Evinrude E Tec 40hp 50hp 60hp 65hp Outboard Shop Manual 2007 – 2014 – PDF DOWNLOAD

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Evinrude E Tec 40hp 50hp 60hp 65hp Outboard Shop Manual 2007 – 2014

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EVINRUDE E TEC 40HP 50HP 60HP 65HP OUTBOARD SHOP MANUAL 2007 – 2014 – PDF DOWNLOAD:

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Evinrude E Tec 40hp 50hp 60hp 65hp Outboard Shop Manual 2007 – 2014

INTRODUCTION:

This manual is written for qualified, factory-trained technicians who are already familiar with the use of Evinrude®/Johnson® 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 identifying important safety messages. 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 notices 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 yourself, as well as the people around you.

• It is understood that this manual may be translated into other languages. In the event of any discrepancy, the English version shall prevail. To reduce the risk of personal injury, safety warnings are provided at appropriate times throughout the manual.
• DO NOT make 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 procedure. Human error is caused by many factors: carelessness, fatigue, overload, preoccupation, unfamiliarity with the product, and drugs and alcohol 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.

TABLE OF CONTENTS:

Evinrude E Tec 40hp 50hp 60hp 65hp Outboard Shop Manual 2007 – 2014

INTRODUCTION...................................................................  5
	ABBREVIATIONS USED IN THIS MANUAL..........................................  8
		Units of Measurement...................................................  8
		List of Abbreviations..................................................  8
	ENGINE EMISSIONS INFORMATION...............................................  9
		Manufacturer’s Responsibility..........................................  9
		Dealer’s Responsibility................................................  9
		Owner’s Responsibility.................................................  9
		EPA Emission Regulations...............................................  9
	MODEL DESIGNATION.......................................................... 10
	MODELS COVERED IN THIS MANUAL.............................................. 11
		Identifying Model and Serial Numbers................................... 11
	SERVICE SPECIFICATIONS..................................................... 12
	STANDARD TORQUE SPECIFICATIONS............................................. 14
	PRODUCT REFERENCE AND ILLUSTRATIONS........................................ 14
SPECIAL TOOLS.................................................................. 15
	DIAGNOSTIC TOOLS........................................................... 16
	UNIVERSAL TOOLS............................................................ 16
	ELECTRICAL / IGNITION TOOLS................................................ 18
	FUEL /OIL SYSTEM TOOLS..................................................... 19
	POWERHEAD TOOLS............................................................ 19
	GEARCASE TOOLS............................................................. 20
	TRIM AND TILT TOOLS........................................................ 22
	MANUAL STARTER TOOLS....................................................... 22
	SHOP AIDS.................................................................. 23
	NOTES...................................................................... 26
		Technician’s Notes..................................................... 26
		Related Documents...................................................... 26
INSTALLATION AND PREDELIVERY................................................... 27
	BOAT RIGGING............................................................... 28
		Remote Controls........................................................ 28
		Battery Installation................................................... 29
		Battery Switches and Multiple Batteries................................ 30
		Battery and Switch Wiring Diagrams..................................... 32
		Fuel System Requirements............................................... 34
		Cable and Hose Installation............................................ 36
	OUTBOARD INSTALLATION...................................................... 40
		Hull Preparation....................................................... 40
		Transom Measuring and Drilling......................................... 42
		Drilling and Hardware Diagrams......................................... 44
		Lifting the Outboard................................................... 46
		Steering Systems....................................................... 46
		Outboard Mounting...................................................... 48
	OUTBOARD RIGGING........................................................... 50
		Cable, Hose, and Wire Routing.......................................... 50
		Control Cable Adjustments.............................................. 50
		Electrical Harness Connections......................................... 52
		Water Pressure Gauge................................................... 52
		CANbus Connections..................................................... 53
	FUEL AND OIL PRIMING....................................................... 55
		Fuel Requirements...................................................... 55
		Fuel System Priming.................................................... 56
		Oil Requirements....................................................... 56
		Oil Injection Rate..................................................... 57
		Break-In Oiling........................................................ 58
		Oil Supply Priming..................................................... 58
	BEFORE START-UP............................................................ 59
		Gearcase Lubricant..................................................... 59
		Oil Level.............................................................. 59
		Trim and Tilt Fluid.................................................... 59
	RUNNING CHECKS............................................................. 60
		Engine Monitoring System............................................... 60
		Fuel System............................................................ 60
		Emergency Stop / Key Switch............................................ 60
		Remote Control Operation............................................... 60
		Start-In-Gear Prevention............................................... 60
		Tachometer Pulse Setting............................................... 60
		Water Pump Overboard Indicator......................................... 61
		Operating Temperature.................................................. 61
		Idle Speed............................................................. 61
		Break-In............................................................... 61
	PROPELLERS................................................................. 62
		Propeller Selection.................................................... 62
		Propeller Hardware Installation........................................ 63
