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SERVICE MANUAL MODELS Mercury/Mariner 40·45·50·50 Bigfoot (4-Stroke) With Starting Serial Numbers United States . . . . . . 0G231123 Printed in U.S.A. W1999, Mercury Marine 90-828631R3 MARCH 1999 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. 90-828631R3 MARCH 1999 Page i It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Mismatched or incorrect fasteners can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the same locations whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original. Cleanliness and Care of Outboard Motor A marine power product is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten thousands of an inch/mm. When any product component is serviced, care and cleanliness are important. Throughout this manual, it should be understood that proper cleaning, and protection of machined surfaces and friction areas is a part of the repair procedure. This is considered standard shop practice even if not specifically stated. Whenever components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed. Personnel should not work on or under an outboard which is suspended. Outboards should be attached to work stands, or lowered to ground as soon as possible. We reserve the right to make changes to this manual without prior notification. Refer to dealer service bulletins for other pertinent information concerning the products described in this manual. EXAMPLE: 90-826148 R1 JANUARY 1996 LOWER UNIT - 6A-7 Revision No. 1 Month of Printing Year of Printing Section Description Section Number Part of Section Letter Page Number Page ii 90-828631R3 MARCH 1999 Service Manual Outline Section 1 - Important Information A - Specifications B - Maintenance C - General Information D - Outboard Motor Installation Section 2 - Electrical A - Ignition B - Charging & Starting System C - Timing,Synchronizing & Adjusting D - Wiring Diagrams Section 3 - Fuel System A - Fuel Pump B - Carburetor C - Emissions Section 4 - Powerhead A - Cylinder Head B - Cylinder Block/Crankcase C - Lubrication Section 5 - Mid-Section A - Clamp/Swivel Brackets & Drive Shaft Housing B - Power Trim (1998 And Earlier Non-Bigfoot) C - Power Trim (1999 And Later Non-Bigfoot/ All Big-Foot Model Years) D - 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 1 2 3 4 5 6 7 Important Information Electrical Fuel System Powerhead Mid-Section Gear Housing Attachments/ Control Linkage 90-828631R3 MARCH 1999 Page iii SPECIFICATIONS IMPORTANT INFORMATION Section 1A - Specifications Table of Contents 1 A Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1 Mercury/Mariner 50 (4-Stroke) Gear Case Design Identification . . . . . . . . . . . . . 1A-7 1.83:1 Non Bigfoot . . . . . . . . . . . . . . . . . . . . . . 1A-9 Propeller Information Charts . . . . . . . . . . . . . . . . 1A-8 Mercury/Mariner 50 (4-Stroke) Mercury/Mariner 50 (4-Stroke) 2.3:1 Bigfoot . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-10 2.00:1 Non Bigfoot . . . . . . . . . . . . . . . . . . . . . . 1A-8 Specifications Models 40/45/50/50 (4-Stroke) HORSEPOWER (kW) Model 50 Model 45 Model 40 50 hp (37.3 Kw) @ 6000 rpm 45 hp (33.5 Kw) @ 6000 rpm 40 hp (29.8 Kw) @ 6000 rpm OUTBOARD WEIGHT Electric 40/45/50 ELPT 224 lb (102 kg) FUEL RECOMMENDED GASOLINE Automotive Unleaded with a Minimum Pump Posted Octane Rating of 87 OIL ENGINE OIL CAPACITY ENGINE OIL +20 +40 +60 +80 F° C° 0 +100 –7 +4 +16 +27 –18 +38 SAE 10W-30 SAE 25W-40 Either 3 Quarts or 3 Liters SAE 10W-30 viscosity oil is recommended for use in all temperatures. SAE 25W-40 viscosity oil may be used at temperatures above 40° F (4° C). Use Quicksilver 4-Cycle Marine Oil with the proper viscosity for the expected temperature in your area (see range thermometer on left). If not available, use a premium quality 4-cycle engine oil, certified to meet or exceed anyone of the following American Petroleum Institute (API) service classification SH, SG, SF, CF-4, CE, CD, CDll. 90-828631R3 MARCH 1999 Page 1A-1 SPECIFICATIONS IGNITION SYSTEM* *Readings taken @ 68°F (20°C). Type Spark Plug Type (NGK) Spark Plug Gap Firing Order Ignition Timing: 40/45 HP Fully Retarded Fully Advanced (2500-3000 rpm) 50 HP Fully Retarded Fully Advanced (2500-3000 rpm) Charge Coil Resistance Trigger Coil Resistance Ignition Coil Resistance: Primary Secondary cdi Engine Speed Limiter cdi Overheat Speed Control Engine Temperature Switch Above 131° F (55° C) Below 104° F (40° C) Capacitor Discharge Ignition NGK DPR6EA-9 0.035 in. (1.0 mm) 1-3-4-2 5° B.T.D.C 25° B.T.D.C 5° B.T.D.C 35° B.T.D.C 272 - 408 W (BRN-BLU) 396 - 594 W (WHT/BLK-WHT/RED) 0.1 - 0.7 W 3.5 - 4.7 kW 6120 - 6280 rpm 1600 - 2400 rpm No Continuity Continuity CHARGING SYSTEM Alternator Type Alternator Output: Electric Start Lighting Coil Resistance (Grn - Grn) Lighting Coil Output Peak Voltage Three Phase 12 Volts - 10 Amps. (Regulated) 1.2 - 3.2 Ohms @ 68°F (20°C) 8.9 Volts @ 1500 rpm STARTING SYSTEM P/N 50-825095 Top Mounted Electric Start: Starter Type Output Ampere Draw Under: (Load) (No Load) P/N 50-834749 Side Mounted Bendix 1.1 kW 106.0 Amps 21.1 Amps Starter Type Output Ampere Draw Under: (Load) (No Load) Bendix 1.1 kW 95.0 Amps 20.0 Amps Battery Rating Minimum Requirement 465 Marine Cranking Amps (MCA) BATTERY or 350 Cold Cranking Amps (CCA). For operation below 32° F (0° C) 1000 Marine Cranking Amps (MCA) or 775 Cold Cranking Amps (CCA) ENRICHMENT CONTROL SYSTEM Choke Solenoid Electro-thermal ram projection 3.2 - 4.8 W @ 68°F (20 °C) 0.3 in. (7 mm) after 5 min. of power FUEL SYSTEM Fuel Pump Type Fuel Pump: Pressure Diaphragm Stroke Plunger Stroke Fuel Tank Capacity External (Plunger/Diaphragm) 3-6 psi (21-41 kPa) 0.14 - 0.20 in. (3.5 - 5.1 mm) 0.23 - 0.38 in. (5.85 - 9.65 mm) Accessory Page 1A-2 90-828631R3 MARCH 1999 SPECIFICATIONS CARBURETOR Idle rpm (Out Of Gear) 45 hp 40/50 hp Idle rpm (In Forward Gear) 45 hp 40/50 hp Wide Open Throttle rpm (WOT) Range Main Jet Size 40/45 hp Carburetors 1 and 2 Carburetors 3 and 4 50 hp Pilot Jet Float Height 950 ± 25 rpm 825 ± 25 rpm 850 ± 25 rpm 725 ± 25 rpm 5500–6000 rpm #104 #103 #112 #42 0.39 ± 0.02 in. (10.0 ± 0.5 mm) CYLINDER BLOCK Type Displacement Number of Cylinders 4 Stroke Cycle – Over Head Camshaft 57 cu. in. (935cc) 4 STROKE Length 2.953 in. (75 mm) CYLINDER BORE Diameter Standard Oversize-0.020 in. (0.050 mm) Taper/Out of Round Maximum Bore Type 2.4803 in. (63.0 mm) 2.5003 in. (63.5 mm) 0.003 in. (0.08 mm) Steel PISTON Piston Type O.D. at Skirt Standard Oversize-0.020 in. (0.50mm) Aluminum 2.4783-2.4789 in. (62.950-62.965 mm) 2.4983-2.4989 in. (63.450-63.465 mm) PISTON CLEARANCE Piston to Cylinder Clearance 0.0014 - .0026 in. (0.035 - 0.065 mm) RINGS Ring End Gap (Installed) Top Middle Bottom (Oil Ring) Side Clearance: Top Middle 0.006 - 0.012 in. (0.15 - 0.30 mm) 0.012 - 0.020 in. (0.30 - 0.50 mm) 0.008 - 0.028 in. (0.20 - 0.70 mm) 0.002 - 0.003 in. (0.04 - 0.08 mm) 0.001 - 0.003 in. (0.03 - 0.08 mm) COMPRESSION RATIO Compression Ratio Cylinder Compression (cold engine @ W.O.T.) 9.8:1 170 -190 lb/in2 (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) 90-828631R3 MARCH 1999 Page 1A-3 SPECIFICATIONS Main Bearing Clearance 0.0005 - 0.0017 in. (0.012 - 0.044 mm) CRANKSHAFT Crankshaft Run-out 0.0012 in. (0.03 mm) CAMSHAFT VALVE SPRING Camshaft Dimensions Intake “A” Exhaust “A” A Intake “B” Exhaust “B” B Run-out Limit Free Length “a” Tilt Limit “b” b a Compressed Pressure (Installed) Intake Exhaust Tilt Limit (Intake & Exhaust) Dir. of Winding (Intake & Exhaust) 1.216 - 1.220 in. (30.89 - 30.99 mm) 1.213 - 1.217 in. (30.82 - 30.92 mm) 1.022 - 1.025 in. (25.95 - 26.05 mm) 1.022 - 1.025 in. (25.95 - 26.05 mm) 0.0039 in. (0.1 mm) 1.491-1.569 in. (37.85-39.85 mm) Less than 0.060 in. (1.7 mm) 19.8 - 22.0 lb (9.0 - 10.0 kg) 19.8 - 22.0 lb (9.0 - 10.0 kg) 0.043 in. (1.1 mm) Left Hand Warp Limit * Lines indicate straight edge measurement 0.004 in. (0.1 mm) CYLINDER HEAD Page 1A-4 90-828631R3 MARCH 1999 SPECIFICATIONS Valve/Valve Seat/Valve Guides: Valve Clearance (cold) Intake 0.006 - 0.010 in. (0.15 - 0.25 mm) Exhaust Valve Dimensions: “A” Head Diameter 0.010 - 0.014 in. (0.25 - 0.35 mm) Intake 1.177 - 1.185 in. (29.9 - 30.1 mm) Exhaust “B” Face Width 1.020 - 1.028 in. (25.9 - 26.1 mm) Intake 0.079 - 0.124 in. (2.00 - 3.14 mm) Exhaust “C” Seat Width 0.079 - 0.124 in. (2.00 - 3.14 mm) Intake 0.035 - 0.043 in. (0.9 - 1.1 mm) Exhaust “D” Margin Thickness 0.035 - 0.043 in. (0.9 - 1.1 mm) VALVES Intake 0.020 - 0.035 in. (0.5 - 0.9 mm) Exhaust Stem Outside Diameter 0.020 - 0.035 in. (0.5 - 0.9 mm) Intake 0.2156 - 0.2161 in. (5.475 - 5.490 mm) Exhaust Guide Inside Diameter 0.2150 - 0.2156 in. (5.460 - 5.475 mm) Intake 0.2165 - 0.2170 in. (5.500 - 5.512 mm) Exhaust Stem To Guide Clearance 0.2165 - 0.2170 in. (5.500 - 5.512 mm) Intake 0.0004 - 0.0015 in. (0.010 - 0.037 mm) Exhaust 0.0010 - 0.0020 in. (0.025 - 0.052 mm) Stem Run-out Limit (max.) 0.0006 in. (0.016 mm) “A” “B” “C” “D” Valve Dimensions Head Diameter Face Width Seat Width Margin Thickness 90-828631R3 MARCH 1999 Page 1A-5 SPECIFICATIONS THERMOSTAT Valve Opening Temperature Full Open Temperature Valve Lift 136° F - 143° F (58° C - 62° C) 158° F (70° C) 0.12 in. (3 mm) LUBRICATION SYSTEM Pump Type Engine Oil Pressure Engine Oil Pan Capacity Oil Pump: Outer Rotor to Housing “a” Inner Rotor to Outer Rotor “b” Rotor to Housing “c” a b Trochoid 30-40 psi at 3000 rpm (Warm Engine) Either 3 Qts. or 3 Liters 0.001 - 0.006 in. (0.03 - 0.15 mm) 0.005 in. (0.12 mm) 0.001 - 0.003 in. (0.03 - 0.08 mm) c Transom Height: Long Shaft 20 in. (51 cm) MID-SECTION Steering Pivot Range Tilt Pin Positions 90° 5 + Shallow Water Full Tilt Up Angle 70° Allowable Transom Thickness 2-3/8 in. (60.3 mm) 1995/1996 GEAR HOUSING (2.00:1) 45/50 1995/1996 models Gear Ratio Gearcase Capacity Lubricant Type Forward Gear Number of Teeth Pinion Gear Number of Teeth Pinion Height Forward Gear Backlash Water Pressure @ Idle @ WOT 2.00:1 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) @ 750 rpm 12-17 psi (83-117 kPa) @ 6000 rpm Page 1A-6 90-828631R3 MARCH 1999 SPECIFICATIONS 1997 AND NEWER GEAR HOUSING (1.83:1) 40/45/50 1997 and Newer models Gear Ratio Gearcase Capacity Lubricant Type Forward Gear Number of Teeth Pinion Gear Number of Teeth Pinion Height Forward Gear Backlash Water Pressure @ Idle @ WOT 1.83:1 14.9 fl oz (440 mL) Quicksilver Gear Lube-Premium Blend 22 Spiral/Bevel 12 Spiral/Bevel 0.025 in. (0.64 mm) No Adjustment 2-4 psi (14-28 kPa) @ 750 rpm 12-17 psi (83-117 kPa) @ 6000 rpm 1998 AND NEWER BIGFOOT GEAR HOUSING (2.3:1) Gear Ratio Gearcase Capacity Lubricant Type Forward Gear Number of Teeth Pinion Gear Number of Teeth Pinion Height Forward Gear Backlash Water Pressure @ 750 rpm (Idle) @ 6000 rpm (WOT) 2.3:1 22.5 fl oz (655 mL) Quicksilver Gear Lube-Premium Blend 30 Spiral/Bevel 13 Spiral/Bevel 0.025 in. (0.64 mm) 0.012-0.019 in. (0.30-0.48 mm) 2-4 psi (14-28 kPa) 10-15 psi (69-103 kPa) Gear Case Design Identification a b “3 Jaw Reverse Clutch” “6 Jaw Reverse Clutch” a-Design I - “3 Jaw Reverse Clutch” Gear Case Identifier b-Design II - “6 Jaw Reverse Clutch” Gear Case Identifier Identify gear case design to ensure correct components are being installed. Design I “ 3 Jaw Reverse Clutch” (a) gear case identified with straight machined edge for trim tab screw mounting surface. Design II - “6 Jaw Reverse Clutch” (b) gear case identified with angled machined edge for trim tab screw mounting surface. 90-828631R3 MARCH 1999 Page 1A-7 SPECIFICATIONS Propeller Information Charts Mercury/Mariner 50 (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. (lb) Approx. Boat Length Speed Range (mph) Propeller Part Number 10” 19” 3 Alum Up to 800 Up to 14’ 43-51 48-73146A40 10” 17” 3 Alum Up to 900 Up to 15’ 40-46 48-73144A40 10” 16” 3 Steel 800-1000 Up to 15’ 37-43 48-91818A5 10” 16” 3 Alum 800-1000 Up to 15’ 37-43 48-73142A40 10-1/8” 15” 3 Steel 900-1300 13-15’ 34-41 48-76232A5 10-1/8” 15” 3 Alum 900-1300 13-15’ 34-41 48-73140A40 10-3/8” 14” 3 Alum 1000-1500 14-16’ 32-37 48-816706A40 10-1/4” 14” 3 Steel 1000-1500 14-16’ 32-37 48-76230A5 10-1/4” 14” 3 Alum 1000-1500 14-16’ 32-37 48-73138A40 10-1/2” 13” 3 Alum 1100-1700 14-17’ 29-34 48-816704A40 10-3/8” 13” 3 Steel 1100-1700 14-17’ 29-34 48-76228A5 10-3/8” 13” 3 Alum 1100-1700 14-17’ 29-34 48-73136A40 10-3/4” 12” 3 Alum 1200-1900 15-17’ 25-31 48-816702A40 10-5/8” 12” 3 Steel 1200-1900 15-17’ 25-31 48-79792A5 10-5/8” 12” 3 Alum 1200-1900 15-17’ 25-31 48-73134A40 10-7/8” 11” 3 Alum 1400-2100 16-18’ 22-27 48-85632A45 11-5/8” 11” 3 Steel 1400-2100 16’ + 22-27 48-823478A5 11-5/8” 10-1/2” 3 Alum 1500-2300 16’ + 20-25 48-827312A10 11-1/4” 10” 3 Alum 1700-2500 17’ + 18-23 48-73132A40 12-1/4” 9” 3 Steel 1900+ 18’ + 13-20 48-97868A10 12-1/4” 9” 3 Alum 1900+ 18’ + 13-20 48-87818A10 12-1/2” 8” 3 Alum 2100+ 18’ + 1-16 48-42738A10 12-1/2” 8” Cup 3 Alum pontoon 48-42738A12 Page 1A-8 90-828631R3 MARCH 1999 SPECIFICATIONS Mercury/Mariner 50 (4-Stroke) 1.83:1 Non Bigfoot Wide Open Throttle rpm : 5500-6000 Recommended Transom Heights : 15”, 20”, 22.5” Right Hand Rotation Standard Gear Reduction : 1.83:1 Diameter Pitch No. of Blades Material Approx. Gross Boat Wgt. (lb) Approx. Boat Length Speed Range (mph) Propeller Part Number 10” 19” 3 Alum Up to 800 Up to 14’ 49-58 48-73146A40 10” 17” 3 Alum Up to 900 Up to 15’ 43-50 48-73144A40 10” 16” 3 Steel 900-1300 Up to 15’ 39-46 48-91818A5 10” 16” 3 Alum 900-1300 Up to 15’ 39-46 48-73142A40 10-1/8” 15” 3 Steel 1000-1400 13-15’ 36-43 48-76232A5 10-1/8” 15” 3 Alum 1000-1400 13-15’ 36-43 48-73140A40 10-1/4” 14” 3 Steel 1100-1600 14-16’ 33-39 48-76230A5 10-1/4” 14” 3 Alum 1100-1600 14-16’ 33-39 48-73138A40 10-3/8” 13” 3 Steel 1300-1800 14-17’ 30-35 48-76228A5 10-3/8” 13” 3 Alum 1300-1800 14-17’ 30-35 48-73136A40 10-5/8” 12” 3 Steel 1400-2000 15-17’ 27-32 48-79792A5 10-5/8” 12” 3 Alum 1400-2000 15-17’ 27-32 48-73134A40 11-5/8” 11” 3 Steel 1700-2400 16-18’ 24-29 48-823478A5 10-7/8” 11” 3 Alum 1700-2400 16-18’ 24-29 48-85632A45 11-5/8” 10-1/2” 3 Alum 1900-2700 16’ + 21-25 48-827312A10 11-1/4” 10” 3 Alum 2100-3000 17’ + 19-24 48-73132A40 12-1/4” 9” 3 Steel 2500+ pontoon 17-21 48-97868A10 12-1/4” 9” 3 Alum 2500+ pontoon 17-21 48-87818A10 12-1/2” 8” 3 Alum 3000+ pontoon/ houseboat 1-18 48-42738A10 12-1/2” 8” Cup 3 Alum pontoon 48-42738A12 90-828631R3 MARCH 1999 Page 1A-9 SPECIFICATIONS Mercury/Mariner 50 (4-Stroke) 2.3:1 Bigfoot Wide Open Throttle rpm : 5500-6000 Recommended Transom Heights : 20”, 25” Right Hand Rotation Standard Gear Reduction : 2.31:1 Diameter Pitch No. of Blades Material Approx. Gross Boat Wgt. (lb) Approx. Boat Length Speed Range (mph) Propeller Part Number 13” 18” 3 Steel Up to 1400 Up to 14’ 34-40 48-16988A45 13-1/4” 17” 3 Alum 1300-1600 Up to 14’ 32-38 48-77344A45 13-1/8” 16” 3 Steel 1400-1700 14-16’ 29-35 48-16986A45 13-3/4” 15” 3 Alum 1500-1900 14-16’ 27-32 48-77342A45 13-3/8” 14” 3 Steel 1700-2200 15-17’ 24-30 48-17314A45 14” 13” 3 Alum 1900-2400 16-18’ 22-27 48-77340A45 14” 12” 3 Steel 2500-3200 17’+ 18-24 48-17312A45 14” 11” 3 Alum 2800-4000 pontoon 17-21 48-77338A45 14” 10” 3 Alum 3000+ pontoon/work 14-19 48-854342A45 14” 9” 3 Alum 5000+ houseboat/ work 1-15 48-854340A45 Mercury/Mariner 50 (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 50 horsepower MAXIMUM. Diameter Pitch No. of Blades Material Approx. Gross Boat Wgt. (lbs) Approx. Boat Length Speed Range (mph) Propeller Part Number 14” 13” 3 Alum 1900-2400 16-18’ 22-27 48-77340A33 14” 11” 3 Alum 2800-4000 pontoon 17-21 48-77338A33 14” 10” 3 Alum 3000+ pontoon/work 14-19 48-854342A33 14” 9” 3 Alum 5000+ houseboat/ work 1-15 48-854340A33 Page 1A-10 90-828631R3 MARCH 1999 MAINTENANCE 1 B IMPORTANT INFORMATION Section 1B - Maintenance Table of Contents Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-1 Quicksilver Lubricant/Sealant . . . . . . . . . . . . . . . 1B-2 Inspection And Maintenance Schedule . . . . . . . 1B-4 Before Each Use . . . . . . . . . . . . . . . . . . . . . . . 1B-4 After Each Use. . . . . . . . . . . . . . . . . . . . . . . . . 1B-4 Every 100 Hours of Use or Once yearly, Whichever occurs first . . . . . . . . . . . . . . . . . . 1B-5 Every 300 Hours of Use or Three Years . . . 1B-5 Before Periods of Storage . . . . . . . . . . . . . . . 1B-5 Corrosion Control Anode . . . . . . . . . . . . . . . . . . . 1B-6 Spark Plug Inspection. . . . . . . . . . . . . . . . . . . . . . 1B-7 Battery Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 1B-7 Fuse Replacement – Electric Start Models . . . . 1B-8 Timing Belt Inspection . . . . . . . . . . . . . . . . . . . . . 1B-8 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9 Checking Power Trim Fluid . . . . . . . . . . . . . . . . 1B-10 Changing Engine Oil. . . . . . . . . . . . . . . . . . . . . . 1B-11 Oil Changing Procedure. . . . . . . . . . . . . . . . 1B-11 Changing Oil Filter. . . . . . . . . . . . . . . . . . . . . 1B-12 Oil Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-12 Gear Case Lubrication . . . . . . . . . . . . . . . . . . . . 1B-13 3-1/4 In. (83mm) Diameter Gear Case . . . 1B-13 4-1/4 In. (108mm) Diameter Gear Case . . 1B-14 Storage Preparation . . . . . . . . . . . . . . . . . . . . . . 1B-16 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-16 Protecting External Outboard Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-16 Protecting Internal Engine Components . . 1B-16 Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-16 Positioning Outboard for Storage . . . . . . . . 1B-17 Battery Storage . . . . . . . . . . . . . . . . . . . . . . . 1B-17 Special Tools 1. Flushing Attachment P/N 44357A2 2. Crankcase Oil Pump P/N 90265A2 3. Oil Filter Wrench P/N 91-802653 90-828631R3 MARCH 1999 Page 1B-1 MAINTENANCE Quicksilver Lubricant/Sealant 1. Quicksilver Anti-Corrosion Grease P/N 92-78376A6 2. 2-4-C Marine Lubricant with Teflon P/N 92-825407A12 3. Special Lubricant 101 P/N 92-13872A1 4. Quicksilver Power Trim and Steering Fluid P/N 92-190100A12 Page 1B-2 90-828631R3 MARCH 1999 MAINTENANCE 5. Quicksilver 4-Stroke Outboard Oil P/N 92-828000A12 6. Gear Lube-Premium Blend P/N 92-19007A24 7. Quicksilver 4-Cycle Marine Engine Oil P/N 92-832111A1 4-CYCLE MARINE ENGINE OIL Premium Blend SAE 25W-40 NET 32 OZ (1 QT) 946 ml 90-828631R3 MARCH 1999 Page 1B-3 MAINTENANCE Inspection And Maintenance Schedule To keep your outboard in the best operating condition, it is important that your outboard receive the periodic inspections and maintenance listed in the Inspection and Maintenance Schedule. We urge you to keep it maintained properly to ensure the safety of you and your passengers and retain its dependability. WARNING Neglected inspection and maintenance service of your outboard or attempting to perform maintenance or repair on your outboard if you are not familiar with the correct service and safety procedures could cause personal injury, death, or product failure. Before Each Use 1. Check engine oil level. 2. Check that lanyard stop switch stops the engine. 3. Visually inspect the fuel system for deterioration or leaks. 4. Check outboard for tightness on transom. 5. Check steering system for binding or loose components. 6. Visually check steering link rod fasteners for proper tightness. 7. Check propeller blades for damage. After Each Use 1. Flush out the outboard cooling system if operating in salt or polluted water. 2. Wash off all salt deposits and flush out the exhaust outlet of the propeller and gear case with fresh water if operating in salt water. Page 1B-4 90-828631R3 MARCH 1999 MAINTENANCE Every 100 Hours of Use or Once yearly, Whichever occurs first 1. Lubricate all lubrication points. Lubricate more frequently when used in salt water. 2. Change engine oil and replace the oil filter. The oil should be changed more often when the engine is operated under adverse conditions such as extended trolling. 3. Inspect thermostat visually for corrosion, broken spring, and to determine that the valve is completely closed at room temperature. If questionable, inspect thermostat as outlined in Section 4B “Thermostat”. 4. Inspect and clean spark plugs. 5. Check engine fuel filter for contaminants. 6. Adjust carburetor(s) (if required). 7. Check engine timing setup. 8. Check corrosion control anodes. Check more frequently when used in salt water. 9. Drain and replace gear case lubricant. 10. Lubricate splines on the drive shaft. 11. Check and adjust valve clearance, if necessary. 12. Check power trim fluid. 13. Inspect battery. 14. Check control cable adjustments. 15. Inspect timing belt. 16. Remove engine deposits with Quicksilver Power Tune Engine Cleaner. 17. Check tightness of bolts, nuts, and other fasteners. Every 300 Hours of Use or Three Years 1. Replace water pump impeller (more often if overheating occurs or reduced water pressure is noted). Before Periods of Storage 1. Refer to Storage procedure (this section). 90-828631R3 MARCH 1999 Page 1B-5 MAINTENANCE Corrosion Control Anode Your outboard has control anodes at different locations. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard metals. Each anode requires periodic inspection especially in salt water which will accelerate the erosion. To maintain this corrosion protection, always replace the anode before it is completely eroded. Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode. 1. An anode is installed on the bottom of the transom bracket assembly. Trim tab is also an anode on the 3-1/4 in. (83 mm) diameter gear case. The 4-1/4 in. (108 mm) diameter gear case has three anodes. One of the anodes is the trim tab and two anodes are located on the side. a b c a-Bottom Anode b-Trim Tab c-Side Anodes 2. Four anodes are installed in the engine block. Remove anodes at locations shown. Install each anode with rubber seal and cover. Torque bolts to specified torque. ab c a-Anodes-Engine Block b-Rubber Seal c-Cover Bolt Torque 70 lb-in. (8 Nm) Page 1B-6 90-828631R3 MARCH 1999 MAINTENANCE Spark Plug Inspection Inspect spark plugs at the recommended intervals. 1. Remove the spark plug leads by twisting the rubber boots slightly and pull off. 2. Remove the spark plugs to inspect and clean. Replace spark plug if electrode is worn or the insulator is rough, cracked, broken, blistered or fouled. 3. Set the spark plug gap. See Specification Chart. 4. Before reinstalling spark plugs, clean away dirt on the spark plug seats. Install plugs finger tight, and tighten 1/4 turn or torque to specified torque. Spark Plug Torque 20 lb-in. (27 Nm) Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability. IMPORTANT: Read the safety and maintenance instructions which accompany your battery. 1. Turn off the engine before servicing the battery. 2. Add water as necessary to keep the battery full. 3. Make sure the battery is secure against movement. 4. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive and negative to negative. 5. Make sure the battery is equipped with a nonconductive shield to prevent accidental shorting of battery terminals. 90-828631R3 MARCH 1999 Page 1B-7 MAINTENANCE Page 1B-8 90-828631R3 MARCH 1999 Fuse Replacement – Electric Start Models The electric starting circuit is protected from overload by an SFE 20 AMP fuse. If the fuse is blown, the electric starter motor will not operate. Try to locate and correct the cause of the overload. If the cause is not found, the fuse may blow again. Replace the fuse with a fuse of the same rating. 1. Open the fuse holder and look at the silver colored band inside the fuse. If band is broken replace the fuse. Replace fuse with a new fuse with the same rating. a a - Blown Fuse Timing Belt Inspection 1. Inspect the timing belt and replace if any of the following conditions are found. a. Cracks in the back of the belt or in the base of the belt teeth. b. Excessive wear at the roots of the cogs. c. Rubber portion swollen by oil. d. Belt surfaces roughened. e. Signs of wear on edges or outer surfaces of belt. a a - Timing Belt MAINTENANCE Lubrication Points Lubricate Point 1 with Quicksilver Anti-Corrosion Grease or 2-4-C Marine Lubricant with Teflon 1. Propeller Shaft – Refer to Propeller Replacement for removal and installation of the propeller. Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft. 1 Lubricate Points 2 thru 4 with Quicksilver 2-4-C Marine Lubricant with Teflon or Special Lubricant 101. 2. Swivel Bracket – Lubricate through fitting. 3. Tilt Support Lever – Lubricate through fitting. 2 3 90-828631R3 MARCH 1999 Page 1B-9 MAINTENANCE Lubricate Point 4 with light weight oil. 4. Steering Cable Grease Fitting – Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube. Lubricate through fitting. Lubricate steering link rod pivot points with light weight oil. b a 4 a-Steering Cable End b-Fitting WARNING The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant. Adding lubricant to steering cable when fully extended could cause steering cable to become hydraulically locked. An hydraulically locked steering cable will cause loss of steering control, possibly resulting in serious injury or death. Checking Power Trim Fluid 1. Tilt outboard to the full up position and engage the tilt support lock. a a-Tilt Support Lock 2. Remove fill cap and check fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver Power Trim & Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. a a-Fill Cap Page 1B-10 90-828631R3 MARCH 1999 MAINTENANCE Changing Engine Oil Engine Oil Capacity 3 U.S. Quarts (3.0 Liters) Oil Changing Procedure Pump Method 1. Place the outboard in an vertical upright position. 2. Remove dipstick and thread a Quicksilver Crankcase Oil Pump onto the dipstick tube. Pump out the engine oil into an appropriate container. a a-Crankcase Oil Pump Drain Plug Method 1. Tilt the outboard up to the trailer position. 2. Turn the steering on the outboard so that the drain hole is facing downward. Remove drain plug and drain engine oil into an appropriate container. Lubricate the seal on the drain plug with oil and reinstall. a a-Drain Hole 90-828631R3 MARCH 1999 Page 1B-11 MAINTENANCE Page 1B-12 90-828631R3 MARCH 1999 Changing Oil Filter 1. Place a rag or towel below the oil filter to absorb any spilled oil. 2. Unscrew old filter by turning the filter counterclockwise. 3. Clean the mounting base. Apply film of clean oil to filter gasket. Do not use grease. Screw new filter on until gasket contacts base, then tighten 3/4 to 1 turn. 91-802653 a a - Oil Filter Oil Filling 1. Remove the oil fill cap and add oil to the proper operating level. 2. Idle engine for five minutes and check for leaks. Stop engine and check oil level on dipstick. Add oil if necessary. a a - Oil Fill Cap MAINTENANCE Gear Case Lubrication When adding or changing gear case lubricant, visually check for the presence of water in the lubricant. If water is present, it may have settled to the bottom and will drain out prior to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance. If water is noticed, have the gear case checked by your dealer.Water in the lubricant may result in premature bearing failure or, in freezing temperatures, will turn to ice and damage the gear case. Whenever you remove the fill/drain plug, examine the magnetic end for metal particles. A small amount of metal filings or fine metal particles indicates normal gear wear. An excessive amount of metal filings or larger particles (chips) may indicate abnormal gear wear and should be checked by an authorized dealer. 3-1/4 In. (83mm) Diameter Gear Case DRAINING GEAR CASE 1. Place outboard in a vertical operating position. 2. Place a drain pan below outboard. 3. Remove vent plug and fill/drain plug and drain lubricant. a a-Vent Plug and Fill/Drain Plug GEAR CASE LUBRICANT CAPACITY Gear case lubricant capacity is approximately 14.9 fl oz (440 ml). 90-828631R3 MARCH 1999 Page 1B-13 MAINTENANCE CHECKING GEAR CASE LUBRICANT LEVEL AND REFILLING GEAR CASE 1. Place outboard in a vertical operating position. 2. Remove vent plug. 3. Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole. IMPORTANT: Replace sealing washers if damaged. 4. Stop adding lubricant. Install the vent plug and sealing washer before removing the lubricant tube. 5. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer. a b c d a-Vent Plug/Sealing Washer b-Lubricant Tube c-Vent Hole d-Fill/Drain Plug and Sealing Washer 4-1/4 In. (108mm) Diameter Gear Case When adding or changing gear case lubricant, visually check for the presence of water in the lubricant. If water is present, it may have settled to the bottom and will drain out prior to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance. If water is noticed, have the gear case checked by your dealer. Water in the lubricant may result in premature bearing failure or, in freezing temperatures, will turn to ice and damage the gear case. Whenever you remove the fill/drain plug, examine the magnetic end for metal particles. A small amount of metal filings or fine metal particles indicates normal gear wear. An excessive amount of metal filings or larger particles (chips) may indicate abnormal gear wear and should be checked by an authorized dealer. Page 1B-14 90-828631R3 MARCH 1999 MAINTENANCE DRAINING GEAR CASE 1. Place outboard in a vertical operating position. 2. Place a drain pan below outboard. 3. Remove vent plugs and fill/drain plug and drain lubricant. a a-Vent Plugs and Fill/Drain Plug GEAR CASE LUBRICANT CAPACITY Gear case lubricant capacity is approximately 22.5 fl oz (655 ml). CHECKING LUBRICANT LEVEL AND FILLING GEAR CASE 1. Place outboard in a vertical operating position. 2. Remove the front vent plug and rear vent plug. 3. Place lubricant tube into the fill hole and add lubricant until it appears at the front vent hole. At this time install the front vent plug and sealing washer. 4. Continue adding lubricant until it appears at the rear vent hole. 5. Stop adding lubricant. Install the rear vent plug and sealing washer before removing lubricant tube. 6. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer. a c d e b a-Front Vent Plug b-Rear Vent Plug c-Front Vent Hole d-Rear Vent Hole e-Fill/Drain Plug and Sealing Washer 90-828631R3 MARCH 1999 Page 1B-15 MAINTENANCE Storage Preparation The major consideration in preparing your outboard for storage is to protect it from rust, corrosion, and damage caused by freezing of trapped water. The following storage procedures should be followed to prepare your outboard for out-ofseason storage or prolonged storage (two months or longer). CAUTION Never start or run your outboard (even momentarily) without water circulating through the cooling water intake in the gear case to prevent damage to the water pump (running dry) or overheating of the engine. Fuel System IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a formation of acid during storage and can damage the fuel system. If the gasoline being use contains alcohol, it is advisable to drain as much of the remaining gasoline as possible from the fuel tank, remote fuel line, and engine fuel system. Fill the fuel system (tank, hoses, fuel pump, and carburetor) with treated (stabilized) fuel to help prevent formation of varnish and gum. Proceed with following instructions. 1. Portable Fuel Tank – Pour the required amount of Quicksilver Gasoline Stabilizer (follow instructions on container) into fuel tank. Tip fuel tank back and forth to mix stabilizer with the fuel. 2. Permanently Installed Fuel Tank – Pour the required amount of Quicksilver Gasoline Stabilizer (follow instructions on container) into a separate container and mix with approximately one quart (one liter) of gasoline. Pour this mixture into fuel tank. 3. Place the outboard in water or connect flushing attachment for circulating cooling water. Run the engine for ten minutes to allow treated fuel to reach the carburetor. Protecting External Outboard Components 1. Lubricate all outboard components listed in the Inspection and Maintenance Schedule. 2. Touch up any paint nicks. 3. Spray Quicksilver Corrosion Guard on external metal surfaces (except corrosion control anodes). Protecting Internal Engine Components 1. Remove the spark plugs and inject a small amount of engine oil inside of each cylinder. 2. Rotate the flywheel manually several times to distribute the oil in the cylinders. Reinstall spark plugs. 3. Change the engine oil. Gear Case 1. Drain and refill the gear case lubricant (refer to maintenance procedure). Page 1B-16 90-828631R3 MARCH 1999 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 may have entered the propeller exhaust outlet in the gear case could freeze and cause damage to the outboard. Battery Storage 1. Follow the battery manufacturer’s instructions for storage and recharging. 2. Remove the battery from the boat and check water level. Recharge if necessary. 3. Store the battery in a cool, dry place. 4. Periodically check the water level and recharge the battery during storage. 90-828631R3 MARCH 1999 Page 1B-17 GENERAL INFORMATION IMPORTANT INFORMATION Section 1C - General Information Table of Contents 1 C Serial Number Location . . . . . . . . . . . . . . . . . . . . 1C-1 Conditions Affecting Performance . . . . . . . . . . . 1C-2 Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2 Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-4 Following Complete Submersion . . . . . . . . . . . . 1C-5 Submerged While Running (Special Instructions) . . . . . . . . . . . . . . . . . . . 1C-5 Salt Water Submersion (Special Instructions) . . . . . . . . . . . . . . . . . . . 1C-5 Fresh Water Submersion (Special Instructions) . . . . . . . . . . . . . . . . . . . 1C-5 Propeller Selection . . . . . . . . . . . . . . . . . . . . . . . . 1C-6 Propeller Removal/Installation . . . . . . . . . . . . . . 1C-7 Standard Models . . . . . . . . . . . . . . . . . . . . . . . 1C-7 Power Trim System . . . . . . . . . . . . . . . . . . . . . . . . 1C-9 General Information . . . . . . . . . . . . . . . . . . . . 1C-9 Power Trim Operation . . . . . . . . . . . . . . . . . . . 1C-9 Trim “In” Angle Adjustment . . . . . . . . . . . . . 1C-10 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . 1C-12 Compression Check . . . . . . . . . . . . . . . . . . . . . . 1C-12 Cylinder Leakage Testing . . . . . . . . . . . . . . . . . . 1C-13 Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-13 Painting Procedures . . . . . . . . . . . . . . . . . . . . . . 1C-14 Cleaning & Painting Aluminum Propellers & Gear Housings . . . . . . . . . . . . 1C-14 Decal Application. . . . . . . . . . . . . . . . . . . . . . . . . 1C-15 Decal Removal. . . . . . . . . . . . . . . . . . . . . . . . 1C-15 Instructions for “Wet” Application . . . . . . . . 1C-15 Serial Number Location The Outboard serial number is located on the lower starboard side of the engine block. A serial number is also located on the starboard side of the swivel bracket. 19XX OGXXXXXX XXXX XX e d c b a a-Serial Number b-Model Year c-Model Description d-Year Manufactured e-Certified Europe Insignia 90-828631R3 MARCH 1999 Page 1C-1 GENERAL INFORMATION Conditions Affecting Performance Weather Rated hp Summer hp Horsepower Loss Due to Atmosphere Conditions Secondary Loss Due to Propeller Becoming To Large for Summer Horsepower RPM Drop Due to Weather ENGINE RPM Rated RPM It is a known fact that weather conditions exert a profound effect on power output of internal combustion engines. Therefore, established horsepower ratings refer to the power that the engine will produce at its rated rpm under a specific combination of weather conditions. Corporations internationally have settled on adoption of I.S.O. (International Standards Organization) engine test standards, as set forth in I.S.O. 3046 standardizing the computation of horsepower from data obtained on the dynamometer, correcting all values to the power that the engine will produce at sea level, at 30% relative humidity at 77° F (25° C) temperature and a barometric pressure of 29.61 inches of mercury. Summer Conditions of high temperature, low barometric pressure and high humidity all combine to reduce the engine power. This, in turn, is reflected in decreased boat speeds--as much as 2 or 3 miles-per-hour (3 or 5 Km per-hour) in some cases. (Refer to previous chart.) Nothing will regain this speed for the boater, but the coming of cool, dry weather. In pointing out the practical consequences of weather effects, an engine--running on a hot, humid summer day--may encounter a loss of as much as 14% of the horsepower it would produce on a dry, brisk spring or fall day. The horsepower, that any internal combustion engine produces, depends upon the density of the air that it consumes and, in turn, this density is dependent upon the temperature of the air, its barometric pressure and water vapor (or humidity) content. Accompanying this weather-inspired loss of power is a second but more subtle loss. At rigging time in early spring, the engine was equipped with a propeller that allowed the engine to turn within its recommended rpm range at full throttle. With the coming of the summer weather and the consequent drop in available horsepower, this propeller will, in effect, become too large. Consequently, the engine operates at less than its recommended rpm. Page 1C-2 90-828631R3 MARCH 1999 GENERAL INFORMATION Due to the horsepower/rpm characteristics of an engine, this will result in further loss of horsepower at the propeller with another decrease in boat speed. This secondary loss, however, can be regained by switching to a smaller pitch propeller that allows the engine to again run at recommended rpm. For boaters to realize optimum engine performance under changing weather conditions, it is essential that the engine have the proper propeller to allow it to operate at or near the top end of the recommended maximum rpm range at wide-open-throttle with a normal boat load. Not only does this allow the engine to develop full power, but equally important is the fact that the engine also will be operating in an rpm range that discourages damaging detonation. This, of course, enhances overall reliability and durability of the engine. Boat WEIGHT DISTRIBUTION 1. Proper positioning of the weight inside the boat (persons and gear) has a significant effect on the boat’s performance, for example: a. Shifting weight to the rear (stern) (1.) Generally increases top speed. (2.) If in excess, can cause the boat to porpoise. (3.) Can make the bow bounce excessively in choppy water. (4.) Will increase the danger of the following - wave splashing into the boat when coming off plane. b. Shifting weight to the front (bow) (1.) Improves ease of planing off. (2.) Generally improves rough water ride. (3.) If excessive, can make the boat veer left and right (bow steer). BOTTOM For maximum speed, a boat bottom should be nearly a flat plane where it contacts the water and particularly straight and smooth in fore-and-aft direction. 1. Hook: Exists when bottom is concave in fore-and-aft direction when viewed from the side. When boat is planing, “hook” causes more lift on bottom near transom and allows bow to drop, thus greatly increasing wetted surface and reducing boat speed. “Hook” frequently is caused by supporting boat too far ahead of transom while hauling on a trailer or during storage. 2. Rocker: The reverse of hook and much less common. “Rocker” exists if bottom is convex in fore-and-aft direction when viewed from the side, and boat has strong tendency to porpoise. 3. Surface Roughness: Moss, barnacles, etc., on boat or corrosion of outboard’s gear housing increase skin friction and cause speed loss. Clean surfaces when necessary. WATER ABSORPTION It is imperative that all through hull fasteners be coated with a quality marine sealer at time of installation. Water intrusion into the transom core and/or inner hull will result in additional boat weight (reduced boat performance), hull decay and eventual structural failure. 90-828631R3 MARCH 1999 Page 1C-3 GENERAL INFORMATION CAVITATION Cavitation is caused by water vapor bubbles forming either from a sharp edge or angle on the gear case or from an irregularity in the propeller blade itself. These vapor bubbles flow back and collapse when striking the surface of the propeller blade resulting in the erosion of the propeller blade surface. If allowed to continue, eventual blade failure (breakage) will occur. Engine DETONATION Detonation in a 4-cycle engine resembles the “pinging” heard in an automobile engine. It can be otherwise described as a tin-like “rattling” or “plinking” sound. Detonation is an explosion of an unburned portion of the fuel/air charge after the spark plug has fired. Detonation creates severe shock waves in the engine, and these shock waves often find or create a weakness: The dome of a piston, cylinder head/gasket, piston rings or piston ring lands, piston pin and roller bearings. A few of the most common causes of detonation in a marine 4-cycle application are as follows: • Over-advanced ignition timing. • Use of low octane gasoline. • Propeller pitch too high (engine rpm below recommended maximum range). • Lean fuel mixture at or near wide-open-throttle. • Spark plugs (heat range too hot - incorrect reach - cross-firing). • Inadequate engine cooling (deteriorated cooling system). • Combustion chamber/piston deposits (result in higher compression ratio). Detonation usually can be prevented if: 1. The engine is correctly set up. 2. Diligent maintenance is applied to combat the detonation causes. 51115 Damaged Piston Resulting from Detonation Page 1C-4 90-828631R3 MARCH 1999 GENERAL INFORMATION Following Complete Submersion Submerged While Running (Special Instructions) When an engine is submerged while running, the possibility of internal engine damage is greatly increased. If, after engine is recovered and with spark plugs removed, engine fails to turn over freely when turning flywheel, the possibility of internal damage (bent connecting rod and/or bent crankshaft) exists. If this is the case, the powerhead must be disassembled. Salt Water Submersion (Special Instructions) Due to the corrosive effect of salt water on internal engine components, complete disassembly is necessary before any attempt is made to start the engine. Fresh Water Submersion (Special Instructions) 1. Recover engine as quickly as possible. 2. Remove cowling. 3. Flush exterior of outboard with fresh water to remove mud, weeds, etc. DO NOT attempt to start engine if sand has entered powerhead, as powerhead will be severely damaged. Disassemble powerhead if necessary to clean components. 4. Remove spark plugs and get as much water as possible out of powerhead. Most water can be eliminated by placing engine in a horizontal position (with spark plug holes down) and rotating flywheel. 5. Change engine oil and filter as outlined in Section 1B “Changing Engine Oil”. Run outboard for short time and check for presence of water in oil. If water present (milky appearance) drain and refill as previously mentioned. 6. Pour alcohol into carburetor throats (alcohol will absorbed water). Again rotate flywheel. 7. Turn engine over and pour alcohol into spark plug openings and rotate flywheel. 8. Turn engine over (place spark plug openings down) and pour engine oil into throat of carburetors while rotating flywheel to distribute oil throughout crankcase. 9. Again turn engine over and pour approximately one teaspoon of engine oil into each spark plug opening. Again rotate flywheel to distribute oil in cylinders. 10. Remove and clean carburetors and fuel pump assembly. 11. Dry all wiring and electrical components using compressed air. 12. Disassemble the engine starter motor and dry the brush contacts, armature and other corrodible parts. 13. Reinstall spark plugs, carburetors and fuel pump. 14. Attempt to start engine, using a fresh fuel source. If engine starts, it should be run for at least one hour to eliminate any water in engine. 15. If engine fails to start, determine cause (fuel, electrical or mechanical). Engine should be run within 2 hours after recovery of outboard from water, or serious internal damage may occur. If unable to start engine in this period, disassemble engine and clean all parts. Apply oil as soon as possible. 90-828631R3 MARCH 1999 Page 1C-5 GENERAL INFORMATION Propeller Selection For in-depth information on marine propellers and boat performance - written by marine engineers - see your Authorized Dealer for the illustrated “What You Should Know About Quicksilver Propellers...and Boat Performance Information” (Part No. 90-86144). For best all around performance from your outboard/boat combination, select a propeller that allows the engine to operate in the upper half of the recommended full throttle rpm range with the boat normally loaded (refer to Specifications). This rpm range allows for better acceleration while maintaining maximum boat speed. If changing conditions cause the rpm to drop below the recommended range (such as warmer, more humid weather, operation at higher elevations, increased boat load or a dirty boat bottom/gear case) a propeller change or cleaning may be required to maintain performance and ensure the outboard’s durability. Check full-throttle rpm using an accurate tachometer with the engine trimmed out to a balanced- steering condition (steering effort equal in both directions) without causing the propeller to “break loose”. Refer to “Quicksilver Accessory Guide” for a complete list of available propellers. 1. Select a propeller that will allow the engine to operate at or near the top of the recommended full throttle rpm range (listed in “Specifications,” preceding) with a normal load. Maximum engine speed (rpm) for propeller selection exists when boat speed is maximum and trim is minimum for that speed. (High rpm, caused by an excessive trim angle, should not be used in determining correct propeller.) Normally, there is a 150-350 rpm change between propeller pitches. 2. If full throttle operation is below the recommended range, the propeller MUST BE changed to one with a lower pitch to prevent loss of performance and possible engine damage. 3. After initial propeller installation, the following common conditions may require that the propeller be changed to a lower pitch: a. Warmer weather and great humidity will cause an rpm loss. b. Operating in a higher elevation causes an rpm loss. c. Operating with a damaged propeller or a dirty boat bottom or gear housing will cause an rpm loss. d. Operation with an increased load (additional passengers, equipment, pulling skiers, etc.). Page 1C-6 90-828631R3 MARCH 1999 GENERAL INFORMATION Propeller Removal/Installation Standard Models WARNING If the propeller shaft is rotated while the engine is in gear, there is the possibility that the engine will crank over and start. To prevent this type of accidental engine starting and possible serious injury caused from being struck by a rotating propeller, always shift outboard to neutral position and remove spark plug leads when you are servicing the propeller. 1. Shift outboard to neutral position. N N 2. Remove the spark plug leads to prevent engine from starting. 3. Straighten the bent tabs on the tab washer. a 90-828631R3 MARCH 1999 Page 1C-7 GENERAL INFORMATION 4. Place a block of wood between gear case and propeller to hold propeller and remove propeller nut. 5. Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. 6. Coat the propeller shaft with Quicksilver Anti-Corrosion Grease or 2-4-C Marine Lubricant with Teflon. IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft, especially in salt water, always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed. 7. Flo-Torque I Drive Hub Propellers d c b a a-Forward Thrust Hub b-Propeller c-Tab Washer d-Propeller Nut Page 1C-8 90-828631R3 MARCH 1999 GENERAL INFORMATION 8. Flo-Torque II Drive Hub Propellers e d c b a f a -Forward Thrust Hub b -Propeller c -Drive Sleeve d -Rear Thrust Hub e -Tab Washer f -Propeller Nut 9. Place propeller nut retainer over pins. Place a block of wood between gear case and propeller and tighten propeller nut to 55 lb-ft (75 Nm), aligning flat sides of the propeller nut with tabs on the tab washer. 10. Secure propeller nut by bending tabs up and against the flats on the propeller nut. a a b b a-Tab Washer Pins b-Tabs 11. Reinstall spark plug leads. Power Trim System General Information The power trim system is filled at the manufacturer and is ready for use. Trim outboard through entire trim and tilt range several times to remove any air from the system. The trim system is pressurized and is not externally vented. Power Trim Operation With most boats, operating around the middle of the “trim” range will give satisfactory results. However, to take full advantage of the trimming capability there may be times when you choose to trim your outboard all the way in or out. Along with an improvement in some performance aspects comes a greater responsibility for the operator, and this is being aware of some potential control hazards. The most significant control hazard is a pull or “torque” that can be felt on the steering wheel or tiller handle. This steering torque results from the outboard being trimmed so that the propeller shaft is not parallel to the water surface. 90-828631R3 MARCH 1999 Page 1C-9 GENERAL INFORMATION WARNING Avoid possible serious injury or death. When the outboard is trimmed in or out beyond a neutral steering condition, a pull on the steering wheel or tiller handle in either direction may result. Failure to keep a continuous firm grip on the steering wheel or tiller handle when this condition exists can result in loss of boat control as the outboard can turn freely. The boat can now “spin out” or go into a very tight maximum turn which, if unexpected, can result in occupants being thrown within the boat or out of the boat. Consider the following lists carefully: TRIMMING IN OR DOWN CAN: 1. Lower the bow. 2. Result in quicker planing off, especially with a heavy load or a stern heavy boat. 3. Generally improve the ride in choppy water. 4. Increase steering torque or pull to the right (with the normal right hand rotation propeller). 5. In excess, lower the bow of some boats to a point where they begin to plow with their bow in the water while on plane. This can result in an unexpected turn in either direction called “bow steering” or “over steering” if any turn is attempted or if a significant wave is encountered. WARNING Avoid possible serious injury or death. Adjust outboard to an intermediate trim position as soon as boat is on plane to avoid possible ejection due to boat spin-out. Do not attempt to turn boat when on plane if outboard is trimmed extremely in or down and there is a pull on the steering wheel or tiller handle. TRIMMING OUT OR UP CAN: 1. Lift the bow higher out of the water. 