20D, 25N

PREFACE

NOTICE
MANUAL FORMAT
MANUAL RELATION

MODEL IDENTIFICATION
THE ILLUSTRATIONS
REFERENCES

WARNINGS, CAUTIONS AND NOTES

HOW TO READ DESCRIPTIONS

SYMBOLS

INDEX

CHAPTER 1. GENERAL INFORMATION

IDENTIFICATION
SERIAL NUMBER
STARTING SERIAL NUMBERS

SAFETY WHILE WORKING

FIRE PREVENTION
VENTILATION
SELF-PROTECTION
OILS, GREASES AND SEALING FLUIDS

GOOD WORKING PRACTICES

DISASSEMBLY AND ASSEMBLY

SPECIAL TOOLS
MEASURING

REMOVAL AND INSTALLATION

CHAPTER 2. SPECIFICATIONS

GENERAL SPECIFICATIONS

MAINTENANCE SPECIFICATIONS
ENGINE

LOWER
ELECTRICAL

DIMENSION

TIGHTENING TORQUE
GENERAL TORQUE SPECIFICATIONS

CHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENT

MAINTENANCE INTERVAL CHART

PERIODIC SERVICE
FUEL SYSTEM
Fuel line
CONTROL SYSTEM
Throttle cable adjustment
Start-in-gear protection adjustment

Idle speed adjustment

Ignition timing adjustment

Carburetor link adjustment

Neutral opening adjustment
OIL INJECTION SYSTEM
Oil pump link adjustment

LOWER UNIT
Gear oil
Lower unit leakage check

GENERAL
Anode
Battery

Spark plug

Grease points

CHAPTER 4. FUEL SYSTEM

FUEL AND LUBRICATION SYSTEM

COMPONENTS

FUEL FILTER
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

SERVICE POINTS
Fuel joint inspection

CARBURETOR REMOVAL
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

CARBURETOR DISASSEMBLY
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

SERVICE POINTS
Carburetor inspection
Carburetor assembly

FUEL PUMP
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

OIL TANK
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Check valve inspection

OIL PUMP
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

CHAPTER 5. POWER UNIT

CONTROL CABLE, LINK AND HOSE

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

LEAD WIRE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART

POWER UNIT
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART

RECOIL STARTER
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

SERVICE POINTS
Sheave drum removal
Spiral spring removal

Starter rope installation

Sheave drum installation
Spiral spring setting
Recoil starter checking

STATOR
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

SERVICE POINTS
Flywheel magneto removal

ELECTRICAL UNIT
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART

ELECTRICAL UNIT DISASSEMBLY

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

CONTROL UNIT
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

REEDVALVE
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

SERVICE POINTS
Reed valve inspection

CYLINDER HEAD, THERMOSTAT AND EXHAUST COVER

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

SERVICE POINTS
Cylinder head inspection

Thermostat inspection

CYLINDER BODY
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

SERVICE POINTS
Piston to cylinder clearance

Cylinder body and crankcase installation

CRANKSHAFT
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

SERVICE POINTS
Bearing removal
Piston inspection
Piston pin inspection

Piston ring inspection

Crankshaft inspection
Piston and piston ring installation

Crankshaft and piston installation

CHAPTER 6. LOWER UNIT

LOWER UNIT
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART

WATER PUMP
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Propeller shaft housing assembly

REVERSE GEAR
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

SERVICE POINTS
Propeller shaft housing removal
Propeller shaft housing disassembly

Propeller shaft housing assembly

FORWARD GEAR
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

SERVICE POINTS
Pinion nut removal
Forward gear disassembly
Lowercase disassembly

Lowercase assembly

Forward gear assembly

Pinion nut installation

SHIMMING
SHIM SELECTION (FOR USA AND CANADA)
Pinion gear shim

Forward gear shim

Reverse gear shim

SHIM SELECTION (EXCEPT FOR USA AND CANADA)
Pinion gear shim

Forward gear shim

Reverse gear shim

BACKLASH MEASUREMENT

Forward gear

Reverse gear

CHAPTER 7. BRACKET UNIT

STEERING BRACKET, SHIFT LEVER AND TILLER HANDLE

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

BOTTOM COWLING
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART

UPPER CASE
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

CLAMP BRACKET
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

SWIVEL BRACKET
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART

STEERING BRACKET DISASSEMBLY

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

CHAPTER 8. ELECTRICAL SYSTEM

ELECTRICAL COMPONENTS

ELECTRICAL ANALYSIS
INSPECTION
Peak voltage measurement

IGNITION SYSTEM

IGNITION SPARK GAP

DI SYSTEM PEAK VOLTAGE

SPARK PLUG
SPARK PLUG CAP

MAIN SWITCH
ENGINE STOP SWITCH

STARTING SYSTEM

BATTERY
FUSE
WIRING HARNESS
WIRING CONNECTION
ENGINE STOP SWITCH
MAIN SWITCH
STARTER SWITCH
NEUTRAL SWITCH

STARTER RELAY

STARTING MOTOR
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Pinion inspection
Armature inspection
Brush holder inspection

CHARGING SYSTEM

CHARGING SYSTEM PEAK VOLTAGE

FUSE
BATTERY

WARNING SYSTEM

THERMO SWITCH
OIL LEVEL SENSOR
WARNING LAMP

CHAPTER 9. TROUBLE-SHOOTING

TROUBLE ANALYSIS
TROUBLE ANALYSIS CHART