Eska Specs Adn Service 3.5 1703b Tecumseh Av-520

 

3, 3.5, 4.5, 5, 5,5, 7 & Z.SHp Eska3, Eska Z.SHp

OUTBOARDMOTOR

SE R

ESKA 3, 3.5,4.5r 3.5,4.5r5 5 , 5.5, 5.5,7 7 AND 7.5 H P (1969.1995)

Year Produced Model No. HP 1969 . . .1199, 700, 703, ?034, 1704,1709,1773, 1713A 3.5 1Lgg,1194,1701,1705, 1706,1710,1715 5 l"196, 199, 702, 707, o 1709,177I,7\7 7\ 7 1970 ...1188, 7038, 704F, 17098, 7138, 7138,17238 17238 11898, 1948, 7018, 1705B,13068, ?158, 17338 1199, 7028, 7028,17078, 17078, 17088, 7I7B,1723B, 17348 1971 ...1703C, 713C, 713C,770A 770A 1701C, 705C, 706C, 1715C,1733C,766A, 7 66A, 177TA 7702C,1709C,72t[, 77274;Ll45A, 74TA, t767/., 772A, 777A

3.5

Tecumseh Power Head

Tecumseh Power

b

Head AV-520 AV-520 AV-600

D.O

AV-600

7. 5

AV-817

1976....19?38 79748 19758 t944D,797.68

3 4 .5

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

\977 ...14038 140358, 40368 140378, 4039A, 40594

3.5

1 9 7 8 . . . 114035C, 4 0 3 4 C 4106A 14107A,141084

3D. 5 3.5

AV-750

1979 ...14034D 14035D, 41068 141078, 410'88

AV-520

1980....14139A 141404 747414

3.5 J.D

AV-520 AV-600 AV-817

3.5

AV-520

o

AV-600 AV-817

AV-520 AV-600 AV-750 AV-520 AV-600 AV-750

3.5

Year Produced 7975...1973 Model 4 No. 1903c,19418,974A 1997.{ 19044,19048, 19044, 19048, 9104, 19694,19704, 19694, 19704,1975A 1975A 1905C, 909C, 914C, r944C, 966C, 967C, 1976A

AV-520 AV-600

HP3 4 .5

o. a t.D

b t.D

t.a

D I.O

L 9 7 2 "..1703D, 713D, 7 7 0 8 , 1788A, 791A 3.5 1705D, 706D, .715D, 17668, 771F' 7g4A, 1789A. 17278,7746A, 17278, 7746A,17478, 1756A, 7678,1772B., o 17764,1790A I

AV-817

1981 ...14178A,4183A 14035E, 41408, 141798,14189A 14r4tB'14180A

1973 ...1929A, 945A 19034

3.5 4 .5

AV-520 AV-520

1982 ...141788,41838 14140C, 41798

3.5

1705E, 909A,g13A, 1928A,909A, 930Ag13A, D q 1747C,1931A a 1905A, 909A, 914A, 't.b 1932A, This website stores966A data such as cookies to enable essential site t974 . .. .19298, 9458 functionality, as well as marketing, 3. 5 19038 4.5 personalization, analytics. 1705F, and g0gB, 9138, You 19288, may change your settings 9308 at any time5 a 9318 or accept174?D, the default settings. 19058, 9098, 9148, 19328. 9448 t.o

AV-600 AV-817

I414IC,141808 1983 ...14207 14208 14209

J.O

I

A.V-600

AV-817 AV-520 AV-520 AV-600 AV-817 AV-817

o

,.D

D

3.5 D '1.D

1984 ...14207 14208 74209

3.5

1985 ...14207 14208 r4209

3.5

D J.O

o

7. 5

Personalization Analytics

10 0

Save

Strok

Numb Displ

Spark Cha AC. Elec

Conv Bre Pist A Solld Max Fuel:

AV-520 AV-600 AV-817

SIZE

AV-520 AV-600 AV-817

Pisto End

AV AV-600 AV-817

Pisto

Cran Top Bott Cra End En d

AV-520 AV-600 AV-817

TIGHl Conn Plai

AV-520 AV-600 AV-817

Nee

Cylind

AV-520 AV-600 AV-817

Flywh

Shrou Cra

AV-520 AV-600 AY-817

Privacy Policy Marketing

TUNE Bore

*Reco

: il*

_t. Ine rce rcepar par to ene

These motors are also sold as Explorer, Federal, GoldenThesemotors jet, Hanimex, Hiawatha, Pathfinder, Seaco, SeacruiserG"?4, Sea King, Sea Hawk, Sears, Skipper, Sportfisher and Wizard models.

Accept All

When lllustrations ourtesy ska

lllustra

 

roR

, 5 ,5 .5 , 7 & 7 .5 H P Eska 3, 3.5, 4 .5 ,5

SERVICE ANUAL

CONDENSEDERVICE A T A CONDENSEDERVICE

mseh iler ,ad

r-520 r-520 r-600 r-600 '-81? '-520 '-520 -600 -81? -520 -600 -817 -520 -600 -817 .600 .81? .520 600 81 7 520

TUNE.T]P Bore . Stroke Numberof Cylinders Displacement SparkPlugChampion AC .. Electrode aP ConventionalMagnetoBreaker Point Gap . . . Piston iston Position Max. Advance Timing Solid State MagnetoMax. AdvanceTiming

Fuel:Oil atio.

SIZES-CLEARANCES PistonRingsEndgap End gap

Clearance SkirtClearance PistonSkirt C learanceCrankshaftClearanceTop main bearing . . . Bottom main bearing Crankpin End play

AY52O 2.09 n. (53mm ) n. 1.50n. 1.50 (38.1mm) 1

AY6OO 2.09 n. (53 mm) 1.76 n. (44.7mm (44.7 mm)) 1

AV750 2.375 n. 2.375n. (60.3mm ) n. 1.68n. 1.68 (42.7mm mm)) 1

l. / Dm Dmm (44.4mm mm)) 1

5.16 (84.6u.c)n.

6.05 6.05cu. cu. (99.1 cc cc)n. )

7.50 7.50cu. cu. c) n, (122.9

8.1? 8.1?cu. cu. cn.) (133.9

J13Y* 45 S n. 0.030n. 0.030 (0.76mm mm))

J13Y* 45S 45 S 0.030 n. (0.76mm (0.76 mm))

J13Y* 4 5S 0.030n. 0.030 n. (0.76mm mm))

J13Y* 45 S 0.030 n. (0.76mm

SeeText SeeText

Text SeeText See

SeeText SeeText

Text SeeText See

SeeText SeeText

Text SeeText See

SeeText SeeText

Text SeeText See

SeeText SeeText Text SeeText See

See Text SeeText Text SeeText See

SeeText SeeText Text SeeText See

SeeText SeeText

0.007-0.017 n. n. 0.005-0.013 (0.13-0.33m) (0.13-0.33 m) (0.18-0.43m) (0.18-0.43 m) Text SeeText See Text SeeText See SeeText See Text n. n. 0.4997-0.4999 n. 0.4997'0.4999 n. 0.4997'0.4999 0.499?-0.4999 (12,6-9-2--12.697 m) (1-2.,6-9-2'L2.697 m) (12.692'12.697m) m) m) (12.692'12.697 (12.6s2-12.697m) (12.6s2-12.697 ' n. n. 0'0058-0.0078 0.0055-0.0075 n. 0.005'0'00?n. n. 0.005-0.00? (0'147-0.198m) (0'147-0.198 m) (0.14-0.19 m) (0.13-0.18m) (0.13-0.18 m) (0.13-0.18m) (0.13-0.18 m) Text See Text SeeText See

Text SeeText See

Ball or Needle Needle Text SeeText See Text SeeText See

Ball or Needle Ballor Needle Text' SeeText' See n. 0.003-0.016 (0.07-0.40m) (0.07-0.40 m)

50-57n.-lbs. (5.6-6.4'' m ) (5.6-6.4 n.-lbs. 70-80n.-lbs. 70-80 (7.9-9 'm) 80-100n.-lbs. (9-11.3 'm) 25 t.-lbs. (34N'm) (34 N'm)

bu-D ln.-lps.

(5.6-6.4 ' m ) (5.6-6.4' n.-lbs. 70-80n.-lbs. 70-80 (7.9-9 ' m) 80-100n.-lbs. (9-11.3 ' m ) 25 t.-lbs. (34N'm)

zo.so;.-m,.

