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Starting Model Year 1999 Starting Serial Number 0G760300 30/40 FourStroke Starting Model Year 1999 30/40 FourStroke 90-857046R1 NOVEMBER 2001 Notice Throughout this publication, “Dangers”, “Warnings” and “Cautions” (accompanied by the International HAZARD Symbol ) are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. OBSERVE THEM CAREFULLY! These “Safety Alerts” alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus “Common Sense” operation, are major accident prevention measures. DANGER DANGER - Immediate hazards which WILL result in severe personal injury or death. WARNING WARNING -Hazards or unsafe practices which COULD result in severe personal injury or death. CAUTION Hazards or unsafe practices which could result in minor personal injury or product or property damage. Notice to Users of This Manual This service manual has been written and published by the Service Department of Mercury Marine to aid our dealers’ mechanics and company service personnel when servicing the products described herein. It is assumed that these personnel are familiar with the servicing procedures of these products, or like or similar products manufactured and marketed by Mercury Marine, that they have been trained in the recommended servicing procedures of these products which includes the use of mechanics’ common hand tools and the special Mercury Marine or recommended tools from other suppliers. We could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of the possible hazards and/or results of each method. We have not undertaken any such wide evaluation. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered by the service procedure selected. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service these products. It should be kept in mind, while working on the product, that the electrical system and ignition system are capable of violent and damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables should be disconnected at the battery. Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive internal damage when the engine is started. 90-857046R1 NOVEMBER 2001 Page i It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Mismatched or incorrect fasteners can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the same locations whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original. Cleanliness and Care of Outboard Motor A marine power product is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten thousands of an inch/mm. When any product component is serviced, care and cleanliness are important. Throughout this manual, it should be understood that proper cleaning, and protection of machined surfaces and friction areas is a part of the repair procedure. This is considered standard shop practice even if not specifically stated. Whenever components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed. Personnel should not work on or under an outboard which is suspended. Outboards should be attached to work stands, or lowered to ground as soon as possible. We reserve the right to make changes to this manual without prior notification. Refer to dealer service bulletins for other pertinent information concerning the products described in this manual. Page ii 90-857046R1 NOVEMBER 2001 Service Manual Outline Section 1 - Important Information A - Specifications B - Maintenance C - General Information D - Outboard Motor Installation Section 2 - Electrical A - Ignition B - Charging & Starting System C - Timing,Synchronizing & Adjusting 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 Section 9 - Color Diagrams Important Information Electrical Fuel System Powerhead Mid-Section Gear Housing Attachments/ Control Linkage Manual Starter Color Diagrams 90-857046R1 NOVEMBER 2001 Page iii SPECIFICATIONS IMPORTANT INFORMATION Section 1A - Specifications Table of Contents 1 A Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1 Mercury/Quicksilver Lubricants and Sealants 1A-11 Propeller Information Charts . . . . . . . . . . . . . . 1A-8 Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-13 Specifications Models 30/40 EFI (4-Stroke) HORSEPOWER (kW) Model 30 Model 40 30 hp (22.4 Kw) @ 5750 rpm 40 hp (29.8 Kw) @ 5750 rpm Electric OUTBOARD 30/40 MH 204 lb (93 kg) WEIGHT 30/40 ELPT 224 lb (112.7 kg) 40 ELPT BIGFOOT 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 91-802653Q1 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 4-Stroke Outboard 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-stroke 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. 90-857046R1 NOVEMBER 2001 Page 1A-1 SPECIFICATIONS IGNITION SYSTEM Readings taken @ 68°F (20°C). Type Spark Plug: Type Gap Hex Size Torque Hole Size Firing Order Ignition Timing: @ Idle (800 rpm) @ WOT (6000 rpm) Charge Coil Resistance Crank Position Sensor Resistance Ignition Coil Resistance: Capacitor Discharge Ignition NGK DPR6EA-9 0.035 in. (0.9 mm) 18 mm 150 lb-in. (17 Nm) 12mm 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) Primary Secondary (W/o Boots) ECM Engine Speed Limiter Soft Reduction (Retards Timing) Spark Cut-Out Reduction (Percentages of ignition spark are Cut-Out) ECM Overheat/Low Oil Pressure Speed Control Engine Temperature Sensor 0.08 - 0.7 W (BLK - BLK/WHT) 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 Start Bendix 1.1 kW 174.0 Amps 23.7 Amps Battery Rating Minimum Requirement 465 Marine Cranking Amps (MCA) or 350 Cold Cranking Amps (CCA) For operation below 32° F (0° C) 1000 Marine Cranking Amps (MCA) or BATTERY Ampere-Hours (Ah) Minimum 775 Cold Cranking Amps (CCA) For operation above 32° F (0° C) 70 For operation below 32° F (0° C) 105 IMPORTANT: Use resistive spark plugs only. Page 1A-2 90-857046R1 NOVEMBER 2001 SPECIFICATIONS ENRICHMENT Auto Enrichener Resistance 15 - 25 Ohms (YEL/BLK - YEL/BLK) CONTROL Electrothermal Ram Projection 0.3 in. (7mm) after 5 min. of power SYSTEM Readings taken @ 68°F (20°C). FUEL SYSTEM Fuel Pump Type Fuel Pump: Pressure Fuel Tank Capacity Mechanical Water Cooled (Plunger/Diaphragm) 3-6 psi Accessory Idle rpm (Out Of Gear) 900 ± 25 rpm Idle rpm (In Forward Gear) Wide Open Throttle rpm (WOT) 800 ± 25 rpm Range 5500–6000 Main Jet Size #98 Pilot Jet #38 CARBURETOR Idle Jet #42 Float Height 0.47-0.63 in. (12.0-16.0 mm) CYLINDER BLOCK Type Displacement Number of Cylinders 4 Stroke – Over Head Camshaft 45.6 cu. in. (747 cc) 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) Ring End Gap (Installed) Top 0.006 - 0.012 in. (0.15 - 0.03 mm) Middle 0.012 - 0.020 in. (0.30 - 0.50 mm) RINGS Bottom (Oil Ring) Side Clearance: 0.008 - 0.028 in. (0.20 - 0.70 mm) Top 0.0008 - 0.0024 in. (0.02 - 0.06 mm) Middle 0.0008 - 0.0024 in. (0.02 - 0.06 mm) 90-857046R1 NOVEMBER 2001 Page 1A-3 SPECIFICATIONS COMPRESSION RATIO Compression Ratio Cylinder Compression* (Electric Models Only, Cold Engine @ W.O.T.) 9.7:1 180 - 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) CAMSHAFT Camshaft Dimensions Intake “A” Exhaust “A” Intake “B” Exhaust “B” Run-out Limit Camshaft Bearing Diameter “b” A B bb b b 1.214 - 1.222 in. (30.83 - 31.03 mm) 1.214 - 1.222 in. (30.83 - 31.03 mm) 1.020 - 1.028 in. (25.90 - 26.10 mm) 1.020 - 1.028 in. (25.90 - 26.10 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 1A-4 90-857046R1 NOVEMBER 2001 SPECIFICATIONS 90-857046R1 NOVEMBER 2001 Page 1A-5 CYLINDER HEAD Warp Limit * Lines indicate straight edge measurement Camshaft Bore Inside Diameter “a” 56900 56899 a a a a 0.004 in. (0.1 mm) 1.4567 - 1.4577 in. (37.000 - 37.025 mm) VALVES Valve/Valve Seat/Valve Guides: Valve Clearance (cold) Intake Exhaust Valve Dimensions: “A” Head Diameter Intake Exhaust “B” Face Width Intake Exhaust “C” Seat Width Intake Exhaust “D” Margin Thickness Intake Exhaust Stem Outside Diameter Intake Exhaust Guide Inside Diameter Intake Exhaust Stem To Guide Clearance Intake Exhaust Stem Run-out Limit (max.) 0.006 - 0.010 in. (0.15 - 0.25 mm) 0.010 - 0.014 in. (0.25 - 0.35 mm) 1.256 - 1.264 in. (31.9 - 32.1 mm) 1.020 - 1.028 in. (25.9 - 26.1 mm) 0.079 - 0.124 in. (2.00 - 3.14 mm) 0.079 - 0.124 in. (2.00 - 3.14 mm) 0.035 - 0.043 in. (0.9 - 1.1 mm) 0.035 - 0.043 in. (0.9 - 1.1 mm) 0.020 - 0.035 in. (0.5 - 0.9 mm) 0.020 - 0.035 in. (0.5 - 0.9 mm) 0.2156 - 0.2161 in. (5.475 - 5.490 mm) 0.2150 - 0.2156 in. (5.460 - 5.475 mm) 0.2165 - 0.2170 in. (5.500 - 5.512 mm) 0.2165 - 0.2170 in. (5.500 - 5.512 mm) 0.0004 - 0.0015 in. (0.010 - 0.037 mm) 0.0010 - 0.0020 in. (0.025 - 0.052 mm) 0.0006 in. (0.016 mm) SPECIFICATIONS “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 in. (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. (3mm) LUBRICATION SYSTEM Pump Type Engine Oil Pressure (Warm Engine) @ 3000 rpm Engine Oil Pan Capacity Oil Pump: S/N OT427437 & Up (Electric) S/N OT426439 & Up (Manual) Outer Rotor to Housing “a” Inner Rotor to Outer Rotor “b” Rotor to Housing “c” Oil Pump: S/N OT427436 & Below (Electric) S/N OT426438 & Below (Manual) Outer Rotor to Housing “a” Inner Rotor to Outer Rotor “b” Trochoid 30-40 psi (207-278 kPa) Either 3 Qts. or 3 Liters 0.0045 - 0.009 in. (0.11 - 0.23 mm) 0.005 in. (0.12 mm) 0.0015 - 0.003 in. (0.04 - 0.08 mm) 0.0035 - 0.006 in. (0.09 - 0.15 mm) 0.005 in. (0.12 mm) Rotor to Housing “c” a b 0.001 - 0.003 in. (0.03 - 0.08 mm) c Transom Height: Short Shaft 15 in. (38 cm) Long Shaft Steering Pivot Range: 20 in. (51 cm) MID-SECTION Tiller 90° Remote 60° Tilt Pin Positions 5 + Shallow Water Full Tilt Up Angle 69° Allowable Transom Thickness 2-3/4 in. (69.8 mm) Page 1A-6 90-857046R1 NOVEMBER 2001 SPECIFICATIONS 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 (Warm Engine) @ 800 rpm @ 6000 rpm (WOT) Leak Test Pressure 2.00:1 14.9 fl oz (440 mL) Premium Blend Gear Lube 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) 10-12 psi (68-83 kPa) for 5 Minutes 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) Leak Test Pressure 2.31:1 24 fl oz (710 mL) Premium Blend Gear Lube 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 2-7 psi (14-41 kPa) 12-17 psi (83-172 kPa) 10-12 psi (69-83 kPa) for 5 Minutes 90-857046R1 NOVEMBER 2001 Page 1A-7 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 Page 1A-8 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 Page 1A-9 SPECIFICATIONS Mercury/Mariner 40 (4-Stroke) 2.3:1 Bigfoot Special soft rubber hub propellers designed to reduce clutch rattle Wide Open Throttle rpm: 5500-6000 Recommended Transom Heights : 20”, 25” Right Hand Rotation Standard Gear Reduction : 2.31:1 IMPORTANT: These specially designed rubber hub propellers are rated for 60 horsepower MAXIMUM. Diameter Pitch No. of Blades Material Approx. Gross Boat Wgt. (lbs) Approx. Boat Length Speed Range (mph) Propeller Part Number 13-3/4” 15” 3 Alum 1200-1500 14-16’ 27-32 48-77342A33 14” 13” 3 Alum 1500-2000 16-18’ 22-27 48-77340A33 14” 11” 3 Alum 2000-3000 pontoon 17-21 48-77338A33 14” 10” 3 Alum 2500+ pontoon/work 14-19 48-854342A33 14” 9” 3 Alum 3500+ houseboat/ work 1-15 48-854340A33 Page 1A-10 90-857046R1 NOVEMBER 2001 SPECIFICATIONS Mercury/Quicksilver Lubricants and Sealants Description Mercury Part Number Quicksilver Part Number Needle Bearing Assy. Lubricant [8 oz. (226.8 grams)] tube 92-802868A1 N/A Dielectric Grease [8 oz. (226.8 grams)] can 92-823506-1 92-823506-1 Loctite 271 – Thread Locker (10 ml) tube 92-809819 92-809819 Loctite 567 PST Pipe Sealant (50 ml) tube 92-809822 92-809822 Loctite Master Gasket Kit 92-12564-2 92-12564-2 2 Cycle Premium Outboard Oil [1 Gallon (3.7 liter)] 92-802815A1 92-802815Q1 Perfect Seal [16 oz. (0.45 kg)] can 92-34227-1 92-34227-1 Liquid Neoprene [8 oz. (226.8 grams)] can 92-25711-3 92-25711-3 Cyanacrylate Adhesive Obtain Locally Obtain Locally Bellows Adhesive N/A 92-86166Q1 Loctite 680 Retaining Compound (10 ml) tube 92-809833 92-809833 Loctite 222 Thread Locker (10 ml) tube 92-809818 92-809818 3M Permabond #3M08155 Obtain Locally Obtain Locally Loctite 242 Thread Locker (10 ml) tube 92-809821 92-809821 Loctite 609 Obtain Locally Obtain Locally Loctite 405 Obtain Locally Obtain Locally 90-857046R1 NOVEMBER 2001 Page 1A-11 SPECIFICATIONS Description Mercury Part Number Quicksilver Part Number RTV 587 Silicone Sealer [3 oz. (85.05 grams)] 92-809825 92-809825 Loctite 262 Obtain Locally Obtain Locally Premium Gear Lubricant [1 Quart (0.94 liter)] 92-802846A1 92-802846Q1 Loctite 7649 Primer [4.5 oz (127.57 grams)] 92-809824 92-809824 Anti-Corrosion Grease [8 oz. (226.8 grams)] tube 92-802867A1 92-802867Q1 2-4-C with Teflon [8 oz. (226.8 grams)] tube 92-802859A1 92-802859Q1 Loctite Quick Tite Obtain Locally Obtain Locally Isopropyl Alcohol Obtain Locally Obtain Locally Hot Glue Obtain Locally Obtain Locally Special Lubricant 101 [8 oz. (226.8 grams)] tube 92-802865A1 92-802865Q1 4 Stroke 10W30 Outboard Oil [1 Quart (0.94 liter)] 92-802833A1 92-802833Q1 4 Cycle 25W40 Engine Oil [1 Quart (0.94 liter)] 92-802837A1 92-802837Q1 Power Trim & Steering Fluid [8 oz. (226.8 grams)] 92-802880A1 92-802880Q1 Engine Coupler Spline Grease [14 oz. (0.39 kg)] cartridge 92-802869A1 92-802869Q1 Power Tune Engine Cleaner [13 oz. (384 ml)] spray can 92-802878 92-802878Q57 Fuel System Treatment & Stabilizer [12 oz. (355 ml)] plastic bottle 92-802875A1 92-802875Q1 Page 1A-12 90-857046R1 NOVEMBER 2001 SPECIFICATIONS Torque Chart Fastener Location Diameter x Length (mm) Torque lb-in. lb-ft.. Nm Ignition Coil Mounting Nuts M5 30 3.5 Coil Mount Plate Screw (Rear) M6 x 25 60 7 Coil Mount Plate Screw M6 x 30 75 8.5 Coil Plate Ground Screw M6 x 10 60 7 Spark Plug 12 mm 150 17 Charging & Starting System Flywheel Cover Screws M6 x 25 75 8.5 Flywheel Nut N/A 116 157 Stator Screws (Electric) M5 x 30 85 9.5 Stator Screws (Manual) M5 x 25 85 9.5 Voltage Regulator Screws M6 x 40 75 8.5 Starter Motor Mount Bolts M8 x 45 21.5 29.5 Starter Cable Nut 1/4-20 60 7 Starter Motor Thru Bolts N/A 70 8 Battery Cable (+) Nut M6 60 7 Solenoid Plate Screw M6 x 14 45 5 Harness Retainer Screws M6 x 14 45 5 Wire Clamp Screw (Top of Block) M5 x 12 45 5 Cylinder Head Cylinder Head Bolts (*) M9 x 95 34.5 47 Cylinder Head Bolts (*) M6 x 25 106 12 Baffle Plate Screws M4 x 10 Drive Tight Valve Cover Screws M6 x 20 70 8 Valve Adjusting Nuts M6 120 13.5 Rocker Arm Shaft Screws M8 x 23 160 13 18 Driven Gear Screw M10 x 40 28 38 Cylinder Block/Crankcase Crankcase Cover Bolts - Center (*) M8 x 82 22 30 Crankcase Cover Bolts - Outer (*) M6 x 35 106 12 Exhaust Cover Screws M6 x 35 106 12 Connecting Rod Bolts (*) Special 150 17 Oil Filter N/A 70 8 Oil Filter Nipple N/A 29.5 40 Powerhead Mounting Bolts (*) M8 x 110 33 44.5 Lifting Eye Screw M8 x 35 29 39.5 Oil Pressure Switch N/A 75 8.5 Oil Galley Plug 1/8-27 Pipe Plug 80 9 Oil Galley Plug 3/4-14 Pipe Plug 30 40.5 Oil Galley Plug 1/2-14 Pipe Plug 30 40.5 *NOTE:Two Step Torque - See appropriate section of component for details. 90-857046R1 NOVEMBER 2001 Page 1A-13 SPECIFICATIONS Fastener Location Diameter x Length (mm) Torque lb-in. lb-ft. Nm Lubrication Oil Pump Mounting Screws M6 x 40 70 8 Oil Pump Cover Screws M6 x 16 70 8 Mid-Section Top Cowl Latch Screw/Nut M4 x 14 Drive Tight Top Rear Cowl Latch Screw/Nut M6 x 16 90 10 Bottom Cowl Screws M6 x 30 60 7 Bottom Cowl Screws M6 x 60 60 7 Rear Cowl Latch Screw (Bottom) M6 x 16 60 7 Oil Drain Plug N/A 17.5 23.5 Gear Housing Mounting Stud M10 144 12 16 Adaptor Plate Mounting Screw M8 x 45 33 44.5 Co-Pilot Plate Bolt (Shoulder) 1/4-20 x 0.68 70 8 Steering Bracket Bolts M10 x 30 32.5 44 Steering Link Rod Bolt Special 20 27 Steering Link Rod Nut 3/8-24 Torque to 120 lb-in. then back off 1/4 turn. Upper Mount Bolts M6 x 20 130 14.5 Upper Mount Bolts M12 x 154 24 32.5 Upper Mount Nuts M12 24 32.5 Lower Mount Bolts M10 x 105 32.5 44 Lower Mount Nuts M12 32.5 44 Ground Screws 10-16 x 0.38 Drive Tight Tilt Lever Bolt (Shoulder) 3/8-16 x 0.62 18 25 Tilt Stop Bolt M10 x 40 Tilt Tube Nut 3/414 Torque to 32 lb-ft., then back off 1/4 turn. Anchor Bracket Screws M8 x 30 25 34 Anchor Bracket Screws M8 x 35 25 34 Anode Screws M6 x 25 60 7 Adaptor Plate (Socket Head) Screw M6 x 55 150 17 Oil Pressure Relief Valve N/A 34 46 Oil Pickup/Gasket Screw M6 x 20 75 8.5 Oil Gallery Plug 1/214 Pipe Plug 24 33 Power Trim Shock Rod Piston N/A 90 122 Piston Spring Plate Screws N/A 35 4 Cylinder End Cap N/A 45 61 Trim Cylinder/Reservoir Screws N/A 100 11 Pump to Manifold Screws N/A 70 8 Check Valve Plug N/A 120 13 Reservoir Screws N/A 80 9 Page 1A-14 90-857046R1 NOVEMBER 2001 SPECIFICATIONS Fastener Location Diameter x Length (mm) Torque lb-in. lb-ft. Nm Manual Tilt Assist Plug, Velocity Valve N/A 75 8.5 Plug, Plunger (2) N/A 75 8.5 Shock Rod Piston N/A 90 122 Piston Spring Plate Screws N/A 35 4 Cylinder End Cap N/A 45 61 Tilt Cylinder/Reservoir Screws N/A 100 11 Accumulator N/A 35 47 Non-Bigfoot Gear Housing Pinion Nut N/A 50 68 Bearing Carrier Screws M8 x 25 19 25.5 Vent, Fill/Drain Screw NA 60 7 Water Pump Cover Screws M6 x 16 60 7 Gear Housing Mounting Screws M10 x 45 40 54 Gear Housing Mounting Nut M10 40 54 Trim Tab Screw M8 x 20 23 31.5 Propeller Nut N/A 55 74.5 Bigfoot Gear Housing Bearing Carrier Nut M8 25 34 Water Pump Base Screws M6 x 25 60 7 Water Pump Cover Screws M6 x 30 60 7 Vent, Fill/Drain, Oil Level Screw N/A 60 7 Gear Housing Mounting Bolts M10 x 45 40 54 Gear Housing Mounting Nut M10 40 54 Trim Tab Screw 7/16 x 1-1/4 in 22 30 Anode Screw M6 x 40 60 7 Propeller Nut Throttle/Shift Linkage Throttle/Shift Lever Screw M8 x 70 100 11.5 Throttle Cam Mounting Screw M6 x 40 75 8.5 Throttle Cam Screw 10-16 x 5/8 in. Drive Tight Remote Control Cable Anchor Bracket Screws M6 x 16 75 8.5 Shift Spring Screw M5 x 16 45 5 Neutral Start Switch Screws M3 x 20 20 2.5 Shift Link Nut (Bigfoot) M6 Tiller Handle Tiller Mounting Bracket Screws M10 x 90 35 47.5 Shift Handle Screw M8 x 150 100 11 Tiller Tube Retainer Screw M5 x 16 35 4 Tiller Mount Cover Screws M8 x 25 135 15 Pulley Case Screws Self Tapping 10-16 x 1/2 20 2.5 90-857046R1 NOVEMBER 2001 Page 1A-15 MAINTENANCE 1 B IMPORTANT INFORMATION Section 1B - Maintenance Table of Contents Table of Contents . . . . . . . . . . . . . . . . . . . . . . . 1B-1 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-11 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-2 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-11 Mercury/Quicksilver Lubricants and Sealants 1B-2 Fuel Line Inspection . . . . . . . . . . . . . . . . . . 1B-11 Inspection And Maintenance Schedule . . . . . 1B-3 Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . 1B-12 Before Each Use . . . . . . . . . . . . . . . . . . . . . 1B-3 Oil Changing Procedure . . . . . . . . . . . . . . . 1B-12 After Each Use . . . . . . . . . . . . . . . . . . . . . . . 1B-3 Changing Oil Filter . . . . . . . . . . . . . . . . . . . . 1B-13 Every 100 Hours of Use or Once yearly . 1B-3 Checking and Adding Engine Oil . . . . . . . 1B-13 Every 300 Hours of Use or Three Years . 1B-4 Changing Gear Case Lubricant . . . . . . . . . . . 1B-14 Before Periods of Storage . . . . . . . . . . . . . 1B-4 3-1/4 In. (83mm) Diameter Gear Case . . 1B-14 Flushing the Cooling System . . . . . . . . . . . . . . 1B-4 4-1/4 In. (108mm) Diameter Gear Case . 1B-15 Steering Link Rod Fasteners . . . . . . . . . . . . . . 1B-5 Storage Preparation . . . . . . . . . . . . . . . . . . . . . 1B-17 Corrosion Control Anode . . . . . . . . . . . . . . . . . 1B-6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . 1B-17 Spark Plug Inspection and Replacement . . . 1B-7 Protecting External Outboard Battery Inspection . . . . . . . . . . . . . . . . . . . . . . . 1B-7 Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-17 Fuse Replacement - Electric Start Models . . 1B-8 Protecting Internal Engine Components . 1B-17 Timing Belt Inspection . . . . . . . . . . . . . . . . . . . 1B-8 Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-17 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . 1B-9 Positioning Outboard for Storage . . . . . . . 1B-18 Checking Power Trim Fluid . . . . . . . . . . . . . . . 1B-10 Battery Storage . . . . . . . . . . . . . . . . . . . . . . 1B-18 90-857046R1 NOVEMBER 2001 Page 1B-1 MAINTENANCE Special Tools 1. Crankcase Oil Pump P/N 90265A5 2. Oil Filter Wrench P/N 91-802653Q1 3. Flushing Attachment P/N 44357A2 Mercury/Quicksilver Lubricants and Sealants NOTE:See section 1A for lubricants and sealants chart. Page 1B-2 90-857046R1 NOVEMBER 2001 MAINTENANCE Inspection And Maintenance Schedule To keep your outboard in the best operating condition, it is important that your outboard receive the periodic inspections and maintenance listed in the Inspection and Maintenance Schedule. We urge you to keep it maintained properly to ensure the safety of you and your passengers and retain its dependability. WARNING Neglected inspection and maintenance service of your outboard or attempting to perform maintenance or repair on your outboard if you are not familiar with the correct service and safety procedures could cause personal injury, death, or product failure. Before Each Use 1. Check engine oil level. 2. Check that lanyard stop switch stops the engine. 3. Visually inspect the fuel system for deterioration or leaks. 4. Check outboard for tightness on transom. 5. Check steering system for binding or loose components. 6. Visually check steering link rod fasteners for proper tightness. 7. Check propeller blades for damage. After Each Use 1. Flush out the outboard cooling system if operating in salt or polluted water. 2. If operating in salt water, wash off all salt deposits and flush out the exhaust outlet of the propeller and gear case with fresh water. Every 100 Hours of Use or Once yearly, Whichever occurs first 1. Lubricate all lubrication points. Lubricate more frequently when used in salt water. 2. Change engine oil and replace the oil filter. The oil should be changed more often when the engine is operated under adverse conditions such as extended trolling. 3. Inspect thermostat visually for corrosion, broken spring, and to determine that the valve is completely closed at room temperature. If questionable, inspect thermostat as outlined in Section 4B “Thermostat”. 4. Inspect and clean spark plugs. 5. Check engine fuel filter for contaminants. 6. Check engine timing setup. 7. Check corrosion control anodes. Check more frequently when used in salt water. 8. Drain and replace gear case lubricant. 9. Lubricate splines on the drive shaft. 10. Check and adjust valve clearance, if necessary. 11. Check power trim fluid. 12. Inspect battery. 13. Check control cable adjustments. 14. Inspect timing belt. 90-857046R1 NOVEMBER 2001 Page 1B-3 MAINTENANCE 15. Remove engine deposits with Power Tune Engine Cleaner. 16. Check tightness of bolts, nuts, and other fasteners. Every 300 Hours of Use or Three Years, Whichever Occurs First 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). Flushing the Cooling System Flush the internal water passages of the outboard with fresh water after each use in salt, polluted or muddy water. This will help prevent a buildup of deposits from clogging the internal water passages. IMPORTANT: The engine must be run during flushing in order to open the thermostat and circulate water through the water passages. NOTE:You can have the outboard tilted or in the vertical operating position during flushing. WARNING To avoid possible injury when flushing, remove the propeller. Refer to Propeller Replacement. 1. Place the outboard in either the operating position (vertical) or in a tilted position. 2. Remove propeller (refer to Propeller Replacement). 3. Thread a water hose into the rear fitting. Partially open the water tap (1/2 maximum). Do not open the water tap all the way, as this allows a high pressure flow of water. a a-Water Hose Threaded into Rear Fitting IMPORTANT: Do not run engine above idle when flushing. 4. Shift outboard into neutral. Start the engine and flush the cooling system for at least 5 minutes. Keep engine speed at idle. 5. Stop the engine. Turn off the water and remove hose. Reinstall the propeller. Page 1B-4 90-857046R1 NOVEMBER 2001 MAINTENANCE Steering Link Rod Fasteners 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. IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt (“a” – Part Number 10-823919) and self locking nylon insert locknuts (“b” & “c” – Part Number 11-826709113). These locknuts must never be replaced with common nuts (non locking) as they will work loose and vibrate off, freeing the link rod to disengage. a c b d e f a-Special Washer Head Bolt (10-823919) b-Nylon Insert Locknut (11-826709113) c-Nylon Insert Locknut (11-826709113) d-Flat Washers e-Spacer (12-71970) f-Link Rod Mount Hole 1. Assemble steering link rod to steering cable with two flat washers (d) and nylon insert locknut (“c” – Part Number 11-826709113). Tighten locknut (c) until it seats, then back nut off 1/4 turn. 2. Assemble steering link rod to engine with special washer head bolt (“a” – Part Number 10-823919), locknut (“b” – Part Number 11-826709113) and spacer (“e” – 12-71970). First torque bolt (a) to 20 lb. ft. (27 Nm), then torque locknut (b) to 20 lb. ft. (27 Nm). 90-857046R1 NOVEMBER 2001 Page 1B-5 MAINTENANCE Page 1B-6 90-857046R1 NOVEMBER 2001 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. On the 3-1/4 in. (83 mm) diameter gear case the trim tab is also an anode. The 4-1/4 in. (108 mm) diameter (Bigfoot) gear case has three anodes. One of the anodes is the trim tab and two anodes (one on each side) are located on the side of the housing. b c a a - Bottom Anode b - Trim Tab c - Side Anodes (Big Foot Models Only) MANUAL START MODELS S/N OT426439 AND BELOW ELECTRIC START MODELS S/N OT427437 AND BELOW 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 screws to 70 lb-in. (8 Nm) torque. Reinstall the ignition coils. Tighten coil screws 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 and Replacement Inspect spark plugs at the recommended intervals. WARNING Avoid serious injury or death from fire or explosion caused by damaged spark plug boots. Damaged spark plug boots can emit sparks. Sparks can ignite fuel vapors under the engine cowl. To avoid damaging spark plug boots, do not use any sharp object or metal tool such as pliers, screwdriver, etc. to remove spark plug boots. 1. Remove the spark plug leads by twisting the rubber boots slightly and pulling off. 2. Remove the spark plugs to inspect and clean. Replace spark plug if electrode is worn or the insulator is rough, cracked, broken, blistered or fouled. IMPORTANT: Use resistive spark plugs only. 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 12.5 lb-ft (17 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. 90-857046R1 NOVEMBER 2001 Page 1B-7 MAINTENANCE Fuse Replacement – Electric Start Models IMPORTANT: Always carry spare 20 AMP Fuses. The electric starting circuit is protected from overload by a 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 amperage rating. 1. Disconnect fuse holder, and remove fuse. 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 amperage rating. b a a-Fuse Holder and 20 Amp. Fuse b-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 Page 1B-8 90-857046R1 NOVEMBER 2001 MAINTENANCE Lubrication Points Lubricate Point 1 with Anti-Corrosion Grease or 2-4-C Marine Lubricant with Teflon. 1. Propeller Shaft – Refer to Propeller Replacement for removal and installation of the propeller. Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft. 1 Lubricate Points 2 thru 6 with 2-4-C Marine Lubricant with Teflon or Special Lubricant 101. 2. Swivel Bracket – Lubricate through fitting. 3. Tilt Support Lever – Lubricate through fitting. 4. Tilt Tube – Lubricate through fitting. 4 2 3 90-857046R1 NOVEMBER 2001 Page 1B-9 MAINTENANCE WARNING The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant. Adding lubricant to steering cable when fully extended could cause steering cable to become hydraulically locked. A hydraulically locked steering cable will cause loss of steering control, possibly resulting in serious injury or death. 5. Steering Cable Grease Fitting (5) (If equipped) - Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube. Lubricate through fitting. Lubricate Pivot Points with light weight oil. 6. This grease fitting (6) is for lubricating the threaded rod for the co-pilot. a 5 6 b a-Steering Cable End b-Pivot Points Checking Power Trim Fluid 1. Tilt outboard to the full up position and engage the tilt support lock. a a-Tilt Support Lock 2. Remove fill cap and check fluid level. The fluid level should be even with the bottom of the fill hole. Add Power Trim & Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. a a-Fill Cap Page 1B-10 90-857046R1 NOVEMBER 2001 MAINTENANCE Fuel System WARNING Avoid serious injury or death from gasoline fire or explosion. Carefully follow all fuel system service instructions. Always stop the engine and DO NOT smoke or allow open flames or sparks in the area while servicing any part of the fuel system. Before servicing any part of the fuel system, stop engine and disconnect the battery. Drain the fuel system completely. Use an approved container to collect and store fuel. Wipe up any spillage immediately. Material used to contain spillage must be disposed of in an approved receptacle. Any fuel system service must be performed in a well ventilated area. Inspect any completed service work for signs of fuel leakage. Fuel Filter IMPORTANT: Visually inspect for fuel leakage from the filter by squeezing the primer bulb until firm, forcing fuel into the filter. Inspect the fuel line filter. If the filter appears to be contaminated, remove and replace. a a-Filter Fuel Line Inspection Visually inspect the fuel line and primer bulb for cracks, swelling, leaks, hardness, or other signs of deterioration or damage. If any of these conditions are found, the fuel line or primer bulb must be replaced. 90-857046R1 NOVEMBER 2001 Page 1B-11 MAINTENANCE Changing Engine Oil Oil Changing Procedure Pump Method 1. Place the outboard in an vertical upright position. 2. Remove dipstick and slide adaptor tube/pump down dipstick tube. Pump out the engine oil into an appropriate container. a 90265A5 a-Crankcase Oil Pump Drain Plug Method 1. Tilt the outboard up to the trailer position. 2. Turn the steering on the outboard so that the drain hole is facing downward. Remove drain plug and drain engine oil into an appropriate container. Lubricate the seal on the drain plug with oil and reinstall. a a-Drain Hole Page 1B-12 90-857046R1 NOVEMBER 2001 MAINTENANCE 90-857046R1 NOVEMBER 2001 Page 1B-13 Changing Oil Filter 1. Place a rag or towel below the oil filter to absorb any spilled oil. 2. Unscrew old filter by turning the filter counterclockwise. 3. Clean the mounting base. Apply film of clean oil to filter gasket. Do not use grease. Screw new filter on until gasket contacts base, then tighten 3/4 to 1 turn. 91-802653Q1 a a - Oil Filter Checking and Adding Engine Oil IMPORTANT: Do not overfill. Be sure that the outboard is upright (not tilted) when checking oil. 1. Remove the oil fill cap and add oil to to proper operating level. 2. Idle engine for five minutes and check for leaks. Stop engine and check oil level on dipstick. Oil must be between full mark and add mark. Add oil if necessary. a c d b a - Dipstick b - Oil Fill Cap c - Full Mark d - Add Mark Engine Oil Capacity 3 U.S. Quarts or (3.0 Liters) MAINTENANCE Changing Gear Case Lubricant 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. Examine the drained gear case lubricant for metal particles. A small amount of fine metal particles indicates normal gear wear. An excessive amount of metal filings or larger particles (chips) may indicate abnormal gear wear and should be checked by an authorized dealer. DRAINING GEAR CASE 1. Place outboard in a vertical operating position. 2. Place a drain pan below outboard. 3. Remove vent plugs and fill/drain plug. Drain lubricant. a b a-Fill/drain Plug b-Vent Plug CHECKING GEAR CASE LUBRICANT LEVEL AND REFILLING GEAR CASE Gear Case Lubricant Capacity 14.9 fl oz (440 ml) a b c d 1. Place outboard in a vertical operating position. Remove vent plug (a). 2. Place lubricant tube (b) into the fill hole and add lubricant until it appears at the vent hole (c). IMPORTANT: Replace sealing washers if damaged. 3. Stop adding lubricant. Install the vent plug and sealing washer (a) before removing the lubricant tube. 4. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer (d). Page 1B-14 90-857046R1 NOVEMBER 2001 MAINTENANCE 4-1/4 In. (108mm) Diameter Gear Case When adding or changing gear case lubricant, visually check for the presence of water in the lubricant. If water is present, it may have settled to the bottom and will drain out prior to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance. If water is noticed, have the gear case checked by your dealer. Water in the lubricant may result in premature bearing failure or, in freezing temperatures, will turn to ice and damage the gear case. Examine the drained gear case lubricant for metal particles. A small amount of fine metal particles indicates normal gear wear. An excessive amount of metal filings or larger particles (chips) may indicate abnormal gear wear and should be checked by an authorized dealer. DRAINING GEAR CASE 1. Place outboard in a vertical operating position. 2. Place a drain pan below outboard. 3. Remove vent plugs and fill/drain plug. Drain lubricant. a b c a-Fill/drain Plug b-Rear Vent Plug c-Front Vent Plug 90-857046R1 NOVEMBER 2001 Page 1B-15 MAINTENANCE CHECKING LUBRICANT LEVEL AND FILLING GEAR CASE Gear Case Lubricant Capacity 24 fl oz (710 ml) 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 Page 1B-16 90-857046R1 NOVEMBER 2001 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 used contains alcohol, it is advisable to drain as much of the remaining gasoline as possible from the fuel tank, remote fuel line, and engine fuel system. Fill the fuel tank and engine fuel system with treated (stabilized) fuel to help prevent formation of varnish and gum. Proceed with following instructions. 1. Portable Fuel Tank – Pour the required amount of Gasoline Stabilizer (follow instructions on container) into fuel tank. Tip fuel tank back and forth to mix stabilizer with the fuel. 2. Permanently Installed Fuel Tank – Pour the required amount of Gasoline Stabilizer (follow instructions on container) into a separate container and mix with approximately one quart (one liter) of gasoline. Pour this mixture into fuel tank. 3. Place the outboard in water or connect flushing attachment for circulating cooling water. Run the engine for 15 minutes to allow treated fuel to fill the engine fuel system. Protecting External Outboard Components 1. Lubricate all outboard components listed in the Inspection and Maintenance Schedule. 2. Touch up any paint nicks. 3. Spray Corrosion Guard on external metal surfaces (except corrosion control anodes). Protecting Internal Engine Components 1. Remove the spark plugs and inject a small amount of engine oil inside of each cylinder. 2. Rotate the flywheel manually several times to distribute the oil in the cylinders. Reinstall spark plugs. 3. Change the engine oil. Gear Case 1. Drain and refill the gear case lubricant (refer to maintenance procedure). 90-857046R1 NOVEMBER 2001 Page 1B-17 MAINTENANCE Positioning Outboard for Storage Store outboard in an upright (vertical) position to allow water to drain out of outboard. CAUTION If outboard is stored tilted up in freezing temperature, trapped cooling water, or rain water that 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. Page 1B-18 90-857046R1 NOVEMBER 2001 GENERAL INFORMATION IMPORTANT INFORMATION Section 1C - GENERAL INFORMATION Table of Contents 1 C Serial Number Location . . . . . . . . . . . . . . . . . . 1C-2 Conditions Affecting Performance . . . . . . . . . 1C-2 Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2 Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-5 Following Complete Submersion . . . . . . . . . . 1C-6 Submerged While Running . . . . . . . . . . . . . . 1C-6 Salt Water Submersion . . . . . . . . . . . . . . . 1C-6 Fresh Water Submersion . . . . . . . . . . . . . 1C-6 Model 30/40 (4-Stroke) Powerhead Views Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-7 Starboard View . . . . . . . . . . . . . . . . . . . . . . 1C-8 Port View . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-9 Top View . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-10 Aft View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-11 Propeller Selection . . . . . . . . . . . . . . . . . . . . . . 1C-12 Propeller Removal/Installation . . . . . . . . . . . . 1C-13 3-1/4 In. (83mm) Diameter Gear Case . . 1C-13 4-1/4 In. (108mm) Diameter Gear Case . 1C-14 Power Trim System . . . . . . . . . . . . . . . . . . . . . . 1C-15 General Information . . . . . . . . . . . . . . . . . . 1C-15 Power Trim Operation . . . . . . . . . . . . . . . . . 1C-15 Trim “In” Angle Adjustment . . . . . . . . . . . . 1C-16 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . 