1986 Four Winns 190 Horizon Repair Manual

The 1986 Four Winns 190 Horizon is a classic 19-foot bowrider boat featuring a deep-V hull design, comfortable seating for 8 passengers, and various engine options including OMC and Volvo Penta stern drives. This comprehensive repair manual covers maintenance procedures, troubleshooting, engine systems, electrical systems, hull repair, and safety information for proper upkeep and restoration of your vessel.

1. General Information 2. Safety Precautions 3. Engine Systems 4. Electrical Systems 5. Hull & Deck Repair 6. Steering & Controls 7. Fuel System 8. Cooling System 9. Propulsion System 10. Maintenance Schedule 11. Troubleshooting

General Information

Basic specifications and identification details for the 1986 Four Winns 190 Horizon.

Specification	Details
Length Overall	19' 2" (5.84 m)
Beam	7' 6" (2.29 m)
Weight (approx.)	2,350 lbs (1,066 kg)
Maximum Capacity	8 persons or 1,450 lbs (658 kg)
Fuel Capacity	28 gallons (106 liters)
Hull Type	Deep-V with 19-degree deadrise
Standard Engine	OMC 3.0L or Volvo Penta AQ131
Hull Identification Number	Located on starboard transom

Safety Precautions

Essential safety procedures for working on your Four Winns 190 Horizon.

Always disconnect battery before electrical work.
Work in well-ventilated area when handling fuel.
Use proper lifting equipment for engine removal.
Wear safety glasses and gloves during repairs.
Ensure boat is properly supported on trailer or blocks.

WARNING! Gasoline fumes are explosive. Always work in ventilated areas and avoid sparks or open flames near fuel system.

Engine Systems

Repair and maintenance procedures for OMC and Volvo Penta engine options.

Engine removal: Disconnect fuel lines, electrical, and steering cables.
Tune-up procedures: Spark plugs, points, condenser replacement.
Carburetor adjustment: Float level and mixture settings.
Ignition system: Distributor timing and advance mechanisms.
Compression testing: Acceptable range 120-150 psi.

CAUTION! Always relieve fuel pressure before disconnecting fuel lines. Have fire extinguisher nearby.

Electrical Systems

Battery: Group 24 or 27 marine starting battery.
Charging System: 40-55 amp alternator with voltage regulator.
Wiring: Color-coded marine grade tinned copper.
Fuses: ATC blade fuses in waterproof holders.
Navigation Lights: Bow and stern lights, 20W maximum.
Bilge Pump: Automatic float switch with manual override.
Instrumentation: Speedometer, tachometer, fuel gauge, temperature.

Hull & Deck Repair

Fiberglass repair procedures for common damage types.

Materials needed: Fiberglass cloth, resin, hardener, gelcoat, mixing tools, sandpaper.

Small crack repair: Grind V-groove, apply resin and cloth, sand smooth. Gelcoat blister repair: Grind out blisters, dry thoroughly, fill with epoxy, re-gelcoat. Deck hardware rebedding: Remove old sealant, clean surfaces, apply marine sealant, reinstall.

Steering & Controls

Maintenance and repair of mechanical steering system and control cables.

Steering cable replacement: Measure exact length, order correct part.
Control box disassembly: Remove bezel, inspect internal mechanisms.
Cable lubrication: Use marine-grade grease on pivot points.
Shift cable adjustment: Ensure proper engagement in forward/neutral/reverse.
Steering wheel removal: Use puller tool to avoid damage.

Tip: Always use anti-seize compound on stainless steel threads.

Fuel System

Fuel tank, lines, and carburetor maintenance procedures.

Fuel tank inspection: Check for corrosion and proper venting.
Fuel line replacement: Use USCG approved hose and clamps.
Fuel filter service: Replace water-separating filter annually.
Fuel pump testing: Check pressure and volume specifications.
Carburetor rebuild: Complete disassembly and cleaning.
Fuel tank sending unit: Test ohms reading (empty: 240Ω, full: 33Ω).

WARNING! Gasoline is highly flammable. No smoking or open flames during fuel system work.

Cooling System

Raw water and closed cooling system maintenance.

Propulsion System

Stern drive unit maintenance and repair procedures.

Component	Maintenance Interval	Procedure
Outdrive Oil	Every 100 hours or annually	Drain and refill with marine gear lube
Gimbal Bearing	Inspect annually	Check for smooth rotation, no play
U-Joints	Inspect annually	Check for wear and proper lubrication
Propeller	Inspect monthly	Check for damage and secure mounting
Trim System	Test monthly	Check fluid level and operation

Maintenance Schedule

Regular maintenance tasks to keep your Four Winns in optimal condition.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Dead battery, bad starter, fuel issue	Check battery voltage, fuel delivery, spark
Overheating	Clogged water intake, bad impeller	Check water flow, replace impeller
Poor performance	Fouled plugs, dirty fuel filter	Replace plugs, clean fuel system
Electrical failure	Blown fuse, corroded connections	Check fuses, clean battery terminals
Steering stiffness	Bad cable, lack of lubrication	Lubricate or replace steering cable

Technical Support: Contact Four Winns customer service at 1-800-416-7447

Parts: Genuine Four Winns parts available through authorized dealers