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SERVICE MANUAL MODELS 6  8  9.9  10  15 With Starting Serial Numbers United States . . . . . . . . . . . . . . . . . 0D281000 Belgium Produced . . . . . . . . . . . . 09792200 Printed in U.S.A. W1998, Mercury Marine 90-827242R1 MAY 1998 Notice Throughout this publication, “Dangers”, “Warnings” and “Cautions” (accompanied by the International HAZARD Symbol ) are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. OBSERVE THEM CAREFULLY! These “Safety Alerts” alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus “Common Sense” operation, are major accident prevention measures. DANGER DANGER - Immediate hazards which WILL result in severe personal injury or death. WARNING WARNING - Hazards or unsafe practices which COULD result in severe personal injury or death. CAUTION Hazards or unsafe practices which could result in minor personal injury or product or property damage. Notice to Users of This Manual This service manual has been written and published by the Service Department of Mercury Marine to aid our dealers’ mechanics and company service personnel when servicing the products described herein. It is assumed that these personnel are familiar with the servicing procedures of these products, or like or similar products manufactured and marketed by Mercury Marine, that they have been trained in the recommended servicing procedures of these products which includes the use of mechanics’ common hand tools and the special Mercury Marine or recommended tools from other suppliers. We could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of the possible hazards and/or results of each method. We have not undertaken any such wide evaluation. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered by the service procedure selected. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service these products. It should be kept in mind, while working on the product, that the electrical system and ignition system are capable of violent and damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables should be disconnected at the battery. Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive internal damage when the engine is started. 90-827242R1 MAY 1998 Page i It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Mismatched or incorrect fasteners can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the same locations whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original. Cleanliness and Care of Outboard Motor A marine power product is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten thousands of an inch/mm. When any product component is serviced, care and cleanliness are important. Throughout this manual, it should be understood that proper cleaning, and protection of machined surfaces and friction areas is a part of the repair procedure. This is considered standard shop practice even if not specifically stated. Whenever components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed. Personnel should not work on or under an outboard which is suspended. Outboards should be attached to work stands, or lowered to ground as soon as possible. We reserve the right to make changes to this manual without prior notification. Refer to dealer service bulletins for other pertinent information concerning the products described in this manual. Page ii 90-827242R1 MAY 1998 Service Manual Outline Section 1 - General Information & Specifications A - Specifications B - Maintenance C - General Information D - Outboard Installation Section 2 - Electrical and Ignition A - Ignition System B - Charging & Starting System C - Timing/Synchronizing & Adjusting D - Wiring Diagrams Section 3 - Fuel System A - Fuel Delivery System B - Emissions Section 4 - Powerhead Section 5 - Mid-Section A - Clamp/Swivel Brackets and Drive Shaft Housing Section 6 - Lower Unit Section 7 - Attachments/Control Linkage A - Throttle/Shift Linkage (Tiller Handle Shift Models) B - Throttle/Shift Linkage (Side Shift Models) C - Tiller Handle Section 8 - Manual Starter General Information & Specifications Electrical and Ignition Fuel System Powerhead Mid-Section Lower Unit Attachments/ Control Linkage Manual Starter 90-827242R1 MAY 1998 Page iii Propeller Information 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). How To Use This Manual The manual is divided into SECTIONS (shown, right) which represents major components and systems. Some SECTIONS are further divided into PARTS. Each PART has a title page. A “Table of Contents” for the particular PART is printed on the back of the title page. SECTIONS and PARTS are listed on the “Service Manual Outline” sheet which immediately follows the cover of this book. Page Numbering Two number groups appear at the bottom of each page. The example, below, is self-explanatory. EXAMPLE: 90-827242R1 MAY 1998 Page 2B-7 Revision No. 1 Month of Printing Year of Printing Section Number Part of Section Letter Page Number Page iv 90-827242R1 MAY 1998 SPECIFICATIONS GENERAL INFORMATION & SPECIFICATIONS Section 1A – Specifications Table of Contents 1 A General Specifications . . . . . . . . . . . . . . . . . . . 1A-1 Propeller Information Chart -9.9/10 HP . . . . . 1A-7 Propeller Information Chart - 6 HP . . . . . . . . . 1A-6 Propeller Information Chart -15 HP . . . . . . . . 1A-7 Propeller Information Chart - 8 HP . . . . . . . . . 1A-6 General Specifications Model 6/8/9.9/10/15 HORSEPOWER Model 6 6 (4.5) (KW) Model 8 8 (5.9) Model 8 Sailmate 8 (5.9) Model 9.9 9.9 (7.4) Model 9.9 Sailpower 9.9 (7.4) XR10/MAG10 10.0 (7.5) Model Sea Pro/Marathon 10 10.0 (7.5) Model 15 15 (11.2) Model Sea Pro/Marathon 15 15 (11.2) STATIC THRUST Model 9.9 Sailpower W.O.T. in Forward – 207 Lbs. (920.7 N) W.O.T. in Reverse – 150 Lbs. (667.2 N) OUTBOARD Manual Start 6 73.0 lbs. (31.1kg) WEIGHT 8 73.0 lbs. (31.1kg) 9.9 74.5 lbs. (31.8kg) 9.9 Sailpower 76.5 lbs. (34.7kg) 10 Sea Pro/Marathon 74.5 lbs. (31.8kg) XR10/MAG10 74.5 lbs. (31.8kg) 15 75.0 lbs. (34.0kg) 15 Sea Pro/Marathon 75.0 lbs. (34.0kg) Electric Start 6 79.5 lbs. (36.1kg) 8 79.5 lbs. (36.1kg) 9.9 79.5 lbs. (36.1kg) 9.9 Sailpower 84.0 lbs. (38.1kg) 15 82.5 lbs. (37.4kg) 90-827242R1 MAY 1998 Page 1A-1 SPECIFICATIONS Model 6/8/9.9/10/15 CYLINDER BLOCK Type Displacement (1994 Model) 6 8 9.9 9.9 Sailpower 10 Sea Pro/Marathon XR10/MAG10 15 Displacement (1995 and Newer) 9.9 9.9 Sailpower 10 Sea Pro/Marathon XR10/MAG10 15 15 Sea Pro/Marathon Two-Stoke Cycle – Cross Flow 12.8 cu. in. (209cc) 12.8 cu. in. (209cc) 12.8 cu. in. (209cc) 12.8 cu. in. (209cc) 16.0 cu. in. (262cc) 16.0 cu. in. (262cc) 16.0 cu. in. (262cc) 16.0 cu. in. (262cc) 16.0 cu. in. (262cc) 16.0 cu. in. (262cc) 16.0 cu. in. (262cc) 16.0 cu. in. (262cc) 16.0 cu. in. (262cc) STROKE Length 1.800 in. (45.7mm) CYLINDER BORE Diameter (Standard)(1994 Model) 6 8 8 Sailmate 9.9 9.9 Sailpower 10 Sea Pro/Marathon XR10/Mag10 15 Diameter (Standard)(1995 Model) 9.9 9.9 Sailpower 10 Sea Pro/Marathon XR10/Mag10 15 15 Sea Pro/Marathon Taper/Out of Round Maximum Bore Type 2.125 in. (53.975mm) 2.125 in. (53.975mm) 2.125 in. (53.975mm) 2.125 in. (53.975mm) 2.125 in. (53.975mm) 2.375 in. (60.325mm) 2.375 in. (60.325mm) 2.375 in. (60.325mm) 2.375 in. (60.325mm) 2.375 in. (60.325mm) 2.375 in. (60.325mm) 2.375 in. (60.325mm) 2.375 in. (60.325mm) 2.375 in. (60.325mm) 0.004 in. (0.1016mm) Cast Iron CRANKSHAFT Top Main Bearing Journal 0.7517 Center Main Bearing Journal 0.8108 Bottom Ball Bearing Journal 0.7880 Connecting Rod Journal 0.8125 Runout 0.003 in. (0.076mm) CONNECTING ROD Piston Pin End (I.D.) Crankpin End (I.D.) 0.8195 1.0635 PISTON Piston Type Ring End Gap Aluminum 0.010 in. - 0.018 in. (0.25 mm - 0.46 mm) REEDS Reed Stand Open (Maximum) All Models Reed Stop Opening (Maximum) 0.007 in. (0.178mm) All Models 0.296 in. (7.54mm) Page 1A-2 90-827242R1 MAY 1998 SPECIFICATIONS Model 6/8/9.9/10/15 GEAR HOUSING Gear Ratio Gearcase Capacity Lubricant Type Forward Gear - No. of Teeth-Type Pinion Gear - No. of Teeth-Type Pinion Height Forward Gear Backlash Reverse Gear Backlash Water Pressure With Thermostat – @ W.O.T – @ Idle W/O Thermostat – @ W.O.T – @ Idle 2.0:1 6.8 fl. oz. (200 ml) Quicksilver Gear Lube Premium Blend 26 Spiral/Bevel 13 Spiral/Bevel Floating No Adjustment No Adjustment 5 – 7 PSI @ 5000 RPM 1/2 – 1-1/2 PSI @ 750 RPM 5 – 7 PSI @ 5000 RPM 0 – 1 PSI @ 750 RPM MID Transom Height - Short Shaft 15 in. (38 cm) SECTION - Long Shaft 20 in. (51 cm) - Extra Long Shaft 25 in. (63.5 cm) Steering Pivot Range 78° Tilt Pin Positions 3 + 3 Shallow Water Total Tilt Angle 78° Allowable Transom Thickness 2-3/8 in. (60.3mm) FUEL SYSTEM Fuel Recommended Gasoline Recommended