Policy & Terms of use

Back to Library
Show Menu
Hide Menu

|

Boatinfo requires FlashPlayer 9 or newer to display this document!

Get Adobe Flash player



115 FourStroke Electronic Fuel Injection Starting Model Year 2001 Starting Serial Number 0T178500 Starting Model Year 2001 115 FourStroke EFI 90-881980R1 NOVEMBER 2001 Notice Throughout this publication, “Dangers”, “Warnings” and “Cautions” (accompanied by the International HAZARD Symbol ) are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. OBSERVE THEM CAREFULLY! These “Safety Alerts” alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus “Common Sense” operation, are major accident prevention measures. DANGER DANGER - Immediate hazards which WILL result in severe personal injury or death. WARNING WARNING -Hazards or unsafe practices which COULD result in severe personal injury or death. CAUTION Hazards or unsafe practices which could result in minor personal injury or product or property damage. Notice to Users of This Manual This service manual has been written and published by the Service Department of Mercury Marine to aid our dealers’ mechanics and company service personnel when servicing the products described herein. It is assumed that these personnel are familiar with the servicing procedures of these products, or like or similar products manufactured and marketed by Mercury Marine, that they have been trained in the recommended servicing procedures of these products which includes the use of mechanics’ common hand tools and the special Mercury Marine or recommended tools from other suppliers. We could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of the possible hazards and/or results of each method. We have not undertaken any such wide evaluation. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered by the service procedure selected. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service these products. It should be kept in mind, while working on the product, that the electrical system and ignition system are capable of violent and damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables should be disconnected at the battery. Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive internal damage when the engine is started. 90-881980R1 NOVEMBER 2001 Page i It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Mismatched or incorrect fasteners can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the same locations whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original. Cleanliness and Care of Outboard Motor A marine power product is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten thousands of an inch/mm. When any product component is serviced, care and cleanliness are important. Throughout this manual, it should be understood that proper cleaning, and protection of machined surfaces and friction areas is a part of the repair procedure. This is considered standard shop practice even if not specifically stated. Whenever components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed. Personnel should not work on or under an outboard which is suspended. Outboards should be attached to work stands, or lowered to ground as soon as possible. We reserve the right to make changes to this manual without prior notification. Refer to dealer service bulletins for other pertinent information concerning the products described in this manual. EXAMPLE: 90-826148R1 JANUARY 1996 Page 6A-7 Revision No. 1 Month of Printing Year of Printing Section Number Part of Section Letter Page Number Page ii 90-881980R1 NOVEMBER 2001 Service Manual Outline Section 1 - Important Information A - Specifications B - Maintenance C - General Information D - Outboard Motor Installation Section 2 - Electrical A - Ignition B - Charging & Starting System C - Timing, Synchronizing & Adjusting Section 3 - Electronic Fuel Injection A - Theory of Operation B - Diagnostics & Troubleshooting C - Service Procedures D - Emissions Section 4 - Powerhead A - Cylinder Head B - Cylinder Block/Crankcase C - Lubrication Section 5 - Mid-Section A - Clamp/Swivel Brackets & Drive Shaft Housing B - Power Trim Section 6 - Lower Unit A - Gear Housing Section 7 - Attachments/Control Linkage A - Throttle/Shift Linkage Section 8 - Color Diagrams Important Information Electrical Electronic Fuel Injection Powerhead Mid-Section Lower Unit Attachments/ Control Linkage Color Diagrams 90-881980R1 NOVEMBER 2001 Page iii SPECIFICATIONS IMPORTANT INFORMATION Section 1A - Specifications Table of Contents 1 A Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1 Mercury/Quicksilver Lubricants Propeller Information Charts . . . . . . . . . . . . . . 1A-9 and Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-10 Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-12 Specifications Models 115 EFI (4-Stroke) PERFORMANCE Horsepower: Model 115 Wide Open Throttle (WOT) rpm Range 115 hp (85.8 Kw) @ 5500 rpm 5000 - 6000 OUTBOARD WEIGHT Electric 115 EFI ELPT 386 lb (175 kg) FUEL Recommended Gasoline Automotive Unleaded with a Minimum Pump Posted Octane Rating of 87 Oil Filter Oil Filter Wrench Engine Oil Capacity Engine Oil F° C° SAE 10W-30 SAE 25W-40 p/n 35-822626A2 p/n 91-802653Q1 Either 5 Quarts or 5 Liters SAE 10W-30 viscosity oil is recommended for use in all temperatures. SAE 25W-40 viscosity oil may be used at temperatures above 40° F (4° C). OIL +20 +40 +60 +80 0 +100 –7 +4 +16 +27 –18 +38Use Mercury/Quicksilver 4-Cycle Marine Oil with the proper viscosity for the expected temperature in your area (see range thermometer on left). If not available, use a premium quality 4-cycle engine oil certified to meet or exceed any one of the following American Petroleum Institute (API) service classifications SH, SG, SF, CF-4, CE, CD, CDll. 90-881980R1 NOVEMBER 2001 Page 1A-1 SPECIFICATIONS IGNITION SYSTEM Readings taken @ 68°F (20°C). Type Spark Plug: Type Gap Hex Size Torque Hole Size Firing Order Ignition Timing: @ Idle (750 rpm) in Neutral @ WOT (6000 rpm) Stator Coil Output - Peak Voltage: @ 400 rpm (Cranking) @ 750 rpm (Idle) @ 1500 rpm @ 3500 rpm Stator Coil Resistance Crank Position Sensor - Peak Voltage: @ 400 rpm (Cranking) @ 750 rpm (Idle) @ 1500 rpm @ 3500 rpm Crank Position Sensor Resistance ECM (Coil Primary) - Peak Voltage: @ 400 rpm (Cranking) @ 750 rpm (Idle) @ 1500 rpm @ 3500 rpm Ignition Coil Resistance Primary Secondary (Between Boots) Coil for Cylinders 1 & 4 Coil for Cylinders 2 & 3 Engine Protection Controls: Engine Speed Limiter Spark Cut-Out to Cylinders #1 or #4 #1 and #4 #1, #4, and #2 or #3 #1, #2, #3, and #4 Overheat/Low Oil Pressure Engine Speed Control (Spark Cut-Out to Cylinders #1 and #4). Water Temperature Sensor: Warning Horn/rpm Reduction. Reset Temperature and Closed Throttle. Engine Oil Pressure Switch: Warning Horn/rpm Reduction Microcomputer-ECM NGK LFR6A-11 0.039 - 0.043 in. (1.0 - 1.1 mm) 5/8 in. (16 mm) 18 lb-ft (25 Nm) 14 mm 1-3-4-2 4° A.T.D.C 20° B.T.D.C 10 - 18 V 16 - 24 V 16 - 24 V 16 - 24 V 0.2 - 0.8 W 3.0 -6.3 V 9 - 16 V 18 - 28 V 35 - 55 V 445 - 565 W 180 - 320 V 180 - 235 V 230 -290 V 280 - 340 V 1.8 - 2.6 W 18.97 - 35.23 kW 18.55 - 34.45 kW 6200 rpm 6250 rpm 6350 rpm 6450 rpm Gradually Lowers to 2000 rpm 194°F (90°C) 167°F (75°C) Continuity Below 21.78 psi (150 kPa) Page 1A-2 90-881980R1 NOVEMBER 2001 SPECIFICATIONS Reset Pressure and Closed IGNITION Throttle. Engine Water Temperature Sensor Resistance: No Continuity Above 21.78 psi (150 kPa) SYSTEM @ 41°F (5°C) 4.62 kW Readings taken @ @ 68°F (20°C) 2.44 kW 68°F (20°C). @ 212°F (100°C) Throttle Position Sensor (TPS): 0.19 kW Input Voltage @ Idle (750 rpm) 5.0 ± 0.25 V Output [email protected] Idle (750 rpm) 0.718 - 0.746 V CHARGING SYSTEM Readings taken @ 68°F (20°C). Alternator Type: Alternator Output Stator Coil - Peak Voltage: @ 400 rpm (Cranking) @ 750 rpm (Idle) @ 1500 rpm @ 3500 rpm Stator Coil Resistance Rectifier/Regulator Output - Peak Voltage: @ 750 rpm (Idle) @ 1500 rpm @ 3500 rpm Quicksilver Tachometer Setting Three Phase Stator Coil (12 Pole) 12.0 V; 25 Amps. (300 Watts) (Rectified/Regulated) 10 - 18 V 16 - 24 V 16 - 24 V 16 - 24 V 0.2 - 0.8 W 12.5 - 15.5 V 13.0 - 16.0 V 13.0 - 16.0 V “6P” or “4” STARTING SYSTEM Electric Start: Starter Type Model/Manufacturer Output Rating Reduction Gear Ratio Brush: Length Minimum Length Commutator: Sliding Gear S114-838A/Hitachi 1.4 kW - 12 V 30 Seconds 7.85 (102:13) 0.610 in. (15.5 mm) 0.374 in. (9.5 mm) Diameter Minimum Diameter Undercut Undercut Limit Ampere Draw Under: (Load) (No Load) 1.113 in. (29.0 mm) 1.100 in. (28.0 mm) 0.020 in. (0.5 mm) 0.008 in. (0.2 mm) 165 Amps 80 Amps Battery Rating Minimum Requirement 465 Marine Cranking Amps (MCA) BATTERY For operation below 32° F (0° C) or 350 Cold Cranking Amps (CCA) 1000 Marine Cranking Amps (MCA) or 775 Cold Cranking Amps (CCA) Ampere-Hours (Ah) 70 - 100 FUEL SYSTEM Fuel Pump Type Fuel Pump: Discharge (@ 3000 rpm) Pressure (Maximum) Plunger Stroke Fuel Tank Capacity External (Plunger/Diaphragm) 17 gph (65 L/h) 7 psi (49 kPa) 0.23 - 0.36 in. (5.85 - 9.05 mm) Accessory 90-881980R1 NOVEMBER 2001 Page 1A-3 SPECIFICATIONS FUEL INJECTION Fuel Injection System Idle rpm (In Neutral) Warm Idle rpm (In Forward Gear) Warm Fuel Pressure @ 1500rpm Batch (1 & 4) - (2 & 3) 750 ± 50 rpm 700 ± 50 rpm 41-44 psi (283-304 kPa) CYLINDER BLOCK Type Displacement Number of Cylinders In–Line, 4 Stroke – DOHC, 16 Valves 106.2 cid (1,741 cc) 4 STROKE Length 3.496 in. (88.8 mm) CYLINDER BORE Diameter Standard Oversize-0.010 in. (0.25 mm) Taper/Out of Round Maximum Bore Type 3.110 - 3.111 in. (79.000 - 79.020 mm) 3.120 - 3.121 in. (79.250 - 79.270 mm) 0.003 in. (0.08 mm) Cast Iron PISTON Piston Type Measure Point (H) O.D. at Skirt (H) Standard (D) Oversize-0.010 in. (0.25 mm) Pin Boss Inside Diameter Aluminum 0.51 in. (13 mm) 3.1074 - 3.1082 in. (78.928 - 78.949 mm) 3.1174 - 3.1182 in. (79.178 - 79.199 mm) 0.7090 - 0.7093 in. (18.008 - 18.015 mm) H D PISTON CLEARANCE Piston to Cylinder Clearance 0.0028 - .0031 in. (0.070 - 0.080 mm) Top Ring Dimension “B” B 0.046 - 0.047 in. (1.17 - 1.19 mm) Dimension “T” 0.114 - 0.115 in. (2.89 - 2.91 mm) End Gap (Installed) Side Clearance T 0.006 - 0.012 in. (0.15 - 0.30 mm) 0.001 - 0.003 in. (0.03 - 0.08 mm) Middle Ring Dimension “B” 0.058 - 0.059 in. (1.47 - 1.49 mm) RINGS Dimension “T” End Gap (Installed) B 0.118 - 0.126 in. (3.00 - 3.20 mm) 0.028 - 0.035 in. (0.70 - 0.90 mm) Side Clearance Bottom (Oil Ring) T 0.001 - 0.003 in. (0.03 - 0.08 mm) Dimension “B” 0.094 - 0.098 in. (2.38 - 2.48 mm) Dimension “T” 0.094 in. (2.40 mm) End Gap (Installed) Side Clearance B 0.008 - 0.028 in. (0.20 - 0.70 mm) 0.001 - 0.006 in. (0.03 - 0.15 mm) T COMPRESSION RATIO Compression Ratio Cylinder Compression (Minimum) 9.7:1 138 psi (950 kPa) PISTON PIN Piston Pin Outside Diameter 0.7085 - 0.7087 in. (17.997 - 18.000 mm) Page 1A-4 90-881980R1 NOVEMBER 2001 SPECIFICATIONS Small End Inside Diameter 0.7073 - 0.7081 in. (17.965 - 17.985 mm) Big End Inside Diameter 1.7726 - 1.7734 in. (45.025 - 45.045 mm) CONNECTING Oil Clearance (Big End) Big End Bearing Thickness 0.0010 - 0.0012 in. (0.025 - 0.031 mm) ROD Yellow 0.0591 - 0.0594 in. (1.502 -1.508 mm) Green 0.0594 - 0.0596 in. (1.508 - 1.514 mm) Blue 0.0596 - 0.0598 in. (1.514 - 1.520 mm) Red 0.0598 - 0.0601 in. (1.520 - 1.526 mm) Crankshaft Journal Diameter 1.8891 - 1.8898 in. (47.984 - 48.000 mm) Minimum Diameter Crankshaft Pin 1.8887 in. (47.972 mm) Diameter 1.6535 - 1.6528 in. (42.000 - 41.982 mm) CRANKSHAFT Minimum Diameter 1.7311 in. (43.971 mm) Crankshaft Run-out 0.001 in. (0.03 mm) Crankcase Main Journal Inside Diameter 2.1269 - 2.1276 in. (54.023 - 54.042 mm) Crankshaft Journal Oil Clearance Upper Crankcase Main Journal Bearing Thickness 0.0009 - 0.0017 in. (0.024 - 0.044 mm) Green 0.1178 - 0.1181 in. (2.992 - 2.999 mm) Blue 0.1181 - 0.1183 in. (2.999 - 3.006 mm) CRANKCASE Red Lower Crankcase Main Journal Bearing Thickness 0.1183 - 0.1186 in. (3.006 - 3.013 mm) Yellow 0.1185 -0.1188 in. (3.010 - 3.017 mm) Green 0.1188 - 0.1191 in. (3.017- 3.024 mm) Blue 0.1191 - 0.1193 in. (3.024 - 3.031 mm) Red No. 3 Main Journal Bearing Thickness 0.1193 - 0.1196 in. (3.031 - 3.038 mm) Green 0.1178 - 0.1181 in. (2.992 - 2.999 mm) Blue 0.1181 - 0.1183 in. (2.999 - 3.006 mm) Red 0.1183 - 0.1186 in. (3.006 - 3.013 mm) 90-881980R1 NOVEMBER 2001 Page 1A-5 SPECIFICATIONS Camshaft Dimensions Intake “A” 1.465 - 1.472 in. (37.22 - 37.38 mm) Exhaust “A” 1.453 - 1.459 in. (36.90 - 37.06 mm) Intake “B” A 1.178 - 1.184 in. (29.92 - 30.08 mm) Exhaust “B” Valve Lift 1.178 - 1.184 in. (29.92 - 30.08 mm) Intake 0.287 in. (7.30 mm) CAMSHAFT Exhaust Run-out Limit B 0.275 in. (6.98 mm) 0.004 in. (0.1 mm) Camshaft Bearing Diameter “a” 0.9827 - 0.9835 in. (24.96 - 24.98 mm) Camshaft Bearing Oil Clearance 0.0008-0.0024 in.(0.020-0.061 mm) A Free Length “a” 2.094 in. (53.20 mm) Minimum Free Length 2.057 in. (52.25 mm) VALVE SPRING Tilt Limit “b” a b Less than 0.10 in. (2.6 mm) Warp Limit 0.004 in. (0.1 mm) CYLINDER HEAD Camshaft Bearing Inside Diameter a 0.984 - 0.985 in. (25.000 - 25.021 mm) Valve Lifter Bore Inside Diameter 1.102 - 1.103 in. (28.000 - 28.021 mm) Page 1A-6 90-881980R1 NOVEMBER 2001 SPECIFICATIONS Valve/Valve Seat/Valve Guides: Valve Clearance (cold) Intake 0.007 - 0.009 in. (0.17 - 0.23 mm) Exhaust Valve Face Angle 0.012 - 0.014 in. (0.31 - 0.37 mm) Intake 120°, 91°, 110° Exhaust Valve Dimensions: “A” Head Diameter 140°, 91°, 110° Intake 1.142 - 1.150 in. (29.00 - 29.20 mm) Exhaust “B” Face Width 0.945 - 0.953 in. (24.00 - 24.20 mm) Intake 0.078 - 0.094 in. (1.98 - 2.40 mm) Exhaust “C” Seat Width 0.089 - 0.106 in. (2.26 - 2.69 mm) Intake 0.062 - 0.076 in. (1.58 - 1.94 mm) VALVES Exhaust “D” Margin Thickness 0.071 - 0.080 in. (1.80 - 2.02 mm) Intake 0.031 - 0.047 in. (0.80 - 1.20 mm) Exhaust Stem Outside Diameter 0.039 - 0.055 in. (1.00 - 1.40 mm) Intake 0.2352 - 0.2358 in. (5.975 - 5.990 mm) Exhaust Guide Inside Diameter 0.2346 - 0.2352 in. (5.960 - 5.975 mm) Intake 0.2364 - 0.2369 in. (6.005 - 6.018 mm) Exhaust Stem To Guide Clearance 0.2364 - 0.2369 in. (6.005 - 6.018 mm) Intake 0.0006 - 0.0017 in. (0.015 - 0.043 mm) Exhaust 0.0012 - 0.0023 in. (0.030 - 0.058 mm) Stem Run-out Limit (max.) 0.001 in. (0.03 mm) “A” “B” “C” “D” Valve Dimensions Head Diameter Face Width Seat Width Margin Thickness VALVE LIFTERS Valve Lifter Outside diameter Valve Lifter to Lifter Bore Clearance 1.1010 - 1.1016 in. (27.965 - 27.980 mm) 0.0008 - 0.0022 in. (0.020 -0.056 mm) VALVE SHIM Valve shim Thickness (in 0.025 mm increments) 0.0787 - 0.1299 in. (2.000 - 3.300 mm) THERMOSTAT Valve Opening Temperature Full Open Temperature Valve Lift (Minimum) 122° F (50° C) 140° F (60° C) 0.17 in. (4.3 mm) 90-881980R1 NOVEMBER 2001 Page 1A-7 SPECIFICATIONS LUBRICATION SYSTEM Pump Type Oil Pump Drive Discharge at 212°F (100°C) with 10W-30 Oil at 1000 rpm Engine Oil Pressure (Warm Engine) @ 750 rpm Engine Oil Pan Capacity Relief Valve Opening Pressure Oil Pump: Non-Serviceable Trochoid with Relief Valve Drive shaft Spline 1.56 gph (5.9 L/h) 50.75 psi (350 kPa) Either 5 Qts. or 5 Liters 71 psi (490 kPa) Recommended Transom Height: Short Shaft 20 in. (51 cm) MID-SECTION Long Shaft Steering Pivot Range 25 in. (64 cm) 60° Full Tilt Up Angle 71° Allowable Transom Thickness (Max) 3 in. (76.2 mm) GEAR HOUSING BIGFOOT (2.07:1) Gear Ratio Gearcase Capacity Lubricant Type Forward Gear Number of Teeth Pinion Gear Number of Teeth Pinion Height Pinion Gear Locating Tool Flat Number Disc Number Forward Gear Backlash Backlash Indicating Tool Mark Number Water Pressure @ 1000 rpm @ 6000 rpm (WOT) 2.07:1 24 fl oz (710 mL) Premium Gear Lubricant 29 Spiral/Bevel 14 Spiral/Bevel 0.025 in. (0.64 mm) 91-12349A2 #2 #3 0.015-0.022 in. (0.38-0.55 mm) 91-19660--1 #1 5 psi (34.5 kPa) 20.5 psi (141.5 kPa) Page 1A-8 90-881980R1 NOVEMBER 2001 SPECIFICATIONS Propeller Information Charts Mercury/Mariner 115 EFI (4-Stroke) 2.07:1 Wide Open Throttle RPM : 5000-6000 Recommended Transom Heights : 20 in. (50.8 cm), 25 in. (63.5 cm) Right Hand Rotation Standard Gear Reduction : 2.07:1 Diameter Pitch No. of Blades Material Approx. Gross Boat Wgt. (lbs) Approx. Boat Length Speed Range (mph) Propeller Part Number 13-1/2. 26. 3 Steel Up to 1700 Up to 17' 51-67 48-16996A45 13-1/2. 24. 3 Steel Up to 2000 Up to 18' 45-60 48-16994A45 12-1/2. 23. 3 Alum 1700-2400 16-18' 43-57 48-77350A45 13-1/2. 22. 3 Steel 1800-2600 16-18' 40-54 48-16992A45 12-3/4. 21. 3 Alum 2000-2800 16-19' 38-51 48-77348A45 13-1/4. 20. 3 Steel 2100-3100 17-19' 36-48 48-16990A45 13. 19. 3 Alum 2300-3400 17-19' 33-45 48-77346A45 13. 18. 3 Steel 2500-3700 18-20' 31-42 48-16988A45 13-1/4. 17. 3 Alum 2800-4100 18-21' 29-39 48-77344A45 13-1/8. 16. 3 Steel 3100-4500 19-22' 26-36 48-16986A45 13-1/4. 16. 3 Alum 3100-4500 19-22' 26-36 48-85360A45 13-3/4. 15. 3 Alum 3400-5000 19-23' 24-33 48-77342A45 13-3/8. 14. 3 Steel 3800-5700 21-25' 22-30 48-17314A45 14. 13. 3 Alum 4200-6400 22-26' 20-28 48-77340A45 14. 12. 3 Steel 5000+ pontoon 17-24 48-17312A45 14. 11. 3 Alum 6000+ pontoon/work 15-21 48-77338A45 14. 10. 3 Steel 8000+ houseboat/ work 1-19 48-17310A45 90-881980R1 NOVEMBER 2001 Page 1A-9 SPECIFICATIONS Mercury/Quicksilver Lubricants and Sealants Description Mercury Part Number Quicksilver Part Number Needle Bearing Assy. Lubricant [8 oz. (226.8 grams)] tube 92-802868A1 N/A Dielectric Grease [8 oz. (226.8 grams)] can 92-823506-1 92-823506-1 Loctite 271 – Thread Locker (10 ml) tube 92-809819 92-809819 Loctite 567 PST Pipe Sealant (50 ml) tube 92-809822 92-809822 Loctite Master Gasket Kit 92-12564-2 92-12564-2 2 Cycle Premium Outboard Oil [1 Gallon (3.7 liter)] 92-802815A1 92-802815Q1 Perfect Seal [16 oz. (0.45 kg)] can 92-34227-1 92-34227-1 Liquid Neoprene [8 oz. (226.8 grams)] can 92-25711-3 92-25711-3 Cyanacrylate Adhesive Obtain Locally Obtain Locally Bellows Adhesive N/A 92-86166Q1 Loctite 680 Retaining Compound (10 ml) tube 92-809833 92-809833 Loctite 222 Thread Locker (10 ml) tube 92-809818 92-809818 3M Permabond #3M08155 Obtain Locally Obtain Locally Loctite 242 Thread Locker (10 ml) tube 92-809821 92-809821 Loctite 609 Obtain Locally Obtain Locally Loctite 405 Obtain Locally Obtain Locally Page 1A-10 90-881980R1 NOVEMBER 2001 SPECIFICATIONS Description Mercury Part Number Quicksilver Part Number RTV 587 Silicone Sealer [3 oz. (85.05 grams)] 92-809825 92-809825 Loctite 262 Obtain Locally Obtain Locally Premium Gear Lubricant [1 Quart (0.94 liter)] 92-802846A1 92-802846Q1 Loctite 7649 Primer [4.5 oz (127.57 grams)] 92-809824 92-809824 Anti-Corrosion Grease [8 oz. (226.8 grams)] tube 92-802867A1 92-802867Q1 2-4-C with Teflon [8 oz. (226.8 grams)] tube 92-802859A1 92-802859Q1 Loctite Quick Tite Obtain Locally Obtain Locally Isopropyl Alcohol Obtain Locally Obtain Locally Hot Glue Obtain Locally Obtain Locally Special Lubricant 101 [8 oz. (226.8 grams)] tube 92-802865A1 92-802865Q1 4 Stroke 10W30 Outboard Oil [1 Quart (0.94 liter)] 92-802833A1 92-802833Q1 4 Cycle 25W40 Engine Oil [1 Quart (0.94 liter)] 92-802837A1 92-802837Q1 Power Trim & Steering Fluid [8 oz. (226.8 grams)] 92-802880A1 92-802880Q1 Engine Coupler Spline Grease [14 oz. (0.39 kg)] cartridge 92-802869A1 92-802869Q1 90-881980R1 NOVEMBER 2001 Page 1A-11 SPECIFICATIONS Torque Specifications Fastener Location DIameter x Length (mm) Torque lb-in. lb-ft. Nm ELECTRICAL Flywheel Cover Screw M6 x 20 70 8 Stator Screw M6 x 28 70 8 Flywheel Nut N/A 140 190 Belt Tensioner Screw N/A 29 40 Ignition Components Crank Position Sensor Mounting Screw N/A 43 5 Voltage Regulator/Rectifier Mounting Screw M6 x 25 70 8 ECM Mounting Screw M6 x 28 70 8 Coil Mounting Screw M6 x 25 70 8 Spark Plug Cover Screw M6 x 16 70 8 Water Temperature Sensor Screw M6 x 16 70 8 Charging and Starting System Starter Through Screw M6 x 120 70 8 Starter Solenoid Screw M6 x 52 70 8 Solenoid - Spade Connector Terminal Nut N/A 78 9 Solenoid - Red Wire Terminal Nut N/A 70 8 Starter Motor Mounting Screw M8 x 45 156 13 18 Positive Battery Terminal Nut N/A 70 Negative Battery Terminal Screw M6 x 20 70 8 ELECTRONIC FUEL INJECTION Intake and Intake Silencer Intake Silencer Mounting Screw M6 x 16 70 8 Intake Assembly Mounting Screw M8 x 40 156 13 18 Intake Bracket Mounting Screw M6 x 20 70 8 Throttle Body Throttle Body Mounting Screw M8 x 70 56 13 18 Throttle Body Bracket Screw M6 x 25 70 8 Accelerator Cam Nut N/A 70 8 Throttle Control Lever Mounting Screw M6 x 30 70 8 Fuel Injection Fuel Rail Joint Screw M5 x 16 43 5 Fuel Rail Mounting Screw M8 x 45 13 18 Fuel Rail/Fuel Cooler Mounting Screw M6 x 25 70 8 Vapor Separator Mounting Screw M6 x 30 70 8 Pressure Regulator Screw M6 x 12 70 8 Idle Air Control Assembly Mounting Screw M8 x 60 M8 x 24 156 13 18 Page 1A-12 90-881980R1 NOVEMBER 2001 SPECIFICATIONS Fastener Location DIameter x Length (mm) Torque lb-in. lb-ft. Nm Manifold Absolute Pressure Sensor Mounting Screw M5 x 15 43 5 Idle Air Control Mounting Screw M4 x 15 18 2 Throttle Position Sensor Tamper Proof Screw M4 x 12 18 2 Bracket Tamper Proof Screw M5 x 12 40 5 Spark Plug Cover Screw M6 x 16 70 8 Fuel Filter Mounting Screw M6 x 16 70 8 Fuel Pump Mounting Screw M6 x 30 70 8 Fuel Pump Cover Screw M6 x 35 70 8 POWERHEAD Cylinder Head * Cylinder Head Screw M8 x 55 20 28 * Cylinder Head Screw M10 x 145 22 30 Head Cover Screws M6 x 30 70 8 Spark Plug Cover Screws M6 x 16 65 7.5 Anode Screw M6 x 20 70 8 Anode Cover Screw M8 x 25 156 13 18 Thermostat Screw M6 x 25 70 8 Camshaft/Oil Pump * Camshaft Cap Screw N/A 150 17 Driven Sprocket Screw M10 x 35 44 60 Timing Belt Tensioner Screw M10 x 45 29.5 40 Cylinder Block/Crankcase * Crankcase Cover Outer Screws M8 x 55 20 28 * Crankcase Cover Center Screws M8 135 14 19 * Exhaust Cover Screw M6 x 30 105 12 * Powerhead Mounting Nut N/A 35 47.5 * Powerhead Mounting Screw M8 x 35 20 27 * Connecting Rod Screw M8 x 38 132 11 15 Drive Sprocket Nut N/A 195 265 Powerhead/Oil Pump N/A Powerhead Mounting Nut N/A 40 54.5 Powerhead Mounting Screw M8 x 35 20 27 Oil Pump Cover Screw M6 x 10 70 8 Oil Pick-up Tube Mounting Screw M6 x 20 100 11.5 Oil Pump Mounting Screw M6 x 45 85 9.5 NOTE:* = Must be tightened in sequence and/or multiple stages, and/or requires torque plus rotation. See appropriate section of component for details. 90-881980R1 NOVEMBER 2001 Page 1A-13 SPECIFICATIONS Fastener Location DIameter x Length (mm) Torque lb-in. lb-ft. Nm MID-SECTION Bottom Cowl/Adaptor Plate Bottom Cowl Screw M6 x 40 65 7.5 Grommet Cover Screw M6 x 20 65 7.5 Oil Drain Plug N/A 17.5 24 Lower Mounting Bolt M12 X 154 50 68 Upper Mounting Bolt M12 x 154 55 75 Adaptor Plate Screw M8 x 50 25 34 Oil Sump/Adaptor Plate M6 x 35 100 11.5 Check Valve N/A 15 1.5 Exhaust Tube Screw M6 x 60 100 11.5 Adaptor Plate Screw M6 x 36 100 11.5 Shift Linkage Bracket/Adaptor Screw M6 x 20 80 9 Drive Shaft Housing/Lower Unit Nut N/A 40 54 Lower Mount Clamp Screw Front Handle Assembly Bolt N/A 17 23 M6 x 75 65 7.5 Power Trim Shock Rod Piston N/A 90 122 Shock Piston Screw N/A 35 4 End Cap N/A 45 61 Trim Motor/Manifold Assembly Screw N/A 80 9 Pump/Motor Assembly Screw N/A 70 8 Pump Plug N/A 120 13.5 Manifold Screw N/A 100 11 Clamp/Swivel Bracket Grease Fitting N/A 40 3.5 4.5 Swivel Bracket Screw 1/4–28 x 1/2 in. 100 11.5 Link Arm Nut 3/8 in. 120 13.5 Link Arm Bolt 3/8-28 x 1/2 in. 20 27 Anchor Bracket Screw M10 x 30 40 54 Anchor Bracket Nut M10 40 54 Tilt Tube Nut (Port) N/A Drive Tight * Tilt Tube Nut (Starboard) N/A * Anode Assembly Screw M6 x 25 60 7 * Shift Link Nut N/A * NOTE:* = Drive Nut until Assembly is drawn together; but must be free to pivot. Page 1A-14 90-881980R1 NOVEMBER 2001 SPECIFICATIONS Fastener Location DIameter x Length (mm) Torque lb-in. lb-ft. Nm LOWER UNIT Gear Housing Bearing Carrier Stud/Nut M8 x 48 225 25 34 Drive Shaft/Pinion Nut N/A 70 95 Water Pump Cover Screws M6 x 30 60 7 Water Pump Mounting Screw M6 x 25 60 7 Vent, Fill/Drain, Oil Level Screw N/A 60 7 Drive Shaft Housing/Lower Unit Nut N/A 40 54.2 Trim Tab Retaining Screw 7/16-14 x 1-1/4 in. 22 30 Propeller Nut N/A 55 75 Shift Shaft Bushing Assembly Screw M6 x 25 35 4 Anode Screw M6 x 40 60 7 CONTROL LINKAGE/ ATTACHMENTS Throttle/Shift Linkage Steering Cable Nut N/A 35 47.5 Throttle Lever Collar Nut N/A 70 8 Throttle Control Lever Mounting Bolt M6 x 30 70 8 Shift Bracket Screw M6 x 20 80 9 90-881980R1 NOVEMBER 2001 Page 1A-15 MAINTENANCE 1 B IMPORTANT INFORMATION Section 1B - Maintenance Table of Contents Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-1 Checking Power Trim Fluid 1B-8. . . . . . . . . . . . . . . . . Inspection And Maintenance Schedule . . . . . . . 1B-2 Changing Engine Oil 1B-9. . . . . . . . . . . . . . . . . . . . . . . Before Each Use . . . . . . . . . . . . . . . . . . . . . . . 1B-2 Oil Changing Procedure 1B-9. . . . . . . . . . . . . . . . . After Each Use . . . . . . . . . . . . . . . . . . . . . . . . . 1B-2 Changing Oil Filter 1B-10. . . . . . . . . . . . . . . . . . . . . Every 100 Hours of Use or Once yearly, Checking and Adding Engine Oil 1B-10. . . . . . . . Whichever occurs first . . . . . . . . . . . . . . . . . . 1B-3 4-1/4 In. (108mm) Diameter Gear Case 1B-11 . . Every 300 Hours of Use or Three Years . . . 1B-3 Storage Preparation 1B-12. . . . . . . . . . . . . . . . . . . . . . Every 400 Hours of Use or Four Years . . . . 1B-3 Fuel System 1B-13. . . . . . . . . . . . . . . . . . . . . . . . . . Before Periods of Storage . . . . . . . . . . . . . . . 1B-3 Protecting External Outboard Corrosion Control Anode . . . . . . . . . . . . . . . . . . . 1B-4 Components 1B-13. . . . . . . . . . . . . . . . . . . . . . . . . . Spark Plug Inspection . . . . . . . . . . . . . . . . . . . . . . 1B-5 Protecting Internal Engine Components . . 1B-13 Battery Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5 Gear Case 1B-13. . . . . . . . . . . . . . . . . . . . . . . . . . . Fuse Replacement – Electric Start Models . . . . 1B-6 Positioning Outboard for Storage . . . . . . . . 1B-13 Timing Belt Inspection . . . . . . . . . . . . . . . . . . . . . 1B-6 Battery Storage 1B-13. . . . . . . . . . . . . . . . . . . . . . . Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . 1B-7 Special Tools 1. Flushing Attachment P/N 44357A2 2. Crankcase Oil Pump P/N 90265A5 3. Oil Filter Wrench P/N 91-802653Q1 90-881980R1 NOVEMBER 2001 Page 1B-1 MAINTENANCE Inspection And Maintenance Schedule To keep your outboard in the best operating condition, it is important that your outboard receive the periodic inspections and maintenance listed in the Inspection and Maintenance Schedule. We urge you to keep it maintained properly to ensure the safety of you and your passengers and retain its dependability. WARNING Neglected inspection and maintenance service of your outboard or attempting to perform maintenance or repair on your outboard if you are not familiar with the correct service and safety procedures could cause personal injury, death, or product failure. Before Each Use 1. Check engine oil level. 2. Check that lanyard stop switch stops the engine. 3. Visually inspect the fuel system for deterioration or leaks. 4. Check outboard for tightness on transom. 5. Check steering system for binding or loose components. 6. Visually check steering link rod fasteners for proper tightness. 7. Check propeller blades for damage. After Each Use 1. Flush out the outboard cooling system if operating in salt or polluted water. 2. If operating in salt water, wash off all salt deposits and flush out the exhaust outlet of the propeller and gear case with fresh water. Page 1B-2 90-881980R1 NOVEMBER 2001 MAINTENANCE Every 100 Hours of Use or Once yearly, Whichever occurs first 1. Lubricate all lubrication points. Lubricate more frequently when used in salt water. 2. Change engine oil and replace the oil filter. The oil should be changed more often when the engine is operated under adverse conditions such as extended trolling. 3. Inspect thermostat visually for corrosion, broken spring, and to determine that the valve is completely closed at room temperature. If questionable, inspect thermostat as outlined in Section 4B “Thermostat”. 4. Inspect and clean spark plugs. 5. Check engine fuel filter for contaminants. 6. Check engine timing setup. 7. Check corrosion control anodes. Check more frequently when used in salt water. 8. Drain and replace gear case lubricant. 9. Lubricate splines on the drive shaft. 10. Check power trim fluid. 11. Inspect battery. 12. Check control cable adjustments. 13. Inspect timing belt. 14. Remove engine deposits with Power Tune Engine Cleaner. 15. Check tightness of screws, nuts, and other fasteners. Every 300 Hours of Use or Three Years 1. Replace water pump impeller (more often if overheating occurs or reduced water pressure is noted). Every 400 Hours of Use or Four Years 1. Check and adjust valve clearance if necessary. Before Periods of Storage 1. Refer to Storage procedure (this section). 90-881980R1 NOVEMBER 2001 Page 1B-3 MAINTENANCE Page 1B-4 90-881980R1 NOVEMBER 2001 Corrosion Control Anode Each anode requires periodic inspection especially in salt water which will accelerate the erosion. To maintain this corrosion protection, always replace the anode before it is completely eroded. Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode. 1. The gear case has two corrosion control anodes. Another anode is installed on the bottom of the transom bracket assembly. b c a a - Bottom Anode b - Trim Tab c - Side Anodes 2. Three anodes are installed in the engine block. Remove anodes at locations shown. Install each anode with rubber seal and cover. Tighten screws to specified torque. NOTE: Do not remove center screw (b) until cover had been removed from engine. Do Not Remove b a e c d b a a - Anode b - Screw c - Cover d - Anode e - Rubber Seal Anode Screw Torque 70 lb-in. (8 Nm) MAINTENANCE Spark Plug Inspection Inspect spark plugs at the recommended intervals. 1. Remove the spark plug leads by twisting the rubber boots slightly and pull off. 2. Remove the spark plugs to inspect and clean. Replace spark plug if electrode is worn or the insulator is rough, cracked, broken, blistered or fouled. 3. Set the spark plug gap. See Specification Chart. 4. Before reinstalling spark plugs, clean away dirt on the spark plug seats. Install plugs finger tight, and tighten 1/4 turn or torque to 20 lb-ft (27 Nm). Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability. IMPORTANT: Read the safety and maintenance instructions which accompany your battery. 1. Turn off the engine before servicing the battery. 2. Add water as necessary to keep the battery full. 3. Make sure the battery is secure against movement. 4. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive and negative to negative. 5. Make sure the battery is equipped with a nonconductive shield to prevent accidental shorting of battery terminals. 90-881980R1 NOVEMBER 2001 Page 1B-5 MAINTENANCE Page 1B-6 90-881980R1 NOVEMBER 2001 Fuse Replacement – Electric Start Models The electric starting circuit is protected by overload fuses. If the fuse is blown, the electric starter motor will not operate. Try to locate and correct the cause of the overload. If the cause is not found, the fuse may blow again. Replace the fuse with a fuse of the same amperage rating. 1. Open the electrical cover and pull fuse with fuse puller. Look at the silver colored band inside the fuse. If band is broken replace the fuse. Replace fuse with a new fuse of the same amperage rating. b a d c e a a - Fuse Puller b - Electrical Cover c - Fuses - 20 Amp. d - Fuses - 30 Amp. e - Blown Fuse Timing Belt Inspection 1. Inspect the timing belt and replace if any of the following conditions are found. a. Cracks in the back of the belt or in the base of the belt teeth. b. Excessive wear at the roots of the cogs. c. Rubber portion swollen by oil. d. Belt surfaces roughened. e. Signs of wear on edges or outer surfaces of belt. a a - Timing Belt MAINTENANCE Lubrication Points Lubricate Point 1 with Anti-Corrosion Grease or 2-4-C Marine Lubricant with Teflon 1. Propeller Shaft – Refer to Propeller Replacement for removal and installation of the propeller. Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft. 1 Lubricate Points 2 thru 4 with 2-4-C Marine Lubricant with Teflon or Special Lubricant 101. 2. Swivel Bracket – Lubricate through fitting. 3. Tilt Support Lever – Lubricate through fitting. 2 3 4. Tilt Tube-Lubricate through fitting. 4 90-881980R1 NOVEMBER 2001 Page 1B-7 MAINTENANCE 5. Steering Cable Grease Fitting (If equipped) – Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube. Lubricate through fitting. Lubricate Point 5 with light weight oil. a b 5 a-Steering Cable End b-Fitting WARNING The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant. Adding lubricant to steering cable when fully extended could cause steering cable to become hydraulically locked. An hydraulically locked steering cable will cause loss of steering control, possibly resulting in serious injury or death. Checking Power Trim Fluid 1. Tilt outboard to the full up position and engage the tilt support lock. a a-Tilt Support Lock 2. Remove fill cap and check fluid level. The fluid level should be even with the bottom of the fill hole. Add Power Trim & Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. a a-Fill Cap Page 1B-8 90-881980R1 NOVEMBER 2001 MAINTENANCE Changing Engine Oil Oil Changing Procedure Pump Method 1. Place the outboard in an vertical upright position. 2. Remove dipstick and slide adaptor tube/pump down dipstick tube. Pump out the engine oil into an appropriate container. a 90265A5 a-Crankcase Oil Pump Drain Plug Method 1. Tilt the outboard up to the trailer position. 2. Turn the steering on the outboard so that the drain hole is facing downward. Remove drain plug and drain engine oil into an appropriate container. Lubricate the seal on the drain plug with oil and reinstall. a a-Drain Hole 90-881980R1 NOVEMBER 2001 Page 1B-9 MAINTENANCE Page 1B-10 90-881980R1 NOVEMBER 2001 Changing Oil Filter 1. Place a rag or towel below the oil filter to absorb any spilled oil. 2. Unscrew old filter by turning the filter counterclockwise. 3. Clean the mounting base. Apply film of clean oil to filter gasket. Do not use grease. Screw new filter on until gasket contacts base, then tighten 3/4 to 1 turn. 91-802653Q1 a a - Oil Filter Checking and Adding Engine Oil IMPORTANT: Do not overfill. Be sure that the outboard is upright (not tilted) when checking oil. 1. Remove the oil fill cap and add oil to to proper operating level. 2. Idle engine for five minutes and check for leaks. Stop engine and check oil level on dipstick. Oil must be between full mark and add mark. Add oil if necessary. c d 58653 b a 58655 a - Dipstick b - Oil Fill Cap c - Full Mark d - Add Mark Engine Oil Capacity 5 U.S. Quarts or (5.0 Liters) MAINTENANCE 4-1/4 In. (108mm) Diameter Gear Case When adding or changing gear case lubricant, visually check for the presence of water in the lubricant. If water is present, it may have settled to the bottom and will drain out prior to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance. If water is noticed, have the gear case checked by your dealer. Water in the lubricant may result in premature bearing failure, or in freezing temperatures, will turn to ice and damage the gear case. Whenever you remove the fill/drain plug, examine the magnetic end for metal particles. A small amount of metal filings or fine metal particles indicates normal gear wear. An excessive amount of metal filings or larger particles (chips) may indicate abnormal gear wear and should be checked by an authorized dealer. DRAINING GEAR CASE 1. Place outboard in a vertical operating position. 2. Place a drain pan below outboard. 3. Remove vent plugs and fill/drain plug and drain lubricant. a b c a-Fill/drain Plug b-Rear Vent Plug c-Front Vent Plug Gear Case Lubricant Capacity 24 fl oz (710 ml) 90-881980R1 NOVEMBER 2001 Page 1B-11 MAINTENANCE CHECKING LUBRICANT LEVEL AND FILLING GEAR CASE 1. Place outboard in a vertical operating position. 2. Remove the front vent plug and rear vent plug. 3. Place lubricant tube into the fill hole and add lubricant until it appears at the front vent hole. At this time install the front vent plug and sealing washer. 4. Continue adding lubricant until it appears at the rear vent hole. 5. Stop adding lubricant. Install the rear vent plug and sealing washer before removing lubricant tube. 6. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer. a c d e b a-Front Vent Plug b-Rear Vent Plug c-Front Vent Hole d-Rear Vent Hole e-Fill/Drain Plug and Sealing Washer Storage Preparation The major consideration in preparing your outboard for storage is to protect it from rust, corrosion, and damage caused by freezing of trapped water. The following storage procedures should be followed to prepare your outboard for out-ofseason storage or prolonged storage (two months or longer). CAUTION Never start or run your outboard (even momentarily) without water circulating through the cooling water intake in the gear case to prevent damage to the water pump (running dry) or overheating of the engine. Page 1B-12 90-881980R1 NOVEMBER 2001 MAINTENANCE Fuel System IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a formation of acid during storage and can damage the fuel system. If the gasoline being used contains alcohol, it is advisable to drain as much of the remaining gasoline as possible from the fuel tank, remote fuel line, and engine fuel system. Fill the fuel system (tank, hoses, fuel pump, and carburetor) with treated (stabilized) fuel to help prevent formation of varnish and gum. Proceed with following instructions. 1. Portable Fuel Tank – Pour the required amount of Fuel System Treatment & Stabilizer (follow instructions on container) into fuel tank. Tip fuel tank back and forth to mix stabilizer with the fuel. 2. Permanently Installed Fuel Tank – Pour the required amount of Fuel System Treatment & Stabilizer (follow instructions on container) into a separate container and mix with approximately one quart (one liter) of gasoline. Pour this mixture into fuel tank. 3. Place the outboard in water or connect flushing attachment for circulating cooling water. Run the engine for ten minutes to allow treated fuel to fill the engine fuel system. Protecting External Outboard Components 1. Lubricate all outboard components listed in the Inspection and Maintenance Schedule. 2. Touch up any paint nicks. 3. Spray Corrosion Guard on external metal surfaces (except corrosion control anodes). Protecting Internal Engine Components 1. Remove the spark plugs and inject a small amount of engine oil inside of each cylinder. 2. Rotate the flywheel manually several times to distribute the oil in the cylinders. Reinstall spark plugs. 3. Change the engine oil. Gear Case 1. Drain and refill the gear case lubricant (refer to maintenance procedure). Positioning Outboard for Storage Store outboard in an upright (vertical) position to allow water to drain out of outboard. CAUTION If outboard is stored tilted up in freezing temperature, trapped cooling water or rain water that may have entered the propeller exhaust outlet in the gear case could freeze and cause damage to the outboard. Battery Storage 1. Follow the battery manufacturer’s instructions for storage and recharging. 2. Remove the battery from the boat and check water level. Recharge if necessary. 3. Store the battery in a cool, dry place. 4. Periodically check the water level and recharge the battery during storage. 90-881980R1 NOVEMBER 2001 Page 1B-13 GENERAL INFORMATION IMPORTANT INFORMATION Section 1C - General Information Table of Contents 1 C Table of Contents . . . . . . . . . . . . . . . . . . . . . . . 1C-1 Propeller Removal/Installation . . . . . . . . . . . . 1C-13 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2 Standard Models . . . . . . . . . . . . . . . . . . . . . 1C-13 Serial Number Location . . . . . . . . . . . . . . . . . . 1C-2 Power Trim System . . . . . . . . . . . . . . . . . . . . . . 1C-15 Conditions Affecting Performance . . . . . . . . . 1C-3 General Information . . . . . . . . . . . . . . . . . . 1C-15 Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-3 Power Trim Operation . . . . . . . . . . . . . . . . . 1C-15 Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-4 Trim “In” Angle Adjustment . . . . . . . . . . . . 1C-16 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-5 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . 1C-17 Following Complete Submersion . . . . . . . . . . 1C-6 Compression Check . . . . . . . . . . . . . . . . . . . . . 1C-18 Submerged While Running . . . . . . . . . . . . 1C-6 Cylinder Leakage Testing . . . . . . . . . . . . . . . . . 1C-19 Salt Water Submersion . . . . . . . . . . . . . . . . 1C-6 Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-20 Fresh Water Submersion . . . . . . . . . . . . . . 1C-6 Water Pressure Measurement . . . . . . . . . . . . 1C-21 Model 115 (4-Stroke) Powerhead Views Painting Procedures . . . . . . . . . . . . . . . . . . . . . 1C-22 Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-7 Cleaning & Painting Aluminum Propellers Starboard View . . . . . . . . . . . . . . . . . . . . . . 1C-8 & Gear Housings . . . . . . . . . . . . . . . . . . . . . 1C-22 Port View . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-9 Decal Application . . . . . . . . . . . . . . . . . . . . . . . . 1C-23 Top View . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-10 Decal Removal . . . . . . . . . . . . . . . . . . . . . . . 1C-23 Aft View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-11 Instructions for “Wet” Application . . . . . . . 1C-23 Propeller Selection . . . . . . . . . . . . . . . . . . . . . . 1C-12 90-881980 NOVEMBER 2001 Page 1C-1 GENERAL INFORMATION Special Tools 1. Compression Gauge MT26J (Snap-on) Adaptor MT26J300 (Snap-on) (or equivalent). 2. Water Pressure Gauge 91-79250A2. 3. Adapter P/N 22-86306. 4. Connector P/N 22-89772. Serial Number Location The Outboard serial number is located on the lower starboard side of the engine block. A serial number is also located on the starboard side of the swivel bracket. 19XX OGXXXXXX XXXX XX e d c b a a-Serial Number b-Model Year c-Model Description d-Year Manufactured e-Certified Europe Insignia Page 1C-2 90-881980 NOVEMBER 2001 GENERAL INFORMATION Conditions Affecting Performance Weather Rated hp Summer hp Horsepower Loss Due to Atmosphere Conditions Secondary Loss Due to Propeller Becoming To Large for Summer Horsepower RPM Drop Due to Weather ENGINE RPM Rated RPM It is a known fact that weather conditions exert a profound effect on power output of internal combustion engines. Therefore, established horsepower ratings refer to the power that the engine will produce at its rated rpm under a specific combination of weather conditions. Corporations internationally have settled on adoption of I.S.O. (International Standards Organization) engine test standards, as set forth in I.S.O. 3046, standardizing the computation of horsepower from data obtained on the dynamometer. All values are corrected to the power that the engine will produce at sea level, at 30% relative humidity, at a 77° F (25° C) temperature and a barometric pressure of 29.61 inches of mercury. Summer conditions of high temperature, low barometric pressure and high humidity all combine to reduce the engine power. This, in turn, is reflected in decreased boat speeds--as much as 2 or 3 miles-per-hour (3 or 5 Km per-hour) in some cases. (Refer to previous chart.) Nothing will regain this speed for the boater, but the coming of cool, dry weather. In pointing out the practical consequences of weather effects, an engine--running on a hot, humid summer day--may encounter a loss of as much as 14% of the horsepower it would produce on a dry, brisk spring or fall day. The horsepower that any internal combustion engine produces, depends upon the density of the air that it consumes, and in turn, this density is dependent upon the temperature of the air, its barometric pressure and water vapor (or humidity) content. Accompanying this weather-inspired loss of power is a second but more subtle loss. At rigging time in early spring, the engine was equipped with a propeller that allowed the engine to turn within its recommended rpm range at full throttle. With the coming of the summer weather and the consequent drop in available horsepower, this propeller will, in effect, become too large. Consequently, the engine operates at less than its recommended rpm. 90-881980 NOVEMBER 2001 Page 1C-3 GENERAL INFORMATION Due to the horsepower/rpm characteristics of an engine, this will result in further loss of horsepower at the propeller with another decrease in boat speed. This secondary loss, however, can be regained by switching to a smaller pitch propeller that allows the engine to again run at recommended rpm. For boaters to realize optimum engine performance under changing weather conditions, it is essential that the engine have the proper propeller to allow it to operate at or near the top end of the recommended maximum rpm range at wide-open-throttle with a normal boat load. Not only does this allow the engine to develop full power, but equally important is the fact that the engine also will be operating in an rpm range that discourages damaging detonation. This, of course, enhances overall reliability and durability of the engine. Boat WEIGHT DISTRIBUTION 1. Proper positioning of the weight inside the boat (persons and gear) has a significant effect on the boat’s performance, for example: a. Shifting weight to the rear (stern) (1.)Generally increases top speed. (2.)If in excess, can cause the boat to porpoise. (3.)Can make the bow bounce excessively in choppy water. (4.)Will increase the danger of the following - wave splashing into the boat when coming off plane. b. Shifting weight to the front (bow) (1.)Improves ease of planing off. (2.)Generally improves rough water ride. (3.)If excessive, can make the boat veer left and right (bow steer). BOTTOM For maximum speed, a boat bottom should be nearly a flat plane where it contacts the water and particularly straight and smooth in fore-and-aft direction. 1. Hook: Exists when bottom is concave in fore-and-aft direction when viewed from the side. When boat is planing, “hook” causes more lift on bottom near transom and allows bow to drop, thus greatly increasing wetted surface and reducing boat speed. “Hook” frequently is caused by supporting boat too far ahead of transom while hauling on a trailer or during storage. 2. Rocker: The reverse of hook and much less common. “Rocker” exists if bottom is convex in fore-and-aft direction when viewed from the side, and boat has strong tendency to porpoise. 3. Surface Roughness: Moss, barnacles, etc., on boat or corrosion of outboard’s gear housing increase skin friction and cause speed loss. Clean surfaces when necessary. WATER ABSORPTION It is imperative that all through hull fasteners be coated with a quality marine sealer at time of installation. Water intrusion into the transom core and/or inner hull will result in additional boat weight (reduced boat performance), hull decay and eventual structural failure. Page 1C-4 90-881980 NOVEMBER 2001 GENERAL INFORMATION CAVITATION Cavitation is caused by water vapor bubbles forming either from a sharp edge or angle on the gear case or from an irregularity in the propeller blade itself. These vapor bubbles flow back and collapse when striking the surface of the propeller blade resulting in the erosion of the propeller blade surface. If allowed to continue, eventual blade failure (breakage) will occur. Engine DETONATION Detonation in a 4-cycle engine resembles the “pinging” heard in an automobile engine. It can be otherwise described as a tin-like “rattling” or “plinking” sound. Detonation is an explosion of an unburned portion of the fuel/air charge after the spark plug has fired. Detonation creates severe shock waves in the engine, and these shock waves often find or create a weakness: The dome of a piston, cylinder head/gasket, piston rings or piston ring lands, piston pin and roller bearings. A few of the most common causes of detonation in a marine 4-cycle application are as follows: • Over-advanced ignition timing. • Use of low octane gasoline. • Propeller pitch too high (engine rpm below recommended maximum range). • Lean fuel mixture at or near wide-open-throttle. • Spark plugs (heat range too hot - incorrect reach - cross-firing). • Inadequate engine cooling (deteriorated cooling system). • Combustion chamber/piston deposits (result in higher compression ratio). Detonation usually can be prevented if: 1. The engine is correctly set up. 2. Diligent maintenance is applied to combat the detonation causes. 51115 Damaged Piston Resulting from Detonation 90-881980 NOVEMBER 2001 Page 1C-5 GENERAL INFORMATION Following Complete Submersion Submerged While Running (Special Instructions) When an engine is submerged while running, the possibility of internal engine damage is greatly increased. If, after engine is recovered and with spark plugs removed, engine fails to turn over freely when turning flywheel, the possibility of internal damage (bent connecting rod and/or bent crankshaft) exists. If this is the case, the powerhead must be disassembled. Salt Water Submersion (Special Instructions) Due to the corrosive effect of salt water on internal engine components, complete disassembly is necessary before any attempt is made to start the engine. Fresh Water Submersion (Special Instructions) 1. Recover engine as quickly as possible. 2. Remove cowling. 3. Flush exterior of outboard with fresh water to remove mud, weeds, etc. DO NOT attempt to start engine if sand has entered powerhead, as powerhead will be severely damaged. Disassemble powerhead if necessary to clean components. 4. Remove spark plugs and get as much water as possible out of powerhead. Most water can be eliminated by placing engine in a horizontal position (with spark plug holes down) and rotating flywheel. 5. Change engine oil and filter as outlined in Section 1B “Changing Engine Oil”. Run outboard for short time and check for presence of water in oil. If water present (milky appearance) drain and refill as previously mentioned. 6. Pour alcohol into throttle body throats (alcohol will absorb water). Again rotate flywheel. 7. Turn engine over and pour alcohol into spark plug openings and rotate flywheel. 8. Turn engine over (place spark plug openings down) and pour engine oil into throat of throttle bodies while rotating flywheel to distribute oil throughout crankcase. 9. Again turn engine over and pour approximately one teaspoon of engine oil into each spark plug opening. Again rotate flywheel to distribute oil in cylinders. 10. Remove and clean intake manifold assembly (fuel rail, vapor separator, idle air control, and throttle body assembly) and fuel pump assembly. 11. Dry all wiring and electrical components using compressed air. 12. Disassemble the engine starter motor and dry the brush contacts, armature and other corrodible parts. 13. Reinstall spark plugs, intake manifold assembly, and fuel pump. 14. Attempt to start engine, using a fresh fuel source. If engine starts, it should be run for at least one hour to eliminate any water in engine. 15. If engine fails to start, determine cause (fuel, electrical or mechanical). Engine should be run within 2 hours after recovery of outboard from water, or serious internal damage may occur. If unable to start engine in this period, disassemble engine and clean all parts. Apply oil as soon as possible. Page 1C-6 90-881980 NOVEMBER 2001 GENERAL INFORMATION 90-881980 NOVEMBER 2001 Page 1C-7 Model 115 (4-Stroke) Powerhead Front View a b c d e f g a - ECM b - Voltage Regulator/Rectifier c - Air Temperature Sensor d - Engine Wiring Harness Connector e - Power Trim Relay f - 20 Amp Fuse (2) g - 30 Amp Fuse (2) GENERAL INFORMATION Page 1C-8 90-881980 NOVEMBER 2001 Model 115 (4-Stroke) Powerhead Starboard View 58566 9 l a b c d e f g h i j k m n a - Starter Motor b - Lifting Eye c - 30 Amp Fuse (2) d - 20 Amp Fuse (2) e - Oil Dip Stick f - Oil Filter g - Anode Cover h - Tell-Tale i - Water Pressure Control Valve j - Ignition Coil Cylinders #2  k - Ignition Coil Cylinders #1  l - Engine Water Temperature Sensor m - Access Port, Water Pressure/ Temperature n - Adaptor (22-86306) GENERAL INFORMATION 90-881980 NOVEMBER 2001 Page 1C-9 Model 115 (4-Stroke) Powerhead Port View 58567 a a b c d e f a - Lifting Eye (2) b - Throttle Position Sensor (TPS) c - Fuel Cooler d - Fuel Pump e - Fuel Filter f - Shift Position Switch GENERAL INFORMATION Page 1C-10 90-881980 NOVEMBER 2001 Model 115 (4-Stroke) Powerhead Top View 57870 c d c f e a a b a - Camshaft Gear (2) b - Timing Belt c - Lifting Eye (2) d - Flywheel e - Timing Belt Tensioner f - Thermostat Housing GENERAL INFORMATION 90-881980 NOVEMBER 2001 Page 1C-11 Model 115 (4-Stroke) Powerhead Aft View a b c d e f g h i j a - Spark Plug Cover b - Ignition Coil Cylinders #1 & #4 c - Ignition Coil Cylinders #2 & #3 d - Tell-Tale e - Fuel Filter f - Fuel Pump g - Electronic Fuel Injectors (4) h - Fuel Rail i - Fuel Regulator j - Oil Fill Cap GENERAL INFORMATION Propeller Selection For in-depth information on marine propellers and boat performance - written by marine engineers - see your Authorized Dealer for the illustrated “What You Should Know About Quicksilver Propellers... and Boat Performance Information” (Part No. 90-86144). For best all around performance from your outboard/boat combination, select a propeller that allows the engine to operate in the upper half of the recommended full throttle rpm range with the boat normally loaded (refer to Specifications). This rpm range allows for better acceleration while maintaining maximum boat speed. If changing conditions cause the rpm to drop below the recommended range (such as warmer, more humid weather, operation at higher elevations, increased boat load or a dirty boat bottom/gear case) a propeller change or cleaning may be required to maintain performance and ensure the outboard’s durability. Check full-throttle rpm using an accurate tachometer with the engine trimmed out to a balanced- steering condition (steering effort equal in both directions) without causing the propeller to “break loose”. Refer to “Quicksilver Accessory Guide” for a complete list of available propellers. 