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Manual
40 THRU 55
t:~!1
[ EVlnRUDE
DUTBDARDS
1992 OUTBOARD MARINE CORPORATION. PRINTED IN USA
it Safety Warning
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
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.
1-2 45C/eng
Service Specifications
PCE0023
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.
1-4 45C1eng
Arrangement of Service Manual
45C/eng 1-5
Service Policy
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.
Symbols
Throughout this service manual, symbols are used to interpret
electrical troubleshooting results or to assign values in drawings.
Electrical
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
Values
7
DR4207
45C/eng 1-7
Engine Specifications
250,40,48,50
Operation _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Powerhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .
Crankshaft Dimensions:
Piston Ring Groove Side Clearance, Lower 0.004 in. (0,10 mm) maximum
1-8 4 5C
Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .
Sustained
Model Recommended Alternate High Speed Alternate
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .
45C/eng 1-9
Engine Specifications
40 Comm.
Operation _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Crankshaft Dimensions:
Piston Ring Groove Side Clearance, Lower 0.004 in. (0,10 mm) maximum
1-1 45C1eng
Gearcase ................................................................... .
Sustained
Model Recommended Alternate High Speed Alternate
AC Model 60 Watts
FueISystem . ._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _..
45C/e ng 1-11
Engine Specifications
45 and 55 Comm.
Operation _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Crankshaft Dimensions:
Piston Ring Groove Side Clearance, Lower 0.004 in. (0,10 mm) maximum
1-12 45C/eng
Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .
Sustained
Model Recommended Alternate High Speed Alternate
AC Model 60 Watts
45C/eng 1-13
NOTES
1-14 45Cleng
Gearcase Lubrication - All Models
Remove oil drain/fill plug and oil level plug from gearcase. With
motor in normal operating position, allow oil to drain completely.
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.
FREQUENCY
[!] 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
~
Starboard) Swivel Bracket
60 days
30 days
30 days
~
Shift and Throttle
""
60 days 30 days
Shaft Fittings
~
Control Shaft Bushings and
"
60 days 30 days
Control Lever Bearing
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
[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
60 days
30 days
30 days
~
~
Cover Latches Front and Rear
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
HI'VIS
GIARCASE
LUBI
~
DR4Z63
1-18 45C
45C/eng 1-19
Fuel/Oil Ratios
Lubricant
Automotive oils
Premix fuel of unknown oil quantity
Premix fuel richer than the recommended ratio
Oil and gasoline leaner than the recommended ratio
Normal Service
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.
Severe Service
The fuel/oil ratio for recreational models is 50:1 (2% oil) when
used in commercial, rental, or extended severe service .
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.
Mix the lubricant slowly with the fuel as the tank is filled .
Oil Requirements
Minimum Octane
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.
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.
3. Install test wheel and put engine into test tank. City I Sta te I Z;p
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
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 .
OMC propellers available for these engines are listed in the OMC
SysteMatched Parts and Accessories Dealer Catalog.
Procedure
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.
70%
60%
50%
40%
30%
~ .. - @ --..
@Q @ ~
1
DR1261
45Cleng 1-25
Rated Power
Hot Weatherl
-------
High Altitude
....
Q)
~
o RPM
CL
~----------------------------~-----
DR4013
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 _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
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 _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ___
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.
5. Stop engine and remove all spark plugs. Spray a liberal amount
of OMC Storage Fogging Oil into the spark plug holes.
'" Avoid fire or explosion hazards; store all portable fuel tanks
i l l in a well ventilated area, away from any open flames.
~ 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.
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.
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.
1-30 45Cleng
Preseason Service
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.
11. Run engine in test tank with correct test propeller. Check
cool ing system operation.
& 14. Momentarily pressurize fuel system and check for leaks.
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.
1-34 45C/eng
Submerged Engines
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:
2. Twist and remove spark plug leads and remove spark plugs.
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.
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.
1-36 45C/eng
1
DR4551
45C/eng 1-37
2
DR4552
3. Rotate both throttle shafts slightly and allow them to snap shut.
1. Move the throttle cam and cam follower toward each other.
~ 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.
f613. Loosen the locknut and adjust the W.O.T. stop screw @ to
~ adjust pin orientation to exactly vertical.
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.
f816. Install the spark control rod @ on the spark lever CD, and
~ verify maximum spark advance following Steps 1 thru 3.
