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SERVICE MANUAL MODELS MERCURY/MARINER 30/40 (4-Stroke) With Serial Numbers United States . . . . . . 0G760300 and Above Printed in U.S.A. W1998, Mercury Marine 90-857046 AUGUST 1998 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. 90-857046 AUGUST 1998 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 90-857046 AUGUST 1998 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 Bracket & Drive Shaft Housing B - Power Trim C - Manual Tilt Assist Section 6 - Gear Housing A - Non-Bigfoot Gear Housing B - Bigfoot Gear Housing Section 7 - Attachments/Control Linkage A - Throttle/Shift Linkage B - Tiller Handle Section 8 - Manual Starter Important Information Electrical Fuel System Powerhead Mid-Section Gear Housing Attachments/ Control Linkage Manual Starter 90-857046 AUGUST 1998 Page iii SPECIFICATIONS IMPORTANT INFORMATION Section 1A - Specifications Table of Contents 1 A Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1 Propeller Information Charts . . . . . . . . . . . . . . 1A-7 Specifications Models 30/40 (4-Stroke) HORSEPOWER (kW) Model 30 Model 40 30 hp (22.4 Kw) @ 5750 rpm 40 hp (29.8 Kw) @ 5750 rpm OUTBOARD WEIGHT Electric 30/40 ELPT 40 ELPT BIGFOOT 212 lb (96.2 kg) 235 lb (106.6 kg) FUEL RECOMMENDED GASOLINE Automotive Unleaded with a Minimum Pump Posted Octane Rating of 87 OIL FILTER OIL FILTER WRENCH ENGINE OIL CAPACITY ENGINE OIL F° C° SAE 10W-30 SAE 25W-40 p/n 35-822626A2 p/n 91-802653 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). OIL +20 +40 +60 +80 0 +100 –7 +4 +16 +27 –18 +38Use Quicksilver 4-Cycle Marine Oil with the proper viscosity for the expected temperature in your area (see range thermometer on left). If not available, use a premium quality 4-cycle engine oil, certified to meet or exceed anyone of the following American Petroleum Institute (API) service classifications SH, SG, SF, CF-4, CE, CD, CDll. IMPORTANT: Use resistive spark plugs only. 90-857046 AUGUST 1998 Page 1A-1 SPECIFICATIONS IGNITION SYSTEM Readings taken @ 68°F (20°C). Type Spark Plug: Type Gap Hex Size Firing Order Ignition Timing: @ Idle (800 rpm) @ WOT (6000 rpm) Charge Coil Resistance Crank Position Sensor Resistance Ignition Coil Resistance: Primary Capacitor Discharge Ignition NGK DPR6EA-9 0.035 in. (1.0 mm) 18 mm 1-2-3 10° A.T.D.C 28° B.T.D.C 660 - 710 W (GRN/WHT - WHT/GRN) 300 - 350 W (RED - WHT) 0.08 - 0.7 W (BLK - BLK/WHT) Secondary (W/o Boots) ECM Engine Speed Limiter Soft Reduction (Retards Timing) Spark Cut-Out Reduction (Percent ages of ignition spark are Cut-Out) ECM Overheat/Low Oil Pressure Speed Control Engine Temperature Sensor 3.5 - 4.7 kW (BLK - High Tension) 6200 rpm 6250 rpm Approximately 2000 rpm See Graph Section 2A-Ignition CHARGING SYSTEM Readings taken @ 68°F (20°C). Alternator Type: 6 Amp. Manual Lighting Coil Output Lighting Coil Resistance 15 Amp. Electric Alternator Output Battery Charging Coil Resistance Power Bobbin Resistance (For Electrothermal Valve) Quicksilver Tachometer Setting Single Phase (12 Pole) 6 Amps. 0.9 - 1.1 Ohms (YEL-YEL) 12.6 V-15 Amps. (185 Watts) (Rectified/Regulated) 0.22 - 0.24 Ohms (YEL-YEL) 6.7-7.1 Ohms (YEL/BLK-YEL/BLK) “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 Resistance 15 - 25 Ohms (YEL/BLK - YEL/BLK) CONTROL Electrothermal ram projection 0.3 in. (7 mm) after 5 min. of power SYSTEM Readings taken @ 68°F (20°C). 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 Page 1A-2 90-857046 AUGUST 1998 SPECIFICATIONS CARBURETOR Idle rpm (Out Of Gear) Idle rpm (In Forward Gear) Wide Open Throttle rpm (WOT) Range Main Jet Size Pilot Jet Idle Jet Float Height 900 ± 25 rpm 800 ± 25 rpm 5500–6000 #98 #38 #42 0.47-0.63 in. (12.0-16.0 mm) CYLINDER BLOCK Type Displacement Number of Cylinders 4 Stroke Cycle – Over Head Camshaft 45.6 cu. in. (747cc) 3 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. (0.25 mm) Oversize-0.020 in. (0.50 mm) 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 - 0.03 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) 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) 0.0018 in. (0.046 mm) *NOTE:Manual start models are equipped with compression relief mechanism which will not allow compression testing. 90-857046 AUGUST 1998 Page 1A-3 SPECIFICATIONS Page 1A-4 90-857046 AUGUST 1998 CAMSHAFT Camshaft Dimensions Intake “A” Exhaust “A” Intake “B” Exhaust “B” Run-out Limit Camshaft Bearing Diameter “b” A B b b b b 1.216 - 1.220 in. (30.89 - 30.99 mm) 1.216 - 1.220 in. (30.89 - 30.99 mm) 1.022 - 1.025 in. (25.95 - 26.05 mm) 1.022 - 1.025 in. (25.95 - 26.05 mm) 0.0039 in. (0.1 mm) 1.4541 - 1.4549 in. (36.935 - 36.955 mm) VALVE SPRING Free Length “a” Tilt Limit “b” Compressed Pressure (Installed) Intake Exhaust Tilt Limit (Intake & Exhaust) Dir. of Winding (Intake & Exhaust) a b 1.491-1.569 in. (37.85-39.85 mm) Less than 0.060 in. (1.7 mm) 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 CYLINDER HEAD Warp Limit * Lines indicate straight edge measurement Camshaft Bore Inside Diameter “a” 56900 a a a a 56899 0.004 in. (0.1 mm) 1.4567 - 1.4577 in. (37.000 - 37.025 mm) SPECIFICATIONS Valve/Valve Seat/Valve Guides: Valve Clearance (cold) Intake 0.006 - 0.010 in. (0.15 - 0.25 mm) Exhaust Valve Dimensions: “A” Head Diameter 0.010 - 0.014 in. (0.25 - 0.35 mm) Intake 1.256 - 1.264 in. (31.9 - 32.1 mm) Exhaust “B” Face Width 1.020 - 1.028 in. (25.9 - 26.1 mm) Intake 0.079 - 0.124 in. (2.00 - 3.14 mm) Exhaust “C” Seat Width 0.079 - 0.124 in. (2.00 - 3.14 mm) Intake 0.035 - 0.043 in. (0.9 - 1.1 mm) Exhaust “D” Margin Thickness 0.035 - 0.043 in. (0.9 - 1.1 mm) VALVES Intake 0.020 - 0.035 in. (0.5 - 0.9 mm) Exhaust Stem Outside Diameter 0.020 - 0.035 in. (0.5 - 0.9 mm) Intake 0.2156 - 0.2161 in. (5.475 - 5.490 mm) Exhaust Guide Inside Diameter 0.2150 - 0.2156 in. (5.460 - 5.475 mm) Intake 0.2165 - 0.2170 in. (5.500 - 5.512 mm) Exhaust Stem To Guide Clearance 0.2165 - 0.2170 in. (5.500 - 5.512 mm) Intake 0.0004 - 0.0015 in. (0.010 - 0.037 mm) Exhaust 0.0010 - 0.0020 in. (0.025 - 0.052 mm) Stem Run-out Limit (max.) 0.0006 in. (0.016 mm) “A” “B” “C” “D” Valve Dimensions Head Diameter Face Width Seat Width Margin Thickness 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) 90-857046 AUGUST 1998 Page 1A-5 SPECIFICATIONS LUBRICATION SYSTEM Pump Type Engine Oil Pressure (Warm Engine) @ 3000 rpm 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 (207-278 kPa) 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 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 (2.00:1) Gear Ratio Gearcase Capacity Lubricant Type Forward Gear Number of Teeth Pinion Gear Number of Teeth Pinion Height Forward Gear Backlash Water Pressure @ 800 rpm (Idle) @ 6000 rpm (WOT) 2.00:1 14.9 fl oz (440 mL) Quicksilver Gear Lube-Premium Blend 26 Spiral/Bevel 13 Spiral/Bevel 0.025 in. (0.64 mm) No Adjustment 2–4 psi (14-28 kPa) 12–17 psi (69-103 kPa) GEAR HOUSING BIGFOOT (2.3:1) Gear Ratio Gearcase Capacity Lubricant Type Forward Gear Number of Teeth Pinion Gear Number of Teeth Pinion Height Pinion Gear Locating Tool Flat Number Disc Number Forward Gear Backlash Backlash Indicating Tool Mark Number Water Pressure @ 800 rpm (Idle) @ 6000 rpm (WOT) 2.31:1 22.5 fl oz (655 mL) Quicksilver Gear Lube-Premium Blend 30 Spiral/Bevel 13 Spiral/Bevel 0.025 in. (0.64 mm) 91-12349A2 #8 #3 0.012-0.019 in. (0.30-0.48 mm) 91-78473 #4 2–4 psi (14-28 kPa) 10–15 psi (69-103 kPa) Page 1A-6 90-857046 AUGUST 1998 SPECIFICATIONS Propeller Information Charts Mercury/Mariner 30 (4-Stroke) 2.00:1 Non-Bigfoot Wide Open Throttle RPM: 5500-6000 Recommended Transom Heights : 15”, 20”, 22.5” Right Hand Rotation Standard Gear Reduction : 2.00:1 Diameter Pitch No. of Blades Material Approx. Gross Boat Wgt. (lbs) Approx. Boat Length Speed Range (mph) Propeller Part Number 10” 19” 3 Alum Up to 600 Up to 14’ 45-53 48-73146A40 10” 17” 3 Alum Up to 700 Up to 14’ 39-46 48-73144A40 10” 16” 3 Steel 600-800 Up to 14’ 36-42 48-91818A5 10” 16” 3 Alum 600-800 Up to 14’ 36-42 48-73142A40 10-1/8” 15” 3 Steel 700-900 13-14’ 33-39 48-76232A5 10-1/8” 15” 3 Alum 700-900 13-14’ 33-39 48-73140A40 10-1/4” 14” 3 Steel 800-1000 14-15’ 30-36 48-76230A5 10-1/4” 14” 3 Alum 800-1000 14-15’ 30-36 48-73138A40 10-3/8” 13” 3 Steel 900-1100 14-16’ 27-33 48-76228A5 10-3/8” 13” 3 Alum 900-1100 14-16’ 27-33 48-73136A40 10-5/8” 12” 3 Steel 1000-1200 15-17’ 24-29 48-79792A5 10-5/8” 12” 3 Alum 1000-1200 15-17’ 24-29 48-73134A40 11-5/8” 11” 3 Steel 1100-1400 15-17’ 21-26 48-823478A5 10-7/8” 11” 3 Alum 1100-1400 15-17’ 21-26 48-85632A40 11-5/8” 10-1/2” 3 Alum 1300-1700 15-18’ 19-24 48-827312A10 11-1/4” 10” 3 Alum 1400-1900 16’ + 18-22 48-73132A40 12-1/4” 9” 3 Steel 2000+ pontoon 15-19 48-97868A10 12-1/4” 9” 3 Alum 2000+ pontoon 15-19 48-87818A10 12-1/2” 8” 3 Alum 2400+ Pontoon/ houseboat 1-17 48-42738A10 12-1/2” 8” Cup 3 Alum pontoon 48-42738A12 90-857046 AUGUST 1998 Page 1A-7 SPECIFICATIONS Mercury/Mariner 40 (4-Stroke) 2.00:1 Non-Bigfoot Wide Open Throttle RPM: 5500-6000 Recommended Transom Heights : 15”, 20”, 22.5” Right Hand Rotation Standard Gear Reduction : 2.00:1 Diameter Pitch No. of Blades Material Approx. Gross Boat Wgt. (lbs) Approx. Boat Length Speed Range (mph) Propeller Part Number 10” 19” 3 Alum Up to 800 Up to 14’ 45-53 48-73146A40 10” 17” 3 Alum Up to 1000 Up to 15’ 39-46 48-73144A40 10” 16” 3 Steel 900-1100 Up to 15’ 36-42 48-91818A5 10” 16” 3 Alum 900-1100 Up to 15’ 36-42 48-73142A40 10-1/8” 15” 3 Steel 1000-1200 13-15’ 33-39 48-76232A5 10-1/8” 15” 3 Alum 1000-1200 13-15’ 33-39 48-73140A40 10-1/4” 14” 3 Steel 1100-1300 14-16’ 30-36 48-76230A5 10-1/4” 14” 3 Alum 1100-1300 14-16’ 30-36 48-73138A40 10-3/8” 13” 3 Steel 1200-1500 14-17’ 27-33 48-76228A5 10-3/8” 13” 3 Alum 1200-1500 14-17’ 27-33 48-73136A40 10-5/8” 12” 3 Steel 1400-1700 15-17’ 24-29 48-79792A5 10-5/8” 12” 3 Alum 1400-1700 15-17’ 24-29 48-73134A40 11-5/8” 11” 3 Steel 1600-2000 16-18’ 21-26 48-823478A5 10-7/8” 11” 3 Alum 1600-2000 16-18’ 21-26 48-85632A40 11-5/8” 10-1/2” 3 Alum 1800-2400 16’ + 19-24 48-827312A10 11-1/4” 10” 3 Alum 2000-2600 17’ + 18-22 48-73132A40 12-1/4” 9” 3 Steel 2300+ pontoon 15-19 48-97868A10 12-1/4” 9” 3 Alum 2300+ pontoon 15-19 48-87818A10 12-1/2” 8” 3 Alum 2700+ Pontoon/ houseboat 1-17 48-42738A10 12-1/2” 8” Cup 3 Alum pontoon 48-42738A12 Page 1A-8 90-857046 AUGUST 1998 MAINTENANCE 1 B IMPORTANT INFORMATION Section 1B - Maintenance Table of Contents Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-1 Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . 1B-11 Quicksilver Lubricant/Sealant . . . . . . . . . . . . . 1B-2 Oil Changing Procedure . . . . . . . . . . . . . . . 1B-11 Inspection And Maintenance Schedule . . . . . 1B-4 Changing Oil Filter . . . . . . . . . . . . . . . . . . . . 1B-12 Before Each Use . . . . . . . . . . . . . . . . . . . . . 1B-4 Oil Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-12 After Each Use . . . . . . . . . . . . . . . . . . . . . . . 1B-5 Gear Case Lubrication . . . . . . . . . . . . . . . . . . . 1B-13 Every 100 Hours of Use or Once yearly, 3-1/4 In. (83mm) Diameter Gear Case . . 1B-13 Whichever occurs first . . . . . . . . . . . . . . . . 1B-5 4-1/4 In. (108mm) Diameter Gear Case . 1B-14 Every 300 Hours of Use or Three Years . 1B-5 Storage Preparation . . . . . . . . . . . . . . . . . . . . . 1B-16 Before Periods of Storage . . . . . . . . . . . . . 1B-5 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . 1B-16 Corrosion Control Anode . . . . . . . . . . . . . . . . . 1B-6 Protecting External Outboard Spark Plug Inspection . . . . . . . . . . . . . . . . . . . . 1B-7 Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-16 Battery Inspection . . . . . . . . . . . . . . . . . . . . . . . 1B-7 Protecting Internal Engine Components . 1B-16 Fuse Replacement – Electric Start Models . . 1B-8 Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-16 Timing Belt Inspection . . . . . . . . . . . . . . . . . . . 1B-8 Positioning Outboard for Storage . . . . . . . 1B-16 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . 1B-9 Battery Storage . . . . . . . . . . . . . . . . . . . . . . 1B-17 Checking Power Trim Fluid . . . . . . . . . . . . . . . 1B-11 Special Tools 1. Flushing Attachment P/N 44357A2 2. Crankcase Oil Pump P/N 90265A2 3. Oil Filter Wrench P/N 91-802653 90-857046 AUGUST 1998 Page 1B-1 MAINTENANCE Quicksilver Lubricant/Sealant 1. Quicksilver Anti-Corrosion Grease P/N 92-78376A6 2. 2-4-C Marine Lubricant with Teflon P/N 92-825407A12 3. Special Lubricant 101 P/N 92-13872A1 4. Quicksilver Power Trim and Steering Fluid P/N 92-190100A12 Page 1B-2 90-857046 AUGUST 1998 MAINTENANCE 5. Quicksilver 4-Stroke Outboard Oil P/N 92-828000A12 6. Gear Lube-Premium Blend P/N 92-19007A24 7. Quicksilver 4-Cycle Marine Engine Oil P/N 92-832111A1 4-CYCLE MARINE ENGINE OIL Premium Blend SAE 25W-40 NET 32 OZ (1 QT) 946 ml 90-857046 AUGUST 1998 Page 1B-3 MAINTENANCE Inspection And Maintenance Schedule To keep your outboard in the best operating condition, it is important that your outboard receive the periodic inspections and maintenance listed in the Inspection and Maintenance Schedule. We urge you to keep it maintained properly to ensure the safety of you and your passengers and retain its dependability. WARNING Neglected inspection and maintenance service of your outboard or attempting to perform maintenance or repair on your outboard if you are not familiar with the correct service and safety procedures could cause personal injury, death, or product failure. Before Each Use 1. Check engine oil level. 2. Check that lanyard stop switch stops the engine. 3. Visually inspect the fuel system for deterioration or leaks. 4. Check outboard for tightness on transom. 5. Check steering system for binding or loose components. 6. Visually check steering link rod fasteners for proper tightness. 7. Check propeller blades for damage. Page 1B-4 90-857046 AUGUST 1998 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 Quicksilver 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). 90-857046 AUGUST 1998 Page 1B-5 MAINTENANCE Page 1B-6 90-857046 AUGUST 1998 Corrosion Control Anode Your outboard has control anodes at different locations. 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. An anode is installed on the bottom of the transom bracket assembly. Trim tab is also an anode on the 3-1/4 in. (83 mm) diameter gear case. The 4-1/4 in. (108 mm) diameter gear case has three anodes. One of the anodes is the trim tab and two anodes are located on the side. a b c a - Bottom Anode b - Trim Tab c - Side Anodes 2. Three anodes are installed in the engine block. Remove the three ignition coils for clearance. Remove anodes at locations shown. Install each anode with rubber seal and cover. Tighten bolts to 70 lb-in. (8 Nm) torque. Reinstall the ignition coils. Tighten coil bolts to 70 lb–in. (8 Nm) torque b c a d a - Anodes-Engine Block b - Ignition Coils c - Rubber Seal d - Cover MAINTENANCE Spark Plug Inspection Inspect spark plugs at the recommended intervals. 1. Remove the spark plug leads by twisting the rubber boots slightly and pull off. IMPORTANT: Use resistive spark plugs only. 2. Remove the spark plugs to inspect and clean. Replace spark plug if electrode is worn or the insulator is rough, cracked, broken, blistered or fouled. 3. Set the spark plug gap. See Specification Chart. 4. Before reinstalling spark plugs, clean away dirt on the spark plug seats. Install plugs finger tight, and tighten 1/4 turn or torque to 20 lb-ft (27 Nm). Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability. IMPORTANT: Read the safety and maintenance instructions which accompany your battery. 1. Turn off the engine before servicing the battery. 2. Add water as necessary to keep the battery full. 3. Make sure the battery is secure against movement. 4. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive and negative to negative. 5. Make sure the battery is equipped with a nonconductive shield to prevent accidental shorting of battery terminals. 90-857046 AUGUST 1998 Page 1B-7 MAINTENANCE Page 1B-8 90-857046 AUGUST 1998 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 replace the fuse. Replace fuse with a new fuse with the same rating. a a - Blown Fuse Timing Belt Inspection 1. Inspect the timing belt and replace if any of the following conditions are found. a. Cracks in the back of the belt or in the base of the belt teeth. b. Excessive wear at the roots of the cogs. c. Rubber portion swollen by oil. d. Belt surfaces roughened. e. Signs of wear on edges or outer surfaces of belt. a a - Timing Belt MAINTENANCE Lubrication Points Lubricate Point 1 with Quicksilver 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 7 with Quicksilver 2-4-C Marine Lubricant with Teflon or Special Lubricant 101. 2. Swivel Bracket – Lubricate through fitting. 3. Tilt Support Lever – Lubricate through fitting. 2 3 4. Tilt Tube-Lubricate through fitting. 4 90-857046 AUGUST 1998 Page 1B-9 MAINTENANCE 5. Steering Cable Grease Fitting (If equipped) – Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube. Lubricate through fitting. 5 a b a-Fitting b-Steering cable End 6. This grease fitting is for lubricating the threaded rod for the co-pilot. 6 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 Page 1B-10 90-857046 AUGUST 1998 MAINTENANCE Checking Power Trim Fluid 1. Tilt outboard to the full up position and engage the 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 Quicksilver Power Trim & Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. a-Fill Cap Changing Engine Oil a 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 90-857046 AUGUST 1998 Page 1B-11 MAINTENANCE Page 1B-12 90-857046 AUGUST 1998 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 Changing Oil Filter 1. Place a rag or towel below the oil filter to absorb any spilled oil. 2. Unscrew old filter by turning the filter counterclockwise. 3. Clean the mounting base. Apply film of clean oil to filter gasket. Do not use grease. Screw new filter on until gasket contacts base, then tighten 3/4 to 1 turn. 91-802653 a a - Oil Filter 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. a a - Oil Fill Cap MAINTENANCE Gear Case Lubrication 3-1/4 In. (83mm) Diameter Gear Case When adding or changing gear case lubricant, visually check for the presence of water in the lubricant. If water is present, it may have settled to the bottom and will drain out prior to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance. If water is noticed, have the gear case checked by your dealer.Water in the lubricant may result in premature bearing failure or, in freezing temperatures, will turn to ice and damage the gear case. Whenever you remove the fill/drain plug, examine the magnetic end for metal particles. A small amount of metal filings or fine metal particles indicates normal gear wear. An excessive amount of metal filings or larger particles (chips) may indicate abnormal gear wear and should be checked by an authorized dealer. DRAINING GEAR CASE 1. Place outboard in a vertical operating position. 2. Place a drain pan below outboard. 3. Remove vent plug and fill/drain plug and drain lubricant. 3 2 1 GEAR CASE LUBRICANT CAPACITY Gear case lubricant capacity is approximately 14.68 fl oz (440 ml). 90-857046 AUGUST 1998 Page 1B-13 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. 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. a b c d a-Vent Plug/Sealing Washer b-Lubricant Tube c-Vent Hole d-Fill/Drain Plug and Sealing Washer 4-1/4 In. (108mm) Diameter Gear Case When adding or changing gear case lubricant, visually check for the presence of water in the lubricant. If water is present, it may have settled to the bottom and will drain out prior to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance. If water is noticed, have the gear case checked by your dealer. Water in the lubricant may result in premature bearing failure or, in freezing temperatures, will turn to ice and damage the gear case. Whenever you remove the fill/drain plug, examine the magnetic end for metal particles. A small amount of metal filings or fine metal particles indicates normal gear wear. An excessive amount of metal filings or larger particles (chips) may indicate abnormal gear wear and should be checked by an authorized dealer. Page 1B-14 90-857046 AUGUST 1998 MAINTENANCE DRAINING GEAR CASE 1. Place outboard in a vertical operating position. 2. Place a drain pan below outboard. 3. Remove vent plugs and fill/drain plug and drain lubricant. 1 2 3 GEAR CASE LUBRICANT CAPACITY Gear case lubricant capacity is approximately 22.5 fl oz (666 ml). CHECKING LUBRICANT LEVEL AND FILLING GEAR CASE 1. Place outboard in a vertical operating position. 2. Remove the front vent plug and rear vent plug. 3. Place lubricant tube into the fill hole and add lubricant until it appears at the front vent hole. At this time install the front vent plug and sealing washer. 4. Continue adding lubricant until it appears at the rear vent hole. 5. Stop adding lubricant. Install the rear vent plug and sealing washer before removing lubricant tube. 6. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer. a c d e b a-Front Vent Plug b-Rear Vent Plug c-Front Vent Hole d-Rear Vent Hole e-Fill/Drain Plug and Sealing Washer 90-857046 AUGUST 1998 Page 1B-15 MAINTENANCE Storage Preparation The major consideration in preparing your outboard for storage is to protect it from rust, corrosion, and damage caused by freezing of trapped water. 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. 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 Quicksilver 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 Quicksilver 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 Quicksilver 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. Page 1B-16 90-857046 AUGUST 1998 MAINTENANCE 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. 90-857046 AUGUST 1998 Page 1B-17 GENERAL INFORMATION IMPORTANT INFORMATION Section 1C - General Information Table of Contents 1 C Serial Number Location . . . . . . . . . . . . . . . . . . 1C-1 Power Trim System . . . . . . . . . . . . . . . . . . . . . . 1C-9 Conditions Affecting Performance . . . . . . . . . 1C-2 General Information . . . . . . . . . . . . . . . . . . 1C-9 Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2 Power Trim Operation . . . . . . . . . . . . . . . . . 1C-9 Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-3 Trim “In” Angle Adjustment . . . . . . . . . . . . 1C-10 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-4 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . 1C-11 Following Complete Submersion . . . . . . . . . . 1C-5 Compression Check . . . . . . . . . . . . . . . . . . . . . 1C-12 Submerged While Running Cylinder Leakage Testing . . . . . . . . . . . . . . . . . 1C-13 (Special Instructions) . . . . . . . . . . . . . . . . . 1C-5 Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-13 Salt Water Submersion Painting Procedures . . . . . . . . . . . . . . . . . . . . . 1C-14 (Special Instructions) . . . . . . . . . . . . . . . . . 1C-5 Cleaning & Painting Aluminum Propellers & Gear Fresh Water Submersion Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-14 (Special Instructions) . . . . . . . . . . . . . . . . . 1C-5 Decal Application . . . . . . . . . . . . . . . . . . . . . . . . 1C-15 Propeller Selection . . . . . . . . . . . . . . . . . . . . . . 1C-6 Decal Removal . . . . . . . . . . . . . . . . . . . . . . . 1C-15 Propeller Removal/Installation . . . . . . . . . . . . 1C-7 Instructions for “Wet” Application . . . . . . . 1C-15 Standard Models . . . . . . . . . . . . . . . . . . . . . 1C-7 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. e a a-Serial Number b-Model Year c-Model Description d-Year Manufactured e-Certified Europe Insignia 19XX OGXXXXXX XXXX c b XX d 90-857046 AUGUST 1998 Page 1C-1 GENERAL INFORMATION Conditions Affecting Performance Weather Rated hp Summer hp Horsepower Loss Due to Atmosphere Conditions Secondary Loss Due to Propeller Becoming To Large for Summer Horsepower RPM Drop Due to Weather ENGINE RPM Rated RPM It is a known fact that weather conditions exert a profound effect on power output of internal combustion engines. Therefore, established horsepower ratings refer to the power that the engine will produce at its rated rpm under a specific combination of weather conditions. Corporations internationally have settled on adoption of I.S.O. (International Standards Organization) engine test standards, as set forth in I.S.O. 3046 standardizing the computation of horsepower from data obtained on the dynamometer, correcting all values 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 90-857046 AUGUST 1998 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. 90-857046 AUGUST 1998 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. 51115 Damaged Piston Resulting from Detonation Page 1C-4 90-857046 AUGUST 1998 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. 90-857046 AUGUST 1998 Page 1C-5 GENERAL INFORMATION Propeller Selection For in-depth information on marine propellers and boat performance - written by marine engineers - see your Authorized Dealer for the illustrated “What You Should Know About Quicksilver Propellers... and Boat Performance Information” (Part No. 90-86144). For best all around performance from your outboard/boat combination, select a propeller that allows the engine to operate in the upper half of the recommended full throttle rpm range with the boat normally loaded (refer to Specifications). This rpm range allows for better acceleration while maintaining maximum boat speed. If changing conditions cause the rpm to drop below the recommended range (such as warmer, more humid weather, operation at higher elevations, increased boat load or a dirty boat bottom/gear case) a propeller change or cleaning may be required to maintain performance and ensure the outboard’s durability. Check full-throttle rpm using an accurate tachometer with the engine trimmed out to a balanced- steering condition (steering effort equal in both directions) without causing the propeller to “break loose”. Refer to “Quicksilver Accessory Guide” for a complete list of available propellers. 1. Select a propeller that will allow the engine to operate at or near the top of the recommended full throttle rpm range (listed in “Specifications,” preceding) with a normal load. Maximum engine speed (rpm) for propeller selection exists when boat speed is maximum and trim is minimum for that speed. (High rpm, caused by an excessive trim angle, should not be used in determining correct propeller.) Normally, there is a 150-350 rpm change between propeller pitches. 2. If full throttle operation is below the recommended range, the propeller MUST BE changed to one with a lower pitch to prevent loss of performance and possible engine damage. 3. After initial propeller installation, the following common conditions may require that the propeller be changed to a lower pitch: a. Warmer weather and great humidity will cause an rpm loss. b. Operating in a higher elevation causes an rpm loss. c. Operating with a damaged propeller or a dirty boat bottom or gear housing will cause an rpm loss. d. Operation with an increased load (additional passengers, equipment, pulling skiers, etc.). Page 1C-6 90-857046 AUGUST 1998 GENERAL INFORMATION Propeller Removal/Installation Standard Models WARNING If the propeller shaft is rotated while the engine is in gear, there is the possibility that the engine will crank over and start. To prevent this type of accidental engine starting and possible serious injury caused from being struck by a rotating propeller, always shift outboard to neutral position and remove spark plug leads when you are servicing the propeller. 1. Shift outboard to neutral position. N N 2. Remove the spark plug leads to prevent engine from starting. 3. Straighten the bent tabs on the propeller nut retainer. a 90-857046 AUGUST 1998 Page 1C-7 GENERAL INFORMATION 4. Place a block of wood between gear case and propeller to hold propeller and remove propeller nut. 5. Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. 6. Coat the propeller shaft with Quicksilver Anti-Corrosion Grease or 2-4-C Marine Lubricant with Teflon. 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 d c b a a-Forward Thrust Hub b-Propeller c-Propeller Nut Retainer d-Propeller Nut Page 1C-8 90-857046 AUGUST 1998 GENERAL INFORMATION 8. Flo-Torque II Drive Hub Propellers e d c b a f 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 55 lb-ft (75 Nm), 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 a b b a-Retainer Pins b-Tabs 11. Reinstall spark plug leads. Power Trim System General Information The power trim system is filled at the manufacturer and is ready for use. Trim outboard through entire trim and tilt range several times to remove any air from the system. The trim system is pressurized and is not externally vented. Power Trim Operation With most boats, operating around the middle of the “trim” range will give satisfactory results. However, to take full advantage of the trimming capability there may be times when you choose to trim your outboard all the way in or out. Along with an improvement in some performance aspects comes a greater responsibility for the operator, and this is being aware of some potential control hazards. The most significant control hazard is a pull or “torque” that can be felt on the steering wheel or tiller handle. This steering torque results from the outboard being trimmed so that the propeller shaft is not parallel to the water surface. 90-857046 AUGUST 1998 Page 1C-9 GENERAL INFORMATION WARNING Avoid possible serious injury or death. When the outboard is trimmed in or out beyond a neutral steering condition, a pull on the steering wheel or tiller handle in either direction may result. Failure to keep a continuous firm grip on the steering wheel or tiller handle when this condition exists can result in loss of boat control as the outboard can turn freely. The boat can now “spin out” or go into a very tight maximum turn which, if unexpected, can result in occupants being thrown within the boat or out of the boat. Consider the following lists carefully: TRIMMING IN OR DOWN CAN: 1. Lower the bow. 2. Result in quicker planing off, especially with a heavy load or a stern heavy boat. 3. Generally improve the ride in choppy water. 4. Increase steering torque or pull to the right (with the normal right hand rotation propeller). 5. In excess, lower the bow of some boats to a point where they begin to plow with their bow in the water while on plane. This can result in an unexpected turn in either direction called “bow steering” or “over steering” if any turn is attempted or if a significant wave is encountered. WARNING Avoid possible serious injury or death. Adjust outboard to an intermediate trim position as soon as boat is on plane to avoid possible ejection due to boat spin-out. Do not attempt to turn boat when on plane if outboard is trimmed extremely in or down and there is a pull on the steering wheel or tiller handle. TRIMMING OUT OR UP CAN: 1. Lift the bow higher out of the water. 2. Generally increase top speed. 3. Increase clearance over submerged objects or a shallow bottom. 4. Increase steering torque or pull to the left at a normal installation height (with the normal right hand rotation propeller). 5. In excess, cause boat “porpoising” (bouncing) or propeller ventilation. 6. Cause engine overheating if any water intake holes are above the water line. Trim “In” Angle Adjustment Some outboard boats, particularly some bass boats, are built with a greater than normal transom angle which will allow the outboard to be trimmed further “in” or “under”. This greater trim “under” capability is desirable to improve acceleration, reduce the angle and time spent in a bow high boat, altitude during planing off, and in some cases, may be necessary to plane off a boat with aft live wells, given the variety of available propellers and height range of engine installations. However, once on plane, the engine should be trimmed to a more intermediate position to a avoid a bow-down planing condition called “plowing”. Plowing can cause “bow steering” or “over steering” and inefficiently consumes horsepower. In this condition, if attempting a turn or encountering a diagonal, moderate wake, a more abrupt turn than intended may result. Page 1C-10 90-857046 AUGUST 1998 GENERAL INFORMATION In rare circumstances, the owner may decide to limit the trim in. This can be accomplished by repositioning the tilt stop pins into whatever adjustment holes in the transom brackets is desired. WARNING Avoid possible serious injury or death. Adjust outboard to an intermediate trim position as soon as boat is on plane to avoid possible ejection due to boat spin-out. Do not attempt to turn boat when on plane if outboard is trimmed extremely in or down and there is a pull on the steering wheel or tiller handle. aa a-Tilt Stop Pins 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. 90-857046 AUGUST 1998 Page 1C-11 GENERAL INFORMATION If adjustment is necessary, loosen trim tab bolt and make small adjustments at a time. If the boat turns more easily to the left, move the trailing edge of trim tab to the left. If the boat turns more easily to the right move the trailing edge of trim tab to the right. Retighten bolt and retest. a a-Trim Tab 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. 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 compression relief cam will give inaccurate (low) readings, instead use the following “Cylinder Leakage Testing” procedure. Page 1C-12 90-857046 AUGUST 1998 GENERAL INFORMATION Cylinder Leakage Testing NOTE:Cylinder leakage testing*, along with compression testing, can help the mechanic pinpoint the source of a mechanical failure by gauging the amount of leakage in an engine cylinder. Refer to the manufactures tester instructions for proper testing procedures. * 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 90-857046 AUGUST 1998 Page 1C-13 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 Quicksilver’s 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 Quicksilver’s EDP Propeller Black. GEAR HOUSINGS The following procedures should be used in refinishing gear housings. This procedure will provide the most durable paint system available in the field. The materials recommended are of high quality and approximate marine requirements. The following procedure will provide a repaint job that compares with a properly applied factory paint finish. It is recommended that the listed materials be purchased from a local Ditzler Automotive Finish Supply Outlet. The minimum package quantity of each material shown following is sufficient to refinish several gear housings. Procedure: 1. Wash gear housing with a muriatic acid base cleaner to remove any type of marine growth, and rinse with water, if necessary. 2. Wash gear housing with soap and water, then rinse. 3. Sand blistered area with 3M 180 grit sandpaper or P180 Gold Film Disc to remove paint blisters only. Feather edge all broken paint edges. 4. Clean gear housing thoroughly with (DX-330) wax and grease remover. 5. Spot repair surfaces where bare metal is exposed with (DX-503) alodine treatment. IMPORTANT: Do not use any type of aerosol spray paints as the paint will not properly adhere to the surface nor will the coating be sufficiently thick to resist future paint blistering. 6. Mix epoxy chromate primer (DP-40) with equal part catalyst (DP-401) per manufacturers instructions, allowing proper induction period for permeation of the epoxy primer and catalyst. 7. Allow a minimum of one hour drying time and no more than one week before top coating assemblies. 8. Use Ditzler Urethane DU9000 for Mercury Black, DU34334 for Mariner Grey, and DU35466 for Force Charcoal, and DU33414M for Sea Ray White. Catalyze all four colors with Ditzler DU5 catalyst mixed 1:1 ratio. Reduce with solvents per Ditzler label. Page 1C-14 90-857046 AUGUST 1998 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** “Joy” and “Drift” are known to be compatible for this process. * Automotive Body Filler Squeegee ** Do not use a soap that contains petroleum based solvents. SERVICE TIP: Placement of decals using the “Wet” application will allow time to position decal. Read entire installation instructions on this technique before proceeding. TEMPERATURE IMPORTANT: Installation of vinyl decals should not be attempted while in direct sun light. Air and surface temperature should be between 60°F (15°C) and 100°F (38°C) for best application. SURFACE PREPARATION IMPORTANT: Do not use a soap or any petroleum based solvents to clean application surface. Clean entire application surface with mild dish washing liquid and water. Rinse surface thoroughly with clean water. 90-857046 AUGUST 1998 Page 1C-15 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). Page 1C-16 90-857046 AUGUST 1998 OUTBOARD MOTOR INSTALLATION IMPORTANT INFORMATION Section 1D - Outboard Motor Installation Table of Contents 1 D Electric Fuel Pump . . . . . . . . . . . . . . . . . . . . . . 1D-1 Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . 1D-7 Boat Horsepower Capacity . . . . . . . . . . . . . . . 1D-1 Battery Cable Connections . . . . . . . . . . . . . . . 1D-8 Start in Gear Protection . . . . . . . . . . . . . . . . . . 1D-2 Single Outboards . . . . . . . . . . . . . . . . . . . . . 1D-8 Selecting Accessories For The Outboard . . . 1D-2 Dual outboards . . . . . . . . . . . . . . . . . . . . . . . 1D-8 Installation Specifications . . . . . . . . . . . . . . . . . 1D-2 Shift and Throttle Cable . . . . . . . . . . . . . . . . . . 