1965 EVINRUDE SERVICE MANUAL STARFLITE 90HP MODELS 90582 90583 90592 90593 OUTBOARD MARINE CORPORATION 1965 SECTION INTRODUCTION GENERAL SERVICE INFORMATION FUEL SYSTEM IGNITION SYSTEM POWER • L-- __ H E_A._D __ LOWER UNIT ELECTRICAL SYSTEM REMOTE CONTROL Get this Manual on www.PDFSale.com )C )C SECTION 1 INTRODUCTION Table of Contents Page Arrangement of Manual ... • . • . .. .. . . .. 1-2 Parts Catalog •• • . • • . • • . . . • . . . . . . . . • 1-2 Service Policy. • • . . • • . • • . . . . . . . • . . .. 1-2 Special Serv i ce Tools. . . . . • . . . . . . . • • . . 1-2 Outboard Motor Nomenclature .. . . . . . . . . • . 1-2 Get this Manual on www.PDFSale.com STARFLITE 90 S The Evinrude Starflite 90S outboard motor is de- signed and built for dependable high performance. To assure continued peak operation, it is important that every Evinrude owner be able to receive skilled and thorough service for his motor. Customer sat- isfaction and profitable service operation depend on service "know-how" and training. Read this manual carefully so that you are familiar with the service procedures - then keep it readily available as a reference book in your service de- partment. Always remember, each service job is a chance for you to maintain motor performance that will keep your customer happy to be an Evinrude owner. ARRANGEMENT OF MANUAL This Service Manual includes the specific informa- tion you will need to service the Starflite 90S. All general procedures are covered in abbreviated form, mostly by reference to procedural illustrations. The specific procedures which apply only, or primarily, to this motor are covered in fully-illustrated, de- tailed, step-by-step instructions. The General Service Information section will help you diagnose a malfunctioning motor. It includes specifications, tune-up procedures, and a Trouble Check Chart. Clearances and torque values are also included for quick reference during servicing op- erations. Each of the following sections, Fuel Sys- tem, Ignition System, Power Head, Lower Unit, Electrical System, and Remote Control, gives de- tailed instructions for disassembly, inspection, re- assembly, and operating adjustments of the compo- nents. These procedures will help you service a specific system, or completely overhaul the Star- flite 90S. PARTS CATALOG The Evinrude Starflite 90S Parts Catalog contains exploded views illustrating the correct sequence of all parts as well as a complete listing of the parts for replacement. This catalog can be of considera- ble help as a reference during disassembly and re- assembly. SERVICE POLICY Whether within or following the warranty period, Evinrude Motors has a constant interest in its products. 1-2 It is Evinrude's policy to assist dealers in building up their service knowledge and facilities so that they can give prompt, efficient service. The Evinrude Service School, frequent Service Bulletins, and this Service Manual represent tangible efforts to give Evinrude owners the best and most prompt service possible. This Service Manual covers all phases of servicing the Starflite 90S. However, new situations sometimes arise in servicing a motor. If a service question does not appear to be · answered in this manual, you are invited to write to the Service De- partment for additional help. Always be sure to give complete information, including motor model number and serial number. Write to: Evinrude Motors 4143 North 27th Street Milwaukee, Wisconsin 53216 Attention: Service Dep artment Be sure that you are familiar with the Evinrude