MAINTENANCE

Inspection and Maintenance Schedule

Before Each Use
1. Check that lanyard stop switch stops the engine.
2. Visually inspect the fuel system for deterioration or leaks.
3. Check outboard for tightness on transom.
4. Check steering system for binding or loose components.
5. Visually check steering link rod fasteners for proper tightness.
6. Check propeller blades for damage.
After Each Use
1. Flush out the outboard cooling system if operating in salt or polluted water.
2. Wash off all salt deposits and flush out the exhaust outlet of the propeller and gear
case with fresh water if operating in salt water.
Every 100 Hours of Use or Once Yearly, Whichever Occurs First
1. Lubricate all lubrication points. Lubricate more frequently when used in salt water.
2. Inspect and clean spark plugs.
3. Check fuel line filter for contaminants.
4. Check carburetor adjustments, if required.
5. Check corrosion control anodes. Check more frequently when used in salt water.
6. Drain and replace gear case lubricant.
7. Lubricate splines on the drive shaft.∗
8. Electric start models – Inspect battery.
9. Remote control models – Check control cable adjustments.∗
10. Remove engine deposits with Power Tune Engine Cleaner.
11. Check tightness of bolts, nuts, and other fasteners.
12. Clean fuel tank pick up filter.
Every 300 Hours of Use or Three Years
1. Replace water pump impeller (more often if overheating occurs or reduced water
pressure is noted).*
∗ These items should be serviced by an authorized dealer.

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Flushing The Cooling System

Flush the internal water passages of the outboard with fresh water after each use in salt,
polluted, or muddy water. This will help prevent a buildup of deposits from clogging the
internal water passages.
Use Flushing Attachment (P/N 44357A2) or equivalent.

WARNING
To avoid possible injury when flushing, remove the propeller. Refer to Propeller
Replacement.
1. Remove propeller (refer to Propeller Replacement). Install the flushing attachment so
the rubber cups fit tightly over the cooling water intake holes.

CAUTION
Never start or run your outboard (even momentarily) without water circulating
through the cooling water intake in the gear case to prevent damage to the water
pump (running dry) or overheating of the engine.
2. Attach a water hose to the flushing attachment. Turn on the water and adjust the flow
so water is leaking around the rubber cups to ensure the engine receives an adequate
supply of cooling water.

3. Start the engine and run it at idle speed in neutral shift position.

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4. Adjust water flow (if necessary) so excess water continues leaking out from around
the rubber cups to ensure the engine is receiving an adequate supply of cooling water.

5. Check for a steady stream of water flowing out of the water pump indicator hole. Con-
tinue flushing the outboard for 3 to 5 minutes, carefully monitoring water supply at all
times.
6. Stop the engine, turn off the water, and remove the flushing attachment. Reinstall the
propeller.

Fuel System
WARNING
Avoid serious injury or death from gasoline fire or explosion. Carefully follow all
fuel system service instructions. Always stop the engine and DO NOT smoke or
allow open flames or sparks in the area while servicing any part of the fuel sys-
tem.
Before servicing any part of the fuel system, stop engine and disconnect the battery. Drain
the fuel system completely. Use an approved container to collect and store fuel. Wipe up
any spillage immediately. Material used to contain spillage must be disposed of in an ap-
proved receptacle. Any fuel system service must be performed in a well ventilated area.
Inspect any completed service work for sign of fuel leakage.
Fuel Line Inspection
Visually inspect the fuel line and primer bulb for cracks, swelling, leaks, hardness or other
signs of deterioration or damage. If any of these conditions is found, the fuel line or primer
bulb must be replaced.
Engine Fuel Filter
Inspect the sight bowl for water accumulation and inspect the filter element for sediment.
Clean filter as follows.
REMOVAL
1. Hold onto the cover to prevent it from turning.
2. Turn off the sight bowl.
3. Pull out the filter element and wash it with cleaning solvent.

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INSTALLATION
1. Push the filter element (with open end toward cover) into cover.
2. Place the O-ring seal into the sight bowl and screw the sight bowl hand tight into the
cover.

a - Cover
b - Filter Element
c - O-Ring
d - Sight Bowl

3. Visually inspect for fuel leakage around the sight bowl by squeezing the primer bulb
until firm, forcing fuel into the sight bowl.

Corrosion Control Anode

Your outboard has a corrosion control anode installed on the gear case. An anode helps
protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded
instead of the outboard metals.
The anode requires periodic inspection especially in salt water which will accelerate the
erosion. To maintain this corrosion protection, always replace the anode before it is com-
pletely eroded. Never paint or apply a protective coating on the anode as this will reduce
effectiveness of the anode.

a - Anode

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Spark Plug Inspection

Inspect spark plugs at the recommended intervals.
1. Remove the spark plug leads by twisting the rubber boots slightly and pull off.

2. Remove the spark plugs to inspect and clean. Replace spark plug if electrode is worn
or the insulator is rough, cracked, broken, blistered or fouled.

3. Set the spark plug gap. See Specification Chart in General Information Section.

4. Before reinstalling spark plugs, clean away dirt on the spark plug seats. Install plugs
finger tight, and tighten 1/4 turn or torque to 20 lb. ft. (27.1 N·m).

Battery Inspection
The battery should be inspected at periodic intervals to ensure proper engine starting
capability.
IMPORTANT: Read the safety and maintenance instructions which accompany
your battery.
1. Turn off the engine before servicing the battery.
2. Add water as necessary to keep the battery full.
3. Make sure the battery is secure against movement.
4. Battery cable terminals should be clean, tight, and correctly installed. Positive to posi-
tive and negative to negative.
5. Make sure the battery is equipped with a nonconductive shield to prevent accidental
shorting of battery terminals.