(7.9-9 ' m ) n.-lbs. 80-100n.-lbs. 80-100 (9-11.3 'm) 25 t.-lbs. (34N'm)

(5.6-6.4 ' m ) (5.6-6.4' n.lbs. 70-80n.lbs. 70-80 (?.9-9 ' m) 80-100n.-lbs. (9-11.3 ' m) 25 t.-lbs. (3aN'm) (3a N'm)

70-75n.-lbs. 70-75n.-lbs. (7.9-8.4 'm)

n.-lbs. 70-75n.-lbs. 70-75 (7.9-8.4 ' m ) (7.9-8.4'

n.-lbs. 70-75n.-lbs. 70-75 (7.9-8.4 ' m )

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

600 817 520 600 8 17 520 600 t77

TIGHTENINGTORQUES Connecting odbearing Aluminum) Plain Needle earing Steel)

Cylinder H ead Head This website stores data. such as 120 cookies to enable essential site Flywheel. 100 functionality, as well as marketing, )t7 Shroudand o Base personalization, analytics. You Crankcase ,2 0 may change your settings at any time i00 or accept the default settings. t77

AY817 2.437n. 2.437n. (61.9m m)

Needle Ball Needle Zero

Needle Ball or Needle Needle Zeto

bu-a, rn.-Ips,

s ChampionRJ13Y' 1976s plug for models fter 1976 sparkplug spark . *Recommended Privacy5 Policy o the generai onstrucllon.f serv' nly.o .il *" ensinemodelnumber s for easy eference nly. AV-817)s A V-?50 r AV-817) A V-600,AV-?50 number AV-520,AV-600, on atag u Ct t-".d lowerhousing r onatag n_ttre sitamped numbersitamped T The he ype ypenumber Marketing used. beused. uuSt be trr"-ivpu i". prri""*" ili"iifi, such s643-09). numbers "o*ri* morenumbers more two by oilowedby oilowed riiti".*tty consist f three iumbers, dash to ,ingin".a ,ingin".a "o""".iiyp"'nrifiL"i. Personalization ag is reinstalled. identificationag certain hat identification akecertain When'servicingower-head, ake Analytics

lllustrations ourtesy ska

Save

Accept All

101

 

Eska3, 3.5,4.S,5, S.S, & Z.S Z.SH Hp

OUTBOARDMOTOR

should be used. Lubricant should be checkedat least every 20 hours otop.o_ tron and maintained at level of the upper vent pJug U-Fie. E2-l), when motb'r s m upright position. The gearcaseshould be bedrained drained and andfilled filled with new oil at least onceeachseason.Removeboth plugs (U & L) and lay motor on side to draii tire /" gearcase. If excessive water is noted when draining, seals sealsand and gaskets shoulJ be renewed as outlined in the LOWER .UNIT section. Motor should be in uoright position when filling gearcase gearcasewiih wiih lubricant. Insert filler tu6e-in ower plue Fi :-E2,:3.-F. :-E2,:3.-F.ue ueump etement4-Fig. 4 -Fig. 82.2) (L) opening and fill until lubricant is aT snoutd e ,stallad t a 45o nglc a shown. level of.upper plug (II) opening. Install upper plug, then remove filler tube and I t\.{p install plug. Use new gaskets on p.tu-gs.lower r _necessaryo provide a water CAUTION:Do not attempt to remove showtng upper 7g...e2..1.; jcw ot g""r")"" (vcnt)plu-g (vcnt) plu-g U) and owcr dntnfitil) ptugl4. Non. tight seal. carburetor rom AV750modelswithout e. g.at shtn typa unltE hate dralnlllll plug on op moving he reedvalve reed valveassembly. posrfr side ol gcarcasc,

SE

U

FUEL YSTEM

NOTE:Several variationsol this car. CARBURETOR. The Tecumseh loat buretor hauebaen.usad,and haue baen.usad,anddifferences in LUBRICATtOfit type carburetor is shown in Fig. E2-2. servicing rocedurewiil be noied. 161snifture 161s nifture is adjusted at ne6dle 1L; The power head is lubricated bv oil and-high_speedmixture is adjusted'a[ Disassemblyof carburetor will depend mixed with regular grade gasoline. needle (H). Clockwise rotation of both upon extent of service required. Farts Itecommended uel to oil ratio is 16:l for needles eans he mixture. Initial setting (4, 20, 20L, 27, 25,25D, 25, 25D, 26, 26F 26 F 1969model 1969 model motors. Oil used -1lr \6, should be a is approximately 1 turn open for botfr usedshould and 26Q 4ay be damagedby most'comgoodgrade good grade of oil intended for use n out- needles. board motors. Fuel and oil should be , Carburetor adjustments should only merctal merctalcarburetor carburetor cleaning cleaningsolvents solventsand and mixed in a ratio of 24:l for 1920through Tg:t be_lqoved. The gravity feed nlet 1920 through be made madewith with motor in water so a load s fitting (26F) and early tlpe check checkvalves valves 1973model 1973 modelmotors. Fuel:oil ratio of B2-:1 plaeed on engine. Start and run motor (25-and 26) are presied into carburetor, may be used on 19?4 19?4and and later models f until it reaches operating temperature, body. The fitting (2G or 26F) shoutd oil used s BIA certified TC-W. If BIA then adjust to provide smoothestopera- pulled out _of bore, then carefully d certified TC-W oil is not available. available.use use a tion__in tion__ingear. gear. The high speed mixture outlet check valve (2b) with a 9t6Z inch good grade of outboard motor oil in a needle needle(H) (H) should be adjusled first. Idle (3.57 mm) drill to a depthof % nch B. Z 24:1 uel to oil mixture onTg74and ater mixture (L) shouldbe set rich enough o mm) as shown in Fig E2-4. models. provide smooth acceleration from idlle o . The lower unit gears and bearings are high-- peed. Use caution when setting CAUTION:D Do o nol drifl too lar or car. Iubricated by oil contained in the-gear- needles to prevent mixture from bein[buretor body will be damaged. ease. SAE 90 outboard gear lubri-cant too lean and causing engine damage. Thread an 8-82 tap into the outlet checkvalve, check valve, then use he proper size sizenut nut and flat washer to eonvert-tap into a H. High speed speedmixture mixture needle puller as shown in Fis. E2-b. pull check L. Idle mixhre needle valve out by tightening nut. 1. Throttle shaft 2. Throttle sDrins 3. Throttle oiate_-.lnlet needle (20-Fig. EZ-Z) has a 4. Pmping-element Viton tip that seats directly into car5. Welch plus buretor body on some modeis or into a tf^ lo 6. Lead shot' 7. Choke shaft renewable Viton seat (20L) on later at 8, Det€nt models. Seat (20L) may be removed bv 7- , 9. Choke plate Sts i This website stores data such as tu. sDrms inserting 3^ a small wire hbok through hol af, \\ 10L. Clip cookies to enable essential site and pulling seat out of brass iner] Viton 11. Spiing 12. Washer seat shouldbe rene'wed f removed removedfrom functionality, as well as marketing, from 13. "O" ring carburetor body. 14. Washer New seat shouldbe should be inpersonalization, and analytics. You 16. Bowl drain stalled u--o $rr with grooved side toward car19. Float $r r may change your settings at any time buretor_body,away from needle 20). 20. Inlet needle 20t 4-20 n€ 20L. Inlet needle needle& & seat or accept the default settings. 21. Seating ring .Onall models, nstall throttle piate (S) r*t 0 t3*-* with 23, Bowl retainer stamped lines facins out ?to*ai<i /-10[ r2--6 25. Outlet check valve glrqne) and at 72 and 3 o'clockpositions. andat 25D. Check Checkvalves valves 25S. Scren If the choke plate (9) is provi^dedwith Privacy checkvalve valve & fitting \ . /Policy - 2 . Inlet check stamped mark, the mark should be. , 26F. Inlet fittine 26c. csket toward inside of carburetor and flad 1 26L. Inlet cover Marketing should be toward fuel inlet fittinE (26.t / Flg' E2'2-Exptoclcd tewol Tccumjoh catbutcto.tOn gftvttl laed modets, aaily uel pum.pmodels, umptngol.ment 1),ouitit ciic* yaive25), ntet tttlng 26F)is uaed.On 26F_ or 26L). If. choke plate ii noi' checi iZivi ana ttting ee1 r. uscd.onPersonalization tttast modcts modctswuhluy wuhluy pumn cnec* vatvei zsq, m;i;;;;r-ii6lj';;;icrccn marked, the flat side should be down (2ss)arc used. toward float bowl. Fioat setting should Analytics

,@:: ,@ \">)

