20d_25n

20D, 25N

PREFACE

NOTICEMANUAL FORMATMANUAL RELATION

MODEL IDENTIFICATIONTHE ILLUSTRATIONSREFERENCES

WARNINGS, CAUTIONS AND NOTES

HOW TO READ DESCRIPTIONS

SYMBOLS

INDEX

CHAPTER 1. GENERAL INFORMATION

IDENTIFICATIONSERIAL NUMBERSTARTING SERIAL NUMBERS

SAFETY WHILE WORKINGFIRE PREVENTIONVENTILATIONSELF-PROTECTIONOILS, GREASES AND SEALING FLUIDS

GOOD WORKING PRACTICES

DISASSEMBLY AND ASSEMBLY

SPECIAL TOOLSMEASURING

REMOVAL AND INSTALLATION

CHAPTER 2. SPECIFICATIONS

GENERAL SPECIFICATIONS

MAINTENANCE SPECIFICATIONSENGINE

LOWERELECTRICAL

DIMENSION

TIGHTENING TORQUEGENERAL TORQUE SPECIFICATIONS

CHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENT

MAINTENANCE INTERVAL CHART

PERIODIC SERVICEFUEL SYSTEMFuel lineCONTROL SYSTEMThrottle cable adjustmentStart-in-gear protection adjustment

Idle speed adjustment

Ignition timing adjustment

Carburetor link adjustmentNeutral opening adjustmentOIL INJECTION SYSTEMOil pump link adjustment

LOWER UNITGear oilLower unit leakage check

GENERALAnodeBattery

Spark plug

Grease points

CHAPTER 4. FUEL SYSTEM

FUEL AND LUBRICATION SYSTEMCOMPONENTS

FUEL FILTEREXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHARTSERVICE POINTSFuel joint inspection

CARBURETOR REMOVALEXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

CARBURETOR DISASSEMBLYEXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

SERVICE POINTSCarburetor inspectionCarburetor assembly

FUEL PUMPEXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

OIL TANKEXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHARTCheck valve inspection

OIL PUMPEXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

CHAPTER 5. POWER UNIT

CONTROL CABLE, LINK AND HOSEEXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

LEAD WIREEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART

POWER UNITEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART

RECOIL STARTEREXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

SERVICE POINTSSheave drum removalSpiral spring removal

Starter rope installationSheave drum installationSpiral spring settingRecoil starter checking

STATOREXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

SERVICE POINTSFlywheel magneto removal

ELECTRICAL UNITEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART

ELECTRICAL UNIT DISASSEMBLYEXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

CONTROL UNITEXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

REEDVALVEEXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHARTSERVICE POINTSReed valve inspection

CYLINDER HEAD, THERMOSTAT AND EXHAUST COVEREXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

SERVICE POINTSCylinder head inspection

Thermostat inspection

CYLINDER BODYEXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

SERVICE POINTSPiston to cylinder clearance

Cylinder body and crankcase installation

CRANKSHAFTEXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

SERVICE POINTSBearing removalPiston inspectionPiston pin inspection

Piston ring inspection

Crankshaft inspectionPiston and piston ring installation

Crankshaft and piston installation

CHAPTER 6. LOWER UNIT

LOWER UNITEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART

WATER PUMPEXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Propeller shaft housing assembly

REVERSE GEAREXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

SERVICE POINTSPropeller shaft housing removalPropeller shaft housing disassembly

Propeller shaft housing assembly

FORWARD GEAREXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

SERVICE POINTSPinion nut removalForward gear disassemblyLowercase disassembly

Lowercase assembly

Forward gear assemblyPinion nut installation

SHIMMINGSHIM SELECTION (FOR USA AND CANADA)Pinion gear shim

Forward gear shim

Reverse gear shimSHIM SELECTION (EXCEPT FOR USA AND CANADA)Pinion gear shim

Forward gear shim

Reverse gear shimBACKLASH MEASUREMENT

Forward gear

Reverse gear

CHAPTER 7. BRACKET UNIT

STEERING BRACKET, SHIFT LEVER AND TILLER HANDLEEXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

BOTTOM COWLINGEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART

UPPER CASEEXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

CLAMP BRACKETEXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

SWIVEL BRACKETEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART

STEERING BRACKET DISASSEMBLYEXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

CHAPTER 8. ELECTRICAL SYSTEM

ELECTRICAL COMPONENTS

ELECTRICAL ANALYSISINSPECTIONPeak voltage measurement

IGNITION SYSTEM

IGNITION SPARK GAPDI SYSTEM PEAK VOLTAGE

SPARK PLUGSPARK PLUG CAP

MAIN SWITCHENGINE STOP SWITCH

STARTING SYSTEM

BATTERYFUSEWIRING HARNESSWIRING CONNECTIONENGINE STOP SWITCHMAIN SWITCHSTARTER SWITCHNEUTRAL SWITCH

STARTER RELAY

STARTING MOTOREXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Pinion inspectionArmature inspectionBrush holder inspection

