Eska 3, 3.5, 4.5, 5, 5,5, 7 & Z.S Hp

YearProduced Model No.1969 . . . .1199, 1700, 1703, 1?034,

1704,1709,1773,1713A

1Lgg,1194,1701,1705,1706,1710,1715

l"196, 1199, 1702, 1707,1709,177I, l7\7

1970 . . . .1188, 17038, 1704F,17098, 17138, 17238

11898, 11948, 17018,1705B,13068, 1?158,17338

1199, 17028, 17078,17088, I7I7B,1723B,17348

1971 . . . .1703C, 1713C, t770A1701C, 1705C, 1706C,

1715C,1733C, 1766A,177TA

7702C,1709C, r72t[,77274; Ll45A, I74TA,t767/., r772A, I777A

L972 . " . .1703D, 1713D, 77708,1788A, 1791A

1705D, 1706D, 1.715D,17668, 7771F' t7g4A,1789A.

17278, 7746A, 17478,1756A, 17678,1772B.,17764,1790A

1973 . . . .1929A, 1945A190341705E, 1909A, tg13A,

1928A, 1930A1747C,1931A1905A, 1909A, 1914A,

1932A, 1966A

t974 . .. .19298, 19458190381705F, 1g0gB, 19138,

19288, 19308174?D, 1931819058, 19098, 19148,

19328. 19448

HP3

4.5b

D.O

HP

3.5

5

o

3.5

TecumsehPowerHeadAV-520AV-520AV-600

AV-600

AV-817

AV-520AV-520AV{00AV-817

AV-520AV-600AV-817

AV-520AV-600AV-817

TUNE,Bore

Stroke

NumbeDispla<

SparkChanA C .Elecl

ConvetBreaPisto

AdSolld S

Max.Fuel:O

SIZESPiston

End

3.5

7.5

34.5o.at . D

3.5b

t . D

3.5D

t . a

3.5D

I . O

3.5o

J . D

3.5

o, . D

3.5D

'1 .D

3.5D

J . O

3.5o

7.5

AVAV-600AV-817

3.5 AV-520AV-600AV-817

AV-520

AV-600AV-817

AV-520AV-600AV-817

AV-520AV-600AV-817

AV-520AV-600AV-817

AV-520AV-600AY-817

CranksTop rBottrCranEnd

oI

3.54.5

Dqa

' t . b

3.54.5

5aI

t . o

3.5D

J . O

TIGHlConne<

Plain

Need

Cylind<

Flywht

ShroucCran

100

: *Recor

i l *_t. Ine I

rce parto eneiWhen

lllustratic

ESKA 3, 3.5, 4.5r 5, 5.5, 7AND 7.5 HP (1969.1995)

TecumsehPowerHead

AV-520

AV-600

AV-750

AV-520

AV-600

AV-750

AV-520

AV-600

AV-750

AV-520

A.V-600

AV-817

AV-520AV-520

AV-600AV-817

AV-817

AV-520AV-520

AV-600AV-817

AV-817

These motors are also sold as Explorer, Federal, Golden-jet, Hanimex, Hiawatha, Pathfinder, Seaco, Seacruiser-G"?4, Sea King, Sea Hawk, Sears, Skipper, Sportfisherand Wizard models.

YearProduced Model No.7 9 7 5 . . . . 1 9 7 3 4

1903c,19418, 1974A1997.{19044, 19048, 19104,

19694, 19704, 1975A1905C, 1909C, 1914C,

r944C, 1966C, 1967C,1976A

1 9 7 6 . . . . 1 9 ? 3 87974819758t944D,797.68

\ 9 7 7 . . . . 1 4 0 3 8140358, 140368140378, 14039A, 140594

1978 . . . .14034C14035C, 14106A14107A,141084

1979 . . . .14034D14035D, 141068141078, 1410'88

1 9 8 0 . . . . 1 4 1 3 9 A141404747414

1981 . . . .14178A, 14183A14035E, 141408,

141798,14189A14r4tB'14180A

1982 . . . .141788, 14183814140C, 141798I414IC,141808

1983 . . . .142071420814209

1984 . . . .142071420874209

1985 . . . .1420714208r4209

OUTBOARD MOTOR SER\

Piston

lllustrations Courtesy Eska

CONDENSED SERVICE DATA

TUNE.T]PBore .

Stroke

Number of Cylinders .Displacement

Spark Plug-ChampionA C . . .Electrode gaP

Conventional Magneto-Breaker Point Gap . . .Piston Position Max.Piston Position Max.

Advance TimingSolid State Magneto-

Max. Advance TimingFuel:Oil Ratio.

SIZES-CLEARANCESPiston Rings-

End gap

Piston Skirt Clearance

Crankshaft Clearance-

TIGHTENING TORQUESConnecting Rod-

Plain bearing (Aluminum)

Needle bearing (Steel)

Cylinder Head .

Flywheel.

Shroud Base toCrankcase

roR SERVICE MANUAL Eska 3, 3.5,4.5, 5,5.5, 7 & 7.5 HP

msehiler,adr-520r-520r-600

r-600

'-81?

'-520'-520-600-81?

-520-600-817

-520-600-817

AY52O2.09 in.(53 mm)1.50 in.

(38.1mm)1

5.16 cu. in.(84.6 cc)

J13Y*45S

0.030 in.(0.76 mm)

See Text

See Text

See TextSee Text

See Text

See Text

50-57 in.-lbs.(5.6-6.4 N'm)70-80 in.-lbs.(7.9-9 N'm)

80-100 in.-lbs.(9-11.3 N'm)

25 ft.-lbs.(34 N'm)

70-75 in.-lbs.(7.9-8.4 N'm)

AY6OO2.09 in.(53 mm)1.76 in.

(44.7 mm)1

6.05 cu. in.(99.1 cc)

J13Y*45S

0.030 in.(0.76 mm)

See Text

See Text

See TextSee Text

See Text

See Text

Ball or NeedleNeedle

See Text'0.003-0.016 in.(0.07-0.40 mm)

bu-D / ln.-lps.(5.6-6.4 N'm)70-80 in.-lbs.(7.9-9 N'm)

80-100 in.-lbs.(9-11.3 N'm)

25 ft.-lbs.(34 N'm)

70-75 in.-lbs.(7.9-8.4 N'm)

AV7502.375 in.

(60.3 mm)1.68 in.

(42.7 mm)1

7.50 cu. in,(122.9 cc)

J13Y*45S

0.030 in.(0.76 mm)

See Text

See Text

See TextSee Text

NeedleBall

NeedleZero

zo.so;.-m,.(7.9-9 N'm)

80-100 in.-lbs.(9-11.3 N'm)

25 ft.-lbs.(34 N'm)

70-75 in.-lbs.(7.9-8.4 N'm)

AY8172.437 in.

(61.9 mm)l . /D mm

(44.4 mm)1

8.1? cu. in.(133.9 cc)

J13Y*45S

0.030 in.(0.76 mm

See Text

See Text

See TextSee Text

NeedleBall or Needle

NeedleZeto

bu-a, rn.-Ips,(5.6-6.4 N'm)70-80 in.lbs.(?.9-9 N'm)

80-100 in.-lbs.(9-11.3 N'm)

25 ft.-lbs.(3a N'm)

?0-75 in.-lbs.(7.9-8.a N'm)

0.005-0.013 in. 0.007-0.017 in.(0.13-0.33 mm) (0.18-0.43 mm)

See Text See Text

.600

.81?

