General Outboard Repair Manual

DOCUMENT 'non
Cl 013 346
NO 146 393'
BardwaY,Aack
AUTHOR',,;
,
TITLE
INSTITUTION
.Qutboatd'Repair.
,
'
J.
Aid-America VocationalCureiculus Consortium,

Stillwater, Okla.
.
Oklahoma State Dept. of Vocational and Technical
Education, Stillwater.,
,
SPONS AGENCY
.
POE DATE
NOTE
,
.77
180p.; Some diagrais may not reproduce well in:

)
microfiche
Mid-America Vocational Curricula' Consortium, 1t15
Rest Sixth, Stillwater, pklahoaa 74074 ($10.00
.
AVAILABLE FROM
DRS PRICE
DESCRIPTORS
IDENTIFIERS'
AF-S0.83 Plus Postage. BC, Not Available frosj.EDRS.

Behavioral Objectives; Criterion Referenced Tests;
Curricdlum Gaidetv Engines; Equipment Maintenance;
Instructional Materials;' *Learning Activities;
Machine Repairmen; Manuals; *ffechanics_(Process);
*Repair;, Task Performance; *Trade and-Indzstrial
r.
Education: Visual Aids; Vocational Eddcation

*Outboard Motors
ABSTRACT
t-
This vonsorige-developed instructor's-manual for

small engine repair (with focus. on outboard actors) consists of the
.following nine instructional units: electrical remote control
assembly, mechanical remote control assembly, tilt assemblies,
exhaust housing, propeller and trim tabs, cooling system, mechanical
_
gearcaie, electrical gearcase,A0 fuel supply Systems. Each

instructional unit includes performance objectives, suggested
activities for teacher and students, information sheets, assignment
,
',sheets, job sheets, tests,' and answers to the.tists. Many of the

units intlude.visualiiids. (BM)
S.
***********************************************************************
*
Documents acquired by ERIC include many informal unpublithed
* materials not available from'other sources.. ERIC makes every,effort'*
*,to obtain the best copy available.-Nevertheless, items of marginal *
* reproducibility are often. encountered and this affec40 the quality
*
*
* of the icroriche and hardcopy reproductions ERIC makes available
* via the ERIC Document Reproduction Service (EDW. EONS is not
* responsible -for the quality of the Original document. Reproductions *
*
* supplied-by EDRS are.the best that can be made from the original.
.***********************************************************************
.
IOW
*-.
11
OUTBOARD REPAIR
I.
by
Jack Hedway
"PERMISSION TO REPRODUCE THIS
U $ DEPARTMENT OF HEALTH,
EDUCATION & WELFARE
NATIONAL INSTITUTE OF
MATERIAL BY MICROFICHE ONLY

HAS BEEN GRANTED.RY
nn
EOUCATION
aeri.ST)
THIS DOCUMENT HAS BEEN REPRO.

OUCEO EXACTLY AS RECEIVED FROM
THE PERSON OR ORGANIZATION ORIGIN.

ATING IT POINTS OF VIEW OR OPINIONS'
SiTATE0 DO NOT NECESSARILY REPRESENT OFFICIAL NATIONAL INSTITUTE OF
EOUCATION POSITION OR POLICY
TO THE EDUCATIONAL RESOURCES

INFORMATION CENTER (ERIC) AND
THE ERIC SYSTEM CONTRACTORS"
Developed lity the

Mid-America Vocational Curriculum Consortium, Inc
Board of Directors
Don Eshelby, North Dakota, Chairman
Bob Perry, Colorado, Vice Chairman
George Amsbary, New Mexico
Merle Rudebusch,-Nebraska
David Merrill, SoTith (Dakota
Bob Patton, Oklahoma
Pia Lindley, Texai.

Grady Knight, Arkansas
Willard Mayfield, Louisiana
Hilda Jo Jennings, Arizona
Amon Herd, Missouri
Dean Prochaska, Kansas
Ann Benson, Executive Director

1977
4,
1
COPYRIGHT - 1977
Mid-America Vocational Curriculum Consortium, Inc
,
Printed by
State Depaitment of Vocational and Technical Education_

Stillwater, Okithoma 74074
fit
"O.
ft
North Dakota
Sou th Dakota
7.1
4
-et)
.'
..
.,
TABLE OF d9NTENI,TS
Unit I
Unit II
(
.10
Unit III
Unit IV.
Unit V
,
_
Exhaust Ho Using-,
Propeller and Trim Tabs

Cooling System
MecanicaLfGercase
Unit VI
Unit VII
Unit VIII: El'ecTiical Geartase,
Unit IX
. Fuel Supply Syst6ms
..
4..,,
;.,
'
0-1
0-27
0-49
0-71
0-891
I.
IF
.'
-,
Electrical Remote Control Assembly

Mechanical Remote Control Assembly
Tilt Assemblies
0-107
0-135
0-165
.0-189
4.
FOREWORD
The Mid-America V,ocationalCurriculum ConsortiUm (MAVCC) was, organiteel for The
purpose of developing instructional material for the twelve 'member states.-Priorities for
developing MAVCC, rpaterial are determined. annually liased on the needs as identified
memb4rstates. One of the first priorities identified was comprehensive small engine
repair. This publication isa,part of a project designed to provkle the needed instructional
ma rial for small eritine repair. programs.
,,
111
Thi success of this publication is due, in large part, to the cap(bilities of the personnel
who worked with its - development. The technical writers have nurWous' ye,?rs of industry
as well as teaching experience. Assisting them in their efforts were representatives of. each
of the member states who brought with then technical expertise and the experience related
t'ci_thes,taisroom and to\the trade. To assure that the materials woufcl parallel the industry
environment and be accepted as a transportable basic teaching toot; organizatiOns and
industry representives were involved in the developmental phases of the 'manual.
Appreciation is extended to them for their valuable contributions to the manual.
This publication is desigried to assist teachers in improving instruction.- As these

publications are used, it is'rhoped that the student performance will improve and that
students will be better able to assume a role
their chosen occupation, small engine
repair,
Instructional materials in this publication are written in terms of student performance

using measurable objedtives. This is an innovative approach 'Po teaching that accents and'
augments the teaching/learning process. Criterion referenced evaluation instruments are
provided for uniform meastillerneat of student progress. In addition to evaluating recall
information, teachers ate encouraged to evaluate the other areas including processand.
,product as indicated at the end of each instructional
unit'..
It is thesincere belief of the MAVCC personnel and all those members who served
on the committees that this publicatidn will allow thestudents to becbme 'better prepared
and more 'effective members of the work force.
il
Don Eshelby, Chairman

Board of Director's
Yid-America Vocational
CUrriulum Consortium
:
-4
I.
PREFACE.
For many years those responsible fur teaching small engine repair have felt a need
for instructional materials to use in tills area. A team of teachers, industry representatives,
and trade and industrial educ'ation staff rnemters accepted this challenge andheve produced
manuals WhichWill meet 'the heede.of many types of courses where students are expected
to become proficient in the area of rnall engine .repair. The MAVCC Outboard Repair
publication is designed to supplement the MAVCC Comprehensive Small Engihe Repair
publication by covering an detail all aspects of outboard mechanics not incAded in general
engine repair or the reparli of other small engines.

'Every effort has been made to make this publication basic, readable; and: by all means
usable. Three vital parts of instruction have been intentionally omitted from this
publication: -motivation, personalization, and localizatitn. These areas are left to the
individual instructors and the instructors should capitalize on them. Only then Will this
publication really become a vital part of the teaching-learning process.
-,
In addition, we would appreciate yourhelp. We check fr content quality, spelling,

ancKpographical errors many times in the development of a manual. It is still possible,
however, -for an error to show up in a publication.
If, in the use of this publication, you should find something questionable, we would
appreciate you bringing it to our attentitn. ,A copy of the page or-pages in question
with your suggestions for correction would certainly help. Us when we revise and .update
materials.
We're trying tb provide you with the 'best possible curriculum- materials and. will
certainly appreciate your help in detecting areas where possible corrections are needed
to maintain the quality you want arkl deserve.
=
Ann -Benson
Executive Direct&
Mid - America Vocational Curriculum
Consortium, Inc.
0
SI
0.
%.!
Appreciation is extended to those indigiduals whocontributed their time and talents to

the deverophient of Outboard Repair.
The contents of this publication wereplanned an d reviewed by:

1
*it
'
Mid-America Vocational Curriculum Consortium Committee
I
George Alexander
.
Lincoln, Nebraska
Albuquerque, New Mexico
Fargo, North Dakota
Hot Springs, Arkansas
-
Kent Boyer'
Thomas. Cary
Bartork Elmore
Arnold GarCia
Jack Hardway
Ponderosa& New Mexico

Shawnee, Oklahoma'
Greeley, Colorado
Jim Hein
Wayne Helbling
Mandan, North Dakota

Austin, Texas
Wilbur Hull
.
Bob Jackson
Larry Judd
Jerome Kohl
Commerce, Texas
Mesa, Arizona
Lincoln, Nebraska
Topeka, Kansas
,.....--
I-
Thomas Owen
James Schnaible
Curtis Weston
Rapid City, South Dakota

.,
Columbia, fYiissouri
Allan Mikkilson
.....
Minot North Dakota
-Thanks are extended 'to Mike Bundy, for technical assistance and to Mercury Marine
,Outboard and Outboard Marine Corporation for providing technical materials.
Special thanks 'are extended to Amon Herd, Gtrector, Instructional Materials Laboratory,
University of Missouri
Cloumbia and his staff for their* contributions toward the
'development of this book.
,
Gratitude is expressed to Piegina Decker and Mary KeIlLinvfor editing and to the Graphics
Division .of the Oklahoma State Department of Vocational and Technical Education for
typing.
.
. .
,
Special appreciation goes to Dan Stapleton for tfie illustrations and drawings used 4 this
publication.-
The_ printing staff of the Oklahoma State Department of Vocatjonal and Technical
Education are deserving of much credit for printing this publication.
-J
ix
I. or
i
y
.I
USE OF THIS,PUBLICATION
Instructional Units
L
.
'1
.
.
Nii
The Outboard Repair curriculum includes nine units. Each instructional unit includes
some or all, of the' basic. components of a unit t of instruction: performance pbjectives, 1
suggested activities for teacher and students, information sheets, assignment sheets, job
sheets, visual aids, tests, arid answers ,to the test. -Units are planne'd for more thittn one
lesson or class period of instruction.
t'
Careful study. of each instructional unit by the teacher will help to determine: .,
.
A.
B.
The arpount of material that ran be cowered in each class period,
2.
..4
Equipment -needed,
iv
,
3. v_ Amount of practibe needed
4.
. Amount of class' time needed for demonstrations
...
C.
D.
Supplementary materials such as pamphlets or.filmstrips that must be ordered,

ResOurce people that must be contacted.
\,
F.
Each unit of instruction is based on performance objectives. These objectives ate

the goals of the course thus providing a sense of direction and accomplishment for he
student.
N
ilko forms: unit objectives, stating the subject

Performance objectives are stated in.t
Matter to be covered in a unit of instruc ion and specific objectives,%Stating the student
performante necessary to reach the unit objective.
,I
Since the objectives V the unit-provide direction for the teaching-learn ng process,
it is important for the teacher and students to have a commonunderstanding of the intent
of the objectives. A limited number of performance terms have been, used in'the objectives
for this curriculum to assist in promoting the effebtivenessof the communication among
all individuhls using the, materials.
,\
*
I
;,
Following is a list of performance terms and their synonyms which may have been
.
used in this material:
t
Name
Label
List in writing
List orally
Letter
Recor
Repe
.,
,.
The skills which must 13etclemonstrated.

1..
Supplies needed .
-
..
Identify
Describe
Select
Mark
Define
Point out
Pick out
Discuss orally
Interpret
Tell hOw
Tell "what
ffxplain
Discuss in writing
Choose
L-treate
Give
* .
xi
9
,
---6
-%
.as
Construct
Draw. ,
Distinguish
DiscriminSte
Order
Arrange
Make
Seqbence
Build
List in order
' Classify
Design
Formulate
Repioduce
Transcribe
Divide.
Isolate
'Sort
Reduce
Increase
F igure
y Demo i-ist rate"
Additional Terms Used
Evaluate
Complete
Analyze
Calculate
Show your work

hotv,procedure
Perform an experiment
Perform the steps
Turn off/on
I
(Ciis) ,assemble.
Tell
Teach
Estimate.
Operate
Remove
Replace
Prepare
Make
Read
Plan
Observe
Compare
Converse
Lead
Determine
Write
1.
State
Perform
(bis) connect
the studerft should be followed by a class discussioF

Reading of the objectives
to answer any questions concerning performance' requirements for each instruction unft.
446
Teachers should feel' free tq add objectives which will-fit the material to the ne s
r
of the students and community. When teachers add objectives, they should rem
..
and/or
job
stleets,
and
criterjon
to
to supplY, the needed information, assignment
.
Suggested Activities
e--
Each unit of instruction has a suhgested activities sheet outlining steps to follow
in accomplishing specific 'objectives. The activities are listed according to whether they
are the responsibility of the instructor or the student.
4
Instructor: Duties of ,the instructor will vary according to the particular unit; however,
f6best use of the material they should-include the folloIlPhis.prOvidestudents with
objective sheet, informaSion sheep, assignment; sheets, and job sheets; preview
filmstrips, make transparencies, and arrange for resource materials and people; discuss'
unv,And specific objectives acid information sheet; give test. Teachers are encouraged
to use any .additional instructional activities and teaching methods to aid students
in aceomplishrng the objectives.
111
Students: Student activities are, listed which will help the student to achieve the
objectives for the unit.
10
I..
-w
ft.
information Sheets
Information sheets provide content essential for meeting the cognitive (knowledge)
objectives of the .unit. The teacher will find that information sheets serve as an excellent
guide for presenting the background knowledge necessary to develop the *skills specified,
in the unit objective.
r./.,
Students should read the infdrmation sheets beforsi the information is discussed in
class. Students may take additional notes on the information sheets.
transparency Masters
Transparency masters provide information in a special way. The students may see
'as well as hear the' material' being presented, thus reinforcing the learning, proms.
Transparencies may present new infdrmation or .they may reinfOrce information presented
in the inforrhation sheets. They are particularly effective when identification is necessary.
Transparendies should be made and (placed in the notebook where they will be
immediately available for'use. Transparencies,direct.the,class's attention to the taplc of
discussion,They should be left on the screen only when topics shown are under di
ssion.
.
Job' Sheets
Job sheets are an important segment of each unit. The instructor should be able
to and in most situations should denitnitrate the skills outlined in the job sheets.
Pieceduies outlined in the job sheets give direction to the skill being taught and alloW
both student and teacher to.check.student progreit tdraard the accomplishment of the
Skill. Job .sheets ,provide a ready outline fdr students lo'-follow if they have missed a
demonstration. Job sheets also furnish potential employers with kpicture of the skills
being taught and the performances which might reasonably be- expected from a person
who-has had this training it
Assignment Sheets
Assignment sheets give direction to study 'and furnish practice for paper and peAcil
activities to develop theknowledges which tire necessary prerequisites to skill devglopment.
These may be given to the student for torripletion
in
class or used for homework
assignments. Answer sheets are provided which may be used by the student and/or teacher,
for checking-student progress.
ti
Test and Evaluation

Paper-pencil and performance tests have been constructed to measure student
achievement of each objective listed in the unit of instructiOn. Individual test items may
be pulled. out and used as a short test tb determine student achievement of a particular
objective. This kind of testing may be used as a daily quiz and will help the teacher
spot
being encountered by; students in their efforts to accomplish' the 41
objective. Test items for objectives odded by the teather should be constructed and added
to the test.
Test Answer's
'
Test answers are prolided for each unit. These may be used by the teacher and/or
student for bhecking student achievement of the objectives.
A
.
i:
OWEBO.AAD AEFAIP)
,
A'
TIONA4., ANALYSIS f
1NSTRUCTICINAq0CCUP
,
.
' .1
JOB TRAINING: What the
Worker' Should Be 'Able to Do
(Psychomotor?)
',.
*-
.;-.1I,r4.41,
--7-;_f
'
'
.
.
:. RFLATED INFORMATION:, What

",' /the Worker. Should Know .
''''
(Cogrritive)
44
?UNIT I:. ELECTRICAL REMOTE CONTROL ASSEMBLY

4
ri
.2
Parts identification
2.
5.
'
compOnent ,operation
3.
Choke solenoid parts
4.
Types of shift controls
Disassemble and reassemble
electrical remote control

assembly
Inspect and adjust safety

switch and w,arm-up lever
6.
SerVice elec,/rical 'component
: parts of remote ,control

assembly
UNIT II:
MECHANICAL REMOYECO,NTROL ASSEMBLY

.
Identify parts
1.
Disassemble* and re'a\tiesoble
2.
mechanical .rerhote control

'
assembly
1
Replace a nylon, barrel arid an

inner core wire-
S.
4.
Adjust shift and throttle

control. tables
'
UNIT III:
TILT ASSEMBLIES
1.
Terms' and definitions
2.
Types of assemblies -.
Parts of a hydraulic -tiit
3.
4'
4.
Parts of. a manual tilt
'
JO! ',T R
hd: What the
RELAYED INFORMATION: What

-thecYliorker STiould Know
Psych .n*0
(Cognitive)
'Se ice hydraUlic, tilt assembly
Disassemble and reassemble th

manual tilt 'assemble
,
UNIT IV: EXHAUST HOUSING

-' Terms' and definitions
1.
Identify parts
2.
Func.tions of 'we
exhaust
relief
exhaust housings
3.
-
4.
Remove, inspect, and replace

ah exhaust housing,
ee es,'
.
gnd
11
\c
UNIT V:, PROPELLER AND
RIM TABS
Terms and definitions
1.
,
_Parts
Types of propellers
'.
4. -
Materials for constructing

propellerg,
,Titim tab purposes

6.
Remove, inspect and` install a,
-.
..0
.
'Propeller
7.
Remov,,,'InsPect, install and

adiUst a trim' tab,_
-
ilk T...vt:
COO El NG' SYSTEM

:,
..
1.
-2.
.,. di.
Terms' and definitions .
Parts of cooling system,

,
'. ,'4:
Parts of water purnp'

impeller positions
5.-
Thermostat operation
6.
Coolihg system operation,
..,
,.-,0',
t.
J..
JOB TRA+NING: Whit the

Worker'
op sci pe Able to 1)9
,e
,RE'LAtE,D INFORM/0v' ION: What

the Wbrk(e Should.,Know
.
.' C
(Cognitive)
>
Remove, inspect and install a

water pump
-
8.0
Remove, inspect, and instill'

a thermostat
'UNIT VII: "MECHANICAL GEARCASE

1.
2.
Pis of gearcase-
3.
'Purposes of ports
Disas mble, reassemble and

dery e a one piece, gearcase,
4.
11.
.Dfiassemble, inspect,.
reassemble and se'rvice a
-two-piece mechanical gearcase
5.
UNIT VIII:
ELECTRICAL GEARCASE
1.
2.