Idle Speed _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Tiller Models
'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.
Remote Models
1-40 45C/eng
NOTES
45Cle ng 1-41
31270
[':;11. As you face the steering handle, turn the idle speed
L!J adjustment knob counterclockwise to minimum slow speed
position.
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.
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.
3. Start the engine and observe spark advance with a timing light.
The proper pickup timing is indicated in chart.
Pickup Timing
45
55
~ Run the engine with the proper test wheel. Do not run the
~ engine with a propeller or a flushing adapter for the
adjustment.
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 @ .
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.
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)
10 No. Part No. Size 10 No. Part No. Size
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)
10 No. Part No. Size 10 No. Part No. Size
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)
10 No. Part No. Size 10 No. Part No. 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
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.
PCE0027
Installation Instructions
1. Drill to adequate depth using drill size supplied with kit.
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
45C1eng 2-1
it. General Safety Warnings
Before working on any part of the fuel system, read the .section
called Safety at the end of this manual.
2-2 45C/eng
Service Specifications
45C/eng 2-3
NOTES
2-4 45C/eng
Fuel Requirements
Minimum Octane
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.
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.
~ 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.
5
30393
2-6 45C/eng
In-Line Fuel Filter Servicing
Commercial Models
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
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.
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.
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 .
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).
131 ----~
72112
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.
1. Remove fuel cap and disengage from tank. Empty fuel tank
completely.
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
4. Twist the hook around to grasp the O-ring, then pull out.
Discard O-ring.
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)
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.
Install filter with lip facing the fuel pump body. DR3000
Conduct this test with the motor in a test tank or on the boat.
Pressure
600 1 7
2500-3000 1.5 10
4500 2.5 17
PCE0072
45C/eng 2-15
Primer System Servicing
Function Test
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.
3
803395
2-16 45C/eng
Electric Primer
Installation
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
2. Squeeze fuel tank primer bulb to fill carburetor bowls with fuel.
6. Operate primer pump and watch for fuel squirting from hose.
rr;t:l The three smaller a-rings are made with a special material;
~ use only the proper a -rings.
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~
45C 2-19
Disassembly
Inspection
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.
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
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.
18
Recommendations
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:
45C/e ng 2-23
Testing VRO~ System
Purpose
Testing Procedure
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.
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.
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.
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.
45C/eng 2-25
VRO~ Oil Supply System
Optional Equipment
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.
2-26 45C/eng
Installation Recommendations
5. Test the "low oil" warning circuit before filling the oil reservoir:
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.
After the residual oil is exhausted from the oil line, the
"no oil" circuit should activate the warning horn.
~ 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.
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.
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.
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.
If you suspect the oil supply to the VRO~ pump is being restricted,
check two areas.
2. With the pickup assembly out of the reservoir, vacuum test the
system to check for air leaks:
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.
f2l
2. Backflush the valve with a mild aerosol solvent to remove
~ any carbon deposits.
3. Position the fitting in the pulse hose with blue nipple facing the
VRO~ pump.
Pump
r::=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.
3. Carefully remove the oil supply hose from the pump's oil inlet
fitting.
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) @ .
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 .
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 ,
fj,
~:0
co
Disassembly
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.
'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
Clean all parts with OMC Cleaning Solvent and inspect for wear
and damage. Replace any suspect parts.
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
~ separate hose and fitting, carefully cut the hose along its
side and peel it back to avoid damaging the fittings.
A complete procedure for testing the VRO~ "low oil" circuit can
be found in VRO~ Installation Recommendations,this section.
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.
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.
~ 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
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.
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.
2-38 45C/eng
Float Valve Assembly
Carburetor Body
f12l 1. Check all drillings and passages with a syringe filled with
~ isopropyl alcohol.
3. Check for excessive throttle shaft play. Check for throttle valve
misalignment.
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 .
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:
Assembly
16
9489
40,45, 48
[m~ 1. Install a new high speed nozzle gasket .
f171 f18l 4. Install the high speed orifice , gasket, and drain
~~ plug.
~ ~, 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 .
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
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.
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 .
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.
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.
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
Disassembly
1. Remove the two screws per leaf plate assembly, and remove
the leaf plate assemblies as required.
Inspection
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.