1D-9 Lifting Outboard . . . . . . . . . . . . . . . . . . . . . . . . . 1D-3 Shift Cable Installation . . . . . . . . . . . . . . . . 1D-9 Steering Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-3 Throttle Cable Installation . . . . . . . . . . . . . 1D-11 Steering Cable Seal . . . . . . . . . . . . . . . . . . . . . 1D-4 Trim-In Stop Adjustment – Power Steering Link Rod . . . . . . . . . . . . . . . . . . . . . . . 1D-4 Trim Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-12 Installing Outboard – Thumb Screw Models . 1D-5 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . 1D-12 Installing Outboard – Non Thumb Screw Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-6 Electric Fuel Pump If an electric fuel pump is used, the fuel pressure must not exceed 4 psig at the engine. If necessary, install a pressure regulator to regulate the pressure. Boat Horsepower Capacity U.S. COAST GUARD CAPACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY (POUNDS) XXX MAXIMUM WEIGHT CAPACITY XXX Do not overpower or overload the boat. Most boats will carry a required capacity plate indicating the maximum acceptable power and load as determined by the manufacturer following certain federal guidelines. If in doubt, contact your dealer or the boat manufacturer. WARNING Using an outboard that exceeds the maximum horsepower limit of a boat can: 1. cause loss of boat control 2. place too much weight at the transom, altering the designed flotation characteristics of the boat or 3. cause the boat to break apart, particularly around the transom area. Overpowering a boat can result in serious injury, death, or boat damage. 90-857046 AUGUST 1998 Page 1D-1 OUTBOARD MOTOR INSTALLATION Start in Gear Protection The remote control connected to the outboard must be equipped with a start-in-gear protection device. This prevents the engine from starting in gear. WARNING Avoid serious injury or death from a sudden unexpected acceleration when starting your engine. The design of this outboard requires that the remote control used with it must have a built in start-in-gear protection device. Selecting Accessories For The Outboard Genuine Quicksilver Parts and Accessories have been specifically designed and tested for this outboard. Some accessories not manufactured or sold by Quicksilver are not designed to be safely used with this outboard or outboard operating system. Acquire and read the Installation, Operation, and Maintenance manuals for all selected accessories. Installation Specifications a b a Transom Opening “A” (Minimum) Single Engine (Remote) 19 in. (483 mm) Single Engine (Tiller) 30 in. (762 mm) Dual Engines 40 in. (1016 mm) Engine Center Line For Dual Engines “B” (Minimum) 26 in. (660mm) Page 1D-2 90-857046 AUGUST 1998 OUTBOARD MOTOR INSTALLATION 90-857046 AUGUST 1998 Page 1D-3 Lifting Outboard 1. Use lifting eye on engine. Steering Cable STARBOARD SIDE ROUTED CABLE 1. Lubricate the entire cable end with 2-4-C Lubricant with Teflon. 95 2-4-C w/Teflon (92-850736A1) 95 2. Insert steering cable into tilt tube. 3. Torque nut to 35 lb. ft. (47.5 N·m). OUTBOARD MOTOR INSTALLATION Steering Cable Seal 1. Mark tilt tube 1/4 in. (6.4 mm) from end. Install seal components. 2. Thread cap to the mark. 1/4 in. (6.4mm) b da c a-1/4 in. (6.4 mm) Mark b-Plastic Spacer c-O-Ring Seal d-Cap Steering Link Rod 1. Install steering link rod per illustration. a b c d e f a-Special Bolt (10-90041) Torque to 20 lb. ft. (27.1 N·m) b-Nylon Insert Locknut (11-34863) Torque to 20 lb. ft. (27.1 N·m) c-Spacer (12-71970) d-Flat Washer (2) e-Nylon Insert Locknut (11-34863) Tighten Locknut Until it Seats, Then Back Nut Off 1/4 Turn f-Use Middle Hole IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special bolt (“a” - Part Number 10-90041) and self locking nuts (“b” & “e” - Part Number 11-34863). These locknuts must never be replaced with common nuts (non locking) as they will work loose and vibrate off, freeing the link rod to disengage. Page 1D-4 90-857046 AUGUST 1998 OUTBOARD MOTOR INSTALLATION 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. 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. IMPORTANT: 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 1. Center outboard on the transom. 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 - 25 mm) a a-Anti-Ventilation Plate 90-857046 AUGUST 1998 Page 1D-5 OUTBOARD MOTOR INSTALLATION 2. Fasten outboard with provided mounting hardware shown. ab c d e a-1/2 in. Diameter Bolts (2) b-Flat Washers c-Locknuts d-Marine Sealer - Apply to Shanks of Bolts, Not Threads e-Thumb Screws - Tighten Securely Installing Outboard – Non Thumb Screw Models 1. Attach (tape) engine mounting template (located in this manual) to boat transom. 2. Mark and drill four 17/32 in. (13.5 mm) 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 - 25 mm) a a-Anti-Ventilation Plate Page 1D-6 90-857046 AUGUST 1998 OUTBOARD MOTOR INSTALLATION 90-857046 AUGUST 1998 Page 1D-7 4. Fasten outboard with provided mounting hardware shown. a b c d c b a d a - 1/2 in. Diameter Bolts (2) b - Flat Washers c - Locknuts d - Marine Sealer - Apply to Shanks of Bolts, Not Threads 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. Place harness into the holder. GRN/WHT BLU/WHT BRN/WHT TAN BLU/WHT GRN/WHT a b a - Power Trim Connections b - Holder – Place Harness Into Holder OUTBOARD MOTOR INSTALLATION Page 1D-8 90-857046 AUGUST 1998 Battery Cable Connections Single Outboards (+) (–) a b c a - Red Sleeve (Positive) b - Black Sleeve (Negative) c - Starting Battery Dual outboards 1. Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. (–) (–) a a - 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 c b a-Distance Between Pin And Center of Lower Hole b-Pin c-Lower Hole 4. Fit shift cable through rubber grommet. 90-857046 AUGUST 1998 Page 1D-9 OUTBOARD MOTOR INSTALLATION 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. b a a-Place Barrel Into Barrel Holder b-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 thru 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 thru d. Page 1D-10 90-857046 AUGUST 1998 OUTBOARD MOTOR INSTALLATION 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. 4. Adjust the throttle cable barrel until a 1/16 in. (1.6 mm) gap exists between the oval shaped boss and the cam. 1/16 in. (1.6 mm) a b c e d a-Throttle Cable b-Retainer Pin c-Throttle Cable Barrel d-Oval Shaped Boss e-Cam 90-857046 AUGUST 1998 Page 1D-11 OUTBOARD MOTOR INSTALLATION 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. Trim-In Stop Adjustment – Power Trim Models If an adjustment is required, purchase a stainless steel tilt pin (P/N 17-49930A1) and insert it through whatever pin hole is desired. The non-stainless steel shipping bolt should not be used in this application other than on a temporary basis. a a-Tilt Pin Trim Tab Adjustment The trim tab can be adjusted within limits to help compensate for steering torque. Adjust trim tab as follows: 1. If boat tends to pull to the right, move the rear edge of the trim tab to the right. 2. If boat tends to pull to the left, move the rear edge of the trim tab to the left. NOTE: Trim tab adjustment will have little effect reducing steering torque if the anti-ventilation plate is raised 2 inches (50 mm) or more above the boat bottom. Page 1D-12 90-857046 AUGUST 1998 IGNITION ELECTRICAL Section 2A - Ignition Table of Contents 2 A Table of Contents . . . . . . . . . . . . . . . . . . . . . . . 2A-1 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-3 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-6 Electrical Components . . . . . . . . . . . . . . . . . . . 2A-8 Ignition Description . . . . . . . . . . . . . . . . . . . . . . 2A-10 Ignition Component Description . . . . . . . . . . . 2A-10 Electronic Control Module (ECM) . . . . . . . 2A-10 Crank Position Sensor . . . . . . . . . . . . . . . . 2A-11 Stator Assembly. . . . . . . . . . . . . . . . . . . . . . 2A-11 Flywheel Assembly . . . . . . . . . . . . . . . . . . . 2A-12 Ignition Coils. . . . . . . . . . . . . . . . . . . . . . . . . 2A-12 Ignition Test Procedures . . . . . . . . . . . . . . . . . . 2A-12 Direct Voltage Adapter (DVA) . . . . . . . . . . 2A-12 Ignition Troubleshooting . . . . . . . . . . . . . . . . . . 2A-13 Tool: Multimeter/DVA Tester 91-99750A1 2A-13 Ignition Diagnostic Procedures . . . . . . . . . . . . 2A-14 Testing Ignition Components . . . . . . . . . . . . . . 2A-17 Resistance Tests . . . . . . . . . . . . . . . . . . . . . 2A-17 Spark Plug Cap Removal. . . . . . . . . . . . . . 2A-18 Spark Plug Cap Resistor Test . . . . . . . . . . 2A-19 Flywheel Removal and Installation . . . . . . . . . 2A-21 Stator Removal and Installation . . . . . . . . . . . 2A-24 Timing Belt Removal and Installation . . . . . . . 2A-25 ECM Removal and Installation . . . . . . . . . . . . 2A-26 Ignition Coil Removal and Installation . . . . . . 2A-27 Voltage Regulator Removal and Installation . 2A-28 Crank Position Sensor Removal/Inst. . . . . . . 2A-29 Temperature Sensor Removal/Inst. . . . . . . . . 2A-30 90-857046 AUGUST 1998 Page 2A-1 IGNITION Specifications IGNITION SYSTEM Readings taken @ 68°F (20°C). Type Spark Plug: Type Gap Hex Size Firing Order Ignition Timing: @ Idle (800 rpm) @ WOT (6000 rpm) Charge Coil Resistance Crank Position Sensor Resistance Ignition Coil Resistance: Primary Capacitor Discharge Ignition NGK DPR6EA-9 0.035 in. (1.0 mm) 18 mm 1-2-3 10° B.T.D.C 28° B.T.D.C 660 - 710 W (GRN/WHT - WHT/GRN) 300 - 350 W (RED - WHT) 0.08 - 0.7 W (BLK - BLK/WHT) Secondary (W/o Boots) ECM Engine Speed Limiter Soft Reduction (Retards Timing) Spark Cut-Out Reduction (Percent ages of ignition spark are Cut-Out) ECM Overheat/Low Oil Pressure Speed Control Engine Temperature Sensor 3.5 - 4.7 kW (BLK - High Tension) 6200 rpm 6250 rpm Approximately 2000 rpm See Graph Section 2A-Ignition CHARGING SYSTEM Readings taken @ 68°F (20°C). Alternator Type: 6 Amp. Manual Lighting Coil Output Lighting Coil Resistance 15 Amp. Electric Alternator Output Battery Charging Coil Resistance Power Bobbin Resistance (For Electrothermal Valve) Quicksilver Tachometer Setting Single Phase (12 Pole) 6 Amps. 0.9 - 1.1 Ohms (YEL-YEL) 12.6 V-15 Amps. (185 Watts) (Rectified/Regulated) 0.22 - 0.24 Ohms (YEL-YEL) 6.7-7.1 Ohms (YEL/BLK-YEL/BLK) “6P” or “4” IMPORTANT: Use resistive spark plugs only. Page 2A-2 90-857046 AUGUST 1998 IGNITION Special Tools 1. Flywheel Holder P/N 91-83163M. 2. Flywheel Puller P/N 91-83164M. 3. Timing Light P/N 91-99379 4. Direct Voltage Adapter P/N 91-89045 90-857046 AUGUST 1998 Page 2A-3 IGNITION 5. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1 6. Digital Diagnostic Tester 91-823686A2 7. Cartridge 91-822608--5 8. Adapter Harness 84-822560A7 and 84-822560A10 Page 2A-4 90-857046 AUGUST 1998 IGNITION Notes: 90-857046 AUGUST 1998 Page 2A-5 IGNITION Page 2A-6 90-857046 AUGUST 1998 FLYWHEEL 110 4-stroke Outboard Oil (92-828000A12) 110 1 2 4 6 5 7 8 9 10 11 12 13 51 Loctite 222 3 IGNITION FLYWHEEL REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 FLYWHEEL COVER ELECTRIC SCREW (M6 x 25) DECAL-EPA Information 2 4 45 5.1 3 1 4 1 FLYWHEEL (ELECTRIC) 5 1 FLYWHEEL (MANUAL) 6 1 DECAL-Warning Spinning flywheel 7 1 DECAL-Timing Marks 8 1 DECAL-Warning-Neutral 9 1 NUT 116 157 10 1 WASHER 11 3 SCREW (M5 x 25) 85 9.6 1212 1 STATOR (ELECTRIC) 1 STATOR (MANUAL) 13 1 LOAD RING 90-857046 AUGUST 1998 Page 2A-7 IGNITION Page 2A-8 90-857046 AUGUST 1998 ELECTRICAL COMPONENTS 34 9 6 6 6 9 35 30 29 10 5 36 11 24 23 22 40 31 18 17 19 21 20 15 16 14 4 2 3 8 5 5 7 12 13 26 25 28 27 32 33 37 38 39 9 Loctite Pipe Sealant W/Teflon (92-88504) 1 41 42 6 Dielectric Grease (92-823506--1) IGNITION ELECTRICAL COMPONENTS REF.TORQUE 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 2.8 5 3 NUT (1/4-20) 60 6.8 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) 260 22 29 11 1 SCREW (M8 x 25) (MANUAL) 260 22 29 12 2 SCREW (M6 x 30) (ELECTRIC) 75 8.5 12 1 SCREW (M6 x 16) (MANUAL) 75 8.5 13 1 J CLIP (ELECTRIC) 14 1 PRESSURE SWITCH 50 5.7 15 1 SENSOR-Crank Position 16 2 SCREW (M5 x 16) 45 5.1 17 3 SCREW (M6 x 25) 18 3 WASHER 19 1 PLATE 20 3 BUSHING 21 3 GROMMET 22 1 ECM 23 3 BUSHING 24 3 SCREW (M6 x 40) 45 5.1 25 3 SPARK PLUG (NGK DPR6EA-9) 150 12.5 17 1 DECAL-Coil Identification (1#) 26 1 DECAL-Coil Identification (2#) 1 DECAL-Coil Identification (3#) 27 3 IGNITION COIL 28 3 SCREW (M6 x 20) 75 8.5 29 1 ENGINE WIRING HARNESS (MANUAL) 29 1 ENGINE WIRING HARNESS (ELECTRIC) 30 1 FUSE (SFE 20 AMP) (ELECTRIC) 31 1 COVER (ELECTRIC) 32 1 CLAMP (ELECTRIC) 33 2 SCREW (M6 x 16) (ELECTRIC) 34 1 HARNESS-EXTENSION (ELECTRIC HANDLE) 35 AR STA-STRAP 36 1 J CLIP (MANUAL) 37 1 VOLTAGE REGULATOR 38 1 J-CLIP 39 2 SCREW (M6 x 40) ELECTRIC 105 11.9 39 1 SCREW (MANUAL) 40 1 SCREW (M6 x 10) 41 1 PLUG 42 1 SCREW (M6 x 16) 90-857046 AUGUST 1998 Page 2A-9 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, therefor 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 28° 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-10 90-857046 AUGUST 1998 IGNITION RPM % Spark Cut-Out 6250 11% 6281 33% 6313 66% 6. Over Heat Protection: Limits engine RPM to 2000 if the engine temperature exceeds 192.2° F (89° 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 183.2° F (84° C) and engine RPM is momentarily dropped below 1000 RPM as a reset condition. The ECM incorporates a 20 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. The ECM incorporates a 10 second warning system delay to allow engine to achieve operating oil pressure. NOTE:The ECM controls all timing operations. There are no timing adjustment required on this engine. Crank Position Sensor 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 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. 90-857046 AUGUST 1998 Page 2A-11 IGNITION Page 2A-12 90-857046 AUGUST 1998 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 Coils The primary (+) side of the ignition coil receives voltage discharged from a capacitor in the ignition (CDI) circuit located inside the ECM. The voltage is multiplied by the coil until it can jump the spark plug gap. Each ignition coil will produce a high voltage spark at each crankshaft revolution, producing a spark at each cylinder at the proper time (pre-determined by the ECM). 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. 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. IGNITION 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. Tool: Multimeter/DVA Tester 91-99750A1 Component Test Selector Sw. Position DVA Lead Red DVA Lead Black Voltage Read- ing(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. 90-857046 AUGUST 1998 Page 2A-13 IGNITION 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 Black/White Black (B) R x 1 W 0.18 - 0.24 Ignition Coil Secondary (test with coil leads disconnected) Red Black High Tension Lead Black (B) R x 1k W 2.72 - 3.68 NOTE: Copper is an excellent conductor, however, resistance may notably vary between low and high temperature. Therefore, reasonable differences can be accepted between resistance readings and specifications. The above readings are for a cold (room temperature) engine. Resistance will increase if the engine is warm. Ignition Diagnostic Procedures TROUBLESHOOTING TIP: With engine running, use inductive timing light to check spark advance of each cylinder as throttle is opened and closed. If timing advances and retards on each cylinder, ignition system is MOST LIKELY functioning properly. IMPORTANT: If outboard appears to have an ignition system failure, it is recommended that before beginning in-depth troubleshooting: a. Ensure that the engine is mechanically sound condition. (Fuel System, Cylinder Compression etc.). b. Check all engine ground leads for loose or corroded connections. c. Disconnect and reconnect ignition harness connectors to verify proper continuity. SUGGESTED TESTING PROCEDURES NOTE:The following recommended tests and probable causes are not listed in any specific order. The technician should use this table as a guide to help isolate and test the specific problem/condition. Always perform the DVA tests first (if applicable), then perform resistance test to validate suspected component failure. Page 2A-14 90-857046 AUGUST 1998 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 (All 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 supplied) 2 d- remote control harness 2 Ignition Coil 2 a - primary Circuit Shorted to Ground 2 Spark Plugs Open Ground Condition: 3 a - ignition coil 2 b - stator ground 3 c - (ECM) 3 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 *Recommended Test (cont.) (1) DVA TEST (Direct Voltage Adapter) (2) OHM TEST (Resistance Testing) (3) Replace Component and Retest (4) Mechanical Test/Repair 90-857046 AUGUST 1998 Page 2A-15 IGNITION 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) 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) 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 6200 RPM While Under Load NOTE:The engine (ECM) will retard timing and reduce RPM above 6200 RPM. Boat Under Propped Propeller Hub Spun 4 4 Page 2A-16 90-857046 AUGUST 1998 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° F(20° C). STATOR (IGNITION CHARGE COIL) METER TEST LEADS METER SCALE READING () RED BLACK RX1RX1 660 710660 -710GRN/WHT WHT/GRN STATOR AUTO ENRICHENER (POWER BOBBIN CHARGE COIL) METER TEST LEADS METER SCALE READING () RED BLACK RX1RX1 67 716.7 -7.1YEL/BLK YEL/BLK 90-857046 AUGUST 1998 Page 2A-17 IGNITION IGNITION COIL (PRIMARY) METER TEST LEADS METER SCALE READING () RED BLACK RX1RX1 018 024 0.18 -0.24BLK/WHT BLACK 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. Page 2A-18 90-857046 AUGUST 1998 IGNITION IGNITION COIL (SECONDARY) METER TEST LEADS METER SCALE READING () RED BLACK RX1KRX1K 272 368 2.72 -3.68HIGH TENSION LEAD BLK Spark Plug Cap Resistor Test-P/N VDFP METER TEST LEADS METER SCALE READING () RED BLACK RX1KRX1K 00 WIRE END PLUG END Spark Plug Cap Resistor Test-P/N VDO5FP METER TEST LEADS METER SCALE READING () RED BLACK RX1KRX1K 35-523.5 5.2 WIRE END PLUG END 90-857046 AUGUST 1998 Page 2A-19 IGNITION CRANK POSITION SENSOR METER TEST LEADS METER SCALE READING () RED BLACK RX1RX1 300 -350 300 350 RED WHT TEMPERATURE SENSOR Insert digital or analog ohmmeter test leads into both Black sensor leads. With engine at temperature (F) indicated, ohm rating should be as indicated. Resistance (k) 0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 Temperature (  F) Temperature Sensor Page 2A-20 90-857046 AUGUST 1998 IGNITION 90-857046 AUGUST 1998 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. Remove flywheel cover (manual start models refer to section 8). a a - Bolts (4) IGNITION Page 2A-22 90-857046 AUGUST 1998 2. Loosen flywheel nut. Hold flywheel using flywheel holder (91-83163M). 3. Remove nut and washer. 91-83163M b a c d a - Flywheel Holder (91-83163M) b - Breaker Bar with 30 mm Socket c - Nut d - Washer 4. Loosen flywheel using puller (91-83164M). Remove flywheel and key. 91-83164M a b c a - Flywheel Puller (91-83164M) b - Flywheel c - Key IGNITION 90-857046 AUGUST 1998 Page 2A-23 Installation 1. Place flywheel key into slot. 2. Install flywheel. Apply oil to threads on crankshaft. 3. Install washer and nut. 4. Hold flywheel using flywheel holder (91-83163M) and tighten nut to the specified torque. b a 91-83163M c d e f a - Key b - Flywheel c - Washer d - Nut e - Torque Wrench f - Flywheel Holder (91-83163M) Flywheel Nut Torque 116 lb. ft. (157 N·m) IGNITION Page 2A-24 90-857046 AUGUST 1998 Stator Removal and Installation 1. Remove stator harness from j-clips. 2. Remove cable tie from bundled wire connectors. 3. Disconnect stator wires. 4. Remove stator mounting bolts. 5. Reverse steps for installation (refer to wiring diagram Section 2D for correct stator wire connections). NOTE: Apply Loctite 222 to threads of stator screws. 51 51 Loctite “222” (92-809818) d c a b b a - Stator b - J-Clips c - Cable Tie d - Screws (3) Stator Screw Torque 85 lb. in. (9.6 N·m) IGNITION 90-857046 AUGUST 1998 Page 2A-25 Timing Belt Removal and Installation Removal 1. Remove timing belt from driven sprocket. a a - Timing Belt Installation 1. Align marks on driver and driven gear with marks on cylinder block as shown. 2. Install timing belt onto drive sprocket. Slide timing belt onto driven sprocket. NOTE: Install timing belt with parts name up. 1 a b c c d e a - Drive Gear Mark b - Driven Gear Mark c - Cylinder Block Marks d - Timing Belt e - Parts Name Up On Timing Belt IGNITION ECM Removal and Installation 1. Remove and install ECM as shown. a b a-Bolts (3) b-Harness Clip ECM Mounting Bolt Torque 45 lb. in. (5.1 N·m) Page 2A-26 90-857046 AUGUST 1998 IGNITION 90-857046 AUGUST 1998 Page 2A-27 Ignition Coil Removal and Installation 1. Disconnect spark plug leads from spark plugs. 2. Remove bundled wires from J-clip. 3. Cut cable tie securing bundled wire connectors. 4. Disconnect wires (BLK and BLK/WHT). 5. Remove ignition coil mounting bolts. 6. Reverse steps for installation. a a a b c d a - Spark Plug Leads b - J-Clip c - Cable Tie d - Mounting Bolts-M6x20 Ignition Coil Mounting Bolt Torque 75 lb. in. (8.5 N·m) IGNITION Page 2A-28 90-857046 AUGUST 1998 Voltage Regulator Removal and Installation 1. Remove bundled wire connectors from j-clip. 2. Remove cable tie. 3. Disconnect voltage regulator wires. 4. Remove mounting bolts and ground wires. 5. Reverse steps for installation (refer to wiring diagram section 2D for correct wire connections). a b c d d e a - Voltage Regulator b - J-Clip c - Cable Tie d - Bolts (2) e - Ground Wires Voltage Regulator Mounting Bolt Torque 105 lb. in. (11.9 N·m) IGNITION 90-857046 AUGUST 1998 Page 2A-29 Crank Position Sensor Removal and Installation 1. Disconnect sensor from wiring harness. 2. Remove sensor mounting bolts. 3. Reverse steps for installation. a b c a - Crank Position Sensor b - Harness Connector c - Bolts (2)-M5x16 Crank Position Sensor Mounting Bolt Torque 45 lb. in. (5.1 N·m) IGNITION Page 2A-30 90-857046 AUGUST 1998 Temperature Sensor Removal and Installation 1. Disconnect sensor from wiring harness. 2. Remove sensor from exhaust cover. 3. Reverse steps for installation. a b c a - Harness Connector b - Temperature Sensor c - Exhaust Cover Temperature Position Sensor Mounting Torque 35 lb. in. (3.9 N·m) CHARGING & STARTING SYSTEM ELECTRICAL Section 2B - Charging & Starting System Table of Contents 2 B Table of Contents . . . . . . . . . . . . . . . . . . . . . . . 2B-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3 Recommended Battery . . . . . . . . . . . . . . . . 2B-3 Operating Engine Without Battery . . . . . . 2B-3 Battery Charging System Troubleshooting 2B-3 Battery Charging System . . . . . . . . . . . . . . . . . 2B-4 Description (15 Ampere) . . . . . . . . . . . . . . 2B-4 Wiring Diagram (15 Ampere) . . . . . . . . . . . 2B-4 Alternator System Test . . . . . . . . . . . . . . . . . . . 2B-5 6 Ampere Stator . . . . . . . . . . . . . . . . . . . . . . 2B-5 15 Ampere Stator . . . . . . . . . . . . . . . . . . . . 2B-6 Stator Ohms Test . . . . . . . . . . . . . . . . . . . . . . . . 2B-7 Rectifier/Regulator (P/N 854514) Diode Test 2B-8 Specifications Analog Meter . . . . . . . . . . . . . . . . . . . . . . . . 2B-8 Digital Meter . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9 Starting System Components . . . . . . . . . . . . . 2B-10 Description . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-10 Troubleshooting the Starting Circuit . . . . . . . . 2B-10 Starter Solenoid Test . . . . . . . . . . . . . . . . . . 2B-11 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-14 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 2B-14 Cleaning and Inspection . . . . . . . . . . . . . . . 2B-16 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-17 Brush Replacement . . . . . . . . . . . . . . . . . . . 2B-19 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 2B-20 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-23 CHARGING SYSTEM Readings taken @ 68°F (20°C). Alternator Type: 6 Amp. Manual Lighting Coil Output Lighting Coil Resistance 15 Amp. Electric Alternator Output Battery Charging Coil Resistance Power Bobbin Resistance (For Electrothermal Valve) Quicksilver Tachometer Setting Single Phase (12 Pole) 6 Amps. 0.9 - 1.1 Ohms (YEL-YEL) 12.6 V-15 Amps. (185 Watts) (Rectified/Regulated) 0.22 - 0.24 Ohms (YEL-YEL) 6.7-7.1 Ohms (YEL/BLK-YEL/BLK) “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) 90-857046 AUGUST 1998 Page 2B-1 CHARGING & STARTING SYSTEM STARTER MOTOR 1 2 3 4 5 6 7 8 9 10 11 8 STARTER MOTOR REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 STARTER MOTOR 2 2 THRU BOLT 70 8.0 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 Page 2B-2 90-857046 AUGUST 1998 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. 90-857046 AUGUST 1998 Page 2B-3 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) –+ YEL_BLK YEL_BLK WHT_GRN GRN_WHT RED BLK GRY RED YEL YEL RED YEL YEL YELYELYEL_BLKYEL_BLKWHT_GRNGRN_WHT YEL_BLKYEL_BLKWHT_GRNGRN_WHTRED RED BLK a b c d e f Blk = Black Blu = Blue Brn = Brown Gry = GrayGrn = Green Orn = OrangePnk = Pink Pur = PurpleRed = Red Tan = Tan Wht = White Yel = Yellow a-Voltage Regulator b-To Starter Motor Bolt Boss c-12V Battery d-Fuse-20A e-ECM f-Stator Page 2B-4 90-857046 AUGUST 1998 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 amp meter 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: 0 1 2 3 4 5 6 7 8 0 1 2 3 4 5 6 Alternator Current (Amps) RPM x 1000 4. If proper ampere readings are not obtained, replace stator. 90-857046 AUGUST 1998 Page 2B-5 CHARGING & STARTING SYSTEM 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: Alternator current (Amps) 16 14 12 10 8 6 4 2 0 0123456 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 Ohms Test ”). If stator tests OK, replace rectifier/regulator. Page 2B-6 90-857046 AUGUST 1998 CHARGING & STARTING SYSTEM Stator Ohms Test STATOR (BATTERY CHARGE COIL) 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 90-857046 AUGUST 1998 Page 2B-7 CHARGING & STARTING SYSTEM Rectifier/Regulator (P/N 854514) Diode Test Analog Meter NOTE:Voltage regulator/rectifier specifications are given for informational purposes only, use the appropriate troubleshooting techniques previously mentioned to find the faulty component in the charging system. YEL Blk = Black Gry = Gray Red = Red BLK Yel = Yellow RED YEL GRY 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  OHMS TEST RESULTS (2ND READING):  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) 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) Page 2B-8 90-857046 AUGUST 1998 CHARGING & STARTING SYSTEM Digital Meter NOTE:Voltage regulator/rectifier specifications are given for informational purposes only, use the appropriate troubleshooting techniques previously mentioned to find the faulty component in the charging system. YEL Blk = Black Gry = Gray Red = Red BLK Yel = Yellow RED YEL GRY 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 -o or OUCH or OL TACHOMETER CIRCUIT TEST: 1. Not measurable with digital meter. 90-857046 AUGUST 1998 Page 2B-9 CHARGING & STARTING SYSTEM Starting System Components Description The function of the starting system is to crank the engine. The battery supplies electrical energy to crank the starter motor. When the ignition switch is turned to “START” position, the starter solenoid is activated and completes the starting circuit between the battery and starter. The neutral start switch opens the start circuit when the shift control lever is not in neutral. This prevents accidental starting when engine is in gear. The starting system consists of the following components. 1. Battery 2. Starter Solenoid 3. Neutral Safety Switch 4. Starter Motor 5. Ignition Switch CAUTION The starter motor may be damaged if operated continuously. DO NOT operate continuously for more than 30 seconds. Allow a 2 minute cooling period between starting attempts. 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. Page 2B-10 90-857046 AUGUST 1998 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 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. 90-857046 AUGUST 1998 Page 2B-11 CHARGING & STARTING SYSTEM NEUTRAL START SWITCH + AB IGNITION SWITCH STARTER STARTER SOLENOID BATTERY 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 Blk1 2 3 45 6 7 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. Page 2B-12 90-857046 AUGUST 1998 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. 12 Volt Reading* Neutral start switch is open, or YELLOW/ RED or BLACK wire is open between Test Points 4 and 3. Electric Start Tiller Handle Model Neutral start switch is open or BLACK leads are disconnected or damaged. * 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* 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. 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. 90-857046 AUGUST 1998 Page 2B-13 CHARGING & STARTING SYSTEM Page 2B-14 90-857046 AUGUST 1998 Starter Motor Removal WARNING Always disconnect the battery and remove spark plug leads from spark plugs before working on motor. 1. Disconnect battery leads and black starter motor lead from battery. 2. Remove 3 bolts. Remove starter. a a a b a - Bolts (3) b - Starter Motor Lead Disassembly 1. Remove 2 thru bolts and commutator end cap, taking care not to lose brush springs. a a c c b a - Thru Bolts b - Commutator End Cap c - Brush Springs 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 90-857046 AUGUST 1998 Page 2B-15 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. De-burr 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 and 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”. Page 2B-16 90-857046 AUGUST 1998 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. 90-857046 AUGUST 1998 Page 2B-17 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 11673 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. b a a-Negative (-) Brushes b-End Cap Page 2B-18 90-857046 AUGUST 1998 CHARGING & STARTING SYSTEM Brush Replacement IMPORTANT: Replace brushes that are pitted or worn to less than 1/4 in. (6.4mm) in length. a b c d e f g a-Positive (+) Terminal b-Long Brush Lead c-Push Lead Into Slot d-Insulating Washer e-Flat Washer f-Lock Washer g-Nut a bc d a b d a-Positive (+) Brushes b-Negative (–) Brushes c-Brush Holder d-Bolts (Fasten Negative Brushes and Holder) 90-857046 AUGUST 1998 Page 2B-19 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 a b c d a-Circlip b-Pinion Stopper c-Spring d-Pinion Page 2B-20 90-857046 AUGUST 1998 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) 90-857046 AUGUST 1998 Page 2B-21 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. a b 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 thru bolts (c) and torque to 70 lbs. in. (7.9 N·m). a b c c Page 2B-22 90-857046 AUGUST 1998 CHARGING & STARTING SYSTEM 90-857046 AUGUST 1998 Page 2B-23 Installation 1. Secure starter to block with 3 bolts. Torque bolts to 22 lb. ft. (29 N·m). Secure NEGATIVE battery lead and starter motor lead as shown. a a a b c a - Bolts (3) b - Negative Battery Lead c - Starter Motor Lead Starter Motor Bolt Torque 22 lb. ft. (29 N·m) TIMING, SYNCHRONIZING, & ADJUSTING ELECTRICAL Section 2C - Timing, Synchronizing, & Adjusting Table of Contents 2 C Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1 Carburetor Synchronization . . . . . . . . . . . . . . . 2C-5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-2 Idle Speed Adjustment . . . . . . . . . . . . . . . . . . . 2C-9 Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-3 Specifications IGNITION SYSTEM Readings taken @ 68°F (20°C). Type Spark Plug: Type Gap Hex Size Firing Order Ignition Timing: @ Idle (800 rpm) @ WOT (6000 rpm) Charge Coil Resistance Crank Position Sensor Resistance Ignition Coil Resistance: Primary Capacitor Discharge Ignition NGK DPR6EA-9 0.035 in. (1.0 mm) 18 mm 1-2-3 10° A.T.D.C 28° B.T.D.C 660 - 710 W (GRN/WHT - WHT/GRN) 300 - 350 W (RED - WHT) 0.08 - 0.7 W (BLK - BLK/WHT) Secondary (W/o Boots) ECM Engine Speed Limiter Soft Reduction (Retards Timing) Spark Cut-Out Reduction (Percent ages of ignition spark are Cut-Out) ECM Overheat/Low Oil Pressure Speed Control Engine Temperature Sensor 3.5 - 4.7 kW (BLK - High Tension) 6200 rpm 6250 rpm Approximately 2000 rpm See Graph Section 2A-Ignition NOTE:The 30/40 four stroke ECM unit electronically controls the ignition timing, therefore making the ignition timing non adjustable. When initially running the outboard, use a timing light to verify that the ignition timing falls within the timing windows. If the ignition timing does not stay within the timing windows, replace the ignition ECM unit and retest. 90-857046 AUGUST 1998 Page 2C-1 TIMING, SYNCHRONIZING, & ADJUSTING Special Tools 1. Carburetor Tuner P/N 91-809641A1 2. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1. 3. Timing Light P/N 91-99379. 4. Tubing Clamp P/N 91-804063 Page 2C-2 90-857046 AUGUST 1998 TIMING, SYNCHRONIZING, & ADJUSTING Timing WARNING To prevent personal injury or possible death, from loss of balance or stability while servicing the motor, DO NOT attempt to check timing while boat is in motion. Failure to follow one of the recommended servicing procedures may result in the person falling overboard or causing personal injury from fall in boat. WARNING To prevent personal injury from spinning flywheel, Do Not attempt to remove flywheel cover or place hands on top of cover when checking ignition timing. Ignition timing is not adjustable. The Electronic Control Module unit electronically controls the ignition timing. When initially running the outboard, use a timing light to verify that the ignition timing falls within the timing windows as described within the following tests. If the ignition timing does not stay within the timing windows, replace the ignition E.C.M. unit and retest. (Refer to the Ignition Diagnostic Procedures tests in Section 2A.) IMPORTANT: When checking the timing with the engine running, one of the following test procedures must be followed. Check maximum timing per specification while running the outboard: •IN A TEST TANK •ON A DYNAMOMETER •ON A BOAT SECURED ON A TRAILER “Backed in Water” 90-857046 AUGUST 1998 Page 2C-3 TIMING, SYNCHRONIZING, & ADJUSTING Page 2C-4 90-857046 AUGUST 1998 1. Attach timing light to #1 spark plug lead. b a c d e a - Timing Light Clamp b - #1 Spark Plug Lead c - Ground Lead d - Timing Window-Electric Start Models e - Timing Window-Manual Start Models 2. Place the outboard in “Forward” gear and check timing at idle “Retarded.” (If not within specification window, refer to Diagnostic Test Procedures Section 2A.) a a a - Timing Mark (Full Retarded) TIMING, SYNCHRONIZING, & ADJUSTING 90-857046 AUGUST 1998 Page 2C-5 3. Slowly increase the engine RPM while watching the ignition timing marks. The timing should increase to the maximum timing specification “Full Advance” at approximately 6000 RPM. (If not within specification window, refer to Diagnostic Test Procedures Section 2A.) a a a - Timing Mark (Full Advance) Carburetor Synchronization NOTE: The carburetors are synchronized by adjusting the intake manifold vacuum on the carburetors. Use Carburetor Tuner (91-80964A1) to measure the vacuum. INSTALLING CARBURETOR TUNER (91-809641A1) 1. Remove three plugs from the intake manifold. 2. Install intake manifold hose adaptor in each plug hole. Tighten securely. NOTE: Intake manifold hose adaptors are provided with the Carburetor Tuner. a a a a b a - Intake Manifold Plugs (3) b - Intake Manifold Hose Adaptor (3) TIMING, SYNCHRONIZING, & ADJUSTING Page 2C-6 90-857046 AUGUST 1998 3. Connect the Carburetor Tuner to the hose adaptors. 4. Install filters to prevent mercury being drawn into carburetors during an abrupt throttle change. 5. Pinch off enrichener lines between carburetors with a tubing clamp. a a b a c 91-804063 a a - Tubing Clamp (91-804063) b - Filters (35-18206) c - Carburetor Tuner (P/N 91-809641A1) CAUTION To avoid the possibility of drawing mercury from the vacuum gauge into the engine, do not run engine at high rpm speed or abruptly change throttle position. TIMING, SYNCHRONIZING, & ADJUSTING 90-857046 AUGUST 1998 Page 2C-7 SYNCHRONIZING CARBURETORS 1. With the outboard in water, start engine and allow to warm up. Shift the outboard to neutral. 2. Connect a tachometer to the engine. 3. Adjust idle RPM screw (a) on bottom carburetor to obtain an idle setting of 1000 RPM in neutral. If necessary, keep adjusting the idle screw. NOTE: Keep engine speed set at 1000 RPM in neutral while synchronizing carburetors. a a - Idle RPM Screw TIMING, SYNCHRONIZING, & ADJUSTING Page 2C-8 90-857046 AUGUST 1998 4. Read the vacuum of cylinder #3. It’s not important to be at any specific vacuum setting. 5. Adjust the carburetor synchronization screws of cylinders #2 and #1 to match the base vacuum of cylinder #3. NOTE: Keep viewing the tachometer, as the engine RPM may fluctuate during adjustments. Keep adjusting the idle RPM screw in order to keep the engine speed at 1000 RPM. Example 32 cm 30 cm 28 cm 26 cm Cyl. # 3 Cyl. #. 2 Cyl. # 1 If the vacuum reading of Cyl. #3 (base vacuum) is 30 cm, then adjust carburetor synchronization screws of cylinders #2, and #1 to 30 cm. a b a - Carburetor Synchronization Screw #1 b - Carburetor Synchronization Screw #2 6. Rev engine a few times and let engine idle for 15 seconds. Check that the vacuum values remain the same between cylinders. Re-adjust if necessary. CAUTION To avoid the possibility of drawing mercury from the vacuum gauge into the engine, do not run engine at high rpm speed or abruptly change throttle position. 