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Atomic 4 Owners And Service Manual




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THE COMPLETE OWNERS SERVICE MANUAL FOR THE UNIVERSAL ATOMIC 4 GAS ENGINE
Photo Courtesy of Jayne Boat Works St Petersburg FL ATOMIC FOUR
OWNERS SERVICE AND REPAIR OPERATION TO INSURE PROPER OPERATION OF YOU ENGINE AT ALL TIMES IT IS WELL TO OBSERVE BASIC RULES THIS IS ESPECIALLY TRUE
DURING WINTER MONTHS WHEN THE BOAT IS EITHER IN STORAGE OR USED INFREQUENTLY SEE THE INSTRUCTION BOOK FOR PREPARING THE ENGINE FOR WINTER STORAGE IN
ADDITION TO FOGGING THE ENGINE WE ALSO SUGGEST THAT OIL BE PLACED IN EACH CYLINDER AND THE ENGINE TURNED OVER THREE 3 OR FOUR 4 TIMES TO INSURE ADDED
PROTECTION FOR THE VALVES DURING STORAGE DURING COLDER WEATHER WHEN BOATS ARE NOT USED REGULARLY THE ENGINES REQUIRE EXTRA CARE AND ATTENTION WHENEVER
THE ENGINE IS PLACED IN OPERATION IT SHOULD BE RUN UNTIL THE ENGINE IS THOROUGHLY WARMED UP TO NORMAL OPERATING TEMPERATURE AND THEN IT SHOULD BE
OPERATED AT THIS TEMPERATURE FOR 15 TO 30 MINUTES JUST STARTING AN ENGINE BRIEFLY CHANGES THE TEMPERATURE SLIGHTLY AND INDUCES CONDENSATION TO FORM
THIS CONDITION IS ONE OF THE MAIN CAUSES FOR STICKY VALVES IF THE BOAT WILL NOT BE USED FOR A MONTH OR SO IT IS WELL TO FOG THE ENGINE AND PLACE OIL
IN THE CYLINDERS IT IS NOT ALWAYS POSSIBLE TO CLOSE THE EXHAUST AND THE VALVE MECHANISM IS EXPOSED TO SALT AIR BACKING UP THE EXHAUST PIPE ALSO
CONDENSATION FORMS INTERNALLY DURING STORAGE DO NOT JUST START THE ENGINE EACH WEEK OR SO AND RUN IT FOR A FEW MINUTES SEE PRECEDING PARAGRAPH
REMEMBER YOUR BOAT IS IN THE WATER AND SUBJECT TO THE CORROSIVE ACTION OF SALT AIR AND WATER PROBLEMS THAT MIGHT DEVELOP DUE TO IMPROPER CARE OR
OPERATION IN THE FIELD CANNOT BE CONSIDERED AN ENGINE DEFECT AND ARE NOT COVERED BY THE NORMAL ENGINE WARRANTY IT IS IMPORTANT TO CHANGE OIL
FREQUENTLY AS RECOMMENDED IN THE OWNERS MANUAL CONTAMINATED OIL DOES NOT PROVIDE ADEQUATE LUBRICATION IMPORTANT NOTE AT ALL TIMES REGARDLESS OF
FREQUENCY OF OPERATION IT IS NOT GOOD PRACTICE TO RUN THE ENGINE FOR ONLY A SHORT PERIOD OF TIME IT SHOULD BE OPERATED 30 MINUTES AT A VERY MINIMUM TO
REACH NORMAL OPERATING ATOMIC FOUR
OWNERS SERVICE AND REPAIR MANUAL
IT IS ALSO GOOD PRACTICE TO OCCASIONALLY RUN THE ENGINE AT FULL LOAD FOR A PERIOD OF TIME A MINIMUM OF 5 MINUTES TO KEEP THE ENGINE CLEAN OF MOISTURE
AND CARBON ACCUMULATIONS FROM SHORT RUN PERIODS OR LONG IDLE PERIODS NEVER START THE MOTOR UNTIL THE MOTOR COMPARTMENT HAS BEEN VENTILATED BY EITHER
OPENING THE HATCH OR OPERATING THE BLOWER TO REMOVE ANY POSSIBLE FUEL FUMES MARINE ENGINE WARRANTY PRODUCT WARRANTY SELLER WARRANTS ALL PRODUCTS AND
PARTS OF ITS OWN MANUFACTURE AGAINST DEFECTS IN MATERIAL OR WORKMANSHIP FOR A PERIOD OF ONE 1 YEAR FROM DATE OF SHIPMENT WHEN GIVEN NORMAL AND PROPER
USAGE AS DETERMINED BY SELLER UPON EXAMINATION AND WHEN OWNED BY THE ORIGINAL PURCHASER COMPONENTS PURCHASED BY SELLER AS COMPLETE UNITS AND USED AS
AN INTEGRAL PART OF SELLERS EQUIPMENT WILL BE COVERED BY THE STANDARD WARRANTY OF THE MANUFACTURE THEREOF SELLER WILL REPAIR OR REPLACE FOB ORIGINAL
SHIPPING POINT BUT NOT INSTALL ANY PART OR PARTS OF ITS MANUFACTURE WHICH IN ITS JUDGMENT SHALL DISCLOSE DEFECTS IN EITHER MATERIAL OR WORKMANSHIP IF
REQUESTED BY SELLER PARTS FOR WHICH A WARRANTY CLAIM IS MADE ARE TO BE RETURNED PREPAID TO OUR FACTORY THIS WARRANTY BECOMES VOID IF ARTICLE CLAIMED
TO BE DEFECTIVE HAS BEEN REPAIRED OR ALTERED IN ANY WAY OR WHEN THE ARTICLE HAS BEEN SUBJECT TO MISUSE NEGLIGENCE OR ACCIDENT OR WHEN INSTRUCTIONS FOR
INSTALLING OR OPERATING HAS BEEN DISREGARDED WE MAKE NO OTHER WARRANTY EXPRESS OR IMPLIED AND MAKE NO WARRANTY OF OF OF FITNESS FOR ANY PARTICULAR
PURPOSE AND THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION OF THE FACE HEREOF NO EMPLOYEE OR IS AUTHORIZED TO CHANGE THIS WARRANTY IN
ANY WAY OR GRANT ANY OTHER WARRANTY THE REMEDIES HEREINABOVE AFFORDED TO THE PURCHASER ARE EXCLUSIVE OF ALL OTHER REMEDIES PROVIDED BY LAW SELLER
SHALL NOT BE LIABLE FOR INDIRECT OR CONSEQUENTIAL DAMAGES WHERE THE LOSS SUSTAINED IS OF A COMMERCIAL NATURE
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR IMPROVEMENTS THE MANUFACTURER RESERVES THE RIGHT TO MAKE PRODUCT IMPROVEMENTS AT ANY TIME WITHOUT TAKING OR OBLIGATION TO
MAKE SIMILAR CHANGES OR ADD SIMILAR IMPROVEMENTS ON ANY ENGINES DELIVERED PRIOR TO THOSE CHANGES WARRANTY REGISTRATION ENCLOSED WITH EACH ENGINE IS A
WARRANTY REGISTRATION CARD THIS CARD MUST CONTAIN THE OWNERS NAME ADDRESS SERIAL NUMBER OF THE ENGINE VDRIVE AND REVERSE GEARS AND RETURNED TO
MEDALIST BEFORE THE WARRANTY BECOMES EFFECTIVE THIS WARRANTY REGISTRATION MUST TAKE PLACE WITHIN 24 HOURS AFTER RECEIPT OF THE EXCLUSIONS THE
FOLLOWING SERVICES AND EQUIPMENTS WILL NOT BE REIMBURSED UNDER THE WARRANTY 1 REPAIRS DUE TO NEGLECT MISUSE IMPROPER APPLICATION ACCIDENT RACING AND
INSTALLATIONS THAT DO NOT MEET MINIMUM STANDARDS AS SET FORTH IN THE INSTRUCTION MANUAL TUNEUP OR ADJUSTMENT EXPENSES NEEDED FOR CLEANING OF FUEL
SYSTEM COMPONENTS DUE TO DAMAGE OR LOSS TO PERSONAL PROPERTY LOSS OF REVENUE TOWING CHARGES STORAGE FEES FUEL AND TELEPHONE CALLS DAMAGES OR LOSSES
RELATED TO HANDLING AND SHIPPING EXPENSES RELATED TO REPLACEMENT OF LUBRICANTS ANTIFREEZE OR SPECIAL ADDITIVES FAILURE DUE TO NOT FOLLOWING
RECOMMENDED MAINTENANCE SCHEDULES ALL CHARGES WILL BE THE OBLIGATION OF THE OWNER SUCH AS FREIGHT TRAVEL TIME AND ATOMIC FOUR
OWNERS SERVICE AND REPAIR ITEMS RETURNED TO THE FACTORY COLLECT WILL BE BILLED TO THE SHIPPER WARRANTY AUTHORIZATION IS REQUIRED FROM THE FACTORY
WHERE COMPLETE REPLACEMENT OR OVERHAULING OF THE FOLLOWING IS NECESSARY COMPLETE ENGINE ASSEMBLY CYLINDER HEADS OR ENGINE BLOCK MARINE REVERSE GEAR OR
ATOMIC FOUR
OWNERS SERVICE AND REPAIR Models UJ UJS UJR UJSR UJVD Type 4 cycle Lhead Number of Cylinders Bore and Stroke x 318 Total Piston Displacement in
cu Inches Spark Plug J8 14 mm Compression Ratio to 1 Engine Rotation viewed from flywheel end Reduction Gear Ratio to 1 VDrive Reduction Ratios
to 1 129 to 1 167 to 1 20 to 1 Fuel Gasoline 9294 octane Maximum Operating Angle 12 to 15 degrees maximum Length Overall in inches 351316 UJ 2634
UJR 311516 Height above crankshaft center line Maximum Width in Inches Offset Crank to Prop shaft Base Depth Below Center line in inches Exhaust
Flange National Pipe Thread Size Water Inlet National Pipe Thread Size Water Outlet National Pipe Thread Size Fuel Pump Connection NPT Fuel Line
Copper Tubing OD Weight of engine net pounds UJR 330 UJVD 335 Firing Order No 1 on Flywheel End Inlet Valve Opens degrees before TDC Inlet Valve
Closes degrees after LDC Exhaust Valve Opens degrees before LDC Exhaust Valve Closes degrees after TDC Dwell Angle to 34 degrees Brake Horsepower
RPM 600 UJSUJSR 4 UJUJRUJVD 5
1000 1500 2000 2500 3000 3500 71 11 15 18 73 119 162 20 25 30
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR Zenith 68 Series Reversing Gear Paragon Reduction Gear Electrical Equipment UJUJR 12 volt 35 amp alternator Piston
Skirt Clearance 0015 feeler to 5 lbs Pull Piston Ring Cap Clearance 007 to 015 Connecting Rod End Play 004 to 008 Crankshaft End Play Maintained
at front bearing only 002 to 003 Valve seat angle degrees Oil pump drive end play 001 to 003 Distributor point gap clearance 018 to 020 Magneto
Breaker 014 to 018 Spark Plug Gap Clearance Ignition Timing breaker points just starting to open Main Bearing Clearance on Crankshaft 001 to
0025 Piston Ring Side Clearance Compression Ring 0003 Compression Ring middle 00025 Oil Ring 00025 Piston Pin Clearance in Piston 00002 Connecting
Rod Clearance dia 00025 on Rod toward camshaft Valve Tappet Clearance Intake hot 0008 Valve Tappet Clearance Intake cold Valve Tappet Clearance
Exhaust hot Valve Tappet Clearance exhaust cold Valve Seat Width intake Valve Seat Width exhaust Valve Seat Angle degrees Valve Stem Clearance
Intake 00035 Valve Stem Clearance Exhaust 00035 Camshaft Gear Back Lash 0004 Idler Gear Back Lash 0004 Accessory Gear Back Lash 0004 Oil Pump
Gear Back Lash 0005 Camshaft Bearing Clearance 00025 Camshaft Bearing Journal 0005 0000
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR WRENCH TENSION Flywheel Stud Nuts ft lbs Cylinder Head Stud Nuts ft lbs Connecting Rod Bolt Nuts ft lbs Main Bearing
ft lbs Main Bearing rear ft lbs Manifold Studs ft lbs Spark Plugs ft lbs
Note to Atomic Stevedore Owners All instructions in this book apply equally to Atomic Four and Atomic Stevedore models Where there is a difference in
or adjustments it is so ATOMIC FOUR
OWNERS SERVICE AND REPAIR 1
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR 2
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR INSTRUCTIONS Give your engine every chance to perform properly If you become familiar with the operating requirements it
will give you long dependable service Check the alignment of the engine to the propeller shaft after the boat is first placed in the water If you are
in doubt how to proceed write the factory for special service bulletin Add the necessary lubricating oil to the engine The quantity is dependent upon
the angle of installation and whether your engine is a direct or reduction drive model Fill the oil base with 4 to 5 quarts of good grade SAE 30
detergent oil or until the dipstick shows full The dipstick is located just forward of the water pump on the reverse gear housing Check the oil level
after the engine has been operated for a short time Check choke control to make sure choke valve fully closes Then push choke back to normal position
and make sure choke butterfly in carburetor fully opens Check throttle control to make sure it provides for full movement of the throttle lever from
idling position to fully open position Reversing gear controls must allow the clutch to lock in forward position and also into reverse position
Restricted or partial engagement will cause undue wear Reversing gears and reduction gears are lubricated by the engine oiling system Fuel like must
be connected to fuel pump located just forward of reversing gear on carburetor side of the engine A hand primer is provided to fill the fuel bowl for
initial start Use 516 copper tubing for fuel line An unrestricted water supply must be provided Use a2 through hull fitting with scoop forward Locate
scoop where it will have a supply of water at all times regardless of running position or rough seas Water pump has 38 suction and manifold has 38
water outlet Use hose for suction side Exhaust pipe is 114 iron pipe size It should be installed without sharp bends and slop downward to its outlet
to discharge water The connection for discharge water should be at least 4 below the bottom of the manifold exhaust flange opening See Figure 1
Figure 1 Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR before starting your new engine CAUTION ENGINE IS SHIPPED LESS OIL FILL WITH SAE 30 CLASS A DETERGENT OIL BEFORE STARTING
Ventilate engine compartment by opening hatches and starting blower fans if you have them Check fuel supply and make sure fuel lines are tight Any
fuel seepage or leaks should be corrected before you attempt to start engine Check all electrical connections A wiring diagram for your particular
model is included in this book Ground is negative Ground terminal should be attached to engine block Do not allow flames or sparks near battery
openings Gases produced during normal charging are explosive Make sure water pump is lubricated with water pump grease Starting you new engine 1 2 3 4
5 6 7 8 9 Clutch lever should be in neutral position Fill fuel pump bowl using the hand primer on the fuel pump Place throttle lever at 14 open
position Pull out choke rod Turn on ignition and start engine As soon as engine starts gradually push in choke lever until choke valve is completely
open Run engine at idling speed of 600 to 1000 rpm Check oil pressure 45 to 55 pounds when engine is cold Check oil after about 10 minute of running
Add oil to bring level to full mark if needed Check cooling system and make sure water pump is operating by checking water out of exhaust pipe
Temperature indicated on gauge should gradually go up to 140160 degrees If oil pressure or water flow or operating temperature is not normal stop
engine at once and check installation to correct problem When shifting into forward or reverse position engine should be running at 6001000 rpm
10 11
After the breakin period a good cruising speed for sail boat installations is about 2000 RPM or about 80 of the maximum engine speed ATOMIC FOUR
OWNERS SERVICE AND REPAIR MARINE CARBURETORS 61 Series 1967 and before 1 Venturi 2 Main Jet 3 Main Dis Jet 4 Well Vent 5 Idling Jet 6 Idling Needle
Valve 7 Throttle Plate 8 Idle Discharge Plug 9 Throttle Shaft 10 Restriction Bushing 1111IA Pick up tube 12 Throttle stop screw Not Illustrated 13
Pickup Tube metering orifice 14 Main jet adjustment 15 Idle fuel channel 16 Idle air channel
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR MANUAL
If the adjustments have been altered start with a standard setting which is 1 Throttle stop screw 112 turns to right from fully closed position of
throttle plate 7 2 Idling needle valve 6 one turn open to left from seat The main jet adjustment 14 212 turns open to left from If the engine after
running suddenly ceases to perform properly look over the intake manifold and the carburetor flange gaskets throttle choke and fuel connections Make
sure that throttle and choke valves open and close correctly and that fuel enters the carburetor in a free and steady stream Do not change carburetor
adjustments until other causes of trouble have been investigated Changes in adjustment should be necessary only with change in fuel or climate Before
making any adjustments warm up the engine thoroughly so that the intake manifold feels warm to the hand IDLE AND LOW SPEED ADJUSTMENT Close the
throttle slowly until desired idling speed is reached Turn idling needle valve 6 gradually to right and left until the engine runs steady and as fast
as this throttle position will permit Turning the idling needle valve to right in makes the mixture richer to left out makes the mixture leaner If a
satisfactory adjustment cannot be obtained examine the idling jet 5 and the idle discharge plug 8 to make sure that dirt or water does not obstruct
the free flow of the moisture through these parts After completing the adjustments set throttle stop screw 12 for desired idling speed
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR AND HIGH SPEED ADJUSTMENT The mixture at intermediate and high speed is controlled by the main jet 2 and the wall vent 4
The main jet may be either of fixed size or adjustable Whether fixed or adjustable remove main jet 2 and blow out with compressed air or rinse in
clean gasoline to remove water or dirt which may obstruct the metering orifice If adjustable adjustment should be made as follows i Open throttle
about onethird ii loosen packing nut on main jet adjustment 14 iii turn main jet adjustment to right in until the engine speed is noticeably reduced
iv turn main jet adjustment slowly to left out until the engine runs smoothly and as fast as this throttle position will permit v hold needle valve in
position and tighten packing nut after completing the adjustment Compensation is controlled by the well vent 4 A richer mixture at high speeds is
obtained with a smaller well vent and a leaner mixture with a larger well vent If the mixture suddenly becomes too rich at high speeds examine the
well vent and make sure that it is not obstructed Inspect these jets for water and dirt STARTING Open the throttle about onequarter Pull the choke