.520600817

520

600817

520600817

520600t77

120100)t7

,20i00t77

0.499?-0.4999 in. 0.4997'0.4999 in. 0.4997'0.4999 in. 0.4997-0.4999 in.(12.6s2-12.697 mm) (12.692'12.697 mm) (1-2.,6-9-2'L2.697 mm) (12,6-9-2--12.697 mm)'

0.005-0.00? in. 0.005'0'00? in. 0.0055-0.0075 in. 0'0058-0.0078 in.(0.13-0.18 mm) (0.13-0.18 mm) (0.14-0.19 mm) (0'147-0.198 mm)

Top main bearing . . . Ball or NeedleBottom main bearing NeedleCrankpin See TextEnd play See Text

. 5 *Recommended spark plug for models after 1976 is Champion RJ13Y'

.il *" ensine model number (AV-520, AV-600, AV-?50 or AV-817) is for easy reference only. to the generai construcllon. rf serv'-

i". prri""*" ili"iifi, trr"-ivpu "o*ri*

uuSt be used. The type number isitamped in_ttre blowerhousing or on atag u!!Ct!t-".dto ,ingin". a

"o""".iiyp"'nrifiL"i. riiti".*tty consist of three riumbers, a dash foilowed by two more numbers (such as 643-09).

When'servicing power-head, make certain that identification tag is reinstalled.

lllustrations Courtesy Eska 101

Eska 3, 3.5, 4.S, 5, S.S, 7 & Z.S Hp OUTBOARD MOTOR SEF

/ "

It\.{p7g...e2..1.;!jcw ot g""r")"" showtng upper(vcnt) plu-g (U) and lowcr (dntnfitil) ptugl4. Non.g.at shtn typa unltE hate dralnlllll plug on op

posrfr side ol gcarcasc,

LUBRICATtOfit

The power head is lubricated bv oilmixed with regular grade gasoline.Itecommended fuel to oil ratio is 16:l for1969 model motors. Oil used should be agood grade of oil intended for use in out-board motors. Fuel and oil should bemixed in a ratio of 24:l for 1920 through1973 model motors. Fuel:oil ratio of B2-:1may be used on 19?4 and later models ifoil used is BIA certified TC-W. If BIAcertified TC-W oil is not available. use agood grade of outboard motor oil in a24:1 fuel to oil mixture onTg74and latermodels.

. The lower unit gears and bearings areIubricated by oil contained in the-gear-ease. SAE 90 outboard gear lubri-cant

should be used. Lubricant should bechecked at least every 20 hours otop.o_tron and maintained at level of the uppervent pJug (U-Fie. E2-l), when motb'r ism upright position. The gearcase shouldbe drained and filled with new oil at leastonce each season. Remove both plugs (U& L) and lay motor on side to draii tiregearcase. If excessive water is notedwhen draining, seals and gaskets shoulJbe renewed as outlined in the LOWERUNIT section. Motor should be in uo-right position when filling gearcase wiihlubricant. Insert filler tu6e-in lower plue(L) opening and fill until lubricant is aTlevel of.upper plug (II) opening. Installupper plug, then remove filler tube andinstall .lower plug. Use new gaskets onp.tu-gs tr _necessary to provide a watertight seal.

FUEL SYSTEM

CARBURETOR. The Tecumseh floattype carburetor is shown in Fig. E2-2.161s nifture is adjusted at ne6dle 1L;and-high_speed mixture is adjusted'a[needle (H). Clockwise rotation of bothneedles leans the mixture. Initial settingis approximately 1 turn open for botfrneedles.

, Carburetor adjustments should onlybe made with motor in water so a load isplaeed on engine. Start and run motoruntil it reaches operating temperature,then adjust to provide smoothest opera-tion__in gear. The high speed mixtureneedle (H) should be adjusled first. Idlemixture (L) should be set rich enough toprovide smooth acceleration from idlle tohigh-- speed. Use caution when settingneedles to prevent mixture from bein[too lean and causing engine damage.

-

H. High speed mixture needleL. Idle mixhre needle1. Throttle shaft2. Throttle sDrins3. Throttle oiate-4. Pmping-element5. Welch plus

lo 6. Lead shot'7. Choke shaft8, Det€nt9. Choke plate

tu. sDrms10L. Clip

-

11. Spiing12. Washer13. "O" ring14. Washer16. Bowl drain19. Float20. Inlet needle

20L. Inlet needle & seat21. Seating ring23, Bowl retainer25. Outlet check valve

25D. Check valves25S. Scren- 2!. Inlet check valve & fitting26F. Inlet fittine26c. csket

Fi!:-E2,:3.-F.ue! pump etement (4-Fig. 82.2)snoutd De l,stallad at a 45o anglc aa shown.

CAUTION: Do not attempt to removecarburetor lrom AV750 models without re.moving lhe reed valve assembly.

NOTE: Several variations ol this car.buretor haue baen.usad,and differences inservicing procedure wiil be noied.

U

Disassembly of carburetor will dependupon extent of service required. Farts(4, -1lr \6, 20, 20L, 27, 25, 25D, 26, 26Fand 26Q 4ay be damaged by most'com-merctal carburetor cleaning solvents andTg:t be_lqoved. The gravity feed inletfitting (26F) and early tlpe check valves(25-and 26) are presied into carburetor,

' be loc.r or 261: The, ' ber b,

due trr, The l: stalle<

E2-3.'terfer' On,.: buret<

Deror(:. SPI. . icn*i€._ contrc. . b y a c i

plate.: openir

vide cpropriing ththrott

body. The fitting (2G or 26F) shoutdpulled out _of bore, then carefully doutlet check valve (2b) with a 9t6Z inch(3.57 mm) drill to a depth of % inch (B. tZmm) as shown in Fig E2-4.

CAUTION: Do nol drifl too lar or car.buretor body will be damaged.

Thread an 8-82 tap into the outletcheck valve, then use the proper size nutand flat washer to eonvert-tap into apuller as shown in Fis. E2-b. pull checkvalve out by tightening nut._-.lnlet .needle (20-Fig. EZ-Z) has aViton tip that seats directly into car-buretor body on some modeis or into arenewable Viton seat (20L) on latermodels. Seat (20L) may be removed bvinserting a small wire hbok through hol!and pulling seat out of brass liner] Vitonseat should be rene'wed if removed fromcarburetor body. New seat should be in-stalled with grooved side toward car-buretor_body, away from needle (20).

.On all models, install throttle piate (S)with stamped lines facins out ?to*ai<iglrqne) and at 72 and 3 o'clock positions.If the choke plate (9) is provi^ded withstamped mark, the mark should be. ,toward inside of carburetor and flad 1should be toward fuel inlet fittinE (26.t /26F_ or 26L). If. choke plate ii noi'marked, the flat side should be downtoward float bowl. Fioat setting should

breaktditioncorrecparaglremovdenselbreaktE2-8).

OnpresseE2-2),

tf^

a t

,t-,f\\ . /

,@:i Sts

af, \\

\">)u--o $rrn-€t3*-*r2--6

"+'-d

7-,

3 ^

20t 4-20r*t 0/-10[

26L. Inlet coverFlg' E2'2-Exptoclcd vtew ol Tccumjoh catbutcto.t On gftvttl laed modets, ltttlng (26F)is uaed. Onaaily luel pum.p models, pumptng ol.ment (1), ouitit ciic* yaive (25), intet checi iZivi ana tttting ee1tr. uscd. on tttast modcts wuhluy pumn cnec* vatvei (zsq, m;i;;;;r-ii6lj';;;icrccn (2ss) arcused.

