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CHAPTER 1 GENERAL INFORMATION
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IDENTIFICATION NUMBERS
PRIMARY ID NUMBER
ENGINE SERIAL NUMBER
PUMP SERIAL NUMBER
HULL IDENTIFICATION NUMBER (HIN)
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SAFETY WHILE WORKING
GOOD WORKING PRACTICES
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DISASSEMBLY AND ASSEMBLY
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SPECIAL TOOLS
MEASUR ING
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REMOVAL AND INSTALLATION
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CHAPTER 2 SPECIFICATIONS
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GENERAL SPECIFICATIONS
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MAINTENANCE SPECIFICATIONS
ENGINE
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JET UNIT
ELECTRICAL
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TIGHTENING TORQUE
SPECIFIED TORQUE
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GENERAL TORQUE
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CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENT
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MAINTENANCE INTERVAL CHART
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PERIODIC SERVICE
CONTROL SYSTEM
Pivot shaft bushing inspection
Steering cable inspection and adjustment
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Throttle cable inspection and adjustment
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Choke cable inspection and adjustment
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Trim cable inspection and adjustment
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FUEL SYSTEM
Fuel filter inspection
Trolling speed inspection and adjustment
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Carburetor adjustment
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OIL INJECTION SYSTEM
Oil filter inspection
Oil injection pump air bleeding
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POWER UNIT
Spark plug inspection
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ELECTRICAL
Battery inspection
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JET PUMP UNIT
Impeller inspection
Bilge strainer inspection
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GENERAL
Drain plug inspection
Greasing point
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CHAPTER 4 FUEL SYSTEM
FUEL LINE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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SERVICE POINTS
Fuel filter inspection
Fuel cock inspection
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OIL TANK
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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SERVICE POINTS
Check valve inspection
Oil level sensor inspection
Oil tank inspection
Oil filter inspection
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FUEL TANK REMOVAL
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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FUEL TANK
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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SERVICE POINTS
Check valve inspection
Fuel level sensor inspection
Fuel tank inspection
Pipe joint inspection
Pipe joint installation
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CARBURETOR REMOVAL
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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CARBURETOR REMOVAL
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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SERVICE POINTS
Diaphragm inspection
Float arm inspection
Body assembly inspection
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Needle valve inspection
Jet and carburetor body inspection
High and low speed screws inspection
High and low speed screws adjustment
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Throttle valve synchronization inspection and adjustment
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Choke valve synchronization inspection and adjustment
Carburetor assembly
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FUEL PUMP
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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SERVICE POINTS
Fuel pump inspection
Filter inspection
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OIL PUMP
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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SERVICE POINTS
Oil pump inspection
Oil hose inspection
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CHAPTER 5 POWER UNIT
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REED VALVE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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SERVICE POINTS
Reed valve inspection
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EXHAUST RING
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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EXHAUST CHAMBER
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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MUFFLER
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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CYLINDER HEAD
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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SERVICE POINTS
Cylinder head inspection
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CYLINDER
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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SERVICE POINTS
Cylinder inspection
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PISTON
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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SERVICE POINTS
Piston pin clip removal and installation
Piston inspection
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Piston ring inspection
Piston pin and bearing inspection
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ENGINE UNIT REMOVAL
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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SERVICE POINTS
Shim removal
Mount bracket inspection
Coupling clearance inspection
Pilot water hose installation
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FLYWHEEL MAGNETO AND BASE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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SERVICE POINTS
Coupling flange removal and installation
Flywheel magneto removal and installation
Coupling flange inspection
Flywheel magneto inspection
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ELECTRICAL UNIT
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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STARTER MOTOR
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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SERVICE POINTS
Pinion inspection
Armature inspection
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Brush holder inspection
Cover inspection
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CRANKCASE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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SERVICE POINTS
Crankcase inspection
Crankcase installation
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CRANKSHAFT
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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SERVICE POINTS
Crankshaft inspection
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INTERMEDIATE HOUSING REMOVAL
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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INTERMEDIATE HOUSING
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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SERVICE POINTS
Coupling removal and installation
Bearing removal and installation
Bearing inspection
Coupling inspection
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Oil seal installation
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CHAPTER 6 JET PUMP UNIT
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JET PUMP UNIT REMOVAL
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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DEFLECTOR AND TRIM RING
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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NOZZLE AND DUCT
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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IMPELLER AND DRIVE SHAFT
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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SERVICE POINTS
Impeller removal
Drive shaft and bearing removal
Impeller inspection
Drive shaft inspection
Bearing inspection
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Oil seal and bearing installation
Impeller installation
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CHAPTER 7 ELECTRICAL SYSTEM
COOLING AND BILGE SYSTEM
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Bilge strainer inspection
Hose inspection
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ELECTRICAL COMPONENTS
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SERVICE POINTS
Spiral tube installation
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ELECTRICAL ANALYSIS 3
INSPECTION
Low resistance measurement
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IGNITION SYSTEM
WIRING DIAGRAM
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IGNITION SPARK GAP
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SPARK PLUG
SPARK PLUG CAP
IGNITION COIL
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ENGINE STOP SWITCH
CHARGE COIL
PULSER COIL
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THERMO SWITCH
CDI UNIT
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STARTING SYSTEM
WIRING DIAGRAM
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BATTERY
STARTER MOTOR
WIRING CONNECTION
FUSE
STARTER SWITCH
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STARTER RELAY
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CHARGING SYSTEM
WIRING DIAGRAM
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FUSE
BATTERY
LIGHTING COIL
RECTIFIER REGULATOR
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INDICATION SYSTEM
WIRING DIAGRAM
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FUSE
BATTERY
LIGHTING COIL
RECTIFIER REGULATOR
OIL LEVEL SENSOR
FUEL LEVEL SENSOR
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MULTI FUNCTION METER
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CHAPTER 8 HULL AND HOOD
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ENGINE HOOD REMOVAL
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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HANDLE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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SERVICE POINTS
Handle inspection
Handle switch installation
Handle holder installation
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TRIM GRIP AND CONTROL CABLE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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SERVICE POINTS
Trim control cable inspection
Grip guide inspection
Trim grip assembly installation
Trim cable adjustment
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ENGINE HOOD COVER
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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HANDLE COLUMN
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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SERVICE POINTS
Handle column inspection
Bearing inspection
Seal packing installation
Bushing joint installation
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ENGINE HOOD
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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SERVICE POINTS
Hood support inspection
Engine hood inspection
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STEERING CABLE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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SERVICE POINTS
Cable inspection
Jet pump side cable joint installation
Steering cable adjustment
Spiral tube installation
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THROTTLE CABLE AND CHOKE CABLE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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SERVICE POINTS
Cable inspection
Cable installation
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TRIM CABLE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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SERVICE POINTS
Cable inspection
Jet pump side cable joint installation
Trim cable adjustment
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SEAT, STORAGE BOX AND BATTERY CASE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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SERVICE POINTS
Seat inspection
Battery case inspection
Storage box inspection
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EXHAUST SYSTEM
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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SERVICE POINTS
Exhaust system inspection
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DECK
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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SERVICE POINTS
Ventilation system inspection
Hood packing inspection
Hood lock hook inspection
Hood packing installation
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GUNWALE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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SERVICE POINTS
Gunwale inspection
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MAT
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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SERVICE POINTS
Mat inspection
Mat installation
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HULL
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
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HULL REPAIR
Light scratching
Deep scratching
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Hull damage (punctured)
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insert nut
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Removing a graphic
Applying a graphic
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CHAPTER 9 TROUBLE ANALYSIS
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TROUBLE ANALYSIS
TROUBLE ANALYSIS CHART
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