1C-17 Compression Check . . . . . . . . . . . . . . . . . . . . . 1C-18 Cylinder Leakage Testing . . . . . . . . . . . . . . . . . 1C-19 Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-19 Water Pressure Measurement . . . . . . . . . . . . 1C-20 Painting Procedures . . . . . . . . . . . . . . . . . . . . . 1C-21 Cleaning & Painting Aluminum Propellers & Gear Housings. . . . . . . . . . . 1C-21 Decal Removal/Application . . . . . . . . . . . . . . . 1C-22 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-22 Instructions for “Wet” Application . . . . . . . 1C-22 90-857046R1 NOVEMBER 2001 Page 1C-1 GENERAL INFORMATION 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 top side of the swivel bracket. 19XX OGXXXXXX XXXX XX a e d c b a-Serial Number b-Model Year c-Model Description d-Year Manufactured e-Certified Europe Insignia Conditions Affecting Performance Weather Rated hp Summer hp Horsepower Loss Due to Atmosphere Conditions Secondary Loss Due to Propeller Becoming To Large for Summer Horsepower RPM Drop Due to Weather ENGINE RPM Rated RPM It is a known fact that weather conditions exert a profound effect on power output of internal combustion engines. Therefore, established horsepower ratings refer to the power that the engine will produce at its rated rpm under a specific combination of weather conditions. Corporations internationally have settled on adoption of I.S.O. (International Standards Organization) engine test standards, as set forth in I.S.O. 3046 standardizing the computation of horsepower from data obtained on the dynamometer. All values are corrected to the power that the engine will produce at sea level, at 30% relative humidity, at a temperature of 77° F (25° C) and a barometric pressure of 29.61 inches of mercury. Page 1C-2 90-857046R1 NOVEMBER 2001 GENERAL INFORMATION 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. 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). and/or c. Adjusting tilt pin to achieve best performance and handling. (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). 90-857046R1 NOVEMBER 2001 Page 1C-3 GENERAL INFORMATION 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. CAVITATION Cavitation is caused by water vapor bubbles forming either from a sharp edge or angle on the gear case, from an irregularity in the propeller blade itself or from improper engine installation (too high). 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. Page 1C-4 90-857046R1 NOVEMBER 2001 GENERAL INFORMATION 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 bearings. A few of the most common causes of detonation in a marine 4-cycle application are as follows: • Over-advanced ignition timing. • Use of low octane gasoline. • Propeller pitch too high (engine rpm below recommended maximum range). • Lean fuel mixture at or near wide-open-throttle. • Spark plugs (heat range too hot - incorrect reach - cross-firing). • Inadequate engine cooling (deteriorated cooling system). • Combustion chamber/piston deposits (result in higher compression ratio). Detonation usually can be prevented if: 1. The engine is correctly set up. 2. Diligent maintenance is applied to combat the detonation causes. 51115 Damaged Piston Resulting from Detonation 90-857046R1 NOVEMBER 2001 Page 1C-5 GENERAL INFORMATION Following Complete Submersion Submerged While Running (Special Instructions) When an engine is submerged while running, the possibility of internal engine damage is greatly increased. If, after engine is recovered and with spark plugs removed, engine fails to turn over freely when turning flywheel, the possibility of internal damage (bent connecting rod and/or bent crankshaft) exists. If this is the case, the powerhead must be disassembled. Salt Water Submersion (Special Instructions) Due to the corrosive effect of salt water on internal engine components, complete disassembly is necessary before any attempt is made to start the engine. Fresh Water Submersion (Special Instructions) 1. Recover engine as quickly as possible. 2. Remove cowling. 3. Flush exterior of outboard with fresh water to remove mud, weeds, etc. DO NOT attempt to start engine if sand has entered powerhead, as powerhead will be severely damaged. Disassemble powerhead if necessary to clean components. 4. Remove spark plugs and get as much water as possible out of powerhead. Most water can be eliminated by placing engine in a horizontal position (with spark plug holes down) and rotating flywheel. 5. Change engine oil and filter as outlined in Section 1B - Changing Engine Oil. Run outboard for short time and check for presence of water in oil. If water is present (milky appearance) drain and refill as previously mentioned. 6. Pour alcohol into carburetor throats (alcohol will absorb water). Again rotate flywheel. 7. Turn engine over and pour alcohol into spark plug openings and rotate flywheel. 8. Turn engine over (place spark plug openings down) and pour engine oil into intake manifold plug holes (plugs removed) while rotating flywheel to distribute oil throughout crankcase. 9. Again turn engine over and pour approximately one teaspoon of engine oil into each spark plug opening. Again rotate flywheel to distribute oil in cylinders. 10. Remove and clean intake manifold assembly and fuel pump assembly. 11. Dry all wiring and electrical components using compressed air. 12. Disassemble the engine starter motor and dry the brush contacts, armature and other corrodible parts. 13. Reinstall spark plugs, intake manifold and fuel pump. 14. Attempt to start engine, using a fresh fuel source. If engine starts, it should be run for at least one hour to eliminate any water in engine. 15. If engine fails to start, determine cause (fuel, electrical or mechanical). Engine should be run within 2 hours after recovery of outboard from water, or serious internal damage may occur. If unable to start engine in this period, disassemble engine and clean all parts. Apply oil as soon as possible. Page 1C-6 90-857046R1 NOVEMBER 2001 GENERAL INFORMATION Model 30/40 (4-Stroke) Powerhead Front View a d g ij h e 59244 b c f a-Remote Control and Engine Harness Connection b-Fuse – 20 Amp. c-Negative Battery Cable d-DDT Test Port e-Fuel Connection f-Battery Cables g-Throttle and Shift Cables h-Remote Control Harness i-ECM j-Intake Manifold 90-857046R1 NOVEMBER 2001 Page 1C-7 GENERAL INFORMATION Page 1C-8 90-857046R1 NOVEMBER 2001 Model 30/40 (4-Stroke) Powerhead Starboard View c f a e 59245 b d g a - Lifting Eye b - Engine Harness Connection to Remote Control Harness c - Intake Manifold d - Shift Arm (Non Bigfoot) e - Shift Linkage f - Throttle Cam g - Throttle Lever GENERAL INFORMATION 90-857046R1 NOVEMBER 2001 Page 1C-9 Model 30/40 (4-Stroke) Powerhead Port View a j i h g 59247 c d e f b k a - Starter Motor b - Negative Battery Cable c - Access Port, Water Pressure/Temperature Sender Accessory d - Thermostat Housing e - Voltage Regulator f - Ignition Coils g - Oil Dip Stick h - Engine Coolant Temperature (ECT) Sender i - Oil Filter j - Oil Pressure Port k - Positive Battery Cable GENERAL INFORMATION Page 1C-10 90-857046R1 NOVEMBER 2001 Model 30/40 (4-Stroke) Powerhead Top View a b c d e f 59251 a - Cam Shaft Timing Gear b - Timing Belt c - Crank Position Sensor d - Flywheel e - Remote Control and Engine Harness Connection f - Enrichener Valve GENERAL INFORMATION 90-857046R1 NOVEMBER 2001 Page 1C-11 Model 30/40 (4-Stroke) Powerhead Aft View b d 59250 a c a - Valve Cover b - Crankcase Breather Hose c - Oil Fill Plug d - Fuel Pump (Water Cooled) GENERAL INFORMATION Propeller Selection For in-depth information on marine propellers and boat performance - written by marine engineers - see your Authorized Dealer for the illustrated “What You Should Know About Quicksilver Propellers and Boat Performance Information” (Part No. 90-86144). For best all around performance from your outboard/boat combination, select a propeller that allows the engine to operate in the upper half of the recommended full throttle rpm range with the boat normally loaded (refer to Specifications). This rpm range allows for better acceleration while maintaining maximum boat speed. If changing conditions cause the rpm to drop below the recommended range (such as warmer, more humid weather, operation at higher elevations, increased boat load or a dirty boat bottom/gear case) a propeller change or cleaning may be required to maintain performance and ensure the outboard’s durability. Check full-throttle rpm using an accurate tachometer with the engine trimmed out to a balanced- steering condition (steering effort equal in both directions) without causing the propeller to “break loose”. Refer to “Quicksilver Accessory Guide” for a complete list of available propellers. 1. Select a propeller that will allow the engine to operate at or near the top of the recommended full throttle rpm range (listed in “Specifications,” preceding) with a normal load. Maximum engine speed (rpm) for propeller selection exists when boat speed is maximum and trim is minimum for that speed. (High rpm, caused by an excessive trim angle, should not be used in determining correct propeller.) Normally, there is a 150-350 rpm change between propeller pitches. 2. If full throttle operation is below the recommended range, the propeller MUST BE changed to one with a lower pitch to prevent loss of performance and possible engine damage. 3. After initial propeller installation, the following common conditions may require that the propeller be changed to a lower pitch: a. Warmer weather and great humidity will cause an rpm loss. b. Operating in a higher elevation causes an rpm loss. c. Operating with a damaged propeller or a dirty boat bottom or gear housing will cause an rpm loss. d. Operation with an increased load (additional passengers, equipment, pulling skiers, etc.). Page 1C-12 90-857046R1 NOVEMBER 2001 GENERAL INFORMATION Propeller Removal/Installation 3-1/4 In. (83mm) Diameter Gear Case WARNING If the propeller shaft is rotated while the engine is in gear, there is the possibility that the engine will crank over and start. To prevent this type of accidental engine starting and possible serious injury caused from being struck by a rotating propeller, always shift outboard to neutral position and remove spark plug leads when you are servicing the propeller. 1. Shift outboard to neutral (N) position. 2. Remove the spark plug leads to prevent engine from starting. a 3. Straighten the bent tabs (a) on the propeller nut retainer. 4. Place a block of wood between gear case and propeller to hold propeller and remove propeller nut. Pull propeller straight off shaft. 5. Coat the propeller shaft with 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. a b c d Flo-Torque I Drive Hub Propellers 6. Flo-Torque I Drive Hub Propellers – Install forward thrust hub (a), propeller (b), propeller nut retainer (c) and propeller nut (d) onto the shaft. 7. 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 N·m), aligning flat sides of the propeller nut with tabs on the propeller nut retainer. 8. Secure propeller nut by bending tabs up and against the flats on the propeller nut. 9. Reinstall spark plug leads. 90-857046R1 NOVEMBER 2001 Page 1C-13 GENERAL INFORMATION 4-1/4 In. (108mm) Diameter Gear Case WARNING If the propeller shaft is rotated while the engine is in gear, there is the possibility that the engine will crank over and start. To prevent this type of accidental engine starting and possible serious injury caused from being struck by a rotating propeller, always shift outboard to neutral position and remove spark plug leads when you are servicing the propeller. 1. Shift outboard to neutral (N) position. 2. Remove the spark plug leads to prevent engine from starting. a 3. Straighten the bent tabs (a) on the propeller nut retainer. 4. Place a block of wood between gear case and propeller to hold propeller and remove propeller nut. Pull propeller straight off shaft. 5. Coat the propeller shaft with 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. a b ab c d e f c d e f Flo-Torque I Drive Hub Propellers Flo-Torque II Drive Hub Propellers 6. Flo-Torq I Drive Hub Propellers – Install thrust washer (a), propeller (b), continuity washer (c), thrust hub (d), propeller nut retainer (e), and propeller nut (f) onto the shaft. 7. Flo-Torq II Drive Hub Propellers – Install forward thrust hub (a), replaceable drive sleeve (b), propeller (c), thrust hub (d), propeller nut retainer (e) and propeller nut (f) onto the shaft. 8. Place a block of wood between gear case and propeller and torque propeller nut to 55 lb. ft. (75 N·m). 9. Secure propeller nut by bending three of the tabs into the thrust hub grooves. 10. Reinstall spark plug leads. Page 1C-14 90-857046R1 NOVEMBER 2001 GENERAL INFORMATION Power Trim System General Information The power trim system is filled at the manufacturer and is ready for use. Trim outboard through entire trim and tilt range several times to remove any air from the system. The trim system is pressurized and is not externally vented. Power Trim Operation With most boats, operating around the middle of the “trim” range will give satisfactory results. However, to take full advantage of the trimming capability there may be times when you choose to trim your outboard all the way in or out. Along with an improvement in some performance aspects comes a greater responsibility for the operator, and this is being aware of some potential control hazards. The most significant control hazard is a pull or “torque” that can be felt on the steering wheel or tiller handle. This steering torque results from the outboard being trimmed so that the propeller shaft is not parallel to the water surface. WARNING Avoid possible serious injury or death. When the outboard is trimmed in or out beyond a neutral steering condition, a pull on the steering wheel or tiller handle in either direction may result. Failure to keep a continuous firm grip on the steering wheel or tiller handle when this condition exists can result in loss of boat control as the outboard can turn freely. The boat can now “spin out” or go into a very tight maximum turn which, if unexpected, can result in occupants being thrown within the boat or out of the boat. Consider the following lists carefully: TRIMMING IN OR DOWN CAN: 1. Lower the bow. 2. Result in quicker planing off, especially with a heavy load or a stern heavy boat. 3. Generally improve the ride in choppy water. 4. Increase steering torque or pull to the right (with the normal right hand rotation propeller). 5. In excess, lower the bow of some boats to a point where they begin to plow with their bow in the water while on plane. This can result in an unexpected turn in either direction called “bow steering” or “over steering” if any turn is attempted or if a significant wave is encountered. WARNING Avoid possible serious injury or death. Adjust outboard to an intermediate trim position as soon as boat is on plane to avoid possible ejection due to boat spin-out. Do not attempt to turn boat when on plane if outboard is trimmed extremely in or down and there is a pull on the steering wheel or tiller handle. 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. 90-857046R1 NOVEMBER 2001 Page 1C-15 GENERAL INFORMATION 4. Increase steering torque or pull to the left at a normal installation height (with the normal right hand rotation propeller). 5. In excess, cause boat “porpoising” (bouncing) or propeller ventilation. 6. Cause engine overheating if any water intake holes are above the water line. Trim “In” Angle Adjustment Some outboard boats, particularly some bass boats, are built with a greater than normal transom angle which will allow the outboard to be trimmed further “in” or “under”. This greater trim “under” capability is desirable to improve acceleration, reduce the angle and time spent in a bow high boat during planing off, and in some cases, may be necessary to plane off a boat with aft live wells, given the variety of available propellers and height range of engine installations. However, once on plane, the engine should be trimmed to a more intermediate position to a avoid a bow-down planing condition called “plowing”. Plowing can cause “bow steering” or “over steering” and inefficiently consumes horsepower. In this condition, if attempting a turn or encountering a diagonal, moderate wake, a more abrupt turn than intended may result. In rare circumstances, the owner may decide to limit the trim in. This can be accomplished by repositioning the tilt stop pins into whatever adjustment holes in the transom brackets is desired. WARNING Avoid possible serious injury or death. Adjust outboard to an intermediate trim position as soon as boat is on plane to avoid possible ejection due to boat spin-out. Do not attempt to turn boat when on plane if outboard is trimmed extremely in or down and there is a pull on the steering wheel or tiller handle. If an adjustment is required, purchase a stainless steel tilt pin (P/N 17-49930A1) and insert it through whatever pin hole is desired. The non-stainless steel shipping bolt should not be used in this application other than on a temporary basis. a a-Optional Tilt Pin Page 1C-16 90-857046R1 NOVEMBER 2001 GENERAL INFORMATION Trim Tab Adjustment Propeller steering torque will cause your boat to pull in one direction. This steering torque is a normal thing that results from your outboard not being trimmed so the propeller shaft is parallel to the water surface. The trim tab can help to compensate for this steering torque in many cases and can be adjusted within limits to reduce any unequal steering effort. NOTE:Trim tab adjustment will have little effect reducing steering torque if the outboard is installed with the anti-ventilation plate approximately 2 inches (50mm) or more above the boat bottom. Operate your boat at normal cruising speed, trimmed to desired position. Turn your boat left and right and note the direction the boat turns more easily. If adjustment is necessary, loosen trim tab bolt and make small adjustments at a time. If the boat turns more easily to the left, move the trailing edge of trim tab to the left. If the boat turns more easily to the right move the trailing edge of trim tab to the right. Retighten bolt and retest. a a-Trim Tab 90-857046R1 NOVEMBER 2001 Page 1C-17 GENERAL INFORMATION Page 1C-18 90-857046R1 NOVEMBER 2001 Compression Check CAUTION Compression/Cylinder Leakage Tests Must be performed with the ignition/injection system disabled. To do this, the lanyard stop switch MUST BE placed to the “OFF” position. IMPORTANT: Compression check should be done with throttle in WOT position. 1. Check valve clearance (refer to “Valve Clearance Adjustment” in section 4A), adjust if out of specification. 2. Warm up the engine. Remove all spark plugs. 3. Lubricate threads in cylinder head and on compression gauge. Install compression gauge in spark plug hole. 110 4-Stroke Outboard Oil 110 a P/N EEPV303A / MT26-18 b a - Compression Gauge (EEPV303A - Snap-on) b - Adaptor (MT26-18 - Snap-on) 4. Hold throttle plate at W.O.T. and 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. Compression Pressure (Minimum) 135 psi (950 Kpa, 9.5 kg/cm2) Example of compression test differences: Maximum (psi) Minimum (psi) 180 162 150 127.5 6. Remove compression gauge. Install spark plugs. NOTE: Compression check is important because an engine with low or uneven compression cannot be tuned successfully to give peak performance. It is essential, therefore, that improper compression be corrected before proceeding with an engine tuneup. GENERAL INFORMATION Cylinder Leakage Testing CAUTION Compression/Cylinder Leakage Tests Must be performed with the ignition/injection system disabled. To do this, the lanyard stop switch MUST BE placed to the “OFF” position. 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 EEPV309A) 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 through the carburetor, 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 Cylinder Head Gasket 90-857046R1 NOVEMBER 2001 Page 1C-19 GENERAL INFORMATION Water Pressure Measurement 1. Warm up engine. 2. Remove plug. 3. Attach hose fitting and water pressure gauge to cylinder block. NOTE:Water pressure measurements should be done on a warm engine with thermostat operating 140°F (60°C). Pump Pressure (psi)91-79250A2 22-89772 a Water Pump Pressure 24 22 20 18 16 14 12 10 8 6 4 2 0 012345 rpm x 1000 a-Plug Page 1C-20 90-857046R1 NOVEMBER 2001 GENERAL INFORMATION Painting Procedures Cleaning & Painting Aluminum Propellers & Gear Housings WARNING Avoid serious injury from flying debris. Avoid serious injury from airborne particles. Use eye and breathing protection with proper ventilation. PROPELLERS 1. Sand the entire area to be painted with 3M 120 Regalite Polycut or coarse Scotch-Brite, disc or belts. 2. Feather edges of all broken paint edges. Try not to sand through the primer. 3. Clean the surface to be painted using PPG Industries DX330 Wax and Grease Remover or equivalent (Xylene or M.E.K.). 4. If bare metal has been exposed, use Mercury/Quicksilver Light Gray Primer. 5. Allow a minimum of 1 hour dry time and no more than 1 week before applying the finish coat. 6. Apply the finish coat using Mercury/Quicksilver EDP Propeller Black. GEAR HOUSINGS The following procedures should be used in refinishing gear housings. This procedure will provide the most durable paint system available in the field. The materials recommended are of high quality and approximate marine requirements. The following procedure will provide a repaint job that compares with a properly applied factory paint finish. It is recommended that the listed materials be purchased from a local Ditzler Automotive Finish Supply Outlet. The minimum package quantity of each material shown following is sufficient to refinish several gear housings. Procedure: 1. Wash gear housing with a muriatic acid base cleaner to remove any type of marine growth, and rinse with water, if necessary. 2. Wash gear housing with soap and water, then rinse. 3. Sand blistered area with 3M 180 grit sandpaper or P180 Gold Film Disc to remove paint blisters only. Feather edge all broken paint edges. 4. Clean gear housing thoroughly with (DX-330) wax and grease remover. 5. Spot repair surfaces where bare metal is exposed with (DX-503) alodine treatment. IMPORTANT: Do not use any type of aerosol spray paints as the paint will not properly adhere to the surface nor will the coating be sufficiently thick to resist future paint blistering. 6. Mix epoxy chromate primer (DP-40) with equal part catalyst (DP-401) per manufacturers instructions, allowing proper induction period for permeation of the epoxy primer and catalyst. 7. Allow a minimum of one hour drying time and no more than one week before top coating assemblies. 8. Use Ditzler Urethane DU9000 for Mercury Black, DU34334 for Mariner Grey, and DU35466 for Force Charcoal, and DU33414M for Sea Ray White. Catalyze all four colors with Ditzler DU5 catalyst mixed 1:1 ratio. Reduce with solvents per Ditzler label. 90-857046R1 NOVEMBER 2001 Page 1C-21 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 Removal/Application 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.** * 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 sunlight. Air and surface temperature should be between 60°F (15°C) and 100°F (38°C) for best application. SURFACE PREPARATION IMPORTANT: Do not use a soap or any petroleum based solvents to clean application surface. Clean entire application surface with mild dish washing liquid and water. Rinse surface thoroughly with clean water. Page 1C-22 90-857046R1 NOVEMBER 2001 GENERAL INFORMATION DECAL APPLICATION 1. Mix 1/2 ounce (16 ml) of dish washing liquid in one gallon (4 l) of cool water to use as wetting solution. NOTE:Leave protective masking, if present, on the face of decal until final steps of decal installation. This will ensure that the vinyl decal keeps it’s shape during installation. 2. Place the decal face down on a clean work surface and remove the paper backing from “adhesive side” of decal. 3. Using a spray bottle, flood the entire “adhesive side” of the decal with the pre-mixed wetting solution. 4. Flood area where the decal will be positioned with wetting solution. 5. Position pre-wetted decal on wetted surface and slide into position. 6. Starting at the center of the decal, “lightly” squeegee out the air bubbles and wetting solution with overlapping strokes to the outer edge of the decal. Continue going over the decal surface until all wrinkles are gone and adhesive bonds to the cowl surface. 7. Wipe decal surface with soft paper towel or cloth. 8. Wait 10 - 15 minutes. 9. Starting at one corner, “carefully and slowly” pull the masking off the decal surface at a 180° angle. NOTE: To remove any remaining bubbles, pierce the decal at one end of the bubble with stick pin and press out the entrapped air or wetting solution with your thumb (moving toward the puncture). 90-857046R1 NOVEMBER 2001 Page 1C-23 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 Shift and Throttle Cable Installation . . . . . . . . 1D-9 Selecting Accessories For The Outboard . . . 1D-2 Trim-In Stop Adjustment Power Trim Models 1D-13 Installation Specifications . . . . . . . . . . . . . . . . . 1D-2 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . 1D-13 Lifting Outboard . . . . . . . . . . . . . . . . . . . . . . . . . 1D-3 Instrument/Lanyard Stop SwitchSteering Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-3 Wiring Diagram (Dual Outboard) . . . . . . . . . 1D-14 Steering Cable Seal . . . . . . . . . . . . . . . . . . . . . 1D-4 Steering Link Rod . . . . . . . . . . . . . . . . . . . . . . . 1D-4 Installing Outboard Thumb Screw Models . . . . . . . . . . . . . . . . . 1D-5 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. 90-857046R1 NOVEMBER 2001 Page 1D-1 OUTBOARD MOTOR INSTALLATION Start in Gear Protection The remote control connected to the outboard must be equipped with a start-in-gear protection device. This prevents the engine from starting in gear. WARNING Avoid serious injury or death from a sudden unexpected acceleration when starting your engine. The design of this outboard requires that the remote control used with it must have a built in start-in-gear protection device. Selecting Accessories For The Outboard Genuine Quicksilver Parts and Accessories have been specifically designed and tested for this outboard. Some accessories not manufactured or sold by Quicksilver are not designed to be safely used with this outboard or outboard operating system. Acquire and read the Installation, Operation, and Maintenance manuals for all selected accessories. Installation Specifications a b a 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 90-857046R1 NOVEMBER 2001 OUTBOARD MOTOR INSTALLATION 90-857046R1 NOVEMBER 2001 Page 1D-3 Lifting Outboard Use lifting eye on engine. Steering Cable STARBOARD SIDE ROUTED CABLE 1. Lubricate the entire cable end. 95 95 2-4-C with Teflon 2. Insert steering cable into tilt tube. 3. Torque nut to 35 lb. ft. (47.5 Nm). 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 (10-823919) Torque to 20 lb. ft. (27.1 N·m) b-Nylon Insert Locknut (11-826709113) Torque to 20 lb. ft. (27.1 N·m) c-Spacer (12-71970) d-Flat Washer (2) e-Nylon Insert Locknut (11-826709113) Tighten Locknut Until it Seats, Then Back Nut Off 1/4 Turn f-Use Middle Hole – Steer Outboard to the Side to Gain Hole Access IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special bolt (“a” - Part Number 10-823919) and self locking nuts (“b” & “e” - Part Number 11-826709113). These locknuts must never be replaced with common nuts (non locking) as they will work loose and vibrate off, freeing the link rod to disengage. WARNING Disengagement of a steering link rod can result in the boat taking a full, sudden, sharp turn. This potentially violent action can cause occupants to be thrown overboard exposing them to serious injury or death. Page 1D-4 90-857046R1 NOVEMBER 2001 OUTBOARD MOTOR INSTALLATION 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 - 25mm) a a-Anti-Ventilation Plate 2. Fasten outboard with provided mounting hardware shown. ab c d e a-1/2 in. Diameter Bolts (2) d-Marine Sealer - Apply to Shanks of b-Flat Washers Bolts, Not Threads c-Locknuts e-Thumb Screws - Tighten Securely 90-857046R1 NOVEMBER 2001 Page 1D-5 OUTBOARD MOTOR INSTALLATION Installing Outboard – Non Thumb Screw Models 1. Attach (tape) engine mounting template to boat transom. 2. Mark and drill four 17/32 in. (13.5mm) mounting holes. 3. Install the outboard so that the anti-ventilation plate is in-line or within 1 in. (25 mm) below the bottom of the boat. 0 - 1 in. (0 - 25mm) a a-Anti-Ventilation Plate 4. Fasten outboard with provided mounting hardware shown. a b d c b a d c a-1/2 in. Diameter Bolts (2) b-Flat Washers c-Locknuts d-Marine Sealer - Apply to Shanks of Bolts, Not Threads Page 1D-6 90-857046R1 NOVEMBER 2001 OUTBOARD MOTOR INSTALLATION 90-857046R1 NOVEMBER 2001 Page 1D-7 Wiring Harness IMPORTANT: Warning Horn Requirement – The remote control or key switch assembly must be wired with a warning horn. This warning horn is used with the engine warning system. 1. Route wiring harness into bottom cowl. a a - Wiring Harness 2. Connect wiring. Push the wiring harness connectors together inside the rubber sleeve. Push the retainer over the exposed ends of the connectors. This will hold the connectors together. BLU/WHT GRN/WHT BRN/WHT BLU/WHT GRN/WHT TAN c b a a- Power Trim Connections b- Rubber Sleeve – Place Harness Connectors Inside c- Retainer – Push Over Connector Ends OUTBOARD MOTOR INSTALLATION Page 1D-8 90-857046R1 NOVEMBER 2001 Battery Cable Connections SINGLE OUTBOARD (+) (–) a b c a- Red Sleeve (Positive) b- Black Sleeve (Negative) c- Starting Battery DUAL OUTBOARDS Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. (–) (–) d d- Ground Cable (Same Wire Size As Engine Battery Cable) - Connect Between Negative (–) Terminals OUTBOARD MOTOR INSTALLATION Shift and Throttle 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. Shift Cable Installation 1. Position remote control into neutral. N 2. Shift outboard into neutral. 3. Measure the distance (a) between pin and center of lower hole. a b c a-Distance Between Pin And Center of Lower Hole b-Pin c-Lower Hole 4. Fit shift cable through rubber grommet. 90-857046R1 NOVEMBER 2001 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 (b) to attain the measured distance (a) taken in Step 3. a b a-Adjust Cable Barrel To Attain The Measured Distance Taken In Step 3 b-Cable Barrel 7. Place cable barrel into the barrel holder. Fasten cable with retainer. 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 90-857046R1 NOVEMBER 2001 OUTBOARD MOTOR INSTALLATION 90-857046R1 NOVEMBER 2001 Page 1D-11 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. Place throttle cable onto the throttle lever pin. Lock in place with retainer. a b a - Throttle Cable b - Retainer OUTBOARD MOTOR INSTALLATION Page 1D-12 90-857046R1 NOVEMBER 2001 5. Adjust cable barrel until the center of the roller lines up with the alignment mark on the cam. a b c a - Cable Barrel b - Alignment Mark c - Roller 6. Fasten control cables with the cable latch. OUTBOARD MOTOR INSTALLATION 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. aa 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 (50mm) or more above the boat bottom. 90-857046R1 NOVEMBER 2001 Page 1D-13 OUTBOARD MOTOR INSTALLATION 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 1D-14 90-857046R1 NOVEMBER 2001 OUTBOARD MOTOR INSTALLATION 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 90-857046R1 NOVEMBER 2001 Page 1D-15 IGNITION ELECTRICAL Section 2A - Ignition Table of Contents 2 A Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2 Component Resistance Tests . . . . . . . . . . . . . 2A-18 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-3 Spark Plug Cap Removal . . . . . . . . . . . . . . 2A-19 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-6 Spark Plug Cap Resistor Test-P/N VDFP 2A-20 Electrical Components . . . . . . . . . . . . . . . . . . . 2A-8 Spark Plug Cap Resistor Test Ignition Description . . . . . . . . . . . . . . . . . . . . . . 2A-10 P/N VDO5FP . . . . . . . . . . . . . . . . . . . . . . . . 2A-20 Ignition Component Description . . . . . . . . . . . 2A-10 Engine Coolant Temperature Electronic Control Module (ECM) . . . . . . . 2A-10 (ECT) Sensor . . . . . . . . . . . . . . . . . . . . . . . . 2A-21 Crank Position Sensor . . . . . . . . . . . . . . . . 2A-11 Flywheel Removal/Installation . . . . . . . . . . . . . 2A-22 Stator Assembly . . . . . . . . . . . . . . . . . . . . . . 2A-11 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-22 Flywheel Assembly . . . . . . . . . . . . . . . . . . . 2A-12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-24 Ignition Coils . . . . . . . . . . . . . . . . . . . . . . . . . 2A-12 Stator Removal/Installation . . . . . . . . . . . . . . . 2A-25 Ignition Test Procedures . . . . . . . . . . . . . . . . . . 2A-12 Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-26 Direct Voltage Adapter (DVA) . . . . . . . . . . 2A-12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-26 Ignition Troubleshooting . . . . . . . . . . . . . . . . . . 2A-13 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-27 Ignition Diagnostic Procedures . . . . . . . . . . . . 2A-14 ECM Removal/Installation . . . . . . . . . . . . . . . . 2A-28 Recommended Test . . . . . . . . . . . . . . . . . . 2A-15 Ignition Coil Removal/Installation . . . . . . . . . . 2A-29 Troubleshooting with the Voltage Regulator Removal/Installation . . . . 2A-30 Digital Diagnostical Terminal . . . . . . . . . . . . . . 2A-17 Crank Position Sensor Removal/Installation 2A-31 Using the Digital Diagnostical Engine Coolant Temperature Terminal (DDT) . . . . . . . . . . . . . . . . . . . . . . . 2A-17 (ECT) Sensor Removal/Installation . . . . . . . . 2A-32 90-857046R1 NOVEMBER 2001 Page 2A-1 IGNITION Specifications IGNITION SYSTEM Readings taken @ 68°F (20°C). Type Spark Plug: Type Gap Hex Size Torque Hole Size Firing Order Ignition Timing: @ Idle (800 rpm) @ WOT (6000 rpm) Charge Coil Resistance Crank Position Sensor Resistance Ignition Coil Resistance: Capacitor Discharge Ignition NGK DPR6EA-9 0.035 in. (0.9 mm) 18 mm 150 lb-in. (17 Nm) 12mm 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) Primary Secondary (W/o Boots) ECM Engine Speed Limiter Soft Reduction (Retards Timing) Spark Cut-Out Reduction (Percentages of ignition spark are Cut-Out) ECM Overheat/Low Oil Pressure Speed Control Engine Temperature Sensor 0.08 - 0.7 W (BLK - BLK/WHT) 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 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 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. DDT Reference Manual 90-881204--2 Page 2A-4 90-857046R1 NOVEMBER 2001 IGNITION 9. DDT Cable 10’ (3.05m) Extension 84-825003A1 10. DDT Test Harness 84-822560A7 11. DDT Test Harness 84-822560A10 90-857046R1 NOVEMBER 2001 Page 2A-5 IGNITION Page 2A-6 90-857046R1 NOVEMBER 2001 FLYWHEEL 110 4-Stroke Outboard Oil 110 1 2 4 5 6 7 8 9 10 11 12 14 51 Loctite 222 3 13 IGNITION FLYWHEEL REF 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 5.0 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 1111 3 SCREW (M5 x 25) (MANUAL) 85 9.5 3 SCREW (M5 x 30) (ELECTRIC) 85 9.5 12 1 STATOR (OG 960499 and Below) 13 1 STATOR (OG 960500 and Up) 14 1 LOAD RING 90-857046R1 NOVEMBER 2001 Page 2A-7 IGNITION Page 2A-8 90-857046R1 NOVEMBER 2001 ELECTRICAL COMPONENTS 34 9 6 6 6 9 35 30 29 10 5 36 11 24 23 22 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 40 9 Loctite Pipe Sealant With Teflon 1 42 43 6 Dielectric Grease 39 38 41 IGNITION ELECTRICAL COMPONENTS REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 SOLENOID ASSEMBLY BUSHING GROMMET NUT (8-32) (ELECTRIC) NUT (1/4-20) BATTERY CABLE (POSITIVE) INSULATOR BOOT CABLE BATTERY CABLE (NEGATIVE) STARTER MOTOR (See breakdown on Starter Motor) 2 2 3 2 4 2 25 3.0 5 3 60 7.0 6 1 7 1 8 1 9 1 10 1 1111 3 SCREW (M8 x 45) (ELECTRIC) 21.5 29.5 1 SCREW (M8 x 25) (MANUAL) 21.5 29.5 1212 2 SCREW (M6 x 30) (ELECTRIC) 75 8.5 1 SCREW (M6 x 16) (MANUAL) 75 8.5 13 1 J CLIP (ELECTRIC) 14 1 PRESSURE SWITCH 75 8.5 15 1 SENSOR-Crank Position 16 2 SCREW (M5 x 16) 45 5.0 17 3 SCREW (M6 x 25) 75 8.5 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 5.0 25 3 SPARK PLUG (NGK DPR6EA-9) 12.5 17 2626 1 DECAL-Coil Identification (1#) 1 DECAL-Coil Identification (2#) 1 DECAL-Coil Identification (3#) 27 3 IGNITION COIL 28 3 SCREW (M6 x 20) 75 8.5 2929 1 ENGINE WIRING HARNESS (MANUAL) 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 (S/N OG960499 and Below) VOLTAGE REGULATOR (S/N OG960500 and Up) J-CLIP SCREW (M6 x 40) ELECTRIC 38 1 39 1 40 4040 2 105 12.0 1 SCREW (MANUAL) 41 1 SCREW (M6 x 10) 42 1 PLUG 43 1 SCREW (M6 x 16) 90-857046R1 NOVEMBER 2001 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, therefore making this CDI unit virtually maintenance free. As the flywheel rotates, electrical power (alternating current) is produced by the capacitor charging coil. This power is rectified by diodes so that direct current voltage is utilized by the ignition system. When the ignition driver is off, the D.C. voltage is stored by the capacitor. Once capacitor voltage is charged to its potential, a gate signal is applied on the SCR and the residual current is dissipated through the capacitor charging coils. The electronic control module (ECM) activates the ignition driver in the ECM which allows the capacitor to discharge, causing the spark to occur. Ignition timing is regulated by the ECM which receives status input from a variety of sensors. These sensors include the crank position sensor, engine temperature and oil pressure sender. The voltage discharged to the primary winding of the ignition coil causes a surge of high voltage to be induced in the secondary winding of the ignition coil. This induced voltage of sufficient amplitude causes the spark plugs to fire. Ignition Component Description Electronic Control Module (ECM) Under normal operating conditions the ECM unit controls the following: 1. Controls ignition spark timing by monitoring the crank position sensor, the engine temperature sensor, and the oil pressure sensor. 