"-d+

,t-,f\

102

Save

Accept All

lllustrations ourtesy ska

' be o .r or 26 : Th , ' b e rb rb due r, The l : stall E2-3 'terfe ' On .: buret Dero .: SP ..icn*i ._contr

.. byac plate. : openir vide c propri ing th thrott

MO

breakt dition corre paragl remov dense breakt E2-8). On press E2-2),

 

SERVICE ANUAL

tg. E2.2) ahown,

r9fltov€ : loul re. t: ris car.',.. nces n ,...:

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

be 0.200-0.220 nch (b.08-b.58 mm). *measured_with body and float ".r"*bt'u and flrverted, between free end of float preferred olb_ody. {ilr. ^carburetor -fmethod lor , checking float level is to placea _number.4-drill it shank (0.209 5.30mm) between loat and carinchor 5.30mm) buretor body (Fig. E2-6). When install_ ing fuel bowl, the flat under side should be ocatedbelow the fuel inlet (26,26i or 26L-Fig. E2-2). The fuel pumping element (4) s a rub_ ber boot which expands and contracts due to changeselement n crankcar" prurr*". pumping The should be installed at 45o angle as shown in FiE. E2-3. Incorrect installation may ifrterfere with pumping action. 0n AV750 models,coat threads of carburetor retaining screws with ,,Loctite', beforeassembling. SPEED CONTROL LINKAGE. The ignition timing is advancedby the speed control ever and the throttleis ope"Ltud by a call attached to the magneto stator plate- The ignition timing and throttle must be synchronized to nro_ openingmust opening vide correct operation. Refer to the aopropriate following paragraphs for timii,g lI" ignition and synchronizing the throtile openlng.

be checkcdy ptac. llo_. ,oZtchilt ".y? ry0.209 tng tnga a rr_f: numoet btt ncho, s.io'iit oeaween loat and ca|d,urcaor ody,

Fig. E2-s-Tho 0.32 tap can canbe be uscdas a Dullel

'o emoYe "" ";:';;i2i;l;i:::.,-^

eaiv uar TYPE

NUMBER 639-06

TIMING BTDC

0.095n . (2.47mm) lepend 640-72thru 40-19A 0.115n . Move speedcontrol lever until side s Parts (2.92mm) 6,26F 642-07hru 642-0?8 ?.Jiglqd with edge of sn.oua--asJ 0.100n . (2-Tig. EZ-Z): h; follower€) sfroufj it com(2.54 mm)) mm be bealmost almost ouching he cam. rtsand 642-07C 0.085n. d inlet (2.15n .) NOTE: There should be slight clearance (lhlckness valves 642-08 0.110n . LS WITH BREAKER POINT follower. of paper) between cam an d (2.79mm mm)) uld 642-08Ahru 642-t0 'GNETO. Before attempting to set 0.100n 0.100 n. Y itr" (2.54mm ) timing, make certain that 4 inch 642-73hru 642-16C breakerpoints breaker points are in good (or new; con_ , If clearancebetween ollower and cam 0.085n. 0.085 n. is incorrect, loosen screw (S), mouu ai" r 3.1? ouon and gap at maximum openinE s (2.15 mm) mm ) end of cam as required,'then tiEhten 642-76D correct as described in the IGNITIbN 0.078n. 0.078 n. scr.ew3). 3). Make certain that there iSonly paragraphs. The flywheel must be scr.ew (1.98mm) a slight amount of clearance. rr Cat. 642-77hra64?-I9 642-77 hra64?-I9 removedand wires from coil and con_ 0.085n. Ori models with fuel inlet fittine on denser must be disconnected from (2.15mm mm)) carburetor plate (26L-Fig .82-2), &teii 642-19A breaker oint termina ft-tr'ie. bZ-?; 0.078n. Ene hrotile prckup as follows: Set the lutlet E2-8). (1.98mm mm)) prston at 0.003 inch After Top Dead 642-20 e nut On rnodels with fuel inlet fittins 0.085n. 0.085 n. Center as described n Fig. nZ-g.^ettacfi nto a g1eryed n to carburetor nto (2.15mm) carburetor26 26&26F_Fi;' 642-20Athru642-22 :heck E2-2), heck hrottle piikup as followi: 1^tiTing light .with battery (B-Fig. 'to 0.078n. 0.078 n. or continuity meter th"e .E2-q) (1.98mm) breaker point terminal (1) and to 642-23 as a ::: 0.085n . magn-eto stator (ground). Move the (2.15mm ) 9t''.: speed control lever t o starboard 642-24 rto a ,, 0.085n. (cloclwiqe) until the timing light giows (2.15mm) later 'l (continuity exists through-br6aker rd 642-25 by ,j 0.078n. points). -Move the speed cintrol lever hole .:: (1.98mm ) riton ,, tolvard_ ast position until the breaker 642-26 0.085n. This website stores data such as pornts ust open (light goes out). hg.',i (2.15mm mm)) e m- : cookies ,,; to enable essential site 642-27hru642-28A 0.078n. NOTE:D Do o not movespeed ontrol ever C&f'::.:n functionality, as well as marketing, (1.98 m) loo far. The )). cam follower F) should ust us t 642-29 l;l 0.085n. and analytics. You contactcam as the timing tight e (3) personalization, tightgoes goes ou t :1 (2.15 mm ) (breaker ointsopen). open).ff lollowercontacts 642-30hru642-B1 rard may -l change your settings at any time 0.078n . cam beforebreaker olnls open ons. or accept the default settings. openor or f there (1.98mm mm)) is clearancebetween ollower and cam ffith 643-01hru 643-74 ca m 0.090 n. when breaker breakerpoints points open, oosenscrew be (2.28mm) (3) and move he idle end of cam as re. 643-7 A, A,6 6 43-748,6 643_4C 43_ 4C 0.085n . Privacy Policy quired, hen lghtenscrew 3). (26; (2.15mm mm)) not 643-15 0.090n. Marketing )w]l 'b. (2.28mm) 9n all -models,refer to the followine mm;" i"rroo tabte.and ocate piston ot removtno ruld at 643-154. correct h hru ru timin[ 643-32.L caily ypachcck 0.085n. 0.085 n. chcckar-vc Personalization ar-vczs_Fd. ei-ti""" posluon: (2.15 m ) lllustrations Analytics Courtesy ska 103 Save

Accept All

 

Eska3, 3.5,4.5,5, S.S, & 2.5 2.5H Hp

OUTBOARDMOTOR

SE

Il

@

.lg. E2.9-plston

ffiF

positton can be measured

t.htoug.h.the .paft ius openiniusiig ;;n;';; g_a91Q Toaucts Wn nu-mbet 70124), R)ot diat tndtcatol lvaitgllc romrutat ecumseh Ci.

t: ^: :eldatermlning top dead cantaL tun cnnKsnatt counterclockwisa lo sct piston l?tot?. lop dead centet @roq. crcnisiiii snoutdbe tuned clockwlso o set piston altcr top deed centet ATDC),

FIg. E, FIg.E, Irors. sDow |rl:

,_l4g-D_E_LSrTH SOLrD STATE MAGNETOS.he he lywhe"t ".i l","1

no-ve_d nd a special tool (part number

Fig. .82.7-Uiew showtng spead contrcls an d p.o,n$ ot.adiustmen.t lot motorc with prcssed in ruet ,ntet type carburctors and brcaket polnt . magncao, Rclet to tex/-

Refer. o ,. -Fig. EZ-9. Attach a timins trCn:.wllh trCn:. wllh battery (B_Fig. EZ_10)oi conttnutty the breaker point terminal (l) meter and toto magneto stator'plate (ground). Move the speed control iever crockwrseuntil the timing liEht slows

(breaker oints losedl. tiueif," 3pL"J

control lever toward fast position (countercloekwise) until th" ;;;;k;; pornts Sustopen (light goes out).

670286Aor AVo0oa"a eVisO moaJs and.part number 670281A o" Avgii and.part models) vailablerom Tecums"f, "oal ucts Co. Co.must must be used. To set he maximumgnitionadvance. _- NOTE: l may be necessary o loosen re.fgr to following tabTeand ;t;; the stop bracket (4) in order to allow plston o the proper BTDC position as enoughmovemento openbreaker oints, per rnstructionsn Fig. E2-9.