control out all the way Step on the starter As soon as the engine starts push the choke control in about onethird of the way and as the engine warms
up continue to push it in gradually until the choke valve is wide open FUEL LEVEL Correct setting of the float which controls the fuel level is of
utmost importance The fuel level is set at the factory for regular motor gasoline and a pump pressure of 2lbsper square inch
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR 68 SERIES CARBURETOR OPERATION AND SERVICE The Zenith 68 series carburetors are of updraft single venturi design They are
made in 78 and I SAE barrel sizes with 78 and 1 SAE flange sizes They are made with selective fuel inlet and with or without a main jet adjustment
These carburetors are balanced and sealed and the fuel bowl allows operation to quite extreme angles without flooding or starving This design makes
them particularly adaptable to smaller form tractors and a great variety of agricultural machines and industrial units FUEL SUPPLY SYSTEM The fuel
supply system is made up of the threaded fuel inlet the fuel valve seat fuel valve need float and fuel boat as illustrated in Figure A
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR MANUAL
The fuel supply line is connected to the threaded inlet The fuel travels through the fuel valve seat and passes around the fuel valve and into the
fuel bowl The level of the fuel in the fuel chamber is regulated by the float through its control of the fuel valve The fuel valve does not open and
close alternately but assumes an opening regulated by the float sufficient to maintain a proper level in the fuel chamber equal to the demand of the
engine according to its speed and load The inside bowl vent as illustrated by the passage originating in the air intake and continuing through to the
fuel bowl is a method of venting the fuel bowl to maintain proper air fuel mixtures even though the air cleaner may become restricted This balancing
is frequently referred to as an inside bowl vent IDLE SYSTEM The idle system as shown in Figure B consists of two idle discharge holes idle air
passage idle adjusting needle idle jet and fuel pickup ATOMIC FOUR
OWNERS SERVICE AND REPAIR MANUAL
The fuel for idle is supplied through the main jet to a well directly below the main discharge jet The pickup passage is connected to this well by a
restricted drilling at the bottom of this passage The fuel travels through this channel to the idle jet calibration The air for the idle mixture
originates back of or from behind the main venturi The position of the idle adjusting needle in this passage controls the suction on the idle jet and
thereby the idle mixture Turning the needle in closer to its seat results in a greater suction with a smaller amount of air and therefore a richer
mixture Turning the needle out away from its seat increases the amount of air and reduces the suction and a leaner mixture is delivered The fuel is
atomized and mixed with the air in the passage leading to the discharge holes and enters the air stream at this point HIGH SPEED SYSTEM The high speed
system Figure C controls the fuel mixture at part throttle speeds and at wide open throttle This system consists of a venturi controlling the maximum
volume of air admitted into the engine the main jet which regulates the flow of fuel from the float chamber to the main discharge jet the well vent
which maintains uniform mixture ratio under changing suction and engine speeds and a main discharge jet which delivers the fuel into the air stream
The main jet controls the fuel delivery during the part throttle range from onequarter to full throttle opening To maintain a proper mixture ration a
small amount of air is admitted through the well vent into the discharge jet through the air bleed holes in the discharge jet at a point below the
level in the metering well
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR MANUAL
At high speeds the fuel flows from the fuel chamber through the main jet and into the main discharge jet where it is mixed with air admitted by the
well vent and the airfuel mixture is then discharged into the air stream of the carburetor CHOKE SYSTEM The choke system consists of a valve mounted
on a shaft located in the air entrance and operated externally by a lever mounted on the shaft The choke valve is used to restrict the air entering
the carburetor This increases the suction on the jets when starting the engine The choke valve is of a type having a poppet valve incorporated in its
design which is controlled by a spring The poppet valve opens automatically when the engine starts and admits air to avoid overchoking or flooding of
the engine The mixture required for starting is considerably richer than that needed to develop power at normal temperatures As the engine fires and
speed and suction are increased the mixture ratio must be rapidly reduced This change is accomplished through adjustment of the choke valve and the
automatic opening of the poppet valve to admit more air when the engine fires
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR MANUAL
FLOAT SYSTEM The A dimension should be 1532 plus or minus 364 Float Level Check position or float assembly for correct measurement to obtain proper
float level using depth gauge NOTE Do not bend twist or apply pressure on the float bodies With bowl cover assembly in an inverted position viewed
from free end of float the float bodies must be centered and at right angles to the machined surface The float setting is measured from the machine
surface no gasket of cover to top side of flat bodies at highest point Bending Float Lever To increase or decrease distance between float body and
machined surface use long nosed pliers and bend lever close to float body NOTE Replace with new float if position is off more than 116
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR Diagram Motorola Alternator 12Volt 35 Ampere Solid State Regulator NOTES Lead 1 is customer installed Use min of 1 heavy
duty battery cable This wire must be grounded back to engine Lead 2 is customer installed Use min of 1 heavy duty battery cable Lead 3 is customer
installed Use min of 8 wire Do not install this wire if a panel mounted Ammeter is used Alternator regulator starting motor are ground to engine at
factory Alternator field is internally connected under ATOMIC FOUR
OWNERS SERVICE AND REPAIR MANUAL
Back side of 3 unit panel NOTES Leads 1 are customer installed Use 8 GA wire for circuits under 15 ft 6 GA wire for circuits from 15 to 25 ft Leads 2
are customer installed Use 16 GA wire for circuits under 15 ft 14 GA wire for circuits from 15 to 15 ft When nonmetallic flexible oil tube is used
ground instrument panel directly to engine
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR MANUAL
5 Unit Mechanical Instrument Panel Wiring Diagram NOTES Leads 1 are customer installed use 8 GA wire for circuits under 15 ft 6 GA wire for circuits
from 15 to 25 ft Leads 2 are customer installed Use 16 GA wire for circuits under 15 ft 14 wire for circuits from 15 to 25 ft Lead 3 is customer
installed Use 16 GA wire connect leads from panel lights to this wire When nonmetallic flexible oil tube and heat indicator tube are used ground
instrument panel directly to engine
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR MANUAL
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR MANUAL
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR MANUAL
WATER COOLING SYSTEMS The two drain plugs and a pipe cap removed at the factory are in a small bag attached to the carburetor lever Replace one plug
in the bottom of water purr and one in the rear of the manifold near the exhaust flange Replace the pipe cap on the drain nipple out of the cylinder
block water jacket located immediately alongside the ATOMIC FOUR
OWNERS SERVICE AND REPAIR MANUAL
WATER TEMPERATURE An automatic bypass temperature control is standard equipment on the engine This temperature control valve is required to maintain
proper engine operating temperatures If an engine is operated too cold condensation may form in the valve chamber causing sticky valves and other
ATOMIC FOUR
OWNERS SERVICE AND REPAIR MANUAL
OIL CIRCULATING DIAGRAM The lubricating system on the ATOMIC FOUR Model is full pressure to all camshaft bearings all main bearings all connecting rod
bearings and also to the reverse gear Fill the base with from four to five quarts of good grade SAE 30 oil or until the oil level gauge shows full as
directed on the name plate mounted on top at the reverse gear housing The reduction gear model will take slightly more It is not necessary to oil the
reversing gear or the reduction gear separately as both are oiled by pressure from the main oiling system through a drilled hole in the end of the
crankshaft and the tailshaft The oil is carried in the base and a gear driven gear type oil pump which is submerged in the oil in the base circulates
the oil through the motor under pressure The oil pressure regulator screw is located on the carburetor side of the motor under the fuel pump If it is
necessary to adjust the oil pressure turning the adjusting screw to the right or in will increase the pressure turning the screw to the left or out
will decrease the pressure The oil pressure gauge connection is also on the carburetor side and is located on the crankcase immediately behind the
flywheel housing The oil pressure regulator screw is adjusted at the factory so that the gauge will show about 45 to 55 pounds cold for normal engine
speeds but may go as low as 10 pounds at idling speed when hot and should not require adjusting CAUTION We recommend that you change the oil after
every forty or fifty hours of service The oil should be drained while the motor is warm as cold oil will not drain readily The hand sump pump is
provided for the easy removal of old oil The bayonet gauge indicates the proper oil level Check oil level daily to maintain proper level
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR MANUAL
VALVE CLEARANCE When the motor is worm set the exhaust valves far O10 clearance and the intake valves for 008 clearance VALVE TIMING Timing gears are
marked for proper valve timing IGNITION TIMING The points in the distributor should break when the piston its at top load center If it is necessary to
retime turn the engine until compression stroke on No 1 cylinder is reached Then make starting Crank pin in crankshaft line up vertically with raised
timing mark on the flywheel housing Loosen tire clamp screw on the distributor arm directly beneath the distributor base Set the rotor on line with
the No 1 spark plug and turn distributor base until the points just begin to open After the distributor hose has been turned so the points lust begin
to open and the rotor is in line with No 1 Spark plug wire tighten the clamp screw on the arm Take the boat out for a trial run end after bringing
engine to normal operating temperature and the boat running at top speed loosen the distributor clamp bolt and carefully advance the ignition timing
by slowly rotating the distributor body until the RPM begins to fall off Then rotate the distributor body in the opposite direction to obtain the
greatest number of RPMs without rough running of the engine The timing is now set properly in the advanced position The spark automatically adjusts as
the engine speed changes VENTILATION VENTILATION OF THE MOTOR COMPARTMENT IS VERY IMPORTANT Inlet and exhaust tunnels of adequate size must tie
provided to permit complete air circulation It is recommended practice to ventilate the engine compartment each time before the engine is started SAFE
PRECAUTIONS Keep the motor and especially the motor comportment clean and free from oily waste or cloths Likewise keep gasoline and oil out of the
bilge This may be prevented by periodically inspecting the carburetor gasoline line and connections for leaks
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR MANUAL
Be very careful not to spill gasoline when filling your supply tank as it may drain into places where it is trot easily detected In case your boat
accidentally receives an unusually hard jolt from a collision with a dock or some other object be sure to carefully inspect the gasoline supply tank
and all gasoline lines for leaks NEVERS START THE MOTOR UNTILT1L THE MOTOR COMPARTMENT HAS BEEN VENTILATED BY EITHER OPENING THE HATCH OR OPERATING
THE BLOWER TO REMOVE FUEL FUMES Have all wiring properly insulated to prevent short circuiting and CHECK ALL WIRE TERMINALS PERIODICALLY TO BE SURE
THERE ARE NO LOOSE CONNECTIONS TO CAUSE ELECTRIC SPARKS RACING THE MOTOR Do not race the motor when not under load This practice is harmful to the
motor and unnecessary Driving the boat at high speed before the motor is warmed up may result in scored pistons and cylinder walls
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR The reverse gear on the ATOMIC FOUR is lubricated by pressure lubrication through a drilled hole in the crankshaft and it
also runs in a bath of oil OPERATION When the reverse gear lever is pushed forward into the Go Ahead position it pushes the friction cone backward
thereby spreading the fingers and causing the back of the fingers to engage the friction plungers which in turn press the discs together This in turn
acts as a solid connection between the motor and the propeller shaft To reverse the boat pull the reverse gear lever backward When the lever is pulled
backward the action clamps the broke bond to the reverse gear drum and power is then transmitted through the internal gears in the reverse direction
thus reversing the propeller rotation ADJUSTMENT FOR THE FORWARD DRIVE If the gear slips in the forward drive back out the lockscrew No 74 until the
end of it is clear just of the notch in the adjusting collar No 28 now turn collar to the right until the lockscrew No 76 is in line with one of the
notches in the adjusting collar No 28 Then tighten up the lockscrew No 76 and be sure that the end of screw enters the notch in the adjusting collar
No 28 Repeat this procedure until the reverse gear holds on the forward drive An adjustment of one or two notches is usually ATOMIC FOUR
OWNERS SERVICE AND REPAIR MANUAL
FOR THE REVERSE DRIVE Pull the lever into the reverse position Then tighten up the adjusting bolt No 330 until the brake band clamps or grips the gear
drum No 1 and holds it from revolving It is well to screw up this adjusting bolt No 330 a little tighter than is necessary This will compensate for
any wear on the brake bond The lock wire holds the adjusting bolt nut and keeps it from loosening FIRST Make sure that the shifting control actually
engages and disengages the forward and reverse action of the clutch and reverse gear Unless these contacts are properly executed avoidable wear will
result involving annoyance and expense SECOND Throw tie remote control shifting lever into forward position as far as it will go Then disconnect the
short reverse gear lever and see if it can be shifted further forward If this can be done the connection should be changed so as to permit the remote
control shifting lever to throw tire gear shift lever as fear forward as ATOMIC FOUR
OWNERS SERVICE AND REPAIR ENGINE FOR SPRING SERVICE Preparation of the engine should include all these items of overhaul necessary to permit
satisfactory operation of the engine Many engines properly serviced in the spring will give a full season of carefree pleasure The amount of effort to
be expended will be determined somewhat by the storage of layup procedure of the previous fall Refer to preparations for starting the engine for the
