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These types of manuals are how-to materials that provide simple repair instructions that aid boat owners in repairing and servicing their outboard without hassle. Honda Repair manuals contain information on engine upgrade specifications, colored wiring diagrams, advanced troubleshooting processes, as well as disassembly and re-assembly of the machine. Originally, factory service manuals are written to the approved marine specialists but, somehow, it finds its way into the hands of dealership technicians and other backyard mechanics. These handbooks contain information that covers the following areas: introduction, service specifications, maintenance, engine, electrical and ignition, fuel system, cooling system, safety, amongst others. Though they focus on total maintenance of the outboard, especially disassembly and re-assembly, workshop manuals also cover step-by-step instructions of maintenance, repair, and service aspects, diagrams, photographs, and actual illustrations of procedures. They also equip users with the necessary mechanical knowledge to diagnose and fix basic outboard issues before the availability of additional support. They provide details on how to maintain, repair, and service the outboard efficiently. They help outboard owners reduce the cost of maintenance. Through information on proper maintenance, they help users prolong the life of their vehicle. This is why it is advisable that you get yourself the right type of manual that will help you understand your motor properly and give it the required care. Contains everything you need to service or repair your ” Contains everything you need to service or repair your outboard motor. You will receive a link to download your manual shortly after purchase and a copy on CD mailed as well. Fully searchable and printable Adobe PDF format. ”. Owner-installation is not permitted by the Manufacturer. Rigging components are sold separately. Factory Warranty Begins on Date of Purchase.
Owner-installation is not permitted by the Manufacturer. Factory Warranty Begins on Date of Purchase.Sorry, no shipping on remote steering motors unless part of a pre-rigged boat and motor package (ships by boat hauler). Any Honda tiller-controlled motor can be picked up at our Warehouse Outlet Store in Waterford, CT. Defender recommends shipping to a commercial address with material handling equipment to minimize off-loading damage. Defender can ship to a local truck terminal if our carrier services your area. You will be prompted to read about and acknowledge these tasks prior to check out. For Customer Service, please click here Let us know you've found something wrongPlease mark each that apply.Please include your e-mail address below if you would like us to respond to your comments or questions. Not responsible for typographical errors. Any and all products may be withdrawn from sale at any time. Some products featured may be limited quantity. Today, it is one of the world leaders in this field, constantly presenting to customers the updated product lines of its products.These motors are distinguished by their very reliable uninterrupted work, which no one hasOn the contrary, Honda engines, as boatmen note, are capable of serving a very long time. Sometimes even for several decades.Most of all, of course, are the four-stroke outboard motors of this brand. They are the most powerful, safe and reliable boat. From basic maintenance and troubleshooting to complete overhauls, our Honda Four-Stroke Outboard manuals provide the information you need. The most important tool in your toolbox may be your Clymer manual -- get one today. Includes Honda Outboard Marine Repair ManualsIncludes Honda Outboard Marine Repair ManualsDates of Publications Vary By Manual. All Rights Reserved. Click Here for Details.Click Here for Details.Click Here for Details.Sorry for any inconvenience. Assures a working engine.
We install a deep cycle marine battery, fully rig steering components, complete electrical and systems check. We conduct a full system check on the motor, fill with oil, fluids, and fuel, then test run in a test tank. Once everything is tuned and prepared, a sea trial is performed with two Specialists to achieve ideal RPM-to-top-speed ratio, ensuring the boat gets on plane properly, and all systems operate on water. Afterwards a full detail is performed on the tubes, deck, and hull to be turn-key ready for the customer. We will email over a Power of Attorney to be signed and sent back. Once we have that, we mail out the temporary pink slip and stickers. Yamaha ships these brand new motors to us in the box ranging from 2.5-350 HP with ZERO water time, and FULL manufacturer warranty Usually it is just the shipping crate that is damaged.Cracks are rarely present on the exterior and if present are small in scale.When mechanical damage present, it is always repaired by Yamaha factory trained technicians at no additional charge.
Once fu el reaches the pump, interna l pump pressure force s the fuel from the pump The fuel syste m includes the following compo- through the fuel filter and into the vapor separator. Fuel Supply Fuel Supply Manifold The pump is moun ted to the va por separator and The fuel supply manifold supplies pressurized fuel. Each injector and its location on Fuel is supplied to the injectors by the fuel circula- the outboard is identified by the EMM. DO NOT tion pump and the fuel supply manifold. Perform with a fuel vapor separator must be shipped with a the following procedure in a well venti- vent line clamp inst alled. Mo nitor pr essure gaug e. FUEL SYSTEM TESTS Pressure should not drop below 15 psi (103 kPa). If outb oard does not run, prime WARNING IMPORTANT: fuel system and crank outboard; check circulation Use caution when working on any pres- pump operation;. Clean or r eplace Disconnect the battery cables at the battery. Disconnect the battery cables at the battery. Use a digital multimeter to measure the injector Use a digital multimeter with app ropriate adapter coil resistance. Install pected. This test does not confirm the p erfor- adapter fitt ings and a 36 in. Apply from the grooves of the isolator mounts. Nut Lock to mounting screws. Tighten screws to a torque of 24 to 36 in. Lubricate O-rings with outboard lubri- Disconnect the battery cables at the battery.NOTICE Fuel injectors must be installed in the correct cylinder locations. Use Evinrude Diagnostics Software to make sure that EMM programming matches injector positioning. The Injector Coefficients screen displays injector serial numbers for each cylinder. Ref er to th e instructions provided with the injector kit. Upload Coefficient Files to EMM If using Diagnostic Power Supply. DO contamination: NOT use strong ca rburetor cleane r or the hot Leaf plates must not be distorted. Apply Nut Lock to threads. Position reed valve ward.