2. Generally increase top speed. 3. Increase clearance over submerged objects or a shallow bottom. 4. Increase steering torque or pull to the left at a normal installation height (with the normal right hand rotation propeller). 5. In excess, cause boat “porpoising” (bouncing) or propeller ventilation. 6. Cause engine overheating if any water intake holes are above the water line. Trim “In” Angle Adjustment Some outboard boats, particularly some bass boats, are built with a greater than normal transom angle which will allow the outboard to be trimmed further “in” or “under”. This greater trim “under” capability is desirable to improve acceleration, reduce the angle and time spent in a bow high boat, altitude during planing off, and in some cases, may be necessary to plane off a boat with aft live wells, given the variety of available propellers and height range of engine installations. However, once on plane, the engine should be trimmed to a more intermediate position to a avoid a bow-down planing condition called “plowing”. Plowing can cause “bow steering” or “over steering” and inefficiently consumes horsepower. In this condition, if attempting a turn or encountering a diagonal, moderate wake, a more abrupt turn than intended may result. Page 1C-10 90-828631R3 MARCH 1999 GENERAL INFORMATION In rare circumstances, the owner may decide to limit the trim in. This can be accomplished by repositioning the tilt stop pins into whatever adjustment holes in the transom brackets is desired. WARNING Avoid possible serious injury or death. Adjust outboard to an intermediate trim position as soon as boat is on plane to avoid possible ejection due to boat spin-out. Do not attempt to turn boat when on plane if outboard is trimmed extremely in or down and there is a pull on the steering wheel or tiller handle. 50 HP NON-BIGFOOT MODELS aa a-Tilt Stop Pins 50 HP BIGFOOT MODELS If an adjustment is required, purchase a stainless steel tilt pin (P/N 17-49930A1) and insert it through whatever pin hole is desired. The non-stainless steel shipping bolt should not be used in this application other than on a temporary basis. a 28216 a-Optional Tilt Pin 90-828631R3 MARCH 1999 Page 1C-11 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 Compression Check 1. Remove spark plugs. 2. Install compression gauge in spark plug hole. 3. Hold throttle plate at W.O.T. 4. Crank the engine over until the compression reading peaks on the gauge. Record the reading. 5. Check and record compression of each cylinder. The highest and lowest reading recorded should not differ by more than 15% (see example chart below). A reading below 120 psi might indicate a total engine wear problem. Example of compression test differences Maximum (psi) Minimum (psi) 180 162 150 127.5 6. Compression check is important because an engine with low or uneven compression cannot be tuned successfully to give peak performance. It is essential, therefore, that improper compression be corrected before proceeding with an engine tuneup. 7. Cylinder scoring: If powerhead shows any indication of overheating, such as discolored or scorched paint, visually inspect cylinders for scoring or other damage as outlined in Section 4 “Powerhead.” Page 1C-12 90-828631R3 MARCH 1999 GENERAL INFORMATION Cylinder Leakage Testing NOTE:Cylinder leakage testing*, along with compression testing, can help the mechanic pinpoint the source of a mechanical failure by gauging the amount of leakage in an engine cylinder. Refer to the manufactures tester instructions for proper testing procedures. * Courtesy of Snap-On-Tools Cylinder Leakage Tester (Snap-On-Tools MT324) NOTE: Spark plug hole is a 12 mm diameter. Use Snap-On-Tool MT26-18 adapter with valve core removed. Analysis Due to standard engine tolerances and engine wear, no cylinder will maintain a 0% of leakage. It is important only that cylinders have somewhat consistent reading between them. Differences of 15 to 30% indicate excessive leakage. Larger engines tend to have a larger percentage of cylinder leakage than smaller engines. If excessive leakage is present, first check that the piston is at top dead center of its compression stroke. Leakage will naturally occur if the exhaust or intake valve is open. To determine the cause of high percentage leaks, you must locate where the air is escaping from. Listen for air escaping thru the carburetor intake, adjacent spark plug holes, exhaust pipe, crankcase fill plug. Use the following table to aid in locating the source of cylinder leakage: Air Escaping From: Indicates Possible Defective: Carburetor Intake Valve Exhaust System Exhaust Valve Crankcase Fill Plug Piston or Rings Adjacent Cylinders Head Gasket 90-828631R3 MARCH 1999 Page 1C-13 GENERAL INFORMATION Painting Procedures Cleaning & Painting Aluminum Propellers & Gear Housings WARNING Avoid serious injury from flying debris. Avoid serious injury from airborne particles. Use eye and breathing protection with proper ventilation. PROPELLERS 1. Sand the entire area to be painted with 3M 120 Regalite Polycut or coarse Scotch-Brite, disc or belts. 2. Feather edges of all broken paint edges. Try not to sand through the primer. 3. Clean the surface to be painted using PPG Industries DX330 Wax and Grease Remover or equivalent (Xylene or M.E.K.). 4. If bare metal has been exposed, use Quicksilver’s Light Gray Primer. 5. Allow a minimum of 1 hour dry time and no more than 1 week before applying the finish coat. 6. Apply the finish coat using Quicksilver’s EDP Propeller Black. GEAR HOUSINGS The following procedures should be used in refinishing gear housings. This procedure will provide the most durable paint system available in the field. The materials recommended are of high quality and approximate marine requirements. The following procedure will provide a repaint job that compares with a properly applied factory paint finish. It is recommended that the listed materials be purchased from a local Ditzler Automotive Finish Supply Outlet. The minimum package quantity of each material shown following is sufficient to refinish several gear housings. Procedure: 1. Wash gear housing with a muriatic acid base cleaner to remove any type of marine growth, and rinse with water, if necessary. 2. Wash gear housing with soap and water, then rinse. 3. Sand blistered area with 3M 180 grit sandpaper or P180 Gold Film Disc to remove paint blisters only. Feather edge all broken paint edges. 4. Clean gear housing thoroughly with (DX-330) wax and grease remover. 5. Spot repair surfaces where bare metal is exposed with (DX-503) alodine treatment. IMPORTANT: Do not use any type of aerosol spray paints as the paint will not properly adhere to the surface nor will the coating be sufficiently thick to resist future paint blistering. 6. Mix epoxy chromate primer (DP-40) with equal part catalyst (DP-401) per manufacturers instructions, allowing proper induction period for permeation of the epoxy primer and catalyst. 7. Allow a minimum of one hour drying time and no more than one week before top coating assemblies. 8. Use Ditzler Urethane DU9000 for Mercury Black, DU34334 for Mariner Grey, and DU35466 for Force Charcoal, and DU33414M for Sea Ray White. Catalyze all four colors with Ditzler DU5 catalyst mixed 1:1 ratio. Reduce with solvents per Ditzler label. Page 1C-14 90-828631R3 MARCH 1999 GENERAL INFORMATION CAUTION Be sure to comply with instructions on the label for ventilation and respirators. Using a spray gun, apply one half to one mil even film thickness. Let dry, flash off for five minutes and apply another even coat of one half to one mil film thickness. This urethane paint will dry to the touch in a matter of hours, but will remain sensitive to scratches and abrasions for a few days. 9. The type of spray gun used will determine the proper reduction ratio of the paint. IMPORTANT: Do not paint sacrificial zinc trim tab or zinc anode. 10. Cut out a cardboard “plug” for trim tab pocket to keep paint off of mating surface to maintain good continuity circuitry between trim tab and gear housing. Decal Application Decal Removal 1. Mark decal location before removal to assure proper alignment of new decal. 2. Carefully soften decal and decal adhesive with a heat gun or heat blower while removing old decal. 3. Clean decal contact area with a 1:1 mixture of isopropyl alcohol and water. 4. Thoroughly dry decal contact area and check for a completely cleaned surface. Instructions for “Wet” Application NOTE: The following decal installation instructions are provided for a “Wet” installation. All decals should be applied wet. TOOLS REQUIRED 1. Plastic Squeegee* 2. Stick Pin 3. Dish Washing Liquid/Detergent without ammonia** “Joy” and “Drift” are known to be compatible for this process. * Automotive Body Filler Squeegee ** Do not use a soap that contains petroleum based solvents. SERVICE TIP: Placement of decals using the “Wet” application will allow time to position decal. Read entire installation instructions on this technique before proceeding. TEMPERATURE IMPORTANT: Installation of vinyl decals should not be attempted while in direct sun light. Air and surface temperature should be between 60°F (15°C) and 100°F (38°C) for best application. SURFACE PREPARATION IMPORTANT: Do not use a soap or any petroleum based solvents to clean application surface. Clean entire application surface with mild dish washing liquid and water. Rinse surface thoroughly with clean water. 90-828631R3 MARCH 1999 Page 1C-15 GENERAL INFORMATION DECAL APPLICATION 1. Mix 1/2 ounce (16 ml) of dish washing liquid in one gallon (4 l) of cool water to use as wetting solution. NOTE:Leave protective masking, if present, on the face of decal until final steps of decal installation. This will ensure that the vinyl decal keeps its shape during installation. 2. Place the decal face down on a clean work surface and remove the paper backing from “adhesive side” of decal. 3. Using a spray bottle, flood the entire “adhesive side” of the decal with the pre-mixed wetting solution. 4. Flood area where the decal will be positioned with wetting solution. 5. Position pre-wetted decal on wetted surface and slide into position. 6. Starting at the center of the decal, “lightly” squeegee out the air bubbles and wetting solution with overlapping strokes to the outer edge of the decal. Continue going over the decal surface until all wrinkles are gone and adhesive bonds to the cowl surface. 7. Wipe decal surface with soft paper towel or cloth. 8. Wait 10 - 15 minutes. 9. Starting at one corner, “carefully and slowly” pull the masking off the decal surface at a 180° angle. NOTE: To remove any remaining bubbles, pierce the decal at one end of the bubble with stick pin and press out the entrapped air or wetting solution with your thumb (moving toward the puncture). Page 1C-16 90-828631R3 MARCH 1999 OUTBOARD MOTOR INSTALLATION IMPORTANT INFORMATION Section 1D - Outboard Motor Installation Table of Contents 1 D Electric Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . 1D-1 Boat Horsepower Capacity . . . . . . . . . . . . . . . . . 1D-1 Start in Gear Protection . . . . . . . . . . . . . . . . . . . . 1D-2 Selecting Accessories For The Outboard . . . . . 1D-2 Installation Specifications . . . . . . . . . . . . . . . . . . . 1D-2 Lifting Outboard. . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-3 Steering Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-3 Steering Cable Seal . . . . . . . . . . . . . . . . . . . . . . . 1D-4 Steering Link Rod . . . . . . . . . . . . . . . . . . . . . . . . . 1D-4 Installing Outboard – Thumb Screw Models . . . 1D-5 Installing Outboard – Non Thumb Screw Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-6 Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-7 Battery Cable Connections . . . . . . . . . . . . . . . . . 1D-8 Single Outboards . . . . . . . . . . . . . . . . . . . . . . . 1D-8 Dual outboards . . . . . . . . . . . . . . . . . . . . . . . . . 1D-8 Shift and Throttle Cable 45 and 50 hp Models . 1D-9 45-50 hp - Shift Cable Installation . . . . . . . . 1D-9 45-50 hp - Throttle Cable Installation . . . . . 1D-11 Trim-In Stop Adjustment – Power Trim Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-13 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . 1D-13 Electric Fuel Pump If an electric fuel pump is used, the fuel pressure must not exceed 4 psi 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. 90-828631R3 MARCH 1999 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) 22 1/2 in. (572 mm) Page 1D-2 90-828631R3 MARCH 1999 OUTBOARD MOTOR INSTALLATION 90-828631R3 MARCH 1999 Page 1D-3 Lifting Outboard 1. Use lifting eye on engine. Steering Cable STARBOARD SIDE ROUTED CABLE 1. Lubricate the entire cable end with 2-4-C Lubricant with Teflon. 95 2-4-C w/Teflon (92-850736A1) 95 2. Insert steering cable into tilt tube. 3. Torque nut to specified torque. Nut Torque 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. (6.4 mm) 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 d ef c a-Special Bolt (10-90041) Torque to 20 lb-ft (27.1 Nm) b-Nylon Insert Locknut (11-34863) Torque to 20 lb-ft (27.1 Nm) c-Spacer (12-71970) d-Flat Washer (2) e-Nylon Insert Locknut (11-34863) Tighten Locknut Until it Seats, Then Back Nut Off 1/4 Turn f-Use Middle Hole IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special bolt (“a” - Part Number 10-90041) and self locking nuts (“b” & “e” - Part Number 11-34863). These locknuts must never be replaced with common nuts (non locking) as they will work loose and vibrate off, freeing the link rod to disengage. 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 90-828631R3 MARCH 1999 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 - 25 mm) a a-Anti-Ventilation Plate 2. Fasten outboard with provided mounting hardware shown. 3. Mark and drill two 17/32 in. (13.5 mm) lower mounting holes. ab c d e a-1/2 in. Diameter Bolts (2) b-Flat Washers c-Locknuts d-Marine Sealer - Apply to Shanks of Bolts, Not Threads e-Thumb Screws - Tighten Securely 90-828631R3 MARCH 1999 Page 1D-5 OUTBOARD MOTOR INSTALLATION Installing Outboard – Non Thumb Screw Models 1. Attach (tape) engine mounting template (located in this manual) to boat transom. 2. Mark and drill four 17/32 in. (13.5 mm) mounting holes. 3. Install the outboard so that the anti-ventilation plate is in-line or within 1 in. (25 mm) below the bottom of the boat. 0 - 1 in. (0 - 25 mm) a a-Anti-Ventilation Plate 4. Fasten outboard with provided mounting hardware shown. a b c d c b a d a-1/2 in. Diameter Bolts (2) b-Flat Washers c-Locknuts d-Marine Sealer - Apply to Shanks of Bolts, Not Threads Page 1D-6 90-828631R3 MARCH 1999 OUTBOARD MOTOR INSTALLATION 90-828631R3 MARCH 1999 Page 1D-7 Wiring Harness IMPORTANT: Warning Horn Requirement – The remote control or key switch assembly must be wired with a warning horn. This warning horn is used with the engine warning system. 1. Route wiring harness into bottom cowl. 2. Connect wiring. Place harness into the holder. GRN/WHT BLU/WHT BRN/WHT TAN BLU/WHT GRN/WHT a b a - Power Trim Connections b - Holder – Place Harness Into Holder OUTBOARD MOTOR INSTALLATION Page 1D-8 90-828631R3 MARCH 1999 Battery Cable Connections Single Outboards (+) (–) a b c a - Red Sleeve (Positive) b - Black Sleeve (Negative) c - Starting Battery Dual outboards 1. Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. (–) (–) a a - Ground Cable (Same Wire Size As Engine Battery Cable) – Connect Between Negative (–) Terminals OUTBOARD MOTOR INSTALLATION Shift and Throttle Cable 45 and 50 hp Models 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. 45-50 hp - Shift Cable Installation 1. Position remote control into neutral. N 2. Shift outboard into neutral. 3. Measure the distance between pin and center of lower hole. c b a a-Distance Between Pin And Center of Lower Hole b-Pin c-Lower Hole 4. Fit shift cable through rubber grommet. a a-Shift Cable 90-828631R3 MARCH 1999 Page 1D-9 OUTBOARD MOTOR INSTALLATION 5. Push in on the cable end until resistance is felt. 6. While pushing in on the cable end, adjust the cable barrel to attain the measured distance taken in Step 3. a b a-Adjust Cable Barrel To Attain The Measured Distance Taken In Step 3 b-Cable Barrel 7. Place cable barrel into the barrel holder. Fasten cable to pin 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 90-828631R3 MARCH 1999 OUTBOARD MOTOR INSTALLATION 45-50 hp - Throttle Cable Installation 1. Position remote control into neutral. N 2. Fit throttle cable through rubber grommet. a a-Throttle Cable 3. Install throttle cable with retainer pin. Lock retainer pin in place. ab a-Throttle Cable b-Retainer Pin 90-828631R3 MARCH 1999 Page 1D-11 OUTBOARD MOTOR INSTALLATION Page 1D-12 90-828631R3 MARCH 1999 4. Move the throttle linkage arm down. a a - Throttle Linkage Arm 5. While holding down the throttle linkage arm (“a” Step 4), adjust the throttle barrel until a 1/8 in. (3.2 mm) gap exists between the oval shaped boss and the cam. 1/8 in. (3.2 mm) a b c a - Throttle Barrel b - Oval Shaped Boss c - Cam OUTBOARD MOTOR INSTALLATION 6. Fasten control cables with the cable latch. IMPORTANT: After installation, move the remote control handle a few times from the neutral position to the wide-open-throttle position in forward gear. Move handle back to neutral and repeat Step 6. Visually Check for the specified gap between the oval shaped boss and the throttle cam. If necessary, readjust the barrel. Trim-In Stop Adjustment – Power Trim Models If an adjustment is required, purchase a stainless steel tilt pin (P/N 17-49930A1) and insert it through whatever pin hole is desired. The non-stainless steel shipping bolt should not be used in this application other than on a temporary basis. a a-Tilt Pin Trim Tab Adjustment The trim tab can be adjusted within limits to help compensate for steering torque. Adjust trim tab as follows: • If boat tends to pull to the right, move the rear edge of the trim tab to the right. 90-828631R3 MARCH 1999 Page 1D-13 OUTBOARD MOTOR INSTALLATION • If boat tends to pull to the left, move the rear edge of the trim tab to the left. NOTE: Trim tab adjustment will have little effect reducing steering torque if the anti-ventilation plate is raised 2 inches (50 mm) or more above the boat bottom. Page 1D-14 90-828631R3 MARCH 1999 IGNITION ELECTRICAL Section 2A - Ignition Table of Contents 2 A Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-3 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-4 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-5 Electrical Components . . . . . . . . . . . . . . . . . . . 2A-6 Electrical Components . . . . . . . . . . . . . . . . . . . 2A-7 Ignition Description . . . . . . . . . . . . . . . . . . . . . . 2A-8 Ignition Component Description . . . . . . . . . . . 2A-8 Capacitor Discharge Unit (CDI) . . . . . . . . . 2A-8 Trigger Coil . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-9 Stator Assembly . . . . . . . . . . . . . . . . . . . . . . 2A-9 Flywheel Assembly . . . . . . . . . . . . . . . . . . . 2A-10 Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-10 Ignition Test Procedures . . . . . . . . . . . . . . . . . . 2A-11 Direct Voltage Adapter (DVA) . . . . . . . . . . 2A-11 Ignition Troubleshooting . . . . . . . . . . . . . . . . . . 2A-12 Tool: Multimeter/DVA Tester 91-99750A1 2A-12 Ignition Diagnostic Procedures . . . . . . . . . . . . 2A-13 Suggested Testing Procedures . . . . . . . 2A-13 *Recommended Test . . . . . . . . . . . . . . . . . . 2A-13 Testing Ignition Components . . . . . . . . . . . . . . 2A-15 Resistance Tests . . . . . . . . . . . . . . . . . . . . . 2A-15 Trigger Coil Test . . . . . . . . . . . . . . . . . . . 2A-15 Stator Test (Ignition Charge Coil) . . . . 2A-16 Lighting Coil . . . . . . . . . . . . . . . . . . . . . . 2A-16 Ignition Coil (Primary) . . . . . . . . . . . . . . 2A-17 Spark Plug cap Removal . . . . . . . . . . . 2A-17 Ignition Coil (Secondary) . . . . . . . . . . . 2A-17 Spark Plug Cap Resistor Test . . . . . . . 2A-18 Thermo Switch . . . . . . . . . . . . . . . . . . . . 2A-18 Flywheel Removal and Installation . . . . . . . . . 2A-19 Flywheel Removal. . . . . . . . . . . . . . . . . . . . 2A-19 Flywheel Installation . . . . . . . . . . . . . . . . . . 2A-20 Flywheel without load ring & Spacer . 2A-20 Flywheel with load ring & Spacer . . . . 2A-21 (CDI) Unit Removal and Installation . . . . . . . . 2A-22 Ignition Coil Removal and Installation . . . . . . 2A-23 Rectifier Removal and Installation . . . . . . . . . 2A-24 Stator Removal and Installation . . . . . . . . . . . 2A-25 Trigger Coil Removal and Installation . . . . . . 2A-26 90-828631R3 MARCH 1999 Page 2A-1 IGNITION Specifications Type Capacitor Discharge Ignition Spark Plug Type (NGK) NGK DPR6EA-9 Spark Plug Gap 0.035 in. (1.0 mm) Firing Order 1-3-4-2 Ignition Timing: 40/45 hp Fully Retarded 5° B.T.D.C Fully Advanced (2500-3000 rpm) 25° B.T.D.C 50 hp Fully Retarded IGNITION SYSTEM* 5° B.T.D.C Fully Advanced (2500-3000 rpm) 35° B.T.D.C *Readings taken @ 68°F Charge Coil Resistance 272 - 408 W (BRN-BLU) Trigger Coil Resistance 396 - 594 W (WHT/BLK-WHT/RED) (20°C). Ignition Coil Resistance: Primary 0.1 - 0.7 W Secondary 3.5 - 4.7 kW C.D.I. Engine Speed Limiter 6120 - 6280 rpm C.D.I. Overheat Speed Control 1600 - 2400 rpm Engine Temperature Switch Above 131° F (55° C) No Continuity Below 104° F (40° C) Continuity Page 2A-2 90-828631R3 MARCH 1999 IGNITION Special Tools 1. Flywheel Holder P/N 91-83163M. 2. Flywheel Puller P/N 91-83164M. 90-828631R3 MARCH 1999 Page 2A-3 IGNITION Flywheel 17 1 2 4 3 5 6 7 9 10 11 12 13 14 15 16 4-stroke Outboard Oil (92-828000A12)110 51 110 8 18 19 Loctite “222” Small Screw Threadlocker (92-809818)51 Page 2A-4 90-828631R3 MARCH 1999 IGNITION Flywheel REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 COVER 2 2 GROMMET 3 1 TUBING (19 IN.) 4 2 DAMPER 5 1 NUT 116 157 6 1 WASHER 7 1 FLYWHEEL 8 1 DECAL-Warning Spinning flywheel 9 3 SCREW (M6 x 25) 75 8.5 10 1 STATOR 11 1 BASE–Stator 12 2 SCREW 100 11.5 13 2 PIN 14 1 KEY 15 1 COIL–Pulser 16 2 SCREW (M5 x 10) 45 5.0 17 1 DECAL-Warning Neutral 18 1 DECAL-Engine Oil/Valve clearance 19 1 DECAL-EPA INFO (1999)(SEE NOTE) NOTE: THE EPA LABEL HAS IMPORTANT INFORMATION ON EPA EMISSION REGULATIONS. REPLACE ANY MISSING OR UNREADABLE EPA LABEL. 90-828631R3 MARCH 1999 Page 2A-5 IGNITION Page 2A-6 90-828631R3 MARCH 1999 Electrical Components NOTE: APPLY LIQUID NEOPRENE TO ALL EYELET WIRING TERMINAL CONNECTIONS. 1 2 23 5 6 7 8 9 10 11 12 13 14 15 17 18 20 19 21 22 24 26 25 27 28 29 30 31 24 32 3 4 6 9 6 6 Dielectric Grease (92-823506--1) 9 Loctite PST Pipe Sealant (92-809822) 16 14 17 6 IGNITION Electrical Components REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 2 SCREW (M6 x 25) 100 11.5 22 1 ELECTRIC CONTROLLER (50) 1 ELECTRIC CONTROLLER (4045) 3 1 BRACKET (NON-BIGFOOT) 4 1 BRACKET (BIGFOOT) 5 4 SCREW (M8 x 35) 210 17.5 23.7 6 1 SOLENOID PLATE 7 1 SCREW (M6 x 16) 75 8.5 8 2 NUT 30 3.5 9 1 STARTER SOLENOID 10 1 BRACKET 11 1 VOLTAGE REGULATOR 12 2 SCREW (M6 x 25) 100 11.5 13 1 PRESSURE SWITCH 75 8.5 14 2 PLATE 15 1 TEMPERATURE SWITCH 16 1 TEMPERATURE SWITCH 17 2 SCREW (M6 x 13) 75 8.5 18 4 GROMMET 19 4 HI–TENSION CABLE 20 4 SPARK PLUG 150 12.5 17 21 2 IGNITION COIL 22 4 SCREW (M6 x 30) 75 8.5 2323 1 DECAL-(Coil Identification #1) 1 DECAL-(Coil Identification #2) 1 DECAL-(Coil Identification #3) 1 DECAL-(Coil Identification #4) 24 1 ENGINE WIRING HARNESS 25 1 FUSE 2626 1 SCREW (M5 x 10) (NON-BIGFOOT) 30 3.5 1 SCREW (M6 x 13) (BIGFOOT) 30 3.5 27 1 SCREW (M6 x 13) 28 AR STA–STRAP 29 1 BATTERY CABLE (NEGATIVE) 30 1 INSULATOR BOOT 31 BATTERY CABLE (POSITIVE) 32 1 HARNESS–Auxiliary (HANDLE) 90-828631R3 MARCH 1999 Page 2A-7 IGNITION Ignition Description The ignition system uses CDI (Capacitor Discharge Ignition). This system provides quick voltage buildup and strong spark required for high power and high performance engines. The CDI ignition system does not incorporate mechanically operated points, therefor making this CDI unit virtually maintenance free. As the flywheel rotates, electrical power (alternating current) is produced by the capacitor charging coil. This power is rectified by diodes so that direct current voltage is utilized by the ignition system. When the silicone controlled rectifier (SCR) is off, the D.C. voltage is stored by the capacitor. As the flywheel rotates 360° from the point at which charging of the system began, the trigger coil produces voltage which is rectified and applied to the (SCR) gate. This gate signal then turns on the (SCR) and the stored voltage is shorted to ground thru the primary winding of the ignition coil. 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. The voltage stored by the capacitor holds the (SCR) on until the ignition coil current is discharged. Then once the capacitor has discharged, the (SCR) turns off and the ignition cycle is repeated. Actuating the stop switch shorts the power being produced by the charge coil to ground. This prevents charging of the capacitor and thus stops spark plug firing. Ignition Component Description Capacitor Discharge Unit (CDI) a a-Ignition CDI Unit (Capacitor Discharge Ignition) Under normal operating conditions the CDI unit controls the following: 1. Control ignition spark timing by monitoring the trigger pulses. 2. Maintains an idle timing of 5° BTDC. 3. Advances spark timing quickly to 35° BTDC under hard acceleration conditions. 4. Limits rpm of the engine to 2000 rpm in the event of low oil pressure conditions. 5. Limits rpm of the engine to 2000 rpm in the event of overheat condition. 6. Limits rpm of the engine in the event of over-speed (@ 6200 rpm). NOTE:The CDI unit controls all timing operations. There is no timing adjustment required on this outboard engine. Page 2A-8 90-828631R3 MARCH 1999 IGNITION Trigger Coil 12 a a-Trigger Coil A single wound coil with magnet core mounted to one side of the stator mounting base. The trigger is positioned on the outside of the flywheel assembly and is charged when a raised boss on the flywheel passes the trigger/magnet winding. A pulse voltage is then sent to an (SCR) switch within the CDI unit. The trigger is mounted in a fixed timing position. Stator Assembly 1 2 3 1 2 a b a-Ignition Charge Coil b-Lighting System Coils and Electrothermal Valve Coils The stator assembly located under the flywheel contains the Ignition Charge Coils, and lighting system Coils. All of these coils make up the stator assembly. As the flywheel permanent magnets pass the respective stator coil windings, an AC pulse current is produced at each coil winding when magnet polarity changes. (South to North), (North to South) etc. 90-828631R3 MARCH 1999 Page 2A-9 IGNITION Flywheel Assembly The flywheel assembly contains one permanently charged magnet which is bonded and retained to the inner wall of the flywheel. This magnet is segmented with 3 positive and 3 negative poles. (12 pole) (6 positive pulses per revolution). Ignition Coil a a-Ignition Coil and High Tension Lead Assembly The primary (+) side of the ignition coil receives voltage discharged from a capacitor in the ignition (CDI) unit. The voltage is multiplied by the coil until it can jump the spark plug gap. The ignition coil will produce a high voltage current each crankshaft revolution, producing a spark at each cylinder at the same time (Waisted Spark Ignition). Ignition coil maximum output is approximately 40,000 volts. Page 2A-10 90-828631R3 MARCH 1999 IGNITION Ignition Test Procedures Direct Voltage Adapter (DVA) WARNING DANGER – HIGH VOLTAGE/SHOCK HAZARD! Do not touch ignition components and/or metal test probes while engine is running and/or being “cranked”. STAY CLEAR OF SPARK PLUG LEADS. To assure personal safety, each individual spark plug lead should be grounded to engine. WARNING When testing or servicing the ignition system, high voltage is present. DO NOT TOUCH OR DISCONNECT any ignition parts while engine is running, while key switch is on or while battery cables are connected. CAUTION Failure to comply with the following items may result in damage to the ignition system. 1. DO NOT reverse battery cable connections. The battery negative cable is (–) ground. 2. DO NOT “spark” battery terminals with battery cable connections to check polarity. 3. DO NOT disconnect battery cables while engine is running. 4. DO NOT crank engine with CDI or Ignition Coils not grounded. CAUTION To protect against meter and/or component damage, observe the following precautions: • 400 VDC* test position (or higher) MUST BE used for all tests. • INSURE the Positive (+) lead/terminal of DVA is connected to the Positive (+) receptacle of meter. • DO NOT CHANGE meter selector switch position while engine is running and/or being “cranked”. • ALL COMPONENTS MUST BE GROUNDED during tests. Running or “cranking” engine with CDI or Ignition Coils ungrounded may damage components. * If using a meter with a built-in DVA, the DVA/400 or DVA/500 VDC test position should be used. NOTE: Test leads are not supplied with the Direct Voltage Adapter. Use test leads supplied with multi meter. Test procedures and specifications are provided for checking primary ignition voltage while the engine is running and/or being “cranked” with all harnesses connected. 90-828631R3 MARCH 1999 Page 2A-11 IGNITION Ignition Troubleshooting WARNING DANGER - HIGH VOLTAGE/SHOCK HAZARD! Do not touch ignition components and/or metal test probes while engine is running and/or being “cranked”. STAY CLEAR OF SPARK PLUG LEADS. To assure personal safety, each individual spark plug lead should be grounded to engine. WARNING When testing or servicing the ignition system, high voltage is present. DO NOT TOUCH OR DISCONNECT any ignition parts while engine is running. Tool: Multimeter/DVA Tester 91-99750A1 Component Test Selector Switch Position DVA Lead Red DVA Lead Black Voltage Reading(1) @300-3000 RPM Coil Primary 400 DVA* Coil (–) Black (B) Lead (2) ** Coil (+) Orange (O) Lead (2) ** 160 - 280 (1) Stator Charge Coil 400 DVA* Brown (Br) Lead (2) Ground 160 - 280 (1) (CDI) Unit Stop Circuit 20 DVA (CDI) Unit White (W) Lead (2) Ground 3 - 7 * If using a meter that requires a DVA adapter, place selector switch to the 400 VDC position. ** Reverse Polarity (1) Readings may vary at cranking speed or at idle speed. (2) Back probe the electrical lead bullet connector in order to make connection. Multimeter Ohm Checks Tested Part Multimeter Wires Connected To: Meter Scale Meter Reading Stator Charge Coil Red Black Blue (2) Brown (1) R x 1 W 272 - 408 Trigger Coil Red Black White/Red (1) White/Blk (2) R x 1 W 396 - 594 Ignition Coil Primary (with wires disconnected) Red Black Orange (O) Black (B) R x 1 W 0.1 - 0.7 Ignition Coil Secondary (test with coil leads disconnected and the high tension lead cap removed)*** Red Black High Tension Lead #1 High Tension Lead #2 k W 3.5 - 5.2 NOTE: Copper is an excellent conductor, however, resistance may notably vary between low and high temperature. Therefore, reasonable differences can be accepted between resistance readings and specifications. The above readings are for a cold (room temperature) engine. Resistance will increase if the engine is warm. *** High tension lead cap contain a 5k ohm resister. Remove caps when making secondary ignition coil test. Page 2A-12 90-828631R3 MARCH 1999 IGNITION Ignition Diagnostic Procedures TROUBLESHOOTING TIP: With engine running, use inductive timing light to check spark advance of each cylinder as throttle is opened and closed. If timing advances and retards on each cylinder, ignition system is MOST LIKELY functioning properly. IMPORTANT: If outboard appears to have an ignition system failure, it is recommended that before beginning in-depth troubleshooting: • Ensure that the engine is mechanically sound condition. (Fuel System, Cylinder Compression etc.) • Check all engine ground leads for loose or corroded connections. • 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. *Recommended Test (1) DVA TEST (Direct Voltage Adapter) (2) OHM TEST (Resistance Testing) (3) Replace Component and Retest (4) Mechanical Test/Repair PROBLEM/CONDITION Probable Cause *Perform Test No. No Spark Condition (Both Cylinders) Trigger 2 Stator 1-2 (CDI) Unit Stop Circuit Short to Ground: 1-3 a - stop circuit lead 2 b - lanyard stop switch 2 c - tiller handle stop button 2 d- remote control harness 2 Ignition Coil 2 Spark Plugs Open Ground Condition: 3 a - ignition coil 2 b - (CDI) unit 3 c - stator ground 2 No Spark Condition (One Cylinder) High Tension Lead Spark Plug Cap (Resistor) Spark Plug 2 2 3 90-828631R3 MARCH 1999 Page 2A-13 IGNITION Weak Spark Condition Ground Connection at: (Low Primary Voltage) a - ignition coil 2 b - (CDI) unit 2 c - stator 2 High Resistance To Ground at: a - stop/lanyard switch (water/corrosion) 2 Weak Charge Coil 1-2 (CDI) Unit Failure 1-3 Ignition Coil/High Tension Lead(s) 2 Spark Plug(s) 3 Spark Plug Cap (Resistor) 2 Timing Fluctuates Loss Of Oil Pressure: Note: It is considered normal for the timing to fluctuate approximately 1° - 2° within the a - timing retards and fluctuates, rpm will drop below 2000 rpm 4 designated timing window. Flywheel Key Sheared 4 (CDI) Unit 3 *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. Timing Will Not Advance Low Oil Pressure: a - timing retards and fluctuates, rpm will remain below 2000 rpm 4 (CDI) Unit 1-3 Engine Misfires At High RPM Low Oil Pressure: a - timing retards and fluctuates, rpm will remain below 2000 rpm 4 Ignition Coil/High Tension Lead(s) 2 Spark Plug Cap(s) 5k W Resistor 2 Spark Plug(s) 3 (CDI) Unit Ground Connection: 1-3 a - (CDI) unit 2 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 1 Engine Will Not Run Over 2000 RPM Low Oil Pressure a - timing retards and fluctuates, rpm will remain below 2000 rpm 4 Stator 1-2 Ignition Coil/High Tension Lead(s) 2 (CDI) Unit 1-3 Spark Plug(s) 3 Page 2A-14 90-828631R3 MARCH 1999 IGNITION Engine Occasionally Misfires Charge Coil 1-2 (CDI) Unit 1-3 Ignition Coil/High Tension Lead(s) 2 Spark Plug Cap(s) 5k W Resistor 2 Spark Plug(s) Ground Connection at: 3 a - ignition coil 2 b - (CDI) unit 2 c - stator High Resistance To Ground at: 2 a - stop/lanyard switch (water/corrosion) 2 Engine Surges Over 5700 RPM While Boat Under Propped 4 Under Load Note: The engine (CDI) unit will retard timing and reduce RPM above 5700 RPM. Propeller Hub Spun 4 Testing Ignition Components Resistance Tests When performing resistance tests, all component leads must be disconnected. Readings may very slightly due to temperature changes. Reading listed taken at 68° (20° C). TRIGGER COIL TEST 12 VOLTS DC AMPS OHMS 0 2 4 6 8 10 DCV ACV DVA 0 0 5 10 20 10 30 15 40 20 05101520304060100200 12 METER TEST LEADS METER SCALE OHMS READING RED BLACK RX1 396 - 5941 2 90-828631R3 MARCH 1999 Page 2A-15 IGNITION STATOR TEST (IGNITION CHARGE COIL) 1 2 3 1 2 VOLTS DC AMPS OHMS 0 2 4 6 8 10 DCV ACV DVA 0 0 5 10 20 10 30 15 40 20 05101520304060100200 1 2 GRNGRNGRNBRNBLU METER TEST LEADS METER SCALE OHMS READING RED BLACK RX1RX1 272 408272 -4081 2 LIGHTING COIL 1 2 3 1 2 VOLTS DC AMPS OHMS 0 2 4 6 8 10 DCV ACV DVA 0 0 5 10 20 10 30 15 40 20 0 5101520304060100200 1 2 3 GRNGRNGRNBRNBLU METER TEST LEADS METER SCALE OHMS READING RED BLACK RX1 1.2-3.21 2 1 3 RX1 1.2-3.2 2 3 RX1 1.2-3.2 Page 2A-16 90-828631R3 MARCH 1999 IGNITION IGNITION COIL (PRIMARY) METER TEST LEADS METER SCALE OHMS READING RED BLACK RX1RX1 01 070.1 -0.7ORANGE BLACK SPARK PLUG CAP REMOVAL NOTE:High tension cables must have spark plug cap removed before testing. Cap contains 5k ohm resistor. IMPORTANT: To remove spark plug cap from high tension leads, turn cap counter clockwise while applying slight outward pressure. DO NOT PULL HARD or lead may be damaged. To install cap, turn cap clockwise threading cap onto high tension lead. IGNITION COIL (SECONDARY) 55852 #1 # 2 METER TEST LEADS METER SCALE OHMS READING RED BLACK RXKWRXKW 35 473.5 -4.7#1 CABLE #2 CABLE 90-828631R3 MARCH 1999 Page 2A-17 IGNITION SPARK PLUG CAP RESISTOR TEST 55853 METER TEST LEADS METER SCALE OHMS READING RED BLACK RXKW 3.5 - 5.2 THERMO SWITCH 57398 a a-Thermo Switch 1. Check continuity of switch. Thermo Switch Continuity Check Above 131° F (50° C) No Continuity Below 104° F (40° C) Continuity Page 2A-18 90-828631R3 MARCH 1999 IGNITION 90-828631R3 MARCH 1999 Page 2A-19 Flywheel Removal and Installation Flywheel Removal WARNING Engine could possibly start when turning flywheel during removal and installation. To prevent this type of accidental engine starting and possible serious injury, always remove spark plug leads from spark plugs. 1. Disconnect spark plug leads from spark plugs. 2. Hold flywheel using flywheel holder (91-83163M). Remove nut and washer. 30026 a a - Flywheel Holder (91-83163M) 3. Remove flywheel using puller (91-83164M). 30025 a a - Flywheel Puller (91-83164M) IGNITION Flywheel Installation 1. Place flywheel key into slot. 2. Install flywheel. 3. Hold flywheel using flywheel holder (91-83163M). Apply oil to threads on crankshaft and tighten nut to the specified torque. FLYWHEEL WITHOUT LOAD RING & SPACER a b c d a-Flywheel Key b-Washer c-Nut d-Apply Oil to Threads Flywheel Nut Torque 116 lb-ft (157 Nm) 53278 Page 2A-20 90-828631R3 MARCH 1999 IGNITION FLYWHEEL WITH LOAD RING & SPACER 53278 110 a c b d e 110 4-Stroke Outboard Oil (92-828000A12) a-Flywheel Key b-Washer c-Nut d-Spacer e-Load Ring NOTE:Load Ring is for one time use and must be replaced if flywheel is removed. Flywheel Nut Torque 116 lb-ft (157 Nm) 90-828631R3 MARCH 1999 Page 2A-21 IGNITION (CDI) Unit Removal and Installation 1. Remove and install the (CDI) unit as shown. 2. Refer to Section 2 Part D for wiring diagrams. a b 28341 a-(CDI) Unit b-Mounting Bolts (2) (CDI) Mounting Bolt Torque 100 lb-in. (11.3 Nm) Page 2A-22 90-828631R3 MARCH 1999 IGNITION 90-828631R3 MARCH 1999 Page 2A-23 Ignition Coil Removal and Installation 1. Remove and install ignition coils as shown. 2. Refer to Section 2 Part D for wiring diagrams. 28342 1 2 3 4 a c b a - Top Ignition Coil b - Bottom Ignition Coil c - Bolt - Fasten (and Ground) Coil Ground Leads Ignition Coil Mounting Bolt Torque 75 lb-in. (8.5 Nm) 3. Reconnect spark plug leads. 2 3 4 1 1 2 3 4 IGNITION Rectifier Removal and Installation 1. Remove and install rectifier as shown. 2. Refer to Section 2 Part D for wiring diagrams. 55625b a a-Rectifier b-Bolts (2) Rectifier Mounting Bolt Torque 100 lb-in. (11.3 Nm) Page 2A-24 90-828631R3 MARCH 1999 IGNITION Stator Removal and Installation 1. Remove and install flywheel. Refer to Flywheel Removal and Installation. 2. Remove and install the stator as shown. 3. Fasten wiring together with sta-strap. 4. Refer to Section 2 Part D for Wiring Diagrams. 28338 c a b Loctite “222” (92-809818)51 51 a-Stator b-Mounting Bolts (3) Apply Loctite 222 to Threads c-Sta-Strap Stator Bolt Torque 75 lb-in. (8.5 Nm) 90-828631R3 MARCH 1999 Page 2A-25 IGNITION Page 2A-26 90-828631R3 MARCH 1999 Trigger Coil Removal and Installation 1. Remove and install the trigger coil as shown. 2. Fasten wiring together with sta-strap. 3. Set the air gap at .030 in. (0.77 mm) between the trigger and flywheel. 4. Refer to Section 2 Part D for wiring diagrams. .030 in. (0.77 mm) 55625 d b a c a - Trigger Coil b - Screw (2) c - Sta-Strap d - Air Gap .030 in. (0.77 mm) Air Gap Between Trigger and Flywheel .030 in. (0.77 mm) Screw Torque 45 lb-in. (5.1 Nm) CHARGING AND STARTING SYSTEM ELECTRICAL Section 2B - Charging And Starting System Table of Contents 2 B Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3 Starter Motor (S/N-0G472132 & Below) . . . . . . 2B-4 Starter Motor (S/N-0G472133 & UP) . . . . . . . . . 2B-6 Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-8 Recommended Battery. . . . . . . . . . . . . . . . . . 2B-8 Operating Engine Without Battery . . . . . . . . 2B-8 Battery Charging System Troubleshooting . 2B-8 Battery Charging System. . . . . . . . . . . . . . . . . . . 2B-9 Description (10 Ampere) . . . . . . . . . . . . . . . . 2B-9 Wiring Diagram (10 Ampere). . . . . . . . . . . . . 2B-9 Alternator System Test (10 Ampere Stator) . . . . . . . . . . . . . . . . . . . . 2B-10 Stator Ohms Test (Alternator Lighting/Charging Coil). . . . . . . . . . . . . . . . . 2B-11 Rectifier/Regulator Diode Test . . . . . . . . . . . 2B-12 Rectifier/Regulator Diode Test Chart Digital Meter (Scale) . . . . . . . . . . . . . . . . . . . 2B-12 Starting System Components . . . . . . . . . . . . . . 2B-13 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-13 Troubleshooting the Starting Circuit . . . . . . . . . 2B-13 Starter Solenoid Test . . . . . . . . . . . . . . . . . . . 2B-14 Starter Motor P/N 50-825095 (Top Mounted) . 2B-17 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-17 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-18 Cleaning and Inspection . . . . . . . . . . . . . . . . 2B-18 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-22 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-25 Starter Motor P/N 50-834749 (Side Mounted) . 2B-26 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-26 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-27 Cleaning and Inspection . . . . . . . . . . . . . . . . 2B-28 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-29 Brush Replacement. . . . . . . . . . . . . . . . . . . . 2B-31 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-32 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-35 90-828631R3 MARCH 1999 Page 2B-1 CHARGING AND STARTING SYSTEM Specifications CHARGING SYSTEM Alternator Type Alternator Output: Electric Start Lighting Coil Resistance (Grn - Grn) Lighting Coil Output Peak Voltage Three Phase 12 Volts - 10 Amps (Regulated) 1.2 - 3.2 Ohms @ 68°F (20°C) 8.9 Volts @ 1500 rpm STARTING SYSTEM P/N 50-825095 Top Mounted Electric Start: Starter Type Output Ampere Draw Under: (Load) (No Load) P/N 50-834749 Side Mounted Bendix 1.1 kW 106.0 Amps 21.1 Amps Starter Type Output Ampere Draw Under: (Load) (No Load) Bendix 1.1 kW 95.0 Amps 20.0 Amps Battery Rating Minimum Requirement 465 Marine Cranking Amps (MCA) BATTERY or 350 Cold Cranking Amps (CCA) For operation below 32° F (0° C) 1000 Marine Cranking Amps (MCA) or 775 Cold Cranking Amps (CCA) Page 2B-2 90-828631R3 MARCH 1999 CHARGING AND STARTING SYSTEM Special Tools 91-99750A1 Multi Meter/DVA Tester 91-854009A1 Digital Tack Multi Meter 90-828631R3 MARCH 1999 Page 2B-3 CHARGING AND STARTING SYSTEM Starter Motor (S/N-0G472132 & Below) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1516 17 18 19 20 21 6 10 22 25 95 110 95 25 Liquid Neoprene (92-25711--2) 95 2-4-C w/Teflon (92-850736A1) 110 4-Stroke Outboard Oil (92-828000A12) Page 2B-4 90-828631R3 MARCH 1999 CHARGING AND STARTING SYSTEM Starter Motor (S/N-0G472132 & Below) REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 STARTER MOTOR 2 1 RETAINER 3 1 GEAR 4 1 BRACKET–front 5 1 METAL 6 2 O RING 7 1 WASHER KIT 8 1 ARMATURE 9 1 STATOR 10 3 SPRING 11 1 BRUSH HOLDER ASSEMBLY 12 1 BRUSH SET 13 1 WASHER 14 1 BRACKET–rear 15 2 BOLT 16 1 BOLT (M8 x 45) 22.5 31.0 17 2 BOLT (M8 x 30) 22.5 31.0 18 1 BOLT (M8 x 20) 155 13.0 17.5 19 1 LOCKWASHER 20 1 NUT 60 7.0 21 1 J CLAMP 22 1 CABLE 90-828631R3 MARCH 1999 Page 2B-5 CHARGING AND STARTING SYSTEM Starter Motor (S/N-0G472133 & UP) 1 15 14 13 12 2 3 4 5 6 7 8 9 10 8 11 Page 2B-6 90-828631R3 MARCH 1999 CHARGING AND STARTING SYSTEM Starter Motor (S/N-0G472133 & UP) REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 STARTER MOTOR 2 1 THRU BOLT 70 8.0 3 1 DRIVE KIT 4 1 DRIVE ASSEMBLY 5 1 DRIVE CAP 6 1 ARMATURE 7 1 COMMUTATOR CAP 8 1 BRUSH & SPRING KIT 9 1 BRUSH HOLDER 10 2 SCREW 11 3 SCREW (M8 x 50) 16.5 22.5 12 1 LOCKWASHER 13 1 NUT 60 7.0 14 1 DECAL-Warning-High Voltage 15 1 CABLE 90-828631R3 MARCH 1999 Page 2B-7 CHARGING AND STARTING SYSTEM Battery Recommended Battery A 12 volt battery with a minimum rating of 465 marine cranking amps (MCA) or 350 cold cranking amps (CCA). For operation below 32° F (0° C) a rating of 1000 Marine Cranking Amps (MCA) or 775 Cold Cranking Amps (CCA) is recommended. Operating Engine Without Battery If desired (or in an emergency), engines equipped with an electric start and alternator can be started and operated without a battery (either disconnected or removed) if “WARNING”, below, is followed. WARNING Before operating engine with battery leads disconnected from battery, disconnect the three wire (stator harness plug) from rectifier. Battery Charging System Troubleshooting CAUTION The charging system may be damaged by: 1) reversed battery cables, 2) running the engine with battery cables disconnected and stator leads connected to rectifier, and 3) an open circuit, such as a broken wire or loose connection. A fault in the battery charging system usually will cause the battery to become undercharged. Check battery electrolyte level, and charge battery. See “Electrolyte Level”, and “Charging a Discharged Battery”. If battery will NOT accept a satisfactory charge, replace battery. If battery accepts a satisfactory charge, determine the cause of the charging system problem as follows. 1. Check for correct battery polarity [RED cable to POSITIVE (+) battery terminal]. If polarity was incorrect, check for damaged rectifier. See “RECTIFIER TEST/REGULATOR DIODE TEST”. 2. Check for loose or corroded battery connections. 3. Visually inspect wiring between stator and battery for cuts, chafing; and disconnected, loose or corroded connection. 4. Excessive electrical load (from too many accessories) will cause battery to run down. If visual inspection determines that battery connections and wiring are OK, perform the following stator and rectifier tests. Page 2B-8 90-828631R3 MARCH 1999 CHARGING AND STARTING SYSTEM Battery Charging System Description (10 Ampere) The battery charging system components are the stator lighting coils, rectifier/regulator and battery. Alternating current (generated in stator lighting coils) flows to the rectifier/regulator, which changes the alternating current to a regulated direct current for charging the battery. Wiring Diagram (10 Ampere) 1 2 3 1 2 3 BLK AB + – 1 2 3 4 5 6 7 8 GRNGRNGRN GRN GRN/WHT BLK RED GRN GRN/WHT RED/PPL RED/PPL RED 1–GRN 2–GRN 3–GRN/WHT 1–GRN 2–GRN 3–GRN Blk e a b Blk = Black Blu = Blue Brn = Brown Gry = GrayGrn = Green Orn = OrangePnk = Pink Pur = PurpleRed = Red Tan = Tan Wht = White Yel = Yellow f c d a-Stator b-20 Ampere Fuse c-Rectifier/Regulator d-Battery e-Starter Solenoid f-Auto Starter 90-828631R3 MARCH 1999 Page 2B-9 CHARGING AND STARTING SYSTEM Alternator System Test (10 Ampere Stator) 1. Check battery voltage at battery with engine running. 2. If battery voltage is above 14.5-15.0 volts, replace voltage regulator/rectifier. Check condition of battery as overcharging may have damaged battery. 3. If battery voltage is below 14.5 volts, charge battery; refer to “CHARGING A DISCHARGED BATTERY”. If battery can NOT be satisfactorily charged, replace battery. 4. If battery accepts a satisfactory charge, check battery voltage while cranking engine; refer to “CHARGING A DISCHARGED BATTERY”. If cranking voltage is not acceptable, replace battery. 5. If cranking voltage is acceptable, disconnect the RED (voltage regulator) wire bullet connector from the RED/PUR wire. 6. Connect RED (+) ammeter lead to RED wire and the BLACK (–) ammeter lead to the Red/PUR wire. 7. Secure starter wires away from flywheel. 8. With engine running at the indicated rpm, the ammeter should indicate the following appropriate amperes: 10 Ampere Stator RPM AMPERES Idle 4.2 1000 6.0 2000 8.0 3000 8.4 4000 8.5 5000 8.6 9. A reading of 8.5-8.6 amperes at 5000 rpm indicates the charging system is functioning properly. 10. If ammeter reads less than required amperes @ 5000 rpm, test the stator; refer to “Stator Ohm Test”. If stator tests OK, replace rectifier/regulator. Page 2B-10 90-828631R3 MARCH 1999 CHARGING AND STARTING SYSTEM Stator Ohms Test (Alternator Lighting/Charging Coil) NOTE:Stator can be tested without removing from engine. 1. Disconnect the three wire (stator harness plug). 2. Use an ohm meter and perform the following test. NOTE: When measuring the resistance of 10 ohms or less using a digital ohm meter, if the correct measurement cannot be obtained, place the meter selector to a lower resistance measurement. LIGHTING COIL 1 2 3 GRNGRNGRN 1 2 3 METER TEST LEADS METER SCALE OHMS READING RED BLACK RX1 1.2-3.21 2 1 3 RX1 1.2-3.2 2 3 RX1 1.2-3.2 90-828631R3 MARCH 1999 Page 2B-11 CHARGING AND STARTING SYSTEM Rectifier/Regulator Diode Test 1 2 3 GRN GRN/WHT BLK RED GRN GRN/WHT a c b f e d a-Voltage Regulator/Rectifier b-Test Point - BLK c-Test Point- GRN (1) d-Test Point- GRN (2) e-Test Point- GRN/WHT f-Test Point- RED IMPORTANT: When performing a diode test on the rectifier/regulator, use only a digital meter with the capability of selecting a diode inspection mode. NOTE: Due to differences in the manufacturing of ohmmeters, the internal polarity may vary. As a result, the test readings may be a direct reversal of the readings specified. If so, reverse the meter leads and perform the test again. A slight variance from the listed specification does not necessarily indicate a defective component. Rectifier/Regulator Diode Test Chart-Digital Meter ( Scale) Red (+) Meter Lead To: BLk GRN (1) GRN (2) GRN/WHT RED BLK -OUCH OUCH OUCH OUCH GRN (1) 0.3 to 0.8 -OUCH OUCH OUCH GRN (2) 0.3 to 0.8 OUCH -OUCH OUCH GRN/WHT 0.3 to 0.8 OUCH OUCH -OUCH RED 0.8 to 1.3 0.3 to 0.8 0.3 to 0.8 0.3 to 0.8 - NOTE:OUCH=OL=Full Meter Deflection NOTE:All rectifier/regulator leads MUST BEdisconnected to obtain accurate diode test readings. Page 2B-12 90-828631R3 MARCH 1999 CHARGING AND STARTING SYSTEM Starting System Components The starting system consists of the following components. 1. Battery 2. Starter Solenoid 3. Neutral Safety Switch 4. Starter Motor 5. Ignition Switch Description The function of the starting system is to crank the engine. The battery supplies electrical energy to crank the starter motor. When the ignition switch is turned to “START” position, the starter solenoid is activated and completes the starting circuit between the battery and starter. The neutral start switch opens the start circuit when the shift control lever is not in neutral. This prevents accidental starting when engine is in gear. CAUTION The starter motor may be damaged if operated continuously. DO NOT operate continuously for more than 30 seconds. Allow a 2 minute cooling period between starting attempts. Troubleshooting the Starting Circuit Before beginning the starting circuit troubleshooting flow chart, following, check first for the following conditions: 1. Make sure that battery is fully charged. 