CHARGING SYSTEM

CHARGING SYSTEM PEAK VOLTAGEFUSEBATTERY

WARNING SYSTEM

THERMO SWITCHOIL LEVEL SENSORWARNING LAMP

CHAPTER 9. TROUBLE-SHOOTING

TROUBLE ANALYSISTROUBLE ANALYSIS CHART

20D, 25NPREFACENOTICEMANUAL FORMATMANUAL RELATIONMODEL IDENTIFICATIONTHE ILLUSTRATIONSREFERENCESWARNINGS, CAUTIONS AND NOTESHOW TO READ DESCRIPTIONSSYMBOLS

INDEXCHAPTER 1. GENERAL INFORMATIONIDENTIFICATIONSERIAL NUMBERSTARTING SERIAL NUMBERS

SAFETY WHILE WORKINGFIRE PREVENTIONVENTILATIONSELF-PROTECTIONOILS, GREASES AND SEALING FLUIDSGOOD WORKING PRACTICESDISASSEMBLY AND ASSEMBLY

SPECIAL TOOLSMEASURINGREMOVAL AND INSTALLATION

CHAPTER 2. SPECIFICATIONSGENERAL SPECIFICATIONSMAINTENANCE SPECIFICATIONSENGINELOWERELECTRICALDIMENSION

TIGHTENING TORQUEGENERAL TORQUE SPECIFICATIONS

CHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENTMAINTENANCE INTERVAL CHARTPERIODIC SERVICEFUEL SYSTEMFuel line

CONTROL SYSTEMThrottle cable adjustmentStart-in-gear protection adjustmentIdle speed adjustmentIgnition timing adjustmentCarburetor link adjustmentNeutral opening adjustment

OIL INJECTION SYSTEMOil pump link adjustment

LOWER UNITGear oilLower unit leakage check

GENERALAnodeBatterySpark plugGrease points

CHAPTER 4. FUEL SYSTEMFUEL AND LUBRICATION SYSTEMCOMPONENTS

FUEL FILTEREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTSERVICE POINTSFuel joint inspection

CARBURETOR REMOVALEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART

CARBURETOR DISASSEMBLYEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTSERVICE POINTSCarburetor inspectionCarburetor assembly

FUEL PUMPEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART

OIL TANKEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTCheck valve inspection

OIL PUMPEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART

CHAPTER 5. POWER UNITCONTROL CABLE, LINK AND HOSEEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART

LEAD WIREEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART

POWER UNITEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART

RECOIL STARTEREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTSERVICE POINTSSheave drum removalSpiral spring removalStarter rope installationSheave drum installationSpiral spring settingRecoil starter checking

STATOREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTSERVICE POINTSFlywheel magneto removal

ELECTRICAL UNITEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART

ELECTRICAL UNIT DISASSEMBLYEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART

CONTROL UNITEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART

REEDVALVEEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTSERVICE POINTSReed valve inspection

CYLINDER HEAD, THERMOSTAT AND EXHAUST COVEREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTSERVICE POINTSCylinder head inspectionThermostat inspection

CYLINDER BODYEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTSERVICE POINTSPiston to cylinder clearanceCylinder body and crankcase installation

CRANKSHAFTEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTSERVICE POINTSBearing removalPiston inspectionPiston pin inspectionPiston ring inspectionCrankshaft inspectionPiston and piston ring installationCrankshaft and piston installation

CHAPTER 6. LOWER UNITLOWER UNITEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART

WATER PUMPEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTPropeller shaft housing assembly

REVERSE GEAREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTSERVICE POINTSPropeller shaft housing removalPropeller shaft housing disassemblyPropeller shaft housing assembly

FORWARD GEAREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTSERVICE POINTSPinion nut removalForward gear disassemblyLowercase disassemblyLowercase assemblyForward gear assemblyPinion nut installation

SHIMMINGSHIM SELECTION (FOR USA AND CANADA)Pinion gear shimForward gear shimReverse gear shim

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

BACKLASH MEASUREMENTForward gearReverse gear

CHAPTER 7. BRACKET UNITSTEERING BRACKET, SHIFT LEVER AND TILLER HANDLEEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART

BOTTOM COWLINGEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART

UPPER CASEEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART

CLAMP BRACKETEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART

SWIVEL BRACKETEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART

STEERING BRACKET DISASSEMBLYEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART

CHAPTER 8. ELECTRICAL SYSTEMELECTRICAL COMPONENTSELECTRICAL ANALYSISINSPECTIONPeak voltage measurement

IGNITION SYSTEMIGNITION SPARK GAPDI SYSTEM PEAK VOLTAGESPARK PLUGSPARK PLUG CAPMAIN SWITCHENGINE STOP SWITCH

STARTING SYSTEMBATTERYFUSEWIRING HARNESSWIRING CONNECTIONENGINE STOP SWITCHMAIN SWITCHSTARTER SWITCHNEUTRAL SWITCHSTARTER RELAY

STARTING MOTOREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTPinion inspectionArmature inspectionBrush holder inspection

CHARGING SYSTEMCHARGING SYSTEM PEAK VOLTAGEFUSEBATTERY

WARNING SYSTEMTHERMO SWITCHOIL LEVEL SENSORWARNING LAMP

CHAPTER 9. TROUBLE-SHOOTINGTROUBLE ANALYSISTROUBLE ANALYSIS CHART