Oil Gasoline/Oil Ratio Fuel Tank Capacity 6/8/9.9/9.9 Sailpower XR10/MAG10/10 Sea Pro/Marathon/ 15 Pre-Mixed Gasoline and Oil Automotive Lead-Free Quicksilver TC-W II or TC-W3 2 Cycle Outboard Oil 25:1 (During Break-In) 50:1 (After Break-In) 3.2 U.S. Gal./2.7 Imp. Gal./12.0 Liters 6.6 U.S. Gal/5.5 Imp. Gal./25.0 Liters STARTING SYSTEM Manual Start Electric Start Starter Draw (Under Load) (No Load) Recoil 12 Volt 55 Amperes 15 Amperes CHARGING Alternator Output SYSTEM BLACK Stator - 2 Magnet Flywheel 4 Amp. (48 Watt) (8 Pole)(4 Pulses) @ 6000 RPM RED Stator - 4 Magnet Flywheel 6 amp (72 Watt) (10 Pole)(5 Pulses) @ 6000 RPM 90-827242R1 MAY 1998 Page 1A-3 SPECIFICATIONS Model 6/8/9.9/10/15 BATTERY Battery Rating 465 Marine Cranking Amps (MCA) or 350 Cold Cranking Amps (CCA) IGNITION SYSTEM Type SPARK PLUG (1994) 6/8/9.9 10/15 SPARK PLUG GAP (1994) 6/8/9.9 10/15 SPARK PLUG (1995 AND NEWER) 6/8 9.9/10/15 SPARK PLUG GAP (1995 AND NEWER) 6/8 9.9/10/15 Firing Order Stator High Speed Winding Stator Low Speed Winding Diode Test Ignition Coil Resistance: Primary Secondary Trigger Capacitor Discharge NGK BP8H-N-10 NGK BP8HS-15 NGK BPZ8H-N-10* 0.040 IN. (1.0MM) 0.060 IN. (1.5MM) NGK BP8H-N-10 NGK BP8HS-15 NGK BPZ8H-N-10* 0.040 IN. (1.0MM) 0.060 IN. (1.5MM) 1-2 120 - 180 W (BLK/WHT - GRD) 3200 - 3800 W (BLK/YEL - GRD) 3100 – 3700 W (BLK/YEL - BLK/WHT) 0.02 - 0.04 W 8000 - 11000 W 6500 - 8500 W * Use NGK BPZ8H-N-10 Where Radio Frequency Interference (RFI) Suppression is required. Page 1A-4 90-827242R1 MAY 1998 SPECIFICATIONS Models 6/8/9.9/10/15 CARBURETOR SPECIFICATIONS Type Idle RPM (In Gear) – 6 8 9.9/9.9 Sailpower 10 Sea Pro/Marathon XR10/MAG10 15 Wide Open Throttle RPM 6 8 9.9/9.9 Sailpower 10 Sea Pro/Marathon XR10/MAG10 15 15 Sea Pro/Marathon Idle Mixture Screw (Initial Setting) Float Setting (All Models) Main Jet – 6 8 9.9/9.9 Sailpower 10 Sea Pro/Marathon XR10/MAG10 15 15 Sea Pro/Marathon 1995-1999 .042 .046 .052 .064 .052 .066 .042 .046 .048 .052 .052 .072 1994 .072 Center Bowl, Integral Fuel Pump 650 ± 75 725 ± 50 725 ± 50 850 ± 50 725 ± 50 725 ± 50 4000 – 5000 4500 – 5500 5000 – 6000 5000 – 6000 5000 – 6000 5000 – 6000 5000 – 6000 Refer to Section 3 for Specifics 1 in. (25.4mm) TIMING Idle – SPECIFICATIONS 6 8° BTDC ± 1° 8/8 Sailmate 8° BTDC ± 1° 9.9/9.9 Sailpower 8° BTDC ± 1° 10 Sea Pro/Marathon 8° BTDC ± 1° XR10/MAG10 8° BTDC ± 1° 15 8° BTDC ± 1° 15 Sea Pro/Marathon 8° BTDC ± 1° Maximum BTDC @ 4500 RPM – All Models 36° BTDC 90-827242R1 MAY 1998 Page 1A-5 SPECIFICATIONS Propeller Information Chart - 6 HP Wide Open Throttle RPM: 4000-5000 Recommended Transom Height: 15,, 20,, 25. Right Hand Rotation Standard Gear Reduction: 2:1 Diameter Pitch No. Of Material Typical Gross Typical Boat Speed Propeller Part Blades Boat WGT. Length Range Number (LBS) (MPH) 9. 9. 3 Alum. Up To 1400 Up To 15' 10-19 48-42522A12 9. 8. 3 Alum. 1000 – 2200 124 - 16' 8-15 48-42521A12 9-1/4. 7. 3 Alum. 1200 – 2600 134 - 17' 5-12 48-42520A12 9-3/4. 6-1/2. 3 Alum. 1500+ High Reverse Thrust 3-10 48-42524A12 9-3/4. 5-1/2. 3 Alum. 1900+ Workboat 1-8 48-42518A11 Thrust Hub: 42630 (Forward) Propeller Drive Hub: 42630--1 Diffuser Ring: 42594 (Aluminum) Propeller Information Chart - 8 HP Wide Open Throttle RPM: 4500-5500 Recommended Transom Height: 15,, 20,, 25. Right Hand Rotation Standard Gear Reduction: 2:1 Diameter Pitch No. Of Material Typical Gross Typical Boat Speed Propeller Part Blades Boat WGT. Length Range Number (LBS) (MPH) 9. 9. 3 Alum. Up To 1200 Up To 16' 12-22 48-42522A12 9. 8. 3 Alum. 1100 – 2000 144 - 17' 10-20 48-42521A12 9-1/4. 7. 3 Alum. 900 – 2400 144 - 18' 7-15 48-42520A12 9-3/4. 6-1/2. 3 Alum. 1400+ High Reverse Thrust 4-12 48-42524A12 9-3/4. 5-1/2. 3 Alum. 1700+ Workboat 1-10 48-42518A11 Thrust Hub: 42630 (Forward) Propeller Drive Hub: 42630--1 Diffuser Ring: 42594 (Aluminum) Page 1A-6 90-827242R1 MAY 1998 SPECIFICATIONS Propeller Information Chart -9.9/10 HP Wide Open Throttle RPM: 5000-6000 Recommended Transom Height: 15,, 20,, 25. Right Hand Rotation Standard Gear Reduction: 2:1 Diameter Pitch No. Of Material Typical Gross Typical Boat Speed Propeller Part Blades Boat WGT. Length Range Number (LBS) (MPH) 9. 9. 3 Alum. Up To 1200 Up To 16' 12-24 48-42522A12 9. 8. 3 Alum. 1100 – 2000 144 - 17' 12-22 48-42521A12 9-1/4. 7. 3 Alum. 900 – 2400 144 - 18' 8-18 48-42520A12 9-3/4. 6-1/2. 3 Alum. 1400+ High Reverse Thrust 5-15 48-42524A12 9-3/4. 5-1/2. 3 Alum. 1700+ Workboat 1-13 48-42518A11 Thrust Hub: 42630 (Forward) Propeller Drive Hub: 42630--1 Diffuser Ring: 42594 (Aluminum) Propeller Information Chart -15 HP Wide Open Throttle RPM: 5000-6000 Recommended Transom Height: 15,, 20,, 25. Right Hand Rotation Standard Gear Reduction: 2:1 Diameter Pitch No. Of Material Typical Gross Typical Boat Speed Propeller Part Blades Boat WGT. Length Range Number (LBS) (MPH) 9. 10-1/2. 3 Alum. Up To 1000 Up To 16' 18-28 48-17874A12 9. 9. 3 Alum. 600 – 1500 144 - 18' 14-24 48-42522A12 9. 8. 3 Alum. 800 – 2400 154 - 20' 15-25 48-42521A12 9-1/4. 7. 3 Alum. 1000 – 3400 164 - 22' 8-18 48-42520A12 9-3/4. 6-1/2. 3 Alum. 1800+ High Reverse Thrust 1-15 48-42524A12 Thrust Hub: 42630 (Forward) Propeller Drive Hub: 42630--1 Diffuser Ring: 42594 (Aluminum) 90-827242R1 MAY 1998 Page 1A-7 MAINTENANCE GENERAL INFORMATION & SPECIFICATIONS Section 1B - --Maintenance Table of Contents 1 B GearCaseLubricantCapacity ............... 1B-1 SpecialTools ............................. 1B-1 Quicksilver Lubricant/Sealant . . . . . . . . . . . . . 1B-2 Inspection and Maintenance Schedule . . . . . . . . 1B-2 BeforeEachUse ....................... 1B-2 AfterEachUse ......................... 1B-2 Every 100 Hours of Use or Once yearly, Whicheveroccursfirst .................. 1B-2 Every 300 Hours of Use or Three Years . . . . 1B-3 FlushingTheCoolingSystem ............... 1B-3 FuelSystem .............................. 1B-5 FuelLineInspection..................... 1B-5 EngineFuelFilter ....................... 1B-5 CorrosionControlAnode ................... 1B-6 SparkPlugInspection ...................... 1B-6 BatteryInspection ......................... 1B-7 Fuse Replacement - --Electric Start Remote ControlModels ........................... 1B-7 LubricationPoints ......................... 1B-7 GearCaseLubrication ..................... 1B-9 GearCaseLubricantCapacity ............ 1B-9 DrainingGearCase ..................... 1B-9 Checking Lubricant Level and Refilling Gearcase ........................... 1B-10 StoragePreparations ..................... 1B-10 Fuelsystem .......................... 1B-10 Protecting External Engine Components . . 1B-11 Protecting Internal Engine Components . . . 1B-11 GearCase ............................ 1B-11 Positioning Outboard for Storage . . . . . . . . 1B-11 BatteryStorage ....................... 1B-11 Gear Case Lubricant Capacity Gear Case Ratio Capacity 2.00:1 6.8 fl. oz. (200.0ml) Special Tools 1. Flushing Attachment 12612A2 2. Grease Gun 91-37299A1 21 90-827242R1 MAY 1998 Page 1B-1 MAINTENANCE Quicksilver Lubricant/Sealant 1. Quicksilver Anti-Corrosion Grease P/N 92-78376A6 2. 2-4-C Marine Lubricant with Teflon P/N 92-825407A12 3. Quicksilver Gear Lubricant P/N 92-19007A24 Inspection and Maintenance Schedule Before Each Use 1. Check that lanyard stop switch stops the engine. 2. Visually inspect the fuel system for deterioration or leaks. 3. Check outboard for tightness on transom. 4. Check steering system for binding or loose components. 5. Visually check steering link rod fasteners for proper tightness. 6. 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. 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. Inspect and clean spark plugs. 3. Check fuel line filter for contaminants. 4. Check carburetor adjustments, if required. 5. Check corrosion control anodes. Check more frequently when used in salt water. 6. Drain and replace gear case lubricant. 7. Lubricate splines on the drive shaft.* 8. Electric start models - --Inspect battery. 9. Remote control models - --Check control cable adjustments. * 10. Remove engine deposits with Quicksilver Power Tune Engine Cleaner. 11. Check tightness of bolts, nuts, and other fasteners. 12. Clean fuel tank pick up filter. Page 1B-2 90-827242R1 MAY 1998 MAINTENANCE Every 300 Hours of Use or Three Years 1. Replace water pump impeller (more often if overheating occurs or reduced water pressure is noted).* * These items should be serviced by an authorized dealer. Flushing The Cooling System Flush the internal water passages of the outboard with fresh water after each use in salt, polluted, or muddy water. This will help prevent a buildup of deposits from clogging the internal water passages. Use a Quicksilver accessory (or equivalent) flushing attachment. WARNING To avoid possible injury when flushing, remove the propeller. Refer to Propeller Replacement. 