Functions
of
shift
solenoids
I
3.
Parts of b& gearcase
Disassemble an electrical
.4.
gearcase
5.
Reassemble an .electrical
gear'case
FUEL SUPPLY SYSTEMS
%UNIT IX:
.
1.
2..
Parts of a pressurized
fuel system)
3.
Parts of a vacuumfuel
J
r
systri
,
xvii
14
4.
Fuel system problems
5.
Engine problems
'L./
JOB TRAINING: What th'e

-1/Vork#r, Shod Be- Al i to -{:lo
bI
(
RELATED INFORMATION: What

,;
ihe. Worker ShoUld Know
(Cognitive)
(Psychomotor)"
Disassemble, servioe and
reassemble' a pressurized
6.
111
7.
s'
isal system
Disassemble, service and
reassemble a vacuum fuel

system
a.
,ar
\A
15
TOOLS
(NOTE:. These are the recot*mended tools'

-these
these instructional Materials.)
equipment necessary" to complete the jobs
- Hand Tool Assortment:
3/8" drive phillips screwdriver
Balt-peen hammer - ones Pound
socket
Slip joint pliers
.Soft face' hammer
Screyvdrivers
Tape 'measure
Cleaning pan
'4" standard
1
1/2" standard:.
8" 'standard
6" standard
Adjustable wrench
Phillips screwdrivers
Cleaning brush
Grease pan
-`
'Hot plate
Thermomelt stick
Plastic hammer
Parts washing pan
1/2
8"
3/8" drive reversible ratchet
3/8" drive standard socket set,
1/4" drive reversible ratchet
1/4" drive standard socket set
3/8" drive extension bar 3 in.
3/8" drive extension bar 7 1/2 in.
Starter punch
Combination wrench set 7/16 to 7/8 in.

Universal joint
.
Open end wrench set metric.
3/8 drive socket set metric
Safety glases
Feeler gauge.
Flat surface plate

Machinist's steel rule
Calipers
Pliers
elf
Measuring container
Cylirider gauge
Hydraulic preiC,
Drift punch-
."r4
V- blocks
Surface'plate
tle
metric
DC
. voltmeter ,
DC ammeter
Test, lampOhmmeter
Tachometer
Flywheel pullers
Flgal level gauge ,t9:1 ""telescppirig gauge
"d
End wrenches
Impact screwdriver set
Snap ring pliers
TThandle box wrench, 1.6 mm
Arbor press or bench vise
,e
Pty, bar
Cold chisel
Other Tools and Equipment:

Combination wrench set
Vernier caliper
Drain pan
Hex key set
Inside micrometer
Outside micrometer
Dial indicator
Pin wrench
Propane torch
Seal driver - set
'Meter/kilogram torque wrench
Soft -drift
Nipple wrench
Buthingcdriver set
Brass drift .
Clutch head screwdriver set

Battery ,clamp. puller
Battery hydrometer
Battery post ,cleaner
Funnel
/
Thfead repair kit

Drill motor
Chisel,-set
a
Twjs't -Drill set

Special tools as required
Surface block
Ca'e divider ,t9o1
Impact .8river
:1
IX
4#
,REFOIENCES
.
Evinrude Service Manual. Milwaukee: Evinrude Motors/Outboard Marine Corp., 1971.

Outboard Motor Service Manual.
M9tors/Outboard Marine Corp.; 1973.
Johnson
Waukegan,
Johnson
Mercury Marine Service Manual. yodels 1966

1,976. Fond du Lac, Wisconsin:
Mercury Marine Outboard /Brunswick Corp., 1976.
-
Miller, Conrad: Small -Boat Engine.- New Ybrk: -Sheridan' House,--1970.

Outboard Motor Service. Manua/. Vol. 2. 6th ed. Kansas City, Missouri: Abos. Marine
Publications Division/lntertec Publishing Corp., 1973.
Ur
The R.P.M. Sylremt-Milwaukee, Wiscontsin: Evinrude Motors /Outboard Marine Corp:, .

1972.
4.
xxi
17
ti
ELECTRICAL REMOTE CONTROL ASSEMBLY

UNIT .1
UNIT OBJECTIVE
Aftercompletion of this unit; the student,shbuld, be able. to identify the parts of an

electrical remote control assembly, match the parts to the operations, and'identity the
parts of an electrical choke solenoid assembly. The student should also be able to name
two types of .shift controls and demonstrate the ability to disassemble and. rea'ssemble,
an electrical remote control assembly, service the eleotrical parts, and ,inspgpt-and_a`cliyst
the, safety switch and -the- warm-up lever. This knowledge- will be evidenced through
demonstration and by scoring eighty-five percent on the unit test.
SPECIFIC OBJECTIVES
;So-
After completion of this unit, the. student should be able- to:

. Identify' the{ parts of an electrical to note control assembly.
1.'
..
Match the parts of ti-fe electrical remote control assembly to the correct
(Vexations.
,
Identify tliscpartsof the electrical choke solenoid assembly.

4
4'
Name two tlpies of .shift controls.
5.
Demonstrate the ability to:
ars- -
a.
bisassemble." and reassemble electrical' remote control assembly.

. ,
b.
- Inspect and adjUst safety switch anti warm-up lever.
c..- Service electrical component parts of remote control assembly,

\41`:
18
t.teri-At.---v---NiQ
0-3
ELECTRICAL .RMOTE CONTROL'. ASSEMBLY
UNIT I
,._14&44;41444.
SUGGESTED ACTIVITIES
1
Instructor '
I.
'objr.ctive sheet.
A.
Provide stp.cle
B.
Provide student With, information.- and job `41egts.
C.
Make trarisparericieg,
Discuss unit and specific
D.
,
..
F.
-.
H.
Demonstrate 'and .discuss the procedures Ouilin4d in the job, sheem-,
'
: ,,
'.
.
,.
StuderC'
I.
s.
-----,
B.
Study information sheet.
C.
Complete job. sheets.
-t
I .'
..
Read ottljective .Sheet,
'
Os
.
.
D.
G.-. Give.test,
. -.,
A.
--,
.
.
olpjit ectrA(es. ,
Discuss oformation. sbeet.
E,
.
4 ...
..
.4
,.
..
.-.
,*
Complete activities isgigneda4.9i. instructor
TI
E.
Take test.
IN
INSTRUeTibNAL MATERI-;ILS
-.-.
Included in this unit:

ObjeCtive sheet
"Information s t-; eet
C.
,
-
Transparency masters
.
1.
TM 1--Parts. of .Electrical Remote ControlAssembl;

,
2.
TM 2--Par'tg of Electrical Choe Solenoid 'Assembly
19
fi
.4
4,
4.
D.
Jab sheets...,
t.
...---r - ----,.........--. __,..-44, .....- ...

,
.:7.:'.
..
1.
`Stietr=i I -Orsassts-mtile
Control -Asnmt\-).1y_______.
2-41;b
.
''
-.
2--1nspect and Adjust Safety Switch and Warmup.

.
.
3:
'-n-d. -Freasettibl'i'llectricat Rthiigte
r.
Job Sheet
,1,,.eyer
H.
'I
'IP-
I'
I..
Job Sheet ;'.'3:-Service Electrical Component Tarts of Remote

Control Assembly
E.
Test
F.
Answers to test
References:
A.
Johnson Outboard Motor Service Manual. Waukegan, Illinois: Johnion

Motors'Outboard Marine..Corp., 1973.
B.
(Wier, Conrad. Small Boat Engine: New York: Sheridan House, 1970.
C.
Outticard Motor Secyice Manual. Vol 2. 6th ed. Kansas City, Missouri:
Abos:Warine, Publications Diyision/Intertec Publistpng Corp., 1973.
..
r.
20
L'
I
,
`L0-5
t,

UNIT
",
INFORMATION SHEET
,
Parts of electrical, remote control assembly 4Transparency 1)

A.
Warm-up Iver stop screw
Shift control clevis
C.
Control lever friction adju-stment
D.
Choke switch
E:
Starting ignition switch
Throttle 'control clews,
G.
Throttle cam
'
I,
I.
òf
Casing guide,
9
.
11-
I.
J.
Trunpidns
K.
Cover housing
L.
Throttle corkrol Irver
Motor temperature warning. horn
N.
Neutril safety switch
09erattorls of 'eiect4a1 remote control assembly parts

A.
Warm up' lever stop screw. Limits tVot4iiiadvance during warm up

,
Shift control cleyis-tonnecting device for control ,cables

,
-C.
Choke switch Operates the choke solenoid on engine
/hvttle cam -Changes the orbital movement of the throttle control lever
to a vertical movement of the control cable
E.
'Warm up leyer Opens the throttle sufficiently) to start the engine and to *t
control the fast idle speed for warm up_
2'21
.
It
INF,ORMPO-CON SNEET
Casing guide Provides stiffness to keejPthe Ala les from bending as they
f
moye in and out during the controlling process
G.
Trunnions Adjust the length of the casing guides
H.
Throttle control lever--Apphes force to the throttle cam
I.
Motor temperature warning hornWarning deVice if the engine is overheating
J.
: Neutral s afety switch Completes the starting circuit only when'ththrottle

control lever is:in\ neutral position
,K.
Solenoid assembly -'Iron core surrounded by a coil of wire which moves
clue to magnetic attraction when an electrical curKent is fed to the coil

..P4rts of electfical ch(Ske solenoid assembly, (Transparency; 2)'
.;"
IV
Solenoid plunger
Solenoid assembly
G.
Solenoid plunger spring
D.
Ground *ire
E.
Solenoid choke spring
F,
,Primary wire to choke switch
Types of shift controls

A
Manual
---Electrical
Irr
.c
6-7
c.
s -9f Electrical Remoto cantrqi Assembly

..z4 3015.1.',024
I-
arm-up Lever
Stop Screw
Throttle Control Clevis
it
NeUfral
Throttle Cam
Starting Ignition,
Safety Switch
Switch
Choke Switch:,,,
Shift tntrol Clevis
Contfol Lever 27Friction. Adjustment
Motor Temperatur
Warning Horn ,
Throttle Control Lever t
i
Cover Housittig
Throttle Control Clevis
Warm-up
Lever
Trunnions
23
TM 1
4.
0-9
SCLENC)ID
Electrical Choke
Solenoid Assembly
CHOKE SPRING
SOLENOID PLUNGER
SOLENOID PLUNGER
SPR1N
GROUND WIRE
ti
/- SOLENOID
ASSEMBLY
PRIMARY WIRE
TO CHOKE SWITCH
.
TM 2
.24
ELECTRICAL REMOTE CONTROL 'AS5EMBL'Y
UNIT I
JOB SHEET, #1 DISASSEMBLE AND REASSEMBLE ELECTRICAL,,
4
REMOTE CONTROL ASSEMBLY
Tools and materials
A.
Hand tool assortment
B.
Parts tray,
C,
Electrical remote control assembly
Shop towels
a
.
E.
H.
Appropriate servide r-naqual
Procedure , '
A.
Disconnect battery cables before attempting to .work on remote control

assembly
Remove control box from boat, if needed

Remove control access cover screws and cover (Figure 1)
(NOTE: On some models the control lever must be placed 'In the neutral
position.)
-Screws
(T
./
Access Cover
Grommet'
Electric Cable
FIGURE 1
JOB -SHLET .#1
D.
Lift both control cable casing guides and trunnions qom control assembly
(Figure 2)
_
(NOTE: Some casing giiides have Ore clamp screws thatIV as clevis'pins.)
44 41.1111k
kr
Throttle Control tevis
Ah
err
Casing Guide
FIGURE 2
*
,/
Rear Control Wiie, Clamp Screws.

Front Control, Wire:Clamp Screws
E.
Lrft electric, cable and grommdt out of scot
F.
Remove throttle control cable at engine (Figure 3)

(NOTE: Some throttle, cables are secured with a locknut and washer.)
:Anti-chafe Sleeve
FIGURE 3
Spring Clip
Trunnion Nut r
26
of
1'
4.
4
a
JOB SHEET #1.

Remove shift control cable from shift lever at engine (Figure 4)
0
(NOTE: Some shift. cerntriot. cables are secured. with a spring clip.)
G.
Shift
/r,
te
L ey
11
r-
tigillNk
..011111111fthisZ
011111mm.
4.`
---- ex
14111111.411","
411k
Shift Control Cable
Ca
Retainer
4144%
FIGURE 4
,j
Clean 'for reassembly
Inspect parts for wear or damage

Repteice all engine components
.1
Reasiemble remote control assembly
wir
.4
.)
21
.
Oft
41r
0:15
. ELECTRICAL REMOTE CdNTROL ASSEMBLY

ONIT1
JOB SHEET =-2--INSPECT AND ADJUST SAFETY SWITCH

AND WARM-UP LEVERS'
I.
Tools, and materials

A.
- Appropriate sarvice manual
B.
II.
Procedure
4
A.
Adjust. safety switch
Loosen adjustment screws
2.
With ignition, off put gearshift in neutral
Advance, throttle control lever to full open p ition
4.
ta .
':
Hold starter key on, and slowly retard'throttle cbntrol fever until
engint starts (Figure 1)
Screw
FIGURE 1
-:#
415
6.
.4
4djust slotted cam on throttle control lever.

,
B.
Spotted Cam
4.
(NOTE: Engine should turn over between 2500 and 3000 RPM,
or within service manual specifications.)
-"N.,,,,....--.
.Tighten scre
er adjustmer,,.../.
..
Adjust wa
lever
.1*
28
'
JOB SHEET #2
1.
Place throttle control river in neutral po

in fillkstart position. (Figure 2)
n and warm-up lever
Throttle Control Lever
-4'.
141
_
Warin-Li
FIGURE 2
Lever
2.
Back off "warm -u
lever stop screw until engine will not crank
with key switch
Holding key swat h in the start position, adjust stop screw until
the engine starts ranking with the warm-up lever in the full-start
position (Figure I .-"`
,
Stop-Screw
FIGURE 3
*
^
29.
.4.

UNIT
I
JOB SHEET 4;t3--SERVICE ELECTRICAL COMPONENT PARTS

OF REMOTE ~CONTROL ASSEMBLY
ci
I.
Tools and materials

A.
Hand tool "assortment
B.
Parts tray
C.
Contmuity test light or ohmmeter
D.
Allprcipriatt service manual
E.
ThermOmeter
F.
Pan of oil
st,
II.
Procedure,
(NOTE: Compare your checks with service manual specifications and replace
parts as needed.)
1
A.
Remove remote control outer cover.
B.
Check neutral safety switch
sing a continuit* test light (Figure 1).
Test Light
,
Switch, Adjustment Screws

,
:
FIGURE 1
1'
'',Plunger on Flat of Com

Check choke switch using e test light
D.
Check choke wire from remote control' to chOke solenoid using a test light
30
18
OB SHEET #3
#
Check choke solenoicf .using a test ItgFit or,,an ohmmeter (Figure 2)
FIGURE 2
Lo-ohms Scale-
'
Check 41010r temperature warning horn
F.
1.
Turn key switch to on position
2.
Touch horn connector to ground

(MOTE: Horn shoulrblolv. If it does not,, check for shorts, opeh
circusX, or. faulty horn.)
G.
Check temperittire heat switcb..

1.
Remove heat switch. from engine' block (Figure 3)
FIGURE 3"
*r
{:7
2.
Submerge the heat switch in a pan of ,oil with the thermdmeter
31
A-21
ELECTRICAL REMOTE CONT. OL ASSEN113LY,0,
UNIT I
NA E
TEST .
laentify the parts of an electrical remote control assembly.

