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25 BigFoot FourStroke Starting Model Year 1998 Starting Serial Number 0G590000 Starting Model Year 1998 25 BigFoot FourStroke 90-854785R2 NOVEMBER 2001 Notice Throughout this publication, “Dangers”, “Warnings” and “Cautions” (accompanied by the International HAZARD Symbol ) are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. OBSERVE THEM CAREFULLY! These “Safety Alerts” alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus “Common Sense” operation, are major accident prevention measures. DANGER DANGER - Immediate hazards which WILL result in severe personal injury or death. WARNING WARNING -Hazards or unsafe practices which COULD result in severe personal injury or death. CAUTION Hazards or unsafe practices which could result in minor personal injury or product or property damage. Notice to Users of This Manual This service manual has been written and published by the Service Department of Mercury Marine to aid our dealers’ mechanics and company service personnel when servicing the products described herein. It is assumed that these personnel are familiar with the servicing procedures of these products, or like or similar products manufactured and marketed by Mercury Marine, that they have been trained in the recommended servicing procedures of these products which includes the use of mechanics’ common hand tools and the special Mercury Marine or recommended tools from other suppliers. We could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of the possible hazards and/or results of each method. We have not undertaken any such wide evaluation. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered by the service procedure selected. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service these products. It should be kept in mind, while working on the product, that the electrical system and ignition system are capable of violent and damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables should be disconnected at the battery. Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive internal damage when the engine is started. 90-854785R2 DECEMBER 2001 Page i It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Mismatched or incorrect fasteners can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the same locations whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original. Cleanliness and Care of Outboard Motor A marine power product is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten thousands of an inch/mm. When any product component is serviced, care and cleanliness are important. Throughout this manual, it should be understood that proper cleaning, and protection of machined surfaces and friction areas is a part of the repair procedure. This is considered standard shop practice even if not specifically stated. Whenever components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed. Personnel should not work on or under an outboard which is suspended. Outboards should be attached to work stands, or lowered to ground as soon as possible. We reserve the right to make changes to this manual without prior notification. Refer to dealer service bulletins for other pertinent information concerning the products described in this manual. Page ii 90-854785R2 DECEMBER 2001 Service Manual Outline Section 1 - Important Information A - Specifications B - Maintenance C - General Information D - Outboard Motor Installation Section 2 - Electrical A - Ignition B - Charging & Starting System C - Timing, Synchronizing & Adjusting D - Wiring Diagrams Section 3 - Fuel System A - Fuel Pump B - Carburetor C - 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 C - Gas Assist Manual Tilt Section 6 - Lower Unit Section 7 - Attachments/Control Linkage A - Throttle/Shift Linkage B - Tiller Handle Section 8 - Manual Starter Section 9 -Color Diagrams Important Information Electrical Fuel System Powerhead Mid-Section Lower Unit Attachments/Control Linkage Manual Starter Color Diagrams 90-854785R2 DECEMBER 2001 Page iii Page iv 90-854785R2 DECEMBER 2001 SPECIFICATIONS IMPORTANT INFORMATION Section 1A - Specifications Table of Contents 1 A Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-2 Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-11 Propeller Information Chart . . . . . . . . . . . . . . . 1A-8 Mercury/Quicksilver Lubricants and Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-9 90-854785R2 DECEMBER 2001 Page 1A-1 SPECIFICATIONS Specifications Models 25 Bigfoot (4-Stroke) PERFORMANCE Power Model 25 Full Throttle RPM Range 25 h.p. (18.6 Kw) @5750 RPM 5500 - 6000 OUTBOARD WEIGHT Electric 25 EL 178 lbs. (80.7 kg) FUEL RECOMMENDED GASOLINE Automotive Unleaded with a Minimum Pump Posted Octane Rating of 87 OIL OIL FILTER OIL FILTER WRENCH ENGINE OIL CAPACITY ENGINE OIL +20 +40 +60 +80 F° C° 0 +100 –7 +4 +16 +27 –18 +38 SAE 10W-30 SAE 25W-40 p/n 35-822626A2 p/n 91-802653 Either 3 Quarts or 3 Liters SAE 10W-30 viscosity oil is recommended for use in all temperatures. SAE 25W-40 viscosity oil may be used at temperatures above 40° F (4° C). Use 4-Cycle Marine Oil with the proper viscosity for the expected temperature in your area (see range thermometer on left). If not available, use a premium quality 4-cycle engine oil, certified to meet or exceed anyone of the following American Petroleum Institute (API) service classifications SH, SG, SF, CF-4, CE, CD, CDll. Page 1A-2 90-854785R2 DECEMBER 2001 SPECIFICATIONS IGNITION SYSTEM Readings taken @ 68°F (20°C). Type Spark Plug Type Gap Hex Size Hole Size Torque Firing Order Ignition Timing: Below 800 RPM ECM (p/n 855311--) ECM (p/n 856058--/856190--) ECM (p/n 856190-–/856482-–) ECM (p/n 856177--/856178-–) ECM (p/n 878433--) Fully Advanced (6000 RPM) Charge Coil Resistance Crank Position Sensor Resistance Ignition Coil Resistance: Primary Secondary (W/o Boots) ECM Engine Speed Limiter Soft Reduction (Retards Timing) Spark Cut-Out Reduction (Percentages of ignition spark are Cut-Out) ECM Overheat/Low Oil Pressure Speed Control Oil Pressure Switch Capacitor Discharge Ignition NGK DPR6EA-9 0.035 in. (1.0 mm) 18 mm 12 mm 150 lb-in. (17 Nm) 1-2 10° B.T.D.C 5° B.T.D.C 5° B.T.D.C 5° B.T.D.C 5° B.T.D.C 30° B.T.D.C 660 - 710 W (GRN/WHT - WHT/GRN) 300 - 350 W (RED - WHT) 0.08 - 0.7 W 3.5 - 4.7 kW 6200 RPM 6250 RPM Approximately 2000 RPM Below 2.5 psi (17 kPa) Continuity Alternator Type 6 AMP Manual Alternator: Single Phase (12 Pole) Output 12 Volts-6 Amps. CHARGING SYSTEM Battery Charging Resistance 15 AMP Electric Alternator: 0.9 - 1.1 Ohms (YEL-YEL) Readings taken @ Output 12V-15 Amps. (Rectified/Regulated) 68°F (20°C). Battery Charging Coil Resistance Power Bobbin Resistance 0.22 - 0.24 Ohms (YEL-YEL) (For Electrothermal Valve) 6.7-7.1 Ohms (YEL/BLK-YEL/BLK) Quicksilver Tachometer Setting “6P” or “4” STARTING SYSTEM Manual Start Electric Start: Starter Type Output Ampere Draw Under: (Load) (No Load) Recoil Starter Bendix 1.1 kW 106.0 Amps 21.1 Amps Battery Rating Minimum Requirement 465 Marine Cranking Amps (MCA) BATTERY or 350 Cold Cranking Amps (CCA) For operation below 32° F (0° C) 1000 Marine Cranking Amps (MCA) or 775 Cold Cranking Amps (CCA) ENRICHMENT Auto Enrichener 15 - 25 W CONTROL Electrothermal ram projection 0.3 in. (7 mm) after 5 min. of power SYSTEM Readings taken @ 68°F (20°C). 90-854785R2 DECEMBER 2001 Page 1A-3 SPECIFICATIONS FUEL SYSTEM Fuel Pump Type Fuel Pump: Pressure Plunger Stroke Fuel Tank Capacity External (Plunger/Diaphragm) 3-6 PSI 0.23 - 0.38 in. (5.85 - 9.65 mm) Accessory CARBURETOR Idle RPM (Out Of Gear) Idle RPM (In Forward Gear) Wide Open Throttle RPM (WOT) Range Standard Model Main Jet Size Pilot Jet Idle Jet Bodensee Model Main Jet Pilot Jet Idle Jet Float Height (a) a 825 ± 25 RPM 775 ± 25 RPM 5500-6000 #110 #50 #45 #105 #50 #50 0.47-0.63 in. (12.0-16.0 mm) CYLINDER BLOCK Type Displacement Number of Cylinders 4 Stroke Cycle – Over Head Camshaft 30.4 cu. in. (498cc) 2 STROKE Length 2.953 in. (75 mm) CYLINDER BORE Diameter Standard Oversize-0.010 in. (0.25 mm) Oversize-0.020 in. (0.50 mm) Taper/Out of Round Maximum Bore Type 2.5591 in. (65 mm) 2.5689 in. (65.25 mm) 2.5787 in. (65.5 mm) 0.003 in. (0.08 mm) Cast Iron PISTON Piston Type O.D. at Skirt Standard Oversize-0.010 in. (0.25mm) Oversize-0.020 in. (0.50mm) Aluminum 2.5570 - 2.5578 in. (64.950 - 64.965 mm) 2.5669 - 2.5675 in. (65.2 - 65.215 mm) 2.5768 - 2.5774 in. (65.450 - 65.465 mm) PISTON CLEARANCE Piston to Cylinder Clearance 0.0014 - .0026 in. (0.035 - 0.065 mm) RINGS Ring End Gap (Installed) Top Middle Bottom (Oil Ring) Side Clearance: Top Middle 0.006 - 0.012 in. (0.15 - 0.30 mm) 0.012 - 0.020 in. (0.30 - 0.50 mm) 0.008 - 0.028 in. (0.20 - 0.70 mm) 0.0008 - 0.0024 in. (0.02 - 0.06 mm) 0.0008 - 0.0024 in. (0.02 - 0.06 mm) BALANCE PISTON Wear Limit 3.735 in. (94.883 mm) CRANKCASE COVER Bore Wear Limit 3.802 in. (95.045 mm) COMPRESSION RATIO Compression Ratio Cylinder Compression* (Electric Models Only, Cold Engine @ W.O.T.) 9.8:1 180 -210 psi (Peak) (1241 - 1448 kPa) PISTON PIN Piston Pin Diameter 0.6285 - 0.6287 in. (15.965 - 15.970 mm) Page 1A-4 90-854785R2 DECEMBER 2001 SPECIFICATIONS CONNECTING ROD Oil Clearance (Big End) Small End Inside Diameter 0.0008 - 0.0020 in. (0.020 - 0.052 mm) 0.6293 - 0.6298 in. (15.985 - 15.998 mm) CRANKSHAFT Main Bearing Clearance Crankshaft Run-out 0.0005 - 0.0017 in. (0.012 - 0.044 mm) 0.0012 in. (0.03 mm) *NOTE:Manual start models are equipped with compression relief mechanism which will not allow compression testing. Camshaft Dimensions Intake “A” 1.216 - 1.220 in. (30.89 - 30.99 mm) Exhaust “A” A 1.216 - 1.220 in. (30.89 - 30.99 mm) Intake “B” 1.022 - 1.025 in. (25.95 - 26.05 mm) Exhaust “B” 1.022 - 1.025 in. (25.95 - 26.05 mm) Run-out Limit B 0.0039 in. (0.1 mm) Camshaft Bearing Diameter “b” 1.4541 - 1.4549 in. CAMSHAFT (36.935 - 36.955 mm) b b b Free Length “a” Tilt Limit “b” b 1.491-1.569 in. (37.85-39.85 mm) Less than 0.060 in. (1.7 mm) VALVE SPRING a Compressed Pressure (Installed) Intake Exhaust Tilt Limit (Intake & Exhaust) Dir. of Winding (Intake & Exhaust) 19.8 - 22.0 lbs. (9.0 - 10.0 kg) 19.8 - 22.0 lbs. (9.0 - 10.0 kg) 0.043 in. (1.1 mm) Left Hand 90-854785R2 DECEMBER 2001 Page 1A-5 SPECIFICATIONS Page 1A-6 90-854785R2 DECEMBER 2001 CYLINDER HEAD Warp Limit * Lines indicate straight edge measurement Camshaft Bore Inside Diameter “a” a a a 0.004 in. (0.1 mm) 1.4567 - 1.4577 in. (37.000 - 37.025 mm) VALVES Valve/Valve Seat/Valve Guides: Valve Clearance (cold) Intake Exhaust Valve Dimensions: “A” Head Diameter Intake Exhaust “B” Face Width Intake Exhaust “C” Seat Width Intake Exhaust “D” Margin Thickness Intake Exhaust Stem Outside Diameter Intake Exhaust Guide Inside Diameter Intake Exhaust Stem To Guide Clearance Intake Exhaust Stem Run-out Limit (max.) 0.006 - 0.010 in. (0.15 - 0.25 mm) 0.010 - 0.014 in. (0.25 - 0.35 mm) 1.256 - 1.264 in. (31.9 - 32.1 mm) 1.020 - 1.028 in. (25.9 - 26.1 mm) 0.079 - 0.124 in. (2.00 - 3.14 mm) 0.079 - 0.124 in. (2.00 - 3.14 mm) 0.035 - 0.043 in. (0.9 - 1.1 mm) 0.035 - 0.043 in. (0.9 - 1.1 mm) 0.020 - 0.035 in. (0.5 - 0.9 mm) 0.020 - 0.035 in. (0.5 - 0.9 mm) 0.2156 - 0.2161 in. (5.475 - 5.490 mm) 0.2150 - 0.2156 in. (5.460 - 5.475 mm) 0.2165 - 0.2170 in. (5.500 - 5.512 mm) 0.2165 - 0.2170 in. (5.500 - 5.512 mm) 0.0004 - 0.0015 in. (0.010 - 0.037 mm) 0.0010 - 0.0020 in. (0.025 - 0.052 mm) 0.0006 in. (0.016 mm) SPECIFICATIONS “B” “C” Valve Dimensions Head Diameter Face Width Seat Width Margin Thickness “A” “D” ROCKER SHAFT Outside Diameter 0.6288 - 0.6296 in. (15.971 - 15.991 mm) ROCKER ARM Inside Diameter of Bore 0.6299 - 0.6306 (16.000 - 16.018 mm) THERMOSTAT Valve Opening Temperature Full Open Temperature Valve Lift (Minimum) 136° F - 143° F (58° C - 62° C) 158° F (70° C) 0.12 in. (3 mm) LUBRICATION SYSTEM Pump Type Engine Oil Pressure Engine Oil Pan Capacity Oil Pump: Outer Rotor to Housing “a” Inner Rotor to Outer Rotor “b” Rotor to Housing “c” a b Trochoid 30-40 PSI at 3000 RPM (Warm Engine) Either 3 Qts. or 3 Liters 0.0035 - 0.006 in. (0.09 - 0.15 mm) 0.005 in. (0.12 mm) 0.001 - 0.003 in. (0.03 - 0.08 mm) c 90-854785R2 DECEMBER 2001 Page 1A-7 SPECIFICATIONS Transom Height: Short Shaft 15 in. (38 cm) Long Shaft 20 in. (51 cm) MID-SECTION Steering Pivot Range 90° Tilt Pin Positions 5 + Shallow Water Full Tilt Up Angle 70° Allowable Transom Thickness 2-3/8 in. (60.3 mm) GEAR HOUSING (2.42:1) Gear Ratio Gearcase Capacity Lubricant Type Forward Gear Number of Teeth Pinion Gear Number of Teeth Pinion Height Forward Gear Backlash Water Pressure @ Idle @ WOT 2.42:1 14.9 fl. oz. (440 mL) Premium Blend Gear Lube 29 Spiral/Bevel 12 Spiral/Bevel 0.025 in. (0.64 mm) No Adjustment 2 - 4 PSI @ 800 rpm 12-17 PSI @ 6000 rpm Propeller Information Chart Wide Open Throttle RPM: 5500-6000 Recommended Transom Heights : 15”, 20”, 22.5” Right Hand Rotation Standard Gear Reduction : 2.42 : 1 *Standard with outboard Diameter Pitch No. of Blades Material Approx. Gross Boat Wgt. (lbs) Approx. Boat Length Speed Range (mph) Propeller Part Number 10-1/8” 15” 3 Steel Up to 800 Up to 14’ 28-34 48-76232A5 10-1/8” 15” 3 Alum Up to 800 Up to 14’ 28-34 48-73140A40 10-1/4” 14” 3 Steel 600-900 Up to 14’ 26-31 48-76230A5 10-1/4” 14” 3 Alum 600-900 Up to 14’ 26-31 48-73138A40 10-3/8” 13” 3 Steel 700-1000 13-15’ 24-29 48-76228A5 10-3/8” 13” 3 Alum 700-1000 13-15’ 24-29 48-73136A40 10-5/8” 12” 3 Steel 800-1100 14-16’ 21-26 48-79792A5 10-5/8” 12” 3 Alum 800-1100 14-16’ 21-26 48-73134A40 11-5/8” 11” 3 Steel 1000-1300 15-17’ 19-23 48-823478A5 10-7/8” 11” 3 Alum 1000-1300 15-17’ 19-23 48-85632A45* 11-5/8” 10-1/2” 3 Alum 1200-1500 16-18’ 17-21 48-827312A10 11-1/4” 10” 3 Alum 1300-1700 17-20’ 15-20 48-73132A40 12-1/4” 9” 3 Steel 1500+ 18’+ 10-16 48-97868A10 12-1/4” 9” 3 Alum 1500+ 18’+ 10-16 48-87818A10 12-1/2” 8” 3 Alum 2000+ 20’+ 1-4 48-42738A10 Page 1A-8 90-854785R2 DECEMBER 2001 SPECIFICATIONS Mercury/Quicksilver Lubricants and Sealants Description Mercury Part Number Quicksilver Part Number Needle Bearing Assy. Lubricant [8 oz. (226.8 grams)] tube 92-802868A1 N/A Dielectric Grease [8 oz. (226.8 grams)] can 92-823506-1 92-823506-1 Loctite 271 – Thread Locker (10 ml) tube 92-809819 92-809819 Loctite 567 PST Pipe Sealant (50 ml) tube 92-809822 92-809822 Loctite Master Gasket Kit 92-12564-2 92-12564-2 2 Cycle Premium Outboard Oil [1 Gallon (3.7 liter)] 92-802815A1 92-802815Q1 Perfect Seal [16 oz. (0.45 kg)] can 92-34227-1 92-34227-1 Liquid Neoprene [8 oz. (226.8 grams)] can 92-25711-3 92-25711-3 Cyanacrylate Adhesive Obtain Locally Obtain Locally Bellows Adhesive N/A 92-86166Q1 Loctite 680 Retaining Compound (10 ml) tube 92-809833 92-809833 Loctite 222 Thread Locker (10 ml) tube 92-809818 92-809818 3M Permabond #3M08155 Obtain Locally Obtain Locally Loctite 242 Thread Locker (10 ml) tube 92-809821 92-809821 Loctite 609 Obtain Locally Obtain Locally Loctite 405 Obtain Locally Obtain Locally SAE 10W Oil Obtain Locally Obtain Locally Moly Grease Obtain Locally Obtain Locally Power Tune Engine Cleaner [13 oz. (384 ml)] spray can 92-802878 57 92-802878Q57 Corrosion Guard [11 oz. (325 ml)] spray can 92-802878 55 92-802878Q55 Fuel System Treatment & Stabilizer [12 oz. (355 ml)] plastic bottle 92-802875A1 92-802875Q1 90-854785R2 DECEMBER 2001 Page 1A-9 SPECIFICATIONS Description Mercury Part Number Quicksilver Part Number RTV 587 Silicone Sealer [3 oz. (85.05 grams)] 92-809825 92-809825 Loctite 262 Obtain Locally Obtain Locally Premium Gear Lubricant [1 Quart (0.94 liter)] 92-802846A1 92-802846Q1 Loctite 7649 Primer [4.5 oz (127.57 grams)] 92-809824 92-809824 Anti-Corrosion Grease [8 oz. (226.8 grams)] tube 92-802867A1 92-802867Q1 2-4-C with Teflon [8 oz. (226.8 grams)] tube 92-802859A1 92-802859Q1 Loctite Quick Tite Obtain Locally Obtain Locally Isopropyl Alcohol Obtain Locally Obtain Locally Hot Glue Obtain Locally Obtain Locally Special Lubricant 101 [8 oz. (226.8 grams)] tube 92-802865A1 92-802865Q1 4 Stroke 10W30 Outboard Oil [1 Quart (0.94 liter)] 92-802833A1 92-802833Q1 4 Cycle 25W40 Engine Oil [1 Quart (0.94 liter)] 92-802837A1 92-802837Q1 Power Trim & Steering Fluid [8 oz. (226.8 grams)] 92-802880A1 92-802880Q1 Engine Coupler Spline Grease [14 oz. (0.39 kg)] cartridge 92-802869A1 92-802869Q1 Page 1A-10 90-854785R2 DECEMBER 2001 SPECIFICATIONS Torque Specifications Fastener Location Diameter x Length (mm) Torque lb-in. lb-ft Nm ELECTRICAL Flywheel Cover Screw M6 x 25 45 5 Stator Screw 85 9.6 Flywheel Nut 116 157 Electrical Components Solenoid – Ignition Wire Nut 8-32 (in.) 25 3 Solenoid – Battery Cable Nut 1/4-20 (in.) 60 7 Starter Mounting (Electric) M8 x 45 22 29 Starter Mounting (Manual) M8 x 25 22 29 Solenoid Mounting Screw (Electric) M6 x 30 75 8.5 Solenoid Mounting Screw (Manual) M6 x 16 75 8.5 Crank Position Sensor Mounting Screw M5 x 16 45 5 ECM Mounting Screw M6 x 40 45 5 Sparkplug 12mm 150 17 Coil Mounting Screw M6 x 30 75 8.5 Voltage Regulator Mounting Screw M6 x 40 105 12 Temperature Sensor Retainer Screw M6 x 13 75 8.5 Starter Motor Through Screw 70 8.0 FUEL SYSTEM Fuel Pump Assembly Through Screw Drive Tight Check Valve Screw Drive Tight Mounting Screw M6 x 30 75 8.5 Carburetor Mounting Screw M6 x 25 75 8.5 Mounting Screw M6 x 100 75 8.5 90-854785R2 DECEMBER 2001 Page 1A-11 SPECIFICATIONS Fastener Location Diameter x Length (mm) Torque lb-in. lb-ft Nm POWERHEAD Cylinder Head * Cylinder Head Screws M9 x 95 34.5 47 * Cylinder Head Screws M6 x 25 106 12 Anode Cover Screw M6 x 20 70 8 Cylinder Head Cover Screws M6 x 20 70 8 Intake/Exhaust Valves Valve Adjusting Nuts M6 120 13.5 Rocker Arm Shaft Screws M8 x 30 13 18 Camshaft/Oil Pump Driven Gear Screw M8 x 40 28 38 Oil Pump Mounting Screw M6 x 35 70 8 Oil Pump Cover Screw 70 8 Camshaft Retaining Screw 57 6.5 Cylinder Block/Crankcase * Crankcase Cover Screws – Center M8 x 82 22 30 Crankcase Cover Screws – Outer M6 x 35 106 12 Cover Screw M6 x 20 115 13 Exhaust and Thermostat Cover Screws M6 x 35 106 12 Connecting Rod Screws Special 150 17 Oil Filter N/A 70 8 Oil Filter Nipple N/A 29.5 40 Powerhead Mounting Screws 20 38 Lifting Eye Screw M8 x 35 17.5 24 Breather Cover Screw M6 x 20 115 13 Balance Piston Nut 116 158 NOTE:* = Must be tightened in sequence and two stages. See appropriate section. Page 1A-12 90-854785R2 DECEMBER 2001 SPECIFICATIONS Fastener Location DIameter x Length (mm) Torque lb-in. lb-ft Nm MID-SECTION Clamp Bracket / Swivel Bracket Grease Fittings 33 3.5 * Tilt Tube Nut 32 43.5 * Link Rod Nylon Insert Nut 20 Anode Screw M6x25 60 6.8 Clamp Bracket Stud Nut M10 x 1.5 28 37.9 Thumb Screw Assembly 60 7 Reverse Lock Link Nut 90 10 Gas Assist Trim Anchor Pin Nut 17.5 23.5 Gas Assist Trim Lever Arm Link Nut 90 10 Driveshaft Housing Adaptor Plate Mounting Screw 28 38 Oil Drain Plug N/A 17.5 23.5 Gear Housing Mounting Stud M10 144 16.5 Mounting Stud Nut M10 40 54.5 Driveshaft Housing Mounting Screw M8 x 45 28 38 Adaptor Plate Adaptor Plate Screw M6 x 1 x 20 75 8.5 Oil Pressure Relief Body N/A 34 46 Steering Arm Co-Pilot Plate Screw (Shoulder) ¼-20 x 0.68 in. 70 8 Upper Mount Screw/Nut M6 x 20 130 14.5 Steering Arm Bracket Screw M10 x 30 32.5 44 Upper Mount Bolt/Nuts M12 x 154 50 68 Lower Mount Screw/Nut M10 x 105 32.5 44 Ground Screws 10-16 x 0.38 Drive Tight Power Trim Shock Rod Piston N/A 45 61 Cylinder End Cap N/A 45 61 Tilt Relief Assembly Plug N/A 120 13.5 Suction Seat Assembly Plug N/A 120 13.5 Pilot Check Valve Plug N/A 120 13.5 Pump Assembly Screw 10-32 x 1-1/4 in. 70 8 Motor Assembly Screw 1/4-28 x 5/8 in. 80 9.0 Manual Release Valve N/A Drive Tight Reservoir Plug N/A Drive Tight Power Trim Anchor Pin Nut 14mm 18 24.5 NOTE: * = Tighten to specified torque, then back off 1/4 turn. 90-854785R2 DECEMBER 2001 Page 1A-13 SPECIFICATIONS Fastener Location DIameter x Length (mm) Torque lb-in. lb-ft Nm Manual Tilt Assist Shock Rod Piston N/A 45 61 Cylinder End Cap N/A 45 61 Anchor Pin Nuts 14mm 17.5 23.5 LOWER UNIT Bigfoot Gear Housing Bearing Carrier Nut M8 x 25 16.5 22.5 Input Shaft Nut 50 68 Water Pump Cover Screws M6 x 16 60 7 Vent, Fill/Drain, Oil Level Screw N/A 60 7 Gear Housing Mounting Bolt/Nut 40 54 Trim Tab Screw M8 x 20 16 21.5 Propeller Nut N/A 55 75 CONTROL LINKAGE Throttle/Shift Linkage Throttle/Shift Lever Screw M8 x 70 100 11.3 Throttle Cam Mounting Screw M6 x 35 85 9.6 Throttle Cable Bracket Screws – Electric Handle Models M3 x 20 20 2.5 Throttle Cable Bracket Screws – Manual Handle Models M6 x 16 75 8.5 Shift Spring Screw M5 x 16 45 5 Neutral Start Switch Screws M3 x 20 20 2.3 Tiller Handle Tiller Mounting Bracket Screws M10 x 90 35 47.5 Shift Handle Screw M8 x 35 100 11.5 Tiller Mount Cover Screws M8 x 25 135 15.5 Pulley Case Screws Self Tapping 10-16 x ½ in. 20 2.5 Stop Wire Retaining Screw M5 x 16 35 4 Pulley Cover Screw 20 2.5 Page 1A-14 90-854785R2 DECEMBER 2001 MAINTENANCE IMPORTANT INFORMATION Section 1B - Maintenance Table of Contents 1 B Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-2 Checking Power Trim Fluid . . . . . . . . . . . . . . . . 1B-12 Inspection And Maintenance Schedule . . . . . . 1B-2 Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . 1B-13 Before Each Use . . . . . . . . . . . . . . . . . . . . . . 1B-2 Oil Changing Procedure . . . . . . . . . . . . . . . . 1B-13 After Each Use . . . . . . . . . . . . . . . . . . . . . . . . 1B-3 Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . 1B-14 Every 100 Hours of Use or Once yearly, Oil Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-14 Whichever occurs first . . . . . . . . . . . . . . . . . 1B-3 Gear Case Lubrication . . . . . . . . . . . . . . . . . . . . 1B-15 Every 300 Hours of Use or Three Years . . 1B-3 Draining Gear Case . . . . . . . . . . . . . . . . . . . 1B-15 Before Periods of Storage . . . . . . . . . . . . . . 1B-3 Gear Case Lubricant Capacity . . . . . . . . . . 1B-15 Flushing The Cooling System . . . . . . . . . . . . . . 1B-4 Checking Gear Case Lubricant Level Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5 and Refilling Gear Case . . . . . . . . . . . . . . . . 1B-16 Fuel Line Filter . . . . . . . . . . . . . . . . . . . . . . . . 1B-5 Storage Preparation . . . . . . . . . . . . . . . . . . . . . . 1B-16 Fuel Line Inspection . . . . . . . . . . . . . . . . . . . 1B-5 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-17 Corrosion Control Anode . . . . . . . . . . . . . . . . . . 1B-6 Protecting External Outboard Components 1B-17 Spark Plug Inspection . . . . . . . . . . . . . . . . . . . . . 1B-7 Protecting Internal Engine Components . . 1B-17 Battery Inspection . . . . . . . . . . . . . . . . . . . . . . . . 1B-8 Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-17 Fuse Replacement – Electric Start Models . . . 1B-9 Positioning Outboard for Storage . . . . . . . . 1B-17 Timing Belt Inspection . . . . . . . . . . . . . . . . . . . . 1B-9 Battery Storage . . . . . . . . . . . . . . . . . . . . . . . 1B-17 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . 1B-10 90-854785R2 DECEMBER 2001 Page 1B-1 MAINTENANCE Special Tools 1. Crankcase Oil Pump P/N 90265A2. 2. Oil Filter Wrench (P/N 91-802653). Inspection And Maintenance Schedule To keep your outboard in the best operating condition, it is important that your outboard receive the periodic inspections and maintenance listed in the Inspection and Maintenance Schedule. We urge you to keep it maintained properly to ensure the safety of you and your passengers and retain its dependability. WARNING Neglected inspection and maintenance service of your outboard or attempting to perform maintenance or repair on your outboard if you are not familiar with the correct service and safety procedures could cause personal injury, death, or product failure. Before Each Use 1. Check engine oil level. 2. Check that lanyard stop switch stops the engine. 3. Visually inspect the fuel system for deterioration or leaks. 4. Check outboard for tightness on transom. 5. Check steering system for binding or loose components. 6. Visually check steering link rod fasteners for proper tightness. 7. Check propeller blades for damage. Page 1B-2 90-854785R2 DECEMBER 2001 MAINTENANCE After Each Use 1. Flush out the outboard cooling system if operating in salt or polluted water. 2. Wash off all salt deposits and flush out the exhaust outlet of the propeller and gear case with fresh water if operating in salt water. Every 100 Hours of Use or Once yearly, Whichever occurs first 1. Lubricate all lubrication points. Lubricate more frequently when used in salt water. 2. Change engine oil and replace the oil filter. The oil should be changed more often when the engine is operated under adverse conditions such as extended trolling. 3. Inspect thermostat visually for corrosion, broken spring, and to determine that the valve is completely closed at room temperature. If questionable, inspect thermostat as outlined in Section 4B “Thermostat”. 4. Inspect and clean spark plugs. 5. Check engine fuel filter for contaminants. 6. Adjust carburetor(s) (if required). 7. Check engine timing setup. 8. Check corrosion control anodes. Check more frequently when used in salt water. 9. Drain and replace gear case lubricant. 10. Lubricate splines on the drive shaft. 11. Check and adjust valve clearance, if necessary. 12. Check power trim fluid. 13. Inspect battery. 14. Check control cable adjustments. 15. Inspect timing belt. 16. Remove engine deposits with Power Tune Engine Cleaner. 17. Check tightness of bolts, nuts, and other fasteners. Every 300 Hours of Use or Three Years 1. Replace water pump impeller (more often if overheating occurs or reduced water pressure is noted). Before Periods of Storage 1. Refer to Storage procedure (this section). 90-854785R2 DECEMBER 2001 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. IMPORTANT: The engine must be run during flushing in order to open the thermostat and circulate water through the water passages. NOTE:You can have the outboard tilted or in the vertical operating position during flushing. WARNING To avoid possible injury when flushing, remove the propeller. Refer to Propeller Replacement. 1. Place the outboard in either the operating position (vertical) or in a tilted position. 2. Remove propeller (refer to Propeller Replacement). 3. Thread a water hose into the rear fitting. 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. a b a-Water Hose b-Rear Fitting IMPORTANT: Do not run engine above idle when flushing. 4. Shift outboard into neutral. Start the engine and flush the cooling system for at least 5 minutes. Keep engine speed at idle. 5. Stop the engine. Turn off the water and remove hose. Reinstall the propeller. Page 1B-4 90-854785R2 DECEMBER 2001 MAINTENANCE Fuel System WARNING 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 engine and disconnect the battery. Drain the fuel system completely. Use an approved container to collect and store fuel. Wipe up any spillage immediately. Material used to contain spillage must be disposed of in an approved receptacle. Any fuel system service must be performed in a well ventilated area. Inspect any completed service work for sign of fuel leakage. Fuel Line Filter 55771 a a-Fuel Line Filter 1. Inspect the fuel line filter. If the filter appears to be contaminated, remove and replace. IMPORTANT: Visually inspect for fuel leakage from the filter connections by squeezing the primer bulb until firm, forcing fuel into the filter. Fuel Line Inspection Visually inspect the fuel line and primer bulb for cracks, swelling, leaks, hardness, or other signs of deterioration or damage. If any of these conditions is found, the fuel line or primer bulb must be replaced. 90-854785R2 DECEMBER 2001 Page 1B-5 MAINTENANCE Corrosion Control Anode Your outboard has four corrosion control anodes. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard metals. Each anode requires periodic inspection especially in salt water which will accelerate the erosion. To maintain this corrosion protection, always replace the anode before it is completely eroded. Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode. 1. One of the anodes is the trim tab installed on the gear case. A second anode is installed on the bottom of the transom bracket assembly. a b a-Trim Tab b-Anode Page 1B-6 90-854785R2 DECEMBER 2001 MAINTENANCE 2. Two anodes are installed in the engine block. Remove anodes at locations shown. Install each anode with rubber seal and cover. Tighten screws to the specified torque. c-Anodes d-Rubber Seal e-Cover cd e Anode Cover Torque 70 lb. in. (8 N·m) Spark Plug Inspection Inspect spark plugs at the recommended intervals. 1. Remove the spark plug leads by twisting the rubber boots slightly and pull off. 90-854785R2 DECEMBER 2001 Page 1B-7 MAINTENANCE 2. Remove the spark plugs to inspect and clean. Replace spark plug if electrode is worn or the insulator is rough, cracked, broken, blistered or fouled. 3. Set the spark plug gap. See Specification Chart. 4. Before reinstalling spark plugs, clean away dirt on the spark plug seats. Install plugs finger tight, and tighten 1/4 turn or to the specified torque. Spark Plug Torque 150 lb. in. (17 N·m) Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability. IMPORTANT: Read the safety and maintenance instructions which accompany your battery. 1. Turn off the engine before servicing the battery. 2. Add water as necessary to keep the battery full. 3. Make sure the battery is secure against movement. 4. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive and negative to negative. 5. Make sure the battery is equipped with a nonconductive shield to prevent accidental shorting of battery terminals. Page 1B-8 90-854785R2 DECEMBER 2001 MAINTENANCE 90-854785R2 DECEMBER 2001 Page 1B-9 Fuse Replacement – Electric Start Models The electric starting circuit is protected from overload by an SFE 20 AMP fuse. 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 rating. 1. Open the fuse holder and look at the silver colored band inside the fuse. If band is broken (a), replace the fuse. Replace fuse with a new fuse with the same rating. a Timing Belt Inspection 1. Inspect the timing belt and replace if any of the following conditions are found. a. Cracks in the back of the belt or in the base of the belt teeth. b. Excessive wear at the roots of the cogs. c. Rubber portion swollen by oil. d. Belt surfaces roughened. e. Signs of wear on edges or outer surfaces of belt. a a - Timing Belt MAINTENANCE Lubrication Points Lubricate Point 1 with Anti-Corrosion Grease or 2-4-C Marine Lubricant with Teflon 1. Propeller Shaft – Refer to Propeller Replacement for removal and installation of the propeller. Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft. 1 Lubricate Points 2 thru 4 with 2-4-C Marine Lubricant with Teflon or Special Lubricant 101. 2. Swivel Bracket – Lubricate through fitting. 2 3. Tilt Tube – Lubricate through fittings. 4. Co-Pilot shaft (Tiller Handle Models)-Lubricate through fitting. Move steering friction lever back and forth while lubricating. 334 Page 1B-10 90-854785R2 DECEMBER 2001 MAINTENANCE 5. Lubricate threads on transom clamp screws (if equipped). 5 6. Steering Cable – Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube. Lubricate through fitting. 66ab a-Steering Cable End b-Fitting WARNING The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant. Adding lubricant to steering cable when fully extended could cause steering cable to become hydraulically locked. An hydraulically locked steering cable will cause loss of steering control, possibly resulting in serious injury or death. Lubricate Point 7 with light weight oil. 7. Steering Link Rod Pivot Points – Lubricate points. 7 90-854785R2 DECEMBER 2001 Page 1B-11 MAINTENANCE Checking Power Trim Fluid 1. Tilt outboard to the full up position and engage the tilt support lock. a a-Tilt Support Lock 2. Remove fill cap and check fluid level. The fluid level should be even with the bottom of the fill hole. Add Power Trim & Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. a a-Fill Cap Page 1B-12 90-854785R2 DECEMBER 2001 MAINTENANCE 90-854785R2 DECEMBER 2001 Page 1B-13 Changing Engine Oil Engine Oil Capacity 3 U.S. Quarts (3.0 Liters) Oil Changing Procedure Pump Method 1. Place the outboard in an vertical upright position. 2. Remove dipstick and thread a Quicksilver Crankcase Oil Pump onto the dipstick tube. Pump out the engine oil into an appropriate container. a a - Crankcase Oil Pump Drain Plug Method 1. Tilt the outboard up to the trailer position. 2. Turn the steering on the outboard so that the drain hole is facing downward. Remove drain plug and drain engine oil into an appropriate container. Lubricate the seal on the drain plug with oil and reinstall. a a - Drain Hole MAINTENANCE Page 1B-14 90-854785R2 DECEMBER 2001 Changing Oil Filter 1. Place a rag or towel below the oil filter to absorb any spilled oil. 2. Unscrew old filter by turning the filter to the left. 3. Clean the mounting base. Apply film of clean oil to filter gasket. Do not use grease. Screw new filter on until gasket contacts base, then tighten 3/4 to 1 turn. 55854 91-802653 a b a - Oil Filter b - Oil Filter Wrench (91-802653) Oil Filling 1. Remove the oil fill cap and add oil to to proper operating level. 2. Idle engine for five minutes and check for leaks. Stop engine and check oil level on dipstick. Add oil if necessary. c c - Oil Fill Cap MAINTENANCE Gear Case Lubrication When adding or changing gear case lubricant, visually check for the presence of water in the lubricant. If water is present, it may have settled to the bottom and will drain out prior to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance. If water is noticed, have the gear case checked by your dealer. Water in the lubricant may result in premature bearing failure, or in freezing temperatures, will turn to ice and damage the gear case. Whenever you remove the fill/drain plug, examine the magnetic end for metal particles. A small amount of metal filings or fine metal particles indicates normal gear wear. An excessive amount of metal filings or larger particles (chips) may indicate abnormal gear wear and should be checked by an authorized dealer. Draining Gear Case 1. Place outboard in a vertical operating position. 2. Place a drain pan below outboard. 3. Remove vent plug and fill/drain plug and drain lubricant. c b a a-Drain Pan b-Vent Plug c-Drain Plug Gear Case Lubricant Capacity Gear case lubricant capacity is approximately 14.9 fl. oz. (440 mL). 90-854785R2 DECEMBER 2001 Page 1B-15 MAINTENANCE Checking Gear Case Lubricant Level and Refilling Gear Case 1. Place outboard in a vertical operating position. 2. Remove vent plug. 3. Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole. a b c a-Vent Plug c-Vent Hole b-Lubricant Tube IMPORTANT: Replace sealing washers if damaged. 4. Stop adding lubricant. Install the vent plug and sealing washer before removing the lubricant tube. 5. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer. d d-Sealing Washer Storage Preparation The major consideration in preparing your outboard for storage is to protect it from rust, corrosion, and damage caused by freezing of trapped water. The following storage procedures should be followed to prepare your outboard for out-ofseason storage or prolonged storage (two months or longer). CAUTION Never start or run your outboard (even momentarily) without water circulating through the cooling water intake in the gear case to prevent damage to the water pump (running dry) or overheating of the engine. Page 1B-16 90-854785R2 DECEMBER 2001 MAINTENANCE Fuel System IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a formation of acid during storage and can damage the fuel system. If the gasoline being use 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 reach the carburetor. Protecting External Outboard Components 1. Lubricate all outboard components listed in the Inspection and Maintenance Schedule. 2. Touch up any paint nicks. 3. Spray Corrosion Guard on external metal surfaces (except corrosion control anodes). Protecting Internal Engine Components 1. Remove the spark plugs and inject a small amount of engine oil inside of each cylinder. 2. Rotate the flywheel manually several times to distribute the oil in the cylinders. Reinstall spark plugs. 3. Change the engine oil. Gear Case 1. Drain and refill the gear case lubricant (refer to maintenance procedure). Positioning Outboard for Storage Store outboard in an upright (vertical) position to allow water to drain out of outboard. CAUTION If outboard is stored tilted up in freezing temperature, trapped cooling water or rain water that may have entered the propeller exhaust outlet in the gear case could freeze and cause damage to the outboard. Battery Storage 1. Follow the battery manufacturer’s instructions for storage and recharging. 2. Remove the battery from the boat and check water level. Recharge if necessary. 3. Store the battery in a cool, dry place. 4. Periodically check the water level and recharge the battery during storage. 90-854785R2 DECEMBER 2001 Page 1B-17 GENERAL INFORMATION IMPORTANT INFORMATION Section 1C - General Information Table of Contents 1 C Serial Number Location . . . . . . . . . . . . . . . . . . . 1C-1 Propeller Removal/Installation . . . . . . . . . . . . . 1C-12 Conditions Affecting Performance . . . . . . . . . . 1C-2 Power Trim System . . . . . . . . . . . . . . . . . . . . . . . 1C-15 Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2 General Information . . . . . . . . . . . . . . . . . . . 1C-15 Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-3 Power Trim Operation . . . . . . . . . . . . . . . . . . 1C-15 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-4 Trim “In” Angle Adjustment . . . . . . . . . . . . . 1C-16 Following Complete Submersion . . . . . . . . . . . 1C-5 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . 1C-17 Submerged While Running . . . . . . . . . . . . . 1C-5 Compression Check . . . . . . . . . . . . . . . . . . . . . . 1C-17 Salt Water Submersion) . . . . . . . . . . . . . . . . 1C-5 Cylinder Leakage Testing . . . . . . . . . . . . . . . . . . 1C-18 Fresh Water Submersion . . . . . . . . . . . . . . . 1C-5 Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-18 Powerhead Front View . . . . . . . . . . . . . . . . . . . . 1C-6 Painting Procedures . . . . . . . . . . . . . . . . . . . . . . 1C-19 Powerhead Starboard View . . . . . . . . . . . . . . . . 1C-7 Cleaning & Painting Aluminum Propellers Powerhead Port View . . . . . . . . . . . . . . . . . . . . . 1C-8 & Gear Housings . . . . . . . . . . . . . . . . . . . . . . 1C-19 Powerhead Top View . . . . . . . . . . . . . . . . . . . . . 1C-9 Decal Application . . . . . . . . . . . . . . . . . . . . . . . . . 1C-20 Powerhead Aft View . . . . . . . . . . . . . . . . . . . . . . 1C-10 Decal Removal . . . . . . . . . . . . . . . . . . . . . . . . 