2. Check that control lever is in “NEUTRAL” position. 3. Check terminals for corrosion and loose connections. 4. Check cables and wiring for frayed and worn insulation. 5. Check 20 Amp fuse. 90-828631R3 MARCH 1999 Page 2B-13 CHARGING AND STARTING SYSTEM Starter Solenoid Test 1. Inspect starter solenoid for cracks, loose terminals or loose terminal lead connections. 2. Connect ohm meter between terminals of starter solenoid. 3. Connect the BLACK lead from solenoid to battery negative (–) terminal and momentarily connect the BROWN 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-BROWN Lead b-Starter Solenoid c-BLACK Lead d-Battery Page 2B-14 90-828631R3 MARCH 1999 CHARGING AND STARTING SYSTEM The following “STARTING CIRCUIT TROUBLESHOOTING FLOW CHART” is designed as an aid to troubleshooting the starting circuit. This flow chart will accurately locate any existing malfunction. Location of “TEST POINTS” (called out in the chart) are numbered in diagram below. NEUTRAL START SWITCH + AB IGNITION SWITCH STARTER STARTER SOLENOID 20 AMP FUSE – Blk Blk = Black Blu = Blue Brn = Brown Gry = GrayGrn = Green Orn = OrangePnk = Pink Pur = PurpleRed = Red Tan = Tan Wht = White Yel = Yellow Yel Red/ Pur Red Red Yel/ Red Yel/ Red Yel/ Red Blk Blk1 2 3 45 6 7 BATTERY Starting Circuit Troubleshooting Flow Chart Starter Motor Does Not Turn SAFETY WARNING: Disconnect BLACK (starter motor) cable from starter solenoid test point 1 BEFORE making tests 1-thru-7 to prevent unexpected engine cranking. TEST 1 Use an ohmmeter (R x 1 scale) and connect meter leads be- tween NEGATIVE (-) battery post and common powerhead ground. No continuity indicated; there is an open circuit in the BLACK NEGATIVE (-) battery cable between the NEGATIVE (-) battery post and the powerhead. • Check cable for loose or corroded connections. • Check cable for open. Continuity Indicated Proceed to TEST 2, on next page. 90-828631R3 MARCH 1999 Page 2B-15 CHARGING AND 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 starter solenoid; proceed to TEST 7. Neutral start switch is open, or YELLOW/RED or BLACK wire is open between Test Points 4 and 3. a. Connect voltmeter between common engine ground and Test Point 4. b. Turn ignition key to “Start” position. Defective starter solenoid. Connect voltmeter between common engine ground and Test Point 5. Defective ignition switch. Connect voltmeter between common engine ground and Test Point 6. No voltage reading; check BLACK wire be- tween battery (+) positive terminal and Test Point 6. Check fuse in RED wire between test points 5 and 6. Check for open RED wire between test points 5 and 6. a. Connect voltmeter between common engine ground and Test Point 1. b. Turn ignition key to “Start” position. No voltage reading; De- fective starter solenoid. Should hear solenoid click; proceed to TEST 8. a. Reconnect Yellow (starter motor) cable to starter solenoid Test Point 1. b. Connect voltmeter between common engine ground and Test Point 7 c. Turn ignition key to “Start” position. No voltage reading; check Yellow cable for poor connection or open circuit. Check BLACK ground cable at starter for loose or corroded connection, or open circuit. If cable is O.K., check starter motor. Electric Start Tiller Handle Model Neutral start switch is open or BLACK leads are disconnected or damaged. Page 2B-16 90-828631R3 MARCH 1999 CHARGING AND STARTING SYSTEM Starter Motor P/N 50-825095 (Top Mounted) Removal CAUTION Disconnect the battery leads from the battery before removing starter. 1. Disconnect the battery leads from the battery. 2. Disconnect the ground cables. 3. Remove starter mounting bolts. 4. Remove starter. 53866 c b a d a-Yellow Cable b-Mounting Bolts c-Ground Cables d-J Clamp 90-828631R3 MARCH 1999 Page 2B-17 CHARGING AND STARTING SYSTEM Disassembly 1. Press down the pinion stopper and remove the circlip. Remove the pinion. a b c a-Pinion b-Pinion Stopper c-Circlip (discard and use new circlip on assembly) 2. Remove through bolts and disassemble starter motor assembly. Cleaning and Inspection 1. Clean all motor parts. 2. Check pinion teeth for chips, cracks or excessive wear. 3. Replace the drive clutch spring and/or collar, if tension is not adequate, or if wear is excessive. 4. Check that the brush holder is not damaged or is not holding the brushes against the commutator. 5. Replace brushes that are pitted or worn to less than 0.35 - 0.49 in. (9.0 - 12.5 mm) in length. Refer to “BRUSH HOLDER”, following. 6. Replace rear or front bracket for excessively worn bushings. 7. Check the armature (commutator) for wear, or being burnt. (A poor connection usually results in a burned commutator bar.) 8. Re-surface and undercut a rough commutator. Refer to “Armature Inspection/Testing”. PINION 9. Check pinion teeth for chips, cracks or excessive wear. a a-Pinion Gear Page 2B-18 90-828631R3 MARCH 1999 CHARGING AND STARTING SYSTEM BRUSH HOLDER 10. Inspect brushes for wear. Replace brush holder if not within specifications. a a-Wear Limit - 0.47 (12.0 mm) 11. Ohm test the brush holder. The positive (+) brushes should not show continuity to brush holder. Replace brush holder assembly if ohm test shows continuity. a ba a-Positive (+) Brushes b-Brush Holder Assembly ARMATURE INSPECTION/TESTING 12. Inspect the commutator surface of the armature for burnt marks and dirt in commutator grooves. 13. Using a piece of #600 grit wet-or-dry sand paper, clean the surface of the commutator. a b a-Commutator b-Sand Paper (#600 Grit) 90-828631R3 MARCH 1999 Page 2B-19 CHARGING AND STARTING SYSTEM 14. Measure the armature shaft for deflection. If the armature has greater than 0.002 in. (0.05 mm) deflection, replace armature. c b a a-Armature b-V-Block c-Dial Indicator Gauge 15. Measure the commutator diameter. Replace if not within specification. MIN. a bb a-Commutator b-Commutator Diameter Wear Limit - 1.22 in. (31.0 mm) 16. Measure the mica undercut of the commutator. Clean out and undercut mica and build up of brush material to a depth of 0.003 - 0.008 in. (0.2 - 0.8 mm). a b a-Commutator Depth b-File (or use commutator cutter) Page 2B-20 90-828631R3 MARCH 1999 CHARGING AND STARTING SYSTEM 17. After cleaning, ohm test each segment of the commutator as shown. If ohm test reading is other than listed, replace the armature. ARMATURE COIL CONTINUITY METER TEST LEADS METER SCALE READING RED BLACK X1X1 CONTINUITYCONTINUITY SEGMENT SEGMENT a b c a-Commutator b-Lamination c-Shaft ARMATURE COIL CONTINUITY METER TEST LEADS METER SCALE READING RED BLACK X1X1 NO CONTINUITYSEGMENT LAMINATION SEGMENT SHAFT X1 NO CONTINUITY 90-828631R3 MARCH 1999 Page 2B-21 CHARGING AND STARTING SYSTEM Reassembly 1. Place washers on the armature shaft. 2. Place armature shaft into front bracket. a c bd a-Washer (Fiber) .08 in. (2.0 mm) Thick b-Washer .04 in. (1.0 mm) Thick c-Washers (Use as Required) (Adjust Washers Until 0.05 - 0.010 in. (0.05 - 0.25 mm) Axial Play Exist on the Armature Shaft d-Front Bracket 1. Install the pinion, spring, and pinion stopper onto starter shaft. 2. Place circlip into groove on shaft. 3. Press the pinion stopper over the circlip. IMPORTANT: Install new circlip for reassembly. NOTE:Make sure the circlip fits tightly into pinion stopper. a b d c a b c d a-Circlip b-Pinion Stopper c-Spring d-Pinion Page 2B-22 90-828631R3 MARCH 1999 CHARGING AND STARTING SYSTEM 4. Install stator onto the front bracket. Align Projection with cut in the cover. NOTE:Make sure stator is installed so magnets are positioned correctly. 3/4 in. (19.0 mm) 53833 a b e c d a-O-Ring Seal b-Space Between Magnets and Stator End c-Align Projection with Cut in the Bracket d-Stator e-Front Bracket 5. Spread the brushes and slide the brush card onto the commutator. 53831a a a-Brush Card 90-828631R3 MARCH 1999 Page 2B-23 CHARGING AND STARTING SYSTEM 6. Install rear bracket. Insert wire insulator into slot and align projection with cut in bracket. 53832 d c a b a-O-Ring Seal b-Wire Insulator c-Align Projection with Cut in the Rear Bracket d-Rear Bracket 7. Fasten brush card to rear bracket with two screws. 8. Fasten the starter motor together with two through bolts. 53834 a b a-Screw (2) Fasten Brush Card In-Place b-Through Bolts (2) Page 2B-24 90-828631R3 MARCH 1999 CHARGING AND STARTING SYSTEM Installation 1. Tighten mounting bolts to specified torque. Connect yellow cable and J-clamp with bottom bolt. 2. Reconnect the ground cables. 53866 c d b a a-Yellow Cable b-Mounting Bolts c-Ground Cables d-J Clamp Starter Motor Mounting Bolt Torque 22.7 lb-ft (30.8 Nm) 90-828631R3 MARCH 1999 Page 2B-25 CHARGING AND STARTING SYSTEM Starter Motor P/N 50-834749 (Side Mounted) Removal WARNING Always disconnect the battery and remove spark plug leads from spark plugs before working on motor. 1. Disconnect battery leads from battery. 2. Disconnect BLACK cable. 3. Remove 3 bolts. 4. Remove starter. 50- a c b b a-Black Cable b-Bolts (3) c-Part Number Location 55626 Page 2B-26 90-828631R3 MARCH 1999 CHARGING AND STARTING SYSTEM Disassembly 1. Remove 2 thru bolts and commutator end cap, taking care not to lose brush springs. a a c c b a-Thru Bolts b-Commutator End Cap c-Brush Springs 2. Press down the pinion stopper and remove the circlip. Remove the pinion. c ba a-Pinion b-Pinion Stopper c-Circlip (discard and use new circlip on assembly) 3. Pull armature from starter frame. Remove locknut. 4. Remove components from armature. c e a b fd a-Spacer b-Spring c-Drive Assembly d-Drive End Cap e-Armature Shaft f-Washer 90-828631R3 MARCH 1999 Page 2B-27 CHARGING AND 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. (6.4 mm) in length. Refer to “BRUSH REPLACEMENT”, following. 6. Replace a damaged or excessively worn bushing in the end cap. 7. Check the armature conductor (commutator bar junction) for a firm connection. A poor connection usually results in a burned commutator bar. 8. 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 rEsin 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-28 90-828631R3 MARCH 1999 CHARGING AND STARTING SYSTEM Testing ARMATURE TEST FOR SHORTS Check armature for short circuits by placing on growler and holding hack saw blade over armature core while armature is rotated. If saw blade vibrates, armature is shorted. Recheck after cleaning between commutator bars. If saw blade still vibrates, replace armature. ARMATURE TEST FOR GROUND 1. Set ohmmeter to (R x 1 scale). Place one lead of ohmmeter on armature core (or shaft) and other lead on commutator, as shown. 2. If meter indicates continuity, armature is grounded and must be replaced. 11675 90-828631R3 MARCH 1999 Page 2B-29 CHARGING AND 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-30 90-828631R3 MARCH 1999 CHARGING AND STARTING SYSTEM Brush Replacement IMPORTANT: Replace brushes that are pitted or worn to less than 1/4 in. (6.4mm) in length. 11660 a c d e f g b a-Positive (+) Terminal b-Long Brush Lead c-Push Lead Into Slot d-Insulating Washer e-Flat Washer f-Lock Washer g-Nut d 11656 a c b a b d a-Positive (+) Brushes b-Negative (–) Brushes c-Brush Holder d-Bolts (Fasten Negative Brushes and Holder) 90-828631R3 MARCH 1999 Page 2B-31 CHARGING AND STARTING SYSTEM Reassembly 1. Lubricate helix threads and drive end cap bushing with SAE 10W oil. 2. Install the pinion, spring, and pinion stopper onto starter shaft. 3. Place circlip into groove on shaft. 4. Press the pinion stopper over the circlip. IMPORTANT: Install new circlip for reassembly. NOTE:Make sure the circlip fits tightly into pinion stopper. a b d c d c a b a-Circlip b-Pinion Stopper c-Spring d-Pinion Page 2B-32 90-828631R3 MARCH 1999 CHARGING AND STARTING SYSTEM 5. Construct a brush retainer tool as shown. Brush Retainer Tool Layout (Full Size) 18-Gauge Sheet Metal METRIC SCALE 3” = 76.2mm 2” = 50.8mm 1-3/4” = 44.5mm 1-11/16” = 42.9mm 3/4” = 19.1mm 1/2” = 12.7mm Brush Retainer Tool Side View (Full Size) 90-828631R3 MARCH 1999 Page 2B-33 CHARGING AND STARTING SYSTEM 6. Place springs and brushes into brush holder and hold in place with brush retainer tool. 7. Lubricate bushing with one drop of SAE 10W oil. DO NOT over-lubricate. 11661 b a a-Brush Retainer Tool b-Bushing 8. Position armature into starter frame so that commutator end of armature is at end of starter frame where permanent magnets are recessed 1 in. (25.4mm). Align marks (a) as shown. 9. Install commutator end cap onto starter frame; align marks (b) as shown, and remove brush retainer tool. 10. Install thru bolts (c) and torque to specified torque. 52659 a b c c a-Alignment Marks b-Alignment Marks c-Bolts (2) End Cap Bolt Torque 70 lb-in. (7.9 Nm) Page 2B-34 90-828631R3 MARCH 1999 CHARGING AND STARTING SYSTEM Installation 1. Secure starter to block with 3 bolts. Torque bolts to specified torque. Secure NEGATIVE battery lead to block with bottom bolt. 2. Connect battery lead (BLACK cable) to starter. Torque attaching nut to specified torque. a b b a-Black Cable b-Bolts (3) 55626 Starter Bolt Torque 16.5 lb-ft (22.3 Nm) Attaching Nut Torque 60 lb-in. (6.8 Nm) 90-828631R3 MARCH 1999 Page 2B-35 TIMING, SYNCHRONIZING, & ADJUSTING ELECTRICAL Section 2C - Timing, Synchronizing, & Adjusting Table of Contents 2 C Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1 Carburetor Sync. – Dynamic Adjustment . . 2C-4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-2 Idle Mixture Screw Adjustment . . . . . . . . . . . 2C-7 Carburetor Adjustments . . . . . . . . . . . . . . . . . . . . 2C-3 Dash-Pot Adjustment . . . . . . . . . . . . . . . . . . . 2C-9 Idle Speed Adjustment . . . . . . . . . . . . . . . . . . 2C-3 Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-10 Specifications IGNITION SYSTEM* *Readings taken @ 68°F (20°C). Type Spark Plug Type (NGK) Spark Plug Gap Firing Order Ignition Timing: 40/45 HP Fully Retarded Fully Advanced (2500-3000 rpm) 50 HP Fully Retarded Fully Advanced (2500-3000 rpm) Charge Coil Resistance Trigger Coil Resistance Ignition Coil Resistance: Primary Secondary C.D.I. Engine Speed Limiter C.D.I. Overheat Speed Control Engine Temperature Switch Below 131° F (55° C) Above 104° F (40° C) Capacitor Discharge Ignition NGK DPR6EA-9 0.035 in. (1.0 mm) 1-3-4-2 5° B.T.D.C 25° B.T.D.C 5° B.T.D.C 35° B.T.D.C 272 - 408 W (BRN-BLU) 396 - 594 W (WHT/BLK-WHT/RED) 0.1 - 0.7 W 3.5 - 4.7 kW 6120 - 6280 rpm 1600 - 2400 rpm No Continuity Continuity Idle rpm (Out Of Gear) 45 hp 950 ± 25 rpm 40/50 hp Idle rpm (In Forward Gear) 825 ± 25 rpm 45 hp 850 ± 25 rpm 40/50 hp 725 ± 25 rpm CARBURETOR Wide Open Throttle rpm (WOT) Range Main Jet Size 40/45 hp 5500–6000 rpm Carburetors 1 and 2 #104 Carburetors 3 and 4 #103 50 hp #112 Pilot Jet #42 Float Height 0.39 ± 0.02 in. (10.0 ± 0.5 mm) 90-828631R3 MARCH 1999 Page 2C-1 TIMING, SYNCHRONIZING, & ADJUSTING Special Tools 1. Carburetor Tuner P/N 91-809641A1 2. Timing Light P/N 91-99379 3. Exhaust Manifold Adaptor P/N 91-809905A1 4. Idle Mixture Screw Adjuster (45 HP Bodensee Models Only) P/N 91-809906A1 5. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1 Page 2C-2 90-828631R3 MARCH 1999 TIMING, SYNCHRONIZING, & ADJUSTING 90-828631R3 MARCH 1999 Page 2C-3 Carburetor Adjustments 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 neutral gear and in the water, start engine and allow to warm up. 2. Shift outboard into forward gear. 3. Turn the idle adjustment screw located on the #4 (bottom) carburetor to attain the specified idle rpm. a a - Idle rpm Adjustment Screw Idle rpm in Forward Gear 45 hp 850 ± 25 rpm 40/50 hp 725 ± 25 rpm 4. Rev engine 2 or 3 times and allow to idle for 15 seconds. • If the engine holds a stable idle condition, then no other adjustments are necessary. • If the engine has an unstable idle condition, then carburetor synchronization is required. Refer to Carburetor Synchronization following. TIMING, SYNCHRONIZING, & ADJUSTING Page 2C-4 90-828631R3 MARCH 1999 Carburetor Synchronization – Dynamic Adjustment NOTE: The carburetors are synchronized by adjusting the intake manifold vacuum on the top three carburetors. Use Carburetor Tuner (91-809641A1) to measure the vacuum. NOTE: The engine should be completely warmed up for the adjustment. Correct adjustments can not be obtained in a cold condition. INSTALLING CARBURETOR TUNER (91-809641A1) 1. Remove four plugs from the intake manifold. 2. Install a intake manifold hose adaptor in each plug hole. NOTE: Intake manifold hose adaptors are provided with the Carburetor Tuner. 3. Connect the carburetor tuner to the hose adaptors. a b c d a - Intake Manifold Plugs (4) b - Intake Manifold Hose Adaptor (4) c - Filters (35-18206) d - Carburetor Tuner (91-809641A1) CAUTION To avoid the possibility of drawing mercury from the vacuum gauge into the engine, do not run engine at high rpm speed and avoid rapid throttle deceleration (high vacuum situations). SYNCHRONIZING CARBURETORS 1. With the outboard in water, start engine and allow to warm up. Shift the outboard to neutral. 2. Connect a tachometer to the engine. 3. Adjust idle rpm screw (a) on #4 carburetor to obtain an idle setting of approximately1000 rpm in neutral. If necessary, keep adjusting the idle screw. TIMING, SYNCHRONIZING, & ADJUSTING 90-828631R3 MARCH 1999 Page 2C-5 NOTE: Keep engine speed set at approximately 1000 rpm in neutral while synchronizing carburetors. a a - Idle rpm Screw 4. Read the vacuum of cylinder #4. It’s not important to be at any specific vacuum setting. a 1 2 3 4 1 2 3 a - Vacuum Reading Cylinder #4. – Note, that it’s not Important to be at any Specific Vacuum Setting 5. Adjust cylinder # 3 vacuum (turn screw 3) to read one cm less vacuum than cylinder #4. 6. Adjust cylinder #2 vacuum (turn screw 2) to read two cm less vacuum than cylinder #4. 7. Adjust cylinder #1 vacuum (turn screw 1) to read three cm less vacuum than cylinder #4. TIMING, SYNCHRONIZING, & ADJUSTING 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 approximately 1000 rpm. Example If the vacuum reading of Cyl. #4 is 32 cm, then adjust carburetor screws 3, 2, and 1 to obtain the listed averaged vacuum values at the other cylinders. Cyl. #4: (Base ) . . . . . . . . . . . . . . . . . . . . . = 32 cm Cyl. #3: . . . . . . . . . . . . . . . 32 cm – 1 cm = 31 cm Cyl. #2: . . . . . . . . . . . . . . . 32 cm – 2 cm = 30 cm Cyl. #1: . . . . . . . . . . . . . . . 32 cm – 3 cm = 29 cm 34 cm 32 cm 30 cm 28 cm Cyl. # 1 Cyl. #. 2 Cyl. # 3 Cyl. # 4 26 cm 8. Rev engine a few times and let engine idle for 15 seconds. Check that the average vacuum values remain between cylinders. Readjust if necessary. 9. Stop engine, remove adaptors and reinstall plugs. Refer to Idle Speed Adjustment and adjust the idle rpm back to specification. Page 2C-6 90-828631R3 MARCH 1999 TIMING, SYNCHRONIZING, & ADJUSTING 90-828631R3 MARCH 1999 Page 2C-7 Idle Mixture Screw Adjustment NOTE: Idle mixture screw adjustment is required when stable idling could not be obtained after synchronization. NOTE: The engine should be completely warmed up for the adjustment. Correct adjustments can not be obtained in a cold condition. NOTE: The idle mixture screw is: Adjustable: -All model years for the 45 hp version -1995-1997 model years for all other versions Non-adjustable: -1998 model year and later (50 hp). NOTE: Screw Adjuster (91-809906A1) is required to adjust the idle mixture screws on 45 hp models. DYNAMIC ADJUSTMENT (50 HP MODELS) 1995-1997 MODEL YEAR 1. Connect tachometer. 2. With engine idling, turn the #4 carburetor idle mixture screw an 1/8 turn both directions (clockwise and counterclockwise). 3. If the engine speed drops when turning screw both directions, leave screw at initial position. 4. If the engine speed increases in one direction, keep turning it in that direction by 1/8 turn increments to find the point of highest idle speed. 5. Adjust the idle mixture screw on the #1, #2 and #3 cylinders in the same manner. 6. Rev engine two or three times and let idle for 15 seconds, if a stable idle is obtained, perform the Idle Speed Adjustment. 1 2 3 4 a b a - Remove Plug b - Idle Mixture Screw TIMING, SYNCHRONIZING, & ADJUSTING DYNAMIC ADJUSTMENT (45 HP MODELS) NOTE:CO metering equipment has to be used to accurately adjust the idle mixture screws within the exhaust emissions limits. 1. Remove four plugs from the exhaust manifold. 2. Install a exhaust manifold hose adaptor (91-809905A1) in each plug hole. a bc a-Exhaust Manifold Plugs (4) b-Exhaust Manifold Hose Adaptor (91-809905A1) c-Plug - Hose Adaptor 3. Install the CO metering equipment to the hose adaptors. NOTE:Keep all the hose adaptors plugged that are not connected to the CO metering equipment. 4. With engine in water, start engine and run at the recommended idle speed in neutral. Idle Speed-Neutral 950 ± 25 rpm 5. Check CO reading on each cylinder to verify if CO is within 4-6% range. While checking CO readings, allow time for the readings to stabilize. 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 850 RPM. 6. Adjust CO as follows: • Adjust CO starting from No. 1 cylinder. • If CO reading on any cylinder is higher than 6.0%, turn idle mixture screw clockwise (leaner). • If CO reading on any cylinder is lower than 4.0%, turn idle mixture screw counterclockwise (richer). • Changes to any one cylinder can effect other cylinders, so If changes are made to any cylinder, all previous cylinders checked must be rechecked/adjusted. 7. Remove hose adaptors and reinstall plugs. 8. Recheck carburetor synchronization. Page 2C-8 90-828631R3 MARCH 1999 TIMING, SYNCHRONIZING, & ADJUSTING Dashpot Adjustment NOTE:Dash-pot adjustment is required when engine stalls upon quick deceleration. NOTE:The engine should be completely warmed up for the adjustment. Correct adjust ments can not be obtained in a cold condition. 1. Pull out the retarder plunger fully. 2. Loosen the locknut. 3. Turn the dashpot until the dashpot ram is just touching the lever at the specified engine speed. 4. Tighten lock nut. ab c d a-Retarder Plunger b-Locknut c-Dashpot d-Lever Dash-pot Adjustment Speed 1700 rpm  50 rpm 90-828631R3 MARCH 1999 Page 2C-9 TIMING, SYNCHRONIZING, & ADJUSTING Timing WARNING To prevent personal injury or possible death, from loss of balance or stability while servicing the motor, DO NOT attempt to check timing while boat is in motion. Failure to follow one of the recommended servicing procedures may result in the person falling overboard or causing personal injury from fall in boat. WARNING To prevent personal injury from spinning flywheel, Do Not attempt to remove flywheel cover or place hands on top of cover when checking ignition timing. Timing Specifications 40/45 HP Full Retarded - 5° B.T.D.C. Full Advanced (2500-3000 rpm) - 25° B.T.D.C. 50 HP Full Retarded - 5° B.T.D.C. Full Advanced (2500-3000 rpm) - 35° B.T.D.C. Ignition timing is not adjustable. The C.D.I. 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 C.D.I. 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 THAT SECURED ON A TRAILER “Backed in Water” Page 2C-10 90-828631R3 MARCH 1999 TIMING, SYNCHRONIZING, & ADJUSTING 1. Place the outboard in “Forward” gear and check timing at idle “Retarded.” (If not within specification window, refer to Diagnostic Test Procedures Section 2A.) 5°a a-Timing Mark (Full Retarded) 2. Slowly increase the engine rpm while watching the ignition timing marks. The timing should increase to the maximum timing specification “Full Advance” at approximately 2500-3000 RPM. (If not within specification window, refer to Diagnostic Test Procedures Section 2A.) 35°25° 40/45 hp 50 hp a a-Timing Mark (Full Advance) 90-828631R3 MARCH 1999 Page 2C-11 WIRING DIAGRAMS ELECTRICAL Section 2D - Wiring Diagrams Table of Contents 2 D Electric Start Wiring Diagram . . . . . . . . . . . . . . . 2D-2 Tiller Handle Wiring Diagram . . . . . . . . . . . . . . . 2D-3 Commander Remote Control (Electric Start) . . 2D-4 Commander 2000 Remote Control (Electric Start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-5 Commander 3000 Panel Mount Control . . . . . . 2D-6 Power Trim Switch Wiring Diagram . . . . . . . . . . 2D-7 Remote Wiring Harness Connection to Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-8 Electric Start Remote Control Model . . . . . . 2D-8 90-828631R3 MARCH 1999 Page 2D-1 LT.BLU/WHT BLUE 14 BLACK RED BLACK GRN/WHT GREEN 14 BLACK RED BLACK DN UP RED/PPL GRN/WHT LT.BLU/WHT GRN/WHT LT.BLU/WHT LT.BLU/WHT GRN/WHT WHT/BLK WHT/RED BLU BRN BLK/ORG BLK BLK/WHT YEL/RED WHT YEL/BLK PNK/WHT PNK PNK/BLK GRY/BLK 1 2 3 4 5 6 7 8 9 PNK/BLK PNK PNK/WHT YEL/BLK WHT YEL/RED BLK/WHT BLK BLK/ORG GRY/BLK BRN BLU WHT/BLK WHT/RED BRN BLU WHT/BLK WHT/RED 7 9 3 6 4 2 85 1 1 1 1 2 1 2 2 2 WHT/RED WHT/BLK BLU BRN GRN GRN GRN 1–BLK/WHT 2–BLK 3–BLK/ORG 4–YEL/BLK 5–WHT 6–YEL/RED 7–PNK/BLK 8–PNK 9–PNK/WHT 1–BLK/WHT 2–BLK 3–RED/WHT 4–EMPTY 5–BLK/YEL 6–EMPTY 7–TAN/BLK 8–TAN/BLU 9–TAN/WHT TAN/BLK TAN/BLU TAN/WHT BLK/YEL BLK/WHT BLK RED/WHT GRY GRN BLK GRN RED GRN/WHT GRN/WHT 1 2 3 1 2 3 GRN GRN GRN/WHT GRN GRN GRN BLK GRN/WHT GRN/WHT RED RED/PPL 1–GRN 2–GRN 3–GRN/WHT 1–GRN 2–GRN 3–GRN 1 2 3 4 7 6 5 8 BLACK GRN/WHT YEL/RED RED/PPL BLK/YEL PURPLE TAN/BLU BLK BLK BLK BLK GND BLK BLK BLK BLK ORG ORG ORG ORG PPL TAN/BLK RED/WHT BLK/WHT TAN/WHT TAN/WHT TAN/WHT BLK BLK BRN YEL/RED YEL W/BLK ENDS RED RED GRY/BLK PNK/BLK PNK PNK/WHT YEL/BLK WHT YEL/RED BLK/WHT BLK BLK/ORG BRN BLU WHT/RED WHT/BLK GND B A RED RED/PPL RED RED BLK BLK BLK BLK BLU/YEL BLU BLU/YEL BLK BLK BLK BLK BLK BLK BLK BLK BLK GRN/WHT GRN/WHT GRN/WHT GRY GRY/BLK BLK BLK 1 2 3 4 1 4 2 3 YEL/BLK YEL/BLK a b c d e f g h i j k l m n o p q r o s WIRING DIAGRAMS Page 2D-2 90-828631R3 MARCH 1999 Electric Start Wiring Diagram a - PTC Heater b - Solenoid Coil c - CDI Unit d - Trim Down Relay e - Trim Up Relay f - Starter g - Trim Pump h - 20 Amp Fuse i - Starter Relay j - Voltage Regulator k - Cowl Mounted Trim Switch l - Stator m - Trigger n - Oil Pressure Switch o - Ignition Coil p - Remote Wiring Plug q - Spark Plugs r - Block Temperature Switch s - Thermo Switch WIRING DIAGRAMS Tiller Handle Wiring Diagram YEL/RED BLK = Black BLU = Blue GRY = Gray GRN = Green PUR = Purple RED = Red TAN = Tan YEL = Yellow RED BLK/YEL BLK BLK/YEL BLK TAN/BLU TAN PUR RED BLK/YEL BLK RED BLK BLK BLK/YEL BLK GRY YEL/RED PUR YEL/ BLK g f e d c b a a-Neutral Start Switch b-Auxiliary Harness c-Not Used d-Horn e-Lanyard f-Stop Switch g-Start Switch 90-828631R3 MARCH 1999 Page 2D-3 WIRING DIAGRAMS Commander Remote Control (Electric Start) BLK = Black BRN = Brown GRY = Gray GRN = Green RED = Red WHT = White YEL = Yellow a d e c b a-Ignition Choke Switch b-Emergency Stop Switch c-Neutral Start Switch d-Tachometer/Accessories Harness Connector e-Wiring Harness Connector Page 2D-4 90-828631R3 MARCH 1999 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 90-828631R3 MARCH 1999 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 a b c BLK = Black BLU = Blue BRN = Brown GRN = Green GRY = Gray PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow a-Lanyard stop switch leads must be soldered and covered with shrink tube for a water proof connection. If alternate method of connection is made, (use of electrical butt connector) verify connection is secure and sealed for moisture proof connection. b-Connect wires together with screw and hex nut (2 places); apply Quicksilver Liquid Neoprene to connections and slide heat shrink tubing over each connection. c-Keyswitch Page 2D-6 90-828631R3 MARCH 1999 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 a b GRN = Green BLU = Blue RED = Red WHT = White a-Trim Switch b-Starter Relay 90-828631R3 MARCH 1999 Page 2D-7 WIRING DIAGRAMS Page 2D-8 90-828631R3 MARCH 1999 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. Plug the remote wiring harness into the engine wiring harness connector. Push the harness connection into the holder. 3. Connect additional wires leads (if equipped). a b a - Remote Wiring Harness b - Engine Wiring Harness Connector FUEL PUMP FUEL SYSTEM Section 3A - Fuel Pump Table of Contents Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1 Fuel Pump Disassembly . . . . . . . . . . . . . . . . . . . 3A-6 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-2 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . . . 3A-7 Fuel Pump Operation. . . . . . . . . . . . . . . . . . . . . . 3A-4 Fuel Pump Reassembly. . . . . . . . . . . . . . . . . . . . 3A-8 Fuel Pump Removal . . . . . . . . . . . . . . . . . . . . . . . 3A-5 Fuel Pump Installation . . . . . . . . . . . . . . . . . . . . 3A-10 3 A Specifications FUEL SYSTEM Fuel Pump Type Fuel Pump: Pressure Diaphragm Stroke Plunger Stroke Fuel Tank Capacity External (Plunger/Diaphragm) 3-6 psi 0.14 - 0.20 in. (3.5 - 5.1 mm) 0.23 - 0.38 in. (5.85 - 9.65 mm) Accessory 90-828631R3 MARCH 1999 Page 3A-1 FUEL PUMP Fuel Pump 22 1 2 3 4 5 6 7 910 11 12 7 6 5 8 16 17 19 20 21 20 20 14 20 18 13 Page 3A-2 90-828631R3 MARCH 1999 FUEL PUMP Fuel Pump REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 FUEL PUMP 2 4 SCREW Drive Tight 3 1 O RING 4 1 DIAPHRAGM 5 2 SCREW Drive Tight 6 2 NUT 7 2 CHECK VALVE 8 1 DIAPHRAGM 9 1 PIN 10 1 SPRING 11 4 NUT 12 1 SPRING 13 1 PLUNGER 14 1 O RING 15 2 SCREW 75 8.5 16 1 J CLAMP 17 1 FUEL CONNECTOR – 1 O RING 18 1 TUBING (19 IN.) 19 1 TUBING (16 IN.) 20 AR STA STRAP 21 1 FUEL FILTER 22 1 COWL DEFLECTOR 90-828631R3 MARCH 1999 Page 3A-3 FUEL PUMP Fuel Pump Operation 1. The fuel pump is a diaphragm pump which is mechanically driven off of the rocker arm. 2. The black mounting block (insulator) and the two outlets on the fuel pump help prevent vapor lock. 3. If the engine runs out of fuel, or has a restriction preventing adequate fuel flow, the pump will make a “clicking” noise. WARNING FIRE AND EXPLOSION HAZARD. Observe fire prevention rules, particularly NO SMOKING. Before servicing any part of the fuel system, disconnect electrical system at the battery. Drain the fuel system completely. Use an approved container to collect and store fuel. Wipe up any spillage immediately. Materials used to contain spillage must be disposed of in an approved receptacle. Any fuel system service must be performed in a well ventilated area. FUEL LEAKAGE FROM ANY PART OF THE FUEL SYSTEM CAN BE A FIRE AND EXPLOSION HAZARD WHICH CAN CAUSE SERIOUS BODILY INJURY OR DEATH. Careful periodic inspection of the entire fuel system is mandatory, particularly after engine storage. All fuel components, including fuel tanks, whether plastic, metal, or fiberglass, fuel lines, primer bulbs, fittings, swelling, and must be inspected for corrosion. Any sign of leakage or deterioration necessitates replacement before further engine operation. Page 3A-4 90-828631R3 MARCH 1999 FUEL PUMP Fuel Pump Removal 1. Remove sta-straps from fuel lines. IMPORTANT: The hose fittings on the fuel pump can break if you try twisting or pulling the hoses off. Remove hoses by slowly prying off the hoses using a small screwdriver. 2. Disconnect fuel lines from pump. 3. Separate fuel pump from cylinder head cover by removing mounting bolts. 53668 out out in a c d b a-Mounting Bolts-10mm (2) b-Fuel Lines (3) c-J-Clamp d-Fuel Filter 90-828631R3 MARCH 1999 Page 3A-5 FUEL PUMP Fuel Pump Disassembly 1. Remove screws to separate pump cover, cover seal, and diaphragm, from pump body. 28378 c d b a e f a-Screws (4) b-Pump Cover c-Cover Seal d-Diaphragm e-Pump Body f-Nuts (4) 2. Rotate plunger to line up slots. b a 53615 a-Slots Offset b-Slots Aligned 3. Compress pump assembly to free spring load on pin. 4. Tilt assembly to allow pin to slide out. 53617 a a-Pin Page 3A-6 90-828631R3 MARCH 1999 FUEL PUMP Cleaning/Inspection/Repair 1. Inspect fuel filter for cracks/clogs, replace if necessary. 2. Inspect the check valves for damage, replace if necessary. 3. Inspect springs for damage, replace if necessary. 4. Inspect cover seal and diaphragm, replace if damaged. ab a-Cover Seal b-Diaphragm 90-828631R3 MARCH 1999 Page 3A-7 FUEL PUMP Fuel Pump Reassembly 1. Assemble springs, diaphragm, and plunger onto pump body. a b c d e a-Diaphragm b-Diaphragm Spring c-Pump Body d-Spring e-Plunger 2. Line up slots and compress assembly. 3. Insert pin into hole. a b c a-Pump Body b-Slots c-Pin 4. Rotate plunger 90° to offset slots. 53615 a b a-Slots Aligned b-Slots Offset Page 3A-8 90-828631R3 MARCH 1999 FUEL PUMP 5. Assemble diaphragm, seal, and cover, to pump body, secure with screws and nuts. NOTE:Seal installs in one direction only. c d b a e f a-Screws (4) b-Cover c-Cover Seal d-Diaphragm e-Pump Body f-Nuts (4) 6. Install a new O-ring onto the pump assembly. NOTE:Always install a new O-ring. a 53620 a-O-ring 90-828631R3 MARCH 1999 Page 3A-9 FUEL PUMP Fuel Pump Installation 1. Secure fuel pump and cowl deflector to cylinder head cover with 2 bolts. 2. Connect fuel lines to pump and secure with sta-straps. d e d out out in c a b c e f a-Outlet Fuel Hose b-Inlet Fuel Hose c-Mounting Bolts (2)-M6x30 d-Cowl Deflector e-J-Clip f-Cable Ties (3) Fuel Pump Mounting Bolt Torque 75 lb-in. (8.5 Nm) Page 3A-10 90-828631R3 MARCH 1999 CARBURETOR FUEL SYSTEM Section 3B - Carburetor Table of Contents Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-3 Carburetor Linkage . . . . . . . . . . . . . . . . . . . . . . . . 3B-4 Carburetor (40/45). . . . . . . . . . . . . . . . . . . . . . . . . 3B-6 Carburetor (50) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-8 Intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-10 Carburetor Adjustments . . . . . . . . . . . . . . . . . . . 3B-12 Carburetor Synchronization-Static Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-12 Idle Mixture Screw Adjustment-Static Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-13 Choke Cam Angle Adjustment . . . . . . . . . . 3B-14 Fast Idle Adjustment . . . . . . . . . . . . . . . . . . . 3B-15 Unloader Adjustment . . . . . . . . . . . . . . . . . . 3B-16 Choke Shutter Closing Adjustment . . . . . . . 3B-17 Carburetor Unit Removal . . . . . . . . . . . . . . . . . . 3B-18 Carburetor Link Removal. . . . . . . . . . . . . . . . . . 3B-21 Solenoid Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-22 Electrothermal Plunger Removal . . . . . . . . . . . 3B-22 Acceleration Pump . . . . . . . . . . . . . . . . . . . . . . . 3B-23 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-23 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-23 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-24 Fuel Piping Removal. . . . . . . . . . . . . . . . . . . . . . 3B-24 Silencer Removal . . . . . . . . . . . . . . . . . . . . . . . . 3B-25 Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-25 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-25 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-27 Carburetor Assembly . . . . . . . . . . . . . . . . . . . . . 3B-28 Silencer Installation . . . . . . . . . . . . . . . . . . . . . . . 3B-31 Acceleration Pump . . . . . . . . . . . . . . . . . . . . . . . 3B-31 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-31 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-32 Fuel Piping Installation . . . . . . . . . . . . . . . . . . . . 3B-33 Electrothermal Plunger Installation . . . . . . . . . 3B-34 Solenoid Coil Installation . . . . . . . . . . . . . . . . . . 3B-34 Carburetor Link Installation . . . . . . . . . . . . . . . . 3B-35 Carburetor Unit Installation . . . . . . . . . . . . . . . . 3B-36 3 B 90-828631R3 MARCH 1999 Page 3B-1 CARBURETOR Specifications Idle rpm (Out Of Gear) 45 hp 950 ± 25 rpm 40/50 hp 825 ± 25 rpm Idle RPM (In Forward Gear) 45 hp 850 ± 25 rpm 40/50 hp 725 ± 25 rpm CARBURETOR Wide Open Throttle rpm (WOT) Range 5500–6000 Main Jet Size 40/45 hp #104 for Carburetors 1 and 2 #103 for Carburetors 3 and 4 50 hp #112 Pilot Jet #42 Float Height 0.39 ± 0.02 in. (10.0 ± 0.5 mm) Page 3B-2 90-828631R3 MARCH 1999 CARBURETOR Special Tools 1. Carburetor Scale (P/N 91-36392) 2. Idle Mixture Screw Adjuster (45 HP Bodensee Models Only) P/N 91-809906A1 90-828631R3 MARCH 1999 Page 3B-3 2 3 4 5 6 7 8 11 10 9 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 30 31 32 33 34 28 35 36 37 5 3 10 13 14 9 9 9 17 1 29 CARBURETOR Page 3B-4 90-828631R3 MARCH 1999 Carburetor Linkage CARBURETOR Carburetor Linkage REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 DIAPHRAGM 2 1 JOINT 3 3 SCREW Drive Tight 4 1 PIPE 5 1/2 PIPE (Qty. of 2 with carb with adjustable pilot screw/ Qty. of 1 with carb with non-adjustable pilot screw) 6 1 PIPE 7 1 PIPE 8 1 CHOKE ROD 9 4 JOINT 10 2 WASHER 11 1 CHOKE ROD 12 1 CHOKE ROD 13 2 COLLAR 14 2 JOINT 15 1 CHOKE ROD 16 1 CHOKE ROD 17 2 SCREW Drive Tight 18 1 THROTTLE DAMPER 19 1 SPRING 20 1 CHOKE ROD 21 1 STARTER LEVER 22 1 STARTER LEVER 23 1 WASHER 24 1 SCREW 25 1 WASHER 26 2 SCREW Drive Tight 27 1 AUTO STARTER 28 1 SOLENOID 29 1 COVER 30 1 BRACKET (Included W/825105A1 ON INTAKE) 31 2 SCREW Drive Tight 32 1 NUT 33 1 WASHER 34 1 WIRE PULL 35 1 SPRING 36 1 PLATE 37 1 SCREW Drive Tight 90-828631R3 MARCH 1999 Page 3B-5 2 3 4 5 6 7 8 9 10 11 12 13 14 1516 17 18 19 20 2122 23 24 25 26 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 5 5 5 7 7 7 43 43 42 30 32 2 3 4 5 6 7 8 9 10 11 12 13 14 1516 17 18 19 20 2122 23 24 25 26 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 5 5 5 7 7 7 43 43 42 30 32 CARBURETOR Carburetor (40/45) 1 Page 3B-6 90-828631R3 MARCH 1999 CARBURETOR Carburetor (40/45) REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 CARBURETOR (1) 2 1 CARBURETOR (2) 3 1 CARBURETOR (3) 4 1 CARBURETOR (4) 5 8 SCREW 6 1 COVER (1) 7 4 VALVE 8 4 SEAL 9 4 PILOT SCREW SET 10 4 O RING 11 4 SPRING–air adjusting 12 3 WASHER (1/2/3) 13 3 SPRING–pilot adjusting (1/2/3) 14 3 SCREW– throttle (1/2/3) 15 4 WASHER 16 4 CIRCLIP 17 1 LEVER (1) 18 1 LOCKWASHER (1) 19 1 NUT (1) 20 4 NEEDLE VALVE 21 4 SCREW 22 4 MAIN NOZZLE 23 4 O RING 24 4 MAIN NOZZLE 25 4 PILOT JET (#42) 26 2 MAIN JET (#104)(1/2) 27 2 MAIN JET (#103)(3/4) 28 4 FLOAT 29 4 FLOAT PIN 30 4 GASKET 31 3 BODY (1/2/3) 32 16 SCREW 33 4 SCREW–drain 34 4 GASKET 35 1 COVER (2) 36 1 CLIP (2) 37 1 ROLLER (2) 38 1 COVER (3) 39 1 JOINT–throttle lever (4) 40 1 ROD–starter (4) 41 1 JOINT–choke lever (4) 42 2 SCREW (4) 43 3 SPRING–pilot adjusting (4) 44 1 COVER (4) 45 1 SCREW (4) 46 1 WASHER (4) 47 1 LEVER (4) 48 1 SCREW–throttle (4) 49 1 BODY (4) 90-828631R3 MARCH 1999 Page 3B-7 2 3 4 5 6 7 8 9 10 1112 13 14 15 16 1718 19 20 21 22 23 24 25 26 27 28 29 30 3132 33 34 35 36 37 38 39 40 41 42 43 44 7 5 5 5 7 7 38 37 38 25 27 2 3 4 5 6 7 8 9 10 1112 13 14 15 16 1718 19 20 21 22 23 24 25 26 27 28 29 30 3132 33 34 35 36 37 38 39 40 41 42 43 44 7 5 5 5 7 7 38 37 38 25 27 CARBURETOR Carburetor (50) 1 Page 3B-8 90-828631R3 MARCH 1999 CARBURETOR Carburetor (50) REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 CARBURETOR (1) 2 1 CARBURETOR (2) 3 1 CARBURETOR (3) 4 1 CARBURETOR (4) 5 8 SCREW 6 1 COVER (1) 7 4 VALVE 8 3 WASHER (1/2/3) 9 3 SPRING–pilot adjusting (1/2/3) 10 3 SCREW– throttle (1/2/3) 11 4 WASHER 12 4 CIRCLIP 13 1 LEVER (1) 14 1 LOCKWASHER (1) 15 1 NUT (1) 16 4 NEEDLE VALVE 17 4 SCREW 18 4 MAIN NOZZLE 19 4 O RING 20 4 MAIN NOZZLE 21 4 PILOT JET (#44) 22 4 MAIN JET (#112) 23 4 FLOAT 24 4 FLOAT PIN 25 4 GASKET 26 3 BODY (1/2/3) 27 16 SCREW 28 4 SCREW–drain 29 4 GASKET 30 1 COVER (2) 31 1 CLIP (2) 32 1 ROLLER (2) 33 1 COVER (3) 34 1 JOINT–throttle lever (4) 35 1 ROD–starter (4) 36 1 JOINT–choke lever (4) 37 2 SCREW (4) 38 3 SPRING–pilot adjusting (4) 39 1 COVER (4) 40 1 SCREW (4) 41 1 WASHER (4) 42 1 LEVER (4) 43 1 SCREW–throttle (4) 44 1 BODY (4) 90-828631R3 MARCH 1999 Page 3B-9 1 2 3 4 5 6 7 8 9 10 12 11 13 14 15 16 17 18 19 20 22 21 23 24 25 26 27 28 29 30 31 32 33 2 21 21 21 21 21 24 23 24 24 23 27 34 35 CARBURETOR Page 3B-10 90-828631R3 MARCH 1999 Intake CARBURETOR Intake REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 8 SCREW 70 8 2 8 O RING 3 1 INSULATOR 4 2 PLUG 5 1 JOINT–carburetor 6 2 DOWEL PIN 7 4 O RING 8 4 O RING 9 4 O RING 10 4 GROMMET 11 AR STA–STRAP 12 1 BREATHER PIPE 13 1 CLAMP 14 8 COLLAR 15 8 SCREW 50 5.7 16 2 SCREW 75 8.5 17 2 COLLAR 18 1 INTAKE SILENCER ASSEMBLY 19 1 CABLE TIE 20 1 PLUG 21 16 CLAMP 22 1 HOSE 23 3 CONNECTOR 24 4 HOSE 25 1 HOSE 26 1 CLAMP 27 2 HOSE 28 1 FUEL HOSE 29 1 CLAMP 30 1 CONNECTOR 31 1 HOSE 32 1 HOSE 33 1 CLIP 34 1 DECAL-SERVICING REFERRAL 35 1 DECAL-Caution-Start in Gear 90-828631R3 MARCH 1999 Page 3B-11 CARBURETOR Page 3B-12 90-828631R3 MARCH 1999 Carburetor Adjustments Carburetor Synchronization-Static Adjustment NOTE: This static adjustment is necessary if the throttle stop screws were loosened or tampered with. The initial static setting is preparation for the Carburetor Synchronization-dynamic adjustment (Section 2C). 1. Remove the carburetors as a unit. 2. Disconnect throttle link (a) and auto choke “Z” link (b). 3. Adjust the idle rpm screw #4 until the throttle shutter covers half of bypass hole. 4. Install throttle link. 5. Adjust throttle stop screws #1, #2 and #3 until the throttle shutters cover half of bypass hole. 6. Re-install “Z” link. 7. Re-install the carburetors as a unit. 1 2 4 3 b a c a - Throttle Link (Disconnect) b - Auto Choke “Z” Link (Disconnect) c - Bypass Hole CARBURETOR 90-828631R3 MARCH 1999 Page 3B-13 Idle Mixture Screw Adjustment-Static Adjustment NOTE: Idle mixture screw adjustment is required when carburetor has been overhauled. NOTE: Screw Adjuster (91-809906A1) is required to adjust the idle mixture screws on 45 hp models. NOTE: The idle mixture screw is: Adjustable: -All model years for the 45 hp version. -1995-1997 model years for all other versions. Non-adjustable: -1998 model year and later. 1. Screw in the idle mixture screw on each carburetor until it is lightly seated, than back-out specified number of turns. 1 2 3 4 a b a - Remove Plug b - Idle Mixture Screw Idle Mixture Screw-Turns Out 2.5 CARBURETOR Page 3B-14 90-828631R3 MARCH 1999 Choke Cam Angle Adjustment NOTE: Choke cam angle adjustment is required when #4 carburetor has been replaced or overhauled. 1. Measure gap “a” and refer to the thermal gap graph, if out of specification adjust. 2. Adjustment steps: a. Loosen cam angle adjustment screw. b. Find the gap for the temperature on the graph. c. Adjust and tighten the cam angle adjustment screw with the specified gap “a”. a b a - Gap b - Cam Angle Adjustment Screw THERMAL GAP GRAPH Gap (mm) Temp. (°C) CARBURETOR 90-828631R3 MARCH 1999 Page 3B-15 Fast Idle Adjustment NOTE: Fast idle adjustment is required when fast idle exceeds 1500 rpm or engine stalls during a cold start. 1. Remove the link rods (a & b) and loosen fast idle screw (c). 2. Loosen idle stop screw (d) until the screw is free from the lever. 3. Tighten the idle stop screw (d) until the bypass hole is half visible. 4. Tighten the idle stop screw (d) to the specified number of turns from the graph. 5. Connect the link rods (a &b). 6. Hold the fast idle lever (f) to the roller (g) and secure the fast idle screw (c). e a d c f g b a - Link Rod b - Link Rod c - Fast Idle Screw d - Idle Stop Screw e - Bypass Hole (Reference View Only) f - Fast Idle Lever g - Roller Turns Temp. (°C) CARBURETOR Page 3B-16 90-828631R3 MARCH 1999 Unloader Adjustment NOTE: Unloader adjustment is required when the unloader adjustment screw has been loosened. 1. Disconnect the choke actuator rod (a). 2. Loosen the unloader adjustment screw (c). 3. Close the choke valve fully. NOTE: Check for a fully closed choke valve by depressing the #4 carburetor choke lever, then check the #1 carburetor choke lever to see that it is touching the stopper. 4. Turn the unloader adjustment screw (c) in until the screw tip touches the lever. a b d c a - Choke Actuator Rod b - #1 Choke Shutter Stop c - Unloader Adjustment Screw d - Lever CARBURETOR 90-828631R3 MARCH 1999 Page 3B-17 Choke Shutter Closing Adjustment 1. Measure gap “a” and refer to the thermal gap graph below, if out of specification adjust. 2. Adjust gap by tightening/loosening the choke valve closing screw (b) to obtain the specified gap found on the graph. a b a - Gap b - Choke Shutter Closing Screw THERMAL GAP GRAPH Gap (mm) Temp. (°C) CARBURETOR Page 3B-18 90-828631R3 MARCH 1999 Carburetor Unit Removal 1. Remove fuel line sta-straps. 2. Disconnect fuel lines and breather hose. 3. Disconnect solenoid and plunger leads. 28379 a b c d e a a - Sta-Straps (3) b - Breather Hose c - Fuel Lines (2) d - Solenoid Leads (Blue, Black) e - Plunger Leads (Green/White, Black) 4. Remove bolts and collars. 28379 b a c a - Bolt w/Washer-M6x30 mm (2) b - Collar (2) c - Mounting Bolt w/Washer-M6x25 mm (8) CARBURETOR 5. Remove carburetor unit from intake manifold. 53679 6. Remove dowel pins. 7. Remove insulator from carburetor by prying near the plugs. 53679 a b c c a a-Dowel Pin (2) b-Insulator c-Plug (2) 90-828631R3 MARCH 1999 Page 3B-19 CARBURETOR Page 3B-20 90-828631R3 MARCH 1999 NOTE: Do not loosen or remove screw a, b, c, or d. Fine adjustments will be required if these screws are tampered with. 28379 a b c d a - Screw “a” b - Screw “b” c - Screw “c” d - Screw “d” CARBURETOR 90-828631R3 MARCH 1999 Page 3B-21 Carburetor Link Removal 1. Unsnap links from retainer clips. 28379 a e d b f g c a - Upper Choke Link-“C” Link b - Lower Choke Link-“J” Link c - Auto Choke Link-“Z” Link d - Unloader Link-Small “J” Link e - Throttle Link f - Joint Plate g - Retainer Clips CARBURETOR Page 3B-22 90-828631R3 MARCH 1999 Solenoid Coil 1. Unhook spring and remove screws. 2. Loosen locknut to free wire pull from coil assembly. 28379 a b c d a - Spring b - Screw (2) c - Lock Nut d - Wire Pull Electrothermal Plunger Removal 1. Remove cover (if so equipped). 2. Remove screws. 28379 a b a - Cover b - Screw (2) CARBURETOR 90-828631R3 MARCH 1999 Page 3B-23 Acceleration Pump Removal 1. Disconnect delivery hoses, remove screws, and un-clip retainer. 53681 a b c a - Delivery Hoses (4) b - Screw (3) c - Retainer Disassembly 1. Remove screws. 53752 a b a - Cover Screw (2) b - Diaphragm Screw (2) CARBURETOR Inspection 1. Inspect check valve and diaphragm, replace if worn or damaged. 53752 Fuel Piping Removal 1. Cut sta-straps and remove fuel hoses. a a a a 53725 a-Sta-Strap (4) Page 3B-24 90-828631R3 MARCH 1999 CARBURETOR 90-828631R3 MARCH 1999 Page 3B-25 Silencer Removal 1. Remove bolts and collars. 2. Remove plate, silencer, and retaining plate. 53679 a b d e c a - Bolt w/Washer-M6x90mm (8) b - Collar (8) c - Silencer Assembly d - Retaining Plate e - Plate Carburetor Disassembly 1. Remove float bowl. 53674 a b a - Screw (4) b - Float Bowl CARBURETOR 2. Remove float and needle valve. 53676 a b c d a-Float Pin Retaining Screw b-Float c-Float Pin d-Needle Valve 3. Remove cover and seal. ab c a-Screws (2) b-Cover c-Seal 4. Remove nozzles and jets. 53676 a c db a-Plug b-Nozzle c-Main Jet d-Pilot Jet Page 3B-26 90-828631R3 MARCH 1999 CARBURETOR 90-828631R3 MARCH 1999 Page 3B-27 5. Remove idle mixture screw. NOTE: 45 hp Models – Screw Adjuster (91-809906A1) is required to remove idle mixture screw. 53674 a b c a - Idle Mixture Spring b - Idle Mixture Screw c - Plug Inspection 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. 1. Inspect carburetor body, replace if cracked or damaged. 53671 2. Inspect float, replace if cracked or damaged. 53673 3. Inspect pilot screw. Replace if bent or damaged. 53673 CARBURETOR 4. Inspect main jet, pilot jet and main nozzle. Clean if they are contaminated. 53672 5. Inspect needle valve, replace if end is worn or grooved. 28375 Carburetor Assembly NOTE:Note different carburetor design from old style to new style for top carburetor (#1). New style does not have breather port. a Old Style New Style a-Breather Port Page 3B-28 90-828631R3 MARCH 1999 CARBURETOR 90-828631R3 MARCH 1999 Page 3B-29 1. Install idle mixture screw. Lightly seat idle mixture screw and then back out 2.5 turns. NOTE: 45 hp Models – Use Screw Adjuster (91-809906A1) to install idle mixture screw. c 53674 a b a - Idle Mixture Spring b - Idle Mixture Screw c - Plug 2. Install nozzle and jets. 53676 b c d a a - Plug b - Nozzle c - Main Jet d - Pilot Jet (#42) 3. Install float pin and needle valve. Needle valve should slide into valve seat on float. 53676 a b c d a - Retaining Screw b - Float c - Float Pin d - Needle Valve CARBURETOR NOTE:Measure float height with carb. scale, replace float if height is not within specification [0.390.02 in. (10.00.5mm)]. Take measurements at the mid-line of the float opposite its pivot side. After installing, check for smooth movement of the float. 28380 4. Install cover and seal. ab c a-Screws (2) b-Cover c-Seal 5. Install float bowl. 53674 a b a-Screw (4) b-Float Bowl Page 3B-30 90-828631R3 MARCH 1999 CARBURETOR 90-828631R3 MARCH 1999 Page 3B-31 Silencer Installation 1. Install plate, silencer, and retaining plate. Install bolts and collars. 53679 95 95 2-4-C With Teflon (92-825407A12) a b c d e NOTE: Dowel pins must match between carb. flange and retaining plate. a - Bolt w/Washer-M6x90mm (8) b - Collar (8) c - Silencer d - Retaining Plate e - Plate Bolt Torque 50 lb-in. (5.7 Nm) Acceleration Pump Assembly 1. Install screws. 53752 b a a - Cover Screw (2) b - Diaphragm Screw (2) CARBURETOR Page 3B-32 90-828631R3 MARCH 1999 Installation 1. Secure pump link with retainer, install screws, and connect delivery hoses. 53681 a b d c a - Delivery Hoses (4) b - Screw (3) c - Retainer d - Breather Hose NOTE: On older models with breather port located on the top carburetor (#1), route breather hose through bracket flange. If replacing top carburetor with new carburetor, breather hose is not needed. 57265 b a b c a - Bracket Flange b - Breather Hose c - Breather Port CARBURETOR Fuel Piping Installation 1. Install fuel hoses and secure with sta-straps. a a a a 53752 a-Sta-Strap (4) 90-828631R3 MARCH 1999 Page 3B-33 CARBURETOR Page 3B-34 90-828631R3 MARCH 1999 Electrothermal Plunger Installation 1. Install screws. 2. Install cover (if so equipped). 28378 a b a - Screw (2) b - Cover Solenoid Coil Installation 1. Connect wire pull to coil assembly with lock nut. 2. Install screws and hook spring onto carburetor assembly. 28378 c d b a a - Wire Pull b - Lock Nut c - Screw (2) d - Spring CARBURETOR 90-828631R3 MARCH 1999 Page 3B-35 Carburetor Link Installation 1. Snap links onto retainer clips. Apply a light oil to link balls. 28378 14 14 4 Cycle Outboard Oil (92-828000A1) 14 14 14 g b c f a e d a - Upper Choke Link-“C” Link b - Lower Choke Link-“J” Link c - Auto Choke Link-“Z” Link d - Unloader Link-Small “J” Link e - Throttle Link f - Joint Plate g - Retainer Clips CARBURETOR Carburetor Unit Installation NOTE:Carburetor synchronization/static adjustment is required after rebuilding carburetors. Refer tobeginning of sectionfor adjustments. 