7. Stop engine, remove adaptors and reinstall plugs. Refer to Idle Speed Adjustment and adjust the idle RPM back to specification. TIMING, SYNCHRONIZING, & ADJUSTING 90-857046 AUGUST 1998 Page 2C-9 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 water, start engine and allow to warm up. Shift the outboard to neutral. 2. With the outboard in neutral, turn the idle adjustment screw located on the #3 (bottom) carburetor to attain the specified idle RPM. a a - Idle RPM Adjustment Screw 3. Rev engine 2 or 3 times and allow to idle for 15 seconds. a. If the engine holds a stable idle condition, then no other adjustments are necessary. b. If the engine has an unstable idle condition, then carburetor synchronization is required. Refer to Carburetor Synchronization preceding. WIRING DIAGRAMS ELECTRICAL Section 2D - Wiring Diagrams Table of Contents 2 D 30/40 ELPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-2 30/40 EHPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-3 30/40 MH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-4 Commander 2000 Remote Control (Electric Start) . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-5 Commander 3000 Panel Mount Control . . . . 2D-6 Instrument/Lanyard Stop Switch Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 2D-7 Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard) . . . . . . . . . . 2D-8 Commander 2000 Key Switch Test . . . . . . . . 2D-10 Instrument Wiring Connections . . . . . . . . . . . . 2D-11 Without Light Switch . . . . . . . . . . . . . . . . . . 2D-11 With Light Switch. . . . . . . . . . . . . . . . . . . . . 2D-11 Oil Pressure Wiring Diagram. . . . . . . . . . . . . . 2D-12 QSI Gauge Wiring Diagrams. . . . . . . . . . . . . . 2D-13 Tachometer Wiring Diagram . . . . . . . . . . . 2D-13 Water Temperature Gauge . . . . . . . . . . . . 2D-14 Engine Synchronizer Wiring Diagram . . . 2D-15 Remote Wiring Harness Connection to Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-18 Electric Start Remote Control Model . . . . . 2D-18 Remote Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-19 Power Trim Switch Wiring Diagram . . . . . . . . 2D-20 90-857046 AUGUST 1998 Page 2D-1 WIRING DIAGRAMS Page 2D-2 90-857046 AUGUST 1998 30/40 ELPT + – DDT S1 DN UP S2 S3 BLK TAN_LTBLU GRY BLK_DKBLU TAN_BLK TAN_WHT BLK_YEL GRN BLK_ORG BLK_GRN BLK_WHT RED_WHT TAN_GRN LTBLU DKBLU YEL_BLK WHT_GRN GRN_WHT BLK_GRN BLK_WHT GRN BLK BLK GRN GRN BLK_WHT BLK_YEL BLK_ORG GRN BLK_YEL TAN_WHT TAN_BLK BLK_YEL TAN_LTBLU GRY BLK YEL_RED RED_PPL GRN_WHT LTBLU_WHT RED_PPL BLU GRN YEL_BLK YEL_BLK RED_PPL RED GRN_WHT LTBLU_WHT RED_PPL GRN_WHT GRN BLK RED BLK BLK RED BLK BLU LTBLU_WHT BLK BLK BLK BLK BLK BLK YEL_RED RED RED BLK BLK GRY RED YEL YEL RED YEL YEL YEL YEL YEL_BLK YEL_BLK WHT_GRN GRN_WHT YEL_BLK YEL_BLK WHT_GRN GRN_WHT YEL_BLK YEL_BLK YEL_BLK YEL_BLK LTBLU BLK BLK BLK BLK BLK BLK BLK RED_WHT BLK BLK_DKBLU DKBLU RED WHT RED RED a b c d e f g h i k j l m p t r w o n q v u s BLK BLK GRN x 3 2 1 YEL_BLK BLK_WHT BLK_WHT BLK BLK A B C D a - ECM b - DDT c - Crank Position Sensor d - Temperature Sensor e - Oil Switch f - Auto Enrichener g - Stator h - Voltage Regulator i - Starter j - Start Solenoid k - 12V Battery l - To Trim Pump m - Trim Up Relay n - Trim Down Relay o - Cowl Mounted Trim Switch p - Fuse-20A Acc. and Trim q - To Remote Trim Switch r - To Remote Control s - To Over-Heat Lamp t - To Oil Pressure Lamp u - Ignition Coil #1 v - Ignition Coil #2 w - Ignition Coil #3 x - Diode Harness (Early Production) Ground Connects to Upper Fuel Pump Bolt WIRING DIAGRAMS 90-857046 AUGUST 1998 Page 2D-3 30/40 EHPT + –1 S1 DN UP S2 S3 – + BLK_YEL BLK_YEL BLK_YEL GRY YEL_BLK YEL_BLK BLK_YEL PPL YEL_BLK BLK BLK GRN_WHT LTBLU_WHT RED_PPL GRN BLU GRN GRN_WHT BLK BLU LTBLU_WHT BLK RED_PPL RED_PPL YEL_BLK YEL_BLK YEL YEL YEL YEL RED YEL YEL GRY BLK BLK BLK BLK YEL_RED RED RED BLK BLK BLK RED RED BLK BLK TAN_LTBLU GRY BLK_DKBLU TAN_BLK TAN_WHT BLK_YEL GRN BLK_ORG BLK_WHT RED_WHT TAN_GRN LTBLU DKBLU YEL_BLK YEL_BLK WHT_GRN GRN_WHT GRN BLK_GRN BLK_WHT BLK GRN GRN BLK_WHT BLK_YEL BLK_YEL BLK_ORG GRN BLK BLK BLK_YEL BLK_YEL BLK_YEL BLK_YEL PPL PPL BLK YEL_RED BLK_YEL RED YEL_BLK PPL TAN TAN_WHT TAN_BLK TAN_LTBLU BLK YEL_RED RED_PPL TAN BLK YEL_RED RED RED LTBLU_WHT GRN_WHT RED BLK RED BLK BLK RED YEL_BLK YEL_BLK WHT_GRN GRN_WHT WHT_GRN GRN_WHT YEL_BLK YEL_BLK YEL_BLK YEL_BLK LTBLU BLK BLK BLK BLK BLK BLK RED_WHT RED WHT DKBLU BLK_DKBLU BLK BLK_GRN 57184 a b c d e f h i k j l p o n q m r s u v y x w t g BLK GRN z BLK_WHT BLK BLK_WHT BLK 3 2 1 BLK BLK a - ECM b - DDT c - Crank Position Sensor d - Temperature Sensor e - Oil Switch f - Auto Enrichener g - Stator h - Voltage Regulator i - Starter j - Start Solenoid k - 12V Battery l - To Trim Pump m - Trim Up Relay n - Trim Down Relay o - Cowl Mounted Trim Switch p - Fuse-20A Acc. and Trim q - To Remote Trim Switch r - To Remote Control s - Key-switch t - Warning Horn u - Lanyard Stop Switch v - Push Button Stop Switch w - Ignition Coil #1 x - Ignition Coil #2 y - Ignition Coil #3 z - Diode Harness (Early Production) Ground Connects to Upper Fuel Pump Bolt WIRING DIAGRAMS Page 2D-4 90-857046 AUGUST 1998 30/40 MH S1 S2 S3 BLK TAN_LTBLU GRY BLK_DKBLU PPL BLK_YEL GRN BLK_ORG BLK_GRN BLK_WHT RED_WHT TAN_GRN LTBLU DKBLU YEL_BLK YEL_BLK WHT_GRN GRN_WHT BLK_GRN BLK_WHT GRN BLK GRN GRN BLK_WHT BLK_ORG GRN YEL_BLK YEL_BLK WHT_GRN GRN_WHT YEL_BLK YEL_BLK WHT_GRN GRN_WHT YEL YEL TAN_LTBLU PPL BLK BLK_YEL BLK_YEL BLK YEL_BLK YEL_BLK TAN_LTBLU PPL BLK BLK_YEL BLK_YEL BLK YEL_BLK YEL_BLK LTBLU BLK TAN_GRN BLK BLK GRY DKBLU BLK_DKBLU BLK RED_WHT BLK RED WHT 57186 d e f g h i j m l k a b c BLK GRN n BLK_WHT BLK BLK_WHT BLK 3 2 1 BLK BLK A B C D a - ECM b - DDT c - Crank Position Sensor d - Temperature Sensor e - Oil Switch f - Warning Horn g - Lanyard Stop Switch h - Push Button Stop Switch i - Auto Enrichener j - Stator k - Ignition Coil #1 l - Ignition Coil #2 m - Ignition Coil #3 n - Diode Harness (Early Production) Ground Connects to Upper Fuel Pump Bolt WIRING DIAGRAMS Commander 2000 Remote Control (Electric Start) BLK = Black BRN = Brown GRY = Gray GRN = Green RED = Red WHT = White YEL = Yellow a b c d e a-Wiring Harness Connector b-Tachometer/Accessories Harness Connector c-Ignition/Choke Switch d-Emergency Stop Switch e-Neutral Start Switch 90-857046 AUGUST 1998 Page 2D-5 WIRING DIAGRAMS Commander 3000 Panel Mount Control B A C S M M ÂÂÂÂÂÂÂÂÂYEL/RED RED YEL/RED YEL/RED YEL/RED PUR GRN BLU/WHT GRN/WHT RED BLK/YEL BLK BLK=BLACK BLU=BLUE BRN=BROWN GRN=GREEN GRY=GRAY PUR=PURPLE RED=RED TAN=TAN WHT=WHITE YEL=YELLOW a b c a-Lanyard stop switch leads must be soldered and covered with shrink tube for a water proof connection. If alternate method of connection is made, (use of electrical butt connector) verify connection is secure and sealed for moisture proof connection. b-Connect wires together with screw and hex nut (2 places); apply Quicksilver Liquid Neoprene to connections and slide heat shrink tubing over each connection. c-Keyswitch Page 2D-6 90-857046 AUGUST 1998 WIRING DIAGRAMS Instrument/Lanyard Stop Switch Wiring Diagram IMPORTANT: On installations where gauge options will not be used, tape back any unused wiring harness leads. 52715 BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow LIT = Light DRK = Dark c g d f e a b j h i j k a-Ignition/Choke Switch b-Lanyard Stop Switch c-Lead Not Used On Outboard Installations d-Retainer e-Tachometer f-Trim Indicator Gauge (Optional) g-Temperature Gauge h-Remote Control i-Power Trim Harness Connector j-Connect Wires Together with Screw and Hex Nut (2 Places); Apply Quicksilver Liquid Neoprene to Connections and Slide Rubber Sleeve over Each Connection k-Lead to Optional Visual Warning Kit 90-857046 AUGUST 1998 Page 2D-7 WIRING DIAGRAMS Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard) BLK = BLU = BRN = GRY = GRN = ORN = PNK = PUR = RED = TAN = WHT = YEL = LIT = DRK = a-Ignition/Choke Switch f-Trim Indicator Gauge b-Lanyard Stop Switch g-Temperature Gauge c-Lead Not Used on Outboard Installations h-Remote Control d-Retainer i-Synchronizer Gauge e-Tachometer j-Synchronizer Box BATT GND SENDER 52716 Black Blue Brown Gray Green Orange Pink Purple Red Tan White Yellow Light Dark g d k d e l c b d f a o h n n PORT INSTALLATION Page 2D-8 90-857046 AUGUST 1998 WIRING DIAGRAMS IMPORTANT: On installations where gauge options will not be used, tape back and isolate any unused wiring harness leads. BATT GND SENDER STARBOARD INSTALLATION j i a g m f e o k-Lanyard/Diode l-“Y” Harness m-Power Trim Harness Connector 52654 n-Connect Wires Together with Screw and Hex Nut (4 Places);Apply Quicksilver Liquid Neoprene to Connections and Slide Rubber Sleeve over Each Connection. o-Lead to Visual Warning Kit 90-857046 AUGUST 1998 Page 2D-9 WIRING DIAGRAMS Commander 2000 Key Switch Test 1. Disconnect remote control wiring harness and instrument panel connector. 2. Set ohmmeter on R x 1 scale for the following tests: KEY POSITION OFF RUN START CHOKE* CONTINUITY SHOULD BE INDICATED AT THE FOLLOWING POINTS: BLK BLK/YEL RED YEL/RED PUR YEL/BLK BLK = Black PUR = Purple RED = Red YEL = Yellow *Key switch must be positioned to “RUN” or “START” and key pushed in to actuate choke for this test. NOTE:If meter readings are other than specified in the preceding tests, verify that switch and not wiring is faulty. If wiring checks ok, replace switch. Page 2D-10 90-857046 AUGUST 1998 WIRING DIAGRAMS Instrument Wiring Connections Without Light Switch NOTE: ANY INSTRUMENT WIRING HARNESS LEADS NOT USED MUST BE TAPED BACKTO THE HARNESS. Speedometer Tachometer Temperature/Oil Warning Panel Volt Meter TAN/WHTTAN/BLK 51820 a b c d a-Tachometer Receptacle-From Control Box or Ignition/Choke Switch b-Tachometer Wiring Harness c-Lead to Optional Visual Warning Kit (Taped Back to Harness) d-Cable Extension (For Two Function Warning Panel) e-Light Switch With Light Switch Wire Where To BLK=BLACK GROUND TAN/WHT=TAN/WHITE OIL LIGHT TAN/BLK=TAN/BLACK TEMPERATURE LIGHT TAN=TAN TEMPERATURE GAUGE PUR=PURPLE IGNITION 12 VOLT GRY=GRAY TACHOMETER BRN/WHT=BROWN/WHITE TRIM GAUGE TAN/BLU=TAN/BLUE VISUAL WARNING KIT (OPT.) TAN/WHTTAN/BLK Speedometer Tachometer Temperature/Oil Warning Panel Volt Meter 51819 To 12V a b d c e 90-857046 AUGUST 1998 Page 2D-11 WIRING DIAGRAMS NOTE:Refer to individual oil pressure gauge instructions for proper installation procedures for installing gauge in boat. 1. Install LIGHT BLUE sensor lead to oil pressure gauge as shown. NOTE:Normal oil pressure readings will be as follows: Outboard at normal operating temperature – • Wide-Open Throttle - 30-60 psi (207-414 kPa) • Minimum Oil Pressure @ W.O.T. - No Less than 10 psi (69 kPa) • Oil Pressure @ Idle - 5-10 psi (34-69 kPa) NOTE: Cold engine oil pressure readings will be approximately 10% higher. Oil Pressure Wiring Diagram SEND 12V GNDLT 53771 Page 2D-12 90-857046 AUGUST 1998 WIRING DIAGRAMS QSI Gauge Wiring Diagrams Tachometer Wiring Diagram Tachometer dial on back side of case must be set to position number 4. WIRING DIAGRAM A Use this wiring diagram when using a separate light switch for instrument lighting. 51106 cb e d a a-PURPLE or WHITE - Connect to Positive (+) 12 Volt b-Light Switch Wire - 12 Volt c-Position Light Bulb to the Switched Position d-BLACK - Connect to Negative (-) Ground e-GRAY or BROWN Wire WIRING DIAGRAM B Use this wiring diagram when instrument lighting is wired directly to the ignition key switch. (Instrument lights are on when ignition key switch is turned on.) 51106 b d c a a-PURPLE or WHITE - Connect to Positive (+) 12 Volt b-Position Light Bulb to the Unswitched Position c-BLACK - Connect to Negative (-) Ground d-GRAY or BROWN Wire 90-857046 AUGUST 1998 Page 2D-13 WIRING DIAGRAMS Water Temperature Gauge WIRING DIAGRAM A Use this wiring diagram when using a separate light switch for instrument lighting. SEND c b e d a a-PURPLE - Connect to Positive (+) 12 Volt b-Light Switch Wire - 12 Volt c-Position Light Bulb to the Switched Position d-BLACK - Connect to Negative (-) Ground e-TAN - Connect to TAN lead located at the tachometer receptacle on Com mander Side Mount Remote Control or TAN lead coming from Accessary Ignition/ Choke Assembly. WIRING DIAGRAM B Use this wiring diagram when instrument lighting is wired directly to the ignition key switch. (Instrument lights are on when ignition key is turned on). 51105 SEND b d c a a-PURPLE - Connect to Positive (+) 12 Volt b-Position Light Bulb to the Unswitched Position c-BLACK - Connect to Negative (-) Ground d-TAN - Connect to TAN lead located at the tachometer receptacle on Commander Side Mount Remote Control or TAN lead coming from Accessary Ignition/ Choke Assembly. Page 2D-14 90-857046 AUGUST 1998 WIRING DIAGRAMS Route TAN lead on starboard side of engine to engine/remote control harness. Connect as shown. IMPORTANT: Tape back and isolate any unused wiring harness leads. 28086 a b a-Lead from Temperature Sender b-Engine/Remote Control Harness Engine Synchronizer Wiring Diagram LIGHT BULB POSITION A Use this position when using a separate light switch for instrument lighting. SEND 51105 a b a-Light Switch Wire - 12 Volt b-Position Light Bulb to the Unswitched Position LIGHT BULB POSITION B Use this position when instrument lighting is wired directly to the ignition key switch. (Instrument lights are on when ignition key switch is turned on). SEND 51106 a a-Position Light Bulb to the Switched Position 90-857046 AUGUST 1998 Page 2D-15 WIRING DIAGRAMS Synchronizer wiring can be accomplished two different ways as an option to the user. Wiring Diagram – Gauge needle to point toward slow running engine 52566 a b c d a-Tachometer - Starboard Engine b-Synchronizer Gauge c-Tachometer - Port Engine d-Synchronizer Box Wiring Diagram – Gauge needle to point toward fast running engine 52565 a b c d a-Tachometer - Starboard Engine b-Synchronizer Gauge c-Tachometer - Port Engine d-Synchronizer Box Page 2D-16 90-857046 AUGUST 1998 WIRING DIAGRAMS 90-857046 AUGUST 1998 Page 2D-17 CLEANING GAUGES Clean gauge by washing with fresh water to remove sand and salt deposits. Wipe off with a soft cloth moistened with water. The gauge may be scored or damaged if wiped with abrasive material (sand, saline or detergent compounds, etc.) or washed with solvents such as trichloroethylene, turpentine, etc. 2 Function Gauge 1. Route extension harness thru grommet opening. Connect TAN/WHITE and TAN/ BLACK of harness to TAN/WHITE and TAN/BLACK wires on engine harness. a b a - Grommet Opening b - TAN/WHITE and TAN/BLACK WIRES ON ENGINE HARNESS LT. BLU TAN/WHT TAN/BLK c b a BLK BLK a - Harness Extension Plugging Into Engine Harness b - Oil Pressure Sensor c - Engine Temperature Sensor WIRING DIAGRAMS Page 2D-18 90-857046 AUGUST 1998 Remote Wiring Harness Connection to Engine Electric Start Remote Control Model 1. Route the remote wiring harness to the back of the engine block as shown. a a - Remote Wiring Harness 2. Connect wiring. Place harness into the holder. GRN/WHT BLU/WHT BRN/WHT TAN BLU/WHT GRN/WHT a b a - Power Trim Connections b - Holder – Place Harness Into Holder WIRING DIAGRAMS Remote Key 1. Connect the remote key harness and engine harness, secure harness in holder. BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White 1 2 3 4 5 6 7 8 YEL = Yellow LT = Light DRK = Dark – + 1 2 3 4 5 6 7 8 PPL PPL BLK YEL/RED BLK/YEL RED YEL/BLK PPL TAN d e BLK_YELPPLYEL_BLKTANBLKYEL_REDRED a b c f a-Keyswitch Assembly Transom Mount b-Keyswitch c-Horn d-Remote Key Harness Connector e-Engine Harness Connector f-Harness Connector Holder 90-857046 AUGUST 1998 Page 2D-19 WIRING DIAGRAMS Power Trim Switch Wiring Diagram DN UP DN UP BLU/WHT GRN/WHT RED LT. BLU/WHT LT. GRN/WHT RED RED LT. GRN/WHT RED LT. BLU/WHT GRN = Green BLU = Blue RED = Red WHT = White a b a-Trim Switch b-Starter Relay Page 2D-20 90-857046 AUGUST 1998 FUEL PUMP FUEL SYSTEM Section 3A - Fuel Pump Table of Contents Table of Contents . . . . . . . . . . . . . . . . . . . . . . . 3A-1 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-2 Fuel Pump Operation . . . . . . . . . . . . . . . . . . . . 3A-4 Fuel Pump Removal . . . . . . . . . . . . . . . . . . . . . 3A-5 Specifications Fuel Pump Disassembly . . . . . . . . . . . . . . . . . 3A-6 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . 3A-7 Fuel Pump Reassembly . . . . . . . . . . . . . . . . . . 3A-8 Fuel Pump Installation . . . . . . . . . . . . . . . . . . . 3A-10 3 A 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 90-857046 AUGUST 1998 Page 3A-1 FUEL PUMP FUEL PUMP 2 1 2 3 4 5 6 7 8 9 10 11 12 1314 15 16 17 18 19 20 21 22 2 2 2 2 11 10 12 23 Page 3A-2 90-857046 AUGUST 1998 FUEL PUMP FUEL PUMP REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 FUEL FILTER 2 7 STA–STRAP 3 1 TUBING (14 IN.) 4 1 TUBING (19 IN.) 5 1 FUEL CONNECTOR – 1 O RING 6 1 FUEL PUMP 7 4 SCREW Drive Tight 8 1 O RING 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 J CLIP 23 1 COWL DEFLECTOR 90-857046 AUGUST 1998 Page 3A-3 FUEL PUMP Fuel Pump 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 two outlets on the fuel pump help 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, whether plastic, metal, or fiberglass, fuel lines, primer bulbs, fittings, swelling, and must be inspected for corrosion. Any sign of leakage or deterioration necessitates replacement before further engine operation. Page 3A-4 90-857046 AUGUST 1998 FUEL PUMP Fuel Pump Removal 1. Cut sta-straps and remove inlet and outlet hoses. 2. Remove fuel pump mounting bolts and cowl deflector. 3. Separate fuel pump from cylinder head cover. a c c b e d a-Outlet Fuel Hose b-Inlet Fuel Hose c-Mounting Bolts (2) d-Cowl Deflector e-Cap On Unused Outlet Fitting 90-857046 AUGUST 1998 Page 3A-5 FUEL PUMP Fuel Pump Disassembly 1. Remove screws to separate pump cover, cover seal, and diaphragm, from pump body. 28378 c d b a e f a-Screws (4) b-Pump Cover c-Cover Seal d-Diaphragm e-Pump Body f-Nuts (4) 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. 53617 a a-Pin Page 3A-6 90-857046 AUGUST 1998 FUEL PUMP Cleaning/Inspection/Repair 1. Inspect fuel filter for cracks/clogs, replace if necessary. 2. Inspect the check valves for damage, replace if necessary. 3. Inspect springs for damage, replace if necessary. 4. Inspect cover seal and diaphragm, replace if damaged. ab a-Cover Seal b-Diaphragm 90-857046 AUGUST 1998 Page 3A-7 FUEL PUMP 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. a b c a-Pump Body b-Slots c-Pin 4. Rotate plunger 90° to offset slots. Page 3A-8 90-857046 AUGUST 1998 a b a b FUEL PUMP 53615 a-Slots Aligned b-Slots Offset 5. Assemble diaphragm, seal, and cover, to pump body, secure with screws and nuts. NOTE:Seal installs in one direction only. c d b a e 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 53620 a-O-ring 90-857046 AUGUST 1998 Page 3A-9 FUEL PUMP Page 3A-10 90-857046 AUGUST 1998 Fuel Pump Installation 1. Secure fuel pump and cowl deflector to cylinder head cover with 2 bolts. 2. Connect fuel lines to pump and secure with sta-straps. a f d c e f g b e a - Outlet Fuel Hose b - Inlet Fuel Hose c - Cap on Unused Outlet d - Cowl Deflector e - J-Clip f - Mounting Bolts (2)-M6x30 g - Cable Ties (3) Fuel Pump Mounting Bolt Torque 75 lb. in. (8.5 N·m) CARBURETOR FUEL SYSTEM Section 3B - Carburetor Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-2 Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-4 Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-6 Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-8 Carburetor Adjustments . . . . . . . . . . . . . . . . . . 3B-9 Float Level . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-9 Specifications Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-10 Carburetor Removal . . . . . . . . . . . . . . . . . . . . . 3B-11 Carburetor Disassembly . . . . . . . . . . . . . . . . . . 3B-12 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-16 Carburetor Reassembly . . . . . . . . . . . . . . . . . . 3B-18 Carburetor Installation . . . . . . . . . . . . . . . . . . . 3B-21 3 B CARBURETOR Idle rpm (Out Of Gear) Idle rpm (In Forward Gear) Wide Open Throttle rpm (WOT) Range Main Jet Size Pilot Jet Idle Jet Float Height 900 ± 25 rpm 800 ±25 rpm 5500–6000 #98 #38 #42 0.47-0.63 in. (12.0-16.0 mm) 90-857046 AUGUST 1998 Page 3B-1 CARBURETOR Special Tools 1. Carburetor Scale P/N 91-36392. 2. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1. Page 3B-2 90-857046 AUGUST 1998 CARBURETOR Notes: 90-857046 AUGUST 1998 Page 3B-3 CARBURETOR Page 3B-4 90-857046 AUGUST 1998 FUEL LINES 1 2 3 5 6 7 4 8 1 5 5 5 5 5 5 5 5 1 4 CARBURETOR FUEL LINES REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 3 HOSE 2 1 HOSE 3 1 LINKAGE 4 3 BUSHING 5 12 CABLE TIE 6 1 HOSE 7 1 HOSE 8 1 PROTECTIVE SLEEVE 90-857046 AUGUST 1998 Page 3B-5 CARBURETOR Page 3B-6 90-857046 AUGUST 1998 CARBURETOR 2 3 4 6 7 21 23 9 10 11 12 15 14 16 17 20 18 25 26 27 24 13 22 1 5 1 1 2 5 8 2 2 18 18 20 19 17 20 19 21 19 28 29 CARBURETOR CARBURETOR REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in lb-ft Nm. 1 1 CARBURETOR (TOP) 1 CARBURETOR (CENTER) 1 CARBURETOR (BOTTOM) 2 10 SCREW 3 3 PLATE 4 3 GASKET 5 1 ENRICHENER 6 1 O RING 7 1 PLATE 8 3 JET (IDLE) 9 3 JET (SLOW) 10 3 RUBBER PLUG 11 3 JET (MAIN) 12 3 FLOAT VALVE 13 3 MAIN NOZZLE 14 3 FLOAT 15 3 FLOAT PIN 16 3 GASKET 1717 1 FLOAT BOWL (TOP) 2 FLOAT BOWL (CENTER/BOTTOM) 18 12 SCREW 19 3 DRAIN SCREW 20 3 WASHER 2121 2 SYNCHRONIZATION SCREW (TOP/CENTER) 1 STOP SCREW (BOTTOM) 22 2 SPRING (TOP/CENTER) 23 2 SPRING (TOP/CENTER) 24 1 SPRING (BOTTOM) 25 1 SPRING 26 1 PLUNGER 27 3 RUBBER, BELLOWS 28 3 PLUNGER RETAINING SCREW 29 3 PLUNGER ROD 90-857046 AUGUST 1998 Page 3B-7 CARBURETOR Page 3B-8 90-857046 AUGUST 1998 INTAKE 1 2 3 4 5 6 12 13 14 7 8 9 10 11 15 16 10 12 12 CARBURETOR INTAKE REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 6 SCREW 2 1 AIR INTAKE 3 3 O RING 4 1 PLATE 55 1 ISOLATOR (40) 1 ISOLATOR (30) 6 2 PLUG 7 1 SOUND ATTENUATOR 8 2 SCREW (M6 x 20) 9 2 BUSHING 10 6 STA-STRAP 11 3 SEAL 12 9 O RING 13 2 DOWEL PIN 14 6 SCREW (M6 x 25) 15 1 BREATHER HOSE 16 1 STA-STRAP 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. Float Height 0.47-0.63 in. (12.0-16.0 mm) 90-857046 AUGUST 1998 Page 3B-9 CARBURETOR Page 3B-10 90-857046 AUGUST 1998 Idle Speed NOTE: Outboard should be completely warmed up for the idle speed adjustment. 1. With the outboard in forward gear adjust idle speed screw to obtain the specified idle speed. a b a - Idle Speed Screw b - Phillips Head Screwdriver Idle Speed (Forward Gear) 800 ± 25 RPM CARBURETOR 90-857046 AUGUST 1998 Page 3B-11 Carburetor Removal 1. Disconnect auto enrichener wires, breather hose, and fuel supply lines. a b c a - Auto Enrichener Wires (Yellow) b - Breather Hose c - Fuel Supply Line CARBURETOR Page 3B-12 90-857046 AUGUST 1998 2. Remove intake and carburetor mounting bolts. a a b a - Intake Mounting Bolts (3)-M6x20 b - Carburetor Mounting Bolts (6) Carburetor Disassembly 1. Remove air intake and plate from carburetor assembly. a b c d e f a - Sound Attenuator b - Screw (6) c - Air Intake d - Carburetor Assembly e - Plate f - Isolator CARBURETOR 90-857046 AUGUST 1998 Page 3B-13 2. Remove auto enrichener. a b c d a - Auto Enrichener b - Plate c - Screw d - O-Ring 3. Remove fuel lines and unsnap linkage. a b b b b b a - Linkage b - Fuel Lines CARBURETOR Page 3B-14 90-857046 AUGUST 1998 4. Remove float bowl. 5. Remove plunger, spring, and gasket. a b c d e f a - Screws (4) b - Float Bowl c - Plunger d - Spring e - Gasket f - Retaining Screw 6. Remove float, plug, nozzles and jets. a b c d e f g a - Screw b - Float Pin c - Float d - Plug e - Slow Jet f - Main Jet g - Main Nozzle CARBURETOR 7. Remove cover, gasket, and idle jet. a-Screws (3) b-Cover c-Gasket d-Idle jet a b c d 90-857046 AUGUST 1998 Page 3B-15 CARBURETOR Inspection 1. Inspect needle and piston valve. Replace if worn or damaged. 2. Measure auto enrichener resistance. Replace if out of specification. Auto Enrichener Resistance 15-25 W @ 68°F (20°C) 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. Page 3B-16 90-857046 AUGUST 1998 CARBURETOR 6. Inspect float, replace if cracked or damaged. 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, idle jet, slow jet and main nozzle. Clean if they are contaminated. 8. Inspect needle valve, replace if end is worn or grooved. 28375 90-857046 AUGUST 1998 Page 3B-17 CARBURETOR Page 3B-18 90-857046 AUGUST 1998 Carburetor Reassembly 1. Install idle jet, gasket, and cover. a b c d a - Screws (3) b - Cover c - Gasket d - Idle jet 2. Install jets, nozzles, plug and float. a b c c b d e f g h a - Screw b - Float Pin c - Float d - Needle Valve e - Plug f - Slow Jet g - Main Jet h - Main Nozzle CARBURETOR 3. Install plunger and spring. 4. Install gasket bowl and float. a b c d e f a-Screws (4) b-Float Bowl c-Plunger d-Spring e-Gasket f-Retaining Screw 5. Install fuel lines and throttle linkage. Secure lines with cable ties where shown. 90-857046 AUGUST 1998 Page 3B-19 CARBURETOR Page 3B-20 90-857046 AUGUST 1998 a b b b b b a - Linkage b - Fuel Lines 6. Install auto enrichener. a b c d a - Auto Enrichener b - Plate c - Screw d - O-Ring 7. Install air intake and plate onto carburetor assembly. CARBURETOR 90-857046 AUGUST 1998 Page 3B-21 a b c d e f a - Sound Attenuator b - Screw (6) c - Air Intake d - Carburetor Assembly e - Plate f - Isolator CARBURETOR Page 3B-22 90-857046 AUGUST 1998 Carburetor Installation 1. Install intake and carburetor mounting bolts. a a b a - Intake Mounting Bolts (3)-M6x20 b - Carburetor Mounting Bolts (6) Carburetor Mounting Bolt Torque 70 lb. in. (8 N·m) CARBURETOR 90-857046 AUGUST 1998 Page 3B-23 2. Connect auto enrichener wires, breather hose and fuel supply lines. a b c a - Auto Enrichener Wires (Yellow) b - Breather Hose c - Fuel Supply Lines NOTE: Carburetor synchronization is required after rebuilding carburetors. Refer to section 2C, Timing/Synchronizing/Adjusting. EMISSIONS FUEL SYSTEM Section 3C – Emissions Table of Contents Exhaust Emissions Standards . . . . . . . . . . . . 3C-2 Stratified Vs Homogenized Charge . . . . . . . . 3C-4 What Are Emissions? . . . . . . . . . . . . . . . . . 3C-2 Homogenized Charge . . . . . . . . . . . . . . . . . 3C-4 Hydrocarbons – HC . . . . . . . . . . . . . . . . . . . 3C-2 Stratified Charge . . . . . . . . . . . . . . . . . . . . . 3C-5 Carbon Monoxide – CO . . . . . . . . . . . . . . . 3C-2 Emissions Information . . . . . . . . . . . . . . . . . . . 3C-6 Oxides of Nitrogen - NOx . . . . . . . . . . . . . . 3C-2 Manufacturer’s Responsibility: . . . . . . . . . 3C-6 Controlling Emissions . . . . . . . . . . . . . . . . . 3C-2 Dealer Responsibility: . . . . . . . . . . . . . . . . . 3C-6 Stoichiometric (14.7:1) Air/Fuel Ratio . . . 3C-3 Owner Responsibility: . . . . . . . . . . . . . . . . . 3C-6 Outboard Hydrocarbon EPA Emission Regulations: . . . . . . . . . . . . 3C-7 Emissions Reductions . . . . . . . . . . . . . . . . . . . 3C-3 Decal Location for 1999 Models: . . . . . . . 3C-9 8 1/3% # Per Year Over 9 Model Years . . 3C-3 3 C 90-857046 AUGUST 1998 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 90-857046 AUGUST 1998 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 90-857046 AUGUST 1998 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 90-857046 AUGUST 1998 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. 90-857046 AUGUST 1998 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. Exceptions: • Carburetor jets may be changed for high altitude use in accordance with factory recommendations. • Single engine exceptions may be allowed with permission from the EPA for racing and testing. Page 3C-6 90-857046 AUGUST 1998 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 90-857046 AUGUST 1998 Page 3C-7 EMISSIONS 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). JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC Emission Control Information 1999 PART # 37–856984 22 This engine conforms to 1998 Model Year U.S. EPA regulations for marine SI engines. Idle Speed (in gear): 775 RPM Timing: Not Adjustable Standard Spark Plug: NGK DPR6EA-9 Gap: .035, Valve Clearance (Cold) mm Intake: 0.15-0.25 Exhaust: 0.25-0.35 Refer to Owners Manual for required maintenance. Family: WM9XM.747220 FEL: 32.20 GM/KW-HR 747 cc 30-40 HP 4-Stroke e ba k j i d f g h c a-Spark Ignition (SI) b-Cubic Centimeter c-Model year of engine and production decal part number d-Idle Speed (In Gear) e-Timing specifications when adjustable f-Recommended spark plug for best engine performance g-Valve Clearance (Four Stroke engines only) h-Engine Horsepower rating i-Month of production (Boxing month will punched) j-FEL: Represents (Mercury Marine) statement of the maximum emissions output for the engine family k-Family example W M9X M. 747 2 2 0 Model Year Regulation Application Unspecified W=1998 M=Marine 1=PWC X=1999 2=OB Manufacturer Displacement Technology type Mercury Marine Liter 1=Existing Cubic Inch 2=New Page 3C-8 90-857046 AUGUST 1998 EMISSIONS Decal Location for 1999 Models: Model Production Part No. Service Part No. Location on Engine 1999 Merc/Mar 747 cc 37-856984 22 37-856985 22 Flywheel/Rewind Cover 90-857046 AUGUST 1998 Page 3C-9 CYLINDER HEAD Section 4A - Cylinder Head Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . 4A-27 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-5 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-31 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-6 Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . 4A-33 Camshaft/Oil Pump . . . . . . . . . . . . . . . . . . . . . . 4A-8 Cylinder Head Reassembly . . . . . . . . . . . . . . . 4A-34 Intake/Exhaust Valves . . . . . . . . . . . . . . . . . . . 4A-10 Valve Installation . . . . . . . . . . . . . . . . . . . . . 4A-34 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-12 Camshaft Oil Seal Installation . . . . . . . . . . 4A-35 Valve Clearance . . . . . . . . . . . . . . . . . . . . . . 4A-12 Camshaft Installation . . . . . . . . . . . . . . . . . 4A-35 Preparing Cylinder Head for Removal . . . . . . 4A-18 Rocker Arm Shaft Assembly . . . . . . . . . . . 4A-37 Cylinder Head Removal . . . . . . . . . . . . . . . . . . 4A-19 Rocker Arm Shaft Installation . . . . . . . . . . 4A-38 Cylinder Head Disassembly . . . . . . . . . . . . . . 4A-22 Cylinder Head Gasket . . . . . . . . . . . . . . . . . 4A-39 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . 4A-25 Cylinder Head Installation . . . . . . . . . . . . . 4A-40 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-25 Cylinder Head Cover Installation . . . . . . . 4A-42 4 A 90-857046 AUGUST 1998 Page 4A-1 CYLINDER HEAD Specifications CAMSHAFT Camshaft Dimensions Intake “A” Exhaust “A” Intake “B” Exhaust “B” Run-out Limit Camshaft Bearing Diameter “b” A B b b b b 1.216 - 1.220 in. (30.89 - 30.99 mm) 1.216 - 1.220 in. (30.89 - 30.99 mm) 1.022 - 1.025 in. (25.95 - 26.05 mm) 1.022 - 1.025 in. (25.95 - 26.05 mm) 0.0039 in. (0.1 mm) 1.4541 - 1.4549 in. (36.935 - 36.955 mm) VALVE SPRING Free Length “a” Tilt Limit “b” Compressed Pressure (Installed) Intake Exhaust Tilt Limit (Intake & Exhaust) Dir. of Winding (Intake & Exhaust) a b 1.491-1.569 in. (37.85-39.85 mm) Less than 0.060 in. (1.7 mm) 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 90-857046 AUGUST 1998 CYLINDER HEAD 90-857046 AUGUST 1998 Page 4A-3 CYLINDER HEAD Warp Limit * Lines indicate straight edge measurement Camshaft Bore Inside Diameter “a” 56900 a a a a 56899 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 “A” “B” Valve Dimensions Head Diameter Face Width Seat Width “C” “D” Margin Thickness 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) Page 4A-4 90-857046 AUGUST 1998 CYLINDER HEAD 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 4. Valve Guide Reamer P/N 91-809497A1 5. Valve Spring Compressor P/N 91-809494A1 6. Valve Seat Cutter Kit (Obtain Locally). 90-857046 AUGUST 1998 Page 4A-5 CYLINDER HEAD Page 4A-6 90-857046 AUGUST 1998 CYLINDER HEAD 22 4 110 110 2 3 5 6 7 20 110 14 15 23 24 19 8 9 21 12 1 18 16 17 110 4-stroke Outboard Oil (92-828000A12) 25 26 27 28 29 30 10 11 31 13 CYLINDER HEAD CYLINDER HEAD REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m – –– 1 CYLINDER HEAD (ELECTRIC) 1 CYLINDER HEAD (MANUAL) 1 1 CYLINDER HEAD 2 6 GUIDE 3 6 CIRCLIP 4 3 ANODE 5 3 GROMMET 6 3 COVER 7 3 SCREW (M6 x 20) 70 8 8 1 BOLT 57 6.4 9 1 GASKET 10 3 BOLT 11 3 GASKET 12 1 OIL SEAL 13 5 PIPE PLUG 14 1 O RING 15 1 COVER 16 1 DECAL-Servicing Referral 17 1 DECAL-Engine Oil/Valve Clearance 18 1 GASKET 19 7 SCREW (M6 x 20) 70 8 20 4 SCREW (M6 x 25) 106 12 21 8 SCREW (M9 x 1.5 x 95) 34.7 47 22 2 DOWEL PIN 23 1 PLUG 24 1 O RING 25 1 BAFFLE PLATE 26 4 SCREW (M4 x 10) 27 1 ELBOW 28 1 BREATHER PIPE 29 1 BRACKET (HANDLE) 30 2 SCREW (M6 x 13) (HANDLE) 31 1 J CLAMP 90-857046 AUGUST 1998 Page 4A-7 CYLINDER HEAD Page 4A-8 90-857046 AUGUST 1998 CAMSHAFT/OIL PUMP 110 4-stroke Outboard Oil (92-828000A12) 110 110 51 51 Loctite 222 1 2 3 4 5 6 8 9 10 12 11 13 7 CYLINDER HEAD CAMSHAFT/OIL PUMP REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 SCREW (M8 x 40 x 1.25) 28 38 2 1 WASHER 3 1 BELT 4 1 GEAR-Driven 5 1 DOWEL PIN 6 1 CAMSHAFT (MANUAL) 7 1 CAMSHAFT (ELECTRIC) 8 1 PIN 9 1 OIL PUMP ASSEMBLY 10 1 O RING 11 1 O RING 12 1 O RING 13 4 SCREW (M6 x 35) 70 8 90-857046 AUGUST 1998 Page 4A-9 CYLINDER HEAD INTAKE/EXHAUST VALVES 110 4-stroke Outboard Oil (92-828000A12) Page 4A-10 90-857046 AUGUST 1998 CYLINDER HEAD INTAKE/EXHAUST VALVES REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 3 EXHAUST VALVE 2 3 INTAKE VALVE 3 6 SEAT–Valve Spring 4 6 SEAL–Valve Stem 5 6 VALVE SPRING–Outer 6 6 RETAINER–Valve Spring 7 12 KEY 8 6 ROCKER ARM 9 6 SCREW 10 6 NUT 120 10 13.5 11 1 ROCKER SHAFT 12 2 PLUG 13 1 BRACKET 14 1 BRACKET 15 1 SPRING 16 1 SPRING 17 4 SCREW (M8 x 30)160 160 13.3 18 90-857046 AUGUST 1998 Page 4A-11 CYLINDER HEAD Page 4A-12 90-857046 AUGUST 1998 Adjustments Valve Clearance WARNING Engine could possibly start when turning flywheel during adjustment. To prevent this type of accidental engine starting and possible serious injury, always remove spark plug leads from spark plugs. 1. Remove components: a. Flywheel cover/manual starter. NOTE: Refer to section 8 for removal of manual starter. a b a - Bolts (4) - M6x25 b - Flywheel Cover CYLINDER HEAD 90-857046 AUGUST 1998 Page 4A-13 b. Inlet and outlet fuel pump hoses. c. Breather hose. c b a a - Inlet Hose b - Outlet Hose c - Breather Hose d. Cylinder head cover. a b a - Bolts (7) - M6x20 b - Cylinder Head Cover CYLINDER HEAD Page 4A-14 90-857046 AUGUST 1998 2. Measure valve clearance with a feeler gauge. Adjust if out of specification. Valve Clearance (Cold) Intake 0.006 - 0.010 in. (0.15 - 0.25 mm) Exhaust 0.010 - 0.014 in. (0.25 - 0.35 mm) a b d c a - Lock nut b - Adjusting Screw c - Intake Valve Clearance d - Exhaust Valve Clearance NOTE: When loosening lock nuts, hold the adjusting screw with a screw driver to prevent it from moving. CYLINDER HEAD 90-857046 AUGUST 1998 Page 4A-15 3. Perform the following adjustment steps: a. Turn the driven gear and align the “1 / D” mark on the driven gear with the “D” mark on the cylinder block. b. Adjust the intake and exhaust valve clearance for cylinder #1. c. Turn the driven gear 120° clockwise and align the “D” mark on the driven gear with the “D” on the cylinder block. d. Adjust the intake and exhaust valve clearance for cylinder #2 e. Turn the driven gear 120° clockwise and align the “D” mark on the driven gear with the “D” on the cylinder block. f. Adjust the intake and exhaust valve clearance for cylinder #3 a c 57191 b d a - Cylinder Block “D” Mark b - Driven Gear “1 or D” Mark (Cylinder #1) c - Driven Gear “D” Mark at 120° (Cylinder #2) d - Driven Gear “D” Mark at 240° (Cylinder #3) 4. Tighten the lock nuts. NOTE: When tightening lock nuts, hold the adjusting screw with a screw driver to prevent it from moving. Lock Nut Torque 120 lb. in. (13.5 N·m) CYLINDER HEAD Page 4A-16 90-857046 AUGUST 1998 5. Install cylinder head cover. a b a - Cylinder Head Cover b - Bolts (7) - M6x20 Cylinder Head Cover Bolt Torque 70 lb. in. (8 N·m) 6. Install inlet and outlet fuel pump hoses. 7. Install breather hose. NOTE: Secure fuel and breather hoses with cable ties. c b a a - Inlet Hose b - Outlet Hose c - Breather Hose CYLINDER HEAD 90-857046 AUGUST 1998 Page 4A-17 8. Install flywheel cover/manual starter. NOTE: Refer to section 8 for installation of manual starter. a b a - Flywheel Cover b - Bolts (4) - M6x25 Flywheel Cover Bolt Torque 45 lb. in. (5.1 N·m) CYLINDER HEAD Page 4A-18 90-857046 AUGUST 1998 Preparing Cylinder Head for Removal 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. Flywheel cover/manual starter. NOTE: Refer to section 8 for removal of manual starter. a b a - Bolts (4) - M6x25 b - Flywheel Cover CYLINDER HEAD 90-857046 AUGUST 1998 Page 4A-19 2. Inlet and outlet fuel pump hoses. 3. Breather hose. c b a a - Inlet Hose b - Outlet Hose c - Breather Hose Cylinder Head Removal 1. Cylinder head cover. a b a - Bolts (7) - M6x20 b - Cylinder Head Cover CYLINDER HEAD Page 4A-20 90-857046 AUGUST 1998 2. Remove timing belt from driven sprocket. a a - Timing Belt 3. Remove screws. a b a - Screws (6)-M6x25 b - Screws (4)-M6x25 CYLINDER HEAD 90-857046 AUGUST 1998 Page 4A-21 4. Remove cylinder head screws. a a - Screws (8)-M9x95 5. Separate cylinder head from cylinder block. NOTE: Cylinder head gasket is not reusable. a b a a - Gasket (Discard) b - Dowel Pins (2) CYLINDER HEAD Page 4A-22 90-857046 AUGUST 1998 Cylinder Head Disassembly NOTE: Refer to section 4C Lubrication for oil pump removal. 