Johnson J10RLSRD User manual

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BOMBARDIER
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http://motorka.org

BOMBARDIER
RECREATIONAL PRODUCTS
Bombardier Motor Corporation of America
Technical Publications
250 Sea Horse Drive
Waukegan, Illinois 60085 United States
tAMP, Superseal 1.5, Super Seal, Power Timer, and Pro-Crimper II are registered trademarks of Tyco
International, Ltd.
t Amphenol
is a registered trademark of The Amphenol Corporation.
t Champion
is a registered trademark of Federal-Mogul Corporation.
t Deutsch is a registered trademark of The Deutsch Company.
t Dexron is a registered trademark of The General Motors Corporation.
t Fluke
is a registered trademark of The Fluke Corporation.
t Frahm
is a registered trademark of James G. Biddle Co.
t Gasoila
is a registered trademark of The Federal Process Corporation.
t
GE is a registered trademark of The General Electric Company.
t
GM is a registered trademark of The General Motors Corporation.
t Loctite and Locquic are registered trademarks of The Henkel Group.
t Lubriplate
is a registered trademark of Fiske Brothers Refining Company.
t Oetiker
is a registered trademark of Hans Oetiker AG Maschinen.
t Permatex
is a registered trademark of Permatex.
t Sea-Lube
is a registered trademark of Wilcox Crittenden.
t Snap-on
is a registered trademark of Snap-on Technologies, Inc.
The following trademarks are the property of Bombardier Motor Corporation of America
or its affiliates:
Evinrude@
Evinrude@ E-
TECTM
Evinrude@ / Johnson@ XD30™ Formula
Evinrude@ / Johnson@
XD50™ Formula
Evinrude@ / Johnson@
XD100™ Formula
Evinrude@ / Johnson@ Genuine Parts
Extreme Pressure Grease™
FasTrakTM
Gel-Seal JJTM
Hi- Vis@ Gearcase Lubricant
Printed in the United States.
Johnson@
QuikStart™
SLO.W. ™
Speed Adjusting Failsafe Electronics (S.A.F.E. TM)
System Check@
Triple-Guard@ Grease
Twist-Grip™
2+4@
Fuel Conditioner
U/tra-HPFTM Gearcase Lubricant
© 2003 Bombardier Motor Corporation of America. All rights reserved.
TM, ® Trademarks and registered trademarks of Bombardier Motor Corporation of America or its affiliates. 1
http://motorka.org

SAFETY INFORMATION
Before working on any part of the outboard, read the SAFETY section at the end of this manual.
This manual is written for qualified, factory-trained
technicians who are already familiar with the use
of Bombardier Special Tools. This manual is not a
substitute for work experience. It
is an organized
guide for reference, repair, and maintenance of
the outboard(s).
This manual uses the following signal words iden-
tifying important safety messages.
~ DANGER ~
Indicates an imminently hazardous situa-
tion which, if not avoided, WILL result in
death
or serious injury.
~ WARNING ~
Indicates a potentially hazardous situation
which, if not avoided, CAN result in severe
injury or death.
6 CAUTION ~
Indicates a potentially hazardous situation
which, if not avoided, MAY result in minor
or moderate personal injury or property
damage. It also may be used
to alert
against unsafe practices.
IMPORTANT: Identifies information that will help
prevent damage
to machinery and appears next
to information that controls correct assembly and
operation of the product.
These safety alert signal words mean:
ATTENTION!
BECOME ALERT!
YOUR SAFETY IS INVOLVED!
Always follow common shop safety practices. If
you have not had training related to common shop
safety practices, you should do so to protect your-
self, as well as the people around you.
It is understood that this manual may be trans-
lated into other languages. In the event of any dis-
crepancy, the English version shall prevail.
To reduce the risk of personal injury, a safety
review is provided at the beginning of each sec-
tion.
DO NOT do any repairs until you have read the
instructions and checked the pictures relating to
the repairs.
Be careful, and never rush or guess a service pro-
cedure. Human error
is caused by many factors:
carelessness, fatigue, overload, preoccupation,
unfamiliarity with the product, and drugs and alco-
hol use, to name a few. Damage to a boat and
outboard can be fixed
in a short period of time, but
injury or death has a lasting effect.