1. Snap plugs into carburetor to secure insulator. 2. Install dowel pins. 53679 a b c a c a-Dowel Pin (2) b-Insulator c-Plug (2) 3. Install carburetor unit to intake manifold. 53679 Page 3B-36 90-828631R3 MARCH 1999 CARBURETOR 90-828631R3 MARCH 1999 Page 3B-37 4. Install bolts and collars. 28378 c b a a - Bolt w/Washer-M6x30mm (2) b - Collar (2) c - Mounting Bolt w/Washer-M6x25mm (8) 5. Connect solenoid and plunger leads. 6. Connect fuel lines and breather hose. 7. Install sta-straps. 28378 a b c d e a a - Sta-Straps (3) b - Breather Hose c - Fuel Lines (2) d - Solenoid Leads (Blue, Black) e - Plunger Leads (Green/White, Black) EMISSIONS FUEL SYSTEM Section 3C – Emissions Table of Contents Exhaust Emissions Standards . . . . . . . . . . . . . . 3C-2 What Are Emissions? . . . . . . . . . . . . . . . . . . . 3C-2 Hydrocarbons – HC. . . . . . . . . . . . . . . . . . . . . 3C-2 Carbon Monoxide – CO . . . . . . . . . . . . . . . . . 3C-2 Oxides of Nitrogen – NOx . . . . . . . . . . . . . . . 3C-2 Controlling Emissions . . . . . . . . . . . . . . . . . . . 3C-2 Stoichiometric (14.7:1) Air/Fuel Ratio . . . . . 3C-3 Outboard Hydrocarbon Emissions Reductions . . . . . . . . . . . . . . . . . . . . . 3C-3 8 1/3%  Per Year Over 9 Model Years . . . . 3C-3 Stratified Vs Homogenized Charge . . . . . . . . . . 3C-4 Homogenized Charge . . . . . . . . . . . . . . . . . . . 3C-4 Stratified Charge . . . . . . . . . . . . . . . . . . . . . . . 3C-5 Emissions Information . . . . . . . . . . . . . . . . . . . . . 3C-6 Manufacturer’s Responsibility: . . . . . . . . . . . 3C-6 Dealer Responsibility: . . . . . . . . . . . . . . . . . . . 3C-6 Owner Responsibility: . . . . . . . . . . . . . . . . . . . 3C-6 EPA Emission Regulations: . . . . . . . . . . . . . . 3C-7 Decal Location for 1999 Models: . . . . . . . . . 3C-8 3 C 90-828631R3 MARCH 1999 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; gasoline contains mainly hydrogen and carbon. These four elements combine chemically during combustion. If combustion were complete, the mixture of air and gasoline would result in these emissions: water, carbon dioxide and nitrogen, which are not harmful to the environment. But combustion is not usually complete. Also, potentially harmful gases can be formed during and after combustion. All marine engines must reduce the emission of certain pollutants, or potentially harmful gases, in the exhaust to conform with levels legislated by the EPA. Emissions standards become more stringent each year. Standards are set primarily with regard to three emissions: hydrocarbons (HC), carbon monoxide (CO) and oxides of nitrogen (NOx). Hydrocarbons – HC Gasoline is a hydrocarbon fuel. The two elements of hydrogen and carbon are burned during combustion in combination with oxygen. But they are not totally consumed. Some pass through the combustion chamber and exit the exhaust system as unburned gases known as hydrocarbons. Carbon Monoxide – CO Carbon is one of the elements that make up the fuel burned in the engine along with oxygen during the combustion process. If the carbon in the gasoline could combine with enough oxygen (one carbon atom with two oxygen atoms), it would come out of the engine in the form of carbon dioxide (CO2). CO2 is a harmless gas. But carbon often combines with insufficient oxygen (one carbon atom with one oxygen atom). This forms carbon monoxide, CO. Carbon monoxide is the product of incomplete combustion and is a dangerous, potentially lethal gas. Oxides of Nitrogen – NOx NOx is a slightly different byproduct of combustion. Nitrogen is one of the elements that makes up the air going into the engine. Under extremely high temperatures it combines with oxygen to form oxides of nitrogen (NOx). This happens in the engine’s combustion chambers when temperatures are too high. NOx itself is not harmful, but when exposed to sunlight it combines with unburned hydrocarbons to create the visible air pollutant known as smog. Smog is a serious problem in California as well as many other heavily populated areas of the United States. Controlling Emissions There are two principle methods of reducing emissions from a two-stroke-cycle marine engine. The first method is to control the air/fuel ratio that goes into the combustion chamber. The second is to control the time when this air/fuel mixture enters the combustion chamber. Timing is important, to prevent any unburned mixture from escaping out of the exhaust port. Page 3C-2 90-828631R3 MARCH 1999 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 90-828631R3 MARCH 1999 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 air/fuel 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 90-828631R3 MARCH 1999 EMISSIONS Stratified Charge A stratified charge engine only pulls air through the transfer system. The fuel required for combustion is forced into the cylinder through an injector placed in the top of the cylinder (head). The injector sprays an air/fuel mixture in the form of a 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. 90-828631R3 MARCH 1999 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 90-828631R3 MARCH 1999 EMISSIONS EPA Emission Regulations: All new 1998 and later outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors. This certification is contingent on certain adjustments being set to factory standards. For this reason, the factory procedure for servicing the product must be strictly followed and, whenever practicable, the product returned to the original intent of the design. The responsibilities listed above are general and in no way a complete listing of the rules and regulations pertaining to the EPA laws on exhaust emissions for marine products. For more detailed information on this subject, you may contact the following locations: VIA U.S. POSTAL SERVICE: Office of Mobile Sources Engine Programs and Compliance Division Engine Compliance Programs Group (6403J) 401 M St. NW Washington, DC 20460 VIA EXPRESS or COURIER MAIL: Office of Mobile Sources Engine Programs and Compliance Division Engine Compliance Programs Group (6403J) 501 3rd St. NW Washington, DC 20001 EPA INTERNET WEB SITE: http:/www.epa.gov/omswww 90-828631R3 MARCH 1999 Page 3C-7 EMISSIONS CERTIFICATION LABEL: The certification label must be placed on each engine at the time of manufacture and must be replaced in the same location if damaged or removed. Shown below is a typical certification label and is not representative of any one model. Label shown below is not to scale; (shown at twice the normal size). JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC Emission Control Information 1999 PART # 37-856985 23 This engine conforms to 1998 Model Year U.S. EPA regulations for marine SI engines. Idle Speed (in gear): XXX RPM Timing: XXXX Standard Spark Plug: NGK DPR6EA-9 Gap: .035, Valve Clearance (Cold) mm Intake: XXXX Exhaust: XXXX Refer to Owners Manual for required maintenance. Family: WM9XM.935220 FEL: 32.20 GM/KW-HR 935 cc 40-50 HP 4-Stroke e ba k j i d f g h c a -Spark Ignition (SI) b -Cubic Centimeter c -Model year of engine and production decal part number d -Idle Speed (In Gear) e -Timing specifications when adjustable f -Recommended spark plug for best engine performance g -Valve Clearance (Four Stroke engines only) h -Engine Horsepower rating i -Month of production (Boxing month will punched) j -FEL: Represents (Mercury Marine) statement of the maximum emissions output for the engine family k -Family example W M9X M. 747 2 2 0 Model Year Regulation Application Unspecified W=1998 M=Marine 1=PWC X=1999 2=OB Manufacturer Displacement Technology type Mercury Marine Liter 1=Existing Cubic Inch 2=New Decal Location for 1999 Models: Model Production Part No. Service Part No. Location on Engine 1998 Merc/Mar 935 cc 37-855211-25 37-855577-25 (1998 Carb with non-adjustable pilot screw) Inside Top Cowl 1998 Merc/Mar 935 cc 37-855211-39 37-855577-39 (1998 Carb with adjustable pilot screw) Inside Top Cowl 1999 Merc/Mar 935 cc 37-856984 23 37-856985 22 Flywheel/Rewind Cover Page 3C-8 90-828631R3 MARCH 1999 CYLINDER HEAD POWERHEAD Section 4A - Cylinder Head Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-3 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-4 Camshaft/Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . 4A-6 Intake/Exhaust Valves . . . . . . . . . . . . . . . . . . . . . 4A-8 Valve Clearance Adjustment . . . . . . . . . . . . . . . 4A-10 Cylinder Head Cover Removal . . . . . . . . . . 4A-10 Adjusting Valves . . . . . . . . . . . . . . . . . . . . . . 4A-11 Cylinder Head Cover Installation . . . . . . . . 4A-13 Timing Belt Inspection . . . . . . . . . . . . . . . . . . . . 4A-14 Timing Belt Removal . . . . . . . . . . . . . . . . . . . . . . 4A-14 Timing Belt Installation . . . . . . . . . . . . . . . . . . . . 4A-17 Cylinder Head Disassembly . . . . . . . . . . . . . . . 4A-21 Cylinder Head Cover Removal . . . . . . . . . . 4A-21 Cylinder Head Removal . . . . . . . . . . . . . . . . 4A-22 Rocker Arm Assembly Removal . . . . . . . . . 4A-23 Oil Pump Removal . . . . . . . . . . . . . . . . . . . . 4A-23 Camshaft Removal . . . . . . . . . . . . . . . . . . . . 4A-24 Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . 4A-25 Anode Removal . . . . . . . . . . . . . . . . . . . . . . . 4A-26 Oil Pump Disassembly . . . . . . . . . . . . . . . . . 4A-26 Specifications Cleaning and Inspection . . . . . . . . . . . . . . . . . . . 4A-27 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-27 Rocker Shaft and Rocker Arm. . . . . . . . . . . 4A-27 Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-28 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . 4A-29 Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . 4A-29 Valve Guide Replacement . . . . . . . . . . . . . . 4A-30 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-31 Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . 4A-32 Valve Seat Reconditioning . . . . . . . . . . . . . . 4A-33 Valve Refacing Steps . . . . . . . . . . . . . . . . . . 4A-34 Cylinder Head Reassembly. . . . . . . . . . . . . . . . 4A-35 Valve Installation . . . . . . . . . . . . . . . . . . . . . . 4A-35 Camshaft Oil Seal Installation . . . . . . . . . . . 4A-37 Camshaft Installation . . . . . . . . . . . . . . . . . . 4A-38 Oil Pump Assembly. . . . . . . . . . . . . . . . . . . . 4A-39 Oil Pump Installation. . . . . . . . . . . . . . . . . . . 4A-40 Rocker Arm Shaft Assembly . . . . . . . . . . . . 4A-41 Rocker Arm Shaft Installation . . . . . . . . . . . 4A-41 Cylinder Head Gasket. . . . . . . . . . . . . . . . . . 4A-42 Cylinder Head Installation . . . . . . . . . . . . . . 4A-42 Cylinder Head Cover Installation . . . . . . . . 4A-44 4 A CAMSHAFT Camshaft Dimensions Intake “A” Exhaust “A” Intake “B” Exhaust “B” Run-out Limit A B 1.216 - 1.220 in. (30.89 - 30.99 mm) 1.213 - 1.217 in. (30.82 - 30.92 mm) 1.022 - 1.025 in. (25.95 - 26.05 mm) 1.022 - 1.025 in. (25.95 - 26.05 mm) 0.0039 in. (0.1 mm) 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 lb (9.0 - 10.0 kg) 19.8 - 22.0 lb (9.0 - 10.0 kg) 0.043 in. (1.1 mm) Left Hand 90-828631R3 MARCH 1999 Page 4A-1 CYLINDER HEAD CYLINDER HEAD Warp Limit * Lines indicate straight edge measurement 0.004 in. (0.1 mm) Valve/Valve Seat/Valve Guides: Valve Clearance (cold) Intake 0.006 - 0.010 in. (0.15 - 0.25 mm) Exhaust Valve Dimensions: “A” Head Diameter 0.010 - 0.014 in. (0.25 - 0.35 mm) Intake 1.177 - 1.185 in. (29.9 - 30.1 mm) Exhaust “B” Face Width 1.020 - 1.028 in. (25.9 - 26.1 mm) Intake 0.079 - 0.124 in. (2.00 - 3.14 mm) Exhaust “C” Seat Width 0.079 - 0.124 in. (2.00 - 3.14 mm) Intake 0.035 - 0.043 in. (0.9 - 1.1 mm) Exhaust “D” Margin Thickness 0.035 - 0.043 in. (0.9 - 1.1 mm) VALVES Intake 0.020 - 0.035 in. (0.5 - 0.9 mm) Exhaust Stem Outside Diameter 0.020 - 0.035 in. (0.5 - 0.9 mm) Intake 0.2156 - 0.2161 in. (5.475 - 5.490 mm) Exhaust Guide Inside Diameter 0.2150 - 0.2156 in. (5.460 - 5.475 mm) Intake 0.2165 - 0.2170 in. (5.500 - 5.512 mm) Exhaust Stem To Guide Clearance 0.2165 - 0.2170 in. (5.500 - 5.512 mm) Intake 0.0004 - 0.0015 in. (0.010 - 0.037 mm) Exhaust 0.0010 - 0.0020 in. (0.025 - 0.052 mm) Stem Run-out Limit (max.) 0.0006 in. (0.016 mm) Page 4A-2 90-828631R3 MARCH 1999 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). 90-828631R3 MARCH 1999 Page 4A-3 CYLINDER HEAD Cylinder Head 1 4 5 19 20 6 7 21 8 9 10 11 22 12 23 13 14 24 25 27 15 1617 18 29 30 31 20 28 23 26 4-Stroke Outboard Oil (92-828000A12)110 110 9 95 95 Loctite PST Pipe Sealant (92-809822)9 95 2-4-C w/Teflon (92-825407A12) Page 4A-4 90-828631R3 MARCH 1999 CYLINDER HEAD Cylinder Head REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm – 1 CYLINDER HEAD ASSEMBLY 1 1 CYLINDER HEAD 2 4 SCREW 3 4 WASHER 4 8 GUIDE 5 8 CIRCLIP 6 4 BOLT Drive Tight 7 4 GASKET 8 4 ANODE 9 4 GROMMET 10 4 COVER 11 4 SCREW (M6 x 20) Drive Tight 12 1 BOLT 57 6.4 13 4 SCREW (M4 x 10) Drive Tight 14 1 COVER 15 1 O RING 16 1 COVER 17 1 BREATHER PIPE 18 7 SCREW (M6 x 20) 70 8 19 1 GASKET 20 2 DOWEL PIN 21 5 SCREW (M6 x 25) 106 12 22 10 SCREW (M9 x 1.5 x 95) 34.7 47 23 1 GASKET 24 1 DIAPHRAGM Drive Tight 25 1 BRACKET (NON HANDLE) 26 1 BRACKET (HANDLE) 27 2 SCREW (M6 x 13) 75 8.5 28 1 ELBOW 29 1 CLAMP 30 1 PLUG 31 1 O RING 90-828631R3 MARCH 1999 Page 4A-5 CYLINDER HEAD Camshaft/Oil Pump 1 2 3 4 5 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 8 6 7 4-Stroke Outboard Oil (92-828000A12)110 110 110 95 95 2-4-C With Teflon (92-825407A12) 23 Page 4A-6 90-828631R3 MARCH 1999 CYLINDER HEAD Camshaft/Oil Pump REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 PIN (Included with Cyl. Block) 2 1 SPRING 3 1 TENSIONER ASSEMBLY 4 1 SCREW (M8 x 20) 220 18.5 25 5 1 SCREW 70 8 6 1 SPACER 7 1 LOAD RING 8 2 WASHER 9 1 GEAR–Drive 10 1 KEY 11 1 BELT 12 1 SCREW (M8 x 40 x 1.25) 28 38 13 1 WASHER 14 1 GEAR–Driven 15 1 OIL SEAL 16 1 DOWEL PIN 17 1 CAMSHAFT 18 1 PIN 19 1 OIL PUMP ASSEMBLY 20 1 O RING 21 1 O RING 22 1 O RING 23 4 SCREW (M6 x 40) 68.0 7.5 90-828631R3 MARCH 1999 Page 4A-7 CYLINDER HEAD Intake/Exhaust Valves 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 3 4 5 6 7 7 7 8 9 10 14 12 4-Stroke Outboard Oil (92-828000A12)110 110 110 110 Page 4A-8 90-828631R3 MARCH 1999 CYLINDER HEAD Intake/Exhaust Valves REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 4 EXHAUST VALVE 2 4 INTAKE VALVE 3 8 SEAT–Valve Spring 4 8 SEAL–Valve Stem 5 8 VALVE SPRING–Outer 6 8 RETAINER–Valve Spring 7 16 KEY 8 8 ROCKER ARM 9 8 SCREW 10 8 NUT 120 10 13.5 11 1 ROCKER SHAFT 12 2 PLATE 13 1 PLATE 14 2 SPRING 15 5 SCREW (M8 x 30)160 160 13.3 18 16 2 PLUG 90-828631R3 MARCH 1999 Page 4A-9 CYLINDER HEAD Page 4A-10 90-828631R3 MARCH 1999 Valve Clearance Adjustment 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. Cylinder Head Cover Removal 1. Disconnect the breather hose and vent hose. 2. Remove fuel pump assembly. 53726 b a c a - Fuel Pump Assembly b - Vent Hose c - Breather Hose 3. Remove cylinder head cover. 53734 b c a a - Cylinder Head Cover b - Bolts (7) c - Harness Retainer CYLINDER HEAD 90-828631R3 MARCH 1999 Page 4A-11 Adjusting Valves NO. 1 AND NO. 2 INTAKE VALVES NO. 1 AND NO. 3 EXHAUST VALVES 1. Disconnect spark plug leads. 2. Turn the driven gear and align the “1” mark on the gear with the cylinder head mark “”. 3. Adjust the valve clearance for No. 1 and No. 2 intake valves and No. 1 and No. 3 exhaust valves. #1 (b) #3 (b) 3 1 2 4 #1 (a) #2 (a) (b) (a) Valve Clearance Specifications (Cold) Intake Valve (a) 0.006 - 0.010 in. (0.15 - 0.25 mm) Exhaust Valve (b) 0.010 - 0.014 in. (0.25 - 0.35 mm) Valve Adjusting Nut Torque 120 lb-in. (13.5 Nm) CYLINDER HEAD Page 4A-12 90-828631R3 MARCH 1999 Adjusting Valves NO. 3 AND NO. 4 INTAKE VALVES NO. 2 AND NO. 4 EXHAUST VALVES 1. Turn the driven gear and align the “4” mark on the gear with the cylinder head mark “”. 2. Adjust the valve clearance for No. 3 and No. 4 intake valves and No. 2 and No. 4 exhaust valves. #2 (b) #4 (b) 3 1 2 4 #3 (a) #4 (a) (b) (a) Valve Clearance Specifications (Cold) Intake Valve (a) 0.006 - 0.010 in. (0.15 - 0.25 mm) Exhaust Valve (b) 0.010 - 0.014 in. (0.25 - 0.35 mm) Valve Adjusting Nut Torque 120 lb-in. (13.5 Nm) CYLINDER HEAD 90-828631R3 MARCH 1999 Page 4A-13 Cylinder Head Cover Installation 1. Reinstall the cylinder head cover. Tighten bolts to the specified torque. 53734 a b a - Retainer b - Mounting Bolts (7) Cylinder Head Cover Bolt Torque 70 lb-in. (8 Nm) 2. Reinstall the fuel pump. Tighten bolts to the specified torque. 3. Reconnect the breather hose and vent hose. Use sta-straps to fasten all hose connections. 53726 b a b c a - Fuel Pump b - Vent Hose c - Breather Hose Fuel Pump Mounting Bolt Torque 75 lb-in. (8.5 Nm) CYLINDER HEAD Timing Belt Inspection Replace timing belt if any of the following conditions are found: • Cracks in the back of the belt or in the base of the belt teeth. • Excessive wear at the roots of the cogs. • Rubber portion swollen by oil. • Belt surfaces roughened. • Signs of wear on edges or outer surfaces of belt. Timing Belt Removal WARNING Engine could possibly start when turning flywheel during removal and installation. To prevent this type of accidental engine starting and possible serious injury, always remove spark plug leads from spark plugs. 1. Disconnect spark plug leads from spark plugs. 2. Hold flywheel using flywheel holder (91-83163M). Remove nut and washer. a a-Flywheel Holder (91-83163M) 30026 Page 4A-14 90-828631R3 MARCH 1999 CYLINDER HEAD 3. Remove flywheel using puller (91-83164M). a 30025 a-Flywheel Puller (91-83164M) 4. Remove the stator. a b 53745 a-Stator b-Stator Mounting Bolts 90-828631R3 MARCH 1999 Page 4A-15 CYLINDER HEAD Page 4A-16 90-828631R3 MARCH 1999 5. Remove the trigger base. 30027 a a - Trigger Base 6. Turn the driven gear and align the “1” mark with the cylinder head mark “”. 30033 3 1 2 4 7. Loosen belt tensioner fastening bolt to release the tension. 8. Remove the timing belt. 30033 1 4 2 3 a b a - Belt Tensioner Fastening Bolt b - Timing Belt CYLINDER HEAD Timing Belt Installation Timing Belt Installation Notes: • Protect the timing belt from water and oil. • Use care not to scratch the belt. • Do not use any metal device to help stretch the belt onto the driven gear. 1. Align drive gear mark with cylinder mark. 30033 a b a-Drive Gear Mark b-Cylinder Mark 2. Align the “1” mark on the driven gear with the cylinder head mark “”. 30033 3 1 2 4 90-828631R3 MARCH 1999 Page 4A-17 CYLINDER HEAD 3. Install timing belt as follows: • Align both gears with their alignment marks (Steps 1 and 2). IMPORTANT: Make sure the Part Number on the belt is upright, not inverted. • Install the timing belt around the gears as shown. NOTE:The spring loaded belt tensioner will automatically apply the correct tension against the belt. • Allow the spring loaded belt tensioner to pivot against the belt. Fasten the belt tensioner at this position. 1 4 23 a b c a-Belt Tensioner b-Belt Tensioner Fastening Bolt c-Belt Tensioner Pivot Bolt 30033 Belt Tensioner Bolt Torque Fastening Bolt (b) 221 lb–in. (25 Nm) Pivot Bolt (c) 70 lb-in. (8.0 Nm) 4. Reinstall trigger base with four bolts. a b a-Trigger Base b-Mounting Bolts (4) 30033 Trigger Base Bolt Torque 75 lb-in. (8.5 Nm) Page 4A-18 90-828631R3 MARCH 1999 CYLINDER HEAD 5. Reinstall stator with three bolts. a b a-Stator b-Mounting Bolts (3) Apply Loctite 222 to Threads Stator Bolt Torque 75 lb-in. (8.5 Nm) 53745 6. Place flywheel key into slot. 7. Install flywheel. 8. Hold flywheel using flywheel holder (91-83163M). Apply oil to threads on crankshaft. Tighten nut to the specified torque. FLYWHEEL WITHOUT LOAD RING & SPACER a b c d a-Flywheel Key b-Washer c-Nut d-Apply Oil to Threads 53278 Flywheel Nut Torque 116 lb-ft (157 Nm) 90-828631R3 MARCH 1999 Page 4A-19 CYLINDER HEAD FLYWHEEL WITH LOAD RING & SPACER a b c d e f a-Flywheel Key 53278 b-Washer c-Nut d-Apply Oil to Threads e-Spacer f-Load Ring NOTE:Load Ring is for one time use and must be replaced if flywheel is removed. Flywheel Nut Torque 116 lb-ft (157 Nm) Page 4A-20 90-828631R3 MARCH 1999 CYLINDER HEAD 90-828631R3 MARCH 1999 Page 4A-21 Cylinder Head Disassembly Cylinder Head Cover Removal 1. Disconnect the breather hose and vent hose from the cylinder head cover. IMPORTANT: The hose fittings on the fuel pump can break if you try twisting or pulling off the hoses. Remove hoses by slowly prying off the hoses using a small screwdriver. 2. Disconnect the top fuel hose from the fuel pump. 3. Remove fuel pump. 53726 a b c e d a - Fuel Pump b - Pry Fuel Hoses Off Fuel Pump. DO NOT Twist or Pull Hoses c - Top Fuel Hose d - Breather Hose e - Vent Hose 4. Remove cylinder head cover. 53734 a b c a - Cover b - Bolts (7) c - Harness Retainer CYLINDER HEAD Page 4A-22 90-828631R3 MARCH 1999 Cylinder Head Removal 1. Remove timing belt from driven gear. 2. Remove spark plugs leads from spark plugs. 3. Remove the throttle and shift levers from side of cylinder head. 4. Remove the cylinder head mounting bolts. 5. Separate the cylinder head from the block. 53727 a b c a - Center Bolts (10) b - Flange Bolts (5) c - Carburetor Bolts (8) CYLINDER HEAD 90-828631R3 MARCH 1999 Page 4A-23 Rocker Arm Assembly Removal 1. Remove five bolts and the rocker arm shaft. 53740 a b a - Rocker Arm Shaft b - Bolts (5) Oil Pump Removal 1. Remove four bolts and pull out the oil pump assembly. 53732 b a a - Oil Pump Assembly b - Bolts (4) CYLINDER HEAD Camshaft Removal 1. Hold driven gear using tool (91-83163M) and remove bolt and flat washer. Remove driven gear. 2. Remove camshaft retaining bolt. Slide camshaft out of cylinder head. NOTE:The cam can also be removed from the top without removing the cylinder head from engine. 53729 a b c a-Driven Gear b-Camshaft c-Camshaft Retaining Bolt Page 4A-24 90-828631R3 MARCH 1999 CYLINDER HEAD Valve Removal VALVE COMPONENTS a b c d e f a-Valve b-Spring Seat c-Valve Seal d-Valve Spring e-Spring Retainer f-Valve Keepers REMOVING VALVES 1. Anytime a valve is removed, replace the valve seal. 2. Remove valves as shown. 53735 a b a-Use Spring Compressor Tool (91-809494A1) to Compress the Springs for Removal b-Compress the Spring and Remove the Valve Keepers 90-828631R3 MARCH 1999 Page 4A-25 CYLINDER HEAD Anode Removal 1. Check condition of the anodes. Replace, if anodes show sign of deterioration. NOTE:If anodes are not deteriorated, wire brush corrosion off before installation. bacd 2-4-C w/Teflon (92-850736A1) 95 95 a-Anode Cover b-Bolt c-Rubber Seal d-Anode Oil Pump Disassembly 1. Heat screws to loosen Loctite sealant. Remove screws. 53731 a a-Screw (2) Heat Screws to Loosen Loctite Sealant. 2. Disassemble Oil Pump. c e d b a a-Cover Seal b-Outer Rotor c-Inner Rotor d-Shaft e-Cross Pin 53741 Page 4A-26 90-828631R3 MARCH 1999 CYLINDER HEAD 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: • between outer rotor and pump housing (a) • between the inner rotor and outer rotor (b) • between the outer rotor and pump housing (c) 55803 a b c Oil Pump Clearances a 0.001 - 0.006 in. (0.03 - 0.15 mm) b 0.005 in. (0.12 mm) c 0.001 - 0.003 in. (0.03 -0.08 mm) 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) 90-828631R3 MARCH 1999 Page 4A-27 CYLINDER HEAD Camshaft 1. Inspect the camshaft for pitting, heat discoloration, scratches and for the following measurements. Replace camshaft if worn or not within specification. 2. Measure the cam lobe length (a) and width (b). 55805 a b Cam Lobe Specifications a Intake 1.216 - 1.220 in. (30.89 - 30.99 mm) Exhaust 1.213 - 1.217 in. (30.82 - 30.92 mm) b Intake 1.022 - 1.025 in. (25.95 -26.05 mm) Exhaust 1.022 - 1.025 in. (25.95 -26.05 mm) 3. Measure the camshaft bore diameters (a) and camshaft bearing diameters (b and c). ccc b a a a a Camshaft Bore Inside Diameter “a” 1.4567 - 1.4577 in. (37.000 - 37.025 mm) Camshaft Bearing Diameter “b” 1.4541 - 1.4549 in. (36.935 - 36.955 mm) Camshaft Bearing Diameter “c” 1.4537 - 1.4545 in. (36.925 - 36.945 mm) Page 4A-28 90-828631R3 MARCH 1999 CYLINDER HEAD 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. Inspect cylinder head for warpage. Replace cylinder head If out of specification. Cylinder Head Warpage Limit 0.004 in. (0.1 mm) Valve Guides NOTE:Inspect the valve guides for wear or damage. If valve guide wear is out of specification, replace the valve guide. Measure valve guide bore. a 53736 Valve Guide Inside Diameter Intake Valve 0.2165 - 0.2170 in. (5.500 - 5.512 mm)Exhaust Valve 90-828631R3 MARCH 1999 Page 4A-29 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. 55806 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. 55807 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. 55808 a a-Valve Guide Reamer (91-809497A1) Page 4A-30 90-828631R3 MARCH 1999 CYLINDER HEAD Valves 1. Clean the carbon deposits from the valve. Discard any cracked, warped, or burned valves. 2. Measure the valve stem to check for wear. Replace valves if not in specification. 55810 a Valve Stem Diameter “a” 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. IMPORTANT: Do not lap the valves. 4. Check the margin thickness of the valves after the valves have been ground. Any valve with a margin thickness of less than the specification, should be replaced. 55809 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) 90-828631R3 MARCH 1999 Page 4A-31 CYLINDER HEAD Valve Springs Check free length limit of each spring. Replace valve springs if not in specification. 55846 Valve Spring Free Length 1.569 - 1.491 in. (39.85 – 37.85 mm) 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. 55797 a Valve Spring Tilt Specification “a” Less than 0.06 in. (1.7 mm) Page 4A-32 90-828631R3 MARCH 1999 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. 55799 a Valve Seat Width Specification “a” Intake Valve 0.035 - 0.043 in. (0.9 - 1.1 mm) Exhaust Valve If resurfacing the valve seats is required, resurface the valve seats to the specified angles shown in chart. 55798 a b c Valve Seat Angle Specifications a 15° b 45° c 60° 90-828631R3 MARCH 1999 Page 4A-33 CYLINDER HEAD Valve Refacing Steps Condition: The valve seat is centered on valve face but it is too wide. 55799 Valve Seat Cutter Set Desired Results Use Li htlLightly 15° Cutter To reduce valve seat width 60° Cutter Condition: The valve seat is in the middle of the valve face but it is too narrow. 55800 Valve Seat Cutter Set Desired Results Use 45° Cutter To achieve a uniform valve t idthseat width Condition: Valve seat is too narrow and it is near valve margin. 55801 Valve Seat Cutter Set Desired Results Use 15° Cutter, First To center the seat and to hi it idthachieve its width45° Cutter Page 4A-34 90-828631R3 MARCH 1999 CYLINDER HEAD Condition: Valve seat is too narrow and is located near the bottom edge of the valve face. 55802 Valve Seat Cutter Set Desired Results Use 60° Cutter, First To center the seat and to in- its Width crease its Width45° Cutter Cylinder Head Reassembly Valve Installation INTAKE AND EXHAUST VALVE COMPONENTS a b c d e f a-Valve b-Spring Seat c-Valve Seal d-Valve Spring e-Spring Retainer f-Valve Keepers 90-828631R3 MARCH 1999 Page 4A-35 CYLINDER HEAD INSTALLING VALVES 1. Always use new valve seals. 2. Apply engine oil to the valves and valve seats. 3. Install valves as shown. 53735 a b c 91-809494A1 a-End of the Valve Spring with the Pre-Compressed Coils gets Installed Towards the Cylinder Head b-Use Spring Compressor Tool to Compress the Springs for Installation c-Compress the Spring and Retainer and Install the Valve Keepers Around the Valve Stem. You May have to Tap Lightly on End of Valve to Seat the Keepers Page 4A-36 90-828631R3 MARCH 1999 CYLINDER HEAD Camshaft Oil Seal Installation 1. If removed, install Oil Seal. Position seal so part number side is facing outward. Press seal in until it makes contact with the inside flat surface. NOTE:Seal must be properly seated before it is secured in place with a bead of Loctite 499 Super Bonder. 2. Apply a continuous bead of Loctite 499 Super Bonder (Quicksilver p/n 92-852882) into the chamfer around O.D. of the oil seal and I.D. of the seal bore. 3. Allow Loctite to cure overnight before placing unit into service. a b a-Upper Camshaft Oil Seal b-Chamfer Around O.D. of Oil Seal 90-828631R3 MARCH 1999 Page 4A-37 CYLINDER HEAD Camshaft Installation 1. Apply engine oil to the main journals (5 places) on the camshaft. 2. Slide camshaft into cylinder head (threaded end towards driven gear). 3. Install camshaft retaining bolt. Tighten bolt to the specified torque. 4. Place driven gear on camshaft so alignment pin is in hole. Hold gear with tool (91-83163M) and fasten with washer and bolt. Tighten bolt to the specified torque. 5. Remove any oil from the camshaft lobes and apply Moly Grease to the lift portion of the lobes. Obtain Moly Grease from a local source. NOTE:Rotate camshaft after assembly to ensure it rotates smoothly. 53739 a b d f e c a-Camshaft b-Camshaft Retaining Bolt c-Alignment Pin d-Driven Gear e-Washer f-Bolt Driven Gear Bolt Torque (f) 28 lb-ft (38 Nm) Camshaft Retaining Bolt Torque (b) 57 lb-in. (6.4 Nm) Page 4A-38 90-828631R3 MARCH 1999 CYLINDER HEAD Oil Pump Assembly 1. Reassemble the oil pump assembly. 2. Lubricate the outer and inner rotors thoroughly with engine oil. 53741 ac d e b 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 53731 a-Screws (2) Apply Loctite 222 to Threads Oil Pump Cover Screw Torque 68 lb-in. (7.6 Nm) 90-828631R3 MARCH 1999 Page 4A-39 CYLINDER HEAD Oil Pump Installation 1. Place O-ring seals on the oil pump. Lubricate the O-rings with oil. 2. Prime the oil pump by pouring approximately 1 fl oz (30 ml) of engine oil into the oil pump body. 53730 b a a a a-O-Ring Seals b-Pour Approximately 1 fl oz (30 ml) of Engine Oil into the Oil Pump Body 3. Align oil pump shaft with the camshaft and install the oil pump. 4. Fasten with 4 bolts. Tighten bolts to the specified torque. b a c a-Oil Pump Assembly b-Align Slot with Camshaft Projection c-Bolt (4) 53738 Oil Pump Mounting Bolt Torque 68 lb-in. (7.6 Nm) Page 4A-40 90-828631R3 MARCH 1999 CYLINDER HEAD 90-828631R3 MARCH 1999 Page 4A-41 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 a - Rocker Shaft b - Rocker Arms Rocker Arm Shaft Installation 1. Install the rocker arm shaft assembly as shown. Tighten bolts to the specified torque. NOTE: Leave all adjustment screws loose at this time. 53740 c b a b c d a - Rocker Arm Retainer (1) b - Rocker Arm Retainer (2) Arrow Must Point Towards Driven Gear c - Rocker Arm Retainer (2) d - Mounting Bolts (5) Rocker Arm Shaft Mounting Bolt Torque 160 lb-in. (18 Nm) CYLINDER HEAD Page 4A-42 90-828631R3 MARCH 1999 Cylinder Head Gasket 1. Install cylinder head gasket and dowel pins. a b c a a - Dowel Pin (2) b - Gasket c - Flange Seals (4) Cylinder Head Installation 1. Apply engine oil to the threads of each bolt and seat surface. 2. Fasten cylinder head with bolts shown. 53727 a b c a - Center Bolts (10) b - Cylinder Head Flange Bolts (5) c - Carburetor Flange Bolts (8) CYLINDER HEAD 90-828631R3 MARCH 1999 Page 4A-43 3. Torque center bolts in sequence and in two steps, than torque the Cylinder Head and carburetor flange bolts. 53740 8 5 3 4 1 2 5 9 10 6 7 1 1 6 4 4 8 7 3 3 2 2 5 Cylinder Head Bolt Torque Center Bolts Qty. 10 (Larger Dia. M9) 1st: 17 lb-ft (23 Nm) 2nd: 34.7 lb-ft (47 Nm) Cyl. Head Flange Bolts Qty. 5 (Smaller Dia. M6) 1st: 53 lb-in. (6 Nm) 2nd: 106 lb-in. (12 Nm) Carburetor Flange Bolts Qty. 8 (Smaller Dia. M6) 75 lb-in. (8.5 Nm) 4. Install timing belt. Refer to Section 4 Part B. 5. Adjust valves. Refer to Section 4 Part A. 30033 1 4 2 3 a a - Timing Belt CYLINDER HEAD Cylinder Head Cover Installation 1. Install cover seal into groove. 2. If removed, reinstall diaphragm. a c b d e a-Baffle Plate b-Screw (4) c-Cover Seal d-Diaphragm e-Bolt (2) 3. Install cylinder head cover. Tighten bolts to the specified torque. 53734 a b a-Retainer b-Mounting Bolts (7) Cylinder Head Cover Bolt Torque 70 lb-in. (8 Nm) Page 4A-44 90-828631R3 MARCH 1999 CYLINDER HEAD 90-828631R3 MARCH 1999 Page 4A-45 4. Reinstall the fuel pump. Tighten bolts to the specified torque. 5. Reconnect hoses. Use sta-straps to fasten all hose connections. 6. Reconnect the throttle and shift levers. 53726 e c d b a a - Breather Hose b - Top Fuel Hose c - Vent Hose d - Throttle and Shift Levers e - Sta-Straps Fuel Pump Mounting Bolt Torque 75 lb-in. (8.5 Nm) CYLINDER BLOCK/CRANKCASE POWERHEAD Section 4B - Cylinder Block/Crankcase Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-2 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-4 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-6 Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . 4B-8 Powerhead Removal . . . . . . . . . . . . . . . . . . . . . . 4B-9 Removing Powerhead Components . . . . . . . . 4B-11 Cylinder Block Disassembly . . . . . . . . . . . . . . . 4B-15 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-18 Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . . 4B-18 Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-19 Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-20 Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-21 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-22 Checking Main Bearing Clearance . . . . . . . 4B-22 Checking Connecting Rod Bearing Clearance. . . . . . . . . . . . . . . . . . . . . 4B-24 Specifications Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-26 Oil Pressure Switch. . . . . . . . . . . . . . . . . . . . 4B-26 Cylinder Block Reassembly. . . . . . . . . . . . . . . . 4B-27 Selecting New Main Bearings . . . . . . . . . . . 4B-27 Main Bearing Installation . . . . . . . . . . . . . . . 4B-28 Selecting New Connecting Rod Bearings . 4B-29 Installing Connecting Rod Bearings . . . . . . 4B-29 Connecting Rod Installation . . . . . . . . . . . . . 4B-30 Piston Ring Installation . . . . . . . . . . . . . . . . . 4B-30 Piston Installation . . . . . . . . . . . . . . . . . . . . . 4B-31 Crankshaft Installation . . . . . . . . . . . . . . . . . 4B-32 Crankcase Cover Installation . . . . . . . . . . . . 4B-34 Exhaust Cover Installation . . . . . . . . . . . . . . 4B-35 Drive Gear Installation . . . . . . . . . . . . . . . . . 4B-36 Installing Powerhead Components . . . . . . . 4B-37 Powerhead Installation . . . . . . . . . . . . . . . . . . . . 4B-43 4 B CYLINDER BLOCK Type Displacement Number of Cylinders 4 Stroke Cycle – Over Head Camshaft 57 cu. in. (935cc) 4 STROKE Length 2.953 in. (75 mm) CYLINDER BORE Diameter Standard Oversize-0.020 in. (0.050 mm) Taper/Out of Round Maximum Bore Type 2.4803 in. (63.0mm) 2.5003 in. (63.5 mm) 0.003 in. (0.08 mm) Steel PISTON Piston Type O.D. at Skirt Standard Oversize-0.020 in. (0.50mm) Aluminum 2.4783-2.4789 in. (62.950-62.965 mm) 2.4983-2.4989 in. (63.450-63.465 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) 0.002 - 0.003 in. (0.04 - 0.08 mm) 0.001 - 0.003 in. (0.03 - 0.08 mm) COMPRESSION RATIO Compression Ratio Cylinder Compression (cold engine @ W.O.T.) 9.8:1 170 -190 lb./in2 (Peak) PISTON PIN Piston Pin Diameter 0.6285 - 0.6287 in. (15.965 - 15.970 mm) 90-828631R3 MARCH 1999 Page 4B-1 CYLINDER BLOCK/CRANKCASE CONNECTING ROD Oil Clearance (Big End) Small End Inside Diameter 0.0008 - 0.0020 in. (0.020 - 0.052 mm) 0.6293 - 0.6298 in. (15.985 - 15.998 mm) CRANKSHAFT Main Bearing Clearance Crankshaft Run-out 0.0005 - 0.0017 in. (0.012 - 0.044 mm) 0.0012 in. (0.03 mm) Special Tools 1. Oil Filter Wrench (P/N 91-802653) 2. Flywheel Holder (P/N 91-83163M) 3. Flywheel Puller (P/N 91-83164M) 4. Piston Ring Compressor (P/N FT2997) 5. Piston Ring Expander (P/N 91-24697) Page 4B-2 90-828631R3 MARCH 1999 CYLINDER BLOCK/CRANKCASE 6. Powerhead Stand (Bigfoot)P/N 91-812549 7. Powerhead Stand (Non-Bigfoot)P/N 91-827001A1 8. 1-5/8 in. socket P/N 91-809646A1 90-828631R3 MARCH 1999 Page 4B-3 CYLINDER BLOCK/CRANKCASE Crankshaft 1 2 9 45 6 7 10 11 8 11 3 12 110 110 110 110 110 110 110 110 110 4-Stroke Outboard Oil (92-828000A12) Page 4B-4 90-828631R3 MARCH 1999 CYLINDER BLOCK/CRANKCASE Crankshaft REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 11 1 CRANKSHAFT (NON-BIGFOOT) 1 CRANKSHAFT (BIGFOOT) 2 1 OIL SEAL 3 1 OIL SEAL 4 4 CONNECTING ROD 5 8 BOLT 150 12.5 17 6 8 BEARING (BROWN) 8 BEARING (BLACK) 8 BEARING (BLUE) 77 4 PISTON (STANDARD) 4 PISTON (.5MM O/S) 88 4 PISTON RING (TOP) (STANDARD) 4 PISTON RING (TOP) (.5 MM O/S) 9 4 PISTON RING (SECOND) 10 4 PISTON OIL RING 11 4 PISTON PIN 12 8 RETAINER 90-828631R3 MARCH 1999 Page 4B-5 CYLINDER BLOCK/CRANKCASE Cylinder Block 1 2 3 7 8 9 10 11 12 13 15 16 17 18 19 20 21 2 3 18 6 110 12 9 9 14 4 5 22 Loctite PST Pipe Sealant (92-809822) 12 Loctite “514” Master Gasket (92-12564-2) 110 4-Stroke Outboard Oil (92-828000A12) Page 4B-6 90-828631R3 MARCH 1999 CYLINDER BLOCK/CRANKCASE Cylinder Block REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 CYLINDER BLOCK 2 2 DOWEL PIN 3 3 PLUG 4 1 PIPE PLUG (1/4-14) 5 1 PIPE PLUG (3/4-14) 6 10 BEARING (BROWN) 10 BEARING (BLACK) 10 BEARING (BLUE) 7 10 SCREW (M8 x 1.25 x 82) 264 22 30 8 10 SCREW (M6 x 35) 106 12 9 1 GASKET 10 1 OIL FILTER 155 12.9 17.5 11 1 NIPPLE 29.5 40 12 1 GASKET 13 1 EXHAUST COVER 14 1 PIPE PLUG 15 1 THERMOSTAT 16 1 GASKET 17 1 COVER 18 12 SCREW (M6 x 35) 106 12 19 1 TUBING (11 IN.) 20 1 STA STRAP 21 1 ELBOW 22 1 PLUG-Serial Number 90-828631R3 MARCH 1999 Page 4B-7 CYLINDER BLOCK/CRANKCASE Torque Sequence 1 2 34 5 6 78 9 10 1112 13 14 1516 1 5 8 6 2 3 7 9 10 4 Exhaust Cover Crankcase Cover Page 4B-8 90-828631R3 MARCH 1999 CYLINDER BLOCK/CRANKCASE 90-828631R3 MARCH 1999 Page 4B-9 Powerhead Removal WARNING Engine could possibly start when turning flywheel during removal and installation. To prevent this type of accidental engine starting and possible serious injury, always remove spark plug leads from spark plugs. 1. Remove the bottom cowls. 2. Open the latch and disengage the vertical shift shaft. 3. Disconnect the power trim harness wires. 53859 c a b a - Open Latch and Disengage Vertical Shift Shaft b - Power Trim Harness Wires c - Cut Sta-Strap 4. Disconnect the vent hose. 53726 a a - Vent Hose CYLINDER BLOCK/CRANKCASE Page 4B-10 90-828631R3 MARCH 1999 5. Remove powerhead mounting bolts. 53868 a a - Powerhead Mounting Bolts (4 Each Side) 6. Lift powerhead from drive shaft housing. a a - Hoist CYLINDER BLOCK/CRANKCASE 90-828631R3 MARCH 1999 Page 4B-11 Removing Powerhead Components 1. Place powerhead on Powerhead Stand. a 91-827001A1 91-812549 a - Powerhead Stand (91-827001A1-Non-Bigfoot) (91-812549-Bigfoot) 2. Remove flywheel, stator, trigger base, and timing belt. Refer to Section 4 Part A. 30033 1 4 2 3 CYLINDER BLOCK/CRANKCASE Page 4B-12 90-828631R3 MARCH 1999 3. Remove 8 flange bolts and 2 side mounting bolts and lift carburetor assembly from powerhead. Disconnect hoses and wiring as necessary. IMPORTANT: The hose fittings on the fuel pump can break if you try twisting or pulling off the hoses. Remove hoses by slowly prying off the hoses using a small screwdriver. out out in e d b c a a - Carburetor Assembly b - Pry Fuel Hoses Off Fuel Pump. DO NOT Twist or Pull Hoses c - Flange Bolts (8) d - Side Mounting Bolts (2) e - Collar (2) CYLINDER BLOCK/CRANKCASE 90-828631R3 MARCH 1999 Page 4B-13 4. Remove the control cable anchor bracket. 5. Remove shift and throttle lever. 53869 b a a - Control Cable Anchor Bracket b - Shift and Throttle Lever 6. Remove cylinder head. Refer to Section 4 Part A. 53740 CYLINDER BLOCK/CRANKCASE Page 4B-14 90-828631R3 MARCH 1999 7. Remove four bolt securing starter bracket. 8. Cut sta-straps and lift starter bracket, electrical components and wiring harness from engine. Disconnect wiring as necessary. 53866 b a b b b a - Starter Bracket b - Mounting Bolts (4) CYLINDER BLOCK/CRANKCASE Cylinder Block Disassembly 1. Hold crankshaft from turning using Powerhead Stand (91-827001A1). Remove nut using 1-5/8 in. Socket Tool (91-809646A1). 2. Remove the drive gear components. CRANKSHAFT WITH NUT a b c d e b 53742 a-Drive Gear Nut b-Washer (2) c-Drive Gear d-Key e-1-5/8 in. Socket Tool (91-809646A1) Use for Removing Drive Gear Nut CRANKSHAFT WITHOUT NUT a c d e f b a-Washer, Lower b-Woodruff Key c-Drive Gear d-Washer, Upper e-Load Ring f-Spacer 90-828631R3 MARCH 1999 Page 4B-15 CYLINDER BLOCK/CRANKCASE 3. Remove exhaust cover and gasket. 4. Remove oil filter. a b c d e f a-Exhaust Cover b-Gasket c-Thermostat d-Gasket e-Thermostat Cover f-Oil Filter 5. Remove crankcase cover bolts. a 53743 a-Crankcase Cover Bolts (20) Page 4B-16 90-828631R3 MARCH 1999 CYLINDER BLOCK/CRANKCASE 6. Insert a screwdriver at the pry points between the crankcase cover and block to separate. a 53744 7. Use a 5/16 in. 12 point socket and remove connecting rod bolts. 8. Remove carbon ridge from the cylinder bore using a burr knife. Push out the pistons. Keep each piston, connecting rod, and cap together as an assembly. NOTE:Each connecting rod and cap are a matched set. They must not be interchanged. ab d c 53824 a-Remove Circlips with a Needle Nose Pliers b-Connecting Rod and Cap are a Matched Set, Don’t Interchange c-Scribe the Cylinder Number (1 thru 4) on Inside of Each Piston and Connecting Rod so they can be Reinstalled in their Original Location d-Connecting Rod Bearings – Do Not Interchange. Reinstall in Original Locations 90-828631R3 MARCH 1999 Page 4B-17 CYLINDER BLOCK/CRANKCASE 9. Remove crankshaft from block. a a-Main Bearings – Do Not Interchange. Reinstall in Original Locations Inspection Cylinder Bore MEASURING CYLINDER BORE 1. Measure the cylinder bore diameter “d” 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. 55837 Diameter (Standard) Cylinder Bore Specifications 2.4803 - 2.4809 in. (63.000 - 63.015 mm) Taper or Out-of-Round Maximum Limit 0.003 in. (0.08 mm) Diameter 0.020 in. (0.50 mm) Oversize 2.5003 - 2.5009 in. (63.500 - 63.515 mm) Taper or Out-of-Round Maximum Limit 0.003 in. (0.08 mm) Page 4B-18 90-828631R3 MARCH 1999 CYLINDER BLOCK/CRANKCASE Piston MEASURING PISTON 1. Measure the piston at a point 0.2 in. (5.0 mm) from the bottom. 55838 b a a-Piston Diameter b-0.2 in. (5.0 mm) Piston Diameter “a” Diameter (Standard) 2.4783 - 2.4789 in. (62.950 - 62.965 mm) (Oversize) 0.020 in. (0.50 mm) 2.4983 - 2.4989 in. (63.450 - 63.465 mm) Piston to Cylinder Clearance 0.0014 - 0.0026 in. (0.035 - 0.065 mm) Minimum bore measurement – maximum piston measurement = piston to cylinder clearance 90-828631R3 MARCH 1999 Page 4B-19 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 Page 4B-20 90-828631R3 MARCH 1999 CYLINDER BLOCK/CRANKCASE Piston Rings PISTON RING SIDE CLEARANCE 1. Measure piston ring side clearance. Replace piston and/or piston rings if out of specification. 55842 Piston Ring Side Clearance Top 0.002 - 0.003 in. (0.04 - 0.08 mm) 2nd 0.001 - 0.003 in. (0.03 - 0.08 mm) PISTON RING END GAP CLEARANCE 1. Measure piston ring end gap clearance. Replace piston ring if out of specification. 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) 90-828631R3 MARCH 1999 Page 4B-21 CYLINDER BLOCK/CRANKCASE Crankshaft 1. Thoroughly clean crankshaft and inspect bearing surfaces. Replace crankshaft if bearing surfaces are pitted, scored, or discolored. 2. Measure Run-out. Replace crankshaft if out of specification. Crankshaft Run-out 0.0012 in. (0.03 mm) 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 inCylinder Block Reassemblyfor selecting and installing main bearings. 3. Install main bearings. 4. Place crankshaft into cylinder block. 53811 Page 4B-22 90-828631R3 MARCH 1999 CYLINDER BLOCK/CRANKCASE 5. Place a piece of plastigauge onto each crankshaft bearing surface. 53812 a a-Plastigauge 6. Install crankcase cover. Apply oil to the cover bolts and torque cover bolts in sequence and in two steps. 19 15 11 18 14 2 1 2 34 5 6 78 9 10 20 16 17 13 12 53743 Crankcase Cover Bolt Torque Center Bolts Qty. 10 (Larger Diameter M8) 1st: 11 lb-ft (15 Nm) 2nd: 22 lb–ft (30 Nm) Outer Bolts Qty. 10 (Smaller Diameter M6) 1st: 53 lb–in. (6 Nm) 2nd: 106 lb-in. (12 Nm) 90-828631R3 MARCH 1999 Page 4B-23 CYLINDER BLOCK/CRANKCASE 7. Remove the crankcase cover. Measure the compressed plastigauge to check the main bearing clearance. Replace bearings if clearance is not in specification. 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. 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. Page 4B-24 90-828631R3 MARCH 1999 CYLINDER BLOCK/CRANKCASE 3. Install the connecting rod to the respective journal. Tighten connecting rod bolts in sequence and in two steps to the specified torque. 53814 a a-Connecting Rod Bolts Connecting Rod Bolt Torque 1st: 53 lb-in. (6 Nm) 2nd: 150 lb-in. (17 Nm) 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) 90-828631R3 MARCH 1999 Page 4B-25 CYLINDER BLOCK/CRANKCASE Thermostat 1. Measure the lift of the thermostat at the operating water temperature listed. 55843 Water Temperature Valve Lift 136° -143° F (58° - 62° C) 0 in. (0 mm) Above 158° F (70° C) Minimum 0.12 in. (3 mm) Oil Pressure Switch 1. Check continuity of switch. 55845 Oil Switch Continuity Check Below 2.9 psi (20.0 kPa) Continuity Above 2.9 psi (20.0 kPa) No Continuity Page 4B-26 90-828631R3 MARCH 1999 CYLINDER BLOCK/CRANKCASE 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 A B C a b a-Main Bearing Code Letters b-Main Bearing Identification Color Location #1 #2 #3 #4 #5 #1 #2 #3 #4 #5 53819 90-828631R3 MARCH 1999 Page 4B-27 CYLINDER BLOCK/CRANKCASE Page 4B-28 90-828631R3 MARCH 1999 Main Bearing Installation IMPORTANT: Do not interchange used main bearings. Reinstall in their original position. 1. Check clearance of each bearing, following procedure in Cleaning and Inspection. 2. Clean all the oil from the main bearing surfaces on the cylinder block and crankcase cover. 3. Install main bearings. Make sure the locking lug on each bearing fits into its notch. a b a - Main Bearings b - Fit the Locking Lugs into the Notches 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. a b 53815 a-Connecting Rod Bearings b-Fit the Locking Lugs into the Notches 90-828631R3 MARCH 1999 Page 4B-29 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 side of connecting rod marked with a “Y” towards “UP” on piston. c b a a Y a-Circlip b-Piston Pin c-Side Marked “Y” is Installed Towards “UP” on Piston Piston Ring Installation 1. Install the oil ring components as shown. Align upper oil ring rail ends with locating pin. Spread rings just enough to slip over piston. d c a e b f 53818 a-Lower Oil Ring Rail b-Lower Rail has Flat Ends c-Upper Oil Ring Rail d-Upper Rail has Notched Ends e-Oil Ring Spacer f-Locating Pin (Align Upper Oil Ring Rail Ends with Pin) Page 4B-30 90-828631R3 MARCH 1999 CYLINDER BLOCK/CRANKCASE 2. Install the second and top compression rings (“T” side up). Spread rings just enough to slip over piston. 53818 a b c a-Top Compression Ring ( “T” Side Up) b-Second Compression Ring ( “T” Side Up) c-Install Side of Ring Stamped “T” Towards Top of Piston Piston Installation 1. Align piston ring end gaps as shown. UP b d a c a-End Gap – Top Compression Ring b-End Gap – Second Compression Ring c-End Gap – Upper Oil Ring Rail (Align with Locating Pin) d-End Gap – Lower Oil Ring Rail 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. 90-828631R3 MARCH 1999 Page 4B-31 CYLINDER BLOCK/CRANKCASE 2. Lubricate pistons, rings, and cylinder walls with engine oil. 3. Install each piston in its respective cylinder. NOTE:Install used pistons into same cylinder from which they were removed. 4. Use Piston Ring Compressor (FT2997) to compress rings. 5. Position the “UP” mark on the piston toward the flywheel side. Push each piston into the cylinder until all rings enter the bore. IMPORTANT: Position the “UP” mark on the piston toward the flywheel end. 53748 a a-Piston Ring Compressor (FT2997) 53818 Crankshaft Installation 1. Lubricate the crankshaft bearing surfaces with engine oil. 53822 2. Carefully lower crankshaft into place. 3. Lubricate the connecting rod journals with engine oil. 4. Assemble the connecting rods to the crankshaft. Install the connecting rod caps, aligning the code letter marked on the connecting rod and cap. Page 4B-32 90-828631R3 MARCH 1999 CYLINDER BLOCK/CRANKCASE 90-828631R3 MARCH 1999 Page 4B-33 5. Apply oil to the connecting rod bolts. Tighten bolts in sequence and in two steps to the specified torque. 53823 a a a - Apply Oil to Bolt Threads Connecting Rod Bolt Torque 1st: 53 lb-in. (6 Nm) 2nd: 150 lb-in. (17 Nm) 6. Lubricate the oil seals lips with oil. 7. Install upper and lower oil seals. Position oil seal lips as shown. 8. If removed, install dowel pins. a 53824 c b a a - Dowel Pin (2) b - Upper Oil Seal c - Lower Oil Seal (Flat) or (Raised Rib) CYLINDER BLOCK/CRANKCASE Crankcase Cover Installation 1. Clean off all oil from the contacting surfaces of the crankcase cover and cylinder block. IMPORTANT: Make sure the contacting surface of the crankcase cover and cylinder block are clean before applying gasket sealant. 2. Apply a smooth even coat of Loctite Master Gasket Sealant to the contacting surfaces on the crankcase cover. Use a small (paint type) roller to spread out the sealant for a smooth even coverage. Instructions in gasket sealant kit must be followed exactly. NOTE:Do not apply gasket sealant to the main bearings or the bolt holes. 53821 b a a-Apply Loctite Master Gasket Sealant b-Use a Roller to Apply a Smooth Even Coat 3. Apply oil to bolt threads. Tighten bolts in sequence and in two steps to the specified torque. 2 a b 1 2 34 5 6 78 9 10 11 12 1314 15 16 1718 19 20 a-Center Bolts (10) b-Outer Bolts (10) 53743 Crankcase Cover Bolt Torque Center Bolts Qty. 10 (Larger Diameter M8) 1st: 11 lb-ft (15 Nm) 2nd: 22 lb-ft (30 Nm) Outer Bolts Qty. 10 (Smaller Diameter M6) 1st: 53 lb-in. (6 Nm) 2nd: 106 lb-in. (12 Nm) Page 4B-34 90-828631R3 MARCH 1999 CYLINDER BLOCK/CRANKCASE Exhaust Cover Installation 1. Install oil filter. 2. Install exhaust cover along with the thermostat and thermostat cover. Use new gaskets. 3. Tighten bolts in sequence and in two steps to the specified torque. 4. Install the oil pressure and temperature switch. 53746 a h e dc bgf 8 11 7 4 1 3 2 5 6 10 9 12 a-Exhaust Cover b-Gasket c-Thermostat d-Gasket e-Thermostat Cover f-Oil Pressure Switch g-Temperature Switch h-Oil Filter Exhaust and Thermostat Cover Bolt Torque 1st: 53 lb-in. (6 Nm) 2nd: 106 lb-in. (12 Nm) 90-828631R3 MARCH 1999 Page 4B-35 CYLINDER BLOCK/CRANKCASE Drive Gear Installation CRANKSHAFT WITH NUT 1. Install the drive gear components. 