1. Remove propeller (refer to Propeller Replacement). Install the flushing attachment so the rubber cups fit tightly over the cooling water intake holes. 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. 2. Attach a water hose to the flushing attachment. Turn on the water and adjust the flow so water is leaking around the rubber cups to ensure the engine receives an adequate supply of cooling water. 3. Start the engine and run it at idle speed in neutral shift position. 4. Adjust water flow (if necessary) so excess water continues leaking out from around the rubber cups to ensure the engine is receiving an adequate supply of cooling water. 5. Check for a steady stream of water flowing out of the water pump indicator hole. Continue flushing the outboard for 3 to 5 minutes, carefully monitoring water supply at all times. 6. Stop the engine, turn off the water, and remove the flushing attachment. Reinstall the propeller. 90-827242R1 MAY 1998 Page 1B-3 MAINTENANCE Fuel System WARNING Avoid serious injury or death from gasoline fire or explosion. Carefully follow all fuel system service instructions. Always stop the engine and DO NOT smoke or allow open flames or sparks in the area while servicing any part of the fuel system. Before servicing any part of the fuel system, stop engine and disconnect the battery. Drain the fuel system completely. Use an approved container to collect and store fuel. Wipe up any spillage immediately. Material used to contain spillage must be disposed of in an approved receptacle. Any fuel system service must be performed in a well ventilated area. Inspect any completed service work for sign of fuel leakage. Fuel Line Inspection Visually inspect the fuel line and primer bulb for cracks, swelling, leaks, hardness or other signs of deterioration or damage. If any of these conditions is found, the fuel line or primer bulb must be replaced. Engine Fuel Filter Inspect the sight bowl for water accumulation and inspect the filter element for sediment. Clean filter as follows. REMOVAL 1. Hold onto the cover to prevent it from turning. 2. Turn off the sight bowl. 3. Pull out the filter element and wash it with cleaning solvent. INSTALLATION 4. Push the filter element (with open end toward cover) into cover. 5. Place the O-ring seal into the sight bowl and screw the sight bowl hand tight into the cover. 2 3/4 5 1 6. Visually inspect for fuel leakage around the sight bowl by squeezing the primer bulb until firm, forcing fuel into the sight bowl. Page 1B-4 90-827242R1 MAY 1998 MAINTENANCE Corrosion Control Anode The outboard has a corrosion control anode installed to the gear case. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard metals. 1. The anode (a) 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. a 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 in General Information Section. 4. Before reinstalling spark plugs, clean away dirt on the spark plug seats. Install plugs finger tight, and tighten 1/4 turn or torque to 20 lb. ft. (27 N·m). 90-827242R1 MAY 1998 Page 1B-5 MAINTENANCE Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability. IMPORTANT: Read the safety and maintenance instructions which accompany your battery. 1. Turn off the engine before servicing the battery. 2. 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. Fuse Replacement - --Electric Start Remote Control Models The electric starting circuit is protected from overload by a 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. Replace with a new SFE 20 AMP fuse. Lubrication Points Lubricate Points 1 thru 8 with Quicksilver 2-4-C with Teflon Marine Lubricant or Special Lubricant 101. 1. Tilt Tube - --Lubricate fittings. 2. Transom Clamp Screws --Lubricate threads. 1 1 2 Page 1B-6 90-827242R1 MAY 1998 MAINTENANCE 3. Swivel Bracket - --Lubricate fitting. 4. Steering Friction Adjustment Shaft (tiller handle models) - --Lubricate fitting. 5. Tilt Lock Pins - --Apply lubricant to pins. Pin (a) is spring loaded. Make sure this pin is free to push in and out. 6. Lubricate along the entire tilt pin track on both transom brackets. 6 5 5-a 3 4 7. Lubricate the throttle and shaft cables, moving components and pivot locations. 7 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 ordeath. 8. Steering Cable Grease Fitting (If Equipped) - --Rotate steering wheel to fully retract the steering cable end (a) into the outboard tilt tube. Lubricate through fitting (b). Lubricate points 9 With Light Weight Oil 9. Steering Link Rod Pivot Points --Lubricate points. 8-a 9 8-b 90-827242R1 MAY 1998 Page 1B-7 MAINTENANCE Lubricate Point 10 with Quicksilver Anti-Corrosion Grease or 2-4-C Marine Lubricant with Teflon. 10. 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 to the shaft. 10 Gear Case Lubrication Gear Case Lubricant Capacity Gear Case Ratio Capacity 2.00:1 6.8 fl. oz. (200.0ml) Draining 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. 1. Place outboard in a vertical operating position. 2. Place drain pan below outboard. 3. Remove fill/drain plug (a) and vent plug (b) and drain lubricant. a bab Page 1B-8 90-827242R1 MAY 1998 MAINTENANCE Checking Lubricant Level and Refilling Gear case 1. Place outboard in a vertical operating position. 2. Remove vent plug from vent hole (a). 3. Place lubricant tube into the fill hole (b) and add lubricant until it appears at the vent hole (a). 4. Stop adding lubricant. Install the vent plug and sealing washer before removing the lubricant tube. a b 5. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer. Storage Preparations Fuel system IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a formation of acid during storage and can damage the fuel system. If the gasoline being used contains alcohol, It is advisable to drain as much of the remaining gasoline as possible from the fuel tank, remote fuel line, and engine fuel system. Fill the fuel system (tank, hoses, fuel pumps, and fuel injection systems) 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 fill the fuel system. 90-827242R1 MAY 1998 Page 1B-9 MAINTENANCE Protecting External Engine 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 NOTE: Before performing Steps 1 and 2, make sure the fuel system has been prepared for storage. 1. Place the outboard in water or connect flushing attachment for circulating cooling water. Start the engine and let it run in neutral to warm up. 2. With engine running at fast idle, stop the fuel flow by disconnecting the remote fuel line. When engine begins to stall, quickly spray Quicksilver Storage Seal into carburetor until engine stops from lack of fuel. 3. Remove the spark plugs and inject a five second spray of Quicksilver Storage Seal around the inside of each cylinder. 4. Rotate the flywheel manually several times to distribute the storage seal in the cylinders. Reinstall spark plugs. Gear Case Drain and refill the gear case lubricant (refer to maintenance procedure). Positioning Outboard for Storage Store outboard in an upright 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 manufacturers instructions for storage and recharging. 2. Remove the battery from the boat and check water level. Recharge if necessary. 3. Store the battery in a cool, dry place. 4. Periodically check the water level and recharge the battery during storage. Page 1B-10 90-827242R1 MAY 1998 GENERAL INFORMATION GENERAL INFORMATION & SPECIFICATIONS Section 1C - --General Information Table of Contents 1 C Table of Contents .......................... 1C-1 SerialNumberLocation .................... 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 PropellerSelection ........................ 1C-6 Propeller Removal/Installation . . . . . . . . . . . . . . . 1C-7 CompressionCheck ....................... 1C-9 PaintingProcedures ....................... 1C-9 Cleaning & Painting Aluminum Propellers & GearHousings ........................ 1C-9 DecalApplication ......................... 1C-11 DecalRemoval ........................ 1C-11 Instructions for “Wet”Application . . . . . . . . . 