Evinrude & Johnson 1975 E265RC, Service Manual

Page 1: ...j265RC OUTBOARD MARINE CORPORATION 1974 ALL RIGHTS RESER VED SN MOBILE DIVISION OUTBOARD MARINE CORPORATION 3031 NORTH 114th STREET MILWAUKEE WISCONSIN 53222 OUTBOARD MARINE CORPORA TION OF CANADA LTD...

Page 2: ...INJURY TO YOU OR TO OTHERS WARNS YOU AGAINST AN ACTIVITY WHICH IS OR MAY BE ILLEGAL IN YOUR AREA ADVISES YOU OF INFOR MATION OF INSTRUC TIONS VIT AL TO THE OPERATION OR MAINTE NANCE OR YOUR EQUIP MENT...

Page 3: ...but will also provide more basic information for the guidance of the less experienced man The Parts Catalogs contain complete lfstings of the parts required for replacement In addition the exploded v...

Page 4: ...n to give better service to the snowmobile owner and thereby build and maintain a reputation for reliable service This service manual covers all phases of servicing the snowmobile however new service...

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Page 6: ...14146 162282 263308 318665 385996 DESCRIPTION Flywheel Puller Center Guide for Flywheel Puller Three Screws for Flywheel Puller Wrench Flywheel Nut Truarc Pliers Spring Winder Reli Coil Installers Ins...

Page 7: ...cation Gasoline Carburetor OMC float type RPM Ratings Idle Transmission belt engaging speed Maximum RPM at which neutral control will operate Ignition Breakerless magneto C D Capacitor Discharge ignit...

Page 8: ...r Suspension to Frame 5 16 24 Nut Runner to Ski 5 16 18 90 100 Screw Secondary End Cap to Shaft 3 8 16 Screw Sensor Shield to Flywheel End Housing 10 24 25 35 Screw Shifter Clevis to Pinion Shaft 1 4...

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Page 10: ...ll ROTARY COMBUSTION ENGINE THEORY 3 2 RC ENGINE PARTS NOMENCLATURE AND FUNCTION 3 3 COMPRESSION 3 5 CARBURETION 3 5 COOLING 3 6 IGNITION 3 7 LIGHTING SYSTEM 3 8 POWER FLOW 3 8 PRIMARY DRIVE 3 8 NEUTR...

Page 11: ...ions 1 4 and a fuel air mixture from the carburetor is thus induced into the engine through the open intake port CD In positions 5 7 the intake port is closed and compression of the fuel air mixture t...

Page 12: ...oling fins on the outside peripheral intake and exhaust ports through the trochoid surface and the spark plug hole and fuel pump pulse pressure port It has the high performance inlet port passage and...

Page 13: ...side seals fit in grooves in side of rotor Their function is to seal combustion chambers from the eccentric shaft caVity A wave spring behind Side seal provides a light pressure of side seal against s...

Page 14: ...otor flanks perform two functions They compress the fuel air mixture before ignition and receive the force of combustion after ignition Escape of the combustion gases past the rotor seals is referred...

Page 15: ...rt At high speeds progressive linkage on the carburetor admits the fuel air mixture to the engine by opening the peripheral port throttle Use of the side inlet port provides good engine performance at...

Page 16: ...k plug gap within the chamber and thus ignites the compressed fueVair mixture in the chamber This system is made up of the following major components 1 Flywheel assembly 2 Stator and charge coil assem...

Page 17: ...arge when lights are turned on POWER FLOW The transmission assembly transmits power from the engine to the front axle which propels the vehicle along the track The primary sheave assembly is attached...

Page 18: ...nly when the engine is below apprOximately 2000 RPM When the engine is running above approximatley 2000 RPM the garter spring will expand by centrifugal effect See Figure 3 10 The garter spring will t...

Page 19: ...ed from the secondary sheave assembly through a drive chain to the front axle The ratio between the secondary sheave assembly and the front axle is 17 39 REVERSE TRANSMISSION The reverse gear is desig...