5. Assemble leaf valve shim (if required) and leaf stop. Install two
screws near center of leaf stop. Do not tighten. 2683
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.
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
45C/eng 2-45
FUEL SYSTEM TROUBLE CHECK CHART
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.
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.
3-2 45C/eng
Service Specifications
Special Torque Chart _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
CD II
12 Amp Stator Screws 120-144 14-16 OMC Nut Lock
45C/eng 3-3
Service Specifications
UFI
PCE0074
CD II
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
OMC Special Tools Required
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
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.
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
Model Recommended Alternate High Speed Alternate
40 OL78C @ 0L16V @
NA NA
48, 50 0.030 in. (0,8 mm) 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.
Removal
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.
'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.
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.
Specifications
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
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.
INoteI when
Do not e~ce~d the coil's maximum
testmg It.
specified amperage
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
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.
Stop Circuit
Ignition Coil
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.
25DR,40R,48 6100
40RS,45,55 5800
3-14 45C/eng
1 2 ~3~__________~
1942 2804 16489
~ 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
45C1eng 3-15
Amphenol Connectors, Servicing Information
Terminal Removal
4
30387
3-16 45Cle ng
Terminal Installation
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.
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.
9
45C/eng & Safety Related 3-17
30392
Ignition Plate Servicing - UFI CD II - 4 Amp
Removal
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).
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).
Is' 19l9.
Route leads and install clamp , plate @, and spiral
~~wrap.
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).
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.
Removal
Installation
f614. Apply OMC Moly Lube grease around powerhead boss and
~ timer base bushing @, and into retainer groove .
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.
Installation
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.
45C/eng 3-23
Function Tests, S.L.O. W. - UFI
This ignition system incorporates the S.L.O. W. warning system
TAl
activated, the engine must cool to 1620 F (72 0 C) and the engine
must be slowed to an idle.
2. Install correct test propeller. Start engine in test tank and run at
3500 RPM.
rv engine
~
3. Calibrate ohmmeter on appropriate scale. Connect between
harness tan lead and engine harness tan pin @. Note
reading .
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.
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.
Elimination Test
3-28 45C/eng
7
DR4256
& To prevent accidental starting of engine while testing, twist and remove both spark plug leads.
~ 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.
0 4. Connect voltmeter red lead to adapter red lead and meter black lead to a clean engine ground .
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.
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 .
8. If either cylinder shows less than 200 volts, test charge coil. Refer to STEP 4 - CHARGE COIL TEST .
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.
[!] 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.
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.
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.
f51 3. Calibrate an ohmmeter on appropriate scale. Connect meter leads between ignition plate end of
~ connector, terminaIIE", and a clean engine ground.
it To avoid sudden loss of control, replace the stop button assembly if your test results vary.
6. Complete all circuits disconnected during this test.
INotel All ohmmeter tests must be performed with the engine NOT running.
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.
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.
4. Separate emergency stop switch lead from harness black/yellow lead at key switch.
5. If engine fails to shut off, test for open black/yellow lead, damaged key switch, or damaged power
pack.
Ground Test
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.
"A", "0"
PCE0068
Output Test
1sl 2. Attach voltmeter black lead to charge coil terminal " A". Attach meter red lead to the other charge
~ coil terminal.
3-36 45C/eng
Ohmmeter Test
INotel All ohmmeter tests must be performed with the engine NOT running.
PCE0068
~ 2. Calibrate ohmmeter on appropriate scale. Connect between jumpers. Meter must show :
PCE0068
f101 3. To test !or a grounded condition, connect ohmmeter, alternately, between each jumper and a
~ clean engine ground .
45C/eng 3-37
CD II
STEP 4 - SENSOR COIL TEST
Ground Test
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.
PCE0068
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.
PCE0068
INotel All ohmmeter tests must be performed with the engine NOT running.
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
& 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:
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.
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:
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
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.
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.
INotel Do not run the engine with power coil leads disconnected.
3-42 45C/eng
Powerhead
Table of Contents
45C 4-1
& General Safety Warnings
Before working on any part of the powerhead, read the section
called Safety at the end of this manual.
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.
Twist and remove all spark plug leads from spark plugs.
4-2 45C1eng
Service Specifications
45C/eng 4-3
Sealants and Lubricants Required _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
4-4 45C/eng
Engine Temperature Check
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.
