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225 FourStroke Electronic Fuel Injection Starting Model Year 2003 Starting Serial Number 0T653945 Starting Model Year 2003 225 FourStroke EFI 90-888465 JUNE 2002 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 in- jury 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. 90-888465 JUNE 2002 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 2002 Page 6A-7 Revision No. 1 Month of Printing Year of Printing Section Number Part of Section Letter Page Number Page ii 90-888465 JUNE 2002 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 - Standard Rotation Gear Housing B - Counter Rotation 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 90-888465 JUNE 2002 Page iii SPECIFICATIONS IMPORTANT INFORMATION Section 1A - Specifications Table of Contents 1 A Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1 Mercury/Quicksilver Lubricants/Sealants . . . 1A-12 Propeller Information Charts . . . . . . . . . . . . . . 1A-10 Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-14 Specifications Models 225 EFI (4-Stroke) Horsepower: Model 225 165.5 Kw (225 hp) @ 5500 rpm PERFORMANCE Wide Open Throttle (WOT) rpm Range 5000 - 6000 Electric OUTBOARD 225EXLPT 272 kg (600 lb) WEIGHT 225EXXLPT 278 kg (613 lb) Overall Length 892 mm (35.1 in.) Overall Width 634 mm (25.0 in.) Overall Height X DIMENSION 1805 mm (71.1 in.) U 1932 mm (76.1 in.) Recommended Gasoline Automotive Unleaded FUEL with a Minimum Pump Posted Octane Rating of 86 Oil Filter p/n 35-822626T7 Oil Filter Wrench - 74 mm p/n 91-888734 Engine Oil Capacity (with oil filter replacement) 6.0L (6.3 Qt) (without oil filter replacement) 5.8L (6.1 Qt) Engine Oil SAE 10W-30 or 10W-40 viscosity oil is recommended for use in all temperatures. SAE SAE 25W-40 viscosity oil may be used 10W-30 C° F° at temperatures above 4° C (40° F). +38 +100 Use 4-Cycle Marine Oil with the proper OIL +27 viscosity for the expected temperature in your area (see range thermometer +80 +16 +60 on left). If not available, use a premium +40 +4 quality 4-cycle engine oil certified to meet or exceed any one of the follow –7 +20 ing American Petroleum Institute (API) –18 0 service classifications SJ, SH, SG, SF, SE. 90-888465 JUNE 2002 Page 1A-1 SPECIFICATIONS IGNITION SYSTEM Readings taken @ 68°F (20°C). Type Microcomputer-ECM Spark Plug: Type NGK LFR5A-11 Gap 1.0 - 1.1 mm (0.39 - .0.43) Hex Size 16 mm (5/8 in.) Torque 25 Nm (18 lb-ft) Hole Size 14 mm Firing Order 1-2-3-4-5-6 Ignition Timing: @ Idle (750 rpm) T.D.C @ WOT (5500 rpm) 24° B.T.D.C Stator Coil Output - Peak Voltage: . . GRN-GRN Unloaded. . @ 400 rpm (Cranking) 8 V minimum @ 1500 rpm 42 V minimum @ 3500 rpm 93 V minimum . . GRN/WHT-GRN/WHT Unloaded. . @ 400 rpm (Cranking) 7 V minimum @ 1500 rpm 34 V minimum @ 3500 rpm 78 V minimum Stator Coil Resistance Rx1 @ 20 C (68 F) . . GRN-GRN 0.10-0.60 W GRN/WHT-GRN/WHT . . 0.10-0.50 W Crank Position Sensor - Peak Voltage: . . Unloaded @ 400 rpm (Cranking) 5.3 V . . Loaded @ 400 rpm (Cranking) 5.3 V @ 1500 rpm 20 V @ 3500 rpm 43 V Crank Position Sensor Resistance 459-561 W ECM (Coil Primary) - Peak Voltage: . . Loaded @ 400 rpm (Cranking) 160 V minimum @ 1500 rpm 260 V minimum @ 3500 rpm 260 V minimum Voltage Regulator Output (unloaded) . . @1500rpm 10.5 V minimum @3500rpm. . 10.5 V minimum Page 1A-2 90-888465 JUNE 2002 SPECIFICATIONS Ignition Coil Resistance Primary 1.5-2.5 W Secondary (Between Boots) Engine Temperature Sensor . . Resistance 19.6-35.4 kW @ 20 C (68 F). . 54.2-69.2 kW IGNITION SYSTEM Readings taken @ 68°F (20°C). @ 100 C (212 F). . Air Temperature Sensor Resistance @0 C (32 F). . @80 C (176 F). . Oil Pressure Sensor Output Voltage 3.12-3.48 kW 5.4-6.6 kW 0.29-0.39 kW 3.8 V @700rpm Throttle Position Sensor Output Voltage Thermoswitch Continuity 3.8 V . . On 84-90 °C (183-194 F) . . Off (Reset) 68-82 °C (154-179 F) CHARGING SYSTEM Readings taken @ 68°F (20°C). Alternator Type: Alternator Output Stator Coil - Peak Voltage: (G-G) @ (Cranking) (Unloaded) @ 1500 rpm (Unloaded) @ 3500 rpm (G/W-G/W) @ (Cranking) (Unloaded) @ 1500 rpm (Unloaded) @ 3500 rpm Stator Coil Resistance (G-G) Stator Coil Resistance (G/W-G/W) Rectifier/Regulator Output - Peak Voltage (R-B, R/Y-B): @ 1500 rpm (unloaded) @ 3500 rpm (unloaded) Quicksilver Tachometer Setting Three Phase Stator Coil (12 Pole) 12.0 V; 45 Amps. (Rectified/Regulated) Minimum 8 V 42 V 93 V 7 V 34 78 0.10 - 0.60 W 0.10 - 0.50 10.5 V 10.5 V STARTING SYSTEM Electric Start: Starter Type Output Rating Brush: Length Minimum Length Commutator: Diameter Minimum Diameter Undercut Undercut Limit Sliding Gear 1.4 kW - 12 V 30 Seconds 15.5 mm (0.610 in.) 9.5 mm (0.374 in.) 29.0 mm. (1.140 in) 28.0 mm (1.100 in.) 0.5-0.8 mm (0.020-0.030 in.) 0.2 mm (0.010 in.) 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) 100 - 120 90-888465 JUNE 2002 Page 1A-3 SPECIFICATIONS FUEL SYSTEM Fuel Pump Type Fuel Pump: Low Pressure High Pressure Electric 11-15 lbs. 38-44 lbs. FUEL INJECTION Fuel Injection System Idle rpm (In Neutral) Warm Fuel Pressure @ Rail Engine cold (start-up) Warm Batch (1 & 4) - (2 & 5) - (3 & 6) 650 - 750 rpm 303 kPa (44 psi) 262 kPa (38 psi) CYLINDER BLOCK Type Displacement Number of Cylinders V6, 4 Stroke - DOHC 24 Valves 3352 cc (205 cid) 6 STROKE Length 80.5 mm (3.17 in.) CYLINDER BORE Diameter Standard Taper Out of Round Maximum 94.00 - 94.020 mm (3.7008 - 3.7016 in.) 0.05 mm (0.0020 in.) 0.01 mm (0.0004 in.) CYLINDERS Bore Diameter Taper Limit Out-of-Round Limit 1.17 - 1.19 mm (0.0461 - 0.0468 in.) 2.80-3.00 mm (0.1100 - 0.1180 in.) 0.15 -0.30 mm (0.0059 - 0.0118 in.) PISTON Piston Type Measure Point (H) Piston Diameter (D) Pin Boss Inside Diameter H D Aluminum 5 mm (0.2 in.) 93.921 - 93.941 mm (3.6977 - 3.6985 in.) 21.02 - 21.03 mm (0.8276 - 0.8280 in.) PISTON PIN Outside Diameter 21.00 mm (0.827 in.) RINGS Top Ring Dimension “B” Dimension “T” End Gap (Installed) Side Clearance Middle Ring Dimension “B” Dimension “T” End Gap (Installed) Side Clearance Bottom (Oil Ring) Dimension “B” Dimension “T” End Gap (Installed) Side Clearance T B T B T B 1.17 - 1.19 mm. (0.0461 - 0.0468 in) 2.8 - 3.0 mm (0.110 - 0.118 in.) 0.15 - 0.30 mm (0.0059 - 0.0118 in.) 0.04 - 0.08 mm (0.0016 - 0.0031 in.) 1.17 - 1.19 mm (0.0461 - 0.0468 in.) 3.6 - 3.8 mm (0.142 - 0.150 in.) 0.30 - 0.45 mm (0.0118 - 0.0177 in.) 0.03 - 0.07 mm (0.0012 - 0.0027 in.) 2.40 - 2.47 mm (0.0945 - 0.0972 in.) 2.3 - 2.7 mm (0.091 - 0.106 in.) 0.15 - 0.60 mm (0.0059 - 0.0236 in.) 0.13 - 0.07 mm (0.0016 - 0.0051 in.) Page 1A-4 90-888465 JUNE 2002 SPECIFICATIONS POWER UNIT Cooling System Exhaust System Lubrication System Water Through Propeller Boss Wet Sump COMPRESSION RATIO Compression Ratio Cylinder Compression (Minimum) 9.9:1 880 kPa (125 psi) PISTON PIN Piston Pin Outside Diameter 21.00 mm (0.827 in.) Small End Inside Diameter 21.00 mm (0.827 in.) Big End Inside Diameter 53.00 mm (2.087 in.) CONNECTING Oil Clearance (Big End) Big End Bearing Thickness 0.035 - 0.071 mm (0.0014 - 0.0028 in.) ROD Yellow 1.492 -1.496 mm (0.0587 - 0.0588 in.) Green 1.496 - 1.500 mm (0.0588 - 0.0591 in.) Blue Red 1.500 - 1.504 mm (0.0591 - 0.0592 in.) Crankshaft Journal Diameter 62.968 - 62.992 mm Crankshaft Pin (2.4791 - 2.4800 in.) Diameter 49.976 - 50.000 mm (1.9676 - 1.9685 in.) Width 21.50 - 21.55 mm (0.8465 - 0.8484 in.) CRANKSHAFT Crankshaft Run-out 0.03 mm (0.0012 in.) Crankcase Main Journal Oil Clearance 0.025-0.050 mm (0.0010-0.0020 in.) Upper Crankcase Main Journal Bearing Thickness 1 2.494 - 2.500 mm (0.0981 - 0.0984 in.) 2 2.498 - 2.504 mm (0.0983 - 0.0986 in.) CRANKCASE 3 Lower Crankcase Main Journal Bearing Thickness 2.502 - 2.508 mm (0.0985 - 0.0987 in.) 1 2.494 - 2.500 mm (0.0981 - 0.0984 in.) 2 2.498 - 2.504 mm (0.0983 - 0.0986 in.) 3 No. 3 Main Journal Bearing Thick2.502 - 2.508 mm (0.0985 - 0.0987 in.) ness 2.492 -2.500 mm (0.0980 - 0.0984 in.) 1 2.496 - 2.504 mm (0.0982 - 0.0986 in.) 2 3 2.500 - 2.508 mm (0.0984 - 0.0987 in.) 90-888465 JUNE 2002 Page 1A-5 SPECIFICATIONS Camshaft Dimensions Intake “A” 45.30 - 45.40 mm (1.7835 - 1.7874 in.) Exhaust “A” 45.35 - 45.45 mm 1.7854 - 1.7894 in.() Intake “B” A 39.95 - 36.05 mm (1.4154 - 1.4193 in.) Exhaust “B” 39.95 - 36.05 mm (1.4154 - 1.4193 in.) Run-out Limit 0.1 mm (0.004 in.) CAMSHAFT Camshaft Bearing Diameter “a” Camshaft Bearing Oil Clearance B 24.96 - 24.98 mm (0.9827 - 0.9835 in.) 0.02-0.06 mm (0.0008-0.0023 in.) A Free Length “a” 44.20 mm (1.740 in.) Minimum Free Length 42.60 mm (1.677 in.) VALVE SPRING Tilt Limit “b” a b Less than 1.5 mm (0.06 in.) Warp Limit 0.1 mm (0.004 in.) CYLINDER HEAD Camshaft Bearing Inside Diameter a 25.000 - 25.020 mm (0.9843 - 0.9850 in.) Valve Lifter Bore Outside Diameter 32.98-33.00 mm (1.2984-1.2992 in.) Valve lifter to cylinder head clearance 0.02-0.05 mm (0.0008-0.0020 in.) Page 1A-6 90-888465 JUNE 2002 SPECIFICATIONS Valve/Valve Seat/Valve Guides: Valve Clearance (cold) Intake 0.20 ± 0.03 mm (0.008 ± 0.001 in.) Exhaust Valve Dimensions: “A” Head Diameter 0.34 ± 0.03 mm (0.013 ± 0.001 in.) Intake 34.85 - 35.15 mm (1.3720 - 1.3839 in.) Exhaust “B” Face Width 29.85 - 30.15 mm (1.1752 - 1.1870 in.) Intake 2.11 mm (0.0831 in.) Exhaust “C” Seat Width 2.43 mm (0.0957 in.) Intake 1.1 - 1.4 mm (0.043 - 0.055 in.) Exhaust “D” Margin Thickness 1.4 - 1.7 mm (0.055 - 0.067 in.) Intake 0.7 mm (0.028 in.) VALVES Exhaust Stem Outside Diameter 1.00 mm (0.039 in.) Intake 5.477 - 5.492 mm (0.2156 - 0.2162 in.) Exhaust Guide Inside Diameter 5.464 - 5.479 mm (0.2151 - 0.2157 in.) Intake 5.51 - 5.52 mm (0.2169 - 0.2173 in.) Exhaust Stem To Guide Clearance 5.51 - 5.52 mm (0.2169 - 0.2173 in.) Intake 0.01 - 0.02 mm (0.0004 - 0.0008 in.) Exhaust 0.01 - 0.02 mm (0.0004 - 0.0008 in.) Stem Run-out Limit (max.) 0.01 mm (0.0004 in.) “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 32.98 - 33.00 mm (1.2984 - 1.2992 in.) 0.010 - 0.020 mm (0.0004 - 0.0008 in.) VALVE SHIM Valve shim Thickness (in 0.020 mm increments) 2.320 - 2.960 mm (0.0913 - 0.1165 in.) 90-888465 JUNE 2002 Page 1A-7 SPECIFICATIONS THERMOSTAT Valve Opening Temperature Full Open Temperature Valve Lift (Minimum) 60° C (140° F) 70° C (158° F) 4.3 mm (0.17 in.) LUBRICATION SYSTEM Pump Type Oil Pump Drive Discharge at 212°F (100°C) with 10W-40 Oil at 1000 rpm Engine Oil Pressure (Warm Engine) @ 700 rpm Engine Oil Capacity (with filter replacement) Trochoid with Relief Valve Drive shaft Spline 8.8 l/min (2.32 gpm) 138 kPa (19.6 psi) 6.0 L (6.3 Qt) Engine Oil Capacity (without filter replacement) Relief Valve Opening Pressure Oil Pump: Non-Serviceable 5.8 L (6.1 Qt) 530 - 650 kPa (75 - 92 psi) Recommended Transom Height: X 25 in. (64 cm) U 76 cm (30 in.) MID-SECTION Steering Pivot Range 64° Trim Angle –3° to 16° Full Tilt Up Angle 70° Allowable Transom Thickness (Max) 3 in. (76.2 mm) Hydraulic Pressure Trim Down 6.7-8.7 mPa (970-1260 psi) POWER TRIM SYSTEM Trim Up Trim Sensor Resistance @ 20 C (68 F) 12.2-14.2 mPa (1770-2060 psi) Full Down 9-11 W Full Up 247.6-387.6 W Page 1A-8 90-888465 JUNE 2002 SPECIFICATIONS GEAR HOUSING (2.00:1) Gearshift Positions Clutch Type Propeller Shaft Type Gear Ratio Propeller Direction F225AET FL225AET Propeller Identification Mark F225AET FL225AET Gearcase Capacity Standard Rotation Counter Rotation Lubricant Type Gear Oil Grade Forward Gear Number of Teeth Pinion Gear Number of Teeth Forward Gear Backlash Water Pressure @ Idle (700 rpm) @ 5700 rpm F-N-R Dog Clutch Spline 2.00:1 (30/15) Clockwise Counterclockwise T, M TL, ML 1.15 L (39 fl oz) 1.00 L (34 fl oz) Hypoid Gear Oil API GL-4 SAE 90 30 Spiral/Bevel 15 Spiral/Bevel 0.21-0.44 mm (0.008-0.017 in.) 8-10 kPa (1.1-1.5 psi) ±10% 117-143 kPa (17-20.7 psi) ±10% Model F225AET FL225AET GEAR GEARGEAR BACKLASHBACKLASH Pinion-to-Forward Gear 0.008-0.017 in. (0.21-0.44 mm) 0.014-0.028 in. (0.35-0.70 mm) Pinion-to-Reverse GearPinion to Reverse Gear 0.028-0.041 in.0.028 0.041 in. (0.70-1.03 mm) 0.028-0.041 in.0.028 0.041 in. (0.70-1.03 mm) Pinion Shims (mm)( ) Forward Gear Shims (mm)( ) Reverse Gear Shims (mm) 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 010 012 015 018 030 040 0500.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 010 012 015 018 030 040 0500.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Propeller Shaft Shims (mm) 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 90-888465 JUNE 2002 Page 1A-9 SPECIFICATIONS Propeller Information Charts MERCURY 225 EFI (4-STROKE) 2.00:1 Wide Open Throttle RPM : 5000-6000 Recommended Transom Heights : 51 cm (20 in.), 64 cm (25 in.), 76 cm (30 in.) Right Hand Rotation Standard (Left Hand Available) Gear Reduction : 2.00:1 Right Hand Rotation Propellers 14.5 25 3 Mirage Plus 2600-3300 19-22 53-66 48-13706A46 13.25 25 5 Hi-Five 2600-3300 19-22 53-66 48-816374A46 14.63 23 3 Mirage Plus 2900-3800 20-23 47-59 48-13704A46 14.63 23 4 Revolution 4 2900-3800 20-23 47-59 48-857030A46 13.25 23 5 Hi-Five 2900-3800 20–23 47-59 48-815762A46 13.5 23 3 Vengeance 2900-3800 20–23 47-59 48-16320A46 14 23 3 Aluminum 2900-3800 20-23 47-59 48-832834A45 14.62 21 3 Tempest Plus 3200-4300 21-24 42-54 48-825862A47 14.75 21 3 Mirage Plus 3200-4300 21-24 42-54 48-13702A46 14.63 21 4 Revolution 4 3200-4300 21-24 42–54 48-857028A46 13.25 21 5 Hi-Five 3200-4300 21-24 42-54 48-815760A46 13.75 21 3 Vengeance 3200-4300 21-24 42-54 48-16318A46 14.25 21 3 Aluminum 3200-4300 21-24 42-54 48-832832A45 14.62 19 3 Tempest PLus 3700-5100 21-25 36-48 48-825860A47 15.25 19 3 Mirage Plus 3700-5100 21-25 36-48 48-13700A46 14.63 19 4 Revolution 4 3700-5100 21-25 36-48 48-857026A46 13.25 19 5 Hi-Five 3700-5100 21-25 36-48 48-815758A46 14 19 3 Vengeance 3700-5100 21-25 36-48 48-16316A46 14.5 19 3 Aluminum 3700-5100 21-25 36-48 48-832830A45 15.38 18 3 Mirage Plus 3800-5600 22-25 33-46 48-90160A46 14.63 18 4 Revolution 4 3800-5600 22-25 33-46 NA 15.5 18 3 Aluminum 3800-5600 22-25 33-46 48-11324A45 15.5 17 3 Mirage Plus 4100-6200 22-26 30-43 48-18278A46 14.63 17 4 Revolution 4 4100-6200 22-26 30-43 48-857024A46 13.5 17 5 Hi-Five 4100-6200 22-26 30-43 48-821154A46 14.5 17 3 Vengeance 4100-6200 22-26 30-43 48-16314A46 15 17 3 Aluminum 4100-6200 22-26 30-43 48-832828A45 16 16 3 Aluminum 4500-7000 23-27 27-40 48-16440A45 Page 1A-10 90-888465 JUNE 2002 SPECIFICATIONS Right Hand Rotation Propellers, (continued from previous page) Diameter (in.) Pitch (in.) No. of Blades Material Approx. Gross Boat Wgt. (lbs) Approx. Boat Length (ft) Speed Range (mph) Right Hand Propeller Part Number 15.75 15 3 Mirage Plus 4900-8000 23-28 24-37 48-19838A46 14.5 15 3 Vengeance 4900-8000 23-28 24-37 48-16312A46 15.25 15 3 Aluminum 4900-8000 23-28 24-37 48-78116A45 16 14 3 Aluminum 5400-9300 24-30 21-34 48-16438A45 16 13 3 Mirage Plus 6500+ 25-32 17-30 48-826072A46 16 13 3 Aluminum 6500+ 25-32 17-30 48-78114A45 16 12 3 Aluminum 8000+ Work 14-27 48-16436A45 16 11 3 Aluminum 9500+ House/Work 1-24 48-78112A45 Left Hand Rotation Propellers Diameter (in.) Pitch (in.) No. of Blades Material Approx. Gross Boat Wgt. (lbs) Approx. Boat Length (ft) Speed Range (mph) Left Hand Propeller Part Number 14.5 25 3 Mirage Plus 2600-3300 19-22 53-66 48-13707A46 14.63 23 3 Mirage Plus 2900-3800 20-23 47-59 48-13705A46 14.63 23 4 Revolution 4 2900-3800 20-23 47-59 48-857031A46 13.5 23 3 Vengeance 2900-3800 20–23 47-59 48-16321A46 14.75 21 3 Mirage Plus 3200-4300 21-24 42-54 48-13703A46 14.63 21 4 Revolution 4 3200-4300 21-24 42–54 48-857029A46 13.75 21 3 Vengeance 3200-4300 21-24 42-54 48-16319A46 15.25 19 3 Mirage Plus 3700-5100 21-25 36-48 48-13701A46 14.63 19 4 Revolution 4 3700-5100 21-25 36-48 48-857027A46 14 19 3 Vengeance 3700-5100 21-25 36-48 48-16317A46 15.38 18 3 Mirage Plus 3800-5600 22-25 33-46 48-90161A46 14.63 18 4 Revolution 4 3800-5600 22-25 33-46 NA 15.5 17 3 Mirage Plus 4100-6200 22-26 30-43 48-90159A46 14.63 17 4 Revolution 4 4100-6200 22-26 30-43 48-857025A46 14.5 17 3 Vengeance 4100-6200 22-26 30-43 48-16315A46 15.75 15 3 Mirage Plus 4900-8000 23-28 24-37 48-19481A46 16 11 3 Aluminum 9500+ House/Work 1-24 48-78117A40 90-888465 JUNE 2002 Page 1A-11 SPECIFICATIONS Mercury/Quicksilver Lubricants and Sealants Tube Ref. # Description Container Size Mercury Part Num- ber Quicksilver Part Number 4 Needle Bearing Assy. Lubricant 8 oz (226.8 g) tube 92-802868A1 N/A 6 Dielectric Grease 8 oz (226.8 g) can 92-823506-1 92-823506-1 7 Loctite 271 – Thread Locker 10 ml tube 92-809819 92-809819 9 Loctite 567 PST Pipe Sealant 50 ml tube 92-809822 92-809822 12 Loctite Master Gasket Kit 92-12564-2 92-12564-2 14 2 Cycle Premium Out- board Oil 1 US qt (0.94 L) 92-802813A1 92-802813Q1 19 Perfect Seal 16 oz (0.45 kg) can 92-34227-1 92-34227-1 25 Liquid Neoprene 8 oz (226.8 g) can 92-25711-3 92-25711-3 27 Bellows Adhesive 1.5 oz (42.5 g) tube N/A 92-86166Q1 33 Loctite 680 Retaining Compound 10 ml tube 92-809833 92-809833 34 Special Lubricant 101 8 oz (226.8 g) tube 92-802865A1 92-802865Q1 42 U-Joint and Gimbal Bearing Grease 92-802870A1 92-802870Q1 51 Loctite 222 Thread Locker 10 ml tube 92-809818 92-809818 66 Loctite 242 Thread Locker 10 ml tube 92-809821 92-809821 79 4 Cycle 25W40 En- gine Oil 92-802837A1 92-802837Q1 82 Premium Gear Lubri- cant 1 US qt (0.94 L) 92-802846A1 92-802846Q1 87 High Performance Gear Lube 1 US qt (0.94 L) 92-802854A1 92-802854Q1 91 Engine Coupler Spline Grease 14 oz (0.39 kg) car- tridge 92-802869A1 92-802869Q1 94 Anti-Corrosion Grease 8 oz (226.8 g) tube 92-802867A1 92-802867Q1 95 2-4-C with Teflon 8 oz (226.8 g) tube 92-802859A1 92-802859Q1 110 4 Stroke 10W30 Out- board Oil 1 US qt (0.94 L) 92-802833A1 92-802833Q1 114 Power Trim & Steer- ing Fluid 8 oz (226.8 g) 92-802880A1 92-802880Q1 Page 1A-12 90-888465 JUNE 2002 SPECIFICATIONS Tube Ref. # Description Container Size Mercury Part Num- ber Quicksilver Part Number 115 Premium Plus 2 Cycle TC-W3 Out- board Oil 1 US qt (0.94 L) 92-802824A1 92-802824Q1 116 RTV 587 Silicone Sealer 3 oz (85.05 g) 92-809825 92-809825 117 Loctite 7649 Primer N 4.5 oz (127.57 g) 92-809824 92-809824 119 Storage Seal Rust In- hibitor 12 oz (325 ml) spray can 92-802878-56 92-802878Q56 120 Corrosion Guard 12 oz (325 ml) spray can 92-802878 55 92-802878Q55 121 15W40 4-cycle Diesel Engine Oil 1.06 US gal.(4 L) 92-877695K1 92-877695Q1 122 Extended Life Anti- freeze/Coolant 1 US gal. (3.78 L) 92-877770K1 92-877770K1 123 Marine Engine Cool- ant 1.33 US gal. (5 L) NA 92-813054A2 124 Fuel System Treat- ment and Stabilizer Concentrate 16 oz (437 ml) 92-802876A1 92-802876Q1 125 Heat Transfer Com- pound 1.5 oz (42.5 g) tube 92-805701 1 126 Liquid Gasket 92-808137 NA 127 T442 Sealant 92-862258 NA 128 Loctite 5900 Ultra Black RTV Silicone Sealant 13 oz (371 g) tube 92-809826 NA 129 Loctite Gasket Re- mover 18 oz (532 ml) spray can 92-809828 1 NA 130 Sealer Kit, Two Part Epoxy NA 92-65150 1 Dexron III Automatic Transmission Fluid Obtain Locally Obtain Locally Loctite 592 Obtain Locally Obtain Locally Loctite Quick Tite Obtain Locally Obtain Locally Isopropyl Alcohol Obtain Locally Obtain Locally Molybedenum Disul- fide Grease Obtain Locally Obtain Locally Loctite 405 Obtain Locally Obtain Locally Cyanacrylate Adhe- sive Obtain Locally Obtain Locally 3M Permabond #3M08155 Obtain Locally Obtain Locally Loctite 262 Obtain Locally Obtain Locally Loctite 290 Obtain Locally Obtain Locally 90-888465 JUNE 2002 Page 1A-13 SPECIFICATIONS Torque Specifications Fastener Location DIameter x Length (mm) Torque lb-in. lb-ft. Nm Fuel Injection Fuel Filter Holder Bolt M6 70 8 Fuel Filter Bracket Bolt M6 70 8 Intake Air Temperature Sensor N/A 35 4 Low-Pressure Fuel Pump Bracket Bolt M5 44 5 Fuel Cooler Nut N/A 44 5 Float Chamber Bracket Bolt M8 62 7 High-Pressure Fuel Pump Relay Nut N/A 27 3 Vapor Separator Cover Screw M4 18 2 Link Rod Nut N/A 35 4 Magnet Control Lever Joint N/A 35 4 Throttle Cam Bolt N/A 70 8 Power Unit PTT Motor Lead Bolt M6 35 4 Upper Case Cover Bolt M6 70 8 Apron Bolt M6 70 8 Power Unit Bolt M9, M10 31 42 Flywheel Magnet Nut N/A 177 240 PTT Relay Nut N/A 35 4 Starter Rely Lead Bolt M6 35 4 Battery Cable Nut N/A 80 9 Starter Motor Bolt M8 21.5 29 Rectifier/Regulator 1st 2nd M6 53 106 6 12 Link Rod Nut N/A 35 4 Oil Pressure Sensor N/A 159 18 Oil Filter Union Bolt N/A 25 34 Oil Filter N/A 159 18 Driven Sprocket Bolt M10 44.5 60 Timing Belt Tensioner Bolt N/A 29 39 Drive Sprocket Bolt M5 62 7 Cylinder Head Cover Plate Screw M4 18 2 Cylinder Head Cover Bolt 1st 2nd M6 70 70 8 8 Camshaft cap Bolt 1st 2nd M7 70 150 8 17 Exhaust Cover Bolt 1st 2nd M6 53 106 6 12 Exhaust Outer Cover Bolt 1st 2nd M8 124 248 14 28 Exhaust outer Cover Plug M18 40.5 55 Timing Chain Tensioner Bolt M6 106 12 Spark Plug N/A 18.5 25 NOTE: * = Must be tightened in sequence and/or multiple stages, and/or requires torque plus rotation. See appropriate section of component for details. Page 1A-14 90-888465 JUNE 2002 SPECIFICATIONS Fastener Location DIameter x Length (mm) Torque lb-in. lb-ft. Nm Cylinder Head Bolt 1st 2nd 3rd M10 14 27.5 90° 19 37 90° Cylinder Head Bolt 1st 2nd M8 124 248 10.5 20.5 14 28 Engine Hanger Bolt M6 106 12 Cooling Water Cover Bolt M6 106 12 Starboard Cylinder Head Plug N/A 17 23 Cylinder Block Plug N/A 17 23 Engine Temperature Sensor N/A 133 15 Connecting Rod Cap 1st 2nd 3rd N/A 17 35.5 90° 23 48 90° Baffle Plate Nut N/A 106 12 Crankcase Cover Bolt 1st 2nd M8 124 248 10.5 20.5 14 28 Crankcase Cover Plate Screw M4 18 2 Oil Pump Screw N/A 35 4 Crankcase Stud Bolt 1st 2nd M8 18.5 90° 25 90° Crankcase Bolt 1st 2nd M10 29.5 90° 40 90° Crankcase Bolt 1st 2nd M8 124 248 10.5 20.5 14 28 Lower Unit (Regular Rotation Model) Trim Tab Bolt M10 31.5 43 Lower Unit Bolt M10 34.5 47 Propeller Nut N/A 40.5 55 Propeller Shaft Housing Grease Fitting N/A 53 6 Propeller Shaft Housing Bolt M8 22 30 Pinion Nut N/A 104.5 142 Lower Unit (Counter Rotation Model) Trim Tab Bolt M10 31.5 43 Lower Unit Bolt M10 34.5 47 Propeller Nut N/A 40.5 55 Ring Nut N/A 79.6 108 Propeller Shaft Housing Grease Fitting N/A 53 6 Propeller Shaft Housing Bolt M8 22 30 Pinion Nut N/A 104.5 142 90-888465 JUNE 2002 Page 1A-15 SPECIFICATIONS Fastener Location DIameter x Length (mm) Torque lb-in. lb-ft. Nm Bracket Unit Shift Rod Detent Bolt N/A 159 18 Flushing Hose adaptor Screw M6 44 5 Upper Case Mount Nut N/A 53 72 Engine Oil Drain Bolt M14 20 27 Apron Stay N/A 70 8 Pressure Control Valve N/A 70 8 Upper Exhaust Guide Bolt M8 M10 177 15 31 20 42 Oil Strainer Bolt M6 89 10 Oil Pan Bolt M8 177 15 20 Exhaust Manifold Bolt M8 177 15 20 Muffler Bolt M8 177 15 20 Baffle Plate Screw M6 35 4 Clamp Bracket Self-Locking Nut N/A 16 22 friction Plate Screw M6 35 4 Trim Stopper Nut N/A 26.5 36 Power Trim and Tilt Unit Power Trim and Tilt Unit Bolt M10 31 42 Reservoir Bolt M8 159 18 Reservoir Cap M12 62 7 Manual Valve N/A 18 2 Fluid Pipe N/A 133 15 Trim Cylinder End Screw N/A 118 160 Trim Piston Bolt 28 38 Trim Piston Bolt M8 28 38 Tilt Ram N/A 40.5 55 Tilt Cylinder End Screw N/A 66.5 90 Tilt Piston Bolt M6 62 7 Gear Housing Bolt M5 62 7 Gear Housing Bracket Bolt M5 62 7 Page 1A-16 90-888465 JUNE 2002 MAINTENANCE 1 B IMPORTANT INFORMATION Section 1B - Maintenance Table of Contents Table of Contents . . . . . . . . . . . . . . . . . . . . . . . 1B-1 Checking The Power Trim Fluid . . . . . . . . 1B-12 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-1 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-13 Inspection And Maintenance Schedule . . . . . 1B-2 Checking the Fuel Joint and Fuel Hoses . 1B-13 Before Each Use . . . . . . . . . . . . . . . . . . . . . 1B-2 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-14 After Each Use . . . . . . . . . . . . . . . . . . . . . . . 1B-2 Checking/Changing Engine Oil . . . . . . . . . . . . 1B-16 After First 20 Hours (Break-in) . . . . . . . . . 1B-2 Checking the Engine Oil . . . . . . . . . . . . . . . 1B-16 Every 100 Hours or 6 Months . . . . . . . . . . 1B-3 Changing the Engine Oil . . . . . . . . . . . . . . 1B-17 Every 300 Hours or 3 Years . . . . . . . . . . . . 1B-3 Changing Oil Filter . . . . . . . . . . . . . . . . . . . . 1B-19 Every 400 Hours or 2 Years . . . . . . . . . . . . 1B-3 Lower Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-20 Every 1000 Hours or 5 Years . . . . . . . . . . 1B-3 Checking Lubricant Level . . . . . . . . . . . . . . 1B-20 Flushing the Cooling System . . . . . . . . . . . . . . 1B-4 Changing Lubricant . . . . . . . . . . . . . . . . . . . 1B-20 Corrosion Control Anode . . . . . . . . . . . . . . . . . 1B-5 Storage Preparation . . . . . . . . . . . . . . . . . . . . . 1B-22 Battery Inspection . . . . . . . . . . . . . . . . . . . . . . . 1B-6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . 1B-23 Spark Plug Inspection . . . . . . . . . . . . . . . . . . . . 1B-7 Protecting External Outboard Timing Belt Inspection . . . . . . . . . . . . . . . . . . . 1B-8 Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-23 Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . 1B-9 Protecting Internal Engine Components . 1B-23 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . 1B-10 Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-23 Power Trim/Tilt Unit . . . . . . . . . . . . . . . . . . . . . . 1B-12 Positioning Outboard for Storage . . . . . . . 1B-23 Checking The Power Trim and Battery Storage . . . . . . . . . . . . . . . . . . . . . . 1B-23 Tilt Operation . . . . . . . . . . . . . . . . . . . . . . . . 1B-12 Special Tools 1. Crankcase Oil Pump P/N 90265A5 2. Oil Filter Wrench P/N 91-888734 90-888465 JUNE 2002 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. Check fuel filter (water separator) for debris. 4. Visually inspect the fuel system for deterioration or leaks. 5. Check outboard for tightness on transom. 6. Check steering system for binding or loose components. 7. Visually check steering link rod fasteners for proper tightness. 8. 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. After First 20 Hours (Break-in) 1. Inspect/Replace fuel filter (disposable type). 2. Change engine oil and replace oil filter. 3. Inspect and clean spark plugs. 4. Check flywheel nut tightness. 5. Check for oil leaks. 6. Check idle speed. 7. Drain and replace gear lubricant. 8. Check wiring and connectors. 9. Check/tighten fasteners* . 10. Check control cable adjustment. NOTE: Do not retighten the cylinder head and crankcase bolts. Page 1B-2 90-888465 JUNE 2002 MAINTENANCE Every 100 Hours or 6 Months 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 or 3 Years 1. Replace water pump impeller (more often if overheating occurs or reduced water pressure is noted). Every 400 Hours or 2 Years 1. Check oil pump. 2. Check/replace timing chain tensioner. 3. Check and adjust valve clearance, if necessary. Every 1000 Hours or 5 Years 1. Replace timing belt. 2. Replace timing chain. 90-888465 JUNE 2002 Page 1B-3 MAINTENANCE Flushing the Cooling System Flush the internal water passages of the outboard with fresh water after each use in salt, polluted or muddy water. This will help prevent a buildup of deposits from clogging the internal water passages. NOTE: When flushing the engine with the boat in the water, tilting up the engine until it is completely out of the water will achieve better results. WARNING To avoid possible injury when flushing, remove the propeller. Refer to Propeller Replacement. CAUTION Do not leave the garden hose connector loose on the bottom of the cowling fitting or let the hose hang free during normal operation. Water will leak out of the connector instead of cooling the engine, which can cause serious overheating. Be sure the connector is tightened securely on the fitting after flushing the engine. 1. After shutting off the engine, unscrew the garden-hose connector from the fitting on the bottom cowl. 2. Remove propeller (refer to Propeller Replacement). 3. Screw the garden hose connector onto a garden hose which is connected to a fresh-water supply. Partially open the water tap (1/2 maximum). Do not open the water tap all the way, as this allows a high pressure flow of water. 4. With the engine off, turn on the water tap and let the water flush through the cooling passages for about 15 minutes. Turn off the water and disconnect the garden hose. 5. When flushing is complete, reinstall the garden hose connector on the fitting on the bottom cowling. Tighten the connector securely. a a-Water Hose Threaded into Fitting Page 1B-4 90-888465 JUNE 2002 MAINTENANCE Corrosion Control Anode Inspect each anode periodically. 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 one corrosion control anode in the form of the trim tab. Another anode is installed on the bottom of the transom bracket assembly. a b a-Trim Tab b- Transom Bracket Anode Trim Tab Screw Torque 42 Nm (31 lb-ft.) Transom Bracket Anode Screw Torque 8 Nm (70 lb-in.) 2. Four anodes are installed in the engine block. Remove anodes at locations shown and check for scales, grease or oil. Clean if necessary. Install each anode with rubber seal and cover. Tighten screws to specified torque. NOTE: Do not remove anode screw until cover has been removed from engine. b c d a e a-Anode Screw d-Anode b-Cover Screw e-Rubber Seal c-Cover Anode Screw Torque 8 Nm (70 lb-in.) Cover Screw Torque 17 Nm (150 lb-in.) 90-888465 JUNE 2002 Page 1B-5 MAINTENANCE 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. Check the battery electrolyte level. If the level is at or below the minimum level mark, add distilled water until the level is between the maximum and minimum level marks. 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. a a-Minimum level mark Page 1B-6 90-888465 JUNE 2002 MAINTENANCE Spark Plug Inspection Inspect spark plugs at the recommended intervals (See Specifications). 1. Remove the ignition coil cover. a a-Ignition Coil Cover 2. Disconnect the spark plug wires and remove the spark plugs. 3. Clean the electrodes with a spark plug cleaner or wire brush. Check the electrodes for erosion, excessive carbon or other deposits, and the gasket for damage. Replace spark plug if necessary. a b a-Electrodes b-Gasket 4. Check the spark plug gap. Adjust if out of specification - 1.1 mm (0.043 in.). 5. Before reinstalling spark plugs, clean away dirt on the spark plug seats. Install plugs finger tight, and tighten 1/4 turn or torque to 25 Nm (18 lb-ft). 90-888465 JUNE 2002 Page 1B-7 MAINTENANCE Timing Belt Inspection 1. Remove the flywheel cover. 2. While turning the flywheel clockwise check the interior and exterior of the timing belt for the following conditions. Replace if necessary. a. Cracks in the back of the belt on 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. f. Belt is loose. a a-Timing Belt Page 1B-8 90-888465 JUNE 2002 MAINTENANCE 90-888465 JUNE 2002 Page 1B-9 Fuse Replacement 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. Remove the fuse cover and pull fuse with fuse puller. Look at the silver colored band inside the fuse. If band is broken, replace the fuse with a new one of the same amperage rating. 59447 b a e f g h c d i a - Fuse Puller b - Fuel Feed Pump - SFE 5 Ampere Fuse. c - Main Switch/Trim Switch - SFE 20 Ampere Fuse d - Engine Control Unit/Ignition Coil/Fuel Injection Pump/Fuel Injection Nozzle/Idle Speed Control - SFE 20 Ampere Fuse e - Main Fuse #1 – SFE 30 Ampere Fuse f - Main Fuse #2 – SFE 30 Ampere Fuse g - Starter Relay – SFE 30 Ampere Fuse h - Blown Fuse i - Spare Fuses MAINTENANCE Lubrication Points Lubricate the following areas with Anti-Corrosion Grease or 2-4-C with Teflon as indicated. or 94 Anti-Corrosion Grease 95 2-4-C With Teflon 94 95 95 95 95 95 95 95 95 95 95 Page 1B-10 90-888465 JUNE 2002 MAINTENANCE Lubrication Points 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. A hydraulically locked steering cable will cause loss of steering control, possibly resulting in serious injury or death. Lubricate the following areas with light weight oil. Steering Cable Grease Fitting (If equipped) – Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube. Lubricate through fitting. c a2-4-C With Teflon 30W 4 Cycle Engine Oil 95 80 b a-Steering Cable End b-Fitting c-Lubricate with light weight oil 95 90-888465 JUNE 2002 Page 1B-11 MAINTENANCE Power Trim/Tilt Unit Checking The Power Trim and Tilt Operation 1. Fully tilt the outboard motor up and down a few times and check the entire trim and tilt range for smooth operation. Check the power trim and tilt fluid level if necessary. Checking The Power Trim Fluid 1. Fully tilt the outboard motor up and engage the tilt support lock lever. a a-Tilt Support Lock 2. Remove fill cap and check fluid level. The fluid level should overflow out of the filler hole when the cap is removed. 3. If necessary, add sufficient Power Trim & Steering Fluid until it overflows out of the filler hole. If not available, use automotive (ATF) Dexron II automatic transmission fluid. 4. Install the reservoir cap and tighten to specified torque. a a-Reservoir Cap Reservoir Cap Torque 7 Nm (60 lb-in) Page 1B-12 90-888465 JUNE 2002 MAINTENANCE Fuel System WARNING To avoid serious injury or death from gasoline fire or explosion carefully follow all fuel system service instructions. Always stop the engine and DO NOT smoke or allow open flames or sparks in the area while servicing any part of the fuel system. Before servicing any part of the fuel system stop the engine and disconnect the battery. Drain the fuel system completely using an approved container to collect and store fuel. Wipe up any spillage immediately and dispose of material used to contain spillage in an approved receptacle. Checking the Fuel Joint and Fuel Hoses 1. Remove the flywheel cover and intake silencer. Refer to Section 3C -Intake Silencer Removal. 59443 a b a-Flywheel Cover b-Intake Silencer 90-888465 JUNE 2002 Page 1B-13 MAINTENANCE 2. Check the low pressure fuel hose connections, fuel joint, fuel filter, low pressure fuel pump and check valve for leaks and deterioration. Replace if necessary. 3. Check the high pressure fuel hose connections, fuel joint, vapor separator, fuel rail, fuel injectors, pressure regulator, and fuel cooler for leaks and deterioration. Replace if necessary. e h c b b d c fg i a a-Fuel rail e-Pressure regulator b-Fuel injector f-Low pressure fuel pump c-Fuel joint g-Check valve d-Vapor separator tank h-Fuel cooler (VST) i-Fuel filter Fuel Filter REMOVAL If any water is in the fuel, the red ring in the sight bowl will float. Inspect the filter element for sediment. Clean filter as follows. 1. Remove the two screws that secures the fuel filter bracket in place. 2. Remove bolt and remove ring nut lock. 3. Remove fuel filter from the bracket. 4. Pull out the filter element. Wash it with cleaning solvent and allow it to dry. a a-Filter Bracket Attaching Screws Page 1B-14 90-888465 JUNE 2002 MAINTENANCE INSTALLATION 1. Push the filter element into the cover. 2. Place the O-ring seal onto the sight bowl and reinstall sight bowl with ring nut. Tighten ring nut securely. 3. Reinstall fuel filter to the bracket. Align slot on the ring nut lock with one of the tabs on the ring nut. Torque filter screws to 8 Nm (70 lb. in.). 4. Reinstall bracket to the engine. Torque bracket attaching screws to 8 Nm (70 lb. in.) IMPORTANT: Visually inspect for fuel leakage from the filter by squeezing the primer bulb until firm, forcing fuel into the filter. i h g f e d a b c jk a-Ring Nut b-Sight Bowl c-Spring d-O-ring e-Filter Element f-O-ring g-Cover h-Bracket i-Filter Screws j-Flat Washer k-Ring Nut Lock 90-888465 JUNE 2002 Page 1B-15 MAINTENANCE Checking/Changing Engine Oil Checking the Engine Oil 1. Place the outboard motor in an upright position. 2. Wait one minute after engine shut off. 3. Remove the engine oil dipstick, wipe it clean and then insert it back into the oil filler hole. 4. Remove the dipstick again to check the oil level and the oil for discoloration and its viscosity. Change the oil if it appears milky or dirty. 5. The oil level should be between the “H” and “L” marks on the dipstick. If it is above the “H” drain sufficient oil until the level is between the “H” and “L” marks. If it is below the “L” add sufficient oil until the level is between the “H” and “L” marks. a b c a-Dipstick b-Full Mark c-Add Mark Page 1B-16 90-888465 JUNE 2002 MAINTENANCE 90-888465 JUNE 2002 Page 1B-17 Changing the Engine Oil Pump Method 1. Start the engine and warm it up. Place the outboard in a vertical upright position. 2. Remove the engine oil dipstick and oil filler cap. 3. Insert the tube of the oil pump into the dipstick guide. Pump out the engine oil into an appropriate container. 4. Pour the specified amount of the recommended engine oil into the oil filler hole (see specifications). 5. Install the oil filler cap and dipstick. Start the engine and warm it up for 5 minutes. Turn the engine off and check the oil level, correct it if necessary. a b a - Oil Filler Cap b - Dipstick Engine Oil Capacity (Without oil filter replacement) 5.8 Liters (6.1 U.S. Quarts) Engine Oil Capacity (With oil filter replacement) 6.0 Liters (6.3 U.S. Quarts) MAINTENANCE Drain Plug Method 1. Start the engine and warm it up. Place the outboard in a vertical upright position. 2. Remove the engine oil dipstick and oil filler cap. 3. Loosen seven screws and remove the starboard apron. 4. Place a drain pan under the drain hole and remove the drain plug. Let the oil drain completely. 5. Install the drain plug and tighten to specified torque. 6. Pour 5.8 liters (6.0 U.S. Quarts) of the recommended engine oil into the oil filler hole (see specifications). 7. Install the oil filler cap and dipstick. Start the engine and warm it up for 5 minutes. Turn the engine off and check the oil level, correct it if necessary. 8. Install the starboard apron. Tighten screws to specified torque. a c b a-Oil Filler Cap b-Starboard Apron c-Drain Plug Drain Plug Torque 27 Nm (20 ft-lb) Apron Screw Torque 8 Nm (70 lb-in) Page 1B-18 90-888465 JUNE 2002 MAINTENANCE Changing Oil Filter 1. Extract the engine oil with a pump or drain it. 2. Remove the oil filter cover. Place a rag or towel below the oil filter to absorb any spilled oil. 3. Unscrew old filter using a 74 mm (14 flat) oil filter wrench. 4. Clean the mounting base. Apply film of clean oil to filter gasket. Do not use grease. Screw new filter on until gasket contacts base and tighten to specified torque. Install the oil filter cover. 5. Pour the specified amount of the recommended engine oil into the oil filler hole. 6. Install the oil filler cap and dipstick. Start the engine and warm it up for 5 minutes. Turn the engine off and check the oil level, correct it if necessary. a b 91-888734 a-Oil filter cover b-Oil filter Oil Filter Torque 18 Nm (13 lb-ft) 90-888465 JUNE 2002 Page 1B-19 MAINTENANCE Lower Unit Checking Lubricant Level 1. Place outboard in a vertical operating position. 2. Remove the vent plug and check the oil level in the gearcase. If the gear lube is at the correct level it should overflow out of the vent screw hole when the vent screw is removed. 3. If necessary add sufficient gear lube until it overflows out of the vent screw hole. a a-Vent screw Changing Lubricant 1. Tilt the outboard motor up slightly. 2. Place a drain pan below outboard. 3. Remove vent plug and fill/drain plug and drain lubricant. NOTE: When 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. NOTE: 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. If this is the case have the gearcase checked by an authorized dealer. Page 1B-20 90-888465 JUNE 2002 MAINTENANCE 4. Install the lubricant tube into the fill/drain hole and slowly add lubricant until it flows out of the vent screw hole and no air bubbles are present. 5. Stop adding lubricant. Install the vent plug screw before removing lubricant tube. 6. Clean any debris off magnet of fill/drain screw. Remove lubricant tube and quickly install fill/drain plug and sealing washer. a a-Vent screw Gear Case Lubricant Capacity (Standard Rotation) 1150 ml (39 fl oz) Gear Case Lubricant Capacity (Counter Rotation) 1000 ml (34 fl oz) 90-888465 JUNE 2002 Page 1B-21 MAINTENANCE 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. When storing your outboard motor for prolonged periods of time (2 months or longer), several important procedures must be performed to prevent expensive damage. It is advisable to have your outboard serviced by an authorized Mercury dealer prior to storage. However, the following storage procedures can be performed by the owner with a minimum of tools. 1. To prevent problems which can be caused by oil entering the cylinder from the sump, keep the engine in the vertical position when transporting and storing it. 2. Do not place the engine on its side before the cooling water has drained from it completely, or water may enter the cylinder through the exhaust port and cause problems. 3. Store the engine in a dry, well ventilated place, not in direct sunlight. 4. Drain the remaining gasoline from the vapor separator. Gasoline left in the vapor separator for a prolonged period of time will break down and possibly cause damage to the fuel line. 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-22 90-888465 JUNE 2002 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 Gasoline 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 Gasoline 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 and oil filter. 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. 90-888465 JUNE 2002 Page 1B-23 GENERAL INFORMATION IMPORTANT INFORMATION Section 1C - General Information Table of Contents 1 C Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2 Propeller Selection . . . . . . . . . . . . . . . . . . . . . . 1C-12 Serial Number Location . . . . . . . . . . . . . . . . . . 1C-2 Propeller Removal/Installation . . . . . . . . . . . . 1C-13 Conditions Affecting Performance . . . . . . . . . 1C-3 Standard Models . . . . . . . . . . . . . . . . . . . . . 1C-13 Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-3 Power Trim System . . . . . . . . . . . . . . . . . . . . . . 1C-15 Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-4 General Information . . . . . . . . . . . . . . . . . . 1C-15 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-5 Power Trim Operation . . . . . . . . . . . . . . . . . 1C-15 Following Complete Submersion . . . . . . . . . . 1C-6 Trim “In” Angle Adjustment . . . . . . . . . . . . 1C-16 Submerged While RunningTrim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . 1C-17 (Special Instructions) . . . . . . . . . . . . . . . . . 1C-6 Compression Check . . . . . . . . . . . . . . . . . . . . . 1C-18 Salt Water SubmersionCylinder Leakage Testing . . . . . . . . . . . . . . . . . 1C-20 (Special Instructions) . . . . . . . . . . . . . . . . . 1C-6 Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-22 Fresh Water SubmersionWater Pressure Measurement . . . . . . . . . . . . 1C-23 (Special Instructions) . . . . . . . . . . . . . . . . . 1C-6 Painting Procedures . . . . . . . . . . . . . . . . . . . . . 1C-24 Model 225 (4-Stroke) Powerhead Front View . 1C-7 Color Impregnated Top Cowls . . . . . . . . . . 1C-24 Model 225 (4-Stroke) PowerheadCleaning & Painting Aluminum Starboard View . . . . . . . . . . . . . . . . . . . . . . . . . 1C-8 Propellers & Gear Housings . . . . . . . . . . . 1C-24 Model 225 (4-Stroke) Powerhead Port View . . 1C-9 Decal Application . . . . . . . . . . . . . . . . . . . . . . . . 1C-26 Model 225 (4-Stroke) Powerhead Top View . . 1C-10 Decal Removal . . . . . . . . . . . . . . . . . . . . . . . 1C-26 Model 225 (4-Stroke) Powerhead Aft View . . . 1C-11 Instructions for “Wet” Application . . . . . . . 1C-26 90-888465 JUNE 2002 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. Tee Fitting P/N 22-73318. 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. XX e d c b a d-Year Manufactured e-Certified Europe Insignia 20xx OGXXXXXX XXXX a-Serial Number b-Model Year c-Model Description Page 1C-2 90-888465 JUNE 2002 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 25° C (77° F) 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, be- come too large. Consequently, the engine operates at less than its recommended rpm. 90-888465 JUNE 2002 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 90-888465 JUNE 2002 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. Damaged Piston Resulting from Detonation 90-888465 JUNE 2002 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 90-888465 JUNE 2002 GENERAL INFORMATION 90-888465 JUNE 2002 Page 1C-7 Model 225 (4-Stroke) Powerhead Front View b c a d e f g h i j d 59541 k a- Secondary Vapor Separator (SVS) b- Fuses (3-30 amp, 2-20 amp, 1-5 amp) c- ECM d- Throttle body assembly e- Power trim and tilt relay f - Starter relay g- Main relay h- Fuel filter i - Oil filter j - Starter k- Flywheel GENERAL INFORMATION Page 1C-8 90-888465 JUNE 2002 Model 225 (4-Stroke) Powerhead Starboard View b e g f h c a d i 00103 a- Breather b- Idle air control (IAC) hose c- Throttle position sensor (TPS) d- Oil fill e- Air intake f - Oil filter g- Battery cable terminals h- Oil dipstick i - Throttle body (3) GENERAL INFORMATION 90-888465 JUNE 2002 Page 1C-9 Model 225 (4-Stroke) Powerhead Port View d f a c b e g h 00104 a- Fuse - 30 amp (3) b- Fuse - 5 amp (1) c- Fuse - 20 amp (2) d- Manifold absolute pressure sensor (MAP) e- Idle air control (IAC) f - Throttle body (3) g- Low pressure fuel pump h- Vapor separator tank (VST) GENERAL INFORMATION Page 1C-10 90-888465 JUNE 2002 Model 225 (4-Stroke) Powerhead Top View a b c a d e f 00076 g h a- Camshaft gear (2) b- Timing belt c- IAC air inlet hose d- Idle air control (IAC) hose e- High pressure fuel hose f - Secondary vapor separator (SVS) g- Flywheel h- Breather hose GENERAL INFORMATION 90-888465 JUNE 2002 Page 1C-11 Model 225 (4-Stroke) Powerhead Aft View a b c f e g h i d 59452 a- Ignition coil cylinders #1 & #4 b- Ignition coil cylinders #3 & #6 c- Ignition coil cylinders #2 & #5 d- Cylinder #1 e- Cylinder #3 f - Cylinder #5 g- Cylinder #2 h- Cylinder #4 i - Cylinder #6 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 90-888465 JUNE 2002 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 cotter pin and pull it out using a pair of pliers. 4. Place a block of wood between gear case and propeller to hold propeller and remove propeller nut. 90-888465 JUNE 2002 Page 1C-13 GENERAL INFORMATION 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. 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. 6. Coat the propeller shaft with Anti-Corrosion Grease or 2-4-C with Teflon. 95 2-4-C with Teflon 95 7. Install the components as shown below. Tighten nut to specified torque. 8. Align the propeller nut with the propeller shaft hole. Insert a new cotter pin in the hole and bend the cotter pin ends. NOTE: If the propeller nut does not align with the propeller shaft hole after tightening to the specified torque, then tighten the nut further to align it with the hole. 9. Reinstall spark plug leads. a c d e f g b a-Forward thrust hub b-Replaceable drive sleeve c-Propeller e-Washer f -Propeller nut g-Cotter pin d-Rear thrust hub Propeller Nut Torque 75 Nm (55 lb-ft) Page 1C-14 90-888465 JUNE 2002 GENERAL INFORMATION 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. 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. 90-888465 JUNE 2002 Page 1C-15 GENERAL INFORMATION 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, 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. 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. Page 1C-16 90-888465 JUNE 2002 GENERAL INFORMATION 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 90-888465 JUNE 2002 Page 1C-17 GENERAL INFORMATION Page 1C-18 90-888465 JUNE 2002 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 Section 4A - Valve Clearance Adjustment), adjust if out of specification. 2. Warm up the engine. Remove all spark plugs. 3. 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) GENERAL INFORMATION 4. Hold throttle plate at W.O.T. 5. Crank the engine over until the compression reading peaks on the gauge. Record the reading. 6. 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 879 kPa might indicate a total engine wear problem. Compression Pressure (Minimum) 880 Kpa (125 psi) Example of compression test differences: Maximum (kPa) Minimum (kPa) 1241 (180psi) 1117 (162) 1034 (150) 879 (127.5) 7. Remove compression gauge. 8. 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. 90-888465 JUNE 2002 Page 1C-19 GENERAL INFORMATION 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. 1. Remove flywheel cover and ignition coil cover. 2. Disconnect the ignition coil wire terminals and spark plug caps. Remove the spark plugs. c a b a-Flywheel cover and ignition coil cover b-Ignition coil wire terminals (6) c-Spark plug caps (6) CAUTION Do NOT rotate the flywheel counterclockwise. 