
c=J
N
Disconnect battery cables before proceeding with this
~ check.
[!] 1. Disconnect all stator leads from the terminal board.

1al 2. Calibrate ohmmeter on appropriate scale. Connect the
~ meter black lead @ to the stator yellow/blue lead.
[!] 3. Connect the meter red lead @ to the stator yellow lead.
Ohmmeter should show 0.55 0.05 ohm .
[!] 4. Move the meter red lead @ to the stator yellow/gray lead.
Ohmmeter should show 0.55 0.05 ohm.
~ 5. Check for a grounded condition - disconnect both meter

~ leads. Calibrate ohmmeter on appropriate scale. Connect one
meter lead to a clean engine ground.
~ 6. Connect the other meter 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.

Results should be similar.
8. If a stator lead is grounded, repair it or replace the stator

assembly.
fN=J After replacing the stator assembly, verify correct maxi-

~ mum spark advance using the procedure outlined in Sec-
tion 1.
45C/eng 8-23
Rectifier Ohmmeter Tests - 4 Amp Models
~ Disconnect battery cables before proceeding with this

~ check.
[!] 1. Disconnect all rectifier leads from the terminal board.

rv
~
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.
[!] 3. Repeat Step 2 using the rectifier yellow lead.

5] 4. Repeat Step 2 using the rectifier yellow/blue lead.
~ 5. Move meter lead @ from engine ground to rectifier red lead.

f'2l 6. Repeat Step 2 with meter 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.
07. Repeat Step 6 using rectifier red and yellow leads.
~ 8. Repeat Step 6 using rectifier red and yellow/blue leads.

9. Replace the rectifier if your test results vary.
8-24
Stator Resistance Check - 12 Amp Models
C':'l Disconnect battery cables before proceeding with this
~ check.
1al 1. Disconnect stator yellow and yellow/gray leads from termi-
~ nal board.
1al 2. Calibrate ohmmeter on appropriate scale. Connect one

~ ohmmeter lead to stator yellow lead and the other ohmmeter
lead to stator yellow/gray lead.
Ohmmeter should show 0.4 - 0.6 ohm.
Repair or replace stator if reading is not correct.
f4'l 3. To check for a grounded condition , disconnect both ohm -

L!J meter leads. Calibrate ohmmeter on appropriate scale. Con-
nect one ohmmeter lead to a clean engine ground @ and the
other ohmmeter lead alternately to both stator leads.
Ohmmeter should show a high reading.
If ohmmeter shows a low reading , stator is grounded DR4133

and should be repaired or replaced.
~ After replacing the stator and charge coil assembly, verify

~ correct maximum spark advance using the procedure out-
lined in Section 1.
45C/e ng 8-25
Rectifier/Regulator Tests - 12 Amp Models
Variable Load Tests
To test the operation of the rectifier/regulator, you must be able to

run the engine continuously at approximately 4500 RPM, either in
a test tank, on a marine dynamometer, or on the boat.
The test consists of monitoring the system's response to a

partially discharged battery. Two methods for performing this
test are described below.
Variable Load High Rate Discharge Tester
~ The rectifier/regulator requires battery voltage on the pur-

~ pie lead to operate. Before proceeding, verify battery
voltage at terminal strip purple leads when key is ON.
1. Disconnect battery cables.
rv 2. Connect a 0 to 40 amp ammeter in series between the

L.:1 rectifier/regulator red lead and the battery side of the starter
solenoid.
3. Reconnect the engine's battery cables.
rv 4. Following the manufacturer's directions, connect the varia-

L.:1 ble load tester (carbon pile) across the battery terminals.
Steven's Instrument Model No. LB-85 and Snap-on Model No.
MT540D are examples of testers available.
'" Excessive battery discharge rates might overheat battery

i l l causing electrolyte gassing. This might create an explosive
atmosphere.
111 5. Start the engine and run it at approximately 4500 RPM. Use
~ the variable load tester to draw the battery down at a rate
equ ivalent to the stator's full output.
6. The engine's ammeter should indicate full output - 12 amps.
111 7. Decrease the battery load toward zero amps. The engine's
~ ammeter should show a reduced output. As the current draw
decreases, the battery voltage should stabilize at approximately
14.5 volts .
If the engine's ammeter doesn't indicate the above,

check stator condition before replacing rectifier/regula -
tor.
& Safety Related 8-26 45C1eng

I

I
j
@ Stator
@ Rectifier and Regulator Assembly
Red Wire
@ Ammeter (0 to 40)
Jumper Wire
Starter Solenoid
@ Red Battery Cable
Carbon Pile
CD Battery
Q) Engine Ground
1
DR451H1
45CJeng 8-27
Cranking Discharge Met hod
1. Check battery voltage .
If voltage is greater than 12.5 volts, go to Step 2.
If voltage is less than 12.5 volts, go to Step 3.
2. Separate the ignition charge coil connector(s). Crank engine in

short bursts until battery voltage is less than 12.5 volts. Check
battery voltage with key in the "Off" position.
R Disconnect engine battery cables before proceeding with

~ this check.
3. Connect a 0 to 40 amp ammeter in series between the

rectifier/regulator red lead and the battery side of the starter
solenoid.
4. Reconnect the engine's battery cables. Reconnect the ignition

charge coil connector(s).
~ The rectifier/regulator requires battery voltage on the pur-

~ pie lead to operate. Before proceeding, verify battery
voltage at terminal strip purple leads when key is ON .
5. Start the engine and run it at approximately 4500 RPM . The

engine's ammeter should indicate nearly full output - 12 amps.
As the engine continues to run at 4500 RPM, the voltage should
stabilize at approximately 14.5 volts and the alternator output
should begin to decrease.
If the engine's ammeter doesn't indicate the above,

check stator condition before replacing rectifier/regula-
tor.
Tachometer Circuit
1. Ifthe VRO "no oil" warning signal is in question or ifthe boat's

tachometer is not working , test the tachometer circuit.
2. Verify that all wiring and Amphenol connectors are in good

condition.
3. Set a peak reading voltmeter to "pas" and "50".
4. Attach the meter red lead to terminal strip gray terminal and
meter black lead to a clean engine ground.
f2\ 5. With the engine running at 1000 RPM, the voltmeter should
~ indicate 9 1 volts.
If the voltmeter shows specified voltage, go to Step 7.

If the voltmeter shows less than 8 volts, go to Step 6.
If the voltmeter does not show voltage, replace the
rectifier/regu lator.
8-28 45C/eng
6. With the engine running at 1000 RPM, disconnect the tachome-
ter and observe the voltmeter. Voltage should increase approxi-
mately 1 volt. Disconnect the VRO pump's 4-pin Amphenol
connector. Voltage should increase approximately 2 volts.
If the voltmeter shows higher voltage than specified on

both components, replace the rectifier/regulator.
If the voltmeter shows higher voltage than specified on
one component, replace that component.
c=J Do not energize primer solenoid when performing Steps 7,

~ 8, and 9.
~ 7.Check for voltage at the gray terminal with the engine not
~ running and the key switch in the "ON" position .
If the voltmeter does not show voltage, the tachometer

circuit is okay. Check the warning horn circuit. Refer to
Warning Horn Test, Section 1.
If the voltmeter shows voltage, go to Step 8.
~ 8. With the engine not running and the key switch in the "ON"
~ position, disconnect the gray leads from the terminal board .
Check for voltage at the rectifier/regulator gray lead.
If voltmeter does not show voltage, go to Step 9.

If voltmeter shows voltage, replace the rectifier/regula-
tor.
f'5l 9. With the engine not running and the key switch in the "ON"
~ position, connect voltmeter to engine wiring harness gray
lead. Disconnect the tachometer from the circuit. Check to see if
voltage disappears, then disconnect the VRO pump's 4-pin Am-
phenol connector and check voltmeter.
If voltage disappears after disconnecting a component,

replace that component.
If voltmeter shows voltage after disconnecting both
components, substitute the remote control wiring har-
ness with a known good harness. If voltmeter still shows
voltage, replace the engine wiring harness.
R The "Iow oil" and fIno oil" signals alert the operator to
~ possible VRO problems. To prevent possible serious power-
head damage, you must be sure these signals are working .
45C/eng 8-29
Rectifier/Regulator Replacement
\~
1. Disconnect the battery cables at the battery.
2. Remove the rectifier/regulator leads from the terminal board.
3. Remove the two screws retaining the rectifier/regulator to

powerhead.
4. Place the rectifier/regulator on the powerhead. Install and

tighten the two screws to a torque of 60-84 in. Ibs. (7-9 Nm).
DR4159
5. Connect the rectifier/regulator leads to the terminal board.
Apply OMC Black Neoprene Dip to the connections. - -@
6. Reconnect the battery cables.
AC Lighting Coil Resistance Check
f11 1. Calibrate ohmmeter on appropriate scale. Connect between

L.!.J yellow/gray and yellow leads.
2
Meter must show 0.86 0.05 ohm . DR4160
rv 2. Connect meter between yellow/gray

~ Ieads.
and yellow/blue @
~
~ 3.
Meter must show 1.21 0.02 ohms.
Calibrate ohmmeter on appropriate scale. Connect one lead

EJ Q) Qd
~ to a clean engine ground . Probe each of the connector pins
with the other ohmmeter jumper wire.
The ohmmeter should show a high reading. .,.