warranty. If you have any questions, write the Evinrude Service Department. SPECIAL SERVICE TOOLS Evinrude has specially-designed tools to simplify Some of the disassembly and reassembly operations. These tools are illustrated in this Service Manual, in many cases in actual use. Refer to the Evinrude Special Service Tool Catalog for a descriptio n and ordering instructions for these tools. OUTBOARD MOTOR NOMENCLATURE Sometimes the words "right'" and "left" are very confusing when referring to the sides of an outboard motor. Therefore, the sides are referred to as STARBOARD or PORT sides. STARBOARD means on the right hand while facing the bow (FRONT) of the boat; PORT means left hand. See Figures 1-1 and 1-2. Service required for the Evinrude Starflite 90S is generally one of three kinds ..... 1. NORMAL CARE AND MAINTENANCE, which in- cludes putting a new motor into operation, storing motors, lubrication, and care under special op- erating conditions such as salt water and cold weather. 2. OPERATING MALFUNCTIONS due to improper motor mounting, propeller condition or size, boat condition, or the malfunction of some part of the 90 5 Get this Manual on www.PDFSale.com motor. This includes motor tune-up procedures to keep the motor in prime operating condition. 3. COMPLETE DISASSEMBLY and overhaul, such as inspecting a motor that has been submerged, or rebuilding trade-in units. It is important to you as the service man to deter- mine before disassembly just what the trouble is, and how to correct it quickly and with minimum ex- pense to the owner. Refer to the Trouble Check Chart in Section 2 to help you diagnose motor malfunctions • ~ •• i;i~~~ i"=~~---- ALTERNATOR POWER HEAD 13 3 65 Figure 1-1. Starboard Side THROTTLE AND DIS TRIB UTOR LINKAGE FUEL PUMP FUEL CONNECTOR STERN BRACKET FRONT EXHAUST COVER OIL LEVEL PLUG GEARCASE OIL DRAIN PLUG 10 14 Figure 1-2. Port Side 90S '- 1-3 AUTOMA TIC CHOKE CARBURETOR ~ MOTOR COV E R LATCH TILT SHAFT STERN BRACKET THRUST ROD ANGLE ADJUSTMENT IGNITION COIL DISTRIBUTOR LEADS REAR E XHAUST COVER PROPELLER SKEG Get this Manual on www.PDFSale.com )c )c SECTION 2 GENERAL SERVICE INFORMATION Table of Cont ents Page Specifications • • • • • • • • • • . • . • • • • • . . .. 2-2 Clearance Chart. • . . . . . • • . . . . . . . . . . •. 2-3 Torque Chart . • • • • • • • • • • • • . . . . • • . . .• 2-3 Lubri cation Chart. • • . • • . • • . . . • . • . • • .• 2-4 Tune-up Procedure • • . • • • . . . • • • . • . . . .• 2-6 Trouble Check Chart. • • • • . • • . • • . • . • • .. 2-6 • Get this Manual on www.PDFSale.com SPECIFICATIONS Model Numbers *Horsepower (O.B.C.- certified) Full throttle operating range Engine type Bore and stroke 90582-Standard length (15" tran- som) (Blue) 90583-5" longer (20" transom) (Blue) 90592-Standard length (15" tran- som) (Gray) 90593-5" longer (20" transom) (Gray) 90 hp at 4500 rpm 4000 to 5000 rpm 90 0 V-type 4 cylinder, 2 cycle 3-3/8" bore x 2-1/2" stroke Piston displace- 89.5 cubic inches ment Piston ring sets (3 per set) standard Part Number 380110 .020" oversize Part Number 380111 .040" oversize Part Number 380112 Diameter of ring 3.375 in. (standard) Width of ring .0935 - .0925 in. Lbs. compression 9.7 to 13.7 lbs. recommended when compressed Piston less rings standard .020" oversize .040" oversize Crankshaft size top journal center journal bottom journal Connecting rod crank pin Cooling system Propeller gear ratio Propeller drive pin Part Number 380569 Part Number 378814 Part Number 378815 1.2658 - 1.2653 in. 1.3752 - 1.3748 in. 1.1815 - 1.1810 in. 1.1828 - 1.1823 in. Thermostatically controlled recirculating system 20:23 Part #307217 9/32" x 2-5 / 32" stainless steel *Horsepower established at sea level. Allow 2% re- duction per 1000' above sea level. 