1. Hold driven gear using tool and loosen screw. Remove screw, washer, driven gear and dowel pin. 91-83163M a b c d e a - Holder 91-83163M b - Driven Gear c - Screw-M8x40 d - Washer e - Dowel Pin CYLINDER HEAD 90-857046 AUGUST 1998 Page 4A-23 2. Remove screws securing rocker arm to cylinder head. Remove rocker arm and retainers. a a a a c b d a - Screws (4)-M8x30 b - Retaining Bolt c - Gasket d - Rocker Arm Assembly CYLINDER HEAD Page 4A-24 90-857046 AUGUST 1998 3. Remove oil seal and camshaft. a b a - Oil Seal b - Camshaft 4. Remove valve springs with spring compressor. 91-809494A1 a a - Valve Spring Compressor P/N 91-809494A1 CYLINDER HEAD Cleaning/Inspection/Repair 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 90-857046 AUGUST 1998 Page 4A-25 CYLINDER HEAD Page 4A-26 90-857046 AUGUST 1998 3. Measure the cam lobe length (a) and width (b). 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). a 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 90-857046 AUGUST 1998 Page 4A-27 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. Cylinder Head Warpage Limit 0.004 in. (0.1 mm) VALVE GUIDE INSPECTION 1. Measure the valve guide bore (a). If valve guide wear is out of specification, replace the valve guide. a Valve Guide Inside Diameter Intake Valve 0.2165 - 0.2170 in. Exhaust Valve (5.500 - 5.512 mm) CYLINDER HEAD 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) 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-28 90-857046 AUGUST 1998 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. Reface valve seat, use a 60°, 45°, 15° valve seat cutter. NOTE: When twisting cutter, keep an even downward pressure to prevent chatter marks. a Valve Seat Width Specification “a” Intake Valve 0.035 - 0.043 in. (0.9 - 1.1 mm)Exhaust Valve NOTE:If resurfacing the valve seats is required, resurface the valve seats to the specified angles shown in chart following. a b c Valve Seat Angle Specifications a 15° b 45° c 60° 90-857046 AUGUST 1998 Page 4A-29 CYLINDER HEAD Condition: The valve seat is centered on valve face but it is too wide. Valve Seat Cutter Set Desired Results Use LightlLightly 15° Cutter To reduce valve seat idthwidth60° Cutter 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 t 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 achie its Width achieve its Width45° Cutter Page 4A-30 90-857046 AUGUST 1998 CYLINDER HEAD 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 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) 90-857046 AUGUST 1998 Page 4A-31 CYLINDER HEAD 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) 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) Page 4A-32 90-857046 AUGUST 1998 CYLINDER HEAD 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) 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) 90-857046 AUGUST 1998 Page 4A-33 CYLINDER HEAD 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 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 Page 4A-34 90-857046 AUGUST 1998 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 bolt. Tighten bolt to the specified torque. a a-Camshaft Retaining Bolt Camshaft Retaining Bolt Torque 57 lb. in. (6.4 N·m) 90-857046 AUGUST 1998 Page 4A-35 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 bolt. Tighten bolt 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 b a d c a-Alignment Pin b-Driven Gear c-Washer d-Bolt Driven Gear Bolt Torque (d) 28 lb. ft. (38 N·m) Page 4A-36 90-857046 AUGUST 1998 CYLINDER HEAD 90-857046 AUGUST 1998 Page 4A-37 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. 4. Install brackets on rocker shaft as shown. a c b 110 4-Stroke Outboard Oil (92-828000A12) 110 a - Rocker Shaft b - Rocker Arms (6) c - Brackets (4) CYLINDER HEAD Page 4A-38 90-857046 AUGUST 1998 Rocker Arm Shaft Installation 1. Install the rocker arm shaft assembly as shown. Tighten bolts to the specified torque. NOTE: Leave all adjustment screws loose at this time. a a 110 4-Stroke Outboard Oil (92-828000A12) 110 a - Mounting Bolts (4)-M8x30 Rocker Arm Shaft Mounting Bolt Torque 160 lb. in. (18 N·m) CYLINDER HEAD 90-857046 AUGUST 1998 Page 4A-39 Cylinder Head Gasket 1. Install new cylinder head gasket and dowel pins. a b a a - Gasket (New) b - Dowel Pins (2) CYLINDER HEAD Page 4A-40 90-857046 AUGUST 1998 Cylinder Head Installation 1. Apply engine oil to the threads of each bolt and seat surface. Torque bolts in sequence and in two steps. a 110 4-Stroke Outboard Oil (92-828000A12) 110 1 2 3 4 5 6 7 8 a - Screws (8)-M9x95 Cylinder Head Bolt Torque Qty. 8 (M9x95) 1st: 17 lb. ft. (23 N·m) 2nd: 34.7 lb. ft. (47 N·m) CYLINDER HEAD 90-857046 AUGUST 1998 Page 4A-41 2. Fasten cylinder head with bolts shown. Torque bolts in sequence and in two steps. b a a - Screws (6)-M6x25 b - Screws (4)-M6x25 Cylinder Head Bolt Torque Cyl. Head Flange Bolts Qty. 4 (M6x25) 1st: 53 lb. in. (6 N·m) 2nd: 106 lb. in. (12 N·m) Carburetor Flange Bolts Qty. 6 (M6x25) 75 lb. in. (8.5 N·m) CYLINDER HEAD Page 4A-42 90-857046 AUGUST 1998 Cylinder Head Cover Installation 1. Install cover o-ring into groove. 2. Install cylinder head cover. Secure cylinder head cover with bolts. b a c 110 4-Stroke Outboard Oil (92-828000A12) 110 a - O-Ring b - Cylinder Head Cover c - Bolts (7) - M6x20 Cylinder Head Cover Bolt Torque 70 lb. in. (8 N·m) 3. Refer to section 2A for installation of the timing belt. 4. Install inlet and outlet fuel pump hoses. 5. Install breather hose. NOTE: Secure fuel and breather hoses with cable ties. c b a a - Inlet Hose b - Outlet Hose c - Breather Hose CYLINDER HEAD 90-857046 AUGUST 1998 Page 4A-43 6. Install flywheel cover/manual starter. NOTE: Refer to section 8 for installation of manual starter. a b a - Flywheel Cover b - Bolts (4) - M6x25 Flywheel Cover Bolt Torque 45 lb. in. (5.1 N·m) CYLINDER BLOCK/CRANKCASE POWERHEAD Section 4B - Cylinder Block/Crankcase Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-2 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-19 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-3 Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-20 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-4 Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . 4B-20 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-6 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-21 Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . 4B-8 Crankcase and Bearings . . . . . . . . . . . . . . 4B-21 Preparation for Powerhead Removal . . . . . . . 4B-9 Connecting Rod Oil Clearance . . . . . . . . . 4B-25 Tiller Handle Models . . . . . . . . . . . . . . . . . . 4B-10 Installing Connecting Rod Bearings . . . . . 4B-27 Powerhead Removal . . . . . . . . . . . . . . . . . . . . 4B-11 Powerhead Reassembly . . . . . . . . . . . . . . . . . 4B-28 Removing Powerhead Components . . . . . . . 4B-11 Piston Reassembly . . . . . . . . . . . . . . . . . . . 4B-28 Ignition Components . . . . . . . . . . . . . . . . . . 4B-11 Piston Installation . . . . . . . . . . . . . . . . . . . . 4B-30 Charging/Starting System Components . 4B-12 Crankcase and Crankshaft Installation . . 4B-30 Fuel Components . . . . . . . . . . . . . . . . . . . . 4B-12 Crankcase Cover Installation . . . . . . . . . . . 4B-33 Harness and Battery Cable Removal . . . . 4B-12 Thermostat/Exhaust Cover Installation . . 4B-35 Cylinder Head Removal . . . . . . . . . . . . . . . 4B-12 Ignition Components . . . . . . . . . . . . . . . . . . 4B-36 Powerhead Disassembly . . . . . . . . . . . . . . . . . 4B-12 Charging/Starting System Components . 4B-36 Thermostat and Exhaust Cover Removal 4B-12 Fuel Components . . . . . . . . . . . . . . . . . . . . 4B-36 Crankcase and Crankshaft Removal . . . . 4B-13 Harness and Battery Cable Installation . . 4B-36 Piston Disassembly . . . . . . . . . . . . . . . . . . . 4B-15 Powerhead Installation . . . . . . . . . . . . . . . . . . . 4B-36 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . 4B-16 Following Powerhead Installation . . . . . . . . . . 4B-37 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-16 Tiller Handle Models . . . . . . . . . . . . . . . . . . 4B-38 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-18 4 B 90-857046 AUGUST 1998 Page 4B-1 CYLINDER BLOCK/CRANKCASE Specifications CYLINDER BLOCK Type Displacement Number of Cylinders 4 Stroke Cycle – Over Head Camshaft 45.6 cu. in. (747cc) 3 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. (0.25 mm) Oversize-0.020 in. (0.50 mm) 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 - 0.03 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) 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) 0.0018 in. (0.046 mm) NOTE:Manual start models are equipped with compression relief mechanism which will not allow compression testing. Page 4B-2 90-857046 AUGUST 1998 CYLINDER BLOCK/CRANKCASE Special Tools 1. Oil Filter Wrench (P/N 91-802653) 2. Flywheel Holder (P/N 91-83163M) 3. Flywheel Puller (P/N 91-83164M) 4. Piston Ring Compressor (P/N FT2997) 5. Powerhead Stand (P/N 91-855662A1) 6. Piston Ring Expander (P/N 91-24697) 90-857046 AUGUST 1998 Page 4B-3 CYLINDER BLOCK/CRANKCASE CRANKSHAFT 10 110 110 110 110 110 1 2 3 4 5 67 8 9 11 12 13 14 15 14 110 4-stroke Outboard Oil (92-828000A12) Page 4B-4 90-857046 AUGUST 1998 CYLINDER BLOCK/CRANKCASE CRANKSHAFT REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 11 1 CRANKSHAFT 1 CRANKSHAFT (BIGFOOT) 2 1 KEY 3 1 KEY 4 1 OIL SEAL 5 1 OIL SEAL 6 3 CONNECTING ROD 7 6 BOLT 150 12.5 17 8 6 BEARING (BROWN) 6 BEARING (BLACK) 6 BEARING (BLUE) 9 3 PISTON (STANDARD) AR PISTON (.25 O/S) AR PISTON (.50 O/S) 10 3 PISTON RING (TOP) (STANDARD) AR PISTON RING (TOP) (.25mm O/S) AR PISTON RING (TOP) (.50mm O/S) 11 3 PISTON RING (2 ND.) (STANDARD) AR PISTON RING (2 ND.) (.25mm O/S) AR PISTON RING (2 ND.) (.50mm O/S) 12 3 PISTON OIL RING (STANDARD) 3 PISTON OIL RING (.25mm O/S) 3 PISTON OIL RING (.50mm O/S) 13 3 PISTON PIN 14 6 RETAINER 15 1 GEAR-Drive 90-857046 AUGUST 1998 Page 4B-5 CYLINDER BLOCK/CRANKCASE Page 4B-6 90-857046 AUGUST 1998 CYLINDER BLOCK 110 4-stroke Outboard Oil (92-828000A12) 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 25 26 27 28 29 3 21 19 21 9 Loctite Pipe Sealant W/Teflon (92-88504) 12 Loctite 514 Gasket Eliminator 3 23 24 A – TO TELL-TALE B = TO FITTING IN ADAPTOR PLATE CYLINDER BLOCK/CRANKCASE CYLINDER BLOCK REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 11 1 CYLINDER BLOCK 1 CYLINDER BLOCK (BIGFOOT) 2 2 DOWEL PIN 3 3 PLUG 4 1 PIPE PLUG (1/2-14) 5 1 PIPE PLUG (3/4-14) 6 8 BEARING (BROWN) 8 BEARING (BLACK) 8 BEARING (BLUE) 7 1 NIPPLE 29.5 40 8 8 SCREW (M8 x 1.25 x 82) 264 22 30 9 8 SCREW (M6 x 35) 106 8.8 12 10 1 GASKET 11 1 OIL FILTER 70 8 12 1 GASKET 13 1 EXHAUST COVER 14 1 DECAL-EPA Label (1999) 15 1 PIPE PLUG 16 1 THERMOSTAT 17 1 GASKET 18 1 COVER 19 10 SCREW (M6 x 35) 106 8.8 12 20 1 ELBOW 21 3 STA STRAP 22 1 TUBING (11 IN.) 23 1 TEMPERATURE SENSOR 24 1 O RING 25 1 LIFTING EYE 26 1 SCREW (M8 x 35) 210 17.5 24 27 1 PLUG-Serial Number 28 1 HOSE (18 IN.) 29 1 J CLIP 90-857046 AUGUST 1998 Page 4B-7 CYLINDER BLOCK/CRANKCASE Torque Sequence Exhaust Cover 1 2 34 5 6 78 9 10 1112 13 14 1516 Crankcase Cover Page 4B-8 90-857046 AUGUST 1998 CYLINDER BLOCK/CRANKCASE 90-857046 AUGUST 1998 Page 4B-9 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 b a - Screws (6) b - Screw M6x60 4. Disconnect vent hose. a a - Vent Hose CYLINDER BLOCK/CRANKCASE Page 4B-10 90-857046 AUGUST 1998 5. Disconnect inlet hose from fuel pump. a a - Inlet Fuel Hose 6. Push retainer up and slide over to disengage the vertical shift shaft. a 1 2 a - Retainer Tiller Handle Models 1. Refer to Tiller Handle Section 7B for removal of throttle cable, shift rod, and tiller handle wiring. CYLINDER BLOCK/CRANKCASE 90-857046 AUGUST 1998 Page 4B-11 Powerhead Removal 1. Remove powerhead mounting bolts. a a - Bolts (8) 2. Lift powerhead from drive shaft housing. Place powerhead on Powerhead Stand P/N 91-855662A1. 55773 91-855662A1 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 Coils e. ECM f. Crank Position Sensor g. Temperature Sensor CYLINDER BLOCK/CRANKCASE Page 4B-12 90-857046 AUGUST 1998 Charging and Starting System Components 1. Refer to Section 2B for removal of the following ignition components. a. Starter Motor b. Start Solenoid c. Voltage Regulator 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. Cylinder Head Removal 1. See Section 4A for cylinder head removal. Powerhead Disassembly Thermostat and Exhaust Cover Removal 1. Remove thermostat cover, gasket, and thermostat. 2. Remove exhaust cover and gasket. 3. Remove oil filter. a b d c e f g 91-802653 h g a - Bolts w/Washers (10)-M6x35 b - Thermostat Cover c - Gasket (Discard) d - Thermostat e - Exhaust Cover f - Gasket g - Oil Filter h - Oil Filter Wrench (91-802653) CYLINDER BLOCK/CRANKCASE 90-857046 AUGUST 1998 Page 4B-13 Crankcase and Crankshaft Removal 1. Remove crankcase cover and dowel pins. 56875 a b c d a - Bolts w/Washers (8)-M8x82 b - Bolts w/Washers (8)-M6x35 c - Crankcase Cover d - Dowel Pins (2) 2. Remove connecting rod caps. IMPORTANT: Note locations of connecting rod bolts, caps, rods, and pistons for reassembly. 56876 a b a - Bolt-Connecting Rod (6). Use 5/6 in. 12 point socket head. b - Connecting Rod Cap (3) CYLINDER BLOCK/CRANKCASE Page 4B-14 90-857046 AUGUST 1998 3. Remove crankshaft and oil seals. 56877 a b c a - Crankshaft b - Upper Oil Seal c - Lower Oil Seal NOTE: Do not interchange main bearings, re-install in their original locations. 4. Remove main bearing halves from crankcase cover and cylinder block. 56878 a b a - Main Bearing Halves-Crankcase Cover (4) b - Main Bearing Halves-Cylinder Block (4) CYLINDER BLOCK/CRANKCASE 90-857046 AUGUST 1998 Page 4B-15 5. Remove connecting rod/piston assembly. NOTE: Remove carbon ridge from the cylinder bore using a burr knife. Pistons should be taken out through the cylinder head side of block. 56879 a a - Connecting rod/piston assembly (3) Piston Disassembly NOTE: Disassemble each piston separately, make sure components are not mixed. 1. Remove piston pin clip and piston pin. Separate connecting rod from piston. a b c a d a - Piston Pin Clip (2) b - Piston Pin c - Connecting Rod d - Bearing CYLINDER BLOCK/CRANKCASE 2. Remove top and second ring. 3. Remove oil ring (bottom rail, top rail, and scraper). NOTE:Use piston ring expander tool (P/N 91-24697) to prevent rings from breaking. If reusing rings mark their location (piston #1, #2, or #3) for correct installation. ab c d 91-24697 a-Top Ring b-Second Ring c-Oil Ring d-Piston Cleaning/Inspection/Repair Thermostat 1. Inspect thermostat, replace if stuck or damaged. 2. Use Measurement Test following to measure: a. Valve opening temperature. b. Valve lift. Page 4B-16 90-857046 AUGUST 1998 CYLINDER BLOCK/CRANKCASE MEASUREMENT TEST 1. Tie a piece of thread (or other non-conductive material) onto the thermostat. 2. Suspend the thermostat in water. 3. Heat water slowly while observing the thermostat. Water Temperature Valve Lift Below 140° F (60° C) 0 in. (0 mm) Above 158° F (70° C) Minimum 0.12 in. (3 mm) 90-857046 AUGUST 1998 Page 4B-17 CYLINDER BLOCK/CRANKCASE Cylinder MEASURING CYLINDER BORE 1. Measure the cylinder bore diameter at three locations in both X and Y axis. 2. If the cylinder bore is beyond the standard limits listed in the tables below, it will be necessary to re-bore the cylinder to accept the oversize piston. NOTE:Measure at three locations (L1, L2, and L3) in both X and Y axis (D1-6). L1=0.8 in. (20 mm) L2=1.6 in. (40 mm) L3=2.4 in. (60 mm) 1. Inspect: a. Water jacket for mineral deposits/corrosion, clean if necessary. b. Inner surface for score marks, repair if necessary. 2. Measure bore diameter with a cylinder gauge, re-bore or replace if necessary. 55837 D1,2 D3,4 D5,6 L1 L2 L3 Cylinder Bore Specifications Bore Size Maximum Taper/Out-of-Round Standard Bore 2.5591 in. (65 mm) 0.003 in.(0.08 mm) Oversize Bore-0.10 in. (0.25 mm) 2.5689 in. (65.25 mm) 0.003 in.(0.08 mm) Oversize Bore-0.20 in. (0.50 mm) 2.5787 in. (65.5 mm) 0.003 in.(0.08 mm) NOTE: Taper=(Maximum of D1 or D2)–(Minimum of D5 or D6) Page 4B-18 90-857046 AUGUST 1998 CYLINDER BLOCK/CRANKCASE Piston 1. Inspect piston wall wear/damage, replace if necessary. 2. Measure the piston at a point 0.2 in (5.0 mm) from the bottom, replace if out of specification. b a a-Piston Diameter b-0.2 in. (5.0 mm) Piston Diameter “a” Piston Size Diameter Standard 2.5570 - 2.5578 in. (64.950 - 64.965 mm) Oversize-0.010 in. (0.50 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) 3. Measure piston to cylinder clearance. If out of specification examine piston and cylinder bore further to determine repair/replacement. a. Piston to Cylinder Clearance can be defined by: MBM–MPM=PCC where: MBM=Minimum Bore Measurement MPM=Maximum Piston Measurement PCC=Piston to Cylinder Clearance Piston to Cylinder Clearance 0.0014 - 0.0026 in. (0.035 - 0.065 mm) 90-857046 AUGUST 1998 Page 4B-19 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. Replace the pin and/or connecting rod as necessary. 3. Place the piston pin into the piston and check for free play. There should be no noticeable free play. Replace the pin and/or piston as necessary. Piston Rings PISTON RIND SIDE CLEARANCE 1. Measure piston ring side clearance. Replace piston and or piston rings if out of specification. Piston Ring Side Clearance Top 0.0008 - 0.0024 in. (0.02 - 0.06 mm) Middle 0.0008 - 0.0024 in. (0.02 - 0.06 mm) Page 4B-20 90-857046 AUGUST 1998 CYLINDER BLOCK/CRANKCASE PISTON RIND END GAP CLEARANCE 1. Measure piston ring end gap clearance. Replace piston ring if out of specification. NOTE:Ring should be level for measurement, push ring into bore with crown of 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) Crankshaft 1. Thoroughly clean crankshaft and inspect bearing surfaces. Replace crankshaft if bearing surfaces are pitted, scored, or discolored. 2. Measure run-out. Replace crankshaft if out of specification. 3. Clean oil holes in crankshaft. Crankshaft Run-out 0.0018 in. (0.046 mm) Crankcase and Bearings 1. Measure crankshaft main bearing clearance using the test below, replace the bearings as a set if out of specification (see Crankcase and Bearing Indication Marks). Main Bearing Clearance 0.0005 - 0.0017 in. (0.012 - 0.044 mm) 90-857046 AUGUST 1998 Page 4B-21 CYLINDER BLOCK/CRANKCASE Page 4B-22 90-857046 AUGUST 1998 CRANKSHAFT MAIN BEARING CLEARANCE MEASUREMENT 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. 3. Install main bearings halves into the cylinder block. 4. Install crankshaft. NOTE: Align each bearing projection with the notch in the cylinder block. a b c d a - Main Bearing Halves-Cylinder Block (4) b - Projection in Bearing c - Notch in Cylinder Block d - Crankshaft 5. Place a piece of plastigauge onto each crankshaft bearing surface. NOTE: Do not put plastigauge over the oil hole on the bearing surface of the crankshaft. a a - Plastigauge CYLINDER BLOCK/CRANKCASE 90-857046 AUGUST 1998 Page 4B-23 6. Install main bearing halves into the crankcase. NOTE: Align each bearing projection with the notch in the crankcase. a b c a - Main Bearing Halves-Crankcase (4) b - Projection in Bearing c - Notch in Crankcase 7. Install crankcase onto cylinder block. 8. Apply oil to the cover bolts and torque cover bolts in sequence and in two steps. IMPORTANT: Do not move crankshaft until measurement has been completed. 110 4-Stroke Outboard Oil (92-828000A12) 110 1 2 4 3 5 6 8 7 9 10 12 11 13 14 16 15 a 110 b a - Center Bolts M8x82 (8) b - Outer Bolts M6x35 (8) Crankcase Cover Bolt Torque Center Bolts Qty. 8 1st Torque: 11 lb. ft. (15 N·m) (M8x82) 2nd Torque: 22 lb. in. (30 N·m) Outer Bolts Qty. 8 1st Torque: 53 lb. in. (6 N·m) (M6x35) 2nd Torque: 106 lb. in. (12 N·m) CYLINDER BLOCK/CRANKCASE Page 4B-24 90-857046 AUGUST 1998 9. Remove the bolts and crankcase. 10. Measure the compressed plastigauge to check the main bearing clearance. Replace bearings if clearance is not within specification. a a - Compressed Plastigauge Main Bearing Clearance 0.0005 - 0.0017 in. (0.012 - 0.044 mm) SELECTING NEW MAIN BEARINGS 1. Locate the main bearing code letters on the cylinder block. #1 #2 #3 A B C a b #4 a - Main Bearing Code Letters (A, B, or C) b - Main Bearing Identification Color 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. Crankcase And Bearing Indication Marks Main Bearing Code Letter Main Bearing Color Code A Blue B Black C Brown CYLINDER BLOCK/CRANKCASE Connecting Rod Oil Clearance 1. Measure the connecting rod oil clearance using the measurement steps below, replace the connecting rod as a set if out of specification. Connecting Rod Oil Clearance 0.0008 - 0.0020 in. (0.020 - 0.052 mm) CONNECTING ROD OIL CLEARANCE MEASUREMENT 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. 2. Install the connecting rod to the crankshaft. a b a-Connecting Rod b-Driveshaft End of Crankshaft 3. Place a piece of plastigauge on the crankpin journals. a a-Plastigauge 90-857046 AUGUST 1998 Page 4B-25 CYLINDER BLOCK/CRANKCASE 4. Assemble the connecting rod caps onto their respective crankpins. NOTE:Make sure “Flat” sides of cap and rod are together and scribe marks match. a b c c a-Connecting Rod Cap b-Crankpin c-Scribe Marks on Cap and Rod 5. Tighten connecting rod bolts in alternating sequence and in two stages. IMPORTANT: Do not rotate connecting rod when checking clearance. Connecting Rod Bolt Torque 1st Torque: 53 lb. in. (6 N·m) 2nd Torque: 150 lb. in. (17 N·m) 6. Remove the connecting rod cap. 7. Measure the width of the compressed plastigauge on each crankpin to check the connecting rod oil clearance. Replace connecting rod as a set if oil clearance is not within specification. a a-Compressed Plastigauge SELECTING NEW CONNECTING ROD BEARINGS 1. Locate the 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. Page 4B-26 90-857046 AUGUST 1998 CYLINDER BLOCK/CRANKCASE 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 a A B C b a-Connecting Rod Bearing Code Letters b-Connecting Rod Bearing Identification Color Installing Connecting Rod Bearings IMPORTANT: Do not interchange used connecting rod bearings. Reinstall bearings in their original position. 1. Clean all the 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. a b a-Connecting Rod Bearings b-Fit the Locking Lugs into the Notches 90-857046 AUGUST 1998 Page 4B-27 CYLINDER BLOCK/CRANKCASE Powerhead Reassembly Piston Reassembly 1. Assemble connecting rod to piston, secure with piston pin and new piston pin clips. IMPORTANT: Make sure the “Y” mark on the connecting rod and the “UP” on piston crown are both facing the same direction. IMPORTANT: Piston pin clip should be installed with end gap facing opposite of pry point. c d a b 110 e f 110 4-stroke Outboard Oil (92-828000A12) a-Connecting Rod b-Piston c-Piston Pin d-Piston Pin Clip (2) e-Piston Pin Clip End Gap f-Pry Point Page 4B-28 90-857046 AUGUST 1998 CYLINDER BLOCK/CRANKCASE PISTON RING INSTALLATION IMPORTANT: Use caution when installing piston rings to avoid scratching piston. 1. Install the oil ring components as shown. Spread rings just enough to slip over piston. 2. Install the second and top compression rings (“T” side up). Spread rings just enough to slip over piston. 3. Offset the piston ring end gaps. 110 a b c f e d 110 91-24697 110 4-stroke Outboard Oil (92-828000A12) UP 50° g h i j k a-Oil Ring Spacer b-Bottom Rail c-Top Rail d-Second Compression Ring (“T” side up) e-Top Compression Ring (“T” side up) f-“T” Mark Should Face Piston Crown g-End Gap – Top Compression Ring h-End Gap – Second Compression Ring i-End Gap – Upper Oil Ring Rail j-End Gap – Lower Oil Ring Rail k-End Gap – Oil Ring Spacer 90-857046 AUGUST 1998 Page 4B-29 CYLINDER BLOCK/CRANKCASE Page 4B-30 90-857046 AUGUST 1998 Piston Installation 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. 1. Lubricate pistons, rings. and cylinder walls with engine oil. 2. Install piston/connecting rod assembly using piston ring compressor tool. NOTE: Install used pistons in their original locations(cylinders). Install piston with “UP” mark on piston crown facing toward the flywheel end of block. P/N FT2997 a b ÎÎ ÎÎ ÎÎ a - Piston Ring Compressor (P/N FT2997) b - Flywheel End Crankcase and Crankshaft Installation 1. Install crankshaft main bearings. NOTE: Align the projection of the bearings with the notch in the cylinder body/crankcase. Apply oil to bearings before installing. a b c d 110 4-Stroke Outboard Oil (92-828000A12) 110 a - Main Bearing Halves-Crankcase Cover (4) b - Main Bearing Halves-Cylinder Block (4) c - Projection in Bearing d - Notch in Cylinder Body/Crankcase CYLINDER BLOCK/CRANKCASE 90-857046 AUGUST 1998 Page 4B-31 2. Install upper and lower oil seal. 3. Lubricate crankshaft bearing surfaces with engine oil. 4. Install crankshaft. NOTE: Install oil seal with manufacturers marks/numbers facing outward. Apply oil to seals before installing. 110 110 110 4-stroke Outboard Oil (92-828000A12) a b a - Upper Oil Seal b - Lower Oil Seal IMPORTANT: Assemble connecting rod bolts, caps, rods, and pistons in their original locations. CYLINDER BLOCK/CRANKCASE Page 4B-32 90-857046 AUGUST 1998 5. Lubricate connecting rod, rod journals with engine oil. 6. Install connecting rod cap and bolts onto their respective crankpins. NOTE: Apply oil to connecting rod bolts before installing. Make sure scribe marks on cap and rod align. 7. Tighten connecting rod bolts in alternating sequence and in two stages. 110 110 4-stroke Outboard Oil (92-828000A12) c a b a - Connecting Rod Cap (3) b - Bolt-Connecting Rod (6) c - Scribe Marks Connecting Rod Bolt Torque 1st Torque: 53 lb. in. (6 N·m) 2nd Torque: 150 lb. in. (17 N·m) 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 the contacting surfaces on the crankcase cover. Use a small (paint type) roller to spread out the sealant for a smooth even coverage. Instructions in gasket sealant kit must be followed exactly. NOTE:Do not apply gasket sealant to the main bearings or the bolt holes. 12 12 a b Loctite Master Gasket “514” (92-12564-2) a-Contact Surface of Crankcase b-Use Roller To Apply A Smooth Even Coat. 90-857046 AUGUST 1998 Page 4B-33 CYLINDER BLOCK/CRANKCASE Page 4B-34 90-857046 AUGUST 1998 3. Install dowel pins and crankcase cover. Oil bolts and torque cover in sequence and in two steps. d c b a 110 4-Stroke Outboard Oil (92-828000A12) 110 1 2 4 3 5 6 8 7 9 10 12 11 13 14 a 16 15 a - Dowel Pins (2) b - Crankcase Cover c - Bolts w/Washers (8)-M6x35 d - Bolts w/Washers (8)-M8x82 Crankcase Cover Bolt Torque Center Bolts Qty. 8 1st Torque: 11 lb. ft. (15 N·m) (M8x82) 2nd Torque: 22 lb. in. (30 N·m) Outer Bolts Qty. 8 1st Torque: 53 lb. in. (6 N·m) (M6x35) 2nd Torque: 106 lb. in. (12 N·m) CYLINDER BLOCK/CRANKCASE 90-857046 AUGUST 1998 Page 4B-35 Thermostat and Exhaust Cover Installation 1. Install oil filter. 2. Install new exhaust cover gasket and exhaust cover. 3. Install thermostat, new gasket, and thermostat cover. NOTE: Torque exhaust and thermostat covers in sequence and in two steps. h g e f d c b 91-802653 a b a - Oil Filter Wrench (91-802653) b - Oil Filter c - Gasket d - Exhaust Cover e - Thermostat f - Gasket (New) g - Thermostat Cover h - Bolts w/Washers (10)-M6x35 Exhaust and Thermostat Cover Bolt Torque Qty 10 (M8x35) 1st Torque: 53 lb. in. (6 N·m) Qty. 2nd Torque: 106 lb. in. (12 N·m) Oil Filter Torque 70 lb. in. (8 N·m) CYLINDER BLOCK/CRANKCASE Ignition Components 1. Refer to Section 2A for installation of the following ignition components. a. Flywheel b. Stator c. Timing Belt d. Ignition Coils e. ECM f. Crank Position Sensor Charging and Starting System Components 1. Refer to Section 2B for installation of the following ignition components. a. Starter Motor b. Start Solenoid c. Voltage Regulator Fuel Components 1. Refer to Section 3A and 3B for installation of the following components. a. Fuel Pump b. Carburetor Harness and Battery Cable Installation 1. Install battery and harness cable assembly. Powerhead Installation 1. Install powerhead mounting bolts. a a-Bolts (8)-M8x25 Powerhead Mounting Bolt Torque 28 lb. ft. (38 N·m) Page 4B-36 90-857046 AUGUST 1998 CYLINDER BLOCK/CRANKCASE 90-857046 AUGUST 1998 Page 4B-37 Following Powerhead Installation 1. Push retainer up and slide over to engage the vertical shift shaft. a 1 2 a - Retainer 2. Connect inlet hose to fuel pump. b a a - Inlet Fuel Hose b - Cable Tie CYLINDER BLOCK/CRANKCASE Page 4B-38 90-857046 AUGUST 1998 3. Connect vent hose, secure with cable tie. a b a - Vent Hose b - Cable Tie 4. On electric start models, install battery cables on engine. Connect the battery cables to the battery. 5. Connect the power trim wires (if so equipped). 6. Install bottom cowl. a b a - Screws (6) b - Screw M6x60 Bottom Cowl Bolt Torque 60 lb. in. (7 N·m) Tiller Handle Models 1. Refer to Tiller Handle Section 7B for installation of throttle cable, shift rod, and tiller handle wiring. LUBRICATION POWERHEAD Section 4C - Lubrication Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-1 Cleaning and Inspection . . . . . . . . . . . . . . . . . . 4C-3 Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . 4C-2 Oil Pump Assembly . . . . . . . . . . . . . . . . . . . . . . 4C-4 Oil Pump Disassembly . . . . . . . . . . . . . . . . . . . 4C-2 Oil Pump Installation . . . . . . . . . . . . . . . . . . . . . 4C-5 Specifications Pump Type Engine Oil Pressure (Warm Engine) @ 3000 rpm Engine Oil Pan Capacity Oil Pump: Outer Rotor to Housing “a” Inner Rotor to Outer Rotor “b” Rotor to Housing “c” b c a LUBRICATION SYSTEM Trochoid 30-40 psi (207-278 kPa) 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) 4 C 90-857046 AUGUST 1998 Page 4C-1 LUBRICATION Page 4C-2 90-857046 AUGUST 1998 Oil Pump Removal 1. Refer to section 4A for Cylinder Head Removal. 2. Remove oil pump bolts, separate oil pump from cylinder head. a a - Bolts (4) M6x35 Oil Pump Disassembly 1. Heat screws to loosen Loctite sealant. Remove screws. a a - Screw (2) Heat Screws to Loosen Loctite Sealant. LUBRICATION 2. Disassemble Oil Pump. a b c d e a-Cover Seal b-Outer Rotor c-Inner Rotor d-Shaft e-Cross Pin 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). 55803a 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) 90-857046 AUGUST 1998 Page 4C-3 LUBRICATION Oil Pump Assembly 1. Reassemble the oil pump assembly. 2. Lubricate the outer and inner rotors thoroughly with engine oil. a b c d e 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 Loctite “222” (92-809818)51 51 a-Screws (2) Apply Loctite 222 to Threads Oil Pump Cover Screw Torque 70 lb. in. (8 N·m) Page 4C-4 90-857046 AUGUST 1998 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. a a a b 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 bolts. Tighten bolts to the specified torque. c a b a-Oil Pump Assembly b-Align Slot with Camshaft Projection c-Bolts (4)-M6x35 Oil Pump Mounting Bolt Torque 70 lb. in. (8.0 N·m) 90-857046 AUGUST 1998 Page 4C-5 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING MID-SECTION Section 5A - Clamp/Swivel Brackets & Drive Shaft Housing Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-1 Driveshaft Housing . . . . . . . . . . . . . . . . . . . . . . 5A-6 Quicksilver Lubricants and Service Aids . . . . 5A-1 Adaptor Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-8 Transom Bracket . . . . . . . . . . . . . . . . . . . . . . . . 5A-2 Steering Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-10 Swivel Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-4 Bottom Cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-12 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 Quicksilver Lubricants and Service Aids Part No. Description 92-88504 Loctite Pipe Sealant w/Teflon 92-850735A1 Anti-Corrosion Grease 92-850736A1 2-4-C w/Teflon 92-828000A12 4-Stroke Outboard Oil 90-857046 AUGUST 1998 Page 5A-1 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Transom Bracket 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 2728 29 30 31 32 33 3435 36 37 38 39 40 41 11 22 42 1 4 43 44 45 43 21 20 2-4-C w/Teflon (92-850736A1) 95 95 95 95 Page 5A-2 90-857046 AUGUST 1998 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Transom Bracket REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 11 1 TRANSOM BRACKET (PORT) 1 TRANSOM BRACKET (PORT - MANUAL LONG BIGFOOT) 2 1 GREASE FITTING 3 1 GROOVE PIN 44 1 TRANSOM BRACKET (STARBOARD) 1 TRANSOM BRACKET (PORT - MANUAL LONG BIGFOOT) 5 1 TILT LOCK LEVER 6 1 SPRING 7 1 NYLINER 8 1 SPRING 9 1 KNOB 10 1 GROOVE PIN 11 2 WASHER 12 1 ANCHOR BRACKET 13 1 ANODE ASSEMBLY 14 2 SCREW (M6 x 25) 60 6.8 15 2 WASHER 1616 5 SCREW (30 MM) 1 SCREW (35 MM) 17 4 LOCKWASHER 18 2 NUT 19 1 TILT PIN ASSEMBLY NON POWER TRIM SPRING20 1 21 1 TILT TUBE 22 2 NUT Tighten nut to 32 lb. ft. and then back off 1/4 turn 23 1 SEAL KIT O RING NON-HANDLE SPACER 24 1 25 1 26 2 CLIP C-WASHER POWER TRIM SCREW 27 1 28 1 Drive Tight 29 4 SCREW Drive Tight 30 4 WASHER Drive Tight 31 4 NUT 32 1 LINK TILT LEVER BUSHING NON POWER TRIM WASHER WAVE WASHER TILT KNOB SCREW (.375-16 x .62) 33 1 34 2 35 2 36 1 37 1 38 1 220 18.3 24.9 39 2 SCREW (M10 x 40) 40 2 WASHER 41 2 NUT 42 1 DECAL-Tilt Lock 43 1 THRUM SCREW 44 1 WASHER 45 1 SCREW 90-857046 AUGUST 1998 Page 5A-3 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5A-4 90-857046 AUGUST 1998 Swivel Bracket A = TORQUE NUT 120 LB. (13.5 N_M) AND THEN BACK OFF 1/4 TURN. A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 10 95 2-4-C w/Teflon (92-850736A1) 95 95 95 95 10 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Swivel Bracket REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 LINK ROD SCREW (1-1/2 IN.) WASHER ELECTRIC NON HANDLE WASHER NUT (.375-24) PUCK 2 1 20 27.0 3 1 4 2 5 2 120 13.5 6 1 7 1 BUSHING 8 1 SWIVEL BRACKET 9 2 BEARING 10 2 GREASE FITTING (Quantity 3 required on Handle Versions) 11 1 DECAL-Co-Pilot 12 1 DECAL-Serial Overlaminate 13 1 BUSHING (LOWER) 14 1 SEAL 1515 1 SCREW (M8 x 10) (HANDLE) 1 SCREW (M8 x 25) ELECTRIC SEAL16 1 90-857046 AUGUST 1998 Page 5A-5 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5A-6 90-857046 AUGUST 1998 Driveshaft Housing 1 2 3 4 5 6 8 7 9 10 11 12 13 14 15 17 18 19 20 21 22 23 24 16 25 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Driveshaft Housing REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 SEAL–water tube 22 1 DRIVESHAFT HOUSING (SHORT) 1 DRIVESHAFT HOUSING (LONG) 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 210 17.5 23.5 7 1 GASKET 8 2 BUMPER 9 1 GROMMET (LONG) 1010 1 STUD (NON-BIGFOOT) 12 16.3 1 STUD (BIGFOOT) 12 16.3 11 1 WASHER 12 1 NUT 40 54.5 1313 1 WATER TUBE (SHORT) 1 WATER TUBE (LONG) 14 1 GUIDE 15 1 BUMPER (LONG) 16 1 DRIVESHAFT HOUSING PLATE SCREW M10 X 25) SPEEDOMETER PICK UP BIGFOOT CONNECTOR FITTING SPACER COUPLING BUSHING WASHER 17 1 18 1 19 1 20 1 21 1 22 1 23 1 24 1 25 2 90-857046 AUGUST 1998 Page 5A-7 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5A-8 90-857046 AUGUST 1998 Adaptor Plate 110 4-stroke Outboard Oil (92-828000A12) 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 9 Loctite Pipe Sealant W/Teflon (92-88504) CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Adaptor Plate REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 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 (NON-BIGFOOT) 1 SEAL–driveshaft (BIGFOOT) 9 1 BUSHING (NON-BIGFOOT) 10 1 PLUG–oil passage 11 1 GROMMET (NON-BIGFOOT) 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 90-857046 AUGUST 1998 Page 5A-9 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5A-10 90-857046 AUGUST 1998 Steering Arm 94 1 2 3 5 6 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 30 29 94 Anti-Corrosion Grease (92-78376-A6) 7 4 95 2-4-C w/Teflon (92-850736A1) 95 95 95 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Steering Arm REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 2 NUT 50 67.8 2 1 STRAP 3 2 MOUNT 4 2 WASHER (BIGFOOT) 5 8 SCREW (M6 x 20) 130 11 6 1 BUMPER 7 1 BUMPER (BIGFOOT) 8 1 RETAINING RING 9 1 STEERING ARM 10 1 BRACKET TAB WASHER ELECTRIC SCREW (M10 x 1.5 x) 11 1 12 2 32.5 44 13 2 SCREW (M12 x 1.75 x ) 50 68.0 1414 1 SPACER (SHORT) 1 SPACER (LONG) 1515 1 SWIVEL TUBE (SHORT) 1 SWIVEL TUBE (LONG) 16 1 GROUND STRAP 17 1 GROUND STRAP 18 2 SCREW (M10 x 1.5 x 105) 32.5 44 19 1 BRACKET 20 3 SCREW(SELF–TAPPING) Drive Tight 21 2 NUT 22 1 NUT (.375-24) LEVER–Co-Pilot WASHER ROD (THREADED) HANDLE BRACKET PLATE DISC PLATE DISC SCREW (Hex Shoulder) 23 1 24 1 25 1 26 1 27 1 28 1 29 1 30 2 70 8.0 90-857046 AUGUST 1998 Page 5A-11 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5A-12 90-857046 AUGUST 1998 Bottom Cowl 95 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 13 14 3 3 95 2-4-C w/Teflon (92-850736A1) CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Bottom Cowl REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 11 1 BOTTOM COWL (SHORT-PORT) 1 BOTTOM COWL (LONG-PORT) 22 1 BOTTOM COWL (SHORT-STBD.) 1 BOTTOM COWL (LONG-STBD.) 3 6 SCREW 60 7.0 4 1 WASHER 5 1 SEAL 6 1 WASHER 7 1 GASKET 8 1 SCREW (M6 x 1 x 60) 60 7.0 9 1 FITTING-telltale 10 1 BOOT 11 2 STA-STRAP 12 1 LEVER-Cowl Latch 13 2 BUSHING 14 2 WAVE WASHER 15 1 LATCH HOOK 16 1 SCREW (M6 x 16) 60 7.0 1717 1 GROMMET (NON POWER TRIM) 1 GROMMET (SPLIT -POWER TRIM) 18 1 PLUG- Trim Switch (NON POWER TRIM) 19 1 SWITCH (POWER TRIM) 20 1 HANDLE 21 1 RIVET 90-857046 AUGUST 1998 Page 5A-13 POWER TRIM MID-SECTION Section 5B - Power Trim Table of Contents Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-2 Power Trim Disassembly . . . . . . . . . . . . . . . . . 5B-30 Quicksilver Lubricants and Service Aids . . . . 5B-2 Trim Motor Removal . . . . . . . . . . . . . . . . . . 5B-31 Power Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-4 Pump and Components Removal . . . . . . . 5B-31 Theory Of Operation . . . . . . . . . . . . . . . . . . . . . 5B-6 Manifold Removal . . . . . . . . . . . . . . . . . . . . 5B-32 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-6 Shock Rod Removal . . . . . . . . . . . . . . . . . . 5B-33 Trimming Characteristics . . . . . . . . . . . . . . 