3. Turn the flywheel clockwise and align the “1TDC” mark on the flywheel with the pointer. Check that “I” marks on the driven sprockets are aligned with cylinder head timing marks. 4. Measure and record the cylinder leakage for cylinder #4. 5. Turn the flywheel an additional 120° clockwise and align the “2TDC” mark on the flywheel with the pointer. 6. Measure and record the cylinder leakage for cylinder #5. 7. Turn the flywheel an additional 120° clockwise and align the “3TDC” mark on the flywheel with the pointer. 8. Measure and record the cylinder leakage for cylinder #6. 9. Similarly, check the cylinder leakage of cylinders #1, #2 and #3 in order. Be sure to rotate the flywheel 120° clockwise each time. Page 1C-20 90-888465 JUNE 2002 GENERAL INFORMATION a b c c c d P/N MT324 d d a-“1TDC” timing mark b-Timing pointer c-Driven sprocket timing marks d-Cylinder head timing marks S69J5120 a c b d a-“1TDC” timing mark c-“3TDC” timing mark TDC for Cylinder #1 & 4 TDC for Cylinder #3 & 6 b-“2TDC” timing mark d-Timing pointer TDC for Cylinder #2 & 5 NOTE: Spark plug hole is a 14 mm diameter. Use Snap-On Tool MT26J300 adapter with valve core removed. 90-888465 JUNE 2002 Page 1C-21 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 through the intake manifold, 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-22 90-888465 JUNE 2002 GENERAL INFORMATION 90-888465 JUNE 2002 Page 1C-23 Water Pressure Measurement 1. Locate water line on port side of engine. Install a short hose section and tee fitting, P/N 22-73318, in-line with the tee fitting used for the dashboard water pressure gauge. Secure hose ends with tie straps. 2. Attach water pressure gauge hose to the tee fitting. 3. Warm up engine until thermostat opens. NOTE: Water pressure measurements should be done on a warm engine with thermostat operating 60°C (140°F). rpm x 1000 Pump Pressure, kPa (psi) Water Pump Pressure 22-73318 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 0 1 2 3 4 5 6 91-79250A2 a c b 00105 (2.9) (5.8) (8.7) (11.6) (14.5) (17.4) (20.3) e d (psi) kPa a- Water pressure gauge P/N 91-79250A2 b- Water line c- Tee fitting P/N 22-73318 d- Short hose section e- Dashboard water pressure gauge tee NOTE: Water pressure should be within 10% of chart pressure. GENERAL INFORMATION Painting Procedures Color Impregnated Top Cowls The Model Year 2002 3 Liter V-6 EFI, 2.5 Liter Optimax and 3 Liter Optimax top cowls are constructed of a new material in which the exterior color is impregnated to a depth of approximately 1.58 mm (1/16 in.). MAINTENANCE The cowl can be cleaned using a mild non-abrasive soap. The surface luster can be preserved by using a non-abrasive automotive polish (polish designed for clear coat finishes) and buffing with a terry cloth type towel. Abrasive type polishes or cleaners should not be used as they will damage the cowl finish. REPAIR Light scratches should be removed by using a non-abrasive automotive polish (polish de- signed for clear coat finishes) and buffing with a terry cloth type towel. Abrasive type polishes should not be used as they will damage the cowl finish. Medium scratches can be removed by using 600 to 1000 grit sandpaper. The surface luster can then be restored by using a non-abrasive automotive polish (polish designed for clear coat finishes) and buffing with a terry cloth type towel. Abrasive type polishes should not be used as they will damage the cowl finish. For deep scratches or for those that penetrate through the exterior finish, automotive body filler can be used to fill the damaged area. 600 to 1000 grit sand paper should be used to smooth the surface area. It is then recommended that the entire cowl then be painted, to achieve an even luster, using normal Mercury Marine approved paint and 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. Page 1C-24 90-888465 JUNE 2002 GENERAL INFORMATION 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. CAUTION Be sure to comply with instructions on the label for ventilation and respirators. Us- ing 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. 90-888465 JUNE 2002 Page 1C-25 GENERAL INFORMATION 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 (automotive body filler squeegee) 2. Stick pin 3. Dish washing liquid detergent without ammonia. Do NOT use a soap that contains petroleum based solvents. 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 sunlight. Air and surface temperature should be between 60°F (15°C) and 100°F (38°C) for best application. Page 1C-26 90-888465 JUNE 2002 GENERAL INFORMATION 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. 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). 90-888465 JUNE 2002 Page 1C-27 OUTBOARD MOTOR INSTALLATION IMPORTANT INFORMATION Section 1D - Outboard Motor Installation Table of Contents Electric Fuel Pump . . . . . . . . . . . . . . . . . . . . . . 1D-1 Installing Outboard . . . . . . . . . . . . . . . . . . . . . . 1D-6 Boat Horsepower Capacity . . . . . . . . . . . . . . . 1D-1 Front Cable Clamp Assembly . . . . . . . . . . . . . 1D-7 Start in Gear Protection . . . . . . . . . . . . . . . . . . 1D-2 Remote Wiring Harness . . . . . . . . . . . . . . . . . . 1D-8 Warning Horn Requirement . . . . . . . . . . . . . . . 1D-2 Battery Cable Connections to the Engine . . . 1D-9 Selecting Accessories For The Outboard . . . 1D-2 Battery Cable Connections to the Battery . . . 1D-10 Dual Engine Center Line Dimension . . . . . . . 1D-2 Fuel Hose Connection . . . . . . . . . . . . . . . . . . . 1D-11 Lifting Outboard . . . . . . . . . . . . . . . . . . . . . . . . . 1D-3 Shift Cable Installation . . . . . . . . . . . . . . . . . . . 1D-12 Steering Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-3 Throttle Cable Installation . . . . . . . . . . . . . . . . 1D-14 Steering Cable Seal . . . . . . . . . . . . . . . . . . . . . 1D-4 Propeller Installation . . . . . . . . . . . . . . . . . . . . . 1D-15 Steering Link Rod . . . . . . . . . . . . . . . . . . . . . . . 1D-5 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . 1D-16 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 1 D 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 de- signed 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. 90-888465 JUNE 2002 Page 1D-1 MAINTENANCE 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. Warning Horn Requirement 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. 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. Dual Engine Center Line Dimension a b c d a-28.5 in. (724 mm) b-12.5 in. (317 mm) c-17.8 in. (453 mm) d-32 Degree Page 1D-2 90-888465 JUNE 2002 OUTBOARD MOTOR INSTALLATION 90-888465 JUNE 2002 Page 1D-3 Lifting Outboard Use 3 point strap 91-883705T. a a - 3 point lift strap 91-883705T Steering Cable STARBOARD SIDE ROUTED CABLE 1. Lubricate entire cable end. a a - 2-4-C Marine Lubricant with Teflon MAINTENANCE 2. Insert steering cable into tilt tube. 3. Torque nut to 47.5 Nm (35 lb. ft). Steering Cable Seal Install O-ring seal and cap. a-O-ring Seal b-Cap ba Page 1D-4 90-888465 JUNE 2002 OUTBOARD MOTOR INSTALLATION Steering Link Rod 1. Install steering link rod to rear hole on steering arm per illustration. a c d b f g e a-Special Bolt (10-856680) Torque to 27.1 Nm (20 lb. ft) b-Nylon Insert Locknut (11-34932) Torque to 27.1 Nm (20 lb. ft) c-Flat Washer d-Nylon Insert Locknut (11-826709113) Tighten Locknut Until it Seats, Then Back Nut Off 1/4 Turn e-Flat Washer (2) f-Install Steering Link Rod into Rear Hole g-Steering Link Rod IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt (“a” – Part Number 10-856680) and self locking nylon insert locknut (“d” - Part Number 11-826709113) and self locking nylon insert locknut (“b” – Part Number 11-34932). 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. 90-888465 JUNE 2002 Page 1D-5 MAINTENANCE Installing Outboard 1. Use transom drilling fixture (91-98234A2) or attach (tape) engine mounting template (located in the installation manual) to boat transom. 2. Mark and drill four 17/32 in. (13.5mm) mounting holes. 3. Install the outboard so that the anti-ventilation plate is in-line with the bottom of the boat. a a-Anti-Ventilation Plate 4. Fasten outboard with provided mounting hardware shown. c a b d e a-1/2 in. Diameter Bolts (4) b-Flat Washers(4) c-Locknuts (4) d-Flat Washers(4) e-Marine Sealer - Apply to Shanks of Bolts, Not Threads Page 1D-6 90-888465 JUNE 2002 OUTBOARD MOTOR INSTALLATION Front Cable Clamp Assembly IMPORTANT: Sufficient slack must exist in engine wiring harness, battery cables, and fuel hose routed between cable clamp and engine attachment point, to relieve stress. 1. Bundle the fuel line, battery cables and wiring together and wrap with the piece of foam (provided) as shown. Secure the wiring, battery cables, fuel line and foam together with sta-straps. 2. Push the flap down over the top of the shift and throttle cable. 3. Lay the wrapped foam over the top of flap. a b c d a-Shift and throttle cables b-Flap - Position over the shift and throttle cables c-Foam d-Sta-Straps 90-888465 JUNE 2002 Page 1D-7 MAINTENANCE Page 1D-8 90-888465 JUNE 2002 4. Install the top half of the cable clamp and reinstall the cowl bracket. 5. Slide the rigging tube onto the cable clamp and fasten with collar and hose clamp. a b c d e a -Top Half Cable Clamp b -Cowl Bracket c -Rigging Tube d -Collar e -Hose Clamp Remote Wiring Harness Route wiring harness through the front cable clamp. Connect wiring. Push the retainer over the ends of the connectors. This will hold the connectors together. Secure connection in the cowl with the releasable cable tie. a BLU/WHT GRN/WHT BRN/WHT TAN BLU/WHT GRN/WHT b c a - Power trim connectors b - Retainer – Push Over Connector Ends c - Releasable Cable Tie OUTBOARD MOTOR INSTALLATION OUTBOARD MOTOR INSTALLATION Battery Cable Connections to the Engine Route battery cables through the front cable clamp. Connect the battery cables to the terminals on the engine as shown. NOTE: Bolts for fastening the battery cables terminals are located in the same packaging kit that contains the front cable clamp. (+) (–)a (+) (–) c b d a-Battery Cable – Red Sleeve (Positive) b-Battery Cable – Black Sleeve (Negative) c-Screw M6 x 13 (10–821300 12) – Torque to 8 Nm (71 lb in.) d-Screw M8 x 20 (10–818934 20) – Torque to 18 Nm (159 lb in.) 90-888465 JUNE 2002 Page 1D-9 MAINTENANCE Page 1D-10 90-888465 JUNE 2002 Battery Cable Connections to the Battery 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 Connection 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 8mm (5/16 in.), with separate fuel line/fuel tank pickup for each engine. FUEL HOSE CONNECTION Route fuel hose through the front cable clamp. Fasten fuel hose to fitting with hose clamp. b a a-Fuel Hose b-Hose Clamp 90-888465 JUNE 2002 Page 1D-11 MAINTENANCE 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. N 1. Position remote control into neutral. 2. Shift outboard into neutral. 3. Align the shift pin with the center mark. R NF a b a-Shift Pin b-Center Mark Page 1D-12 90-888465 JUNE 2002 OUTBOARD MOTOR INSTALLATION 4. Place shift cable on the shift pin. Adjust cable barrel so it slips freely into the barrel holder. 5. Fasten cable to the shift pin with hairpin cotter. c d c-Cable Barrel d-Hair Pin Cotter 6. 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. 90-888465 JUNE 2002 Page 1D-13 MAINTENANCE 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 until the alignment mark on the cam lines up with center of the roller. 4. Place cable barrel into retainer. 5. Lock the cable barrels in place with the cable latch. c a b d e f a-Throttle Cable b-Hairpin Cotter c-Cable Barrel d-Throttle Cam e-Alignment Mark f-Cable Latch Page 1D-14 90-888465 JUNE 2002 OUTBOARD MOTOR INSTALLATION Propeller Installation 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. Flo-Torq I Drive Hub Propellers b a c d ef g a-Forward Thrust Hub b-Replaceable Drive Sleeve c-Propeller d-Rear Thrust Hub e-Washer f-Propeller Nut- Torque To 54 Nm (40 lb- ft) g-Cotter Pin – Bend the cotter pin ends. NOTE: If the propeller nut does not align with the propeller shaft after tightening to the specified torque, then tighten the nut further to align it with the hole. 90-888465 JUNE 2002 Page 1D-15 MAINTENANCE 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 50mm (2 in.) or more above the boat bottom. Page 1D-16 90-888465 JUNE 2002 IGNITION ELECTRICAL Section 2A - Ignition Table of Contents 2 A Table of Contents . . . . . . . . . . . . . . . . . . . . . . . 2A-1 Ignition Coil (Primary) . . . . . . . . . . . . . . . . . 2A-28 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2 Ignition Coil (Secondary) . . . . . . . . . . . . . . 2A-28 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-3 Ignition Spark Gap . . . . . . . . . . . . . . . . . . . . 2A-28 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-6 Engine Temperature Sensor . . . . . . . . . . . 2A-29 Electrical Components . . . . . . . . . . . . . . . . . . . 2A-8 Temperature Switch . . . . . . . . . . . . . . . . . . 2A-29 Ignition Components . . . . . . . . . . . . . . . . . . . . . 2A-10 Air Temperature Sensor . . . . . . . . . . . . . . . 2A-30 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-12 Shift Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-30 Theory of Operation . . . . . . . . . . . . . . . . . . . . . 2A-14 Neutral Switch . . . . . . . . . . . . . . . . . . . . . . . 2A-30 Ignition Component Description . . . . . . . . . . . 2A-15 Oil Pressure Switch . . . . . . . . . . . . . . . . . . . 2A-31 Electronic Control Module (ECM) . . . . . . . 2A-15 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-32 Ignition Timing Control During Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-32 Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-15 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-33 Normal Operation . . . . . . . . . . . . . . . . . . . . 2A-15 Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-34 Protection Controls . . . . . . . . . . . . . . . . . . . . . . 2A-15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-34 Over-revolution Control . . . . . . . . . . . . . . . 2A-15 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-35 Overheating Control . . . . . . . . . . . . . . . . . . 2A-16 Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-36 Shift Cut Out Switch . . . . . . . . . . . . . . . . . . 2A-16 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-36 Neutral Switch . . . . . . . . . . . . . . . . . . . . . . . 2A-16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-37 Low Oil Pressure Protection . . . . . . . . . . . 2A-17 Crank Position Sensor (CPS) . . . . . . . . . . . . . 2A-38 Throttle Position Sensor (TPS) . . . . . . . . . 2A-18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-38 Engine Water Temperature Thermoswitch 2A-18 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-38 Engine Temperature Sender . . . . . . . . . . . 2A-18 Voltage Regulator/Rectifier . . . . . . . . . . . . . . . 2A-39 Flywheel Assembly . . . . . . . . . . . . . . . . . . . 2A-19 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-39 Stator Assembly . . . . . . . . . . . . . . . . . . . . . . 2A-19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-42 Crank Position Sensors (CPS) . . . . . . . . . 2A-19 ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-45 Ignition Coils . . . . . . . . . . . . . . . . . . . . . . . . . 2A-20 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-45 Ignition Test Procedures . . . . . . . . . . . . . . . . . . 2A-21 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-45 Direct Voltage Adapter (DVA) . . . . . . . . . . 2A-21 Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-46 Ignition Troubleshooting . . . . . . . . . . . . . . . . . . 2A-22 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-46 Tool: Multimeter/DVA Tester 91-99750A1 or DMT Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-46 2000 Multimeter with Direct Voltage Adaptor Port Thermoswitch . . . . . . . . . . . . . . . . . . . . . . 2A-47 (91-89045) . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-22 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-47 Ignition Diagnostic Procedures . . . . . . . . . . . . 2A-22 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-47 *Recommended Test . . . . . . . . . . . . . . . . . . 2A-23 Starboard Thermoswitch . . . . . . . . . . . . . . . . . 2A-48 Testing Ignition Components . . . . . . . . . . . . . . 2A-25 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-48 ECM Peak Voltage (Coil Primary) . . . . . . . 2A-25 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-49 Crank Position Sensor (CPS) -Engine Temperature Sensor . . . . . . . . . . . . . . 2A-50 Peak Voltage . . . . . . . . . . . . . . . . . . . . . . . . 2A-26 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-50 Throttle Position Sensor . . . . . . . . . . . . . . . 2A-27 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-50 90-888465 JUNE 2002 Page 2A-1 IGNITION Specifications Type Microcomputer-ECM Spark Plug: Type NGK LFR5A-11 Gap 1.0 - 1.1 mm (0.39 - .0.43) Hex Size 5/8 in. (16 mm) Torque 18 lb-ft (25 Nm) Hole Size 14 mm Firing Order 1-2-3-4-5-6 Ignition Timing: @ Idle (750 rpm) T.D.C @ WOT (5500 rpm) 24° B.T.D.C Stator Coil Output - Peak Voltage: . . GRN-GRN . . Unloaded @ 400 rpm (Cranking) 8 V minimum @ 1500 rpm 42 V minimum @ 3500 rpm 93 V minimum . . GRN/WHT-GRN/WHT . . Unloaded IGNITION SYSTEM Readings taken @ 68°F (20°C). @ 400 rpm (Cranking) @ 1500 rpm @ 3500 rpm Stator Coil Resistance Rx1 @ 20 C (68 F) 7 V minimum 34 V minimum 78 V minimum . . GRN-GRN 0.10-0.60 W . . GRN/WHT-GRN/WHT 0.10-0.50 W Crank Position Sensor - Peak Voltage: . . Unloaded @ 400 rpm (Cranking) 5.3 V . . Loaded @ 400 rpm (Cranking) 5.3 V @ 1500 rpm 20 V @ 3500 rpm 43 V Crank Position Sensor Resistance 459-561 W ECM (Coil Primary) - Peak Voltage: . . Loaded @ 400 rpm (Cranking) 160 V minimum @ 1500 rpm 260 V minimum @ 3500 rpm 260 V minimum Voltage Regulator Output (unloaded) . . @1500rpm 10.5 V minimum . . @3500rpm 10.5 V minimum Page 2A-2 90-888465 JUNE 2002 IGNITION Ignition Coil Resistance Primary Secondary (Between Boots) 1.5-2.5 W 19.6-35.4 kW Engine Temperature Sensor IGNITION SYSTEM Readings taken @ 68°F (20°C). . . Resistance @ 20 C (68 F). . @ 100 C (212 F). . Air Temperature Sensor Resistance @0 C (32 F). . @80 C (176 F). . Oil Pressure Sensor Output Voltage 54.2-69.2 kW 3.12-3.48 kW 5.4-6.6 kW 0.29-0.39 kW 3.8 V @700rpm Throttle Position Sensor Output Voltage 3.8 V Thermoswitch Continuity . . On . . Off (Reset) 84-90 °C (183-194 F) 68-82 °C (154-179 F) Special Tools 1. Flywheel Holder P/N 91-83163M 2. Flywheel Puller P/N 91-83164M 3. Timing Light P/N 91-99379 90-888465 JUNE 2002 Page 2A-3 IGNITION 4. Direct Voltage Adapter P/N 91-89045 or P/N 91-89045--1 91-89045-1 91-89045 5. Spark Board P/N 91-850439T 6. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1 7. Crank Position Sensor Test Harness 91-888863 00070 8. Stator Coil Test Harness 91-804772 00072 Page 2A-4 90-888465 JUNE 2002 IGNITION 9. Throttle Position Sensor Test Harness 91-881827 58678 10. ECM (Coil Primary) Test Harness 91-881826 58679 11. Oil pressure test harness 91-888860 00071 12. Rectifier regulator test harness 91-888862 00073 90-888465 JUNE 2002 Page 2A-5 IGNITION Flywheel 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Page 2A-6 90-888465 JUNE 2002 IGNITION Flywheel REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 FLYWHEEL COVER 2 3 SCREW (M6 X 28) 71 8 3 3 GROMMET 4 3 BUSHING 5 1 NUT 177 240 6 1 WASHER 7 2 GROMME 8 1 FLYWHEEL 9 4 SCREW (M6 X 35) 71 8 10 4 LOCKWASHER 11 4 WASHER 12 1 STATOR 13 4 SCREW (M6 X 30) 71 8 14 1 TRIGGER 15 AR STA-STRAP 16 2 DOWEL PIN 17 1 ROTOR 18 1 SCREW 19 1 WASHER 20 1 TIMING PLATE 21 1 PLATE 22 1 SCREW (M6 X16) 71 8 90-888465 JUNE 2002 Page 2A-7 IGNITION Electrical Components 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1516 17 18 19 20 21 2223 24 25 26 27 28 29 30 31 32 3334 3536 37 38 39 40 41 4243 44 Page 2A-8 90-888465 JUNE 2002 IGNITION Electrical Components REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 COVER 2 4 WASHER 3 4 SCREW (M6 X 16) 71 8 4 2 SCREW (M8 X 20) 159 18 5 1 SCREW (M6 X 14) 71 8 6 1 BRACKET 7 1 WASHER 8 1 WASHER 9 1 TERMINAL 10 1 BATTERY CABLE 11 1 WASHER 12 1 SCREW (M6 X 14) 71 8 13 1 COVER 14 4 SCREW 15 2 CLAMP 16 1 RELAY 17 2 WASHER 18 2 LOCKWASHER 19 2 NUT 35 4 20 2 SCREW (M6 X 25) 71 8 21 2 WASHER 22 1 SCREW 23 1 RELAY 24 6 SCREW (M6 X 28) 71 8 25 1 CLAMP 26 1 SCREW 27 2 WASHER 28 2 LOCKWASHER 29 2 SCREW (M6 X 12) 35 4 30 1 BOOT 31 2 FUSE 32 1 ENGINE WIRE HARNESS 33 3 SCREW (M6 X 35) 71 8 34 3 WASHER 35 1 RELAY 36 AR STA-STRAP 37 6 GROMMET 38 6 BUSHING 39 1 WIRE HARNESS 40 2 WASHER 41 2 LOCKWASHER 42 2 SCREW (M6 X 10) 35 4 43 1 TRIM SENDER ADAPTOR HARNESS 44 1 REMOTE ADAPTOR HARNESS 90-888465 JUNE 2002 Page 2A-9 IGNITION Ignition Components 15 1 2 3 4 56 7 89 10 11 12 13 14 10 10 11 11 Page 2A-10 90-888465 JUNE 2002 IGNITION Ignition Components REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 ENGINE CONTROL UNIT 2 1 GROMMET 3 6 SCREW (M6 X 20) 71 8 4 2 SCREW (M6 X 12) 35 4 5 2 WASHER 6 1 GROUND WIRE 7 3 IGNITION COIL 8 6 SCREW (M6 X 20) 71 8 9 6 WASHER 10 3 CLAMP 11 3 CLAMP 12 1 COVER 13 2 GROMMET 14 4 SCREW (M6 X 14) 35 4 15 1 WASHER 16 1 THERMOSENSOR 133 15 90-888465 JUNE 2002 Page 2A-11 IGNITION Sensors 1 2 3 4 8 9 10 11 12 13 5 6 7 14 15 16 17 18 12 11 10 Page 2A-12 90-888465 JUNE 2002 IGNITION Sensors REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 THROTTLE POSITION SENSOR (TPS) 2 1 O-RING 3 1 SPACER PLATE 4 1 STARBOARD THROTTLE BODIES 5 1 IDLE AIR CONTROL (IAC) 6 1 O-RING 7 1 MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP) 8 1 HOUSING 9 1 IAC HOSE 10 2 WATER TEMPERATURE SENSOR 11 2 THERMOSTAT HOUSING 12 2 THERMOSTAT 13 1 OIL PRESSURE SENSOR 160 18 14 1 BLOCK TEMPERATURE SENSOR 133 15 15 1 WASHER 16 1 PORT INTAKE ASSEMBLY 17 1 PORT INTAKE SILENCER 18 1 AIR TEMPERATURE SENSOR 35 4 90-888465 JUNE 2002 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. When the ignition key is turned to the RUN position, battery voltage is applied to the main power relay. When the ECM receives a signal form the CPS (Crank Position Sensor) the main power relay ground is completed through the ECM. The main power relay is then closed and battery voltage is transferred to the coils, and fuel injectors. The coils and fuel injectors are protected by a 20 amperage fuse. The negative terminal of the coil primary is connected to the engine ground through the ECM. When this circuit is closed a magnetic field is allowed to be built up in the ignition coil. The CPS sends a signal to the ECM supplying information on the engine position (degrees of rotation) and the rpm of the engine. The ECM opens the ground circuit of the coil primary. The magnetic field of the ignition coil primary collapses causing high voltage charge in the secondary winding of the coil. This high voltage charge is then sent to the spark plug. Page 2A-14 90-888465 JUNE 2002 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 TDC. The ignition timing is normally controlled between TDC and 24° BTDC. At rapid acceleration or deceleration ignition timing changes according to the throttle valve opening angle. Normal Operation This mode operates between TDC and 24° 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. Three 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. Protection Controls This ignition system incorporates four protection controls that are described below. Over-revolution Control If the engine speed exceeds 4,500 rpm in neutral, either cylinder #1 or #4 will misfire. If the engine speed exceeds 4,750 in neutral, the ignition is cut. If the engine speed in gear exceeds 6,200 rpm, cylinders #1 or #4 will misfire. If the engine speed exceeds 6,350 rpm, cylinder #1 and #4, #2 and #5 will misfire. If the engine speed exceeds 6,450 rpm, the ignition on all cylinders is cut. 90-888465 JUNE 2002 Page 2A-15 IGNITION Overheating Control When the engine speed is less than 2,000 rpm, this control mode is delayed 75 seconds. When the engine speed is 2,000 rpm or more, this control mode is delayed 25 seconds. The engine is considered to be over-heating if its temperature reaches 120 °C (248 °F) or higher. When the ECM has entered the overheat control mode, and the delay time has elapsed, the ECM causes cylinder pair #2 and #5, #3 and #6 to misfire, and will not operate the fuel injector to the misfiring cylinders, until the engine speed has decreased to 2000 rpm or less. At this time the warning indicator will illuminate and the warning horn will sound. The control will not deactivate until the ignition key is turned to the OFF position Shift Cut Out Switch When the shift cut out switch is activated with the engine speed under 2000 rpm, one or two cylinders will misfire in order to facilitate shifting. The ECM causes cylinder #1 and #2 or #4 and #5 to misfire when the engine speed is over 850 rpm. Cylinder #1 or #4 will misfire when the engine speed is below 850 rpm. Neutral Switch The neutral switch provides out of gear over-revolution protection as described in the overrevolution control. a b c e d a-Bracket b-Shift slide c-Neutral switch d-Shift cut out switch e-Bracket Page 2A-16 90-888465 JUNE 2002 IGNITION Low Oil Pressure Protection The low oil pressure warning activation varies in accordance with the engine speed. When the value detected by the oil pressure sensor drops below the specified value on the graph, the ECM determines a drop in oil pressure has occurred and activates the oil pressure control. When the oil pressure control mode is activated, the oil warning light is illuminated and the warning horn sounds. This warning mode will not be deactivated until the ignition switch is turned to the OFF position. When the system enters low oil pressure protection, the engine will not exceed 2000 rpm. If operating above 2000 rpm, the ECM causes cylinder pairs #2 and #5, #3 and #6 to misfire until the engine speed decreases to 2000 rpm and will continue to misfire until the oil pressure has exceeded the specified value. The ECM will not open the fuel injectors to the specified cylinder pairs when the oil pressure is lower than the specified value (see graph below). 7.0 14.5 22.0 29.0 36.0 43.5 51.0 58.0 Oil pressure specified values (psi) 0.0 600700800100015002000 2500300035004000450050005500 RPM Specified value (PSI) 90-888465 JUNE 2002 Page 2A-17 IGNITION Throttle Position Sensor (TPS) If the TPS is faulty, the ignition timing will automatically be fixed at 10° BTDC, corrections are made to the basic injection map, the IAC opening angle is fixed to 60 % and idle speed in neutral increases to 900 rpm. a b a-Throttle Position Sensor b-Starboard throttle body Engine Water Temperature Thermoswitch If the water temperature sensor is faulty, the ECU will adjust to read 40 °C (104 °F). This will activate normal fuel injection control and the idle speed increases. Engine Temperature Sender If the engine temperature sender fails, the engine will idle at 900 rpm in neutral and the overheating control will activate. a b c a b a-Thermostat b-Engine water thermoswitch c-Engine temperature sender Page 2A-18 90-888465 JUNE 2002 IGNITION 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. Stator Assembly The stator assembly, located under the flywheel, contains coil windings which provides three-phase AC voltage to the voltage regulator. 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) As the crankshaft rotates, the CPS’s (3) 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. 90-888465 JUNE 2002 Page 2A-19 IGNITION Page 2A-20 90-888465 JUNE 2002 Ignition Coils 59452 a a - Ignition Coils The primary (+) side of the ignition coil receives battery voltage from the main power relay. When the ECM receives a signal from the CPS, the main power relay ground circuit is completed through the ECM. The main power relay transfers battery voltage to 3 coils. The negative side of the coil is connected to the engine ground through the ECM. When this circuit is closed, a magnetic field is allowed to be built up in the ignition coils. When the ECM is supplied with a trigger signal, the ECM opens the circuit and the magnetic field collapses across the coil secondary winding creating a high voltage charge that is sent to the spark plugs. 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. 90-888465 JUNE 2002 Page 2A-21 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. 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-22 90-888465 JUNE 2002 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) (ECM) Stop Circuit Short to Ground: 1-3 a - stop circuit lead 3 b - lanyard stop switch 2 c - remote control harness 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 - (ECM) Primary Coil Supply Leads High Resistance To Ground, Corroded 1-2 a - stop/lanyard switch (water/corrosion) 3 Ignition Coil/High Tension Lead(s) 2 Spark Plug(s) 1-2-3 Spark Plug Cap (Resistor) 2-3 Spark Plug Cap Leak 2 (ECM) Failure 1-3 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/Shift Interrupt Switch: 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/Failed TPS: a - timing retards and fluctuates, rpm will remain below 2000 rpm (ECM) 1-2-3-4 3 90-888465 JUNE 2002 Page 2A-23 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 4 Ignition Coil/High Tension Lead(s) 2 Spark Plug Cap(s) 2 Spark Plug(s) 3 (ECM) Ground Connection: 3 a - (ECM) 3 Incorrect Fuel Pressure 4 Engine Hard To Start Cold Debris In Fuel Injection Circuit 4 Weak Spark Condition 1 Throttle Plate in Open Position 4 Low Fuel Pressure 4 Engine Hard To Start Hot Weak Spark Condition 4 Vapor Lock 4 Debris In Fuel Injectors 4 Incorrect Fuel Pressure 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 b - (ECM) High Resistance To Ground at: 3 a - stop/lanyard switch (water/corrosion) 3 (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-24 90-888465 JUNE 2002 IGNITION Testing Ignition Components ECM Peak Voltage (Coil Primary) 1. Disconnect the high pressure fuel pump harness connector 2. Remove the ignition coil cover and disconnect the ignition coil wire harness. Plug test harness between each coil harness (test both coils), and perform tests as specified in chart below. If the reading obtained is below specification, measure the trigger peak voltage. Replace the ECM if the output peak voltage on the trigger is above specification. b a 91-881826 91-89045-1 c 91-854009A1 a-Direct Voltage Adaptor (91-89045-1) b-DMT 2000 Multi-meter (91-854009A1) c-Ignition Coil Test Harness (91-881826) 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 DC VOLTS DVA LOADED KEY ON ENGINE NOT RUNNINGKEY ON ENGINE NOT RUNNING 12 V 160-252 V @ 400 RPM (CRANKING*)( ) 260 V @ 1500 RPM 260 V @ 3500 RPM TEST HARNESS LEADS BLK/WHT GROUND *Cranking specifications obtained with high tension spark plug leads removed from spark plugs. 90-888465 JUNE 2002 Page 2A-25 IGNITION 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 c 91-854009A1 90-888863 00070 a-Direct Voltage Adaptor (91-89045-1) b-DMT 2000 Multi-meter (91-854009A1) c-CPS Test Harness (91-888863) 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 DC VOLTS UNLOADED 3 8 5 3 V @ 400 RPM (CRANKING*) 3.8-5.3 V @ 400 RPM (CRANKING*) LOADEDLOADED 3.8-5.3 V @ 400 RPM (CRANKING*)( ) 20-27 V @ 1500 RPM 43 70 V @ 3500 RPM 43-70 V @ 3500 RPM TEST HARNESS LEADSRED BLU BLK/RED BLU BRN BLU *Cranking specifications obtained with high tension spark plug leads removed from spark plugs. Page 2A-26 90-888465 JUNE 2002 IGNITION Throttle Position Sensor NOTE: The Throttle Position Sensor and throttle shaft are pre-set at the 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. See section 2C for proper adjustment of the TPI. 1. Plug in the test harness and perform test as specified in chart below. Measure the TPI input voltage. Replace the ECM if out of specification. Measure the TPI output voltage. If out of specification, refer to section 2C for proper adjustment. 91-881827 91-854009A1 METER TEST LEADS METER SCALE READING (V) RED BLACK DC VOLTSDC VOLTS INPUT VOLTAGE ORN BLKORN- -- BLK 5 V OUTPUT VOLTAGE (IDLE)OUTPUT VOLTAGE (IDLE) PNK PNKPNK - -- BLK BLKBLK 695 - 705 mV TEST HARNESS LEADS BLK ORN PNK ORN 90-888465 JUNE 2002 Page 2A-27 IGNITION Ignition Coil (Primary) 1. Disconnect coil wire primary harness connector. Measure the ignition coil primary winding as specified in the chart below Out of specification – replace. METER TEST LEADS METER SCALE READING () RED BLACK RX1 1.5 - 1.9  @ 20 C (68 F) 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 19 6 35 k @20 C (68 F)19.6 - 35 k @ 20 C (68 F)HIGH 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. Page 2A-28 90-888465 JUNE 2002 IGNITION Engine Temperature Sensor 1. Place the engine engine 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. METER SCALE READING TEMPERATURE RX1k 54.2-69.0k. 20C (68F) 3.12-3.48k. 100C (212F) Temperature Switch 1. Place the temperature switch in a container filled with water. 2. Place a thermometer in the water and slowly heat the water. 3. Measure for continuity between the pink and black wire. Out of specification - replace. METER SCALE CONTINUITY TEMPERATURE RX1 NO CONTINUITY CONTINUITY NO CONTINUITY BELOW 84C (183F) 84C + (183F +)C( ) RESET 68-82C (154-179F) 90-888465 JUNE 2002 Page 2A-29 IGNITION Air Temperature Sensor 1. Place the air 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 METER SCALE READING () RX1K 5.4-6.6k @0C (32F) 0.29-0.39 k @80C (175F) Shift Switch 1. Measure for continuity between the BLU/YEL and BLK wires. METER SCALE CONTINUITY ARM POSITION RX1 YES FREE NO PUSHED Neutral Switch 1. Measure for continuity between the BRN and BLK wires. METER SCALE CONTINUITY ARM POSITION RX1 NO FREE YES PUSHED Page 2A-30 90-888465 JUNE 2002 IGNITION Oil Pressure Switch 1. Connect test harness to the oil pressure sensor. 2. Start the engine and warm up for 5 minutes. 3. Measure the oil pressure sensor input voltage. If out of specification, check the harness for corrosion or replace the ECM. 4. Measure the oil pressure sensor output voltage (for reference only). Replace if out of specification or if oil pressure is above 92.4 psi. 00071 91-888860 Oil pressure specified values (kPa) (psi) 350.0 51.0 300.0 43.5 250.0 36.0 200.0 29.0 150.0 22.0 100.0 14.5 50.0 7.0 0.0 6007008001000150020002500300035004000450050005500 RPM Specified value (PSI) METER TEST LEADS METER SCALE READING () RED BLACK VOLTS @ IDLE VOLTS @ IDLE (700 RPM ) INPUT VOLTAGE INPUT VOLTAGE 5V OUTPUT VOLTAGE OUTPUT VOLTAGE (REFERENCE ONLY) 3.8V GRN BLK GRN/WHT BLK 90-888465 JUNE 2002 Page 2A-31 IGNITION Flywheel 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. 59440 a a-Screws (3) 2. Hold flywheel using flywheel holder (91-83163M). Loosen flywheel nut. 3. Remove nut and washer. 4. Remove flywheel with flywheel puller a b a-Flywheel Holder (91-83163M) b-Flywheel remover (91-83164M) IMPORTANT: Clean flywheel/crankshaft taper with solvent and assemble dry. Page 2A-32 90-888465 JUNE 2002 IGNITION Installation 1. Place flywheel key into slot. b a a-Key slot b-Woodruff key 2. Install flywheel. 3. Lubricate nut and washer. 4. Install washer and nut. 5. Hold flywheel using flywheel holder (91-83163M) and tighten nut to the specified torque. a b a-Flywheel holder (91–83163M) b-Torque wrench CAUTION Apply force in the direction of the arrows shown to prevent the flywheel holder from slipping. Flywheel Nut Torque 240 Nm (177 lb-ft) 90-888465 JUNE 2002 Page 2A-33 IGNITION Page 2A-34 90-888465 JUNE 2002 Stator Removal 1. Remove flywheel. Refer to Flywheel Removal. 2. Cut sta-straps holding the stator wire harness to the oil filler neck and support bracket. 3. Disconnect stator connector from rectifier/regulator. a 59449 b a - Stator harness connector b - Oil filler neck 4. Remove stator mounting screws (4). a b a - Stator b - Stator Mounting Screws IGNITION 90-888465 JUNE 2002 Page 2A-35 Installation 1. Guide the stator wire harness under the breather hose and behind the starter. 59441 a b c d e a - Breather hose b - Oil filler neck c - Starter d - Stator harness e - Support Bracket 2. Install the stator mounting screws (4). Tighten to specified torque. 3. Connect the stator connector to the voltage regulator connector. 4. Sta-strap the stator wire harness to the oil filler neck and to the support bracket. 5. Install flywheel. Refer to Flywheel Installation. a b 59449 c d e a - Stator b - Stator mounting screw (M6 x 30) c - Oil filler neck d - Stator wire harness e - Stator harness connector. Stator Mounting Screw Torque 8 Nm (71 lb in.) IGNITION Timing Belt Removal 1. Check that the “I” timing marks on the driven sprockets are aligned with the timing marks on the cylinder head, and that the “_” mark on the plate is aligned with the “_” mark on the cylinder block. Align if necessary. 2. Remove the flywheel, stator and trigger. c d a b a b a-Driven sprocket timing mark b-Cylinder head timing mark c-“_” mark on plate d-“_” mark on cylinder block WARNING Do NOT rotate the drive sprocket counterclockwise. 3. Using a hexagon wrench, turn the timing belt tensioner clockwise to release timing belt tension. Increase the force gradually and then insert a 5 mm diameter (0.200 in.) pin into the hole. 4. Remove the timing belt from the driven sprockets and crankshaft sprocket. b a d e c a-Belt tensioner b-Timing belt c-Hexagon wrench d-Pin e-Tensioner pin hole Page 2A-36 90-888465 JUNE 2002 IGNITION Installation 1. Install the timing belt from the drive sprocket side with its part number in the upright position. Turn the belt a half turn counterclockwise to align it and then remove the pin. CAUTION Do NOT twist, turn inside out or bend the timing belt beyond the maximum limit of 25 mm (1 in.), otherwise the belt may be damaged. Do NOT get oil or grease on the timing belt a a-Maximum limit of 25 mm (1 in.) a b a-Pin b-Timing belt 2. Rotate the drive sprocket clockwise 2 turns and check the alignment of the timing marks. 3. Install flywheel. Refer to Flywheel Installation. WARNING Do NOT rotate the drive sprocket counterclockwise. a a a a-Timing marks aligned 90-888465 JUNE 2002 Page 2A-37 IGNITION Page 2A-38 90-888465 JUNE 2002 Crank Position Sensor (CPS) Removal 1. Remove flywheel. Refer to Flywheel Removal. 2. Remove stator. Refer to Stator Removal. 3. Disconnect the CPS harness connector. 4. Remove the CPS mounting screws (4). NOTE: Do not loose the 2 collars under the trigger assembly. a b c d e a - CPS harness connector b - CPS mounting screw (4) c - Breather tube d - CPS assembly e - Collar (2) Installation 1. Install CPS assembly to powerhead. Tighten to specified torque. 2. Connect CPS wire harness connector to engine wire harness. 3. Install stator. Refer to Stator Installation. 4. Install flywheel. Refer to Flywheel Installation. CPS Mounting Screw Torque 8 Nm (71 lb in.) IGNITION 90-888465 JUNE 2002 Page 2A-39 Voltage Regulator/Rectifier Removal 1. Remove intake silencer. Refer to Intake Silencer Removal. 2. Disconnect the battery. 3. Disconnect engine harness. 4. Disconnect the starter power wire. 5. Disconnect the oil pressure sender harness. 6. Remove battery cable from the power terminal. 7. Remove power terminal mounting screw. 59441 a b 59459 c d a - Power terminal mounting screw b - Power terminal c - Oil pressure sender d - Starter power wire IGNITION Page 2A-40 90-888465 JUNE 2002 8. Disconnect the trim sender harness (PNK, BLU/WHT, PNK/WHT). 9. Disconnect trim harness. (BLU, RED, GRN) 10. Remove power trim relay cover screws (4). 11. Remove fuel filter bracket. 59456 59449 a b c d BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow LT = Light DRK = Dark a - Trim sender b - Trim harness c - Relay cover screws d - Fuel filter mounting screws 12. Remove ground screw. 13. Disconnect the stator harness connector from voltage regulator. 14. Disconnect the starter exciter wire (BRN/WHT). 15. Remove screws (6) holding bracket to power head. 59448 d d a b c a - Ground screw b - Stator harness connector c - Starter exciter wire d - Bracket screw IGNITION 16. Pull bracket out and lay on top of flywheel. 17. Remove the voltage regulator water hose. 18. Remove voltage regulator mounting screws (2). 19. Remove screws (4) holding the voltage regulator water jacket cover a b c d e f g a-Voltage regulator mounting screw b-Voltage regulator c-Gasket d-Voltage regulator water jacket cover e-Water jacket cover mounting screw f-Water hose g-Voltage regulator ground screw 90-888465 JUNE 2002 Page 2A-41 IGNITION Installation 1. Install gasket and voltage regulator water jacket cover on voltage regulator. Tighten screws to specified torque. 2. Install voltage regulator. Tighten screws to specified torque. 3. Install voltage regulator cooling lines. 4. Install bracket. Tighten screws to specified torque. ab c c a-Water jacket cover mounting screw (M6 X 25) b-Voltage regulator mounting screw (M6 X 35) c-Bracket mounting screw (M6 X 28) Water Jacket Cover Mounting Screw Torque 1st Torque: 6 Nm (53 lb in.) 2nd Torque: 12 Nm (106 lb in.) Voltage Regulator Mounting Screw Torque 1st Torque: 6 Nm (53 lb in.) 2nd Torque: 12 Nm (106 lb in.) Bracket Mounting Screw Torque 8 Nm (71 lb in.) Page 2A-42 90-888465 JUNE 2002 IGNITION 90-888465 JUNE 2002 Page 2A-43 5. Connect the starter exciter wire (BRN/WHT)to relay terminal. 6. Connect stator harness connector to the voltage regulator harness. 7. Install ground screw. NOTE: The ground screw holds 3 ring terminals. 8. Install fuel filter bracket. Tighten screws to specified torque. 9. Install power trim relay cover screws 59448 a b c 59449 d e a - Stator harness connector b - Ground screw (M6 X 20) c - Starter exciter wire d - Power trim relay cover screw e - Fuel filter bracket mounting screw (M6 X 19) Ground Screw Mounting Torque 8 Nm (71 lb in.) Fuel Filter Mounting Screw Torque 8 Nm (71 lb in.) IGNITION Page 2A-44 90-888465 JUNE 2002 10. Connect trim harness connector (BLU, RED, GRN). 11. Connect trim sender harness connector (PNK, BLU/WHT, PNK/WHT). 12. Install power terminal. Tighten to specified torque. 13. Install oil pressure sender harness. 14. Install power wire to starter. Tighten starter power wire mounting nut to specified torque. 15. Install battery cable to power terminal. 16. Connect engine harness 17. Install Intake silencer. Refer to Intake Silencer Installation. 59441 59459 c 59456 d a b e f a - Trim sender harness b - Trim harness c - Power terminal mounting screw (M8 X 20) d - Power terminal e - Starter power wire mounting nut f - Oil presser sender harness Power Terminal Mounting Screw Torque 18 Nm (159 lb in.) Starter Power Wire Mounting Nut Torque 9 Nm (80 lb in.) IGNITION 90-888465 JUNE 2002 Page 2A-45 ECM Removal 1. Remove the intake silencer. Refer to Intake Silencer Removal. 2. Disconnect battery. 3. Disconnect the ECM harness connector. 4. Remove ECM screws (4). 59449 a b c a - ECM mounting screws (4) b - ECM harness connector c - Ground screw Installation 1. Install ECM. Tighten screws to specified torque. 2. Connect ECM harness connector. 3. Connect Battery. 4. Install intake silencer. Refer to Intake Silencer Installation. ECM Mounting Screw Torque 8 Nm (71 lb in.) IGNITION Page 2A-46 90-888465 JUNE 2002 Ignition Coil Removal 1. Remove Ignition coil cover mounting screws (4). 59455 a b a a - Ignition coil cover mounting screws (4) M6 x 30 b - Grommets 2. Disconnect the coil primary wire harness connector. 3. Disconnect the spark plug lead. 4. Remove the coil mounting screws. 59452 a b a - Coil mounting screw. (2 per coil) M6 x 20 b - Coil primary wire harness connector Installation 1. Secure coils with mounting screws. 2. Connect coil primary wire harness connector. 3. Connect spark wire to plug. 4. Install ignition coil cover. Tighten Screws to specified torque. Ignition Coil Mounting Screw Torque 8 Nm (71 lb in.) Ignition Coil Cover Mounting Screw Torque 8 Nm (71 lb in.) IGNITION 90-888465 JUNE 2002 Page 2A-47 Port Thermoswitch Removal 1. Remove the flywheel cover. 2. Disconnect the thermoswitch harness connectors. 3. Remove the thermoswitch retainer mounting screw. 4. Remove thermoswitch. b a b c d a - Thermoswitch harness connectors b - Thermoswitch c - Thermoswitch retainer mounting screw d - Thermoswitch retainer Installation 1. Install thermoswitch. Tighten retainer screw to specified torque. 2. Connect thermoswitch harness connectors. 3. Install flywheel cover. Thermoswitch Retainer Mounting Screw Torque 8 Nm (71 lb in.) IGNITION Page 2A-48 90-888465 JUNE 2002 Starboard Thermoswitch Removal 1. Remove flywheel cover. 2. Cut sta-strap holding thermoswitch harness to wire guide. 3. Disconnect the thermoswitch harness connector. 4. Remove the port side wire harness guide screw. NOTE: Push the wire harness guide towards the flywheel to gain access to the port thermoswitch. 5. Remove the thermoswitch retainer mounting screw. 6. Remove thermoswitch. a b c d e f a - Thermoswitch retainer b - Thermoswitch retainer screw (M6 X 20) c - Thermoswitch d - Throttle position sensor e - Thermoswitch harness f - Wire harness guide screw (M6 X 35) IGNITION 90-888465 JUNE 2002 Page 2A-49 Installation 1. Push wire harness guide towards the flywheel to gain access to the thermoswitch bore. 2. Insert thermoswitch. Install thermoswitch retainer and retainer screw. Tighten screw to specified torque. 3. Install wire harness guide screw. Tighten screw to specified torque. 4. Connect thermoswitch harness connector. 5. Sta strap the thermoswitch harness to the wire harness guide. 6. Install flywheel cover. a b c d e f a - Thermoswitch retainer b - Thermoswitch retainer mounting screw (M6 X 20) c - Thermoswitch d - Throttle position sensor e - Thermoswitch harness f - Wire harness guide mounting screw (M6 X 35) Thermoswitch Retainer Mounting Screw Torque 8 Nm (71 lb in.) Wire Harness Guide Mounting Screw Torque 8 Nm (71 lb in.) IGNITION Page 2A-50 90-888465 JUNE 2002 Engine Temperature Sensor Removal 1. Disconnect the engine temperature sensor wire harness connector. 2. Remove engine temperature sensor. 59451 a b d b e c a - Engine temperature sensor harness connector b - Engine temperature sensor c - Gasket d - MAP e - IAC Installation 1. Install gasket onto engine temperature sensor. 2. Install engine temperature sensor. Tighten to specified torque. 3. Connect engine temperature sensor harness connector. Engine Temperature Sensor Torque 15 Nm (133 lb in.) CHARGING & STARTING SYSTEM ELECTRICAL Section 2B - Charging & Starting System Table of Contents 2 B Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Stator Coil Peak Voltage Test . . . . . . . . . . . . . 2B-14 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3 Rectifier/Voltage Regulator Test . . . . . . . . . . . 2B-16 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-5 Starting System Components . . . . . . . . . . . . . 2B-17 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-6 Description . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-17 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-8 Starting System Wiring Diagram . . . . . . . . 2B-18 Recommended Battery . . . . . . . . . . . . . . . . 2B-8 Troubleshooting the Starting Circuit . . . . . . . . 2B-19 Operating Engine Without Battery . . . . . . 2B-8 Starter Solenoid Test . . . . . . . . . . . . . . . . . . 2B-19 Battery Charging System Troubleshooting 2B-8 Starter Relay . . . . . . . . . . . . . . . . . . . . . . . . 2B-20 Battery Charging System . . . . . . . . . . . . . . . . . 2B-9 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-21 Description . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-21 Charging System Wiring Diagram . . . . . . 2B-9 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 2B-22 Alternator System Test . . . . . . . . . . . . . . . . . . . 2B-10 Cleaning and Inspection . . . . . . . . . . . . . . . 2B-24 45 Ampere Stator . . . . . . . . . . . . . . . . . . . . 2B-10 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-26 Stator Coil Continuity Test . . . . . . . . . . . . . . . . 2B-11 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 2B-29 Stator Coil Resistance Test . . . . . . . . . . . . . . . 