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CHAPTER 1 GENERAL INFORMATION

IDENTIFICATION NUMBERS
PRIMARY ID NUMBER
ENGINE SERIAL NUMBER
PUMP SERIAL NUMBER
HULL IDENTIFICATION NUMBER (HIN)
SAFETY WHILE WORKING
GOOD WORKING PRACTICES
DISASSEMBLY AND ASSEMBLY
SPECIAL TOOLS
MEASUR ING
REMOVAL AND INSTALLATION
CHAPTER 2 SPECIFICATIONS
GENERAL SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE
JET UNIT
ELECTRICAL
TIGHTENING TORQUE
SPECIFIED TORQUE
GENERAL TORQUE
CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENT
MAINTENANCE INTERVAL CHART
PERIODIC SERVICE
CONTROL SYSTEM
Pivot shaft bushing inspection
Steering cable inspection and adjustment
Throttle cable inspection and adjustment
Choke cable inspection and adjustment
Trim cable inspection and adjustment
FUEL SYSTEM
Fuel filter inspection
Trolling speed inspection and adjustment
Carburetor adjustment
OIL INJECTION SYSTEM
Oil filter inspection
Oil injection pump air bleeding
POWER UNIT
Spark plug inspection
ELECTRICAL
Battery inspection
JET PUMP UNIT
Impeller inspection
Bilge strainer inspection
GENERAL
Drain plug inspection
Greasing point
CHAPTER 4 FUEL SYSTEM
FUEL LINE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Fuel filter inspection
Fuel cock inspection
OIL TANK
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Check valve inspection
Oil level sensor inspection
Oil tank inspection
Oil filter inspection
FUEL TANK REMOVAL
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
FUEL TANK
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Check valve inspection
Fuel level sensor inspection
Fuel tank inspection
Pipe joint inspection
Pipe joint installation
CARBURETOR REMOVAL
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
CARBURETOR REMOVAL
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Diaphragm inspection
Float arm inspection
Body assembly inspection
Needle valve inspection
Jet and carburetor body inspection
High and low speed screws inspection
High and low speed screws adjustment
Throttle valve synchronization inspection and adjustment
Choke valve synchronization inspection and adjustment
Carburetor assembly
FUEL PUMP
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Fuel pump inspection
Filter inspection
OIL PUMP
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Oil pump inspection
Oil hose inspection
CHAPTER 5 POWER UNIT
REED VALVE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Reed valve inspection
EXHAUST RING
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
EXHAUST CHAMBER
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
MUFFLER
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
CYLINDER HEAD
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Cylinder head inspection
CYLINDER
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Cylinder inspection
PISTON
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Piston pin clip removal and installation
Piston inspection
Piston ring inspection
Piston pin and bearing inspection
ENGINE UNIT REMOVAL
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Shim removal
Mount bracket inspection
Coupling clearance inspection
Pilot water hose installation
FLYWHEEL MAGNETO AND BASE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Coupling flange removal and installation
Flywheel magneto removal and installation

Coupling flange inspection


Flywheel magneto inspection
Idle gear assembly inspection
ELECTRICAL UNIT
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
STARTER MOTOR
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Pinion inspection
Armature inspection
Brush holder inspection
Cover inspection
CRANKCASE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Crankcase inspection
Crankcase installation
CRANKSHAFT
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Crankshaft inspection
INTERMEDIATE HOUSING REMOVAL
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
INTERMEDIATE HOUSING
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Coupling removal and installation
Bearing removal and installation
Bearing inspection
Coupling inspection
Oil seal installation
CHAPTER 6 JET PUMP UNIT
JET PUMP UNIT REMOVAL
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
DEFLECTOR AND TRIM RING
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
NOZZLE AND DUCT
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
IMPELLER AND DRIVE SHAFT
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Impeller removal
Drive shaft and bearing removal
Impeller inspection
Drive shaft inspection
Bearing inspection
Oil seal and bearing installation
Impeller installation
CHAPTER 7 ELECTRICAL SYSTEM

COOLING AND BILGE SYSTEM


EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Bilge strainer inspection
Hose inspection
ELECTRICAL COMPONENTS
SERVICE POINTS
Spiral tube installation
ELECTRICAL ANALYSIS 3
INSPECTION
Low resistance measurement
IGNITION SYSTEM
WIRING DIAGRAM
IGNITION SPARK GAP
SPARK PLUG
SPARK PLUG CAP
IGNITION COIL
ENGINE STOP SWITCH
CHARGE COIL
PULSER COIL
THERMO SWITCH
CDI UNIT
STARTING SYSTEM
WIRING DIAGRAM
BATTERY
STARTER MOTOR
WIRING CONNECTION
FUSE
STARTER SWITCH
STARTER RELAY
CHARGING SYSTEM
WIRING DIAGRAM
FUSE
BATTERY
LIGHTING COIL
RECTIFIER REGULATOR
INDICATION SYSTEM
WIRING DIAGRAM
FUSE
BATTERY
LIGHTING COIL
RECTIFIER REGULATOR
OIL LEVEL SENSOR
FUEL LEVEL SENSOR
MULTI FUNCTION METER
CHAPTER 8 HULL AND HOOD
ENGINE HOOD REMOVAL
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
HANDLE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Handle inspection
Handle switch installation
Handle holder installation
TRIM GRIP AND CONTROL CABLE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Trim control cable inspection
Grip guide inspection
Trim grip assembly installation
Trim cable adjustment
ENGINE HOOD COVER
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
HANDLE COLUMN
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Handle column inspection
Bearing inspection
Seal packing installation
Bushing joint installation
ENGINE HOOD
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Hood support inspection
Engine hood inspection
STEERING CABLE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Cable inspection
Jet pump side cable joint installation
Steering cable adjustment
Spiral tube installation
THROTTLE CABLE AND CHOKE CABLE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Cable inspection
Cable installation
TRIM CABLE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Cable inspection
Jet pump side cable joint installation
Trim cable adjustment
SEAT, STORAGE BOX AND BATTERY CASE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Seat inspection
Battery case inspection
Storage box inspection
EXHAUST SYSTEM
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Exhaust system inspection
DECK
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Ventilation system inspection
Hood packing inspection
Hood lock hook inspection
Hood packing installation
GUNWALE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Gunwale inspection
MAT
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Mat inspection
Mat installation
HULL
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
HULL REPAIR
Light scratching
Deep scratching
Hull damage (punctured)
insert nut
Removing a graphic
Applying a graphic
CHAPTER 9 TROUBLE ANALYSIS
TROUBLE ANALYSIS
TROUBLE ANALYSIS CHART