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Complete Factory Repair manual - hundreds pages of diagrams and instructions.
With this Step by Step Manual You can easily disassembly and assembly (overhaul) even engine.
This is same manual which mechanics use to service and repair your Stern Drive
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-----MODELS

OMC Stern Drive 1965 1966 1967 1968 1969 1970
1971 1972 1973 1974 1975 1976 1977 1978 1979 1980
1981 1982 1983 1984 1985 1986 1987 1988 1989 1990
1991 1992 1993 1994 1995 1996 1997 1998 1999

4 Cylinder Engines
V6 & V8 Engines
V8 Engines


----CONTENT

1) SAFETY

INTRODUCTION
CLEANING, WAXING, POLISHING
CONTROLLING CORROSION
Using Zinc
PROPELLERS
FUEL SYSTEh4
LOADING
FLOTATION
HORSEPOWER
EMERGENCY EQUIPMENT
COMPASS
STEERING
ANCHORS
MISCELLANEOUS EQUIPMENT
BOATING ACCIDENT REPORTS
NAVIGATION

2 TUNING

TUNING FOR PERFORMANCE
IGNITION
FUEL SYSTEM

* ENGINE

GENERAL PRINCIPLES
Valve Timing
Engine Types
Service Procedures
Troubleshooting Mechanical
Engine Problems
Removal
Installation
Oil Pump
Intake Manifold
Exhaust Manif old
Cylinder Head Service
Reconditioning
Installation
Valve Lash Adjustment
Piston Ring and Rod Service
Disassembling
Assembling
Installat ion
Camshaft Service
Removal
Installation
Crankcase Front Cover
Crankshaft Service

* FUEL

TROUBLESHOOTING
Fuel Pump
Fuel Line
Rough Engine Idle
Excessive Fuel Consumption
Engine Surge
SINGLE-DIAPHRAGM FUEL PUMP
DUAL-DIAPHRAGM FUEL PUMP
FUEL FILTER REPLACEMENT
CARBURETORS
Rochester BC Carburetor
Removal
Assembling
Adjusting
Carter RBS Carburetor
Description & Operation
Disassembling
Assembling
Bench Adjustments
Rochester 2GC
Disassembling
Assembling
Bench Adjustments
Rochester 4MV
Description
Disassembling
Assembling
Bench Adjustments
Holley
Description
Disassembling
Assembling
Adjustments

* IGNITION

DESCRIPTION
TROUBLESHOOTING
Compression
General Tests
Primary Circuit Tests
Contact Point Test
condenser Test
Secondary Circuit Test
Rotor Test
Ignition Voltage Tests
Spark Plug Troubleshooting
Polarity Check
DISTRIBUTOR SERVICE
Removal
SERVICING A DELCO-REMY
Disassembling - from a
4- or 6-cylinder
in-line engine
Assembling
Disassembling from a
GMC V6 1964-72 or V8
Assembling
Gapping Con tact Points
SERVICING A MALLORY
Disassembling from
All V6 and V8 engines
1981 and on
Assembling
SERVICING AN AUTOLITE OR
PRESTOLITE
Disassembling-
Assembling
ADJUSTING POINT GAP ALL
DISTRIBUTOR INSTALLATION
Adjusting the Dwell
Adjusting Timing
Adjusting Idle Speed
and Mixture

* ELECTRICAL

INTRODUCTION
BATTERIES
JUMPER CABLES
DUAL BATTERY INSTALLATION
GAUGES AND HORNS
Oil and Temperature Gauges
Warning Lights
Fuel Gauges
Troubleshooting
Tachometer
Horns
CHARGING SYSTEM
Alternator
Troubles hooting
Servicing Charging System
with Separate Regulator
Servicing Charging System
with Integral Regulator
CRANKING SYSTEM
Troubleshooting
Delco-Remy Starter
Description & Operation
Servicing
Testing
Assembling
Autolite Starter
Description & Operation
Disassembling
Bench Tests
Assembling
Prestolite Starter
Description & Operation
Disassembling
Assembling