Page 20: ...ING t till TABLE OF CONTENTS DESCRIPTION 4 2 TROUBLE SHOOTING PROCEDURES 4 3 STARTING 4 3 STARTING MANUAL STARTER 4 3 STARTING ELECTRIC STARTER 4 4 RUNNING LOW SPEED 4 4 RUNNING HIGH SPEED 4 4 RUNNING...

Page 21: ...ermining the cause of the problem and 3 Correcting the problem Familiarity with the factors which affect rotary combustion engine performance is important in making a correct service diagnosis Fac tor...

Page 22: ...properly e Carburetor low speed needle not adjusted correctly f Bad spark plug g No spark h Air cleaner or intake blocked or restricted i Clogged fuel line or filter j Engine flooded 4 3 k Faulty or m...

Page 23: ...starter motor g Broken or worn brushes or broken brush spring h Faulty field or armature shorted or open windings i Starter does not engage with engine because drive gear is not free on helix 3 Start...

Page 24: ...cked RUNNING mGH AND LOW SPEED 1 Engine overheats a Incorrect gas lubricant ratio b Improper engine assembly 4 5 c Cooling fins blocked by foreign material d Cooling fan intake restricted e Cooling ai...

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Page 26: ...N 5 2 FACTORS AFFECTING PERFORMANCE 5 2 FUEL SYSTEM 5 2 IGNITION SYSTEM 5 2 COMPRESSION 5 2 NEW VEffiCLE DELIVERY 5 3 TUNE UP PROCEDURES 5 3 STATIC AIR LEAK CHECK 5 5 CARBURETOR ADJUSTMENTS 5 7 LOW SP...

Page 27: ...moved emptied of old fuel rinsed out installed and refilled with a fresh supply at the beginning of the season and at every tune up A stale fuel mix ture may cause hard starting stalling and faulty op...

Page 28: ...stands how to operate the engine correctly espeCially such things as the neutral control choke electric starting and reverse shift lever TUNE UP PROCEDURES Components which affect engine power and per...

Page 29: ...replaced d If static air leak check is not satisfactory engine overhaul is re quired see Section 9 e Test ignition system using spark checker and neon Tester Inspect high tension lead See Section 7 f...

Page 30: ...ivel at F and thru the 12 m m adapter at G threaded into the spark plug hole and into the combustion cham ber from which it escapes by leaking past the side seals and apex seals of the chamber being t...

Page 31: ...ow Readings One of the two likely conditions if a performance fault is noted after the first few hours of operation One damaged apex seal will affect the pressure readings for both combustion chambers...

Page 32: ...needle counterclockwise 1 8 turn at a time Reset idle adjust ment screw to attain 1100 1400 rpm each time low speed needle is adjusted 7 Accelerate engine then release throttle engine should return t...

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Page 34: ...FLOW 6 2 CARBURETOR 6 2 REMOVAL 6 3 DISASSEMBLY 6 3 CLEANING INSPECTION AND REPAIR 6 5 REASSEMBLY 6 6 INSTALLATION 6 6 FUEL PUMP 6 7 REMOVAL 6 7 CLEANING INSPECTION AND REPAIR 6 7 REASSEMBLY 6 7 FUEL...

Page 35: ...removes dirt or other impurities from the fuel before the fuel passes through the pump or carburetor The primer assembly operated from the control panel injects raw fuel into the manifold before start...

Page 36: ...t carburetor and gasket out of compartment and disconnect fuel line from carburetor o NOTE Some solvents and cleaners have a damaging effect on the syn thetic rubber parts used in carburetors It is be...

Page 37: ...6 4 4 FLOAT CHAMBER ATTACHING ____ SCREW I d Figure 6 4 I I r PCJ l f r FLOAT CHAMBER 5 8 fff J 37013...