first time 1 2 3 4 5 6 7 8 9 10 Tighten all nuts and bolts to proper torque Replace all drain plugs and caps Manifold Replace drain plug Check
manifold bolts for tightness since some gaskets shrink more than others Water Pump Close drain cock and replace drain plug Lubricate pump by grease
cups Replace packing if required DO NOT OPERATE PUMP WITHOUT WATER Lubrication System Remove all oil from oil pan and reverse gear housing Refill
with quantity specified in Lubrication Group Cylinders Remove spark plugs Pour one or two ounces of oil in cylinders to lubricate walls rings etc
turn engine over without spark plugs in place Valves and tappets Check and lubricate if required Remove seal over breather tube end Distributor
Clean and lubricate as required Remove any moisture seals Clean and set distributor points Spark plugs clean spark plugs and reset gap to 035 Replace
burned or broken plugs Ignition wires Replace damaged or brittle ignition wires High tension electrical leakage prevents good operation of engine
Starting Motor See that the starter pinion is clean and lubricated with light oil Remove any moisture seals Lubricate bearings Clean commutator and
brushes with sandpaper Do not use emery cloth Alternator Does not require any special care or lubrication Battery Reinstall fully charged batter
Clean the cable terminals and fasten securely to clean battery terminals Coat terminals with vaseline or grease to reduce corrosion and then attach
battery cables Fuel system See that fuel system is clean and free from scale sludge or obstructions Drain out any water that has accumulated in tanks
or fuel lines Check over for loose connections tightening any found Remove cover from carburetor air intake Oil carburetor choke and throttle
carburetor air intake Oil carburetor choke and throttle shafts Check for easy operation Clean flame arrestor Exhaust system remove moisture seal Turn
engine over by hand with the spark plugs out to see that all bearings are free With boat in water check freedom of propeller shaft in bearings and
alignment of propeller shaft with engine Tighten stuffing box just enough to stop leakage along shaft Excessive tightening will cause power loss and
burned stuffing material Clean motor thoroughly and repaint
11 12
14 15 16 17 18
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR ENGINES FOR WINTER STORAGE Neglect in preparing an engine for winter storage may lead to annoying or costly damage which
will not be seen until the engine is prepared for use the following spring The engine should be carefully covered to give complete protection from
rain and snow Drain completely to avoid damage from freezing 1 Fog the engine Run the engine at about 800 RPM and using about 4 ounces of oil slowly
pour it into the carburetor to coat the combustion chamber and cylinder walls Stall the engine by pouring the last two ounces in rapidly Also add
about two tablespoons of oil in each cylinder through spark plug hole Lubrication system The oil pan and lubrication system should be drained of old
or contaminated oil so that any moisture or acid present in the oil will not cause corrosion damage during winter Two or three quarts of new clean oil
should be pumped through the system by turning the motor by hand or electric starter This should distribute a film of clean oil to act as a rust
preventive Regular rust preventive oils can be obtained Cylinder blocks A pipe cap is found on the distributor side of the engine Remove and leave
off Manifold A pipe plug will be found in the right side and to the rear end of the exhaust manifold Remove and leave out Water Pump Pumps are
particularly susceptible to damage from freezing because of the restricted space and clearances The pump should be carefully drained by loosening the
cover The pump should be dry during the winter Electrical system Remove the battery and store it at the boat yard or at your local battery dealer
Loosen the distributor cap for ventilation and protect all other electrical parts for moisture Fuel System All gasoline should be drained from
carburetor fuel pump feed lines filters and tanks This is to prevent development of sludge or gum in the system The carburetor air intake should be
covered by waterproof paper or cloth and sealed to prevent entrance of moisture into engine by way of the intake valves that are open Exhaust system
Exhaust pipes should be drained free of water Allow the exhaust pipes to dry out Seal exhaust pipe end to prevent entrance of moisture into the engine
through exhaust valves that are open Rust prevention exposed metal parts liable to rust should be coated with grease or rust preventive 4 ATOMIC
FOUR
OWNERS SERVICE AND REPAIR MANUAL
WHAT TO DO WHEN YOUR MOTOR DOES NOT OPERATE PROPERLY The following suggestions will be of assistance in locating and remedying motor troubles They are
also mentioned to assist the operator in making emergency repairs However when serious trouble occurs a competent service man should be called The
operation of a motor depends primarily on three factors an unfailing fuel supply uninterrupted ignition and good compression Failure of either the
first two will prevent starting or cause loss of power It may also cause difficult starting or sudden stopping If a motor which has previously been
operating refuses to start or stops with but slight warning and without the noise of a breaking part it is reasonable to assume that either the fuel
supply has been cut off or the ignition has failed The first step should therefore be to determine which of the two systems is at fault FIRST SECOND
See that there is gasoline in the tank Use regular gasoline It is possible to have plenty of fuel and still be unable to fill the carburetor This may
be caused by too small a vent hole in the gasoline tank cap The gasoline pipe may be air bound Test the carburetor by uncoupling the pipe at the
carburetor connection If the fuel does not flow freely the fuel line may be plugged Blow or run a wire through the pipe to clean it The strainer in
the fuel pump or in the carburetor may also be plugged Flooding a carburetor by overusing the choke may cause the moisture to become too rich In this
instance remove the spark plugs and turn the engine over several revolutions Look for water in the fuel If water is found clean the fuel tank fuel
pump fuel line and carburetor Check for an air leak in the intake manifold This can be easily tested by squirting oil around the intake the fuel
system is OK check as follows for ignition troubles FIRST SECOND Be sure the ignition switch is turned to the ON position Look for a fouled or broken
spark plug
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR for weak spark If a bright spark jumps across the gap between the two points of the plug when the engine is turned over the
ignition system is undoubtedly in working order This may be verified by making the same test with each wire The gap between the spark plug points
should be approximately 035 or the thickness of a thin dime Check for a broken electrical circuit The cause may be due to a ground Poor installation
will cause a ground Be sure all electrical wires are clean and well insulated Poor contact at distributor breaker Distributor may be out of time
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR SHOOTING A gasoline engine depends upon three main factors for proper operation an unfailing fuel supply uninterrupted
ignition and good compression When any one of these are not present or present only engine failure will result The following trouble shooting
information is designed to help the operator locate and overcome some of the most probable causes of engine failure or improper operation Probable
Causes are listed in the most likely order of occurrence Only one correction should be attempted at a time and that possibility eliminated before
going on to the next TROUBLE SHOOTING PROCEDURES TROUBLE Starter will not crank engine PROBABLE CAUSE Discharged Battery Corroded battery terminals
Loose connection in starting circuit Defective starting switch Starter motor brushed dirty Jammed Bendix gear Defective Starter Motor Starter motor
turns but does not crank engine Partially discharged battery Defective wiring or wiring of too low capacity Broken Bendix Drive Empty fuel tank
Flooded Engine Water in fuel system CORRECTION Charge or replace battery Clean Terminals Check and tighten all connections Replace switch Clean or
replace brushes Loosen starter motor to free gear Replace Motor Charge or replace battery Check wiring for worn acid spots Remove starter motor and
repair drive Fill tank with proper fuel Remove spark plugs and crank engine several times Replace plugs If water is found clean tank fuel lines and
carburetor Refill with proper fuel Check valve linkage and choke rod or cable for proper operation Adjust will not or sticking choke valve
Improperly adjusted ATOMIC FOUR
OWNERS SERVICE AND REPAIR fuel lines or defective fuel fuel line at carburetor If fuel does not flow freely when engine is cranked clean fuel line
and sediment bowl If fuel still does not flow freely after cleaning repair or replace pump Check for leak by squirting oil around intake connections
If leak is found tighten manifold and if necessary replace gaskets Check all plugs for proper seating gasket and tightness Replace all damaged plugs
and gaskets Check for broken or weak valve springs warped stems carbon and gum deposits and insufficient tappet clearance Check for leaks around
gasket when engine is cranked If a leak is found replace gasket Replace broken and worn rings Check cylinders for out of roundand taper Check for
clogged water lines and Restricted inlets and outlets Check for broken or stuck thermostat Look for worn or damaged water pump or water pump drive
Replace thermostat Turn on switch or replace Remove plugs and inspect for cracked porcelain dirty points or improper gap
Engine will not start Poor compression and other causes
Air leak around intake Spark seating cylinder head Gasket Worn or broken piston engine water circulation temperature Broken or stuck thermostat
too low Engine will not start Ignition switch offor Ignition System defective Fouled or broken spark plugs
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR set worn or pitted distributor points Defective ignition coil
No Oil of RPM Boat or associated center wire from distributor cap and hold within 38 of motor block Crank engine Clean sharp spark should jump
between wire and block when points open Clean and adjust points If spark is week or yellow after adjustment at points replace condenser If spark still
is weak or not present replace ignition coil Wet cracked or broken distributor Wipe inside surfaces of distributor Dry with clean cloth Inspect for
cracked or broken parts Replace parts where necessary Improperly set worn or pitted Remove spark plug wire and hold magneto breaker points within 38
of engine block Clean Magneto models only sharp spark should jump between wire and block when engine is cranked If spark is weak or not present clean
and adjust breaker points Improperly set worn or pitted Remove spark plug wire and hold timer points Defective coil or within 38of engine block A
clean compression and defective sharp spark should jump between condenser wire and block when engine is cranked Clean and set timer points If spark
still is not present when engine is cranked replace coil Improper timing Adjust timing Defective gauge or tube Replace gauge or tube No oil in engine
Refill with proper grade oil Dirt in pressure relief valve Clean valve Defective oil pump leak in oilCheck oil pump and oil pump drive Lines or broken
oil pump oil for worn or broken connections Lines or oil pump drive Damaged propeller Repair propeller Bent rudder Repair Misalignment Realign engine
to shaft Too tight stuffing box packing Adjust gland Dirty boat bottom Clean bottom
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR or preignition Loose foundation or foundation bolts Propeller shaft out of line or bent Propeller bent or pitch out of true
Defective spark plugs
See correction under misfiring and timing Engine carbons Engine overheating BackFiring Insufficient fuel reaching engine due to dirty lines strainer
or blacked fuel tank vent Water in fuel Poorly adjusted distributor Too light body oil Oil leak in pressure line Weak or broken pressure relief valve
spring Worn oil pump Worn or loose bearings Too heavy body oil Stuck pressure relief valve Dirt or obstruction in lines
Check all spark plugs for broken porcelain burned electrodes or electrodes out of adjustment Replace all defective plugs or clean and reset See
instructions for retiming Remove cylinder head and clean out carbon See correction under Engine Temp portion of this table See correction under Engine
will not startportion of this table
Low Oil Pressure
See correction under Engine will not start portion of this table Replace with proper weight oil Inspect all oil lines Tighten all connections Replace
spring Replace pump Replace bearings Drain oil and replace with oil of proper weight Clean or replace valve Drain and clean oil system Check for bent
or flattened oil lines and replace where necessary Drain and refill with proper weight oil Drain and refill If trouble persists check for cracked
block defective head gasket and cracked head Replace filer if one is mounted on engine
Oil Pressure too high
Sludge in oil changes Water in oil
Dirty oil filter
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR MANUAL
A FINAL WORD Universals interest in both customer and product continues long after the engine is installed Within the limits of our the companys
service department is ready to serve your maintenance and repair needs quickly In addition all Universal factory personnel will promptly answer
inquiries regarding maintenance installation or special adaptions If you will use judgment and care in operating your Universal engine use sufficient
quantities of the recommended lubricants stay on the alert for the first signs of trouble and contact Universal whenever you need aid the life and
usefulness of your Universal power package will be greatly ATOMIC FOUR
OWNERS SERVICE AND REPAIR AND REPAIR MANUAL FOR
ATOMIC 4 MARINE ENGINE
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR INFORMATION INTRODUCTION This manual provides service information and repair procedures for your Atomic 4 marine engine How
well your engine will continue to deliver the performance originally built into it depends on the service and care it receives The information
provided is adequate for performing all maintenance required and carrying out repairs to the level of a minor overhaul Detailed disassembly repair and
assembly procedures are provided in stepbystep format Where repair is impractical for the amateur mechanic this is indicated A dealer or other repair
shop should carry out complex repairs For boat owners who are installing an Atomic 4 engine to replace an existing engine of another make this manual
provides information on major installation such as engine dimensions exhaust systems and ORGANIZATION The manual is divided into nine sections
GENERAL INFORMATION provides general a description of the engine and components safety preparation of new engines engine breakin and operation
significant engine changes engine serial number locations and sparerepair parts sources MAINTENANCE AND LUBRICATION details the procedures to keep
your engine at peak operating efficiency and procedures for spring commissioning and winter layup ELECTRICAL SYSTEM gives information on the operation
