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 / Specifications

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 / Specifications

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP

Lubrication / Oil recommendations / Premix models / Oil injection models / Gearcase lubrication / Gearcase lubricant level check / Gearcase lubricant oil change / Jet drive lubrication / Throttle and shift linkage lubrication / Steering cable lubrication / Swivel shaft and tilt tube lubrication / Title lock mechanism lubrication / Bearing carrier lubrication / Maintenance / Propeller shaft and propeller maintenance / Cooling system maintenance / Flushing the cooling system / Battery maintenance / Starter maintenance / Fuel requirements / Fuel additives / Fuel filter service / High-pressure fuel pump maintenance / Drive belt inspection / Pump oil level check / Changing the pump oil / Fuel hoses and clamps/ Corrosion prevention / Storage / Submersion / Tune-up / Compression check / Spark plugs / Timing adjustment / Throttle position sensor (TPS) adjustment / Carburetor adjustment / Engine break-in / Specifications

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 / Specifications

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 / Specifications

CHAPTER SIX / ELECTRICAL AND IGNITION SYSTEMS

Battery / Starting system components / Charging system / Ignition system / Sensors, switches and relays / Warning system components / Specifications

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 / Specifications

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 / Specifications

CHAPTER NINE / JET DRIVE

Jet drive operation / Jet drive mounting height / Jet drive repair / Specifications

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 / Specifications

CHAPTER ELEVEN / MIDSECTION

Midsection / Specifications

CHAPTER TWELVE / OIL INJECTION SYSTEM

Oil injection system operation / Oil injection system / Specifications

CHAPTER THIRTEEN / REMOTE CONTROL

Remote control / Specifications

INDEX

COLOR WIRING DIAGRAMS