Page 38: ...must be replaced Use a new gasket when reinstalling the needle seat Needle Valves a Inspect the tapered end of the needle valve for grooves nicks or scratches replace if necessary See Figure 6 7 b DO...

Page 39: ...mbly Be sure that parts are clean and free from gum varnish and corrosion when reassembling them Replace all gaskets and 0 rings 00 NOT attempt to use original gaskets and 0 rings because leaks may de...

Page 40: ...ning and inspection without removing pump assembly by removing filter cap screw SAFETY WARNING Do not allow fuel to drip on hot engine or exhaust manifold because of potential fire hazard CLEANING INS...

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Page 42: ...H TEST BLOCKING DIODE TEST BRAKELAMP SWITCH TEST CHECKING RECTIFIER DIODES 7 2 7 3 7 3 7 3 7 3 7 5 7 5 7 6 7 7 7 8 7 9 7 10 7 11 7 11 7 13 7 13 7 13 7 13 7 14 7 14 7 14 7 14 7 14 7 14 IGNITION SYSTEM...

Page 43: ...d fuel air mixture The following sequence of events will illustrate how this system works The flywheel rotates around the stator and charge coil assembly See Figure 3 7 The magnets in the flywheel and...

Page 44: ...for a discussion of the C D ignition theory All the fol lowing tests can be conducted without the removal of the flywheel C D IGNITION SYSTEM DO S AND OONT S 1 Do make sure that all connections are c...

Page 45: ...ht cause damage to the system 11 Don t attempt any tests other than those listed in the trouble shoot ing procedure You might cause damage to the system 12 Don t connect an electric tachometer into ig...

Page 46: ...r H cranking manually put ignition switch in Run position and use rewind starter See Figure 7 10 1 Strong steady spark from ignition coil system is good Check spark plug Then refer to fuel system sect...

Page 47: ...ss than 500k ohm reading remove terminal connectors from ignition switch see Figure 7 12 and remove ignition switch from dash panel Turn ignition key to RUN position and take a resist ance reading acr...

Page 48: ...7 14 C Put ignition switch in RUN position for manual cranking D Hold load button A and crank engine with starter or recoil starter and observe neon light See Figure 7 14 1 If light check ignition co...

Page 49: ...al cranking D Set neon tester rotary switch to position 2 Hold load button B E Crank engine with starter or recoil starter and observe tester neon light See Figure 7 15 1 If light charge coils are goo...

Page 50: ...st 1 4 volts B Connect S80 or M80 tester black lead to Power Pack RE terminal 2 and blue lead to terminal 8 Set tester selector switch to posi tion 3 C Put ignition switch in Run position for manual c...

Page 51: ...ome within these tolerances it must be replaced Check on low ohms scale B Ignition sensor coil or lead must not be shorted to ground On ohm meter high ohms scale check for a reading of infinity from b...

Page 52: ...n ignition analyzer should be used Without the use of test equipment coil may be replaced needlessly A wide variety of ignition analyzers are avail able from various manufacturers In addition some aut...

Page 53: ...and turn meter selector switch to Coil Continuity See Figure 7 19 Index reading should be between 22 and 26 B POWER TEST using MERC O TRONIC TESTER Connect meter leads to adapter adapter red lead to...

Page 54: ...preventing one or more of the electrical circuits from operating To eliminate problems due to improper connections examine the terminals on both halves of the connectors after as sembly to be sure th...

Page 55: ...diode leads and connect continuity meter HI ohms scale between gray and yellow lead Reverse leads and note reading Meter should read in one direction only B Repeat blocking diode test on gray and blue...

Page 56: ...ssembly to the fly wheel end side housing Install two brass washers between sensor and side housing Use Loctite TL242 on the screws I_ I NOTE The tolerances in the bearings make it necessary to push d...

Page 57: ...performance and premature spark plug failure may re sult from improper spark plug installation Before installing the plug be sure the plug seat in the cylinder head is cleaned and free from obstructio...