102

.-

MO1

lllustrations Courtesy Eska

SERVICE MANUAL

be 0.200-0.220 inch (b.08-b.58 mm).*measured_with body and float

".r"*bt'uflrverted, between free end of float and{ilr. ol- ^carburetor b_ody. preferred

-fmethod lor , checking float level is toplace a _number.4-drill bit shank (0.209inch or 5.30 mm) between float and car-buretor body (Fig. E2-6). When install_ing fuel bowl, the flat under side shouldbe located below the fuel inlet (26,26ior 26L-Fig. E2-2).

The fuel pumping element (4) is a rub_ber boot which expands and contractsdue to changes in crankcar" prurr*".The pumping element should be in-stalled at 45o angle as shown in FiE.E2-3. Incorrect installation may ifr-terfere with pumping action.

0n AV750 models, coat threads of car-buretor retaining screws with ,,Loctite',

before assembling.

SPEED CONTROL LINKAGE. Theignition timing is advanced by the speedcontrol lever and the throttleis ope"Ltudby a call attached to the magneto statorplate- The ignition timing and throttleopening must be synchronized to nro_vide correct operation. Refer to the ao-propriate following paragraphs for tim-ii,g lI" ignition and synchronizing thethrotile openlng.

Eska 3, 3.S, 4.S, 5, S.5, Z & Z.S Hp

llo_. -rr_f:!,oZt !".y?! pry be checkcd by ptac.tng a numoet 4 chilt btt (0.209 lnch o, s.io'iitoeaween iloat and ca|d,urcaor body,

tg. E2.2)ahown,

r9fltov€ :loul re. t:

ris car.',..nces in

,...:

lependParts

6 ,26Fit com-rts andd inletvalves

uld

4 inchr (3.1?

rr Cat.

lutlete nutnto a:heck

Y'GNETO. Before attempting to setitr" timing, make certain that

lllustrations Courtesy Eska

TIMINGBTDC

0.095 in.(2.47mm)0.115 in.

(2.92mm)0.100 in.

(2.54 mm)0.085 in.(2.15 in.)0.110 in.

(2.79 mm)0.100 in.

(2.54 mm)0.085 in.

(2.15 mm)0.078 in.

(1.98mm)0.085 in.

(2.15 mm)0.078 in.

(1.98 mm)0.085 in.

(2.15 mm)0.078 in.

(1.98mm)0.085 in.

(2.15 mm)0.085 in.

(2.15mm)0.078 in.

(1.98 mm)0.085 in.

(2.15 mm)0.078 in.

(1.98 mm)0.085 in.

(2.15 mm)0.078 in.

(1.98 mm)0.090 in.

(2.28mm)0.085 in.

(2.15 mm)0.090 in.

(2.28mm)0.085 in.

(2.15 mm)

103

LS WITH BREAKER POINT

Fig. E2-s-Tho 0.32 tap can be uscd as a Dullel'o 'emoYe "" ";:';;i2i;l;i:::.,-^ eaiv tuar

Move speed control lever until side is?.Jiglqd with edge of sn.oua-- lasJ(2-Tig. EZ-Z): Th; follower €) sfroufjbe almost touching the cam.

NOTE: There should be slight clearance(lhlckness of paper) between cam andfollower.

, If clearance between follower and camis incorrect, loosen screw (S), mouu iai"end of cam as required,'then tiEhtenscr.ew (3). Make certain that there iSonlya slight amount of clearance.

Ori models with fuel inlet fittine oncarburetor plate (26L-Fig .82-2), &teiiEne rhrotile prckup as follows: Set theprston at 0.003 inch After Top DeadCenter as described in Fig. nZ-g.^ettacfi1^tiTing light .with battery (B-Fig..E2-q) or continuity meter

'to th"e

breaker point terminal (1) and tomagn-eto stator (ground). Move thespeed control lever to starboard(cloclwiqe) until the timing light giows(continuity exists through-br6akerpoints). -Move the speed cintrol levertolvard_ tast position until the breakerpornts just open (light goes out).

NOTE: Do not move speed control leverloo far. The cam follower (F) should justcontact cam as the timing tight goes out(breaker points open). lf lollower contactscam before breaker polnls open or if thereis clearance between lollower and camwhen breaker points open, loosen screw(3) and move the idle end of cam as re.quired, then tlghten screw (3).

9n all -models, refer to the followinetabte.and locate piston at correct timin[posluon:

TYPENUMBER

639-06

640-72thru 640-19A

642-07 thru 642-0?8

642-07C

642-08

642-08A thru 642-t0

642-73 thru 642-16C

642-76D

642-77 thra64?-I9

642-19A

642-20

642-20Athru642-22

642-23

642-24

642-25

642-26

642-27 thru642-28A

642-29

642-30 thru642-B1

643-01 thru 643-74

6 43-7 4A, 6 43-748, 643_ 14C

643-15

643-154. thru 643-32.L

breaker points are in good (or new; con_ouon and gap at maximum openinE iscorrect as described in the IGNITIbNparagraphs. The flywheel must beremoved and wires from coil and con_denser must be disconnected frombreaker point termina ft-tr'ie. bZ-?;E2-8).

as a :::

9t' ' . :rto a ,,!later 'lrd by ,jhole .::riton ,, jhg.',ie m-: , , ;C&f'::.:n)). l;le (3) :1rard -l

On rnodels with fuel inlet fittinsg1eryed into carburetor (26 &26F_Fi;'E2-2), check throttle piikup as followi:

'b. mm;" i"rroo ot removtnocaily typa chcck tar-vc tzs_Fd. ei-ti"""

ons.ffith

be

(26;not)w]lruld

Eska 3, 3.5, 4.5, 5, S.S, 7 & 2.5 Hp OUTBOARD MOTOR SEF

Fig. .82.7-Uiew showtng spead contrcls andp.o,n$ ot.adiustmen.t lot motorc with prcssed in

ruet ,ntet type carburctors and brcaket polnt. magncao, Rclet to tex/-

Fig. .E2.8-View showing speed contrcls and

l:!!ts gr adlustmerrts lor motors with luet inlet,ocated. on. cover plate and breakar potnimagneto. pistor position tarOq snouia {c-iii

as described in Flg. E2.9.

104

Il

@ffiF

F.lg. E2.9-plston positton can be measuredt.htoug.h.the s.paft pius openini usiig i;;n;';;g_a91 {Q lvaitgllc trom iecumseh pToaucts Ci.Wn nu-mbet 670124), a rutat (R) ot diat tndtcatolt:!^:!:eldatermlning top dead cantaL tuncnnKsnatt counterclockwisa lo sct pistonl?tot?. lop dead centet @roq. crcnisiiiisnoutd be tuned clockwlso to set piston altcr

top deed centet (ATDC),

Fig.. E2'10-Uiew showing contrcts and points otadtustment tot adlusting maxlmum tgiitton ad.yanco anct maximum thrcttle opening. The caman4/or .cerburctor may be damaged tf cam atremprs to open thrctile fufther than possiDla.

,_l4g-D_E_LS WrTH SOLrD STATEMAGNETOS. The flywhe"t *".i l","1no-ve_d and a special tool (part number670286A for AVo0o a"a eVisO moaJsand. part number 670281A fo" Avgiimodels) available from Tecums"f, F"oalucts Co. must be used.

To set the maximum ignition advance.re.fgr to following tabTe and ;t;;plston to the proper BTDC position asper rnstructions in Fig. E2-9.

_- NOTE: ll may be necessary to loosenthe stop bracket (4) in order to allowenough movement lo open breaker points,Also, make certain that follower (Fj is notbinding against cam.