When replacement parts are required, use
Evinrude/Johnson Genuine Parts or parts with
equivalent characteristics, including type, strength
and material. Using substandard parts could result
in injury or product malfunction.
Torque wrench tightening specifications must be
strictly followed. Replace any locking fastener
(locknut or patch screw) if its locking feature
becomes weak. Definite resistance to turning
must be felt when reusing a locking fastener. If
replacement is specified or required because the
locking fastener has become weak, use only
authorized Evinrude/Johnson Genuine Parts.
If you use procedures or service tools that are not
recommended
in this manual, YOU ALONE must
decide if your actions might injure people or dam-
age the outboard.
-

TABLE
OF
CONTENTS
INTRODUCTION .................................. 5
SPECIAL TOOLS AND SERVICE SPECIFICATIONS .... 17
INSTALLATION AND PREDELIVERY ................ 33
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . •. . . . . . .
.. 57
ELECTRICAL
................................... 81
IGNITION ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 111
FUEL SYSTEM ................................. 137
POWERHEAD
.................................. 169
MIDSECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 225
GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.. 253
MANUAL STARTER
............................. 291
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1
INDEX
.................................... Index-1
3
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INTRODUCTION
TABLE OF CONTENTS
INTRODUCTION
TABLE OF CONTENTS
ARRANGEMENT OF THIS MANUAL .................................................... 6
MODELS COVERED IN THIS MANUAL ...........................•...................... 6
IDENTIFYING MODEL AND SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6
MODEL DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7
MODEL LIST ....................................................................... 7
TYPICAL PAGE - A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8
TYPICAL PAGE - B . . . . . . . . . . . . . . . •. . •. •. . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . .. 9
TYPICAL PAGE - C ................................................................. 10
TYPICAL PAGE - D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . •. . . . . . . . . . .
.. 11
ABBREVIATIONS USED IN THIS MANUAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 12
UNITS OF MEASUREMENT • • • • • • • • . . . • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • . • • • • • . • .. 12
LIST OF ABBREVIATIONS ••••••••••••••••••.••••••••••••••••••••••••••••.•••.••.••.. 12
ENGINE EMISSIONS INFORMATION ................................................... 13
MANUFACTURER'S RESPONSIBILITY • • • • • • • • • • • • • • • • • • • • • • • • • . • • • • • • • • • • • • • • • • • • • • • • •• 13
DEALER'S RESPONSIBILITY. • • • • • . • • • • • • • • • • • . • • • • • • • • • • • • • • • • • • • • • • • • • • • . • . . • • . • • .• 13
OWNER'S RESPONSIBILITY •••.••••••••••••••••••••••••••..••••••••••••.••..••..•••. 13
EPA EMISSION REGULATIONS ••••••••••••••••••••••••••••••••••••••••••••••••••••••• 13
PRODUCT REFERENCE AND ILLUSTRATIONS .......................................... 14
SyMBOLS .........................•.............................................. 14
ELECTRICAL • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • . •• 14
VALUES ••••••••••••••••••••.•••••••••..••••••••••••••••••••••••••••••..••.•••. 15
NOTES ........................................................................... 16
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INTRODUCTION
ARRANGEMENT OF THIS MANUAL
ARRANGEMENT OFTHIS
MANUAL
This manual is divided into 13 major sections:
INTRODUCTION
1. SPECIAL TOOLS & SERVICE SPECS
2. INSTALLATION AND PREDELIVERY
3. MAINTENANCE
4. ELECTRICAL
5. IGNITION
6. FUEL SYSTEM
7. POWERHEAD
8. MIDSECTION
9.GEARCASE
10. MANUAL STARTER
11. SAFETY
WIRING DIAGRAMS
MODELS COVERED IN
THIS MANUAL
This manual covers service information on
Johnson 9.9 through 30
HP 2-Stroke models. Use
this manual together with the proper Parts Catalog
for part numbers and for exploded views of the
outboard, which are a valuable aid to disassembly
and reassembly.
This manual presents the U.S. values and dimen-
sions first and the metric values and dimensions
second, inside parentheses (
).
IDENTIFYING MODEL AND SERIAL NUMBERS
Outboard model and serial numbers are located on the swivel bracket and on the powerhead.