2. Hold crankshaft from turning using Powerhead Stand (91-827001A1). Tighten nut to the specified torque using 1-5/8 in. Socket Tool. 53742 a b c d f e e b a-Drive Gear Nut b-Washer (2) c-Drive Gear d-Drive Key e-Insert Projections (3) on the Drive Gear into the Holes in the washers f-1-5/8 in. Socket Tool (91-809646A1) Use for Tightening Drive Gear Nut Drive Gear Nut Torque 103 lb-ft (140 Nm) Page 4B-36 90-828631R3 MARCH 1999 CYLINDER BLOCK/CRANKCASE 90-828631R3 MARCH 1999 Page 4B-37 CRANKSHAFT WITHOUT NUT 113 113 4-Stroke Outboard Oil (92-828000A12) a c d e f b g g NOTE: Load Ring is for one time use and must be replaced if flywheel is removed. a - Washer, Lower b - Woodruff Key c - Drive Gear d - Washer, Upper e - Load Ring f - Spacer g - Insert Projections (3) on the Drive Gear into washer holes Installing Powerhead Components 1. Reinstall cylinder head. Refer to Section 4 Part A. 53740 CYLINDER BLOCK/CRANKCASE Page 4B-38 90-828631R3 MARCH 1999 2. Install Timing belt. Refer to Section 4 Part A. 30033 1 4 2 3 3. Install starter bracket with 4 bolts. Tighten bolts to the specified torque. 53866 b b b b a a - Starter Bracket b - Mounting Bolts (4) Starter Bracket Mounting Bolt Torque 210 lb–in. (23.7 Nm) CYLINDER BLOCK/CRANKCASE 90-828631R3 MARCH 1999 Page 4B-39 4. Install ignition coils and reattach engine wiring harness. 30028 c b a d a - Top Ignition Coil b - Bottom Ignition Coil c - Fasten (and Ground) Coil Ground Leads with Bolt d - Sta-Strap Ignition Coil Mounting Bolt Torque 62 lb-in. (7 Nm) 5. Reinstall trigger base with four bolts. 30027 a b a - Trigger Base b - Mounting Bolts (4) Trigger Base Bolt Torque 75 lb-in. (8.5 Nm) CYLINDER BLOCK/CRANKCASE 6. Reinstall stator with three bolts. 53745 c a b a-Stator b-Mounting Bolts (3) Apply Loctite 222 to Threads c-Sta-Strap Stator Bolt Torque 75 lb-in. (8.5 Nm) 7. Place flywheel key into slot. 8. Install flywheel. 9. Apply oil to threads on crankshaft and tighten nut to the specified torque. a c b d a-Flywheel Key b-Washer c-Nut d-Apply Oil to Threads Flywheel Nut Torque 116 lb-ft (157 Nm) Page 4B-40 90-828631R3 MARCH 1999 CYLINDER BLOCK/CRANKCASE 90-828631R3 MARCH 1999 Page 4B-41 10. Install shift and throttle lever. 11. Install control cable anchor bracket. 53869 d c b e a a - Cable Anchor Bracket b - Shift and Throttle Lever c - Bushing d - Bolt (1) e - Bolt and Bushing (2) Shift and Throttle Lever Mounting Bolt Torque 100 lb-in. (11.3 Nm) Cable Anchor Bracket Mounting Bolt Torque 75 lb-in. (8.5 Nm) CYLINDER BLOCK/CRANKCASE Page 4B-42 90-828631R3 MARCH 1999 12. Reinstall carburetor assembly with 8 flange bolts and 2 side mounting bolts. Tighten bolts to the specified torque. c e d a b 8 4 2 6 7 5 1 3 a - Carburetor Assembly b - O-Ring Flange Seals (4) c - Flange Bolts (8) d - Side Mounting Bolts (2) e - Collar (2) Flange Bolt Torque 50 lb-in. (5.7 Nm) Side Bolt Torque 75 lb-in. (8.5 Nm) CYLINDER BLOCK/CRANKCASE 90-828631R3 MARCH 1999 Page 4B-43 13. Reconnect hoses. Use sta-straps to fasten all hose connections. 53726 d c b b a a - Breather Hose b - Fuel Hose (2) c - Remote Fuel Hose d - Sta-Straps Powerhead Installation 1. Install powerhead and new gasket with 8 bolts. Tighten bolts to the specified torque. 53868 a b a - Powerhead Mounting Bolts (4 Each Side) b - Gasket Powerhead Mounting Bolt Torque 28.0 lb-ft (38.0 Nm) CYLINDER BLOCK/CRANKCASE Page 4B-44 90-828631R3 MARCH 1999 2. Reconnect the vent hose. Use sta-strap to fasten hose connections. 53726 a a - Vent Hose 3. Engage the vertical shift shaft. 4. Reconnect the power trim harness wires. 5. Position the trim wiring harness away from the moving horizontal shift shaft. Fasten harness to mounting boss with sta-strap as shown. 53859 c d b a a - Engage Vertical Shift Shaft and Close the Latch b - Power Trim Harness Wires c - Use Sta-strap to Fasten Wiring Harness Away from the Moving Horizontal Shift Shaft d - Horizontal Shift Shaft LUBRICATION POWERHEAD Section 4C - Lubrication Table of Contents Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-1 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . 4C-3 Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . 4C-2 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-3 Oil Pump Disassembly . . . . . . . . . . . . . . . . . . . . . 4C-2 Oil Pump Assembly. . . . . . . . . . . . . . . . . . . . . . . . 4C-4 Oil Pump Installation. . . . . . . . . . . . . . . . . . . . . . . 4C-5 Specifications Pump Type Engine Oil Pressure (Warm Engine) @ 3000 rpm Engine Oil Pan Capacity Oil Pump: Outer Rotor to Housing “a” Inner Rotor to Outer Rotor “b” Rotor to Housing “c” b c a LUBRICATION SYSTEM Trochoid 30-40 psi (207-278 kPa) Either 3 Qts. or 3 Liters 0.001 - 0.006 in. (0.03 - 0.15 mm) 0.005 in. (0.12 mm) 0.001 - 0.003 in. (0.03 - 0.08 mm) 4 C 90-828631R3 MARCH 1999 Page 4C-1 LUBRICATION Oil Pump Removal 1. Refer to section 4A for Cylinder Head Removal. 2. Remove oil pump bolts, separate oil pump from cylinder head. a a-Bolts (4) M6x35 Oil Pump Disassembly 1. Heat screws to loosen Loctite sealant. Remove screws. a a-Screw (2) Heat Screws to Loosen Loctite Sealant Page 4C-2 90-828631R3 MARCH 1999 LUBRICATION 2. Disassemble Oil Pump. a b c d e a-Cover Seal b-Outer Rotor c-Inner Rotor d-Shaft e-Cross Pin Cleaning and Inspection Oil Pump 1. Check oil pump components for pitting, scratches, and for the following measurements. Replace oil pump if worn or out of specification. 2. Using a feeler gauge, measure the following oil pump clearances: a. Between outer rotor and pump housing (a). b. Between the inner rotor and outer rotor (b). c. Between the outer rotor and pump housing (c). 55803 a b c Oil Pump Clearances a 0.001 - 0.006 in. (0.03 - 0.15 mm) b 0.005 in. (0.12 mm) c 0.001 - 0.003 in. (0.03 - 0.08 mm) 90-828631R3 MARCH 1999 Page 4C-3 LUBRICATION Oil Pump Assembly 1. Reassemble the oil pump assembly. 2. Lubricate the outer and inner rotors thoroughly with engine oil. a b c d e a-Cover Seal b-Outer Rotor c-Inner Rotor d-Shaft e-Cross Pin 3. Fasten cover with two screws. Apply Loctite 222 to threads. Tighten screws to the specified torque. a Loctite “222” (92-809818)51 51 a-Screws (2) Apply Loctite 222 to Threads Oil Pump Cover Screw Torque 68 lb-in. (7.5 Nm) Page 4C-4 90-828631R3 MARCH 1999 LUBRICATION Oil Pump Installation 1. Place O-ring seals on the oil pump. Lubricate the O-rings with oil. 2. Prime the oil pump by pouring approximately 1 fl oz (30 ml) of engine oil into the oil pump body. a a a b a-O-Ring Seals b-Pour Approximately 1 fl oz (30 ml) of Engine Oil into the Oil Pump Body 3. Align oil pump shaft with the camshaft and install the oil pump. 4. Fasten with 4 bolts. Tighten bolts to the specified torque. c a b a-Oil Pump Assembly b-Align Slot with Camshaft Projection c-Bolts (4)-M6x35 Oil Pump Mounting Bolt Torque 68 lb-in. (7.5 Nm) 90-828631R3 MARCH 1999 Page 4C-5 CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING MID-SECTION Section 5A - Clamp/Swivel Brackets & Driveshaft Housing Table of Contents Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-1 Transom Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-2 Swivel Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-4 Driveshaft Housing . . . . . . . . . . . . . . . . . . . . . . . . 5A-6 Adaptor Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-8 Specifications Steering Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-10 Bottom Cowl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-12 Bottom Cowl Removal . . . . . . . . . . . . . . . . . . . . 5A-14 Bottom Cowl Installation. . . . . . . . . . . . . . . . . . . 5A-15 Co-Pilot Installation . . . . . . . . . . . . . . . . . . . . . . . 5A-17 Transom Height: Long Shaft 20 in. (51 cm) MID-SECTION Steering Pivot Range Tilt Pin Positions 90° 5 + Shallow Water Full Tilt Up Angle 70° Allowable Transom Thickness 2-3/8 in. (60.3 mm) 5 A Part No. Description 92-88504 Loctite Pipe Sealant w/Teflon 92-850735A1 Anti-Corrosion Grease 92-850736A1 2-4-C w/Teflon 92-828000A12 4-Stroke Outboard Oil 90-828631R3 MARCH 1999 Page 5A-1 CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING Transom Bracket 9 1 2 3 4 5 6 7 8 10 11 12 13 14 15 16 17 18 39 19 20 21 22 23 24 25 26 27 28 29 30 32 33 34 35 36 37 38 95 95 95 41 22 40 42 31 95 2-4-C w/Teflon (92-825407A12) Page 5A-2 90-828631R3 MARCH 1999 CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING Transom Bracket REF.TORQUE REF. NO. QTY. DESCRIPTION lb-in. lb-ft Nm 1 1 TRANSOM BRACKET (PORT)(BLACK) 1 1 TRANSOM BRACKET (PORT)(GRAY) 2 1 GREASE FITTING (NON-BIGFOOT) 3 1 GROOVE PIN 4 1 TRANSOM BRACKET (STBD.)(BLACK) 4 1 TRANSOM BRACKET (STBD.)(GRAY) 5 1 TILT LOCK LEVER (BLACK) 5 1 TILT LOCK LEVER (GRAY) 6 1 SPRING 7 1 NYLINER 8 1 SPRING 9 1 KNOB (BLACK) 9 1 KNOB (GRAY) 10 1 GROOVE PIN 11 2 WASHER 12 1 ANCHOR BRACKET (BLACK) 12 1 ANCHOR BRACKET (GRAY) 13 1 ANODE ASSEMBLY 14 2 SCREW (M6 x 25) 60 6.8 15 2 WASHER 16 5 SCREW (30 MM) 16 1 SCREW (35 MM) 17 4 LOCKWASHER 18 2 NUT 19 1 TILT PIN ASSEMBLY NON POWER TRIM 20 1 SPRING 21 1 TILT TUBE 22 2 NUT Tighten nut to 32 lb-ft and then back off 1/4 turn 23 1 SEAL KIT 24 1 O RING NON-HANDLE 25 1 SPACER 26 2 CLIP 27 1 C-WASHER POWER TRIM 28 1 SCREW Drive Tight 29 4 SCREW Drive Tight 30 4 WASHER Drive Tight 31 4 NUT 32 1 LINK 33 1 TILT LEVER 34 1 BUSHING NON POWER TRIM 35 1 WASHER 36 1 WAVE WASHER 37 1 TILT KNOB 38 1 SCREW (.375-16 x .62) 220 18.3 24.9 39 2 SCREW (M10 x 40) 40 2 WASHER 41 2 NUT 42 1 DECAL-Tilt Lock 90-828631R3 MARCH 1999 Page 5A-3 1 2 3 4 5 6 11 13 14 15 16 17 7 95 95 95 95 A 8 10 9 10 12 95 2-4-C w/Teflon (92-825407A12) CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING Page 5A-4 90-828631R3 MARCH 1999 Swivel Bracket A = TORQUE NUT 120 LB-IN. (13.5 NM) AND THEN BACK OFF 1/4 TURN. CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING Swivel Bracket REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 LINK ROD 2 1 SCREW (1-1/2 IN.) 20 27.0 3 1 WASHER NON HANDLE 4 2 WASHER 5 2 NUT (.375-24) 120 13.5 6 1 PUCK 7 1 BUSHING 88 1 SWIVEL BRACKET (BLACK) 1 SWIVEL BRACKET (GRAY) 9 2 BEARING 10 2 GREASE FITTING 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 16 1 SEAL 17 2 BUSHING (NON-BIGFOOT) 90-828631R3 MARCH 1999 Page 5A-5 1 2 8 9 10 12 11 13 14 15 16 4 17 18 7 5 6 3 19 20 21 22 23 24 25 26 CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING Page 5A-6 90-828631R3 MARCH 1999 Driveshaft Housing CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING Driveshaft Housing REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 SEAL–water tube 22 1 DRIVESHAFT HOUSING (NON-BIGFOOT) (BLACK) 1 DRIVESHAFT HOUSING (NON-BIGFOOT) (GRAY) 33 1 DRIVESHAFT HOUSING (BIGFOOT) (BLACK) 1 DRIVESHAFT HOUSING (BIGFOOT) (GRAY) 4 1 EXHAUST TUBE RETAINER 5 1 PLATE BIGFOOT 6 1 SCREW (M10 x 25) 7 8 SCREW–Adaptor Plate 336 28 38 8 5 SCREW (M8 x 1.25 x 45) 336 28 38 9 1 BUMPER 10 1 DRAIN PLUG 210 17.5 23.5 11 1 GASKET 12 2 BUMPER 13 1 GROMMET 1414 1 STUD (NON-BIGFOOT) 1 STUD (BIGFOOT) 15 1 WASHER 16 1 NUT 40 54.5 17 1 WATER TUBE 18 1 GUIDE 19 4 SCREW 20 4 WASHER 21 1 SPEEDOMETER PICK UP ASSEMBLY 22 1 CONNECTOR (STRAIGHT) 23 1 FITTING 24 1 SPACER BIGFOOT 25 1 COUPLING 26 1 BUSHING 90-828631R3 MARCH 1999 Page 5A-7 1 2 3 5 9 10 11 12 21 22 13 19 25 27 28 6 7 8 26 5 5 4 20 110 110 9 23 15 16 17 18 18 23 14 24 110 4-Stroke Outboard Oil (92-828000A12) 9 Loctite PST Pipe Sealant (92-809822) CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING Page 5A-8 90-828631R3 MARCH 1999 Adaptor Plate CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING Adaptor Plate REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 DIPSTICK 2 1 DIPSTICK TUBE 3 1 SEAL 4 1 HEAT SHIELD 5 5 DOWEL PIN 6 1 ELBOW 7 2 STA-STRAP 8 1 TUBING (20 IN.) 99 1 SEAL–driveshaft (NON-BIGFOOT) 1 SEAL–driveshaft (BIGFOOT) 10 1 PLUG–oil passage 11 1 GROMMET (NON BIGFOOT) 12 1 ADAPTOR PLATE 13 1 GASKET 14 1 O RING 15 1 PLATE 16 1 HOSE 17 1 BAFFLE 18 2 CLAMP 19 1 BUSHING (NON BIGFOOT) 20 1 GROMMET (POWER TRIM) 21 1 GROMMET (NON-POWER TRIM) 22 8 SCREW (M6x 1 x 20) 130 11 23 3 SCREW (M6 x 1 x 20) 75 8.5 24 1 DEFLECTOR-Oil 25 1 BODY–oil pressure relief 34 46 26 1 COTTER PIN 27 1 PLUNGER 28 1 SPRING 90-828631R3 MARCH 1999 Page 5A-9 1 2 3 4 6 7 8 9 10 11 13 14 20 15 16 17 19 21 22 23 24 25 26 27 28 30 29 94 95 95 95 18 12 18 5 95 2-4-C w/Teflon (92-825407A12) 94 Anti-Corrosion Grease (92-78376A6) CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING Page 5A-10 90-828631R3 MARCH 1999 Steering Arm CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING Steering Arm REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 2 NUT 2 1 STRAP 3 2 MOUNT 4 1 BUMPER 5 1 BUMPER (BIGFOOT) 6 1 RETAINING RING 77 1 STEERING ARM (BLACK) 1 STEERING ARM (GRAY) 8 1 BRACKET 9 1 TAB WASHER NON HANDLE 10 2 SCREW (M10 x 1.5 x 30) 32.5 44 11 2 SCREW (M12 x 1.75 x 154) 50 68 12 2 WASHER (BIGFOOT) 13 1 SPACER 1414 1 SWIVEL TUBE (NON-BIGFOOT) 1 SWIVEL TUBE (BIGFOOT) 15 1 GROUND STRAP 16 1 GROUND STRAP 17 2 SCREW (M10 x 1.5 x 105) 32.5 44 18 2 WASHER (BIGFOOT) 19 1 BRACKET 20 3 SCREW(SELF–TAPPING) Drive Tight 21 2 NUT 22 1 NUT (.375-24) 23 1 LEVER–Co-Pilot 24 1 WASHER 25 1 ROD (THREADED) HANDLE 26 1 BRACKET PLATE 27 1 DISC 28 1 PLATE 29 1 DISC 30 2 SCREW (Hex Shoulder) 70 8.0 90-828631R3 MARCH 1999 Page 5A-11 1 2 3 5 6 8 10 12 13 14 15 16 17 15 3 3 7 4 9 95 11 18 19 20 95 2-4-C w/Teflon (92-825407A12) CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING Page 5A-12 90-828631R3 MARCH 1999 Bottom Cowl CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING Bottom Cowl REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 11 1 BOTTOM COWL (PORT) (BLACK) 1 BOTTOM COWL (PORT) (GRAY) 22 1 BOTTOM COWL (STBD.) (BLACK) 1 BOTTOM COWL (STBD.) (GRAY) 3 6 SCREW 60 7.0 4 1 WASHER 5 1 SEAL 6 1 SCREW (M6 x 1 x 60) 60 7.0 7 1 GASKET 8 1 FITTING-telltale 9 1 WASHER 10 1 BOOT 11 2 STA-STRAP 12 1 SCREW (M6 x 1 x 16) 60 7.0 13 1 HOOK-Latch 14 1 WAVE WASHER 15 2 BUSHING 16 1 WAVE WASHER 1717 1 LEVER (BLACK) 1 LEVER (GRAY) 18 1 PLUG (NON-POWER TRIM) 19 1 SWITCH (POWER TRIM) 20 2 PLUG (HANDLE) 90-828631R3 MARCH 1999 Page 5A-13 CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING Page 5A-14 90-828631R3 MARCH 1999 Bottom Cowl Removal 1. Disconnect trim wires. 53860 UP DN c a b a - Green/White b - Lt. Blue/White c - Red/Purple 2. Remove fuel connector bolt. a b a - Fuel Connector Bolt-M6 x 60 b - Fuel Connector CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING 90-828631R3 MARCH 1999 Page 5A-15 3. Remove screws holding cowl halves together. a a - Cowl Screws (6) Bottom Cowl Installation 1. Check for proper placement of boot between cowl halves. Verify trim wires are clear. 2. Secure cowl halves together with screws. a b a - Boot b - Screws (6) CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING Page 5A-16 90-828631R3 MARCH 1999 3. Secure fuel connector with bolt. a b a - Bolt - M6 x 60 b - Fuel Connector 4. Connect trim wires. 53860 UP DN a b c a - Green/White b - Lt. Blue/White c - Red/Purple CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING Co-Pilot Installation 1. Apply 2-4-C Marine Lubricant with Teflon to threads on the threaded rod. 2. Thread rod into swivel bracket to a height of 7/8 in. (22.2 mm). 54275 7/8 in. (22.2 mm) a 95 95 2-4-C w/Teflon (92-850736A1) a-Threaded Rod 3. Install one of the brake discs on the threaded rod. 4. Install the swivel head plate with two hex shoulder screws. ac b a-Brake Disc b-Swivel Head Plate c-Hex Shoulder Screw (2) Swivel Head Plate Screw Torque 70 lb-in. (8 Nm) 90-828631R3 MARCH 1999 Page 5A-17 CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING 5. Install remaining co-pilot components. 54275 54276 a b c d e f g a-Brake Disc (2) b-Swivel Head Plate c-Hex Shoulder Screw (2) d-Brake Plate e-Nylon Washer f-Co-Pilot Lever g-Lock Nut (Tighten Next Step) Page 5A-18 90-828631R3 MARCH 1999 CLAMP/SWIVEL BRACKETS & DRIVESHAFT HOUSING 6. Adjust the co-pilot steering friction as follows: • Loosen the secondary steering friction screw. This screw can be used after the co-pilot lever has been adjusted to add steering friction on the tiller handle. a a-Secondary Steering Friction Screw • Set the co-pilot lever to the full friction (left side) position. • Tighten locknut to the desired co-pilot friction. Move the co-pilot lever to the less friction (right side) position, the outboard should steer freely. More Friction Less Friction 90-828631R3 MARCH 1999 Page 5A-19 POWER TRIM MID-SECTION Section 5B – Power Trim 1998 and Earlier Non-Bigfoot Table of Contents Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-2 Power Trim Mounting . . . . . . . . . . . . . . . . . . . . . . 5B-3 Power Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-4 Theory Of Operation. . . . . . . . . . . . . . . . . . . . . . . 5B-6 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-6 Trimming Characteristics . . . . . . . . . . . . . . . . 5B-6 Trailering Outboard . . . . . . . . . . . . . . . . . . . . . 5B-7 Tilting Outboard Up and Down Manually . . . 5B-7 Trim “In” Angle Adjustment . . . . . . . . . . . . . . 5B-8 Power Trim Flow Diagrams . . . . . . . . . . . . . . . . 5B-10 Trim Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-11 Tilt Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-13 Maximum Tilt . . . . . . . . . . . . . . . . . . . . . . . . . 5B-15 Down Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-17 Shock Function Up . . . . . . . . . . . . . . . . . . . . 5B-19 Shock Function Return . . . . . . . . . . . . . . . . . 5B-21 Manual Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-23 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-24 Preliminary Checks . . . . . . . . . . . . . . . . . . . . 5B-24 Hydraulic System Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-25 Troubleshooting the Power Trim Electrical System . . . . . . . . . . . . . . . . . . . . . . 5B-29 Power Trim System Removal . . . . . . . . . . . . . . 5B-31 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-32 Shock Rod Removal . . . . . . . . . . . . . . . . . . . 5B-32 Shock Rod Disassembly . . . . . . . . . . . . . . . . . . 5B-33 Memory Piston Removal . . . . . . . . . . . . . . . 5B-35 Trim Motor Removal . . . . . . . . . . . . . . . . . . . 5B-36 Oil Pump Removal . . . . . . . . . . . . . . . . . . . . 5B-37 Tilt Relief Valve Removal . . . . . . . . . . . . . . . 5B-37 Suction Seat Removal . . . . . . . . . . . . . . . . . 5B-39 Pilot Check Valve Assembly Removal . . . . 5B-39 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . . 5B-41 Trim Motor Electrical Tests . . . . . . . . . . . . . . 5B-41 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-42 O-Ring and Seal Placement . . . . . . . . . . . . 5B-42 Power Trim Reassembly . . . . . . . . . . . . . . . . . . 5B-44 Tilt Relief Valve Reassembly . . . . . . . . . . . . 5B-44 Suction Seat Reassembly . . . . . . . . . . . . . . 5B-45 Pilot Check Valve Reassembly . . . . . . . . . . 5B-45 Oil Pump Reassembly . . . . . . . . . . . . . . . . . 5B-46 Trim Motor Reassembly . . . . . . . . . . . . . . . . 5B-47 Shock Rod Reassembly . . . . . . . . . . . . . . . . 5B-48 Shock Rod Installation . . . . . . . . . . . . . . . . . 5B-49 Manual Release Valve Installation . . . . . . . 5B-50 Bleeding Power Trim Unit . . . . . . . . . . . . . . 5B-51 Power Trim System Installation . . . . . . . . . . . . 5B-51 5 B 90-828631R3 MARCH 1999 Page 5B-1 POWER TRIM Special Tools 1. Spanner Wrench P/N 91-74951 2. Lock-Ring Pliers P/N SRP-2 (Snap-On) 3. Expanding Rod P/N CG 41-11 (Snap-On) 4. Collet P/N CG 41-12 (Snap-On) Address Snap-On Tools Company 2801 - 80th Street Kenosha, Wisconsin 53143 Phone 414.656.5200 Page 5B-2 90-828631R3 MARCH 1999 POWER TRIM Power Trim Mounting 1 2 3 4 5 6 7 8 9 10 11 12 13 14 95 2-4-C w/Teflon (92-850736A1) 95 95 REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 PIN-anchor (14MM) 2 2 BUSHING 3 2 BUSHING 4 2 WASHER 5 2 NUT 18.0 24.5 6 2 SCREW (M10 x 40) 7 2 WASHER 8 2 NUT 9 1 SCREW (10-16 x .35) Drive Tight 10 1 C-WASHER 11 2 CLIP 12 1 PIN 13 1 PIN 14 1 BUSHING 90-828631R3 MARCH 1999 Page 5B-3 1 2 3 4 5 17 18 19 20 21 22 23 24 25 26 3 6 11 7 8 9 10 12 13 14 15 16 27 30 29 28 31 32 33 25 Liquid Neoprene (92-25711--2) 25 25 B A G D F E C D POWER TRIM Page 5B-4 90-828631R3 MARCH 1999 Power Trim NOTE: Lubricate all O-rings using Quicksilver Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. NOTE: It is recommended that all O-rings be replaced when servicing tilt system. POWER TRIM Power Trim REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 POWER TRIM ASSEMBLY – 1 O RING KIT 2 1 SHOCK ROD ASSEMBLY 45 61 3 1 PILOT CHECK ASSEMBLY 120 13.5 4 1 TILT RELIEF VALVE ASSEMBLY 120 13.5 5 1 SUCTION SEAT ASSEMBLY 120 13.5 6 1 PUMP ASSEMBLY 7 1 SPRING/DOWN RELIEF BALL 8 2 SCREW (10-32 x 1-1/4 IN.) 70 8.0 9 1 FILTER 10 1 SEAL RING 11 1 MOTOR ASSEMBLY 12 4 SCREW (1/4-28 x 5/8 IN.) 80 9.0 13 1 GROUND STRAP 14 1 LOCKWASHER 15 1 O RING 16 1 COUPLER 17 1 MEMORY PISTON 18 1 MANUAL RELEASE VALVE ASSY. Drive Tight 19 1 RESERVOIR PLUG Drive Tight – 1 HARNESS ASSEMBLY - Trim 20 1 HARNESS ASSEMBLY - Trim 21 2 RELAY 22 2 BRACKET (S/N-0G472132 & BELOW) 23 2 GROMMET 24 2 BUSHING 25 2 SCREW (M6 x 1 x 25) 26 2 PLUG–Male – 1 HARNESS ASSEMBLY - Trim 27 1 HARNESS ASSEMBLY-Trim 28 2 RELAY ASSEMBLY 29 2 BRACKET (S/N-0G472133 & UP) 30 2 GROMMET 31 2 BUSHING 32 2 SCREW (M6 x 25) 33 1 HARNESS A -Torque Cylinder Cap To 45 lb-ft (61 Nm) B -Torque Screw To 80 lb-in. (9.0 Nm) C -Torque Screw To 70 lb-in. (7.9 Nm) D -Torque Pilot Check Plug To 120 lb-in. (13.6 Nm) E -Torque Tilt Relief Plug To 120 lb-in. (13.6 Nm) F -Torque Suction Seat Plug To 120 lb-in. (13.6 Nm) G -Torque Shock Piston To 45 lb-ft (61 Nm) 90-828631R3 MARCH 1999 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, general increasing top speed. • Transfers steering torque harder to port on installations below 23 in. (58.5 cm) 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. Page 5B-6 90-828631R3 MARCH 1999 POWER TRIM The engine can be raised beyond the 20 maximum trim angle for shallow water operation, etc., by keeping the engine rpm below 2000 rpm. If engine rpm increases above 2000 rpm, the thrust created by the propeller (if deep enough in the water) will cause the trim system to automatically lower the engine back to the 20 maximum trim angle. TRIMMING OUTBOARD “DOWN” (“IN”) WARNING Excessive speed at minimum trim “In” may cause undesirable and/or unsafe steering conditions. Each boat should be tested for handling characteristics after any adjustment is made to the tilt angle (tilt pin relocation). • Will help planing off, particularly with a heavy load. • Usually improves ride in choppy water. • In excess, can cause boat to veer to port or starboard (bow steer). • Transfers steering torque harder to starboard (or less to port). • Improves planing speed acceleration (by moving tilt pin one hole closer to transom). Operating “Down” circuit will actuate the “down” relay (located under engine cowl) and close the electric motor circuit (motor will run in opposite direction of the “Up” circuit). The electric motor will drive the pump, thus forcing automatic transmission fluid through internal passageways into the “down” side of the trim cylinder. The trim rod will move the engine downward to the desired angle. Trailering Outboard WARNING Excessive engine trim angle will result in insufficient water supply to water pump causing water pump and/or powerhead overheating damage. Make sure that water level is above gear housing water intake holes whenever engine is running. While operating “up” circuit, the cylinder rod will continue to tilt the outboard to a full up position for trailering. Tilting Outboard Up and Down Manually WARNING Before loosening the manual release valve, make sure all persons are clear of engine as engine will drop to full “down” position when valve is loosened. With power trim installed, the outboard can be raised or lowered manually by opening the manual release valve 3 to 4 turns (counterclockwise). a a-Manual Release Valve 90-828631R3 MARCH 1999 Page 5B-7 POWER TRIM Trim “In” Angle Adjustment WARNING Operating some boats with engine trimmed to the full “in” trim angle at planing speed will cause undesirable and/or unsafe steering conditions. Each boat must be water tested for handling characteristics after engine installation and after any trim adjustments. IMPORTANT: Some boat/motor combinations that are trimmed to the full “in” trim angle, will not experience any undesirable and/or unsafe steering conditions during planing speed. However, some boats with engine trimmed to the full “in” trim angle at planing speed will cause undesirable and/or unsafe steering conditions. If these steering conditions are experienced, adjust the left and right tilt stop pins to prevent unsafe handling characteristics. Water test the boat. If undesirable and/or unsafe steering conditions are experienced (boat runs with nose down), adjust the left and right tilt stop pins in proper hole to prevent unsafe handling characteristics. a b a-Left Tilt Stop Pin b-Right Tilt Stop Pin IMPORTANT: In order to remove the right tilt stop pin it may be necessary to remove the upper pivot pin and pivot the tilt/trim assembly out of the clamp brackets. See “Power Trim System Removal” to remove the upper pivot pin. Page 5B-8 90-828631R3 MARCH 1999 POWER TRIM Notes: 90-828631R3 MARCH 1999 Page 5B-9 POWER TRIM Page 5B-10 90-828631R3 MARCH 1999 Power Trim Flow Diagrams Á Á Á Á ÁÁ TRIM UP Reservoir and Feed Oil Oil Under Pressure Return Oil Up Pressure 2530 psi (min) aa b c d e f g h i j k l m n o p q r t s u w v w POWER TRIM Trim Up When the trim switch is activated in the up position, the electric motor (a) begins to rotate the oil pump gears (n), the oil pump draws a small amount of oil through the filter, up circuit pick-up and past the up circuit feed check ball (o). The oil pump gear (n) rotation forces oil into the passages for the up circuit. Oil, under pressure, will slide the shuttle valve (p) against the down circuit pressure operated valve (h). The shuttle valve will mechanically open the down circuit pressure operated valve, allowing oil from the down cavity of the trim cylinder, to flow into the oil pump. This returning oil, from the down cavity, will supply most of the oil required for the up circuit. Oil in the up circuit is blocked from returning into the reservoir (t) by the ball inside the down circuit feed check ball (m). The pressure of the oil will force the up circuit pressure operated valve (l) to open, allowing the oil to enter the passages inside the manifold (f) leading to the trim cylinder up cavity. Oil is blocked from all other passages by the closed manual release valve (j) and closed tilt relief valve (k). Oil under pressure will enter the trim cylinder below the memory piston (e). With an increasing amount of oil entering the cylinder, the memory piston contacts the shock piston (d) and forces the trim rod (b) up and out, raising the outboard motor. Oil on the top of the shock piston exits through a passage running down along the side of the cylinder and enters the manifold passages. Inside the manifold the oil seats the ball (r) inside the suction valve (g), closing the passage into the reservoir. The oil is drawn back into the pump (n) through the opened down circuit pressure operated valve (h) and enters the pump as supply for the up circuit. a-Electric Motor b-Trim Rod c-Impact Relief Valve d-Shock Piston e-Memory Piston f-Manifold g-Suction Valve h-Down Circuit Pressure Operated Valve i-Tilt Relief Actuator j-Manual Release Valve k-Tilt Relief Valve l-Up Circuit Pressure Operated Valve m-Down Circuit Feed Check Ball n-Oil Pump Gears o-Up Circuit Feed Check Ball p-Shuttle Valve q-Down Circuit Pressure Relief Valve r-Check Ball s-Reservoir Oil t-Oil Reservoir u-Oil Fill Cap v-Shock Return Valve w-Filter 90-828631R3 MARCH 1999 Page 5B-11 POWER TRIM Page 5B-12 90-828631R3 MARCH 1999 ÁÁ ÁÁ Á ÁÁ Á TILT UP Reservoir and Feed Oil Oil Under Pressure Return Oil Tilt Relief Pressure 500-600 psi a b c d e f g h i j k l m n o p q r s u t v w w POWER TRIM Tilt Up In the up mode, as the trim rod (b) extends from the cylinder, the memory piston (e) clears or uncovers the pressure relief passage. Oil from the up cavity will enter this passage and open the tilt pressure relief valve (k). 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 decreases or if engine is not in forward gear, the oil pressure is available to extend the trim rod (b) up into the tilt range. a-Electric Motor b-Trim Rod c-Impact Relief Valve d-Shock Piston e-Memory Piston f-Manifold g-Suction Valve h-Down Circuit Pressure Operated Valve i-Tilt Relief Actuator j-Manual Release Valve k-Tilt Relief Valve l-Up Circuit Pressure Operated Valve m-Down Circuit Feed Check Ball n-Oil Pump Gears o-Up Circuit Feed Check Ball p-Shuttle Valve q-Down Circuit Pressure Relief Valve r-Check Ball s-Reservoir Oil t-Oil Reservoir u-Oil Fill Cap v-Shock Return Valve w-Filter 90-828631R3 MARCH 1999 Page 5B-13 POWER TRIM Page 5B-14 90-828631R3 MARCH 1999 Á Á ÁÁ Á ÁÁ MAXIMUM TILT Reservoir and Feed Oil Oil Under Pressure Return Oil Tilt Relief Pressure 500-600 psi a b c d e f g h i j k l m n o p q r u t s v w w POWER TRIM Maximum Tilt With the cylinder at maximum travel, and due to no ram movement, the pressure inside of the trim cylinder will increase to the pressure required to move the tilt relief actuator (i). The tilt relief actuator’s “pin” opens the tilt relief valve (k). Up pressure flows into the trim relief passage, and return back into the reservoir (t). a-Electric Motor b-Trim Rod c-Impact Relief Valve d-Shock Piston e-Memory Piston f-Manifold g-Suction Valve h-Down Circuit Pressure Operated Valve i-Tilt Relief Actuator j-Manual Release Valve k-Tilt Relief Valve l-Up Circuit Pressure Operated Valve m-Down Circuit Feed Check Ball n-Oil Pump Gears o-Up Circuit Feed Check Ball p-Shuttle Valve q-Down Circuit Pressure Relief Valve r-Check Ball s-Reservoir Oil t-Oil Reservoir u-Oil Fill Cap v-Shock Return Valve w-Filter 90-828631R3 MARCH 1999 Page 5B-15 POWER TRIM Page 5B-16 90-828631R3 MARCH 1999 ÁÁÁ ÁÁ ÁÁ ÁÁ TRIM DOWN Reservoir and Feed Oil Oil Under Pressure Return Oil Down Relief 500-800 psi l k a b c d e f g h i j k l m n o p q r s u t w v w POWER TRIM Trim Down When the trim switch is activated in the down position, the electric motor (a) will rotate the oil pump gears (n) in the opposite direction. With the oil pump gears rotating backwards, the flow of oil is reversed. Oil is drawn through the filter, past the up circuit feed check ball (m), into the down circuit oil pick-up and finally into the oil pump. The pump feeds pressurized oil into the down passages, oil will slide the shuttle valve (p) into the up circuit pressure operated valve (l). The shuttle valve will mechanically open the pressure operated valve and allow oil, from the up cavity of the trim cylinder (f), to return into the oil pump. This returning oil, from the up cavity, will supply the oil required for the down circuit. The oil is blocked from returning into the reservoir by the shuttle valve (p) inside the up circuit feed check ball. Oil, under pressure, opens the down circuit pressure operated valve (h) and enters the down passages inside of the manifold (f). The manifold passage connects into the trim cylinder passage leading to the top of the cylinder. The cavity, inside the cylinder, above the shock piston (d) is the down cavity. As the down cavity fills with oil, the trim rod (b) retracts into the cylinder, lowering the outboard motor. Oil from the up cavity exits the cylinder and is drawn back into the pump through the opened up circuit pressure operated valve (l). When the trim rod reaches full travel, the oil pressure inside the down circuit will rise until the down circuit pressure relief valve (q) opens, bypassing oil back into the reservoir(t). When the trim button is released, and the oil pump stops supplying pressure, both of the pressure operated valves (h & l) will close and; if open, the down circuit pressure relief valve (q) will close. The closed valves will lock the fluid on either side of the shock piston (d), holding the outboard motor in position. a-Electric Motor b-Trim Rod c-Impact Relief Valve d-Shock Piston e-Memory Piston f-Manifold g-Suction Valve h-Down Circuit Pressure Operated Valve i-Tilt Relief Actuator j-Manual Release Valve k-Tilt Relief Valve l-Up Circuit Pressure Operated Valve m-Down Circuit Feed Check Ball n-Oil Pump Gears o-Up Circuit Feed Check Ball p-Shuttle Valve q-Down Circuit Pressure Relief Valve r-Check Ball s-Reservoir Oil t-Oil Reservoir u-Oil Fill Cap v-Shock Return Valve w-Filter 90-828631R3 MARCH 1999 Page 5B-17 POWER TRIM Page 5B-18 90-828631R3 MARCH 1999 Á Á ÁÁ Á Á SHOCK FUNCTION UP Reservoir and Feed Oil Oil Under Pressure Return Oil 1550-1850 psi a b c d e f g h i j k l m n o p q r u t s v w w POWER TRIM Shock Function Up Oil inside the down cavity is locked in a static position by the closed down circuit pressure operated valve (h), the manual release valve (j) and the tilt relief valve (k). If the outboard strikes an underwater object while in forward gear the trim rod (b) will try to rapidly extend from the cylinder , the pressure increases inside the trim cylinder down cavity and connecting passages. The rise in pressure will seat the check ball (r) inside the suction valve (g), preventing fluid from returning into the reservoir. When the pressure increases to the level required, the impact relief valves (c), located inside the shock piston (d), will open and allow the fluid to pass through the shock piston. As the fluid passes through the piston, the trim rod (b) will extend from the trim cylinder. The memory piston (e) is held in position by vacuum, created by the oil in the up cavity being locked in a static position. Therefore; oil passing through the trim rod piston is trapped between the memory piston (e) and shock piston (d). a-Electric Motor b-Trim Rod c-Impact Relief Valve d-Shock Piston e-Memory Piston f-Manifold g-Suction Valve h-Down Circuit Pressure Operated Valve i-Tilt Relief Actuator j-Manual Release Valve k-Tilt Relief Valve l-Up Circuit Pressure Operated Valve m-Down Circuit Feed Check Ball n-Oil Pump Gears o-Up Circuit Feed Check Ball p-Shuttle Valve q-Down Circuit Pressure Relief Valve r-Check Ball s-Reservoir Oil t-Oil Reservoir u-Oil Fill Cap v-Shock Return Valve w-Filter 90-828631R3 MARCH 1999 Page 5B-19 POWER TRIM Page 5B-20 90-828631R3 MARCH 1999 Á Á Á Á ÁÁ SHOCK FUNCTION RETURN Reservoir and Feed Oil Oil Under Pressure Return Oil a b c d e f g h i j k l m n o p q r s u t v w w POWER TRIM Shock Function Return After the engine clears the under water object, the weight of the engine will increase the oil pressure between the memory piston (e) and shock piston (d) to the level required to open the shock return valve (v), inside the shock piston, 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 suction valve (g). This will return the engine back against the memory piston (e) in to the original running position. a-Electric Motor b-Trim Rod c-Impact Relief Valve d-Shock Piston e-Memory Piston f-Manifold g-Suction Valve h-Down Circuit Pressure Operated Valve i-Tilt Relief Actuator j-Manual Release Valve k-Tilt Relief Valve l-Up Circuit Pressure Operated Valve m-Down Circuit Feed Check Ball n-Oil Pump Gears o-Up Circuit Feed Check Ball p-Shuttle Valve q-Down Circuit Pressure Relief Valve r-Check Ball s-Reservoir Oil t-Oil Reservoir u-Oil Fill Cap v-Shock Return Valve w-Filter 90-828631R3 MARCH 1999 Page 5B-21 POWER TRIM Page 5B-22 90-828631R3 MARCH 1999 Á Á Á MANUAL TILT Á ÁÁ Reservoir and Feed Oil Return Oil a b c d e f g h i j k l m n o p q r s t u w v w POWER TRIM Manual Tilt To manually tilt the outboard engine, the owner will need to back out the manual release valve (j). With the valve backed out, the internal passages inside the manifold are connected together. These passages connect both the cylinder down and up cavities together, along with the reservoir (t), allowing the engine to be raised or lowered. Trim rod (b) movement will continue until the manual release valve is closed, locking the fluid inside of the cylinder and manifold. a-Electric Motor b-Trim Rod c-Impact Relief Valve d-Shock Piston e-Memory Piston f-Manifold g-Suction Valve h-Down Circuit Pressure Operated Valve i-Tilt Relief Actuator j-Manual Release Valve k-Tilt Relief Valve l-Up Circuit Pressure Operated Valve m-Down Circuit Feed Check Ball n-Oil Pump Gears o-Up Circuit Feed Check Ball p-Shuttle Valve q-Down Circuit Pressure Relief Valve r-Check Ball s-Reservoir Oil t-Oil Reservoir u-Oil Fill Cap v-Shock Return Valve w-Filter 90-828631R3 MARCH 1999 Page 5B-23 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-24 90-828631R3 MARCH 1999 POWER TRIM Hydraulic System Troubleshooting Flow Chart OUTBOARD WILL NOT HOLD TILTED POSITION DURING REVERSE AND/OR TRAILS OUT DURING HIGH SPEED DECELERATION Inspect manual release valveManual release valve and O-ring damaged Manual release valve and O-rings appear to be O.K. Clean and reinstall manu- al release valve Trim system holds reverse thrust: Testing complete Trim will not hold reverse thrust Replace manual release valve and O-rings Trim system holds reverse thrust: Testing complete Remove and inspect pis- ton rod assembly for de- bris and/or shock ball hang up Shock piston appears O.K. - Clean and reinstall piston rod assembly Trim system holds reverse thrust: Testing complete Debris and/or shock ball hang up identified Replace piston rod assembly Trim system holds reverse thrust: Testing complete Trim will not hold reverse thrust Remove PO check valve assembly, inspect O- rings and seals for dam- age Debris and/or dam- age identified PO check valve appears O.K. - Clean and reinstall PO check valve assembly Replace PO check valve assembly Trim system holds reverse thrust: Testing complete Trim will not hold reverse thrust Trim system holds reverse thrust: Testing complete continued on next page 90-828631R3 MARCH 1999 Page 5B-25 POWER TRIM continued Replace trim system Replace suction seat assembly Remove suction seat as- sembly and inspect for debris and/or damage Debris and/or damage identified Trim system holds reverse thrust: Testing complete Trim will not hold reverse thrust Suction seat assembly appears O.K. - Clean and reinstall suction seat as- sembly Trim system holds reverse thrust: Testing complete Page 5B-26 90-828631R3 MARCH 1999 POWER TRIM Hydraulic System Troubleshooting Flow Chart TRIM SYSTEM LEAKS DOWN WITH MANUAL RELEASE VALVE CLOSED Inspect manual release valveManual release valve and O-ring damaged Replace manual re- lease valve and O- rings Trim system does not leak down: Testing complete Trim system leaks down Manual release valve and O- rings appear to be O.K. - Clean and reinstall manual release valve Trim system does not leak down: Testing complete Remove tilt relief valving and inspect O-rings and seals for debris and/or damage Debris and/or dam- age identified Replace tilt relief valving Trim system does not leak down: Testing complete Trim system leaks down Tilt relief valving and O-rings appear to be O.K. - Clean and reinstall tilt relief valving Trim system does not leak down: Testing complete continued on next page 90-828631R3 MARCH 1999 Page 5B-27 POWER TRIM continued Replace trim system Replace memory pis- ton and shock piston O-rings Inspect memory piston 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: Testing complete Remove PO check valve assembly, inspect O- rings and seals for dam- age Debris and/or damage identified Replace PO check valve assembly PO check valve appears O.K. - Clean and reinstall PO check valve assembly Trim system leaks down Trim system does not leak down: Testing complete Trim system does not leak down: Testing complete Page 5B-28 90-828631R3 MARCH 1999 POWER TRIM Troubleshooting the Power Trim Electrical System LT.BLU/WHT GRN/WHT BLUE14 BLKREDBLK DN UP AB RED RED/PUR DN UP LT. GRN/WHT LT. BLU/WHT RED GRN/WHT BLU/WHT DN UP GRN/WHT BLU/WHT RED GRN/WHT or GRN BLU/WHT or PUR GRN14 BLKREDBLK +– LT. GRN/WHT LT. BLU/WHT RED/PUR 1 2 3 4 a b c d e f g h i j k l a-Trim Switch (Remote Control Mounted) b-Trim Switch (Panel Mounted) c-Fuse Holder d-Remote Control e-Fuse Holder f-Battery g-Starter Bolt h-Solenoid i-Down Relay j-Up Relay k-Trim Pump Motor l-Cowl Switch 90-828631R3 MARCH 1999 Page 5B-29 POWER TRIM Troubleshooting the Power Trim Electrical System Refer to wiring diagram on preceding page for location of wire connections. Problem Possible Cause Remedy Trim Switch “UP” is inoperative, but the Cowl Switch “UP” does operate. 1. Open wire between Wire Connection (1) and Trim Switch. 2. Faulty Trim Switch. 1. Check for a open connection or cut wire. 2. Replace Cowl Switch “UP” is inoperative, but the Trim Switch “UP” does operate. 1. Open wire between Wire Connection (2) and Solenoid. 2. Faulty Cowl Switch. 1. Check for a open connection or cut wire. 2. Replace Trim Switch “UP” and Cowl Switch “UP” are both inop1. Open wire between Wire Connection (1) and the Up Relay 1. Check for an open connection. erative. 2. Open BLK wire between ground and UP Relay. 2. Check for an open connection. 3. Open RED wire between Solenoid and Up Relay 3. Check for an open connection. 4. Faulty Up Relay. 4. Replace Trim Switch “DOWN” is inoperative, but the Cowl Switch “DOWN” does operate. 1. Open wire between Wire Connection (3) and Trim Switch. 2. Faulty Trim Switch. 1. Check for a open connection or cut wire. 2. Replace Cowl Switch “DOWN” is inoperative, but the Trim Switch “DOWN” does operate. 1. Open wire between Wire Connection (2) and Solenoid. 2. Faulty Cowl Switch. 1. Check for a open connection or cut wire. 2. Replace Trim Switch “DOWN” and Cowl Switch “DOWN” are 1. Open wire between Wire Connection (3) and the Up Relay. 1. Check for an open connection. both inoperative. 2. Open BLK wire between ground and Down Relay. 2. Check for an open connection. 3. Open RED wire between Solenoid and Down Relay. 3. Check for an open connection. 4. Faulty Down Relay. 4. Replace Trim Switch “UP” and “DOWN” are both inoperative, but the Cowl Switch does operate. 1. 20 AMP Fuse blown. 2. Faulty trim switch. 3. Wire is open between fuse holder and solenoid. 4. Wire is open between fuse holder and trim switch. 1. Replace fuse. Locate the cause of the blown fuse. Check electrical wiring for a shorted circuit. 2. Replace 3. Check for a open connection or cut wire. 4. Check for a loose or corroded connection. Trim Switch and Cowl Switch are both inoperative. 1. One of the Trim Pump Motor wires is open between the motor and the Relays. 2. Faulty trim pump motor. 1. Check wire connections (4) for loose or corroded condition. 2. If voltage is present at connections (4) when the appropriate trim button is pressed, then the motor is faulty. Replace motor. Trim system operates (motor runs) without pressing the switches. 1. The Trim or Cowl switch is shorted. 1. Replace Page 5B-30 90-828631R3 MARCH 1999 POWER TRIM 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 clamps. a b a-Tilt Lock Pin b-Power Trim Wire Harness Clamps 3. Remove the trilobe pin. 4. Drive out the upper pivot pin. 5. Remove the sacrificial anode. a b c a-Trilobe Pin b-Upper Pivot Pin c-Sacrificial Anode 90-828631R3 MARCH 1999 Page 5B-31 POWER TRIM 6. Remove nuts and washers securing the lower pivot pin. Remove lower pivot pin. Retain the pivot pin bushings from the clamp brackets and trim unit. 7. Remove the trim unit. Disassembly Shock Rod Removal IMPORTANT: Power trim system is pressurized. Outboard must be in the full “UP” position (trim rod fully extended) prior to fill/drain plug, or manual release valve removal. 1. Remove reservoir cap. 2. Remove manual release valve assembly. 3. Drain power trim fluid as shown. a b a-Reservoir Cap b-Manual Release Valve Page 5B-32 90-828631R3 MARCH 1999 POWER TRIM 90-828631R3 MARCH 1999 Page 5B-33 4. Secure power trim assembly in a soft jaw vise. 5. Unscrew end cap assembly from cylinder using spanner wrench 91-74951. 6. Remove shock rod assembly from cylinder. 91-74951 Shock Rod Disassembly NOTE: The only serviceable items on the shock rod assembly are the O-rings and wiper ring. If shock rod requires any other repair, replace shock rod assembly. a c c c c b c c d a - End Cap b - Shock Piston c - O-ring d - Wiper Ring 1. Place shock rod assembly on clean work surface. 2. Remove bolt from end of shock rod. a a a - Bolt POWER TRIM 3. Remove check ball components from shock rod piston. 4. Remove O-ring from shock rod piston. 51147 a b c d 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 90-828631R3 MARCH 1999 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. 11. Remove cylinder end cap assembly from shock rod. 12. Inspect shock. If wiper (located in cap) has failed to keep rod clean, replace wiper. 13. Place end cap on clean work surface. 14. Remove rod wiper, inner O-ring, and outer O-ring. a b c d e 51199 a-Shock Piston b-O-ring c-Rod Wiper d-Inner O-ring e-Outer O-ring Memory Piston Removal 1. Remove memory piston from cylinder using one of two methods: a. Using lock ring pliers P/N SRP-2 (Snap-On) or suitable tool. SRP-2 (Snap-On) 90-828631R3 MARCH 1999 Page 5B-35 POWER TRIM 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. a b c d e a-Adaptor b-Air Hose c-Memory Piston Exit d-Shop Rag e-O-ring Trim Motor Removal 1. Secure power trim assembly in soft jawed vise. 2. Remove screws securing trim motor to manifold. 3. Remove motor assembly. a b a-Trim Motor b-Screw (4) Page 5B-36 90-828631R3 MARCH 1999 POWER TRIM Oil Pump Removal 1. Remove oil filter and pump from manifold. IMPORTANT: DO NOT disassemble the oil pump. The pump is not serviceable. a b c d e f a-Screw (2) b-Oil Pump c-Spring d-Filter e-O-Ring f-Down Relief Ball Tilt Relief Valve Removal NOTE:The following procedures requires the use of a Snap-On blind hole removal tool #CG-41-11 with 5/16” attachment #CG-41-12. Or a removal tool can be fabricated with the material and specifications listed below. 4 1/2” 3 1/4” 1/4” a a-Removal Tool made from .060 Stainless Steel Rod 90-828631R3 MARCH 1999 Page 5B-37 POWER TRIM Page 5B-38 90-828631R3 MARCH 1999 1. Unscrew plug from manifold and remove spring and poppet assembly. NOTE: Do not lose shim that may be lodged in the plug. 2. Use the removal tool and pull out the pilot valve. c f h b b a b b d e g h a - Tilt Relief Valve Assembly b - O-Rings c - Actuator Pin d - Pilot Valve e - Poppet Assembly f - Spring g - Shim h - Plug IMPORTANT: Inspect poppet assembly for debris in the area shown. If debris is found on poppet replace poppet. a b a - Debris Under Valve Tip b - Rubber Seat POWER TRIM 90-828631R3 MARCH 1999 Page 5B-39 Suction Seat Removal 1. Unscrew plug from manifold and remove ball. 2. Use a pin punch and knock the filter and suction seat out from the inside of the manifold cavity. CAUTION DO NOT use any tool on the suction seat as any damage to the surface will not allow the ball to seat. d a b c a - Filter b - Suction Seat c - Ball d - Plug Pilot Check Valve Assembly Removal 1. Unscrew both plugs. 2. Remove both springs and poppets. POWER TRIM Page 5B-40 90-828631R3 MARCH 1999 3. Use the (.060 wire) removal tool (see previous page) and push out the spool and one seat. 4. From opposite side, use a punch and push out the remaining seat. a b c d e d c b a a - Plug (2) b - Spring (2) c - Poppet Assembly (2) d - Seat (2) e - Spool (1) IMPORTANT: Inspect poppet assemblies for debris in the area shown. If debris is found on poppets replace poppets. a b a - Debris Under Valve Tip b - Rubber Seat 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 25-827668A1. Lubricate all O-rings with power trim fluid. Trim Motor Electrical Tests 1. Connect a 12 volt supply to motor leads. If motor fails to run, replace pump motor. IMPORTANT: Trim Motor is not serviceable. If motor fails to run, replace motor assembly. 90-828631R3 MARCH 1999 Page 5B-41 POWER TRIM Page 5B-42 90-828631R3 MARCH 1999 Reassembly O-Ring and Seal Placement O-Rings and Seals are part of O-Ring Kit 25-827668A1 a b c d e f h g i j k l m n o p q r t s u v w w w h i POWER TRIM O-Ring and Seal Placement O-Ring Description O-Ring I.D. O-Ring O.D. O-Ring Width a Actuator Pin 0.07 in. (1.78 mm) 0.21 in. (5.33 mm) 0.07 in. (1.78 mm) b Tilt Relief Cartridge 0.239 in. (6.07 mm) 0.379 in. (9.63 mm) 0.07 in. (1.78 mm) c Tilt Relief Cartridge 0.301 in. (7.65 mm) 0.441 in. (11.20 mm) 0.07 in. (1.78 mm) d Tilt Relief Plug 0.359 in. (9.12 mm) 0.565 in. (14.35 mm) 0.139 in. (3.53 mm) e Suction Seat 0.301 in. (7.65 mm) 0.441 in. (11.20 mm) 0.07 in. (1.78 mm) f Suction Seat Plug 0.487 in. (12.37 mm) 0.693 in. (17.60 mm) 0.103 in. (2.62 mm) g Spool 0.239 in. (6.07 mm) 0.379 in. (9.63 mm) 0.07 in. (1.78 mm) h P. O. Check Seat 0.364 in. (9.25 mm) 0.504 in. (12.80 mm) 0.07 in. (1.78 mm) i P. O. Check Plug 0.489 in. (12.42 mm) 0.629 in. (15.98 mm) 0.07 in. (1.78 mm) j Pump Ports 0.145 in. (3.68 mm) 0.285 in. (7.24mm) 0.07 in. (1.78 mm) k Pump Filter O-ring, Pump Filter - Square Cut l Reservoir/Motor 2.614 in. (66.40 mm) 2.754 in. (70.0 mm) 0.07 in. (1.78 mm) m Memory Piston 1.037 in. (26.34 mm) 1.457 in. (37.0 mm) 0.21 in. (5.33 mm) n Piston Bolt 0.364 in. (9.25 mm) 0.504 in. (12.80 mm) 0.07 in. (1.78 mm) o Shock Piston 1.171 in. (29.74 mm) 1.449 in. (36.80 mm) 0.139 in. (3.53 mm) p Cylinder Cap 1.364 in. (34.65 mm) 1.50 in. (38.10 mm) 0.07 in. (1.78 mm) q Wiper Ring r Cylinder Cap - Inner 0.546 in. (13.87 mm) 0.752 in. (19.10 mm) 0.139 in. (3.53 mm) s Manual Release Valve 0.239 in. (6.07 mm) 0.379 in. (9.63 mm) 0.07 in. (1.78 mm) t Manual Release Valve 0.176 in. (4.47 mm) 0.316 in. (8.03 mm) 0.07 in. (1.78 mm) u Manual Release Valve 0.114 in. (2.90 mm) 0.254 in. (6.45 mm) 0.07 in. (1.78 mm) v Reservoir Plug 0.426 in. (10.82 mm) 0.566 in. (14.38 mm) 0.07 in. (1.78 mm) w Check Valve O.D. I.D. Cutaway View of O-ring Width 90-828631R3 MARCH 1999 Page 5B-43 POWER TRIM Page 5B-44 90-828631R3 MARCH 1999 Power Trim Reassembly IMPORTANT: Lubricate all O-rings with Quicksilver Power Trim Fluid (92-90100A12). If not available, use automotive (ATF) automatic transmission fluid. Tilt Relief Valve Reassembly 1. Lubricate O-rings with power trim fluid. 2. Place actuator pin into pilot valve. 3. Install and seat the pilot valve into manifold. Seat the pilot valve using a 9/32, or 7 mm socket on OUTSIDE diameter of the pilot valve. IMPORTANT: The pilot valve must be seated using a suitable mandrel on the OUTSIDE diameter. 4. Install poppet, spring, shim (if used) and plug. Torque plug to specified torque. c f h b b b b d e g h a a - Tilt Relief Valve Assembly b - O-Rings c - Actuator Pin d - Pilot Valve e - Poppet Assembly f - Spring g - Shim h - Plug Plug Torque 120 lb-in. (13.5 Nm) POWER TRIM 90-828631R3 MARCH 1999 Page 5B-45 Suction Seat Reassembly 1. Lubricate O-rings with power trim fluid. 