DR4161
If the ohmmeter reading is low, repair the grounded coil
lead or replace the coil assembly.
8-30 45C/eng
Remote Control
Table of Contents

Description of Prewired Surface Mount Remote Control . . 9- 4
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 6
Function Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 7
Emergency Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . 9- 7
Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 8
Control Handle Position .......................... 9- 9
Neutral Start Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 9
Control Cable Identification. . . . . . . . . . . . . . . . . . . . . . . 9-10
Control Handle Friction .......................... 9-10
Trim/Tilt Switch ............................... 9-10
Service Chart - Prewired Surface Mount Remote Control . 9-11
Prewired Surface Mount Remote Control Servicing ...... 9-12
Disassembly ....................... .. ......... 9-12
Cleaning and Inspection ............. . ........... 9-13
Assembly ..................................... 9-14
OMC Snap-ln@Cables - Installation .. ... ...... . ...... 9-16
OMC Long-Life Cables - Installation .............. . .. 9-18
Cable Installation - Engine . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
Throttle Cable ........................ . ........ 9-21
Shift Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Routing of Electrical Cables - 40, 48, 50 Remote Electric . . 9-23
45C/e ng 9-1
Before working on any part of the remote control, read the

indicated, use only an authorized replacement or equivalent.
Lessen the possibility of fire and explosion under the engine

cover; make sure electrical wires are routed and clamped in their
original positions, away from rotating parts which can damage
wire insulation.
After installation, verify that there is sufficient clearance for all

cables to avoid binding or chafing through all engine steering
and tilting angles.
When servicing a remote control, be sure to use the correct

Service Manual and Parts Catalog.

ing flywheel.
9-2 45C/eng
Refer to Service Chart - Prewired Surface Mount Remote Control, Page 9-11.
OMC Triple -Guard@Grease

OMC Moly Lube
OMC Locquic Primer
OMC Screw Lock
RTVSealer
45C/eng 9-3
Description of Prewired Surface M ount Remote Control
The prewired surface mount remote control has a number of features with which you should be
familiar.
l' When servicing this remote control, you must be sure all these features are working properly to
ill avoid sudden loss of control over engine speed or direction.
To test the operation of these features, refer to Function Tests, Page 9-7.
Emergency stop switch

Neutral lockout
Control handle
@ Throttle friction adjustment
Key switch and primer
Fast idle lever
@ Accessory connector
Neutral start switch
CD Warning horn
Q) Trim/tilt switch (optional)
2331 3
Emergency Stop Switch
This feature stops the engine when the clip and lanyard are pulled away from the remote control. The
clip must be in place to start the engine.
To function properly, the lanyard must be firmly attached to a life vest or sturdy piece of clothing. The
lanyard must be free of any obstructions and must not be frayed or cut.
Neutral Lockout
This feature prevents movement into FORWARD or REVERSE when the control handle is in NEUTRAL.
While the engine is running, lift the knob to select FORWARD or REVERSE. The lockout will
automatically engage when the control handle is moved to NEUTRAL.
Control Handle
This feature controls the engine's direction and amount of thrust. Moving the control handle 32 0 away
from NEUTRAL selects either FORWARD or REVERSE. Continued movement in the same direction will
increase engine speed in that gear.

@ Throttle Friction Adjustment
This feature controls the return friction on the control handle. Clockwise rotation will increase throttle
friction and counterclockwise rotation will decrease throttle friction .
The adjustment should be just tight enough to prevent unwanted throttle "creep" under normal
operating conditions.
Key Switch and Primer

This feature controls the engine accessories, starting, priming, and stopping.
Turning the key clockwise to the first detent turns on all engine-controlled accessories. Continuing to
the second detent will energize the engine's electric starter. Pushing the key in at the first or second
detent will energize the fuel primer solenoid.
Turning the key fully counterclockwise will turn off the ignition system and all engine-controlled
accessories.
Fast Idle lever

This feature controls engine speed when the control handle is in NEUTRAL.
The lever should be raised high enough to ensure consistent idle speed and cold run-on while starting
the engine. The lever must be returned to the RUN position before selecting FORWARD or REVERSE.
@ Accessory Connector
This feature allows convenient access to the engine accessory and tachometer circuits.
Several OMC tachometers and wiring kits provide a mating connector to simplify accessory installa-
tion. Maximum draw on this circuit must be limited to 5 amps.
Neutral Start Switch

This feature will not allow the operator to energize the engine's starter when the control is in FORWARD
or REVERSE.
When the remote control is properly assembled, the switch will only allow the key switch START
position to function when the control handle is in NEUTRAL.
CD Warning Horn
This feature alerts the operator to several critical operating conditions. Depending on the engine model,
the conditions might be:
Overheat - continuous tone

No Oil - continuous short pulses
low Oil - short pulse every 40 seconds
Fuel Restriction - continuous tone at or near full throttle
Q) Trim/Tilt Switch
This feature, where equipped, allows the operator to change the engine's operating angle (0-21 ) while
under forward thrust loads.
When the engine is stopped or operating below 1500 RPM, the switch also controls the tilt function
(22-75).
45C/eng 9-5
Introduction
~ Throughout this section, two symbols are used to interpret

~ electrical troubleshooting results.
[!] This symbol indicates continuity or very low resistance.

~ This symbol indicates no continuity or very high resistance.
Use an ohmmeter calibrated on high ohms scale or a continuity 1
light to test continuity.
9-6 45C/eng
Function Tests
'" After servicing the prewired surface mount remote control,

i l l the following static tests must be performed to be sure all
safety related features are functioning ; to avoid a sudden loss of
control over engine speed or direction.
Emergency stop switch

Key switch
Control handle position
Neutral start switch
Control cable identification
Control handle friction
Trim/tilt switch
1. Disconnect the engine battery cables at the battery.
2. Disconnect the throttle and shift cables from the engine.
3. Disconnect the engine harness connector at the engine.
Emergency Stop Switch
1. Install the stop switch clip and lanyard.
2. Use an ohmmeter calibrated on appropriate scale or a continu -

ity light to test continuity.
3. Turn the key to the ON position.
[!J 4. Connect meter as shown.

Meter must show no continuity.
~ 5. Remove the stop switch clip and lanyard.

Meter must show continuity.
6. Test stop switch and wiring if your test results vary.
C020n
45C/e ng & Safety Rel1a ted 9-7

4 6
C02072 C02072 C02072 C02072
Key Switch
1. Install the stop switch clip and lanyard.
2. Use an ohmmeter calibrated on appropriate scale or a continuity light to test continuity.
3. Turn the key to the OFF position.
[!] 4. Connect meter as shown.

~ 5. Turn the key to the ON position.

~ 6. With meter connected as shown, push key in while in the ON and START positions.
Meter must show no continuity when key is released.
7. Place the control handle in NEUTRAL position .
~ 8. With meter connected as shown, turn key to the START position.

Meter must show no continuity when key is released .
9. Test key switch and wiring if your test results vary.
9-8 45C/eng
I
Control Handle Positions
When the control handlei is in NEUTRAL:

the neutral lockt ut slider must engage the index plate
notch securely
the neutral lock0ut knob must be down
the fast idle levbr must be free to move to the START
position I
When the control handle is in FORWARD :

the neutral lockout knob must be up
the lockout slider must not engage the index plate
notch
the fast idle lever must be locked in the RUN position
As you move the control handle into NEUTRAL:

the neutral lockout knob must snap down
the lockout slider must engage the index plate notch
the fast idle lever must be free to move into the START
position
When the control handle is in REVERSE:

the neutral lockout knob must be up
the lockout slider must not engage the index plate
notch
the fast idle lever must be locked in the RUN position
If your test results vary, check the true NEUTRAL position of the
control handle and index plate. Refer to Assembly, Page 9-14.
Neutral Start Switch
1. Verify that the control handle is in true NEUTRAL position. C02072

Refer to Control Handle Positions.
2. Use an ohmmeter calibrated on appropriate scale or a continu-

o 3. Connect meter as shown.
0 4. Turn the key to the START position.

1sl 5. Move control handle to FORWARD position, and turn key to

~ the START position.
1sl 6. Move control handle to REVERSE position, and turn key to

~ the START position.
7. If your test results vary, test neutral start switch and wiring.
8
C02072
45C/eng 9-9
Control Cable Identification
1. Install the throttle and shift cables in the remote control. Refer
to Cable Installation, Page 9-16.
19l 2. Put the control handle into NEUTRAL position. The throttle
EI cable casing guide will retract completely and the shift =:JJi'iE:j!:"'~'di~iJ-_ _ _":"C1='O)
't:
,
cable casing guide @ will go to the midpoint of its travel.
19l 3. As you move the control handle into FORWARD, the shift
EI cable casing guide @ must retract and the throttle cable
casing guide must begin to extend.
4. As you move the control handle into REVERSE, both casing

guides must extend.
5. Identify each control cable for proper installation later.
"'" Control cable identification and function must be correct

i l l before continuing with installation.
Control Handle Friction
The throttle friction knob must be adjusted just tight enough to

eliminate unwanted throttle "creep" under normal operating
conditions.
f.Iol 1. Turn the knob clockwise to increase friction and counter-

~ clockwise to decrease friction.
2. Make a preliminary, light adjustment before operating the

engine.
3. Make your final adjustment with the boat and engine operating 11
under normal conditions.
~~------------------~DR~20~68~
Trim/Tilt Switch
1. Temporarily disconnect the control handle trim/tilt harness

from the trim/tilt motor harness.
2. Use an ohmmeter calibrated on appropriate scale or a continu-

'111 3: Co~nect meter as shown. Press the switch in the UP

~ direction.
Meter must show continuity. DR2068
Meter must show no continuity when switch is released.
f121 4: Co~nect meter as shown. Press the switch in the DOWN

~ direction.
Meter must show no continuity when switch is released .
5. If your test results vary, check wire location or replace switch .

Service Chart - Prewired Surface Mount Remote Control
& All special torques are safety related.
40-50 in. Ibs. 25-35 in. IbS.

(4,6-5,5 Nm) (2,8-3,9 N m)
~
-'1
/1
I
I
I
/
I
~~
20-30 in. Ibs.
(2,3-3,4 Nm)
5-7 in. Ibs.