1C-11 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 a b c d e a-Serial Number b-Model Year c-Model Description d-Year Manufactured e-Certified Europe Insignia 90-827242R1 MAY 1998 Page 1C-1 GENERAL INFORMATION Conditions Affecting Performance Weather ENGINE RPM 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 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 90-827242R1 MAY 1998 GENERAL INFORMATION Due to the horsepower/RPM characteristics of an engine, this will result in further loss of horsepower at the propeller with another decrease in boat speed. This secondary loss, however, can be regained by switching to a smaller pitch propeller that allows the engine to again run at recommended RPM. For boaters to realize optimum engine performance under changing weather conditions, it is essential that the engine have the proper propeller to allow it to operate at or near the top end of the recommended maximum RPM range at wide-open-throttle with a normal boat load. Not only does this allow the engine to develop full power, but equally important is the fact that the engine also will be operating in an RPM range that discourages damaging detonation. This, of course, enhances overall reliability and durability of the engine. Boat WEIGHT DISTRIBUTION 1. Proper positioning of the weight inside the boat (persons and gear) has a significant effect on the boat’s performance, for example: a. Shifting weight to the rear (stern) (1.)Generally increases top speed. (2.)If in excess, can cause the boat to porpoise. (3.)Can make the bow bounce excessively in choppy water. (4.)Will increase the danger of the following -wave splashing into the boat when coming off plane. b. Shifting weight to the front (bow) (1.)Improves ease of planing off. (2.)Generally improves rough water ride. (3.)If excessive, can make the boat veer left and right (bow steer). BOTTOM For maximum speed, a boat bottom should be nearly a flat plane where it contacts the water and particularly straight and smooth in fore-and-aft direction. 1. Hook: Exists when bottom is concave in fore-and-aft direction when viewed from the side. When boat is planing, “hook”causes more lift on bottom near transom and allows bow to drop, thus greatly increasing wetted surface and reducing boat speed. “Hook” frequently is caused by supporting boat too far ahead of transom while hauling on a trailer or during storage. 2. Rocker: The reverse of hook and much less common. “Rocker”exists if bottom is convex in fore-and-aft direction when viewed from the side, and boat has strong tendency to porpoise. 3. Surface Roughness: Moss, barnacles, etc., on boat or corrosion of outboard’s gear housing increase skin friction and cause speed loss. Clean surfaces when necessary. WATER ABSORPTION It is imperative that all through hull fasteners be coated with a quality marine sealer at time of installation. Water intrusion into the transom core and/or inner hull will result in additional boat weight (reduced boat performance), hull decay and eventual structural failure. 90-827242R1 MAY 1998 Page 1C-3 GENERAL INFORMATION CAVITATION Cavitation is caused by water vapor bubbles forming either from a sharp edge or angle on the gear case or from an irregularity in the propeller blade itself. These vapor bubbles flow back and collapse when striking the surface of the propeller blade resulting in the erosion of the propeller blade surface. If allowed to continue, eventual blade failure (breakage) will occur. Engine DETONATION Detonation in a 2-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 2-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 90-827242R1 MAY 1998 GENERAL INFORMATION Following Complete Submersion Submerged While Running (Special Instructions) When an engine is submerged while running, the possibility of internal engine damage is greatly increased. If, after engine is recovered and with spark plugs removed, engine fails to turn over freely when turning flywheel, the possibility of internal damage (bent connecting rod and/or bent crankshaft) exists. If this is the case, the powerhead must be disassembled. Salt Water Submersion (Special Instructions) Due to the corrosive effect of salt water on internal engine components, complete disassembly is necessary before any attempt is made to start the engine. Fresh Water Submersion (Special Instructions) 1. Recover engine as quickly as possible. 2. Remove cowling. 3. Flush exterior of outboard with fresh water to remove mud, weeds, etc. DO NOT attempt to start engine if sand has entered powerhead, as powerhead will be severely damaged. Disassemble powerhead if necessary to clean components. 4. Remove spark plugs and get as much water as possible out of powerhead. Most water can be eliminated by placing engine in a horizontal position (with spark plug holes down) and rotating flywheel. 5. Pour alcohol into carburetor throats (alcohol will absorbed water). Again rotate flywheel. 6. Turn engine over and pour alcohol into spark plug openings and rotate flywheel. 7. Turn engine over (place spark plug openings down) and pour engine oil into throat of carburetors while rotating flywheel to distribute oil throughout crankcase. 8. 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. 9. Remove and clean carburetors and fuel pump assembly. 10. Dry all wiring and electrical components using compressed air. 11. Disassemble the engine starter motor and dry the brush contacts, armature and other corrodible parts. 12. Reinstall spark plugs, carburetors and fuel pump. 13. 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. 14. 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. 90-827242R1 MAY 1998 Page 1C-5 GENERAL INFORMATION Propeller Selection For in-depth information on marine propellers and boat performance -written by marine engineers -see your Authorized Dealer for the illustrated “What You Should Know About Quicksilver Propellers... and Boat Performance Information”(Part No. 90-86144). For best all around performance from your outboard/boat combination, select a propeller that allows the engine to operate in the upper half of the recommended full throttle RPM range with the boat normally loaded (refer to Specifications). This RPM range allows for better acceleration while maintaining maximum boat speed. If changing conditions cause the RPM to drop below the recommended range (such as warmer, more humid weather, operation at higher elevations, increased boat load or a dirty boat bottom/gear case) a propeller change or cleaning may be required to maintain performance and ensure the outboard’s durability. Check full-throttle RPM using an accurate tachometer with the engine trimmed out to a balanced- steering condition (steering effort equal in both directions) without causing the propeller to “break loose”. Refer to “Quicksilver Accessory Guide”for a complete list of available propellers. 1. Select a propeller that will allow the engine to operate at or near the top of the recommended full throttle RPM range (listed in “Specifications,”preceding) with a normal load. Maximum engine speed (RPM) for propeller selection exists when boat speed is maximum and trim is minimum for that speed. (High RPM, caused by an excessive trim angle, should not be used in determining correct propeller.) Normally, there is a 150-350 RPM change between propeller pitches. 2. If full throttle operation is below the recommended range, the propeller MUST BE changed to one with a lower pitch to prevent loss of performance and possible engine damage. 3. After initial propeller installation, the following common conditions may require that the propeller be changed to a lower pitch: a. Warmer weather and great humidity will cause an RPM loss. b. Operating in a higher elevation causes an RPM loss. c. Operating with a damaged propeller or a dirty boat bottom or gear housing will cause an RPM loss. d. Operation with an increased load (additional passengers, equipment, pulling skiers, etc.). Page 1C-6 90-827242R1 MAY 1998 GENERAL INFORMATION Propeller Removal/Installation WARNING If the propeller shaft is rotated while the engine is in gear, there is the possibility that the engine will crank over and start. To prevent this type of accidental engine starting and possible serious injury caused from being struck by a rotating propeller, always shift outboard to neutral position and remove spark plug leads when youare servicing the propeller. 1. Shift outboard to neutral position. N N 2. Remove the spark plug leads to prevent engine from starting. 3. Place a block of wood between gear case and propeller to hold propeller and remove propeller nut. 4. Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. 5. 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. 