Page 58: ...plosive hydrogen gases generated when charging or jumping a battery are therefore vented a safe distance from the hazard of spark at the battery terminals Check vent tube periodically to make sure tha...

Page 59: ...ery to full charge at once Charging the battery will mix the water with the electrolyte and prevent water freezing in the battery CAUTION Do not overfill Spilled acid may damage surrounding parts 4 Ke...

Page 60: ...arger occa sionally to keep battery fully charged during long storage periods or in extreme cold weather if engine is started repeatedly Battery should be removed from compartment for charging and ini...

Page 61: ...operating prop erly If the starter motor does not crank the engine or if it cranks too slowly check the battery cables and connections Inspect all wiring connections in the starter circuit to insure t...

Page 62: ...tch to START to crank engine NOTE By placing voltmeter leads against battery solenOid and starter motor terminals rather than against connecting cable ends each connection can be tested for high resis...

Page 63: ...continuity means that the armature windings are grounded and armature must be replaced c Check armature for open windings by using an ohmmeter Meas ure resistance between adjacent commutator segments...

Page 64: ...lly throughout the circuit cannot be overemphasized The largest percentage of electrical system failures are caused by one or more loose or dirty connections Check for corroded or loose connections an...

Page 65: ...at a distance of 25 ft rom head lamp For right or left throw of beam adjust either screw until proper aim is obtained HIGH INTENSITY ZONE Figure 7 43 t HEIGHT OF HEADLAMP 37060 PEAK VOLTAGE TEST USING...

Page 66: ...c SECTION a MANUAL STAR TER TABLE OF CONTENTS DESCRIPTION 8 2 REMOVAL AND DISASSEMBLY 8 2 CLEANING INSPECTION AND REPAIR 8 3 REASSEMBLY 8 3 STARTER ROPE REPLACEMENT 8 4...

Page 67: ...OVAL AND DISASSEMBLY a Raise hood b Pull starter rope out and untie knot in handle while holding rope c Ease rope back into starter until starter spring is fully unwound d Remove three screws securing...

Page 68: ...of pulley Slide one end of pin through holes in pulley and spring loop e Carefully remove the hand crank and bushing Lift pulley off base plate holding spring in pulley f Place pulley and spring into...

Page 69: ...Pull starter handle until rope is fully unwound Lock starter pulley in position by aligning holes in housing and pulley and inserting a nail or pin through them c Untie knot and remove rope from rope...

Page 70: ...ION AND REPAIR 9 8 ROTOR 9 8 ROTOR HOUSING 9 8 FAN END SIDE HOUSING 9 9 FLYWHEEL END SIDE HOUSING 9 9 ECCENTRIC SHAFT 9 9 SEALS 9 10 FLYWHEEL 9 10 STATOR AND SENSOR 9 10 ASSEMBLY OF ENGINE 9 10 USED S...

Page 71: ...k slightly 9 Disconnect speedometer cable and wires tachometer ignition switch connector and throttle and choke cables and primer hose from the carburetor Remove primer cable from fuel tank 10 Disconn...

Page 72: ...t No 263308 See Figure 9 6 5 Remove the end cap bolt and plunger and rod assembly Use flywheel holding tool See Figure 9 6 6 Remove the end cap assembly Clamp can now be removed Remove sliding sheave...

Page 73: ...ve the drivetube and ratchet assembly outer fan inner fan and eccentric shaft counterweight See Figure 9 10 12 Remove the fan end woodruff key from the eccentric shaft us ing screwdriver on underside...

Page 74: ...ut of nylon bushing See Figure 9 14 16 Remove the starter held with three screws and flat washers See Figure 9 15 17 Cut the electrical Wlrlllg tie straps and remove the electrical wire clips securing...

Page 75: ...thru bolts See Figure 9 22 26 Remove all of the remaining rotor housing thru bolts except the two minor axis thru bolts See Figure 9 22 27 Scribe engine frame for proper engine alignment during re as...