	FINAL ADJUSTMENTS.......................................................... 64
		Trim Sending Unit Adjustment........................................... 64
		Trim Tab Adjustment.................................................... 65
		Dual-Outboard Alignment................................................ 66
MAINTENANCE.................................................................... 67
	INSPECTION AND MAINTENANCE SCHEDULE........................................ 68
	ANTI-CORROSION PROTECTION.................................................. 69
		Sacrificial Anodes..................................................... 69
		Testing Procedure - Continuity......................................... 69
		Metallic Component Protection.......................................... 69
		Exterior Finishes...................................................... 69
	COOLING SYSTEM............................................................. 70
		Flushing............................................................... 70
		Water Intake Screens................................................... 71
		Additional Maintenance................................................. 71
	LUBRICATION................................................................ 71
		Steering System........................................................ 71
		Swivel Bracket and Trailering Bracket.................................. 72
		Tilt Tube.............................................................. 72
		Throttle and Shift Linkage............................................. 72
		Propeller Shaft........................................................ 73
		Gearcase Lubricant..................................................... 73
		Trim and Tilt.......................................................... 75
	BATTERY AND BATTERY CONNECTIONS............................................ 76
	FUEL AND OIL SYSTEMS....................................................... 76
		Fuel Filter............................................................ 76
		Oil Filters and Oil Reservoir.......................................... 76
		Air Silencer........................................................... 77
		Hoses and Connections.................................................. 77
	SPARK PLUGS................................................................ 78
		Removal................................................................ 78
		Indexing............................................................... 78
	STORAGE.................................................................... 79
		Fuel System Treatment.................................................. 79
		Internal Engine Treatment.............................................. 79
		Additional Recommendations............................................. 80
	PRE-SEASON SERVICE......................................................... 80
		Outboard Mounting Bolts................................................ 80
		Gearcase Lubricant..................................................... 80
		Battery(s)............................................................. 80
		Power Trim and Tilt.................................................... 80
		Operational Checks..................................................... 80
	SUBMERGED ENGINES.......................................................... 81
		Engine Dropped Overboard (Not Running)................................. 81
		Engine Dropped Overboard (Running)..................................... 81
		Engine Dropped Overboard (In Salt Water)............................... 81
		Prolonged Submersion (Fresh or Salt Water)............................. 81
	NOTES...................................................................... 82
		Technician’s Notes..................................................... 82
		Related Documents...................................................... 82
ENGINE COVER SERVICE........................................................... 83
	UPPER COVER SERVICE........................................................ 84
		Latch Hook Installation................................................ 84
	LOWER COVER SERVICE........................................................ 84
		Lower Cover Removal.................................................... 84
		Lower Cover Installation............................................... 85
		Latch Handle Installation.............................................. 86
		Trim Switch Installation............................................... 86
ENGINE MANAGEMENT MODULE (EMM)................................................. 87
	DESCRIPTION................................................................ 88
		EMM Functions.......................................................... 88
		EMM Connections........................................................ 88
		LED Indicators......................................................... 88
	EMM INPUTS AND OUTPUTS DIAGRAM............................................. 89
	INTERNAL SENSORS........................................................... 90
		EMM Temperature Sensor................................................. 90
		55 V Circuit Sensor.................................................... 90
		12 V Circuit Sensor.................................................... 90
		Barometric Pressure Sensor............................................. 91
	EXTERNAL SENSORS........................................................... 91
		Air Temperature Sensor................................................. 91
		Engine Temperature Sensor.............................................. 92
		Low Oil Switch......................................................... 92
		Throttle Position Sensor............................................... 92
		Crankshaft Position Sensor............................................. 93
		Neutral Switch......................................................... 93
	INTERNAL EMM FUNCTIONS..................................................... 94
		ROM Verification....................................................... 94
		Idle Controller........................................................ 94
		RPM Limiter............................................................ 94
		Neutral RPM Limiter.................................................... 94
		Exhaust Water Valve Activation (60 HP)................................. 94
		Engine Monitor and Warning Systems..................................... 94
		Fault Code Creation and Storage........................................ 94
	ENGINE MONITORING SYSTEM................................................... 95
		System Self-Test....................................................... 95
		Service Mode........................................................... 95
		Engine Running......................................................... 95
	S.A.F.E. WARNING SYSTEM.................................................... 96
		Activation............................................................. 96
		Recovery............................................................... 96
	SHUTDOWN MODE.............................................................. 96
		Recovery............................................................... 96