(0,5-0,8 Nm)
G) OMC Triple-Guard Grease

OMC Screw Lock
@Replace each time removed .
DR 2079
45CJeng 9-11
Prewired Surface Mount Remote Control
Servicing
Disassembly
I:A. 1. Disconnect battery cables before servicing electrical

ill 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.
1sl 2. Remove control handle - loosen hex head screw three

~ complete turns.
19l 3. Support control on blocks to allow the control handle to be

t=J driven off the contro\.
Place center punch in head of hex head
screw, and tap with plastic hammer to disengage the control
handle splines from the hub splines. Remove the hex head screw
and the control handle.
1sl 4. Remove three screws from remote control, and pull

~ halves apart.
r;Ql 5. Remove shift cable pin @ from shift control clevis, and
~ disengage cable.
f111 6. To remove throttle cable, lift throttle cable trunnion from

~ its pocket, and move cable rearward to expose cable pin @ .
Remove cable pin and cable.
f121 7. Remove retainer plate screw and retainer plate @ from

~ control.
1121 8. Remove friction adjustment lever @ with adjustment screw

CD as an assembly.
\12\ 9. Remove two screws retaining neutral start switch Q) .

Remove neutral start switch.

'131 if' 10. Lift shift and throttle plate from housing. Use
~ i l l caution when removing shift and throttle plate as
detent spring is highly compressed. It might fly out, causing
personal injury. Wear safety glasses.
'131 11 .. Remove detent roller (1), detent shoe ~, and detent

~ spnng .
@] 12. Lift shift lever assembly @ from control.

'14l 13. To remove throttle lever assembly , remove flat-head
~ screw and countersunk washer from control. Discard the
patch screw. Lift throttle lever assembly and throttle lever spacer
from control.
r:;;l r:;;l 14. Remove screw @ and locknut retaining the shift
~ ~ lockout cam to the fast idle lever. Discard the locknut.
Remove keeper plate screw . Lift shift lockout cam and shift
lockout lever CD from housing. Remove spring washer and fast
idle lever from housing.
15. The key switch, warning horn, neutral start switch, and
emergency stop switch are serviceable, if necessary. Replace
defective components.
r:;:;l 16. To disassemble control handle, remove two screws

~ securing the plate @ to the control handle @. Lift neutral lock
slide @ and slide return spring from control handle. Remove
screw retaining control handle knob and four screws retaining
control handle cover @. Remove control handle knob and control
handle cover from control handle. To remove trim/tilt switch
assembly, remove screw retaining switch to cover.
I.j81 lnspect bosses of the flange in the shift lockout cam. If there
~ is any sign of rounding of the edges, replace the shift lockout
cam.
I.j81 lnspect slots in the fast idle lever for wear. Replace the fast
~ idle lever, if necessary.
Remove electrical components, and disassemble mechanical

parts. Clean mechanical parts in solvent but DO NOT immerse
electrical components in solvent.
Inspect mechanical parts for wear or cracks. Replace worn or

damaged parts.

Assembly
'" Failure to follow assembly instructions closely could result

i l l in operator losing control of direction and amount of
propeller thrust.
~ Lubricate friction points on mechanical parts with OMC

~ Triple-Guard grease.
1. To reassemble control handle, place control handle knob on

control handle and secure with screw. Tighten screw to a torque 5904
of 20-30 in. Ibs. (2,3-3,4 Nm).
Position trim/tilt switch into control handle cover. Secure

with screw.
Secure control handle cover to control handle with four

screws.
Apply OMC Triple-Guard grease to slide return spring.

Place slide return spring @ onto control handle as
shown.
20
Compress the slide return spring with neutral lock slide
and snap neutral lock slide onto control handle. After
installed, spring tension must be felt when pulling up on
neutral lock slide.
Install plate with two screws to control handle. Tighten

2. Install the key switch, warning horn, and emergency stop

switch, if removed. Apply OMC Black Neoprene Dip to the key
switch terminals.
12013. Cle~n th.reads of the shift lockout cam screw with OMC
Locqwc Primer.
12114. Install fast idle bushing and fast idle lever into housing.
Install shift and throttle plate bushing into housing. Place
spring washer @ over fast idle lever boss.
12215. Install shift lockout lever and shift lockout cam @ . Place
shift lockout cam over spring washer. Apply OMC Screw Lock
to shift lockout cam retaining screw, and install the screw. Be sure
to align the two bosses on the shift lockout cam with the two slots
in the fast idle lever. Install a new locknut onto screw and tighten
to a torque of 25-35 in. Ibs. (2,8-3,9 Nm). Install keeper plate and
screw. Torque screw to 10-15 in. Ibs. (1,1-1,7 Nm).

1231 6. Place throttle lever spacer over throttle lever bushing
in the throttle lever assembly @.
1241 "" 7. Place throttle lever assembly @ onto shift lockout

i l l cam boss. Place countersunk washer on throttle lever

assembly with countersink facing outward. Secure throttle lever
assembly using a new patch screw. Tighten screw to a torque of
@
25-35 in. Ibs. (2,S-3,9 Nm).
1241 "" 8. If removed, install lever separator plate into

i l l housing. Apply OMC Screw Lock to threads of the two
screws and tighten screws to a torque of 10-15 in. Ibs.
(1,1-1,7 Nm). Do not operate the remote control without the
separator plate installed and the two retaining screws properly
torqued.
1251 9. Place shift lever assembly CD into housing. Be sure teeth of

shift lever are free of dirt and lubricated.

\26\ If'. 10. Install detent roller @, detent shoe @, and detent
i l l spring into housing . To prevent possible eye injury
from detent spring, wear safety glasses while installing shift and
throttle plate.
\27\ 11. Place spring washer @ onto splined hub of shift and
throttle plate @.
\28\ 12. Be sure shift and throttle plate @ is clean . Install shift and
throttle plate bushing into housing. Retract detent spring and
install shift and throttle plate. Teeth of shift and throttle plate
must engage teeth of shift lever assembly.
128\ 13. Place neutral start switch mounting plate in position.

Install neutral start switch with two screws. Tighten
\28\ 14. Install fricti?n adjust.ment lever @ with friction adjust-

ment screw mto housmg.
128\ 15. Install retainer plate CD into housing . Tighten screw to a

torque of 25-35 in. Ibs. (2,8-3,9 Nm) .
16. Check to be sure no wires are pinched . Lubricate shift lever

post and three assembly screws with OMC Triple-Guard grease.
17. Reassemble two halves of remote control, taking care to

properly pilot the electrical cable grommet into the housing .
Tighten screws to a torque of 40-50 in. Ibs. (4,6-5,5 Nm).
18. Pull up on the neutral lock slide, and install handle spline into
spline of remote control so slide will engage notch of index plate.
Install hex head screw. Tighten screw to a torque of 100-120 in.
Ibs. (11 -14 Nm).
If'. Neutral lock slide in control handle must engage neutral

i l l notch in index plate when control is in NEUTRAL shift
position, or control handle may lock with motor's gearcase "in
gear."
OMC Snap-In@ Cables - Installation
1. Remove three cover screws from remote control and pull two
halves apart.
\29\130\ 2. Place housing half Q) and cover half on a flat

surface. Apply OMC Triple-Guard grease to all points
shown in figures. Be sure to grease the three cover screws'
threaded holes.
30
& Safety Related 9-16
164388
45C/eng
3. Lubricate cable ends with OMC Triple-Guard grease.
f31l '" 4. Begin cable installation with housing half of control.

~ i l l To install throttle cable, move throttle lever arm from
behind plastic plate to expose hole in lever arm. Do not remove
plastic separator plate from housing. If it is missing, cable pins
will fall out. Place eyelet of throttle cable between the halves of
the throttle lever arm, in line with holes. Grease cable pin CD and
drop cable pin through upper lever arm, through eyelet, and into
lower lever arm.
31
1321 5. Grease cable trunnion pocket and insert cable trunnion ~ 15578
into trunnion pocket in housing half.
~ 6. The throttle lever must be in the idle position before

~ reassembly. Move it forward , toward the front of the housing
half until it contacts the stop.
1341 7. To install shift cable, grease trunnion pocket in cover half.

Grease cable pin, place eyelet of shift cable between the shift
lever halves, and press cable trunnion into trunnion pocket in
cover half. Insert cable pin @.
1341 '" 8. Shift lever must be in NEUTRAL before reassembly of 15579

illremote control. Position neutral start switch on
center of neutral start cam @ while making sure neutral lock
slide of control handle is engaged in notch. Control handle
should not be able to move without releasing neutral lock slide. If
the neutral lock slide does not engage notch in index plate when
neutral switch is centered on neutral cam, it will be necessary to
,
reposition either the control handle or the index plate.
1351 ~
9. Reassemble two halves of remote control by posi-
ill tioning housing half onto cover half while cover half is
on flat surface. Flat surface will keep cable pins from falling out.
~:. ... -
Take care to properly pilot the electrical cable grommet into the 33
housing. Tighten the three cover screws to a torque of 40-50 in.
Ibs. (4,6-5,5 Nm).
~ To protect the internal components, apply a coating of RTV

~ sealer PIN 263753 to the mating edges of the control
halves during assembly.

38
30500
OMC Long Life Cables - Installation

OMCCable Adapter Kit, PIN 173600, must be used to install OMC
Long Life cables into the remote control.
1. Remove three cover screws from remote control, and pull two
halves apart.
1361137\ 2.Place housing half and cover half @ on a flat

surface. Apply OMC Triple-Guard grease to all points 39
shown in figures. Be sure to grease the three cover screws' COB5630
threaded holes.
138\ 3. Lu bricate outside of brass sleeves at control end of both

remote control cables with OMC Triple-Guard grease.
\39\ 4. Place trunnion caps over cable trunnions and slide

casing guides @ over cable sleeves.
\40\ 5. Using a 3/32 in. hex wrench, start the set screws into each
end of both control end wire clamps.
f41l\42\ 6. Begin cable installations with housing half of control. C1070

~ To install throttle cable, make certain fast idle lever is
completely down. Move throttle lever from behind separator
plate to expose hole in lever. It is not necessary to remove
separator plate to install control cable. Place casing guide be-
tween halves of throttle lever @ and position guide as shown.
Grease outside surface of wire clamp and insert clamp through
throttle lever and cable casing guide.
'" If the separator plate is removed, apply OMC Screw Lock to

ill threads of the two screws. Tighten the screws to a torque
of 10-15 in. Ibs. (1,1-1,7 Nm). Do not operate the remote control
without the separator plate installed and the two retaining screws
properly torqued.

