Used Force 40hp 50hp Outboard Engine 1995 Printed Repair Service Manual

Description

This used and rare printed and bound paper Force 40hp 50hp Outboard Engine 1995 Printed Repair Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for Force 40hp 50hp Outboard Engines made in 1995. This is the original factory manual that is no longer in print. In excellent condition and looks brand new.

With Starting Serial Numbers (United States)
40 HP 0E093728
50 HP 0E093742

Table of Contents
General Information
Propeller Information
How to Use This Manual
Page Numbering
40 and 50 HP
Torque Chart (40/50 HP)
Standard Hardware
Propeller Selection
Propeller Installation
Trim “In” Angle Adjustment
Trim Tab Adjustment
Boat Performance
Test Instructions
Flushing Outboard Cooling System
Following Complete Submersion
Salt Water Submersion (Special Instructions)
Submerged While Running (Special Instructions)
Submerged Engine (Fresh Water) Plus Special Instructions
Out-of-Season Outboard Storage
Out-of-Season Battery Storage
Conditions Affecting Operation
Detonation: Causes and Prevention
Compression Check
Water Pressure Check

Electrical and Ignition
Ignition System
Special Tools Required
General
Principles of Operation
Test Procedures
Testing for Spark
Testing Primary Input Voltage
Test Switch Box “Stop” Circuit
Testing Stator Output
Testing Stator Resistance
Testing Trigger Resistance
Testing Ignition Coils
Erratic/Misfire or No Fire Condition
Removing Flywheel
Installing Flywheel
Removing Stator
Installing Stator
Removing Trigger
Installing Trigger
Removing Switch Box
Installing Switch Box
Removing Coils
Installing Coils
Ignition Diagram

Battery, Charging and Starting System
Special Tools
Precautions
Recommended Battery
Operating Engine Without Battery
Electrolyte Level
Charging a Discharged Battery
Winter Storage of Batteries
Battery Charging System
Description
Battery Charging System Troubleshooting
Stator Ohms Test (Alternator Coils Only)
9 Ampere Stator
Alternator System Test
40/50 9 Ampere Stator Charging Diagram
Starting System
Starting System Components
Description
Troubleshooting the Starting Circuit
Starter Motor
Removal
Disassembly
As Needed
Testing Armature for Ground
Testing Brushes and Terminals
Reassembly
Installing Starter
Testing Starter Solenoid

Timing / Synchronizing / Adjusting
Timing/Synchronizing/Adjusting
Specifications
Special Tools
Checking for Top Dead Center (TDC)
Checking Timing (At Cranking Speed)
Adjusting Throttle Pickup
Check WOT Position with Engine Not Running
Adjusting Idle Mixture
Adjusting Idle Speed

Fuel System and Carburetion
Carburetor
Removing Carburetor
Disassembling Carburetor
Assembling Carburetor
Adjusting Throttle Pickup
Check WOT Throttle Position with Engine Not Running
Adjusting Idle Mixture
Adjusting Idle Speed
High Altitude Jetting
Exploded View – Carburetor – 40/50 HP

Fuel Pump
Fuel Pumps
General Information
Fuel Pump Description/Operation
Checking for Restricted Fuel Flow Caused by Anti-Siphon Valves
Testing
Troubleshooting Fuel Pump
Fuel Pump Components
Fuel Pump Reassembly
Check Valve Assembly
Fuel Pump Assembly
Fuel Recirculation System
System Description
Testing Fuel Recirculation System
Reed Valve Assembly
Removing and Disassembling Reed Valve Assembly
Inspecting and Replacing Reeds
Installing Reed Valve Assembly
Fuel Primer Circuit
Testing Fuel Primer Valve
Testing Fuel Primer Manual Operation

Powerhead
Powerhead Specifications
Finished Hone Bore Size
Special Tools
Piston Ring
Powerhead Removal
Separating Crankcase Halves
Removing Connecting Rod Caps
Disassembling Crankshaft
Disassembling Piston
Assembling Piston
Dissembling Cylinder Head
Inspecting and Repairing
Assembling Cylinder Head
Assembling Crankshaft
Assembling Crankcase
Completing Assembly/Installation
Test Run Procedure
Break-in Procedure