	DIAGNOSTIC SOFTWARE FUNCTIONS.............................................. 97
		Communication.......................................................... 97
		Static Information..................................................... 97
		Dynamic Information.................................................... 98
		Stored Service Codes (Faults).......................................... 98
		Hard Faults............................................................ 98
		Persistent Faults...................................................... 98
		Static Tests........................................................... 98
		Dynamic Tests.......................................................... 99
		Oil Control Settings...................................................100
		Tiller/Remote Programming..............................................100
		Ignition Timing........................................................101
		TPS Calibration........................................................101
		Idle Speed Control.....................................................101
		Fuel Injector Servicing................................................102
		Reports................................................................102
		Software Replacement...................................................103
		EMM Transfer...........................................................103
	EMM SERVICING..............................................................104
		Installation...........................................................104
SYSTEM ANALYSIS................................................................105
	DIAGNOSTIC PROCEDURES......................................................106
		Visual Inspections.....................................................106
		Operational Inspections................................................106
		Troubleshooting........................................................107
	DYNAMIC TESTS..............................................................108
		Cylinder Drop Tests....................................................108
		Fuel Control Adjustment................................................108
		Inductive Amp Meter Test...............................................108
	EMM LED INDICATORS.........................................................109
		Key ON.................................................................109
		Starting...............................................................109
		Running................................................................110
	IGNITION OUTPUT TESTS......................................................111
		Ignition System Requirements...........................................111
		Wiring Inspection......................................................111
		Crankshaft Position Sensor (CPS) Test..................................112
		System Voltage Test....................................................112
		Static Ignition Test...................................................113
		Running Ignition Tests.................................................114
		Ignition Control Circuit Tests.........................................115
		Ignition Coil Tests....................................................115
		Capacitor Test.........................................................115
	FUEL DELIVERY TESTS........................................................116
		Fuel Pump Static Test..................................................116
		Fuel Injector Static Test..............................................116
		Running Fuel System Tests..............................................117
	EXHAUST WATER VALVE........................................................118
		Exhaust Water Valve Static Test........................................118
		Exhaust Water Valve Dynamic Test.......................................118
ELECTRICAL AND IGNITION........................................................119
	SERVICE CHART..............................................................120
	DASH CONNECTIONS, INSTRUMENT HARNESS.......................................122
	ELECTRICAL HARNESS CONNECTIONS.............................................123
		Engine Harness to Stator Connector.....................................123
		EMM J1-A Connector.....................................................123
		EMM J1-B Connector.....................................................124
		EMM J2 Connector.......................................................124
	GROUND CIRCUITS............................................................125
		EMM Ground Tests.......................................................125
		Additional Ground Tests................................................125
	FUSE.......................................................................125
	SENSOR TESTS...............................................................126
		Crankshaft Position Sensor (CPS) Test..................................126
		Throttle Position Sensor (TPS) Test....................................126
		Engine Temperature Sensor Test.........................................127
		Air Temperature Sensor (AT) Test.......................................127
	STATOR TESTS...............................................................128
		Stator Resistance Tests................................................128
		Stator Voltage Output Test.............................................128
	CHARGING SYSTEM TESTS......................................................129
		12 V Charging Circuit..................................................129
		55 V Alternator Circuit................................................130
	ELECTRIC START CIRCUIT.....................................................131
		Start Circuit Diagram..................................................131
		Start Circuit Operation................................................132
	ELECTRIC START TESTS.......................................................133
		Starter Solenoid Test..................................................133
		No Load Current Draw Test..............................................134
	REMOTE CONTROL SWITCH TESTS................................................135
		Key Switch Test........................................................135
		Neutral Start Circuit Test.............................................135
		Neutral Start Switch Test..............................................136
		Emergency Stop Switch Test.............................................136
	TILT/TRIM RELAY TEST.......................................................137
		Operation..............................................................137
		Test Procedure.........................................................137
	EXHAUST WATER VALVE TEST...................................................138
	SystemCheck CIRCUIT TESTS..................................................138
		Gauge Self-Test Check..................................................138
		CHECK ENGINE Circuit Test..............................................139
		WATER TEMP/ HOT Circuit Test...........................................140
		LOW OIL Circuit Test...................................................140
		NO OIL Circuit.........................................................140