2. Maintains normal idle timing (see specification). 3. Engine stall. a. The stall saver feature will advance the ignition timing to 15° BTDC if engine falls below 615 RPM. 4. Advances spark timing quickly to 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 90-857046R1 NOVEMBER 2001 IGNITION 90-857046R1 NOVEMBER 2001 Page 2A-11 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 a b a - S/N OG960499 and Below b - S/N OG960500 and Up The stator assembly located under the flywheel contains the Ignition, auto enrichener, and battery charge coils. All of these coils make up the stator assembly. As the flywheel permanent magnets pass the respective stator coil windings, an AC pulse current is produced at each coil winding when magnet polarity changes. (South to North), (North to South) etc. IGNITION Page 2A-12 90-857046R1 NOVEMBER 2001 Flywheel Assembly The flywheel assembly contains six permanently charged magnet segments which are bonded and retained to the inner wall of the flywheel. Each magnet contains a north and a south pole providing a 12 pole system. Ignition Coils a b a - S/N OG960499 and Below b - S/N OG960500 and Up 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 (p/n 91-89045). 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 or DMT 2000 Multi-Meter with Direct Voltage Adaptor (p/n 91-89045). 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 NOTE:If using DMT 2000 turn the selector switch to DC volts. Allow the meter to auto-range. (1) Readings may vary at cranking speed or at idle speed. (2) Back probe the electrical lead bullet connector in order to make connection. 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 IGNITION *Recommended Test (1) DVA TEST (Direct Voltage Adapter) (2) OHM TEST (Resistance Testing) (3) Replace Component and Retest (4) Mechanical Test/Repair 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 Timing Will Not Advance Low Oil Pressure/Engine Over Heating: a - timing retards and fluctuates, rpm will remain below 2000 rpm 4 (ECM) 3 90-857046R1 NOVEMBER 2001 Page 2A-15 IGNITION *Recommended Test (cont.) (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. 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 90-857046R1 NOVEMBER 2001 IGNITION Troubleshooting with the Digital Diagnostical Terminal The ECM is designed such that if a sensor fails the ECM will compensate so that the engine does not go into an over-rich condition. Because of this, disconnecting a sensor for troubleshooting purposes may have no noticeable effect. Using the Digital Diagnostical Terminal (DDT) IMPORTANT: Any sensor that is disconnected while the engine is running will be recorded as a fault in the ECM Fault History. Use the DDT to view and clear the fault history when troubleshooting/repair is completed. a b c d fe a-Digital Diagnostic Terminal (91-823686A2) b-Software Cartridge (91-822608--6) c-DDT Reference Manual (90-825159--3) d-DDT Cable 10ft. (3.05m) Extension (84-825003A1) e-DDT Test Harness (84-822560A7) f-DDT Test Harness (84-822560A10) The Quicksilver Digital Diagnostic Terminal (DDT) has been developed specifically to help technicians diagnose and repair Mercury Marine 2 and 4 cycle engines. Attach the diagnostic cable to the ECM diagnostic connector and plug in the software cartridge. You will be able to monitor sensors and ECM data values including status switches. The ECM program can help diagnose intermittent engine problems. It will record the state of the engine sensors and switches for a period of time and then can be played back to review the recorded information. Refer to the Digital Diagnostic Terminal Reference Manual for complete diagnostic procedures. 90-857046R1 NOVEMBER 2001 Page 2A-17 IGNITION Component Resistance Tests When performing resistance tests, all component leads must be disconnected. Readings may very slightly due to temperature changes. NOTE: Refertosection1C General Information(powerhead reference views) for location of sensors. NOTE:If using DMT 2000 turn the selector switch toW .. Allow the meter to auto-range. NOTE:Readings listed are taken at 68° F(20° C). STATOR (IGNITION CHARGE COIL) b a a-S/N OG960499 and Below b-S/N OG960500 and Up METER TEST LEADS METER SCALE READING () RED BLACK RX1RX1 660 710660 - 710GRN/WHT WHT/GRN STATOR AUTO ENRICHENER (POWER BOBBIN CHARGE COIL) b a a-S/N OG960499 and Below b-S/N OG960500 and Up METER TEST LEADS METER SCALE READING () RED BLACK RX1RX1 67 716.7 - 7.1YEL/BLK YEL/BLK Page 2A-18 90-857046R1 NOVEMBER 2001 IGNITION 90-857046R1 NOVEMBER 2001 Page 2A-19 IGNITION COIL (PRIMARY) a b a - S/N OG960499 and Below b - S/N OG960500 and Up METER TEST LEADS METER SCALE READING ( RED BLACK BLK/WHT BLACK RX1 0.18 - 0.24 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 counterclockwise while applying slight outward pressure. DO NOT PULL HARD or lead may be damaged. To install cap, turn cap clockwise threading cap onto high tension lead. IGNITION COIL (SECONDARY) a b a - S/N OG960499 and Below b - S/N OG960500 and Up METER TEST LEADS METER SCALE READING ( RED BLACK HIGH TENSION LEAD BLK RX1K 2.72 - 3.68 IGNITION Spark Plug Cap Resistor Test-P/N VDFP METER TEST LEADS METER SCALE READING () RED BLACK RX1K RX1KRX1K 0 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 -5.2WIRE END PLUG END CRANK POSITION SENSOR METER TEST LEADS METER SCALE READING () RED BLACK RX1RX1 300 350300 - -- 350RED WHT Page 2A-20 90-857046R1 NOVEMBER 2001 IGNITION Engine Coolant Temperature (ECT) Sensor 1. Place the engine coolant temperature sensor in a container filled with water. 2. Place a thermometer in the water and slowly heat the water. 3. Measure the resistance when the specified temperature is reached. If the reading is out of specification, replace the sensor. a 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 Resistance (k) Test Water Temperature(  F) Temperature Sensor 90-857046R1 NOVEMBER 2001 Page 2A-21 IGNITION Page 2A-22 90-857046R1 NOVEMBER 2001 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 b a - Screw (4) M6 x 25 b - Flywheel Cover IGNITION 90-857046R1 NOVEMBER 2001 Page 2A-23 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 Page 2A-24 90-857046R1 NOVEMBER 2001 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 (with 30mm socket) f - Flywheel Holder (91-83163M) Flywheel Nut Torque 116 lb. ft. (157 N·m) IGNITION 90-857046R1 NOVEMBER 2001 Page 2A-25 Stator Removal and Installation 1. Remove stator harness from j-clips (s/n OG960499 and below). 2. Remove cable tie from bundled wire connectors (s/n OG960499 and below). 3. Disconnect stator wires. 4. Remove stator mounting screws. 5. Reverse steps for installation (refer to wiring diagram Section 2D for correct stator wire connections). 51 51 Loctite “222” d b a e f c b a - Stator b - J-Clips c - Cable Tie d - Screws (3) M5 x 30 (Electric) or M5 x 25 (Manual) e - Voltage Regulator/Rectifier (s/n og960499 and below) f - Voltage Regulator/Rectifier (s/n og960500 and up) Stator Screw Torque 85 lb. in. (9.5 N·m) IGNITION Timing Belt Removal 1. Remove flywheel and stator as outlined previously in this section. 2. Remove timing belt from driven gear and drive gear. a a-Timing Belt Page 2A-26 90-857046R1 NOVEMBER 2001 IGNITION 90-857046R1 NOVEMBER 2001 Page 2A-27 Installation Timing Belt Installation Notes: • Protect the timing belt from water and oil. • Use care not to scratch the belt. • Do not use any metal device to help stretch the belt onto the driven gear. 1. Align marks on drive and driven gear with marks on cylinder block as shown. 2. Install timing belt onto drive gear as shown. Numbers/letters on belt should be readable once belt is installed. 3. Install stator and flywheel as outlined previously in this section. 1 a b c c d e a - Drive Gear Mark b - Driven Gear Mark c - Cylinder Block Marks d - Timing Belt Installed Correctly e - Timing Belt Installed Incorrectly IGNITION ECM Removal and Installation 1. Remove and install ECM as shown. a b a-Screw (3) M6 x 40 b-Harness Clip ECM Mounting Screw Torque 45 lb. in. (5 N·m) Page 2A-28 90-857046R1 NOVEMBER 2001 IGNITION 90-857046R1 NOVEMBER 2001 Page 2A-29 Ignition Coil Removal and Installation 1. Disconnect spark plug leads from spark plugs. 2. Remove bundled wires from J-clip. Cut cable tie securing wire connectors. Disconnect wires (BLK/WHT). These steps are required for s/n OG960499 and below. 3. Disconnect ignition coil harness connectors (s/n OG960500 and up). 4. Remove ignition coil mounting screws. 5. Reverse steps for installation. a a 59247 b c d e a - Spark Plug Leads b - Coil Mounting Screw (2) M6 x 20 c - J-Clip d - Cable Tie e - Harness Connectors (3) (S/N OG960500 and Up) Ignition Coil Mounting Screw Torque 75 lb. in. (8.5 N·m) IGNITION Page 2A-30 90-857046R1 NOVEMBER 2001 Voltage Regulator Removal and Installation 1. Remove bundled wire connectors from j-clip (s/n OG960499 and below). 2. Remove cable tie (s/n OG960499 and below). 3. Disconnect voltage regulator wires. 4. Remove mounting screws and ground wires. 5. Reverse steps for installation (refer to wiring diagram section 2D for correct wire connections). a b c d d e d f g 59247 a - Voltage Regulator (s/n OG960499 and below) b - J-Clip (s/n OG960499 and below) c - Cable Tie (s/n OG960499 and below) d - Screw (2) M6 x 40 e - Ground Wires (s/n OG960499 and below) f - Multi Pin Connectors (s/n OG960500 and up) g - Voltage Regulator (s/n OG960500 and up) Voltage Regulator Mounting Screw Torque 105 lb. in. (12 N·m) IGNITION 90-857046R1 NOVEMBER 2001 Page 2A-31 Crank Position Sensor Removal and Installation 1. Disconnect sensor from wiring harness. 2. Remove sensor mounting screws. 3. Reverse steps for installation. a b c a - Crank Position Sensor b - Harness Connector c - Screw (2) M5x16 Crank Position Sensor Mounting Screw Torque 45 lb. in. (5 N·m) IGNITION Engine Coolant Temperature (ECT) Sensor Removal/Installation 1. Disconnect sensor from wiring harness. 2. Remove sensor from exhaust cover. 3. Reverse steps for installation. Tighten to specified torque. CAUTION Over-tightening the engine coolant temperature sensor can lead to failing the plastic threads. Be sure to tighten to the specified torque. b 58225 a c a-Harness Connector b-Temperature Sensor c-Exhaust Cover Temperature Sensor Mounting Torque 15 lb. in. (1.5 N·m) Page 2A-32 90-857046R1 NOVEMBER 2001 CHARGING & STARTING SYSTEM ELECTRICAL Section 2B - Charging & Starting System Table of Contents 2 B 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) (S/N OG960499 and Below) . . . . . . . . . . . 2B-4 Wiring Diagram (15 Ampere) (S/N OG960500 and Up) . . . . . . . . . . . . . . 2B-5 Alternator System Test . . . . . . . . . . . . . . . . . . . 2B-6 6 Ampere Stator . . . . . . . . . . . . . . . . . . . . . . 2B-6 15 Ampere Stator . . . . . . . . . . . . . . . . . . . . 2B-7 Stator Ohms Test . . . . . . . . . . . . . . . . . . . . . . . . 2B-8 Specifications Rectifier/Regulator (P/N 854514) Diode Test 2B-9 Analog Meter . . . . . . . . . . . . . . . . . . . . . . . . 2B-9 Digital Meter . . . . . . . . . . . . . . . . . . . . . . . . . 2B-10 Starting System Components . . . . . . . . . . . . . 2B-11 Description . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-11 Troubleshooting the Starting Circuit . . . . . . . . 2B-11 Starter Solenoid Test . . . . . . . . . . . . . . . . . . 2B-12 Starting Circuit Troubleshooting Chart . . . 2B-13 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-15 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 2B-16 Cleaning and Inspection . . . . . . . . . . . . . . . 2B-18 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-19 Brush Replacement . . . . . . . . . . . . . . . . . . . 2B-21 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 2B-22 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-25 CHARGING SYSTEM Readings taken @ 68°F (20°C). Alternator Type: 20 Amp. Electric Alternator Output Stator Resistance Quicksilver Tachometer Setting Single Phase (12 Pole) 12.6 V-20 Amps. (252 Watts) (Rectified/Regulated) 0.20 - 0.30 Ohms (YEL-YEL) “6P” or “4” STARTING SYSTEM Electric Start: Starter Type Output Ampere Draw Under: (Load) (No Load) Bendix 1.1 kW 174.0 Amps 23.7 Amps Battery Rating Minimum Requirement 465 Marine Cranking Amps (MCA) or 350 Cold Cranking Amps (CCA) For operation below 32° F (0° C) 1000 Marine Cranking Amps (MCA) or BATTERY Ampere-Hours (Ah) Minimum 775 Cold Cranking Amps (CCA) For operation above 32° F (0° C) 70 For operation below 32° F (0° C) 105 90-857046R1 NOVEMBER 2001 Page 2B-1 CHARGING & STARTING SYSTEM STARTER MOTOR 1 2 3 5 6 4 7 8 9 10 11 8 REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in lb-ft Nm. 1 1 STARTER MOTOR 2 2 THRU BOLT 70 8.0 3 1 DRIVE KIT 4 1 ARMATURE 5 1 PINION 6 1 DRIVE CAP 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 90-857046R1 NOVEMBER 2001 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 or two wire (stator harness plug) from rectifier. Battery Charging System Troubleshooting CAUTION The charging system may be damaged by: 1) reversed battery cables, 2) running the engine with battery cables disconnected and stator leads connected to rectifier, 3) an open circuit, such as a broken wire or loose connection. A fault in the battery charging system usually will cause the battery to become undercharged. Check battery electrolyte level, and charge battery. If battery will NOT accept a satisfactory charge, replace battery. If battery accepts a satisfactory charge, determine the cause of the charging system problem as follows. 1. Check for correct battery polarity [RED cable to POSITIVE (+) battery terminal]. If polarity was incorrect, check for damaged regulator/rectifier. See “REGULATOR/RECTIFIER TEST”. 2. Check for loose or corroded battery connections. 3. Visually inspect wiring between stator and battery for cuts, chafing, and a 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. 90-857046R1 NOVEMBER 2001 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) (S/N OG960499 and Below) YEL_BLK YEL_BLK WHT_GRN GRN_WHT BLK GRY RED YEL YEL RED YEL YEL YELYELYEL_BLKYEL_BLKWHT_GRNGRN_WHT YEL_BLKYEL_BLKWHT_GRNGRN_WHT RED b c d f Blk = Black Blu = Blue Brn = Brown Gry = GrayGrn = Green Orn = OrangePnk = Pink Pur = PurpleRed = Red Tan = Tan Wht = White Yel = Yellow RED a BLK e a-Stator b-Voltage Regulator/Rectifier c-To Starter d-To Battery Positive (Red) Terminal e-Start Solenoid f-ECM Page 2B-4 90-857046R1 NOVEMBER 2001 CHARGING & STARTING SYSTEM Wiring Diagram (15 Ampere) (S/N OG960500 and Up) BLK = Black GRY = Gray RED = Red YEL = Yellow e c b a YELYEL YEL YEL GRY RED RED BLK BLK RED RED f d a-Stator b-Voltage Regulator/Rectifier c-Connector d-To Engine Ground e-To Battery Positive (Red) Terminal f-To Battery Negative (Black) Terminal 90-857046R1 NOVEMBER 2001 Page 2B-5 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. Page 2B-6 90-857046R1 NOVEMBER 2001 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 the battery. If battery can NOT be satisfactorily charged, replace battery. 4. If battery accepts a satisfactory charge, check battery voltage while cranking engine. A minimum of 10 volts should be maintained while cranking (at room temperature of 75°F/23°C). 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 voltage regulator wire and the BLACK (–) ammeter lead to the Red wiring harness 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. 90-857046R1 NOVEMBER 2001 Page 2B-7 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 Page 2B-8 90-857046R1 NOVEMBER 2001 CHARGING & STARTING SYSTEM Rectifier/Regulator (P/N 854514) Diode Test Analog Meter NOTE:Voltage regulator/rectifier specifications are given for informational purposes only, usethe appropriate troubleshooting techniques previously mentioned to find the faulty component in the charging system. Blk = Black Gry = Gray Red = Red Yel = Yellow YEL GRY YEL RED BLK YEL GRY YEL RED BLK b a a-S/N OG960499 and Below b-S/N OG960500 and Up DIODE TEST: 1. Set Ohm meter to R X 10 scale. 2. Connect Red (+) meter lead to RED regulator lead. 3. Connect Black (–) meter lead to either YELLOW regulator lead. TEST RESULTS: 100 - 400 OHMS DIODE TEST: 1. Set Ohm meter to R X 1k scale. 2. Connect Black (–) meter lead to RED regulator lead. 3. Connect Red (+) meter lead to YELLOW regulator lead. Test. Then change Red (+) meter lead to the other YELLOW regulator lead for 2ND test reading. TEST RESULTS (1ST READING): 20,000 to 8 OHMS TEST RESULTS (2ND READING): 8 OHMS (No needle movement) SCR TEST: 1. Set Ohm meter to R X 1k scale. 2. Connect Red (+) meter lead to regulator case. 3. Connect Black (–) meter lead to one YELLOW regulator lead. Test. Connect Black (–) meter lead to the other YELLOW lead. TEST RESULTS (BOTH TESTS): 8,000 - 15,000 OHMS (8k - 15K) 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) 90-857046R1 NOVEMBER 2001 Page 2B-9 CHARGING & STARTING SYSTEM Digital Meter NOTE:Voltage regulator/rectifier specifications are given for informational purposes only, usethe appropriate troubleshooting techniques previously mentioned to find the faulty component in the charging system. Blk = Black Gry = Gray Red = Red Yel = Yellow YEL GRY YEL RED BLK YEL GRY YEL RED BLK b a a-S/N OG960499 and Below b-S/N OG960500 and Up 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): 8 or OUCH or OL SCR TEST: 1. Set meter to . 2. Connect Black (–) meter lead to regulator case. 3. Connect Red (+) meter lead to either YELLOW regulator lead. TEST RESULTS (BOTH TESTS): 1.5 V -8 or OUCH or OL TACHOMETER CIRCUIT TEST: 1. Not measurable with digital meter. Page 2B-10 90-857046R1 NOVEMBER 2001 CHARGING & STARTING SYSTEM Starting System Components Description The function of the starting system is to crank the engine. The battery supplies electrical energy to crank the starter motor. When the ignition switch is turned to “START” position, the starter solenoid is activated and completes the starting circuit between the battery and starter. The neutral start switch opens the start circuit when the shift control lever is not in neutral. This prevents accidental starting when engine is in gear. The starting system consists of the following components. 1. Battery 2. Starter Solenoid 3. Neutral Safety Switch 4. Starter Motor 5. Ignition Switch CAUTION The starter motor may be damaged if operated continuously. DO NOT operate continuously for more than 30 seconds. Allow a 2 minute cooling period between starting attempts. 90-857046R1 NOVEMBER 2001 Page 2B-11 CHARGING & STARTING SYSTEM Troubleshooting the Starting Circuit Before beginning the starting circuit troubleshooting flow chart, following, check first for the following conditions: 1. Make sure that battery is fully charged. 2. Check that control lever is in “NEUTRAL” position. 3. Check terminals for corrosion and loose connections. 4. Check cables and wiring for frayed and worn insulation. 5. Check 20 Amp fuse. Starter Solenoid Test 1. Inspect starter solenoid for cracks, loose terminals or loose terminal lead connections. 2. Connect ohm meter between terminals of starter solenoid. 3. Connect the BLACK lead from solenoid to battery negative (–) terminal and momentarily connect the YELLOW/RED lead to the positive (+) terminal of battery. 4. Verify continuity between the starter solenoid terminals when 12 volts are applied. a b c d a-YELLOW/RED Lead b-Starter Solenoid c-BLACK Lead d-Battery Page 2B-12 90-857046R1 NOVEMBER 2001 CHARGING & STARTING SYSTEM Starting Circuit Troubleshooting Flow Chart The following “STARTING CIRCUIT TROUBLESHOOTING FLOW CHART” is designed as an aid to troubleshooting the starting circuit. This flow chart will accurately locate any existing malfunction. Location of “TEST POINTS” (called out in the chart) are numbered in diagram below. + NEUTRAL START SWITCH IGNITION SWITCH STARTER STARTER SOLENOID BATTERY FUSE HOLDER ASSEMBLY – BLK = Black BLU = Blue BRN = Brown GRY = GrayGRN = Green ORN = OrangePNK = Pink RED/PUR RED YEL/RED BLK BLK1 2 3 4 5 6 BLK (with YEL SLEEVES) BLK (with RED SLEEVES) BLKBLK BRN YEL/RED 71 RED/PUR YEL/REDBRN DIODE 15 PUR = PurpleRED = Red TAN = Tan WHT = White YEL = Yellow Starting Circuit Troubleshooting Flow Chart Starter Motor Does Not Turn SAFETY WARNING: Disconnect BLACK (with Yellow Sleeve) (starter motor) cable from starter solenoid test point 1 BEFORE making tests 1-thru-7 to prevent unex- pected 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 circuit. Continuity Indicated Proceed to TEST 2, on next page. 90-857046R1 NOVEMBER 2001 Page 2B-13 CHARGING & STARTING SYSTEM a. Disconnect BLACK ground wire(s) from Test Point 2. b. Connect voltmeter between common engine ground and Test Point 2. c. Turn ignition key to “Start” position. * Battery Voltage TEST 2 TEST 3 TEST 4 TEST 5 TEST 6 TEST 7 TEST 8 12 Volt Reading* 12 Volt Reading 12 Volt Reading* 12 Volt Reading* 12 Volt Reading* 12 Volt Reading* 12 Volt Reading* No voltage reading; proceed to TEST 3. No voltage reading; proceed to TEST 4. No voltage reading; proceed to TEST 5. No voltage reading; proceed to TEST 6. a. Reconnect BLACK ground wire(s). b. Connect voltmeter between common engine ground and Test Point 3. c. Turn ignition key to “Start” position. Check BLACK ground wire for poor connection or open circuit. Reconnect ground wire to start- er solenoid; proceed to TEST 7. Neutral start switch is open, or YELLOW/ RED or BLACK wire is open between Test Points 4 and 3. a. Connect voltmeter between common engine ground and Test Point 4. b. Turn ignition key to “Start” position. Defective starter solenoid. Connect voltmeter between common engine ground and Test Point 5. Defective ignition switch. Connect voltmeter between common engine ground and Test Point 6. No voltage reading; check BLACK wire be- tween battery (+) positive terminal and Test Point 6. Check fuse in RED wire between test points 5 and 6. Check for open RED wire between test points 5 and 6. a. Connect voltmeter between common engine ground and Test Point 1. b. Turn ignition key to “Start” position. No voltage reading; De- fective starter solenoid. Should hear solenoid click; proceed to TEST 8. a. Reconnect Black (with yellow sleeve) (starter motor) cable to starter sole- noid 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 Black (with yellow sleeve)cable for poor connection or open circuit. Check BLACK ground cable at starter for loose or corroded connection, or open circuit. If cable is O.K., check starter motor. Electric Start Tiller Handle Model Neutral start switch is open or BLACK leads are disconnected or damaged. Page 2B-14 90-857046R1 NOVEMBER 2001 CHARGING & STARTING SYSTEM 90-857046R1 NOVEMBER 2001 Page 2B-15 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 starter terminal. 2. Remove upper mounting screws and loosen bottom screw. Lift starter motor in an upward direction and remove. a a a b a - Starter Mounting Screw (3) M8 x 45 b - Starter Motor Lead CHARGING & STARTING SYSTEM Disassembly IMPORTANT: Before separating components mark them with an awl or marker. This will ensure proper orientation during reassembly. 1. Remove 2 through bolts and commutator end cap, taking care not to lose brush springs. a c c b d d a a-Thru Bolts b-Commutator End Cap c-Brush Springs d-I.D. Marks 2. Remove the nut, washer, spring, pinion stopper and pinion drive assembly. You may need to lightly clamp the armature in a vise while removing the nut. NOTE:DISPOSE OF NUT AFTER REMOVING IT. USE A NEW ONE FOR REASSEMBLY. 58223 d a b c e c a-Nut (Discard) b-Washer c-Pinion Stopper d-Spring e-Pinion Page 2B-16 90-857046R1 NOVEMBER 2001 CHARGING & STARTING SYSTEM 3. Pull armature from starter frame. a b d e g h c d f a-Nut b-Washer c-Spring d-Pinion Stopper (2) e-Pinion f-Drive End Cap g-Armature Shaft h-Washer 90-857046R1 NOVEMBER 2001 Page 2B-17 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 an open circuit is obvious and repairable. The most likely place for an open circuit is at the commutator bars. Long cranking periods overheat the starter motor so that solder in the connections melts. The poor connections cause arcing and burning of the commutator bars. 10. Repair bars, that are not too badly burned, by re-soldering the leads in bars (using rosin flux solder) and turning down the commutator in a lathe to remove burned material, then undercut the mica. 11. Clean out the copper or brush dust from slots between the commutator bars. 12. Check the armature for shorts and ground. See “TESTING”. Page 2B-18 90-857046R1 NOVEMBER 2001 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. 90-857046R1 NOVEMBER 2001 Page 2B-19 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-20 90-857046R1 NOVEMBER 2001 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) 90-857046R1 NOVEMBER 2001 Page 2B-21 CHARGING & STARTING SYSTEM Reassembly 1. Lubricate helix threads and drive end cap bushing with SAE 10W oil. 2. Install the pinion, pinion stopper, spring, second pinion stopper, washer, and NEW nut onto armature shaft. 3. Lightly clamp the armature in a vise and torque nut to specified torque. a b c f d e g h d a-Nut (New) b-Washer c-Spring d-Pinion Stopper (2) e-Pinion f-Drive End Cap g-Armature Shaft h-Washer Starter Shaft Nut Torque 22.5 lb.-ft. (30.5 Nm) Page 2B-22 90-857046R1 NOVEMBER 2001 CHARGING & STARTING SYSTEM 4. 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) 90-857046R1 NOVEMBER 2001 Page 2B-23 CHARGING & STARTING SYSTEM 5. Place springs and brushes into brush holder and hold in place with brush retainer tool. 6. Lubricate bushing with one drop of SAE 10W oil. DO NOT over-lubricate. a b a-Brush Retainer Tool b-Bushing 7. 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 as shown. 8. Install commutator end cap onto starter frame; align marks as shown, and remove brush retainer tool. 9. Install through bolts and tighten to specified torque. 70 lbs. in. (7.9 N·m). a b c d e a-Drive Cap I.D. Marks b-Drive Cap c-Commutator End Cap d-Commutator End Cap I.D. Marks e-Through Bolts (2) Fuel Pump Cover Screw Torque 30 lb. in. (3.5 N·m) Page 2B-24 90-857046R1 NOVEMBER 2001 CHARGING & STARTING SYSTEM 90-857046R1 NOVEMBER 2001 Page 2B-25 Installation 1. Secure starter to block with (3) mounting screws. Tighten screws to specified torque. Secure NEGATIVE battery lead and starter motor lead as shown. a a a b c a - Starter Mounting Screw (3) M8 x 45 b - Negative Battery Lead c - Starter Motor Lead Starter Motor Mounting Screw 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-6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-2 Idle Speed Adjustment . . . . . . . . . . . . . . . . . . . 2C-10 Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-4 Specifications IGNITION SYSTEM Readings taken @ 68°F (20°C). Type Spark Plug: Type Gap Hex Size Torque Hole Size Firing Order Ignition Timing: @ Idle (800 rpm) @ WOT (6000 rpm) Charge Coil Resistance Crank Position Sensor Resistance Ignition Coil Resistance: Capacitor Discharge Ignition NGK DPR6EA-9 0.035 in. (0.9 mm) 18 mm 150 lb-in. (17 Nm) 12mm 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) Primary Secondary (W/o Boots) ECM Engine Speed Limiter Soft Reduction (Retards Timing) Spark Cut-Out Reduction (Percentages of ignition spark are Cut-Out) ECM Overheat/Low Oil Pressure Speed Control Engine Temperature Sensor 0.08 - 0.7 W (BLK - BLK/WHT) 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. 90-857046R1 NOVEMBER 2001 Page 2C-1 TIMING, SYNCHRONIZING, & ADJUSTING Special Tools 1. New Style Vacuummate Carburetor Tuner P/N 91-809871-1 2. Old Style Mercury Filled Carburetor Tuner P/N 91-809641A1 with Filters P/N 35-18206 3. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1 4. Timing Light P/N 91-99379 Page 2C-2 90-857046R1 NOVEMBER 2001 TIMING, SYNCHRONIZING, & ADJUSTING 5. Digital Diagnostic Tester 91-823686A2 6. DDT Cartridge 91-822608-–5 and DDT Reference Manual 90-859769. 91-822608-–5 90-859769 7. DDT Cable 10’ (3.05m) Extension 84-825003A1 8. DDT Test Harness 84-822560A7 and 84-822560A10 84-822560A7 84-822560A10 9. Tubing Clamp P/N 91-804063 90-857046R1 NOVEMBER 2001 Page 2C-3 TIMING, SYNCHRONIZING, & ADJUSTING Page 2C-4 90-857046R1 NOVEMBER 2001 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” 1. Attach timing light to #1 spark plug lead. c d 59252 b a a - Timing Light Clamp b - #1 Spark Plug Lead c - Timing Window - Electric Start Models d - Timing Window - Manual Start Models TIMING, SYNCHRONIZING, & ADJUSTING 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 10° ATDC a-Timing Mark (Full Retarded) 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 28° BTDC a-Timing Mark (Full Advance) 90-857046R1 NOVEMBER 2001 Page 2C-5 TIMING, SYNCHRONIZING, & ADJUSTING Page 2C-6 90-857046R1 NOVEMBER 2001 Carburetor Synchronization NOTE: The carburetors are synchronized by adjusting the intake manifold vacuum on the carburetors. Use Carburetor Tuner (91-809641A1) or Vacuummate Tuner (p/n 91-809871-1) to measure the vacuum. INSTALLING CARBURETOR TUNER 1. Remove the 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 c a - Intake Manifold Plugs (3) b - Intake Manifold Hose Adaptor (3) c - Intake Manifold Hose Adaptor (3) From Mercury Filled Carb Tuner TIMING, SYNCHRONIZING, & ADJUSTING 90-857046R1 NOVEMBER 2001 Page 2C-7 3. Connect the Carburetor Tuner to the hose adaptors. 4. Pinch off enrichener lines between carburetors with a tubing clamp. CAUTION When using the old style mercury filled carb. tuner (p/n 91-809641A1) install filters (p/n 35-18206) in each line. This will prevent mercury from being drawn into carburetors during an abrupt throttle change. a a a 91-804063 b a a - Tubing Clamp (91-804063) b - Carburetor Tuner (P/N 91-809871-1) TIMING, SYNCHRONIZING, & ADJUSTING Page 2C-8 90-857046R1 NOVEMBER 2001 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 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 90-857046R1 NOVEMBER 2001 Page 2C-9 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. c a b a - Carburetor Synchronization Screw #1 b - Carburetor Synchronization Screw #2 c - Throttle Cam TIMING, SYNCHRONIZING, & ADJUSTING Page 2C-10 90-857046R1 NOVEMBER 2001 CAUTION When using the old style mercury filled carb. tuner (91-809641A1) install filters (3) in each line. This will prevent mercury from being drawn into carburetors during an abrupt throttle change. WARNING When revving the engine move the throttle cam to increase RPM. Do not use remote control or tiller handle twist throttle to increase RPM. If you do, the throttle linkage will contact the bottom intake manifold hose adaptor and damage the fitting. 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. 7. Stop engine, remove adaptors and reinstall plugs. Refer to Idle Speed Adjustment and adjust the idle RPM back to specification. 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 forward gear. 2. With the outboard in forward gear, 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 Without Light Switch . . . . . . . . . . . . . . . . . . 2D-11 30/40 EHPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-3 With Light Switch . . . . . . . . . . . . . . . . . . . . . 2D-11 30/40 MH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-4 Oil Pressure Wiring Diagram . . . . . . . . . . . . . . 2D-12 Commander 2000 Remote Control QSI Gauge Wiring Diagrams . . . . . . . . . . . . . . 2D-13 (Electric Start) . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-5 Tachometer Wiring Diagram . . . . . . . . . . . 2D-13 Commander 3000 Panel Mount Control . . . . 2D-6 Water Temperature Gauge . . . . . . . . . . . . 2D-14 Instrument/Lanyard Stop Switch Engine Synchronizer Wiring Diagram . . . 2D-15 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 2D-7 Remote Wiring Harness Connection Instrument/Lanyard Stop Switch to Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-18 Wiring Diagram (Dual Outboard) . . . . . . . . . . 2D-8 Electric Start Remote Control Model . . . . . 2D-18 Commander 2000 Key Switch Test . . . . . . . . 2D-10 Remote Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-19 Instrument Wiring Connections . . . . . . . . . . . . 2D-11 Power Trim Switch Wiring Diagram . . . . . . . . 2D-20 90-857046R1 NOVEMBER 2001 Page 2D-1 WIRING DIAGRAMS Page 2D-2 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 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 aa 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 aa - Neutral Start Switch WIRING DIAGRAMS Page 2D-4 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 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 Liquid Neoprene to connections and slide heat shrink tubing over each connection. c-Keyswitch Page 2D-6 90-857046R1 NOVEMBER 2001 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 a b j h i j k e 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 Liquid Neoprene to Connections and Slide Rubber Sleeve over Each Connection k-Lead to Optional Visual Warning Kit 90-857046R1 NOVEMBER 2001 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 PORT INSTALLATION 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 Page 2D-8 90-857046R1 NOVEMBER 2001 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 Liquid Neoprene to Connections and Slide Rubber Sleeve over Each Connection. o-Lead to Visual Warning Kit 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 WIRING DIAGRAMS Instrument Wiring Connections Without Light Switch NOTE: ANY INSTRUMENT WIRING HARNESS LEADS NOT USED MUST BE TAPED BACK TO 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 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 WIRING DIAGRAMS 90-857046R1 NOVEMBER 2001 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 through 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 90-857046R1 NOVEMBER 2001 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 8 YEL = Yellow LT = Light DRK = Dark 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 YEL/RED BLK/YEL YEL/BLK BLK_YELPPLYEL_BLKTANBLKYEL_REDRED e f d – + a b c PPL PPL BLK RED PPL TAN a-Keyswitch Assembly Transom Mount b-Keyswitch c-Horn d-Remote Key Harness Connector e-Engine Harness Connector f-Harness Connector Holder 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 FUEL PUMP FUEL SYSTEM Section 3A - Fuel Pump Table of Contents Table of Contents . . . . . . . . . . . . . . . . . . . . . . . 3A-1 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1 S/N OG960499 and Below . . . . . . . . . . . . . 3A-1 S/N OG960499 and Up . . . . . . . . . . . . . . . 3A-1 Fuel Pump (S/N OG960499 and Below) . . . . 3A-2 Fuel Pump (S/N OG960500 and Up) . . . . . . . 3A-4 Fuel Pump Operation . . . . . . . . . . . . . . . . . . . . 3A-6 S/N OG960499 and Below . . . . . . . . . . . . . 3A-6 S/N OG960500 and Up . . . . . . . . . . . . . . . 3A-6 Fuel Pump Removal . . . . . . . . . . . . . . . . . . . . . 3A-7 S/N OG960499 and Below . . . . . . . . . . . . . 3A-7 S/N OG960500 and Up . . . . . . . . . . . . . . . 3A-7 Specifications S/N OG960499 and Below S/N OG960499 and Up Fuel Pump Installation . . . . . . . . . . . . . . . . . . . 3A-8 S/N OG960499 and Below . . . . . . . . . . . . . 3A-8 S/N OG960500 and Up . . . . . . . . . . . . . . . 3A-9 Fuel Pump Disassembly . . . . . . . . . . . . . . . . . 3A-10 Cleaning/Inspection/Repair (All Serial Numbers) . . . . . . . . . . . . . . . . . . . . . 3A-11 Check Valve Inspection/Replacement (S/N OG960499 and Below) . . . . . . . . . . . 3A-11 Check Valve Inspection/Replacement (S/N OG960500 and Up) . . . . . . . . . . . . . . 3A-12 Fuel Pump Assembly . . . . . . . . . . . . . . . . . . . . 