Pyrometer Procedure
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 .
1314. Increase engine speed to 5000 RPM. At 5000 RPM, the digital
~ pyrometer must not indicate more than 1200 F (50 0 C) .
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.
Testing
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
"'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
[!] @ Front
~ Lower
~ Rear
Separate the two lower engine covers.
1sl6. Remove the twelve exhaust cover screws. Remove the cover
~ and discard the gasket.
4-12 45Cle n9
22352
45C/e ng 4-13
o
14 22348
1191 21. Remove the ten cylinder head screws. Remove the
cylinder head and discard the gasket.
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.
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
The cylinder taper must not exceed 0.002 in. (0,05 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
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.
'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.
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.
5572
4-18 45C/eng
1 2
22535 24908
Assembly
bearing using OMC Seal Installer, PIN 334500. Coat the lip of the
seal with OMC Triple-Guard grease.
r4J f51
4. Place the two wrist pin thrust washers on the tool with
~ ~ flat side of the washers facing out.
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
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.
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.
I
4-
\
\
\
DR2814
4-20 45C/e ng
DR1676
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.
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
1241 ~6. Gently lower the crankshaft and main bearing assembly
mto place.
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).
\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.
132133. When the cra~kcase is seated, install and firmly seat the
crankcase taper pm.
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).
139142. Lightly coat both sides of a new exhaust cover gasket with
OMC Gasket Sealing Compound. Install the gasket and ex-
haust cover.
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).
Installation
[':;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.
f4l If'.
6. Engage the shift rod in the shift rod link. Install and
~ ill tighten the shift rod retaining screw.
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
45C/eng 5-1
& General Safety Warnings
Before working on any part of the midsection, read the section
called Safety at the end of this manual.
Twist and remove all spark plug leads from the spark
plugs.
Make sure all electrical and ignition leads are routed and
clamped in their original positions away from rotating
engine parts.
5-2 45C/eng
Service Specifications
Special Torque Chart _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
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
45C/eng 5-3
Cleaning and Inspection
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.
/]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.
1
DR2223
5-4 45C/eng
Steering Handle Servicing
Removal
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.
\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
Assembly
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.
5-S 45C/eng
26
Installation
13016. Using OMC Pin Insert Tool, PIN 322697, insert stop button
wire into plug and place connector in clamp.
45C/eng 5-9
Exhaust Housing Servicing - 40, 48, 50
Removal
Disassembly
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
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
17528
45C/eng 5-11
Stern Bracket Servicing - 40, 48, 50
Disassembly
f213. Pull the steering arm out of the swivel bracket. Remove the
~ upper seal, liner and thrust washer.
~ 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.
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.
1
12 17. Place the bumpers on the upper mount screws.
45C/eng 5-13
Midsection Adjustment - 40, 48, 50
Steering Friction 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:
Remove locknut @.
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.
7. Loop cable down from lever, up past clamp, across and in front
of cylinder, and down port side to valve .
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).
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.
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 .
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).
Isl a. Rerneasure lever reserve motion and readjust until reserve DR2840
45C/e ng 5-17
Exhaust Housing Servicing - 45, 55
Removal
Disassembly
fs1 1. Remove the two lower rubber mounts @ and the thrust
~ mount from the exhaust housing.
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.
Assembly
\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) .
r:jl 3. Install the port and the starboard lower mount bracket
~ screws.
45C/eng 5-19
COA2952
Disassembly
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.
5-20 45C/eng
C0A2960
C0A2962
1141 r,st. Dri~e the steering friction bushing up and out of the
~ sWivel bracket.
'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.
Assembly
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.
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:
1251 Position the tang on the port washer Q) toward rear of the
stern bracket. Install the nut loosely on the tilt shaft bolt.
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).
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.
\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
torque of 24-26 ft. Ibs. (32-35 Nm).
5-24 45C/eng
Midsection Adjustment - 45, 55
Steering Friction Adjustment
45C/e ng 6-1
& General Safety Warnings
Before working on any part of the gearcase, read the section
called Safety at the end of this manual.
6-2 45C/eng
Service Specifications
Special Torque Chart _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
45C/eng 6-3
Sealants and Lubricants Required
Propeller Installation
'" 1. To avoid accidental starting of engine while servicing,
i l l twist and remove all spark plug leads.