5B-6 Shock Rod Disassembly . . . . . . . . . . . . . . . . . 5B-33 Trailering Outboard . . . . . . . . . . . . . . . . . . . 5B-7 Memory Piston Removal . . . . . . . . . . . . . . 5B-36 Tilting Outboard Up and Down Manually . 5B-7 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . 5B-37 Power Trim Flow Diagrams . . . . . . . . . . . . . . . 5B-8 Trim Motor Electrical Tests . . . . . . . . . . . . . 5B-37 Trim Up Circuit . . . . . . . . . . . . . . . . . . . . . . . 5B-8 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-38 Tilt Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-10 O-Ring and Seal Placement . . . . . . . . . . . 5B-38 Maximum Tilt . . . . . . . . . . . . . . . . . . . . . . . . 5B-12 O-ring Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-39 Down Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 5B-14 Power Trim Reassembly . . . . . . . . . . . . . . . . . 5B-41 Shock Function Up . . . . . . . . . . . . . . . . . . . 5B-16 Shock Rod Reassembly . . . . . . . . . . . . . . . 5B-41 Shock Function Return . . . . . . . . . . . . . . . . 5B-18 Shock Rod Installation . . . . . . . . . . . . . . . . 5B-43 Manual Release . . . . . . . . . . . . . . . . . . . . . . 5B-20 Trim Limit Assembly Installation . . . . . . . . 5B-44 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 5B-22 Manual Release Valve Installation . . . . . . 5B-44 Preliminary Checks . . . . . . . . . . . . . . . . . . . 5B-22 Manifold Installation . . . . . . . . . . . . . . . . . . 5B-45 Hydraulic System Troubleshooting Oil Pump Installation . . . . . . . . . . . . . . . . . . 5B-46 Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-23 Pressure Operated Assembly Installation 5B-46 Troubleshooting the Power Trim Reservoir/Motor Installation . . . . . . . . . . . . 5B-47 Electrical System . . . . . . . . . . . . . . . . . . . . . 5B-27 Bleeding Power Trim Unit . . . . . . . . . . . . . 5B-48 Power Trim System Removal . . . . . . . . . . . . . 5B-29 Installation of Power Trim System . . . . . . . . . 5B-48 5 B 90-857046 AUGUST 1998 Page 5B-1 POWER TRIM Special Tools 1. Spanner Wrench P/N 91-74951 2. Lock-Ring Pliers P/N 91-822778A3 3. Expanding Rod P/N CG 41-11* 4. Collet P/N CG 41-14* 5. Heat Lamp P/N 91-63209 Quicksilver Lubricants and Service Aids Part No. Description 92-90100A12 Power Trim Fluid 92-850736A1 2-4-C w/Teflon Page 5B-2 90-857046 AUGUST 1998 POWER TRIM Notes: 90-857046 AUGUST 1998 Page 5B-3 POWER TRIM Page 5B-4 90-857046 AUGUST 1998 Power Trim 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 26 21 22 23 24 4 6 11 6 11 6 11 17 15 11 11 11 6 11 25 A E D C D B F NOTE: Lubricate all O-rings using Quicksilver Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. NOTE: It is recommended that all O-rings be replaced when servicing tilt system. POWER TRIM Power Trim REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm – 1 POWER TRIM PUMP (NON-BIGFOOT) – 1 POWER TRIM PUMP (BIGFOOT) 1 1 SHOCK ROD KIT 2 1 MEMORY PISTON ASSEMBLY 3 1 O RING REBUILD KIT 4 2 O RING 5 1 CYLINDER ASSEMBLY 66 1 TRIM LIMIT VALVE KIT (NON-BIGFOOT) 1 TRIM LIMIT VALVE KIT (BIGFOOT) 7 1 PUMP ASSEMBLY 8 1 MOTOR KIT 9 1 RESERVOIR PLUG 10 1 MANUAL RELEASE ASSEMBLY 11 1 MANIFOLD KIT 12 1 SCREW KIT (MOTOR) 13 1 DRIVE SHAFT 14 1 FILTER KIT 15 1 P.O. CHECK ASSEMBLY KIT 16 1 CABLE – 1 O RING KIT (COMPLETE TRIM) 17 2 GROOVE PIN 18 1 ANCHOR PIN 19 1 PIN – 1 TRIM HARNESS/RELAY ASSEMBLY 20 1 HARNESS-Trim 21 2 RELAY 22 2 BRACKET 23 2 GROMMET 24 2 BUSHING 25 2 DECAL-Trim Relay 26 2 SCREW (M6 x 30) A -Torque cylinder cap to 45 lb-ft (61 Nm) B -Torque screws to 80 lb-in. (9.0 Nm) C -Torque screws to 70 lb-in. (7.9 Nm) D -Torque plugs to 120 lb-in. (13.5 Nm) E -Torque screws to 100 lb-in. (11 Nm) F -Torque shock piston to 90 lb-ft (122 Nm) 90-857046 AUGUST 1998 Page 5B-5 POWER TRIM Theory Of Operation The Power Trim system consists of an electric motor, pressurized fluid reservoir, pump and trim cylinder. The remote control (or trim panel) is equipped with a switch that is used for trimming the outboard “up” 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, generally increasing top speed. • Transfers steering torque harder to left on installations below 23 in. transom height. • Increases clearance over submerged objects. • In excess, can cause porpoising and/or ventilation. • In excess, can cause insufficient water supply to water pump resulting in serious water pump and/or powerhead overheating damage. WARNING Excessive engine trim angle will result in insufficient water supply to water pump causing water pump and/or powerhead overheating damage. Make sure that water level is above gear housing water intake holes whenever engine is running. Operating “Up” circuit will actuate the “up” relay (located under engine cowl) and close the electric motor circuit. The electric motor will drive the pump, thus forcing automatic transmission fluid through internal passageways into the “up” side of the trim cylinder. The trim cylinder/trim rod will position the engine at the desired trim angle within the 20° 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. Page 5B-6 90-857046 AUGUST 1998 POWER TRIM TRIMMING OUTBOARD “DOWN” (“IN”) WARNING Excessive speed at minimum trim “In” may cause undesirable and/or unsafe steering conditions. Each boat should be tested for handling characteristics after any adjustment is made to the tilt angle (tilt pin relocation). • Will help planing off, particularly with a heavy load. • Usually improves ride in choppy water. • In excess, can cause boat to veer to the left or right (bow steer). • Transfers steering torque harder to right (or less to the left). • Improves planing speed acceleration (by moving tilt pin one hole closer to transom). Operating “Down” circuit will actuate the “down” relay (located under engine cowl) and close the electric motor circuit (motor will run in opposite direction of the “Up” circuit). The electric motor will drive the pump, thus forcing automatic transmission fluid through internal passageways into the “down” side of the trim cylinder. The trim rod will move the engine downward to the desired angle. Trailering Outboard WARNING Excessive engine trim angle will result in insufficient water supply to water pump causing water pump and/or powerhead overheating damage. Make sure that water level is above gear housing water intake holes whenever engine is running. While operating “up” circuit, the cylinder rod will continue to tilt the outboard to a full up position for trailering. Tilting Outboard Up and Down Manually WARNING Before loosening the manual release valve, make sure all persons are clear of engine, as engine will drop to full “down” position when valve is loosened. With power trim installed, the outboard can be raised or lowered manually by opening the manual release valve 3 to 4 turns (counterclockwise). 55170 a a-Manual Release Valve 90-857046 AUGUST 1998 Page 5B-7 POWER TRIM Page 5B-8 90-857046 AUGUST 1998 Power Trim Flow Diagrams ÍÍ ÍÍ Reservoir Oil Filtered Feed Oil Oil Under Pressure Return Oil Up Pressure 1625 psi (30-60 hp) 2800 psi (75-125 hp) mininmum Tilt Relief Pressure 250-400 psi (30-60 hp) 500-700 psi (40-60 hp Bigfoot) 540-990 psi (75-125 hp) Impact Relief Pressure #22 880-1110 psi (30-60 hp) 1220-1420 psi (75-125 hp) a b c d e g f h i j k l m o g p q s r t u v w TRIM UP CIRCUIT n a - Piston Rod b - End Cap c - Electric Motor d - Reservoir Oil e - Down Circuit Pressure Relief Valve f - Down Circuit Pressure Operated Valve g - Filter (2 shown for clarity) h - Shock Return Valve i - Up Circuit Suction Port j - Oil Pump k - Down Circuit Suction Port l - Oil Fill Cap m - Shuttle Valve n - Up Circuit Pressure Operated Valve o - Manifold Reverse Suction Valve p - Manual Release Valve q - Manifold r - Tilt Relief Valve s - Tilt Relief Piston t - Memory Piston u - Shock Piston v - Impact Relief Valve w - Cylinder POWER TRIM Trim Up When the trim switch is activated in the up position, the electric motor (c) begins to rotate the oil pump gears (j), the oil pump draws a small amount of oil through the filter (g) and through the up circuit suction port (i). The oil pump gear (j) rotation forces oil into the passages for the up circuit. Oil, under pressure, will slide the shuttle valve (m) against the down circuit pressure operated valve (f). The shuttle valve will mechanically open the down pressure operated valve, allowing oil from the down cavity of the trim cylinder, to flow into the oil pump. This returning oil, from the down cavity, will supply most of the oil required for the up circuit. Oil in the up circuit is blocked from returning into the reservoir by the ball inside the down circuit suction port (k). The pressure of the oil will force the up circuit pressure operated valve (n) to open, allowing the oil to enter the passages inside the manifold (q) leading to the trim cylinder (w) up cavity. Oil is blocked from all other passages by the closed manual release valve (p). Oil under pressure will enter the trim cylinder below the memory piston (t). With an increasing amount of oil entering the cylinder, the memory piston contacts the shock piston (u) and forces the piston rod (a) up and out, raising the outboard motor. Oil on the top of the shock piston exits through a passage running down along the side of the cylinder and enters the manifold passages. The oil is drawn back into the pump (j) through the open down circuit pressure operated valve (f) and enters the pump as supply for the up circuit. 90-857046 AUGUST 1998 Page 5B-9 POWER TRIM Page 5B-10 90-857046 AUGUST 1998 Tilt Circuit Tilt Relief Pressure 250-400 psi (30-60 hp) 500-700 psi (40-60 hp Bigfoot) 540-990 psi (75-125 hp) Up Pressure 1625 psi (30-60 hp) 2800 psi (75-125 hp) minimun Reservoir Oil Filtered Feed Oil Oil Under Pressure Return Oil ÍÍ ÍÍ Impact Relief Pressure #22 880-1110 psi (30-60 hp) 1220-1420 psi (75-125 hp) a b c d w u v t h e f g s r p o g m n j k i l q a - Piston Rod b - End Cap c - Electric Motor d - Reservoir Oil e - Down Circuit Pressure Relief Valve f - Down Circuit Pressure Operated Valve g - Filter (2 shown for clarity) h - Shock Return Valve i - Up Circuit Suction Port j - Oil Pump k - Down Circuit Suction Port l - Oil Fill Cap m - Shuttle Valve n - Up Circuit Pressure Operated Valve o - Manifold Reverse Suction Valve p - Manual Release Valve q - Manifold r - Tilt Relief Valve s - Tilt Relief Piston t - Memory Piston u - Shock Piston v - Impact Relief Valve w - Cylinder POWER TRIM Tilt Up In the up mode, as the piston rod (a) extends from the cylinder (w), the memory piston (t) clears or uncovers the pressure relief passage. Oil from the up cavity will enter this passage and, if required, causes the tilt relief piston (s) to open the tilt pressure relief valve (r). This valve lowers the amount of pressure available to lift the outboard motor. With the engine in forward gear, and at high engine rpm, the oil pressure available will not be able to overcome the propeller thrust, limiting the trim range to below the pressure relief orifice. When the engine rpm’s fall or if engine is not in forward gear, the oil pressure is available to extend the piston rod (a) up into the tilt range. 90-857046 AUGUST 1998 Page 5B-11 POWER TRIM Page 5B-12 90-857046 AUGUST 1998 Maximum Tilt Up Pressure 1625 psi (30-60 hp) 2800 psi (75-125 hp) minimum ÍÍ ÍÍ Reservoir Oil Filtered Feed Oil Oil Under Pressure Return Oil Tilt Relief Pressure 250-400 psi (30-60 hp) 500-700 psi (40-60 hp Bigfoot) 540-990 psi (75-125 hp) Impact Relief Pressure #22 880-1110 psi (30-60 hp) 1220-1420 psi (75-125 hp) a v t w b h c d e f g s r p o n g m i j k l u q a - Piston Rod b - End Cap c - Electric Motor d - Reservoir Oil e - Down Circuit Pressure Relief Valve f - Down Circuit Pressure Operated Valve g - Filter (2 shown for clarity) h - Shock Return Valve i - Up Circuit Suction Port j - Oil Pump k - Down Circuit Suction Port l - Oil Fill Cap m - Shuttle Valve n - Up Circuit Pressure Operated Valve o - Manifold Reverse Suction Valve p - Manual Release Valve q - Manifold r - Tilt Relief Valve s - Tilt Relief Piston t - Memory Piston u - Shock Piston v - Impact Relief Valve w - Cylinder POWER TRIM Maximum Tilt With the piston rod at maximum travel, and due to no rod movement, the pressure inside of the trim cylinder (w) will increase to the pressure required to move the tilt relief piston (s). The tilt relief piston’s “pin” opens the tilt relief valve (r). Up pressure flows into the trim relief passage, and returns back into the reservoir. 90-857046 AUGUST 1998 Page 5B-13 POWER TRIM Page 5B-14 90-857046 AUGUST 1998 Down Circuit Up Pressure 1625 psi (30-60 hp) 2800 psi (75-125 hp) minimum ÍÍ ÍÍ ÍÍ Reservoir Oil Filtered Feed Oil Oil Under Pressure Return Oil Tilt Relief Pressure 250-400 psi (30-60 hp) 500-700 psi (40-60 hp Bigfoot) 540-990 psi (75-125 hp) Impact Relief Pressure #22 880-1110 psi (30-60 hp) 1220-1420 psi (75-125 hp) a w b c d i j k l m n g o p s r h g f e t u v q a - Piston Rod b - End Cap c - Electric Motor d - Reservoir Oil e - Down Circuit Pressure Relief Valve f - Down Circuit Pressure Operated Valve g - Filter (2 shown for clarity) h - Shock Return Valve i - Up Circuit Suction Port j - Oil Pump k - Down Circuit Suction Port l - Oil Fill Cap m - Shuttle Valve n - Up Circuit Pressure Operated Valve o - Manifold Reverse Suction Valve p - Manual Release Valve q - Manifold r - Tilt Relief Valve s - Tilt Relief Piston t - Memory Piston u - Shock Piston v - Impact Relief Valve w - Cylinder POWER TRIM Down Mode When the trim switch is activated in the down position, the electric motor (c) will rotate the pump (j) in the opposite direction. With the oil pump gears rotating backwards, the flow of oil is reversed. Oil is drawn through the filter (g), through the down circuit suction port (k) and into the oil pump (j). The pump forces pressurized oil into the down passages, oil will slide the shuttle valve (m) into the up circuit pressure operated valve (n). The shuttle valve will mechanically open the up circuit pressure operated valve and allow oil, from the up cavity of the trim cylinder (w), to return into the oil pump. This returning oil, from the up cavity, will supply the oil required for the down circuit. The oil is blocked from returning into the reservoir by the ball (i) inside the up circuit suction port. Oil, under pressure, opens the down circuit pressure operated valve (f) and enters the down passages inside of the manifold (q). The manifold passage connects into the trim cylinder passage leading to the top of the cylinder. The cavity, inside the cylinder, above the shock piston (u) is the down cavity. As the down cavity fills with oil, the piston rod (a) retracts into the cylinder, lowering the outboard motor. Oil from the up cavity exits the cylinder and is drawn back into the pump through the open up circuit pressure operated valve (n). When the piston rod reached full travel, the oil pressure inside the down circuit will rise until the down pressure regulating valve (e) opens, bypassing oil back into the reservoir. When the trim button is released, and the oil pump stops supplying pressure, both of the pressure operated valves (f & n) will close and; if open, the down pressure relief valve (e) will close. The closed valves will lock the fluid on either side of the shock piston (u) & memory piston (t), holding the outboard motor in position. 90-857046 AUGUST 1998 Page 5B-15 POWER TRIM Page 5B-16 90-857046 AUGUST 1998 Shock Function Up Up Pressure 1625 psi (30-60 hp) 2800 psi (75-125 hp) minimum ÍÍ ÍÍ Reservoir Oil Oil Under Pressure Return Oil Tilt Relief Pressure 250-400 psi (30-60 hp) 500-700 psi (40-60 hp Bigfoot) 540-990 psi (75-125 hp) Impact Relief Pressure #22 880-1110 psi (30-60 hp) 1220-1420 psi (75-125 hp) a b c w v u t h d e f g i j k l m n g o p q s r a - Piston Rod b - End Cap c - Electric Motor d - Reservoir Oil e - Down Circuit Pressure Relief Valve f - Down Circuit Pressure Operated Valve g - Filter (2 shown for clarity) h - Shock Return Valve i - Up Circuit Suction Port j - Oil Pump k - Down Circuit Suction Port l - Oil Fill Cap m - Shuttle Valve n - Up Circuit Pressure Operated Valve o - Manifold Reverse Suction Valve p - Manual Release Valve q - Manifold r - Tilt Relief Valve s - Tilt Relief Piston t - Memory Piston u - Shock Piston v - Impact Relief Valve w - Cylinder POWER TRIM Shock Function Up Oil inside the down cavity is locked in a static position by the closed down circuit pressure operated valve (f), the manual release valve (p) and the manifold reverse suction valve (o). If the outboard strikes an underwater object while in forward gear, the piston rod (a) will try to rapidly extend from the cylinder (w), the pressure increases inside the trim cylinder down cavity and connecting passages. When the pressure increases to the level required, the impact relief valves (v), located inside the shock piston (u), will open and allow the fluid to pass through the shock piston. As the fluid passes through the piston, the piston rod (a) will extend from the trim cylinder. The memory piston (t) is held in position by vacuum, created by the oil in the up cavity being locked in a static position. Therefore; oil passing through the shock piston is trapped between the memory piston (t) and shock piston (u). 90-857046 AUGUST 1998 Page 5B-17 POWER TRIM Page 5B-18 90-857046 AUGUST 1998 Shock Function Return Up Pressure 1625 psi (30-60 hp) 2800 psi (75-125 hp) minimum ÍÍÍ ÍÍ Reservoir Oil Oil Under Pressure Return Oil Tilt Relief Pressure 250-400 psi (30-60 hp) 500-700 psi (40-60 hp Bigfoot) 540-990 psi (75-125 hp) Impact Relief Pressure #22 880-1110 psi (30-60 hp) 1220-1420 psi (75-125 hp) a b c w v u t h d i j k l m n e f g g o p q s r a - Piston Rod b - End Cap c - Electric Motor d - Reservoir Oil e - Down Circuit Pressure Relief Valve f - Down Circuit Pressure Operated Valve g - Filter (2 shown for clarity) h - Shock Return Valve i - Up Circuit Suction Port j - Oil Pump k - Down Circuit Suction Port l - Oil Fill Cap m - Shuttle Valve n - Up Circuit Pressure Operated Valve o - Manifold Reverse Suction Valve p - Manual Release Valve q - Manifold r - Tilt Relief Valve s - Tilt Relief Piston t - Memory Piston u - Shock Piston v - Impact Relief Valve w - Cylinder POWER TRIM Shock Function Return After the engine clears the under water object, the weight of the engine will increase the oil pressure between the memory piston (t) and shock piston (u) to the level required to open the shock return valve (h), inside the shock piston, allowing the oil to bleed back through the shock piston into the down cavity. If required, additional oil will enter the down cavity through the manifold reverse suction valve (o). This will return the engine back against the memory piston (t) and into the original running position. 90-857046 AUGUST 1998 Page 5B-19 POWER TRIM Page 5B-20 90-857046 AUGUST 1998 Manual Release ÍÍ ÍÍ Reservoir Oil Return Oil Filtered Oil Down Pressure 525-880 psi Up Pressure 1625 psi (30-60 hp) 2800 psi (75-125 hp) minimum Tilt Relief Pressure 250-400 psi (30-60 hp) 500-700 psi (40-60 hp Bigfoot) 540-990 psi (75-125 hp) Impact Relief Pressure #22 880-1110 psi (30-60 hp) 1220-1420 psi (75-125 hp) e f g a b c w v u t h d i j k l m n g o p q s r a - Piston Rod b - End Cap c - Electric Motor d - Reservoir Oil e - Down Circuit Pressure Relief Valve f - Down Circuit Pressure Operated Valve g - Filter (2 shown for clarity) h - Shock Return Valve i - Up Circuit Suction Port j - Oil Pump k - Down Circuit Suction Port l - Oil Fill Cap m - Shuttle Valve n - Up Circuit Pressure Operated Valve o - Manifold Reverse Suction Valve p - Manual Release Valve q - Manifold r - Tilt Relief Valve s - Tilt Relief Piston t - Memory Piston u - Shock Piston v - Impact Relief Valve w - Cylinder POWER TRIM Manual Tilt To manually tilt the outboard engine, the owner will need to back out the manual release valve (p) 3-4 turns. With the valve backed out, the internal passages inside the manifold are connected together. These passages connect both the cylinder down and up cavities together, along with the reservoir, allowing the engine to be raised or lowered. Piston rod (a) movement will continue until the manual release valve (p) is closed, locking the fluid inside of the cylinder and manifold. 90-857046 AUGUST 1998 Page 5B-21 POWER TRIM Troubleshooting Support outboard with tilt lock pin when servicing power trim system. IMPORTANT: After debris or failed components have been found (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-22 90-857046 AUGUST 1998 POWER TRIM Hydraulic System Troubleshooting Flow Chart OUTBOARD WILL NOT HOLD TILTED POSITION DURING REVERSE AND/OR TRAILS OUT DURING HIGH SPEED DECELERATION. Inspect manual release valve.Manual release valve and O-ring damaged. Manual release valve and O-rings appear to be O.K. - Clean and reinstall manual release valve. Trim system holds re- verse thrust. Testing complete. Trim will not hold reverse thrust. Replace manual re- lease valve and O-rings. Trim system holds re- verse thrust. Testing complete. Remove and inspect pis- ton rod assembly for de- bris and/or shock ball hang up. Shock piston appears O.K. - Clean and reinstall piston rod assembly. Trim system holds re- verse thrust. Testing complete. Debris and/or shock ball hang up identi- fied. Replace piston rod assembly. Trim system holds re- verse thrust. Testing complete. Trim will not hold reverse thrust. Remove PO check valve assembly, inspect O-rings and seals for damage. Debris and/or dam- age identified. Replace PO check valve assembly. Trim system holds re- verse thrust. Testing complete. PO check valve appears O.K. - Clean and reinstall PO check valve assem- bly. Trim will not hold reverse thrust. Trim system holds reverse thrust. Test- ing complete. continued on next page 90-857046 AUGUST 1998 Page 5B-23 POWER TRIM Hydraulic System Troubleshooting Flow Chart continued Replace trim system. Replace suction seat assembly. Remove suction seat as- sembly and inspect for debris and/or damage. Debris and/or damage identified. Trim system holds reverse thrust. Test- ing complete. Trim will not hold reverse thrust. Suction seat assembly appears O.K. - Clean and reinstall suction seat assembly. Trim system holds reverse thrust. Test- ing complete. Page 5B-24 90-857046 AUGUST 1998 POWER TRIM Hydraulic System Troubleshooting Flow Chart TRIM SYSTEM LEAKS DOWN WITH MANUAL RELEASE VALVE CLOSED. Inspect manual release valve.Manual release valve and O-ring damaged. Replace manual re- lease valve and O-rings. Trim system does not leak down. Test- ing complete. Trim system leaks down. Manual release valve and O- rings appear to be O.K. - Clean and reinstall manual release valve. Trim system does not leak down. Test- ing complete. Remove tilt relief valving and inspect O-rings and seals for debris and/or damage. Debris and/or dam- age identified. Replace tilt relief valving. Trim system does not leak down. Test- ing complete. Trim system leaks down. Tilt relief valving and O-rings appear to be O.K. - Clean and reinstall tilt relief valving. Trim system does not leak down. Test- ing complete. Remove PO check valve assembly, inspect O- rings and seals for dam- age. Debris and/or dam- age identified. Replace PO check valve assembly. PO check valve appears O.K. - Clean and reinstall PO check valve assem- bly. continued on next page Trim system leaks down. Trim system does not leak down. Testing complete. Trim system does not leak down. Test- ing complete. 90-857046 AUGUST 1998 Page 5B-25 POWER TRIM Hydraulic System Troubleshooting Flow Chart continued Replace trim system. Replace memory pis- ton and shock piston O-rings. Inspect memory pis- ton O-ring and cylinder bore. Cylinder bore appears smooth with no debris. Cylinder bore appears rough and/or debris found in cylinder. Trim leaks down. Trim system does not leak down. Test- ing complete. Page 5B-26 90-857046 AUGUST 1998 POWER TRIM Troubleshooting the Power Trim Electrical System LT.BLU/WHT GRN/WHT BLUE 14 BLKRED 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 RED GRN/WHT or GRN BLU/WHT or PUR GRN 14 BLKRED BLK +– LT. GRN/WHT LT. BLU/WHT RED/PUR a j k h g e f c d c b 1 2 3 4 i a -Trim Switch (Remote Control Mounted) g -Down Relay b -Trim Switch (Panel Mounted) h -Up Relay c -Fuse Holder i -Solenoid d -Remote Control Wiring Plug Connector j -Trim Pump Motor e -Battery k -Cowl Switch f -Starter Bolt 90-857046 AUGUST 1998 Page 5B-27 POWER TRIM Troubleshooting the Power Trim Electrical System Refer to wiring diagram on preceding page for location of wire connections. Problem Possible Cause Remedy Trim Switch “UP” is inoperative, but the Cowl Switch “UP” does operate. 1. Open wire between Wire Connection (1) and Trim Switch. 2. Faulty Trim Switch. 1. Check for an open connection or cut wire. 2. Replace. Cowl Switch “UP” is inoperative, but the Trim Switch “UP” does operate. 1. Open wire between Wire Connection (2) and Solenoid. 2. Faulty Cowl Switch. 1. Check for an open connection or cut wire. 2. Replace. Trim Switch “UP” and Cowl Switch “UP” are both inop1. Open wire between Wire Connection (1) and the “Up” Relay. 1. Check for an open connection. erative. 2. Open BLK wire between ground and “UP” Relay. 2. Check for an open connection. 3. Open RED wire between Solenoid and “UP” Relay. 3. Check for an open connection. 4. Faulty “UP” Relay. 4. Replace. Trim Switch “DOWN” is inoperative, but the Cowl Switch “DOWN” does operate. 1. Open wire between Wire Connection (3) and Trim Switch. 2. Faulty Trim Switch. 1. Check for an open connection or cut wire. 2. Replace. Cowl Switch “DOWN” is inoperative, but the Trim Switch “DOWN” does operate. 1. Open wire between Wire Connection (2) and Solenoid. 2. Faulty Cowl Switch. 1. Check for a open connection or cut wire. 2. Replace Trim Switch “DOWN” and Cowl Switch “DOWN” are 1. Open wire between Wire Connection (3) and the “UP” Relay. 1. Check for an open connection. both inoperative. 2. Open BLK wire between ground and “DOWN” Relay. 2. Check for an open connection. 3. Open RED wire between Solenoid and “DOWN” Relay. 3. Check for an open connection. 4. Faulty “DOWN” Relay 4. Replace. Trim Switch “UP” and “DOWN” are both inoperative, but the Cowl Switch does operate. 1. 20 AMP Fuse blown. 2. Faulty trim switch. 3. Wire is open between fuse holder and solenoid. 4. Wire is open between fuse holder and trim switch. 1. Replace fuse. Locate the cause of the blown fuse. Check electrical wiring for a shorted circuit. 2. Replace. 3. Check for a open connection or cut wire. 4. Check for a loose or corroded connection. Trim Switch and Cowl Switch are both inoperative. 1. One of the Trim Pump Motor wires is open between the motor and the Relays. 2. Faulty trim pump motor. 1. Check wire connections (4) for loose or corroded condition. 2. If voltage is present at connections (4) when the appropriate trim button is pressed, then motor is faulty. Replace motor. Trim system operates (motor runs) without pressing the switches. 1. The Trim or Cowl switch is shorted. 1. Replace. Page 5B-28 90-857046 AUGUST 1998 POWER TRIM 90-857046 AUGUST 1998 Page 5B-29 Power Trim System Removal 1. Tilt outboard to the full up position and support with tilt lock pin. 2. Disconnect the power trim wire harness and remove clamp. 55264 b c 55464 a a - Tilt Lock Pin b - Power Trim Wire Harness Clamp c - Harness 3. Remove the trilobe pin. 4. Drive out the upper pivot pin. 5. Remove the sacrificial anode. 55331 c b a a - Trilobe Pin b - Upper Pivot Pin c - Sacrificial Anode POWER TRIM 6. Use suitable punch to remove (Drive Down) lower pin. Retain dowel pin. 7. Use suitable punch to drive out lower pivot pin. 51144 51144 ba a-Dowel Pin b-Lower Pivot Pin Power Trim Disassembly IMPORTANT: Power trim system is pressurized. Trim rod must be in the full “UP” position (fully extended) prior to fill/drain plug, or manual release valve removal. 1. Remove reservoir cap. 2. Remove manual release valve assembly to drain oil. 55263 b a a-Reservoir Cap b-Manual Release Valve Page 5B-30 90-857046 AUGUST 1998 POWER TRIM 90-857046 AUGUST 1998 Page 5B-31 Trim Motor Removal 1. Secure power trim assembly in a soft jaw vise. 2. Remove four (4) screws to remove motor/reservoir. Remove reservoir seal and coupler. e d c b a a - Screw (4) b - Reservoir c - Reservoir Seal d - Coupler e - Manifold Assembly Pump and Components Removal 1. Remove pressure operated plugs on pump. Remove spring and check valve/poppet (both sides). Use special tool CG 41-11 and special tool CG 41-14 with 5/16, end to remove spool. d b a c a b d e c a - Plug (2) b - Spring (2) c - Check Valve/Poppet (2) d - Seat (2) e - Spool POWER TRIM Page 5B-32 90-857046 AUGUST 1998 IMPORTANT: Inspect poppet assembly for debris in the area shown. If debris is found on poppet replace poppet. 2. Remove three (3) screws to remove pump. Remove filter and filter seal under pump. Remove suction seat assembly. d c e f b a a - Debris Under Valve Tip b - Rubber Seat c - Screws (3) d - Filter Seal e - Filter f - Suction Seat Assembly Manifold Removal 1. Remove two (2) screws to remove manifold from cylinder. 2. Remove tilt relief components. 51146 a 51008 b c d e a - Screw (2) b - Spring c - Poppet d - Spool Housing e - Trim Limit Spool POWER TRIM Shock Rod Removal 1. Unscrew end cap assembly from cylinder using spanner wrench [1/4 in. x 5/16 in. (6.4mm x 8mm) long pegs]. 2. 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. b b c a a-End Cap b-O-ring (2) c-Wiper Ring 1. Place shock rod assembly on clean work surface. 2. Remove three (3) screws and remove plate from shock rod piston. 51143 a b c a-Screw (3) b-Plate c-Shock Rod Piston 90-857046 AUGUST 1998 Page 5B-33 POWER TRIM 3. Remove check ball components from shock rod piston. 4. Remove o-ring from shock rod piston. 51147 d a b c a-Spring (5) b-Seat (5) c-Ball (5) d-O-ring CAUTION When removing shock piston, spanner wrench must have 1/4 in. x 5/16 in. long pegs to avoid damage to shock piston. 5. Place shock rod into soft jawed vise and apply heat to loosen piston using torch lamp (P/N 91-63209). 6. Loosen shock rod piston using spanner wrench [1/4 in. x 5/16 in. (6.4mm x 8mm) long pegs]. 7. Allow shock rod piston to cool. Remove from shock rod. 51146 51146 a b a-Spanner Wrench b-Shock Rod Piston Page 5B-34 90-857046 AUGUST 1998 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. 51199 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 90-857046 AUGUST 1998 Page 5B-35 POWER TRIM Memory Piston Removal 1. Remove memory piston from cylinder using one of two methods: a. Using lock ring pliers (P/N 91-822778A3) or suitable tool. 51144 b. Blowing compressed air into manual release valve hole using air nozzle. WARNING Memory piston cup may be expelled at a high velocity when air pressure is applied. Failure to place cylinder as shown below could result in personal injury. NOTE: Point cylinder opening down and away. Use a shop rag or towel to avoid damage to the memory piston. 2. Remove o-ring from memory piston. 51144 d e 55466 a c b a-Adaptor/Air Hose b-Memory Piston Exit c-Shop Rag d-O-Ring e-Memory Piston Page 5B-36 90-857046 AUGUST 1998 POWER TRIM Cleaning/Inspection/Repair IMPORTANT: Components must be dirt and lint free. Slightest amount of debris in Power Trim system could cause system to malfunction. Clean shock rod and components with parts cleaner and dry with compressed air. It is recommended that all O-rings in trim system be replaced. Use O-Ring Kit 25-809880A1. Lubricate all o-rings with Quicksilver Power Trim Fluid (92-90100A12). If not available, use automotive (ATF) automatic transmission fluid. Trim Motor Electrical Tests 1. Connect a 12 volt supply to motor leads. If motor fails to run, replace pump motor. IMPORTANT: Trim Motor is not serviceable. If motor fails to run, replace motor assembly. 90-857046 AUGUST 1998 Page 5B-37 POWER TRIM Page 5B-38 90-857046 AUGUST 1998 Reassembly O-Ring and Seal Placement O-Rings and Seals are part of O-Ring Kit 25-809880A1 3 21 22 19 22 4 5 1 20 8 9 10 18 9 7 6 15 16 17 8 9 10 14 13 11 12 1 2 3 5 8 10 16 19 O.D. I.D. Cutaway View of O-Ring Width O-RINGS SHOWN ARE ACTUAL SIZE 9 13 14 2 22 4 7 13 11 6 5 21 20 15 18 17 12 POWER TRIM 90-857046 AUGUST 1998 Page 5B-39 O-ring Sizes POWER TRIM O-ring Description and Sizes O-Ring Description O-Ring I.D. O-Ring O.D. O-Ring Width 1 Wiper Ring 2 Cyl. Cap, Inner 0.671 in. (17.04 mm) 0.949 in. (24.10 mm) 0.139 in. (3.53 mm) 3 Cyl. Cap 1.864 in. (47.34 mm) 2.004 in. (50.90 mm) 0.07 in. (1.78 mm) 4 Shock Piston 1.6 in. (40.64 mm) 2.02 in. (53.086 mm) 0.21 in. (5.334 mm) 5 Piston Bolt 0.676 in. (17.17 mm) .816 in. (20.726 mm) 0.07 in. (1.78 mm) 6 Reservoir Plug 0.549 in. (13.94 mm) 0.755 in. (19.17 mm) 0.103 in. (2.616 mm) 7 Motor Seal 8 (2) P.O. Check Plug 0.489 in. (12.42 mm) 0.629 in. (15.97 mm) 0.07 in. (1.78 mm) 9 (3) Poppet Assy. 10 (2) P.O. Check Seat 0.364 in. (9.25 mm) 0.504 in. (12.80 mm) 0.07 in. (1.78 mm) 11 (2) Pump Port 0.145 in. (3.683 mm) 0.285 in. (7.239 mm) 0.07 in. (1.78 mm) 12 Suction Seat 0.239 in. (6.07 mm) 0.379 in. (9.626 mm) 0.07 in. (1.78 mm) 13 Filter Seal 14 Filter 15 Manual Release 0.114 in. (2.90 mm) 0.254 in. (6.451 mm) 0.07 in. (1.78 mm) 16 Manual Release 0.176 in. (4.47 mm) 0.316 in. (8.026 mm) 0.07 in. (1.78 mm) 17 Manual Release 0.239 in. (6.07 mm) 0.379 in. (9.626 mm) 0.07 in. (1.78 mm) 18 Spool 0.239 in. (6.07 mm) 0.379 in. (9.626 mm) 0.07 in. (1.78 mm) 19 (3) Spool Housing 0.301 in. (7.645 mm) 0.441 in. (11.20 mm) 0.07 in. (1.78 mm) 20 Trim Limit Spool 0.114 in. (2.895 mm) 0.254 in. (6.451 mm) 0.07 in. (1.78 mm) 21 (2) Manifold 0.208 in. (5.283 mm) 0.348 in. (8.839 mm) 0.07 in. (1.78 mm) 22 Memory Piston 1.6 in. (40.64 mm) 2.02 in. (53.086 mm) 0.21 in. (5.334 mm) Page 5B-40 90-857046 AUGUST 1998 POWER TRIM Power Trim Reassembly IMPORTANT: Lubricate all o-rings with Quicksilver Power Trim Fluid (92-90100A12). If not available, use automotive (ATF) automatic transmission fluid. Shock Rod Reassembly 1. Install lubricated o-rings to end cap. 2. Install rod wiper. 3. Install lubricated o-rings to shock piston. 51199 f d e a b c 51145 a-Rod Wiper b-Inner O-ring c-Outer O-ring d-Shock Piston e-O-ring f-O-ring 4. Clamp shock rod in soft jawed vise. 5. Position cylinder end cap onto rod as shown. 51146 CAUTION When installing shock rod piston, spanner wrench must have1/4 in. x 5/16 in. (6.4mm x 8mm) long pegs to avoid damage to shock rod piston. 6. Apply Loctite Grade “A” (271) to threads on shock rod. 7. Install shock rod piston. 90-857046 AUGUST 1998 Page 5B-41 POWER TRIM 8. Tighten shock rod piston securely using spanner wrench (1/4 in. x 5/16 in. long pegs). If a torquing type spanner tool is used to tighten shock piston, then torque to 90 lb-ft (122 Nm). 51146 b a a-Shock Rod Piston - Torque to 90 lb-ft (122 Nm) b-Spanner Wrench 9. Remove shock rod assembly from vise. 10. Install ball, seat, and spring (five sets) to shock rod piston. 11. Secure components with plate. Torque screws to 35 lb-in. (4.0 Nm). 51147 e d c a b a-Screw (3) Torque to 35 lb-in. (4.0 Nm) b-Plate c-Spring (5) d-Seat (5) e-Ball (5) Page 5B-42 90-857046 AUGUST 1998 POWER TRIM Shock Rod Installation 1. Place trim cylinder in soft jawed vice. 2. Install lubricated o-ring to memory piston and place into cylinder. Push memory piston all the way to bottom. 3. Fill cylinder three inches (76.2 mm) from top of cylinder using Quicksilver Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. 4. Install shock rod into cylinder until power trim fluid flows through oil blow off ball passage. Fill remaining cylinder to just below the cylinder threads. c a b a-Memory Piston b-O-ring c-Oil Blow Off Ball Passage CAUTION End cap must not make contact with shock rod piston when tightening. Shock rod piston must be positioned in cylinder deep enough to avoid contact. 5. Tighten end cap securely using spanner wrench [1/4 in. x 5/16 in. (6.4mm x 8mm) long pegs]. If a torquing type spanner tool is used to tighten end cap, then torque to 45 lb-ft (61.0 Nm). 90-857046 AUGUST 1998 Page 5B-43 POWER TRIM Trim Limit Assembly Installation 1. Lubricate all O-rings. Install spring, poppet, spool housing and trim limit spool into manifold. NOTE:There are three different size springs used in this manifold. The heavy spring is used on 75-125 hp outboards. The medium spring is used on 40-60 hp Bigfoot outboards. The light spring is used on 30-60 hp outboards. 51008 or a b c d or a-Spring b-Poppet c-Spool Housing d-Trim Limit Spool Manual Release Valve Installation 1. Install “E” clip (if removed) and lubricate o-rings to manual release valve. 2. Install manual release valve assembly into manifold. a b c a-Manifold b-Manual Release Valve c-E Clip Page 5B-44 90-857046 AUGUST 1998 POWER TRIM Manifold Installation 1. Install dowel pin and two (2) lubricated o-rings into trim cylinder. b a a-O-Ring (2) b-Dowel Pin 2. Align the trim cylinder and pump/reservoir assembly together. 3. Install the two (2) long screws and torque to 100 lb-in. (11 Nm). 51146 a b c a-Trim Cylinder Assembly b-Reservoir/Manifold Assembly c-Screw (2) Torque to 100 lb-in. (11 Nm) 90-857046 AUGUST 1998 Page 5B-45 POWER TRIM Page 5B-46 90-857046 AUGUST 1998 Oil Pump Installation 1. Install spring, ball, lubricated o-ring and plastic seat to manifold. 