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Fuse Replacement – Electric Start Remote Control Models

The electric starting circuit is protected from overload by a SFE 20 AMP fuse. If the fuse
is blown, the electric starter motor will not operate. Try to locate and correct the cause of
the overload. If the cause is not found, the fuse may blow again. Replace the fuse with
a fuse of the same rating.

Replace with a new SFE 20 AMP fuse.

Lubrication Points
Lubricate Points 1 through 6 with 2-4-C with Teflon or Special Lubricant 101.
1. Steering Friction Adjustment Shaft (Tiller Handle Models) – Lubricate fitting.
2. Swivel Bracket – Lubricate fitting.

3. Transom Clamp Screws – Lubricate threads.

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4. Tilt Tube – Lubricate fittings.

5. Lubricate the throttle and shaft cables, moving components and pivot locations.

5
WARNING
The end of the steering cable must be fully retracted into the outboard tilt tube
before adding lubricant. Adding lubricant to steering cable when fully extended
could cause steering cable to become hydraulically locked. An hydraulically
locked steering cable will cause loss of steering control, possibly resulting in
serious injury or death.
6. Steering Cable Grease Fitting (If Equipped) – Rotate steering wheel to fully retract the
steering cable end (a) into the outboard tilt tube. Lubricate through fitting (b).
Lubricate points 7 With Light Weight Oil
7. Steering Link Rod Pivot Points – Lubricate points.

6-b 6-a

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Lubricate Point 8 with Anti-Corrosion Grease or 2-4-C with Teflon.

8. Propeller Shaft – Refer to Propeller Replacement for removal and installation of the
propeller. Coat the entire propeller shaft with lubricant to prevent the propeller hub
from corroding to the shaft.

Gear Case Lubrication

Gear Case Lubricant Capacity
Gear Case Ratio Capacity
2.25:1 8.8 fl. oz. (260.0 ml)

Draining Gear Case

When adding or changing gear case lubricant, visually check for the presence of water
in the lubricant. If water is present, it may have settled to the bottom and will drain out prior
to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance.
If water is noticed, have the gear case checked by your dealer. Water in the lubricant may
result in premature bearing failure or, in freezing temperatures, will turn to ice and damage
the gear case.
Whenever you remove the fill/drain plug, examine the magnetic end for metal particles.
A small amount of metal filings or fine metal particles indicates normal gear wear. An ex-
cessive amount of metal filings or larger particles (chips) may indicate abnormal gear
wear and should be checked by an authorized dealer.

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Draining Gear Case

1. Place outboard in a vertical operating position.
2. Place drain pan below outboard.
3. Remove fill/drain plug (a) and vent plug (b) and drain lubricant.

a - Fill/Drain Plug
b - Vent Plug
Checking Lubricant Level and Refilling Gear Case
1. Place outboard in a vertical operating position.
2. Remove vent plug from vent hole (a).
3. Place lubricant tube into the fill hole (b) and add lubricant until it appears at the vent
hole (a).

a - Fill/Drain Plug
b - Vent Plug
4. Stop adding lubricant. Install the vent plug and sealing washer before removing the
lubricant tube.

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5. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer.

Storage Preparations
Fuel System
IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a for-
mation of acid during storage and can damage the fuel system. If the gasoline be-
ing used contains alcohol, it is advisable to drain as much of the remaining gaso-
line as possible from the fuel tank, remote fuel line, and engine fuel system.
Fill the fuel system (tank, hoses, fuel pumps, and fuel injection systems) with treated (sta-
bilized) fuel to help prevent formation of varnish and gum. Proceed with following instruc-
tions.
1. Portable Fuel Tank – Pour the required amount of Gasoline Stabilizer (follow instruc-
tions on container) into fuel tank. Tip fuel tank back and forth to mix stabilizer with the
fuel.
2. Permanently Installed Fuel Tank – Pour the required amount of Gasoline Stabilizer
(follow instructions on container) into a separate container and mix with approximate-
ly one quart (one liter) of gasoline. Pour this mixture into fuel tank.
3. Place the outboard in water or connect flushing attachment for circulating cooling
water. Run the engine for ten minutes to allow treated fuel to fill the fuel system.
Protecting External Engine Components
1. Lubricate all outboard components listed in the Inspection and Maintenance
Schedule.
2. Touch up any paint nicks.
3. Spray Corrosion Guard on external metal surfaces (except corrosion control anodes).

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Protecting Internal Engine Components

NOTE: Before performing Steps 1 and 2, make sure the fuel system has been prepared
for storage.
1. Place the outboard in water or connect flushing attachment for circulating cooling
water. Start the engine and let it run in neutral to warm up.
2. With engine running at fast idle, stop the fuel flow by disconnecting the remote fuel
line. When engine begins to stall, quickly spray Storage Seal Rust Inhibitor into carbu-
retor until engine stops from lack of fuel.
3. Remove the spark plugs and inject a five second spray of Storage Seal Rust Inhibitor
around the inside of each cylinder.
4. Rotate the flywheel manually several times to distribute the storage seal in the cylin-
ders. Reinstall spark plugs.
Gear Case
Drain and refill the gear case lubricant (refer to maintenance procedure).
Positioning Outboard for Storage
Store outboard in an upright position to allow water to drain out of outboard.

CAUTION
If outboard is stored tilted up in freezing temperature, trapped cooling water or
rain water that may have entered the propeller exhaust outlet in the gear case
could freeze and cause damage to the outboard.
Battery Storage
1. Follow the battery manufacturers instructions for storage and recharging.
2. Remove the battery from the boat and check water level. Recharge if necessary.
3. Store the battery in a cool, dry place.
4. Periodically check the water level and recharge the battery during storage.

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