FLYWHEEL AND STATOR SERVICING
IMPORTANT: Weak flywheel magnets can cause low alternator output and affect outboard performance. Weak flywheel magnets can also cause low readings on ignition test equipment, such as a peak-reading voltmeter, which might cause unnecessary parts replacement.
An accurate test of alternator output can help determine the flywheel’s condition. Refer to CHARGING SYSTEM TESTS on p. 127.
Flywheel Removal
To prevent accidental starting while servicing, disconnect the battery cables at battery.
Remove the electrical cover from flywheel cover.
- Electrical cover
Disconnect wiring harness and remove wiring from cover.
- MWS harness
Remove fuse holder from flywheel cover.
- Fuse holder
Lift flywheel cover to remove.
Use Flywheel Holder, P/N 771311, or equivalent, and a 1 5/16 in. socket to remove flywheel nut. Discard flywheel nut.
Apply Moly Lube grease to the threads of the puller pressing screw, P/N 307637, and the center hole of the crankshaft.
Assemble the following components from Universal Puller Set, P/N 378103:
- Body, P/N 307636
- Screw, P/N 307637
- Handle, P/N 307638
- Three screws P/N 309492
- Three washers, P/N 307640
Put the puller on flywheel with body flat side up. Attach the puller body with the three shoulder screws and washers. Hold puller body with handle, and tighten pressing screw until flywheel releases. Turn the center screw and lift the fly wheel off of the crankshaft.
- Universal puller
Stator Service
Disconnect stator harness connector.
Remove three allen head screws to remove stator.
- Stator screws
To install stator, position stator on cylinder block. Apply Nut Lock to screw threads. Install screws and tighten in crossing pattern to a torque of 84 to 106 in. lbs. (9.5 to 12 N•m).
Flywheel Installation
Install the outer edge of flywheel key parallel with centerline of crankshaft.
- Flywheel key
Thoroughly clean the crankshaft and flywheel tapers with Cleaning Solvent™ and let dry.
Align the flywheel keyway and install flywheel. Coat the threads of a new flywheel nut with Triple- Guard grease. Install the washer and nut and tighten to a torque of 100 to 115 ft. lbs. (136 to 156 N•m).
Replace flywheel cover and recoil starter (rope start models).
IMPORTANT: Check ignition timing after fly wheel removal or replacement. Refer to TIMING ADJUSTMENTS on p. 142.