1C-20 Propeller Selection . . . . . . . . . . . . . . . . . . . . . . . 1C-11 Instructions for “Wet” Application . . . . . . . . 1C-20 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. 20XX XX OGXXXXXX XXXX e b c d a a-Serial Number b-Model Year c-Model Description d-Year Manufactured e-Certified Europe Insignia 90-854785R2 DECEMBER 2001 Page 1C-1 GENERAL INFORMATION Conditions Affecting Performance Weather 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 77 °F (25 °C) temperature and a barometric pressure of 29.61 inches of mercury. Summer conditions of high temperature, low barometric pressure and high humidity all combine to reduce the engine power. This, in turn, is reflected in decreased boat speeds--as much as 2 or 3 miles-per-hour (3 or 5 Km per-hour) in some cases. (Refer to previous chart.) Nothing will regain this speed for the boater, but the coming of cool, dry weather. In pointing out the practical consequences of weather effects, an engine--running on a hot, humid summer day--may encounter a loss of as much as 14% of the horsepower it would produce on a dry, brisk spring or fall day. The horsepower that any internal combustion engine produces, depends upon the density of the air that it consumes, and in turn, this density is dependent upon the temperature of the air, its barometric pressure and water vapor (or humidity) content. Accompanying this weather-inspired loss of power is a second but more subtle loss. At rigging time in early spring, the engine was equipped with a propeller that allowed the engine to turn within its recommended RPM range at full throttle. With the coming of the summer weather and the consequent drop in available horsepower, this propeller will, in effect, become too large. Consequently, the engine operates at less than its recommended RPM. Page 1C-2 90-854785R2 DECEMBER 2001 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. 90-854785R2 DECEMBER 2001 Page 1C-3 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 Page 1C-4 90-854785R2 DECEMBER 2001 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 carburetor throats (alcohol will absorbed 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 carburetors 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 carburetors 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, carburetors 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. 90-854785R2 DECEMBER 2001 Page 1C-5 GENERAL INFORMATION Model 25 (4-Stroke) Powerhead Front View 59165 a b c d e h g i f a-Remote Control and Engine Harness Connection b-20 Amp. Fuse c-ECM d-Engine Harness e-Fuel Connection f-Battery Cables g-Throttle and Shift Cable Opening h-Fuel Filter i-Air Intake Page 1C-6 90-854785R2 DECEMBER 2001 GENERAL INFORMATION 90-854785R2 DECEMBER 2001 Page 1C-7 Model 25 (4-Stroke) Powerhead Starboard View 59167 4115h04 a b c d e f h i l k j m n o p g a - Air Intake b - Breather Line c - Lifting Eye d - Auto Enrichener e - Flywheel Cover f - Engine Wiring Harness g - EMC h - Auto Enricher Wires i - Fuel Filter j - Carburetor Vent Line k - Carburetor l - Throttle Cam m - Fuel Pump Inlet n - Fuel Pump Outlet o - Cowl Deflector p - Fill Plug GENERAL INFORMATION Page 1C-8 90-854785R2 DECEMBER 2001 Model 25 (4-Stroke) Powerhead Port View a b c d e f h i g 59174 j o n m l k a - 20 Amp. Fuse b - Start Solenoid c - Oil Pressure Sensor d - Oil Filter e - Thermostat Housing f - Lifting Eye g - Water Temperature Sensor h - Voltage Regulator/Rectifier i - Fuel Pump j - Fuel Pump Cooler Inlet Hose k - Breather Hose l - Oil Dip Stick m - Exhaust Cover n - Engine harness o - Starter Motor GENERAL INFORMATION 90-854785R2 DECEMBER 2001 Page 1C-9 Model 25 (4-Stroke) Powerhead Top View a b d e f g h i j l m c k a - Lift Eye b - Timing Belt c - Crank Position Sensor d - Dipstick e - Thermostat Housing f - Oil Filter g - Start Solenoid h - Starter Motor i - Remote Control and Engine Harness Connection j - Flywheel k - Breather l - Air Intake m - Cam Shaft Timing Gear GENERAL INFORMATION Page 1C-10 90-854785R2 DECEMBER 2001 Model 25 (4-Stroke) Powerhead Aft View 59166 59172 a b d e f g h i j k l c a - Flywheel Cover b - Air Intake c - Breather Hose d - Oil Fill Plug e - Fuel Lines f - Ignition Coil g - Tell Tale Hose h - Fuel Pump i - Valve Cover j - Voltage Regulator k - Fuel Pump Cooler Inlet Hose l - Lifting Eye 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 Section 1A – Specifications) 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.). 90-854785R2 DECEMBER 2001 Page 1C-11 GENERAL INFORMATION Propeller Removal/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. 1. Shift outboard to neutral (N) position. NN 2. Remove the spark plug leads to prevent engine from starting. 3. Straighten the bent tabs on the propeller nut retainer. a a-Propeller Nut Retainer Page 1C-12 90-854785R2 DECEMBER 2001 GENERAL INFORMATION 4. Place a block of wood between gear case and propeller to hold propeller and remove propeller nut. 5. Pull propeller straight off shaft. 6. Coat the propeller shaft with Anti-Corrosion Grease or 2-4-C Marine Lubricant with Teflon. a a-Propeller Shaft IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft, especially in salt water, always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed. 7. Flo-Torque I Drive Hub Propellers – Install forward thrust hub, propeller, propeller nut retainer and propeller nut onto the shaft. b cd a a-Forward Thrust Hub c-Propeller Nut Retainer b-Propeller d-Propeller Nut 90-854785R2 DECEMBER 2001 Page 1C-13 GENERAL INFORMATION 8. Flo-Torque II Drive Hub Propellers – Install forward thrust hub, propeller, replaceable drive sleeve, rear thrust hub retainer and propeller nut onto the shaft. c def a b a-Forward Thrust Hub b-Propeller c-Drive Sleeve d-Rear Thrust Hub e-Retainer f-Propeller Nut 9. Place propeller nut retainer over pins. Place a block of wood between gear case and propeller and tighten propeller nut to the specified torque, aligning flat sides of the propeller nut with tabs on the propeller nut retainer. 10. Secure propeller nut by bending tabs up and against the flats on the propeller nut. a b b a a-Retainer Pins b-Tabs Propeller Nut Torque 55 lb. ft. (75 N·m) 11. Reinstall spark plug leads. Page 1C-14 90-854785R2 DECEMBER 2001 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. 90-854785R2 DECEMBER 2001 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 is desirable to improve acceleration, reduce the angle and time spent in a bow high boat during planing off, and in some cases, may be necessary to plane off a boat with aft live wells, given the variety of available propellers and height range of engine installations. However, once on plane, the engine should be trimmed to a more intermediate position to 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. In rare circumstances, the owner may decide to limit the trim in. This can be accomplished by repositioning the tilt stop pins into whatever adjustment holes in the transom brackets is desired. WARNING Avoid possible serious injury or death. Adjust outboard to an intermediate trim position as soon as boat is on plane to avoid possible ejection due to boat spin-out. Do not attempt to turn boat when on plane if outboard is trimmed extremely in or down and there is a pull on the steering wheel or tiller handle. a a a-Tilt Stop Pins Page 1C-16 90-854785R2 DECEMBER 2001 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 screw 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 screw and retest. Compression Check 1. Remove spark plugs. 2. Install compression gauge in spark plug hole. 3. Hold throttle plate at W.O.T. 4. Crank the engine over until the compression reading peaks on the gauge. Record the reading. 5. Check and record compression of each cylinder. The highest and lowest reading recorded should not differ by more than 15% (see example chart below). A reading below 120 psi might indicate a total engine wear problem. Example of compression test differences Maximum (psi) Minimum (psi) 180 162 150 127.5 6. 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. 90-854785R2 DECEMBER 2001 Page 1C-17 GENERAL INFORMATION 7. Cylinder scoring: If powerhead shows any indication of overheating, such as discolored or scorched paint, visually inspect cylinders for scoring or other damage as outlined in Section 4 “Powerhead.” IMPORTANT: Performing a compression check on engines containing the compres sion relief cam will give inaccurate (low) readings, instead use the following “Cylin der Leakage Testing” procedure. 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. * Courtesy of Snap-On-Tools Cylinder Leakage Tester (Snap-On-Tools MT324) NOTE: Spark plug hole is a 12 mm diameter. Use Snap-On-Tool MT26-18 adapter with valve core removed. 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 it’s compression stroke. Leakage will naturally occur if the exhaust or intake valve is open. To determine the cause of high percentage leaks, you must locate where the air is escaping from. Listen for air escaping thru the carburetor intake, adjacent spark plug holes, exhaust pipe, crankcase fill plug. Use the following table to aid in locating the source of cylinder leakage: Air Escaping From: Indicates Possible Defective: Carburetor Intake Valve Exhaust System Exhaust Valve Crankcase Fill Plug Piston or Rings Adjacent Cylinders Head Gasket Page 1C-18 90-854785R2 DECEMBER 2001 GENERAL INFORMATION Painting Procedures Cleaning & Painting Aluminum Propellers & Gear Housings WARNING Avoid serious injury from flying debris. Avoid serious injury from airborne particles. Use eye and breathing protection with proper ventilation. PROPELLERS 1. Sand the entire area to be painted with 3M 120 Regalite Polycut or coarse Scotch-Brite, disc or belts. 2. Feather edges of all broken paint edges. Try not to sand through the primer. 3. Clean the surface to be painted using PPG Industries DX330 Wax and Grease Remover or equivalent (Xylene or M.E.K.). 4. If bare metal has been exposed, use Mercury/Quicksilver Light Gray Primer. 5. Allow a minimum of 1 hour dry time and no more than 1 week before applying the finish coat. 6. Apply the finish coat using Mercury/Quicksilver EDP Propeller Black. GEAR HOUSINGS The following procedures should be used in refinishing gear housings. This procedure will provide the most durable paint system available in the field. The materials recommended are of high quality and approximate marine requirements. The following procedure will provide a repaint job that compares with a properly applied factory paint finish. It is recommended that the listed materials be purchased from a local Ditzler Automotive Finish Supply Outlet. The minimum package quantity of each material shown following is sufficient to refinish several gear housings. Procedure: 1. Wash gear housing with a muriatic acid base cleaner to remove any type of marine growth, and rinse with water, if necessary. 2. Wash gear housing with soap and water, then rinse. 3. Sand blistered area with 3M 180 grit sandpaper or P180 Gold Film Disc to remove paint blisters only. Feather edge all broken paint edges. 4. Clean gear housing thoroughly with (DX-330) wax and grease remover. 5. Spot repair surfaces where bare metal is exposed with (DX-503) alodine treatment. IMPORTANT: Do not use any type of aerosol spray paints as the paint will not properly adhere to the surface nor will the coating be sufficiently thick to resist future paint blistering. 6. Mix epoxy chromate primer (DP-40) with equal part catalyst (DP-401) per manufacturers instructions, allowing proper induction period for permeation of the epoxy primer and catalyst. 7. Allow a minimum of one hour drying time and no more than one week before top coating assemblies. 8. Use Ditzler Urethane DU9000 for Mercury Black, DU34334 for Mariner Grey, and DU35466 for Force Charcoal, and DU33414M for Sea Ray White. Catalyze all four colors with Ditzler DU5 catalyst mixed 1:1 ratio. Reduce with solvents per Ditzler label. 90-854785R2 DECEMBER 2001 Page 1C-19 GENERAL INFORMATION CAUTION Be sure to comply with instructions on the label for ventilation and respirators. Using a spray gun, apply one half to one mil even film thickness. Let dry, flash off for five minutes and apply another even coat of one half to one mil film thickness. This urethane paint will dry to the touch in a matter of hours, but will remain sensitive to scratches and abrasions for a few days. 9. The type of spray gun used will determine the proper reduction ratio of the paint. IMPORTANT: Do not paint sacrificial zinc trim tab or zinc anode. 10. Cut out a cardboard “plug” for trim tab pocket to keep paint off of mating surface to maintain good continuity circuitry between trim tab and gear housing. Decal Application Decal Removal 1. Mark decal location before removal to assure proper alignment of new decal. 2. Carefully soften decal and decal adhesive with a heat gun or heat blower while removing old decal. 3. Clean decal contact area with a 1:1 mixture of isopropyl alcohol and water. 4. Thoroughly dry decal contact area and check for a completely cleaned surface. Instructions for “Wet” Application NOTE: The following decal installation instructions are provided for a “Wet” installation. All decals should be applied wet. TOOLS REQUIRED 1. Plastic Squeegee* 2. Stick Pin 3. Dish Washing Liquid/Detergent without ammonia. Do not use a soap that contains petroleum based solvents. * Automotive Body Filler Squeegee SERVICE TIP: Placement of decals using the “Wet” application will allow time to position decal. Read entire installation instructions on this technique before proceeding. TEMPERATURE IMPORTANT: Installation of vinyl decals should not be attempted while in direct sun light. Air and surface temperature should be between 60°F (15°C) and 100°F (38°C) for best application. SURFACE PREPARATION IMPORTANT: Do not use a soap or any petroleum based solvents to clean application surface. Clean entire application surface with mild dish washing liquid and water. Rinse surface thoroughly with clean water. Page 1C-20 90-854785R2 DECEMBER 2001 GENERAL INFORMATION DECAL APPLICATION 1. Mix 1/2 ounce (16 ml) of dish washing liquid in one gallon (4 l) of cool water to use as wetting solution. NOTE:Leave protective masking, if present, on the face of decal until final steps of decal installation. This will ensure that the vinyl decal keeps it’s 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). 90-854785R2 DECEMBER 2001 Page 1C-21 OUTBOARD MOTOR INSTALLATION IMPORTANT INFORMATION Section 1D - Outboard Motor Installation Table of Contents 1 D Installation Specifications . . . . . . . . . . . . . . . . . . 1D-1 Lifting Outboard. . . . . . . . . . . . . . . . . . . . . . . . . . 1D-2 Installing Outboard – Non Thumb Screw Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-2 Installing Outboard – Thumb Screw Models . . 1D-3 Steering Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-4 Steering Cable Seal . . . . . . . . . . . . . . . . . . . . . . 1D-5 Steering Link Rod . . . . . . . . . . . . . . . . . . . . . . . . 1D-6 Installation Specifications Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-7 Battery Cable Connections . . . . . . . . . . . . . . . . 1D-8 Shift and Throttle Cable . . . . . . . . . . . . . . . . . . . 1D-9 Shift Cable Installation . . . . . . . . . . . . . . . . . 1D-9 Throttle Cable Installation . . . . . . . . . . . . . . 1D-11 Trim-In Stop Adjustment – Power Trim Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-13 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . 1D-13 a b a a – Transom Opening – Minimum Single Engine (Remote) – 19 in. (483 mm) Single Engine (Tiller) – 30 in. (762 mm) Dual Engines – 40 in. (1016 mm) b – Engine Center Line For Dual Engine 26 in. (660 mm) Minimum 90-854785R2 DECEMBER 2001 Page 1D-1 OUTBOARD MOTOR INSTALLATION Page 1D-2 90-854785R2 DECEMBER 2001 Lifting Outboard 1. Use lifting eye on engine. Installing Outboard – Non Thumb Screw Models 1. Attach (tape) engine mounting template (located in installation manual P/N 90-10184000) 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 or within 1 in. (25 mm) below the bottom of the boat. 0 - 1 in. (0 - 25mm) a a - Anti-Ventilation Plate OUTBOARD MOTOR INSTALLATION 4. Fasten outboard with provided mounting hardware shown. Apply RTV 587 Silicone Sealer to shanks of bolts, not threads. 117 b c a 117 RTV 587 Silicone Sealer a-1/2 in. Diameter Bolts (4) b-Flat Washers (4) c-Locknuts (4) Installing Outboard – Thumb Screw Models WARNING Outboard must be fastened to boat transom one of two ways: 1. permanently fastened to transom with thumb screws, and mounting bolts (provided), or 2. secured to the transom using the optional outboard mounting kit (shown below). Should the outboard strike an underwater object or be steered into a sharp turn, failure to fasten outboard correctly to the boat transom with mounting bolts or optional mounting kit could result in outboard ejecting suddenly off boat transom causing serious injury, death, boat damage, or loss of outboard. 1. Optional outboard mounting kits shown, must be used if outboard will not be permanently fastened to the transom with mounting bolts. a a-Outboard Mounting Kit Part No. 812432A4 90-854785R2 DECEMBER 2001 Page 1D-3 OUTBOARD MOTOR INSTALLATION 2. Center outboard on the transom. 3. Install the outboard so that the anti-ventilation plate is in line or within 1 in. (25 mm) below the bottom of the boat. 0 - 1 in (0 - 25mm) a a-Anti-Ventilation Plate 4. Fasten outboard with provided mounting hardware shown. Apply RTV 587 Silicone Sealer to shanks of bolts, not threads. 117 b c d a 117 RTV 587 Silicone Sealer a-1/2 in. Diameter Bolts (2) b-Flat Washers c-Locknuts d-Thumb Screws - Tighten Securely Steering Cable STARBOARD SIDE ROUTED CABLE 1. Lubricate the entire cable end. 95 95 2-4-C Marine Lubricant with Teflon Page 1D-4 90-854785R2 DECEMBER 2001 OUTBOARD MOTOR INSTALLATION 2. Insert steering cable into tilt tube. 3. Tighten nuts to the specified torque. Steering Cable Nut Torque 35 lb. ft. (47.5 N·m) Steering Cable Seal 1. Mark tilt tube 1/4 in. (6.4 mm) from end. Install seal components. 1/4 in. (6.4mm) b a c d a-1/4 in. (6.4 mm) Mark b-Plastic Spacer c-O-Ring Seal d-Cap 2. Thread cap to the mark. 90-854785R2 DECEMBER 2001 Page 1D-5 OUTBOARD MOTOR INSTALLATION Steering Link Rod 1. Install steering link rod per illustration. b d f c e a a-Special Bolt (10-823919) b-Nylon Insert Locknut (11-826709113) c-Spacer (12-71970) d-Flat Washer (2) e-Nylon Insert Locknut (11-826709113) f-Use Middle Hole (a) Special Bolt Torque 20 lb. ft. (27 N·m) (b) Nylon Insert Locknut Torque 20 lb. ft. (27 N·m) (e) Nylon Insert Locknut Torque Tighten Until It Seats, Then Back Nut Off 1/4 Turn IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special bolt (“a” - P/N 10-823919) and self locking nuts (“b” & “e” - P/N 11-826709113). These locknuts must never be replaced with common nuts (non locking) as they will work loose and vibrate off, freeing the link rod to disengage. WARNING Disengagement of a steering link rod can result in the boat taking a full, sudden, sharp turn. This potentially violent action can cause occupants to be thrown overboard exposing them to serious injury or death. Page 1D-6 90-854785R2 DECEMBER 2001 OUTBOARD MOTOR INSTALLATION 90-854785R2 DECEMBER 2001 Page 1D-7 Wiring Harness 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. 1. Route wiring harness into bottom cowl. 2. Connect wiring. Push the wiring harness connectors together inside the rubber sleeve. Push the retainer over the exposed ends of the connectors. This will hold the connectors together. GRN/WHT BLU/WHT BRN/WHT TAN BLU/WHT GRN/WHT aa BLU/WHT GRN/WHT BRN/WHT BLU/WHT GRN/WHT TAN a c b a - Power Trim Connections b - Rubber Sleeve (25 hp) – Place Harness Connectors Inside c - Retainer (25 hp) – Push Over Connector Ends OUTBOARD MOTOR INSTALLATION Page 1D-8 90-854785R2 DECEMBER 2001 Battery Cable Connections SINGLE OUTBOARD (+) (–) a b c a - Red Sleeve (Positive) b - Black Sleeve (Negative) c - Starting Battery DUAL OUTBOARD 1. 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 Shift and Throttle Cable 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. Shift Cable Installation 1. Position remote control into neutral. N 2. Shift outboard into neutral. 3. Measure the distance between pin and center of lower hole. a b c a-Distance Between Pin And Center of Lower Hole b-Pin c-Lower Hole 90-854785R2 DECEMBER 2001 Page 1D-9 OUTBOARD MOTOR INSTALLATION Page 1D-10 90-854785R2 DECEMBER 2001 4. Fit shift cable through rubber grommet. 5. Push in on the cable end until resistance is felt. 6. While pushing in on the cable end, adjust the cable barrel to attain the measured distance taken in Step 3. a b a - Adjust Cable Barrel To Attain The Measured Distance Taken In Step 3 b - Cable Barrel 7. Place cable barrel into the barrel holder. Fasten cable with retainer. c d c - Place Barrel Into Barrel Holder d - Retainer OUTBOARD MOTOR INSTALLATION 90-854785R2 DECEMBER 2001 Page 1D-11 8. 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. Throttle Cable Installation 1. Position remote control into neutral. N 2. Fit throttle cable through rubber grommet. 3. Install throttle cable with retainer pin. Lock retainer pin in place. a b a - Throttle Cable b - Retainer Pin OUTBOARD MOTOR INSTALLATION Page 1D-12 90-854785R2 DECEMBER 2001 4. Adjust cable barrel until the alignment mark on the cam lines up with center of the roller. a b c a - Cable Barrel b - Alignment Mark c - Roller 5. Fasten control cables with the cable latch. IMPORTANT: After installation, move the remote control handle a few times from the neutral position to the wide-open-throttle position in forward gear. Check for the specified gap between the oval shaped boss and the throttle cam. If necessary, readjust the barrel. OUTBOARD MOTOR INSTALLATION Trim-In Stop Adjustment – Power Trim Models If an adjustment is required to the the trim-in stop, reposition the tilt stop pins as follows: 1. Lock the outboard in the full tilt position. 2. Remove bottom pivot pin. 3. Swing the power trim system outward to gain access to the tilt stop pins. Reposition the tilt stop pins in the desired holes. 4. Reinstall the bottom pivot pin. Tighten nuts to the specified torque. 28216 a b a a-Tilt Stop Pins b-Bottom Pivot Pin Bottom Pivot Pin Nut Torque 18 lb. ft. (24.5 N·m) Trim Tab Adjustment The trim tab can be adjusted within limits to help to 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 the anti-ventilation plate is raised 2 inches (50mm) or more above the boat bottom. 90-854785R2 DECEMBER 2001 Page 1D-13 IGNITION ELECTRICAL Section 2A - Ignition Table of Contents 2 A Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-3 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-4 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-5 Electrical Components . . . . . . . . . . . . . . . . . . . 2A-6 Electrical Components . . . . . . . . . . . . . . . . . . . 2A-7 Ignition Description . . . . . . . . . . . . . . . . . . . . . . 2A-8 Ignition Component Description . . . . . . . . . . . 2A-8 Electronic Control Module (ECM) . . . . . . . 2A-8 Crank Position Sensor . . . . . . . . . . . . . . . . 2A-9 Stator Assembly. . . . . . . . . . . . . . . . . . . . . . 2A-9 Flywheel Assembly . . . . . . . . . . . . . . . . . . . 2A-10 Ignition Coil. . . . . . . . . . . . . . . . . . . . . . . . . . 2A-10 Ignition Test Procedures . . . . . . . . . . . . . . . . . . 2A-10 Direct Voltage Adapter (DVA) . . . . . . . . . . 2A-10 Ignition Troubleshooting . . . . . . . . . . . . . . . . . . 2A-11 Tool: Multimeter/DVA Tester . . . . . . . . . . . 2A-12 Ignition Diagnostic Procedures . . . . . . . . . . . . 2A-14 Recommended Test . . . . . . . . . . . . . . . . . . 2A-15 Testing Ignition Components . . . . . . . . . . . . . . 2A-17 Resistance Tests . . . . . . . . . . . . . . . . . . . . . 2A-17 Engine Coolant Temperature (ECT) Sensor . . . . . . . . . . . . . . . . . . . . . . . . 2A-21 Flywheel Removal and Installation . . . . . . . . . 2A-22 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-22 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-23 Stator Removal and Installation . . . . . . . . . . . 2A-24 Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-25 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-25 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-25 (ECM) Removal and Installation . . . . . . . . . . . 2A-26 Ignition Coil Removal and Installation . . . . . . 2A-27 Voltage Regulator Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 2A-27 Crank Position Sensor Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 2A-28 90-854785R2 DECEMBER 2001 Page 2A-1 IGNITION Specifications IGNITION SYSTEM Readings taken @ 68°F (20°C). Type Spark Plug Type Gap Hex Size Hole Size Torque Firing Order Ignition Timing: Below 800 RPM ECM (p/n 855311--) ECM (p/n 856058--/856190--) ECM (p/n 856190-–/856482-–) ECM (p/n 856177--/856178-–) ECM (p/n 878433--) Fully Advanced (6000 RPM) Charge Coil Resistance Crank Position Sensor Resistance Ignition Coil Resistance: Primary Secondary (W/o Boots) ECM Engine Speed Limiter Soft Reduction (Retards Timing) Spark Cut-Out Reduction (Percentages of ignition spark are Cut-Out) ECM Overheat/Low Oil Pressure Speed Control Oil Pressure Switch Capacitor Discharge Ignition NGK DPR6EA-9 0.035 in. (1.0 mm) 18 mm 12 mm 150 lb-in. (17 Nm) 1-2 10° B.T.D.C 5° B.T.D.C 5° B.T.D.C 5° B.T.D.C 5° B.T.D.C 30° B.T.D.C 660 - 710 W (GRN/WHT - WHT/GRN) 300 - 350 W (RED - WHT) 0.08 - 0.7 W 3.5 - 4.7 kW 6200 RPM 6250 RPM Approximately 2000 RPM Below 2.5 psi (17 kPa) Continuity Alternator Type 6 AMP Manual Alternator: Single Phase (12 Pole) Output 12 Volts-6 Amps. CHARGING SYSTEM Battery Charging Resistance 15 AMP Electric Alternator: 0.9 - 1.1 Ohms (YEL-YEL) Readings taken @ Output 12V-15 Amps. (Rectified/Regulated) 68°F (20°C). Battery Charging Coil Resistance Power Bobbin Resistance 0.22 - 0.24 Ohms (YEL-YEL) (For Electrothermal Valve) 6.7-7.1 Ohms (YEL/BLK-YEL/BLK) Quicksilver Tachometer Setting “6P” or “4” Page 2A-2 90-854785R2 DECEMBER 2001 IGNITION Special Tools 1. Flywheel Holder P/N 90-83163M. 2. Flywheel Puller P/N 91-83164M. 3. Timing Light P/N 91-99379 4. Direct Voltage Adapter P/N 91-89045 5. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1 90-854785R2 DECEMBER 2001 Page 2A-3 IGNITION Page 2A-4 90-854785R2 DECEMBER 2001 FLYWHEEL 110 4-stroke Outboard Oil 110 51 1 2 3 5 4 6 7 8 9 10 11 12 13 51 Loctite 222 Thread Locker 14 IGNITION FLYWHEEL REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 FLYWHEEL COVER ELECTRIC SCREW (M6 x 25)2 4 45 5 3 1 FLYWHEEL (ELECTRIC) 4 1 FLYWHEEL (MANUAL) 5 1 DECAL-Warning Spinning flywheel 6 1 DECAL-Timing Marks 7 1 DECAL-Warning-Neutral 8 1 NUT 116 157 9 1 WASHER 10 1010 3 SCREW MANUAL 85 9.5 3 SCREW ELECTRIC STATOR STATOR 85 9.5 11 1 11 1 12 1 LOAD RING 13 1 DECAL Bodensee Certification 14 1 DECAL-EPA INFORMATION (1999)(SEE NOTE) NOTE: THE EPA LABEL HAS IMPORTANT INFORMATION ON EPA EMISSION REGULATIONS. REPLACE ANY MISSING OR UNREADABLE EPA LABEL. 90-854785R2 DECEMBER 2001 Page 2A-5 IGNITION ELECTRICAL COMPONENTS 6 9 6 6 9 Dielectric Grease Loctite PST Pipe Sealant Page 2A-6 90-854785R2 DECEMBER 2001 IGNITION ELECTRICAL COMPONENTS REFTORQUE REF. NO. QTY. DESCRIPTION lb. in. lb. ft. N·m 1 1 SOLENOID ASSEMBLY 2 2 BUSHING 3 2 GROMMET 4 2 NUT (8-32) (ELECTRIC) 25 3 5 3 NUT (1/4-20) 60 7 6 1 BATTERY CABLE (POSITIVE) 7 1 INSULATOR BOOT 8 1 CABLE 9 1 BATTERY CABLE (NEGATIVE) 10 1 STARTER MOTOR (See breakdown on Starter Motor) 11 3 SCREW (M8 x 45) (ELECTRIC) 22 2911 1 SCREW (M8 x 25) (MANUAL) 22 29 12 2 SCREW (M6 x 30) (ELECTRIC) 75 8.512 1 SCREW (M6 x 16) (MANUAL) 75 8.5 13 1 J CLIP (ELECTRIC) 14 1 J CLIP (MANUAL) 15 1 PRESSURE SWITCH 50 5.5 16 1 SENSOR-Crank Position 17 2 SCREW (M5 x 16) 45 5 18 1 BRACKET (ELECTRIC) 19 1 RETAINER (ELECTRIC) 20 1 RETAINER (ELECTRIC) 21 3 SCREW (M6 x 25) 22 3 WASHER 23 1 PLATE 24 3 BUSHING 25 3 GROMMET 26 1 ECM 27 1 DECAL-Caution Start in Gear 28 3 BUSHING 29 3 SCREW (M6 x 40) 45 5 30 2 SPARK PLUG (NGK DPR6EA-9) 150 12.5 17 31 1 DECAL-Coil Identification31 1 DECAL-Coil Identification 32 1 IGNITION COIL 33 2 GROMMET 34 2 HI–TENSION CABLE 35 2 SCREW (M6 x 30) 75 8.5 36 1 J CLIP 37 1 ENGINE WIRING HARNESS (MANUAL) 37 1 ENGINE WIRING HARNESS (ELECTRIC) 38 1 FUSE (SFE 20 AMP) (ELECTRIC) 39 1 COVER-Autofuse Housing (ELECTRIC) 40 1 SCREW (M6 x 10) (ELECTRIC) 41 1 HARNESS-EXTENSION (ELECTRIC HANDLE) 42 AR STA-STRAP 43 1 J CLIP (MANUAL) 44 1 VOLTAGE REGULATOR 45 2 SCREW (M6 x 40) ELECTRIC 105 12 46 1 OVERSLEEVE 47 1 TEMPERATURE SENSOR 48 1 RETAINER 49 1 SCREW (M6 x 13) 75 8.5 50 1 HORN DRIVER (MANUAL) 90-854785R2 DECEMBER 2001 Page 2A-7 IGNITION Ignition Description The ignition system uses CDI (Capacitor Discharge Ignition). This system provides quick voltage buildup and strong spark required for high power and high performance engines. The CDI ignition system does not incorporate mechanically operated points, therefore making this CDI unit virtually maintenance free. As the flywheel rotates, electrical power (alternating current) is produced by the capacitor charging coil. This power is rectified by diodes so that direct current voltage is utilized by the ignition system. When the ignition driver is off, the D.C. voltage is stored by the capacitor. Once capacitor voltage is charged to its potential, a gate signal is applied on the SCR and the residual current is dissipated through the capacitor charging coils. The electronic control module (ECM) activates the ignition driver in the ECM which allows the capacitor to discharge, causing the spark to occur. Ignition timing is regulated by the ECM which receives status input from a variety of sensors. These sensors include the crank position sensor, engine temperature and oil pressure sender. The voltage discharged to the primary winding of the ignition coil causes a surge of high voltage to be induced in the secondary winding of the ignition coil. This induced voltage of sufficient amplitude causes the spark plugs to fire. Ignition Component Description Electronic Control Module (ECM) Under normal operating conditions the ECM unit controls the following: 1. Controls ignition spark timing by monitoring the crank position sensor, the engine temperature sensor, and the oil pressure sensor. 2. Maintains normal idle timing (see specification). 3. Engine stall. a. The stall saver feature will advance the ignition timing to 15° BTDC if engine falls below 615 RPM. 4. Advances spark timing quickly to 30° BTDC under hard acceleration conditions. 5. Limits RPM of the engine in the event of a over speed condition (cavitation, no load on propeller, and/or under propped), as listed in the following steps: a. Soft Reduction: Ignition timing is gradually retarded to keep engine RPM below 6200. b. Spark Cut-Out Reduction: Percentages of ignition spark will be cut-out according to the degree of over speed RPM reached. Page 2A-8 90-854785R2 DECEMBER 2001 IGNITION 90-854785R2 DECEMBER 2001 Page 2A-9 RPM % Spark Cut-Out 6250 11% 6281 33% 6313 66% 6. Over Heat Protection: Limits engine RPM to 2000 if the engine temperature exceeds 194° F (93° C). The ECM will sound the over heat warning horn (a continuous tone) and turn on the optional Over Heat Warning lamp. Over heat warning will subside if the engine temperature drops below 188° F (87° C) and engine RPM is momentarily dropped below 1000 RPM as a reset condition. The ECM incorporates a 60 second warning system delay to compensate for a warm restart (heat soak) condition. 7. Low Oil Pressure Protection: Limits the engine RPM to 2000 if oil pressure drops below 2.25 +/– 0.75 psi. The ECM will sound the low oil pressure warning horn (intermittent 1 second on - 1 second off) and turn on the optional Low Oil Pressure Warning lamp. Low oil pressure warning will reset by shutting the engine off and restarting at a normal oil pressure. NOTE: The ECM controls all timing operations. There are no timing adjustment required on this engine. Crank Position Sensor 56790 Contains a permanent magnet and is positioned 0.030 ± 0.010, (0.762 ± 0.254mm) from the flywheel teeth. The timed passing of the flywheel teeth through the sensor’s magnetic field enables the ECM to determine engine RPM and crankshaft angle. Stator Assembly a b a - S/N 0G960499 and Below b - S/N 0G960500 and Above The stator assembly located under the flywheel contains the Ignition, auto enrichener, and battery charge coils. All of these coils make up the stator assembly. As the flywheel permanent magnets pass the respective stator coil windings, an AC pulse current is produced at each coil winding when magnet polarity changes. (South to North), (North to South) etc. IGNITION Page 2A-10 90-854785R2 DECEMBER 2001 Flywheel Assembly The flywheel assembly contains six permanently charged magnet segments which are bonded and retained to the inner wall of the flywheel. Each magnet contains a north and a south pole providing a 12 pole system. Ignition Coil The primary (+) side of the ignition coil receives voltage discharged from a capacitor in the ignition (CDI) circuit located inside the ECM. The voltage is multiplied by the coil until it can jump the spark plug gap. The ignition coil will produce a high voltage current each crankshaft revolution, producing a spark at each cylinder at the same time (Waisted Spark Ignition). Ignition coil maximum output is approximately 40,000 volts. 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. IGNITION 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 CDI 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 CDI 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: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. 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. 90-854785R2 DECEMBER 2001 Page 2A-11 IGNITION Tool: Multimeter/DVA Tester 91-99750A1 Component Test Selector Sw. Position DVA Lead Red DVA Lead Black Voltage Reading(1) @300-3000 RPM Coil Primary 400 DVA* Coil (–) Black (B) Lead (2) ** Coil (+) Orange (O) Lead (2) ** 250 - 320 (1) Stator Charge Coil 400 DVA* Green/White (2) Ground 250 - 330 (1) Stator Charge Coil 400 DVA* White/Green Lead (2) Ground 250 - 330 (1) *If using a meter that requires a DVA adapter, place selector switch to the 400 VDC position. ** Reverse Polarity (1) Readings may vary at cranking speed or at idle speed. (2) Back probe the electrical lead bullet connector in order to make connection. Multimeter Ohm Checks Tested Part Multimeter Wires Connected To: Meter Scale Meter Reading Stator Charge Coil Red Black Green/White (2) White/Green (1) R x 1 W 660 - 710 Power Bobbin Charge Coil Red Black Yel/Blk Yel/Blk R x 1 W 6.7-7.1 Stator Battery Charge Coil (6 Amp.) Red Black Yel Yel R x 1 W 0.9-1.1 Stator Battery Charge Coil (15 Amp.) Red Black Yel Yel R x 1 W 0.22-0.24 Crank Position Sensor Red Black Red (1) White (2) R x 1 W 300 - 350 Ignition Coil Primary (with wires disconnected) Red Black Orange (O) Black (B) R x 1 W 0.08 - 0.7 Ignition Coil Secondary (test with coil leads disconnected and the high tension lead cap removed)*** Red Black High Tension Lead #1 High Tension Lead #2 k W 3.5 - 4.7 NOTE: Copper is an excellent conductor, however, resistance may notably vary between low and high temperature. Therefore, reasonable differences can be accepted between resistance readings and specifications. The above readings are for a cold (room temperature) engine. Resistance will increase if the engine is warm. *** High tension lead cap contain a 5k ohm resister. Remove caps when making secondary ignition coil test. Page 2A-12 90-854785R2 DECEMBER 2001 IGNITION 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. 90-854785R2 DECEMBER 2001 Page 2A-13 IGNITION *Recommended Test (1) DVA TEST (Direct Voltage Adapter) (2) OHM TEST (Resistance Testing) (3) Replace Component and Retest (4) Mechanical Test/Repair PROBLEM/CONDITION Probable Cause *Perform Test No. No Spark Condition (Both Cylinders) Crank Position Sensor 2 Stator 1-2 (ECM) Stop Circuit Short to Ground: 3 a - stop circuit lead 2 b - lanyard stop switch 2 c - tiller handle stop button (if sup2 plied) 2 d- remote control harness 2 Ignition Coil 2 Primary Circuit Shorted to Ground Spark Plugs 3 Open Ground Condition: 2 a - ignition coil 3 b - stator ground c - (ECM) 3 No Spark Condition (One Cylinder) High Tension Lead Spark Plug Cap (Resistor) Spark Plug 2 2 3 Weak Spark Condition Ground Connection at: a - Ignition Coil Primary Leads 2 b - Stator 2 c - (ECM) Primary Coil Supply Leads High Resistance To Ground at: 3 a - stop/lanyard switch (water/ corrosion) 2 Weak Charge Coil 1-2 Ignition Coil/High Tension Lead(s) 1-3 Spark Plug(s) 2 Spark Plug Cap (Resistor) 3 Spark Plug Cap Leak 3 (ECM) Failure 3 Timing Fluctuates NOTE: It is considered normal for the timing to fluctuate approximately 1° - 2° within the designated timing window. Loss Of Oil Pressure/Over Heating: a - timing retards and fluctuates, rpm will drop below 2000 rpm Flywheel Key Sheared (ECM) Unit 4 4 3 Page 2A-14 90-854785R2 DECEMBER 2001 IGNITION *Recommended Test (continued) (1) DVA TEST (Direct Voltage Adapter) (2) OHM TEST (Resistance Testing) (3) Replace Component and Retest (4) Mechanical Test/Repair PROBLEM/CONDITION Probable Cause *Perform Test No. Timing Will Not Advance Low Oil Pressure/Engine Over Heating: a - timing retards and fluctuates, rpm will remain below 2000 rpm 4 (ECM) 3 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) 5k W Resistor 2 Spark Plug(s) 3 (ECM) Unit Ground Connection: 3 a - (ECM) 3 b - ignition coil 2 c - stator 2 Engine Hard To Start Cold Debris In Carburetor Enrichener Circuit Weak Spark Condition Throttle Plate in Open Position 4 1 4 Engine Hard To Start Hot Weak Spark Condition Vapor Lock 4 4 Engine Will Not Run Over 2000 RPM Low Oil Pressure/Engine Over Heating: a - timing retards and fluctuates, rpm will remain below 2000 rpm 4 Stator 1-2 Ignition Coil/High Tension Lead(s) 2 (ECM) 3 Spark Plug(s) 3 Engine Occasionally Misfires Charge Coil 1-2 Ignition Coil/High Tension Lead(s) 2 Spark Plug Cap(s) 5k W Resistor 2 Spark Plug(s) Ground Connection at: 3 a - ignition coil 2 b - (ECM) 3 c - stator High Resistance To Ground at: a - stop/lanyard switch (water/corro2 sion) 2 (ECM) 3 Engine Surges Over Boat Under Propped 4 6200 RPM While Under Load NOTE: The engine (ECM) will retard timing and reduce RPM above 6200 RPM. Propeller Hub Spun 4 90-854785R2 DECEMBER 2001 Page 2A-15 IGNITION Testing Ignition Components Resistance Tests When performing resistance tests, all component leads must be disconnected. Readings may very slightly due to temperature changes. NOTE:Readings listed taken at 68° (20° C). NOTE:Refer to section1C General Information(powerhead reference views) for location of components. STATOR (IGNITION CHARGE COIL) b a a-S/N 0G960499 and Below b-S/N 0G960500 and Above METER TEST LEADS METER SCALE READING () RED BLACK RX1RX1 660 710660 - 710GRN/WHT WHT/GRN Page 2A-16 90-854785R2 DECEMBER 2001 IGNITION STATOR AUTO ENRICHENER (POWER BOBBIN CHARGE COIL) b a a-S/N 0G960499 and Below b-S/N 0G960500 and Above METER TEST LEADS METER SCALE READING () RED BLACK RX1RX1 67 716.7 - 7.1YEL/BLK YEL/BLK IGNITION COIL (PRIMARY) a b a-S/N 0G960499 and Below b-S/N 0G960500 and Above METER TEST LEADS METER SCALE READING () RED BLACK RX1RX1 008 070.08 - 0.7ORANGE BLACK NOTE:Should show short circuit condition on meter. 