.
a.
b.
c.
f,
h.
m.
n:
t.
33
Match the partseof the electrical, remote control assembly on the right'
o
.
correct operations.
2.
Changes, the orbitaf movement of the

throttle control levee id a vertical
movement of the control cable '
- 1.
2.
411
Applies force to the throttle cam
Warning deDice
overheating
if
the
,engine
clle sole
3.
Choke switch
,4.
Throttle carn,
5.
Warm-up lever
6.
Casing guide
on /engine
e.
'Operates the
f.
Provides stiffness to -keep the cables
from bending as they move in and out

during the controlling process
7.
8.
g.
. Shift coptrol
clevis
b. Limit throttle, advance dining warm-uif

c.
Warm-up reter
stop screw
Opens the throttle' sufficiently -to, start

the engine and to.control the fast idlespeed for warm-up
'Trunnions
Thrittle_control
lever
9.
Motor temperature
C warning horn
h. Adjust the length of the casing guides
1(Y.
i.
Ciiipecting device for control cables

Completes the starting circuit only when
the throttle control lever
is
..N/einral safety
switch
SolecIdid assembly
in neutral
position
k.
core su-rr ounded by a coif of wire

I
w ich moves due to magnetic attraction
when an electrical current isiffed to the
coil
r.
101
31-V
'
4
..
11,
ti
ss.
Identify The parts of thq electrical iloke solenoid asserribly.
a.
b.
c.
d.
e.
f.
.01
e.
0-23
-
'
.
24
Name two types of shifty- controls.
4.
a.'
b,
5.
.
ass'embl.Y.
a.
Disassenible and reassemble electricatillemote control
b.
Inspect and adjust safety switch and warm-up lev/.
o.
Service electrical component parts of remote control assembly.
If these activities have not ,been' accomplished prior td

your instructor when they should V completed.)
(NOTE
coo
-36'
at:
test, ask
rJ
0-25

UNIT
I
ANSWERS TO TEST
-1
1.
a.
Warm-up le,ver strip screw
b.
Shift control clews

Control lever friction adjustment
d.
Choke switch
e.
Starting ignition switch;
f.
.Throttle pontrol_crevls
ThropleP cam
h.
Warm-up leVer
1.
Casing guide.
j.
44
Trunnions
+1,
2.
3,
k.
Cover housing
I.
Throttle control 'lever .
Motor temperature warning horn
n.
Neutral safety switch
a.
e.
i.
b.
f.
j.
10.*
c.
g.
5,
k.
11
ci.
h.
.7
a.
Solenc0 plunger__
b.
Solenoid assembly
c.
Solenoid plunger spring
d.
Ground wire
e.
Solenoid choke(spring
f.
Primary wire to choke switch
,'
b
5.
.Electrical
Performance skills evaluated to the satisfaction of the instructor
38
of7
0-27
11,
/
MECHANICAL REMOTE CONTROL ASSEMBLY
UNIT II
UNIT OBJECTIVE
its
After' completion of this unit, the sur-dent should be able to identify the main parts of
the mechanical rempte control assembly. The student shouldalso be able to dissasserhble
and rpassemble, remote control assembly, replace a 'nylon barrel and an inner core wire,
and adjust the shift and throttle contrdi cables. Thieknowledge' will be evidenced through
SPECIFIC OBJECTIVES
After completion_ of this unit,,th'e student should be able to:

,
1.
Identify the main parts.of the mechanical-remote control assembly.
2.

a.
Disassemble and reassemble a mechanical remote control assembly.
b.
Replace a nylon barrel and an inner core
c.-
Adjust shift ant throttle control cables.
ti
39
0-29
7
o
MECHANICAL REMOTE CONTROL ASSEMBLY'

UNIT -II
.
,SVGGESTED ACTIVITIES
4
I.
Instructor:
A.
Provide student with 'objective sheet.
B.
Provide student with information and -job sheets.
G.
Make trarisparency.,
D.
Discuss Unit and specific objectives:
E.
Discuss, information sheet.
F.
Demonstrate 'and. discuss the procedures_ outlined in the job sheets.
G.
Give test.
.,
I t.
Student:
A.
Read objecdve sheet.
B.
Study informatiori sheet.
C.
Complete job sheets.
D.
Complete activities assigned by instructor.
E.
Take test.
INSTRUCTIONAL MATERIALS
I.
Included in taus unit -:
.
'14
"'A.
A. 40bjective sheet
B.
Information sheet
C.
Transparency master: TM.1--Parts of Mechanical Remote Control Assembly
.
D.
Job sheets
1.
Job Sheet #1--Disassemble and Reassemble a Mechanical Remote le
Control Assembly
Cr
4
rA.1114,
30
4-
Job Sheet #2--Replace a Nylon Barrel and an lnQer Core Wire
2.
3.
,r--
f.
Job Sheet
3.--Adjust Shift and Throttle Control. Cables
Test
4
F.
IL
Answers to test
References:
41.
A,
Mercury Marin
Wisconsin. Me
B.
Sert)Ice: MaNual. Models 1966

197& Fond du Lac,
ry Mi?ine OutboardtBrunswick Corp., .1976.
Johnson Outh ar Motor Service Manual Waukegan,lllinois ;Johnson

Motors/Outboard Marine Corp., 1973,
4:*
zr
6-
.11
01.
I
v.
n
1
41.
Ps
I.
. As
t.
41.
40
.4
41
.
...
,
I
7.7
0-31
UNIT II
I.
INFORMATION SHEET,
.1
Parts df mechanical remote control assembly 0..ransparency47
I.
A.
Warm-up lever
B.
Remote control housing
C.
Tbrotti. lever
D.
Face cam
E.
);Cam followqr
F.
hitt lever
G.
lohtrol
lever
.H.
I.
DeVikt_spring roller
J.
Deterit spring
tr
systair
-^4
42
'-
44,
PARTS OF MECHANICAL
REMOTE CONTROL ASSEMBLY
40
4.
[WARM-UP LEVER
REMOTE CONTROL
A
HOUSING (Starboord)
THROTTLE
EVER
F CE CAM
CAM F011.0WER
SHIFT LEVER,
DETENT
SPRING
4.
DETENT SPRING
ROLLER
REMbIE CONTROL HOUS NG (Port)

t
,
"r
CONTROL LEVER
I
A.!
43
TN 1
0_350
UNIT II
,
..,..
JOB SH.EET :=1 -DISASSEMBLE AND REASSEMBLE A MECHANICAL

_ REMOTE CONTROL ASSEMBLY
.
,
Tools and materials

MO. Hand tool assortment
11.
B.
Anticorrosion grease
C.
Parts tray
D.
Appropriate service manual'
Rrocedu re
A.
Disassemble remote* control assembly:.

,
which hold -.1-ibbsi4; halves together
Remove' screw
Separate halves ( O'tgure
4-
1)
'0,
Detent spring
roller .
Face
cam
:Cam roller
Spring
Throttlelever
Step
dowel pin
\:throfile cable
FIGURE 1
14
'' Remove detent springs and detent sprihi rollef( Figure 1)
3.
1111110
44
.
3.
4*-
36,
J06 SHEET #1
41$
4.
Lift face cam 'out- (Figure 2)

11
Shift lever
Notch
Roller
otter
pin
tep
ti
dowel
pin
Face cam
FIGURE 2
Shift cable
5.
-Remove cotter pin and step dowel pin from 5h,ift lever (Figure
2)
6.
Remove shift cable (Figure 2)
7..
Remove cotter. pin and step dowel pin from throttle lever,(Figure
1)
Remove throttle cable (Figure 1)

9.
Clean and inspect all parts
Reassemble remote control assembly

1.
Place anticorrosion grease in cable socket and install shift cable
Coat step dowel pin with a thin film of anticorrosion grease and
ihstall stet' dowel pin tf-iru shift leer and lever cable'end
3.
.Place face cam in posrtion clr shift le'Ver (Fkgure 2)
(NOTE Roller on face cam !roastfit- inturratcli- on shift lever.)

A
45
7
4
0-37',
lb
OP ,
..
JOB SHEET =1
.1
Install detent spring * and 'deteilt spr,n(1 tdikr- -SP
aetent
spring roller
.
Spring
Face corn
4-4
FIGUPF 3
5.
Place anticotrOsiory grese it cable socket anti ,rstz,'
6.
Coat stip dowel pin vitth a tr'in ti r- of a,,-1-10-r-cos,onw grease *nd
install sTep dowel pin thru

7
Dowel
8.
Place
9,
Set handi
noted
,hto
not
47)\
:-P.6,t;bn 6 +
Reset handle so
-in
.)
_4 6
/-
tO1'.
rt;
thn.,
Instal nandir- err
evF,'
;:;e747.7<.
ern
-4Roller 4
Stec)
10
caole
Place halves :together (Plgtit
(NOTE. If housing halves do nu'

eiltenny àce tam slotel.
11111F
re 3)
0-39
MECHANICAL REMOTE CON-1-ROL'ASSEMBLY
UNIT II
2 -REPLACE A NYLON BARREL-AND AN INNER CORE WIRE
--JOi SHEET
Tools and materials
II.
A.
land tool assortment
B.
Anticorrqsion grease
C.
Locktite-
Ruler
Procedure'
A.
Replace nylon barrel

1
2.
ry
'Remove cables, from remote control box

Remove control wire clamp screw from casing- guide (Figure 1)
LUBRICATE SI (EVE
BEFORE /ASSEPBLY
CLAMP
INSPECTION
HOLE
SCREW
CONTROL. WIRE
CAS-4C, GU DE
/Mt
1
i.L
"0" RING SEAL
IP' lb'
LEVER
SIDE
CLAMP
FIGURE 1
SCREW
CLAMP (THROTTLE
CABLE ONLY)
3.
Remove casing guide
4.
Remove control -wire
5. A
Remove burrs on control wire and round off the end of the were
6.
Remove damaged *Ion barrel

k
47
.40
4
r
5;
*k.
JOB SHEET :2
N
....
Measure the distance from end of cable to center of nylon barrel

v
.
(Figure 2)
.;
5.
(1:....U.',-%*1
,s
FIGURE 2
8.
Install new nylon barrel on the cable the same distance as damaged
ual specifies
barrel or as service m
(NOTE: Large diameter of hole in barrel faces cable. Brass bagel
assembly must be staked or locked in place with locktite.)

B.
Replace inner core wire

1.
Round-T:ifferld of new wire

,(NOTE: This will prevent damage-to,inner liner of cable when
wire
is
inserted.)
Lubricate the core wire and slide it into the outer. cable
3.
4.
Insert core wire until able to grip opposite end

'Pull core wire out of outer cable and measure ,to service manual
specifications (Figure 3)
Stainless Steel
Tegrninal Wire
Cable Brass Barrel
.1Insert
..I
r.
...1..
. _,
1=-----
Rounded End
5.
,===C-1Ingi2larmOrr;:-1
\Inner
Brass
Cc re Wire
Barrel/1-
FIGURE 3
Install into remote control box
48
.....N,"
: ..)
....if,'
4
0-41
'1,
MECHAN4-CAIL REMOTE CONTROL ASSEMBLY
UNIT II
AO,
JOB SHEET =3- -ADJUST SHIFT ArCID THROTTLE CONTROL CABLES
I.
..
A.
.
.....43
Ruler
C.
II.
Anticorrosion grease'
\_....
-Tools and materials
Atocedure
.
NO
Adjust shift control cable
A.
a
Place remote control lever handle in forward position and

' warm-up lever...completely down
Install cable into grommet on engine cowling with barrgi inside
2.
cowling
3.
Shift transmission into forward gear
4.
Adjust barrel connector on cable so that hole in barrel aligns with

hole in clevis, and hole in cable end aligns With peg on shift cable
end anchor (Figure 1)
we
I
FIGURE-1
[Cable
.
aligned'
with Peg
Barrel connector
%aligned
with clevis pin
"
a
.b
49
I
.,,,
JOB SHEET #3
'5.
Insert clevis pin thru barrel and opposite side of clevis.and turn
90 to lock the pin in place (Figure" 2)
Barrel connector
locked in place
FIGURE 2
Latchspring-installe
.
Clevis
---
rr
SI
Fasten cable end in place by latching hairpin spring clamb7iFigure
2)
,.
.
lk
Place reinote control lever handle4n neutral, and Check that engine
is in neutral gear
7.
.-
.(NOTE
If not in neutral gear, repeal steps 3, 4, and 5.)
Adjust throttle control cable
P4Ice remote control lever in neutral) position and warm-up lever

completely dawn
.
..1
es....., ,
r.
Install cable into grommet on engine cowling wSth barrel inside
cowling
Adjust barrel on throttle cable to service manual specifications
3.
(Figure- 3)
4
Swivel and link assembly
et
Cable end
on peg
i
4.
FIGURE 3
..--
Barrel in anchor ,socket
Distance to be measured
50
A
0-43
,JOB- SHEET #3
4.
Snap cable enct latch over cable end, and lock barrel in socket
(Figure 4)
FIGURE 4
Throttle cable end installed
_Locking pin installed

5.
Move lever remote control handle to forward poiltion and then

back_to neutral position
(NOTE; Check that. idle stop screw rests lightly against idle stop
when control handle is in nedtral position. If hot, repeat steps

-2, 3, and 4.)
s,
"N
01.
-'51
'46
2..
a.
Disassemble and reassemble ajnechanical remote control assenibly,
Replace a 'nylon barrel and an inner core wire.'
c.
...,
Adjiist shift and throttle control cables.

.
(NOTE: If these activities have not been accdmplished pnor to the test, ask
your instructor when they should be completed)
I.,
...
t
VI
r
)
6
MP
53
_0-47
UNIT II
'V
ANSWERS TO -TEST
Warm-up lever

Aft
2.
c.
Throttle lever
d.
Face cam
e.
CRITI follower
f.
Shift lever
g.
Control lever
h.
i.
Detent spring roller
j.
Detent spring
sk.
Performance:skills evaluated to the satisfaction, of theinStructor
v,
.1
4'
54
0-49
PILT.4S3EM LIES
B.JECTIVE
.101:NIT
Alter domPtetion of this upit, the student should 'be able -to ide tify the rn"-----This..pausof
the fiY,dtluffc and manual ,fi4t assemblies. Thi student should' also be able to service a
hydraulic iilviassembly and disassemble and reasse le a manual tilt assembly. This
knowledge v ia l, b6 .evidenced through demonstcation
scoring eighty-five percent
on the unit test.

44,
OBJECTIVE5
After completiostr thil unit, the itutlent should be, able to:
Match terms associated With tilt assa-n6ties to the correct definitions.
1.
2.
.....-----,...
-,.
'..,
NaMe two ty'rks of tilt assemble
.3.
00.
Identif'y the parts of the hydraulic t assembly:`

.
..,
.
.
the parts of the manual titt assembly.
4.
..
Deplonstrate 'the aability to.:
5,
..
,.
Service 'the hydraWic tilt assembly.
a:
.
b.
11
Disassemble and reassemble the manual tilt .assembly.
401
y.
.*,
a
''.
TILT ASSE,p/113L1E,
t-
UNIT" III
SUGGESTED AC7IV11-1E5
L4i;
.Z.44N
Instructor.
,
oviderstudent with objeaive sheet
II
r
.
B. p Provide student with information and job".heets.

Make
transparenciV
#
4
c).
Discuss unit and specific objectives.
E,
Discuss information sheet.
F.
Demonstrate and discuss ofr procedures outlined in the job sheets.
G.
Give test
Student
A.
Read. objeetwe sheet
Study information sheet
C.
Complete job sbeeta-
Take test
:e
VI
I NSTRUC.T116,NAL MAME RAKS
Intluqed in this unit

I
Objective sheet
A.
fdrmation sheet
-ranspaqtricy masters
C.
th TM 1Hydraulic Tilt' Assembly

2..
TM 2-- Manual Tilt Assembly
,D
Joh she
1
,.
Joh Sheet #1.Service the Hydradic Tilt Assembly

I
V3
56taN
ro)
..
Assetnbly
Test
.
2Disassemblq and 4assemble the, Manual Tilt
Jeb Sheet
.14
'
p
F..11.
- A
References:.
A.
.1"
Answers to test.
..
..
.,
Johnson Outboard Motor, Service , Manual. Waukegan, Illinois. Johnson

"Motors /Outboard Marine 'Corp., '197a.
B.
.,
''").'
Mercury Marine ServIce Manual Models, 1966

Wisconsin. Mercury_EaDne,'Outboard/Brunswick
.
1976.
orp.,
....\
F
ratzi1
du
Lac,
-1976.
a.
ai
ti
4.
,J
Alt
57.
e
0-53
TILT ASSEMBLIES_
UNIT
..0
INFOOMATION SHEET--
'ks
..
.
F
`rte
I.