90-827242R1 MAY 1998 Page 1C-7 GENERAL INFORMATION 6. Flo-Torque I Drive Hub Propellers - --Install forward thrust hub (a), propeller (b), rear thrust hub (c) and propeller nut (d) onto the shaft. ab cd a-Forward Thrust Hub b-Propeller c-Rear Thrust Hub d-Propeller Nut 7. Flo-Torque II Drive Hub Propellers - --Install forward thrust hub (a), replaceable drive sleeve (b) propeller (c), rear thrust hub (d) and propeller nut (e) onto the shaft. c b a de a-Forward Thrust Hub b-Replaceable Drive Sleeve c-Propeller d-Rear Thrust Hub e-Propeller Nut 8. Place a block of wood between gear case and propeller and tighten propeller nut. Page 1C-8 90-827242R1 MAY 1998 GENERAL INFORMATION Compression Check Normal Compression (All Models) 115 --125psi (787 --856kPa) 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. 5. Check and record compression of each cylinder. The difference in compression readings between each cylinder should not vary more than 15%. If compression varies by more than 15% or compression for both cylinders is less than 100psi (685kPa), the powerhead should be disassembled and inspected. 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.” 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. 90-827242R1 MAY 1998 Page 1C-9 GENERAL INFORMATION GEAR HOUSINGS The following procedures should be used in refinishing gear housings. This procedure will provide the most durable paint system available in the field. The materials recommended are of high quality and approximate marine requirements. The following procedure will provide a repaint job that compares with a properly applied factory paint finish. It is recommended that the listed materials be purchased from a local Ditzler Automotive Finish Supply Outlet. The minimum package quantity of each material shown following is sufficient to refinish several gear housings. Procedure: 1. Wash gear housing with a muriatic acid base cleaner to remove any type of marine growth, and rinse with water, if necessary. 2. Wash gear housing with soap and water, then rinse. 3. Sand blistered area with 3M 180 grit sandpaper or P180 Gold Film Disc to remove paint blisters only. Feather edge all broken paint edges. 4. Clean gear housing thoroughly with (DX-330) wax and grease remover. 5. Spot repair surfaces where bare metal is exposed with (DX-503) alodine treatment. IMPORTANT: Do not use any type of aerosol spray paints as the paint will not properly adhere to the surface nor will the coating be sufficiently thick to resist future paint blistering. 6. Mix epoxy chromate primer (DP-40) with equal part catalyst (DP-401) per manufacturers instructions, allowing proper induction period for permeation of the epoxy primer and catalyst. 7. Allow a minimum of one hour drying time and no more than one week before top coating assemblies. 8. Use Ditzler Urethane DU9000 for Mercury Black, DU34334 for Mariner Grey, and DU35466 for Force Charcoal, and DU33414M for Sea Ray White. Catalyze all three colors with Ditzler DU5 catalyst mixed 1:1 ratio. Reduce with solvents per Ditzler label. CAUTION Be sure to comply with instructions on the label for ventilation and respirators. 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 sensitiveto 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. Page 1C-10 90-827242R1 MAY 1998 GENERAL INFORMATION Decal Application Decal Removal 1. Mark decal location before removal to assure proper alignment of new decal. 2. Carefully soften decal and decal adhesive with a heat gun or heat blower while removing old decal. 3. Clean decal contact area with a 1:1 mixture of isopropyl alcohol and water. 4. Thoroughly dry decal contact area and check for a completely cleaned surface. Instructions for “Wet” Application NOTE: The following decal installation instructions are provided for a “Wet”installation. All decals should be applied wet. TOOLS REQUIRED 1. Plastic Squeegee* 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 sunlight. Air and surface temperature should be between 60°F (15°C) and 100°F (38°C) for best application. SURFACE PREPARATION IMPORTANT: Do not use a soap or any petroleum based solvents to clean application surface. Clean entire application surface with mild dish washing liquid and water. Rinse surface thoroughly with clean water. 90-827242R1 MAY 1998 Page 1C-11 GENERAL INFORMATION DECAL APPLICATION 1. Mix 1/2 ounce (16 ml) of dish washing liquid in one gallon (4 l) of cool water to use as wetting solution. NOTE: Leave protective masking, if present, on the face of decal until final steps of decal installation. This will ensure that the vinyl decal keeps it’s shape during installation. 2. Place the decal face down on a clean work surface and remove the paper backing from “adhesive side”of decal. 3. Using a spray bottle, flood the entire “adhesive side”of the decal with the pre-mixed wetting solution. 4. Flood area where the decal will be positioned with wetting solution. 5. Position pre-wetted decal on wetted surface and slide into position. 6. Starting at the center of the decal, “lightly”squeegee out the air bubbles and wetting solution with overlapping strokes to the outer edge of the decal. Continue going over the decal surface until all wrinkles are gone and adhesive bonds to the cowl surface. 7. Wipe decal surface with soft paper towel or cloth. 8. Wait 10 -15 minutes. 9. Starting at one corner, “carefully and slowly”pull the masking off the decal surface at a 180°angle. NOTE: To remove any remaining bubbles, pierce the decal at one end of the bubble with stick pin and press out the entrapped air or wetting solution with your thumb (moving toward the puncture). Page 1C-12 90-827242R1 MAY 1998 OUTBOARD INSTALLATION GENERAL INFORMATION & SPECIFICATIONS Section 1D - --Outboard Installation Table of Contents 1 D Notice to Installer and Owner ................ 1D-1 Boat Horsepower Capacity .................. 1D-1 Outboard Remote Control ................ 1D-2 Selecting Accessories For The Outboard . . . 1D-2 Selecting Steering Cables and Remote Control Cables .................................. 1D-2 InstallingOutboard ........................ 1D-2 Steering Cable and Steering Link Rod Installation ............................... 1D-3 Installing Ride Guide Steering Cable to the Outboard ............................. 1D-3 Steering Cable Seal ..................... 1D-4 Steering Link Rod Installation............. 1D-4 RemoteControlInstallation ................. 1D-6 Shift and Throttle Cable Installation to the Outboard ................................ 1D-6 Remote Wiring Harness Connection to Engine .............................. 1D-12 Battery Cable Connections ................. 1D-12 Tilt Pin Adjustment ........................ 1D-13 Placing Tilt Pin in Lower Holes ........... 1D-13 Placing Tilt Pin in Upper Holes ........... 1D-13 Notice to Installer and Owner This manual as well as safety labels posted on the outboard use the following safety alerts to draw your attention to special safety instructions that should be followed. 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 CAUTION - -- Hazards or unsafe practices which could result in minor injury or product or property damage. 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 your 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. 90-827242R1 MAY 1998 Page 1D-1 OUTBOARD INSTALLATION 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. Outboard Remote Control The remote control connected to your outboard must be equipped with a start-in-gear protection device. This prevents the engine from starting when the outboard is 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 Mercury Marine Quicksilver Accessories have been specifically designed and tested for your outboard. Mercury Marine Quicksilver accessories are available from Mercury Marine dealers. Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation, and maintenance manuals for all your selected accessories. Selecting Steering Cables and Remote Control Cables Install steering mount and steering wheel in accordance with installation instructions that accompany each. IMPORTANT: Steering cable must be correct length. Sharp bends on too-short of a cable result in “kinks;” too-long of a cable require unnecessary bends and/or loops. Both conditions place extra stress on the cable. Refer to “Quicksilver Accessories Guide”to determine correct length of steering cable. Installing Outboard 1. Measure the transom height of your boat. The boat bottom should be aligned or be within 1 in. (25mm) above the anti-ventilation plate (a) of the outboard. 2. Place outboard on center line of transom. 0 -1in. (0 -25mm) a a-Anti-Ventilation Plate Page 1D-2 90-827242R1 MAY 1998 OUTBOARD INSTALLATION 3. Tighten transom clamp handles. 