The speed control lever should contactstop bracket (4) just as breaker pointsopen. If incorrect, loosen the retiininEscrew and reposition stop bracket (4). "

After the maximum advance stopil; iscorrectly. set, move the speed conti.otIever against stop bracket (4) and checktfre .c.aln follower (F). The followersnoutct have opened the throttle com_

FIg. E,Irors.sDows

|rl:

-'Tr

IEU

,. Refer. to -Fig. EZ-9. Attach a timinstrCn:. wllh battery (B_Fig. EZ_10) oiconttnutty meter to the breaker pointterminal (l) and to magneto stator'plate(ground). Move the speed control ievercrockwrse until the timing liEht slows(breaker points closedl. Vtiueif," 3pL"Jcontrol lever toward fast position(countercloekwise) until th" ;;;;k;;pornts Sust open (light goes out).

MODELNUMBER

AV6OO

AV75O

AV817

TIMINGBTDC

0.085 in.(2.15mm)0.095 in.

Type640-02thru640-068 0.118in.

rype64o-o?thru64o-21 %3t?ll](2.92mm)

Position the proper Tecumseh specialtool-over the flywheel key in cranlishaftas shown in Fig. Ez-Il, lhen move con-trols to maximum speed position(counterclockwise). The iun trigger @jsnor+d be. aligned with edge ,,1" ofspecrar tool as shown in the inset. If in_correct, loosen stop bracket (4) andreposltlon as necessary to stop move_ment of speed control i,rhen run trieeerx atrgned with edge,,1". After stop (-+-i isco.rrectly positioned, check thd

'cam

tollower (F) with controls in maximumspeed position. The follower should haveope.ngd throttle completely, but makecertaln that cam and follower are notbinding. If throttle is not completelvopen or if follower is binding, joosei,screw (5), reposition the high speed endor cam as required then tighten screw(b) .

,, To check the throttle pickup point, settne plston to the same BTDC position as;for.high speed adjustment (see p""uiou#rgnluon trming table). Move the speed\go-ntrol until the run trigger (R-Fig.E2-72) is aligned with th;-"Z" ,n".[ o]ithe special tool for AVT50 models or the

(2.4lmm i&' "

Ftg. Itdte p

: e n d a

,r4r, n

SpecAV8throlconnbe jrE2-1not;eorrridle

Thfor Iidlecamendonlychec

AIcam

, spe€i l i .tri- - l n u

statmot,touc

l l lustn

ATIIC

l l lustrations Courlesy Eska

)R

and.e isr is,

EF

f;I&f,

$SERVICE MANUAL

Ftg. E2.11 - Reler lo lext lot adlustment ol con'tots. Vlew sttotvs higfi speed position, ,nsertshows location ol stefting tigget (S) and run

ttiggq 6) In rclation to tha speclal lool.

Ez.1z-Rotet to text lot adiustment ol theplckup. Changing tha posltlon ot ldle spaedol can wlll altect hlgh speed adruslmenl

whlch shoutd be rcchecked.

REED YALVES. The reed valves arelocated between the carburetor and thecrankcase and should be checked eachtime the carburetor is removed for serv-ice.

On AV520, AV600 and AV817 mod-els, the carburetor may be removedbefore removing reed valves. Reeds andreed plates may be renewed separatelyon most modeis but must be renewed asan assembly on certain early models.Check reeds for proper seating anddamage. Reed petals should not bendaway from plate more than 0.010 inch(0.25 mm).

On AV750 models, the reed valveassembly and carburetor must beremoved as a unit by removing fourscrews that secure reed plate (6-Fig.E2-15). Removal of the carburetor anddisassembly of the reed valve can be ac-complished by removing the two screws(5) and nuts (12). The reed petals can berenewed without renewing reed plate(6); however, make certain that seatingsurface is not damaged. The rough edgeof reed petals must be away from reedplate. New reed petals (3) are marked onthe smooth side and the marked surfaceshould be against the reed plate (6).When assembling, coat threads of screw(5) with Loctite and tighten to 50-60in.-lbs. (5.6-6.7 N'm) torque.

IGNITIONSolid state, breakerless magnetos and

conventional, breaker-point timed, mag-netos are used on these motors. Refer tothe appropriate following paragraphsfor service.

Ftg. E2-13-The stop (grcund) scrcw (1) shouldbe adlustad as descriled ln text to stop motol

altat leeet is past shtoud brackct(2).

Eska _3, 3.5, 4.5, S, S.S, Z & 7.5 Hp

Fig. E2.'S-Exploded view ol the rced valvaused on 4V750 models. Catburctot and rcedvalve must be rcmoyed and installed as a unit

;hen

ad-fternts.rttlebherrectlnds

,TEI re-rberdels'817

rod-

nce,the

l a s

1. Gasket2. Reed stop3. Reed petals4. Wroher5. Caburetor attaching

screw6. Reed plate?. Gsket

8. Carburetor9. Idle adjustment knob

10. Set screw11. Bracket12. Nut13. Choke link14. Choke rod15. Stop spring

BREAKER POINT MAGNETO.Breaker point gap should be 0.018 inch(0.45 mm) for type numbers 642-07through 642-078, 642-08A through642-\0, 643-01 through 643-05A, 643-06through 643-09, and 643-15. Breakerpoint gap for all other engines should be0.020 inch (0.5 mm). It is important lhatbreaker point gap is eorect and breakerpoints are in good (or new) conditionbefore adjusting the speed controllinkage. Ignition timing and throttleopening must be synchronized correctlyto provide best operation. Refer toSPEED CONTROL LINI(AGE para-graphs in the FUEL SYSTEM sectionfor checking ignition timing.

If the magneto mounting plate mustbe remwed, loosen {rietion serew thenIift assembly off. When installing, applya small amount of grease to frictionscrew, then install and tighten screw to12-15 in.ibs. (1.3-1.7 N'm) torque. Makecertain that cam follower (F-Fig.E2-10) is on outside of cam.

SOLID STATE MAGNETO. TheTecumseh solid state magneto does notuse breaker points. The only movingpart of the system is the rotating fly-wheel with the magnets. Refer to Fig.E2-16. Refer to the SPEED CONTROLLINKAGE paragraphs in the FUELSYSTEM section for synchronizing igni-tion timing to carburetor opening.

If the system fails to produce a sparkat the spark plug, first check the condi-tion of wire terminals and gtound con-nections. Check condition of high ten-sion lead (5) and if questionable, renewpulse transformer (4) and lead (5). Makecertain that low tension lead (3) is notshorted against motor and renew if in-

tNG:DC

5 in.nm)5 in.nm)

:cialhaftcon-tion(R)

OI

f in-and

3 in.nm)5 in.nm)

ove-tger4) iscamlUmIaverakenot

,tely)senendrew

, setilj

Fig.( o n' the

ffiFrg.ldleend

"4" mark on the tool for AV600 models.Special tool 6?0238A, used to checkAV817 models, has only "2" mark forthrottle pickup point check. With speedcontrol in this position, the cam shouldbe just touching the follower (F-Fig.E2-11). Make certain that throttle hasnot yet moved, but is touching cam. If in-correct loosen screw and reposition theidle speed end of cam as required.

The throttle cam should be recheckedfor full throttle opening after adjustingidle pickup. Changes at either end ofcam will affect the location of the otherend slightly. Position of cam is correctonly after both low and high speed endscheck satisfactorily.

After the high speed stop and throttlecam are accurately adjusted, move the

* speed control lever clockwise until iever$ils past the shroud bracket (2-Fig.