* ACCESSORIES

INTRODUCTION
SHIFT BOXES
Troubleshooting
Single- and Side-Mount Boxes
Removal & Repair
Push Button Shift Box
Removal & Repair
Binnacle-Mounted Shift Box
Removal & Repair
THROTTLE CABLE INSTALLATION 7-8
SELECTRIM FOR IN-LINE ENGINES 7-9
Description & Operation 7-9
Removal & Disassembling 7-10
Assembling 7- 15
Installation
SELECTRIM FOR
FORD V8 ENGINES
Description & Operation
Removal & Disassembling
Cylinder Disassembling
Cylinder Assembling
installation
HYDRAULIC PUMP & MOTOR
Removal
Disassembling
Assembling ,_
Installation
Replacing Manual Release
Valve
Adding Fluid or
Filling a Dry System
Electrical Checks
TRU-COURSE STEERING
Cable Drum-and-Bracket
Disassembling
Assembling
Adjustments
MECHANICAL STEERING
Cable Removal
Cable Installation
OVER-UNDER STEERING HELM
Description
Cable Replacement
Helm Installation
FINAL CHECKS & ADJUSTMENTS

* Tilt MECHANISM

DESCRIPTION AND OPERATION
TROUBLESHOOTING
TILT MOTOR SERVICE
Removal
Testing
Disassembling
Assembling
Installation
HAMMER BLOW COUPLING
TILT CLUTCH & WORV GEAR
Disassembling

* COOLING

DESCRIPTION
TROUBLESHOOTING
EXHAUST MANIFOLDS
THERMOSTAT REPLACEMENT
WATER PUMP REMOVAL
Assembling
Assembling & Installation

* STERN DRIVE

Troubleshooting
Removal
Upper Gear Housing Removal
Water Pump Removal
Ball Gear Disassembling
Bearing Housing
Disassembling
Worm Gear Steering
Disassembly
Ball Gear Assembling
Bearing Housing Assembling
Water Pump Assembling
Exhaust Housing Removal
Swivel Housing R emoval
Lower Unit
Removal & Disassembling
Assembling
Swivel Housing Assembling
Exhaust Housing Assembling
Upper Gear Housing
Installation
Stern Drive Installation
STERN DRIVE
Troubles hooting
Shift Converter Service
Cable Removal
Disassembling
Assembling
Stern Crive Removal
Upper Gear Housing Removal
Water Pump Removal
Ball Gear Disassembling
Bearing Housing
Disassembling
Worm Gear Steering
Disassembling
Ball Gear Assembling
Bearing Housing Assembling
Water Pump Assembling
Exhaust Housing Removal
Swivel Housing Removal
Swivel Housing Assembling
Lower Unit
Removal & Disassembling
Assembling
Propeller Shaft
Driveshaf t Bearing
Housing
Oil Pump & Forward Gear
Disassembling
Assembling
Propeller Shaft and
Shif ter Disassembling
Assembling
Power Assist Servo
Disassembling
Assembling
Shift Cable Removal
or Replacement
Assembling
Pinion Bearing Shimming
Pinion Bearing Race
Installation
Oil Pump & Forward Gear
Installation
Driveshaft & Pinion Gear
Installation
Propeller Shaft, Assist
Valve, & Plunger
Installation
Exhaust Housing
Installation
Upper Gear Housing
Installation
Stern Drive Installation
Shift Converter Cable
Installation
Shift Adjustment
Trim Tab Adjustment

* INTER MEDIATE HOUSING

TROUBLESHOOTING
SERVICING THE BOOT
Removal
Installation
BALL GEAR DRIVESHAFT
Disassembling
Assembling
INTERMEDIATE HOUSING
Removal
Installation

* MAINTENANCE

FIBERGLASS HULLS
BELOW WATERLINE SERVICE
OFF-SEASON STORAGE
PRE-SEASON PREPARATION


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