1. Select a propeller that will allow the engine to operate at or near the top of the recommended full throttle rpm range (listed in “Specifications,” preceding) with a normal load. Maximum engine speed (rpm) for propeller selection exists when boat speed is maximum and trim is minimum for that speed. (High rpm, caused by an excessive trim angle, should not be used in determining correct propeller.) Normally, there is a 150-350 rpm change between propeller pitches. 2. If full throttle operation is below the recommended range, the propeller MUST BE changed to one with a lower pitch to prevent loss of performance and possible engine damage. 3. After initial propeller installation, the following common conditions may require that the propeller be changed to a lower pitch: a. Warmer weather and great humidity will cause an rpm loss. b. Operating in a higher elevation causes an rpm loss. c. Operating with a damaged propeller or a dirty boat bottom or gear housing will cause an rpm loss. d. Operation with an increased load (additional passengers, equipment, pulling skiers, etc.). Page 1C-12 90-881980 NOVEMBER 2001 GENERAL INFORMATION Propeller Removal/Installation Standard Models WARNING If the propeller shaft is rotated while the engine is in gear, there is the possibility that the engine will crank over and start. To prevent this type of accidental engine starting and possible serious injury caused from being struck by a rotating propeller, always shift outboard to neutral position and remove spark plug leads when you are servicing the propeller. 1. Shift outboard to neutral position. N 2. Remove the spark plug leads to prevent engine from starting. 3. Straighten the bent tabs on the tab washer. a a-Tab Washer 90-881980 NOVEMBER 2001 Page 1C-13 GENERAL INFORMATION 4. Place a block of wood between gear case and propeller to hold propeller and remove propeller nut. 5. Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. 6. Coat the propeller shaft with Anti-Corrosion Grease or 2-4-C Marine Lubricant with Teflon. 95 2-4-C Marine Lubricant with Teflon 95 IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft, especially in salt water, always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed. 7. Flo-Torque I Drive Hub Propellers de f c b a a-Thrust Washer b-Propeller c-Continuity Washer d-Thrust Hub e-Propeller Nut Retainer f-Propeller Nut Page 1C-14 90-881980 NOVEMBER 2001 GENERAL INFORMATION 8. Flo-Torque II Drive Hub Propellers ab c d ef a-Forward Thrust Hub b-Replaceable Drive Sleeve c-Propeller d-Rear Thrust Hub e-Propeller Nut Retainer f-Propeller Nut 9. Place a block of wood between gear case and propeller and torque propeller nut to 55 lb-ft (75 Nm), aligning flat sides of the propeller nut with tabs on the tab washer. 10. Secure propeller nut by bending three of the tabs into the thrust hub grooves. b a b a a b a-Thrust Hub Grooves b-Tabs Propeller Nut Torque 55 lb-ft (75 Nm) 11. Reinstall spark plug leads. Power Trim System General Information The power trim system is filled at the manufacturer and is ready for use. Trim outboard through entire trim and tilt range several times to remove any air from the system. The trim system is pressurized and is not externally vented. Power Trim Operation With most boats, operating around the middle of the “trim” range will give satisfactory results. However, to take full advantage of the trimming capability there may be times when you choose to trim your outboard all the way in or out. Along with an improvement in some performance aspects comes a greater responsibility for the operator, and this is being aware of some potential control hazards. The most significant control hazard is a pull or “torque” that can be felt on the steering wheel or tiller handle. This steering torque results from the outboard being trimmed so that the propeller shaft is not parallel to the water surface. 90-881980 NOVEMBER 2001 Page 1C-15 GENERAL INFORMATION WARNING Avoid possible serious injury or death. When the outboard is trimmed in or out beyond a neutral steering condition, a pull on the steering wheel or tiller handle in either direction may result. Failure to keep a continuous firm grip on the steering wheel or tiller handle when this condition exists can result in loss of boat control as the outboard can turn freely. The boat can now “spin out” or go into a very tight maximum turn which, if unexpected, can result in occupants being thrown within the boat or out of the boat. Consider the following lists carefully: TRIMMING IN OR DOWN CAN: 1. Lower the bow. 2. Result in quicker planing off, especially with a heavy load or a stern heavy boat. 3. Generally improve the ride in choppy water. 4. Increase steering torque or pull to the right (with the normal right hand rotation propeller). 5. In excess, lower the bow of some boats to a point where they begin to plow with their bow in the water while on plane. This can result in an unexpected turn in either direction called “bow steering” or “over steering” if any turn is attempted or if a significant wave is encountered. WARNING Avoid possible serious injury or death. Adjust outboard to an intermediate trim position as soon as boat is on plane to avoid possible ejection due to boat spin-out. Do not attempt to turn boat when on plane if outboard is trimmed extremely in or down and there is a pull on the steering wheel or tiller handle. TRIMMING OUT OR UP CAN: 1. Lift the bow higher out of the water. 2. Generally increase top speed. 3. Increase clearance over submerged objects or a shallow bottom. 4. Increase steering torque or pull to the left at a normal installation height (with the normal right hand rotation propeller). 5. In excess, cause boat “porpoising” (bouncing) or propeller ventilation. 6. Cause engine overheating if any water intake holes are above the water line. Trim “In” Angle Adjustment Some outboard boats, particularly some bass boats, are built with a greater than normal transom angle which will allow the outboard to be trimmed further “in” or “under”. This greater trim “under” capability improves acceleration, reduces the angle and time spent in a bow high boat position during planing off, and in some cases, may be necessary to plane off a boat with aft live wells (given the variety of available propellers and height range of engine installations). However, once on plane, the engine should be trimmed to a more intermediate position to a avoid a bow-down planing condition called “plowing”. Plowing can cause “bow steering” or “over steering” and inefficiently consumes horsepower. In this condition, if attempting a turn or encountering a diagonal, moderate wake, a more abrupt turn than intended may result. Page 1C-16 90-881980 NOVEMBER 2001 GENERAL INFORMATION In rare circumstances, the owner may decide to limit the trim in. This can be accomplished by repositioning the tilt stop pins into whatever adjustment holes in the transom brackets is desired. WARNING Avoid possible serious injury or death. Adjust outboard to an intermediate trim position as soon as boat is on plane to avoid possible ejection due to boat spin-out. Do not attempt to turn boat when on plane if outboard is trimmed extremely in or down and there is a pull on the steering wheel or tiller handle. If an adjustment is required, purchase a stainless steel tilt pin (P/N 17-49930A1) and insert it through whatever pin hole is desired. The non-stainless steel shipping bolt should not be used in this application other than on a temporary basis. a a-Optional Tilt Pin Trim Tab Adjustment Propeller steering torque will cause your boat to pull in one direction. This steering torque is a normal thing that results from your outboard not being trimmed so the propeller shaft is parallel to the water surface. The trim tab can help to compensate for this steering torque in many cases and can be adjusted within limits to reduce any unequal steering effort. NOTE:Trim tab adjustment will have little effect reducing steering torque if the outboard is installed with the anti-ventilation plate approximately 2 inches (50mm) or more above the boat bottom. Operate your boat at normal cruising speed, trimmed to desired position. Turn your boat left and right and note the direction the boat turns more easily. If adjustment is necessary, loosen trim tab bolt and make small adjustments at a time. If the boat turns more easily to the left, move the trailing edge of trim tab to the left. If the boat turns more easily to the right move the trailing edge of trim tab to the right. Retighten bolt and retest. a a-Trim Tab 90-881980 NOVEMBER 2001 Page 1C-17 GENERAL INFORMATION Page 1C-18 90-881980 NOVEMBER 2001 Compression Check CAUTION Before removing the spark plugs, use compressed air to blow away dirt accumulated in the spark plug well. NOTE: Use Snap-on compression gauge with adaptor (or equivalent) MT26J-MT26J300. Spark plug size is 14 mm. IMPORTANT: Compression check should be done with throttle in WOT position. 1. Check valve clearance (refer to “Valve Clearance Adjustment” in section 4A), adjust if out of specification. 2. Warm up the engine. 3. Remove all spark plugs. 4. Lubricate threads in cylinder head and on compression gauge. Install compression gauge in spark plug hole. 110 4-Stroke Outboard Oil 110 110 a P/N MT26J/MT26J300 b a - Compression Gauge (MT26J - Snap-on) b - Adaptor (MT26J300 - Snap-on) 5. Hold throttle plate at W.O.T. 6. Crank the engine over until the compression reading peaks on the gauge. Record the reading. 7. Check and record compression of each cylinder. The highest and lowest reading recorded should not differ by more than 15% (see example chart below). A reading below 120 psi might indicate a total engine wear problem. Compression Pressure (Minimum) 138 psi (950 Kpa, 9.5 kg/cm2) Example of compression test differences: Maximum (psi) Minimum (psi) 180 162 150 127.5 GENERAL INFORMATION 8. Remove compression gauge. 9. Install spark plugs. NOTE:Compression check is important because an engine with low or uneven compression cannot be tuned successfully to give peak performance. It is essential, therefore, that improper compression be corrected before proceeding with an engine tuneup. Cylinder Leakage Testing NOTE:Cylinder leakage testing, along with compression testing, can help the mechanic pinpoint the source of a mechanical failure by gauging the amount of leakage in an engine cylinder. Refer to the manufactures tester instructions for proper testing procedures. NOTE:Cylinders #1 and #4 TDC positions should show TDC mark on flywheel with timing marks (f). Cylinders #2 and #3 TDC positions should show TDC mark alone (g). #1 #2 #3 #4 a b c d e f g P/N MT324 a-TDC for Cylinder #1 e-Cylinder Leakage Tester b-TDC for Cylinder #2 (Snap-On-Tools MT324) c-TDC for Cylinder #3 f-Flywheel Position For Arrow Positions #1 & #4 d-TDC for Cylinder #4 g-Flywheel Position For Arrow Positions #2 & #3 NOTE: Spark plug hole is a 14 mm diameter. Use Snap-On Tool MT26J300 adapter with valve core removed. 90-881980 NOVEMBER 2001 Page 1C-19 GENERAL INFORMATION Analysis Due to standard engine tolerances and engine wear, no cylinder will maintain a 0% of leakage. It is important only that cylinders have somewhat consistent reading between them. Differences of 15 to 30% indicate excessive leakage. Larger engines tend to have a larger percentage of cylinder leakage than smaller engines. If excessive leakage is present, first check that the piston is at top dead center of its compression stroke. Leakage will naturally occur if the exhaust or intake valve is open. To determine the cause of high percentage leaks, you must locate where the air is escaping from. Listen for air escaping thru the carburetor intake, adjacent spark plug holes, exhaust pipe, and crankcase fill plug. Use the following table to aid in locating the source of cylinder leakage: Air Escaping From: Indicates Possible Defective: Throttle Bodies Intake Valve Exhaust System Exhaust Valve Crankcase Fill Plug Piston or Rings Adjacent Cylinders Head Gasket Page 1C-20 90-881980 NOVEMBER 2001 GENERAL INFORMATION 90-881980 NOVEMBER 2001 Page 1C-21 Water Pressure Measurement 1. Warm up engine. 2. Remove plug. 3. Attach adaptor, hose fitting and water pressure gauge to cylinder block. NOTE: Water pressure measurements should be done on a warm engine with thermostat operating 140°F (60°C). rpm x 1000 Pump Pressure (psi) Water Pump Pressure 91-79250A2 22-86306 22-89772 a 0 2 4 6 8 10 12 14 16 18 20 22 24 0 1 2 3 4 5 6 a - Plug GENERAL INFORMATION Painting Procedures Cleaning & Painting Aluminum Propellers & Gear Housings WARNING Avoid serious injury from flying debris. Avoid serious injury from airborne particles. Use eye and breathing protection with proper ventilation. PROPELLERS 1. Sand the entire area to be painted with 3M 120 Regalite Polycut or coarse Scotch-Brite, disc or belts. 2. Feather edges of all broken paint edges. Try not to sand through the primer. 3. Clean the surface to be painted using PPG Industries DX330 Wax and Grease Remover or equivalent (Xylene or M.E.K.). 4. If bare metal has been exposed, use Mercury/Quicksilver Light Gray Primer. 5. Allow a minimum of 1 hour dry time and no more than 1 week before applying the finish coat. 6. Apply the finish coat using Mercury/Quicksilver EDP Propeller Black. GEAR HOUSINGS The following procedures should be used in refinishing gear housings. This procedure will provide the most durable paint system available in the field. The materials recommended are of high quality and approximate marine requirements. The following procedure will provide a repaint job that compares with a properly applied factory paint finish. It is recommended that the listed materials be purchased from a local Ditzler Automotive Finish Supply Outlet. The minimum package quantity of each material shown following is sufficient to refinish several gear housings. Procedure: 1. Wash gear housing with a muriatic acid base cleaner to remove any type of marine growth, and rinse with water, if necessary. 2. Wash gear housing with soap and water, then rinse. 3. Sand blistered area with 3M 180 grit sandpaper or P180 Gold Film Disc to remove paint blisters only. Feather edge all broken paint edges. 4. Clean gear housing thoroughly with (DX-330) wax and grease remover. 5. Spot repair surfaces where bare metal is exposed with (DX-503) alodine treatment. IMPORTANT: Do not use any type of aerosol spray paints as the paint will not properly adhere to the surface nor will the coating be sufficiently thick to resist future paint blistering. 6. Mix epoxy chromate primer (DP-40) with equal part catalyst (DP-401) per manufacturers instructions, allowing proper induction period for permeation of the epoxy primer and catalyst. 7. Allow a minimum of one hour drying time and no more than one week before top coating assemblies. 8. Use Ditzler Urethane DU9000 for Mercury Black, DU34334 for Mariner Grey, and DU35466 for Force Charcoal, and DU33414M for Sea Ray White. Catalyze all four colors with Ditzler DU5 catalyst mixed 1:1 ratio. Reduce with solvents per Ditzler label. Page 1C-22 90-881980 NOVEMBER 2001 GENERAL INFORMATION CAUTION Be sure to comply with instructions on the label for ventilation and respirators. Using a spray gun, apply one half to one mil even film thickness. Let dry, flash off for five minutes and apply another even coat of one half to one mil film thickness. This urethane paint will dry to the touch in a matter of hours, but will remain sensitive to scratches and abrasions for a few days. 9. The type of spray gun used will determine the proper reduction ratio of the paint. IMPORTANT: Do not paint sacrificial zinc trim tab or zinc anode. 10. Cut out a cardboard “plug” for trim tab pocket to keep paint off of mating surface to maintain good continuity circuitry between trim tab and gear housing. Decal Application Decal Removal 1. Mark decal location before removal to assure proper alignment of new decal. 2. Carefully soften decal and decal adhesive with a heat gun or heat blower while removing old decal. 3. Clean decal contact area with a 1:1 mixture of isopropyl alcohol and water. 4. Thoroughly dry decal contact area and check for a completely cleaned surface. Instructions for “Wet” Application NOTE: The following decal installation instructions are provided for a “Wet” installation. All decals should be applied wet. TOOLS REQUIRED 1. Plastic Squeegee* 2. Stick Pin 3. Dish Washing Liquid/Detergent without ammonia. Do not use a soap that contains petroleum based solvents. * Automotive Body Filler Squeegee SERVICE TIP: Placement of decals using the “Wet” application will allow time to position decal. Read entire installation instructions on this technique before proceeding. TEMPERATURE IMPORTANT: Installation of vinyl decals should not be attempted while in direct sun light. Air and surface temperature should be between 60°F (15°C) and 100°F (38°C) for best application. SURFACE PREPARATION IMPORTANT: Do not use a soap or any petroleum based solvents to clean application surface. Clean entire application surface with mild dish washing liquid and water. Rinse surface thoroughly with clean water. 90-881980 NOVEMBER 2001 Page 1C-23 GENERAL INFORMATION DECAL APPLICATION 1. Mix 1/2 ounce (16 ml) of dish washing liquid in one gallon (4 l) of cool water to use as wetting solution. NOTE:Leave protective masking, if present, on the face of decal until final steps of decal installation. This will ensure that the vinyl decal keeps its shape during installation. 2. Place the decal face down on a clean work surface and remove the paper backing from “adhesive side” of decal. 3. Using a spray bottle, flood the entire “adhesive side” of the decal with the pre-mixed wetting solution. 4. Flood area where the decal will be positioned with wetting solution. 5. Position pre-wetted decal on wetted surface and slide into position. 6. Starting at the center of the decal, “lightly” squeegee out the air bubbles and wetting solution with overlapping strokes to the outer edge of the decal. Continue going over the decal surface until all wrinkles are gone and adhesive bonds to the cowl surface. 7. Wipe decal surface with soft paper towel or cloth. 8. Wait 10 - 15 minutes. 9. Starting at one corner, “carefully and slowly” pull the masking off the decal surface at a 180° angle. NOTE: To remove any remaining bubbles, pierce the decal at one end of the bubble with stick pin and press out the entrapped air or wetting solution with your thumb (moving toward the puncture). Page 1C-24 90-881980 NOVEMBER 2001 OUTBOARD MOTOR INSTALLATION IMPORTANT INFORMATION Section 1D - Outboard Motor Installation Table of Contents 1 D Electric Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . 1D-1 Boat Horsepower Capacity . . . . . . . . . . . . . . . . . 1D-1 Start in Gear Protection . . . . . . . . . . . . . . . . . . . . 1D-2 Selecting Accessories For The Outboard . . . . . 1D-2 Installation Specifications . . . . . . . . . . . . . . . . . . . 1D-2 Lifting Outboard. . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-3 Steering Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-3 Steering Link Rod . . . . . . . . . . . . . . . . . . . . . . . . . 1D-4 Installing Outboard . . . . . . . . . . . . . . . . . . . . . . . . 1D-5 Electrical, Hoses, and Control Cables . . . . . . . . 1D-7 Front Cowl Grommet . . . . . . . . . . . . . . . . . . . . 1D-7 Remote Wiring Harness . . . . . . . . . . . . . . . . . 1D-7 Battery Cable Connections . . . . . . . . . . . . . . 1D-8 Fuel Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-9 Speedometer (Optional) Water Pick-up . . . . 1D-9 Shift Cable Installation . . . . . . . . . . . . . . . . . 1D-10 Throttle Cable Installation . . . . . . . . . . . . . . 1D-12 Trim-In Stop Adjustment . . . . . . . . . . . . . . . . . . 1D-13 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . 1D-14 Installation Drawing . . . . . . . . . . . . . . . . . . . . . . . 1D-15 Electric Fuel Pump If an electric fuel pump is used, the fuel pressure must not exceed 4 psig at the engine. If necessary, install a pressure regulator to regulate the pressure. Boat Horsepower Capacity U.S. COAST GUARD CAPACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY (POUNDS) XXX MAXIMUM WEIGHT CAPACITY XXX Do not overpower or overload the boat. Most boats will carry a required capacity plate indicating the maximum acceptable power and load as determined by the manufacturer following certain federal guidelines. If in doubt, contact your dealer or the boat manufacturer. WARNING Using an outboard that exceeds the maximum horsepower limit of a boat can: 1. cause loss of boat control 2. place too much weight at the transom, altering the designed flotation characteristics of the boat or 3. cause the boat to break apart, particularly around the transom area. Overpowering a boat can result in serious injury, death, or boat damage. 90-881980R1 NOVEMBER 2001 Page 1D-1 OUTBOARD MOTOR INSTALLATION Start in Gear Protection The remote control connected to the outboard must be equipped with a start-in-gear protection device. This prevents the engine from starting in gear. WARNING Avoid serious injury or death from a sudden unexpected acceleration when starting your engine. The design of this outboard requires that the remote control used with it must have a built in start-in-gear protection device. Selecting Accessories For The Outboard Genuine Quicksilver Parts and Accessories have been specifically designed and tested for this outboard. Some accessories not manufactured or sold by Quicksilver are not designed to be safely used with this outboard or outboard operating system. Acquire and read the Installation, Operation, and Maintenance manuals for all selected accessories. Installation Specifications a b a a – Transom Opening – Minimum Single Engine (Remote) – 19 in. (483 mm) Single Engine (Tiller) – 30 in. (762 mm) Dual Engines – 40 in. (1016 mm) b – Engine Center Line For Dual Engine 26 in. (660mm) Minimum Page 1D-2 90-881980R1 NOVEMBER 2001 OUTBOARD MOTOR INSTALLATION 90-881980R1 NOVEMBER 2001 Page 1D-3 Lifting Outboard Use Flywheel Puller/Lifting Eye (91-83164M). Steering Cable STARBOARD SIDE ROUTED CABLE 1. Lubricate O-ring seal and entire cable end. 95 2-4-C with Teflon 95 2. Insert steering cable into tilt tube. 3. Tighten nut to specified torque. Cable Nut Torque 35 lb-ft (47.5 Nm) OUTBOARD MOTOR INSTALLATION Steering Link Rod Installation Note NOTE:For ease of installation of special bolt (a) separate the front end of the bottom cowl. 1. Install steering link rod per illustration. a c d b a-Special Bolt (10-90041) b-Nylon Insert Locknut (11-34863) c-Flat Washer (2) d-Nylon Insert Locknut (11-34863) Special Bolt Torque 20 lb. ft. (27.1 N·m) b - Nylon Insert Locknut Torque 20 lb. ft. (27.1 N·m) d - Nylon Insert Locknut Torque Tighten Locknut Until it Seats, Then Back Nut Off 1/4 Turn IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special bolt (“a” - Part Number 10-90041) and self locking nuts (“b” & “d” - Part Number 11-34863). These locknuts must never be replaced with common nuts (non locking) as they will work loose and vibrate off, freeing the link rod to disengage. WARNING Disengagement of a steering link rod can result in the boat taking a full, sudden, sharp turn. This potentially violent action can cause occupants to be thrown overboard exposing them to serious injury or death. Page 1D-4 90-881980R1 NOVEMBER 2001 OUTBOARD MOTOR INSTALLATION Installing Outboard Determining Recommended Outboard Mounting Height 20 in. 21 in. 22 in. 23 in. 24 in. 25 in. 26 in. 19 in. 10 20 30 40 50 60 70 Maximum Boat Speed Anticipated a c b d NOTE:Add 5 in. (127mm) for XL mod- els to the listed outboard mounting (660mm) (635mm) (609mm) (584mm) (560mm) (533mm) (508mm) (482mm) (e) e Outboard Mounting Height (See NOTE Below) height. IMPORTANT NOTICE TO INSTALLER 1. The outboard should be mounted high enough on the transom so that the exhaust relief hole will stay at least 1 in. (25.4 mm) above the water line when the engine is running at idle speed. Having the exhaust relief hole above the water line will prevent exhaust restriction. Exhaust restriction will result in poor performance at idle. 2. However, keep in mind that the mounting height (e) of the outboard must not exceed 25 in. (635 mm) for L models, 30 in. (762 mm) for XL models. Mounting the outboard higher may cause damage to the gear case components. a. This solid line is recommended to determine the out-c. This line may be preferred to determine outboard board mounting height. mounting height dimension, if maximum speed is the only objective. IMPORTANT: Increasing the height of outboard generally will provide the following: 1) Less steering torque, This line may be preferred to determine outboard d. 2) more top speed, 3) greater boat stability, but, 4) will mounting height dimension for dual outboard installacause more prop “break loose” which may be particu-tion. larly noticeable when planing off or with heavy load. Outboard mounting height (height of outboard transom b. These broken lines represent the extremes of known e. brackets from bottom of boat transom). For heights over successful outboard mounting height dimensions. 22 in. (560mm), a propeller, that is designed for surfacing operation is usually preferred. 90-881980R1 NOVEMBER 2001 Page 1D-5 OUTBOARD MOTOR INSTALLATION 1. Use transom drilling fixture (91-98234A2) or attach (tape) engine mounting template to boat transom. 2. Mark and drill four 17/32 in. (13.5mm) mounting holes. 3. Refer to “Determining Recommended Outboard Motor Mounting Height”, preceding, and install outboard to the nearest recommended mounting height. 4. Fasten outboard with provided mounting hardware shown. NOTE:The addition of the four flat washers (d) is a manufacturing running change. Outboards built before the running change will not have the flat washers. c a b d 109e 109 RTV 587 Silicone Sealer a-1/2 in. Diameter Bolts (4) b-Flat Washers (4) c-Locknuts (4) d-Flat Washers (4) e-Apply to Shanks of Bolts, Not Threads Page 1D-6 90-881980R1 NOVEMBER 2001 OUTBOARD MOTOR INSTALLATION Electrical, Hoses, and Control Cables IMPORTANT: Warning Horn Requirement – The remote control or key switch assembly must be wired with a warning horn. This warning horn is used with the engine warning system. Front Cowl Grommet Pull up the cowl seal and remove the cover from the bottom cowl. Route the hoses, wiring and cables through the correct openings in the rubber grommet as shown. a b c d e fgh i a-Cover b-Rubber Grommet c-Fuel Hose Opening d-Remote Wiring Harness Opening e-Throttle Cable Opening f-Battery Cables Opening g-Shift Cable Opening h-Speedometer Tube i-Sta-Strap (Included in Parts Bag), Tie Around Grommet After Com- ponents are Installed Remote Wiring Harness Route wiring harness through the rubber grommet. Connect wiring. Push the retainer over the exposed ends of the connectors. This will hold the connectors together. b BLU/WHTGRN/WHTBRN/WHTTAN BLU/WHTGRN/WHT a a-Power Trim Connections b-Retainer – Push Over Connector Ends 90-881980R1 NOVEMBER 2001 Page 1D-7 OUTBOARD MOTOR INSTALLATION Page 1D-8 90-881980R1 NOVEMBER 2001 Battery Cable Connections SINGLE OUTBOARD (+) (–) a b c a - Red Sleeve (Positive) b - Black Sleeve (Negative) c - Starting Battery DUAL OUTBOARDS Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. (–) (–) d d - Ground Cable (Same Wire Size As Engine Battery Cable) – Connect Between Negative (–) Terminals OUTBOARD MOTOR INSTALLATION Fuel Hose PORTABLE FUEL TANK Select a suitable location in boat within engine fuel line length limitations and secure tank in place. PERMANENT FUEL TANK These should be installed in accordance with industry and federal safety standards which include recommendations applicable to grounding, anti-siphon protection, ventilation, etc. FUEL HOSE SIZE Minimum fuel line inside diameter (I.D.) is 5/16 in. (8mm), with separate fuel line/fuel tank pickup for each engine. FUEL HOSE CONNECTION Fasten remote fuel hose to fitting with hose clamp. Speedometer (Optional) Water Pick-up This outboard is equipped with a speedometer water pick-up located in the leading edge of the gear case. If this water pick-up is to be used, locate the hose coming out of the front grommet. Cut off the end of the hose fitting and make the connection. a b c NOTE:If the speedometer water pick-up hose is not used, keep the hose routed out of the rubber grommet. a-Fuel Hose b-Hose Clamp – Secure Remote Fuel Hose c-Speedometer Water Pick-up Hose for Optional Speedometer CAUTION Prevent possible water leakage. Water pick up hose must be routed through grommet and outside of lower cowl at all times. 90-881980R1 NOVEMBER 2001 Page 1D-9 OUTBOARD MOTOR INSTALLATION Shift Cable Installation Install cables into the remote control following the instructions provided with the remote control. NOTE:Install the shift cable to the engine first. The shift cable is the first cable to move when the remote control handle is moved out of neutral. 1. Position remote control into neutral. N 2. Shift outboard into neutral. 3. Measure the distance between pin and center of barrel pocket. a b c FNR a-Distance Between Pin And Center of Barrel Pocket b-Pin c-Barrel Pocket Page 1D-10 90-881980R1 NOVEMBER 2001 OUTBOARD MOTOR INSTALLATION 90-881980R1 NOVEMBER 2001 Page 1D-11 4. Push in on the shift cable end until resistance is felt. Adjust the cable barrel to attain distance (a) taken in Step 3. d e d - Shift Cable End e - Cable Barrel 5. Fit shift cable through rubber grommet. 6. Place cable barrel into pocket. Fasten cable with hairpin cotter. f g f - Place Barrel Into Barrel Pocket g - Hairpin Cotter 7. Check shift cable adjustments as follows: a. Shift remote control into forward. The propeller shaft should be locked in gear. If not, adjust the barrel closer to the cable end. b. Shift remote control into neutral. The propeller shaft should turn freely without drag. If not, adjust the barrel away from the cable end. Repeat steps a and b. c. Shift remote control into reverse while turning propeller. The propeller shaft should be locked in gear. If not, adjust the barrel away from the cable end. Repeat steps a through c. d. Shift remote control back to neutral. The propeller shaft should turn freely without drag. If not, adjust the barrel closer to the cable end. Repeat steps a through d. OUTBOARD MOTOR INSTALLATION Throttle Cable Installation Install cables into the remote control following the instructions provided with the remote control. 1. Position remote control into neutral. N 2. Install throttle cable to the throttle arm with hairpin cotter. 3. Adjust the cable barrel so that the installed throttle cable will hold the throttle arm against the idle stop. 4. Place cable barrel into retainer and install. 5. Fit throttle cable through the rubber grommet. 6. Lock the retainer in place with the cable latch. a bc d f e a-Flat Washer b-Hairpin Cotter c-Barrel Retainer d-Throttle Arm e-Cable Latch f-Throttle Cable Opening Page 1D-12 90-881980R1 NOVEMBER 2001 OUTBOARD MOTOR INSTALLATION Trim-In Stop Adjustment Some outboard boats, particularly some bass boats, are built with a greater than normal transom angle which will allow the outboard to be trimmed further “in” or “under”. This greater trim “under” capability improves acceleration, reduces the angle and time spent in a bow high boat during planing off, and in some cases, may be necessary to plane off a boat with aft live wells (given the variety of available propellers and height range of engine installations). However, once on plane, the engine should be trimmed to a more intermediate position to avoid a bow-down planing condition called “plowing”. Plowing can cause “bow steering” or “over steering” and inefficiently consumes horsepower. In this condition, if attempting a turn or encountering a diagonal, moderate wake, a more abrupt turn than intended may result. In rare circumstances, the owner may decide to limit the trim under. This can be accomplished by purchasing a stainless steel tilt pin (P/N 17-49930A1) and inserting it through whatever pin hole is desired. The non-stainless steel shipping bolt should not be used in this application other than on a temporary basis. WARNING Avoid possible serious injury or death. Adjust outboard to an intermediate trim position as soon as boat is on plane to avoid possible ejection due to boat spin-out. Do not attempt to turn boat when engine is trimmed extremely under or in. a a-Stainless Steel Tilt Pin 90-881980R1 NOVEMBER 2001 Page 1D-13 OUTBOARD MOTOR INSTALLATION Trim Tab Adjustment The trim tab can be adjusted within limits to help compensate for steering torque. Adjust trim tab as follows: 1. If boat tends to pull to the right, move the rear edge of the trim tab to the right. 2. If boat tends to pull to the left, move the rear edge of the trim tab to the left. NOTE:Trim tab adjustment will have little effect reducing steering torque if the anti-ventilation plate is raised 2 inches (50mm) or more above the boat bottom. Page 1D-14 90-881980R1 NOVEMBER 2001 OUTBOARD MOTOR INSTALLATION 90-881980R1 NOVEMBER 2001 Page 1D-15 Installation Drawing IGNITION ELECTRICAL Section 2A - Ignition Table of Contents 2 A Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2 Stator Coil Peak Voltage . . . . . . . . . . . . . . 2A-25 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-3 Rectifier/Regulator Output - Peak Voltage 2A-26 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-6 Throttle Position Sensor (TPS) Electrical Components . . . . . . . . . . . . . . . . . . . 2A-8 Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . 2A-27 Ignition Components . . . . . . . . . . . . . . . . . . . . . 2A-10 Throttle Position Sensor Output Voltage . 2A-28 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-12 Throttle Position Sensor Adjustment . . . . 2A-28 Theory of Operation . . . . . . . . . . . . . . . . . . . . . 2A-14 Resistance Tests . . . . . . . . . . . . . . . . . . . . . . . . 2A-29 Ignition Component Description . . . . . . . . . . . 2A-15 Stator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-29 Electronic Control Module (ECM) . . . . . . . 2A-15 Crank Position Sensor (CPS) . . . . . . . . . . 2A-30 Ignition Timing Control During Engine Ignition Coil (Primary) . . . . . . . . . . . . . . . . . 2A-30 Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-15 Ignition Coil (Secondary) . . . . . . . . . . . . . . 2A-31 Normal Operation . . . . . . . . . . . . . . . . . . . . 2A-15 Ignition Spark Gap . . . . . . . . . . . . . . . . . . . . 2A-31 Protection Controls . . . . . . . . . . . . . . . . . . . 2A-16 Engine water Temperature Sensor . . . . . . 2A-32 Shift Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-16 Oil Pressure Switch . . . . . . . . . . . . . . . . . . . 2A-33 Throttle Position Sensor (TPS) . . . . . . . . . 2A-17 Flywheel Removal and Installation . . . . . . . . . 2A-34 Engine Water Temperature Sensor . . . . . 2A-17 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-34 Flywheel Assembly . . . . . . . . . . . . . . . . . . . 2A-17 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-36 Stator Assembly . . . . . . . . . . . . . . . . . . . . . . 2A-18 Stator Removal and Installation . . . . . . . . . . . 2A-37 Crank Position Sensors (CPS) . . . . . . . . . 2A-18 Timing Belt Removal and Installation . . . . . . . 2A-38 Ignition Coils . . . . . . . . . . . . . . . . . . . . . . . . . 2A-18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-38 Ignition Test Procedures . . . . . . . . . . . . . . . . . . 2A-19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-39 Direct Voltage Adapter (DVA) . . . . . . . . . . 2A-19 Crank Position Sensor Removal . . . . . . . . . . . 2A-40 Ignition Troubleshooting . . . . . . . . . . . . . . . . . . 2A-20 Crank Position Sensor Installation . . . . . . . . . 2A-40 Multimeter/DVA Tester or DMT 2000 Voltage Regulator/Rectifier Removal Multimeter with Direct Voltage Adaptor . . 2A-20 and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-41 Ignition Diagnostic Procedures . . . . . . . . . . . . 2A-20 ECM Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-43 Recommended Test . . . . . . . . . . . . . . . . . . 2A-21 ECM Installation . . . . . . . . . . . . . . . . . . . . . . . . 2A-44 Testing Ignition Components . . . . . . . . . . . . . . 2A-23 Ignition Coil Removal . . . . . . . . . . . . . . . . . . . . 2A-45 ECM Peak Voltage (Coil Primary) . . . . . . . 2A-23 Ignition Coil Installation . . . . . . . . . . . . . . . . . . 2A-46 Crank Position Sensor (CPS) Water Temperature Sensor Removal Peak Voltage . . . . . . . . . . . . . . . . . . . . . . . . 2A-24 and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-47 90-881980R1 NOVEMBER 2001 Page 2A-1 IGNITION Specifications Type Microcomputer-ECM Spark Plug: Type NGK LFR6A-11 Gap 0.039 - 0.043 in. (1.0 - 1.1 mm) Hex Size 5/8 in. (16 mm) Torque 18 lb-ft (25 Nm) Hole Size 14 mm Firing Order 1-3-4-2 Ignition Timing: @ Idle (850 rpm) 4° A.T.D.C @ WOT (6000 rpm) 20° B.T.D.C Stator Coil Output - Peak Voltage: @ 400 rpm (Cranking) 10 - 18 V @ 750 rpm (Idle) 16 - 24 V @ 1500 rpm 16 - 24 V @ 3500 rpm 16 - 24 V Stator Coil Resistance 0.2 - 0.8 W Crank Position Sensor - Peak Voltage: @ 400 rpm (Cranking) 3.0 -6.3 V @ 750 rpm (Idle) 9 - 16 V @ 1500 rpm 18 - 28 V @ 3500 rpm 35 - 55 V Crank Position Sensor Resistance 445 - 565 W IGNITION ECM (Coil Primary) - Peak Voltage: SYSTEM @ 400 rpm (Cranking) 180 - 320 V Readings taken @ @ 750 rpm (Idle) 180 - 235 V 68°F (20°C). @ 1500 rpm 230 -290 V @ 3500 rpm 280 - 340 V Ignition Coil Resistance Primary 1.8 - 2.6 W Secondary (Between Boots) Coil for Cylinders #1 & #4 18.97 - 35.23 kW Coil for Cylinders #2 & #3 18.55 - 34.45 kW Engine Protection Controls: Engine Speed Limiter Spark Cut-Out to Cylinders #1 or #4 6200 rpm #1 and #4 6250 rpm #1, #4, and #2 or #3 6350 rpm #1, #2, #3, and #4 6450 rpm Overheat/Low Oil Pressure Engine Speed Control (Spark Cut-Out to Cylinders #1 and #4). Gradually Lowers to 2000 rpm Water Temperature Sensor: Warning Horn/rpm Reduction. 194°F (90°C) Reset Temperature and Closed Throttle. 167°F (75°C) Engine Oil Pressure Switch: Warning Horn/rpm Reduction Continuity Below 21.78 psi (150 kPa) Page 2A-2 90-881980R1 NOVEMBER 2001 IGNITION Reset Pressure and Closed Throttle. No Continuity Above 21.78 psi (150 kPa) Engine Water Temperature Sensor IGNITION SYSTEM Readings taken @ 68°F (20°C). Resistance: @ 41°F (5°C) @ 68°F (20°C) @ 212°F (100°C) 4.62 kW 2.44 kW 0.19 kW Throttle Position Sensor (TPS): Input Voltage @ Idle (750 rpm) 5.0 ± 0.25 V Output [email protected] Idle (750 rpm) 0.718 - 0.746 V Special Tools 1. Flywheel Holder P/N 91-83163M 2. Flywheel Puller P/N 91-83164M 3. Timing Light P/N 91-99379 90-881980R1 NOVEMBER 2001 Page 2A-3 IGNITION 4. Direct Voltage Adapter P/N 91-89045 or P/N 91-89045--1 5. 91-89045 Spark Board P/N 91-850439T 91-89045-1 6. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1 7. Crank Position Sensor Test Harness 91-881825 58677 Page 2A-4 90-881980R1 NOVEMBER 2001 IGNITION 8. Stator Coil Test Harness 91-881824 58676 9. Throttle Position Sensor Test Harness 91-881827 58678 10. ECM (Coil Primary) Test Harness 91-881826 58679 90-881980R1 NOVEMBER 2001 Page 2A-5 IGNITION Flywheel 22 21 3 5 6 7 10 9 8 14 15 16 17 18 12 11 19 1 24 23 20 2 3 4 13 14 Page 2A-6 90-881980R1 NOVEMBER 2001 IGNITION Flywheel REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 FLYWHEEL COVER 2 2 SCREW (M6 X 20 MM) 65 7.5 3 4 COLLAR 4 2 GROMMET 5 1 NUT (36 MM HEX) 140 190 6 1 WASHER 7 1 FLYWHEEL – 1 STATOR KIT 8 2 CRANK POSITION SENSOR 9 1 STATOR 10 3 SCREW (M6 X 28 MM) 65 7.5 11 1 SCREW (M4 X 8 MM) 18 2 12 1 CLAMP 13 4 SCREW (M6 X 28 MM) 70 8 14 2 DOWEL PIN 15 1 ROTOR 16 1 KEY 17 1 TIMING PLATE 18 1 SCREW 19 1 DECAL - Warning Neutral 20 1 DECAL - Warning Spinning Flywheel 21 1 DECAL - Servicing Referral 22 1 DECAL - Engine Oil/Valve 23 1 DECAL – Emergency Starting 24 1 DECAL - EPA 90-881980R1 NOVEMBER 2001 Page 2A-7 IGNITION Electrical Components 18 17 19 22 21 20 15 16 13 14 8 6 7 91011 12 5 26 27 24 23 28 33 34 37 35 36 38 29 31 30 32 Dielectric Grease 6 6 6 6 6 6 39 40 25 2 3 41 Page 2A-8 90-881980R1 NOVEMBER 2001 IGNITION Electrical Components REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 COVER 2 1 WIRE HARNESS 3 4 FUSE (20A) 4 4 FUSE (30A) 5 1 FUSE PULLER 6 1 BRACKET 7 1 SCREW 8 1 RELAY 9 2 WASHER 10 2 LOCKWASHER 11 2 SCREW 12 2 BOOT 13 1 RELAY 14 1 SCREW 15 1 CLAMP 16 1 SCREW 17 1 BRACKET 18 1 CLAMP 19 1 CLAMP 20 5 SCREW (M6 X 28 MM) 70 8 21 5 DAMPER 22 5 BUSHING 23 1 RELAY ASSEMBLY 24 1 LEAD WIRE 25 2 CAP 26 2 SCREW (M6 X 10 MM) 70 8 27 1 SCREW (M6 X 14 MM) 70 8 28 1 SCREW (M6 X 28 MM) 70 8 29 1 BATTERY CABLE (POSITIVE) 30 1 BATTERY CABLE (NEGATIVE) 31 1 NUT (M8) 70 8 32 1 SCREW (M6 X 20 MM) 70 8 33 1 HARNESS - Adaptor/Trim 34 1 HARNESS - Trim Motor Adaptor 35 1 HARNESS - Adaptor Assy.-Remote 36 1 RETAINER 37 1 CONNECTOR 38 AR STA-STRAP 39 1 DECAL - Warning-High Voltage 40 1 DECAL - Warning-Start in Gear 90-881980R1 NOVEMBER 2001 Page 2A-9 IGNITION Ignition Components 12 12 11 10 9 11 10 14 1413 11 5 7 2 1 3 4 8 6 Page 2A-10 90-881980R1 NOVEMBER 2001 IGNITION Ignition Components REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 ENGINE CONTROL UNIT 2 4 SCREW (M6 X 28 MM) 70 8 3 4 GROMMET 4 4 BUSHING 5 1 RECTIFIER & REGULATOR ASSEMBLY 6 2 SCREW (M6 X 25 MM) 70 8 7 1 SCREW (M6 X 20 MM) 70 8 8 1 IGNITION COIL 9 1 IGNITION COIL 10 2 PLATE 11 2 STA-STRAP 12 4 SCREW (M6 X 25 MM) 70 8 13 2 CLAMP 14 2 CLAMP 90-881980R1 NOVEMBER 2001 Page 2A-11 IGNITION Sensors 6 1 3 2 5 4 8 7 10 9 11 12 16 12 13 14 15 12 12 Page 2A-12 90-881980R1 NOVEMBER 2001 IGNITION Sensors REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 WATER TEMPERATURE SENSOR 2 1 RETAINER 3 2 SCREW (M6 X 16 MM) 70 8 4 1 GASKET 5 1 CLAMP 6 1 SCREW (M6 X 10 MM) 70 8 7 1 PLATE 8 1 SCREW (M6 X 10 MM) 70 8 9 1 PLATE 10 2 SCREW (M6 X 16 MM) 70 8 11 1 WIRE HARNESS 12 6 STA-STRAP 13 1 CLAMP 14 1 OIL PRESSURE SWITCH 70 8 15 1 LEAD WIRE 16 1 SCREW (M6 X 10 MM) 70 8 90-881980R1 NOVEMBER 2001 Page 2A-13 IGNITION Theory of Operation The ignition system uses a microcomputer-controlled CDI (Capacitor Discharge Ignition) system. This system provides quick voltage buildup and strong spark required for high power and high performance engines. The ECM ignition system does not incorporate mechanically operated points, therefore making this CDI unit virtually maintenance free. As the flywheel rotates, electrical power (alternating current) is produced by the stator coils. This power is rectified by diodes so that direct current voltage is utilized by the ignition system. When the ignition driver is off, the D.C. voltage is stored by the capacitor. Once capacitor voltage is charged to its potential, a gate signal is applied on the SCR and the residual current is dissipated through the capacitor charging coils. Ignition timing is regulated by the ECM which receives status input from three different signals. These signals include the crankshaft position, engine revolution and throttle position. The voltage discharged to the primary winding of the ignition coil causes a surge of high voltage to be induced in the secondary winding of the ignition coil. This induced voltage of sufficient amplitude causes the spark plugs to fire. Page 2A-14 90-881980R1 NOVEMBER 2001 IGNITION Ignition Component Description Electronic Control Module (ECM) Under normal operating conditions the microcomputer-controlled CDI system has two basic modes of operation: Ignition Timing Control During Engine Start-up, and Normal Operation. Ignition Timing Control During Engine Start Up The ignition timing is mainly determined by signals from the throttle position sensor and the crank position sensors. Corrections are controlled by the water temperature sensor, the oil pressure switch, the shift position switch, the engine stop switch after engine start and the main switch. During cranking, the ignition timing is 10° BTDC until the engine starts, then it is retarded 1° per second until it reaches 4° ATDC. The ignition timing is normally controlled between 4° ATDC and 26° BTDC. While the engine is warming up, the ignition timing is fixed at 4° ATDC. At rapid acceleration or deceleration ignition timing changes according to the throttle valve opening angle. Normal Operation This mode operates between 4° ATDC and 26° BTDC. The ignition timing is automatically adjusted by the microcomputer. The microcomputer receives three signals (i.e., crankshaft position, engine revolution, and throttle position) every 5ms (microseconds) and then adjusts the ignition timing accordingly. Two crank position sensors (CPS) send signals to the microcomputer which then determines the crankshaft position and engine revolution. The throttle position sensor (TPS) also sends signals to the microcomputer which then determines the throttle position. The microcomputer uses these three signals to determine the proper ignition timing. 90-881980R1 NOVEMBER 2001 Page 2A-15 IGNITION Protection Controls This ignition system incorporates three protection controls that are described below. OVER-REVOLUTION CONTROL If the engine speed exceeds 6,200 rpm, the ignition of either cylinder #1 or #4 is cut. If the engine speed exceeds 6,250 rpm, the ignition of both cylinders #1 and #4 is cut. If the engine speed exceeds 6,350 rpm, the ignition of cylinders #1 and #4, and either cylinder #2 or #3 is cut. If the engine speed exceeds 6,450 rpm, the ignition of all four cylinders is cut. OVERHEATING CONTROL When the engine speed is less than 2,000 rpm, this control mode is delayed 60 seconds after the engine is started. When the engine speed is 2,000 rpm or more, this control mode is delayed 20 seconds after the engine is started. The engine is considered to be over-heating if its temperature increases from 167° F (75° C) to 185° F (85° C). If its temperature exceeds 194° F (90° C), this control mode begins. The warning buzzer sounds (constant tone), and the ignition and injection are cut according to the misfiring rate, gradually reducing engine speed to approximately 2000 rpm. If the engine overheats, the ignition/injection of both cylinders #1 and #4 is cut. However the ignition/injection of cylinders #2 and #3 is not cut. After the engine temperature decreases to less than 167° F (75° C), the overheat warning can be cancelled by decreasing the throttle opening angle to less than 2°, and turning the ignition key to the off position. LOW OIL PRESSURE CONTROL When the oil pressure switch turns on (oil pressure 21.75 psi (150 kPa) or below), this mode starts. The warning buzzer sounds (constant tone) and the ignition/injection are cut according to the misfiring rate, gradually reducing engine speed to approximately 2000 rpm. If the engine’s oil pressure is low, the ignition/injection of both cylinders #1 and #4 is cut, however the ignition/injection of cylinders #2 and #3 is not cut. Once the oil pressure increases to 21.75 psi (150 kPa) or higher, the warning can be cancelled by decreasing the throttle opening angle to less than 2°, and turning the ignition key to the “OFF” position. Shift Switch As the remote control handle is shifted from forward gear to neutral (idle position), the switch is monitored by the ECM which will adjust engine idle rpm accordingly – NEUTRAL @ 750 ± 50 rpm; – IN GEAR @ 700 ± 50 rpm.. a b c a-Shift Switch b-Bracket c-Alternate Mounting Holes Page 2A-16 90-881980R1 NOVEMBER 2001 IGNITION 90-881980R1 NOVEMBER 2001 Page 2A-17 Throttle Position Sensor (TPS) If the TPS is faulty, the ignition timing will automatically be fixed at 10° BTDC. a a - Throttle Position Sensor Engine Water Temperature Sensor If the engine temperature sensor is faulty, the ignition timing will automatically be fixed at 10° BTDC. a a - Engine Temperature Sensor Flywheel Assembly The flywheel assembly contains six permanently charged magnet segments which are bonded and retained to the inner wall of the flywheel. Each magnet contains a north and a south pole providing a 12 pole system. IGNITION Page 2A-18 90-881980R1 NOVEMBER 2001 Stator Assembly The stator assembly, located under the flywheel, contains coil windings which provides three-phase AC voltage to power the ignition, electronic engine controls, and battery charging. As the flywheel permanent magnets pass the coil windings, an AC pulse current is produced at each coil winding as the magnet polarity changes. (South to North), (North to South) etc. Crank Position Sensors (CPS) 57673 a a - Crank Position Sensors (CPS) As the crankshaft rotates, the CPS’s (2) sense a passing tooth on the rotor (located on the crankshaft, under the cam belt drive gear). The CPS’s send signals to the microcomputer (located within the ECM), which then determines both the crankshaft position and engine speed. Ignition Coils 58566 a a - Ignition Coils The primary (+) side of the ignition coil receives voltage discharged from a capacitor in the ignition (CDI) circuit located inside the ECM. The voltage is multiplied by the coil until it can jump the spark plug gap. The ignition coil will produce a high voltage current each crankshaft revolution, producing a spark at each cylinder at the same time (Wasted Spark Ignition). Ignition coil maximum output is approximately 40,000 volts. IGNITION Ignition Test Procedures Direct Voltage Adapter (DVA) WARNING DANGER – HIGH VOLTAGE/SHOCK HAZARD! Do not touch ignition components and/or metal test probes while engine is running and/or being “cranked”. STAY CLEAR OF SPARK PLUG LEADS. To assure personal safety, each individual spark plug lead should be grounded to engine. WARNING When testing or servicing the ignition system, high voltage is present. DO NOT TOUCH OR DISCONNECT any ignition parts while engine is running, while key switch is on or while battery cables are connected. CAUTION Failure to comply with the following items may result in damage to the ignition system. 1. DO NOT reverse battery cable connections. The battery negative cable is (–) ground. 2. DO NOT “spark” battery terminals with battery cable connections to check polarity. 3. DO NOT disconnect battery cables while engine is running. 4. DO NOT crank engine with ECM or Ignition Coils not grounded. CAUTION To protect against meter and/or component damage, observe the following precautions: • 400 VDC* test position (or higher) MUST BE used for all tests. • INSURE the Positive (+) lead/terminal of DVA is connected to the Positive (+) receptacle of meter. • DO NOT CHANGE meter selector switch position while engine is running and/or being “cranked”. • ALL COMPONENTS MUST BE GROUNDED during tests. Running or “cranking” engine with ECM or Ignition Coils ungrounded may damage components. * If using a meter with a built-in DVA, the DVA/400 or DVA/500 VDC test position should be used. NOTE: If test leads are not supplied with the Direct Voltage Adapter,use test leads supplied with multi meter. Test procedures and specifications are provided for checking primary ignition voltage while the engine is running and/or being “cranked” with all harnesses connected. 