90-854785R2 DECEMBER 2001 Page 2A-17 IGNITION SPARK PLUG CAP REMOVAL NOTE:High tension cables must have spark plug cap removed before testing. Cap contains 5k ohm resistor. IMPORTANT: To remove spark plug cap from high tension leads, turn cap counter clockwise while applying slight outward pressure. DO NOT PULL HARD or lead may be damaged. To install cap, turn cap clockwise threading cap onto high tension lead. IGNITION COIL (SECONDARY) a b a-S/N 0G960499 and Below b-S/N 0G960500 and Above METER TEST LEADS METER SCALE READING () RED BLACK RX1KRX1K 35 473.5 - 4.7#1 CABLE #2 CABLE Page 2A-18 90-854785R2 DECEMBER 2001 IGNITION SPARK PLUG CAP RESISTOR TEST 55853 METER TEST LEADS METER SCALE READING () RED BLACK RX1KRX1K 35-523.5 -5.2WIRE END PLUG END CRANK POSITION SENSOR 12 1 2 METER TEST LEADS METER SCALE READING () RED BLACK RX1RX1 300 350300 - -- 350#1 #2 90-854785R2 DECEMBER 2001 Page 2A-19 IGNITION Engine Coolant Temperature (ECT) Sensor 1. Place the engine coolant 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. If the reading is out of specification, replace the sensor. a a-Temperature Sensor Insert digital or analog ohmmeter test leads into both Tan/Black sensor leads. With engine at temperature (F) indicated, ohm rating should be as indicated. 270 255 240 225 210 195 180 165 150 135 120 105 90 75 60 45 30 15 0 Temperature Sensor Between Black and EACH Tan/Blk wire No Continuity Temperature Sensor 0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 3.2 Resistance (k) Temperature ( F) Page 2A-20 90-854785R2 DECEMBER 2001 IGNITION 90-854785R2 DECEMBER 2001 Page 2A-21 Flywheel Removal and Installation WARNING Engine could possibly start when turning flywheel during removal and installation. To prevent this type of accidental engine starting and possible serious injury, always remove spark plug leads from spark plugs. Removal 1. Disconnect spark plug leads from spark plugs. 2. Remove flywheel cover (electric models) or manual starter (refer to section 8). 55860 a a - Screws (4) 3. Hold flywheel using flywheel holder (91-83163M). Remove nut (30mm) and washer. 55774 91-83163M a a - Flywheel Holder (91-83163M) IGNITION Page 2A-22 90-854785R2 DECEMBER 2001 4. Remove flywheel using puller (91-83164M). 55776 91-83164M a a - Flywheel Puller (91-83164M) Installation 1. Place flywheel key into slot. 2. Install flywheel. Apply oil to threads on crankshaft. a a - Key 3. Hold flywheel using flywheel holder (91-83163M) and tighten nut to the specified torque. 91-83163M 55774 a a - Flywheel Holder (91-83163M) Flywheel Nut Torque 116 lb. ft. (157 N·m) IGNITION 90-854785R2 DECEMBER 2001 Page 2A-23 Stator Removal and Installation 1. Remove sta-strap. 2. Remove stator mounting screws. 3. Reverse steps for installation (refer to wiring diagram Section 2D for correct wire connections). NOTE: Apply Loctite 222 to Threads. 55861 51 a b 51 Loctite 222 Thread Locker a - Stator b - Screws (3) Stator Screw Torque 85 lb. in. (9.5 N·m) 4. Route wires through j-clip and secure bundled connectors with sta-strap. 55862 a b a - J-Clip b - Sta-Strap IGNITION Page 2A-24 90-854785R2 DECEMBER 2001 Timing Belt Removal 1. Remove flywheel and stator. Refer to section 2B Charging and Starting System. 2. Remove timing belt from driven gear and drive gear. a a - Timing Belt Installation Timing Belt Installation Notes: • Protect the timing belt from water and oil. • Use care not to scratch the belt. • Do not use any metal device to help stretch the belt onto the driven gear. 1. Align marks on drive and driven gear with marks on cylinder block as shown. 2. Install timing belt onto drive gear as shown. Numbers/letters on belt should be readable once belt is installed. 3. Install stator and flywheel. Refer to section 2B Charging & Starting System. 1 a c d b e c a - Drive Gear Mark b - Driven Gear Mark c - Cylinder Block Marks d - Timing Belt Installed Correctly e - Timing Belt Installed Incorrectly IGNITION 90-854785R2 DECEMBER 2001 Page 2A-25 (ECM) Removal and Installation 1. Remove and install ECM as shown. 55738 a b Starboard Connecting ECM a - Screws (3) b - Harness Clip a b Port Connecting ECM a - Screws (3) b - Harness Clip (ECM) Mounting Screw Torque 45 lb. in. (5 N·m) IGNITION Ignition Coil Removal and Installation 1. Disconnect spark plug leads from spark plugs. 2. Disconnect ignition coil wires from harness (ORN and BLK/WHT). 3. Remove ignition coil mounting screws. 4. Reverse steps for installation. 55739 b c a a-Cylinder Head Cover b-Ignition Coil c-Screws (2) Ignition Coil Mounting Screw Torque 75 lb. in. (8.5 N·m) Voltage Regulator Removal and Installation 1. Remove sta-strap. 2. Disconnect voltage regulator wires, YEL (2), GRY, and RED. 3. Remove mounting screws and ground wires. Page 2A-26 90-854785R2 DECEMBER 2001 IGNITION 90-854785R2 DECEMBER 2001 Page 2A-27 4. Reverse steps for installation (refer to wiring diagram section 2D for correct wire connections). 55864 a b c b a - Voltage Regulator b - Screws (2) c - Sta-Strap Voltage Regulator Mounting Screw Torque 105 lb. in. (12 N·m) Crank Position Sensor Removal and Installation 1. Disconnect sensor from wiring harness. 2. Remove sensor mounting screws. 3. Reverse steps for installation. a b a - Crank Position Sensor b - Screws (2) Crank Position Sensor Mounting Screw Torque 45 lb. in. (5 N·m) CHARGING & STARTING SYSTEM ELECTRICAL Section 2B - Charging & Starting System Table of Contents 2 B Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-4 Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-6 Recommended Battery. . . . . . . . . . . . . . . . . 2B-6 Operating Engine Without Battery . . . . . . . 2B-6 Battery Charging System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 2B-6 Battery Charging System. . . . . . . . . . . . . . . . . . 2B-7 Description (15 Ampere) . . . . . . . . . . . . . . . 2B-7 Wiring Diagram (15 Ampere). . . . . . . . . . . . 2B-7 Alternator System Test (6 Ampere Stator) . . . . . . . . . . . . . . . . . . . . . 2B-8 Alternator System Test (15 Ampere Stator) . . . . . . . . . . . . . . . . . . . . 2B-9 Stator Ohms Test . . . . . . . . . . . . . . . . . . . . . . . . . 2B-10 Regulator/Rectifier Diode Test . . . . . . . . . . . . . 2B-11 Analog Meter . . . . . . . . . . . . . . . . . . . . . . . . . 2B-11 Digital Meter . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-12 Starting System Components . . . . . . . . . . . . . . 2B-13 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-13 Troubleshooting the Starting Circuit . . . . . . . . . 2B-13 Starter Solenoid Test . . . . . . . . . . . . . . . . . . . 2B-14 Starting Circuit Troubleshooting Flow Chart . . . . . . . . . . . . . 2B-15 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-17 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-17 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-17 Cleaning and Inspection . . . . . . . . . . . . . . . . 2B-19 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-20 Brush Replacement. . . . . . . . . . . . . . . . . . . . 2B-22 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-23 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-26 90-854785R2 DECEMBER 2001 Page 2B-1 CHARGING & STARTING SYSTEM Specifications Alternator Type 6 AMP Manual Alternator: Single Phase (12 Pole) Output 12 Volts-6 Amps. CHARGING SYSTEM Battery Charging Resistance 15 AMP Electric Alternator: 0.9 - 1.1 Ohms (YEL-YEL) Readings taken @ Output 12V-15 Amps. (Rectified/Regulated) 68°F (20°C). Battery Charging Coil Resistance Power Bobbin Resistance 0.22 - 0.24 Ohms (YEL-YEL) (For Electrothermal Valve) 6.7-7.1 Ohms (YEL/BLK-YEL/BLK) Quicksilver Tachometer Setting “6P” or “4” STARTING SYSTEM Manual Start Electric Start: Starter Type Output Ampere Draw Under: (Load) (No Load) Recoil Starter Bendix 1.1 kW 106.0 Amps 21.1 Amps Battery Rating Minimum Requirement 465 Marine Cranking Amps (MCA) BATTERY or 350 Cold Cranking Amps (CCA) For operation below 32° F (0° C) 1000 Marine Cranking Amps (MCA) or 775 Cold Cranking Amps (CCA) Special Tools 1. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1. Page 2B-2 90-854785R2 DECEMBER 2001 CHARGING & STARTING SYSTEM Notes: 90-854785R2 DECEMBER 2001 Page 2B-3 CHARGING & STARTING SYSTEM STARTER MOTOR 11 2 3 4 5 6 7 8 9 10 8 Page 2B-4 90-854785R2 DECEMBER 2001 CHARGING & STARTING SYSTEM STARTER MOTOR REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 STARTER MOTOR 2 1 THRU SCREW 70 8 3 1 DRIVE KIT 4 1 DRIVE ASSEMBLY 5 1 DRIVE CAP 6 1 ARMATURE 7 1 COMMUTATOR CAP 8 1 BRUSH & SPRING KIT 9 1 BRUSH HOLDER 10 2 SCREW 11 1 DECAL-Warning-High voltage 90-854785R2 DECEMBER 2001 Page 2B-5 CHARGING & STARTING SYSTEM Battery Recommended Battery A 12 volt battery with a minimum rating of 465 marine cranking amps (MCA) or 350 cold cranking amps (CCA). For operation below 32° F (0° C) a rating of 1000 Marine Cranking Amps (MCA) or 775 Cold Cranking Amps (CCA) is recommended. Operating Engine Without Battery If desired (or in an emergency), engines equipped with an electric start and alternator can be started and operated without a battery (either disconnected or removed) if “WARNING”, below, is followed. WARNING Before operating engine with battery leads disconnected from battery, disconnect the three wire (stator harness plug) from rectifier. Battery Charging System Troubleshooting CAUTION The charging system may be damaged by: 1) reversed battery cables, 2) running the engine with battery cables disconnected and stator leads connected to rectifier, 3) an open circuit, such as a broken wire or loose connection. A fault in the battery charging system usually will cause the battery to become undercharged. Check battery electrolyte level, and charge battery. See “Electrolyte Level”, and “Charging a Discharged Battery”. If battery will NOT accept a satisfactory charge, replace battery. If battery accepts a satisfactory charge, determine the cause of the charging system problem as follows. 1. Check for correct battery polarity [RED cable to POSITIVE (+) battery terminal]. If polarity was incorrect, check for damaged rectifier. See “RECTIFIER TEST”. 2. Check for loose or corroded battery connections. 3. Visually inspect wiring between stator and battery for cuts, chafing, and disconnected, loose or corroded connection. 4. Excessive electrical load (from too many accessories) will cause battery to run down. If visual inspection determines that battery connections and wiring are OK, perform the following stator and rectifier tests. Page 2B-6 90-854785R2 DECEMBER 2001 CHARGING & STARTING SYSTEM Battery Charging System Description (15 Ampere) The battery charging system components are the stator battery charge coils, regulator and battery. Alternating current (generated in battery charge coils) flows to the regulator, which changes the alternating current to a regulated direct current for charging the battery. Wiring Diagram (15 Ampere) BLK = Black GRY = Gray RED = Red YEL = Yellow e c b a YELYEL YEL YEL GRY RED RED BLK BLK RED RED f d a-Stator b-Voltage Regulator c-Connector d-To Engine Ground e-To Battery Positive (Red) Terminal f-To Battery Negative (Black) Terminal 90-854785R2 DECEMBER 2001 Page 2B-7 CHARGING & STARTING SYSTEM Alternator System Test (6 Ampere Stator) CAUTION When testing any charging system, the technician must use an ammeter capable of reading the maximum current output for the test being performed or higher. Failure to use a ammeter that can handle the specific current load could possibly damage the meter being used. IMPORTANT: Rectifier (optional accessory) must be functioning properly for accurate test results to be obtained. 1. Remove RED lead from (+) terminal of rectifier. 2. Connect RED (+) ammeter lead to rectifier (+) terminal and BLACK (–) ammeter lead to RED rectifier lead. 3. With engine running at the indicated RPM, the ammeter should indicate the following approximate amperes: 8 7 6 5 4 3 2 1 0 4. If proper ampere readings are not obtained, replace stator. Alternator Current (Amps) 0123456 RPM x 1000 Page 2B-8 90-854785R2 DECEMBER 2001 CHARGING & STARTING SYSTEM Alternator System Test (15 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. Refer to “CHARGING A DISCHARGED BATTERY”. If battery can NOT be satisfactorily charged, replace battery. 4. If battery accepts a satisfactory charge, check battery voltage while cranking engine. Refer to “CHARGING A DISCHARGED BATTERY”. If cranking voltage is not acceptable, replace battery. 5. If cranking voltage is acceptable, disconnect the RED (voltage regulator) wire bullet connector from the RED/PUR wire. 6. Connect RED (+) ammeter lead to RED wire and the BLACK (–) ammeter lead to the Red/PUR wire. 7. Secure starter wires away from flywheel. 8. With engine running at the indicated RPM’s, the ammeter should indicate the following appropriate amperes: 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 RPM x 1000 9. A reading of 15 amperes at 5000 RPM indicates the charging system is functioning properly. 10. If ammeter reads less than required amperes @ 5000 RPM, test the stator. Refer to “Stator Ohm Test ”. If stator tests OK, replace rectifier/regulator. Alternator Current (Amps) 0123456 90-854785R2 DECEMBER 2001 Page 2B-9 CHARGING & STARTING SYSTEM Stator Ohms Test STATOR (BATTERY CHARGE COIL) b a a-S/N 0G960499 and Below b-S/N 0G960500 and Above 6 Amp. Stator METER TEST LEADS METER SCALE READING () RED BLACK RX1RX1 09 110.9 - 1.1YEL YEL 15 Amp. Stator METER TEST LEADS METER SCALE READING () RED BLACK RX1RX1 022 024 0.22 - 0.24YEL YEL Page 2B-10 90-854785R2 DECEMBER 2001 CHARGING & STARTING SYSTEM Regulator/Rectifier (P/N 854514-1) Diode Test Analog Meter NOTE:Voltage regulator/rectifier specifications are given for informational purposes only, usethe appropriate troubleshooting techniques previously mentioned to find the faulty component in the charging system. Blk = Black Gry = Gray Red = Red Yel = Yellow YEL GRY YEL RED BLK DIODE TEST: 1. Set Ohm meter to R X 10 scale. 2. Connect Red (+) meter lead to RED regulator lead. 3. Connect Black (–) meter lead to either YELLOW regulator lead. TEST RESULTS: 100 - 400 OHMS DIODE TEST: 1. Set Ohm meter to R X 1k scale. 2. Connect Black (–) meter lead to RED regulator lead. 3. Connect Red (+) meter lead to YELLOW regulator lead. Test. Then change Red (+) meter lead to the other YELLOW regulator lead for 2ND test reading. TEST RESULTS (1ST READING): 20,000 to 8 OHMS TEST RESULTS (2ND READING): 8 OHMS (No needle movement) SCR TEST: 1. Set Ohm meter to R X 1k scale. 2. Connect Red (+) meter lead to regulator case. 3. Connect Black (–) meter lead to one YELLOW regulator lead. Test. Connect Black (–) meter lead to the other YELLOW lead. TEST RESULTS (BOTH TESTS): 8,000 - 15,000 OHMS (8k - 15K) 90-854785R2 DECEMBER 2001 Page 2B-11 CHARGING & STARTING SYSTEM TACHOMETER CIRCUIT TEST: 1. Set Ohm meter to R X 1k scale. 2. Connect Red (+) meter lead to GREY regulator lead. 3. Connect Black (–) meter lead to regulator case. TEST RESULTS: 10,000 - 50,000 OHMS (10k - 50k) Digital Meter NOTE:Voltage regulator/rectifier specifications are given for informational purposes only, usethe appropriate troubleshooting techniques previously mentioned to find the faulty component in the charging system. Blk = Black Gry = Gray Red = Red Yel = Yellow YEL GRY YEL RED BLK DIODE TEST: 1. Set meter to . 2. Connect Black (–) meter lead to RED regulator lead. 3. Connect Red (+) meter lead to either YELLOW regulator lead. TEST RESULTS: 0.4-0.8 V DIODE TEST: 1. Set meter to . 2. Connect Red (+) meter lead to RED regulator lead. 3. Connect Black (–) meter lead to either YELLOW regulator lead. TEST RESULTS (1ST READING):  or OUCH or OL SCR TEST: 1. Set meter to . 2. Connect Black (–) meter lead to regulator case. 3. Connect Red (+) meter lead to either YELLOW regulator lead. TEST RESULTS (BOTH TESTS): 1.5 V -8 or OUCH or OL Page 2B-12 90-854785R2 DECEMBER 2001 CHARGING & STARTING SYSTEM Starting System Components The starting system consists of the following components. 1. Battery 2. Starter Solenoid 3. Neutral Safety Switch 4. Starter Motor 5. Ignition Switch 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. 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. 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 20 Amp fuse. 90-854785R2 DECEMBER 2001 Page 2B-13 CHARGING & STARTING SYSTEM Starter Solenoid Test 1. Inspect starter solenoid for cracks, loose terminals or loose terminal lead connections. 2. Connect ohm meter between terminals of starter solenoid. 3. Connect the BLACK lead from solenoid to battery negative (–) terminal and momentarily connect the YELLOW/RED lead to the positive (+) terminal of battery. 4. Verify continuity between the starter solenoid terminals when 12 volts are applied. a b c d a-YELLOW/RED Lead b-Starter Solenoid c-BLACK Lead d-Battery Page 2B-14 90-854785R2 DECEMBER 2001 CHARGING & STARTING SYSTEM The following “STARTING CIRCUIT TROUBLESHOOTING FLOW CHART” is designed as an aid to troubleshooting the starting circuit. This flow chart will accurately locate any existing malfunction. Location of “TEST POINTS” (called out in the chart) are numbered in diagram below. NEUTRAL START SWITCH + AB IGNITION SWITCH STARTER STARTER SOLENOID 20 AMP FUSE – Blk Blk = Black Blu = Blue Brn = Brown Gry = GrayGrn = Green Orn = OrangePnk = Pink Pur = PurpleRed = Red Tan = Tan Wht = White Yel = Yellow Yel Red/ Pur Red Red Yel/ Red Yel/ Red Yel/ Red Blk Blk 1 7 2 3 6 45 BATTERY Starting Circuit Troubleshooting Flow Chart Starter Motor Does Not Turn SAFETY WARNING: Disconnect BLACK (starter motor) cable from starter solenoid test point 1 BEFORE making tests 1-thru-7 to prevent unexpected engine cranking. TEST 1 Use an ohmmeter (R x 1 scale) and connect meter leads be- tween NEGATIVE (-) battery post and common powerhead ground. No continuity indicated; there is an open circuit in the BLACK NEGATIVE (-) battery cable between the NEGATIVE (-) battery post and the powerhead. • Check cable for loose or corroded connections. • Check cable for open. Continuity Indicated Proceed to TEST 2, on next page. 90-854785R2 DECEMBER 2001 Page 2B-15 CHARGING & STARTING SYSTEM a. Disconnect BLACK ground wire(s) from Test Point 2. b. Connect voltmeter between common engine ground and Test Point 2. c. Turn ignition key to “Start” position. * Battery Voltage TEST 2 TEST 3 TEST 4 TEST 5 TEST 6 TEST 7 TEST 8 12 Volt Reading* 12 Volt Reading 12 Volt Reading* 12 Volt Reading* 12 Volt Reading* 12 Volt Reading* 12 Volt Reading* No voltage reading; proceed to TEST 3. No voltage reading; proceed to TEST 4. No voltage reading; proceed to TEST 5. No voltage reading; proceed to TEST 6. a. Reconnect BLACK ground wire(s). b. Connect voltmeter between common engine ground and Test Point 3. c. Turn ignition key to “Start” position. Check BLACK ground wire for poor connection or open circuit. Reconnect ground wire to start- er solenoid; proceed to TEST 7. Neutral start switch is open, or YELLOW/ RED or BLACK wire is open between Test Points 4 and 3. a. Connect voltmeter between common engine ground and Test Point 4. b. Turn ignition key to “Start” position. Defective starter solenoid. Connect voltmeter between common engine ground and Test Point 5. Defective ignition switch. Connect voltmeter between common engine ground and Test Point 6. No voltage reading; check BLACK wire be- tween battery (+) positive terminal and Test Point 6. Check fuse in RED wire between test points 5 and 6. Check for open RED wire between test points 5 and 6. a. Connect voltmeter between common engine ground and Test Point 1. b. Turn ignition key to “Start” position. No voltage reading; De- fective starter solenoid. Should hear solenoid click; proceed to TEST 8. a. Reconnect Yellow (starter motor) cable to starter solenoid Test Point 1. b. Connect voltmeter between common engine ground and Test Point 7 c. Turn ignition key to “Start” position. No voltage reading; check Yellow cable for poor connection or open circuit. Check BLACK ground cable at starter for loose or corroded connection, or open circuit. If cable is O.K., check starter motor. Electric Start Tiller Handle Model Neutral start switch is open or BLACK leads are disconnected or damaged. Page 2B-16 90-854785R2 DECEMBER 2001 CHARGING & STARTING SYSTEM Starter Motor Removal WARNING Always disconnect the battery and remove spark plug leads from spark plugs before working on motor. 1. Disconnect battery leads from battery. 2. Remove 3 screws. Remove starter. a a-Screws (3) Disassembly 1. Remove 2 through screws and commutator end cap, taking care not to lose brush springs. a b c a c a-Through Screws b-Commutator End Cap c-Brush Springs 90-854785R2 DECEMBER 2001 Page 2B-17 CHARGING & STARTING SYSTEM 2. Press down the pinion stopper and remove the circlip. Remove the pinion. a b c a-Pinion b-Pinion Stopper c-Circlip (discard and use new circlip on assembly) 3. Pull armature from starter frame. Remove locknut. 4. Remove components from armature. a b c d e f a-Spacer b-Spring c-Drive Assembly d-Drive End Cap e-Armature Shaft f-Washer Page 2B-18 90-854785R2 DECEMBER 2001 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 1/4 in. (6.4mm) in length. Refer to “BRUSH REPLACEMENT”, following. 6. Replace a damaged or excessively worn bushing in the end cap. 7. Check the armature conductor (commutator bar junction) for a firm connection. A poor connection usually results in a burned commutator bar. 8. Re-surface and undercut a rough commutator, as follows: CAUTION Do not turn down the commutator excessively. a. Re-surface the commutator and undercut the insulation between the commutator bars 1/3 in. (0.8mm) to the full width of the insulation. Make sure that the undercut is flat. b. Clean the commutator slots after undercutting. c. Deburr the commutator lightly with No. 00 sandpaper, then clean the commutator. d. Check the armature on a growler for shorts. See “TESTING”, following. 9. Open-circuited armatures often can be saved where an open circuit is obvious and repairable. The most likely place for an open circuit is at the commutator bars. Long cranking periods overheat the starter motor so that solder in the connections melts. The poor connections cause arcing and burning of the commutator bars. 10. 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. 11. Clean out the copper or brush dust from slots between the commutator bars. 12. Check the armature for shorts and ground. See “TESTING”. 90-854785R2 DECEMBER 2001 Page 2B-19 CHARGING & STARTING SYSTEM Testing ARMATURE TEST FOR SHORTS Check armature for short circuits by placing on growler and holding hack saw blade over armature core while armature is rotated. If saw blade vibrates, armature is shorted. Recheck after cleaning between commutator bars. If saw blade still vibrates, replace armature. ARMATURE TEST FOR GROUND 1. Set ohmmeter to (R x 1 scale). Place one lead of ohmmeter on armature core (or shaft) and other lead on commutator, as shown. 2. If meter indicates continuity, armature is grounded and must be replaced. 11675 Page 2B-20 90-854785R2 DECEMBER 2001 CHARGING & STARTING SYSTEM CHECKING POSITIVE BRUSHES AND TERMINALS 1. Connect ohmmeter (R x 1 scale) leads between positive brushes. 2. Ohmmeter must indicate full continuity (zero resistance). If resistance is indicated, check lead to positive terminal solder connection. If connection cannot be repaired, brushes must be replaced. Refer to “BRUSH REPLACEMENT”. a a-Positive Brushes TESTING NEGATIVE BRUSHES FOR GROUND Set ohmmeter to (R x 1 scale). Place one lead of ohmmeter on the negative brush and the other lead on the end cap (bare metal). If the meter indicates NO continuity, replace the negative brush. Repeat this procedure on the other negative brush. a b a-Negative (-) Brushes b-End Cap 90-854785R2 DECEMBER 2001 Page 2B-21 CHARGING & STARTING SYSTEM Brush Replacement IMPORTANT: Replace brushes that are pitted or worn to less than 1/4 in. (6.4mm) in length. 11660 a b d e f g c a-Positive (+) Terminal b-Long Brush Lead c-Push Lead Into Slot d-Insulating Washer e-Flat Washer f-Lock Washer g-Nut 11656 a c b d b d a a-Positive (+) Brushes b-Negative (–) Brushes c-Brush Holder d-Screws (Fasten Negative Brushes and Holder) Page 2B-22 90-854785R2 DECEMBER 2001 CHARGING & STARTING SYSTEM Reassembly 1. Lubricate helix threads and drive end cap bushing with SAE 10W Oil. 2. Install the pinion, spring, and pinion stopper onto starter shaft. 3. Place circlip into groove on shaft. 4. Press the pinion stopper over the circlip. IMPORTANT: Install new circlip for reassembly. NOTE:Make sure the circlip fits tightly into pinion stopper. a b c d b c d a a-Circlip b-Pinion Stopper c-Spring d-Pinion 90-854785R2 DECEMBER 2001 Page 2B-23 CHARGING & STARTING SYSTEM 5. Construct a brush retainer tool as shown. Brush Retainer Tool Layout (Full Size) 18-Gauge Sheet Metal METRIC SCALE 3” = 76.2mm 2” = 50.8mm 1-3/4” = 44.5mm 1-11/16” = 42.9mm 3/4” = 19.1mm 1/2” = 12.7mm Brush Retainer Tool Side View (Full Size) Page 2B-24 90-854785R2 DECEMBER 2001 CHARGING & STARTING SYSTEM 6. Place springs and brushes into brush holder and hold in place with brush retainer tool. 7. Lubricate bushing with one drop of SAE 10W Oil. DO NOT over-lubricate. ba a-Brush Retainer Tool b-Bushing 8. Position armature into starter frame so that commutator end of armature is at end of starter frame where permanent magnets are recessed 1 in. (25.4mm). Align marks (a) as shown. 9. Install commutator end cap onto starter frame; align marks (b) as shown, and remove brush retainer tool. 10. Install through screws and tighten to specified torque. a b c c a-Marks c-Through Screws b-Marks Starter Through Screw Torque 70 in. in. (8 N·m) 90-854785R2 DECEMBER 2001 Page 2B-25 CHARGING & STARTING SYSTEM Page 2B-26 90-854785R2 DECEMBER 2001 Installation 1. Secure starter to block with 3 screws. Tighten screws to the specified torque. Secure NEGATIVE battery lead and wires to block. a a b 58213 a - Screws (3) M8 x 45 b - Starter Motor Lead Starter Mounting Screw Torque 22 lb. ft. (30 N·m) TIMING, SYNCHRONIZING & ADJUSTING ELECTRICAL Section 2C - Timing, Synchronizing & Adjusting Table of Contents Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-2 Idle Speed Adjustment . . . . . . . . . . . . . . . . . . . . 2C-4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-3 2 C 90-854785R2 DECEMBER 2001 Page 2C-1 TIMING, SYNCHRONIZING & ADJUSTING Specifications IGNITION SYSTEM Readings taken @ 68°F (20°C). Type Spark Plug Type Gap Hex Size Hole Size Torque Firing Order Ignition Timing: Below 800 RPM ECM (p/n 855311--) ECM (p/n 856058--/856190--) ECM (p/n 856190-–/856482-–) ECM (p/n 856177--/856178-–) ECM (p/n 878433--) Fully Advanced (6000 RPM) Charge Coil Resistance Crank Position Sensor Resistance Ignition Coil Resistance: Primary Secondary (W/o Boots) ECM Engine Speed Limiter Soft Reduction (Retards Timing) Spark Cut-Out Reduction (Percentages of ignition spark are Cut-Out) ECM Overheat/Low Oil Pressure Speed Control Oil Pressure Switch Capacitor Discharge Ignition NGK DPR6EA-9 0.035 in. (1.0 mm) 18 mm 12 mm 150 lb-in. (17 Nm) 1-2 10 ° B.T.D.C 5 ° B.T.D.C 5 ° B.T.D.C 5 ° B.T.D.C 5 ° B.T.D.C 30 ° B.T.D.C 660 - 710 W (GRN/WHT - WHT/GRN) 300 - 350 W (RED - WHT) 0.08 - 0.7 W 3.5 - 4.7 k W 6200 RPM 6250 RPM Approximately 2000 RPM Below 2.5 psi (17 kPa) Continuity NOTE:The 25 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. Page 2C-2 90-854785R2 DECEMBER 2001 TIMING, SYNCHRONIZING & ADJUSTING Special Tools 1. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1. 2. Timing Light P/N 91-99379. 90-854785R2 DECEMBER 2001 Page 2C-3 TIMING, SYNCHRONIZING & ADJUSTING Idle Speed Adjustment NOTE:The engine should be completely warmed up for the adjustment. Correct adjustments can not be obtained in a cold condition. 1. With the outboard in the water, start engine and allow to warm up. Shift the outboard to neutral. 2. With the outboard in neutral, turn the idle speed adjustment screw to obtain the specified idle RPM. a a-Idle Adjustment Screw Page 2C-4 90-854785R2 DECEMBER 2001 WIRING DIAGRAMS ELECTRICAL Section 2D - Wiring Diagrams USA S/N 0G760299 and Below Belgium S/N 0P058999 and Below See Section 9 for Revised Wiring Diagrams Table of Contents 2 D Electric Start Power Trim Wiring Diagram . . . . 2D-2 Electric Start Wiring Diagram . . . . . . . . . . . . . . 2D-4 Electric Start Tiller Handle Wiring Diagram . . . 2D-3 Manual Start Wiring Diagram . . . . . . . . . . . . . . 2D-5 90-854785R2 DECEMBER 2001 Page 2D-1 WIRING DIAGRAMS BLK/YEL 30 WHT/GRN TAN/WHT TAN/LT.BLU BLK 123 45 67 TAN/LT.BLU DC AB BLK W/RED ENDS 30858687a 8786 TO REMOTE TRIM SWITCH DDT TAN/BLK OVER HEAT LAMP LOW OIL PRESSURE LAMP KS12V PPL WHT/GRNGRN/WHTTAN/BLKTAN/WHT RED/PPL BLK/WHT GRN WHT RED/WHTLT.BLU ORGBLK/WHTTAN/GRN YEL BA BLK/DK.BLU DK.BLU TAN/GRN ORGBLK BLK BLK DK.BLU 8 PPL PPL LT.BLU/WHT GRN/WHT RED/PPL RED/PPL RED RED/WHT BLKBA BLK BLK BLK TAN/BLK TAN/BLK LT.BLU YEL/BLKYEL/BLK YEL/BLK YEL/BLK YEL/BLK YEL/BLK YEL/BLK YEL/BLK WHT/GRNGRN/WHT GRN/WHT YEL YEL YEL YELYELRED YELYELREDGRY YEL/REDREDRED BLK RED BLU BLU LT.BLU/WHT BLK RED 87 87a86 BLK GRN GRN/WHT RED BLK BLK GRN/WHT RED/PPLLT.BLU/WHT BLK RED RED RED PPL RED/PPLYEL/RED GRY BLK GRN/WHTLT.BLU/WHT BLK/DK.BLU ORG YEL/BLKYEL/BLK BLK BLK BLK BLK BLK GRY BLK g i j k h n e f b c d a p r o l m 123456789101112131415161718211920242223 q Electric Start Power Trim Wiring Diagram a-Crank Position Sensor b-Coolant Temp. Sensor c-Oil Pressure Switch d-Auto Enrichener e-Stator f-Voltage Regulator g-Starter h-Start Solenoid i-Trim-Down Relay j-Trim-Up Relay k-Cowl Mounted Trim Switch l-12 V Battery m-Trim Pump n-20 Amp. Fuse o-Remote Control p-Diagnostic Device q-Ignition Coil r-ECU Page 2D-2 90-854785R2 DECEMBER 2001 WIRING DIAGRAMS Electric Start Tiller Handle Wiring Diagram a-Crank Position Sensor 123456789101112131415161718211920242223 YEL 12 3 4 5 6 7 8DC AB DDT GRY OVER HEAT LAMP LOW OIL PRESSURE LAMP KS12V BA 12 3 456 7 8 BLKTAN/LT.BLUBLK/DK.BLUTAN/BLKTAN/WHTORGBLK/WHTRED/WHTTAN/GRNLT.BLUDK.BLUYEL/BLKYEL/BLKWHT/GRNGRN/WHT RED RED/WHT WHT BLK BLK TAN/BLK TAN/GRN TAN/BLK LT.BLU YEL YEL/BLK YEL YEL/BLKYEL/BLK YEL/BLK YEL/BLK YEL/BLK YEL/BLK YEL/BLK YEL/BLK WHT/GRN GRN/WHT YEL WHT/GRN GRN/WHT YELYELRED YELYELREDBLK REDYEL/RED BLK W/RED ENDS BLK RED BLK RED/PPL RED/PPL YEL/RED GRY BLK/DK.BLU TAN/LT.BLU BLK PPL BLK/YEL PPL TAN/WHT TAN/BLK BLKBLK/YEL BLKBLK/YELGRYBLK BLKBLK/YELBLK/YELBLK/YEL RED GRY BLK PPL BLK/YEL YEL/RED YEL/REDYEL/REDRED/PPLRED/PPLYEL/REDBLKBLK ORG BLK BLK/WHT DK.BLU PPL BLK BLK BLK BLK BLK BLK BLK RED ORG PPL BLK BLK A B GRY RED g b c de f h a r q p no i l k m j b-Coolant Temp. Sensor c-Oil Pressure Switch d-Auto Enrichener e-Stator f-Voltage Regulator g-Starter h-Start Solenoid i-12 V Battery j-20 Amp. Fuse k-Remote Control l-Push Button Stop Switch m-Lanyard Stop Switch n-Push Button Start Switch o-Neutral Start Switch p-Diagnostic Device q-Ignition Coil r-ECU 90-854785R2 DECEMBER 2001 Page 2D-3 WIRING DIAGRAMS Electric Start Wiring Diagram 12 34567 8 GRY DC AB DDT GRY AB OVER HEAT LAMP LOW OIL PRESSURE LAMP KS12V BA BLKTAN/LT.BLUBLK/DK.BLUTAN/BLKTAN/WHTORGBLK/WHTRED/WHTTAN/GRNLT.BLUDK.BLUYEL/BLKYEL/BLKWHT/GRNGRN/WHT ORGBLK BLK/WHT BLK BLK BLK BLK BLK BLK BLK/DK.BLU BLK PPL PPL TAN/WHT TAN/BLK RED/PPL RED/WHTRED BLKWHT BLK BLK BLK TAN/BLK TAN/GRN TAN/BLK LT.BLU YEL/BLKYEL YEL YEL/BLK YEL/BLK YEL/BLK YEL/BLK YEL/BLK YEL/BLK YEL/BLK YEL YEL WHT/GRN GRN/WHT WHT/GRN GRN/WHT YELYEL YELYEL RED BLK REDYEL/RED BLK W/RED ENDS BLK BLK RED YEL/RED TAN/LT.BLU BLK PPL RED/PPL RED RED BLK/YEL ORG DK.BLU PPL RED GRY d a n j 123456789101112131415161718211920242223 lm k b c h e g f i a-Crank Position Sensor b-Coolant Temp. Sensor c-Oil Pressure Switch d-Auto Enrichener e-Stator f-Voltage Regulator g-Starter h-Start Solenoid i-12 V Battery j-20 Amp. Fuse k-Remote Control l-Diagnostic Device m-Ignition Coil n-ECU Page 2D-4 90-854785R2 DECEMBER 2001 WIRING DIAGRAMS Manual Start Wiring Diagram WHT AB DDT A B BLK C D BLKTAN/LT.BLUBLK/DK.BLUORGBLK/WHTRED/WHTTAN/GRNLT.BLUDK.BLUYEL/BLKYEL/BLKWHT/GRNGRN/WHT RED RED/WHT BLK TAN/BLK TAN/GRN BLKTAN/BLK LT.BLU BLK BLK BLK WHT DK.BLU RED YEL/BLK TAN/LT.BLU YEL/BLK YEL/BLK YEL/BLK YEL/BLK YEL YEL YEL/BLK YEL/BLK WHT/GRN WHT/GRN GRN/WHTGRN/WHT YEL YEL YEL/BLK YEL/BLK BLK/YELBLK/YEL BLK/YELBLKBLKBLK/YEL BLK/YEL TAN/LT.BLU ORG BLK BLK/WHT ORG TAN/LT.BLU PPL a b d fg i 123456789101112131415161718211920242223 h jkl m e c a-Crank Position Sensor b-Coolant Temp. Sensor c-Oil Pressure Switch d-Auto Enrichener e-Stator f-Push Button Stop Switch g-Lanyard Switch h-Horn Driver i-Warning Horn j-External Battery Supply k-Diagnostic Device l-Ignition Coil m-ECU 90-854785R2 DECEMBER 2001 Page 2D-5 FUEL PUMP FUEL SYSTEM Section 3A - Fuel Pump Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1 Fuel Pump (USA S/N 0T408999 and Below, Belgium S/N 0P153499 and Below) . . . . . . . . . 3A-2 Fuel Pump ( USA S/N 0T409000 and Up, Belgium S/N 0P153500 and Up) . . . . . . . . . . . . 3A-4 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-6 Fuel Pump USA S/N 0T408999 and Below . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-6 Fuel Pump Belgium S/N 0P153499 and Below . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-6 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-7 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-8 Specifications Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-9 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-11 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-12 Fuel Pump USA S/N 0T409000 and Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-12 Fuel Pump Belgium S/N 0P153500 and Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-12 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-13 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-14 Cleaning/Inspection/Repair . . . . . . . . . . . . . 3A-15 Check Valve Inspection/Replacement . . . . 3A-15 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-16 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-18 3 A Fuel Pump Type External (Plunger/Diaphragm) FUEL SYSTEM Fuel Pump: Pressure Plunger Stroke 3-6 PSI 0.23 - 0.38 in. (5.85 - 9.65 mm) Fuel Tank Capacity Accessory 90-854785R2 DECEMBER 2001 Page 3A-1 FUEL PUMP FUEL PUMP FUEL PUMP (USA S/N 0T408999 and Below, Belgium S/N 0P153499 and Below) A 1 2 3 4 5 6 7 8 9 10 11 12 1314 15 16 1718 19 20 21 22 23 24 2 2 2 2 2 2 11 10 12 66 66 Loctite 242 6 A = TO FLOAT BOWL Page 3A-2 90-854785R2 DECEMBER 2001 FUEL PUMP FUEL PUMP (USA S/N 0T408999 and Below, Belgium S/N 0P153499 and Below) REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 FUEL FILTER 2 7 STA–STRAP 3 1 TUBING (16 IN.) 4 1 TUBING (19 IN.) 5 1 FUEL CONNECTOR – 1 O RING 6 1 FUEL PUMP 7 4 SCREW Drive Tight 8 1 COVER 9 1 DIAPHRAGM 10 2 SCREW Drive Tight 11 2 NUT 12 2 CHECK VALVE 13 1 DIAPHRAGM 14 1 PIN 15 1 SPRING 16 4 NUT 17 1 SPRING 18 1 PLUNGER 19 1 O RING 20 2 SCREW (M6 x 30) 75 8.5 21 1 PLUG 22 1 HOSE 23 1 CONDUIT (ELECTRIC) 24 1 COWL DEFLECTOR 90-854785R2 DECEMBER 2001 Page 3A-3 FUEL PUMP FUEL PUMP ( USA S/N 0T409000 and Up, Belgium S/N 0P153500 and Up) 66 66 Loctite 242 A = TO FLOAT BOWL B = BLOCK EXHAUST COVER C = TO TELL TALE Page 3A-4 90-854785R2 DECEMBER 2001 FUEL PUMP FUEL PUMP ( USA S/N 0T409000 and Up, Belgium S/N 0P153500 and Up) REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 FUEL PUMP 2 4 SCREW 3 1 DIAPHRAGM/O RING KIT 4 1 SPRING 5 4 NUT 6 1 SPRING 7 1 CAP 8 1 COWL DEFLECTOR 9 2 SCREW (M6 x 30) 10 1 TUBING (13 in.) 11 1 TUBING (6 IN.) 12 2 CONDUIT (13 IN.) 13 1 CONDUIT (6 IN.) 14 2 TUBING (19 IN.) 15 1 FUEL FILTER 16 1 TUBING (7 IN.) 17 AR STA STRAP 18 1 FUEL CONNECTOR 19 1 O RING 90-854785R2 DECEMBER 2001 Page 3A-5 FUEL PUMP Fuel Pump Fuel Pump USA S/N 0T408999 and Below Fuel Pump Belgium S/N 0P153499 and Below Operation 1. The fuel pump is a diaphragm pump which is mechanically driven off of the rocker arm. 2. The black mounting block (insulator) helps prevent vapor lock. 3. If the engine runs out of fuel, or has a restriction preventing adequate fuel flow, the pump will make a “clicking” noise. WARNING FIRE AND EXPLOSION HAZARD. Observe fire prevention rules, particularly NO SMOKING. Before servicing any part of the fuel system, disconnect electrical system at the battery. Drain the fuel system completely. Use an approved container to collect and store fuel. Wipe up any spillage immediately. Materials used to contain spillage must be disposed of in an approved receptacle. Any fuel system service must be performed in a well ventilated area. FUEL LEAKAGE FROM ANY PART OF THE FUEL SYSTEM CAN BE A FIRE AND EXPLOSION HAZARD WHICH CAN CAUSE SERIOUS BODILY INJURY OR DEATH. Careful periodic inspection of the entire fuel system is mandatory, particularly after engine storage. All fuel components, including fuel tanks (plastic, metal, or fiberglass), fuel lines, primer bulbs and fittings, must be inspected for cracks, swelling, and/or corrosion. Any sign of leakage or deterioration necessitates replacement before further engine operation. Removal 1. Cut sta-straps and remove inlet and outlet hoses. 2. Remove fuel pump screws. 3. Separate fuel pump from cylinder head cover. 55780 a b e d c a-Outlet Fuel Hose b-Inlet Fuel Hose c-Mounting Screws d-Cylinder Head Cover e-Cowl Deflector Page 3A-6 90-854785R2 DECEMBER 2001 FUEL PUMP Disassembly IMPORTANT: Before separating fuel pump components mark each component with an awl or marker. This will ensure the components are oriented correctly during reassembly. 1. Remove screws to separate pump cover, cover seal, and diaphragm, from pump body. a c d e f b a-Screws (4) b-Pump Cover c-Cover Seal d-Diaphragm g e-Pump Body f-Nuts (4) g-I.D. Marks (Create These) 2. Inspect cover seal and diaphragm. Replace if damaged. 28379 b a a-Cover Seal b-Diaphragm 3. Inspect check valves. Replace if damaged. a a-Check Valves 90-854785R2 DECEMBER 2001 Page 3A-7 FUEL PUMP 4. Rotate plunger to line up slots. 