A.
I.
4o,
Transon-Part of the boat from which the engine is' hung
141:;411".49
BleedRemov
air -frotn -a system
Tilt angle- -Any Oc110 of the outbord away

.
D.
Limit switch-Limits the tilt angle of :the outboard
Thrust rodAeep's correct engine tilt angle and locks engine tilt'dnwn
reverse ope-r.it ion
11.
III.
rn, akertical position
..
,r
n0
Ass
Steeringarrri and. ply t, shaft-:Pivot point for' engine's turning, radius--
G.
Tilt tube -Pivot point fo engine's tilt angle
Types of tilt -assembAgs

A
Hydraulic
B.
Manual
Parts of hydraulic tilt assembly (Transparency 1)

.
Hydraulic pump
Or
Solenoid'
Swrfkh
Vent screw
Control knob
Harness spo,nnector
Down bleed Port
Up bleed port,
Fill screw
va.
4.
58
to
INFORMATION SHEET
kt
IV. Parts of manual tilt assembly (Transparency 2)

.
A. "Steering arm and pRibt shaft
-1
1"
B.
Ster,,n brackets (port aAd starbpard)

.
4.
'C.
Thrust rod.
..
D.
Swivel bracket
E.
Keepers
F.
Nut
Shock absorber:
Reverse lock components
.Stern' bFacket
to
Tilt tube
,
A.
fl
,
.
^
".
59;
a
If
ir
1
Ili
Jo%
'1
'
,
',..4
PM1
1 /gb'k:i.M.L.m..
----'-
i.o:_fir,'"
44----,
1,
ailrir
I
-V-
11
...11
stsio.:P
111111116116.41600..
CU
%
h1,:;kk
(tLe't,
%,411WilkeiNbSgi
4$11.1
1t,Nt11114
dd
g,
lks
111,
1"
"Auk
111111;
11111111
iMi11111
OD
0-57
MANUAL TILT ASSEMBLY

STEERING ARM AND
PIVOT SHAFT.
TILT TUBE
THRUST ROD
STERN.
BRACKET
PORT,
STERN BRACKEPLATE
KNOB
THRUST WASHER
-
SEAL
SWIVEL BRACKET
14
REVERSE LOCK
BIAOHING'
STERN BRACKeT,
SYARBOARD
toMPONENTS.
SHOCK
ABSORBER
KEEPER
MOUNT BRACKET
-NUT
(
I
61,
Ty 2
0-59
TI LT ASSEMBLIES.
*ft
UNIT III
.10B SHEET #1--SERVICE THE HYDRAULIC TILT ASSEMBLY
1.
Tools and Flierials

A.
B.
Hydraulic fluid
C.
Oil pan
D.
Appropriate service manual
11,
Procedure
A,
Check hydraulic system fluid level
(NOTE--This needs to be done periodically.)

1
Tilt outboard to
2.
Remove "fill" plugs (Figure
11 up position
1)
FIGURE.1
imik2/
3.
Fill to bottom of thread-with type of fluid specified in service

manual
.
(NOTE: If specified type is not available, use a high quality SAE

20-20w specification MS automotive oil. Do not 00er-fill.)
62
60
tr 'JOB SHEET #1 ------
4fi-r
Replace "fir ,plug and return outboard to normal operating

position
B.
'Bleed hydraulic system
;
1.
Bleed "down" side of h raulic system

a.
Remove "down" bleed screw and 0 ring at top of cylinder

(Figure 2)
BI ed Screw Removed
b.,
Press the "in" button on the switch panel for a few seconds,
release, and wait for approximately one minute (Figure 3)
!
.or
...lryounimp7t.g.
--rounnao.,:-
11,0
4111111111110
gralft1116
Inallmor
MIUMBlia
IMIIIIIMM
611211MINIAL
11111%)2111..
..FAILI/4/1,:%
Wet 'NIA
WADI
=UM
=MN
AM
/MEM
AINIMIMIN
4
FIGURE 3
c.
Repeat pumping procedure until fluid, which flows from

bleed port, is free of air bubbles
ti
. .0-61
I
N\
JOB -SHEET #1
V
d.
Replace bleed screw and. 0 ring seal and tighten securely
e.
Repeat bleeding procedure with opposite cylinder

(NOTE: This may not be necessary because not all models
have two cylinders.)
2.
Bleed "ujo" 'sid
of hydraulic systetn,,
ti
Loosen
a.
hydraulic lift
Place cylinder i
b.
grommets
from
role
cover
ylinder from its mou
and .remove
a horizontal positio rr with hose ports facing..,

,
up (Figure 4)
Bleed Screw Removed
c.
9emove "up" bleed screw and 0 ring seaLfrom no. 1 port

(Figure 4)
d.
'Presiup/out button on the switch panel forioew seconds,

release, and wait, for approximately one minute.
e.
Repeat ,pumping procedure until fluid, which flows from

bleed port, is free of air bubbles
Replace bleed screw and '0 ring seal and tighten securely
Install cylinder and hose grommets
g.
.
h.
Repeat bleeding procedure with opposite cylinder
(NOTE Ndt all models have two cylinders.)
Fill pump with' hydraulic fluid to appropriate level as specified in service

manual
64
0-63,
(
`"STILT ASSEMBLIES
UNIT III
JOB SHEET =2 DISAS
I.
MBLE AND. REASSEMBLE THE MANUAL TILT ASSEMBLY
Tools and materials

A.
Handtool assortment
1,2" socket set and ratchet,
C.
Truarc pliers
,..
Parts tray
E
Amisoorrosion grease
ApprOpriate service manual
A*,
I I
Procedure
Remove exhaust housing
-A.
Remove nut from bottom of pivot shaft (Figures 1 and 2)
'
(NOTE $Ome engines will h6ve Truarc rings holdiong pivot shaft.)
Lower bracket
.w
Trunrc ring removed with

pliers
FIGURE 2,
FIGURE 1
65
C.
Remove piv'ot shaft, split keepers, and thrust washer (Figure 3)

(NOTE: Some pivot shafts and bracket splines have to be heated before
vitt/the mount brcket can be removed from the pivot shaft)
*lb,
_Swivel Bracket
Thrust Washer
Splines
f.ower Bracket
,
FIGURE 3
D.
E.
Drive out ripper and lower. seals

'Remove bronze bushing In Swivel bracket
F.
Remove thrust rbd, thrust seiring and retainer
G.
Remove screw and plate holding port and starboard Stern, brackets together
H.
Remove tilt tube bolt, nut, and washer from stern brackets
I.
Remove shocktisorbers
J.
Clean parts
K.
Inspecl parts for damage
L.
Fieaksemble reversihq steps A through
0I
(NOTE: During reassembly coat spline with anticorrosion grease and torque
pivot shaft nut to service roOnual specifications.)
/66
I
t.
vat
el.
TILT ASSEMBLIES
UNIT HI
NAME.
TEST
1.
Match the terms on the right to 'the correct definitions.

Any incline of the outbodrd away from
a vertical position
Transon
2.
Bleed
Tilt angle
Limit switch
is. hung
5.
Thrust rod
e.
Pivot point for engine's tilt angle
Steering arritrand
Pivot point for engine'smturning radius,
a.
'b. Remove air from a systeai

4
c.
Limits the tilt angle of 'the outboard
-d.
Pai/ of the boat frOm which the engine
pivot sh7t
,
2.
Tilt tube
7.
Keeps correct engine tilt angle and locks

enginivtilt down during riaverse operation
Name two types of tilt assemblies..

a.
b.
a
,f.
Mi
40
67
0-65
I.
.414k
1111.11P.-
,,w
1..alif
i4;464,,...211
"ef. '
CT)
"
"TN
_ftea11111
k.1
oar
I
0-67
4.'"
I
.
ft_
._,,
4.
..
..
Vir
'.,
1-1-
IdentITY the parts of ...

the manual tilt assetribly.:
a.
4:
b.
'C.
d.
1M.
I
ti
DIY
1.
.t
Demongtrat.-dv ability toz
5.
a.
I ...
'
'Service the hydraulic 'tilt assembly.

.
tle and reassemble the manual tilt assembly.
b.
4e,
(NaTE: L#, these' activities have not been, accomplished. prior to the test, ask
your instructor when they ,should be completed.)
.
hp'
.
...
69
to.
...
0'
SSEMBLIE
UNIT III
WE RS TO TEST
e.
c.
f.
g.
r
, 2.
a.
b.
'Ffy,draulic
Manual
P Solenoid:
f.
Control
Sidi panel
,-
b.
-Harntss cdnnector
Ita
st
c., 'Vent screw

d.
t'D1n bleed poli' f
41",
Fifl ,screw
Up bleed pott
i.
45:
4;
e.
HyiElra'Clics pump
a.
Steering firm and pivot ,shaft
b.
Stern brackets (port and starboard)
citt
'
c. 11/1J3rust rod
d.
Swivel bracikei
e..
Keepers
ihr
g.
,Nut
p
....
hock 'abkirlzker
'1
rr
h.
Reverse lock components
i.
Tilt tube
Stern bracket plate
.:t.i.
.
5.
Performance skA evaluated to the satisfaction of the instructor,

.
_
',
.,
.70
4
ir
lik
0-71
EXHAVST HOUSING
UNIT IV
UNIT. OBJECTIVE
.
exhaust housinialfd list the functions of the wet sleeve, exhaust relief, and exhaust housing.
The student should also bit able to remove, inspect, and .replace the exhaust houeing
This kno,vvledge w- ill beevidenced"through demonstration and by scoring eighty-five percept
go
on the unit test4.s.;..

.
..
'1
'SPECIFIC OBJECTIVES
'N
After completion of this unit, the student s,hoUld be able to:

-et
1.
Match terms associated with the exhaust housing to th6 correct definitions.
2.'
Identify the parts of -the exhaust housing..
3.
List -the functions_of' the wet sleeve, exhaust rek,i,ef, and exhadst housing.
ti
Demonstrate the ability to remove, inspect, and replace an exhaust housing.
11
.
[
After completio9'bf' this uptt, the student should be able to identify the parts of the
F.
71
4
4.
0-73
,Amit
EXHAUST HOUSIN.G.
UNIT IV
- ;SUGGESTED ACTIVITIES
I.
'I
Instructor
rovide student with objective sheet
Provide student with irtformation and job sheet..
B'
.1
Make transparency
Distuss unit an
PP\
..
specific objectives.
.7.-
Discuss informatio'n sheet

;
eemonstrate and discuss the procedure/ outlined -irI the jbb sheet
ite test
4
Id
Student
.
Fear.1 objective sheet

47,
Study information sheet',
C.
Complete job sheet
Complete acts
ties wired by instructor

V.'
,,
Take. test
INSTRUCTIONAL MA--1--ERIALS
Included irlethis
A
Objective sheet
B.
lvtforrnation*sheet
Transparent
D'I)
E
:Job Sheer --.`-`1
,
master TM 1 -Parts of Exhatist. HOUSIng
4
.r
-.
S?
,
Remove, Inspect, .anclo.Replace an Exhaust Housing
.Test
..
F.
Answers to test
II.
References
0;,thoarr/ 'Motor. Service 11,731n:131 Viaukegab,

4
Moturs,Outboard Marine Corp 1973
I Ilino Is
Johnson
Sex,i e Manual
ial Models 1966
1976. Food di] Lac,
Mercury Marine Outboard Bruntviick Corp., +1976'
B.
\1:scoersin
.
I.
.
94
,.
4s.
t
P
s
,
A
est
'A
7
4
s
t.
0-75
,r
XHAQ$T HOUSING.
UNIT IV
a
*INFORMATI.ON,SHEET
`.
1.
'Terms and definitions

,
A.
Wet sleeve -Area betmen the-Itmer,aAd outer exhaust housing which is full
of water at all times
Powerhead-Engihe anti all ins component parts

.
Shock mount-Redatthe shoO'k betwee6
C.
e po.werhtad and the exhaust
h.oUsing
exhaust relief Outlet above t'he water ine
H.
Parts of the exhaust -housing (TransOarency

A.
Outer dxhaust housing*
Inher exhaust housing
Cs
Sear
Aft exhauL cover
F.
4.
Rubber Mount cover

F.
G.
H
HI.
'
Ober 'mount
.Clamp
Mount cover
Water, tube
Fu.nctions of the we*t sleeve, exhaust $elief, and exhaust housing

,
A
eeve
2. -
.-'3
rA
Acts as an exhaust silencer
....,
'
Cbols outer Atxhaust housing

a
.
'4
Codls lower shock mount
---- .'
'
Exhaust relief -Relieves exhaust 'back Pressure,for easy

ot
ttiqing
Exhanst hckising -Acts

Acts as an extension 'so theme .gearcase wilLre.ach the water..
.
PS
.
4
A
'
(177.
41,
PARTS OF
EXHAUST HOUSING
S
SEAL
AFT .EXHAiiST.COVEK
INNER EXHAUST
4A--HOUSING
RUBBER MOUNT
COVER'
*
I
1-7-
RUBBER MOUNT,
WATER TUBE .
OUTER EXHAUST
0010 nr===0
HOUSING
t.
ato
se,
11
MOUNT COVER
75
TM .1
079 -d*
EXHAUST
UST HOUSING"
UNIT
JOB SHEET 1 REMOVE, INSPECT, AND REPLACE AN EXHAUST HOUSING
Tools and materials

A.
Hand .tool assortment
B.
Appropriate service manual

Hoist
Sirface gauge and scriber
D.
- Powerhead stand
Lift rrng
F;
11 "'Procedure
.
Remove gearcasi
Remove powerhead
.11
1.
Remove screvys from afi exhaust cover and remove the cover
2.
Place sh;ft >arm in neutral position
Disconnect battery cables from .battery
Remove ertgine cgver
5..
Rernoyor locknuts from top and bottom cowl support 0)04

MOU-fliS
'6:
.Remove fuel, lines from, fuel pump

4.,
Remove water hose ,from exhaust plate

,
8',
.t."--.
..-4
let-
Disconnect al! electrical ;connectioq,s including
Initibn, starter
:sol,enold, safetysmtch, temperature switch, choke solenoid, *and.
lit
stater lead..
(NOTE Di5connec* electric shift control cables on electric shift

,
models-)
76
JOB SHEET #1
a
Remove powerhead exhaust housing huts (Figure 1)
f
ao
Grqund straps
FIGURE 1
10.
Remove sta-straps
11
Remove
12.
Remove center cowl
lead wires from spark plugs and lead wire retainers

upport
(NOTE'. Some models' do not have center cowl 'support.)

13.
Remove'plastic protector from flywheel nut and install lifting ring

(NOTE: This step is not necessary OR all models because some
enginet already have lifting rings.)
14.
Remove ,Tear cold ,support shock mount nuts and rear; Cowl
support-bracket
15.
Remove shift Mk attaching nut
It.
,1
r
1
0-81
J04 SHEET #1
1'61
Lift powerhead and place on powerhead stand (Figure .2)

.
4..
.:.....
,.
fl
FIGURE 2
C.
Remove exhaust housing

1.
11
Fiemove- cross pin which holds reverse lock lever in exhaust

housing
(NOTE. A cross pin is not used on all models.)

2.
Remove lower mount covers (Figure 3)

(CAUTION Some covers are spring-loaded.)
I
vorwimeie&NAia,,
Leenmen,:eN.b11So'et%SihipvitIR4.
04.44.
17111.1!`:".
", ;91.04n1'
;711.'"Cr4i
78
..,
JOB SHEET #1
Remove nuts from lower mounting botts'(Figuref_4)
4.
Remove nuts from upper yoke studs (Figure 5)
5.
Remove exbaust housing by pulling from' upper and lower_ yokes

(Figure 5)
6.
Clean all partsWith cleaning solvent avid dry
7.
Inspect parts for damage
.k
79
4-
JOB SHEET' #1
Inspect exhaus/ housing
Check exhaust housing for cracks and nicks
1:
(NOTE: Do not attempt to weld cracks ori nicks.)

2.
Check parallelism. of exhaust housing. (Figure 6)
(NOTE: 11 exhaust housing is bent, replace tile housing, do not

attempt to straighten.)
FIGURE 6
*
Check water tubes for obFtructions or kinks
(NOTE R'eplace these tubes as needed )

,
E.
Reassemble and replace by reyersirrg procedures\A throughD
44 4
41
80
./
0-85
EXHAUST I-IOUS(NG
UNIT IV
Jc
NAME--
St
4'
TEST
Match- thiterms on the right to the correct cthfinitions.
1._
a.
'Outlet above the water line
1.
Wet sleeve
.
the
Reduces
b.
shock
the
between
2!
Powerhead
3.
Shock mount
4.
Exhaust
r3owerheid and the exhaust housing
c. Engine and all its component parts
relLef
and .outer
d. Area between the
exhaust hOusing which is full of water
at all tirries
inner
'
.
Identify the parts of the-exhaust housing,
2..
4
1
_I
e.
O
h.
"e4
V,
I
4.0`..
v9
',-;9-04.
r.4"14
NIP
List the functions of the wet sleeve, exhaust reef, and exhaust housing
Wet ,sleeve
2:*14).
2)
b.
Exhaust relief-
isk
`1
c.
Exhaust- housing-
.)
'''.
.
_
Demonstrate the ability to remove, inspect, and replace an exhaust housing.