90-881980R1 NOVEMBER 2001 Page 2A-19 IGNITION Ignition Troubleshooting WARNING DANGER - HIGH VOLTAGE/SHOCK HAZARD! Do not touch ignition components and/or metal test probes while engine is running and/or being “cranked”. STAY CLEAR OF SPARK PLUG LEADS. To assure personal safety, each individual spark plug lead should be grounded to engine. WARNING When testing or servicing the ignition system, high voltage is present. DO NOT TOUCH OR DISCONNECT any ignition parts while engine is running. IMPORTANT: This ignition system requires proper battery voltage to obtain proper spark voltage. Tool: Multimeter/DVA Tester 91-99750A1 or DMT 2000 Multimeter with Direct Voltage Adaptor (91-89045) *If using a meter that requires a DVA adapter, place selector switch to the 400 VDC position. NOTE: Copper is an excellent conductor, however resistance may notably vary between low and high temperature. Therefore, reasonable differences can be accepted between resistance readings and specifications. The above readings are for a cold (room temperature) engine. Resistance will increase if the engine is warm. Ignition Diagnostic Procedures TROUBLESHOOTING TIP: With engine running, use inductive timing light to check spark advance of each cylinder as throttle is opened and closed. If timing advances and retards on each cylinder, ignition system is MOST LIKELY functioning properly. IMPORTANT: If outboard appears to have an ignition system failure, it is recommended that before beginning in-depth troubleshooting: a. Ensure that the engine is mechanically sound condition. (Fuel System, Cylinder Compression etc.). b. Check all engine ground leads for loose or corroded connections. c. Disconnect and reconnect ignition harness connectors to verify proper continuity. SUGGESTED TESTING PROCEDURES NOTE:The following recommended tests and probable causes are not listed in any specific order. The technician should use this table as a guide to help isolate and test the specific problem/condition. Always perform the DVA tests first (if applicable), then perform resistance test to validate suspected component failure. Page 2A-20 90-881980R1 NOVEMBER 2001 IGNITION *Recommended Test (1) DVA TEST (Direct Voltage Adapter) (2) OHM TEST (Resistance Testing) (3) Replace Component and Retest (4) Mechanical Test/Repair (5) Battery Voltage Check PROBLEM/CONDITION Probable Cause *Perform Test No. No Spark Condition (All Cylinders) Stator 1-2 (ECM) Stop Circuit Short to Ground: 3 a - stop circuit lead 2 b - lanyard stop switch 2 c - tiller handle stop button (if supplied) 2 d- remote control harness 2 Ignition Coil 2 a - primary Circuit Shorted to Ground 2 Spark Plugs Open Ground Condition: 3 a - ignition coil 2 b - stator ground 3 c - (ECM) 3 d - battery to ECM 5 Rectifier/Regulator 1-2 No Spark Condition (One or two Cylinder) High Tension Lead (Resistance Lead) Spark Plug Cap (Resistor) Spark Plug 2 2 3 Weak Spark Condition Ground Connection at: a - Ignition Coil Primary Leads 2 b - Stator 2 c - (ECM) Primary Coil Supply Leads High Resistance To Ground at: 3 a - stop/lanyard switch (water/corrosion) 2 Weak Charge Coil (Stator) 1-2 Ignition Coil/High Tension Lead(s) 1-2-3 Spark Plug(s) 2 Spark Plug Cap (Resistor) 3 Spark Plug Cap Leak 3 (ECM) Failure 3 Battery Voltage Condition 5 Rectifier/Regulator 1-2 Timing Fluctuates NOTE: It is considered normal for the timing to fluctuate approximately 1° - 2° within the designated timing window. Loss Of Oil Pressure/Over Heating: a - timing retards and fluctuates, rpm will drop below 2000 rpm Flywheel Key Sheared (ECM) 4 4 3 Timing Will Not Advance Low Oil Pressure/Engine Over Heating: a - timing retards and fluctuates, rpm will remain below 2000 rpm 4 (ECM) 3 90-881980R1 NOVEMBER 2001 Page 2A-21 IGNITION *Recommended Test (cont.) (1) DVA TEST (Direct Voltage Adapter) (2) OHM TEST (Resistance Testing) (3) Replace Component and Retest (4) Mechanical Test/Repair (5) Battery Voltage Check Engine Misfires At High RPM Low Oil Pressure/Engine Over Heating: a - timing retards and fluctuates, rpm will remain below 2000 rpm (Cyl. #1 & #4) 4 Ignition Coil/High Tension Lead(s) 2 Spark Plug Cap(s) 2 Spark Plug(s) 3 (ECM) Ground Connection: 3 a - (ECM) 3 b - ignition coil 2 Engine Hard To Start Cold Debris In Fuel Injection Circuit Weak Spark Condition Throttle Plate in Open Position 4 1 4 Engine Hard To Start Hot Weak Spark Condition Vapor Lock Debris In Fuel Injectors 4 4 4 Engine Will Not Run Over 3000 RPM Low Oil Pressure/Engine Over Heating: a - timing retards and fluctuates, rpm will remain below 2000 rpm 4 Ignition Coil/High Tension Lead(s) 2 (ECM) 3 Spark Plug(s) 3 Engine Occasionally Misfires Ignition Coil/High Tension Lead(s) 2 Spark Plug Cap(s) 2 Spark Plug(s) Ground Connection at: 3 a - ignition coil 2 b - (ECM) High Resistance To Ground at: 3 a - stop/lanyard switch (water/corrosion) 2 (ECM) 3 Engine Surges Over Boat Under Propped 4 6200 RPM While Under Load NOTE: The engine (ECM) will retard timing and reduce rpm above 6200 rpm. Propeller Hub Spun 4 Page 2A-22 90-881980R1 NOVEMBER 2001 IGNITION 90-881980R1 NOVEMBER 2001 Page 2A-23 Testing Ignition Components ECM Peak Voltage (Coil Primary) 1. Plug test harness between each coil harness (test both coils), and perform tests as specified in chart below. • If the reading obtained is above specification on any of the tests - replace the ignition coil. • If the reading obtained is below specification on any of the tests - measure the stator coil output peak voltage. b a 58657 91-881826 91-89045-1 c 91-854009A1 d e a - Direct Voltage Adaptor (91-89045-1) b - DMT 2000 Multi - Meter (91-854009A1) c - Ignition Coil Test Harness (91-881826) d - To Ignition Coil Harness e - To Engine Wiring Harness NOTE: Use direct voltage adaptor, DMT 2000 digital multi-meter and test harness (91-881826) while performing test. METER TEST LEADS METER SCALE READING (V) RED BLACK TEST HARNESS LEADS #1 AND #4 CYL. BLK/WHT #1 AND #4 CYL. GROUND DC VOLTS 180-320 V @ 400 RPM (CRANKING*) 180-235 V @ 750 RPM (IDLE) #2 AND #3 CYL. BLK/WHT #2 AND #3 CYL. GROUND 180 230-290 V @ 1500 RPM 280-340 V @ 3500 RPM *Cranking specifications obtained with high tension spark plug leads removed from spark plugs. IGNITION Page 2A-24 90-881980R1 NOVEMBER 2001 Crank Position Sensor (CPS) - Peak Voltage 1. Plug in the test harness and perform tests as specified in chart below. • If the reading obtained is above specification on any of the tests - replace the ECM unit. • If the reading obtained is below specification on any of the tests - replace the CPS. b a 91-89045-1 91-881825 c 91-854009A1 58645 d e a - Direct Voltage Adaptor (91-89045-1) b - DMT 2000 Multi - Meter (91-854009A1) c - CPS Test Harness (91-881825) d - To Engine Wiring Harness e - To CPS Harness NOTE: Use direct voltage adaptor, DMT 2000 digital multi-meter and test harness 91-881825 while performing test. METER TEST LEADS METER SCALE READING (V) RED BLACK TEST HARNESS LEADS #1 AND #4 CYL. WHT/RED #1 AND #4 CYL. BLK DC VOLTS 3.0 - 6.3 V @ 400 RPM (CRANKING*) 9.0 - 16.0 V @ 750 RPM (IDLE) #2 AND #3 CYL. WHT/BLK #2 AND #3 CYL. BLK 18.0 - 28.0 V @ 1500 RPM 35.0 - 55.0 V @ 3500 RPM *Cranking specifications obtained with high tension spark plug leads removed from spark plugs. IGNITION 90-881980R1 NOVEMBER 2001 Page 2A-25 Stator Coil Peak Voltage 1. Plug in the test harness and perform tests as specified in chart below. • If the reading obtained is above specification on any of the tests - measure the ECM unit output peak voltage. • If the reading obtained is below specification on any of the tests - replace the stator. 91-881824 58658 b 91-89045-1 a 91-854009A1 c a - Direct Voltage Adaptor (91-89045-1) b - DMT 2000 Multi - Meter (91-854009A1) c - CPS Test Harness (91-881825) NOTE: Use direct voltage adaptor 91-89045-1, DMT 2000 digital multi-meter 91-854009A1 and test harness (91-881824) while performing test. METER TEST LEADS METER SCALE READING (V) RED BLACK TEST HARNESS LEADS 10-18 V @ 400 RPM (CRANKING) GREEN 1 GREEN 2 DC VOLTS 16 - 24 V @ 750 RPM ( IDLE) GREEN 1 GREEN 3 @ ) 16 - 24 V 1500 RPM 16 - 24 V @ 3500 RPM GREEN 2 GREEN 3 *Cranking specifications obtained with high tension spark plug leads removed from spark plugs. GRN 1 GRN 2 GRN 1 GRN 3 GRN 2 GRN 3 91-881824 a b a b a b 58676 RED RED RED BLACK BLACK BLACK a - To Stator Harness b - To Voltage Regulator/Rectifier IGNITION Page 2A-26 90-881980R1 NOVEMBER 2001 Rectifier/Regulator Output - Peak Voltage 1. Plug in the test harness and perform tests as specified in chart below. • If the reading obtained is excessively below specification - check the stator coil output peak voltage. 91-881824 58658 b a c 91-89045-1 91-854009A1 a - Direct Voltage Adaptor (91-89045-1) b - DMT 2000 Multi - Meter (91-854009A1) c - Stator Test Harness (91-881824) NOTE: Use direct voltage adaptor 91-89045-1, DMT 2000 digital multi-meter 91-854009A1 and test harness (91-881824) while performing test. METER TEST LEADS METER SCALE READING (V) RED BLACK TEST HARNESS LEADS DC VOLTS 12.5 - 15.5 V @ 750 RPM (IDLE) 13.0 - 16.0 V @ 1500 RPM RED BLACK 13.0 - 16.0 V @ 3500 RPM RED BLK 91-881824 a b 58676 RED BLACK a - To Stator Harness b - To Voltage Regulator/Rectifier IGNITION 90-881980R1 NOVEMBER 2001 Page 2A-27 Throttle Position Sensor (TPS) Input Voltage 1. Disconnect Throttle Position Sensor harness. 2. Connect TPS Test Harness (91-881827) between TPS and TPS harness. 3. If the reading obtained is out of specification - check ECM. 91-881827 58659 91-854009A1 NOTE: Use DMT 2000 digital multimeter (91-854009A1) and test harness (91-881827) while performing test. METER TEST LEADS METER SCALE READING (V) RED BLACK TEST HARNESS LEADS DC VOLTS 5 0 ± 0 25 V @ 750 RPM ORANGE BLACK IGNITION Page 2A-28 90-881980R1 NOVEMBER 2001 Throttle Position Sensor Output Voltage 1. Disconnect Throttle Position Sensor (TPS) Harness. 2. Connect TPS Test Harness (91-881827) between TPS and TPS Harness. 3. Start engine and allow it to warm up for several minutes. 4. Measure the voltage at engine idle speed in forward gear. 5. If the reading obtained is out of specification – adjust the TPS position. 6. Slowly open and close the throttle valves. Voltage should change gradually. If not, replace TPS. 91-881827 58659 91-854009A1 NOTE: Use DMT 2000 digital multimeter (91-854009A1) and test harness (91-881827) while performing test. METER TEST LEADS METER SCALE READING (V) RED BLACK TEST HARNESS LEADS DC VOLTS 0.718 ± 0.746 V @ 750 RPM PINK BLACK (IDLE) Throttle Position Sensor Adjustment The Throttle Position Sensor and throttle shaft are pre-set at factory during emission calibration. No adjustments should normally be made to these components as emission performance will be compromised. However, should it be necessary to replace the Throttle Position Sensor or throttle body, the new components should be adjusted to initial factory emission specifications. Refer to Section 2C for proper procedure. IGNITION 90-881980R1 NOVEMBER 2001 Page 2A-29 Resistance Tests When performing resistance tests, all component leads must be disconnected. Readings may very slightly due to temperature changes. Readings listed taken at 68° F (20° C). Stator Coil 1. Plug test harness into stator harness and perform tests as specified in chart below. • Out of specification – replace. 91-881824 NOTE: Use ohm meter and test harness 91-881824 while performing test. METER TEST LEADS METER SCALE READING () RED BLACK TEST HARNESS LEADS GREEN 1 GREEN 2 RX1 0.2 - 0.8 GREEN 1 GREEN 3 GREEN 2 GREEN 3 GRN 1 GRN 2 GRN 1 GRN 3 GRN 2 GRN 3 91-881824 a a a 58676 RED RED RED BLACK BLACK BLACK a - To Stator Harness IGNITION Page 2A-30 90-881980R1 NOVEMBER 2001 Crank Position Sensor (CPS) 1. Plug test harness into crank position sensor harness and perform tests as specified in chart below. • Out of specification – replace 91-881825 58645 a b a - CPS Test Harness (91-881825) b - To CPS Harness NOTE: Use ohm meter and test harness 91-881825 while performing test. METER TEST LEADS METER SCALE READING () RED BLACK TEST HARNESS LEADS #1 AND #4 CYL. WHT/RED #1 AND #4 CYL. BLK RX1 445 - 565 #2 AND #3 CYL. WHT/BLK #2 AND #3 CYL. BLK Ignition Coil (Primary) 1. Plug test harness into each ignition coil harness (test both coils), and perform tests as specified in chart below. • Out of specification – replace. 58657 91-881826 b a a - Ignition Coil Test Harness (91-881826) b - To Ignition Coil Harness NOTE: Use ohm meter and test harness 91-881826 while performing test. METER TEST LEADS METER SCALE READING () RED BLACK TEST HARNESS LEADS RX1 1.8 - 2.6 BLK/WHT RED/YEL IGNITION Ignition Coil (Secondary) NOTE:DO NOT remove high tension spark plug leads/spark plug caps when performing this test. METER TEST LEADS METER SCALE READING () RED BLACK RX1KRX1K COIL FOR CYL. #1 & #4 – 18.97 - 35.23 COIL FOR CYL. #2 & #3 – 18.55 - 34.45HIGH TENSION LEAD HIGH TENSION LEAD Ignition Spark Gap 1. Remove the spark plugs from the engine. Connect the spark plug cap to the spark gap tester (P/N 91-850439). 2. Set the spark gap length on the adjusting tool (Spark Gap 0.4 in. 11mm). 3. Crank the engine and observe the ignition system spark through the discharge window. • Below specification - continue to check the ECM unit output. 90-881980R1 NOVEMBER 2001 Page 2A-31 IGNITION Engine water Temperature Sensor 1. Place the engine cooling water temperature sensor in a container filled with water. 2. Place a thermometer in the water and slowly heat the water. 3. Measure the resistance when the specified temperature is reached. • Out of specification - replace. a BLK BLK/YEL a-Engine Temperature Sensor METER TEST LEADS METER SCALE READING () RED BLACK RX1K 4.62 @ 41°F (5°C)[email protected] (5 C) 2.44 @ 68°F (20°C) 0.19 @ 212°F (100°C) BLK/YELLOW BLK Temperature (  F) –10 5 20 35 50 65 80 95 110 125 140 155 170 185 200 215 230 245 260 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 Temperature Sensor Resistance (k) Page 2A-32 90-881980R1 NOVEMBER 2001 IGNITION Oil Pressure Switch • If the reading obtained is out of specification - replace. METER TEST LEADS READING PRESSURE RED BLACK ityContin ContinContin uity and andand below belowbelow 21.78 psi (150 kPa)SWITCH END SWITCH EDGE 90-881980R1 NOVEMBER 2001 Page 2A-33 IGNITION Flywheel Removal and Installation WARNING Engine could possibly start when turning flywheel during removal and installation. To prevent this type of accidental engine starting and possible serious injury, always remove spark plug leads from spark plugs. Removal 1. Remove flywheel cover. 57601 a a-Screws (2) Page 2A-34 90-881980R1 NOVEMBER 2001 IGNITION 90-881980R1 NOVEMBER 2001 Page 2A-35 2. Loosen flywheel nut. Hold flywheel using flywheel holder (91-83163M). 3. Remove nut and washer. 91-83163M b 57583 a c d a - Flywheel Holder (91-83163M) b - Breaker Bar with 36 mm Socket c - Nut (36 mm Hex) d - Washer 4. Loosen flywheel using puller (91-83164M). Remove flywheel and key. 91-83164M 57582 b c a a - Flywheel Puller (91-83164M) b - Flywheel c - Key IGNITION Page 2A-36 90-881980R1 NOVEMBER 2001 Installation 1. Place flywheel key into slot. 2. Install flywheel. 3. Install washer and nut. 4. Hold flywheel using flywheel holder (91-83163M) and tighten nut to the specified torque. 91-83163M c d f e b a 110 110 4-Stroke Outboard Oil a - Key b - Flywheel c - Washer d - Nut (36 mm Hex) e - Torque Wrench f - Flywheel Holder (91-83163M) Flywheel Nut Torque 140 lb-ft (190 Nm) IGNITION 90-881980R1 NOVEMBER 2001 Page 2A-37 Stator Removal and Installation 1. Remove flywheel. 2. Remove electrical cover. 3. Disconnect stator coupler from rectifier/regulator. 4. Remove screw from j-clip. 5. Remove stator mounting screws (3). 6. Disconnect RED wire connector and remove ground lead. 7. Reverse steps for installation. 57586 e d b 58665 c 58662 a a - Press Clips to Release b - Electrical Cover c - Stator Coupler d - J-clip e - Screws (3) M6 x 30 mm Stator Screw Torque 70 lb-in. (8 Nm) IGNITION Page 2A-38 90-881980R1 NOVEMBER 2001 Timing Belt Removal and Installation Removal 1. Remove flywheel (refer to flywheel removal section). 2. Remove stator (refer to stator removal on previous page). 3. Remove stator coil assembly base screws (4). 4. Remove timing belt tensioner spring. 5. Loosen timing belt tensioner screw. 6. Remove timing belt. 57585 57550 a b c a - Base Screws (4) b - Timing Belt Tensioner Spring c - Timing Belt Tensioner Screw IGNITION Installation 1. Align marks on driven gears as shown. 2. Align mark on drive gear as shown. 3. Follow sequence in note below and install timing belt onto drive gear. Slide timing belt onto driven sprockets. 4. Install belt tensioner spring. 5. Tighten belt tensioner screw. NOTE:Install timing belt with parts name up. NOTE:Install timing belt over drive gear first (1), then around driven gear (2) making sure belt is tight from drive gear to driven gear. Continue to keep belt tight while installing belt around other driven gear (3). Make sure timing marks are lined up on drive gear and driven gears, then place belt around belt tensioner (4). Install spring and tighten screw. 57550 b c d a e1 23 4 a-Timing Mark on Driven Gears b-Timing Belt Tensioner Spring c-Timing Belt Tensioner Screw d-Timing Mark on Drive Gear e-Parts Name Up On Timing Belt Belt Tensioner Screw Torque 29 lb-ft (40 Nm) 90-881980R1 NOVEMBER 2001 Page 2A-39 IGNITION Page 2A-40 90-881980R1 NOVEMBER 2001 Crank Position Sensor Removal 1. Remove stator (refer to stator removal on previous page). 2. Remove stator coil assembly base screws. 3. Remove j-clips and 2 screws per crank position sensor from under side of stator coil base assembly. d b c c 57585 a 57673 b a - Stator Coil Base Screws (4) b - J-clips (2) c - Crank Position Sensor Screws (4) d - Crank Position Sensors (2) Crank Position Sensor Installation 1. Position crank position sensors on stator plate. 2. Route sensor harnesses through respective j-clip and retainer. 3. Secure sensors with screws. Tighten screws to the specified torque. Crank Position Sensor Screw Torque 43 in-ft. (5 Nm) IGNITION Voltage Regulator/Rectifier Removal and Installation 1. Disconnect regulator harness. 2. Remove 2 screws securing regulator and remove regulator. 58665 a b a-Regulator Harness b-Screws (2) 90-881980R1 NOVEMBER 2001 Page 2A-41 IGNITION 3. Reverse steps for installation. 58665 a b a-Regulator Harness b-Screws (2) Voltage Regulator/Rectifier Mounting Screw Torque 70 lb-in. (8 Nm) Page 2A-42 90-881980R1 NOVEMBER 2001 IGNITION 90-881980R1 NOVEMBER 2001 Page 2A-43 ECM Removal 1. Depress clips and remove electrical cover. b 58662 a a - Clips b - Electrical Cover 2. Remove intake silencer retaining screw and remove silencer. 58663 b a a - Intake Silencer b - Screw M6 x 20 mm IGNITION Page 2A-44 90-881980R1 NOVEMBER 2001 3. Disconnect ECM harness connectors. 4. Remove 4 screws securing ECM and remove ECM. 58570 b a b a - Harness Connectors b - Screws (4) M6 x 28 mm ECM Installation 1. Secure ECM with 4 screws. 2. Connect harness connectors. 3. Reinstall electrical cover. 4. Reinstall intake silencer and secure with screw. Intake Silencer and ECM Mounting Screw Torque 70 lb-in. (8 Nm) IGNITION 90-881980R1 NOVEMBER 2001 Page 2A-45 Ignition Coil Removal 1. Remove 5 screws securing spark plug cover. 58654 a a b a a - Screws (5) M6 x 16 mm b - Spark Plug Cover 2. Disconnect spark plug leads from spark plugs. 3. Disconnect coil harness connectors. 4. Remove ignition coil mounting screws and remove coils. 58661 b b a a - Harness Connectors b - Screws (4) M6 x 25 mm IGNITION Page 2A-46 90-881980R1 NOVEMBER 2001 Ignition Coil Installation 1. Secure coils with screws. Ignition Coil Mounting Screw Torque 70 lb-in. (8 Nm) 2. Reconnect coil harnesses. 3. Reconnect spark plug leads. 4. Reinstall spark plug cover and secure cover with 5 screws (a). 58654 a a b a Spark Plug Cover Mounting Screw Torque 65 lb-in. (7.5 Nm) IGNITION Water Temperature Sensor Removal and Installation 1. Remove wiring harness connector. 2. Remove 2 screws to remove sensor from exhaust cover. 3. Reverse steps for installation. UP b a c d 58686 a-Gasket b-Water Temperature sensor c-Retainer d-Screws (2) M6 x 16 mm Temperature Sensor Mounting Screws Torque 70 lb-in. (8 Nm) 90-881980R1 NOVEMBER 2001 Page 2A-47 CHARGING & STARTING SYSTEM ELECTRICAL Section 2B - Charging & Starting System Table of Contents 2 B Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Digital Meter . . . . . . . . . . . . . . . . . . . . . . . . . 2B-14 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3 Starting System Components . . . . . . . . . . . . . 2B-18 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-4 Description . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-18 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-6 Starting System Schematic . . . . . . . . . . . . 2B-18 Recommended Battery . . . . . . . . . . . . . . . . 2B-6 Troubleshooting the Starting Circuit . . . . . . . . 2B-19 Operating Engine Without Battery . . . . . . 2B-6 Starter Solenoid Test . . . . . . . . . . . . . . . . . . 2B-19 Battery Charging System Troubleshooting 2B-6 Starter Relay . . . . . . . . . . . . . . . . . . . . . . . . 2B-20 Battery Charging System . . . . . . . . . . . . . . . . . 2B-7 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-21 Description (25 Ampere) . . . . . . . . . . . . . . 2B-7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-21 Wiring Diagram (25 Ampere) . . . . . . . . . . . 2B-7 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 2B-22 Alternator System Test . . . . . . . . . . . . . . . . . . . 2B-8 Cleaning and Inspection . . . . . . . . . . . . . . . 2B-24 25 Ampere Stator . . . . . . . . . . . . . . . . . . . . 2B-8 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-26 Stator Coil Resistance Test . . . . . . . . . . . . . . . 2B-9 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 2B-27 Rectifier/Regulator Diode Test . . . . . . . . . . . . 2B-10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-31 Analog Meter . . . . . . . . . . . . . . . . . . . . . . . . 2B-10 90-881980R1 NOVEMBER 2001 Page 2B-1 CHARGING & STARTING SYSTEM Specifications CHARGING SYSTEM Readings taken @ 68°F (20°C). Alternator Type: Alternator Output Stator Coil - Peak Voltage: @ 400 rpm (Cranking) @ 750 rpm (Idle) @ 1500 rpm @ 3500 rpm Stator Coil Resistance Rectifier/Regulator Output - Peak Voltage: @ 750 rpm (Idle) @ 1500 rpm @ 3500 rpm Quicksilver Tachometer Setting Three Phase Stator Coil (12 Pole) 12.0 V; 25 Amps. (300 Watts) (Rectified/Regulated) 10 - 18 V 16 - 24 V 16 - 24 V 16 - 24 V 0.2 - 0.8 W 12.5 - 15.5 V 13.0 - 16.0 V 13.0 - 16.0 V “6P” or “4” STARTING SYSTEM Electric Start: Starter Type Model/Manufacturer Output Rating Reduction Gear Ratio Brush: Length Minimum Length Commutator: Sliding Gear S114-838A/Hitachi 1.4 kW - 12 V 30 Seconds 7.85 (102:13) 0.610 in. (15.5 mm) 0.374 in. (9.5 mm) Diameter Minimum Diameter Undercut Undercut Limit Ampere Draw Under: (Load) (No Load) 1.113 in. (29.0 mm) 1.100 in. (28.0 mm) 0.020 in. (0.5 mm) 0.008 in. (0.2 mm) 165 Amps 80 Amps Battery Rating Minimum Requirement 465 Marine Cranking Amps (MCA) BATTERY For operation below 32° F (0° C) or 350 Cold Cranking Amps (CCA) 1000 Marine Cranking Amps (MCA) or 775 Cold Cranking Amps (CCA) Ampere-Hours (Ah) 70 - 100 Page 2B-2 90-881980R1 NOVEMBER 2001 CHARGING & STARTING SYSTEM Special Tools 1. Brush Holder P/N91-875216 2. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1 3. Stator Coil Test Harness 91-881824 58676 90-881980R1 NOVEMBER 2001 Page 2B-3 22 21 2220 26 23 25 24 10 11 12 14 13 15 16 17 18 29 28 27 54 5 26 11 7 8 30 31 19 39 110 95 95 22 21 2220 26 23 25 24 10 11 12 14 13 15 16 17 18 29 28 27 54 5 26 11 7 8 30 31 19 39 110 95 95 CHARGING & STARTING SYSTEM STARTER MOTOR 1 2 5 11 6 95 2-4-C with Teflon 110 4-Stroke Outboard Oil Page 2B-4 90-881980R1 NOVEMBER 2001 CHARGING & STARTING SYSTEM STARTER MOTOR REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm – 1 STARTER MOTOR 1 1 STATOR 2 1 ARMATURE 3 1 BRUSH HOLDER ASSEMBLY 4 1 BRUSH SET 5 4 BRUSH SPRING 6 1 BRACKET 7 2 SCREW (M4 X 16 MM) 18 2 8 2 SCREW (M6 X 120 MM) 70 8 9 1 GEAR ASSEMBLY 10 1 CLUTCH 11 1 WASHER KIT 12 1 BRACKET 13 1 RING GEAR 14 1 GASKET 15 1 BEARING 16 1 PINION SHAFT 17 3 IDLER GEAR 18 1 BRACKET 19 1 COVER 20 2 SCREW (M6 X 52 MM) 70 8 21 1 PINION 22 1 STOP SET 23 1 LEVER 24 1 COVER 25 1 STARTER RELAY 26 3 SCREW (M8 X 45 MM) 156 13 17.5 27 1 TERMINAL 28 1 LOCKWASHER 29 1 NUT 30 1 NUT 31 1 COVER 90-881980R1 NOVEMBER 2001 Page 2B-5 CHARGING & STARTING SYSTEM Battery Recommended Battery A 12 volt battery with a minimum rating of 465 marine cranking amps (MCA) or 350 cold cranking amps (CCA). For operation below 32° F (0° C) a rating of 1000 Marine Cranking Amps (MCA) or 775 Cold Cranking Amps (CCA) is recommended. Operating Engine Without Battery If desired (or in an emergency), engines equipped with an electric start and alternator can be started and operated without a battery (either disconnected or removed) if “WARNING”, below, is followed. WARNING Before operating engine with battery leads disconnected from battery, disconnect the three wire (stator harness plug) from rectifier. Battery Charging System Troubleshooting CAUTION The charging system may be damaged by: 1) reversed battery cables, 2) running the engine with battery cables disconnected and stator leads connected to rectifier, 3) an open circuit, such as a broken wire or loose connection. A fault in the battery charging system usually will cause the battery to become undercharged. Check battery electrolyte level, and charge battery. If battery will NOT accept a satisfactory charge, replace battery. If battery accepts a satisfactory charge, determine the cause of the charging system problem as follows. 1. Check for correct battery polarity [RED cable to POSITIVE (+) battery terminal]. If polarity was incorrect, check for damaged rectifier. See “RECTIFIER TEST”. 2. Check for loose or corroded battery connections. 3. Visually inspect wiring between stator and battery for cuts, chafing; and disconnected, loose or corroded connection. 4. Excessive electrical load (from too many accessories) will cause battery to run down. If visual inspection determines that battery connections and wiring are OK, perform the following stator and rectifier tests. Page 2B-6 90-881980R1 NOVEMBER 2001 CHARGING & STARTING SYSTEM Battery Charging System Description (25 Ampere) The battery charging system components are the stator coils, rectifier/regulator and battery. Alternating current (generated in the stator coils) flows to the rectifier/regulator, which changes the alternating current to a regulated direct current for charging the battery. Wiring Diagram (25 Ampere) a c e BLK BLKWHT WHTRED RED BLK WHT WHT WHT RED RED BLK BLK (with RED Sleeve) b BLK a-Rectifier/Regulator b-12V Battery c-Fuse-30A d-Stator Coil e-Connector d BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORG = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow 90-881980R1 NOVEMBER 2001 Page 2B-7 CHARGING & STARTING SYSTEM Alternator System Test 25 Ampere Stator 1. Check battery voltage at battery with engine running. 2. If battery voltage is above 14.5-15.0 volts, replace voltage regulator/rectifier. Check condition of battery as overcharging may have damaged battery. 3. If battery voltage is below 14.5 volts, charge battery. If battery can NOT be satisfactorily charged, replace battery. 4. If battery accepts a satisfactory charge, check battery voltage while cranking engine. If cranking voltage is not acceptable, replace battery. 5. If cranking voltage is acceptable, disconnect the RED (voltage rectifier/regulator) wire bullet connector from the RED engine wiring harness. 6. Connect RED (+) ammeter lead to RED voltage rectifier/regulator wire and the BLACK (–) ammeter lead to the RED engine wiring harness. 7. Secure starter wires away from flywheel. 8. With engine running at the indicated rpm, the ammeter should indicate the following appropriate amperes: 24 22 20 18 16 14 12 10 8 6 4 2 0 RPM x 1000 9. A reading of 22 amperes at 6000 rpm indicates the charging system is functioning properly. 10. If ammeter reads less than required amperes @ 6000 rpm, test the stator (refer to “Stator Coil Resistance Test”). If stator tests OK, replace rectifier/regulator. 0123456 Alternator current (Amps) Page 2B-8 90-881980R1 NOVEMBER 2001 CHARGING & STARTING SYSTEM 90-881980R1 NOVEMBER 2001 Page 2B-9 Stator Coil Resistance Test 1. Plug test harness (91-881824) into stator harness and perform test as specified in chart below. • Out of specification - replace. 58658 58676 58676 RED RED RED BLACK BLACK BLACK a a a 91-881824 GRN 1 GRN 1 GRN 2 GRN 3 GRN 2 GRN 3 91-854009A1 a - To Stator Harness NOTE: Use ohm meter and test harness 91-881824 while performing test. METER TEST LEADS METER SCALE READING () RED BLACK TEST HARNESS LEADS GREEN 1 GREEN 2 RX1 0.2 - 0.8 GREEN 1 GREEN 3 GREEN 2 GREEN 3 CHARGING & STARTING SYSTEM Page 2B-10 90-881980R1 NOVEMBER 2001 Rectifier/Regulator Diode Test Analog Meter NOTE: Voltage regulator/rectifier specifications are given for informational purposes only. Use the appropriate troubleshooting techniques previously mentioned to find the faulty component in the charging system. Install Stator Coil Test Harness 91-881824 onto voltage regulator/rectifier. POSITIVE SIDE OF BRIDGE DIODE TEST 1: 1. Set Ohm meter to R X 10 scale. 2. Connect RED (+) meter lead to RED regulator lead. 3. Connect BLACK (–) meter lead to each of GREEN regulator test harness leads. 58658 RED BLACK 91-881824 58676 91-99750A1 a a - To Voltage Regulator/Rectifier TEST RESULTS: 100 - 300 OHMS CHARGING & STARTING SYSTEM 90-881980R1 NOVEMBER 2001 Page 2B-11 DIODE TEST 2: 1. Set Ohm meter to R X 1k scale. 2. Connect BLACK (–) meter lead to RED regulator lead. 3. Connect RED (+) meter lead to each of GREEN regulator test harness leads. 58658 RED BLACK 91-881824 58676 91-99750A1 a a - To Voltage Regulator/Rectifier TEST RESULTS: 8 OHMS (No needle movement) CHARGING & STARTING SYSTEM Page 2B-12 90-881980R1 NOVEMBER 2001 GROUND SIDE OF BRIDGE DIODE TEST 3: 1. Set Ohm meter to R X 1k scale. 2. Connect RED (+) meter lead to BLACK ground wire. 3. Connect BLACK (–) meter lead to each of GREEN regulator test harness leads. 58658 RED BLACK 91-881824 58676 91-99750A1 a a - To Voltage Regulator/Rectifier TEST RESULTS: 8 OHMS (No needle movement) CHARGING & STARTING SYSTEM 90-881980R1 NOVEMBER 2001 Page 2B-13 DIODE TEST 4: 1. Set Ohm meter to R X 10 scale. 2. Connect BLACK (–) meter lead to BLACK ground lead. 3. Connect RED (+) meter lead to each of GREEN regulator test harness leads. 58658 RED BLACK 91-881824 58676 91-99750A1 a a - To Voltage Regulator/Rectifier TEST RESULTS: 100 - 300 OHMS CHARGING & STARTING SYSTEM Page 2B-14 90-881980R1 NOVEMBER 2001 Digital Meter NOTE: Voltage regulator/rectifier specifications are given for informational purposes only. Use the appropriate troubleshooting techniques previously mentioned to find the faulty component in the charging system. Install Stator Coil Test Harness 91-881824 onto voltage regulator/rectifier. POSITIVE SIDE OF BRIDGE DIODE TEST 1: 1. Set meter to . 2. Connect RED (+) meter lead to RED regulator lead. 3. Connect BLACK (–) meter lead to each of GREEN regulator test harness leads. 58658 RED BLACK 91-881824 58676 91-854009A1 a a - To Voltage Regulator/Rectifier TEST RESULTS: No continuity - Ouch - OL CHARGING & STARTING SYSTEM 90-881980R1 NOVEMBER 2001 Page 2B-15 DIODE TEST 2: 1. Set meter to . 2. Connect BLACK (–) meter lead to RED regulator lead. 3. Connect RED (+) meter lead to each of GREEN regulator test harness leads. 58658 RED BLACK 91-881824 58676 91-854009A1 a a - To Voltage Regulator/Rectifier TEST RESULTS: 0.4 - 0.85 OHMS CHARGING & STARTING SYSTEM Page 2B-16 90-881980R1 NOVEMBER 2001 GROUND SIDE OF BRIDGE DIODE TEST 3: 1. Set meter to . 2. Connect RED (+) meter lead to BLACK ground wire. 3. Connect BLACK (–) meter lead to one GREEN regulator test harness lead. Test. Connect BLACK (–) meter lead to each of other GREEN leads. 58658 RED BLACK 91-881824 58676 91-854009A1 a a - To Voltage Regulator/Rectifier TEST RESULTS: 0.4 - 0.85 OHMS CHARGING & STARTING SYSTEM 90-881980R1 NOVEMBER 2001 Page 2B-17 DIODE TEST 4: 1. Set meter to . 2. Connect BLACK (–) meter lead to BLACK ground lead. 3. Connect RED (+) meter lead to each of 3 GREEN regulator test harness leads. 58658 RED BLACK 91-881824 58676 91-854009A1 a a - To Voltage Regulator/Rectifier TEST RESULTS: No Continuity - Ouch - OL CHARGING & STARTING SYSTEM Starting System Components Description The function of the starting system is to crank the engine. The battery supplies electrical energy to crank the starter motor. When the ignition switch is turned to “START” position, the starter solenoid is activated and completes the starting circuit between the battery and starter. The neutral start switch opens the start circuit when the shift control lever is not in neutral. This prevents accidental starting when engine is in gear. The starting system consists of the following components. 1. Battery 2. Starter Solenoid 3. Neutral Safety Switch 4. Starter Motor 5. Ignition Switch CAUTION The starter motor may be damaged if operated continuously. DO NOT operate continuously for more than 30 seconds. Allow a 2 minute cooling period between starting attempts. Starting System Schematic BRN/WHT RED BLK BRN BRN BLK a b c d e f BLK (with RED Sleeve) a-Starter Motor d-12 Volt Battery b-Starter Solenoid e-Starter Relay c-Engine Wiring Harness f-30 Ampere Fuse Connector Page 2B-18 90-881980R1 NOVEMBER 2001 CHARGING & STARTING SYSTEM Troubleshooting the Starting Circuit Before beginning the starting circuit troubleshooting flow chart, following, check first for the following conditions: 1. Make sure that battery is fully charged. 2. Check that control lever is in “NEUTRAL” position. 3. Check terminals for corrosion and loose connections. 4. Check cables and wiring for frayed and worn insulation. 5. Check 30 Amp fuse. 6. Check starter relay. 7. Check shift position switch. Refer to Section 2A Ignition. Starter Solenoid Test 1. Inspect starter solenoid for cracks, loose terminals or loose terminal lead connections. 2. Connect ohm meter between relay (magnetic switch) terminals as shown. 3. Connect the starter motor body to the negative (–) battery terminal. 4. Connect the BROWN/WHITE lead to the positive (+) battery terminal. 5. Check that there is continuity between the relay (magnetic switch) terminals. 6. Check that there is no continuity after the BROWN/ WHITE lead is removed. NOTE:The pinion gear should be pushed out while the magnet switch is ON. a b c a-Relay Terminals b-BROWN/WHITE Lead c-Battery 90-881980R1 NOVEMBER 2001 Page 2B-19 CHARGING & STARTING SYSTEM Starter Relay 1. Inspect starter relay for cracks, loose terminals, or loose terminal lead connections. 2. Connect ohm meter between starter relay terminals as shown. 3. Connect BLACK wire lead of starter relay to negative (–) terminal of 12 volt battery. 4. Connect BROWN/WHITE wire lead of starter relay to positive (+) terminal of 12 volt battery. 5. Replace starter relay if no continuity is found. –+ +– a b c d e a-Ohm Meter Test Lead - BLACK b-Ohm Meter Test Lead - RED c-Starter Relay Wire Lead - BROWN/WHITE d-Starter Relay Wire Lead - BLACK e-12 Volt Battery Page 2B-20 90-881980R1 NOVEMBER 2001 CHARGING & STARTING SYSTEM 90-881980R1 NOVEMBER 2001 Page 2B-21 Starter Motor Removal WARNING Always disconnect the battery and remove spark plug leads from spark plugs before working on motor. 1. Disconnect battery leads. Remove electrical component cover. Disconnect RED wires from starter solenoid. Disconnect BLACK (negative) battery cable from starter. Disconnect BROWN/WHITE wire from slave solenoid. 2. Remove 3 screws. Remove starter. a c 58566 58672 d b a - Screws (3) M8 x 45 mm b - Positive (RED) Starter Motor Lead (Battery) c - Negative (BLACK) Starter Motor Lead d - BROWN/WHITE CHARGING & STARTING SYSTEM Disassembly 1. Place starter in vise. 2. Rotate pinion gear clip opening towards front. Using a screwdriver push down on pinion gear. Using a hammer tap pinion gear stopper until pinion gear clip is protruded enough to pry out with a small screwdriver. a b a-Pinion Gear b-Pinion Gear Stopper 3. Loosen nut to disconnect spade connector on start solenoid from starter motor. 4. Remove 2 screws to separate start solenoid from starter motor. b a a-Spade Connector b-Screws (2) M6 x 52 mm Page 2B-22 90-881980R1 NOVEMBER 2001 CHARGING & STARTING SYSTEM 5. Remove 2 through screws from commutator end cap to separate commutator from gear end. 6. Remove 2 screws from end cap to separate end cap from commutator. a b a a-Thru Screws (2) M6 x 120 mm b-Commutator End Cap Screws (2) M4 x 14 mm 7. Pull commutator along with grommet and brush assembly from end cap. 8. Using a suitable punch, tap plate from brush holder assembly. 9. Pull brush assembly from commutator. a a-Plate 10. For pinion gear disassembly refer to exploded view. 57621 90-881980R1 NOVEMBER 2001 Page 2B-23 CHARGING & STARTING SYSTEM Cleaning and Inspection 1. Clean all motor parts. 2. Check pinion teeth for chips, cracks or excessive wear. 3. Replace the drive clutch spring and/or collar, if tension is not adequate, or if wear is excessive. 4. Check that the brush holder is not damaged or is not holding the brushes against the commutator. 5. Replace brushes that are pitted or worn to less than 0.374 in. (9.5 mm) in length. Refer to “BRUSH REPLACEMENT”, following. 6. Replace a damaged or excessively worn bushing in the end cap. 7. Check the armature conductor (commutator bar junction) for a firm connection. A poor connection usually results in a burned commutator bar. 8. Measure commutator undercut. • Out of specification - replace. a a-Undercut Commutator Undercut Limit 0.008 in. (0.2 mm) 9. Open-circuited armatures often can be saved where an open circuit is obvious and repairable. The most likely place for an open circuit is at the commutator bars. Long cranking periods overheat the starter motor so that solder in the connections melts. The poor connections cause arcing and burning of the commutator bars. 10. Armature inspection. • Clean with 600 grit sandpaper. Page 2B-24 90-881980R1 NOVEMBER 2001 CHARGING & STARTING SYSTEM 11. Measure commutator diameter. • Out of specification - replace. Commutator Diameter Limit 1.10 in. (28.0 mm) 12. Repair bars, that are not too badly burned, by re-soldering the leads in bars (using rosin flux solder) and turning down the commutator in a lathe to remove burned material, then undercut the mica. 13. Clean out the copper or brush dust from slots between the commutator bars. 14. Check the armature for shorts and ground. See “TESTING”. 90-881980R1 NOVEMBER 2001 Page 2B-25 CHARGING & STARTING SYSTEM Testing ARMATURE TEST FOR GROUND 1. Set ohmmeter to (R x 1 scale). 2. To test commutator segments, place leads as shown. Should have continuity. If not replace. 3. To test armature core, place leads as shown. Should have no continuity. If continuity exists, replace armature. 4. To test armature shaft, place leads as shown. Should have no continuity. If continuity exists, replace armature. a b c a-Commutator Test c-Armature Shaft Test b-Armature Test BRUSH HOLDER INSPECTION 1. Measure brush length. If out of specification, replace brushes. Brush Length Limit 0.374 in. (9.5 mm) 2. Set ohmmeter to (R x 1 scale). NOTE:Only positive brushes 1 and 2 can be replaced. If negative brushes need to be replaced, then the entire brush holder assembly must be replaced. 3. Place leads on one positive brush and one negative brush. Should have no continuity. If so, replace brushes. Repeat this procedure on the other brushes. Should have no continuity. If so replace brushes. a b 2 1 a-Negative (–) Brushes b-Positive (+) Brushes Page 2B-26 90-881980R1 NOVEMBER 2001 CHARGING & STARTING SYSTEM Reassembly 1. Using special tool (91-875216) slide brush assembly over tool as shown. Slide brush holder assembly onto commutator. 2. Replace plate onto armature end shaft by tapping with a hammer. 57635 d c 57647 b a 91-875216 a-Brush Holder Tool (91-875216) b-Brush Assembly c-Plate d-Threaded Holes 3. Slide armature assembly into end cap. 4. Secure armature assembly with 2 screws. NOTE:Make sure thrust plate is installed inside cover. NOTE:Make sure plate is aligned with threaded holes as shown above. Use punch to align holes. c a b 95 2-4-C with Teflon 95 a-Thrust Plate b-End Cap c-Screws (2) M4 x 16 5. Install armature stator cover over armature. 57900 a b a-Armature Stator Cover b-End Cap 90-881980R1 NOVEMBER 2001 Page 2B-27 CHARGING & STARTING SYSTEM 6. Install lever into pinion shaft as shown. 7. Insert pinion shaft into top cover making sure it is seated properly. 8. Install bracket cover as shown. b 57901 a c a-Lever b-Pinion Shaft c-Bracket Cover 9. Align marks and insert armature shaft assembly into top cover. 10. Secure with 2 through screws. Torque screws to specified torque. b b 57636 a 57902 a-Alignment Marks b-Through Screws (2) M6 x 120 Starter Through Screw Torque 70 lb-in. (8 Nm) Page 2B-28 90-881980R1 NOVEMBER 2001 CHARGING & STARTING SYSTEM 11. Install starter solenoid to starter making sure grommet is in place and lever spring is in proper holes of dust cover plate. 12. Slide lever into starter solenoid assembly shaft hole while inserting spring below lever as shown. 13. Secure solenoid with 2 screws. Tighten to specified torque. a b g d f e f c 57626 a-Spring e-Lever b-Dust Cover Plate Holes f-Shaft Hole c-Screw M4 x 20 g-Solenoid Screws (2) M6 x 52 d-Grommet Starter Solenoid Screw Torque 70 lb-in. (8 Nm) 14. Connect spade connector on start solenoid. a b a-Spade Connector b-Nut Terminal Nut Torque 78 lb-in. (9 Nm) 90-881980R1 NOVEMBER 2001 Page 2B-29 CHARGING & STARTING SYSTEM 15. Lubricate helix threads and drive end cap bushing with SAE 10W oil. 16. Install the spring, pinion and pinion stopper onto starter shaft. 17. Place circlip into groove on shaft. 18. Press the pinion stopper over the circlip. IMPORTANT: Make sure the circlip fits tightly into pinion stopper. a b d c a b c d a-Circlip b-Pinion Stopper c-Pinion d-Spring Page 2B-30 90-881980R1 NOVEMBER 2001 CHARGING & STARTING SYSTEM 90-881980R1 NOVEMBER 2001 Page 2B-31 Installation 1. Secure RED leads to starter solenoid with nut. 58671 a a - Nut Terminal Nut Torque 70 lb-in. (8 Nm) 2. Install terminal cover over nut. 58669 a a - Cover CHARGING & STARTING SYSTEM Page 2B-32 90-881980R1 NOVEMBER 2001 3. Secure starter motor to cylinder block with 3 screws. 58566 a a - Screws Starter Motor Mounting Screw Torque 13 lb-ft (18 Nm) 4. Secure BRN/WHT lead to slave solenoid. 58672 b a a - BRN/WHT Lead b - Slave Solenoid CHARGING & STARTING SYSTEM 90-881980R1 NOVEMBER 2001 Page 2B-33 5. Connect RED positive battery cable to starter solenoid. a c 58566 b a - Positive (RED) Battery Cable b - Starter Solenoid c - Negative (BLACK) Battery Cable Positive Battery Terminal Nut Torque 70 lb-in. (8 Nm) Negative Battery Terminal Screw Torque* 70 lb-in. (8 Nm) 6. Reinstall electrical cover. 7. Reconnect battery cables to battery. * If removed. TIMING, SYNCHRONIZING, & ADJUSTING ELECTRICAL Section 2C - Timing, Synchronizing, & Adjusting Table of Contents Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-2 Throttle Shutter Synchronization . . . . . . . 2C-7 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-4 Throttle Cam Adjustment . . . . . . . . . . . . . . 2C-11 Throttle Position Sensor (TPS) and Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-5 Throttle Shaft Adjustment. . . . . . . . . . . . . . 2C-13 2 C 90-881980R1 NOVEMBER 2001 Page 2C-1 TIMING, SYNCHRONIZING, & ADJUSTING Specifications Type Microcomputer-ECM Spark Plug: Type NGK LFR6A-11 Gap 0.039 - 0.043 in. (1.0 - 1.1 mm) Hex Size 5/8 in. (16 mm) Torque 18 lb-ft (25 Nm) Hole Size 14 mm Firing Order 1-3-4-2 Ignition Timing: @ Idle (750 rpm) 4° A.T.D.C @ WOT (6000 rpm) 20° B.T.D.C Stator Coil Output - Peak Voltage: @ 400 rpm (Cranking) 10 - 18 V @ 750 rpm (Idle) 16 - 24 V @ 1500 rpm 16 - 24 V @ 3500 rpm 16 - 24 V Stator Coil Resistance 0.2 - 0.8 W Crank Position Sensor - Peak Voltage: @ 400 rpm (Cranking) 3.0 -6.3 V @ 750 rpm (Idle) 9 - 16 V @ 1500 rpm 18 - 28 V @ 3500 rpm 35 - 55 V Crank Position Sensor Resistance 445 - 565 W IGNITION ECM (Coil Primary) - Peak Voltage: SYSTEM @ 400 rpm (Cranking) 180 - 320 V Readings taken @ @ 750 rpm (Idle) 180 - 235 V 68°F (20°C). @ 1500 rpm 230 -290 V @ 3500 rpm 280 - 340 V Ignition Coil Resistance Primary 1.8 - 2.6 W Secondary (Between Boots) Coil for Cylinders 1 & 4 18.97 - 35.23 kW Coil for Cylinders 2 & 3 18.55 - 34.45 kW Engine Protection Controls: Engine Speed Limiter Spark Cut-Out to Cylinders #1 or #4 6200 rpm #1 and #4 6250 rpm #1, #4, and #2 or #3 6350 rpm #1, #2, #3, and #4 6450 rpm Overheat/Low Oil Pressure Engine Speed Control (Spark Cut-Out to Cylinders #1 and #4). Gradually Lowers to 2000 rpm Water Temperature Sensor: Warning Horn/rpm Reduction. 194°F (90°C) Reset Temperature and Closed Throttle. 167°F (75°C) Engine Oil Pressure Switch: Warning Horn/rpm Reduction Continuity Below 21.78 psi (150 kPa) Page 2C-2 90-881980R1 NOVEMBER 2001 TIMING, SYNCHRONIZING, & ADJUSTING Reset Pressure and Closed Throttle. No Continuity Above 21.78 psi (150 kPa) Engine Water Temperature Sensor IGNITION SYSTEM Readings taken @ 68°F (20°C). Resistance: @ 41°F (5°C) @ 68°F (20°C) @ 212°F (100°C) 4.62 k W 2 .44 k W 0.19 k W Throttle Position Sensor (TPS): Input Voltage @ Idle (750 rpm) 5.0 ± 0.25 V Output [email protected] Idle (750 rpm) 0.718 - 0.746 V NOTE: The 115 four stroke ECM unit electronically controls the ignition timing, therefore making the ignition timing non adjustable. When initially running the outboard, use a timing light to verify that the ignition timing falls within the timing windows. If the ignition timing does not stay within the timing windows, replace the ignition ECM unit and retest. 90-881980R1 NOVEMBER 2001 Page 2C-3 TIMING, SYNCHRONIZING, & ADJUSTING Special Tools 1. New Style Vacuummate Carburetor Tuner P/N 91-809871-1 2. Old Style Mercury Filled Carburetor Tuner P/N 91-809641A1 Filters (4) P/N 35-18206 3. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1 4. Timing Light P/N 91-99379 Page 2C-4 90-881980R1 NOVEMBER 2001 TIMING, SYNCHRONIZING, & ADJUSTING Timing WARNING To prevent personal injury or possible death, from loss of balance or stability while servicing the motor, DO NOT attempt to check timing while boat is in motion. Failure to follow one of the recommended servicing procedures may result in the person falling overboard or causing personal injury from fall in boat. WARNING To prevent personal injury from spinning flywheel, Do Not attempt to remove flywheel cover or place hands on top of cover when checking ignition timing. Ignition timing is not adjustable. The ECM unit electronically controls the ignition timing. When initially running the outboard, use a timing light to verify that the ignition timing falls within the timing windows as described within the following tests. If the ignition timing does not stay within the timing windows, replace the ignition ECM unit and retest. (Refer to the Ignition Diagnostic Procedures tests in Section 2A.) IMPORTANT: When checking the timing with the engine running, one of the following test procedures must be followed. Check maximum timing per specification while running the outboard: • IN A TEST TANK (with a cut down propeller). • ON A DYNAMOMETER. • ON A BOAT SECURED ON A TRAILER “Backed in Water” (with a cut down propeller). 1. Attach timing light to #1 spark plug lead. 2. Place the outboard in “Forward” gear and check timing at idle “Retarded.” (If not within specification window, refer to Diagnostic Test Procedures Section 2A.) a b 58684 a-Timing Mark (4° ATDC) (Full Retarded) b-Pointer 90-881980R1 NOVEMBER 2001 Page 2C-5 TIMING, SYNCHRONIZING, & ADJUSTING 3. Slowly increase the engine rpm while watching the ignition timing marks. The timing should increase to the maximum timing specification “Full Advance” at approximately 6000 RPM. (If not within specification window, refer to Diagnostic Test Procedures Section 2A.) a b 20 a-Timing Mark (26° BTDC) (Full Advance) b-Timing Pointer Page 2C-6 90-881980R1 NOVEMBER 2001 TIMING, SYNCHRONIZING, & ADJUSTING 90-881980R1 NOVEMBER 2001 Page 2C-7 Throttle Shutter Synchronization NOTE: The cylinders are synchronized by adjusting the intake manifold vacuum on the intake manifold. Use Carburetor Tuner (91-809641A1) or Vacuummate Tuner (91-809871--1) to measure the vacuum. 1. Remove four plugs from the intake manifold. a a 58673 a a a a - Plugs (4) TIMING, SYNCHRONIZING, & ADJUSTING Page 2C-8 90-881980R1 NOVEMBER 2001 2. Install intake manifold hose adaptor in each plug hole. Tighten securely. 3. Connect the Vacuummate to the hose adaptors. 4. If using Carburetor Tuner (91-809641A1), install filters to prevent mercury being drawn into engine during an abrupt throttle change. a b c 58682 a - Intake Manifold Hose Adaptor (4) From Vacuummate Carb. Tuner b - Intake Manifold Hose Adaptor (4) From Mercury Filled Carb Tuner c - Vacuummate Carb. Tuner (91-809871--1) CAUTION Do not run engine at high rpm or abruptly change throttle position when using the old style liquid mercury filled carb. tuner (91-809641). The possibility exists of drawing liquid mercury from the carb tuner into the engine during high rpm running or an abrupt throttle change. Installing filters (4) (35-18206) in each line will help to prevent liquid mercury from being drawn into engine during an accidental abrupt throttle change. TIMING, SYNCHRONIZING, & ADJUSTING 90-881980R1 NOVEMBER 2001 Page 2C-9 5. With the outboard in water, start engine and allow to warm up until engine idles at 750 ± 50 rpm in neutral. 6. Connect a tachometer onto the spark plug lead of cylinder #4. 7. Turn the synchronizing screw so that vacuum pressures on cylinders #3 and #4 are within 3 cm Hg (40 mbar, 1.18 in Hg) of minimum and maximum vacuum pressures of cylinders #1 and #2. It’s not important to be at any specific vacuum setting. NOTE: The vacuum pressure of cylinders #3 and #4 will most likely never be exactly the same as cylinders #1 and #2 due to mechanical tolerances and different operating efficiencies of individual cylinders. 58682 Example 32 cm 30 cm 28 cm 26 cm Cyl. # 4 Cyl. #3 Cyl. # 2 If the vacuum reading of Cyl. #1 and #2 (base vacuum) is 30 cm, then adjust synchronization screw to achieve 30 cm for cylinders #3 and #4. Cyl. # 1 NOTE: Tighten screw to increase vacuum. Loosen screw to decrease vacuum. TIMING, SYNCHRONIZING, & ADJUSTING a 58641 a-Synchronizing Screw 8. Rev engine a few times and then allow engine to idle for 15 seconds. 9. Check that vacuum reading of each cylinder did not change more than 30 mm Hg (40 mbar, 1.18 in Hg). Readjust if necessary. 10. Verify idle speed is 750 ± 50 rpm in neutral. 11. Stop engine, remove adaptors and reinstall plugs. Page 2C-10 90-881980R1 NOVEMBER 2001 TIMING, SYNCHRONIZING, & ADJUSTING 90-881980R1 NOVEMBER 2001 Page 2C-11 Throttle Cam Adjustment Remove screws attaching sound attenuator. Remove attenuator to provide access to throttle cam. 58681 a a a a a a - Screws (9) Check throttle pickup timing (using “Checking Steps” below, adjust if incorrectly set using “Adjustment Steps” below). CHECKING STEPS 1. Move throttle control lever to the full retard position (throttle arm against throttle stop at idle). 2. Verify idle speed arm is against idle speed screw. 58576 a b c d e a - Throttle Control Lever b - Throttle Stop c - Throttle Arm d - Idle Speed Arm e - Idle Speed Screw TIMING, SYNCHRONIZING, & ADJUSTING 3. Pointer on cam should align with center of cam follower while maintaining a 0.020 in. (0.5 mm) gap between follower and cam. a b c 58683 a-Pointer c-0.020 in. (0.5 mm) b-Cam Follower ADJUSTMENT STEPS 1. If 0.020 in. (0.5 mm) gap does not exist, unsnap ball connector from ball on cam. 2. Thread connector in or out to obtain proper clearance. Tighten jam nut on connector. NOTE:Proper clearance between cam follower and cam will take precedence to exact alignment of pointer on cam to center of cam follower. a b c d e a-Ball Connector b-Throttle Cam c-Pointer 58683 d-Cam Follower e-Jam Nut Page 2C-12 90-881980R1 NOVEMBER 2001 TIMING, SYNCHRONIZING, & ADJUSTING 90-881980R1 NOVEMBER 2001 Page 2C-13 3. Reinstall sound attenuator. Tighten screws to specified torque. Sound Attenuator Screw Torque 70 lb-in. (8 Nm) Throttle Position Sensor (TPS) and Throttle Shaft Adjustment The Throttle Position Sensor and throttle shaft are pre-set at factory during emission calibration. No adjustments should normally be made to these components as emission performance will be compromised. However, should it be necessary to replace the Throttle Position Sensor or throttle body, the new components should be adjusted to initial factory emission specifications as follows: 1. Remove 9 screws attaching sound attenuator and remove attenuator. 2. Disconnect the Throttle Position Sensor harness. 3. Install TPS Test Harness (91-881827) between TPS and TPS harness. 91-881827 58659 b a c 58659 a - Throttle Position Sensor b - TPS Test Harness (91-881827) c - TPS Harness 4. Turn ignition switch to the “RUN” position. 5. Connect DMT 2000 (91-854009A1) test leads to the TPS Test Harness – RED to PINK; BLACK to BLACK. TIMING, SYNCHRONIZING, & ADJUSTING 6. Loosen synchronizing screw to allow cylinders #3 and #4 throttle shutter to open. 7. Loosen throttle plate screw to fully close cylinders #1 and #2 throttle shutter. a 58641 b a-Synchronizing Screw b-Throttle Plate Screw 8. Adjust the position of Throttle Position Sensor until the (DC) output voltage is 0.7 ± 0.01 volts. 