, ffiD2-i3). Turn the ground (stop) screw (I)"ryin until it contacts the stop plate on

stator. The ignition will be grounded andmotor will stop when the stop platetouches screw (1).

lllustrations Courtesy Eska 105

.u1,"!j9n is faulty. The ignition chargingcoil (1), electronic triggenng system andmounting plate are "*it"Ui"-6"fy'".*"iassembly..If the mountrng plate must beremoved, lo_osen friction icrew, then lifiassembly off. When instafiing, A;i;;small arnount of grease to friction

99r91v, th.gn instail aid tighten;;;;12-15. in.-lbs. (1.8-1.2 N.m-) t";d;:ili;k;::j_t ll that cam foilower'(F) is ;; ;l:slae oI cam.

COOLING SYSTEM

,.T1". p,o*:r hgad is air-cooled b.y a fanbuilt into the flywheel. Make srir;;h;lf::ljr P place and fl,"t .""i,"g ri;,are kept clean,

The lower motor leg and exhaustgases are water_cooled. All models withm_ore than B hp -are "q"ipp;;;;h;Illu,r pr.p: Coolant intate is toc"i"JJust below the antiventilation plate on3lcir sidg of gearcase, ,na .oituni

"i.puTpgd_ to exhaust deflector at upperpart ,o{ Iower unit where it cools th6 ix-haust housins.

_ Motors nol equipped with a waterpump use a coolant tube to aid in coolinemotor.leg. An open end "f

ih;-;;ffiTb,u i: locatgd- below antiveriil"li""p.la.te, facing forward. fo"*u.a

-_oiiJn

1::,_.p.top:il"r. wash force water upfg_o,,:nr tube to motor adapter platellvlat{e sure that coolant tube is free ofobstructions.

, -Coolant outlet consists of a series ofholes arranged vertically on each side oithe lower unit upper leg, just b"l;;;h;

Eska 3, 3.S, 4.5, 5, S.S, Z & Z.S Hp OUTBOARD MOTOR

lg;5ffi'i. bearin| ria-rb. Ei.;i ;

I

sElI23

_,The crankshaft can be removed fromall models after removing ,lr"ood br.;

E_;[;f: d'.il;,#-r"# rX ii,fltrlower main AV8IZ models), it ;;;:€necessary. to bump crankshaft oul oi \t4

t3

ITt8l9

_-AFSEM.B!y. Because of the rwo-stroke cycle d_esign, ti," "r"nLc"s"

_uJt::

comptetely sealed against bothpressure and vacuum. It is-recommend_eo tnat all gasket surfaces be carefullvcleanecl and checked for burrs, nicks oiy_flI"q. surface.s which may

'i;;;;f";;wlrn a tlght seal.. Refer to.the appropriate paraEraphsror mspection and reassembly oflo#er

fi"fft 'Eili8tf ll.B"Bl+,1'1"":?);recommended tightening torques.

*j,ISTON, PrN, RrNGS AND CYLIN-DER. Before detaching roa from crank-snaft, cieck the correlation marks onroo and cap. If rod and cap are not

10..t4 .t3-qt

t51

<2l

c

22P

Flg. Eienglne.

. 1 . M r1T. Mr

2. Sr3. R{4. Se5. Sh

. 6 . T c7. G.8. Cr

8TW. Tl9. Cc

I0. Nr11. N(12. Pir13. Pir14. Sn15. Pir

. swivel braeket. If a spray of water does4 not emerge from outlet fr"f".-^*fr""

motgr isrunning, first chect< coolaniln-3

lel ror ptuggtng, then if not corrected.:

remove.g€arcase from lower unit andz overnaut the pump.

"-xYwl,

Fi,g.._E-2.20- Exploded view typtcal ot Tecumseh4V520 aad AV6a0 modets.'Eary ioai"'ii|equipped wtth ptein. bearinss "t ""iiiiiiri'iiiIarge and.

1. Magreto2. Snap ring U

l:3""ii'ff if: Fi:1i"'';1f,r.S. i|;t'"lt1;I,,r ii

r'owtrnain bearins

i. diili!r,"r, re. Snap,ring - .. .;:;::li,:*,# a,Hfft;*."''"'ii ii""iJiipr" 31. Siilii.*"

POWER HEAD

DISASSEMBLy. Unbolt and removecylrnder,shroud, flywheel, mameto.cyunder head, reed valve and c6vers,jnT9_"," cornecting rod cap and push:?"^j,?glld piston unit out ihrougfi topor cyltnder.

.!OTE: On AV520 and AV600 modetswith plain rod bearing, lock tab rnu"i-0"Dent away from connecting rod screwsbelore loosening. On other models, makecertain that bearing needles are nof'fo"i'incrankcase, On all models, it may bene.cessary to remove ridge from top ofcylinder before pushing piston anO con.nectrng rod assembly out.

z1%=J-=-_\_

.^qt.. -€-l

rE. E2.1! - Vlew ol thc sottd stete lgniilon com_.porents wlth llywheat rcmo7ed.r. unagrng coil

i:;ff*."#g, f:ilJi:,!fflii3:"6. Groud (stop) screw

06

f,!0,. .eZ-Z_l-exclodcd vtew tr|,',tcat ol AVTSOmodets. some models may niie areii"i'iiiittype megneto.

i i,iF,UUt-*'* it il$;rii","."",i. iiiluot""cr.et ir. *"*,n""i. dlo.uTi,n

o"*na 1e. snap ring;.ff#:h.t if.3liil5f*&crrinderf )1i:!::iiJiffi 313:3ti5i, \ /rr. fleedte beanng 22P. coverrz. rNron zi. Gasketld. nsron pm 24. Cylinder head

2tc20l tl9

2423

22Pil4markrassemcation

AVs2Cylinc

dian

Pistorclea

tffi.643_

l l lustrations Courtesy Eska

)TOR

ed fromud baserr Fig.

SERVICE MANUAL

-

Eska 3, 3.5, 4.5, 5,5.S, Z & 7.S Hp

bearingmay beout of

i2-27 or

All other type nos. , . . .0.006-0.016 in.

Ring side clearance: (0'15-0'40 mm)

Topr ing . . . . . 0 .008 -0 .00b in .

Bottomring . . . . .. ..[lrtJr9df%?il](0.05-0.10 mm)

Piston pin diameter . . .0.4992-0.4999 in.

AV75OCylinder bore

(72.692-72.697 mm)

diameter . . . . .2.375-2.8Z6in.(60.32-60.35 mm)

Piston-cylinder

Cylinder borediameter .2.437-2.438in.

clearance. . .0.00bb-0.00?5 in.(0.189-0.190 mm)

Ring end gap . . .0.00b-0.013 in.

Ring side clearance: (0'13-0'33 mm)

Topr ing . . . . . 0 .003 -0 .005 in .

Bottomring ..[%'0;9dfr?il1piston pin diameter . . . r.13ff;lriHll]

(12.692-12.697 mm)AV817

Fig. E2.23-The.V,, ma* ot "1111" me* on toool piston msst De towad side snown. LuOrii[-tion hole in slde of rcd must arso De towarcl top,

te two-Je mustt bothnmend-rrefullyLicks orterfere

graphspowerCON-

lle for

rLIN.crank-,rks onre not

-21C-20-17. lgtV750polnt

10t4l3

,,ffi;ANFtg. E2.22-Exploded vlew ol typlcal AV817.nglne. All models arc equippad with a solld

slafa ,nagneto.

(61.89-61.92 mm)Piston-cylinder

clearance. ..0.0058-0.0078in.(0.142-0.198 mm)

Ring end gap . . .0.007-0.017 in.(0.18-0.43 mm)

Ring side clearance:Top r i ng . . . . . 0 .003 -0 .005 in .