3A-13 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 FUEL SYSTEM Fuel Pump Type Fuel Pump: Pressure Fuel Tank Capacity Mechanical Water Cooled (Plunger/Diaphragm) 3-6 psi Accessory 90-857046R1 NOVEMBER 2001 Page 3A-1 FUEL PUMP FUEL PUMP (S/N OG960499 AND BELOW) 2 2 3 4 5 1 7 8 9 10 11 12 1314 15 16 17 18 19 20 21 22 2 2 2 2 11 10 12 23 Loctite 24266 66 66 6 Page 3A-2 90-857046R1 NOVEMBER 2001 FUEL PUMP FUEL PUMP REF 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 90-857046R1 NOVEMBER 2001 Page 3A-3 FUEL PUMP FUEL PUMP (S/N OG960500 AND UP) 66 66 66 Loctite 242 Page 3A-4 90-857046R1 NOVEMBER 2001 FUEL PUMP FUEL PUMP REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 FUEL PUMP 2 4 SCREW Drive Tight 3 1 DIAPHRAGM/O RING KIT 4 1 SPRING 5 4 NUT 6 1 SPRING 7 1 PLUNGER 8 1 COWL DEFLECTOR 9 2 SCREW (M6 x 30) 75 8.5 10 1 TUBING (13 IN.) 11 1 TUBING (6 IN.) 12 1 HOSE 13 1 J CLIP 14 1 TUBING (14 IN.) 15 1 FUEL FILTER 16 1 TUBING (19 IN.) 17 AR STA–STRAP 18 1 FUEL CONNECTOR -1 O-RING 90-857046R1 NOVEMBER 2001 Page 3A-5 FUEL PUMP Fuel Pump Operation S/N OG960499 and Below NOTE:S/N OG960499 and below can be updated with the new water cooled fuel pump. The fuel pump is a diaphragm pump which is mechanically driven off of the rocker arm. The pump base insulates the fuel pump from the heat of the engine block. If the engine runs out of fuel, or has a restriction (on the inlet side of the pump) 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. S/N OG960500 and Up The fuel pump is a diaphragm pump which is mechanically driven off of the rocker arm. The pump base insulates the fuel pump from the heat of the engine block. The fuel pump is water cooled to help prevent vapor lock by cooling the fuel. If the engine runs out of fuel, or has a restriction (on the inlet side of the pump) preventing adequate fuel flow, the pump will make a “clicking” noise. a b d c a-Fuel From Filter/Tank b-Fuel Outlet to Carburetors c-Water Inlet From Exhaust Cover d-Water Outlet to Tell-tale Page 3A-6 90-857046R1 NOVEMBER 2001 FUEL PUMP 90-857046R1 NOVEMBER 2001 Page 3A-7 Fuel Pump Removal S/N OG960499 and Below 1. Cut sta-straps and remove fuel pump inlet and outlet hoses. 2. Remove fuel pump mounting screws 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 Screw (2) M6 x 30 d - Cowl Deflector e - Cap On Unused Outlet Fitting S/N OG960500 and Up 1. Cut sta-straps, remove fuel pump inlet/outlet hoses, and fuel cooler water inlet/outlet hoses. 2. Remove fuel pump mounting screws and cowl deflector. 3. Separate fuel pump from cylinder head cover. g f d c a b e a - Inlet Fuel Hose b - Outlet Fuel Hose c - Fuel Cooler Water Inlet Hose d - Fuel Cooler Water Outlet Hose (to tell-tale outlet) e - Mounting Screw (2) M6 x 30 f - Cowl Deflector g - Fuel Pump FUEL PUMP Page 3A-8 90-857046R1 NOVEMBER 2001 Fuel Pump Installation S/N OG960499 and Below 1. Secure fuel pump and cowl deflector to cylinder head cover with screws. Tighten to specified torque. 2. Connect fuel lines to pump and secure with new sta-straps. d c e f g f f 66 Loctite 242 66 b a a - Outlet Fuel Hose b - Inlet Fuel Hose c - Cap on Unused Outlet d - Cowl Deflector e - J-Clip f - Mounting Screw (2) M6 x 30 g - Sta-strap (3) Fuel Pump Mounting Screw Torque 75 lb. in. (8.5 N·m) FUEL PUMP 90-857046R1 NOVEMBER 2001 Page 3A-9 S/N OG960500 and Up (Installation) 1. Secure fuel pump and cowl deflector to cylinder head cover with screws. Tighten to specified torque. 2. Connect fuel lines to pump and secure with new sta-straps. b h d 66 66 Loctite 242 a f g e c 59250 f a - Inlet Fuel Hose (from fuel filter) b - Outlet Fuel Hose (to carburetors) c - Fuel Cooler Water Inlet Hose (from exhaust cover) d - Fuel Cooler Water Outlet Hose (to tell-tale outlet) e - Mounting Screw (2) M6 x 30 f - Cowl Deflector g - Fuel Pump h - Sta-strap Fuel Pump Mounting Screw Torque 75 lb. in. (8.5 N·m) FUEL PUMP Fuel Pump Disassembly IMPORTANT: Before separating fuel pump components mark each component with an awl or marker. This will ensure the components are oriented correctly during reassembly. 1. Remove screws to separate pump cover, cover seal, diaphragm and valve body from pump base. 28378 c d b a e f g a-Screws (4) b-Pump Cover c-Cover Seal d-Diaphragm h e-Valve Body f-Pump Base g-Nuts (4) h-I.D. Marks (Create These) 2. Rotate plunger to line up slots. 53615 a b a-Slots Offset b-Slots Aligned 3. Compress pump assembly to free spring load on pin. 4. Tilt assembly to allow pin to slide out. 53617 a a-Pin Page 3A-10 90-857046R1 NOVEMBER 2001 FUEL PUMP Cleaning/Inspection/Repair (All Serial Numbers) 1. Inspect fuel filter for cracks/clogs, replace if necessary. 2. Inspect springs for damage, replace if necessary. 3. Inspect cover seal and diaphragm, replace if damaged. ab a-Cover Seal b-Diaphragm Check Valve Inspection/Replacement (S/N OG960499 and Below) 1. Inspect the check valves for damage, replace if necessary. a a-Check Valve 90-857046R1 NOVEMBER 2001 Page 3A-11 FUEL PUMP Check Valve Inspection/Replacement (S/N OG960500 and Up) 1. Inspect the check valves for damage, replace if necessary. REMOVAL 2. If replacement is needed remove old check valves by grabbing the seal and pulling. 58831 a a-Check Valve/Seal Assembly (2) INSTALLATION 1. Fabricate an installation tool to the dimensions specified. 2. Lubricate the end of the seal and push the assembly into the valve body. NOTE:Drill into the handle using a 5/64 in. (2mm) drill bit. Insert the peg into the drilled hole until 0.312 in. (8mm) remains exposed. 58831 .312 in. ±0.010 in. a c b (7.7 - 8.2mm) (9.5mm) a-Check Valve/Seal Assembly (2) b-Installation Tool (make yourself) c-Valve Body 58832 5/64 in. dia. 0.375 in. dia. (2mm) Page 3A-12 90-857046R1 NOVEMBER 2001 FUEL PUMP Fuel Pump Assembly 1. Assemble springs, diaphragm, and plunger onto pump base. a b c d e a-Diaphragm b-Diaphragm Spring c-Pump Body d-Spring e-Plunger 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. 53615 a b a-Slots Aligned b-Slots Offset 90-857046R1 NOVEMBER 2001 Page 3A-13 FUEL PUMP 5. Assemble valve body, diaphragm, seal, and cover to pump base. Be sure to line up I.D. marks that were made before disassembly. Apply Loctite 242 to screws and secure with nuts. NOTE:Seal installs in one direction only. 66 28378 c d b a e f g h 66 Loctite 242 a-Screws (4) M5 x 40 b-Pump Cover c-Cover Seal d-Diaphragm e-Valve Body f-Pump Base g-Nuts (4) h-I.D. Marks Fuel Pump Cover Screw Torque 30 lb. in. (3.5 N·m) 6. Inspect O-ring and replace if necessary. Install onto fuel pump assembly. 53620 a a-O-ring Page 3A-14 90-857046R1 NOVEMBER 2001 CARBURETOR FUEL SYSTEM Section 3B - Carburetor Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-1 Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-10 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-2 Idle Mixture Screw Adjustment . . . . . . . . . 3B-11 Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-4 Carburetor Removal . . . . . . . . . . . . . . . . . . . . . 3B-12 Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-6 Carburetor Disassembly . . . . . . . . . . . . . . . . . . 3B-13 Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-8 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-17 Carburetor Adjustments . . . . . . . . . . . . . . . . . . 3B-10 Carburetor Reassembly . . . . . . . . . . . . . . . . . . 3B-19 Float Level . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-10 Carburetor Installation . . . . . . . . . . . . . . . . . . . 3B-23 Specifications 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) 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 CARBURETOR Notes: 90-857046R1 NOVEMBER 2001 Page 3B-3 CARBURETOR Page 3B-4 90-857046R1 NOVEMBER 2001 FUEL LINES (S/N OG960499 and Below) 1 2 3 5 6 7 4 8 1 5 5 5 5 5 5 5 5 1 4 CARBURETOR FUEL LINES REF 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 90-857046R1 NOVEMBER 2001 Page 3B-5 CARBURETOR FUEL LINES (S/N OT178500 and Up) Page 3B-6 90-857046R1 NOVEMBER 2001 CARBURETOR FUEL LINES REF 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 & SLEEVE 8 2 CONNECTOR 9 1 FITTING (45 DEGREE) 10 1 HOSE 11 1 HOSE (3-1/2 IN.) 12 3 HOSE (90MM) 13 1 CLIP 14 1 STA-STRAP 15 3 WASHER 16 3 COTTER PIN 17 1 Y-CONNECTOR 90-857046R1 NOVEMBER 2001 Page 3B-7 CARBURETOR Page 3B-8 90-857046R1 NOVEMBER 2001 CARBURETOR (S/N OT178499 and Below) 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 REF 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 90-857046R1 NOVEMBER 2001 Page 3B-9 CARBURETOR CARBURETOR (S/N OT178500 and Up) Page 3B-10 90-857046R1 NOVEMBER 2001 CARBURETOR CARBURETOR REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in lb-ft Nm 1 1 CARBURETOR (TOP) 1 CARBURETOR (CENTER) 1 CARBURETOR (BOTTOM) 2 16 SCREW 3 3 PLATE 4 3 GASKET 5 1 ENRICHENER 6 1 O RING 7 1 PLATE 8 3 CAP 9 3 IDLE MIXTURE SCREW 10 3 O-RING 11 3 SPRING 12 3 JET (SLOW) 13 3 O-RING 14 3 PLUG 15 3 JET (MAIN) 16 3 MAIN NOZZLE 17 3 FLOAT VALVE 18 3 FLOAT 19 3 FLOAT PIN 20 3 SCREW 21 3 GASKET 22 2222 1 FLOAT BOWL (TOP) 2 FLOAT BOWL (CENTER/BOTTOM) 23 12 SCREW 24 3 DRAIN SCREW 25 3 WASHER 26 2 SYNCHRONIZATION SCREW (TOP/CENTER) 27 2 SPRING (TOP/CENTER) 28 2 SPRING (TOP/CENTER) 29 1 STOP SCREW (BOTTOM) 30 1 SPRING (BOTTOM) 31 1 SPRING 32 1 PLUNGER 33 3 PLUNGER RETAINING SCREW 34 3 RUBBER, BELLOWS 35 3 PLUNGER ROD 90-857046R1 NOVEMBER 2001 Page 3B-11 CARBURETOR Page 3B-12 90-857046R1 NOVEMBER 2001 INTAKE 1 2 3 4 5 6 12 13 14 7 8 9 10 11 15 16 10 12 12 CARBURETOR INTAKE REF 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 90-857046R1 NOVEMBER 2001 Page 3B-13 CARBURETOR Page 3B-14 90-857046R1 NOVEMBER 2001 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) Idle Speed NOTE: Outboard should be completely warmed up for the idle speed adjustment. NOTE: Turning the idle speed adjustment screw clockwise will increase idle speed. Turning the adjustment screw counterclockwise will decrease idle speed. 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 90-857046R1 NOVEMBER 2001 Page 3B-15 Idle Mixture Screw Adjustment NOTE: Access to idle mixture screws can only be made by removing the sealing plug. Drilling a small hole in the center of the plug and using an awl to pry out the plug must be done with extreme caution. The sealing plug is very thin and the idle mixture screw is located directly behind the plug. It is recommended that additional idle mixture screws be ordered for stock should the original mixture screw be damaged during drilling or the removal process. Idle mixture screw adjustment is strictly regulated by the Environmental Protection Agency. However, if the carburetor is overhauled, the EPA allows the adjustment of the mixture screws. Each idle mixture screw (1 per carburetor) is located behind a sealing plug. The sealing plug can be removed by carefully drilling a small hole in the center of the plug and prying the plug out with an awl. After mixture screws have been adjusted, a new sealing plug MUST BE installed over each mixture screw. 58474 58473 a b c 59245 a - Plug b - Idle Mixture Screw (behind plug) c - Install new plug and seat flush with casting after adjusting idle mixture screw Idle Mixture Screw – Turns Out 1-5/8 ± 1/2 CARBURETOR Page 3B-16 90-857046R1 NOVEMBER 2001 Carburetor Removal 1. Disconnect auto enrichener wires, breather hose, and fuel supply lines. b c a a - Auto Enrichener Wires (Yellow) b - Breather Hose c - Fuel Supply Line CARBURETOR 90-857046R1 NOVEMBER 2001 Page 3B-17 2. Remove intake and carburetor mounting screws. b a a a - Intake Mounting Screw (3)-M6x20 b - Carburetor Mounting Screw (6) Carburetor Disassembly Carburetors Not Equipped With Bowl Vent Hoses 1. Remove sound attenuator, 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 Page 3B-18 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 Page 3B-19 Carburetors Equipped With Bowl Vent Hoses 1. Remove sound attenuator and plate from carburetor assembly. a b c d a - Sound Attenuator b - Carburetor Assembly c - Plate d - Isolator 2. Remove auto enrichener. a b c d 59258 a - Auto Enrichener b - Plate c - Screw d - O-Ring CARBURETOR Page 3B-20 90-857046R1 NOVEMBER 2001 1. Remove fuel hoses and disconnect the throttle linkage. 59259 59260 b d e a c c c e d d d a - Linkage b - Fuel Lines c - Enrichener/Balance Hoses d - Bowl Vent Hoses e - Enrichener Vent Hose CARBURETOR 90-857046R1 NOVEMBER 2001 Page 3B-21 DISASSEMBLY CONTINUED (ALL MODELS) 2. Remove float bowl. 3. 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 4. Remove float, plug, nozzles and jets. NOTE: Earlier models are likely equipped with the old style float.. a b c e f g d h a - Screw b - Float Pin c - Old Style Float d - New Style Float e - Plug f - Slow Jet g - Main Jet h - Main Nozzle CARBURETOR 5. Remove cover and gasket. a b c d a-Screws (3) b-Cover c-Gasket d-Idle jet Page 3B-22 90-857046R1 NOVEMBER 2001 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. 90-857046R1 NOVEMBER 2001 Page 3B-23 CARBURETOR 6. Inspect float, replace if cracked or damaged. a b a-Old Style Float b-New Style Float 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 idle mixture screw (if equipped). Replace if bent or damaged. 53673 8. Inspect main jet, idle jet, slow jet and main nozzle. Clean if they are contaminated. 9. Inspect needle valve, replace if end is worn or grooved. 28375 Page 3B-24 90-857046R1 NOVEMBER 2001 CARBURETOR 90-857046R1 NOVEMBER 2001 Page 3B-25 Carburetor Reassembly 1. Install idle jet (if equipped), gasket, and cover. a b c d a - Screws (3) b - Cover c - Gasket d - Idle jet 2. Install jets, nozzles, plug and float. NOTE: Earlier models are likely equipped with the old style float.. a b c c b d e f g h i a - Screw b - Float Pin c - Old Style Float d - New Style Float e - Needle Valve f - Plug g - Slow Jet h - Main Jet i - Main Nozzle CARBURETOR 3. Install plunger and spring. 4. Install gasket bowl and float. a b c d e f a-Screws (4) d-Spring b-Float Bowl e-Gasket c-Plunger f-Retaining Screw Page 3B-26 90-857046R1 NOVEMBER 2001 CARBURETOR 90-857046R1 NOVEMBER 2001 Page 3B-27 Carburetors Not Equipped With Bowl Vent Hoses 5. Install fuel hoses and throttle linkage. Secure hoses with cable ties where shown. a b b b b b a - Linkage b - Fuel Hoses CARBURETOR Page 3B-28 90-857046R1 NOVEMBER 2001 Carburetors Equipped With Bowl Vent Hoses 1. Install hoses and throttle linkage. Secure hoses with cable ties where shown. 59259 59260 b d e a c c c e d d d a - Throttle Linkage b - Fuel Hoses c - Enrichener/Balance Hoses d - Bowl Vent Hoses e - Enrichener Vent Hose 2. Install auto enrichener. a b c d a - Auto Enrichener b - Plate c - Screw d - O-Ring CARBURETOR 90-857046R1 NOVEMBER 2001 Page 3B-29 3. Install air intake and plate onto 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 Page 3B-30 90-857046R1 NOVEMBER 2001 Carburetor Installation 1. Install intake and carburetor mounting screws. b a a a - Intake Mounting Screw (3)-M6 x 20 b - Carburetor Mounting Screw (6) Carburetor Mounting Screw Torque 70 lb. in. (8 N·m) CARBURETOR 90-857046R1 NOVEMBER 2001 Page 3B-31 2. Connect auto enrichener wires, breather hose, fuel supply hose, and bowl vent hoses. b c a d e a - Auto Enrichener Wires (Yellow) b - Breather Hose c - Fuel Supply Hose d - Bowl Vent Hose (if equipped) e - Through Hole in Adaptor Plate 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 Homogenized Charge . . . . . . . . . . . . . . . . . 3C-4 What Are Emissions? . . . . . . . . . . . . . . . . . 3C-2 Stratified Charge . . . . . . . . . . . . . . . . . . . . . 3C-5 Hydrocarbons – HC . . . . . . . . . . . . . . . . . . . 3C-2 Emissions Information . . . . . . . . . . . . . . . . . . . 3C-6 Carbon Monoxide – CO . . . . . . . . . . . . . . . 3C-2 Manufacturer’s Responsibility: . . . . . . . . . 3C-6 Oxides of Nitrogen - NOx . . . . . . . . . . . . . . 3C-2 Dealer Responsibility: . . . . . . . . . . . . . . . . . 3C-6 Controlling Emissions . . . . . . . . . . . . . . . . . 3C-2 Owner Responsibility: . . . . . . . . . . . . . . . . . 3C-6 Stoichiometric (14.7:1) Air/Fuel Ratio . . . 3C-3 EPA Emission Regulations: . . . . . . . . . . . . 3C-7 Outboard Hydrocarbon Decal Location for 1999 Models: . . . . . . . 3C-8 Emissions Reductions . . . . . . . . . . . . . . . . . . . 3C-3 Decal Location for 2000 and 8 1/3% O Per Year Over 9 Model Years . . 3C-3 Newer Models: . . . . . . . . . . . . . . . . . . . . . . . 3C-9 Stratified Vs Homogenized Charge . . . . . . . . 3C-4 Service Replacement Certification Label . . . 3C-10 3 C 90-857046R1 NOVEMBER 2001 Page 3C-1 EMISSIONS Exhaust Emissions Standards Through the Environmental Protection Agency (EPA), the federal government has established exhaust emissions standards for all new marine engines sold in the U.S. What Are Emissions? Emissions are what comes out of the exhaust system in the exhaust gas when the engine is running. They are formed as a result of the process of combustion or incomplete combustion. To understand exhaust gas emissions, remember that both air and fuel are made of several elements. Air contains oxygen and nitrogen among other elements; gasolene contains mainly hydrogen and carbon. These four elements combine chemically during combustion. If combustion were complete, the mixture of air and gasoline would result in these emissions: water, carbon dioxide and nitrogen, which are not harmful to the environment. But combustion is not usually complete. Also, potentially harmful gases can be formed during and after combustion. All marine engines must reduce the emission of certain pollutants, or potentially harmful gases, in the exhaust to conform with levels legislated by the EPA. Emissions standards become more stringent each year. Standards are set primarily with regard to three emissions: hydrocarbons (HC), carbon monoxide (CO) and oxides of nitrogen (NOx). Hydrocarbons – HC Gasoline is a hydrocarbon fuel. The two elements of hydrogen and carbon are burned during combustion in combination with oxygen. But they are not totally consumed. Some pass through the combustion chamber and exit the exhaust system as unburned gases known as hydrocarbons. Carbon Monoxide – CO Carbon is one of the elements that make up the fuel burned in the engine along with oxygen during the combustion process. If the carbon in the gasoline could combine with enough oxygen (one carbon atom with two oxygen atoms), it would come out of the engine in the form of carbon dioxide (CO2). CO2 is a harmless gas. But carbon often combines with insufficient oxygen (one carbon atom with one oxygen atom). This forms carbon monoxide, CO. Carbon monoxide is the product of incomplete combustion and is a dangerous, potentially lethal gas. Oxides of Nitrogen - NOx NOx is a slightly different byproduct of combustion. Nitrogen is one of the elements that makes up the air going into the engine. Under extremely high temperatures it combines with oxygen to form oxides of nitrogen (NOx). This happens in the engine’s combustion chambers when temperatures are too high. NOx itself is not harmful, but when exposed to sunlight it combines with unburned hydrocarbons to create the visible air pollutant known as smog. Smog is a serious problem in California as well as many other heavily populated areas of the United States. Controlling Emissions There are two principle methods of reducing emissions from a two-stroke-cycle marine engine. The first method is to control the air/fuel ratio that goes into the combustion chamber. The second is to control the time when this air/fuel mixture enters the combustion chamber. Timing is important, to prevent any unburned mixture from escaping out of the exhaust port. Page 3C-2 90-857046R1 NOVEMBER 2001 EMISSIONS Stoichiometric (14.7:1) Air/Fuel Ratio In the search to control pollutants and reduce exhaust emissions, engineers have discovered that they can be reduced effectively if a gasoline engine operates at an air/fuel ratio of 14.7:1. The technical term for this ideal ratio is stoichiometric. An air/fuel ratio of 14.7:1 provides the best control of all three elements in the exhaust under almost all conditions. The HC and CO content of the exhaust gas is influenced significantly by the air/fuel ratio. At an air/fuel ratio leaner than 14.7:1, HC and CO levels are low, but with a ratio richer than 14.7:1 they rise rapidly. It would seem that controlling HC and CO by themselves might not be such a difficult task; the air/fuel ratio only needs to be kept leaner than 14.7:1. However, there is also NOx to consider. As the air/fuel ratio becomes leaner, combustion temperatures increase. Higher combustion temperatures raise the NOx content of the exhaust. But, enrichening the air/fuel ratio to decrease combustion temperatures and reduce NOx also increases HC and CO, as well as lowering fuel economy. So the solution to controlling NOx - as well as HC and CO - is to keep the air/fuel ratio as close to 14.7:1 as possible. OUTBOARD HYDROCARBON EMISSIONS REDUCTIONS 8 1/3%  PER YEAR OVER 9 MODEL YEARS 120 100 80 60 40 20 0 96 97 98 99200001 02 03 04 05 06 07 08 90-857046R1 NOVEMBER 2001 Page 3C-3 EMISSIONS STRATIFIED VS HOMOGENIZED CHARGE DFI engines use a stratified charge inside the combustion chamber to aid in reducing emissions. All other models use a homogenized charge. The difference between the two is: Homogenized Charge A homogenized charge has the fuel/air particles mixed evenly throughout the cylinder. This mixing occurs inside the carburetor venturi, reed blocks and crankcase. Additional mixing occurs as the fuel is forced through the transfer system into the cylinder. The homogenized charge is easy to ignite as the air/fuel ratio is approximately 14.7:1. Page 3C-4 90-857046R1 NOVEMBER 2001 EMISSIONS Stratified Charge A stratified charge engine only pulls air through the transfer system. The fuel required for combustion is forced into the cylinder through an injector placed in the top of the cylinder (head). The injector sprays 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. 90-857046R1 NOVEMBER 2001 Page 3C-5 EMISSIONS Emissions Information Manufacturer’s Responsibility: Beginning with 1998 model year engines, manufacturers of all marine propulsion engines must determine the exhaust emission levels for each engine horsepower family and certify these engines with the United States Environmental Protection Agency (EPA). A certification decal/emissions control information label, showing emission levels and engine specifications directly related to emissions, must be placed on each engine at the time of manufacture. Dealer Responsibility: When performing service on all 1998 and later outboards that carry a certification, attention must be given to any adjustments that are made that affect emission levels. Adjustments must be kept within published factory specifications. Replacement or repair of any emission related component must be executed in a manner that maintains emission levels within the prescribed certification standards. Dealers are not to modify the engine in any manner that would alter the horsepower or allow emission levels to exceed their predetermined factory specifications. Exceptions include manufacturers prescribed changes, such as that for altitude adjustments. Owner Responsibility: The owner/operator is required to have engine maintenance performed to maintain emission levels within prescribed certification standards. The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications. 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 90-857046R1 NOVEMBER 2001 EMISSIONS EPA Emission Regulations: All new 1998 and later outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors. This certification is contingent on certain adjustments being set to factory standards. For this reason, the factory procedure for servicing the product must be strictly followed and, whenever practicable, 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 90-857046R1 NOVEMBER 2001 Page 3C-7 EMISSIONS 1999 MODEL YEAR 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). EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO 2001 CALIFORNIA AND U.S. EPA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES IDLE SPEED (IN GEAR): 800 ±25 RPM TIMING (IN DEGREES): NOT ADJUSTABLE Spark Plug: NGK DPR6EA-9 Gap: 0.9 mm (0.035,) Intake: 0.15 – 0.25 REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE. FAMILY: WM9XM.747220 FEL: 32.20 g/kW-hr 30 HP 747 cc JAN 1999 Cold Valve Clearance (mm) Exhaust: 0.25 – 0.35 c b d e f g h i a a-Family Example b-FEL: Represents (Mercury Marine) statement of the maximum emissions output for the engine family c-Timing specifications when adjustable d-Recommended spark plug for best engine performance e-Valve Clearance (Four Stroke engines only) f-Date of Manufacture g-Cubic Centimeter h-Engine Horsepower rating i-Idle Speed (In Gear) 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 Decal Location for 1999 Models: Model Production Part No. Service Part No. Location on Engine 1999 Merc/Mar 747 cc 37-856984 22 37-856985A22 Flywheel/Rewind Cover Page 3C-8 90-857046R1 NOVEMBER 2001 EMISSIONS 2000 MODEL YEAR AND NEWER 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). EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO 2001 CALIFORNIA AND U.S. EPA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES IDLE SPEED (IN GEAR): 800 ±25 RPM TIMING (IN DEGREES): NOT ADJUSTABLE Spark Plug: NGK DPR6EA-9 Gap: 0.9 mm (0.035,) Intake: 0.15 – 0.25 REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE. FAMILY: 2M9XM.7472G0 FEL: 32.20 g/kW-hr 30 HP 747 cc JAN 2000 Cold Valve Clearance (mm) Exhaust: 0.25 – 0.35 c b d e f g h i a j-Family Example k-FEL: Represents (Mercury Marine) statement of the maximum emissions output for the engine family l-Timing specifications when adjustable m-Recommended spark plug for best engine performance n-Valve Clearance (Four Stroke engines only) o-Date of Manufacture p-Cubic Centimeter q-Engine Horsepower rating r-Idle Speed (In Gear) 2 M9X M. 747 2 G 0 0=Unspecified Model Year Regulation 3=Ultra Clean California Rated Eng. Technology type 2=2002 M=Marine E=EFI Sport Jet 1=Existing H=Hi-Perf. 2=New Manufacturer J=Jet Drive 3=Jet Drive Mercury Marine Displacement Application Liter C=2 Stroke Cubic Inch G=4 Stroke Decal Location for 2000 and Newer Models: Model Production Part No. Service Part No. Location on Engine 2000 Merc/Mar 747 cc None 37-804654A00 Flywheel/Rewind Cover 2001 Merc/Mar 747 cc None 37-804654A01 Flywheel/Rewind Cover 2002 Merc/Mar 747 cc None 37-804654A02 Flywheel/Rewind Cover 90-857046R1 NOVEMBER 2001 Page 3C-9 EMISSIONS Service Replacement Certification Label IMPORTANT: By federal law, it is required that all 1998 and newer Mercury Marine outboards have a visible and legible emission certification label. If this label is missing or damaged, contact Mercury Marine Service for replacement if appropriate. Removal Remove all remaining pieces of the damaged or illegible label. Do not install new label over the old label. Use a suitable solvent to remove any traces of the old label adhesive from the display location. Date Code Identification Cut and remove a “V” notch through the month of engine manufacture before installing the new label. The month of manufacture can be found on the old label. If the label is missing or the date code illegible, contact Mercury Marine Technical Service for assistance. EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO 2001 CALIFORNIA AND U.S. EPA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES IDLE SPEED (IN GEAR): 800 ±25 RPM TIMING (IN DEGREES): NOT ADJUSTABLE Spark Plug: NGK DPR6EA-9 Gap: 0.9 mm (0.035,) Intake: 0.15 – 0.25 REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE. FAMILY: WM9XM.747220 FEL: 32.20 g/kW-hr 30 HP 747 cc Cold Valve Clearance (mm) Exhaust: 0.25 – 0.35 JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC a b a-“V” Notch b-Month of Manufacture Installation Install the label on a clean surface in the original factory location. Decal Location: Model Service Part No. Location on Engine 2002 Merc/Mar 747 cc 37-883927AO2 Flywheel/Rewind Cover Page 3C-10 90-857046R1 NOVEMBER 2001 CYLINDER HEAD POWERHEAD Section 4A - Cylinder Head Table of Contents Table of Contents . . . . . . . . . . . . . . . . . . . . . . . 4A-1 Valve Removal . . . . . . . . . . . . . . . . . . . . . . . 4A-26 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2 Rocker Shaft and Rocker Arm . . . . . . . . . . 4A-27 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-5 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . 4A-28 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-6 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-28 Camshaft/Oil Pump . . . . . . . . . . . . . . . . . . . . . . 4A-8 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . 4A-30 Intake/Exhaust Valves . . . . . . . . . . . . . . . . . . . 4A-10 Valve Guide inspection . . . . . . . . . . . . . . . . 4A-30 Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . 4A-12 Valve Guide Replacement . . . . . . . . . . . . . 4A-31 Valve Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-13 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-32 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-13 Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . 4A-33 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-15 Valve Seat Reconditioning . . . . . . . . . . . . . 4A-35 Valve Clearance Adjustment . . . . . . . . . . . . . . 4A-18 Valve Refacing Steps . . . . . . . . . . . . . . . . . 4A-36 Checking Valve Clearance . . . . . . . . . . . . . 4A-18 Cylinder Head Reassembly . . . . . . . . . . . . . . . 4A-37 Adjusting Valves . . . . . . . . . . . . . . . . . . . . . 4A-19 Valve Installation . . . . . . . . . . . . . . . . . . . . . 4A-37 Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-20 Camshaft Oil Seal Installation . . . . . . . . . . 4A-38 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-20 Camshaft Installation . . . . . . . . . . . . . . . . . 4A-39 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-21 Oil Pump Installation . . . . . . . . . . . . . . . . . . 4A-40 Cylinder Head Removal . . . . . . . . . . . . . . . . . . 4A-22 Rocker Arm Shaft Assembly . . . . . . . . . . . 4A-40 Cylinder Head Disassembly . . . . . . . . . . . . . . 4A-24 Rocker Arm Shaft Installation . . . . . . . . . . 4A-41 Rocker Arm Assembly Removal . . . . . . . . 4A-24 Cylinder Head Gasket . . . . . . . . . . . . . . . . . 4A-42 Oil Pump Removal . . . . . . . . . . . . . . . . . . . 4A-24 Cylinder Head Installation . . . . . . . . . . . . . . . . 4A-43 Camshaft Removal . . . . . . . . . . . . . . . . . . . 4A-25 4 A 90-857046R1 NOVEMBER 2001 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 bb b b 1.214 - 1.222 in. (30.83 - 31.03 mm) 1.214 - 1.222 in. (30.83 - 31.03 mm) 1.020 - 1.028 in. (25.90 - 26.10 mm) 1.020 - 1.028 in. (25.90 - 26.10 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 90-857046R1 NOVEMBER 2001 CYLINDER HEAD 90-857046R1 NOVEMBER 2001 Page 4A-3 CYLINDER HEAD Warp Limit * Lines indicate straight edge measurement Camshaft Bore Inside Diameter “a” 56900 56899 a a a a 0.004 in. (0.1 mm) 1.4567 - 1.4577 in. (37.000 - 37.025 mm) VALVES Valve/Valve Seat/Valve Guides: Valve Clearance (cold) Intake Exhaust Valve Dimensions: “A” Head Diameter Intake Exhaust “B” Face Width Intake Exhaust “C” Seat Width Intake Exhaust “D” Margin Thickness Intake Exhaust Stem Outside Diameter Intake Exhaust Guide Inside Diameter Intake Exhaust Stem To Guide Clearance Intake Exhaust Stem Run-out Limit (max.) 0.006 - 0.010 in. (0.15 - 0.25 mm) 0.010 - 0.014 in. (0.25 - 0.35 mm) 1.256 - 1.264 in. (31.9 - 32.1 mm) 1.020 - 1.028 in. (25.9 - 26.1 mm) 0.079 - 0.124 in. (2.00 - 3.14 mm) 0.079 - 0.124 in. (2.00 - 3.14 mm) 0.035 - 0.043 in. (0.9 - 1.1 mm) 0.035 - 0.043 in. (0.9 - 1.1 mm) 0.020 - 0.035 in. (0.5 - 0.9 mm) 0.020 - 0.035 in. (0.5 - 0.9 mm) 0.2156 - 0.2161 in. (5.475 - 5.490 mm) 0.2150 - 0.2156 in. (5.460 - 5.475 mm) 0.2165 - 0.2170 in. (5.500 - 5.512 mm) 0.2165 - 0.2170 in. (5.500 - 5.512 mm) 0.0004 - 0.0015 in. (0.010 - 0.037 mm) 0.0010 - 0.0020 in. (0.025 - 0.052 mm) 0.0006 in. (0.016 mm) CYLINDER HEAD “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 in. (16.000 - 16.018 mm) Page 4A-4 90-857046R1 NOVEMBER 2001 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). 90-857046R1 NOVEMBER 2001 Page 4A-5 CYLINDER HEAD CYLINDER HEAD 110 110 110 110 4-Stroke Outboard Oil Page 4A-6 90-857046R1 NOVEMBER 2001 CYLINDER HEAD CYLINDER HEAD REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m – 1 CYLINDER HEAD (ELECTRIC) 1 CYLINDER HEAD (MANUAL) 1 1 CYLINDER HEAD 2 6 GUIDE 3 3 SCREW M6 X 8 57 6.0 4 3 GASKET 5 1 OIL SEAL 6 5 PIPE PLUG 7 1 O RING 8 1 COVER 9 1 BREATHER PIPE 10 1 DECAL-Servicing Referral 11 1 DECAL-Engine Oil/Valve Clearance 12 8 SCREW (M9 x 1.5 x 95) 35.0 47 13 4 SCREW (M6 x 25) 106 12 14 1 GASKET 15 7 SCREW (M6 x 20) 70 8 16 1 BAFFLE PLATE 17 4 SCREW (M4 x 10) 18 1 ELBOW 19 1 BRACKET (HANDLE) 20 2 SCREW (M6 x 13) (HANDLE) 21 1 PLUG 22 1 O RING 2323 1 DECAL - HP ID (30) 1 DECAL - HP ID (40) 24 2 DOWEL PIN 90-857046R1 NOVEMBER 2001 Page 4A-7 CYLINDER HEAD Page 4A-8 90-857046R1 NOVEMBER 2001 CAMSHAFT/OIL PUMP 110 4-Stroke Outboard Oil 110 110 51 1 2 3 4 5 6 8 9 10 12 11 13 51 Loctite 222 7 CYLINDER HEAD CAMSHAFT/OIL PUMP REF 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 90-857046R1 NOVEMBER 2001 Page 4A-9 CYLINDER HEAD INTAKE/EXHAUST VALVES 110 110 110 110 110 4-Stroke Outboard Oil Page 4A-10 90-857046R1 NOVEMBER 2001 CYLINDER HEAD INTAKE/EXHAUST VALVES REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 3 EXHAUST VALVE 2 3 INTAKE VALVE 3 6 SEAL–Valve Stem 4 6 VALVE SPRING–Outer 5 6 RETAINER–Valve Spring 6 12 KEY 7 6 ROCKER ARM 8 6 SCREW 9 6 NUT 120 10 13.5 10 1 ROCKER SHAFT 11 2 PLUG 12 1 BRACKET 13 1 SPRING 14 1 BRACKET 15 1 SPRING 16 1 SEAL 17 1 PIN - CAM THRUST 18 4 SCREW (M8 x 23) 160 13.3 18 19 2 SPRING - Overload (If Equipped) 160 13.3 18 90-857046R1 NOVEMBER 2001 Page 4A-11 CYLINDER HEAD Page 4A-12 90-857046R1 NOVEMBER 2001 Torque Sequence 2 3 4 5 6 1 1 2 4 6 7 8 1 2 5 3 4 3 CYLINDER HEAD 90-857046R1 NOVEMBER 2001 Page 4A-13 Valve Cover NOTE: Valves should be adjusted when engine is cold. WARNING Engine could possibly start when turning flywheel during adjustment. To prevent this type of accidental engine starting and possible serious injury, always remove spark plug leads from spark plugs. Removal 1. Disconnect spark plug leads and remove spark plugs. 2. Remove flywheel cover/manual starter components (if equipped). 3. Remove lower cowl (if desired) for easier access to lower screws. NOTE: Refer to section 8 for removal of manual starter. a b a - Screw (4) M6 x 25 b - Flywheel Cover CYLINDER HEAD Page 4A-14 90-857046R1 NOVEMBER 2001 4. Disconnect the crankcase breather hose, vent hose, and fuel pump in/out hoses. 5. Disconnect fuel cooler in/out hoses (If equipped). IMPORTANT: The hose fittings on the fuel pump can break if you try twisting or pulling off the hoses. Remove fuel pump hoses by slowly prying them off using a small screwdriver. 6. Remove coils from valve cover. Refer to section 2A - Ignition Coil Removal. 7. Remove valve cover. 59250 c d f g h e b a a - Screw (7) M6 x 20 b - Valve Cover c - Crankcase Breather Hose d - Crankcase Vent Hose e - Fuel Pump Output Hose f - Fuel Pump Input Hose g - Fuel Cooler OUT Hose h - Fuel Cooler IN Hose CYLINDER HEAD Installation 1. Install valve cover seal into groove. 2. If removed, reinstall baffle plate. Tighten screws securely. a c b a-Baffle Plate b-Screw (4) M4 x 10 c-Cover Seal 90-857046R1 NOVEMBER 2001 Page 4A-15 CYLINDER HEAD Page 4A-16 90-857046R1 NOVEMBER 2001 3. Reinstall the valve cover. Tighten screws to the specified torque. 4. Install coils. Refer to section 2A - Ignition Coil Installation. 5. Install fuel pump. Refer to section 3C - Fuel Pump Installation. 6. Connect fuel pump in/out hoses, fuel cooler in/out hoses, crankcase breather and vent hose. Secure all with sta-straps. 7. Reinstall spark plugs and spark plug leads. 59250 c d f g h e b a a - Screw (7) M6 x 20 b - Valve Cover c - Crankcase Breather Hose d - Crankcase Vent Hose e - Fuel Pump Output Hose f - Fuel Pump Input Hose g - Fuel Cooler OUT Hose h - Fuel Cooler IN Hose Valve Cover Screw Torque 70 lb-in. (8 Nm) Coil Mounting Screw 75 lb-in. (8.5 Nm) CYLINDER HEAD 90-857046R1 NOVEMBER 2001 Page 4A-17 8. Install flywheel cover/manual starter components (if equipped). Tighten screws to specified torque. NOTE: Refer to section 8 for installation of manual starter. a b a - Flywheel Cover b - Screw (4) M6 x 25 Flywheel Cover Screw Torque 75 lb. in. (8.5 N·m) CYLINDER HEAD Page 4A-18 90-857046R1 NOVEMBER 2001 Valve Clearance Adjustment NOTE: Valve should be adjusted when the engine is cold. WARNING Engine could possibly start when turning flywheel during adjustment. To prevent this type of accidental engine starting and possible serious injury, always remove spark plug leads from spark plugs. Checking Valve Clearance 1. Remove valve cover as outlined in “Valve Cover Removal”. 