Sears/Clinton 3.5 HP Outboard Service Info--Points, Impeller, and Manuals

atucker1

Seaman Apprentice
Joined
Jul 19, 2014
Messages
40
Just wanted to post some info on the 1960's Sears/Clinton 3.5 Hp motors that I see around a lot. I just sold mine so I wrote this all up for the new owner. Hope it helps someone!


Service and Operation Info


Operation:
1. Fill gas tank with premixed 24:1 gas:eek:il mixture (use TCW-3 outboard motor oil)
2. Ensure motor is in water with the water level about an inch below the 4 holes on the lower unit
3. Connect rubber hose to the adapter below the control panel on the motor
4. Pump in-line fuel bulb until hard
5. Place throttle at "Start" position and choke about halfway
6. Pull like hell
7. If it doesn't start in a few pulls try adjusting the choke both directions. Sometimes pulling on full choke and then again on half choke seems to do the trick for some reason
-Note: the outboard starts in gear, you can turn it around to reverse
-After running in salt water, make sure to flush motor by running in clean tank
-Make sure that whenever the motor is running, spray is felt coming out of the 4 holes right above the water on the lower unit. This is the cooling circuit outlet and if no water is running through, the motor could be damaged by continued operation. When running in a lake and the motor is moving, the spray will be clearly visible. In a tank the spray might be hard to see but you should be able to feel it with your hand.
-Starting fluid is not recommended for two strokes since it usually does not have oil in it and would therefore lead to motor damage. You may be able to find two-stroke-specific starting fluid and that should be okay to use.

Service:
-See attached manual and parts list for specifications and service information
-Motor is essentially a 1965 J5 except sold by Sears and tuned to 3.5 instead of 3 or 5 hp
-Recommend yearly lower unit gear oil change, reset points, and change spark plug
-Change impeller as needed, available here: http://www.boatsportandtackle.com/water-pump-impeller-and-pin-eska-96616-also-fits-clinton-engines/

Setting points:
1. Remove the two screws holding the plastic cover and flywheel assembly and remove cover
2. Remove metal housing on top of engine (4 screws)
3. Use strap wrench to hold flywheel steady
4. Remove flywheel bolt
5. Place a screwdriver under the edge of the flywheel and gently pry up. While holding tension on the flywheel, tap the top of the crankshaft with a hammer. Flywheel should pop free. Remove flywheel.
6. Under flywheel, open the points box and clean the points by dragging a strip of paper grocery bag between them.
7. Set point gap to 0.020 inches using the points box cover as a gauge. Turn the crankshaft until the points are fully open (cam on crankshaft will engage the arm on the points, opening the gap). Set gap to 0.020 inches and tighten down points carefully (will try to move as you tighten).
8. Replace points box cover
9. Replace flywheel and tighten bolt to 30 lb-ft
10. Replace metal cover and 4 screws
11. Replace plastic cover and pull-start assembly, replace screws

Replacing impeller (recently done, probably don't need to worry about for a couple of years):
1. Remove lower unit screw right near the exhaust port.
2. Remove the metal clip on the front of the lower unit near the exhaust port, right next to the water intake holes
3. Remove the nut under this metal clip
4. Pull the lower unit off of the motor
5. Unscrew the two bolts holding the water pump housing onto the gearcase
6. Remove water pump housing
7. Tap out the roll pin in the middle of the impeller with a hammer and punch
8. Remove impeller, noting blade orientation direction
9. Replace with new impeller and tap in new roll pin
10. Replace water pump housing, turning it to fit over water pump impeller blades with correct orientation
11. Replace bolts
12. Place lower unit back onto the outboard, taking care to line up both the splines of the crankshaft in the powerhead and the water tube into the receiving end of the powerhead water tube
13. Replace screw and bolt on the lower unit and the metal clip covering the bolt
 

Attachments

  • clinton manual.pdf
    780.4 KB · Views: 32
  • IMG_6759.JPG
    IMG_6759.JPG
    1.1 MB · Views: 12

RCO

Petty Officer 1st Class
Joined
Jun 15, 2016
Messages
350
Most people would recommend that you use TC (chainsaw/small engine) rated oil, not TC-W3 in that motor. The powerhead is air cooled, and TCW-3 oil is designed for the much cooler operating temperatures of water cooled engines. The impeller only cools the exhaust leg .
 
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