Page 76: ...g each in its appro priate location in your seal holding fixture 35 Use screwdriver in pry tabs to loosen rotor housing from fly wheel side housing See Figure 9 28 DNOTE Care should be taken when usin...

Page 77: ...ions The seal should fit freely to the bottom of the groove from end to end of the rotor B Remove all carbon from the side seals Insert each side seal in a groove The seal should fit in the seal groov...

Page 78: ...urface FLYWHEEL END SIDE HOUSING See Figure 9 36 27 Inspect the flywheel end side housing rotor sealing surface for scratches gouges or scuffing 28 Inspect the side housing to rotor housing clamping s...

Page 79: ...l ring gear STATOR AND SENSORS See Section 7 ASSEMBLY OF ENGINE See Figure 9 39 Begin the reassembly procedure by cleaning all parts thoroughly 1 Lubricate the roller bearing with RC oil in the flywhe...

Page 80: ...f ri tJij l r THRUI a_BOLTl KEY J COUNTERWEIGHT ______ CRANKSHAFT __SEAL END HOUSING FLYWHEEL ROTOR SIDE INNER FAN HOUSING HOUSING ____ OVER t I I I I I I I I I I I I I ROTOR J HOUSING 1 1 I I fi ____...

Page 81: ...firmly 10 Turn the eccentric shaft one revolution to be sure the rotor and fixed gear are timed properly 11 Insert one apex seal spring behind each apex seal See Figure 9 40B 12 Insert the apex seal c...

Page 82: ...38 39 Position the sensor using the sensor gauge assembly and snug the sensor screws to 25 35 in Ibs See Figure 9 41 Install the stator and coil assembly to the flywheel end housing Use Lactite TL242...

Page 83: ...proper placement Check sheave alignment per procedure in Section 10 under SHEAVE ALIGNMENT Install the throttle cable to the carburetor With throttle lever on carburetor in fully open pOSition adjust...

Page 84: ...ION 10 5 10 5 10 5 10 5 10 6 10 6 SHEAVE ALIGNMENT 10 6 ALIGNMENT 10 6 ADJUSTMENT PROCEDURES 10 6 BRAKE 10 7 DESCRIPTION 10 7 ADJUSTMENT 10 7 REMOVAL 10 7 REPAIR 10 7 BRAKE CABLE AND CAM ASSEMBLY 10 9...

Page 85: ...Y WARNING Keep fingers from between halves of secondary sheave when per forming next step Sliding sheave is spring loaded and could pinch fingers e Ride belt off sheave as sheave is twisted to right a...

Page 86: ...pecial clamp OMC Tool No 263308 be fore proceeding with disassembly i Remove the end cap bolt and plunger and rod assembly Hold fly wheel with holding tool See Figure 10 10 j Remove the end cap assemb...

Page 87: ...and blow dry with compressed air b Inspect main shaft and sheave assembly splines for wear c Inspect neutral lockout plunger for wear Replace if required d Inspect transmission belt A glazed or burned...

Page 88: ...l lockout is pushed in the Sliding sheave must not slide on spline When neutral lockout is out normal operating position the sliding sheave must slide freely on spline restricted only by the primary s...

Page 89: ...must be checked as follows ALIGNMENT Using service tool check for 3 58 03 from outside edge of primary fixed sileave to outside edge of secondary fixed sheave at top and bottom of sheaves as shown in...

Page 90: ...REMOVAL a Loosen brake adjustment nut See Figure 10 21 b Remove cotter pin and washer from brake control pivot pin Com press brake return spring and remove pivot pin from control cable c Remove brake...

Page 91: ...T GEAR GEAR AND SHAFT I CRADLE I NEEDLE OUTER BEARING N BE ARING VENT J THRUST 4 l SUPPORT WASHERS _ J I I ROD SHIM 0 If 0 RING t 0 PINION fY SEAL I THRUST f I I SGH T BEARING TR UMJO I ____ ANSMISSIO...