43
C02817
14317. Push core wire CD (from engine end) through wire clamp Q)
until wire is flush, 1/32 in. (0,8 mm), with end of casing
guide @.
14418. Turn in set screw on large end of wire clamp until it touches
core wire, then tighten one more full turn to kink and position
core wire.
14519. Grease trunnion pocket in housing half. Lift throttle cable

and rotate cable forward until trunnion cap can be inserted
into trunnion pocket.
146110. Position throttle lever by hand to align rear hex screw

with access hole in control. Insert hex wrench through hole
and tighten second set screw.
147111. The throttle lever @ must be in the idle position before

reassembly. Move the throttle lever forward, toward the front
of housing half, until it contacts the stop CD.
148112. To install shift cable, grease trunnion pocket in cover half.

Place casing guide of shift cable between halves of shift lever
~ and shift cable trunnion cap in its pocket. Grease outside
surface of wire clamp. Insert clamp through shift lever and casing
guide.
143113. Push core wire CD (from engine end) through wire clamp
Q) until wire is flush, 1/32 in. (0,8 mm), with end of casing
guide @.
149114. Turn set screw in on large end of clamp until it touches

core wire, then tighten one more full turn to kink and position
core wire.
45C/eng 9-19
1501 15. Move control handle to align rear set screw with access
hole in housing. Insert hex wrench through hole and tighten
second set screw.
'51l ~ 16. Shift lever must be in NEUTRAL before reassembly

~ i l l of remote control. Position neutral start switch @ on
center of neutral start cam @ while making sure neutral lock
slide of control handle is engaged in notch. Control handle
should not be able to move without releasing neutral lock slide. If
the neutral lock slide does not engage notch in index plate when
neutral switch is centered on neutral cam, it will be necessary to
reposition either the control handle or the index plate.
1521 ~ 17. Reassemble two halves of remote control by posi-

ill tioning housing half onto cover half while cover half is
on flat surface. Flat surface will keep cable pins from falling out.
Take care to properly pilot the electrical cable grommet into the
housing. Tighten the three cover screws to a torque of 40-50 in.
Ibs. (4,6-5,5 Nm).
~ To protect the internal components, apply a coating of RTV

~ sealer, PIN 263753, to the mating edges of the control
halves during assembly.

Cable Installation - Engine
'" To prevent accidental starting of engine, verify that battery

ill cables are disconnected at battery.
Throttle Cable
1. Remove the rubber grommet from front of lower engine cover.

Remove cable retainer. Apply a liberal amount of OMC Triple-
Guard grease to both anchor block pockets.
rv grease.
~
2. Extend throttle cable and lubricate with OMC Triple -Guard
3. Verify that the fast idle lever is down in the RUN position.
4. While rotating the propeller shaft, move the remote control

handle from NEUTRAL to the FORWARD detent and then halfway
back to NEUTRAL. This positions the control for proper throttle
cable adjustment.
~ Failure to follow this procedure exactly might cause accel-

~ erated wear of shift system components and high shifting
effort.
~ 5. Mo~e eng.ine ~hrottle lever @ so that the spark lever stop

~ screw IS agamst ItS stop @.
~ 6. Attach the throttle cable casing guide to the throttle lever

~ lower hole using pin and cotter clip supplied. The cotter clip
must be installed parallel to the raised rib.
14l 7. Pull firmly on throttle cable to remove backlash and install

~ trunnion nut in anchor pocket.
~ 8. Temporarily install cable retainer and screw @.

9. Check cable adjustment.
If throttle cable adjustment is too loose, idle speed might

be high and inconsistent .
If throttle cable adjustment is too tight, control effort

might be high through the shifting range .
1sl 10. Move control handle to FORWARD and pull back slowly to
~ NEUTRAL. Check that the idle stop screw is against the stop @.
If not, remove backlash by adjusting cable trunnion nut @.
45C/on9 & Safety Related 9-21

Shift Cable
1. Extend shift cable and lubricate with OMC Triple-Guard grease.
2. Verify that the fast idle lever is down in the RUN position.
3. Move the remote control handle to NEUTRAL.
'" Before connecting shift cable, verify control handle position

i l l and neutral lockout index plate orientation. Refer to Page
9-9.
r&1 4. With engine in NEUTRAL, install the shift cable to the shift
~ lever using the pin and cotter clip @ as shown.
f71 5. Rotate the propeller shaft and shift the gearcase into
~ FORWARD.
6. Move the remote control handle to full throttle in FORWARD.
7. Apply a liberal amount of OMC Triple-Guard grease to anchor

block pocket.
1sl 8. Pull firmly on cable casing to remove backlash and adjust

~ cable trunnion nut to locate in anchor pocket.
[!I 9. Temporarily install the anchor pocket cover and screw @.

10. Shift the remote control to NEUTRAL.
fN=J If the gearcase has been serviced, verify the powerhead

~ neutral detent adjustment. Refer to Installation, Section 6.
r,Ql 11. The neutral detent must be in NEUTRAL (center
~ position) when the control lever is in NEUTRAL.
12. Remove the shift cable from anchor pocket and verify that the
gearcase is in its neutral detent. Reinstall shift cable into anchor
pocket and install the anchor pocket cover and screw. Torque the
screw to 60-84 in. Ibs. (7-9 Nm).
~ If there are not enough threads on the shift cable to allow

~ the adjustment in Step 12, or if the gearcase detent does
not correspond with remote control NEUTRAL in Step 11 , refer to
Section 6 for shift rod height adjustment.
r::=1 When installing OMC Accessory Controls, except for pre-

~ wired surface mount, the shift cable must be adjusted and
installed when the control and engine are NEUTRAL.
13. Slip rubber grommet onto control cables and press grommet
into groove in lower engine cover.
'" 14. Inspect installation to ensure that the control cables are
i l l attached to the proper engine levers by lifting the fast idle
lever to the START position. If correctly attached, the throttle
cable and engine throttle lever will move.

Routing of Electrical Cables - 40, 48, 50 Remote
Electric
l' Disconnect battery cables from battery before servicing
ill electrical systems. Failure to do so could result in injury
from electrical sparks or from contact with moving parts if
accidental cranking or starting occurs.
rvL!..I figure.
1: Apply OMC Triple-Guard grease to shaded area @ shown in
[!] 2. Align arrows and push connectors firmly together.

~ 3. Secure the connectors with retainer @ .
r;J
t!J
~ 4. Route the positive (red) battery cable @ to starter
ill solenoid. Secure cable to starter solenoid. Cover terminal
with rubber boot.
~
,
.
.
.::~
r.v l'
L!.J ill
5. Secure the negative (black) battery cable to power-
head ground terminal.

1sl 6. Reposition fuel manifold to make room for the routing of
EJ electrical cables.
7. Remove fuel connector bracket and lay to the side of the lower
engine cover.
f61 8. Route the power tilt and trim cable past starter and opening
~ in lower cover and air silencer.
rJl 9. Route battery cables in the same manner with the narrow
~ side of the cable facing down.
f81 10. Route remote control electrical harness into lower motor
~ cover. Position harness and connector so they will not inter-
fere with the upper motor cover when installed.
11 . Route the VRO tank wires along the same path .
1nl 12. Raise grommet to expose slot. Leave power tilt and trim
l!J motor wire and sleeve assembly @ in position in the grommet.
f101 13 .. Place battery cable @ into grommet with the flat side
~ faCing down.
f101 14. Place power tilt and trim electrical cable to the
~ starboard side opening of grommet.
f101 15. In the remaining opening, route the remote control

~ electrical cable @ and VRO wires @.
f111 16. Lower the grommet into position on the lower engine
~ cover.
17. Install fuel nipple and bracket assembly into position on the
lower motor cover and retain with screw. Place fuel manifold into
its proper position.
l' After installation, verify that there is sufficient clearance for

~ all cables to avoid binding or chafing through all engine
steering and tilting angles.

Power Trim
Table of Contents
General Safety Warnings ...... . ............ . ..... 10- 2

Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10- 3
Description of System .. . ........ . ..... . ......... . 10- 4
Component Description . . . . . . . . . . . . . . . . . . . . . . . . .. 10- 5
Modes of Operation
UP .................... . ....... . ............ 10- 6
DOWN ... . ............ . .................. . .. 10- 7
MANUAL RELEASE . ........................... 10- 8
IMPACT RELIEF .......... . .................... 10- 9
THERMAL EXPANSION RELIEF ....... . ........... 10-10
Routine Inspections .. .. ......................... 10-11
Troubleshooting Trim Gauge ....................... 10-12
Troubleshooting - Power Supply . .. .. .. ... ... ....... 10-14
Relay Ohmmeter Tests ....... . .................. . 10-16
Troubleshooting - Ammeter . . .. ................... 10-18
Performance Chart . ....... .. .. . ... .. . . . . ........ 10-19
Motor Test - No Load . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-20
Trouble Check Chart ............... . ............. 10-21
Hydraulic Unit Servicing ......... ... .. . ... . . . ..... 10-22
Motor Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-32
Sending Unit Adjustment . ... . .................... 10-33
45C/eng 10-1
Before working on any part of the hydraulic system, read the
Before returning motor to owner, verify that manual release

valve is torqued.