(0.07-0.13 mm)Bottomring . . . . . . . . .0.002-0.004in.

(0.05-0.10 mm)Piston pin diameter . . .0.4997-0.4999 in.

(72.692-72.697 mm)

Piston, rings and piston pin are avail-able in standard eiae only. Pistoa ringsshould be installed on piston with bev-eled inside edge toward top of piston.The piston pin should be a press fit inheated piston on models with needlebearing in rod upper end. On modelswithout needle bearing in rod upper end,the piston pin should be a palm push fitin piqton and thumb push fit in rod.When assembling piston in connectingrod, observe the following. Open end ofpiston pin must be down, toward ex-haust. The lubrication hole inside ofcon-necting rod must be toward top ofengine. On AV520 and AV600 modelsequipped with offset piston, make cer-tain that "V" mark or "1111" markstamped on top of piston is toward theright side as shown in Fig. E2-23.

A piston ring compressor should beused when installing piston in cylinder.Make certain that rings do not catch inrecess at top of cylinder. The cylinderhead retaining screws should be tight-ened to the torque listed in the CON-

DENSED SERVICE DATA tabte.Refer to the CONNECTING ROD para-graphs for installation of connectinErods.

CONNECTING ROD AND BEAR.INGS. Several types of connecting rodsare used and it is important that the cor-rect rod is installed.

On models with an aluminum connect-ing rod and plain bearing at cranlrpinend, clearance on crankpin should be0.0011-0.0020 inch (0.0028-0.051 mm).Crankpin journal should be 0.685i-0.6865 inch (17.416-77.437 mm). Crank-shaft should be renewed if crankpintaper or out-of-round exceeds 0.001 inch(0.02 mm). Only standard size parts areavailable.

On models with aluminum connectingrod with steel liners and bearing needlesat crankpin, observe the following:Crankpin journal standard diameter is0.8442-0.8450 inch (27.442-21.463 mm)on AV600 engines or 0.6919-0.6927 inch(17.574-17.594 mm) on AV817 engines.Be sure that none of the 74 bearingrollers are lost and that ends of linerscorrectly engage when match marks onrod and cap are aligned. Piston pindiameter is 0.4997-0.4999 ft2.692-12.697 mm) inch and rides in cartridgeneedle bearing that is pressed intopiston end of connecting rod.

All models with steel connecting rodare provided with loose needle rollers atcrankpin end of connecting rod and acartridge needle bearing at piston pinend. Standard crankpin jownal diame-ter is 0.6259-0.6266 inch (15.897-15.915mm). Model AV750 uses 33 needlerollers in the 0.7588-0. 7 592 inch 19.273-19.283 mm) diameter connecting rodbore. Model AV817 uses 66 short (halflength) needle rollers placed in two rowsin the 0.7588-0.7592 inch (19.273-19.283mm) diameter connecting rod bore.

2526

2728

t7l8t9

-4

-5

1. Magneto sy,1T. Magnetotransformer

2. Snap ring3. Retainer4. Seal5. Shroud bracket6. Top main bering?. Gasket8. Cmnkshaft

8IW. Thmst msher9. Connecting rod

10. Needle beaing11. N€edle rollers12. Pist n13. Piston pin14. Snap ring15. Piston rings

16. Lower main beaing@all or roller)

17. Seal18. Retainer19. Snap ring20. Cmnkcase21. Gsket

21C. Gasket22C. Cover22P. Cover

23. Head gasket24. Cylinder head25. Gcket26. Reed stop27. Reed28. Reed plate

marked, scribe a line to indicate properassembly. Refer to the following specifi-cation data:

AV52O AND AV6OOCylinder bore

diameter . . . . .2.093-2.094in.(53.16-53.18 mm)

Piston-cylinderclearance. . . . .0.005-0.007in.

(0.13-0.18 mm)gRing end gap:".il Type nos. 642-01 thru:s/ 642-078, 642-084 thru

642-10. 643-01 thru643-14 and 643-15 . . . .0.007-0.01? in.

(0.18-0.43 mm)

lllustrations Courtesy Eska 107

Eska 3, 7 &7 .5HP3.5, 4.5, 5, 5.5,

11 ffi'o*srP't4@;ifr*'3--'-y-tt

Flg:.E2:2-6-Exptoded ytew ol stertat. Relat to,r,!:_rj.r, tot rnstalrauon ot piii ti,;Z'il'-r . nanole

OUTBOARD MOTORCrankshafJ end play should be ZEROfor all _ AvTbo

-"nt evbif

-;#ir:Crankshaft end play ,f,ouid--li0.008-0.016 inch (0bz_"0.a0 rnrni rffiModels Avszo

"ni avbbb "diiipp"T_dj.h.t*g needle roller marn Deannes.

rr rs- rmportant to exercise extiemecare when renewing ""rnkshart s"a['iTprevent their being du*"g"J d;G"inlstallation. If a pr"otector

-sleeve is]notavailable, use t?ll to cover uny ,piin*,

-I:{Y"yj, shoulders or ttre.al oviiwhrch_the seal must pass during instaila-ll^n; l-:1. should be i"rt rr;d'; tip;ilne tower seal is towards outside 6ot-fom) a,nd. t\e- top (magneto end) sei-istowards inside (center) of engin6.---'

'"

MANUAL STARTER

The rope f91 the recoil starter can berenewed_without disassembling -i[J

starter. Remove the starter asimblvrro,1n motor, pull rope out fulh and holipllley to prevent rewinding. Refer toFig. E2-28. Remove on,op8"na inrt*fi,ne1 Tope, making certain that the innerflg.t rs l1 pocket on underside of pullev.rr tne otd.rope was broken, prelo'ad tlierecoll sprlng by turning the pullev an_proxlmately- 6 turns before

-instillingnew roDe.

sEl

2, Rone3. Reiainer screw4. Retainer housine5. Bmke sprine

-

6. Starterfog-

FIC.. E2-27-Whea assembllng, meka ccrtatntrrrlprrts (5, 6 & 7) arc asscmblcd as shown. iniot aog rctun spilng (7) should pult dog ln.

108

F19..E2.28-Relu to taxl when rcmovlng or In.stalllng. rcpc. Bctalnot scrcw (g) sno-uni ietoryuod to 45.SS tn,.t!f,. F-b'N,nL -

, CTANKSIIAFT. Crankshaft mainDeanngs may be either ball type or car-rnoge needle ro.ller. If ball

-type main

Deanngs a_re used, it should be necessarvto bump the crankshaft out of the bear-lng lnner races. Ball and roller bearinsouter races should be a tight fit itb;;;:Iq o,grqs. It new ball bearings are to belnstalled, heat the crankcase when::T"Iiq otd bearings

"na inrturhng

new ones.

NOTE: Do not use an open flame.

, O,,n ?ll models, bearings should be in-salled w^lth printed face on race towardcenter of enErne.

.,If .the crinkshaft is equipped withtnrust washers at ends, rirai<-e certainthat they are installed when assembling.