maintenance and repair or the electrical system components and wire sizes for auxiliary equipment FUEL SYSTEM deals with the fuel supply system
including electrical and mechanical hid pumps COOLING SYSTEM provides data on the operation and maintenance of the cooling system ENGINE contains
information necessary to carry out a minor overhaul and replace the main engine components such as piston rings valves and bearings TRANSMISSION AND
REDUCTION GEAR DRIVES gives information on adjustment and maintenance of these components SUPPLEMENTARY INFORMATION provides information for
diagnosing engine trouble exhaust systems engine alignment propeller selection shaft stuffing box refueling recommended spare parts and tools Page
ATOMIC FOUR
OWNERS SERVICE AND REPAIR lists all engine dimensions wear limits torque values and adjustments WARNINGS CAUTIONS AND NOTES are used throughout to
emphasize important instructions These inserts generally precede the applicable text or instruction and do not contain procedural steps Warnings
cautions and notes are used to highlight information as An operating procedure practice etc which if not correctly followed could result in personal
injury CAUTION An operating procedure practice etc which if not strictly observed could result in damage to components NOTE An operating procedure or
condition which is essential to OF ENGINE The Atomic4 is an in4ine four cylinder fourcycle engine of conventional design and robust construction
These engines have side valves mounted in replaceable guides Valves operate off a geardriven camshaft by solid lifters tappets The cylinder block is
cast iron with cast cylinder walls for maximum strength The cylinders have a full length waterjacket to minimize hot spots The cast walls permit more
uniform heat absorption and dissipation which allows equal expansion and contraction sufficient for heavyduty operation and less frequent overhauls A
castiron manifold contains the air intake and exhaust passages Pistons are aluminum alloys with two compression rings and one oil control ring above
the piston pin The forged alloy crankshaft runs in two large diameter aluminumtin bearings The engine is pressure lubricated by a geartype oil pump
driven directly off the crankshaft An oil pressure adjustment is provided in the cylinder block
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR MANUAL
The fuel system includes an electric fuel pump mechanical fuel pump on engines before serial No 202987 delivering fuel to an updraft carburetor with
a manual choke A removable flame arrester is fitted at the carburetor throat The water pump is driven off the accessory drive and circulates cooling
water through the engine and exhaust system A special threespring thermostat located in the cylinder head controls engine operating temperature while
permitting a constant supply of water to the exhaust system The electrical system is an 12volt system Main components are an alternator with
solidstate regulator starter distributor and ignition coil All engines are equipped with transmissions providing forward as well as reverse drive
Three finaldrive arrangements are available directdrive 21 reduction drive or Vdrive with reduction Engines are on a dynamometer under load
conditions After testing each engine is fogged and drained of oil and water prior to ATOMIC FOUR
OWNERS SERVICE AND REPAIR Operation of power driven vessels requires attention to safety procedures and potentially dangerous conditions Some of the
major conditions that operators should be aware of are listed below Fumes and Vapours Gasoline vapours are heavier than air and can collect in the
bilge therefore the vessel should be closed up when refueling to prevent vapours from entering the cabin Also the condition of the fuel system should
be checked as often as possible to detect any gasoline leakage which must be corrected before the engine is started An approved bilge blower should
be installed and operated before attempting to start the engine Do not operate the engine with the removed from the carburetor intake Open Flames
During periods of charging leadacid batteries give off hydrogen gas which combines with air to form a potentially explosive atmosphere Open flames or
sparks should be kept away from batteries at all times Exhaust System Leaks One of the main products of combustion from gasoline engines is carbon
monoxide a colourless odourless gas which is harmful if inhaled Care should be taken to ensure that the engine exhaust system is gastight to prevent
the buildup of carbon monoxide gas in the cabin Passengers should not be permitted to sleep below when the engine is operating Cleanliness The engine
and engine compartment should be kept clean and free from oil or oilsaturated rags When carrying out routine maintenance and inspection check for
leaks and correct them immediately Dispose of dirty cloths after use Moving Parts In some instances it may be necessary to carry out some maintenance
or repair operation while the engine is running Take special care to avoid the exterior rotating elements such as the alternator drivebelt and pulleys
and shaft ATOMIC FOUR
OWNERS SERVICE AND REPAIR Shocks Electrical shocks can occur from the charging or ignition systems if electrical components are shorted out when the
engine is operating Be careful not to ground the positive terminal of the battery PREPARATIONS FOR STARTING ENGINE See Fig 1 and 2 All engines are
factory tested for at least three hours prior to delivery After testing engines are drained of water and oil and fogged with a oil Before starting
new engines the following should be done Lubricating Oil Add 3 to 5 quarts of SAE3O or 10W30 detergent oil depending on the engine model arid angle of
installation of the boat units and transmissions are supplied with oil from the engine supply For engines equipped with Vdrive units special oil must
be added ATOMIC FOUR
OWNERS SERVICE AND REPAIR 1
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR 2
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR Drain Plugs Check that all drain plugs are installed two on the engine block and one each on the manifold and water pump
Cooling Water Supply A continuous water supply s required for engine and exhaust system cooling A seacock should be installed at the throughhull water
fitting The water pump suction and discharge connections are 38 inch diameter as is the water discharge connection at the rear of the manifold Water
pump suction hose should be suitable for full vacuum service ie CAUTION Do not run the engine without a water supply or the water pump impeller will
be permanently damaged Make sure that the seacock is open and the water pump shaft is lubricated see Figure 3
Figure 3 Choke and Throttle Linkage Remove the flame arrester and check that the choke butterfly valve in the carburetor throat fully opens and closes
when the choke control is operated see Figure 4 Replace the flame arrester before attempting to start the engine Operate the throttle control to make
sure that there is free movement from idle to full throttle ATOMIC FOUR
OWNERS SERVICE AND REPAIR 4 ADJUSTING CHOKE BUTTERFLY VALVE STARTING ENGINE Before attempting to start your engine the following preliminary checks
should be carried out 1 Ventilate the engine compartment by turning on blower fan and opening hatches Run the blower fan for at least five minutes 2
Open fuel shutoff valve Check fuel system for leaks 3 Turn on battery isolator switch 4 Open seacock to provide cooling water to water pump 5 Check
oil level in engine and Vdrive unit oil level should be between marks on dipsticks 6 Lubricate water pump seats by turning grease cup cover in 34 turn
7 Pull out choke control 8 Set throttle at 14 open position 9 If equipped with exhaust shutoff valve open valve CAUTION Do not operate the starter for
more than 152O seconds cooling water enters lifttype mufflers during cranking and may back up into the engine when cranking is stopped if muffler
overfills 10 11 12 13 Turn on ignition switch and start engine When engine starts slowly push choke control all the way in Adjust throttle for idling
speed of 6001000 rpm fast idle Check oilpressure gauge reading oil pressure should be 3545 psi for cold engine
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR MANUAL
14 15 16
Check for discharge of cooling water at exhaust fitting temperature gauge reading should gradually rise to 140160 degrees F Allow engine to run for
ten minutes if gauge readings are satisfactory Stop engine and check oil level Add oil if required to bring level within marks on dipsticks Do not
overfill as this can cause oil RUNNINGIN PERIOD For new engines some care should be taken for the first 10 hours of operation in order to properly
break in components such as bearings piston rings and valves Operate your engine at approximately 1500 rpm of normal cruising speed to ensure proper
running in of the engine Do not allow the engine to idle for extended lengths of time during the breakin period After this initial 10hour operating
period change the engine oil refer to Chapter 2 Maintenance A suitable cruising speed for most installations is about 2000 rpm 80 of maximum engine
speed obtainable ENGINE OPERATION 1 2 3 When shifting into forward or reverse engine speed should be 6001000 rpm fast idle Do not open the battery
circuit or change batteries when the engine is running as this can cause alternator or regulator damage Periodically check engine gauges for proper
readings Readings should be within the following ranges engine cold engine warm 3545 psi 1025 psi at idle 2535 psi at 2400 rpm 140160 degrees F 0 50
amps
Oil temperature Ammeter
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR ENGINE The manufacturer incorporates design improvements periodically to reflect the best current practices for marine
engines Some modifications are minor while others have been major Listed below are the significant changes made to date Up to Serial No79475 all
parts Dole thermostat on manifold Prestolite ignition Serial No79476 through No170508 new style engine not interchange able with above Holley
thermostat in head Delco Remy ignition Zenith Series 61 carburetor Serial No170509 and later Motorola alternator Zenith Series 68 carburetor
Serial No171514 and later valve chamber oil line deleted Serial No174340 and later Oberdorfer water pump inter changeable Serial No174802 and later
new style valves Serial No176500 and later revised valve guide tolerances 3150 3145 Serial No192787 and later new style flywheel and cover Serial
No202987 electric fuel pump and low oil pressure switch ENGINE SERIAL NUMBER LOCATIONS An engine plate is located on the flywheel cover or on the
manifold In addition the engine number is cast into the engine block on the right side below the carburetor and on the transmission housing SPARE AND
REPAIR PARTS When ordering parts from your dealer always order by engine model and serial number since changes are made to engines from time to time
If possible compare new parts to old before purchasing them If they are not identical have the dealer explain the difference A special onboard spare
parts kit is available The kit contains parts required for emergency needs such as contact points spark plugs water pump impeller and alternator drive
belt You can obtain the onboard spare parts kit from your Atomic4 dealer Dealers are located throughout Canada and the United States They have an
ample inventory of parts and can provide prompt expert service for the maintenance and repair of your engine
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR Engine type Bore Stroke Displacement Compression Ratio Brake Horsepower Engine Rotation Final Drive Inline 4cylinder Lhead
2562 inches 3125 inches 645 cubic inches 631 303500 rpm viewed from flywheel end of engine Ratio Directdrive 1 to 1 2 to 1 Vdrive 129 to 1 167 to I
or 2 to 1 Reg grade gasoline 9094 Octane SAE3O or 10W30 Vdrive 90 gear oil Champion US 14 mm 1243 Model 5101 310 lbs 5102 330 lbs 5103 335 lbs
Model 5102 3218 inches 5103 36 inches All models 19516 inches All models 18316 inches 15 degrees 90125 psi all spark plugs removed and throttle open
Fuel Lubricating Oil Engine Spark Plugs Firing Order Weight length Overall height Overall width Maximum Operating Angle fore to aft Compression
ATOMIC FOUR
OWNERS SERVICE AND REPAIR GENERAL To ensure good performance dependability and safety regular maintenance of your engine is necessary This chapter
outlines routine checks and periodic maintenance required under normal service Engines operating for extended periods or in severe service may require
more frequent inspections and maintenance Regular attention to maintenance requirements will help avoid unnecessary repairs A systematic engine tuneup
procedure is provided at the end of this chapter ROUTINE CHECKS The following checks should be performed at least every two weeks 1 Engine oil Oil
level should be checked with the engine warm and should he between the two marks on the dipstick never below or above Add oil if necessary Oil level
will vary from engine to engine based on the angle of installation Water in the crankcase will cause the oil to turn a gray or milky colour If your
engine is equipped with Vdrive also check oil level Alternator drive belt see Figure 5 Examine for fraying and proper tension A spare belt should be
carried aboard Water pump see Figure 6 Check grease cup for adequate amount of grease If the grease cup is turned in as Off as it will go it should be
refilled Use a good grade of water pump grease Fuel oil or water leaks daily check the engine and oil and water lines for leaks Fuel leaks must be
corrected before attempting to start the engine Hightension wires and electrical connections Check for cracked insulation loose or corroded
connections or wires which may have been accidentally damaged Shaft coupling bolts Inspect the bolts fastening the engine shaft couplings These bolts
should be tight at all times
4 5 6
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR 5 7
Figure 6
Water intake seacock If equipped check that the seacock operates freely and that the valve can be easily closed if required
A general inspection of the engine accessories should be made In particular check the condition of the following 1 battery cables and terminals 2
exhaust system connections 3 throttle and choke controls and linkage 4 shift lever and linkage 5 propeller shaft stuffing box 6 engine mounting bolts
7 flexible connections PERIODIC MAINTENANCE Changing Engine Oil The oil change interval will vary depending on the type of use the engine gets If
operation is primarily for short periods of time change the oil more frequently As a general rule under normal use the oil should be changed every two
months and before winter layup Detergent type oil should be used
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR MANUAL
To change oil 1 2 3 4 5 6 Warm engine to operating temperature Remove dipstick and insert engine sump pump tube Transfer oil to disposal container
Replace dipstick Refill engine until dipstick shows full 3 to 5 US quarts or 3 to 5 litres depending on engine model and angle of Check oil level
after rerunning engine Top up oil if required Do not overfill as this can cause oil Water Pump see Figure 6 Lubrication of the water pump seals is
provided from the grease cup located on the pump body Periodically tighten the cup until some resistance is felt to force the grease into the drive
shaft housing When the grease cup cannot be turned further in refill with a good grade of water pump grease Instructions for dismantling and repairing