2B-12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-33 90-888465 JUNE 2002 Page 2B-1 CHARGING & STARTING SYSTEM Specifications CHARGING SYSTEM Readings taken @ 68°F (20°C). Alternator Type: Alternator Output Stator Coil - Peak Voltage: (G-G) @ (Cranking) (Unloaded) @ 1500 rpm (Unloaded) @ 3500 rpm (G/W-G/W) @ (Cranking) (Unloaded) @ 1500 rpm (Unloaded) @ 3500 rpm Stator Coil Resistance (G-G) Stator Coil Resistance (G/W-G/W) Rectifier/Regulator Output - Peak Voltage (R-B, R/Y-B): @ 1500 rpm (unloaded) @ 3500 rpm (unloaded) Quicksilver Tachometer Setting Three Phase Stator Coil (12 Pole) 12.0 V; 45 Amps. (Rectified/Regulated) Minimum 8 V 42 V 93 V 7 V 34 78 0.10 - 0.60 W 0.10 - 0.50 10.5 V 10.5 V “6P” or “4” STARTING SYSTEM Electric Start: Starter Type Output Rating Brush: Length Minimum Length Commutator: Diameter Minimum Diameter Undercut Undercut Limit Sliding Gear 1.4 kW - 12 V 30 Seconds 15.5 mm (0.610 in.) 9.5 mm (0.374 in.) 29.0 mm. (1.140 in) 28.0 mm (1.100 in.) 0.5-0.8 mm (0.020-0.030 in.) 0.2 mm (0.010 in.) 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) 100 - 120 Page 2B-2 90-888465 JUNE 2002 CHARGING & STARTING SYSTEM Special Tools 1. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1 2. Brush Holder P/N91-875216 3. Dynamic Spark Tester 4. Direct Voltage Adapter P/N 91-89045 or P/N 91-89045--1 91-89045 91-89045-1 90-888465 JUNE 2002 Page 2B-3 CHARGING & STARTING SYSTEM 5. Stator Coil Test Harness 91-804772 00072 6. Voltage regulator test harness 91-888862 00073 Page 2B-4 90-888465 JUNE 2002 CHARGING & STARTING SYSTEM Notes: 90-888465 JUNE 2002 Page 2B-5 CHARGING & STARTING SYSTEM Starter Motor 110 4 Stroke Outboard Oil 95 95 2-4-C with Teflon 110 95 Page 2B-6 90-888465 JUNE 2002 CHARGING & STARTING SYSTEM Starter Motor REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 CLIP 2 1 PINION STOPPER 3 1 STARTER MOTOR PINION 4 1 SPRING 5 2 SCREW (M6 X 35) 70 8 6 1 HOUSING 7 1 RUBBER SEAL 8 1 BEARING 9 1 CLUTCH ASSEMBLY 10 1 E-CLIP 11 1 THRUST WASHER 12 1 CENTER BRACKET 13 3 PINION SHAFT 14 1 PLANETARY GEAR 15 1 OUTER GEAR 16 1 PLATE 17 1 ARMATURE 18 1 STATOR 19 1 BRUSH HOLDER ASSEMBLY 20 1 PLATE 21 1 THRUST WASHER 22 1 LOWER BRACKET 23 2 SCREW (M4 X 15) 24 2 SCREW (M6 X 120) 70 8 25 1 SHIFT LEVER 26 1 SPRING 27 1 METAL GASKET 28 1 GASKET 29 1 MAGNET SWITCH 30 1 BRUSH ASSEMBLY 31 1 NUT 78 9 90-888465 JUNE 2002 Page 2B-7 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 in this section. 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-8 90-888465 JUNE 2002 CHARGING & STARTING SYSTEM Battery Charging System Description 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. Charging System Wiring Diagram / / / / / / RED BLK BLK BLK REDRED RED/YEL RED RED/YEL RED/YEL RED RED/YEL RED REDRED/YELRED GRN/WHT GRN/WHT GRN/WHT GRN/WHT GRN/WHT GRN/WHT GRN GRN GRNGRN GRN GRN GRN/WHT GRN GRN RED d cc a b BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORG = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow a-Stator coil b-Regulator/rectifier c-Fuse (30A) d-Battery 90-888465 JUNE 2002 Page 2B-9 CHARGING & STARTING SYSTEM Alternator System Test 45 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: 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 9. A reading of 41 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 RPM x 1000 Alternator current (Amps) Page 2B-10 90-888465 JUNE 2002 CHARGING & STARTING SYSTEM 90-888465 JUNE 2002 Page 2B-11 Stator Coil Continuity Test 91-854009A1 RED BLACK a b c d e 59539 91-804772 b Stator Coil Continuity Test Diagram a - Stator coil harness connector b - Engine ground c - GRN/WHT coil wire test connector to stator harness d - GRN coil wire test connector to stator harness e - Meter test leads 1. Remove the intake silencer. Refer to Section 3A for intake silencer removal. 2. Disconnect the GRN wire stator harness connectors. 3. Connect female test harness (91-804772) connector into stator harness and perform test as specified in chart below. Do NOT connect male test harness connector to voltage regulator. 4. Measure stator continuity. Replace if out of specification. 5. Connect the GRN wire stator harness connectors. 6. Disconnect the GRN/WHITE wire stator harness connectors. 7. Connect male test harness (91-804772) connector into stator harness and perform test as specified in chart below. Do NOT connect female test harness connector to voltage regulator. 8. Measure stator continuity. Replace if out of specification. 9. Connect the GREEN/WHITE wire stator harness connectors. METER TEST LEADS METER SCALE CONTINUITY RED BLACK TEST HARNESS LEADS RED Engine Ground RX1 NO BLACK Engine Ground WHITE Engine Ground CHARGING & STARTING SYSTEM Page 2B-12 90-888465 JUNE 2002 Stator Coil Resistance Test 91-854009A1 RED BLACK a 59539 91-804772 c d b Stator Coil Resistance Test Diagram a - Stator coil harness connector b - GRN/WHT coil wire test connector to stator harness c - GRN coil wire test connector to stator harness d - Meter test leads 1. Remove the intake silencer. Refer to Section 3A for intake silencer removal. 2. Disconnect the GRN wire stator harness connectors. 3. Connect female test harness (91-804772) connector into stator harness and perform test as specified in chart below. Do NOT connect male test harness connector to voltage regulator. CHARGING & STARTING SYSTEM 4. Measure stator resistance. Replace if out of specification. METER TEST LEADS METER SCALE READING () RED BLACK RX1 0.10-0.60 TEST HARNESS LEADS RED BLACK RED WHITE BLACK WHITE 5. Connect the GREEN wire stator harness connectors. 6. Disconnect the GREEN/WHITE wire stator harness connectors. 7. Connect male test harness (91-804772) connector into stator harness and perform test as specified in chart below. Do NOT connect female test harness connector to voltage regulator. 8. Measure stator resistance. Replace if out of specification. 9. Connect the GREEN/WHITE wire stator harness connectors. METER TEST LEADS METER SCALE READING () RED BLACK RX1 0.10 - 0.50 TEST HARNESS LEADS RED BLACK RED WHITE BLACK WHITE 90-888465 JUNE 2002 Page 2B-13 CHARGING & STARTING SYSTEM Page 2B-14 90-888465 JUNE 2002 Stator Coil Peak Voltage Test 91-854009A1 RED BLACK a 59539 91-804772 c d b Stator Coil Peak Voltage Test Diagram a - Stator coil harness connector b - GRN/WHT coil wire test connector to stator harness c - GRN coil wire test connector to stator harness d - Meter test leads 1. Remove the intake silencer. Refer to Section 3A for intake silencer removal. 2. Disconnect the GRN wire stator harness connectors. 3. Connect female test harness (91-804772) connector into stator harness and perform test as specified in chart below. Do NOT connect male test harness connector to voltage regulator. 4. Install the intake silencer. CAUTION Do NOT start the engine WITHOUT the intake silencer installed. 5. Crank or start engine as required. CHARGING & STARTING SYSTEM 6. Measure the stator output peak voltage. Replace if out of specification. METER TEST LEADS METER SCALE READING MINIMUM READING MINIMUM READING MINIMUM RED BLACK CRANKING 1500 RPM 3500 RPM TEST HARNESS LEADS DC VOLTS 8V8 V 42 V 42 V 93 V 93 V RED BLACK RED WHITE BLACK WHITE 7. Connect the GRN wire stator harness connectors. 8. Disconnect the GRN/WHT wire stator harness connectors. 9. Connect male test harness (91-804772) connector into stator harness and perform test as specified in chart below. Do NOT connect female test harness connector to voltage regulator. 10. Crank or start engine as required. 11. Measure the stator output peak voltage. Replace if out of specification. METER TEST LEADS METER SCALE READING MINIMUM READING MINIMUM READING MINIMUM RED BLACK CRANKING 1500 RPM 3500 RPM TEST HARNESS LEADS DC VOLTS 7V7 V 34 V 34 V 78 V 78 V RED BLACK RED WHITE BLACK WHITE 12. Connect the GREEN/WHITE wire stator harness connectors. 90-888465 JUNE 2002 Page 2B-15 CHARGING & STARTING SYSTEM Page 2B-16 90-888465 JUNE 2002 Rectifier/Voltage Regulator Test 1. Remove the intake silencer. Refer to Section 3A for intake silencer removal. 2. Disconnect the voltage rectifier/regulator harness connectors. 3. Connect male test harness (91-888862) connector into rectifier/regulator harness and perform test as specified in chart below. Do NOT connect female test harness connector to main harness connector. 4. Install the intake silencer. CAUTION Do NOT start the engine WITHOUT the intake silencer installed. 5. Start engine. 6. Measure the voltage regulator output peak voltage. a. If below specification, measure the stator coil output peak voltage. b. If the stator coil output peak voltage is above specification, replace the voltage regulator. 59540 91-888862 a RED BLACK 91-854009A1 00073 a b b c a - To voltage regulator/rectifier b - Engine ground c - Voltage regulator/rectifier harness connector METER TEST LEADS METER SCALE 1500 RPM UNLOADED 3500 RPM UNLOADED RED BLACK TEST HARNESS LEADS RED Engine Ground DC VOLTS 10.5 10.5 BLACK Engine Ground (MINIMUM) 10.5 10.5 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. 90-888465 JUNE 2002 Page 2B-17 CHARGING & STARTING SYSTEM Starting System Wiring Diagram RED c e Br / / REDRED RED RED BLK BLK BLK BLKBLK BRN/WHT BRN/WHT RED RED RED RED BRN BRN BRN a b d a a-Fuse (30Amp) b-Fuse (20Amp) c-Starter relay d-Stator motor e-Battery BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORG = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow Page 2B-18 90-888465 JUNE 2002 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 BRN/WHT 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 BRN/ WHT lead is removed. NOTE: The pinion gear should be pushed out while the magnet switch is ON. a b c a-Relay terminals b-BRN/WHT lead c-Battery 90-888465 JUNE 2002 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 BRN/WHT 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 - BLK b-Ohm meter test lead - RED c-Starter relay wire lead - BRN/WHT d-Starter relay wire lead - BLK e-12 volt battery Page 2B-20 90-888465 JUNE 2002 CHARGING & STARTING SYSTEM 90-888465 JUNE 2002 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. 2. Disconnect RED wires from starter solenoid. 3. Disconnect BRN/WHT wire from starter relay. 4. Remove 3 screws. Remove starter. a c d b e 59541 59541 f a -Starter b -Starter mounting screws c -Positive starter solenoid lead (RED) d -Starter solenoid lead (BRN/WHT) e -Starter relay f -Electrical component plate CHARGING & STARTING SYSTEM Page 2B-22 90-888465 JUNE 2002 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. 57637 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 CHARGING & STARTING SYSTEM 90-888465 JUNE 2002 Page 2B-23 5. Remove 2 thru-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 b - Commutator End Cap Screws (2) M4 x 14 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. 57621 a a - Plate 10. For pinion gear disassembly refer to exploded view. 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, in this section. 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 Minimum Commutator Undercut Limit 0.2 mm (0.008 in.) 9. Open-circuited armatures often can be saved where an open circuit is obvious and re- pairable. 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 90-888465 JUNE 2002 CHARGING & STARTING SYSTEM 11. Measure commutator diameter. • Out of specification - replace. Minimum Commutator Diameter Limit 28.0 mm (1.10 in.) 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 in this section. 90-888465 JUNE 2002 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 b-Armature Test c-Armature Shaft Test Commutator Segment Continuity Test Continuity Armature Core Continuity Test NO Continuity Armature Shaft Continuity Test NO Continuity Page 2B-26 90-888465 JUNE 2002 CHARGING & STARTING SYSTEM BRUSH HOLDER INSPECTION 1. Measure brush length. If out of specification, replace brushes. Minimum Brush Length Limit 9.5 mm (0.374 in.) 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 90-888465 JUNE 2002 Page 2B-27 CHARGING & STARTING SYSTEM MAGNET SWITCH TEST 1. Set ohmmeter to (R1 x 1 scale). 2. Connect the meter test leads between the magnet switch terminals. 3. Connect the positive battery terminal to the BRN/WHT lead. 4. Connect the negative battery terminal to the starter motor body. a a-BROWN/WHITE wire CAUTION Do NOT connect the battery for more than one second, otherwise the magnet switch may be damaged. 5. Check that there is continuity between the magnet switch terminals. Replace if there is no continuity. 6. With battery cables removed, check that there is no continuity. Replace if there is continuity. NOTE: The starter motor pinion should be pushed out while the magnet switch is on. Page 2B-28 90-888465 JUNE 2002 CHARGING & STARTING SYSTEM 90-888465 JUNE 2002 Page 2B-29 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 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 thru-screws. Torque screws to specified torque. b b 57636 a 57902 a-Alignment marks b-Thru-screws (2) M6 x 120 Starter Thru-Screw Torque 8 Nm (70 lb-in.) Page 2B-30 90-888465 JUNE 2002 CHARGING & STARTING SYSTEM 90-888465 JUNE 2002 Page 2B-31 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 57626 d f e f c a - Spring b - Dust Cover Plate Holes c - Screw M4 x 20 d - Grommet e - Lever f - Shaft Hole g - Solenoid Screws (2) M6 x 35 Starter Solenoid Screw Torque (g) 8 Nm (70 lb-in.) 14. Connect spade connector on start solenoid. a b a - Spade Connector b - Nut Terminal Nut Torque 9 Nm (78 lb-in.) 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-32 90-888465 JUNE 2002 CHARGING & STARTING SYSTEM 90-888465 JUNE 2002 Page 2B-33 Installation 1. Secure starter motor to cylinder block with 3 screws. 2. Connect RED positive lead to starter terminal. 3. Install terminal cover over nut. 4. Secure BRN/WHT lead to starter relay. 5. Install terminal cover over nut. 6. Reinstall electrical cover. a d b e 59541 f c g g a -Starter b -Starter mounting screws c -Positive starter solenoid lead (RED) d -Starter solenoid lead (BRN/WHT) e -Starter relay f -Electrical cover g -Terminal cover Starter Motor Mounting Screw Torque 13 lb-ft (18 Nm) CHARGING & STARTING SYSTEM 7. Install RED battery cable to cable terminal. 8. Install BLACK battery cable to cable terminal. 59533 a b a-RED battery cable (M6 x 14 screw) b-BLACK battery cable (M8 x 20 screw) Positive Battery Terminal Screw Torque 8 Nm (70 lb-in.) Negative Battery Terminal Screw Torque 18 Nm (160 lb-in.) 9. Install covers over battery cable ends and terminal screws. 10. Reconnect battery cables to battery. Page 2B-34 90-888465 JUNE 2002 TIMING, SYNCHRONIZING, & ADJUSTING ELECTRICAL Section 2C - Timing, Synchronizing, & Adjusting Table of Contents 2 C Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-4 Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-5 Checking Ignition Timing . . . . . . . . . . . . . . 2C-6 Throttle Shutter Synchronization . . . . . . . . . . 2C-8 Engine Idle Speed . . . . . . . . . . . . . . . . . . . . . . . 2C-19 Engine Idle Speed Check . . . . . . . . . . . . . . 2C-19 Engine Idle Speed Adjustment . . . . . . . . . 2C-20 Throttle Cable Adjustment . . . . . . . . . . . . . 2C-22 90-888465 JUNE 2002 Page 2C-1 TIMING, SYNCHRONIZING, & ADJUSTING Specifications Type Microcomputer-ECM Spark Plug: Type NGK LFR5A-11 Gap 1.0 - 1.1 mm (0.39 - .0.43) Hex Size 16 mm (5/8 in.) Torque 25 Nm (18 lb-ft) Hole Size 14 mm Firing Order 1-2-3-4-5-6 Ignition Timing: @ Idle (750 rpm) T.D.C @ WOT (5500 rpm) 24° B.T.D.C Stator Coil Output - Peak Voltage: GRN-GRN Unloaded @ 400 rpm (Cranking) 8 V minimum @ 1500 rpm 42 V minimum @ 3500 rpm 93 V minimum GRN/WHT-GRN/WHT Unloaded IGNITION SYSTEM Readings taken @ 68°F (20°C). @ 400 rpm (Cranking) @ 1500 rpm @ 3500 rpm Stator Coil Resistance Rx1 @ 20 C (68 F) 7 V minimum 34 V minimum 78 V minimum GRN-GRN 0.10-0.60 W GRN/WHT-GRN/WHT 0.10-0.50 W Crank Position Sensor - Peak Voltage: Unloaded @ 400 rpm (Cranking) 5.3 V Loaded @ 400 rpm (Cranking) 5.3 V @ 1500 rpm 20 V @ 3500 rpm 43 V Crank Position Sensor Resistance 459-561 W ECM (Coil Primary) - Peak Voltage: Loaded @ 400 rpm (Cranking) 160 V minimum @ 1500 rpm 260 V minimum @ 3500 rpm 260 V minimum Voltage Regulator Output (unloaded) @1500rpm 10.5 V minimum @3500rpm 10.5 V minimum Page 2C-2 90-888465 JUNE 2002 TIMING, SYNCHRONIZING, & ADJUSTING Ignition Coil Resistance Primary Secondary (Between Boots) 1.5-2.5 W 19.6-35.4 kW Engine Temperature Sensor IGNITION SYSTEM Readings taken @ 68°F (20°C). Resistance @ 20 C (68 F) @ 100 C (212 F) Air Temperature Sensor Resistance @0 C (32 F) @80 C (176 F) Oil Pressure Sensor Output Voltage 54.2-69.2 kW 3.12-3.48 kW 5.4-6.6 kW 0.29-0.39 kW 3.8 V @700rpm Throttle Position Sensor Output Voltage 3.8 V Thermoswitch Continuity On Off (Reset) 84-90 °C (183-194 F) 68-82 °C (154-179 F) NOTE: The 225 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. 90-888465 JUNE 2002 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 90-888465 JUNE 2002 TIMING, SYNCHRONIZING, & ADJUSTING 5. Throttle Position Sensor Test Harness 91-881827 58678 6. Tamper-proof screw Torx bit set p/n 91-881828. 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. Timing Ignition timing is not adjustable. The ECM unit electronically controls the ignition timing. The 225 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 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). 90-888465 JUNE 2002 Page 2C-5 TIMING, SYNCHRONIZING, & ADJUSTING Checking Ignition Timing 1. Remove ignition coil cover. 2. Start engine and let it warm for 5 minutes. 3. Attach digital tachometer, 91-854009A1, to spark plug wire #1. Check engine idle speed. Adjust if out of specification. Refer to “Engine Idle Speed” in this section. a b a-Sparkplug wire #1 b-Digital tachometer 91-854009A1 Engine Idle Speed 650 - 750 rpm Page 2C-6 90-888465 JUNE 2002 TIMING, SYNCHRONIZING, & ADJUSTING 4. Attach timing light, 91-99379, to spark plug wire #1. a a b a-Timing light 91-99379 b-Sparkplug wire #1 5. Check that the “1TDC” mark on the flywheel is aligned with the magnet base pointer. a b a-”1 TDC timing mark b-Timing pointer Ignition Timing TDC 90-888465 JUNE 2002 Page 2C-7 TIMING, SYNCHRONIZING, & ADJUSTING Throttle Shutter Synchronization NOTE: The cylinders are synchronized by adjusting the intake manifold vacuum on the in- take manifold. Use Carburetor Tuner (91-809641A1) or Vacuummate Tuner (91-809871--1) to measure the vacuum. 1. Loosen the bank synchronizing screw. 2. Remove the port link rod and starboard link rod. d a b c a Port Starboard a-Bank synchronizing screw b-Port link rod c-Starboard link rod d-Throttle position sensor 3. Loosen the starboard throttle stop screw until it separates from the throttle body lever. a b a-Starboard throttle stop screw (T-25 Torx) b-Starboard throttle body lever Page 2C-8 90-888465 JUNE 2002 TIMING, SYNCHRONIZING, & ADJUSTING 4. Loosen the synchronizing screw of cylinder #3 to open throttle valve #3. 5. Loosen the synchronizing screw of cylinder #5 to open throttle valve #5. a b a-#3 Synchronizing screw (T-25 Torx) b-#5 Synchronizing screw (T-25 Torx) 6. Loosen the port throttle stop screw until it separates from the throttle body lever. b a a-Port throttle stop screw (T-25 Torx) b-Port throttle body lever 90-888465 JUNE 2002 Page 2C-9 TIMING, SYNCHRONIZING, & ADJUSTING 7. Loosen the synchronizing screw of cylinder #4 to open throttle valve #4. 8. Loosen the synchronizing screw of cylinder #6 to open throttle valve #6. b a a-#4 Synchronizing screw (T-25 Torx) b-#6 Synchronizing screw (T-25 Torx) 9. Connect the Throttle Position Sensor Test Harness 91-881827 to the throttle position sensor (TPS). 91-881827 Page 2C-10 90-888465 JUNE 2002 TIMING, SYNCHRONIZING, & ADJUSTING 90-888465 JUNE 2002 Page 2C-11 10. Connect DMT 2000 (91-854009A1) test leads to the TPS test harness: • RED to PINK • BLACK to ORANGE 11. Turn the ignition switch to the “RUN” position. 12. Measure the throttle position sensor output voltage. 13. Adjust the throttle position sensor if out of specification. Turn TPS clockwise to decrease voltage, counterclockwise to increase voltage. 59542 a 91-881827 c d b e 91-854009A1 f a - TPS test harness (91-881827) b - PINK test harness lead c - ORANGE test harness lead d - BLACK DMT 2000 lead e - RED DMT 2000 lead f - TPS screw (Torx-20) 14. Record voltage reading. METER TEST LEADS METER SCALE READING (mV) RED BLACK TEST HARNESS LEADS PINK ORANGE DC VOLTS 6505 TIMING, SYNCHRONIZING, & ADJUSTING 15. Tighten the synchronizing screw of cylinder #3 until the TPS voltage increases by 1 mV. 16. Tighten the synchronizing screw of cylinder #5 until the TPS voltage increases by 1 mV. NOTE: Do NOT push on screw head while performing above adjustment. a b a-Cylinder #3 synchronizing screw (Torx-25) b-Cylinder #5 synchronizing screw (Torx-25) 17. Tighten the starboard throttle stop screw until a 40 mV TPS output voltage increase over the previously recorded value is observed. • Example: 662 mV + 40 mV = 702 mV. a a-Starboard throttle stop screw Page 2C-12 90-888465 JUNE 2002 TIMING, SYNCHRONIZING, & ADJUSTING 18. Bend a piece of wire or paper clip as shown to act as a throttle plate-positioning pointer. Secure pointer to port #2 throttle body using a M6 x 16 screw and align (bend) pointer with timing mark on throttle plate. a b a b a-Throttle plate b-Positioning pointer 19. Tighten the synchronizing screw of cylinder #4 until the throttle plate just starts to move as indicated at the pointer. 20. Tighten the synchronizing screw of cylinder #6 until the throttle plate just starts to move as indicated at the pointer. a b a-Cylinder #4 synchronizing screw (Torx-25) b-Cylinder #6 synchronizing screw (Torx-25) 90-888465 JUNE 2002 Page 2C-13 TIMING, SYNCHRONIZING, & ADJUSTING Page 2C-14 90-888465 JUNE 2002 21. Tighten the port throttle stop screw until it contacts the throttle body lever, then tighten the screw 1 additional turn. b a a - Port throttle stop screw (Torx-25) b - Throttle body lever 22. Remove the plugs from the intake manifolds of cylinders #1, #3 and #5. 23. Install intake manifold hose adaptors into each plug hole. Tighten securely (finger-tight). 24. Connect hoses of Vacuumate Tuner (91-80971-1) or vacuum gauge to hose adaptors. a b 91-809871--1 a c a - Intake manifold hose adaptor from Vacuummate Carb. Tuner b - Intake manifold hose adaptor from mercury filled Carb Tuner c - Plug TIMING, SYNCHRONIZING, & ADJUSTING 25. With the engine in water, start engine and allow it warm up for 5 minutes. Engine idle rpm in neutral should be 650 - 750 rpm. 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 (35-18206) in each line will help to prevent liquid mercury from being drawn into engine during an accidental abrupt throttle change. 26. Observe vacuum of cylinders #1, #3 and #5. Vacuum readings should be within specified range. NOTE: It is not important that the vacuum be at any specific setting. Maximum Vacuum Difference Between Cylinders 2 cm Hg (0.8 in. Hg) 27. Adjust the synchronizing screws of cylinders #3 and #5 if readings are out of specification. 28. Record vacuum readings of cylinders #1, #3 and #5. 29. Shut engine off. Move Vacuumate hoses and adaptors 2, 3 and 4 to cylinders #2, #4 and #6 on the port cylinder bank respectively. NOTE: Leave Vacuumate hose 1 connected to cylinder #1. This will be used as a baseline reading for final synchronizing adjustment. 30. Reinstall plugs into the manifolds of cylinders #3 and #5. 31. Start engine and allow to idle to 650-750 rpm. 32. Observe vacuum of cylinders #2, #4 and #6. Vacuum readings should be within specified range. NOTE: It is not important that the vacuum be at any specific setting. Maximum Vacuum Difference Between Cylinders 2 cm Hg (0.8 in. Hg) NOTE: Cylinder #2 is the base reading for the port cylinder bank synchronizing. NOTE: At this time, disregard cylinder #1 vacuum reading for this portion of the procedure. 90-888465 JUNE 2002 Page 2C-15 TIMING, SYNCHRONIZING, & ADJUSTING 33. Adjust the synchronizing screws of cylinders #4 and #6 if readings are out of specification. 34. Record vacuum readings of cylinders #2, #4 and #6 35. Calculate the average vacuum difference between the port and starboard cylinder banks. Maximum Vacuum Difference Between Cylinder Banks 4 cm Hg (1.6 in. Hg) 36. Adjust the PORT throttle stop screw if the cylinder bank average readings are out of specifications. ab a-Port throttle stop screw (Torx-25) b-Throttle body lever Example If the vacuum reading of Cyl. #1 (starboard base vacuum) is 32 cm Hg and cylinder #2 (port base vacuum) is 27 cm, then ad- just port throttle stop screw to achieve 32 cm for cylinders #2, #4 and #6. 32 cm 30 cm 28 cm 26 cm Cyl. Cyl. Cyl. # 2#4 # 6 Cyl. # 1 CAUTION Do NOT back throttle stop screw off throttle body lever. Page 2C-16 90-888465 JUNE 2002 TIMING, SYNCHRONIZING, & ADJUSTING 37. Measure the throttle position sensor output voltage with engine at idle speed of 650-750 rpm. Adjust throttle position sensor if out of specification. METER TEST LEADS METER SCALE READING (mV) RED BLACK DC VOLTS 7005 TEST HARNESS LEADS PINK ORANGE 38. Stop engine. Reattach port link rod and starboard link rod. d a b c Port Starboard a-Synchronizing screw b-Port link rod c-Starboard link rod d-Throttle position sensor Link Rod Nut Torque 4 Nm (35 lb-in.) 90-888465 JUNE 2002 Page 2C-17 TIMING, SYNCHRONIZING, & ADJUSTING 39. Start engine. Allow engine speed to stabilize. 40. Tighten the bank synchronizing screw without moving the throttle plate linkage. NOTE: Observe engine speed during tightening while tightening synchronizing screw. Speed should NOT change while tightening. a a-Bank synchronizing screw Bank Synchronizing Screw Torque 4 Nm (35 lb-in.) 41. Check that no clearance exists between the port and starboard throttle stop screws and the throttle body levers. If clearance exists, repeat step 40. a a db d c a-No clearance - screw should touch lever b-Starboard throttle stop screw c-Port throttle stop screw d-Throttle body lever 42. Start engine and allow it to idle to 650-750 rpm. 43. Re-check average vacuum difference between the port and starboard cylinder banks. Adjust if out of specification. Maximum Vacuum Difference Between Cylinders Banks 4 cm Hg (1.6 in. Hg) Page 2C-18 90-888465 JUNE 2002 TIMING, SYNCHRONIZING, & ADJUSTING Engine Idle Speed Engine Idle Speed Check 1. Remove ignition coil cover. 2. Start engine and let it warm for 5 minutes. 3. Attach digital tachometer, 91-854009A1, to spark plug wire #1. Check engine idle speed. Adjust if out of specification. Refer to “Engine Idle Speed Adjustment” in this section. a b a-Sparkplug wire #1 b-Digital tachometer 91-854009A1 Engine Idle Speed 650 - 750 rpm 90-888465 JUNE 2002 Page 2C-19 TIMING, SYNCHRONIZING, & ADJUSTING Engine Idle Speed Adjustment 1. Turn the engine off. Loosen the locknut and disconnect the link rod from the magnet control lever. b a c a-Locknut b-Link rod c-Magnet control lever 2. Loosen the port throttle stop screw until it separates from the throttle body lever. ab a-Port throttle stop screw b-Throttle body lever Page 2C-20 90-888465 JUNE 2002 TIMING, SYNCHRONIZING, & ADJUSTING 3. Start the engine. Turn the throttle stop screw until the specified engine idle speed is obtained. ab c a-Increase idle speed b-Decrease idle speed c-Throttle stop screw (Torx-25) Engine Idle Speed 650 - 750 rpm 4. Tighten the port throttle stop screw until it contacts the throttle body lever. ab a-Throttle stop screw (Torx-25) b-Throttle body lever 90-888465 JUNE 2002 Page 2C-21 TIMING, SYNCHRONIZING, & ADJUSTING Page 2C-22 90-888465 JUNE 2002 Throttle Cable Adjustment 1. Loosen the locknut on the link rod. Disconnect the link rod from the ball joint on the magnet control lever. 2. Push the magnet control lever in the direction of the arrow. a c b a - Locknut b - Link rod c - Control lever 3. Adjust the throttle cable so the alignment mark on the throttle cam lever points to the center of the roller. Adjust cable length if necessary. b 59521 a c a - Throttle cam lever alignment mark b - Roller c - Throttle cable end TIMING, SYNCHRONIZING, & ADJUSTING 90-888465 JUNE 2002 Page 2C-23 4. If necessary, adjust the cable barrel to obtain the correct length. Refer to Shift Cable Installation in Section 1D. 59519 a b a - Throttle cable b - Cable barrel 5. Adjust the control lever to obtain a 1 mm (0.040 in.) gap between the cam surface and the roller. a d b c a - Magnet control lever b - 1 mm (0.040 in.) gap c - Throttle cam lever d - Roller TIMING, SYNCHRONIZING, & ADJUSTING 6. Adjust link rod to obtain vertical alignment with the ball joint on the control lever, while maintaining the 1 mm (0.040 in.) gap at the throttle cam lever/roller. 7. Push link rod onto the ball joint. Observe throttle plate to ensure that no movement occurs during installation. 8. Tighten locknut. a c d b a-Link rod b-Ball joint c-Locknut d-Magnet control lever 9. Check the throttle cable for smooth operation. Adjust cable length if necessary and repeat adjustment procedure. Page 2C-24 90-888465 JUNE 2002 THEORY OF OPERATION ELECTRONIC FUEL INJECTION Section 3A - Theory of Operation Table of Contents Electronic Control System . . . . . . . . . . . . . . . . 3A-2 Idle Air Control (IAC) . . . . . . . . . . . . . . . . . . . . . 3A-4 EFI System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-2 Step-Motor-Type Actuator . . . . . . . . . . . . . 3A-4 Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . 3A-2 Starting and Idling . . . . . . . . . . . . . . . . . . . . 3A-4 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-3 Warming Up . . . . . . . . . . . . . . . . . . . . . . . . . 3A-4 Intake Air Temperature Sensor . . . . . . . . . 3A-3 Rapid Deceleration . . . . . . . . . . . . . . . . . . . 3A-5 Crank Position Sensors . . . . . . . . . . . . . . . 3A-3 Air Induction System . . . . . . . . . . . . . . . . . . . . . 3A-6 Oil Pressure Switch . . . . . . . . . . . . . . . . . . . 3A-3 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-7 Manifold Absolute Pressure (MAP) Sensor 3A-3 Low Pressure Fuel Pump . . . . . . . . . . . . . . 3A-8 Throttle Position Sensor (TPS) . . . . . . . . . 3A-3 Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-8 Engine Water Temperature Sensor . . . . . 3A-3 Pressure Regulator . . . . . . . . . . . . . . . . . . . 3A-9 Shift Cutoff Control . . . . . . . . . . . . . . . . . . . 3A-3 Vapor Separator . . . . . . . . . . . . . . . . . . . . . . 3A-9 Neutral Switch . . . . . . . . . . . . . . . . . . . . . . . 3A-3 Secondary Vapor Separator (SVS) . . . . . . 3A-10 Thermoswitch . . . . . . . . . . . . . . . . . . . . . . . . 3A-3 3 A 90-888465 JUNE 2002 Page 3A-1 THEORY OF OPERATION Electronic Control System The ECM of the 225 EFI (4-Stroke) controls the ignition timing, the fuel injection timing, the fuel injection volume, and the IAC, while 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. Crank position sensor Throttle position sensor Low pressure fuel pump Thermoswitch Intake air temperature sensor Manifold absolute pressure sensor Stop switch Engine temperature sensor Oil pressure sensor Shift interrupt switch Neutral switch High pressure fuel pump Injectors Idle air control (IAC) Ignition coils Overheat monitor Oil pressure monitor Warning horn Tachometer Diagnostic system ECMINPUT OUTPUT EFI System The injection system employs a 120° synchronous (batch) injection method which groups cylinders #1 and #4, and cylinders #2 and #5, and cylinders #3 and #6. 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 225 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. Ignition System The 225 EFI (4-Stroke) has an ignition system which provides a 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. The ECM controls the signal to the ignition coils. Ignition occurs on two cylinders at once; #1 and #4, #2 and #5, #3 and #6. This type of ignition is called wasted spark. Page 3A-2 90–888465 JUNE 2002 THEORY OF OPERATION Sensors Intake 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 Sensors 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 (TPS) Provides the ECM with throttle angle information which the ECM uses in determining optimal air-fuel ratio, fuel injection timing and fuel injection volume. Engine 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. Shift Cutoff Control If the shift switch is activated with the engine operating under 2000 rpm, the ECU causes one or two cylinders to misfire in order to facilitate shifting. The ECU causes cylinders #1 and #2, or #4 and #5 to misfire when the engine speed is over 850 rpm, and cylinder #1 or #4 to misfire when the engine speed is under 850 rpm. Neutral Switch Sends a signal to the ECM indicating in gear or neutral. When the outboard is in neutral, the switch is closed. When the switch is in the closed position, the ECM will limit the engine speed to less than 4500 rpm as described in the over-revolution control. Thermoswitch Sends a signal to the ECM that the engine temperature has reached 120 °C (248 °F) or higher. The ECM causes cylinder pairs #2 and #5, #3 and #6 to misfire until the engine decreases speed to 2000 rpm. The warning light will illuminated and the warning horn will sound continuously until the thermoswitch is deactivated and the throttle is fully closed. 90-888465 JUNE 2002 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. bf a c d e a-Screw–type mechanism b-Rotor c-Valve d-Valve Shaft e-Stator coil f-Bearing 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. Page 3A-4 90–888465 JUNE 2002 THEORY OF OPERATION 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 to prevent the engine from stalling. a b c d e b g-Throttle position sensor h-IAC hose i-Map sensor j-IAC motor k-Throttle body 90-888465 JUNE 2002 Page 3A-5 THEORY OF OPERATION Page 3A-6 90–888465 JUNE 2002 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 quiet operation. The throttle valves are installed in six independent throttle bodies. 59446 a b c d e f a - Intake silencer b - MAP sensor c - Throttle position sensor (Located on #1 throttle body) d - IAC motor e - Throttle bodies with throttle valves f - Intake air temperature sensor (Located on lower front of intake silencer) THEORY OF OPERATION Fuel System The fuel system consists of a low pressure fuel pump, a high pressure fuel injection pump, a fuel rail, fuel injectors, a pressure regulator, and a fuel cooler. The low pressure fuel pump pulls fuel from the fuel tank, sends fuel to the vapor separator tank, which is then pressurized to 44 psi (310 kPa) by the high pressure fuel injection 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 38 psi (270 kPa) between the high pressure injection fuel pump and the fuel injectors by the pressure regulator when the engine is running. High fuel injection pressure maximizes the atomization of the fuel, resulting in increased combustion efficiency. 00031 a b g h i j k lmnop e f q c d r a-Intake manifold b-Fuel pressure regulator c-To MAP sensor d-Over flow check valve e-Secondary VST overflow to adaptor plate f-Secondary VST g-Low pressure fuel pump h-Fuel bypass check valve i-Fuel filter j-From fuel tank k-High pressure fuel pump filter l-High pressure fuel pump m-Fuel return from fuel cooler n-Fuel cooler o-Port fuel rail p-High pressure fuel hose from VST q-Fuel injectors r-Starboard fuel rail 90-888465 JUNE 2002 Page 3A-7 THEORY OF OPERATION Low Pressure Fuel Pump The 225EFI (4-stroke) has a low pressure electric fuel pump, in place of the mechanical fuel pump used in the previous electronic fuel injection systems. With the electric fuel pump, the routing of the fuel system is more compact. After start up, the fuel pump will operate continuously for 3 minutes. After the 3 minutes, to prevent the over pumping of fuel, the pump operates for 10 seconds, and stops for 20 seconds when the engine is operating below 1200 rpm. The pump operates constantly when the engine speed is 1200 rpm or higher. a b c d e e f a-VST b-Fuel pump c-Low pressure fuel bypass check valve d-Fuel filter e-Pump operation for 10 seconds f-Pump not operating for 20 seconds Fuel Cooler The 225 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 90–888465 JUNE 2002 THEORY OF OPERATION Pressure Regulator A pressure regulator is installed in the upper part of the port 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. a d e g h i b c f a-Intake manifold f-To fuel cooler b-Spring chamber g-Fuel chamber c-Spring h-Valve d-Diaphragm i-Housing e-From fuel rail 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 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 elbow on the vapor separator. c d e g a b f h a-Fuel inlet b-Check valve c-Vapor separator d-High pressure fuel pump e-Filter f-Fuel return from fuel cooler. g-Fuel float h-Inlet needle 90-888465 JUNE 2002 Page 3A-9 THEORY OF OPERATION Secondary Vapor Separator (SVS) The secondary vapor separator is a reservoir to hold liquid fuel if the vapor separator float or needle valve fail. The SVS has a check valve (float ball) used to close the SVS atmosphere vent. It also is a purge for the vapor separator, eliminating the chance of vapor lock. The SVS eliminates any possibility of uncontrolled liquid fuel or fuel vapors to enter the engine and alter the running quality. 00083 a b c d e a a-SVS locating tab b-Check valve (float ball) c-Atmosphere vent hose d-SVS mounting screw grommet e-SVS inlet Page 3A-10 90–888465 JUNE 2002 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-4 Pressure Regulator Test . . . . . . . . . . . . . . . 3B-4 Checking the Fuel Pump and High Pressure Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-5 Checking the High Pressure Fuel Pump Relay Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-5 Specifications Injector Operation Test . . . . . . . . . . . . . . . . 3B-6 Fail Safe Function Table . . . . . . . . . . . . . . . . . . 3B-7 Self-Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-8 Diagnosis Code Information . . . . . . . . . . . 3B-8 Diagnosis of the Electronic Control System 3B-9 Diagnostic Code Chart . . . . . . . . . . . . . . . . 3B-10 Diagnosis/Correction Complete . . . . . . . . 3B-10 3 B FUEL SYSTEM Fuel Pump Type Fuel Pump: Low Pressure High Pressure Electric 11-15 lbs. 38-44 lbs. FUEL INJECTION Fuel Injection System (synchronous) Idle rpm (in neutral) Warm Fuel Pressure @ Rail Batch (1 & 4) - (2 & 5) - (3 & 6) 650 to 750 rpm 44 psi (304 kPa) engine cold (start up) 38 psi (262 kPa) engine warm 90-888465 JUNE 2002 Page 3B-1 TROUBLESHOOTING AND DIAGNOSTICS Page 3B-2 90-888465 JUNE 2002 Special Tools 1. Fuel Pressure Gauge 91-16850A7 or Fuel Pressure Gauge 91-852087A3. 91-16850A7 91-852087A3 2. Malfunction Indicator Lamp 91-888859 Diagnostic adaptor harness 91-884793A1 91-99056A1 91-884793A1 59129 3. DMT 2000 Digital Tachometer Multi-meter 91-584009A1, DVA adaptor 91-89045-1 91-89045-1 91-584009A1 TROUBLESHOOTING AND DIAGNOSTICS Control and Function Ignition Timing Fuel Injection Timing Air/Fuel Control Function Crank Position Sensor . . . Detects the crankshaft position and engine speed Throttle Position Sensor . . . Detects the open degree of the throttle valve Water Temperature Sensor . . . Detects engine temperature Manifold Absolute Pressure (MAP) Sensor . Detects intake air pressure of the intake manifold Intake Air Temperature Sensor . Detects intake air temperature Shift Position Switch . . Determines the shift position. (neutral: on, forward or reverse: off) Oil Pressure Switch . . Detects oil pressure 90-888465 JUNE 2002 Page 3B-3 TROUBLESHOOTING AND DIAGNOSTICS EFI System Diagnostic Procedures Pressure Regulator Test 1. Install the fuel pressure gauge onto the pressure check valve (located on the port fuel rail). 2. Turn the key switch to ON. While pump is operating, fuel pressure should be within specification. Pressure will decrease gradually when pump is not operating. 3. Start the engine. Pressure should be within specification while engine is running. 4. If pressure is above specifications, replace regulator. 5. If pressure is below specifications, proceed with checking the fuel pump and high pressure fuel pump. ENGINE CONDITION FUEL PUMP PRESSURE READING ENGINE COLD (START UP) 44 PSI ENGINE WARM 38 PSI 91-16850A7a b c d a-Screwdriver b-Pressure gauge c-Pressure check valve d-Pressure check valve protective cap Page 3B-4 90-888465 JUNE 2002 TROUBLESHOOTING AND DIAGNOSTICS 90-888465 JUNE 2002 Page 3B-5 Checking the Fuel Pump and High Pressure Fuel Pump 1. Disconnect the starter relay lead (BROWN/WHITE ) to prevent engine from starting. 2. Turn the key switch to ON. 3. Listen for the operating sound of the fuel pump and the high pressure fuel pump. NOTE: After the key switch is turned on, the low pressure fuel pump will operate for 5 seconds and the high pressure pump will operate for 5 Seconds. After starting, the low pressure pump will operate continuously for 3 minutes. After 3 minutes the low pressure pump will cycle off and on as described in section 3A, Theory of Operation. a b c a - Starter relay lead b- High pressure fuel pump c - Low pressure fuel pump Checking the High Pressure Fuel Pump Relay Continuity 1. Connect the DMT 2000 leads to the high pressure fuel pump relay terminals identified “a” and “b”. 2. Connect a 12V positive supply lead to terminal identified “c”. 3. Connect a 12V negative supply lead to terminal identified “d” 4. Check for continuity between the high pressure fuel pump relay terminals “a” and “b”. Replace if there is no continuity. 5. Check that there is no continuity between the high pressure fuel pump relay terminals after disconnecting terminal “c” or “d”. Replace if there is continuity. a b c d a b c d e a - Fuel pump relay terminal b- Fuel pump relay terminal c - 12V positive d- 12V negative e - Relay TROUBLESHOOTING AND DIAGNOSTICS Injector Operation Test 1. Start the engine. Run at idle. 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 (6) 3. Check injector for proper ohm resistance. Fuel Injector Resistance 14.0 - 15.0 W @ 20 °C (68 °F) Page 3B-6 90-888465 JUNE 2002 TROUBLESHOOTING AND DIAGNOSTICS Fail Safe Function Table S tSymptoms FAIL SAFE FUNCTIONIgnition Fuel Injection IAC Engine Conditions Code Abnormal signal Engine starting: All cylinders  Engine idling from crank Only cylinders inject In neutral only: speed increases. position sensor. with normal CPS fire at 10° BTDC. All others there after. simultaneously based on the cylinder with a normal CPS. 900 rpm.  Top speeds cannot be reached. 13 Abnormal engine Engine  Engine idling temperature temperature sen-In neutral only: speed increases. sensor signal. Normal control. sor is fixed to 40°C to activate normal control. 900 rpm.  Top speeds cannot be reached. 15 Abnormal throttle Ignition timing is Correction is Opening angle is  Engine idling position sensor fixed to 10° made to the fixed to 60% speed increases. signal. BTDC. basic injection map.  Top speeds can be reached. 18 Abnormal intake air temperature . Intake air temperature In neutral only:  Engine idling speed increases. sensor signal. Normal control. sensor is fixed to 40°C in order to activate normal control. 900 rpm.  Top speeds can be reached. 23 Abnormal neutral switch signal. . Normal control. . Normal control. Normal control. Normal control. 28 Abnormal intake . Correction is  Engine idling air pressure sen-Normal control. made to the ba-In neutral only: speed increases. 29 sor (MAP). sic injection map. 900 rpm.  Top speeds can be reached. Abnormal oil pressure sensor signal. . Normal control. . Normal control. In neutral only: 900 rpm.  Engine idling speed increases. 39 Incorrect shift cut . . In neutral:  Engine idling switch signal. Normal control. Normal control. 900 rpm. In gear: 850 rpm. speed increases.  Top speeds can be reached. 45 Incorrect thermoswitch signal. Normal control. Normal control. In neutral only: 900 rpm.  Engine idling speed increases. 46 90-888465 JUNE 2002 Page 3B-7 TROUBLESHOOTING AND DIAGNOSTICS 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. NOTE: When more than one problem is detected, the light of the diagnostic tester flashes in the pattern of the lowest numbered problem. After the lowest number problem is corrected, the light flashes the pattern of the next lowest numbered problem. This continues until all of the problems are detected and corrected. Page 3B-8 90-888465 JUNE 2002 TROUBLESHOOTING AND DIAGNOSTICS 90-888465 JUNE 2002 Page 3B-9 Diagnosis of the Electronic Control System 1. Connect the diagnostic flash harness blue wire to the diagnostic adaptor harness connector. a b c e f d BLK = Black BLU = Blue GRY = Gray GRN = Green RED = Red WHT = White BRN = Brown a - Diagnostic flash harness 91-99056A1 b- Diagnostic flash harness BLK wire c - Diagnostic flash harness BLU wire d- Diagnostic flash adaptor 91-884793A1 e - Diagnostic flash adaptor wire (GRN/RED, do not use) f - Diagnostic flash adaptor to diagnostic flash harness connector 2. Remove diagnostic connector cap from the GRY diagnostic connector. 3. Remove the black rubber plug from BLU/WHT bullet connector. 4. Connect the harness adaptor to the diagnostic adaptor harness. WARNING Do not allow the GRN/RED wire to touch ground. During diagnosis of the electronic control system, the GRN/RED wire is supplied with battery voltage. Any contact with ground will damage a fuse. b 00102 a c d e a - Diagnostic flasher b- BLU/WHT wire harness c - WHT/BLK, RED/BLK, BLK wire harness d- GRY diagnostic connector e - GRN/RED connector (Do not use) TROUBLESHOOTING AND DIAGNOSTICS 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 1 Normal 13 Incorrect crank position sensor input signal 15 Incorrect engine cooling water temperature sensor input signal 18 Incorrect throttle position sensor input signal 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) 39 Ignition oil pressure sensor signal 45 Incorrect shift cut out switch signal 44 Incorrect engine stop switch signal 46 Incorrect thermo-switch signal Diagnosis/Correction Complete 1. Remove Malfunction Indicator Lamp (MIL). 2. Reinstall rubber plug in engine harness bullet connector. 3. Reinstall GRY diagnostic connector cap. Page 3B-10 90-888465 JUNE 2002 SERVICE PROCEDURES ELECTRONIC FUEL INJECTION Section 3C - Service Procedures Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-2 High Pressure Fuel Line . . . . . . . . . . . . . . . . . . 3C-38 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-2 Releasing Fuel Pressure . . . . . . . . . . . . . . 3C-38 Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-3 Releasing Fuel Pressure in the VST . . . . 3C-39 Intake Silencer . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-4 Port Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-40 Vapor Separator Hose Routing . . . . . . . . . . . . 3C-6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-40 Vapor Separator . . . . . . . . . . . . . . . . . . . . . . . . 3C-8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-41 Throttle Body Starboard . . . . . . . . . . . . . . . . . . 3C-10 Fuel Pressure Regulator . . . . . . . . . . . . . . . . . 3C-43 Throttle Body Port . . . . . . . . . . . . . . . . . . . . . . . 3C-12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-43 Throttle Body Hose Routing . . . . . . . . . . . . . . 3C-14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-44 Throttle Linkage . . . . . . . . . . . . . . . . . . . . . . . . . 3C-16 MAP Sensor Hoses . . . . . . . . . . . . . . . . . . . . . . 3C-45 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-45 Fuel Injection Hose Routing . . . . . . . . . . . . . . 3C-20 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-45 Idle Air Control (IAC) Motor . . . . . . . . . . . . . . . 3C-21 Port Rail Fuel Hose . . . . . . . . . . . . . . . . . . . . . . 3C-46 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-21 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-46 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-21 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-46 MAP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-22 Port Fuel Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-47 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-22 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-47 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-22 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-47 Intake Silencer Assembly . . . . . . . . . . . . . . . . . 3C-23 Port Fuel Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-48 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-23 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3C-48 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-23 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-49 High Pressure Fuel Line . . . . . . . . . . . . . . . . . . 