9.9/15 HP Swivel Bracket
1. Model and serial number
1
9.9/15 HP Powerhead
1. Serial number
6
000820
1
000821 25/30 HP Powerhead
1. Serial number 001006
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INTRODUCTION
MODEL DESIGNATION
MODEL DESIGNATION
PREFIX
STYLE:
J = Johnson
E = Evinrude
I HORSEPOWER LENGTH:
L = 20" Long
~
J 30 E L SR
r .---------'t_
~D-E-S-I-G-N-F-E-A-TU-R-E-S-:--~--~ MODELYR:
C = Counter Rotation
D = Evinrude E-TEC
E = Electric Start w/Remote Steering
F = Direct Injection
G= Graphite Johnson / Evinrude
J = Jet
M = Military
P = Power Trim and Tilt
R = Rope Start wlTilier Steering
S = Special Styling (paint color)
T = Tiller Steering
W = Commercial Model
V = White Johnson / Evinrude
I = 1
N =2
T =3
R=4
0=5
D=6
U=7
C=8
E =9
S=O
Ex: SR =2004
MODEL LIST
Model Number Start Shaft Steer Model Number Start
J10RSRD Rope 15" Tiller J25TESRA Electric
J10RLSRD Rope 20" Tiller J25TELSRA Electric
BJ10RHSRC Rope 15" Tiller J25ELSRM Electric
BJ10RHLSRC Rope 20" Tiller J30RSRE Rope
J15RSRS Rope 15" Tiller J30RLSRE Rope
J15RLSRS Rope 20" Tiller J30ELSRE Electric
J25RSRR Rope 15" Tiller J30MLSRC Rope
J25RLSRR Rope 20" Tiller
MODEL RUN
or SUFFIX
Shaft Steer
15" Tiller
20" Tiller
20" Remote
15" Tiller
20" Tiller
20" Remote
20" Tiller
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INTRODUCTION
TYPICAL PAGE - A
TYPICAL PAGE - A
GEARCASE
SERVICE CHART
A
Subsection title
indicates beginning of
the subsection.
Italic subheading
above Service Chart
indicates pertaining
models.
~~~\,"i~~'''.:
.o'AIIo... D B
E< (~l)J
24""6 In . Ibs / C B" ~.-:fJ
(27-41N~, ~ D .... -0
-" \ 1 I ._ ... ~I __ ~
.~t'n Ib : ~ ~"'- ' i: ~:
(6.8-9.5 N· m) '0' I I
F
('iT Fl ..... ·l : ~_ : i
s..Wa'erPUmp C-o 1
A.umb~/n·~~0 ~ : 1
--
: ; -~~ - j"A
Q \ 20-24 Fn. Ibs.
(27-33 N om )
A~ :' G ;' ., ~~ ~t f f
C - ~ 26-2.F' ~ b'~
~ (35-38N .",J .. "'"' 1- !
/ ~ : rr: ~~) ,
t: ~,,1 ~ I~ -
B- t( ~~ ~ ~ I i
~ ! ~ : 3~O~b'"
F
. '" "' .. J ~ ;fO:;~;::~ , ~t (4r-64N 'm) i I
- t~8( must tie cle an lind dry . J _"
J
...
i' "' ... ~ ..... Use Gearc~j~Lub,'canton threllds bnly,
.- __ --1 __ --, ___ , ~ -I U ' ..
Tightening torque for ist~ lrDfj - ~O ~l tq ..
tI ' StJ..HI".lbS.
." ..... ~ . (6.8-9.5 N'M)
a fastener. '. " ,~ (ifd.l) ff1) 111
. 1Jri) , ~ ( 1!?rr~:B & l~@
(£~ __ ~ ~ ~ r ' _" (JI Q
/ 1zQ..1.uln . lbs .' -' "- ..... ~ ~ B'
~ ,........- (13. 6·1fS3Nm) .... Jl
~ ,f,~ / /~ ... ~-.... f'B-f32 In lb •.
\i~ .. / I . (122-,. 9Nm)
(_L~ (,?fl'?".; .. !.)) )@) .. ' '--c~0;::-rre:;;s:-:p07n:-::d-;;in-:;g~to~
~ _____ ~J applicable letter in
'''-- ---,- ,.--//' exploded view of the
\./ Service Chart.