Flg, E2.Zg-Exptoded vtcwol low.t motot teg typtcat otmodets wlth neutnl clutch.Leret (12) ts attachcd to shttt

shaft (9) wtth sphot ptn.1. Lower motor lep2. Neutral speed a-dvance

stoD rod3. Neirtral shift cam4. Swivel brrcket cao5. FIat washem6, Brass collar7. Gskets8. Spring wroher9. Shift shaft

10. Cerying hudle11. Neutral clutch knobs12. L€ver15. Steerins handle16. Sher pin holder1?. Swivel bracket18. Stem clamps19. Thrust bniket20. SDrins21. Bizss-liner

^22. Lower adapter plateza. .tj.xhaust deflector plaCe

zo. upper adapter platez{. Exhaust port g-asket

,.ij: $:ffi t"ii'"il'unt g6ket

,, To overhaul the starter, first removetne rope, then allow the pulley (g) to un-

7. Dog return springd. Puilev9. Sprin-g & keoer

10. Housins11. Centeri-ng pin

.. On models with short (half leneth) nee-dle rollers, bearing n""d". ur" ir"J.a"ii_,[wo r-ows around crankpin with flat endstggethgr toward centei of """ntpirr'iiiall models. equipped *ith nu;dl; 6;;;;

ar.crankpln, rollers should be renewedo4J u! a set. Renew b"u"inE;;;li;;;roller is damaged. If rollerE;;;;#-agect, check condition of crankpin andconnecting rod carefully

"na "lnu, ifDearu:lg races are damaged. New rollersare.-serviced in a strifand

";;6-;;:stalled. by.wrapping'tt" .t"ip *o*acrankpln. After new needle rollers andconnecting rod cap are installed, fo"c;l?cquer thinner into needles to removeth.f n::yql, then lubricate be;G;with SAE B0 oil.

On. all models, make certain thatT.atch marks on rod and cap arealigned. Some AVIZ}

""a

-TVoOo

models are stamped with ,T'" o"llrii;mark on piston as shown in Fig. EZ_28.vn mooels so equipped, make certainlhat TaLk stamped on top of piston istoward the. rig-ht side as ahow.n. On allmooels wrth aluminum connecting rod,t,^g!t-q rod cap retairung screws to40-50 in_.lbs. (4:b-5.6 lt.rnj t"rq";i"JIock with the tab washer. On all modelswilh a steel.connecting rod, i[h;;; th;roct cap retainins screws.(self locking) to70-80 in.-lbs. 1Z.b-O N.ml rorque.

windthen

NOavalla

25

?c220

whlightl;'(9) anbrakesprinlFig.(3-Fin.-lbrrecoilproxi:beforE2-2t

t$

Flg. Ez

22

lllustrations Courtesy Eska

roRZEROodels.

$'Kuppedlgs.tremerals to lng in-is. not ,.rlines,over ,

rtalla-lip of(bot-

eal is

SERVICE MANUAL

- ,fu1g. *2.3l-Exploded ytew ot tfplc.l, nong.at shll| low.,, unll.tvoto tDsf watot pump Impcttil may

" il d/ren wtth a ne.dtc (3) or a rctt ptn (2). waterrri:"i:i?:ir;.* thtoush axhaust openins on motots

wind slowly. Remove retainer screw (3),then lift parts out of housing (10).

NOTE: Sprlng and keeper (9) areavallable only as a unlt.

When assembling, grease spring (g)lightly then position spring and keeper(9) and pulley (8) in housing (10). Installbrake spring (5), starter dog returnspring (7) and starter dog (6) as shown inFig. E2-27. Install retainer screw(3-Fig. E2-26) and tighten to 45-bbin.-lbs. (5-6.2 N.m) torque. Preload therecoil spring by turning the pulley ap-proximately six turns counterclockwisebefore installing the rope. Refer to Fig.E2-28.

Flg. E2.31 - R.moy. tnsp.cilon covcr (C) ior ac.c.sg lo srrrtl llnkagc sct w.

lllustrations Court€sy Eska

Eska 3, 3.5, 4.5, 5, 5.5, 7 & 7.5 HPe-41

Rll'38

case hqusing lower cover (31-Fig.E2-30). To remove the gearcase, removeclip (13) then remove gearcase retainingnut and screw. The front gearcase re--taining stud nut (14) is behind clip (13)and the rear gearcase housing cap screwis accessible from inside exhaust outlet.On later models, the front stud nut islocated at front of motor leg.

To remove the propeller shaft or dis-assemble gearcase, drive the gear re-taining roll pins (28 & 29) a shortdistance into gear hub, rotate propellershaft %-turn and pull the roll pins outwith vise grip plieis. Gearcase must becompletely sealed against water orgrease leakage when reassembling.

Drive shaft should have a diametralclearance of 0.002-0.0035 inch (0.05-0.088 mm) in bushings (12 & 19). Pro-peller shaft should have a clearance of0.0025-0.004 inch (0.063-0.10'mm) inbushings (23 & 27). Renew any partswhich are worn or damaged. Backlashand mesh position of gears is fixed andnot adjustable. If backlash is excessive,renew the worn parts. Renew seals (5 &32) whenever unit is disassembled orwhenever water or grease leaks are ap-parent.

Gear (25) is secured to propeller shaftby a small diameter roll pin (29) pressedinto roll pin (28). A steel shear pin (35),part number 96284 should be used.When assembling gearcase to motorlower leg, make certain that water tubeis correctly installed and not damaged.Tighten the (front) retaining stud nut toa torque of 50-60 in.-lbs. (5.6-6.7 N.m)and the (rear) retaining screw to a tor-que of 75-90 in.lbs. (8.4-10.1 N.m).

Ful l Gear Shif t Lower Unit

R&R AND OVDRHAUL. Tsrernovelower unit from motor leg, remove in-spection cover (Fig. E2-31) and shiftlinkage screw (2-Fig. E2-33). Be

PROPELLER

A three-blade propeller is used on 7and 7.5 hp motors. All others areequipped with a two-blade unit. Variousdiameter and pitch propellers have beenused. Steel shearpin, partg6284, is usedon.propellerof modeJs not equipped witha forward/neutral or full gear shift lowerunit. Models with forward/neutral lowerunit use shear pin 95718. Motors equip-ped with full gear shift lower unit (Fig.E2-32) use shear pin part 96683.

LOWER UNIT

Three types of lower units are used.Some motors are equipped with a non-shifting lower unit (Fig. E2-30) whileothers are equipped with a full gear shiftlower unit (Fig. E2-33) or for-ward/neutral lower unit (Fig. E2-S6).Refer to the appropriate following para-graphs for servicing procedwe.

Non-Shifting Lower Unit

R&R AND OYERHAUL. Most serv-ice on the lower unit can be performedby removing gearcase assembly fromlower motor leg; or by removing gear-

pn

rl,,T

1. Drive shaft1A. Drive shaft

2. Roll pin3. Needle pin4. Screw5. Seal6. "O" ring7. Water pmp housing8. Impeller9. Bse plate

IU. SEA11. Roll pin12. Sleeve13. Clip14. Stud nut15. Screw16. FilVdrain plug17. Vent plug18. Germe19. Bushing20. Snap ring21. Pinion gear22. Snap ring23. Bushing24. Sprcer25. Drive geu26. Shim27. Bushing28. Roll pin (large)29. Roll pin (small)30. Gsket31. Lower cover32. Seal33. l{asher34. Propeller shaft35. Shear pin36. Propeller3?- Water tube38. Nut39. Sealing washer40. lVasher41. Nut

an bethe

rmblytholder tonstallinnerulley.d they ap-illing

l im-3 C2-

Flg. E2.g2-Lowat unlt may be rcmoyad lrcmmolot lcg allu rcmoval ol nut (29) and scrcw

(31)'

109

28I

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/29

OUTBOARD MOTOR SE345

6

(61). Detent (67) and spring (68) will bereleased as bracket is pulled awav.. Remove _ screws (b6) securinglever bracket (58) to cover. R-e

as lmproper service procedures maydamage gearcase. A combination re,movaliinstallation tool for drive shafdmoval/installation tool for drive shaf{needle bearing (35) may be constructedusing drawing in Fig. EZ-84.