---..
ti' :
If this activity has hot beet, accomplished prior to the. test, ask your
instructor when it shopld be compteted.)
(NOTE
far
82
Igo
EXHAUST HOUSING
UNIT IV
t
A_
ANSWERS TG T.EST
1.
a.
b.
c.
.d.
,oe
a.
Outer exhaust. housing,
b,
Inne'r, exhaust housli-ig
041b
*IF
Seal
d. Aft exhacht co\kr

'Rubber mount cover
Rubber rrlounfi
g..
1,arr,)p
Mount cover:
r.
IWater tube
Wet sleeve
Acts as Sh.'ex'haust sill

,
2)
3)
"7-
dooli.outer exha'ust housing
cools lower shock. mount
Exhaust rehief Rl eves exhaust back prestu
for ,easy starting

o t'
-.
Exhaust housing Acts as an extengion so the gearcase will reach the vkAtei-
Performartce-skill evaluated. to the satisfactioti of '.the iristryafer
p
'
.
*-,-2111
411aiwund
'zi
0-89
PROPELLER AND TRIM TABS

UNIT. V
UNIT OBJECTIVE
'After completicv-i of this unit, the student ihouldba able to match terms associated with I'
propeller and trim tabs and identify the parts. The, student shout' also be -able to narro-,
the common' types of propellers, list the kinds of materials of which they are made, list.
-the purposes',50 a":trim tab, and demonstrate the ability to remspue,-inapect, and install
alepeller and a trim tab: This knowledge will -be,evidenced through demonstratiot apd
by. scoring eighty-five pertent on the unit test.
.
SPECIFIC OBJECTIVES -
After completion of this unit, the student should be able to:

. .
1.
-*
,.
2.
.4
,.
7I4
Identify the parts of the- propeller and the trim_tab.

_
4,'
.3.
Name the two common, types of propellers.
4..
List 'the four kinds of) materials used to makpropellers".
5.
OP
List, the purposes, of the -trim tab:
.t-
Demonstrate the abiNic to
Remove, inspect, and install a propoir.

.
b.
Remove,_ inal5ecir install, )arO adjustia trim tab",
4,
41.
41,
.4
Match terms associated with propeller pnd trim tabs to ,the correct
_
.
.
idefinitions.
.4
84
4.
PROPELLER AND T1311\./1. TABS
UNIT V
-Instructor
Provide studeift with objective sheet
...._,
Provide student with information and jOb sheets.'

4.
Make, transparencies
Ap.
Discuss unit and specific objectives

,
Discuss information sheet

Demonstrate and discuss the procedures oOtlirted
in
the job sheets
G'ive ,test
Student
II
A,
Read objecti
sheet.,
*C
Complete 16 sheets
iA
uornplete activities assignediby-instructor.
E,
Take. te-3t.
*1
ots
Cc
tS
INSTRUCTIONAL MATFIRJALS
Included in this
Objective sheet
Infomath:an Meet
:
C
I
.
4,
,00,
-a
Tfansparer:ey masters
lilt.
.1
4,
TM 1- -Pitch and Propeller Diameter
2:
'M '2 'Parts of th,e Propeller and thti Trim
T ab
10,
92
4
P, ;Job sheets
I
1
in- Sheet =1--Remove, Inspect, and criAtall a Propeller
lb1ZSheet -1----2--Remove, Inspect, Install, and Adjust a Trirn Tab
E:
Test
F.
Answers- to- te.5t
H.
Refelentest $'`
,
C:
f.
Johnson OujboarCi Motor, Service Manila'

MotorSOutboard Marine Corp., 1973.
V1/4.
Waukegan,
Illinois: Johnson
Outhoarti Motor
vice Manual. Kansas City, Missouri- Abos Marine
Publications DivisiMilntertec Publishing Corp., 1973.
-The RPM iSys`tem. Milwaukee, Wisconsin
Marine Corp , 1972
MPrcury. Mainne Servic: e
Wisconsin'. Mercury Marine
Evinrude Motors/Outboard
/al Models 1966

1976' Fond. du Lac,
utboard/Brunswick Corp , 1976.
re'
to
VI
aV
.11(
.
86
040
.11
0"9 3'
PROPELCER AND TRIM TAB'S
UNIT V
SHEET
N F.0 R M
ièrms and definitions (Transparescy 1),

.
,
A.
Propeller Device hair
Pitch-Distance traveled in one revolution
'
bides forispfonallmgr a ;craft throtigh ;ha.av;ater

S
fr"
c
PrOpeller diameter- Width off, the circle defined by the tips of the rotaiingblades
R.P M- Revolution per minute
Torque Twisting or rotary effect, produced b.y a propeller 11
*.
Starboard -Right side of a bqat looking forward from the .driver's,seat
Port-- Left side of vif,/ boat..eking forward 'from the driver's seat
Parts of the orOpeller and the trim tab (TransParency" 2)
LI,
Cotter, pin
pacer-
Propeller nut
1/4
Propeller,
, Propeller huh
a
F.
Theist bushing
CoMmon tyres òf propellers
Two
B
Throe blade
,
.
(NOTE For pecial app1.ication, four bi le and five blade P e 0 lie I he'S are used
to gain hr,eate' thru. t
)
87 ow
94
4
sai
INFORMATION SHEET
Ite
r.
Kinds of materials used to make prope'ller.1

Cast bronze
.A
A
Cast alltiminum alloy
i
1
P lastk
C.
(N0TE.
.../
,---
I,
-,
Plastic is used mostly on small, outboards )

,,
Stainless steel, Teflon cover ',(SST) ".
V
4
Purposes of, the 'trim tab.

A
B
Overcomes .the torque ofthe engine
H ps to acbieve better steering results
,
I.
lo
'it
PITCH AND. PROPELLER'DIAMETER

O
PIT
tonce
traS,eled .iri
one-
revolution
I
a
,
DIAMETER
.12
0-97^ `,/.4'
C
PARTS OF
w,
PROPELLER AND TRIM 'TAB
q.
4-7
'&
PROPELLER
HUB
.
1
COTTER -PIN
THRUSt BUSHING
PROPELLER
SPACER.
PROPELLER NUT
-4
TRIM TAB
90
TM4 7
-.404411*.
-4ft.
tir

UNIT V
,
a
'JOB SHEET 7---11-REMnVE, INSPECT, AND INSTALL A PFZWELLR

.
Tools and/ mate/la's

.1
"A.
Hand -tool assortment
B.
Parts tray
Anticorroston grease
Appropr (te service manual

I
Procedure
neutral and cii,sconne.ct Spark plug leads from spark plugs.
Put shift levdr
Remove cotter ptn and propeller nut
B.
MOTE. SOMEr1:71700eirerr wi
'e
field by .a shear pin.)
C.
Remove propeller spacer and prteller
D..
Remove thrustii,bush4ng
(NOTEl 8e sure to check the position Of the<thrust" bus'hing at this time.)

1
Insplitts propeller for rucks, broken bladfs, and cracks/
(NOTE: Do not attempt to weld- a cracked 'or broken' p'ropell'er

i
i"
,,
1/4
Remove ,lminnyticks with a file

.
(NOTE. The aft side olOe-orerei4tPresipphilethe'other side is rounded.)

.
0-
44:
100
JOB SHEET #1
Check rubber slip clutch using a torque wrench" and compare with service,
manual for torque specifiCation 4Figure 1)
.
V
Some propellers will not have a rubber slip clutch:)
(NtCrTE
14
Torquing fixture
.4P
Lightly coat propeller shaft with anticorrosion grease

P
ii
Install propete reversing steps A through E
Check the correct position of the thrust bushing.)
(N011E
7.1
awiner--
11'
41
41.
Of
r

UNIT V
JOB SHE.ET =2 -REMOVE, INSPECT, INSTALL, AND 'ADJUST A TRIM TAB
T6oli- Hand tool assortment
Procedure
I I
:--
11
.-
Mark traillhg edge location 041 cavitation plate and remove plug Which is
located directly above trim tab (Figure .1)
Trim retainer
screw cap
Plug
Trailing edge
qt.
fi
Remove cap and loosen screw which h

. i.
1-louing (Figure 21 :
i
--,r4/'
---ir---,
r-*g.(NOTE Same triirr tab'-Itqrstr Vre
-tab through hole in drive
-,,
--.-- --R-.4.4-4.-.74,...2,,....,..._
.c. ......
-ion -the'...bottbm.
...
Cap screw,
r
1
ir
FIGURE-2
93
102
I
,
I
.
JOS SH E ET zt 2
,
C.
..
Clean recess area to assure metal-to-metal coriact between--drive and OW
fil!
i,
tab
(NOTE Do' not;Paint or place protectivedpating on the ,trim tab grits .

corrosion inhibit!' g valuer will be lost.). ;",
' s!. .
, g
,
.
gl- D Reptac. the.
tri
tab Ifs -IF-
an anodte stab' -in= an advanCead s ageof
deterioration
-..-.
Ihstall trim tab and secure in' ppsition

F:.
,Operate boat to desired throttle setting and turn steering'wheel to left and
rigilt, noting in which direction wheel turns more easily'

(NOTE If boat perfo'rrns satisfactorily, Wad but do' nit proceed on the,
following steps )
(CAUTION 'Put ignition

G
LoOsen
in
"off" position .5nd remove ,k41/s.)
trim. tab cap screw

IND
'H
If steering Wheel turns more easily to left, position trailing edge on trim
tab td left (Figure 3)
(NOT.. Make aajustrelents in small increments )
STARBOARD
tRIGHT),
FORE Or BOW
(FRONT
_4
,4C
AFT or STERN
PORE
FIGURE 3
I.
.
11 steering Whole I
(REAR)
(LEFT)
turns more easily to right, position trailing edge on trim
tab to right ( igure 3)

1.!
Tighten cap screw
K.
Operate boat to check Nihon setting and readjust trim tab, if necessary
p
.4
I-
94
<
r
0-103
P
PROPELLOR AND TRIM TAB
I.
:*
NAME
.0111
TEST
.
1
f
,
.4
Match the terms 9n the right to the correct idefirirtion$.

a
-1/11tdth Of the cirrcledelined by the fip5:....,

-of the totatIng -bla-des-.__
rr
Pitch;
.
V.
.._
,.-.,
c.
,<
_____.
dr.
Propeller,
b.
diameter
,
Left 'side of a boat looking forwa.rd frbm

the driver's seat
,
d.
propeller\,
3'.
/ ,
4 R P.M.
Twisting or rotary effect produCed by a

.
propeller
\.
;.
Revolution Per minute
p.
N Device having blades for propelling a

craft thrc-)ugh the water
Torque
Right side of a boat looking forward

from the driver's seat
Distance .traveled Ire one revolution,
v.
.,
,
Starboard
Port
f.
IMP
2.
Identify the parts of the propeller and the trim tab.
'
5
.11(
AS
104
Warne fhe two common types of propeller's.

r
a
.
_b.
List Ole four.kinds, of materials Iiipsed to Fnakfpeopellers.--
-c
I-
--e
.6.
4
c.
41
..
5,
List the purposes of the trim tab.
if
ip
a.
-b
1/emoastrate the ,ability to'

a.
Remove, inspeot, and install a propeller?
b.
Remove, inspect, iristall, and adjust'a -trim tab.
(NOTE. If these activities have not Ile vit accomplished prior tothe.....test, ask
en they should be,cMp(i_ted.)
your instructor
.
t ;
14,
v'
141181411.*****ra4.4")-'
'141i
I
#
PROPELLER AND,J111M TABS 0
,---
.1.1NIT. V.
I.
ANSWERS TO TEST
4
1.
.2.
b.
e.
b.
f..
g.
a.
Cotter .pin
b.
Spacer
c.
Propeller nut
d.
.Propeller' hub
e.
Propeller
f.
Thrust bushing
Trim tab
g.
.
3.
4. )
Two blade
a.
. tr.
Three blade
a.
Cast bronze
b.
Cast aluminum alloy

4
Plastic
*.
d. .*'Stainless steel, Teflon, cover (SST)

5.
a.
b
6.
Overcomes the torque of the engine

Helps to achieve better steering results
Performance skills evaluated to the satisfaction of the instructor
97*
11111,
_ _11
'21
V107
COOLING-SYSTEM
UNIT VI
UNIT OBJECTIVE
1'
After completion of this unit, the student should be able to identify the parts of the,
cooling system, discuss the operation of the cooling system, -and remoVe, inspect, find
ipstall 'a water pump and a thermostat. This knowledge will -be evidericed through
demonstration and 1314 scoring eighty-five percent on tlfg unit .test.
SPECIFIgOBJECTIVES
After completion of this unit, the student should" be able to:
1.
Allatdh terms associated with cooling systems to the correct aefiniti
2.
Identify the parts of the cooling system.
3.
Identify The parts of the water pump.
4.
Distinguish between impeller positions.
5.
Discuss the operation of a thermostat.
6.
Discuss the operation of the cooling system.
7.

a.
b.'
'Remove, inspect, and install- a water pump.

Remove, inspect, and install a thereto
4'
5,
0-109
4
1
V
At*
COOLING SYSTEM
UNIT VI
.
SUGGESTED ACTIVITFES
k
\ .. Instructor
ft
"""
A.
.
--
46B:.
Provide student with objective, sheet.
Provide student with infbrmation and job sheets.
C.
D.
II.
Make transparencies.
, Dlscuss unit and specific oFjectives.
E.
F.
Demonstrate and discuss the procedures outlined in the job sheets.
G.
Give test
&Kient
4
A.
Read objective sheet.
B.
C.
Corriplete job sheets.
D.
E.
Take test.
I.
Included in this 'unit:

A.
Objective sheet
Information sheet
C.
-.
1.
TM 1--Parts of the Cooling System
2.
.TM 2--Parts of the Water Pump
3.
M .3--Water'Pump I mpeVer Positions.
99
4..
' '4.
5.
TIK4.--Operation of Thermostat.
TM 5- -Operation of Cooling Systems
Job sheets
D.
1.
Job Sheet #1--Remove Inspect, and Insfall a Water Pump

Job Sheet #Q-Remove, Inspect, and .Install a Thermostat
1,1.
E.
Test
F.
Answers tol tesf
4,
References
A.
Johnson Outboard Motor Service Manual., Waukegan, Illinois: Johnson

Motors/Outboard Marine Corp., 1973. _ '',
,
B.
Outboard 'Motor Service Manual. Kansas City, Missouri: Abos Marine

Publications Division/Intertec Publishing corp., 1973.
I
.
Mercury Marine Service, Manual. Models -1966 ' 1976. Fond du 'ac,
Wisconsin: Mercury Marne Outboard/Brunswick Corp., 1976.
C.
D.
Miller, Conrad. Small Boat Engine. New Y-ork:.Stieridan House, 1970.
100
4I
-a
COOLING SYSTEM
UNIT, VI '--
I N FORMATION SHE ET
'is
A. kW at" eri puro'p--. F urrtp Jocated at top of aearcasg and operated directly by drive
shaft usincentrifugal or displacement Pumping action

,
...
Pump hOusing--Contains" the component carts of the water pump.
Centrifugal pumping action- -High speed impeller action which certnfugally
forces wear into the water jacket

Thermostat-Automatic device for regulating 'tempera ture \,vhich Opens or
closes 'the valve controlling the flown of coolipg water in tke engine
1
Displacement purnpini-3 ac''on -Low speed impeller action which displaces
water by each rotation of impeller

Water tube- Tube that transfers the water from the water Damp to the engine
,Nater lackets
G Water jacket- Outer casing around the engine cylinders that forms ti. space
*nermitting the circulation of water, for cinoling ,purooses
H.
4%,
I.
Parts..k' of the cooling system (Trarrsparency

jacket
Vilate7-
'Pressure contro valve
Therr14osta-t
Water outie-`,
by pass ty be
Er, intake
F.
g
C.. wait
III
rUMP
t.
Parts of The ,,:-.:dter pump (Tlansrdrencv 2)
A,
Putri,-) Tvotisinj
Insert
,v
-
101
112
,a
M
INFORMATION SHEET
A/
Impeller drive pin
.D.
Gaskets
E.
Face plate
IV
bons, (Transparency43)
Imp eller p
A.
LosoLA e --Impeller 'works as Pdisplacemertit pump
B.
High ipeed--ImpglIer works as a centrifugal pump
V.
Operation of the thermostat (Transparency 4)

When the, engine is cold, the thermostat shuts off the flow of water from
.A.
the engrne to the lake to allow quicker engine warm-up B.
VI.
When the engine is at operating temperature, the thermostat is open arid

allows the water to cirdu late through, the system
.
Operation of the cooling system ( Transparency 5)

A
Water pump pulls water from the lake
B.
Water pump forces water up to the engine
C.
Water is. circulated through the water jackets,
D.
Water is' pushed out the outlet and back into the lake'
.1
JP
I
-4
102:
4
aria
.
THE COOLING SYSTEM.
PART.
Alo
I+,
t
4TER JACKET
PRESSURE
CONTROL
VALVE'
THERMOSTAT
-WATER OUTLET
WATER BY -PASS TUBE
/WATER PUMP
WATER INTAKE, (Cold)
4.
.1 3a
..
0-115,
r-
PARTS OF THE WATER /PUMP,

.
'y1
'4,4f.
-,._'
.",
7 'Th.7firf
.a
.-
,;
PUMP HOUSING
-INSERT
t
IMPELLER
=
,
IMPELLER
.^
GASKETS
104
a
TM 2
..0.44
I.
.WATERPUMP IMPELLER POSIT.10i1S,
IMPELLER AY
,
a,
LOW SPEED,
.I-UGH SPEED
./
S.
(4'
6.
s
sok
-e<
'a
105
et- ,
TM 3
0-119
'OPERATION
THERMOSTAT
4'
'4
....
111
PRESSURE
t
CONTROL
VALVE
THERMOSTAT TO OPEN AT 150

.
WATER 150 F
.
OR LESS. GOES
OUTLET FOR WATER
BACK THRU PUMP
OVER 1509,
EXHAUST TUBE ,COOLING.
WATER PUMP
wit
WATER INTAKE (Cold)

t
.
106
ti
TM 4
ft*
N
OPERATION OF COOLING
WOW
WATER 13ì-PASS .
THERMOSTAT HOUSING.
J
a.' WATER 9.1 T L ET(
WATER OUTLET
'INTAKE MAis40141
CYLINDER HEAD
I.
WATER 'PUMP
r
INLET 't
107
-TM 5
4
0;1123
COOLING SWS,TE M
"sr
1"
JOB SHEET #1-.:REM'Ot, INSPECT_ AND;JNSTALL tok WATER. PUMP
Tools and materials
A.