DSSl33
~ Page Number
8
Triple-Guard Grease
Gasket Sealing Compound
AdhesiveM Seslant
Moly Lube
Red Ultra
Lock
Blue Nut Lock
SlUt Lube Bearing Lubricant
Bold letter indicates
liquid product to be
applied to a surface
to
torque specifications.
Some units appear
as in. Ibs. Use
Exploded view of
Service Chart assists
in identifying parts
and positions
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TYPICAL PAGE - B
Section Title
Cable, Hose, and Wire Rou mg
Route all hoses, control cables, and wiring
through a protective sleeve or conduit into
the
boat and through the grommet.
Refer to the following diagram to ensure proper
positioning of rigging components
in grommet.
1. Fuel supply hose
2. Oil return hose
3. Oilsupply hose
4. Battery cables
5. Main wire harness (MWS)
6. Throttle cable
7. Shift cable
8. Oil tank sending unit harness
9. Water pressure hose
10 . Accessory charge wire
Model specific
illustrations
designated with
image captions
000084
Connect outboard main wire harness to boat m
wire harness.
Before installing electrical connectors, check tha
the seal
is in place. Clean off dirt from con-
nectors. Apply a light coat of ~~!!!I!!
to the seal. Push connec~rs
latched.
1. Seal
INTRODUCTION
TYPICAL PAGE - B
a water pressure gauge is to be used, install the
water pressure hose fitting
in the cylinder block.
Use Pipe Sealant with Teflon (PIN 910048) on the
threads of the hose fitting. Refer to installation
instructions supplied with gauge.
Route the water pressure hose through cover
grommet with
oil tank sending unit harness. Route
hose along battery cables toward the back of
the
powerhead. Use tie straps to fasten in place.
pressure fitting location: top , starboard side
of cylinder/crankcase assembly, below throttle
position sensor.
If temperature gauge is to be used, route sending
unit wire through grommet
with hose for water
pressure gauge. Follow the
path of battery cables.
Provide adequate length to reach cylinder head.
Refer to installation instructions supplied
with
gauge.
47
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INTRODUCTION
TYPICAL PAGE - C
TYPICAL PAGE - C
10
POWERHEAD
INSTALLATION
motor mount, washer, and
sll~lc:ed as an assembly. Do not disas-
39820
Installation
Place mount assemblies in position, with flats fac-
ing away from each other.
49557
Apply Extreme Pressure Grease to all sides of
retainer and install between mounts.
Apply Nut Lock to retainer screw, install the screw,
and torque
to 15 to 20 ft . Ibs. (20 to 27 N·m).
1. Mount retainer screw
272
a procedure
concerning a
particular model
Title indicates the
mstex
procedure specific to inner
V4 Models is
finished. From this
from this
pOint,
All Models
a new are concerned ensure
proper sealing, clean
and free of oil, grease, and foreign matter.
23497
Coat the driveshaft splines with Moly Lube. Do not
apply lubricant to end of driveshaft.
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TYPICAL PAGE - D
Two pulse hoses connect the pump to pulse fit-
tings
on the front of the cylinder/crankcase.
• V4 Models -cylinders 1 and 3
• V6 Models -cylinders 1 and 4
Typ ica l illu s tr a ti on for
lower puls e ho se of the oil sup-
V4 or V6 Mode ls lift pump. A pressure-sensing
switch monitors oil injection pressure.
Oil Injector-Manifold Cp.n:lnlllllQ.DlS~---,
• 40 V oil injector Cross r efe ren ces
• Oil distribution manifold direct read ers to
related to pi cs
• Oil pressure switch
• Pressure regulator (oil return hose)
• Oil distribution hoses
• Oil to fuel check valve
3 3
2
1
TYPICAL
1. Oil injector
2. Oil distribution manifold
3. Oil distribution hoses
4. Oil to fuel check valve
INTRODUCTION
TYPICAL PAGE - D
OILING SYSTEM
COMPONENTS
Oil Pressure Switch
The oil pressure switch is located in the oil injec-
tor-manifold and reacts to changes in oil manifold
pressure. The EMM supplies and monitors electri-
cal current to the switch.
components
numbered to
The switch opens or correspond to
oil manifold pressures: image
53 psi (365 kPa) (nominal) to close
43 psi (296 kPa) (nominal) to reopen
Service Code 38
A faulty electrical circuit or an inoperative pres-
sure switch activates service code
38 (no oil sen-
sor feedback
or lack of oil pressure) and the EMM:
Activates the System Check "NO OIL" light I I
1
Stores a service code
Section tabs allow for
Initiates S.L.O. W.
quicker reference
when thumbing
Service Code 39
through manua l
If no oil pressure
is detected during startup, the
EMM initiates an oil injector "recovery mode" to
pressurize the system. If inadequate oil pressure
is still detected after the recovery mode
is com-
pleted, the EMM:
Activates the System Check "NO OIL" light
Stores a service code
Initiates S.L.O. W.
