Old Outboard Motor Service Manual Vol. 2 30 HP and Above

The Old Outboard Motor Service Manual: Volume 2 by Clymer, covers engines from the following manufacturers:

• Buccaneer
• Chrysler, Commodore, Corsair
• Elgin, Evinrude
• Firestone, Fisher-Pierce
• Gale
• Hiawatha, Homelite
• Johnson
• McCulloch
• Mercury
• Scott, Sea Bee, Sea King, Sears
• West Bend, Wizard

Book Excerpt: Old Outboard Motor Service Manual: Volume 2: 30hp and above prior to 1969 CHRYSLER 35 TO 55 HP

COOLING SYSTEM Water Pump. All motors are equipped with a rubber impeller type water pump. Refer to Fig. C4-18. The water pump is mounted in the lower unit drive shaft housing (upper gearcase). When cooling system problems are encountered, first check the thermostat to see that it is operating properly. Check the water inlet for plugging or partial stoppage, then if trouble is not corrected, remove the lower unit gearcase as outlined in LOWER UNIT section, and check the condition of water pump, water passages and sealing surfaces. THERMOSTAT The thermostat is located beneath a separate housing on top, rear face of cylinder head as shown in Fig. C4-11. When installing the thermostat, position with "Vee" slot in visible end up as shown.

MERCURY TWO CYLINDER MODELS

POWER HEAD | RandR AND DISASSEMBLE To remove the power head assembly, first remove the top cowl and disconnect stop switch wire, speed control linkage and choke linkage. Remove the two screws which secure fuel line check unit to lower cowl and nuts securing power head to lower unit; then lift off the complete power head assembly. Place the unit on power head stand or equivalent and remove fuel pump, carburetor flywheel and magneto. Exhaust cover plate (19- Fig. M6-19), cylinder block cover plate (13) and transfer power cover (14) should be removed for inspection and cleaning. Remove the cap screws which retain end caps (2and6) to power head, remove center main bearing screw (S); then unbolt and remove crankcase half (17). Use extra care not to spring the parts or to mar the machined, mating surfaces. Crankcase half (17) and cylinder (16) are matched and align bored, and are available as an assembly. The crankshaft and bearings assembly, with pistons and connecting rods attached can now be lifted out of cylinder block for service or overhaul as outlined in the appropriate following paragraphs. Assemble by following the procedures outlined in the ASSEMBLY paragraph.

SEA KING 35, 45 and 55 HP (1967-1968)

PUDDLE DRAIN VALVES All models are equipped with a puddle drain system designed to remove any liquid fuel or oil which might build up in the crankcase; thus providing smoother operation at all speeds and lessening the possibility of spark plug fouling during slow speed operation. The puddle drain valve housing is located on the starboard side of power head, and can be removed as shown in Fig. SK1-7. The reed-type puddle drain valve petals must seat lightly and evenly against valve plate. Reed stops should be adjusted to 0.017-0.023 clearance at the tip. Blow out drain passages with compressed air while housing is off.

This comprehensive service manual provides detailed information on how to operate, maintain and repair older outboard motors produced prior to 1969.

Hundreds of exploded views and illustrations guide you through the complete adjustment and repair process on models with 30 hp and above.

Subject: Outboard motors, 30hp and larger, 1969-prior service, maintenance, and repair procedures. ISBN-10: 0872881873 | ISBN-13: 9780872881877 | Clymer OOS2