-\
'B.
Gdsket sealer
,C.: Torque 'wrench
I I.
D.
Parts tray
Approwike service -manual

r'
Procedure
A:
B.
Disconnecr spark*galug wires from plugs

43emoVe inspection plate frOm exhaust housing to expose shift .ro
tdnnector, and remove lower .connector screw (Figure 1)
:
le
ExhaUst Housing
FIGURE 1
Disconnect: shift rod

(Not:E: On .engines that have. c rectric -start
may. b. 'necessary to 'rer'nove
starter' and then shift rod )

,
D.
%5criee a mark atio'g6rpse ,cross t9 adihtable trim 'tab so it can be

reinstalled in the Same position
.0!
'
124
JOB
so*
HEET #1
9:
Remoye' retaining screw and adjustable trite tab (Figure 2)

(NOTE: On s ome models it is not necessary to remove trim tab.)
''Exhciust HoUsing
Gearcase
Adjustabl
..ab
,
Retaining .tre.w
-FIQUSE 2
Scribe Mark
a
RemoVe screws avtaching gearcase. to exhaust housing,' and remove the
gearcase (Figure-'3)
Exhaust Housing
Two POryiand Two

Starboard 'Screws
Countersunk
Hex 4crew
9
Gearcase
Remove Trim Tab
FIG6RE 3
G.
Remove pum
bouSing screws tf igure 44
A.
ump Housing Screws
4.
0
FIGURE 4
4
109
I
r
.JOB SFIEET**t
.
.
3-I.
.
..
..
....
Slide purrip hous'ng and impeller off drjve shaft (Figure
5)
Pump' Housing
Impeller Pkite
B
ring Housing
GE4cet
,FIGURE 5
Clean for reassembly
J.
Inspect parts for wear, or damage'
K.
Reassemble and replace by reversing step A through
110
0-127
1.1
t.
t.
'4
COOLING SYSTEM
UNIT' VI
308 SHEET tt2 REMOVE. INSPECT, AND INSTALL A THERMOSTAT

46 I.
Tools and materiols

A.
a.
Gasket sealer
C.
Torque 'wrench
Parts tray
*Appropriate service manual,
II.
125F thermomelt stick
G.
163 F thermomel.t stick.
H.
Test tank
4.1
Procedure
A.
Install outboard in test tank
B.
Remove engine cover
C.
'Run engine until, it reaches norm operating tempera
D.
Check engine temperature with thermorn,elt stick (Figure 1)
re
low NDT. After engine reaches n ormal operating temperature, a 125F. stick
should melt, but a 163F. stick should not melt. If the cooling system
does not meet the specificatiori, the thermostat Mould be replaced.)
111
,
11,
o.
fir
JOB SHEET .#2
o Otlet,
eirooye kibso-e
kr -
it required
Rehaave the -thermostat cover retaining bolts
N Sgme thermostat covers Ave spring pressure.)

__
,,,
s,
-(4.-- Remove thermostat -con'trOl unit from the. cover

. o
"..
..
1 NOTE: The: thermostat control unit cannot be serviced. The thermostat

control unit should be replaced if q6estionable.)
Inspect pressure valve, valve seats, and gasket for leakage jiF,igure' 2)
Fit
,,
Pressure Valve
Thermostat Control Unit
Gasket,
Valve Spring.
-iv
FIGURE 2
Valve Seat
I.
Reassemble and ipstall by reversing steps E through H
112
6-129;<-
w
COOLING SYSTEM
UNIT, VI
NAME
TEST
,
'r
1.
:,
-.
' Match the terms. on the right tp the, correct definitions.

..,
,-
regulating
for
temperature which opens Of closes the
"a. Automatic
'
device
water in the engine
pUITTP
Pump
housing
Low greed, itn:peller action which disblaces
..
Centrifugal
Pumping action,
3.
.,
Pufnpt located at top of gearcase and

operated directly by drive shaft using
centrifugal' or displacement .pumping
action
-r
d. Tube that transfers the water from the
.water pump to the engine water jackets
-2.
water: by each rotation of impeller
'
Water.
controlling the flow pf Cooling
yalve
b.
1:
c# .
.i.
e.
speed
impeller
5.
Displacement
puMping ectib,n
6.
Water ube
which
centrifugally forces water into the water
jacket
High
Therms_ tat
4%
actidn
7.
Water
jacet
40-
f.
Outer casing around the engine cylinders

that forms a space permitting the
circulation of.water: for. cooling purposes
g.
Contains the component parts of the
a'
water pump
rr
130
2.
Identify the parts of the -cooling system.
"4.
/.
4
At
f
b..
g.
d.
f.
0-131
Identify the parts of
3.
,4
.
II :
iP44.
water pump.
V.
1
.,
4'
a
...
.,
4.
...
-t
.`
I.
4.:
,..
2.'
. #
..
'
.,
p.
a.
b.
#.
4,
d.
.
.
ill,
., . .
e.
,:
f.
c.
0,
I
Distinguish between Atie Impeller osit-ions by. placing"gn "X" next to the picts.ire
of the high speed impeller 'posi ori.

.." ".
.
ital
,,
..,
..
.
I
: 4
/
.
4',
b.
115
>.
,
;
a-n Discuss .the operatiOn 'of a othermostat.

,44
Discuss the 7:operVion 'of the cooling system.
7.
Demonstrate the. ability, to:

a.,
Remove, inspect; and install a water pump.
a
I
b. , Remove, inspect,
(NOTE. If these activities have not been accomplished

your instructor when they. should be completed.)
41
116
a
and install a thermostat.

ro the fest, ask
-s,,,
%
I
COOLING SYSTEM
UNIT VI,
f.%
ANSWERS TO TEST
',
"-
-2
..
-..
, -a.., -....,.........t..--,_,...t. ,,..

t
__E: __II-
.,
b.
d.
...,...;--, '
,<:
f-:-.
g.
.-__
''-
"'.
..
---'
-: r.
..4
1-
c.
__*
or"-
6 ,
.Water jacket
a.
b.
Pressures control valve
c..
Thermostat
d.
Water outlet
5C.
>.
Water by-pass-.tube
11
111
f.
Water intake
g.
Wathr pump
a.
Pump hotising
b.
Imperier
d.' Impeller drive pin

,e.
f.
,Gaskets
Face. plate
4.
-, Discussion should include:
5.
shuts off the flow

( g., ' leen the en'gine is cold, the,per..mdstat
.
. of water from
the engine to the lake to allow quicker engine warm-up
",'
...
b.'
When the engine is at operating temperaturp, the thermostat .15 open and
allows the.water tocirculate through the system
r%
.1
134
.1
6:
. .
'
i,
DiscusAkon should incli.ide:'

.
a.
-s-414'
. Water pump pulls water fronrthe lake
4
:-
-.--
.. -.
b.
Watef, puanp forcei water- up' to the engine
c.
Watcr is circulated thi-ough the water jacket;-
d.
Water
...
i pushed out the outlet an
7.,
..
back into the. lake.
..
,._;
P,e/formance skills evaluated to the satisfaction of the instructor,:

. I, "
:11
1
0
.
.0
'r
J.
1'
-*
VOL
118
4
.0-135.
'4
- MECHANICAL GEARCASE
UNIT VII
UNIT OBJECTIVE
After completion of this unit, the student ,should be able to match the terms to.the
definitions and identify. the parts of a mechanical gearcase. The student should also be
able to state the purposes Of the main parts and demonstrate the ability to disassemble,
reassemble, and service a one-piece end a two-piece mechanical gearcase*This.knowledge
will be evjdenced through 'demonstration and by scoring eighty-five percent on the unit
test.'
It*
SPECIFIC OBJECTIVES
4
%
After completion of this' unit, the student should be ,able to:
1.
Match terms associated .with the Mechanical gearcase to the correct

definitions.
2.
Identify the parts of a mechanical gearcase.
3.
I. 4:
State the purposes of the main parts of, the mechanical gearcase.
pi
.4"
...
i
a.
Ilk,
Disassemble, reassemble, and ser ice a ane-piece mechanical gearcoe.

.
b.
445."-
Disassemble; inspect, reassemble, and service a two-piece mechanical,

gearcase.
441
'
o- 1 3
MECHANICAL GEARCASE
UNIT VII
SUGGESTEIT ACTIVITIES
Instructor:
A.
PVide, student with objective sheet.
B.
Provide student with ipfo.cmation and job sheet's,
C.
'Make transpa'rencies.
Discuss unit and specific objectives.
Demonstrate and discuss the pr.ocedures outlled in the job sheets.
/'
G. -Give test.
H.
Student
A,
"Read objective sheet
B.
Complete job sheets '
D.
Take test.
I
444
.
[NST-R:4CT1ONAL MATERIALS
4
. rncluded in this unit:
A. -Objective sheet
B
Information sheet
6.
T nsparency masters
e
1.
TM 1- Drive Snaft"aind Shift Shaft
TM 2-- Propeller Shalt
120
tr
Job sheets
D.
410
tt--
1.
-,Job Sheet It 1D isakeetrible, Reasseitthle, and Service 'Om-Piece

Mechanical Gearcase
2.
Job Sheet #2 Disassemble; Inspect,) Reassetble, and Service. a
Two-Piece Mechanical Gearcase

Test
F.
An4ers to test
R eferen ces
Q.
MerPrr-7 Marine Service Manual. Models 1966

1976. Fond du Lac,'
Wisconsin Mercury Marine Outboard/Brunswick Corp., 1976.
1
B.
Outboard Motor Ser.v.4,,ce Manual Vol. 2. 6th ed. Kansas City, Missouri:
Abos Marine Publicatipn Division /Intertec Publishing Corp., 1973.
44139
#
MECHANICAL GEARCASE' .-
UNIT VII
,
INFORMATION "SHET
A.
Dot clutchMating collars or flanges with projecting lugs or. fingers whichinterlock when engaged
'(NOTE: ThiS is sometimes carted ,a srithrig clutch.)

Gearcase--Housing containing theparts of the transmission
C.
Backlash-Motion, betweeti.'a driving part and a driven part whi,ch does not,
cause motion of the driven p.,grt
(NOTE: This is also called lost motion or clearance between fWQ mating
surfa
.)
Piniorti ..gov-Gear on the r of the ,drive shaft.

16
E.
F.
Shims-Thin sheets used as spacers between two parts

Thrust washer Bronze or hardened steel washe( placed between two moving
Aprts
II.
Main parts of a mechanical gearcase (Transparencies') "and -2)

A.
Gearcase
B.' Shift shaft

'C.
Reverse locking cam,
P.
Bearings
E.
Drive shaft
F.
Pinion gear
Ca.
Shift carhgl
H.
Cdm follower
I.
Tapered, roller - bearing assembly
It
1'
INFORMATION SKEET
41
J.
Forward gear issembly
K.
Cross pin
L.
Retaining king
Dog-clutch'
,
1H.
0.
Reverse gear
P.'
Thrust washer
Q.
Bearpg carrier assembly
't
Shafts-Transmit the power frgm the engine to the propeller

Gear and bearing assemblies -- Transform the rotary.enerby of thdrive shaft
B.
into forward motion, of the bbat
r--,
a
Propeller shaft
Purposes 9f the main parts of the mechanical gearcase

A.
N.
'C.
Seals--.Retain lubrication and prevent Water from entering gear housing,.

.
_-:
a
.
wok., 123
40"
DRIVE SHAFT AND SHIFT SHAFT.

BEARING
SHIM
Alb
DRIVE SHAFT
REVERSE LOCKING CAM
te/
SPACER,-(4
LUBRICATION SLEEVE
WASHER,
OIL, SEAL
13
BEARING
410---'-PINION GEAR
BUSHING ASSEMBLY
701! RING
4). -77 P11)110N NUT
SHIFT. SHAFT
GAtT
SCREW
GASKET
$CREW
124
4
TIM 1
.
0-143
4
PROPELLER SHAFT
SHIFT CAM
CAM FOLLOWER
CROSS. PI
SLIDE
COMPRESSION N SPRING
SHIM
,
0
g
a
'Om
'TAPERED
ROLLER
BEARING
'T RUST WASHER
,.-ASSEMBLY
BEARING
SEARING
"4".13ING
'BEARING'
CROSS
PIN---\
BEARING CARRIER
..
ASSEMBLY
c,,
FORWARD
GEAR.
ASSEMBLY
RETAINING
.RING
DOCK
OIL SEAL
CLUTCH
PROPELLER
SHAFT
WASHER.
GEAl HOUSING
.
COVER
'REVERSE
THRUST HUB
-GEAR
A,
ASSEMBLY
OUPPVASHER
SPLINED
TAB WASHk
PROPELLER NUT
SHIM
TM 2
-125
0-1115'.!
4.4
14
MECHANICAL GEARCASE
UNIT VII
JOB SHEET #1-DISASSEMBLE, REASSEMBLE, AND SERVICE
A ONE-PtCCE VECHANICAL GEARCASE
21..
Tools and material{

A
Parts tray
B.
Appropriate service rribnua' I
C. Hand tool assortment

.
'D. "j ear puller

E
F.
Bench vise
Two blocks of wood
G; Reè-ommended gear lubridant

V
H:
Geafcase leak tester

wr'ench
wrench
I.
II.
Procedure"
A.
Remove- 15ropeller shaft

1.
Drain
------and
lubr'icant from gearcase by removing grease filler hole screw

air vent 'hole screw .(Figure 1)
(NOTE: Do not lose washer,)

11.
Flushing.Hole
F
FIGURE 1
.126
t
411.111.1MMIMFM1111
I
146. .
JOB SHEET .#1

2.
Replace washer and screws after draining
3:',
Remove propeller
4.
Remove, gearcase assembly from exhaust housing
5.
Set gegrcase. in vise in upright position with skeg held between

blocks of wood (Frgurg
.,
Wooden Brock
FIGURE 2
Viie
6.
'Remove water pump
7.
Check backlash between gear (Figure 3)

(NOTE Backlash sildtrid meet service manual specification; if not,
shimming will be required during.reassembly.)
FIGURE 3
JO
. 11
127
0-147
JOB SHEET #1
.
~bend r or talq washer
8..
Remove hlegica,se cover washer (Figure 4)
92
(NOTE: Some geakase covers are left-hand thread, and some
gearcases do not have covers but are positioned-by two large trunc
rings.)
FIGURE 4
v't
!,
I
4,
1Q Q.
Place propeller shaft in vise, between iwb pieces of wood and

remove bearing carrier assembly (Figure 5)
SO
4.
Cdirier
,Assemfly
Wood
Vice
FIGURE 5
12,8
C
'
JOB SHEET #1
11.
Remove reverse gear assembly and ball bearing from bearing

carries assembly (Figure 6)
Reverse Gear
Assembly
Bearing Carrie Assembly
""...*
FIGURE 6
12.
Remove "0" ring from carrier
13.
Press or tap roller bearing and seal from carrier (Figure 7)
Bearing C-0-7rier
Assembly'
FIGURE 7
B..
d shift shaft
Disassemble propeller sh
1.
etach retaining ring from dog clutch (Figure 8)

(NOTE: Do notol4rstretch or ring will lose its shape and tension.)
129.
0-149
ter
JOB SHEET
2.
. Remove dog clutch from 'prOpeOer shaft (Figure .9)
(NOTE: Do not lose cross pin and spring.)
Remove lower reverse locking cam from shift shaft" _hushing
Remove shift shaft bushing (Figur
'5.*
Remove shift shaft from gearcase assembly

shiftingcam )
(NOT Do not lose shifting
130
10)
sT
am
:150
JOB SHEET x1
jr
Remove drive shaft

1
2.
-- Place drive shaft in vise as close to gear assembly as possible
Bend back tab washer and remove screw from drive shaft pinion
gear (Figure 11)
-
..
Pinion Gear
Pinion Gear Screw
Forlarcl Gear
3.
Remove' drive shaft (Figure 121'

,
Some drive shafts have 'shims under the ball bearing.