2. Measure valve clearance with a feeler gauge. Adjust if out of specification. NOTE: When loosening lock nuts, hold the adjusting screw with a screw driver to prevent it from moving. 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 CYLINDER HEAD 90-857046R1 NOVEMBER 2001 Page 4A-19 Adjusting Valves 1. 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 1 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) 2. Tighten the lock nuts. NOTE: When tightening lock nuts, hold the adjusting screw with a screw driver to prevent it from moving. Valve Adjusting Lock Nut Torque 120 lb. in. (13.5 N·m) CYLINDER HEAD Timing Belt Removal 1. Remove flywheel and stator. Refer to section 2B Charging and Starting System. 2. Remove timing belt from driven gear and drive gear. a a-Timing Belt Page 4A-20 90-857046R1 NOVEMBER 2001 CYLINDER HEAD 90-857046R1 NOVEMBER 2001 Page 4A-21 Installation Timing Belt Installation Notes: • Protect the timing belt from water and oil. • Use care not to scratch the belt. • Do not use any metal device to help stretch the belt onto the driven gear. 1. Align marks on drive and driven gear with marks on cylinder block as shown. 2. Install timing belt onto drive gear as shown. Numbers/letters on belt should be readable once belt is installed. 3. Install stator and flywheel. Refer to section 2A - Ignition. 1 a b c c d e a - Drive Gear Mark b - Driven Gear Mark c - Cylinder Block Marks d - Timing Belt Installed Correctly e - Timing Belt Installed Incorrectly CYLINDER HEAD Page 4A-22 90-857046R1 NOVEMBER 2001 Cylinder Head 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. Remove valve cover. Refer to Valve Cover Removal. 2. Remove timing belt from driven gear. a b a - Timing Belt b - Driven Gear 3. Remove the throttle and shift levers from side of cylinder head. 4. Remove the cylinder head and intake manifold assembly mounting screws. a c b a - Center Screw (8) M9 x 95 b - Flange Screw (4) M6 x 25 c - Intake Manifold Screw (6) CYLINDER HEAD 90-857046R1 NOVEMBER 2001 Page 4A-23 5. Separate cylinder head from cylinder block. NOTE: Cylinder head gasket is not reusable. b a b a - Gasket (Discard) b - Dowel Pins (2) (Retain) CYLINDER HEAD Page 4A-24 90-857046R1 NOVEMBER 2001 Cylinder Head Disassembly Rocker Arm Assembly Removal 1. Remove screws securing rocker arm shaft to cylinder head. Remove rocker arm assembly and retainers. a a a a b a - Screws (4) M8 x 30 b - Rocker Arm Assembly Oil Pump Removal 1. Refer to section 4C - Oil Pump Removal. CYLINDER HEAD 90-857046R1 NOVEMBER 2001 Page 4A-25 Camshaft Removal 1. Hold driven gear using tool (91-83163M) and loosen screw. Remove screw, washer, driven gear and dowel pin. NOTE: The camshaft can be removed from the top without removing the cylinder head from the engine. 91-83163M a b c d e a - Holder 91-83163M b - Driven Gear c - Screw M8 x 40 d - Washer e - Dowel Pin 2. Remove camshaft retaining pin and seal. 3. Remove oil seal and camshaft. a b c a - Oil Seal b - Camshaft c - Camshaft Retaining Pin with Seal CYLINDER HEAD Page 4A-26 90-857046R1 NOVEMBER 2001 Valve Removal VALVE COMPONENTS a b c d e a - Valve b - Valve Seal c - Valve Spring d - Spring Retainer e - Valve Keepers REMOVING VALVES NOTE: Anytime a valve is removed, replace the valve seal. 1. Compress valve springs using tool (91-809494A1). Remove valve keepers and valves. a b 58256 91-809494A1 a - Valve Spring Compressor (P/N 91-809494A1) b - Valve Keepers CYLINDER HEAD Rocker Shaft and Rocker Arm 1. Measure rocker shaft diameter. Replace shaft if out of specification. Rocker Shaft Diameter 0.6288 - 0.6296 in. (15.971 -15.991 mm) 2. Measure rocker arm inside diameter. Replace rocker arms if out of specification. 55804 Rocker Arm Inside Diameter 0.6299 - 0.6306 in. (16.000 -16.018 mm) 90-857046R1 NOVEMBER 2001 Page 4A-27 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. b a a-Exhaust Valve Rocker Arm b-Decompression Lever 1. Inspect the camshaft for pitting, heat discoloration, or scratches, and for the following measurements. Replace camshaft if worn or not within specification. 2. Inspect the compression relief cam lever (if equipped) for free movement. Replace camshaft if necessary. a a-Compression Relief Cam Page 4A-28 90-857046R1 NOVEMBER 2001 CYLINDER HEAD 90-857046R1 NOVEMBER 2001 Page 4A-29 3. Measure the cam lobe length (a) and width (b). a b Cam Lobe Specifications a Intake 1.214 - 1.222 in. (30.83 - 31.03 mm) Exhaust 1.214 - 1.222 in. (30.83 - 31.03 mm) b Intake 1.020 - 1.028 in. (25.90 -26.10 mm) Exhaust 1.020 - 1.028 in. (25.90 -26.10 mm) 4. Measure the camshaft bore diameters (a) and camshaft bearing diameters (b). a b b b b Camshaft Bore Inside Diameter “a” 1.4567 - 1.4577 in. (37.000 - 37.025 mm) Camshaft Bearing Inside Diameter “b” 1.4541 - 1.4549 in. (36.935 - 36.955 mm) CYLINDER HEAD Page 4A-30 90-857046R1 NOVEMBER 2001 Cylinder Head 1. Inspect the cylinder head for the following conditions: • Mineral deposits/corrosion in water passage ways. • Carbon deposits in combustion chamber (use round scraper to clean away deposits). Be careful not to scratch or remove material. 2. Using a straight edge and a thickness gauge inspect cylinder head for warpage. Replace cylinder head if out of specification. Measure in locations illustrated. 56899 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 58257 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) 90-857046R1 NOVEMBER 2001 Page 4A-31 CYLINDER HEAD Valves 1. Clean the carbon deposits from the valve. Discard any cracked, warped, or burned valves. 2. Measure the valve stem diameter to check for wear. Replace valves if not within specification. a Valve Stem Diameter Intake Valve 0.2156 - 0.2161 in. (5.475 - 5.490 mm) Exhaust Valve 0.2150 - 0.2156 in. (5.460 - 5.475 mm) 3. Check the valve face for pitting. Valves faces that are pitted must be refaced. NOTE:Several different types of equipment are available for refacing valves. Follow the equipment manufacturer’s instructions. NOTE:After refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped. 4. Check the margin thickness (a) of the valves after the valves have been ground. Any valve with a margin thickness of less than the specification, should be replaced. 45 ° a Margin Thickness “a” Intake Valve 0.020 - 0.035 in. (0.5 - 0.9 mm) Exhaust Valve 0.020 - 0.035 in. (0.5 - 0.9 mm) Page 4A-32 90-857046R1 NOVEMBER 2001 CYLINDER HEAD 5. Measure valve stem runout, replace if out of specification. Valve Stem Runout Limit (Max.) Intake Valve Exhaust Valve 0.0006 in. (0.016 mm) Valve Springs 1. Check each spring under load on a spring tester. Replace any weak springs. 2. Check free length limit of each spring. Replace valve springs if not in specification. Valve Spring Free Length 1.491 - 1.569 in. (37.85 – 39.85 mm) 90-857046R1 NOVEMBER 2001 Page 4A-33 CYLINDER HEAD 3. Check each spring on a flat surface using a square. Rotate spring and check space between the top coil and square. Replace valve springs if not in specification. a Valve Spring Tilt Specification “a” Less than 0.06 in. (1.7 mm) Page 4A-34 90-857046R1 NOVEMBER 2001 CYLINDER HEAD Valve Seat Reconditioning Clean the carbon deposits from the combustion chambers and valve seats and check for pitting. Several different types of equipment are available for reseating valve seats. Follow the equipment manufacturer’s instructions. Measure valve seat width (a). Resurface the valve seat if not in specification. 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.0.035 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° 90-857046R1 NOVEMBER 2001 Page 4A-35 CYLINDER HEAD Valve Refacing Steps Condition: The valve seat is centered on valve face but it is too wide. Valve Seat Cutter Set Desired Results Use Li htlLightly 15° Cutter To reduce valve seat idthwidth60° Cutter Condition: The valve seat is in the middle of the valve face but it is too narrow. Valve Seat Cutter Set Desired Results Use 45° Cutter To achieve a uniform valve idthseat width Condition: Valve seat is too narrow and it is near valve margin. Valve Seat Cutter Set Desired Results Use 15° Cutter, First To center the seat and to hi it Widthachieve its Width45° Cutter Page 4A-36 90-857046R1 NOVEMBER 2001 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 Cylinder Head Reassembly Valve Installation INTAKE AND EXHAUST VALVE COMPONENTS a b c d e a-Valve b-Valve Seal c-Valve Spring d-Spring Retainer e-Valve Keepers 90-857046R1 NOVEMBER 2001 Page 4A-37 CYLINDER HEAD Page 4A-38 90-857046R1 NOVEMBER 2001 INSTALLING VALVES NOTE: Always use new valve seals. 1. Apply engine oil to the valves and valve seats. 2. Compress the valve spring and retainer and install the valve keepers around the valve stem. You may have to tap lightly on the end of the valve to seat the keepers. NOTE: Valve springs are symmetrical and may be installed in either direction. 91-809494A1 b a a - Valve Spring Compressor Tool (91-809494A1) b - Valve Keepers Camshaft Oil Seal Installation 1. If removed, install new oil seal. Position seal so part number side is facing outward. Press seal in until it makes contact with the inside flat surface. a 58261 a - Upper Camshaft Oil Seal CYLINDER HEAD 90-857046R1 NOVEMBER 2001 Page 4A-39 Camshaft Installation 1. Apply engine oil to the main journals (4 places) on the camshaft. 2. Slide camshaft into cylinder head (threaded end towards driven gear). NOTE: Camshaft retaining pin groove must align with retaining pin hole in cylinder head. 3. Install camshaft retaining pin. Install seal over pin. 4. Place driven gear on camshaft so alignment pin is in hole. Hold gear with tool (91-83163M) and fasten with washer and screw. Tighten screw to the specified torque. 5. Remove any oil from the camshaft lobes and apply Moly Grease to the lift portion of the lobes. Obtain Moly Grease from a local source. NOTE: Rotate camshaft after assembly to ensure it rotates smoothly. d f e c 58287 58278 91-83163M b 58477 a b a - Camshaft b - Camshaft Retaining Pin w/Seal c - Alignment Pin d - Driven Gear e - Washer f - Screw M10 x 40 Driven Gear Screw Torque 28 lb-ft (38 Nm) CYLINDER HEAD Oil Pump Installation 1. Refer to section 4C - Oil Pump Installation. 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. 53739 a b 110 4-Stroke Outboard Oil 110 c c c c a-Rocker Shaft b-Rocker Arm (6) c-Oil Holes (4) Page 4A-40 90-857046R1 NOVEMBER 2001 CYLINDER HEAD 90-857046R1 NOVEMBER 2001 Page 4A-41 Rocker Arm Shaft Installation 1. Install the rocker arm shaft assembly as shown. 2. Install rocker arm retainers on rocker shaft as shown. Tighten screws to the specified torque. NOTE: Leave all adjustment screws loose at this time. a 110 4-Stroke Outboard Oil 110 58987 b d c e f a - Mounting Screw (4)-M8 x 30 b - Rocker Arm Bracket (1) c - Rocker Arm Spring - Overload (2) Arrow Must Point Toward Driven Gear d - Rocker Arm Spring (1) e - Rocker Arm Bracket (1) f - Rocker Arm Spring (1) Arrow Must Point Toward Driven Gear Rocker Arm Shaft Mounting Screw Torque 160 lb. in. (18 N·m) CYLINDER HEAD Page 4A-42 90-857046R1 NOVEMBER 2001 Cylinder Head Gasket 1. Install new cylinder head gasket and dowel pins. a b b a - Gasket (New) b - Dowel Pin (2) CYLINDER HEAD 90-857046R1 NOVEMBER 2001 Page 4A-43 Cylinder Head Installation 1. Apply engine oil to the threads of each screw and seat surface. 2. Fasten cylinder head with screws shown. Do not tighten. a 110 4-Stroke Outboard Oil 110 b a - Screw (8) M9 x 95 b - Flange Screw (4) M6 x 25 CYLINDER HEAD Page 4A-44 90-857046R1 NOVEMBER 2001 3. Torque center screws (first) in sequence and in two steps. 4. Torque the cylinder head and carburetor intake manifold screws in sequence and in two steps. 5. Refer to “Timing Belt Installation” preceding, and install timing belt. 6. Refer to “Valve Clearance Adjustment” preceding, to perform valve clearance adjustments. 7. Refer to “Valve Cover Installation” preceding, and install valve cover. 2 3 4 5 6 1 1 2 3 4 5 6 7 8 1 2 3 4 b a c a - Center Screw (8) M9 x 95 b - Flange Screw (4) M6 x 25 c - Intake Manifold Screw (6) M6 x 25 Intake Manifold Screw Torque 70 lb. in. (8 N·m) Cylinder Head Screw Torque Center Screw (Qty. 8) 1st: 17 lb-ft (23 Nm) 2nd: 35 lb-ft (47 Nm) Cyl. Head Flange Screw (Qty. 4) 1st: 53 lb-in. (6 Nm) 2nd: 106 lb-in. (12 Nm) CYLINDER BLOCK/CRANKCASE POWERHEAD Section 4B - Cylinder Block/Crankcase Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-2 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-24 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-3 Oil Pressure Switch . . . . . . . . . . . . . . . . . . . 4B-24 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-4 Cylinder Block Reassembly . . . . . . . . . . . . . . . 4B-25 Cylinder Block And Crankcase . . . . . . . . . . . . 4B-6 Selecting New Main Bearings . . . . . . . . . . 4B-25 Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . 4B-8 Main Bearing Installation . . . . . . . . . . . . . . 4B-26 Powerhead Removal . . . . . . . . . . . . . . . . . . . . 4B-9 Selecting New Connecting Rod Bearings 4B-27 Removing Powerhead Components . . . . . . . 4B-12 Installing Connecting Rod Bearings . . . . . 4B-27 Cylinder Block Disassembly . . . . . . . . . . . . . . 4B-13 Connecting Rod Installation . . . . . . . . . . . . 4B-28 Crankcase and Crankshaft Removal . . . . 4B-14 Piston Ring Installation . . . . . . . . . . . . . . . . 4B-29 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-17 Piston Installation . . . . . . . . . . . . . . . . . . . . 4B-30 Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . 4B-17 Crankshaft Installation . . . . . . . . . . . . . . . . 4B-30 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-18 Crankcase Cover Installation . . . . . . . . . . . 4B-32 Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-19 Thermostat and Exhaust Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . 4B-19 Cover Installation . . . . . . . . . . . . . . . . . . . . . 4B-33 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-20 Drive Gear Installation . . . . . . . . . . . . . . . . 4B-34 Checking Main Bearing Clearance . . . . . . 4B-21 Installing Powerhead Components . . . . . . 4B-35 Checking Connecting Rod Powerhead Installation . . . . . . . . . . . . . . . . . . . 4B-36 Bearing Clearance . . . . . . . . . . . . . . . . . . . . 4B-23 Tiller Handle Models . . . . . . . . . . . . . . . . . . 4B-39 4 B 90-857046R1 NOVEMBER 2001 Page 4B-1 CYLINDER BLOCK/CRANKCASE Specifications CYLINDER BLOCK Type Displacement Number of Cylinders 4 Stroke Cycle – Over Head Camshaft 45.6 cu. in. (747 cc) 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) Page 4B-2 90-857046R1 NOVEMBER 2001 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. Powerhead Stand (P/N 91-855662A1) 5. Piston Ring Compressor (P/N FT2997) 6. Piston Ring Expander (P/N 91-24697) 90-857046R1 NOVEMBER 2001 Page 4B-3 CYLINDER BLOCK/CRANKCASE Page 4B-4 90-857046R1 NOVEMBER 2001 CRANKSHAFT 1 2 9 5 4 6 7 10 8 11 3 12 110 4-stroke Outboard Oil 110 110 110 110 110 110 110 12 CYLINDER BLOCK/CRANKCASE CRANKSHAFT REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in lb-ft Nm. 1 1 CRANKSHAFT 2 1 OIL SEAL 3 1 OIL SEAL 4 4 CONNECTING ROD 5 6 BOLT 150 12.5 17 6 6 BEARING (BROWN) 6 BEARING (BLACK) 6 BEARING (BLUE) 7 3 PISTON 8 3 PISTON RING (TOP) 9 3 PISTON RING (SECOND) 10 3 PISTON OIL RING 11 3 PISTON PIN 12 6 RETAINER 90-857046R1 NOVEMBER 2001 Page 4B-5 CYLINDER BLOCK/CRANKCASE CYLINDER BLOCK AND CRANKCASE 4 Stroke Oil110 12 Loctite Master Gasket Loctite PST Pipe Sealant9 A = TO FUEL PUMP COOLER B = TO FITTING IN ADAPTOR PLATE Page 4B-6 90-857046R1 NOVEMBER 2001 CYLINDER BLOCK/CRANKCASE CYLINDER BLOCK AND CRANKCASE REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in lb-ft Nm. 1 1 CYLINDER BLOCK 2 2 DOWEL PIN 3 3 PLUG 79 9 4 1 PIPE PLUG (1/2-14) 24 33 5 1 PIPE PLUG (3/4-14) 24 33 6 8 BEARING (BROWN) 8 BEARING (BLACK) 8 BEARING (BLUE) 7 1 NIPPLE 29.5 40 8 8 SCREW (M8 X 82) 22 30 9 8 SCREW (M6 X 35) 106 12 10 1 GASKET 11 1 OIL FILTER 70 8 12 1 GASKET 13 1 EXHAUST COVER 14 1 PIPE PLUG Drive Tight 15 1 THERMOSTAT 16 1 GASKET 17 1 COVER 18 10 SCREW (M6 X 35) 106 12 19 1 ELBOW Drive Tight 20 3 STA STRAP 21 1 TUBING (10 IN.) 22 1 ENGINE COOLANT TEMPERATURE (ECT) SENSOR 15 1.5 23 1 O RING 24 1 LIFTING EYE 25 1 SCREW (M8 X 35) 29 39.5 26 1 HOSE (19 IN.) 90-857046R1 NOVEMBER 2001 Page 4B-7 CYLINDER BLOCK/CRANKCASE Page 4B-8 90-857046R1 NOVEMBER 2001 Torque Sequence Exhaust Cover Crankcase Cover 1 2 4 3 5 6 8 7 9 10 12 11 13 14 16 15 6 10 2 1 3 4 5 8 9 7 Intake Manifold Powerhead 2 3 4 5 6 1 1 2 3 4 5 6 7 8 CYLINDER BLOCK/CRANKCASE 90-857046R1 NOVEMBER 2001 Page 4B-9 Powerhead Removal WARNING The possibility exists that the engine could start when turning the flywheel. To avoid possible serious injury, always disconnect the battery and remove spark plug leads from spark plugs before working on motor. 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 the bottom cowls. c a b a - Screw (6) M6 x 30 b - Lower Cowl c - Screw M6 x 60 4. Drain the engine oil. 5. Remove the control cable anchor bracket screws (remote control models). 6. Remove the throttle/shift lever screw and swing the entire shift linkage to the side. REMOTE CONTROL MODEL (BIGFOOT) 58254 b c a a - Control Cable Anchor Bracket Screw (2) M6 x 16 b - Throttle/Shift Lever c - Shift Lever Screw (1) M8 x 70 CYLINDER BLOCK/CRANKCASE 7. Push retainer up and slide over to disengage the vertical shift shaft. REMOTE CONTROL MODEL (NON - BIGFOOT) a 1 2 a-Retainer 8. Remove the shift guide bracket screws. TILLER HANDLE MODEL 58479 a b a-Shift Guide Bracket b-Screw (2) M6 x 25 Page 4B-10 90-857046R1 NOVEMBER 2001 CYLINDER BLOCK/CRANKCASE 90-857046R1 NOVEMBER 2001 Page 4B-11 9. Disconnect the crankcase vent hose. 10. Disconnect inlet hose from fuel pump. a b 59250 a - Crankcase Vent Hose b - Fuel Pump Inlet hose 11. Remove powerhead mounting bolts. 12. Lift powerhead from driveshaft housing. b a a - Powerhead Mounting Bolts (4 Each Side) M8 x 45 b - Hoist CYLINDER BLOCK/CRANKCASE Removing Powerhead Components 1. Place powerhead on bench. 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 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. Refer to Section 4A for cylinder head removal. Page 4B-12 90-857046R1 NOVEMBER 2001 CYLINDER BLOCK/CRANKCASE 90-857046R1 NOVEMBER 2001 Page 4B-13 Cylinder Block Disassembly 1. Remove the drive gear components. b a c a - Load Ring (Discard) b - Drive Gear c - Woodruff Key 2. Remove exhaust cover and gasket. 3. Remove oil filter. a b d c e f 91-802653 h g a - Screw and Washer (10) M6 x 35 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 Page 4B-14 90-857046R1 NOVEMBER 2001 Crankcase and Crankshaft Removal 1. Remove crankcase cover and dowel pins. 56875 a b c d a - Screw and Washer (8)-M8 x 82 b - Screw and Washer (8)-M6 x 35 c - Crankcase Cover d - Dowel Pin (2) 2. With a rubber or plastic hammer, lightly strike the crankcase cover in order to separate it from the block. If the cover will not separate, try prying it off with a screwdriver. Do not damage the split line sealing surface when prying the cover off. CYLINDER BLOCK/CRANKCASE 90-857046R1 NOVEMBER 2001 Page 4B-15 3. Use a 5/16 in. 12 point socket and remove connecting rod bolts and caps. NOTE: Each connecting rod , cap and bearing are a matched set. They must not be interchanged. 4. Remove carbon ridge from the cylinder bore using a burr knife. Push out the connecting rod/piston assembly. Keep each piston, connecting rod, and cap together as an assembly. 56876 a b c d a - Connecting Rod Screw (6) b - Connecting Rod Cap (3) c - Connecting Rod Bearings d - Connecting Rod/Piston Assembly (3) NOTE: Scribe the cylinder number (1 thru 3) on the inside of each piston and connecting rod so they can be reinstalled in their original location. 5. Disassemble piston/connecting rod assembly. Remove circlips with a needle nose pliers. 6. Remove piston rings. Use piston ring expander tool 91-24697 to prevent rings from breaking during removal. NOTE: If reusing rings, mark their location (piston #1, #2, or #3) for correct installation. 53824 b a d c 91-24697 e a - Circlips b - Connecting Rod and Cap c - Scribe the Cylinder Number Here d - Connecting Rod Bearings e - Piston Rings CYLINDER BLOCK/CRANKCASE Page 4B-16 90-857046R1 NOVEMBER 2001 7. Remove crankshaft from block. 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. 8. 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 Inspection Cylinder Bore MEASURING CYLINDER BORE 1. Measure the cylinder bore diameter at three locations in both X and Y axis. 2. If the cylinder bore is beyond the standard limits listed in the tables below, it will be necessary to re-bore the cylinder to accept the oversize piston. NOTE:Measure at three locations (L1, L2, and L3) in both X and Y axis (D1-6). L1=0.8 in. (20 mm) L2=1.6 in. (40 mm) L3=2.4 in. (60 mm) 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-0.010 in. (0.25 mm) 2.5689 in. (65.25 mm) 0.003 in.(0.08 mm) Oversize Bore-0.020 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) 90-857046R1 NOVEMBER 2001 Page 4B-17 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. (0.25 mm) 2.5669 - 2.5675 in. (65.2 - 65.215 mm) Oversize -0.020 in. (0.50 mm) 2.5768 - 2.5774 in. (65.450 - 65.465 mm) 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) Page 4B-18 90-857046R1 NOVEMBER 2001 CYLINDER BLOCK/CRANKCASE Piston Pin 1. Measure piston pin diameter. Replace piston pin if out of specification. 55839 Piston Pin Diameter 0.6285 - 0.6287 in. (15.965 - 15.970 mm) 1. Place the piston pin into the connecting rod and check for free play. There should be no noticeable free play. 55840 2. Place the piston pin into the piston and check for free play. There should be no noticeable free play. 55841 Piston Rings PISTON RING SIDE CLEARANCE 1. Measure piston ring side clearance. Replace piston and/or piston rings if out of specification. 55842 Piston Ring Side Clearance Top 0.0008 - 0.0024 in. (0.02 - 0.06 mm) Middle 0.0008 - 0.0024 in. (0.02 - 0.06 mm) 90-857046R1 NOVEMBER 2001 Page 4B-19 CYLINDER BLOCK/CRANKCASE PISTON RING END GAP CLEARANCE 1. Measure piston ring end gap clearance. Replace piston ring if out of specification. 53747 a a-Push Piston Rings into Cylinder 0.8 in. (20 mm) Deep. Push in the Rings Using the Piston. Piston Ring End Gap Top 0.006 - 0.012 in. (0.15 - 0.30 mm) 2nd 0.012 - 0.020 in. (0.30 - 0.50 mm) Oil 0.008 - 0.028 in. (0.20 - 0.70 mm) 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) Page 4B-20 90-857046R1 NOVEMBER 2001 CYLINDER BLOCK/CRANKCASE Checking Main Bearing Clearance IMPORTANT: Do not interchange the main bearings. Reinstall in their original position. 1. Clean all the old sealing material from the split line on the crankcase cover and cylinder block. 2. Clean all the oil from the following areas: • Main bearing surfaces on the cylinder block and crankcase cover. • Main bearings. • Crankshaft bearing surfaces. NOTE:Refer to instructions in Cylinder Block Reassemblyfor selecting and installing main bearings. 3. Install main bearings. 4. Place crankshaft into cylinder block. 53811 5. Place a piece of plastigauge onto each crankshaft bearing surface. 53812 a a-Plastigauge NOTE:Do not put plastigauge over the oil hole on the bearing surface of the crankshaft. 90-857046R1 NOVEMBER 2001 Page 4B-21 CYLINDER BLOCK/CRANKCASE 6. Install crankcase cover. Apply oil to the cover bolts and torque cover bolts in sequence and in two steps. 12 34 56 78 910 1112 1314 1516 Crankcase Cover Bolt Torque Center Bolts Qty. 8Center Bolts Qty. 8 (M8x82) 1st Torque: 11 lb-ft. (15 Nm) 2nd Torque: 22 lb-ft. (30 Nm) Outer Bolts Qty. 8Outer Bolts Qty. 8 (M6x35) 1st Torque: 53 lb-in. (6 Nm) 2nd Torque: 106 lb-in. (12 Nm) 7. Remove the crankcase cover. Measure the compressed plastigauge to check the main bearing clearance. Replace bearings if clearance is not in specification. 53751 Main Bearing Clearance 0.0005 - 0.0017 in. (0.012 - 0.044 mm) 8. If replacement of the main bearings is required, refer to Main Bearing Selection and Installation in Cylinder Block Reassembly. Page 4B-22 90-857046R1 NOVEMBER 2001 CYLINDER BLOCK/CRANKCASE Checking Connecting Rod Bearing Clearance IMPORTANT: Do not interchange used connecting rod bearings. Reinstall bearings in their original position. 1. Clean all the oil from the connecting rod bearing surfaces and connecting rod journals on the crankshaft. NOTE:Refer to instructions in Cylinder Block Reassemblyfor selecting and installing connecting rod bearings. 2. Place a piece of plastigauge on the connecting rod journals. 53751 a a-Plastigauge IMPORTANT: Do not rotate connecting rod when checking clearance. 3. Install the connecting rod to the respective journal. Tighten connecting rod bolts in sequence and in two steps to the specified torque. a b c c d a-Connecting Rod Cap b-Crankpin c-Scribe Marks on Cap and Rod d-Connecting Rod Bolts Connecting Rod Bolt Torque 1st Torque: 53 lb-in. (6 Nm) 2nd Torque: 150 lb-in. (17 Nm) 90-857046R1 NOVEMBER 2001 Page 4B-23 CYLINDER BLOCK/CRANKCASE 4. Remove the connecting rod cap. Measure the compressed plastigauge to check the connecting rod oil clearance. Replace bearings if oil clearance is not in specification. 53810 Connecting Rod Oil Clearance 0.0008 – 0.0020 in. (0.020 - 0.052 mm) Thermostat 1. Measure the lift of the thermostat at the operating water temperature listed. Water Temperature Valve Lift 118 - 123° F (48° - 51° C) Starts to Open Above 145° F (63° C) Minimum 0.12 in. (3 mm) Oil Pressure Switch 1. Check continuity of switch. 55845 Oil Switch Continuity Check Below 2.9 psi (20.0 kPa) Continuity Above 2.9 psi (20.0 kPa) No Continuity Page 4B-24 90-857046R1 NOVEMBER 2001 CYLINDER BLOCK/CRANKCASE 90-857046R1 NOVEMBER 2001 Page 4B-25 Cylinder Block Reassembly Selecting New Main Bearings 1. Locate the main bearing code letters on the cylinder block. 2. Refer to the following reference chart to select the correct main bearings. 3. Use the color coded main bearings that match the main bearing code letter. Main Bearing Code Letter Main Bearing Color Code A Blue B Black C Brown #1 #2 #3 A B C b a #4 a - Main Bearing Code Letters b - Main Bearing Identification Color Location CYLINDER BLOCK/CRANKCASE Page 4B-26 90-857046R1 NOVEMBER 2001 Main Bearing Installation IMPORTANT: Do not interchange used main bearings. Reinstall in their original position. 1. Check clearance of each bearing, as outlined in Main Bearing Clearance procedure. 2. Clean all the oil from the main bearing surfaces on the cylinder block and crankcase cover. 3. Install main bearings. Make sure the locking tab on each bearing fits into its notch in the cylinder block. a b c d 110 4-Stroke Outboard Oil 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 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. 3. Use the color coded connecting rod bearings that match the connecting rod bearing code letter. Connecting Rod Bearing Code Letter Connecting Rod Bearing Color Code A Blue B Black C Brown 53816 A B C a b a-Connecting Rod Bearing Code Letters b-Connecting Rod Bearing Identification Color Location 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. 53815 a b a-Connecting Rod Bearings b-Fit the Locking Lugs into the Notches 90-857046R1 NOVEMBER 2001 Page 4B-27 CYLINDER BLOCK/CRANKCASE Connecting Rod Installation 1. Lubricate the piston pin with oil and assemble the piston to the connecting rod. Always use new circlips. IMPORTANT: Install the split end of the circlip into the groove first, push the other end down until it snaps into the groove. If the shape of the circlip is permanently distorted when attempting installation, discard it and use a new one. IMPORTANT: Install side of connecting rod marked with a “Y” towards “UP” on piston face. 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 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 90-857046R1 NOVEMBER 2001 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 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 90-857046R1 NOVEMBER 2001 Page 4B-29 CYLINDER BLOCK/CRANKCASE Page 4B-30 90-857046R1 NOVEMBER 2001 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 ÎÎÎ ÎÎÎ ÎÎÎ a - Piston Ring Compressor (FT2997) b - Flywheel End Crankshaft Installation 1. Lubricate the crankshaft bearing surfaces, connecting rod journals, and oil seal lips with engine oil. 110 110 110 4-Stroke Outboard Oil a b c a - Upper Oil Seal b - Lower Oil Seal c - Crankshaft Bearing Surface CYLINDER BLOCK/CRANKCASE 90-857046R1 NOVEMBER 2001 Page 4B-31 2. Install upper and lower oil seals on crankshaft. Position oil seal lips as shown. 3. Carefully lower crankshaft into place. IMPORTANT: Make sure the lower oil seal notch is positioned into the groove in the crankcase. a b c 58273 b a - Upper Oil Seal b - Lower Oil Seal (Raised Rib) c - Oil Seal Groove 4. Assemble the connecting rods to the crankshaft. Install the connecting rod caps, aligning the code letter scribed on the connecting rod and cap. 5. Apply oil to the connecting rod bolts. Tighten bolts in sequence and in two steps to the specified torque. 110 110 4-Stroke Outboard Oil c a b a - Connecting Rod Cap (3) b - Connecting Rod Bolt (6) c - Scribe Code Letter Connecting Rod Bolt Torque 1st Torque: 53 lb-in. (6 Nm) 2nd Torque: 150 lb-in. (17 Nm) CYLINDER BLOCK/CRANKCASE Page 4B-32 90-857046R1 NOVEMBER 2001 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 Loctite Master Gasket “514” a 12 b a - Apply Loctite Master Gasket Sealant b - Use a Roller to Apply a Smooth Even Coat 3. Install crankcase cover on cylinder block. Dowel pins will lineup the two mating surfaces, be sure they are installed. 4. Apply oil to screw threads. Torque the screws in the sequence shown below. Tighten to the 1st torque value specified below. Repeat this torque sequence for the 2nd torque value. a 110 4-Stroke Outboard Oil 110 1 2 4 3 5 6 8 7 9 10 12 11 13 14 16 15 a a - Dowel Pin (2) Crankcase Cover Screw Torque Center Screws Qty. 1st Torque: 11 lb-ft. (15 Nm) 8 (M8x82) 2nd Torque: 22 lb-ft. (30 Nm) Outer Screws Qty. 8 1st Torque: 53 lb-in. (6 Nm) (M6x35) 2nd Torque: 106 lb-in. (12 Nm) CYLINDER BLOCK/CRANKCASE 90-857046R1 NOVEMBER 2001 Page 4B-33 Thermostat and Exhaust Cover Installation 1. Install oil filter. Tighten to specified torque using wrench p/n 91-802653. 2. Install exhaust cover along with the thermostat and thermostat cover. Use new gaskets. 3. Tighten screws to the first torque value in the sequence shown below. Repeat this procedure for the second torque value. h e c d 91-802653 g a b 6 10 2 1 3 4 5 8 9 7 f a - Exhaust Cover b - Gasket c - Thermostat d - Gasket e - Thermostat Cover f - Oil Filter g - Oil Filter Wrench h - Exhaust Cover Screw (10) M6 x 35 Exhaust and Thermostat Cover Screw Torque 1st Torque: 53 lb-in. (6 Nm) 2nd Torque: 106 lb-in. (12 Nm) Oil Filter Torque 70 lb-in. (8 Nm) CYLINDER BLOCK/CRANKCASE Drive Gear Installation 1. Install the drive gear components. NOTE:Load ring is for one time use and must be replaced if flywheel is removed. b c a a-Load Ring b-Drive Gear c-Drive Key Page 4B-34 90-857046R1 NOVEMBER 2001 CYLINDER BLOCK/CRANKCASE 90-857046R1 NOVEMBER 2001 Page 4B-35 Installing Powerhead Components 1. Reinstall cylinder head. Refer to Section 4A Cylinder Head Installation. 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. CYLINDER BLOCK/CRANKCASE Powerhead Installation CAUTION When lubricating the driveshaft splines do not allow any grease on top of the drive- shaft. Grease on top of the driveshaft will force the shaft down when installing the gearcase, causing the pinion gear to bind with the forward gear. This can result in damage or failure of the gears. 1. Install powerhead and new base gasket. 2. Tighten the powerhead mounting bolts to the first torque value in the sequence shown below. Repeat this procedure for the second torque value. IMPORTANT: If the crank shaft splines do not line up with the driveshaft splines, shift the gearcase into forward, place a prop on the propshaft and rotate it counterclockwise. This will allow the splines to line up. b a 12 34 56 78 c a-Powerhead Mounting Bolts (4 Each Side) M8 x 110 b-Hoist c-Base Gasket Powerhead Mounting Bolt Torque 1st Torque: 27.5 lb-ft. (37 Nm) 2nd Torque: 34 lb-ft. (46 Nm) Page 4B-36 90-857046R1 NOVEMBER 2001 CYLINDER BLOCK/CRANKCASE 90-857046R1 NOVEMBER 2001 Page 4B-37 3. Re-connect throttle/shift linkage and control cable anchor bracket. Torque fasteners to specified torque. Remote Control Model (Bigfoot Gearcase) 58254 a b c a - Control Cable Anchor Bracket Screw (2) M6 x 16 b - Throttle/Shift Lever c - Throttle/Shift Lever Screw (1) M8 x 70 Throttle/Shift Lever Mounting Screw Torque 100 lb-in. (11 Nm) Cable Anchor Bracket Mounting Screw Torque 75 lb-in. (8.5 Nm) 4. Install the shift guide bracket screws. Tighten to specified torque. Tiller Handle Model (Bigfoot Gearcase) 58479 a b a - Shift Guide Bracket b - Screw (2) M6 x 25 Shift Guide Bracket Mounting Screw Torque 70 lb-in. (8 Nm) CYLINDER BLOCK/CRANKCASE Page 4B-38 90-857046R1 NOVEMBER 2001 Non Bigfoot Model 5. Push retainer up and slide over to engage the vertical shift shaft. a 1 2 a - Retainer 6. Reconnect hoses. Use sta-straps to fasten all hose connections. a 59250 b a - Crankcase Vent Hose b - Fuel Pump Inlet hose CYLINDER BLOCK/CRANKCASE 90-857046R1 NOVEMBER 2001 Page 4B-39 7. Reconnect the power trim harness wires. 8. Install spark plugs 9. Install bottom cowl. Tighten screws to specified torque. c a b a - Screw (6)-M6 x 30 b - Lower Cowl c - Screw-M6 x 60 Bottom Cowl Screw Torque 60 lb-in. (7 Nm) 10. Connect battery cables to battery terminals (red goes to positive terminal). 11. Check engine oil level. Tiller Handle Models 1. Refer to section 7B for installation of throttle cables, shift rod and tiller handle wiring. LUBRICATION POWERHEAD Section 4C - Lubrication Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-1 Cleaning and Inspection . . . . . . . . . . . . . . . . . . 4C-6 Camshaft/Oil Pump . . . . . . . . . . . . . . . . . . . . . . 4C-2 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-6 Oil Pump Identification . . . . . . . . . . . . . . . . . . . 4C-4 Oil Pump Reassembly . . . . . . . . . . . . . . . . . . . 4C-7 Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . 4C-4 Oil Pump Installation . . . . . . . . . . . . . . . . . . . . . 4C-8 Oil Pump Disassembly . . . . . . . . . . . . . . . . . . . 4C-5 Specifications 4 C LUBRICATION SYSTEM Pump Type Engine Oil Pressure (Warm Engine) @ 3000 rpm Engine Oil Pan Capacity Oil Pump: S/N OT427437 & Up (Electric) S/N OT426439 & Up (Manual) Outer Rotor to Housing “a” Inner Rotor to Outer Rotor “b” Rotor to Housing “c” Oil Pump: S/N OT427436 & Below (Electric) S/N OT426438 & Below (Manual) Outer Rotor to Housing “a” Inner Rotor to Outer Rotor “b” Trochoid 30-40 psi (207-278 kPa) Either 3 Qts. or 3 Liters 0.0045 - 0.009 in. (0.11 - 0.23 mm) 0.005 in. (0.12 mm) 0.0015 - 0.003 in. (0.04 - 0.08 mm) 0.0035 - 0.006 in. (0.09 - 0.15 mm) 0.005 in. (0.12 mm) Rotor to Housing “c” a b 0.001 - 0.003 in. (0.03 - 0.08 mm) c 90-857046R1 NOVEMBER 2001 Page 4C-1 LUBRICATION CAMSHAFT/OIL PUMP Page 4C-2 90-857046R1 NOVEMBER 2001 LUBRICATION CAMSHAFT/OIL PUMP REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in lb-ft Nm. 1 1 CAMSHAFT 2 1 PIN 3 1 DOWEL PIN 4 1 OIL PUMP ASSEMBLY 5 1 O-RING 6 1 O-RING 7 1 O-RING 8 1 O-RING 9 2 SCREW (M6 X 16) 70 8.0 10 4 SCREW (M6 X 40) 70 8.0 90-857046R1 NOVEMBER 2001 Page 4C-3 LUBRICATION Page 4C-4 90-857046R1 NOVEMBER 2001 Oil Pump Identification There was a change made to the oil pump starting with the following serial numbers: ELECTRIC S/N OT427437 and up MANUAL S/N 0T426439 and up The oil hole on the new style pump is elongated into an oval shape. a b a - Old Style Oil Pump - Circular Hole b - New Style Oil Pump - Oval Hole Oil Pump Removal IMPORTANT: Do not twist/turn oil pump from side to side while removing it from cylinder head, as oil pump sealing o-rings will be cut. Pull oil pump away from cylinder head by inserting a screwdriver in the pry points on oil pump body. 1. Refer to section 4A for Cylinder Head Removal. 2. Remove oil pump mounting screws. Separate oil pump from cylinder head. a a - Mounting Screw (4) M6x40 LUBRICATION Oil Pump Disassembly 1. If screws cannot be loosened with a screwdriver, heat them with a non-flame type heat source (heat lamp). This will loosen the Loctite sealant on the screw threads. Remove screws. a a-Screw (2) 2. Disassemble oil pump. a b c d e a-Cover Seal b-Outer Rotor c-Inner Rotor d-Shaft e-Cross Pin 90-857046R1 NOVEMBER 2001 Page 4C-5 LUBRICATION Cleaning and Inspection Oil Pump 1. Check oil pump components for pitting, scratches, and for the following measurements. Replace oil pump if worn or out of specification. 2. Using a feeler gauge, measure the following oil pump clearances: a. Between outer rotor and pump housing (a). b. Between the inner rotor and outer rotor (b). c. Between the outer rotor and pump housing (c). 