2. Check to see that o-rings are placed on bottom of pump. 3. Install filter and filter seal under pump. Install pump onto manifold. Torque screws to 70 lb-in. (7.7 Nm). b a a - Screw (3) Torque to 70 lb-in. (7.7 Nm) b - Suction Seat Assembly Pressure Operated Assembly Installation IMPORTANT: Inspect poppet assembly for debris in the area shown. If debris is found on poppet, replace poppet. a b a - Debris Under Valve Tip b - Rubber Seat 1. Lubricate o-rings. POWER TRIM 90-857046 AUGUST 1998 Page 5B-47 2. Install spool, seat with o-ring, check valve/poppet, spring and plug with o-ring into pump. Repeat for other side. Torque plugs to 120 lb-in. (13.5 Nm). d b a c a b d e c a - Plug (2) Torque to 120 lb-in. (13.5 Nm) b - Spring (2) c - Check Valve/Poppet (2) d - Seat (2) e - Spool Reservoir/Motor Installation 1. Install coupler into top of pump. Make sure reservoir seal is in the reservoir groove and place reservoir onto pump/manifold assembly. Install ground strap under screw shown Torque screws to 80 lb-in. (9 Nm). a b c d f e a - Screw (4) Torque to 80 lb-in. (9 Nm) b - Reservoir c - Reservoir Seal d - Coupler e - Manifold Assembly f - Ground Strap 2. Fill reservoir to bottom of fill hole using Quicksilver Power Trim Fluid (92-90100A12). If not available, use automotive (ATF) automatic transmission fluid. POWER TRIM Bleeding Power Trim Unit 1. Secure power trim unit in soft jawed vise. 2. Add power trim fluid until it’s even with the bottom of the fill hole. Reinstall plug. 3. Close the manual release valve. (Turn full clockwise). 55263 a b a-Reservoir Plug/Fill Hole b-Manual Release Valve 4. Using a 12 volt power supply, 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. Repeat three times. 5. 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, add fluid if required and repeat cycle until fluid level stays even with the bottom of the fill hole. Installation of Power Trim System 1. Lubricate lower pivot pin, mounting holes with 2-4-C Marine Lubricant. 2. Start lower pivot pin into pivot pin bore and position lower dowel pin (retained) in its respective hole. 51148 95 b a 95 2-4-C w/Teflon (92-850736A1) a-Lower Pivot Pin b-Lower Dowel Pin Page 5B-48 90-857046 AUGUST 1998 POWER TRIM 3. Position trim cylinder assembly (bottom first) between clamp brackets. 4. Apply 2-4-C Marine Lubricant to lower pivot pin. Using a suitable punch, drive lower pivot pin into clamp bracket and trim cylinder assembly until pivot pin is flush with outside surface. 51147 95b 55467 a 95 2-4-C w/Teflon (92-850736A1) a-Trim Cylinder Assembly b-Lower Pivot Pin 5. Using a suitable punch, drive lower dowel pin into its hole until seated. 6. Apply 2-4-C Marine Lubricant to surface of upper pivot pin, pivot pin bore and trim ram bore. 51148 95 b c d 51148 a 95 2-4-C w/Teflon (92-850736A1) a-Lower Dowel Pin b-Pivot Pin c-Pivot Pin Bore d-Trim Ram Bore 90-857046 AUGUST 1998 Page 5B-49 POWER TRIM Page 5B-50 90-857046 AUGUST 1998 7. Using a suitable mallet, drive upper pivot pin into swivel bracket and through trim ram until pivot pin is flush with swivel bracket. 8. Drive pivot pin into its hole until seated. 55464 d 51148 b c a a - Pivot Pin b - Swivel Bracket c - Trim Ram d - Trilobe Pin 9. Install sacrificial aluminum anode to reservoir bracket placing ground strap between bracket and anode, as shown. 10. Route trim harness through clamp bracket and cowling. 55264 d c 55465 b a a - Sacrificial Anode b - Ground Strap c - Bracket d - Trim Harness POWER TRIM 11. Secure trim harness with clamp, as shown. a-Clamp 55264 a 90-857046 AUGUST 1998 Page 5B-51 MANUAL TILT ASSIST MID-SECTION Section 5C - Manual Tilt Assist Table of Contents Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-1 Memory Piston Removal . . . . . . . . . . . . . . 5C-24 Manual Tilt Components . . . . . . . . . . . . . . . . . 5C-2 Valve Block Disassembly . . . . . . . . . . . . . . . . . 5C-26 Manual Trim Flow Diagrams . . . . . . . . . . . . . . 5C-4 Reassembly - O-Ring and Seal Placement . 5C-27 Up Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-4 Actual O-Ring Sizes . . . . . . . . . . . . . . . . . . . . . 5C-28 Down Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 5C-6 O-ring Description and Sizes . . . . . . . . . . . . . . 5C-29 Slow Tilt Down Under High Thrust . . . . . . 5C-8 Manual Tilt System Cleaning and Inspection 5C-29 Under Water Strike (Valves Open) . . . . . . 5C-10 Manual Tilt System Reassembly . . . . . . . . . . 5C-29 Shock Function (Valve Closed) . . . . . . . . . 5C-12 Valve Block Installation . . . . . . . . . . . . . . . . 5C-32 Shock Function Return . . . . . . . . . . . . . . . . 5C-14 Shock Rod Reassembly . . . . . . . . . . . . . . . 5C-33 Hydraulic System Troubleshooting . . . . . . . . . 5C-16 Shock Rod Installation and Fluid Manual Tilt System Removal . . . . . . . . . . . . . . 5C-18 Filling Procedure . . . . . . . . . . . . . . . . . . . . . 5C-35 Manual Tilt System Disassembly . . . . . . . . . . 5C-19 Filling Procedure Option Two Instructions Accumulator Removal . . . . . . . . . . . . . . . . . 5C-20 for Making Retaining Tool . . . . . . . . . . . . . . . . 5C-37 Shock Rod Removal . . . . . . . . . . . . . . . . . . 5C-21 Bleeding Manual Tilt System . . . . . . . . . . . . . . 5C-38 Shock Rod Disassembly . . . . . . . . . . . . . . . . . 5C-21 Manual Tilt System Installation . . . . . . . . . . . . 5C-40 Valve Block Removal . . . . . . . . . . . . . . . . . 5C-24 Manual Release Valve Adjustment . . . . . . 5C-42 5 C Special Tools 1. Spanner Wrench P/N 91-74951 2. Lock-Ring Pliers P/N 91-822778A3 3. Heat Lamp P/N 91-63209 90-857046 AUGUST 1998 Page 5C-1 MANUAL TILT ASSIST Page 5C-2 90-857046 AUGUST 1998 Manual Tilt Components 7 95 7 Loctite 271 (92-809819) 95 2-4-C With Teflon (92-850736A1) 95 a f e b c d 1 13 12 3 4 4 2 7 9 9 8 11 12 13 5 8 11 11 8 10 6 8 11 6 8 11 NOTE: Lubricate all O-rings using Quicksilver Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. NOTE: It is recommended that all o-rings be replaced when servicing tilt system. MANUAL TILT ASSIST Manual Tilt Components REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 11 1 SHOCK ROD ASSEMBLY 45 61 1 SHOCK ROD ASSEMBLY (BEACHING) 2 1 MEMORY PISTON ASSEMBLY 3 1 O RING REBUILD KIT-Cylinder 4 2 O RING 5 1 CYLINDER ASSEMBLY 6 1 SCREW AND SEAL KIT 7 1 ACCUMULATOR ASSEMBLY 35 47 8 1 VALVE BODY ASSEMBLY 9 1 CAM KIT 10 1 VELOCITY VALVE KIT 75 6.2 8.5 11 1 CHECK SYSTEM REPAIR KIT 75 6.2 8.5 – 1 O RING KIT 12 2 PIN 13 2 GROOVE PIN abcdef – Torque cylinder cap to 45 lb-ft (61 Nm) – Torque Accumulator to 35 lb-ft (47 Nm) – Torque Velocity Valve to 75 lb-in. (8.5 Nm) – Torque Transfer Valve Plug to 75 lb-in. (8.5 Nm) – Torque Screw to 100 lb-in. (11 Nm) – Torque Shock Piston to 90 lb-ft (122 Nm) 90-857046 AUGUST 1998 Page 5C-3 MANUAL TILT ASSIST Page 5C-4 90-857046 AUGUST 1998 Manual Trim Flow Diagrams Up Circuit a b c d e f j i h g k l m n o p a - Shock Rod b - End Cap c - Accumulator d - Accumulator Piston e - Accumulator Check Valve f - Camshaft Lever g - Manifold h - Down Circuit Fast Transfer Valve i - Down Circuit Slow Transfer Valve j - Up Circuit Fast Transfer Valve k - Surge Valve l - Cylinder m - Memory Piston n - Shock Piston o - Shock Return Valve p - Impact Relief Valve MANUAL TILT ASSIST Up Circuit With the engine in the down position, the accumulator piston (d) will be at the top of the accumulator (c) with the gas at maximum pressure. To raise the engine, the camshaft lever (f) is rotated all the way down. The internal shaft connected to the camshaft lever will move the push rods, opening the accumulator check valve (e), both fast transfer valves (h & j) and the down circuit slow transfer valve (i). As the operator lifts the engine, oil, under pressure inside the accumulator, will flow around both the slow transfer valve (i) and the down circuit fast transfer valve (h). Oil flows into the bottom of the tilt cylinder forcing the memory piston (m) into the shock piston (n) and then forcing the shock rod up and out. Oil above the shock piston exits the cylinder (l) through an interconnecting passage along side of the cylinder and returns into the manifold (g). Inside the manifold the oil flows past the groove in the surge valve (k), through the up circuit fast transfer valve (j) and mixes with the oil flowing from the accumulator into the up cavity. With the engine in the correct position, the camshaft lever (f) is rotated up and the push rods allow the check valves (e, h, i, & j) to close. The closed check valves prevent the oil from traveling between cavities and locks the engine into position. 90-857046 AUGUST 1998 Page 5C-5 MANUAL TILT ASSIST Page 5C-6 90-857046 AUGUST 1998 Down Circuit a b c d p o n m l j k i h g f e a - Shock Rod b - End Cap c - Accumulator d - Accumulator Piston e - Accumulator Check Valve f - Camshaft Lever g - Manifold h - Down Circuit Fast Transfer Valve i - Down Circuit Slow Transfer Valve j - Up Circuit Fast Transfer Valve k - Surge Valve l - Cylinder m - Memory Piston n - Shock Piston o - Shock Return Valve p - Impact Relief Valve MANUAL TILT ASSIST Down Circuit With the engine tilted up, the piston inside the accumulator piston (d) will be at the bottom of the accumulator (c) and the gas pressure is low. To lower the engine, the camshaft lever (f) is rotated down, the internal cam will cause the push rods to open the accumulator check valve (e), both fast transfer valves (h & j) and the down circuit slow transfer valve (i). The operator will have to press down on the engine cowl to overcome the pressure inside cylinder. Fluid will flow out of the bottom of the cylinder, past both the down circuit fast transfer valve (h) and down circuit slow transfer valve (i). Fluid will flow past the up circuit fast transfer valve (j), surge valve (k) and through the interconnecting passage into the top of the cylinder (l). Due to the shock rod (a), the tilt cylinder cavities differ in volume, the extra fluid from the up cavity [forced into the accumulator (c)] will cause the internal accumulator piston (d) to compress the gas. With the engine in the correct position, the camshaft lever is rotated up and the push rods allow the check valves (e, h, i, & j) to close. 90-857046 AUGUST 1998 Page 5C-7 MANUAL TILT ASSIST Page 5C-8 90-857046 AUGUST 1998 Slow Tilt Down Under High Thrust a b p c d e f j i h g k l m n o a - Shock Rod b - End Cap c - Accumulator d - Accumulator Piston e - Accumulator Check Valve f - Camshaft Lever g - Manifold h - Down Circuit Fast Transfer Valve i - Down Circuit Slow Transfer Valve j - Up Circuit Fast Transfer Valve k - Surge Valve l - Cylinder m - Memory Piston n - Shock Piston o - Shock Return Valve p - Impact Relief Valve MANUAL TILT ASSIST Slow Tilt Down Under High Thrust To tilt the engine down under high thrust conditions [where the propeller thrust forces the shock rod down, creating higher pressure below the memory piston (m)], the camshaft lever (f) is rotated slightly downward. The internal shaft connected to the lever will open the down circuit slow transfer valve (i) allowing oil under pressure into the cavity around the shaft. The higher oil pressure will open the up circuit fast transfer valve (j) allowing oil from the bottom of the cylinder to flow above the shock piston (n) while lowering the engine. Additional oil will flow into the accumulator (c) as the internal pressure forces the accumulator check valve (e) to open. Oil flowing into the accumulator moves the accumulator piston (d) and compresses the gas. 90-857046 AUGUST 1998 Page 5C-9 MANUAL TILT ASSIST Page 5C-10 90-857046 AUGUST 1998 Under Water Strike (Valves Open) a b p o n m l k j i h g f e d c a - Shock Rod b - End Cap c - Accumulator d - Accumulator Piston e - Accumulator Check Valve f - Camshaft Lever g - Manifold h - Down Circuit Fast Transfer Valve i - Down Circuit Slow Transfer Valve j - Up Circuit Fast Transfer Valve k - Surge Valve l - Cylinder m - Memory Piston n - Shock Piston o - Shock Return Valve p - Impact Relief Valve MANUAL TILT ASSIST Under Water Strike (Valves Open) Should the drive unit strike a submerged object while in forward motion, the shock rod (a) will extend from the tilt cylinder (l). Fluid will attempt to exit the cylinder through the interconnecting passage. The rapid fluid flow will increase the pressure below the surge valve (k), causing the valve to move, closing the oil return passage back into the accumulator (c). Oil inside the up cavity is locked in a static position by the closed surge valve. As the shock rod extends outward, the pressure inside the up cavity will reach sufficient pressure to open the shock valve (p) which opens at 880-1110 PSI. Oil will flow into the cavity created as the shock rod & shock piston (a & n) moves away from the memory piston (m). 90-857046 AUGUST 1998 Page 5C-11 MANUAL TILT ASSIST Page 5C-12 90-857046 AUGUST 1998 Shock Function (Valve Closed) Accumulator Gas Pressure 400 PSI a b o n m p l k j i h g f d c e a - Shock Rod b - End Cap c - Accumulator d - Accumulator Piston e - Accumulator Check Valve f - Camshaft Lever g - Manifold h - Down Circuit Fast Transfer Valve i - Down Circuit Slow Transfer Valve j - Up Circuit Fast Transfer Valve k - Surge Valve l - Cylinder m - Memory Piston n - Shock Piston o - Shock Return Valve p - Impact Relief Valve MANUAL TILT ASSIST Shock Function (Valves Closed) Should the drive unit strike a submerged object while in forward motion, the shock rod (a) will extend from the cylinder (l). Oil inside the up cavity is locked in a static position by the closed up circuit fast transfer valve (j), the closed down circuit slow transfer valve (i) and closed down circuit fast transfer valve (h). Fluid will attempt to exit the cylinder through the interconnecting passage back into the accumulator (c). The closed up circuit fast transfer valve (j) will prevent the fluid return. As the shock rod extends outward, the pressure inside the up cavity will reach sufficient pressure to open the shock valve (p) which opens at 880-1110 PSI. Oil will flow into the cavity created as the shock rod & shock piston (n) moves away from the memory piston (m). 90-857046 AUGUST 1998 Page 5C-13 MANUAL TILT ASSIST Page 5C-14 90-857046 AUGUST 1998 Shock Function Return a b p o n m l j k i h g f e d c a - Shock Rod b - End Cap c - Accumulator d - Accumulator Piston e - Accumulator Check Valve f - Camshaft Lever g - Manifold h - Down Circuit Fast Transfer Valve i - Down Circuit Slow Transfer Valve j - Up Circuit Fast Transfer Valve k - Surge Valve l - Cylinder m - Memory Piston n - Shock Piston o - Shock Return Valve p - Impact Relief Valve MANUAL TILT ASSIST Shock Function Return After the drive clears the object, the shock return valve (o) will allow the oil to flow from between the shock piston (n) and memory piston (m) onto the down cavity as the drive returns to its original running position. 90-857046 AUGUST 1998 Page 5C-15 MANUAL TILT ASSIST Hydraulic System Troubleshooting Refer to disassembly/reassembly instructions (following) if disassembly is required when servicing. 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 components and castings must be cleaned using engine cleaner and compressed air or replaced prior to reassembly. Support outboard with tilt lock lever when servicing manual tilt system. 1. Check manual release cam adjustment. Cam must open and close freely. Adjust cam link rod as necessary. 51143 b a c a-Link Rod b-Manual Release Lever c-Accumulator Page 5C-16 90-857046 AUGUST 1998 MANUAL TILT ASSIST 2. Check for external leaks in the manual tilt system. Replace defective part(s) if leak is found. IMPORTANT: If cut or damaged o-rings are found, inspect machined surfaces for scoring, burrs or debris. 3. Check for discharged accumulator. 35 to 50 lb-ft (47-68 Nm) of pulling force must be attained when tilting outboard from full “down” to full “up” position. If more than 50 lb-ft (68 Nm) of force is required, replace accumulator. 50431 a b a-Weight Scale b-Valve Lever (open position) 90-857046 AUGUST 1998 Page 5C-17 MANUAL TILT ASSIST Manual Tilt System Removal CAUTION Remove cowling and remove all spark plug leads from spark plugs to prevent accidental starting while servicing outboard. WARNING Service or installation of the tilt system may result in loss of pressure in the shock cylinder. If the outboard is not in the full down position, such loss of pressure will cause the engine to fall to the full down position with a potential for damaging engine or causing personal injury. To avoid such injury support outboard in the up position using tilt lock lever. WARNING Manual tilt system is pressurized. Accumulator must be removed when shock rod is in the full up position, prior to servicing, otherwise oil spray-back may occur. 1. Support outboard in the up position using tilt lock lever. 2. Remove link rod. 3. Position piece of wood under transom bracket instead of tilt lock for access of removing pin. Use suitable punch to remove (DRIVE DOWN) upper dowel pin. Retain dowel pin. 51143 b a a-Link Rod b-Accumulator c-Dowel Pin d-Wood 51144 c d Page 5C-18 90-857046 AUGUST 1998 MANUAL TILT ASSIST 4. Position tilt lock and remove piece of wood. Use suitable punch to drive out upper pivot pin. 5. Use punch to remove (Drive Down) lower dowel pin. Retain dowel pin. 51144 51144 b a c a-Pivot Pin b-Tilt Lock c-Dowel Pin 6. Use suitable punch to drive out lower pivot pin. 7. Tilt shock absorber assembly (TOP FIRST) out from clamp bracket and remove assembly. 51144 b 1 2 51144 a a-Pivot Pin b-Manual Tilt System Manual Tilt System Disassembly NOTE: Accumulator contains a high pressure nitrogen charge and is NOT SERVICEABLE. Replace if necessary. WARNING This tilt system is pressurized. Remove accumulator only when shock rod is in full up position. 90-857046 AUGUST 1998 Page 5C-19 MANUAL TILT ASSIST Accumulator Removal 1. Place manual tilt system in soft jawed vise. 2. Position shock rod to full up position. 3. Open cam shaft valve (Down Position). 4. Loosen velocity valve enough to drip, wait until dripping stops. 5. When fluid stops dripping, loosen and remove accumulator. 6. If plunger can be compressed into accumulator by hand, accumulator is defective. Replace accumulator. 51143 d 51143 c a b a-Accumulator b-Cam Lever c-Velocity Valve d-Plunger 7. Once accumulator is removed, remove o-ring, conical spring, steel ball and plunger. 51145 d c b a a-Conical Spring b-Steel Ball c-Plunger d-O-ring Page 5C-20 90-857046 AUGUST 1998 MANUAL TILT ASSIST Shock Rod Removal 1. Unscrew cylinder end cap assembly using spanner wrench [1/4 in. x 5/16 in. long pegs]. 2. Remove shock rod assembly from cylinder. 91-74951 51145 Shock Rod Disassembly NOTE:The only serviceable items on the shock rod assembly are the O-rings and wiper ring. If shock rod requires any other repair, replace shock rod assembly. b c a a-End Cap b-O-ring (2) c-Wiper Ring 1. Place shock rod assembly on clean work surface. 2. Remove three (3) screws and remove plate from shock rod piston. 51143 a b c a-Screw (3) b-Plate c-Shock Rod Piston 90-857046 AUGUST 1998 Page 5C-21 MANUAL TILT ASSIST 3. Remove check ball components from shock rod piston. 4. Remove o-ring. 51147 d c b 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. 91-63209 a-Spanner Wrench b-Shock Rod Piston b a 91-74951 Page 5C-22 90-857046 AUGUST 1998 MANUAL TILT ASSIST 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. 51199 b a 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 51147 c b a a-Rod Wiper b-Inner O-ring c-Outer O-ring 90-857046 AUGUST 1998 Page 5C-23 MANUAL TILT ASSIST Valve Block Removal 1. Remove two screws from the shock rod cylinder to separate the valve block. 2. Remove o-rings and dowel pins. 51148 51146 b c a d e a-Screw b-Valve Block c-Shock Rod Cylinder d-O-ring (2) e-Dowel Pin (2) Memory Piston Removal 1. Remove memory piston from cylinder using one of two methods: a. Using lock ring pliers. 91-822778A3 51144 Page 5C-24 90-857046 AUGUST 1998 MANUAL TILT ASSIST b. Blowing compressed air into center o-ring hole. 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. Fluid will blow out also. 2. Remove O-ring from memory piston. 51144 e d 55466 a c b a-Adaptor/Air Hose b-Memory Piston Exit c-Shop Rag d-O-Ring e-Memory Piston 90-857046 AUGUST 1998 Page 5C-25 MANUAL TILT ASSIST Page 5C-26 90-857046 AUGUST 1998 Valve Block Disassembly 1. Remove check retainer plug and components. 2. Remove hydraulic oil transfer valve plugs and components. 3. Remove surge valve assembly. d c e f 51142 a b a - Transfer Valve Plug Assembly (2) b - Check Retainer Plug or Screw Assembly c - Spool d - Spring e - O-ring f - Velocity Valve 4. Remove screw and remove cam assembly. a b c d e a - Spacer Retainer Clip b - Retainer Clip c - Screw d - Shaft Seal e - Cam MANUAL TILT ASSIST 90-857046 AUGUST 1998 Page 5C-27 Reassembly - O-Ring and Seal Placement 1 2 3 5 4 14 6 7 9 11 12 10 13 8 NOTE: Lubricate all O-rings using Quicksilver Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. NOTE: It is recommended that all o-rings be replaced when servicing tilt system. MANUAL TILT ASSIST Actual O-Ring Sizes 1 2 9 3 4 14 5 10 (2)6 7 (2) 8 12 11 13 O.D. I.D. Cutaway View of O-Ring Width O-RINGS SHOWN ARE ACTUAL SIZE Page 5C-28 90-857046 AUGUST 1998 MANUAL TILT ASSIST O-Ring Description and Sizes O-Ring Description O-Ring I.D. O-Ring O.D. O-Ring Width 1 Wiper Ring 2 Cyl. Cap, Inner 0.671 in. (17.04 mm) 0.949 in. (24.10 mm) 0.139 in. (3.53 mm) 3 Cyl. Cap 1.864 in. (47.34 mm) 2.004 in. (50.90 mm) 0.07 in. (1.78 mm) 4 Shock Piston 1.6 in. (40.64 mm) 2.02 in. (53.086 mm) 0.21 in. (5.334 mm) 5 Piston Bolt 0.676 in. (17.17 mm) .816 in. (20.726 mm) 0.07 in. (1.78 mm) 6 (2) Manifold Split Line 0.208 in. (5.283 mm) 0.348 in. (8.839 mm) 0.07 in. (1.78 mm) 7 Slow Valve 0.114 in. (2.90 mm) 0.254 in. (6.451 mm) 0.07 in. (1.78 mm) 8 (2) Plug 0.489 in. (12.42 mm) 0.629 in. (15.97 mm) 0.07 in. (1.78 mm) 9 Accumulator 2.114 in. (53.69 mm) 2.254 in. (57.25 mm) 0.07 in. (1.78 mm) 10 Lip Seal 11 Cam Shaft 0.301 in. (7.645 mm) 0.441 in. (11.20 mm) 0.07 in. (1.78 mm) 12 Back Up Ring 13 Surge Valve 0.301 in. (7.645 mm) 0.441 in. (11.20 mm) 0.07 in. (1.78 mm) 14 Memory Piston 1.6 in. (40.64 mm) 2.02 in. (53.086 mm) 0.21 in. (5.334 mm) Manual Tilt System Cleaning and Inspection 1. It is recommended that all o-rings exposed during disassembly be replaced. 2. Clean components, filter, and check valve seats using engine cleaner and compressed air. Do not use cloth rags. 3. Inspect all machined surfaces for burrs or scoring to assure o-ring longevity. 4. Inspect shock rod. If scraper (located in cap) has failed to keep rod clean, replace scraper. Manual Tilt System Reassembly IMPORTANT: Components must be dirt and lint free. Slightest amount of debris in tilt system could cause system to malfunction. Apply Quicksilver Power Trim and Steering Fluid to all o-rings during reassembly. If not available, use automotive (ATF) automatic transmission fluid. 90-857046 AUGUST 1998 Page 5C-29 MANUAL TILT ASSIST Page 5C-30 90-857046 AUGUST 1998 CAM SHAFT REASSEMBLY IMPORTANT: Cam shaft O-ring must be lubricated using 2-4-C with Teflon. 1. Install lubricated o-ring and back up seal to cam. 2. Install shaft seal in valve block with lips facing out. 3. Install cam shaft assembly in valve block. 4. Secure cam shaft in place using insulator, retainer plate, and screw. Tighten screw securely. 95 2-4-C w/Teflon (92-850736A1) 95 a b c d e f g a - Spacer Retainer Clip b - Retainer Clip c - Screw d - Shaft Seal e - O-ring f - Back up Seal g - Cam VALVE BODY CHECK REASSEMBLY 1. Install lubricated o-ring, plunger, steel ball and conical spring to valve block. 51145 a b c d a - Conical Spring b - Steel Ball c - Plunger d - O-ring MANUAL TILT ASSIST VELOCITY VALVE REASSEMBLY 1. Install spool, spring, lubricated o-ring and screw plug (surge valve assembly) into valve block. 2. Torque velocity valve to 75 lb-in. (8.5 Nm). d c b a a-Spool b-Spring c-O-ring d-Velocity Valve - Torque to 75 lb-in. (8.5 Nm) CHECK RETAINER REASSEMBLY 1. Install plunger, spring (large), ball, spring (small), and plug into valve block. a b c d e 51142 a-Plunger b-Spring (Large) c-Ball d-Spring (Small) e-Plug 90-857046 AUGUST 1998 Page 5C-31 MANUAL TILT ASSIST VALVE PLUG REASSEMBLY 1. Install plunger, steel ball, spring, lubricated o-ring and screw plug. Torque screw plugs to 75 lb-in. (8.5 Nm). 51142 a b c d e a-Plunger (2) b-Steel Ball (2) c-Spring (2) d-O-ring (2) e-Screw Plug (2) Torque to 75 lb-in. (8.5 Nm) Valve Block Installation 1. Install lubricated O-rings and dowel pins. 2. Install valve block to shock rod cylinder. Insert screws to shock rod cylinder and torque to 100 lb-in. (11 Nm). 51146 51148 1 a b c d e a-O-ring (2) b-Dowel Pin (2) c-Valve Block d-Screw (2) Torque to 100 lb-in. (11 Nm) e-Shock Rod Cylinder Page 5C-32 90-857046 AUGUST 1998 MANUAL TILT ASSIST Shock Rod Reassembly 1. Install lubricated o-rings to end cap. 2. Install rod wiper. 3. Install lubricated o-rings to shock piston. 51199 f e d51145 a b c a-Rod Wiper b-Inner O-ring c-Outer O-ring d-Shock Piston e-O-ring f-O-ring 4. Clamp shock rod in soft jawed vise. 5. Position cylinder end cap onto rod, as shown. 51146 90-857046 AUGUST 1998 Page 5C-33 MANUAL TILT ASSIST 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 Grade “A” (271) 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. (6.4mm x 8mm) long pegs]. If a torquing type spanner tool is used to tighten shock piston, then torque to 90 lb-ft (122 Nm). 7 Loctite “271” (92-809819) 7 a b 91-74951 51146 a-Spanner Wrench b-Shock Rod Piston - Torque to 90 lb-ft (122 Nm) 9. Install ball, seat, and spring (five sets) to shock rod piston. 10. Secure components with plate. Torque screws to 35 lb-in. (3.9 Nm). 11. Remove shock rod assembly from vise. 51147 e d c a b a-Screw (3) Torque to 35 lb-in. (3.9 Nm) b-Plate c-Spring (5) d-Seat (5) e-Ball (5) Page 5C-34 90-857046 AUGUST 1998 MANUAL TILT ASSIST Shock Rod Installation and Fluid Filling Procedure NOTE:There are two ways for the filling procedure. The first is the easiest and less time consuming. Filling Procedure Option One 1. Place trim cylinder in soft jawed vice. 2. With manifold cam lever closed (Up Position), fill cylinder and manifold to top with Quicksilver Power trim and steering fluid, or (ATF) automatic transmission fluid. Let bubbles disperse. 3. Install lubricated o-ring to memory piston. 4. Using lock ring pliers (P/N 91-822778A3). Set memory piston in top of cylinder then open cam lever (Down Position) and push memory piston down just below cylinder treads. Close cam lever (Up Position). 51144 5. Fill top of cylinder again with fluid to top and install shock rod assembly on top memory piston. Open cam lever (Down Position) and push shock rod assembly down to 1/8, below cylinder threads. Close cam lever (Up Position). 6. Fill top of shock rod assembly with fluid to top of cylinder. Open cam lever (Down Position) and screw cylinder cap down. 7. Tighten end cap securely using spanner wrench [1/4 in. x 5/16 in. (6.4mm x 8mm) long pegs]. If a torquing type spanner tool is used to tighten end cap, then torque the end cap to 45 lb-ft (61.0 Nm). Close cam lever (Up Position). 51145 90-857046 AUGUST 1998 Page 5C-35 MANUAL TILT ASSIST 8. Open and close cam lever, watching for bubbles coming from accumulator check ball hole. When bubbles stop, fill accumulator opening to top with fluid. Grease threads on accumulator and opening with 2-4-C with Teflon. Start accumulator in threads and open cam lever (Down Position). Torque accumulator to 35 lb–ft (47 Nm). 51143 ba a-Accumulator b-Cam Lever (Down Position) NOTE: If filling procedure is done correctly, it should be hard to turn cylinder rod assembly by hand. Page 5C-36 90-857046 AUGUST 1998 MANUAL TILT ASSIST Filling Procedure Option Two Instructions for Making 3/8 in. x 13 in. (10 mm x 33 cm) Threaded Rod 3/16 in x 3 in. (5 x 7.5 cm) Steel Plate 4in. x 1/4 in. min. (10cm x 6.4 mm) minimum Channel Iron Retaining Tool 1 in. (25mm) 10 in. (25 cm) 8 in. (20 cm) 2 holes, 7/16 in. dia. (11 mm) 3 in. (76mm) 5 in. (125mm) 1 1/4 in. dia. (30m) 20 in. (508mm) 8 in. (203mm) 6 in. (152mm) 4 in. (100 mm) 2 in. (50mm) 3/8 in. dia. 2 holes 90-857046 AUGUST 1998 Page 5C-37 MANUAL TILT ASSIST Bleeding Manual Tilt System IMPORTANT: While bleeding tilt system, time must be allowed between each stroke to allow air bubbles to dissipate. 1. With shock rod in the full up position and manifold cam lever open (facing down), secure tilt system to retaining tool and container. (A No. 10 can or 3 lb coffee can could be used.) 2. Fill container to near full level using Quicksilver Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. IMPORTANT: Fluid level must remain above accumulator opening during bleeding process. 50447d e a b c a a-Retaining Tool b-Tilt System c-Container d-Cam Lever e-Accumulator Opening 3. Bleed unit by pushing rod down slowly (18-20 seconds per stroke) until stopped at base. Wait until all air bubbles exit accumulator base. 50432 Page 5C-38 90-857046 AUGUST 1998 MANUAL TILT ASSIST 4. During up stroke, pull up on rod slowly 3 in. (76 mm) from base. 5. Wait until all air bubbles to exit accumulator base. 50433 6. Slowly cycle unit 5-8 times (round trip per cycle) using short strokes 3 in. (76 mm) from base allowing bubbles to disappear during each stroke. 7. Allow unit to stand five minutes, then proceed to cycle unit 2-3 more times using short strokes. No air bubbles should appear from accumulator port at this time. 8. With oil level well above accumulator port, slowly pull rod to full up position. 9. Install accumulator making sure air bubbles do not enter system. 10. Tighten accumulator snugly at this time. 50432 50432 90-857046 AUGUST 1998 Page 5C-39 MANUAL TILT ASSIST 11. With cam lever remaining open (facing down), remove tilt assembly from oil and secure in soft jawed vise. Torque accumulator to 35 lb-ft (47 Nm). 50433 Manual Tilt System Installation 1. Apply 2-4-C Marine Lubricant to lower pivot pin hole and pivot pin surface. 2. Start lower pivot pin into pivot pin hole and position lower dowel pin (retained) in its hole. 3. Reinstall manual tilt system, bottom first. Reconnect release valve link rod. 51144 2 151148 95 2-4-C w/Teflon (92-850736A1) 95 a b c a-Lower Pivot Pin b-Lower Dowel Pin c-Manual Tilt System Page 5C-40 90-857046 AUGUST 1998 MANUAL TILT ASSIST 4. Using a suitable punch, drive lower pivot pin into clamp bracket and trim cylinder assembly until pivot pin is flush with outside surface. 5. Using a punch, drive lower dowel pin in until seated. 51148 b 51147 a a-Lower Pivot Pin b-Lower Dowel Pin 6. Apply 2-4-C Marine Lubricant to surface of upper pivot pin, pivot pin hole and shock rod hole. 7. Using a mallet, drive upper pivot pin into swivel bracket and through shock rod until pivot pin is flush with swivel bracket. 51148 95 b c a 95 2-4-C w/Teflon (92-850736A1) a-Pivot Pin b-Pivot Pin Bore c-Shock Rod Bore d-Pivot Pin e-Swivel Bracket f-Shock Rod 51148 f e d 90-857046 AUGUST 1998 Page 5C-41 MANUAL TILT ASSIST 8. Drive upper dowel pin (a) into its hole until seated. 51147 a a-Dowel Pin 9. Check manual release cam adjustment. Cam must open and close freely. Adjust link rod as necessary. Manual Release Valve Adjustment 1. With outboard in full up position, place tilt lock lever forward. 2. Lift cam lever (with link rod) to full up position. 51143 b a c a-Tilt Lock Lever b-Cam Lever c-Link Rod 3. Link rod end must snap onto ball of tilt lock lever without moving tilt lock lever or cam lever. Page 5C-42 90-857046 AUGUST 1998 NON-BIGFOOT GEAR HOUSING LOWER UNIT Section 6A - Non-Bigfoot Gear Housing Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2 Quicksilver Lubricants and Service Aids . . . . 6A-5 Gear Housing (Driveshaft)(2:1 Gear Ratio) . 6A-6 Gear Housing (Propeller Shaft) (2:1 Gear Ratio) . . . . . . . . . . . . . . . . . . . . . . . . . 6A-8 General Service Recommendations . . . . . . . 6A-10 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-10 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-10 Draining and Inspecting Gear Lubricant . . . . 6A-11 Gear Housing Removal . . . . . . . . . . . . . . . . . . 6A-12 2-Stroke Models . . . . . . . . . . . . . . . . . . . . . . 6A-12 4-Stroke Models . . . . . . . . . . . . . . . . . . . . . . 6A-13 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-15 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . 6A-15 Water Pump Seals . . . . . . . . . . . . . . . . . . . . 6A-21 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-23 Upper Drive Shaft Bearing . . . . . . . . . . . . . 6A-23 Pinion Gear Bearing . . . . . . . . . . . . . . . . . . 6A-24 Pinion Gear . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-24 Forward Gear . . . . . . . . . . . . . . . . . . . . . . . . 6A-24 Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-27 Specifications Propeller Shaft Disassembly . . . . . . . . . . . 6A-28 Propeller Shaft and Carrier Inspection . . . . . 6A-29 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-29 Cam Follower . . . . . . . . . . . . . . . . . . . . . . . . 6A-29 Reverse Gear . . . . . . . . . . . . . . . . . . . . . . . . 6A-29 Reverse Gear Bearing . . . . . . . . . . . . . . . . 6A-30 Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . . 6A-31 Gear Housing Reassembly . . . . . . . . . . . . . . . 6A-35 Shift Shaft Assembly . . . . . . . . . . . . . . . . . . 6A-35 Pinion Bearing Race . . . . . . . . . . . . . . . . . . 6A-36 Forward Gear . . . . . . . . . . . . . . . . . . . . . . . . 6A-37 Pinion Gear/Drive Shaft Assembly . . . . . . 6A-38 Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . 6A-39 Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . . 6A-41 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . 6A-42 Gear Housing Pressure Test . . . . . . . . . . . . . . 6A-45 Gear Housing Installation . . . . . . . . . . . . . . . . . 6A-46 2-Stroke Models . . . . . . . . . . . . . . . . . . . . . . 6A-47 4-Stroke Models . . . . . . . . . . . . . . . . . . . . . . 6A-47 Trim Tab Adjustment and Replacement . . . . 6A-48 Filling Gear Housing with Lubricant . . . . . 6A-50 6 A Gear Ratio 2.00:1 Gearcase Capacity 14.9 fl oz (440 mL) Lubricant Type Quicksilver Gear Lube-Premium Blend GEAR HOUSING (2.00:1) Forward Gear Number of Teeth Pinion Gear Number of Teeth 26 Spiral/Bevel 13 Spiral/Bevel Pinion Height Forward Gear Backlash 0.025 in. (0.64 mm) No Adjustment Water Pressure @ 800 rpm (Idle) 2–4 psi (14-28 kPa) @ 6000 rpm (WOT) 12–17 psi (69-103 kPa) 90-857046 AUGUST 1998 Page 6A-1 NON-BIGFOOT GEAR HOUSING Special Tools 1. Bearing 31-85560 54978 2. Driver 91-13779 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 Page 6A-2 90-857046 AUGUST 1998 NON-BIGFOOT GEAR HOUSING 6. Universal Puller Plate 91-37241 7. Driver Head 91-37312 8. Driver 91-817011 9. Driver Rod 91-37323 90-857046 AUGUST 1998 Page 6A-3 NON-BIGFOOT GEAR HOUSING 10. Drive Shaft Holding Tool a. 2-stroke models 91-825196 b. 4-stroke models 91-83180M 11. Mandrel 91-825197 12. Driver 91-817007 13. Mandrel 91-825198 14. Pilot 91-825199 15. Spring Hook 91-825200A1 Page 6A-4 90-857046 AUGUST 1998 NON-BIGFOOT GEAR HOUSING 16. Driver 91-826872 17. Leakage Tester FT8950 Quicksilver Lubricants and Service Aids Part No. Description 92-809819 Loctite “271” Purchase Local Loctite “405” 92-891601-1 RTV Silicone Sealer 92-850737A1 Super Duty Gear Lubricant 92-809824 Loctite Primer “7649” 92-850735A1 Anti-Corrosion Grease 92-850736A1 2-4-C w/Teflon 90-857046 AUGUST 1998 Page 6A-5 NON-BIGFOOT GEAR HOUSING Gear Housing (Driveshaft)(2:1 Gear Ratio) Loctite “271”(92-809819) Loctite “405”(Purchase Locally) 7 74 87 92 95 Super Duty Gear Lubricant (92-850737A1) Loctite Primer “7649”(92-809824) 2-4-C w/Teflon (92-850736A1) 3.44 IN./135MM TORPEDO DIA. Page 6A-6 90-857046 AUGUST 1998 NON-BIGFOOT GEAR HOUSING Gear Housing (Driveshaft)(2:1 Gear Ratio) REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm – 1 GEAR HOUSING (SHORT) – 1 GEAR HOUSING (LONG) 1 1 GEAR HOUSING (BASIC) 2 1 SEAL/PLATE KIT 3 1 PLATE (Part Of Ref #2) 4 1 SCREW (.375–16 x .25) 60 6.8 5 1 WASHER–Sealing 6 1 DRAIN SCREW (MAGNETIC) 60 6.8 7 1 WASHER–Sealing 8 1 NUT 50 68.0 9 1 PINION GEAR (13 TEETH) 10 1 BEARING ASSEMBLY–Roller 11 1 CUP (Part Of Ref #10) 12 4 SCREW (M6 x 16) 60 6.8 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 2626 1 DRIVESHAFT (SHORT) 1 DRIVESHAFT (LONG) 27 1 BALL BEARING 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 3434 1 SHIFT SHAFT (SHORT) 1 SHIFT SHAFT (LONG) 35 1 WASHER 36 1 ROLL PIN 37 1 CAM–Shift 38 1 PIN 90-857046 AUGUST 1998 Page 6A-7 NON-BIGFOOT GEAR HOUSING Gear Housing (Propeller Shaft)(2:1 Gear Ratio) 3.44 IN./135MM TORPEDO DIA. 42 7 87 95 94 1 95 95 87 95 87 7 95 56 87 87 394045 48 41 43 44 46 47 49 50 51 52 5354 55 57 58 59 60 61 62 63 6465 66 67 68 69 70 71 72 73 39 Loctite “271” (92-809819) Super Duty Gear Lubricant (92-850737A1) Anti-Corrosion Grease (92-850735A1) 2-4-C w/Teflon (92-850736A1) Page 6A-8 90-857046 AUGUST 1998 NON-BIGFOOT GEAR HOUSING Gear Housing (Propeller Shaft)(2:1 Gear Ratio) REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm – 1 GEAR HOUSING (SHORT) GEAR HOUSING (LONG)– 1 1 1 GEAR HOUSING (BASIC) 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 (26 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 (26 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 (2:1) 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 54.2 72 4 WASHER REPLACEMENT 73 1 PLUG 90-857046 AUGUST 1998 Page 6A-9 NON-BIGFOOT GEAR HOUSING General Service Recommendations There may be more than one way to “disassemble” or “reassemble” a particular part(s), therefore, it is recommended that the entire procedure be read prior to repair. IMPORTANT: Read the following before attempting any repairs. In many cases, disassembly of a sub-assembly may not be necessary until cleaning and inspection reveals that disassembly is required for replacement of one or more components. Service procedure order in this section is a normal disassembly-reassembly sequence. Threaded parts are right hand (RH), unless otherwise indicated. When holding, pressing or driving is required, use soft metal vise jaw protectors or wood for protection of parts. Use a suitable mandrel (one that will contact only the bearing race) when pressing or driving bearings. 