53615 a b a-Slots Offset b-Slots Aligned 5. Compress pump assembly to free spring load on pin. 6. Tilt assembly to allow pin to slide out. a a-Pin Inspection 1. Inspect diaphragm, diaphragm spring, and spring. Replace if damaged. a b c d a-Diaphragm b-Diaphragm Spring c-Spring d-Plunger Page 3A-8 90-854785R2 DECEMBER 2001 FUEL PUMP Reassembly 1. Assemble springs, diaphragm, and plunger onto pump body. a b c d e a-Diaphragm b-Diaphragm Spring c-Pump Body d-Spring e-Plunger 2. Line up slots and compress assembly. 3. Insert pin into hole. 53619 b c a a-Pump Body b-Slots c-Pin 90-854785R2 DECEMBER 2001 Page 3A-9 FUEL PUMP 4. Rotate plunger 90° to offset slots. 53615 a b a-Slots Aligned b-Slots Offset 5. Assemble diaphragm, seal, and cover, onto pump body. Secure with screws and nuts. NOTE:Seal installs in one direction only. 28378 a b d e c f a-Screws (4) b-Cover c-Cover Seal d-Diaphragm e-Pump Body f-Nuts (4) 6. Install a new O-ring onto the pump assembly. NOTE:Always install a new O-ring. a a-O-ring Page 3A-10 90-854785R2 DECEMBER 2001 FUEL PUMP Installation 1. Secure fuel pump (and cowl deflector if equipped) to cylinder head cover with 2 screws. 2. Connect fuel lines to pump and secure with sta-straps. a b d e c f a-Outlet Fuel Hose b-Inlet Fuel Hose c-Mounting Screws d-Sta-Straps e-Cowl Deflector (if equipped) f-Cap/Sta-Strap Fuel Pump Mounting Screw Torque 75 lb. in. (8.5 N·m) 90-854785R2 DECEMBER 2001 Page 3A-11 FUEL PUMP Fuel Pump Fuel Pump USA S/N 0T409000 and Up Fuel Pump Belgium S/N 0P153500 and Up Operation 1. The fuel pump is a diaphragm pump which is mechanically driven off of the rocker arm. 2. The black mounting block (insulator) and the water cooling lines helps prevent vapor lock. 3. If the engine runs out of fuel, or has a restriction preventing adequate fuel flow, the pump will make a “clicking” noise. WARNING FIRE AND EXPLOSION HAZARD. Observe fire prevention rules, particularly NO SMOKING. Before servicing any part of the fuel system, disconnect electrical system at the battery. Drain the fuel system completely. Use an approved container to collect and store fuel. Wipe up any spillage immediately. Materials used to contain spillage must be disposed of in an approved receptacle. Any fuel system service must be performed in a well ventilated area. FUEL LEAKAGE FROM ANY PART OF THE FUEL SYSTEM CAN BE A FIRE AND EXPLOSION HAZARD WHICH CAN CAUSE SERIOUS BODILY INJURY OR DEATH. Careful periodic inspection of the entire fuel system is mandatory, particularly after engine storage. All fuel components, including fuel tanks (plastic, metal, or fiberglass), fuel lines, primer bulbs and fittings, must be inspected for cracks, swelling and/or corrosion. Any sign of leakage or deterioration necessitates replacement before further engine operation. Page 3A-12 90-854785R2 DECEMBER 2001 FUEL PUMP 90-854785R2 DECEMBER 2001 Page 3A-13 Removal 1. Cut sta-straps. Remove fuel inlet and outlet hoses, and fuel cooler water inlet and outlet hoses. 2. Remove fuel pump screws. 3. Separate fuel pump from cylinder head cover. e c 59173 a b d i h g f a - Fuel Pump b - Outlet Fuel Hose c - Inlet Fuel Hose d - Fuel Cooler Water Inlet Hose e - Fuel Cooler Water Outlet Hose (Tell Tale Hose) f - Mounting Screws g - Cowl Deflector h - Conduit i - Sta-Strap (4) FUEL PUMP Disassembly IMPORTANT: Before separating fuel pump components mark each component with an awl or marker. This will ensure the components are oriented correctly during reassembly. 1. Remove screws to separate pump cover, cover seal, diaphragm and valve body from pump base. c d b a e f g a-Screws (4) b-Pump Cover c-Cover Seal d-Diaphragm h e-Valve Body f-Pump Base g-Nuts (4) h-I.D. Marks (Create These) 2. Rotate plunger to line up slots. 53615 a b a-Slots Offset b-Slots Aligned 3. Compress pump assembly to free spring load on pin. 4. Tilt assembly to allow pin to slide out. a a-Pin Page 3A-14 90-854785R2 DECEMBER 2001 FUEL PUMP Cleaning/Inspection/Repair 1. Inspect springs for damage. Replace if necessary. 2. Inspect cover seal and diaphragm. Replace if damaged. ab a-Cover Seal b-Diaphragm Check Valve Inspection/Replacement 1. Inspect the check valves for damage. Replace if necessary. REMOVAL 2. If replacement is needed remove old check valves by grabbing the seal and pulling. 58831 a a-Check Valve/Seal Assembly (2) 90-854785R2 DECEMBER 2001 Page 3A-15 FUEL PUMP INSTALLATION 1. Fabricate an installation tool to the dimensions specified. 2. Lubricate the end of the seal with light oil, and push the assembly into the valve body. NOTE:Drill into the handle using a 5/64 in. (2mm) drill bit. Insert the peg into the drilled hole until 0.312 in. (8mm) remains exposed. 58831 58832 .312 in. ±0.010 in. 5/64 in. dia. 0.375 in. dia. a c b (7.7 - 8.2mm) (9.5mm) (2mm) a-Check Valve/Seal Assembly (2) b-Installation Tool (make yourself) c-Valve Body Assembly 1. Assemble springs, diaphragm, and plunger onto pump base. a b c d e a-Diaphragm b-Diaphragm Spring c-Pump Body d-Spring e-Plunger Page 3A-16 90-854785R2 DECEMBER 2001 FUEL PUMP 2. Line up slots and compress assembly. 3. Insert pin into hole. a b c c-Pin a-Pump Body b-Slots 4. Rotate plunger 90° to offset slots. a b a-Slots Aligned b-Slots Offset 5. Assemble valve body, diaphragm, seal, and cover to pump base. Be sure to line up I.D. marks that were made before disassembly. Apply Loctite 242 to screws and secure with nuts. NOTE:Seal installs in one direction only. h 66 Loctite 242 a-Screws (4) M5 x 40 b-Pump Cover c-Cover Seal d-Diaphragm 66 28378 c d b a e f g e-Valve Body f-Pump Base g-Nuts (4) h-I.D. Marks Fuel Pump Cover Screw Torque 30 lb. in. (3.5 N·m) 90-854785R2 DECEMBER 2001 Page 3A-17 FUEL PUMP Page 3A-18 90-854785R2 DECEMBER 2001 Installation 1. Secure fuel pump and cowl deflector to cylinder head cover with screws. Tighten to specified torque. 2. Connect fuel lines to pump and secure with new sta-straps. 3. Connect fuel cooler water lines to pump and secure with new sta-straps. a 58974 66 Loctite 242 g h c d 66 e i i f b 59172 i a - Inlet Fuel Hose (from fuel filter) b - Outlet Fuel Hose c - Fuel Cooler Water Inlet Hose d - Fuel Cooler Water Outlet Hose (to tell-tale outlet) e - Mounting Screw (2) M6 x 30 f - Cowl Deflector g - Fuel Pump h - Conduit (2) i - Sta-strap (4) Fuel Pump Mounting Screw Torque 75 lb. in. (8.5 N·m) CARBURETOR FUEL SYSTEM Section 3B - Carburetor Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-2 Carburetor Removal Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-2 USA S/N 0T409000 and Up . . . . . . . . . . . . . 3B-12 Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-3 Carburetor Removal Carburetor (USA S/N 0T408999 and Below, Belgium S/N 0P153500 and Up . . . . . . . . . 3B-12 Belgium S/N 0T153499 and Below) . . . . . . . . . 3B-4 Carburetor Disassembly . . . . . . . . . . . . . . . . . . . 3B-13 Carburetor (USA S/N 0T409000 and Up, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-16 Belgium S/N 0P153500 and Up) . . . . . . . . . . . . 3B-6 Carburetor Assembly . . . . . . . . . . . . . . . . . . . . . 3B-18 Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-8 Carburetor Installation . . . . . . . . . . . . . . . . . . . . 3B-21 Carburetor Adjustments . . . . . . . . . . . . . . . . . . . 3B-10 Carburetor Installation Float Level . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-10 USA S/N 0T408999 and Below . . . . . . . . . . 3B-21 Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-10 Carburetor Installation Carburetor Removal . . . . . . . . . . . . . . . . . . . . . . 3B-11 Belgium S/N 0P153499 and Below . . . . . . 3B-21 Carburetor Removal Carburetor Installation USA S/N 0T408999 and Below . . . . . . . . . . 3B-11 USA S/N 0T409000 and Up . . . . . . . . . . . . . 3B-23 Carburetor Removal Carburetor Installation Belgium S/N 0P153499 and Below . . . . . . 3B-11 Belgium S/N 0P153500 and Up . . . . . . . . . 3B-23 3 B 90-854785R2 DECEMBER 2001 Page 3B-1 CARBURETOR Specifications Idle RPM (Out Of Gear) 825 ± 25 RPM Idle RPM (In Forward Gear) Wide Open Throttle RPM (WOT) 775 ± 25 RPM Range Standard Model 5500–6000 CARBURETOR Main Jet Size Pilot Jet a #110 #50 Idle Jet Bodensee Model #45 Main Jet #105 Pilot Jet #50 Idle Jet #50 Float Height (a) 0.47-0.63 in. (12.0-16.0 mm) ENRICHMENT Auto Enrichener 15 - 25 W CONTROL Electrothermal ram projection 0.3 in. (7 mm) after 5 min. of power SYSTEM Readings taken @ 68°F (20°C). Special Tools 1. Carburetor Scale (P/N 91-36392) 2. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1. Page 3B-2 90-854785R2 DECEMBER 2001 CARBURETOR Notes: 90-854785R2 DECEMBER 2001 Page 3B-3 1 2 3 4 5 6 7 8 9 10 11 13 12 15 14 16 17 18 19 20 21 22 23 24 25 2 26 27 1 5 1 CARBURETOR Page 3B-4 90-854785R2 DECEMBER 2001 CARBURETOR (USA S/N 0T408999 and Below, Belgium S/N 0T153499 and Below) CARBURETOR CARBURETOR (USA S/N 0T408999 and Below, Belgium S/N 0T153499 and Below) REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 11 1 CARBURETOR 1 CARBURETOR (BODENSEE) 2 4 SCREW 3 1 PLATE 4 1 GASKET 5 1 ENRICHENER 6 1 O RING 7 1 PLATE 8 1 STOP SCREW 9 1 SPRING 10 1 JET (SJ) 11 1 RUBBER PLUG 1212 1 JET (MJ) (110) 1 JET (MJ) (105) (BODENSEE) 13 1 FLOAT VALVE 14 1 FLOAT 15 1 FLOAT PIN 16 1 GASKET 17 1 FLOAT BOWL 18 4 SCREW 19 1 DRAIN SCREW 20 1 WASHER 21 1 SPRING 22 1 PLUNGER 23 1 RUBBER CAP 24 1 COLLAR 2525 1 MAIN NOZZLE 1 MAIN NOZZLE (BODENSEE) 26 1 JET (PO) 27 1 O RING 90-854785R2 DECEMBER 2001 Page 3B-5 CARBURETOR CARBURETOR (USA S/N 0T409000 and Up, Belgium S/N 0P153500 and Up) Page 3B-6 90-854785R2 DECEMBER 2001 CARBURETOR CARBURETOR (USA S/N 0T409000 and Up, Belgium S/N 0P153500 and Up) REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 11 1 CARBURETOR 1 CARBURETOR (BODENSEE) 2 4 SCREW 3 1 PLATE 4 1 GASKET 5 1 ENRICHENER 6 1 O RING 7 1 PLATE 8 1 STOP SCREW 9 1 SPRING 10 1 JET (SJ) 11 1 RUBBER PLUG 1212 1 JET (MJ) (110) 1 JET (MJ) (105) (BODENSEE) 13 1 FLOAT VALVE 14 1 FLOAT 15 1 FLOAT PIN 16 1 GASKET 17 1 FLOAT BOWL 18 4 SCREW 19 1 DRAIN SCREW 20 1 WASHER 21 1 SPRING 22 1 PLUNGER 23 1 RUBBER CAP 24 1 COLLAR 2525 1 MAIN NOZZLE 1 MAIN NOZZLE (BODENSEE) 26 1 JET (PO) 27 1 O RING 90-854785R2 DECEMBER 2001 Page 3B-7 CARBURETOR INTAKE A A = To Breather Cover Page 3B-8 90-854785R2 DECEMBER 2001 CARBURETOR INTAKE REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 2 O RING 2 1 CARB ISOLATOR 3 1 DIFFUSER 4 1 INSERT 5 1 O RING 6 3 SCREW (M6 x 25) 75 8.5 7 2 SCREW (M6 x 100) 75 8.5 8 CLAMP 9 1 HOSE-Breather 10 1 SEAL 11 1 AIR INTAKE 12* 1 CLIP (USA S/N 0T409000, Belgium S/N 0T153500 and Up) 13* 1 SCREW (USA S/N 0T409000, Belgium S/N 0T153500 and Up) A = TO BREATHER COVER, REF.#28-CYLINDER BLOCK 90-854785R2 DECEMBER 2001 Page 3B-9 CARBURETOR Carburetor Adjustments Float Level 1. With carburetor turned upside down and carb scale seated on inner edge, check float level from top of float to float bowl flange as shown. 55835 Float Height 0.47-0.63 in. (12.0-16.0 mm) Idle Speed NOTE:Outboard should be completelywarmed upfor the idle speed adjustment. A cold engine will idle at approximately 1200± 100 RPM (out of gear). 1. With the outboard in forward gear adjust idle speed screw to obtain the specified idle speed. a a-Idle Speed Screw Idle Speed (Forward Gear) 775 ± 25 RPM Page 3B-10 90-854785R2 DECEMBER 2001 CARBURETOR 90-854785R2 DECEMBER 2001 Page 3B-11 Carburetor Removal Carburetor Removal USA S/N 0T408999 and Below Carburetor Removal Belgium S/N 0P153499 and Below 1. Disconnect breather hose from air intake. 2. Disconnect auto enrichener wires (Yellow). 55781 a c b a - Air Intake b - Breather Hose c - Auto Enrichener Wires 3. Cut sta-strap and disconnect fuel pump outlet hose (refer to “Fuel Pump Removal” - Section 3A). 4. Disconnect cam link. 55736 a a - Cam Link CARBURETOR Page 3B-12 90-854785R2 DECEMBER 2001 5. Remove screws securing carburetor assembly to intake manifold. 55780 a a - Screws (3) Carburetor Removal USA S/N 0T409000 and Up Carburetor Removal Belgium S/N 0P153500 and Up 1. Disconnect breather hose from air intake. 2. Disconnect auto enrichener wires (Yellow). 3. Remove screw securing fuel line clip. 4. Disconnect cam link. c a b e d 59167 a - Breather Hose b - Air Intake c - Auto Enrichener Wires d - Screw and Clip e - Cam Link 5. Cut sta-strap and disconnect fuel pump outlet hose (refer to “Fuel Pump Removal” - Section 3A). CARBURETOR 90-854785R2 DECEMBER 2001 Page 3B-13 6. Remove screws securing carburetor assembly to intake manifold. 55780 a a - Screws (3) Carburetor Disassembly 1. Remove screws, air intake, isolator, and diffuser. b c f g a e h j k i d a - Screws (2) b - Air Intake c - Clamp d - Seal e - Carburetor f - O–Ring g - Isolator h - Diffuser i - Bumper j - Insert k - O–Ring CARBURETOR Page 3B-14 90-854785R2 DECEMBER 2001 2. Remove auto enrichener. 3. USA S/N 0T409000 and Up, Belgium S/N 0P153500 and Up: Cut sta-straps and remove carburetor vent hose. a b 55827 59169 d c a b e a - Screw b - Auto Enrichener c - Carburetor Vent Hose d - USA S/N 0T408999 and Below, Belgium S/N 0P153499 and Below e - USA S/N 0T409000 and Up, Belgium S/N 0P153500 and Up 4. Remove float bowl. 55828 a a a - Screws (4) CARBURETOR 90-854785R2 DECEMBER 2001 Page 3B-15 5. Remove plunger and spring. 55834 a b a - Plunger b - Spring 6. Remove float. 55829 a c b a - Screw b - Float Pin c - Float 7. Remove plug, pilot jet, and main jet. 55833 a b c a - Plug b - Pilot Jet c - Main Jet CARBURETOR 8. Remove cover. a a-Screws (3) Inspection 1. Inspect needle and piston valve. Replace if worn or damaged. a b a-Needle Valve b-Piston Valve 2. Measure auto enrichener resistance. Replace if out of specification. Auto Enrichener Resistance 15-25 W @ 68°F (20°C) Page 3B-16 90-854785R2 DECEMBER 2001 CARBURETOR 3. Perform piston valve height test below. Piston Valve Height Test: a. Measure piston valve height b. Connect to 12 V battery c. Wait several minutes d. Measure piston valve height 4. Replace auto enrichener if no change was observed. a a-Piston Valve Height Measurement 5. Inspect carburetor body, replace if cracked or damaged. 6. Inspect float, replace if cracked or damaged. 90-854785R2 DECEMBER 2001 Page 3B-17 CARBURETOR CAUTION Do not use steel wire for cleaning the jets as this may enlarge the jet diameters and seriously affect performance. Use a petroleum based solvent for cleaning and blow out all passages with compressed air. 7. Inspect main jet, pilot jet and main nozzle. Clean if they are contaminated. 8. Inspect needle valve, replace if end is worn or grooved. 28375 Carburetor Assembly 1. Install cover. a a-Screws (3) Page 3B-18 90-854785R2 DECEMBER 2001 CARBURETOR 90-854785R2 DECEMBER 2001 Page 3B-19 2. Install plug, pilot jet, and main jet. 55833 b c a a - Plug b - Pilot Jet c - Main Jet 3. Install float. 55829 a b c a - Screw b - Float Pin c - Float 4. Install plunger and spring. 55834 a b a - Plunger b - Spring CARBURETOR Page 3B-20 90-854785R2 DECEMBER 2001 5. Install float bowl. 55828 a a a - Screws (4) 6. Install auto enrichener. 7. USA S/N 0T409000 and Up, Belgium S/N 0P153500 and Up: Install carburetor vent hose and secure with sta-straps. a b 55827 59169 d e b c a a - Screw b - Auto Enrichener c - Carburetor Vent Hose d - USA S/N 0T408999 and Below, Belgium S/N 0P153499 and Below e - USA S/N 0T409000 and Up, Belgium S/N 0P153500 and Up CARBURETOR 90-854785R2 DECEMBER 2001 Page 3B-21 8. Install screws, air intake, isolator, and diffuser. b c f g a e h j k i d a - Screws (2) b - Air Intake c - Clamp d - Seal e - Carburetor f - O–Ring g - Isolator h - Diffuser i - Bumper j - Insert k - O–Ring Air Intake Mounting Screw Torque 75 lb. in. (8.5 N·m) Carburetor Installation Carburetor Installation USA S/N 0T408999 and Below Carburetor Installation Belgium S/N 0P153499 and Below 1. Install screws securing carburetor assembly to intake manifold. 55780 a a - Screws (3) Carburetor Mounting Screw Torque 75 lb. in. (8.5 N·m) CARBURETOR Page 3B-22 90-854785R2 DECEMBER 2001 2. Connect cam link. 55736 a a - Cam Link 3. Connect auto enrichener wires (Yellow). 4. Connect breather hose into air intake. 55781 a c b a - Air Intake b - Breather Hose c - Auto Enrichener Wires 5. Connect fuel pump outlet hose to carburetor bowl. Secure hose with sta-strap (refer to “Fuel Pump Installation/Removal” - Section 3A). CARBURETOR 90-854785R2 DECEMBER 2001 Page 3B-23 Carburetor Installation USA S/N 0T409000 and Up Carburetor Installation Belgium S/N 0P153500 and Up 1. Install screws securing carburetor assembly to intake manifold. 55780 a a - Screws (3) Carburetor Mounting Screw Torque 75 lb. in. (8.5 N·m) 2. Connect cam link. 3. Connect auto enrichener wires (Yellow). 4. Connect breather hose into air intake. 5. Route fuel line through clip. c a b d e 59167 f a - Cam Link b - Air Intake c - Breather Hose d - Auto Enrichener Wires e - Clip and Screw f - Carburetor Vent Hose 6. Connect fuel pump outlet hose to carburetor bowl. Secure hose with sta-strap (refer to “Fuel Pump Installation/Removal” - Section 3A). 7. Secure clip to diffuser housing. 8. Route carburetor vent hose over the top of of the fuel line and through hole in the adaptor plate so the hose extends 1 in. (25 mm) below opening. EMISSIONS FUEL SYSTEM Section 3C - Emissions Table of Contents Exhaust Emissions Standards . . . . . . . . . . . . . 3C-2 Emissions Information . . . . . . . . . . . . . . . . . . . . 3C-6 What Are Emissions? . . . . . . . . . . . . . . . . . . 3C-2 Manufacturer’s Responsibility: . . . . . . . . . . 3C-6 Hydrocarbons – HC . . . . . . . . . . . . . . . . . . . . 3C-2 Dealer Responsibility: . . . . . . . . . . . . . . . . . . 3C-6 Carbon Monoxide – CO . . . . . . . . . . . . . . . . 3C-2 Owner Responsibility: . . . . . . . . . . . . . . . . . . 3C-6 Oxides of Nitrogen - NOx . . . . . . . . . . . . . . . 3C-2 EPA Emission Regulations: . . . . . . . . . . . . . 3C-7 Controlling Emissions . . . . . . . . . . . . . . . . . . 3C-2 Manufacturer’s Certification Label: . . . . . . . . . . 3C-8 Stoichiometric (14.7:1) Air/Fuel Ratio . . . . 3C-3 Service Replacement Certification Label . . . . 3C-9 Outboard Hydrocarbon Emissions Reductions . 3C-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-9 Stratified Vs Homogenized Charge . . . . . . . . . 3C-4 Date Code Identification . . . . . . . . . . . . . . . . 3C-9 Homogenized Charge . . . . . . . . . . . . . . . . . . 3C-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-9 Stratified Charge . . . . . . . . . . . . . . . . . . . . . . 3C-5 Decal Location: . . . . . . . . . . . . . . . . . . . . . . . 3C-9 3 C 90-854785R2 DECEMBER 2001 Page 3C-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; gasolene contains mainly hydrogen and carbon. These four elements combine chemically during combustion. If combustion were complete, the mixture of air and gasoline would result in these emissions: water, carbon dioxide and nitrogen, which are not harmful to the environment. But combustion is not usually complete. Also, potentially harmful gases can be formed during and after combustion. All marine engines must reduce the emission of certain pollutants, or potentially harmful gases, in the exhaust to conform with levels legislated by the EPA. Emissions standards become more stringent each year. Standards are set primarily with regard to three emissions: hydrocarbons (HC), carbon monoxide (CO) and oxides of nitrogen (NOx). Hydrocarbons – HC Gasoline is a hydrocarbon fuel. The two elements of hydrogen and carbon are burned during combustion in combination with oxygen. But they are not totally consumed. Some pass through the combustion chamber and exit the exhaust system as unburned gases known as hydrocarbons. Carbon Monoxide – CO Carbon is one of the elements that make up the fuel burned in the engine along with oxygen during the combustion process. If the carbon in the gasoline could combine with enough oxygen (one carbon atom with two oxygen atoms), it would come out of the engine in the form of carbon dioxide (CO2). CO2 is a harmless gas. But carbon often combines with insufficient oxygen (one carbon atom with one oxygen atom). This forms carbon monoxide, CO. Carbon monoxide is the product of incomplete combustion and is a dangerous, potentially lethal gas. Oxides of Nitrogen - NOx NOx is a slightly different byproduct of combustion. Nitrogen is one of the elements that makes up the air going into the engine. Under extremely high temperatures it combines with oxygen to form oxides of nitrogen (NOx). This happens in the engine’s combustion chambers when temperatures are too high. NOx itself is not harmful, but when exposed to sunlight it combines with unburned hydrocarbons to create the visible air pollutant known as smog. Smog is a serious problem in California as well as many other heavily populated areas of the United States. Controlling Emissions There are two principle methods of reducing emissions from a two-stroke-cycle marine engine. The first method is to control the air/fuel ratio that goes into the combustion chamber. The second is to control the time when this air/fuel mixture enters the combustion chamber. Timing is important, to prevent any unburned mixture from escaping out of the exhaust port. Page 3C-2 90-854785R2 DECEMBER 2001 EMISSIONS Stoichiometric (14.7:1) Air/Fuel Ratio In the search to control pollutants and reduce exhaust emissions, engineers have discovered that they can be reduced effectively if a gasoline engine operates at an air/fuel ratio of 14.7:1. The technical term for this ideal ratio is stoichiometric. An air/fuel ratio of 14.7:1 provides the best control of all three elements in the exhaust under almost all conditions. The HC and CO content of the exhaust gas is influenced significantly by the air/fuel ratio. At an air/fuel ratio leaner than 14.7:1, HC and CO levels are low, but with a ratio richer than 14.7:1 they rise rapidly. It would seem that controlling HC and CO by themselves might not be such a difficult task; the air/fuel ratio only needs to be kept leaner than 14.7:1. However, there is also NOx to consider. As the air/fuel ratio becomes leaner, combustion temperatures increase. Higher combustion temperatures raise the NOx content of the exhaust. But, enrichening the air/fuel ratio to decrease combustion temperatures and reduce NOx also increases HC and CO, as well as lowering fuel economy. So the solution to controlling NOx - as well as HC and CO - is to keep the air/fuel ratio as close to 14.7:1 as possible. Outboard Hydrocarbon Emissions Reductions 8 1/3%  PER YEAR OVER 9 MODEL YEARS 120 100 80 60 40 20 0 96 97 98 99200001 02 03 04 05 06 07 08 90-854785R2 DECEMBER 2001 Page 3C-3 EMISSIONS Stratified Vs Homogenized Charge DFI engines use a stratified charge inside the combustion chamber to aid in reducing emissions. All other models use a homogenized charge. The difference between the two is: Homogenized Charge A homogenized charge has the fuel/air particles mixed evenly throughout the cylinder. This mixing occurs inside the carburetor venturi, reed blocks and crankcase. Additional mixing occurs as the fuel is forced through the transfer system into the cylinder. The homogenized charge is easy to ignite as the air/fuel ratio is approximately 14.7:1. Page 3C-4 90-854785R2 DECEMBER 2001 EMISSIONS Stratified Charge A stratified charge engine only pulls air through the transfer system. The fuel required for combustion is forced into the cylinder through an injector placed in the top of the cylinder (head). The injector sprays a fuel/air mixture in the form of a bubble into the cylinder. Surrounding this bubble is air supplied by the transfer system. As the bubble is ignited and burns, the surrounding air provides almost complete combustion before the exhaust port opens. A stratified charge is hard to ignite, the fuel/air bubble is not evenly mixed at 14.7:1 and not easily ignited. 90-854785R2 DECEMBER 2001 Page 3C-5 EMISSIONS Emissions Information Manufacturer’s Responsibility: Beginning with 1998 model year engines, manufacturers of all marine propulsion engines must determine the exhaust emission levels for each engine horsepower family and certify these engines with the United States Environmental Protection Agency (EPA). A certification decal/emissions control information label, showing emission levels and engine specifications directly related to emissions, must be placed on each engine at the time of manufacture. Dealer Responsibility: When performing service on all 1998 and later outboards that carry a certification, attention must be given to any adjustments that are made that affect emission levels. Adjustments must be kept within published factory specifications. Replacement or repair of any emission related component must be executed in a manner that maintains emission levels within the prescribed certification standards. Dealers are not to modify the engine in any manner that would alter the horsepower or allow emission levels to exceed their predetermined factory specifications. Exceptions include manufacturers prescribed changes, such as that for altitude adjustments. Owner Responsibility: The owner/operator is required to have engine maintenance performed to maintain emission levels within prescribed certification standards. The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications. Single engine exceptions may be allowed with permission from the EPA for racing and testing. Page 3C-6 90-854785R2 DECEMBER 2001 EMISSIONS EPA Emission Regulations: All new 1998 and later outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors. This certification is contingent on certain adjustments being set to factory standards. For this reason, the factory procedure for servicing the product must be strictly followed and, whenever practicable, 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 90-854785R2 DECEMBER 2001 Page 3C-7 EMISSIONS Manufacturer’s Certification Label: The certification label must be placed on each engine at the time of manufacture and must be replaced in the same location if damaged or removed. Shown below is a typical certification label and is not representative of any one model. Label shown below is not to scale; (shown at twice the normal size). Gap: 0.035” (1.0 mm) Emission Control Information Refer to Owners Manual for required maintenance Family: 2M9XM.4982G0 Idle Speed (in neutral): 825 RPM FEL: 19.29 GM/KW-HR 25 HP 498 cc Timing (in degrees): Not Adjustable CDI Controlled Standard Spark Plug: NGK DPR6EA-9 Suppressor Spark Plug: NGK DPR6EA-9 Valve Clearance (Cold) mm Intake: 0.15-0.25 Exhaust: 0.25-0.35 Gap: 0.035, (1.0 mm) This engine conforms to 2002 Model Year U.S. EPA regulations for Marine SI engines. JANUARY 2002 f g h i j a b c e d a-Spark Ignition (SI) b-Idle Speed (In Gear) c-Cubic Centimeter d-Engine Horsepower rating e-Month and Year of Production f-Valve Clearance (Four Stroke engines only) g-Recommended spark plug for best engine performance h-Timing specifications when adjustable i-FEL: Represents (Mercury Marine) statement of the maximum emissions output for the engine family j-Family example Type of Product 0=All except; J=Sport Jet E=EFI Sport Jet & EFI 4-strokes 3=OptiMax 135 H=High Performance 2 M9X M.498 2 G 0 Model Year 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 3C-8 90-854785R2 DECEMBER 2001 EMISSIONS Service Replacement Certification Label IMPORTANT: By federal law, it is required that all 1998 and newer Mercury Marine outboards have a visible and legible emission certification label. If this label is missing or damaged, contact Mercury Marine Service for replacement if appropriate. 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. EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO 2002 CALIFORNIA AND U.S. EPA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES IDLE SPEED (IN GEAR): 775 ±25 RPM TIMING (IN DEGREES): NOT ADJUSTABLE Spark Plug: NGK DPR6EA-9 Gap: 0.9 mm (0.035,) Intake: 0.15 – 0.25 REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE. FAMILY: 2M9XM.4982G0 FEL: 19.29 g/kW-hr 25 HP 498 cc Cold Valve Clearance (mm) Exhaust: 0.25 – 0.35 JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC 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 2002 Merc/Mar (25 4-Stroke) 37-804653 02 Flywheel/Rewind Cover 2001 Merc/Mar (25 4-Stroke) 37-804653 01 Flywheel/Rewind Cover 2000 Merc/Mar (25 4-Stroke) 37-804653 00 Flywheel/Rewind Cover 1999 Merc/Mar (25 4-Stroke) 37-856985 21 Flywheel/Rewind Cover 1998 Merc/Mar (25 4-Stroke) 37-855577 24 Inside Cover Top Cowl 90-854785R2 DECEMBER 2001 Page 3C-9 CYLINDER HEAD POWERHEAD Section 4A - Cylinder Head Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2 Rocker Shaft and Rocker Arm . . . . . . . . . . 4A-21 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-4 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-22 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-6 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . 4A-24 Intake/Exhaust Valves . . . . . . . . . . . . . . . . . . . 4A-8 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-30 Camshaft/Oil Pump . . . . . . . . . . . . . . . . . . . . . . 4A-10 Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . 4A-31 Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . 4A-12 Cylinder Head Reassembly . . . . . . . . . . . . . . . 4A-32 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . 4A-12 Valve Installation . . . . . . . . . . . . . . . . . . . . . 4A-32 Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . 4A-13 Camshaft Oil Seal Installation . . . . . . . . . . 4A-34 Checking Valve Clearance . . . . . . . . . . . . . 4A-13 Camshaft Installation . . . . . . . . . . . . . . . . . 4A-34 Adjusting Valve Clearance . . . . . . . . . . . . . 4A-15 Rocker Arm Shaft Assembly . . . . . . . . . . . 4A-36 Preparation for Cylinder Head Removal . . . . 4A-17 Rocker Arm Shaft Installation . . . . . . . . . . 4A-36 Cylinder Head Removal . . . . . . . . . . . . . . . . . . 4A-18 Cylinder Head Gasket . . . . . . . . . . . . . . . . . 4A-37 Cylinder Head Disassembly . . . . . . . . . . . . . . 4A-19 Cylinder Head Installation . . . . . . . . . . . . . 4A-37 Cleaning and Inspection . . . . . . . . . . . . . . . . . . 4A-21 Cylinder Head Cover Installation . . . . . . . 4A-38 4 A 90-854785R2 DECEMBER 2001 Page 4A-1 CYLINDER HEAD Specifications Camshaft Dimensions Intake “A” 1.216 - 1.220 in. (30.89 - 30.99 mm) Exhaust “A” A 1.216 - 1.220 in. (30.89 - 30.99 mm) Intake “B” 1.022 - 1.025 in. (25.95 - 26.05 mm) Exhaust “B” 1.022 - 1.025 in. (25.95 - 26.05 mm) Run-out Limit B 0.0039 in. (0.1 mm) Camshaft Bearing Diameter “b” 1.4541 - 1.4549 in. CAMSHAFT (36.935 - 36.955 mm) b b b Free Length “a” Tilt Limit “b” b 1.491-1.569 in. (37.85-39.85 mm) Less than 0.060 in. (1.7 mm) VALVE SPRING a Compressed Pressure (Installed) Intake Exhaust Tilt Limit (Intake & Exhaust) Dir. of Winding (Intake & Exhaust) 19.8 - 22.0 lbs. (9.0 - 10.0 kg) 19.8 - 22.0 lbs. (9.0 - 10.0 kg) 0.043 in. (1.1 mm) Left Hand Page 4A-2 90-854785R2 DECEMBER 2001 CYLINDER HEAD 90-854785R2 DECEMBER 2001 Page 4A-3 CYLINDER HEAD Warp Limit * Lines indicate straight edge measurement Camshaft Bore Inside Diameter “a” a a a 0.004 in. (0.1 mm) 1.4567 - 1.4577 in. (37.000 - 37.025 mm) VALVES Valve/Valve Seat/Valve Guides: Valve Clearance (cold) Intake Exhaust Valve Dimensions: “A” Head Diameter Intake Exhaust “B” Face Width Intake Exhaust “C” Seat Width Intake Exhaust “D” Margin Thickness Intake Exhaust Stem Outside Diameter Intake Exhaust Guide Inside Diameter Intake Exhaust Stem To Guide Clearance Intake Exhaust Stem Run-out Limit (max.) 0.006 - 0.010 in. (0.15 - 0.25 mm) 0.010 - 0.014 in. (0.25 - 0.35 mm) 1.256 - 1.264 in. (31.9 - 32.1 mm) 1.020 - 1.028 in. (25.9 - 26.1 mm) 0.079 - 0.124 in. (2.00 - 3.14 mm) 0.079 - 0.124 in. (2.00 - 3.14 mm) 0.035 - 0.043 in. (0.9 - 1.1 mm) 0.035 - 0.043 in. (0.9 - 1.1 mm) 0.020 - 0.035 in. (0.5 - 0.9 mm) 0.020 - 0.035 in. (0.5 - 0.9 mm) 0.2156 - 0.2161 in. (5.475 - 5.490 mm) 0.2150 - 0.2156 in. (5.460 - 5.475 mm) 0.2165 - 0.2170 in. (5.500 - 5.512 mm) 0.2165 - 0.2170 in. (5.500 - 5.512 mm) 0.0004 - 0.0015 in. (0.010 - 0.037 mm) 0.0010 - 0.0020 in. (0.025 - 0.052 mm) 0.0006 in. (0.016 mm) CYLINDER HEAD “B” Valve Dimensions Head Diameter Face Width Seat Width “A” “C” Margin Thickness “D” ROCKER SHAFT Outside Diameter 0.6288 - 0.6296 in. (15.971 - 15.991 mm) ROCKER ARM Inside Diameter of Bore 0.6299 - 0.6306 (16.000 - 16.018 mm) Special Tools 1. Flywheel Holder P/N 91-83163M 2. Valve Guide Remover P/N 91-809495A1 3. Valve Guide Installer Bushing P/N 91-809496A1 Page 4A-4 90-854785R2 DECEMBER 2001 CYLINDER HEAD 4. Valve Guide Reamer P/N 91-809497A1 5. Valve Spring Compressor P/N 91-809494A1 90-854785R2 DECEMBER 2001 Page 4A-5 CYLINDER HEAD Page 4A-6 90-854785R2 DECEMBER 2001 CYLINDER HEAD 110 4-stroke Outboard Oil 110 110 110 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 CYLINDER HEAD CYLINDER HEAD REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m – 1 CYLINDER HEAD (ELECTRIC) 1 CYLINDER HEAD (MANUAL) 1 1 CYLINDER HEAD 2 4 GUIDE 3 4 CIRCLIP 4 2 ANODE 5 2 GROMMET 6 2 COVER 7 2 SCREW (M6 x 20) 70 8 8 1 SCREW 57 6.5 9 1 GASKET 10 1 OIL SEAL 11 1 O RING 12 1 COVER 13 1 DECAL-Servicing Referral 14 1 DECAL-Engine Oil/Valve Clearance 15 1 GASKET 16 5 SCREW (M6 x 20) 70 8 17 3 SCREW (M6 x 25) 106 12 18 6 SCREW (M9 x 1.5 x 95) 34.5 47 19 2 DOWEL PIN 20 1 PLUG 21 1 O RING 90-854785R2 DECEMBER 2001 Page 4A-7 CYLINDER HEAD Page 4A-8 90-854785R2 DECEMBER 2001 INTAKE/EXHAUST VALVES 110 110 110 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 3 4 5 6 7 7 7 8 9 10 12 13 15 15 110 4-stroke Outboard Oil CYLINDER HEAD INTAKE/EXHAUST VALVES REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 2 EXHAUST VALVE 2 2 INTAKE VALVE 3 4 SEAT–Valve Spring 4 4 SEAL–Valve Stem 5 4 VALVE SPRING–Outer 6 4 RETAINER–Valve Spring 7 8 KEY 8 4 ROCKER ARM 9 4 SCREW 10 4 NUT 120 13.5 11 1 ROCKER SHAFT 12 2 PLUG 13 2 BRACKET 14 1 SPRING 15 3 SCREW (M8 x 30) 13 18 90-854785R2 DECEMBER 2001 Page 4A-9 CYLINDER HEAD Page 4A-10 90-854785R2 DECEMBER 2001 CAMSHAFT/OIL PUMP 110 4-stroke Outboard Oil 110 110 51 Loctite 222 Thread Locker 51 1 2 3 4 5 6 7 8 9 10 11 12 CYLINDER HEAD CAMSHAFT/OIL PUMP REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 SCREW (M8 x 40) 28 38 2 1 WASHER 3 1 BELT 4 1 GEAR-Driven 5 1 DOWEL PIN 66 1 CAMSHAFT (ELECTRIC) 1 CAMSHAFT (MANUAL) 7 1 PIN 8 1 OIL PUMP ASSEMBLY 9 1 O RING 10 1 O RING 11 1 O RING 12 4 SCREW (M6 x 35) 70 8 90-854785R2 DECEMBER 2001 Page 4A-11 CYLINDER HEAD Torque Sequence Cylinder Head 1 2 34 5 6 a b a-Center Screws (6) b-Cylinder head Flange Screws (3) Cylinder Head Screw Torque Center Screws Qty. 6 (Larger Dia. M9) 1st: 17 lb. ft. (23 N·m) 2nd: 34.5 lb. ft. (47 N·m) Cyl. Head Flange Screws Qty. 3 (Smaller Dia. M6) 1st: 53 lb. in. (6 N·m) 2nd: 106 lb. in. (12 N·m) Page 4A-12 90-854785R2 DECEMBER 2001 CYLINDER HEAD Valve Clearance NOTE: Valves should be adjusted when engine is cold. 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. 1. Remove flywheel cover (refer to Section 2A - Ignition). 2. Remove cylinder head cover (refer to Cylinder Head Removal). Checking Valve Clearance IMPORTANT: Timing belt must be properly installed with timing marks on the drive gear and the driven gear aligned with corresponding marks on powerhead. 1. Position the driven gear for cylinder #1 or #2 (see instructions following). 2. Measure the valve clearance using a feeler gauge. If out of specification refer to Adjusting Valves following. (b) (a) Valve Clearance Specifications (Cold) Intake Valve (a) 0.006 - 0.010 in. (0.15 - 0.25 mm) Exhaust Valve (b) 0.010 - 0.014 in. (0.25 - 0.35 mm) 90-854785R2 DECEMBER 2001 Page 4A-13 CYLINDER HEAD Page 4A-14 90-854785R2 DECEMBER 2001 POSITIONING OF TOP CYLINDER (#1) Position the #1 piston (top) at top dead center (TDC) on the compression stroke. 1. Rotate the driven gear clockwise to align the “1” mark on the driven gear with the cylinder head mark “”. 55779 1 a b a - Cylinder Head Mark b - Driven Gear Mark POSITIONING OF BOTTOM CYLINDER (#2) Position the #2 piston (bottom) at top dead center (TDC) on the compression stroke. 1. Rotate the driven gear clockwise 180° to align the “” mark on the driven gear with the cylinder head mark “”. 55779 1 a b a - Cylinder Head Mark b - Driven Gear Mark CYLINDER HEAD 90-854785R2 DECEMBER 2001 Page 4A-15 Adjusting Valve Clearance a b c d a - #1 Intake b - #1 Exhaust c - #2 Intake d - #2 Exhaust 1. Loosen locknut. a a - Locknut CYLINDER HEAD 2. Insert the feeler gauge (specification size) between the valve stem and valve adjusting screw. a a-Feeler Gauge 3. Adjust the valve adjusting screw against the feeler gauge using a screwdriver until slight resistance is felt on the feeler gauge. 4. Tighten nut to specified torque with gauge inserted. Valve Adjusting Nut Torque 120 lb. in. (13.5 N·m) 5. Re-check the valve clearance and readjust if necessary. 6. Reinstall the cylinder head and flywheel cover. Tighten screws to the specified torque. Page 4A-16 90-854785R2 DECEMBER 2001 CYLINDER HEAD 90-854785R2 DECEMBER 2001 Page 4A-17 Preparation for Cylinder Head Removal 1. Remove bottom cowl. a a - Screws (7) 2. Remove flywheel cover or manual starter (see section 8). 55860 a a - Screws (4) 3. Refer to section 2A for removal of the following components. a. Timing belt b. Ignition Coil c. Spark plug 4. Refer to section 3A for removal of fuel pump. CYLINDER HEAD Page 4A-18 90-854785R2 DECEMBER 2001 Cylinder Head Removal 1. Remove cylinder head cover screws. 2. Remove cylinder head cover. 55785 b a b a - Cylinder Head Cover b - Screws (5) 3. Remove cylinder head mounting screws. Separate cylinder head from cylinder block. 55786 a a a - Screws (9) CYLINDER HEAD 90-854785R2 DECEMBER 2001 Page 4A-19 Cylinder Head Disassembly 1. Hold driven gear using tool and remove screw and flat washer. Remove driven gear. 55789 91-83163M a a - Holder 91-83163M 2. Remove screws securing rocker arm to cylinder head. Remove rocker arm and retainers. 3. Remove retaining screw. 55787 b a a c a - Screws (3) b - Rocker Arm c - Retaining Screw CYLINDER HEAD Page 4A-20 90-854785R2 DECEMBER 2001 4. Remove oil seal and camshaft. a b a - Oil Seal b - Camshaft 5. Remove valve springs with spring compressor. 55783 91-809494A1 a a - Valve Spring Compressor P/N 91-809494A1 CYLINDER HEAD Cleaning and Inspection Rocker Shaft and Rocker Arm 1. Check rocker arm for pitting (a), clogging (b), or wear (c). Replace if necessary. Measure rocker shaft outside diameter (d) and rocker arm inside diameter (e). Replace if out of specification. 