3C-25 Port Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . 3C-51 Releasing Fuel Pressure . . . . . . . . . . . . . . 3C-25 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-51 Releasing Fuel Pressure in the VST . . . . 3C-26 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-51 Starboard Intake Assembly . . . . . . . . . . . . . . . 3C-27 Port Throttle Body . . . . . . . . . . . . . . . . . . . . . . . 3C-52 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-27 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-52 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-29 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-53 Starboard Rail Fuel Hoses . . . . . . . . . . . . . . . . 3C-30 Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-55 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-30 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-55 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-30 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-57 Starboard Fuel Rail . . . . . . . . . . . . . . . . . . . . . . 3C-31 Vapor Separator . . . . . . . . . . . . . . . . . . . . . . . . 3C-60 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-31 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-60 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-31 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-63 Starboard Fuel Rail . . . . . . . . . . . . . . . . . . . . . . 3C-32 Vapor Separator . . . . . . . . . . . . . . . . . . . . . . . . 3C-67 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3C-32 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3C-67 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-33 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-69 Starboard Fuel Injector . . . . . . . . . . . . . . . . . . . 3C-34 Secondary Vapor Separator (SVS) . . . . . . . . 3C-71 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-34 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-71 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-34 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-72 Starboard Throttle Body . . . . . . . . . . . . . . . . . . 3C-35 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-73 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-35 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3C-73 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-36 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-73 3 C 90-888465 JUNE 2002 Page 3C-1 SERVICE PROCEDURES Page 3C-2 90-888465 JUNE 2002 Specifications FUEL SYSTEM Fuel Pump Type Fuel Pump: Low Pressure High Pressure Electric 11-15 lbs. 38-44 lbs. FUEL INJECTION Fuel Injection System Idle rpm (In Neutral) Warm Fuel Pressure @ Rail Batch (1 & 4) - (2 & 5) - (3 & 6) 650–750 rpm 44.0 psi (303 kPa) engine cold (start up) 38.0 psi (262 kPa) after warm up Special Tools 1. Fuel Pressure Gauge 91-16850A7, Fuel Pressure Gauge 91-852087A3, Clamp Tool Kit 91-803146A2 . 51796 91-16850A7 91-852087A3 57316 a 91-803146A2 a - Clamp Tool 91-803146T 2. Tamper proof screw torx bit set p/n 91-881828. SERVICE PROCEDURES Notes: 90-888465 JUNE 2002 Page 3C-3 SERVICE PROCEDURES Intake Silencer 27 28 29 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 3 4 6 7 12 17 16 22 Page 3C-4 90-888465 JUNE 2002 SERVICE PROCEDURES Intake Silencer REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 INTAKE SILENCER (STARBOARD) 2 1 INTAKE SILENCER (PORT) 3 4 NUT 71 8 4 4 STUD 5 6 SEAL 6 8 BUSHING 7 2 COLLAR 8 4 SCREW (M6 X 45) 71 8 9 1 AIR TEMPERATURE SENSOR 35 4 10 2 TUBE 11 4 STA-STRAP 12 18 SCREW (8 X 35) 159 18 13 4 BOLT (8 X 16) 159 18 14 1 PLATE 15 1 BOLT (M6 X 10) 71 8 16 2 GASKET 17 4 PIN 18 3 SCREW (M6 X20) 71 8 19 1 COVER 20 1 DAMPER 21 1 CLIP 22 2 CLIP 23 1 HOSE 24 1 VENT PIPE 25 1 HOSE 26 1 HOSE 27 1 HOSE 28 1 SECONDARY VAPOR SEPARATOR (SVS) 29 1 HOSE 90-888465 JUNE 2002 Page 3C-5 SERVICE PROCEDURES Vapor Separator Hose Routing Page 3C-6 90-888465 JUNE 2002 SERVICE PROCEDURES Vapor Separator Hose Routing REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 CONNECTOR 2 3 CLAMP 3 1 HOSE 4 6 CLAMP 5 7 CLAMP 6 1 HOSE 7 1 CONNECTOR 8 1 BRACKET 9 2 SCREW (M6 X 10) 71 8 10 4 CLAMP 11 1 HOSE 12 4 STA-STRAP 13 1 HOSE 14 1 TEE 15 1 HOSE 16 1 CHECK VALVE 17 1 HOSE 18 1 CLAMP 19 1 HOSE 20 1 TEE 21 1 HOSE 22 1 HOSE 23 1 FUEL FILTER 24 1 COVER 25 1 HOSE 26 1 CONNECTOR 90-888465 JUNE 2002 Page 3C-7 SERVICE PROCEDURES SERVICE PROCEDURES Vapor Separator 10 Page 3C-8 90-888465 JUNE 2002 SERVICE PROCEDURES Vapor Separator REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 COVER ASSEMBLY 2 1 PLATE 3 2 PLATE 4 2 SCREW (M4 X 8) 18 2 5 7 SCREW (M4 X 15) 18 2 6 1 CAP PLUG 7 2 HOSE 8 1 TEE FITTING 9 1 HOSE 10 1 SECONDARY VAPOR SEPARATOR (SVS) 11 1 NEEDLE & SEAT 12 1 O-RING 13 1 PLATE 14 1 SCREW (M4 X 8) 18 2 15 1 FLOAT 16 1 FLOAT PIN 17 1 FUEL PUMP 18 1 FILTER 19 1 COVER 20 1 GROMMET 21 1 GASKET 22 1 BODY ASSEMBLY-VAPOR SEPARATOR 23 1 DRAIN SCREW 18 2 24 1 WASHER 25 4 GROMMET 26 8 BUSHING 27 1 BRACKET 28 2 BUSHING 29 2 SCREW (M5 X 12) 44 5 30 1 FUEL PUMP 31 1 RELAY 32 1 SPACER 33 1 LOCKWASHER 34 1 WASHER 35 1 NUT 27 3 36 1 PLATE 37 3 SCREW (M8 X 16) 62 7 38 2 COLLAR 39 1 FUEL COOLER 40 2 WASHER 41 2 NUT 44 5 90-888465 JUNE 2002 Page 3C-9 SERVICE PROCEDURES Throttle Body Starboard Page 3C-10 90-888465 JUNE 2002 SERVICE PROCEDURES Throttle Body Starboard REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 THROTTLE BODY-TOP 2 1 THROTTLE BODY-CENTER 3 1 THROTTLE BODY-BOTTOM 4 3 NUT 18 2 5 3 LOCKWASHER 6 6 DOWEL PIN 7 3 GASKET 8 3 INJECTOR 9 3 O-RING KIT 10 5 SPRING 11 6 SCREW (M8 X 80) 159 18 12 9 WASHER 13 2 SCREW 14 1 SPRING 15 1 SCREW-AIR ADJUSTING 16 1 SPACER PLATE 17 1 O-RING 18 1 THROTTLE POSITION SENSOR 19 2 WASHER 20 2 LOCKWASHER 21 2 SCREW, TAMPER PROOF TORX 22 2 SCREW (M5 x 15) 44 5 23 2 BRACKET 24 1 MANIFOLD 25 3 SCREW (M6 X 10) 71 8 26 3 GASKET 27 1 CONNECTOR 28 4 CLAMP 29 1 CONNECTOR 30 1 HOSE 31 1 FUEL RAIL ASSEMBLY 32 1 FUEL RAIL JOINT 33 1 FUEL RAIL JOINT 34 2 O-RING 35 4 SCREW (M5 X 15) 44 5 36 3 SCREW (M8 X 45) 159 18 37 3 COLLAR 38 1 HOSE 90-888465 JUNE 2002 Page 3C-11 SERVICE PROCEDURES Throttle Body Port Page 3C-12 90-888465 JUNE 2002 SERVICE PROCEDURES Throttle Body Port REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 THROTTLE BODY-TOP 2 1 THROTTLE BODY-CENTER 3 1 THROTTLE BODY-BOTTOM 4 4 NUT 18 2 5 4 LOCKWASHER 6 1 SCREW-AIR ADJUSTING 7 1 SPRING 8 3 GASKET 9 2 SCREW 10 4 SPRING 11 6 SCREW (M8 X 80) 159 18 12 6 WASHER 13 3 INJECTOR 14 3 O-RING KIT 15 1 IAC CONTROL VALVE 16 1 O-RING 17 3 SCREW (M4 X 16) 35 4 18 3 WASHER 19 2 SCREW (M6 X 30) 71 8 20 1 PLATE 21 1 MAP SENSOR 22 2 SCREW (M5 X 15) 44 5 23 1 BRACKET 24 1 SCREW (M6 X 55) 71 8 25 1 HOUSING 26 1 HOSE 27 1 MANIFOLD 28 6 DOWEL PIN 29 3 SCREW (M6 X 10) 71 8 30 3 GASKET 90-888465 JUNE 2002 Page 3C-13 SERVICE PROCEDURES Throttle Body Hose Routing Page 3C-14 90-888465 JUNE 2002 SERVICE PROCEDURES Throttle Body Hose Routing REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 FUEL RAIL 2 1 FUEL RAIL JOINT 3 1 O-RING 4 2 SCREW (M5 X 15) 44 5 5 1 CAP 6 1 PRESSURE REGULATOR 7 2 SCREW (M6 X 12) 71 8 8 2 LOCKWASHER 9 3 WASHER 10 3 SCREW (M8 X 45) 159 18 11 3 COLLAR 12 1 HOSE 13 2 CLAMP 14 1 CONNECTOR 15 1 HOSE 16 2 HOSE 17 1 HOSE 18 1 TEE 19 1 HOSE 20 1 HOSE 21 1 CONNECTOR 22 1 STA-STRAP 23 1 HOSE 24 1 HOSE 25 1 HARNESS 26 1 HOSE 27 1 CLAMP 90-888465 JUNE 2002 Page 3C-15 SERVICE PROCEDURES Throttle Linkage 1016 1 2 3 4 5 6 7 8 9 10 11 12 1314 15 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 3334 8 6 9 9 8 10 10 1027 27 27 Page 3C-16 90-888465 JUNE 2002 SERVICE PROCEDURES Throttle Linkage REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 BALL JOINT 2 1 LEVER 3 1 BRACKET 4 2 SCREW (M6 X 20) 71 8 5 2 WASHER 6 2 PIN 7 1 THROTTLE CONTROL SHAFT 8 2 PIN 9 3 WASHER 10 5 BUSHING 11 1 BRACKET 12 2 SCREW (M6 X 14) 71 8 13 7 WASHER 14 2 CLAMP 15 1 CIRCLIP 16 2 GEAR 17 1 THROTTLE CONTROL LEVER 18 1 BUSHING 19 5 SCREW (M6 X 45) 71 8 20 1 SPRING 21 1 THROTTLE CAM 22 1 WAVE WASHER 23 1 SCREW 71 8 24 1 SCREW (M6 X 30) 71 8 25 1 WASHER 26 1 ACCELERATOR ARM ASSEMBLY 27 5 NUT 35 4 28 1 LINK 29 1 ROD 30 1 BUSHING 31 1 PIN 32 1 LINK ROD 33 1 BALL JOINT 34 1 NUT 90-888465 JUNE 2002 Page 3C-17 SERVICE PROCEDURES Fuel Filter Page 3C-18 90-888465 JUNE 2002 SERVICE PROCEDURES Fuel Filter REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 FUEL FILTER ASSEMBLY 2 1 CUP 3 1 NUT 4 1 O-RING 5 1 FLOAT 6 1 SPRING 7 1 FILTER ELEMENT 8 1 O-RING 9 4 STA-STRAP 10 1 HOSE 11 1 STA-STRAP 12 1 SCREW (M6 X 14) 71 8 13 1 WASHER 14 1 BRACKET 15 1 SCREW (M6 X 16) 71 8 16 1 LOCKWASHER 17 1 WASHER 18 1 BRACKET 19 2 SCREW (M6 X 19) 71 8 20 1 HOSE 21 1 CONNECTOR 22 1 DAMPER 90-888465 JUNE 2002 Page 3C-19 SERVICE PROCEDURES Fuel Injection Hose Routing a a b b c d e f g h b i k j l a-High pressure fuel hose (VST to starboard fuel rail) b-Fuel hose (pressure regulator to fuel cooler) c-High pressure fuel hose (starboard fuel rail to port fuel rail) d-Hose to MAP sensor e-Crankcase breather hose f-Fuel hose to VST g-Check valve h-Fuel bypass hose i-Fuel return from fuel cooler j-Fuel filter k-Fuel pump l-Secondary Vapor Separator (SVS) Page 3C-20 90-888465 JUNE 2002 SERVICE PROCEDURES 90-888465 JUNE 2002 Page 3C-21 Idle Air Control (IAC) Motor Removal 1. Disconnect IAC motor harness connector. 2. Remove IAC motor mounting screws. Remove IAC motor from body. 3. Inspect O-ring and replace if necessary. Installation 1. Install IAC motor to body. 2. Install IAC motor mounting screws. Tighten to specified torque. 3. Connect IAC motor harness connector. 59446 c b a a - IAC motor b- IAC motor mounting screw (3) M4 x 16 c - O-ring IAC Motor Mounting Screw Torque 2 Nm (18 lb-in.) SERVICE PROCEDURES Page 3C-22 90-888465 JUNE 2002 MAP Sensor Removal 1. Disconnect MAP sensor harness connector. 2. Remove MAP sensor mounting screws. Remove MAP sensor from body. 3. Inspect O-ring and replace if necessary. Installation 1. Install MAP sensor to body. 2. Install MAP sensor mounting screws. Tighten to specified torque. 3. Install MAP sensor harness connector. 59446 a c b a - MAP sensor b- MAP sensor mounting screw (2) M5 x 15 c - O-ring MAP Sensor Mounting Screw Torque 5 Nm (44 lb-in.) SERVICE PROCEDURES 90-888465 JUNE 2002 Page 3C-23 Intake Silencer Assembly Removal 1. Disconnect battery cables. 2. Unplug air temperature sensor harness connector. 3. Remove intake silencer mounting screws and nuts. 4. Remove the intake silencer assembly. c 59450 d a b e a - Battery cables b- Air temperature sensor harness connector c - Intake silencer mounting screw (4) M6 x 45 d- Intake silencer mounting nut (4) e - Secondary vapor separator (SVS ) Installation 1. Connect crankcase breather hose to intake silencer. 2. Lift the SVS slightly while installing the intake silencer 3. Install intake silencer mounting screws and nuts. Tighten to specified torque. 4. Align the SVS locating tabs with the holes in the intake silencer. 5. Connect air temperature sensor harness connector. 6. Connect battery cables. SERVICE PROCEDURES Page 3C-24 90-888465 JUNE 2002 59450 c d a b e g h f e a - Battery cables b- Air temperature sensor harness connector c - Intake silencer mounting screw (4) M6 x 45 d- Intake silencer mounting nut (4) e - Secondary vapor separator (SVS) f - Crankcase breather hose g- Intake silencer hole h- SVS location tabs Air Intake Silencer Mounting Screw/Nut Torque 8 Nm (71 lb-in.) SERVICE PROCEDURES 90-888465 JUNE 2002 Page 3C-25 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 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. 91-16850A7 a b c 59466 a - Fuel pressure gauge b- Valve c - Drain Hose SERVICE PROCEDURES Releasing Fuel Pressure in the VST 1. Remove pressure relief valve plug. 2. Release the VST pressure by depressing the valve. 3. Place a container under the VST drain screw. Remove the drain screw and drain VST. b c a a-VST pressure release valve b-Pressure release valve plug c-VST drain screw Page 3C-26 90-888465 JUNE 2002 SERVICE PROCEDURES 90-888465 JUNE 2002 Page 3C-27 Starboard Intake Assembly Removal 1. Remove the intake silencer assembly. Refer to Intake Silencer Assembly Removal. 2. Disconnect TPS harness connector. 3. Disconnect IAC hose. 4. Disconnect fuel injector harness connectors. b a c a - TPS harness connector b- IAC hose c - Injector harness SERVICE PROCEDURES Page 3C-28 90-888465 JUNE 2002 1. Cut sta-straps holding high pressure fuel line to wire harness guide. 2. To disconnect the high pressure fuel hose joints, push in the collar and pull high pressure fuel line apart. 3. Disconnect throttle link ball joint from throttle body. 4. Remove intake manifold mounting screws. 5. Remove intake manifold from head. a b c d a - Sta-strap b- Collar c - Throttle link ball joint d- Intake manifold screw (9) M8 x 35 SERVICE PROCEDURES 90-888465 JUNE 2002 Page 3C-29 Installation 1. Install intake manifold with the mounting screws. Tighten to specified torque. 2. Connect throttle link ball joint to throttle body. Tighten nut to specified torque. 3. To connect high pressure fuel lines, push hoses together. 4. Connect fuel injector harness connectors. 5. Secure high pressure fuel lines to wire harness guide with sta-strap. 6. Connect the IAC hose to the manifold. 7. Connect the TPI harness connector. a c d e f g b a - Intake manifold screws (9) M8 x 35 b- Throttle link ball joint. c - Sta-strap d- High pressure fuel line e - Fuel injector harness connector f - IAC hose g- TPI harness Manifold Mounting Screw Torque 18 Nm (159 lb-in.) Throttle Link Ball Joint Nut Torque 4 Nm (35 lb-in.) SERVICE PROCEDURES Page 3C-30 90-888465 JUNE 2002 Starboard Rail Fuel Hoses Removal 1. Remove the intake silencer assembly. Refer to Intake Silencer Assembly Removal. 2. Remove the starboard intake assembly. Refer to Starboard Intake Assembly Removal. 3. Cut the clamps holding fuel hose to fuel rail joint. 4. Remove the high pressure fuel line from the fuel rail joint. 59476 a a b b d c a - Hose clamp b- Fuel rail joint c - High pressure fuel hose from VST d- High pressure fuel hose to port fuel rail Installation 1. Clamp high pressure fuel line to fuel rail joint. NOTE: Only use tool 91-803146T (0r Snap-On equivalent YA3080) to crimp full circle hose clamps. Using a different tool could result in a crimp that is too loose or too tight. Do not use screw type metal hose clamps as it may damage the hose. 2. Install starboard intake assembly. Refer to Starboard Intake Assembly Installation. 3. Install intake silencer. Refer to Intake Silencer Assembly Installation. SERVICE PROCEDURES 90-888465 JUNE 2002 Page 3C-31 Starboard Fuel Rail Removal 1. Remove the intake silencer assembly. Refer to Intake Silencer Assembly Removal. 2. Remove starboard intake. Refer to Starboard Intake Removal. 3. Remove fuel rail mounting screws. Remove fuel rail. a 59472 a - Fuel rail screws M8 x 45 Installation 1. Insert the collar into the throttle body cavity. 2. Insert fuel rail assembly into the throttle body assembly. 3. Insert the fuel rail mounting screws. Tighten to specified torque. 4. Install starboard intake. Refer to Starboard Intake Installation. 5. Install intake silencer. Refer to Intake Silencer Assembly Installation. 59475 a b c d b e a - Fuel rail b- Collar c - Throttle body collar cavity d- Throttle body e - Fuel rail mounting screw (3) M8 x 45 Fuel Rail Mounting Screw Torque 18 Nm (159 lb in.) SERVICE PROCEDURES Starboard Fuel Rail Disassembly 1. Remove the intake silencer assembly. Refer to Intake Silencer Assembly Removal. 2. Remove starboard intake. Refer to Starboard Intake Removal. 3. Remove starboard fuel rail. Refer to Starboard Fuel Rail Removal. 4. Remove the upper and lower fuel rail joint. 5. Remove the fuel injector. a b c e f g h a d i a-Fuel rail joint screw (4) M5 x 15 b-Fuel line bracket c-Fuel injector d-Collar e-Fuel rail joint (lower) f-Fuel rail joint O-ring g-Fuel rail h-Fuel rail joint O-ring i-Fuel rail joint (upper) Page 3C-32 90-888465 JUNE 2002 SERVICE PROCEDURES Assembly 1. Lubricate O-ring on upper and lower fuel rail joint. Install fuel rail joints to fuel rail. Tighten to specified torque. 2. Lubricate fuel injector seals and O-rings. Push fuel injectors into fuel rail. NOTE: The fuel rail has location tabs to ensure proper orientation of the fuel injector. 3. Install starboard fuel rail. Refer to Starboard Fuel Rail Installation. 4. Install starboard intake. Refer to Starboard Intake Installation. 5. Install intake silencer. Refer to Intake Silencer Assembly Installation. a b e f d a c h i g 110 110 4 Stroke Outboard Oill a-Fuel rail joint screw (4) M5 x 15 b-Fuel line bracket c-Fuel rail joint (upper) d-O-ring e-Fuel rail f-O-ring g-Fuel rail joint (lower) h-Fuel injector i-Fuel rail location tab Fuel Rail Joint Screw 5 Nm (44 lb-in.) 90-888465 JUNE 2002 Page 3C-33 SERVICE PROCEDURES Starboard Fuel Injector Removal 1. Remove intake silencer. Refer to Intake Silencer Assembly Removal. 2. Remove starboard intake. Refer to Starboard Intake Removal. 3. Remove starboard fuel rail. Refer to Starboard Fuel Rail Removal. 4. Remove fuel injectors. Installation 1. Clean or replace fuel injector filter. 2. Install new O-rings and seals. Lubricate fuel injector O-rings and seals. 3. Install fuel injector to fuel rail. Refer to Starboard Fuel Rail Assembly. 4. Install the fuel rail into the throttle body. Refer to Starboard Fuel Rail Installation. 5. Install starboard intake. Refer to Starboard Intake Installation. 6. Install intake silencer. Refer to Intake Silencer Assembly Installation. b c f g a hd e f 110 4 Stroke Outboard Oill 110 a-Fuel rail b-Collar c-O-ring d-Grommet e-Fuel injector filter f-Fuel injector g-Rubber seal h-Fuel rail location tabs Page 3C-34 90-888465 JUNE 2002 SERVICE PROCEDURES Starboard Throttle Body Removal 1. Remove intake silencer. Refer to Intake Silencer Assembly Removal. 2. Remove starboard intake. Refer to Starboard Intake Removal 3. Remove starboard fuel rail. Refer to Starboard Fuel Rail Removal. 4. Remove throttle body mounting screws. NOTE: When separating the throttle body assemblies be careful not to loose the tension springs and the throttle linkage spring. a b c d e f g a-Screw-air adjusting b-Dowel pin (3) c-Synchronize screw (2) d-Throttle linkage spring (starboard side throttle body only) e-Tension spring (5) f-Collar (3) g-Injector (3) 90-888465 JUNE 2002 Page 3C-35 SERVICE PROCEDURES Installation 1. Install O-ring onto throttle body. 2. Install dowel pin into the intake manifold. 3. Install the top throttle body to the intake manifold. Tighten to specified torque. a b c d a-Dowel pin b-O-ring c-Throttle body d-Throttle body mounting screw (2) M8 x 80 Throttle Body Mounting Screw Torque 18 Nm (159 lb-in.) 4. Install the center throttle body to the intake manifold. Be careful to align the linkage between the top and center throttle bodies. Push the tension spring between the throttle actuating levers. Tighten the center throttle body mounting screws to specified torque. 59474 a b a c a-Tension spring b-Throttle linkage spring (starboard side only) c-Throttle body mounting screw (2) M8 x 80 Throttle Body Mounting Screw Torque 18 Nm (159 lb-in.) Page 3C-36 90-888465 JUNE 2002 SERVICE PROCEDURES 5. Install the bottom throttle body to the intake manifold. Be careful to align the linkage between the center and bottom throttle bodies. Push the tension spring between the throttle actuating levers. Tighten the bottom throttle body to specified torque. 59474 a a b a-Tension spring b-Throttle body mounting screw. (2) M8 x 80 6. Install starboard fuel rail. Refer to Starboard Fuel Rail Installation. 7. Install starboard intake. Refer to Starboard Intake Installation. 8. Install intake silencer. Refer to Intake Silencer Assembly Installation. Throttle Body Mounting Screw Torque 18 Nm (159 lb-in.) 90-888465 JUNE 2002 Page 3C-37 SERVICE PROCEDURES Page 3C-38 90-888465 JUNE 2002 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 1. Install the fuel pressure gauge onto the pressure check valve. 2. Place the drain hose into a container. 3. Open the valve to release the pressure. 91-16850A7 a b c 59466 a - Fuel pressure gauge b- Valve c - Drain Hose SERVICE PROCEDURES Releasing Fuel Pressure in the VST 1. Remove pressure relief valve plug. 2. Release the VST pressure by depressing the valve. 3. Place a container under the VST drain screw. Remove the drain screw and drain VST. b c a a-VST pressure release valve b-Pressure release valve plug c-VST drain screw 90-888465 JUNE 2002 Page 3C-39 SERVICE PROCEDURES Page 3C-40 90-888465 JUNE 2002 Port Intake Removal 1. Remove intake silencer. Refer to Intake Silencer Removal. 1. Cut sta-straps holding high pressure fuel line to wire harness guide. 2. To disconnect the high pressure fuel hose joints, push in the collar and pull apart. 3. Disconnect IAC motor harness. 4. Disconnect MAP sensor harness. 5. Cut sta-strap holding temperature sender wires to support bracket. a b c d f e a - Sta-strap b- Collar c - IAC hose d- Temperature sender wire support bracket e - IAC motor harness f - MAP sensor harness SERVICE PROCEDURES 90-888465 JUNE 2002 Page 3C-41 6. Remove the throttle link ball joint nut. 7. Disconnect the fuel return line (fuel regulator to fuel cooler). 8. Remove intake manifold mounting screws. Remove intake manifold assembly. 9. Disconnect fuel injector harness connectors. a b c e d f a - Throttle link ball joint nut b- Map sensor c - IAC harness d- Manifold screws (9) M8 x 35 e - Fuel line (fuel regulator to fuel cooler) f - Fuel injector harness connector Installation 1. Connect fuel injector harness to fuel injectors. 2. Guide the high pressure hose through the wire harness guide. Install the intake manifold. Tighten to specified torque. 3. Connect the fuel return line (fuel regulator to the fuel cooler). b c e d a a - Fuel injector harness connector b- Map sensor c - IAC harness d- Manifold screws (9) M8 x 35 e - Fuel line (fuel regulator to fuel cooler) Intake Manifold Screw Torque 18 Nm (159 lb-in.) SERVICE PROCEDURES Page 3C-42 90-888465 JUNE 2002 4. Connect the high pressure fuel hose joints by pushing the fuel lines together. 5. Install the throttle link ball joint to the throttle lever. Tighten to specified torque. 6. Connect IAC motor harness. 7. Connect MAP sensor harness. 8. Secure temperature sender wires to support bracket. 9. Secure high pressure fuel hoses to wire guide. 10. Install intake silencer. Refer to Intake Silencer Installation. a c d f e b a - Sta-strap b- Throttle link ball joint nut c - IAC hose d- Temperature sender wire support bracket e - IAC motor harness f - MAP sensor harness Throttle Link Ball Joint Nut Torque 4 Nm (35 lb-in.) SERVICE PROCEDURES Fuel Pressure Regulator Removal 1. Remove intake silencer. Refer to Intake Silencer Removal. 2. Remove port intake. Refer to Port Intake Removal. 3. Remove hose from MAP sensor. 4. Remove the fuel return hose. 5. Remove fuel pressure regulator mounting screws. a b c e d a-Fuel pressure regulator b-Hose from MAP sensor c-Fuel pressure regulator screws (2) M6 x 12 d-Joint e-Fuel hose (fuel return to fuel cooler) 90-888465 JUNE 2002 Page 3C-43 c d e a b 110 c d e a b 110 SERVICE PROCEDURES Installation 1. Install O-ring on fuel pressure regulator. 2. Lubricate O-ring. Install fuel pressure regulator to fuel rail. 3. Install fuel pressure regulator mounting screws. Tighten to specified torque. 4. Install the fuel return hose. 5. Install the MAP sensor hose to the top of the fuel pressure regulator. 6. Install port intake. Refer to Port Intake Installation. 7. Install intake silencer. Refer to Intake Silencer Installation. 110 4 Stroke Outboard Oil a-Screw (2) M6 x 12 b-Fuel pressure regulator c-O-ring d-Map sensor hose e-Fuel return hose Fuel Pressure Regulator Mounting Screw 8 Nm (71 lb-in.) Page 3C-44 90-888465 JUNE 2002 SERVICE PROCEDURES MAP Sensor Hoses Removal 1. Remove intake silencer. Refer to Intake Silencer Removal. 2. Remove port intake. Refer to Port Intake Removal. 3. Remove MAP hoses attached to the intake manifold and the MAP sensor manifold joint. a b c e d f a-Fuel pressure regulator b-Fuel pressure regulator hose c-Map sensor manifold joint d-MAP sensor hose ports on intake manifold e-Hose to MAP sensor from Map sensor manifold joint f-MAP sensor Installation 1. Install hoses as pictured. 2. Install port intake. Refer to Port Intake Installation. 3. Install intake silencer. Refer to Intake Silencer Installation. 90-888465 JUNE 2002 Page 3C-45 SERVICE PROCEDURES Page 3C-46 90-888465 JUNE 2002 Port Rail Fuel Hose Removal 1. Remove port intake assembly. Refer to Port Intake Removal. 2. Cut the metal hose clamp. 3. Remove the high pressure fuel line from the fuel rail joint. a c b a - Metal hose clamp b- Crimping tool c - High pressure fuel hose Installation 1. Push high pressure fuel hose onto fuel rail joint. 2. Clamp the high pressure fuel line to the fuel rail joint. NOTE: Only use tool 91-803146T (0r Snap-On equivalent YA3080) to crimp metal hose clamps. Using a different tool could result in a crimp that is too loose or too tight. Do not use screw type metal hose clamps as it may damage the hose. 3. Install port intake. Refer to Port Intake Installation. SERVICE PROCEDURES 90-888465 JUNE 2002 Page 3C-47 Port Fuel Rail Removal 1. Remove port intake. Refer to Port Intake Removal. 2. Remove fuel rail mounting screws. 3. Pull fuel rail away from throttle body. 59472 a a - Fuel rail screws (3) M8 x 35 Installation 1. Insert the collar into the throttle body cavity. 2. Insert fuel rail assembly into throttle body assembly. 3. Insert fuel rail mounting screws. Tighten to specified torque. 4. Install port Intake assembly. Refer to Port Intake Installation. 59475 a b c d b e a - Fuel rail b- Collar c - Throttle body collar cavity d- Throttle body e - Fuel rail mounting screw (3) M8 x 35 Fuel Rail Mounting Screw 18 Nm (159 lb-in.) SERVICE PROCEDURES Page 3C-48 90-888465 JUNE 2002 Port Fuel Rail Disassembly 1. Remove port intake. Refer to Port Intake Removal. 2. Remove fuel pressure regulator. Refer to Fuel Pressure Regulator Removal. 3. Remove fuel rail joint mounting screws (2). 4. Remove port fuel rail. Refer to Port Fuel Rail Removal. 59475 e a b c d f h g a - Fuel rail joint mounting screw (2) M5 x 15 b- Fuel rail joint c - Fuel rail joint o-ring d- Fuel rail screws (3) M8 x 35 e - Collar f - Fuel pressure regulator g- Fuel pressure regulator screw (2) M6 x 12 h- Fuel pressure regulator o-ring SERVICE PROCEDURES Assembly 1. Install fuel pressure regulator. Refer to Fuel Pressure Regulator Installation. 2. Install fuel injectors onto the fuel rail. 3. Install fuel rail joint O-ring to fuel rail joint. 4. Lubricate fuel rail joint O-ring. Install fuel rail joint to fuel rail. Tighten to specification. NOTE: The fuel rail has location tabs to ensure proper orientation of the fuel injector. a b c d e f g i j h g k 4 Stroke Outboard Oil110 110 110 a-Fuel pressure regulator screw (2) M6 x 12 b-Fuel pressure regulator c-Fuel pressure regulator O-ring d-Port fuel rail e-Collar f-Fuel rail location tabs g-Fuel injector h-Fuel rail screw (3) M8 x 45 i-Fuel rail joint O-ring j-Fuel rail joint k-Fuel rail joint screw (2) M5 x 15 Fuel Rail Joint Mounting Screw Torque 5 Nm (44 lb-in.) 90-888465 JUNE 2002 Page 3C-49 SERVICE PROCEDURES Page 3C-50 90-888465 JUNE 2002 5. Install the fuel rail into the throttle body. Refer to Fuel Rail Installation. 6. Install starboard intake. Refer to Port Intake Installation. 7. Install intake silencer. Refer to Intake Silencer Assembly Installation. 59475 a b a - Fuel rail screws (3) M8 x 35 b- Collar Fuel Rail Mounting Screw Torque (18 Nm)159 lb-in. SERVICE PROCEDURES Port Fuel Injectors Removal 1. Remove intake silencer. Refer to Intake Silencer Assembly Removal. 2. Remove starboard intake. Refer to Port Intake Removal. 3. Remove starboard fuel rail. Refer to Port Fuel Rail Removal. 4. Remove fuel injectors. Installation 1. Clean or replace fuel injector filter. 2. Install new O-rings and seals. Lubricate fuel injector O-rings and seals. 3. Install fuel injectors into the fuel rail. NOTE: The fuel rail has location tabs to ensure proper orientation of the fuel injector. 4. Install the fuel rail into the throttle body. Refer to Port Fuel Rail Installation. 5. Install port intake. Refer to Port Intake Installation. 6. Install intake silencer. Refer to Intake Silencer Assembly Installation. g h e a b c d ff 4 Stroke Outboard Oil110 110 a-Fuel rail b-Collar c-O-ring d-Grommet e-Fuel injector filter f-Fuel injector g-Rubber seal h-Fuel rail location tabs 90-888465 JUNE 2002 Page 3C-51 SERVICE PROCEDURES Port Throttle Body Removal 1. Remove port intake. Refer to Port Intake Removal. 2. Remove port fuel rail. Refer to Port Fuel Rail Removal. 3. Remove throttle body mounting screws. NOTE: When separating the throttle body assemblies, be careful not to lose the tension springs. d b a c f e a-Screw-air adjusting b-Dowel (6) c-Synchronize screw (2) d-Tension spring (5) e-Throttle body mounting screw (6) M8 x 80 f-Washer (6) Page 3C-52 90-888465 JUNE 2002 SERVICE PROCEDURES Installation 1. Install O-rings onto throttle body. 2. Install throttle body collar into the intake manifold. 3. Install the top throttle body to the intake manifold. Tighten to specified torque. b c a a-Dowel pin b-O-ring c-Top throttle body Throttle Body Mounting Screw 18 Nm (159 lb-in.) 4. Install the middle throttle body to the intake manifold. Be careful to align the linkage between the top and middle throttle bodies. Push the tension spring between the throttle actuating levers. Tighten to specified torque. 59474 ab a a-Tension spring b-Dowel pin Throttle Body Mounting Screw 18 Nm (159 lb-in.) 90-888465 JUNE 2002 Page 3C-53 SERVICE PROCEDURES 5. Install the bottom throttle body to the intake manifold. Be careful to align the linkage between the middle and bottom throttle bodies. Push the tension spring between the throttle actuating levers. Tighten to specified torque. 59474 a a b a-Tension spring b-Dowel pin 6. Install starboard fuel rail. Refer to Starboard Fuel Rail Installation. 7. Install starboard intake. Refer to Starboard Intake Installation. Throttle Body Mounting Screw 18 Nm (159 lb-in.) Page 3C-54 90-888465 JUNE 2002 SERVICE PROCEDURES 90-888465 JUNE 2002 Page 3C-55 Fuel Cooler 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. Removal 1. Remove the air silencer. Refer to Intake Silencer Removal. 2. Remove the power ground screw. 3. Remove fuel filter support bracket mounting screws (2). 4. Remove bracket mounting screws (6). 59451 a b d d c a - Fuel filter support bracket screws (2) M6 x 19. b- Power ground screw (1) M6 x 20. c - ECM connection harness. d- Bracket screws (6) M6 x 28. SERVICE PROCEDURES Page 3C-56 90-888465 JUNE 2002 5. Pull bracket away from the power head to expose the top water hose. (The top fuel cooler water hose is connected to the water cooled voltage regulator. The voltage regulator is hidden behind the ECM.) 6. Remove the bottom water hose. (The bottom fuel cooler water hose exits through the tell tale). 7. Remove top and bottom fuel hoses. 8. Remove nuts retaining fuel cooler. b d f 59478 a c e a - Bottom water line (exit). b- Top water line (entry). c - Water cooled voltage regulator. d- Fuel return hose from fuel pressure regulator. e - Fuel cooler retaining nut f - Fuel return to VST. SERVICE PROCEDURES Installation 1. Install collar onto the plate studs. 2. Install fuel cooler, washers and nuts. Tighten nuts to specified torque. a b c d e a-Fuel cooler b-Collar c-Nut d-Washer e-Studs Fuel Cooler Mounting Nut Torque 5 Nm (44 lb-in.) 90-888465 JUNE 2002 Page 3C-57 SERVICE PROCEDURES Page 3C-58 90-888465 JUNE 2002 3. Install water hoses to fuel cooler. 4. Install fuel hoses to the fuel cooler. b d f 59478 a c f e a - Bottom water hose (exit) b- Top water hose (entry) c - Water cooled voltage regulator d- Fuel return hose from fuel pressure regulator e - Fuel cooler nut f - Fuel return hose to VST 5. Install bracket mounting screws (6). Torque to specification. a a - Bracket mounting screw (6) M6 x 20 Bracket Mounting Screw Torque 8 Nm (71 lb-in.) SERVICE PROCEDURES 90-888465 JUNE 2002 Page 3C-59 6. Install fuel filter support bracket mounting screws. Tighten to specified torque. 7. Install power ground screw. Tighten to specified torque. 8. Install air silencer. Refer to Intake Silencer Installation. 59451 a b c a - Fuel filter support bracket mounting screws (2) M6 x 19. b- Power ground screw (1) M6 x 20. c - ECM connection harness. Fuel Filter Support Bracket Mounting Screw Torque 8 Nm (71 lb-in.) Power Ground Mounting Screw Torque 8 Nm (71 lb-in.) SERVICE PROCEDURES Page 3C-60 90-888465 JUNE 2002 Vapor Separator 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. Removal 1. Remove air silencer. Refer to Intake Silencer Removal. 2. Remove the power ground screw. 3. Remove fuel filter support bracket mounting screws. 4. Remove bracket mounting screws. 59451 a b d d c a - Fuel filter support bracket mounting screws (2) M6 x 19 b- Power ground screw (1) M6 x 20 c - ECM connection harness d- Bracket mounting screws (6) M6 x 28 SERVICE PROCEDURES 90-888465 JUNE 2002 Page 3C-61 5. Pull bracket away from power head to expose the upper water hose on the fuel cooler. 6. Remove top and bottom fuel cooler water hoses. 7. Disconnect fuel hose (fuel regulator to fuel cooler). 8. Remove fuel line retainer mounting screw. d e b f 59478 a c d a - Bottom water hose (water exit) b- Top water hose (water entry) c - Water cooled voltage regulator d- Fuel line (fuel regulator to fuel cooler) e - Fuel line retainer mounting screw f - Fuel line (fuel cooler to VST) 9. Disconnect high pressure fuel line. Refer to Port Intake Removal. 10. Disconnect the high pressure fuel pump harness connector a a - High pressure fuel pump harness connector SERVICE PROCEDURES Page 3C-62 90-888465 JUNE 2002 11. Disconnnect the fuel pump harness connector. 12. Disconnect the fuel pump driver harness connector. 13. Disconnect the high pressure fuel pump relay harness connector. 59458 a b c a - Fuel pump harness b- Fuel pump driver harness c - High pressure fuel pump relay harness 14. Remove screws (4) holding VST and plate to powerhead. 15. Carefully pull VST out. Lay down so the back side of VST faces up. 16. Remove wire harness mounts from the plate with pliers. NOTE: While pinching the retainer clips, push retainer through the plate. 17. Remove plate mounting screws (3). 59470 a a c b a - VST mounting screw b- Wire harness mount retainer clips c - Plate mounting screw M8 x 16 SERVICE PROCEDURES 90-888465 JUNE 2002 Page 3C-63 Installation 1. Install plate. Tighten plate screws to specified torque. a b c a - Plate mounting screw (M8 x 16) b- Plate c - VST body Plate Mounting Screws 18 Nm (159 lb-in.) 2. Guide the high pressure fuel line up and through the wire harness guide. 3. Align the VST mounting holes with the holes on the powerhead. 4. Insert VST mounting screws (4). Tighten to specified torque. 59470 a b b a - High pressure fuel line b- VST mounting screw M8 x 16 VST Mounting Screw Torque 18 Nm (159 lb-in.) SERVICE PROCEDURES Page 3C-64 90-888465 JUNE 2002 5. Insert the fuel pump harness mount in the top hole. 6. Insert the fuel pump driver harness mount in the bottom hole. 59458 a b BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green RED = Red WHT = White YEL = Yellow a - Fuel pump harness. (RED/BLU, RED/YEL) b- Fuel pump driver harness. (BLK, BLK/WHT, RED/BLU, RED/WHT) 7. Connect the high pressure fuel pump harness connector. 8. Connect the fuel pump harness connector. 9. Connect the fuel pump driver harness connector. 10. Connect the high pressure fuel pump relay harness. 11. Connect the high pressure fuel line. Refer to Port Intake Installation. 59458 b c d a a - High pressure fuel pump harness connector b- Fuel pump harness connector c - Fuel pump driver harness connector d- High pressure fuel pump relay harness connector SERVICE PROCEDURES 90-888465 JUNE 2002 Page 3C-65 12. Pull bracket away from powerhead to expose water hose from water cooled voltage reguator. 13. Connect top and bottom water hoses to fuel cooler. a b c d e a - Bottom fuel cooler water hose (exit) b- Top water hose from voltage regulator (entry) c - Water cooled voltage regulator d- Fuel hose (fuel regulator to fuel cooler) e - Fuel hose (fuel cooler to VST) 14. Connect fuel hose (fuel regulator to fuel cooler). a a - Fuel line (fuel regulator to fuel cooler) SERVICE PROCEDURES Page 3C-66 90-888465 JUNE 2002 15. Install bracket mounting screws. Tighten to specified torque. a a - Bracket mounting screw (6) M6 x 28 Bracket Mounting Screw Torque 8 Nm (71 lb-in.) 16. Install fuel filter support bracket mounting screws. Tighten to specified torque. 17. Install power ground screw. Tighten to specified torque. 18. Connect the ECU harness. 19. Install air silencer. Refer to Intake Silencer Installation. 59451 a b c a - Fuel filter support bracket mounting screw (2) M6 x 19. b- Power ground screw (1) M6 x 20. c - ECU connection harness. Fuel fIlter Support Bracket Mounting Screw Torque 8 Nm (71 lb-in.) Power Ground Mounting Screw Torque 8 Nm (71 lb-in.) SERVICE PROCEDURES 90-888465 JUNE 2002 Page 3C-67 Vapor Separator Disassembly 1. Remove vapor separator. Refer to Vapor Separator Removal. 2. Remove top cover screws. Remove top cover assembly. 3. 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 4. 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 SERVICE PROCEDURES 5. 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. 6. Remove the collar if required. 7. Disconnect the high pressure fuel pump connector. 8. 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-68 90-888465 JUNE 2002 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 90-888465 JUNE 2002 Page 3C-69 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 top cover screws (7). 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 Top Cover Screw Torque 4 Nm (35 lb-in.) Page 3C-70 90-888465 JUNE 2002 SERVICE PROCEDURES Secondary Vapor Separator (SVS) Removal 1. Remove flywheel cover. 2. Remove the VST vent hose. 3. Remove SVS mounting screw. 4. Remove SVS. 59440 e a b c d a-Flywheel mounting screw b-SVS mounting screw c-SVS inlet d-SVS vent hose e-SVS 90-888465 JUNE 2002 Page 3C-71 SERVICE PROCEDURES Page 3C-72 90-888465 JUNE 2002 Installation 1. Guide SVS vent hose between the 2 rows of fuses and behind the intake silencer. 2. Push the SVS vent hose nipple into the bottom cowl grommet. 3. Install the SVS mounting screw. Tighten to specification. 59446 a b c d b c d e a - SVS b- SVS vent hose c - SVS vent hose nipple d- Bottom cowl grommet e - SVS mounting screw (M6 X 35) SVS Mounting Screw Torque 8 Nm (71 lb-in.) 4. Install the VST vent hose to the SVS inlet port. 5. Install Flywheel cover. Tighten to specified torque. 59440 c d e a b a - SVS b- SVS vent c - VST vent hose d- VST e - Flywheel cover mounting screws (M6 X 28) Flywheel Cover Mounting Screw Torque 8 Nm (71 lb-in.) SERVICE PROCEDURES Fuel Filter Disassembly 1. Loosen both screws holding fuel filter to mounting bracket. 2. Move bracket off of filter nut. Unscrew filter nut. 3. Remove 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. 3. Hand tighten fuel filter nut. 4. Lock filter nut with bracket. Tighten to specified torque. a b d g h i j e k l c f a-Screw (1) M6 x 16 b-Bracket c-Screw (1) M6 x 14 d-Fuel Filter Mounting Bracket e-Fuel Filter Cap f-O-ring g-Fuel Filter Element h-Spring i-O-ring j-Fuel Filter Cup k-Nut l-Float Fuel Filter Mounting Screw Torque 8 Nm (71 lb- in.) 90-888465 JUNE 2002 Page 3C-73 EMISSIONS FUEL SYSTEM Section 3D - Emissions Table of Contents Exhaust Emissions Standards . . . . . . . . . . . . 3D-2 Manufacturer’s Responsibility . . . . . . . . . . 3D-4 What Are Emissions? . . . . . . . . . . . . . . . . . 3D-2 Dealer Responsibility . . . . . . . . . . . . . . . . . 3D-4 Hydrocarbons - HC . . . . . . . . . . . . . . . . . . . 3D-2 Owner Responsibility . . . . . . . . . . . . . . . . . 3D-4 Carbon Monoxide - CO . . . . . . . . . . . . . . . . 3D-2 EPA Emission Regulations . . . . . . . . . . . . 3D-5 Oxides of Nitrogen - NOx . . . . . . . . . . . . . . 3D-2 Manufacturer’s Certification Label . . . . . . . . . 3D-6 Controlling Emissions . . . . . . . . . . . . . . . . . 3D-2 Service Replacement Certification Label . . . 3D-7 Stoichiometric (14.7:1) Air/Fuel Ratio . . . 3D-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-7 Outboard Hydrocarbon Date Code Identification . . . . . . . . . . . . . . . 3D-7 Emissions Reductions . . . . . . . . . . . . . . . . . . . 3D-3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-7 Emissions Information . . . . . . . . . . . . . . . . . . . 3D-4 Decal Location . . . . . . . . . . . . . . . . . . . . . . . 3D-7 3 D 90-888465 JUNE 2002 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 be- come 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 90-888465 JUNE 2002 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 90-888465 JUNE 2002 Page 3D-3 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-4 90-888465 JUNE 2002 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 90-888465 JUNE 2002 Page 3D-5 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: 3M9XM03.42G0 Idle Speed (in neutral): 750 RPM FEL: 30.94 GM/KW-HR 225 HP 3352 cc Timing (in degrees): Not Adjustable CDI Controlled Standard Spark Plug: NGK LFR5A-11 Suppressor Spark Plug: NGK LFR5A-11 Intake: 0.20+ –0.03 Exhaust: 0.34+ –0.03 Gap: 0.043, (1.1 mm) This engine conforms to 2003 Model Year California and U.S.. EPA regulations for marine SI engines. OCTOBER 2002 f g h i j b c e a d Valve Clearance (Cold) mm a -Spark Ignition (SI) b -Idle Speed 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 3 M9X M03.4 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-6 90-888465 JUNE 2002 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 2003 PART # 37–889307 - 03 This engine conforms to 2002 Model Year California and U.S. EPA regulations for marine SI engines. Idle Speed (in neutral): 750 RPM Timing: Not Adjustable CDI Controlled Spark Plug: NGK LFR5A-11 Gap: 0.043” (1.1 mm) Valve Clearance (Cold) mm Intake: 0.20+ – 0.03 Exhaust: 0.34+ –0.03 Family: 3M9XM03.42G0 FEL: 30.94 GM/KW-HR 3352 cc 225 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 2003Merc/Mar 225 hp (4-Stroke) 37-889307-03 Top of Flywheel Cover 90-888465 JUNE 2002 Page 3D-7 CYLINDER HEAD POWERHEAD Section 4A - Cylinder Head Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2 Preparing Cylinder Head for Removal . . . 4A-24 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-4 Cylinder Head Removal . . . . . . . . . . . . . . . 4A-27 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-6 Cylinder Head Disassembly . . . . . . . . . . . . . . 4A-28 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-8 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . 4A-30 Timing Belt and Head Covers . . . . . . . . . . . . . 4A-10 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-30 Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . 4A-11 Timing Chain Tensioner . . . . . . . . . . . . . . . 4A-32 Cylinder Head Screws . . . . . . . . . . . . . . . . 4A-11 Timing Chain . . . . . . . . . . . . . . . . . . . . . . . . 4A-33 Camshaft Caps Screws . . . . . . . . . . . . . . . 4A-11 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-33 Exhaust Cover Screws . . . . . . . . . . . . . . . . 4A-12 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-34 Removing the Oil Filter . . . . . . . . . . . . . . . . . . . 4A-12 Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . 4A-35 Timing Belt and Sprocket . . . . . . . . . . . . . . . . . 4A-13 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . 4A-36 Valve Clearance MeasurementValve Guides . . . . . . . . . . . . . . . . . . . . . . . . 4A-37 and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . 4A-13 Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-39 Preparation for Valve ClearanceRefacing the valve seat . . . . . . . . . . . . . . . 4A-41 Measurement . . . . . . . . . . . . . . . . . . . . . . . 4A-13 Cylinder Head Reassembly . . . . . . . . . . . . . . . 4A-44 Valve Clearance Measurement Steps . . . 4A-14 Cylinder Head Installation . . . . . . . . . . . . . . . . 4A-46 Changing Shim Thickness . . . . . . . . . . . . . 4A-18 Following Cylinder Installation . . . . . . . . . . . . . 4A-48 Powerhead Removal . . . . . . . . . . . . . . . . . . . . 4A-24 4 A 90-888465 JUNE 2002 Page 4A-1 CYLINDER HEAD Specifications Camshaft Dimensions Intake “A” 45.30 - 45.40 mm (1.7835 - 1.7874 in.) Exhaust “A” 45.35 - 45.45 mm 1.7854 - 1.7894 in.() Intake “B” A 39.95 - 36.05 mm (1.4154 - 1.4193 in.) Exhaust “B” 39.95 - 36.05 mm (1.4154 - 1.4193 in.) Run-out Limit 0.1 mm (0.004 in.) CAMSHAFT Camshaft Bearing Diameter “a” B 24.96 - 24.98 mm (0.9827 - 0.9835 in.) Camshaft Bearing Oil Clearance 0.02-0.06 mm (0.0008-0.0023 in.) A Free Length “a” 44.20 mm (1.740 in.) Minimum Free Length 42.60 mm (1.677 in.) VALVE SPRING Tilt Limit “b” a b Less than 1.5 mm (0.06 in.) Warp Limit 0.1 mm (0.004 in.) CYLINDER HEAD Camshaft Bearing Inside Diameter a 25.000 - 25.020 mm (0.9843 - 0.9850 in.) Valve Lifter Bore Outside Diameter 32.98-33.00 mm (1.2984-1.2992 in.) Valve lifter to cylinder head clearance 0.02-0.05 mm (0.0008-0.0020 in.) Page 4A-2 90-888465 JUNE 2002 CYLINDER HEAD Valve/Valve Seat/Valve Guides: Valve Clearance (cold) Intake 0.20 ± 0.03 mm (0.008 ± 0.001 in.) Exhaust Valve Dimensions: “A” Head Diameter 0.34 ± 0.03 mm (0.013 ± 0.001 in.) Intake 34.85 - 35.15 mm (1.3720 - 1.3839 in.) Exhaust “B” Face Width 29.85 - 30.15 mm (1.1752 - 1.1870 in.) Intake 2.11 mm (0.0831 in.) Exhaust “C” Seat Width 2.43 mm (0.0957 in.) Intake 1.1 - 1.4 mm (0.043 - 0.055 in.) Exhaust “D” Margin Thickness 1.4 - 1.7 mm (0.055 - 0.067 in.) Intake 0.7 mm (0.028 in.) VALVES Exhaust Stem Outside Diameter 1.00 mm (0.039 in.) Intake 5.477 - 5.492 mm (0.2156 - 0.2162 in.) Exhaust Guide Inside Diameter 5.464 - 5.479 mm (0.2151 - 0.2157 in.) Intake 5.51 - 5.52 mm (0.2169 - 0.2173 in.) Exhaust Stem To Guide Clearance 5.51 - 5.52 mm (0.2169 - 0.2173 in.) Intake 0.01 - 0.02 mm (0.0004 - 0.0008 in.) Exhaust 0.01 - 0.02 mm (0.0004 - 0.0008 in.) Stem Run-out Limit (max.) 0.01 mm (0.0004 in.) “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 32.98 - 33.00 mm (1.2984 - 1.2992 in.) 0.010 - 0.020 mm (0.0004 - 0.0008 in.) VALVE SHIM Valve shim Thickness (in 0.020 mm increments) 2.320 - 2.960 mm (0.0913 - 0.1165 in.) THERMOSTAT Valve Opening Temperature Full Open Temperature Valve Lift (Minimum) 60° C (140° F) 70° C (158° F) 4.3 mm (0.17 in.) 90-888465 JUNE 2002 Page 4A-3 CYLINDER HEAD Special Tools 1. Flywheel Holder P/N 91-83163M 2. Valve Guide Remover/Installer P/N 91-888864 3. Valve Guide Installer P/N 91–888865 4. Flywheel Puller/Lifting Eye P/N 91-83164M 5. Valve Guide Reamer P/N 91-888866 Page 4A-4 90-888465 JUNE 2002 CYLINDER HEAD 6. Valve Spring Compressor with attachment (Obtain Locally) a b a-Valve spring compressor b-Attachment 7. Valve Seat Cutter Kit containing 30°, 45°,60° cutters and holder (Obtain Locally) 8. Crankshaft Alignment Stand (Obtain Locally) 90-888465 JUNE 2002 Page 4A-5 CYLINDER HEAD Cylinder Head 12 110 116 M110 110 110 110 M 110 M Molybdenum Disulfide Grease 4 Stroke 10W30 Outboard Oil 110 116 RTV 587 Silicone Sealer A S69J5650 Page 4A-6 90-888465 JUNE 2002 CYLINDER HEAD Cylinder Head REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. Nm 1 1 CYLINDER HEAD 2 4 SCREW (M6 X 25) 105 12 3 1 TIMING CHAIN TENSIONER 4 32 SCREW (M7 X 37) 1st TORQUE 2nd TORQUE 70 150 8 17 5 4 SCREW (M7 X 48) 1st TORQUE 2nd TORQUE 70 150 8 17 6 16 CAMSHAFT CAP 7 2 CAMSHAFT CAP 8 2 TIMING CHAIN 9 2 OIL SEAL 10 1 CAMSHAFT 1 11 1 CAMSHAFT 2 12 1 CAMSHAFT 3 13 1 CAMSHAFT 4 14 28 SCREW (M6 X 50) 1st TORQUE 2nd TORQUE 53 105 6 12 15 4 SCREW (M8 X 14) 1st TORQUE 2nd TORQUE 20.5 14 28 16 4 GASKET 17 2 PLUG (M18 X 16) 40.5 55 18 2 GASKET 19 1 PORT EXHAUST OUTER COVER 20 1 STARBOARD EXHAUST OUTER COVER 21 2 GASKET 22 1 PORT EXHAUST INNER COVER 23 1 STARBOARD EXHAUST INNER COVER 24 2 GASKET A = Torque sequence 90-888465 JUNE 2002 Page 4A-7 CYLINDER HEAD Cylinder Head S69J5660 95 110 4 Stroke 10W30 Outboard Oil 66 Loctite 242 Thread Locker 2-4-C with Teflon 110 110 95 66 110 110 110 A Page 4A-8 90-888465 JUNE 2002 CYLINDER HEAD Cylinder Head REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. Nm 1 6 SPARK PLUG 18.5 25 2 16 SCREW (M10 x 120) 1st TORQUE 2nd TORQUE 3rd TORQUE 170 27.5 90° 19 37 90° 3 4 SCREW (M8 X 55) 1st TORQUE 2nd TORQUE 125 20.5 14 28 4 2 SCREW 9M8 X 90) 1st TORQUE 2nd TORQUE 125 20.5 14 28 5 1 PORT CYLINDER HEAD 6 4 SCREW (M6 X 20) 105 12 7 2 ENGINE HANGER 8 2 SCREW (M6 X 12) 9 1 GROUND LEAD 10 1 GASKET 11 1 STARBOARD CYLINDER HEAD 12 1 GASKET 13 4 COLLAR 14 1 JOINT 15 2 CABLE TIE 16 1 COOLING WATER HOSE 17 13 SCREW (M6 X 30) 105 12 18 1 COOLING WATER PASSAGE COVER 19 1 GASKET 20 4 SCREW (M8 X 40) 21 4 SCREW 22 4 COVER 23 4 ANODE 24 4 GROMMET 25 1 PLUG 18.5 25 26 1 GASKET 27 24 VALVE SHIM 28 24 VALVE LIFTER 29 48 VALVE COTTER 30 24 VALVE SPRING RETAINER 31 24 VALVE SPRING 32 24 VALVE SEAL 33 24 VALVE GUIDE 34 12 EXHAUST VALVE 35 12 INTAKE VALVE A = Torque sequence 90-888465 JUNE 2002 Page 4A-9 CYLINDER HEAD Timing Belt and Head Covers 116 RTV 587 Silicone Sealer 110 4 Stroke 10W30 Outboard Oil 116 116 110 116 66 RTV 587 Silicone Sealer 66 REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. Nm 1 1 TIMING BELT 2 4 SCREW (M5 X 45) 7 3 1 DRIVE SPROCKET 4 1 PLATE 5 1 WOODRUFF KEY 6 1 TIMING BELT TENSIONER 29 39 7 2 SCREW (M10 X 35) 44 60 8 2 DRIVEN SPROCKET 9 2 DOWEL PIN 10 28 SCREW (M6 X 30) 1st TORQUE 2nd TORQUE 70 70 8 8 11 1 PORT CYLINDER HEAD COVER 12 1 GASKET 13 1 STARBOARD CYLINDER HEAD COVER 14 1 GASKET 15 1 PLATE 16 8 SCREW (M4 X 8) 18 2 Page 4A-10 90-888465 JUNE 2002 CYLINDER HEAD Torque Sequence Cylinder Head Screws 12 34 56 78 9 1011 12 34 5 6 78 9 1011 Cylinder Head Screw Torque - M10 x 145 mm 1st Torque 19 Nm (168 lb-in.) 2nd Torque 37 Nm (27 lb-ft) 3rd Torque 90° Cylinder Head Screw Torque - M8 x 55 mm 1st Torque 14 Nm (124 lb-in.) 2nd Torque 28 Nm (20.5 lb-ft) Camshaft Caps Screws 1 2 3 4 1 2 3 4 5 1 2 3 4 5 1 2 3 4 Camshaft Cap Screw Torque 1st Torque 8 Nm (70 lb-in.) 2nd Torque 17 Nm (150 lb-in.) 90-888465 JUNE 2002 Page 4A-11 CYLINDER HEAD Exhaust Cover Screws 12 34 56 7 8 9 10 11 12 13 14 8 9 11 12 13 1 34 5 7 2 6 10 14 Exhaust Cover Screw Torque 1st Torque 6 Nm (53 lb-in.) 2nd Torque 12 Nm (106 lb-in.) Removing the Oil Filter 1. Place a cloth or rag under the oil filter. Remove the oil filter using a 74 mm (2.9 in.) 14 flats oil filter wrench. (91–888734) NOTE: Be sure to clean up any oil spills. Page 4A-12 90-888465 JUNE 2002 CYLINDER HEAD Timing Belt and Sprocket See Section 2A for timing belt and driven sprocket removal, inspection and installation. Valve Clearance Measurement and Adjustments Preparation for Valve Clearance Measurement 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 ignition coil cover. 