When servicing this hydraulic unit, only use the service proce-
dures outlined and the correct parts catalog for this specific unit.
Some internal components may appear similar to those in other
hydraulic units but may have different operating pressures and
characteristics. Interchanging these components may have an
adverse effect on the unit's operation.
Be sure the thrust rod is correctly adjusted. This will prevent the
possibility of loss of boat control should the motor trim "in" too
far.
10-2 45C/eng
DESCRIPTION IN. LBS. N.m
& Manual Release Valve 45-55 5-6
Check Valve Housing 50-60 6-7
Fill Plug 45-55 5-6
Pump Motor Retaining Screw 35-52 4-6
Filter Valve Plug 70-105 8-12

PCE0044
Universal Spanner Wrench, PIN 912084

Retaining Ring Pliers, PIN 303857

Description of System
rv The hydraulic unit consists of a manifold that contains all
~ valving, fluid reservoir, pump, motor, and cylinder.
The hydraulic unit pivots on the lower thrust rod and the piston
rod attaches to the underside of the engine swivel bracket.
As the cylinder begins to extend, the first 15 of engine movement

is considered the trim range because the swivel bracket is
supported by the port and starboard stern brackets. As the
cylinder continues to extend, the remaining 50 of engine move-
ment is considered the tilt range. Total engine movement is 65.
f21 The engine can be manually lowered from a tilted position by

t=I opening the manual release valve a minimum of three
turns. The slotted end of the manual release valve is accessible
through the port stern bracket's thrust rod hole. When this cycle is
complete, the manual release valve must be closed and
torqued to 45-55 in . Ibs. (5-6 Nm) before normal operation can be
resumed.
f3l A trim angle gauge is provided with the engine. The gauge's
~ sending unit is located on the port side of the swivel
bracket.
f41 When the engine is tilted for long periods of time or trailered in
~ the tilted position, the engine's weight must be mechanically
supported. The engine is equipped with trailering locks @ . When
they are engaged, the cylinder must be retracted until the trailer-
ing locks are firmly seated on the stern brackets.
10-4 45C/eng
1 20861
Component Description
r:;l UP CHECK VALVE - When opened by pump pressure, it
L.!J directs fluid to bottom of cylinder to move piston UP. When
opened by pump control piston, it allows low pressure fluid to
return to the pump as the piston moves DOWN.
r:;l DOWN CHECK VALVE - When opened by pump pressure, it

~ directs fluid to top of cylinder to move piston DOWN. When
opened by pump control piston, it allows low pressure fluid to
return to the pump as the piston moves UP.
r:;;l PUMP CONTROL PISTON - Moved by pump pressure, it

~ controls the UP and DOWN check valves. Together, they
control fluid direction and cylinder movement.
r4J MANUAL RELEASE VALVE @ - When opened a minimum of

~ three turns, it allows cylinder fluid to bypass the UP check
valve and return directly to the reservoir. The engine can be
lowered manually when the MANUAL RELEASE VALVE is open.
The MANUAL RELEASE VALVE has integral expansion relief to

protect the unit from extreme pressures caused by thermal 18891
expansion of the fluid.
Isl DOWN RELIEF VALVE - Opens at approximately 1600 PSI

~ (11,032 kPa) to protect the unit from extreme operating pres-
sures when the cylinder is completely extracted.
f61 UP RELIEF VALVE - Opens mechanically when the cylinder is

~ completely extended to protect the unit from extreme opera-
ting pressures.
f61 IMPACT RELIEF VALVES @ - Open under the extreme cylinder

~ pressure generated by an underwater impact and allows the
cylinder rod to extend.
rJl FILTER VALVE <ED - Allows filtered fluid to flow from the
~ reservoir to the top of the cylinder when the cylinder rod is
retracted manually using the MANUAL RELEASE VALVE.
45C/eng 10-5
Modes of Operation
UP
1. When the UP button is pressed, the pump @ rotates in a counterclockwise direction.
2. Fluid pressure opens the UP check valve and moves the pump control piston , mechanical ly
opening the DOWN check valve @.
3. Fluid pressure is directed to the bottom of the cylinder to move the piston UP.
4. Low pressure fluid leaves the top of the cylinder, moves through the open DOWN check valve @ , and
returns to the pump @ .
5. To allow for the volume differential caused by the piston rod , additional fluid is drawn into the pump
@ from the reservoir.
6. When the piston is completely extended, the UP relief valve @ is mechanically opened to protect the
unit from extreme operating pressures.
7. When the unit is operated in the UP direction or when the engine is running in FORWARD gear, the
following components must hold pressure:
Up check valve @
Up relief valve @
Impact relief valves
'. Piston a-rings @
Expansion relief valve
_HIGH
DLOW

..~@
DR2818
10-6 45C/eng
DOWN
1. When the DOWN button is pressed, the pump @ rotates in a clockwise direction.
2. Fluid pressure opens the DOWN check valve @ and moves the pump control piston , mechanically
opening the UP check valve @.
3. Fluid pressure is directed to the top of the cylinder to move the piston DOWN.
4. Low pressure fluid leaves the bottom of the cylinder, moves through the open UP check valve @, and
returns to the pump @.
5. To allow for the volume differential caused by the piston rod , excess fluid is vented to the reservoir
through the DOWN relief valve CD.
6. When the piston is completely retracted, pump output is vented to the reservoir through the DOWN
relief valve CD to protect the unit from extreme operating pressures.
7. When the unit is operated in the DOWN direction or when the engine is running in REVERSE gear, the
following components must hold pressure:

Up relief valve
Piston a-rings @
Down check va Ive @
Filter valve and seat Q)
_HIGH
DLOW
O\\ \ \1 }[~-@
DR2819
45C/e ng 10-7
MANUAL RELEASE
1. The engine can be manually lowered from a tilted position by opening the manual release valve @ .
2. When the manual release valve @ is opened a minimum of three turns, hydraulic fluid flows from the
bottom of the cylinder, bypasses the UP check valve @ , and into the reservoir .
3. As the piston moves down, the filter valve and seat @ opens and allows fluid to flow to the top of the
cylinder.
4. When this cycle is complete, the manual release valve @ must be closed and torqued to 45-55 in. Ibs.
(5-6 Nm) before normal operation can be resumed.
_ HIGH
DLOW
DR2820
10-8 45C
IMPACT RELIEF
1. When the engine hits an underwater obstruction, extreme pressure develops above the piston .
2. The extreme pressure must be vented and the cylinder rod must extend to allow the engine's
gearcase to clear the obstruction.
3. Under extreme pressure, five IMPACT relief valves @ and one UP relief valve will open to allow
fluid to pass through the piston as the cylinder rod extends.
4. To return the engine to its original operating position after impact, the hydraulic unit must be
operated in the DOWN direction.
5. To properly absorb the extreme pressure caused by impact, the following components must function
correctly:
Impact relief valves @

Up relief valve
Filter valve and seat @
Down check valve
_HIGH
DLOW
45C/eng 10-9
THERMAL EXPANSION RELIEF
1. Under certain conditions, external temperature variations can cause the unit's hydraulic fluid to
expand.
2. The extreme pressure caused by thermal expansion is vented directly to the reservoir @ by the
EXPANSION relief valve @ built into the manual release valve.
3. When internal pressure reaches approximately 8000 PSI (55,000 kPa), the EXPANSION relief valve @
opens and allows fluid to flow into the reservoir @ .
_HIGH
DR2822
10-10 45C
Routine Inspections
1. Check reservoir fluid level at least once per season or every 100
operating hours. System capacity is approximately 11 .7 fl. oz.
(345 ml).
Tilt the motor and engage the trail lock levers.
Support the engine's weight with a suitable hoist.
Remove the fill plug.
Add OMC Power TrimlTilt and Power Steering Fluid or

GM Dexron 1/, as needed, to bring its level to the bottom
of the fill plug threads.
Install the fill plug and torque to 45-55 in. Ibs. (5-6 Nm).
Disengage the trail lock levers and the hoist.
Cycle the unit at least 5 complete cycles to purge all air

from the system. When cycling the unit, hold the trim
switch ON an additional 5 to 10 seconds after the unit
reaches the end of its travel before activating the switch
in the opposite direction.
1- 2. Check the manual release valve with a torque wrench.

L..ll The valve must be torqued to 45-55 in. Ibs. (5-6 Nm).
3. Check for external signs of fluid leakage. Correct causes as
necessary.
4. Inspect the stern brackets for binding with the swivel bracket in
the thrust rod area. Retorque the tilt tube nut as follows:
Tighten the nut to a torque of 40-45 ft. Ibs. (54-60 Nm).
Loosen one nut Va to 1/4 turn after torquing.
5. Check the battery's state of charge. It must be charged to a

specific gravity of 1.260 to 1.280, corrected to a temperature of 80
F (2r C). Refer to Battery Specifications, Electrical Section.

Troubleshooting Trim Gauge
~ To avoid immediate meter damage, never apply an ohm-
~ meter to an electrical circuit where voltage is present.
r.;l1 1. Turn key switch ON and use a voltmeter to check for voltage
~ between trim gauge terminals "I" and "G".
If voltage, go to Step 4.
If no voltage, go to Step 2.
\.jl 2. With key switch ON, check for voltage between trim gauge
~ "G" terminal and Point V1.
If voltage, check condition of accessory harness purple
16 gauge lead.
If no voltage, go to Step 3.
\.jl 3. W~th key switch ON, check for voltage at key switch "A"
~ terminal.
If voltage, check condition of remote control purple 16
gauge leads.
If no voltage, check condition of key switch and engine
harness 20 amp fuse, PIN 510884.
rv terminals
~
4. Turn key switch OFF. Remove trim harness leads from gauge
"S" and "G". Calibrate an ohmmeter on low ohms
scale and connect between the leads. Test results should be :
engine fully down - approximately 88 ohms, engine fully up -
approximately 1 ohm.
If your values are the same, replace trim gauge.
If your test results vary, go to Step 5.
[TI 5. Repeat test in Step 4 at connector C3.