Also,make ertain hat ollower F j s no t Also,make binding gainst a m. The speedcontrol lever should shouldcontact contact stop bracket (4) just as breaker points open. If incorrect, loosen the retiininE screw and reposition stop bracket (4). " After the maximum advancestopil; is correctly. set, move the speed conti.ot Iever against stop bracket (4) and check tfre .c.aln follower (F). The follower snoutcthave opened the throttle com_

MODEL NUMBER

TIMING BTDC

AV6OO

0.085n. (2.15mm) 0.095n. (2.4lmm

AV75O AV817

-'Tr

Type640-02thru640-068

0.118in.

rype64o-o?thru64o-21 3t?ll]

IE

U

i& '"

:

F tg. tdte p enda

(2.92mm)

Position the proper Tecumsehspecial tool-over the flywheel key in cranlishaft as shown in Fig. Ez-Il, lhen move controls to maximum speed position (counterclockwise).The iun trigger @j snor+d be. aligned with edge ,,1" of specrar ool as shown in the inset. If in_ correct, stop bracket and reposltlonloosen as necessary to stop(4)move_ ment of speedcontrol i,rhen run trieeer x atrgnedwith edge,,1".After stop (-+-is 'cam co.rrectly positioned, check thd tollower (F) with controls in maximum speedposition. speed position. The follower shouldhave ope.ngd hrottle completely, but make certaln that cam and follower are not binding. If throttle is not completelv open or if follower is binding, joosei, screw (5), reposition the high speed speedend end or cam as required then tighten screw

ATIIC

This website stores data such as cookies to enable essential site functionality, as well as marketing, personalization, and analytics. You may change your settings at any time or accept the default settings.

(b).

Privacy Policy Fig.

Marketing showing

speed contrcls an d .E2.8-View l: ts gr adlustmerrts lor motors with luet inlet ,ocated. on.Personalization cover plate and breakar potni magneto. pistor position tarOq snouia {c-iii as described in Analytics Flg. E2.9.

10 4

Save

Accept All

Fig.. 2'10-Uiew showing contrcts and points ot adtustment tot adlusting maxlmum tgiitton ad . yanco anct maximum thrcttle opening. The cam an4/or may remprs .cerburctor damaged tf cam at to open thrctile befufther than possiDla.

To check he hrottle hrottlepickup pickup oint,se sett ,, Tocheck tne plston o the thesame sameBTDC BTDCposition positionas; for.highspeed djustment djustmentsee see ""uiou# rgnluon rming table).Move the speed\ go-ntrol ntil the run trigger (R-Fig. E2-72) s aligned alignedwith th;-"Z" ,n".[r the o]i the special ool orwith AVT50 models lllustrationsCourlesy CourlesyEska Eska

,r4r, n

Spec AV8 throl conn be jr E2-1 not; eorrr idle Th for I idle cam end en d only chec AI cam , spe€

ili.

tri tr- l ni u

stat mot, touc

lllustn

 

F

)R and .e s r is,

f; I & f,

$

SERVICE ANUAL

REED YALVES. The reed reedvalves valvesar ar e located between between the carburetor and the crankcase and should be checked each time the carburetor is removed or service. On AV520, AV600 and AV817 models, the carburetor may be removed valves. Reedsand before removing reed valves.Reeds and reed plates may be renewed separately on most modeisbut must be renewed as an assembly on certain early models. Check reeds for proper seating and damage. Reed petals should not bend

;hen adfter nts. rttle bher rect lnds

,T E

I re-

rber dels '817

Ftg. E2.11 Reler lo lext lot adlustment ol con' tots. Vlew sttotvs higfi speed position, ,nsert shows location ol stefting tigget (S) and run ttiggq 6) In rclation to tha speclal lool.

rodnce, the

las

tNG :DC 5 n. nm) 5 n. nm) 3n n.. nm) 5n n.. nm) :cial haft contion (R) OI

f inand

ovetger s 4) cam

lUm Iave rake no nott ,tely )sen end rew , set

Eska 3, .5, .5,4.5, 4.5,S, S, S.S,Z & 7.5 7.5Hp Hp

ffi

adiustmentol the Frg. Ez.1z-Rotet to text lot adiustmentol spaed d ha posltlonot l dle spae Changingha ldle plckup.Changing end ol can wlll altect hlgh speed adruslmenl whlch shoutdbe shoutdbe rcchecked.

away from plate more than 0.010 inch (0.25mm). On AV750 models, the reed valve assembly and carburetor must be removed as a unit by removing four screws that secure reed plate (6-Fig. E2-15). Removal of the carburetor and of the reed valve can be acdisassemblyof disassembly by removing the two screws complishedby complished (5) and nuts (12). The reed petals can be renewed without renewing reed plate (6); however, make certain that seating surface s not damaged.The damaged.The rough edge of reed petals must be away from reed (3) are marked on plate. New reed petals (3)are the smooth sideand side and the marked surface should be against the reed plate (6). When assembling,coat assembling,coat threads of screw (5) with Loctite and tighten to 50-60 in.-lbs. 5.6-6.7N'm) torque.

IGNITION

magnetosand and Solid state, breakerlessmagnetos breaker-point timed, magconventional,breaker-point conventional, these motors. Refer to are usedon used on thesemotors. netosare netos the appropriate following paragraphs for service.

"4" mark on the tool for AV600 models. Special tool 6?0238A, used to check AV817 models, has only "2" mark for throttle pickup point check. With speed control in this position, the cam should be just touching the follower (F-Fig. E2-11). Make certain that throttle has not yet moved, moved,but but is touching cam. If incorrect loosen screw and reposition the idle speedend of cam as required. The throttle cam should be rechecked This website such as for full stores opening after adjusting throttledata cookiesidle to enable essential pickup. Changessite at either end of cam will themarketing, location of the other functionality, asaffect well as end slightly. Position of cam is correct personalization, and analytics. You only after both low and high speed speedends ends may change your settings at any time checksatisfactorily. or acceptAfter the default settings. the high speedstop and throttle speedstop cam are accurately adjusted, move the * speed ontrol lever clockwise until iever past the shroud bracket (2-Fig. $ilsPolicy Privacy "ryin until it contacts the stop plate on Marketing stator. The gnition will be grounded and motor will stop when the stop plate Personalization touches screw (1).

Analytics

lllustrationsourtesyska

Save

Accept All

1. 2. 3. 4. 5.

Gasket Reed stop Reed petals Reedpetals Wroher Caburetor attaching screw 6. Reed plate ?. Gsket

8. Carburetor 9. Idle adjustment knob 10. Set screw 11. Bracket 12. Nut 13. Choke ink 14. Choke od 15. Stop spring

BREAKER POINT MAGNETO. shouldbe be 0.018 nch Breaker point gap should (0.45 mm) for type numbers 642-07 through 642-078, 642-08A through 642-\0, 643-01 hrough 643-05A, 43-06 through and engines 643-15.shouldbe Breaker gap643-09, point enginesshould be for all other (0.5 mm). It is impor important tant lhat 0.020 nch breaker point gap is eorect and breaker points are in good (or new) condition before adjusting the speed control linkage. Ignition timing and throttle synchronizedcorrectly opening must be synchronizedcorrectly to provide best operation. Refer to SPEED CONTROL LINI(AGE paragraphs in the FUEL SYSTEM section for checking gnition timing. If the magneto mounting plate must be remwed, loosen {rietion serew then Iift assemblyoff. assemblyoff. When installing, apply a small amount of grease to friction screw, then install and tighten screw to M ake n.ibs. (1.3-1.7 'm) torque.Make 12-15n.ibs. 12-15 (F-Fig. follower certain that cam E2-10) s on outsideof outsideof cam.

stop) crewI) groundstop) , fiD2-i3).Turn heground

Fig. (on ' t he

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

(grcund)scrcw scrcw 1) should Ftg. E2-13-The stop (grcund) be adlustadas adlustadas descriled ln text to stop motol altat leeet s past shtoudbrackct(2).