9. Operate the throttle shaft several times. 10. Record the value. 11. Slowly tighten the synchronizing screw until throttle shutters for cylinders #3 and #4 just close. 12. Slowly tighten the throttle plate screw until a 0.032 ± 0.004 volt increase over the previously recorded value is observed. 13. Operate the throttle shaft several times. Page 2C-14 90-881980R1 NOVEMBER 2001 TIMING, SYNCHRONIZING, & ADJUSTING 90-881980R1 NOVEMBER 2001 Page 2C-15 14. With the throttle arm against the throttle stop, verify throttle cam mark is aligned with the center of the cam follower while maintaining a 0.020 in. (0.5 mm) gap between follower and cam. Check that output voltage has not changed. NOTE: Proper clearance between cam follower and cam will take precedence to exact alignment of pointer on cam to center of cam follower. 58683 g e h f 58576 c b d a a - Synchronizing Screw b - Throttle Plate Screw c - Throttle Arm d - Throttle Stop e - Cam Mark f - Cam g - Cam Follower h - 0.020 in. (0.5 mm) 15. Reinstall sound attenuator. Tighten attaching screws to specified torque. Sound Attenuator Screw Torque 70 lb-in. (8 Nm) 16. Start engine. 17. Check output voltage of Throttle Position Sensor. If TPS voltage is not within 0.718 – 0.746 volts, readjust TPS sensor. 18. Verify throttle shutters are synchronized. Refer to “Throttle Shutter Synchronization,” preceding. THEORY OF OPERATION ELECTRONIC FUEL INJECTION Section 3A - Theory of Operation Table of Contents Electronic Fuel Injection System . . . . . . . . . . . 3A-2 Rapid Deceleration . . . . . . . . . . . . . . . . . . . 3A-5 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-3 Shut Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-5 Air Temperature Sensor . . . . . . . . . . . . . . . 3A-3 Air Induction System . . . . . . . . . . . . . . . . . . . . . 3A-6 Crank Position Sensor . . . . . . . . . . . . . . . . 3A-3 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-7 Oil Pressure Switch . . . . . . . . . . . . . . . . . . . 3A-3 Pressure Regulator . . . . . . . . . . . . . . . . . . . 3A-8 Manifold Absolute PressureFuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-8 (MAP) Sensor . . . . . . . . . . . . . . . . . . . . . . 3A-3 Vapor Separator . . . . . . . . . . . . . . . . . . . . . . 3A-9 Throttle Position Sensor . . . . . . . . . . . . . . . 3A-3 Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . 3A-10 Water Temperature Sensor . . . . . . . . . . . . 3A-3 Electronic Control System . . . . . . . . . . . . . . . . 3A-10 Idle Air Control (IAC) . . . . . . . . . . . . . . . . . . . . . 3A-4 Outline of Control System . . . . . . . . . . . . . 3A-11 Step-Motor-Type Actuator . . . . . . . . . . . . . 3A-4 Control and Function . . . . . . . . . . . . . . . . . . 3A-12 IAC Features . . . . . . . . . . . . . . . . . . . . . . . . 3A-4 Basic Injection Volume . . . . . . . . . . . . . . . . . . . 3A-13 Starting and Idling . . . . . . . . . . . . . . . . . . . . 3A-5 Features Of The Throttle Position Sensor . . 3A-13 Warming Up . . . . . . . . . . . . . . . . . . . . . . . . . 3A-5 3 A 90-881980R1 NOVEMBER 2001 Page 3A-1 THEORY OF OPERATION Electronic Fuel Injection System The electronic fuel-injection system of the 115 EFI (4-Stroke) operates based on the combination of the throttle opening angle and engine speed, as well as the combination of engine speed, Manifold Absolute Pressure (MAP) and intake air temperature. When engine speed is low, from fully closed to 10° open throttle, the fuel injection volume is determined by the Manifold Absolute Pressure (MAP) and the engine speed map. From 7° open to fully open (high speed), the fuel injection volume is determined by the throttle opening angle and the engine speed map. Between 7° and 10° open, where the fuel injection volume depends on a overlap of both MAP and throttle opening angle, the fuel injection volume is determined more by the higher efficiency signal source (MAP vs throttle opening angle). The injection volume is determined by the ECM using signals from the Manifold Absolute Pressure (MAP) sensor, water temperature sensor, intake air temperature sensor, throttle position sensor, and crank position sensors. A stoichiometric (optimal) air-fuel ratio can be achieved at all speeds, including starting and warm-up, rapid acceleration and deceleration. Air Electric Fuel Pump Fuel Pump Fuel coolerPressure Regulator Engine Control Module Ignition control Idle speed control Fuel control Relay control :Electric Signal :Fuel Flow Idle Air Control Sensors Crank Position Throttle Position Sensor Engine Temperature Sensor Intake Air Temperature Sensor Manifold Absolute Pressure (MAP) Sensor Main Relay Battery Fuel Fuel Tank Fuel Filter Vapor Separator Sensors Page 3A-2 90-881980R1 NOVEMBER 2001 THEORY OF OPERATION EFI SYSTEM CONT. The injection system employs a 180° synchronous (batch) injection method which groups cylinders #1 and #4, and cylinders #2 and #3. In order to make corrections according to the engine conditions, an asynchronous injection is performed in all modes regardless of the crank angle signal. In addition, the injector of the 115 EFI (4-Stroke) is equipped with a function that cleans the nozzle by operating it one time to prevent the injector needle from sticking when the main switch is turned to ON. Sensors Air Temperature Sensor Monitors the intake air temperature. Sends signals to the ECM which aid in determining the optimal air-fuel ratio, fuel injection timing and fuel injection volume. Crank Position Sensor Provides the ECM with crank position information and engine speed which the ECM uses in determining optimal air-fuel ratio, fuel injection volume, ignition timing, and ignition/injection cut-off/warning for over revolution control. Oil Pressure Switch Monitors engine oil pressure. Sends signals to the ECM which activates ignition/injection cut-off/warning for low oil pressure. Manifold Absolute Pressure (MAP) Sensor Monitors the intake manifold pressure. Sends signals to the ECM which aid in determining the optimal air-fuel ratio and fuel injection volume. Throttle Position Sensor Provides the ECM with throttle angle information which the ECM uses in determining optimal air-fuel ratio, fuel injection timing and fuel injection volume. Water Temperature Sensor Monitors the engine temperature. Sends signals to the ECM which aid in determining the optimal air-fuel ratio, fuel injection volume, and ignition/injection cut-off/warning for engine overheat control. 90-881980R1 NOVEMBER 2001 Page 3A-3 THEORY OF OPERATION Idle Air Control (IAC) Step-Motor-Type Actuator This system consists of a motor (constructed of a magnet-operated rotor and a stator coil), a threaded portion (which converts the rotation into a linear movement of the valve), and a valve. The electric current flowing through the stator coils is switched in steps. The regular rotation and counter-rotation of the rotor raises or lowers the valve to adjust the amount of air that flows through. The direction that the rotor rotates is determined by the electric flow through the stator coils. The valve of this IAC can be opened from fully closed to fully open in 120 steps. Stator coil Valve shaft Valve Rotor Screw–type mechanismBearing IAC Features No. of steps 0 60 80 120 Bypass air volume (g/sec) 0.47 1.45 3 9.8 Bypass air volume (g/sec) Difference (g/sec) + 0.3 + 0.4 + 0.4 + 1.0 S1 Power S3 S4 Power S2 Bypass air volume (g/sec) 10 9 8 7 6 5 4 3 2 1 0 Condition 1 Condition 2 Condition 3 Condition 4 Terminal Condition 1 Condition 2 Condition 3 Condition 4 S1 ON ON S2 ON ON S3 ON ON S4 ON ON Open Close 0 50 100 150 No. of steps Page 3A-4 90-881980R1 NOVEMBER 2001 THEORY OF OPERATION Starting and Idling The IAC controls an optimum idling engine speed depending on the cooling-water temperature and the condition of the engine. With the throttle valve fully closed, the air quantity in the bypass is controlled by the step-motor-type actuator equipped in the IAC. Warming Up To warm up the engine, the IAC valve located in the bypass is opened and air is supplied to the engine to increase the engine speed. After the engine is warmed up, the valve is closed to decrease the engine speed and to maintain the specified idling speed. Rapid Deceleration When the throttle valve quickly returns to the fully closed position, the IAC valve will open just before the throttle valve is fully closed and act as a dashpot to prevent the engine from stalling. Shut Off The idle air control (IAC) is supplied current from the green EMC wire for a short period of time at key shut off. During this time period the IAC is cycled to a predetermined setting for the next start up. The fuel injectors are cycled once to provide extra fuel on the surfaces for quicker restart. Idle Air Control Manifold Absolute Pressure (MAP) Sensor (IAC) 90-881980R1 NOVEMBER 2001 Page 3A-5 THEORY OF OPERATION Air Induction System The air induction system consists of the throttle bodies, throttle valves, throttle position sensor, intake air temperature sensor, Manifold Absolute Pressure (MAP) sensor, and the Idle Air Control (IAC). The intake silencer attenuates the sound of the air drawn into the engine to provide quite operation. The throttle valves are installed in two independent throttle bodies (two sets of two throttle bodies). Air From IAC Throttle Position Sensor Throttle Body Air Page 3A-6 90-881980R1 NOVEMBER 2001 THEORY OF OPERATION Fuel System The fuel system consists of a low-pressure fuel pump, a high-pressure fuel pump, a fuel rail, fuel injectors, a pressure regulator, and a fuel cooler. The low-pressure pump sends fuel to the vapor separator tank, which is then pressurized to 43.5 psi (300 kPa) by the high-pressure pump. The pressurized fuel then travels through the fuel rail where it is injected from the fuel injectors into the intake manifold. Fuel not injected into the intake manifold goes through the pressure regulator, the fuel cooler, and is then returned to the vapor separator tank. The fuel pressure is maintained at 43.5 psi (300 kPa) between the high pressure fuel pump and the fuel injectors by the pressure regulator. High fuel-injection pressure maximizes the atomization of the fuel, resulting in increased combustion efficiency. Fuel tank Low–pressure fuel pump Fuel filter FilterFloat High–pressure fuel pump Manifold Absolute Pressure (MAP) sensor Intake manifold Pressure regulator E xhaust Air ventilation Adaptor Plate Fuel cooler Fuel injector Filter Filter Fuel rail Vapor separator 90-881980R1 NOVEMBER 2001 Page 3A-7 THEORY OF OPERATION Pressure Regulator A pressure regulator is installed in the upper part of the fuel rail. The pressure regulator maintains a stable fuel pressure according to the vacuum pressure in the intake manifold. With a maintained fuel pressure, control of an accurate fuel injection volume is increased. Spring Chamber Intake Manifold Spring From Fuel Rail Diaphragm To fuel cooler Fuel Chamber Valve Housing Fuel Cooler The 115 EFI (4-Stroke) is equipped with a fuel cooler that uses the engine cooling water to decrease the fuel temperature and reduce vapors. A brass pipe is used to prevent corrosion. WATER FUEL FUEL WATER Page 3A-8 90-881980R1 NOVEMBER 2001 THEORY OF OPERATION Vapor Separator The vapor separator maintains a liquid fuel supply for the high pressure fuel pump located in the vapor separator tank. Fuel delivered from the mechanical low pressure fuel pump is supplied to the top port of the vapor separator and is controlled by the inlet needle/float. Low pressure fuel returning from the pressure regulator, passes through the fuel cooler and is supplied to the lower port of the vapor separator. From the Low Pressure Fuel Pump Return Fuel To Fuel Rail From Pressure Regulator b c d f a e a-Check Valve b-Vapor Separator c-High Pressure Electric Fuel Pump d-Filter e-Fuel Float f-Inlet Needle 90-881980R1 NOVEMBER 2001 Page 3A-9 THEORY OF OPERATION Ignition System The 115 EFI (4-Stroke) has a newly designed ignition system, which provides the longer discharge duration required to burn the fuel injected into the cylinder in an extremely short period. The ECM induces a high voltage in the ignition coil by allowing battery current to flow into the ignition circuit and turning on and off the ECM’s ignition signals with the transistor. Electronic Control System The ECM of the 115 EFI (4-Stroke) controls the ignition timing, the fuel injection timing, the fuel injection volume, and the IAC, maintaining the optimal air-fuel ratio in all operating conditions. The ECM converts the signals from the input sensors and sends instructions to each part of the fuel injection system. Diagnostic system ECM (Electronic control module) Water temperature sensor Throttle position sensor Fuel pump Tachometer Buzzer Crank position sensor Oil Pressure Switch Stop switch Shift position switch Intake air temperature sensor Pressure (MAP) Sensor Manifold Absolute Injectors IAC Ignition coils Overheat monitor Oil pressure monitor Page 3A-10 90-881980R1 NOVEMBER 2001 THEORY OF OPERATION Outline of Control System Ignition Timing Control ECM Sensors IAC Control 0 0 0 0 0 0 0 0 0 0 Throttle opening angle/engine speed map Throttle position sensor Crank position sensor Engine temperature correction Water temperature sensor Starting correction Water temperature sensor Crank position sensor Rapid acceleration correction Throttle position sensor Crank position sensor Ignition cutoff for decreased engine speed Water temperature sensor Oil pressure sensor Over–revolution prevention Crank position sensor Shift position switch Idle advancing when in neutral Shift position switch Engine cutoff Stop switch Main switch Idling stabilizer Crank position switch Safety control Sensors and switches Crank position sensor ECM Sensors Starting correction Water temperature sensor Engine heating control Water temperature sensor Crank position sensor Throttle position sensor Rapid deceleration correction Throttle position sensor Crank position sensor Rapid deceleration preparation Throttle position sensor Idling speed feedback Crank position sensor Water temperature sensor Increased engine speed when in neutral Shift position switch Variable idling speed control Throttle position sensor Crank position sensor Starting preparation Water temperature sensor Power switch OFF Idling stabilizer Crank position sensor Safety control Sensors and switches 0 0 0 0 0 0 0 0 0 0 90-881980R1 NOVEMBER 2001 Page 3A-11 THEORY OF OPERATION ECM Sensors Fuel system Throttle opening angle/engine speed map Manifold air pressure/engine speed map Manifold Absolute Pressure Throttle position sensor Manifold air pressure correction Voltage correction Engine temperature correction Water temperature sensor Intake air temperature correction Intake air temperature sensor Starting correction W ater temperature sensor Throttle position sensor Rapid acceleration correction Throttle position sensor Crank position sensor Rapid deceleration correction Throttle position sensor Crank position sensor Fuel cutoff for decreased engine speed Crank position sensor Oil pressure switch Water temperature sensor Clogged injector prevention M ain switch turned on Idling stabilizer Crank position sensor Safety control Sensors and switches 0 0 0 0 0 0 0 0 0 0 0 0 (MAP) sensor Manifold Absolute Pressure (MAP) sensor Control and Function Ignition Timing Fuel Injection Timing Air/Fuel Control Function Crank Position Sensor 0 0 0 Detects the crankshaft position and engine speed Throttle Position Sensor 0 0 0 Detects the open degree of the throttle valve Water Temperature Sensor 0 0 0 Detects engine temperature Manifold Absolute Pressure (MAP) Sensor 0 Detects intake air pressure of the intake manifold Intake Air Temperature Sensor 0 Detects intake air temperature Shift Position Switch 0 0 Determines the shift position. (Neutral: ON, Forward or Reverse: OFF) Oil Pressure Switch 0 0 Detects Oil Pressure Page 3A-12 90-881980R1 NOVEMBER 2001 THEORY OF OPERATION Basic Injection Volume Basically, from fully closed to 10° open throttle (low speed), the fuel injection volume is determined by the intake air pressure and the engine speed map. From 7° open to fully open (high speed), the fuel injection volume is determined by the throttle opening angle and the engine speed map. Between 7° and 10° open, where the throttle valve is open and the intake air pressure is gradually decreasing, the fuel injection volume is determined by the throttle opening angle and the engine speed map. With a throttle valve opening angle of 8.5°, which is between 7° and 10° open (intake air pressure and throttle opening angle), the fuel injection volume is determined based more on the air detection accuracy. Map percentage 0 Close (%) 100 Low speed High speed Open 7 8.5 10 Throttle opening angle Features Of The Throttle Position Sensor The relationship between the throttle opening angle and the voltage is shown below. 107.5 0 - 17.5 Throttle opening angle [0.1] = V 5 8 1250–175Throttle opening angle (deg) 0 0.7 5.0 Voltage 90-881980R1 NOVEMBER 2001 Page 3A-13 TROUBLESHOOTING AND DIAGNOSTICS ELECTRONIC FUEL INJECTION Section 3B - Troubleshooting and Diagnostics Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-2 Control and Function . . . . . . . . . . . . . . . . . . . . 3B-3 EFI System Diagnostic Procedures . . . . . . . . 3B-3 Pressure Regulator Test . . . . . . . . . . . . . . . 3B-3 Mechanical Fuel Pump Test . . . . . . . . . . . . 3B-4 Specifications Injector Operation Test . . . . . . . . . . . . . . . . 3B-5 Fail Safe Function Table . . . . . . . . . . . . . . . . . . 3B-6 Self-Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-7 Diagnosis Code Information . . . . . . . . . . . 3B-7 Diagnosis of Electronic Control System . . 3B-7 Diagnostic Code Chart . . . . . . . . . . . . . . . . 3B-10 3 B FUEL SYSTEM Fuel Pump Type Fuel Pump: Discharge (@ 3000 rpm) Pressure (Maximum) Plunger Stroke Fuel Tank Capacity External (Plunger/Diaphragm) 17 gph (65 L/h) 7 psi (49 kPa) 0.23 - 0.36 in. (5.85 - 9.05 mm) Accessory FUEL INJECTION Fuel Injection System Idle rpm (In Neutral) Warm Idle rpm (In Forward Gear) Warm Fuel Pressure @ Rail Batch (1 & 4) - (2 & 3) 750 ± 50 rpm 700 ± 50 rpm 41-44 psi (283-304 kPa) 90-881980R1 NOVEMBER 2001 Page 3B-1 TROUBLESHOOTING AND DIAGNOSTICS Special Tools 1. Fuel Pressure Gauge 91-16850A7 or Fuel Pressure Gauge 91-852087A3. 91-16850A7 91-852087A3 2. Mighty Vac vacuum gauge (obtain locally). 3. Malfunction Indicator Lamp 99056A1 or Diagnostic Lamp 91-8847931A1 99056A1 91-884793A1 58680 59129 Page 3B-2 90-881980R1 NOVEMBER 2001 TROUBLESHOOTING AND DIAGNOSTICS Control and Function Ignition Timing Fuel Injection Timing Air/Fuel Control Function Crank Position Sensor 0 0 0 Detects the crankshaft position and engine speed Throttle Position Sensor 0 0 0 Detects the open degree of the throttle valve Water Temperature Sensor 0 0 0 Detects engine temperature Manifold Absolute Pressure (MAP) Sensor 0 Detects intake air pressure of the intake manifold Intake Air Temperature Sensor 0 Detects intake air temperature Shift Position Switch 0 0 Determines the shift position. (Neutral: ON, Forward or Reverse: OFF) Oil Pressure Switch 0 0 Detects Oil Pressure EFI System Diagnostic Procedures Pressure Regulator Test 1. Install the fuel pressure gauge onto the pressure check valve (located on top of the fuel rail). 2. Start the engine. Fuel pressure should be within specification. a b c 91-16850A7 a -Fuel Pressure Gauge b -Pressure Check Valve c -Pressure Regulator 90-881980R1 NOVEMBER 2001 Page 3B-3 TROUBLESHOOTING AND DIAGNOSTICS Mechanical Fuel Pump Test NOTE:Do not over-pressurize the fuel pump. Excessive pressure may cause air to leak out. 1. Install the mighty vac onto the fuel pump as shown. 2. Test 1: Pressurize the fuel pump to 7psi (50 kPa). Fuel pump should hold this amount of pressure. Perform this test on input and output side of fuel pump. 3. Test 2: Apply 4 in./mm Hg (14 kPa) vacuum to fuel pump. Fuel pump should hold this amount of vacuum. a Test 1 Test 2 Test 1 b a -Fuel Pump b -Mighty Vac Page 3B-4 90-881980R1 NOVEMBER 2001 TROUBLESHOOTING AND DIAGNOSTICS Injector Operation Test 1. Start the engine. Fully close the throttle valves. 2. Hold the screwdriver so it is making contact with the fuel injector body. The fuel injector should have a solenoid valve operating sound. Verify this on all injectors. IMPORTANT: If no sound is coming from the injector then no fuel is being sprayed. Verify the high pressure fuel pump is operating properly. a b a -Screwdriver b -Fuel Injector (4) NOTE:Refer tosection 2Afor testing of theThrottle Position SensorandEngine Temperature Sensor. 90-881980R1 NOVEMBER 2001 Page 3B-5 TROUBLESHOOTING AND DIAGNOSTICS Fail Safe Function Table Symptoms FAIL SAFE FUNCTION Ignition Fuel Injection IAC Engine Conditions Abnormal signal  Four cylinder igni Cylinders with no  Engine idling from crank position tion is fixed at 40 input signal will be speed increases. sensor ATDC stopped 900 rpm  Top speeds cannot be reached. Abnormal signal  When throttle  When the throttle  Engine idling from throttle posiopening angle is opening angle is speed increases. tion sensor less than -100 or more than 1000: Ignition is fixed at 100 BTDC less than -100 or more than 1000: Injection is controlled only by the boost map 900 rpm  Top speeds cannot be reached. Abnormal signal  When the intake  When the intake  Engine idling from Manifold Ab-air pressure is less air pressure is less speed increases. solute Pressure (MAP) sensor than 1.9 psi (100 mmHg) or more than 17.4 psi (900 mmHg): Ignition is fixed at 100 BTDC than 1.9 psi (100 mmHg) or more than 17.4 psi (900 mmHg): Injection is controlled with throttle opening map 900 rpm  Top speeds can be reached. Abnormal signal  When less than  When less than  Engine idling from water temper0.1 V or more than 0.1 V or more than speed increases. ature sensor 4.52 V are detected (substitutes 4.52 V are detected (substitutes 900 rpm  Top speeds can be reached. the intake air tem-the intake air temperature sensor): perature sensor): Ignition is fixed at Normal Operation 100 BTDC Abnormal signal  When less than  When less than  Engine idling from intake air tem0.1 V or more than 0.1 V or more than speed increases. perature sensor 4.52 V are detected (the intake air temperature sensor is fixed at 40): Ignition is fixed at 100 BTDC 4.52 V are detected (the intake air temperature sensor is fixed at 40): Normal Operation 900 rpm  Top speed can be reached. Abnormal signal from engine stop switch  On is detected Ignition is cut  On is detected Ignition is cut IAC is stopped Engine is stopped. Shift switch open 900 rpm  Engine idling speed increases.  Top speeds can be reached. Page 3B-6 90-881980R1 NOVEMBER 2001 TROUBLESHOOTING AND DIAGNOSTICS 90-881980R1 NOVEMBER 2001 Page 3B-7 Self-Diagnosis Diagnosis Code Information 1. Normal condition (no defective part or irregular processing is found). Single flash is given every 5 seconds. a. Light on, 0.33 second b. Light off, 5 seconds 2. Trouble code indication. Example: The illustration indicates code number 23. a. Light on, 0.33 second b. Light off, 0.33 second c. Light off, 1.65 seconds d. Light off, 5 seconds. Diagnosis of the Electronic Control System 1. Remove wire connector test plug cap. TROUBLESHOOTING AND DIAGNOSTICS 2. Install Malfunction Indicator Lamp a. Model Year 2001 and Prior Install Malfunction Indicator Lamp (MIL) p/n 99056A1, or create your own test light. (1.) Remove rubber plugs from engine harness bullet connectors. (2.)Connect leads of the Malfunction Indicator Lamp (MIL) p/n 99056A1 to the engine harness connectors. RED/BLK BLU/WHT99056A1 NOTE:When performing this diagnosis, all of the electrical wires must be properly connected. RED/BLK BLU/WHT Page 3B-8 90-881980R1 NOVEMBER 2001 TROUBLESHOOTING AND DIAGNOSTICS 90-881980R1 NOVEMBER 2001 Page 3B-9 b. Model Year 2002 and Newer Install Malfunction Indicator Lamp (MIL) p/n 91-884793A1. NOTE: This new service tool must be used on 2002 model year product. The new tool consists of the previous diagnostic lam 99056A1 and an additional harness with a 3 pin terminal connector. (1.) Remove rubber plug from engine harness bullet connector. (2.) Connect the harness terminal to the diagnostic test terminal. (3.) Connect the lamp wire bullet terminal to the blue/white wire bullet terminal on the engine harness. 59129 a b c d a - Lamp Wire b - Lamp Wire c - Green/Red Wire (Not Used) d - Harness Terminal 59130 a b a - Harness terminal b - Bullet terminal TROUBLESHOOTING AND DIAGNOSTICS 3. Check diagnosis code(s) (reference chart) a. Code 1 is indicated - normal b. Code 13-29 indicated - Check the applicable parts. c. Code 33-44 indicated - Microcomputer processing information. CHECKING STEPS 1. Start the engine and let it idle. 2. Check the malfunction indicator lamp’s flash pattern to determine if there are any malfunctions. NOTE:The ignition key must be returned to the “OFF” position for 5 seconds to clear a corrected failure code. NOTE: When more than one problem is detected, the malfunction indicator lamp light flashes in the pattern of the lowest numbered problem. After that problem is corrected and the failure code is cleared, the lamp flashes in the pattern of the next lowest numbered problem. This continues until all of the problems are detected and corrected. Diagnostic Code Chart Code Symptoms 13 Incorrect crank position sensor input signal 15 Incorrect engine cooling water temperature sensor input signal 18 Incorrect throttle position sensor input signal 19 Incorrect battery positive voltage 23 Incorrect intake air temperature sensor input signal 28 Incorrect shift position switch 29 Incorrect manifold air pressure sensor input signal (out of normal operating range) (33) Ignition timing is being slightly corrected (when starting a cold engine) (37) Intake passage air leakage (44) Engine stop switch control operating Page 3B-10 90-881980R1 NOVEMBER 2001 TROUBLESHOOTING AND DIAGNOSTICS 90-881980R1 NOVEMBER 2001 Page 3B-11 DIAGNOSIS/CORRECTION COMPLETED 1. Remove Malfunction Indicator Lamp (MIL). 2. Reinstall rubber plug(s) in engine harness bullet connector(s). 3. Reinstall connector test plug cap. a a - Plug Cap SERVICE PROCEDURES ELECTRONIC FUEL INJECTION Section 3C - Service Procedures Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-2 Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-32 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-2 Removal/Installation . . . . . . . . . . . . . . . . . . 3C-32 Intake Silencer . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-4 Fuel Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-33 Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-6 Disassembly/Assembly . . . . . . . . . . . . . . . . 3C-33 Fuel Injection Nozzle . . . . . . . . . . . . . . . . . . . . 3C-8 Vapor Separator . . . . . . . . . . . . . . . . . . . . . . . . 3C-34 Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . 3C-10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-34 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-34 Intake Silencer Assembly . . . . . . . . . . . . . . . . . 3C-14 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3C-35 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-14 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-37 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-15 Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . 3C-39 Intake Assembly . . . . . . . . . . . . . . . . . . . . . . . . 3C-16 Removal/Installation . . . . . . . . . . . . . . . . . . 3C-39 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-16 Idle Speed Control Assembly . . . . . . . . . . . . . 3C-40 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-19 Removal/Installation . . . . . . . . . . . . . . . . . . 3C-40 Throttle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-22 Disassembly/Assembly . . . . . . . . . . . . . . . . 3C-41 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-22 Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . 3C-42 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-24 Disassembly/Assembly . . . . . . . . . . . . . . . . 3C-42 Throttle Control Lever and Linkage . . . . . . . . 3C-25 Throttle Position Sensor . . . . . . . . . . . . . . . . . . 3C-43 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-25 Removal/Installation . . . . . . . . . . . . . . . . . . 3C-43 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-26 Low Pressure Fuel Line/Fuel Pump . . . . . . . . 3C-44 High Pressure Fuel Line . . . . . . . . . . . . . . . . . . 3C-27 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-44 Releasing Fuel Pressure in the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-45 High-Pressure Fuel Line . . . . . . . . . . . . . . . 3C-27 Disassembly/Assembly . . . . . . . . . . . . . . . . 3C-46 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-28 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-47 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-29 Disassembly/Assembly . . . . . . . . . . . . . . . . 3C-47 Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-30 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-48 Removal/Installation . . . . . . . . . . . . . . . . . . 3C-30 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3C-48 Fuel Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-31 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-50 Removal/Installation . . . . . . . . . . . . . . . . . . 3C-31 3 C 90-881980R1 NOVEMBER 2001 Page 3C-1 SERVICE PROCEDURES Specifications FUEL SYSTEM Fuel Pump Type Fuel Pump: Discharge (@ 3000 rpm) Pressure (Maximum) Plunger Stroke Fuel Tank Capacity External (Plunger/Diaphragm) 17 gph (65 L/h) 7 psi (49 kPa) 0.23 - 0.36 in. (5.85 - 9.05 mm) Accessory FUEL INJECTION Fuel Injection System Idle rpm (In Neutral) Warm Idle rpm (In Forward Gear) Warm Fuel Pressure @ Rail Batch (1 & 4) - (2 & 3) 750 ± 50 rpm 700 ± 50 rpm 43.5 psi (300 kPa) Special Tools 1. Fuel Pressure Gauge 91-16850A7 or Fuel Pressure Gauge 91-852087A3. 51796 91-16850A7 91-852087A3 2. Tamper proof screw torx bit set p/n 91-881828. Page 3C-2 90-881980R1 NOVEMBER 2001 SERVICE PROCEDURES Notes: 90-881980R1 NOVEMBER 2001 Page 3C-3 SERVICE PROCEDURES INTAKE SILENCER 16 18 6 5 21 17 13 12 20 20 3 3 19 1 2 9 1011 14 15 16 15 8 7 8 8 7 84 Page 3C-4 90-881980R1 NOVEMBER 2001 SERVICE PROCEDURES INTAKE SILENCER REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 INTAKE SILENCER 2 1 INTAKE AIR TEMPERATURE SENSOR 3 4 O-RING 4 6 BOLT (M6 X 16 MM) 70 7.9 5 2 BOLT (M8 X 20 MM) 13 18 6 1 BRACKET 7 2 BRACKET 8 8 BOLT (M6 X 20 MM) 70 7.9 9 1 INDUCTION SILENCER 10 1 MOUNTING BRACKET 11 1 SCREW (M6 X 20 MM) 70 7.9 12 2 PIN 13 1 GASKET 14 1 BREATHER PIPE 15 2 CLAMP 16 2 BOLT (M6 X 12 MM) 70 7.9 17 1 CLIP 18 1 CLAMP 19 2 BOLT (M6 X 105 MM) 70 7.9 20 5 BOLT (M8 X 40 MM) 13 18 21 1 SCREEN 90-881980R1 NOVEMBER 2001 Page 3C-5 SERVICE PROCEDURES INTAKE 23 22 20 21 34 9 9 33 27 26 29 28 35 32 31 25 1 30 2 3 2 43 18 19 24 10 12 11 12 13 6 5 9 8 7 9 8 16 17 15 17 Page 3C-6 90-881980R1 NOVEMBER 2001 SERVICE PROCEDURES INTAKE REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 MANIFOLD 2 4 O-RING 3 4 DOWEL PIN 4 3 BOLT 5 1 THROTTLE BODY 6 1 SPRING 7 2 SCREW 8 6 BOLT (M8 X 70 MM) 13 18 9 9 WASHER 10 1 THROTTLE BODY 11 1 SCREW 12 2 SPRING 13 1 SCREW 14 2 SCREW 15 1 LINK JOINT 16 1 LINK JOINT 17 1 NUT 18 1 THROTTLE POSITION SENSOR 19 1 O-RING 20 2 SCREW (M5 X 15 MM) 43 5 21 2 WASHER 22 1 BRACKET 23 3 SCREW (TAMPERPROOF) 40 4.5 24 1 HOSE – 1 CONTROL VALVE ASSEMBLY 25 1 BODY 26 1 CONTROL VALVE 27 1 O-RING 28 3 SCREW (M4 X 12 MM) 18 2 29 3 WASHER 30 1 FILTER 31 1 MAP SENSOR 32 2 SCREW (M5 X 6 MM) 43 5 33 1 BOLT (M6 X 24 MM) 70 7.9 34 2 BOLT (M6 X 60 MM) 70 7.9 35 1 WIRE HARNESS 90-881980R1 NOVEMBER 2001 Page 3C-7 SERVICE PROCEDURES FUEL INJECTION NOZZLE 1 2 3 4 5 9 8 4 7 21 10 13 22 2324 18 24 23 26 6 27 25 15 14 7 1213 20 19 14 11 25 1213 10 9 8 9 8 10 9 8 4 4 1617 Page 3C-8 90-881980R1 NOVEMBER 2001 SERVICE PROCEDURES FUEL INJECTION NOZZLE REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 PRESSURE REGULATOR 2 2 SCREW (M6 X 12 MM) 70 7.9 3 2 LOCKWASHER 4 4 CLIP 5 1 HOSE 6 2 SCREW (M5 X 16 MM) 43 5 7 2 CLIP 8 4 BOLT 9 4 GASKET 10 3 COLLAR 11 1 COOLER 12 2 BOLT (M6 X 30 MM) 70 7.9 13 3 WASHER 14 2 CLAMP 15 1 HOSE 16 1 HOSE 17 1 CLAMP 18 1 FUEL RAIL 19 4 INJECTOR UNIT 20 1 O-RING 21 1 CAP 22 1 BOLT (M6 X 25 MM) 70 7.9 23 2 BOLT (M8 X 45 MM) 13 18 24 2 WASHER 25 2 COLLAR 26 1 NIPPLE 27 1 O-RING 90-881980R1 NOVEMBER 2001 Page 3C-9 SERVICE PROCEDURES FUEL INJECTION PUMP A = To fitting in exhaust plate 30 22 22 23 21 20 11 12 13 14 15 5 6 4 16 17 10 1 19 19 18 31 32 31 20 20 2829 2020 27 27 23 27 23 27 23 27 27 26 24 23 25 A 3 2 7 8 9 Page 3C-10 90-881980R1 NOVEMBER 2001 SERVICE PROCEDURES FUEL INJECTION PUMP REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm – 1 VAPOR SEPARATOR 1 1 COVER 2 1 VALVE SEAT 3 1 O-RING 4 1 BODY 5 1 FLOAT 6 1 FLOAT PIN 7 1 NEEDLE VALVE 8 1 PLATE 9 1 SCREW (M3 X 8 MM) 10 7 SCREW (M4 X 16 MM) 18 2 11 1 GASKET 12 1 DAMPER 13 1 FUEL PUMP 14 1 FILTER 15 1 COVER 16 1 DRAIN SCREW 17 1 GASKET 18 1 HOSE KIT 19 2 CLIP 20 5 CLIP 21 1 HOSE 22 2 HOSE 23 5 TEE 24 1 HOSE 25 1 HOSE 26 1 HOSE 27 6 HOSE 28 1 HOSE 29 1 HOSE 30 1 HOSE 31 6 COLLAR 32 3 DAMPER 90-881980R1 NOVEMBER 2001 Page 3C-11 SERVICE PROCEDURES FUEL PUMP 11 10 98 6 7 5 2 12 3 4 13 1 14 15 16 14 18 19 25 33 17 20 25 34 35 36 37 29 30 32 31 32 28 26 27 29 21 22 23 24 Page 3C-12 90-881980R1 NOVEMBER 2001 SERVICE PROCEDURES FUEL PUMP REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 FUEL PUMP 2 1 BODY 3 1 SPRING 4 1 PLUNGER 5 1 SPRING 6 1 DIAPHRAGM 7 1 PIN 8 1 BODY 9 1 DIAPHRAGM 10 1 BODY 11 3 SCREW 12 3 NUT 13 1 O-RING 14 2 CLAMP 15 2 BOLT (M6 X 30 MM) 70 7.9 16 1 HOSE 17 1 BRACKET 18 1 BOLT (M6 X 16 MM) 70 7.9 19 1 NUT 70 7.9 20 1 FILTER ASSEMBLY 21 1 CUP 22 1 O-RING 23 1 FLOAT 24 1 ELEMENT 25 2 CLAMP 26 1 BRACKET 27 2 BOLT (M7 X 48 MM) 150 17 28 2 DOWEL PIN 29 2 WASHER 30 1 FUEL CHANGE LEVER 31 1 SHAFT 32 2 PIN 33 1 HOSE (55 IN.) 34 1 STA-STRAP 35 1 CONNECTOR 36 1 CAP 37 1 CONDUIT 90-881980R1 NOVEMBER 2001 Page 3C-13 SERVICE PROCEDURES Intake Silencer Assembly Removal 1. Remove access panel from port side bottom cowl. a a-Access Panel 2. Disconnect the air temperature sensor connector. 3. Remove the following breather hoses: cylinder head to intake silencer, idle air control assembly to intake silencer. 4. Remove mounting screws from intake silencer and mounting screw from induction silencer. 5. Remove intake silencer. a b c d f g e h i j a-Air Temperature Sensor b-Mounting Screw (6) M6 x 20 c-Mounting Screw (2) M6 x 105 d-Cylinder Head Breather Hose e-Vapor Separator Vent Hose g-Intake Silencer h-Induction Silencer i-Induction Silencer Mounting Screw(1) M6x20 j-O-ring (4) f-Idle Air Control Assembly Breather Hose Page 3C-14 90-881980R1 NOVEMBER 2001 SERVICE PROCEDURES Installation 1. Connect idle air control assembly breather hose to intake silencer. 2. Install intake/induction silencer mounting screws and tighten to specified torque. 3. Connect vapor separator vent hose to adaptor plate fitting. 4. Connect cylinder head breather hose to intake silencer and secure the hose ends with a plastic sta-strap. 5. Plug-in the air temperature sensor connector. a b c d f g e h i j a-Air Temperature Sensor b-Mounting Screw (6) M6 x 20 c-Mounting Screw (2) M6 x 105 d-Cylinder Head Breather Hose e-Vapor Separator Vent Hose g-Intake Silencer h-Induction Silencer i-Induction Silencer Mounting Screw(1) M6x20 j-O-ring (4) f-Idle Air Control Assembly Breather Hose Intake Silencer Mounting Screw Torque 70 lb-ft. (8 Nm) 90-881980R1 NOVEMBER 2001 Page 3C-15 SERVICE PROCEDURES Page 3C-16 90-881980R1 NOVEMBER 2001 Intake Assembly Removal 1. Remove the intake silencer assembly. Refer to Intake Silencer Assembly Removal. 2. Remove lower cowl. Refer to Mid - Section segment of this manual. 3. Disconnect throttle and shift cables. Refer to Attachments/Control Linkage section of this manual. 4. Disconnect the vapor separator vent hose from the adaptor plate fitting. 58565 a 58632 a - Vapor Separator Vent Hose SERVICE PROCEDURES 5. Disconnect the following wire connectors: throttle position sensor, idle air control harness, MAP sensor and high pressure fuel pump. 6. Disconnect the upper and lower water hoses from the fuel cooler. Retain the metal hose clamps for reassembly. 7. Disconnect the fuel pump hose (fuel pump to vapor separator). ab c d e f h i g g a-Throttle Position Sensor Connector b-Idle Air Control Connector c-MAP Sensor Connector d-High Pressure Fuel Pump Connector e-Fuel Cooler Upper Water Hose f-Fuel Cooler Lower Water Hose g-Metal Hose Clamp (2) (Retain) h-Sta-strap (Discard) i-Fuel Pump Hose (fuel pump to vapor separator) 90-881980R1 NOVEMBER 2001 Page 3C-17 SERVICE PROCEDURES Page 3C-18 90-881980R1 NOVEMBER 2001 8. Disconnect the shift position switch and fuel injector connectors. Cut the sta-straps from the injector harness. Place the injector harness out of the way (on the top of the engine). a 58639 b c c a - Shift Position Switch b - Fuel Injector Connector (4) c - Sta-strap (2) (Discard) 9. Remove the intake assembly mounting screws and the bracket mounting screws. 58640 b a a b a - Intake Assembly Mounting Screws (5) b - Bracket Mounting Screws (4) SERVICE PROCEDURES 90-881980R1 NOVEMBER 2001 Page 3C-19 Installation 1. Install the intake assembly and tighten mounting screws to specified torque. 2. Install the bracket mounting screws and tighten to specified torque. 58640 b a a b a - Intake Assembly Mounting Screws (5) M8 x 40 b - Bracket Mounting Screws (4) M6 x 20 Intake Assembly Mounting Screw Torque 13 lb-ft. (18 Nm) Bracket Mounting Screw Torque 70 lb-in (8 Nm) 3. Install vapor separator vent hose onto adaptor plate fitting. 58565 58632 a a - Vapor Separator Vent Hose SERVICE PROCEDURES Page 3C-20 90-881980R1 NOVEMBER 2001 4. Route the fuel injector harness as shown and secure with sta-straps in locations shown. 5. Plug in the fuel injector connectors and the shift position switch connector. a 58639 b c c a - Shift Position Switch Connector b - Fuel Injector Connector (4) c - Sta-strap (2) (New) SERVICE PROCEDURES 6. Plug in the following connectors: idle air control, throttle position sensor, MAP sensor, high pressure fuel pump. 7. Connect the fuel cooler water hoses (upper and lower) and secure with metal hose clamp (retained from disassembly). 8. Connect the fuel pump hose and secure with sta-strap. 9. Install throttle and shift cables. Refer to Attachments/Control Linkage section of this manual. 10. Install lower cowl. Refer to Mid - Section segment of this manual. 11. Install intake silencer assembly. Refer to Intake Silencer Assembly Installation. ab c d e f h i g g a-Throttle Position Sensor Connector b-Idle Air Control Connector c-MAP Sensor Connector d-High Pressure Fuel Pump Connector e-Fuel Cooler Upper Water Hose f-Fuel Cooler Lower Water Hose g-Metal Hose Clamp (2) (Retained) h-Sta-strap (New) i-Fuel Pump Hose (fuel pump to vapor separator) 90-881980R1 NOVEMBER 2001 Page 3C-21 SERVICE PROCEDURES Throttle Body Removal 1. Remove the intake silencer assembly. Refer to Intake Silencer Assembly Removal. 2. Disconnect the throttle link rod from the throttle control lever by carefully prying the plastic end off of the ball joint. 3. Remove bracket mounting screws. 58640 a a c b a-Bracket Mounting Screws (4) M6 x 25 b-Throttle Link Rod c-Throttle Control Lever Page 3C-22 90-881980R1 NOVEMBER 2001 SERVICE PROCEDURES 4. Remove throttle body mounting screws. 5. Disconnect air lines (throttle body to idle air control). Retain metal hose clamps for reassembly. 6. Remove the bracket mounting screws and remove the brackets from each throttle body (if required). NOTE:When removing the throttle body assemblies be careful not to lose the dowel pins and o-rings. NOTE:When separating the upper and lower throttle body assemblies be careful not to lose the spring. a b c d c f e g a-Bracket Mounting Screw (4) M6 x 25 b-Air Lines (2) (throttle body to idle air control) c-Throttle Body Mounting Screw (6) M8 x 70 d-Spring e-Locating Pin (4) f-O-ring (4) g-Metal Hose Clamp (2) (Retain) 90-881980R1 NOVEMBER 2001 Page 3C-23 SERVICE PROCEDURES Installation 1. Assemble throttle body to intake manifold. Tighten screws to specified torque. 2. Assemble mounting brackets to throttle body. Tighten screws to specified torque. 3. Install spring between upper and lower throttle body as shown. 4. Connect air lines and secure with metal hose clamps. 5. Install intake silencer assembly. Refer to Intake Silencer Assembly Installation. a b c c f e g d a-Bracket Mounting Screw (4) M6 x 25 b-Air Lines (2) (throttle body to idle air control) c-Throttle Body Mounting Screw (6) M8 x 70 d-Spring e-Locating Pin (4) f-O-ring (4) g-Metal Hose Clamp (2) (Retain) Throttle Body Mounting Screw Torque 13 lb-ft.. (18 Nm) Bracket Screw Torque 70 lb-in (8 Nm) Page 3C-24 90-881980R1 NOVEMBER 2001 SERVICE PROCEDURES 90-881980R1 NOVEMBER 2001 Page 3C-25 Throttle Control Lever and Linkage Removal 1. Remove intake silencer assembly. Refer to Intake Silencer Assembly Removal. 2. Remove throttle control lever mounting screw. 3. Remove remaining components as shown. 4. Remove accelerator cam nut. 5. Remove remaining components as shown. LT 4020 a b c d e f g h i c d 95 95 2-4-C with Teflon 95 a - Mounting Screw (1) M6 x 30 b - Collar(2) c - Wave Washer(2) d - Washer(3) e - Throttle Control Lever f - Spring g - Accelerator Cam Nut h - Accelerator Cam i - Stud Bolt SERVICE PROCEDURES Page 3C-26 90-881980R1 NOVEMBER 2001 Installation 1. Install spring so tab locks into notch as shown. LT 4020 a b c d e f g h i c d 95 95 2-4-C with Teflon 95 58564 j a - Mounting Screw (1) M6 x 30 b - Collar(2) c - Wave Washer(2) d - Washer(3) e - Throttle Control Lever f - Spring g - Nut h - Accelerator Cam i - Stud Bolt j - Spring Tab 2. Reassemble components as shown above. Tighten accelerator cam nut and mounting screw to specified torque. Accelerator Cam Nut Torque 70 lb-in (8 Nm) Throttle Control Lever Mounting Screw Torque 70 lb-in (8 Nm) SERVICE PROCEDURES High Pressure Fuel Line WARNING Always release the fuel pressure in the high-pressure fuel line before servicing the line or the vapor separator. If the fuel pressure is not released, pressurized fuel may spray out. Releasing Fuel Pressure in the High-Pressure Fuel Line 1. Install the fuel pressure gauge onto the pressure check valve. 2. Place the drain hose into a container. 3. Open the valve and release the pressure. a b c 91-16850A7 a a-Fuel Pressure Gauge b-Valve c-Drain Hose 90-881980R1 NOVEMBER 2001 Page 3C-27 SERVICE PROCEDURES Removal 1. Remove intake assembly. Refer to Intake Assembly Removal. 2. Remove the vapor separator mounting screws. 3. Disconnect hoses as needed. 4. Remove fuel rail mounting screws. 5. Remove fuel cooler mounting screws. a b c d f g h i e k j l m a-Vapor Separator Mounting Screw (3) M6 x 30 b-Vapor Separator c-Pressure Regulator Hose (to intake manifold fittings and idle air control filter) d-Pressure Regulator e-Fuel Rail Mounting Screw (2) M8 x 45 f-Fuel Rail Mounting Screw (1) M6 x 25 g-Fuel Rail h-Fuel Cooler Mounting Screw (2) M6 x 25 i-Fuel Cooler j-Flat Washer(3) k-Collar(3) l-Plastic Collar (3) m-Plastic Collar (2) (stepped) Page 3C-28 90-881980R1 NOVEMBER 2001 SERVICE PROCEDURES Installation 1. Assemble vapor separator to intake manifold. Tighten screws to specified torque. 2. Assemble fuel cooler and fuel rail to intake manifold. Tighten screws to specified torque. 3. Attach hoses as shown. 4. Assemble intake manifold assembly to engine. Refer to Intake Assembly Installation. a b c d f g h i e k j l m a-Vapor Separator Mounting Screw (3) M6 x 30 b-Vapor Separator c-Pressure Regulator Hose (to intake manifold fittings and idle air control filter) d-Pressure Regulator e-Fuel Rail Mounting Screw (2) M8 x 45 f-Fuel Rail Mounting Screw (1) M6 x 25 g-Fuel Rail h-Fuel Cooler Mounting Screw (2) M6 x 25 i-Fuel Cooler j-Flat Washer(3) k-Collar(3) l-Plastic Collar (3) m-Plastic Collar (2) (stepped) Vapor Separator Mounting Screw Torque 70 lb-in (8 Nm) Fuel Rail Mounting Screw Torque (M8 x 45) 13 lb-ft. (18 Nm) Fuel Rail/Fuel Cooler Mounting Screw Torque (M6 x 25) 70 lb-in (8 Nm) 90-881980R1 NOVEMBER 2001 Page 3C-29 SERVICE PROCEDURES Page 3C-30 90-881980R1 NOVEMBER 2001 Fuel Cooler Removal/Installation REMOVAL 1. Cut sta-straps and remove fuel cooler mounting screws. NOTE: When removing the mounting screws, be careful not to lose the spacers between fuel cooler base and intake manifold. 2. Disconnect the fuel cooler water and fuel hoses. Retain metal hose clamps. INSTALLATION 1. Connect fuel cooler water and fuel hoses and secure with metal hose clamps (retained from disassembly). 2. Install fuel cooler mounting screws and spacers. Tighten screws to specified torque. 3. Attach sta-straps as shown. 58639 c f e a b g g g g e c d f a - Fuel Cooler b - Sta-Strap (2) c - Mounting Screw (2)(M6 x 30) d - Spacer (2) e - Water Hose f - Fuel Hose g - Metal Hose Clamp (4) (Retain) Fuel Cooler Mounting Screw Torque 70 lb-in (8 Nm) SERVICE PROCEDURES Fuel Hoses Removal/Installation REMOVAL 1. Remove intake assembly. Refer to Intake Assembly Removal. 2. Remove hoses as shown below. Retain metal hose clamps. INSTALLATION 1. Reconnect hoses as shown below. 2. Secure fuel hoses with metal hose clamps (retained from disassembly). 3. Install intake assembly. Refer to Intake Assembly Installation. c a b da a a a a-Metal Hose Clamp (6) (Retain) b-Fuel Hose (Vapor Separator to Fuel Rail) c-Fuel Hose (Pressure Regulator to Fuel Cooler) d-Fuel Hose (Fuel Cooler to Vapor Separator) 90-881980R1 NOVEMBER 2001 Page 3C-31 SERVICE PROCEDURES Fuel Injectors Removal/Installation REMOVAL 1. Remove fuel rail from intake manifold. Refer to High Pressure Fuel Line Removal. 2. Remove the fuel injectors from the fuel rail (twist while pulling out). INSTALLATION 1. Lubricate the o-ring. 2. Install the fuel injector into the fuel rail. 3. Install the fuel rail assembly to the intake manifold. Refer to High Pressure Fuel Line Installation. b c a d e f a-Fuel Injector b-Fuel Rail c-Intake Manifold d-O-ring e-Rubber Damper f-Rubber Seal Page 3C-32 90-881980R1 NOVEMBER 2001 SERVICE PROCEDURES Fuel Rail Disassembly/Assembly DISASSEMBLY 1. Remove fuel rail from intake manifold. Refer to High Pressure Fuel Line Removal. 2. Remove fuel injectors from fuel rail. Refer to Fuel Injector Removal. 3. Remove fuel hoses. Refer to Fuel Hose Removal. 4. Remove pressure regulator. Refer to Pressure Regulator Removal. 5. Remove fuel rail joint screws. Remove fuel rail joint. ASSEMBLY 1. Lubricate o-ring and install onto fuel rail joint. 2. Install fuel rail joint onto fuel rail and tighten screws to specified torque. 3. Install pressure regulator. Refer to Pressure Regulator Installation. 4. Install fuel hoses. Refer to Fuel Hose Installation. 5. Install fuel injectors onto fuel rail. Refer to Fuel Injector Installation. 6. Install fuel rail onto intake manifold. Refer to High Pressure Fuel Line Installation. a b c d e a-Cap b-Fuel Rail c-O-ring d-Fuel Rail Joint e-Fuel Rail Joint Screw (2) M5 x 10 Fuel Rail Joint Screw Torque 43 lb-in (5 Nm) 90-881980R1 NOVEMBER 2001 Page 3C-33 SERVICE PROCEDURES Page 3C-34 90-881980R1 NOVEMBER 2001 Vapor Separator Removal 1. Remove the intake manifold assembly. Refer to Intake Assembly Removal. 2. Remove the following fuel lines: vapor separator to fuel cooler (reuse metal hose clamps), vapor separator to fuel rail (discard the metal hose clamps from this hose). a b 58639 a - Fuel Hose (vapor separator to fuel cooler) b - Fuel Hose (vapor separator to fuel rail) 3. Remove the vapor separator mounting screws. Remove the vapor separator. a b a - Vapor Separator Mounting Screw (3) M6 x 30 b - Vapor Separator Installation 1. Assemble the vapor separator to the intake manifold as shown in the illustration above. Tighten mounting screws to specified torque. 2. Connect the following fuel lines: vapor separator to fuel cooler (secure with metal hose clamps retained from disassembly), vapor separator to fuel rail (install new metal hose clamps on this hose). 3. Install the intake manifold assembly. Refer to Intake Assembly Installation. Vapor Separator Mounting Screw Torque 70 lb-in (8 Nm) SERVICE PROCEDURES Disassembly 1. Remove top cover screws. Remove top cover assembly. 2. Remove high pressure fuel pump filter and holder. Inspect filter for debris and clean if necessary. a b c d e f a-Top Cover Screw (7) M4 x 16 b-Top Cover Assembly c-High Pressure Fuel Pump Filter d-Holder e-O-ring f-Float Chamber 3. Remove float pin by pressing on the round end, NOT THE SQUARE END. Drive the pin out in the direction shown. a b c a-Float Pin b-Square End c-Round End 90-881980R1 NOVEMBER 2001 Page 3C-35 SERVICE PROCEDURES 4. Remove needle valve, screw and retainer. CAUTION When removing the collar do not grab the I.D. with a pliers or similar tool. Doing this may cause damage to the bore and result in the needle valve sticking or not seating properly. 5. Remove the collar if required. 6. Disconnect the high pressure fuel pump connector. 7. Remove the high pressure fuel pump (may have to twist while pulling out). a b c d e f g h a-Needle Valve b-Screw (1) M3 x 8 c-Retainer d-Collar e-O-ring f-High Pressure Fuel Pump Connector g-Rubber Grommet h-High Pressure Fuel Pump Page 3C-36 90-881980R1 NOVEMBER 2001 SERVICE PROCEDURES Assembly 1. Lubricate o-ring on collar and install collar (if removed). Twist collar while pushing in. 2. Install retainer and tighten screw. 3. Install needle valve in collar. 4. Install float and float pin (round end of pin should be installed first). Float pin end should be flush with surface. 5. Plug in high pressure fuel pump connector. 6. Install the rubber grommet into the top cover assembly. Install the high pressure fuel pump barb end into the rubber grommet (apply lubricant if necessary). a b c d e f g i j h k a-Needle Valve b-Screw (1) M3 x 8 c-Retainer d-Collar e-O-ring f-High Pressure Fuel Pump Connector g-Rubber Grommet h-High Pressure Fuel Pump i-Float Pin j-Square End k-Round End 90-881980R1 NOVEMBER 2001 Page 3C-37 SERVICE PROCEDURES 7. Install high pressure fuel pump filter and holder. 8. Install top cover assembly into float chamber. Tabs on high pressure fuel pump filter need to be aligned with notches at bottom of float chamber. 9. Install and tighten screws. a b d e f g c a-Top Cover Screw (7) M4 x 16 b-Top Cover Assembly c-High Pressure Fuel Pump d-High Pressure Fuel Pump Filter e-Holder f-O-ring g-Float Chamber Page 3C-38 90-881980R1 NOVEMBER 2001 SERVICE PROCEDURES Pressure Regulator Removal/Installation REMOVAL 1. Remove metal hose clamps (retain) and hoses. 2. Remove screws and pull pressure regulator from injector rail (twist while pulling). INSTALLATION 1. Lubricate o-ring and install pressure regulator. 2. Tighten screws to specified torque. 3. Install hoses. Install hose clamp on hose (pressure regulator to fuel cooler). a b c d e f a-Metal Hose Clamp (Retain) b-Hose (pressure regulator to fuel cooler) c-Hose (intake manifold to pressure regulator) d-Screw (2) M6 x 15 e-Pressure Regulator f-O-ring Pressure Regulator Screw Torque 70 lb-in (8 Nm) 90-881980R1 NOVEMBER 2001 Page 3C-39 SERVICE PROCEDURES Idle Speed Control Assembly Removal/Installation REMOVAL 1. Remove intake assembly. Refer to Intake Assembly Removal. 2. Disconnect vacuum hose from filter. 3. Remove idle air control mounting screws. 4. Remove idle air control assembly. 5. Remove metal hose clamps (retain) and hoses as needed. INSTALLATION 1. Install idle air control assembly. Tighten screws to specified torque. 2. Connect vacuum hose to filter. 3. Connect air hoses and secure with metal hose clamps (retained from disassembly). a b c d e f h g i j a-Filter b-Vacuum Hose (idle air control to intake manifold) c-Idle Air Control Mounting Screw (2) M8 x 60 d-Idle Air Control Mounting Screw (1) M8 x 24 e-Idle Air Control Assembly f-Hose (idle air control assembly to throttle body #2) g-Hose (idle air control assembly to throttle body #1) h-Metal Hose Clamp (4) (Retain) i-Throttle Body #1 j-Throttle Body #2 Idle Air Control Assembly Mounting Screw Torque 156 lb-in (18 Nm) Page 3C-40 90-881980R1 NOVEMBER 2001 SERVICE PROCEDURES Disassembly/Assembly DISASSEMBLY 1. Remove pressure sensor screws and pressure sensor (twist while pulling). 2. Remove idle air control screws. Remove air speed control from idle air control body. 3. Remove filter. ASSEMBLY 1. Install filter. 