If your test results are correct, check condition of trim
harness and connector C1.
If your test results vary, replace trim sending unit.
10-12 45Cfeng
-~
CDRed
White/Tan
Black/Tan
@ Red/Purple
Purple
~ Green/White
o Red/White

Blue/White 0~'
45~ ' ------~~~~1o~-1~3~~~~~~~~~lj

-
DR2993
Troubleshooting - Pow er Supply
Before beginning this procedure:
Charge battery and connect battery cables.
Turn key switch OFF, and remove key.
Remove clip from emergency stop switch .
All tests are made from the RELAY SIDE of the trim/tilt relay
bracket.
1. Connect voltmeter black lead to a clean engine ground.
2. Check for voltage at battery side of starter solenoid.

If no voltage, check battery and wiring.
If voltage, go to Step 3 (or Step 10, if problem is only with
tilt down/trim in).
UP CIRCUIT
3. Remove relays from relay bracket.
[!] 4. Check for voltage at V1 (red).

If no voltage, check voltage at terminal strip. If voltage at
terminal strip, check wire.
If voltage at V1 , go to Step 5.
rv 5. Push UP trim button.

~ white).
Check for voltage at V2 (blue/
If no voltage, check trim switch, red/purple wire.

6. Reinstall one relay. Push blades only halfway into bracket in

UP (blue) end of bracket.
2
rv ~
7. Check for voltage at V3 on relay blade (M terminal of
~~ relay).
DR3950
If no voltage, go to Relay Ohmmeter Test.

8. Disconnect trim motor's blue and green power wire connector

(leave relay in bracket).
9. Push UP trim button. Check for voltage on blue wire.

If no voltage, check blue wire from relay bracket to motor
connector.
If voltage, check motor and lead.
10-14 45C/eng
DOWN CIRCUIT
10. Remove relays from relay bracket.
[!] 11. Check for voltage at V4 (red) .

If no voltage, check for voltage at terminal strip. If voltage at terminal strip, check lead.
If voltage at V4, go to Step 12.
f1l 12. Push DOWN trim button . Check for voltage at V5 (green/white) .
~ If no voltage, check trim switch, red/purple wire to switch .
13. Reinstall one relay. Push blades only half way into bracket in DOWN (green) end of bracket.
f1l f21 14. Check for voltage at V6 on relay blade (M terminal of relay) .
~ ~ . If no voltage, go to Relay Ohmmeter Test.
15. Disconnect trim motor blue-green power wire connector (leave relay in bracket).
16. Push DOWN trim button. Check for voltage on green wire.
If no voltage, check green wire from relay bracket to motor connector.
If voltage, check motor and lead.
45C/eng 10-15
B+
@
s "
@
,
~
B-
1
DR3950a
Relay Ohmmeter Tests
rv~ Throughout this section two symbols are used to interpret

electrical troubleshooting results:
indicates continuity or very low resistance.
indicates no continuity or very high resistance (00 ).
f21 The orientation and location of the UP and DOWN relays in the
~ bracket will vary from motor to motor, but the relay terminals
are always connected to the electrical system and trim motor as 4
DR3950b
follows:
S = Switch (+ or -I, (Wire Color = Blue/White or
GreenIWhite).
B+ = 12 Volt (+) Battery, (Wire Color = Red).
B- = 12 Volt (-) Battery (Ground), (Wire Color = Black).
M = Motor, (Wire Color = Blue or Green).
~ To avoid damaging test light or ohmmeter, remove relays

~ from sockets before proceeding with test.
1. Use a continuity light, or ohmmeter calibrated on high ohms

scale (or continuity scale) to test continuity.
5
DR3950c
f'3l 2. Connect meter leads to relay terminals "B-" Ground and

~ "M" Motor. ( 12V)
The meter must show continuity.
~ 3. Connect meter leads to relay terminals "B+" Battery and

~ "M" Motor.
The meter must show no continuity.
6
DR3950d
( 12V)
7
DR3950e
10-16 45C/eng
f51 4. C~librate ohmmeter on appropriate scale and connect the leads to the two relay "S" Switch
~ terminals.
~ To avoid immediate meter damage, never apply an ohmmeter to an electrical circuit where
~ voltage is present.
The meter must show 70-100 ohms.
r,;'] 5. Connect a 12 volt source to the relay "S" terminals. Use a continuity light, or ohmmeter calibrated
~ on high ohms scale (or continuity scale) to test for continuity on relay terminals "B+" battery and
"M" motor.
The meter must show continuity.
hl7 6. Leave the 12 volt source connected to the "S" terminals. Connect meter leads to relay terminals
~ "B-" ground and "M" motor.
The meter must show no continuity.
7. Replace relay if your test results are different.
45C/eng 10-17
Troubleshooting - Ammeter
Careful analysis of the hydraulic unit current requirements allows evaluation of the electric motor and
certain mechanical components.
The specifications contained in the chart are for static hydraulic tests. Do not attempt to perform the
following tests while the boat is under power.
1. Connect a 0-25 amp DC ammeter in series with the Red lead between the terminal strip and relay
bracket.
r:jl 2. Observe the ammeter and a stopwatch while running the hydraulic unit through several complete
~ cycles.
Range (0 - 15) represents the engine's trim range .
Range (16 - 65) represents the engine's tilt range.
3. Compare your test results to the values listed in the Performance Chart for your specific motor style.
4. As you interpret your test results, there are three basic possibilities.
Low Current Draw - check for:
a. Leaking valves
b. Weak relief valve springs
c. Damaged pump
d. Leaking a-rings
High Current Draw - check for:
a. Pump binding
b. Engine binding
c. Sticking valves
d. Damaged relief valve springs
Normal Current Draw - check for:
a. Damaged pump control piston
b. Malfunctioning check valves
5. Refer to Page 10-22 for hydraulic unit servicing information.
=
1 DR2151
10-18 45C/eng
Performance Chart
Current Time
Draw (Seconds)
Stall UP 7-12
Stall DOWN 15-20
Full Range UP 13-19
Full Range DOWN 10-16

PCE00918
45Cleng 10-19
Motor Test - No Load
~ Securely fasten motor in a suitable fixture before proceed-

~ ing with this test.
1. Use a battery rated at 360 cold cranking amps or higher that is

in good condition and fully charged to perform this test.
2. Connect a 0-25 amp ammeter in series with the battery's "+"
terminal, ammeter Red lead toward terminal.
1
3. Attach or hold a vibration or mechanical tachometer to the DR4238
motor while performing this test.
4. Monitor motor RPM and current draw. Refer to the chart below
for the correct specifications for your motor.
r:jl 5. Viewed from the pump end, the motor shaft must rotate in a
~ clockwise direction when battery "+" is applied to the Blue
lead.

~ 6. Viewed from the pump end, the motor shaft must rotate in a
~ counterclockwise direction when battery "+" is applied to the 2
Green lead. DR4239
7. Service the motor if your test results vary.
No Load Current Specifications
Amps RPM
Model Voltage (Maximum) (Minimum)
Showa
2.4 in . (61 mm) Dia. 12.5 4.5 5000
PCE0059
10-20 45C/eng
Trouble Check Chart
1. Cylinder leakdown
Up check valve
Manual release valve
Up relief valve
Piston O-rings
External leaks
2. No reverse lock
Filter valve and seat
Up relief valve
Down check valve
Piston O-rings
External leaks
3. No operation, motor runs

Pump coupler
Hydraulic pump
Fluid level
4. No tilt down
Down relief valve
Filter valve and seat
Pump control piston
Down check valve
5. Slow performance
Hydraulic pump
Electric motor
Mechanical binding
Manual release valve
Down relief valve
Fluid level
6. Unit locked in tilt up

Manual release valve (thermal expansion)
45C 10-21
Hydraulic Unit Servicing
Removal
1. Raise the motor and engage the trailering levers.
2. Remove the blue and green wires from pump motor connector
housing .
ru 3. Remove the spring clip from the cylinder pin .
~ 4. Remove the cylinder pin.

rJl 5. Remove one of the 3/4 in. locknuts from the angle adjustment
~ rod . Remove the rod from the stern brackets.
f41 6. Remove the unit from the stern brackets far enough to
~ remove the ground lead from the pump motor mounting
screw.
Disassembly
Thoroughly clean unit before disassembling. Scrub all outside

surfaces with a stiff bristle brush and hot soapy water. This will
prevent dirt particles or other foreign matter from entering the
unit while you are working on it.
~ There may be high pressure behind some check valves. To

ill avoid injury when removing check valves, be sure to keep a
shop cloth covering them until the pressure is released. Wear
safety glasses.
Always use a "lint free" shop cloth when handling hydraulic

components.
~ If painting the unit is required, paint the unit after it is

~ completely assembled. Painting of individual components
may cause flakes of paint to enter the hydraulic passages during
assembly. Tape hydraulic ram before painting.

f1l 1. Be sure the manual release valve is screwed in all the way.
~ Remove the retaining ring using OMC Retaining Ring Pliers,
PIN 303857.
~ 2. Remove the manual release valve assembly.

r:;J 3. Inspect the components of the manual release valve, the
t!J housing @, spring @, and needle @. Discard the O-ring on the
housing.
~ 4. Remove the up check valve housing using a drag link socket.

~ Remove the components of the up check valve from the
manifold.
~ 5. Inspect the components of the up check valve - housing @,

~ spring @, seat , and poppet @. Discard the O-rings from the
housing and seat.
161 6. Remove the down check valve housing. Remove the compo-
~ nents of the down check valve. Inspect the components
following Step 5.
@
18882
07. Remove the pump control piston from the manifold.
18828
45C/eng 10-23
40,48,50
101 8. Remove the four large motor flange retaining screws.
~ Remove the motor and discard the O-ring.
~ 9. Remove the filter.