2. Install filter and suction seat using a 9/32” or 7 mm socket on OUTSIDE diameter of suction seat. 3. Install ball and plug. Torque plug to 120 lb-in. (13.5 Nm). d a b c a - Filter b - Suction Seat c - Ball d - Plug - Torque to 120 lb-in. (13.5 Nm) Pilot Check Valve Reassembly 1. Lubricate O-rings with power trim fluid. 2. Install one of the seats into manifold. Push the seat into place using a 9/32” or 7 mm socket on the OUTSIDE diameter of the seat. 3. Install corresponding poppet, spring and plug. 4. From the opposite side of the manifold, install spool and the other seat. Push the seat into place using a 9/32” or 7 mm socket on OUTSIDE diameter of seat. 5. Install remaining poppet, spring and plug. Torque plugs to 120 lb-in. (13.5 Nm). a a b b c c d d e a - Plug (2) - Torque to 120 lb-in. (13.5 Nm) b - Spring (2) c - Poppet (2) d - Seat (2) e - Spool POWER TRIM Oil Pump Reassembly 1. Install the down relief ball and spring into manifold. 2. Check to see that O-rings are placed on bottom of pump. 3. Place O-ring (square cut) on filter. 4. Place filter over the oil pump. 5. Install oil pump with two (2) screws. Torque screws to specified torque. a b c d e f g a-Screws (2) b-Oil Pump c-O-ring d-Filter e-Spring f-Down Relief Ball g-Pump O-Ring (2) Screw Torque 70 lb-in. (7.9 Nm) Page 5B-46 90-828631R3 MARCH 1999 POWER TRIM Trim Motor Reassembly 1. Align coupler between oil pump and motor. 2. Install trim motor and secure with four (4) screws. Torque screws to specified torque. a b c d e f a-Coupler b-O-ring c-Trim Pump Motor d-Ground Strap e-Lock Washer (1) f-Screws (4) Screw Torque 80 lb-in. (9.0 Nm) 90-828631R3 MARCH 1999 Page 5B-47 POWER TRIM Shock Rod Reassembly 1. Install lubricated O-rings to end cap. 2. Install rod wiper. 3. Install lubricated O-rings to shock piston. 51199 d e f 51145 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. CAUTION When installing shock rod piston, spanner wrench must have1/4 in. x 5/16 in. (6.4mm x8mm) long pegs to avoid damage to shock rod piston. 6. Apply Loctite Grade “A” (271) to threads on shock rod. 7. Install shock rod piston. 8. Tighten shock rod piston securely using spanner wrench (1/4 in. x 5/16 in. long pegs). If a torquing type spanner tool is used to tighten shock piston, then torque to specified torque. 51146 ab 51146 a-Shock Rod Piston b-Spanner Wrench Shock Rod Piston Torque 45 lb-ft (61 Nm) Page 5B-48 90-828631R3 MARCH 1999 POWER TRIM 9. Remove shock rod assembly from vise. 10. Install ball, seat, and spring (five sets) to shock rod piston. 51147 a b c a-Spring (5) b-Seat (5) c-Ball (5) 11. Secure components with shock piston bolt. Torque bolt to specified torque. a a-Bolt Bolt Torque 45 lb-ft (61 Nm) Shock Rod Installation 1. Place trim cylinder in soft jawed vice. 2. Install lubricated O-ring to memory piston and place into cylinder. Push memory piston all the way to bottom. a b a-Memory Piston b-O-ring 90-828631R3 MARCH 1999 Page 5B-49 POWER TRIM 3. Fill cylinder three inches (76.2 mm) from top of cylinder using Dexron III, (ATF) automatic transmission fluid. If not available, use Quicksilver Power Trim and Steering 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. CAUTION End cap must not make contact with shock rod piston when tightening. Shock rod piston must be positioned in cylinder deep enough to avoid contact. 5. Tighten end cap securely using spanner wrench [3/16 in. x 5/16 in. (4.8mm x 8mm) long pegs]. If a torquing type spanner tool is used to tighten end cap, then torque to specified torque. a a-Oil Blow Off Ball Passage End Cap Torque 45 lb-ft (61 Nm) Manual Release Valve Installation 1. Install “E” clip (if removed) and lubricate O-rings with power trim fluid. 2. Insert manual release valve into manifold and tighten securely. Page 5B-50 90-828631R3 MARCH 1999 POWER TRIM Bleeding Power Trim Unit 1. Secure power trim unit in soft jawed vise. 2. Remove reservoir plug. Add power trim fluid until it is even with the bottom of the fill hole. Reinstall plug. 3. Close the manual release valve. (Turn full clockwise.) a a-Reservoir Plug 4. Cycle system full up and down 3 times or until fluid level remains at proper level. Connect power trim wire to 12 volt source. . Up Direction . Down Blue + Positive Blue – Negative Green – Negative Green + Positive 5. Recheck fluid level with rod fully extended, add fluid if required and repeat cycle until fluid level stays even with the bottom of the fill hole. Power Trim System Installation 1. Lubricate lower pivot pin, mounting holes and bushings with 2-4-C Marine Lubricant. 2. Install lower pivot pin bushings into the clamp brackets and trim unit. a b2-4-C w/Teflon (92-850736A1) 95 a-Bushing (2) Install into each Clamp Bracket b-Bushing (2) Install into each side of Trim Unit 95 90-828631R3 MARCH 1999 Page 5B-51 POWER TRIM 3. Install lower pivot pin. Secure with flat washers and nuts. Torque nuts to specified torque. aa a-Nuts Nut Torque 18 lb-ft (24.4 Nm) 4. Install sacrificial anode to clamp brackets. Fasten ground strap between anode and clamp bracket. Torque bolts to specified torque. a b a-Ground Wire b-Sacrificial Anode Bolt Torque 60 lb-in. (6.8 Nm) 5. Lubricate the upper pivot pin and mounting holes with 2-4-C Marine Lubricant. 6. Fasten shock rod with the upper pivot pin. NOTE:Pivot pin should be installed with grooved end inserted first. 95 2-4-C w/Teflon (92-850736A1) 95 Page 5B-52 90-828631R3 MARCH 1999 POWER TRIM 7. Secure upper pivot pin with trilobe pin. Press trilobe pin in until its fully seated. a a-Trilobe Pin 8. Re-connect trim wire harness leads (see wiring diagram Section 2D for proper connections). 9. Recheck fluid level (tilt/trim rod fully extended). 10. Route wire harness through clamp bracket and cowling. 11. Secure wire harness with clamps as shown. 90-828631R3 MARCH 1999 Page 5B-53 POWER TRIM MID-SECTION Section 5C - Power Trim 1999 and Later Non-Bigfoot/All Big-Foot Model Years Table of Contents Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-2 Quicksilver Lubricants and Service Aids . . . . . . 5C-2 Power Trim Components . . . . . . . . . . . . . . . . . . . 5C-4 Theory Of Operation. . . . . . . . . . . . . . . . . . . . . . . 5C-6 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-6 Trimming Characteristics . . . . . . . . . . . . . . . . 5C-6 Trailering Outboard . . . . . . . . . . . . . . . . . . . . . 5C-7 Tilting Outboard Up and Down Manually . . . 5C-7 Power Trim Flow Diagrams . . . . . . . . . . . . . . . . . 5C-8 Trim Up Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 5C-8 Tilt Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-10 Maximum Tilt . . . . . . . . . . . . . . . . . . . . . . . . . 5C-12 Down Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . 5C-14 Shock Function Up . . . . . . . . . . . . . . . . . . . . 5C-16 Shock Function Return . . . . . . . . . . . . . . . . . 5C-18 Manual Release. . . . . . . . . . . . . . . . . . . . . . . 5C-20 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-22 Preliminary Checks . . . . . . . . . . . . . . . . . . . . 5C-22 Hydraulic System Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-23 Troubleshooting the Power Trim Electrical System . . . . . . . . . . . . . . . . . . . . . . 5C-27 Power Trim System Removal . . . . . . . . . . . . . . 5C-29 Power Trim Disassembly . . . . . . . . . . . . . . . . . . 5C-30 Trim Motor Removal . . . . . . . . . . . . . . . . . . . 5C-31 Pump and Components Removal . . . . . . . . 5C-31 Manifold Removal . . . . . . . . . . . . . . . . . . . . . 5C-32 Shock Rod Removal . . . . . . . . . . . . . . . . . . . 5C-33 Shock Rod Disassembly . . . . . . . . . . . . . . . . . . 5C-33 Memory Piston Removal . . . . . . . . . . . . . . . 5C-36 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . . 5C-37 Trim Motor Electrical Tests . . . . . . . . . . . . . . 5C-37 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-38 O-ring and Seal Placement . . . . . . . . . . . . . 5C-38 O-ring Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-39 O-ring Description and Sizes. . . . . . . . . . . . . . . 5C-40 Power Trim Reassembly . . . . . . . . . . . . . . . . . . 5C-41 Shock Rod Reassembly . . . . . . . . . . . . . . . . 5C-41 Shock Rod Installation . . . . . . . . . . . . . . . . . 5C-43 Trim Limit Assembly Installation . . . . . . . . . 5C-44 Manual Release Valve Installation . . . . . . . 5C-44 Manifold Installation . . . . . . . . . . . . . . . . . . . 5C-45 Oil Pump Installation. . . . . . . . . . . . . . . . . . . 5C-46 Pressure Operated Assembly Installation . 5C-46 Reservoir/Motor Installation . . . . . . . . . . . . . 5C-47 Bleeding Power Trim Unit . . . . . . . . . . . . . . 5C-48 Installation of Power Trim System . . . . . . . . . . 5C-48 5 C 90-828631R3 MARCH 1999 Page 5C-1 POWER TRIM Special Tools 1. Spanner Wrench P/N 91-74951 2. Lock-Ring Pliers P/N SRP-4 (Snap-On) 3. Expanding Rod P/N CG 41-11 (Snap- On) 4. Collet P/N CG 41-12 (Snap- On) Address Snap-On Tools Company 2801 - 80th Street Kenosha, Wisconsin 53143 Phone 414.656.5200 5. Heat Lamp P/N 91-63209 Quicksilver Lubricants and Service Aids Part No. Description 92-90100A12 Power Trim Fluid 92-850736A1 2-4-C w/Teflon Page 5C-2 90-828631R3 MARCH 1999 POWER TRIM Notes: 90-828631R3 MARCH 1999 Page 5C-3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 26 21 23 22 24 4 6 11 6 11 6 11 17 15 11 11 6 11 25 27 28 A E D C D B F POWER TRIM Page 5C-4 90-828631R3 MARCH 1999 Power Trim NOTE: Lubricate all O-rings using Quicksilver Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. NOTE: It is recommended that all O-rings be replaced when servicing tilt system. POWER TRIM Power Trim REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm – 1 POWER TRIM PUMP (NON-BIGFOOT) S/N- & UP POWER TRIM PUMP (BIGFOOT)– 1 – 1 POWER TRIM PUMP (NON-BIGFOOT) S/N- & BELOW POWER TRIM PUMP (BIGFOOT)– 1 1 1 SHOCK ROD KIT (S/N- & UP) 1 SHOCK ROD KIT (NON-BIGFOOT) S/N- & BELOW SHOCK ROD KIT (BIGFOOT)1 2 1 MEMORY PISTON ASSEMBLY 3 1 O RING REBUILD KIT 4 2 O RING 5 1 CYLINDER ASSEMBLY 66 1 TRIM LIMIT VALVE KIT (NON-BIGFOOT) 1 TRIM LIMIT VALVE KIT (BIGFOOT) 7 1 PUMP ASSEMBLY 8 1 MOTOR KIT 9 1 RESERVOIR PLUG 10 1 MANUAL RELEASE ASSEMBLY 11 1 MANIFOLD KIT 12 1 SCREW KIT (MOTOR) 13 1 DRIVE SHAFT 14 1 FILTER KIT 15 1 P.O. CHECK ASSEMBLY KIT 16 1 CABLE – 1 O RING KIT (COMPLETE TRIM) 17 2 GROOVE PIN 18 1 ANCHOR PIN 19 1 PIN – 1 TRIM HARNESS 20 1 HARNESS-Trim 21 2 RELAY 22 2 BRACKET 23 2 GROMMET 24 2 BUSHING 25 2 DECAL-Trim Relay 26 2 SCREW (M6 x 25) 27 2 PLUG 28 1 ADAPTOR HARNESS 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) 90-828631R3 MARCH 1999 Page 5C-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 5C-6 90-828631R3 MARCH 1999 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 90-828631R3 MARCH 1999 Page 5C-7 POWER TRIM Page 5C-8 90-828631R3 MARCH 1999 Power Trim Flow Diagrams ÍÍ ÍÍ Reservoir Oil Filtered Feed Oil Oil Under Pressure Return Oil Up Pressure 1625 psi (30-60 hp) 2800 psi (75-125 hp) mininmum Tilt Relief Pressure 250-400 psi (30-60 hp) 500-700 psi (40-60 hp Bigfoot) 540-990 psi (75-125 hp) Impact Relief Pressure #22 880-1110 psi (30-60 hp) 1220-1420 psi (75-125 hp) a b c d e g f h i j k l m o g p s r t u v w TRIM UP n q POWER TRIM Trim Up When the trim switch is activated in the up position, the electric motor (c) begins to rotate the oil pump gears (j), the oil pump draws a small amount of oil through the filter (g) and through the up circuit suction port (i). The oil pump gear (j) rotation forces oil into the passages for the up circuit. Oil, under pressure, will slide the shuttle valve (m) against the down circuit pressure operated valve (f). The shuttle valve will mechanically open the down pressure operated valve, allowing oil from the down cavity of the trim cylinder, to flow into the oil pump. This returning oil, from the down cavity, will supply most of the oil required for the up circuit. Oil in the up circuit is blocked from returning into the reservoir by the ball inside the down circuit suction port (k). The pressure of the oil will force the up circuit pressure operated valve (n) to open, allowing the oil to enter the passages inside the manifold (q) leading to the trim cylinder (w) up cavity. Oil is blocked from all other passages by the closed manual release valve (p). Oil under pressure will enter the trim cylinder below the memory piston (t). With an increasing amount of oil entering the cylinder, the memory piston contacts the shock piston (u) and forces the trim rod (a) up and out, raising the outboard motor. Oil on the top of the shock piston exits through a passage running down along the side of the cylinder and enters the manifold passages. The oil is drawn back into the pump (j) through the open down circuit pressure operated valve (f) and enters the pump as supply for the up circuit. a-Trim Rod b-End Cap c-Electric Motor d-Reservoir Oil e-Down Circuit Pressure Relief Valve f-Down Circuit Pressure Operated Valve g-Filter (2 shown for clarity) h-Shock Return Valve i-Up Circuit Suction Port j-Oil Pump Gears k-Down Circuit Suction Port l-Oil Fill Cap m-Shuttle Valve n-Up Circuit Pressure Operated Valve o-Manifold Reverse Suction Valve p-Manual Release Valve q-Manifold r-Tilt Relief Valve s-Tilt Relief Piston t-Memory Piston u-Shock Piston v-Impact Relief Valve w-Cylinder 90-828631R3 MARCH 1999 Page 5C-9 POWER TRIM Page 5C-10 90-828631R3 MARCH 1999 Tilt Up Tilt Relief Pressure 250-400 psi (30-60 hp) 500-700 psi (40-60 hp Bigfoot) 540-990 psi (75-125 hp) Up Pressure 1625 psi (30-60 hp) 2800 psi (75-125 hp) minimun Reservoir Oil Filtered Feed Oil Oil Under Pressure Return Oil ÍÍ ÍÍ Impact Relief Pressure #22 880-1110 psi (30-60 hp) 1220-1420 psi (75-125 hp) a b c d w u v t h e f g s r p o g m n j k i l q POWER TRIM Tilt Up In the up mode, as the trim rod (a) extends from the cylinder (w), the memory piston (t) clears or uncovers the pressure relief passage. Oil from the up cavity will enter this passage and, if required, causes the tilt relief piston (s) to open the tilt 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 decreases or if engine is not in forward gear, the oil pressure is available to extend the trim rod (a) up into the tilt range. a-Trim Rod b-End Cap c-Electric Motor d-Reservoir Oil e-Down Circuit Pressure Relief Valve f-Down Circuit Pressure Operated Valve g-Filter (2 shown for clarity) h-Shock Return Valve i-Up Circuit Suction Port j-Oil Pump Gears k-Down Circuit Suction Port l-Oil Fill Cap m-Shuttle Valve n-Up Circuit Pressure Operated Valve o-Manifold Reverse Suction Valve p-Manual Release Valve q-Manifold r-Tilt Relief Valve s-Tilt Relief Piston t-Memory Piston u-Shock Piston v-Impact Relief Valve w-Cylinder 90-828631R3 MARCH 1999 Page 5C-11 POWER TRIM Page 5C-12 90-828631R3 MARCH 1999 Maximum Tilt Up Pressure 1625 psi (30-60 hp) 2800 psi (75-125 hp) minimum ÍÍ ÍÍ Reservoir Oil Filtered Feed Oil Oil Under Pressure Return Oil Tilt Relief Pressure 250-400 psi (30-60 hp) 500-700 psi (40-60 hp Bigfoot) 540-990 psi (75-125 hp) Impact Relief Pressure #22 880-1110 psi (30-60 hp) 1220-1420 psi (75-125 hp) a v t w b h c d e f g s r p o n g m i j k l u q POWER TRIM Maximum Tilt With the trim 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 allowing the oil to flow into the trim relief passage, and returns back into the reservoir. a-Trim Rod b-End Cap c-Electric Motor d-Reservoir Oil e-Down Circuit Pressure Relief Valve f-Down Circuit Pressure Operated Valve g-Filter (2 shown for clarity) h-Shock Return Valve i-Up Circuit Suction Port j-Oil Pump Gears k-Down Circuit Suction Port l-Oil Fill Cap m-Shuttle Valve n-Up Circuit Pressure Operated Valve o-Manifold Reverse Suction Valve p-Manual Release Valve q-Manifold r-Tilt Relief Valve s-Tilt Relief Piston t-Memory Piston u-Shock Piston v-Impact Relief Valve w-Cylinder 90-828631R3 MARCH 1999 Page 5C-13 POWER TRIM Page 5C-14 90-828631R3 MARCH 1999 Trim Down Up Pressure 1625 psi (30-60 hp) 2800 psi (75-125 hp) minimum ÍÍ ÍÍ Reservoir Oil Filtered Feed Oil Oil Under Pressure Return Oil Tilt Relief Pressure 250-400 psi (30-60 hp) 500-700 psi (40-60 hp Bigfoot) 540-990 psi (75-125 hp) Impact Relief Pressure #22 880-1110 psi (30-60 hp) 1220-1420 psi (75-125 hp) a w b c d i j k l m n g o p s r h g f e t u v q POWER TRIM Trim Down When the trim switch is activated in the down position, the electric motor (c) will rotate the oil pump gears (j) in the opposite direction. With the oil pump gears rotating backwards, the flow of oil is reversed. Oil is drawn through the filter (g), through the down circuit suction port (k) and into the oil pump gears (j). The pump forces pressurized oil into the down passages, oil will slide the shuttle valve (m) into the up circuit pressure operated valve (n). The shuttle valve will mechanically open the up circuit pressure operated valve and allow oil, from the up cavity of the trim cylinder (w), to return into the oil pump. This returning oil, from the up cavity, will supply the oil required for the down circuit. The oil is blocked from returning into the reservoir by the ball (i) inside the up circuit suction port. Oil, under pressure, opens the down circuit pressure operated valve (f) and enters the down passages inside of the manifold (q). The manifold passage connects into the trim cylinder passage leading to the top of the cylinder. The cavity, inside the cylinder, above the shock piston (u) is the down cavity. As the down cavity fills with oil, the trim rod (a) retracts into the cylinder, lowering the outboard motor. Oil from the up cavity exits the cylinder and is drawn back into the pump through the open up circuit pressure operated valve (n). When the trim rod reached full travel, the oil pressure inside the down circuit will rise until the down circuit pressure relief valve (e) opens, bypassing oil back into the reservoir. When the trim button is released, and the oil pump stops supplying pressure, both of the pressure operated valves (f & n) will close and; if open, the down circuit pressure relief valve (e) will close. The closed valves will lock the fluid on either side of the shock piston (u) & memory piston (t), holding the outboard motor in position. a-Trim Rod b-End Cap c-Electric Motor d-Reservoir Oil e-Down Circuit Pressure Relief Valve f-Down Circuit Pressure Operated Valve g-Filter (2 shown for clarity) h-Shock Return Valve i-Up Circuit Suction Port j-Oil Pump Gears k-Down Circuit Suction Port l-Oil Fill Cap m-Shuttle Valve n-Up Circuit Pressure Operated Valve o-Manifold Reverse Suction Valve p-Manual Release Valve q-Manifold r-Tilt Relief Valve s-Tilt Relief Piston t-Memory Piston u-Shock Piston v-Impact Relief Valve w-Cylinder 90-828631R3 MARCH 1999 Page 5C-15 POWER TRIM Page 5C-16 90-828631R3 MARCH 1999 Shock Function Up Up Pressure 1625 psi (30-60 hp) 2800 psi (75-125 hp) minimum ÍÍ ÍÍ Reservoir Oil Oil Under Pressure Return Oil Tilt Relief Pressure 250-400 psi (30-60 hp) 500-700 psi (40-60 hp Bigfoot) 540-990 psi (75-125 hp) Impact Relief Pressure #22 880-1110 psi (30-60 hp) 1220-1420 psi (75-125 hp) a b c w v u t h d e f g i j k l n m g o p s r q POWER TRIM Shock Function Up Oil inside the down cavity is locked in a static position by the closed down circuit pressure operated valve (f), the manual release valve (p) and the manifold reverse suction valve (o). If the outboard strikes an underwater object while in forward gear, the trim rod (a) will try to rapidly extend from the cylinder (w), the pressure increases inside the trim cylinder down cavity and connecting passages. When the pressure increases to the level required, the impact relief valves (v), located inside the shock piston (u), will open and allow the fluid to pass through the shock piston. As the fluid passes through the piston, the trim rod (a) will extend from the trim cylinder. The memory piston (t) is held in position by vacuum, created by the oil in the up cavity being locked in a static position. Therefore; oil passing through the shock piston is trapped between the memory piston (t) and shock piston (u). a-Trim Rod b-End Cap c-Electric Motor d-Reservoir Oil e-Down Circuit Pressure Relief Valve f-Down Circuit Pressure Operated Valve g-Filter (2 shown for clarity) h-Shock Return Valve i-Up Circuit Suction Port j-Oil Pump Gears k-Down Circuit Suction Port l-Oil Fill Cap m-Shuttle Valve n-Up Circuit Pressure Operated Valve o-Manifold Reverse Suction Valve p-Manual Release Valve q-Manifold r-Tilt Relief Valve s-Tilt Relief Piston t-Memory Piston u-Shock Piston v-Impact Relief Valve w-Cylinder 90-828631R3 MARCH 1999 Page 5C-17 POWER TRIM Page 5C-18 90-828631R3 MARCH 1999 Shock Function Return Up Pressure 1625 psi (30-60 hp) 2800 psi (75-125 hp) minimum ÍÍ ÍÍ Reservoir Oil Oil Under Pressure Return Oil Tilt Relief Pressure 250-400 psi (30-60 hp) 500-700 psi (40-60 hp Bigfoot) 540-990 psi (75-125 hp) Impact Relief Pressure #22 880-1110 psi (30-60 hp) 1220-1420 psi (75-125 hp) a b c w v u t h d i j k l m n e f g g o p s r q POWER TRIM Shock Function Return After the engine clears the under water object, the weight of the engine will increase the oil pressure between the memory piston (t) and shock piston (u) to the level required to open the shock return valve (h), inside the shock piston, allowing the oil to bleed back through the shock piston into the down cavity. If required, additional oil will enter the down cavity through the manifold reverse suction valve (o). This will return the engine back against the memory piston (t) and into the original running position. a-Trim Rod b-End Cap c-Electric Motor d-Reservoir Oil e-Down Circuit Pressure Relief Valve f-Down Circuit Pressure Operated Valve g-Filter (2 shown for clarity) h-Shock Return Valve i-Up Circuit Suction Port j-Oil Pump Gears k-Down Circuit Suction Port l-Oil Fill Cap m-Shuttle Valve n-Up Circuit Pressure Operated Valve o-Manifold Reverse Suction Valve p-Manual Release Valve q-Manifold r-Tilt Relief Valve s-Tilt Relief Piston t-Memory Piston u-Shock Piston v-Impact Relief Valve w-Cylinder 90-828631R3 MARCH 1999 Page 5C-19 POWER TRIM Page 5C-20 90-828631R3 MARCH 1999 Manual Tilt ÍÍ ÍÍ Reservoir Oil Return Oil Filtered Oil Down Pressure 525-880 psi Up Pressure 1625 psi (30-60 hp) 2800 psi (75-125 hp) minimum Tilt Relief Pressure 250-400 psi (30-60 hp) 500-700 psi (40-60 hp Bigfoot) 540-990 psi (75-125 hp) Impact Relief Pressure #22 880-1110 psi (30-60 hp) 1220-1420 psi (75-125 hp) f g a b c w v u t h d i j k l m n g o p s r q e f g POWER TRIM Manual Tilt To manually tilt the outboard engine, the owner will need to back out the manual release valve (p) 3-4 turns. With the valve backed out, the internal passages inside the manifold are connected together. These passages connect both the cylinder down and up cavities together, along with the reservoir, allowing the engine to be raised or lowered. Trim rod (a) movement will continue until the manual release valve (p) is closed, locking the fluid inside of the cylinder and manifold. a-Trim Rod b-End Cap c-Electric Motor d-Reservoir Oil e-Down Circuit Pressure Relief Valve f-Down Circuit Pressure Operated Valve g-Filter (2 shown for clarity) h-Shock Return Valve i-Up Circuit Suction Port j-Oil Pump Gears k-Down Circuit Suction Port l-Oil Fill Cap m-Shuttle Valve n-Up Circuit Pressure Operated Valve o-Manifold Reverse Suction Valve p-Manual Release Valve q-Manifold r-Tilt Relief Valve s-Tilt Relief Piston t-Memory Piston u-Shock Piston v-Impact Relief Valve w-Cylinder 90-828631R3 MARCH 1999 Page 5C-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 5C-22 90-828631R3 MARCH 1999 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 90-828631R3 MARCH 1999 Page 5C-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 5C-24 90-828631R3 MARCH 1999 POWER TRIM Hydraulic System Troubleshooting Flow Chart TRIM SYSTEM LEAKS DOWN WITH MANUAL RELEASE VALVE CLOSED. Inspect manual release valve.Manual release valve and O-ring damaged. Replace manual re- lease valve and O-rings. Trim system does not leak down. Test- ing complete. Trim system leaks down. Manual release valve and O- rings appear to be O.K. - Clean and reinstall manual release valve. Trim system does not leak down. Test- ing complete. Remove tilt relief valving and inspect O-rings and seals for debris and/or damage. Debris and/or dam- age identified. Replace tilt relief valving. Trim system does not leak down. Test- ing complete. Trim system leaks down. Tilt relief valving and O-rings appear to be O.K. - Clean and reinstall tilt relief valving. Trim system does not leak down. Test- ing complete. Remove PO check valve assembly, inspect O- rings and seals for dam- age. Debris and/or dam- age identified. Replace PO check valve assembly. PO check valve appears O.K. - Clean and reinstall PO check valve assem- bly. continued on next page Trim system leaks down. Trim system does not leak down. Testing complete. Trim system does not leak down. Test- ing complete. 90-828631R3 MARCH 1999 Page 5C-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 5C-26 90-828631R3 MARCH 1999 POWER TRIM Troubleshooting the Power Trim Electrical System LT.BLU/WHT GRN/WHT BLUE 14 BLKRED BLK DN UP AB RED RED/PUR DN UP LT. GRN/WHT LT. BLU/WHT RED GRN/WHT BLU/WHT DN UP GRN/WHT BLU/WHT Solenoid RED GRN/WHT or GRN BLU/WHT or PUR GRN 14 BLKRED BLK +– LT. GRN/WHT LT. BLU/WHT RED/PUR a j k h g e f c d c b 1 2 3 4 i a-Trim Switch (Remote Control Mounted) g-Down Relay b-Trim Switch (Panel Mounted) h-Up Relay c-Fuse Holder i-Solenoid d-Remote Control Wiring Plug Connector j-Trim Pump Motor e-Battery k-Cowl Switch f-Starter Bolt 90-828631R3 MARCH 1999 Page 5C-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 5C-28 90-828631R3 MARCH 1999 POWER TRIM 90-828631R3 MARCH 1999 Page 5C-29 Power Trim System Removal 1. Tilt outboard to the full up position and support with tilt lock pin. 2. Disconnect the power trim wire harness and remove clamp. 55264 b c 55464 a a - Tilt Lock Pin b - Power Trim Wire Harness Clamp c - Harness 3. Remove the trilobe pin. 4. Drive out the upper pivot pin. 5. Remove the sacrificial anode. 55331 c b a a - Trilobe Pin b - Upper Pivot Pin c - Sacrificial Anode POWER TRIM 6. Use suitable punch to remove (Drive Down) lower pin. Retain dowel pin. 7. Use suitable punch to drive out lower pivot pin. 51144 51144 ba a-Dowel Pin b-Lower Pivot Pin Power Trim Disassembly IMPORTANT: Power trim system is pressurized. Trim rod must be in the full “UP” position (fully extended) prior to fill/drain plug, or manual release valve removal. 1. Remove reservoir cap. 2. Remove manual release valve assembly to drain oil. 55263 b a a-Reservoir Cap b-Manual Release Valve Page 5C-30 90-828631R3 MARCH 1999 POWER TRIM 90-828631R3 MARCH 1999 Page 5C-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 5C-32 90-828631R3 MARCH 1999 IMPORTANT: Inspect poppet assembly for debris in the area shown. If debris is found on poppet replace poppet. 2. Remove three (3) screws to remove pump. Remove filter and filter seal under pump. Remove suction seat assembly. d c e f b a a - Debris Under Valve Tip b - Rubber Seat c - Screws (3) d - Filter Seal e - Filter f - Suction Seat Assembly Manifold Removal 1. Remove two (2) screws to remove manifold from cylinder. 2. Remove tilt relief components. 51146 a 51008 b c d e a - Screws (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. (6.4 mm x 8 mm) 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 90-828631R3 MARCH 1999 Page 5C-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 5C-34 90-828631R3 MARCH 1999 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 90-828631R3 MARCH 1999 Page 5C-35 POWER TRIM Memory Piston Removal 1. Remove memory piston from cylinder using one of two methods: a. Using lock ring pliers P/N SRP-4 (Snap-On) or suitable tool. SRP-4 (Snap-On) b. Blowing compressed air into manual release valve hole using air nozzle. WARNING Memory piston cup may be expelled at a high velocity when air pressure is applied. Failure to place cylinder as shown below could result in personal injury. NOTE: Point cylinder opening down and away. Use a shop rag or towel to avoid damage to the memory piston. 2. Remove O-ring from memory piston. 51144 d e 55466 a c b a-Adaptor/Air Hose b-Memory Piston Exit c-Shop Rag d-O-ring e-Memory Piston Page 5C-36 90-828631R3 MARCH 1999 POWER TRIM Cleaning/Inspection/Repair IMPORTANT: Components must be dirt and lint free. Slightest amount of debris in Power Trim system could cause system to malfunction. Clean shock rod and components with parts cleaner and dry with compressed air. It is recommended that all O-rings in trim system be replaced. Use O-ring Kit 25-809880A1. Lubricate all O-rings with Quicksilver Power Trim Fluid (92-90100A12). If not available, use automotive (ATF) automatic transmission fluid. Trim Motor Electrical Tests 1. Connect a 12 volt supply to motor leads. If motor fails to run, replace pump motor. IMPORTANT: Trim Motor is not serviceable. If motor fails to run, replace motor assembly. 90-828631R3 MARCH 1999 Page 5C-37 POWER TRIM Page 5C-38 90-828631R3 MARCH 1999 Reassembly O-Ring and Seal Placement O-rings and Seals are part of O-ring Kit 25-809880A1 3 21 22 19 22 4 5 1 20 8 9 10 18 9 7 6 15 16 17 8 9 10 14 13 11 12 POWER TRIM 90-828631R3 MARCH 1999 Page 5C-39 O-ring Sizes O.D. I.D. Cutaway View of O-Ring Width O-RINGS SHOWN ARE ACTUAL SIZE 22 4 11 10 8 6 5 2211 1199 1166 20 15 18 17 12 33 11 2 2 99 77 1133 1144 POWER TRIM O-ring Description and Sizes O-Ring Description O-Ring I.D. O-Ring O.D. O-Ring Width 1 Wiper Ring 2 Cyl. Cap, Inner 0.671 in. (17.04 mm) 0.949 in. (24.10 mm) 0.139 in. (3.53 mm) 3 Cyl. Cap 1.864 in. (47.34 mm) 2.004 in. (50.90 mm) 0.07 in. (1.78 mm) 4 Shock Piston 1.6 in. (40.64 mm) 2.02 in. (53.086 mm) 0.21 in. (5.334 mm) 5 Piston 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 5C-40 90-828631R3 MARCH 1999 POWER TRIM Power Trim Reassembly IMPORTANT: Lubricate all O-rings with Quicksilver Power Trim Fluid (92-90100A12). If not available, use automotive (ATF) automatic transmission fluid. Shock Rod Reassembly 1. Install lubricated O-rings to end cap. 2. Install rod wiper. 3. Install lubricated O-rings to shock piston. 51199 f d e a b c 51145 a-Rod Wiper b-Inner O-ring c-Outer O-ring d-Shock Piston e-O-ring f-O-ring 4. Clamp shock rod in soft jawed vise. 5. Position cylinder end cap onto rod as shown. 51146 CAUTION When installing shock rod piston, spanner wrench must have1/4 in. x 5/16 in. (6.4mm x 8mm) long pegs to avoid damage to shock rod piston. 6. Apply Loctite Grade “A” (271) to threads on shock rod. 7. Install shock rod piston. 90-828631R3 MARCH 1999 Page 5C-41 POWER TRIM 8. Tighten shock rod piston securely using spanner wrench (1/4 in. x 5/16 in. long pegs). If a torquing type spanner tool is used to tighten shock piston, then torque to specified torque. 51146 b a a-Shock Rod Piston b-Spanner Wrench Shock Piston Torque 90 lb-ft (122 Nm) 9. Remove shock rod assembly from vise. 10. Install ball, seat, and spring (five sets) to shock rod piston. 11. Secure components with plate. Torque screws to specified torque. 51147 e d c a b a-Screw (3) b-Plate c-Spring (5) d-Seat (5) e-Ball (5) Screw Torque 35 lb-in. (4 Nm) Page 5C-42 90-828631R3 MARCH 1999 POWER TRIM Shock Rod Installation 1. Place trim cylinder in soft jawed vice. 2. Install lubricated O-ring to memory piston and place into cylinder. Push memory piston all the way to bottom. 3. Fill cylinder three inches (76.2 mm) from top of cylinder using Quicksilver Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. 4. Install shock rod into cylinder until power trim fluid flows through oil blow off ball passage. Fill remaining cylinder to just below the cylinder threads. c a b a-Memory Piston b-O-ring c-Oil Blow Off Ball Passage CAUTION End cap must not make contact with shock rod piston when tightening. Shock rod piston must be positioned in cylinder deep enough to avoid contact. 5. Tighten end cap securely using spanner wrench [1/4 in. x 5/16 in. (6.4 mm x 8 mm) long pegs]. If a torquing type spanner tool is used to tighten end cap, then torque to specified torque. End Cap Torque 45 lb-ft (61 Nm) 90-828631R3 MARCH 1999 Page 5C-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 5C-44 90-828631R3 MARCH 1999 POWER TRIM Manifold Installation 1. Install dowel pin and two (2) lubricated O-rings into trim cylinder. b a a-O-ring (2) b-Dowel Pin 2. Align the trim cylinder and pump/reservoir assembly together. 3. Install the two (2) long screws and torque to specified torque. 51146 a b c a-Trim Cylinder Assembly b-Reservoir/Manifold Assembly c-Screw (2) Screw Torque 100 lb-in. (11 Nm) 90-828631R3 MARCH 1999 Page 5C-45 POWER TRIM Page 5C-46 90-828631R3 MARCH 1999 Oil Pump Installation 1. Install spring, ball, lubricated O-ring and plastic seat to manifold. 2. Check to see that O-rings are placed on bottom of pump. 3. Install filter and filter seal under pump. Install pump onto manifold. Torque screws to specified torque. b a a - Screw (3) b - Suction Seat Assembly Screw Torque 70 lb-in. (7.7 Nm) Pressure Operated Assembly Installation IMPORTANT: Inspect poppet assembly for debris in the area shown. If debris is found on poppet, replace poppet. a b a - Debris Under Valve Tip b - Rubber Seat 1. Lubricate O-rings. POWER TRIM 90-828631R3 MARCH 1999 Page 5C-47 2. Install spool, seat with O-ring, check valve/poppet, spring and plug with O-ring into pump. Repeat for other side. Torque plugs to 120 lb-in. (13.5 Nm). d b a c a b d e c a - Plug (2) Torque to 120 lb-in. (13.5 Nm) b - Spring (2) c - Check Valve/Poppet (2) d - Seat (2) e - Spool Reservoir/Motor Installation 1. Install coupler into top of pump. Make sure reservoir seal is in the reservoir groove and place reservoir onto pump/manifold assembly. Install ground strap under screw shown. Torque screws to 80 lb-in. (9 Nm). a b c d f e a - Screw (4) Torque to 80 lb-in. (9 Nm) b - Reservoir c - Reservoir Seal d - Coupler e - Manifold Assembly f - Ground Strap 2. Fill reservoir to bottom of fill hole using Quicksilver Power Trim Fluid (92-90100A12). If not available, use automotive (ATF) automatic transmission fluid. POWER TRIM Bleeding Power Trim Unit 1. Secure power trim unit in soft jawed vise. 2. Add power trim fluid until it is even with the bottom of the fill hole. Reinstall plug. 3. Close the manual release valve. (Turn full clockwise). 55263 a b a-Reservoir Plug/Fill Hole b-Manual Release Valve 4. Cycle system full up and down 3 times or until fluid level remains at proper level. Connect power trim wire to 12 volt source. . Up Direction . Down Blue + Positive Blue – Negative Green – Negative Green + Positive 5. Recheck fluid level with rod fully extended, add fluid if required and repeat cycle until fluid level stays even with the bottom of the fill hole. Installation of Power Trim System 1. Lubricate lower pivot pin, mounting holes with 2-4-C Marine Lubricant. 2. Start lower pivot pin into pivot pin bore and position lower dowel pin (retained) in its respective hole. 51148 b 95 a 95 2-4-C w/Teflon (92-850736A1) a-Lower Pivot Pin b-Lower Dowel Pin Page 5C-48 90-828631R3 MARCH 1999 POWER TRIM 3. Position trim cylinder assembly (bottom first) between clamp brackets. 4. Apply 2-4-C Marine Lubricant to lower pivot pin. Using a suitable punch, drive lower pivot pin into clamp bracket and trim cylinder assembly until pivot pin is flush with outside surface. 51147 95b 55467 a 95 2-4-C w/Teflon (92-850736A1) a-Trim Cylinder Assembly b-Lower Pivot Pin 5. Using a suitable punch, drive lower dowel pin into its hole until seated. 6. Apply 2-4-C Marine Lubricant to surface of upper pivot pin, pivot pin bore and trim ram bore. 95 a 2-4-C w/Teflon (92-850736A1) a-Lower Dowel Pin b-Pivot Pin c-Pivot Pin Bore d-Trim Ram Bore 51148 95 b c d 51148 90-828631R3 MARCH 1999 Page 5C-49 POWER TRIM Page 5C-50 90-828631R3 MARCH 1999 7. Using a suitable mallet, drive upper pivot pin into swivel bracket and through trim ram until pivot pin is flush with swivel bracket. 8. Drive pivot pin into its hole until seated. 55464 d 51148 b c a a - Pivot Pin b - Swivel Bracket c - Trim Ram d - Trilobe Pin 9. Install sacrificial aluminum anode to reservoir bracket placing ground strap between bracket and anode, as shown. 10. Route trim harness through clamp bracket and cowling. 55264 d c 55465 b a a - Sacrificial Anode b - Ground Strap c - Bracket d - Trim Harness POWER TRIM 11. Secure trim harness with clamp, as shown. a-Clamp 55264 a 90-828631R3 MARCH 1999 Page 5C-51 MANUAL TILT ASSIST MID-SECTION Section 5D - Manual Tilt Assist Table of Contents Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-1 Manual Tilt Components . . . . . . . . . . . . . . . . . . . 5C-2 Manual Trim Flow Diagrams . . . . . . . . . . . . . . . . 5C-4 Up Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-4 Down Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-6 Slow Tilt Down Under High Thrust . . . . . . . . 5C-8 Under Water Strike (Valves Open) . . . . . . . 5C-10 Shock Function (Valves Closed) . . . . . . . . . 5C-12 Shock Function Return . . . . . . . . . . . . . . . . . 5C-14 Hydraulic System Troubleshooting . . . . . . . . . . 5C-16 Manual Tilt System Removal . . . . . . . . . . . . . . . 5C-18 Manual Tilt System Disassembly . . . . . . . . . . . 5C-19 Accumulator Removal . . . . . . . . . . . . . . . . . . 5C-20 Shock Rod Removal . . . . . . . . . . . . . . . . . . . 5C-21 Shock Rod Disassembly . . . . . . . . . . . . . . . . . . 5C-21 Valve Block Removal . . . . . . . . . . . . . . . . . . 5C-24 Memory Piston Removal . . . . . . . . . . . . . . . 5C-24 Valve Block Disassembly . . . . . . . . . . . . . . . . . . 5C-26 Reassembly - O-Ring and Seal Placement . . 5C-27 Actual O-Ring Sizes . . . . . . . . . . . . . . . . . . . . . . 5C-28 O-Ring Description and Sizes. . . . . . . . . . . . . . 5C-29 Manual Tilt System Cleaning and Inspection . 5C-29 Manual Tilt System Reassembly . . . . . . . . . . . 5C-29 Valve Block Installation . . . . . . . . . . . . . . . . . 5C-32 Shock Rod Reassembly . . . . . . . . . . . . . . . . 5C-33 Shock Rod Installation and Fluid Filling Procedure . . . . . . . . . . . . . . . . . . . . . . 5C-35 Filling Procedure Option Two Instructions for Making Retaining Tool . . . . . . . . . . . . . . . . . 5C-37 Bleeding Manual Tilt System . . . . . . . . . . . . . . . 5C-38 Manual Tilt System Installation . . . . . . . . . . . . . 5C-40 Manual Release Valve Adjustment . . . . . . . 5C-42 5 D Special Tools 1. Spanner Wrench P/N 91-74951 2. Heat Lamp P/N 91-63209 3. Lock-Ring Pliers P/N SRP-4 (Snap-On) Address Snap-On Tools Company 2801 - 80th Street Kenosha, Wisconsin 53143 Phone 414.656.5200 90-828631R3 MARCH 1999 Page 5D-1 MANUAL TILT ASSIST Page 5D-2 90-828631R3 MARCH 1999 Manual Tilt Components 7 95 7 Loctite 271 (92-809819) 95 2-4-C With Teflon (92-850736A1) 95 1 13 12 3 4 4 2 7 9 9 8 11 12 13 5 8 11 11 8 10 6 8 11 6 8 11 A F E D B C NOTE: Lubricate all O-rings using Quicksilver Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. NOTE: It is recommended that all O-rings be replaced when servicing tilt system. MANUAL TILT ASSIST Manual Tilt Components REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 11 1 SHOCK ROD ASSEMBLY 45 61 1 SHOCK ROD ASSEMBLY (BEACHING) 2 1 MEMORY PISTON ASSEMBLY 3 1 O RING REBUILD KIT-Cylinder 4 2 O RING 5 1 CYLINDER ASSEMBLY 6 1 SCREW AND SEAL KIT 7 1 ACCUMULATOR ASSEMBLY 35 47 8 1 VALVE BODY ASSEMBLY 9 1 CAM KIT 10 1 VELOCITY VALVE KIT 75 6.2 8.5 11 1 CHECK SYSTEM REPAIR KIT 75 6.2 8.5 – 1 O RING KIT 12 2 PIN 13 2 GROOVE PIN A – Torque cylinder cap to 45 lb-ft (61 Nm) B – Torque Accumulator to 35 lb-ft (47 Nm) C – Torque Velocity Valve to 75 lb-in. (8.5 Nm) D – Torque Transfer Valve Plug to 75 lb-in. (8.5 Nm) E – Torque Screw to 100 lb-in. (11 Nm) F – Torque Shock Piston to 90 lb-ft (122 Nm) 90-828631R3 MARCH 1999 Page 5D-3 MANUAL TILT ASSIST Page 5D-4 90-828631R3 MARCH 1999 Manual Trim Flow Diagrams Up Circuit a b c d e f j i h g k l m n o p 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. 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 90-828631R3 MARCH 1999 Page 5D-5 MANUAL TILT ASSIST Page 5D-6 90-828631R3 MARCH 1999 Down Circuit a b c d p o n m l j k i h g f e 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. 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 90-828631R3 MARCH 1999 Page 5D-7 MANUAL TILT ASSIST Page 5D-8 90-828631R3 MARCH 1999 Slow Tilt Down Under High Thrust a b p c d f e j i h g k l m n o 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. 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 90-828631R3 MARCH 1999 Page 5D-9 MANUAL TILT ASSIST Page 5D-10 90-828631R3 MARCH 1999 Under Water Strike (Valves Open) a b p o n m l k j i h g f e d c 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). 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 90-828631R3 MARCH 1999 Page 5D-11 MANUAL TILT ASSIST Page 5D-12 90-828631R3 MARCH 1999 Shock Function (Valves Closed) Accumulator Gas Pressure 400 psi a b o n m p l k j i h g f d c e 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). 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 90-828631R3 MARCH 1999 Page 5D-13 MANUAL TILT ASSIST Page 5D-14 90-828631R3 MARCH 1999 Shock Function Return a b p o n m l j k i h g f e d c 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. 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 90-828631R3 MARCH 1999 Page 5D-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 5D-16 90-828631R3 MARCH 1999 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) 90-828631R3 MARCH 1999 Page 5D-17 MANUAL TILT ASSIST Manual Tilt System Removal CAUTION Remove cowling and remove all spark plug leads from spark plugs to prevent accidental starting while servicing outboard. WARNING Service or installation of the tilt system may result in loss of pressure in the shock cylinder. If the outboard is not in the full down position, such loss of pressure will cause the engine to fall to the full down position with a potential for damaging engine or causing personal injury. To avoid such injury support outboard in the up position using tilt lock lever. WARNING Manual tilt system is pressurized. Accumulator must be removed when shock rod is in the full up position, prior to servicing, otherwise oil spray-back may occur. 1. Support outboard in the up position using tilt lock lever. 2. Remove link rod. 3. Position piece of wood under transom bracket instead of tilt lock for access of removing pin. Use suitable punch to remove (DRIVE DOWN) upper dowel pin. Retain dowel pin. 51143 b a a-Link Rod b-Accumulator c-Dowel Pin d-Wood 51144 c d Page 5D-18 90-828631R3 MARCH 1999 MANUAL TILT ASSIST 4. Position tilt lock and remove piece of wood. Use suitable punch to drive out upper pivot pin. 5. Use punch to remove (Drive Down) lower dowel pin. Retain dowel pin. 51144 51144 b a c a-Pivot Pin b-Tilt Lock c-Dowel Pin 6. Use suitable punch to drive out lower pivot pin. 7. Tilt shock absorber assembly (TOP FIRST) out from clamp bracket and remove assembly. 51144 b 1 2 51144 a a-Pivot Pin b-Manual Tilt System Manual Tilt System Disassembly NOTE: Accumulator contains a high pressure nitrogen charge and is NOT SERVICEABLE. Replace if necessary. WARNING This tilt system is pressurized. Remove accumulator only when shock rod is in full up position. 90-828631R3 MARCH 1999 Page 5D-19 MANUAL TILT ASSIST Accumulator Removal 1. Place manual tilt system in soft jawed vise. 2. Position shock rod to full up position. 3. Open cam shaft valve (Down Position). 4. Loosen velocity valve enough to drip, wait until dripping stops. 5. When fluid stops dripping, loosen and remove accumulator. 6. If plunger can be compressed into accumulator by hand, accumulator is defective. Replace accumulator. 51143 d 51143 c a b a-Accumulator b-Cam Lever c-Velocity Valve d-Plunger 7. Once accumulator is removed, remove O-ring, conical spring, steel ball and plunger. 51145 d c b a a-Conical Spring b-Steel Ball c-Plunger d-O-ring Page 5D-20 90-828631R3 MARCH 1999 MANUAL TILT ASSIST Shock Rod Removal 1. Unscrew cylinder end cap assembly using spanner wrench [1/4 in. x 5/16 in. long pegs]. 2. Remove shock rod assembly from cylinder. 91-74951 51145 Shock Rod Disassembly NOTE:The only serviceable items on the shock rod assembly are the O-rings and wiper ring. If shock rod requires any other repair, replace shock rod assembly. b c a a-End Cap b-O-ring (2) c-Wiper Ring 1. Place shock rod assembly on clean work surface. 2. Remove three (3) screws and remove plate from shock rod piston. 51143 a b c a-Screw (3) b-Plate c-Shock Rod Piston 90-828631R3 MARCH 1999 Page 5D-21 MANUAL TILT ASSIST 3. Remove check ball components from shock rod piston. 4. Remove O-ring. 51147 d c b a a-Spring (5) b-Seat (5) c-Ball (5) d-O-ring CAUTION When removing shock piston, spanner wrench must have 1/4 in. x 5/16 in. long pegs to avoid damage to shock piston. 5. Place shock rod into soft jawed vise and apply heat to loosen piston using torch lamp (P/N 91-63209). 6. Loosen shock rod piston using spanner wrench [1/4 in. x 5/16 in. (6.4mm x 8mm) long pegs]. 7. Allow shock rod piston to cool. Remove from shock rod. 91-63209 a-Spanner Wrench b-Shock Rod Piston b a 91-74951 Page 5D-22 90-828631R3 MARCH 1999 MANUAL TILT ASSIST 8. Inspect check valve for debris; clean debris from check valve if found. If debris cannot be cleaned from check valve, replace shock piston as an assembly. 9. Clean shock and components with compressed air. 10. Remove inner O-ring. 51199 b a a-Shock Piston b-O-ring 11. Remove cylinder end cap assembly from shock rod. 12. Inspect shock. If wiper (located in cap) has failed to keep rod clean, replace wiper. 13. Place end cap on clean work surface. 14. Remove rod wiper, inner O-ring, and outer O-ring. 51145 51147 c b a a-Rod Wiper b-Inner O-ring c-Outer O-ring 90-828631R3 MARCH 1999 Page 5D-23 MANUAL TILT ASSIST Valve Block Removal 1. Remove two screws from the shock rod cylinder to separate the valve block. 2. Remove O-rings and dowel pins. 51148 51146 b c a d e a-Screw b-Valve Block c-Shock Rod Cylinder d-O-ring (2) e-Dowel Pin (2) Memory Piston Removal 1. Remove memory piston from cylinder using one of two methods: a. Using lock ring pliers P/N SRP-4 (Snap-On) or suitable tool. SRP-4 (Snap-On) Page 5D-24 90-828631R3 MARCH 1999 MANUAL TILT ASSIST b. Blowing compressed air into center O-ring hole. WARNING Memory piston cup may be expelled at a high velocity when air pressure is applied. Failure to place cylinder as shown below could result in personal injury. NOTE: Point cylinder opening down and away. Use a shop rag or towel to avoid damage to the memory piston. Fluid will blow out also. 2. Remove O-ring from memory piston. 51144 e d 55466 a c b a-Adaptor/Air Hose b-Memory Piston Exit c-Shop Rag d-O-ring e-Memory Piston 90-828631R3 MARCH 1999 Page 5D-25 MANUAL TILT ASSIST Page 5D-26 90-828631R3 MARCH 1999 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 90-828631R3 MARCH 1999 Page 5D-27 Reassembly - O-Ring and Seal Placement 1 2 3 5 4 14 6 7 9 11 12 10 13 8 NOTE: Lubricate all O-rings using Quicksilver Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. NOTE: It is recommended that all O-rings be replaced when servicing tilt system. MANUAL TILT ASSIST Actual O-Ring Sizes 1 2 9 3 4 14 5 10 (2)6 7 (2) 8 12 11 13 O.D. I.D. Cutaway View of O-Ring Width O-RINGS SHOWN ARE ACTUAL SIZE Page 5D-28 90-828631R3 MARCH 1999 MANUAL TILT ASSIST O-Ring Description and Sizes O-Ring Description O-Ring I.D. O-Ring O.D. O-Ring Width 1 Wiper Ring 2 Cyl. Cap, Inner 0.671 in. (17.04 mm) 0.949 in. (24.10 mm) 0.139 in. (3.53 mm) 3 Cyl. Cap 1.864 in. (47.34 mm) 2.004 in. (50.90 mm) 0.07 in. (1.78 mm) 4 Shock Piston 1.6 in. (40.64 mm) 2.02 in. (53.086 mm) 0.21 in. (5.334 mm) 5 Piston Bolt 0.676 in. (17.17 mm) .816 in. (20.726 mm) 0.07 in. (1.78 mm) 6 (2) Manifold Split Line 0.208 in. (5.283 mm) 0.348 in. (8.839 mm) 0.07 in. (1.78 mm) 7 Slow Valve 0.114 in. (2.90 mm) 0.254 in. (6.451 mm) 0.07 in. (1.78 mm) 8 (2) Plug 0.489 in. (12.42 mm) 0.629 in. (15.97 mm) 0.07 in. (1.78 mm) 9 Accumulator 2.114 in. (53.69 mm) 2.254 in. (57.25 mm) 0.07 in. (1.78 mm) 10 Lip Seal 11 Cam Shaft 0.301 in. (7.645 mm) 0.441 in. (11.20 mm) 0.07 in. (1.78 mm) 12 Back Up Ring 13 Surge Valve 0.301 in. (7.645 mm) 0.441 in. (11.20 mm) 0.07 in. (1.78 mm) 14 Memory Piston 1.6 in. (40.64 mm) 2.02 in. (53.086 mm) 0.21 in. (5.334 mm) Manual Tilt System Cleaning and Inspection 1. It is recommended that all O-rings exposed during disassembly be replaced. 2. Clean components, filter, and check valve seats using engine cleaner and compressed air. Do not use cloth rags. 3. Inspect all machined surfaces for burrs or scoring to assure O-ring longevity. 4. Inspect shock rod. If scraper (located in cap) has failed to keep rod clean, replace scraper. Manual Tilt System Reassembly IMPORTANT: Components must be dirt and lint free. Slightest amount of debris in tilt system could cause system to malfunction. Apply Quicksilver Power Trim and Steering Fluid to all O-rings during reassembly. If not available, use automotive (ATF) automatic transmission fluid. 90-828631R3 MARCH 1999 Page 5D-29 MANUAL TILT ASSIST Page 5D-30 90-828631R3 MARCH 1999 CAM SHAFT REASSEMBLY IMPORTANT: Cam shaft O-ring must be lubricated using 2-4-C with Teflon. 1. Install lubricated O-ring and back up seal to cam. 2. Install shaft seal in valve block with lips facing out. 3. Install cam shaft assembly in valve block. 4. Secure cam shaft in place using insulator, retainer plate, and screw. Tighten screw securely. 95 2-4-C w/Teflon (92-850736A1) 95 a b c d e f g a - Spacer Retainer Clip b - Retainer Clip c - Screw d - Shaft Seal e - O-ring f - Back up Seal g - Cam VALVE BODY CHECK REASSEMBLY 1. Install lubricated O-ring, plunger, steel ball and conical spring to valve block. 51145 a b c d a - Conical Spring b - Steel Ball c - Plunger d - O-ring MANUAL TILT ASSIST VELOCITY VALVE REASSEMBLY 1. Install spool, spring, lubricated O-ring and screw plug (surge valve assembly) into valve block. 2. Torque velocity valve to specified torque. d c b a a-Spool b-Spring c-O-ring d-Velocity Valve Velocity Valve Torque 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 90-828631R3 MARCH 1999 Page 5D-31 MANUAL TILT ASSIST VALVE PLUG REASSEMBLY 1. Install plunger, steel ball, spring, lubricated O-ring and screw plug. Torque screw plugs to specified torque. 51142 a b c d e a-Plunger (2) b-Steel Ball (2) c-Spring (2) d-O-ring (2) e-Screw Plug (2) Screw Plug Torque 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 specified torque. 