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 Quicksilver 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 w/Teflon on all O-rings and on I.D. of oil seals. Apply 2-4-C w/Teflon to external surfaces of bearing carrier. Page 6A-10 90-857046 AUGUST 1998 NON-BIGFOOT GEAR HOUSING 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. 4. Presence of water indicates the need for disassembly and inspection of oil seals, o- rings, gaskets and components for damage. Pressure check gear case prior to disassembly. 90-857046 AUGUST 1998 Page 6A-11 NON-BIGFOOT GEAR HOUSING 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. 2-Stroke Models MERCURY/MARINER 30/40, AND 40/50, FORCE 40/50 3. Loosen jam nut. Unscrew attaching nut to separate shift shaft. 52832 b a a-Jam Nut b-Attaching Nut Page 6A-12 90-857046 AUGUST 1998 NON-BIGFOOT GEAR HOUSING 4-Stroke Models MERCURY/MARINER 25, 30/40, AND 45/50 4. Disconnect shift shaft by un-snapping retainer to lower clip and sliding retainer to the left. a 1 2 b a-Retainer b-Lower Clip 5. Make a scribe line showing alignment of trim tab to gear case and remove trim tab bolt and washer. 52835 a b a-Bolt and Washer b-Scribe Line 90-857046 AUGUST 1998 Page 6A-13 NON-BIGFOOT GEAR HOUSING 6. Remove nut and washer in trim tab cavity. 52835 a a-Nut and Washer 7. Remove 4 bolts securing gear case to drive shaft housing. 52836 a a-Bolt (4) Page 6A-14 90-857046 AUGUST 1998 NON-BIGFOOT GEAR HOUSING 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 bolts securing pump cover. 52830 a b a-Seal b-Bolt (4) NOTE:Replace cover if thickness of steel at discharge slots is 0.060 in. (1.524 mm) or less, or if groove(s)(other than impeller sealing groove) in cover roof are more than 0.030 in. (0.762 mm) deep. 90-857046 AUGUST 1998 Page 6A-15 NON-BIGFOOT GEAR HOUSING 2. Remove cover, washer (above impeller), impeller, key and washer (below impeller). 3. Remove cover gasket, base plate and base gasket. 52692 a b c d e f g h a-Cover b-Nylon Washer (above impeller) c-Impeller d-Key e-Nylon 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 6A-16 90-857046 AUGUST 1998 NON-BIGFOOT GEAR HOUSING 4. Remove and/or replace exhaust deflector plate if damaged. 52832 a a-Deflector Plate 5. Remove bearing carrier attaching bolts and locking tab washers or flat washers. Discard tab washers. b a a-Bolts 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) 90-857046 AUGUST 1998 Page 6A-17 NON-BIGFOOT GEAR HOUSING NOTE: When removing propeller shaft assembly, cam follower may dislodge. Retrieve follower from gear housing. 7. Remove propeller shaft assembly. a 52864 a-Propeller Shaft Models Drive Shaft Holding Tool 4-Stroke Mercury/Mariner 25, 30/40, and 45/50 91-83180M 2-Stroke Force 40/50 Mercury/Mariner 30/40, 40/50 91-825196 8. Remove pinion nut. 52864 51043 b c a a-Drive Shaft Holding Tool b-Pinion Nut c-Pinion Gear Page 6A-18 90-857046 AUGUST 1998 NON-BIGFOOT GEAR HOUSING 9. Remove drive shaft assembly and pinion gear. 10. Remove forward gear. 52870 a a-Forward Gear 11. Remove shift shaft assembly 52841 a a-Shift Shaft Assembly 90-857046 AUGUST 1998 Page 6A-19 NON-BIGFOOT GEAR HOUSING 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. 52844 b a a-Puller (91-825200A1) b-Driver (91-13779) 13. Remove forward bearing race with puller (91-27780). 91-825200A1 91-13779 53838 91-27780 b a a-Race b-Puller (91-27780) Page 6A-20 90-857046 AUGUST 1998 NON-BIGFOOT GEAR HOUSING 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” (92-809819) a-Neoprene Ribbed Seal b-Metal Cased Seal c-Carrier d-O-ring 2. Apply Loctite 271 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 a b a-Seal (Metal Cased) Lip Facing Down b-Mandrel (91-825197) 90-857046 AUGUST 1998 Page 6A-21 NON-BIGFOOT GEAR HOUSING 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 b a a-Seal (Ribbed Neoprene) Lip Facing Up b-Mandrel (91-825197) NOTE: Apply a light coat of 2-4-C w/Teflon (92-850736A1) to the lips of both seals after installation in carrier. 4. Apply a light coat of 2-4-C w/Teflon to the new o-ring and install on carrier. 52825 95 a 95 2-4-C w/Teflon (92-850736A1) a-O-ring Page 6A-22 90-857046 AUGUST 1998 NON-BIGFOOT GEAR HOUSING 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) 90-857046 AUGUST 1998 Page 6A-23 NON-BIGFOOT GEAR HOUSING 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. 52823 b a a-Bearing b-Race Pinion Gear 1. Inspect pinion gear teeth for rust, chipping, 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. 52839 Forward Gear 1. Inspect forward gear teeth for rust, chipping, excessive wear (teeth are sharped edged), or broken teeth. 2. Inspect forward gear clutch jaws for wear. Rounded jaws indicate the following: • Improper shift cable adjustment. • Engine idle speed too high. • Shifting too slowly. 52874 Page 6A-24 90-857046 AUGUST 1998 NON-BIGFOOT GEAR HOUSING 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 b a a-Bearing Surface b-Bearing 4. Use a suitable mandrel to press needle bearing out of forward gear. 52873 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 Super Duty Gear Lubricant (92-850737A1) 91-826872 a b 87 a-Driver (91-826872) b-Bearing 90-857046 AUGUST 1998 Page 6A-25 NON-BIGFOOT GEAR HOUSING 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. REMOVAL 91-37241 b a a-Universal Puller Plate (91-37241) b-Mandrel (15/16 in. socket) a INSTALLATION a-Mandrel (1-1/8 in. socket) Page 6A-26 90-857046 AUGUST 1998 NON-BIGFOOT GEAR HOUSING 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. 52845 b a 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. 52828 a b a-Boot b-O-ring 90-857046 AUGUST 1998 Page 6A-27 NON-BIGFOOT GEAR HOUSING Propeller Shaft Disassembly 1. Remove propeller shaft from carrier and disassemble shaft. c d e a b f 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). 91-27780 b a 52840 a-Reverse Gear and Bearing b-Puller (91-27780) Page 6A-28 90-857046 AUGUST 1998 NON-BIGFOOT GEAR HOUSING 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. 52824 Cam Follower 1. Inspect cam follower for wear or galling. 2. If wear is present, inspect corresponding shift cam for wear. Replace if worn. 52822 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: • Improper shift cable adjustment. • Engine idle speed too high. • Shifting too slowly. 52875 90-857046 AUGUST 1998 Page 6A-29 NON-BIGFOOT GEAR HOUSING 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). 4. Install new bearing using a suitable mandrel. PRESS ONLY ON INNER RACE when installing bearing. REMOVAL d a b c 91-37312 91-37241 a-Bearing b-Reverse Gear c-Universal Puller Plate (91-37241) d-Driver (91-37312) 87 a b INSTALLATION 52867 a-Mandrel (1-1/4 in. socket) b-Bearing 87 Super Duty Gear Lubricant (92-850737A1) Page 6A-30 90-857046 AUGUST 1998 NON-BIGFOOT GEAR HOUSING 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. 91-37312 91-37323 a b c d 51264 a-Driver Rod (91-37323) b-Driver (91-37312) c-Needle Bearing d-Seals 4. Apply Super Duty Gear Lubricant to O.D. of bearing. 5. Install bearing using Mandrel 91-817011. 90-857046 AUGUST 1998 Page 6A-31 NON-BIGFOOT GEAR HOUSING 6. Press bearing into carrier until mandrel bottoms on carrier. 52861 87 91-817011 a b 87 Super Duty Gear Lubricant (92-850737A1) a-Bearing b-Mandrel (91-817011) 7. Apply Loctite 271 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” (92-809819) 91-817007 b a a-Seal b-Mandrel (91-817007) Page 6A-32 90-857046 AUGUST 1998 NON-BIGFOOT GEAR HOUSING 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 91-817007 b a 7 Loctite “271” (92-809819) 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. 51275 .82 in. (20mm) a a-Bearing 51275 .04 in. (1mm) .44 in. (11mm) a b a-Oil Seal (Install with Lip Down) b-Oil Seal (Install with Lip Up) 90-857046 AUGUST 1998 Page 6A-33 NON-BIGFOOT GEAR HOUSING 11. Bearing carrier o-ring should be inspected for cuts and abrasions. NOTE:It is a good repair procedure to replace all o-rings and seals regardless of appearance. 12. Apply 2-4-C w/Teflon to O.D. of bearing carrier and also to o-ring. Install o-ring onto bearing carrier. 13. Using suitable mandrel, press reverse gear assembly into carrier. 52827 95 95 2-4-C w/Teflon (92-850736A1) b c a a-O-ring b-Mandrel (3/4 in. Socket) c-Reverse Gear Assembly Page 6A-34 90-857046 AUGUST 1998 NON-BIGFOOT GEAR HOUSING 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. Shift Shaft Assembly 1. Apply 2-4-C w/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 bolts. 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. 52841 95 e d b c a 95 2-4-C w/Teflon (92-850736A1) a-O-rings b-Carrier c-Boot d-Sta-strap e-Ramp 90-857046 AUGUST 1998 Page 6A-35 NON-BIGFOOT GEAR HOUSING Pinion Bearing Race 1. Apply Super Duty 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 Super Duty Gear Lubricant (92-850737A1) 91-29310 12-34961 91-825198 91-31229 11-24156 31-85560 91-825199 b e g d a f 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) Page 6A-36 90-857046 AUGUST 1998 NON-BIGFOOT GEAR HOUSING Forward Gear 1. Apply Super Duty 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. 52843 87 91-36571 b a 87 Super Duty Gear Lubricant (92-850737A1) 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 52870 a-Forward Gear Assembly 90-857046 AUGUST 1998 Page 6A-37 NON-BIGFOOT GEAR HOUSING Pinion Gear/Drive Shaft Assembly 1. Clean pinion nut and pinion nut threads of drive shaft with Loctite Primer T. 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, 30/40, and 45/50 91-83180M 2-Stroke Force 40/50 Mercury/Mariner 30/40, 40/50 91-825196 5. Using Drive Shaft Holding Tool to hold drive shaft, torque pinion nut to 50 lb-ft (67.8 Nm). 7 a b c d 7 52864 Loctite “271” (92-809819) a-Pinion Nut [Torque to 50 lb-ft. (67.8 Nm)] b-Pinion Gear c-Pinion Bearing d-Drive Shaft Holding Tool Page 6A-38 90-857046 AUGUST 1998 NON-BIGFOOT GEAR HOUSING 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 d e f c 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. 52851 c a 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 w/Teflon to cam follower will aid in retention of follower in propeller shaft during installation of propeller shaft assembly into gear case. 90-857046 AUGUST 1998 Page 6A-39 NON-BIGFOOT GEAR HOUSING 6. Install cam follower. 95 a 52826 95 2-4-C w/Teflon (92-850736A1) a-Cam Follower 7. Install propeller shaft assembly into gear case. a 52864 a-Propeller Shaft Assembly Page 6A-40 90-857046 AUGUST 1998 NON-BIGFOOT GEAR HOUSING 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 bolts on models listed. Install thicker flat washers and longer bolts. 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 cb a-Bolt 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 bolts. a b a-Bolt (10-855940-30) 1.18 in. (30 mm) Long b-Washer (12-855941) 0.090 in. (2.29 mm) Thick 90-857046 AUGUST 1998 Page 6A-41 NON-BIGFOOT GEAR HOUSING 4. Torque bolts to 225 lb-in./18.8 lb-ft (25.4 Nm). 7 7 Loctite “271” (92-809819) a a 7 a-Torque Bolts to 225 lb-in./18.8 lb-ft. (25.4 Nm) Water Pump 1. Install water pump seal carrier. 2. Install exhaust deflector plate, if removed. 52832 b a a-Seal Carrier b-Exhaust Deflector Page 6A-42 90-857046 AUGUST 1998 NON-BIGFOOT GEAR HOUSING 3. Install base gasket, face plate, pump cover gasket (NEOPRENE STRIP FACES UP), nylon washer and impeller key. 52868 a b c e f d 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. 90-857046 AUGUST 1998 Page 6A-43 NON-BIGFOOT GEAR HOUSING 4. Install impeller and nylon washer. a b 52869 a-Impeller b-Nylon Washer NOTE: Apply a light coat of 2-4-C w/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 bolts and torque bolts to 60 lb-in. (6.8 Nm). 52830 7 b a 7 Loctite “271” (92-809819) a-Cover b-Bolts [Torque to 60 lb-in. (6.8 Nm)] Page 6A-44 90-857046 AUGUST 1998 NON-BIGFOOT GEAR HOUSING 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. 90-857046 AUGUST 1998 Page 6A-45 NON-BIGFOOT GEAR HOUSING Gear Housing Installation 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 w/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 bolts and washers, (two each side). Torque bolts to 40 lb-ft (54.2 Nm). 52836 a-Bolt and Washers (2 each side) [Torque Bolt to 40 lb-ft (54.2 Nm)] a Page 6A-46 90-857046 AUGUST 1998 NON-BIGFOOT GEAR HOUSING 2-Stroke Models MERCURY/MARINER 30/40, AND 40/50, FORCE 40/50 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. 52834 a c b a-Coupler Nut b-Jam Nut c-Spray Plate 4-Stroke Models MERCURY/MARINER 25, 30/40, AND 45/50 7. Connect shift shaft by sliding retainer to the right and snapping into upper “locked” position. 53859 a b a-Retainer b-Lower Clip 90-857046 AUGUST 1998 Page 6A-47 NON-BIGFOOT GEAR HOUSING 8. Install locknut and washer. Torque nut to 40 lb-ft (54.2 Nm). 52833 a a-Locknut and Washer [Torque Nut to 40 lb-ft (54.2 Nm)] 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. 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 bolt 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. Page 6A-48 90-857046 AUGUST 1998 NON-BIGFOOT GEAR HOUSING 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 b c 52835 a-Trim Tab b-Anti-Ventilation Plate c-Retaining Bolt and Washer; Torque Bolt to 15.8 lb-ft (21.4 Nm) 90-857046 AUGUST 1998 Page 6A-49 NON-BIGFOOT GEAR HOUSING 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 Quicksilver 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. Torque “Fill” and “Vent” screws to 55 lb-in. (6.2 Nm). Page 6A-50 90-857046 AUGUST 1998 BIGFOOT GEAR HOUSING LOWER UNIT Section 6B - Bigfoot Gear Housing Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-2 Quicksilver Lubricants and Service Aids . . . . 6B-5 Gear Housing (Drive Shaft) (2.31:1 Gear Ratio) . . . . . . . . . . . . . . . . . . . . . . 6B-6 Gear Housing (Prop Shaft) (2.31:1 Gear Ratio) . . . . . . . . . . . . . . . . . . . . . . 6B-8 General Service Recommendations . . . . . . . 6B-10 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-10 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-10 Draining and Inspecting Gear Lubricant . . . . 6B-11 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-12 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-13 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . 6B-13 Bearing Carrier and Propeller Shaft . . . . . 6B-16 Pinion Gear, Drive Shaft, and Forward Gear . . . . . . . . . . . . . . . . . . . . . . . . 6B-21 Upper Drive Shaft Bearing . . . . . . . . . . . . . 6B-24 Oil Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-25 Lower Drive Shaft Bearing Race . . . . . . . . 6B-26 Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-27 Forward Gear Bearing Race . . . . . . . . . . . 6B-29 Trim Tab Adjustment and Replacement . . 6B-29 Specifications Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-30 Forward Gear Bearing Race . . . . . . . . . . . 6B-30 Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-30 Bearing Carrier Reassembly . . . . . . . . . . . 6B-33 Forward Gear Reassembly . . . . . . . . . . . . 6B-37 Propeller Shaft Reassembly . . . . . . . . . . . 6B-39 Drive Shaft Wear Sleeve Installation . . . . 6B-40 Lower Drive Shaft Bearing Race Installation . . . . . . . . . . . . . . . . . . . . . 6B-42 Oil Sleeve Installation . . . . . . . . . . . . . . . . . 6B-43 Upper Drive Shaft Bearing Installation . . . 6B-43 Forward Gear, Lower Drive Shaft Bearing, Pinion Gear, and Drive Shaft Installation . 6B-45 Pinion Gear Depth and Forward Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . 6B-46 Bearing Carrier and Propeller Shaft Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-51 Water Pump Reassembly and Installation 6B-53 Gear Housing Pressure Test . . . . . . . . . . . 6B-56 Filling Gear Housing With Lubricant . . . . . . . 6B-57 Gearcase Installation . . . . . . . . . . . . . . . . . . . . 6B-58 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . 6B-62 6 B GEAR HOUSING BIGFOOT (2.3:1) Gear Ratio Gearcase Capacity Lubricant Type Forward Gear Number of Teeth Pinion Gear Number of Teeth Pinion Height Pinion Gear Locating Tool Flat Number Disc Number Forward Gear Backlash Backlash Indicating Tool Mark Number Water Pressure @ 800 rpm (Idle) @ 6000 rpm (WOT) 2.31:1 22.5 fl oz (655 mL) Quicksilver Gear Lube-Premium Blend 30 Spiral/Bevel 13 Spiral/Bevel 0.025 in. (0.64 mm) 91-12349A2 #8 #3 0.012-0.019 in. (0.30-0.48 mm) 91-78473 #4 2–4 psi (14-28 kPa) 10–15 psi (69-103 kPa) 90-857046 AUGUST 1998 Page 6B-1 BIGFOOT GEAR HOUSING Special Tools 1. Pinion Gear Locating Tool (91-12349A2) 55079 Disc 3 Disc1 Disc 2 2. Bearing Installation Tool (91-13945) 3. Oil Seal Driver (91-13949) 4. Bearing Race Tool (91-14308A1) 5. Bearing Installation (91-14309A1) 6. Wear Sleeve Installation Tool (91-14310A1) Page 6B-2 90-857046 AUGUST 1998 BIGFOOT GEAR HOUSING 7. Bearing Preload Tool (91-14311A2) 8. Mandrel (91-15755)* 73815 9. Backlash Indicator Tool (91-19660--1) 2.07:1 Gear Ratio (14/29) 19660-1 10. Mandrel (91-31106) 11. Oil Seal Driver (91-31108) 12. Treaded Rod (91-31229) and Nut (91-24156)* 13. Slide Hammer (91-34569A1) 90-857046 AUGUST 1998 Page 6B-3 BIGFOOT GEAR HOUSING 14. Mandrel (91-36569)* 15. Universal Puller Plate (91-37241) 73652 16. Driver Rod (91-37323)* 74184 17. Mandrel (91-37350) 18. Puller Jaws (91-46086A1) 19. Driver Shaft Holding Tool (91-56775, 2-Stroke) (91-817070, 4-Stroke) 20. Dial Indicator (91-58222A1) Page 6B-4 90-857046 AUGUST 1998 BIGFOOT GEAR HOUSING 21. Backlash Indicator Tool (91-78473) 2.31:1 Gear Ratio (13/30) 22. Puller Bolt (91-85716) 23. Dial Indicator Adaptor Kit (91-83155) 24. Bearing Puller Assembly (91-83165M) 25. Bearing Installation Tool (91-856875A1) 56783 * From Bearing Removal and Installation Kit (91-31229A7) Quicksilver Lubricants and Service Aids Part No. Description 92-809819 Loctite “271” 92-891601-1 RTV Silicone Sealer 92-850737A1 Super Duty Gear Lubricant 92-850735A1 Anti-Corrosion Grease 92-850736A1 2-4-C w/Teflon 90-857046 AUGUST 1998 Page 6B-5 BIGFOOT GEAR HOUSING Gear Housing (Drive Shaft)(2.31:1 Gear Ratio) 7 95 7 95 87 7 7 95 95 7 7 4.25 IN./107.95MM TORPEDO DIA. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 13 6 6 4 19 7 Loctite “271” (92-809819) 87 Super Duty Gear Lubricant (92-850737A1) 95 2-4-C w/Teflon (92-850736A1) Page 6B-6 90-857046 AUGUST 1998 BIGFOOT GEAR HOUSING Gear Housing (Drive Shaft)(2.31:1 Gear Ratio) REFREF. .. NO. QTY. DESCRIPTION TORQUE lb–in. lb-ft Nm – 1 GEAR HOUSING 1 1 GEAR HOUSING ASSEMBLY 2 1 DOWEL PIN (FRONT) 3 1 OILER TUBE 4 2 DRAIN SCREW 60 6.8 5 1 SCREW (MAGNETIC) 60 6.8 6 3 WASHER-Sealing 7 1 DOWEL PIN (REAR) 8 1 TRIM TAB 9 1 SCREW (.437-14 x 1.25) 22 29.8 10 1 WASHER 11 1 CARRIER 12 1 NEEDLE BEARING 13 2 ANODE 14 1 NUT 15 1 SCREW (M6 x 40) 60 6.8 16 1 PINION GEAR (13 TEETH) 17 1 NUT 18 1 SHIFT CAM 19 1 TAPERED ROLLER BEARING 20 1 SHIM ASSEMBLY (SIZES 006 THRU 048) 21 1 DRIVE SHAFT ASSEMBLY 22 1 WEAR SLEEVE ASSEMBLY 23 1 RING SEAL 24 1 COVER ASSEMBLY 25 1 GASKET 26 1 GASKET 27 1 OIL SEAL (LOWER) 28 1 OIL SEAL (UPPER) 29 1 GASKET 30 1 WATER PUMP ASSEMBLY 31 1 FACE PLATE 32 4 SCREW (M6 x 1 x 30) 60 6.8 33 1 SEAL 34 1 KEY 35 1 IMPELLER 36 6 SCREW 60 6.8 37 1 SHIFT SHAFT ASSEMBLY 38 1 E-RING 39 1 BUSHING ASSEMBLY 40 1 O-RING 41 1 OIL SEAL 42 2 SCREW (M6 x 1) 60 6.8 90-857046 AUGUST 1998 Page 6B-7 BIGFOOT GEAR HOUSING Gear Housing (Prop Shaft)(2.31:1 Gear Ratio) 4.25 IN./107.95MM TORPEDO DIA. 7 95 Loctite “271”(92-809819) 2-4-C w/Teflon (92-850736A1) Page 6B-8 90-857046 AUGUST 1998 BIGFOOT GEAR HOUSING Gear Housing (Prop Shaft)(2.31:1 Gear Ratio) REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 GEAR HOUSING ASSEMBLY 43 1 TAPERED ROLLER BEARING ASSEMBLY 44 1 CUP 45 1 FORWARD GEAR (30 TEETH) 46 1 ROLLER BEARING 47 1 CAM FOLLOWER ASSEMBLY 48 3 BALL 49 1 SLIDE 50 1 SPRING 51 1 CLUTCH 52 1 CROSS PIN 53 1 SPRING 54 1 PROPELLER SHAFT 55 1 REVERSE GEAR (30 TEETH) 56 1 BEARING CARRIER ASSEMBLY 57 1 O-RING 58 1 ROLLER BEARING 59 1 OIL SEAL (INNER) 60 1 OIL SEAL (OUTER) 61 1 ROLLER BEARING 62 1 THRUST WASHER 63 1 THRUST BEARING 64 2 STUD 100 135 65 2 WASHER 66 2 NUT 25 33.9 67 1 SHIM ASSEMBLY (SIZES 006 THRU 038) 68 2 THREAD INSERT 69 1 DECAL 70 1 THRUST HUB ASSEMBLY PROPELLER NUT ASSEMBLY SERVICE ITEMS TAB WASHER 71 1 72 1 73 4 SCREW 40 54.2 74 4 WASHER 90-857046 AUGUST 1998 Page 6B-9 BIGFOOT GEAR HOUSING General Service Recommendations There may be more than one way to “disassemble” or “reassemble” a particular part(s), therefore, it is recommended that the entire procedure be read prior to repair. IMPORTANT: Read the following before attempting any repairs. In many cases, disassembly of a sub-assembly may not be necessary until cleaning and inspection reveals that disassembly is required for replacement of one or more components. Service procedure order in this section is a normal disassembly-reassembly sequence. Threaded parts are right hand (RH), unless otherwise indicated. When holding, pressing or driving is required, use soft metal vise jaw protectors or wood for protection of parts. Use a suitable mandrel (one that will contact only the bearing race) when pressing or driving bearings. 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 Quicksilver 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 w/Teflon on all O-rings and on I.D. of oil seals. Apply 2-4-C w/Teflon to external surfaces of bearing carrier. Page 6B-10 90-857046 AUGUST 1998 BIGFOOT GEAR HOUSING Draining and Inspecting Gear Lubricant WARNING If gear housing is installed on engine, to avoid accidental starting, disconnect (and isolate) spark plug leads from spark plugs before working near the propeller. 1. With gear housing in normal running position, place a clean pan under housing and remove the two vent screws and one fill/drain screw (with gaskets). 53922 a b c a-Oil Level Screw b-Fill/Drain Screw c-Vent Screw 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 bar magnet indicates normal wear. The presence of metal chips on the drain plug bar magnet indicates the need for gear housing disassembly and component inspection. 3. Note color of gear lubricant. White or cream color MAY indicate presence of water in lubricant. Gear lubricant which has been drained from a gear case recently in operation will have a yellowish color due to lubricant agitation/aeration. Gear lube which is mixed with assembly lubricant (Special Lube 101 or 2-4-C w/Teflon will also be creamy white in color. This is normal and should not be confused with the presence of water. If water is suspected to be present in gearcase, a pressure check of gearcase should be made (with no lubricant in gearcase). Gearcase should hold 10 to 12 psi of pressure for 5 minutes without leaking down. Pouring a portion of the gear lubricant into a glass jar and allowing the lubricant to settle will allow any water in the lube to separate and settle to the bottom of the jar. 4. Presence of water in gear lubricant indicates the need for disassembly and inspection of oil seals, seal surfaces, O-rings, water pump gaskets as well as gear housing components for damage. If gearcase is rebuilt, gearcase should be pressure checked before filling with lubricant. 90-857046 AUGUST 1998 Page 6B-11 BIGFOOT 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 engine into forward gear. 3. Tilt engine to full “Up” position. 4. Remove 4 fasteners. 5. Remove locknut and washer. 6. Remove gear housing. 53992 ab a-Fasteners (2 Each Side) b-Locknut and Washer Page 6B-12 90-857046 AUGUST 1998 BIGFOOT GEAR HOUSING Disassembly Water Pump NOTE:If water tube seal stayed on water tube (inside of drive shaft housing) when gear housing was removed, pull water tube seal from water tube. 1. Replace water tube seal, if damaged. 2. Remove 4 bolts, washers, and isolators. 3. Remove cover. 19212 a b c b a-Water Tube Seal b-Bolts (4 each) c-Cover IMPORTANT: The circular groove formed by the impeller sealing bead should be disregarded when inspecting cover (Step 5) and plate (Step 9), as the depth of the groove will not affect water pump output. 4. Replace cover if thickness of steel at the discharge slots is 0.060 in. or less, or if groove(s) (other than impeller sealing bead groove) in cover roof are more than 0.030 in. (0.762 mm) deep. 5. Lift impeller, drive key, and gasket from drive shaft. a bc 19220 a-Impeller b-Drive Key c-Gasket 90-857046 AUGUST 1998 Page 6B-13 BIGFOOT GEAR HOUSING 6. Inspect impeller. Replace impeller if any of the following conditions exist: • Impeller blade(s) are cracked, torn, or worn. • Impeller is glazed or melted (caused by operation without sufficient water supply). • Rubber portion of impeller is not bonded to impeller hub. 7. Remove plate and gasket. 8. Replace plate if groove(s) (other than impeller sealing bead groove) in plate are more than 0.030 in. (0.762 mm) deep. 19219 a b c a-Plate b-Gasket c-Impeller Sealing Groove 9. Remove bolts and washers. a 19217 a-Bolts and Washers (6 each) Page 6B-14 90-857046 AUGUST 1998 BIGFOOT GEAR HOUSING 10. Remove water pump base. 19226 a a-Water Pump Base 11. Remove (and discard) seals. 19195 a a-Seals 12. Remove gasket. 19218 a a-Gasket 90-857046 AUGUST 1998 Page 6B-15 BIGFOOT GEAR HOUSING Bearing Carrier and Propeller Shaft 1. Remove fasteners. 51117 a a a-Fasteners 2. With propeller shaft horizontal, pull carrier to break seal with gear housing. Remove bearing carrier/propeller shaft components as an assembly, taking care not to lose cam follower or 3 metal balls in end of propeller shaft. 3. Remove propeller shaft from bearing carrier. 51116 a b c d e a-Bearing Carrier b-Puller Jaws (91-46086A1) c-Puller Bolt (91-85716) d-Thrust Hub e-Propeller Shaft Page 6B-16 90-857046 AUGUST 1998 BIGFOOT GEAR HOUSING 4. Lift reverse gear, thrust bearing and thrust washer from bearing carrier. 5. Replace reverse gear if gear teeth or clutch teeth on reverse gear are chipped or worn. If reverse gear must be replaced, pinion gear and sliding clutch should be inspected for damage. 6. Replace thrust bearing and thrust washer if rusted or damaged. 19202 a b c a-Reverse Gear b-Thrust Bearing c-Thrust Washer 7. If bearing is rusted or does not roll freely, replace bearing. Remove bearing using Slide Hammer (91-34569A1). a 91-34569A1 19205 a-Bearing 90-857046 AUGUST 1998 Page 6B-17 BIGFOOT GEAR HOUSING 8. If bearing is rusted or does not roll freely, replace bearing. Remove bearing and oil seals using Mandrel* (91-36569) and Driver Rod* (91-37323). Discard oil seals. NOTE:*From Bearing Removal and Installation Kit (91-31229A7) 51264 a b c 91-37323 91-36569 a-Bearing b-Mandrel (91-26569) c-Driver Rod (91-37323) 9. Remove (if not removed with bearing in Step 9) propeller shaft seals and bearing carrier O-ring. 51263 a a-O-ring Page 6B-18 90-857046 AUGUST 1998 BIGFOOT GEAR HOUSING 10. Remove spring. 51876 a a-Spring 11. Apply constant pressure to cam follower to prevent cam follower assembly from ejecting from propeller shaft while pushing cross pin out of clutch dog. 51800 a b a-Cross Pin b-Cam Follower 90-857046 AUGUST 1998 Page 6B-19 BIGFOOT GEAR HOUSING 12. Remove components from propeller shaft. 13. Replace cam follower if worn or pitted. 14. Replace sliding clutch if jaws are rounded or chipped. Rounded jaws indicate one or more of the following: • Improper shift cable adjustment. • Engine idle speed too high while shifting. • Shifting from neutral to reverse (or forward) too slowly. 51265 a b c d e f f a-Cam Follower b-3 Metal Balls c-Guide Block d-Spring e-Sliding Clutch f-Jaws 15. Check bearing surfaces of propeller shaft for pitting or wear. If shaft is worn or pitted, replace shaft and corresponding bearing. 16. Replace propeller shaft if any of the following exist: • Splines are twisted or worn. • Oil seal surface is grooved. • Shaft has a noticeable “wobble” or is bent more than 0.009 in. (0.228 mm). Prop shaft trueness should be measured with a dial indicator with prop shaft on V- blocks. a bc b 51877 a-V-Blocks b-Bearing Surfaces c-Measure with Dial Indicator at This Point Page 6B-20 90-857046 AUGUST 1998 BIGFOOT GEAR HOUSING Pinion Gear, Drive Shaft, and Forward Gear 1. Hold drive shaft using Drive Shaft Holding Tool; remove (and discard) pinion nut. Model Drive Shaft Holding Tool 40/45/50 Bigfoot (4-Stroke) 91-56775 60 Bigfoot 91-817070 75/90/100/115/125 91-56775 2. Remove drive shaft, pinion gear, bearing and forward gear. 3. Replace pinion gear if it is chipped or worn. 4. Replace bearing and race if either are rusted or damaged; or if bearing does not roll freely. To remove race, refer to “Lower Drive Shaft Bearing Race,” following. 5. Replace forward gear if gear teeth or clutch teeth are chipped or worn. 19175 a b c d e f a-Drive Shaft Holding Tool b-Pinion Nut c-Drive Shaft d-Pinion Gear e-Bearing f-Forward Gear 90-857046 AUGUST 1998 Page 6B-21 BIGFOOT GEAR HOUSING 6. Replace bearing if it is rusted or does not roll freely; use a punch and hammer to remove bearing. 19203a a-Bearing 7. Replace forward gear bearing and race if either are rusted or damaged; or if bearing does not roll freely. Remove bearing from gear using Universal Puller Plate (91-37241) and mandrel. To remove race, refer to “Forward Gear Bearing Race,” following. 51119 a b c 91-37241 a-Forward Gear Bearing b-Universal Puller Plate (91-37241) c-Mandrel Page 6B-22 90-857046 AUGUST 1998 BIGFOOT GEAR HOUSING 8. Replace drive shaft if splines are worn or twisted. 9. If bearing surface is damaged, replace drive shaft and corresponding bearing. IMPORTANT: Do not tighten vise against drive shaft. 10. If wear sleeve is deeply grooved allowing water to enter gear case, remove (and discard) sleeve using Universal Puller Plate (91-37241) and mallet. 19710 a b c e a 91-37241 d a-Splines b-Bearing Surface c-Wear Sleeve d-Universal Puller Plate (91-37241) e-Mallet 11. Remove (and discard) rubber ring. 19152 a a-Rubber Ring 90-857046 AUGUST 1998 Page 6B-23 BIGFOOT GEAR HOUSING Upper Drive Shaft Bearing 1. Replace upper drive shaft bearing and sleeve if either are rust stained, or if bearing will not roll freely. Remove bearing and then sleeve using Puller Assembly (91-83165M) with suitable jaws. 19177 OR a b 91-83165M c a-Upper Drive Shaft Bearing b-Sleeve c-Puller Assembly (91-83165M) IMPORTANT: Upper drive shaft bearing/sleeve must be removed prior to oil sleeve removal. Refer to “Upper Drive Shaft Bearing,” preceding. Page 6B-24 90-857046 AUGUST 1998 BIGFOOT GEAR HOUSING Oil Sleeve 1. Remove oil sleeve (if necessary) using Puller Assembly (91-83165M) with suitable jaws. b a 91-83165M 19222 a-Oil Sleeve b-Puller Assembly (91-83165M) IMPORTANT: Upper drive shaft bearing/sleeve and oil sleeve do not have to be removed for lower drive shaft bearing race removal. 90-857046 AUGUST 1998 Page 6B-25 BIGFOOT GEAR HOUSING Lower Drive Shaft Bearing Race IMPORTANT: Retain shim(s) for reassembly. 1. Remove race and shim(s) using bearing race tool (91-14308A1). 19171 a b c 91-14308A1 a-Race b-Shim(s) c-Bearing Race Tool (91-14308A1) Page 6B-26 90-857046 AUGUST 1998 BIGFOOT GEAR HOUSING Shift Shaft 1. Remove shift shaft coupler and nylon spacer. 75 Tiller Model Shown 53925 a b a-Shift Shaft Coupler b-Spacer 2. Remove bolts. 53926 a a-Bolts NOTE: Gearcase should be in FORWARD for easiest removal of shift shaft. 3. Remove shift shaft bushing and shift shaft. 53927 a b a-Bushing b-Shift Shaft 90-857046 AUGUST 1998 Page 6B-27 BIGFOOT GEAR HOUSING 4. Remove shift cam from housing. 5. Replace shift cam if worn. 60 Bigfoot Shown 51117 a a-Shift Cam NOTE:If shift shaft splines are rough, shift shaft seal lips will be cut during removal/installation. 6. Remove shift shaft bushing and clip from shift shaft. 7. Replace shift shaft if splines are worn or shaft is twisted. 8. Remove (and discard) O-ring. 53928 a b c ded a-Bushing b-Clip c-Shift Shaft d-Splines e-O-ring 9. Remove (and discard) seal. 53929 a a-Seal Page 6B-28 90-857046 AUGUST 1998 BIGFOOT GEAR HOUSING Forward Gear Bearing Race IMPORTANT: Retain shim(s) for reassembly. If shims are damaged, replace with new shims of equal thickness. 1. Remove race and shim(s) using Slide Hammer (91-34569A1). 27653 a b c 91-34569A1 a-Race b-Shim(s) c-Slide Hammer (91-34569A1) Trim Tab Adjustment and Replacement IMPORTANT: The trim tab is now painted and does NOT aid in protecting the drive shaft housing and gear housing from galvanic corrosion (corrosion and pitting of metal surfaces). Side anodes now provide protection. Do not paint or place protective coating on the side anodes, or corrosion protection function will be lost. 1. Replace trim tab if damaged. Mark location of old trim tab on anti-ventilation plate before removal; install new trim tab in same location. 2. The trim tab provides a means to offset (balance) some of the steering load that is caused by propeller torque at higher operating speeds. If at higher speeds the boat turns more easily to the left, loosen bolt, move the trim tab (trailing edge) to the left (when viewed from behind); retighten bolt. Turn trim tab (trailing edge) to the right if the boat turns more easily to the right. 53931ab c a-Trim Tab b-Anti-Ventilation Plate c-Retaining Bolt and Washer; Torque Bolt to 22 lb-ft (29.8 Nm) 90-857046 AUGUST 1998 Page 6B-29 BIGFOOT GEAR HOUSING Reassembly Forward Gear Bearing Race 1. Place shim(s) (retained from disassembly) into housing. If shim(s) were lost, or a new gear housing is being assembled, start with 0.010 in. (0.254 mm) shim(s). 2. Assemble components as shown using mandrel (91-31106); Apply 2-4-C w/Teflon to O.D. of race. Drive race into housing by striking propeller shaft end with lead hammer. 19179 b de a c 91–31106 95 2-4-C w/Teflon (92-850736A1) 95 a-Shim(s) b-Race c-Mandrel (91-31106) d-Disassembled Propeller Shaft e-Assembled Bearing Carrier Shift Shaft 1. Apply Loctite 271 on O.D. of new seal. 2. Press seal into shift shaft bushing until seal is seated against shoulder. 3. Install new O-ring. 4. Apply 2-4-C with Teflon on O-ring and I.D. of seal. 53930 b c d 7 Loctite “271” (92-809819) 7 95 2-4-C w/Teflon (92-850736A1) 95 a 7 a-Seal b-Bushing c-Surface d-O-ring Page 6B-30 90-857046 AUGUST 1998 BIGFOOT GEAR HOUSING 90-857046 AUGUST 1998 Page 6B-31 5. Assemble components as shown. 53928 a b c a - Shift Shaft b - “E” Clip c - Shift Shaft Bushing 6. Install shift cam; align hole in shift cam with hole in gear housing. 60 Bigfoot 75/90/100/115/125 51117 a b a - Shift Cam (marked with “UP” and part number) b - Gear Housing Hole 60 Bigfoot 75/90/100/115/125 51117 a b a - Shift Cam (marked with part number only) b - Gear Housing Hole BIGFOOT GEAR HOUSING 40/45/50 Bigfoot (4-Stroke) 51117 850307 a b a-Shift Cam (Numbers Down) b-Hole 7. Install shift shaft assembly; insert splines into shift cam. 53932 a b a-Shift Shaft Assembly b-Splines 8. Apply Loctite 271 on bottom half of threads of bolts; install bolts and torque to 60 lb-in. (6.8 Nm). 53926 a 7 7 Loctite “271” (92-809819) a-Bolts [Torque to 60 lb-in. (6.8 Nm)] Page 6B-32 90-857046 AUGUST 1998 BIGFOOT GEAR HOUSING Bearing Carrier Reassembly 1. Lubricate O.D. of bearing and bearing carrier bore with Quicksilver 2-4-C w/Teflon. 2. Protect lip on forward side of bearing carrier, using bearing installation tool (91-13945). 3. Press propeller shaft needle bearing (number side toward mandrel 91-15755) into carrier, until bearing bottoms out. 95 21042 a b c 2-4-C w/Teflon (92-850736A1) 95 91-13945 91-15755 a-Bearing Installation Tool (91-13945) b-Mandrel (91-15755) c-Suitable Driver Rod 90-857046 AUGUST 1998 Page 6B-33 BIGFOOT GEAR HOUSING 4. Place smaller diameter seal on longer shoulder of Oil Seal Driver (91-31108) with seal lip away from shoulder. 5. Protect lip on front side of bearing carrier using Bearing Installation Tool (91-13945). Apply Loctite 271 on O.D. of seal. Press seal into carrier until tool bottoms. 7 21040 ab c Loctite “271” (92-809819) 7 91-31108 91-13945 a-Seal b-Oil Seal Driver (91-31108) c-Bearing Installation Tool (91-13945) 6. Place larger diameter seal on shorter shoulder of Oil Seal Driver (91-31108) with seal lip toward shoulder. 7. Protect lip on front side of bearing carrier using Bearing Installation Tool (91-13945). Apply Loctite 271 on O.D. of new seal. Press seal into carrier until tool bottoms. 21041 a b c a 91-31108 91-13945 7 Loctite “271” (92-809819) 7 a-Seal b-Oil Seal Driver (91-31108) c-Bearing Installation Tool (91-13945) Page 6B-34 90-857046 AUGUST 1998 BIGFOOT GEAR HOUSING 8. Install O-ring. Lubricate O-ring with 2-4-C w/Teflon. Lubricate seal lips with 2-4-C w/Teflon. 9. Lubricate outside diameter of reverse gear bearing and bearing carrier bore with a light coating of 2-4-C w/Teflon. 10. Press bearing into carrier until tool bottoms. 19163 a b c 95 95 91-13945 2-4-C w/Teflon (92-850736A1) a-O-ring b-Bearing, Numbered Side Toward Tool c-Bearing Installation Tool (91-13945) 11. Install thrust washer. Coat thrust washer with Super Duty Gear Lubricant. 19167 a 87 Super Duty Gear Lubricant (92-850737A1) 87 a-Thrust Washer 90-857046 AUGUST 1998 Page 6B-35 BIGFOOT GEAR HOUSING 12. Install thrust bearing. Coat thrust bearing with Super Duty Gear Lubricant. a 87 19168 87 Super Duty Gear Lubricant (92-850737A1) a-Thrust Bearing 13. Apply Super Duty Gear Lubricant to bearing surface of reverse gear and install reverse gear. 19202 a b 87 87 Super Duty Gear Lubricant (92-850737A1) a-Reverse Gear b-Bearing Surface Page 6B-36 90-857046 AUGUST 1998 BIGFOOT GEAR HOUSING Forward Gear Reassembly 1. Press bearing onto gear using mandrel 91-37350 (press only on inner race of bearing). 