55804 a b c d e Rocker Shaft Outside Diameter 0.6288 - 0.6296 in. (15.971 - 15.991 mm) Rocker Arm Inside Diameter 0.6299 - 0.6306 in. (16.000 - 16.018 mm) 90-854785R2 DECEMBER 2001 Page 4A-21 CYLINDER HEAD Camshaft Manual start models are equipped with a cam shaft featuring a compression release mechanism. The compression relief mechanism releases a percentage of the cylinder compression during engine cranking which lowers the starter rope pull force. At cranking speeds (RPM) the cam shaft decompression levers rest against the side of the exhaust cam lobes, protruding out from the heal of the lobe. This protrusion contacts the exhaust valve rocker arms during the compression stroke, slightly opening the exhaust valve. With the increase of centrifugal force at engine running speeds, the decompression levers swing out of contact with the exhaust valve rocker arms, allowing the exhaust valves to operate normally (fully closed) during the compression stroke. a b a-Exhaust Valve Rocker Arm b-Decompression Lever 1. Inspect the camshaft for pitting, heat discoloration, scratches and for the following measurements. Replace camshaft if worn or not within specification. 2. Inspect the compression relief cam lever (if equipped) for free movement. Replace camshaft if necessary. a a-Compression Relief Cam Page 4A-22 90-854785R2 DECEMBER 2001 CYLINDER HEAD 90-854785R2 DECEMBER 2001 Page 4A-23 3. Measure the cam lobe length (a) and width (b). 55805 a b Cam Lobe Specifications a Intake 1.216 - 1.220 in. (30.89 - 30.99 mm) Exhaust 1.216 - 1.220 in. (30.89 - 30.99 mm) b Intake 1.022 - 1.025 in. (25.95 - 26.05 mm) Exhaust 1.022 - 1.025 in. (25.95 - 26.05 mm) 4. Measure the camshaft bore diameters (a) and camshaft bearing diameters (b and c). a 55783 a a b b b Camshaft Bore Inside Diameter “a” 1.4567 - 1.4577 in. (37.000 - 37.025 mm) Camshaft Bearing Diameter “b” 1.4541 - 1.4549 in. (36.935 - 36.955 mm) 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. Using a straight edge and a thickness gauge inspect cylinder head for warpage. Replace cylinder head if out of specification. 55791 Cylinder Head Warpage Limit 0.004 in. (0.1 mm) Page 4A-24 90-854785R2 DECEMBER 2001 CYLINDER HEAD VALVE GUIDE INSPECTION 1. Measure the valve guide bore (a). If valve guide wear is out of specification, replace the valve guide. 55794 a Valve Guide Inside Diameter Intake Valve 0.2165 - 0.2170 in. (5 500 5 512 )(5.500 - 5.512 mm)Exhaust Valve VALVE GUIDE REPLACEMENT 1. Heat the cylinder head in an oven to 390° F (200° C). This will help to ease guide removal and installation and to maintain correct interference fit. 2. Remove the valve guide using a valve guide remover. a a-Valve Guide Remover (91-809495A1) 90-854785R2 DECEMBER 2001 Page 4A-25 CYLINDER HEAD 3. Install the new valve guide and circlip using a valve guide installer bushing along with the valve guide remover. a b a-Valve Guide Remover (91-809495A1) b-Valve Guide Installer Bushing (91-809496A1) 4. After installing the valve guide, ream the valve guide using a valve guide reamer to obtain proper stem-to-guide clearance. a a-Valve Guide Reamer (91-809497A1) Page 4A-26 90-854785R2 DECEMBER 2001 CYLINDER HEAD VALVE SEAT RECONDITIONING Clean the carbon deposits from the combustion chambers and valve seats and check for pitting. Several different types of equipment are available for reseating valve seats. Follow the equipment manufacturer’s instructions. Measure valve seat width (a). Resurface the valve seat if not in specification. a Valve Seat Width Specification “a” Intake Valve 0.035 - 0.043 in.0.035 0.043 in. (0.9 - 1.1 mm)Exhaust Valve Reface valve seat, use a 60°, 45°, 15° valve seat cutter. NOTE: When twisting cutter, keep an even downward pressure to prevent chatter marks. 90-854785R2 DECEMBER 2001 Page 4A-27 CYLINDER HEAD NOTE:If resurfacing the valve seats is required, resurface the valve seats to the specified angles shown in chart. a b c Valve Seat Angle Specifications a 15° b 45° c 60° Condition: The valve seat is centered on valve face but it is too wide. Valve Seat Cutter Set Desired Results Use Li htlLightly 15° Cutter To reduce valve seat idthwidth60° Cutter Page 4A-28 90-854785R2 DECEMBER 2001 CYLINDER HEAD Condition: The valve seat is in the middle of the valve face but it is too narrow. Valve Seat Cutter Set Desired Results Use 45° Cutter To achieve a uniform valve idthseat width Condition: Valve seat is too narrow and it is near valve margin. Valve Seat Cutter Set Desired Results Use 15° Cutter, First To center the seat and to hi it Widthachieve its Width45° Cutter Condition: Valve seat is too narrow and is located near the bottom edge of the valve face. Valve Seat Cutter Set Desired Results Use 60° Cutter, First To center the seat and to in- it Widthcrease its Width45° Cutter 90-854785R2 DECEMBER 2001 Page 4A-29 CYLINDER HEAD Valves 1. Clean the carbon deposits from the valve. Discard any cracked, warped, or burned valves. 2. Measure the valve stem diameter to check for wear. Replace valves if not within specification. a Valve Stem Diameter Intake Valve 0.2156 - 0.2161 in. (5.475 - 5.490 mm) Exhaust Valve 0.2150 - 0.2156 in. (5.460 - 5.475 mm) 3. Check the valve face for pitting. Valves faces that are pitted must be refaced. NOTE:Several different types of equipment are available for refacing valves. Follow the equipment manufacturer’s instructions. NOTE:After refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped. 4. Check the margin thickness (a) of the valves after the valves have been ground. Any valve with a margin thickness of less than the specification, should be replaced. 45 ° a Margin Thickness “a” Intake Valve 0.020 - 0.035 in. (0.5 - 0.9 mm) Exhaust Valve 0.020 - 0.035 in. (0.5 - 0.9 mm) Page 4A-30 90-854785R2 DECEMBER 2001 CYLINDER HEAD 5. Measure valve stem runout. Replace if out of specification. Valve Stem Runout Limit (Max.) Intake Valve Exhaust Valve 0.0006 in. (0.016 mm) Valve Springs 1. Check each spring under load on a spring tester. Replace any weak springs. 2. Check free length limit of each spring. Replace valve springs if not in specification. Valve Spring Free Length 1.491 - 1.569 in. (37.85 – 39.85 mm) 90-854785R2 DECEMBER 2001 Page 4A-31 CYLINDER HEAD 3. Check each spring on a flat surface using a square. Rotate spring and check space between the top coil and square. Replace valve springs if not in specification. a Valve Spring Tilt Specification “a” Less than 0.06 in. (1.7 mm) Cylinder Head Reassembly Valve Installation INTAKE AND EXHAUST VALVE COMPONENTS a b c d e f a-Valve b-Spring Seat c-Valve Seal d-Valve Spring e-Spring Retainer f-Valve Keepers Page 4A-32 90-854785R2 DECEMBER 2001 CYLINDER HEAD INSTALLING VALVES 1. Always use new valve seals. 2. Apply engine oil to the valves and valve seats. 3. Install valves as shown. 91-809494A1 a b c a-End of the Valve Spring with the Pre-Compressed Coils gets Installed Towards the Cylinder Head b-Use Spring Compressor Tool (91-809494A1) to Compress the Springs for Installation c-Compress the Spring and Retainer and Install the Valve Keepers Around the Valve Stem. You May have to Tap Lightly on End of Valve to Seat the Keepers 90-854785R2 DECEMBER 2001 Page 4A-33 CYLINDER HEAD Camshaft Oil Seal Installation 1. If removed, install Oil Seal. Position seal so part number side in facing outward. Press seal in until it makes contact with the inside flat surface. a a-Upper Camshaft Oil Seal Camshaft Installation 1. Apply engine oil to the main journals (3 places) on the camshaft. 2. Slide camshaft into cylinder head (threaded end towards driven gear). 3. Install camshaft retaining screw. Tighten screw to the specified torque. a a-Camshaft Retaining Screw Camshaft Retaining Screw Torque 57 lb. in. (6.5 N·m) Page 4A-34 90-854785R2 DECEMBER 2001 CYLINDER HEAD 4. Place driven gear on camshaft so alignment pin is in hole. Hold gear with tool (91-83163M) and fasten with washer and screw. Tighten screw to the specified torque. 5. Remove any oil from the camshaft lobes and apply Moly Grease to the lift portion of the lobes. Obtain Moly Grease from a local source. NOTE:Rotate camshaft after assembly to ensure it rotates smoothly. 91-83163M ab cd a-Alignment Pin b-Driven Gear c-Washer d-Screw Driven Gear Screw Torque (d) 28 lb. ft. (38 N·m) 90-854785R2 DECEMBER 2001 Page 4A-35 CYLINDER HEAD Page 4A-36 90-854785R2 DECEMBER 2001 Rocker Arm Shaft Assembly 1. Apply engine oil to the rocker shaft and arms. 2. Locate the end of the rocker shaft that gets installed towards driven gear (oil holes will line-up with the mating oil holes in the cylinder head). 3. Slide the rocker arms onto rocker shaft as shown. a b a - Rocker Shaft b - Rocker Arms Rocker Arm Shaft Installation 1. Install the rocker arm shaft assembly as shown. Tighten screws to the specified torque. NOTE: Leave all adjustment screws loose at this time. a b a a a - Rocker Arm Retainer (3) b - Mounting Screws (3) Rocker Arm Shaft Mounting Screw Torque 13 lb. ft. (18 N·m) CYLINDER HEAD 90-854785R2 DECEMBER 2001 Page 4A-37 Cylinder Head Gasket 1. Install cylinder head gasket and dowel pins. b a a - Dowel Pin (2) b - Gasket Cylinder Head Installation 1. Apply engine oil to the threads of each screw and seat surface. 2. Fasten cylinder head with screws shown. 55786 a b a - Center Screws (6) b - Cylinder Head Flange Screws (3) CYLINDER HEAD 3. Torque screws in sequence and in two steps. 1 2 34 5 6 Cylinder Head Screw Torque Center Screws Qty. 6 (Larger Dia. M9) 1st: 17 lb. ft. (23 N·m) 2nd: 34.7 lb. ft. (47 N·m) Cyl. Head Flange Screws Qty. 3 (Smaller Dia. M6) 1st: 53 lb. in. (6 N·m) 2nd: 106 lb. in. (12 N·m) Cylinder Head Cover Installation 1. Install cover seal into groove. 2. Install cylinder head cover. Secure cylinder head cover with screws. b a b a-Cylinder Head Cover b-Screws (5) Cylinder Head Cover Screw Torque 70 lb. in. (8 N·m) Page 4A-38 90-854785R2 DECEMBER 2001 CYLINDER HEAD 90-854785R2 DECEMBER 2001 Page 4A-39 3. Refer to section 2A for installation of the following components. a. Timing belt b. Ignition Coil c. Spark plugs 4. Refer to section 3A for installation of fuel pump. 5. Install flywheel cover or manual starter (if equipped). 55860 6. Secure bottom cowl. 55824 a b a - Screws (6) b - Screw (M6x60) CYLINDER BLOCK/CRANKCASE POWERHEAD Section 4B - Cylinder Block/Crankcase Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-2 Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-22 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-3 Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-23 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-4 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-24 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-6 Checking Main Bearing Clearance . . . . . . . 4B-24 Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . 4B-8 Checking Connecting Rod Crankcase Cover . . . . . . . . . . . . . . . . . . . . . . 4B-8 Bearing Clearance . . . . . . . . . . . . . . . . . . . . . 4B-26 Exhaust Cover . . . . . . . . . . . . . . . . . . . . . . . . 4B-9 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-28 Powerhead . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-9 Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . 4B-28 Preparation for Powerhead Removal . . . . . . . . 4B-10 Cylinder Block Reassembly . . . . . . . . . . . . . . . . 4B-29 Powerhead Removal . . . . . . . . . . . . . . . . . . . . . 4B-12 Selecting New Main Bearings . . . . . . . . . . . 4B-29 Removing Powerhead Components . . . . . . . . 4B-13 Main Bearing Installation . . . . . . . . . . . . . . . 4B-30 Ignition Components . . . . . . . . . . . . . . . . . . . 4B-13 Selecting New Connecting Rod Bearings . . 4B-30 Charging and Starting System Installing Connecting Rod Bearings . . . . . . 4B-31 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-13 Connecting Rod Installation . . . . . . . . . . . . . 4B-31 Fuel Components . . . . . . . . . . . . . . . . . . . . . 4B-13 Piston Ring Installation . . . . . . . . . . . . . . . . . 4B-32 Harness and Battery Cable Removal . . . . . 4B-13 Piston Installation . . . . . . . . . . . . . . . . . . . . . 4B-33 Oil Filter, Thermostat, and Crankshaft Installation . . . . . . . . . . . . . . . . . 4B-34 Exhaust Cover Removal . . . . . . . . . . . . . . . . 4B-14 Crankcase Cover Installation . . . . . . . . . . . . 4B-36 Cylinder Head Removal . . . . . . . . . . . . . . . . 4B-15 Cylinder Head Installation . . . . . . . . . . . . . . 4B-38 Powerhead Disassembly . . . . . . . . . . . . . . . . . . 4B-15 Exhaust Cover Installation . . . . . . . . . . . . . . 4B-38 Crankshaft and Piston Removal . . . . . . . . . 4B-15 Ignition Components . . . . . . . . . . . . . . . . . . . 4B-39 Piston Disassembly . . . . . . . . . . . . . . . . . . . . 4B-18 Charging and Starting System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-19 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-39 Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . . 4B-19 Fuel Components . . . . . . . . . . . . . . . . . . . . . 4B-39 Balance Piston . . . . . . . . . . . . . . . . . . . . . . . . 4B-20 Powerhead Installation . . . . . . . . . . . . . . . . . . . . 4B-40 Crankcase Cover Bore . . . . . . . . . . . . . . . . . 4B-20 Following Powerhead Installation . . . . . . . . . . . 4B-41 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-21 4 B 90-854785R2 DECEMBER 2001 Page 4B-1 CYLINDER BLOCK/CRANKCASE Specifications CYLINDER BLOCK Type Displacement Number of Cylinders 4 Stroke Cycle – Over Head Camshaft 30.4 cu. in. (498cc) 2 STROKE Length 2.953 in. (75 mm) CYLINDER BORE Diameter Standard Oversize-0.010 in. (0.25 mm) Oversize-0.020 in. (0.50 mm) Taper/Out of Round Maximum Bore Type 2.5591 in. (65 mm) 2.5689 in. (65.25 mm) 2.5787 in. (65.5 mm) 0.003 in. (0.08 mm) Cast Iron PISTON Piston Type O.D. at Skirt Standard Oversize-0.010 in. (0.25mm) Oversize-0.020 in. (0.50mm) Aluminum 2.5570 - 2.5578 in. (64.950 - 64.965 mm) 2.5669 - 2.5675 in. (65.2 - 65.215 mm) 2.5768 - 2.5774 in. (65.450 - 65.465 mm) PISTON CLEARANCE Piston to Cylinder Clearance 0.0014 - .0026 in. (0.035 - 0.065 mm) RINGS Ring End Gap (Installed) Top Middle Bottom (Oil Ring) Side Clearance: Top Middle 0.006 - 0.012 in. (0.15 - 0.30 mm) 0.012 - 0.020 in. (0.30 - 0.50 mm) 0.008 - 0.028 in. (0.20 - 0.70 mm) 0.0008 - 0.0024 in. (0.02 - 0.06 mm) 0.0008 - 0.0024 in. (0.02 - 0.06 mm) BALANCE PISTON Wear Limit 3.735 in. (94.883 mm) CRANKCASE COVER Bore Wear Limit 3.802 in. (95.045 mm) COMPRESSION RATIO Compression Ratio Cylinder Compression* (Electric Models Only, Cold Engine @ W.O.T.) 9.8:1 180 -210 psi (Peak) PISTON PIN Piston Pin Diameter 0.6285 - 0.6287 in. (15.965 - 15.970 mm) CONNECTING ROD Oil Clearance (Big End) Small End Inside Diameter 0.0008 - 0.0020 in. (0.020 - 0.052 mm) 0.6293 - 0.6298 in. (15.985 - 15.998 mm) CRANKSHAFT Main Bearing Clearance Crankshaft Run-out 0.0005 - 0.0017 in. (0.012 - 0.044 mm) 0.0012 in. (0.03 mm) *NOTE:Manual start models are equipped with compression relief mechanism which will not allow compression testing. Page 4B-2 90-854785R2 DECEMBER 2001 CYLINDER BLOCK/CRANKCASE Special Tools 1. Piston Ring Compressor (P/N FT2997). 2. Powerhead Stand (P/N 91-827001A1). 3. Oil Filter Wrench (P/N 91-802653). 4. Flywheel Puller (P/N 91-83164M). 90-854785R2 DECEMBER 2001 Page 4B-3 CYLINDER BLOCK/CRANKCASE Page 4B-4 90-854785R2 DECEMBER 2001 CRANKSHAFT 110 4-stroke Outboard Oil 110 110 110 110 110 110 1 2 3 4 5 7 6 8 9 10 11 12 13 14 15 16 17 18 14 CYLINDER BLOCK/CRANKCASE CRANKSHAFT REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 CRANKSHAFT 2 1 KEY 3 1 KEY 4 1 OIL SEAL 5 1 OIL SEAL 6 2 CONNECTING ROD 7 4 SCREW 150 17 8 4 BEARING (BROWN) 4 BEARING (BLACK) 4 BEARING (BLUE) 9 2 PISTON (STANDARD) 2 PISTON (.25 O/S) PISTON ONLY PISTON (.50 O/S)2 10 2 PISTON RING (TOP) (STANDARD) 2 PISTON RING (TOP) (.25mm O/S) 2 PISTON RING (TOP) (.50mm O/S) 11 2 PISTON RING (2 ND.) (STANDARD) 2 PISTON RING (2 ND.) (.25mm O/S) 2 PISTON RING (2 ND.) (.50mm O/S) 12 2 PISTON OIL RING 13 2 PISTON PIN 14 4 RETAINER 15 1 BALANCE ROD 16 1 PISTON 17 1 NUT 116 158 18 1 GEAR-Drive 90-854785R2 DECEMBER 2001 Page 4B-5 CYLINDER BLOCK/CRANKCASE Page 4B-6 90-854785R2 DECEMBER 2001 CYLINDER BLOCK 12 Loctite Master Gasket Kit 9 Loctite 567 PST Pipe Sealant 110 4-stroke Outboard Oil A B 12 110 110 9 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 30 29 31 32 33 34 35 3 20 18 20 3 A – TO TELL-TALE B = TO FITTING IN ADAPTOR PLATE CYLINDER BLOCK/CRANKCASE CYLINDER BLOCK REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 CYLINDER BLOCK 2 2 DOWEL PIN 3 3 PLUG 4 1 PIPE PLUG (1/2-14) 5 1 PIPE PLUG (3/4-14) 6 6 BEARING (BROWN) 6 BEARING (BLACK) 6 BEARING (BLUE) 7 1 NIPPLE 29.5 40 8 6 SCREW (M8 x 1.25 x 82) 22 30 9 6 SCREW (M6 x 35) 106 12 10 1 GASKET 11 1 OIL FILTER 70 8 12 1 GASKET 13 1 EXHAUST COVER 14 1 PIPE PLUG 15 1 THERMOSTAT 16 1 GASKET 17 1 COVER 18 9 SCREW (M6 x 35) 106 12 19 1 ELBOW 20 3 STA STRAP 21 1 TUBING (11 IN.) 22 1 LIFTING EYE 23 1 SCREW (M8 x 35) 17.5 24 24 1 BREATHER FILTER 25 1 PLUG-Serial Number 26 1 GASKET-Breather Cover 27 1 BREATHER COVER 28 4 SCREW (M6 x 20) 115 13 29 1 HOSE 30 1 J-CLIP 31 1 J-CLIP 32 1 O RING 33 1 COVER 34 4 SCREW (M6 x 20) 115 13 35 1 J CLIP 90-854785R2 DECEMBER 2001 Page 4B-7 CYLINDER BLOCK/CRANKCASE Torque Sequence Crankcase Cover 1 2 34 5 6 7 8 910 11 12 b a a-Screws M8 (6) b-Screws M6 (6) Crankcase Cover Screw Torque Center Screws Qty. 6 (Larger Dia. M8) 1st: 11 lb. ft. (15 N·m) 2nd: 22 lb. ft. (30 N·m) Outer Screws Qty. 6 (Smaller Dia. M6) 1st: 53 lb. in. (6 N·m) 2nd: 106 lb. in. (12 N·m) Page 4B-8 90-854785R2 DECEMBER 2001 CYLINDER BLOCK/CRANKCASE Exhaust Cover Powerhead 2 3 6 8 9 7 4 1 5 Exhaust and Thermostat Cover Screw Torque 1st: 53 lb. in. (6 N·m) 2nd: 106 lb. in. (12 N·m) 55850 1 2 3 4 5 6 7 8 a b a-Powerhead Mounting Screws (4 Each Side) b-Gasket Powerhead Screw Torque 20 lb. ft. (38 N·m) 90-854785R2 DECEMBER 2001 Page 4B-9 CYLINDER BLOCK/CRANKCASE Page 4B-10 90-854785R2 DECEMBER 2001 Preparation for Powerhead Removal 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. 1. On electric start models, disconnect the battery cables from the battery. Remove battery cables from engine. 2. Disconnect the power trim wires (if so equipped). 3. Remove bottom cowl. a a - Screws (7) 4. Remove sta-strap and disconnect vent hose. 55771 a a - Vent Hose CYLINDER BLOCK/CRANKCASE 90-854785R2 DECEMBER 2001 Page 4B-11 5. Remove sta-strap from inlet fuel hose. Disconnect inlet hose from fuel pump. b c 55780 d d a a - Fuel Pump b - Sta-Strap c - Inlet Fuel Hose d - Fuel Pump Cooler lines 6. Push retainer up and slide over to disengage the vertical shift shaft. 55770 1 2 a a - Retainer CYLINDER BLOCK/CRANKCASE Page 4B-12 90-854785R2 DECEMBER 2001 Powerhead Removal 1. Remove powerhead mounting screws. 55850 a a - Screws (8) 2. Lift powerhead from drive shaft housing. Place powerhead on Powerhead Stand P/N 91-827001A1. 55773 91-827001A1 CYLINDER BLOCK/CRANKCASE 90-854785R2 DECEMBER 2001 Page 4B-13 Removing Powerhead Components Ignition Components 1. Refer to Section 2A for removal of the following ignition components. a. Flywheel b. Stator c. Timing Belt d. Ignition Coil e. ECM Charging and Starting System Components 1. Refer to Section 2B for removal of the following components. a. Starter Motor b. Voltage Regulator c. Start Solenoid Fuel Components 1. Refer to Section 3A and 3B for removal of the following components. a. Fuel Pump b. Carburetor Harness and Battery Cable Removal 1. Remove battery and harness cable assembly. 55782 CYLINDER BLOCK/CRANKCASE Page 4B-14 90-854785R2 DECEMBER 2001 Oil Filter, Thermostat, and Exhaust Cover Removal 1. Remove oil filter by turning counterclockwise as shown. 55854 91-802653 a b a - Oil Filter b - Oil Filter Wrench 91-802653 2. Remove thermostat cover screws. Separate thermostat and cover from cylinder block. a d b c a - Screws (2) b - Thermostat Cover c - Gasket d - Thermostat CYLINDER BLOCK/CRANKCASE 90-854785R2 DECEMBER 2001 Page 4B-15 3. Remove exhaust cover screws. Separate exhaust cover and gasket from cylinder block. a b c a - Screws (7) b - Exhaust Cover c - Gasket Cylinder Head Removal 1. Refer to Section 4A for cylinder head removal. Powerhead Disassembly Crankshaft and Piston Removal 1. Remove balance piston cover and O-ring. 55813 a b a - Screws (4) b - Cover CYLINDER BLOCK/CRANKCASE 2. Remove balance piston nut. Separate balance piston from balance rod. a b a-Nut (30mm) b-Piston 3. Remove crankcase cover screws. Separate crankcase cover from cylinder block. 4. Remove dowel pins. 55815 a b c a b a-Screws (6) b-Screws (6) c-Crankcase Cover Page 4B-16 90-854785R2 DECEMBER 2001 CYLINDER BLOCK/CRANKCASE 90-854785R2 DECEMBER 2001 Page 4B-17 5. Use a 5/16 in. 12 point socket and remove connecting rod screws. NOTE: Each connecting rod and cap are a matched set. They must not be interchanged. 55816 a a - Connecting Rod Screws (4) 6. Remove carbon ridge from the cylinder bore using a burr knife. Pistons should be taken out through the cylinder head side of block. NOTE: Keep each piston, connecting rod, and cap together as an assembly. 55817 7. Remove crankshaft from block. 8. Remove balance rod and main bearings. NOTE: Do not interchange main bearings, re-install in their original locations. CYLINDER BLOCK/CRANKCASE Page 4B-18 90-854785R2 DECEMBER 2001 9. Remove oil seals. a b a c a - Oil Seals b - Balance Rod c - Main Bearings Piston Disassembly NOTE: Disassemble each piston separately, make sure components are not mixed. 1. Remove piston pin clips with needle nose pliers. 2. Remove piston pin and connecting rod. 3. Remove piston rings. 55836 a b d c g f e f i h a - Piston b - Top Piston Ring c - Second Piston Ring d - Oil Ring e - Piston Pin f - Retainer g - Connecting Rod h - Screw i - Bearing CYLINDER BLOCK/CRANKCASE Inspection Cylinder Bore MEASURING CYLINDER BORE 1. Measure the cylinder bore diameter at three locations in both X and Y axis. 2. If the cylinder bore is beyond the standard limits listed in the tables below, it will be necessary to re-bore the cylinder to accept the oversize piston. NOTE:Measure at three locations (L1, L2, and L3) in both X and Y axis (D1-6). L1=0.8 in. (20 mm) L2=1.6 in. (40 mm) L3=2.4 in. (60 mm) 55837 D1,2 D3,4 D5,6 L1 L2 L3 Cylinder Bore Specifications Diameter (Standard) 2.5591 - 2.5597 in. (65.0 - 65.015 mm) Taper or Out-of-Round Maximum Limit 0.003 in. (0.08 mm) Diameter 0.010 in. (0.25 mm) Oversize 2.5689 - 2.5695 in. (65.25 - 65.265 mm) Taper or Out-of-Round Maximum Limit 0.003 in. (0.08 mm) Diameter 0.020 in. (0.50 mm) Oversize 2.5787 - 2.5793 in. (65.5 - 65.15 mm) Taper or Out-of-Round Maximum Limit 0.003 in. (0.08 mm) 90-854785R2 DECEMBER 2001 Page 4B-19 CYLINDER BLOCK/CRANKCASE Page 4B-20 90-854785R2 DECEMBER 2001 Balance Piston 1. Measure the balance piston diameter. Replace piston if worn below 3.735 in. (94.883 mm). a a - Piston Diameter Balance Piston Wear Limit 3.735 in. (94.883) Crankcase Cover Bore 1. Measure the bore diameter. Replace cylinder block if worn over 3.802 in. (95.045 mm). a a - Bore Diameter Crankcase Cover Bore Wear Limit 3.802 in. (95.045) CYLINDER BLOCK/CRANKCASE Piston MEASURING PISTON 1. Measure the piston at a point 0.2 in (5.0 mm) from the bottom. a b a-Piston Diameter b-0.2 in. (5.0 mm) Piston Diameter “a” Diameter (Standard) 2.5570 - 2.5578 in. (64.950 - 64.965 mm) (Oversize) 0.010 in. (0.25 mm) 2.5669 - 2.5675 in. (65.2 - 65.215 mm) (Oversize) 0.020 in. (0.50 mm) 2.5768 - 2.5774 in. (65.450 - 65.465 mm) Piston to Cylinder Clearance 0.0014 - 0.0026 in. (0.035 - 0.065 mm) Minimum bore measurement – maximum piston measurement = piston to cylinder clearance 90-854785R2 DECEMBER 2001 Page 4B-21 CYLINDER BLOCK/CRANKCASE Piston Pin 1. Measure piston pin diameter. Replace piston pin if out of specification. Piston Pin Diameter 0.6285 - 0.6287 in. (15.965 - 15.970 mm) 2. Place the piston pin into the connecting rod and check for free play. There should be no noticeable free play. 3. Place the piston pin into the piston and check for free play. There should be no noticeable free play. Page 4B-22 90-854785R2 DECEMBER 2001 CYLINDER BLOCK/CRANKCASE Piston Rings PISTON RING SIDE CLEARANCE 1. Measure piston ring side clearance. Replace piston and or piston rings if out of specification. 55842 Piston Ring Side Clearance Top 0.0008 - 0.0024 in. (0.02 - 0.06 mm) Middle 0.001 - 0.003 in. (0.03 - 0.08 mm) PISTON RING END GAP CLEARANCE 1. Measure piston ring end gap clearance. Replace piston ring if out of specification. a a-Push Piston Rings into Cylinder 0.8 in. (20 mm) Deep. Push in the Rings Using the Piston. Piston Ring End Gap Top 0.006 - 0.012 in. (0.15 - 0.30 mm) 2nd 0.012 - 0.020 in. (0.30 - 0.50 mm) Oil 0.008 - 0.028 in. (0.20 - 0.70 mm) 90-854785R2 DECEMBER 2001 Page 4B-23 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. Crankshaft Run-out 0.0012 in. (0.03 mm) 3. Clean oil holes in crank rods and block. Checking Main Bearing Clearance IMPORTANT: Do not interchange the main bearings. Reinstall in their original position. 1. Clean all the old sealing material from the split line on the crankcase cover and cylinder block. 2. Clean all the oil from the following areas: a. Main bearing surfaces on the cylinder block and crankcase cover. b. Main bearings. c. Crankshaft bearing surfaces. NOTE:Refer to instructions in Cylinder Block Reassemblyfor selecting and installing main bearings. 3. Install main bearings. 4. Place crankshaft into cylinder block. Page 4B-24 90-854785R2 DECEMBER 2001 CYLINDER BLOCK/CRANKCASE 5. Place a piece of plastigauge onto each crankshaft bearing surface. a a-Plastigauge 6. Install crankcase cover. Apply oil to the cover screws and torque cover screws in sequence and in two steps. 1 2 34 5 6 7 8 910 11 12 b a a-Screws M8 x 82 (6) b-Screws M6 x 35 (6) Crankcase Cover Screw Torque Center Screws Qty. 6 (Larger Diameter M8) 1st: 11 lb. ft. (15 N·m) 2nd: 22 lb. ft. (30 N·m) Outer Screws Qty. 6 (Smaller Diameter M6) 1st: 53 lb. in. (6 N·m) 2nd: 106 lb. in. (12 N·m) 90-854785R2 DECEMBER 2001 Page 4B-25 CYLINDER BLOCK/CRANKCASE 7. Remove the crankcase cover. Measure the compressed plastigauge to check the main bearing clearance. Replace bearings if clearance is not in specification. Main Bearing Clearance 0.0005 - 0.0017 in. (0.012 - 0.044 mm) 8. If replacement of the main bearings is required, refer to Main Bearing Selection and Installation in Cylinder Block Reassembly. Checking Connecting Rod Bearing Clearance IMPORTANT: Do not interchange used connecting rod bearings. Reinstall bearings in their original position. 1. Clean all the oil from the connecting rod bearing surfaces and connecting rod journals on the crankshaft. NOTE:Refer to instructions in Cylinder Block Reassemblyfor selecting and installing connecting rod bearings. 2. Place a piece of plastigauge on the connecting rod journals. a a-Plastigauge IMPORTANT: Do not rotate connecting rod when checking clearance. Page 4B-26 90-854785R2 DECEMBER 2001 CYLINDER BLOCK/CRANKCASE 3. Install the connecting rod to the respective journal. Tighten connecting rod screws in sequence and in two steps to the specified torque. a a-Connecting Rod Screws Connecting Rod Screw Torque 1st: 53 lb. in. (6 N·m) 2nd: 150 lb. in. (17 N·m) 4. Remove the connecting rod cap. Measure the compressed plastigauge to check the connecting rod oil clearance. Replace bearings if oil clearance is not in specification. Connecting Rod Oil Clearance 0.0008 – 0.0020 in. (0.020 - 0.052 mm) 90-854785R2 DECEMBER 2001 Page 4B-27 CYLINDER BLOCK/CRANKCASE Thermostat 1. Measure the lift of the thermostat at the operating water temperature listed. Water Temperature Valve Lift 136° -143° F (58° - 62° C) 0 in. (0 mm) Above 158° F (70° C) Minimum 0.12 in. (3 mm) Oil Pressure Switch 1. Check continuity of switch. 55845 Oil Switch Continuity Check Below 2.25 PSI (15.5 kPa) Continuity Above 2.25 PSI (15.5 kPa) No Continuity Page 4B-28 90-854785R2 DECEMBER 2001 CYLINDER BLOCK/CRANKCASE 90-854785R2 DECEMBER 2001 Page 4B-29 Cylinder Block Reassembly Selecting New Main Bearings 1. Locate the main bearing code letters on the cylinder block. 2. Refer to the following reference chart to select the correct main bearings. 3. Use the color coded main bearings that match the main bearing code letter. Main Bearing Code Letter Main Bearing Color Code A Blue B Black C Brown #1 #2 #3 #1 #2 #3 A BC a b a - Main Bearing Code Letters (A, B, or C) b - Main Bearing Identification Color Location CYLINDER BLOCK/CRANKCASE Page 4B-30 90-854785R2 DECEMBER 2001 Main Bearing Installation IMPORTANT: Do not interchange used main bearings. Reinstall in their original position. 1. Check clearance of each bearing, following procedure in Cleaning and Inspection. 2. Clean all oil from the main bearing surfaces on the cylinder block and crankcase cover. 3. Install main bearings. Make sure the locking lug on each bearing fits into its notch. a b a - Main Bearings b - Fit the Locking Lugs into the Notches Selecting New Connecting Rod Bearings 1. Locate connecting rod bearing code letter that is scribed on the side of the connecting rod. 2. Refer to the following reference chart to select the correct connecting rod bearings. 3. Use the color coded connecting rod bearings that match the connecting rod bearing code letter. Connecting Rod Bearing Code Letter Connecting Rod Bearing Color Code A Blue B Black C Brown 53816 ABC a b a - Connecting Rod Bearing Code Letters b - Connecting Rod Bearing Identification Color Location CYLINDER BLOCK/CRANKCASE Installing Connecting Rod Bearings IMPORTANT: Do not interchange used connecting rod bearings. Reinstall bearings in their original position. 1. Clean all oil from the bearing surfaces on the connecting rod. 2. Install connecting rod bearings. Make sure the locking lug on each bearing fits into its notch. 53815 a b a-Connecting Rod Bearings b-Fit the Locking Lugs into the Notches Connecting Rod Installation 1. Lubricate the piston pin with oil and assemble the piston to the connecting rod. Always use new circlips. IMPORTANT: Install side of connecting rod marked with a “Y” towards “UP” on piston. Y a b a c a-Circlip b-Piston Pin c-Side Marked “Y” is Installed Towards “UP” on Piston 90-854785R2 DECEMBER 2001 Page 4B-31 CYLINDER BLOCK/CRANKCASE Piston Ring Installation 1. Install the oil ring components as shown. Align upper oil ring rail ends with locating pin. Spread rings just enough to slip over piston. 53818 a b d e f c a-Lower Oil Ring Rail b-Lower Rail has Flat Ends c-Upper Oil Ring Rail d-Upper Rail has Notched Ends e-Oil Ring Spacer f-Locating Pin (Align Upper Oil Ring Rail Ends with Pin) 2. Install the second and top compression rings (“T” side up). Spread rings just enough to slip over piston. 53818 a b c a-Top Compression Ring ( “T” Side Up) b-Second Compression Ring ( “T” Side Up) c-Install Side of Ring Stamped “T” Towards Top of Piston Page 4B-32 90-854785R2 DECEMBER 2001 CYLINDER BLOCK/CRANKCASE Piston Installation 1. Align piston ring end gaps as shown. UP 50° a b c d e a-End Gap – Top Compression Ring b-End Gap – Second Compression Ring c-End Gap – Upper Oil Ring Rail d-End Gap – Lower Oil Ring Rail e-End Gap – Oil Ring Spacer 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. 2. Lubricate pistons, rings, and cylinder walls with engine oil. 3. Install each piston in its respective cylinder. NOTE:Install used pistons into same cylinder from which they were removed. 4. Use Piston Ring Compressor (FT2997) to compress rings. 5. Position the “UP” mark on the piston toward the flywheel side. Push each piston into the cylinder until all rings enter the bore. IMPORTANT: Position the “UP” mark on the piston toward the flywheel end. a a-Piston Ring Compressor (FT2997) 90-854785R2 DECEMBER 2001 Page 4B-33 CYLINDER BLOCK/CRANKCASE Page 4B-34 90-854785R2 DECEMBER 2001 Crankshaft Installation 1. Lubricate the crankshaft bearing surfaces with engine oil. 2. Lubricate balance rod journal with engine oil. 3. Install balance rod on crankshaft. 4. Carefully lower crankshaft into place. 5. Lubricate the connecting rod journals with engine oil. 6. Assemble the connecting rods to the crankshaft. Install the connecting rod caps, aligning the code letter marked on the connecting rod and cap. 7. Apply oil to the connecting rod screws. Tighten screws in sequence and in two steps to the specified torque. 55816 a a - Apply Oil to Screw Threads and Tighten to Specified Torque Connecting Rod Screw Torque 1st: 53 lb. in. (6 N·m) 2nd: 150 lb. in. (17 N·m) CYLINDER BLOCK/CRANKCASE 8. Lubricate the oil seals lips with oil. 9. Install upper and lower oil seals. Position oil seal lips as shown. 10. If removed, install dowel pins. a c a b a-Dowel Pin (2) b-Upper Oil Seal c-Lower Oil Seal (Raised Rib) 90-854785R2 DECEMBER 2001 Page 4B-35 CYLINDER BLOCK/CRANKCASE Crankcase Cover Installation 1. 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. 2. Apply a smooth even coat of Loctite Master Gasket Sealant to contacting surfaces on the crankcase cover. Use a small (paint type) roller to spread out 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. a b a-Apply Loctite Master Gasket Sealant b-Use a Roller to Apply a Smooth Even Coat 3. Apply oil to screw threads. Tighten screws in sequence and in two steps to specified torque. 1 2 34 5 6 7 8 910 11 12 a b a-Screws M8 (6) b-Screws M6 (6) Crankcase Cover Screw Torque Center Screws Qty. 6 (Larger Diameter M8) 1st: 11 lb. ft. (15 N·m) 2nd: 22 lb. ft. (30 N·m) Outer Screws Qty. 6 (Smaller Diameter M6) 1st: 53 lb. in. (6 N·m) 2nd: 106 lb. in. (12 N·m) Page 4B-36 90-854785R2 DECEMBER 2001 CYLINDER BLOCK/CRANKCASE 90-854785R2 DECEMBER 2001 Page 4B-37 4. Install balance piston, secure with nut. 55814 a b a - Nut (30mm) b - Piston Balance Piston Nut Torque 116 lb. ft. (157 N·m) 5. Install O-ring and cover. a b c a - Screws (4) b - Cover c - O-Ring Cover Screw Torque 115 lb. in. (13 N·m) CYLINDER BLOCK/CRANKCASE Page 4B-38 90-854785R2 DECEMBER 2001 Cylinder Head Installation 1. Refer to Section 4A for cylinder head installation. Exhaust Cover Installation 1. Install exhaust cover, thermostat, and thermostat cover. NOTE: Always use new gaskets. a b c e f d g a - Screws (7) b - Exhaust Cover c - Gasket d - Thermostat e - Gasket f - Thermostat Cover g - Screws (2) 2. Tighten screws in sequence and in two steps to the specified torque. 55812 1 2 3 4 5 6 8 9 7 Exhaust and Thermostat Cover Screw Torque 1st: 53 lb. in. (6 N·m) 2nd: 106 lb. in. (12 N·m) CYLINDER BLOCK/CRANKCASE 3. Install oil filter. 55854 91-802653 b a a-Oil Filter b-Oil Filter Wrench 91-802653 Ignition Components 1. Refer to Section 2A for installation of the following components. a. Flywheel b. Stator c. Timing Belt d. Ignition Coil e. ECM Charging and Starting System Components 1. Refer to Section 2B for installation of the following components. a. Starter Motor b. Voltage Regulator c. Start Solenoid Fuel Components 1. Refer to Section 3A and 3B for installation of the following components. a. Fuel Pump b. Carburetor 90-854785R2 DECEMBER 2001 Page 4B-39 CYLINDER BLOCK/CRANKCASE Powerhead Installation 1. Install powerhead and new gasket with 8 screws. Tighten screws in sequence and to the specified torque. 1 3 5 6 7 a b 2 4 8 a-Powerhead Mounting Screws (4 Each Side) b-Gasket Powerhead Mounting Screw Torque 20 lb. ft. (38 N·m) Page 4B-40 90-854785R2 DECEMBER 2001 CYLINDER BLOCK/CRANKCASE 90-854785R2 DECEMBER 2001 Page 4B-41 Following Powerhead Installation 1. Slide retainer over and push down to engage the vertical shift shaft. 55770 1 2 a a - Retainer 2. Connect inlet hose from fuel pump. Install sta-strap on inlet fuel hose. d b c d c a 59166 55780 a - Fuel Pump, USA S/N 0T409000 and Above, Belgium S/N 0P153500 and Above b - Fuel Pump, USA S/N 0T408999 and Below, Belgium S/N 0P153499 and Below c - Sta-Strap d - Inlet Fuel Hose CYLINDER BLOCK/CRANKCASE Page 4B-42 90-854785R2 DECEMBER 2001 3. Install sta-strap and connect vent hose. 55771 a a - Vent Hose 4. Install bottom cowl. a b a - Screws (6) b - Screw (M6x60) Bottom Cowl Screw Torque 60 lb. in. (7 N·m) 5. Connect the power trim wires (if so equipped). 6. On electric start models, connect the battery cables from the battery. Install battery cables from engine. LUBRICATION POWERHEAD Section 4C - Lubrication Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-2 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-4 Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . 4C-2 Oil Pump Assembly . . . . . . . . . . . . . . . . . . . . . . 4C-5 Oil Pump Disassembly . . . . . . . . . . . . . . . . . . . 4C-3 Oil Pump Installation . . . . . . . . . . . . . . . . . . . . . 4C-6 Cleaning and Inspection . . . . . . . . . . . . . . . . . . 4C-4 4 C 90-854785R2 DECEMBER 2001 Page 4C-1 LUBRICATION Specifications Pump Type Engine Oil Pressure Engine Oil Pan Capacity Oil Pump: Outer Rotor to Housing “a” Inner Rotor to Outer Rotor “b” Rotor to Housing “c” Trochoid 30-40 PSI at 3000 RPM (Warm Engine) Either 3 Qts. or 3 Liters 0.0035 - 0.006 in. (0.09 - 0.15 mm) 0.005 in. (0.12 mm) 0.001 - 0.003 in. (0.03 - 0.08 mm) a LUBRICATION SYSTEM b c Oil Pump Removal 1. Remove oil pump screws. 2. Separate oil pump from cylinder head. a a a-Screws (4) Page 4C-2 90-854785R2 DECEMBER 2001 LUBRICATION Oil Pump Disassembly 1. Heat screws to loosen Loctite sealant. Remove screws. a a-Screw (2) Heat Screws to Loosen Loctite Sealant 2. Disassemble Oil Pump. ac b e d a-Cover Seal b-Outer Rotor c-Inner Rotor d-Shaft e-Cross Pin 90-854785R2 DECEMBER 2001 Page 4C-3 LUBRICATION Cleaning and Inspection Oil Pump 1. Check oil pump components for pitting, scratches, and for the following measurements. Replace oil pump if worn or out of specification. 2. Using a feeler gauge, measure the following oil pump clearances: a. Between outer rotor and pump housing (a). b. Between the inner rotor and outer rotor (b). c. Between the outer rotor and pump housing (c). a bc Oil Pump Clearances a 0.0035 - 0.006 in. (0.09 - 0.15 mm) b 0.005 in. (0.12 mm) c 0.001 - 0.003 in. (0.03 - 0.08 mm) Page 4C-4 90-854785R2 DECEMBER 2001 LUBRICATION Oil Pump Assembly 1. Reassemble the oil pump assembly. 2. Lubricate the outer and inner rotors thoroughly with engine oil. ac b e d a-Cover Seal b-Outer Rotor c-Inner Rotor d-Shaft e-Cross Pin 3. Fasten cover with two screws. Apply Loctite 222 to threads. Tighten screws to the specified torque. a a-Screws (2) Apply Loctite 222 to Threads Oil Pump Cover Screw Torque 70 lb. in. (8 N·m) 90-854785R2 DECEMBER 2001 Page 4C-5 LUBRICATION Oil Pump Installation 1. Place O-ring seals on the oil pump. Lubricate the O-rings with oil. 2. Prime the oil pump by pouring approximately 1 fl. oz. (30 ml) of engine oil into the oil pump body. 53730 a b a a a-O-Ring Seals b-Pour Approximately 1 fl. oz. (30 ml) of Engine Oil into the Oil Pump Body 3. Align oil pump shaft with the camshaft and install the oil pump. 4. Fasten with 4 screws. Tighten screws to the specified torque. 53738 b a c a-Oil Pump Assembly b-Align Slot with Camshaft Projection c-Screw (4) Oil Pump Mounting Screw Torque 70 lb. in. (8 N·m) Page 4C-6 90-854785R2 DECEMBER 2001 CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING MID-SECTION Section 5A - Clamp/Swivel Brackets & Driveshaft Housing Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-1 Driveshaft Housing . . . . . . . . . . . . . . . . . . . . . . 5A-8 Clamp Bracket (Remote Control) . . . . . . . . . . 