the water pump are contained in Chapter 4 Carburetor Flame Arrester The flame arrester fitted at the carburetor throat should be removed and cleaned
occasionally to permit an unrestricted air supply to the carburetor The flame arrester is easily removed by loosening the clamp screw and pulling the
unit off the carburetor throat Clean by soaking in mineral spirits and allow to dry If available use compressed air to assist cleaning Ignition System
The ignition system is comprised of a highvoltage coil condenser breaker points distributor spark plugs and wiring all of which must function
properly on a continuous basis to provide a strong spark at the spark plugs The condition of the hightension coil and condenser can only be tested
using electrical testing equipment For this reason it is wise to carry a spare condenser and coil on board Note that if the ignition key has been left
ON for an extended period without the engine running the coil can be burned out
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR maintenance of the ignition system includes cleaning and regapping or replacement of spark plugs visual inspection of
breaker points for condition and replacement if necessary visual check of hightension wires for condition resetting of ignition timing Spark Plug
Spark plugs should be examined and cleaned or replaced at least once a year 1 2 3 Remove spark plugs and examine for condition If electrodes are badly
worn or porcelain insulator is damaged replace the spark plugs Clean electrodes with a stiff wire brush and regap to 035 using a feeler gauge see
Figure 8 Replace plugs and tighten with fingers Torque plug to 30 ft lbs approx 114 turn using a spark plug socket TUNEUP To ensure troubleflee
operation an engine tuneup should be carried out at least once per season preferably in the spring for boats which have been laid up through the
winter The following tasks comprise a minor tuneup adequate to produce proper performance from your engine 1 2 3 4 5 6 7 8 9 Clean and regap spark
plugs Replace if badly worn Change engine oil if not done before winter layup Replace ignition points and condenser refer to Chapter 3 Examine and
adjust alternator drivebelt Replace if frayed refer to Chapter 3 Examine ignition hightension wiring Replace if cracked or brittle Clean fuel pump
sediment bowl if mechanical fuel pump fitted see Chapter 4 Replace or clean fuel filter if fitted Check choke and carburetor mixture settings adjust
throttle for proper engine idle speed refer to Chapter 4 Check water pump lubrication cup and add grease if required
A major tuneup comprises all the foregoing and the following additional steps 10 Carburetor overhaul refer to Chapter 4
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR 8 SPARK PLUG GAPPING 11 12 Adjust valve tappet clearances refer to Chapter 6 Reset ignition timing refer to Chapter FOR
SPRING SERVICE Proper preparation of your engine in the spring will contribute to a full season of reliable operation If the crankcase oil was changed
the previous fall before layup it is not necessary to change the oil again In preparation for operation carry out the following steps 1 2 3 Replace
three drain plugs see Figures 1 and 2 Adjust alternator drivebelt for correct tension see Figure 5 Tighten water pump cover and lubricate pump by
turning grease cup in one to one and a half Do not operate engine until a water supply is available to the water pump 4 Remove spark plugs and pour
about two tablespoons of oil into each cylinder turn engine over by hand with ignition off to coat cylinder walls with oil clean and regap plugs to
035 replace plugs and tighten to 30 ft lbs finger tight plus 14 turn Remove distributor cap and clean cap and distributor clean and reset breaker
points refer to Chapter 3 replace if badly pitted or worn replace distributor cap Examine hightension wires to coil and spark plugs for damage or
brittleness replace if required Check hose connections for tightness including Vdrive cooler hoses Reconnect propeller shaft if disconnected Install
fully charged battery remove cover from exhaust outlet turn on fuel supply to engine and check for leaks open water pump seacock
5 6 7 8 9
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR FOR WINTER STORAGE In areas where boats are hauled for storage over the winter proper preparations will avoid damage and
assure troublefree startup next season Before the boat is hauled change the crankcase oil This is best done afloat since the engine should be at
operating temperature before draining the oil Refill the crankcase with the required amount of fresh oil and run the engine for a few minutes to
distribute the oil By changing the oil prior to storage residual acids and moisture are removed and the engine is better protected against internal
corrosion during the layup period After haulout carry out the following steps 1 Remove the three drain plugs located as shown in Figures 1 and 2 2
Loosen the cover on the water pump to drain the remaining water from the pump 3 Drain the exhaust system 4 Remove the spark plugs and add about two
tablespoons of fresh engine oil to each cylinder turn the engine over by hand with ignition off to coat cylinder walls with oil replace spark plugs
fingertight 5 Loosen the two alternator mounting bolts and release the tension from the drive belt see Figure 5 6 Shut off fuel supply 7 Top up the
fuel tank to minimize condensation 8 Cover the carburetor intake and exhaust system outlet to prevent moisture from entering the engine by way of open
valves 9 Drain water from the Vdrive cooler by removing the inlet hose replace hose after draining 10 Remove batteries and store to prevent freezing
11 Loosen the distributor cap for ventilation 12 Coat exposed metal parts with grease or rust inhibitor 13 Cover the engine to provide protection 14
For wooden vessels it is advisable to disconnect the propeller shaft from the engine to allow for hull movement during ATOMIC FOUR
OWNERS SERVICE AND REPAIR SYSTEM This chapter includes descriptions and service procedures for the ignition starting and charging circuits of your
engine Also included is information on battery testing and maintenance location of fuses and engine wiring diagrams IGNITION SYSTEM The ignition
system consists of the battery ignition switch ignition coil distributor spark plug and associated wiring Theory of Operation Two separate circuits
the primary lowtension and the secondary comprise the ignition system The low tension circuit includes the battery distributor points low voltage
ignition coil winding and the condenser The high tension circuit includes the distributor rotor and cap high voltage winding of the ignition coil the
hightension wires and the spark plugs When the ignition is on current from the battery flows to the lowvoltage winding of the coil through the contact
points in the distributor Alternate opening and closing of the contact points causes the current flow to stop and start producing a fluctuating
buildup and collapse of the magnetic field in the lowtension winding of the coil This fluctuating magnetic field induces a highvoltage current in the
secondary winding of the ignition coil which is transmitted to the spark plug via the rotor and contacts in the distributor cap A condenser is wired
across the breaker points to reduce arcing at the points when the lowtension magnetic field in the coil 9 ADJUSTING IGNITION POINT GAP
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR SYSTEM COMPONENT REPLACEMENT Ignition Point Replacement Points which show only a slight and are not badly pitted should be
cleaned with a special contact point file and reset to 018020 gap To replace the contact point assembly proceed as follows CAUTION Make certain that
the ignition switch is off 1 2 3 4 Remove distributor cap held by two screws which remain with cap Pull rotor off shaft to allow access to contact
assembly Remove negative terminal and condenser wire terminal from the inner portion of the insulated bracket see Figure 9 Remove screw holding
contact assembly and remove assembly by gently lifting upward When installing new assembly be sure to press tightly into position on distributor plate
mounting stud Position condenser bracket so that condenser is clear and not touching point assembly Push connectors from the condenser and the
negative post on coil onto the springloaded terminal in distributor Secure assembly lightly in midposition of adjusting slot Turn the engine over by
hand until one of the four cams on the distributor opens the points to maximum Using a feeler gauge adjust point opening with screwdriver in adjusting
slot to provide 018 to 020 gap clearance Replace rotor and cap
5 6 7 8
NOTE It is recommended that the contact assembly and condenser be replaced at the same time to reduce the risk of pitting on point contact surfaces
Ignition Coil Replacement With ignition off disconnect the wires from the negative and positive terminals of the coil remove the hightension wire and
loosen the two bracket bolts and the bracket clamp screw Spark Plug Replacement Refer to Chapter 2 Maintenance for details of spark plug servicing
and ATOMIC FOUR
OWNERS SERVICE AND REPAIR MOTOR see Figure 10 1 2 Disconnect the battery ground cable Disconnect the battery cable from the starter solenoid the
wire from the starter switch yellowred and the wire from the ammeter red CAUTION Support starting motor while removing mounting bolts 3 4 Remove two
mounting bolts and withdraw starting motor from flywheel housing Installation is the reverse of 10 STARTER MOTOR REMOVAL Installation and Service To
inspect the condition of the gear drive commutator and brushes the motor must be partially disassembled Remove the solenoid and end cap to expose the
brushes Pull on the brushes to ensure that they slide freely in their holders If the flexible lead is nearly touching the metal holder the brushes
should be replaced Examine the commutator for wear or scoring Service to the solenoid and starter should be carried out by a dealer or repair shop
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR AND VOLTAGE REGULATOR The alternator generates alternating current AC which is converted to direct current by internal
silicon diodes The voltage regulator controls the rate of charge amperes and voltage to the electrical system Adjustment and repair of these units
requires special equipment not ordinarily available to the amateur mechanic If malfunction occurs remove the units and take to a dealer or competent
repair shop Common problems and probable causes of alternator and voltage regulator malfunctions are 1 2 3 Screaming during acceleration The Vbelt is
loose or has deteriorated or both Tighten or replace Constant growling The bearing on the pulley end of the shaft is defective Have it replaced
Alternator doesnt charge Loose Vbelt defective brushes or slip rings inside alternator defective regulator blown rectifier diodes open field circuit
to regulator open circuit between alternator and battery open circuit between regulator and ignition charge Loose Vbelt poor connections loose
mounting hardware and poor ground connection Excessively high charging rate Defective 5
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR Installation 1 2 3 4 5 Isolate battery or disconnect positive cable at battery Disconnect two wires and tag for see Figure
11 Remove mounting and belt tension adjusting bolts and drive belt Installation is the reverse of removal Adjust drive belt tension by moving
alternator away from engine until drive belt can be deflected to 34 inch Tighten adjustment and mounting bolts see Figure 5
FIGURE 11 ALTERNATOR TIMING ADJUSTMENT 1 2 3 Remove spark plug from No1 cylinder at flywheel end of engine Place thumb over spark plug hole and turn
engine by hand until compression pressure is felt Turn flywheel in normal cranking direction until cranking pin is exactly vertical No1 piston is now
at TDC
NOTE Do not lift distributor which will disengage distributor drive gear or complete retiming may be required 4 5 Loosen distributor clamp bolt and
rotate distributor body until breaker points are just beginning to open Tighten distributor clamp bolt Engine is now roughly timed Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR 8
Replace and fasten distributor cap Number I spark plug wire goes into the connection directly above the flat on the distributor body at which the
rotor is pointing The remaining three high tension wires are inserted in the distributor cap in the proper firing order 1243 going from No1 in a
clockwise direction Final timing adjustment must be made with the engine running With engine running at a fixed speed loosen distributor and rotate
for maximum engine RPM at that throttle setting Retighten distributor clamp MAINTENANCE Removal see Figure 12 1 2 3 Remove the distributor cap held
by two screws which remain with cap Disconnect the wire connected to the coil negative terminal Loosen the clamping bolt at the base of the
distributor NOTE Do not rotate the engine after removing the distributor 4 5 Note the position of the distributor in relation to the engine to
facilitate replacement in the same relative position Remove distributor from 12 DISTRIBUTOR REMOVAL
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR 1 2 Installation 1 2 Replace the distributor in the same position as it was when removed Tighten distributor clamping bolt
Inspect the distributor for cracked broken or worn parts including advance mechanism and for excessive burning Replace all defective parts Clean all
parts with carbon MAINTENANCE The battery supplies current to the starter and electrical system while starting the engine After the engine starts the
alternator supplies all the current required to keep the engine running and also replenishes the current supply drained from the battery during
starting The of the battery is indicated by the specific gravity of the battery solution Check the specific gravity with a hydrometer to determine
the condition of the battery A battery which is used in tropical climates where freezing rarely occurs is supplied with a weaker acid solution
resulting in lower specific gravity values A high specific gravity affords the best protection against freezing A difference in specific gravity
between cells of 20 and 25 indicates battery trouble and the possibility of early failure especially in cold weather Rapid loss of battery solution is
an indication that the battery is being overcharged The alternator and voltage regulator should be checked and adjusted to provide the specified
output Hydrometer testing is the most effective way of determining battery condition Use a hydrometer with numbered graduations from 1100 to 1300 To
test the cell squeeze the rubber ball insert the tip into the cell and release the ball see Figure 13 Draw enough fluid from the cell to float the
weighted float in the hydrometer Note the number on the float in line with the surface of the electrolyte fluid Return the electrolyte to the proper
cell and repeat for each cell
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR 13 CHECKING SPECIFIC GRAVITY The specific gravity of the electrolyte in each cell is an accurate indication of the cells
condition Refer to the chart below to determine the condition of the battery The fluid level in the cells should fully cover the battery plates Add
only distilled water to the battery Keep open flames and sparks away from battery Specific Gravity Temperature Climates Above 1280 1250 1220 1190 1160
