90-817643R1 DECEMBER 1996
ii
Cleanliness and Care of
Outboard Motor
A marine power product is a combination of many ma-
chined, honed, polished and lapped surfaces with toler-
ances that are measured in the ten thousands of an
inch./mm When any product component is serviced, care
and cleanliness are important. Throughout this manual, it
should be understood that proper cleaning, and protection
of machined surfaces and friction areas is a part of the re-
pair procedure. This is considered standard shop practice
even if not specifically stated.
Whenever components are removed for service, they
should be retained in order. At the time of installation, they
should be installed in the same locations and with the same
mating surfaces as when removed.
Before raising or removing and outboard engine from a
boat, the following precautions should be adhered to:
(1) Check that flywheel is secured to end of crankshaft with
a locknut and lifting eye is threaded into flywheel a mini-
mum of 5 turns.
(2) Connect a hoist of suitable strength to the lifting eye.
In addition, personnel should not work on or under an out-
board which is suspended. Outboards should be attached
to work stands, or lowered to ground as soon as possible.
We reserve the right to make changes to this manual with-
out prior notification.
Refer to dealer service bulletins for other pertinent informa-
tion concerning the products described in this manual.
Service Manual Outline
Section 1 - General Information & Specifications
Section 2 - Electrical & Ignition
Part A - Ignition System
Part B - Battery, Charging System &
Starting System
Part C - Timing/Synchronizing &
Adjusting
Part D - Wiring Diagrams
Section 3 - Fuel Systems
Part A - Carburetion
Part B - Fuel Pump
Part C - Fuel Enrichment
Part D - Oil Injection
Section 4 - Powerhead
Section 5 - Mid-Section
Part A - Clamp/Swivel Brackets and
Driveshaft Housing
Part B - Power Trim (Design I)
Part C - Power Trim (Design II)
Part D - Power Trim (Design III)
Part E - Power Trim (Design IV)
Part F - Manual Tilt (Design I, II, III)
Part G - Manual Tilt (Design IV)
Section 6 - Lower Unit
Part A - Standard Gear Housing
Part B - 60 Big Foot, 60 SeaPro &
Marathon Gear Housing
Part C - Jet Drive
Section 7 - Outboard Installation/
Attachments
Part A - Ride-Guide Steering -
Throttle/Shift Cables &
Electrical Connections
Part B - Tiller Handle and Co-Pilot
Part C - Rewind Starter
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