Tighten in st ages to a final to rque of 60 to on reed plate an d inst all screws. OILING SYSTEM TESTS Air must be purged during the priming procedure. Always perform visual inspections IMPORTANT: to identify oiling system lea ks. Make sure th e oil tank is filled and oil supply is not contaminated. Do not lose the brass hose sup- and crankcase assembly allow fluid to move. Insert hose support in manifold end of hose. WARNING DO NOT insert distribution hoses IMPORTANT: into manifold without a hose support. To prevent accidental starting while ser- vicing, twist and remove spark plug leads. Use Evinrude 1. Oil pump connector Diagnostics sof tware to activate “Oil Prime.” Disconnect the electrical co nnector to the lo w oil Check oil flow through oil distrib ution hoses. Install o-ring on oil pump flange. Remove oil distribution h oses fro m oil manifold. Refer to Oil Distribution Hoses on p. 169. Remove oil from oil tank. Be sure oil pick u p assemb ly is IMPORTANT: positioned in front of oil t ank ba ffle to prevent interference with the LOW OIL switch. 008183 1. This hole provides cooling Water Pump and Intakes water for the tip of the exhaust passage. Be sure External water int akes mo unted in t he ge arcase to use the correct parts when replacing the water housing collect water a nd must su pply the inlet. Water flows through the valve to the cylinder head All models use a two-stage cooling system and byp asses the th ermostat. All wa ter flo ws design. Check for proper operation.Use care to Remove the thermostat cover and O-ring from cyl- avoid breaking threads. inder head. 008346 008347 Clean sensor threads, sensor, and sensor cavity. Remove spring, thermostat, and gasket. Refer to Cylinder Head PRESSURE RELIEF Installation on p. 207. VALVE SERVICING The pressure relief valve assembly should be ser- viced at the same time as the thermostat. Disassembly Remove screws and cove r from pressure valve assembly. Re place dama ged p arts.
Clean debris from housing and parts. 002442 Pressure Relief Valve Assembly Components Assembly Assembly is the rever se of disassemb ly. Pa y close attent ion when pe rforming the following additional tasks. WARNING Disconnect crankshaft position sensor (CPS) con- nector. Remove all spark plugs. Protect against hazardous fuel spray. Before starting any fuel system service, Advance throttle linkage to WOT. WARNING Protect against hazardous fuel spray. Before starting any fuel system service, carefully relieve fuel system pressure. Refer to Relieving Fuel System Pressure on p. 142. To prevent accidental starting while ser- vicing, twist and remove spark plug leads. POWERHEAD DISASSEMBLY Systems Removal To simplify reassembly and wirin g installation, lay out the various screws a nd clamps in the order of their proper location. Remove the electric st arter. Remove shoulder screw from shift arm and retain- ing screw from shift rod lever. Remove t he co tter pin and wa sher hold ing t he shift shaft (2-cylinder models). DO NOT Remove thermostat cover and thermostat assem- remove the screws. bly. Re fer to THERMOSTAT SERVICING on p. If nece ssary, use Wrist Pin Pressin g piston rings from pistons. WARNING Wear safety glasses to avoid injury. Use a punch to remove the housing seal. Discard seal. 002034 1. Upper oil seal 2. Upper main bearing 002053 1. Punch Remove the lower bearing seal housing. Inspect housing and replace if necessary. Remove the O-ring from cr ankshaft sleeve a nd inspect it. To remove the sleeve, use Slide Hammer, and press off the crankshaft.CLEANING WARNING Before inspecting or assembling IMPORTANT: To avoid personal injury, wear eye protec- powerhead, all internal components must be com- tion and rubber gloves when using Gel pletely clean and free of co ntaminants. The lower main be aring journal would only b e measu red if the bearing was For d imensions, refer t o SERVICE SPECIFICA- removed for another reason.
ASSEMBLY Inspect sleeve af ter inst allation. IMPORTANT: Proceed slowly. Make no forced IMPORTANT: Sleeve must not be used if surface is damaged. Lubricate upper main bearing with outboard lubri- Lubricate seal lip with Triple-Guard grease.Place seal o n crankshaf t wit h lip do wn and enclosed face up. Inst all the b earings in the small end of the connecting rod.Gap of retaining ring faces up, away from notch in piston. Slowly pull connecting rod matches dot on rod and that both dot s face fly- up to crankshaft and install bearing halves. wheel. Joint must be smooth with no step.Test the Gel-Seal II or replace it if the age of the tube cannot be determined. Insert bush- Apply Nut Lock to threads of throttle lever screw.Apply Triple-Guard grease to the shaft and detent of the sh ift lever assembly. Refer to Intake Manifold Service on p. 149. Install oil recirculatin g hoses and che ck valves. Refer to OIL RECIRCULATION DIAGRAMS on p. UPPER MOUNT The motor mount, washer, and IMPORTANT: SERVICING (3-Cylinder) screw are serviced as an assembly. Do not disas- semble. Removal Remove mount retainer screw. 39820 Installation 002069 Place mount assemblies in position, with flats fac- ing away from each other. Install gasket on exha ust h ousing. T o ensure pro per sealing, mating surfaces must be clean and dry. Install the Connect cooling water hoses to exhaust housing.Refer to RECOIL STARTER INSTALLA- slowly lower powerhead ont o exhaust hou sing. TION on p. 369. Guide into positio n over alignment pin at rear of exhaust housing. Removal WARNING Support the outboard with a suitable hoist. WARNING Replace locknut if definite resistance is not felt. Tighten starboard tilt tube nut to a torque of 45 to 50 ft. The exhaust wate r valve a nd the exhaust relief muffler can both be serviced without removing the exhaust housing. Remove screws and bracket holding valve to exhaust housing. Bring the exhaust housing into positio n with the stern bracket. 17526 1.