	TACHOMETER CIRCUIT TESTS...................................................141
	FLYWHEEL AND STATOR SERVICING..............................................141
		Flywheel Removal.......................................................141
		Stator Service.........................................................143
		Flywheel Installation..................................................143
	TIMING ADJUSTMENTS.........................................................144
		Timing Pointer.........................................................144
		Timing Verification....................................................145
		TPS Calibration........................................................145
	ELECTRIC STARTER SERVICING.................................................146
		Starter Removal........................................................146
		Starter Disassembly....................................................146
		Starter Cleaning and Inspection........................................147
		Starter Assembly.......................................................148
		Starter Installation...................................................150
	CONNECTOR SERVICING........................................................150
		DEUTSCH Connectors.....................................................150
		AMP Connectors.........................................................151
		Packard † Connectors...................................................153
FUEL SYSTEM....................................................................155
	SERVICE CHART..............................................................156
	FUEL SYSTEM HOSE ROUTING...................................................158
	FUEL SYSTEM CIRCUIT DIAGRAM................................................159
	COMPONENTS.................................................................160
		Fuel Lift Pump.........................................................160
		Fuel Filter............................................................160
		Vapor Separator........................................................160
		Fuel Circulation Pump..................................................161
		Fuel Manifolds.........................................................162
		Fuel Injectors.........................................................162
	FUEL SYSTEM TESTS..........................................................163
		Fuel System Pressure Test..............................................163
		Pressure Regulator Test................................................164
		Vapor Separator Vent Check.............................................164
		Fuel Injector Pressure Test............................................164
		Fuel Injector Resistance Test..........................................165
		Circulation Pump Resistance Test.......................................165
		Lift Pump Pressure Test................................................165
		Lift Pump Vacuum Test..................................................166
		Lift Pump Diaphragm Test...............................................167
		Anti-Siphon Valve Test.................................................167
	FUEL COMPONENT SERVICING...................................................168
		Relieving Fuel System Pressure.........................................168
		Fuel Filter Service....................................................169
		Fuel Lift Pump Service.................................................169
		Vapor Separator Service................................................170
		Fuel Manifold Service..................................................170
		Fuel Injector Service..................................................171
		Intake Manifold Service................................................174
OILING SYSTEM..................................................................177
	SERVICE CHART..............................................................178
	OIL SUPPLY DIAGRAMS........................................................179
	OIL RECIRCULATION DIAGRAM..................................................180
	OILING SYSTEM CIRCUIT DIAGRAM..............................................181
	COMPONENTS.................................................................182
		Oil Tank Assembly......................................................182
		Oil Injection Pump.....................................................182
		Electrical Circuit (55 V)..............................................182
		LOW OIL Warning........................................................183
		NO OIL Warning.........................................................183
		Cylinder and Crankcase.................................................183
		Oil Recirculation System...............................................184
	OIL CONTROL SETTINGS.......................................................184
		Oil Priming............................................................184
		Oiling Rates...........................................................184
		Break-in Oiling........................................................184
	OILING SYSTEM TESTS........................................................185
		Oil Injection Pump Static Test.........................................185
		Oil Injection Pump Voltage Test........................................185
		Oil Injection Pump Circuit Resistance Test.............................186
		Oil Injection Pump Function Test.......................................186
		Oil Injection Fittings Flow Test.......................................187
		LOW OIL Sending Unit Test..............................................187
	OIL COMPONENT SERVICING....................................................188
		Oil Distribution Hoses.................................................188
		Oil Tank Assembly......................................................189
	NOTES......................................................................190
		Technician’s Notes.....................................................190
		Related Documents......................................................190
COOLING SYSTEM.................................................................191
	HOSE ROUTING AND WATER FLOW DIAGRAMS.......................................192
	COMPONENTS.................................................................193
		Water Pump and Intakes.................................................193
		Exhaust Housing........................................................193
		Pressure Relief Valve..................................................193
		Thermostat.............................................................194
		Block Venting..........................................................194
		Water Pressure Connection..............................................194
	OPERATION..................................................................195
		Cylinder Block / Cylinder Head Cooling.................................195
		EMM and Vapor Separator Cooling........................................195
	ENGINE TEMPERATURE CHECK...................................................196
		Software Method........................................................196