2. Install idle air control to idle air control body. 3. Install the manifold absolute pressure (MAP) sensor and tighten screws to specified torque. a b c d e f g h a-MAP Sensor Screws (2) M5 x 15 b-MAP Sensor c-O-ring d-Screw (3) M4 x 15 e-Idle Air Control f-O-ring g-Idle Air Control Body h-Filter (24mm Hex) Manifold Absolute Pressure Sensor Mounting Screw Torque 43 lb-in (5 Nm) Idle Air Control Mounting Screw Torque 18 lb-in (2 Nm) 90-881980R1 NOVEMBER 2001 Page 3C-41 SERVICE PROCEDURES Intake Manifold Disassembly/Assembly DISASSEMBLY 1. Remove intake assembly. Refer to Intake Assembly Removal. 2. Remove throttle body, high pressure fuel line, vapor separator, fuel rail and idle air control assembly. Refer to appropriate segment in this section for removal instructions. 3. Remove components as as shown in illustration. ASSEMBLY 1. Install components as shown in illustration. 2. Install throttle body, high pressure fuel line, vapor separator, fuel rail and idle speed control assembly. Refer to appropriate segment in this section for installation instructions. a b c dd e a-Hose (pressure regulator to intake manifold to idle speed control assembly) b-Rubber Seal (4) (Fuel Injector) c-Intake Manifold d-Collar (6) (Vapor Separator Mount) e-Grommet (3) (Vapor Separator Mount) Page 3C-42 90-881980R1 NOVEMBER 2001 SERVICE PROCEDURES 90-881980R1 NOVEMBER 2001 Page 3C-43 Throttle Position Sensor Removal/Installation REMOVAL 1. Disconnect throttle position sensor connector. 2. Remove the tamper proof screws for the bracket (covering the throttle position sensor) and throttle position sensor using special tool p/n 91-881828. INSTALLATION 1. Install throttle position sensor and torque tamper proof screws using special tool 91-882828. 2. Install the bracket and torque tamper proof screws using special tool 91-881828. 3. Connect throttle position sensor connector. Refer to section 2C Timing, Synchronizing and Adjusting for adjustment of the throttle position sensor. 58634 f g h i 58685 91-881828 e b d c a a - Throttle Position Sensor b - Washer (2) c - Washer (2) d - Tamper Proof Screw (2) M4 x 12 (T20) e - Bracket f - Lock Washer (3) g - Spool (3) h - Washer (3) (Cupped) i - Tamper Proof Screw (3) M5 x 12 (T25) Throttle Position Sensor Tamper Proof Screw Torque 18 lb-in (2 Nm) Bracket Tamper Proof Screw Torque 40 lb-in (5 Nm) SERVICE PROCEDURES Low Pressure Fuel Line/Fuel Pump Removal 1. Remove grommet retaining plate. 2. Cut sta-strap and remove fuel hose from grommet. a c d e b a-Grommet Retaining Plate b-Screw (2) M6 x 28 c-Fuel Hose Opening d-Rubber Grommet e-Sta-Strap (Discard) 3. Remove spark plug cover. 4. Disconnect fuel hose from fuel pump and fuel filter. 5. Remove fuel pump. Remove fuel filter mounting bracket assembly. a bc d f g h i e j k a-Spark Plug Cover b-Screw (5) M6 x 16 c-Sta-Strap (4) (Discard) d-Fuel Hose (fuel pump to vapor separator) e-Fuel Filter Mounting Bracket Assembly f-Screw (1) M6 x 16 g-Fuel Pump h-Screw (2) M6 x 30 i-O-ring j-Low Pressure Fuel Line k-Conduit Page 3C-44 90-881980R1 NOVEMBER 2001 SERVICE PROCEDURES Installation 1. Install fuel pump and fuel filter. Tighten mounting screws to specified torque. 2. Connect fuel hoses as shown. Secure with sta-straps. 3. Install spark plug cover. Tighten screws to specified torque. a bc d f g h i e j k a-Spark Plug Cover b-Screw (5) M6 x 16 c-Sta-Strap (4) (New) d-Fuel Hose (fuel pump to vapor separator) e-Fuel Filter Mounting Bracket Assembly f-Screw (1) M6 x 16 g-Fuel Pump h-Screw (2) M6 x 30 i-O-ring j-Low Pressure Fuel Line k-Conduit 4. Route the fuel line through the opening in the rubber grommet and install sta-strap. 5. Install grommet retaining plate. Tighten screws to specified torque. a b c d e a-Grommet Retaining Plate b-Screw (2) M6 x 28 c-Fuel Hose Opening d-Rubber Grommet e-Sta-Strap (New) M6 Mounting Screw Torque 70 lb-in (8 Nm) 90-881980R1 NOVEMBER 2001 Page 3C-45 SERVICE PROCEDURES Disassembly/Assembly DISASSEMBLY 1. Remove fuel hoses from fuel filter assembly and fuel pump as shown. Discard stastraps. ASSEMBLY 2. Connect fuel hoses to fuel filter and fuel pump as shown. Secure with new sta-straps. a b d e e c e f a-Fuel Filter Assembly b-Fuel Hose (fuel supply to fuel filter) c-Fuel Pump d-Fuel Hose (fuel filter to fuel pump) e-Sta-Straps (3) f-Conduit Page 3C-46 90-881980R1 NOVEMBER 2001 SERVICE PROCEDURES Fuel Filter Disassembly/Assembly DISASSEMBLY 1. Remove fuel filter bracket. 2. Unscrew fuel filter cup and remove float, fuel filter element, and o-rings. ASSEMBLY 1. Install fuel filter element onto fuel filter cap. 2. Install float into fuel filter cup. Line up notches in float with ribs on the inside of the fuel filter cup. 3. Hand tighten fuel filter cup. a b c d e f g h a-Nut b-Fuel Filter Mounting Bracket c-Fuel Filter Cap d-O-ring e-O-Ring f-Fuel Filter Element g-Float h-Fuel Filter Cup 90-881980R1 NOVEMBER 2001 Page 3C-47 SERVICE PROCEDURES Fuel Pump Disassembly 1. Remove fuel pump assembly from engine. 2. Remove fuel pump cover. 3. Remove fuel pump body from fuel pump base assembly. 4. Disassemble as shown. 58637 a b c d e a-Fuel Pump Body b-Fuel Pump Base Assembly c-Fuel Pump Cover d-Gasket e-Screw (3) M6 x 35 5. Insert screwdriver in the plunger slot and rotate until the pin lines up with the groove. 58636 a b c a-Plunger b-Groove c-Fuel Pump Base Assembly Page 3C-48 90-881980R1 NOVEMBER 2001 SERVICE PROCEDURES CAUTION Plunger is spring loaded. Place the fuel pump assembly on a bench top (so plunger is facing down) before pulling the pin completely out. Failure to do this could result in injury due to objects flying through the air. 6. Insert screwdriver in back side of slot and push pin out. Grab pin with a needle nose and pull completely out. 58635 b a a-Pin b-Plunger 7. Disassemble components as shown. a b c d e f g a-Diaphragm b-Spring c-Fuel Pump Base d-Spring e-Plunger f-Pin g-Nut 90-881980R1 NOVEMBER 2001 Page 3C-49 SERVICE PROCEDURES Assembly 1. Install components as shown. a b c d e f a-Diaphragm b-Spring c-Fuel Pump Base d-Spring e-Plunger f-Pin 2. Push down on the plunger until the groove lines up with the hole in the end of the diaphragm shaft. Insert pin. 58635 a b c a-Pin b-Plunger c-Hole in Diaphragm Shaft 3. Rotate plunger back to original position (pin should be 90° from groove). b a c 58636 a-Plunger b-Groove c-Fuel Pump Base Assembly Page 3C-50 90-881980R1 NOVEMBER 2001 SERVICE PROCEDURES 4. Alignment marks on fuel pump body, base assembly and cover should be as shown below. Assemble fuel pump body, cover, and new gasket to fuel pump base. Apply Loctite 242 (obtain locally) and tighten screws to specified torque. b ea d c f 66 66 Loctite 242 Thread Locker a-Fuel Pump Body b-Fuel Pump Base Assembly c-Fuel Pump Cover d-Gasket (NEW) e-Screw (3) M6 x 35 f-Nut (3) M6 Mounting Screw Torque 70 lb-in (8 Nm) 90-881980R1 NOVEMBER 2001 Page 3C-51 EMISSIONS FUEL SYSTEM Section 3D – Emissions Table of Contents Exhaust Emissions Standards . . . . . . . . . . . . . . 3D-2 What Are Emissions? . . . . . . . . . . . . . . . . . . . 3D-2 Hydrocarbons - HC . . . . . . . . . . . . . . . . . . . . . 3D-2 Carbon Monoxide - CO. . . . . . . . . . . . . . . . . . 3D-2 Oxides of Nitrogen - NOx. . . . . . . . . . . . . . . . 3D-2 Controlling Emissions . . . . . . . . . . . . . . . . . . . 3D-2 Stoichiometric (14.7:1) Air/Fuel Ratio . . . . . 3D-3 Outboard Hydrocarbon Emissions Reductions . . . . . . . . . . . . . . . . . . . . . 3D-3 8 1/3% # Per Year Over 9 Model Years . . . . 3D-3 Stratified Vs Homogenized Charge . . . . . . . . . . 3D-4 Homogenized Charge . . . . . . . . . . . . . . . . . . . 3D-4 Stratified Charge . . . . . . . . . . . . . . . . . . . . . . . 3D-5 Emissions Information . . . . . . . . . . . . . . . . . . . . . 3D-6 Manufacturer’s Responsibility . . . . . . . . . . . . 3D-6 Dealer Responsibility . . . . . . . . . . . . . . . . . . . 3D-6 Owner Responsibility . . . . . . . . . . . . . . . . . . . 3D-6 EPA Emission Regulations . . . . . . . . . . . . . . 3D-7 Manufacturer’s Certification Label . . . . . . . . . . . 3D-8 Service Replacement Certification Label . . . . . 3D-9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-9 Date Code Identification. . . . . . . . . . . . . . . . . 3D-9 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-9 Decal Location . . . . . . . . . . . . . . . . . . . . . . . . . 3D-9 3 D 90-881980R1 NOVEMBER 2001 Page 3D-1 EMISSIONS Exhaust Emissions Standards Through the Environmental Protection Agency (EPA), the federal government has established exhaust emissions standards for all new marine engines sold in the U.S. What Are Emissions? Emissions are what comes out of the exhaust system in the exhaust gas when the engine is running. They are formed as a result of the process of combustion or incomplete combustion. To understand exhaust gas emissions, remember that both air and fuel are made of several elements. Air contains oxygen and nitrogen among other elements; gasoline contains mainly hydrogen and carbon. These four elements combine chemically during combustion. If combustion were complete, the mixture of air and gasoline would result in these emissions: water, carbon dioxide and nitrogen, which are not harmful to the environment. But combustion is not usually complete. Also, potentially harmful gases can be formed during and after combustion. All marine engines must reduce the emission of certain pollutants, or potentially harmful gases, in the exhaust to conform with levels legislated by the EPA. Emissions standards become more stringent each year. Standards are set primarily with regard to three emissions: hydrocarbons (HC), carbon monoxide (CO) and oxides of nitrogen (NOx). Hydrocarbons – HC Gasoline is a hydrocarbon fuel. The two elements of hydrogen and carbon are burned during combustion in combination with oxygen. But they are not totally consumed. Some pass through the combustion chamber and exit the exhaust system as unburned gases known as hydrocarbons. Carbon Monoxide – CO Carbon is one of the elements that make up the fuel burned in the engine along with oxygen during the combustion process. If the carbon in the gasoline could combine with enough oxygen (one carbon atom with two oxygen atoms), it would come out of the engine in the form of carbon dioxide (CO2). CO2 is a harmless gas. But carbon often combines with insufficient oxygen (one carbon atom with one oxygen atom). This forms carbon monoxide, CO. Carbon monoxide is the product of incomplete combustion and is a dangerous, potentially lethal gas. Oxides of Nitrogen - NOx NOx is a slightly different byproduct of combustion. Nitrogen is one of the elements that makes up the air going into the engine. Under extremely high temperatures it combines with oxygen to form oxides of nitrogen (NOx). This happens in the engine’s combustion chambers when temperatures are too high. NOx itself is not harmful, but when exposed to sunlight it combines with unburned hydrocarbons to create the visible air pollutant known as smog. Smog is a serious problem in California as well as many other heavily populated areas of the United States. Controlling Emissions There are two principle methods of reducing emissions from a two-stroke-cycle marine engine. The first method is to control the air/fuel ratio that goes into the combustion chamber. The second is to control the time when this air/fuel mixture enters the combustion chamber. Timing is important, to prevent any unburned mixture from escaping out of the exhaust port. Page 3D-2 90-881980R1 NOVEMBER 2001 EMISSIONS Stoichiometric (14.7:1) Air/Fuel Ratio In the search to control pollutants and reduce exhaust emissions, engineers have discovered that they can be reduced effectively if a gasoline engine operates at an air/fuel ratio of 14.7:1. The technical term for this ideal ratio is stoichiometric. An air/fuel ratio of 14.7:1 provides the best control of all three elements in the exhaust under almost all conditions. The HC and CO content of the exhaust gas is influenced significantly by the air/fuel ratio. At an air/fuel ratio leaner than 14.7:1, HC and CO levels are low, but with a ratio richer than 14.7:1 they rise rapidly. It would seem that controlling HC and CO by themselves might not be such a difficult task; the air/fuel ratio only needs to be kept leaner than 14.7:1. However, there is also NOx to consider. As the air/fuel ratio becomes leaner, combustion temperatures increase. Higher combustion temperatures raise the NOx content of the exhaust. But, enrichening the air/fuel ratio to decrease combustion temperatures and reduce NOx also increases HC and CO, as well as lowering fuel economy. So the solution to controlling NOx - as well as HC and CO - is to keep the air/fuel ratio as close to 14.7:1 as possible. OUTBOARD HYDROCARBON EMISSIONS REDUCTIONS 8 1/3%  PER YEAR OVER 9 MODEL YEARS 120 100 80 60 40 20 0 96 97 98 99200001 02 03 04 05 06 07 08 90-881980R1 NOVEMBER 2001 Page 3D-3 EMISSIONS STRATIFIED VS HOMOGENIZED CHARGE At certain operating conditions, DFI engines use a stratified charge inside the combustion chamber to aid in reducing emissions. All other models exclusively use a homogenized charge. The difference between the two is: Homogenized Charge A homogenized charge has the air/fuel particles mixed evenly throughout the cylinder. This mixing occurs inside the carburetor venturi, reed blocks, crankcase and/or combustion chamber. Additional mixing occurs as the fuel is forced through the transfer system into the cylinder. The homogenized charge has an air/fuel ratio of approximately 14.7:1 and is uniform throughout the cylinder. Page 3D-4 90-881980R1 NOVEMBER 2001 EMISSIONS Stratified Charge A stratified charge engine only pulls air through the transfer system. The fuel required for combustion is forced into the cylinder through an injector placed in the top of the cylinder (head). The injector sprays an air/fuel mixture in the form of a cloud into the cylinder. Surrounding this cloud is air supplied by the transfer system. As the cloud is ignited and burns, the surrounding air provides almost complete combustion before the exhaust port opens. A stratified charge engine concentrates a rich mixture in the vicinity of the spark plug (air/fuel ratio less than 14.7:1). Elsewhere, the mixture is very lean or is comprised of air only. 90-881980R1 NOVEMBER 2001 Page 3D-5 EMISSIONS Emissions Information Manufacturer’s Responsibility Beginning with 1998 model year engines, manufacturers of all marine propulsion engines must determine the exhaust emission levels for each engine horsepower family and certify these engines with the United States Environmental Protection Agency (EPA). A certification decal/emissions control information label, showing emission levels and engine specifications directly related to emissions, must be placed on each engine at the time of manufacture. Dealer Responsibility When performing service on all 1998 and later outboards that carry a certification, attention must be given to any adjustments that are made that affect emission levels. Adjustments must be kept within published factory specifications. Replacement or repair of any emission related component must be executed in a manner that maintains emission levels within the prescribed certification standards. Dealers are not to modify the engine in any manner that would alter the horsepower or allow emission levels to exceed their predetermined factory specifications. Exceptions include manufacturers prescribed changes, such as that for altitude adjustments. Owner Responsibility The owner/operator is required to have engine maintenance performed to maintain emission levels within prescribed certification standards. The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications. Exceptions: • Carburetor jets may be changed for high altitude use in accordance with factory recommendations. • Single engine exceptions may be allowed with permission from the EPA for racing and testing. Page 3D-6 90-881980R1 NOVEMBER 2001 EMISSIONS EPA Emission Regulations All new 1998 and later outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors. This certification is contingent on certain adjustments being set to factory standards. For this reason, the factory procedure for servicing the product must be strictly followed and, whenever practicable, the product returned to the original intent of the design. The responsibilities listed above are general and in no way a complete listing of the rules and regulations pertaining to the EPA laws on exhaust emissions for marine products. For more detailed information on this subject, you may contact the following locations: VIA U.S. POSTAL SERVICE: Office of Mobile Sources Engine Programs and Compliance Division Engine Compliance Programs Group (6403J) 401 M St. NW Washington, DC 20460 VIA EXPRESS or COURIER MAIL: Office of Mobile Sources Engine Programs and Compliance Division Engine Compliance Programs Group (6403J) 501 3rd St. NW Washington, DC 20001 EPA INTERNET WEB SITE: http:/www.epa.gov/omswww 90-881980R1 NOVEMBER 2001 Page 3D-7 EMISSIONS Manufacturer’s Certification Label The certification label must be placed on each engine at the time of manufacture and must be replaced in the same location if damaged or removed. Shown below is a typical certification label and is not representative of any one model. Label shown below is not to scale; (shown at twice the normal size). Gap: 0.043, (1.1 mm) Emission Control Information Refer to Owners Manual for required maintenance Family: 2M9XM01.72G0 Idle Speed (in neutral): 750 RPM FEL: 16.6 GM/KW-HR 115 HP 1741 cc Timing (in degrees): Not Adjustable CDI Controlled Standard Spark Plug: NGK LFR6A-11 Suppressor Spark Plug: NGK LFR6A-11 Valve Clearance (Cold) mm Intake: 0.17-0.23 Exhaust: 0.31-0.37 Gap: 0.043, (1.1 mm) This engine conforms to 2002 Model Year U.S. EPA regulations for Marine SI engines. OCTOBER 2002 f g h i j a b c e d a -Spark Ignition (SI) b -Idle Speed (In Gear) c -Cubic Centimeter d -Engine Horsepower rating e -Month and Year of Production f -Valve Clearance (Four Stroke engines only) g -Recommended spark plug for best engine performance h -Timing specifications when adjustable i -FEL: Represents (Mercury Marine) statement of the maximum emissions output j for the engine family -Family example Model Year Type of Product 0=All except; J=Sport Jet E=EFI Sport Jet & EFI 4-strokes 3=OptiMax 135 H=High Performance 2 M9X M01.7 2 G 0 2=2002 Manufacturer Mercury Marine Regulation M=Marine Technology Type 1=OB Old Tech 2=OB New Tech 3=SportJet 4=OptiJet Cycle Type C=2 Stroke G=4 Stroke 4 Digits for Displacement Decimal Point = Liters such as 01.7 = 1.7L, .935 = 935 cc No Point = C.I. such as 0113 =113 Cubic Inches Page 3D-8 90-881980R1 NOVEMBER 2001 EMISSIONS Service Replacement Certification Label IMPORTANT: By federal law, it is required that all 1998 and newer Mercury Marine outboards have a visible and legible emission certification label. If this label is missing or damaged, replacement labels can be obtained from Mercury Marine. Removal Remove all remaining pieces of the damaged or illegible label. Do not install new label over the old label. Use a suitable solvent to remove any traces of the old label adhesive from the display location. Date Code Identification Cut and remove a “V” notch through the month of engine manufacture before installing the new label. The month of manufacture can be found on the old label. If the label is missing or the date code illegible, contact Mercury Marine Technical Service for assistance. JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC Emission Control Information 2002 PART # 37–859245 This engine conforms to 2002 Model Year U.S. EPA regulations for marine SI engines. Idle Speed (in neutral): 750 RPM Timing: Not Adjustable CDI Controlled Spark Plug: NGK LFR6A-11 Gap: 0.043” (1.1 mm) Valve Clearance (Cold) mm Intake: 0.17-0.23 Exhaust: 0.31-0.37 Family: 2M9XM01.72G0 FEL: 16.6 GM/KW-HR 1741 cc 115 HP 4-Stroke Refer to Owners Manual for required maintenance a b a -“V” Notch b -Month of Manufacture Installation Install the label on a clean surface in the original factory location. Decal Location Model Service Part No. Location on Engine 2001 Merc/Mar 115 HP (4-Stroke) 37-881839A01 Top of Flywheel Cover 2002 Merc/Mar 115 HP (4-Stroke) 37-881839A02 Top of Flywheel Cover 90-881980R1 NOVEMBER 2001 Page 3D-9 CYLINDER HEAD POWERHEAD Section 4A - Cylinder Head Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-4 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-6 Intake/Exhaust Valves . . . . . . . . . . . . . . . . . . . . . 4A-8 Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . 4A-12 Cylinder Head Screws . . . . . . . . . . . . . . . . . 4A-12 Camshaft Caps Screws . . . . . . . . . . . . . . . . 4A-12 Adjustments Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . 4A-13 Preparing Cylinder Head for Removal . . . . . . . 4A-23 Cylinder Head Removal . . . . . . . . . . . . . . . . . . . 4A-25 Cylinder Head Disassembly . . . . . . . . . . . . . . . 4A-26 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . . 4A-28 Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-28 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-29 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-30 Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . 4A-31 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . 4A-32 Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . 4A-32 Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-35 Cylinder Head Reassembly . . . . . . . . . . . . . . . . 4A-36 Cylinder Head Installation . . . . . . . . . . . . . . . . . 4A-38 Following Cylinder Head Installation . . . . . . . . 4A-39 Timing Belt Installation . . . . . . . . . . . . . . . . . 4A-41 Extra Valve Clearance Work sheets . . . . . . . . . 4A-42 Measurement . . . . . . . . . . . . . . . . . . . . . . . . . 4A-42 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-42 4 A 90-881980R1 NOVEMBER 2001 Page 4A-1 CYLINDER HEAD Specifications Camshaft Dimensions Intake “A” 1.465 - 1.472 in. (37.22 - 37.38 mm) Exhaust “A” 1.453 - 1.459 in. (36.90 - 37.06 mm) Intake “B” A 1.178 - 1.184 in. (29.92 - 30.08 mm) Exhaust “B” Valve Lift 1.178 - 1.184 in. (29.92 - 30.08 mm) Intake 0.287 in. (7.30 mm) CAMSHAFT Exhaust Run-out Limit B 0.275 in. (6.98 mm) 0.004 in. (0.1 mm) Camshaft Bearing Diameter “a” 0.9827 - 0.9835 in. (24.96 - 24.98 mm) Camshaft Bearing Oil Clearance 0.0008-0.0024 in. (0.020-0.061 mm) A Free Length “a” 2.094 in. (53.20 mm) Minimum Free Length 2.057 in. (52.25 mm) VALVE SPRING Tilt Limit “b” a b Less than 0.10 in. (2.6 mm) Warp Limit 0.004 in. (0.1 mm) CYLINDER HEAD Camshaft Bearing Inside Diameter a 0.984 - 0.985 in. (25.000 - 25.021 mm) Valve Lifter Bore Inside Diameter 1.102 - 1.103 in. (28.000 - 28.021 mm) Page 4A-2 90-881980R1 NOVEMBER 2001 CYLINDER HEAD Valve/Valve Seat/Valve Guides: Valve Clearance (cold) Intake 0.007 - 0.009 in. (0.17 - 0.23 mm) Exhaust Valve Face Angle 0.012 - 0.014 in. (0.31 - 0.34 mm) Intake 120°, 91°, 110° Exhaust Valve Dimensions: “A” Head Diameter 140°, 91°, 110° Intake 1.142 - 1.150 in. (29.0 - 29.2 mm) Exhaust “B” Face Width 0.945 - 0.953 in. (24.0 - 24.20 mm) Intake 0.078 - 0.094 in. (1.98 - 2.40 mm) Exhaust “C” Seat Width 0.089 - 0.106 in. (2.26 - 2.69 mm) Intake 0.062 - 0.076 in. (1.58 - 1.94 mm) VALVES Exhaust “D” Margin Thickness 0.071 - 0.080 in. (1.80 - 0.02 mm) Intake 0.031 - 0.047 in. (0.80 - 1.20 mm) Exhaust Stem Outside Diameter 0.039 - 0.055 in. (1.00 - 1.40 mm) Intake 0.2352 - 0.2358 in. (5.975 - 5.990 mm) Exhaust Guide Inside Diameter 0.2346 - 0.2352 in. (5.960 - 5.975 mm) Intake 0.2364 - 0.2369 in. (6.005 - 6.018 mm) Exhaust Stem To Guide Clearance 0.2364 - 0.2369 in. (6.005 - 6.018 mm) Intake 0.0006 - 0.0017 in. (0.015 - 0.043 mm) Exhaust 0.0012 - 0.0023 in. (0.030 - 0.058 mm) Stem Run-out Limit (max.) 0.001 in. (0.03 mm) “A” “B” “C” “D” Valve Dimensions Head Diameter Face Width Seat Width Margin Thickness VALVE LIFTERS Valve Lifter Outside diameter Valve Lifter to Lifter Bore Clearance 1.1010 - 1.1016 in. (27.965 - 27.980 mm) 0.0008 - 0.0022 in. (0.020 -0.056 mm) VALVE SHIM Valve shim Thickness (in 0.025 mm increments) 0.0787 - 0.1299 in. (2.000 - 3.300 mm) THERMOSTAT Valve Opening Temperature Full Open Temperature Valve Lift (Minimum) 122° F (50° C) 140° F (60° C) 0.17 in. (0.43 mm) 90-881980R1 NOVEMBER 2001 Page 4A-3 CYLINDER HEAD Special Tools 1. Flywheel Holder P/N 91-83163M 2. Valve Guide Remover/Installer P/N 91-804774 3. Valve Guide Reamer P/N 91-804775 4. Valve Spring Compressor P/N 91-809494A1 5. Valve Seat Cutter Kit (Obtain Locally). Page 4A-4 90-881980R1 NOVEMBER 2001 CYLINDER HEAD Notes: 90-881980R1 NOVEMBER 2001 Page 4A-5 CYLINDER HEAD Cylinder Head 30 31 21 20 19 7 26 28 29 27 2226 24 23 25 4 5 2 18 17 16 15 14 13 76 13 8 9 8 11 10 12 3 2 7 109 110 110 110 110 7 95 110 7 95 Loctite 271 - Thread Locker 109 110 RTV 587 Silicone Sealer 4 Cycle Oil 2-4-C With Teflon Page 4A-6 90-881980R1 NOVEMBER 2001 CYLINDER HEAD Cylinder Head REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. Nm 1 1 CYLINDER HEAD 2 16 GUIDE PIN 3 4 PLUG 4 4 SCREW (M7 X 48 MM) See Note 4 DOWEL PIN 6 16 SCREW (M7 X 37 MM) See Note 7 10 SCREW (M10 X 145 MM) See Note 8 2 COLLAR 9 1 GASKET 4 SCREW 11 4 WASHER 12 5 SCREW (M8 X 55 MM) See Note 13 2 ANODE 14 2 GROMMET 2 COVER 16 2 SCREW (M6 X 20 MM) 70 8 17 4 SCREW (M8 X 25 MM) 156 13 17.5 18 4 SPARK PLUG (NGK LFR 6A-11) 18 24.5 19 1 THERMOSTAT 1 THERMOSTAT COVER 21 2 SCREW (M6 X 25 MM) 22 1 CYLINDER HEAD COVER 23 1 BREATHER COVER 24 8 SCREW (M4 X 8 MM) 17 2 1 GASKET 26 2 GROMMET 27 14 SCREW (M6 X 30 MM) See Note 28 1 OIL PLUG 29 1 O-RING 1 COVER 31 5 SCREW (M6 X 16 MM) 65 7.5 NOTE:Ref. #4 - 1st Torque 70 lb. in.; 2nd Torque 150 lb. in. NOTE:Ref. #6 - 1st Torque 70 lb. in.; 2nd Torque 150 lb. in. NOTE:Ref. #7 - 1st Torque 11 lb. ft.; 2nd Torque 22 lb. ft.., then turn +90 degrees NOTE:Ref. #12 - 1st Torque 10 lb. ft.; 2nd Torque 20 lb. ft... NOTE:Ref. #27 - Torque all screws to 70 lb. in.; then re-check and re-tighten to 70 lb. in. as necessary 90-881980R1 NOVEMBER 2001 Page 4A-7 CYLINDER HEAD Intake/Exhaust Valves 2 1 2 21 22 23 3 3 25 4 5 24 20 19 4 18 17 16 15 6 14 15 13 12 5 10 9 15 16 17 7 8 10 11 13 14 15 Page 4A-8 90-881980R1 NOVEMBER 2001 CYLINDER HEAD Intake/Exhaust Valves REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. Nm 1 1 BELT 2 2 SCREW (M10 X 35 MM) 44.2 60 3 2 DRIVEN GEAR 4 2 OIL SEAL 5 2 DOWEL PIN 6 1 CAMSHAFT (EXHAUST) 7 1 CAMSHAFT (INTAKE) 8 8 INTAKE VALVE 9 8 EXHAUST VALVE 10 16 SEAT 11 8 SEAL 12 8 SEAL 13 16 SPRING 14 16 RETAINER 15 32 COTTER 16 16 VALVE LIFTER 17 AR ADJUSTING PAD (2.350 mm) AR ADJUSTING PAD (2.375 mm) AR ADJUSTING PAD (2.400 mm) AR ADJUSTING PAD (2.425 mm) AR ADJUSTING PAD (2.450 mm) AR ADJUSTING PAD (2.475 mm) AR ADJUSTING PAD (2.500 mm) AR ADJUSTING PAD (2.525 mm) AR ADJUSTING PAD (2.550 mm) AR ADJUSTING PAD (2.575 mm) AR ADJUSTING PAD (2.600 mm) AR ADJUSTING PAD (2.625 mm) AR ADJUSTING PAD (2.650 mm) AR ADJUSTING PAD (2.675 mm) AR ADJUSTING PAD (2.700 mm) AR ADJUSTING PAD (2.725 mm) AR ADJUSTING PAD (2.750 mm) AR ADJUSTING PAD (2.775 mm) AR ADJUSTING PAD (2.800 mm) AR ADJUSTING PAD (2.825 mm) AR ADJUSTING PAD (2.850 mm) AR ADJUSTING PAD (2.875 mm) AR ADJUSTING PAD (2.900 mm) AR ADJUSTING PAD (2.925 mm) AR ADJUSTING PAD (2.950 mm) AR ADJUSTING PAD (2.975 mm) CONTINUED ON NEXT PAGE 90-881980R1 NOVEMBER 2001 Page 4A-9 CYLINDER HEAD Intake/Exhaust Valves 2 1 2 21 22 23 3 3 25 4 5 24 20 19 4 18 17 16 15 6 14 15 13 12 5 10 9 15 16 17 7 8 10 11 13 14 15 Page 4A-10 90-881980R1 NOVEMBER 2001 CYLINDER HEAD Intake/Exhaust Valves REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. Nm 18 1 VALVE PLATE 19 1 KEY 20 1 TENSIONER ASSEMBLY 21 1 SCREW (M10 X 45 MM) 29.5 40 22 1 SPRING 23 1 HOSE 24 1 DRIVE GEAR 25 1 NUT (40 MM) 195.4 265 90-881980R1 NOVEMBER 2001 Page 4A-11 CYLINDER HEAD Torque Sequence Cylinder Head Screws 12 34 56 78 910 11 12 13 14 15 Cylinder Head Screw Torque-M8 x 55 mm 1st 120 lb-in. (14 Nm) 2nd 20 lb-ft (28 Nm) Cylinder Head Screw Torque-M10 x 145 mm 1st 132 lb-in. (15 Nm) 2nd 22 lb-ft (30 Nm) 3rd 90° 51 lb-ft (70 Nm)* *Torque value given for reference only. Camshaft Caps Screws 1 2 8 4 6 7 3 1091920 5 11 12 17 18 13 14 15 16 Camshaft Cap Screw Torque 1st 70 lb-in. (8 Nm) 2nd 150 lb-in. (17 Nm) Page 4A-12 90-881980R1 NOVEMBER 2001 CYLINDER HEAD 90-881980R1 NOVEMBER 2001 Page 4A-13 Adjustments Valve Clearance WARNING Engine could possibly start when turning flywheel during adjustment. To prevent this type of accidental engine starting and possible serious injury, always remove spark plug leads from spark plugs. NOTE: Valve clearance adjustment should be made on a cold engine at room temperature. 1. Remove flywheel cover and spark plug cap cover. 2. Disconnect spark plug leads and fuel hose. 58654 c c c e d b a a - Screws (2) M6 x 20 b - Flywheel Cover c - Screws (5) M6 x 16 d - Spark Plug Cap Cover e - Fuel Hose CYLINDER HEAD Page 4A-14 90-881980R1 NOVEMBER 2001 3. Align timing marks on driven cams. NOTE: Use flywheel holder (91-83163M) to rotate flywheel and align timing marks. 4. Loosen timing belt tensioner Screw and remove tensioner spring. a c b 91-83163M a - Timing Marks b - Timing Belt Tensioner Screw M10 x 45 c - Tensioner Spring 5. Remove timing belt and driven sprockets. 6. Remove cylinder head cover and spark plugs. a b d c e h g f a - Driven Sprocket Screw (2) M10 x 35 b - Washer (2) c - Driven Sprocket (2) d - Pin (2) e - Breather Hose f - Screw (14) M6 x 30 g - Cylinder Head Cover h - Rubber Gasket CYLINDER HEAD 90-881980R1 NOVEMBER 2001 Page 4A-15 7. Re-install driven sprockets and timing belt. NOTE: Make sure timing marks are still aligned. b a d c e a - Pin (2) b - Washer (2) c - Driven Sprocket (2) d - Driven Sprocket Screw (2) M10 x 35 e - Timing Marks Aligned Driven Sprocket Screw Torque 44 lb-ft (60 Nm) 8. Install tensioner spring and tighten timing belt tensioner. b a a - Timing Belt Tensioner M10 x 45 b - Tensioner Spring Timing Belt Tensioner Screw Torque 29 lb-ft (40 Nm) CYLINDER HEAD Page 4A-16 90-881980R1 NOVEMBER 2001 9. Measure intake and exhaust valve clearance using the Valve Clearance Measurement Steps below. VALVE CLEARANCE MEASUREMENT STEPS: a. Turn flywheel clockwise until cylinder #1’s piston is at TDC. b. Measure and record the intake valve clearance for cylinders #1 and #2. c. Measure and record the exhaust valve clearance for cylinders #1 and #3. d. Turn the flywheel 360° clockwise. e. Measure and record the intake valve clearance for cylinders #3 and #4. f. Measure and record the exhaust valve clearance for cylinders #2 and #4. Intake cylinders #1 and #2 Intake cylinders #3 and #4 Exhaust cylinders #1 and #3 Exhaust cylinders #2 and #4 MEASUREMENT TABLE INTAKE (cold) 0.007-0.009 in. (0.17-0.23 mm) CYL. Clearance Old Pad New Pad New Clearance #1 #2 #3 #4 EXHAUST (cold) 0.012-0.014 in. (0.31-0.37 mm) CYL. Clearance Old Pad New Pad New Clearance #1 #2 #3 #4 #1 #2 #3 #4 Intake Exhaust CYLINDER HEAD 90-881980R1 NOVEMBER 2001 Page 4A-17 10. If Adjustment of intake or exhaust valve clearance is necessary (out of specification) follow Changing Pad Thickness below. If no adjustment is necessary, skip to step #11 under Changing Pad Thickness. CHANGING PAD THICKNESS 1. Align timing marks on driven cams. 2. Loosen timing belt tensioner and remove tensioner spring. NOTE: Do not mix valve train parts (valve pads, camshaft caps, camshafts), keep individual cylinder parts together. a c b a - Timing Marks b - Timing Belt Tensioner M10 x 45 c - Tensioner Spring 3. Remove timing Belt and driven sprockets. 4. Remove camshaft caps and camshafts. IMPORTANT: Remove camshaft cap screws in reverse sequence (ex. #20 #1). b c a d e f g h i j 12 10 19 17 18 13 14 15 16 20 2 8 6 4 11 9 1 7 3 5 a - Driven Sprocket Screw (2) M10 x 35 b - Washer (2) c - Driven Sprocket (2) d - Pin (2) e - Screw (4) M7 x 48 f - Screw (16) M7 x 37 g - Camshaft Cap - Top (2) h - Camshaft Cap (8) i - Oil Seal (2) j - Camshaft (2) CYLINDER HEAD 5. Carefully pry up the valve pad and remove it. 6. Measure and record (in the Measurement Table) the thickness of the removed valve pad with a micrometer. a b c a-Valve Pad b-Screwdriver c-Measure Valve Pad Thickness With a Micrometer a. Select a proper replacement valve pad by calculating its thickness with the following formula. Removed Pad Thickness + Measured Valve Clearance – Specified Valve Clearance = New Pad Thickness NOTE:Measure the thickness of the new valve pads with a micrometer (thickness is not indicated on the pad). NOTE: Lubricate the valve pads withmolybdenum disulfide before installing. b. Insert the proper valve pad into the valve lifter. A A Molybdenum Disulfide Grease (Purchase Locally) Page 4A-18 90-881980R1 NOVEMBER 2001 CYLINDER HEAD 90-881980R1 NOVEMBER 2001 Page 4A-19 7. Install camshafts and camshaft caps IMPORTANT: Install camshaft cap Screws in the proper sequence and torque. 110 4-Stroke Outboard Oil a b c d e f g Intake Exhaust 12 10 19 17 18 13 14 15 16 20 2 8 6 4 11 9 1 7 3 5 h i a - Screw (4) M7 x 48 b - Camshaft Cap Top (2) c - Screw (16) M7 x 37 d - Camshaft Cap (8) e - Oil Seal (2) f - Camshaft - Intake g - Camshaft - Exhaust h - Pink Identification i - Exhaust Cam Tang Camshaft Cap Screw Torque 1st 70 lb-in. (8 Nm) 2nd 150 lb-in. (17 Nm) 8. Install driven sprockets and timing belt. b c a d a - Driven Sprocket Screw (2) M10 x 35 b - Washer (2) c - Driven Sprocket (2) d - Pin (2) Driven Sprocket Screw Torque 44 lb-ft (60 Nm) CYLINDER HEAD 9. Tighten timing belt tensioner and install tensioner spring. b a a-Timing Belt Tensioner M10 x 45 b-Tensioner Spring Timing Belt Tensioner Screw Torque 29 lb-ft (40 Nm) 10. Re-check valve clearance using Valve Clearance Measurement Steps. NOTE: If any valve clearance is still out of specification, repeat all the valve clearance adjustment steps until the specified clearance is obtained. 11. Loosen timing belt tensioner screw and remove tensioner spring. 12. Remove driven sprockets and timing belt. Page 4A-20 90-881980R1 NOVEMBER 2001 CYLINDER HEAD 13. Install cylinder head cover and driven sprockets. a b c d e f g h109 109 RTV 587 Silicone Sealer 109 a-Rubber Gasket e-Pin (2) b-Cylinder Head Cover f-Driven Sprocket (2) c-Screw (14) M6 x 30 g-Washer (2) d-Breather Hose h-Driven Sprocket Screw (2) M10 x 35 Cylinder Head Cover Screw Torque 70 lb-in. (8 Nm) Driven Sprocket Screw Torque 44 lb-ft (60 Nm) 90-881980R1 NOVEMBER 2001 Page 4A-21 CYLINDER HEAD Page 4A-22 90-881980R1 NOVEMBER 2001 14. Install timing belt and spark plugs. 15. Install tensioner spring and tighten timing belt tensioner screw. b a a - Timing Belt Tensioner Screw M10 x 45 b - Tensioner Spring Timing Belt Tensioner Screw Torque 29 lb-ft (40 Nm) 16. Connect fuel hoses and spark plug leads. 17. Install spark plug cap cover and flywheel cover. a b c c c 58654 d e a - Fuel Hoses b - Spark Plug Cap Cover c - Screws (5) M6 x 16 d - Flywheel Cover e - Screws (2) M6 x 20 Spark Cover Screw Torque 65 lb. in. (7.5 Nm) CYLINDER HEAD 90-881980R1 NOVEMBER 2001 Page 4A-23 Preparing Cylinder Head for Removal 1. Remove flywheel cover and spark plug cap cover. 2. Disconnect fuel hoses and spark plug leads. c d c c e 58654 b a a - Screws (2) M6 x 20 b - Flywheel Cover c - Screws (5) M6 x 16 d - Spark Plug Cap Cover e - Fuel Hoses 3. Align timing marks on driven cams. 4. Loosen timing belt tensioner and remove tensioner spring. NOTE: Use flywheel holder (91-83163M) to rotate flywheel and align timing marks. a c b 91-83163M a - Timing Marks b - Timing Belt Tensioner M10 x 45 c - Tensioner Spring CYLINDER HEAD Page 4A-24 90-881980R1 NOVEMBER 2001 5. Remove timing belt and driven sprockets. 6. Remove fuel pump/filter (refer to Section 3C) and cylinder head cover. a b c d e h g f e a - Driven Sprocket Screw (2) M10 x 35 b - Washer (2) c - Pin (2) d - Driven Sprocket (2) e - Breather Hose f - Screw (14) M6 x 30 g - Cylinder Head Cover h - Rubber Gasket 7. Remove camshaft caps and camshafts. NOTE: Do not mix valve train parts (valve pads, camshaft caps, camshafts), keep individual cylinder parts together. IMPORTANT: Remove camshaft cap screws in reverse sequence (ex. #20 #1). a b e c d f Intake Exhaust 12 10 19 17 18 13 14 15 16 20 2 8 6 4 11 9 1 7 3 5 a - Screw (4) M7 x 48 b - Camshaft Cap - Top (2) c - Screw (16) M7 x 37 d - Camshaft Cap (8) e - Oil Seal (2) f - Camshaft (2) CYLINDER HEAD 90-881980R1 NOVEMBER 2001 Page 4A-25 Cylinder Head Removal 1. Remove spark plugs and cylinder head assembly. 2. Remove gasket (discard) and dowel Pins. IMPORTANT: Remove cylinder head screws in reverse order of torque sequence (ex. #15 #1). NOTE: Use Torx socket driver T55 for removal/installation of cylinder head screws. a b d c e f 1 2 4 3 5 6 8 7 9 10 11 12 13 14 15 a - Spark plugs b - Screw (10) M10 x145 c - Screw (5) M8 x 55 d - Cylinder Head Assembly e - Gasket (discard) f - Dowel Pins (2) CYLINDER HEAD Page 4A-26 90-881980R1 NOVEMBER 2001 Cylinder Head Disassembly 1. Remove thermostat and anodes. IMPORTANT: To prevent anode from falling into water jacket use the following procedure for anode removal: a. Remove anode cover screws “d”. b. Remove anode assembly from cylinder block. c. Remove anode screw “e”. a b c d e f g d d e h a - Screw (2) M6 x 25 b - Thermostat Cover c - Thermostat d - Screw (4) M8 x 25 e - Screw (2) M6 x 20 f - Anode Cover (2) g - O-Ring (2) h - Anode (2) 2. Remove valve pad and valve lifter. NOTE: Keep valve pads and lifters organized to prevent them from being installed into the wrong location during cylinder head reassembly. a b c d e a - Pliers b - Valve Pad and Lifter c - Valve Pad d - Valve Lifter e - Lifter Position Fixture CYLINDER HEAD 3. Remove valve cotter, spring retainer, and spring. NOTE: Use valve spring compressor (91-809494A1) for removal of valves. Compress valve and remove valve cotters first. 4. Remove valve stem seal, spring seat, and valve guide* (see note below). 5. Remove valves (intake and exhaust). NOTE: *Do not remove valve guide unless it is out of specification, refer to“Cleaning/Inspection/ Repair” in this section for measurement and removal procedures. 91-809494A1 a-Valve Cotter b-Spring Retainer c-Valve Spring d-Valve Stem Seal b c d e f g h a e-Spring Seat f-Valve Guide g-Exhaust Valve h-Intake Valve 90-881980R1 NOVEMBER 2001 Page 4A-27 CYLINDER HEAD Cleaning/Inspection/Repair Camshaft 1. Measure camshaft lobe dimensions “a” and “b”, replace the camshaft if out of specification. a b Cam Lobe Specifications aa Intake 1.465 - 1.472 in. (37.22 - 37.38 mm) Exhaust 1.453 - 1.459 in. (36.90 - 37.06 mm) bb Intake 1.178 - 1.184 in. (29.92 - 30.08 mm) Exhaust 1.178 - 1.184 in. (29.92 - 30.08 mm) 2. Measure camshaft journal diameter “a”, replace the camshaft if out of specification. a Camshaft Journal Diameter “a” 0.9827 - 0.9835 in. (24.96 - 24.98 mm) Page 4A-28 90-881980R1 NOVEMBER 2001 CYLINDER HEAD 3. Measure camshaft cap inside diameter “b”, replace cylinder head if out of specification. b b Camshaft Cap Inside Diameter “b” 0.984 - 0.985 in. (25.000 - 25.021 mm) Thermostat 1. Inspect thermostat, replace if damaged or valve does not open. 2. Measure valve opening temperature and valve lift “a” using the “Measurement Test” below. Replace thermostat if out of specification. MEASUREMENT TEST 1. Tie a piece of thread (or other non-conductive material) onto the thermostat. 2. Suspend the thermostat in water. 3. Heat water slowly while observing the thermostat. a a-Valve Lift Distance Water Temperature Valve Lift Below 122° F (50° C) 0 in. (0 mm) Above 140° F (60° C) Minimum 0.17 in. (4.3 mm) 90-881980R1 NOVEMBER 2001 Page 4A-29 CYLINDER HEAD Valves 1. Inspect valve for damage/warpage, replace if necessary. 2. Measure margin thickness “a”. Replace valve if out of specification. a Margin Thickness “a” Intake Valve 0.031 - 0.047 in. (0.80 - 1.20 mm) Exhaust Valve 0.039 - 0.055 in. (1.00 - 1.40 mm) 3. Measure the valve stem diameter. Replace valves if out of specification. a Valve Stem Diameter Intake Valve 0.2352 - 0.2358 in. (5.975 - 5.990 mm) Exhaust Valve 0.2346 - 0.2352 in. (5.960 - 5.975 mm) Page 4A-30 90-881980R1 NOVEMBER 2001 CYLINDER HEAD 4. Measure valve stem runout. Replace valves if out of specification. Valve Stem Runout Limit (Max.) Intake Valve Exhaust Valve 0.001 in. (0.03 mm) NOTE: Valve guides, valve seal, and valves should be replaced as a set. Valve Springs 1. Check free length limit “a” of each spring. Replace valve springs if out of specification. a Valve Spring Free Length 2.094 in. (53.20 mm) 2. Measure valve spring tilt “a”. Replace valve springs if out of specification. NOTE:Check each spring on a flat surface using a square. Rotate spring and check space between the top coil and square. a Valve Spring Tilt Specification “a” Less than 0.10 in. (2.6 mm) 90-881980R1 NOVEMBER 2001 Page 4A-31 CYLINDER HEAD Page 4A-32 90-881980R1 NOVEMBER 2001 Cylinder Head 1. Inspect the cylinder head for mineral deposits/corrosion in the water passage ways, clean any deposits/corrosion observed. 2. Inspect the cylinder head for carbon deposits In combustion chamber (use round scraper to clean away deposits). Be careful not to scratch or remove material. 3. Measure cylinder head warpage. Replace cylinder head if out of specification. NOTE: Use a straight edge and a thickness gauge to inspect cylinder head for warpage. b a a - Straight Edge b - Thickness Gauge Cylinder Head Warpage Limit 0.004 in. (0.1 mm) Valve Guides 1. Measure the valve guide bore “a”. If valve guide wear is out of specification, replace the valve guide by following “Valve Guide Replacement” below. a Valve Guide Inside Diameter Intake Valve / Exhaust Valve 0.2364 - 0.2369 in. (6.005 - 6.018 mm) CYLINDER HEAD VALVE GUIDE REPLACEMENT NOTE:Heat the cylinder head in an oven to 390° F (200° C). This will help to ease guide removal and installation and to maintain correct interference fit. 1. Remove the valve guide using a valve guide remover. a 91-804774 a-Valve Guide Remover/Installer (91-804774) 2. Install the new valve guide to the specified position “a” using the valve guide remover/installer. NOTE:Before installing the valve guide, mark the installation depth “b” as shown. a b c 91-804774 a-Valve Guide Depth Position “a” b-Installation Depth Mark c-Valve Guide Remover/Installer (91-804774) Valve Guide Depth Position “a” 0.45 in. (11.5 mm) 90-881980R1 NOVEMBER 2001 Page 4A-33 CYLINDER HEAD 3. After installing the valve guide, bore the valve guide using a valve guide reamer to obtain proper stem-to-guide clearance. a 91-804775 a-Valve Guide Reamer (91-804775) Stem To Guide Clearance Intake 0.0006-0.0017 in. (0.015-0.043 mm) Exhaust 0.0012-0.0023 in. (0.030-0.058 mm) Page 4A-34 90-881980R1 NOVEMBER 2001 CYLINDER HEAD Valve Seats VALVE SEAT RECONDITIONING Clean the carbon deposits from the combustion chambers and valve seats and check for pitting. Several different types of equipment are available for reseating valve seats. Follow the equipment manufacturer’s instructions. Measure valve seat width “a”. Resurface the valve seat if not in specification. Reface valve seat, use a 90° or 45° valve seat cutter. NOTE: When twisting cutter, keep an even downward pressure to prevent chatter marks. NOTE:After refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped. a Valve Seat Width Specification “a” Intake Valve 0.062 - 0.076 in. (1.58 - 1.94 mm) Exhaust Valve 0.071 - 0.080 in. (1.80 - 2.02 mm) NOTE:If resurfacing the valve seats is required, resurface the valve seats to the specified angles shown in chart following. a b Obtain Locally Valve Seat Area Valve Seat Cutter a 90° b 45° 90-881980R1 NOVEMBER 2001 Page 4A-35 CYLINDER HEAD Cylinder Head Reassembly 1. Install valves (intake and exhaust). 2. Install spring seat and valve stem seal. 3. Install spring and spring retainer. 4. Compress valve springs using valve spring compressor and install valve cotters onto their respective valves. 91-809494A1 4-Stroke Outboard Oil 110 f a e d c b a-Valves (Intake And Exhaust) b-Spring Seat c-Valve Stem Seal d-Valve Spring e-Spring Retainer f-Valve Cotter 110 5. Install valve pad and valve lifter into their original locations. 110 4-Stroke Outboard Oil 110 a cb a-Valve Pad and Lifter b-Valve Pad c-Valve Lifter Page 4A-36 90-881980R1 NOVEMBER 2001 CYLINDER HEAD 6. Install anode and thermostat. IMPORTANT: To prevent anode from falling into water jacket use the “Anode Assembly” procedure for anode installation: Anode Assembly a. Install anode screw “a” to secure anode to anode cover. b. Install anode assembly in cylinder block. c. Install anode cover screws “e”. e f g h e e a b c d a 95 2-4-C with Teflon 95 77 Loctite 271 a-Screw M6 x 20 e-Screw M8 x 25 b-Anode Cover (2) f-Thermostat c-Anode (2) g-Thermostat Cover d-O-Ring (2) h-Screw (2) M6 x 25 Anode Screw Torque 70 lb-in. (8 Nm) Anode Cover Screw Torque 156 lb-in. (18 Nm) Thermostat Screw Torque 70 lb-in. (8 Nm) 90-881980R1 NOVEMBER 2001 Page 4A-37 CYLINDER HEAD Page 4A-38 90-881980R1 NOVEMBER 2001 Cylinder Head Installation 1. Install dowel Pins and Gasket (New). 2. Install cylinder head assembly and spark plugs. IMPORTANT: Install cylinder head screws in torque sequence (ex. #1 #15) with proper torque. NOTE: Use Torx socket driver T55 for removal/installation of cylinder head screws. f b a e c d 1 2 4 3 5 6 8 7 9 10 11 12 13 14 15 g h i 110 4-Stroke Outboard Oil 110 110 a - Dowel Pins (2) b - Gasket (New) c - Cylinder Head Assembly d - Screw (5) M8 x 55 e - Screw (10) M10 x 145 f - Spark plugs g - Cylinder Head h - Cylinder Block i - Specified Torque Cylinder Head Screw Torque-M8 x 55 mm 1st 120 lb-in. (14 Nm) 2nd 20 lb-ft (28 Nm) Cylinder Head Screw Torque-M10 x 145 mm 1st 132 lb-in. (15 Nm) 2nd 22 lb-ft (30 Nm) 3rd 90° 51 lb-ft (70 Nm)* *Torque value given for reference only. CYLINDER HEAD 90-881980R1 NOVEMBER 2001 Page 4A-39 Following Cylinder Head Installation 1. Install camshafts and camshaft caps. b c e d f 1 2 8 4 6 7 3 10 9 19 20 5 11 12 17 18 13 14 15 16 g 110 4-Stroke Outboard Oil 109 110 109 110 110 110 110 A A Molybdenum Disulfide Grease (Obtain Locally) h 109 RTV 587 Silicone Sealer i a a - Camshaft (2) b - Oil Seal (2) c - Camshaft Cap (2) d - Screw (4) M7 x 48 e - Camshaft Cap (8) f - Screw (16) M7 x 37 g - Exhaust Cam Tang h - Pink Identification i - Pistons Turned 90° Past TDC IMPORTANT: Install camshaft with tang and pink identifying mark on exhaust side of cylinder head. IMPORTANT: Before installing the intake and exhaust camshafts, turn the crankshaft 90° past TDC (either direction) to prevent bending of valves during cap installation. CYLINDER HEAD Page 4A-40 90-881980R1 NOVEMBER 2001 NOTE: Install the camshaft caps in the proper position and sequence as shown and with the stamped numbers facing upside down. Camshaft Cap Screw Torque 1st 70 lb-in. (8 Nm) 2nd 150 lb-in. (17 Nm) 2. Install cylinder head cover and driven sprockets. a b g h c d e f 109 109 RTV 587 Silicone Sealer a - Rubber Gasket b - Cylinder Head Cover c - Screw (14) M6 x 30 d - Breather Hose e - Pin (2) f - Driven Sprocket (2) g - Washer (2) h - Driven Sprocket Screw (2) M10 x 35 Cylinder Head Cover Screw Torque 70 lb-in. (8 Nm) Driven Sprocket Screw Torque 44 lb-ft (60 Nm) CYLINDER HEAD 90-881980R1 NOVEMBER 2001 Page 4A-41 Timing Belt Installation 1. Align timing marks on driven cams. NOTE: Use flywheel holder (91-83163M) to rotate flywheel and align timing marks. 2. Align pointer with TDC mark on flywheel. 3. Install timing belt. 4. Install tensioner spring and secure timing belt tensioner screw. a c b 91-83163M a - Timing Marks b - Timing Belt Tensioner M10 x 45 c - Tensioner Spring Timing Belt Tensioner Screw Torque 30 lb-ft (40 Nm) 5. Connect fuel hoses and spark plug leads. NOTE: Secure fuel hoses with spring clips. 6. Install spark plug cap cover and flywheel cover. c c c a b d e a - Fuel Hoses b - Spark Plug Cap Cover c - Screws (5) M6 x 25 d - Flywheel Cover e - Screws (2) M6 x 20 CYLINDER HEAD Extra Valve Clearance Work sheets NOTE:Photocopy this page for extra valve clearance measurement work sheets. Measurement 1. Turn flywheel clockwise until cylinder #1’s piston is at TDC. 2. Measure and record the intake valve clearance for cylinders #1 and #2. 3. Measure and record the exhaust valve clearance for cylinders #1 and #3. 4. Turn the flywheel 360° clockwise. 5. Measure and record the intake valve clearance for cylinders #3 and #4. 6. Measure and record the exhaust valve clearance for cylinders #2 and #4. Adjustment 1. If clearance is out of specification, remove and measure the pad. 2. Add or subtract to that measurement a number to put the valve back into specification. 3. Use that measurement to select a new pad. Removed Pad Thickness + Measured Valve Clearance – Specified Valve Clearance = New Pad Thickness Intake cylinders #1 and #2 Intake cylinders #3 and #4 Exhaust cylinders #1 and #3 Exhaust cylinders #2 and #4 MEASUREMENT TABLE INTAKE (cold) 0.007-0.009 in. (0.17-0.23 mm) CYL. Clearance Old Pad New Pad New Clearance #1#1 #2#2 #3#3 #4#4 EXHAUST (cold) 0.012-0.014 in. (0.31-0.37 mm) CYL. Clearance Old Pad New Pad New Clearance #1#1 #2#2 #3#3 #4#4 Page 4A-42 90-881980R1 NOVEMBER 2001 CYLINDER BLOCK/CRANKCASE POWERHEAD Section 4B - Cylinder Block/Crankcase Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-4 Cylinder Block And Crankcase . . . . . . . . . . . . . . 4B-6 Crankshaft, Pistons And Connecting Rods . . . . 4B-8 Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . 4B-10 Crankcase Cover Screws. . . . . . . . . . . . . . . 4B-10 Exhaust Cover Screws . . . . . . . . . . . . . . . . . 4B-11 Powerhead Mounting Screws/Nuts . . . . . . 4B-11 Preparing Powerhead for Removal . . . . . . . . . 4B-12 Powerhead Removal . . . . . . . . . . . . . . . . . . . . . 4B-15 Removing Powerhead Components . . . . . . . . 4B-16 Ignition Components. . . . . . . . . . . . . . . . . . . 4B-16 Charging and Starting System Components. . . . . . . . . . . . . . . . . . . . . . . . . . 4B-16 Fuel Components . . . . . . . . . . . . . . . . . . . . . 4B-16 Harness and Battery Cable Removal . . . . . 4B-16 Cylinder Head Removal . . . . . . . . . . . . . . . . 4B-16 Powerhead Disassembly . . . . . . . . . . . . . . . . . . 4B-17 Drive Sprocket Removal. . . . . . . . . . . . . . . . 4B-17 Exhaust Cover Removal . . . . . . . . . . . . . . . . 4B-18 Crankcase and Crankshaft Removal . . . . . 4B-20 Piston Ring Removal . . . . . . . . . . . . . . . . . . 4B-22 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . . 4B-23 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-23 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-24 Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-25 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-26 Crankcase and Bearings . . . . . . . . . . . . . . . 4B-26 Connecting Rod Oil Clearance . . . . . . . . . . 4B-31 Powerhead Assembly . . . . . . . . . . . . . . . . . . . . . 4B-35 Piston Ring/Piston Installation . . . . . . . . . . . 4B-35 Crankcase and Crankshaft Installation . . . 4B-36 Exhaust Cover Installation . . . . . . . . . . . . . . 4B-40 Drive Sprocket Installation . . . . . . . . . . . . . . 4B-42 Installing Powerhead Components . . . . . . . . . 4B-43 Cylinder Head Installation . . . . . . . . . . . . . . 4B-43 Harness and Battery Cable Removal . . . . . 4B-43 Fuel Components . . . . . . . . . . . . . . . . . . . . . 4B-43 Charging and Starting System Components . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-43 Ignition Components. . . . . . . . . . . . . . . . . . . 4B-43 Powerhead Installation . . . . . . . . . . . . . . . . . . . . 4B-44 Following Powerhead Installation . . . . . . . . . . . 4B-46 4 B 90-881980R1 NOVEMBER 2001 Page 4B-1 CYLINDER BLOCK/CRANKCASE Specifications CYLINDER BLOCK Type Displacement Number of Cylinders In–Line, 4 Stroke – DOHC, 16 Valves 106.2 cid (1,741 cc) 4 STROKE Length 3.496 in. (88.8 mm) CYLINDER BORE Diameter Standard Oversize-0.010 in. (0.25 mm) Taper/Out of Round Maximum Bore Type 3.110 - 3.111 in. (79.000 - 79.020 mm) 3.120 - 3.121 in. (79.250 - 79.270 mm) 0.003 in. (0.08 mm) Cast Iron PISTON Piston Type Measure Point (H) O.D. at Skirt (H) Standard (D) Oversize-0.010 in. (0.25 mm) Pin Boss Inside Diameter Aluminum 0.51 in. (13 mm) 3.1073 - 3.1082 in. (78.928 - 78.949 mm) 3.1174 - 3.1182 in. (79.178 - 79.199 mm) 0.7090 - 0.7093 in. (18.008 - 18.015 mm) H D PISTON CLEARANCE Piston to Cylinder Clearance 0.0028 - .0031 in. (0.070 - 0.080 mm) Top Ring Dimension “B” B 0.046 - 0.047 in. (1.17 - 1.19 mm) Dimension “T” 0.114 - 0.115 in. (2.89 - 2.91 mm) End Gap (Installed) Side Clearance T 0.006 - 0.012 in. (0.15 - 0.30 mm) 0.001 - 0.003 in. (0.02 - 0.08 mm) Middle Ring Dimension “B” 0.058 - 0.059 in. (1.47 - 1.49 mm) RINGS Dimension “T” End Gap (Installed) B 0.118 - 0.126 in. (3.00 - 3.20 mm) 0.028 - 0.035 in. (0.70 - 0.90 mm) Side Clearance Bottom (Oil Ring) T 0.001 - 0.003 in. (0.03 - 0.07 mm) Dimension “B” 0.094 - 0.098 in. (2.38 - 2.48 mm) Dimension “T” 0.094 in. (2.40 mm) End Gap (Installed) Side Clearance B 0.008 - 0.028 in. (0.20 - 0.70 mm) 0.001 - 0.006 in. (0.03 - 0.15 mm) T COMPRESSION RATIO Compression Ratio Cylinder Compression (Minimum) 9.7:1 138 psi (950 kPa) PISTON PIN Piston Pin Outside Diameter 0.7085 - 0.7087 in. (17.997 - 18.000 mm) Page 4B-2 90-881980R1 NOVEMBER 2001 CYLINDER BLOCK/CRANKCASE Small End Inside Diameter 0.7073 - 0.7081 in. (17.965 - 17.985 mm) Big End Inside Diameter 1.7726 - 1.7734 in. (45.025 - 45.045 mm) CONNECTING Oil Clearance (Big End) Big End Bearing Thickness 0.0010 - 0.0012 in. (0.025 - 0.031 mm) ROD Yellow 0.0591 - 0.0594 in. (1.502 -1.508 mm) Green 0.0594 - 0.0596 in. (1.508 - 1.514 mm) Blue 0.0596 - 0.0598 in. (1.514 - 1.520 mm) Red 0.0598 - 0.0601 in. (1.520 - 1.526 mm) Crankshaft Journal Diameter 1.8891 - 1.8898 in. (47.984 - 48.000 mm) Minimum Diameter Crankshaft Pin 1.8887 in. (47.972 mm) Diameter 1.6535 - 1.6528 in. (42.000 - 41.982 mm) CRANKSHAFT Minimum Diameter 1.7311 in. (43.971 mm) Crankshaft Run-out 0.001 in. (0.03 mm) Crankcase Main Journal Inside Diameter 2.1269 - 2.1276 in. (54.023 - 54.042 mm) Crankshaft Journal Oil Clearance Upper Crankcase Main Journal Bearing Thickness 0.0009 - 0.0017 in. (0.024 - 0.044 mm) Green 0.1178 - 0.1181 in. (2.992 - 2.999 mm) Blue 0.1181 - 0.1183 in. (2.999 - 3.006 mm) CRANKCASE Red Lower Crankcase Main Journal Bearing Thickness 0.1183 - 0.1186 in. (3.006 - 3.013 mm) Yellow 0.1185 -0.1188 in. (3.010 - 3.017 mm) Green 0.1188 - 0.1191 in. (3.017- 3.024 mm) Blue 0.1191 - 0.1193 in. (3.024 - 3.031 mm) Red No. 3 Main Journal Bearing Thickness 0.1193 - 0.1196 in. (3.031 - 3.038 mm) Green 0.1178 - 0.1181 in. (2.992 - 2.999 mm) Blue 0.1181 - 0.1183 in. (2.999 - 3.006 mm) Red 0.1183 - 0.1186 in. (3.006 - 3.013 mm) 90-881980R1 NOVEMBER 2001 Page 4B-3 CYLINDER BLOCK/CRANKCASE Special Tools 1. Oil Filter Wrench (P/N 91-802653Q1) 2. Flywheel Holder (P/N 91-83163M) 3. Flywheel Puller/Lifting Eye (P/N 91-83164M) 4. Piston Ring Compressor (P/N FT2997) 5. Piston Ring Expander (P/N 91-24697) 6. Crankshaft Holder (P/N 91-804770A1) 7. 