Using a suitable punch, drive lower pivot pin into Manual Tilt System clamp bracket and trim cylinder assembly until Installation pivot pin is flush with outside surface. Apply Perfect Seal on O. Copyright 2019 Marine Service Manuals. This Force Outboard 40 hp 40hp 2 cyl 2-stroke 1992-1999 Service Manual Free Download is a complete factory service and repair manual for your Force Outboard 40 hp 40hp 2 cyl 2-stroke. Check piston rings to be sure they fit freely in groove. Maintenance and troubleshooting are covered in each manual as well as wiring diagrams.
Install water pump seal carrier. Install piston ring in appropriate groove on piston 1. If shims are damaged, replace with new shims of equal thickness. Install spiral retaining ring into the inner ring groove. The only information I could get from the owner is that the engine bay was filling with water when he was running it on the river. Assemble Pinion Gear Locating Tool 91-12349A2 9. Place one lead of ohmmeter on armature core or shaft and other ohmmeter on the negative brush and the other lead lead on commutator, as shown.
Open wire between Wire Connection 1 1. Remove bearing and then sleeve using Puller Assembly 91-83165M with suitable jaws. Fasten Power Trim System ground strap between anode and clamp bracket. It is recommended that all o-rings exposed during disassembly be replaced. Water Pump Base Seal Installer 91-817006.
Position cylinder end cap onto rod as shown. Use a lead ham- mer to avoid damage to propshaft. Install reverse gear and bearing assembly. Piston Lock Ring Installer 91-77109A3 12. Replace reverse gear if gear teeth or clutch teeth on reverse gear are chipped or worn. Hold bolt Checking for Cavitation Continued from turning, and tighten locknut on bolt.
Reassembly Forward Gear Bearing Race 1. Diligent maintenance is applied to combat the or from an irregularity in the propeller blade itself. Replace shift shaft if splines are twisted or 1. Remove bolts securing oil tank. If the out- board strikes an underwater object while in forward gear the trim ram b will try to rapidly extend from the cylinder, the pressure increases inside the trim cylin- der down cavity and connecting passages.
Replace sliding clutch if jaws are rounded or 1. Store outboard in an upright vertical position to allow water to drain out of outboard. Spread rings just enough to slip over piston. Drain and refill the gear case lubricant refer to maintenance procedure. Wash off immediately Battery with baking soda solution. Positioning Outboard for Storage 1. Remove two screws from the shock rod cylinder 1.
Apply 2-4-C Marine Lubricant to lower pivot pin. This is the Official Service Manual that the dealers and shops use. Disconnect link rod from cam lever. Carbon monoxide is the product of incomplete combustion Through the Environmental Protection Agency and is a dangerous, potentially lethal gas. Impeller is glazed or melted caused by operation without sufficient water supply. Clean shock rod and components with parts cleaner and dry with compressed air.
Replace memory pis- Trim leaks down. Manual release valve Inspect manual release valve. Push-in on the cable end until resistance is felt. Use an ohmmeter, set to R x 1 scale and con- nect between solenoid terminals 3 and 4. Straighten the bent tabs on the impeller nut re- tainer and remove the impeller nut. Install in the area shown. Remove plug from tiller handle bracket 10.
Remove o-ring from memory piston. Remove memory piston from cylinder using one to separate the valve block. Wear Sleeve Installation Tool 91-14310A1 Special Tools 1. Remove nut and washer in trim tab cavity. Remove two bolts securing fuel pump to power- head. Remove o-ring from shock rod piston. With the pump gears rotating backwards, the flow of oil is reversed.
Secure starter to block with 3 bolts. Tilt outboard to the full up position and support with tilt lock pin. Install O-ring seals into the top seats of the three passage holes. Replace plastic cap after installation. Check each connecting rod for correct alignment by carefully running fingernails up and down 2.