1130 or less FUSES Note that on later model engines 20 and 10 amp fuses are mounted behind the instrument panel to provide protection for the ignition
and blower circuits In addition a 3 5amp fuse is fitted in the wire red connecting the starter solenoid and the ammeter to provide protection for the
starter motor see Figure 14 State of Charge Specific Gravity Tropical Climates Above 1225 1220 1175 1150 1120 1090 or less
Fully Charged 75 50 25 Limited Useful Capacity ATOMIC FOUR
OWNERS SERVICE AND REPAIR 14 STARTER CIRCUIT FUSE WIRE SIZES Correct wire size selection is important for safe and proper operation of auxiliary
electrical equipment The table below indicates recommended wire size based on total current for the circuit and length of run For battery cables use
No I heavy duty cable WIRING DIAGRAMS Wiring diagrams are included for engines with and without electric fuel pump 5unit instrument panel and
generator equipped engines see Figures 15 to 18
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR 15 ENGINE WIRING DIAGRAM WITHOUT 16 INSTRUMENT PANEL WIRING DIAGRAM
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR 17 ENGINE WIRING 18 ENGINE WIRING DIAGRAM WITH GENERATOR Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR MANUAL
FUEL SYSTEM The fuel system consists of the fuel tank and lines fuel pump carburetor flame arrester and intake manifold Gasoline enters the fuel pump
from the tank and is pumped into the carburetor float bowl The fuel is vaporized in the carburetor and drawn into the engine through the manifold and
intake valves TYPICAL FUEL SYSTEM The main components of a typical marine engine fuel system are shown in Figure 19 and discussed below
FIGURE 19 TYPICAL FUEL SYSTEM The fuel tank should be designed for marine use with internal baffle plates and a filler pipe extending to within a few
inches of the bottom The outlet should also be on the top of the tank so that if the fuel line fails only a small amount of gasoline will enter the
hull A vent connection must be provided to allow fumes to escape from the tank Other features of the installation include a replaceable fuel filter
and static ground connection between the fuel tank and the fill fitting on deck
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR MANUAL
FUEL PUMPS
FIGURE 20 MECHANICAL FUEL PUMP The function of the fuel pump is to supply an adequate amount of gasoline to the carburetor for all engine speeds The
mechanical fuel pump is of the diaphragm type operated by a push rod acting off an eccentric cam on the camshaft At the high point of the cam the
pushrod is forced down creating a vacuum above the diaphragm which draws fuel from the tank into the pump through the inlet valve The reverse stroke
of the pushrod releases the compressed diaphragm spring forcing fuel through the pump outlet valve and into the carburetor float bowl After a number
of strokes the carburetor floatbowl fills and the bowl inlet is sealed off by the rising float mechanism and the seating of the floatbowl needle valve
creating back pressure on the pump diaphragm With this back pressure on the diaphragm rocker arm movement is taken up by the linkage instead of the
diaphragm and fuel flow to the carburetor is reduced until the level falls in the floatbowl at which time additional fuel is required Fuel flow rate
continuously fluctuates depending upon engine requirements Later engines are equipped with an electric fuel pump operating independently of the engine
by means of an integral electric motor
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR MANUAL
FUEL PUMP MECHANICAL see Figure 20 Defective fuel pumps should be removed and replaced Removal 1 Shut off fuel supply to fuel Drain and dispose of
any fuel when fuel lines are disconnected and pump removed 2 3 4 5 Disconnect fuel lines at pump inlet and outlet Remove two mounting bolts securing
pump to engine and remove pump Withdraw pushrod from engine opening Remove pump sediment bowl screen and gasket Drain pump and bowl and dispose of
fuel
FUEL PUMP ELECTRICAL Electrical fuel pumps are not repairable in the field A faulty pump must be replaced Note that a switch is installed in the fuel
pump electric circuit Failure of this switch or wiring will prevent operation of the fuel pump Servicing of the electrical fuel pump is limited to
replacement of the disposable filter which is accessible after removing the lower cap from the pump The filter should be replaced annually Removal and
Installation 1 2 3 4 5 6 Make certain ignition is off Shut off gas supply Disconnect the inlet and outlet fuel lines at the pump and dispose of fuel
from lines Disconnect the pump electrical wire at the switch Remove two pump mounting bolts Installation is the reverse of ATOMIC FOUR
OWNERS SERVICE AND REPAIR The carburetor atomizes and delivers fuel to the engine in the amount and mixture required for all operating conditions The
fuel is vaporized and preheated in the intake manifold before entering the cylinders through the intake valves A flame arrester fitted at the
carburetor throat prevents fire from occurring from engine backfiring by dissipating heat through a series of curved plates Carburetors are of the
updraft design and allow operation to extreme angles Later engines after serial No 170509 are supplied with carburetors having only an idle
adjustment Earlier installations also provide highspeed mixture 21 CARBURETOR IDLE ADJUSTMENT Idle System Adjustment see Figure 21 1 2 3 4 Turn
idling adjustment screw in until it seats open one turn to left from seat With engine running and warm close the throttle until a satisfactory idling
speed is reached Adjust idling needle valve in right or out left for smoothest engine operation Set throttle stop screw for desired idling speed
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR Adjustment Series 61 carburetors 1 2 3 4 With engine running and warm open throttle approximately one third Loosen packing
nut on main jet adjustment Turn main jet adjustment to right in until engine runs smoothly and as fast as the throttle setting will permit Hold needle
valve in this position and tighten packing nut
FUEL LEVEL FLOAT SETTING Correct setting of the fuel level float located in the carburetor float bowl is essential for proper engine operation These
floats are factory set for a fuel pump pressure of 2 lbs per sq inch Malfunction of the carburetor will sometimes be caused by dirt lodging on the
float needle valve seat preventing complete seating of the needle valve To inspect the setting and condition of the float mechanism the carburetor
bowl cover assembly must be settings for Series 61 and 68 bowl cover assembly in an inverted position viewed from free end of float the float bodies
must be centered and at right angles to the machined surface The float setting is measured from the machined surface no gasket of cover to top side of
float bodies at highest point To increase or decrease distance between float body and machined surface use long nosed pliers and bend lever close to
float body Replace float if position is off more than 116 Do not bend twist or apply pressure directly to the float bodies
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR MANUAL
Choke Setting Adjustment The choke consists of a shaft mounted butterfly valve located in the carburetor throat and operated remotely by an external
lever The choke is used to restrict air entering the carburetor thereby increasing the suction on the jets for engine starting A poppet valve is
provided on the choke plate to admit some air during starting to prevent overchocking or flooding of the engine At startup the engine requires a
fuelair mixture ratio much greater than that necessary during normal operation The mixture ratio must be rapidly reduced once the engine starts and is
accomplished by adjusting opening the choke valve as soon as the engine is running To set the choke for correct operation engine not running carry out
the following 1 2 3 4 Loosen choke control cable at carburetor lever and set choke valve in fully open position With choke control fully in tighten
control cable clamp at carburetor Pull choke control out and check that the choke valve fully closes Readjust if Removal 1 2 3 4 Shut off fuel supply
Disconnect fuel inlet line and manifold air line Disconnect choke and throttle cables Remove two bolts securing carburetor to intake manifold and
remove Installation 1 2 3 4 5 6 Install carburetor flange gasket and two mounting bolts Connect choke and throttle cables Connect manifold air line
and fuel line Adjust choke and throttle controls Turn on fuel supply Check for fuel Overhaul A carburetor rebuilding kit is available from dealers
The kit contains parts which normally require service along with instructions for overhaul carburetors may be serviced at a competent repair shop
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR SYSTEM The Atomic4 cooling system is comprised of a positive displacement water pump and a thermostat to maintain proper
engine operating temperature Figure 22 shows schematically the operation of the cooling system for cold and warm engines Four important points should
be noted regarding the operation of the cooling system 1 The water pump is designed to operate only when a water source is available to it If the
engine is run with the cooling water supply restricted or shut off damage will quickly occur to the rubber water pump impeller If damage occurs to the
rubber water pump impeller one or more blades may break off and lodge in the cooling system hoses If the engine is overheating check the impeller for
broken blades and if this has occurred check all cooling water discharge hoses to see if the blades are preventing proper water flow The thermostat
fined is a special 3spring bypass type which functions to provide water to the exhaust system regardless of engine operating temperature thermostats
must not be substituted for the factory supplied thermostat When laying the engine up for storage in below freezing areas the cylinder block drain
plugs located on the left side of the engine must be removed to positively drain the cylinder block and head If antifreeze is to be run through the
engine as a winterizing fluid one of the engine drain plugs should be removed so that all water in the cylinder block and head will be displaced by
the ATOMIC FOUR
OWNERS SERVICE AND REPAIR 22 COOLING SYSTEM SCHEMATIC WATER PUMP Replacing Water Pump Impeller and Shaft 1 2 3 Shut off water supply to pump The
water pump impeller and shaft may be replaced without removing the water pump from the engine Remove pump coverplate held by four retaining screws
Pull impeller and shaft out of water pump body NOTE Impellers are secured to the shaft with a removable pin or circlip 4 5 Remove pin or circlip
securing impeller to its shaft see Figure 23 Installation is the reverse of removal
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR 24 WATER PUMP REMOVAL If any impeller blades are missing remove the pump discharge hoses and thermostat housing and
inspect for broken blades that may have lodged in the lines and which could cause restrictions and engine overheating Removing Water Pump and
Replacing Seals See Figures 24 and 25 1 2 3 4 5 Shut off water supply to pump Remove the water pump from engine by disconnecting the suction and
discharge hoses and removing two pump mounting bolts Remove coverplate and withdraw impeller shaft assembly Remove grease cup and place pump body in
vice with shaft opening upward Remove seals with expanding type seal removal tool If this tool is not available the seals may be removed with an
offset tool through the shaft opening Care must be taken not to damage the shaft bore surface Replace the inner seal first with the lip toward the
impeller side then the outer seal with the lip toward the drive end and flush with the mounting surface Inspect grease cup for free movement of ball
and spring and fill with a good grade of water pump grease before replacing To lubricate and seal shaft after installation tum is felt to lubricate
and seal shaft
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR 25 WATER PUMP CROSS SECTION ENGINE THERMOSTAT Inline thermostats before engine serial No79476 are of the singlespring type
and may be easily replaced by removing the two slotted capscrews securing the main housing Always install a new gasket when reassembling Engines
beginning with Serial No79476 have a special 3spring bypass thermostat installed in the cylinder head This thermostat permits a continuous supply of
water to the exhaust system regardless of engine operating temperature Do not use thermostats as replacements for units supplied with your engine
Removal and Installation see Figure 26 1 2 3 4 Disconnect water inlet hose on thermostat housing Remove two thermostat housing nuts and carefully lift
housing to expose thermostat When replacing thermostat be sure it is centred in the housing recess groove Clean gasket surfaces and instal a new
gasket Use only a light covering of sealant on gasket or soak in warm water prior to ATOMIC FOUR
OWNERS SERVICE AND REPAIR 26 THERMOSTAT HOUSING CAUTION The two housing nuts also function as cylinder head fasteners and must be torqued to
cylinder head 35 ft lbs max of the housing nuts or tightening of nuts when the thermostat is not seated in the housing recess can result in and
cracking of the housing 5 6 Torque housing nuts to 35 ft lbs maximum Install housing water inlet hose
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR This chapter provides procedures for carrying out adjustments and repair to the level of a minor overhaul pistons piston
rings connection rods and hearings and valves including cylinder head manifold and crankcase pan removal If repair or replacement of major components
such as the crankshaft and camshaft or if cylinder reboring is required the engine should be removed for servicing by a competent repair shop
ADJUSTING VALVE CLEARANCE Correct valve tappet clearances must be maintained to prevent valve damage excessive noise and loss of power If clearances
are too small valves may be burned or distorted Large clearances result in tappet noise In both cases engine power is reduced Before adjusting valves
remove the spark plugs This permits easier engine turning Refer to Figure 27 for location of adjusting nut and Chapter 9 for valve layout Valve
tappet clearances are shown in the table below Valve Tappet Clearances Hot Cold Intake 008 010 Exhaust 010 012 1 2 3 Remove fuel pump carburetor see
Chapter 4 and valve inspection cover on side of engine Turn the engine over so that piston No1 is at TDC on its compression stroke see Chapter 3 Hold
the tappet locknut with an openend wrench insert a feeler gauge between the tappet and valve stem and adjust to proper clearance by turning the
adjusting nut Clockwise increases clearance and reduces clearance Remove wrenches and check that clearance is correct Rotate engine by hand until
piston No2 is at TDC on its compression stroke and adjust valves Repeat for pistons No4 and 3 Reinstal valve inspection cover carburetor and fuel pump
4 5 6
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR 27 ADJUSTING VALVE CLEARANCE REMOVING AND INSTALLING MANIFOLD see Figure 28 1 2 3 4 5 6 Shut off cooling water supply and
drain engine Disconnect and support exhaust at rear of manifold Disconnect water outlet hose at rear of manifold and thermostat housing outlet hose
Remove carburetor refer to Chapter 4 Disconnect wire at water temperature sending unit Remove three nuts securing manifold to engine and remove When