Th e SOLID STATE MAGNETO. The does not Tecumsehsolid state magneto doesnot use breaker points. The only moving part of the system is the rotating flywheel with the magnets. Refer to Fig. Refer to the SPEED CONTROL E2-16.Refer E2-16. LINKAGE paragraphs in the FUEL SYSTEM section or synchronizing gnition timing to carburetor opening. producea a spark If the system fails to produce at the spark plug, first check he condition of wire terminals and gtound connections. Check condition of high tension lead (5) and if questionable, enew pulsetransformer pulse transformer (4) and lead (5). Make certain that low tension lead (3) is not shorted against motor and renew if in-

105

il

 

Eska 3, 3.S, 4.5, 5, S.S,Z & Z.S Hp .u1," j9ns faulty. The gnition charging coil 1),electronicriggenngsystem nd mountingplate are ssembly..If "*it"Ui"-6"fy'".*"i he mountrng latemustbe removed,o_osen riction crew, then ifi riction assembly ff. When nstafiing, small arnount of grease to A;i;; friction 99r91v,h.gnnstailaid tighten;;;; 12-15.n.-lbs.1.8-1.2 .m-) ";d;:ili;k; ::j_t ll that cam oilower'(F) s ;; ;l: slae

OUTBOARDMOTOR

I 2 3

E_;[;f: '.il;,#-r"# Xi,fltr

ower main AV8IZ models), t ;;;:€ necessary. o bump crankshaft oul oi \

t4 t3

lg;5ffi'i.

oI cam.

p,o*:rhgads air-cooled.y fan ,.T1". built into the flywheel. Make srir;;h;

place nd l,"t .""i,"g ri;,

y_flI"q.surface.shichmay

lf::ljr P are kept clean, The lower motor leg and exhaust gasesare water_cooled.All models with m_ore han B hp -are pr.p: Coolant"q"ipp;;;;h; ntate s toc"i"J

wlrn a tlght seal. . Refer to.the appropriate paraEraphs ror mspection and reassemblyoflo#er

tthptein. tthptein.

arge and. "t earinss "t

1. Magreto 2. Snap ring

l:3""ii'ff

S. S.|;t'"lt1;I,,r |;t'"lt1;I,,r i. diili r,"r,

3 : z

recommended ightening torques.

NDCYLINCYLIN*j,ISTON, PrN,RrNGS ND DER.Before etachingoa romcrank-

2l

""iiiiiiri'iii

if: if:Fi:1i"'';1f,r. Fi:1i"'';1f,r. U

c

r'owtrnainearins

22

I

ii re.Snap,ring - .. .

J-=-_\_

31. iilii.*"

swivel braeket. If a spray of water does not emerge from outlet fr"f".-^*fr"" motgr isrunning, first chect< oolanilnlel ror ptuggtng, then if not corrected. remove.g€arcasefrom lower unit and an d overnaut the pump.

POWER HEAD

with plain rod bearing, ock tab rnu"i-0" Dent away from connecting od screws belore oosening.On On other models,make Privacy Policy certain hat bearing eedles re nof'fo"i'in rE. E2.1 Vlewol thc sottd stete gniilon com_ crankcase,O n all models, t may be wlth llywheat cmo7ed. .porentsMarketing r. unagrng ne.cessaryo remove idge from coil top of cylinderbeforepushingpiston Personalization anOcon. anO con. . Groud (stop) screw nectrng od assembly ut .

06

f:ilJi:, fflii3:"

Analytics

Save

Accept All

1

snaft, cieck the correlation marks on roo and cap. If rod and cap are not

Flg. Ei englne.

-€-l

.1.Mr 1T. Mr 2. Sr 3. R{ 4. Se 5. Sh .6.Tc 7. G. 8. Cr 8TW. Tl 9. Cc I0. Nr 1 1 . N( 12. Pir 13. Pir 14. Sn 15. Pir

.^qt..

"-xYwl, l4 24 23

2tc

DISASSEMBLy.Unbolt nd emove This website stores data such as 20 cylrnder,shroud,flywheel, mameto. cookies to enable essential site cyunder head, reed valve and c6vers, lt functionality, as well as marketing, cornecting od cap and push 22P jnT9_"," personalization, and analytics. You l9 pistonunit out ihrougfi op :?"^j,?glld f, 0,. may change your settings at any timeor cyltnder. tew tr|,',tcatl AVTSO tew .eZ-Z_l-exclodcd modets. omemodelsmay niie areii"i'iiiit or accept the default settings. type megneto. . OTE: On AV520 nd AV600modets

i:;ff*."#g,

t5

;:;::li,:*,# a,Hfft;*."''"' z1%=

ii ii""iJiipr"

1 t4 t3

q

fi"fft Eili8tfl.B"Bl+,1'1"":?);

Illu,r

Just below he antiventilationplate on sidg of gearcase, na .oituni "i. 3lcir puTpgd_ o exhaustdeflectorat upper part ,o{ owerunit where t cools h6 xIT hausthousins. t8 Motors nol equippedwith a water _ pumpusea coolantube o aid n l9 cooline motor.leg.An openend ih;-;;ffi Fi,g.._E-2.20-xploded view typtcal "f ot Tecumseh -_oiiJn 4V520aad Tb,u i: locatgd- elow antiveriil"li"" aadAV6a0 AV6a0modets.'Earyoai"'ii| p.la.te, acing orward. fo"*u.a acing equipped

. 4

bearin| ia-rb. Ei.;i

_-AFSEM.B y. Because of the rwostroke cycle d_esign,i," _uJt comptetely sealed"r"nLc"s" against both pressureand pressure :: and vacuum. t is-recommend_ eo tnat all gasket surfaces be carefullv cleanecl nd checked or burrs, nicks i;;;;f";;oi

COOLING YSTEM

wash force water up 1::,_.p.top:il"r. ube to motor adapter platel fg_o,,:nr lvlat{e ure that coolant ube s free of obstructions. , -Coolant utletconsists f a series f holes arranged erticallyon each ideoi the lowerunit upper eg, ust b"l;;;h;

s

crankshaft can be removed rom ro m _,The all models after removing ,lr"ood br.;

markr asse cation

AVs2 Cylin dian

t l$;rii","."", i i,iF,UUt-*'*

i. iiiluot""cr.et "*na i. dlo.uTi,n

;.ff#:h.t

1i: ::iiJiffi

rr. fleedte beanng rz. rNron ld. nsron pm

ir. *"*,n"" 1e. nap naping ing

if.3liil5f*&crrinderf

313:3ti5i, \ / 22P. cover zi. Gasket 24. Cylinder head

lllustrationsCourtesy CourtesyEska Eska

Pistor clea

tff

643_

-

 

)TOR ed rom ud base rr Fig.

SERVICE ANUAL

Eska3 , 3.5, 3.5,4.5, 4.5,5,5.S,Z & 7.SH p

All other ype nos. , . . .0.006-0.016n. (0'15-0'40mm mm)) Ring side sideclearance: clearance: Topring .....0.008-0.00bin.

bearing may be out of i2-27o r

Bottomring. . .[lrtJr9df%?il]

(0.05-0.10m) Piston indiameter in diameter . .0.4992-0.4999 n. (72.692-72.697m) AV75O Cylinderbore Cylinder bore diameter .....2.375-2.8Z6in. (60.32-60.35 m) m)

te two-

Jemust t both nmendrrefully Licks r terfere graphs power CONlle for

Piston-cylinder clearance.

10 t4 l3

. .0.00bb-0.00?5 n . Fig. E2.23-The.V,, ma* ot "1111" me* on to o (0.189-0.190m) ol piston msst De towad side snown. LuOrii[Ring end gap endgap . . .0.00b-0.013n. tion hole in slde of rcd must arso De towarcl top, (0'13-0'33mm mm)) Ring side sideclearance: clearance: Topring .....0.003-0.005in.

Bottomring ..[%'0;9dfr?il1 DENSED SERVICE DATA tabte. pistonin iameter iameter.13ff;lriHll] .13ff;lriHll] Refer to the CONNECTING ROD para-

rLIN.

crank-, rks on re not

AV817 Cylinder bore diameter

,,ffi;AN t7 l8 t9

-4 -5

25 26 27 28

Ftg. E2.22-Exploded vlew ol typlcal AV817 .nglne. All models arc equippad with a solld slafa ,nagneto.

1. Magneto sy, 1T. Magnetotransformer 2. Snap ring 3. Retainer 4. Seal 5. Shroud bracket Shroudbracket 6. Top main bering ?. Gasket 8. Cmnkshaft 8IW. Thmst msher 9. Connecting od 10. Needlebeaing Needlebeaing 11. N€edle ollers 12. Pist n 13. Piston pin 14. Snap ing 15. Piston rings

16. Lower main beaing @all or roller) 17. Seal 18. Retainer 19. Snap ring 20. Cmnkcase 21. Gsket 21C. Gasket 22C. Cover 22P. Cover 23. Head gasket 24. Cylinder head 25. Gcket 26. Reedstop Reed stop 27. Reed 28. Reedplate Reed plate

-21C marked, cribe cribea a line to indicateproper indicateproper -20 assembly. efer o the following followingspecifispecifiThis website stores data such as cation data: -17 .lg tV750 polnt

(12.692-12.697m)

.2.437-2.438in. CONNECTING ROD AND BEAR.