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INTRODUCTION
ABBREVIATIONS USED IN THIS MANUAL
ABBREVIATIONS USED IN THIS MANUAL
Units of Measurement List of Abbreviations
A Amperes ABYC American Boat & Yacht Council
amp-hr Ampere hour ATDC after top dead center
fl. oz. fluid ounce ATS air temperature sensor
ft.lbs. foot pounds BPS barometric pressure sensor
HP horsepower BTDC before top dead center
in. inch-CCA cold cranking amps
in. Hg inches of mercury CPS crankshaft position sensor
in.lbs. inch pounds DI direct injection
kPa kilopascals ECU electronic control unit
ml milliliter EMM engine management module
mm millimeter ICOMIA International Council of Marine
N·m Newton meter Industry Associations
PIN part number MCA marine cranking amps
psi pounds per square inch MWS modular wiring system
RPM revolutions per minute NTC negative temperature coefficient
°C degrees Celsius OMS oil metering system
of degrees Fahrenheit PDP power distribution panel
ms milliseconds PTC positive temperature coefficient
IJs
microseconds ROM read only memory
n Ohms SAC start assist circuit
V Volts SAE Society of Automotive Engineers
VAC Volts Alternating Current SYNC synchronization
VDC Volts Direct Current TDC top dead center
TPS throttle position sensor
WOT wide open throttle
WTS water temperature sensor
12
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ENGINE EMISSIONS
INFORMATION
Maintenance, replacement, or repair of the
emission control devices and systems may be
performed by any marine
51 (spark ignition)
engine repair establishment
or individual.
Manufacturer's Responsibility
Beginning with 1999 model year outboards, man-
ufacturers of marine outboards must determine
the exhaust emission levels for each outboard
horsepower family and certify these outboards
with the United States of America Environmental
Protection Agency (EPA). An emissions control
information label, showing emission levels and
outboard specifications, must be placed on each
outboard at the time of manufacture.
Dealer's Responsibility
When performing service on all 1999 and more
recent Evinrude/Johnson outboards that carry an
emissions control information label, adjustments
must be kept within published factory specifica-
tions.
Replacement or repair of any emission related
component must be executed in a manner that
maintains emission levels within the prescribed
certification standards.
Dealers are not to modify the outboard in any
manner that would alter the horsepower or allow
emission levels to exceed their predetermined
factory specifications.
Exceptions include manufacturer's prescribed
changes, such as altitude adjustments, for exam-
ple.
Owner's Responsibility
The owner/operator is required to have outboard
maintenance performed to maintain emission lev-
els within prescribed certification standards.
The owner/operator is not to, and should not allow
anyone to, modify the outboard in any manner
that would alter the horsepower or allow emis-
sions levels to exceed their predetermined factory
specifications.
INTRODUCTION
ENGINE EMISSIONS INFORMATION
Tampering with the fuel system to change horse-
power or modify emission levels beyond factory
settings
or specifications will void the product war-
ranty.
EPA Emission Regulations
All new 1999 and more recent Evinrude/Johnson
outboards manufactured by Bombardier are certi-
fied to the EPA as conforming to the requirements
of the regulations for the control of air pollution
from new watercraft marine spark ignition out-
boards. This certification is contingent on certain
adjustments being set to factory standards. For
this reason, the factory procedure for servicing the
product must be strictly followed and, whenever
practical, returned to the original intent of the
design. The responsibilities listed above are gen-
eral and in no way a complete listing of the rules
and regulations pertaining to the EPA require-
ments on exhaust emissions for marine products.