~ 10. Remove the drive coupler from the pump assembly.
f11l 11 . Evenly loosen and remove the three Allen head cap
~ screws that retain the pump assembly to the manifold.
Remove the pump assembly.
r:::-=J
The pump assembly is not serviceable. If the pump assem-
~ bly needs flushing, do not clean it in solvent. Only clean the
pump assembly in clear hydraulic fluid.
~ 12. Remove the two pressure port O-rings @.

GJl 13. Remove the down relief valve assembly from the mani -
~ fold.
\14\ 14. Inspect the components of the down relief valve - ball ,
guide , and spring @.
14
18982
10-24 45C/eng
18980
f15l 15. Remove the filter valve plug. Remove the filter valve
~ components from the manifold.
f16l 16. Inspect the components of the filter valve - plug @, ball
~ , seat @, and filter @. Discard the O-rings from the plug and
seat.
02] 17. Remove the fill plug. Discard the O-ring.

f181 18. Using OMC Universal Spanner Wrench, PIN 912084, 18851
~ remove the end cap. .
f191 19. Slide the rod and piston out of the cylinder. Remove the
~ nut and washer from piston end of the rod.
1201 20. Remove six springs - five impact relief and one up relief.
All the springs are identical.
~ 21. Remove five impact relief valve spring guides.
45C/eng 10-25
40,48,50
20845
1221 22. Remove five impact relief valve balls.

1231 23. Remove up relief valve.
r:;;J 24. Remove the valve housing and washer from the rod.
~ Discard the internal O-ring.
1251 25. Remove and discard the quad ring and two backup rings. 25
1261 26. Slide the end cap off the rod. Discard the scraper.
~ 27. Remove the end cap rod backup ring and internal tilt rod
~ end cap seal.
28. Clean the manifold thoroughly in fresh solvent. Blow excess
solvent from the internal passages with compressed air. It is
essential that the manifold and all components be kept absolutely
clean and dust free. Any dirt in the system could cause scoring of
cylinder bores, sticking valves, or damage to pump components.
26018
10-26 45C
1 18881
Assembly
fN='J Use only OMC Power TrimlTilt and Power Steering Fluid or
~ GM Dexron /I automatic transmission fluid to fill the hy-
draulic system.
rv 1. Oil a new backup ring and insert it through the top of the
~ rod end cap. Oil a new seal and, with its lip facing DOWN,
insert it through the bottom of the rod end cap. Oil a new scraper
and install with its lip facing UP. 4
~~-------------------1=89~
60
~ 2. Oil a new a-ring and install on the outside of the end cap.
~ 3. Clean all locking compound from threads of the rod . Slide
~ the end cap onto the rod.
f41 4. Oil a new quad ring and backup rings and install on the
~ valve housing. Stagger backup ring end gaps 180.
1sl 5. Place the valve housing washer and valve housing on the
I.=.J rod .
~ 6. Install a new valve housing a-ring.

~ 7. Install the up relief valve into the valve housing cavity
~ closest to the raised mark @. The tip of the valve must
protrude through the housing.
45C 10-27 40,48,50

20842
1sl 8. Install !i~e impa~~ relief valve balls. Place one ball in each of
~ the remammg cavities.
9. Place one spring guide in each impact relief valve spring.
1nl 10. Place a spring guide and spring assembly on each of the
~ valve balls. Place the remaining valve spring on the up relief
valve.
~ 11 . Place the large washer over the springs with step side
~ facing valve housing . Lightly coat the threads of the rod with
OMC Nut Lock.
r:t1l 12. Install and tighten the nut to a torque of 35-54 ft. Ibs.
~ (47-73 Nm).
r:J2l 13. Lubricate the inside of the cylinder. Slide the piston and
~ rod assembly into the cylinder. Do not engage the threads of
the cap.
1131 14. Oil and install the components of the filter valve .
1141 15. Torque the filter valve plug to 70-105 in Ibs. (8-12 Nm).
10-28 45C/eng
~ 16. Place the ball of the down relief valve in the manifold .
~ 17. Install the down relief valve guide and spring.
~ 18. Oil and install two new pressure port a-rings.

f18119. Install the pump assembly. The pump assembly must be
~ drawn down evenly. Torque the screws to 25-30 in. Ibs. (3-4
Nm).
~ 20. Install the drive coupler.

1201 21 . Install the filter.
45Cleng 10-29
40,48,50
~ 22. Install a new motor a-ring.
122123. Position the motor on the manifold and install the four
screws and lock washers. Tighten the screws to 35-52 in. Ibs.
(4-6 Nm).
1231 24. Oil and place the pump control piston in the manifold.
124125. Oil and i~stall the components of the down check valve.
125126. Torque the down check valve housing to 50-60 in. Ibs. (6-7
Nm).
1261 27. Oil and install and components of the up check valve.
127\28. Torque the up check valve housing to 50-60 in. Ibs. (6-7
Nm).
10-30 45C/eng
1281 1' 29. Oil and install the components of the manual release
i l l valve. Tighten the valve to a torque of 45-55 in . Ibs. (5-6
Nm).
1291 30. Using OMC Retaining Ring Pliers, PIN 303857, install the
retaining ring with sharp edge facing out.
1301 31 . Slide the rod and cap up far enough to be able to install
OMC Universal Spanner Wrench , PI N 912084. Fill the cylin-
der up to bottom of the threads.
f311 32. Thread the end cap into the cylinder. Torque the end cap
~ to 56-84 ft. Ibs. (76-114 Nm).
1321 33. Fill the oil reservoir up to the fill plug. Install and tighten
the fill plug. Do not torque the plug at this time.
r:;.;l 34. Run the motor, then recheck the oil level. Cycle the unit
~ several times and check the oil level when the cylinder is fully
extended. Total oil capacity is 11 .7 flo oz. (345 ml). Install and
tighten the fill plug to a torque of 45-55 in . Ibs. (5-6 Nm).
45C/eng & Safety Related 10-31 40,48,50

Installation
f1l1. Lubricate the cylinder and thrust rod bushings with OMC
~ Triple-Guard grease. Install the bushings.
f212. Install the ground lead. Position the hydraulic unit between
~ the stern brackets.
3. Lubricate the angle adjustment rod with OMC Triple-Guard

grease. Install the rod. Tighten the locknuts to 20-25 ft. Ibs. (27-34
Nm).
4. Connect the pump motor wires.
5. Lubricate the cylinder pin with OMC Triple-Guard grease. Align

the cylinder into the swivel bracket. Install the cylinder pin.
I!I & 6. Secure the cylinder pin with cotter clip.
Motor Servicing
If a performance problem is indicated in Motor Test - No Load or
Troubleshooting Ammeter areas, order the brush and seal kit.
The brush and seal kits come with complete instructions.

Sending Unit Adjustment
1,l 1. The sending unit eccentric cam must be adjusted so that the
~ gauge needle aligns with the lowest card mark @ just as
engine trim DOWN movement stops.
~ 2. Tilt engine UP and engage trailering locks.

'" 3. To avoid personal injury, do not adjust the sending unit
i l l eccentric cam while the engine is being tilted or when the
engine's weight is not supported.
f31 4. Loosen eccentric cam retaining screw and rotate eccen-

~ tric cam to adjust needle movement.
Move cam out to increase needle movement .
Move cam in to decrease needle movement.
5. Tighten eccentric cam retaining screw and check adjustment

following Step 1.

Safety Section
Table of Contents
Part A Marine Products and Safety of

People Who Use Them ......... . ... .. ... . ........ S-2
Outboard Emergency Stop System
and Persons Safety ................. .. .... . . . .. 5-13
Outboard, Fuel, Electrical System
and Persons Safety ............ . ....... . ... .. .. .. 5-7
Outboard Hydraulic Tilt/Trim Shock
Absorption System and Persons Safety . . ....... .. .. 5-12
Outboard Mounting System and
Persons Safety ................................ 5-10
Outboard Shift System and Persons Safety ............ 5-3
Outboard Speed Control System and
Persons Safety .. . .. . .. . . . .. . . . .............. . . 5-4
Outboard Steering System and
Persons Safety .. . . . .. ... ... . . . ... . . .... . .... . .. 5-5
Part B Marine Products and the Safety of 5 16

People Who Fix Them . . . . . . . . . . . . . . . . . . . . . . . . .. -
Gasoline! Handle With Care .... . . . ....... . .. . .. . . . . 5-20
Handling Lead/Acid Batteries . . . .. ... . . . ........... 5 -19
Handling Motors . . . . .. . .. . . . . . .............. . ... 5-16
Hazardous Products .... ... .. ..... . ........... . .. 5-21
45C S-1
Part A Marine Products and the Safety of
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 ..... A!! 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 A!! characteristics.
Second!
Special Locking bolts and nuts are often used to hold steering, shift, and throttle remote control
cables to the motor.
When you take any motor off a boat, Keep Track of Special Nuts and Bolts. Don't mix with other
parts.
When motor is returned to boat, Use Only the Special Nuts and Bolts to hold remote Steering,
Shift, and Throttle cables to the motor.
S-2
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

_ match control
'0"--- lever position .
What Could Happen?
If ..... . I f . . .. .
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 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.
Do Not Shift Gears When Motor is Stopped. Adjustments Can be Lost
and Parts Weakened.
S-3
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.
What's Most Important?
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" & "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.
5-4
Outboard Steering System and
Persons Safety
The outboard steering system st:~ rts 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 w.ater
cou Id 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 course. With some
rigs (at high speed) loose steering could lead to loss of boat control.
S-5
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
"
- - -',
1
I to steering parts here

transom
mounted ~...- ...~
~stop
steerer to
Be aware that Raising 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. If weakened, parts could fail later ....