(61.89-61.92m)

INGS. Several ypes of connecting ods are used and it is important that the cor..0.0058-0.0078in. rect rod is installed. (0.142-0.198 m) Ringend Ring endgap gap . . .0.007-0.017n. ingOnrod models modelswith aluminum connectplainan and with bearing at cranlrpin (0.18-0.43 m) end, clearance on crankpin should be Ring side clearance: clearance: 0.0011-0.0020nch (0.0028-0.051 m) . Topring . . . . . 0 . 0 0 3 - 0 . 0 0 5 i n . Crankpin journal should (0.07-0.13 m) 0.6865 nch (17.416-77.437be 0.685im). CrankBottomring . . . . . . . . .0.002-0.004in. shaft should be renewed if crankpin (0.05-0.10 m) taper or out-of-roun out-of-round d xceeds .001 nch Pistonpin diameter . .0.4997-0.4999 .0.4997-0.4999n. n. (0.02 mm). Only standard sizeparts are (72.692-72.697mm) mm) available. On models with aluminum connecting rod with steel iners and bearing needles Piston, rings and piston pin are avail- at crankpin, observe the following: able in standard eiae only. Pistoa rings Crankpin journal standard diameter is should be installed on piston with bev- 0.8442-0.8450 nch (27.442-21.463mm) eled inside edge toward top of piston. on AV600 engines enginesor or 0.6919-0.6927nch nc h The piston pin should be a press fit in (17.574-17.594 m) on AV817 engines. heated piston on models with needle Be sure that none of the 74 bearing bearing in rod upper end. On models rollers are lost and that ends of liners Piston-cylinder clearance.

without needle needlebearing bearing upper end, piston pin should palm the shouldbe push benarod fit in piqton and thumb push fit in rod. When assemblingpiston assembling piston in connecting rod, observe he following. Open end of cookies to enable essential site piston pin must be down, toward exAV52O ND as AV6OO haust. The lubrication hole nside nsideofconofconfunctionality, as well marketing, Cylinder ore necting rod must be toward top of personalization, and analytics. You diameter .....2.093-2.094in. engine. On AV520 and AV600 models may change your settings at any time (53.16-53.18 m) equipped with offset piston, make ceror acceptPiston-cylinder the default settings. tain that "V" mark or "1111" mark clearance. ....0.005-0.007in.stamped on top of piston is toward the (0.13-0.18m ) right side as shown n Fig. E2-23. gRing end endgap: gap: A piston ring compressor should be Privacy Typenos. ".ilPolicy nos.642-01 642-01hru hru used when installing piston in cylinder. :s/ 642-078, 42-084 hru Make certain certain that rings do not catch in Marketing 642-10. 43-01 43-01hr hr u recess at top of cylinder. The cylinder 643-14nd 643-14 nd643-15 643-15 . . .0.007-0.01? n. head retaining screws should be tightPersonalization (0.18-0.43m) ened to the torque listed in the CON-

Analytics

lllustrations ourtesy ska

Save

Accept All

graphs for installation of connectinE rods.

correctly match markspin on rod and engage cap arewhen aligned. Piston diameter is 0.4997-0.4999 ft2.69212.697 mm) inch and rides in cartridge needle bearing that is pressed into piston end of connecting rod. All models with steel connecting rod connectingrod are provided with looseneedle looseneedle ollers at crankpin end of connecting rod and a cartridge needle bearing at piston pin end. Standard crankpin jownal diameter is 0.6259-0.62 0.6259-0.6266 66nch (15.897-15.915 mm). Model AV750 uses 33 needle rollers n the 0.7588-0.592 0.7588-0. 592 nch19.273nch19.27319.283 mm) diameter connecting rod d connectingro bore. Model AV817 uses 66 short (half length) needle ollers placed n two rows in the 0.7588-0.7592nch (19.273-19.283 mm) diameter connectingrod connecting rod bore.

107

 

Eska 3, .5, 4.5, 5, 5.5, 7 & 7 . 5 H P

OUTBOARDMOTOR

11 fi'o

CrankshafJ end play should

ZERO for all _AvTbo "nt evbif be-;#ir: Crankshaft

*srP'

end play

,f,ouid--li 0.008-0.016 nch 0bz_"0.a0 ffii Models vszo avbbb nrni ff j.h.t*g needle"ni "diiipp"T_ oller marnDeannes.

t4@;

ifr*'

3--'-y-tt Flg:.E2:2-6-Exptoded

ytew ol stertat. Relat to

,r,nanol :_rj.r, totrnstalrauon tot rnstalrauon t piii ti,;Z'il'e

r.

2, 3. 4. 5. 6.

Rone Reiainer screw Retainer housine Bmke sprine Starterfog-

7. d. 9. 10. 11.

Dog return spring Puilev Sprin-g & keoer Housins Centeri-ng in

F19..E2.28-Relu to taxl when rcmovlng r In. stalllng. rcpc. Bctalnot scrcw (g) sno-unietoryuod o 45.SSn,.t f,. F-b'N,nL

.. On modelswith short (half leneth)

neeCrankshaft main dle ollers, earing ""d". ur" r"J.a"ii_, , CTANKSIIAFT. Deanngsmay be either ball type or car[wo r-ows

rr rs- mportant to exerciseextieme carewhen enewing s"a['iT prevent heir beingdu*"g"J ""rnkshart d;G"inl sleeve stallation. f a pr"otector is]not available, se ?ll to coveruny ,piin*, -I:{Y"yj, shouldersor or ttre.al ovii whrch_theshoulders ealmustpass mustpassduring nstaila-

shoulde "rt rr;d'; tip;i ll^n; -:1.seal lne tower s towards

outside6ota,nd.\e- top (magneto nd)sei-is fom) towards nside center)of engin6.---' '" MANUAL STARTER

round rankpinwith flat ends rnoge -type The rope f91 the recoil starter can needle ro.ller. If ball -i[J be main renewed_without tggethgr toward centei of disassembling Deanngs a_re sed, t should be necessarv starter. Remove ll models.quippedith nu;dl; """ntpirr'iii 6;;;; he starter asimblv ar.crankpln, ollers shouldbe renewed to bump the crankshaft out of the bear- rro,1nmotor, pull rope out fulh and lng lnner races. Ball and roller bearins andholi holi o4J u a set. Renewb"u"inE;;;li;;; pllley to prevent rewinding.Refer outer racesshould be a tight fit itb;;;: to roller is damaged.f rollerE;;;;#Fig. E2-28.Remove R emove n,op8"na inrt*fi o,grqs. t new ball bearings are to be agect, heckconditionof crankpinand Iq lnstalled, heat the crankcase when ,ne1 Tope,makingcertain hat the nner ,ne1Tope, connecting od carefully if flg.t rs l1 pocketon underside f pullev. otd bearings inrturhng Dearu:lgacesare "naew "lnu, rr aredamaged. tne otd.ropewas broken,prelo'adlie ::T"Iiq damaged. rollers new ones. "na are.-servicedn a strifand recoll sprlng by turning the pullev NOTE:D Do o not use usean an open lame. talled. y.wrapping'tt" .t"ip ";;6-;;: *o*a proxlmately- turns before instilling an_ crankpln. After new needle ollers and new roDe. O,,n models, bearings should be inconnecting od cap are installed, o"c; , ?ll salled w^lth w^lthprinted printed face on race toward hinner nto needles o remove center of enErne. l?cquer th.f n::yql, then lubricate be;G; crinkshaft is equipped with with SAE B0oil. .,If .the B0oil. tnrust washers at ends, rirai<-e ertain On. all models, make certain that that they are installed when assembling. -TVoOo T.atch marks on rod and cap are ,, To overhaul he starter, first remove aligned. Some AVIZ} tnerope, tne rope, hen allow he pulley g) o unmodels re stampedwith ,T'" ""a o"llrii; mark on pistonas shown n Fig. EZ_28. vn mooelsso equipped,make make certain stampedon top of piston s lhat TaLk toward the. ig-htside as ahow.n. n all mooelswrth aluminumconnecting od, Flg, E2.Zg-Exptoded vtcw t,^g t-q rod cap retairung screws to ol low.t motot teg yptcatot 40-50 n_.lbs. n_.lbs.4:b-5.6 modetswlth neutnl clutch. 4:b-5.6t.rnj t"rq";i"J Iockwith Iock with the tab washer.On all models Leret 12) s attachcd o shttt shaft 9) wtth sphot ptn. wilh a steel.connecting 1. Lower motor lep 2. roct ap etainins etaininsscrews.(self screws.(self od, i[h;;; th;o Neutral speed speeda-dvance 25 ocking) a-dvance stoD rod 70-80n.-lbs. Z.b-O.ml rorque. 3. Neirtral shift cam 4. Swivel brrcket cao 22 5. FIat washem ?c This website stores data such as 6, Brass collar 7. Gskets 220 cookies to enable essential site 8. Spring wroher 9. Shift shaft functionality, as well as marketing, 10. Cerying hudle 11. Neutral clutch knobs personalization, and analytics. You 12. L€ver 15. Steerins handle may change your settings at any time 16. Sher pin holder 1?. Swivel bracket or accept the default settings. 18. Stem clamps 19. Thrust bniket 20. SDrins 21. Bizss-liner ^22. Lower adapter plate za. .tj.xhaustdeflector plaCe zo. upper adapter plate z{. Exhaust port g-asket