For more detailed information
on this subject, you
may contact the following locations:
VIA U.S. POSTAL SERVICE:
Office of Mobile Sources
Engine Programs and Compliance Division
Engine Compliance Programs Group (6403J)
401 M St. NW
Washington, DC 20460
VIA EXPRESS or COURIER MAIL:
Office of Mobile Sources
Engine Programs and Compliance Division
Engine Compliance Programs Group (6403J)
501 3 rd St. NW
Washington, DC 20001
EPA INTERNET WEB SITE:
www.epa.gov
13
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INTRODUCTION
PRODUCT REFERENCE AND ILLUSTRATIONS
PRODUCT REFERENCE
AND ILLUSTRATIONS
Bombardier Motor Corporation of America
reserves the right to make changes at any time,
without notice,
in specifications and models and
also to discontinue models. The right is also
reserved to change any specifications or parts, at
any time, without incurring any obligation to equip
same on models manufactured prior to date of
such change. Specifications used are based
on
the latest product information available at the time
of publication.
The continuing accuracy of this manual cannot be
guaranteed.
All photographs and illustrations used in this man-
ual may not depict actual models or equipment,
but are intended
as representative views for refer-
ence only.
Certain features or systems discussed in this
manual might not be found on all models in all
marketing areas.
All service technicians must be familiar with nauti-
cal orientation. This manual often identifies parts
and procedures using these terms.
FORWARD
Nautical Orientation
14
SYMBOLS
Throughout this service manual, symbols are
used to interpret electrical troubleshooting results
or to assign values in drawings.
Electrical
When "00" shows on the meter face, no continuity,
or very high resistance,
is indicated. The symbol is
referred to as infinity.
When "V" follows a value
on the meter face, the
procedure
is measuring voltage.
v
DR4204
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When "n" follows a value on the meter face, the
procedure
is measuring resistance. n is the sym-
bol for ohm , the unit of measurement for resis-
tance.
DR4205
Values
When "-::;," precedes a value on the meter face, it
indicates your reading must be less than, or equal
to, the value shown.
~O.3n
Q) ad
DR4206
INTRODUCTION
SYMBOLS
When "2" precedes a value on the meter face, it
indicates your reading must be greater than, or
equal to, the value shown.
2::0.30
Q) ad
DR4207
15
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INTRODUCTION
NOTES
NOTES
Technician's Notes
16
Related Documents
Bulletins
Instruction Sheets
Other

SPECIAL TOOLS AND SERVICE SPECIFICATIONS
TABLE OF CONTENTS
SPECIAL TOOLS AND
SERVICE SPECIFICATIONS
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . • . . . . . . . . • . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . .. 19
ELECTRICAL I IGNITION • • • • • • • • • • • • • • • • • • • • • • • • • • • • • . . • • • • • • • • • • . • • • . . • • • • • • • • • • • .. 19
FUEL •••••••••••••••••••••••••.••••.•...•••••••••••.••••••••••••••••••••••.•••• 20
GEARCASE •• • • • • • . • • • • • • . . • • • • • • • • • • • • . • • • • • • • • • • • • . • • • • • • • • • • • • • • • • • • • • • • • • • •• 21
POWERHEAD
•••••••••••••••••.•••••.•••••••••••••••••••• •• ••••••••••••••••.•••• 23
STARTER •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 24
UNIVERSAL • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • . • • • • • • • • • • • • • . . • • • • •• 24
SHOP AIDS ..•.•...............•.................................................. 27
TECHNICAL DATA ................................................................. 30
STANDARD TORQUE SPECIFICATIONS ............................................... 32
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SPECIAL TOOLS AND SERVICE SPECIFICATIONS
SPECIAL TOOLS
SPECIAL TOOLS
Electrical/Ignition
Adapter, powerpack load resistor
PIN 507983 49797 1 2
1. Amphenol insert tool
PIN 322697
2. Amphenolpin removal tool
PIN 322698
3
3. Amphenol socket removal tool
PIN 322699
Amphenol connectors, jumper wire 73158 Analog multimeterPIN 501873
1. No. 16 wire, 8 in. (200 mm)
2. Pin, PIN 511469
3. Socket, PIN 581656
4. Shrink tube, 510628
Amphenol crimping pliers 30387 CD Peak reading voltmeter
PIN 322696 PIN 507972
Coil locating ring PIN 334944 32211
000798
49793 Digital multimeter PIN 500003 DRC7265
49799 Flywheel holder PIN 771311 42938
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