1 a b a-O-ring (2) b-Dowel Pin (2) c-Valve Block d-Screw (2) e-Shock Rod Cylinder 51148 51146 c d e Screw Torque 100 lb-in. (11.3 Nm) Page 5D-32 90-828631R3 MARCH 1999 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 d 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 90-828631R3 MARCH 1999 Page 5D-33 MANUAL TILT ASSIST 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 Grade “A” (271) to threads on shock rod. 7. Install shock rod piston. 8. Tighten shock rod piston securely using spanner wrench [1/4 in. x 5/16 in. (6.4mm x 8mm) long pegs]. If a torquing type spanner tool is used to tighten shock piston, then torque to specified torque. 51146 Loctite “271” (92-809819) 7 a b 91-74951 7 a-Spanner Wrench b-Shock Rod Piston Shock Rod Piston Torque 90 lb-ft (122 Nm) 9. Install ball, seat, and spring (five sets) to shock rod piston. 10. Secure components with plate. Torque screws to 35 lb-in. (3.9 Nm). 11. Remove shock rod assembly from vise. 51147 e d c a b a-Screw (3) Torque to 35 lb-in. (3.9 Nm) b-Plate c-Spring (5) d-Seat (5) e-Ball (5) Page 5D-34 90-828631R3 MARCH 1999 MANUAL TILT ASSIST Shock Rod Installation and Fluid Filling Procedure NOTE:There are two ways for the filling procedure. The first is the easiest and less time consuming. Filling Procedure Option One 1. Place trim cylinder in soft jawed vice. 2. With manifold cam lever closed (Up Position), fill cylinder and manifold to top with Quicksilver Power trim and steering fluid, or (ATF) automatic transmission fluid. Let bubbles disperse. 3. Install lubricated O-ring to memory piston. 4. Using lock ring pliers (P/N 91-822778A3). Set memory piston in top of cylinder then open cam lever (Down Position) and push memory piston down just below cylinder treads. Close cam lever (Up Position). 51144 5. Fill top of cylinder again with fluid to top and install shock rod assembly on top memory piston. Open cam lever (Down Position) and push shock rod assembly down to 1/8, below cylinder threads. Close cam lever (Up Position). 6. Fill top of shock rod assembly with fluid to top of cylinder. Open cam lever (Down Position) and screw cylinder cap down. 7. Tighten end cap securely using spanner wrench [1/4 in. x 5/16 in. (6.4mm x 8mm) long pegs]. If a torquing type spanner tool is used to tighten end cap, then torque the end cap to specified torque. Close cam lever (Up Position). 51145 End Cap Torque 45 lb-ft (61 Nm) 90-828631R3 MARCH 1999 Page 5D-35 MANUAL TILT ASSIST 8. Open and close cam lever, watching for bubbles coming from accumulator check ball hole. When bubbles stop, fill accumulator opening to top with fluid. Grease threads on accumulator and opening with 2-4-C with Teflon. Start accumulator in threads and open cam lever (Down Position). Torque accumulator to specified torque. 51143 ba a-Accumulator b-Cam Lever (Down Position) Accumulator Torque 35 lb-ft (47 Nm) NOTE: If filling procedure is done correctly, it should be hard to turn cylinder rod assembly by hand. Page 5D-36 90-828631R3 MARCH 1999 MANUAL TILT ASSIST Filling Procedure Option Two Instructions for Making 3/8 in. x 13 in. (10 mm x 33 cm) Threaded Rod 3/16 in x 3 in. (5 x 7.5 cm) Steel Plate 4in. x 1/4 in. min. (10cm x 6.4 mm) minimum Channel Iron Retaining Tool 1 in. (25mm) 10 in. (25 cm) 8 in. (20 cm) 2 holes, 7/16 in. dia. (11 mm) 3 in. (76mm) 5 in. (125mm) 1 1/4 in. dia. (30m) 20 in. (508mm) 8 in. (203mm) 6 in. (152mm) 4 in. (100 mm) 2 in. (50mm) 3/8 in. dia. 2 holes 90-828631R3 MARCH 1999 Page 5D-37 MANUAL TILT ASSIST Bleeding Manual Tilt System IMPORTANT: While bleeding tilt system, time must be allowed between each stroke to allow air bubbles to dissipate. 1. With shock rod in the full up position and manifold cam lever open (facing down), secure tilt system to retaining tool and container. (A No. 10 can or 3 lb coffee can could be used.) 2. Fill container to near full level using Quicksilver Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. IMPORTANT: Fluid level must remain above accumulator opening during bleeding process. 50447d e a b c a a-Retaining Tool b-Tilt System c-Container d-Cam Lever e-Accumulator Opening 3. Bleed unit by pushing rod down slowly (18-20 seconds per stroke) until stopped at base. Wait until all air bubbles exit accumulator base. 50432 Page 5D-38 90-828631R3 MARCH 1999 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 90-828631R3 MARCH 1999 Page 5D-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 specified torque. 50433 Accumulator Torque 35 lb-ft (47 Nm) Manual Tilt System Installation 1. Apply 2-4-C Marine Lubricant to lower pivot pin hole and pivot pin surface. 2. Start lower pivot pin into pivot pin hole and position lower dowel pin (retained) in its hole. 3. Reinstall manual tilt system, bottom first. Reconnect release valve link rod. 51144 2 151148 95 2-4-C w/Teflon (92-850736A1) 95 a b c a-Lower Pivot Pin b-Lower Dowel Pin c-Manual Tilt System Page 5D-40 90-828631R3 MARCH 1999 MANUAL TILT ASSIST 4. Using a suitable punch, drive lower pivot pin into clamp bracket and trim cylinder assembly until pivot pin is flush with outside surface. 5. Using a punch, drive lower dowel pin in until seated. 51148 b 51147 a a-Lower Pivot Pin b-Lower Dowel Pin 6. Apply 2-4-C Marine Lubricant to surface of upper pivot pin, pivot pin hole and shock rod hole. 7. Using a mallet, drive upper pivot pin into swivel bracket and through shock rod until pivot pin is flush with swivel bracket. 51148 95 b c a 95 2-4-C w/Teflon (92-850736A1) a-Pivot Pin b-Pivot Pin Bore c-Shock Rod Bore d-Pivot Pin e-Swivel Bracket f-Shock Rod 51148 f e d 90-828631R3 MARCH 1999 Page 5D-41 MANUAL TILT ASSIST 8. Drive upper dowel pin (a) into its hole until seated. 51147 a a-Dowel Pin 9. Check manual release cam adjustment. Cam must open and close freely. Adjust link rod as necessary. Manual Release Valve Adjustment 1. With outboard in full up position, place tilt lock lever forward. 2. Lift cam lever (with link rod) to full up position. 51143 b a c a-Tilt Lock Lever b-Cam Lever c-Link Rod 3. Link rod end must snap onto ball of tilt lock lever without moving tilt lock lever or cam lever. Page 5D-42 90-828631R3 MARCH 1999 NON-BIGFOOT GEAR HOUSING LOWER UNIT Section 6A - Non-Bigfoot Gear Housing Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2 Quicksilver Lubricants and Service Aids . . . . . . 6A-5 Gear Housing (Driveshaft) (1.83:1 Gear Ratio) . . . . . . . . . . . . . . . . . . . . . . . . 6A-6 Gear Housing (Prop Shaft) (1.83:1 Gear Ratio) . . . . . . . . . . . . . . . . . . . . . . . . 6A-8 General Service Recommendations . . . . . . . . 6A-10 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-10 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-10 Draining and Inspecting Gear Lubricant . . . . . 6A-11 Gear Housing Removal . . . . . . . . . . . . . . . . . . . 6A-12 2-Stroke Models. . . . . . . . . . . . . . . . . . . . . . . 6A-12 4-Stroke Models. . . . . . . . . . . . . . . . . . . . . . . 6A-13 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-15 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-15 Water Pump Seals . . . . . . . . . . . . . . . . . . . . . 6A-22 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-24 Upper Drive Shaft Bearing. . . . . . . . . . . . . . 6A-24 Pinion Gear Bearing . . . . . . . . . . . . . . . . . . . 6A-25 Pinion Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-25 Forward Gear. . . . . . . . . . . . . . . . . . . . . . . . . 6A-25 Specifications Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-28 Propeller Shaft Disassembly . . . . . . . . . . . . 6A-29 Propeller Shaft and Carrier Inspection . . . . . . 6A-30 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-30 Cam Follower. . . . . . . . . . . . . . . . . . . . . . . . . 6A-30 Reverse Gear. . . . . . . . . . . . . . . . . . . . . . . . . 6A-30 Reverse Gear Bearing . . . . . . . . . . . . . . . . . 6A-31 Bearing Carrier. . . . . . . . . . . . . . . . . . . . . . . . 6A-32 Gear Housing Reassembly . . . . . . . . . . . . . . . . 6A-36 Shift Shaft Assembly. . . . . . . . . . . . . . . . . . . 6A-36 Pinion Bearing Race . . . . . . . . . . . . . . . . . . . 6A-37 Forward Gear. . . . . . . . . . . . . . . . . . . . . . . . . 6A-38 Pinion Gear/Drive Shaft Assembly . . . . . . . 6A-39 Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . 6A-40 Bearing Carrier. . . . . . . . . . . . . . . . . . . . . . . . 6A-42 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-43 Gear Housing Pressure Test . . . . . . . . . . . . . . . 6A-46 Gear Housing Installation. . . . . . . . . . . . . . . . . . 6A-47 2-Stroke Models. . . . . . . . . . . . . . . . . . . . . . . 6A-48 4-Stroke Models. . . . . . . . . . . . . . . . . . . . . . . 6A-48 Trim Tab Adjustment and Replacement . . . . . 6A-49 Filling Gear Housing with Lubricant . . . . . . 6A-51 6 A 1995/1996 GEAR HOUSING (2.00:1) 45/50 1995/1996 models Gear Ratio Gearcase Capacity Lubricant Type Forward Gear Number of Teeth Pinion Gear Number of Teeth 2.00:1 14.9 fl oz (440 mL) Quicksilver Gear Lube-Premium Blend 26 Spiral/Bevel 13 Spiral/Bevel Forward Gear Backlash Water Pressure @ 750 rpm (Idle) @ 6000 rpm (WOT) No Adjustment 2-4 psi (14-28 kPa) 12-17 psi (69-103 kPa) 1997 AND NEWER GEAR HOUSING (1.83:1) 45/50 1997 and Newer models Gear Ratio Gearcase Capacity Lubricant Type Forward Gear Number of Teeth Pinion Gear Number of Teeth 1.83:1 14.9 fl oz (440 mL) Quicksilver Gear Lube-Premium Blend 22 Spiral/Bevel 12 Spiral/Bevel Forward Gear Backlash Water Pressure @ 750 rpm (Idle) @ 6000 rpm (WOT) No Adjustment 2-4 psi (14-28 kPa) 12-17 psi (69-103 kPa) 90-828631R3 MARCH 1999 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 90-828631R3 MARCH 1999 NON-BIGFOOT GEAR HOUSING 6. Universal Puller Plate 91-37241 7. Driver Head 91-37312 8. Driver 91-817011 9. Driver Rod 91-37323 90-828631R3 MARCH 1999 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 90-828631R3 MARCH 1999 NON-BIGFOOT GEAR HOUSING 16. Driver 91-826872 17. Leakage Tester FT8950 Quicksilver Lubricants and Service Aids Part No. Description 92-809819 Loctite “271” Purchase Local Loctite “405” 92-891601-1 RTV Silicone Sealer 92-850737A1 Super Duty Gear Lubricant 92-809824 Loctite Primer “7649” 92-850735A1 Anti-Corrosion Grease 92-850736A1 2-4-C w/Teflon 90-828631R3 MARCH 1999 Page 6A-5 NON-BIGFOOT GEAR HOUSING Gear Housing (Driveshaft)(1.83:1 Gear Ratio) 7 74 87 92 95 Loctite “271” Adhesive Sealant (92-809819) Loctite “405” (Purchase Locally) Super Duty Gear Lubricant (92-13783A24) Loctite Primer “N” (92-59327-1) 2-4-C w/Teflon (92-825407A12) 23 24 22 74 87 95 7 95 28 25 14 29 7 27 12 13 95 95 95 30 95 15 31 26 21 32 33 16 2 17 18 20 38 19 1 3.44 IN./87.37 MM TORPEDO DIA. 11 5 10 4 3 34 35 36 3795 87 7 92 9 7 8 6 Page 6A-6 90-828631R3 MARCH 1999 NON-BIGFOOT GEAR HOUSING Gear Housing (Driveshaft)(1.83:1 Gear Ratio) REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm – 1 GEAR HOUSING (1.83:1 GEAR RATIO) (BLACK) – 1 GEAR HOUSING (1.83:1 GEAR RATIO) (GRAY) 11 1 GEAR HOUSING (BASIC) (BLACK) 1 GEAR HOUSING (BASIC) (GRAY) 2 1 SEAL/PLATE KIT 3 1 PLATE 4 1 SCREW (.375–16 x .25) 60 7.0 5 1 WASHER–Sealing 6 1 DRAIN SCREW (MAGNETIC) 60 7.0 7 1 WASHER–Sealing 8 1 NUT 50 68.0 9 1 PINION GEAR (1.83:1 GEAR RATIO)(12 TEETH) 10 1 BEARING ASSEMBLY–Roller 11 1 CUP 12 4 SCREW (M6 x 16) 60 7.0 13 1 WATER PUMP ASSEMBLY 14 1 SEAL–Water Tube 15 1 WASHER 16 1 KEY 17 1 WASHER 18 1 GASKET 19 1 GASKET (LOWER) 20 1 FACE PLATE 21 1 IMPELLER 22 1 WATER PUMP BASE ASSEMBLY 23 1 SEAL–Oil 24 1 SEAL–Oil 25 1 O RING 26 1 DRIVESHAFT (30-3/4) 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 1 SHIFT SHAFT (31.14) 35 1 WASHER 36 1 ROLL PIN 37 1 CAM–Shift 38 1 PIN 90-828631R3 MARCH 1999 Page 6A-7 NON-BIGFOOT GEAR HOUSING Gear Housing (Prop Shaft)(1.83:1 Gear Ratio) 3.44 IN./87.37 MM TORPEDO DIA. 42 3940 41 43 44 45 46 47 48 49 50 51 52 5354 55 56 57 58 59 60 61 62 63 64 68 69 70 71 72 1 73 95 95 87 95 87 7 95 87 8766 65 67 39 7 Loctite “271” Adhesive Sealant (92-809819) 87 95 Super Duty Gear Lubricant (92-13783A24) 2-4-C w/Teflon (92-825407A12) Page 6A-8 90-828631R3 MARCH 1999 NON-BIGFOOT GEAR HOUSING Gear Housing (Prop Shaft)(1.83:1 Gear Ratio) REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm – 1 GEAR HOUSING (1.83:1 GEAR RATIO) (BLACK) – 1 GEAR HOUSING (1.83:1 GEAR RATIO) (GRAY) 11 1 GEAR HOUSING (BASIC) (BLACK) 1 GEAR HOUSING (BASIC) (BLACK) 39 2 DOWEL PIN 40 1 GASKET Water Tube 41 1 TUBE 42 1 PLUG–RUBBER 43 1 SCREEN–Water Inlet 44 1 TRIM TAB 45 1 SCREW (M8 x 20) 190 15.8 21.5 46 1 WASHER 47 1 FORWARD GEAR (1.83:1 GEAR RATIO)(22 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 (1.83:1 GEAR RATIO) (22 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 30) 225 18.8 25.4 66 2 THREADED INSERT 67 1 DECAL-Gear Case Gear Ratio 68 1 THRUST HUB 69 1 PROP NUT THESE REPLACEMENT PARTS 55 74.5 70 1 TAB WASHER ARE NOT INCLUDED WITH 71 4 SCREW COMPLETE GEAR HOUSING 40 54.0 72 4 WASHER REPLACEMENT 73 1 PLUG 90-828631R3 MARCH 1999 Page 6A-9 NON-BIGFOOT GEAR HOUSING General Service Recommendations There may be more than one way to “disassemble” or “reassemble” a particular part(s), therefore, it is recommended that the entire procedure be read prior to repair. IMPORTANT: Read the following before attempting any repairs. In many cases, disassembly of a sub-assembly may not be necessary until cleaning and inspection reveals that disassembly is required for replacement of one or more components. Service procedure order in this section is a normal disassembly-reassembly sequence. Threaded parts are right hand (RH), unless otherwise indicated. When holding, pressing or driving is required, use soft metal vise jaw protectors or wood for protection of parts. Use a suitable mandrel (one that will contact only the bearing race) when pressing or driving bearings. Whenever compressed air is used to dry a part, verify that no water is present in air line. Bearings All bearings must be cleaned and inspected. Clean bearings with solvent and dry with compressed air. Air should be directed at the bearing so that it passes through the bearing. DO NOT spin bearing with compressed air, as this may cause bearing to score from lack of lubrication. After cleaning, lubricate bearings with Quicksilver Gear Lubricant. DO NOT lubricate tapered bearing cups until after inspection. Inspect all bearings for roughness, binding and bearing race side wear. Work inner bearing race in-and-out, while holding outer race, to check for side wear. When inspecting tapered bearings, determine condition of rollers and inner bearing race by inspecting bearing cup for pitting, scoring, grooves, uneven wear, imbedded particles and/or discoloration from over-heating. Always replace tapered bearing and race as a set. Inspect gear housing for bearing races that have spun in their respective bores. If race(s) have spun, gear housing must be replaced. Roller bearing condition is determined by inspecting the surface of the shaft that the roller bearing supports. Check shaft surface for pitting scoring, grooving, imbedded particles, uneven wear and/or discoloration from overheating. The shaft and bearing must be replaced if such a condition exists. Seals As a normal procedure, all O-rings and oil seals should be replaced without regard to appearance. To prevent leakage around seals, apply Loctite 271 to outer diameter of all metal case seals. When using Loctite on seals or threads, surfaces must be clean and dry. Apply 2-4-C w/Teflon on all O-rings and on I.D. of oil seals. Apply 2-4-C w/Teflon to external surfaces of bearing carrier. Page 6A-10 90-828631R3 MARCH 1999 NON-BIGFOOT GEAR HOUSING Draining and Inspecting Gear Lubricant WARNING If gear housing is installed on outboard, disconnect (and isolate) spark plug leads from spark plugs before working near the propeller. 1. With gear housing in normal running position, place a clean pan under housing and remove vent plug and fill/drain plug (with gaskets). a b a-Vent Plug/Washer b-Fill/Drain Plug/Washer 2. Inspect gear lubricant for metal particles (lubricant will have a “metal flake” appearance). Presence of fine metal particles (resembling powder) on the drain plug magnet indicates normal wear. Metal chips on the magnet indicate the need for gear housing disassembly and component inspection. 3. Note color of gear lubricant. White or cream color indicates presence of water. 4. Presence of water indicates the need for disassembly and inspection of oil seals, O-rings, gaskets, shift shaft boot and components for damage. Pressure check gear case prior to disassembly. 90-828631R3 MARCH 1999 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 90-828631R3 MARCH 1999 NON-BIGFOOT GEAR HOUSING 4-Stroke Models MERCURY/MARINER 25, 30/40, AND 45/50 4. Disconnect shift shaft by un-snapping retainer to lower clip and sliding retainer to the left. a 1 2 b a-Retainer b-Lower Clip 5. Make a scribe line showing alignment of trim tab to gear case and remove trim tab bolt and washer. 52835 a b a-Bolt and Washer b-Scribe Line 90-828631R3 MARCH 1999 Page 6A-13 NON-BIGFOOT GEAR HOUSING 6. Remove nut and washer in trim tab cavity. 52835 a a-Nut and Washer 7. Remove 4 bolts securing gear case to drive shaft housing. 52836 a a-Bolt (4) Page 6A-14 90-828631R3 MARCH 1999 NON-BIGFOOT GEAR HOUSING Disassembly Water Pump NOTE:If water tube seal remained in drive shaft housing, remove seal from housing and reinstall on water pump cover. Secure seal to cover with Loctite 405. 1. Remove 4 bolts securing pump cover. 52830 a b a-Seal b-Bolt (4) NOTE:Replace cover if thickness of steel at discharge slots is 0.060 in. (1.524 mm) or less, or if groove(s) (other than impeller sealing groove) in cover roof are more than 0.030 in. (0.762 mm) deep. 90-828631R3 MARCH 1999 Page 6A-15 NON-BIGFOOT GEAR HOUSING 2. Remove cover, washer (above impeller), impeller, key and washer (below impeller). 3. Remove cover gasket, base plate and base gasket. 52692 a b c d e f g h a-Cover b-Nylon Washer (above impeller) c-Impeller d-Key e-Nylon Washer (below impeller) f-Cover Gasket g-Face Plate h-Base Gasket NOTE:Replace impeller if: –Impeller blades are cracked, torn or worn. –Impeller is glazed or melted –Rubber portion of impeller is not bonded to impeller hub. Page 6A-16 90-828631R3 MARCH 1999 NON-BIGFOOT GEAR HOUSING 4. Remove and/or replace exhaust deflector plate if damaged. 52832 a a-Deflector Plate 5. Inspect auxiliary water inlet tube for excessive corrosion/erosion. Replace as required. 57830 a a-Water Inlet Tube 90-828631R3 MARCH 1999 Page 6A-17 NON-BIGFOOT GEAR HOUSING 6. Remove bearing carrier attaching bolts and locking tab washers or flat washers. Discard tab washers. b a a-Bolts and Tab Washers or Flat Washers b-Tab Washers Style 2 7. Using Puller (91-27780), remove carrier assembly from gear case. 52829 a a-Puller (91-27780) 91-27780 Page 6A-18 90-828631R3 MARCH 1999 NON-BIGFOOT GEAR HOUSING NOTE: When removing propeller shaft assembly, cam follower may dislodge. Retrieve follower from gear housing. 8. Remove propeller shaft assembly. a a-Propeller Shaft 52864 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 9. Remove pinion nut. 52864 b c a a-Drive Shaft Holding Tool b-Pinion Nut c-Pinion Gear 90-828631R3 MARCH 1999 Page 6A-19 NON-BIGFOOT GEAR HOUSING 10. Remove drive shaft assembly and pinion gear. 11. Remove forward gear. 52870 a a-Forward Gear 12. Remove shift shaft assembly. 52841 a a-Shift Shaft Assembly Page 6A-20 90-828631R3 MARCH 1999 NON-BIGFOOT GEAR HOUSING 13. Insert spring hook (91-825200A1) or bearing cup puller (91-859749) through gear case and position inside of pinion bearing race. Insert driver (91-13779) into spring hook or driver (91-44385) into bearing cup puller through drive shaft cavity and drive out race. 52844 b a 57829 c d 91-825200A191-13779 or 91-859749 91-44385 a-Spring Hook (91-825200A1) b-Driver (91-13779) c-Bearing Cup Puller (91-859749) d-Driver (91-44385) 14. Remove forward bearing race with puller (91-27780). 53838 b a a-Bearing Race b-Puller (91-27780) 91-27780 90-828631R3 MARCH 1999 Page 6A-21 NON-BIGFOOT GEAR HOUSING Water Pump Seals NOTE:All gaskets, seals and O-rings should be replaced as a normal repair procedure during gear case disassembly. NOTE: DO NOT use a screwdriver to remove seals from carrier, as carrier may be damaged. 1. Using a suitable mandrel, press both seals from carrier. 7 a b c d 7 Loctite “271” (92-809819) a-Neoprene Ribbed Seal b-Metal Cased Seal c-Carrier d-O-ring 2. Apply Loctite 271 to the O.D. of the metal cased seal. With seal lip facing away from the large shoulder of mandrel (91-825197), press seal into carrier until mandrel bottoms on carrier. 91-825197 a b 7 Loctite “271” (92-809819) 7 a-Seal (Metal Cased) Lip Facing Down b-Mandrel (91-825197) Page 6A-22 90-828631R3 MARCH 1999 NON-BIGFOOT GEAR HOUSING 3. With lip of ribbed neoprene O.D. seal facing towards small shoulder of Mandrel (91-825197), press seal into carrier until mandrel bottoms on carrier. 52853 91-825197 b a a-Seal (Ribbed Neoprene) Lip Facing Up b-Mandrel (91-825197) NOTE: Apply a light coat of 2-4-C w/Teflon (92-850736A1) to the lips of both seals after installation in carrier. 4. Apply a light coat of 2-4-C w/Teflon to the new O-ring and install on carrier. 52825 95 95 2-4-C w/Teflon (92-850736A1) a a-O-ring 90-828631R3 MARCH 1999 Page 6A-23 NON-BIGFOOT GEAR HOUSING Inspection Upper Drive Shaft Bearing 1. Inspect bearing for rust, roughness or discoloration from lack of lubricant. 2. DO NOT remove bearing from drive shaft unless bearing must be replaced, as removal process will damage bearing. 3. If bearing must be replaced, position drive shaft assembly in vise (jaws of vise supporting only bearing) and while holding drive shaft, strike top of drive shaft with lead hammer and drive bearing off. a a-Bearing 4. To install new bearing, thread old pinion nut 3/4 way onto drive shaft. Position Universal Puller Plate (91-37241) under bearing and press on pinion nut while holding drive shaft until bearing seats against shoulder. 52387 91-37241 a b c a-Old Pinion Nut (Nut Should be Above Drive Shaft) b-Bearing c-Universal Puller Plate (91-37241) Page 6A-24 90-828631R3 MARCH 1999 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, pits, chipping, excessive wear (teeth are sharp edged) or broken. 2. If pinion gear teeth are damaged, also inspect forward and reverse gear teeth for damage. 3. Replace gears as required. 52839 Forward Gear 1. Inspect forward gear teeth for rust, pits, 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 90-828631R3 MARCH 1999 Page 6A-25 NON-BIGFOOT GEAR HOUSING 3. Inspect propeller shaft forward gear bearing surface to determine condition of forward gear needle bearing. If bearing surface is discolored (from lack of lubricant), pitted or worn, propeller shaft and bearing should be replaced. 52846 52874 b a a-Bearing Surface b-Bearing 4. Use a suitable mandrel to press needle bearing out of forward gear. 52873 a b a-Mandrel (14 mm Socket) b-Bearing 5. Use Driver 91-826872 to press new needle bearing into forward gear. Press on numbered side of bearing. 52847 87 Super Duty Gear Lubricant (92-850737A1) 91-826872 a b 87 a-Driver (91-826872) b-Bearing Page 6A-26 90-828631R3 MARCH 1999 NON-BIGFOOT GEAR HOUSING 6. Inspect forward gear tapered bearing and race for rust, roughness or excessive wear (looseness). 7. If bearing is in serviceable condition, DO NOT remove bearing from gear, as removal process will damage bearing. 8. If bearing must be replaced, remove bearing from gear using Universal Puller Plate (91-37241) and suitable mandrel. 9. Replace bearing and race as a set. Use suitable mandrel to press bearing onto gear. PRESS ONLY ON INNER RACE when installing bearing. REMOVAL b a a-Universal Puller Plate (91-37241) b-Mandrel (15/16 in. socket) 91-37241 a INSTALLATION a-Mandrel (1-1/8 in. socket) 90-828631R3 MARCH 1999 Page 6A-27 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 Page 6A-28 90-828631R3 MARCH 1999 NON-BIGFOOT GEAR HOUSING Propeller Shaft Disassembly 1. Remove propeller shaft from carrier and disassemble shaft. c d e a b f a-Prop Shaft b-Retaining Spring c-Clutch Dog d-Cross Pin e-Cam Follower Spring f-Cam Follower 2. Remove reverse gear and bearing from carrier with Puller (91-27780). 91-27780 b a 52840 a-Reverse Gear and Bearing b-Puller (91-27780) 90-828631R3 MARCH 1999 Page 6A-29 NON-BIGFOOT GEAR HOUSING Propeller Shaft and Carrier Inspection Clutch 1. Inspect clutch dogs for chips or rounding off. 2. If wear is present, inspect corresponding forward or reverse gear matching dogs 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, pits, chipping, excessive wear (teeth are sharped edged) or broken teeth. 2. Inspect reverse gear clutch jaws for wear. Rounded jaws indicate the following: • Improper shift cable adjustment. • Engine idle speed too high. • Shifting too slowly. 52875 Page 6A-30 90-828631R3 MARCH 1999 NON-BIGFOOT GEAR HOUSING Reverse Gear Bearing 1. Inspect bearing for rust, roughness or excessive wear (looseness). 2. If bearing is in serviceable condition, DO NOT remove bearing from gear as removal will damage bearing. 3. If bearing must be replaced, remove bearing from gear using Universal Puller Plate (91-37241) and Driver (91-37312). 4. Install new bearing using a suitable mandrel. PRESS ONLY ON INNER RACE when installing bearing. REMOVAL d a b c 91-37312 91-37241 a-Bearing b-Reverse Gear c-Universal Puller Plate (91-37241) d-Driver (91-37312) 87 a b INSTALLATION 52867 87 Super Duty Gear Lubricant (92-850737A1) a-Mandrel (1-1/4 in. socket) b-Bearing 90-828631R3 MARCH 1999 Page 6A-31 NON-BIGFOOT GEAR HOUSING Bearing Carrier NEEDLE BEARING 1. The condition of the carrier needle bearing can be determined by inspecting its running surface on the propeller shaft. 2. If the shaft is discolored (from lack of oil) or pitted, replace bearing and shaft. 3. Bearing can be removed by using Driver Rod (91-37323) and Driver (91-37312). Removing bearing will also remove both propeller shaft seals. 91-37312 91-37323 a b c d 51264 a-Driver Rod (91-37323) b-Driver (91-37312) c-Needle Bearing d-Seals 4. Apply Super Duty Gear Lubricant to O.D. of bearing. 5. Install bearing using Mandrel 91-817011. Page 6A-32 90-828631R3 MARCH 1999 NON-BIGFOOT GEAR HOUSING 6. Press bearing into carrier until mandrel bottoms on carrier. NOTE:Press on number side of bearing. 87 91-817011 a b 52861 87 Super Duty Gear Lubricant (92-850737A1) a-Bearing b-Mandrel (91-817011) 7. Apply Loctite 271 to O.D. of small diameter seal. 8. With seal lip facing away from large shoulder of Mandrel 91-817007, press seal into carrier until mandrel bottoms on carrier. 52862 7 Loctite “271” (92-809819) 91-817007 b a 7 a-Seal b-Mandrel (91-817007) 90-828631R3 MARCH 1999 Page 6A-33 NON-BIGFOOT GEAR HOUSING 9. Apply Loctite 271 to O.D. of large diameter seal. 10. With seal lip FACING TOWARDS SMALL SHOULDER of Mandrel 91-817007, press seal into carrier until mandrel bottoms on carrier. 52863 7 91-817007 b a 7 Loctite “271” (92-809819) a-Seal b-Mandrel (91-817007) Installation Note: If service tools are not available, the following reference dimensions apply for installing bearing and seals to proper depths. 51275 .82 in. (20 mm) 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) Page 6A-34 90-828631R3 MARCH 1999 NON-BIGFOOT GEAR HOUSING 11. Bearing carrier O-ring should be inspected for cuts and abrasions. NOTE:It is a good repair procedure to replace all O-rings and seals regardless of appearance. 12. Apply 2-4-C w/Teflon to O.D. of bearing carrier and also to O-ring. Install O-ring onto bearing carrier. 13. Using suitable mandrel, press reverse gear assembly into carrier. 52827 95 95 2-4-C w/Teflon (92-850736A1) b c a a-O-ring b-Mandrel (3/4 in. Socket) c-Reverse Gear Assembly 90-828631R3 MARCH 1999 Page 6A-35 NON-BIGFOOT GEAR HOUSING Gear Housing Reassembly IMPORTANT: This gear case assembly does not have have any shims for the gear assemblies. Backlash cannot be adjusted. The mechanic must verify that all bearing races are firmly seated in the gear case during reassembly and that all gear case components are in serviceable condition. Prior to installing the seal carrier and water pump assembly on the drive shaft, the FORWARD gear should be held stationary (with a screw driver or similar tool). While pulling up on the drive shaft, lightly turn the shaft back and forth. A light “clicking” sound should be heard indicating the presence of backlash between FORWARD and PINION gears. If this backlash is not present, the pinion gear race and/or forward gear race are not fully seated. Races should be removed and inspected for debris. Reinstall races and check backlash. If backlash is still not present, replace gear housing. Shift Shaft Assembly 1. Apply 2-4-C w/Teflon to new O-rings and install O-rings on shift shaft and carrier. 2. Install carrier on shift shaft. IMPORTANT: When installing shift shaft assembly into gear housing, DO NOT BOTTOM OUT SHAFT IN HOUSING. Pull up on shift shaft until shift boot is not deformed. If shaft is bottomed out, cross pin in clutch dog will be bent by cam follower when tightening carrier bolts. 3. Install shift shaft/carrier assembly into gear housing. 4. Secure boot to carrier with sta-strap. 5. Position shift shaft so ramp faces towards propeller shaft. 52841 95 e d b c a 95 2-4-C w/Teflon (92-850736A1) a-O-rings b-Carrier c-Boot d-Sta-strap e-Ramp Page 6A-36 90-828631R3 MARCH 1999 NON-BIGFOOT GEAR HOUSING Pinion Bearing Race 1. Apply Super Duty Gear Lubricant to O.D. of race. 2. Position race in gear housing (NUMBERS UP - TAPERED SIDE FACING DOWN). 3. Draw race up into housing until seated. 52842 87 91-29310 12-34961 91-825198 91-31229 11-24156 31-85560 91-825199 b e g 87 Super Duty Gear Lubricant (92-850737A1) d c fa a-Threaded Rod (91-31229) b-Washer(2) (12-34961) c-Bearing (31-85560) d-Plate (91-29310) e-Pilot (91-825199) f-Nut (11-24156) g-Mandrel (91-825198) 90-828631R3 MARCH 1999 Page 6A-37 NON-BIGFOOT GEAR HOUSING Forward Gear 1. Apply Super Duty Gear Lubricant to O.D. of race. Install forward gear bearing race into housing using Mandrel 91-36571 and propeller shaft. Use a lead hammer on prop shaft to prevent damage to threads. Bearing carrier should be installed to keep prop shaft centered while seating race. 52843 87 91-36571 b a 87 Super Duty Gear Lubricant (92-850737A1) a-Race b-Mandrel (91-36571) NOTE: Remove drain plug/magnet assembly from gear case (if installed) to prevent possible breakage of magnet if struck by forward gear. 2. Install forward gear and bearing assembly into forward gear race. a 52870 a-Forward Gear Assembly Page 6A-38 90-828631R3 MARCH 1999 NON-BIGFOOT GEAR HOUSING Pinion Gear/Drive Shaft Assembly 1. Clean pinion nut and pinion nut threads of drive shaft with Loctite Primer T. 2. Position pinion bearing into race while installing drive shaft and pinion gear into housing. 3. Apply Loctite 271 to pinion nut threads. 4. Install new pinion nut, with rounded corners FACING pinion gear, onto drive shaft. Models Drive Shaft Holding Tool 4-Stroke Mercury/Mariner 25, 30/40, and 45/50 91-83180M 2-Stroke Force 40/50 Mercury/Mariner 30/40, 40/50 91-825196 5. Using Drive Shaft Holding Tool to hold drive shaft, torque pinion nut to specified torque. 52864 7 a b c d 7 Loctite “271” (92-809819) a-Pinion Nut b-Pinion Gear c-Pinion Bearing d-Drive Shaft Holding Tool Pinion Nut Torque 50 lb-ft (67.8 Nm) 90-828631R3 MARCH 1999 Page 6A-39 NON-BIGFOOT GEAR HOUSING Propeller Shaft 1. Slide clutch (short shoulder faces forward gear) over propeller shaft aligning cross pin hole with slot in propeller shaft. 2. Insert cam follower spring into propeller shaft. a b d e f c a-Prop Shaft b-Retaining Spring c-Clutch Dog d-Cross Pin e-Cam Follower Spring f-Cam Follower 3. Using a 3/16 in. allen wrench or similar device, compress the follower spring enough to insert the cross pin partially through clutch. 4. Remove wrench and press cross pin through clutch and propeller shaft until flush. 52851 c a b a-Short Shoulder b-Allen Wrench c-Cross Pin 5. Reinstall retaining spring. position spring so as spring coils lay flat in clutch groove. a a-Spring Page 6A-40 90-828631R3 MARCH 1999 NON-BIGFOOT GEAR HOUSING NOTE: Applying 2-4-C w/Teflon to cam follower will aid in retention of follower in propeller shaft during installation of propeller shaft assembly into gear case. 6. Install cam follower. 95 a 52826 95 2-4-C w/Teflon (92-850736A1) a-Cam Follower 7. Install propeller shaft assembly into gear case. a 52864 a-Propeller Shaft Assembly 90-828631R3 MARCH 1999 Page 6A-41 NON-BIGFOOT GEAR HOUSING Bearing Carrier 1. Install carrier into gear case. 2. Discard the original tab washers or the thin 0.063 in. (1.60 mm) flat washers and the 25 mm long bolts on models listed. Install thicker flat washers and longer bolts. 25 (2 Cylinder - 4 Stroke) USA. . . . . . . . 0G621670 and below 45/50 (4 Cylinder - 4 Stroke) Non Big Foot USA. . . . . . . . 0G621709 and below 30/40 (2 Cylinder - 2 Stroke) USA. . . . . . . . 0G650736 and below Belgium . . . . NA 40/50 (3 Cylinder - 2 Stroke) USA. . . . . . . . 0G650699 and below Belgium . . . . NA Force 40/50 (2 Cylinder - 2 Stroke) USA. . . . . . . . 0E323508 and below a cb a-Bolt 25 mm Long - Discard b-Tab Washer - Discard c-Thin Flat Washer 0.063 in. (1.60 mm) thick - Discard 3. Install thicker flat washers and longer bolts. a b a-Bolt (10-855940-30) 1.18 in. (30 mm) Long b-Washer (12-855941) 0.090 in. (2.29 mm) Thick Page 6A-42 90-828631R3 MARCH 1999 NON-BIGFOOT GEAR HOUSING 4. Torque bolts to specified torque. 7 7 Loctite “271” (92-809819) a a 7 a-Bolts Bearing Carrier Bolt Torque 18.8 lb-ft (25.4 Nm) Water Pump 1. Install water pump seal carrier. 2. Install exhaust deflector plate, if removed. 52832 b a a-Seal Carrier b-Exhaust Deflector 90-828631R3 MARCH 1999 Page 6A-43 NON-BIGFOOT GEAR HOUSING 3. Install base gasket, face plate, pump cover gasket (NEOPRENE STRIP FACES UP), nylon washer and impeller key. 52868 a b c e f d a-Base Gasket b-Base Plate c-Cover Gasket d-Neoprene Strip e-Nylon Washer f-Key IMPORTANT: If impeller being installed has been previously used and vanes have taken a “set,” DO NOT INSTALL THE IMPELLER WITH THE VANES REVERSED FROM THEIR PREVIOUS “SET” AS VANE BREAKAGE WILL OCCUR SHORTLY AFTER UNIT IS RETURNED TO SERVICE. Page 6A-44 90-828631R3 MARCH 1999 NON-BIGFOOT GEAR HOUSING 4. Install impeller and nylon washer. a b 52869 a-Impeller b-Nylon Washer NOTE: Apply a light coat of 2-4-C w/Teflon to inside of pump cover to ease installation of cover over impeller. 5. Install pump cover. Rotate drive shaft CLOCKWISE while pressing cover down over impeller. 6. Apply Loctite 271 to retaining bolts and torque bolts to specified torque. 52830 7 b a 7 Loctite “271” (92-809819) a-Cover b-Bolts (4) Water Pump Bolt Torque 60 lb-in. (6.8 Nm) 90-828631R3 MARCH 1999 Page 6A-45 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. Repair leak as necessary. Retest housing. NOTE:It should hold 10-12 psi (69-83 kPa) for 5 minutes. 7. Remove tester from housing and install vent plug. Page 6A-46 90-828631R3 MARCH 1999 NON-BIGFOOT GEAR HOUSING Gear Housing Installation WARNING Disconnect (and isolate) spark plug leads before installing gear housing onto drive shaft housing. 1. Position shift lever in NEUTRAL gear position. 2. Tilt engine to full “Up” position. Engage tilt lock lever. 3. Shift gear housing into NEUTRAL. Propeller shaft will rotate freely in either direction. IMPORTANT: Liberally apply 2-4-C Marine Lubricant w/Teflon to drive shaft splines. 4. Position drive shaft into drive shaft housing. Move gear housing upwards in drive shaft housing while aligning both shift shafts, water tube seal and drive shaft splines. NOTE:If the drive shaft splines will not align with the crankshaft splines, rotate flywheel slightly while pushing gear housing into drive shaft housing. 5. Install 4 bolts and washers, (two each side). Torque bolts to specified torque. 52836 a-Bolt and Washers (2 each side) a Gear Housing Bolt Torque 40 lb-ft (54.2 Nm) 90-828631R3 MARCH 1999 Page 6A-47 NON-BIGFOOT GEAR HOUSING 2-Stroke Models MERCURY/MARINER 30/40, AND 40/50 FORCE 40/50 6. Reconnect shift shaft with coupler nut and jam nut. Tighten jam nut against coupler nut. NOTE:After reconnecting shift shaft, bottom of jam nut should be approximately flush with top of spray plate. 52834 a c b a-Coupler Nut b-Jam Nut c-Spray Plate 4-Stroke Models MERCURY/MARINER 25, 30/40, AND 45/50 7. Connect shift shaft by sliding retainer to the right and snapping into upper “locked” position. a b 53859 a-Retainer b-Lower Clip Page 6A-48 90-828631R3 MARCH 1999 NON-BIGFOOT GEAR HOUSING 8. Install locknut and washer. Torque nut to specified torque. 52833 a a-Locknut and Washer Nut Torque 40 lb-ft (54.2 Nm) 9. Check shift operation. a. In NEUTRAL, propeller shaft should turn freely in either direction. b. In FORWARD, propeller shaft SHOULD NOT TURN COUNTERCLOCKWISE. c. In REVERSE, propeller shaft SHOULD NOT TURN IN EITHER DIRECTION. IMPORTANT: If shift operation is not as described, remove the gear housing and correct the shift operation. Trim Tab Adjustment and Replacement IMPORTANT: The trim tab is made of a special alloy to aid in protecting the drive shaft housing and gear housing from galvanic corrosion (corrosion and pitting of metal surfaces). Do not paint or place protective coating on the trim tab, or trim tab corrosion protection function will be lost. Replace trim tab if 50% (or more) corroded. Mark location of old trim tab on anti-ventilation plate before removal; install new trim tab in same location. 1. Check trim tab position as follows: a. Operate boat at the speed at which it would normally be operated. b. If the boat pulls to the right (starboard), the trailing edge of trim tab must be moved to the right. If the boat pulls to the left (port), the trailing edge of trim tab must be moved to the left. 2. If necessary, adjust trim tab as follows: a. Shift engine control into NEUTRAL and turn ignition key to “OFF” position. NOTE:Loosen trim tab bolt sufficiently to allow trim tab to disengage from locking ridges in gear case before attempting to move tab. DO NOT strike trim tab with a hard object to make adjustments. 90-828631R3 MARCH 1999 Page 6A-49 NON-BIGFOOT GEAR HOUSING b. If boat pulls to the left, adjust trailing edge of trim tab to the left. If boat pulls to the right, adjust trailing edge of trim tab to the right. a b c 52835 a-Trim Tab b-Anti-Ventilation Plate c-Retaining Bolt and Washer Bolt Torque 15.8 lb-ft (21.4 Nm) Page 6A-50 90-828631R3 MARCH 1999 NON-BIGFOOT GEAR HOUSING Filling Gear Housing with Lubricant NOTE:Gear housing lubricant capacity is approximately 14.9 fl oz (440 ml). WARNING If gear housing is installed on outboard, disconnect (and isolate) spark plug leads from spark plugs before working near the propeller. CAUTION Do not use automotive grease in the gear housing. Use only Quicksilver Gear Lube. 1. Remove any gasket material from “Fill” and “Vent” plugs and gear housing. Install new gaskets on “Fill” and “Vent” plugs. IMPORTANT: Never add lubricant without removing “Vent” plug. Gear housing cannot be filled because of trapped air. Fill gear housing when driveshaft is in a vertical position. 2. Remove “Fill” plug and gasket. 3. Insert lubricant tube in “Fill” hole, then remove “Vent” plug and gasket. 4. Fill until excess lubricant flows out of “Vent” hole. Let gearcase sit for at least one minute to allow lube to settle out, then top off. 5. Replace this “Vent” plug and gasket. 6. Install “Fill” plug and gasket. a a-“Vent” Plug 7. Torque “Fill” and “Vent” screws to 55 lb-in. (6.2 Nm). 90-828631R3 MARCH 1999 Page 6A-51 BIGFOOT GEAR HOUSING LOWER UNIT Section 6B - Bigfoot Gear Housing Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-2 Quicksilver Lubricants and Service Aids . . . . . . 6B-5 Gear Housing (Driveshaft) (2.31:1 Gear Ratio) . . . . . . . . . . . . . . . . . . . . . . . . 6B-6 Gear Housing (Prop Shaft) (2.31:1 Gear Ratio) . . . . . . . . . . . . . . . . . . . . . . . . 6B-8 General Service Recommendations . . . . . . . . 6B-10 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-10 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-10 Draining and Inspecting Gear Lubricant . . . . . 6B-11 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-12 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-13 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-13 Bearing Carrier and Propeller Shaft . . . . . . 6B-16 Pinion Gear, Driveshaft, and Forward Gear. . . . . . . . . . . . . . . . . . . . . . . . . 6B-21 Upper Driveshaft Bearing. . . . . . . . . . . . . . . 6B-24 Oil Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-25 Lower Driveshaft Bearing Race . . . . . . . . . 6B-26 Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-27 Forward Gear Bearing Race . . . . . . . . . . . . 6B-29 Trim Tab Adjustment and Replacement . . . 6B-29 Specifications Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-30 Forward Gear Bearing Race . . . . . . . . . . . . 6B-30 Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-30 Bearing Carrier Reassembly . . . . . . . . . . . . 6B-33 Forward Gear Reassembly . . . . . . . . . . . . . 6B-37 Propeller Shaft Reassembly . . . . . . . . . . . . 6B-39 Driveshaft Wear Sleeve Installation . . . . . . 6B-40 Lower Driveshaft Bearing Race Installation . . . . . . . . . . . . . . . . . . . . . . 6B-42 Oil Sleeve Installation . . . . . . . . . . . . . . . . . . 6B-43 Upper Driveshaft Bearing Installation . . . . 6B-43 Forward Gear, Lower Driveshaft Bearing, Pinion Gear, and Driveshaft Installation . . 6B-45 Pinion Gear Depth and Forward Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . 6B-46 Bearing Carrier and Propeller Shaft Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-51 Water Pump Reassembly and Installation 6B-53 Gear Housing Pressure Test . . . . . . . . . . . . 6B-56 Filling Gear Housing With Lubricant . . . . . . . . 6B-57 Gearcase Installation . . . . . . . . . . . . . . . . . . . . . 6B-58 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . 6B-62 6 B GEAR HOUSING BIGFOOT (2.3:1) Gear Ratio Gearcase Capacity Lubricant Type Forward Gear Number of Teeth Pinion Gear Number of Teeth Pinion Height Pinion Gear Locating Tool Flat Number Disc Number Forward Gear Backlash Backlash Indicating Tool Mark Number Water Pressure @ 800 rpm (Idle) @ 6000 rpm (WOT) 2.31:1 22.5 fl oz (655 mL) Quicksilver Gear Lube-Premium Blend 30 Spiral/Bevel 13 Spiral/Bevel 0.025 in. (0.64 mm) 91-12349A2 #8 #3 0.012-0.019 in. (0.30-0.48 mm) 91-78473 #4 2-4 psi (14-28 kPa) 10-15 psi (69-103 kPa) 90-828631R3 MARCH 1999 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 90-828631R3 MARCH 1999 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. Threaded Rod (91-31229) and Nut (91-24156)* 13. Slide Hammer (91-34569A1) 90-828631R3 MARCH 1999 Page 6B-3 BIGFOOT GEAR HOUSING 14. Mandrel (91-36569)* 15. Universal Puller Plate (91-37241) 73652 16. Driver Rod (91-37323)* 74184 17. Mandrel (91-37350) 18. Puller Jaws (91-46086A1) 19. Driver Shaft Holding Tool (91-56775, 2-Stroke) (91-817070, 4-Stroke) 20. Dial Indicator (91-58222A1) Page 6B-4 90-828631R3 MARCH 1999 BIGFOOT GEAR HOUSING 21. Backlash Indicator Tool (91-78473) 2.31:1 Gear Ratio (13/30) 22. Puller Bolt (91-85716) 23. Dial Indicator Adaptor Kit (91-83155) 24. Bearing Puller Assembly (91-83165M) 25. Bearing Installation Tool (91-856875A1) 56783 * From Bearing Removal and Installation Kit (91-31229A7) Quicksilver Lubricants and Service Aids Part No. Description 92-809819 Loctite “271” 92-891601-1 RTV Silicone Sealer 92-850737A1 Super Duty Gear Lubricant 92-850735A1 Anti-Corrosion Grease 92-850736A1 2-4-C w/Teflon 90-828631R3 MARCH 1999 Page 6B-5 BIGFOOT GEAR HOUSING Gear Housing (Driveshaft)(2.31:1 Gear Ratio) BIGFOOT 4.25 IN./107.95 MM TORPEDO DIA. 95 13 13 15 7 87 95 Loctite “271” Adhesive Sealant (92-809819) Super Duty Gear Lubricant (92-13783A24) 2-4-C w/Teflon (92-825407A12) 95 95 95 95 7 7 7 7 7 87 7 2 3 4 5 6 7 8 9 10 12 14 16 17 22 33 18 19 20 21 23 24 35 25 26 27 28 29 30 31 32 34 36 37 38 39 40 41 3 5 5 11 1 Page 6B-6 90-828631R3 MARCH 1999 BIGFOOT GEAR HOUSING Gear Housing (Driveshaft)(2.31:1 Gear Ratio) REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm – 1 GEAR HOUSING (BLACK) – 1 GEAR HOUSING (GRAY) 11 1 GEAR HOUSING (BLACK) 1 GEAR HOUSING (GRAY) 2 1 DOWEL PIN (FRONT) 3 2 DRAIN SCREW 60 6.8 4 1 SCREW (MAGNETIC) 60 6.8 5 3 WASHER–Sealing 6 1 DOWEL PIN (REAR) 7 1 TRIM TAB 8 1 SCREW (7/16-14 x 1-1/4) 22 29.8 9 1 WASHER 10 1 CARRIER 11 1 NEEDLE BEARING 12 1 OILER TUBE 13 2 ANODE 14 1 SCREW 15 1 NUT 60 6.8 16 1 PINION GEAR (13 TEETH) 17 1 NUT 70 94.9 18 1 SHIFT CAM 19 1 TAPERED ROLLER BEARING 20 AR SHIM ASSEMBLY 21 1 DRIVESHAFT ASSEMBLY 22 1 WEAR SLEEVE ASSEMBLY 23 1 COVER ASSEMBLY 24 1 GASKET 25 1 OIL SEAL (LOWER) 26 1 OIL SEAL (UPPER) 27 1 GASKET 28 1 GASKET 29 1 WATER PUMP ASSEMBLY 30 1 FACE PLATE 31 4 SCREW (M6 x 30) 60 6.8 32 1 SEAL 33 1 KEY 34 1 IMPELLER 35 6 SCREW (M6 x 25) 60 6.8 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 25) 60 6.8 90-828631R3 MARCH 1999 Page 6B-7 BIGFOOT GEAR HOUSING Gear Housing (Propeller Shaft)(2.31:1 Gear Ratio) Bigfoot 1 95 95 7 95 95 95 95 7 42 43 44 46 47 48 50 5152 53 54 55 56 57 58 59 60 61 62 63 64 6566 67 68 45 4.25 IN./107.95 MM TORPEDO DIA. 49 67 7 Loctite “271” Adhesive Sealant (92-809819) 95 2-4-C w/Teflon (92-825407A12) A 69 70 71 A – TORQUE NUT TO 55 LB-FT (74.6 NM) Page 6B-8 90-828631R3 MARCH 1999 BIGFOOT GEAR HOUSING Gear Housing (Propeller Shaft)(2.31:1 Gear Ratio) REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm – 1 GEAR HOUSING (BLACK) – 1 GEAR HOUSING (GRAY) 11 1 GEAR HOUSING (BASIC) (BLACK) 1 GEAR HOUSING (BASIC) (GRAY) 42 1 FORWARD GEAR (30 TEETH) 43 AR SHIM ASSEMBLY 44 1 TAPERED ROLLER BEARING 45 1 CUP 46 1 ROLLER BEARING 47 1 CAM FOLLOWER ASSEMBLY 48 3 BALL 49 1 SLIDE 50 1 SPRING 51 1 CLUTCH 52 1 CROSS PIN 53 1 SPRING 54 1 PROPELLER SHAFT 55 1 REVERSE GEAR (30 TEETH) 56 1 BEARING CARRIER ASSEMBLY 57 1 O-RING 58 1 ROLLER BEARING 59 1 OIL SEAL (INNER) 60 1 OIL SEAL (OUTER) 61 1 ROLLER BEARING 62 1 THRUST WASHER 63 1 THRUST BEARING 64 2 STUD (M8 x 48) 100 135 65 2 WASHER 66 2 NUT 25 33.9 67 2 THREADED INSERT 68 1 DECAL-Gear Case Identification 69 1 THRUST HUB ASSEMBLY THESE PARTS ARE NOT PROPELLER NUT ASSEMBLY INCLUDED WITH COMPLETE TAB WASHER GEAR HOUSING REPLACEMENT 70 1 55 74.6 71 1 90-828631R3 MARCH 1999 Page 6B-9 BIGFOOT GEAR HOUSING General Service Recommendations There may be more than one way to “disassemble” or “reassemble” a particular part(s), therefore, it is recommended that the entire procedure be read prior to repair. IMPORTANT: Read the following before attempting any repairs. In many cases, disassembly of a sub-assembly may not be necessary until cleaning and inspection reveals that disassembly is required for replacement of one or more components. Service procedure order in this section is a normal disassembly-reassembly sequence. Threaded parts are right hand (RH), unless otherwise indicated. When holding, pressing or driving is required, use soft metal vise jaw protectors or wood for protection of parts. Use a suitable mandrel (one that will contact only the bearing race) when pressing or driving bearings. Whenever compressed air is used to dry a part, verify that no water is present in air line. Bearings All bearings must be cleaned and inspected. Clean bearings with solvent and dry with compressed air. Air should be directed at the bearing so that it passes through the bearing. DO NOT spin bearing with compressed air, as this may cause bearing to score from lack of lubrication. After cleaning, lubricate bearings with Quicksilver Gear Lubricant. DO NOT lubricate tapered bearing cups until after inspection. Inspect all bearings for roughness, catches and bearing race side wear. Work inner bearing race in-and-out, while holding outer race, to check for side wear. When inspecting tapered bearings, determine condition of rollers and inner bearing race by inspecting bearing cup for pitting, scoring, grooves, uneven wear, imbedded particles and/or discoloration from over-heating. Always replace tapered bearing and race as a set. Inspect gear housing for bearing races that have spun in their respective bores. If race(s) have spun, gear housing must be replaced. Roller bearing condition is determined by inspecting the surface of the shaft that the roller bearing supports. Check shaft surface for pitting scoring, grooving, imbedded particles, uneven wear and/or discoloration from overheating. The shaft and bearing must be replaced if such a condition exists. Seals As a normal procedure, all O-rings and oil seals should be replaced without regard to appearance. To prevent leakage around seals, apply Loctite 271 to outer diameter of all metal case seals. When using Loctite on seals or threads, surfaces must be clean and dry. Apply 2-4-C w/Teflon on all O-rings and on I.D. of oil seals. Apply 2-4-C w/Teflon to external surfaces of bearing carrier. Page 6B-10 90-828631R3 MARCH 1999 BIGFOOT GEAR HOUSING Draining and Inspecting Gear Lubricant WARNING If gear housing is installed on engine, to avoid accidental starting, disconnect (and isolate) spark plug leads from spark plugs before working near the propeller. 1. With gear housing in normal running position, place a clean pan under housing and remove the two vent screws and one fill/drain screw (with gaskets). 53922 a b c a-Oil Level Screw b-Fill/Drain Screw c-Vent Screw 2. Inspect gear lubricant for metal particles (lubricant will have a “metal flake” appearance). Presence of fine metal particles (resembling powder) on the drain plug bar magnet indicates normal wear. The presence of metal chips on the drain plug bar magnet indicates the need for gear housing disassembly and component inspection. 3. Note color of gear lubricant. White or cream color MAY indicate presence of water in lubricant. Gear lubricant which has been drained from a gear case recently in operation will have a yellowish color due to lubricant agitation/aeration. Gear lube which is mixed with assembly lubricant (Special Lube 101 or 2-4-C w/Teflon) will also be creamy white in color. This is normal and should not be confused with the presence of water. If water is suspected to be present in gearcase, a pressure check of gearcase should be made (with no lubricant in gearcase). Gearcase should hold 10 to 12 psi of pressure for 5 minutes without leaking down. Pouring a portion of the gear lubricant into a glass jar and allowing the lubricant to settle will allow any water in the lube to separate and settle to the bottom of the jar. 4. Presence of water in gear lubricant indicates the need for disassembly and inspection of oil seals, seal surfaces, O-rings, water pump gaskets as well as gear housing components for damage. If gearcase is rebuilt, gearcase should be pressure checked before filling with lubricant. 