		Pyrometer Method.......................................................196
		Idle Operating Temperature Troubleshooting (Below Range)...............197
	THERMOSTAT SERVICING.......................................................198
		Disassembly............................................................198
		Inspection.............................................................198
		Assembly...............................................................198
	PRESSURE RELIEF VALVE SERVICING............................................199
		Disassembly............................................................199
		Inspection.............................................................199
		Assembly...............................................................199
	NOTES......................................................................200
		Technician’s Notes.....................................................200
		Related Documents......................................................200
POWERHEAD......................................................................201
	SERVICE CHART..............................................................202
	POWERHEAD REMOVAL..........................................................204
	POWERHEAD DISASSEMBLY......................................................206
		General................................................................206
		Throttle Linkage Removal...............................................206
		Shift Linkage Removal..................................................206
		Crankcase Disassembly..................................................207
		Cylinder Head Removal..................................................208
		Connecting Rods and Pistons............................................208
		Crankshaft Removal.....................................................209
	CYLINDER BLOCK CLEANING....................................................212
	POWERHEAD INSPECTION.......................................................213
		Cylinder Head..........................................................213
		Crankshaft.............................................................213
		Cylinder Bore..........................................................213
		Pistons................................................................214
		Piston Rings...........................................................214
		Bearings...............................................................214
	POWERHEAD ASSEMBLY.........................................................215
		Crankshaft Assembly....................................................215
		Pistons and Connecting Rods............................................217
		Cylinder Head Installation.............................................219
		Crankshaft and Connecting Rod Installation.............................220
		Crankcase Assembly.....................................................223
		Shift Linkage Installation.............................................225
		Throttle Linkage Installation..........................................225
		Final Powerhead Assembly...............................................226
	POWERHEAD INSTALLATION.....................................................227
		Powerhead Mounting.....................................................227
		Shift Linkage Adjustment...............................................229
	POWERHEAD VIEWS............................................................230
		Port Short Block.......................................................230
		Starboard Short Block..................................................230
		Port Dressed Powerhead.................................................231
		Starboard Dressed Powerhead............................................231
		Port Rope Start Models.................................................232
		Starboard Rope Start Models............................................232
		Front..................................................................233
		Rear...................................................................234
		Top....................................................................235
		Top, Rope Start Models.................................................236
MIDSECTION.....................................................................237
	SERVICE CHART..............................................................238
	TILT TUBE SERVICE..........................................................242
		Removal................................................................242
		Installation...........................................................243
	EXHAUST HOUSING SERVICE....................................................244
		Exhaust Housing Removal................................................244
		Exhaust Water Valve....................................................245
		Exhaust Relief Muffler.................................................245
		Exhaust Housing Installation...........................................246
	STERN BRACKET - Power Tilt Models..........................................247
		Stern Bracket Disassembly (Power Tilt).................................247
		Stern Bracket Assembly (Power Tilt)....................................248
	STERN BRACKET - Manual Tilt Models.........................................249
		Clamp Screw............................................................249
		Stern Bracket Disassembly (Manual Tilt)................................249
		Stern Bracket Assembly (Manual Tilt)...................................252
		Tilt Assist Cylinder...................................................255
	TILLER HANDLE SERVICE - Standard...........................................256
		Removal................................................................256
		Disassembly............................................................257
		Inspection.............................................................258
		Assembly...............................................................258
		Installation...........................................................260
		Throttle Cable Adjustment..............................................261
	TILLER HANDLE SERVICE - Long Handle........................................262
		Removal................................................................262
		Disassembly............................................................263
		Inspection.............................................................266
		Assembly...............................................................266
		Installation...........................................................270
		Control Cable Installation.............................................271
	MIDSECTION AND TILLER ADJUSTMENTS..........................................273
		Steering Friction Adjustment...........................................273
		Throttle Friction Adjustment...........................................273
	NOTES......................................................................274
		Technician’s Notes.....................................................274
		Related Documents......................................................274