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, ; €

il-n12*@l3---o14-gl5--:16-'A1l-""

28-s27 -0

iarge snap-ring (49) then gently tap pro-peller shatt (52) out of cover. Small rollpins (60) secure left (20) and rieht (?1)shift bracl<et guide pins in coverJOtl. tor9m-9ve. bearing_ (51) from propellersnalt, clamp collar (48) in vise iaws.drive roll pin (47) out then remove iollarand snap ring (50). Place propeller shaftrn a vise so that inner race of ball bear-ing (!t) is supported but jaws are nottouchlng propeller shaft. Use a softtaced hammer to drive shaft out of bear-ing.

To remove drive shaft (18), remove retainer-plate (14) and snap ring (L6). Holdonto drive shaft and use a-soft facedhammer to drive gearcase off shaft.Remove drive pinion (BZ) and forwardgear (40). Ball bearing (1?) may be re-moved from drive shart by irlaciirg shaftin a vise so inner race of bearingis sup-p_orted but jaws are not touching shaft.Use a soft faced hammer to dririe shaftout .of bearing. When installing ballbeanng (17), make swe that shieldedside of-bearing is facing water pump.. Needle -bearing (Bb) ind nusfiing (S+;

should only be serviced with proper tools

29----*€32=-o34

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Flg' E2'33-Exploded Yiew ot fult gaat shllt towet unlt. When assembling lowet unit" use petrcteumlelly to lubilcate watet pump tmpettet (11) anA watii iiie seal (9).

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47 IL.-!

71{

careful not to drop screw in motor leg.Remove clip (28-Fig. EZ-82). Remoiescrew (31) and stud nut (29). Pull lowerunit from motor leg.

Shift lower unit into neutral position.Rem_ove water pump assem-bly. Becareful not to loie impeller drive pin

110

55. Fork lever56. ScrewD I. rtn58. Lever bmckeb59. Screw60. Roll pin61. Cover62. Seal63. Wcher64. Cushion hub65. Propeller66, Nut6?. Detent68. Spring69. Shifter bracket70. Left guide pin?1. Right guide pin

(19-Fig. E2-33). Remove propeller,shear pin and screw (bg) thit iecuregear -cover (61). PuIl propeller shaftassembly from gear box whiie pulling uplightly on shift rod (21). Place thumbover detent hole in shifter bracket (69)while pulling bracket away from covei

35. Needle berins36. Gearme3?. Pinion gear40. Foruard ser41. Bushing

-

42. Shift dog43. Reverse gear44. Bushins45. Shim w:asher47. Roll pin48. CoUar49. Snap ring50. Snap ring51. Ball beainq52. Propeller s[aft53. Shea pin54. "0" ring

r ,126 IE t 7.75

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}IAROENED FOR USEWITH A HAMM€R

Fig. E2.34-Drawing ol a special toot thatshould be used lot rcmoval and Instaltatton ol

needle beailng (35 - Ftg. E2-33).

il

Eska 3, 3.5, 4.So5, 5.5, 7 & 7.5 llP

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1. Shift link2. Screw3. Nut4. Washer5. Seal6. Water tube7. Screw8. Seal9. Seal

10. Pump body11. Impeller12. Base plate13. "O" ring14. Retainer Dlateto. Dea16. Snap rins1?. Shidlded-ball bearing

18. Drive shalt19. Pin

?9'lpr:u' .zl. snm rod22. Cotter pin23. Clevis pin24. "Q" rins25. Rubber boot26. Seal27. Roll pin28. Clip29. Stud nut30. Pilot bushing31. Screw32. Vent93. Drain fill plug34. Bushing

l l lustrations Courtesy Esl€

OTOR

) will be'ay,

mp pro-mall rollght (71)(61). Torropellerie Jaws,re collarer shaftrll bear-are nota soft

of bear-

nove re-6). Hold[t facedf shaft.[orwardI be re-rg shaft; is sup-g shaft.re shaftng ballrhieldedrlllflP.

ing (34),er tools

SERVICE MANUAL

e.IrR'ff]

FIs. E2.ss-Drawtng of"o""i"ir?", which mayDe usad to l|'Etall bushtng (34-Flg. E2.gg)

ln gaarcasa.

h. To remove bearing (35-Fis. E2-BB).,:ffilace tool, without t'i clip, ii bearins:#from top of gearcase and pound on end

of tool. To install bearing (Bb), place ,,C"clip on tool so that new bearinE will beproperly positioned in bore whei drivenin from top of gearcase.

A blind hole bearing puller should beused to pull propeller shaft bushing (84).A special driver (Fig. Ez-Bb) should beused to install new bushine.

.Bushings {41 & 44-FiE: E2-38) mavbe removed and reinstalled with tire aihof an arbor press.

When reassembling lower unit, makesur-e thatoil seals (15, 26 and 62) are in-stalled_ with lips facing inside of gear-case. Shift bracket guide pin (?0) withdetent grooves must-be insialleb o'n f"Ii.Shift shaft (21) is installed with flat onend facing left side. Install retainer plate(14) so notches align with cutouts inwater pump base plate (12).

Eska 3, 3.5, 4.5, 5,5.5, 7 & 7.S HpWhen assembling gearcase ro motor

leg, use a flashlighi to observe throughexhaust outlet that water tube (6)'isproperly seating in water pump. Installwasher and stud nut (29) before install-ing screw (31). Check shift mechanismfor proper engagement. Detents in shiftmechanism in lower units should be feltwhen operating shift lever.

Fonrard/Neutral Lower Unit

R&R AND OVERHAUL. Refer toFig. E2-36 for an exploded yiew of lowerunit. To remove lower unit from motorlgg, remove inspection cover (Fig.92 31) and shift linkage screw (2-Fig.E2-36). Be careful not to drop screw in

motor leg. Remove letaining_screw (10)and stud nut in front erand separate r o*e,. uni fflX,lt *t'"t;,9*Drain lubricant and remove pr"p.liil;and shear pin. Remove water i.,,---assembly. Remove to*". .ou".'6iifRemove propeller shaft assemblr,'Ii'idisassemble as required. Detact" *i"iring (30) and withdraw drive shaft i3;i

Jlspect components und ..nu*'li,uwhich are exc.essively worn or au"nueuj.Backlash a.1d .qe;h p-osition

".. ]i*-"1

ano.nor adJustable. tf backlash is ex-cessive, renew the worn parts.

Reverse disassembly piocedure whenassembling lower unit. Be sure clutchIever (21) properly engages clutch izdjIlange.

Fig, E2.36-Explodad vtewol towad/heut'al lowet unitusod on some rnodsls.Spacer (27A) ts usad on later

modals.r. Shift link2. Screw3. Shift rod4. Clevis pin5. Cotter pin6. "O" ring7. Rubber boot8. Seal9. Pilot bushins

tu. Dcrew11. Nut12. Cotter pin13. Propeller14. Cwhion hub15. Sheu pin16. Washerr r. seat18. Propeller shaft19. Vent plug20. Pin21. Clutch lever22. Shim23. Washer24. "E" riag25. Clutch26. Snap ringzI. Gear

27A. Spacer.28. .Needle.beuinszy. l,lnlon gear30. Snap ring31. Gasket92. Lower cover33. Gearcae34. Water tube35. Driie shaft36. PinJ-/. Seal

38. Seal39. Pump body40. Impeller41. Base plat€42. Seal43. Needle bearins44. Stud45. Roll pin

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ione s

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,ol thatlatlon ol

'sy Eska lllustrations Courtesy Eska