51869 a b 91-37350 95 2-4-C w/Teflon (92-850736A1) 95 a-Mandrel (91-37350) b-Bearing; Lubricate I.D. with Quicksilver 2-4-C w/Teflon 2. Inspect reverse gear end of clutch to determine the number of jaws. Refer to chart, following, for tool end selection. Model Installation End Bearing Position Tool Stamped 3 Jaw Reverse 91-856875 3 0.155 in. (3.94mm) Clutch below surface 6 Jaw Reverse Clutch 91-856875 6 Flush with surface 3 Jaw Reverse Clutch 56783 a b c a-Stamped “3” b-Numbered end of Needle Bearing c-3 Jaw Reverse Clutch 90-857046 AUGUST 1998 Page 6B-37 BIGFOOT GEAR HOUSING 6 Jaw Reverse Clutch 56784 b a c a-Stamped “6” b-Numbered end of Needle Bearing c-6 Jaw Reverse Clutch 3. Apply Quicksilver gear lubricant to I.D. of forward gear. Press bearing into forward gear until tool contacts gear. 56785 87 Quicksilver Gear Lubricant (92-19007A24) 87 a b a-Forward Gear Bearing Installer (91-856875) b-Needle Bearing, Numbered Side Toward Installer Tool Page 6B-38 90-857046 AUGUST 1998 BIGFOOT GEAR HOUSING Propeller Shaft Reassembly 1. Install components into propeller shaft in sequence shown. 19154 abcd a-Spring b-Guide Block c-3 Metal Balls* d-Cam Follower* *Hold in Place With Quicksilver 2-4-C w/Teflon 2. Install cross pin. a b 51800 a-Apply Pressure in This Direction b-Cross Pin 3. Install spring. DO NOT overlap springs. 51876 a a-Spring 90-857046 AUGUST 1998 Page 6B-39 BIGFOOT GEAR HOUSING Drive Shaft Wear Sleeve Installation 1. Install new rubber ring. 2. Apply a light coat of Loctite 271 on outside diameter of rubber ring. a 7 Loctite “271” (92-809819) a-Ring 3. Insert sleeve into holder*. *Component of Wear Sleeve Installation Tool (91-14310A1). 19169 a b a 91-14310A1 a-Sleeve b-Holder 19152 Page 6B-40 90-857046 AUGUST 1998 BIGFOOT GEAR HOUSING 4. Press sleeve onto drive shaft using Wear Sleeve Installation Tool (91-14310A1); continue pressing until surface contacts surface. 19166 a b c d b 91-14310A1 a-Drive Shaft b-Wear Sleeve Installation Tool (91-14310A1) c-Surface d-Surface 5. Remove excess Loctite from assembled shaft. 90-857046 AUGUST 1998 Page 6B-41 BIGFOOT GEAR HOUSING Lower Drive Shaft Bearing Race Installation IMPORTANT: Lower drive shaft bearing cup can be installed with or without upper drive shaft bearing/sleeve and oil sleeve installed. 1. Lubricate O.D. of bearing race with Quicksilver 2-4-C w/Teflon. 2. Install shim(s) and bearing race into housing. NOTE:Verify shim(s) are not cocked when drawing up race. 53933 a b c d f 95 2-4-C w/Teflon (92-850736A1) 95 91-14310A1 f d c e a-Shim(s); Retained From Disassembly. If Shim(s) Were Lost or a New Gear Housing is Being Assembled, Start With 0.025 in. (0.635 mm) Shim(s) b-Bearing Race c-Mandrel* (13780) d-Mandrel* (13781) e-Threaded Rod** (91-31229) f-Nut** (11-24156) *From Bearing Installation Tool (91-14309A1) **From Bearing Removal and Installation Kit (91-31229A7) Page 6B-42 90-857046 AUGUST 1998 BIGFOOT GEAR HOUSING Oil Sleeve Installation 1. Install oil sleeve with tab positioned as shown. 53934 a b a-Oil Sleeve b-Tab Upper Drive Shaft Bearing Installation 1. Lubricate I.D. of bearing holder and O.D. of bearing with 2-4-C w/Teflon. 2. Press bearing into sleeve using mandrel from bearing installation tool (91-14309A1). 19164 a b c d 95 91-13781 95 2-4-C w/Teflon (92-850736A1) a-Bearing Sleeve b-Tapered End c-Bearing; Numbered Side Toward Mandrel d-Mandrel (91-13781); From Bearing Installation Tool (91-14309A1) 90-857046 AUGUST 1998 Page 6B-43 BIGFOOT GEAR HOUSING IMPORTANT: Oil sleeve must be installed prior to upper drive bearing installation. IMPORTANT: Upper drive shaft bearing/sleeve can be installed with or without lower drive shaft bearing cup installed. 3. Install bearing/sleeve into housing. 53935 a b 91-14310A1 e f d c a-Bearing/Sleeve b-Tapered End c-Mandrel* (13781) d-Mandrel* (13780) e-Threaded Rod** (91-31229) f-Nut** (11-24156) *From Bearing Installation Tool (91-14309A1) **From Bearing Removal and Installation Kit (91-31229A7) Page 6B-44 90-857046 AUGUST 1998 BIGFOOT GEAR HOUSING Forward Gear, Lower Drive Shaft Bearing, Pinion Gear, and Drive Shaft Installation 1. Install components in sequence shown. 19175 a b c d e f d 87 Super Duty Gear Lubricant (92-850737A1) 7 Loctite “271” (92-809819) 7 87 Model Drive Shaft Holding Tool 40/45/50 Bigfoot (4-Stroke) 91-56775 60 Bigfoot 91-817070 75/90/100/115/125 91-56775 a-Forward Gear/Bearing: Work Quicksilver gear lube into bearing rollers. b-Lower Drive Shaft Tapered Roller Bearing: Work Super Duty Gear Lube into bearing rollers. c-Pinion Gear d-Drive Shaft e-Drive Shaft Holding Tool f-Pinion Nut (New): Apply Loctite 271 to threads during final assembly (after pin ion gear depth and forward gear backlash have been set), torque to 70 lb-ft. (95 Nm) 90-857046 AUGUST 1998 Page 6B-45 BIGFOOT GEAR HOUSING Pinion Gear Depth and Forward Gear Backlash DETERMINING PINION GEAR DEPTH NOTE:Read entire procedure before attempting any change in shim thickness. IMPORTANT: Forward gear assembly must be installed in gear housing when checking pinion gear depth or an inaccurate measurement will be obtained. 1. Clean the gear housing bearing carrier shoulder and diameter. 2. With gear housing positioned up right (drive shaft vertical), install Bearing Preload Tool (91-14311A2) over drive shaft in sequence shown. a b c d e f g h h a-Adaptor: Bearing surfaces clean and free of e-Nut: Threaded all-the-way onto bolt nicks f-Bolt: Held snug against spring b-Thrust Bearing: Oiled and able to move freely g-Sleeve: Holes in sleeve must align with set c-Thrust Washer: Clean and free of nicks and screws bends h-Set Screw (2): Tightened against drive shaft, d-Spring bolt should not slide on drive shaft. 3. Measure distance between top of nut and bottom of bolt head. 4. Increase distance by 1 in. (25.4 mm). 5. Rotate drive shaft 5 to 10 revolutions. This should properly seat drive shaft tapered roller bearing. 19884 b a c a-1 in. (25.4 mm) b-Nut c-Bolt Head Page 6B-46 90-857046 AUGUST 1998 BIGFOOT GEAR HOUSING 6. Assemble Pinion Gear Locating Tool (91-12349A2) as shown; do not tighten collar retaining bolt at this time. a-Arbor From Split Collar c-Bolt; Gauging Block Retaining a b d e c f c b-Gauging Block; Install With Numbers Away e-Bolt; Collar Retaining d-Split Collar f-Snap Ring 7. Insert tool into forward gear assembly; position gauging block under pinion gear as shown. 22067 a a-Gauging Block 8. Remove tool, taking care not to change gauging block position, and tighten collar retaining bolt. 9. Insert tool into forward gear assembly; position proper numbered flat (from chart) of gauging block – under pinion gear. MODEL GEAR RATIO (PINION GEAR TEETH/REVERSE GEAR TEETH) USE FLAT NO. LOCATING DISC NO. 40/45/50 Bigfoot (4-stroke) 2.31:1 (13/30) 8 3 60 Bigfoot/60 Seapro/60 Marathon 2.31:1 (13/30) 8 3 75-thru-90 (3 Cylinder) 2.31:1 (13/30) 8 3 100/115/125 (4 Cylinder) 2.07:1 (14/29) 2 3 90-857046 AUGUST 1998 Page 6B-47 BIGFOOT GEAR HOUSING 10. Install locating disc against bearing carrier shoulder in gear housing. 11. Position access hole as shown. 24643 b a Disc 3 a-Locating Disc b-Access Hole 12. Determine pinion gear depth by inserting a feeler gauge thru access hole in locating disc. 13. The correct clearance between gauging block and pinion gear is 0.025 in. (0.64 mm). 14. If clearance is correct, leave Bearing Preload Tool on drive shaft and proceed to “Determining Forward Gear Backlash,” following. 15. If clearance is incorrect, add (or subtract) shims from above bearing race to lower (or raise) pinion gear. When reinstalling pinion nut, apply Loctite 271 on threads of nut. 24643 a b c d 7 Loctite “271” (92-809819) 7 a-Feeler Gauge b-Gauging Block c-Pinion Gear d-Bearing Race Page 6B-48 90-857046 AUGUST 1998 BIGFOOT GEAR HOUSING DETERMINING FORWARD GEAR BACKLASH NOTE:Read entire procedure before attempting any change in shim thickness. 1. Obtain correct pinion gear depth; refer to “Determining Pinion Gear Depth,” preceding. 2. Install Bearing Preload Tool (91-14311A2) on drive shaft; refer to “Determining Pinion Gear Depth,” preceding. 3. Install components as shown. 53936 a bd c a-Propeller Shaft* b-Bearing Carrier* (Assembled) c-Puller Jaws (91-46086A1) d-Puller Bolt (91-85716); Torque to 45 lbs-in. (5.0 Nm) *Refer to “Bearing Carrier and Propeller Shaft Installation,” following. 90-857046 AUGUST 1998 Page 6B-49 BIGFOOT GEAR HOUSING 4. Rotate drive shaft 5 to 10 revolutions. This should properly seat forward gear tapered roller bearing. 5. Install components as shown. 51117 a b d e f c c a-Threaded Rod (Obtain Locally) b-Washers c-Nuts d-Dial Indicator Adaptor Kit (91-83155) e-Dial Indicator (91-58222A1) f-Backlash Indicator Tool 6. Position Dial Indicator on appropriate line (from chart) marked on Backlash Indicator Tool. MODEL BACKLASH INDICATOR TOOL ALIGN POINTER OF DIAL INDICATOR WITH MARK 40/45/ 50 Bigfoot (4-stroke) 91-78473 4 60 Seapro/60 Marathon/ 60 Bigfoot 91-78473 4 75-thru-90 (3 Cylinder) 91-78473 4 100/115/125 (4 Cylinder) 91-19660--1 1 Page 6B-50 90-857046 AUGUST 1998 BIGFOOT GEAR HOUSING 7. Lightly turn drive shaft back-and-forth (no movement should be noticed at propeller shaft). 8. Dial Indicator registers amount of backlash, which must be between specification shown in chart. MODEL DIAL INDICATOR MINIMUM READING MAXIMUM 40/45/50 Bigfoot (4-Stroke) 0.012 in. (0.30 mm) 0.019 in. (.48 mm) 60 Bigfoot 0.012 in. (0.30 mm) 0.019 in. (.48 mm) 75-thru-90 (3 Cylinder) 0.012 in. (0.30 mm) 0.019 in. (.48 mm) 100/115/125 (4 Cylinder) 0.015 in. (0.38 mm) 0.022 in. (0.55 mm) 9. If backlash is less than the minimum specification, remove shim(s)* from in front of forward gear bearing race to obtain correct backlash. When reinstalling pinion nut, apply Loctite 271 on threads of nut. 10. If backlash is more than the maximum specification, add shim(s)* in front of forward gear bearing race to obtain correct backlash. When reinstalling pinion nut, apply Loctite 271 on threads of nut. * By adding or subtracting 0.001 in. (0.025 mm) shim, the backlash will change approximately 0.001 in. (.025 mm). Bearing Carrier and Propeller Shaft Installation 1. Insert propeller shaft assembly into bearing carrier. 2. Before installing bearing carrier assembly into gear housing, obtain locally a 6 in. (152.4 mm) long by 1-1/4 in. – 1-1/2 in. (31.7 – 38.1 mm) diameter piece of PVC pipe. Install the PVC pipe over the prop shaft and secure the pipe against the bearing carrier assembly with the propeller nut and tab washer. This will allow the reverse gear to apply pressure to the reverse gear thrust bearing to prevent the thrust bearing from being inadvertently dislodged as the bearing carrier assembly is installed in the gear housing. 21043 d a b c e a-Bearing Carrier Assembly b-PVC Pipe c-Propeller Nut d-Prop Shaft e-Tab Washer 90-857046 AUGUST 1998 Page 6B-51 BIGFOOT GEAR HOUSING 3. Lubricate O-ring and mating surfaces with 2-4-C w/Teflon. 4. Install bearing carrier and propeller shaft into housing with the word “TOP” located on flange toward top of housing. 21044 a b 95 95 2-4-C w/Teflon (92-850736A1) a-O-ring b-TOP NOTE:Use thick 0.090 in. (2.29mm) washers (12-855941) under fasteners if not previously installed. Washer Thickness Fastener Torque 0.090 in. (2.29mm) 22 lb. ft. (29.8 N·m) 0.060 in. (1.53mm) 25 lb. ft. (33.9 N·m) a b a-Washers b-Fasteners, (If using Bolts - Apply Loctite 271 on Threads Page 6B-52 90-857046 AUGUST 1998 BIGFOOT GEAR HOUSING Water Pump Reassembly and Installation 1. Place upper seal on longer shoulder side of Oil Seal Driver (91-13949) with seal lip away from shoulder. 2. Apply Loctite 271 on O.D. of seal; press seal into water pump base until tool bottoms. c 91-13949 7 Loctite “271” (92-809819) 7 ba a-Seal - Lip Faces Toward Power Head b-Spring - Faces Toward Power Head c-Oil Seal Driver (91-13949) 51553 90-857046 AUGUST 1998 Page 6B-53 BIGFOOT GEAR HOUSING 3. Place lower seal on shorter shoulder side of Oil Seal Driver (91-13949) with seal lip toward shoulder. 4. Apply Loctite 271 on O.D. of seal; press seal into water pump base until tool bottoms. 5. Lubricate lip of each seal with Quicksilver 2-4-C w/Teflon (92-825407A12). 51553 c 91-13949 7 Loctite “271” (92-809819) 95 2-4-C w/Teflon (92-850736A1) 7 95 a b a-Seal - Lip Faces Toward Gear Case b-Spring - Faces Toward Gear Case c-Oil Seal Driver (91-13949) 6. Install gasket. a 19218 a-Gasket Page 6B-54 90-857046 AUGUST 1998 BIGFOOT GEAR HOUSING 7. Install components as shown. Apply Loctite 271 on bottom half of threads 19217 a b 7 7 Loctite “271” (92-809819) a-Water Pump Base b-Bolts and Washers; Torque to 60 lb-in. (6.8 Nm) 8. Install gasket and plate. 19219 a b a-Gasket b-Plate IMPORTANT: If the old impeller will be re-used, impeller must be installed in original (clockwise) direction of rotation. 9. Install gasket, drive key and impeller. a b c a-Gasket b-Drive Key c-Impeller 19220 90-857046 AUGUST 1998 Page 6B-55 BIGFOOT GEAR HOUSING 10. Lubricate I.D. of cover with Quicksilver 2-4-C w/Teflon. 11. Rotate drive shaft clockwise and push cover down over impeller. 12. Install cover. 13. If water tube seal stayed on water tube (inside of drive shaft housing) when gear housing was removed, pull water tube seal from water tube. 14. Lubricate I.D. of water tube seal with Quicksilver 2-4-C w/Teflon and install as shown. 19212 c c a b 95 2-4-C w/Teflon (92-850736A1) 95 a-Cover b-Seal c-Bolts (4); Apply Loctite 271 on Threads and Torque to 60 lb-in. (6.8 Nm). NOTE:It is recommended that the gearcase be pressure tested for leaks after reassembly and BEFORE gear lube is added. Gearcase should hold 10 to 12 psi (69-83 kPa) for 5 minutes. Gear Housing Pressure Test 1. Remove vent plug and install pressure test gauge. Page 6B-56 90-857046 AUGUST 1998 BIGFOOT GEAR HOUSING 2. Pressurized housing to 10 to 12 psi (69-83 kPa)and observe gauge for 5 minutes. 3. Rotate drive shaft, prop shaft and move shift shaft while housing is pressurized to check for leaks. 4. If pressure drop is noted, immerse housing in water. 5. Re-pressurize to 10 to 12 psi (69-83 kPa)and check for air bubbles. 6. Replace leaking seals as necessary. Retest housing. NOTE:Gearcase should hold 10 to 12 psi (69-83 kPa) for 5 minutes. 7. Remove tester from housing and install vent plug. Filling Gear Housing With Lubricant NOTE:Gear housing lubricant capacity is 22.5 fl oz (665.2 ml). WARNING If gear housing is installed on engine, to avoid accidental starting, disconnect (and isolate) spark plug leads from spark plugs before working near the propeller. CAUTION Do not use automotive grease in the gear housing. Use only Quicksilver Gear Lube or Quicksilver Super-Duty Lower Unit Lubricant. 1. Remove any gasket material from “Fill” and “Vent” screws and gear housing. 2. Install new gaskets on “Fill” and “Vent” screws. IMPORTANT: Never apply lubricant to gear housing without first removing “Vent” screws or gear housing cannot be filled because of trapped air. Fill gear housing only when housing is in a vertical position. 3. Remove lubricant “Fill” screw and gasket from gear housing. 4. Insert lubricant tube into “Fill” hole, then remove “Vent” screws and gaskets. 5. Fill gear housing with lubricant until excess starts to flow out of one (first) “Vent” screw hole. 90-857046 AUGUST 1998 Page 6B-57 BIGFOOT GEAR HOUSING Page 6B-58 90-857046 AUGUST 1998 6. Replace this lubricant “Vent” screw and gasket only and continue filling until excess starts to flow out of second lubricant “Vent” screw hole. 53922 a b c a - Vent Screw - Torque to 60 lb-in. (6.8 Nm) b - Fill/Drain Screw - Torque to 60 lb-in. (6.8 Nm) c - Oil Level Vent Screw - Torque to 60 lb-in. (6.8 Nm) 7. Replace second lubricant “Vent” screw and gasket. IMPORTANT: Do not lose more than one fluid ounce (30cc) of gear lubricant while reinstalling “FILL” screw. 8. Remove lubricant tube from “Fill” hole; install “Fill” screw and gasket. Gearcase Installation WARNING Disconnect (and isolate) spark plug leads from spark plugs before installing gear housing onto drive shaft housing. Failure to follow this warning could result in accidental engine starting and possible injury. 1. Position outboard shift linkage into forward gear position. Models 40/45/50 Bigfoot (4-Stroke) a Remote Control Model Shown a - Shift Lever BIGFOOT GEAR HOUSING Models 60 Bigfoot a a-Shift Block Models 75/90/100/115/125 19879 a b a-Shift Block; Front of Block MUST Extend 1/8 in. (3.2 mm) Past Front of Rail. b-Rail 2. Tilt engine to full up position and engage tilt lock lever. 3. Shift gear housing into neutral position. Propeller shaft will rotate freely in either direction. 4. Install water tube seal; lube I.D. of seal with Quicksilver 2-4-C w/Teflon. 5. Apply a bead of RTV Sealer as shown. 53938 a b 95 2-4-C w/Teflon (92-850736A1) 85 85 95 RTV Silicone Sealer (92-91601-1) a-Water Tube Seal b-RTV Sealer 90-857046 AUGUST 1998 Page 6B-59 BIGFOOT GEAR HOUSING CAUTION Do not use lubricant on top of drive shaft. Excess lubricant, that is trapped in clearance space, will not allow drive shaft to fully engage with crankshaft. Subsequently, tightening the gear housing fasteners (while lubricant is on top of drive shaft) will load the drive shaft/crankshaft and damage either or both the power head and gear housing. Top of drive shaft is to be wiped free of lubricant. 6. Apply a light coat of Quicksilver 2-4-C w/Teflon onto drive shaft splines. 7. Apply a light coat of Quicksilver 2-4-C w/Teflon on gear case shift shaft splines and upper shift shaft splines. Do not use lubricant on ends of shift shafts. 8. Install components as shown in appropriate photo. ALL EXCEPT 75 W/MECHANICAL REVERSE LOCK 53968 a b c a-Nylon Spacer b-Shift Shaft Coupler c-Bushing 40/45/50 Bigfoot (4-Stroke) Only 75 W/MECHANICAL REVERSE LOCK a 53925 b c a-Nylon Spacer b-Shift Shaft Coupler c-Flat; MUST BE Positioned Toward Front of Gear Housing Page 6B-60 90-857046 AUGUST 1998 BIGFOOT GEAR HOUSING 9. Shift gear housing into forward gear position. In forward gear the gear housing will ratchet when propeller shaft is turned clockwise. Resistance will be felt when propeller shaft is rotated counterclockwise. 10. Apply Loctite Grade 271 on threads of gear housing retaining bolts. NOTE: If, while performing Step 11, the drive shaft splines will not align with the crankshaft splines, place a propeller onto propeller shaft and turn it counterclockwise as the gear housing is being pushed toward drive shaft housing. NOTE:During installation of gear housing, it may be necessary to move the shift block (located under cowl) slightly to align upper shift shaft splines with shift shaft coupler splines. 11. Position gear housing so that the drive shaft is protruding into drive shaft housing. 12. Move gear housing up toward drive shaft housing, while aligning upper shift shaft splines with shift shaft coupler splines, water tube with water tube seal, and crank shaft splines with drive shaft splines. 13. Install 4 fasteners and washers (two each side). 14. Install locknut and washer. 15. Torque bolts and locknut (or nuts only if applicable) to 40 lb-ft (54.0 Nm). 53922 ab 7 Loctite “271” (92-809819) 7 a-Fasteners and Washers (2 Each Side) b-Locknut and Washer 16. Check shift operation as follows: • Place shift lever in forward gear. Gear housing should ratchet when propeller shaft is turned clockwise. Resistance should be felt when propeller shaft is turned counterclockwise. • Place shift lever in neutral. Propeller shaft should rotate freely in either direction. • While rotating propeller shaft, place shift lever in reverse gear. Resistance should be felt when propeller shaft is rotated in either direction. IMPORTANT: If shift operation is not as described, preceding, the gear housing must be removed and the cause corrected. 90-857046 AUGUST 1998 Page 6B-61 BIGFOOT GEAR HOUSING Trim Tab Adjustment 1. Check trim tab position as follows: • Operate boat at the speed at which it normally would be operated. • If the boat pulls to the right (STARBOARD), the trailing edge of trim tab must be moved to the right. If the boat pulls to the left (PORT), the trailing edge of trim tab must be moved to the left. 2. If necessary, adjust trim tab as follows: • Shift engine control into NEUTRAL and turn ignition key to “OFF” position. NOTE:Loosen trim tab bolt sufficiently to allow trim tab to disengage from locking ridges in gear case before attempting to move tab. DO NOT strike trim tab with a hard object to make adjustments. • If boat pulls to the left, adjust trailing edge of trim tab to the left. If boat pulls to the right, adjust trailing edge of trim tab to the right. 3. Tighten trim tab retaining bolt and washer to 22 lb-ft (29.8 Nm). Page 6B-62 90-857046 AUGUST 1998 THROTTLE/SHIFT LINKAGE ATTACHMENTS/CONTROL LINKAGE Section 7A - Throttle/Shift Linkage Table of Contents Linkage (Non Bigfoot). . . . . . . . . . . . . . . . . . . . 7A-2 Shift Cable Installation . . . . . . . . . . . . . . . . . . . 7A-6 Linkage (Bigfoot) . . . . . . . . . . . . . . . . . . . . . . . . 7A-4 Throttle Cable Installation . . . . . . . . . . . . . . . . 7A-8 7 A 90-857046 AUGUST 1998 Page 7A-1 THROTTL/SHIFT LINKAGE Page 7A-2 90-857046 AUGUST 1998 LINKAGE (NON BIGFOOT) 95 95 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 16 18 19 20 21 22 23 24 25 26 27 28 29 95 2-4-C w/Teflon (92-850736A1) THROTTLE/SHIFT LINKAGE LINKAGE (NON BIGFOOT) REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 SCREW (M8 x 70) 100 11.3 2 1 SCREW (M6 x 55) NUT ELECTRIC CAP 3 1 4 1 5 1 RETAINER 6 1 THROTTLE LEVER 7 1 BUSHING 8 1 RETAINER 9 1 SHIFT LEVER 10 1 BRACKET NON HANDLE 11 1 LATCH 12 2 SCREW (M6 x 16) 75 8.5 13 2 SLEEVE 14 1 SHIFT ROD 15 1 THROTTLE CAM 16 1 SPACER 17 1 WASHER 18 1 SCREW (M5 x 16) 75 8.5 19 1 HORIZONTAL SHIFT SHAFT 20 1 RETAINER 21 1 WASHER 22 1 COTTER PIN 23 1 SPRING 24 2 SPRING 25 1 PLATE 26 2 SCREW (M5 x 16) 27 1 SWITCH 28 2 SCREW (M3 x 20) ELECTRIC HANDLE MODELS PLATE–Switch29 1 90-857046 AUGUST 1998 Page 7A-3 THROTTL/SHIFT LINKAGE Page 7A-4 90-857046 AUGUST 1998 LINKAGE (BIGFOOT) 95 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 22 23 24 26 25 17 18 18 27 28 29 30 31 32 33 34 95 95 2-4-C w/Teflon (92-850736A1) THROTTLE/SHIFT LINKAGE LINKAGE (BIGFOOT) REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 SCREW (M8 x 70) 100 11.3 2 1 SCREW (M6 x 55) 3 1 NUT 4 1 CAP 5 1 RETAINER 6 1 THROTTLE LEVER 7 1 BUSHING 8 1 RETAINER 9 1 SHIFT LEVER 10 1 BRACKET 11 1 LATCH 12 2 SCREW (M6 x 16) 75 8.5 13 2 SLEEVE 14 1 SHIFT ROD 15 1 GUIDE-Shift Rod 16 1 SHIFT LINK 17 2 NYLINER 18 2 WASHER 19 1 NUT 20 1 COTTER PIN 21 1 SHIFT SHAFT LEVER 22 1 BUSHING 23 1 THROTTLE CAM 24 1 SPACER 25 1 WASHER 26 1 SCREW (M5 x 16) 75 8.5 27 1 SWIVEL LINKAGE (MANUAL BIGFOOT) 28 1 SHIFT ROD (MANUAL BIGFOOT) 29 1 SHIFT ROD (MANUAL BIGFOOT) 30 1 SHIFT DETENT (MANUAL BIGFOOT) 31 1 SPRING (MANUAL BIGFOOT) 32 1 SWITCH ELECTRIC PLATE–Switch HANDLE MODELS SCREW (M3 x 20) 33 1 34 2 90-857046 AUGUST 1998 Page 7A-5 THROTTL/SHIFT LINKAGE Shift Cable Installation Install cables into the remote control following the instructions provided with the remote control. NOTE:Install the shift cable to the engine first. The shift cable is the first cable to move when the remote control handle is moved out of neutral. 1. Position remote control into neutral. N 2. Shift outboard into neutral. 3. Measure the distance between pin and center of lower hole. a c b a-Distance Between Pin And Center of Lower Hole b-Pin c-Lower Hole 4. Fit shift cable through rubber grommet. Page 7A-6 90-857046 AUGUST 1998 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 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. b a a-Place Barrel Into Barrel Holder b-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 thru 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 thru d. 90-857046 AUGUST 1998 Page 7A-7 THROTTL/SHIFT LINKAGE 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. Page 7A-8 90-857046 AUGUST 1998 THROTTLE/SHIFT LINKAGE 4. Adjust the throttle cable barrel until a 1/16 in. (1.6 mm) gap exists between the oval shaped boss and the cam. 1/16 in. (1.6 mm) a b c e d a-Throttle Cable b-Retainer Pin c-Throttle Cable Barrel d-Oval Shaped Boss e-Cam 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. 90-857046 AUGUST 1998 Page 7A-9 TILLER HANDLE ATTACHMENTS/CONTROL LINKAGE Section 7B - Tiller Handle Table of Contents Tiller Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-2 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . 7B-8 Tiller Handle Assembly Removal . . . . . . . . . . 7B-4 Tiller Handle Reassembly . . . . . . . . . . . . . . . . 7B-9 Tiller Handle Disassembly . . . . . . . . . . . . . . . . 7B-6 Tiller Handle Installation . . . . . . . . . . . . . . . . . . 7B-13 7 B 90-857046 AUGUST 1998 Page 7B-1 TILLER HANDLE TILLER HANDLE Chemtool Duralube Special (92-824501)95 Page 7B-2 90-857046 AUGUST 1998 TILLER HANDLE TILLER HANDLE 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 2.3 5 1 THROTTLE CABLE (30-1/2 IN.) 6 1 THROTTLE CABLE (41-1/2 IN.) 7 1 SLEEVE 8 2 SCREW (M8 x 25) 135 15.3 9 1 COVER 10 1 BUSHING 11 1 ARM–Steering Handle 12 1 RETAINER 13 1 SCREW (M5 x 16) (MANUAL) 35 3.9 14 1 SCREW (M6 x 25) 15 1 LOCK–Throttle 16 1 SPRING 17 1 KNOB–Throttle 18 1 TILLER TUBE 19 1 DECAL 20 1 HANDLE–Throttle 21 1 GRIP 22 1 SWITCH (STOP) 23 1 SCREW (M5 x 12)(MANUAL) 24 1 WASHER (MANUAL) 25 1 ALARM (MANUAL) 26 2 CLIP 27 1 SWITCH (STOP) 28 1 RETAINER 29 1 BRACKET–Tiller 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 LANYARD SWITCH 37 1 SCREW (M8 x 35) 100 11.3 38 1 SHIFT HANDLE 39 1 BUSHING 40 1 SHIFT ROD 41 1 TAB WASHER 42 2 SCREW (M10 x 90) 90-857046 AUGUST 1998 Page 7B-3 TILLER HANDLE Page 7B-4 90-857046 AUGUST 1998 Tiller Handle Assembly Removal 1. Remove lower cowl. a b a - Screws-M6x30 (6) b - Screw-M6x60 2. Remove shift handle. a b c a - Shift Handle b - Bushing c - Screw-M8x35 TILLER HANDLE 90-857046 AUGUST 1998 Page 7B-5 3. Loosen the jam nuts and disconnect the throttle cables from the throttle lever. a b a - Throttle Cable (Long) b - Throttle Cable (Short) 4. Disconnect the tiller handle wiring. 5. Remove two screws (b) securing the tiller handle. Remove the tiller handle assembly from the outboard. 54272 RED BLK TAN/BLU PUR BLK/YEL BLK BLK BLK/YEL YEL/RED BLK YEL/RED BLK/YEL BLK/YEL BLK TAN RED BLK RED b c a a - Disconnect Tiller Handle Wires b - Screws-M10x90 (2) c - Tab Washer 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-6 90-857046 AUGUST 1998 TILLER HANDLE 4. Remove retainer and slide out the tiller tube assembly. 5. Remove the throttle lock assembly. a b c a-Retainer b-Throttle Lock Assembly c-Tiller Tube Assembly 6. Use a flat tip screwdriver to pry/push the rubber grip off the handle. 7. Pull out the stop switch harness. 8. Push the tiller tube out of the handle. a b c a-Stop Switch Harness b-Tiller Tube c-Handle 90-857046 AUGUST 1998 Page 7B-7 TILLER HANDLE 9. Remove cover and disconnect throttle cables from pulley. c b a a-Cover b-Throttle Cables c-Pulley Cleaning/Inspection/Repair 1. Inspect throttle cables for bending/damage and replace if necessary. 2. Inspect steering handle arm for cracks/damage and replace if necessary. Page 7B-8 90-857046 AUGUST 1998 TILLER HANDLE Tiller Handle Reassembly 1. Wrap cables around pulley as shown. a c b a-Short Throttle Cable (30-1/2 in.) Place in Top Groove b-Long Throttle Cable (40-1/2 in.) Place in Bottom Groove c-Pulley 2. Place pulley and cables into case. 3. Install cover with screw. c a b a-Pulley b-Cover c-Screw 10-16x1/2 in. Pulley Cover Bolt Torque 20 lb. in. (2.3 N·m) 90-857046 AUGUST 1998 Page 7B-9 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 b c c 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) c a b a-7/8 in. (22.2 mm) between Tiller Tube and end of Handle b-Engine Stop Switch Harness c-Stop Switch 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. 11. Match the end of the tiller tube with the slots in the pulley assembly. Insert the tiller tube end into the pulley assembly. Page 7B-10 90-857046 AUGUST 1998 TILLER HANDLE 12. Secure tiller tube with retainer. 13. Snap the engine start switch on the tiller tube. a cd b a-Pulley Assembly b-Throttle Lock Knob c-Retainer d-Screw-M5x16 Tiller Tube Retainer Screw Torque 35 lb. in. (3.9 N·m) 14. Place bushing components on the arm mounts. a b c d 95 95 95 2-4-C w/Teflon (92-850736A1) a-Flat Washer b-Bushing c-Wave Washer (2) d-Bushing 90-857046 AUGUST 1998 Page 7B-11 TILLER HANDLE 15. Pull the throttle cables and wiring into the bracket. 16. Fasten arm with cover. Arm Cover Bolt Torque 135 lb. in. (15.3 N·m) 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. 17. Place the throttle cables through the hand grip opening as shown. 18. Place all wiring inside the wiring conduit. 19. 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. Page 7B-12 90-857046 AUGUST 1998 TILLER HANDLE 90-857046 AUGUST 1998 Page 7B-13 20. 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 b d 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) Tiller Handle Installation 1. Install tiller handle, tab washer, and bolts. 2. Bend tabs onto flats of bolts. b c a a - Tiller Handle b - Tab Washer c - Bolts (2) M12x90 Tiller Handle Mounting Bolt Torque 35 lb. ft. (47.5 N·m) TILLER HANDLE 3. Connect wires as shown in wiring diagram. ELECTRIC START TILLER HANDLE WIRING DIAGRAM-30/40 (4-STROKE) –+ 87654321 – + 12 34 56 78BLK_YELBLK_YELBLK_YELGRY BLK_YELPPLYEL_BLK BLK BLK BLK BLK BLK BLK BLK YEL_RED BLK BLK BLK TAN_LTBLU GRY BLK_YEL BLK_YELBLK_YEL BLK BLK BLK_YEL BLK_YEL BLK_YEL BLK_YEL PPL PPL BLK YEL_RED BLK_YEL RED YEL_BLK PPL TAN TAN_LTBLUBLKYEL_RED TANBLKYEL_REDRED BLK BLKBLKBLK BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow LIT = Light DRK = Dark a b c d e f g h i j k l m n a-Ground Harness Under Bottom Solenoid Bolt b-Harness Extension c-Harness Connection d-Keyswitch Assembly Transom Mount e-Keyswitch f-Horn g-Lanyard Stop Switch h-Push Button Stop Switch i-Battery j-Starter k-Voltage Regulator l-Start Solenoid m-Neutral Start Switch n-ECM Page 7B-14 90-857046 AUGUST 1998 TILLER HANDLE 4. Secure wires at connectors with cable tie as shown. a a-Cable Tie 90-857046 AUGUST 1998 Page 7B-15 TILLER HANDLE Page 7B-16 90-857046 AUGUST 1998 5. Rotate throttle grip to idle position. 6. Insert the anchor on the shorter throttle cable into the anchor slot on the throttle lever. 7. Secure cable in position by tightening jam nuts onto bracket (finger tighten only). 8. Insert anchor on remaining cable into the anchor slot on the throttle lever. 9. Secure cable in position by tightening jam nuts onto bracket (finger tighten only). a e d c b a - Throttle Lever b - Anchor of Shorter Throttle Cable Positioned in Anchor Slot c - Jam Nuts Securing shorter Cable Onto Bracket d - Anchor of remaining Throttle Cable Positioned in Anchor Slot e - Jam Nuts Securing remaining Cable Onto Bracket TILLER HANDLE 10. Rotate throttle grip to full throttle and adjust jam nuts until throttle stop screw hits plate. NOTE:No free-play should exist in throttle grip handle once throttle stop screw has hit plate, if this condition exists re-adjust jam nuts. ba a-Throttle Stop Screw Hitting Plate b-No Free play should exist in throttle grip handle past full throttle once throttle stop screw has hit plate. If this condition exists re-adjust jam nuts. IMPORTANT: After installation, move the throttle grip a few times from the idle position too the wide-open-throttle position. If necessary, re-adjust the jam nuts. 90-857046 AUGUST 1998 Page 7B-17 TILLER HANDLE Page 7B-18 90-857046 AUGUST 1998 11. Install lower cowl. c a b a - Screw (6)-M6x30 b - Lower Cowl c - Screw-M6x20 Bottom Cowl Bolt Torque 60 lb. in. (7 N·m) 12. Cables, wires, and shift rod should be routed through grommet as shown. Seat grommet between cowl halves. a c b d e f a - Fuel Connector b - Battery Cables c - Throttle Cables d - Shift Rod e - Tiller Handle Harness Wires f - Remote Key Harness TILLER HANDLE 13. Assemble the shift rod into the shift handle. ab a-Shift Rod b-Shift Handle 14. Install shift handle assembly, bushing, and bolt. 95 95 a b c 2-4-C w/Teflon (92-850736A1) a-Handle Assembly b-Bolt-M8x35 c-Bushing Shift Handle Bolt Torque 100 lb. in. (11.3 N·m) 90-857046 AUGUST 1998 Page 7B-19 MANUAL STARTER MANUAL STARTER Section 8 Table of Contents Manual Starter . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Cleaning and Inspection . . . . . . . . . . . . . . . . . . 8-8 Interlock Cable Adjustment . . . . . . . . . . . . . . . 8-4 Rewind Starter Reassembly . . . . . . . . . . . . . . 8-9 Manual Starter Removal . . . . . . . . . . . . . . . . . 8-5 Adjusting Rewind Spring Tension . . . . . . . 8-10 Manual Starter Disassembly . . . . . . . . . . . . . . 8-6 Manual Starter Installation . . . . . . . . . . . . . . . . 8-14 8 90-857046 AUGUST 1998 Page 8-1 MANUAL STARTER Page 8-2 90-857046 AUGUST 1998 MANUAL STARTER 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 23 32 95 2-4-C w/Teflon (92-850736A1) 95 95 MANUAL STARTER MANUAL STARTER 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 WASHER-Finger Spring 8 1 SPRING 9 1 STARTER SHEAVE 10 2 DOG-CAM 11 2 SPRING 12 2 RETAINING RING 13 1 SPRING 14 1 CAM 15 1 SCREW (1/4-20) 135 15.3 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 3.8 32 1 DECAL-EPA Information 90-857046 AUGUST 1998 Page 8-3 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 b c d e 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. Page 8-4 90-857046 AUGUST 1998 MANUAL STARTER 90-857046 AUGUST 1998 Page 8-5 Manual Starter Removal 1. Remove the adjustment screw from the rewind housing. 2. Remove the retaining clip from the start interlock. 3. Remove the interlock cable. b a a - Adjustment Screw b - Retaining Clip 4. Remove bolts and manual starter. a b a - Bolts (4) - M6x25 b - Manual Starter MANUAL STARTER Page 8-6 90-857046 AUGUST 1998 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. 2. Remove cam, interlock lever, and springs. a b c d f e a - Screws (3) - 10-16x.625 (1/4 in. Hex) b - Cam Retainer c - Cam d - Spring (Cam) e - Interlock Lever f - Spring (Interlock Lever) 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 and allow rewind spring to unwind. b a a - Knot in Starter Rope b - Knot in Starter Rope Handle MANUAL STARTER 90-857046 AUGUST 1998 Page 8-7 5. Remove cam and spring. 6. Remove starter sheave assembly from recoil housing. d a b c e a - Screw b - Cam c - Spring d - Starter Sheave Assembly e - Recoil Housing 7. Remove rope from starter sheave assembly. NOTE: If re-using rope leave end knot tied. a a - Knot MANUAL STARTER Page 8-8 90-857046 AUGUST 1998 8. Remove springwasher and spring assembly from starter sheave. 9. Remove retaining rings, pawls, and springs from starter sheave. a b c d e f a - Springwasher b - Spring Assembly c - Starter Sheave d - Retaining Rings (2) e - Pawls (2) f - 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. Replace as necessary. 3. Inspect starter sheave, rope guide and recoil housing for nicks, grooves, cracks, wear or distortion, especially area of rope travel. Replace as necessary. 4. Inspect cam, pawls and springs for wear or damage. Replace as necessary. MANUAL STARTER 90-857046 AUGUST 1998 Page 8-9 5. Inspect starter rope for wear. Replace as necessary. NOTE: Rope measures 66 in. (1.68 m) long 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. NOTE: Position straight end of spring into recess of starter sheave and angled end of spring across back of pawl as shown. 2. Install spring assembly and springwasher into starter sheave. d e f c b a 95 2-4-C w/Teflon (92-850736A1) 95 95 a - Springs (2) b - Pawls (2 ) c - Retaining Rings (2) d - Spring Assembly e - Springwasher f - Starter Sheave MANUAL STARTER Page 8-10 90-857046 AUGUST 1998 3. Install starter sheave assembly into recoil housing. NOTE: Looped end of spring must engage “V” notch in hub of recoil housing. 4. Secure cam and starter sheave assembly to recoil housing. NOTE: Cam should be positioned as shown with “x” facing up. f a b c d e a - Recoil Housing b - Starter Sheave Assembly c - Looped End of Spring d - Spring e - Cam f - Screw Cam Screw Torque 135 lb. in. (15.3 N·m) Adjusting Rewind Spring Tension 1. Rotate sheave counterclockwise until it stops (coil is bound). MANUAL STARTER 90-857046 AUGUST 1998 Page 8-11 2. Back sheave off until knot recess in sheave aligns with rope bushing. a b a - Rope Bushing b - Knot Recess 3. Thread starter rope thru knot recess in starter sheave, rope guide, and starter housing. Place knot into recess. a b a - Starter Rope b - Knot MANUAL STARTER Page 8-12 90-857046 AUGUST 1998 4. Allow starter rope to pull back into 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. 5. Route starter rope through starter handle. Tie a knot into end of rope and secure in rope retainer. 6. Untie overhand knot from step (4). a b c a - Starter Rope b - Starter Handle c - Retainer 7. Install springs, interlock lever, and cam. IMPORTANT: Interlock lever spring should be installed with squared end of spring seated on interlock lever. IMPORTANT: Cam spring ends should be seated on recoil housing and cam boss. Spring tension should be noticeable when turning cam clockwise. 95 d 95 2-4-C w/Teflon (92-850736A1) 95 a b c e f g h a - Spring (Interlock Lever) b - Squared End of Spring c - Interlock Lever d - Spring (Cam) e - Cam f - Spring (Cam) g - Recoil Housing h - Cam Boss (Hidden) MANUAL STARTER 8. Install cam retainer. Drive screws tight. NOTE:Cam should be held with some pre-load until retainer is seated. a c b 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. 90-857046 AUGUST 1998 Page 8-13 MANUAL STARTER Page 8-14 90-857046 AUGUST 1998 Manual Starter Installation 1. Secure manual starter with bolts. a b a - Bolts (4) - M6x25 b - Manual Starter Manual Starter Bolt 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. b a a - Retaining Clip b - Adjustment Screw