on the water .... when least expected.
5-6
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 . .. .. - C - -- - \
at the carburetor
. . . . . and ends here on the powerhead .
What's Important?
Fuel Leakage must be elim inated .
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 w ire connection making stray sparks.
How Can Fire and Explosion Be Minimized?
Follow warnings marked"& II closely.
Do not substitute fuel or electrical system parts with other parts which may look the same.
Someelectrical parts, like starter motors, are of special design to prevent stray sparks outside
their cases.
Replace wires, sleeves, boots which are cracked or torn or look in poor condition .
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
it has to be Metal to Ground the spout to the tank.
S-7
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
carbu retor float sticks.
So make sure Silencer and all its Gaskets are on motor And Drain Hose is in place.
Air silencer mounting Screws are special lock screws. Use only the special Screws.
S-8
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.)
All Connections
I n transom area .... .
clean
Tight Electrical Cable
(Prevents sparks)
Not rubbing
on sharp objects .. .. .
enough slack to allow full
turning without pull loads
on cable (Prevents Sparks)
.~L_-=;:;;'ioIIIII!~~~--~
~
Batteries
Secure in approved
battery box or bat-
tery tray.
Battery terminals in-
sulated.
No strain on cables.
S-9
Outboard Mounting System and
Persons Safety
The Mounting System includes

-~ _____
.. motor parts
~ bolts, nuts, washers, and

/Yfl--~-------
.....;.._----- boat's transom
What's Important?
Motor must stay in position on boat's transom
What Could Happen?
Motor may SL . . . I . . . 0 . . . E
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 ..... p 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 .... .
S-10
If Boat Plate shows ..... u.s. COAST GUARD
CAPAC ITY INFORMATI.ON
..... use
MAX HP .. ... .. ~
MAX PERSONS Only .....
MAX WEIG HT
Or Smaller!
When Rigging or
Fixing any boat ....
if transom looks
Weak, tell the
owner .....
Mount on Flat Surface only .

motor may come . . . . . Use Shims to make surface flat.
Loose .....
Use Bolts, Nuts, and Washers sent with Motor _ - - - -.....__

They're usually Special ..... won't Rust ... or
Weaken.
. .... High speed blow

to lower unit ... or,
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.
S-11
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 Iln" too far Suddenly
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 I f left Open . .. motor

manufacturers Instructions. has No shock protection
Follow warnings marked II & II 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 ...
and make sure Angle Adjusting Rod Retainer is in locked position.
S-12
Outboard Emergency Stop System and
Persons Safety
the Emergency Stop system begins

here at the Buck Ie .. . ..
. . . 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.
If switch fails .. . ..
. . . . engine will keep running when cap is pulled from switch .
If lanyard is caught ....
. . . engine will keep running.
S- 13
If lanyard is cut or frayed ... ~
or rubber cap worn here
... lanyard or cap may break when pu lied . . ..
,~/~
and engine will continue running .
~-- ...........
I
/ / "\
,'"\ ~",-~
~ ,,~~ ,...
~-
~~ )I'
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.
S-14
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?
S-15
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
Some motors have a fixed lift bracket bolted to the powerhead. Because motor will want to
"'-.. hang like this when
~ lifted off the floor . .. ..
Stand Clear!
Center of gravity --;...;;~
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
if Hoist or Motor Stand are in strong enough. Screws
Poor shape .... or Too small may Break and motor
-- for the job may drop suddenly.
Make sure Shop Aids have Extra Capacity . . ... .. .. . and keep them in Good Repair!
-
* Mechanics, Technicians, backyard do-it-yourselfers.
5-16
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
r=r-~... Y""---- Parts like spark plugs

and coils can shock
you . . .. may cause
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

~ Off-Season Storage
Fogging (oiling)
of motor
~ Removing propeller
with a powered tool
~ Electrical system checks

~ Servicing 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?
NO SPARK NO START NO SURPRISES
S-17
Running Motors Too Fast (Overspeeding)
"Too Fast" means faster than motor

normally runs on the Boat . . ...
Running Too Fast can happen
when . ....
o ... . . 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 " \

"\~
'---..
' Yf
- 1/ fi '
..-"/" ~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
5-18
Handling Lead/Acid Batteries
~ If spilled or splashed on
Any part of Body . ....
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 . .. . .
No Smoking Never remove charger cables from

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
5 - 19
Gasoline! Handle With Care
Gasoline vapor and air mixtures 1 Part
explode easily and violently Gasoline -----.
when mixed as shown ... . ..... .
20 Parts By
When you smell ANY odor of gasoline, Air Volume
explosion is possible
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
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, cigarett es, 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?
$ -20
Hazardous Products
Know How
items in the
Shop can
~~.-
--
hurt people .. ...
---
-- -- DANGER
-- El
--
--"
- ~
~
rUEL
------
- AD ~ES IVE
--:::::::.::
ADDITIVE
--
--
--
-
DANGER
..-;
Read ~ "How and Where to Use,"
~ "How to give First Aid." Have "recommended"

first aid materials on hand - shou Id 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
S-21
WATER FLOW DIAGRAMS
~O
~~
45,55 40,48,50
86 2027
DR2828
REMOTE CONTROL
~------------.....
/ /' "\
/ I
/ I
// l
",
/ I
/ I
{ I e
\'k!
~
\
,I
\ /
./
- -- - - - - - - - - - - - - -
IGNITION SWITCH POSITIONS
OFF ON PRIMER ON
START PUSH IN - START
AND ON POSITION
DR3214 @
40 Rope
c ____
D ~=-I
~ E _ _ _ _ _" ' "
14
DR C4704
40TE, SOTE
I
r--
1""'---
____
( -rr::::u
.......I\fit), ~
: h
L
'0 DRC4705 @
40 BA, 40 RS
A
B~
c ___ ~
D ~~
~_E _ _ _ ____
__________________ ~
16
DRC4 706
_
f-Ji 8
-m--= ~~ E
nlif 40TL,50TL
r-------------------~
+ -
I
J
~CI
-- DRC4707 @
25DTL
+
t__-
.,.
<f-
I
~ 1/
I{
1\ / I
I ,_/ I
-----
.
-- - _.
- -- -
------- DR4292 (18]
- - --
40E, 50BE, 50JE
] I
I
: [
~I=:
re - I ~
+ -
I.............................~~
A
C
B
DRC4709 G:ID
25DE,48E
--+
-
- -- -
---------
-- --
-------------- DR4293 (20)

40TTL,50TTL
1= ..
"i. 'iiWii' I 1=
r - - - - - - - - - - - - - - - - - - - - - -----.
=- ~ ~~-
D~::ij
~o :=
A
- '~
~ [R1(Q)
"""l
Q 11-
~~ ~ -~) .--
( 'IVV
...,
+
-
t--_
DRC4710 @J
Special Equipment Ordering Information
Some tools and equipment demonstrated in this manual are only available directly fro
the manufacturer. Use the following addresses when ordering:
Merc-O-Tronic Instruments Corporation Electronic-Specialties, Inc.

3965 North Mill Street 3148 South Chrysler
Dryden, Michigan 48428 Tucson, Arizona 85713
(313) 796-2261 (602) 747-2914
OTC Division of SPX Corporation Stevens Instrument Company

655 Eisenhower Dr. P.O. Box 193
Owatonna, Minnesota 55060 Waukegan, Illinois 60079
1-800-533-0492 or (708) 336-9375
1-800-533-5338
Do not order this equipment from Outboard Marine Corporation. Contact these manuf.
turers for pricing and ordering information.
Order OMC Special Tools from OMC SysteMatched Parts & Accessories.
United States of America
OMC Service
ICE
3145 Central Avenue
Waukegan, Illinois 60085 U.S.A.
(708)689-5630
OMC SysteMatched Parts & Accessories

3225 N. Prairie Avenue
Beloit, Wisconsin 53511 U.S.A.
(608)364-3333
Canada
Outboard Marine Corporation of Canada, Ltd.
910 Monaghan Road
Peterborough, Ontario, Canada
K9J7B6
(705 )876-2699
Caribbean, Mexico, Central America, South America

OMC Latin America/Caribbean, Inc.
403 Sawgrass Corporate Parkway
Sunrise, Florida 33325 U.S.A.
(305)846-1411
Europe, Middle East, Africa

OMC Europe N.V.
Pathoekeweg 120
8000 Brugge, Belgium
32-50-456611
Australia, New Zealand, Southwest Pacific

Outboard Marine Corporation Australia Pty. Ltd.
84 Canterbury Road
Bankstown, New South Wales
Australia, Sydney 2200
61-2-790-0701
Bangladesh, Brunei, Burma, Guam, Hong Kong, India, Indonesia,

Japan, Korea, Macau, Malaysia, Maldives, Micronesia, Pakistan,
People's Republic of China, Philippines, Singapore, Sri Lanka,
Taiwan, Thailand
Outboard Marine Corporation Asia, Ltd.
No. 35-47 Tsing Vi Road
Tsing Vi Island, New Territories
Hong Kong
852-4312200

Johnson 737 Part Catalog

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Johnson 737 Part Catalog

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Service

This Service Manual will alert you to certain procedures

e 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

When OMC Service Tools are called for, use them.

If you use procedures or service tools that are not

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

Standard Torque Chart _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

Size In. Lbs. Ft. Lbs. Nm

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

V4 in. 60-80 5-7 7-9

5116 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

R These values only apply when a special torque for a specific

~ When tightening two or more screws on the same part, do

OMC Hi-Vis@ Gearcase Lubricant

Good Service Practice

Service required for OMCengines is generally one ofthree kinds:

Normal care and maintenance - which includes putting a

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.

r::-=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

& Safety Related 1-6 45C/eng

[!] This symbol indicates continuity or very low resistance.

Use an ohmmeter calibrated on high ohms scale, or a continuity

measurement for resistance.

f61 When "-:::;," precedes a value on the meter face, it indicates

rJl When "'2:." precedes a value on the meter face, it indicates

Full Throttle Operating Range 4500 to 5500 RPM

Power 250 - 25 HP (18,4 kw)

Power Rated @ 5000 RPM