2. Disconnect the ignition coil caps and spark plug caps. 3. Remove the ignition coil bracket, spark plugs and cylinder head covers. c a b e d e a-Flywheel cover and ignition coil cover b-Ignition coil caps (6) c-Spark plug caps (6) d-Ignition coil bracket e-Cylinder head cover (2) 90-888465 JUNE 2002 Page 4A-13 CYLINDER HEAD Valve Clearance Measurement Steps 1. Measure intake and exhaust valve clearance using the Valve Clearance Measurement Steps below. a. Turn the flywheel clockwise and align the “1TDC” mark on the flywheel with the pointer. Check that “I” marks on the driven sprockets are aligned with cylinder head timing marks. NOTE: Use flywheel holder (91-83163M) to rotate flywheel and align timing marks. WARNING Do NOT turn the flywheel counter clockwise. a b c d d c c d a-“1TDC” timing mark b-Timing pointer c-Driven sprocket timing marks d-Cylinder head timing marks S69J5110 Page 4A-14 90-888465 JUNE 2002 CYLINDER HEAD b. Measure and record the intake and exhaust valve clearance for cylinder #4. MEASUREMENT TABLE INTAKE (cold) 0.17-0.23 mm (0.007-0.009 in.) CYL. Removed Shim Measured Clearance Specified Clearance New Shim #1#1 #2 #2#2 #3#3 #4#4 #5#5 #6#6 EXHAUST (cold) 0.31-0.37 mm (0.012-0.014 in.) CYL. Removed Shim Measured Clearance Specified Clearance New Shim #1#1 #2 #2#2 #3#3 #4#4 #5#5 #6#6 NOTE: Photocopy this table for additional valve clearance measurement work sheets. Removed Valve Shim Thickness + Measured Valve Clearance – Specified Valve Clearance = New Valve Shim Thickness NOTE: Measure the thickness of the new valve shims with a micrometer (thickness is not indicated on the shim). Example: If the “Removed valve shim thickness” is 2.10 mm (0.083 in.), the “Measured valve clearance” is 0.30 mm (0.012 in.) and the “Specified valve clearance” is 0.20 mm (0.008 in.), then “New valve shim thickness” = 2.10 + 0.30 – 0.20 = 2.20 mm (“New valve shim thickness” = 0.083 + 0.012 – 0.008 = 0.087 in.) 90-888465 JUNE 2002 Page 4A-15 CYLINDER HEAD a b b a c a-Intake valve clearance b-Exhaust valve clearance c-Thickness gauge Valve Clearance Specification Intake Valve 0.17–0.23 mm. (0.007-0.009 in.) Exhaust Valve 0.31-0.37 mm (0.012-0.014 in.) c. Turn the flywheel an additional 120° clockwise and align the “2TDC” mark on the flywheel with the pointer. d. Measure and record the intake and exhaust valve clearance for cylinder #5. e. Turn the flywheel an additional 120° clockwise and align the “3TDC” mark on the flywheel with the pointer. f. Measure and record the intake and exhaust valve clearance for cylinder #6. a c b d a-“1TDC” timing mark c-“3TDC” timing mark b-“2TDC” timing mark d-Timing pointer Page 4A-16 90-888465 JUNE 2002 CYLINDER HEAD g. Similarly measure and record valve clearance of cylinders #1, #2, #3 in order. Be sure to turn flywheel 120° clockwise each time. Adjust if out of specification. aba b 1 2 3 4 5 6 a-Intake valves b-Exhaust valves 2. If Adjustment of intake or exhaust valve clearance is necessary (out of specification) follow Changing Shim Thickness following. If no adjustment is necessary, skip to Powerhead Removal. 90-888465 JUNE 2002 Page 4A-17 CYLINDER HEAD Changing Shim Thickness 1. Turn the flywheel an additional 120° clockwise and align the “1TDC” mark on the flywheel with the pointer. Check that “I” marks on the driven sprockets are aligned with marks. 2. Remove the flywheel. NOTE: Do not mix valve train parts (valve shims, camshaft caps, camshafts), keep individual cylinder parts together. a b a-Flywheel holder (91–83163M) b-Flywheel puller (91–83164M) CAUTION Apply force in the direction of the arrows shown to prevent the flywheel holder from slipping. To prevent damage to the engine or tools, thread the flywheel puller set screws evenly and completely so that the flywheel puller plate is parallel to the flywheel. NOTE: Apply force to the end of the crankshaft until the flywheel separates from the tapered portion of the crankshaft. Page 4A-18 90-888465 JUNE 2002 CYLINDER HEAD 3. Remove the wiring harness guide screws. Move harness guide as required to work on engine. a a-Wiring harness guide 4. Use a hexagon wrench to turn the timing belt tensioner clockwise. Increase the force gradually and then insert a 5 mm diameter (0.200 in.) pin into the hole. NOTE: Leave the pin inserted in the timing belt tensioner until the timing belt is installed. 5. Remove the timing belt from the driven sprockets. b a d e c a-Belt tensioner b-Timing belt c-Hexagon wrench d-Pin e-Tensioner pin hole 90-888465 JUNE 2002 Page 4A-19 CYLINDER HEAD 6. Remove the driven sprockets. NOTE: Hold the camshaft with a wrench. Be careful not to damage the camshaft while loosening the driven sprocket screw. a a-Adjustable wrench 7. Remove the timing chain tensioners, then remove the camshaft caps in the order shown. a 1 2 3 4 1 2 3 4 5 1 2 3 4 5 1 2 3 4 a a-Timing chain tensioner Page 4A-20 90-888465 JUNE 2002 CYLINDER HEAD 8. Remove the camshafts and timing chains. 9. Remove the valve shim from the valve lifter using compressed air. NOTE: Identify valve train components (valve shims, camshaft caps, camshafts). Do NOT mix. Keep the valve shims and lifters organized to prevent them from being installed into the wrong location during cylinder head assembly. 10. Measure and record (in the Measurement Table) the thickness of the removed valve shim with a micrometer a b a a-Valve shim b-Valve lifter a. Select a proper replacement valve shim by calculating its thickness with the following formula. Use worksheet provided in section ”Valve Clearance Measurement Steps” Removed Valve Shim Thickness + Measured Valve Clearance – Specified Valve Clearance = New Valve Shim Thickness NOTE: Measure the thickness of the new valve shims with a micrometer (thickness is not indicated on the shim). Example: If the “Removed valve shim thickness” is 2.10 mm (0.083 in.), the “Measured valve clearance” is 0.30 mm (0.012 in.) and the “Specified valve clearance” is 0.20 mm (0.008 in.), then “New valve shim thickness” = 2.10 + 0.30 – 0.20 = 2.20 mm (“New valve shim thickness” = 0.083 + 0.012 – 0.008 = 0.087 in.) 90-888465 JUNE 2002 Page 4A-21 CYLINDER HEAD 11. Insert the correct valve shim into the valve lifter. NOTE: Lubricate the valve shims with molybdenum disulfide before installing. 12. Align the projection (wide slot) on the camshaft sprockets to the gold colored alignment link on the timing chain. Install the camshafts to the cylinder head with new oil seals. NOTE: Tang on exhaust camshaft. 110 4 Stroke 10W30 Outboard Oil 110 aa b b c b a-Projection in wide slot b-Gold colored alignment link c-Projection in narrow slot M 110 Molybdenum Disulfide Grease M a 110 4 Stroke 10W30 Outboard Oil a-Tang on exhaust camshaft Page 4A-22 90-888465 JUNE 2002 CYLINDER HEAD 13. Install the camshaft caps. Tighten screws to specified torque in sequence and in two stages. NOTE: Install the camshaft caps in the proper position with the stamped number facing up- side down. NOTE: Apply engine oil to the camshaft cap screws before installation. 14. Install the timing chain tensioners. Tighten screws to specified toque. 110 4 Stroke 10W30 Outboard Oil 1 2 3 4 5 1 2 3 4 5 1 2 3 4 1 2 3 4 110 110 110 a a a-Chain tensioner Camshaft Cap Screw Torque 1st Torque 8 Nm (70 lb-in.) 2nd Torque 17 Nm (150 lb-in.) Timing Chain Tensioner Screw Torque 12 Nm (105 lb-in.) 15. Install driven sprockets and timing belt. 16. Re-check valve clearance using Valve Clearance Measurement Steps. Adjust if necessary See Section 2A for timing belt and driven sprocket inspection and installation. 90-888465 JUNE 2002 Page 4A-23 CYLINDER HEAD Page 4A-24 90-888465 JUNE 2002 Powerhead Removal Preparing Cylinder Head for Removal 1. Remove the flywheel cover and intake silencer. 2. Remove the retaining plate and clamp brackets. Disconnect the throttle cable and shift cable. a 59519 d c b e e c d b a -Retaining plate b-Clamp bracket c -Throttle cable d-Shift cable e -Hairpin cotter CYLINDER HEAD 3. Remove the dipstick guide. Disconnect the fuel hose, power trim and tilt (PTT) motor leads and flushing device hose (if equipped). a b c d a-Dipstick guide b-Fuel hose c-PTT motor leads d-Flushing device hose 4. Disconnect the following electrical connectors and components: Low pressure fuel pump driver PTT switch Shift cut switch Neutral switch Cooling water pilot hose 5. Remove the lower cowling. a a a-Lower cowling 90-888465 JUNE 2002 Page 4A-25 CYLINDER HEAD 6. Remove the powerhead mounting screws. b a b a-Screw (6) (M10 x 140) b-Screw (7) (M9 x 35) 7. Remove the flywheel. a b a-Flywheel holder (91-83163M) b-Flywheel puller (91-83164M) CAUTION Apply force in the direction of the arrows shown to prevent the flywheel holder from slipping. To prevent damage to the engine or tools, thread the flywheel puller set screws evenly and completely so that the flywheel puller plate is parallel to the flywheel. NOTE: Apply force to the end of the crankshaft until the flywheel separates from the tapered portion of the crankshaft. Page 4A-26 90-888465 JUNE 2002 CYLINDER HEAD Cylinder Head Removal 1. Remove the exhaust cover screws in the sequence shown. 1 2 3 4 56 7 8 9 10 1112 13 14 8 9 1112 13 1 3 4 5 7 2 6 10 14 2. Remove the timing chain tensioner and camshaft caps in the sequence shown. a 1 2 3 4 1 2 3 4 5 1 2 3 4 5 1 2 3 4 a a-Timing chain tensioner 3. Remove the camshafts and timing chain. Disconnect the ground lead. 4. Remove the cylinder head screws in the sequence shown. 12 3 45 67 89 1011 12 3 45 67 89 1011 90-888465 JUNE 2002 Page 4A-27 CYLINDER HEAD Cylinder Head Disassembly CAUTION Do NOT scratch or damage the mating surface of the cylinder head and cylinder block. 1. Remove valve shim and lifter 2. Remove the valve shim from the lifter using compressed air. a bc b c a-Valve lifter and shim b-Valve lifter c-Valve shim NOTE: Identify valve train components (valve shims, camshaft caps, camshafts). Do NOT mix. Keep the valve shims and lifters organized to prevent them from being installed into the wrong location during cylinder head assembly. Page 4A-28 90-888465 JUNE 2002 CYLINDER HEAD VALVE REMOVAL/DISASSEMBLY 3. Remove the intake and exhaust valves. NOTE: Use valve spring compressor for removal of valves. Compress valves and remove cotters first. a e b c d a-Valve cotter b-Spring retainer c-Valve spring d-Spring seal e-Valve NOTE: Do NOT remove valve guide unless it is out of specification. See “Specifications” at beginning of this section. 90-888465 JUNE 2002 Page 4A-29 CYLINDER HEAD Cleaning/Inspection/Repair Camshaft 1. Inspect the timing chain sprocket for damage or wear. Replace if necessary. 2. Measure camshaft lobe dimensions “a” and “b”. Replace the camshaft if out of specification. a b Cam Lobe Specifications aa Intake 45.30-45.40 mm (1.7835-1.7874 in.) Exhaust 45.35-45.45 mm (1.7854–1.7894 in.) bb Intake 35.95-36.05 mm (1.4154-1.4193 in.) Exhaust 35.95-36.05 mm (1.4154-1.4193 in.) Page 4A-30 90-888465 JUNE 2002 CYLINDER HEAD 3. Measure camshaft journal diameter “a” Replace the camshaft if out of specification. a Camshaft Journal Diameter “a” 24.96-24.98 mm (0.9827-0.9834 in.) 4. Measure the camshaft run out. Replace if out of specification. a b a-Camshaft b-Crankshaft alignment stand Camshaft Run Out Limit 0.1 mm (0.004 in.) 90-888465 JUNE 2002 Page 4A-31 CYLINDER HEAD 5. Measure camshaft cap inside diameter “a” with caps installed and torqued in cylinder head. a a a-camshaft cap inside diameter Camshaft Journal Diameter 25.00-25.02 mm (0.9843-0.9850 in) 6. Calculate the camshaft oil clearance as follows: Camshaft oil clearance = Camshaft cap inside diameter – Camshaft journal diameter Camshaft Journal Oil Clearance 0.02-0.06 mm (0.0008-0.0023 in) 7. Replace cylinder head and camshaft as a set if out of specification. Timing Chain Tensioner 1. Measure the plunger extended length. Replace if out of specification. NOTE: Inspect the timing chain tensioner every 400 hours of operation. a a-Plunger extended limit Timing Chain Tensioner Wear limit 1.0 mm (0.004 in) from standard Page 4A-32 90-888465 JUNE 2002 CYLINDER HEAD Timing Chain 1. Inspect the timing chain for damage or wear. Replace if necessary. Thermostat 1. Remove the thermostat cover and thermostat. 2. Inspect thermostat. Replace if damaged or valve does not open. 3. Measure valve opening temperature and valve lift “c” 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. Heat water slowly while observing the thermostat. b a c a-Thermostat b-Cover c-Valve Lift Distance Opening Temperature 60° C (140° F) Fully Open Temperature 70° C (158° F) Water Temperature Valve Lift Above 70° C (158° F) Minimum 4.3 mm (0.17 in.) 90-888465 JUNE 2002 Page 4A-33 CYLINDER HEAD Valves 1. Inspect valve for damage/warpage/pitting. Replace if necessary. 2. Measure margin thickness “a”. Replace valve if out of specification. a Margin Thickness (a) Intake Valve 0.70 mm (0.028 in.) Exhaust Valve 1.00 mm (0.039 in.) 3. Measure the valve stem diameter. Replace valves if out of specification. a Valve Stem Diameter (a) Intake Valve 5.477-5.492 mm (0.2156-0.2162 in.) Exhaust Valve 5.464-5.479 mm (0.2151-0.2157 in.) Page 4A-34 90-888465 JUNE 2002 CYLINDER HEAD 4. Measure valve stem runout. Replace valves if out of specification. Valve Stem Runout Limit (Max.) Intake Valve Exhaust Valve 0.01 mm (0.0004) 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 44.20 mm (1.740 in.) Minimum Valve Spring Free Length 42.60 mm (1.677 in.) 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 1.5 mm (0.060 in.) 90-888465 JUNE 2002 Page 4A-35 CYLINDER HEAD 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. p5–40 a b a-Straight Edge b-Thickness Gauge Cylinder Head Warpage Limit 0.1 mm (0.004 in.) Page 4A-36 90-888465 JUNE 2002 CYLINDER HEAD Valve Guides NOTE: Before measuring the valve guide, make sure that the valve stem is within specifications. 1. Measure the valve guide bore “a”. If valve guide wear is out of specification, replace the valve guide by following “Valve Guide Replacement”. a a-Valve guide inside diameter Valve Guide Inside Diameter (a) Intake Valve / Exhaust Valve 5.51-5.52 mm (0.2169-0.2173 in.) 2. Calculate the valve stem-to-valve guide clearance as follows. Replace the valve guide if out of specification. Valve stem-to-valve guide clearance = Valve guide inside diameter – Valve stem diameter Valve Stem-to-Valve Guide Clearance Intake Valve / Exhaust Valve 0.01-0.02 mm (0.004-0.008 in.) 90-888465 JUNE 2002 Page 4A-37 CYLINDER HEAD VALVE GUIDE REPLACEMENT 1. Remove the valve guide using a valve guide remover. Strike the valve guide removal tool from the combustion chamber side. 91-888864 a a-Valve Guide Remover/Installer (91-888864) 2. Install the new valve guide by striking the valve guide remover/installer from the camshaft side until the valve guide installer strikes contacts the cylinder head. NOTE: Apply engine oil to the surface of the new valve guide. a 110 4 Stroke 10W30 Outboard Oil 110 b 91-888864 91-888865 a-Valve Guide Remover/Installer (91-888864) b-Valve Guide Installer (91-888865) Page 4A-38 90-888465 JUNE 2002 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 91-888866 a-Valve Guide Reamer (91-888866) Valve Stem-to-Valve Guide Clearance Intake Valve / Exhaust Valve 0.01-0.02 mm (0.004-0.008 in.) Valve Seats VALVE SEAT RECONDITIONING 1. Clean the carbon deposits from the combustion chambers and valve seats and check for pitting. 2. Apply a thin, even layer of Mechanic’s bluing dye (Dykem) onto the valve seat. 3. Lap the valve slowly on the valve seat with a valve lapper (obtain locally). 90-888465 JUNE 2002 Page 4A-39 CYLINDER HEAD 4. Measure the valve seat contact width where the bluing dye is adhered to the valve face. Reface the valve seat if the valve is not seated properly or if the valve seat contact width is out of specification. Replace the valve guide if the valve seat contact is uneven. 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 a-Valve seat contact width NOTE: If resurfacing the valve seats is required, resurface the valve seats to the specified angles shown in chart following. Valve Seat Contact Width Specification (a) Intake Valve 1.10 - 1.40 mm (0.043 - 0.055 in.) Exhaust Valve 1.40 - 1.70 mm (0.055 - 0.067 in.) a b Obtain Locally Valve Seat Area Valve Seat Cutter a 90° b 45° Page 4A-40 90-888465 JUNE 2002 CYLINDER HEAD Refacing the valve seat 1. Reface the valve seat with the correct valve seat cutter. 30° 45° 45° 30° 60° 2. Cut the surface of the valve seat with a 45° cutter by turning the cutter clockwise until the valve seat face is smooth. a b a-Valve seat cutter b-Slag or rough surface CAUTION Do NOT over cut the valve seat. Be sure to turn the cutter evenly downward at a pressure of 40-50 N (9-11 lbs.) to prevent chatter marks. 3. Use a 30° cutter to adjust the contact width of the top edge of the valve seat. a 30° a-Previous contact width 90-888465 JUNE 2002 Page 4A-41 CYLINDER HEAD 4. Use a 60° cutter to adjust the contact width of the bottom edge of the valve seat. a 60° a-Previous contact width 5. Use a 45° cutter to adjust the contact width of the valve seat to specification. a b 45° a-Previous contact width b-Specified contact width 6. If the valve seat contact area is too wide and situated in the center of the valve face, use a 30° cutter to cut the top edge of the valve seat, a 60° cutter to cut the bottom edge to center the area and set its width. a a-Previous contact width Page 4A-42 90-888465 JUNE 2002 CYLINDER HEAD 7. If the valve seat contact area is too narrow and situated near the top edge of the valve face, use a 30° cutter to cut the top edge of the valve seat. If necessary, use a 45° cutter to center the area and set its width. a a-Previous contact width 8. If the valve seat contact area is too narrow and situated near the bottom edge of the valve face, use a 60° cutter to cut the bottom edge of the valve seat. If necessary, use a 45° cutter to center the area and set its width. a a-Previous contact width 9. Apply a thin, even layer of lapping compound onto the valve seat, then lap the valve us- ing a valve lapper (commercially obtainable). CAUTION Do not get lapping compound on the valve stem and valve guide. 10. After every lapping procedure, be sure to clean off any remaining lapping compound from the cylinder head and the valve. 11. Check the valve seat contact area of the valve again. 90-888465 JUNE 2002 Page 4A-43 CYLINDER HEAD Cylinder Head Reassembly 1. Install valve seal to the valve guide (intake and exhaust). a 110 4 Stroke 10W30 Outboard Oil 110 a-Valve seal 2. Install spring seat and valve stem seal. 3. Install spring and spring retainer. 110 c b 110 4-Stroke Outboard Oil a a-Valves (intake and exhaust) b-Valve spring c-Valve spring retainer NOTE: The valve springs can be installed in any direction. Page 4A-44 90-888465 JUNE 2002 CYLINDER HEAD 4. Compress valve springs using valve spring compressor and install valve cotters onto their respective valves using a thin screwdriver with a small amount of grease applied to it. 95 a b 2-4-C with Teflon 95 a-Valve cotter b-Small screwdriver 5. Lightly tap the valve spring retainer with a plastic hammer to set the valve cotter securely. 110 4-Stroke Outboard Oil 110 6. Install valve shim and valve lifter into their original locations. 110 110 a cb 4-Stroke Outboard Oil a-Valve shim and lifter b-Valve shim c-Valve lifter 90-888465 JUNE 2002 Page 4A-45 CYLINDER HEAD Cylinder Head Installation 1. Install new gaskets and cylinder head. Tighten screws to specified torque in sequence and in proper stages. IMPORTANT: Tighten the M10 screws to the specified torques in two stages first. Then tighten the M8 screws to the specified torque in two stages. NOTE: Make a mark on the M10 screws and the cylinder head. Tighten the screws 90 from the mark. CAUTION Do NOT reuse the cylinder head gaskets, always replace with new ones. 12 34 56 78 9 1011 12 34 5 6 78 9 1011 a c b b a a-Screw (16) (M10 x 120) b-Screw (4) (M8 x 55) c-Screw (2) M8 x 90) NOTE: Apply a light coat of engine oil to the cylinder head screws before installation. Cylinder Head Screw Torque - M10 1st Torque 19 Nm (168 lb-in.) 2nd Torque 37 Nm (27 lb-ft) 3rd Torque 90° Cylinder Head Screw Torque - M8 1st Torque 14 Nm (124 lb-in.) 2nd Torque 28 Nm (20.5 lb-ft) Page 4A-46 90-888465 JUNE 2002 CYLINDER HEAD Following Cylinder Head Installation 1. Connect the ground lead. 2. Align the projection (wide slot) on the camshaft sprockets to the gold colored alignment link on the timing chain. Install the camshafts to the cylinder head with new oil seals. 110 4 Stroke 10W30 Outboard Oil 110 aa b c b b a-Projection in wide slot b-Gold colored alignment link c-Projection in narrow slot 110 M 110 Molybdenum Disulfide Grease M a 4 Stroke 10W30 Outboard Oil a-Tang on exhaust camshaft 90-888465 JUNE 2002 Page 4A-47 CYLINDER HEAD 3. Install the camshaft caps. Tighten screws to specified torque in sequence and in two stages. NOTE: Install the camshaft caps in the proper position with the stamped number facing up- side down. NOTE: Apply engine oil to the camshaft cap screws before installation. 4. Install the timing chain tensioners. Tighten screws to specified toque. 110 4 Stroke 10W30 Outboard Oil 1 2 3 4 5 1 2 3 4 5 1 2 3 4 1 2 3 4 110 110 110 b d c a a a-Chain tensioner (2) b-Camshaft cap screw (32) (M7 x 37) c-Camshaft cap screw (4) (M7 x 48) d-Chain tensioner screw (4) (M6 x 25) Camshaft Cap Screw Torque 1st Torque 8 Nm (70 lb-in.) 2nd Torque 17 Nm (150 lb-in.) Timing Chain Tensioner Screw Torque 12 Nm (105 lb-in.) 5. Install driven sprockets and timing belt. See Section 2A for timing belt and driven sprocket inspection and installation. Page 4A-48 90-888465 JUNE 2002 CYLINDER HEAD 6. Install the woodruff key. a b a-Woodruff key b-Key slot 7. Install the flywheel. Tighten to specified torque. NOTE: Apply engine oil to the flywheel nut before installation a b a-Flywheel holder (91–83163M) b-Torque wrench CAUTION Apply force in the direction of the arrows shown to prevent the flywheel holder from slipping. Flywheel Nut Torque 240 Nm (177 lb-ft) 90-888465 JUNE 2002 Page 4A-49 CYLINDER HEAD 8. Rotate the flywheel clockwise two revolutions and check that the alignment marks are aligned. WARNING Do NOT rotate the flywheel counterclockwise. a b c d d c c d a-“1TDC” timing mark b-Timing pointer c-Driven sprocket timing marks d-Cylinder head timing marks 9. Install the spark plugs. Tighten to specified torque. Spark Plug Torque 25 Nm (18.5 lb-ft) Page 4A-50 90-888465 JUNE 2002 CYLINDER HEAD 10. Install the plate on the starboard cylinder head cover. Tighten screws to specified torque. 11. Install new gasket and cylinder head cover. Tighten screws to specified torque in two stages. b ad e c 116 RTV 587 Silicone Sealer 66 Loctite 242 Thread Locker 116 66 66 a-Cylinder head cover (Port and starboard) b-Cover gasket (Port and starboard) c-Starboard head cover plate (1) d-Screw (28) (M6 x 30) e-Screw (8) (M4 x 8) Starboard Cylinder Head Cover Plate Screw Torque 2 Nm (18 lb-in.) Cylinder Head Cover Screw Torque 1st Torque 8 Nm (70 lb-in.) 2nd Torque 8 Nm (70 lb-in.) 90-888465 JUNE 2002 Page 4A-51 CYLINDER HEAD 12. Install the ignition coil bracket. Connect the ignition coil couplers and spark plug caps. 13. Install the ignition coil cover, wiring harness guide and flywheel cover. 14. Install new gaskets and exhaust covers. Tighten the screws to specified torque in sequence and in 2 stages. 12 34 56 7 8 9 10 11 12 13 14 8 9 11 12 13 1 34 5 7 2 6 10 14 a a-Screw (28) (M6 x 50) Exhaust Cover Screw Torque 1st Torque 6 Nm (53 lb-in.) 2nd Torque 12 Nm (106 lb-in.) Page 4A-52 90-888465 JUNE 2002 CYLINDER BLOCK/CRANKCASE POWERHEAD Section 4B - Cylinder Block/Crankcase Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-2 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-26 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-4 Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . 4B-27 Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-5 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-32 Cylinder Block And Crankcase . . . . . . . . . . . . 4B-6 Crankcase and Bearings . . . . . . . . . . . . . . 4B-33 Crankshaft, Pistons And Connecting Rods . . 4B-8 Connecting Rod Oil Clearance . . . . . . . . . 4B-39 Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . 4B-10 Powerhead Assembly . . . . . . . . . . . . . . . . . . . . 4B-43 Crankcase Screws . . . . . . . . . . . . . . . . . . . 4B-10 Crankcase and Crankshaft Installation . . 4B-43 Crankcase Cover Screws . . . . . . . . . . . . . . 4B-11 Piston/Connecting Rod Assembly . . . . . . . 4B-46 Powerhead Removal . . . . . . . . . . . . . . . . . . . . 4B-12 Piston Ring/Piston Installation . . . . . . . . . . 4B-47 Preparing Cylinder Head for Removal . . . 4B-12 Baffle Plate Installation . . . . . . . . . . . . . . . . . 4B-50 Removing Powerhead Components . . . . . . . 4B-18 Exhaust Cover Installation . . . . . . . . . . . . . . 4B-51 Ignition Components . . . . . . . . . . . . . . . . . . 4B-18 Oil Filter Installation . . . . . . . . . . . . . . . . . . . . 4B-52 Charging and Starting SystemInstalling Powerhead Components . . . . . . . . 4B-53 Components . . . . . . . . . . . . . . . . . . . . . . . . 4B-18 Cylinder Head Installation . . . . . . . . . . . . . 4B-53 Fuel Components . . . . . . . . . . . . . . . . . . . . 4B-18 Harness and Battery Cable Removal . . . . 4B-53 Harness and Battery Cable Removal . . . . 4B-18 Fuel Components . . . . . . . . . . . . . . . . . . . . 4B-53 Cylinder Head Removal . . . . . . . . . . . . . . . 4B-18 Charging and Starting SystemPowerhead Disassembly . . . . . . . . . . . . . . . . . 4B-19 Components . . . . . . . . . . . . . . . . . . . . . . . . 4B-53 Crankcase and Crankshaft Removal . . . . 4B-19 Ignition Components . . . . . . . . . . . . . . . . . . 4B-53 Piston Ring Removal . . . . . . . . . . . . . . . . . 4B-24 Powerhead Installation . . . . . . . . . . . . . . . . . . . 4B-54 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . 4B-25 Following Powerhead Installation . . . . . . . . . . 4B-58 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-25 4 B 90-888465 JUNE 2002 Page 4B-1 CYLINDER BLOCK/CRANKCASE Specifications POWER UNIT Cooling System Exhaust System Lubrication System Water Through Propeller Boss Wet Sump COMPRESSION RATIO Compression Ratio Cylinder Compression (Minimum) 9.9:1 880 kPa (125 psi) Small End Inside Diameter 21.00 mm (0.827 in.) Big End Inside Diameter 53.00 mm (2.087 in.) CONNECTING ROD Oil Clearance (Big End) Big End Bearing Thickness Yellow 0.035 - 0.071 mm (0.0014 - 0.0028 in.) 1.492 -1.496 mm (0.0587 - 0.0588 in.) Green 1.496 - 1.500 mm (0.0588 - 0.0591 in.) Blue 1.500 - 1.504 mm (0.0591 - 0.0592 in.) Crankshaft Journal Diameter 62.968 - 62.992 mm Crankshaft Pin (2.4791 - 2.4800 in.) Diameter 49.976 - 50.000 mm (1.9676 - 1.9685 in.) Width 21.50 - 21.55 mm (0.8465 - 0.8484 in.) CRANKSHAFT Crankshaft Run-out 0.03 mm (0.0012 in.) Crankcase Main Journal Oil Clearance 0.025-0.050 mm (0.0010-0.0020 in.) Upper Crankcase Main Journal Bearing Thickness 1 2.494 - 2.500 mm (0.0981 - 0.0984 in.) 2 2.498 - 2.504 mm (0.0983 - 0.0986 in.) CRANKCASE 3 Lower Crankcase Main Journal Bearing Thickness 2.502 - 2.508 mm (0.0985 - 0.0987 in.) 1 2.494 - 2.500 mm (0.0981 - 0.0984 in.) 2 2.498 - 2.504 mm (0.0983 - 0.0986 in.) 3 No. 3 Main Journal Bearing Thickness 2.502 - 2.508 mm (0.0985 - 0.0987 in.) 1 2.492 -2.500 mm (0.0980 - 0.0984 in.) 2 2.496 - 2.504 mm (0.0982 - 0.0986 in.) 3 2.500 - 2.508 mm (0.0984 - 0.0987 in.) Page 4B-2 90-888465 JUNE 2002 CYLINDER BLOCK/CRANKCASE Bore Diameter Taper Limit CYLINDERS Out-of-Round Limit Piston Type Measure Point (H) Piston Diameter (D) Pin Boss Inside Diameter PISTON D H 1.17 - 1.19 mm (0.0461 - 0.0468 in.) 2.80-3.00 mm (0.1100 - 0.1180 in.) 0.15 -0.30 mm (0.0059 - 0.0118 in.) Aluminum 5 mm (0.2 in.) 93.921 - 93.941 mm (3.6977 - 3.6985 in.) 21.02 - 21.03 mm (0.8276 - 0.8280 in.) PISTON PIN Outside Diameter CYLINDER BLOCK Type Displacement Number of Cylinders STROKE Length CYLINDER BORE Diameter Standard Taper Out of Round Maximum 21.00 mm (0.827 in.) V6, 4 Stroke - DOHC 24 Valves 3352 cc (205 cid) 6 80.5 mm (3.17 in.) 94.00 - 94.020 mm (3.7008 - 3.7016 in.) 0.05 mm (0.0020 in.) 0.01 mm (0.0004 in.) 90-888465 JUNE 2002 Page 4B-3 CYLINDER BLOCK/CRANKCASE Special Tools 1. Oil Filter Wrench (P/N 91-888734) 2. Flywheel Holder (P/N 91-83163M) 3. Flywheel Puller/Lifting Eye (P/N 91-83164M) 4. Piston Ring Compressor (Obtain Locally) 5. Piston Ring Expander (Obtain Locally) Page 4B-4 90-888465 JUNE 2002 CYLINDER BLOCK/CRANKCASE Notes: 90-888465 JUNE 2002 Page 4B-5 CYLINDER BLOCK/CRANKCASE Cylinder Block And Crankcase 110 4 Stroke 10W30 Outboard Oil 66 Loctite 242 Thread Locker 110 110 66 110 110 110 110 66 110 Page 4B-6 90-888465 JUNE 2002 CYLINDER BLOCK/CRANKCASE Cylinder Block And Crankcase REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 CRANKCASE COVER 2 17 SCREW (M8 X 45) 1st TORQUE 2nd TORQUE 125 20.5 14 28 3 2 SCREW (M6 X 20) 105 12 4 1 ENGINE HANGER 5 1 PLATE 6 14 SCREW (M4 X 8) 18 2 7 1 GASKET (NOT REUSABLE) 8 6 NUT 9 1 BAFFLE PLATE 10 2 DOWEL PIN 11 12 SCREW (NOT REUSABLE) 1st TORQUE 2nd TORQUE 3rd TORQUE 17 35.5 90° 23 48 90° 12 6 CONNECTING ROD CAP 13 12 CONNECTING ROD BEARING 14 6 CONNECTING ROD 15 6 PISTON 16 12 CLIP (NOT REUSABLE) 17 6 PISTON PIN 18 6 OIL RING 19 6 2ND PISTON RING 20 6 TOP RING 21 1 PLUG 17 23 22 1 GASKET (NOT REUSABLE) 23 1 GASKET (NOT REUSABLE) 24 1 ENGINE TEMPERATURE SENSOR 133 15 25 4 SCREW (M6 X 25) 26 2 CAP 27 2 STOPPER 90-888465 JUNE 2002 Page 4B-7 CYLINDER BLOCK/CRANKCASE Crankshaft, Pistons And Connecting Rods 12 Loctite Master Gasket 110 12 110 110 110 110 110 110 110 110 95 2-4-C with Teflon 4 Stroke 10W30 Outboard Oil Page 4B-8 90-888465 JUNE 2002 CYLINDER BLOCK/CRANKCASE Crankshaft, Pistons And Connecting Rods REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 CRANKSHAFT 2 1 CYLINDER BLOCK 3 1 CRANKCASE 4 1 OIL SEAL 5 2 THRUST BEARING 6 1 THRUST BEARING 7 4 MAIN BEARING 8 4 MAIN BEARING 9 6 STUD SCREW (M8 X 95) 1st TORQUE 2nd TORQUE 18.5 90° 25 90° 10 8 SCREW (M10 X 105) 1st TORQUE 2nd TORQUE 29.5 90° 40 90° 11 2 SCREW (M8 X 95) 1st TORQUE 2nd TORQUE 18.5 90° 25 90° 12 13 SCREW (M8 X 55) 1st TORQUE 2nd TORQUE 125 20.5 14 28 13 2 O-RING 14 1 O-RING 15 2 SCREW (M6 X 20) 16 2 HOLDER 17 2 THERMOSWITCH 18 2 COVER 19 2 THERMOSTAT 20 4 SCREW (M6 X 25) 21 4 CLIP 22 2 COOLING WATER HOSE 23 1 OIL SEAL 24 1 OIL SEAL 25 2 O-RING 26 1 OIL PUMP ASSEMBLY 35 4 27 1 GASKET 28 1 OIL SEAL 29 2 OIL SEAL 30 4 SCREW (M6 X 40) 90-888465 JUNE 2002 Page 4B-9 CYLINDER BLOCK/CRANKCASE Torque Sequence Crankcase Screws a 90° b 12 34 56 78 910 1112 1314 1516 17 18 19 20 21 22 2324 25 26 2728 29 1st Torque 2nd Torque a-Screw (10) 1st Torque b-Screw (10) 2nd Torque (90° Torque) Crankcase Screw Torque Middle Screws Qty. 8Middle Screws Qty. 8 (M8 x 95 mm) 1st Torque: 25 Nm (18.5 lb-ft) 2nd Torque: 90° Inner Screws Qty. 8Inner Screws Qty. 8 1st Torque: 40 Nm (29.5 lb-ft) (M10 x 105 mm) 2nd Torque: 90° Outer Screws Qty. 13Outer Screws Qty. 13 1st Torque: 14 Nm (125 lb-in.) (M8 x 55 mm) 2nd Torque: 28 Nm (20.5 lb-ft)* SERVICE TIP 1. To obtain 90° 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 90° 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. Page 4B-10 90-888465 JUNE 2002 CYLINDER BLOCK/CRANKCASE Crankcase Cover Screws 1 2 3 4 5 6 7 8 9 10 11 1213 14 15 16 17 Crankcase Cover Screw Torque Screw Qty. 17Screw Qty. 17 (M8 x 45 mm) 1st Torque: 14 Nm (20.5 lb-ft) 2nd Torque: 28 Nm (41 lb-ft) 90-888465 JUNE 2002 Page 4B-11 CYLINDER BLOCK/CRANKCASE Page 4B-12 90-888465 JUNE 2002 Powerhead Removal Preparing Cylinder Head for Removal 1. Remove air silencer. Refer to Section 3C - Intake Silencer Removal. 2. Remove flywheel cover and disconnect the harness connectors/leads of the following components: a. Air intake temperature switch b. ECM c. Power Trim and Tilt d. Starter relay e. Main relay f. Voltage regulator g. Stator h. Ground lead a g h c d e b f a- Air intake temperature switch connector b- ECM connector c- Power Trim and Tilt leads (Light blue and Light green) d- Starter relay connector e- Main relay connector f - Voltage regulator connector g- Stator connector h- Ground lead CYLINDER BLOCK/CRANKCASE 90-888465 JUNE 2002 Page 4B-13 3. Remove fuel filter support bracket mounting screws. 4. Remove bracket mounting screws. 59451 a b d d c a- Fuel filter support bracket mounting screws (2) M6 x 19 b- Power ground screw (1) M6 x 20 c- ECM connection harness d- Bracket mounting screws (6) M6 x 28 5. Disconnect the high pressure fuel pump harness connector 6. Remove battery cables. 7. Disconnnect the fuel pump harness connector. 8. Disconnect the fuel pump driver harness connector. 9. Disconnect the high pressure fuel pump relay harness connector. 59458 a b c a- Fuel pump harness b- Fuel pump driver harness c- High pressure fuel pump relay harness CYLINDER BLOCK/CRANKCASE Page 4B-14 90-888465 JUNE 2002 10. Remove the neutral start switch connector and shift cut switch connector. 59460 59459 c a b a- Neutral start switch connector b- Shift cut switch connector c- Oil pressure switch 11. Disconnect the cowl mount Power Trim and Tilt (PTT) switch harness connector. 12. Refer to Section 3C for removal of the following components: a. Air temperature sensor and Vapor Separator system b. Air intake c. Fuel cooler d. ECM connection and electrical component mounting plate e. Voltage regulator f. Fuel lines g. Fuel rails h. Throttle bodies CYLINDER BLOCK/CRANKCASE 90-888465 JUNE 2002 Page 4B-15 13. Remove the retaining plate and clamp brackets. Remove the hairpin cotter from the shift and throttle cable ends. Disconnect the throttle cable and shift cable. a 59519 d c b e e c d b a- Retaining plate b- Clamp bracket c- Throttle cable d- Shift cable e- Hairpin cotter CYLINDER BLOCK/CRANKCASE 14. Remove the dipstick guide and o-ring. Disconnect the fuel hose, power trim and tilt (PTT) motor leads and flushing device hose (if equipped). a b c d a-Dipstick guide b-Fuel hose c-PTT motor leads d-Flushing device hose 15. Remove the lower cowling. a a c b b a-Lower cowling b-Screw (11) (M6 x 20) c-Screw (1) (M6 x 35) Page 4B-16 90-888465 JUNE 2002 CYLINDER BLOCK/CRANKCASE 16. Remove the powerhead mounting screws. a-Screw (6) (M10 x 140) b-Screw (7) (M9 x 35) b a b 90-888465 JUNE 2002 Page 4B-17 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. Ignition coils d. Crank Position Sensors e. Temperature sensor f. Timing belt 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. VST system b. Throttle bodies, fuel rails, fuel injectors c. Fuel filter Harness and Battery Cable Removal 1. Remove battery and harness cable assembly. Cylinder Head Removal 1. See Section 4A for removal of the following components: a. Timing sprockets b. Cylinder head cover c. Exhaust cover d. Cylinder head e. Oil filter Page 4B-18 90-888465 JUNE 2002 CYLINDER BLOCK/CRANKCASE Powerhead Disassembly Crankcase and Crankshaft Removal b p a d e f i j k n g o m c l h a-Cylinder block b-Crankcase cover c-Screw (8) (M10 x 105) d-Stud screw (6) (M8 x 95) e-Baffle plate f-Nut (6) g-Crankcase cover h-Screw (17) (M8 x 45) i-Gasket j-Screw and Washer (14) k-Breather cover l-Screw (2) (M8 x 95) m-Screw (13) (M8 x 55) n-Gasket o-Water jacket cover p-Screw (13) 90-888465 JUNE 2002 Page 4B-19 CYLINDER BLOCK/CRANKCASE 1. Remove the water jacket cover screws in the sequence shown. 2. Remove the crankcase cover bolts in the sequence shown. 1 2 3 4 5 6 7 8 9 10 11 1213 1 2 3 4 5 6 7 8 9 10 11 1213 14 15 16 17 NOTE: Do NOT remove the ignition timing pointer from the crankcase cover. 3. Remove the baffle plate. 4. Remove the crankcase screws in the sequence shown. 12 34 56 78 910 1112 1314 1516 17 18 19 20 21 22 2324 25 26 2728 29 Page 4B-20 90-888465 JUNE 2002 CYLINDER BLOCK/CRANKCASE IMPORTANT: Do not interchange connecting rod caps and bearing halves during disassembly. Mark the cylinder number on the rod cap (1 through 6) with a paint pen or scribe mark. Reinstall in their original locations. IMPORTANT: Be sure to keep the bearings in the order as they where removed and to note the bearing color. 5. Remove crankcase and connecting rod caps. a b c d e f g a-Stud/Screw (6) (M8 x 95) b-Screw (8) M10 x 105 c-Screw (2) (M8 x 95) d-Screw (13) (M8 x 55) e-Crankcase f-Connecting Rod Screw (Discard) (12) g-Connecting Rod Cap (6) 90-888465 JUNE 2002 Page 4B-21 CYLINDER BLOCK/CRANKCASE 6. Remove crankshaft and oil seals. a b c a-Crankshaft b-Upper Oil Seal c-Lower Oil Seal IMPORTANT: Do not interchange main bearings. Re-install in their original locations. 7. Remove main bearing halves from the crankcase cover and cylinder block. a d b c a-Main bearing halves-crankcase cover (4) b-Thrust bearing - crankcase cover (1) c-Thrust bearing - cylinder block (2) d-Main bearing halves-cylinder block (4) Page 4B-22 90-888465 JUNE 2002 CYLINDER BLOCK/CRANKCASE IMPORTANT: Scribe (or use paint pen) the cylinder number (1 through 6) 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. 8. Remove piston/connecting rod assembly. Do not interchange bearings, end cap or piston assembly with other cylinders. a a c b a-Piston/Connecting Rod Assembly (6) b-Connecting Rod Bearings (6) c-Connecting Rod Cap (6) 90-888465 JUNE 2002 Page 4B-23 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 to prevent rings from breaking. If re-using rings mark their location for re-installation. a b c d (Obtain locally) a-Top Ring b-Second Ring c-Oil Ring d-Piston 3. Remove the piston wrist pin retaining ring. Remove pin, then piston and connecting rod. a d e f g c b a-Retaining ring b-Wrist pin c-Piston d-Connecting rod e-Bearing cap f-Bearing cap screw g-Piston identification number Page 4B-24 90-888465 JUNE 2002 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 = 20 mm (0.8 in.) L2 = 60 mm (2.4 in.) L3= 100 mm (3.9 in.) 3. Measure bore diameter with a cylinder gauge. If out of specification, re-bore or replace if necessary. D1,2 D3,4 D5,6 L1 L2 L3 (D2, 4, 6) (D1, 3, 5) Cylinder Bore Specifications: Diameter 94.00-94.02 mm (3.7008-3.7016 in.) 90-888465 JUNE 2002 Page 4B-25 CYLINDER BLOCK/CRANKCASE 4. Calculate the taper limit. Replace or rebore the cylinder block if out of specification. NOTE: Taper=(Maximum of D1 or D2)-(Minimum of D5 or D6) Cylinder Bore Specifications: Taper Limit D1-D5 (direction Y) 0.05 mm (0.0020 in.) D2-D6 (direction X) 0.05 mm (0.0020 in.) 5. Calculate the out-of-round limit. Replace or rebore the cylinder block if out of specification. Cylinder Bore Specifications: Out-of-Round Limit D2-D1 0.05 mm (0.0020 in.) (Measuring point L1) D6-D5 0.05 mm (0.0020 in.) (Measuring point L3) 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, 90° to the piston pin. Replace piston/connecting rod assembly if out of specification. b a a-Piston Diameter b-Measuring point = 13 mm (0.5 in.) Piston Diameter (a) 93.921-93.941 mm (3.6977-3.6985 in.) Page 4B-26 90-888465 JUNE 2002 CYLINDER BLOCK/CRANKCASE 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 0.075-0.080 mm (0.0029-0.0031 in.) Piston Rings PISTON RING SIDE CLEARANCE 1. Measure piston ring side clearance. Replace piston rings as a set if out of specification. a c b Piston Ring Side Clearance Top (a) 0.04-0.08 mm (0.0016-0.0031 in.) Middle (b) 0.03-0.07 mm (0.0012-0.0027 in.) Oil (c) 0.04-0.13 mm. (0.0016-0.0051 in) 90-888465 JUNE 2002 Page 4B-27 CYLINDER BLOCK/CRANKCASE PISTON RING GROOVE 1. Measure piston ring groove. Replace the piston if out of specification. a b c Piston Ring Groove Top (a) 1.23-1.25 mm (0.048-0.049 in.) Middle (b) 1.22-1.24 mm (0.048-0.049 in.) Oil (c) 2.51-2.53 mm. (0.099-0.100 in) 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 0.15 - 0.30 mm (0.0059 - 0.0118 in.) 2nd 0.30 - 0.45 mm. (0.0118 - 0.0177 in) Oil 0.15 - 0.60 mm (0.0059 - 0.0236 in.) Page 4B-28 90-888465 JUNE 2002 CYLINDER BLOCK/CRANKCASE PISTON RING DIMENSIONS 1. Measure piston ring dimensions of “B” and “T”. Replace piston rings as a set if out of specification. a b c B T B T B T a-Top ring b-2nd ring c-Oil ring Piston Ring Dimensions Top (a) B: 1.17 - 1.19 mm (0.0461 - 0.0468 in.) Top (a) T: 2.8-3.0 mm (0.110 - 0.118 in.) 2nd (b) B: 1.17 - 1.19 mm (0.0461 - 0.0468 in.) 2nd (b) T: 2.8-3.0 mm (0.110 - 0.118 in.) Oil (c) B: 2.40 - 2.47 mm (0.0945 - 0.028 in.) Oil (c) T: 0.008 - 0.028 in. (0.20 - 0.70 mm) PISTON PIN BOSS BORE 1. Measure the piston pin bore diameter. Replace the piston if out of specification. Piston Pin Bore Diameter 21.02-21.03 mm (0.8276-0.8280 in.) 90-888465 JUNE 2002 Page 4B-29 CYLINDER BLOCK/CRANKCASE PISTON PIN 1. Measure the piston pin diameter. Replace the piston pin if out of specification. Piston Pin Diameter 21.00 mm (0.827 in.) CONNECTING ROD SMALL END INSIDE DIAMETER 1. Measure the connecting rod small end inside diameter. Replace the connecting rod if out of specification. a a-Small end inside diameter Connecting Rod Small End Inside Diameter 21.00 mm (0.827 in.) Page 4B-30 90-888465 JUNE 2002 CYLINDER BLOCK/CRANKCASE CONNECTING ROD LARGE END SIDE CLEARANCE 1. Measure the clearance between the connecting rod and crankshaft thrust faces. Replace the connecting rod or crankshaft, or both if out of specification. a Connecting Rod Large End Side Clearance (a) 0.20-0.25 mm (0.0079-0.0098 in.) 90-888465 JUNE 2002 Page 4B-31 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 0.03 mm (0.0012 in.) 4. Measure crankshaft journal diameter and crankpin diameter. Replace if out of specification. b c a Crankshaft Journal Diameter (a) 62.968-62.992 mm (2.4791-2.4800 in.) Crankpin Diameter (b) 49.976-50.000 mm (1.9676-1.9685 in.) Crankpin Width (c) 21.50-21.55 mm (0.8465-0.8484 in.) Page 4B-32 90-888465 JUNE 2002 CYLINDER BLOCK/CRANKCASE Crankcase and Bearings CRANKSHAFT MAIN BEARING OIL CLEARANCE 1. Measure crankshaft main bearing clearance using the test below, replace the upper and lower bearings as a set if out of specification. NOTE: Measure the main oil bearing clearance at room temperature 68° F (20° C). Main Bearing Oil Clearance 0.025 - 0.050 mm (0.0010 - 0.0020 in.) 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. b. Main bearings. c. Crankshaft bearing surfaces. 3. Install main bearing halves and thrust bearings into the cylinder block. Insert the projection of the bearing into the notch on the cylinder block. 4. Install crankshaft. a b a-Main bearing halves-cylinder block (4) b-Thrust bearings (2) 90-888465 JUNE 2002 Page 4B-33 CYLINDER BLOCK/CRANKCASE 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 6. Install main bearing halves and thrust bearing into the crankcase. a b a-Main Bearing Halves-Crankcase (4) b-Thrust bearing (1) SERVICE TIP 1. To obtain 90° 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 90° 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 90° b c 1st Torque 2nd Torque a-Paint Mark On Screw Head b-Paint Mark On Crankcase Cover c-Screw Head Page 4B-34 90-888465 JUNE 2002 CYLINDER BLOCK/CRANKCASE 2. Install crankcase onto cylinder block. 3. 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. 110 110 12 34 56 78 910 1112 1314 1516 17 18 19 20 21 22 2324 25 26 2728 29 a b c d e 110 4-Stroke Outboard Oil a-Screw (6) (M8 x 95) b-Screw (8) (10 x 105) c-Screw (2) (M8 x 95) d-Screw (13) (M8 x 55) e-Crankcase Crankcase Screw Torque Middle Screws Qty. 8Middle Screws Qty. 8 (M8 x 95 mm) 1st Torque: 25 Nm (18.5 lb-ft) 2nd Torque: 90° Inner Screws Qty. 8Inner Screws Qty. 8 (M10 x 105 mm) 1st Torque: 40 Nm (29.5 lb-in.) 2nd Torque: 90° Outer Screws Qty. 13Outer Screws Qty. 13 (M8 x 55 mm) 1st Torque: 14 Nm (125 lb-in.) 2nd Torque: 28 Nm (20.5 lb-ft) 90-888465 JUNE 2002 Page 4B-35 CYLINDER BLOCK/CRANKCASE 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 Oil Clearance 0.0010 - 0.0020 in. (0.025 - 0.050 mm) Page 4B-36 90-888465 JUNE 2002 CYLINDER BLOCK/CRANKCASE SELECTING NEW CRANKSHAFT MAIN BEARINGS 1. When replacing the main bearings, select the suitable bearing as follows. 2. Check the crankshaft journal mark (a) on the crankshaft and the cylinder block mark (c) on the cylinder block. J2 J3 J1 J4 J2 J3 J1 J4 b J2 J3J1 J4 a c a-Crankshaft journal mark b-Crankshaft journal c-Cylinder block mark 3. Refer to the table on the following page to select the correct main bearings. a a-Main bearing number 90-888465 JUNE 2002 Page 4B-37 CYLINDER BLOCK/CRANKCASE MAIN BEARING SELECTION TABLE Cylinder Block Mark karkMaalourn nn t Johaftshank kk Cra aa C 98 99 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 92 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 91 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 90 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 89 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 88 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 87 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 86 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 85 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 84 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 383 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 82 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 81 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 80 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 79 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 78 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 77 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 76 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 75 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 74 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 73 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 3 72 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 3 3 71 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 70 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 69 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 68 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 NOTE: Example: If the crankshaft journal mark is “81” and the cylinder block mark is “04”, then the main bearing number is “1”. NOTE: Crankshaft bearing #3 is a thrust bearing. Page 4B-38 90-888465 JUNE 2002 CYLINDER BLOCK/CRANKCASE 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 0.035-0.071 mm (0.0014-0.0028 in.) 