2-2 Propeller Speed control Gear shift control Weight (without fuel tank) Fuel capacity Electrical system starter starter amp draw when cranking Ignition Spark plug Spark plug gap Spark plug torque Breaker point gap Condenser capacity Carburetion Float level setting Carburetor orifice plug Propeller options: 9-1 / 2" diameter x 10" pitch 10" diameter x 9-1 / 4" pitch 10" diameter x 11" pitch 10" diameter x 12" pitch 10-1 / 4" diameter x 10" pitch Remote control, synchronized throttle and spark Forward, neutral, reverse - Selectric push-button remote control Models 90582, 90592 - 242 pounds Models 90583, 90593 - 247-1/2 pounds (Fuel tank weight 12 pounds net) 6 gallons, suction type tank Alternating current generator - Maximum output 20 amp at 2500 rpm - 5 amp output at idle Electric Maximum 140 amp Automotive type battery and distributor system AC-M42K, Champion J4J, Auto- Lite A21X - 14mm .030 inch 20 - 20-1/2 foot-pounds .020 inch .37 - .41 mfd. Four-barrel, with straight line manifold, float feed, low-speed adjustment, automatic hot air choke 9/ 16" Hole size .070" Inlet needle seat .050" to .053". Use a # 55 drill as gage 9 05 Get this Manual on www.PDFSale.com CLEARANCE CHART Driveshaft to Roller type gearcase bear- POWER HEAD ing - upper Piston and wrist .0006 Max. - .001 Min. Pinion to gear- Roller type pin - loose end case Piston ring gap .017 Max. - .007 Min. Propeller shaft Tapered roller to gearcase - Piston ring groove .007 Max. - .0045 Min. front clearance Front gear to .0011 Max. - .0003 Min. Cylinder and .006 Max. - .0045 Min. front bushing piston Front gear bush- .0011 Max. - .0003 Min. Crankshaft bearings ing to clutch hub Upper Roller type Center Roller type Propeller shaft to Roller type Lower Ball type gearcase - rear Crankshaft end .007" Maximum play Rear g ear to Roller type clutch hub Connecting rod bearings Piston end Roller type Crankshaft end Roller type Propeller on shaft .006 Max. - .002 Min. at drive pin hole LOWER UNIT Gearcase head Roller type Propeller on shaft .005 Max. - .001 Min. and propeller above the shaft shoulder TORQUE CHART Heat exchanger 192-216Inch-pounds (16-18 Foot- nut to exhaust pounds) POWER HEAD cover Flywheel nut 70-85 Foot-pounds Spark plugs 20-20-1 / 2 Foot-pounds Connecting rod 348-372 Inch-pounds (29-31 Foot- screws pounds) LOWER UNIT Gearcase stud 28-32 Foot-pounds Cylinder head 168-192 Inch-pounds Gear case stud 24- 26 Foot-pounds screws nuts Slip clutch 320-420 Foot-pounds Crankcase to cylinder screws propeller Upper 144-168 Inch-pounds Center 162-168 Inch-pounds STANDARD SCREWS Lower 144-168 Inch-pounds Inch-Pounds F oo t-Pounds No.6 7-10 Crankcase head screws No.8 15-22 Upper 120-144 Inch-pounds (10-12 Foot- No. 10 25-35 2-3 pounds) No. 12 35-40 3-4 Lower 96-120 Inch-pounds (8-10 Foot - 1/ 4" 60-80 5-7 pounds) 5-16" 120-140 10-12 3/ 8" 220-240 18-20 2-3 905 Get this Manual on www.PDFSale.com LUBRICATION CHART FREQUENCY LUBRICATION (PERIOD OF OPERATION) POINT LUBRICANT FRESH WATER #SALT WATER 1. Gearcase OMC Type "c" Check level after first 10 hours of Same as Fresh See Figure 2-3 Lubricant operation and every 50 hours of Water operation thereafter. Add lubri- cant if necessary. Drain and refill every 100 hours Same as Fresh 2. Carburetor Linkage OMC Type "A" See Figure 2-4 3. Distributor OMC Type "A" See Figure 2-5 