55803a b c Oil Pump Clearances S/N OT426439 and Up (Manual) S/N OT427436 and Up (Electric) a 0.0045 - 0.009 in. (0.11 - 0.23 mm) b 0.005 in. (0.12 mm) c 0.0015 - 0.003 in. (0.04 - 0.08 mm) Oil Pump Clearances S/N OT426438 and Below (Manual) S/N OT427435 and Below (Electric) a 0.0035 - 0.006 in. (0.09 - 0.15 mm) b 0.005 in. (0.12 mm) c 0.001 - 0.003 in. (0.03 - 0.08 mm) Page 4C-6 90-857046R1 NOVEMBER 2001 LUBRICATION Oil Pump Reassembly 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”51 51 a-Screw (2) M6 X 16 Oil Pump Cover Screw Torque 70 lb-in. (8 Nm) 90-857046R1 NOVEMBER 2001 Page 4C-7 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. 58260 a b a a-O-Ring Seals b-30 ml of Engine Oil IMPORTANT: When the oil pump mounting surface gets close to the mating surface of the cylinder head, do not twist/turn oil pump from side to side. The sharp edges on the cylinder head will cut the oil pump sealing o-rings. 3. Align oil pump shaft with the camshaft and install the oil pump. 4. Fasten with 4 screws. Tighten screws to the specified torque. c b a d e a-Oil Pump Assembly b-Align Slot with Camshaft Projection c-Screw (4)-M6x40 d-Oil Pump Mounting Surface e-Cylinder Head/Oil Pump Mating Surface Oil Pump Mounting Screw Torque 70 lb-in. (8 Nm) Page 4C-8 90-857046R1 NOVEMBER 2001 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING MID-SECTION Section 5A - Clamp/Swivel Brackets & Drive Shaft Housing Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-1 Adaptor Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-8 Transom Bracket . . . . . . . . . . . . . . . . . . . . . . . . 5A-2 Steering Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-10 Swivel Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-4 Bottom Cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-12 Driveshaft Housing . . . . . . . . . . . . . . . . . . . . . . 5A-6 Specifications Transom Height: Long Shaft 20 in. (51 cm) Steering Pivot Range: MID-SECTION Tiller Remote 90° 60° Tilt Pin Positions 5 + Shallow Water Full Tilt Up Angle 69° Allowable Transom Thickness 2-3/4 in. (69.8 mm) 5 A 90-857046R1 NOVEMBER 2001 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 95 95 95 95 2-4-C Marine Lubricant with Teflon Page 5A-2 90-857046R1 NOVEMBER 2001 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Transom Bracket REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 TRANSOM BRACKET (PORT) 2 1 GREASE FITTING 3 1 GROOVE PIN 4 1 TRANSOM BRACKET (STARBOARD) 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 7 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 1 35 1 36 1 37 1 38 1 18 25 39 2 SCREW (M10 x 40) 40 2 WASHER 41 2 NUT 42 1 DECAL-Tilt Lock 90-857046R1 NOVEMBER 2001 Page 5A-3 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5A-4 90-857046R1 NOVEMBER 2001 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 Marine Lubricant with Teflon 95 95 95 95 10 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Swivel Bracket REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 LINK ROD SCREW (1-1/2 IN.) WASHER 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) NON HANDLE SEAL16 1 90-857046R1 NOVEMBER 2001 Page 5A-5 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5A-6 90-857046R1 NOVEMBER 2001 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 REF 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 33 45 5 5 SCREW (M8 x 45) 33 45 6 1 DRAIN PLUG 17.5 23.5 7 1 GASKET 8 2 BUMPER 9 1 GROMMET (LONG) 1010 1 STUD (NON-BIGFOOT) 12 16 1 STUD (BIGFOOT) 12 16 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 90-857046R1 NOVEMBER 2001 Page 5A-7 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Adaptor Plate 9 110 Loctite PST Pipe Sealant With Teflon 4 Stroke Outboard Oil Page 5A-8 90-857046R1 NOVEMBER 2001 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Adaptor Plate REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 DIPSTICK 2 1 DIPSTICK TUBE 3 1 SEAL 4 1 ADAPTOR PLATE 5 1 PLUG 6 1 TUBING (17 IN.) 7 1 FITTING 8 AR STA-STRAP 9 2 STA-STRAP 10 1 SEAL–driveshaft (NON-BIGFOOT) 1 SEAL–driveshaft (BIGFOOT) 11 1 BUSHING (NON-BIGFOOT) 12 1 PLUG–oil passage 13 1 GROMMET (NON-BIGFOOT) 14 1 GASKET 15 1 O RING 16 3 SCREW (M6 x 20) 75 8.5 17 1 BODY–oil pressure relief 34 46 18 1 PLATE-Top Oil Pickup 19 1 HOSE-Oil Pickup 20 1 BAFFLE 21 2 CLAMP 22 1 SCREW (M6 x 55) 150 17 23 1 HEAT SHIELD 24 5 DOWEL PIN 25 1 ELBOW 90-857046R1 NOVEMBER 2001 Page 5A-9 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5A-10 90-857046R1 NOVEMBER 2001 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 7 4 95 2-4-C Marine Lubricant with Teflon 95 95 95 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Steering Arm REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 2 NUT 50 68 2 1 STRAP 3 2 MOUNT 4 2 WASHER (BIGFOOT) 5 8 SCREW (M6 x 20) 130 15 6 1 BUMPER 7 1 BUMPER (BIGFOOT) 8 1 RETAINING RING 9 1 STEERING ARM 10 1 BRACKET TAB WASHER NON HANDLE SCREW (M10 x 30) 11 1 12 2 32.5 44 13 2 SCREW (M12 x 154) 24 32.5 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 105) 32.5 44 19 1 BRACKET 20 3 SCREW(SELF–TAPPING) Drive Tight 21 2 NUT 32.5 44 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 90-857046R1 NOVEMBER 2001 Page 5A-11 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Bottom Cowl 95 2-4-C Marine Lubricant with Teflon Page 5A-12 90-857046R1 NOVEMBER 2001 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Bottom Cowl REF 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 (M6 X 30) 60 7 4 1 WASHER 5 1 SEAL 6 1 WASHER 7 1 GASKET 8 1 SCREW (M6 x 60) 60 7 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 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 RETAINER 21 1 GROMMET 90-857046R1 NOVEMBER 2001 Page 5A-13 POWER TRIM MID-SECTION Section 5B - Power Trim Table of Contents Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 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-47 Troubleshooting the Power Trim Reservoir/Motor Installation . . . . . . . . . . . . 5B-48 Electrical System . . . . . . . . . . . . . . . . . . . . . 5B-27 Bleeding Power Trim Unit . . . . . . . . . . . . . 5B-49 Power Trim System Removal . . . . . . . . . . . . . 5B-29 Installation of Power Trim System . . . . . . . . . 5B-49 Power Trim Disassembly . . . . . . . . . . . . . . . . . 5B-30 5 B 90-857046R1 NOVEMBER 2001 Page 5B-1 POWER TRIM Special Tools 1. Spanner Wrench P/N 91-74951 2. Lock-Ring Pliers Snap-On P/N SRP2 3. Expanding Rod P/N CG 41-11* 4. Collet P/N CG 41-14* 5. Heat Lamp P/N 91-63209 Page 5B-2 90-857046R1 NOVEMBER 2001 POWER TRIM Notes: 90-857046R1 NOVEMBER 2001 Page 5B-3 POWER TRIM Page 5B-4 90-857046R1 NOVEMBER 2001 Power Trim 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 4 6 11 6 11 6 11 17 15 11 11 11 6 11 A E D C D B F 66 Loctite 242 NOTE: Lubricate all O-rings using Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. NOTE: It is recommended that all O-rings be replaced when servicing tilt system. POWER TRIM Power Trim REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm – 1 POWER TRIM PUMP 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 TRILOBE PIN 18 1 ANCHOR PIN 19 1 PIN 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) 90-857046R1 NOVEMBER 2001 Page 5B-5 POWER TRIM Theory Of Operation The Power Trim system consists of an electric motor, pressurized fluid reservoir, pump and trim cylinder. The remote control (or trim panel) is equipped with a switch that is used for trimming the outboard “up” 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 90-857046R1 NOVEMBER 2001 POWER TRIM TRIMMING OUTBOARD “DOWN” (“IN”) WARNING Excessive speed at minimum trim “In” may cause undesirable and/or unsafe steering conditions. Each boat should be tested for handling characteristics after any adjustment is made to the tilt angle (tilt pin relocation). • Will help planing off, particularly with a heavy load. • Usually improves ride in choppy water. • In excess, can cause boat to veer to the left or right (bow steer). • Transfers steering torque harder to right (or less to the left). • Improves planing speed acceleration (by moving tilt pin one hole closer to transom). Operating “Down” circuit will actuate the “down” relay (located under engine cowl) and close the electric motor circuit (motor will run in opposite direction of the “Up” circuit). The electric motor will drive the pump, thus forcing automatic transmission fluid through internal passageways into the “down” side of the trim cylinder. The trim rod will move the engine downward to the desired angle. Trailering Outboard WARNING Excessive engine trim angle will result in insufficient water supply to water pump causing water pump and/or powerhead overheating damage. Make sure that water level is above gear housing water intake holes whenever engine is running. While operating “up” circuit, the cylinder rod will continue to tilt the outboard to a full up position for trailering. Tilting Outboard Up and Down Manually WARNING Before loosening the manual release valve, make sure all persons are clear of engine, as engine will drop to full “down” position when valve is loosened. With power trim installed, the outboard can be raised or lowered manually by opening the manual release valve 3 to 4 turns (counterclockwise). 55170 a a-Manual Release Valve 90-857046R1 NOVEMBER 2001 Page 5B-7 POWER TRIM Page 5B-8 90-857046R1 NOVEMBER 2001 Power Trim Flow Diagrams ÍÍ ÍÍ Reservoir Oil Filtered Feed Oil Oil Under Pressure Return Oil Up Pressure 1625 psi (3060 hp) 2800 psi (75125 hp) mininmum Tilt Relief Pressure 250400 psi (3060 hp) 500700 psi (4060 hp Bigfoot) 540990 psi (75125 hp) Impact Relief Pressure #22 8801110 psi (3060 hp) 12201420 psi (75125 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. 90-857046R1 NOVEMBER 2001 Page 5B-9 POWER TRIM Page 5B-10 90-857046R1 NOVEMBER 2001 Tilt Circuit Tilt Relief Pressure 250400 psi (3060 hp) 500700 psi (4060 hp Bigfoot) 540990 psi (75125 hp) Up Pressure 1625 psi (3060 hp) 2800 psi (75125 hp) minimun Reservoir Oil Filtered Feed Oil Oil Under Pressure Return Oil ÍÍ ÍÍ Impact Relief Pressure #22 8801110 psi (3060 hp) 12201420 psi (75125 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 falls or if engine is not in forward gear, the oil pressure is available to extend the piston rod (a) up into the tilt range. 90-857046R1 NOVEMBER 2001 Page 5B-11 POWER TRIM Page 5B-12 90-857046R1 NOVEMBER 2001 Maximum Tilt Up Pressure 1625 psi (3060 hp) 2800 psi (75125 hp) minimum ÍÍ ÍÍ Reservoir Oil Filtered Feed Oil Oil Under Pressure Return Oil Tilt Relief Pressure 250400 psi (3060 hp) 500700 psi (4060 hp Bigfoot) 540990 psi (75125 hp) Impact Relief Pressure #22 8801110 psi (3060 hp) 12201420 psi (75125 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. 90-857046R1 NOVEMBER 2001 Page 5B-13 POWER TRIM Page 5B-14 90-857046R1 NOVEMBER 2001 Down Circuit Up Pressure 1625 psi (3060 hp) 2800 psi (75125 hp) minimum ÍÍ ÍÍ ÍÍ Reservoir Oil Filtered Feed Oil Oil Under Pressure Return Oil Tilt Relief Pressure 250400 psi (3060 hp) 500700 psi (4060 hp Bigfoot) 540990 psi (75125 hp) Impact Relief Pressure #22 8801110 psi (3060 hp) 12201420 psi (75125 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 reaches 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. 90-857046R1 NOVEMBER 2001 Page 5B-15 POWER TRIM Page 5B-16 90-857046R1 NOVEMBER 2001 Shock Function Up Up Pressure 1625 psi (3060 hp) 2800 psi (75125 hp) minimum ÍÍ ÍÍ Reservoir Oil Oil Under Pressure Return Oil Tilt Relief Pressure 250400 psi (3060 hp) 500700 psi (4060 hp Bigfoot) 540990 psi (75125 hp) Impact Relief Pressure #22 8801110 psi (3060 hp) 12201420 psi (75125 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), and 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 it. 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). 90-857046R1 NOVEMBER 2001 Page 5B-17 POWER TRIM Page 5B-18 90-857046R1 NOVEMBER 2001 Shock Function Return Up Pressure 1625 psi (3060 hp) 2800 psi (75125 hp) minimum ÍÍÍ ÍÍ Reservoir Oil Oil Under Pressure Return Oil Tilt Relief Pressure 250400 psi (3060 hp) 500700 psi (4060 hp Bigfoot) 540990 psi (75125 hp) Impact Relief Pressure #22 8801110 psi (3060 hp) 12201420 psi (75125 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. 90-857046R1 NOVEMBER 2001 Page 5B-19 POWER TRIM Page 5B-20 90-857046R1 NOVEMBER 2001 Manual Release ÍÍ ÍÍ Reservoir Oil Return Oil Filtered Oil Down Pressure 525880 psi Up Pressure 1625 psi (3060 hp) 2800 psi (75125 hp) minimum Tilt Relief Pressure 250400 psi (3060 hp) 500700 psi (4060 hp Bigfoot) 540990 psi (75125 hp) Impact Relief Pressure #22 8801110 psi (3060 hp) 12201420 psi (75125 hp) a b c w v u t h d i j k l m n g o p q s r e f g 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. 90-857046R1 NOVEMBER 2001 Page 5B-21 POWER TRIM Troubleshooting Support outboard with tilt lock pin when servicing power trim system. IMPORTANT: After debris or failed components have been found (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 90-857046R1 NOVEMBER 2001 POWER TRIM Hydraulic System Troubleshooting Flow Chart OUTBOARD WILL NOT HOLD TILTED POSITION DURING REVERSE AND/OR TRAILS OUT DURING HIGH SPEED DECELERATION. Inspect manual release valve.Manual release valve and O-ring damaged. Manual release valve and O-rings appear to be O.K. - Clean and reinstall manual release valve. Trim system holds re- verse thrust. Testing complete. Trim will not hold reverse thrust. Replace manual re- lease valve and O-rings. Trim system holds re- verse thrust. Testing complete. Remove and inspect pis- ton rod assembly for de- bris and/or shock ball hang up. Shock piston appears O.K. - Clean and reinstall piston rod assembly. Trim system holds re- verse thrust. Testing complete. Debris and/or shock ball hang up identi- fied. Replace piston rod assembly. Trim system holds re- verse thrust. Testing complete. Trim will not hold reverse thrust. Remove PO check valve assembly, inspect O-rings and seals for damage. Debris and/or dam- age identified. Replace PO check valve assembly. Trim system holds re- verse thrust. Testing complete. PO check valve appears O.K. - Clean and reinstall PO check valve assem- bly. Trim will not hold reverse thrust. Trim system holds reverse thrust. Test- ing complete. continued on next page 90-857046R1 NOVEMBER 2001 Page 5B-23 POWER TRIM Hydraulic System Troubleshooting Flow Chart continued Replace trim system. Replace suction seat assembly. Remove suction seat as- sembly and inspect for debris and/or damage. Debris and/or damage identified. Trim system holds reverse thrust. Test- ing complete. Trim will not hold reverse thrust. Suction seat assembly appears O.K. - Clean and reinstall suction seat assembly. Trim system holds reverse thrust. Test- ing complete. Page 5B-24 90-857046R1 NOVEMBER 2001 POWER TRIM Hydraulic System Troubleshooting Flow Chart TRIM SYSTEM LEAKS DOWN WITH MANUAL RELEASE VALVE CLOSED. Inspect manual release valve.Manual release valve and O-ring damaged. Replace manual re- lease valve and O-rings. Trim system does not leak down. Test- ing complete. Trim system leaks down. Manual release valve and O- rings appear to be O.K. - Clean and reinstall manual release valve. Trim system does not leak down. Test- ing complete. Remove tilt relief valving and inspect O-rings and seals for debris and/or damage. Debris and/or dam- age identified. Replace tilt relief valve- ing. 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 valveing. 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. 90-857046R1 NOVEMBER 2001 Page 5B-25 POWER TRIM Hydraulic System Troubleshooting Flow Chart continued Replace trim system. Replace memory pis- ton and shock piston O-rings. Inspect memory pis- ton O-ring and cylinder bore. Cylinder bore appears smooth with no debris. Cylinder bore appears rough and/or debris found in cylinder. Trim leaks down. Trim system does not leak down. Test- ing complete. Page 5B-26 90-857046R1 NOVEMBER 2001 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 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 +– GRN/WHT LT. BLU/WHT RED/PUR a j k h g e f c d c b 1 2 3 4 i l m h-Up Relay i-Solenoid j-Trim Pump Motor k-Cowl Switch l-Solenoid m-3-Pin Connector a-Trim Switch (Remote Control Mounted) b-Trim Switch (Panel Mounted) c-Fuse Holder d-Remote Control Wiring Plug Connector e-Battery f-Starter Bolt g-Down Relay 90-857046R1 NOVEMBER 2001 Page 5B-27 POWER TRIM Troubleshooting the Power Trim Electrical System Refer to wiring diagram on preceding page for location of wire connections. Problem Possible Cause Remedy Trim Switch “UP” is inoperative, but the Cowl Switch “UP” does operate. 1. Open wire between Wire Connection (1) and Trim Switch. 2. Faulty Trim Switch. 1. Check for an open connection or cut wire. 2. Replace. Cowl Switch “UP” is inoperative, but the Trim Switch “UP” does operate. 1. Open wire between Wire Connection (2) and Solenoid. 2. Faulty Cowl Switch. 1. Check for an open connection or cut wire. 2. Replace. Trim Switch “UP” and Cowl Switch “UP” are both inop1. Open wire between Wire Connection (1) and the “Up” Relay. 1. Check for an open connection. erative. 2. Open BLK wire between ground and “UP” Relay. 2. Check for an open connection. 3. Open RED wire between Solenoid and “UP” Relay. 3. Check for an open connection. 4. Faulty “UP” Relay. 4. Replace. Trim Switch “DOWN” is inoperative, but the Cowl Switch “DOWN” does operate. 1. Open wire between Wire Connection (3) and Trim Switch. 2. Faulty Trim Switch. 1. Check for an open connection or cut wire. 2. Replace. Cowl Switch “DOWN” is inoperative, but the Trim Switch “DOWN” does operate. 1. Open wire between Wire Connection (2) and Solenoid. 2. Faulty Cowl Switch. 1. Check for a open connection or cut wire. 2. Replace Trim Switch “DOWN” and Cowl Switch “DOWN” are 1. Open wire between Wire Connection (3) and the “UP” Relay. 1. Check for an open connection. both inoperative. 2. Open BLK wire between ground and “DOWN” Relay. 2. Check for an open connection. 3. Open RED wire between Solenoid and “DOWN” Relay. 3. Check for an open connection. 4. Faulty “DOWN” Relay 4. Replace. Trim Switch “UP” and “DOWN” are both inoperative, but the Cowl Switch does operate. 1. 20 AMP Fuse blown. 2. Faulty trim switch. 3. Wire is open between fuse holder and solenoid. 4. Wire is open between fuse holder and trim switch. 1. Replace fuse. Locate the cause of the blown fuse. Check electrical wiring for a shorted circuit. 2. Replace. 3. Check for a open connection or cut wire. 4. Check for a loose or corroded connection. Trim Switch and Cowl Switch are both inoperative. 1. One of the Trim Pump Motor wires is open between the motor and the Relays. 2. Faulty trim pump motor. 1. Check wire connections (4) for loose or corroded condition. 2. If voltage is present at connections (4) when the appropriate trim button is pressed, then motor is faulty. Replace motor. Trim system operates (motor runs) without pressing the switches. 1. The Trim or Cowl switch is shorted. 1. Replace. Page 5B-28 90-857046R1 NOVEMBER 2001 POWER TRIM 90-857046R1 NOVEMBER 2001 Page 5B-29 Power Trim System Removal 1. Tilt outboard to the full up position and support with tilt lock pin. 2. Disconnect the power trim wire harness and remove clamp. 55264 b c 55464 a a - Tilt Lock Pin b - Power Trim Wire Harness Clamp c - Harness 3. Remove the upper trilobe pin. 4. Drive out the upper pivot pin. 5. Remove the sacrificial anode. 55331 c b a a - Upper Trilobe Pin b - Upper Pivot Pin c - Sacrificial Anode POWER TRIM 6. Use suitable punch to remove lower trilobe pin. Retain trilobe pin. 7. Use suitable punch to drive out lower pivot pin. 51144 51144 ba a-Lower Trilobe 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 90-857046R1 NOVEMBER 2001 POWER TRIM 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 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 - Screw (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 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 POWER TRIM Cleaning/Inspection/Repair IMPORTANT: Components must be dirt and lint free. Slightest amount of debris in Power Trim system could cause system to malfunction. Clean shock rod and components with parts cleaner and dry with compressed air. It is recommended that all O-rings in trim system be replaced. Use O-Ring Kit 25-809880A1. Lubricate all o-rings with Power Trim Fluid. If not available, use automotive (ATF) automatic transmission fluid. Trim Motor Electrical Tests 1. Connect a 12 volt supply to motor leads. If motor fails to run, replace pump motor. IMPORTANT: Trim Motor is not serviceable. If motor fails to run, replace motor assembly. 90-857046R1 NOVEMBER 2001 Page 5B-37 POWER TRIM Page 5B-38 90-857046R1 NOVEMBER 2001 Reassembly O-Ring and Seal Placement O-Rings and Seals are part of O-Ring Kit 25-809880A1. 3 21 22 3 19 21 22 4 5 1 20 8 9 10 18 9 7 6 15 16 17 8 9 10 14 13 11 12 1 2 11 3 6 5 8 10 16 19 21 O.D. I.D. Cutaway View of O-Ring Width O-RINGS SHOWN ARE ACTUAL SIZE 9 7 13 14 1 2 3 22 4 9 13 14 11 10 8 6 5 21 19 16 20 15 18 17 12 POWER TRIM 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 POWER TRIM Power Trim Reassembly IMPORTANT: Lubricate all o-rings with Power Trim Fluid. If not available, use automotive (ATF) automatic transmission fluid. Shock Rod Reassembly 1. Install lubricated o-rings to end cap. 2. Install rod wiper. 3. Install lubricated o-rings to shock piston. 51199 f d e a b c 51145 a-Rod Wiper b-Inner O-ring c-Outer O-ring d-Shock Piston e-O-ring f-O-ring 4. Clamp shock rod in soft jawed vise. 5. Position cylinder end cap onto rod as shown. 51146 90-857046R1 NOVEMBER 2001 Page 5B-41 POWER TRIM CAUTION When installing shock rod piston, spanner wrench must have 1/4 in. x 5/16 in. (6.4mm x 8mm) long pegs to avoid damage to shock rod piston. 6. Apply Loctite 271 to threads on shock rod. Install shock rod piston. 7. 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, tighten to specified torque. 51146 b a B Loctite 271 a-Shock Rod Piston b-Spanner Wrench Shock Rod Piston Torque 90 lb-ft (122 Nm) 8. Remove shock rod assembly from vise. 9. Install ball, seat, and spring (five sets) to shock rod piston. Secure components with plate. 51147 e d c a b a-Screw (3) b-Plate d-Seat (5) e-Ball (5) c-Spring (5) Screw Torque 35 lb-in (4.0 Nm) Page 5B-42 90-857046R1 NOVEMBER 2001 POWER TRIM Shock Rod Installation 1. Place trim cylinder in soft jawed vice. 2. Install lubricated o-ring to memory piston and place into cylinder. Push memory piston all the way to bottom. 3. Fill cylinder three inches (76.2 mm) from top of cylinder using Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. 4. Install shock rod into cylinder until power trim fluid flows through oil blow off ball passage. Fill remaining cylinder to just below the cylinder threads. c a b a-Memory Piston b-O-ring c-Oil Blow Off Ball Passage CAUTION End cap must not make contact with shock rod piston when tightening. Shock rod piston must be positioned in cylinder deep enough to avoid contact. 5. Tighten end cap securely using spanner wrench [1/4 in. x 5/16 in. (6.4mm x 8mm) long pegs]. If a torquing type spanner tool is used to tighten end cap, then tighten to specified torque. End Cap Torque 45 lb-ft (61.0 Nm) 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 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 tighten to specified torque. 51146 a b c a-Trim Cylinder Assembly b-Reservoir/Manifold Assembly c-Screw (2) Screw Torque 100 lb-in (11.0 Nm) 90-857046R1 NOVEMBER 2001 Page 5B-45 POWER TRIM Page 5B-46 90-857046R1 NOVEMBER 2001 Oil Pump Installation 1. Install spring, ball, lubricated o-ring and plastic seat to manifold. 2. Check to see that o-rings are placed on bottom of pump. 3. Install filter and filter seal under pump. Install pump onto manifold. Tighten screws to specified torque. b a a - Screw (3) b - Suction Seat Assembly Screw Torque 70 lb-ft (8.0 Nm) POWER TRIM 90-857046R1 NOVEMBER 2001 Page 5B-47 Pressure Operated Assembly Installation IMPORTANT: Inspect poppet assembly for debris in the area shown. If debris is found on poppet, replace poppet. 1. Lubricate o-rings. 2. Install spool, seat (with o-ring), check valve/poppet, spring and plug (with o-ring) into pump. Repeat for other side. Tighten plugs to specified torque. d c d e c a b e f g f a - Debris Under Valve Tip b - Rubber Seat c - Plug (2) d - Spring (2) e - Check Valve/Poppet (2) f - Seat (2) g - Spool Plug Torque 120 lb-in (13.5 Nm) POWER TRIM Page 5B-48 90-857046R1 NOVEMBER 2001 Reservoir/Motor Installation 1. Install coupler into top of pump. Make sure reservoir seal is in the reservoir groove and place reservoir onto pump/manifold assembly. Install ground strap under screw shown Tighten screws to specified torque. a b c d 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 Screw Torque 80 lb-in (9.0 Nm) POWER TRIM Bleeding Power Trim Unit 1. Secure power trim unit in soft jawed vise. 2. Fill reservoir to bottom of fill hole using Power Trim and steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. 3. Close the manual release valve. (Turn full clockwise). 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. 55263 a b 113 Power Trim & Steering Fluid 113 a-Reservoir Plug/Fill Hole b-Manual Release Valve Installation of Power Trim System 1. Lubricate lower pivot pin mounting holes with 2-4-C Marine Lubricant with teflon. 2. Apply 2-4-C Marine Lubricant with teflon to lower pivot pin and start lower pivot pin into pivot pin bore. 51148 a 95 2-4-C Marine Lubricant with Teflon 95 a-Lower Pivot Pin 90-857046R1 NOVEMBER 2001 Page 5B-49 POWER TRIM 3. Position trim cylinder assembly (bottom first) between clamp brackets. 4. 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 Marine Lubricant with Teflon a-Trim Cylinder Assembly b-Lower Pivot Pin 5. Using a suitable punch, drive lower trilobe pin into its hole until seated. a a-Lower Trilobe Pin Page 5B-50 90-857046R1 NOVEMBER 2001 POWER TRIM 6. Apply 2-4-C Marine Lubricant with Teflon to surface of upper pivot pin, pivot pin bore and trim ram bore. 51148 95 a b c 95 2-4-C Marine Lubricant with Teflon a-Pivot Pin b-Pivot Pin Bore c-Trim Ram Bore 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 upper trilobe pin into its hole until seated. 55464 d 51148 b c a a-Pivot Pin b-Swivel Bracket c-Trim Ram d-Upper Trilobe Pin 90-857046R1 NOVEMBER 2001 Page 5B-51 POWER TRIM 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 55465c b a a-Sacrificial Anode b-Ground Strap c-Bracket d-Trim Harness 11. Secure trim harness with clamp, as shown. 55264 a a-Clamp Page 5B-52 90-857046R1 NOVEMBER 2001 MANUAL TILT ASSIST MID-SECTION Section 5C - Manual Tilt Assist Table of Contents Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-1 Valve Block Removal . . . . . . . . . . . . . . . . . 5C-24 Manual Tilt Components . . . . . . . . . . . . . . . . . 5C-2 Memory Piston Removal . . . . . . . . . . . . . . 5C-25 Manual Trim Flow Diagrams . . . . . . . . . . . . . . 5C-4 Valve Block Disassembly . . . . . . . . . . . . . . . . . 5C-26 Up Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-4 Reassembly - O-Ring and Seal Placement . 5C-27 Down Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 5C-6 Actual O-Ring Sizes . . . . . . . . . . . . . . . . . . . . . 5C-28 Slow Tilt Down Under High Thrust . . . . . . 5C-8 O-ring Description and Sizes . . . . . . . . . . . . . . 5C-29 Under Water Strike (Valves Open) . . . . . . 5C-10 Manual Tilt System Cleaning and Inspection 5C-29 Shock Function (Valve Closed) . . . . . . . . . 5C-12 Manual Tilt System Reassembly . . . . . . . . . . 5C-29 Shock Function Return . . . . . . . . . . . . . . . . 5C-14 Valve Block Installation . . . . . . . . . . . . . . . . 5C-32 Hydraulic System Troubleshooting . . . . . . . . . 5C-16 Shock Rod Reassembly . . . . . . . . . . . . . . . 5C-33 Manual Tilt System Removal . . . . . . . . . . . . . . 5C-18 Shock Rod Installation and Fluid Manual Tilt System Disassembly . . . . . . . . . . 5C-20 Filling Procedure Option One . . . . . . . . . . 5C-35 Accumulator Removal . . . . . . . . . . . . . . . . . 5C-20 Fluid Filling Procedure Option Two . . . . . 5C-37 Shock Rod Removal . . . . . . . . . . . . . . . . . . 5C-21 Manual Tilt System Installation . . . . . . . . . . . . 5C-40 Shock Rod Disassembly . . . . . . . . . . . . . . . . . 5C-21 Manual Release Valve Adjustment . . . . . . 5C-43 5 C Special Tools 1. Spanner Wrench P/N 91-74951 2. Lock-Ring Pliers P/N SRP2 (Snap-On) 3. Heat Lamp P/N 91-63209 90-857046R1 NOVEMBER 2001 Page 5C-1 MANUAL TILT ASSIST Manual Tilt Components 7 Loctite 271 95 2-4-C Marine Lubricant with Teflon a b c d e f 7 95 95 NOTE: Lubricate all O-rings using Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. NOTE:It is recommended that all o-rings be replaced when servicing tilt system. Page 5C-2 90-857046R1 NOVEMBER 2001 MANUAL TILT ASSIST Manual Tilt Components REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 SHOCK ROD ASSEMBLY 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 11 1 CHECK SYSTEM REPAIR KIT – 1 O RING KIT 12 1 CABLE 13 2 PIN 14 2 TRILOBE 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) 90-857046R1 NOVEMBER 2001 Page 5C-3 MANUAL TILT ASSIST Page 5C-4 90-857046R1 NOVEMBER 2001 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. 90-857046R1 NOVEMBER 2001 Page 5C-5 MANUAL TILT ASSIST Page 5C-6 90-857046R1 NOVEMBER 2001 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. 90-857046R1 NOVEMBER 2001 Page 5C-7 MANUAL TILT ASSIST Page 5C-8 90-857046R1 NOVEMBER 2001 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. 90-857046R1 NOVEMBER 2001 Page 5C-9 MANUAL TILT ASSIST Page 5C-10 90-857046R1 NOVEMBER 2001 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). 90-857046R1 NOVEMBER 2001 Page 5C-11 MANUAL TILT ASSIST Page 5C-12 90-857046R1 NOVEMBER 2001 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). 90-857046R1 NOVEMBER 2001 Page 5C-13 MANUAL TILT ASSIST Page 5C-14 90-857046R1 NOVEMBER 2001 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. 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 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) 90-857046R1 NOVEMBER 2001 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. 51143 b a a-Link Rod b-Accumulator Page 5C-18 90-857046R1 NOVEMBER 2001 MANUAL TILT ASSIST 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 trilobe pin. Retain trilobe pin. 4. Position tilt lock and remove piece of wood. Use suitable punch to drive out upper pivot pin. 51144 c d b a 51144 a-Pivot Pin b-Tilt Lock c-Trilobe Pin d-Wood 5. Remove the sacrificial anode. 6. Use punch to remove (Drive Down) lower trilobe pin. Retain trilobe pin. 7. Use suitable punch to drive out lower pivot pin. b c a a-Sacrificial Anode b-Trilobe Pin c-Pivot Pin 90-857046R1 NOVEMBER 2001 Page 5C-19 MANUAL TILT ASSIST 8. Tilt shock absorber assembly (TOP FIRST) out from clamp bracket and remove assembly. 51144 b 1 2 a-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. Accumulator Removal 1. Place manual tilt system in soft jawed vise. Position shock rod to full up position. 2. Open cam shaft valve (Down Position). 3. Loosen velocity valve enough to drip, wait until dripping stops. When fluid stops dripping, loosen and remove accumulator. 4. If plunger can be compressed into accumulator by hand, accumulator is defective. Replace accumulator. 51143 c b a a-Accumulator b-Cam Lever d 51143 c-Velocity Valve d-Plunger Page 5C-20 90-857046R1 NOVEMBER 2001 MANUAL TILT ASSIST 5. 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 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 90-857046R1 NOVEMBER 2001 Page 5C-21 MANUAL TILT ASSIST 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-Platec-Shock Rod Piston 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 Page 5C-22 90-857046R1 NOVEMBER 2001 MANUAL TILT ASSIST 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. b a 91-74951 91-63209 a-Spanner Wrench b-Shock Rod Piston 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 90-857046R1 NOVEMBER 2001 Page 5C-23 MANUAL TILT ASSIST 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 Valve Block Removal 1. Remove two screws from the shock rod cylinder to separate the valve block. 2. Remove o-rings and dowel pins. b c a a-Screw b-Valve Block c-Shock Rod Cylinder d-O-ring (2) e-Dowel Pin (2) d e 51146 Page 5C-24 90-857046R1 NOVEMBER 2001 MANUAL TILT ASSIST Memory Piston Removal 1. Remove memory piston from cylinder using one of two methods: a. Using lock ring pliers. Snap-On SRP2 51144 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 90-857046R1 NOVEMBER 2001 Page 5C-25 MANUAL TILT ASSIST Page 5C-26 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 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 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 29 3 42 142 52 102 O.D. I.D. Cutaway View of O-Ring Width 11 13 (2) 62 72 12 (2) 82 O-RINGS SHOWN ARE ACTUAL SIZE Page 5C-28 90-857046R1 NOVEMBER 2001 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 Power Trim and Steering Fluid to all o-rings during reassembly. If not available, use automotive (ATF) automatic transmission fluid. 90-857046R1 NOVEMBER 2001 Page 5C-29 MANUAL TILT ASSIST Page 5C-30 90-857046R1 NOVEMBER 2001 CAM SHAFT REASSEMBLY IMPORTANT: Cam shaft O-ring must be lubricated using 2-4-C Marine Lubricant 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 Marine Lubricant with Teflon 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 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 Page 5C-33 MANUAL TILT ASSIST CAUTION When installing shock rod piston, spanner wrench must have 1/4 in. x 5/16 in. (6.4mm x8mm) long pegs to avoid damage to shock rod piston. 6. Apply Loctite 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 a b 91-74951 7 Loctite 271 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. (4.0 Nm). 11. Remove shock rod assembly from vise. 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 5C-34 90-857046R1 NOVEMBER 2001 MANUAL TILT ASSIST Shock Rod Installation and Fluid Filling Procedure - Option One NOTE:There are two ways for the filling procedure. The first is the easiest and less time consuming. 1. Place trim cylinder in soft jawed vice. 2. With manifold cam lever closed (Up Position), fill cylinder and manifold to top with 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 SRP2 Snap-On). 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 90-857046R1 NOVEMBER 2001 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 Marine Lubricant 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 90-857046R1 NOVEMBER 2001 MANUAL TILT ASSIST Fluid Filling Procedure - Option Two INSTRUCTIONS FOR MAKING RETAINING TOOL 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 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 90-857046R1 NOVEMBER 2001 Page 5C-37 MANUAL TILT ASSIST FILLING AND BLEEDING PROCEDURE 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 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 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 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. Lubricate lower pivot pin mounting holes with 2-4-C Marine Lubricant with Teflon. 2. Apply 2-4-C Marine Lubricant with Teflon to lower pivot pin and start lower pivot pin into pivot pin bore. 51148 a 95 2-4-C Marine Lubricant with Teflon 95 a-Lower Pivot Pin Page 5C-40 90-857046R1 NOVEMBER 2001 2 1 b 2 1 b MANUAL TILT ASSIST 3. Reinstall manual tilt system, bottom first. Reconnect release valve link rod. 4. Using a suitable punch, drive lower pivot pin into clamp bracket and trim cylinder assembly until pivot pin is flush with outside surface. 51147 a 2-4-C Marine Lubricant with Teflon 51144 95 a-Lower Pivot Pin b-Manual Tilt System 5. Using a suitable punch, drive lower trilobe pin into its hole until seated. a a-Trilobe Pin 90-857046R1 NOVEMBER 2001 Page 5C-41 MANUAL TILT ASSIST 6. Apply 2-4-C Marine Lubricant with Teflon 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 Marine Lubricant with Teflon a-Pivot Pin b-Pivot Pin Bore c-Shock Rod Bore d-Pivot Pin e-Swivel Bracket f-Shock Rod 8. Drive upper trilobe pin into its hole until seated. 51148 f e d 51147 a a-Trilobe Pin Page 5C-42 90-857046R1 NOVEMBER 2001 MANUAL TILT ASSIST 9. Install sacrificial anode. 55465 a a-Sacrificial Anode 10. 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. 90-857046R1 NOVEMBER 2001 Page 5C-43 NON-BIGFOOT GEAR HOUSING LOWER UNIT Section 6A - Non-Bigfoot Gear Housing Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2 Gear Housing (Driveshaft - 2:1) . . . . . . . . . . . 6A-6 Gear Housing (Prop Shaft - 2:1) . . . . . . . . . . . 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 Bearing Carrier and Propeller Shaft . . . . . 6A-17 Pinion Gear, Drive Shaft, and Forward Gear . . . . . . . . . . . . . . . . . . . . 6A-18 Water Pump Seals . . . . . . . . . . . . . . . . . . . . 6A-21 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-23 Drive Shaft Upper Bearing . . . . . . . . . . . . . 6A-23 Pinion Gear Bearing . . . . . . . . . . . . . . . . . . 6A-24 Pinion Gear . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-24 Forward Gear . . . . . . . . . . . . . . . . . . . . . . . . 