Remember to reinstall these 'shims during reassembly )
(NOTE
ref
I4. yew
in Remove toward gear and beanng assembly
D.
,--
Reassemble mechanical gearcase by reversing disassembly procedures A, B,

and C
,
308 SHEET #1
E.
Service mechanical gearcase

1.
Pressure test gearcase (Figure 13)

itOPTE: Gearcase should hold about 16-18 pounds _pressure.
CheEk service manual specifications.)
2.
Fill gearcase with lubricant (Figure 14
Oil Level
(NOTE.: Replace vent plugs before removing filler hose.)
"S
FIGURE 14
132
'
r-
rJ
0-153
1
MECHANICAL GEARCASE
UNIT VII
.4.
INSPECT, REASSEMBLE, AND SIRVICE

A TWO-PIECE MECHANICAL GEARCASE
JOB SHEET-
Tools and materials

A.
Parts tray
B.
Appropriate'service manual
Bench Vise
Two blocks of wood
F.'
commended gear lubricant

Gea
se weak _tester
t
,Proceidure
Disassemble gearcase
1.
Drain lubricant from gearcase by removing grease fillerole screw
and air vent hole screw (Figure
(NOT', Do not lose washer.)
Vent
!Slug
r.
41.
Fill -Drain Plug
133
1)
fro
JOB' SHEET #2
Replace washer and screws after drainingpropeller
3..
4.
Remy exhaust housing cover plate to expose shift rod connector

.
(Figur 2)
11.
r CURE 2
lower Connector Screw
E.
Remove lower.connector screw (Figure 2)
(NOTE: This is not used on all -models.)

.1
.
A
gearcase assembly from exhaust housing
6.
F3emSce
7..
Set gearcaie in vise in upright position with skeg held betWeen

blocks of wood
Remove screws attaching water pump to gearcase (Figure 3)
tse
134
0-155
I.
JOB .SHEET #2
Lift water pump from gearcase (Figure 4)
9.
mpeller Housing
Impeller
J
Impeller Plate
FIGURE 4
10. -
Turn thegearcase upside down and hold it in position by clamping
the drive shaft in the vise

11.,
t--11
Remove shift rod pivot pin and screvJs attaching gearcase halves
'(Figure 5)
tfl Level Plug,
FIGURE 5
eorcase Screws
Port and Starboard
,
e
Drain Plug
,Pivot Pin
135
101#e
156
JOB SHEET :4--2
12.
Separate gearcase halves (Figure 6)
13.
Swirly shifter lever and cradle out of way (Figure 7)
..
Shiftel: Lever
114
Lift propeller shaft with all components from the gearcase a
14.
assembly
Disassemble componentsikom
16.
Remove pin.ion gear and thrust yvasher
;
1
17.
.4'
Remove the gearcae from
...
Inspect gearcase
1-,
.
he .ciiive, shaftAv.
.11
Remove the drive shaft from the vise
18.
..
ropeller shaft ',.
15.
.4
B.
an
1
)
.
Check the driveiShaft, propeller shaft, and shift seals fOr damage
.%
b
..t,
13C
.
.
4.
.) JOB SHEET #i
ti
Remove the lower-to-upper geai-cise seal and oil retainer housing
2.
....
0,41
rtng
(NOTE: AlWays,
/ reassembling.)
f
3.
.r
replace
with
sitch Meals
new
ones when
O.
44
CheCk the.'propeller shaft gears and shift dog clutch for wear
-
GTE: Never attempt to mesh an old' worn gear' arth a new

ar; replace both 'gears in such d case.,1
Check bearings and bushings in the gearcase
4.
(NOTE:
will have
5.1
e bushings are not of the replaceable type; parcate
be replaced.)
.
'
i.
Reasserraible gearcase by reversing 'Isassembly procedure under section- A
D!
Service gearcase
.
.
C.
..
1, a'
,"
11$.4b.
Inspect watk tube and w

intake screen for obstruction or
kinks which-may restrict water flow
-
Pressure. test gearcase, (Pigur'e 8) .
(NOTE: Gearcase sld hold abbbt'.16-18 pounds pressure.

Check service manual specifications.)
'
V-
411
'
..tV
137
.
10
,
111#'-,
159
JOB SHEET #2
2.
51
Till gearcase with lubricant {Figure 9)
ot
Caution Do Not
Remove Pivot Pin
Oil Level
11.
it*
Oa
Main Plug
40.
401
.11A
,.
(NOTE Replace vent plugs before removing lubicant filler hose.)
-'5
s.
4.
M
I
5 -4
5.
,
1
e"
114
o. ,4
138
(
M
4
4
0- 159
I
'MECHANICAL GEARCASE
UNIT .VII
NAME
TEST
.
1.
tylatch the terms on the right to the corfect _definitions.

a.
Gear on the end of the drive shat
1.-
Dog clutch
2.
Backlash
3.
Pinion gear
b. Thin sheets used as spacerbetween two

parts
.
c. 'Bronze or hardened steep washer plac

betwpen twk..5pving parts
Gearcase
5..
r,
d. Motion between a driving part an
t'
5.
Shims
driven part which does not cause f,60tion
Thrust washer
of the driven part

.
e.
f.
Housing containing
transmission
is
the
of tae
lik
Mating co)lars or flanges with projecting

lugs or'
engaged
'fingers which interlock when
5.
160
2.
Identify the parts of the mechanical gearcase.

a.
I
b.
'4 4
f.
ti
4
ylP
4,
c.
''
I
6,
41,4
144
I
464
I,
'
.''State the purposes of Abe 'mair\_parts of the mechanical/ear_case.

a:
Shafts--
-so
Gear and
c.
Seals--
Demopstrate
4.
a.
.
fr).
earing assemblies--
he*
ability to:
'Dlsassemb e, reasserntite-;-and service a one-piece mechanical gearcase.

Disassemble,
--._,;(
gearcase' '
(NOTE
it
reassemble, and service atwo-piece mechanical
inspect,
...
If these. activities have not been accomplished prior to the teSt, ask
1;4
your instructor when theashould be completed.)
4 it
,
/I)
_142
'
---
--7-ms
0-163
MECHANICAL GEARCASE'
N,
UNIT V
1.
a.
3'
b.
c.
, a.
2.
*ANSWERS TO 'TEST
-\.
L- d.
e.
f.
0.
..
Gearcase
b.
Shift shaft
c.
Reverse locking cam
d.
6earing
,-
e.
Drive shaft
f.
. Pinion gear
g.
Shift cam.
h.
Cam follower
i.
Tapered - roller bearing assembly
j.
Forward' gear assembly
'',...
k.- Cross pin

I.
Retaining ring
m.
Dog clUtch
-P.m..n.
41.
Propeller shaft
o.'Reverse gear asse

O-
p.
Thrust washer
t
q.
3.
1#
'Bearing carrier assembly
a.
Shafts-Transmit the power from the engine to the propeller
Gear and bearing assemblies- :Transform the rotary energy of the drive shaft
into forward motion of the boat

I
c.
4.
Seals-Retain lubriCation and prevent water from.'
Performance skills evaluateetto the satisfaction of the instructor

'it
.
()
ring gear housing
143
0-165
ELECTRICAL GEARCASE.
IJNIT VIII
N
UNIT OBJECTIVE
s,
After completion of this unit, the student,should be able to match terms associated with
the electrical gearcase and identify the parts. The student should also be able to list the
functions of the electrical 6,1 ft solenoids and demonstrate the ability to disassemble and
reassemble Vie electrical gearcate._This knowledge will be evidenced through demonstration
and by scoring eighty-five percent on the unit tat.

'
.SPECIFIC OBJECTIVES
After completion. of this Unit, the student should be able to:
ba
1.
Match terms associated with the electrical gearcase to the correct definitions.
2.
List the functions of theiielectrical shift solenoids.
.3.
Identi-fy the parts of the electrical gearcase.
Demonstrate the ability to.
4.
a.
Disassemble an electrical gearcase.
b.
Reassemble an electrical gearcase.
II
144
4
0-167
LECTRICAL GEARCASE
,
UNIT Will
Z-Th
Am.
-I
Instruct,
Ar Provide student with objective sheet.
i*
*OP
B.
Provide student with ,info matron and job sheets.
C.
Make transparencies
Discu3s unit and specific objectives
F.
Demonstrate and discuss the procedures outlined in ;lie job sheets.
G. -
Give test.
Student.
A.
Read objective sheet
B.
Study information sheet
Complete job sheets
.D
Complete activities assigned by, instructer
Ao,
Take test.
fit
Included in this unit

Objective sheet.
B.
Inforrriation sheet
C.
Transparency' masters
.
I
TM 1--Parts of Elgctrical Gearcase
1.
TM 2--Cutawy of Electrical Geal-case
14.5
A
168
D.
E.
Job sheet
1
Job Sheet =1 --,t1--Disassemble an Electrical Gearcase
Job Sheet -4t2--Reassemble an Electrical Gearcase
Test
Answers to test
II.
Service
Reterence Evinrude
Manual.
Milwaukee,
."-
Motors/Outboaril Marine Corp., 1974.
CO.
an,
146
Wisdonsin:
E vinrude
Yil
0-169
ECt 11,1 C A L GEARCASE
'N
,UNIT VIII
a.
INFORMATION SHEET
I.

A.
Oil pump Creates the oil pressure which shifts gears into neutral and reverse
B.
Trtiarc ring--Split ring that is snapped into a groove, used to hold bearing,
thrust washers, and gears in place
(NOTE: This is sometimes called a snap ring.)

C.
Ball check alvePart of oil pump that directs hydraulic pressure to the
correct passage
woo..
D.
Shift piston- -Part of oi! pump that places dog clutch -T thp selected gear
position
Functions of electrical shift solenoids

A.
R.
Ill.
Operate the casing and shift rod up, and 'down movemen.
,Operateffie ball check valves
Parts of electrical gearcase (Transparencies

A.
Upper and lovt) r solenoids
B.
Spacer
C.
Shift lead
D.
Casing
E.
Shift -rod
F.
Plunge
G.
Wave Washer
*it pump
I.
Seal band
J.
Seal
K.
Screen
147
and d 2).
0-171
PARTS OF AN ELECTRICAL GEARCASE

,
SHIFT
LEAD'i
COVER
O.
m
GASKET
0
WAVEWASHER
LOCKNU
PLUNGER
,.
.-
TRIM __,:,c
TAB
-7
;----
UPPER SOLENOID
--
,,.
5
z
SPACER
-j
N
;
.<
PLUNGER
LOWER SOLENOID
r-'SHIFT ROD4-SCREW
&
11&---CASING-
LCAP
-THRUST BEARING
-FORWARD GEAR
OIL PUMP
THRUST '
WASHER
0-RING
,
VALVES
,Abl AND LEVERS
St-BAND
THRUST WASHER
.-SEAL
VALVE HOUSING
GUIDE PIN
41.
SCREEN
TM 1
148
. 6-4143...
*
,_..
p- CUTAWAY
OF AN ELECTRICAL 6EARCASE
TOO OF PLUNGER -
,
PLUNGER FACE
SOLENOID FACE
UPPER PLUNGER
UPPER SHIFT ROD
UPPtR SOLENOID .
-
LOCKSCREW
LOWER SOLENOID
FLUSH TO 1/64" BELOW

TOP OF SOLENOID
.j
0-175.
ELECTRICAL GEARCSE,
UNIT VIII
JOB SHEET 41--DISASEMBLE AN* ;LECTik.ICAit GEARCASt
Tools and materials
I.
A.
II,
\and
tool assortment
B.
Parts tray
Approprite service manual
Slide hammers
No. 7 Truarc pliers
F.
Two 1/4' all thread slide hammer rods
Procedure
41,
A,
Disconnect battery
B.
Drain lubricant from gearcase
Remove propeller
nn
shift cable from motor cable (Figure 1)
SHIFT WIRE
ERMINALS
11,4 SLEEVES
A\
FIGURE 1
E.
Apply oil or .liquid soap !!( cable
-'
sleeve
(NOTE: This i done to ease its passage through hole, in exhaust housing
adapter when removing gearcase.)
F
Remove gearcase
G.
Pldce gearcase in a suitable holditii g fixture
1.50
It
...
ICJ
so'
-,
vs'
.
.
H.
Se t,
- JOB Si-lEET.#
mp and-Tearing housing (Fidure,
Ve.mQve I vpter'
.1
ro
DRI*ESHAF Ts.
5-TWO
--
ACK TO SACK
10
BtARII)IG
FiQUSING
AND SEAL
ASSEMBLY
-/EPtarr.r
a.
FIGURf,2
, L.--S
,.
..
'
ss.
ave washer.Figure 3)
Remove screw sholdin*9 solfenoid_coyer
I.
4
I
'FIGURP3
k
.,-
..
.Fo.
R,:obve sotqnoids .(Figure 3)
,n
K.
Remove bearing housg screws
L.
Using a slide hammer with a hooked end, pull bearing housing from-gear-case
N.._
..
--cfigv.47
**\
414
,"
4.
FIGURE 4
e
t,
,.
;#
8,
.--14#6114
gr.
.1
'Itke
0
'0-177
4e,
,
JOB. SHEET - #,1
111,
M.
40110
Remove TrUarc rings with Truarc

piers (Figure 5)
.
it.'
6,
w--
.
R
FIGURE 5.
ti
N.
Remove propeller shaft assembly (Figure 6)-
L
REVERSE
GEAR
THRUSH'
iTHRUST
WASHER,.
BEARA
THRUST
/WASHER
.
op
FIGURE
r
0.
I,
Remeivq pinion gear locknut (Figure 7)
1*
P.
Remove
pinion gear 4nd pull drive shaft' out of the gearcase
yip
11
11.
12
4,
f70
,
JOEY SHFET
e
II'
Q.
Remove oil pump frOm gearcese using twoslide hampers and 1/4: all thread
slide IlarnMer rods- (Figure .8)
.
<,
r-
4-
Disassemble 'oil pump
ti
Sr
Rpmove rubber oil seal, band, screw, and screen from front of
1.
ci
oii pump JFigalred.9)
FIGURE 9:
92299
Retrfove screws and valve h-ousing from front of pump (Ft
2.
10)
.1
FIGURE 10
4/*/
' 153
41k.
At
.6.,
ti
drIP
NB SHEET
Remoge reverse valve lever (Figure 11).0 4
ThiS is `1410a lever with the hole in it.)

.
to
o
FIGURE 11
ie
Hole
4.
ReMtve guieie pin, valve, arm,.and ball check valves (Figure 12)
FIGURE 12
lever
at
S.
Pin
Seats
Oft
Clea and inspett all parts for reassem
Ball valves
Y
ELECTRICAL GEARCASE
UNIT VIII.
11
JOB SHEET ^ #2 REASSEMBLE AN ELECTRICAL GEARCASE

4-I.
Tools and materials
A.
Hand tool. assortment .
B.
Parts tray.
o-
Appropriate service. manual'
Two 1/4"
all
thread guide rods
Appropriate lubricarTt
F.
II
Pressuregauge
Procedure
iA
A
i.
gs,serpb
1
.61 pump
In tall ball chta valve's and reattach the valve lever with guide
pin
2.
Lubricate pump gears
100TE Use lubricant recommended in service' manual for yotir

make and model of gearcase r.
3
4.
Install oil pump gears
n ;iiurrT and align the slots, on pump and
Install vale ou
valve ho4ng,...j
foriared gear, thrust -bearing, and t!'iru-st washers (Figure

1)
(NOTE: Surfaces of .pump gears and pump housing must be

parallel .when ,forward gear, thrust bearing, and washers 2,5
installed.)
7:AHRNcigTSBTVE*
FIGURE 1
-71.1-72
155.
+di.
182
-1
.
B.
JOB ,SHEET #2 '
6.
Install and 'torque screws as specified in service manual
7..
Install screen, band, and rubber oil
6.
tristall shift piston in pump
seal
Install oil pump 'using slide hammer
(NOTE. Be sure to align pin in front of pump Isel-nbly with hole in gearcase
housing.)
C!
Install' forward gear, thrustAbearing, and thrust washers'
D.
Install' drive shaft irr warcase =and secure pinion gear to drive shaft with
pinion nut
.
(NOTE. Chalk service. manual for correct torqu e.).
E.
F.
1.rtstall propller tget assembly
, Install bearing housing retainer p4ate in the gearcase

.
G.
H.
Install two Truarc retaining rings

Threacr.guide pins into the retainer p late (Figure 2)
'
.07
434
ti
FIGUR! 2
4*
4,
;
Install propeller shaft bearing housing and screws

(NOTE .Check
servrce manual for correct. torque.)
156
A`
0-183
4
JOB SHEET #2
Install thrust bearing, thrust washers, and shims (Figure 3).
FIGURE 3
K.
Adjust and ,;install solenoid'

1'.
Adjust tie solenoid plungers (Figure 4)
(NOTE: Consult service manualoi f justment specifics
2.
Tighten lower solenoid lodknut and upper solenoid locknut

I
-..
.(NOTE: Consult'
onsu service' manual for torque specifications.)
:
. .
3.4
Install lower solenqid and casing
(NOTE: Be sure, the solenoid seats properly in the gearcase

h q usi n .)
157
R.
184
a-
ar
JOB SHEET #2
4.
11
Install solenoid spacer (Figure -5)
FIGURE 5
"us
Install up as illustrated
5.
Install upar solenoid assembly with plunger and- shift rod

assembly into gearcase (Figure 6)
oe$
100
.Llpper solenoid
Green wire
FIGURE 6
Shift rod
Plunger
Lock nut
L.
Install wave washer, soleitoid cover, gasket; and. screws
M.
Install water pump
N.
Pressuie test gearcase
' 0.
et
Install gearcase on exhaust housing

st,
a0
15S
4
/-)
0-185
ELECTRICAL GEARCASE
UNIT wit
1
NAME
TEST
Match the terms on the right' to the correct definitions.
1.
a.
.4
1.
Part of oil pump that directs hydraulic

pressure to the correct passage
'pump
.
Truarc ring
b. Split ring that is snapped into a groove,

3.
used to hold bearing, thrust washers, and

gears in place
c.
Creates the oil pressure which shifts

gears into neutral and reverse
d.
Part of oil pUMP that places dog clutch

in the selected gear position
Shift piton
List the functions of the electrical shift solenoids.
2.
a.
b.
Identify the parts of the electrical gearcase.
3.
b.
c.
d.
e.
1
f.
9.
h.
159
Ball check
valve
c.
k..
1.1-0
e.
mod.

a.
semble an *ctrical gegcase.
Reasserribie an electrical gearcase.