4. To prevent loss of outboard overboard, fasten outboard by drilling two 5/16 in. (7.9 mm) holes through the transom using transom clamp holes as a template. Fasten with two bolts, flat washers and locknuts. Use a marine waterproofing sealer in holes and around bolts to make the installation water tight. c b a a -Bolts (2) b-Flat Washers (2) c-Locknuts (2) Steering Cable and Steering Link Rod Installation Installing Ride Guide Steering Cable to the Outboard IMPORTANT: Before installing steering cable into tilt tube, lubricate entire cable end with Quicksilver 2-4-C w/Teflon Marine Lubricant (92-825407A12). 1. Lubricate the entire cable end. a a -Quicksilver 2-4-C Marine Lubricant with Teflon 2. Insert steering cable end thru outboard tilt tube and secure steering cable to tilt tube with steering cable attaching nut as shown. Torque nut to 35 lb. ft. (47.5 N·m). 53400 b a a -Cable End b-Attaching Nut [Torque to 35 lb. ft. (47.5 N·m)] 90-827242R1 MAY 1998 Page 1D-3 OUTBOARD INSTALLATION Steering Cable Seal 1. Place a mark on tilt tube 5/8 in. (15.9mm) from port end of tube. Slide plastic spacer, o-ring and cap over steering cable end, to tilt tube on engine. 5/8 in. (15.8mm) 53067e a b c d a -Mark b-Spacer c-O-ring d-Cap e-Spacer 2. Thread cap up to the 1/4 in. (6.4mm) mark. 53069 ab a -Cap b-Mark Steering Link Rod Installation IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special self locking nuts. 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. WARNING After installation is complete (and before operating outboard), check that boat will turn right when steering wheel is turned right and that boat will turn left when steering wheel is turned left. Check steering thru full range (left and right) and at all tilt angles to assure interference-free movement. Page 1D-4 90-827242R1 MAY 1998 OUTBOARD INSTALLATION 1. Secure steering bracket to engine. 53398 d a c b a a-Steering Bracket b-Bolt (2) c-Flat Washer (2) d-Locknut (2) [Torque to 140 lb in. (15.8 N·m)] 2. Secure steering link rod between engine steering bracket and steering cable end. 95 95 95 a b c d e f g h i j a-Steering Link Arm b-Ball Joint (Flat End Facing Up) c-Steering Bracket d-Spacer [3/8 in. (9.5mm)] e-Rubber Spacer f-Flat Washer [13/16 in. (20.6mm)] g-Locknut [Torque to 20 lb. ft. (27.1 N·m)] h-Flat Washer [5/8 in. (15.9mm)] (2) i-Spacer j-Locknut. Tighten Until Nut Seats. Do Not Exceed 120 lb. in. (13.6 N·m), Then Back Off 1/4-Turn 95 2-4-C With Teflon (92-825407A12) 90-827242R1 MAY 1998 Page 1D-5 OUTBOARD INSTALLATION Remote Control Installation Refer to Quicksilver Accessory Guide for appropriate electric or manual remote control. Use instructions provided with control for proper installation. Shift and Throttle Cable Installation to the Outboard IMPORTANT: Install control cables to remote control and mount control BEFORE attaching control cables to outboard. Install throttle and shift cables to remote control and mount control as outlined in installation instructions which accompany the remote control. NOTE: Attach shift cable to outboard first. Shift cable is the first cable to move when remote control handle is advanced from NEUTRAL position toward in-gear position. Refer to “Quicksilver Accessories Guide” to determine correct length of remote control cables. IMPORTANT: Remote control cables MUST BE THE CORRECT LENGTH. Sharp bends on too-short cables result in “kinks”. Too-long cables require unnecessary bendsand/or loops. Both conditions place extra stress on the cables and control. INSTALLING CABLE RETAINERS ON CABLES 1. Slip cable retainer over the threaded metal end of control cables. a a-Retainer 2. Push cable retainer onto control cables so that the pointed ends are on the top side of hole. 3. Rotate cable retainer 90°to position end of retainer over hole. c a b a-Retainer b-Pointed Ends c-Hole Page 1D-6 90-827242R1 MAY 1998 OUTBOARD INSTALLATION 4. Install sta-straps on control cables. NOTE: Sta-straps will prevent retainers from slipping off cables whenever cables are removed from engine. 5. Place end of control cables on anchor pins and lock in place with retainers. b a a-Sta-strap b-Pin SHIFT CABLE INSTALLATION 1. If remote control has a NEUTRAL lock release, secure the release in the depressed position using a piece of tape. The true NEUTRAL detent can now be located. WARNING To avoid accidental starting which could result in personal injury, remove and isolate high tension spark leads BEFORE working near propeller. 53258 a b a-Neutral Lock Release b-Tape 90-827242R1 MAY 1998 Page 1D-7 OUTBOARD INSTALLATION 2. Wrap rubber control cable grommet around shift cable. 53212 a b a-Grommet b-Cable 3. Push grommet with cable into opening in starboard bottom cowl. 53249 a a -Grommet 4. Manually shift outboard into NEUTRAL position (propeller will rotate freely in both directions). 5. Adjust barrel on shift cable to attain the same distance between barrel and hole in end of shift cable as exists between barrel recess of control cable anchor bracket and shift lever pin. 6. Slip barrel into barrel recess. Place end of shift cable on shift lever pin and lock in place with cable retainer. Secure barrel after throttle cable is installed. 53253 b c a a-Barrel b-Pin c-Retainer Page 1D-8 90-827242R1 MAY 1998 OUTBOARD INSTALLATION 7. Check shift cable adjustment as follows: a. Shift remote control into “FORWARD”gear. The propeller should not be able to rotate in a counterclockwise direction. If propeller does rotate counterclockwise, adjust barrel closer to end of cable and recheck. b. Shift remote control into “NEUTRAL”. Propeller should turn freely without drag. If not, adjust barrel away from end of cable and repeat STEPS “a”and “b”. c. While rotating propeller shaft, shift remote control into “REVERSE”gear. If propeller can be rotated, adjust barrel away from end of cable and repeat STEPS “a”through “c”. d. Shift remote control into “NEUTRAL”. Propeller should turn freely without drag. If not, adjust barrel closer to end of cable and repeat STEPS “a”through “d”. THROTTLE CABLE INSTALLATION NOTE: For easier installation of throttle cable into control cable grommet, apply a soap and water solution to top and inside of grommet. 1. Install throttle cable into control cable grommet. 2. Move remote control handle FORWARD to wide-open-throttle position. 3. Slide barrel of throttle cable into barrel recess of control cable anchor bracket. Place end of cable on throttle lever pin. 4. With remote control in the wide-open-throttle position, a 1/16 in. (1.6mm) gap must exist between guide of anchor bracket and control cable end. Adjust throttle barrel as required. 5. Secure throttle cable end to throttle lever pin with retainer. 53254 53252 a b cf e g hd a-Throttle Cable b-Grommet c-Barrel d-Throttle Lever Pin e-1/16 in. (1.6mm) Gap f-Guide g-Cable End h-Retainer 90-827242R1 MAY 1998 Page 1D-9 OUTBOARD INSTALLATION SPECIAL INSTRUCTIONS On installations where control cables will frequently be removed and reinstalled after the initial installation (i.e. inflatable boats), a barrel retaining plug has been supplied as an aid for installation. Using this plug allows the control cables to installed as a set without further cable adjustment. Install barrel retaining plug as follows: 1. Without allowing barrels of control cables to rotate, remove cables with cable grommet from outboard. 2. Install barrel retainer plug between control cable barrels. 3. Wrap cable grommet around control cables. 53211 53230 b a d c a-Barrel Retainer Plug b-Control Cable Barrels c-Grommet d-Control Cables 4. Push grommet with control cables into opening in starboard bottom cowl. 5. Place remote control in NEUTRAL position. 6. Manually shift outboard into NEUTRAL position. 7. Slide control cable barrels into barrel recess of anchor bracket. 8. Place ends of control cables onto pins of shift/throttle levers and lock in place with cable retainers. 53244 a a-Grommet b-Control Cable Barrels (2) c-Shift Cable/Lever d-Throttle Cable/Lever e-Cable Retainers 53243 e d c b Page 1D-10 90-827242R1 MAY 1998 b a c b a c OUTBOARD INSTALLATION SECURING CABLES TO ANCHOR BRACKET 1. Position barrel retainer over barrels of control cables. 53254 b a a -Retainer b-Barrels 2. Secure barrel retainer with latch. Latch must snap onto barrel retainer. 3. Align hole in latch with hooks of barrel retainer and secure with latch pin. 53251 c-Latch d-Retainer e-Pin THROTTLE LINK ROD INSTALLATION 1. Adjust throttle link rod to a length of 8-1/2 in. (21.6cm) as measured between ball joint centerlines. 2. Install throttle link rod between ball joint of throttle control lever and ball joint of actuating lever. 8-1/2 in. (21.6cm) 53236 b a a-Retainer b-Latch d e c a-Throttle Link Rod [8-1/2 in. (21.6cm)] b-Throttle Control Lever c-Actuating Lever 90-827242R1 MAY 1998 Page 1D-11 OUTBOARD INSTALLATION Remote Wiring Harness Connection to Engine 1. Apply Quicksilver Dielectric Grease inside the connection. 