reinstalling manifold thoroughly clean mating surfaces and use a new manifold gasket 7 8 Installation is the reverse of removal Torque manifold nuts
to 35 ft lbs
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR 28 REMOVING MANIFOLD CYLINDER HEAD Removal Removal of the cylinder head will only be required when the valves need
renewing the engine needs decarboning or a damaged piston or head gasket is suspected It is not usually necessary to take out the engine to remove the
cylinder head depending on available work space To remove the cylinder head proceed as follows
1 2 3 4 5 6 7 8
Shut off the cooling water supply to engine and drain engine Remove hightension wires from spark plugs Remove alternator refer to Chapter 3 Remove
carburetor refer to Chapter 4 Remove manifold see above Disconnect the water inlet and outlet hoses at the thermostat housing Remove 7 head nuts these
include the two thermostat housing nuts and alternator bracket Separate cylinder head from engine and removing the cylinder head cover the engine to
protect the machined surface and prevent foreign maffer from entering the ATOMIC FOUR
OWNERS SERVICE AND REPAIR and Cleaning 1 2 3 4 Remove all carbon from the combustion chambers with a wire brush A blunt screwdriver or chisel may be
used if care is taken After removing all carbon dean the entire head with solvent Check for cracks A cracked head must be replaced Using a straight
edge check the cylinder head for warping If the head is warped more than 006 it should be resurfaced or replaced Remove all gasket material from the
cylinder head and engine CAUTION Do not remove the carbon ridges at the top of the cylinder bores unless the pistons are to be removed 5 Clean all
carbon from the piston crowns and valves Inspect pistons and valves for wear or each cylinder for wear if wear exceeds 0075 cylinders should be
rebored for oversize pistons and rings or the engine block should be replaced If cylinder diameters are satisfactory but minor scratches or glazing is
evident restore cylinders to good condition by honing Installation CAUTION Two head gaskets are required 1 2 3 4 Position two head gaskets and
cylinder head on engine Locate alternator bracket thermostat and housing on cylinder head Install head nuts but do not tighten Tighten all head nuts
to 35 ft lbs in proper CRANKCASE PAN 1 2 3 4 5 Drain oil from engine Remove or Vdrive unit if equipped Remove two Allenhead bolts at transmission
end of engine Remove starter motor flywheel and flywheel housing Remove sixteen pan bolts and separate pan from engine
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR Do not overtighten pan bolts when 30 INSTALLING VALVE 6 Installation is the reversal of removal Clean pan and engine
mating surfaces and instal anew pan gasket Torque flywheel stud nuts to 35 ft PISTONS CONNECTING RODS AND BEARINGS Pistons and connecting rods may be
removed after removal of the cylinder head and crankcase pan To remove piston and connecting rods proceed as follows 1 2 Check the top of the cylinder
for a carbon ridge If there is a ridge remove it before withdrawing the piston and rod Remove two nuts securing connecting rod bearing cap and remove
cap Note the position of the cap for The lower half of the connecting rod bearing insert may now be removed Separate the connection rod from the
crankshaft The upper half of the connecting rod bearing insert may now be Take care not to damage the cylinder wall when withdrawing the connecting
rod 4 5 Push the piston and connecting rod up and out of the cylinder Reinstall the connecting rod bearing cap on the connecting rod
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR OF PISTON RINGS AND PINS 1 2 Remove piston rings using a ring expander tool Before removing the piston pin hold the
connecting rod firmly and rock the piston back and forth Any rocking movement do not confuse with sliding of the piston on the pin indicates that
there is wear in the piston pin rod bushing or piston pin bore Remove the snap rings at each end of the piston pin and press the piston pin out This
operation may best be left to your dealer or a machine shop where special equipment is 1 2 Clean the piston in solvent and scrape carbon deposits
from the top of the piston and ring grooves Take care not to damage the piston Examine the piston for damage and wear Check each ring and groove for
buns damaged edges and side wear Pay particular attention to the top compression ring which usually wears the most Parts may be measured with a
micrometer to determine which are worn and need replacement refer to Chapter 9 RING FIT AND INSTALLATION 1 Check the gap of each piston ring by
inserting it into its cylinder bore Square it with the wall by tapping with a piston Insert a feeler gauge as shown in Figure 31 Ring gap should be
007 to 015 If the gap is less than 007 place a small file in a vise hold the ends of the ring and enlarge the gap if the gap is greater than 015 check
the cylinder bore diameter which should be 2562 to 2563 Roll each ring around its piston groove to check for binding Using a ring expander tool
carefully install the oil ring then the two compression rings Check the side clearance of each ring in the piston ring groove and compare with 3 4
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR 31 PISTON RING END GAP CAUTION Take care not to damage the cylinder hone when inserting connecting rod and piston NOTE The
piston is installed with the arrow pointing towards the transmission 5 6 7 Position the gaps of the piston rings as shown in Figure 32 Coat the piston
and ring with clean engine oil Lubricate the pin and bearing and work rod back and forth to ensure that oil enters the pin beatings Using a ring
compressor start the piston in the cylinder bore and tap the piston through the compressor and into the 32 PITON RING GAP ATOMIC FOUR
OWNERS SERVICE AND REPAIR CONNECTING ROD BEARINGS The upper rod bearing insert may be installed before the piston is inserted into its cylinder Do
not lubricate the surfaces where the rod and insert mate After installing the piston in the cylinder lubricate the bearing insert rotate the
crankshaft so that the respective journal is at bottom dead center and push the piston down while guiding the connecting rod onto the journal Snap the
lower bearing insert into the rod cap and lubricate Install the cap on the connecting rod and run the cap nuts up until the cap is snug Turn the
crankshaft one or two revolutions to center the rod on the journal and torque the cap nuts to 25 ft lbs REMOVING ENGINE It may be necessary to remove
your engine to carry out major repairs After preparations have been carried out and the engine has been lifted off its bed note the location of any
shims under the engine mounts to facilitate realignment of the engine when it is reinstalled A lifting eye is provided on the cylinder head If engine
disassembly is to be done after removal the engine can be substantially lightened by prior removal of the crankcase oil starter alternator manifold
cylinder head and reduction gear unit To remove the engine proceed as follows 1 2 3 4 5 Disconnect the negative ground battery cable at the engine
first then disconnect the positive cable at the starter solenoid Shut off fuel disconnect the fuel line at fuel pump and drain and dispose of fuel
from lines Shut off cooling water supply to engine and disconnect hose from suction side of water pump Drain water from engine Disconnect the
following exhaust at rear of manifold support exhaust if necessary water discharge hose at rear of manifold propeller shaft instrument wiring harness
or individual wires at engine tag wires for reconnection oil line to pressure gauge if equipped drain and dispose of oil from line shift lever control
cable throttle and choke control cables Remove four engine mounting bolts or ATOMIC FOUR
OWNERS SERVICE AND REPAIR ADJUSTMENTS Adjusting Forward Drive see Figure 33 1 2 3 Remove four transmission cover plate bolts and cover plate Take
care not to damage the cover plate gasket Loosen the lock screw until it is clear of the notch in the adjusting collar Turn collar to the right until
the lock screw is in line with one of the notches in the 33 ADJUSTING TRANSMISSION 4 5 Tighten the lock screw malting certain that the end enters
the collar notch Replace cover plate and try engine in forward drive Repeat adjustment until no gear slip occurs on the forward drive An adjustment of
one or two notches is usually adequate to eliminate Reverse Drive see Figure 33 1 2 3 Remove four transmission cover plate bolts and cover plate Take
care not to damage the cover plate gasket With shift lever in neutral tighten adjusting nut two or three flats 13 to 12 turn Do not loosen the
adjusting nut lock spring Replace cover plate and try engine in reverse drive Repeat adjustment if necessary to eliminate ATOMIC FOUR
OWNERS SERVICE AND REPAIR MANUAL
Shift Control Linkage Adjustment When shifting into forward or reverse drive there must be positive engagement of the forward or reverse clutch other
wise excessive wear will result To check and adjust the shift control linkage proceed as follows 1 2 3 Remove four transmission cover plate bolts and
cover plate Take care not to damage cover plate gasket Place the shift lever in the forward position as far as it will go Disconnect the linkage from
the shift lever and check if the lever can be shifted further forward if so adjust the remote shift linkage to permit the shifting lever to move
forward as far as possible and properly engage the forward drive Repeat adjustment for reverse drive position Replace transmission cover plate
4 and REDUCTION DRIVES Your Atomic4 will be equipped with one of three final drive arrangements direct drive 21 reduction and Vdrive with reduction
Power is transmitted to the forward clutch or reverse drive gear in the transmission The forward clutch consists of a number of friction discs which
can be clamped together by the pressure plate operated by toggle arms mounted to the clutch adjustment plate Manual positioning of the toggles
determines forward reverse or neutral shaft output The reverse clutch is operated when the shifting lever is moved to the rear of the engine thereby
clamping the brake 6and to the drum and preventing drum rotation and causing the tail shaft to be rotated in the opposite direction to the crankshaft
The forward and reverse clutches cannot be activated at the same time On models fitted with the reduction gear unit two herringbone gears of different
sizes supported by heavyduty bearings function to reduce propeller shaft speed to approximately half of the engine speed The reduction unit runs in a
continuous oil bath supplied from the engine crankcase to provide positive and quiet operation The Vdrive unit is made available to permit engine
installation further aft while providing reduction of propeller shaft speed This unit is lubricated and water cooled independently of the engine and
requires very little attention The Vdrive unit is Oil level should be checked periodically and water hoses and connections inspected from time to
time Water must be drained from the unit water jacket for winter ATOMIC FOUR
OWNERS SERVICE AND REPAIR MANUAL
FINAL DRIVE MAINTENANCE The transmission and reduction gear units require very little attention These components are heavily built and will provide
long troublefree service when lubrication requirements adjustments and winterizing Vdrive unit are properly carried Out The most common malfi3nction
is the failure of the rear oil seal caused by engineshaft misplacement Replacement of these seals should be carried out by a dealer or competent
repair shop having the necessary special equipment for removal and installation The reduction drive units can be easily removed from the engine for
seal replacement REDUCTION DRIVE UNIT see Figure 34 1 Disconnect shaft coupling separate coupling halves and move propeller shaft aft two to three
inches CAUTION Support reduction unit while removing mounting bolts NOTE Place a container under the reduction unit and dispose of engine oil which
will be lost when unit is removed 2 3 4 Remove six mounting bolts separate reduction unit from transmission and lift unit up and back from
transmission shaft Installation is the reverse of removal Instal a new housing gasket if necessary Top up engine oil level
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR 34 REDUCTION DRIVE REMOVAL VDRIVE REDUCTION UNIT 1 Disconnect shaft coupling CAUTION Support the VDrive unit while
removing mounting bolts 2 3 4 5 6 Disconnect cooling water inlet and outlet hoses Remove six mounting bolts and separate Vdrive unit from transmission
Drain and dispose of unit lubricating oil Installation is the reverse of removal Check and add oil as required after ATOMIC FOUR
OWNERS SERVICE AND REPAIR INFORMATION INTRODUCTION This chapter contains information on other aspects of your engine including diagnosis of trouble
exhaust systems alignment propellers refueling methods recommended spare parts and tools Proper maintenance of the subsystems will increase operating
reliability and reduce the need for expensive repairs and parts replacement DIAGNOSING TROUBLE Your engine has three main requirements for proper
operation a clean adequate fuel supply strong uninterrupted ignition spark and good compression If any of these conditions are not continuously
present the engine will not operate reliably The following information will assist the owner in detecting and correcting the most likely causes of
engine malfunction When attempting to diagnose the problem carry out only one procedure at a time ENGINE WILL NOT START Cause Ignition switch off or
defective Defective breaker points ignition coil or condenser Action Turn on or replace switch Remove high tension wire from distributor cap and hold
approx 38 from engine block crank engine a clean sharp spark should be present clean and reset breaker points if spark is yellow after adjustment
replace condenser if spark is weak or not present replace ignition coil Remove inspect clean and plug Reset timing Clean inside of distributor
inspect and replace broken or worn parts Dry system and or broken spark plug Incorrect timing Faulty ignition system and high tension wires Empty
fuel tank Fuel shutoff valve closed
Fill fuel tank Open valve
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR spark plugs and turn engine over several times replace plugs Clean fuel system and refill tank Check choke valve and
control repair adjust as required Adjust carburetor Clean fuel system repair or replace fuel pump
Water in fuel system Choke valve inoperative Carburetor out of adjustment Obstructed fuel lines or defective fuel pump Air leak at intake manifold
Loose spark plugs Poorly seated bolts replace gasket if necessary Tighten spark plugs Check for broken or weak springs bent stems carbon deposits
insufficient tappet clearances Check for leaks when engine cranked and replace gaskets if necessary Replace as necessary Change engine oil check for
source of water exhaust system water pump etc Drain and refill fuel cylinder head
Worn broken piston rings Water in engine
Stale fuel
STARTER MOTOR DOES NOT OPERATE Discharged battery Corroded battery terminals Poor connection in starting circuit Defective starter switch Dirty
starter motor brushes Jammed Bendix drive gear Charge battery Clean terminals Clean and tighten all Switch Clean or replace brushes Loosen starter
motor and free gear Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR starter solenoid Fuse defective 35 amp
Service or replace solenoid Replace fuse located in red wire between ammeter and starter solenoid Replace fuse located behind instrument panel in wire