Privacy Policy Marketing FIC..E2-27-Whea assembllng, meka ccrtatn Personalization trrrlprrts (5,6 & 7)arc 7)arc asscmblcd s shown. ni

,.ij: $:ffi

Save

Accept All

wind then NO

avalla

wh

lightl;' (9)an brake sprinl Fig. (3-F in.-lbr recoil proxi: befor E2-2t

t

t"ii'"il'unt 6ket

Analytics ot aog rctun spilng(7) spilng (7)should shouldpult pultdog dog ln.

108

s

Flg.Ez lllustrations Courtesy Eska

 

roR ro R ZERO odels.

$'K

pped lgs. treme rals o l ng nis.not is.not ,. rlines, over , rtallalip of (boteal s

an anbe be the rmbly thold

SERVICE ANUAL e-41

p

Rlll Rl 38

n

rl ,,T

er to nstall inner ulley. d the y apilling l im3C

2-

Eska3, 3.5,4.5, Eska3, 3.5,4.5,5, 5, 5.5,7 5.5,7 & 7.5 H P 1. Drive shaft 1A. Drive shaft 2. Roll pin 3. Needle pin 4. Screw 5. Seal 6. "O" ring 7. Water pmp housing 8. Impeller 9. Bse plate IU. SEA 11. Roll pin 12. Sleeve 13. Clip 14. Stud nut 15. Screw 16. FilVdrain plug 17. Vent plug 18. Germe 19. Bushing 20. Snap ring 21. Pinion gear 22. Snap ring 23. Bushing 24. Sprcer 25. Drive geu 26. Shim 27. Bushing 28. Roll pin (large) 29. Roll pin (small) 30. Gsket 31. Lower cover 32. Seal 33. l{asher 34. Propeller shaft 35. Shearpin Shear pin 36. Propeller 3?- Water tube 38. Nut 39. Sealing washer 40. lVasher 41. Nut

ytewot tfplc.l, nong.at shll| low.,, unll.tvoto Dsf watot pump mpcttil may - ,fu1g. *2.3l-Exploded 3)or a rctt ptn 2).waterrri:"i:i?:ir;.* wttha wtth a ne.dtc d/ren thtoushaxhaust thtoush axhaustopenins openins n motots " il

wind slowly. Remove retainer screw (3), then lift parts out of housing (10). NOTE: Sprlng and keeper (9) ar e avallable nly as a unlt. When assembling, grease spring (g) lightly then position spring and keeper (9) and pulley (8) in housing (10). Install brake spring (5), starter dog return spring(7) and starter dog (6) as shown n Fig. E2-27. Install retainer screw (3-Fig. E2-26) and tighten to 45-bb in.-lbs.(5-6.2 in.-lbs. (5-6.2N.m) N.m) torque. Preload the recoil spring by turning the pulley approximately six turns counterclockwise before nstalling the rope. Refer to Fig. E2-28.

PROPELLER A three-blade propeller is used on 7 and 7.5 hp motors. All others are equippedwith equipped with a tw two-blade o-bladeunit. unit. Various diameter and pitch propellers have been used. Steel Steel shearpin, partg6284, is used on.propellerof modeJs modeJsnot not equipped with a forward/neutral or full gear shift lower unit. Models with forward/neutral lower unit use shear pin 95718. 95718.Motors Motors equipped with full gear shift lower unit (Fig. E2-32)use E2-32) use shear pin part 96683.

LOWER UNIT

This website stores data such as cookies to enable essential site functionality, as well as marketing, personalization, and analytics. You may change your settings at any time or accept the default settings.

Three ypes of lower units are used. Somemotorsare Somemotors are equippedwith a nonshifting lower unit (Fig. E2-30) E2-30)while while othersare others are equippedwith a full gear shift lower unit (Fig. E2-33) or forward/neutral ower unit (Fig. E2-S6). Refer to the appropriate ollowing paragraphs or servicing rocedwe.

Privacy Policy

Non-Shifting Lower Unit

Marketing Flg. E2.31 R.moy. tnsp.cilon covcr C) or ac. Personalization c.sg lo srrrtl llnkagc llnkagcsct sct w.

Analytics

lllustrations ourt€sy ska

Save

Accept All

MostservR&R AND OYERHAUL. Most service on the lower unit can be performed by removing gearcase ssembly rom gearlower motor leg; or by removing removinggear-

case hqusing lower cover (31-Fig. E2-30). To To remove removethe the gearcase, emove clip (13) then remove gearcase etaining nut and screw. The front gearcase e-taining stud nut (14) is behind clip (13) and the rear gearcasehousingcap capscrew screw is accessible rom inside exhaust exhaustoutlet. outlet. On later models, the front stud nut is located at front of motor leg. To remove the propeller shaft or disgearcase, drive the gear reassemblegearcase, assemble taining roll pins (28 & 29) a short distance nto gear hub, rotate propeller shaft %-turn and pull the roll pins out with vise grip plieis. Gearcase Gearcasemust must be completely sealed against water or grease eakage eakagewhen when reassembling. Drive shaft should have a diametral clearance of 0.002-0.0035 nch (0.050.088 mm) in bushings 12 & 19). Propeller shaft should have a clearanceof clearanceof 0.0025-0.004nch 0.0025-0.004 nch (0.063-0.10'mm) n bushings (23 & 27). Renew any parts which are worn or damaged. Backlash and mesh position of gears is fixed and not adjustable. If backlash s excessive, renew the worn parts. Renew Renewseals seals 5 & 32) whenever unit is disassembled r whenever water or grease eaks are apparent. Gear (25) s secured o propeller shaft by small roll pin (29)pin (29)pressed pressed pindiameter (28). A steel intoa roll (35), shearpin shear part number 96284 should be used. When assembling gearcase to motor lower leg, make certain that water tube is correctly installed and not damaged. Tighten the (front) retaining stud nut to a torque of 50-60 n.-lb n.-lbs. s. 5.6-6.7N.m) and the (rear) retaining screw to a torque of 75-90 n. n.lbs. lbs. (8.4-10.1 .m).

Full Gear Shift Lower Unit R&R AND OVDRHAUL. OVDRHAUL.Tsrernove Tsrernove lower unit from motor leg, remove nspectioncover spection cover (Fig. E2-31) E2-31)and and shift linkage screw (2-Fig. E2-33). Be

28 I

st

rA, O

/

29

Flg. E2.g2-Lowat unlt may be rcmoyad lrcm molot lcg allu rcmoval ol nut (29) and scrcw (31)'

10 9

 

Eska 3, 3.5, 4.So5, 5.5, 7 & 7.5 llllP P

OUTBOARDMOTOR

3 4 5

@@-

O.*

fi

(61). Detent (67) and spring (68) will be released s bracket s pulled awav. . Remove _screws (b6) securing lever bracket (58) to cover. R-e iarge snap-ring (49) hen gently tap propeller shatt (52) out of cover. cover.Small Smallroll roll pins (60) secure eft (20) and rieht (?1) shift bracl<et bracl<etguide guide pins in coverJOtl. to r9m-9ve. earing_ 51) from propeller snalt, clamp collar (48) in vise iaws. drive roll pin (47)out then and snap snapring ring (50). Place remove shaft ollar propeller Placepropeller rn a vise so that inner race of ball bearing ( t) is supported but jaws are not touchlng propeller shaft. Use a soft taced hammer to drive shaft out of bearing. To remove drive shaft (18), emove re tainer-plate (14) and snap snapring ring (L6).Hold onto drive shaft and use a-soft faced hammer to drive gearcase off shaft. Remove drive pinion (BZ) and forward gear (40). Ball bearing (1?) may be removed rom drive shart by irlaciirg shaft in a vise so inner race of bearingis supp_orted ut jaws are not touching shaft. Use a soft faced hammer to dririe shaft out .of bearing. When installing ball beanng (17), make swe that shielded

)l-

J_ o 8to

6

lll/

,;€

il-n

12*@ l3---o 14-g l5--: 16-'A 1l-"" -0 27

illj

28-s

29----*€

3l 35 36

32=-o

34

o/,@6lT 67__._._.