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 projection of the upper half of the bearing into the slot on the connecting rod, and the projection of the lower half of the bearing into the slot on the connecting rod cap. a c b a-Connecting rod b-connecting rod cap c-Projection 90-888465 JUNE 2002 Page 4B-39 CYLINDER BLOCK/CRANKCASE 2. Place a piece of Plastigauge onto the crank pin parallel to the crankshaft. NOTE: Do not put plastigauge over the oil hole on the bearing surface of the crankshaft. a a-Plastigauge 3. Assemble the connecting rods onto their respective crankpins. NOTE: Align the marks on the connecting rod cap and connecting rod, which you made during disassembly. 4. Apply engine oil onto the threads and seat of the original connecting rod screws. NOTE: Do not move the crankshaft until the big end oil clearance measurement has been completed. 110 4-Stroke Outboard Oil 110 a a-Connecting rod/rod cap marks 5. Tighten the original connecting rod screws in alternating sequence and in three stages to the specified torque. Connecting Rod Screw Torque 1st Torque: 23 Nm (17 lb-ft ) 2nd Torque: 48 Nm (35.5 lb-ft) 3rd Torque: 90° Page 4B-40 90-888465 JUNE 2002 CYLINDER BLOCK/CRANKCASE 6. Remove the connecting rod cap. 7. Measure the width of the compressed plastigauge on each crankpin to check the connecting rod oil clearance. Replace the connecting rod bearing if out of specification. a a-Compressed Plastigauge Connecting Rod Oil Clearance 0.035-0.071 mm (0.0014-0.0028 in.) CONNECTING ROD BEARING SELECTION 1. When replacing the connecting rod bearing, select the suitable bearing as follows: a. Check the crankpin mark on the crankshaft. P2 P3P1 P4 P5 P6 P2 P3 P1 P5 P4 P6 a a-Crankpin mark 90-888465 JUNE 2002 Page 4B-41 CYLINDER BLOCK/CRANKCASE b. Select the suitable color for the connecting rod bearing from the table. b b-Bearing color mark Crankpin Mark (a) Bearing Color (b) 92-00 Yellow 84-91 Green 76-83 Blue Page 4B-42 90-888465 JUNE 2002 CYLINDER BLOCK/CRANKCASE Powerhead Assembly 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 and thrust bearing halves on the crankcase cover and cylinder block. Insert the projection of the bearing into the notch on the cylinder block. a d b c 110 110 110 e 4-Stroke Outboard Oil a-Main bearing halves-crankcase cover (4) b-Thrust bearing - crankcase cover (1) c-Thrust bearing - cylinder block (2) d-Main bearing halves-cylinder block (4) e-Projection of bearing/slot in block 90-888465 JUNE 2002 Page 4B-43 CYLINDER BLOCK/CRANKCASE 2. Install oil seals on crankshaft. 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. Set crankshaft, oil seals, and thrust bearings into the cylinder block. 110 4-Stroke Outboard Oil 110 a a a-Thrust bearings (2) Page 4B-44 90-888465 JUNE 2002 CYLINDER BLOCK/CRANKCASE 4. 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. 5. 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. 6. Apply oil to screws and torque crankcase screws in sequence and in two steps. a Loctite Master Gasket Kit12 b 110 4-Stroke Outboard Oil 110 110 12 34 56 78 910 1112 1314 1516 17 18 19 20 21 22 2324 25 26 2728 29 S69J5F30 12 g f d e c a-Crankcase e-Screw (13) (M8 x 55) b-Stud/Screw (6) (M8 x 95) f-Contact Surface of Crankcase c-Screw (8) (M10 x 105) g-Paint Roller d-Screw (2) (M8 x 95) Crankcase Screw Torque Middle Screws Qty. 8Middle Screws Qty. 8 (M8 x 95 mm) 1st Torque: 25 Nm (18.5 lb-ft) 2nd Torque: 90° Inner Screws Qty. 8Inner Screws Qty. 8 (M10 x 105 mm) 1st Torque: 40 Nm (29.5 lb-ft) 2nd Torque: 90° Outer Screws Qty. 13Outer Screws Qty. 13 (M8 x 55 mm) 1st Torque: 14 Nm (125 lb-in.) 2nd Torque: 28 Nm (20.5 lb-ft)* 90-888465 JUNE 2002 Page 4B-45 CYLINDER BLOCK/CRANKCASE Piston/Connecting Rod Assembly 1. Assemble the piston, connecting rod, piston pin and new piston pin retaining clips. IMPORTANT: Face the mark on the connecting rod in the same direction as the “UP” mark on the piston, which you made during disassembly. CAUTION Always use new piston pin retaining clips. Do NOT allow the piston pin retaining clip to align with the piston pin slot. S69J5E80 a d b c d e f g d a-Piston b-Connecting rod c-Piston pin d-Retaining clip e-Piston pin slot f-Mark on connecting rod g-“UP” mark Page 4B-46 90-888465 JUNE 2002 CYLINDER BLOCK/CRANKCASE 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 (“R or RN” side up). Spread rings just enough to slip over piston. 3. Offset the piston ring end gaps. 110 f e d R 110 a b c R RN a b c d e 110 4-stroke Outboard Oil a-Top rail b-Oil ring spacer c-Bottom rail d-Top compression ring (“RN” side up) e-Second compression ring (“R” side up) f-“R or RN” mark should face piston crown i j h g Obtain locally UP k g-End gap – lower oil ring rail h-Oil spacer ring i-End gap – upper oil ring rail j-End gap –top compression ring k-End gap – second compression ring 90-888465 JUNE 2002 Page 4B-47 CYLINDER BLOCK/CRANKCASE 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. Install the locating tab of the upper half of the bearing into the slot on the connecting rod, and the locating tab of the lower half of the bearing into the slot on the connecting rod cap. a c b a-Connecting rod b-Connecting rod cap c-Locating tab on piston bearings 5. Lubricate pistons, rings, and cylinder walls with engine oil. 6. Install piston/connecting rod assembly using piston ring compressor tool. IMPORTANT: 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 110 4 Stroke Outboard Oil 110 a-Piston Ring Compressor (FT2997) Page 4B-48 90-888465 JUNE 2002 CYLINDER BLOCK/CRANKCASE 7. Lubricate connecting rod journals with engine oil. IMPORTANT: Apply oil to connecting rod screws before installing. 8. Install connecting rod cap and new screws onto their respective crankpins. 9. Tighten connecting rod screws in alternating sequence and in three stages. IMPORTANT: Assemble connecting rod caps in their original locations. 110 a b110 110 4-Stroke Outboard Oil a-Connecting Rod Cap (6) b-Connecting Rod Screw (New) (12) Connecting Rod Screw Torque 1st Torque: 23 Nm (17 lb-ft) 2nd Torque: 48 Nm (35.5 lb-ft) 3rd Torque: 90° 90-888465 JUNE 2002 Page 4B-49 CYLINDER BLOCK/CRANKCASE Baffle Plate Installation 1. Install baffle plate. Tighten nuts to specified torque. 2. Install breather plate. Tighten screws to specified torque. 3. Install cover gasket, crankcase cover and lift eye. Tighten screws in sequence and two stages to specified torque. 66 110 c e a bd f g h i 1 2 3 4 5 6 7 8 9 10 11 1213 14 15 16 17 66 f-Crankcase cover g-Screw (17) (M8 x 45) h-Lift eye i-Screw (2) (M6 x 20) a-Baffle plate b-Nut (6) c-Cover gasket d-Breather plate e-Screw (14) (M4 x 8) Baffle Plate Nut Torque (b) 12 Nm (105 lb–in.) Breather Plate Screw Torque (e) 2 Nm (18 lb–in.) Crankcase Cover Screw Torque (g) 1st Torque: 14 Nm (125 lb–in.) 2nd Torque: 28 Nm (20.5 lb–ft) Lift Eye Screw Torque (i) 12 Nm (105 lb–in.) Page 4B-50 90-888465 JUNE 2002 CYLINDER BLOCK/CRANKCASE Exhaust Cover Installation 1. Install new gaskets and exhaust covers. Tighten the screws to specified torque in sequence and in 2 stages. 12 34 56 7 8 9 10 11 12 13 14 8 9 11 12 13 1 34 5 7 2 6 10 14 Exhaust Cover Screw Torque 1st Torque: 6 Nm (53 lb-in.) 2nd Torque: 12 Nm (106 lb-in.) 90-888465 JUNE 2002 Page 4B-51 CYLINDER BLOCK/CRANKCASE Oil Filter Installation CAUTION Before installing the powerhead, be sure to fill with engine oil through the oil passage of the oil filter base. NOTE: Apply a thin coat of engine oil to the oil filter seal before installation 1. Install the oil filter. Tighten to specified torque using a 74 mm (2.9 in.) oil filter wrench. a 110 110 4 Stroke Outboard Oil a-Oil passages Oil Filter Torque 18 Nm (160 lb-in.) Oil Capacity (with Filter Replacement) 6.0 L (6.3 qt.) Page 4B-52 90-888465 JUNE 2002 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 removal of the following components: a. Air intake silencer b. VST system c. Throttle bodies, fuel rails, fuel injectors d. Fuel filter 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 (91-83163M) b. Stator c. Timing belt d. Drive sprocket e. Ignition coils f. CDI unit g. Crank Position Sensors h. Temperature Sensor 90-888465 JUNE 2002 Page 4B-53 CYLINDER BLOCK/CRANKCASE Powerhead Installation NOTE: Refer to Following Powerhead Installation for proper hose and adapter connections. 1. Clean the powerhead mating surface. Install dowel pins and new gasket. 2. Lift powerhead using flywheel puller/lifting eye (91-83164M). 3. Place powerhead onto drive shaft housing. Tighten mounting screws to specified torque. b a b 91-83164M a-Screw (6) (M10 x 140) b-Screw (7) (M9 x 35) Powerhead Mounting Screw Torque 42 Nm (31 lb-ft) Page 4B-54 90-888465 JUNE 2002 CYLINDER BLOCK/CRANKCASE 4. Install lower cowling. Tighten attaching screws to specified torque. a a c b b a-Lower cowling b-Screw (11) (M6 x 20) c-Screw (1) (M6 x 35) Lower Cowling Screw Torque 8 Nm (70 lb-in.) 5. Connect the following electrical harness connectors and hoses: a. Low pressure fuel pump driver b. Power Trim and Tilt (PTT) switch c. Shift interrupt switch d. Neutral Switch e. Cooling water pilot hose 90-888465 JUNE 2002 Page 4B-55 CYLINDER BLOCK/CRANKCASE Page 4B-56 90-888465 JUNE 2002 6. Install the dipstick guide. 7. Connect the following components: a. Fuel hose b. PTT motor leads c. Flushing device hose (if equipped) a c d e b a- Dipstick guide b- O-ring c- Fuel hose d- PTT motor leads e- Flushing device hose 8. Connect the shift cable and throttle cable. Adjust length if necessary. 59519 c a b a c b a- Throttle cable b- Shift cable c- Hairpin cotter CYLINDER BLOCK/CRANKCASE NOTE: For adjustment procedures see Section 1D - Shift Cable Installation and Throttle Cable Installation. 9. Install the clamp brackets and retaining plate. a b b c 59519 a-Retaining plate b-Clamp bracket c-Cable rigging kit 10. Install the crank position sensor and stator coil. Refer to Section 2A for installation instructions. 90-888465 JUNE 2002 Page 4B-57 CYLINDER BLOCK/CRANKCASE Following Powerhead Installation 1. Refer to Section 3C for installation of the following components: a. Air temperature sensor and Vapor Separator system b. Air intake c. Fuel cooler d. ECM connection and electrical component mounting plate e. Voltage regulator f. Fuel lines g. Fuel rails h. Throttle bodies 2. Connect the cowl mount Power Trim and Tilt (PTT) switch harness connector. 3. Connect the neutral start switch connector and shift cut switch connector. 4. Connect oil pressure switch connector. 59460 59459 c a b a-Neutral start switch connector b-Shift cut switch connector c-Oil pressure switch Page 4B-58 90-888465 JUNE 2002 CYLINDER BLOCK/CRANKCASE 90-888465 JUNE 2002 Page 4B-59 5. Connect the high pressure fuel pump relay harness connector. 6. Connect the high pressure fuel pump harness connector 7. Connect the fuel pump harness connector. 8. Connect the fuel pump driver harness connector. 59458 a b c a- Fuel pump harness b- Fuel pump driver harness c- High pressure fuel pump relay harness 9. Install bracket mounting screws. 10. Install fuel filter support bracket mounting screws. 59451 a b d d c a- Fuel filter support bracket mounting screws (2) M6 x 19 b- Power ground screw (1) M6 x 20 c- ECM connection harness d- Bracket mounting screws (6) M6 x 28 CYLINDER BLOCK/CRANKCASE Page 4B-60 90-888465 JUNE 2002 11. Connect the harness connectors/leads of the following components: a. Air intake temperature switch b. ECM c. Power Trim and Tilt d. Starter relay e. Main relay f. Voltage regulator g. Stator h. Ground lead a g h c d e b f a- Air intake temperature switch connector b- ECM connector c- Power Trim and Tilt leads (Light blue and Light green) d- Starter relay connector e- Main relay connector f - Voltage regulator connector g- Stator connector h- Ground lead 12. Install electrical component cover. 13. Install air silencer. Refer to Section 3C - Intake Silencer Installation. CYLINDER BLOCK/CRANKCASE 14. Install flywheel cover. a b a-Flywheel Cover b-Screws (3) M6 x 20 Flywheel Cover Screw Torque 7.5 Nm (65 lb-in.) 90-888465 JUNE 2002 Page 4B-61 LUBRICATION POWERHEAD Section 4C - Lubrication Table of Contents Table of Contents . . . . . . . . . . . . . . . . . . . . . . . 4C-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-1 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-2 Low Oil Pressure Protection . . . . . . . . . . . . . . 4C-4 Oil Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-5 Oil Pressure Measurement . . . . . . . . . . . . . . . 4C-6 Oil Pump Reference Drawing . . . . . . . . . . . . . 4C-7 Specifications Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-8 Oil Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-9 4 C Pump Type Trochoid with Relief Valve Oil Pump Drive Discharge at 212°F (100°C) with Drive shaft Spline 10W-40 Oil at 1000 rpm 8.8 l/min (2.32 gpm) Engine Oil Pressure (Warm Engine) LUBRICATION SYSTEM @ 700 rpm Engine Oil Capacity (with filter replacement) 138 kPa (19.6 psi) 6.0 L (6.3 Qt) Engine Oil Capacity (without filter replacement) 5.8 L (6.1 Qt) Relief Valve Opening Pressure 530 - 650 kPa (75 - 92 psi) Oil Pump: Non-Serviceable 90-8888465 JUNE 2002 Page 4C-1 LUBRICATION Oil Pump 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 3536 37 2 2 2 66 Loctite 242 95 2-4-C With Teflon 4 Stroke Outboard Oil110 66 66 66 95 95 95 95 110 66 Page 4C-2 90-8888465 JUNE 2002 LUBRICATION Oil Pump REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 DRIVE SHAFT HOUSING 2 8 DOWEL PIN 3 1 BAFFLE PLATE 4 1 SCREW (M6 X 16) 35 4 5 1 RUBBER SEAL 6 1 RUBBER SEAL 7 1 RUBBER SEAL 8 1 RUBBER SEAL 9 10 SCREW (M8 X 35) 177 20 10 1 MUFFLER 11 1 GASKET 12 1 PLATE 13 1 WATER TUBE 14 1 GASKET 15 2 SCREW (M8 X 35) 159 18 16 1 PRESSURE CONTROL VALVE 71 8 17 1 SCREW (M6 X 20) 71 8 18 1 PLATE 19 7 SCREW (M10 X 45) 31 42 20 1 COLLAR 21 1 EXHAUST PLATE 20 2.5 22 1 GASKET 23 1 EXHAUST EXTENSION 24 1 SEAL 25 3 COLLAR 26 3 SCREW (M6 X 25) 89 10 27 1 OIL STRAINER 28 1 GASKET 29 1 OIL PAN 30 1 GASKET 31 4 SCREW (M8 X 90) 177 20 32 10 SCREW (M 8 X 60) 177 20 33 2 SCREW (M8 X 30) 177 20 34 1 SEAL 35 1 OIL PUMP 36 4 SCREW (M6 X 30) 71 8 37 2 O-RING 90-8888465 JUNE 2002 Page 4C-3 LUBRICATION Low Oil Pressure Protection The low oil pressure warning activation varies in accordance with the engine speed. When the value detected by the oil pressure sensor drops below the specified value on the graph, the ECM determines a drop in oil pressure has occurred and activates the oil pressure control. When the oil pressure control mode is activated, the oil warning light is illuminated and the warning horn sounds. This warning mode will not be deactivated until the ignition switch is turned to the OFF position. When the system enters low oil pressure protection, the engine will not exceed 2000 rpm. If operating above 2000 rpm, the ECM causes cylinder pairs #2 and #5, #3 and #6 to misfire until the engine speed decreases to 2000 rpm and will continue to misfire until the oil pressure has exceeded the specified value. The ECM will not open the fuel injectors to the specified cylinder pairs when the oil pressure is lower than the specified value (see graph below). .5, (7.0) 1.01, (14.5) 1.54, (22.0) 2.03, (29.0) 2.53, (36.0) 3.05, (43.5) 3.58, (51.0) 4.07, (58.0) Oil pressure specified values 0.0 600700800100015002000 2500300035004000450050005500 RPM Specified value kg/cm2 (PSI) Page 4C-4 90-8888465 JUNE 2002 LUBRICATION Oil Flow Chart 90-8888465 JUNE 2002 Page 4C-5 LUBRICATION Oil Pressure Measurement 1. Warm up engine. 2. Remove brass plug NOTE: Brass plug is located behind the oil dip stick. 3. Install oil pressure gauge. NOTE: Use a pressure gauge with a range of 0-10.55 kg/cm2(0-150 PSI) and 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. Page 4C-6 90-8888465 JUNE 2002 LUBRICATION Oil Pump Reference Drawing NOTE: The oil pump is non-serviceable except for o-ring and seal replacement. The assembly drawing below is strictly for reference purposes only. a a-Oil pump screw Oil Pump Screw Torque 4 Nm (35 lb-in.) 90-8888465 JUNE 2002 Page 4C-7 LUBRICATION Page 4C-8 90-8888465 JUNE 2002 Oil Pump Removal NOTE: Powerhead must be removed to gain access to oil pump, refer to Section 4A, Powerhead Removal. 1. Suspend the power head with the appropriate engine lifting harness. 2. Remove the bolts (4) holding oil pump to power head. 59445 a b d c 4 Stroke Outboard Oil 110 110 a - Engine lifting harness b - O-Rings (2) c - Screw (4) M6 x 30 d - Oil Pump Installation 1. Install oil pump. Torque screws to specification 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. 2. Install power head. Refer to Powerhead Installation. Oil Pump Screw Torque 8 Nm (71 lb-in.) LUBRICATION Oil Strainer Removal 1. Remove oil pan. Refer to Section 5A, Oil Pan Removal. 2. Remove the 3 screws holding the oil strainer to the exhaust plate Installation 1. Check the oil strainer for residue and debris. Clean if necessary. 2. Install the o-ring to the exhaust plate. 3. install the oil strainer and the oil strainer screws.Tighten to specified torque. 4. Install the oil pan. Refer to Sectiom 5A, Oil Pan Installation. a b c d a-Collar (3) b-Screw (3) M6 x 25 c-Oil strainer d-O-ring Oil Strainer Screw Torque 10 Nm (89 lb-in.) 90-8888465 JUNE 2002 Page 4C-9 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING MID-SECTION Section 5A - Clamp/Swivel Brackets & Drive Shaft Housing Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-1 Shift Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-2 Bottom Cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-4 Drive Shaft Housing, Steering Arm and Swivel Bracket . . . . . . . . . . . . . . . . . . . . . 5A-6 Drive Shaft Housing, Oil Pan and Muffler . . . 5A-8 Steering Arm, Swivel Bracket and Clamp Bracket . . . . . . . . . . . . . . . . . . . . . 5A-10 Drive Shaft Housing Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . 5A-12 Specifications Oil Pan Removal . . . . . . . . . . . . . . . . . . . . . . . . 5A-14 Oil Pan Installation . . . . . . . . . . . . . . . . . . . . . . 5A-16 Upper and Lower Mount Installation . . . . . 5A-20 Steering Arm Removal . . . . . . . . . . . . . . . . . . . 5A-21 Steering Arm Installation . . . . . . . . . . . . . . . . . 5A-22 Drive Shaft Housing Installation . . . . . . . . . . . 5A-24 Clamp Bracket Removal and Installation . . . 5A-25 Clamp Bracket Removal. . . . . . . . . . . . . . . . 5A-25 Clamp Bracket Installation . . . . . . . . . . . . . . 5A-26 5 A Recommended Transom Height: Short Shaft 64 cm (25 in.) MID-SECTION Long Shaft Steering Pivot Range Trim Angle Full Tilt Up Angle 76 cm (30 in.) 64° -3° to 16° 70° Allowable Transom Thickness (Max) 76.2 mm (3 in.) 90-888465 JUNE 2002 Page 5A-1 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Shift Linkage 95 2-4-C with Teflon 95 95 Page 5A-2 90-888465 JUNE 2002 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Shift Linkage REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 BRACKET 2 2 SCREW (M6 X 35) 70 8 3 1 SCREW (30 MM) 4 1 CLAMP 5 4 SCREW (M4 X 16) 18 2 6 1 SCREW (25 MM) 7 2 PLATE 8 1 SHIFT SWITCH ASSEMBLY 9 1 NEUTRAL SWITCH ASSEMBLY 10 2 BUSHING 11 1 GREASE FITTING 12 1 SCREW 13 1 SCREW (M6 X 30) 70 8 14 1 BRACKET 15 1 WASHER 16 2 BUSHING 17 1 BUSHING 160 18 18 1 SPRING 19 1 BALL 20 1 PIN 21 1 COTTER PIN 22 1 GEAR SHIFT HANDLE 23 1 O-RING 24 1 GROMMET 25 1 BUSHING 26 3 COTTER PIN 27 1 LINK ASSEMBLY 28 1 WASHER 29 1 CLAMP 30 1 CLAMP 31 1 SPRING 32 1 BRACKET 33 1 BUSHING 34 1 ANCHOR BRACKET 35 1 RETAINER 90-888465 JUNE 2002 Page 5A-3 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Bottom Cowl 95 2-4-C with Teflon 95 95 95 Page 5A-4 90-888465 JUNE 2002 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Bottom Cowl REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 BOTTOM COWLING 2 1 RUBBER SEAL 3 2 COWLING LOCK LEVER 4 6 BUSHING 5 2 PLATE 6 6 SCREW (M6 X 30) 70 8 7 3 WAVE WASHER 8 2 LEVER 9 3 WASHER 10 3 SCREW (M6 X 20) 70 8 11 3 SPRING 12 3 HOOK 13 3 SCREW (M6 X 20) 70 8 14 1 BRACKET 15 2 SCREW (M6 X 25) 70 8 16 2 PLATE 17 2 GROMMET 18 1 GROMMET 19 2 GROMMET 20 4 COLLAR 21 8 GROMMET 22 4 SCREW (M6 X 30) 23 1 COOLING WATER PILOT HOLE 24 2 SCREW (M6 X 20) 70 8 25 2 BRACKET 26 1 TRAILER SWITCH 27 1 SCREW (M6 X 18) 70 8 28 1 LOW-PRESSURE FUEL PUMP DRIVER 29 1 BRACKET 30 2 SCREW (M6 X 20) 70 8 31 1 COVER 32 1 GASKET 33 1 COWLING LOCK LEVER 34 1 PLATE 35 1 LEVER 90-888465 JUNE 2002 Page 5A-5 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Drive Shaft Housing, Steering Arm and Swivel Bracket 7–7 95 2-4-C with Teflon 95 66 Loctite 542 Threadlocker 95 95 95 95 66 95 95 66 12 66 Page 5A-6 90-888465 JUNE 2002 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Drive Shaft Housing, Steering Arm and Swivel Bracket REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 DRIVE SHAFT ASSEMBLY 2 2 DAMPER 3 2 BOLT (M14 X 190) 53 72 4 6 WASHER 5 2 UPPER MOUNT 6 1 BRACKET 7 3 SCREW (M10 X 40) 26.5 36 8 4 SCREW M10 X 40) 26.5 36 9 2 MOUNT HOUSING 10 2 BOLT (M14 X 205) 53 72 11 2 WASHER 12 2 RUBBER WASHER 13 2 LOWER MOUNT 14 2 WASHER 15 1 DRAIN PLUG (M14 X 12) 20 27 16 1 METAL GASKET 17 1 COVER 18 2 SCREW (M6 X 14) 70 8 19 1 DAMPER 20 6 APRON STAY 70 8 21 1 GROUND LEAD 22 1 SCREW (M6 X 10) 70 8 23 1 GROUND LEAD 24 1 HOSE 25 1 CABLE TIE 26 1 DOWEL PIN 27 1 ADAPTER 28 1 SCREW (M6 X 25) 70 8 29 1 DRIVE SHAFT BUSHING 30 2 CIRCLIP 31 4 NUT (M14) 53 72 32 4 WASHER 33 1 STEERING ARM 34 2 WASHER 35 2 BUSHING 36 1 O-RING 37 1 BUSHING 38 1 STEERING YOKE 90-888465 JUNE 2002 Page 5A-7 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Drive Shaft Housing, Oil Pan and Muffler 95 2-4-C with Teflon 66 Loctite 542 Threadlocker 66 66 95 66 95 95 66 95 66 Page 5A-8 90-888465 JUNE 2002 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Drive Shaft Housing, Oil Pan and Muffler REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 UPPER EXHAUST GUIDE 2 2 SCREW (M8 X 35) 15 20 3 1 PRESSURE CONTROL VALVE 70 8 4 1 SCREW (M6 X 20) 70 8 5 1 PLATE 6 1 COLLAR 7 7 SCREW (M10 X 45) 31 42 8 1 GASKET 9 2 DOWEL PIN 10 1 LOWER EXHAUST GUIDE 11 1 GASKET 12 1 OIL STRAINER 13 3 COLLAR 14 3 SCREW (M6 X 25) 90 10 15 1 GASKET 16 2 DOWEL PIN 17 1 OIL PAN 18 2 SCREW (M8 X 30) 177 20 19 10 SCREW (M8 X 60) 177 20 20 1 GASKET 21 1 EXHAUST MANIFOLD 22 4 SCREW (M8 X 90) 177 20 23 1 EXHAUST SEAL 24 1 GASKET 25 1 PLATE 26 2 DOWEL PIN 27 1 MUFFLER 28 1 COOLING WATER TUBE 29 1 RUBBER SEAL 30 10 SCREW (M8 X 35) 177 20 31 1 MUFFLER SEAL 32 1 RUBBER SEAL 33 1 RUBBER SEAL 34 2 SCREW (M6 X 16) 35 4 35 1 BAFFLE PLATE 36 2 DOWEL PIN 37 1 DRIVE SHAFT HOUSING 38 1 GASKET 90-888465 JUNE 2002 Page 5A-9 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Steering Arm, Swivel Bracket and Clamp Bracket 2-4-C with Teflon 95 Loctite 242 Thread Locker 95 66 95 95 95 95 66 Page 5A-10 90-888465 JUNE 2002 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Steering Arm, Swivel Bracket and Clamp Bracket REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 TILT TUBE 2 1 PORT CLAMP BRACKET 3 8 SCREW (M10 X 45) 42 4 3 GROUND LEAD 5 1 SCREW 6 2 WASHER 7 10 BUSHING 8 2 FRICTION PLATE 9 4 SCREW (M6 X 10) 35 4 10 2 SCREW (M6 X 15) 70 8 11 1 TRIM SENSOR 12 6 GREASE FITTING 13 1 SCREW (M6 X 12) 70 8 14 2 CLAMP 15 1 STARBOARD CLAMP BRACKET 16 1 SELF-LOCKING NUT 17 1 SCREW (M6 14) 70 8 18 1 COLLAR 19 2 PIN 20 2 TILT STOP LEVER CONNECTOR 21 1 PIN 22 1 SCREW (M6 X 10) 70 8 23 1 SPRING 24 1 SPRING HOLDER 25 1 PORT TILT STOP LEVER 26 1 SHAFT 27 2 TRIM STOP 28 1 STARBOARD TILT STOP LEVER 29 1 CIRCLIP 30 2 NUT 26.5 36 31 1 SWIVEL BRACKET 32 1 POWER TRIM AND TILT UNIT (PTT) 33 1 SCREW (M6 X 10) 70 8 34 4 CABLE TIE 35 4 SCREW (M6 X 25) 70 8 36 2 BRACKET 37 1 ANODE 90-888465 JUNE 2002 Page 5A-11 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Drive Shaft Housing Removal and Disassembly 1. Remove the lower cowl. 2. Remove the powerhead, refer to section 4B. 3. Remove the lower unit, refer to section 6. 4. Place a drain pan under the drain hole. Remove the drain plug and let the oil drain completely. b a a-Starboard lower cowl b-Drain plug 5. Remove the cover and damper. c b a a-Drain plug b-Cover c-Damper Page 5A-12 90-888465 JUNE 2002 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 6. Remove the upper and lower mount nuts. 7. Remove the drive shaft housing from steering arm. b c a a-Upper mounting nuts b-Lower mounting nuts c-Swivel bracket 8. Remove the oil pan muffler assembly from the drive shaft housing. a b d e c a-Muffler assembly screw (2) (M8 x 35) b-Pressure control valve c-Muffler assembly screw (7) (M10 x 45) d-Muffler assembly e-Drive shaft housing 90-888465 JUNE 2002 Page 5A-13 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Oil Pan Removal 1. Remove the muffler plate and exhaust manifold from the oil pan. c a b d a-Muffler plate b-Muffler c-Oil pan d-Exhaust manifold Page 5A-14 90-888465 JUNE 2002 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 2. Remove the oil pan from the upper exhaust guide and lower exhaust guide. 3. Remove the oil strainer from the lower exhaust guide. 4. Check the oil strainer for contamination and residue. Clean if necessary. a b c d a-Upper exhaust guide b-Lower exhaust guide c-Oil strainer d-Oil pan 90-888465 JUNE 2002 Page 5A-15 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Oil Pan Installation 1. Install the gasket and lower exhaust guide onto the upper exhaust guide. a b c a-Upper exhaust guide b-Gasket c-Lower exhaust guide 2. Install the oil strainer with collar and screws. Tighten screws to specified torque. a b c d a-Oil strainer b-Screw (3) (M6 x 25) c-Collar d-Seal Oil Strainer Screw Torque 10 Nm (90 lb-in.) Page 5A-16 90-888465 JUNE 2002 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 3. Install the oil pan. Tighten screws finger-tight. 4. Install the exhaust manifold and screws. Tighten screws finger-tight. a d b b c e 2-4-C with Teflon 95 66 Loctite 242 Thread Locker 66 f 95 66 a-Oil pan b-Oil pan screws c-Exhaust manifold d-Exhaust manifold screws e-Exhaust seal f-Gasket 5. Screw tightening sequence: a. Tighten exhaust manifold screws to 1/2 specified torque. b. Tighten oil pan screws to 1/2 specified torque. c. Tighten exhaust manifold screws to specified torque. d. Tighten oil pan screws to specified torque. 6. Lubricate the exhaust seal with 2-4-C with Teflon and install. Exhaust Manifold Screw Torque 1st Torque: 10 Nm (90 lb-in.) 2nd Torque: 20 Nm (180 lb-in.) Oil Pan Screw Torque 1st Torque: 10 Nm (90 lb-in.) 2nd Torque: 20 Nm (180 lb-in.) 90-888465 JUNE 2002 Page 5A-17 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 7. Install the plate and two gaskets. 8. Install the cooling water tube into the muffler. 9. Install the muffler and screws into the oil pan. Tighten screws to specified torque. a b b c d 66 Loctite 242 Thread Locker 95 2-4-C with Teflon 95 66 a-Plate b-Gasket c-Muffler d-Water cooling tube Muffler Screw Torque 20 Nm (15 lb-ft) Page 5A-18 90-888465 JUNE 2002 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 10. Install the muffler assembly by inserting the tip of the cooling water tube into the joint hole of the drive shaft housing. 11. Install muffler assembly screws and pressure control valve. Tighten screws to specified torque. a b 66 Loctite 242 Thread Locker 95 95 2-4-C with Teflon 66 95 d f c e a-Muffler assembly screw (2) (M8 x 35) b-Pressure control valve c-Muffler assembly screw (7) (M10 x 45) d-Muffler assembly e-Cooling water tube f-Joint hole Muffler Assembly Screw Torque (M8) 20 Nm (15 lb-ft) Muffler Assembly Screw Torque (M10) 42 Nm (31 lb-ft) Pressure Control Valve Screw Torque 8 Nm (70 lb-in.) 90-888465 JUNE 2002 Page 5A-19 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 12. Install damper, cover and drain plug. Tighten to specified torque. a-Drain plug b-Cover c-Damper c b a Drain Plug Torque 27 Nm (20 lb-ft) Upper and Lower Mount Installation 1. Install the upper mounts, washers and bolts into the drive shaft housing. 2. Install the clamp and screws. a b 66 Loctite 242 Thread Locker 95 2-4-C with Teflon 9566 c d ed a-Upper mount (2) b-Clamp c-Bolt (2) (M14 x 190) d-Washer (4) e-Rubber washer (2) Page 5A-20 90-888465 JUNE 2002 66 95 e a b c d b f 66 95 e a b c d b f CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 3. Install the lower mounts and mount housing. 95 2-4-C with Teflon 66 Loctite 242 Thread Locker a-Bolt (2) (M14 x 205) b-Washer (4) c-Rubber washer (2) d-Lower mount (2) e-Mount housing f-Screw (4) (M10 x 40) Steering Arm Removal 1. Remove circlip. 2. Remove the steering yoke by striking it with a plastic hammer. 3. Remove the steering arm from the swivel bracket by pulling the arm out of the bracket. a b c a-Circlip b-Steering yoke c-Steering arm 90-888465 JUNE 2002 Page 5A-21 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Steering Arm Installation 1. Install washer and bushing onto the steering arm. Lubricate with 2-4-C with Teflon. 2. Place the swivel bracket in an upright position. Install the steering arm in the swivel bracket. a c d 95 2-4-C with Teflon 95 b a-Washer b-Bushing c-Steering arm d-Swivel bracket 3. Install bushing, o-ring, bushing and washer in the swivel bracket. Lubricate with 2-4-C with Teflon. 95 2-4-C with Teflon a b c d 95 a-Bushing b-O-ring c-Bushing d-Washer Page 5A-22 90-888465 JUNE 2002 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 4. Install the steering arm on the steering yoke by aligning the center (1) of the yoke with the center (2) of the steering arm. 5. Install the circlip. 95 2-4-C with Teflon a b c 95 2 1 a-Steering arm b-Steering yoke c-Circlip 6. Lubricate the bushings with 2-4-C with Teflon until grease flows from bushings. a 95 2-4-C with Teflon b 95 a-Grease fitting b-Bushings 90-888465 JUNE 2002 Page 5A-23 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Drive Shaft Housing Installation 1. Install the upper and lower mounting bolts into the swivel bracket simultaneously. 2. Install the upper mounting nut and lower mounting nut. Tighten nuts to specified torque. b c a a-Upper mounting nuts b-Lower mounting nuts c-Swivel bracket Upper and Lower Mounting Nut Torque 72 Nm (53 lb-ft) Page 5A-24 90-888465 JUNE 2002 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Clamp Bracket Removal and Installation Power Trim and Tilt Unit Removal See Section 5B for power trim and tilt unit removal. Clamp Bracket Removal 1. Remove the self-locking nut on the tilt tube. Remove the ground lead and the clamp brackets. 2. Remove the trim sensor. a b d e c a-Self-locking nut b-Ground lead c-Clamp bracket d-Clamp bracket e-Trim sensor 90-888465 JUNE 2002 Page 5A-25 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Clamp Bracket Installation 1. Install the trim sensor on the port clamp bracket a a-Trim sensor NOTE: Adjust the trim sensor after installing the power trim and tilt unit. 2. Assemble the clamp brackets and swivel brackets. • Install bushings and washers in swivel bracket. Lubricate with 2-4-C with Teflon. • Attach the ground lead to the clamp bracket and swivel bracket. • Install the tilt tube through the clamp brackets and swivel bracket. • Install self-locking nuts finger-tight. (Torque after installing power trim unit) a b 95 2-4-C with Teflon 95 95 95 d c a-Ground lead b-Tilt tube Power Trim Unit Installation c-Trim sensor d-Self-locking nut See Section 5B for power trim and tilt unit installation. Page 5A-26 90-888465 JUNE 2002 POWER TRIM MID-SECTION Section 5B-Power Trim Table of Contents 5 B Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-2 Power Trim and Tilt Components . . . . . . . . . . . . . 5B-4 Power Trim and Tilt Cylinders . . . . . . . . . . . . . . . . 5B-6 Power Trim Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-8 Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . . . 5B-10 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-10 Trimming Characteristics . . . . . . . . . . . . . . . . . 5B-10 Trailering Outboard . . . . . . . . . . . . . . . . . . . . . . 5B-11 Tilting Outboard Up and Down Manually . . . . 5B-12 Power Trim System Hydraulic Schematic . . . . . . 5B-13 Power Trim Flow Diagrams - Trim Up Circuit . . . 5B-14 Trim Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-15 Power Trim Flow Diagrams - Trim Down Circuit . . 5B-16 Trim Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-17 Power Trim Flow Diagrams - Trim Ram Retraction Circuit . . . . . . . . . . . . . . . . . . . . . . . 5B-18 Trim Ram Retraction . . . . . . . . . . . . . . . . . . . . . . . . 5B-19 Stationary Condition . . . . . . . . . . . . . . . . . . . . . . . . 5B-19 Power Trim Flow Diagrams - Shock System . . . 5B-20 Shock System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-21 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-22 Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . 5B-22 Hydraulic System Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-23 Specifications Electrical System Diagram . . . . . . . . . . . . . . . . 5B-27 Power Trim System . . . . . . . . . . . . . . . . . . . . . . . . . 5B-28 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-30 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-30 Adjusting the Trim Sensor . . . . . . . . . . . . . . . . 5B-32 Motor and Electrical Tests . . . . . . . . . . . . . . . . . . . 5B-34 Motor Disassembly . . . . . . . . . . . . . . . . . . . . . . 5B-34 Motor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-35 Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 5B-37 Electrical System Tests . . . . . . . . . . . . . . . . . . . 5B-39 Pump and Hydraulic System Tests . . . . . . . . . . . . 5B-43 Power Trim and Tilt Unit Disassembly . . . . . . . . . 5B-47 Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . 5B-47 Trim and Tilt Cylinder Disassembly . . . . . . . . 5B-49 Power Trim and Tilt Unit Inspection . . . . . . . . 5B-53 Gear Pump/Valve Inspection . . . . . . . . . . . . . . 5B-55 Power Trim and Tilt Unit Assembly . . . . . . . . . . . 5B-57 Gear Pump Assembly. . . . . . . . . . . . . . . . . . . . 5B-57 Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . 5B-59 Power Trim Motor Installation . . . . . . . . . . . . . 5B-66 Power Trim Reservoir Installation . . . . . . . . . . 5B-68 Tilt Ram Installation . . . . . . . . . . . . . . . . . . . . . . 5B-69 Bleeding the Power Trim and Tilt System . . . 5B-70 Hydraulic Pressure Trim Down Trim Up 6.7-8.7 mPa (970-1260 psi) 12.2-14.2 mPa (1770-2060 psi) POWER TRIM Trim Sensor Resistance SYSTEM @ 20 C (68 F) Full Down 9-11 W Full Up 247.6-387.6 W 90-888465 JUNE 2002 Page 5B-1 POWER TRIM Special Tools 1. Power Trim Test Gauge Kit P/n 91-52915A6 2. Oil pressure gauge adapter P/N 91-888861 3. Cylinder end cap wrench P/N 91-888867 4. Piston vise attachment P/N 888868 5. Tilt rod wrench P/N 91-888869 Page 5B-2 90-888465 JUNE 2002 POWER TRIM 6. Lock-Ring Pliers P/N SRP-4 (Snap-On) 7. 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 90-888465 JUNE 2002 Page 5B-3 POWER TRIM Power Trim and Tilt Components 21 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. Page 5B-4 90-888465 JUNE 2002 POWER TRIM Power Trim and Tilt Components REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 MANIFOLD 2 1 RESERVOIR 3 3 SCREW (M8 X 20) 160 18 4 1 O-RING 5 1 FILL PLUG (M12 X 10) 62 7 6 1 O-RING 7 1 PLATE 8 1 FILTER 9 1 SPACER 10 3 SCREW (M8 X 20) 160 18 11 1 O-RING 12 1 COUPLER 13 1 O-RING 14 1 MANUAL RELEASE VALVE 15 1 CIRCLIP 16 1 SHAFT 17 1 CIRCLIP 18 2 BUSHING 19 1 TUBE 20 1 TUBE 21 1 STATOR 22 2 SCREW (M5 X 12) DRIVE TIGHT 23 4 WASHER 24 1 WAVE WASHER 25 1 WASHER 26 2 BEARING 27 1 ARMATURE 28 4 BRUSH 29 4 SPRING 30 2 SCREW (M4 X 12) DRIVE TIGHT 31 1 BRUSH HOLDER 32 2 NUT 33 2 SCREW (M4 X 6) DRIVE TIGHT 34 1 O-RING 35 1 MOTOR BASE 36 1 OIL SEAL 37 1 MOTOR LEAD 90-888465 JUNE 2002 Page 5B-5 POWER TRIM Power Trim and Tilt Cylinders 95 2-4-C with Teflon 95 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. Page 5B-6 90-888465 JUNE 2002 POWER TRIM Power Trim and Tilt Cylinders REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 2 CIRCLIP 2 2 DUST SEAL 3 2 TRIM CYLINDER END CAP 118 160 4 2 O-RING 5 2 TRIM RAM 6 2 TRIM PISTON 7 2 WASHER 8 2 SCREW 28 38 9 2 BACKUP RING 10 2 O-RING 11 2 SPRING 12 2 ADAPTOR 13 2 CIRCLIP 14 1 TILT RAM 40.5 55 15 1 DUST SEAL 16 1 TILT CYLINDER END CAP 66.5 90 17 1 O-RING 18 1 BACKUP RING 19 1 O-RING 20 1 SPRING 21 1 ADAPTOR 22 1 TILT PISTON 23 1 O-RING 24 1 BACKUP RING 25 5 BALL 26 5 PIN 27 5 SPRING 28 1 WASHER 29 1 PLATE 30 1 WASHER 31 1 SCREW (M6 X 10) 62 7 32 1 MEMORY PISTON 33 1 O-RING 34 1 TILT CYLINDER 90-888465 JUNE 2002 Page 5B-7 POWER TRIM Power Trim Pump 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. Page 5B-8 90-888465 JUNE 2002 POWER TRIM Power Trim Pump REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 GEAR HOUSING 1 2 3 SCREW (M5 X 40) 62 7 3 1 PLATE 4 1 FILTER 5 2 VALVE LOCK SCREW 6 1 DOWN-RELIEF SPRING 7 1 VALVE SUPPORT PIN 8 1 O-RING 9 1 UP-RELIEF SPRING 10 1 VALVE SUPPORT PIN 11 1 O-RING 12 1 BALL 13 2 CIRCLIP 14 2 MAIN VALVE SEAL 15 1 SHUTTLE PISTON 16 1 O-RING 17 2 RETURN SPRING 18 1 SHUTTLE PISTON 19 2 DRIVE GEAR 20 2 BALL 21 1 GEAR HOUSING 2 22 2 BALL 23 1 MANUAL RELEASE SPRING 24 1 DOWEL PIN 25 2 BALL 26 2 SEAT 27 2 SPRING 28 2 PISTON 29 2 O-RING 30 2 DOWEL PIN 31 1 BRACKET 32 2 WASHER 33 2 SCREW (M5 X 25) 62 7 34 2 O-RING 35 2 SPACER 36 2 FILTER 90-888465 JUNE 2002 Page 5B-9 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 the “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 19 degree maximum trim range. The power trim system is designed so the engine cannot be trimmed beyond the 16 degree maximum trim angle as long as engine rpm is above approximately 2000 rpm. Page 5B-10 90-888465 JUNE 2002 POWER TRIM The engine can be raised beyond the 16 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 16 degree maximum trim angle. 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 the “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. 90-888465 JUNE 2002 Page 5B-11 POWER TRIM 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). S69J7510 a a -Manual release valve Page 5B-12 90-888465 JUNE 2002 POWER TRIM Power Trim System Hydraulic Schematic a b d e fg h i j l c k b nn o pq m k a -Gear pump b-Reservoir c -Up circuit check valve d-Down circuit check valve e -Up-main valve f -Down-main valve g-Up shuttle valve h-Down shuttle valve i -Up-relief j -Down relief k -Trim cylinder l -Tilt cylinder m-Impact relief valve n-Manual release valve o-Shock return valve p-Shock piston q-Memory piston 90-888465 JUNE 2002 Page 5B-13 POWER TRIM Page 5B-14 90-888465 JUNE 2002 Power Trim Flow Diagrams - Trim Up Circuit o g j e d a c f b i r s t u v m n p q k l h POWER TRIM Trim Up When the Power Trim and Tilt (PTT) switch is activated in the ”up” position, the electric motor (q) rotates the oil pump (a) gears. As the oil pump gears rotate, inlet fluid to the pump is drawn through the up circuit check valve (c) leading to the reservoir (b) and from the return oil from the top chamber of the tilt cylinder (l). Pressurized oil from the pump forces the upshuttle valve (g) piston upward, fluid flows through the up–main valve (e), through tubing, and then to the bottom chamber of the trim cylinder (k) and tilt cylinder (l) forcing the trim ram (p) and tilt ram (o) upward. Pressurized oil from the pump also forces the down shuttle valve (h) piston downward opening the down-main valve (f) allowing return oil from the top chamber of the tilt cylinder to re- turn to the gear pump. Oil from the top chamber of the trim cylinders return through passages to the reservoir. The tilt cylinder and trim cylinder extend simultaneously. After the trim cylinders extend completely, the tilt cylinder continues to extend to the tilt-up position. If the up-button is not released, pressurized oil from the pump opens the up-relief valve (i) piston and oil flows over the valve back to the reservoir. a -Oil pump b-Reservoir c -Up circuit check valve d-Down circuit check valve e -Up-main valve f -Down-main valve g-Up shuttle valve h-Down shuttle valve i -Up-relief valve j -Down-relief k -Trim cylinder l -Tilt cylinder m-Impact relief valve n-Manual release valve o-Tilt ram p-Trim ram q-Motor r -Memory piston s -Shock piston t -Shock return valve u-Return oil to reservoir v -Pressurized oil from pump 90-888465 JUNE 2002 Page 5B-15 POWER TRIM Page 5B-16 90-888465 JUNE 2002 Power Trim Flow Diagrams - Trim Down Circuit o b i g j r s t u v m n p q k l h e d a c f POWER TRIM Trim Down When the Power Trim and Tilt (PTT) switch is activated in the ”down” position, the electric motor (q) rotates the oil pump (a) gears in the opposite direction. Inlet fluid to the pump is drawn through the down circuit check valve (d) leading to the reservoir (b) and from the re- turn oil from the bottom chamber of the tilt (l) and trim (k) cylinders. Pressurized oil from the pump moves the down–shuttle valve (h) piston upward, enters the tilt cylinder top chamber through the down-main valve (f), and then forces the tilt ram downward. Pressurized oil from the pump also forces the up-shuttle valve (g) piston downward opening the up-main valve (e), allowing return oil back to the gear pump inlet. The gear pump draws oil from the tilt cylinder bottom chamber and trim cylinder bottom chamber while the tilt ram and trim ram is retracting. Since the pressurized fluid from the gear pump supplies only the top–side chamber of the tilt cylinder, the tilt ram moves downward first. The hydraulic oil flows into the trim cylinder upper chamber from the reservoir. The down-relief valve (j) limits pressure in down circuit. When the engine comes in contact with the trim rams, the trim rams move downward simultaneously with the tilt ram due to the weight and thrust of the engine. a -Oil pump b-Reservoir c -Up circuit check valve d-Down circuit check valve e -Up-main valve f -Down-main valve g-Up shuttle valve h-Down shuttle valve i -Up-relief j -Down-relief valve k -Trim cylinder l -Tilt cylinder m-Impact relief valve n-Manual release valve o-Tilt ram p-Trim ram q-Motor r -Memory piston s -Shock piston t -Shock return valve u-Return oil to reservoir v -Pressurized oil from pump 90-888465 JUNE 2002 Page 5B-17 POWER TRIM POWER TRIM Power Trim Flow Diagrams - Trim Ram Retraction Circuit o g jb i r s t u v m n p q k l h cd fe a Page 5B-18 90-888465 JUNE 2002 POWER TRIM Trim Ram Retraction When the outboard engine is tilted up and held in place with the tilt stop lever and the PTT switch is activated in the ”down” position, the trim ram (p) will retract. The electrical motor rotates (q) the oil pump (a) gears and the pump attempts to draw oil from the bottom chamber of the tilt cylinder (l) and trim cylinder (p). Because the tilt cylinder is locked in place by the tilt stop lever, only the oil from the trim cylinder can be drawn into the gear pump. As oil is drawn from the trim cylinder into the pump, the trim ram retracts. Oil is drawn from the reservoir (b) into the top chamber of the trim cylinder as it retracts. Since the tilt cylinder is locked in place, high pressure oil from the pump causes the down– relief valve (j) to open, allowing oil to return to the reservoir (b). Stationary Condition When the PTT switch is not activated, the gear pump is not pumping oil. The up-main valve (e) and down-main valve (f) are closed. Oil in the system is locked in a static position preventing the tilt and trim rams from moving. This prevents the outboard from coming up or trailing out when shifted into reverse and/or throttling back rapidly. a -Gear pump b-Reservoir c -Up circuit check ball d-Down circuit check ball e -Up-main valve f -Down-main valve g-Up shuttle valve h-Down shuttle valve i -Up-relief j -Down-relief k -Trim cylinder l -Tilt cylinder m-Impact relief valve n-Manual release valve o-Tilt ram p-Trim ram q-Motor r -Memory piston s -Shock piston t -Shock return valve u-Return oil to reservoir v -Pressurized oil from pump 90-888465 JUNE 2002 Page 5B-19 POWER TRIM Power Trim Flow Diagrams - Shock System a b c d e f d Page 5B-20 90-888465 JUNE 2002 POWER TRIM Shock System When the boat is in operation and the lower unit hits a submerged object, the tilt ram (b) wants to be pulled out from the cylinder (a). This force causes a rapid increase in pressure in the tilt cylinder top chamber and causes the tilt piston impact relief valve (e) to open and release the fluid pressure from the top chamber into the space between the tilt piston and the memory piston (d). Oil on the bottom side of the tilt cylinder is locked in place by the upmain valve. As a result, the dampening effect of the shock piston impact relief valve (e) prevents the PTT system from being damaged before the shock piston (c) comes in contact with the top of the tilt cylinder. After the collision, propeller thrust and the weight of the outboard provides the force to return the outboard engine to its original trim position. Oil between the memory piston and the tilt piston passes through the shock return valve (f) into the top chamber as the ram retracts. The ram stops when it contacts the memory piston. a -Tilt cylinder b-Tilt ram c -Shock piston d-Memory piston e -Impact relief valve f -Shock return valve 90-888465 JUNE 2002 Page 5B-21 POWER TRIM Troubleshooting Support outboard with tilt lock lever 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 and Tilt System” in this section. 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 90-888465 JUNE 2002 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 Main valve as- sembly, inspect O-rings and seals for damage. Debris and/or dam- age identified. Replace Main valve assembly. Trim system holds re- verse thrust. Testing complete. Main valve appears O.K. - Clean and reinstall Main valve assembly. Trim will not hold reverse thrust. Trim system holds reverse thrust. Test- ing complete. continued on next page 90-888465 JUNE 2002 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 90-888465 JUNE 2002 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 Main valve as- sembly, inspect O-rings and seals for damage. Debris and/or dam- age identified. Replace Main valve assembly. Main valve appears O.K. - Clean and reinstall Main valve assembly. 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. 90-888465 JUNE 2002 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 90-888465 JUNE 2002 POWER TRIM Electrical System Diagram B Sb Lg B a c e h RED RED RED RED RED RED LT.GRN RED LT.GRN LT.BLU LT.BLU LT.GRN RED BLK RED PNK GRY BLK LT.GRN RED REDRED b d f g BLK PNK BLK BLK LT.GRN LT.GRN LT.BLU LT.GRN LT.BLU LT.BLU LT.BLU LT.BLU BLK = BLU = BRN = GRY = GRN = ORN = PNK = PUR = RED = TAN = WHT = YEL = GRY Black Blue Brown Gray Green Orange Pink Purple Red Tan White Yellow LT. = Light DRK = Dark a -Fuse (30 Amp) b-Fuse (20 Amp) c -Relay d-Motor e -10 pin connector f -Battery g-Switch h-Trim sensor 90-888465 JUNE 2002 Page 5B-27 POWER TRIM Power Trim System Removal 1. Tilt outboard to the full up position and support with tilt lock lever. a a -Tilt lock lever a WARNING After tilting the outboard motor up, be sure to support it with the tilt lock lever. Otherwise, the outboard motor could suddenly lower if the power trim and tilt unit should lose fluid pressure. NOTE: If the trim system does not operate, loosen the manual release valve and tilt the outboard up manually. 2. Slowly remove the fill plug to relieve reservoir pressure. 3. Turn the manual release valve counterclockwise to relief remaining pressure. a a-Manual release valve Page 5B-28 90-888465 JUNE 2002 POWER TRIM 4. Remove the anode and 8 screws securing the clamp bracket to the power trim and tilt unit (PTT). 5. Loosen the self-locking nut on the tilt tube. Move the clamp brackets slightly outward in the direction of the arrows. WARNING Do NOT remove the tilt lock lever from the clamp brackets. 6. Remove the sta-straps and J-clips. Disconnect the motor lead from the motor. 7. Remove the circlip from the tilt pin and remove the tilt pin. 8. Remove the power trim and tilt unit. d g i j a b h c e f a -Anode retaining screw (4) (M6 x 25) b-Anode c -Clamp bracket screw (8) (M10 x 45) d-Self-locking nut e -Sta-strap f -PTT motor lead g-Circlip h-Tilt pin i -Ground cable screw (M6 x 10) j -PTT unit 90-888465 JUNE 2002 Page 5B-29 POWER TRIM Installation 1. Tilt outboard to the full up position and support with tilt lock lever. a a a -Tilt lock lever WARNING After tilting the outboard motor up, be sure to support it with the tilt lock lever. Otherwise, the outboard motor could suddenly lower if the power trim and tilt unit should lose fluid pressure. Page 5B-30 90-888465 JUNE 2002 POWER TRIM 2. Lubricate bushings and install into the tilt ram end and swivel bracket. 