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.
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
Installation
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.
45C/eng 6-7
Service Chart - 40, 48, 50
, a
()Ocf~
60-84 in. Ibs.
,~j~7-9N.m)
-, CD
108-132 in. Ibs. ~(j(J m~
(12~15_N.m
o
'"
'- - - - - ~
'\
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
Disassembly
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.
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.
6-10 45C/eng
~ 8. Remove the shift lever pivot screw. Discard the seal.
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.
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.
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.
45CJeng 6-13
40,48,50
Propeller Shaft Bearing Housing Servicing
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.
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.
34
DR2061
DR2062
6-14 45C/eng
DR2061
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. .
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.
6-16 45C/eng
Assembly
rv PIN
~
1. Assemble the following components of OMC Special Tool
391257 and OMC Pinion Service Kit 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.
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:
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
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,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.
45C/e ng 6-19
40,48 50
1181 16. Install the pinion and driveshaft as follows:
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.
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.
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).
6-22 45C/eng
32. Fill the gearcase with 16.4 fl. oz. (485 ml) lubricant as
follows:
- Remove the oil level and the oil fill/drain plugs. Replace
the seals if damaged.
- Inspect the gearcase oil level after the motor test has
been performed .
'~
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.
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.
rJl '"
4. Engage the shift rod in the shift rod link. Install and
~ ~ tighten shift rod retaining screw @.
f51 6. Rotate the propeller shaft and verify that the gearcase is in
~ NEUTRAL detent.
45C/eng 6-25
Service Chart - 45, 55
01
..
OMC Adhesive M Sealant e:
I
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)
6-26 45C/e ng
Gearcase Servicing - 45, 55
Removal
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.
Disassembly
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:;:;] 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
COA3587
COA3588
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.
6-32 45C/eng
-@
COA3580
31
DR2061
32 DR2062
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
away from the bearing housing. Apply OMC Triple-Guard grease
to the seal lips after installing.
\35\2. Remove the O-ring from the bearing housing and discard.
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.
13711. Lightly coat the threads of the pinion nut with outboard
lubricant. Install the pinion . Tighten the pinion nut to a
torque of 40-45 ft. Ibs. (54-60 Nm).
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.
10. Remove the driveshaft from the tool base. Remove the collar
and bearing housing from the driveshaft and add the required
amount of shims.
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.
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.
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.
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 .
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.
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:
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.
29. Fill the gearcase with 20-22 flo oz. (600-650 ml) lubricant as
follows:
Remove the oil level and the oil fill/drain plugs. Replace
the seals if damaged.
Inspect the gearcase oil level after the motor test has
been performed.
68 COA3553
6-40 45C/eng
Shift Rod Heights
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.
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.
6-42 45C/eng
27160
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.
1sl7. Remove the impeller from the driveshaft. Retain the impel-
~ ler key @ and impeller sleeve @.
6-44 45C/eng
Remove Gate - Linkage Models
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
~ 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.
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
unsnapping the ring from the pliers.
'" 25. Allow the bearing housing to cool until it is warm to the
ill touch.
29. Coat three new O-rings with OMC Adhesive M sealant and
install in grooves in the bearing housing.
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. Place roller into cam in position shown. The roller will not
~ assemble in any other position.
f511. Position gate to housing with wave washer CD, bushings Q),
~ and shafts to jet housing .
Both Models
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
6-52 45C/eng
Jet Drive Adjustments
Impeller Clearance Adjustment
0.020 in. (0,5 mm) Minimum to 0.030 in. (0,8 mm) Maximum
PCE0084
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.
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).
Gate Adjustment
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.
r,Ql 1. Install shift cable with remote control and reverse cam in
~ NEUTRAL position. Adjust shift cable trunnion to achieve this
setting.
r:J2l 8. Rotate trunnion to shorten cable and further seat roller into
~ FORWARD position .
r,Ql 10. Install washer and nut to reverse gate cam stud .
~ Tighten nut, then loosen 1fa to 1/4 turn.
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.
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.
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.
45C 7- 1
& General Safety Warnings
Before working on any part of the manual starter, read the
section called Safety at the end of this manual.