5A-2 Adaptor Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-10 Swivel Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-4 Steering Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-12 Swivel Bracket (Remote Control) . . . . . . . . . . 5A-6 Specifications Transom Height: Short Shaft 15 in. (38 cm) Long Shaft 20 in. (51 cm) MID-SECTION Steering Pivot Range 90° Tilt Pin Positions 5 + Shallow Water Full Tilt Up Angle 70° Allowable Transom Thickness 2-3/8 in. (60.3 mm) 5 A 90-854785R2 DECEMBER 2001 Page 5A-1 CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING CLAMP BRACKET (Remote Control) 95 95 95 7 Loctite 271 Thread Locker 2-4-C Marine Lubricant with Teflon Page 5A-2 90-854785R2 DECEMBER 2001 CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING CLAMP BRACKET (Remote Control) REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 11 1 CLAMP BRACKET (PORT) (BLACK) 1 CLAMP BRACKET (PORT) (GRAY) 1 CLAMP BRACKET (PORT) (GRAND CANYON) (BLACK) 22 1 CLAMP BRACKET (STBD) (BLACK) CLAMP BRACKET (STBD) (GRAY) USE W/ .56 O.D. Ref. #10 CLAMP BRACKET (STBD) (GRAND CANYON) (BLACK) 1 1 1 CLAMP BRACKET (STBD) (BLACK) CLAMP BRACKET (STBD) (GRAY) USE W/ .75 O.D. Ref. #6 CLAMP BRACKET (STBD) (GRAND CANYON) (BLACK) 1 1 3 1 CAP–Tilt Stop Pin ROLL PIN O.D. of Ref. # 6 is .75 & BUSHING Ref. # 5 is NOT FLANGED PIN–Tilt Stop 4 1 5 1 6 1 7 1 CAP–Tilt Stop Pin ROLL PIN O.D. of Ref. # 10 is .56 & BUSHING Ref. # 9 is FLANGED PIN–Tilt Stop 8 1 9 1 10 1 11 1 DECAL-Shallow Water 12 1 DECAL-Tilt Lock 13 1 NUT (M10 x 1.5) 28 38 14 1 WASHER 15 1 ANODE WASHER NON GRAND CANYON SCREW (M6 x 25) 16 2 17 2 60 7 18 1 STUD (M10 x 277) 19 1 SPACER 20 4 NUT (M10 x 1.5) Drive Tight 21 4 WASHER 22 4 SCREW (.500-20 x 4 IN.) 23 1 NUT (M10 x 1.5) NON GRAND CANYON 28 38 24 1 WASHER 25 1 TILT LOCK PIN 26 1 SPRING 27 1 LEVER–Shallow Water Drive 28 1 ROLL PIN 29 1 BUSHING (PLASTIC) 30 1 ROD–Shallow Water Drive 31 1 BUSHING (PLASTIC) 32 1 BUSHING 33 1 ARM 34 1 LINK ROD 35 1 SPRING 90-854785R2 DECEMBER 2001 Page 5A-3 CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING SWIVEL BRACKET 23 8 2-4-C Marine Lubricant with Teflon 4-Stroke Outboard Oil A = TORQUE NUT 120 lb. in. (13.5 N.m) AND THEN BACK OFF 1/4 TURN. Page 5A-4 90-854785R2 DECEMBER 2001 CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING SWIVEL BRACKET REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 LINK ROD 2 1 SCREW (1-1/2 IN.) 20 27.0 3 1 WASHER NON HANDLE 4 2 WASHER 5 2 NUT (.375-24) 120* 13.5* 6 1 PUCK (ELECTRIC) 77 1 SWIVEL BRACKET (BLACK) 1 SWIVEL BRACKET (GRAY) 8 1 BUSHING 9 1 BUSHING (LOWER) 10 1 SEAL 11 3 GREASE FITTING 33 3.5 12 1 GREASE FITTING (HANDLE) 33 3.5 13 1 SEAL KIT 14 1 O RING NON HANDLE 15 1 SPACER 16 1 WASHER 17 1 NUT (.875-14) 18 1 DECAL-Serial Overlaminate 1919 1 SCREW (M8 x 10) MANUAL HANDLE Drive Tight 1 SCREW (M8 x 25) ELECTRIC Drive Tight 20 1 SEAL 21 1 WASHER 22 1 TILT TUBE 23 1 NUT 24 1 PIN (TRILOBE) 25 2 BUSHING 26 1 PIVOT PIN (UPPER) 27 1 DECAL–Co-pilot A = TORQUE NUT 120 lb. in. (13.5 N.m) AND THEN BACK OFF 1/4 TURN. 90-854785R2 DECEMBER 2001 Page 5A-5 CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING SWIVEL BRACKET (Remote Control) 95 2-4-C Marine Lubricant with Teflon 66 Loctite 242 4-Stroke Outboard Oil B A B 110 A = TIGHTEN NUT UNTIL IT SEATS AND THEN BACK OFF 1/4 TURN. B = TIGHTEN NUT TO 32 LB. FT. (43 N.M) AND THEN BACK OFF 1/4 TURN. Page 5A-6 90-854785R2 DECEMBER 2001 CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING SWIVEL BRACKET (Remote Control) REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 LINK ROD 2 1 SCREW (1-1/2 IN.) 240 20 27 3 1 WASHER 4 2 WASHER 5 2 NUT (.375-24) * 6 1 PUCK–Co-pilot 7 77 1 SWIVEL BRACKET ASSEMBLY (BLACK) 1 SWIVEL BRACKET ASSEMBLY (GRAY) 8 1 BUSHING (UPPER) 9 3 GREASE FITTING 10 1 BUSHING (LOWER) 11 1 SEAL 12 1 WASHER 13 1 NUT (.875-14) 14 1 COTTER PIN 15 1 PIVOT PIN–Reverse Lock 16 1 DECAL-Serial Overlaminate 17 1 SCREW (M8 x 1.25 x 25) Drive Tight 18 1 SEAL 19 1 WASHER 20 1 TILT TUBE 21 1 NUT (.875-14) ** 22 1 PIN (TRILOBE) 23 2 BUSHING 24 1 PIVOT PIN (UPPER) 25 1 STRAP–Tilt Stop 26 1 LINK–Reverse Lock (UPPER) 27 1 LEVER–Reverse Lock 28 1 NUT 90 10 29 2 PIN–Reverse Lock 30 2 SPRING–Reverse Lock 31 1 LINK–Reverse Lock 32 1 WASHER 33 1 ARM–Reverse Lock 34 1 REVERSE LOCK 35 2 NUT 36 1 SEAL 37 1 O RING 38 1 SPACER *A = TIGHTEN NUT UNTIL IT SEATS AND THEN BACK OFF 1/4 TURN. **B = TIGHTEN NUT TO 32 LB. FT. (43.4 N.M) AND THEN BACK OFF 1/4 TURN. 90-854785R2 DECEMBER 2001 Page 5A-7 CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING Page 5A-8 90-854785R2 DECEMBER 2001 DRIVESHAFT HOUSING 1 2 3 4 5 6 8 7 9 10 11 12 13 14 15 CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING DRIVESHAFT HOUSING REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 SEAL–water tube 22 1 DRIVESHAFT HOUSING (SHORT) (BLACK) 1 DRIVESHAFT HOUSING (SHORT) (GRAY) 1 DRIVESHAFT HOUSING (LONG) (BLACK) 1 DRIVESHAFT HOUSING (LONG) (GRAY) 33 1 EXHAUST PIPE (SHORT) 1 EXHAUST PIPE (LONG) 4 8 SCREW–Adaptor Plate 28 38 5 5 SCREW (M8 x 45) 28 38 6 1 DRAIN PLUG 17.5 23.5 7 1 GASKET 8 2 BUMPER 9 1 GROMMET (LONG) 10 1 STUD 144 16.5 11 1 WASHER 12 1 NUT 40 54 1313 1 WATER TUBE (SHORT) 1 WATER TUBE (LONG) 14 1 GUIDE 15 1 BUMPER (LONG) 90-854785R2 DECEMBER 2001 Page 5A-9 CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING Page 5A-10 90-854785R2 DECEMBER 2001 ADAPTOR PLATE 110 4-Stroke Outboard Oil 9 Loctite PST Pipe Sealant 110 110 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 24 15 5 5 5 CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING ADAPTOR PLATE REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 DIPSTICK 2 1 DIPSTICK TUBE 3 1 SEAL 4 1 HEAT SHIELD 5 5 DOWEL PIN 6 1 ELBOW 7 2 STA-STRAP 8 1 SEAL–driveshaft 9 1 BUSHING 10 1 PLUG–oil passage 11 1 GROMMET 12 1 ADAPTOR PLATE 13 1 GASKET 14 1 O RING 15 3 SCREW (M6 x 1 x 20) 75 8.5 16 1 DEFLECTOR-Oil 17 1 BODY–oil pressure relief 34 46 18 1 COTTER PIN 19 1 PLUNGER 20 1 SPRING 21 1 PLATE-Top Oil Pickup 22 1 HOSE-Oil Pickup 23 1 BAFFLE 24 2 CLAMP 90-854785R2 DECEMBER 2001 Page 5A-11 CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING Page 5A-12 90-854785R2 DECEMBER 2001 STEERING ARM 95 2-4-C Marine Lubricant with Teflon 94 Anti-Corrosion Grease 94 95 95 95 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 28 27 CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING STEERING ARM REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 2 NUT 50 68 2 1 STRAP 3 2 MOUNT 4 8 SCREW (M6 x 20) 130 14.7 5 1 BUMPER 6 1 RETAINING RING 77 1 STEERING ARM (BLACK) 1 STEERING ARM (GRAY) 8 1 BRACKET TAB WASHER ELECTRIC SCREW (M10 x 1.5 x 30) 9 1 10 2 32.5 44 11 2 BOLT (M12 x 1.75 x 154) 50 68 1212 1 SPACER (SHORT) 1 SPACER (LONG) 1313 1 SWIVEL TUBE (SHORT) 1 SWIVEL TUBE (LONG) 14 1 GROUND STRAP 15 1 GROUND STRAP 16 2 BOLT (M10 x 1.5 x 105) 32.5 44 17 1 BRACKET 18 3 SCREW(SELF–TAPPING) Drive Tight 19 2 NUT 25 2.8 20 1 NUT (.375-24) LEVER–Co-Pilot WASHER ROD (THREADED) HANDLE BRACKET PLATE DISC PLATE DISC SCREW (Hex Shoulder) 25 2.8 21 1 22 1 23 1 24 1 25 1 26 1 27 1 28 2 70 8.0 90-854785R2 DECEMBER 2001 Page 5A-13 POWER TRIM MID-SECTION Section 5B - POWER TRIM Table of Contents Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-2 “DOWN” Pressure Check . . . . . . . . . . . . . . . 5B-39 Power Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-4 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-41 Power Trim Mounting . . . . . . . . . . . . . . . . . . . . . 5B-6 Shock Rod Removal . . . . . . . . . . . . . . . . . . . 5B-41 Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . 5B-8 Shock Rod Disassembly . . . . . . . . . . . . . . . . . . 5B-42 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-8 Memory Piston Removal . . . . . . . . . . . . . . . 5B-45 Trimming Characteristics . . . . . . . . . . . . . . . 5B-8 Trim Motor Removal . . . . . . . . . . . . . . . . . . . 5B-46 Trailering Outboard . . . . . . . . . . . . . . . . . . . . 5B-10 Oil Pump Removal . . . . . . . . . . . . . . . . . . . . 5B-47 Tilting Outboard Up and Down Manually . . 5B-10 Tilt Relief Valve Removal . . . . . . . . . . . . . . . 5B-48 Trim “In” Angle Adjustment . . . . . . . . . . . . . 5B-11 Suction Seat Removal . . . . . . . . . . . . . . . . . 5B-49 Power Trim Flow Diagrams - Trim Up . . . . 5B-12 Pilot Check Valve Assembly Removal . . . . 5B-50 Tilt Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-14 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . . 5B-51 Maximum Tilt . . . . . . . . . . . . . . . . . . . . . . . . . 5B-16 Trim Motor Electrical Tests . . . . . . . . . . . . . . 5B-51 Trim Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-18 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-52 Shock Function Up . . . . . . . . . . . . . . . . . . . . 5B-20 O-Ring and Seal Placement . . . . . . . . . . . . 5B-53 Shock Return Function . . . . . . . . . . . . . . . . . 5B-22 Power Trim Reassembly . . . . . . . . . . . . . . . . . . 5B-54 Manual Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-24 Tilt Relief Valve Reassembly . . . . . . . . . . . . 5B-54 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-26 Suction Seat Reassembly . . . . . . . . . . . . . . 5B-55 Preliminary Checks . . . . . . . . . . . . . . . . . . . . 5B-26 Pilot Check Valve Reassembly . . . . . . . . . . 5B-56 Hydraulic System Troubleshooting Oil Pump Reassembly . . . . . . . . . . . . . . . . . 5B-57 Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-27 Trim Motor Reassembly . . . . . . . . . . . . . . . . 5B-58 Troubleshooting the Power Trim Shock Rod Reassembly . . . . . . . . . . . . . . . . 5B-59 Electrical System . . . . . . . . . . . . . . . . . . . . . . 5B-31 Shock Rod Installation . . . . . . . . . . . . . . . . . 5B-62 Power Trim System Removal . . . . . . . . . . . . . . 5B-33 Manual Release Valve Installation . . . . . . . 5B-63 Testing Power Trim System with Bleeding Power Trim Unit . . . . . . . . . . . . . . 5B-63 Test Gauge Kit . . . . . . . . . . . . . . . . . . . . . . . . 5B-36 Power Trim System Installation . . . . . . . . . . . . 5B-64 “UP” Pressure Check . . . . . . . . . . . . . . . . . . 5B-36 5 B 90-854785R2 DECEMBER 2001 Page 5B-1 POWER TRIM Special Tools 1. Spanner Wrench P/N 91-74951 2. Lock-Ring Pliers P/N 91-822778A3, Snap-On P/N SRP2 3. Expanding Rod Snap-On P/N CG41-11 4. Collet Snap-On P/N CG41-12 Page 5B-2 90-854785R2 DECEMBER 2001 POWER TRIM 5. Adaptor Fitting 91-82278A2 and 91-82278A3 54458 6. 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 90-854785R2 DECEMBER 2001 Page 5B-3 POWER TRIM Page 5B-4 90-854785R2 DECEMBER 2001 POWER TRIM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 23 22 24 25 26 3 POWER TRIM POWER TRIM REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 POWER TRIM ASSEMBLY – 1 O RING KIT 2 1 SHOCK ROD ASSEMBLY 45 61 3 1 PILOT CHECK ASSEMBLY 120 13.5 4 1 TILT RELIEF VALVE ASSEMBLY 120 13.5 5 1 SUCTION SEAT ASSEMBLY 120 13.5 6 1 PUMP ASSEMBLY 7 1 SPRING/DOWN RELIEF BALL 8 2 SCREW (10-32 x 1-1/4 IN.) 70 8.0 9 1 FILTER 10 1 SEAL RING 11 1 MOTOR ASSEMBLY 12 4 SCREW (1/4-28 x 5/8 IN.) 80 9.0 13 1 GROUND STRAP 14 1 LOCKWASHER 15 1 O RING 16 1 COUPLER 17 1 MEMORY PISTON 18 1 MANUAL RELEASE VALVE ASSY. Drive Tight 19 1 RESERVOIR PLUG Drive Tight – 1 TRIM HARNESS/RELAY ASSEMBLY 20 1 TRIM HARNESS 21 1 RELAY ASSEMBLY 22 2 BRACKET 23 2 GROMMET 24 2 BUSHING 25 2 DECAL-Trim Relay 26 2 SCREW (M6 x 25) 90-854785R2 DECEMBER 2001 Page 5B-5 POWER TRIM POWER TRIM MOUNTING 95 95 95 1 2 3 4 5 6 7 8 9 10 11 12 13 14 2-4-C Marine Lubricant with Teflon Page 5B-6 90-854785R2 DECEMBER 2001 POWER TRIM POWER TRIM MOUNTING REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 PIN-anchor (14MM) 2 2 BUSHING 3 2 BUSHING 4 2 WASHER 5 2 NUT 18.0 24.5 6 2 SCREW (M10 x 40) 7 2 WASHER 8 2 NUT 9 1 SCREW (10-16 x .35) Drive Tight 10 1 C-WASHER 11 2 CLIP 12 1 PIN 13 1 PIN 14 1 BUSHING 90-854785R2 DECEMBER 2001 Page 5B-7 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” and “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, general 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. Page 5B-8 90-854785R2 DECEMBER 2001 POWER TRIM WARNING Excessive engine trim angle will result in insufficient water supply to water pump causing water pump and/or powerhead overheating damage. Make sure that water level is above gear housing water intake holes whenever engine is running. Operating “Up” circuit will actuate the “up” relay (located under engine cowl) and close the electric motor circuit. The electric motor will drive the pump, thus forcing automatic transmission fluid through internal passageways into the “up” side of the trim cylinder. The trim cylinder/trim rod will position the engine at the desired trim angle within the 20° maximum trim range. The power trim system is designed so the engine cannot be trimmed beyond the 20 maximum trim angle as long as engine RPM is above approximately 2000 RPM. The engine can be raised beyond the 20 maximum trim angle for shallow water operation, etc., by keeping the engine RPM below 2000 RPM. If engine RPM increases above 2000 RPM, the thrust created by the propeller (if deep enough in the water) will cause the trim system to automatically lower the engine back to the 20 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 “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. 90-854785R2 DECEMBER 2001 Page 5B-9 POWER TRIM Trailering Outboard WARNING Excessive engine trim angle will result in insufficient water supply to water pump causing water pump and/or powerhead overheating damage. Make sure that water level is above gear housing water intake holes whenever engine is running. While operating “up” circuit, the cylinder rod will continue to tilt the outboard to a full up position for trailering. Tilting Outboard Up and Down Manually WARNING Before loosening the manual release valve, make sure all persons are clear of engine as engine will drop to full “down” position when valve is loosened. With power trim installed, the outboard can be raised or lowered manually by opening the manual release valve 3 to 4 turns (counterclockwise). a a-Manual Release Valve Page 5B-10 90-854785R2 DECEMBER 2001 POWER TRIM Trim “In” Angle Adjustment WARNING Operating some boats with engine trimmed to the full “in” trim angle at planing speed will cause undesirable and/or unsafe steering conditions. Each boat must be water tested for handling characteristics after engine installation and after any trim adjustments. IMPORTANT: Some boat/motor combinations that are trimmed to the full “in” trim angle, will not experience any undesirable and/or unsafe steering conditions during planing speed. However, some boats with engine trimmed to the full “in” trim angle at planing speed will cause undesirable and/or unsafe steering conditions. If these steering conditions are experienced, adjust the left and right tilt stop pins to prevent unsafe handling characteristics. Water test the boat. If undesirable and/or unsafe steering conditions are experienced (boat runs with nose down), adjust the left and right tilt stop pins in proper hole to prevent unsafe handling characteristics. ba a-Left Tilt Stop Pin b-Right Tilt Stop Pin IMPORTANT: In order to remove the right tilt stop pin it may be necessary to remove the upper pivot pin and pivot the tilt/trim assembly out of the clamp brackets. See “Power Trim System Removal” to remove the upper pivot pin. 90-854785R2 DECEMBER 2001 Page 5B-11 POWER TRIM Page 5B-12 90-854785R2 DECEMBER 2001 Power Trim Flow Diagrams - Trim Up Á Á Á Á Á o v b g h i j k l m n p q r u t s v w w c d e f a 1 a -Electric Motor b -Trim Ram c -Impact Relief Valve d -Shock Piston e -Memory Piston f -Manifold g -Suction Seat h -Down Pressure Operated Valve i -Tilt Relief Actuator j -Manual Release Valve k -Tilt Relief Valve l -Up Pressure Operated Valve m -Down Circuit Feed Valve n -Oil Pump o -Up Circuit Feed Valve p -Shuttle Valve q -Down Pressure Relief Valve r -Check Ball s -Reservoir Oil t -Oil Reservoir u -Oil Fill Cap v -Shock Return Valve w -Filter POWER TRIM Trim Up When the trim switch is activated in the up position, the electric motor (a) begins to rotate the pump gears (n). The oil pump draws a small amount of oil through the filter, up circuit pick-up and past the feed valve check ball (o). The oil pump gear (n) rotation forces oil into the passages for the up circuit. Oil, under pressure, will slide the shuttle valve (p) against the down circuit pressure operated valve (h). The shuttle valve will mechanically open the down pressure operated valve, allowing oil from the down cavity of the trim cylinder, to flow into the oil pump. This returning oil, from the down cavity, will supply most of the oil required for the up circuit. Oil in the up circuit is blocked from returning into the reservoir (t) by the ball inside the down circuit feed valve (m). The pressure of the oil will force the up circuit pressure operated valve (l) to open, allowing the oil to enter the passages inside the manifold (f) leading to the trim cylinder up cavity. Oil is blocked from all other passages by the closed manual tilt valve (j) and closed tilt relief valve (k). Oil under pressure will enter the trim cylinder below the memory piston (e). With an increasing amount of oil entering the cylinder, the memory piston contacts the shock piston (d) and forces the trim rod (b) up and out, raising the outboard motor. Oil on the top of the shock piston exits through a passage running down along the side of the cylinder and enters the manifold passages. Inside the manifold the oil seats the ball (r) inside the suction valve (g), closing the passage into the reservoir. The oil is drawn back into the pump (n) through the open pressure operated valve (h) and enters the pump as supply for the up circuit. 1-Up Pressure - 2520 PSI (17,375 kPa) Minimum Reservoir Oil Oil Under Pressure Return Oil 90-854785R2 DECEMBER 2001 Page 5B-13 POWER TRIM Page 5B-14 90-854785R2 DECEMBER 2001 Power Trim Flow Diagrams - Tilt Up Á Á Á Á Á TILT UP v o p q r w g h i j k l m n o r u t s v w w c d e b f a 1 p a -Electric Motor b -Trim Ram c -Impact Relief Valve d -Shock Piston e -Memory Piston f -Manifold g -Suction Seat h -Down Pressure Operated Valve i -Tilt Relief Actuator j -Manual Release Valve k -Tilt Relief Valve l -Up Pressure Operated Valve m -Down Circuit Feed Valve n -Oil Pump o -Up Circuit Feed Valve p -Shuttle Valve q -Down Pressure Relief Valve r -Check Ball s -Reservoir Oil t - Oil Reservoir u -Oil Fill Cap v -Shock Return Valve w -Filter POWER TRIM Tilt Up In the up mode, as the trim rod (b) extends from the cylinder, the memory piston (e) clears or uncovers the pressure relief passage to the tilt relief actuator (i) and tilt relief valve (k). At this point the trim rod is at its maximum trim position. The tilt relief valve limits the pressure and therefore travel of the piston in the up circuit. When the engine is in forward gear and at high engine rpm, the oil pressure in the up circuit will not overcome the force developed by the propeller thrust. This limits the trim range of the cylinder to the pressure setting of the tilt relief valve (k). High pressure oil causes the tilt relief actuator (i) to open the tilt relief valve (k). Oil from the pump flows over the tilt relief valve (k) and back to reservoir thriugh passages in the manifold (f) until the “up button” is released. As engine speed decreases, or the engine is not in forward gear, less pressure is required to extend the trim rod (b) up into the trim range, so the trim rod can be extended into the tilt range. 1-Tilt Relief Pressure - 500 -600 PSI (3450 -4135 kPa) Reservoir Oil Return Oil Oil Under Pressure 90-854785R2 DECEMBER 2001 Page 5B-15 POWER TRIM Page 5B-16 90-854785R2 DECEMBER 2001 Power Trim Flow Diagrams - Maximum Tilt Á Á ÁÁ Á Á q w d g h i j k l m o p r u t v n w e f a s b c w 1 a -Electric Motor b -Trim Ram c -Impact Relief Valve d -Shock Piston e -Memory Piston f -Manifold g -Suction Seat h -Down Pressure Operated Valve i -Tilt Relief Actuator j -Manual Release Valve k -Tilt Relief Valve l -Up Pressure Operated Valve m -Down Circuit Feed Valve n -Oil Pump o -Up Circuit Feed Valve p -Shuttle Valve q -Down Pressure Relief Valve r -Check Ball s -Reservoir Oil t - Oil Reservoir u -Oil Fill Cap v -Shock Return Valve w -Filter POWER TRIM Maximum Tilt With the cylinder at maximum travel, due to no ram movement, the pressure inside of the trim cylinder will increase to the pressure setting of the tilt relief valve (k). Pressure forces the tilt relief actuator (i) to move and unseat the tilt relief valve (k) allowing oil to return to the reservoir through passages in the manifold (f). Oil flow will continue until the “up button” is released. 1-Tilt Relief Pressure - 500 -600 PSI (3450 -4135 kPa) Reservoir Oil Return Oil Oil Under Pressure 90-854785R2 DECEMBER 2001 Page 5B-17 POWER TRIM Page 5B-18 90-854785R2 DECEMBER 2001 Power Trim Flow Diagrams - Trim Down ÁÁ ÁÁ Á Á k g h o w l b f i g j k h m n o p q r u t s v w w c d e a 1 a -Electric Motor b -Trim Ram c -Impact Relief Valve d -Shock Piston e -Memory Piston f -Manifold g -Suction Seat h -Down Pressure Operated Valve i -Tilt Relief Actuator j -Manual Release Valve k -Tilt Relief Valve l -Up Pressure Operated Valve m -Down Circuit Feed Valve n -Oil Pump o -Up Circuit Feed Valve p -Shuttle Valve q -Down Pressure Relief Valve r -Check Ball s -Reservoir Oil t - Oil Reservoir u -Oil Fill Cap v -Shock Return Valve w -Filter POWER TRIM Down Mode When the trim switch is activated in the down position, the electric motor (a) will rotate the pump (n) in the opposite direction and reverse the flow of oil. Oil is drawn through the filter, past the feed check ball (m), into the down circuit oil pick-up and finally into the oil pump. The pump feeds pressurized oil into the down passages, and slides the shuttle valve (p) into the up circuit pressure operated valve (l). The shuttle valve will mechanically open the pressure operated valve and allow oil, from the up cavity of the trim cylinder (f), to return into the oil pump. This returning oil, from the up cavity, will supply the oil required for the down circuit. The oil is blocked from returning into the reservoir by the ball (p) inside the up circuit feed valve. Oil, under pressure, opens the pressure operated valve (h) and enters the down passages inside of the manifold (f). The manifold passage connects into the trim cylinder passage leading to the top of the cylinder. The cavity, inside the cylinder, above the shock piston (d) is the down cavity. As the down cavity fills with oil, the trim ram (b) retracts into the cylinder, lowering the outboard motor. Oil from the up cavity exits the cylinder and is drawn back into the pump through the open pressure operated valve (l). When the trim ram reached full travel, the oil pressure inside the down circuit will rise until the down pressure relief valve (q) opens, bypassing oil back into the reservoir (t). When the trim button is released, the pump stops supplying oil, both of the pressure operated valves (h & l) will close, and if open, the down pressure regulating valve (q) will close. The closed valves will lock the fluid on either side of the shock piston (d), holding the outboard motor in position. 1-Down Relief Pressure - 500 -800 PSI (3450 -5515 kPa) Reservoir Oil Return Oil Oil Under Pressure 90-854785R2 DECEMBER 2001 Page 5B-19 POWER TRIM Page 5B-20 90-854785R2 DECEMBER 2001 Power Trim Flow Diagrams - Shock Function Up Á Á Á ÁÁ ÁÁ h p q r w b g h i j k l m n o p q r u t v w c d a s f e 1 a -Electric Motor b -Trim Ram c -Impact Relief Valve d -Shock Piston e -Memory Piston f -Manifold g -Suction Seat h -Down Pressure Operated Valve i -Tilt Relief Actuator j -Manual Release Valve k -Tilt Relief Valve l -Up Pressure Operated Valve m -Down Circuit Feed Valve n -Oil Pump o -Up Circuit Feed Valve p -Shuttle Valve q -Down Pressure Relief Valve r -Check Ball s -Reservoir Oil t - Oil Reservoir u -Oil Fill Cap v -Shock Return Valve w -Filter POWER TRIM Shock Function Up Oil inside the down cavity is locked in a static position by the closed pressure operated valve (h), the manual release valve (j) and the tilt relief valve (k). If the outboard strikes an underwater object while in forward gear, the trim ram (b) will try to rapidly extend from the cylinder. The pressure then increases inside the trim cylinder down cavity and connecting passages. The rise in pressure will seat the check ball (r) inside the suction valve (g), preventing fluid from returning into the reservoir. When the pressure increases to the level required, the impact relief valves (c), located inside the shock piston (d), will open and allow the fluid to pass through the shock piston. As the fluid passes through the piston, the trim ram (b) will extend from the trim cylinder. The memory piston (e) is held in position by vacuum, created by the oil in the up cavity being locked in a static position. Therefore; oil passing through the trim ram piston is trapped between the memory piston (e) and shock piston (d). 1-Impact Relief Pressure - 1565 -2000 PSI (10,790-13,790 kPa) Reservoir Oil Return Oil Oil Under Pressure 90-854785R2 DECEMBER 2001 Page 5B-21 POWER TRIM Page 5B-22 90-854785R2 DECEMBER 2001 Power Trim Flow Diagrams - Shock Return Function Á Á ÁÁ Á Á p q r w o b c d e j g h i k l m n o q u t v w w f a s a -Electric Motor b -Trim Ram c -Impact Relief Valve d -Shock Piston e -Memory Piston f -Manifold g -Suction Seat h -Down Pressure Operated Valve i -Tilt Relief Actuator j -Manual Release Valve k -Tilt Relief Valve l -Up Pressure Operated Valve m -Down Circuit Feed Valve n -Oil Pump o -Up Circuit Feed Valve p -Shuttle Valve q -Down Pressure Relief Valve r -Check Ball s -Reservoir Oil t - Oil Reservoir u -Oil Fill Cap v -Shock Return Valve w -Filter POWER TRIM Shock Function Return After the engine clears the under water object, the weight of the engine will increase the oil pressure between the memory piston (e) and shock piston (d), to the level required to open the shock return valve (v), inside the shock piston. This allows the oil to bleed back through the shock piston into the down cavity. If required, additional oil will enter the down cavity through the suction valve (g). This will return the engine back against the memory piston (e) in to the original running position. Reservoir and Feed Oil Return Oil Oil Under Pressure 90-854785R2 DECEMBER 2001 Page 5B-23 POWER TRIM Page 5B-24 90-854785R2 DECEMBER 2001 Power Trim Flow Diagrams - Manual Tilt ÁÁ Á Á Á p q r c d e g f h i j k l m n o p q r u t v w w b a s a -Electric Motor b -Trim Ram c -Impact Relief Valve d -Shock Piston e -Memory Piston f -Manifold g -Suction Seat h -Down Pressure Operated Valve i -Tilt Relief Actuator j -Manual Release Valve k -Tilt Relief Valve l -Up Pressure Operated Valve m -Down Circuit Feed Valve n -Oil Pump o -Up Circuit Feed Valve p -Shuttle Valve q -Down Pressure Relief Valve r -Check Ball s -Reservoir Oil t - Oil Reservoir u -Oil Fill Cap v -Shock Return Valve w -Filter POWER TRIM Manual Tilt To manually tilt the outboard engine, the owner will need to back out the manual tilt valve (j). With the valve backed out, the internal passages inside the manifold are connected together. These passages connect both the cylinder down and up cavities together, along with the reservoir (t), allowing the engine to be raised or lowered. Trim ram (b) movement will continue until the manual tilt valve is closed, locking the fluid inside of the cylinder and manifold. Reservoir and Feed Oil Return Oil 90-854785R2 DECEMBER 2001 Page 5B-25 POWER TRIM Troubleshooting Support outboard with tilt lock pin when servicing power trim system. IMPORTANT: After debris or failed components have been found (during troubleshooting procedure) it is recommended that unit be disassembled completely and ALL O-rings be replaced. Check ball valve components and castings must be cleaned using engine cleaner and compressed air, or replaced prior to re-assembly. IMPORTANT: Power trim system is pressurized. Outboard must be in the full “UP” position (trim rod fully extended) prior to fill/drain plug, or manual release valve removal. Refer to instructions following if disassembly is required when servicing. Follow preliminary checks before proceeding to troubleshooting flow diagrams (following). Preliminary Checks IMPORTANT: Operate Power Trim system after each check to see if problem has been corrected. If problem has not been corrected proceed to next check. 1. Check that manual release valve is tightened to full right (clockwise) position. 2. Check trim pump fluid level with outboard in full “UP” position and fill if necessary. Refer to “Bleeding Power Trim Unit”. 3. Check for external leaks in Power Trim system. Replace defective part(s) if leak is found. 4. Outboard not holding tilted position (falls down to trim position) indicates debris or defective components in trim assembly. Clean or replace components as required. Page 5B-26 90-854785R2 DECEMBER 2001 POWER TRIM Hydraulic System Troubleshooting Flow Chart OUTBOARD WILL NOT HOLD TILTED POSITION DURING REVERSE AND/OR TRAILS OUT DURING HIGH SPEED DECELERATION Inspect manual release valveManual 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 reverse thrust: Testing complete Trim will not hold reverse thrust Replace manual re- lease valve and O- rings Trim system holds reverse 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 reverse thrust: Testing complete Debris and/or shock ball hang up identi- fied Replace pis- ton rod as- sembly Trim system holds reverse thrust: Testing complete Trim will not hold reverse thrust Remove PO check valve assembly, inspect O- rings and seals for dam- age Debris and/or dam- age identified Replace PO check valve as- sembly Trim system holds reverse thrust: Testing complete PO check valve appears O.K. - Clean and reinstall PO check valve assembly Trim will not hold reverse thrust Trim system holds reverse thrust: Testing complete continued on next page 90-854785R2 DECEMBER 2001 Page 5B-27 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: Testing complete Trim will not hold reverse thrust Suction seat assembly appears O.K. - Clean and reinstall suction seat as- sembly Trim system holds reverse thrust: Testing complete Page 5B-28 90-854785R2 DECEMBER 2001 POWER TRIM Hydraulic System Troubleshooting Flow Chart TRIM SYSTEM LEAKS DOWN WITH MANUAL RELEASE VALVE CLOSED Inspect manual release valveManual release valve and O-ring damaged Replace manual re- lease valve and O- rings Trim system does not leak down: Testing 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: Testing 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: Testing 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: Testing complete Remove PO check valve assembly, inspect O- rings and seals for dam- age Debris and/or dam- age identified Replace PO check valve assembly PO check valve appears O.K. - Clean and reinstall PO check valve assembly continued on next page Trim system leaks down Trim system does not leak down: Testing complete Trim system does not leak down: Testing complete 90-854785R2 DECEMBER 2001 Page 5B-29 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 ap- pears rough and/or debris found in cylin- der Trim leaks down Trim system does not leak down: Testing complete Page 5B-30 90-854785R2 DECEMBER 2001 POWER TRIM Troubleshooting the Power Trim Electrical System LT.BLU/WHT GRN/WHT BLUE 14 BLK RED BLK DN UP AB RED RED/PUR DN UP LT. GRN/WHT LT. BLU/WHT RED GRN/WHT BLU/WHT DN UP GRN/WHT BLU/WHT Trim Switch (Remote Control Mounted) Trim Switch (Panel Mounted) Fuse Holder Solenoid Fuse Holder Down Relay Up Relay Cowl Switch RED GRN/WHT or GRN BLU/WHT or PUR GRN 14 BLK RED BLK +– Battery LT. GRN/WHT LT. BLU/WHT Trim Pump Motor RED/PUR Starter Screw Remote Control 21 41 3 90-854785R2 DECEMBER 2001 Page 5B-31 POWER TRIM Troubleshooting the Power Trim Electrical System Refer to wiring diagram on preceding page for location of wire connections. Problem Possible Cause Remedy Trim Switch “UP” is inoperative, but the Cowl Switch “UP” does operate. 1. Open wire between Wire Connection (1) and Trim Switch. 2. Faulty Trim Switch. 1. Check for a open connection or cut wire. 2. Replace Cowl Switch “UP” is inoperative, but the Trim Switch “UP” does operate. 1. Open wire between Wire Connection (2) and Solenoid. 2. Faulty Cowl Switch. 1. Check for a open connection or cut wire. 2. Replace Trim Switch “UP” and Cowl Switch “UP” are both inop1. Open wire between Wire Connection (1) and the Up Relay 1. Check for an open connection. erative. 2. Open BLK wire between ground and UP Relay. 2. Check for an open connection. 3. Open RED wire between Solenoid and Up Relay 3. Check for an open connection. 4. Faulty Up Relay. 4. Replace Trim Switch “DOWN” is inoperative, but the Cowl Switch “DOWN” does operate. 1. Open wire between Wire Connection (3) and Trim Switch. 2. Faulty Trim Switch. 1. Check for a open connection or cut wire. 2. Replace Cowl Switch “DOWN” is inoperative, but the Trim Switch “DOWN” does operate. 1. Open wire between Wire Connection (2) and Solenoid. 2. Faulty Cowl Switch. 1. Check for a open connection or cut wire. 2. Replace Trim Switch “DOWN” and Cowl Switch “DOWN” are 1. Open wire between Wire Connection (3) and the Up Relay. 1. Check for an open connection. both inoperative. 2. Open BLK wire between ground and Down Relay. 2. Check for an open connection. 3. Open RED wire between Solenoid and Down Relay. 3. Check for an open connection. 4. Faulty Down Relay. 4. Replace Trim Switch “UP” and “DOWN” are both inoperative, but the Cowl Switch does operate. 1. 20 AMP Fuse blown. 2. Faulty trim switch. 3. Wire is open between fuse holder and solenoid. 4. Wire is open between fuse holder and trim switch. 1. Replace fuse. Locate the cause of the blown fuse. Check electrical wiring for a shorted circuit. 2. Replace 3. Check for a open connection or cut wire. 4. Check for a loose or corroded connection. Trim Switch and Cowl Switch are both inoperative. 1. One of the Trim Pump Motor wires is open between the motor and the Relays. 2. Faulty trim pump motor. 1. Check wire connections (4) for loose or corroded condition. 2. If voltage is present at connections (4) when the appropriate trim button is pressed, the motor is faulty. Replace motor. Trim system operates (motor runs) without pressing the switches. 1. The Trim or Cowl switch is shorted. 1. Replace Page 5B-32 90-854785R2 DECEMBER 2001 POWER TRIM Power Trim System Removal 1. Tilt outboard to the full up position and support with tilt lock pin. a a-Tilt Lock Pin 2. Disconnect the power trim wire harness and remove clamps. a a-Power Trim Wire Harness Clamps 90-854785R2 DECEMBER 2001 Page 5B-33 POWER TRIM 3. Remove the trilobe pin. 4. Drive out the upper pivot pin. a b a-Trilobe Pin b-Upper Pivot Pin 5. Remove the sacrificial anode. a a-Sacrificial Anode Page 5B-34 90-854785R2 DECEMBER 2001 POWER TRIM 6. Remove nuts and washers securing the lower pivot pin. Remove lower pivot pin. Retain the pivot pin bushings from the clamp brackets and trim unit. 7. Remove the trim unit. 90-854785R2 DECEMBER 2001 Page 5B-35 POWER TRIM Testing Power Trim System With Test Gauge Kit (91-52915A6) IMPORTANT: This test will not locate problems in the trim system. The test will show if the system is correct after a repair. If minimum pressures are not obtainable, the trim system requires additional repair. “UP” Pressure Check IMPORTANT: Insure battery is fully charged before performing tests. 1. Tilt outboard to full “Up” position and engage tilt lock lever. 2. Slowly remove “Fill” plug to bleed pressure from reservoir. 3. Remove circlip securing manual release valve and unscrew release valve from trim assembly. NOTE:A small amount of trim fluid may drip from manual release valve hole. Place a suitable container under trim assembly to collect any leakage. NOTE:Assemble test adaptor by using O-ring installation tool to position small O-ring onto adaptor1st, then install medium O-ring and lastly large O-ring. Thread brass fitting into test adaptor securely using teflon tape on threads. 54457 g a bcdef g a-Test Adaptor (91-822778A2) b-O-ring Installation Tool c-Small O-ring (Install 1st) d-Medium O-ring (Install 2nd) e-Large O-ring (Install Last) f-Brass Fitting g-Apply Teflon Tape 4. Install test adaptor 91-822778A2 into manual release valve hole. a a-Test Adaptor (91-822778A2) Page 5B-36 90-854785R2 DECEMBER 2001 POWER TRIM 5. Thread hose from Test Gauge Kit (91-52915A6) into brass fitting on adaptor. 54459 a b d e c a-Brass Fitting b-Test Gauge Assembly c-Tilt Pin or Hardened Bolt and Nut (Position in Hole Shown) d-Hose e-Hose (Not Used) 6. Reinstall fill plug. 7. Run trim “UP”. 8. Disengage tilt lock lever. 90-854785R2 DECEMBER 2001 Page 5B-37 POWER TRIM CAUTION Failure to install spare tilt pin (or hardened bolts and nuts) in hole shown could result in transom bracket failure and possible injury. 9. Move outboard “IN” until hole in swivel bracket “ear” aligns with the 3rd tilt hole in transom bracket. Lock engine in trim range by installing a 3/8 in. (9.5 mm) diameter tilt pin or two 3/8 in. (9.5 mm) hardened bolts and nuts through the transom brackets and swivel bracket in the hole shown. a a-Tilt Pin Hole (Install Spare Tilt Pin or Hardened Bolts and Nuts) 10. Open valve (a) and close valve (b). 51374 a b 11. Run trim “UP”. The minimum pressure should be 2520 P.S.I. (17,375 kPa). 12. Run trim “DOWN” to release pressure and remove spare tilt pin or bolts and nuts. 13. Tilt outboard full “UP” and engage tilt lock lever. 14. Slowly remove “Fill” plug to bleed pressure. 15. Remove test gauge hose and adapter. 16. Reinstall Manual Release Valve and secure valve with circlip. 17. Retighten “Fill” plug. NOTE: If pressure is less than 2520 PSI (17,375 kPa), troubleshoot system per instructions on Pages 2B-26 to 32. Page 5B-38 90-854785R2 DECEMBER 2001 POWER TRIM “DOWN” Pressure Check IMPORTANT: Insure battery is fully charged before performing tests. 1. Tilt outboard to full “Up” position and engage tilt lock lever. 2. Slowly remove “Fill” plug to bleed pressure from reservoir. 3. Remove circlip securing manual release valve and unscrew release valve from trim assembly. NOTE:A small amount of trim fluid may drip from manual release valve hole. Place a suitable container under trim assembly to collect any leakage. NOTE:Assemble test adaptor by using O-ring installation tool to position small O-ring onto adaptor1st, then install medium O-ring and lastly large O-ring. Thread brass fitting into test adaptor securely using teflon tape on threads. 