3. Install the power trim unit between the clamp brackets. Attach the power trim unit to the clamp brackets with the 8 screws. Tighten screws to specified torque. 4. Tighten the self-locking nut on the tilt tube to the specified torque. 5. Install anode. Tighten screws to specified torque. d g i j a b h c e f 95 95 2-4-C with Teflon a -Anode retaining screw (4) (M6 x 25) b-Anode c -Clamp bracket screw (8) (M10 x 45) d-Self-locking nut e -Sta-strap f -PTT motor lead g-Circlip h-Tilt pin i -Ground cable screw (M6 x 10) j -PTT unit Clamp Bracket Screw Torque 42 Nm (31lb-ft) Self-locking Nut Torque 22 Nm (16 lb-ft) Anode Attaching Screw Torque 8 Nm (71 lb-in.) 90-888465 JUNE 2002 Page 5B-31 POWER TRIM 6. Lubricate all grease fittings with 2-4-C with Teflon. 95 95 2-4-C with Teflon 95 95 95 Adjusting the Trim Sensor 1. Tilt outboard to the full up position and support with tilt lock lever. a a -Tilt lock lever a WARNING After tilting the outboard motor up, be sure to support it with the tilt lock lever. Otherwise, the outboard motor could suddenly lower if the power trim and tilt unit should lose fluid pressure. Page 5B-32 90-888465 JUNE 2002 POWER TRIM 2. Loosen the cam screws. 3. Adjust the position of the trim sensor. Tighten the screws finger-tight. 4. Tilt the motor to full down position. 5. Measure the trim sensor resistance. Repeat steps 1 to 5 if out of specification. 6. Tighten trim sensor screws. a b c d e a-Cam screw (2) b-Trim sensor c-BLK lead d-GRY lead e-PNK lead 7. Tilt outboard to the full up position and support with tilt lock lever. WARNING After tilting the outboard motor up, be sure to support it with the tilt lock lever. Otherwise, the outboard motor could suddenly lower if the power trim and tilt unit should lose fluid pressure. 8. Measure the trim sensor resistance. Check the trim sensor resistance if out of specification. Trim Position Mercury Bullet Connector Sensor Connector Resistance at 20 C (68 F) Full Down Brown/White (BR/WHT) and Ground Black (BLK) and Pink (PNK) 9 - 11 Ohms Full Up Brown/White (BR/WHT) and Ground Black (BLK) and Pink (PNK) 247.6 - 387.6 Ohms 90-888465 JUNE 2002 Page 5B-33 POWER TRIM Motor and Electrical Tests Motor Disassembly 1. Remove the power trim and tilt (PTT) screws and remove the stator. NOTE: Place a clean cloth over the end of the armature shaft and carefully pull the armature from the yoke with a pair of pliers. a b a -Screw (2) (M5 x 12) b-Stator CAUTION Do NOT allow grease or oil to contact the commutator. 2. Remove brush holder screws and motor lead screws. 3. Remove the springs and brushes. a b c d e f g a -Brush (4) b-Spring (4) c -Brush holder screw(M4 x 12) d-Brush holder e -Motor lead screw (2) (M4 x 6) f -Motor leads g-Motor base Page 5B-34 90-888465 JUNE 2002 POWER TRIM Motor Tests INSPECTION AND CLEANING COMMUTATOR 1. Inspect the motor base for corrosion or damage. Replace if necessary. 2. Inspect motor bearing and seal for damage or wear. Replace if necessary 3. Inspect the commutator for contamination. If necessary, clean commutator with #600 grit sandpaper. 4. Inspect the commutator undercut for contamination. If necessary, clean commutator with compressed air. 5. Measure the commutator diameter. Replace if out of specification. 6. If the commutator is worn, it may be turned on an armature conditioner or a lathe. a a -Commutator diameter Commutator Diameter Limit - Minimum 25.0 mm (0.984 in.) TEST FOR SHORTS 1. Check armature on an armature growler per manufacturer’s instructions. Replace armature if short is indicated. 90-888465 JUNE 2002 Page 5B-35 POWER TRIM TEST FOR CONTINUITY 1. Check the armature coil for continuity. Replace if out of specifications. a a -Commutator segments b-Segment laminations c -Segment shaft b c Armature Coil Continuity Commutator segments (a) Continuity Segment laminations (b) No continuity Segment shaft (c) No continuity 2. Check the circuit for continuity. Replace the brush holder if there is no continuity. 3. Measure the brush length. Replace brush if out of specification. a (a) Brush length limit - Minimum 4.0 mm (0.160 in.) Page 5B-36 90-888465 JUNE 2002 POWER TRIM Motor Assembly 1. Install new oil seal and bearing into the motor base. 95 95 2-4-C with Teflon a b c a -Bearing b-Motor base c -Oil seal 2. Connect motor leads to brush holder. Install brush holder to motor base. 3. Install brushes and springs to the brush holder. c d e f g a b a -Brush (4) b-Spring (4) c -Brush holder screw(M4 x 12) d-Brush holder e -Motor lead screw (2) (M4 x 6) f -Motor leads g-Motor base 90-888465 JUNE 2002 Page 5B-37 POWER TRIM CAUTION Do NOT allow grease or oil to contact the commutator. 4. Install bearing to armature. 5. Push the brushes into the holders and then install the armature. 95 95 95 2-4-C with Teflon c a b a -Bearing b-Armature c -Brush (4) 6. Install wave washer and washer into the stator. b c a a -Stator b-Wave washer c -Washer Page 5B-38 90-888465 JUNE 2002 POWER TRIM 7. Install new o-ring and stator to the motor base. 8. Place a clean cloth over the end of the armature shaft. With a pair of pliers on the armature shaft, carefully push the stator over the armature. Tighten screws to specified torque. a b c a -Screw (2) (M5 x 12) b-Stator c -Motor base Motor Base/Stator Screw Torque Drive tight Electrical System Tests FUSE 1. Check the fuse for continuity. Replace fuse if the is no continuity. 90-888465 JUNE 2002 Page 5B-39 POWER TRIM RELAY 1. Check the relay for continuity. Replace if out of specification. BLK LT.GRN LT.BLU 1 BLK 3 4 2 4 LT.GRN LT.BLU 2 a + 3 – – + a b c d a -Measurement range setting 1-Terminal 1 2-Terminal 2 3-Terminal 3 4-Terminal 4 PTT Relay Continuity Light Blue (LT. BLU)-Black (BLK) Light Green (LT. GRN)-Black (BLK) Continuity Terminal 1 - Terminal 4 Terminal 2 - Terminal 4 No continuity Terminal 1 - Terminal 3 Terminal 2 - Terminal 3 No continuity Page 5B-40 90-888465 JUNE 2002 POWER TRIM 2. Connect the Multi-meter or Digital Tachometer Multi-meter between relay terminals 1 and 3. 3. Connect the light green (LT.GRN) lead to the positive battery terminal and the black (BLK) lead to the negative battery terminal. 4. Test for continuity between terminals 1 and 3. Replace if there is no continuity. BLK LT.BLU LT.GRN 1 3+ 2 1-Terminal 1 2-Terminal 2 3-Terminal 3 5. Connect the Multi-meter or Digital Tachometer Multi-meter between relay terminals 2 and 3. 6. Connect the light blue (LT.BLU) lead to the positive battery terminal and the black (BLK) lead to the negative battery terminal. 7. Test for continuity between terminals 2 and 3. Replace if there is no continuity. BLK LT.BLU LT.GRN + 2 3 1 1-Terminal 1 2-Terminal 2 3-Terminal 3 90-888465 JUNE 2002 Page 5B-41 POWER TRIM PTT SWITCH 1. Test the power trim and tilt switch for continuity. Replace if out of specification. RED LT.GRN LT.BLU RED LT.GRN LT.BLU RED = Red LT.BLU = Light Blue LT.GRN = Light Green Switch position Lead UUp Light Blue (LT.BLU) - RED Continuity Light Green(LT.GRN) - RED No continuity Nt lNeutral Light Blue (LT.BLU) - RED No continuity Light Green(LT.GRN) - RED No continuity DDown Light Blue (LT.BLU) - RED No continuity Light Green(LT.GRN) - RED Continuity TRIM SENSOR 1. Test the trim sensor for resistance. Replace if out of specification. NOTE: Measure resistance at position (b). Slowly move the lever to position (a) and measure resistance. BLK PNK a b c BLK = Black PNK = Pink a -Position (a) b-Position (b) c -Trim lever Trim Sensor Resistance - Position (a) PNK-BLK 9-11 ohms at 20 °C (68 °F) Trim Sensor Resistance - Position (b) PNK-BLK 247.6 - 387.6 ohms at 20 °C (68 °F) Page 5B-42 90-888465 JUNE 2002 POWER TRIM Pump and Hydraulic System Tests HYDRAULIC DOWN PRESSURE 1. Fully extend the power trim and tilt rams. 2. Loosen both hydraulic tube nuts. Remove the tube nut and rotate tube away from the port. NOTE: Cover the removed tube end with a clean cloth. 3. Install pressure gauge adaptor set in the open manifold port. a c b a -Hydraulic tube nut b-Removed hydraulic tube end c -Pressure gauge adaptor set 4. Connect the motor leads to the battery terminals to retract the tilt ram. Measure the hydraulic down pressure. a b a -Light blue lead b-Light green lead Direction Motor lead Battery Terminal DDown Light Green Positive Light Blue Negative Hydraulic Down Pressure 6.7-8.7 mPa (970-1260psi) 90-888465 JUNE 2002 Page 5B-43 POWER TRIM 5. Reverse the motor leads between the battery terminals to fully extend the tilt and trim rams. ab a -Light blue lead b-Light green lead Direction Motor Lead Battery Terminal UUp Light Blue Positive Light Green Negative 6. Remove the pressure gauge and adaptor. 7. Install the tube end into the manifold port. Tighten tube nuts to specified torque. Hydraulic Tube Nut Torque 15 Nm (133 lb-in.) HYDRAULIC UP PRESSURE 1. Connect the motor leads to the battery terminals to retract the tilt ram. Measure the hydraulic down pressure. 2. Loosen both hydraulic tube nuts. Remove the tube nut and rotate tube away from the port. NOTE: Cover the removed tube end with a clean cloth. 3. Install pressure gauge and adaptor in the open manifold port. a b c a -Hydraulic tube nut b-Removed hydraulic tube end c -Pressure gauge and adaptor Page 5B-44 90-888465 JUNE 2002 POWER TRIM 4. Connect the motor leads to the battery terminals to extend the tilt ram. Measure the hydraulic up pressure. b a a -Light Blue lead b-Light Green lead Hydraulic Up Pressure 12.2-14.2 mPa (1770-2060 psi) 5. Reverse the motor leads between the battery terminals to fully retract the tilt and trim rams. S69J7265 a b a -Light Blue lead b-Light Green lead 6. Remove the pressure gauge and adaptor 7. Install the tube end into the manifold port. Tighten tube nuts to specified torque. Hydraulic Tube Nut Torque 15 Nm (133 lb-in.) 90-888465 JUNE 2002 Page 5B-45 POWER TRIM CHECKING FLUID LEVEL 1. After measuring the hydraulic pressure, connect the motor leads to the battery terminals to fully extend the trim and tilt rams. ab a -Light Blue lead b-Light Green lead 2. Remove fill plug. Check fluid level. NOTE: Fluid should flow out of the filler hole when fluid is at the correct level. 3. If necessary, add Power Trim and Steering Fluid or Dexron II automotive transmission fluid (ATF) to the correct level. Page 5B-46 90-888465 JUNE 2002 POWER TRIM Power Trim and Tilt Unit Disassembly Pump Disassembly 1. Drain hydraulic fluid from unit. 2. Remove reservoir. 3. Remove the manual release valve, gear pump and filter components. a bc a -Manual release valve b-Gear pump c -Filter components (o-ring, spacer, filter) (2 each) 4. Unscrew relief lock and remove the up-relief valve and down-relief valve components. a b c a a -Relief valve lock b-Up-relief valve components c -Down-relief valve components 90-888465 JUNE 2002 Page 5B-47 POWER TRIM 5. Remove bracket. Remove main valve components and check balls. a d b c e a -Up-main valve b-Down-main valve c -Check ball (2) d-Bracket e -Screw (2) (M5 x 25) and washer (2) 6. Remove gear housing 2 and the shuttle valve components. 7. Remove the pump gears, check balls and dowel pins. a b d b c e a -Gear housing 2 b-Shuttle valve components c -Pump gears d-Check balls (2) e -Dowel pins (3) Page 5B-48 90-888465 JUNE 2002 POWER TRIM Trim and Tilt Cylinder Disassembly 1. Secure the tilt cylinder in a soft-jawed vise. WARNING Fully extend the trim and tilt rams before removing the end cap. 2. Loosen and remove the tilt cylinder end cap. Remove the tilt rod assembly. a c b a -End Cap b-Cylinder end cap wrench P/N 91-888867 c -Tilt rod 3. Drain fluid from cylinder. MEMORY PISTON REMOVAL USING LOCK RING PLIERS 1. Remove memory piston from cylinder using lock ring pliers P/N SRP-4 (Snap-On) or suitable tool. a -Lock Ring Pliers SRP-4 (Snap-On) a 90-888465 JUNE 2002 Page 5B-49 POWER TRIM .MEMORY PISTON REMOVAL USING COMPRESSED AIR 1. Blow compressed air into manual release valve hole to remove memory piston. NOTE: Point cylinder opening down and away. Use a shop rag or towel to avoid damage to the memory piston. 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. 2. Remove o-ring from memory piston. a b a -Memory piston b-Adapter/air hose 3. Secure the tilt piston in a vise using service tool. 4. Remove the tilt rod from the piston using service tool. a b a -Piston vice attachment service tool P/N 888868 b-Tilt rod wrench P/n 91- 888869 Page 5B-50 90-888465 JUNE 2002 POWER TRIM 5. Secure the manifold in a soft-jawed vise. a a -Manifold 6. Loosen the trim cylinder end caps and remove them. a a b a -Trim cylinder end cap (2) b-Cylinder end cap wrench P/N 91-888867 90-888465 JUNE 2002 Page 5B-51 POWER TRIM 7. Remove the trim rod assemblies. 8. Drain fluid. 9. Remove the circlip, adaptor and spring from the trim rod assembly. a b c d a -Trim rod b-Spring c -Adaptor d-Circlip 10. Secure the trim rod in a soft-jawed vise. Remove the trim piston. a b a -Trim ram b-Trim piston Page 5B-52 90-888465 JUNE 2002 POWER TRIM Power Trim and Tilt Unit Inspection RESERVOIR 1. Inspect the reservoir for cracks or corrosion. Replace if necessary. TRIM CYLINDER AND TILT CYLINDER 1. Inspect the manifold and tilt cylinder for cracks and corrosion. Replace if necessary. 2. Inspect the inner cylinder walls for scratches. Replace if necessary. a b c a -Manifold b-Tilt cylinder c -Cylinder inner walls 90-888465 JUNE 2002 Page 5B-53 POWER TRIM 3. Inspect the outer surface of the tilt piston, trim piston, adapter, memory piston and oil seal of the end cap for scratches wear and damage. Replace if necessary. a b c d e a -Tilt piston b-Adapter c -Trim piston d-Oil seal of end cap e -Memory piston 4. Inspect the trim and tilt rods for bends, nicks and corrosion. Polish with #400-600 grit sandpaper if there is light rust. Replace if necessary. 5. Check hydraulic tubes for cracks and corrosion. Replace if necessary. Page 5B-54 90-888465 JUNE 2002 POWER TRIM Gear Pump/Valve Inspection IMPACT RELIEF VALVE 1. Inspect the tilt piston’s impact relief valve for contamination. Clean if necessary. d a b c a -Ball b-Seat c -Spring d-Tilt piston RELIEF VALVES 1. Inspect the up-relief and down-relief valve components for contamination. Clean if necessary. b c d e a a f g h a -Valve lock screw b-Up-relief spring c -Valve support pin d-O-ring e -Ball f -Down-relief spring g-Valve support pin h-Valve seal 90-888465 JUNE 2002 Page 5B-55 POWER TRIM SHUTTLE VALVES 1. Inspect shuttle valve components for contamination. Clean if necessary. a b d e f c f a b a -Circlip d-Down shuttle piston b-Valve seal e-O-ring c -Up Shuttle piston f -Spring MAIN VALVES 1. Inspect main valve components for contamination. Clean if necessary. a c d b e a -Ball b-Seat c -Spring d-Piston e -O-ring FILTERS 1. Inspect filters for contamination. Clean if necessary. a b c a -Pump filter b-Reservoir filter c -Shuttle piston filter Page 5B-56 90-888465 JUNE 2002 POWER TRIM GEAR PUMP AND HOUSING 1. Inspect the drive gear for damage and excessive wear. Replace if necessary. 2. Inspect the gear pump housing for scratches. Replace if necessary. a bc a -Pump gear b-Gear housing 1 c -Gear housing 2 Power Trim and Tilt Unit Assembly Gear Pump Assembly CAUTION Work area must be clean and contamination free. The slightest amount of contamination in the hydraulic system can cause a malfunction. NOTE: Lubricate o-rings and seals with Power Trim and Steering Fluid or Dexron II automotive transmission fluid (ATF) prior to assembly. 1. Install the drive gears, dowel pins, check balls, and shuttle valve components into gear housing 1. 2. Install gear housing 2. a b g c d e f g e -Check balls f -Pump gear g-Dowel pin a -Up shuttle valve b-Down shuttle valve c -Gear housing 1 d-Gear housing 2 90-888465 JUNE 2002 Page 5B-57 POWER TRIM 3. Install the main valve components and manual release spring. 4. Secure components with the bracket. Tighten screw to specified torque. a b cd e a -Up-main valve b-Down-main valve c -Manual release spring d-Bracket e -Screw (2) (M5 x 25) Bracket Screw Torque 7 Nm (62 lb-in.) 5. Install the up-relief valve and down-relief valve components into gear housing 1. a b c a -Up-relief valve b-Down-relief c -Pump gear housing 1 Page 5B-58 90-888465 JUNE 2002 POWER TRIM 6. Install the pump filter and retainer plate into gear housing 1. 7. Install shuttle piston filters, spacers and o-rings into the gear pump housing. Install gear pump into housing. 8. Secure components with 3 screws. Tighten screw to specified torque. a b c d e a -Pump filter b-Retainer c -Shuttle piston filter d-Pump housing e -Screw (3) (M5 x 40) Pump Assembly Screw Torque 7 Nm (62 lb-in.) Cylinder Assembly TILT RAM 1. Install new dust seal, lubricated o-rings and backup ring into the tilt cylinder end cap a b c d e a cd e a -Dust seal b-End cap c -O-ring d-Backup ring e -O-ring 90-888465 JUNE 2002 Page 5B-59 POWER TRIM 2. Position end cap over tilt rod. Attach spring, adapter and piston to the tilt rod. a d e b c a -Spring b-Adapter c -Piston d-End cap with new seals e -Rod 3. Secure the tilt piston in a vise using service tool. 4. Tighten tilt rod to specified torque. a b c a -Piston vise attachment service tool P/N 91-888868 b-Tilt rod wrench P/N 91-888869 c -Tilt Rod Tilt Rod Torque 55 Nm (40.5 lb-ft) Page 5B-60 90-888465 JUNE 2002 POWER TRIM 5. Install new o-ring and backup ring onto the tilt piston. 6. Install ball, seat and spring (5 sets) into the tilt piston. 7. Secure shock valve components with washers, plate and screw. Tighten screw to specified torque. a -Tilt piston b-O-ring c -Backup ring d-Ball (5) e -Seat (5) a b c e f g h g i d e f db c f -Spring (5) g-Washer h-Plate i -Screw (M6 x 10) Shock Valve Plate Torque 7 Nm (62 lb-in.) TRIM RAMS 1. Assemble the trim ram piston to the rod. a b c d a -Rod b-Piston c -Washer d-Screw (M8 x 20) 90-888465 JUNE 2002 Page 5B-61 POWER TRIM 2. Secure trim rod in a soft-jawed vise. 3. Tighten trim piston screw to specified torque. a -Trim rod a Trim Piston Screw Torque 38 Nm (28 lb-ft) 4. Install new o-ring, backup ring, spring, adapter and circlip to the trim piston. d e f g a b c c d a -Washer b-Screw (M8 x 20) c -Backup ring d-O-ring e -Spring f -Adapter g-Circlip Page 5B-62 90-888465 JUNE 2002 POWER TRIM 5. Install new oil seal, circlip and new o-ring into the trim cylinder end cap. 6. Position end cap over trim ram. a -Circlip b-Oil seal c -End cap d-O-ring e -Trim ram a b c d e a b c d 90-888465 JUNE 2002 Page 5B-63 POWER TRIM TILT CYLINDER TO MANIFOLD INSTALLATION 1. Install new lubricated o-ring to the memory piston. 2. Carefully push the memory piston into the tilt cylinder until it bottoms out. 3. Install bushings into tilt cylinder. Install cylinder to manifold with tilt pin. Attach circlip to tilt pin. 4. Install hydraulic tubing. Tighten to tube nuts to specified torque. b a e c f g h d a -Memory piston e-Hydraulic tube b-O-ring f -Manifold c -Tilt cylinder g-Tilt pin d-Bushing (2) h-Circlip Hydraulic Tube Nut Torque 15 Nm (133 lb-in.) TRIM RAM INSTALLATION 1. Secure the cylinder manifold block in a soft-jawed vise. a a -Manifold Page 5B-64 90-888465 JUNE 2002 POWER TRIM 2. Fill the trim cylinders with Power Trim and Steering Fluid or Dexron II automatic transmission fluid (ATF). 114 a Power Trim and Steering Fluid 114 a -Correct fill level 3. Carefully push the trim rams into the cylinder bore until they just enter the bore. WARNING Do NOT push the trim rams down while installing them into the cylinders. Hydraulic fluid will spurt out from the unit. 4. Tighten the end cap to specified torque. a a b a -Trim cylinder end cap P/N 91-888867 b-Cylinder end cap wrench Trim Cylinder End Cap Torque 160 Nm (118 lb-ft) 90-888465 JUNE 2002 Page 5B-65 POWER TRIM Power Trim Motor Installation 1. Install the pump drive coupling into the pump housing. a a -Pump drive coupling 2. Fill the pump housing with Power trim and Steering Fluid or Dexron II automatic transmission fluid (ATF) to the correct level. a a 114 Power Trim and Steering Fluid 114 a -Correct fluid level. 3. Remove air bubbles with a syringe or suitable tool. 4. Rotate the pump coupler with a screwdriver to purge air from the pump. Page 5B-66 90-888465 JUNE 2002 POWER TRIM 5. Install new o-ring and power trim motor. Tighten screws to specified torque. a cb a -O-ring b-Motor c -Screw (3) (M8 x 20) Power Trim Motor Mounting Screw Torque 18 Nm (160 lb-in.) 90-888465 JUNE 2002 Page 5B-67 POWER TRIM Power Trim Reservoir Installation 1. Install spacer, filter and plate to the cylinder block. 2. Install new o-ring and reservoir. Tighten screws to specified torque. 3. Install the fill plug. Tighten to specified torque. c f g a b d e a -Spacer b-Filter c -Plate d-O-ring e -Reservoir f -Screw (3) (M8 x 20) g-Fill plug Power Trim Reservoir Mounting Screw Torque 18 Nm (160 lb-in.) Power Trim Fill Plug Torque 7 Nm (62 lb-in.) Page 5B-68 90-888465 JUNE 2002 POWER TRIM Tilt Ram Installation 1. Fill the tilt cylinder with Power Trim and Steering Fluid or Dexron II automatic transmission fluid (ATF) to the correct level. 2. Add a small amount of fluid through the hole in the cylinder wall. b a 114 Power Trim and Steering Fluid 114 a -Correct fluid level b-Hole in cylinder wall a WARNING Install the tilt ram in the fully extended position to prevent fluid from spurting out during installation. 3. Install the tilt piston assembly into the tilt cylinder. Tighten the end cap to specified torque. a a -Cylinder end cap wrench P/N 91-888867 Tilt Cylinder End Cap Torque 90 Nm (66.5 lb-ft) 90-888465 JUNE 2002 Page 5B-69 POWER TRIM Bleeding the Power Trim and Tilt System UNIT NOT INSTALLED 1. Tighten the manual release valve by turning it clockwise. a a -Manual release valve 2. Place the power trim and tilt unit in an upright position. 3. Check the fluid level in the reservoir. If necessary add Power Trim and Steering Fluid or Dexron II automotive transmission fluid (ATF) to the correct level. 114 114 Power Trim and Steering Fluid NOTE: The fluid level should be at the bottom of the fill hole. 4. Install the fill plug. Page 5B-70 90-888465 JUNE 2002 POWER TRIM 5. Connect the motor leads to battery terminals. a a b c b c a -PTT motor lead b-Light Blue lead c -Light Green lead Direction PTT Motor Lead Battery Terminal UUp Light Blue Positive Light Green Negative DDown Light Green Positive Light Blue Negative 6. Reverse the motor leads between the battery terminals to fully extend the tilt and trim rams. Reverse the leads again to fully retract the rams. 7. Repeat this procedure four or five times. Wait a few seconds before switching motor leads. NOTE: If the rams do not extend or retract easily, push or pull on the rams to assist operation. 8. Check the fluid level again when the rams are fully extended. Add sufficient fluid if necessary. Repeat step 7. 90-888465 JUNE 2002 Page 5B-71 POWER TRIM UNIT INSTALLED 1. Loosen the manual release valve by turning it counter clockwise until it cannot be turned further. a a-manual release valve 2. Tilt the outboard to full up, release it and let it lower by it’s own weight. Repeat 4 or 5 times. 3. Tighten the manual release valve. 4. Let the fluid settle for 5 minutes. 5. Push and hold the power trim switch in the up position until the outboard motor is fully tilted up. 6. Support the outboard motor with the tilt lock lever. Let the fluid settle for 5 minutes. WARNING After tilting the outboard motor up, be sure to support it with the tilt lock lever. Otherwise, the outboard motor could suddenly lower if the power trim and tilt unit should lose fluid pressure. 7. Remove the fill plug and check fluid level in the reservoir. If necessary add Power Trim and Steering Fluid or Dexron II automotive transmission fluid (ATF) to the correct level. NOTE: If the fluid is at the correct, fluid should overflow out of the filler hole when the plug is removed. 114 114 Power Trim and Steering Fluid 8. Install the filler plug. 9. Repeat this procedure until fluid remains at the correct level. Page 5B-72 90-888465 JUNE 2002 GEAR HOUSING LOWER UNIT Section 6A Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-31 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-3 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-31 Gear Housing (Driveshaft) . . . . . . . . . . . . . . . . 6A-8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-32 Gear Housing (Prop shaft) . . . . . . . . . . . . . . . . 6A-12 Driveshaft Bearing Carrier . . . . . . . . . . . . . . . . 6A-33 General Service Recommendations . . . . . . . 6A-14 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 6A-33 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-14 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-33 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-14 Forward Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-34 Draining and Inspecting Gear Lubricant . . . . 6A-15 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 6A-34 Changing Lubricant . . . . . . . . . . . . . . . . . . . 6A-15 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-34 Removing the Gear Housing Assembly . . . . 6A-16 Pinion and Forward Gear . . . . . . . . . . . . . . . . . 6A-34 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-17 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-34 Removing the Water Pump and Shift Rod . . 6A-19 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-35 Checking the Water Pump and Shift Rod . . . 6A-19 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-35 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-21 Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-35 Bearing Carrier Assembly . . . . . . . . . . . . . . . . 6A-24 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-35 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-24 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 6A-35 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-25 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-36 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 6A-26 Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-38 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-27 Selecting the Pinion Shims . . . . . . . . . . . . 6A-38 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-28 Selecting the Forward Gear Shims . . . . . 6A-40 Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-30 Selecting the Reverse Gear Shims . . . . . 6A-42 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 6A-30 Measuring Backlash . . . . . . . . . . . . . . . . . . . . . 6A-43 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-30 Forward Gear . . . . . . . . . . . . . . . . . . . . . . . . 6A-43 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-31 Reverse Gear . . . . . . . . . . . . . . . . . . . . . . . . 6A-45 Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-31 6 A 90-888465 JUNE 2002 Page 6A-1 GEAR HOUSING Specifications Gear Ratio 2.00:1 Gearcase Capacity 1153 mL (39.0 fl oz) Lubricant Type Quicksilver Gear Lube-Premium Blend Forward Gear Number of Teeth 30 Spiral/Bevel Pinion Gear Number of Teeth 15 Spiral/Bevel GEAR HOUSING Pinion Height Pinion Gear Locating Tool 91-888875T Forward Gear Backlash 0.21-0.44 mm (0.008-0.017 in.) Reverse Gear Backlash 0.70-1.03 mm (0.028-0.041 in.) Backlash Indicating Tool 91-888878 Water Pressure @ 700 rpm 8-10 kPa (1.1-1.5 psi) @ 5700 rpm (WOT) 117.0-143 kPa (17-20.7 psi) Leak Test Pressure 69-83 kPa (10-12 psi) for 5 Minutes Page 6A-2 90-888465 JUNE 2002 GEAR HOUSING Special Tools 1. Pinion Height Gauge 91-888875T 2. Shimming Plate 91-889586 06701 3. Driver Rod 91-888882 06652 4. Backlash Indicator Tool 91-888878 (stamped 06706) 5. Universal Treaded Rod 91-85716, Jaws 91-46086A1 90-888465 JUNE 2002 Page 6A-3 GEAR HOUSING 6. Slide Hammer 91-34569A1 7. Driver Rod 91-888870 06605 8. Mandrel 91-888892 06628 9. Mandrel 91-888891 06658 10. Mandrel 91-888890 06636 00112 11. Mandrel 91-888888 06622 12. Driver Rod 91-888887 06606 00113 Page 6A-4 90-888465 JUNE 2002 GEAR HOUSING 13. Mandrel 91-88886 06656 00107 14. Bearing Depth Plate 91-888885 06603 00108 15. Mandrel 91-888884 06610 00111 16. Rod With Stop 91-888883 06604 00110 17. Mandrel 91-888881 06653 00111 18. Universal Puller Plate 91-37241 73652 19. Driver Rod 91-37323 37323 90-888465 JUNE 2002 Page 6A-5 GEAR HOUSING 20. Mandrel 91-37350 21. Mandrel 91-888893 00115 06659 22. Mandrel 91-825198 23. Puller Plate 91-29310 24. Driveshaft Holding Tool 91-888889 (stamped 06520) Page 6A-6 90-888465 JUNE 2002 GEAR HOUSING 25. Dial Indicator 91-58222A1 26. Dial Indicator Adaptor Kit 91-83155 27. Shift Rod 91-888877 90-888465 JUNE 2002 Page 6A-7 GEAR HOUSING Gear Housing (Driveshaft) 37 36 35 34 33 32 31 30 29 2728 26 25 24 23 22 21 20 19 18 1716 15 14 12 13 11 10 45 46 47 41 40 38 39 42 43 44 79 51 55 53 8 58 57 56 6 7 4 5 2 54 523 50 49 1 48 51 7 7 7 7 7 95 95 95 95 95 95 95 95 95 95 95 7 Loctite 271 Thread Locker 2-4-C With Teflon Page 6A-8 90-888465 JUNE 2002 GEAR HOUSING Gear Housing (Driveshaft) REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 GEAR HOUSING 2 1 BEARING 3 1 PINION GEAR 4 1 WASHER 5 1 NUT 103 142 6 1 DRAIN PLUG 7 2 GASKET 8 1 SEAL 9 1 PLUG 10 1 GUIDE 11 1 DAMPER 12 1 DRIVE SHAFT 13 1 KEY 14 1 BEARING 15 AR SHIM SET 16 1 BEARING 17 1 O-RING 18 1 HOUSING 19 4 SCREW 159 18 20 4 WASHER 21 2 OIL SEAL 22 1 COVER 23 1 GASKET 24 1 OUTER PLATE 25 1 IMPELLER 26 1 INSERT 27 2 WASHER 28 1 WAVE WASHER 29 1 SPACER 30 1 COLLAR 31 1 O-RING 32 1 O-RING 33 2 DOWEL PIN 34 1 WATER PUMP HOUSING 35 1 DAMPER 36 1 COVER 37 4 SCREW 159 18 38 1 PLATE 39 1 O-RING 40 1 OIL SEAL NOTE: TORQUE TOLERANCE +/– 10% 90-888465 JUNE 2002 Page 6A-9 GEAR HOUSING Gear Housing (Driveshaft) 37 36 35 34 33 32 31 30 29 2728 26 25 24 23 22 21 20 19 18 1716 15 14 12 13 11 10 45 46 47 41 40 38 39 42 43 44 79 51 55 53 8 58 57 56 6 7 4 5 2 54 523 50 49 1 48 51 7 7 7 7 7 95 95 95 95 95 95 95 95 95 95 Page 6A-10 90-888465 JUNE 2002 GEAR HOUSING Gear Housing (Driveshaft) REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 41 3 SCREW (M6 X 20) 71 8 42 1 SPRING 43 1 SHIFT CAM 44 1 CIRCLIP 45 1 WATER TUBE 46 1 DAMPER 47 2 DAMPER 48 1 SCREW (M10 X 44) 31 43 49 1 TRIM TAB 50 1 SCREW (M10 X 70) 34 47 51 2 DOWEL PIN 52 1 COVER 53 1 COVER 54 1 SCREW 55 1 NUT 56 7 SCREW (M10 X 45) 34 47 57 7 WASHER 58 7 WASHER 90-888465 JUNE 2002 Page 6A-11 GEAR HOUSING Gear Housing (Prop shaft) 7 95 95 95 95 1 23 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 2728 29 30 31 32 33 34 7 8 66 7 95 66 Loctite 271 Thread Locker Locktite 242 Thread Locker 2-4-C With Teflon Page 6A-12 90-888465 JUNE 2002 GEAR HOUSING Gear Housing (Prop Shaft) REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 GEAR HOUSING 2 1 SHIFTER 3 AR SHIM SET 4 1 BEARING 1 FORWARD GEAR 6 1 SHIFT SLIDE 7 2 BALL 8 2 NUT 9 1 SHAFT 2 PLUNGER 11 1 SPRING 12 1 WASHER 13 1 CLUTCH 14 1 CROSS PIN 1 SPRING 16 1 PROP SHAFT 17 1 WASHER 18 1 REVERSE GEAR 19 AR SHIM SET 1 BEARING 21 2 O-RING 22 1 BEARING CARRIER 23 1 GREASE FITTING 53 6 24 2 SCREW (M8 X 30) 22 30 2 WASHER 26 1 BEARING 27 2 OIL SEAL 28 1 CAP 29 2 SCREW (M8 X 20) 159 18 2 WASHER 31 1 THRUST WASHER 32 1 WASHER 33 1 CASTLE NUT 40 55 34 1 COTTER PIN NOTE: TORQUE TOLERANCE +/– 10% 90-888465 JUNE 2002 Page 6A-13 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: 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 6A-14 90-888465 JUNE 2002 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. Changing Lubricant 1. Tilt the outboard motor up slightly. 2. Place a drain pan below outboard. 3. Remove vent plug and fill/drain plug and drain lubricant. a b a-Fill/Drain Screw b-Vent Screw 4. 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) on the drain plug magnet indicates normal wear. The presence of metal chips on the magnet indicate the need for gear housing disassembly and component inspection. 5. 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. 6. 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. 90-888465 JUNE 2002 Page 6A-15 GEAR HOUSING Removing the Gear Housing Assembly WARNING DO NOT hold the propeller with your hands when loosening or tightening it. Disconnect the battery cables from the battery. 1. Set the gearshift to the neutral position, and place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning. Remove the nut and propeller. 2. Mark the trim tab at the area shown, and then remove it. 3. Remove the gear housing mounting screws. b a a-Trim tab b-Gear housing assembly mounting screw (7) NOTE: Check that there is no engine oil on the spline and check it for rust or wear. Check the oil pump if necessary. Page 6A-16 90-888465 JUNE 2002 GEAR HOUSING Installation 1. Set the gearshift to the neutral position at the gear housing assembly. N N a a-Shift rod 91-888877 (stamped 06052) 2. Install the two dowel pins to the lower unit. 3. Install the gear housing assembly to the driveshaft housing. Tighten the screws to the specified torque. 4. Install the trim tab to its original position. Tighten the trim tab screw to the specified torque. Loctite 242 Thread Locker a b c d e 66 66 a-Gear housing mounting screw (7) M10 X 45 b-Trim tab mounting screw M10 X 44 c-Trim tab d-Dowel pin (2) e-Gear housing mounting screw (1) M10 X 70 66 Trim Tab Mounting Screw Torque 43 Nm (31 lb ft) Gear Housing Mounting Screw Torque 47 Nm (37 lb ft) 90-888465 JUNE 2002 Page 6A-17 GEAR HOUSING 5. Install the propeller and propeller nut. Place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning. Tighten to the specified torque. 6. Install cotter key. 95 95 2 4 C With Teflon WARNING DO NOT hold the propeller with your hands when loosening or tightening it. Be sure to disconnect the battery cables from the batteries and the engine shut-off switch. Put a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning. Propeller Nut Torque 55 Nm (40 lb ft) Page 6A-18 90-888465 JUNE 2002 GEAR HOUSING Removing the Water Pump and Shift Rod 1. Remove the water pump assembly. 2. Shift the gear housing assembly into the neutral position and remove the shift shaft as- sembly. a b a-Shift shaft assembly b-Water pump assembly Checking the Water Pump and Shift Rod 1. Check the water pump housing for deformation. Replace if necessary. a a-Water pump housing 90-888465 JUNE 2002 Page 6A-19 GEAR HOUSING 2. Check the impeller and insert cartridge for cracks or wear. Replace if necessary. a b a-Impeller b-Insert cartridge 3. Check the Woodruff key and the groove on the driveshaft for wear. Replace if necessary. b a a-Woodruff key b-Groove 4. Check the shift shaft for cracks or wear. Replace if necessary. a a-Shift shaft Page 6A-20 90-888465 JUNE 2002 GEAR HOUSING Installation 1. Install the shift rod assembly. 66 95 a b Loctite 242 Thread locker 2-4-C with Teflon 6695 a-Shift shaft b-Shift slide 2. Install the new gasket, outer plate cartridge and dowel pins. a b c a-Outer plate b-Gasket c-Dowel pin (2) 3. Install the Woodruff key into the driveshaft. 4. Align the groove on the impeller with the Woodruff key, and then install it to the driveshaft. 90-888465 JUNE 2002 Page 6A-21 GEAR HOUSING a b a-Impeller b-Woodruff key 5. Install the washers, wave washer, spacer and collar to the driveshaft using a suitable mandrel. b c d e f a a-2mm (0.08 in.) b-Washers c-Collar d-Spacer e-Wave washer f-Suitable mandrel NOTE: The collar and spacer should fit together firmly. NOTE: While pulling the driveshaft up, install the collar with a suitable mandrel tool that fits over the driveshaft as shown. 6. Install the O-ring and insert cartridge into the pump housing. c d e a b 95 2-4-C with Teflon a-Pump housing location tab b-Insert cartridge location tab c-Pump housing d-O-ring e-Insert cartridge NOTE: Align the insert cartridge location tabs with the tabs in the pump housing. 95 Page 6A-22 90-888465 JUNE 2002 GEAR HOUSING 7. Install the O-ring and pump housing assembly into the gear housing. Tighten screws to the specified torque. 8. Install the seal and cover. Loctite 242 Thread Locker 2-4-C with Teflon c d e a b 66 95 66 95 a-Pump housing screw (M8 X 45) b-Cover c-Seal d-Pump housing e-O-ring NOTE: When installing the pump housing, apply grease to the inside of the housing, and then turn the driveshaft clockwise while pushing down the pump housing. Pump Housing Screw Torque 18 Nm (159 lb in.) 90-888465 JUNE 2002 Page 6A-23 GEAR HOUSING Bearing Carrier Assembly Removal 1. Remove the cover ring screws and cover ring. 2. Remove the bearing carrier screws. a bc a-Cover ring b-Cover ring screws (2) c-Bearing carrier screws (2) 3. Remove the bearing carrier assembly from the gear housing. d c a b a-Bearing carrier b-Puller jaws 91-46086A1 c-Puller screw 91-85716 d-Propeller shaft Page 6A-24 90-888465 JUNE 2002 GEAR HOUSING Installation 1. Install the washer and propeller shaft assembly into the bearing carrier assembly. 2. Apply grease to the new O-rings. a b2-4-C with Teflon c 95 95 a-Propeller shaft assembly b-Washer c-Bearing carrier assembly 3. Install the bearing carrier assembly into the gear housing. 4. Install the bearing carrier screw, and ring. Tighten screws to the specified torque. Loctite 271 Thread Locker Loctite 242 Thread Locker a b c 66 7 66 7 a-Bearing carrier screw (M8 X 30) b-Ring c-Ring screw (M8 X 20) Bearing Carrier Screw Torque 30 Nm (22 lb–ft) Ring Screw Torque 18 Nm (159 lb–in.) 90-888465 JUNE 2002 Page 6A-25 GEAR HOUSING Disassembly 1. Remove the reverse gear and reverse gear shim(s). a b 51868 a-Bearing carrier b-Slide hammer 2. Remove the reverse gear ball bearing. CAUTION DO NOT reuse the bearing, always replace it with a new one. a a-Slide hammer 91-34569A1 Page 6A-26 90-888465 JUNE 2002 GEAR HOUSING 3. Remove the oil seals and needle bearing. ab c d a-Oil seals (2) b-Needle bearing c-Rod 91-888882 (stamped 06652) d-Mandrel 91-888881 (stamped 06653) Inspection 1. Clean the bearing carrier using a soft brush and cleaning solvent, and then check it for cracks or damage. Replace if necessary. 2. Check the teeth and dogs of the reverse gear for cracks or wear. Replace the gear if necessary. 3. Check the bearings for pitting or rumbling. Replace if necessary. 90-888465 JUNE 2002 Page 6A-27 GEAR HOUSING Assembly 1. Lubricate needle bearing outer race with 2-4-C with Teflon. 2. Install the needle bearing into the bearing carrier to the specified depth. NOTE: Install the needle bearing with the manufacture identification mark facing toward the oil seal (propeller side). NOTE: When using the driver rod, DO NOT strike the special tool in a manner that will force the stopper out of place. 95 2-4-C with Teflon a b c e f d 95 a-Mandrel 91-888884 (stamped 06610) b-Driver rod 91-888883 (stamped 06604) c-Bearing depth plate 91-888885 (stamped 06603) d-Stopper e-Bearing f-25.05-25.55mm (.0986-1.006 in.) 3. Apply 2-4-C with Teflon to the new oil seals, and install them into the bearing carrier to the specified depth. 95 95 a b c 2-4-C with Teflon a-4.75-5.25mm ( 0.187-0.207 in.) b-Rod 91-37323 c-Mandrel 91-825198 NOTE: Install the first oil seal halfway into the bearing carrier, then the other oil seal. Page 6A-28 90-888465 JUNE 2002 GEAR HOUSING 4. Lubricate ball bearing with 2-4-C With Teflon. Install the ball bearing into the bearing carrier. 2-4-C with Teflon a b 95 95 a-Mandrel 91-888886 (stamped 06656) b-Rod 91-888887 (stamped 06606) NOTE: Install the ball bearing with the manufacture identification mark facing toward the bearing carrier. 5. Install the reverse gear and original shim(s) to the bearing carrier using a press. a b c d 95 9. 2 4 C with Teflo. a-Mandrel 91-888888 (stamped 06622) b-Press c-Reverse gear d-Shim (AR) CAUTION Add or remove shim(s), if necessary, when replacing the reverse gear or ball bearing. 90-888465 JUNE 2002 Page 6A-29 GEAR HOUSING Propeller Shaft Disassembly 1. Remove the clutch spring, cross pin, dog clutch, shift slide, shift plunger and shaft. a e f bc d a-Clutch spring b-Cross pin c-Clutch d-Shift slide e-Shaft f-Shift plunger Inspection 1. Check the propeller shaft for bends or wear. Replace if necessary. 2. Check the clutch, shaft, and shift slide for cracks or wear. Replace if necessary. a b c a-Clutch b-Shaft c-Shift slide Page 6A-30 90-888465 JUNE 2002 GEAR HOUSING Assembly 1. Install the dog clutch as shown. NOTE: Install the dog clutch with the “F” mark facing toward the shift plunger. a b a-“F” mark b-Clutch NOTE: Make sure spring coils and not crossed. Drive Shaft Removal 1. Remove the driveshaft, driveshaft bearing carrier, and pinion. Remove the forward gear. a b c a-Driveshaft holder 91-888889 (stamped 06520) b-Socket c-Breaker bar Inspection 1. Check the driveshaft for bends, discolor on bearing contact surfaces, wear on the drive splines or pinion splines. Replace if necessary. 90-888465 JUNE 2002 Page 6A-31 GEAR HOUSING Installation 1. Install the forward gear to the gear housing. 2. Install the driveshaft bearing carrier, thrust bearing and shim(s) to the driveshaft. a b c d2-4-C with Teflon 95 95 a-Driveshaft b-Thrust bearing c-Shim(AR) d-Drive shaft bearing carrier CAUTION Add or remove shim(s), if necessary, when replacing the driveshaft housing or drive shaft. 3. Install the driveshaft and driveshaft bearing carrier into the gear case, then the pinion and pinion nut. Tighten the pinion nut to the specified torque. a b c a-Driveshaft holder 91-888889 (stamped 06520) b-Socket c-Breaker bar NOTE: Install the pinion by lifting the driveshaft up slightly, then aligning the pinion splines and the spline of the driveshaft. 4. Tighten the driveshaft bearing carrier screws to specification. Pinion Nut Torque 142 Nm (103 lb–ft) Driveshaft Bearing Carrier Screw Torque 2 Nm (18 lb–in.) Page 6A-32 90-888465 JUNE 2002 GEAR HOUSING Driveshaft Bearing Carrier Disassembly 1. Remove the cover, oil seals and needle bearing. a b c d e a-Mandrel 91-888884 (stamped 06610) b-Rod 91-888882 ( stamped 06652) c-Bearing d-Seal (2) e-Cover Assembly 1. Install the needle bearing into the driveshaft bearing carrier to the specified depth. 2-4-C with Teflon a b c 95 95 a-4.25-4.75mm (0.167-0.187 in.) b-Mandrel 91-888884 (stamped 06610) c-Rod 91-888887 (stamped 06606) 2. Apply 2-4-C with Teflon to the new oil seals, and install them into the driveshaft bearing carrier to the specified depth. a b c 2-4-C with Teflon 95 95 a-0.25-0.75MM (0.01-0.03 in) b-Rod 91-888892 (stamped 06628) c-Mandrel 91-888887 (stamped 06606) NOTE: Install first oil seal halfway into the driveshaft bearing carrier, then the second oil seal to the specified depth. 90-888465 JUNE 2002 Page 6A-33 GEAR HOUSING Forward Gear Disassembly 1. Remove the taper roller bearing from the forward gear using a press. a b a-Universal puller plate 91-37241 b-Suitable mandrel CAUTION DO NOT reuse the bearing, always replace it with a new one. Assembly 1. Install the new taper roller bearing into the forward gear using a press. 95 2-4-C with Teflon 95 a b 51869 a-Mandrel 91-888893 (stamped 06659) b-Tapered roller bearing Pinion and Forward Gear Inspection 1. Check the teeth of the pinion, and the teeth and dogs of the forward gear for cracks or wear. Replace if necessary. Page 6A-34 90-888465 JUNE 2002 GEAR HOUSING Bearings Inspection 1. Check the bearings for pitting, discolor, scoring or rumbling. Replace if necessary. Gear Case Inspection 1. Check the skeg and torpedo for cracks or damage. Replace if necessary. Disassembly 1. Remove the forward gear taper roller bearing outer race and shim(s) with a slide hammer. 27653 a b c 91-34569A1 a-Forward gear taper roller bearing outer race b-Shims c-Slide hammer 91-34569A1 90-888465 JUNE 2002 Page 6A-35 GEAR HOUSING 2. Remove the needle bearing. a b a-Rod 91-888870 (stamped 06605) b-Mandrel 91-888890 (stamped 06636) Assembly 1. Lubricate taper roller bearing outer race with 2-4-C with Teflon. Install the shim(s) and taper roller bearing outer race. 2-4-C with Teflon a b c d 95 95 a-Mandrel 91-888891 (stamped 06658) b-Rod 91-888870 (stamped 06605) c-Shim d-Forward gear taper roller bearing outer race CAUTION Add or remove shim(s), if necessary, when replacing the forward gear or lower case. Page 6A-36 90-888465 JUNE 2002 GEAR HOUSING 2. Install the needle bearing outer case into the gear housing. b a c 2-4-C with Teflon 95 95 a-Mandrel 91-888892 (stamped 06628) b-Plate (91-29310) NOTE: Apply 2-4-C With Teflon to the needle bearing outer case before installation. NOTE: Manufacture identification numbers face towards the pinion gear. 3. Install the needle bearings into the needle bearing outer case. NOTE: Apply 2-4-C with Teflon to the needle bearings, and install. 90-888465 JUNE 2002 Page 6A-37 GEAR HOUSING Shimming NOTE: Shimming IS NOT required when assembling the original gear housing and inner parts. Shimming IS required when assembling the original inner parts and a new gear housing, or when replacing the inner parts. NOTE: All shimming measurements and adjustments are in millimeters. Selecting the Pinion Shims 1. Install the driveshaft to the shimming tool. a c a-Pinion height gauge (91–888875T) b-Driveshaft NOTE: Select the pinion shim thickness (T3) by using the specified measurement(s) and the calculation formula. NOTE: Install the shimming tool to the driveshaft so the shaft is centered on the plate. NOTE: Tighten the wing nuts another 1/4 of a turn after they contact the fixing plate. Page 6A-38 90-888465 JUNE 2002 GEAR HOUSING 2. Install the pinion and pinion nut, and then tighten the nut to the specified torque. Pinion Nut Torque 142 Nm (103 lb ft) 3. Measure the distance (M4) between the shimming tool and the pinion as shown. 4. Record the measurement. a a-Caliper 5. Turn the thrust bearing (located in the driveshaft bearing carrier) two or three times to seat the driveshaft bearing. Measure from the bearing race to the driveshaft bearing carrier mounting surface, (M3) as shown. 6. Record the measurement. c a b a-Caliper b-Thrust bearing c-Driveshaft bearing carrier NOTE: Measure the thrust bearing at three points to find the height average. 7. Calculate the pinion shim thickness (T3) as shown in the examples below. NOTE: “P” is the deviation of the gear housing dimension from standard. The “P” mark is stamped on the trim tab mounting surface of the gear housing in 0.01 mm units. If the “P” mark is unreadable, assume that “P” is zero and check the backlash when the unit is assembled. 90-888465 JUNE 2002 Page 6A-39 GEAR HOUSING Calculation Formula: Pinion Shim Thickness (T3) = 82.00 + P/100 – M3 – M4 Example 1: Positive number deviation. If “M3” is 50.75 mm and “M4” is 30.52 mm and “P” is (+2), then: • T3 = 82.00 + (+2)100 – 50.75 mm – 30.52 mm • = 82.00 + 0.02 – 50.75 mm – 30.52 mm • = 0.75 mm Example 2: Negative number deviation. If “M3” is 50.75 mm and “M4” is 30.52 mm and “P” is (–2), then: • T3 = 82.00 + (–2)100 – 50.75 mm – 30.52 mm • = 82.00 – 0.02 – 50.75 mm – 30.52 mm • = 0.71 mm 8. Select the pinion shim(s) (T3) as follows. Calculated Numeral at 1/100 Place Rounded Numeral mm 1, 2 0 3, 4, 5 2 6, 7, 8 5 9, 10 8 Available Shim Thickness : 0.10 mm, 0.12 mm, 0.15 mm, 0.18 mm, 0.30 mm, 0.40 mm, and 0.50 mm. Example: • If “T3” is 0.75 mm, then the pinion shim is 0.72 mm. • If “T3” is 0.71 mm. then the pinion shim is 0.70 mm. Selecting the Forward Gear Shims 1. Place the bearing on a flat surface. Turn the taper roller bearing outer race two or three times to seat the bearings. Measure the bearing height (M1) as shown. Record the measurement. c a b d a-Forward gear taper roller bearing b-Caliper c-Shimming plate 91-889586 (06603) d-Forward gear taper boller bearing race Page 6A-40 90-888465 JUNE 2002 GEAR HOUSING NOTE: Select the shim thickness (T1) by using the specified measurement(s) and the calculation formula. NOTE: Measure the bearing outer race at three points to find the height average. 