Page 92: ...ount 0 3cc in groove in bushing b Assemble Secondary sheave assembly on transmission input shaft in reverse order of disassembly Engage spring ends in holes in movable sheave and end cap Preload sprin...

Page 93: ...ANING INSPECTION AND REPAIR a Clean all parts with a cleaning solvent such as Trichloroethylene and blow dry with compressed air See A SAFETY WARNING on page 10 4 b Inspect shafts and output shaft spl...

Page 94: ...s of reverse lock clevis and lock plates These centerlines must cross as shown in Figure 10 28 SHIFT CONTROL ROD ADJUSTMENT a Assemble control rod thru dash panel b Place transmission in forward opera...

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Page 96: ...Y 11 3 SKI ALIGNMENT 11 3 TRACK AND SUSPENSION 11 3 TRACK TENSION ADJUSTMENT 11 3 TRACK ALIGNMENT ADJUSTMENT 11 3 REMOVAL OF TRUCKS AND TRACK 11 4 FRONT AXLE DISASSEMBLY 11 4 REAR A LE DISASSEMBLY 11...

Page 97: ...K NUT AND FLAT WASHER d Remove ski columns BALL JOINT TO CENTER CLEANING INSPECTION AND REPAIR a Remove all dirt and old grease from ski columns and from inside ski column mounts and bushings b Inspec...

Page 98: ...st be checked after the first ten hours of operation and then every 25 hours or as required to maintain efficient economical operation Improper adjustment will result in undue wear to the track and dr...

Page 99: ...r g Remove retaining ring sprocket and spacer from end of axle See Section 10 h Loosen set screws from bearing locking collars and rotate collars clockwise to free axle from bearings i Remove three sc...

Page 100: ...XLE i CROSS SHAFT _ I WHEEL SPROCKET FRONT TRUCK k WHEELS i1J J WHEEL AXLE 7 BE RING I REAR AXLE FRONT AXLE o HO CENTER SPACER V 3P FRONT AXL SPACER OUTER BUSHIN I W BUSH NTG g o l II REARTRUCK AXLE C...

Page 101: ...f damaged FRONT AXLE ASSEMBLY See Figure 11 7 a Assemble bearings flangette gasket and 0 ring to chain case b Assemble flangette assembly bearing and flangette to right end of axle c Insert left end o...

Page 102: ...MBLY a For sequence of assembly of wheels bearings pivot arms and brackets refer to Figures 11 5 and 11 7 b Lubricate the outside of the pivot bushing with OMC Part No 114154 grease c Lubricate outsid...

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Page 104: ...CONTENTS ENGINE LUBRICATION 12 2 LUBRICATION RECOMMENDATIONS 12 4 PREVENTIVE MAINTENANCE 12 5 AIR FILTER 12 5 FUEL FILTER 12 5 STORAGE 12 6 PREPARATION FOR STORAGE 12 6 REMOVAL FROM STORAGE 12 6 INTER...

Page 105: ...peed of the engine Both optimum performance and lubrication depend on maintaining the correct ratio between gasoline and lubricant in the fuel mixture The use of too little lubricant leads to prematur...

Page 106: ...s partial mixture Next add the balance of gaso line necessary to bring the mixture to the required ratio of 50 1 Again thoroughly agitate the mixture A clean funnel equipped with a fine screen should...

Page 107: ...Drive Chain oil bath See page 10 5 OMC Sea Lube every 25 hrs of CD operation Reversing transmission See page 10 10 Dexron ATF Once a season CD Primary Drive disassembly required Lubriplate 907 normal...

Page 108: ...Never run engine without an air filter It is essential for proper carburetor calibration FUEL FILTER 4 SAFETY WARNING Exercise care to prevent fuel spillage when removing fuel filter when engine is ho...

Page 109: ...e 12 5 g Clean or replace air filter See Page 12 5 h Provide for proper battery maintenance as described in Section 7 i Remove transmission belt See Section 10 j Block front and rear of unit off groun...