2. Plug the remote wiring connector into the outboard wiring harness connector. Secure the connection together with retainer, as shown. 6 ab c a-Remote Wiring Connector b-Outboard Wiring Harness Connector c-Retainer 6 Dielectric Grease (92-823506--1) Battery Cable Connections SINGLE OUTBOARD (+) (–) b a c a-Red Sleeve (Positive) b-Black Sleeve (Negative) c-Starting Battery Page 1D-12 90-827242R1 MAY 1998 OUTBOARD INSTALLATION DUAL OUTBOARD 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 Tilt Pin Adjustment Placing Tilt Pin in Lower Holes 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 at which 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. Placing Tilt Pin in Upper Holes 1. Lift the bow 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). 90-827242R1 MAY 1998 Page 1D-13 OUTBOARD INSTALLATION 5. In excess, cause boat “porpoising”(bouncing) or propeller ventilation. Page 1D-14 90-827242R1 MAY 1998 IGNITION SYSTEM ELECTRICAL AND IGNITION Section 2A – Ignition System Table of Contents Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1 Special Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2 Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-3 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . 2A-4 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-6 Specifications Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-6 AIgnition Troubleshooting (BLACK Stator) . . . . . . . . . 2A-8 Ignition Troubleshooting (RED Stator) . . . . . . . . . . . . 2A-9 Ignition Components Removal and Installation . . . 2A-10 Ignition Components Removal and Installation . . . 2A-11 BLACK Stator Stator High Speed Winding Stator Low Speed Winding Diode Test 120 - 180 W (BLK/WHT - GRD) 3200 - 3800 W (BLK/YEL - GRD) 3100 – 3700 W (BLK/YEL - BLK/WHT) IGNITION SYSTEM Readings taken @ Ignition Coil Resistance: Primary Secondary Trigger 0.02 - 0.04 W 8000 - 11000 W 6500 - 8500 W 68°F (20°C). RED Stator Stator Capacitor Charging Winding 370 - 445 W (GRN/WHT - WHT/GRN) Ignition Coil Resistance: Primary Secondary Trigger 0.02 - 0.04 W 8000 - 11000 W 6500 - 8500 W 90-827242R1 MAY 1998 Page 2A-1 IGNITION SYSTEM Special Tools Required 1. Flywheel Holder 91-52344 91–52344 54964 2. Flywheel Holder 91-24937A1 3. DMT 2000 Digital Multimeter 91-854009A1 4. Spark Gap Board 91-850439 55117 5. Flywheel Puller 91-83164M Page 2A-2 90-827242R1 MAY 1998 IGNITION SYSTEM Notes: 90-827242R1 MAY 1998 Page 2A-3 IGNITION SYSTEM Electrical Components 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 5 A – RED Stator B – BLACK Stator Page 2A-4 90-827242R1 MAY 1998 IGNITION SYSTEM Electrical Components REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 STATOR ASSEMBLY 2 2 SCREW (M5 x 30) 40 4.5 3 1 STATOR AUXILIARY (ELECTRIC/ALTERNATOR MODELS) SCREW (M5 x 30)4 3 40 4.5 5 1 SCREW (M5 x 10) (MANUAL) 40 4.5 6 1 TRIGGER ASSEMBLY 7 1 CLIP–trigger lead 8 1 SWITCH BOX 9 3 SCREW–switch box to block (M5 x 35) Drive Tight 10 2 SCREW–ground wire (10-16 x 1/2) Drive Tight 11 2 IGNITION COIL ASSEMBLY 12 2 SCREW–ignition coil 35 3.9 13 2 TAB WASHER 14 2 BUSHING–coil 15 4 NUT–coil terminal 20 2.2 16 1 LEAD ASSEMBLY–high tension 17 2 BOOT ASSEMBLY–spark plug 1818 2 SPARK PLUG (NGK#BP8H-N-10) 6/8 SPARK PLUG (NGK#BPZ-8H-N-10)2 2 SPARK PLUG (NGK#BP8HS-15) 9.9/15 SPARK PLUG (NGK#BPZ8HS-15)2 1919 AR STA-STRAP (8 IN.) AR STA-STRAP (5-1/2 IN.) 20 1 CABLE–grounding 21 1 HARNESS (62 IN. - BLACK/RED) HARNESS (20 IN. - BLACK/RED) SAILPOWER/SAILMATE PLUG 22 1 23 1 24 1 ENGINE WIRING HARNESS FUSE RETAINER REMOTE CONTROL RETAINER J-CLAMP 25 1 26 1 27 1 28 1 29 1 STARTER MOTOR 30 1 DRIVE KIT 31 1 DRIVE 32 1 END CAP 33 1 ARMATURE 34 1 END CAP 35 2 THRU BOLT 36 2 SCREW (M8 x 55) 90-827242R1 MAY 1998 Page 2A-5 IGNITION SYSTEM Description The ignition system is an alternator driven capacitor discharge system. Major components of the ignition system are the flywheel, stator, trigger coil, switch box, 2 ignition coils and 2 spark plugs. The flywheel has permanent magnets mounted in both the outer rim and the center hub. The BLACK stator assembly is mounted below the flywheel and has a low speed (LS) and a high speed (HS) capacitor charging coil. Low speed coil provides primary voltage to the switch box from idle to approximately 2500 RPM. The high speed coil provides primary voltage from 2000 RPM to the maximum RPM the outboard is capable of achieving. The RED stator assembly is mounted below the flywheel and has only one capacitor charging coil. As the flywheel rotates, the magnets mounted in the flywheel outer rim pass the charging coils creating voltage. This voltage is rectified to DC and charges the capacitor located in the switch box. As the flywheel continues to rotate, the magnets in the center hub pass the trigger coil creating voltage pulses. These pulses turn on one of the two electronic switches (SCR) in the switch box. A positive voltage pulse turns on the SCR switch associated with cylinder #1; a negative voltage pulse turns on the SCR switch associated with cylinder #2. The SCR switch discharges the stored capacitor voltage into the primary side of the respective ignition coil. The ignition coil multiplies this voltage to a value high enough to jump the spark plug gap – 34000 volts for standard coils; 40000 volts for high energy coils. This sequence occurs once per engine revolution for each cylinder. Spark timing is changed (advanced/retarded) by rotating the trigger coil on mechanically advanced models which changes the trigger coil position in relation to the magnets in the center hub of the flywheel. Spark timing on electronically advanced models is controlled internally by the switch box with a fixed trigger. The stop switch (or ignition switch) shorts the output of the stator to ground to stop the engine on all models. Test Procedures WARNING When testing or servicing the outboard ignition system, high voltage is present. Be extremely cautious. DO NOT touch or disconnect any ignition components while engine is running or while battery cables are connected on electric start models. It is recommended that the switch box and ignition coils be tested with a Quicksilver Multi- Meter/DVA Tester (91-99750), or a voltmeter (capable of measuring 400 volts DC or higher) in conjunction with Quicksilver Direct Voltage Adaptor (91-89045). All other components can be tested with an ohmmeter. Before troubleshooting the ignition system, check the following: 1. On electric models, verify that the electric harness and ignition switch are not the source of the problem. Check that plug-in connectors are fully engaged and that plug terminals are free of corrosion. 2. Verify that wire connections are tight and free of corrosion. Page 2A-6 90-827242R1 MAY 1998 IGNITION SYSTEM 3. Inspect all electrical components that are grounded directly to the engine and all ground wires that they are properly grounded to engine. 4. Inspect for disconnected wires and short and open circuits. 90-827242R1 MAY 1998 Page 2A-7 IGNITION SYSTEM Ignition Troubleshooting (BLACK Stator) TOOL : MULTIMETER/DVA TESTER 91-99750 Tested Part Multimeter Wires Connected To Scale Resistance (ohms) RED BLACK/WHITE R x 1 120 - 180 BLACK GROUND Stator (BLACK/ YELLOW and RED BLACK/YELLOW BLACK/WHITE R x 100 32 - 38 wires disconnected from switch box) BLACK GROUND RED BLACK/YELLOW R x 100 31 - 37 BLACK BLACK/WHITE Trigger (BROWN/ YELLOW and BROWN/WHITE wires disconnected from switch box) RED BLACK BROWN/YELLOW BROWN/WHITE R x 100 6.5 - 8.5 TOOL : MULTIMETER/DVA TESTER 91-99750 Tested Part Multimeter Connected To Scale Resistance (ohms) Ignition Coils (all wires disconnected) RED BLACK + Terminal – Terminal R x 1 0.02 - 0.04 RED BLACK Spark Plug Tower – Terminal R x 1000 8 - 11 TOOL : MULTIMETER/DVA TESTER 91-99750 Tested Part Multimeter Wires Connected To Selector Position Reading At 300 - 1000 RPM Reading At 1000 - 4000 RPM Switch Box Primary Coil RED BLACK – Terminal + Terminal 400 VDC 125 -260 200 - 360 Stop Circuit Switch Box Stator Low Speed RED BLACK BLACK/YELLOW GROUND 400 VDC 150 - 300 250 - 360 Stator High Speed RED BLACK GROUND BLACK/WHITE 400 VDC 10 - 75 50 - 300 NOTE: Copper is an excellent conductor, but resistance may notably vary between low and high temperature. Therefore, reasonable differences can be accepted between resistance readings and specifications. Page 2A-8 90-827242R1 MAY 1998 IGNITION SYSTEM Ignition Troubleshooting (RED Stator) TOOL : MULTIMETER/DVA TESTER 91-99750 Tested Part Multimeter Wires Connected To Scale Resistance (ohms) Stator (GREEN/ WHITE and WHITE/GREEN wires disconnected from switch boxes) RED BLACK GREEN/WHITE WHITE/GREEN R x 1 370 - 445 Trigger (BROWN/ YELLOW and BROWN/WHITE wires disconnected from switch boxes) RED BLACK BROWN/YELLOW BROWN/WHITE R x 100 6.5 - 8.5 TOOL : MULTIMETER/DVA TESTER 91-99750 Tested Part Multimeter Connected To Scale Resistance (ohms) Ignition Coils (all wires disconnected) RED BLACK + Terminal – Terminal R x 1 0.02 - 0.04 RED BLACK Spark Plug Tower – Terminal R x 1000 8 - 11 TOOL : MULTIMETER/DVA TESTER 91-99750 Tested Part Multimeter Wires Connected To Selector Position Reading At 300 - 1000 RPM Reading At 1000 - 4000 RPM Switch Box Primary Coil RED BLACK – Terminal + Terminal 400 VDC 125 - 320 200 - 320 Stop Circuit Switch Box RED BLACK BLACK/YELLOW GROUND 400 VDC 150 - 330 250 - 330 RED GREEN/WHITE 400 VDC 150 - 330 250 - 330 BLACK GROUND Stator Voltage RED WHITE/GREEN 400 VDC 150 - 330 250 - 330 BLACK GROUND NOTE: Copper is an excellent conductor, but resistance may notably vary between low and high temperature. Therefore, reasonable differences can be accepted between resistance readings and specifications. 