Midsection
Clamp Bracket Components
Swivel Bracket
Drive Shaft Housing
Drive Shaft Housing Disassembly/Reassembly

Power Trim
Power Trim General Information
Description
Trimming Characteristics
Trimming Outboard “Up” (“Out”)
Trimming Outboard “Down” (“In”)
Trailering Outboard
Tilting Outboard Up and Down Manually
Trim “In” Angle Adjustment
Power Trim Components
Hydraulic System Troubleshooting
Preliminary Checks
Hydraulic System Troubleshooting Flow Chart
Electrical System Troubleshooting
Commander 2000 Side Mount Remote Control (Power Trim/Tilt Electric Start with Warning Horn) Wiring Diagram
Power Trim System Wiring Diagram
Troubleshooting the “Down Circuit”
Troubleshooting the “Up” Circuit
Troubleshooting the “Down” and “Up” Circuits (All Circuits Inoperative)
Power Trim System Removal
Power Trim System Disassembly
Shock Rod Removal
Shock Rod Inspection
Trim “Motor” Removal
Oil Pump Removal
Tilt Relief Valve Removal
Suction Seat Removal
PO Check Assembly Removal
Cleaning and Inspection of Trim System Components
Motor Electrical Tests
Power Trim System Reassembly
Tilt Relief Valve Installation
Suction Seat Installation
Pilot Check Assembly Installation
Oil Pump Installation
Trim Pump Motor Installation
Shock Rod Installation
Manual Release Valve Installation
Bleeding Power Trim Unit
Power Trim Unit Installation

Lower Unit
Gear Housing Specifications
Special Tools
Forward/Reverse Gear Backlash and Pinion Depth
General Service Recommendations
Bearings
Seals
Gear Housing Components
Quicksilver Lubrication/Sealant Application Points
Draining and Inspecting Gear Lubricant
Propeller Removal
Gear Housing Removal
Water Pump Seals
Inspection
Upper Drive Shaft Bearing
Pinion Gear Bearing
Pinion Gear
Forward Gear
Shift Shaft
Propeller Shaft Disassembly
Propeller Shaft and Carrier Inspection
Clutch Dog
Cam Follower
Reverse Gear
Reverse Gear Bearing
Bearing Carrier
Needle Bearing
Gear Housing Reassembly
Shift Shaft Assembly
Pinion Bearing Race
Forward Gear
Pinion Gear/Drive Shaft Assembly
Propeller Shaft
Bearing Carrier
Water Pump
Gear Housing Pressure Test
Gear Housing Installation
Filling Gear Housing with Lubricant
Trim Tab Adjustment and Replacement
Propeller Installation

Engine Installation
Force 40/50 Installation Instructions
Selecting Steering Cables and Remote Control Cables
Installing Outboard on Transom
Determining Recommended Outboard Mounting Height
Locating Center-line of Boat Transom
Drilling Outboard Mounting Holes
Lifting Outboard
Securing Outboard to Boat Transom
Ride Guide Steering Cable/Attaching Kit Installation
Installing Ride Guide Cable
Installing Steering Link Rod
Lubrication
Remote Control Installation
Shift and Throttle Cable Installation and Adjustment to Outboard
Shift Cable Installation
Throttle Cable Installation
Required Side Mount Remote Control or Ignition Key Switch Assembly
Boats Equipped with Side Mount Remote Control
Boats Equipped with Panel or Console Mount Remote Control
Connecting Remote Control or Key Switch Wire Harness to Engine Wire Harness
Battery Connections
Fuel Connections
Portable Fuel Tank
Permanent Fuel Tank
Fuel Line
Propeller Selection
Propeller Installation
Power Trim System
Power Trim Operation
Trim “In” Angle Adjustment (Models With Power Trim)
Checking Power Trim Fluid Level
Trim Tab Adjustment
Models Without Power Trim
Models With Power Trim
Boat Performance
Test Instructions