between ammeter and ignition switch
20 discharged battery Damaged Bendix gear in starter Defective wiring or wiring of too low battery Repair gear Check and replace as TOO LOWHIGH
Defective temperature gauge or sending unit Defective water pump Obstruction in cooling system Defective thermostat Water intake seacock closed Oil
level low Engine needs overhaul Overloading engine Engine timing incorrect Replace gauge or or replace pump Remove obstruction check for broken water
pump impeller blades outlet Replace Thermostat Open seacock Top up oil Overhaul engine Reduce engine rpm Reset timing
OIL PRESSURE READING TOO LOWHIGH Defective gauge sending unit or oil tube Repair or ATOMIC FOUR
OWNERS SERVICE AND REPAIR MANUAL
No oil in engine Dirty pressure relief valve Defective or worn oil pump leak in oil lines or broken pump drive Oil grade too light or heavy Weak or
broken pressure relief spring Loose or worn engine bearings Stuck pressure relief valve high oil pressure ENGINE VIBRATION Misfiring or preignition
Loose mounting bolts Engine out of line bent Propeller bent or pitch outoftrue LOSS OF POWER Damaged propeller Bent rudder Engine misaligned Stuffing
box too tight Dirty boat bottom Incorrect valve tappet correct grade of oil Clean valve Replace pump or drive tighten oil line with proper weight
oil Replace bearings Clean or replace valve
Check spark plug condition ignition timing decarbon engine Tighten as required Align engine shaft propeller rudder Align engine Adjust packing nut
Clean Adjust valve tappets Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR valves
Free up by applying penetrating oil at valve stems cylinder head may have to be Defective spark plugs Improper ignition timing Engine carbon Engine
overheating BACKFIRING Inadequate fuel supply Improper ignition timing ROUGH ENGINE IDLE Broken valve spring Carburetor dirty or out of adjustment
Replace spring Clean and adjust carburetor See Chapter4 Fuel System Reset timing Clean adjust or replace plugs Reset timing Remove cylinder head and
decarbonize See Chapter 5 Cooling System
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR SYSTEMS One of the most important in any engine installation is the exhaust system which must permit the exhaust gasses to
be released as quietly and efficiently as possible minimize backpressure and prevent water from entering and reaching the engine itself In addition
the exhaust must be kept cool despite the high operating temperatures of the engine A compact and easily serviced system is desirable because of the
restricted space encountered in most sailboats In most installations cooling water is discharged after mixing with the exhaust gasses thus aiding in
keeping the exhaust system cool The waterlift type system see Figure 35 is now almost exclusively used due to the advantages of being simple to
install and repair and its adaptability to most vessels Where possible the muffler should be located close to and below the engine to minimize the
amount of dry exhaust required but in some cases this is not possible and a longer length of asbestos wrapped exhaust pipe must be used It should be
noted that the waterlift muffler is restricted in the vertical distance that the cooling water can be lifted ENGINE ALIGNMENT Proper alignment of your
engine and drive shaft is essential to keep vibration and noise to a minimum and to reduce engine loading and wear In extreme cases of misalignment
the rear seal of the transmission or reduction gear can fail causing a significant oil leak To determine if an alignment problem exists it is
necessary to separate the engineshaft coupling halves and check the clearances between the two halves at the top and bottom and from side to side
using a feeler gauge From these measurements it is possible to determine to what extent the propeller or engine output shafts or coupling faces are
outoftrue and how much the engine needs to be moved on its mounts to achieve optimum alignment Any of these three conditions may cause noise and
vibration 1 2 3 true shaft couplings engine misaligned bent propeller shaft outof true ATOMIC FOUR
OWNERS SERVICE AND REPAIR 35 TYPICAL EXHAUST SYSTEM In the first case the misalignment can be corrected by shifting the engine to bring the
differences measured across the flange faces to as near zero as possible In the second case lining up the engine with an outof true shaft will result
in some remaining vibration or shaft whip which can only be removed by correcting the bent shaft An outoftrue coupling must be corrected to reduce the
problem The objective should be to achieve a measured misalignment of no more than 0005 per inch of coupling diameter including of shafts or
couplings ie 002 for a four inch diameter coupling To determine the degree of engine misalignment and out oftrueness of shafts and couplings it is
necessary to mark the couplings measure and record coupling clearances calculate the vertical and horizontal misalignment and outof trueness determine
the trueness of the flange faces and realign the engine and shaft to within acceptable limits The first step is to reduce the misalignment as much as
possible Mark the two flanges on the outer edges to provide reference points Using a feeler gauge measure the clearance between the flanges at top
bottom and each side and record the measurements The engine misalignment can now be corrected by shifting the engine on its bed and placing shims
where required By rotating the propeller flange and taking measurements at 90 degree increments any shaft or flange face outof trueness can be
detected Engine output shaft bind or flange misalignment can also be discovered by rotating the engine flange and taking measurements If the is found
to be excessive greater than 002 coupling flanges andor the propeller shaft should be ATOMIC FOUR
OWNERS SERVICE AND REPAIR SELECTION In order to obtain optimum performance from your engine the correct sized propeller must he installed Incorrectly
sized propellers produce cavitation and a substantial loss in thrust Propellers are identified by diameter and pitch with diameter measured at the tip
of the propeller and pitch the distance travelled in one revolution of the propeller disregarding slippage For auxiliary sailboats slippage may be
assumed to be approximately 50 For 2bladed propellers the diameter should be increased by at least 5 Engines with a 21 reduction gear require a larger
diameter propeller to compensate for the slowturning propeller shaft Note that propeller rotation for all engines with and without reduction units is
righthand Suggested propeller sizes for medium displacement auxiliaries are shown below PROPELLER SHAFT The minimum propeller shaft size should be 1
diameter for bronze or steel or 34 diameter if Monel is used If the propeller shaft is over 5 feet long an intermediate shaft bearing may be required
A zinc anode should be attached to the shaft close to the propeller to protect both against corrosion PROPELLER SHAFT STUFFING BOX In order to seal
the opening where the propeller shaft penetrates the hull an adjustable stuffing box is installed The stuffing box usually consists of a hollow tube
mounted in the bull through which the propeller shaft passes After the shaft is installed the box is packed with three or four rings of suitable sized
flax packing and the packing nut tightened by hand After the packing nut is handtight turn an additional halfturn with a wrench Do not tighten further
or the packing may be crushed With the engine running and shaft turning check the stuffing box for leakage There should be a slow drip Periodically
inspect the stuffing box and adjust the packing nut as necessary to maintain a slight drip When the packing nut can no longer be tightened to provide
a slow leak the packing must be renewed With proper care shaft packing should last two or three ATOMIC FOUR
OWNERS SERVICE AND REPAIR Extra care must be taken when refueling and especially when restarting the engine after taking on fuel or when the boat has
been left for an extended period Prior to fueling make sure that there are no open flames such as stoves or cigarettes If possible attempt to position
the boat so that the fill point is leeward of the companionway so that fumes will be blown away from the boat Keep the nozzle of the Gasoline hose in
contact with the fill pipe to prevent a possible static electric spark Clean up any fuel spills immediately After fueling is completed run the engine
room blower for at least five minutes When the ambient humidity is high and there are light breezes the danger of fumes accumulating in or around the
boat is greater Open the engine compartment and smell for fumes in the bilge before starting the engine
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR SPARE PARTS The extent of spare parts that should be carried on board will depend on the type of sailing done and the
degree of that the owner wishes to have Vessels used primarily in protected or coastal waters near urban centres will carry fewer spare parts than
those on long trips for instance on the Intracoastal Waterway or away from areas where parts distributors are numerous eg the Carribean Islands Mexico
etc A spare parts kits is available from dealers containing the minimum spares that should be carried aboard This kit contains the following breaker
points distributor cap spark plugs condenser alternator drive belt thermostat housing gasket water pump impeller and gasket fuel pump filter electric
pump 1 set 1 4 1 1 1 1 each 1
In addition to the spare parts list the following parts are recommended for vessels on extended trips ignition coil 1 engine crankcase oil 4 quarts
fuel pump 1 oil pressure switch 1 for electric fuel pumps instrument panel fuses 2 fuse starter 35 amp water pump complete 1 water pump grease 1 pint
thermostat 1 carburetor overhaul kit 1 head gaskets 2 manifold gasket 1 38 hose 3 feet high tension wire set 1 oil pump gear set 1 hand crank 1
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR MANUAL
TOOLS A basic tool kit should include at least the following to enable the owner to carry out necessary maintenance and repairs set of open end or box
wrenches 38 to 78 spark plug wrench several screwdrivers various sizes set of feeler gauges locking grip pliers long nose pliers adjustable openend
wrench hammer oil can special snapring pliers for Oberdorfer water pump impeller retaining ring OPTIONAL TOOLS 38 ratchet drive and sockets torque
wrench 075 ft lbs wire cutters electrical multimeter set of Allan setscrew wrenches 18 to 58 cold chisel
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR GENERAL Model Type Number of Cylinders Bore and Stroke Total Piston Displacement Brake Horsepower Compression Ratio Firing
Order Fuel Engine Idle rpm Engine Rotation Output Shaft Rotation Maximum Operating drive 5102 Reduction drive 21 5103 Vdrive with reduction
Vertical InLine 4stroke LHead Four 2562 x 3375 inches 6446 cubic inches 303500 rpm 631 1243 Regular grade gasoline 9294 Octane 6001000 rpm when
viewed from flywheel end all models 1215 degrees fore and AND CLEARANCES Spark Plug Gap Ignition Timing Distributor Point Gap Magneto Point Gap
Valve Tappet Clearance Valve Sequence from No I cylinder Alternator Drive Belt Main Bearing Journal Diameter Connecting Rod Journal Diameter Main
Bearing ClearanceOn Crankshaft Connecting Rod Bearing Clearance Connecting Rod Bore Large End Crankshaft End Play Connecting Rod End Play Camshaft
Bearing Journal Camshaft Bearing Clearance Cylinder Bore 035 inches Champion RJ814 mm Breaker points starting to open at TDC Top Dead Centre 018 to
020 inches 014 to 018 inches Intake 008 Hot 010Cold Exhaust 010 Hot 012Cold Exh Int Int Exh 375 in max depression between Tension pulleys 19880
0050000 15625 00000005 001 to 0025 002 to 0025 16678 to 16687 002 to 003 At Front Bearing Only 004 to 008 Instal wNo on Rod Toward Camshaft 12745
0005 0000 0015 to0025 Reamed after Installation 2562 to 2563 Diameter Hone Finish Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR pistons with arrow pointing to transmission end Instal compression rings with groove side up Top of Piston Piston Ring Side
Clearance Width Compression Ring Top Compression Ring Center Oil Ring Piston Ring Gap Clearance Piston Skirt Clearance Piston Pin Size Piston Pin
Clearance in Piston Valve Seat Angle Valve Seat Width Valve Stem Size Valve Stem Clearance In Guide Oil Pump Drive End Play Off Pump Gear Back Lash
Camshaft Gear Back Lash Idler Gear Back Lash Accessory Gear Back Lash TORQUE DATA Cylinder Head Stud Nuts Manifold Stud Nuts Connecting Rod Bolt Nuts
Flywheel Stud Nuts Main Bearing Nuts front and rear Spark Plug MISCELLANEOUS DATA Exhaust Flange Water Inlet Water Outlet Fuel Pump Connection Fuel
Line 114 NPT National Pipe Thread Size 38 NPT 38 NPT 18 NPT 516 OD copper tubing 35 ft lbs Engine Hot 35 ft lbs Engine Hot 25 ft lbs 35 ft lbs 60 ft
lbs 30 ft lbs 0015 to003 001 to 0025 001 to 0025 007 to 015 0015 Feeler to 5 lbs pull 6380 Standard 001 to 002 45 degrees 132 3120 to 3115 002 to 003
001 to 003 003 to 005 002 to 004 002 to 004 002 to 004
Page ATOMIC FOUR
OWNERS SERVICE AND REPAIR AND UNDERSIZE COMPONENTS AVAILABLE Main Bearing Set 010 Undersize 020 Undersize 030 Undersize 010 Undersize 020 Undersize
030 Undersize 010 Oversize 020 Oversize 030 Oversize 010 Oversize 020 Oversize 030 Oversize 005 Oversize 010 Oversize 015 Rod Bearing Set
Piston Ring Set
Piston WPin
Piston Pin
SERIAL NUMBER LOCATIONS On engine nameplate located on engine flywheel cover or manifold Stamped in block directly above flywheel housing under front
oil filter Stamped on upper left hand corner of block ignition side
Page 108

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The information on this web site has not been checked for accuracy. It is for entertainment purposes only and should be independently verified before using for any other reason. There are five sources. 1) Documents and manuals from a variety of sources. These have not been checked for accuracy and in many cases have not even been read by anyone associated with L-36.com. I have no idea of they are useful or accurate, I leave that to the reader. 2) Articles others have written and submitted. If you have questions on these, please contact the author. 3) Articles that represent my personal opinions. These are intended to promote thought and for entertainment. These are not intended to be fact, they are my opinions. 4) Small programs that generate result presented on a web page. Like any computer program, these may and in some cases do have errors. Almost all of these also make simplifying assumptions so they are not totally accurate even if there are no errors. Please verify all results. 5) Weather information is from numerious of sources and is presented automatically. It is not checked for accuracy either by anyone at L-36.com or by the source which is typically the US Government. See the NOAA web site for their disclaimer. Finally, tide and current data on this site is from 2007 and 2008 data bases, which may contain even older data. Changes in harbors due to building or dredging change tides and currents and for that reason many of the locations presented are no longer supported by newer data bases. For example, there is very little tidal current data in newer data bases so current data is likely wrong to some extent. This data is NOT FOR NAVIGATION. See the XTide disclaimer for details. In addition, tide and current are influenced by storms, river flow, and other factors beyond the ability of any predictive program.