54457 3 f a e d c b g a-Test Adaptor (91-822778A3) b-O-ring Installation Tool c-Small O-ring (Install 1st) d-Medium O-ring (Install 2nd) e-Large O-ring (Install Last) f-Brass Fitting g-Apply Teflon Tape 4. Install test adaptor 91-822778A3 into manual release valve hole. a a-Test Adaptor (91-822778A3) 90-854785R2 DECEMBER 2001 Page 5B-39 POWER TRIM 5. Thread hose from Test Gauge Kit (91-52915A6) into brass fitting on adaptor. b d e f g c a a-Brass Fitting b-Test Gauge Assembly c-Tilt Pin or Hardened Bolt and Nut (Position in Hole Shown) d-Hose e-Hose (Not Used) f-OPEN Valve g-CLOSE Valve 6. Reinstall fill plug. 7. Run trim “UP”. 8. Disengage tilt lock lever. 9. Open valve (f) and close valve (g). 10. Run trim “DOWN”. Minimum pressure should be 500 P.S.I. (3450 kPa). 11. Tilt outboard full “UP” and engage tilt lock lever. 12. Slowly remove “Fill” plug to bleed pressure. 13. Remove test gauge hose and adaptor. 14. Reinstall manual release valve and secure valve with circlip. 15. Retighten “Fill” plug. NOTE: If pressure is less than 500 PSI (3450 kPa), troubleshoot system per instructions on Pages 2B-26 to 32. Page 5B-40 90-854785R2 DECEMBER 2001 POWER TRIM Disassembly Shock Rod Removal 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. 1. Remove reservoir cap. 2. Remove manual release valve assembly. a b a-Reservoir Cap b-Manual Release Valve 3. Drain power trim fluid as shown. 4. Secure power trim assembly in a soft jaw vise. 5. Unscrew end cap assembly from cylinder using spanner wrench 91-74951. 90-854785R2 DECEMBER 2001 Page 5B-41 POWER TRIM Page 5B-42 90-854785R2 DECEMBER 2001 6. Remove shock rod assembly from cylinder. Shock Rod Disassembly NOTE: The only serviceable items on the shock rod assembly are the o-rings and wiper ring. If shock rod requires any other repair, replace shock rod assembly. a c d b c c c a - End Cap b - Shock Piston c - O-ring d - Wiper Ring 1. Place shock rod assembly on clean work surface. 2. Remove screw from end of shock rod. a a - Screw POWER TRIM 3. Remove check ball components from shock rod piston. 4. Remove O-ring from shock rod piston. 51147 b d c a a-Spring (5) b-Seat (5) c-Ball (5) d-O-ring CAUTION When removing shock piston, spanner wrench must have 1/4 in. x 5/16 in. long pegs to avoid damage to shock piston. 5. Place shock rod into soft jawed vise and apply heat to loosen piston using torch lamp (P/N 91-63209). 6. Loosen shock rod piston using spanner wrench [1/4 in. x 5/16 in. (6.4mm x 8mm) long pegs]. 7. Allow shock rod piston to cool. Remove from shock rod. a-Spanner Wrench b-Shock Rod Piston a b 90-854785R2 DECEMBER 2001 Page 5B-43 POWER TRIM 8. Inspect check valve for debris; clean debris from check valve if found. If debris cannot be cleaned from check valve, replace shock piston as an assembly. 9. Clean shock and components with compressed air. 10. Remove inner o-ring from shock rod piston. a b a-Shock Piston b-O-ring 11. Remove cylinder end cap assembly from shock rod. 12. Inspect shock. If wiper (located in cap) has failed to keep rod clean, replace wiper. 13. Place end cap on clean work surface. 14. Remove rod wiper, inner O-ring, and outer O-ring. 51145 a b c a-Rod Wiper b-Inner O-ring c-Outer O-ring Page 5B-44 90-854785R2 DECEMBER 2001 POWER TRIM Memory Piston Removal 1. Remove memory piston from cylinder using one of two methods: a. Using lock ring pliers (Craftsman P/N 4735) or suitable tool. b. Blow compressed air into manual release valve hole using adaptor (P/N 91-822778A3). WARNING Memory piston cup may be expelled at a high velocity when air pressure is applied. Failure to place cylinder as shown below could result in personal injury. NOTE: Point cylinder opening down and away. Use a shop rag or towel to avoid damage to the memory piston. a b c d a-Adaptor b-Air Hose c-Memory Piston Exit d-Shop Rag 90-854785R2 DECEMBER 2001 Page 5B-45 POWER TRIM 2. Remove o-ring from memory piston. a a-O-ring Trim Motor Removal 1. Secure power trim assembly in soft jawed vise. 2. Remove screws securing trim motor to manifold. 3. Remove motor assembly. a b a-Trim Motor b-Screw (4) Page 5B-46 90-854785R2 DECEMBER 2001 POWER TRIM Oil Pump Removal 1. Remove oil filter and pump from manifold. IMPORTANT: DO NOT disassemble the oil pump. The pump is not serviceable. d b a c f e a-Screw (2) b-Oil Pump c-Spring d-Filter e-O-Ring f-Down Relief Ball 90-854785R2 DECEMBER 2001 Page 5B-47 POWER TRIM Page 5B-48 90-854785R2 DECEMBER 2001 Tilt Relief Valve Removal NOTE: The following procedures requires the use of a Snap-On blind hole removal tool #CG-41-11 with 5/16” attachment #41-12. Or a removal tool can be fabricated with the material and specifications listed below. 4 1/2” 3 1/4” 1/4” a a - Removal Tool made from .060 Stainless Steel Rod 1. Unscrew plug from manifold and remove spring and poppet assembly. NOTE: Do not lose shim that may be lodged in the plug. 2. Use the removal tool and pull out the pilot valve. a c b b b d e f g h b a - Tilt Relief Valve Assembly b - O-Rings c - Actuator Pin d - Pilot Valve e - Poppet Assembly f - Spring g - Shim h - Plug POWER TRIM IMPORTANT: Inspect poppet assembly for debris in the area shown. If debris is found on poppet replace poppet. a b a-Debris Under Valve Tip b-Rubber Seat Suction Seat Removal 1. Unscrew plug from manifold and remove ball. 2. Use a pin punch and knock the filter and suction seat out from the inside of the manifold cavity. CAUTION DO NOT use any tool on the suction seat as any damage to the surface will not allow the ball to seat. a b c d a-Filter b-Suction Seat c-Ball d-Plug 90-854785R2 DECEMBER 2001 Page 5B-49 POWER TRIM Page 5B-50 90-854785R2 DECEMBER 2001 Pilot Check Valve Assembly Removal 1. Unscrew both plugs. 2. Remove both springs and poppets. 3. Use the (.060 wire) removal tool (see previous page) and push out the spool and one seat. 4. From opposite side, use a punch and push out the remaining seat. d a b e b a c d c a - Plug (2) b - Spring (2) c - Poppet Assembly (2) d - Seat (2) e - Spool (1) POWER TRIM IMPORTANT: Inspect poppet assemblies for debris in the area shown. If debris is found on poppets replace poppets. a b a-Debris Under Valve Tip b-Rubber Seat Cleaning/Inspection/Repair IMPORTANT: Components must be dirt and lint free. Slightest amount of debris in Power Trim system could cause system to malfunction. Clean shock rod and components with parts cleaner and dry with compressed air. It is recommended that all O-rings in trim system be replaced. Use O-Ring Kit 25-827668A1. Lubricate all O-rings with power trim fluid. Trim Motor Electrical Tests 1. Connect a 12 volt supply to motor leads. If motor fails to run, replace trim motor. IMPORTANT: Trim Motor is not serviceable. If motor fails to run, replace motor assembly. 90-854785R2 DECEMBER 2001 Page 5B-51 POWER TRIM Page 5B-52 90-854785R2 DECEMBER 2001 Reassembly O-Ring and Seal Placement O-Rings and Seals are part of O-Ring Kit 25-827668A1. Lubricate O Rings with power trim fluid. r n j v i w g f e s w h i l c d a w b t u h k r m q p o POWER TRIM O-Ring and Seal Placement O-Ring Description O-Ring I.D. O-Ring O.D. O-Ring Width a Actuator Pin 0.07 in. (1.78 mm) 0.21 in. (5.33 mm) 0.07 in. (1.78 mm) b Tilt Relief Cartridge 0.239 in. (6.07 mm) 0.379 in. (9.63 mm) 0.07 in. (1.78 mm) c Tilt Relief Cartridge 0.301 in. (7.65 mm) 0.441 in. (11.20 mm) 0.07 in. (1.78 mm) d Tilt Relief Plug 0.359 in. (9.12 mm) 0.565 in. (14.35 mm) 0.139 in. (3.53 mm) e Suction Seat 0.301 in. (7.65 mm) 0.441 in. (11.20 mm) 0.07 in. (1.78 mm) f Suction Seat Plug 0.487 in. (12.37 mm) 0.693 in. (17.60 mm) 0.103 in. (2.62 mm) g Spool 0.239 in. (6.07 mm) 0.379 in. (9.63 mm) 0.07 in. (1.78 mm) h P. O. Check Seat 0.364 in. (9.25 mm) 0.504 in. (12.80 mm) 0.07 in. (1.78 mm) i P. O. Check Plug 0.489 in. (12.42 mm) 0.629 in. (15.98 mm) 0.07 in. (1.78 mm) j Pump Ports 0.145 in. (3.68 mm) 0.285 in. (7.24mm) 0.07 in. (1.78 mm) k Pump Filter O-ring, Pump Filter - Square Cut l Reservoir/Motor 2.614 in. (66.40 mm) 2.754 in. (70.0 mm) 0.07 in. (1.78 mm) m Memory Piston 1.037 in. (26.34 mm) 1.457 in. (37.0 mm) 0.21 in. (5.33 mm) n Piston Screw 0.364 in. (9.25 mm) 0.504 in. (12.80 mm) 0.07 in. (1.78 mm) o Shock Piston 1.171 in. (29.74 mm) 1.449 in. (36.80 mm) 0.139 in. (3.53 mm) p Cylinder Cap 1.364 in. (34.65 mm) 1.50 in. (38.10 mm) 0.07 in. (1.78 mm) q Wiper Ring r Cylinder Cap - Inner 0.546 in. (13.87 mm) 0.752 in. (19.10 mm) 0.139 in. (3.53 mm) s Manual Release Valve 0.239 in. (6.07 mm) 0.379 in. (9.63 mm) 0.07 in. (1.78 mm) t Manual Release Valve 0.176 in. (4.47 mm) 0.316 in. (8.03 mm) 0.07 in. (1.78 mm) u Manual Release Valve 0.114 in. (2.90 mm) 0.254 in. (6.45 mm) 0.07 in. (1.78 mm) v Reservoir Plug 0.426 in. (10.82 mm) 0.566 in. (14.38 mm) 0.07 in. (1.78 mm) w Check Valve O.D. I.D. Cutaway View of O-Ring Width 90-854785R2 DECEMBER 2001 Page 5B-53 POWER TRIM Page 5B-54 90-854785R2 DECEMBER 2001 Power Trim Reassembly IMPORTANT: Lubricate all O-rings with Power Trim & Steering Fluid . If not available, use automotive (ATF) automatic transmission fluid. Tilt Relief Valve Reassembly 1. Lubricate O-rings with power trim fluid. 2. Place actuator pin into pilot valve. 3. Install and seat the pilot valve into manifold. Seat the pilot valve using a 9/32, or 7 mm socket on OUTSIDE diameter of the pilot valve. IMPORTANT: The pilot valve must be seated using a suitable mandrel on the OUTSIDE diameter. 4. Install poppet, spring, shim (if used) and plug. Tighten plug to the specified torque. a b c b b b d e f g h a - Tilt Relief Valve Assembly b - O-Rings c - Actuator Pin d - Pilot Valve e - Poppet Assembly f - Spring g - Shim h - Plug Plug Torque 120 lb. in. (13.5 N·m) POWER TRIM Suction Seat Reassembly 1. Lubricate O-rings with power trim fluid. 2. Install filter and suction seat using a 9/32” or 7 mm socket on OUTSIDE diameter of suction seat. 3. Install ball and plug. Tighten plug to the specified torque. a b c d a-Filter b-Suction Seat c-Ball d-Plug - Torque to 120 lb. in. (13.5 NVm) Plug Torque 120 lb. in. (13.5 N·m) 90-854785R2 DECEMBER 2001 Page 5B-55 POWER TRIM Page 5B-56 90-854785R2 DECEMBER 2001 Pilot Check Valve Reassembly 1. Lubricate O-rings with power trim fluid. 2. Install one of the seats into manifold. Push the seat into place using a 9/32” or 7 mm socket on the OUTSIDE diameter of the seat. 3. Install corresponding poppet, spring and plug. 4. From the opposite side of the manifold, install spool and the other seat. Push the seat into place using a 9/32” or 7 mm socket on OUTSIDE diameter of seat. 5. Install remaining poppet, spring and plug. Tighten plugs to the specified torque. a b c d e a b c d a - Plug (2) - Torque to 120 lb. in. (13.5 NVm) b - Spring (2) c - Poppet (2) d - Seat (2) e - Spool Plug Torque 120 lb. in. (13.5 N·m) POWER TRIM Oil Pump Reassembly 1. Install the down relief ball and spring into manifold. 2. Check to see that O-rings are placed on bottom of pump. 3. Place O-ring (square cut) on filter. 4. Place filter over the oil pump. 5. Install oil pump with two (2) screws. Tighten screws to the specified torque. a b g c d e f a-Screws (2) e-Spring b-Oil Pump f-Down Relief Ball c-O-ring g-Pump O-Ring (2) d-Filter Oil Pump Screw Torque 70 lb. in. (8 N·m) 90-854785R2 DECEMBER 2001 Page 5B-57 POWER TRIM Trim Motor Reassembly 1. Align coupler between oil pump and motor. 2. Install trim motor and secure with four (4) screws. Tighten screws to the specified torque. a b c e d f a-Coupler b-O-ring c-Trim Pump Motor d-Ground Strap e-Lock Washer (1) f-Screws (4) - Torque to 80 lb. in. (9.0 NVm) g-Torque to 70 lb. in. (7.9 NVm) Trim Motor Screw Torque 80 lb. in. (9 N·m) Page 5B-58 90-854785R2 DECEMBER 2001 POWER TRIM Shock Rod Reassembly 1. Install lubricated o-rings to end cap. 2. Install rod wiper. 51145 a b c a-Rod Wiper b-Inner O-ring c-Outer O-ring 3. Install lubricated o-rings to shock piston. 51199 a b c a-Shock Piston b-O-ring c-O-ring 90-854785R2 DECEMBER 2001 Page 5B-59 POWER TRIM 4. Clamp shock rod in soft jawed vise. 5. Position cylinder end cap onto rod as shown. CAUTION When installing shock rod piston, spanner wrench must have1/4 in. x 5/16 in. (6.4mm x8mm) long pegs to avoid damage to shock rod piston. 6. Apply Loctite 271 Thread Locker to threads on shock rod. 7. Install shock rod piston. 8. Tighten shock rod piston securely using spanner wrench (1/4 in. x 5/16 in. long pegs). If a torquing type spanner tool is used to tighten shock piston, then tighten to the specified torque. a b a-Shock Rod Piston - Torque to 90 lb. ft. (122 NVm) b-Spanner Wrench Shock Rod Piston Torque 90 lb. ft. (122 N·m) Page 5B-60 90-854785R2 DECEMBER 2001 POWER TRIM 9. Remove shock rod assembly from vise. 10. Install ball, seat, and spring (five sets) to shock rod piston. 51147 c b a a-Spring (5) b-Seat (5) c-Ball (5) 11. Secure components with shock piston screw. Tighten screw to the specified torque. a a-Screw Shock Rod Screw Torque 45 lb. ft. (61 N·m) 90-854785R2 DECEMBER 2001 Page 5B-61 POWER TRIM Shock Rod Installation 1. Place trim cylinder in soft jawed vice. 2. Install lubricated O-ring to memory piston and place into cylinder. Push memory piston all the way to bottom. a b a-Memory Piston b-O-ring 3. Fill cylinder three inches (76.2mm) from top of cylinder using Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. 4. Install shock rod into cylinder until power trim fluid flows through oil blow off ball passage. Fill remaining cylinder to just below the cylinder threads. a a-Oil Blow Off Ball Passage CAUTION End cap must not make contact with shock rod piston when tightening. Shock rod piston must be positioned in cylinder deep enough to avoid contact. 5. Tighten end cap securely using spanner wrench [3/16 in. x 5/16 in. (4.8mm x 8mm) long pegs]. If a torquing type spanner tool is used to tighten end cap, then tighten to the specified torque. Cylinder End Cap Torque 45 lb. ft. (61 N·m) Page 5B-62 90-854785R2 DECEMBER 2001 POWER TRIM Manual Release Valve Installation 1. Install “E” clip (if removed) and lubricate O-rings with power trim fluid. 2. Insert manual release valve into manifold and tighten securely. Bleeding Power Trim Unit 1. Secure power trim unit in soft jawed vise. 2. Remove reservoir plug. Add power trim fluid until its even with the bottom of the fill hole. Reinstall plug. 3. Close the manual release valve. (Turn full clockwise.) a a-Reservoir Plug 4. Connect the positive lead to (blue) trim motor wire and negative lead to (green) trim motor wire and drive shock rod to the up position. 5. Using a 12 volt power supply, connect the positive lead to the (green) trim motor wire, and the negative lead to the (blue) trim motor wire and drive the shock rod to the down position. 6. Recheck fluid level with rod fully extended, add fluid if required and repeat cycle until fluid level stays even with the bottom of the fill hole. 90-854785R2 DECEMBER 2001 Page 5B-63 POWER TRIM Power Trim System Installation 1. Lubricate lower pivot pin, mounting holes and bushings with 2-4-C Marine Lubricant with Teflon. 2. Install lower pivot pin bushings into the clamp brackets and trim unit. a b 2-4-C Marine Lubricant with Teflon 95 95 a-Bushing (2) Install into each Clamp Bracket b-Bushing (2) Install into each side of Trim Unit 3. Install lower pivot pin. Secure with flat washers and nuts. Tighten nuts to specified torque. a b 95 95 2-4-C Marine Lubricant with Teflon a-Lower Pivot Pin b-Nut (2) Lower Pivot Pin Nut Torque 18 lb. ft. (24.5 N·m) Page 5B-64 90-854785R2 DECEMBER 2001 POWER TRIM 4. Install sacrificial anode to clamp brackets. Fasten ground strap between anode and clamp bracket. a b a-Ground Wire b-Sacrificial Anode 5. Lubricate the upper pivot pin and mounting holes with 2-4-C Marine Lubricant with Teflon. 6. Fasten shock rod with the upper pivot pin. NOTE:Pivot pin should be installed with grooved end inserted first. 2-4-C Marine Lubricant with Teflon 95 95 90-854785R2 DECEMBER 2001 Page 5B-65 POWER TRIM 7. Secure upper pivot pin with trilobe pin. Press trilobe pin in until its fully seated. a a-Trilobe Pin 8. Re-connect trim wire harness leads (see wiring diagram Section 2D for proper connections). 9. Recheck fluid level (tilt/trim rod fully extended). 10. Route wire harness through clamp bracket and cowling. 11. Secure wire harness with clamps as shown. Page 5B-66 90-854785R2 DECEMBER 2001 GAS ASSIST MANUAL TILT MID-SECTION Section 5C - Gas Assist Manual Tilt Table of Contents Clamp Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-2 Manual Trim System Removal . . . . . . . . . . . . 5C-5 Clamp Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-3 Manual Trim System Installation . . . . . . . . . . . 5C-7 Hydraulic Assist Adjustments . . . . . . . . . . . . . 5C-4 5 C 90-854785R2 DECEMBER 2001 Page 5C-1 GAS ASSIST MANUAL TILT CLAMP BRACKET 95 7 Loctite 271 Thread Locker 2-4-C Marine Lubricant with Teflon Page 5C-2 90-854785R2 DECEMBER 2001 GAS ASSIST MANUAL TILT CLAMP BRACKET REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 11 1 CLAMP BRACKET (PORT) (BLACK) 1 CLAMP BRACKET (PORT) (GRAY) 2 22 1 CLAMP BRACKET (STBD) (BLACK) USE W/ .56 O.D. Ref. #15 CLAMP BRACKET (STBD) (GRAY)1 1 CLAMP BRACKET (STBD) (BLACK) USE W/ .75 O.D. Ref. #11 CLAMP BRACKET (STBD) (GRAY)1 3 2 THUMB SCREW ASSEMBLY HANDLE RIVET MANUAL WASHER SCREW (Hex shoulder) 4 2 5 2 6 2 7 2 60 7 8 1 CAP–Tilt Stop Pin ROLL PIN O.D. of Ref. # 11 is .75 & BUSHING Ref. # 10 is NOT FLANGED PIN–Tilt Stop 9 1 10 1 11 1 12 1 CAP–Tilt Stop Pin ROLL PIN O.D. of Ref. # 15 is .56 & BUSHING Ref. # 14 is FLANGED PIN–Tilt Stop 13 1 14 1 15 1 16 1 ANODE 17 2 WASHER 18 2 SCREW (M6 x 25) 60 7 19 4 NUT (.500-20) Drive Tight 20 4 WASHER 21 4 SCREW (.500-20 x 4 IN.) 22 1 DECAL-Tilt Lock 23 1 TRIM, Hydraulic assist CABLE TILT LEVER TILT KNOB GAS ASSIST TRIM LEVER ARM WAVE WASHER ROLL PIN (1/8 x 3/4 IN.) LINK NUT 24 1 25 1 26 1 27 1 28 1 29 1 30 1 31 1 90 10 32 1 ANCHOR PIN (14MM) BUSHING BUSHING GAS ASSIST TRIM & WASHER POWER TRIM MOUNTING NUT SCREW (M10 x 40) WASHER NUT 33 2 34 2 35 2 36 2 17.5 23.5 37 2 38 2 39 2 28 38 40 1 TILT LOCK PIN HANDLE-NON POWER TRIM SPRING41 1 42 1 DECAL-Warning 90-854785R2 DECEMBER 2001 Page 5C-3 GAS ASSIST MANUAL TILT Hydraulic Assist Adjustments WARNING This hydraulic assist system’s contents are under pressure. Do not puncture disassemble or apply heat or flame. IMPORTANT: If debris or leaking is found, unit must be replaced This hydraulic assist system is NOT SERVICEABLE. Replace as necessary. 1. Check manual release cam adjustment. Cam must open and close freely. Adjust cam link rod as necessary. a b a-Link Rod b-Manual Release Lever 2. Check for external leaks in the manual tilt system. Replace unit if leak is found. Page 5C-4 90-854785R2 DECEMBER 2001 GAS ASSIST MANUAL TILT Manual Trim System Removal 1. Tilt outboard to the full up position and support with tilt stop pin. a a-Tilt Stop Pin 2. Remove the trilobe pin. 3. Drive out the upper pivot pin. a b a-Trilobe Pin b-Upper Pivot Pin 90-854785R2 DECEMBER 2001 Page 5C-5 GAS ASSIST MANUAL TILT 4. Disconnect link rod from cam lever. 5. Remove tilt lock pin. Remove nuts and washers securing the lower pivot pin. Remove anode screw to remove ground strap. Remove lower anchor pin. Retain the anchor pin bushings from the clamp brackets and trim unit. 6. Remove trim unit. b c d e a f a-Tilt Lock Pin b-Link Rod c-Cam Lever d-Nut (2) e-Anode Screw/Ground Strap f-Pivot Pin Page 5C-6 90-854785R2 DECEMBER 2001 GAS ASSIST MANUAL TILT Manual Trim System Installation 1. Apply 2-4-C Marine Lubricant with Teflon to surface of lower anchor pin and anchor pin hole. Place trim into proper position. Install anchor pin and bushings into anchor pin hole and clamp brackets. Install nuts and washers to anchor pin and tighten securely. Install ground strap and anode screw. 2. Install tilt lock pin. a c d b a-Tilt Lock Pin b-Nut (2) c-Anode Screw/Ground Strap d-Pivot Pin 90-854785R2 DECEMBER 2001 Page 5C-7 GAS ASSIST MANUAL TILT 3. Apply 2-4-C Marine Lubricant with Teflon to surface of upper pivot pin, pivot hole and shock rod hole. 4. Position trim into position and drive pivot pin into swivel bracket and through shock rod until pivot pin is flush with swivel bracket. Drive trilobe pin into its hole until seated. a b a-Trilobe Pin b-Upper Pivot Pin 5. Connect link rod onto cam lever. a b a-Link Rod b-Cam Lever Page 5C-8 90-854785R2 DECEMBER 2001 GAS ASSIST MANUAL TILT 6. Check manual release cam adjustment. Cam must open and close freely. Adjust cam link rod as necessary. a b a-Link Rod b-Manual Release Lever 90-854785R2 DECEMBER 2001 Page 5C-9 LOWER UNIT LOWER UNIT Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Propeller Shaft and Carrier Inspection . . . . . . 6-29 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29 Gear Housing (Driveshaft) . . . . . . . . . . . . . . . . . 6-6 Cam Follower . . . . . . . . . . . . . . . . . . . . . . . . . 6-29 Gear Housing (Propeller Shaft) . . . . . . . . . . . . . 6-8 Reverse Gear . . . . . . . . . . . . . . . . . . . . . . . . . 6-30 General Service Recommendations . . . . . . . . 6-10 Reverse Gear Bearing . . . . . . . . . . . . . . . . . 6-30 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . . . 6-32 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Gear Housing Reassembly . . . . . . . . . . . . . . . . 6-35 Draining and Inspecting Gear Lubricant . . . . . 6-11 Shift Shaft Assembly . . . . . . . . . . . . . . . . . . . 6-36 Gear Housing Removal . . . . . . . . . . . . . . . . . . . 6-12 Pinion Bearing Race . . . . . . . . . . . . . . . . . . . 6-37 2-Stroke Models . . . . . . . . . . . . . . . . . . . . . . . 6-12 Forward Gear . . . . . . . . . . . . . . . . . . . . . . . . . 6-38 4-Stroke Models . . . . . . . . . . . . . . . . . . . . . . . 6-13 Pinion Gear/Drive Shaft Assembly . . . . . . . 6-39 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . 6-40 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . . . 6-42 Water Pump Seals . . . . . . . . . . . . . . . . . . . . . 6-21 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Gear Housing Pressure Test . . . . . . . . . . . . . . . 6-46 Upper Drive Shaft Bearing . . . . . . . . . . . . . . 6-23 Gear Housing Installation . . . . . . . . . . . . . . . . . . 6-47 Pinion Gear Bearing . . . . . . . . . . . . . . . . . . . 6-24 Filling Gear Housing with Lubricant . . . . . . 6-47 Pinion Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 Installing Gear Housing to Drive Shaft Forward Gear . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48 Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27 Trim Tab Adjustment and Replacement . . . . . 6-51 Propeller Shaft Disassembly . . . . . . . . . . . . 6-28 6 90-854785R2 DECEMBER 2001 Page 6-1 LOWER UNIT Specifications Gear Ratio Gearcase Capacity 2.42:1 14.9 fl. oz. (440 mL) Lubricant Type Quicksilver Premium Gear Lubricant GEAR HOUSING (2.42:1) Forward Gear Number of Teeth Pinion Gear Number of Teeth Pinion Height Forward Gear Backlash 29 Spiral/Bevel 12 Spiral/Bevel 0.025 in. (0.64 mm) No Adjustment Water Pressure 2 – 4 PSI @ 800 rpm @ Idle 12–17 PSI @ 6000 rpm @ WOT NOTE:Before filling gear case, apply 10-12 PSI of air pressure at the vent hole. Pressure should not drop for 5 minutes while alternately applying a 2-3 pound force to the top of the shift shaft in the fore and aft direction. Special Tools 1. Bearing 31-85560 2. Driver 91-13779 Page 6-2 90-854785R2 DECEMBER 2001 LOWER UNIT 3. Bearing Puller & Installation Tool 91-31229A7 a. Nut 11-24156 b. Washer (2) 12-34961 c. Plate 91-29310 d. Shaft 91-31229 4. Bearing Puller Tool 91-27780 5. Mandrel 91-36571 6. Universal Puller Plate 91-37241 90-854785R2 DECEMBER 2001 Page 6-3 LOWER UNIT 7. Driver Head 91-37312 8. Driver 91-817011 9. Driver Rod 91-37323 10. Drive Shaft Holding Tool a. 2-stroke models 91-825196 b. 4-stroke models 91-83180M 11. Mandrel 91-825197 Page 6-4 90-854785R2 DECEMBER 2001 LOWER UNIT 12. Driver 91-817007 13. Mandrel 91-825198 14. Pilot 91-825199 15. Spring Hook 91-825200A1 16. Driver 91-826872 17. Leakage Tester FT8950 90-854785R2 DECEMBER 2001 Page 6-5 LOWER UNIT GEAR HOUSING (Driveshaft) (2.42:1 Gear Ratio) 74 7 Loctite 271 Thread Locker Loctite 405 95 95 87 92 Premium Gear Lubricant Loctite 7649 Primer 2-4-C Marine Lubricant with Teflon 23 24 22 87 7 95 28 25 14 26 7 29 12 13 95 95 95 30 15 31 27 21 32 95 33 16 2 17 18 20 3 34 35 36 3795 38 19 1 11 87 92 7 4 3.44 IN./135MM 10 TORPEDO DIA. 9 7 8 6 Page 6-6 90-854785R2 DECEMBER 2001 LOWER UNIT GEAR HOUSING (Driveshaft) (2.42:1 Gear Ratio) REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m – 1 GEAR HOUSING (SHORT) (BLACK) – 1 GEAR HOUSING (SHORT) (GRAY) – 1 GEAR HOUSING (LONG) (BLACK) – 1 GEAR HOUSING (LONG) (GRAY) 11 1 GEAR HOUSING (BASIC) (BLACK) 1 GEAR HOUSING (BASIC) (GRAY) 2 1 SEAL/PLATE KIT 3 1 PLATE (Part Of Ref #2) 4 1 SCREW (.375–16 x .25) 60 7 5 1 WASHER–Sealing 6 1 DRAIN SCREW (MAGNETIC) 60 7 7 1 WASHER–Sealing 8 1 NUT 50 68 9 1 PINION GEAR (12 TEETH) (Part of 43-833000A2) 10 1 BEARING ASSEMBLY–Roller 11 1 CUP (Part Of Ref #10) 12 4 SCREW (M6 x 16) 60 7 13 1 WATER PUMP ASSEMBLY 1414 1 SEAL–Water Tube (SHORT - 1-3/4) 1 SEAL–Water Tube (LONG - 2-1/4) 15 1 WASHER 16 1 KEY 17 1 WASHER 18 1 GASKET 19 1 GASKET (LOWER) 20 1 FACE PLATE 21 1 IMPELLER 22 1 WATER PUMP BASE ASSEMBLY 23 1 SEAL–Oil 24 1 SEAL–Oil 25 1 O RING 26 1 BALL BEARING 2727 1 DRIVESHAFT (SHORT) 1 DRIVESHAFT (LONG) 28 1 CABLE TIE 29 1 BOOT–Shift Shaft 30 1 RETAINER–Shift Shaft 31 1 O RING 32 1 O RING 33 1 WASHER 34 3434 1 SHIFT SHAFT (SHORT) 1 SHIFT SHAFT (LONG) 35 1 WASHER 36 1 ROLL PIN 37 1 CAM–Shift 38 1 PIN 90-854785R2 DECEMBER 2001 Page 6-7 LOWER UNIT GEAR HOUSING (Propeller Shaft) (2.42:1 Gear Ratio) 3.44 IN./135MM TORPEDO DIA. 42 1 95 95 87 95 87 7 95 87 87 3940 41 43 44 45 46 47 48 49 50 51 52 5354 55 56 57 58 59 60 61 62 63 6465 66 67 68 69 70 71 72 73 39 95 94 7 87 Loctite 271 Premium Gear Lubricant Anti-Corrosion Grease 2-4-C Marine Lubricant with Teflon Page 6-8 90-854785R2 DECEMBER 2001 LOWER UNIT GEAR HOUSING (Propeller Shaft) (2.42:1 Gear Ratio) REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m – 1 GEAR HOUSING (SHORT) (BLACK) – 1 GEAR HOUSING (SHORT) (GRAY) – 1 GEAR HOUSING (LONG) (BLACK) – 1 GEAR HOUSING (LONG) (GRAY) 11 1 GEAR HOUSING (BASIC) (BLACK) 1 GEAR HOUSING (BASIC) (GRAY) 39 2 DOWEL PIN 40 1 GASKET Water Tube 41 1 TUBE 42 1 PLUG–RUBBER 43 1 SCREEN–Water Inlet 44 1 TRIM TAB 45 1 SCREW (M8 x 20) 190 15.8 21.5 46 1 WASHER 47 1 FORWARD GEAR ASSEMBLY (29 TEETH) 48 1 ROLLER BEARING ASSY. 49 1 CUP 50 1 ROLLER BEARING 51 1 FOLLOWER–Cam 52 1 SPRING 53 1 PIN–Cross 54 1 CLUTCH 55 1 SPRING 56 1 PROPELLER SHAFT 57 1 REVERSE GEAR (29 TEETH) 58 1 BALL BEARING 59 1 BEARING CARRIER 60 1 O RING 61 1 NEEDLE BEARING 62 1 OIL SEAL 63 1 OIL SEAL 64 2 WASHER 65 2 SCREW (M8 x 25 - Cap Screw) 225 16.5 22.5 66 2 THREADED INSERT 67 1 DECAL (2.42:1)(12 x 29) 68 1 THRUST HUB 69 1 PROP NUT KIT THESE REPLACEMENT PARTS 55 75 70 1 TAB WASHER ARE NOT INCLUDED WITH 71 4 SCREW COMPLETE GEAR HOUSING 40 54 72 4 WASHER REPLACEMENT 73 1 PLUG 90-854785R2 DECEMBER 2001 Page 6-9 LOWER UNIT 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. Whenever 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 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 Marine Lubricant with Teflon on all O-rings and on I.D. of oil seals. Apply 2-4-C Marine Lubricant with Teflon to external surfaces of bearing carrier. Page 6-10 90-854785R2 DECEMBER 2001 LOWER UNIT Draining and Inspecting Gear Lubricant WARNING If gear housing is installed on outboard, disconnect (and isolate) spark plug leads from spark plugs before working near the propeller. 1. With gear housing in normal running position, place a clean pan under housing and remove vent plug and fill/drain plug (with gaskets). a b a-Vent Plug/Washer b-Fill/Drain Plug/Washer 2. Inspect gear lubricant for metal particles (lubricant will have a “metal flake” appearance). Presence of fine metal particles (resembling powder) on the drain plug magnet indicates normal wear. Metal chips on the magnet indicate the need for gear housing disassembly and component inspection. 3. Note color of gear lubricant. White or cream color indicates presence of water. Gear lubricant drained from a gear case assembled with Special Lubricant 101 or a gear case recently in operation will have a yellowish color due to lubricant agitation/aeration. This is normal and should not be confused with the presence of water. 4. Presence of water indicates the need for disassembly and inspection of oil seals, o- rings, gaskets and components for damage. 90-854785R2 DECEMBER 2001 Page 6-11 LOWER UNIT Gear Housing Removal WARNING To prevent accidental engine starting, remove (and isolate) spark plug leads from spark plugs before removing gear housing. 1. Remove (and isolate) spark plug leads from spark plugs. 2. Shift into NEUTRAL. 3. Loosen jam nut. Unscrew attaching nut to separate shift shaft. 2-Stroke Models MERCURY/MARINER 30/40, AND 40/50, FORCE 40/50 a b a-Jam Nut b-Attaching Nut Page 6-12 90-854785R2 DECEMBER 2001 LOWER UNIT 4-Stroke Models MERCURY/MARINER 25, 45/50 a b a-Retainer b-Lower Clip 4. Make a scribe line showing alignment of trim tab to gear case and remove trim tab screw and washer. 52835 a b a-Screw and Washer b-Scribe Line 90-854785R2 DECEMBER 2001 Page 6-13 LOWER UNIT 5. Remove nut and washer in trim tab cavity. a a-Nut and Washer 6. Remove 4 screws securing gear case to drive shaft housing. a a-Screw (4) Page 6-14 90-854785R2 DECEMBER 2001 LOWER UNIT Disassembly Water Pump NOTE:If water tube seal remained in drive shaft housing, remove seal from housing and reinstall on water pump cover. Secure seal to cover with Loctite 405. 1. Remove 4 screws securing pump cover. 52830 a b a-Seal b-Screw (4) NOTE:Replace cover if thickness of steel at discharge slots is 0.060 in. (1.524mm) or less, or if groove(s)(other than impeller sealing groove) in cover roof are more than 0.030 in. (0.762mm) deep. 2. Remove cover, washer (above impeller), impeller, key and washer (below impeller). 90-854785R2 DECEMBER 2001 Page 6-15 LOWER UNIT 3. Remove cover gasket, base plate and base gasket. a b c d e f g h a-Cover b-Washer (above impeller) c-Impeller d-Key e-Washer (below impeller) f-Cover Gasket g-Face Plate h-Base Gasket NOTE:Replace impeller if: –Impeller blades are cracked, torn or worn. –Impeller is glazed or melted –Rubber portion of impeller is not bonded to impeller hub. Page 6-16 90-854785R2 DECEMBER 2001 LOWER UNIT 4. Remove and/or replace exhaust deflector plate if damaged. 52832 a a-Deflector Plate 5. Remove bearing carrier attaching screws and locking tab washers or flat washers. Discard tab washers. b a a-Screws and Tab Washers or Flat Washers b-Tab Washers Style 2 6. Using Puller (91-27780), remove carrier assembly from gear case. 52829 91-27780 a a-Puller (91-27780) 90-854785R2 DECEMBER 2001 Page 6-17 LOWER UNIT NOTE: When removing propeller shaft assembly, cam follower may dislodge. Retrieve follower from gear housing. 7. Remove propeller shaft assembly. 52864a a-Propeller Shaft Models Drive Shaft Holding Tool 4-Stroke Mercury/Mariner 25, 45/50 91-83180M 2-Stroke Force 40/50 Mercury 30/40, 40/50 91-825196 8. Remove pinion nut. 52864 51043 ab a-Drive Shaft Holding Tool b-Pinion Gear Page 6-18 90-854785R2 DECEMBER 2001 LOWER UNIT 9. Remove drive shaft assembly and pinion gear. 10. Remove forward gear. a a-Forward Gear 11. Remove shift shaft assembly a a-Shift Shaft Assembly 90-854785R2 DECEMBER 2001 Page 6-19 LOWER UNIT 12. Insert pinion bearing race puller (91-825200A1) through gear case and position inside of pinion bearing race. Insert driver (91-13779) into puller through drive shaft cavity and drive out race. 91-825200A1 91-13779 a b a-Puller (91-825200A1) b-Driver (91-13779) 13. Remove forward bearing race with puller (91-27780). 53838 91-27780 ab a-Race b-Puller (91-27780) Page 6-20 90-854785R2 DECEMBER 2001 LOWER UNIT Water Pump Seals NOTE:All gaskets, seals and o-rings should be replaced as a normal repair procedure during gear case disassembly. NOTE: DO NOT use a screwdriver to remove seals from carrier, as carrier may be damaged. 1. Using a suitable mandrel, press both seals from carrier. 7 a b c d 7 Loctite 271 Thread Locker a-Neoprene Ribbed Seal b-Metal Cased Seal c-Carrier d-O-ring 2. Apply Loctite 271 Thread Locker to the O.D. of the metal cased seal. With seal lip facing away from the large shoulder of mandrel (91-825197), press seal into carrier until mandrel bottoms on carrier. 91-825197 b a a-Seal (Metal Cased) Lip Facing Down b-Mandrel (91-825197) 90-854785R2 DECEMBER 2001 Page 6-21 LOWER UNIT 3. With lip of ribbed neoprene O.D. seal facing towards small shoulder of Mandrel (91-825197), press seal into carrier until mandrel bottoms on carrier. 52853 91-825197 a b a-Seal (Ribbed Neoprene) Lip Facing Up b-Mandrel (91-825197) NOTE: Apply a light coat of 2-4-C Marine Lubricant withTeflon to the lips of both seals after installation in carrier. 4. Apply a light coat of 2-4-C Marine Lubricant with Teflon to the new o-ring and install on carrier. 52825 95 a 95 2-4-C Marine Lubricant with Teflon a-O-ring Page 6-22 90-854785R2 DECEMBER 2001 LOWER UNIT Inspection Upper Drive Shaft Bearing 1. Inspect bearing for rust, roughness or discoloration from lack of lubricant. 2. DO NOT remove bearing from drive shaft unless bearing must be replaced, as removal process will damage bearing. 3. If bearing must be replaced, position drive shaft assembly in vise (jaws of vise supporting only bearing) and while holding drive shaft, strike top of drive shaft with lead hammer and drive bearing off. a a-Bearing 4. To install new bearing, thread old pinion nut 3/4 way onto drive shaft. Position Universal Puller Plate (91-37241) under bearing and press on pinion nut while holding drive shaft until bearing seats against shoulder. 52387 91-37241 a b c a-Old Pinion Nut (Nut Should be Above Drive Shaft) b-Bearing c-Universal Puller Plate (91-37241) 90-854785R2 DECEMBER 2001 Page 6-23 LOWER UNIT Pinion Gear Bearing 1. Inspect bearing for rust, roughness or discoloration from lack of lubricant. 2. If bearing is damaged, bearing and race must be replaced as an assembly. 3. If race appears to have spun in drive shaft bore, gear case housing must be replaced. a b a-Bearing b-Race Pinion Gear 1. Inspect pinion gear teeth for rust, chipping, or excessive wear (teeth are sharp edged or broken). 2. If pinion gear teeth are damaged, also inspect forward and reverse gear teeth for damage. 3. Replace gears as required. Forward Gear 1. Inspect forward gear teeth for rust, chipping, excessive wear (teeth are sharped edged or broken). 2. Inspect forward gear clutch jaws for wear. Rounded jaws indicate the following: a. Improper shift cable adjustment. b. Engine idle speed too high. c. Shifting too slowly. Page 6-24 90-854785R2 DECEMBER 2001 LOWER UNIT 3. Inspect propeller shaft forward gear bearing surface to determine condition of forward gear needle bearing. If bearing surface is discolored (from lack of lubricant), pitted or worn, propeller shaft and bearing should be replaced. 52846 52874 a b a-Bearing Surface b-Bearing 4. Use a suitable mandrel to press needle bearing out of forward gear. a b a-Mandrel (14 mm Socket) b-Bearing 5. Use Driver 91-826872 to press new needle bearing into forward gear. Press on numbered side of bearing. 52847 87 87 Premium Gear Lubricant 91-826872 a b a-Driver (91-826872) b-Bearing 90-854785R2 DECEMBER 2001 Page 6-25 LOWER UNIT 6. Inspect forward gear tapered bearing and race for rust, roughness or excessive wear (looseness). 7. If bearing is in serviceable condition, DO NOT remove bearing from gear, as removal process will damage bearing. 8. If bearing must be replaced, remove bearing from gear using Universal Puller Plate (91-37241) and suitable mandrel. 9. Replace bearing and race as a set. Use suitable mandrel to press bearing onto gear. PRESS ONLY ON INNER RACE when installing bearing. 91-37241 a b REMOVAL a-Universal Puller Plate (91-37241) b-Mandrel (15/16 in. socket) a INSTALLATION a-Mandrel (1-1/8 in. socket) Page 6-26 90-854785R2 DECEMBER 2001 LOWER UNIT Shift Shaft 1. Inspect shift cam for wear or galling. Replace cam if necessary. 2. If cam is worn, inspect cam follower in end of propeller shaft for wear. 52845a b a-Cam Follower b-Shift Cam 3. Inspect shift shaft boot for deterioration. 4. Inspect shift shaft carrier o-ring for cuts or abrasions. It is a good service procedure to replace all o-rings, seals and gaskets regardless of appearance. a b a-Boot b-O-ring 90-854785R2 DECEMBER 2001 Page 6-27 LOWER UNIT Propeller Shaft Disassembly 1. Remove propeller shaft from carrier and disassemble shaft. d e f a b c a-Prop Shaft b-Retaining Spring c-Clutch Dog d-Cross Pin e-Cam Follower Spring f-Cam Follower 2. Remove reverse gear and bearing from carrier with Puller (91-27780). 52840 91-27780 a b a-Reverse Gear and Bearing b-Puller (91-27780) Page 6-28 90-854785R2 DECEMBER 2001 LOWER UNIT Propeller Shaft and Carrier Inspection Clutch 1. Inspect clutch jaws for chips or rounding off. 2. If wear is present, inspect corresponding forward or reverse gear matching jaws for similar wear. Replace appropriate components as required. Cam Follower 1. Inspect cam follower for wear or galling. 2. If wear is present, inspect corresponding shift cam for wear. Replace if worn. 90-854785R2 DECEMBER 2001 Page 6-29 LOWER UNIT Reverse Gear 1. Inspect reverse gear teeth for rust, chipping excessive wear (teeth are sharped edged) or broken teeth. 2. Inspect reverse gear clutch jaws for wear. Rounded jaws indicate the following: a. Improper shift cable adjustment. b. Engine idle speed too high. c. Shifting too slowly. Reverse Gear Bearing 1. Inspect bearing for rust, roughness or excessive wear (looseness). 2. If bearing is in serviceable condition, DO NOT remove bearing from gear as removal will damage bearing. 3. If bearing must be replaced, remove bearing from gear using Universal Puller Plate (91-37241) and Driver (91-37312). Page 6-30 90-854785R2 DECEMBER 2001 LOWER UNIT 4. Install new bearing using a suitable mandrel. PRESS ONLY ON INNER RACE when installing bearing. 91-37312 91-37241 a c d b REMOVAL a-Bearing b-Reverse Gear c-Universal Puller Plate (91-37241) d-Driver (91-37312) 52867 87 a b 87 Premium Gear Lubricant INSTALLATION a-Mandrel (1-1/4 in. socket) b-Bearing 90-854785R2 DECEMBER 2001 Page 6-31 LOWER UNIT Bearing Carrier NEEDLE BEARING 1. The condition of the carrier needle bearing can be determined by inspecting its running surface on the propeller shaft. 2. If the shaft is discolored (from lack of oil) or pitted, replace bearing and shaft. 3. Bearing can be removed by using Driver Rod (91-37323) and Driver (91-37312). Removing bearing will also remove both propeller shaft seals. 51264 91-37312 91-37323 a d c b a-Driver Rod (91-37323) b-Driver (91-37312) c-Needle Bearing d-Seals Page 6-32 90-854785R2 DECEMBER 2001 LOWER UNIT 4. Apply a light coat of 2-4-C Marine Lubricant with Teflon to O.D. of bearing. 5. Install bearing using Mandrel 91-817011. 