7-2 45C/eng
Service Specifications
OMC Special Tools Required
45C 7-3
Manual Starter Servicing
Removal
'" 1. To avoid accidental starting of engine while servicing,
ill twist and remove all spark plug leads.
rv~ 2. Remove the screw retaining the starter lockout cable clamp
@ to the starter housing. Remove starter lockout slide from
the starter housing.
Disassembly
~ 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.
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.
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.
2. Inspect the rewind spring for broken end loops and weak
tension.
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
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.
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.
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.
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.
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.
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).
45C/eng 8-1
& General Safety Warnings
Before working on any part of the electrical system, read the
section called Safety at the end of this manual.
8-2 45C/eng
Service Specifications
Amps
Model Voltage (Maximum) RPM
PCE0059
Model 4Amp
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.
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.
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.
~ 2. Hydrometer
~ Disconnect the positive battery cable whenever charging
~ the battery.
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.
45C/e ng 8-5
3. Capacity Test
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.
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 .
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.
PCE0054
~
+
@ 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
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
,+
I
I I
I I
IL... _ _ _ _ _ _ .J
45C/eng 8-13
~
@ @
rfOl 824005 824005
12
824005
@~
I '
\
.?"
@'
.
. \
.?"
14 15
824005 824005 824005
@
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. . \
~ 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
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.
5. Monitor the starter RPM and current draw and refer to the chart
below for the correct specifications.
Amps
Model Voltage (Maximum) RPM
PCE0059
8-16 45C/eng
Electric Starter Servicing
Removal
rv 3.starter
~
Remove the three screws @ and lock washers retaining the
to the powerhead.
Disassembly
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.
EJ-
3 ~----
45C/eng 8-17
Cleaning and Inspection
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.
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
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.
Installation
3. Using new air silencer base screws, install the air silencer base
and cover on the carburetors.
8-20 45C/eng
Charging System Check Chart - All Models
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
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
45C/eng 8-21
Running Test, Alternator Output - All Models 4AMP
~ Disconnect battery cables before proceeding with this
~ check.
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.
~
LWJ
DR4155 DR41 56
c=J
N
Disconnect battery cables before proceeding with this
~ check.
[!] 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.
45C/eng 8-23
Rectifier Ohmmeter Tests - 4 Amp Models
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.
45C/e ng 8-25
Rectifier/Regulator Tests - 12 Amp Models
Variable Load Tests
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.
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 .
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
Tachometer Circuit
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.
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.
~ 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.
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.
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.
8-30 45C/eng
Remote Control
Table of Contents
45C/e ng 9-1
& General Safety Warnings
Before working on any part of the remote control, read the
section called Safety at the end of this manual.
9-2 45C/eng
Service Specifications
Special Torque Chart _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Refer to Service Chart - Prewired Surface Mount Remote Control, Page 9-11.
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.
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.
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.
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.
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.
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:
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
9-6 45C/eng
Function Tests
C020n
Key Switch
~ 6. With meter connected as shown, push key in while in the ON and START positions.
Meter must show continuity.
9-8 45C/eng
I
Control Handle Positions
If your test results vary, check the true NEUTRAL position of the
control handle and index plate. Refer to Assembly, Page 9-14.
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.
3. Make your final adjustment with the boat and engine operating 11
under normal conditions.
~~------------------~DR~20~68~
Trim/Tilt Switch
~
-'1
/1
I
I
I
/
I
~~
20-30 in. Ibs.
(2,3-3,4 Nm)
45CJeng 9-11
Prewired Surface Mount Remote Control
Servicing
Disassembly
r;Ql 5. Remove shift cable pin @ from shift control clevis, and
~ disengage cable.
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.
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.
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).
\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.
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).
1. Remove three cover screws from remote control and pull two
halves apart.
30
& Safety Related 9-16
164388
45C/eng
3. Lubricate cable ends with OMC Triple-Guard grease.
,
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).
1. Remove three cover screws from remote control, and pull two
halves apart.
\40\ 5. Using a 3/32 in. hex wrench, start the set screws into each
end of both control end wire clamps.
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.
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 @.
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.
Throttle Cable
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.
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 @.
2. Verify that the fast idle lever is down in the RUN position.
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.
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).
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.
rvL!..I figure.
1: Apply OMC Triple-Guard grease to shaded area @ shown in
r.v l'
L!.J ill
5. Secure the negative (black) battery cable to power-
head ground terminal.
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.
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.
