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TABLE OF CONTENTS
QUICK REFERENCE DATA CHAPTER ONE / GENERAL INFORMATION Manual organization / Warnings, cautions and notes / Safety / Model identification / Engine operation / Fasteners / Shop supplies / Galvanic corrosion / Propellers / Basic tools / Special tools / Precision measuring tools / Electrical system fundamentals / Basic mechanical skills CHAPTER TWO / TROUBLESHOOTING Preliminary inspection / Operating requirements / Starting difficulty / Starting system / Charging system / Fuse and wire harness / Warning system / Ignition system / Fuel system (carburetor equipped models) / Fuel system (EFI and HPDI models) / Electronic control system (EFI and HPDI) / Oil injection system / Tilt and trim system / Power head / Cooling system / Gearcase CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP Lubrication / Maintenance / Tune-up / Engine break-in CHAPTER FOUR / TIMING, SYNCHRONIZATION AND ADJUSTMENT Timing, synchronization and adjustment / Synch and link (80 jet, 105 jet and 115-200 hp [except EFI and HPDI models]) / Synch and link (150-250 hp [EFI and HPDI models]) / Miscellaneous adjustments CHAPTER FIVE / FUEL SYSTEM Fuel system safety and general information / Fuel tanks / Primer bulb / Fuel hoses / Fuel hose connector / Fuel pumps / Fuel filters / Vapor separator tank / Silencer cover, fuel rail and injectors (EFI and HPDI models) / Throttle body / High pressure mechanical fuel pump / Carburetor and silencer cover / Reed housing/intake manifold CHAPTER SIX / ELECTRICAL AND IGNITION SYSTEMS Battery / Starting system components / Charging system / Ignition system / Sensors, switches and relays / Warning system components CHAPTER SEVEN / POWER HEAD Power head preliminary information / Service consideration / Power head break-in / Service recommendations / Lubricants, sealants and adhesives / Sealing surfaces / Fasteners and torque / Power head removal/installation / Flywheel / Power head disassembly / Power head components cleaning and inspection / Power head assembly CHAPTER EIGHT / GEARCASE Gearcase operation / Propeller removal/installation / Gearcase removal/installation / Water pump / Gearcase repair / Gearcase disassembly (standard RH rotation gearcase) / Component inspection / Gearcase assembly (standard RH rotation gearcase) / Shim selection (all models) / Counter rotation (LH) gearcases / Gearcase pressure test CHAPTER NINE / JET DRIVE Jet drive operation / Jet drive mounting height / Jet drive repair CHAPTER TEN / POWER TILT/TRIM Hydraulic tilt/trim system removal and installation / Tilt/trim relay replacement / Tilt/trim sender replacement / Electric tilt/trim motor removal and installation / Tilt/trim system electric motor repair / Manual release valve removal and installation / Hydraulic system filling and bleeding CHAPTER ELEVEN / MIDSECTION Midsection CHAPTER TWELVE / OIL INJECTION SYSTEM Oil injection system operation / Oil injection system CHAPTER THIRTEEN / REMOTE CONTROL Remote control INDEX WIRING DIAGRAMS
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