4. Tilt and Trailing Lever OMC Type "A" See Figure 2-6 5. Safety Switch Cam OMC Type "A" See Figure 2-7 6. Throttle Shaft Bearings SAE 90 Oil See Figure 2-8 7. Swivel Bracket Fitting OMC Type "A" See Figure 2-9 8. Starter Pinion Gear Shaft SAE 10 Oil See Figure 2-10 (One drop) # Some areas may require more frequent lubrication. TYPE OF GASOLINE: Use regular automotive gas- oline or white marine gasoline. Higher octane fuels may be used, but generally offer no advantages. NOTE: When operating in any country other than the United States or Canada, use any gasoline that will satisfactorily operate an automotive engine. LUBRICANT: Use a reputable outboard motor oil. If an outboard motor oil is not available, a good quality SAE 30 automotive oil may be used. The oil used should have Service ML-MM or Service MM marked on the container. Additional markings, such as MS, DG, DS designate heavy duty and should be avoided. Avoid low priced, light duty oils (container marked only with ML designation) or multiple vis- cosit y oils, such as SAE 10W-30. IMPORTANT: Additive compounds such as " tune- up" compounds, "tonics," "friction reducing" com- pounds, etc., are unnecessary and are not recom- m ended. The use of OMC engine cleaner and OMC rust preventive oil is recommended. GEARCASE Remove plugs and gasket assemblies marked " OIL DRAIN" and "OIL LEVEL" from port side of gear- case. With propeller shaft in a horizontal plane, allow oil to drain completely. Refill with OMC Type "c" lubricant. With pro- peller shaft still in horizontal pOSition, fill until of operation or once each season, Water whichever occurs first. 60 days 30 days 60 days 30 ' days 60 days 30 days 60 days :30 days 60 days 30 days 60 days 30 days 60 days 30 days TYPES OF L UBRI C AN T OMC OMC T YP E " A " TYPE " C " OIL CAN SA E 90 SAE 10 GR E AS E G UN OMC T YP E "A " lubricant appears at "OIL LEVEL" hole. See Figure 2-3. 2-4 Install "OIL LEVEL" plug before removing lubri- cant filler hose from "OIL DRAIN" hole. Drain plug can then be installed without oil loss If filler type can is not available, install drain plug. Slowly fill gear case through "OIL LEVEL" hole, allowing trapped air to escape. Install plug. 905 Get this Manual on www.PDFSale.com Fi g ure 2-3. Gearcase Figure 2-4. Carburetor Linkage Fi g ure 2-5. Distributor Linka ge Figure 2-6. Tilt and Trailing Lever 905 LUBRICATION POINTS Figure 2-1. Starboard Side Figure 2-2. Port Side 2-5 1 534 Figure 2-7. Safety Switch Cam Fi g ure 2-8. Thr o ttle Sh aft B earings Figure 2-9. Swivel Bracket Fitting Fi g ur e 2-10 St a rter Pinion Gear Shaft Get this Manual on www.PDFSale.com TUNE-UP PROCEDURE When an owner brings a motor to you for a tune-up, or for some minor operating malfunction, the follow- ing procedure should be used as a guide to determine the cause of the malfunction. Write down the owner's comments. Keep an accurate card file on your serv- ice shop operation. Each service operation should be on record as to the: OWNER'S NAME DATE MODEL NO. SERIAL NO. NATURE OF COMPLAINT NATURE OF WORK PERFORMED COST TO THE OWNER WAS WORK PERFORMED UNDER WARRANTY? After writing down the owner's comments, check the motor visually and begin a systematic tune-up pro- cedure. Consult the Trouble Check Chart to find the causes of any malfunction which may be dis- covered when tuning up the motor. 