GEARCASE.......................................................................275
	SERVICE CHART..............................................................276
	PROPELLER SERVICE..........................................................277
		Inspection.............................................................277
	GEARCASE LEAK TEST.........................................................277
	GEARCASE REMOVAL AND INSTALLATION..........................................278
		Gearcase Removal.......................................................278
		Gearcase Installation..................................................278
	WATER PUMP SERVICE.........................................................280
		Disassembly............................................................280
		Inspection.............................................................280
		Assembly...............................................................281
	SHIFT ROD ADJUSTMENT.......................................................282
	GEARCASE DISASSEMBLY.......................................................283
		Pre-Disassembly Inspection.............................................283
		Propeller Shaft Bearing Housing Removal................................284
		Pinion Gear and Driveshaft Removal.....................................285
		Shift Housing, Gear and Propeller Shaft Removal........................286
	INTERNAL GEARCASE SERVICE..................................................287
		Pinion Bearing Removal.................................................287
		Pinion Bearing Installation............................................287
		Shift Housing Disassembly..............................................288
		Shift Housing Assembly.................................................289
		Driveshaft Bearing Housing Service.....................................291
		Propeller Shaft Bearing Housing Service................................292
	DRIVESHAFT SHIMMING........................................................294
	GEARCASE ASSEMBLY..........................................................295
		Shift Housing, Gear, and Propeller Shaft Installation..................295
		Shift Rod Housing Installation.........................................295
		Pinion Gear and Driveshaft Installation................................296
		Propeller Shaft Bearing Housing and Gear Installation..................298
	NOTES......................................................................300
		Technician’s Notes.....................................................300
		Related Documents......................................................300
TRIM AND TILT..................................................................301
	SYSTEM DESCRIPTION.........................................................302
	ROUTINE INSPECTIONS........................................................303
		General................................................................303
		Reservoir Fluid........................................................303
		Manual Release Valve...................................................303
		Stern Brackets.........................................................303
	ELECTRICAL CIRCUIT TESTS...................................................303
		Relay Testing..........................................................303
		Trim and Tilt Motor Current Draw Tests.................................303
		Trim and Tilt Motor No Load Test.......................................304
		Trim Gauge Test........................................................305
		Trim Sender Test.......................................................305
	SERVICING..................................................................306
		Removal................................................................306
		Disassembly............................................................306
		Assembly...............................................................308
		Installation...........................................................309
	ADJUSTMENTS................................................................310
MANUAL STARTER.................................................................311
	SERVICE CHART..............................................................312
	RECOIL STARTER REMOVAL.....................................................313
	RECOIL STARTER DISASSEMBLY.................................................313
	RECOIL STARTER CLEANING AND INSPECTION.....................................315
	RECOIL STARTER ASSEMBLY....................................................315
	RECOIL STARTER INSTALLATION................................................319
	NOTES......................................................................320
		Technician’s Notes.....................................................320
		Related Documents......................................................320
SAFETY.........................................................................321
	TABLE OF CONTENTS..........................................................321
	MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM......................323
		Outboard Shift Systems and Safety......................................324
		Outboard Speed Control System and Safety...............................325
		Outboard Steering Control System and Safety............................326
		Outboard Fuel, Electrical System, and Safety...........................328
		Outboard Mounting System and Safety....................................331
		If weakened, parts could fail later on the water, when not expected....332
		Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety........333
		Outboard Emergency Stop System and Safety..............................334
		Summing up.............................................................336
	MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO FIX THEM......................337
		Handling Outboards.....................................................337
		Handling Lead/Acid Batteries...........................................341
		Gasoline - Handle With Care!...........................................342
		Hazardous Products.....................................................343
		Safety Awareness Test..................................................344
INDEX..........................................................................345
TROUBLE CHECK CHART............................................................353
	OUTBOARD WILL NOT START....................................................353
	OUTBOARD WILL NOT START....................................................354
	OUTBOARD HARD TO START.....................................................355
	OUTBOARD WILL NOT SHUT OFF.................................................356
	OUTBOARD STARTS AND STALLS.................................................356
	OUTBOARD STARTS, LOW MAXIMUM RPM...........................................357
	EXCESSIVE SMOKING..........................................................357
	OUTBOARD SURGES, RUNS ROUGH................................................358
DIAGRAMS.......................................................................359
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