6A-24 Specifications Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-27 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-49 Filling Gear Housing with Lubricant . . . . . 6A-50 6 A 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 (Warm Engine) @ 800 rpm @ 6000 rpm (WOT) Leak Test Pressure 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) 10-12 psi (68-83 kPa) for 5 Minutes 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 NON-BIGFOOT GEAR HOUSING 6. Universal Puller Plate 91-37241 7. Driver Head 91-37312 8. Driver 91-817011 9. Driver Rod 91-37323 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 NON-BIGFOOT GEAR HOUSING 16. Driver 91-826872 17. Leakage Tester FT8950 90-857046R1 NOVEMBER 2001 Page 6A-5 NON-BIGFOOT GEAR HOUSING Gear Housing (Driveshaft)(2:1 Gear Ratio) 7 74 87 92 95 Loctite “271” Loctite “405” (Purchase Locally) Premium Gear Lubricant Loctite Primer “7649” 2-4-C Marine Lubricant with Teflon 23 24 22 87 95 7 95 28 25 14 27 7 29 12 13 95 95 30 95 15 95 31 2621 32 33 16 235 17 34 18 36 95 3 20 37 38 19 1 11 3.44 IN./135MM TORPEDO DIA. 9 10 4 5 8 6 7 Page 6A-6 90-857046R1 NOVEMBER 2001 87 92 7 NON-BIGFOOT GEAR HOUSING Gear Housing (Driveshaft)(2:1 Gear Ratio) REF 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 7 5 1 WASHER-Sealing 6 1 DRAIN SCREW 60 7 7 1 WASHER-Sealing 8 1 NUT 50 68 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 7 13 1 WATER PUMP ASSEMBLY 1414 1 SEAL-Water Tube (SHORT - 1-3/4) 1 SEAL-Water Tube (LONG - 2-1/4) 15 1 WASHER 16 1 KEY 17 1 WASHER 18 1 GASKET 19 1 GASKET (LOWER) 20 1 BASE 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 34 3434 1 SHIFT SHAFT (SHORT) 1 SHIFT SHAFT (LONG) 35 1 WASHER 36 1 ROLL PIN 37 1 CAM-Shift 38 1 PIN 90-857046R1 NOVEMBER 2001 Page 6A-7 NON-BIGFOOT GEAR HOUSING Gear Housing (Propeller Shaft)(2:1 Gear Ratio) 3.44 IN./135MM TORPEDO DIA. 42 1 95 95 87 95 87 7 95 87 87 3940 41 43 44 45 46 47 48 49 50 51 52 5354 55 56 57 58 59 60 61 62 63 6465 66 67 68 69 70 71 72 73 39 Loctite “271” 7 95 87 Premium Gear Lubricant 2-4-C Marine Lubricant with Teflon Page 6A-8 90-857046R1 NOVEMBER 2001 NON-BIGFOOT GEAR HOUSING Gear Housing (Propeller Shaft)(2:1 Gear Ratio) REF 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) 16 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) 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 72 4 WASHER REPLACEMENT 73 1 PLUG 90-857046R1 NOVEMBER 2001 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 Premium Gear Lubricant. DO NOT lubricate tapered bearing cups until after inspection. Inspect all bearings for roughness, catches and bearing race side wear. Work inner bearing race in-and-out, while holding outer race, to check for side wear. When inspecting tapered bearings, determine condition of rollers and inner bearing race by inspecting bearing cup for pitting, scoring, grooves, uneven wear, imbedded particles and/or discoloration from over-heating. Always replace tapered bearing and race as a set. Inspect gear housing for bearing races that have spun in their respective bores. If race(s) have spun, gear housing must be replaced. Roller bearing condition is determined by inspecting the surface of the shaft that the roller bearing supports. Check shaft surface for pitting scoring, grooving, imbedded particles, uneven wear and/or discoloration from overheating. The shaft and bearing must be replaced if such a condition exists. Seals As a normal procedure, all O-rings and oil seals should be replaced without regard to appearance. To prevent leakage around seals, apply Loctite 271 to outer diameter of all metal case seals. When using Loctite on seals or threads, surfaces must be clean and dry. Apply 2-4-C Marine Lubricant with Teflon on all O-rings and on I.D. of oil seals. Apply 2-4-C Marine Lubricant with Teflon to external surfaces of bearing carrier. Page 6A-10 90-857046R1 NOVEMBER 2001 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). Drain lube into a clean pan/container. Presence of fine metal particles (resembling powder) in the gear lube indicates normal wear. The presence of metal chips in the gear lube indicates the need for gear housing disassembly and component inspection. 3. Note color of gear lubricant. White or cream color MAY indicate presence of water in lubricant. Gear lubricant which has been drained from a gear case recently in operation will have a yellowish color due to lubricant agitation/aeration. Gear lube which is mixed with assembly lubricant (Special Lube 101 or 2-4-C with Teflon) will also be creamy white in color. This is normal and should not be confused with the presence of water. If water is suspected to be present in gearcase, a pressure check of gearcase should be made (with no lubricant in gearcase). Gearcase should hold 10 to 12 psi of pressure for 5 minutes without leaking down. Pouring a portion of the gear lubricant into a glass jar and allowing the lubricant to settle will allow any water in the lube to separate and settle to the bottom of the jar. 4. Presence of water in gear lubricant indicates the need for disassembly and inspection of oil seals, seal surfaces, O-rings, water pump gaskets as well as gear housing components for damage. If gearcase is rebuilt, gearcase should be pressure checked before filling with lubricant. 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 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 screw and washer. 52835 a b a-Screw and Washer b-Scribe Line 90-857046R1 NOVEMBER 2001 Page 6A-13 NON-BIGFOOT GEAR HOUSING 6. Remove nut and washer in trim tab cavity. 52835 a a-Nut and Washer 7. Remove mounting screws securing gear case to drive shaft housing. 52836 a a-Screw (4) Page 6A-14 90-857046R1 NOVEMBER 2001 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. 1. Remove screws securing pump cover. 52830 a b a-Water Tube Seal b-Screw (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. 90-857046R1 NOVEMBER 2001 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 4. 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. Page 6A-16 90-857046R1 NOVEMBER 2001 NON-BIGFOOT GEAR HOUSING 5. Remove and/or replace exhaust deflector plate if damaged. 52832 a a-Deflector Plate Bearing Carrier and Propeller Shaft 1. Remove bearing carrier attaching bolts and locking tab washers or flat washers. Discard tab washers. b a a-Screw (2), Tab Washer (2) or Flat Washer (2) b-Tab Washer (2) Style 2 2. Using Puller (91-27780), remove carrier assembly from gear case. 52829 91-27780 a a-Puller (91-27780) 90-857046R1 NOVEMBER 2001 Page 6A-17 NON-BIGFOOT GEAR HOUSING NOTE: When removing propeller shaft assembly, cam follower may dislodge. Retrieve follower from gear housing. 3. 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 Pinion Gear, Drive Shaft, and Forward Gear 1. Remove pinion nut. 52864 51043 b c a a-Drive Shaft Holding Tool b-Pinion Nut c-Pinion Gear Page 6A-18 90-857046R1 NOVEMBER 2001 NON-BIGFOOT GEAR HOUSING 2. Remove drive shaft assembly and pinion gear. 3. Remove forward gear. 52870 a a-Forward Gear 4. Remove shift shaft assembly. 52841 a a-Shift Shaft Assembly 90-857046R1 NOVEMBER 2001 Page 6A-19 NON-BIGFOOT GEAR HOUSING 5. 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) 6.Remove forward bearing race with puller (91-27780). 91-13779 91-825200A1 53838 91-27780 b a a-Raceb-Puller (91-27780) Page 6A-20 90-857046R1 NOVEMBER 2001 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. a b c d 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 ab Loctite “271”7 7 a-Seal (Metal Cased) Lip Facing Down b-Mandrel (91-825197) 90-857046R1 NOVEMBER 2001 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) 4. Install a new o-ring on the carrier. Apply a light coat of 2-4-C Marine Lubricant with Teflon to the new o-ring. Apply a liberal amount of grease on the new seal lips. 52825 a b 95 95 2-4-C Marine Lubricant with Teflon a-O-ring b-Seals Page 6A-22 90-857046R1 NOVEMBER 2001 NON-BIGFOOT GEAR HOUSING Inspection Drive Shaft Upper 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) 90-857046R1 NOVEMBER 2001 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), and signs of teeth breaking. 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 90-857046R1 NOVEMBER 2001 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. Apply gear lubricant to bearing before pressing into gear. 52847 91-826872 a b Premium Gear Lubricant 87 87 a-Driver (91-826872) b-Bearing 90-857046R1 NOVEMBER 2001 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. 91-37241 b a REMOVAL a-Universal Puller Plate (91-37241) b-Mandrel (15/16 in. socket) 9. Replace bearing and race as a set. Use suitable mandrel to press bearing onto gear. PRESS ONLY ON INNER RACE when installing bearing. a INSTALLATION a-Mandrel (1-1/8 in. socket) Page 6A-26 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 Page 6A-27 NON-BIGFOOT GEAR HOUSING Propeller Shaft Disassembly 1. Remove propeller shaft from carrier and disassemble shaft. c e a b f d 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 a b a-Reverse Gear and Bearing b-Puller (91-27780) 52840 Page 6A-28 90-857046R1 NOVEMBER 2001 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 have sharp edges) 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 90-857046R1 NOVEMBER 2001 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). REMOVAL 91-37312 91-37241 d a b c a-Bearing b-Reverse Gear c-Universal Puller Plate (91-37241) d-Driver (91-37312) 4. Apply gear lubricant to I.D. of bearing. Install new bearing using a suitable mandrel. PRESS ONLY ON INNER RACE when installing bearing. a b INSTALLATION 52867 87 87 Premium Gear Lubricant a-Mandrel (1-1/4 in. socket) b-Bearing Page 6A-30 90-857046R1 NOVEMBER 2001 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. 51264 91-37312 91-37323 c b d a a-Driver Rod (91-37323) b-Driver (91-37312) c-Needle Bearing d-Seals 4. Apply gear lubricant to O.D. of bearing. 5. Install bearing using Mandrel 91-817011. 6. Press bearing into carrier until mandrel bottoms on carrier. 87 91-817011 a b 52861 87 Premium Gear Lubricant a-Bearing b-Mandrel (91-817011) 90-857046R1 NOVEMBER 2001 Page 6A-31 NON-BIGFOOT GEAR HOUSING 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. 52862Loctite “271” 91-817007 b a 7 7 a-Seal b-Mandrel (91-817007) Page 6A-32 90-857046R1 NOVEMBER 2001 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. 7 91-817007 ab 52863 Loctite “271” 7 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) 90-857046R1 NOVEMBER 2001 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 Marine Lubricant with 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. 95 b c a 2-4-C Marine Lubricant with Teflon 95 a-O-ring b-Mandrel (3/4 in. Socket) c-Reverse Gear Assembly 52827 Page 6A-34 90-857046R1 NOVEMBER 2001 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 Marine Lubricant with Teflon to new O-rings and install O-rings on shift shaft and carrier. 2. Install carrier on shift shaft. IMPORTANT: When installing shift shaft assembly into gear housing, DO NOT BOTTOM OUT SHAFT IN HOUSING. Pull up on shift shaft until shift boot is not deformed. If shaft is bottomed out, cross pin in clutch dog will be bent by cam follower when tightening carrier 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 e d b c a 2-4-C Marine Lubricant with Teflon 95 95 a-O-rings b-Carrier c-Boot d-Sta-strap e-Ramp 90-857046R1 NOVEMBER 2001 Page 6A-35 NON-BIGFOOT GEAR HOUSING Pinion Bearing Race 1. Apply Premium Gear Lubricant to O.D. of race. 2. Position race in gear housing (NUMBERS UP - TAPERED SIDE FACING DOWN). 3. Draw race up into housing until seated. 52842 91-29310 12-34961 91-825198 91-31229 11-24156 31-85560 91-825199 b e g d a f c Premium Gear Lubricant87 87 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 90-857046R1 NOVEMBER 2001 NON-BIGFOOT GEAR HOUSING Forward Gear 1. Apply Premium Gear Lubricant to O.D. of race. Install forward gear bearing race into housing using Mandrel 91-36571 and propeller shaft. Use a lead hammer on prop shaft to prevent damage to threads. Bearing carrier should be installed to keep prop shaft centered while seating race. 52843 91-36571 b a 87 Premium Gear Lubricant87 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 90-857046R1 NOVEMBER 2001 Page 6A-37 NON-BIGFOOT GEAR HOUSING Pinion Gear/Drive Shaft Assembly 1. Clean drive shaft and pinion nut threads with Loctite Primer or suitable degreaser. 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 recessed shoulder toward the pinion gear. 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 Loctite “271” a c 7 d b a-Pinion Nut [Torque to 50 lb-ft. (67.8 Nm)] b-Pinion Gear c-Pinion Bearing d-Drive Shaft Holding Tool 52864 Page 6A-38 90-857046R1 NOVEMBER 2001 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. Install spring. DO NOT allow spring coils to overlap each other. a a-Spring 90-857046R1 NOVEMBER 2001 Page 6A-39 NON-BIGFOOT GEAR HOUSING NOTE: Apply 2-4-C Marine Lubricant with Teflon to cam follower before installation into the propshaft. This will prevent the cam follower from falling out during installation of the prop- shaft assembly into the gearcase. 6. Install cam follower. 95 a 52826 95 2-4-C Marine Lubricant with Teflon a-Cam Follower 7. Install propeller shaft assembly into gear case. a a-Propeller Shaft Assembly 52864 Page 6A-40 90-857046R1 NOVEMBER 2001 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 screws on models listed. Install thicker flat washers and longer screws. 25 (2 Cylinder - 4 Stroke) USA 0G621670 and below 45/50 (4 Cylinder - 4 Stroke) Non Big Foot USA 0G621709 and below 30/40 (2 Cylinder - 2 Stroke) USA 0G650736 and below Belgium NA 40/50 (3 Cylinder - 2 Stroke) USA 0G650699 and below Belgium NA Force 40/50 (2 Cylinder - 2 Stroke) USA 0E323508 and below a cb a-Screw 25 mm Long - Discard b-Tab Washer - Discard c-Thin Flat Washer 0.063 in. (1.60 mm) thick - Discard 3. Install thicker flat washers and longer screws. a b a-Screw (10-855940-30) 1.18 in. (30 mm) Long b-Washer (12-855941) 0.090 in. (2.29 mm) Thick 90-857046R1 NOVEMBER 2001 Page 6A-41 NON-BIGFOOT GEAR HOUSING 4. Tighten screws to specified torque. a7 Loctite “271” 7 a-Screw (2) Bearing Carrier Screw Torque 19 lb-ft. (25.5 Nm) Water Pump 1. Apply 2-4-C Marine Lubricant with Teflon to seal carrier O-ring and seal lips. Install seal carrier. 2. Install exhaust deflector plate (if removed). 52832 b a 95 2-4-C Marine Lubricant with Teflon 95 a-Seal Carrier b-Exhaust Deflector Page 6A-42 90-857046R1 NOVEMBER 2001 NON-BIGFOOT GEAR HOUSING 3. Install base gasket, base 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 the old impeller is re-used it must be installed in original (clockwise) direction of rotation. 4. Install impeller and nylon washer. 52869 a b a-Impeller b-Nylon Washer 90-857046R1 NOVEMBER 2001 Page 6A-43 NON-BIGFOOT GEAR HOUSING 5. Lubricate I.D. of impeller housing with 2-4-C Marine Lubricant with Teflon. 6. Rotate drive shaft clockwise while pushing impeller housing cover down over impeller. 7. Apply Loctite 271 to bottom threads of screws. Install screws and tighten to specified torque. 7b a 7 Loctite “271” 95 2-4-C Marine Lubricant with Teflon a-Cover b-Screw (4) Bearing Carrier Screw Torque 60 lb-in. (7.0 Nm) 52830 Page 6A-44 90-857046R1 NOVEMBER 2001 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. 90-857046R1 NOVEMBER 2001 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. CAUTION Do not lubricate top of driveshaft. Excess lubricant will not allow driveshaft to fully engage crankshaft. Tightening the gear housing fasteners (if excess lubricant is on top of driveshaft) will load the driveshaft/crankshaft and may damage either or both powerhead and gear housing. Wipe the top of driveshaft free of lubricant. 4. Lightly apply 2-4-C Marine Lubricant with Teflon onto the driveshaft splines. 5. 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. 6. Install 4 screws and washers, (two each side). Tighten screws to specified torque. a-Screw and Washers (2 each side) 52836 a Gear Housing Screw Torque 40 lb-ft (54 Nm) Page 6A-46 90-857046R1 NOVEMBER 2001 NON-BIGFOOT GEAR HOUSING 2-Stroke Models MERCURY/MARINER 30/40, AND 40/50, FORCE 40/50 7. 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 8. Connect shift shaft by sliding retainer to the right and snapping into upper “locked” position. 53859 a b a-Retainer b-Clip 90-857046R1 NOVEMBER 2001 Page 6A-47 NON-BIGFOOT GEAR HOUSING 9. Install locknut and washer. Torque nut to specified torque. 52833 a a-Locknut and Washer Nut Torque 40 lb-ft (54 Nm) 10. Check shift operation. a. In NEUTRAL, propeller shaft should turn freely in either direction. b. In FORWARD, propeller shaft SHOULD NOT TURN COUNTERCLOCKWISE. c. In REVERSE, propeller shaft SHOULD NOT TURN IN EITHER DIRECTION. IMPORTANT: If shift operation is not as described, remove the gear housing and correct the shift operation. Page 6A-48 90-857046R1 NOVEMBER 2001 NON-BIGFOOT GEAR HOUSING 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. TRIM TAB REPLACEMENT Replace trim tab if damaged or 50% (or more) is corroded. Mark location of old trim tab on anti-ventilation plate before removal; install new trim tab in same location. TRIM TAB ADJUSTMENT NOTE:The trim tab provides a means to offset (balance) some of the steering load that is caused by propeller torque at higher operating speeds. NOTE:Loosen trim tab screw sufficiently to allow trim tab to disengage from locking ridges in gear case before attempting to move tab. DO NOT strike trim tab with a hard object to make adjustments. 1. Shift engine control into NEUTRAL and turn ignition key to OFF position. 2. If at higher speeds the boat turns more easily to the left, loosen screw, move the trim tab (trailing edge) to the left (when viewed from behind). Tighten retaining screw to specified torque. 3. If the boat turns more easily to the right, loosen screw, move the trim tab (trailing edge) to the right (when viewed from behind) turn trim tab (trailing edge) to the right . Tighten retaining screw to specified torque. 52835 a b c a-Trim Tab b-Anti-Ventilation Plate c-Trim Tab Screw and Washer Trim Tab Screw Torque 16 lb-ft (21.0 Nm) 90-857046R1 NOVEMBER 2001 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 Premium Gear Lube. 1. Remove any gasket material from “Fill” and “Vent” plugs and gear housing. Install new gaskets on “Fill” and “Vent” plugs. IMPORTANT: Never add lubricant without removing “Vent” plug. Gear housing cannot be filled because of trapped air. Fill gear housing when driveshaft is in a vertical position. 2. Remove “Fill” plug and gasket. 3. Insert lubricant tube in “Fill” hole, then remove “Vent” plug and gasket. 4. Fill until excess lubricant flows out of “Vent” hole. 5. Replace this “Vent” plug and gasket. 6. Install “Fill” plug and gasket. a a-“Vent” Plug 7. Tighten “Fill” and “Vent” screws to specified torque. Fill and Vent Screw Torque 55 lb. in. (6.0 N·m) Page 6A-50 90-857046R1 NOVEMBER 2001 BIGFOOT GEAR HOUSING LOWER UNIT Section 6B - Bigfoot Gear Housing Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-2 Gear Housing (Drive Shaft - 2.31:1) . . . . . . . 6B-6 Gear Housing (Prop Shaft - 2.31:1) . . . . . . . . 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 Reassembly/Installation . . . . . . . . . . . . . . . . . . 6B-30 Specifications Forward Gear Bearing Race . . . . . . . . . . . 6B-30 Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-30 Bearing Carrier. . . . . . . . . . . . . . . . . . . . . . . 6B-33 Forward Gear. . . . . . . . . . . . . . . . . . . . . . . . 6B-37 Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . 6B-39 Drive Shaft Wear Sleeve . . . . . . . . . . . . . . 6B-40 Drive Shaft Lower Bearing Race . . . . . . . . 6B-42 Oil Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-43 Drive Shaft Upper Bearing. . . . . . . . . . . . . 6B-43 Forward Gear, Drive Shaft Lower Bearing Pinion Gear, and Drive Shaft . . . . . . . . . . . 6B-45 Pinion Gear Depth and Forward Gear Backlash . . . . . . . . . . . . . . . 6B-46 Bearing Carrier and Propeller Shaft . . . . . 6B-51 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . 6B-53 Gear Housing Pressure Test . . . . . . . . . . . 6B-57 Filling Gear Housing With Lubricant . . . . . . . 6B-58 Gearcase Installation . . . . . . . . . . . . . . . . . . . . 6B-59 Trim Tab Adjustment and Replacement . . 6B-64 6 B GEAR HOUSING BIGFOOT (2.31:1) 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 @ 6000 rpm (WOT) Leak Test Pressure 2.31:1 24.0 fl oz (710 mL) Premium Blend Gear Lube 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 2-6 psi (14-41 kPa) 12-25 psi (83-172 kPa) 10-12 psi (69-83 kPa) for 5 Minutes 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 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) 90-857046R1 NOVEMBER 2001 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), (91-56775, 40/50 4-Stroke, 747cc/935cc), (91-877840A1, 40/50/60 4-Stroke, 995cc), (91-804776A1, 75/90 4-Stroke) 20. Dial Indicator (91-58222A1) Page 6B-4 90-857046R1 NOVEMBER 2001 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 26. Bearing Installation Tool (91-877321A1) * From Bearing Removal and Installation Kit (91-31229A7) 90-857046R1 NOVEMBER 2001 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. BIGFOOT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 12 5 5 4 18 4 7 95 95 95 7 Loctite 271 87 Premium Gear Lubricant 95 2-4-C Marine Lubricant with Teflon Page 6B-6 90-857046R1 NOVEMBER 2001 BIGFOOT GEAR HOUSING GEAR HOUSING (DRIVE SHAFT)(2.31:1 GEAR RATIO) REF 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 3 DRAIN SCREW 60 7 5 3 WASHER-Sealing 6 1 DOWEL PIN (REAR) 7 1 TRIM TAB 8 1 SCREW (.437-14 x 1.25) 22 30 9 1 WASHER 10 1 CARRIER 11 1 NEEDLE BEARING 12 2 ANODE 13 1 NUT 14 1 SCREW (M6 x 40) 60 7 15 1 PINION GEAR (13 TEETH) 16 1 NUT 70 95 17 1 SHIFT CAM 18 1 TAPERED ROLLER BEARING 19 AR SHIM ASSEMBLY (SIZES 006 THRU 048) 20 1 DRIVE SHAFT ASSEMBLY 21 1 WEAR SLEEVE ASSEMBLY 22 1 RING SEAL 23 1 COVER ASSEMBLY 24 1 GASKET 25 1 GASKET 26 1 OIL SEAL (LOWER) 27 1 OIL SEAL (UPPER) 28 1 GASKET 29 1 WATER PUMP ASSEMBLY 30 1 FACE PLATE 31 4 SCREW (M6x30) 60 7 32 1 SEAL 33 1 KEY 34 1 IMPELLER 35 6 SCREW 60 7 36 1 SHIFT SHAFT ASSEMBLY 37 1 E-RING 38 1 BUSHING ASSEMBLY 39 1 O-RING 40 1 OIL SEAL 41 2 SCREW (M6 x 1) 60 7 90-857046R1 NOVEMBER 2001 Page 6B-7 BIGFOOT GEAR HOUSING GEAR HOUSING (PROP SHAFT)(2.31:1 GEAR RATIO) 4.25 IN./107.95MM TORPEDO DIA. BIGFOOT50 4947 48 70 44 691 45 46 42 43 67 68 68 75 74 57 55 54 53 52 51 72 73 71 60 59 58 66 64 65 56 61 63 95 95 87 95 7 95 77 95 95 95 87 62 7 87 95 Loctite 271 Premium Gear Lubricant 2-4-C Marine Lubricant with Teflon Page 6B-8 90-857046R1 NOVEMBER 2001 BIGFOOT GEAR HOUSING GEAR HOUSING (PROP SHAFT)(2.31:1 GEAR RATIO) REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in lb-ft Nm. 1 1 GEAR HOUSING ASSEMBLY 42 1 TAPERED ROLLER BEARING ASSEMBLY 43 1 CUP 44 1 FORWARD GEAR (30 TEETH) 45 1 ROLLER BEARING 46 1 RETAINING RING 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 22 30 67 AR SHIM ASSEMBLY (SIZES 006 THRU 038) 68 2 THREAD INSERT 69 1 DECAL 70 1 DECAL-PROP OPERATION 71 1 THRUST HUB ASSEMBLY PROPELLER NUT ASSEMBLY SERVICE ITEMS TAB WASHER 72 1 73 1 74 4 SCREW 40 54 75 4 WASHER 90-857046R1 NOVEMBER 2001 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. When compressed air is used to dry a part, verify that no water is present in air line. Bearings All bearings must be cleaned and inspected. Clean bearings with solvent and dry with compressed air. Air should be directed at the bearing so that it passes through the bearing. DO NOT spin bearing with compressed air, as this may cause bearing to score from lack of lubrication. After cleaning, lubricate bearings with Premium Gear Lubricant. DO NOT lubricate tapered bearing cups until after inspection. Inspect ball bearings for roughness, catches and bearing race side wear. Work inner bearing race in-and-out, while holding outer race, to check for side wear. When inspecting tapered bearings, determine condition of rollers and inner bearing race by inspecting bearing cup for pitting, scoring, grooves, uneven wear, imbedded particles and/or discoloration from over-heating. Always replace tapered bearing and race as a set. Inspect gear housing for bearing races that have spun in their respective bores. If race(s) have spun, gear housing must be replaced. Roller bearing condition is determined by inspecting the surface of the shaft that the roller bearing supports. Check shaft surface for pitting, scoring, grooving, imbedded particles, uneven wear and/or discoloration from overheating. The shaft and bearing must be replaced if such a condition exists. Seals As a normal procedure, all O-rings and oil seals should be replaced without regard to appearance. To prevent leakage around seals, apply Loctite 271 to outer diameter of all metal case seals. When using Loctite on seals or threads, surfaces must be clean and dry. Apply 2-4-C Marine Lubricant with Teflon on all O-rings and on I.D. of oil seals. Apply 2-4-C Marine Lubricant with Teflon to external surfaces of bearing carrier. Page 6B-10 90-857046R1 NOVEMBER 2001 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 c b a-Fill/Drain Screw b-Oil Level Screw c-Vent Screw 2. Inspect gear lubricant for metal particles (lubricant will have a “metal flake” appearance). Drain lube into a clean pan/container. Presence of fine metal particles (resembling powder) in the gear lube indicates normal wear. The presence of metal chips in the gear lube indicates the need for gear housing disassembly and component inspection. 3. Note color of gear lubricant. White or cream color MAY indicate presence of water in lubricant. Gear lubricant which has been drained from a gear case recently in operation will have a yellowish color due to lubricant agitation/aeration. Gear lube which is mixed with assembly lubricant (Special Lube 101 or 2-4-C with Teflon) will also be creamy white in color. This is normal and should not be confused with the presence of water. If water is suspected to be present in gearcase, a pressure check of gearcase should be made (with no lubricant in gearcase). Gearcase should hold 10 to 12 psi of pressure for 5 minutes without leaking down. Pouring a portion of the gear lubricant into a glass jar and allowing the lubricant to settle will allow any water in the lube to separate and settle to the bottom of the jar. 4. Presence of water in gear lubricant indicates the need for disassembly and inspection of oil seals, seal surfaces, O-rings, water pump gaskets as well as gear housing components for damage. If gearcase is rebuilt, gearcase should be pressure checked before filling with lubricant. 90-857046R1 NOVEMBER 2001 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. IMPORTANT: 90 hp (4-Stroke) models, when removing or installing gearcase carefully guide driveshaft through drive shaft bushing to avoid scoring bushing surface. 1. Remove (and isolate) spark plug leads from spark plugs. 2. Shift engine into forward gear. 3. Tilt engine to full “Up” position. 4. Remove 4 fasteners. 5. Remove locknut and washer. 6. Remove gear housing. 53992 b a a-Fasteners (2 Each Side) b-Locknut and Washer Page 6B-12 90-857046R1 NOVEMBER 2001 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. NOTE:Newer models will not have the isolators installed on the water pump. 1. Replace water tube seal, if damaged. 2. Remove 4 screws (2 on each side of water pump housing), washers, and isolators. 3. Remove cover. 19212 a b c a-Water Tube Seal b-Screw, Washer, Isolator (4 each) c-Cover IMPORTANT: The circular groove formed by the impeller sealing bead should be disregarded when inspecting cover and face plate, 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 90-857046R1 NOVEMBER 2001 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 face plate and gasket. 8. Replace face 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-Face Plate b-Gasket c-Impeller Sealing Groove 9. Remove screws and washers. a 19217 a-Screws and Washers (6 each) Page 6B-14 90-857046R1 NOVEMBER 2001 BIGFOOT GEAR HOUSING 10. Remove water pump base using flat screwdrivers to lightly pry up on base. 19226 a a-Water Pump Base 11. Remove (and discard) seals (IT MAY BE BENEFICIAL TO CLAMP THE WATER PUMP BASE IN A VISE WHILE REMOVING SEALS). 19195 a a-Seals 12. Remove gasket. 19218 a a-Gasket 90-857046R1 NOVEMBER 2001 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 (using tool shown) to break seal with gear housing. 3. Remove bearing carrier/propeller shaft components as an assembly by pulling back on the propshaft. Take care not to lose cam follower or 3 metal balls in end of propeller shaft. 4. Remove propeller shaft from bearing carrier. a b c d e a-Bearing Carrier b-Puller Jaws (91-46086A1) c-Puller Bolt (91-85716) d-Thrust Hub e-Propeller Shaft 51116 Page 6B-16 90-857046R1 NOVEMBER 2001 BIGFOOT GEAR HOUSING 5. Lift reverse gear, thrust bearing and thrust washer from bearing carrier. Replace thrust bearing and thrust washer if rusted or damaged. 6. Replace reverse gear if gear teeth or clutch teeth on reverse gear are rounded or chipped. If reverse gear must be replaced, pinion gear and sliding clutch should be inspected for damage. 19202 a b c a-Reverse Gear b-Thrust Bearing c-Thrust Washer 7. If reverse gear radial bearing is rusted or does not roll freely, replace bearing. If the bearing needs to be replaced remove it using Slide Hammer (91-34569A1). 91-34569A1 a 19205 a-Radial Bearing 90-857046R1 NOVEMBER 2001 Page 6B-17 BIGFOOT GEAR HOUSING 8. If propshaft roller bearing is rusted or does not roll freely, replace bearing. If replacement is necessary, remove bearing and oil seals using Mandrel* (91-36569) and Driver Rod* (91-37323). Discard oil seals. NOTE:*From Bearing Removal and Installation Kit (91-31229A7). a b c 91-37323 91-36569 58205 a-Propshaft Roller Bearing b-Mandrel (91-36569) c-Driver Rod (91-37323) 9. Remove propeller shaft seals (if not removed with bearing) and bearing carrier O-ring. 51263 a a-O-ring Page 6B-18 90-857046R1 NOVEMBER 2001 BIGFOOT GEAR HOUSING 10. Remove spring. 51876 a a-Spring 11. Apply constant pressure to cam follower in order to prevent it and internal components from ejecting out of the propeller shaft during removal of the cross pin from the clutch. 51800 a b a-Cross Pin b-Cam Follower 90-857046R1 NOVEMBER 2001 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 de f a-Cam Follower b-Metal Balls (3) c-Guide Block d-Spring e-Sliding Clutch f-Jaws 15. Replace propeller shaft if any of the following exist: • Splines are twisted or worn. • Bearing surfaces of propeller shaft are pitted or worn. • Oil seal surface is grooved. • Shaft has a noticeable “wobble” or is bent more than 0.009 in. (0.228 mm). Prop shaft trueness should be measured with a dial indicator with prop shaft on V-blocks. a bc b 51877 a-V-Blocks b-Bearing Surfaces c-Measure with Dial Indicator at This Point Page 6B-20 90-857046R1 NOVEMBER 2001 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 40/50 Bigfoot (4-Stroke, 747cc/935cc) 91-56775 40/50/60 Bigfoot (4-Stroke, 995cc) 91-877840A1 75/90/115 EFI (4-Stroke) 91-804776A1 60 Bigfoot (2-Stroke) 91-56775 75/90/100/115/125 (2-Stroke) 91-56775 2. Remove drive shaft, pinion gear, pinion bearing and forward gear. 3. Replace pinion gear if it is chipped or worn. 4. Replace pinion bearing and race if either are rusted, pitted or damaged; or if bearing does not roll freely. To remove race, refer to “Lower Drive Shaft Bearing Race,” following. 5. Replace forward gear if gear teeth or clutch teeth are chipped or worn. 19175 a b c d e f a-Drive Shaft Holding Tool b-Pinion Nut c-Drive Shaft d-Pinion Gear e-Pinion Bearing f-Forward Gear 90-857046R1 NOVEMBER 2001 Page 6B-21 BIGFOOT GEAR HOUSING Page 6B-22 90-857046R1 NOVEMBER 2001 6. Replace forward gear needle bearing if it is rusted or does not roll freely. 7. Use suitable tools (screwdriver and awl) to remove retaining ring. Use a punch and hammer to remove bearing. 57905 19203 a b a - Retaining Ring b - Forward Gear Needle Bearing 8. Replace forward gear bearing and race if either are rusted, pitted or damaged, or if bearing does not roll freely. Remove bearing from gear using Universal Puller Plate (91-37241) and mandrel. To remove race, refer to “Forward Gear Bearing Race,” following. 51119 a b c 91-37241 a - Forward Gear Bearing b - Universal Puller Plate (91-37241) c - Mandrel BIGFOOT GEAR HOUSING 9. Replace drive shaft if splines are worn or twisted. 10. If bearing surface is damaged, replace drive shaft and corresponding bearing. IMPORTANT: Do not tighten vise against drive shaft. 11. If wear sleeve is deeply grooved allowing water to enter gear case, remove (and discard) sleeve using Universal Puller Plate (91-37241) and mallet. 19710 c f a 91-37241 e a b 75/90/115 4-stroke d a-Crankshaft/Driveshaft Splines b-Oil Pump Drive Splines 75/90 4-Stroke Only c-Bearing Surface d-Wear Sleeve e-Universal Puller Plate (91-37241) f-Mallet 12. Remove (and discard) rubber ring. 19152 a a-Rubber Ring 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 BIGFOOT GEAR HOUSING Oil Sleeve 1. Remove oil sleeve (if necessary) using Puller Assembly (91-83165M) with suitable jaws. 19222 a 91-83165M b a-Oil Sleeve b-Puller Assembly (91-83165M) 90-857046R1 NOVEMBER 2001 Page 6B-25 BIGFOOT GEAR HOUSING Lower Drive Shaft Bearing Race IMPORTANT: Upper drive shaft bearing/sleeve and oil sleeve do not have to be removed for lower drive shaft bearing race removal. IMPORTANT: Retain shim(s) for reassembly. 1. Remove bearing race and shim(s) using bearing race tool (91-14308A1). 19171 a b c 91-14308A1 a-Bearing Race b-Shim(s) c-Bearing Race Tool (91-14308A1) Page 6B-26 90-857046R1 NOVEMBER 2001 BIGFOOT GEAR HOUSING Shift Shaft 1. Remove shift shaft coupler and nylon spacer. 75 (2-Stroke) Tiller Model Shown 53925 a b a-Shift Shaft Coupler b-Spacer 2. Remove shift shaft bushing screws. 53926 a a-Screw (2) M6 x 1 NOTE:Remove rough edges from shift shaft splines before removing shift shaft bushing. 3. Remove shift shaft bushing and shift shaft. 53927 a b a-Bushing b-Shift Shaft 90-857046R1 NOVEMBER 2001 Page 6B-27 BIGFOOT GEAR HOUSING 4. Remove shift cam from housing. 5. Replace shift cam if worn. 60 (2-Stroke) Bigfoot Shown 51117 a a-Shift Cam 6. Remove shift shaft bushing and clip from shift shaft. 7. Replace shift shaft if splines are worn or shaft is twisted. 8. Remove (and discard) O-ring. 53928 a b c ded a-Bushing b-Clip c-Shift Shaft d-Splines e-O-ring 9. Remove (and discard) seal. (Lightly clamp the bushing in a vise when removing seal.) 53929 a a-Seal Page 6B-28 90-857046R1 NOVEMBER 2001 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 91-34569A1 c a-Race b-Shim(s) c-Slide Hammer (91-34569A1) 90-857046R1 NOVEMBER 2001 Page 6B-29 BIGFOOT GEAR HOUSING Reassembly Forward Gear Bearing Race NOTE:Propshaft should be vertical when installing bearing race. 1. Place shim(s) (retained from disassembly) into housing. If shim(s) were lost, or a new gear housing is being assembled, start with 0.010 in. (0.254 mm) shim(s). 2. Assemble components as shown using mandrel (91-31106). Apply 2-4-C Marine Lubricant with Teflon to O.D. of race. Drive race into housing by striking propeller shaft end with lead hammer. NOTE:Install a nut on the end of the propshaft to prevent damage to the propshaft threads while performing step 2. 19179 b de a c 91-31106 95 2-4-C Marine Lubricant with Teflon 95 a-Shim(s) d-Disassembled Propeller Shaft b-Race e-Assembled Bearing Carrier c-Mandrel (91-31106) 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 Marine Lubricant with Teflon on O-ring and I.D. of seal. 53930b 7 Loctite “271” 7 95 95 a c 2-4-C Marine Lubricant with Teflon a-Seal b-Bushing c-O-ring Page 6B-30 90-857046R1 NOVEMBER 2001 BIGFOOT GEAR HOUSING 90-857046R1 NOVEMBER 2001 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 shift shaft pilot bore in gear housing. 60 Bigfoot, 75/90/100/115/125 (2-Stroke) 51117 a b a - Shift Cam (marked with “UP” and part number) b - Shift Shaft Pilot Bore 60 Bigfoot, 75/90/100/115/125 (2-Stroke) & 75/90/115EFI (4-Stroke) 51117 a b a - Shift Cam (marked with part number only) b - Shift Shaft Pilot Bore BIGFOOT GEAR HOUSING 40/50 Bigfoot (4-Stroke,747cc/935cc), 40/50/60 Bigfoot (4-Stroke, 995cc) 51117 850307 a b a-Shift Cam (Numbers Down) b-Shift Shaft Pilot Bore 7. Install shift shaft assembly. Insert splines into shift cam. 53932 a b a-Shift Shaft Assembly b-Splines 8. Apply Loctite 271 to bottom half of threads on each screw. Install screws and tighten to specified torque. 53926 a 7 7 Loctite “271” a-Screw (2) Screw Torque 60 lb-in. (7.0 Nm) Page 6B-32 90-857046R1 NOVEMBER 2001 BIGFOOT GEAR HOUSING Bearing Carrier Reassembly 1. Lubricate O.D. of bearing and bearing carrier bore with 2-4-C Marine Lubricant with Teflon. 2. Protect lip on forward side of bearing carrier, using bearing installation tool (91-13945). 