.
-MOTE:- If these activities have 'not been accompiished prior to the test, ask
your instructor when they should be completed.)
.00
160
*so
ELECTRICAL GEARCASE
UNIT VIII
ANSWERS TO TEST
A
a.
b.
c.
1.
d.
'
2.
a..
Operate:the cas!ng and shift rod up and dban movement
b.
Operate the ball check valves
a.
Upper and lower .solenoids
b.
Spacer
c.
Shift lead
d.
Casing
e.
Shift rod
f.
Plungers
g.
Wave washer
h.
Oil pump
Seal band
Seal
k.
4.
Screen
Pertormaae skills evaluated to the-satisfaction of the instructor
0-189
FUEL SUPPLY SYSTEMS
UNIT IX
UNIT OBJECTIVE
,
After completion of this u_ nit, the student should be able to identify the parts. f the
outboard pressurized fuel syitem.

The student, should also be able to disassemble,
reassemble, and service. a fuel -system. This knowledge. will be evidenced through

SPECIFIC OBJECTIVES
After cogipletion of this unit the student should be able to:

1.
Match terms associated with the outboird fuel system to the correct
definitions.
. at
identify the parts of the outboard pressurized' fuel system.-
3.
Identify the parts of the primer bulbibf an outboard vacuurti fuel system.
4.
Identify the parts of the outboard vacuum fuel system.
5.
List five fuel system probtems which can cause an outboard to-perform
improperly.
6.
List. three .engine prbblems \rom improper fuel supply.
7.

a.
Disassemble, service, and reassemble a pressurized fuel system.
b.
Dissemble, service, anrreassemble a vacuum fuel system.
It
f
L
162-
4.
FUEL SUPPLY SYSTEM
UNIT IX
ft
---...
Instructor:
I.
--ir
A.
PrOvide student with objective sheet.
B.
Provide student with information and job sheets.
C.
Make transparencies.
.
/4'
D.
DISCIISS unit find specific ol;jec-tives.,
E.
F.
Demonstrate and, discuss the procedures outlined in the job sheets.
G.
Give test.
..-
1l. ( Student.
y
.,
,cf.
Read objective sheet.
B.
Stuery information sheet.
C.
Complete job sheets.
D.
--
4-
E.
,.
4,
Study related assignments given by the instructor
Take test
"V
I ticluded in this unit:
A.
Objec ve sheet
B.
Information sheet
C.
.
.
*
t
1.4.
TM 1--Parts .W044 Outboard Pressurized .Fuel System
2.
TM 2--Parts of the Primer Bulb
3.
TM '34arts of the Outboard Vacuum 'Fuel System

.,
163
'
192
D.
Job She ts
1.
Jodb Sheet t-'1--Disassemble, Service, and Reassemble a Pi;essurized
Fuel System
2.
II.
JOsb Shge.tzz.--Disassemble, Service, and Reassemble a Vacuum

Fuel System
E.
Test
F.
Answers to test
References:
A.
Mercury Marine Service Manual. 1966-1976. Fond du Lac, Wisconsiri:
Mercury Marine Outboard/Bruivick Corp.,

B.
Outboafd Motor Service Manual. 6th ed. Vol: 2. Kansas City, Missouri:
Abos Marine Publication Division/Intertec Publishing Corp 1973.
,
C.
Johnson Outboard Motor Service Mpnual Waukegan, Illinois"-Outboard

Marine Corp., 1975.
4
164
,ar
tr
. FUEL
SUPPLY SYSTEMS
UNIT IX'
<
"'
-
A'\ ts
INFORMATION SHEET
4
Term? and defmitions
I.
fir
pump-Pum2 which feeds-the fuel from the gas tan=k to the carburetor
n engine..
of
'
Primer bulb-Strbpie hand squeqed pUmp that instfres fbel in the carburetor
for starting the engine

c
*(NOT. The pumping action is necessary. only \Ag
ressure has been
r-eleaseT1 from the tat. The gas tank mutt be Vented when primer
, bulb
is used.)
1._
C.. Iressure feed-Special air press42 tube...connecting the fuel 'taniz with a
pressurized check vaive, attached to the engine crankcase wilich uses the
engine pressure to pressurize the gas tank
,
D.
Vacuum feed -Type of fuel-system with.' a Kcial vacuurQ pump which ;s

attached to the engine crankcase andtperated s by crankcaste pressure
---
(NOTE: Gas tank- must be vented
E.
Check \ialYeo-Valve which alhows passage- of, fuel in t ne direction only

.
'If!'
7.
...
A.
,,,
,ts-
0.
.
"Fuel line
,'..
Priming t ump4ior'nrimer belb
D.
6.
Pre;sure relief valve.
Air line
.. .
III'
G.
7.r.
folk
Presit4izeci ,crankcase valie

...
5uel pick-up tube
F.
0.
1.
.,
G.
ijE.
Part of the ,outboard pres'su_rized fuel-ssystem (TransP.arency.; "1

A.
,.
. conetor
n
.*-
...
Parts of the prikier.bulb (Transparency 2)

A.
Clamps
1P.
165
4
-----
4
ION. SHEET
IN FO R
B.
Checklvalve assembi
'A
0
C.
Primer bulb
D1,
Check valVe body
fi
IV.
Parts of the outboard vacuum fuel system (Transparency -3)
A. -.Primer bulb
yo#
ars
Housing assembly (fuel connector)
C.tVent assembly
4
V.
SD.
Riel
Fuel system problems causing 'improper performance

rn
--A Onadequate air vent irr fuel tank

B.
InadeqtAate fyel line size
C.
pfalkged
D.
Clogged or too small filters
or lealcing fuel line

111-
-E.
Faulty f44 pump
r.
VI. ***Engine problems from improper fuel

A.
sup*
Motor run leans
a.
.(II,PTE This can cause excessive heat build\L\.,ip in the engine.)*

B.
Loss of RPM
C.
Piston and 'cylinder scoring
S1
.0
rFr
44
0-195
PA'
OF. THE OUTBOARD
.PRESSURIZED FUEL SYSTEM
.4.
/..
CCARBURETOR
FUEL LINE
FUEL LINE
MOTOR
..........
PRIMING PUMP
OR PRIMER BULB
...L.7;114
.z..,
PRESSURIZED
rif#
CRANKCASE VALVE
AIR LINE
BOTTOM COML.
TWIST CONNECTOR
AIR LINE
.#.41.411
101.
1111 1
*PRESSURE RELIEF VALVE

.
ECJEL.FiltK0*
TUBE"
,
FLOAT'
ILOAT, ARM
;1'411
.111T1
. 111:411
it
4
./
FUEL TANK
TM 1
0-197
r
111.
,`
rARTS9F TH PRIMO BULB
of
"...i
ri
CHECKVALVE
BO,DY,-.
.CHECK 'VALVE
ASSEMBLY
CL'AMP.S
,CLAMPS
v
......
ezzzsi,zalszaIr///
14,
zzzzi;---;11"N'As
wggi
ikC1111=01: 1111W
f.0.!:...VP/4ff"7";
'''/4 7 1 7.2".4 7/
P7A r.
./AriArdi
TO FUEL TANK
PRIMER "BULB
"t
I.
16.8
..
a
1'
PARTS OF .THE OUTBOARD VACUUM ;FUEL 'SYSTEM
.r.,..,,, ,.
,..,,,
.
,_
;,, ,,,,
..m.:_,,,....
4_
... ,.
VENT ASSEMBLY
.,:,...
HOUSING. AISEMBLY'
(FUEL CONKECTOR)
0-201
q.
FU,FL SUPPLY ,SYSTEMS
UNIT IX
CZASSEMBLE, SERVICE$ AND REASSEMBLE
A PRESSURIZED FUEL SYSTEM
.1.0B SHEET
I.
'Tools and matetials

A
Parts tray
Factdry s'er'vice -manual
'-land toot assortment
.
.
4,
Safety glasses
Prevecturee,
bisakse-r-lbre pres5rized fuel tan
Remove screws and gasket and .lift entire handle assemblycarefully out .of tank
_
.
(NOTE Do not bend float rod
'fp
Tat
Empty all gas out oVgas tank
>,
I
Be sure to keep room well ventilated. Dispose off.
Caut len
gasolint properly )
.amorir
filter is discolored or clogged replace filter assembfry.)

4
Remove.sCrews, galict, and primer cove/ from handle assembly
(.NOTE
".
,
.44.
Loosel coupitna .nut on ftiel pick-up tube to free filter head '
I.f
(NOTE Prirbei cover will haygya spring pressure
'""!i
Remove printer diaphragm valte and spring
5
a
.4r-(NTE
Check primer diaphragm for` any Boles. or stretch )

.
Check gas tank for leaks
6.
Solder all leaks with good grade of solder and flux, file
E
trnp()tlitand rikpaint red. Use a florneless method of,soidering..)
.
'I
-.
262
111
..
lik
:Reassemble system
install primer cover
1.
.-- L
(NOTE: Be sure prinier diaphragm valve and spring ale in" ioper
order.)
(Install. filter head on fuel pick-up
2.
qr
---...:..
(NOTE: Start coupling nut threads one

to avoid danger of cross- threading.)
two turns with lihger
Install handle assembly back on fuel tank
3.4
,
ii
(NOTE Be sure all joints are air tight)

.........
pt.
..
r.
re
;r
11
31
..%
40
--
.
t
Arr-
.
,
)72
..
r,
4:1. 4
'FUEL SUPPLY SYSTEMS
It
IT IX'
JOB SHEET =2- DISASSEMBLE, SERVICE, AND REASSEMBLE

A VACUUM FUEL SYSTEM
4% I
I.
Tools and materials

A
Parts tray
Factory service manual
Hand tool assortment.
Safety glasses
Procedure'
A
Disassemble vacuum fuel system
Remove filter cap assembly
4Remove screws and washers frOm fuel tank cover
3.
Remove fuel tank cover assembly
Remove filter and pick-up tube,

(INOTE
If filter is discolored or clogged replace filter assembly.)
Remove fuel lines and primer bulb
(NOTE Two different fill lines are

diameter, the other with 1/2"-)
B.
used
one with 7/16'
Reassemblg system
Inspect fordarnaged or inoperative parts

'
2.
Install fuel lines and primer bulb

(NOTE Apply alighticoat of adhesive to outside of check valve
assembly and fuel line stems Care must be exercised not to get
adhesive in stem hole or on valve face)
Install filter and pick-up tube
Replace fuel tank cover assembly
17
.-
44
a.
0-205
V
" FUEL SUPPLY SYSTEMS
UNIT.IX
NAME
)
TEST
Match the terms on the ,right to the correct definitions.
1.
a.
Valve which allows passage of fuel in one
1.
Fuel pump
2.
Primer bulb
3.
Pressure feed
direcin only
Aditi
b. Pump which feeds the fuel from the gas

tank to the/ carburetor of an engine
.
c.
Special air pressor tube connecting

fuel tank with a pressurized check valve;
attached to 'the engine crankcase which,:
uses the engine pressure to pressurize
the gas tank
d. Simple hand squeezed pump that insuips

fuel in the carburetor for starting the
engine
e. Type of
fuel system with a speCial

vacuum pump which is attached to the
engine
crankcase
crankcase pressure
and
11)
1'74
operated by
Vacuum feed
5.
Check valve .
206
'A* A*4-
2.
Idedtify the parts of the outboard, pressurized' fuel system.
a.
71%4_4%:--."
b.
e.
9.
d
Aiwzir
1;41/2
IOW
MEM
rdr!_-_,Ew yvr.r/
0-'
- -4
a.
e.
f.
b.
c.
--
d.
175
41#
3.
Identify the -Parts of the primer bulb of an outboard vacuum fuel system.
41111.11.1
"WORM
'177"Z ".:
Xr4e:42Z4/ral".7
17///7. " (z, r#0.0)
moggft%$'4%).ViaWAINOt
.<=1 TO FUEL TANK
TO ENGINE
b.
c.
.d.
'
'MP
176
208
4.
Identify the parts of the outboard' vacuum fuel system.

a
b.
c.
to
5.
I,
outboard to perform
five fuel system problems which can ceuseSan outboard
Lisp
'mproperly.
C.
40
d.
e.
, 6.
List three eogine p),:pblems from improper fuel supply.

a.
'
4
4r
'177
v,
88,
b.
**1
c.
7.
Demonstrate .themetbility to:

a.
DisasseMble, service, and reassemble a pressurized fuel system:
b.
Disassemble, service, andlreassemble a vacuum fuel system.
If these actiVities have not- been accomplished prior to the test, ask
%your instructor when they should' be completed.)
(NOTE.,
'dr
J
.1
178
- FUEL SUPPLY SYSTEMS
UNIT IX
ANSWERS TO TEST
d.
2.
a.
Fuel -line
'e
b.
.'',,b
.
'I;
ID
Priming, pump or pfrim'er bulb
'
Fuel, pic4 tube

.
c.
..
Pressure rallel valve .
d.
Air, line
.:',
,.
10
:-
-,
'14
Pressurized Senkdase" vale

i,
g.
Twist connector
a.
Clamps
3.:
I.
\
b. ACheck valve asseribly.
.
. "Pr
c:
Pti me r"bul b
ss
d."" - Cheek valve body

4.,
Primer bulb
a.
Itt
A'
i-lousing assembly (fyel connector)

45.
Writ assemi31-y
Ami
Fuel 'line
Inadbquate air vent irPfuel, tank

Inadequate, fuel line,size
h.
..
Damaged or leaking tuel line
d. ,* Clogged, or too small. flitch
Faulty fuel pur9j'y
179
.
,
21'2
6.
a.
Motor run lean
b._
Loss of RPM
c.
Pt ton and cylinder scoring
Performance, skills evaluated
7.
,the satisfacti.onc, of ,:the instructor.-
ge

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DOCUMENT 'non

Aid-America VocationalCureiculus Consortium,

180p.; Some diagrais may not reproduce well in:

AF-S0.83 Plus Postage. BC, Not Available frosj.EDRS.

Education: Visual Aids; Vocational Eddcation

This vonsorige-developed instructor's-manual for

gearcaie, electrical gearcase,A0 fuel supply Systems. Each

',sheets, job sheets, tests,' and answers to the.tists. Many of the

"PERMISSION TO REPRODUCE THIS

MATERIAL BY MICROFICHE ONLY

THIS DOCUMENT HAS BEEN REPRO.

THE PERSON OR ORGANIZATION ORIGIN.

TO THE EDUCATIONAL RESOURCES

Developed lity the

Pia Lindley, Texai.

Ann Benson, Executive Director

State Depaitment of Vocational and Technical Education_

Propeller and Trim Tabs

Electrical Remote Control Assembly

The Mid-America V,ocationalCurriculum ConsortiUm (MAVCC) was, organiteel for The

This publication is desigried to assist teachers in improving instruction.- As these

Instructional materials in this publication are written in terms of student performance

,product as indicated at the end of each instructional

Don Eshelby, Chairman

engine repair or the reparli of other small engines.

In addition, we would appreciate yourhelp. We check fr content quality, spelling,

Appreciation is extended to those indigiduals whocontributed their time and talents to

The contents of this publication wereplanned an d reviewed by:

Mid-America Vocational Curriculum Consortium Committee

Ponderosa& New Mexico

Mandan, North Dakota

Rapid City, South Dakota

Minot North Dakota

The arpount of material that ran be cowered in each class period,

Supplementary materials such as pamphlets or.filmstrips that must be ordered,

Each unit of instruction is based on performance objectives. These objectives ate

ilko forms: unit objectives, stating the subject

The skills which must 13etclemonstrated.

y Demo i-ist rate"

Additional Terms Used

Show your work

the studerft should be followed by a class discussioF

in the unit objective.

These may be given to the student for torripletion

class or used for homework

Test and Evaluation

:. RFLATED INFORMATION:, What

?UNIT I:. ELECTRICAL REMOTE CONTROL ASSEMBLY

Choke solenoid parts

Types of shift controls

Disassemble and reassemble

electrical remote control

Inspect and adjust safety

SerVice elec,/rical 'component

: parts of remote ,control

MECHANICAL REMOYECO,NTROL ASSEMBLY

Disassemble* and re'a\tiesoble

mechanical .rerhote control

Replace a nylon, barrel arid an

Adjust shift and throttle

Terms' and definitions

Parts of a hydraulic -tiit

Parts of. a manual tilt

hd: What the