6. Press bearing into carrier until mandrel bottoms on carrier. 52861 108 91-817011 a b 95 2-4-C Marine Lubricant with Teflon a-Bearing b-Mandrel (91-817011) 7. Apply Loctite 271 Thread Locker to O.D. of small diameter seal. 8. With seal lip facing away from large shoulder of Mandrel 91-817007, press seal into carrier until mandrel bottoms on carrier. 52862 7 7 Loctite 271 Thread Locker 91-817007 b a a-Seal b-Mandrel (91-817007) 90-854785R2 DECEMBER 2001 Page 6-33 LOWER UNIT 9. Apply Loctite 271 to O.D. of large diameter seal. 10. With seal lip FACING TOWARDS SMALL SHOULDER of Mandrel 91-817007, press seal into carrier until mandrel bottoms on carrier. 52863 7 7 Loctite 271 Thread Locker 91-817007 b a a-Seal b-Mandrel (91-817007) Installation Note: If service tools are not available, the following reference dimensions apply for installing bearing and seals to proper depths. a-Bearing 51275 .82 in. (20mm) a 51275 .04 in. (1mm) .44 in. (11mm) a b a-Oil Seal (Install with Lip Down) b-Oil Seal (Install with Lip Up) Page 6-34 90-854785R2 DECEMBER 2001 LOWER UNIT 11. Bearing carrier o-ring should be inspected for cuts and abrasions. NOTE:Itisagoodrepairproceduretoreplaceal llo-ringsandsealsregardlessofappearance. 12. Apply 2-4-C Marine Lubricant with Teflon to o-ring and install on carrier. 13. Using suitable mandrel, press reverse gear assembly into carrier. 95 a b c 95 2-4-C with Teflon a-O-ring b-Mandrel (3/4 in. Socket) c-Reverse Gear Assembly Gear Housing Reassembly IMPORTANT: This gear case assembly does not have have any shims for the gear assemblies. Backlash cannot be adjusted. The mechanic must verify that all bearing races are firmly seated in the gear case during reassembly and that all gear case components are in serviceable condition. Prior to installing the seal carrier and water pump assembly on the drive shaft, the FORWARD gear should be held stationary (with a screw driver or similar tool). While pulling up on the drive shaft, lightly turn the shaft back and forth. A light “clicking” sound should be heard indicating the presence of backlash between FORWARD and PINION gears. If this backlash is not present, the pinion gear race and/or forward gear race are not fully seated. Races should be removed and inspected for debris. Reinstall races and check backlash. If backlash is still not present, replace gear housing. 90-854785R2 DECEMBER 2001 Page 6-35 LOWER UNIT Shift Shaft Assembly 1. Apply 2-4-C Marine Lubricant with Teflon to new o-rings and install o-rings on shift shaft and carrier. 2. Install carrier on shift shaft. IMPORTANT: When installing shift shaft assembly into gear housing, DO NOT BOTTOM OUT SHAFT IN HOUSING. Pull up on shift shaft until shift boot is not deformed. If shaft is bottomed out, cross pin in clutch dog will be bent by cam follower when tightening carrier screws. 3. Install shift shaft/carrier assembly into gear housing. 4. Secure boot to carrier with sta-strap. 5. Position shift shaft so ramp faces towards propeller shaft. a c b d e 95 95 2-4-C Marine Lubricant with Teflon 52841 a-O-rings b-Carrier c-Boot d-Sta-strap e-Ramp Page 6-36 90-854785R2 DECEMBER 2001 LOWER UNIT Pinion Bearing Race 1. Apply Premium Gear Lubricant to O.D. of race. 2. Position race in gear housing (NUMBERS UP - TAPERED SIDE FACING DOWN). 3. Draw race up into housing until seated. 52842 87 87 Premium Gear Lubricant 91-29310 12-34961 91-825198 91-31229 11-24156 31-85560 91-825199 b f g e d a c a-Threaded Rod (91-31229) b-Washer (2) (12-34961) c-Bearing (31-85560) d-Plate (91-29310) e-Pilot (91-825199) f-Nut (11-24156) g-Mandrel (91-825198) 90-854785R2 DECEMBER 2001 Page 6-37 LOWER UNIT Forward Gear 1. Apply Premium Gear Lubricant to O.D. of race. Install forward gear bearing race into housing using Mandrel 91-36571 and propeller shaft. Use a lead hammer on prop shaft to prevent damage to threads. Bearing carrier should be installed to keep prop shaft centered while seating race. 87 91-36571 a b 87 Premium Gear Lubricant a-Race b-Mandrel (91-36571) NOTE: Remove drain plug/magnet assembly from gear case (if installed) to prevent possible breakage of magnet if struck by forward gear. 2. Install forward gear and bearing assembly into forward gear race. a a-Forward Gear Assembly Page 6-38 90-854785R2 DECEMBER 2001 LOWER UNIT Pinion Gear/Drive Shaft Assembly 1. Clean pinion nut and pinion nut threads of drive shaft with Loctite 7649 Primer. 2. Position pinion bearing into race while installing drive shaft and pinion gear into housing. 3. Apply Loctite 271 to pinion nut threads. 4. Install new pinion nut, with rounded corners FACING pinion gear, onto drive shaft. Models Drive Shaft Holding Tool 4-Stroke Mercury/Mariner 25, 45/50 91-83180M 2-Stroke Force 40/50 Mercury 30/40, 40/50 91-825196 5. Using Drive Shaft Holding Tool to hold drive shaft, tighten pinion nut to the specified torque. 52864 7 7 Loctite 271 Thread Locker a b c d a-Pinion Nut [Torque to 50 lb. ft. (67.8 N·m)] b-Pinion Gear c-Pinion Bearing d-Drive Shaft Holding Tool Pinion Gear Nut Torque 50 lb. ft. (68 N·m) 90-854785R2 DECEMBER 2001 Page 6-39 LOWER UNIT Propeller Shaft 1. Slide clutch (short shoulder faces forward gear) over propeller shaft aligning cross pin hole with slot in propeller shaft. 2. Insert cam follower spring into propeller shaft. a b c d e f a-Prop Shaft b-Retaining Spring c-Clutch Dog d-Cross Pin e-Cam Follower Spring f-Cam Follower 3. Using a 3/16 in. allen wrench or similar device, compress the follower spring enough to insert the cross pin partially through clutch. 4. Remove wrench and press cross pin through clutch and propeller shaft until flush. ac b a-Short Shoulder b-Allen Wrench c-Cross Pin 5. Reinstall retaining spring. position spring so as spring coils lay flat in clutch groove. a a-Spring NOTE: Applying 2-4-C Marine Lubricant with Teflon to cam follower will aid in retention of follower in propeller shaft during installation of propeller shaft assembly into gear case. Page 6-40 90-854785R2 DECEMBER 2001 LOWER UNIT 6. Install cam follower. 95 a 95 2-4-C Marine Lubricant with Teflon a-Cam Follower 7. Install propeller shaft assembly into gear case. a a-Propeller Shaft Assembly 90-854785R2 DECEMBER 2001 Page 6-41 LOWER UNIT Bearing Carrier 1. Install carrier into gear case. 2. Discard the original tab washers or the thin 0.063 in. (1.60 mm) flat washers and the 25 mm long screws on models listed. Install thicker flat washers and longer screws. 25 (2 Cylinder - 4 Stroke) USA . . . . . . . 0G621670 and below 45/50 (4 Cylinder - 4 Stroke) Non Big Foot USA . . . . . . . 0G621709 and below 30/40 (2 Cylinder - 2 Stroke) USA . . . . . . . 0G650736 and below Belgium . . . . NA 40/50 (3 Cylinder - 2 Stroke) USA . . . . . . . 0G650699 and below Belgium . . . . NA Force 40/50 (2 Cylinder - 2 Stroke) USA . . . . . . . 0E323508 and below a b c a-Screw 25 mm Long - Discard b-Tab Washer - Discard c-Thin Flat Washer 0.063 in. (1.60 mm) thick - Discard 3. Install thicker flat washers and longer screws. a b a-Screw (10-855940-30) 1.18 in. (30 mm) Long b-Washer (12-855941) 0.090 in. (2.29 mm) Thick Page 6-42 90-854785R2 DECEMBER 2001 LOWER UNIT 4. Tighten screws to the specified torque. 7 7 a a 7 Loctite 271 Thread Locker a-Bolt (2) Bearing Carrier Bolt Torque 19 lb. ft. (25.5 N·m) 90-854785R2 DECEMBER 2001 Page 6-43 LOWER UNIT Water Pump 1. Install water pump seal carrier. 2. Install exhaust deflector plate, if removed. 52832 a b a-Seal Carrier b-Exhaust Deflector 3. Install base gasket, face plate, pump cover gasket (NEOPRENE STRIP FACES UP), nylon washer and impeller key. 52868 a b d e f c a-Base Gasket b-Base Plate c-Cover Gasket d-Neoprene Strip e-Nylon Washer f-Key IMPORTANT: If impeller being installed has been previously used and vanes have taken a “set,” DO NOT INSTALL THE IMPELLER WITH THE VANES REVERSED FROM THEIR PREVIOUS “SET” AS VANE BREAKAGE WILL OCCUR SHORTLY AFTER UNIT IS RETURNED TO SERVICE. Page 6-44 90-854785R2 DECEMBER 2001 LOWER UNIT 4. Install impeller and nylon washer. 52869 ab a-Impeller b-Nylon Washer NOTE: Apply a light coat of 2-4-C Marine Lubricant with Teflon to inside of pump cover to ease installation of cover over impeller. 5. Install pump cover. Rotate drive shaft CLOCKWISE while pressing cover down over impeller. 6. Apply Loctite 271 to retaining screws and tighten screws to the specified torque. 52830 7 7 Loctite 271 Thread Locker a b a-Cover b-Bolts (4) Water Pump Cover Bolt Torque 60 lb. in. (7 N·m) 90-854785R2 DECEMBER 2001 Page 6-45 LOWER UNIT Gear Housing Pressure Test 1. Remove vent plug and install pressure test gauge. Tighten securely. 2. Pressurize housing to 10-12 PSI (69-83 kPa) and observe gauge for 5 minutes. 3. Rotate drive shaft, prop shaft and move shift rod while housing is pressurized to check for leaks. 4. If pressure drop is noted immerse housing in water. 5. Re-pressurize to 10-12 PSI (69-83 kPa) and check for air bubbles. 6. Replace leaking seals as necessary. Retest housing. NOTE:It should hold 10-12 PSI (69-83 kPa) for 5 minutes. 7. Remove tester from housing and install vent plug. Page 6-46 90-854785R2 DECEMBER 2001 LOWER UNIT Gear Housing Installation Filling Gear Housing with Lubricant NOTE:Gear housing lubricant capacity is approximately 14.9 fl. oz. (440 ml). WARNING If gear housing is installed on outboard, disconnect (and isolate) spark plug leads from spark plugs before working near the propeller. CAUTION Do not use automotive grease in the gear housing. Use only Premium Gear Lube. 1. Remove any gasket material from “Fill” and “Vent” plugs and gear housing. Install new gaskets on “Fill” and “Vent” plugs. IMPORTANT: Never add lubricant without removing “Vent” plug. Gear housing cannot be filled because of trapped air. Fill gear housing when driveshaft is in a vertical position. 2. Remove “Fill” plug and gasket. 3. Insert lubricant tube in “Fill” hole, then remove “Vent” plug and gasket. 4. Fill until excess lubricant flows out of “Vent” hole. 5. Replace this “Vent” plug and gasket. 6. Install “Fill” plug and gasket. a a-“Vent” Plug 7. Tighten Fill and Vent plugs to the specified torque. Fill and Vent Plug Torque 55 lb. in. (6 N·m) 90-854785R2 DECEMBER 2001 Page 6-47 LOWER UNIT Installing Gear Housing to Drive Shaft Housing WARNING Disconnect (and isolate) spark plug leads before installing gear housing onto drive shaft housing. 1. Position shift lever in NEUTRAL gear position. 2. Tilt engine to full “Up” position. Engage tilt lock lever. 3. Shift gear housing into NEUTRAL. Propeller shaft will rotate freely in either direction. IMPORTANT: Liberally apply 2-4-C Marine Lubricant with Teflon to drive shaft splines. 4. Position drive shaft into drive shaft housing. Move gear housing upwards in drive shaft housing while aligning both shift shafts, water tube seal and drive shaft splines. NOTE: If the drive shaft splines will not align with the crankshaft splines, rotate flywheel slightly while pushing gear housing into drive shaft housing. 5. Install 4 screws and washers, (two each side). Tighten screws to the specified torque. a a-Bolt and Washers (2 each side) Gear Housing Bolt Torque 40 lb. ft. (54 N·m) Page 6-48 90-854785R2 DECEMBER 2001 LOWER UNIT 6. Reconnect shift shaft with coupler nut and jam nut. Tighten jam nut against coupler nut. NOTE:After reconnecting shift shaft, bottom of jam nut should be approximately flush with top of spray plate. 30/40, 40/50, FORCE 40/50 52834 a b c a-Coupler Nut b-Jam Nut c-Spray Plate 7. Connect shift shaft by sliding retainer to the right and snapping into upper “locked” position. 25 (4 STROKE), 45/50 (4 STROKE) 53859 a b a-Retainer b-Lower Clip 90-854785R2 DECEMBER 2001 Page 6-49 LOWER UNIT 8. Install locknut and washer. Tighten nut to the specified torque. 52833 a a-Locknut and Washer Gear Housing Mounting Stud Nut Torque 40 lb. ft. (54 N·m) 9. Check shift operation. a. In NEUTRAL, propeller shaft should turn freely in either direction. b. In FORWARD, propeller shaft SHOULD NOT TURN COUNTERCLOCKWISE. c. In REVERSE, propeller shaft SHOULD NOT TURN IN EITHER DIRECTION. IMPORTANT: If shift operation is not as described, remove the gear housing and correct the shift operation. Page 6-50 90-854785R2 DECEMBER 2001 LOWER UNIT Trim Tab Adjustment and Replacement IMPORTANT: The trim tab is made of a special alloy to aid in protecting the drive shaft housing and gear housing from galvanic corrosion (corrosion and pitting of metal surfaces). Do not paint or place protective coating on the trim tab, or trim tab corrosion protection function will be lost. Replace trim tab if 50% (or more) corroded. Mark location of old trim tab on anti-ventilation plate before removal. Install new trim tab in same location. 1. Check trim tab position as follows: a. Operate boat at the speed at which it would normally be operated. b. If the boat pulls to the right (starboard), the trailing edge of trim tab must be moved to the right. If the boat pulls to the left (port), the trailing edge of trim tab must be moved to the left. 2. If necessary, adjust trim tab as follows: a. Shift engine control into NEUTRAL and turn ignition key to “OFF” position. NOTE:Loosen trim tab screw sufficiently to allow trim tab to disengage from locking ridges in gear case before attempting to move tab. DO NOT strike trim tab with a hard object to make adjustments. b. If boat pulls to the left, adjust trailing edge of trim tab to the left. If boat pulls to the right, adjust trailing edge of trim tab to the right. a bc a-Trim Tab b-Anti-Ventilation Plate c-Retaining Bolt and Washer Trim Tab Retaining Bolt Torque 16 lb. ft. (21.5 N·m) 90-854785R2 DECEMBER 2001 Page 6-51 THROTTLE/SHIFT LINKAGE ATTACHMENTS/CONTROL LINKAGE Section 7A - Throttle/Shift Linkage Table of Contents Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-2 Throttle Cable Installation . . . . . . . . . . . . . . . . . 7A-6 Shift Cable Installation . . . . . . . . . . . . . . . . . . . . 7A-4 7 A 90-854785R2 DECEMBER 2001 Page 7A-1 THROTTLE/SHIFT LINKAGE Page 7A-2 90-854785R2 DECEMBER 2001 LINKAGE 95 2-4-C Marine Lubricant with Teflon 95 1 95 2 3 4 5 6 7 8 9 10 11 12 17 18 13 14 15 16 19 20 21 22 23 24 25 26 27 28 29 30 31 32 12 33 THROTTLE/SHIFT LINKAGE LINKAGE REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 SCREW (M8 x 70) SCREW (M6 x 55) NUT ELECTRIC NON HANDLE CAP RETAINER THROTTLE LEVER BUSHING RETAINER SHIFT LEVER SHIFT ROD THROTTLE ROD SWIVEL BUSHING BRACKET LATCH SCREW (M6 x 16) SLEEVE WASHER COTTER PIN 100 11.5 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 10 1 11 1 12 2 13 1 14 1 15 2 105 12 16 2 17 1 18 1 19 1 THROTTLE CAM 20 1 BUSHING 21 1 WASHER 22 1 SCREW (M6 x 35) 85 9.5 23 1 HORIZONTAL SHIFT SHAFT 24 1 RETAINER 25 1 SPRING 26 2 SPRING 27 1 PLATE 28 2 SCREW (M5 x 16) 75 8.5 29 1 SWITCH ELECTRIC HANDLE MODELS SCREW (M3 x 20) PLATE–Switch 30 2 20 2.5 31 1 32 1 BRACKET-Throttle Cable HANDLE MODELS SCREW (M6 x 16)33 1 75 8.5 90-854785R2 DECEMBER 2001 Page 7A-3 THROTTLE/SHIFT LINKAGE Page 7A-4 90-854785R2 DECEMBER 2001 Shift Cable Installation Install cables into the remote control following the instructions provided with the remote control. NOTE: Install the shift cable to the engine first. The shift cable is the first cable to move when the remote control handle is moved out of neutral. 1. Position remote control into neutral. N 2. Shift outboard into neutral. 3. Measure the distance (a) between pin and center of lower hole. a b c a - Distance Between Pin And Center of Lower Hole b - Pin c - Lower Hole 4. Fit shift cable through rubber grommet. THROTTLE/SHIFT LINKAGE 5. Push in on the cable end until resistance is felt. 6. While pushing in on the cable end, adjust the cable barrel to attain the measured distance (a) taken in Step 3. a b a-Adjust Cable Barrel To Attain The Measured Distance Taken In Step 3 b-Cable Barrel 7. Place cable barrel into the barrel holder. Fasten cable with retainer. c d c-Place Barrel Into Barrel Holder d-Retainer 8. 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. 90-854785R2 DECEMBER 2001 Page 7A-5 THROTTLE/SHIFT LINKAGE Page 7A-6 90-854785R2 DECEMBER 2001 Throttle Cable Installation 1. Position remote control into neutral. N 2. Fit throttle cable through rubber grommet. 3. Install throttle cable (a) with retainer pin (b). Lock retainer pin in place. b a a - Throttle Cable b - Retainer Pin THROTTLE/SHIFT LINKAGE 90-854785R2 DECEMBER 2001 Page 7A-7 4. Adjust cable barrel until the alignment mark on the cam lines up with center of the roller. a b c a - Cable Barrel b - Alignment Mark c - Roller 5. Fasten control cables with the cable latch. TILLER HANDLE ATTACHMENTS/CONTROL LINKAGE Section 7B - Tiller Handle Table of Contents Tiller Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-2 Tiller Handle Disassembly . . . . . . . . . . . . . . . . . 7B-8 Throttle Cable Adjustment . . . . . . . . . . . . . . . . . 7B-4 Tiller Handle Reassembly . . . . . . . . . . . . . . . . . 7B-11 Tiller Handle Assembly Removal . . . . . . . . . . . 7B-6 Tiller Handle Installation . . . . . . . . . . . . . . . . . . . 7B-17 7 B 90-854785R2 DECEMBER 2001 Page 7B-1 TILLER HANDLE TILLER HANDLE 95 2-4-C Marine Lubricant with Teflon Page 7B-2 90-854785R2 DECEMBER 2001 TILLER HANDLE TILLER HANDLE REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 COVER KIT 2 1 PULLEY 3 1 CASE 4 1 SCREW (10-16 x 1/2 IN. Self Tapping) 20 2.5 5 1 THROTTLE CABLE (26-1/2 IN.) 6 1 THROTTLE CABLE (27-1/2 IN.) 7 1 SLEEVE 8 2 SCREW (M8 x 25) 135 15.5 9 99 1 COVER (BLACK) 1 COVER (GRAY) 10 1 BUSHING 11 1111 1 ARM–Steering Handle (BLACK) 1 ARM–Steering Handle (GRAY) 1 ARM–Steering Handle (BLACK) GRAND CANYON 1 ARM–Steering Handle (GRAY) 12 1 RETAINER 13 1 SCREW (M5 x 16) 35 4 14 1 SCREW (M6 x 25) 15 1 LOCK–Throttle 16 1 SPRING 17 1 KNOB–Throttle 1818 1 TILLER TUBE 1 TILLER TUBE (GRAND CANYON) 19 1 DECAL 20 1 HANDLE–Throttle 21 1 GRIP 22 2222 1 SWITCH (STOP) 1 SWITCH (STOP) (GRAND CANYON) 23 1 SCREW (M5 x 12) 24 1 WASHER 25 1 ALARM 26 2 CLIP 2727 1 SWITCH (STOP) 1 SWITCH (STOP) (GRAND CANYON) 28 1 RETAINER 2929 1 BRACKET–Tiller (BLACK) 1 BRACKET–Tiller (GRAY) 30 1 WAVE WASHER 31 1 BUSHING 32 1 WASHER 33 1 CONDUIT 34 1 CABLE TIE 35 1 DECAL-Shift (F-N-R) 36 1 TAB WASHER 37 2 SCREW (M10 x 90) 35 47.5 38 1 LANYARD SWITCH 39 1 SCREW (M8 x 35) 100 11.5 40 1 SHIFT HANDLE 41 1 BUSHING 42 1 SHIFT ROD 90-854785R2 DECEMBER 2001 Page 7B-3 TILLER HANDLE Page 7B-4 90-854785R2 DECEMBER 2001 Throttle Cable Adjustment 1. Attach shorter throttle cable to throttle cam as shown. 55855 a a - Shorter Cable 2. Route longer cable under throttle cam and attach. 3. Secure cables by tightening jam nuts. 55855 b b a a - Longer Cable b - Jam Nuts TILLER HANDLE 4. Adjust jam nuts so W.O.T. occurs with a slight gap. a a-Gap IMPORTANT: After installation, move the throttle grip a few times from the idle position to the wide-open-throttle position. Return throttle grip to the wide open throttle position and visually check for the specified gap. If necessary, readjust the jam nuts. 90-854785R2 DECEMBER 2001 Page 7B-5 TILLER HANDLE Page 7B-6 90-854785R2 DECEMBER 2001 Tiller Handle Assembly Removal 1. Remove shift handle. a b c a - Shift Handle b - Bushing c - Screw 2. Loosen the jam nuts and disconnect the throttle cables from the throttle cam. a a b 55855 a - Jam Nuts b - Throttle Cam TILLER HANDLE 3. Cut sta-straps securing tiller handle/harness wires and battery cables. 4. Disconnect the tiller handle wiring. YEL/RED BLK BLK RED TAN/BLU PUR BLK/YEL BLK BLKBLK/YELYEL/RED RED BLK/YEL BLK BLK/YEL BLK TAN RED 5. Remove two screws securing the tiller handle. Remove the tiller handle assembly from the outboard. 55858a b a-Screws (2) b-Tab Washer, Lock 90-854785R2 DECEMBER 2001 Page 7B-7 TILLER HANDLE Tiller Handle Disassembly 1. Pry the two clips out of the hand grip. 2. Remove the side cover. a b a-Clips (2) b-Side Cover 3. Pull the arm along with the throttle cables and wiring from the bracket. Page 7B-8 90-854785R2 DECEMBER 2001 TILLER HANDLE 4. Pry the engine start switch off the tiller tube. 5. Remove retainer and slide out the tiller tube assembly. 6. Remove the throttle lock assembly. b a c d a-Engine Start Switch b-Retainer c-Throttle Lock Assembly d-Tiller Tube 7. Use a flat tip screwdriver to pry/push the rubber grip off the handle. 90-854785R2 DECEMBER 2001 Page 7B-9 TILLER HANDLE 8. Pull out the stop switch harness. 9. Push the tiller tube out of the handle. a cb a-Stop Switch Harness b-Tiller Tube c-Handle 10. Remove cover and disconnect throttle cables from pulley. b a c a-Throttle Cables b-Cover c-Pulley Page 7B-10 90-854785R2 DECEMBER 2001 TILLER HANDLE Tiller Handle Reassembly 1. Wrap cables around pulley as shown. b c a a-Short Throttle Cable (23-1/2 in. [60 cm] ) Place in Top Groove b-Long Throttle Cable (25 in.[63.5 cm] ) Place in Bottom Groove c-Pulley 2. Place pulley and cables into case. 3. Install cover with screw. Tighten screw to the specified torque. b c a a-Pulley b-Cover c-Screw Cover Screw Torque 20 lb. in. (2.5 N·m) 90-854785R2 DECEMBER 2001 Page 7B-11 TILLER HANDLE 4. Match tiller tube end with the slots and pull the tube end into the handle until it bottoms out. 5. Install the throttle lock components on tiller tube. a c c b d e f g a-Tiller Tube b-Handle c-Match the Tube End with Slots d-Screw e-Lock f-Spring g-Knob 6. Check to make sure tiller tube is pushed in 7/8 in. (22.2mm). 7. Insert the engine stop switch harness through the tiller tube. Place the stop switch into end on handle. 7/8 in. (22.2mm) a c b a-Engine Stop Switch Harness b-Stop Switch c-7/8 in. (22.2 mm) between Tiller Tube and end of Handle Page 7B-12 90-854785R2 DECEMBER 2001 TILLER HANDLE 8. Align the grooves inside the rubber grip with the ridges on the handle. Push the rubber grip onto the handle. NOTE:Applying a soapy/water solution to the inside of the rubber grip will ease installation. 9. Place pulley assembly into arm. 10. Slide the tiller tube into the arm. Position the throttle lock knob into its slot. NOTE:Place engine start switch wiring harness under the tiller tube as shown. 11. Route the stop switch wiring harness through the pulley assembly. 12. Match the end of the tiller tube with the slots in the pulley assembly. Insert the tiller tube end into the pulley assembly. 13. Secure tiller tube with retainer. Tighten the screw to the specified torque. 14. Snap the engine start switch on the tiller tube. a b c d ef a-Engine Start Switch Harness (Place under Tiller Tube) b-Engine Start Switch c-Pulley Assembly d-Throttle Lock Knob e-Retainer f-Screw - Tighten to specified torque Retainer Screw Torque 35 lb. in. (4 N·m) 90-854785R2 DECEMBER 2001 Page 7B-13 TILLER HANDLE 15. Place bushing components on the arm mounts. a b c d 95 95 95 2-4-C Marine Lubricant with Teflon a-Flat Washer b-Bushing c-Wave Washer (2) d-Bushing 16. Pull the throttle cables and wiring into the bracket. Page 7B-14 90-854785R2 DECEMBER 2001 TILLER HANDLE 17. Fasten arm with cover. Tighten screws to the specified torque. Arm Cover Screw Torque 135 lb. in. (15.5 N·m) 18. Place the throttle cables through the hand grip opening as shown. CAUTION Wiring passing through the hand grip opening must be protected from chaffing or being cut, by using the wiring conduit described in the following steps. Failure to protect wiring as described could result in electrical system failure. 19. Place all wiring inside the wiring conduit. 20. Route the wiring through the hand grip opening and position the wiring conduit inside the opening so that at least 1/2 in. (12.7mm) extends inside the handle grip. 90-854785R2 DECEMBER 2001 Page 7B-15 TILLER HANDLE 21. Push the wiring and throttle cables down into the handle grip and hold in place with two clips. 1/2 in. (12mm) 1/2 in. (12mm) a b d b a c a-Wiring Conduit (Place all Wiring Inside – See CAUTION above) b-Place Wiring Conduit inside opening 1/2 in. (12.7mm) c-Throttle Cables (Position toward outer side) d-Clips (2) Page 7B-16 90-854785R2 DECEMBER 2001 TILLER HANDLE Tiller Handle Installation 1. Install tiller handle assembly on outboard. Install two screws securing the tiller handle. Torque screws to the specified torque. Bend tabs on tab washer. 55858a b a-Screws (2) b-Tab Washer, Lock Tiller Handle Screw Torque 35 lb. ft. (47.5 N·m) 2. Connect the tiller handle wiring. YEL/RED BLK BLK RED TAN/BLU PUR BLK/YEL BLK BLKBLK/YELYEL/RED RED BLK/YEL BLK BLK/YEL BLK TAN RED 90-854785R2 DECEMBER 2001 Page 7B-17 TILLER HANDLE Page 7B-18 90-854785R2 DECEMBER 2001 3. Connect the throttle cables to the throttle cam. Secure the jam nuts (refer to throttle cable adjustment in this section). 55855 a a a - Jam Nuts 4. Secure wires at connectors with sta-strap as shown. 5. Secure harness and battery cables to fuel connector with sta-strap as shown. 55855 a a - Sta-Strap TILLER HANDLE 6. Install shift handle. a-Shift Handle b-Bushing c-Screw a b c Shift Handle Screw Torque 100 lb. in. (11.5 N·m) 90-854785R2 DECEMBER 2001 Page 7B-19 MANUAL STARTER MANUAL STARTER Table of Contents Manual Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Rewind Starter Reassembly . . . . . . . . . . . . . . . 8-9 Manual Starter Removal . . . . . . . . . . . . . . . . . . 8-4 Adjusting Rewind Spring Tension . . . . . . . . 8-11 Manual Starter Disassembly . . . . . . . . . . . . . . . 8-5 Manual Starter Installation . . . . . . . . . . . . . . . . . 8-16 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . 8-8 Interlock Cable Adjustment . . . . . . . . . . . . . . . . 8-17 8 90-854785R2 DECEMBER 2001 Page 8-1 MANUAL STARTER Page 8-2 90-854785R2 DECEMBER 2001 MANUAL STARTER 95 2-4-C Marine Lubricant with Teflon 95 95 95 95 95 1 2 3 4 5 6 7 8 9 10 11 13 12 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 23 MANUAL STARTER MANUAL STARTER REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m – 1 RECOIL STARTER ASSEMBLY 1 1 RECOIL HOUSING 2 1 SEAL 3 1 ROLLER 4 1 BUSHING 5 1 WASHER 6 1 SCREW (M6 x 30) 70 8.0 7 1 LOCKWASHER 8 1 SPRING 9 1 STARTER SHEAVE 10 2 CAM 11 2 SPRING 12 2 RETAINING RING 13 1 SPRING 14 1 CAM 15 1 SCREW (1/4-20) 135 15.3 5 16 1 STARTER CORD 17 1 CAM 18 1 SPRING 19 1 INTERLOCK LEVER 20 1 RETAINER 21 1 SPRING 22 1 BUSHING 23 5 SCREW (10-16 x 1) Drive Tight 24 1 HANDLE 25 1 RETAINER 26 4 SCREW (M6 x 25) 60 7.0 27 1 INTERLOCK CABLE 28 1 SCREW (10-16 x .625) Drive Tight 29 1 WASHER 30 1 COTTER PIN 31 1 SCREW (M5 x 16) 33.6 4 32 1 J-CLIP 33 1 SCREW (M6 x 16) 90-854785R2 DECEMBER 2001 Page 8-3 MANUAL STARTER Page 8-4 90-854785R2 DECEMBER 2001 Manual Starter Removal 1. Remove the adjustment screw from the rewind housing. Remove the retaining clip from the start interlock. Remove the interlock cable. a b a - Retaining Clip b - Adjustment Screw 2. Remove screws and manual starter. b a a - Screws (4) - M6x25 b - Manual Starter MANUAL STARTER 90-854785R2 DECEMBER 2001 Page 8-5 Manual Starter Disassembly WARNING When disassembling and reassembling rewind starter, SAFETY GLASSES must be worn in case rewind spring uncoils out of the housing. 1. Remove cam retainer. a b a - Screws (3) - 10-16x.625 (1/4 in. Hex) b - Cam Retainer 2. Remove cam, interlock lever, and springs. a b d c a - Cam b - Spring (Cam) c - Interlock Lever d - Spring (Interlock Lever) MANUAL STARTER 3. Pull starter rope handle out from rewind starter about 1 ft. (30.5cm) and tie a overhand knot at this point to prevent rope from being pulled back into rewind starter. 4. Untie the knot in the starter rope handle. Untie knot in starter rope (from previous step). Release starter rope to allow rewind spring to unwind. a a-Knot 5. Remove cam. a b d c a-Screw b-Cam c-Spring d-Starter Sheave Page 8-6 90-854785R2 DECEMBER 2001 MANUAL STARTER 90-854785R2 DECEMBER 2001 Page 8-7 6. Remove starter sheave assembly from recoil housing. a b a - Starter Sheave Assembly b - Recoil Housing 7. Remove rope from starter sheave assembly. 8. Remove springwasher and spring assembly from starter sheave. a b c a - Springwasher b - Spring Assembly c - Starter Sheave MANUAL STARTER 9. Remove retaining rings, pawls, and springs from starter sheave. a b c a-Retaining Rings (2) b-Pawls (2) c-Springs (2) Cleaning and Inspection 1. Clean components in solvent and dry with compressed air. 2. Inspect rewind spring for kinks, burrs, corrosion of breakage. 3. Inspect starter sheave, rope guide and starter housing for nicks, grooves, cracks, wear or distortion, especially area of rope travel. 4. Inspect bushing, starter drive pawl and spring for wear or damage. 5. Inspect starter rope for wear. 6. Replace components as necessary. Page 8-8 90-854785R2 DECEMBER 2001 MANUAL STARTER 90-854785R2 DECEMBER 2001 Page 8-9 Rewind Starter Reassembly WARNING When reassembling rewind starter, SAFETY GLASSES must be worn in case rewind spring uncoils out of the housing. 1. Install springs, pawls, and retaining rings onto starter sheave. a b c a - Springs (2) b - Pawls (2) c - Retaining Rings (2) 2. Install spring assembly and springwasher into starter sheave. 95 2-4-C Marine Lubricant with Teflon 95 a b c a - Spring Assembly b - Springwasher c - Starter Sheave MANUAL STARTER Page 8-10 90-854785R2 DECEMBER 2001 3. Install starter sheave assembly into recoil housing. NOTE: Looped end of spring must engage “V” notch in hub of starter housing. a c b a - Recoil Housing b - Starter Sheave Assembly c - Looped End of Spring 4. Secure cam and starter sheave assembly to recoil housing. NOTE: Cam should have “x” facing up. b a c a - Spring b - Cam c - Screw Cam Screw Torque 135 lb. in. (15.5 N·m) MANUAL STARTER 90-854785R2 DECEMBER 2001 Page 8-11 Adjusting Rewind Spring Tension 1. Rotate sheave counterclockwise until it stops (coil is bound). 2. Back sheave off until rope hole in sheave aligns with rope bushing. MANUAL STARTER Page 8-12 90-854785R2 DECEMBER 2001 3. If less than 90° rotation required to achieve, then back off one additional turn. IMPORTANT: Never back off sheave less than one full turn. a b a - Rope Guide Hole b - Knot Recess 4. Thread starter rope through rope guide, starter housing, and starter sheave. Tie knot in end of rope and place knot into recess. b a a - Starter Rope b - Knot MANUAL STARTER 5. Allow starter rope to pull back into rewind starter until about 1 ft. (30.5cm) of rope is left. Tie a overhand knot at this point to prevent rope from being pulled back into rewind starter. 6. Route starter rope through starter handle. Tie a knot into end of rope and secure in rope retainer. 7. Untie overhand knot from step 5. a b c a-Starter Rope b-Starter Handle c-Retainer 90-854785R2 DECEMBER 2001 Page 8-13 MANUAL STARTER Page 8-14 90-854785R2 DECEMBER 2001 8. Install springs, interlock lever, and cam. IMPORTANT: Interlock lever spring should be installed with squared end of spring seated on interlock lever. 95 2-4-C Marine Lubricant with Teflon 95 95 a b d c e a - Spring (Interlock Lever) b - Squared End of Spring c - Interlock Lever d - Spring (Cam) e - Cam IMPORTANT: Cam spring ends should be seated on recoil housing and cam boss. Spring tension should be noticeable when turning cam clockwise. 56721 a b c a - Spring (Cam) b - Recoil Housing c - Cam Boss (Hidden) MANUAL STARTER 9. Install cam retainer. Drive screws tight. NOTE:Cam should be held with some preload until retainer is seated. a b c a-Cam Retainer b-Cam c-Screws (3) - 10-16x.625 Drive Tight NOTE:Hold interlock lever back and check the operation of the rewind and rewind tension before installation. 90-854785R2 DECEMBER 2001 Page 8-15 MANUAL STARTER Page 8-16 90-854785R2 DECEMBER 2001 Manual Starter Installation 1. Secure manual starter with screws. a b a - Screws (4) - M6x25 b - Manual Starter Manual Starter Screw Torque 60 lb. in. (7 N·m) 2. Install interlock cable onto cam boss and secure with retaining clip. 3. Secure interlock cable to rewind housing with adjustment screw. NOTE: Interlock cable should be adjusted after installation. Refer to interlock cable adjustment procedures. a b a - Retaining Clip b - Adjustment Screw MANUAL STARTER Interlock Cable Adjustment IMPORTANT: Lubricate core wire of interlock cable with light oil prior to making adjustments. 1. While rotating the propeller shaft, place the gear shift lever into REVERSE. 2. Return the gear shift lever to NEUTRAL without going past neutral detent. 3. Place end of interlock cable over pin of cam lever and secure with retaining clip. 4. Secure interlock cable to starter housing using adjusting screw. Do not tighten screw at this time. 5. Adjust interlock cable to align raised mark of cam lever with pointer of rewind housing. a c bed a-Interlock Cable b-Retaining Clip c-Adjustment Screw d-Raised Mark of Cam Lever e-Pointer of Rewind Housing 6. Tighten cable adjustment screw and check adjustment after 4 or 5 shift cycles. 90-854785R2 DECEMBER 2001 Page 8-17 COLOR DIAGRAMS COLOR DIAGRAMS Table of Contents Remote Control Electric Wiring Diagram Manual Start Wiring Diagram USA S/N 0G760300 and Up USA S/N 0G760300 and Up Belgium S/N 0P059000 and Up . . . . . . . . . . . . 9-3 Belgium S/N 0P059000 and Up . . . . . . . . . . . . 9-9 Tiller Handle Electric Oil Flow Diagram (All Model Years) . . . . . . . . . 9-11 USA S/N 0G760300 and Up Water Flow Diagram (All Model Years) . . . . . . 9-13 Belgium S/N 0P059000 and Up . . . . . . . . . . . . 9-5 Remote Control Electric (Gas Assist) Wiring Diagram USA S/N 0G760300 and Up Belgium S/N 0P059000 and Up . . . . . . . . . . . . 9-7 See Section 2D for 2001 Model Year and Prior Wiring Diagrams 9 90-854785R2 DECEMBER 2001 Page 9-1 COLOR DIAGRAMS Page 9-2 90-884294 OCTOBER 2001 COLOR DIAGRAMS 25 BIGFOOT (4 STROKE) REMOTE CONTROL ELECTRIC 2002 MODEL YEAR USA S/N 0G760300 AND UP BELGUIM S/N 0P059000 AND UP COLOR WIRING DIAGRAM 90-854785R2 DECEMBER 2001 Page Page 9-3 25 Bigfoot (4 Stroke) Remote Control Electric Wiring Diagram 2002 Model Year USA S/N 0G760300 and Up Belgium S/N 0P059000 and Up 1. ECM 2. ECM 24 Pin Connector 3. Crank Position Sensor 4. Oil Pressure Switch 5. Diagnostic Tool Connector 6. Coolant Temperature Sensor 7. Auto Enrichener 8. Stator 9. Voltage Regulator / Rectifier 10. Start Solenoid 11. Starter 12. 20 Amp Fuse 13. Cowl Mounted Trim Switch 14. To Remote Trim Switch 15. Trim Up Relay 16. Trim Down Relay 17. To Trim Pump 18. To 12 Volt Battery 19. To Oil Pressure Lamp 20. To Over-Heat Lamp 21. Engine Harness Connector 22. ignition Coil 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 12 12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 21 17 18 19 20 59253 1 12 13 24 22 COLOR DIAGRAMS 25 BIGFOOT (4 STROKE) TILLER HANDLE ELECTRIC 2002 MODEL YEAR USA S/N 0G760300 AND UP BELGUIM S/N 0P059000 AND UP COLOR WIRING DIAGRAM 90-854785R2 OCTOBER 2001 Page 9-5 25 Bigfoot (4 Stroke) Tiller Handle Electric Wiring Diagram 2002 Model Year USA S/N 0G760300 and Up Belgium S/N 0P059000 and Up 1. ECM 1. ECM 24 Pin Connector 2. Crank Position Sensor 3. Oil Pressure Switch 4. Diagnostic Device 5. Coolant Temperature Sensor 6. Auto Enrichener 7. Stator 8. Voltage Regulator / Rectifier 9. Start Solenoid 10. Starter 11. 20 Amp Fuse 12. Cowl Mounted Trim Switch 13. To Remote Trim Switch 14. Trim Up Relay 15. Trim Down Relay 16. To Trim Pump 17. Battery Connectors 18. To Oil Pressure Lamp 19. To Over-Heat Lamp 20. Remote Control 21. Engine Harness Connector 22. Tiller Handle Harness Connector 23. Horn 24. Key Switch 25. Lanyard Stop Switch 26. Push-Button Stop Switch 27. Neutral Start Switch 28. Ignition Coil 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 12 12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 59254 20 21 22 23 24 25 26 1 12 13 24 27 28 COLOR DIAGRAMS 25 BIGFOOT (4 STROKE) REMOTE CONTROL ELECTRIC (GAS ASSIST) 2002 MODEL YEAR USA S/N 0G760300 AND UP BELGUIM S/N 0P059000 AND UP COLOR WIRING DIAGRAM 90-854785R2 OCTOBER 2001 Page Page 9-7 25 Bigfoot (4 Stroke) Remote Control Electric (Gas Assist) Wiring Diagram USA S/N 0G760300 and Up Belgium S/N 0P059000 and Up 1. ECM 2. ECM 24 Pin Connector 3. Crank Position Sensor 4. Oil Pressure Switch 5. Diagnostic Device Connector 6. Coolant Temperature Sensor 7. Auto Enrichener 8. Stator 9. Voltage Regulator / Rectifier 10. Start Solenoid 11. Starter 12. 20 Amp Fuse 13. Battery Connectors 14. To Oil Pressure Lamp 15. To Over-Heat Lamp 16. Remote Control 17. ignition Coil 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 12 12 1 2 3 4 5 6 7 8 9 10 11 12 14 15 59255 13 16 1 12 13 24 17 COLOR DIAGRAMS 25 BIGFOOT (4 STROKE) TILLER HANDLE MANUAL 2002 MODEL YEAR USA S/N 0G760300 AND UP BELGUIM S/N 0P059000 AND UP COLOR WIRING DIAGRAM 90-854785R2 OCTOBER 2001 Page Page 9-9 25 Bigfoot (4 Stroke) Tiller Handle Manual Wiring Diagram USA S/N 0G760300 and Up Belgium S/N 0P059000 and Up 1. ECM 2. ECM 24 Pin Connector 3. To Tachometer 4. Crank Position Sensor 5. Oil Pressure Switch 6. Diagnostic Device Connector 7. Coolant Temperature Sensor 8. Auto Enrichener 9. Stator 10. Not Used 11. Horn 12. Push-Button Stop Switch 13. Lanyard Stop Switch 14. Ignition Coil 24 12 1 13 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 12 12 12 2 3 4 5 6 7 8 9 10 11 59256 13 12 13 COLOR DIAGRAMS 25 (4-STROKE) OIL FLOW DIAGRAM 90-854785R2 DECEMBER 2001 Page 9-11 25 Bigfoot (4 Stroke) Oil Flow Diagram 1. Sump 2. Oil Pick–up - Oil in the sump is drawn through the pick–up tube, passages in the adapter plate, and cylinder block to the pump inlet 3. Oil Passages in Adapter Plate 4. Oil Passages in Cylinder Block 5. Oil Passages in Cylinder Head 6. Oil Pump - Pumps oil through passages in the adapter plate to the oil filter. 7. Oil Pressure Regulator - Maintains oil pressure in the circuit. 8. Oil Filter - Filtered oil exits from center of filter and flows to a distribution passage in the cylinder block. 9. Crankshaft - Filtered oil flows through passages in the crankshaft and cylinder block to lubricate bearings. 10. Piston, Rod, Wrist-Pin 11. Rocker Arm Shaft - Filtered oil enteres the rocker arm shaft and lubricates the rocker arm and camshaft. 12. Rocker Arm 13. Camshafts 14. Return to Sump - Oil drains back to sump through passages in the cylinder block and adapter plate. 58855                 COLOR DIAGRAMS 25 (4-STROKE) WATER FLOW DIAGRAM 90-854785R2 DECEMBER 2001 Page 9-13 25 Bigfoot (4 Stroke) Water Flow Diagram 1. Water Inlet 2. Water Pump - Water is drawn through the inlet passages to the water pump. 3. Driveshaft Housing 4. Water Tube - Pressurized water flows through the water tube, adaptor plate, and cylinder block to the exhaust cover. 5. Adaptor Plate 6. Cylinder Block - Passages allow water to flow around cylinder walls and to cylinder head. 7. Cylinder Head - Water flows through passages and back down through cylinde block out to thermostat housing. 8. Exhaust Cover 9. Thermostat - Opens at 138 to 148 degrees F. 10. Fuel Cooler / Fuel Pump - Continous water flow is used to cool fuel pump housing to prevent vapor lock in fuel lines. 11. Tell-Tale 12. Water discharged with exhaust. 58914