46 mm Socket (P/N 91-881847A1) Page 4B-4 90-881980R1 NOVEMBER 2001 CYLINDER BLOCK/CRANKCASE Notes: 90-881980R1 NOVEMBER 2001 Page 4B-5 CYLINDER BLOCK/CRANKCASE Cylinder Block And Crankcase 31 30 14 291315 23 24 2526 27 28 16 17 18 19 20 22 21 8 7 2 12 117 8 6 5 4 1 9 10 3 3433 32 35 110 110 4-Stroke Outboard Oil Page 4B-6 90-881980R1 NOVEMBER 2001 CYLINDER BLOCK/CRANKCASE Cylinder Block And Crankcase REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 CYLINDER BLOCK 2 10 DOWEL PIN 3 1 GASKET 4 10 SCREW (M8 X 55 MM) See Note 5 10 SCREW (M10 X 135 MM) See Note 6 1 GROMMET 7 2 LIFTING EYE 8 4 SCREW (M6 X 20 MM) 70 8 9 1 PLUG (M14 X 12 MM) 10 1 GASKET 11 1 OIL FILTER 12 1 SCREW 13 1 OUTER EXHAUST COVER 14 1 GASKET 15 18 SCREW (M6 X 30 MM) See Note 16 1 SCREW PLUG 17 1 GASKET 18 1 ANODE 19 1 GROMMET 20 1 COVER 21 1 SCREW (M6 X 16 MM) 70 8 22 2 SCREW (M8 X 25 MM) 156 13 17.5 23 1 GROMMET 24 1 PRESSURE CONTROL VALVE 25 1 SPRING 26 1 GASKET 27 1 COVER 28 3 SCREW (M6 X 20 MM) 70 8 29 1 CLIP 30 1 HOSE 31 1 CLAMP 32 6 STUD 33 6 WASHER 34 6 NUT 35 47.5 35 2 SCREW (M8 X 35 MM) 20 27 NOTE:Ref. #4 - 1st Torque 10 lb. ft.; 2nd Torque 20 lb. ft. NOTE:Ref. #5 - 1st Torque 14 lb. ft., then torque +60 degrees NOTE:Ref. #15 - 1st Torque 50 lb. in.; 2nd Torque 105 lb. in. 90-881980R1 NOVEMBER 2001 Page 4B-7 CYLINDER BLOCK/CRANKCASE Crankshaft, Pistons And Connecting Rods 5 5 5 5 5 10 9 7 84 4 6 4 4 3 2 1 110 110 110 110 110 110 110 4 Cycle Oil Page 4B-8 90-881980R1 NOVEMBER 2001 CYLINDER BLOCK/CRANKCASE Crankshaft, Pistons And Connecting Rods REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 CRANKSHAFT 2 1 OIL SEAL 3 1 OIL SEAL 4 4 BEARING (GREEN) 4 BEARING (BLUE) 4 BEARING (RED) 5 5 BEARING (YELLOW) 5 BEARING (GREEN) 5 BEARING (BLUE) 5 BEARING (RED) 6 1 BEARING (GREEN) 1 BEARING (BLUE) 1 BEARING (RED) 7 4 PISTON/CONNECTING ROD ASSEMBLY (STANDARD) AR PISTON/CONNECTING ROD ASSEMBLY (.25 MM O/S) 8 2 SCREW (M8 X 38 MM) See Note 9 4 PISTON RING SET (STANDARD) AR PISTON RING SET (.25 MM O/S) 10 8 BEARING (YELLOW) 8 BEARING (GREEN) 8 BEARING (BLUE) 8 BEARING (RED) NOTE:Ref. #8 - 1st Torque 132 lb. in./15 N-m; 2nd Torque +60 degrees 90-881980R1 NOVEMBER 2001 Page 4B-9 CYLINDER BLOCK/CRANKCASE Torque Sequence Crankcase Cover Screws 121 34 5161 781 910 1112 1314 1516 18 19120 171 a b 60° 1st Torque 2nd Torque b a-Center Screw (10) 1st Torque b-Center Screw (10) 2nd Torque (60° Torque) Crankcase Cover Screw Torque Outer Screws QtyOuter Screws Qty. .. 10 (M8 x 55 mm) 1st Torque: 120 lb-in. (14 Nm) 2nd Torque: 20 lb-ft (28 Nm) Center Screws QtyCenter Screws Qty. 10 (M10 x 135 mm) 1st Torque: 14 lb-ft. (19 Nm) 2nd Torque: 60° 37 lb-ft (50 Nm)* *Torque value for reference only. Page 4B-10 90-881980R1 NOVEMBER 2001 CYLINDER BLOCK/CRANKCASE Exhaust Cover Screws 4 1 5 9 8 1312 7 18 16 3 14 2 156 17 11 10 Exhaust Cover Screw Torque 1st Torque: 50 lb-in. (6 Nm) 2nd Torque: 105 lb-in. (12 Nm) Powerhead Mounting Bolts/Nuts 12 3 4 5 678 Powerhead Mounting Nut Torque 35 lb-ft (47.5 Nm) Powerhead Mounting Bolt Torque 20 lb-ft (27 Nm) 90-881980R1 NOVEMBER 2001 Page 4B-11 CYLINDER BLOCK/CRANKCASE Page 4B-12 90-881980R1 NOVEMBER 2001 Preparing Powerhead for Removal 1. Remove top cowl. 2. Remove flywheel cover. b a a - Screws (2) M6 x 20 mm b - Flywheel Cover 3. Disconnect cowl switch power trim wires. b c a d 58655 a - Green/White b - Lt. Blue/White c - Red d - Cowl Switch CYLINDER BLOCK/CRANKCASE 4. Remove cowl grommet. 5. Remove 2 screws from grommet cover. Remove grommet cover and grommet. 6. Remove 8 screws holding cowl halves together. a b c d e b c f g h a-Cowl Grommet b-Cowl Screws (8) M6 x 40 c-Screws (2) M6 x 20 d-Grommet Cover e-Grommet f-Cowl Latch g-Grommet h-Idle Exhaust Grommet 90-881980R1 NOVEMBER 2001 Page 4B-13 CYLINDER BLOCK/CRANKCASE Page 4B-14 90-881980R1 NOVEMBER 2001 7. Remove dipstick and drain oil. 8. Disconnect shift switch harness. 9. Remove vapor separator vent hose. 10. Disconnect power trim pump wires. 11. Remove incoming fuel hose. 58681 58655 a b c d e a - Dipstick b - Shift Position Switch Harness c - Vapor Separator Vent Hose d - Power Trim Pump Wires (BLUE & GREEN) e - Fuel Hose CYLINDER BLOCK/CRANKCASE 90-881980R1 NOVEMBER 2001 Page 4B-15 Powerhead Removal 1. Remove nuts (6) and bolts (2) to free powerhead from drive shaft housing. c b a 58654 a - Nuts (6) b - Washers (6) c - Bolts (2) M8 x 35 2. Lift powerhead from driveshaft housing using flywheel puller/lifting eye (91-83164M). 3. Place powerhead on suitable stand. a 91-83164M a - Flywheel Puller/Lifting Eye (91-83164M) CYLINDER BLOCK/CRANKCASE Removing Powerhead Components Ignition Components 1. Refer to Section 2A for removal of the following ignition components. a. Flywheel - must use Crankshaft Holder Tool (91-804770A1) b. Stator c. Timing belt d. Ignition coils e. ECM unit f. Crank Position Sensors g. Temperature sensor Charging and Starting System Components 1. Refer to Section 2B for removal of the following ignition components. a. Starter motor/relay b. Voltage regulator/rectifier Fuel Components 1. Refer to Section 3C for removal of the following components. a. Fuel pump b. EFI Assembly Harness and Battery Cable Removal 1. Remove battery and harness cable assembly. Cylinder Head Removal 1. See Section 4A for cylinder head removal. Page 4B-16 90-881980R1 NOVEMBER 2001 CYLINDER BLOCK/CRANKCASE Powerhead Disassembly Drive Sprocket Removal 1. Remove nut. NOTE:Use 46 mm socket with an internal depth of 76 mm (91-881847A1) to hold drive sprocket nut. Use crankshaft holder tool (P/N 91-804770A1) to hold crankshaft. a b c d 91-804770A1 91-881847A1 e f a-Drive Sprocket Nut b-Drive Sprocket c-Crank Position Sensor Rotor d-Key e-46 mm, 76 mm Deep Socket (91-881847A1) f-Crankshaft Holder Tool (P/N 91-804770A1) 90-881980R1 NOVEMBER 2001 Page 4B-17 CYLINDER BLOCK/CRANKCASE Page 4B-18 90-881980R1 NOVEMBER 2001 Exhaust Cover Removal 1. Remove oil filter. 2. Remove water hose, exhaust cover and gasket. a b d 91-802653Q1 c e 58574 a - Oil Filter b - Water Hose c - Screw (18) M6 x 30 mm d - Exhaust Cover e - Gasket (Discard) CYLINDER BLOCK/CRANKCASE 90-881980R1 NOVEMBER 2001 Page 4B-19 3. Remove Pressure Control Valve (PCV) Cover. 4. Remove anode and engine temperature sensor. IMPORTANT: If removing anode from outboard with exhaust plate installed use the following procedure to prevent anode from falling into water jacket: ANODE REMOVAL PROCEDURE 1. Remove anode cover screws “g”. 2. Remove anode assembly from cylinder block. 3. Remove anode screw “h” to separate anode from anode cover. a i j k n 58686 m o f e d c h g b p q l 7 Loctite 271 7 a - Screw (3) M6 x 20 b - PCV Cover c - Spring d - Pressure Control Valve (PCV) e - Grommet f - Gasket (Discard) g - Screw (2) M8 x 25 h - Screw M6 x 20 i - Anode Cover j - Anode k - O-Ring l - Screw (2) M6 x 16 m - Engine Temperature Sensor Retainer n - Engine Temperature Sensor o - Gasket (Discard) p - J Clip q - Screw CYLINDER BLOCK/CRANKCASE Page 4B-20 90-881980R1 NOVEMBER 2001 Crankcase and Crankshaft Removal 1. Remove crankcase and connecting rod caps. IMPORTANT: Do not interchange connecting rod caps and bearing halves during disassembly. Mark the cylinder number on the rod cap (1 through 4) with a paint pen or scribe mark. Reinstall in their original locations. NOTE: Use 5/16 in. 12 point socket for removal of connecting rod screws. a b c d e a - Screw (10) M8 x 55 b - Screw (10) M10 x 135 c - Crankcase d - Connecting Rod Screw (Discard) (8) M8 x 38 e - Connecting Rod Cap (4) 2. Remove crankshaft and oil seals. a b c a - Crankshaft b - Upper Oil Seal c - Lower Oil Seal CYLINDER BLOCK/CRANKCASE 90-881980R1 NOVEMBER 2001 Page 4B-21 IMPORTANT: Do not interchange main bearings. Re-install in their original locations. 3. Remove main bearing halves from the crankcase cover and cylinder block. a b a - Main Bearing Halves-Crankcase Cover (5) b - Main Bearing Halves-Cylinder Block (5) IMPORTANT: Scribe (or use paint pen) the cylinder number (1 through 4) on the inside of each piston/connecting rod assembly and connecting rod cap for re-assembly into their original cylinders. Be sure to keep connecting rod bearings with the appropriate piston/connecting rod assembly. 4. Remove piston/connecting rod assembly. Do not interchange bearings, end cap or piston assembly with other cylinders. a b 58563 a c a - Piston/Connecting Rod Assembly (4) b - Connecting Rod Bearings (4) c - Connecting Rod Cap (4) CYLINDER BLOCK/CRANKCASE Piston Ring Removal 1. Remove top and second ring. 2. Remove oil ring (bottom rail, top rail, and scraper). NOTE:Use piston ring expander tool (91-24697) to prevent rings from breaking. If re-using rings mark their location for re-installation. 91-24697 a b c d a-Top Ring b-Second Ring c-Oil Ring d-Piston Page 4B-22 90-881980R1 NOVEMBER 2001 CYLINDER BLOCK/CRANKCASE Cleaning/Inspection/Repair Cylinder MEASURING CYLINDER BORE 1. Measure the cylinder bore diameter at three locations in both X and Y axis. 2. If the cylinder bore is beyond the standard limits listed in the tables below, it will be necessary to re-bore the cylinder to accept the oversize piston. NOTE:Measure at three locations (L1, L2, and L3) in both X and Y axis (D1-6). L1=0.8 in. (20 mm) L2=2.8 in. (70 mm) L3=4.7 in. (120 mm) 3. Measure bore diameter with a cylinder gauge, re-bore or replace if necessary. D1,2 D3,4 D5,6 L1 L2 L3 Cylinder Bore Specifications Bore Size Maximum Taper/Out-of-Round Standard Bore 3.110-3.111 in. (79.000-79.020 mm) 0.003 in. (0.08 mm) Oversize Bore-0.010 in. (0.25 mm) 3.120-3.121 in. (79.250-79.270 mm) 0.003 in. (0.08 mm) NOTE: Taper=(Maximum of D1 or D2)–(Minimum of D5 or D6) 90-881980R1 NOVEMBER 2001 Page 4B-23 CYLINDER BLOCK/CRANKCASE Piston 1. Inspect piston wall wear/damage, replace piston/connecting rod assembly if necessary. 2. Measure the piston at a point 0.51 in (13 mm) from the bottom, replace piston/connecting rod assembly if out of specification. b a a-Piston Diameter b-0.51 in. (13 mm) Piston Diameter “a” Piston Size Diameter Standard 3.1074-3.1082 in. (78.928-78.949 mm) Oversize-0.010 in. (0.25 mm) 3.1174-3.1182 in. (79.178-79.199 mm) 3. Measure piston to cylinder clearance. If out of specification examine piston and cylinder bore further to determine repair/replacement. a. Piston to Cylinder Clearance can be defined by: MBM–MPM=PCC where: MBM=Minimum Bore Measurement MPM=Maximum Piston Measurement PCC=Piston to Cylinder Clearance Piston to Cylinder Clearance 0.0028-0.0031 in. (0.070-0.080 mm) Page 4B-24 90-881980R1 NOVEMBER 2001 CYLINDER BLOCK/CRANKCASE Piston Rings PISTON RING SIDE CLEARANCE 1. Measure piston ring side clearance. Replace piston rings as a set if out of specification. Piston Ring Side Clearance Top 0.001-0.003 in. (0.020-0.080 mm) Middle 0.001-0.003 in. (0.03-0.08 mm) Oil 0.001-0.006 in. (0.03-0.15 mm) PISTON RING END GAP CLEARANCE 1. Measure piston ring end gap clearance. Replace piston rings as a set if out of specification. NOTE:Ring should be level for measurement. Push ring into bore with crown of piston. NOTE:Measure end gap clearance at a depth of 0.8 in. (20 mm). a a-Measurement Depth Piston Ring End Gap Top 0.006 - 0.012 in. (0.15 - 0.30 mm) 2nd 0.028 - 0.035 in. (0.70 - 0.90 mm) Oil 0.008 - 0.028 in. (0.20 - 0.70 mm) 90-881980R1 NOVEMBER 2001 Page 4B-25 CYLINDER BLOCK/CRANKCASE Crankshaft 1. Thoroughly clean crankshaft and inspect bearing surfaces. Replace crankshaft if bearing surfaces are pitted, scored, or discolored. 2. Measure run-out. Replace crankshaft if out of specification. 3. Clean oil holes in crankshaft. Crankshaft Run-out 0.001 in. (0.03 mm) 4. Measure crankshaft journal diameter and crankpin diameter, replace if out of specification. Crankshaft Journal Diameter Limit 1.8887 in. (47.972 mm) Crankpin Diameter Limit 1.7311 in. (43.971 mm) Crankcase and Bearings 1. Measure crankshaft main bearing clearance using the test below, replace the upper and lower bearings as a set if out of specification (see Crankcase and Bearing Indication Marks). NOTE:Measure the main oil bearing clearance at room temperature 68° F (20° C). Main Bearing Clearance 0.0009 - 0.0017 in. (0.024 - 0.044 mm) Page 4B-26 90-881980R1 NOVEMBER 2001 CYLINDER BLOCK/CRANKCASE 90-881980R1 NOVEMBER 2001 Page 4B-27 CRANKSHAFT MAIN BEARING CLEARANCE MEASUREMENT IMPORTANT: Do not interchange the main bearings. Re-install in their original position. 1. Clean all the old sealing material from the split line on the crankcase cover and cylinder block. 2. Clean all the oil from the following areas: a. Main bearing surfaces on the cylinder block and crankcase cover. b. Main bearings. c. Crankshaft bearing surfaces. 3. Install main bearing halves into the cylinder block. 4. Install crankshaft. a a - Main Bearing Halves-Cylinder Block (5) 5. Place a piece of plastigauge onto each crankshaft bearing surface. NOTE: Do not put plastigauge over the oil hole on the bearing surface of the crankshaft. a a - Plastigauge CYLINDER BLOCK/CRANKCASE Page 4B-28 90-881980R1 NOVEMBER 2001 6. Install main bearing halves into the crankcase. a a - Main Bearing Halves-Crankcase (5) 7. Install crankcase onto cylinder block. 8. Apply oil to the cover screws and torque cover screws in sequence and in two steps. IMPORTANT: Do not move crankshaft until measurement has been completed. 110 4-Stroke Outboard Oil 1 2 4 3 5 6 8 7 9 10 11 12 14 13 15 16 18 19 20 17 a 110 110 b a - Screw (10) M10x135mm b - Screw (10) M8x55mm Crankcase Cover Screw Torque Outer Screws Qty. 1st Torque: 120 lb-in. (14 Nm) 10 (M8x55) 2nd Torque: 20 lb-ft. (28 Nm) Center Screws Qty 1st Torque: 14 lb-ft. (19 Nm) Qty. 10 (M10x135) 2nd Torque: 60° 37 lb-ft. (50 Nm)* *Torque value for reference only. CYLINDER BLOCK/CRANKCASE SERVICE TIP 1. To obtain 60° rotation of crankcase cover screws (after initial torque has been set) put a paint mark on corner point of the screw head and a second paint mark one corner point clockwise on crankcase cover as shown. Rotate screw until paint marks align. NOTE:When using this procedure for final assembly use different color paint on crankcase cover to avoid confusion with previous paint marks. a b a-Paint Mark On Screw Head b-Paint Mark On Crankcase Cover c-Screw Head MAIN BEARING CLEARANCE 1. Remove the screws and crankcase. 2. Measure the width of the compressed plastigauge to check the main bearing clearance. Replace bearings if clearance is not within specification (see Selecting New Main Bearings following). a a-Compressed Plastigauge Main Bearing Clearance 0.0009 - 0.0017 in. (0.024 - 0.044 mm) 90-881980R1 NOVEMBER 2001 Page 4B-29 CYLINDER BLOCK/CRANKCASE SELECTING NEW MAIN BEARINGS 1. Subtract the crankshaft journal diameters (#1-#5) from the cylinder block journal diameters (#1-#5). 2. Select a suitable bearing from the table below according to the calculated values. NOTE:The cylinder block journal diameters (#1-#5) and the crankshaft journal diameters, (#1-#5) can be determined by the stamped value as described below. Crankshaft journal diameter = 47.900+(stamped value/1000) Example: If the stamped value of position #1 reads 92 then using the previous formula would yield a crankshaft journal diameter of: 47.900+(92/1000) = 47.992 Cylinder block journal diameter = 54.000+(stamped value/1000) Example: If the stamped value of position #1 reads 32 then using the previous formula would yield a cylinder block journal diameter of: 54.000+(32/1000) = 54.032 #1 #2 #3 #4 #5 #1 #2 #3 #4 #5 3. Refer to the following reference table to select the correct main bearings. Crankshaft Bearing Selection Table Cylinder Block journal diameters–crankshaft journal diameters (mm) Bearing (cylinder side) (with oil groove) Bearing (crankcase side) (w/o oil groove) 6.023-6.026 Green Yellow* 6.027-6.034 Blue Green* 6.035-6.042 Blue Blue 6.043-6.049 Red Blue* 6.050-6.058 Red Red Page 4B-30 90-881980R1 NOVEMBER 2001 CYLINDER BLOCK/CRANKCASE CAUTION The (*) mark indicates that the color of the upper and lower bearings are different. Install the main bearings in the middle of the cylinder block and crankcase journals so they do not block the oil holes. NOTE:Crankshaft bearing #3 is a thrust bearing. NOTE:If the difference between the cylinder block journal diameter and crankshaft journal diameter is more than the maximum value (6.058mm), replace the crankshaft, cylinder block, or both. Connecting Rod Oil Clearance 1. Measure the connecting rod oil clearance using the Connecting Rod Oil Clearance Measurement steps below. Replace the upper and lower bearings as a set if out of specification. Connecting Rod Oil Clearance 0.0010 - 0.0012 in. (0.025 - 0.031 mm) CONNECTING ROD OIL CLEARANCE MEASUREMENT IMPORTANT: Mark the original connecting rod screws to avoid confusion with new screws. CAUTION The original connecting rod screws are to be used for measurement and adjustment of the oil clearance only. Do not use the original connecting rod screws for reassembly of the engine. NOTE:Clean all the oil from the connecting rod bearing surfaces and connecting rod journals on the crankshaft. CAUTION Install the bearings in their original positions. Incorrect oil clearance measurements can result in engine damage. 1. Install the upper half of the bearing into the connecting rod, and the lower half of the bearing into the connecting rod cap. 2. Place a piece of Plastigauge onto the crank pin parallel to the crankshaft. a a-Plastigauge 90-881980R1 NOVEMBER 2001 Page 4B-31 CYLINDER BLOCK/CRANKCASE 3. Assemble the connecting rods onto their respective crankpins. IMPORTANT: Make sure the dimple side “a” on the connecting rod faces toward the flywheel side. NOTE:Do not move the crankshaft until the big end oil clearance measurement has been completed. 58563 b a a-Connecting Rod/Rod Cap Dimples b-Connecting Rod/Piston Assembly 4. Apply engine oil onto the threads and seat of the original connecting rod screws. 5. Tighten the original connecting rod screws in alternating sequence and in two stages. Connecting Rod Screw Torque 1st Torque: 132 lb-in. (15 Nm) 2nd Torque: 60° 6. Remove the connecting rod cap. 7. Measure the width of the compressed plastigauge on each crankpin to check the connecting rod oil clearance. Refer to Connecting Rod Oil Clearance Adjustment below if oil clearance is not within specification. a a-Compressed Plastigauge Connecting Rod Oil Clearance 0.0010 - 0.0012 in. (0.025 - 0.031 mm) Page 4B-32 90-881980R1 NOVEMBER 2001 CYLINDER BLOCK/CRANKCASE CONNECTING ROD OIL CLEARANCE ADJUSTMENT NOTE:Measure big end oil clearance at room temperature 68° F (20° C). 1. Install new yellow bearings into the connecting rods and connecting rod caps. NOTE:Yellow bearings are used as a “reference” bearing to help determine clearance. 2. Place a piece of Plastigauge onto the crank pin parallel to the crankshaft. 3. Assemble the connecting rod caps onto their respective crankpins. IMPORTANT: Make sure the dimple side “a” on the connecting rod faces toward the flywheel side. NOTE:Do not move the crankshaft until the big end oil clearance measurement has been completed. b a 58563 a-Connecting Rod/Rod Cap Dimples b-Connecting Rod/Piston Assembly 90-881980R1 NOVEMBER 2001 Page 4B-33 CYLINDER BLOCK/CRANKCASE 4. Apply engine oil onto the threads and seat of the original connecting rod screws. 5. Tighten the original connecting rod screws in alternating sequence and in two stages. Connecting Rod Screw Torque 1st Torque: 132 lb-in. (15 Nm) 2nd Torque: 60° 6. Remove the connecting rod cap. 7. Measure the width of the compressed plastigauge on each crankpin to check the connecting rod oil clearance. 8. Select a suitable bearing from the table below according to the measurement values. a a-Compressed Plastigauge Connecting Rod Bearing Selection Table Measurement value with new yellow bearing using plastigauge (mm) Upper Bearing (Piston) Lower Bearing (Cap) 0.025-0.031 Yellow Yellow 0.032-0.039 Yellow Green* 0.040-0.046 Green Green 0.047-0.052 Green Blue* 0.053-0.058 Blue Blue 0.059-0.063 Blue Red* CAUTION The (*) mark indicates that the color of the upper and lower bearings are different. NOTE:If the measurement value is more than the maximum value (0.063 mm), replace the crankshaft, cylinder block, or both. Page 4B-34 90-881980R1 NOVEMBER 2001 CYLINDER BLOCK/CRANKCASE Powerhead Assembly Piston Ring/Piston Installation IMPORTANT: If re-using rings, install in their original locations. IMPORTANT: Use caution when installing piston rings to avoid scratching piston. 1. Install the oil ring components as shown. Spread rings just enough to slip over piston. 2. Install the second and top compression rings (“T” side up). Spread rings just enough to slip over piston. 3. Offset the piston ring end gaps. 4-stroke Outboard Oil110 110 91-24697 a b c f e d 110 i j h g a-Oil Ring Spacer b-Bottom Rail c-Top Rail d-Second Compression Ring (“T” side up) e-Top Compression Ring (“T” side up) f-“T” Mark Should Face Piston Crown g-End Gap – Lower Oil Ring Rail h-End Gap – Upper Oil Ring Rail i-End Gap – Second Compression Ring j-End Gap – Top Compression Ring 90-881980R1 NOVEMBER 2001 Page 4B-35 CYLINDER BLOCK/CRANKCASE Page 4B-36 90-881980R1 NOVEMBER 2001 NOTE: Cylinder bores must be clean before installing pistons. Clean with light honing as necessary. After honing, clean cylinder bores with water and detergent. After cleaning, swab cylinder bores several times with engine oil and a clean cloth, then wipe with a clean dry cloth. 4. Lubricate pistons, rings, and cylinder walls with engine oil. 5. Install piston/connecting rod assembly using piston ring compressor tool. NOTE: Install used pistons in their original locations (cylinders). Install piston with “UP” mark on piston crown facing toward the flywheel end of block. P/N FT2997 a a - Piston Ring Compressor (FT2997) Crankcase and Crankshaft Installation IMPORTANT: Do not interchange main bearings, re-install in their original locations. NOTE: Apply oil to bearings before installing. NOTE: Bearing #3 is a thrust bearing. 1. Install main bearing halves on the crankcase cover and cylinder block. a 110 4-Stroke Outboard Oil 110 110 b c a - Main Bearing Halves-Crankcase Cover (5) b - Main Bearing Halves-Cylinder Block (with holes) (5) c - #3 Thrust Bearing CYLINDER BLOCK/CRANKCASE 90-881980R1 NOVEMBER 2001 Page 4B-37 2. Install crankshaft and oil seals. NOTE: Apply oil to seals before installation. a b c 110 4-Stroke Outboard Oil 110 110 a - Crankshaft b - Upper Oil Seal c - Lower Oil Seal 3. Lubricate connecting rod journals with engine oil. NOTE: Apply oil to connecting rod Screws before installing. 4. Install connecting rod cap and new Screws onto their respective crankpins. 5. Tighten connecting rod screws in alternating sequence and in two stages. NOTE: Use 5/16 in. 12 point socket for installation of connecting rod screws. IMPORTANT: Assemble connecting rod caps in their original locations. 110 110 4-Stroke Outboard Oil a b a - Connecting Rod Cap (4) b - Connecting Rod Screw (New) (8) M8 x 38 Connecting Rod Screw Torque 1st Torque: 132 lb-in. (15 Nm) 2nd Torque: 60° CYLINDER BLOCK/CRANKCASE Page 4B-38 90-881980R1 NOVEMBER 2001 6. Clean off all oil from the contacting surfaces of the crankcase cover and cylinder block. IMPORTANT: Make sure the contacting surface of the crankcase cover and cylinder block are clean before applying gasket sealant. 7. Apply a smooth even coat of Loctite Master Gasket Sealant to the contacting surfaces on the crankcase cover. Use a small (paint type) roller to spread out the sealant for a smooth even coverage. Instructions in gasket sealant kit must be followed exactly. NOTE: Do not apply gasket sealant to the main bearings or the screw holes. 8. Oil screws and torque cover in sequence and in two steps. a c 12 Loctite Master Gasket Kit 12 b 1 2 4 3 5 6 8 7 9 10 11 12 14 13 15 16 18 19 20 17 d e 110 4-Stroke Outboard Oil 110 110 a - Crankcase b - Screw (10) M8 x 55 c - Screw (10) M10 x 135 d - Contact Surface of Crankcase e - Use Roller To Apply A Smooth Even Coat Crankcase Cover Screw Torque Outer Screws Qty. 1st Torque: 120 lb-in. (14 Nm) 10 (M8 x 55 mm) 2nd Torque: 20 lb-ft (28 Nm) Center Screws Qty 1st Torque: 14 lb-ft. (19 Nm) Qty. 10 (M10 x 135 mm) 2nd Torque: 60° 37 lb-ft (50 Nm)* *Torque value for reference only. CYLINDER BLOCK/CRANKCASE SERVICE TIP 1. To obtain 60° rotation of crankcase cover screws (after initial torque has been set) put a paint mark on corner point of the screw head and a second paint mark one corner point clockwise on crankcase cover as shown. Rotate screw until paint marks align. NOTE:When using this procedure for final assembly use different color paint on crankcase cover to avoid confusion with previous paint marks. a b a-Paint Mark On Screw Head b-Paint Mark On Crankcase Cover 90-881980R1 NOVEMBER 2001 Page 4B-39 CYLINDER BLOCK/CRANKCASE Page 4B-40 90-881980R1 NOVEMBER 2001 Exhaust Cover Installation 1. Install gasket, exhaust cover, and water hose. Tighten exhaust cover screws to specified torque and in sequence. 2. Install oil filter and oil return hose. 91-802653Q1 a b c d e 4 13 8 18 12 7 16 3 14 1 2 5 6 15 17 9 10 11 a - Gasket (New) b - Exhaust Cover c - Screw (18) M6 x 30 d - Water Hose e - Oil Filter Exhaust Cover Screw Torque 1st Torque: 50 lb-in. (6 Nm) 2nd Torque: 105 lb-in. (12 Nm) CYLINDER BLOCK/CRANKCASE 90-881980R1 NOVEMBER 2001 Page 4B-41 ANODE INSTALLATION 1. Install Pressure Control Valve (PCV) Cover. 2. Install anode and engine temperature sensor. IMPORTANT: To prevent anode from falling into water jacket use the following procedure for anode installation: • Install anode screw “h” securing cover to anode. • Install anode assembly onto cylinder block. • Install anode cover screws “g”. a i j k n 58686 m o f c b h g p q l 7 Loctite 271 7 e d a - Screw (3) M6 x 20 b - PCV Cover c - Spring d - Pressure Control Valve (PCV) e - Grommet f - Gasket (Discard) g - Screw (2) M8 x 25 h - Screw M6 x 20 i - Anode Cover j - Anode k - O-Ring l - Screw (2) M6 x 16 m - Engine Temperature Sensor Retainer n - Engine Temperature Sensor o - Gasket (Discard) p - J Clip q - Screw Temperature Sensor, PCV and Anode Screw Torque 70 lb-in. (8 Nm) Anode Cover Screw Torque 156 lb-in. (18 Nm) CYLINDER BLOCK/CRANKCASE Drive Sprocket Installation 1. Install drive sprocket nut. NOTE:Use 46 mm, 76mm deep socket (P/N 91-881847A1) to hold drive sprocket nut and crankshaft holder tool (P/N 91-804776A1) to hold crankshaft. d a c b e f 91-804776A1 91-881847A1 a-Key b-Crank Position Sensor Rotor c-Drive Sprocket d-Drive Sprocket Nut e-46 mm, 76mm Deep Socket (91-881847A1) f-Crankshaft Holder Tool (P/N 91-804776A1) Drive Sprocket Nut Torque 195 lb-ft (265 Nm) Page 4B-42 90-881980R1 NOVEMBER 2001 CYLINDER BLOCK/CRANKCASE Installing Powerhead Components Cylinder Head Installation 1. See Section 4A for cylinder head installation. Harness and Battery Cable Removal 1. Install battery and harness cable assembly. Fuel Components 1. Refer to Section 3C for installation of the following components. a. Fuel pump b. EFI Assembly Charging and Starting System Components 1. Refer to Section 2B for installation of the following ignition components. a. Starter motor b. Voltage rectifier/regulator Ignition Components 1. Refer to Section 2A for installation of the following ignition components. a. Flywheel - must use Crankshaft Holder Tool (91-804770A1) b. Stator c. Timing belt d. Ignition coils e. CDI unit f. Crank Position Sensors g. Temperature Sensor 90-881980R1 NOVEMBER 2001 Page 4B-43 CYLINDER BLOCK/CRANKCASE Page 4B-44 90-881980R1 NOVEMBER 2001 Powerhead Installation NOTE: Refer to Following Powerhead Installation for proper hose and adapter connections. 1. Lift powerhead using flywheel puller/lifting eye (91-83164M). 2. Install new powerhead gasket and dowel pins. 3. Place powerhead onto drive shaft housing. a 91-83164M b b c 58575 a - Flywheel Puller/Lifting Eye (91-83164M) b - Dowel Pins (2) c - Powerhead Gasket (New) CYLINDER BLOCK/CRANKCASE 90-881980R1 NOVEMBER 2001 Page 4B-45 4. Secure powerhead to drive shaft housing with nuts (6) and bolts (2). Torque in sequence. 1 2 3 4 5 6 7 8 b a c d 58654 a - Nut (6) b - Washer (6) c - Bolts (2) M8 x 35 d - Torque Sequence Powerhead Mounting Nut Torque 40 lb-ft (54.5 Nm) Powerhead Mounting Bolt Torque 20 lb-ft (27 Nm) CYLINDER BLOCK/CRANKCASE Page 4B-46 90-881980R1 NOVEMBER 2001 Following Powerhead Installation 1. Connect vapor separator vent hose to adaptor plate fitting. 2. Connect shift switch harness. 3. Fill oil tank (refer to Section 1B-Maintenance) and install dipstick. 4. Connect power trim wires. 5. Connect incoming fuel hose. 58681 58655 a b c d e a - Dipstick b - Shift Position Switch Harness c - Vapor Separator Vent Hose d - Power Trim Pump Wires (BLUE & GREEN) e - Fuel Hose CYLINDER BLOCK/CRANKCASE 6. Install 8 screws holding cowl halves together. 7. Install grommet and grommet cover. a b c d e b c fg h a-Cowl Grommet b-Cowl Screws (8) M6 x 40 c-Screws (2) M6 x 20 d-Grommet Cover e-Grommet f-Cowl Latch g-Grommet h-Idle Exhaust Grommet Bottom Cowl Screw Torque 65 lb-in. (7.5 Nm) Grommet Cover Screw Torque 65 lb-in. (7.5 Nm) 90-881980R1 NOVEMBER 2001 Page 4B-47 CYLINDER BLOCK/CRANKCASE Page 4B-48 90-881980R1 NOVEMBER 2001 8. Connect trim wires. b c a d 58655 a - Green/White b - Lt. Blue/White c - Red d - Cowl Switch 9. Install flywheel cover. 10. Install top cowl. a b a - Flywheel Cover b - Screws (2) M6 x 20 Flywheel Cover Screw Torque 65 lb-in. (7.5 Nm) LUBRICATION POWERHEAD Section 4C - Lubrication Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-1 Oil Pump Removal 4C-7. . . . . . . . . . . . . . . . . . . . . . . . Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-2 Oil Pickup Removal 4C-8. . . . . . . . . . . . . . . . . . . . . . . . Oil Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-4 Cleaning and Inspection 4C-9. . . . . . . . . . . . . . . . . . . . Oil Pressure Measurement . . . . . . . . . . . . . . . . . 4C-5 Oil Pickup Installation . . . . . . . . . . . . . . . . . . . . . 4C-10 Oil Pump Reference Drawing . . . . . . . . . . . . . . . 4C-6 Oil Pump Installation 4C-11 . . . . . . . . . . . . . . . . . . . . . . Specifications 4 C LUBRICATION SYSTEM Pump Type Oil Pump Drive Discharge at 212°F (100°C) with 10W-30 Oil at 1000 rpm Engine Oil Pressure (Warm Engine) @ 750 rpm Engine Oil Pan Capacity Relief Valve Opening Pressure Oil Pump: Non-Serviceable Trochoid with Relief Valve Drive shaft Spline 1.56 gph (5.9 L/h) 50.75 psi (350 kPa) Either 5 Qts. or 5 Liters 71 psi (490 kPa) 90-881980R1 NOVEMBER 2001 Page 4C-1 1 2 3 4 5 10 11 12 13 4 6 8 7 9 19 10 91 3 91 Engine Coupler Spline Grease 95 14 18 17 15 21 16 20 16 95 2-4-C With Teflon LUBRICATION Page 4C-2 90-881980R1 NOVEMBER 2001 Oil Pump LUBRICATION Oil Pump REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 PIPE PLUG 25 34 2 1 PIPE PLUG 100 11.5 3 2 O-RING 4 2 DOWEL PIN 5 1 MOUNT 6 2 BOLT (M12 X 175 MM) 55 75 7 2 WASHER 8 2 WASHER 9 2 NUT 10 8 SCREW (M8 X 50 MM) 25 34 11 1 OIL PUMP 12 6 BOLT (M6 X 45 MM) 85 9.5 13 1 SEAL 14 1 SHIFT LINKAGE BRACKET 15 2 DRIVE SCREW 16 3 SCREW (M6 X 20 MM) 80 9 17 1 CUP 18 1 LATCH 19 1 SEAL 20 1 SWITCH 21 2 SCREW 20 2.5 NOTE:TorqueTolerance +/– 10% 90-881980R1 NOVEMBER 2001 Page 4C-3 LUBRICATION LOW OIL PRESSURE PROTECTION When the oil pressure switch turns on (oil pressure 21.75 psi (150 kPa) or below), this mode starts. The warning buzzer sounds (constant tone) and the ignition/injection are cut according to the misfiring rate, gradually reducing engine speed to approximately 2000 rpm. If the engine’s oil pressure is low, the ignition/injection of both cylinders #1 and #4 is cut, however the ignition/injection of cylinders #2 and #3 is not cut. Once the oil pressure can be increased to 21.75 psi (150 kPa) or higher, the warning can be cancelled by decreasing the throttle opening angle to less than 2°, and turning the ignition key to the “OFF” position. Oil Flow Chart Cylinder Page 4C-4 90-881980R1 NOVEMBER 2001 LUBRICATION Oil Pressure Measurement 1. Warm up engine. 2. Remove oil pressure switch. 3. Install oil pressure gauge. NOTE:Use a pressure gauge with a range of 0-10 kg/cm2and an adaptor with a 1/8-28 BSPT thread. a a-Oil Pressure Gauge 4. Measure the oil pressure at idle. If out of specification, check oil pump, oil suction pipe, and oil strainer. Oil Pressure @ 750 rpm with warm engine - 149 ° F (65 °C) 50.75 psi (350 kPa) 90-881980R1 NOVEMBER 2001 Page 4C-5 LUBRICATION Page 4C-6 90-881980R1 NOVEMBER 2001 Oil Pump Reference Drawing NOTE: The oil pump is non-serviceable, the assembly drawing below is strictly for reference purposes only. NOTE: If removing pump cover follow torque sequence for removal and installation. a 1 2 3 4 6 5 b a - Screw (6) M6 x 10 b - Torque Sequence Oil Pump Screw Torque 70 lb-in. (8 Nm) LUBRICATION 90-881980R1 NOVEMBER 2001 Page 4C-7 Oil Pump Removal NOTE: Powerhead must be removed to gain access to oil pump, refer to section 4B Powerhead Removal. 1. Remove oil pump from adaptor plate. a b c d d a - Seal b - Oil Pump c - Screw (6) M8 x 45 d - O-Rings (2) LUBRICATION Page 4C-8 90-881980R1 NOVEMBER 2001 Oil Pickup Removal 1. Adapter plate must be removed to gain access to the oil sump and pick-up, refer to Section 5A for adaptor plate and oil sump removal. 2. Remove oil pick-up tube from adaptor plate. c e a d b a - Screw (4) M6 x 20 b - Oil Pick-Up Tube c - O-Ring d - Gasket e - Adaptor Plate LUBRICATION Cleaning and Inspection 1. Inspect pick up tube screen for debris, clean if necessary. a a-Pick-Up Tube Screen 2. Replace seals and gaskets. 3. Inspect oil pump, replace if gears are worn. NOTE:Pump should be replaced if there is a problem with oil pressure relief valve. 90-881980R1 NOVEMBER 2001 Page 4C-9 LUBRICATION Page 4C-10 90-881980R1 NOVEMBER 2001 Oil Pickup Installation 1. Install oil pick-up tube on adaptor plate, use proper torque sequence. 2. Refer to Section 5A for adaptor plate and oil sump installation. a b c d e 1 2 3 4 a - Adaptor Plate b - Gasket (New) c - O-Ring (New) d - Oil Pick-Up Tube e - Screw (4) M6 x 20 Oil Pick-up Tube Mounting Bolt Torque 100 lb-in. (11.5 Nm) LUBRICATION 90-881980R1 NOVEMBER 2001 Page 4C-11 Oil Pump Installation NOTE: Make sure dowel pins are inserted before securing oil pump to adaptor plate. IMPORTANT: Oil pump must be primed before installation. Prime oil pump by filling inlet hole with 4-stroke outboard oil and rotating gear several revolutions. 1. Install O-Rings. 2. Apply spline grease to coupling. 3. Install oil pump. Tighten screws to specified torque and in sequence. a e b c d 110 4-Stroke Outboard Oil 110 f 1 2 3 4 6 5 91 Engine Coupler Spline Grease 91 a - Dowel Pins (2) b - O-Rings (2) c - Oil Pump d - Screw (6) M6 x 45 e - Seal f - Inlet Hole Oil Pump Mounting Screw Torque 85 lb-in. (9.5 Nm) CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING MID-SECTION Section 5A - Clamp/Swivel Brackets & Drive Shaft Housing Table of Contents Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-1 Swivel Bracket And Steering Arm . . . . . . . . . . . . 5A-2 Transom Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-4 Exhaust Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-6 Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-8 Specifications Drive Shaft Housing . . . . . . . . . . . . . . . . . . . . . . 5A-10 Bottom Cowl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-12 Bottom Cowl Removal . . . . . . . . . . . . . . . . . . . . 5A-14 Bottom Cowl Installation. . . . . . . . . . . . . . . . . . . 5A-15 Adaptor Plate Removal . . . . . . . . . . . . . . . . . . . 5A-16 Adaptor Plate Reassembly . . . . . . . . . . . . . . . . 5A-21 Recommended Transom Height: Short Shaft 20 in. (51 cm) MID-SECTION Long Shaft Steering Pivot Range 25 in. (64 cm) 60° Full Tilt Up Angle 71° Allowable Transom Thickness (Max) 3 in. (76.2 mm) 5 A Special Tools 1. Drive Shaft Bushing Installer Tool (91-875215) 90-881980R1 NOVEMBER 2001 Page 5A-1 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Swivel Bracket And Steering Arm 12 3 4 5 6 7 8 9 1011 12 13 14 15 16 3 Quicksilver Lubrication/Sealant Application Points 95 95 95 95 95 95 95 TORQUE NUT TO 120 LB-IN. THEN BACK OFF 1/4 TURN TORQUE NUT TO 20 LB-FT (27.1 NM) 17 95 2-4-C With Teflon Page 5A-2 90-881980R1 NOVEMBER 2001 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Swivel Bracket And Steering Arm REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 SWIVEL BRACKET 2 1 OIL SEAL (LOWER) 3 2 BUSHING 4 1 O-RING 5 1 SPACER 6 2 GREASE FITTING 40 4.5 7 2 BUSHING 8 2 SCREW (1/4-28 X 1/2 IN.) 100 11.5 9 1 SWIVEL PIN/STEERING ARM 10 1 STEERING LINK ASSEMBLY 11 1 SCREW (3/8-28 X 1/2 IN.) 20 27 12 2 NUT See View 13 2 WASHER 14 1 BOTTOM YOKE 15 1 RETAINING RING 16 1 THRUST WASHER 17 1 DECAL-SERIAL OVERLAMINATE NOTE:TorqueTolerance +/– 10% 90-881980R1 NOVEMBER 2001 Page 5A-3 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Transom Bracket 7 95 87 7 87 95 Loctite 271 - Thread Locker Premium Gear Lubricant 2-4-C With Teflon Page 5A-4 90-881980R1 NOVEMBER 2001 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Transom Bracket REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 TRANSOM BRACKET (STARBOARD) 2 1 TRANSOM BRACKET (PORT) 3 1 GREASE FITTING (PORT) 40 4.5 4 1 TILT TUBE 5 1 O-RING 6 2 WAVE WASHER 7 1 NUT See Note 8 1 NUT See Note 9 4 BOLT (1/2-24 X 4.5 IN.) 10 4 WASHER 11 4 WASHER 12 4 NUT 13 1 SPRING 14 1 TILT LOCK LEVER 15 2 BUSHING 16 1 SPRING 17 1 KNOB 18 1 GROOVE PIN 19 1 PIN 20 1 ANCHOR BRACKET 21 6 SCREW (M10 X 30 MM) 40 54 22 6 WASHER 23 1 NUT 40 54 24 1 ANODE ASSEMBLY 25 2 SCREW (M6 X 25 MM) 60 7 26 2 WASHER NOTE:TorqueTolerance +/– 10% NOTE:Ref. #7’s - Tighten Nut until Bottomed on Shoulder of Tilt Tube NOTE:Ref. #8’s - Drive Nut until Assembly is drawn together; but must be free to pivot 90-881980R1 NOVEMBER 2001 Page 5A-5 1 2 4 5 6 7 8 30 10 11 12 13 14 15 17 18 19 20 21 23 24 25 16 22 26 2 2 2 27 28 29 2 2 3 95 9 95 2-4-C with Teflon CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5A-6 90-881980R1 NOVEMBER 2001 Exhaust Plate CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Exhaust Plate REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 ADAPTOR PLATE ASSEMBLY 2 7 DOWEL PIN 3 1 FITTING 15 1.5 4 2 CHECK VALVE 5 1 GROMMET 6 1 GASKET 7 1 OIL SUMP 8 1 EXHAUST TUBE 9 1 O-RING 10 1 GROMMET 11 1 WATER TUBE 12 1 SEAL (UPPER) 13 1 OIL PICK-UP TUBE 14 1 O-RING 15 4 SCREW (M6 X 20 MM) 100 11.5 16 12 SCREW (M6 X 35 MM) 100 11.5 17 1 DIPSTICK 18 1 BUSHING 19 1 SHIFT SHAFT 20 1 SHIFT LINK 21 1 BUSHING 22 1 SHIFT SLIDER 23 1 NUT See Note 24 1 SPACER 25 1 COUPLING 26 2 HAIRPIN COTTER 27 1 SEAL 28 1 DRAIN PLUG 29 1 GASKET 30 4 SCREW (M6 X 60 MM) 100 11.5 NOTE:TorqueTolerance +/– 10% NOTE:Ref. #23 - Drive Tight, but Joint must be free to Pivot 90-881980R1 NOVEMBER 2001 Page 5A-7 91 Engine Coupler Spline Grease 95 2-4-C with Teflon 1 2 3 4 5 10 11 12 13 4 6 8 7 9 19 10 91 3 95 14 18 17 15 21 16 20 16 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5A-8 90-881980R1 NOVEMBER 2001 Oil Pump CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Oil Pump REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 PIPE PLUG 25 34 2 1 PIPE PLUG 100 11.3 3 2 O-RING 4 2 DOWEL PIN 5 1 MOUNT 6 2 BOLT (M12 X 175 MM) 55 75 7 2 WASHER 8 2 WASHER 9 2 NUT 45 61 10 8 SCREW (M8 X 50 MM) 25 34 11 1 OIL PUMP 12 6 SCREW (M6 X 45 MM) 85 9.5 13 1 SEAL 14 1 SHIFT LINKAGE BRACKET 15 2 DRIVE SCREW 16 3 SCREW (M6 X 20 MM) 80 9 17 1 RETAINER 18 1 LATCH 19 1 SEAL 20 1 SWITCH 21 2 SCREW 20 2.5 NOTE:TORQUE TOLERANCE +/– 10% 90-881980R1 NOVEMBER 2001 Page 5A-9 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Drive Shaft Housing 36 Rubber Lubricant 36 Page 5A-10 90-881980R1 NOVEMBER 2001 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Drive Shaft Housing REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 DRIVE SHAFT HOUSING ASSEMBLY 22 1 STUD (LONG) 4 STUD (X-LONG) 33 STUD (LONG) STUD (X-LONG) 4 5 WASHER 5 5 NUT 40 54 6 1 SPEEDOMETER PICK-UP ASSEMBLY 7 1 CONNECTOR (90 Degrees) 8 1 CONNECTOR (STRAIGHT) 9 2 MOUNT 10 2 BOLT (M12 x 154 mm) 11 2 WASHER 12 2 NUT 50 68 13 2 GROUND WIRE ASSEMBLY 14 1 SCREW (1/4-20 x 3/8) Drive Tight 15 2 CLAMP 16 4 SCREW 17 23 17 4 CAP 18 1 BUSHING 19 1 PIN-ALIGNMENT 20 1 ELBOW 21 1 SPACER (X-LONG) 2222 1 DOWEL PIN (X-LONG)(WHOLE) 1 DOWEL PIN (X-LONG) NOTE:TorqueTolerance +/– 10% 90-881980R1 NOVEMBER 2001 Page 5A-11 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Bottom Cowl 95 2-4-C with Teflon 3 10 8 11 9 11 14 12 11 6 7 11 11 15 11 13 11 18 16 4 17 1 25 24 23 21 22 21 95 20 19 5 2 26 Page 5A-12 90-881980R1 NOVEMBER 2001 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Bottom Cowl REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 BOTTOM COWL ASSEMBLY (PORT) 2 1 BOTTOM COWL ASSEMBLY (STARBOARD) 3 2 SEAL KIT 4 1 INSERT 5 8 SCREW (M6 X 40 MM) 65 7.5 6 1 RETAINER 7 1 IDLE EXHAUST BOOT 8 1 GROMMET 9 1 TELLTALE FITTING 10 1 WASHER 11 6 STA-STRAP 12 1 HOSE (5 IN.) 13 1 HOSE (32 IN.) 14 1 HOSE (26 IN.) 15 1 TEE 16 2 SCREW (M6 X 20 MM) 65 7.5 17 1 GROMMET 18 1 SWITCH ASSEMBLY 19 1 SCREW (M6 X 75 MM) 20 1 FRONT HANDLE 21 2 BUSHING 22 1 O-RING 23 1 PAWL-FRONT HANDLE 24 1 WASHER 25 1 NUT 65 7.5 26 2 PLUG NOTE:TorqueTolerance +/– 10% 90-881980R1 NOVEMBER 2001 Page 5A-13 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5A-14 90-881980R1 NOVEMBER 2001 Bottom Cowl Removal 1. Disconnect trim wires. b c a d 58655 a - Green/White b - Lt. Blue/White c - Red d - Cowl Switch 2. Remove 2 screws from grommet cover to free grommet. 3. Remove 8 screws holding cowl halves together. a a d b c a - Cowl Screws (8) M6 x 40 mm b - Screws (2) M6 x 20 mm c - Cover d - Grommet CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 90-881980R1 NOVEMBER 2001 Page 5A-15 Bottom Cowl Installation 1. Check for proper placement of boot and grommet between cowl halves. Make sure engine wiring, water hoses and trim wires are not pinched during bottom cowl installation. 2. Place retainer between cowls. 3. Secure cowl halves together with screws. 4. Replace grommet, cover and screws. a a d b c e f g a - Cowl Screws (8) M6 x 40 b - Screws (2) M6 x 20 c - Cover d - Grommet e - Boot f - Grommet g - Retainer 5. Connect trim wires. b c a d 58655 a - Green/White b - Lt. Blue/White c - Red d - Cowl Switch CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5A-16 90-881980R1 NOVEMBER 2001 Adaptor Plate Removal 1. Remove the following components: • Remove powerhead, refer to section 4B. • Remove oil pump, refer to section 4C. • Remove lower unit, refer to section 6. 2. Remove gearcase first. 3. Disconnect shift link from shift shaft and remove shift shaft. 4. Remove wire grommet from adaptor plate. Pull power trim wire and speedometer hose out of grommet. 5. Pull water hose from adaptor plate. 57667 57668 a c e d b a - Shift Link b - Nut c - Power Trim Wire/Grommet/Speedometer Hose d - Water Hose (drive shaft bushing) e - Shift Shaft CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 90-881980R1 NOVEMBER 2001 Page 5A-17 6. Remove nuts and washers from lower mount bolts. NOTE: Note placement of ground straps on port side mounting bolt. 57666 b a a c a - Ground Strap (port side) b - Nut c - Lower Mount Bolts (2) M12 x 154 7. Remove nuts and washers from upper mount bolts. 57669 a a a b d c e a - Upper Mount Bolts (2) M12 x 154 b - Upper Mount c - Washers (2) d - Washers (2) e - Nuts (2) CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5A-18 90-881980R1 NOVEMBER 2001 8. Pull speedometer hose down through swivel pin arm. 9. Separate driveshaft housing from lower mounting bolts by pulling backward. 57664 b c a d e a - Driveshaft Housing b - Speedometer hose c - Lower Mounting Bolt (2) M12 X 154 d - Washers (2) e - Water Hose (Drive Shaft Bushing) 10. Remove drain plug on port side of driveshaft housing to drain remaining oil from sump. 57663 a a - Drain Plug CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 90-881980R1 NOVEMBER 2001 Page 5A-19 11. Remove 4 screws from top/back of adaptor plate. 12. Remove adaptor plate from driveshaft housing. a a - Screws (4) M8 x 50 13. Remove 4 screws to remove exhaust tube. 14. Remove 12 screws to remove oil sump. c b b c b b a c c c c 57665 a - Exhaust Tube b - Exhaust Tube Screws (4) M6 x 60 c - Adaptor Plate Screws (12) M6 x 35 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5A-20 90-881980R1 NOVEMBER 2001 DRIVE SHAFT BUSHING REMOVAL 1. Using a suitable punch, drive roll pin to inside of drive shaft housing. 2. Remove drive shaft bushing with suitable mandrel or socket. 57673 a b c a - Roll Pin b - Suitable Mandrel or Socket c - Water Hose CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 90-881980R1 NOVEMBER 2001 Page 5A-21 Adaptor Plate Reassembly NOTE: Use soapy water on drive shaft bushing for ease of installation. 1. Snap driveshaft bushing onto driveshaft bushing installer tool, and install into housing until seated. 2. Insert roll pin into drive shaft housing until flush with outside of driveshaft housing. 57638 57639 91-875215 c a b a - Driveshaft Installer Tool (91-875215) b - Bushing c - Roll Pin 3. Place oil sump onto adaptor plate and secure with 12 screws. Install exhaust tube to oil sump and secure with 4 screws. Torque in sequence to specified torque. c 57665 c a 8 9 10 11 12 14 15 13 16 7 c b c 4 b 6 b 2 c b 1 5 3 c a - Exhaust Tube b - Exhaust Tube Screws (4) M6 x 60 c - Adaptor Plate Screws (12) M6 x 35 Exhaust and Adaptor Plate Screw Torque 100 lb-in. (11.5 Nm) CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5A-22 90-881980R1 NOVEMBER 2001 4. Align water tube/grommet while installing adaptor plate onto drive shaft housing. 5. Install drain plug into housing and tighten to specified torque. 57663 b 57904 a a - Water Tube/Grommet b - Drain Plug Drain Plug Torque 17.5 lb-ft (24 Nm) 6. Install 4 screws into adaptor plate (torque later). a a - Screws (4) M8 x 50 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 90-881980R1 NOVEMBER 2001 Page 5A-23 7. Attach drive shaft housing assembly to transom bracket. 8. Install speedometer hose up through swivel pin bracket. 57664 a b a - Speedometer Hose b - Washers (2) 9. Install nuts onto lower mount bolts. Torque to specified torque. NOTE: Note placement of ground straps on port side mounting bolt. 57666 b a a c a - Ground Strap (port side) b - Nut c - Lower Mount Bolt (2) M12 x 154 Lower Mounting Bolts Torque 50 lb-ft (68 Nm) CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5A-24 90-881980R1 NOVEMBER 2001 10. Install nuts to upper mounting bolts. Torque to specified torque. 11. Torque adaptor plate bolts (4) to specified torque. a 57669 a b a c d e f a - Upper Mount Bolts (2) M12 x 154 b - Adaptor Plate Bolts (4) M8 x 50 c - Upper Mount d - Washer (2) e - Washer (2) f - Nut (2) Upper Mounting Bolts Torque 55 lb-ft (75 Nm) Adaptor Plate Bolts Torque 25 lb-ft (34 Nm) CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 90-881980R1 NOVEMBER 2001 Page 5A-25 12. Install shift shaft. Make sure engine is in neutral. 57668 a a - Shift Shaft 13. Reconnect shift link to shift shaft. 14. Replace grommet. Pull power trim wire and speedometer hose up through grommet in adaptor plate. 15. Pull water hose (drive shaft bushing) up through adaptor plate. a b c d e a - Nut b - Shift Shaft c - Speedometer Hose d - Power Trim Wire e - Water Hose (drive shaft bushing) 16. Replace the following components: • Replace oil pump, refer to section 4C. • Replace lower unit, refer to section 6. • Replace powerhead, refer to section 4B. POWER TRIM MID-SECTION Section 5B - Power Trim Table of Contents Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-2 Power Trim Components . . . . . . . . . . . . . . . . . . . 5B-4 Theory Of Operation. . . . . . . . . . . . . . . . . . . . . . . 5B-6 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-6 Trimming Characteristics . . . . . . . . . . . . . . . . 5B-6 Trailering Outboard . . . . . . . . . . . . . . . . . . . . . 5B-7 Tilting Outboard Up and Down Manually . . . 5B-7 Power Trim Flow Diagrams . . . . . . . . . . . . . . . . . 5B-8 Trim Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-8 Tilt Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-10 Maximum Tilt . . . . . . . . . . . . . . . . . . . . . . . . . 5B-12 Trim Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-14 Shock Function Up . . . . . . . . . . . . . . . . . . . . 5B-16 Shock Function Return . . . . . . . . . . . . . . . . . 5B-18 Manual Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-20 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-22 Preliminary Checks . . . . . . . . . . . . . . . . . . . . 5B-22 Hydraulic System Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-23 Troubleshooting the Power Trim Electrical System. . . . . . . . . . . . . . . . . . . . . . 5B-27 Power Trim System Removal . . . . . . . . . . . . . . 5B-29 Testing Power Trim System With Test Gauge Kit (91-52915A6) . . . . . . . . . . . . . 5C-32 Power Trim Disassembly . . . . . . . . . . . . . . . . . . 5B-37 Trim Motor Removal . . . . . . . . . . . . . . . . . . . 5B-37 Pump and Components Removal . . . . . . . . 5B-38 Manifold Removal . . . . . . . . . . . . . . . . . . . . . 5B-39 Shock Rod Removal . . . . . . . . . . . . . . . . . . . 5B-39 Shock Rod Disassembly . . . . . . . . . . . . . . . . . . 5B-40 Memory Piston Removal . . . . . . . . . . . . . . . 5B-43 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . . 5B-44 Trim Motor Electrical Tests . . . . . . . . . . . . . . 5B-44 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-45 O-Ring and Seal Placement . . . . . . . . . . . . 5B-45 O-ring Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-46 O-ring Description and Sizes. . . . . . . . . . . . . . . 5B-47 Power Trim Reassembly . . . . . . . . . . . . . . . . . . 5B-48 Shock Rod Reassembly . . . . . . . . . . . . . . . . 5B-48 Shock Rod Installation . . . . . . . . . . . . . . . . . 5B-50 Trim Limit Assembly Installation . . . . . . . . . 5B-51 Manual Release Valve Installation . . . . . . . 5B-51 Manifold Installation . . . . . . . . . . . . . . . . . . . 5B-52 Oil Pump Installation. . . . . . . . . . . . . . . . . . . 5B-53 Pressure Operated Assembly Installation . 5B-53 Reservoir/Motor Installation . . . . . . . . . . . . . 5B-55 Bleeding Power Trim Unit . . . . . . . . . . . . . . 5B-56 Installation of Power Trim System . . . . . . . . . . 