55 56

IL.-

47 70 71

::t.

pI

S

\

I

-'i-t'

uf l'qr/ o l)'/ e //

side of-bearing is facing water pump. . Needle-bearing (Bb) nd nusfiing (S+; shouldonly be servicedwith proper tools as lmproper service procedures may damage gearcase. A combination re, movaliinstallation oval/installation tool for drive shafd shaf{ needle bearing (35) may be constructed using drawing in Fig. EZ-84.

4t \--

,'l -

t

3 f

Ftg' ber

:]ril .:r:'{L

,

#rili oft, clio

Drot rnI A use( As use(

{

1. Shift link 2. Screw 3. Nut

4. Washer 5. Seal 6. Water tube 7. Screw 8. Seal 9. Seal 10. Pump body 11. Impeller 12. Base plate Baseplate 13. "O" ring 14. Retainer Dlate to. Dea 16. Snap rins 1?. Shidlded-ball earing

18. Drive shalt 19. Pin

?9'lpr:u'

zl. snm rrod od 22. Cotter pin 23. Clevis pin 24. "Q" rins 25. Rubber boot 26. Seal 27. Roll pin 28. Clip 29. Stud nut 30. Pilot bushing 31. Screw 32. Vent 93. Drain fill plug 34. Bushing

This website stores data such as cookies to enable essential site functionality, as well as marketing, personalization, and analytics. You may change your settings at any time or accept the default settings.

Privacy Policy

careful not to drop screw in motor leg. Remove clip (28-Fig. EZ-82). Remoie Marketing screw (31) and stud nut (29). Pull lower unit from motor leg. Personalization Shift lower unit into neutral position.

Analytics Rem_ove Rem_ovewater water pump assem-bly. Be careful not to loie impeller drive pin

110

Save

Accept All

35. Needleberins Needle berins 36. Gearme 3?. Pinion gear 40. Foruard ser 41. Bushing 42. Shift dog 43. Reverse gear Reversegear 44. Bushins 45. Shim w: w:asher asher 47. Roll pin 48. CoUar 49. Snap ring 50. Snap ring 51. Ball beainq 52. Propeller s[aft 53. Shea pin 54. "0" ring

55. Fork lever 56. Screw D . rtn 58. Lever bmckeb 59. Screw 60. Roll pin 61. Cover 62. Seal 63. Wcher 64. Cushion hub 65. Propeller 66, Nut 6?. Detent 68. Spring 69. Shifter bracket 70. Left guide pin ?1. Right guide pin

.B

(19-Fig. E2-33). Remove propeller, shear pin and screw (bg) thit iecure gear -cover (61). PuIl propeller shaft assembly rom gear box whiie pulling up lightly on shift rod (21). Place thumb over detent in shifter bracket (69) while pullinghole bracket away from covei

.

r ,126 t

E

- Ta

.t25

"c"cuP

}IAROENED ORUSE ORUSE WITHA WITH A HAMM€R

7.75

l| .q*l ll

ll-li , I r

6^8

.l

Fig. E2.34-Drawing ol a and special toot that should be used lot rcmoval Instaltatton ol needle beailng (35 Ftg. E2-33). lllustrationsCourtesy CourtesyEsl€ Esl€

ll

,trr^-

.

Flg' E2'33-ExplodedYiew t fult gaat shllt towet unlt. When Whenassembling assemblingowet owet unit" use petrcteum pump tmpettet11) anA lelly to lubilcate watet watetpump anAwatii watii iiie seal (9).

KN

ber ofa \\ stu( stal cas( detr

shii

end (14) wat

il

 

OTOR ) will be 'ay, mp promall roll ght (71) (61).To rropeller ie Jaws, re collar er shaft rll bearare not a soft of bearnove e6). Hold [t faced f shaft. [orward I be rerg shaft ; is supg shaft. re shaft ng ball rhielded rlllflP.

ing (34) ,er ools ]S may io n es

SERVICEMANUAL

e.IrR'ff]

When assemblinggearcase o motor leg, use a flashlighi to observe hrough exhaust outlet that water tube (6)'is properly seating in water pump. Install washer and stud nut (29) before installing screw (31). Check shift mechanism for proper engagement.Detents in shift mechanism n lower units should be felt when operating shift lever.

Fonrard/Neutral owerUnit R&R AND OVERHAUL.Refer Refer o

Fig. E2-36for E2-36 for an explodedyiew of lower unit. To remove lower unit from motor lgg, remove inspection cover (Fig. 92 31) and shift linkage screw (2-Fig. E2-36).Be E2-36). Be careful not to drop screw in

Fig, E2.36-Explodadvtew ol towad/heut'al lowet unit usod on some rnodsls. Spacer 27A) s usad usadon on later modals.

-i FIs. E2.ss-Drawtng f"o""i"ir?", whichay f"o""i"ir?", De usad to l|'Etall bushtng (34-Flg. ln gaarcasa.

E2.gg)

h. To remove bearing (35-Fis. E2-BB). ,:ffilace tool, without t'i clip, ii bearins :#from top of gearcaseand pound on end of tool. To install bearing (Bb),place ,C" clip on tool so that new bearinE will be properly positioned n bore whei driven in from top of gearcase. A blind hole bearing puller should be used o pull propeller shaft bushing (84). bushing(84). A special driver (Fig. Ez-Bb) should be used o install new bushine. .Bushings {41 & 44-FiE: E2-38) mav be removed and reinstalled with tire aih of an arbor press. When reassembling ower unit, make sur-ehatoil sur-e hatoil seals 15, 26 and and62) 62) are installed_with lips facing inside of geariE0 case. {URL bracket guide pin (?0) detentShift grooves must-be nsialleb o'nwith "Ii. t26 Shift shaft (21) is installed with flat on - L z75 end acing left side. nstall retainer plate T This website data such (14)stores so notches alignaswith cutouts in I I cookies towater pump enable essential site (12). base plate

I

I I I functionality, as well as marketing,

896 I

I II

+ 68

I personalization, and analytics. You I

I

may change your settings at any time or accept the default settings.

I

Privacy Policy

c@ 00 1 624DtA.

Marketing

,ol that latlon ol

Personalization Analytics

'sy Eska

Eska3, 3.5,4.5, Eska3, 3.5,4.5,5,5.5, 7 & 7.SH p

lllustrations ourtesy ska

Save

Accept All

r. Shift link 2. Screw 3. Shift rod pin 4. Clevis Clevispin 5. Cotter pin 6. "O" ring 7. Rubber boot 8. Seal 9. Pilot bushins tu. Dcrew 11. Nu t 12. Cotter pin 13. Propeller 14. Cwhion hub 15. Sheu pin 16. Washer r r. seat 18. Propeller shaft 19. Vent plug 20. Pin 21. Clutch lever 22. Shim 23. Washer 24. "E" riag 25. Clutch 26. Snap ring zI. Gear 27A. Spacer .28. Needle.beuins zy. l,lnlon gear 30. Snap ring 31. Gasket 92. Lower cover 33. Gearcae 34. Water tube 35. Driie shaft 36. Pin J-/.

38. 39. 40. 41. 42. 43. 44. 45.

Seal

Seal Pump body Impeller plat€ Baseplat€ Base Seal Needle bearins Needlebearins Stud Roll pin

motor eg.Remove eg. Removeetaining_screw (10) and studnut stud nut in front er

and eparate o*e,. niflX,lt niflX,lt t'"t;,9*

Drain lubricant and removepr"p.liil; and shear pin. Removewater i.,,--assembly.Remove R emove o*". .ou".'6iif Remove ropellershaft assemblr,'Ii'i disassembles required.Detact" i"i i" i ring (30)and withdraw driveshafti3;i Jlspect componentsnd ..nu*'li,u whichare which are exc.essivelyorn or au"nueuj. Backlasha.1d Backlash a.1d p-osition ano.noradJustable. ano.nor adJustable. .qe;h f backlash ".. ]i*-"1 s ex cessive,enew cessive, enew he worn parts. Reverse isassemblyiocedurewhen assemblingower assembling ower unit. Be sure clutch (21)properly Iever(21) Iever properly engages lutchizdj Ilange.

E