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.
45C/eng 10-1
& General Safety Warnings
Before working on any part of the hydraulic system, read the
section called Safety at the end of this manual.
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
Service Specifications
The hydraulic unit pivots on the lower thrust rod and the piston
rod attaches to the underside of the engine swivel bracket.
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.
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:
_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:
_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).
Install the fill plug and torque to 45-55 in. Ibs. (5-6 Nm).
4. Inspect the stern brackets for binding with the swivel bracket in
the thrust rod area. Retorque the tilt tube nut as follows:
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.
10-12 45Cfeng
-~
CDRed
White/Tan
Black/Tan
@ Red/Purple
Purple
~ Green/White
o Red/White
Blue/White 0~'
All tests are made from the RELAY SIDE of the trim/tilt relay
bracket.
UP CIRCUIT
10-14 45C/eng
DOWN CIRCUIT
f1l 12. Push DOWN trim button . Check for voltage at V5 (green/white) .
~ If no voltage, check trim switch, red/purple wire to switch .
If voltage, go to Step 13.
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.
If voltage, go to Step 15.
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
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).
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.
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
=
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
45Cleng 10-19
Motor Test - No Load
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
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
Impact relief valves
Up relief valve
Piston O-rings
External leaks
2. No reverse lock
Filter valve and seat
Impact relief valves
Up relief valve
Down check valve
Piston O-rings
External leaks
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
45C 10-21
Hydraulic Unit Servicing
Removal
2. Remove the blue and green wires from pump motor connector
housing .
f41 6. Remove the unit from the stern brackets far enough to
~ remove the ground lead from the pump motor mounting
screw.
Disassembly
161 6. Remove the down check valve housing. Remove the compo-
~ nents of the down check valve. Inspect the components
following Step 5.
@
18882
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.
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.
\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.
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.
45C/eng 10-25
40,48,50
20845
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 .
1sl 8. Install !i~e impa~~ relief valve balls. Place one ball in each of
~ the remammg cavities.
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.
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).
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.
Motor Servicing
If a performance problem is indicated in Motor Test - No Load or
Troubleshooting Ammeter areas, order the brush and seal kit.
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 ....
Rig Boats
Fix Machinery
Maintain Equipment
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!
"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
If ..... . I f . . .. .
Forward
or Reverse
Reverse
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.
If Operator can't slow down the motor Or shift into Neutral gear (stop propeller), Operator could panic
and lose control of boat.
5-4
Outboard Steering System and
Persons Safety
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.
S-5
How Can Loss of Steering Control be Minimized?
When Transom Mounted steering systems (see picture) are used, check to uncover possible Trouble!
,I
"
- - -',
1
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
5-6
Outboard Fuel, Electrical System and
Persons Safety
at the carburetor
. . . . . and ends here on the powerhead .
What's Important?
Fuel Leakage must be elim inated .
Stray electric sparks must be avoided .
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.
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 .
To avoid those
Static Electric
Sparks .. . . .
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 .
When Running:
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:
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
What's Important?
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.
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 .....
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.
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
,----"""'~ '!=:!:=~
must STOP the engine when the emergency stop switch 's cap is pulled from switch.
If switch fails .. . ..
S- 13
If lanyard is cut or frayed ... ~
,~/~
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.
S-14
Summing Up
Now You know some things that can take the Joy out of enjoyable boating.
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 ... . .
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) .....
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 . . .. .
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.
o Always .....
Turn Key Switch "Off"
Shift to
Neutral
Twist and remove ALL
spark plug leads shaft ..... is motor
really in Neutral?
S-17
Running Motors Too Fast (Overspeeding)
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 .. .. .
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.
..-"/" ~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 . ....
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
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 . ... .
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
~????????
$ -20
Hazardous Products
Know How
items in the
Shop can
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hurt people .. ...
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And remember . . .. .
little children are very curious and will try to taste everything, so . .. . .
..... mummmmmmmm
S-21
WATER FLOW DIAGRAMS
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45,55 40,48,50
86 2027
DR2828
REMOTE CONTROL
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START PUSH IN - START
AND ON POSITION
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DR C4704
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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:
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
Canada
Outboard Marine Corporation of Canada, Ltd.
910 Monaghan Road
Peterborough, Ontario, Canada
K9J7B6
(705 )876-2699