5B-57 5 B 90-881980R1 NOVEMBER 2001 Page 5B-1 POWER TRIM Special Tools 1. Spanner Wrench P/N 91-74951 2. Lock-Ring Pliers P/N SRP-4 (Snap-On) 3. Expanding Rod P/N CG 41-11 (Snap- On) 4. Collet P/N CG 41-12 (Snap- On) 5. Heat Lamp P/N 91-63209 Address Snap-On Tools Company 2801 - 80th Street Kenosha, Wisconsin 53143 Phone 414.656.5200 Page 5B-2 90-881980R1 NOVEMBER 2001 POWER TRIM 6. Power Trim Test Gauge Kit 91-52915A6 73835 7. Adaptor Fitting 91-82278A2 and 91-82278A3 54458 8. Multi-Meter DVA Tester 91-99750A1 or DMT 2000 Digital Tachometer Multi-meter 91-854009A1 a b a-Multi-Meter DVA Tester 91-99750A1 b-DMT 2000 Digital Tachometer Multi-meter 91-854009A1 90-881980R1 NOVEMBER 2001 Page 5B-3 1 2 3 4 5 6 7 8 9 10 11 13 14 15 2 2 5 10 5 10 10 10 10 10 5 5 10 15 10 16 17 18 16 19 20 21 12 A E D C D B F POWER TRIM Page 5B-4 90-881980R1 NOVEMBER 2001 Power Trim Components NOTE: Lubricate all O-rings using Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. NOTE: It is recommended that all O-rings be replaced when servicing tilt system. POWER TRIM Power Trim Components REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm – 1 POWER TRIM PUMP 1 1 SHOCK ROD KIT 2 1 O RING REBUILD KIT 3 1 MEMORY PISTON ASSEMBLY 4 1 CYLINDER ASSEMBLY 5 1 TRIM LIMIT VALVE KIT 6 1 PUMP ASSEMBLY 7 1 MOTOR KIT 8 1 RESERVOIR PLUG 9 1 MANUAL RELEASE ASSEMBLY 10 1 MANIFOLD KIT 11 1 SCREW KIT (MOTOR) 12 1 CABLE 13 1 DRIVE SHAFT 14 1 FILTER KIT 15 1 P.O. CHECK ASSEMBLY KIT – 1 O RING KIT (COMPLETE TRIM) 16 2 GROOVE PIN 17 1 ANCHOR PIN 18 1 SHAFT 19 2 CLAMP 20 1 SCREW 21 1 C WASHER A -Torque cylinder cap to 45 lb-ft (61 Nm) B -Torque screws to 80 lb-in. (9.0 Nm) C -Torque screws to 70 lb-in. (7.9 Nm) D -Torque plugs to 120 lb-in. (13.5 Nm) E -Torque screws to 100 lb-in. (11 Nm) F -Torque shock piston to 90 lb-ft (122 Nm) 90-881980R1 NOVEMBER 2001 Page 5B-5 POWER TRIM Theory Of Operation The Power Trim system consists of an electric motor, pressurized fluid reservoir, pump and trim cylinder. The remote control (or trim panel) is equipped with a switch that is used for trimming the outboard “up” or “down”, and for tilting the outboard for shallow water operation (at slow speed) or for “trailering”. The outboard can be trimmed “up” or “down” while engine is under power or when engine is not running. Adjustments Trimming Characteristics NOTE: Because varying hull designs react differently in various degrees of rough water, it is recommended to experiment with trim positions to determine whether trimming “up” or “down” will improve the ride in rough water. When trimming your outboard from a mid-trim position (trim tab in neutral, straight fore-andaft, position), you can expect the following results: TRIMMING OUTBOARD “UP” (“OUT”) WARNING Excessive trim “out” may reduce the stability of some high speed hulls. To correct instability at high speed, reduce the power gradually and trim the motor “In” slightly before resuming high speed operation. (Rapid reduction in power will cause a sudden change of steering torque and may cause additional momentary boat instability.) • Will lift bow of boat, generally increasing top speed. • Transfers steering torque harder to left on installations below 23 in. transom height. • Increases clearance over submerged objects. • In excess, can cause porpoising and/or ventilation. • In excess, can cause insufficient water supply to water pump resulting in serious water pump and/or powerhead overheating damage. WARNING Excessive engine trim angle will result in insufficient water supply to water pump causing water pump and/or powerhead overheating damage. Make sure that water level is above gear housing water intake holes whenever engine is running. Operating “Up” circuit will actuate the “up” relay (located under engine cowl) and close the electric motor circuit. The electric motor will drive the pump, thus forcing automatic transmission fluid through internal passageways into the “up” side of the trim cylinder. The trim cylinder/trim rod will position the engine at the desired trim angle within the 20 degree maximum trim range. The power trim system is designed so the engine cannot be trimmed beyond the 20 degree maximum trim angle as long as engine rpm is above approximately 2000 rpm. The engine can be raised beyond the 20 degree maximum trim angle for shallow water operation, etc., by keeping the engine rpm below 2000 rpm. If engine rpm increases above 2000 rpm, the thrust created by the propeller (if deep enough in the water) will cause the trim system to automatically lower the engine back to the 20 degree maximum trim angle. Page 5B-6 90-881980R1 NOVEMBER 2001 POWER TRIM TRIMMING OUTBOARD “DOWN” (“IN”) WARNING Excessive speed at minimum trim “In” may cause undesirable and/or unsafe steering conditions. Each boat should be tested for handling characteristics after any adjustment is made to the tilt angle (tilt pin relocation). • Will help planing off, particularly with a heavy load. • Usually improves ride in choppy water. • In excess, can cause boat to veer to the left or right (bow steer). • Transfers steering torque harder to right (or less to the left). • Improves planing speed acceleration (by moving tilt pin one hole closer to transom). Operating “Down” circuit will actuate the “down” relay (located under engine cowl) and close the electric motor circuit (motor will run in opposite direction of the “Up” circuit). The electric motor will drive the pump, thus forcing automatic transmission fluid through internal passageways into the “down” side of the trim cylinder. The trim rod will move the engine downward to the desired angle. Trailering Outboard WARNING Excessive engine trim angle will result in insufficient water supply to water pump causing water pump and/or powerhead overheating damage. Make sure that water level is above gear housing water intake holes whenever engine is running. While operating “up” circuit, the cylinder rod will continue to tilt the outboard to a full up position for trailering. Tilting Outboard Up and Down Manually WARNING Before loosening the manual release valve, make sure all persons are clear of engine, as engine will drop to full “down” position when valve is loosened. With power trim installed, the outboard can be raised or lowered manually by opening the manual release valve 3 to 4 turns (counterclockwise). a a-Manual Release Valve 90-881980R1 NOVEMBER 2001 Page 5B-7 POWER TRIM Page 5B-8 90-881980R1 NOVEMBER 2001 Power Trim Flow Diagrams - Trim Up Circuit ÍÍ ÍÍ Reservoir Oil Filtered Feed Oil Oil Under Pressure Return Oil a b c d e f g h i j k l m o g p s r t u v w n 1 q 2 3 POWER TRIM Trim Up When the trim switch is activated in the up position, the electric motor (c) begins to rotate the oil pump gears (j), the oil pump draws a small amount of oil through the filter (g) and through the up circuit suction port (i). The oil pump gear (j) rotation forces oil into the passages for the up circuit. Oil, under pressure, will slide the shuttle valve (m) against the down circuit pressure operated valve (f). The shuttle valve will mechanically open the down pressure operated valve, allowing oil from the down cavity of the trim cylinder, to flow into the oil pump. This returning oil, from the down cavity, will supply most of the oil required for the up circuit. Oil in the up circuit is blocked from returning into the reservoir by the ball inside the down circuit suction port (k). The pressure of the oil will force the up circuit pressure operated valve (n) to open, allowing the oil to enter the passages inside the manifold (q) leading to the trim cylinder (w) up cavity. Oil is blocked from all other passages by the closed manual release valve (p). Oil under pressure will enter the trim cylinder below the memory piston (t). With an increasing amount of oil entering the cylinder, the memory piston contacts the shock piston (u) and forces the trim rod (a) up and out, raising the outboard motor. Oil on the top of the shock piston exits through a passage running down along the side of the cylinder and enters the manifold passages. The oil is drawn back into the pump (j) through the open down circuit pressure operated valve (f) and enters the pump as supply for the up circuit. a-Trim Rod b-End Cap c-Electric Motor d-Reservoir Oil e-Down Circuit Pressure Relief Valve f-Down Circuit Pressure Operated Valve g-Filter (2 shown for clarity) h-Shock Return Valve i-Up Circuit Suction Port j-Oil Pump Gears k-Down Circuit Suction Port l-Oil Fill Cap m-Shuttle Valve n-Up Circuit Pressure Operated Valve o-Manifold Reverse Suction Valve p-Manual Release Valve q-Manifold r-Tilt Relief Valve s-Tilt Relief Piston t-Memory Piston u-Shock Piston v-Impact Relief Valve w-Cylinder 1-Up Pressure- 2640 PSI (18,200 kPa) (F75–F115) Minimum 2-Tilt Relief Pressure - 540-990 PSI (3725-6825 kPa) (F75-F115) 3-Impact Relief Pressure -1170-1360 PSI (8065-9375 kPa)(F75-F115) 90-881980R1 NOVEMBER 2001 Page 5B-9 POWER TRIM Page 5B-10 90-881980R1 NOVEMBER 2001 Tilt Up Reservoir Oil Filtered Feed Oil Oil Under Pressure Return Oil ÍÍ ÍÍ a b c d w v u t h e f g s r p o g n m i j k l 1 q 2 3 POWER TRIM Tilt Up In the up mode, as the trim rod (a) extends from the cylinder (w), the memory piston (t) clears or uncovers the pressure relief passage. Oil from the up cavity will enter this passage and, if required, causes the tilt relief piston (s) to open the tilt pressure relief valve (r). This valve lowers the amount of pressure available to lift the outboard motor. With the engine in forward gear, and at high engine rpm, the oil pressure available will not be able to overcome the propeller thrust, limiting the trim range to below the pressure relief orifice. Up pressure flows into the trim relief passage, and returns back into the reservoir. When the engine rpm’s fall or if engine is not in forward gear, the oil pressure is available to extend the trim rod (a) up into the tilt range. Trim Limit When the weight of the outboard and propeller thrust reach sufficient levels, the pressure inside the trim cylinder (w) will increase to the pressure required to move the tilt relief piston (s). The tilt relief piston’s “pin” opens the tilt relief valve (r). Up pressure flows into the trim relief passage, and returns back into the reservoir. If the outboard engine is positioned in the “tilt” range (beyond full “trim” position) when the tilt relief valve opens, it will move back down to the full “trim” position (trim limit). a-Trim Rod b-End Cap c-Electric Motor d-Reservoir Oil e-Down Circuit Pressure Relief Valve f-Down Circuit Pressure Operated Valve g-Filter (2 shown for clarity) h-Shock Return Valve i-Up Circuit Suction Port j-Oil Pump Gears k-Down Circuit Suction Port l-Oil Fill Cap m-Shuttle Valve n-Up Circuit Pressure Operated Valve o-Manifold Reverse Suction Valve p-Manual Release Valve q-Manifold r-Tilt Relief Valve s-Tilt Relief Piston t-Memory Piston u-Shock Piston v-Impact Relief Valve w-Cylinder 1-Up Pressure- 2640 PSI (18,200 kPa) (F75–F115) Minimum 2-Tilt Relief Pressure - 540-990 PSI (3725-6825 kPa) (F75-F115) 3-Impact Relief Pressure -1170-1360 PSI (8065-9375 kPa)(F75-F115) 90-881980R1 NOVEMBER 2001 Page 5B-11 POWER TRIM Page 5B-12 90-881980R1 NOVEMBER 2001 Maximum Tilt ÍÍ ÍÍ Reservoir Oil Filtered Feed Oil Oil Under Pressure Return Oil a v t w b h c d e f g s r p o g m n i j k l u 1 q 2 3 POWER TRIM Maximum Tilt With the cylinder at maximum travel, due to no ram movement, the pressure inside of the trim cylinder will increase to the pressure setting of the tilt relief valve (r). Pressure forces the tilt relief actuator (s) to move and unseat the tilt relief valve (r) allowing oil to return to the reservoir through passages in the manifold (q). Oil flow will continue until the “up button” is released. a-Trim Rod b-End Cap c-Electric Motor d-Reservoir Oil e-Down Circuit Pressure Relief Valve f-Down Circuit Pressure Operated Valve g-Filter (2 shown for clarity) h-Shock Return Valve i-Up Circuit Suction Port j-Oil Pump Gears k-Down Circuit Suction Port l-Oil Fill Cap m-Shuttle Valve n-Up Circuit Pressure Operated Valve o-Manifold Reverse Suction Valve p-Manual Release Valve q-Manifold r-Tilt Relief Valve s-Tilt Relief Piston t-Memory Piston u-Shock Piston v-Impact Relief Valve w-Cylinder 1-Up Pressure- 2640 PSI (18,200 kPa) (F75–F115) Minimum 2-Tilt Relief Pressure - 540-990 PSI (3725-6825 kPa) (F75-F115) 3-Impact Relief Pressure -1170-1360 PSI (8065-9375 kPa)(F75-F115) 90-881980R1 NOVEMBER 2001 Page 5B-13 POWER TRIM Page 5B-14 90-881980R1 NOVEMBER 2001 Trim Down ÍÍ ÍÍ Reservoir Oil Filtered Feed Oil Oil Under Pressure Return Oil a w b c d i j k l m n g o p s r h g f e t u v q 1 2 3 POWER TRIM Trim Down When the trim switch is activated in the down position, the electric motor (c) will rotate the oil pump gears (j) in the opposite direction. With the oil pump gears rotating backwards, the flow of oil is reversed. Oil is drawn through the filter (g), through the down circuit suction port (k) and into the oil pump gears (j). The pump forces pressurized oil into the down passages. Oil will slide the shuttle valve (m) into the up circuit pressure operated valve (n). The shuttle valve will mechanically open the up circuit pressure operated valve and allow oil, from the up cavity of the trim cylinder (w), to return into the oil pump. This returning oil, from the up cavity, will supply the oil required for the down circuit. The oil is blocked from returning into the reservoir by the ball (i) inside the up circuit suction port. Oil, under pressure, opens the down circuit pressure operated valve (f) and enters the down passages inside of the manifold (q). The manifold passage connects into the trim cylinder passage leading to the top of the cylinder. The cavity, inside the cylinder, above the shock piston (u) is the down cavity. As the down cavity fills with oil, the trim rod (a) retracts into the cylinder, lowering the outboard motor. Oil from the up cavity exits the cylinder and is drawn back into the pump through the open up circuit pressure operated valve (n). When the trim rod reached full travel, the oil pressure inside the down circuit will rise until the down circuit pressure relief valve (e) opens, bypassing oil back into the reservoir. When the trim button is released, the pump stops supplying oil, both of the pressure operated valves (f & n) will close and; if open, the down circuit pressure relief valve (e) will close. The closed valves will lock the fluid on either side of the shock piston (u) & memory piston (t), holding the outboard motor in position. a-Trim Rod b-End Cap c-Electric Motor d-Reservoir Oil e-Down Circuit Pressure Relief Valve f-Down Circuit Pressure Operated Valve g-Filter (2 shown for clarity) h-Shock Return Valve i-Up Circuit Suction Port j-Oil Pump Gears k-Down Circuit Suction Port l-Oil Fill Cap m-Shuttle Valve n-Up Circuit Pressure Operated Valve o-Manifold Reverse Suction Valve p-Manual Release Valve q-Manifold r-Tilt Relief Valve s-Tilt Relief Piston t-Memory Piston u-Shock Piston v-Impact Relief Valve w-Cylinder 1-Tilt Relief Pressure - 540-990 PSI (3725-6825 kPa) (F75-F115) 2-Impact Relief Pressure -1170-1360 PSI (8065-9375 kPa) (F75-F115) 3-Down Pressure - 505-850 PSI (3480-5860 kPa) (F75-F115) 90-881980R1 NOVEMBER 2001 Page 5B-15 POWER TRIM Page 5B-16 90-881980R1 NOVEMBER 2001 Shock Function Up ÍÍ ÍÍ Reservoir Oil Oil Under Pressure Return Oil a b c w v u t h d e f g i j k l n m g o p s r q 1 2 POWER TRIM Shock Function Up Oil inside the down cavity is locked in a static position by the closed down circuit pressure operated valve (f), the manual release valve (p) and the manifold reverse suction valve (o). If the outboard strikes an underwater object while in forward gear, the trim rod (a) will try to rapidly extend from the cylinder (w), the pressure increases inside the trim cylinder down cavity and connecting passages. When the pressure increases to the level required, the impact relief valves (v), located inside the shock piston (u), will open and allow the fluid to pass through the shock piston. As the fluid passes through the piston, the trim rod (a) will extend from the trim cylinder. The memory piston (t) is held in position by vacuum, created by the oil in the up cavity being locked in a static position. Therefore; oil passing through the shock piston is trapped between the memory piston (t) and shock piston (u). a-Trim Rod b-End Cap c-Electric Motor d-Reservoir Oil e-Down Circuit Pressure Relief Valve f-Down Circuit Pressure Operated Valve g-Filter (2 shown for clarity) h-Shock Return Valve i-Up Circuit Suction Port j-Oil Pump Gears k-Down Circuit Suction Port l-Oil Fill Cap m-Shuttle Valve n-Up Circuit Pressure Operated Valve o-Manifold Reverse Suction Valve p-Manual Release Valve q-Manifold r-Tilt Relief Valve s-Tilt Relief Piston t-Memory Piston u-Shock Piston v-Impact Relief Valve w-Cylinder 1-Tilt Relief Pressure - 540-990 PSI (3725-6825 kPa) (F75-F115) 2-Impact Relief Pressure -1170-1360 PSI (8065-9375 kPa)(F75-F115) 90-881980R1 NOVEMBER 2001 Page 5B-17 POWER TRIM Page 5B-18 90-881980R1 NOVEMBER 2001 Shock Function Return ÍÍ ÍÍ Reservoir Oil Oil Under Pressure Return Oil a b c w v u t h d i j k l n m e f g g o p s r q 1 2 POWER TRIM Shock Function Return After the engine clears the under water object, the weight of the engine will increase the oil pressure between the memory piston (t) and shock piston (u) to the level required to open the shock return valve (h), inside the shock piston, allowing the oil to bleed back through the shock piston into the down cavity. If required, additional oil will enter the down cavity through the manifold reverse suction valve (o). This will return the engine back against the memory piston (t) and into the original running position. a-Trim Rod b-End Cap c-Electric Motor d-Reservoir Oil e-Down Circuit Pressure Relief Valve f-Down Circuit Pressure Operated Valve g-Filter (2 shown for clarity) h-Shock Return Valve i-Up Circuit Suction Port j-Oil Pump Gears k-Down Circuit Suction Port l-Oil Fill Cap m-Shuttle Valve n-Up Circuit Pressure Operated Valve o-Manifold Reverse Suction Valve p-Manual Release Valve q-Manifold r-Tilt Relief Valve s-Tilt Relief Piston t-Memory Piston u-Shock Piston v-Impact Relief Valve w-Cylinder 1-Tilt Relief Pressure - 540-990 PSI (3725-6825 kPa) (F75-F115) 2-Impact Relief Pressure -1170-1360 PSI (8065-9375 kPa)(F75-F115) 90-881980R1 NOVEMBER 2001 Page 5B-19 POWER TRIM Page 5B-20 90-881980R1 NOVEMBER 2001 Manual Tilt ÍÍ ÍÍ Reservoir Oil Return Oil Filtered Oil a b c w v u t h d i j k l m n g o p s r q e f g 1 2 POWER TRIM Manual Tilt To manually tilt the outboard engine, the owner will need to back out the manual release valve (p) 3-4 turns. With the valve backed out, the internal passages inside the manifold are connected together. These passages connect both the cylinder down and up cavities together, along with the reservoir, allowing the engine to be raised or lowered. Trim rod (a) movement will continue until the manual release valve (p) is closed, locking the fluid inside of the cylinder and manifold.If the outboard motor is to be raised manually, turn the manual release (tilt) valve counterclockwise to the full out position. When in the full (out) position, oil in the trim cylinder can flow freely from the up side to the down side or from the down side to the up side. The oil return line into the reservoir is also open, allowing free oil flow to either side of the tilt cylinder to accommodate the differential oil capacities between the tilt cylinder up side and down side cavities When trimming the outboard in either the up or down position, with the manual tilt valve open or leaking, little or no movement will occur. Oil pressure from the pump will move to both, the up cavity and through the manual tilt valve into the down cavity, each cavity would have equal pressure resulting in little or no movement. Reverse Operation To prevent the outboard from coming up or trailing out, when shifted into reverse and/or throttling back rapidly, oil in the trim system must be locked in a static position. This is accomplished with the up and down pilot check valves. Thus, not allowing oil in the system to move in either direction. a-Trim Rod b-End Cap c-Electric Motor d-Reservoir Oil e-Down Circuit Pressure Relief Valve f-Down Circuit Pressure Operated Valve g-Filter (2 shown for clarity) h-Shock Return Valve i-Up Circuit Suction Port j-Oil Pump Gears k-Down Circuit Suction Port l-Oil Fill Cap m-Shuttle Valve n-Up Circuit Pressure Operated Valve o-Manifold Reverse Suction Valve p-Manual Release Valve q-Manifold r-Tilt Relief Valve s-Tilt Relief Piston t-Memory Piston u-Shock Piston v-Impact Relief Valve w-Cylinder 1-Tilt Relief Pressure - 540-990 PSI (3725-6825 kPa) (F75-F115) 2-Impact Relief Pressure -1170-1360 PSI (8065-9375 kPa)(F75-F115) 90-881980R1 NOVEMBER 2001 Page 5B-21 POWER TRIM Troubleshooting Support outboard with tilt lock pin when servicing power trim system. IMPORTANT: After debris or failed components have been found, it is recommended that unit be disassembled completely and ALL o-rings be replaced. Check valve components and castings must be cleaned using engine cleaner and compressed air or replaced prior to reassembly. IMPORTANT: Power trim system is pressurized. Outboard must be in the full “UP” position (trim rod fully extended) prior to fill/drain plug or manual release valve removal. Refer to instructions following if disassembly is required when servicing. Follow preliminary checks before proceeding to troubleshooting flow diagrams (following). Preliminary Checks IMPORTANT: Operate Power Trim system after each check to see if problem has been corrected. If problem has not been corrected proceed to next check. 1. Check that manual release valve is tightened to full right (clockwise) position. 2. Check trim pump fluid level with outboard in full “UP” position and fill if necessary. Refer to “Bleeding Power Trim Unit”. 3. Check for external leaks in Power Trim system. Replace defective part(s) if leak is found. 4. Outboard not holding tilted position (falls down to trim position) indicates debris or defective components in trim assembly. Clean or replace components as required. Page 5B-22 90-881980R1 NOVEMBER 2001 POWER TRIM Hydraulic System Troubleshooting Flow Chart OUTBOARD WILL NOT HOLD TILTED POSITION DURING REVERSE AND/OR TRAILS OUT DURING HIGH SPEED DECELERATION. Inspect manual release valve.Manual release valve and O-ring damaged. Manual release valve and O-rings appear to be O.K. - Clean and reinstall manual release valve. Trim system holds re- verse thrust. Testing complete. Trim will not hold reverse thrust. Replace manual re- lease valve and O-rings. Trim system holds re- verse thrust. Testing complete. Remove and inspect pis- ton rod assembly for de- bris and/or shock ball hang up. Shock piston appears O.K. - Clean and reinstall piston rod assembly. Trim system holds re- verse thrust. Testing complete. Debris and/or shock ball hang up identi- fied. Replace piston rod assembly. Trim system holds re- verse thrust. Testing complete. Trim will not hold reverse thrust. Remove PO check valve assembly, inspect O-rings and seals for damage. Debris and/or dam- age identified. Replace PO check valve assembly. Trim system holds re- verse thrust. Testing complete. PO check valve appears O.K. - Clean and reinstall PO check valve assem- bly. Trim will not hold reverse thrust. Trim system holds reverse thrust. Test- ing complete. continued on next page 90-881980R1 NOVEMBER 2001 Page 5B-23 POWER TRIM Hydraulic System Troubleshooting Flow Chart continued Replace trim system. Replace suction seat assembly. Remove suction seat as- sembly and inspect for debris and/or damage. Debris and/or damage identified. Trim system holds reverse thrust. Test- ing complete. Trim will not hold reverse thrust. Suction seat assembly appears O.K. - Clean and reinstall suction seat assembly. Trim system holds reverse thrust. Test- ing complete. Page 5B-24 90-881980R1 NOVEMBER 2001 POWER TRIM Hydraulic System Troubleshooting Flow Chart TRIM SYSTEM LEAKS DOWN WITH MANUAL RELEASE VALVE CLOSED. Inspect manual release valve.Manual release valve and O-ring damaged. Replace manual re- lease valve and O-rings. Trim system does not leak down. Test- ing complete. Trim system leaks down. Manual release valve and O- rings appear to be O.K. - Clean and reinstall manual release valve. Trim system does not leak down. Test- ing complete. Remove tilt relief valving and inspect O-rings and seals for debris and/or damage. Debris and/or dam- age identified. Replace tilt relief valving. Trim system does not leak down. Test- ing complete. Trim system leaks down. Tilt relief valving and O-rings appear to be O.K. - Clean and reinstall tilt relief valving. Trim system does not leak down. Test- ing complete. Remove PO check valve assembly, inspect O- rings and seals for dam- age. Debris and/or dam- age identified. Replace PO check valve assembly. PO check valve appears O.K. - Clean and reinstall PO check valve assem- bly. continued on next page Trim system leaks down. Trim system does not leak down. Testing complete. Trim system does not leak down. Test- ing complete. 90-881980R1 NOVEMBER 2001 Page 5B-25 POWER TRIM Hydraulic System Troubleshooting Flow Chart continued Replace trim system. Replace memory pis- ton and shock piston O-rings. Inspect memory pis- ton O-ring and cylinder bore. Cylinder bore appears smooth with no debris. Cylinder bore appears rough and/or debris found in cylinder. Trim leaks down. Trim system does not leak down. Test- ing complete. Page 5B-26 90-881980R1 NOVEMBER 2001 POWER TRIM Troubleshooting the Power Trim Electrical System GRN BLK DN UP RED RED DN UP LT.BLU/WHT RED BLU GRN DN UP BLU/WHT GRN/WHT RED GRN/WHT or GRN BLU/WHT or PUR +– GRN/WHT RED/PUR a j k e f c b 1 2 3 42 BLU RED GRN/WHTRED/PUR LT. BLU/WHT RED LT.GRN A 30 (A) 20 (A) c BLK LT.GRN LT.BLU BLK LT.BLU h g LT.BLU RED d i ABB a-Trim Switch (Remote Control Mounted) g-Up Relay b-Trim Switch (Panel Mounted) h-Down Relay c-Fuses (20A, 30A) i-Solenoid - Start d-Remote Control Wiring Plug Connector j-Trim Pump Motor e-Battery k-Cowl Switch f-Block Screw 90-881980R1 NOVEMBER 2001 Page 5B-27 POWER TRIM Troubleshooting the Power Trim Electrical System Refer to wiring diagram on preceding page for location of wire connections. Problem Possible Cause Remedy Trim Switch “UP” is inoperative, but the Cowl Switch “UP” does operate. 1. Open wire between Wire Connection (1) and Trim Switch. 2. Faulty Trim Switch. 1. Check for an open connection or cut wire. 2. Replace. Cowl Switch “UP” is inoperative, but the Trim Switch “UP” does operate. 1. Open wire between Wire Connection (2) and Solenoid. 2. Faulty Cowl Switch. 1. Check for an open connection or cut wire. 2. Replace. Trim Switch “UP” and Cowl Switch “UP” are both inop1. Open wire between Wire Connection (1) and the “Up” Relay. 1. Check for an open connection. erative. 2. Open BLK wire between ground and “UP” Relay. 2. Check for an open connection. 3. Open RED wire between Solenoid and “UP” Relay. 3. Check for an open connection. 4. Faulty “UP” Relay. 4. Replace. Trim Switch “DOWN” is inoperative, but the Cowl Switch “DOWN” does operate. 1. Open wire between Wire Connection (3) and Trim Switch. 2. Faulty Trim Switch. 1. Check for an open connection or cut wire. 2. Replace. Cowl Switch “DOWN” is inoperative, but the Trim Switch “DOWN” does operate. 1. Open wire between Wire Connection (2) and Solenoid. 2. Faulty Cowl Switch. 1. Check for a open connection or cut wire. 2. Replace Trim Switch “DOWN” and Cowl Switch “DOWN” are 1. Open wire between Wire Connection (3) and the “UP” Relay. 1. Check for an open connection. both inoperative. 2. Open BLK wire between ground and “DOWN” Relay. 2. Check for an open connection. 3. Open RED wire between Solenoid and “DOWN” Relay. 3. Check for an open connection. 4. Faulty “DOWN” Relay 4. Replace. Trim Switch “UP” and “DOWN” are both inoperative, but the Cowl Switch does operate. 1. 20 AMP Fuse blown. 2. Faulty trim switch. 3. Wire is open between fuse holder and solenoid. 4. Wire is open between fuse holder and trim switch. 1. Replace fuse. Locate the cause of the blown fuse. Check electrical wiring for a shorted circuit. 2. Replace. 3. Check for a open connection or cut wire. 4. Check for a loose or corroded connection. Trim Switch and Cowl Switch are both inoperative. 1. One of the Trim Pump Motor wires is open between the motor and the Relays. 2. Faulty trim pump motor. 1. Check wire connections (4) for loose or corroded condition. 2. If voltage is present at connections (4) when the appropriate trim button is pressed, then motor is faulty. Replace motor. Trim system operates (motor runs) without pressing the switches. 1. The Trim or Cowl switch is shorted. 1. Replace. Page 5B-28 90-881980R1 NOVEMBER 2001 POWER TRIM 90-881980R1 NOVEMBER 2001 Page 5B-29 Power Trim System Removal 1. Tilt outboard to the full up position and support with tilt lock pin. 2. Disconnect the power trim wire harness and remove J-Clips. 53949 55264 a c b a - Tilt Lock Pin b - J-Clips c - Harness 3. Remove the trilobe pin. 4. Drive out the upper pivot pin. a b a - Trilobe Pin b - Upper Pivot Pin POWER TRIM 5. Use suitable punch to remove lower cross pin. a a-Lower Cross Pin 6. Use suitable punch to drive out lower pivot pin. 7. Remove the sacrificial anode. a b a-Lower Pivot Pin b-Sacrificial Anode Page 5B-30 90-881980R1 NOVEMBER 2001 POWER TRIM 8. Tilt power trim assembly (top first) out from clamp bracket and remove assembly. 53944 WARNING Electrical wires passing through cowl openings must be protected from chafing or being cut. Follow the recommended procedures outlined in Section 1D of this Manual. Failure to protect wires as described could result in electrical system failure and/or injury to occupants of boat. 90-881980R1 NOVEMBER 2001 Page 5B-31 POWER TRIM Testing Power Trim System With Test Gauge Kit (91-52915A6) IMPORTANT: This test will not locate problems in the trim system. The test will show if the system is correct after a repair. If minimum pressures are not obtainable, the trim system requires additional repair. “UP” Pressure Check IMPORTANT: Insure battery is fully charged before performing tests. 1. Tilt outboard to full “Up” position and engage tilt lock lever. 2. Slowly remove “Fill” plug to bleed pressure from reservoir. 3. Remove circlip securing manual release valve and unscrew release valve from trim assembly. NOTE:A small amount of trim fluid may drip from manual release valve hole. Place a suitable container under trim assembly to collect any leakage. NOTE:Assemble test adaptor by using O-ring installation tool to position small O-ring onto adaptor1st, then install medium O-ring and lastly large O-ring. Thread brass fitting into test adaptor securely using teflon tape on threads. 54457 gga bcdef a-Test Adaptor (91-822778A1) b-O-ring Installation Tool c-Small O-ring (Install 1st) d-Medium O-ring (Install 2nd) e-Large O-ring (Install Last) f-Brass Fitting g-Apply Teflon Tape Page 5B-32 90-881980R1 NOVEMBER 2001 POWER TRIM 4. Install test adaptor 91-822778A1 into manual release valve hole. a a-Test Adaptor (91-822778A1) 5. Thread hose from Test Gauge Kit (91-52915A6) into brass fitting on adaptor. 54459 a b c d e a-Brass Fitting b-Test Gauge Assembly c-Tilt Pin (Position in Hole Shown) d-Hose e-Hose (Not Used) 6. Reinstall fill plug. 7. Run trim “UP”. 8. Disengage tilt lock lever. 90-881980R1 NOVEMBER 2001 Page 5B-33 POWER TRIM CAUTION Failure to install spare tilt pin (or hardened bolts and nuts) in hole shown could result in transom bracket failure and possible injury. 9. Move outboard “IN” until hole in swivel bracket “ear” aligns with the 3rd tilt hole in transom bracket. Lock engine in trim range by installing a 3/8 in. (9.5 mm) diameter tilt pin or two 3/8 in. (9.5 mm) hardened bolts and nuts through the transom brackets and swivel bracket in the hole shown. a a-Tilt Pin Hole (Install Spare Tilt Pin or Hardened Bolts and Nuts) 10. Open valve (a) and close valve (b). 51374 a b 54460 11. Run trim “UP”. The minimum pressure should be 2640 P.S.I. (18,200 kPa). 12. Run trim “DOWN” to release pressure and remove spare tilt pin or bolts and nuts. 13. Tilt outboard full “UP” and engage tilt lock lever. 14. Slowly remove “Fill” plug to bleed pressure. 15. Remove test gauge hose and adapter. 16. Reinstall Manual Release Valve and secure valve with circlip. 17. Retighten “Fill” plug. NOTE: If pressure is less than 2640 P.S.I. (18,200kPa), troubleshoot system per instructions on pages 5B-22 to 28. Page 5B-34 90-881980R1 NOVEMBER 2001 POWER TRIM “DOWN” Pressure Check IMPORTANT: Insure battery is fully charged before performing tests. 1. Tilt outboard to full “Up” position and engage tilt lock lever. 2. Slowly remove “Fill” plug to bleed pressure from reservoir. 3. Remove circlip securing manual release valve and unscrew release valve from trim assembly. NOTE:A small amount of trim fluid may drip from manual release valve hole. Place a suitable container under trim assembly to collect any leakage. NOTE:Assemble test adaptor by using O-ring installation tool to position small O-ring onto adaptor1st, then install medium O-ring and lastly large O-ring. Thread brass fitting into test adaptor securely using teflon tape on threads. 54457f a e d c b g 3 a-Test Adaptor (91-822778A3) b-O-ring Installation Tool c-Small O-ring (Install 1st) d-Medium O-ring (Install 2nd) e-Large O-ring (Install Last) f-Brass Fitting g-Apply Teflon Tape 4. Install test adaptor 91-822778A3 into manual release valve hole. a 3 a-Test Adaptor (91-822778A3) 90-881980R1 NOVEMBER 2001 Page 5B-35 POWER TRIM 5. Thread hose from Test Gauge Kit (91-52915A6) into brass fitting on adaptor. 54459 a b c d e a-Brass Fitting b-Test Gauge Assembly c-Tilt Pin (Position in Hole Shown) d-Hose e-Hose (Not Used) f-OPEN Valve g-CLOSE Valve 6. Reinstall fill plug. 7. Run trim “UP”. 8. Disengage tilt lock lever. 9. Open valve (f) and close valve (g). 10. Run trim “DOWN”. Minimum pressure should be 505 P.S.I. (3480 kPa). 11. Tilt outboard full “UP” and engage tilt lock lever. 12. Slowly remove “Fill” plug to bleed pressure. 13. Remove test gauge hose and adaptor. 14. Reinstall manual release valve and secure valve with circlip. 15. Retighten “Fill” plug. NOTE: If pressure is less than 505 PSI (3480 kPa), troubleshoot system per instructions on pages 5B-22 to 28. Page 5B-36 90-881980R1 NOVEMBER 2001 POWER TRIM 90-881980R1 NOVEMBER 2001 Page 5B-37 Power Trim Disassembly IMPORTANT: Power trim system is pressurized. Trim rod must be in the full “UP” position (fully extended) prior to fill/drain plug, or manual release valve removal. 1. Remove reservoir cap. 2. Remove manual release valve assembly to drain oil. 55263 b a a - Reservoir Cap b - Manual Release Valve Trim Motor Removal 1. Secure power trim assembly in a soft jaw vise. 2. Remove four (4) screws to remove motor/reservoir. Remove reservoir seal and coupler. e d c a b a - Screw (4) b - Reservoir c - Reservoir Seal d - Coupler e - Manifold Assembly POWER TRIM Page 5B-38 90-881980R1 NOVEMBER 2001 Pump and Components Removal 1. Remove pressure operated plugs on pump. Remove spring and check valve/poppet (both sides). Use special tool CG 41-11 and special tool CG 41-14 with 5/16, end to remove spool. d b a c a b d e c a - Plug (2) b - Spring (2) c - Check Valve/Poppet (2) d - Seat (2) e - Spool IMPORTANT: Inspect poppet assembly for debris in the area shown. If debris is found on poppet replace poppet. 2. Remove three (3) screws to remove pump. Remove filter and filter seal under pump. Remove suction seat assembly. d c e f b a a - Debris Under Valve Tip b - Rubber Seat c - Screws (3) d - Filter Seal e - Filter f - Suction Seat Assembly POWER TRIM Manifold Removal 1. Remove two (2) screws to remove manifold from cylinder. 2. Remove tilt relief components. b c d e 51146 a-Screws (2) b-Spring c-Poppet d-Spool Housing e-Trim Limit Spool Shock Rod Removal 1. Unscrew end cap assembly from cylinder using spanner wrench [1/4 in. x 5/16 in. (6.4 mm x 8 mm) long pegs]. 2. Remove shock rod assembly from cylinder. a 90-881980R1 NOVEMBER 2001 Page 5B-39 POWER TRIM Shock Rod Disassembly NOTE:The only serviceable items on the shock rod assembly are the O-rings and wiper ring. If shock rod requires any other repair, replace shock rod assembly. b b c a a-End Cap b-O-ring (2) c-Wiper Ring 1. Place shock rod assembly on clean work surface. 2. Remove three (3) screws and remove plate from shock rod piston. a b c a-Screw (3) b-Plate c-Shock Rod Piston Page 5B-40 90-881980R1 NOVEMBER 2001 POWER TRIM 3. Remove check ball components from shock rod piston. 4. Remove O-ring from shock rod piston. d a b c a-Spring (5) b-Seat (5) c-Ball (5) d-O-ring CAUTION When removing shock piston, spanner wrench must have 1/4 in. x 5/16 in. long pegs to avoid damage to shock piston. 5. Place shock rod into soft jawed vise and apply heat to loosen piston using torch lamp (P/N 91-63209). 6. Loosen shock rod piston using spanner wrench [1/4 in. x 5/16 in. (6.4mm x 8mm) long pegs]. 7. Allow shock rod piston to cool. Remove from shock rod. 51146 a b 51146 a-Spanner Wrench b-Shock Rod Piston 90-881980R1 NOVEMBER 2001 Page 5B-41 POWER TRIM 8. Inspect check valve for debris. Clean debris from check valve if found. If debris cannot be cleaned from check valve, replace shock piston as an assembly. 9. Clean shock and components with compressed air. 10. Remove inner O-ring from shock rod piston. a b a-Shock Piston b-O-ring 11. Remove cylinder end cap assembly from shock rod. 12. Inspect shock. If wiper (located in cap) has failed to keep rod clean, replace wiper. 13. Place end cap on clean work surface. 14. Remove rod wiper, inner O-ring, and outer O-ring. a b c a-Rod Wiper b-Inner O-ring c-Outer O-ring Page 5B-42 90-881980R1 NOVEMBER 2001 POWER TRIM Memory Piston Removal 1. Remove memory piston from cylinder using one of two methods: a. Using lock ring pliers P/N SRP-4 (Snap-On) or suitable tool. SRP-4 (Snap-On) b. Blowing compressed air into manual release valve hole using air nozzle. WARNING Memory piston cup may be expelled at a high velocity when air pressure is applied. Failure to place cylinder as shown below could result in personal injury. NOTE: Point cylinder opening down and away. Use a shop rag or towel to avoid damage to the memory piston. 2. Remove o-ring from memory piston. 51144 d e 55466 a c b a-Adaptor/Air Hose b-Memory Piston Exit c-Shop Rag d-O-Ring e-Memory Piston 90-881980R1 NOVEMBER 2001 Page 5B-43 POWER TRIM Cleaning/Inspection/Repair IMPORTANT: Components must be dirt and lint free. Slightest amount of debris in Power Trim system could cause system to malfunction. Clean shock rod and components with parts cleaner and dry with compressed air. It is recommended that all o-rings in trim system be replaced. Use O-Ring Kit 25-809880A1. Lubricate all o-rings with Power Trim & Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. Trim Motor Electrical Tests 1. Connect a 12 volt supply to motor leads. If motor fails to run, replace pump motor. IMPORTANT: Trim Motor is not serviceable. If motor fails to run, replace motor assembly. Page 5B-44 90-881980R1 NOVEMBER 2001 POWER TRIM 90-881980R1 NOVEMBER 2001 Page 5B-45 Reassembly O-Ring and Seal Placement O-Rings and Seals are part of O-Ring Kit 25-809880A1 21 2 3 19 21 22 4 5 1 20 8 9 10 18 9 7 6 15 16 17 8 9 10 14 13 11 12 POWER TRIM Page 5B-46 90-881980R1 NOVEMBER 2001 O-Ring Sizes O.D. I.D. Cutaway View of O-Ring Width O-RINGS SHOWN ARE ACTUAL SIZE 22 4 11 10 8 6 5 2211 19 16 20 15 18 17 12 33 11 2 2 99 7 13 1144 POWER TRIM O-Ring Description and Sizes O-Ring Description O-Ring I.D. O-Ring O.D. O-Ring Width 1 Wiper Ring 2 Cyl. Cap, Inner 0.671 in. (17.04 mm) 0.949 in. (24.10 mm) 0.139 in. (3.53 mm) 3 Cyl. Cap 1.864 in. (47.34 mm) 2.004 in. (50.90 mm) 0.07 in. (1.78 mm) 4 Shock Piston 1.6 in. (40.64 mm) 2.02 in. (53.086 mm) 0.21 in. (5.334 mm) 5 Piston Screw 0.676 in. (17.17 mm) .816 in. (20.726 mm) 0.07 in. (1.78 mm) 6 Reservoir Plug 0.549 in. (13.94 mm) 0.755 in. (19.17 mm) 0.103 in. (2.616 mm) 7 Motor Seal 8 (2) P.O. Check Plug 0.489 in. (12.42 mm) 0.629 in. (15.97 mm) 0.07 in. (1.78 mm) 9 (3) Poppet Assy. 10 (2) P.O. Check Seat 0.364 in. (9.25 mm) 0.504 in. (12.80 mm) 0.07 in. (1.78 mm) 11 (2) Pump Port 0.145 in. (3.683 mm) 0.285 in. (7.239 mm) 0.07 in. (1.78 mm) 12 Suction Seat 0.239 in. (6.07 mm) 0.379 in. (9.626 mm) 0.07 in. (1.78 mm) 13 Filter Seal 14 Filter 15 Manual Release 0.114 in. (2.90 mm) 0.254 in. (6.451 mm) 0.07 in. (1.78 mm) 16 Manual Release 0.176 in. (4.47 mm) 0.316 in. (8.026 mm) 0.07 in. (1.78 mm) 17 Manual Release 0.239 in. (6.07 mm) 0.379 in. (9.626 mm) 0.07 in. (1.78 mm) 18 Spool 0.239 in. (6.07 mm) 0.379 in. (9.626 mm) 0.07 in. (1.78 mm) 19 (3) Spool Housing 0.301 in. (7.645 mm) 0.441 in. (11.20 mm) 0.07 in. (1.78 mm) 20 Trim Limit Spool 0.114 in. (2.895 mm) 0.254 in. (6.451 mm) 0.07 in. (1.78 mm) 21 (2) Manifold 0.208 in. (5.283 mm) 0.348 in. (8.839 mm) 0.07 in. (1.78 mm) 22 Memory Piston 1.6 in. (40.64 mm) 2.02 in. (53.086 mm) 0.21 in. (5.334 mm) 90-881980R1 NOVEMBER 2001 Page 5B-47 POWER TRIM Power Trim Reassembly IMPORTANT: Lubricate all O-rings with Power Trim & Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. Shock Rod Reassembly 1. Install lubricated O-rings to end cap. 2. Install rod wiper. 3. Install lubricated O-rings to shock piston. 51199 f d e a b c 51145 a-Rod Wiper b-Inner O-ring c-Outer O-ring d-Shock Piston e-O-ring f-O-ring 4. Clamp shock rod in soft jawed vise. 5. Position cylinder end cap onto rod as shown. 51146 CAUTION When installing shock rod piston, spanner wrench must have 1/4 in. x 5/16 in. (6.4mm x 8mm) long pegs to avoid damage to shock rod piston. 6. Apply Loctite 271 Thread Locker to threads on shock rod. 7. Install shock rod piston. Page 5B-48 90-881980R1 NOVEMBER 2001 POWER TRIM 8. Tighten shock rod piston securely using spanner wrench (1/4 in. x 5/16 in. long pegs). If a torquing type spanner tool is used to tighten shock piston, then torque to specified torque. b a a-Shock Rod Piston b-Spanner Wrench Shock Piston Torque 90 lb-ft (122 Nm) 9. Remove shock rod assembly from vise. 10. Install ball, seat, and spring (five sets) to shock rod piston. 11. Secure components with plate. Tighten screws to specified torque. e d c a b a-Screw (3) b-Plate c-Spring (5) d-Seat (5) e-Ball (5) Screw Torque 35 lb-in. (4 Nm) 90-881980R1 NOVEMBER 2001 Page 5B-49 POWER TRIM Shock Rod Installation 1. Place trim cylinder in soft jawed vice. 2. Install lubricated O-ring to memory piston and place into cylinder. Push memory piston all the way to bottom. 3. Fill cylinder three inches (76.2 mm) from top of cylinder using Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. 4. Install shock rod into cylinder until power trim fluid flows through oil blow off ball passage. Fill remaining cylinder to just below the cylinder threads. c a b a-Memory Piston b-O-ring c-Oil Blow Off Ball Passage CAUTION End cap must not make contact with shock rod piston when tightening. Shock rod piston must be positioned in cylinder deep enough to avoid contact. 5. Tighten end cap securely using spanner wrench [1/4 in. x 5/16 in. (6.4 mm x 8 mm) long pegs]. If a torquing type spanner tool is used to tighten end cap, then torque to specified torque. End Cap Torque 45 lb-ft (61 Nm) Page 5B-50 90-881980R1 NOVEMBER 2001 POWER TRIM Trim Limit Assembly Installation 1. Lubricate all O-rings. Install spring, poppet, spool housing and trim limit spool into manifold. NOTE:There are three different size springs used in this manifold. The heavy spring is used on 75-125 hp outboards. The medium spring is used on 40-60 hp Bigfoot outboards. The light spring is used on 30-60 hp outboards. or a b c d or 51008 a-Spring b-Poppet c-Spool Housing d-Trim Limit Spool Manual Release Valve Installation 1. Install “E” clip (if removed) and lubricate O-rings to manual release valve. 2. Install manual release valve assembly into manifold. a b c a-Manifold b-Manual Release Valve c-E Clip 90-881980R1 NOVEMBER 2001 Page 5B-51 POWER TRIM Manifold Installation 1. Install dowel pin and two (2) lubricated O-rings into trim cylinder. b a a-O-Ring (2) b-Dowel Pin 2. Align the trim cylinder and pump/reservoir assembly together. 3. Install the two (2) long screws and torque to specified torque. 51146 a b c a-Trim Cylinder Assembly b-Reservoir/Manifold Assembly c-Screw (2) Screw Torque 100 lb-in. (11.5 Nm) Page 5B-52 90-881980R1 NOVEMBER 2001 POWER TRIM 90-881980R1 NOVEMBER 2001 Page 5B-53 Oil Pump Installation 1. Install spring, ball, lubricated O-ring and plastic seat to manifold. 2. Check to see that O-rings are placed on bottom of pump. 3. Install filter and filter seal under pump. Install pump onto manifold. Tighten screws to specified torque. b a a - Screw (3) b - Suction Seat Assembly Screw Torque 70 lb-in. (8 Nm) Pressure Operated Assembly Installation IMPORTANT: Inspect poppet assembly for debris in the area shown. If debris is found on poppet, replace poppet. a b a - Debris Under Valve Tip b - Rubber Seat 1. Lubricate O-rings. POWER TRIM Page 5B-54 90-881980R1 NOVEMBER 2001 2. Install spool, seat with O-ring, check valve/poppet, spring and plug with O-ring into pump. Repeat for other side. Tighten plugs to specified torque. d b a c a b d e c a - Plug (2) b - Spring (2) c - Check Valve/Poppet (2) d - Seat (2) e - Spool Plug Torque 120 lb-in. (13.5 Nm) POWER TRIM 90-881980R1 NOVEMBER 2001 Page 5B-55 Reservoir/Motor Installation 1. Install coupler into top of pump. Make sure reservoir seal is in the reservoir groove and place reservoir onto pump/manifold assembly. Install ground strap under screw shown. Tighten screws to specified torque. a b c d e f a - Screw (4) b - Reservoir c - Reservoir Seal d - Coupler e - Manifold Assembly f - Ground Strap Reservoir/Motor Screw Torque 80 lb-in. (9 Nm) 2. Fill reservoir to bottom of fill hole using Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. POWER TRIM Bleeding Power Trim Unit 1. Secure power trim unit in soft jawed vise. 2. Add power trim fluid until it is even with the bottom of the fill hole. Reinstall plug. 3. Close the manual release valve. (Turn full clockwise). a b 55263 a-Reservoir Plug/Fill Hole b-Manual Release Valve 4. Cycle system full up and down 3 times or until fluid level remains at proper level. Connect power trim wire to 12 volt source. . Up Direction . Down Blue + Positive Blue – Negative Green – Negative Green + Positive 5. Recheck fluid level with rod fully extended, add fluid if required and repeat cycle until fluid level stays even with the bottom of the fill hole. Page 5B-56 90-881980R1 NOVEMBER 2001 POWER TRIM Installation of Power Trim System 1. Apply 2-4-C with Teflon to lower pivot pin bore and pivot pin surface. 2. Position trim cylinder assembly (BOTTOM FIRST) between clamp brackets and route trim pump electrical harness through access hole in starboard clamp bracket. 3. Start lower pivot pin into pivot pin bore and position lower cross pin (RETAINED) in its respective hole. 4. Using a suitable punch, drive lower pivot pin into clamp bracket and trim cylinder assembly until pivot pin is flush with outside surface. 95 95 2-4-C with Teflon ab c 53965 a-Trim Cylinder Assembly b-Lower Pivot Pin c-Lower Cross Pin 5. Using a suitable punch, drive lower cross pin into its respective bore until seated. 6. Install sacrificial aluminum anode to reservoir bracket placing ground strap to anode, as shown. a b c a-Lower Cross Pin b-Sacrificial Anode c-Ground Strap 53967 90-881980R1 NOVEMBER 2001 Page 5B-57 POWER TRIM 7. Apply 2-4-C with Teflon to surface of upper pivot pin, pivot pin bore and trim ram bore. NOTE:Install trim ram with cross hole located as shown. If trim ram is installed reversed, the trim sender (if installed) will not operate. 95 95 2-4-C with Teflon 95 a b c d e f a-Pivot Pin b-Trim Ram Bore c-Install Trim Ram As Shown d-Engine Side e-Transom Side f-Cross Hole Page 5B-58 90-881980R1 NOVEMBER 2001 POWER TRIM 8. Using a suitable mallet, drive upper pivot pin into swivel bracket and through trim ram until pivot pin is flush with swivel bracket. a b c a-Pivot Pin b-Swivel Bracket c-Trim Ram 9. Drive upper retaining pin in until seated. a a-Retaining Pin 52941 53966 90-881980R1 NOVEMBER 2001 Page 5B-59 POWER TRIM 10. Secure trim harness with clamps. a 55264 a-Clamps 11. Recheck fluid level. 12. Power trim may now be operated to lower outboard to desired position. Trim system is self purging. 13. Reconnect power trim leads to relays under ignition cover. 14. Reinstall spark plug leads to spark plugs. 15. Reinstall cowls. 16. Connect battery leads to battery terminals. Page 5B-60 90-881980R1 NOVEMBER 2001 GEAR HOUSING LOWER UNIT Section 6 Table of Contents Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Quicksilver Lubricants and Service Aids . . . . . . . 6-6 Gear Housing (Drive Shaft) (2.07:1 Gear Ratio). . . . . . . . . . . . . . . . . . . . . . . . 6-8 Gear Housing (Prop Shaft) (2.07:1 Gear Ratio). . . . . . . . . . . . . . . . . . . . . . . 6-10 General Service Recommendations . . . . . . . . . 6-10 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Draining and Inspecting Gear Lubricant . . . . . . . 6-11 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Bearing Carrier and Propeller Shaft . . . . . . . 6-16 Pinion Gear, Drive Shaft, and Forward Gear. . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Upper Drive Shaft Bearing. . . . . . . . . . . . . . . 6-24 Oil Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 Lower Drive Shaft Bearing Race . . . . . . . . . . 6-26 Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27 Forward Gear Bearing Race . . . . . . . . . . . . . 6-29 Trim Tab Adjustment and Replacement . . . . 6-29 Specifications Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30 Forward Gear Bearing Race . . . . . . . . . . . . . 6-30 Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 Bearing Carrier Reassembly . . . . . . . . . . . . . 6-33 Forward Gear Reassembly . . . . . . . . . . . . . . 6-37 Propeller Shaft Reassembly . . . . . . . . . . . . . 6-39 Drive Shaft Wear Sleeve Installation . . . . . . 6-40 Lower Drive Shaft Bearing Race Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42 Oil Sleeve Installation . . . . . . . . . . . . . . . . . . . 6-43 Upper Drive Shaft Bearing Installation . . . . . 6-44 Forward Gear, Lower Drive Shaft Bearing, Pinion Gear, and Drive Shaft Installation . . . 6-45 Pinion Gear Depth and Forward Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . 6-46 Bearing Carrier and Propeller Shaft Installation. . . . . . . . . . . . . . . 6-51 Water Pump Reassembly and Installation . 6-53 Gear Housing Pressure Test . . . . . . . . . . . . . 6-56 Filling Gear Housing With Lubricant . . . . . . . . . 6-57 Gearcase Installation . . . . . . . . . . . . . . . . . . . . . . 6-58 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . 6-64 6 GEAR HOUSING BIGFOOT (2.07:1) Gear Ratio Gearcase Capacity Lubricant Type Forward Gear Number of Teeth Pinion Gear Number of Teeth Pinion Height Pinion Gear Locating Tool Flat Number Disc Number Forward Gear Backlash Backlash Indicating Tool Mark Number Water Pressure @ 1000 rpm @ 6000 rpm (WOT) Leak Test Pressure 2.07:1 24.0 fl oz (710 mL) Premium Gear Lubricant 29 Spiral/Bevel 14 Spiral/Bevel 0.025 in. (0.64 mm) 91-12349A2 #2 #3 0.015 - 0.022 in. (0.38 - 0.55 mm) 91-19660--1 #1 5 psi (34.5 kPa) 20.5 psi (141.5 kPa) 10-12 psi (69-83 kPa) for 5 Minutes 90-881980R1 NOVEMBER 2001 Page 6-1 GEAR HOUSING Special Tools 1. Pinion Gear Locating Tool (91-12349A2) 55079 Disc 3 Disc1 Disc 2 2. Bearing Installation Tool (91-13945) 3. Oil Seal Driver (91-13949) 4. Bearing Race Tool (91-14308A1) 5. Bearing Installation (91-14309A1) 6. Wear Sleeve Installation Tool (91-14310A1) Page 6-2 90-881980R1 NOVEMBER 2001 GEAR HOUSING 7. Bearing Preload Tool (91-14311A2) 8. Mandrel (91-15755)* 73815 9. Backlash Indicator Tool (91-19660--1) 2.07:1 Gear Ratio (14/29) 19660-1 10. Mandrel (91-31106) 11. Oil Seal Driver (91-31108) 12. Treaded Rod (91-31229) and Nut (11-24156)* * From Bearing Removal and Installation Kit (91-31229A7) 90-881980R1 NOVEMBER 2001 Page 6-3 GEAR HOUSING 13. Slide Hammer (91-34569A1) 14. Mandrel (91-36569)* 15. Universal Puller Plate (91-37241) 73652 16. Driver Rod (91-37323)* 74184 17. Mandrel (91-37350) 18. Puller Jaws (91-46086A1) 19. Driver Shaft Holding Tool (91-56775, 2-Stroke), (91-817070, 40/50 4-Stroke), (91-817070A1, 50/60 4- Stroke), (91-804776A1, 75/90 4-Stroke) Page 6-4 90-881980R1 NOVEMBER 2001 GEAR HOUSING 20. Dial Indicator (91-58222A1) 21. Backlash Indicator Tool (91-78473) 2.31:1 Gear Ratio (13/30) 22. Puller Bolt (91-85716) 23. Dial Indicator Adaptor Kit (91-83155) 24. Bearing Puller Assembly (91-83165M) 25. Bearing Installation Tool (91-856875A1) 56783 26. Bearing Installation Tool (91-877321A1) 90-881980R1 NOVEMBER 2001 Page 6-5 GEAR HOUSING GEAR HOUSING (DRIVE SHAFT)(2.07:1 GEAR RATIO) 4.25 IN./107.95MM TORPEDO DIA. 95 12 12 14 7 87 95 Loctite 271 THREAD LOCKER Premium Gear Lubricant 2-4-C With Teflon 95 95 95 95 7 7 7 7 7 87 7 1 2 3 4 5 6 7 8 9 11 13 15 16 17 18 20 21 22 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 4 4 3 10 19 23 7 3 Page 6-6 90-881980R1 NOVEMBER 2001 GEAR HOUSING GEAR HOUSING (DRIVE SHAFT)(2.07:1 GEAR RATIO) REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 GEAR HOUSING (BLACK) 2 1 DOWEL PIN (FRONT) 3 3 DRAIN SCREW 60 7 4 3 WASHER-SEALING 5 1 DOWEL PIN (REAR) 6 1 TRIM TAB 7 1 SCREW (7/16-14 X 1-1/4 IN.) 22 30 8 1 WASHER 9 1 CARRIER 10 1 NEEDLE BEARING 11 1 OILER TUBE 12 2 ANODE 13 1 SCREW (M6 X 40 MM) 14 1 NUT 60 7 15 1 PINION GEAR (14 TEETH) 16 1 NUT 70 95 17 1 SHIFT CAM 18 1 TAPERED ROLLER BEARING 19 1 CUP 20 1 SHIM ASSEMBLY (006 THRU 048) 21 1 DRIVE SHAFT ASSEMBLY 22 1 WEAR SLEEVE ASSEMBLY 23 1 SEAL RING 24 1 COVER ASSEMBLY 25 1 GASKET 26 1 OIL SEAL (LOWER) 27 1 OIL SEAL (UPPER) 28 1 GASKET 29 1 GASKET 30 1 WATER PUMP ASSEMBLY 31 1 FACE PLATE 32 4 SCREW (M6 X 30 MM) 60 7 33 1 SEAL 34 1 KEY 35 1 IMPELLER 36 6 SCREW (M6 X 25 MM) 60 7 37 1 SHIFT SHAFT ASSEMBLY 38 1 E-RING 39 1 BUSHING ASSEMBLY 40 1 O-RING 41 1 OIL SEAL 42 2 SCREW (M6 X 25 MM) 35 4 NOTE:TORQUE TOLERANCE +/– 10% 90-881980R1 NOVEMBER 2001 Page 6-7 GEAR HOUSING GEAR HOUSING (PROP SHAFT)(2.07:1 GEAR RATIO) 7 Loctite 271 Thread Locker 87 Premium Gear Lubricant 95 2-4-C With Teflon 87 87 Page 6-8 90-881980R1 NOVEMBER 2001 GEAR HOUSING GEAR HOUSING (PROP SHAFT)(2.07:1 GEAR RATIO) REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 GEAR HOUSING 2 1 TAPERED ROLLER BEARING 3 1 CUP 4 1 FORWARD GEAR (29 TEETH) 5 1 ROLLER BEARING 6 1 RETAINING RING 7 1 CAM FOLLOWER ASSEMBLY 8 3 BALL 9 1 SLIDE 10 1 SPRING 11 1 CLUTCH 12 1 CROSS PIN 13 1 SPRING 14 1 PROPELLER SHAFT 15 1 REVERSE GEAR (29 TEETH) 16 1 BEARING CARRIER ASSEMBLY 17 1 O-RING 18 1 ROLLER BEARING 19 1 OIL SEAL (INNER) 20 1 OIL SEAL (OUTER) 21 1 ROLLER BEARING 22 1 THRUST WASHER 23 1 THRUST BEARING 24 2 STUD (M8 X 48 MM) 25 2 WASHER 26 2 NUT 25 34 27 1 SHIM ASSEMBLY (006 THROUGH 038) 28 2 INSERT 29 1 DECAL-G/H PINION IDENTIFICATION NOTE:TORQUE TOLERANCE +/– 10% 90-881980R1 NOVEMBER 2001 Page 6-9 GEAR HOUSING General Service Recommendations There may be more than one way to “disassemble” or “reassemble” a particular part(s), therefore, it is recommended that the entire procedure be read prior to repair. IMPORTANT: On Read the following before attempting any repairs. In many cases, disassembly of a sub-assembly may not be necessary until cleaning and inspection reveals that disassembly is required for replacement of one or more components. Service procedure order in this section is a normal disassembly-reassembly sequence. Threaded parts are right hand (RH), unless otherwise indicated. When holding, pressing or driving is required, use soft metal vise jaw protectors or wood for protection of parts. Use a suitable mandrel (one that will contact only the bearing race) when pressing or driving bearings. When compressed air is used to dry a part, verify that no water is present in air line. Bearings All bearings must be cleaned and inspected. Clean bearings with solvent and dry with compressed air. Air should be directed at the bearing so that it passes through the bearing. DO NOT spin bearing with compressed air, as this may cause bearing to score from lack of lubrication. After cleaning, lubricate bearings with Premium Blend Gear Lubricant. DO NOT lubricate tapered bearing cups until after inspection. Inspect all bearings for roughness, catches and bearing race side wear. Work inner bearing race in-and-out, while holding outer race, to check for side wear. When inspecting tapered bearings, determine condition of rollers and inner bearing race by inspecting bearing cup for pitting, scoring, grooves, uneven wear, imbedded particles and/or discoloration from over-heating. Always replace tapered bearing and race as a set. Inspect gear housing for bearing races that have spun in their respective bores. If race(s) have spun, gear housing must be replaced. Roller bearing condition is determined by inspecting the surface of the shaft that the roller bearing supports. Check shaft surface for pitting scoring, grooving, imbedded particles, uneven wear and/or discoloration from overheating. The shaft and bearing must be replaced if such a condition exists. Seals As a normal procedure, all O-rings and oil seals should be replaced without regard to appearance. To prevent leakage around seals, apply Loctite 271 to outer diameter of all metal case seals. When using Loctite on seals or threads, surfaces must be clean and dry. Apply 2-4-C with Teflon on all O-rings and on I.D. of oil seals. Apply 2-4-C with Teflon to external surfaces of bearing carrier. Page 6-10 90-881980R1 NOVEMBER 2001 GEAR HOUSING Draining and Inspecting Gear Lubricant WARNING If gear housing is installed on engine, to avoid accidental starting, disconnect (and isolate) spark plug leads from spark plugs before working near the propeller. 1. With gear housing in normal running position, place a clean pan under housing and remove the two vent screws and one fill/drain screw (with gaskets). 53922 a bc a-Fill/Drain Screw b-Oil Level Screw c-Vent Screw 2. Inspect gear lubricant for metal particles (lubricant will have a “metal flake” appearance). Drain lube into a clean pan/container. Presence of fine metal particles (resembling powder) in the gear lube indicates normal wear. The presence of metal chips in the gear lube indicates the need for gear housing disassembly and component inspection. 3. Note color of gear lubricant. White or cream color MAY indicate presence of water in lubricant. Gear lubricant which has been drained from a gear case recently in operation will have a yellowish color due to lubricant agitation/aeration. Gear lube which is mixed with assembly lubricant (Special Lube 101 or 2-4-C with Teflon) will also be creamy white in color. This is normal and should not be confused with the presence of water. If water is suspected to be present in gearcase, a pressure check of gearcase should be made (with no lubricant in gearcase). Gearcase should hold 10 to 12 psi of pressure for 5 minutes without leaking down. Pouring a portion of the gear lubricant into a glass jar and allowing the lubricant to settle will allow any water in the lube to separate and settle to the bottom of the jar. 4. Presence of water in gear lubricant indicates the need for disassembly and inspection of oil seals, seal surfaces, O-rings, water pump gaskets as well as gear housing components for damage. If gearcase is rebuilt, gearcase should be pressure checked before filling with lubricant. 90-881980R1 NOVEMBER 2001 Page 6-11 GEAR HOUSING Removal WARNING To prevent accidental engine starting, remove (and isolate) spark plug leads from spark plugs before removing gear housing. IMPORTANT: On 90 hp (4-Stroke) models, when removing or installing gearcase carefully guide driveshaft through drive shaft bushing to avoid scoring bushing surface. 1. Remove (and isolate) spark plug leads from spark plugs. 2. Shift engine into forward gear. 3. Tilt engine to full “Up” position. 4. Remove 4 fasteners. 5. Remove locknut and washer. 6. Remove gear housing. 53992 ab a-Fasteners (2 Each Side) b-Locknut and Washer Page 6-12 90-881980R1 NOVEMBER 2001 GEAR HOUSING Disassembly Water Pump NOTE:If water tube seal stayed on water tube (inside of drive shaft housing) when gear housing was removed, pull water tube seal from water tube. 1. Replace water tube seal, if damaged. 2. Remove 4 screws, washers, and isolators. 3. Remove cover. 19212 a b c a-Water Tube Seal b-Screws (4 each) c-Cover IMPORTANT: On The circular groove formed by the impeller sealing bead should be disregarded when inspecting cover (Step 5) and plate (Step 9), as the depth of the groove will not affect water pump output. 4. Replace cover if thickness of steel at the discharge slots is 0.060 in. or less, or if groove(s) (other than impeller sealing bead groove) in cover roof are more than 0.030 in. (0.762 mm) deep. 5. Lift impeller, drive key, and gasket from drive shaft. a b c 19220 a-Impeller b-Drive Key c-Gasket 90-881980R1 NOVEMBER 2001 Page 6-13 GEAR HOUSING 6. Inspect impeller. Replace impeller if any of the following conditions exist: • Impeller blade(s) are cracked, torn, or worn. • Impeller is glazed or melted (caused by operation without sufficient water supply). • Rubber portion of impeller is not bonded to impeller hub. 7. Remove plate and gasket. 8. Replace plate if groove(s) (other than impeller sealing bead groove) in plate are more than 0.030 in. (0.762 mm) deep. 19219 a b c a-Plate b-Gasket c-Impeller Sealing Groove 9. Remove screws and washers. a 19217 a-Screws and Washers (6 each) Page 6-14 90-881980R1 NOVEMBER 2001 GEAR HOUSING 10. Remove water pump base using flat screwdrivers to lightly pry up on base. 19226 a a-Water Pump Base 11. Remove (and discard) seals. (IT MAY BE BENEFICIAL TO CLAMP THE WATER PUMP BASE IN A VISE WHILE REMOVING SEALS) 19195 a a-Seals 12. Remove gasket. 19218 a a-Gasket 90-881980R1 NOVEMBER 2001 Page 6-15 GEAR HOUSING Bearing Carrier and Propeller Shaft 1. Remove fasteners. 51117 a a a-Fasteners 2. With propeller shaft horizontal, pull carrier to break seal with gear housing. Remove bearing carrier/propeller shaft components as an assembly, taking care not to lose cam follower or 3 metal balls in end of propeller shaft. 3. Remove propeller shaft from bearing carrier. 51116 a b c d e a-Bearing Carrier b-Puller Jaws (91-46086A1) c-Puller Screw (91-85716) d-Thrust Hub e-Propeller Shaft Page 6-16 90-881980R1 NOVEMBER 2001 GEAR HOUSING 4. Lift reverse gear, thrust bearing and thrust washer from bearing carrier. Replace thrust bearing and thrust washer if rusted or damaged. 5. Replace reverse gear if gear teeth or clutch teeth on reverse gear are rounded or chipped. If reverse gear must be replaced, pinion gear and sliding clutch should be inspected for damage. 19202 a b c a-Reverse Gear b-Thrust Bearing c-Thrust Washer 6. If reverse gear radial bearing is rusted or does not roll freely, replace bearing. If necessary, remove bearing using Slide Hammer (91-34569A1). 91-34569A1 a 19205 a-Radial Bearing 90-881980R1 NOVEMBER 2001 Page 6-17 GEAR HOUSING 7. If bearing is rusted or does not roll freely, replace bearing. If necessary, remove bearing and oil seals using Mandrel* (91-36569) and Driver Rod* (91-37323). Discard oil seals. NOTE:*From Bearing Removal and Installation Kit (91-31229A7). a b c 91-37323 91-36569 58205 a-Bearing b-Mandrel (91-36569) c-Driver Rod (91-37323) 8. Remove (if not removed with bearing in Step 9) propeller shaft seals and bearing carrier O-ring. 51263 a a-O-ring Page 6-18 90-881980R1 NOVEMBER 2001 GEAR HOUSING 9. Remove spring. 51876 a a-Spring 10. Apply constant pressure to cam follower in order to prevent it and internal components from ejecting out of the propeller shaft during removal of the cross pin from the clutch. 51800 a b a-Cross Pin b-Cam Follower 90-881980R1 NOVEMBER 2001 Page 6-19 GEAR HOUSING 11. Remove components from propeller shaft. 12. Replace cam follower if worn or pitted. 13. Replace sliding clutch if jaws are rounded or chipped. Rounded jaws indicate one or more of the following: • Improper shift cable adjustment. • Engine idle speed too high while shifting. • Shifting from neutral to reverse (or forward) too slowly. 51265 a cf b de a-Cam Follower b-Metal Balls (3) c-Guide Block d-Spring e-Sliding Clutch f-Jaws 14. Replace propeller shaft if any of the following exist: • Splines are twisted or worn. • Bearing surfaces of propeller shaft are pitted or worn. • Oil seal surface is grooved. • Shaft has a noticeable “wobble” or is bent more than 0.009 in. (0.228 mm). Prop shaft trueness should be measured with a dial indicator with prop shaft on V-blocks. a bc b 51877 a-V-Blocks b-Bearing Surfaces c-Measure with Dial Indicator at This Point Page 6-20 90-881980R1 NOVEMBER 2001 GEAR HOUSING Pinion Gear, Drive Shaft, and Forward Gear 1. Hold drive shaft using Drive Shaft Holding Tool; remove (and discard) pinion nut. Model Drive Shaft Holding Tool 40/50 Bigfoot (4-Stroke) 91-56775 50/60 Bigfoot (4-Stroke) 91-817070A1 75/90/115 EFI (4-Stroke) 91-804776A1 60 Bigfoot (2-Stroke) 91-56775 75/90/100/115/125 (2-Stroke) 91-56775 2. Remove drive shaft, pinion gear, pinion bearing and forward gear. 3. Replace pinion gear if it is chipped or worn. 4. Replace pinion bearing and race if either are rusted, pitted or damaged; or if bearing does not roll freely. To remove race, refer to “Lower Drive Shaft Bearing Race,” following. 5. Replace forward gear if gear teeth or clutch teeth are chipped or worn. 19175 b d e f ca a-Drive Shaft Holding Tool b-Pinion Nut c-Drive Shaft d-Pinion Gear e-Pinion Bearing f-Forward Gear 90-881980R1 NOVEMBER 2001 Page 6-21 GEAR HOUSING Page 6-22 90-881980R1 NOVEMBER 2001 6. Replace forward gear needle bearing if it is rusted or does not roll freely. 7. Use suitable tools (screwdriver and awl) to remove retaining ring. Use a punch and hammer to remove bearing. 57905 19203 a b a - Retaining Ring b - Forward Gear Needle Bearing 8. Replace forward gear bearing and race if either are rusted, pitted or damaged; or if bearing does not roll freely. Remove bearing from gear using Universal Puller Plate (91-37241) and mandrel. To remove race, refer to “Forward Gear Bearing Race,” following. 51119 b c 91-37241 a a - Forward Gear Bearing b - Universal Puller Plate (91-37241) c - Mandrel GEAR HOUSING 9. Replace drive shaft if splines are worn or twisted. 10. If bearing surface is damaged, replace drive shaft and corresponding bearing. IMPORTANT: On Do not tighten vise against drive shaft. 11. If wear sleeve is deeply grooved allowing water to enter gear case, remove (and discard) sleeve using Universal Puller Plate (91-37241) and mallet. 19710 c f a 91-37241 e 75/90/115 4-stroke a a b d a-Crankshaft/Driveshaft Splines b-Oil Pump Drive Splines 75/90 4-Stroke Only c-Bearing Surface d-Wear Sleeve e-Universal Puller Plate (91-37241) f-Mallet 12. Remove (and discard) rubber ring. 19152 a a-Rubber Ring 90-881980R1 NOVEMBER 2001 Page 6-23 GEAR HOUSING Upper Drive Shaft Bearing 1. Replace upper drive shaft bearing and sleeve if either are rust stained, or if bearing will not roll freely. Remove bearing and then sleeve using Puller Assembly (91-83165M) with suitable jaws. 19177 OR a b 91-83165M c a-Upper Drive Shaft Bearing b-Sleeve c-Puller Assembly (91-83165M) IMPORTANT: On Upper drive shaft bearing/sleeve must be removed prior to oil sleeve removal. Refer to “Upper Drive Shaft Bearing,” preceding. Page 6-24 90-881980R1 NOVEMBER 2001 GEAR HOUSING Oil Sleeve 1. Remove oil sleeve (if necessary) using Puller Assembly (91-83165M) with suitable jaws. b a 91-83165M 19222 a-Oil Sleeve b-Puller Assembly (91-83165M) 90-881980R1 NOVEMBER 2001 Page 6-25 GEAR HOUSING Lower Drive Shaft Bearing Race IMPORTANT: On Upper drive shaft bearing/sleeve and oil sleeve do not have to be removed for lower drive shaft bearing race removal. IMPORTANT: On Retain shim(s) for reassembly. 1. Remove race and shim(s) using bearing race tool (91-14308A1). 19171 a b c 91-14308A1 a-Race b-Shim(s) c-Bearing Race Tool (91-14308A1) Page 6-26 90-881980R1 NOVEMBER 2001 GEAR HOUSING Shift Shaft 1. Remove shift shaft coupler and nylon spacer. 53925 a b 75 (2-Stroke) Tiller Model Shown a-Shift Shaft Coupler b-Spacer 2. Remove screws. 53926 a a-Screws NOTE:Remove rough edges from shift shaft splines before removing shift shaft bushing. 3. Remove shift shaft bushing and shift shaft. 53927 a b a-Bushing b-Shift Shaft 90-881980R1 NOVEMBER 2001 Page 6-27 GEAR HOUSING 4. Remove shift cam from housing. 5. Replace shift cam if worn. 60 (2-Stroke) Bigfoot Shown 51117 a a-Shift Cam 6. Remove shift shaft bushing and clip from shift shaft. 7. Replace shift shaft if splines are worn or shaft is twisted. 8. Remove (and discard) O-ring. 53928 a b c ed d a-Bushing b-Clip c-Shift Shaft d-Splines e-O-ring 9. Remove (and discard) seal. (Lightly clamp the bushing in a vise when removing seal) 53929 a a-Seal Page 6-28 90-881980R1 NOVEMBER 2001 GEAR HOUSING Forward Gear Bearing Race IMPORTANT: On Retain shim(s) for reassembly. If shims are damaged, replace with new shims of equal thickness. 1. Remove race and shim(s) using Slide Hammer (91-34569A1). 27653 a b c 91-34569A1 a-Race b-Shim(s) c-Slide Hammer (91-34569A1) Trim Tab Adjustment and Replacement IMPORTANT: On The trim tab is now painted and does NOT aid in protecting the drive shaft housing and gear housing from galvanic corrosion (corrosion and pitting of metal surfaces). Side anodes now provide protection. Do not paint or place protective coating on the side anodes, or corrosion protection function will be lost. 1. Replace trim tab if damaged. Mark location of old trim tab on anti-ventilation plate before removal; install new trim tab in same location. 2. The trim tab provides a means to offset (balance) some of the steering load that is caused by propeller torque at higher operating speeds. If at higher speeds the boat turns more easily to the left, loosen screw, move the trim tab (trailing edge) to the left (when viewed from behind); retighten screw. Turn trim tab (trailing edge) to the right if the boat turns more easily to the right. Torque retaining screw to specified torque. 53931b a c a-Trim Tab b-Anti-Ventilation Plate c-Retaining Screw and Washer Retaining Screw Torque 22 lb-ft (30 Nm) 90-881980R1 NOVEMBER 2001 Page 6-29 GEAR HOUSING Reassembly Forward Gear Bearing Race NOTE:Propshaft should be vertical when installing bearing race. 1. Place shim(s) (retained from disassembly) into housing. If shim(s) were lost, or a new gear housing is being assembled, start with 0.010 in. (0.254 mm) shim(s). 2. Assemble components as shown using mandrel (91-31106); Apply 2-4-C with Teflon to O.D. of race. Drive race into housing by striking propeller shaft end with lead hammer. NOTE:Install a nut on the end of the propshaft to prevent damage to the propshaft threads while performing step 2. 19179 b de a c 91-31106 95 2-4-C with Teflon 95 a-Shim(s) d-Disassembled Propeller b-Race Shaft c-Mandrel (91-31106) e-Assembled Bearing Carrier Shift Shaft 1. Apply Loctite 271 Thread Lockeron O.D. of new seal. 2. Press seal into shift shaft bushing until seal is seated against shoulder. 3. Install new O-ring. 4. Apply 2-4-C with Teflon on O-ring and I.D. of seal. 53930 b c d 7 Loctite 271 Thread Locker 7 95 2-4-C with Teflon 95 a a-Seal c-Surface b-Bushing d-O-ring Page 6-30 90-881980R1 NOVEMBER 2001 GEAR HOUSING 90-881980R1 NOVEMBER 2001 Page 6-31 5. Assemble components as shown. 53928 a b c a - Shift Shaft b - “E” Clip c - Shift Shaft Bushing 6. Install shift cam; align hole in shift cam with shift shaft pilot bore in gear housing. 60 Bigfoot, 75/90/100/115/125 (2-Stroke) 51117 a b a - Shift Cam (marked with “UP” and part number) b - Shift Shaft Pilot Bore 60 Bigfoot, 75/90/100/115/125 (2-Stroke) & 75/90/115EFI (4-Stroke) 51117 a b a - Shift Cam (marked with part number only) b - Shift Shaft Pilot Bore GEAR HOUSING 40/50 Bigfoot (4-Stroke), 50/60 Bigfoot(4-Stroke) 51117 850307 a b a-Shift Cam (Numbers Down) b-Shift Shaft Pilot Bore 7. Install shift shaft assembly; insert splines into shift cam. 53932 a b a-Shift Shaft Assembly b-Splines 8. Apply Loctite 271 to bottom half of threads on each screw. Install screws and torque to specified torque. 53926 a 7 7 Loctite 271 Thread Locker a-Screws (2) Screw Torque 60 lb-in. (7 Nm) Page 6-32 90-881980R1 NOVEMBER 2001 GEAR HOUSING Bearing Carrier Reassembly 1. Lubricate O.D. of bearing and bearing carrier bore with 2-4-C with Teflon. 2. Protect lip on forward side of bearing carrier, using bearing installation tool (91-13945). 3. Press propeller shaft needle bearing (number side toward mandrel 91-15755) into carrier, until bearing bottoms out. 2-4-C with Teflon 21042 a b 95 91-13945 91-15755 c 95 a-Bearing Installation Tool (91-13945) b-Mandrel (91-15755) c-Suitable Driver Rod 90-881980R1 NOVEMBER 2001 Page 6-33 GEAR HOUSING 4. Place smaller diameter seal on longer shoulder of Oil Seal Driver (91-31108) with seal lip away from shoulder. 5. Protect lip on front side of bearing carrier using Bearing Installation Tool (91-13945). Apply Loctite 271 on O.D. of seal. Press seal into carrier until tool bottoms. 7 21040 ab c Loctite 271 Thread Locker 7 91-31108 91-13945 a-Seal b-Oil Seal Driver (91-31108) c-Bearing Installation Tool (91-13945) 6. Place larger diameter seal on shorter shoulder of Oil Seal Driver (91-31108) with seal lip toward shoulder. 7. Protect lip on front side of bearing carrier using Bearing Installation Tool (91-13945). Apply Loctite 271 Thread Locker on O.D. of new seal. Press seal into carrier until tool bottoms. 21041 a b c a 91-31108 91-13945 7 Loctite 271 Thread Locker 7 a-Seal b-Oil Seal Driver (91-31108) c-Bearing Installation Tool (91-13945) Page 6-34 90-881980R1 NOVEMBER 2001 GEAR HOUSING 8. Install O-ring. Lubricate O-ring with 2-4-C with Teflon. Lubricate seal lips with 2-4-C with Teflon. 9. Lubricate outside diameter of reverse gear bearing and bearing carrier bore with a light coating of 2-4-C with Teflon. 10. Press bearing into carrier until tool bottoms. 19163 a c 95 95 91-13945 b 2-4-C with Teflon a-O-ring b-Bearing, Numbered Side Toward Tool c-Bearing Installation Tool (91-13945) 11. Install thrust washer. Coat thrust washer with Premium Gear Lubricant. 19167 a 87 87 Premium Gear Lubricant a-Thrust Washer 90-881980R1 NOVEMBER 2001 Page 6-35 GEAR HOUSING 12. Install thrust bearing. Coat thrust bearing with Premium Gear Lubricant. 19168 87 87 a Premium Gear Lubricant a-Thrust Bearing 13. Apply Premium Gear Lubricant to bearing surface of reverse gear and install reverse gear. 19202 a 87 Premium Gear Lubricant 87 b a-Reverse Gear b-Bearing Surface Page 6-36 90-881980R1 NOVEMBER 2001 GEAR HOUSING Forward Gear Reassembly 1. Apply Quicksilver 2-4-C with Teflon grease to the I.D. of the bearing. Press bearing onto gear using suitable mandrel (press only on inner race of bearing). Because the gear hub is longer than the bearing, a tube type mandrel should be used to install the bearing. This will allow the bearing to bottom out on the gear. 51869 a b 95 2-4-C with Teflon 95 a-Mandrel (91-37350) b-Bearing; Lubricate I.D. with 2-4-C with Teflon 2. Inspect reverse gear end of clutch to determine the number of jaws. Refer to chart, following, for tool end selection. Model Installation End Bearing Position Tool Stamped 3 Jaw Reverse 91-856875A 1 3 0.155 in. (3.94mm) Clutch below surface 6 Jaw Reverse Clutch 91-856875A 1 6 Flush with surface FORWARD GEAR NEEDLE BEARING INSTALLATION 3 Jaw Reverse Clutch c a b a-Stamped “3” b-Numbered end of Needle Bearing c-3 Jaw Reverse Clutch 90-881980R1 NOVEMBER 2001 Page 6-37 GEAR HOUSING 6 Jaw Reverse Clutch 56784 c a b a b87 91-877321A1 a-Stamped “6” b-Numbered end of Needle Bearing c-6 Jaw Reverse Clutch 3. Apply Premium Gear Lubricant to I.D. of forward gear, and O.D. of needle bearing. Press needle bearing into forward gear (using forward gear bearing installer tool) until tool bottoms out on gear. 87 Premium Gear Lubricant a-Forward Gear Bearing Installer (91-877321A1) b-Needle Bearing, Numbered Side Toward Installer Tool 4. Install retaining ring into groove of forward gear by starting at one end of retaining ring and working it around until seated in groove. 57905 a b a-Retaining Ring b-Groove in Forward Gear Page 6-38 90-881980R1 NOVEMBER 2001 GEAR HOUSING Propeller Shaft Reassembly 1. Install components into propeller shaft in sequence shown. NOTE:When installing the clutch make sure the ratcheting clutch teeth (angled) are toward forward gear, and non-ratcheting (square on both sides) are toward reverse gear. 51265a b cd e gf Assembly Sequence a-Spring b-Guide Block c-Clutch d-3 Metal Balls e-Cam Follower f-Forward Clutch Teeth g-Reverse Clutch Teeth 2. Align the hole in the clutch with the hole in the guide block, install cross pin. ab 51800 a-Apply Pressure in This Direction b-Cross Pin 90-881980R1 NOVEMBER 2001 Page 6-39 GEAR HOUSING 3. Install spring. DO NOT allow spring coils to overlap each other. 51876 a a-Spring Drive Shaft Wear Sleeve Installation 1. Install new rubber ring. 2. Apply a light coat of Loctite 271 Thread Locker on outside diameter of rubber ring. a 7 Loctite 271 Thread Locker a-Ring 3. Insert sleeve into holder*. *Component of Wear Sleeve Installation Tool (91-14310A1). 19169 a b a 91-14310A1 19152 a-Sleeve b-Holder Page 6-40 90-881980R1 NOVEMBER 2001 GEAR HOUSING 4. Press sleeve onto drive shaft using Wear Sleeve Installation Tool (91-14310A1); continue pressing until the upper and lower part of the tool make surface to surface contact. 19166 b 91-14310A1 d c ab a-Drive Shaft b-Wear Sleeve Installation Tool (91-14310A1) c-Upper part of tool (Surface C) d-Lower part of tool (Surface D) 5. Remove excess Loctite from assembled shaft. 90-881980R1 NOVEMBER 2001 Page 6-41 GEAR HOUSING Lower Drive Shaft Bearing Race Installation 1. Lubricate O.D. of bearing race with 2-4-C with Teflon. 2. Install shim(s) and bearing race into housing. NOTE:Verify shim(s) are not cocked when drawing up race. Once shims and bearing cup are in place, position gearcase assembly so the driveshaft is vertical. This will aid in preventing the bearing cup from becoming cocked in the bore. a b c d f 95 2-4-C with Teflon 95 91-14309A1 d c e 58207 f a-Shim(s); Retained From Disassembly. If Shim(s) Were Lost or a New Gear Housing is Being Assembled, Start With 0.025 in. (0.635 mm) Shim(s) b-Bearing Race c-Mandrel* (13780) d-Mandrel* (13781) e-Threaded Rod** (91-31229) f-Nut** (11-24156) *From Bearing Installation Tool (91-14309A1) **From Bearing Removal and Installation Kit (91-31229A7) Page 6-42 90-881980R1 NOVEMBER 2001 GEAR HOUSING Oil Sleeve Installation 1. Install oil sleeve with tab positioned as shown. 53934 a b a-Oil Sleeve b-Tab Upper Drive Shaft Bearing Installation 1. Lubricate I.D. of bearing sleeve and O.D. of bearing with 2-4-C with Teflon. 2. Press bearing into sleeve using mandrel from bearing installation tool (91-14309A1). 1916495 2-4-C with Teflon 91-13781 95 a b c d a-Bearing Sleeve b-Tapered End c-Bearing; Numbered Side Toward Mandrel d-Mandrel (91-13781); From Bearing Installation Tool (91-14309A1) 90-881980R1 NOVEMBER 2001 Page 6-43 GEAR HOUSING 3. Install bearing/sleeve into housing. IMPORTANT: On Oil sleeve must be installed prior to upper driveshaft bearing installation. IMPORTANT: On Lower driveshaft bearing cup pilots the mandrel (13780) during installation of the upper driveshaft bearing/sleeve. Lower bearing cup must be installed prior to installing upper bearing/sleeve. 91-14309A1 a b d e e f c 58206 a-Bearing/Sleeve b-Tapered End Of Sleeve c-Mandrel* (13781) d-Mandrel* (13780) e-Threaded Rod** (91-31229) f-Nut** (11-24156) *From Bearing Installation Tool (91-14309A1) **From Bearing Removal and Installation Kit (91-31229A7) Page 6-44 90-881980R1 NOVEMBER 2001 GEAR HOUSING Forward Gear, Lower Drive Shaft Bearing, Pinion Gear, and Drive Shaft Installation 1. Install components per assembly sequence shown. 19175 a b c f 7 87 d d e 87 Premium Gear Lubricant 7 Loctite 271 Thread Locker Assembly Sequence: a-Forward Gear/Bearing: Work Premium Blend gear lube into bearing rollers. b-Lower Drive Shaft Tapered Roller Bearing: Work Premium Blend Gear Lube into bearing rollers. c-Pinion Gear d-Drive Shaft e-Drive Shaft Holding Tool f-Pinion Nut (New): Clean nut and driveshaft threads with Loctite Primer or suitable de-greaser. Apply Loctite 271 Thread Locker to threads (not necessary if using a new nut with drylock patch on threads) during final assembly (after pinion gear depth and forward gear backlash have been set), tighten to specified torque. Model Drive Shaft Holding Tool 40/50 Bigfoot (4-Stroke) 91-56775 50/60 Bigfoot (4-Stroke) 91-817070A1 75/90/115EFI (4-Stroke) 91-804776A1 60 Bigfoot/75/90/100/115/125 (2-Stroke) 91-56775 Pinion Nut Torque 70 lb-ft (95 Nm) 90-881980R1 NOVEMBER 2001 Page 6-45 GEAR HOUSING Pinion Gear Depth and Forward Gear Backlash DETERMINING PINION GEAR DEPTH NOTE:Read entire procedure before attempting any change in shim thickness. IMPORTANT: On Forward gear assembly pilots the end of the pinion gage and must be installed in gear housing when checking pinion gear depth. Without it, an inaccurate measurement will be obtained. 1. Clean the gear housing bearing carrier shoulder and diameter. 2. With gear housing positioned upright (drive shaft vertical), install Bearing Preload Tool (91-14311A2) over drive shaft in sequence shown. a b c d e f g h h a-Adaptor: Bearing surfaces clean and free of nicks b-Thrust Bearing: Oiled and able to move freely c-Thrust Washer: Clean and free of nicks and bends d-Spring e-Nut: Threaded all-the-way onto screw f-Screw: Held snug against spring g-Sleeve: Holes in sleeve must align with set screws h-Set Screw (2): Tightened against drive shaft, screw should not slide on drive shaft. 3. Measure distance between top of nut and bottom of screw head. 4. Increase distance by 1 in. (25.4 mm). 5. Rotate drive shaft 5 to 10 revolutions. This should properly seat drive shaft tapered roller bearing. 19884 a b c a-1 in. (25.4 mm) c-Screw Head b-Nut Page 6-46 90-881980R1 NOVEMBER 2001 GEAR HOUSING 6. Assemble Pinion Gear Locating Tool (91-12349A2) as shown; do not tighten collar retaining screw at this time. a b d e c f c a-Arbor d-Split Collar b-Gauging Block; Install With e-Screw; Collar Retaining Numbers Away From Split Collar f-Snap Ring c-Screw; Gauging Block Retaining 7. Insert tool into forward gear assembly; position gauging block under pinion gear as shown. 22067 a a-Gauging Block 8. Remove tool, taking care not to change gauging block position, and tighten collar retaining screw. 9. Insert tool into forward gear assembly; position proper numbered flat (from chart) of gauging block – under pinion gear. MODEL GEAR RATIO (PINION GEAR TEETH/REVERSE GEAR TEETH) USE FLAT NO. LOCATING DISC NO. 40/50 Bigfoot (4-stroke) 2.31:1 (13/30) 8 3 50/60 Bigfoot (4-stroke) 2.31:1 (13/30) 8 3 75/90/115EFI (4-stroke) 2.07:1 (14/29) 2 3 60 Bigfoot/60 Seapro 60 Marathon 2.31:1 (13/30) 8 3 75-thru-90 (3 Cylinder) 2.31:1 (13/30) 8 3 100/115/125 (4 Cylinder) 2.07:1 (14/29) 2 3 90-881980R1 NOVEMBER 2001 Page 6-47 GEAR HOUSING 10. Install locating disc against bearing carrier shoulder in gear housing. 11. Position access hole as shown. 24643 Disc 3 b a a-Locating Disc b-Access Hole 12. Determine pinion gear depth by inserting a feeler gauge through access hole in locating disc. 13. The correct clearance between gauging block and pinion gear is 0.025 in. (0.64 mm). 14. If clearance is correct, leave Bearing Preload Tool on drive shaft and proceed to “Determining Forward Gear Backlash,” following. 15. If clearance is more than 0.025in. (.064mm) add shims behind the bearing race. If clearance is less than 0.025in. (.064mm) remove shims from behind the bearing race. When reinstalling pinion nut, apply Loctite 271 Thread Locker on threads of nut. NOTE:Clean driveshaft and pinion nut threads with Loctite Primer or suitable de-greaser before applying Loctite. 24643 a b c 7 Loctite 271 Thread Locker 7 d a-Feeler Gauge b-Gauging Block c-Pinion Gear d-Bearing Race Page 6-48 90-881980R1 NOVEMBER 2001 GEAR HOUSING DETERMINING FORWARD GEAR BACKLASH NOTE:Read entire procedure before attempting any change in shim thickness. 1. Obtain correct pinion gear depth; refer to “Determining Pinion Gear Depth,” preceding. 2. Install Bearing Preload Tool (91-14311A2) on drive shaft; refer to “Determining Pinion Gear Depth,” preceding. 3. Install components as shown. 4. While holding the driveshaft, tighten the puller bolt to specified torque. 5. Rotate driveshaft 5-10 revolutions. This should properly seat the forward gear tapered roller bearing. Repeat step 4. 53936 c a bd a-Propeller Shaft* b-Bearing Carrier* (Assembled) c-Puller Jaws (91-46086A1) d-Puller Bolt (91-85716) Puller Bolt Torque 45 lb-in. (5 Nm) *Refer to “Bearing Carrier and Propeller Shaft Installation,” following. 90-881980R1 NOVEMBER 2001 Page 6-49 GEAR HOUSING 6. Install components as shown. 51117 a b e c g cd f a-Threaded Rod (Obtain Locally) b-Washers c-Nuts d-Dial Indicator Adaptor Kit (91-83155) e-Dial Indicator (91-58222A1) f-Backlash Indicator Tool g-Pre-Load Tool Screw Head 7. Position Dial Indicator on appropriate line (from chart below) marked on Backlash Indicator Tool. Make sure the dial indicator is perpendicular (^) to the indicator tool or an inaccurate reading will be obtained. MODEL BACKLASH INDICATOR TOOL ALIGN POINTER OF DIAL INDICATOR WITH MARK 40/50 Bigfoot (4-stroke) 91-78473 4 50/60 Bigfoot (4-stroke) 91-78473 4 75/90/115EFI (4-Stroke) 91-19660--1 1 60 Seapro/60 Marathon 60 Bigfoot 91-78473 4 75-thru-90 (3 Cylinder) 91-78473 4 100/115/125 (4 Cylinder) 91-19660--1 1 Page 6-50 90-881980R1 NOVEMBER 2001 GEAR HOUSING 8. Grasp the driveshaft pre-load tool bolt head and lightly turn drive shaft back-and-forth (no movement should be noticed at propeller shaft). 9. Dial Indicator registers amount of backlash, which must be between specification shown in chart. MODEL DIAL INDICATOR MINIMUM READING MAXIMUM 40/50 Bigfoot (4-Stroke) 0.012 in. (0.30 mm) 0.019 in. (.48 mm) 50/60 Bigfoot (4-Stroke) 0.012 in. (0.30 mm) 0.019 in. (.48 mm) 75/90/115EFI (4-Stroke) 0.013 in. (0.38 mm) 0.019 in. (.55 mm) 60 Bigfoot 0.012 in. (0.30 mm) 0.019 in. (.48 mm) 75-thru-90 (3 Cylinder) 0.012 in. (0.30 mm) 0.019 in. (.48 mm) 100/115/125 (4 Cylinder) 0.013 in. (0.38 mm) 0.019 in. (0.55 mm) 10. If backlash is less than the minimum specification, remove shim(s) from in front of forward gear bearing race. If backlash is more than the maximum specification, add shim(s) in front of forward gear bearing race. When reinstalling pinion nut, apply Loctite 271 on threads of nut. NOTE: By adding or subtracting 0.001 in. (0.025 mm) shim, the backlash will change approximately 0.001 in. Bearing Carrier and Propeller Shaft Installation 1. Insert propeller shaft assembly into bearing carrier. 2. Before installing bearing carrier assembly into gear housing, obtain locally a 6 in. (152.4 mm) long by 1-1/4 in. - 1-1/2 in. (31.7 - 38.1 mm) diameter piece of PVC pipe. Install the PVC pipe over the prop shaft and secure the pipe against the bearing carrier assembly with the propeller nut and tab washer. This holds the reverse gear and thrust bearing tight against the bearing carrier preventing possible bearing damage during installation. 21043 d a b c e a-Bearing Carrier Assembly d-Prop Shaft b-PVC Pipe e-Tab Washer c-Propeller Nut 90-881980R1 NOVEMBER 2001 Page 6-51 GEAR HOUSING 3. Generously lubricate O-ring, bearing carrier, and gear housing mating surfaces with 2-4-C with Teflon. 4. Install bearing carrier and propeller shaft into housing with the word “TOP” (located on flange) toward top of housing. 21044 a b 95 2-4-C with Teflon 95 a-O-ring b-TOP NOTE:Use thick 0.090 in. (2.29mm) washers (12-855941) under fasteners if not previously installed. Washer Thickness Fastener Torque 0.090 in. (2.29mm) 22 lb-ft (29.8 Nm) 0.060 in. (1.53mm) 25 lb-ft (33.9 Nm) a b a-Washers b-Fasteners (If using Screws - Apply Loctite 271 Thread Locker on Threads) Page 6-52 90-881980R1 NOVEMBER 2001 GEAR HOUSING Water Pump Reassembly and Installation 1. Place water pump base upper seal on longer shoulder side of Oil Seal Driver (91-13949) with seal lip away from shoulder. 2. Apply Loctite 271 Thread Locker on O.D. of seal; press seal into water pump base until tool bottoms. c 91-13949 7 Loctite 271 Thread Locker 7 a d e b 51553 a-Seal - Lip Faces Toward Power Head b-Spring - Faces Toward Power Head (when base is installed on gearcase) c-Oil Seal Driver (91-13949) d-Longer Shoulder Side of Tool e-Shorter Shoulder Side of Tool 90-881980R1 NOVEMBER 2001 Page 6-53 GEAR HOUSING 3. Place water pump base lower seal on shorter shoulder side of Oil Seal Driver (91-13949) with seal lip toward shoulder. 4. Apply Loctite 271 Thread Locker on O.D. of seal; press seal into water pump base until tool bottoms. 5. Lubricate lip of each seal with 2-4-C with Teflon. 51553 c 91-13949 7 Loctite 271 Thread Locker 95 2-4-C with Teflon 7 95 a b e d a-Seal - Lip Faces Toward Gear Case b-Spring - Faces Toward Gear Case c-Oil Seal Driver (91-13949) d-Longer Shoulder Side of Tool e-Shorter Shoulder Side of Tool 6. Install gasket. a 19218 a-Gasket Page 6-54 90-881980R1 NOVEMBER 2001 GEAR HOUSING IMPORTANT: On To prevent cutting the seal lips remove any burrs or sharp edges from the driveshaft splines before installing water pump base assembly. 7. Install components as shown. Apply Loctite 271 Thread Locker on bottom half of threads and tighten to specified torque in sequence shown. 192177 Loctite 271 Thread Locker 14 2 4 54 64 b a 34 a-Water Pump Base b-Screws (6) M6 x 1 and Washers (6) Screw Torque 60 lb-in. (7 Nm) 8. Install gasket and plate. 19219 b a a-Gasket b-Plate IMPORTANT: On If the old impeller is re-used it must be installed in original (clockwise) direction of rotation. 9. Install gasket, drive key and impeller. a b c a-Gasket b-Drive Key 19220 c-Impeller 90-881980R1 NOVEMBER 2001 Page 6-55 GEAR HOUSING 10. Lubricate I.D. of cover with 2-4-C with Teflon. 11. Rotate drive shaft clockwise and push impeller housing down (over impeller) until it contacts water pump base. 12. Install cover screws and torque to specified torque. ba 2-4-C with Teflon 95 b 19212 95 a-Impeller Housing b-Screws (4); Apply Loctite 271 on Threads Screw Torque 60 lb-in. (7 Nm) NOTE:It is recommended that the gearcase be pressure tested for leaks after reassembly andBEFOREgear lube is added. Gearcase should hold 10-12 psi (69-83 kPa) for 5 minutes. Gear Housing Pressure Test 1. Remove vent plug and install pressure test gauge. 2. Pressurize housing to 10-12 psi (69-83 kPa)and observe gauge for 5 minutes. 3. Rotate drive shaft, prop shaft and move shift shaft while housing is pressurized to check for leaks. Page 6-56 90-881980R1 NOVEMBER 2001 GEAR HOUSING 4. If pressure drop is noted, immerse housing in water. 5. Re-pressurize to 10-12 psi (69-83 kPa)and check for air bubbles. 6. Replace leaking seals as necessary. Retest housing. NOTE:Gearcase should hold 10-12 psi (69-83 kPa) for 5 minutes. 7. Remove tester from housing and install vent plug and sealing washer. Filling Gear Housing With Lubricant NOTE:Gear housing lubricant capacity is 24 fl oz (710 mL). WARNING If gear housing is installed on engine, to avoid accidental starting, disconnect (and isolate) spark plug leads from spark plugs before working near the propeller. CAUTION Do not use automotive grease in the gear housing. Use only Premium Blend Gear Lubricant. 1. Remove any gasket material from “Fill/Drain” and “Vent” screws and gear housing. 2. Install new sealing washer on “Fill/Drain” and “Vent” screws. IMPORTANT: On Never apply lubricant to gear housing without first removing “Vent” screws or gear housing cannot be filled because of trapped air. Fill gear housing only when driveshaft is in a vertical position. 3. Remove lubricant “Fill/Drain” screw and sealing washer from gear housing. 4. Insert lubricant tube into “Fill” hole, then remove “Vent” screws and sealing washer. 5. Fill gear housing with lubricant until excess starts to flow out of one (first) “Vent” screw hole. 6. Install this “Vent” screw and sealing washer only and continue filling until excess starts to flow out of second “Vent” screw hole. 7. Rotate driveshaft clockwise approximately 10 revolutions. Let gearcase sit for at least one minute to allow any trapped air to settle out, then top off lubricant level. 90-881980R1 NOVEMBER 2001 Page 6-57 GEAR HOUSING 53922 a c b a-Vent Screw - Tighten to specified torque b-Fill/Drain Screw - Tighten to specified torque c-Oil Level Vent Screw - Tighten to specified torque Vent Screw, Fill/Drain Screw, Oil Level Vent Screw Torque 60 lb-in. (7 Nm) 8. Replace second lubricant “Vent” screw and sealing washer. IMPORTANT: On Do not lose more than one fluid ounce (30cc) of gear lubricant while reinstalling “FILL/DRAIN” screw. 9. Remove lubricant tube from Fill/Drain hole; install Fill/Drain screw and sealing washer. Gearcase Installation WARNING Disconnect (and isolate) spark plug leads from spark plugs before installing gear housing onto drive shaft housing. Failure to follow this warning could result in accidental engine starting and possible injury. 1. Position outboard shift linkage into forward gear position. Models 40-60 Bigfoot (4-Stroke) a Remote Control Model Shown a-Shift Lever Page 6-58 90-881980R1 NOVEMBER 2001 GEAR HOUSING Models 60 Bigfoot (2-Stroke) a a-Shift Block Models 75/90/100/115/125 (2-Stroke) 19879 a b a-Shift Block; Front of Block MUST Extend 1/8 in. (3.2 mm) Past Front of Rail. b-Rail Models 75/90/115EFI (4-Stroke) a NRF a-Shift Block 2. Tilt engine to full up position and engage tilt lock lever. 3. Shift gear housing into neutral position. Propeller shaft will rotate freely in either direction. 90-881980R1 NOVEMBER 2001 Page 6-59 GEAR HOUSING 4. Install water tube seal; apply 2-4-C with Teflon to I.D. of seal. 5. Apply a bead of RTV Sealer as shown. NOTE:For ease of gear housing installation, install water tube seal (labyrinth end) onto water tube in drive shaft housing. Tapered end of water tube seal goes onto water pump. 5393895 2-4-C with Teflon 85 85 95 a b RTV Silicone Sealer a-Water Tube Seal b-RTV Sealer CAUTION Do not use lubricant on top of drive shaft. Excess lubricant, that is trapped in clearance space, will not allow drive shaft to fully engage with crankshaft. Subsequently, tightening the gear housing fasteners (while lubricant is on top of drive shaft) will load the drive shaft/crankshaft and damage either or both the power head and gear housing. Top of drive shaft is to be wiped free of lubricant. 6. Apply a light coat of 2-4-C with Teflon onto drive shaft splines. 7. Apply a light coat of 2-4-C with Teflon on gear case shift shaft splines and upper shift shaft splines. Do not use lubricant on ends of shift shafts. 8. Install components as shown in appropriate photo. ALL MODELS EXCEPT 75 (2-STROKE) W/MECHANICAL REVERSE LOCK a b c c-Bushing 40-60 Bigfoot 4-Stroke Only a-Nylon Spacer b-Shift Shaft Coupler Page 6-60 90-881980R1 NOVEMBER 2001 GEAR HOUSING 75 (2-STROKE) W/MECHANICAL REVERSE LOCK 53925 a b c a-Nylon Spacer b-Shift Shaft Coupler c-Flat; MUST BE Positioned Toward Front of Gear Housing 9. Shift gear housing into forward gear position. In forward gear the gear housing will ratchet when propeller shaft is turned clockwise. Resistance will be felt when propeller shaft is rotated counterclockwise. 10. Apply Loctite 271 Thread Locker on threads of gear housing retaining screws. 90-881980R1 NOVEMBER 2001 Page 6-61 GEAR HOUSING CAUTION Use limited force when inserting the lower unit driveshaft into the oil pump. The oil pump lower seal is exposed and the driveshaft is not piloted to the center of the oil pump splines. Excessive force on contact by the driveshaft may damage the seal. NOTE:During installation of gear housing, it may be necessary to move the shift block (located under cowl) slightly to align upper shift shaft splines with shift shaft coupler splines. NOTE:On 4-Stroke models. If, while performing Step 11, the drive shaft splines will not align with the oil pump splines, place a propeller onto propeller shaft and turn it counterclockwise as the gear housing is being pushed toward drive shaft housing. Continue rotating the propshaft until the driveshaft splines align with the crankshaft splines. IMPORTANT: On 4-Stroke models, when removing or installing gearcase, carefully guide driveshaft through driveshaft bushing to avoid scoring bushing surface. 5928 9 b 95 95 a 2-4-C with Teflon a-Centerline of Oil Pump and Driveshaft Misaligned. b-Centerline of Oil Pump and Driveshaft Aligned. 11. Position gear housing so that the driveshaft is protruding into driveshaft housing. 12. Move gear housing up toward driveshaft housing, while aligning upper shift shaft splines with shift shaft coupler splines, water tube with water tube seal, and crankshaft splines/ oil pump splines with driveshaft splines. Page 6-62 90-881980R1 NOVEMBER 2001 GEAR HOUSING 13. Install 4 fasteners and washers (two each side). 14. Install locknut and washer. 15. Torque screws and locknut (or nuts only if applicable) to specified torque. 53922 7 Loctite 271 Thread Locker 7ab a-Fasteners and Washers (2 Each Side) b-Locknut and Washer Screw or Nut Torque 40 lb-ft (54 Nm) 16. Check shift operation as follows: • Place shift lever in forward gear. Gear housing should ratchet when propeller shaft is turned clockwise. Resistance should be felt when propeller shaft is turned counterclockwise. • Place shift lever in neutral. Propeller shaft should rotate freely in either direction. • While rotating propeller shaft, place shift lever in reverse gear. Resistance should be felt when propeller shaft is rotated in either direction. IMPORTANT: On If shift operation is not as described, preceding, the gear housing must be removed and the cause corrected. 90-881980R1 NOVEMBER 2001 Page 6-63 GEAR HOUSING Trim Tab Adjustment 1. Check trim tab position as follows: • Operate boat at the speed at which it normally would be operated. • If the boat pulls to the right (STARBOARD), the trailing edge of trim tab must be moved to the right. If the boat pulls to the left (PORT), the trailing edge of trim tab must be moved to the left. 2. If necessary, adjust trim tab as follows: • Shift engine control into NEUTRAL and turn ignition key to “OFF” position. NOTE:Loosen trim tab screw sufficiently to allow trim tab to disengage from locking ridges in gear case before attempting to move tab. DO NOT strike trim tab with a hard object to make adjustments. • If boat pulls to the left, adjust trailing edge of trim tab to the left. If boat pulls to the right, adjust trailing edge of trim tab to the right. 3. Tighten trim tab retaining screw and washer to specified torque. 53931ab c a-Trim Tab b-Anti-Ventilation Plate c-Retaining Screw and Washer Retaining Screw Torque 22 lb-ft (30 Nm) Page 6-64 90-881980R1 NOVEMBER 2001 THROTTLE/SHIFT LINKAGE ATTACHMENTS/CONTROL LINKAGE Section 7 - Throttle/Shift Linkage Table of Contents Throttle Lever and Linkage . . . . . . . . . . . . . . . 7-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Throttle Lever and Linkage Removal . . . . . . . 7-4 Shift Bracket Removal/Installation . . . . . . . . . 7-5 7 90-881980R1 NOVEMBER 2001 Page 7-1 THROTTLE/SHIFT LINKAGE Throttle Lever and Linkage 1 2 3 4 5 6 7 8 9 10 5 11 13 12 95 95 95 2-4-C with Teflon Page 7-2 90-881980R1 NOVEMBER 2001 THROTTLE/SHIFT LINKAGE Throttle Lever and Linkage REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 THROTTLE LEVER 2 1 WASHER 3 1 WAVE WASHER 4 1 NUT 70 7.9 5 2 COLLAR 6 1 WASHER 7 1 SPRING 8 1 THROTTLE CONTROL LEVER 9 1 WASHER 10 1 WAVE WASHER 11 1 BOLT (M6 X 30 MM) 70 7.9 12 1 WASHER 13 1 COTTER PIN NOTE:TORQUE TOLERANCE +/– 10% 90-881980R1 NOVEMBER 2001 Page 7-3 THROTTLE/SHIFT LINKAGE Page 7-4 90-881980R1 NOVEMBER 2001 Throttle Lever and Linkage Removal 1. Remove intake silencer. Refer to Section 3C. 2. Remove throttle control lever mounting screw. 3. Remove remaining components as shown. 4. Remove accelerator cam nut. 5. Remove remaining components as shown. LT 4020 a b c d e f g h i c d 95 95 2-4-C With Teflon 95 a - Mounting Screw (1) M6 x 30 b - Collar (2) c - Wave Washer (2) d - Washer (3) e - Throttle Control Lever f - Spring g - Accelerator Cam Nut h - Accelerator Cam i - Stud Bolt Installation 1. Reassemble components as shown above. Tighten screw to specified torque. Throttle Control Lever Mounting Screw/Nut Torque 70 lb-in. (8 Nm) THROTTLE/SHIFT LINKAGE 90-881980R1 NOVEMBER 2001 Page 7-5 Shift Bracket Removal/Installation 1. Remove/install shift bracket as shown. a b c e 58568 i h g d b f a - Shift Bracket b - Screw (3) M6 x 20 c - Retainer d - Latch e - Shift Link f - Switch g - Screw (2) h - Cotter Pin i - Shift Slide Shift Bracket Screw Torque 80 lb-in. (9 Nm) NOTE: Refer to section “1D-Outboard Installation” for proper installation of shift and throttle cables. COLOR DIAGRAMS COLOR DIAGRAMS Table of Contents 115 EFI (4-Stroke) 2002 Model Year Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . Page 8-3 115 EFI (4-Stroke) 2001 Model Year Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . Page 8-5 115 EFI (4-Stroke) 2001 Model Year Typical Gauges with Tach Signal Converter Page 8-7 115 EFI (4-Stroke) 2001 Model Year Fuel Flow Diagram . . . . . . . . . . . . . . . . . . . . . Page 8-9 115 EFI (4-Stroke) 2001 Model Year Oil Flow Diagram. . . . . . . . . . . . . . . . . . . . . . . Page 8-11 115 EFI (4-Stroke) 2001 Model Year Water Flow Diagram . . . . . . . . . . . . . . . . . . . . Page 8-13 8 90-881980R1 NOVEMBER 2001 Page 8-1 COLOR DIAGRAMS Page 8-2 90-881980R1 NOVEMBER 2001 COLOR DIAGRAMS 115 4-STROKE EFI COLOR WIRING DIAGRAM 2002 MODEL YEAR 90-881980R1 NOVEMBER 2001 Page 8-3 115 4-STROKE EFI WIRING DIAGRAM 2002 MODEL YEAR 1. Cowl Mounted Trim Switch 2. Starter and Solenoid 3. Starter Relay 4. Main Relay 5. Engine Water Temperature Sensor 6. Stator 7. Voltage Regulator/Rectifier 8. Ignition Coil 2 & 3 9. Ignition Coil 1 & 4 10. Not Used 11. Malfunction Indicator Lamp (MIL) Connections 12. Idle Air Control (IAC) 13. Fuel Pump 14. Injector 1 15. Injector 2 16. Injector 3 17. Injector 4 18. Oil Pressure Switch 19. Shift Position Switch 20. Manifold Absolute Pressure Sensor (MAP) 21. Throttle Position Sensor (TPS) 22. Engine Air Temperature Sensor 23. Crankshaft Position Sensor (CPS) 24. ECM 25. Remote Control Wiring From Boat 26. Adapter Harness 27. Engine Harness Connection 28. Trim Relay 29. To 12 Volt Battery 30. Main Relay Fuse 20 Amp 31. Trim System, Key Switch Fuse 20 Amp 32. Charging System Fuse 30 Amp 33. Starter Relay Fuse 30 Amp Q R S T U V W X Y QP QQ QR QS QT QU QV QW QX QY RP RQ RR RS RT RW SP SQ SR SS UYRWU RX RU RV RY Q QS QR RT RU SQ SP SV COLOR DIAGRAMS 115 4-STROKE EFI COLOR WIRING DIAGRAM 2001 MODEL YEAR 90-881980R1 NOVEMBER 2001 Page 8-5 115 4-STROKE EFI WIRING DIAGRAM 2001 MODEL YEAR 1. Cowl Mounted Trim Switch 2. Starter and Solenoid 3. Starter Relay 4. Main Relay 5. Engine Water Temperature Sensor 6. Stator 7. Voltage Regulator/Rectifier 8. Ignition Coil 2 & 3 9. Ignition Coil 1 & 4 10. Not Used 11. Malfunction Indicator Lamp (MIL) Connections 12. Plug Cap 13. Idle Air Control (IAC) 14. Fuel Pump 15. Injector 1 16. Injector 2 17. Injector 3 18. Injector 4 19. Oil Pressure Switch 20. Shift Position Switch 21. Manifold Absolute Pressure Sensor (MAP) 22. Throttle Position Sensor (TPS) 23. Engine Air Temperature Sensor 24. Crankshaft Position Sensor (CPS) 25. ECM 26. Remote Control Wiring From Boat 27. Adapter Harness 28. Engine Harness Connection 29. Trim Relay 30. To 12 Volt Battery 31. Main Relay Fuse 20 Amp 32. Trim System, Key Switch Fuse 20 Amp 33. Charging System Fuse 30 Amp 34. Starter Relay Fuse 30 Amp Q R S T U V W X Y QP QQ QR QS QT QU QV QW QX QY RP RQ RR RS RT RU RW RV RX SP SQ SR SS ST UXVSP RY COLOR DIAGRAMS 115 4-STROKE EFI TYPICAL GAUGES WITH TACH SIGNAL CONVERTER 2002 MODEL YEAR 90-881980R1 NOVEMBER 2001 Page 8-7 115 EFI (4-STROKE) TYPICAL GAUGES WITH TACH SIGNAL CONVERTER 2002 MODEL YEAR 1. MPC 4000 2. Neutral Lock Button 3. Trim Switch 4. Throttle Only Button 5. Lanyard Stop Switch 6. Lanyard stop switch leads must be soldered and covered with shrink tube for a water proof connection. If alternate method of connection is made (use of electrical butt connector) verify connection is secure and seal for moisture proof connection. 7. Trim Harness Connection 8. Connect wires together with screw and hex nut (2 places); apply Quicksilver Liquid Neoprene to connections and slide heat shrink tubing over each connection. 9. Key Switch 10. 5–Pin Tachometer Harness Connector 11. Warning Horn 12. Speedometer 13. Temperature Gauge 14. Trim Position Gauge 15. Tachometer 16. Light Switch Connection 17. Tachometer Signal Converter (required for correct tachometer operation) 18. To Warning Light ( if equipped) 19. To Trim Sender (if equipped) 20. To Engine Trim Harness Connections 21. To Temperature Sensor (if equipped) 22. Remote Control Harness Connection c d e a b QQ QP s i g ignN calN sendN grdN ltN Up Vp Rp Sp Xc Tp Tc Vc s i g Q W X Y U V T S R QR QS QT QU QV QW QX QY RP RR RQ COLOR DIAGRAMS 115 4-STROKE EFI FUEL FLOW DIAGRAM 2002 MODEL YEAR 90-881980R1 NOVEMBER 2001 Page 8-9 115 4-STROKE EFI FUEL FLOW DIAGRAM 2002 MODEL YEAR 1. From Boat Fuel Tank 2. Fuel Filter Assembly 3. Fuel Pump 4. Vapor Separator Tank (VST) ”Low–pressure In” 5. Vapor Separator Tank (VST) ”High–pressure Out” 6. Fuel Rail 7. Filter 8. Fuel Injectors 9. Fuel Pressure Regulator 10. Fuel Return (to Fuel Cooler) 11. Fuel Pressure Regulator Vent (to Intake Manifold) 12. Fuel Cooler 13. Vapor Separator Tank (VST) ”Fuel Return” 14. Vapor Separator Tank (VST) Vent (to Adapter Plate) 15. Float Valve Assembly 16. Filter 17. High Pressure Fuel Pump 18. Check Valve 90-881980 DECEMBER 2001 Page 8-10 WATER FUEL Q R S T T U U V W X X X X W W W Y Y QP QP QQ QQ QS QS QT QU QV QW QX QR COLOR DIAGRAMS 115 4-STROKE EFI OIL FLOW DIAGRAM 2002 MODEL YEAR 90-881980R1 NOVEMBER 2001 Page 8-11 115 4-STROKE EFI OIL FLOW DIAGRAM 2002 MODEL YEAR 1. Sump 2. Oil Pick-up 3. Adapter Plate 4. Oil Pump and Pressure Regulator 5. Cylinder Block with oil passages 6. Oil Filter 7. Crankshaft with oil passages 8. Cylinder Head with oil passages 9. Camshafts 10. Oil drains from head to block 11. Oil in block drains through adapter plate back to the sump. 1 2 3 4 5 5 6 7 8 9 10 11 COLOR DIAGRAMS 115 4-STROKE EFI WATER FLOW DIAGRAM 2002 MODEL YEAR 90-881980R1 NOVEMBER 2001 Page 8-13 115 4-STROKE EFI WATER FLOW DIAGRAM 2002 MODEL YEAR 1. Water Inlet 2. Water Pump 3. Driveshaft Housing 4. Water Tube 5. Oil Sump 6. Adapter Plate 7. Cylinder Block 8. Cylinder Head 9. Thermostat 10. Water Jacket Cover and Pressure Relief Valve 11. Fuel Cooler 12. Tee Fitting 13. Tell-Tale 14. Driveshaft Bushing Q R S T U V W X Y QP QQ QR QS QT QT