2. Calculate the forward gear shim thickness (T1) as shown in the examples below. NOTE: “F” is the deviation of the gear housing dimension from standard. The “F” mark is stamped on the trim tab mounting surface of the gear housing in 0.01 mm units. If the “F” mark is unreadable, assume that “F” is zero and check the backlash when the unit is assembled. Calculation Formula: Forward Gear Shim Thickness (T1) = 29.50 + F/100 – M1 Example 1: Positive number deviation If “M1” is 29.10 mm and “F” is (+ 5), then: • T1 = 29.50 + (+ 5)/100 – 29.10 mm • = 29.50 + 0.05 – 29.10 mm • = 0.45 mm Example 1: Negative number deviation If “M1” is 29.10 mm and “F” is (– 5), then: • T1 = 29.50 + (– 5)/100 – 29.10 mm • = 29.50 – 0.05 – 29.10 mm • = 0.35 mm 3. Select the forward gear shim(s) (T1) as follows. Calculated Numeral at 1/100 Place Rounded Numeral mm 1, 2 0 3, 4, 5 2 6, 7, 8 5 9, 10 8 Available Shim Thickness : 0.10 mm, 0.12 mm, 0.15 mm, 0.18 mm, 0.30 mm, 0.40 mm, and 0.50 mm. Example: • If “T1” is 0.45 mm, then the forward gear shim is 0.42 mm. • If “T1” is 0.60 mm. then the forward gear shim is 0.58 mm. 90-888465 JUNE 2002 Page 6A-41 GEAR HOUSING Selecting the Reverse Gear Shims 1. Place the ball bearing on a flat surface. Turn the ball bearing two of three times, measure the bearing height (M2) as shown. Record the measurement. c a b a-Caliper b-Reverse gear ball bearing c-Shimming plate (91-889586) NOTE: Select the shim thickness (T2) by using the specified measurement(s) and the calculation formula. NOTE: Measure the reverse gear at three points to find the height average. 2. Calculate the reverse gear shim thickness (T2) as shown in the examples below. NOTE: “R” is the deviation of the gear housing dimension from standard, and “A” is the deviation of the bearing carrier housing from standard. The “R” mark is stamped on the trim tab mounting surface of the gear housing, and the “A” mark is stamped on the bearing carrier housing in 0.01 mm units. If the “R” mark or “A” mark is unreadable, assume that “R” and “A” are zero and check the backlash when the unit is assembled. Page 6A-42 90-888465 JUNE 2002 GEAR HOUSING Calculation Formula: Reverse Gear Shim Thickness (T2) = 21.00 + R/100 – A/100 – M2 Example 1: Negative number deviation on “R” and Positive number devation on “A”. If “M2” is 19.92 mm and “R” is (-3) and “A” is (+5), then: • T2 = 21.00 + (– 3)/100 – (+5)/100 – 19.92 mm • = 21.00 – 0.03 – 0.05 – 19.92 mm • = 1.0 Example 1: Positive number deviation on “R” and Negative number devation on “A”. If “M2” is 19.92 mm and “R” is (+3) and “A” is (–5), then: • T2 = 21.00 + (+ 3)/100 – (–5)/100 – 19.92 mm • = 21.00 + 0.03 + 0.05 – 19.92 mm • = 1.16 3. Select the reverse gear shim(s) (T2) as follows. Calculated Numeral at 1/100 Place Rounded Numeral mm 1, 2 0 3, 4, 5 2 6, 7, 8 5 9, 10 8 Available Shim Thickness : 0.10 mm, 0.12 mm, 0.15 mm, 0.18 mm, 0.30 mm, 0.40 mm, and 0.50 mm. Example: • If “T2” is 1.0 mm, then the reverse gear shim is 0.08 mm. • If “T2” is 1.16 mm, then the reverse gear shim is 1.15 mm. Measuring Backlash Forward Gear 1. Remove the water pump assembly. 2. Set the gearshift to the neutral position. a a-Shift rod 91-88877 (stamped 06052) 90-888465 JUNE 2002 Page 6A-43 GEAR HOUSING 3. Install the special service tool so that it pushes against the propeller shaft. a b a-Puller jaws (91-46086A1) b-Universal puller screw (91-85716) NOTE: Tighten the universal puller screw while turning the driveshaft until the driveshaft can no longer be turned. 4. Install the backlash indicator onto the driveshaft (22.4 mm [0.88 in] in diameter), then the dial gauge onto the gear housing. 5. Set the gear housing assembly upside down. 00101 a b c a-Backlash indicator b-Puller c-Dial indicator NOTE: Install the dial gauge so that the plunger contacts the mark on the backlash indicator. 6. Slowly turn the driveshaft clockwise and counterclockwise and measure the backlash when the driveshaft stops in each direction. Forward Gear Backlash Specification 0.21mm-0.44mm Page 6A-44 90-888465 JUNE 2002 GEAR HOUSING 7. Add or remove shim(s) if out of specification. Forward Gear Backlash Shim Thickness Less than 0.21 mm To be decreased by (0.33 – M) x 0.71 More than 0.44 mm To be increased by (M – 0.33) x 0.71 M = Measurement Available Shim Thickness: 0.10 mm, 0.12 mm, 0.15 mm, 0.18 mm, 0.30 mm, 0.40 mm, and 0.50 mm. Reverse Gear 8. Remove the special service tools from the propeller shaft. 9. Apply a load to the reverse gear by installing the propeller, the spacer (do not use the spline washer), then the washer as shown. a b c d e a-Propeller b-Spline washer (DO NOT USE) c-Spacer d-Washer e-Nut NOTE: Tighten the propeller nut while turning the driveshaft until the driveshaft can no longer be turned. 90-888465 JUNE 2002 Page 6A-45 GEAR HOUSING 10. Slowly turn the driveshaft clockwise and counterclockwise and measure the backlash when the driveshaft stops in each direction. a b a-Dial gauge plunger b-Backlash indicator 11. Add or remove shim(s) if out of specification. Reverse Gear Backlash Shim Thickness Less than 0.70 mm To be increased by (0.87 – M) x 0.71 More than 1.03 mm To be decreased by (M – 0.87) x 0.71 M = Measurement Available Shim Thickness: 0.10 mm, 0.12 mm, 0.15 mm, 0.18 mm, 0.30 mm, 0.40 mm, and 0.50 mm. 12. Remove the special service tools, and then install the water pump assembly. Page 6A-46 90-888465 JUNE 2002 GEAR HOUSING LOWER UNIT Section 6B Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-2 Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-32 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-32 Gear Housing (Driveshaft)(Counter Rotation) 6B-8 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-32 Gear housing (Prop Shaft)(Counter Rotation) 6B-12 Drive Shaft Bearing Carrier . . . . . . . . . . . . . . . 6B-34 General Service Recommendations . . . . . . . 6B-14 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 6B-34 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-14 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-34 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-14 Reverse Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-35 Draining and Inspecting Gear Lubricant . . . . 6B-15 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 6B-35 Changing Lubricant . . . . . . . . . . . . . . . . . . . 6B-15 Pinion and Reverse Gear Inspection . . . . 6B-35 Gear Housing Assembly . . . . . . . . . . . . . . . . . 6B-16 Checking the Bearings . . . . . . . . . . . . . . . . 6B-36 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-16 Reverse Gear Assembly . . . . . . . . . . . . . . 6B-36 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-17 Gear Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-36 Water Pump and Shift Rod . . . . . . . . . . . . . . . 6B-19 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 6B-36 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-19 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-37 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-19 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-38 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-21 Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-40 Bearing Carrier Assembly . . . . . . . . . . . . . . . . 6B-24 Selecting the Pinion Shims . . . . . . . . . . . . 6B-40 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-24 Selecting the Reverse Gear Shims . . . . . 6B-43 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 6B-24 Selecting the Forward Gear Shims . . . . . 6B-45 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-27 Selecting Propeller Shaft Shims . . . . . . . . 6B-46 Propeller Shaft Inspection . . . . . . . . . . . . . 6B-27 Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-48 Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . . . . 6B-28 Measuring Forward and Reverse Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-28 Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-48 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-31 6 B 90-888465 JUNE 2002 Page 6B-1 GEAR HOUSING Specifications Gear Ratio 2.00:1 Gearcase Capacity 1 L (34.0 fl oz) Lubricant Type Quicksilver Gear Lube-Premium Blend Forward Gear Number of Teeth 30 Spiral/Bevel Pinion Gear Number of Teeth 15 Spiral/Bevel GEAR HOUSING Pinion Height Pinion Gear Locating Tool 91-888875T Forward Gear Backlash 0.008 - 0.017 in. (0.21 - 0.44 mm) Reverse Gear Backlash 0.028 - 0.041 (0.70 - 1.03 mm) Backlash Indicating Tool 91-888878 Water Pressure @ 1000 rpm 25-31 kPa (3.5-4.5 psi) @ 5700 rpm (WOT) 117 - 143 kPa (17-20.5 psi) Leak Test Pressure 69-83 kPa (10-12 psi) for 5 Minutes Page 6B-2 90-888465 JUNE 2002 GEAR HOUSING Special Tools 1. Pinion Height Gauge 91-888875T 2. Shimming Plate 91-889586 06701 3. Driver Rod 91-888882 06652 4. Backlash Indicator Tool 91-888878 (Stamped 06706) 5. Universal Treaded Rod (91-85716), Jaws 91-46086A1 90-888465 JUNE 2002 Page 6B-3 GEAR HOUSING 6. Slide Hammer 91-34569A1 7. Driver Rod 91-888870 06605 8. Mandrel 91-888892 06628 9. Mandrel 91-888891 06658 10. Mandrel 91-888890 06636 00112 11. Mandrel 91-888888 06622 12. Driver rod 91-888887 06606 00113 Page 6B-4 90-888465 JUNE 2002 GEAR HOUSING 13. Mandrel 91-88886 06656 00107 14. Bearing depth plate 91-888885 06603 00108 15. Mandrel 91-888884 06610 00111 16. Rod with stop 91-888883 06604 00110 17. Mandrel 91-888881 06653 00111 90-888465 JUNE 2002 Page 6B-5 GEAR HOUSING 18. Universal Puller Plate 91-37241 73652 19. Driver Rod 91-37323 37323 20. Ring Nut Wrench 91-888880T 06578 21. Puller 91-83164M 22. Mandrel 91-888894 06657 00109 23. Mandrel 91-37350 37350 24. Driveshaft Holding Tool 91-888889 Page 6B-6 90-888465 JUNE 2002 GEAR HOUSING 25. Propeller shaft adaptor 91-888879 06514 26. Dial Indicator 91-58222A1 27. Dial Indicator Adaptor Kit 91-83155 28. Shift rod 91-888877 29. Puller Plate 91-29310 90-888465 JUNE 2002 Page 6B-7 GEAR HOUSING Gear Housing (Driveshaft)(Counter Rotation) 37 36 35 34 33 32 31 30 29 2728 26 25 24 23 22 21 20 19 18 1716 15 14 12 13 11 10 45 46 47 41 40 38 39 42 43 44 79 51 55 53 8 58 57 56 6 7 4 5 2 54 523 50 49 1 48 51 7 7 7 7 7 95 95 95 95 95 95 95 95 95 95 95 7 Loctite 271 Thread Locker 2-4-C With Teflon Page 6B-8 90-888465 JUNE 2002 GEAR HOUSING Gear Housing (Driveshaft)(Counter Rotation) REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 GEAR HOUSING 2 1 BEARING 3 1 PINION GEAR 4 1 WASHER 5 1 NUT 103 142 6 1 DRAIN PLUG 7 2 GASKET 8 1 SEAL 9 1 PLUG 10 1 GUIDE 11 1 DAMPER 12 1 DRIVE SHAFT 13 1 KEY 14 1 BEARING 15 AR SHIM SET 16 1 BEARING 17 1 O-RING 18 1 HOUSING 19 4 SCREW (M8 X 25) 159 18 20 4 WASHER 21 2 OIL SEAL 22 1 COVER 23 1 GASKET 24 1 OUTER PLATE 25 1 IMPELLER 26 1 INSERT 27 2 WASHER 28 1 WAVE WASHER 29 1 SPACER 30 1 COLLAR 31 1 O-RING 32 1 O-RING 33 2 DOWEL PIN 34 1 WATER PUMP HOUSING 35 1 DAMPER 36 1 COVER 37 4 SCREW (M8 X 45) 159 18 38 1 PLATE 39 1 O-RING 40 1 OIL SEAL NOTE: TORQUE TOLERANCE +/– 10% 90-888465 JUNE 2002 Page 6B-9 GEAR HOUSING Gear Housing (Driveshaft)(Counter Rotation) 37 36 35 34 33 32 31 30 29 2728 26 25 24 23 22 21 20 19 18 1716 15 14 12 13 11 10 45 46 47 41 40 38 39 42 43 44 79 51 55 53 8 58 57 56 6 7 4 5 2 54 523 50 49 1 48 51 95 2-4-C With Teflon 7 Loctite 271 Thread Locker 7 7 7 7 7 95 95 95 95 95 95 95 95 95 95 Page 6B-10 90-888465 JUNE 2002 GEAR HOUSING Gear Housing (Driveshaft)(Counter Rotation) REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 41 3 SCREW (M6 X 20) 71 8 42 1 SPRING 43 1 SHIFT CAM 44 1 CIRCLIP 45 1 WATER TUBE 46 1 DAMPER 47 2 DAMPER 48 1 SCREW (M 10 X 44) 31 43 49 1 TRIM TAB 50 1 SCREW (M10 X 70) 34 47 51 2 DOWEL PIN 52 1 COVER 53 1 COVER 54 1 SCREW 55 1 NUT 56 7 SCREW (M10 X 45) 34 47 57 7 WASHER 58 7 WASHER 90-888465 JUNE 2002 Page 6B-11 GEAR HOUSING Gear housing (Prop Shaft)(Counter Rotation) 7 Loctite 271 Thread Locker 95 2-4-C With Teflon 7 95 95 95 95 95 Page 6B-12 90-888465 JUNE 2002 GEAR HOUSING Gear Housing (Prop Shaft)(Counter Rotation) REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 GEAR HOUSING 2 1 SHIFTER 3 AR SHIM SET 4 1 SPACER 5 1 BEARING 6 1 BEARING 7 1 REVERSE GEAR 8 2 BEARING 9 1 SHIFT SLIDE 10 2 BALL 11 2 NUT 12 1 SHAFT 13 2 PLUNGER 14 1 SPRING 15 1 WASHER 16 1 CLUTCH 17 1 CROSS PIN 18 1 SPRING 19 1 FORWARD GEAR 20 1 NUT 78 108 21 1 TAB WASHER 22 AR SHIM SET 23 1 BEARING 24 1 PROP SHAFT 25 1 BEARING 26 1 SHIM SET 27 1 BEARING 28 2 O-RING 29 1 BEARING CARRIER 30 1 GREASE FITTING 53 6 31 2 SCREW (M8 X 30) 22 30 32 2 WASHER 33 2 OIL SEAL 34 1 CAP 35 2 SCREW (M8 X 20) 159 18 36 2 WASHER 37 1 THRUST WASHER 38 1 WASHER 39 1 CASTLE NUT 40 55 40 1 COTTER PIN NOTE: TORQUE TOLERANCE +/– 10% 90-888465 JUNE 2002 Page 6B-13 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: 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 6B-14 90-888465 JUNE 2002 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. Changing Lubricant 1. Tilt the outboard motor up slightly. 2. Place a drain pan below outboard. 3. Remove vent plug and fill/drain plug and drain lubricant. a b a-Fill/Drain Screw b-Vent Screw 4. 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) on the drain plug magnet indicates normal wear. The presence of metal chips on the magnet indicates the need for gear housing disassembly and component inspection. 5. 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 (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. 6. 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. 90-888465 JUNE 2002 Page 6B-15 GEAR HOUSING Gear Housing Assembly Removal 1. Set the gearshift to the neutral position, and place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning. Remove the nut and propeller. WARNING DO NOT hold the propeller with your hands when loosening or tightening it. Be sure to disconnect the battery cables from the batteries and the engine shut-off switch. Put a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning. 2. Mark the trim tab at the area shown, and then remove it. 3. Loosen the bolts, and then remove the gear housing assembly from the driveshaft housing. a a-Trim tab NOTE: Check that there is no oil on the spline and check it for rust or wear. Check the oil pump if necessary. Page 6B-16 90-888465 JUNE 2002 GEAR HOUSING Installation 1. Set the gearshift to the neutral position at the gear housing assembly. N N a a-Shift rod 2. Install the two dowel pins to the lower unit. 3. Install the gear housing assembly to the driveshaft housing. Tighten the screws to the specified torque. 4. Install the trim tab to its original position. Tighten the trim tab mounting screw to the specified torque. Loctite 242 Thread Locker a b c d e 66 66 a-Gear housing mounting screw (7) M10 X 45 b-Trim tab mounting screw M10 X 44 c-Trim tab d-Dowel pin (2) e-Gear housing mounting screw (1) M10 X 70 66 Gear Housing Mounting Screw Torque 47 Nm (34 lb ft) Trim Tab Mounting Screw Torque 43 Nm (31 lb ft) 90-888465 JUNE 2002 Page 6B-17 GEAR HOUSING 5. Install the propeller and propeller nut. Place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning. Tighten to the specified torque. 6. Install cotter key. 95 95 2-4-C with Teflon WARNING DO NOT hold the propeller with your hands when loosening or tightening it. Be sure to disconnect the battery cables from the batteries and the engine shut-off switch. Put a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning. Propeller Nut Torque 55 Nm (40 lb ft) Page 6B-18 90-888465 JUNE 2002 GEAR HOUSING Water Pump and Shift Rod Removal 1. Remove the water pump assembly. 2. Shift the gear housing assembly into the neutral position and remove the shift shaft assembly. a b a-Shift shaft assembly b-Water pump assembly Inspection 1. Check the water pump housing for deformation. Replace if necessary. a a-Water pump housing 90-888465 JUNE 2002 Page 6B-19 GEAR HOUSING 2. Check the impeller and insert cartridge for cracks or wear. Replace if necessary. a b a-Impeller b-Insert 3. Check the Woodruff key and the groove on the driveshaft for wear. Replace if necessary. b a a-Woodruff key b-Groove 4. Check the shift shaft for cracks or wear. Replace if necessary. a Page 6B-20 90-888465 JUNE 2002 GEAR HOUSING Installation 1. Install the shift rod assembly. 66 95 a b Loctite 242 Thread Locker 2-4-C with Teflon 6695 a-Shift shaft b-Shift slide 2. Install the new gasket, outer plate cartridge and dowel pins. a b c a-Outer plate b-Gasket c-Dowel pin (2) 90-888465 JUNE 2002 Page 6B-21 GEAR HOUSING 3. Install the Woodruff key into the driveshaft. 4. Align the groove on the impeller with the Woodruff key, and then install it to the driveshaft. a b a-Impeller b-Woodruff key 5. Install the washers, wave washer, spacer and collar to the driveshaft using a suitable mandrel. b c d e a f a-2mm (0.08 in.) b-Washers c-Collar d-Spacer e-Wave washer f-Suitable mandrel NOTE: The collar and spacer should fit together firmly. NOTE: While pulling the driveshaft up, install the collar with a suitable mandrel tool that fits over the driveshaft as shown. Page 6B-22 90-888465 JUNE 2002 GEAR HOUSING 6. Install the O-ring and insert cartridge into the pump housing. 95 2-4-C with Teflon a-Pump housing location tab b-Insert cartridge location tab c-Pump housing d-O-ring e-Insert cartridge c d 95 e a b NOTE: Align the insert cartridge location tabs with the tabs in the pump housing. 7. Install the O-ring and pump housing assembly into the gear housing. Tighten to the specified torque. 8. Install the seal and cover. 66 95 Loctite 242 Thread Locker 2-4-C with Teflon a-Pump housing screw (M8 X 45) b-Cover c-Seal d-Pump housing e-O-ring c d e a b 66 95 NOTE: When installing the pump housing, apply 2-4-C with Teflon to the inside of the housing, and then turn the driveshaft clockwise while pushing down the pump housing. Pump Housing Screw Torque 18 Nm (159 lb in.) 90-888465 JUNE 2002 Page 6B-23 GEAR HOUSING Bearing Carrier Assembly Removal 1. Remove the cover ring screws and cover ring. 2. Remove the bearing carrier screws. a bc a-Cover ring b-Cover ring screws (2) M8 x 20 c-Bearing carrier screws (2) M8 x 30 3. Remove the bearing carrier assembly from the gear housing. a b a-Propeller shaft adaptor (91-888879) (Stamped 06514) b-Slide hammer (91-34569A1) Disassembly 1. Remove the spring, cross pin, dog clutch, shift slide, shift plunger and shaft. a b c d e a-Shift slide b-Shaft c-Cross pin d-Spring e-Clutch Page 6B-24 90-888465 JUNE 2002 GEAR HOUSING 2. Remove the forward gear and forward gear shim(s) from the bearing carrier assembly using a press. a a-Universal puller plate (91-37241) 3. Install the propeller shaft assembly in the reverse direction into the gear housing. 4. Tighten bearing carrier mounting screw to the specified torque. a a-Bearing carrier mounting screws (M8 X 30) Bearing Carrier Mounting Screw Torque 18 Nm (159 lb in.) 5. Remove the nut and tab washer. a b c a-Ring nut wrench (91-888880T) (Stamped 06578) b-Tab washer c-Nut 90-888465 JUNE 2002 Page 6B-25 GEAR HOUSING 6. Remove the bearing outer race, taper roller bearing, thrust bearing, and propeller shaft shim(s) using a press. a b c d e a-Propeller shaft b-Propeller shaft shims c-Thrust bearing d-Taper bearing e-Taper roller bearing race CAUTION DO NOT press the propeller shaft threads directly. CAUTION DO NOT reuse the taper roller bearing. Always replace it with a new one. 7. Remove the oil seals and needle bearing. a b a-Driver rod (91-888882) (Stamped 06652) b-Mandrel (91-888881) (Stamped 06653) Page 6B-26 90-888465 JUNE 2002 GEAR HOUSING Inspection 1. Clean the bearing carrier using a soft brush and cleaning solvent. Visually inspect it for cracks or damage. Replace if necessary. 2. Check the teeth and dogs of the forward gear for cracks or wear. Replace the gear if necessary. 3. Check the bearings for pitting or rumbling. Replace if necessary. Propeller Shaft Inspection 1. Check the propeller shaft for bends or wear. Replace if necessary. 2. Check the dog clutch, shaft, and shift slide for cracks or wear. Replace if necessary. a bc a-Clutch b-Shaft c-Shift slide 90-888465 JUNE 2002 Page 6B-27 GEAR HOUSING Bearing Carrier Assembly 1. Install the needle bearing into the bearing carrier to the specified depth. a b c d a-Mandrel (91-888884) (Stamped 06610) b-Driver rod (91-888883) (Stamped 06604) c-Depth adjusting collar d-25.05-25.55mm (0.986-1.006 in.) NOTE: Install the needle bearing with the manufacture identification mark facing toward the oil seal (propeller side). NOTE: When using the driver rod, DO NOT strike the special tool in a manner that will force the depth adjusting collar out of place. 2. Apply 2-4-C With Teflon to the new oil seals. Install them into the bearing carrier to the specified depth. a b c 95 95 2-4-C with Teflon a-4.75-5.25mm ( 0.187-0.207 in.) b-Rod (91-37323) c-Mandrel (91-825198) NOTE: Install the first oil seal halfway into the bearing carrier, then the other oil seal. Page 6B-28 90-888465 JUNE 2002 GEAR HOUSING 3. Install shim(s) and thrust bearing with the propeller shaft into the bearing carrier. a b 95 95 2-4-C with Teflon a-Thrust bearing b-Shim(AR) CAUTION Add or remove shim(s), if necessary, when replacing the propeller shaft, thrust bearing, or bearing carrier. 4. Install the new taper roller bearing and bearing outer race into the bearing carrier using a press. a b c a-Ring nut wrench (91-888880T) b-Taper bearing outer race c-Taper bearing 5. Install the bearing carrier assembly in the reverse direction into the gear housing. 6. Tighten the bearing carrier mounting screw to the specified torque. a a-Bearing carrier mounting screw (M8 X 30) Bearing Carrier Mounting Screw Torque 18 Nm (159 lb in.) 90-888465 JUNE 2002 Page 6B-29 GEAR HOUSING 7. Install the nut and tab washer. Tighten the nut to the specified torque. a b c a-Ring nut wrench (91-888880T) b-Tab washer c-Nut Nut Torque 108 Nm (78 ft lb) 8. Install the forward gear, shim(s) and dog clutch using a press. NOTE: Assure the clutch dog is engaged while pressing the forward gear onto the bearing. a a-Ring Nut wrench (91-888880T) NOTE: Install the clutch dog with the “F” mark facing toward the forward gear. CAUTION Add or remove shim(s), if necessary, when replacing the forward gear or taper roller bearing. Page 6B-30 90-888465 JUNE 2002 GEAR HOUSING 9. Install the shift plunger, shaft and shift slide into the propeller shaft, and then install the cross pin and spring. a b c d e a-Shift slide b-Shaft c-Plunger d-Spring e-Cross pin NOTE: Make sure spring coils are not crossed. Installation 1. Install the bearing carrier assembly into the gear housing. 95 2-4-C with Teflon 95 NOTE: Apply grease to the new O-rings before installation. 2. Install the bearing carrier screw, and ring. Tighten to the specified torque. 66 Loctite 242 Thread Locker 7 Loctite 271 Thread Locker a b c 66 7 a-Bearing carrier screw (M8 X 30) b-Ring c-Ring screw (M8 X 20) Bearing Carrier Screw Torque 30 Nm (22 lb–ft) Ring Screw Torque 18 Nm (159 lb–in.) 90-888465 JUNE 2002 Page 6B-31 GEAR HOUSING Drive Shaft Removal 1. Remove bearing carrier. Refer to Bearing Carrier Assembly Removal 2. Remove the driveshaft, driveshaft bearing carrier, and pinion. Remove the forward gear. a b c a-Drive shaft holder (91-888889) b-Socket c-Breaker bar Inspection 1. Check the driveshaft for bends or wear. Replace if necessary. Page 6B-32 90-888465 JUNE 2002 GEAR HOUSING Installation 1. Install the forward gear to the gear housing. 2. Install the driveshaft bearing carrier, thrust bearing and shim(s) onto the driveshaft. a b c d2-4-C with Teflon 95 95 a-Driveshaft b-Thrust bearing c-Shim (AR) d-Driveshaft bearing carrier CAUTION Add or remove shim(s), if necessary, when replacing the driveshaft housing or drive shaft. 3. Install the driveshaft and driveshaft bearing carrier into the gear case, then the pinion and pinion nut. Tighten the nut to the specified torque. a b c a-Driveshaft holder (91-888889) b-Socket c-Breaker bar NOTE: Install the pinion by lifting up the driveshaft slightly, then aligning the pinion splines and the spline of the driveshaft. 4. Tighten the driveshaft bearing carrier bolts to specification. Pinion Nut Torque 142 Nm (103 lb–ft) Driveshaft Bearing Carrier Screw Torque 2 Nm (18 lb–in.) 90-888465 JUNE 2002 Page 6B-33 GEAR HOUSING Drive Shaft Bearing Carrier Disassembly 1. Remove the cover, oil seals and needle bearing. a b c d e a-Mandrel (91-888884) b-Rod (91-888882) c-Needle Bearing d-Seal (2) e-Cover Assembly 1. Install the needle bearing into the driveshaft bearing carrier to the specified depth. 2-4-C with Teflon a b c 95 95 a-4.25-4.75mm (0.167-0.187 in.) b-Mandrel (91-888884) (Stamped 06610) c-Rod (91-888887) (Stamped 06606) Page 6B-34 90-888465 JUNE 2002 GEAR HOUSING 2. Apply grease to the new oil seals, and then install them into the driveshaft bearing carrier to the specified depth. a b c 95 95 2-4-C with Teflon a-0.25-0.75MM (0.01-0.03 in) b-Rod (91-888887) (Stamped 06606) c-Mandrel (91-888892) (Stamped 06628) NOTE: Install first oil seal halfway into the driveshaft bearing carrier, then the second oil seal to the specified depth. Reverse Gear Disassembly 1. Remove the needle bearing from the reverse gear using a chisel. Pinion and Reverse Gear Inspection 1. Check the teeth of the pinion, and the teeth and dogs of the reverse gear for cracks or wear. Replace if necessary. 90-888465 JUNE 2002 Page 6B-35 GEAR HOUSING Checking the Bearings 1. Check the bearings for pitting or rumbling. Replace if necessary. Reverse Gear Assembly 2. Install the new needle bearings into the reverse gear to the specified depth. a b c d e c d 2 4 C With Teflon 95 95 a-20.75-21.25mm (0.817-0.836 in.) b-Shimming plate (91-888885) (Stamped 06603) c-Driver rod (91-888883) (Stamped 06604) d-Mandrel (91-888881) (Stamped 06653) e-4.25-4.75mm (0.167-0.187 in.) Gear Housing Disassembly 1. Remove the retainer and shim(s). a 00117 d b c a-Spacer b-Flywheel puller (91-83164M) c-6m screws d-Puller plate (91-29310) Page 6B-36 90-888465 JUNE 2002 GEAR HOUSING 2. Remove the needle bearing from the retainer using a suitable mandrel and driver rod. a b a-Mandrel b-Driver rod 3. Remove the driveshaft needle bearing. a b a-Rod (91-888870) (Stamped 06605) b-Mandrel (91-888890) (Stamped 06636) Inspection 1. Check the skeg and torpedo for cracks or damage. Replace if necessary. 90-888465 JUNE 2002 Page 6B-37 GEAR HOUSING Assembly 1. Install the needle bearing into the spacer, to the specified depth. a b 2-4-C with Teflon 95 95 a-Suitable mandrel b--0.25 - 0.25mm (-0.010-0.010 in.) 2. Install the shim(s) and retainer into the gear housing. NOTE: Lubricate the O.D. of reverse gear bearing adaptor with 2-4-C with Teflon. 2-4-C with Teflon 95 95 a b a-Mandrel (91-8888891) (Stamped 06657) b-Driver rod (91-8888870) (Stamped 06605) CAUTION Add or remove shim(s), if necessary, when replacing the forward gear or lower case. Page 6B-38 90-888465 JUNE 2002 GEAR HOUSING 3. Lubricate the bearing race with 2-4-C With Teflon. Install the needle bearing outer race into the gear housing. b a c 2-4-C with Teflon 95 95 a-Mandrel (91-888892) (Stamped 06628) b-Puller plate (91-29310) NOTE: Manufacture identification numbers face towards the pinion gear. 4. Install the needle bearings into the needle bearing outer race. NOTE: Apply 2-4-C with Teflon to the needle bearings, and install. 5. Install the thrust bearing and reverse gear into the gear housing. 55102 90-888465 JUNE 2002 Page 6B-39 GEAR HOUSING Shimming NOTE: Shimming IS NOT required when assembling the original gear housing and inner parts. Shimming IS required when assembling the original inner parts and a new gear housing, or when replacing the inner parts. NOTE: All shimming measurements and adjustments are in millimeters Selecting the Pinion Shims 1. Install the driveshaft to the shimming tool. a b a-Pinion height gauge (91–888875T) b-Driveshaft NOTE: Select the pinion shim thickness (T3) by using the specified measurement(s) and the calculation formula. NOTE: Install the shimming tool to the driveshaft so that the driveshaft is at the center of the plate. NOTE: Tighten the wing nuts another 1/4 of a turn after they contact the fixing plate. 2. Install the pinion and pinion nut, and then tighten the nut to the specified torque. Pinion Nut Torque 142 Nm (103 lb ft) 3. Measure the distance (M4) between the shimming tool and the pinion as shown. 4. Record the measurement a a-Caliper Page 6B-40 90-888465 JUNE 2002 GEAR HOUSING 5. Turn the thrust bearing (located in the driveshaft bearing carrier) two or three times to seat the driveshaft bearing. Measure from the bearing race to the driveshaft bearing carrier mounting surface, (M3) as shown. 6. Record the measurement. c a b a-Caliper b-Thrust bearing c-Driveshaft bearing carrier NOTE: Measure the thrust bearing at three points to find the height average. 90-888465 JUNE 2002 Page 6B-41 GEAR HOUSING 7. Calculate the pinion shim thickness (T3) as shown in the examples below. NOTE: “P” is the deviation of the gear housing dimension from standard. The “P” mark is stamped on the trim tab mounting surface of the gear housing in 0.01 mm units. If the “P” mark is unreadable, assume that “P” is zero and check the backlash when the unit is assembled. Calculation Formula: Pinion Shim Thickness (T3) = 82.00 + P/100 – M3 – M4 Example: Positive number deviation If “M3” is 50.75 mm and “M4” is 30.52 mm and “P” is (+2), then: • T3 = 82.00 + (+2)/100 – 50.75 mm – 30.52 mm • = 82.00 + 0.02 – 50.75 mm – 30.52 mm • = 0.75 mm Example: Negative number deviation If “M3” is 50.75 mm and “M4” is 30.52 mm and “P” is (–2), then: • T3 = 82.00 + (–2)/100 – 50.75 mm – 30.52 mm • = 82.00 – 0.02 – 50.75 mm – 30.52 mm • = 0.71 mm 8. Select the pinion shim(s) (T3) as follows. Calculated Numeral at 1/100 Place Rounded Numeral 1, 2 0 3, 4, 5 2 6, 7, 8 5 9, 10 8 Available Shim Thickness : 0.10 mm, 0.12 mm, 0.15 mm, 0.18 mm, 0.30 mm, 0.40 mm, and 0.50 mm. Example: • If “T3” is 0.68 mm, then the pinion shim is 0.65 mm. • If “T3” is 0.70 mm, then the pinion shim is 0.68 mm. Page 6B-42 90-888465 JUNE 2002 GEAR HOUSING Selecting the Reverse Gear Shims 1. Turn the thrust bearing two or three times to seat the bearing. Measure the bearing height (M1) as shown. 2. Record the measurement. a b a-Spacer b-Thrust bearing NOTE: Select the shim thickness (T1) by using the specified measurement(s) and the calculation formula. NOTE: Measure the thrust bearing with spacer at three points to find the height average. 90-888465 JUNE 2002 Page 6B-43 GEAR HOUSING 3. Calculate the reverse gear shim thickness (T1) as shown in the examples below. NOTE: “F” is the deviation of the gear housing dimension from standard. The “F” mark is stamped on the trim tab mounting surface of the gear housing in 0.01 mm units. If the “F” mark is unreadable, assume that “F” is zero and check the backlash when the unit is assembled. Calculation Formula: Reverse Gear Shim Thickness (T1) = 30.60 + F/100 – M1 Example: Positive number deviation If “M1” is 29.90 mm and “F” is (+ 5), then: • T1 = 30.60 + (+ 5)/100 – 29.90 mm • = 30.60 + 0.05 – 29.90 mm • = 0.75 mm Example: Negative number deviation If “M1” is 29.90 mm and “F” is (– 5), then: • T1 = 30.60 + (– 5)/100 – 29.90 mm • = 30.60 – 0.05 – 29.90 mm • = 0.65 mm 4. Select the reverse gear shim(s) (T1) as follows. Calculated Numeral at 1/100 Place Rounded Numeral 1, 2 0 3, 4, 5 2 6, 7, 8 5 9, 10 8 Available Shim Thickness: 0.10 mm , 0.12 mm, 0.15 mm, 0.18 mm, 0.30 mm, 0.40 mm, and 0.50 mm. Example: • If “T1” is 0.75 mm, then the reverse gear shim is 0.72 mm. • If “T1” is 0.80 mm. then the reverse gear shim is 0.78 mm. Page 6B-44 90-888465 JUNE 2002 GEAR HOUSING Selecting the Forward Gear Shims 1. Turn the taper roller bearing two or three times to seat the rollers, and then measure the bearing height (M5) and (M6) as shown. a b a a-Shimming plate (91-889586) (Stamped 06701) b-Forward gear tapered roller bearing outer race NOTE: Select the shim thickness (T2) by using the specified measurement(s) and the cal- culation formula. NOTE: Measure the taper roller bearing at three points to find the height average. 2. Calculate the forward gear shim thickness (T2) as shown in the examples below. NOTE: “R” is the deviation of the gear housing dimension from standard, and “A” is the deviation of the bearing carrier from standard. The “R” mark is stamped on the trim tab mounting surface of the gear housing, and the “A” mark is stamped on the bearing carrier in 0.01 mm units. If the “R” mark or “A” mark is unreadable, assume that “R” and “A” are zero and check the backlash when the unit is assembled. 90-888465 JUNE 2002 Page 6B-45 GEAR HOUSING Calculation formula: Forward Gear Shim Thickness (T2) = 8.45 + R/100 – A/100 – M5 + M6 Example: Positive number deviation If “M5” is 22.95 mm and “M6” is 15.73 mm and “R” is (+ 1) and “A” is (+3), then: • T2 = 8.45 + (+ 1)/100 – (+3)/100 – 22.95 mm + 15.73 mm • = 8.45 + 0.01 – 0.03 – 22.95 mm+ 15.73 mm • = 1.21 mm Example: Negative number deviation If “M5” is 22.95 mm and “M6” is 15.73 mm and “R” is (– 1) and “A” is (–3), then: • T2 = 8.45 + (– 1)/100 – (–3)/100 – 22.95 mm + 15.73 mm • = 8.45 – 0.01 + 0.03 – 22.95 mm + 15.73 mm • = 1.25 mm 3. Select the forward gear shim(s) (T2) as follows. Calculated Numeral at 1/100 Place Rounded Numeral 1, 2 0 3, 4, 5 2 6, 7, 8 5 9, 10 8 Available Shim Thickness : 0.10 mm, 0.12 mm, 0.15 mm, 0.18 mm, 0.30 mm, 0.40 mm, and 0.50 mm. Example: • If “T2” is 1.18 mm, then the forward gear shim is 1.15 mm. • If “T2” is 1.20 mm. then the reverse gear shim is 1.18 mm. Selecting Propeller Shaft Shims 1. Install the shims, thrust bearing, propeller shaft, taper roller bearing, and tab washer. a b c d e a-Nut b-Tab washer c-Taper roller bearing d-Thrust bearing e-Shim (AR) Page 6B-46 90-888465 JUNE 2002 GEAR HOUSING 2. Install the bearing carrier assembly in the reverse direction into the gear housing. 3. Tighten the bearing carrier screw to the specified torque. a a-Bearing carrier mounting screw (M8 X 30) Bearing Carrier Mounting Screw Torque 18 Nm (159 lb in.) 4. Install the nut and tab washer. Tighten the nut to the specified torque. a b c a-Ring nut wrench (91-888880T) (Stamped 06578) b-Tab washer c-Nut Nut Torque 108 Nm (78 ft lb) 5. Measure the propeller shaft free play as shown. a a-0.25-0.35mm (0.01-0.014 in.) 90-888465 JUNE 2002 Page 6B-47 GEAR HOUSING 6. Select the propeller shaft shim(s) (T4). T4 NOTE: Add or remove shim(s), if the free play is out of specification. Available Shim Thickness : 0.10 mm, 0.12 mm, 0.15 mm, 0.18 mm, 0.30 mm, 0.40 mm, and 0.50 mm. Backlash Measuring Forward and Reverse Gear Backlash 1. Remove the water pump assembly. 2. Set the gearshift to the neutral position. a a-Shift rod (91-888877) Page 6B-48 90-888465 JUNE 2002 GEAR HOUSING 3. Install the special service tool so that it pushes against the propeller shaft. a b a-Threaded rod (91-85716) b-Puller jaws (91-40686A1) NOTE: Tighten the puller bolt while turning the driveshaft until the driveshaft can no longer be turned. 4. Install the backlash indicator onto the driveshaft (22.4 mm [0.88 in] in diameter), then the dial gauge onto the lower unit. 5. Set the gear housing assembly upside down. 00101 b c a a-Back lash indicator 91-888878 (stamped 06706) b-Universal puller c-Dial indicator NOTE: Install the dial gauge so that the plunger contacts the mark on the backlash indicator. 6. Slowly turn the driveshaft clockwise and counterclockwise and measure the backlash when the driveshaft stops in each direction. 90-888465 JUNE 2002 Page 6B-49 GEAR HOUSING 7. Add or remove shim(s) if out of specification. Forward Gear Backlash Shim Thickness Less than 0.35 mm To be decreased by (0.53 – M) x 0.71 More than 0.70 mm To be increased by (M – 0.53) x 0.71 M = Measurement Available Shim Thickness : 0.10 mm, 0.12 mm, 0.15 mm, 0.18 mm, 0.30 mm, 0.40 mm, and 0.50 mm. 8. Remove the special service tools from the propeller shaft. 9. Turn the shift rod into the reverse position. 10. Turn the driveshaft clockwise until the dog clutch is fully engaged. a a-Shift rod (91-888877) Page 6B-50 90-888465 JUNE 2002 GEAR HOUSING 11. Turn the shift rod to the neutral position with the shift rod arm. 12. Turn the driveshaft counterclockwise approximately 30°. 13. Turn the shift rod to the reverse position with the shift rod push arm. 14. Slowly turn the driveshaft clockwise and counterclockwise and measure the backlash when the driveshaft stops in each direction. NOTE: When measuring the reverse gear backlash, turn the shift rod push arm towards the reverse position with constant force while checking reverse gear backlash . 15. Add or remove shim(s) if backlash is out of specification. Reverse Gear Backlash Shim Thickness Less than 0.70 mm To be increased by (0.87 – M) x 0.71 More than 1.03 mm To be decreased by (M – 0.87) x 0.71 M = Measurement Available Shim Thickness : 0.10 mm, 0.12 mm, 0.15 mm, 0.18 mm, 0.30 mm, 0.40 mm, and 0.50 mm. 16. Remove the special service tools, and then install the water pump assembly. 90-888465 JUNE 2002 Page 6B-51 THROTTLE/SHIFT LINKAGE ATTACHMENTS/CONTROL LINKAGE Section 7 - Throttle/Shift Linkage Table of Contents Throttle Linkage . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 Shift Linkage,Detent Bracket . . . . . . . . . . . . . . 7-4 Shift Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 Throttle Linkage . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Detent Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18 Accelerator Arm Assembly . . . . . . . . . . . . . . . 7-9 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 7-18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18 7 90-888465 JUNE 2002 Page 7-1 THROTTLE/SHIFT LINKAGE Throttle Linkage 10 16 1 2 3 4 5 6 7 8 9 10 11 12 1314 15 17 18 1920 21 22 23 24 25 26 27 28 2930 31 32 3334 6 8 9 9 10 10 10 27 27 27 Page 7-2 90-888465 JUNE 2002 THROTTLE/SHIFT LINKAGE Throttle Linkage REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 1 BALL JOINT 2 1 LEVER 3 1 BRACKET 4 2 SCREW (M6 X 20) 71 8 5 2 WASHER 6 2 PIN 7 1 THROTTLE CONTROL SHAFT 8 2 PIN 9 3 WASHER 10 5 BUSHING 11 1 BRACKET 12 2 SCREW (M6 X 14) 71 8 13 7 WASHER 14 2 CLAMP 15 1 CIRCLIP 16 2 GEAR 17 1 THROTTLE CONTROL LEVER 18 1 BUSHING 19 5 SCREW (M6 X 45) 71 8 20 1 SPRING 21 1 THROTTLE CAM 22 1 WAVE WASHER 23 1 SCREW 71 8 24 1 SCREW (M6 X 30) 71 8 25 1 WASHER 26 1 ACCELERATOR ARM ASSEMBLY 27 5 NUT 35 4 28 1 LINK 29 1 ROD 30 1 BUSHING 31 1 PIN 32 1 LINK ROD 33 1 BALL JOINT 34 1 NUT 90-888465 JUNE 2002 Page 7-3 THROTTLE/SHIFT LINKAGE Shift Linkage,Detent Bracket 1 2 3 4 5 6 7 8 9 10 11 121314 1516 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Page 7-4 90-888465 JUNE 2002 THROTTLE/SHIFT LINKAGE Shift Linkage, Detent Bracket REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb.ft. Nm 1 2 SCREW (M4 X 16) 35 4 2 1 PLATE 3 2 COTTER PIN 4 1 NEUTRAL SWITCH 5 1 BUSHING 6 1 BRACKET 7 1 WASHER 8 1 LINK ASSEMBLY 9 1 SPRING 10 1 SCREW (M6 X 35) 71 8 11 2 SCREW (M4 X 16) 35 4 12 1 CLAMP 13 1 PLATE 14 2 BUSHING 15 1 SHIFT INTERRUPT SWITCH 16 1 SCREW (M6 X 35) 71 8 17 1 BRACKET 18 1 GREASE FITTING 19 2 BUSHING 20 1 SCREW 159 18 21 1 COTTER PIN 22 1 WASHER 23 1 SCREW (M6 X 30) 71 8 24 1 BUSHING 25 1 DETENT BRACKET 26 1 BALL 27 1 SPRING 28 1 DETENT SCREW 159 18 29 1 COTTER PIN 30 1 BUSHING 31 1 GEAR SHIFT HANDLE 32 1 BOTTOM COWL 90-888465 JUNE 2002 Page 7-5 THROTTLE/SHIFT LINKAGE Page 7-6 90-888465 JUNE 2002 Throttle Linkage Removal 1. Remove intake silencer assembly. 2. Remove throttle link arm from ball joint. 3. Remove power terminal mounting screw. 4. Remove bracket screws. 5. Remove throttle bracket screws. a c e 59521 d b a - Power terminal mounting screw M8 x 20 b - Throttle link arm ball joint c - Bracket screw (2) M6 x 20 d - Throttle bracket screw (5) M6 x 45 e - Throttle cam THROTTLE/SHIFT LINKAGE 90-888465 JUNE 2002 Page 7-7 Installation 1. Install throttle bracket screws. Tighten to specified torque. 2. Install bracket screws. Tighten to specified torque. 3. Install power terminal screw. Tighten to specified torque. 4. Install throttle link arm to ball joint. 5. Install the intake silencer. Refer to Section 3C, Intake Silencer Installation. a c e 59521 b d a - Power terminal mounting screw M8 x 20 b - Throttle link arm ball joint c - Bracket screw (2) M6 x 20 d - Throttle bracket screw (5) M6 x 45 e - Throttle cam Power Terminal Mounting Screw Torque 18 Nm (159 lb-in.) Bracket Screw Torque 8 Nm (71 lb-in.) Throttle Bracket Screw Torque 8 Nm (71 lb-in.) THROTTLE/SHIFT LINKAGE Disassembly 1. Remove the throttle cam screw. 2. Remove dowel pin holding the gear to the throttle shaft. 3. Remove the throttle shaft from the throttle control bracket. 4. Remove the dowel pin holding the gear to the throttle control lever. 5. Remove the circlip from the throttle control lever. 6. Remove the throttle control lever from the throttle control bracket. c e g h d a b f gi 95 95 2-4-C With Teflon a-Throttle cam screw b-Throttle cam c-Throttle control bracket d-Bushing (5) e-Throttle shaft f-Circlip g-Dowel pin (3) h-Gear (2) i-Throttle control lever Assembly NOTE: Lubricate all bushings and gears with 2-4-C with Teflon. 1. Assemble components as shown above. Tighten throttle cam screw to specified torque. Throttle Cam Screw Torque 8 Nm (71 lb-in.) Page 7-8 90-888465 JUNE 2002 THROTTLE/SHIFT LINKAGE 90-888465 JUNE 2002 Page 7-9 Accelerator Arm Assembly Removal 1. Remove the coil cover. 2. Disconnect the coils. 3. Remove the coil wire harness sta strap from the coil plate. 4. Remove the IAC hose from the starboard manifold. 5. Remove air silencer. Refer to Section 3C, Intake Silencer Removal. 6. Disconnect the engine temperature switches, IAC motor, MAP sensor and TPI harness. 7. Cut sta straps holding the high pressure fuel hoses to the wire harness guide. Pull high pressure hoses out of the wire guide. 8. Remove the wire harness guide mounting screws (3). a b c c d e f g h i a - Coil harness b - Coil wire harness sta strap c - Engine temperature switch d - TPI harness e - IAC hose to starboard manifold f - IAC motor harness g - MAP harness h - Sta straps i - Wire harness guide screws (3) THROTTLE/SHIFT LINKAGE Page 7-10 90-888465 JUNE 2002 9. Disconnect the starboard fuel injector harness connectors. 10. Disconnect the neutral switch and the shift interrupt switch harness connectors. 11. Move wire harness guide to a position that will make servicing the accelerator arm assembly easy. 59442 59460 a b c d a - Fuel injector harness b - Shift interrupt switch c - Neutral switch d - Wire harness guide THROTTLE/SHIFT LINKAGE 12. Remove the throttle link ball joint nut port side and starboard side. 13. Remove actuator link from the control lever. 14. Loosen the timing belt tensioner screw. Do not remove the tensioner screw. 15. Use a hexagon wrench to turn the timing belt tensioner clockwise. 16. Slip a 5mm pin in the hole on the belt tensioner. Move timing belt off of the tensioner. Do not remove pin until the belt is replaced. a b c d e f g a-Port throttle link ball joint. b-Actuator link rod. c-Throttle control lever. d-Starboard throttle link ball joint. e-Hexagon wrench f-5 mm pin (0.200 in.) g-Belt tensioner hole location for 5mm pin. 90-888465 JUNE 2002 Page 7-11 THROTTLE/SHIFT LINKAGE 17. Remove screw holding accelerator arm assembly to power head. (Flywheel has been removed for easy identification where accelerator arm assembly screw is located). 18. Remove accelerator arm assembly. a b c d a-Link b-Link rod c-Accelerator arm assembly d-Rod Installation 1. Install the link, link rod and rod to the accelerator arm. Tighten to specified torque. 2. Install the accelerator arm assembly to the power head. Tighten to specified torque. a d b e c a-Link b-Link rod c-Accelerator arm screw M6 x 30 d-Accelerator arm assembly e-Rod Link and Link Rod Ball Joint Nut Torque 4 Nm (35 lb- in.) Accelerator Arm Screw Torque 8 Nm (71 lb- in.) Page 7-12 90-888465 JUNE 2002 THROTTLE/SHIFT LINKAGE 3. Snap the actuator link rod to the throttle control lever ball joint. 4. Install the port and starboard throttle link ball joints. Tighten the throttle link ball joint nut to specified torque. 5. Install timing belt. Refer to Section 2A, Timing Belt Removal. a b c d a-Port throttle link ball joint b-Actuator link rod c-Throttle control lever d-Starboard throttle link ball joint Throttle Linkage Ball Joint Nut Torque 4 Nm (35 lb- in.) 90-888465 JUNE 2002 Page 7-13 THROTTLE/SHIFT LINKAGE Page 7-14 90-888465 JUNE 2002 6. Install wire harness guide. Tighten to specified torque. 7. Connect the engine temperature switches, TPI, MAP, and IAC motor harness connectors. 8. Install the IAC hose to the port manifold. 9. Place high pressure fuel hoses, and IAC hose into the wire harness guide. 10. Sta strap the engine temperature wire harness and high pressure hoses. a b c d e f g a a - Engine Temperature switch harness b - TPI harness c - IAC hose d - IAC harness e - MAP harness f - Wire guide screw (3) M6 x 35 g - Sta strap Wire Harness Guide Screw Torque 8 Nm (71 lb- in.) THROTTLE/SHIFT LINKAGE 90-888465 JUNE 2002 Page 7-15 11. Connect the coil harness connectors to the coils. Push the coil wire harness sta strap into the coil plate. a b a - Coil harness connector b - Coil wire harness sta strap 12. Connect the neutral switch, shift cut out and the starboard fuel injector harness connectors. 59460 b a 59442 c a - Shift interrupt switch b - Neutral switch c - Injector harness connector THROTTLE/SHIFT LINKAGE Shift Bracket Removal 1. Disconnect neutral switch and shift interrup switch connectors. 2. Remove the cotter pin holding the shift link to the bushing. 3. Remove the screw holding the shift and neutral bracket assembly to the bottom cowl. a b c d e a-Shift interrrupt switch b-Bushing c-Cotter pin d-Neutral switch e-Screw M6 x 35 Installation 1. Align the shift link with the shift bracket bushing. 2. Install the screw holding shift bracket to bottom cowl. Tighten to specified torque. 3. Install the cotter pin holding the shift link to the bushing. 4. Connect the neutral switch and shift interrrupt switch connector. Shift Bracket Mounting Screw Torque 8 Nm (71 lb-in.) NOTE: Refer to Section 1D, Outboard Installation for proper installation of shift and throttle cables. Page 7-16 90-888465 JUNE 2002 THROTTLE/SHIFT LINKAGE Disassembly 1. Remove shift bracket from bottom cowl. Refer to Shift Bracket Removal. 2. Remove the neutral safety switch mounting screws. 3. Remove bracket screw. 4. Remove the shift interrupt switch mounting screws. a b c 95 95 95 2-4-C with Teflon a-Shift interrupt switch and neutral safety switch mounting screw (4) M4 x 16 b-Bracket screw (2) M6 x 35 c-Bracket screw (1) M6 x 35 Assembly 1. Install shift interrupt switch. Tighten to specified torque. 2. Insert bushings into bracket. Lubricate bushing with 2-4-C with Teflon. 3. Install spring onto bracket. Align spring with the other bracket. Install bracket screw and tighten to specified torque. 4. Install the neutral switch to the bracket assembly. 5. Install bracket assembly to bottom cowl. Refer to Shift Bracket Installation. Neutral Switch/Shift Interrupt Switch Screw Torque 4 Nm (35 lb-in.) Bracket Screw Torque 18 Nm (159 lb-in.) 90-888465 JUNE 2002 Page 7-17 THROTTLE/SHIFT LINKAGE Detent Bracket Disassembly 1. Remove detent screw holding the detent spring and the detent ball. NOTE: Do not lose the detent ball during disassembly. 9595 a b c d 2-4-C with Teflon95 a-Detent screw b-Spring c-Ball d-Detent bracket Assembly 1. Lubricate the spring and ball with 2-4-C with Teflon. NOTE: The grease will hold the ball in place until the detent screw is installed. 2. Install the spring into the detent screw. Place the ball onto the spring. 3. Install the detent screw with the spring and ball into the detent bracket. Tighten to specified torque. Detent Screw Torque 18 Nm (159 lb-in.) Page 7-18 90-888465 JUNE 2002 COLOR DIAGRAMS COLOR DIAGRAMS Table of Contents 225 EFI (4-Stroke) Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . Page 8-3 8 90-888465 JUNE 2002 Page 8-1 COLOR DIAGRAMS Page 8-2 90-888465 JUNE 2002 COLOR DIAGRAMS 225 4-STROKE EFI COLOR WIRING DIAGRAM 90-888465 JUNE 2002 Page 8-3 225 4-STROKE EFI WIRING DIAGRAM 1. ECM 35. Stator 2. Splice Pack 36. Oil Pressure Sensor 3. Fuel Injector 6 37. Starter Motor 4. Fuel Injector 4 38. Starter Relay 5. Fuel Injector 2 39. Trim Relay 6. Fuel Injector 1 40. Cowl Trim Switch 7. Fuel Injector 3 41. Battery Cable(s) 8. Fuel Injector 5 42. Warning Indicators 9. Engine Temperature Sensor 43. Remote Control 10. Diagnostic Indicator 44. Ignition Coil 1,4 11. To Computer 45. Ignition Coil 3,6 12. Diagnostic 46. Ignition Coil 2,5 13. Shift Cut Switch 14. Thermoswitch 15. Thermoswitch 16. Throttle Position Sensor (TPS) 17. Neutral Switch 18. Splice Pack 19. Main Relay 20. Low Pressure Fuel Pump 21. Low Pressure Fuel Pump Driver 22. High Pressure Fuel Pump Relay 23. High Pressure Fuel Pump 24. Splice Pack 25. Idle Air Control 26. Intake Air Pressure Sensor 27. Intake Air Temperature Sensor 28. 30 AMP. Fuse 29. 30 AMP. Fuse 30. 30 AMP. Fuse 31. 20 AMP. Fuse 32. 20 AMP. Fuse 33. 5 AMP. Fuse 34. Rectifier/Regulator Page 8-4 90-888465 JUNE 2002 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1 5 2 4 6 4 2 1 3 5 3 6 B 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 25 26 27 29 30 31 33 34 35 36 37 38 39 40 41 44 45 46 42 43 00118 28 32 24