3. Press propeller shaft needle bearing (number side toward mandrel 91-15755) into carrier, until bearing bottoms out. 21042 b c 95 2-4-C Marine Lubricant with Teflon 95 91-13945 91-15755 a a-Bearing Installation Tool (91-13945) b-Mandrel (91-15755) c-Suitable Driver Rod 90-857046R1 NOVEMBER 2001 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. 21040 a b c 7 Loctite “271” 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 c 91-31108 91-13945 7 Loctite “271” 77 a b a-Seal b-Oil Seal Driver (91-31108) c-Bearing Installation Tool (91-13945) Page 6B-34 90-857046R1 NOVEMBER 2001 BIGFOOT GEAR HOUSING 8. Install O-ring. Lubricate O-ring and propshaft seal lips with 2-4-C Marine Lubricant with Teflon. 9. Lubricate outside diameter of reverse gear bearing and bearing carrier bore with a light coating of 2-4-C Marine Lubricant with Teflon. 10. Press bearing into carrier until tool bottoms. 19163 a b c 95 95 91-13945 2-4-C Marine Lubricant with Teflon a-O-ring b-Bearing, Numbered Side Toward Tool c-Bearing Installation Tool (91-13945) 11. Install thrust washer. Coat thrust washer with Premium Gear Lubricant. 19167 a 87 87 Premium Gear Lubricant a-Thrust Washer 90-857046R1 NOVEMBER 2001 Page 6B-35 BIGFOOT GEAR HOUSING 12. Install thrust bearing. Coat thrust bearing with Premium Gear Lubricant. 19168 87 87 a Premium Gear Lubricant a-Thrust Bearing 13. Apply Premium Gear Lubricant to bearing surface of reverse gear and install reverse gear. 19202 a 87 Premium Gear Lubricant 87 b a-Reverse Gear b-Bearing Surface Page 6B-36 90-857046R1 NOVEMBER 2001 BIGFOOT GEAR HOUSING Forward Gear Reassembly 1. Apply 2-4-C Marine Lubricant with Teflon to the I.D. of the bearing. Press bearing onto gear using suitable mandrel (press only on inner race of bearing). Because the gear hub is longer than the bearing, a tube type mandrel should be used to install the bearing. This will allow the bearing to bottom out on the gear. 51869 a b 95 2-4-C Marine Lubricant with Teflon 95 a-Mandrel (91-37350) b-Bearing 2. Inspect reverse gear end of clutch to determine the number of jaws. Refer to chart, following, for tool end selection. Model Installation End Bearing Position Tool Stamped 3 Jaw Reverse 91-856875A 1 3 0.155 in. (3.94mm) Clutch below surface 6 Jaw Reverse Clutch 91-856875A 1 6 Flush with surface FORWARD GEAR NEEDLE BEARING INSTALLATION 3 Jaw Reverse Clutch c a b a-Stamped “3” b-Numbered end of Needle Bearing c-3 Jaw Reverse Clutch 90-857046R1 NOVEMBER 2001 Page 6B-37 BIGFOOT GEAR HOUSING 6 Jaw Reverse Clutch 56784 c a b a b87 91-877321A1 a-Stamped “6” b-Numbered end of Needle Bearing c-6 Jaw Reverse Clutch 3. Apply Premium Gear Lubricant to I.D. of forward gear, and O.D. of needle bearing. Press needle bearing into forward gear (using forward gear bearing installer tool) until tool bottoms out on gear. 87 Premium Gear Lubricant a-Forward Gear Bearing Installer (91-877321A1) b-Needle Bearing, Numbered Side Toward Installer Tool 4. Install retaining ring into groove of forward gear by starting at one end of retaining ring and working it around until seated in groove. 57905 a b a-Retaining Ring b-Groove in Forward Gear Page 6B-38 90-857046R1 NOVEMBER 2001 BIGFOOT GEAR HOUSING Propeller Shaft Reassembly 1. Install components into propeller shaft in sequence shown. NOTE:When installing the clutch make sure the ratcheting clutch teeth (angled) are toward forward gear, and non-ratcheting (square on both sides) are toward reverse gear. 51265a b cd e gf 95 2-4-C Marine Lubricant with Teflon 95 Assembly Sequence a-Spring b-Guide Block c-Clutch d-3 Metal Balls e-Cam Follower f-Forward Clutch Teeth g-Reverse Clutch Teeth 2. Align the hole in the clutch with the hole in the guide block, install cross pin. a b 51800 a-Apply Pressure in This Direction b-Cross Pin 90-857046R1 NOVEMBER 2001 Page 6B-39 BIGFOOT GEAR HOUSING 3. Install spring. DO NOT allow spring coils to overlap each other. 51876 a a-Spring Drive Shaft Wear Sleeve Installation 1. Install new rubber ring. 2. Apply a light coat of Loctite 271 on outside diameter of rubber ring. a 7 Loctite “271” a-Ring 3. Insert sleeve into holder*. *Component of Wear Sleeve Installation Tool (91-14310A1). 19169 a 91-14310A1 b 19152 a-Sleeve b-Holder Page 6B-40 90-857046R1 NOVEMBER 2001 BIGFOOT GEAR HOUSING 4. Press sleeve onto driveshaft using Wear Sleeve Installation Tool (91-14310A1). Continue pressing until the upper and lower part of the tool make surface to surface contact. 5. Remove excess Loctite from assembled shaft. 19166 a b b 91-14310A1 c d a-Drive Shaft b-Wear Sleeve Installation Tool (91-14310A1) c-Upper part of tool (Surface C) d-Lower part of tool (Surface D) 90-857046R1 NOVEMBER 2001 Page 6B-41 BIGFOOT GEAR HOUSING Drive Shaft Lower Bearing Race Installation 1. Lubricate O.D. of bearing race with 2-4-C Marine Lubricant with Teflon. 2. Install shim(s) and bearing race into housing. If shim(s) were lost or a new gear housing is being assembled, start with 0.025 in. (0.635 mm) shim(s). NOTE:Verify shim(s) are not cocked when drawing up race. Once shims and bearing cup are in place, position gearcase assembly so the driveshaft is vertical. This will aid in preventing the bearing cup from becoming cocked in the bore. a b c d f 95 2-4-C Marine Lubricant with Teflon 95 91-14309A1 f d c e 58207 a-Shim(s) (Retained From Disassembly) 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 90-857046R1 NOVEMBER 2001 BIGFOOT GEAR HOUSING Oil Sleeve Installation 1. Install oil sleeve with tab positioned as shown. 53934 a b a-Oil Sleeve b-Tab Drive Shaft Upper Bearing Installation 1. Lubricate I.D. of bearing sleeve and O.D. of bearing with 2-4-C Marine Lubricant with Teflon. 2. Press bearing into sleeve using mandrel from bearing installation tool (91-14309A1). 19164 a b c d 95 2-4-C Marine Lubricant with Teflon 91-1378195 a-Bearing Sleeve b-Tapered End c-Bearing; Numbered Side Toward Mandrel d-Mandrel* (91-13781) *From Bearing Installation Tool (91-14309A1) 90-857046R1 NOVEMBER 2001 Page 6B-43 BIGFOOT GEAR HOUSING 3. Install bearing/sleeve into housing. IMPORTANT: Oil sleeve must be installed prior to upper driveshaft bearing installation. IMPORTANT: Lower driveshaft bearing cup pilots the mandrel (13780) during installation of the upper driveshaft bearing/sleeve. Lower bearing cup must be installed prior to installing upper bearing/sleeve. 91-14309A1 a b d e e f c 58206 a-Bearing/Sleeve b-Tapered End Of Sleeve c-Mandrel* (13781) d-Mandrel* (13780) e-Threaded Rod** (91-31229) f-Nut** (11-24156) *From Bearing Installation Tool (91-14309A1) **From Bearing Removal and Installation Kit (91-31229A7) Page 6B-44 90-857046R1 NOVEMBER 2001 BIGFOOT GEAR HOUSING Forward Gear, Drive Shaft Lower Bearing, Pinion Gear, and Drive Shaft Installation 1. Install components per assembly sequence shown. 19175 a b c d e f d 87 Premium Gear Lubricant 7 Loctite “271” 7 87 Assembly Sequence: a-Forward Gear/Bearing: Apply Premium Gear Lube to bearing rollers. b-Drive Shaft Lower Tapered Roller Bearing: Apply Premium Gear Lube to bearing rollers. c-Pinion Gear d-Drive Shaft e-Drive Shaft Holding Tool f-Pinion Nut (New): Clean nut and driveshaft threads with Loctite Primer or suitable de-greaser. Apply Loctite 271 to threads (not necessary if using a new nut with drylock patch on threads) during final assembly (after pinion gear depth and forward gear backlash have been set), tighten to specified torque. Model Drive Shaft Holding Tool 40/50 Bigfoot (4-Stroke, 747cc/935cc) 91-56775 40/50/60 Bigfoot (4-Stroke, 995cc) 91-877840A1 75/90/115EFI (4-Stroke) 91-804776A1 60 Bigfoot/75/90/100/115/125 (2-Stroke) 91-56775 Pinion Nut Torque 70 lb-ft (95 Nm) 90-857046R1 NOVEMBER 2001 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 pilots the end of the pinion gauge and must be installed in gear housing when checking pinion gear depth. Without it an inaccurate measurement will be obtained. 1. Clean the gear housing bearing carrier shoulder and diameter. 2. With gear housing positioned 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 nicks b-Thrust Bearing: Oiled and able to move freely c-Thrust Washer: Clean and free of nicks and bends d-Spring e-Nut: Threaded all-the-way onto bolt f-Bolt: Held snug against spring g-Sleeve: Holes in sleeve must align with set screws h-Set Screw (2): Tightened against drive shaft, 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 a b c a-1 in. (25.4 mm) c-Bolt Head b-Nut Page 6B-46 90-857046R1 NOVEMBER 2001 BIGFOOT GEAR HOUSING 6. Assemble Pinion Gear Locating Tool (91-12349A2) as shown. Do not tighten collar retaining screw at this time. Install gauging block with numbers away from split collar. a b c d e f c a-Arbor d-Split Collar b-Gauging Block e-Collar Retaining Screw c-Screw (2) 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 40/50 Bigfoot (4-stroke, 747cc/935cc) 40/50/60 Bigfoot (4-stroke, 995cc) GEAR RATIO (PINION GEAR TEETH/REVERSE GEAR TEETH) 2.31:1 (13/30) 2.31:1 (13/30) USE FLAT NO. 8 8 LOCATING DISC NO. 3 3 60 Bigfoot/60 Seapro 60 Marathon 75/90/115EFI (4-stroke) 2.31:1 (13/30) 2.07:1 (14/29) 8 2 3 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 90-857046R1 NOVEMBER 2001 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 through access hole in locating disc. 13. The correct clearance between gauging block and pinion gear is 0.025 in. (0.64 mm). 14. If clearance is correct, leave Bearing Preload Tool on drive shaft and proceed to “Determining Forward Gear Backlash,” following. 15. If clearance is more than 0.025 in. (.064 mm) add shims behind the bearing race. If clearance is less than 0.025 in. (.064 mm) remove shims from behind the bearing race. When reinstalling pinion nut, apply Loctite 271 on threads of nut. NOTE:Clean driveshaft and pinion nut threads with Loctite Primer or suitable de-greaser before applying Loctite. 24643 a b c d 7 Loctite “271” 7 a-Feeler Gauge b-Gauging Block c-Pinion Gear d-Bearing Race Page 6B-48 90-857046R1 NOVEMBER 2001 BIGFOOT GEAR HOUSING DETERMINING FORWARD GEAR BACKLASH NOTE:Read entire procedure before attempting any change in shim thickness. 1. To obtain correct pinion gear depth, refer to “Determining Pinion Gear Depth,” preceding. 2. Install Bearing Preload Tool (91-14311A2) on drive shaft. Refer to “Determining Pinion Gear Depth,” preceding. 3. Install components as shown. 4. While holding the driveshaft (to prevent from turning), torque the puller bolt to 45 lb-in. 5. Rotate driveshaft 5-10 revolutions. This should properly seat the forward gear tapered roller bearing. Repeat step 4. a bd c a-Propeller Shaft* b-Bearing Carrier* (Assembled) c-Puller Jaws (91-46086A1) d-Puller Bolt (91-85716) Puller Bolt Torque 45 lb-in. (5 Nm) 53936 *Refer to “Bearing Carrier and Propeller Shaft Installation,” following. 90-857046R1 NOVEMBER 2001 Page 6B-49 BIGFOOT GEAR HOUSING 6. 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 7. Position Dial Indicator on appropriate line (from chart below) marked on Backlash Indicator Tool. Make sure the dial indicator is perpendicular (^) to the indicator tool or an inaccurate reading will be obtained. MODEL BACKLASH INDICATOR TOOL ALIGN POINTER of DIAL INDICATOR with MARK 40/50 Bigfoot (4-stroke, 747cc/935cc) 91-78473 4 40/50/60 Bigfoot (4-stroke, 995cc) 91-78473 4 75/90/115EFI (4-Stroke) 91-19660--1 1 60 Seapro/60 Marathon 60 Bigfoot 91-78473 4 75-thru-90 (3 Cylinder) 91-78473 4 100/115/125 (4 Cylinder) 91-19660--1 1 Page 6B-50 90-857046R1 NOVEMBER 2001 BIGFOOT GEAR HOUSING 8. Grasp the driveshaft pre-load tool bolt head and lightly turn drive shaft back-and-forth (no movement should be noticed at propeller shaft). 9. Dial Indicator registers amount of backlash, which must be between specification shown in chart. MODEL DIAL INDICATOR MINIMUM READING MAXIMUM 40/50 Bigfoot (4-Stroke, 747cc/935cc) 0.012 in. (0.30 mm) 0.019 in. (.48 mm) 40/50/60 Bigfoot (4-Stroke, 995cc) 0.012 in. (0.30 mm) 0.019 in. (.48 mm) 75/90/115EFI (4-Stroke) 0.013 in. (0.38 mm) 0.019 in. (.55 mm) 60 Bigfoot 0.012 in. (0.30 mm) 0.019 in. (.48 mm) 75-thru-90 (3 Cylinder) 0.012 in. (0.30 mm) 0.019 in. (.48 mm) 100/115/125 (4 Cylinder) 0.013 in. (0.38 mm) 0.019 in. (0.55 mm) 10. If backlash is less than the minimum specification, remove shim(s) from in front of forward gear bearing race. If backlash is more than the maximum specification, add shim(s) in front of forward gear bearing race. When reinstalling pinion nut, apply Loctite 271 on threads of nut. NOTE: By adding or subtracting 0.001 in. (0.025 mm) shim, the backlash will change approximately 0.001 in. Bearing Carrier and Propeller Shaft Installation 1. Insert propeller shaft assembly into bearing carrier. 2. Before installing bearing carrier assembly into gear housing, obtain locally a 6 in. (152.4 mm) long by 1-1/4 in. – 1-1/2 in. (31.7 – 38.1 mm) diameter piece of PVC pipe. Install the PVC pipe over the prop shaft and secure the pipe against the bearing carrier assembly with the propeller nut and tab washer. This holds the reverse gear and thrust bearing tight against the bearing carrier preventing possible bearing damage during installation. 21043 d a b c e a-Bearing Carrier Assembly b-PVC Pipe c-Propeller Nut d-Prop Shaft e-Tab Washer 90-857046R1 NOVEMBER 2001 Page 6B-51 BIGFOOT GEAR HOUSING 3. Generously lubricate O-ring, bearing carrier, and gear housing mating surfaces with 2-4-C Marine Lubricant with Teflon. 4. Install bearing carrier and propeller shaft into housing with the word “TOP” (located on flange) toward top of housing. 5. Install bearing carrier fasteners and tighten to specified torque. 21044 a 95 2-4-C Marine Lubricant with Teflon 95 b 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 (30 Nm) 0.060 in. (1.53mm) 25 lb-ft (34 Nm) b a a-Washers b-Fasteners (If using Screws Apply Loctite 271 on Threads) Page 6B-52 90-857046R1 NOVEMBER 2001 BIGFOOT GEAR HOUSING Water Pump Reassembly and Installation 1. Place water pump base upper seal on longer shoulder side of Oil Seal Driver (91-13949) with seal lip away from shoulder. 2. Apply Loctite 271 on O.D. of seal. Press seal into water pump base until tool bottoms. 51553 c 91-13949 7 a d e b 7 Loctite “271” a-Seal - Lip Faces UP (when water pump base is installed on gearcase) b-Spring - Faces UP (when water pump base is installed on gearcase) c-Oil Seal Driver (91-13949) d-Longer Shoulder Side of Oil Seal Driver e-Shorter Shoulder Side of Oil Seal Driver 90-857046R1 NOVEMBER 2001 Page 6B-53 BIGFOOT GEAR HOUSING 3. Place water pump base lower seal on shorter shoulder side of Oil Seal Driver (91-13949) with seal lip toward shoulder. 4. Apply Loctite 271 on O.D. of seal. Press seal into water pump base until tool bottoms. 5. Lubricate lip of each seal with 2-4-C Marine Lubricant with Teflon. 51553 c 91-13949 7 Loctite “271”7 95 a b e d 95 2-4-C with Teflon a-Seal - Lip Faces DOWN (when water pump base is installed on gearcase) b-Spring - Faces DOWN (when water pump base is installed on gearcase) c-Oil Seal Driver (91-13949) d-Longer Shoulder Side of Oil Seal Driver e-Shorter Shoulder Side of Oil Seal Driver 6. Install gasket. a 19218 a-Gasket Page 6B-54 90-857046R1 NOVEMBER 2001 BIGFOOT GEAR HOUSING IMPORTANT: To prevent cutting the seal lips remove any burrs or sharp edges from the driveshaft splines before installing water pump base assembly. 7. Install components as shown. Apply Loctite 271 on bottom half of screw threads and tighten to specified torque (in sequence shown). 19217 a 7 Loctite “271” 1 2 3 4 5 6 b a-Water Pump Base b-Screw (6) M6 x 1 and Washers(6) Screw Torque 60 lb-in. (6.8 Nm) 8. Install gasket and plate. 19219 a b a-Gasket b-Plate IMPORTANT: If the old impeller is re-used it must be installed in original (clockwise) direction of rotation. 9. Install gasket, drive key and impeller. 19220 a b c a-Gasket b-Drive Key c-Impeller 90-857046R1 NOVEMBER 2001 Page 6B-55 BIGFOOT GEAR HOUSING 10. Lubricate I.D. of cover with 2-4-C Marine Lubricant with Teflon. 11. Rotate drive shaft clockwise and push impeller housing down (over impeller) until it contacts water pump base. 12. Apply Loctite 271 to bottom threads of cover screws. Install cover screws and tighten to specified torque. b a 95 2-4-C Marine Lubricant with Teflon 95 b 19212 a-Impeller Housing b-Screw (4) M6 x 30 Screw Torque 60 lb-in. (6.8 Nm) NOTE:It is recommended that the gearcase be pressure tested for leaks after reassembly andBEFOREgear lube is added. Gearcase should hold 10-12 psi (69-83 kPa) for 5 minutes. Page 6B-56 90-857046R1 NOVEMBER 2001 BIGFOOT GEAR HOUSING Gear Housing Pressure Test 1. Remove vent plug and install pressure test gauge. 2. Pressurize housing to 10-12 psi (69-83 kPa)and observe gauge for 5 minutes. 3. Rotate drive shaft, prop shaft and shift shaft while housing is pressurized to check for leaks. 4. If pressure drop is noted, immerse housing in water. 5. Re-pressurize to 10-12 psi (69-83 kPa)and check for air bubbles. 6. Replace leaking seals as necessary. Retest housing. NOTE:Gearcase should hold 10-12 psi (69-83 kPa) for 5 minutes. 7. Remove tester from housing and install vent plug and sealing washer. Tighten to specified torque. Vent Screw Torque 60 lb. in. (7.0 Nm) 90-857046R1 NOVEMBER 2001 Page 6B-57 BIGFOOT GEAR HOUSING Filling Gear Housing With Lubricant NOTE:Gear housing lubricant capacity is 24 fl oz (710 mL). WARNING If gear housing is installed on engine, to avoid accidental starting, disconnect (and isolate) spark plug leads from spark plugs before working near the propeller. CAUTION Do not use automotive grease in the gear housing. Use only Premium Blend Gear Lube. 1. Remove any gasket material from “Fill/Drain” and “Vent” screws and gear housing. 2. Install new sealing washer on “Fill/Drain” and “Vent” screws. IMPORTANT: Never apply lubricant to gear housing without first removing “Vent” screws or gear housing cannot be filled because of trapped air. Fill gear housing only when driveshaft is in a vertical position. 3. Remove lubricant “Fill/Drain” screw and sealing washer from gear housing. 4. Insert lubricant tube into “Fill” hole, then remove “Vent” screws and sealing washer. 5. Fill gear housing with lubricant until excess starts to flow out of one (first) “Vent” screw hole. 6. Install this “Vent” screw and sealing washer only and tighten to specified torque. Continue filling until excess starts to flow out of second “Vent” screw hole. 7. Rotate driveshaft clockwise approximately 10 revolutions. Let gearcase sit for at least one minute to allow any trapped air to settle out, then top off lubricant level. 53922 a c b a-Vent Screw b-Fill/Drain Screw c-Oil Level Vent Screw 8. Install second lubricant “Vent” screw and sealing washer. Tighten to specified torque. IMPORTANT: Do not lose more than one fluid ounce (30cc) of gear lubricant while reinstalling “FILL/DRAIN” screw. 9. Remove lubricant tube and install Fill/Drain screw and sealing washer. Tighten to specified torque. Fill/Drain and Vent Screw Torque 60 lb. in. (7.0 N·m) Page 6B-58 90-857046R1 NOVEMBER 2001 BIGFOOT GEAR HOUSING 90-857046R1 NOVEMBER 2001 Page 6B-59 Gearcase Installation WARNING Disconnect (and isolate) spark plug leads from spark plugs before installing gear housing onto drive shaft housing. Failure to follow this warning could result in accidental engine starting and possible injury. 1. Position outboard shift linkage into forward gear position. Models 40-60 Bigfoot (4-Stroke EFI) a Remote Control Model Shown a - Shift Lever Models 40-60 Bigfoot (4-Stroke Carb) a Remote Control Model Shown a - Shift Lever BIGFOOT GEAR HOUSING Models 60 Bigfoot (2-Stroke) a a-Shift Block Models 75/90/100/115/125 (2-Stroke) 19879 a b a-Shift Block; Front of Block MUST Extend 1/8 in. (3.2 mm) Past Front of Rail. b-Rail Models 75/90/115EFI (4-Stroke) NRF a a-Shift Block Page 6B-60 90-857046R1 NOVEMBER 2001 BIGFOOT GEAR HOUSING 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. Apply 2-4-C Marine Lubricant with Teflon to I.D. of seal. 5. Apply a bead of RTV Sealer as shown. NOTE:For ease of gear housing installation, install water tube seal (labyrinth end) onto water tube in drive shaft housing. Tapered end of water tube seal goes onto water pump. 53938 95 2-4-C Marine Lubricant with Teflon 78 95 a b G. E. RTV Sealant 78 a-Water Tube Seal b-RTV Sealer 90-857046R1 NOVEMBER 2001 Page 6B-61 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 2-4-C Marine Lubricant with Teflon onto drive shaft splines. 7. Apply a light coat of 2-4-C Marine Lubricant with Teflon on gear case shift shaft splines and upper shift shaft splines. Do not use lubricant on ends of shift shafts. 8. Install components as shown in appropriate photo. ALL MODELS EXCEPT 75 (2-STROKE) W/MECHANICAL REVERSE LOCK a c b a-Nylon Spacer b-Shift Shaft Coupler c-Bushing 40-60 Bigfoot 4–Stroke Only 75 (2-STROKE) W/MECHANICAL REVERSE LOCK 53925 a b c a-Nylon Spacer b-Shift Shaft Coupler c-Flat; MUST BE Positioned Toward Front of Gear Housing Page 6B-62 90-857046R1 NOVEMBER 2001 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 screws. NOTE:During installation of gear housing, it may be necessary to move the shift block (located under cowl) slightly to align upper shift shaft splines with shift shaft coupler splines. NOTE:On 75/90 hp (4-Stroke)models. If, while performing Step 11, the drive shaft splines wil llnot align with the oil pump splines, place a propeller onto propeller shaft and turn it counterclockwiseas the gear housing is being pushed toward drive shaft housing. Continue rotating the propshaft until the driveshaft splines align with the crankshaft splines. IMPORTANT: 75/90 hp (4-Stroke) models, when removing or installing gearcase, carefully guide driveshaft through driveshaft bushing to avoid scoring bushing surface. 11. Position gear housing so that the driveshaft is protruding into driveshaft housing. 12. Move gear housing up toward driveshaft housing, while aligning upper shift shaft splines with shift shaft coupler splines, water tube with water tube seal, and crankshaft splines with driveshaft splines. 13. Install 4 fasteners and washers (two each side). Install locknut and washer. 14. Torque bolts and locknut (or nuts only if applicable) to specified torque. 53922 ab 7 Loctite “271” 7 a-Fasteners and Washers (2 Each Side) b-Locknut and Washer Screw or Nut Torque 40 lb-ft (54 Nm) 15. 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 above, the gear housing must be removed and the cause of the problem corrected. 90-857046R1 NOVEMBER 2001 Page 6B-63 BIGFOOT GEAR HOUSING 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. TRIM TAB REPLACEMENT 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. TRIM TAB ADJUSTMENT NOTE:The trim tab provides a means to offset (balance) some of the steering load that is caused by propeller torque at higher operating speeds. 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. 1. Shift engine control into NEUTRAL and turn ignition key to OFF position. 2. If at higher speeds the boat turns more easily to the left, loosen screw, move the trim tab (trailing edge) to the left (when viewed from behind). Tighten retaining screw to specified torque. 3. If the boat turns more easily to the right, loosen screw, move the trim tab (trailing edge) to the right (when viewed from behind) turn trim tab (trailing edge) to the right . Tighten retaining screw to specified torque. 53931ab c a-Trim Tab b-Anti-Ventilation Plate c-Retaining Screw and Washer Retaining Screw Torque 22 lb-ft (29.8 Nm) Page 6B-64 90-857046R1 NOVEMBER 2001 THROTTLE/SHIFT LINKAGE ATTACHMENTS/CONTROL LINKAGE Section 7A - Throttle/Shift Linkage Table of Contents Linkage (Non Bigfoot). . . . . . . . . . . . . . . . . . . . 7A-2 Linkage (Bigfoot) . . . . . . . . . . . . . . . . . . . . . . . . 7A-4 7 A 90-857046R1 NOVEMBER 2001 Page 7A-1 THROTTLE/SHIFT LINKAGE Page 7A-2 90-857046R1 NOVEMBER 2001 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 Marine Lubricant with Teflon THROTTLE/SHIFT LINKAGE LINKAGE (NON BIGFOOT) REF 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 SHIFT LEVER BRACKET NON HANDLE LATCH SCREW (M6 x 16) SLEEVE SHIFT ROD 9 1 10 1 11 1 12 2 75 8.5 13 2 14 1 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 SCREW (M3 x 20) ELECTRIC HANDLE MODELS PLATE–Switch 28 2 29 1 90-857046R1 NOVEMBER 2001 Page 7A-3 THROTTLE/SHIFT LINKAGE Page 7A-4 90-857046R1 NOVEMBER 2001 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 Marine Lubricant with Teflon THROTTLE/SHIFT LINKAGE LINKAGE (BIGFOOT) REF 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 90-857046R1 NOVEMBER 2001 Page 7A-5 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-14 7 B 90-857046R1 NOVEMBER 2001 Page 7B-1 TILLER HANDLE TILLER HANDLE 95 2-4-C Marine Lubricant with Teflon Page 7B-2 90-857046R1 NOVEMBER 2001 TILLER HANDLE TILLER HANDLE REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in lb-ft Nm. 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) 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 SHIFT ROD 24 1 TAB WASHER 25 2 SCREW (M10 x 90) 35 47.5 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 90-857046R1 NOVEMBER 2001 Page 7B-3 TILLER HANDLE Page 7B-4 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 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 securing the tiller handle. Remove the tiller handle assembly from the outboard. 54272 b c a BLK/YEL BLK BLK BLK/YEL BLK/YEL BLK BLK 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 tiller arm, along with the throttle cables and wiring, from the tiller bracket. a b c a-Tiller Arm b-Throttle Cables/Wiring c-Tiller Bracket Page 7B-6 90-857046R1 NOVEMBER 2001 TILLER HANDLE 4. Remove retainer and slide out the tiller tube assembly. 5. Remove the throttle friction knob assembly. a b c a a-Retainer b-Throttle Friction Knob 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. a-Stop Switch Harness 8. Push the tiller tube out of the handle. b c b-Tiller Tube c-Handle 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 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. Install cover with screw. c a b a-Pulley b-Cover c-Screw 10-16x1/2 in. Pulley Cover Screw Torque 20 lb. in. (2.3 Nm) 3. Match tiller tube end with slots in the handle. Pull the tube end into the handle until it bottoms out. 4. Install the throttle friction knob components on tiller tube. a b c c d e f g a-Tiller Tube b-Handle c-Slots In Handle d-Screw M6x25 e-Lock f-Spring g-Knob 90-857046R1 NOVEMBER 2001 Page 7B-9 TILLER HANDLE 5. Check to make sure tiller tube is recessed in the end of the handle 7/8 in. (22.2mm). 7/8 in. (22.2mm) a a-7/8 in. (22.2 mm) 6. Insert the engine stop switch harness through the tiller tube. a a-Engine Stop Switch Harness 7. Place the stop switch into end on handle. a a-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 soap/water solution to the inside of the rubber grip will ease installation. ab a-Rubber Grip b-Handle Page 7B-10 90-857046R1 NOVEMBER 2001 TILLER HANDLE 9. Place pulley assembly into arm. 10. Slide the tiller tube into the arm. Position the throttle friction 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. 12. Secure tiller tube with retainer. 13. Snap the engine start switch on the tiller tube. a cd b a-Pulley Assembly b-Throttle Friction Knob c-Retainer d-Screw-M5x16 Tiller Tube Retainer Screw Torque 35 lb. in. (3.9 Nm) 14. Place bushing components on the arm mounts. a b c d 95 2-4-C Marine Lubricant with Teflon 95 95 a-Flat Washer b-Bushing c-Wave Washer (1) d-Bushing 90-857046R1 NOVEMBER 2001 Page 7B-11 TILLER HANDLE 15. Pull the throttle cables and wiring into the bracket. a a-Tiller Bracket 16. Push the arm into the tiller bracket. Secure the arm by installing the cover and screws. Tighten screws to specified torque. abc a-Arm b-Cover c-Screw (2) M8 x 25 Arm Cover Screw Torque 135 lb. in. (15 Nm) Page 7B-12 90-857046R1 NOVEMBER 2001 TILLER HANDLE 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 past each end of the opening. 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) b d c a e c a-Hand Grip Opening b-Wiring Conduit (Place all Wiring Inside – See CAUTION above) c-Wiring Conduit 1/2 in extending past opening d-Throttle Cables (Position toward outer side) e-Clips (2) 90-857046R1 NOVEMBER 2001 Page 7B-13 TILLER HANDLE Page 7B-14 90-857046R1 NOVEMBER 2001 Tiller Handle Installation 1. Install tiller handle, new tab washer, and screws. Tighten screws to specified torque. 2. Bend tabs onto flats of screws. b c a a - Tiller Handle b - Tab Washer c - Screw (2) M10 x 90 Tiller Handle Mounting Screw Torque 35 lb. ft. (47.5 Nm) 3. Connect wires as shown in wiring diagram (on next page). 4. Secure wires at connectors with cable tie as shown. a a - Cable Tie TILLER HANDLE ELECTRIC START TILLER HANDLE WIRING DIAGRAM-30/40 (4-STROKE) –+ 87654321 – + 12 34 56 7 8BLK_YELBLK_YELBLK_YELGRY BLK_YELPPLYEL_BLK BLK BLK BLK BLK BLK BLK YEL_RED 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 BLKBLK 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 YEL_RED BRN BLK a-Ground Harness below Starter Motor M6x16 screw b-Harness Extension c-Harness Connection d-Key Switch Assembly Transom Mount e-Key Switch f-Horn g-Lanyard Stop Switch h-Push Button Stop Switch i-Battery j-Starter Motor k-Voltage Regulator/Rectifier l-Start Solenoid m-Neutral Start Switch n-ECM 90-857046R1 NOVEMBER 2001 Page 7B-15 TILLER HANDLE Page 7B-16 90-857046R1 NOVEMBER 2001 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 e b a - Throttle Lever b - Anchor of Shorter Throttle Cable c - Jam Nut d - Anchor of Longer Throttle Cable e - Jam Nut 58829 TILLER HANDLE 90-857046R1 NOVEMBER 2001 Page 7B-17 10. Rotate throttle grip to the wide open throttle position. The throttle stop screw should be contacting the plate. If there is a gap between the throttle stop screw and plate, loosen the jam nut on the shorter throttle cable, turn the adjustment nut clockwise, tighten the jam nut finger tight, and rotate the throttle grip to full throttle. Keep adjusting until the throttle stop screw lightly contacts the plate. NOTE: No free-play should exist in throttle grip handle once the throttle stop screw has hit the plate. If this condition exists, re-adjust jam nuts on appropriate throttle cable. a b 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, cycle the throttle grip a few times from the idle position to the wide-open-throttle position. Make sure the throttle stop is still contacting the plate. If it is not, re-adjust the jam nuts. 11. Install lower cowl. c a b a - Screw (6)-M6x30 b - Lower Cowl c - Screw-M6x60 Bottom Cowl Bolt Torque 60 lb. in. (7 N·m) TILLER HANDLE Page 7B-18 90-857046R1 NOVEMBER 2001 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 13. Assemble the shift rod into the shift handle by sliding the rod into the hole. a b a - Shift Rod b - Shift Handle 14. Install shift handle assembly, bushing, and screw. Tighten screw to specified torque. 95 95 2-4-C Marine Lubricant with Teflon a b c a - Handle Assembly b - Screw M8 x 35 c - Bushing Shift Handle Screw Torque 100 lb. in. (11.3 N·m) 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 90-857046R1 NOVEMBER 2001 Page 8-1 MANUAL STARTER Page 8-2 90-857046R1 NOVEMBER 2001 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 Marine Lubricant with Teflon 95 95 MANUAL STARTER MANUAL STARTER REF REFREF . NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m – 1 RECOIL STARTER ASSEMBLY 1 1 RECOIL HOUSING 2 1 SEAL 3 1 ROLLER 4 1 BUSHING 5 1 WASHER 6 1 SCREW (M6 x 30) 70 8.0 7 1 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 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 MANUAL STARTER 90-857046R1 NOVEMBER 2001 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 screws and manual starter. a b a - Screw (4) M6x25 b - Manual Starter MANUAL STARTER Page 8-6 90-857046R1 NOVEMBER 2001 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 - Screw (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 an 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 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 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 Ring (2) e - Pawl (2) f - Spring (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 90-857046R1 NOVEMBER 2001 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 Marine Lubricant with Teflon 95 95 a - Spring (2) b - Pawl (2 ) c - Retaining Ring (2) d - Spring Assembly e - Springwasher f - Starter Sheave MANUAL STARTER Page 8-10 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 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 90-857046R1 NOVEMBER 2001 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). b c a 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 Marine Lubricant with Teflon 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-Screw (3) 10-16x.625 NOTE:Hold interlock lever back and check the operation of the rewind and rewind tension before installation. 90-857046R1 NOVEMBER 2001 Page 8-13 MANUAL STARTER Page 8-14 90-857046R1 NOVEMBER 2001 Manual Starter Installation 1. Secure manual starter with screws. a b a - Screws (4) - M6x25 b - Manual Starter Manual Starter Screw Torque 60 lb. in. (7 N·m) 2. Install interlock cable onto cam boss and secure with retaining clip. 3. Secure interlock cable to rewind housing with adjustment screw. NOTE: Interlock cable should be adjusted after installation. Refer to interlock cable adjustment procedures. b a a - Retaining Clip b - Adjustment Screw COLOR DIAGRAMS COLOR DIAGRAMS Table of Contents 30/40 (4-Stroke) Tiller Handle Electric 30/40 (4-Stroke) Remote Control Electric Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 30/40 (4-Stroke) Tiller Handle Manual 30/40 (4 Stroke) Oil Flow Diagram . . . . . . . . . . . . 9-9 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 30/40 (4 Stroke) Water Flow Diagram . . . . . . . . . 9-11 9 90-857046R1 NOVEMBER 2001 Page 9-1 COLOR DIAGRAMS Notes: Page 9-2 90-857046R1 NOVEMBER 2001 COLOR DIAGRAMS 30/40 (4-STROKE) TILLER HANDLE ELECTRIC COLOR WIRING DIAGRAM 2001 MODELS (S/N 0T178500 AND UP) 90-857046R1 NOVEMBER 2001 Page 9-3 30/40 (4-Stroke) Tiller Handle Electric 2001 Models and Newer (S/N 0T178500 and Up) 1. ECM 2. Crank Position Sensor 3. Temperature Sensor 4. Oil Switch 5. DDT Connection 6. Auto Enrichener 7. Stator 8. Tachometer Signal (Secondary) 9. Voltage Regulator 10. Starter 11. Start Solenoid 12. To Trim Motor 13. Trim Down Relay 14. Trim Up Relay 15. To 12 Volt Battery 16. Panel Mounted Trim Switch 17. 12 Volt Switched Auxiliary Power Source 18. Key Switch 19. Warning Horn 20. Push Button Stop Switch 21. Lanyard Stop Switch 22. Tachometer Signal 23. Cowl Mounted Trim Switch 24. Neutral Start Switch 25. Tiller Handle Harness Connection 26. Engine Harness Connection 27. To Warning Lamps 28. 20 Amp. Fuse 29. 20 Amp. Fuse 30. Ignition Coil #1 31. Ignition Coil #2 32. Ignition Coil #3 33. Diode Q R S T U V W X Y QP QQ QR QU QW QX QY RP RQ RR RS RT RU RW SP SQ RY RX QV SR SS UYRVR RV QR QS QT COLOR DIAGRAMS 30/40 (4-STROKE) TILLER HANDLE MANUAL COLOR WIRING DIAGRAM 2001 MODELS (S/N 0T178500 AND UP) 90-857046R1 NOVEMBER 2001 Page 9-5 30/40 (4-Stroke) Tiller Handle Manual 2001 Models and Newer (S/N 0T178500 and Up) 1. ECM 2. Crank Position Sensor 3. Temperature Sensor 4. Oil Switch 5. DDT Connection 6. Auto Enrichener 7. Stator 8. Alternator (Lighting Coil) 9. Warning Horn 10. Lanyard Stop Switch 11. Push Button Stop Switch 12. Ignition Coil #1 13. Ignition Coil #2 14. Ignition Coil #3 15. Diode QRSTUVWXYQRQSQTQUQRSTUVWXYQRQSQTQU QP QQ UYRXQ COLOR DIAGRAMS 30/40 (4-STROKE) REMOTE CONTROL ELECTRIC COLOR WIRING DIAGRAM 2001 MODELS (S/N 0T178500 AND UP) 90-857046R1 NOVEMBER 2001 Page 9-7 30/40 (4-Stroke) Remote Control Electric 2001 Models and Newer (S/N 0T178500 and Up) 1. ECM 2. Crank Position Sensor 3. Temperature Sensor 4. Oil Switch 5. DDT Connection 6. Auto Enrichener 7. Stator 8. Tachometer Signal 9. Voltage Regulator 10. Starter 11. Start Solenoid 12. To Trim Motor 13. Trim Down Relay 14. Trim Up Relay 15. To 12 Volt Battery 16. Cowl Mounted Trim Switch 17. Engine Harness Connection 18. To Warning Lamps 19. 20 Amp. Fuse 20. Ignition Coil #1 21. Ignition Coil #2 22. Ignition Coil #3 23. Diode UYRXR Q R S T U V W X Y QP QQ QR QS QT QU QV QW QX QY RP RQ RR RS QR COLOR DIAGRAMS 30/40 (4-STROKE) OIL FLOW DIAGRAM 90-857046R1 NOVEMBER 2001 Page 9-9 30/40 (4-Stroke) Oil Flow Diagram . Sump . Oil Pick-up . Oil Passages in Adapter Plate . Oil Passages in Cylinder Block . Oil Passages In Cylinder Head . Oil Pump . Oil Pressure Regulator . Oil Filter . Crankshaft . Piston, Rod, Wrist-Pin . Rocker Arm Shaft . Rocker Arms . Camshaft . Return to Sump 59091                COLOR DIAGRAMS 30/40 (4-STROKE) WATER FLOW DIAGRAM 90-857046R1 NOVEMBER 2001 Page 9-11 30/40 (4-Stroke) Water Flow Diagram . Water Inlet . Water Pump . Driveshaft Housing . Water Tube . Adapter Plate . Cylinder Block . Cylinder Head . Water Jacket Cover . Thermostat . Fuel Cooler . Fuel Pump . Tell-Tale . Water Discharged with Exhaust 59264