1. Remove cylinder heads exhaust covers, and in- take by-pass covers. Slowly rotate flywheel and visually inspect pistons, rings, and cylinders for wear, freeness, and carbon deposits. Crankshaft end play should not exceed .005" - .007". SPECIAL NOTE Piston ring condition should be determined before continuing tune-up. Gum and varnish deposits on rings or pistons may be removed with an application of OMC Accessory En- gine Cleaner. If pistons, cylinders and rings are considered to be in satisfactory condition, remove carbon and reinstall covers, using new gaskets. 2. Clean carbon from cylinder heads and tops of pistons. Surface and reinstall cylinder heads, using new gaskets. 3. Inspect and test points, condenser, coil, and ig- nition wires. See Section 4 for test procedures. Check for spark at each cylinder. 4. Inspect spark plugs. Clean and regap or replace as necessary. 5. Inspect carburetor and automatic choke. 6. Inspect fuel pump and hoses. Clean filter bowl and inspect for chips or cracks. Replace filter element and gasket. 7. Synchronize distributor and carburetor linkage. See Section 4. 8. Inspect push-button electric shift operation. See Section 8 for test procedures. 9. Check propeller for condition and correct pitch. See Section 6. 10. Drain and refill gearcase and thoroughly lubri- cate all components of the motor. See Pages 2-4 and 2-5. 11. Tighten all screws and nuts, etc., to specified torque. See Page 2-3. 12. Tank-test and adjust cariJuretor low-speed nee- dles; check cooling system operation. Use a tachometer and test wheel for accurate rpm tests. Re-torque cylinder screws after motor has cooled off. See page 2-3. 13. Fog motor for storage, using OMC Accessory Rust Preventative Oil. TROUB LE C HECK CHART TROUBLE POSSIBLE CAUSE 1. MOTOR WILL NOT START A. FUEL SYSTEM - See Section 3 Fuel line improperly connected Engine not primed Speed control not advanced (throttle closed) Engine flooded Old fuel Clogged fuel filter Automatic choke not closing completely Choke spring broken or disconnected Fuel system faulty B. IGNITION SYSTEM - See Section 4 Timing, cam, or linkage improperly adjusted Inverted breaker cam Sheared flywheel key Safety switch screws loose Ignition system faulty C. ELECTRICAL SYSTEM - See Section 7 Starter circuit faulty 2-6 905 Get this Manual on www.PDFSale.com TROUBLE CHECK CHART (CONT) TRO UBLE POSSIBLE CAUSE 2. LO SS OF POWER - (Assuming A. POWER HEAD - See Section 5 Ignition OK) Lower bearing head loose (check end play) Carb u retor and distributor not synchronized Throttle contro l lever bent (won't advance) Air leak at manifold gaskets - warped manifold (backfires) Broken leaf valves (backfires) Cracked carbon seal (water in cylinders) Excessive carbon on pistons and cylinder head Stuck piston rings, or scored cylinder or piston B. CARBURETOR - See Section 3 Old fuel - too much oil Carburetor adjustment - (too l ean - backfires) (too rich - excessive fuel) Linkage screws loose Automatic choke not operating Air leaks at packing nuts Inlet need le and seat worn or sticky Incorrect carburetor float setting Incorrect orifice plug C. FUEL PUMP AND TANK - See Section 3 Faulty fuel hose (poor clamps or sea l s) (kinked) Fuel tank or pump filter plugged Fuel filter restricted Fuel and vent valves not opening Valves not operating Operating hose passage restricted Diaphragm leaking or damaged Fuel system hoses plugged D. EXHAUST GAS ENTERING CARBURETOR - See Section 6 Exhaust cover screws l eaking Cover plate gasket damaged Damaged exhaust housing seal Exhaust relief boot cut Adapter gaskets leaking Cracked exhaust housing Exhaust tube to cylinder screws l oose or missing E. OVERHEATING POWER HEAD - See Section 5 Exha u st cover gasket leaking Inner exhaust