90-828631R3 MARCH 1999 Page 6B-11 BIGFOOT GEAR HOUSING Removal WARNING To prevent accidental engine starting, remove (and isolate) spark plug leads from spark plugs before removing gear housing. 1. Remove (and isolate) spark plug leads from spark plugs. 2. Shift engine into forward gear. 3. Tilt engine to full “Up” position. 4. Remove 4 fasteners. 5. Remove locknut and washer. 6. Remove gear housing. 53992 a b a-Fasteners (2 Each Side) b-Locknut and Washer Page 6B-12 90-828631R3 MARCH 1999 BIGFOOT GEAR HOUSING Disassembly Water Pump NOTE:If water tube seal stayed on water tube (inside of driveshaft housing) when gear housing was removed, pull water tube seal from water tube. 1. Replace water tube seal, if damaged. 2. Remove 4 bolts, washers, and isolators. 3. Remove cover. 19212 a b c b a-Water Tube Seal b-Bolts (4 each) c-Cover IMPORTANT: The circular groove formed by the impeller sealing bead should be disregarded when inspecting cover (Step 5) and plate (Step 9), as the depth of the groove will not affect water pump output. 4. Replace cover if thickness of steel at the discharge slots is 0.060 in. or less, or if groove(s) (other than impeller sealing bead groove) in cover roof are more than 0.030 in. (0.762 mm) deep. 5. Lift impeller, drive key, and gasket from driveshaft. a bc 19220 a-Impeller b-Drive Key c-Gasket 90-828631R3 MARCH 1999 Page 6B-13 BIGFOOT GEAR HOUSING 6. Inspect impeller. Replace impeller if any of the following conditions exist: • Impeller blade(s) are cracked, torn, or worn. • Impeller is glazed or melted (caused by operation without sufficient water supply). • Rubber portion of impeller is not bonded to impeller hub. 7. Remove plate and gasket. 8. Replace plate if groove(s) (other than impeller sealing bead groove) in plate are more than 0.030 in. (0.762 mm) deep. 19219 a b c a-Plate b-Gasket c-Impeller Sealing Groove 9. Remove bolts and washers. a 19217 a-Bolts and Washers (6 each) Page 6B-14 90-828631R3 MARCH 1999 BIGFOOT GEAR HOUSING 10. Remove water pump base. 19226 a a-Water Pump Base 11. Remove (and discard) seals. 19195 a a-Seals 12. Remove gasket. 19218 a a-Gasket 90-828631R3 MARCH 1999 Page 6B-15 BIGFOOT GEAR HOUSING Bearing Carrier and Propeller Shaft 1. Remove fasteners. 51117 a a a-Fasteners 2. With propeller shaft horizontal, pull carrier to break seal with gear housing. Remove bearing carrier/propeller shaft components as an assembly, taking care not to lose cam follower or 3 metal balls in end of propeller shaft. 3. Remove propeller shaft from bearing carrier. 51116 a b c d e a-Bearing Carrier b-Puller Jaws (91-46086A1) c-Puller Bolt (91-85716) d-Thrust Hub e-Propeller Shaft Page 6B-16 90-828631R3 MARCH 1999 BIGFOOT GEAR HOUSING 4. Lift reverse gear, thrust bearing and thrust washer from bearing carrier. 5. Replace reverse gear if gear teeth or clutch teeth on reverse gear are chipped or worn. If reverse gear must be replaced, pinion gear and sliding clutch should be inspected for damage. 6. Replace thrust bearing and thrust washer if rusted or damaged. 19202 a b c a-Reverse Gear b-Thrust Bearing c-Thrust Washer 7. If bearing is rusted or does not roll freely, replace bearing. Remove bearing using Slide Hammer (91-34569A1). a 91-34569A1 19205 a-Bearing 90-828631R3 MARCH 1999 Page 6B-17 BIGFOOT GEAR HOUSING 8. If bearing is rusted or does not roll freely, replace bearing. Remove bearing and oil seals using Mandrel* (91-36569) and Driver Rod* (91-37323). Discard oil seals. NOTE:*From Bearing Removal and Installation Kit (91-31229A7) 51264 a b c 91-37323 91-36569 a-Bearing b-Mandrel (91-26569) c-Driver Rod (91-37323) 9. Remove (if not removed with bearing in Step 9) propeller shaft seals and bearing carrier O-ring. 51263 a a-O-ring Page 6B-18 90-828631R3 MARCH 1999 BIGFOOT GEAR HOUSING 10. Remove spring. 51876 a a-Spring 11. Apply constant pressure to cam follower to prevent cam follower assembly from ejecting from propeller shaft while pushing cross pin out of clutch dog. 51800 a b a-Cross Pin b-Cam Follower 90-828631R3 MARCH 1999 Page 6B-19 BIGFOOT GEAR HOUSING 12. Remove components from propeller shaft. 13. Replace cam follower if worn or pitted. 14. Replace sliding clutch if jaws are rounded or chipped. Rounded jaws indicate one or more of the following: • Improper shift cable adjustment. • Engine idle speed too high while shifting. • Shifting from neutral to reverse (or forward) too slowly. 51265 a b c d e f f a-Cam Follower b-3 Metal Balls c-Guide Block d-Spring e-Sliding Clutch f-Jaws 15. Check bearing surfaces of propeller shaft for pitting or wear. If shaft is worn or pitted, replace shaft and corresponding bearing. 16. Replace propeller shaft if any of the following exist: • Splines are twisted or worn. • Oil seal surface is grooved. • Shaft has a noticeable “wobble” or is bent more than 0.009 in. (0.228 mm). Prop shaft trueness should be measured with a dial indicator with prop shaft on V-blocks. a bc b 51877 a-V-Blocks b-Bearing Surfaces c-Measure with Dial Indicator at This Point Page 6B-20 90-828631R3 MARCH 1999 BIGFOOT GEAR HOUSING Pinion Gear, Driveshaft, and Forward Gear 1. Hold driveshaft using Driveshaft Holding Tool; remove (and discard) pinion nut. Model Driveshaft Holding Tool 40/50 Bigfoot (4-Stroke) 91-56775 60 Bigfoot 91-817070 75/90/100/115/125 91-56775 2. Remove driveshaft, pinion gear, bearing and forward gear. 3. Replace pinion gear if it is chipped or worn. 4. Replace bearing and race if either are rusted, pitted or damaged; or if bearing does not roll freely. To remove race, refer to “Lower Driveshaft 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-Driveshaft Holding Tool b-Pinion Nut c-Driveshaft d-Pinion Gear e-Bearing f-Forward Gear 90-828631R3 MARCH 1999 Page 6B-21 BIGFOOT GEAR HOUSING 6. Replace bearing if it is rusted or does not roll freely; use a punch and hammer to remove bearing. 19203a a-Bearing 7. Replace forward gear bearing and race if either are rusted, 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 Page 6B-22 90-828631R3 MARCH 1999 BIGFOOT GEAR HOUSING 8. Replace driveshaft if splines are worn or twisted. 9. If bearing surface is damaged, replace driveshaft and corresponding bearing. IMPORTANT: Do not tighten vise against driveshaft. 10. If wear sleeve is deeply grooved allowing water to enter gear case, remove (and discard) sleeve using Universal Puller Plate (91-37241) and mallet. 19710 a b c e a 91-37241 d a-Splines b-Bearing Surface c-Wear Sleeve d-Universal Puller Plate (91-37241) e-Mallet 11. Remove (and discard) rubber ring. 19152 a a-Rubber Ring 90-828631R3 MARCH 1999 Page 6B-23 BIGFOOT GEAR HOUSING Upper Driveshaft Bearing 1. Replace upper driveshaft 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 Driveshaft Bearing b-Sleeve c-Puller Assembly (91-83165M) IMPORTANT: Upper driveshaft bearing/sleeve must be removed prior to oil sleeve removal. Refer to “Upper Driveshaft Bearing,” preceding. Page 6B-24 90-828631R3 MARCH 1999 BIGFOOT GEAR HOUSING Oil Sleeve 1. Remove oil sleeve (if necessary) using Puller Assembly (91-83165M) with suitable jaws. b a 91-83165M 19222 a-Oil Sleeve b-Puller Assembly (91-83165M) IMPORTANT: Upper driveshaft bearing/sleeve and oil sleeve do not have to be removed for lower driveshaft bearing race removal. 90-828631R3 MARCH 1999 Page 6B-25 BIGFOOT GEAR HOUSING Lower Driveshaft Bearing Race IMPORTANT: Retain shim(s) for reassembly. 1. Remove race and shim(s) using bearing race tool (91-14308A1). 19171 a b c 91-14308A1 a-Race b-Shim(s) c-Bearing Race Tool (91-14308A1) Page 6B-26 90-828631R3 MARCH 1999 BIGFOOT GEAR HOUSING Shift Shaft 1. Remove shift shaft coupler and nylon spacer. 53925 a b 75 Tiller Model Shown a-Shift Shaft Coupler b-Spacer 2. Remove bolts. 53926 a a-Bolts NOTE: Gearcase should be in FORWARD for easiest removal of shift shaft. 3. Remove shift shaft bushing and shift shaft. 53927 a b a-Bushing b-Shift Shaft 90-828631R3 MARCH 1999 Page 6B-27 BIGFOOT GEAR HOUSING 4. Remove shift cam from housing. 5. Replace shift cam if worn. 60 Bigfoot Shown 51117 a a-Shift Cam NOTE: If shift shaft splines are rough, shift shaft seal lips will be cut during removal/ installation. 6. Remove shift shaft bushing and clip from shift shaft. 7. Replace shift shaft if splines are worn or shaft is twisted. 8. Remove (and discard) O-ring. 53928 a b c ded a-Bushing b-Clip c-Shift Shaft d-Splines e-O-ring 9. Remove (and discard) seal. 53929 a a-Seal Page 6B-28 90-828631R3 MARCH 1999 BIGFOOT GEAR HOUSING Forward Gear Bearing Race IMPORTANT: Retain shim(s) for reassembly. If shims are damaged, replace with new shims of equal thickness. 1. Remove race and shim(s) using Slide Hammer (91-34569A1). 27653 a b c 91-34569A1 a-Race b-Shim(s) c-Slide Hammer (91-34569A1) Trim Tab Adjustment and Replacement IMPORTANT: The trim tab is now painted and does NOT aid in protecting the drive- shaft housing and gear housing from galvanic corrosion (corrosion and pitting of metal surfaces). Side anodes now provide protection. Do not paint or place protective coating on the side anodes, or corrosion protection function will be lost. 1. Replace trim tab if damaged. Mark location of old trim tab on anti-ventilation plate before removal; install new trim tab in same location. 2. The trim tab provides a means to offset (balance) some of the steering load that is caused by propeller torque at higher operating speeds. If at higher speeds the boat turns more easily to the left, loosen bolt, move the trim tab (trailing edge) to the left (when viewed from behind); retighten bolt. Turn trim tab (trailing edge) to the right if the boat turns more easily to the right. Torque retaining bolt to specified torque. 53931ab c a-Trim Tab b-Anti-Ventilation Plate c-Retaining Bolt and Washer Retaining Bolt Torque 22 lb-ft (29.8 Nm) 90-828631R3 MARCH 1999 Page 6B-29 BIGFOOT GEAR HOUSING Reassembly Forward Gear Bearing Race 1. Place shim(s) (retained from disassembly) into housing. If shim(s) were lost, or a new gear housing is being assembled, start with 0.010 in. (0.254 mm) shim(s). 2. Assemble components as shown using mandrel (91-31106); Apply 2-4-C w/Teflon to O.D. of race. Drive race into housing by striking propeller shaft end with lead hammer. 19179 b de a c 91-31106 95 2-4-C w/Teflon (92-850736A1) 95 a-Shim(s) b-Race c-Mandrel (91-31106) d-Disassembled Propeller Shaft e-Assembled Bearing Carrier Shift Shaft 1. Apply Loctite 271 on O.D. of new seal. 2. Press seal into shift shaft bushing until seal is seated against shoulder. 3. Install new O-ring. 4. Apply 2-4-C with Teflon on O-ring and I.D. of seal. 53930 b c d 7 Loctite “271” (92-809819) 7 95 2-4-C w/Teflon (92-850736A1) 95 a a-Seal b-Bushing c-Surface d-O-ring Page 6B-30 90-828631R3 MARCH 1999 BIGFOOT GEAR HOUSING 90-828631R3 MARCH 1999 Page 6B-31 5. Assemble components as shown. 53928 a b c a - Shift Shaft b - “E” Clip c - Shift Shaft Bushing 6. Install shift cam; align hole in shift cam with hole in gear housing. 60 Bigfoot 75/90/100/115/125 51117 a b a - Shift Cam (marked with “UP” and part number) b - Gear Housing Hole 60 Bigfoot 75/90/100/115/125 51117 a b a - Shift Cam (marked with part number only) b - Gear Housing Hole BIGFOOT GEAR HOUSING 40/50 Bigfoot (4-Stroke) 51117 850307 a b a-Shift Cam (Numbers Down) b-Hole 7. Install shift shaft assembly; insert splines into shift cam. 53932 a b a-Shift Shaft Assembly b-Splines 8. Apply Loctite 271 on bottom half of threads of bolts; install bolts and torque to specified torque. 53926 a 7 Loctite “271” (92-809819) 7 a-Bolts (2) Bolt Torque 60 lb-in. (6.8 Nm) Page 6B-32 90-828631R3 MARCH 1999 BIGFOOT GEAR HOUSING Bearing Carrier Reassembly 1. Lubricate O.D. of bearing and bearing carrier bore with Quicksilver 2-4-C w/Teflon. 2. Protect lip on forward side of bearing carrier, using bearing installation tool (91-13945). 3. Press propeller shaft needle bearing (number side toward mandrel 91-15755) into carrier, until bearing bottoms out. 95 21042 a b c 2-4-C w/Teflon (92-850736A1) 95 91-13945 91-15755 a-Bearing Installation Tool (91-13945) b-Mandrel (91-15755) c-Suitable Driver Rod 90-828631R3 MARCH 1999 Page 6B-33 BIGFOOT GEAR HOUSING 4. Place smaller diameter seal on longer shoulder of Oil Seal Driver (91-31108) with seal lip away from shoulder. 5. Protect lip on front side of bearing carrier using Bearing Installation Tool (91-13945). Apply Loctite 271 on O.D. of seal. Press seal into carrier until tool bottoms. 7 21040 ab c Loctite “271” (92-809819) 7 91-31108 91-13945 a-Seal b-Oil Seal Driver (91-31108) c-Bearing Installation Tool (91-13945) 6. Place larger diameter seal on shorter shoulder of Oil Seal Driver (91-31108) with seal lip toward shoulder. 7. Protect lip on front side of bearing carrier using Bearing Installation Tool (91-13945). Apply Loctite 271 on O.D. of new seal. Press seal into carrier until tool bottoms. 21041 a b c a 91-31108 91-13945 7 Loctite “271” (92-809819) 7 a-Seal b-Oil Seal Driver (91-31108) c-Bearing Installation Tool (91-13945) Page 6B-34 90-828631R3 MARCH 1999 BIGFOOT GEAR HOUSING 8. Install O-ring. Lubricate O-ring with 2-4-C w/Teflon. Lubricate seal lips with 2-4-C w/Teflon. 9. Lubricate outside diameter of reverse gear bearing and bearing carrier bore with a light coating of 2-4-C w/Teflon. 10. Press bearing into carrier until tool bottoms. 19163 a b c 95 95 91-13945 2-4-C w/Teflon (92-850736A1) a-O-ring b-Bearing, Numbered Side Toward Tool c-Bearing Installation Tool (91-13945) 11. Install thrust washer. Coat thrust washer with Super Duty Gear Lubricant. 19167 a 87 Super Duty Gear Lubricant (92-850737A1) 87 a-Thrust Washer 90-828631R3 MARCH 1999 Page 6B-35 BIGFOOT GEAR HOUSING 12. Install thrust bearing. Coat thrust bearing with Super Duty Gear Lubricant. a 87 19168 87 Super Duty Gear Lubricant (92-850737A1) a-Thrust Bearing 13. Apply Super Duty Gear Lubricant to bearing surface of reverse gear and install reverse gear. 19202 a b 87 87 Super Duty Gear Lubricant (92-850737A1) a-Reverse Gear b-Bearing Surface Page 6B-36 90-828631R3 MARCH 1999 BIGFOOT GEAR HOUSING Forward Gear Reassembly 1. Press bearing onto gear using mandrel 91-37350 (press only on inner race of bearing). 51869 a b 91-37350 95 2-4-C w/Teflon (92-850736A1) 95 a-Mandrel (91-37350) b-Bearing; Lubricate I.D. with Quicksilver 2-4-C w/Teflon 2. Inspect reverse gear end of clutch to determine the number of jaws. Refer to chart, following, for tool end selection. Model Installation End Bearing Position Tool Stamped 3 Jaw Reverse 91-856875 3 0.155 in. (3.94mm) Clutch below surface 6 Jaw Reverse Clutch 91-856875 6 Flush with surface 3 Jaw Reverse Clutch c a b a-Stamped “3” b-Numbered end of Needle Bearing c-3 Jaw Reverse Clutch 90-828631R3 MARCH 1999 Page 6B-37 BIGFOOT GEAR HOUSING 6 Jaw Reverse Clutch 56784 c a b a-Stamped “6” b-Numbered end of Needle Bearing c-6 Jaw Reverse Clutch 3. Apply Quicksilver gear lubricant to I.D. of forward gear. Press bearing into forward gear until tool contacts gear. 56785 87 Quicksilver Gear Lubricant (92-19007A24) 87 a b a-Forward Gear Bearing Installer (91-856875) b-Needle Bearing, Numbered Side Toward Installer Tool Page 6B-38 90-828631R3 MARCH 1999 BIGFOOT GEAR HOUSING Propeller Shaft Reassembly 1. Install components into propeller shaft in sequence shown. 19154 abcd a-Spring b-Guide Block c-3 Metal Balls* d-Cam Follower* *Hold in Place With Quicksilver 2-4-C w/Teflon 2. Install cross pin. a b 51800 a-Apply Pressure in This Direction b-Cross Pin 3. Install spring. DO NOT overlap springs. 51876 a a-Spring 90-828631R3 MARCH 1999 Page 6B-39 BIGFOOT GEAR HOUSING Driveshaft Wear Sleeve Installation 1. Install new rubber ring. 2. Apply a light coat of Loctite 271 on outside diameter of rubber ring. a 7 Loctite “271” (92-809819) a-Ring 3. Insert sleeve into holder*. *Component of Wear Sleeve Installation Tool (91-14310A1). 19169 a b a 91-14310A1 a-Sleeve b-Holder 19152 Page 6B-40 90-828631R3 MARCH 1999 BIGFOOT GEAR HOUSING 4. Press sleeve onto driveshaft using Wear Sleeve Installation Tool (91-14310A1); continue pressing until surface contacts surface. 19166 a b c d b 91-14310A1 a-Driveshaft b-Wear Sleeve Installation Tool (91-14310A1) c-Surface d-Surface 5. Remove excess Loctite from assembled shaft. 90-828631R3 MARCH 1999 Page 6B-41 BIGFOOT GEAR HOUSING Lower Driveshaft Bearing Race Installation IMPORTANT: Lower driveshaft bearing cup can be installed with or without upper driveshaft bearing/sleeve and oil sleeve installed. 1. Lubricate O.D. of bearing race with Quicksilver 2-4-C w/Teflon. 2. Install shim(s) and bearing race into housing. NOTE:Verify shim(s) are not cocked when drawing up race. 53933 a b c d f 95 2-4-C w/Teflon (92-850736A1) 95 91-14310A1 f d c e a-Shim(s); Retained From Disassembly. If Shim(s) Were Lost or a New Gear Housing is Being Assembled, Start With 0.025 in. (0.635 mm) Shim(s) b-Bearing Race c-Mandrel* (13780) d-Mandrel* (13781) e-Threaded Rod** (91-31229) f-Nut** (11-24156) *From Bearing Installation Tool (91-14309A1) **From Bearing Removal and Installation Kit (91-31229A7) Page 6B-42 90-828631R3 MARCH 1999 BIGFOOT GEAR HOUSING Oil Sleeve Installation 1. Install oil sleeve with tab positioned as shown. 53934 a b a-Oil Sleeve b-Tab Upper Driveshaft Bearing Installation 1. Lubricate I.D. of bearing holder and O.D. of bearing with 2-4-C w/Teflon. 2. Press bearing into sleeve using mandrel from bearing installation tool (91-14309A1). 19164 a b c d 95 91-13781 95 2-4-C w/Teflon (92-850736A1) a-Bearing Sleeve b-Tapered End c-Bearing; Numbered Side Toward Mandrel d-Mandrel (91-13781); From Bearing Installation Tool (91-14309A1) 90-828631R3 MARCH 1999 Page 6B-43 BIGFOOT GEAR HOUSING IMPORTANT: Oil sleeve must be installed prior to upper drive bearing installation. IMPORTANT: Upper driveshaft bearing/sleeve can be installed with or without lower driveshaft bearing cup installed. 3. Install bearing/sleeve into housing. 53935 a b c 91-14310A1 e f d a-Bearing/Sleeve b-Tapered End c-Mandrel* (13781) d-Mandrel* (13780) e-Threaded Rod** (91-31229) f-Nut** (11-24156) *From Bearing Installation Tool (91-14309A1) **From Bearing Removal and Installation Kit (91-31229A7) Page 6B-44 90-828631R3 MARCH 1999 BIGFOOT GEAR HOUSING Forward Gear, Lower Driveshaft Bearing, Pinion Gear, and Driveshaft Installation 1. Install components in sequence shown. 19175 a b c d e f d 87 Super Duty Gear Lubricant (92-850737A1) 7 Loctite “271” (92-809819) 7 87 Model Driveshaft Holding Tool 40/50 Bigfoot (4-Stroke) 91-56775 60 Bigfoot 91-817070 75/90/100/115/125 91-56775 a-Forward Gear/Bearing: Work Quicksilver gear lube into bearing rollers. b-Lower Driveshaft Tapered Roller Bearing: Work Super Duty Gear Lube into bearing rollers. c-Pinion Gear d-Driveshaft e-Driveshaft Holding Tool f-Pinion Nut (New): Apply Loctite 271 to threads during final assembly (after pin ion gear depth and forward gear backlash have been set), torque to specified torque. Pinion Nut Torque 70 lb-ft (95 Nm) 90-828631R3 MARCH 1999 Page 6B-45 BIGFOOT GEAR HOUSING Pinion Gear Depth and Forward Gear Backlash DETERMINING PINION GEAR DEPTH NOTE:Read entire procedure before attempting any change in shim thickness. IMPORTANT: Forward gear assembly must be installed in gear housing when checking pinion gear depth or an inaccurate measurement will be obtained. 1. Clean the gear housing bearing carrier shoulder and diameter. 2. With gear housing positioned up right (driveshaft vertical), install Bearing Preload Tool (91-14311A2) over driveshaft in sequence shown. a b c d e f g h h a-Adaptor: Bearing surfaces clean and free of e-Nut: Threaded all-the-way onto bolt nicks f-Bolt: Held snug against spring b-Thrust Bearing: Oiled and able to move freely g-Sleeve: Holes in sleeve must align with set c-Thrust Washer: Clean and free of nicks and screws bends h-Set Screw (2): Tightened against driveshaft, d-Spring bolt should not slide on driveshaft. 3. Measure distance between top of nut and bottom of bolt head. 4. Increase distance by 1 in. (25.4 mm). 5. Rotate driveshaft 5 to 10 revolutions. This should properly seat driveshaft tapered roller bearing. 19884 a b c a-1 in. (25.4 mm) b-Nut c-Bolt Head Page 6B-46 90-828631R3 MARCH 1999 BIGFOOT GEAR HOUSING 6. Assemble Pinion Gear Locating Tool (91-12349A2) as shown; do not tighten collar retaining bolt at this time. a-Arbor From Split Collar c-Bolt; Gauging Block Retaining a b d e c f c b-Gauging Block; Install With Numbers Away e-Bolt; Collar Retaining d-Split Collar f-Snap Ring 7. Insert tool into forward gear assembly; position gauging block under pinion gear as shown. 22067 a a-Gauging Block 8. Remove tool, taking care not to change gauging block position, and tighten collar retaining bolt. 9. Insert tool into forward gear assembly; position proper numbered flat (from chart) of gauging block – under pinion gear. MODEL GEAR RATIO (PINION GEAR TEETH/REVERSE GEAR TEETH) USE FLAT NO. LOCATING DISC NO. 40/50 Bigfoot (4-stroke) 2.31:1 (13/30) 8 3 60 Bigfoot/60 Seapro/60 Marathon 2.31:1 (13/30) 8 3 75-thru-90 (3 Cylinder) 2.31:1 (13/30) 8 3 100/115/125 (4 Cylinder) 2.07:1 (14/29) 2 3 90-828631R3 MARCH 1999 Page 6B-47 BIGFOOT GEAR HOUSING 10. Install locating disc against bearing carrier shoulder in gear housing. 11. Position access hole as shown. 24643 b a Disc 3 a-Locating Disc b-Access Hole 12. Determine pinion gear depth by inserting a feeler gauge thru access hole in locating disc. 13. The correct clearance between gauging block and pinion gear is 0.025 in. (0.64 mm). 14. If clearance is correct, leave Bearing Preload Tool on driveshaft and proceed to “Determining Forward Gear Backlash,” following. 15. If clearance is incorrect, add (or subtract) shims from above bearing race to lower (or raise) pinion gear. When reinstalling pinion nut, apply Loctite 271 on threads of nut. 24643 a b c d 7 Loctite “271” (92-809819) 7 a-Feeler Gauge b-Gauging Block c-Pinion Gear d-Bearing Race Page 6B-48 90-828631R3 MARCH 1999 BIGFOOT GEAR HOUSING DETERMINING FORWARD GEAR BACKLASH NOTE:Read entire procedure before attempting any change in shim thickness. 1. Obtain correct pinion gear depth; refer to “Determining Pinion Gear Depth,” preceding. 2. Install Bearing Preload Tool (91-14311A2) on driveshaft; refer to “Determining Pinion Gear Depth,” preceding. 3. Install components as shown. 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. 90-828631R3 MARCH 1999 Page 6B-49 BIGFOOT GEAR HOUSING 4. Rotate driveshaft 5 to 10 revolutions. This should properly seat forward gear tapered roller bearing. 5. Install components as shown. 51117 a b d e f c c a-Threaded Rod (Obtain Locally) b-Washers c-Nuts d-Dial Indicator Adaptor Kit (91-83155) e-Dial Indicator (91-58222A1) f-Backlash Indicator Tool 6. Position Dial Indicator on appropriate line (from chart) marked on Backlash Indicator Tool. MODEL BACKLASH INDICATOR TOOL ALIGN POINTER OF DIAL INDICATOR WITH MARK 40/50 Bigfoot (4-Stroke) 91-78473 4 60 Seapro/60 Marathon/ 60 Bigfoot 91-78473 4 75-thru-90 (3 Cylinder) 91-78473 4 100/115/125 (4 Cylinder) 91-19660--1 1 Page 6B-50 90-828631R3 MARCH 1999 BIGFOOT GEAR HOUSING 7. Lightly turn driveshaft back-and-forth (no movement should be noticed at propeller shaft). 8. Dial Indicator registers amount of backlash, which must be between specification shown in chart. MODEL DIAL INDICATOR MINIMUM READING MAXIMUM 40/50 Bigfoot (4-Stroke) 0.012 in. (0.30 mm) 0.019 in. (.48 mm) 60 Bigfoot 0.012 in. (0.30 mm) 0.019 in. (.48 mm) 75-thru-90 (3 Cylinder) 0.012 in. (0.30 mm) 0.019 in. (.48 mm) 100/115/125 (4 Cylinder) 0.015 in. (0.38 mm) 0.022 in. (0.55 mm) 9. If backlash is less than the minimum specification, remove shim(s)* from in front of forward gear bearing race to obtain correct backlash. When reinstalling pinion nut, apply Loctite 271 on threads of nut. 10. If backlash is more than the maximum specification, add shim(s)* in front of forward gear bearing race to obtain correct backlash. When reinstalling pinion nut, apply Loctite 271 on threads of nut. * By adding or subtracting 0.001 in. (0.025 mm) shim, the backlash will change approximately 0.001 in. (.025 mm). Bearing Carrier and Propeller Shaft Installation 1. Insert propeller shaft assembly into bearing carrier. 2. Before installing bearing carrier assembly into gear housing, obtain locally a 6 in. (152.4 mm) long by 1-1/4 in. – 1-1/2 in. (31.7 – 38.1 mm) diameter piece of PVC pipe. Install the PVC pipe over the prop shaft and secure the pipe against the bearing carrier assembly with the propeller nut and tab washer. This will allow the reverse gear to apply pressure to the reverse gear thrust bearing to prevent the thrust bearing from being inadvertently dislodged as the bearing carrier assembly is installed in the gear housing. 21043 d a b c e a-Bearing Carrier Assembly b-PVC Pipe c-Propeller Nut d-Prop Shaft e-Tab Washer 90-828631R3 MARCH 1999 Page 6B-51 BIGFOOT GEAR HOUSING 3. Lubricate O-ring and mating surfaces with 2-4-C w/Teflon. 4. Install bearing carrier and propeller shaft into housing with the word “TOP” located on flange toward top of housing. 21044 a b 95 95 2-4-C w/Teflon (92-850736A1) a-O-ring b-TOP NOTE:Use thick 0.090 in. (2.29mm) washers (12-855941) under fasteners if not previously installed. Washer Thickness Fastener Torque 0.090 in. (2.29mm) 22 lb-ft (29.8 Nm) 0.060 in. (1.53mm) 25 lb-ft (33.9 Nm) a b a-Washers b-Fasteners (If using Bolts - Apply Loctite 271 on Threads) Page 6B-52 90-828631R3 MARCH 1999 BIGFOOT GEAR HOUSING Water Pump Reassembly and Installation 1. Place upper seal on longer shoulder side of Oil Seal Driver (91-13949) with seal lip away from shoulder. 2. Apply Loctite 271 on O.D. of seal; press seal into water pump base until tool bottoms. c 91-13949 7 Loctite “271” (92-809819) 7 ba a-Seal - Lip Faces Toward Power Head b-Spring - Faces Toward Power Head c-Oil Seal Driver (91-13949) 51553 90-828631R3 MARCH 1999 Page 6B-53 BIGFOOT GEAR HOUSING 3. Place lower seal on shorter shoulder side of Oil Seal Driver (91-13949) with seal lip toward shoulder. 4. Apply Loctite 271 on O.D. of seal; press seal into water pump base until tool bottoms. 5. Lubricate lip of each seal with Quicksilver 2-4-C w/Teflon (92-825407A12). 51553 c 91-13949 7 Loctite “271” (92-809819) 95 2-4-C w/Teflon (92-850736A1) 7 95 a b a-Seal - Lip Faces Toward Gear Case b-Spring - Faces Toward Gear Case c-Oil Seal Driver (91-13949) 6. Install gasket. a 19218 a-Gasket Page 6B-54 90-828631R3 MARCH 1999 BIGFOOT GEAR HOUSING 7. Install components as shown. Apply Loctite 271 on bottom half of threads and torque to specified torque. 19217 a b 7 7 Loctite “271” (92-809819) a-Water Pump Base b-Bolts and Washers Bolt Torque 60 lb-in. (6.8 Nm) 8. Install gasket and plate. 19219 a b a-Gasket b-Plate IMPORTANT: If the old impeller will be re-used, impeller must be installed in original (clockwise) direction of rotation. 9. Install gasket, drive key and impeller. a b c a-Gasket b-Drive Key c-Impeller 19220 90-828631R3 MARCH 1999 Page 6B-55 BIGFOOT GEAR HOUSING 10. Lubricate I.D. of cover with Quicksilver 2-4-C w/Teflon. 11. Rotate driveshaft clockwise and push cover down over impeller. 12. Install cover. 13. If water tube seal stayed on water tube (inside of driveshaft housing) when gear housing was removed, pull water tube seal from water tube. 14. Lubricate I.D. of water tube seal with Quicksilver 2-4-C w/Teflon and install as shown. 15. Install cover bolts and torque to specified torque. 19212 c c a b 95 2-4-C w/Teflon (92-850736A1) 95 a-Cover b-Seal c-Bolts (4); Apply Loctite 271 on Threads Bolt Torque 60 lb-in. (6.8 Nm) NOTE:It is recommended that the gearcase be pressure tested for leaks after reassembly and BEFORE gear lube is added. Gearcase should hold 10 to 12 psi (69-83 kPa) for 5 minutes. Gear Housing Pressure Test 1. Remove vent plug and install pressure test gauge. Page 6B-56 90-828631R3 MARCH 1999 BIGFOOT GEAR HOUSING 2. Pressurized housing to 10 to 12 psi (69-83 kPa)and observe gauge for 5 minutes. 3. Rotate driveshaft, prop shaft and move shift shaft while housing is pressurized to check for leaks. 4. If pressure drop is noted, immerse housing in water. 5. Re-pressurize to 10 to 12 psi (69-83 kPa)and check for air bubbles. 6. Replace leaking seals as necessary. Retest housing. NOTE:Gearcase should hold 10 to 12 psi (69-83 kPa) for 5 minutes. 7. Remove tester from housing and install vent plug. Filling Gear Housing With Lubricant NOTE:Gear housing lubricant capacity is 22.5 fl oz (665.2 ml). WARNING If gear housing is installed on engine, to avoid accidental starting, disconnect (and isolate) spark plug leads from spark plugs before working near the propeller. CAUTION Do not use automotive grease in the gear housing. Use only Quicksilver Gear Lube or Quicksilver Super-Duty Lower Unit Lubricant. 1. Remove any gasket material from “Fill” and “Vent” screws and gear housing. 2. Install new gaskets on “Fill” and “Vent” screws. IMPORTANT: Never apply lubricant to gear housing without first removing “Vent” screws or gear housing cannot be filled because of trapped air. Fill gear housing only when housing is in a vertical position. 3. Remove lubricant “Fill” screw and gasket from gear housing. 4. Insert lubricant tube into “Fill” hole, then remove “Vent” screws and gaskets. 5. Fill gear housing with lubricant until excess starts to flow out of one (first) “Vent” screw hole. 90-828631R3 MARCH 1999 Page 6B-57 BIGFOOT GEAR HOUSING 6. Replace this lubricant “Vent” screw and gasket only and continue filling until excess starts to flow out of second lubricant “Vent” screw hole. 7. Let gearcase sit for at least on minute to allow lube to settle out, then top off. 53922 a b c a-Vent Screw - Torque to 60 lb-in. (6.8 Nm) b-Fill/Drain Screw - Torque to 60 lb-in. (6.8 Nm) c-Oil Level Vent Screw - Torque to 60 lb-in. (6.8 Nm) 8. Replace second lubricant “Vent” screw and gasket. IMPORTANT: Do not lose more than one fluid ounce (30cc) of gear lubricant while reinstalling “FILL” screw. 9. Remove lubricant tube from “Fill” hole; install “Fill” screw and gasket. Gearcase Installation WARNING Disconnect (and isolate) spark plug leads from spark plugs before installing gear housing onto driveshaft 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 40/50 Bigfoot (4-Stroke) a Remote Control Model Shown a-Shift Lever Page 6B-58 90-828631R3 MARCH 1999 BIGFOOT GEAR HOUSING Models 60 Bigfoot a a-Shift Block Models 75/90/100/115/125 19879 a b a-Shift Block; Front of Block MUST Extend 1/8 in. (3.2 mm) Past Front of Rail. b-Rail 2. Tilt engine to full up position and engage tilt lock lever. 3. Shift gear housing into neutral position. Propeller shaft will rotate freely in either direction. 4. Install water tube seal; lube I.D. of seal with Quicksilver 2-4-C w/Teflon. 5. Apply a bead of RTV Sealer as shown. 53938 a b 95 2-4-C w/Teflon (92-850736A1) 85 85 95 RTV Silicone Sealer (92-91601-1) a-Water Tube Seal b-RTV Sealer 90-828631R3 MARCH 1999 Page 6B-59 BIGFOOT GEAR HOUSING CAUTION Do not use lubricant on top of driveshaft. Excess lubricant, that is trapped in clearance space, will not allow driveshaft to fully engage with crankshaft. Subsequently, tightening the gear housing fasteners (while lubricant is on top of driveshaft) will load the driveshaft/crankshaft and damage either or both the power head and gear housing. Top of driveshaft is to be wiped free of lubricant. 6. Apply a light coat of Quicksilver 2-4-C w/Teflon onto driveshaft splines. 7. Apply a light coat of Quicksilver 2-4-C w/Teflon on gear case shift shaft splines and upper shift shaft splines. Do not use lubricant on ends of shift shafts. 8. Install components as shown in appropriate photo. ALL EXCEPT 75 W/MECHANICAL REVERSE LOCK 53968 a b c a-Nylon Spacer b-Shift Shaft Coupler c-Bushing 40/45/50 Bigfoot (4-Stroke) Only 75 W/MECHANICAL REVERSE LOCK a 53925 b c a-Nylon Spacer b-Shift Shaft Coupler c-Flat; MUST BE Positioned Toward Front of Gear Housing Page 6B-60 90-828631R3 MARCH 1999 BIGFOOT GEAR HOUSING 9. Shift gear housing into forward gear position. In forward gear the gear housing will ratchet when propeller shaft is turned clockwise. Resistance will be felt when propeller shaft is rotated counterclockwise. 10. Apply Loctite Grade 271 on threads of gear housing retaining bolts. NOTE: If, while performing Step 11, the driveshaft splines will not align with the crankshaft splines, place a propeller onto propeller shaft and turn it counterclockwise as the gear housing is being pushed toward driveshaft housing. NOTE:During installation of gear housing, it may be necessary to move the shift block (located under cowl) slightly to align upper shift shaft splines with shift shaft coupler splines. 11. Position gear housing so that the 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 crank shaft splines with driveshaft splines. 13. Install 4 fasteners and washers (two each side). 14. Install locknut and washer. 15. Torque bolts and locknut (or nuts only if applicable) to specified torque. 53922 ab 7 Loctite “271” (92-809819) 7 a-Fasteners and Washers (2 Each Side) b-Locknut and Washer Bolt or Nut Torque 40 lb-ft (54 Nm) 16. Check shift operation as follows: • Place shift lever in forward gear. Gear housing should ratchet when propeller shaft is turned clockwise. Resistance should be felt when propeller shaft is turned counterclockwise. • Place shift lever in neutral. Propeller shaft should rotate freely in either direction. • While rotating propeller shaft, place shift lever in reverse gear. Resistance should be felt when propeller shaft is rotated in either direction. IMPORTANT: If shift operation is not as described, preceding, the gear housing must be removed and the cause corrected. 90-828631R3 MARCH 1999 Page 6B-61 BIGFOOT GEAR HOUSING Trim Tab Adjustment 1. Check trim tab position as follows: • Operate boat at the speed at which it normally would be operated. • If the boat pulls to the right (STARBOARD), the trailing edge of trim tab must be moved to the right. If the boat pulls to the left (PORT), the trailing edge of trim tab must be moved to the left. 2. If necessary, adjust trim tab as follows: • Shift engine control into NEUTRAL and turn ignition key to “OFF” position. NOTE:Loosen trim tab bolt sufficiently to allow trim tab to disengage from locking ridges in gear case before attempting to move tab. DO NOT strike trim tab with a hard object to make adjustments. • If boat pulls to the left, adjust trailing edge of trim tab to the left. If boat pulls to the right, adjust trailing edge of trim tab to the right. 3. Tighten trim tab retaining bolt and washer to 22 lb-ft (29.8 Nm). Page 6B-62 90-828631R3 MARCH 1999 THROTTLE/SHIFT LINKAGE ATTACHMENTS/CONTROL LINKAGE Section 7A - Throttle/Shift Linkage Table of Contents Linkage (Non Bigfoot) . . . . . . . . . . . . . . . . . . . . . . 7A-2 Shift Cable Installation . . . . . . . . . . . . . . . . . . 7A-6 Linkage (Bigfoot) . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-4 Throttle Cable Installation . . . . . . . . . . . . . . . 7A-7 Shift and Throttle Cable Installation To The Outboard . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-6 7 A 90-828631R3 MARCH 1999 Page 7A-1 23 25 26 1 2 3 4 5 6 8 9 7 10 11 12 13 14 17 16 18 21 22 27 28 29 19 20 15 95 95 24 95 2-4-C w/Teflon (92-825407A12) THROTTLE/SHIFT LINKAGE Page 7A-2 90-828631R3 MARCH 1999 Linkage (Non Bigfoot) THROTTLE/SHIFT LINKAGE Linkage (Non Bigfoot) REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 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 NON HANDLE 11 1 LATCH 12 2 SCREW (M6 x 16) 75 8.5 13 2 SLEEVE 14 1 SHIFT ROD 1515 1 THROTTLE CAM 1 THROTTLE CAM (40 ITALIAN) 16 1 SPACER 17 1 WASHER 18 1 SCREW (M5 x 16) 75 8.5 19 1 HORIZONTAL SHIFT SHAFT 20 1 RETAINER 21 1 WASHER 22 1 COTTER PIN 23 1 SPRING 24 2 SPRING 25 1 PLATE 26 2 SCREW (M5 x 16) 27 1 SWITCH 28 2 SCREW (M3 x 20) HANDLE MODELS 29 1 PLATE–Switch 90-828631R3 MARCH 1999 Page 7A-3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 17 18 22 95 95 2-4-C w/Teflon (92-825407A12) 23 24 26 25 THROTTLE/SHIFT LINKAGE Page 7A-4 90-828631R3 MARCH 1999 Linkage (Bigfoot) THROTTLE/SHIFT LINKAGE Linkage (Bigfoot) REFREF. .. NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 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 90-828631R3 MARCH 1999 Page 7A-5 THROTTLE/SHIFT LINKAGE Shift and Throttle Cable Installation To The Outboard Install the shift cable and throttle cable into the remote control and mount the remote control following instructions which are provided with the remote control. NOTE:Install the shift cable before the throttle cable. The shift cable is the first cable to move when the remote control handle is moved into gear. Shift Cable Installation 1. Position the remote control handle into neutral detent. 2. Fit the shift cable thru the front rubber grommet and into the bottom cowl. 3. Place the engine shift lever pin into neutral position. The propeller shaft will rotate in either direction when in neutral position. 4. Open up the cable latch. 5. Install the shift cable onto the shift lever pin. lock in place with the cable latch. 6. Adjust the barrel on the shift cable so the barrel will fit into the bottom hole of the barrel holder with a slight pre-load toward reverse when installed. ab d c a-Shift Lever Pin b-Cable Latch c-Barrel d-Cable End Guide 7. Check shift cable adjustments as follows: a. With remote control in forward, the propshaft should lock solidly in gear. If it does not, adjust the cable barrel closer to the cable end guide. b. Shift remote control into neutral. The propshaft should turn freely without drag. If not, adjust the barrel away from the cable end guide. Repeat Steps a and b. c. Shift remote control into reverse while turning propeller. The propshaft should lock solidly in gear. If not, adjust the barrel away from the cable end guide. Repeat Steps a thru c. d. Return remote control handle to neutral. The propeller should turn freely without drag. If not, adjust the barrel closer to the cable end guide. Repeat Steps a thru d. Page 7A-6 90-828631R3 MARCH 1999 THROTTLE/SHIFT LINKAGE 90-828631R3 MARCH 1999 Page 7A-7 Throttle Cable Installation NOTE: Attach Shift cable to engine prior to attaching throttle cable. 1. Position the remote control handle into neutral detent. 2. Fit the throttle cable thru the front rubber grommet and into the bottom cowl. 3. Install the throttle cable to the throttle lever with retainer pin. Lock retainer pin in place. b a a - Throttle Cable b - Retainer Pin 4. Move the throttle linkage arm down. a a - Throttle Linkage THROTTLE/SHIFT LINKAGE Page 7A-8 90-828631R3 MARCH 1999 5. Pull the throttle cable adjustment barrel out of the holder. 6. While holding down the throttle linkage arm (Step 4), position throttle lever so there is a 1/8 inch (3.2mm) gap between the top side of the oval shaped boss and top inside surface of the carburetor cam. With the throttle lever at this position, adjust barrel on the throttle cable to fit into the barrel holder. 1/8 in. (3.2mm) b a c d a - Cable Adjustment Barrel b - Throttle Lever c - Oval Shaped Boss d - Carburetor Cam 7. Fasten the cable barrels with cable latch. a a - Cable Latch IMPORTANT: After installation, move the remote control handle a few times from the neutral position to the wide-open-throttle position in forward gear. Move handle back to neutral and repeat Step 6. Visually Check for the specified gap between the oval shaped boss and the throttle cam. If necessary, readjust the barrel. TILLER HANDLE ATTACHMENTS/CONTROL LINKAGE Section 7B - Tiller Handle Table of Contents Tiller Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-2 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . . . 7B-8 Tiller Handle Removal . . . . . . . . . . . . . . . . . . . . . 7B-4 Tiller Handle Reassembly . . . . . . . . . . . . . . . . . . 7B-8 Tiller Handle Disassembly . . . . . . . . . . . . . . . . . . 7B-6 Tiller Handle Installation . . . . . . . . . . . . . . . . . . . 7B-12 7 B 90-828631R3 MARCH 1999 Page 7B-1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 15 17 18 19 20 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 41 42 43 44 45 95 95 21 40 95 2-4-C w/Teflon (92-825407A12) TILLER HANDLE Page 7B-2 90-828631R3 MARCH 1999 Tiller Handle TILLER HANDLE Tiller Handle 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 2.5 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) 16.5 22.5 99 1 COVER (BLACK) 1 COVER (GRAY) 10 1 BUSHING 1111 1 ARM–Steering Handle (BLACK) 1 ARM–Steering Handle (GRAY) 12 1 RETAINER 13 1 SCREW (M5 x 16) 35 4.0 14 1 SCREW (M6 x 25) 15 1 LOCK–Throttle 16 1 SPRING 17 1 KNOB–Throttle 18 1 CLIP 19 1 SWITCH (START) 20 1 HOUSING 21 1 DECAL-Start 22 1 TILLER TUBE 23 1 DECAL 24 1 HANDLE–Throttle 25 1 GRIP 26 1 SWITCH (STOP) 27 1 SCREW (M5 x 12) 28 1 WASHER 29 1 ALARM 30 2 CLIP 31 1 STA-STRAP 32 1 DECAL-Shift 33 1 SWITCH (STOP) 34 1 LANYARD SWITCH 35 1 RETAINER 36 1 SCREW (M8 x 35) 37 1 SHIFT HANDLE 38 1 BUSHING 39 1 SHIFT ROD 40 1 WASHER 4141 1 BRACKET–Tiller (BLACK) 1 BRACKET–Tiller (GRAY) 42 1 WAVE WASHER 43 1 BUSHING 44 1 WASHER 45 1 CONDUIT 90-828631R3 MARCH 1999 Page 7B-3 TILLER HANDLE Page 7B-4 90-828631R3 MARCH 1999 Tiller Handle 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 90-828631R3 MARCH 1999 Page 7B-5 3. Loosen the jam nuts and disconnect the throttle cables from the throttle lever. 54283 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 RED BLK TAN/BLU PUR BLK/YEL BLK BLK BLK/YEL YEL/RED BLK YEL/RED BLK/YEL BLK/YEL BLK TAN RED BLK RED b c a a - Disconnect Tiller Handle Wires b - Screws-M10x90 (2) c - Tab Washer TILLER HANDLE Page 7B-6 90-828631R3 MARCH 1999 Tiller Handle Disassembly 1. Pry the two clips out of the hand grip. 2. Remove the side cover. a b a - Clips (2) b - Side Cover 3. Pull the arm along with the throttle cables and wiring from the bracket. 4. Remove retainer and slide out the tiller tube assembly. 5. Remove the throttle lock assembly. a b c a - Retainer b - Throttle Lock Assembly c - Tiller Tube Assembly TILLER HANDLE 6. Use a flat tip screwdriver to pry/push the rubber grip off the handle. 7. Pull out the stop switch harness. 8. Push the tiller tube out of the handle. a b c c b a a-Cover b-Throttle Cables c-Pulley a-Stop Switch Harness b-Tiller Tube c-Handle 9. Remove cover and disconnect throttle cables from pulley. 90-828631R3 MARCH 1999 Page 7B-7 TILLER HANDLE 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. Tiller Handle Reassembly 1. Wrap cables around pulley as shown. a c b a-Short Throttle Cable (30-1/2 in.) Place in Top Groove b-Long Throttle Cable (40-1/2 in.) Place in Bottom Groove c-Pulley 2. Place pulley and cables into case. 3. Install cover with screw. c a b a-Pulley b-Cover c-Screw 10-16x1/2 in. Pulley Cover Screw Torque 20 lb. in. (2.3 N·m) Page 7B-8 90-828631R3 MARCH 1999 TILLER HANDLE 4. Match tiller tube end with the slots and pull the tube end into the handle until it bottoms out. 5. Install the throttle lock components on tiller tube. a b c c d e f g a-Tiller Tube b-Handle c-Match the Tube End with Slots d-Screw e-Lock f-Spring g-Knob 6. Check to make sure tiller tube is pushed in 7/8 in. (22.2mm). 7. Insert the engine stop switch harness through the tiller tube. Place the stop switch into end on handle. 7/8 in. (22.2mm) c a b a-7/8 in. (22.2 mm) between Tiller Tube and end of Handle b-Engine Stop Switch Harness c-Stop Switch 8. Align the grooves inside the rubber grip with the ridges on the handle. Push the rubber grip onto the handle. NOTE:Applying a soapy/water solution to the inside of the rubber grip will ease installation. 90-828631R3 MARCH 1999 Page 7B-9 TILLER HANDLE 9. Place pulley assembly into arm. 10. Slide the tiller tube into the arm. Position the throttle lock knob into its slot. 11. Match the end of the tiller tube with the slots in the pulley assembly. Insert the tiller tube end into the pulley assembly. 12. Secure tiller tube with retainer. 13. Snap the engine start switch on the tiller tube. a cd b a-Pulley Assembly b-Throttle Lock Knob c-Retainer d-Screw-M5x16 Tiller Tube Retainer Screw Torque 35 lb-in. (3.9 Nm) 14. Place bushing components on the arm mounts. a b c d 95 2-4-C w/Teflon (92-850736A1) 95 95 a-Flat Washer b-Bushing c-Wave Washer (2) d-Bushing Page 7B-10 90-828631R3 MARCH 1999 TILLER HANDLE 90-828631R3 MARCH 1999 Page 7B-11 15. Pull the throttle cables and wiring into the bracket. 16. Fasten arm with cover. Arm Cover Screw Torque 135 lb-in. (15.3 Nm) 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. (12.7 mm) extends inside the handle grip. 20. Push the wiring and throttle cables down into the handle grip and hold in place with two clips. 1/2 in. (12mm) 1/2 in. (12mm) a b b d c a - Wiring Conduit (Place all Wiring Inside – See CAUTION above) b - Place Wiring Conduit inside opening 1/2 in. (12.7 mm) c - Throttle Cables (Position toward outer side) d - Clips (2) TILLER HANDLE Page 7B-12 90-828631R3 MARCH 1999 Tiller Handle Installation 1. Install diaphragm to the cable bracket. Refer to Section 2C for adjustment after tiller handle is installed. 2. Install cable bracket. 54281 a b c a - Diaphragm b - Cable Bracket c - Screws (2) Cable Bracket Screw Torque 75 lb-in. (8.5 Nm) CAUTION Tiller handle outboard must have the reinforced throttle lever. A non-reinforced throttle lever could break and inactivate the throttle control. Reinforced Throttle Lever Non-reinforced Throttle Lever Support Ribs DO NOT USE TILLER HANDLE 90-828631R3 MARCH 1999 Page 7B-13 3. If removed, install hardware to the throttle lever as shown. 50 HP Models 45 HP Models a b c d a a - Screw b - Nut c - Cap d - Bushing 4. Install throttle lever. a b 95 2-4-C w/Teflon (92-850736A1) 95 a - Bushing (Existing) b - Screw (Existing) Throttle Lever Screw Torque 100 lb-in. (11.3 Nm) TILLER HANDLE Page 7B-14 90-828631R3 MARCH 1999 5. 50 HP Models – adjust screw to allow for some free play in the carburetor linkage at wide open throttle. Do not allow the carburetor shutters to act as throttle stops. NOTE: 45 HP Models – the throttle stop is fixed and does not require adjustment. 54281 6. Install switch assembly. NON-BIGFOOT a. S/N 0G472132 and below. 54277 a b c a - Switch Assembly b - Backing Plate c - Screw (2) TILLER HANDLE 90-828631R3 MARCH 1999 Page 7B-15 b. S/N 0G472133 and up. 54277 a b c a - Switch Assembly b - Backing Plate c - Screw (2) BIGFOOT 56243 a b c a - Switch b - Backing Plate c - Screws (2)-Fully Tighten TILLER HANDLE 7. Install tiller handle assembly. 8. Pry up the left side lower corner of the rubber grommet in order to fit the wiring in the lower opening. 9. Connect the auxiliary harness. Refer to wiring diagram on next page. 10. Bundle all the wiring connections and fasten together with a sta-strap. 54272a b f c d e a-Screw (2) b-Tab Washer, Lock - Bend Tabs Against the Screw Heads c-Rubber Grommet d-Throttle Cables e-Auxiliary Harness f-Sta-Strap Tiller Handle Screw Torque 32 lb-ft (43.4 Nm) Page 7B-16 90-828631R3 MARCH 1999 TILLER HANDLE 11. Reconnect wires. RED BLK TAN/BLU PUR BLK/YEL BLK BLK BLK/YEL YEL/RED BLK YEL/RED BLK/YEL BLK/YEL BLK TAN RED BLK RED BLK = Black BLU = Blue GRY = Gray GRN = Green PUR = Purple RED = Red TAN = Tan YEL = Yellow 12. Connect wiring harness into the engine wiring harness. Push the harness connection into the holder. a a-Engine Wiring Harness 90-828631R3 MARCH 1999 Page 7B-17 TILLER HANDLE Page 7B-18 90-828631R3 MARCH 1999 13. Rotate throttle grip to idle position. 14. Insert the anchor on the shorter throttle cable into the anchor hole on the throttle lever. Push in the anchor until it bottoms out. Cable has to be aligned with the slot. 54282 b a a - Shorter Throttle Cable b - Cable Must be able to Rotate in Slot 15. Bring the throttle cable to the back side of the throttle lever. Place the throttle cable into the notch in the cable bracket. NOTE: Throttle cam was removed to show cable installation. 54283 TILLER HANDLE 90-828631R3 MARCH 1999 Page 7B-19 16. Route the longer throttle cable behind the cable bracket as shown. 17. Insert the anchor into the anchor hole on the throttle cable. 18. Place the throttle cable into the notch in the cable bracket. 54284 a b a - Longer Throttle Cable (Position Behind Cable Bracket as Shown) b - Cable Must be able to Rotate in Slot 19. Adjust the throttle cables as follows: a. Position the throttle grip to idle position. b. Move the throttle linkage arm down. a a - Throttle Linkage Arm TILLER HANDLE c. While holding down the throttle linkage arm (Step b), adjust the throttle cable jam nuts so there is a 1/8 in. (3.2mm) gap between the top side of the oval shaped boss and top inside surface of the throttle cam. With the throttle lever at this position, tighten the jam nuts. 1/8 in. (3.2mm) a b a-Oval Shape Boss b-Top Inside Surface of the Throttle Cam IMPORTANT: After installation, move the throttle grip a few times from the idle position to the wide-open-throttle position. Return throttle grip to the idle position and visually check for the specified gap between the oval shaped boss and the throttle cam. If necessary, readjust the jam nuts. 20. Install the shift rod. Page 7B-20 90-828631R3 MARCH 1999 TILLER HANDLE 90-828631R3 MARCH 1999 Page 7B-21 NON-BIGFOOT s/n 0G472132 and below s/n 0G472133 and above c c a b a - Cotter Pin b - Washer c - Shift Rod BIGFOOT 56249 d c a b a - Shift Rod Assembly b - Shift Link c - Washer d - Cotter Pin TILLER HANDLE Page 7B-22 90-828631R3 MARCH 1999 21. Attach swivel linkage to shift rod. Attach swivel/rod assembly to shift link. Make sure threads are fully engaged but do not tighten completely. 22. Secure bracket and shift rod assembly to side of powerhead with bolts. Torque bolts to specified torque. 56250 a b c d e f a - Bolts, M6x16-(2) b - Bracket Assembly c - Shift Rod Assembly d - Swivel Linkage e - Shift Link f - Shift Rod Shift Rod Assembly Bolt Torque 75 lb-in. (8.5 Nm) 23. Install lower cowl. c a b 56251 a - Screws (6)-M6x30 b - Lower Cowl c - Screw-M6x20 Bottom Cowl Bolt Torque 60 lb-in. (7 Nm) TILLER HANDLE 24. Assemble the shift rod into the shift handle. 54286 a b a-Shift Rod b-Shift Handle 25. Secure the shift handle as shown. c b a 95 2-4-C w/Teflon (92-850736A1) 95 a-Shift Handle b-Bushing c-Screw Screw Torque 100 lb-in. (11.3 Nm) 90-828631R3 MARCH 1999 Page 7B-23