cover leaking Thermostat housing broke n Pressure contro l valve damaged Power head gasket damaged Head gasket leaking (warped head) (water in cylinders) F. LOWER UNIT - See Section 6 Water intakes obstructed Pump housing air bleed restricted Water passages obstructed P ump plate not sealing (bottom) Pu mp impeller damaged P u mp housing or plate worn Pu mp housing seal worn (driveshaft grooved) Water tube bushing damaged Exha u st ou tlet damaged G. EXHAU ST GASES ENTERING COOLING SYSTEM - See Section 6 Pump impe ll er plate not seali ng (bottom) D amaged water tube grommets or " 0 " rings Gearcase stud lockwasher leaking Pump housing seal damaged (5" adapter seals) Exha u st outlet gasket missing Exha u st tube to adapter gasket damaged 90S 2-7 Get this Manual on www.PDFSale.com TROUBLE CHECK CHART (CONT) TROUBLE POSSIBLE CAUSE 3. ENGINE MISFIRES (Assuming A. SPARK PLUGS - See Section 4 Fuel System & Carburetor OK) Crossed or reversed leads Cover or inner terminal damaged (spark plug point out of H.T. lead) Faulty leads Loose - low torque Incorrect heat range Defective (cracked insulator) B. DISTRIBUTOR - See Section 4 Incorrectly adjusted pOints (vibration) Incorrect timing Loose wiring Coil or condenser damaged (loose) Fibre breaker block worn Points dirty or pitted Defective breaker cam CORRODED OR CRACKED DISTRIBUTOR CAP & ROTOR - See Section 4 Incorrect rotor Loos e distributor ground cable Rotor brush stuck or worn Carbon pa th in distributor cap Worn shaft bearings 4. POOR PERFORMANCE ON BOAT A. INCORRECT PROPELLER Incorrect tilt angle (smoking) Poor fuel mix - too much oil (smoking) Remote controls incorrectly adjusted Propeller hub slipping Bent or worn propeller Exhaust outlet damaged or missing Bent ge a r housing or exhaust housin g (broken driveshafts) Altitude horsepower loss Catamaran (single engine) - venturi effect Exh a ust leaks Overheating B. CA VIT ATION Protruding hull attachments Keel too long Bent propeller (vibration) Transom too high C. BOAT Improper load distribution Marine growth on bottom Added weight (water absorption) Hook in bottom 5. SELECTRIC SHIFT WILL NOT A. CONTROL BOX AND ELECTRICAL CONNECTIONS - OPERATE See Section 8 Control box and / or power head connections not coupled or corroded Ammeter to key switch fuse blown Faulty push-button switch Open circuit (broken wires) Faulty key switch B. LOWER UNIT - See Section 6 Incorrect lubricant (Type "C" only) Loose clutch spring screws Damaged coil, worn clutch sprin g, or hub Burned shift cable Loose knife disconnect terminals 6. GENERATOR WILL NOT A. CHARGING CIRCUIT - See Section 7 OPERATE Blown fuse Shorted or open windings - rotor or field Regulator damaged Diodes damaged Ammeter to key switch fuse blown 2-8 905 Get this Manual on www.PDFSale.com TROUBLE CHECK CHART (CONT) TROUBLE POSSIBLE CAUSE 7. STARTER MOTOR WILL NOT A. STARTING CIRCUIT - See Section 7 OPERATE Loose or corroded battery connections Safety switch inoperative (loose) Throttle advanced too far Poor or broken battery connections Weak or shorted battery Defective key or starter switch Jammed starter drive Damaged starter drive parts Worn brushes Broken brush spring Open circuit in solenoid Burned commutator Broken field terminal Shorted or open windings - armature or field B. EXCESSIVE STARTER CURRENT DRAW - See Section 7 Worn or dry armautre shaft bearings Excessive friction in engine Brushes not seating Dirty or corroded commutator Loose pole pieces Shorted armature or field Bearing heads buckled 90S 2-9 Get this Manual on www.PDFSale.com