90-827242R1 MAY 1998 Page 2A-9 IGNITION SYSTEM Ignition Components Removal and Installation CAUTION Do not strike flywheel with a hard object as flywheel damage could occur. Inspect flywheel magnets for clinging debris before installation. WARNING Engine could possibly start when turning flywheel during removal and installation. Disconnect (and isolate) spark plug leads. 5 Torque Specifications a b c 50 lb. ft. (67.8 N·m) 40 lb. in. (4.5 N·m) 70 lb. in. (7.9 N·m) 1 2 c 3 4 a 6b 7 8 b 9 10 95 53053 1-Recoil Assembly 2-Bolt (3) 3-Flywheel Nut 4-Washer 5-Flywheel 6-Screw (2) 7-Stator 8-Screw (Manual) 9-Trigger 10 -Retainer (Trigger) 95 2-4-C With Teflon (92-825407A12) Page 2A-10 90-827242R1 MAY 1998 IGNITION SYSTEM Ignition Components Removal and Installation 53047 1 2 4 6 5 3 7 8 9 10 11 a b c c 25 35 lb. in. (4.0 N·m) 20 lb. in. (2.3 N·m) Torque Specifications No Torque; Drive Tight a b c 1-Bolt (2) 2-Retainer (2) 3-Washer (2) 4-Nut (4) 5-Sta-strap (2) 6-Spark Plug Lead 7-Ignition Coil 8-Switch Box 9-Screw (3) 10 -Screw (2) 11 -Terminal Block 25 Liquid Neoprene (92-25711--2) 90-827242R1 MAY 1998 Page 2A-11 CHARGING AND STARTING SYSTEM ELECTRICAL AND IGNITION Section 2B – Charging and Starting System Table of Contents 2 B Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Recommended Battery. . . . . . . . . . . . . . . . . . 2B-2 Operating Engine Without Battery . . . . . . . . 2B-2 Voltage Regulator Test . . . . . . . . . . . . . . . . . . . . . 2B-2 Lamps Burn Out When Engine RPM is Increased . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Lamps Burn Dim at Wide-Open-Throttle . . . 2B-2 Battery Charging System. . . . . . . . . . . . . . . . . . . 2B-3 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3 Alternator Amperes Output (BLACK Stator – 8 Pole/4 Pulse – 1998 and previous) . . . . . 2B-3 Alternator Amperes Output (RED Stator – 10 Pole/5 Pulse – 1999 and newer) . . . . . . 2B-4 Battery Charging System Troubleshooting . 2B-4 Alternator Test . . . . . . . . . . . . . . . . . . . . . . . . . 2B-4 Rectifier Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-5 Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-6 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-6 Troubleshooting the Starting Circuit . . . . . . . 2B-6 COMMANDER 2000 Key Switch Test . . . . 2B-10 Emergency Stop Switch (Lanyard Type) . . 2B-11 Push Button Stop Switch . . . . . . . . . . . . . . . 2B-11 Electrical Component Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-12 Specifications Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-13 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-13 Cleaning and Inspection . . . . . . . . . . . . . . . . 2B-14 Testing Motor Armature . . . . . . . . . . . . . . . . 2B-14 Starter Motor Reassembly . . . . . . . . . . . . . . 2B-15 Starter Solenoid Test . . . . . . . . . . . . . . . . . . . 2B-17 Flywheel Ring Gear . . . . . . . . . . . . . . . . . . . . . . 2B-18 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-18 Neutral Start Switch (Electric Start Tiller Handle Shift Models) . . . 2B-18 Tiller Handle Start Button . . . . . . . . . . . . . . . . . . 2B-19 Choke Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-20 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-20 Battery Cables/Engine Wiring Harness (Remote Electric Start Models) . . . . . . . . . . . . 2B-21 Battery Cables (Tiller Handle Push Button Electric Start Models) . . . . . . . . . . . . . . 2B-23 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-23 Plug Harness (Battery Charging Kit) . . . . . . . . 2B-24 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-24 Emergency Stop Switch (Lanyard Type) . . . . . 2B-24 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-24 STARTING SYSTEM Manual Start Electric Start Starter Draw (Under Load) (No Load) Recoil 12 Volt 55 Amperes 15 Amperes CHARGING SYSTEM Alternator Output BLACK Stator - 2 Magnet Flywheel (8 Pole)(4 Pulses) RED Stator - 4 Magnet Flywheel (10 Pole)(5 Pulses) 4 Amp. (48 Watt) @ 6000 RPM 6 amp (72 Watt) @ 6000 RPM BATTERY Battery Rating 465 Marine Cranking Amps (MCA) or 350 Cold Cranking Amps (CCA) 90-827242R1 MAY 1998 Page 2B-1 CHARGING AND STARTING SYSTEM Recommended Battery A 12 volt battery with a “Marine Cranking Amperage” rating minimum of 465 amperes or or a “Cold Cranking Amperage” of 400. Battery Precautions When charging batteries, an explosive gas mixture forms in each cell. A portion of this gas escapes thru holes in vent plugs and may form an explosive atmosphere around battery if ventilation is poor. This explosive gas may remain in or around battery for several hours after it has been charged. Sparks or flames can ignite this gas and cause an internal explosion which may shatter the battery. The following precautions should be observed to prevent an explosion. 1. DO NOT smoke near batteries being charged or which have been charged very recently. 2. DO NOT break live circuits at terminals of batteries because a spark usually occurs at the point where a live circuit is broken. Always be careful when connecting or disconnecting cable clamps on chargers. Poor connections are a common cause of electrical arcs which cause explosions. 3. DO NOT reverse polarity of battery cables on battery terminals. CAUTION If battery acid comes into contact with skin or eyes, wash skin immediately with a mild soap. Flush eyes with water immediately and see a doctor. Operating Engine Without Battery If desired (or in an emergency), engines equipped with an 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 stator leads (Yellow) from rectifier. Insulate (tape) stator lead ring terminals. Voltage Regulator Test Lamps Burn Out When Engine RPM is Increased The voltage regulator is defective. Replace regulator. Lamps Burn Dim at Wide-Open-Throttle 1. Run engine at mid-range (approximately 3000 RPM) with 3 number 94 lamps connected to voltage regulator output leads. Note lamp brightness. 2. Disconnect the leads at one terminal of regulator. Connect the leads together using a screw and nut. Isolate (tape) connection. 3. Run engine at mid-range (approximately 3000 RPM) and note lamp brightness. If lamps are considerably brighter than with leads connected to regulator, the regulator is defective. If lamps are NOT considerably brighter, check the alternator (refer to “ Alternator Test” , following. Page 2B-2 90-827242R1 MAY 1998 CHARGING AND STARTING SYSTEM Battery Charging System Description The battery charging system components are the alternator, rectifier and battery. Alternating current (generated in alternator coils) flows to the rectifier which changes AC current to direct current (DC) for charging the battery. a b c a-Alternator b-Rectifier c-Battery The charging system may be damaged by: a. Reversed battery cables. b. Running the engine with battery cables disconnected and alternator leads connected to rectifier. c. An open circuit – such as a broken wire or loose connection. Alternator Amperes Output (BLACK Stator – 8 Pole/4 Pulse – 1998 and previous) Amperage output can be measured by installing a 10 ampere (minimum) amp meter in series between the rectifier and the battery or by clamping an inductive type amp meter (10 amp minimum) over the RED output lead from the rectifier to the battery. NOTE:Acceptable alternator amperage output should be within±10% of the amperes listed below. RPM AMPERES Idle 0 1000 0 2000 .9 3000 2.5 4000 3.5 5000 4.0 6000 4.3 90-827242R1 MAY 1998 Page 2B-3 CHARGING AND STARTING SYSTEM Alternator Amperes Output (RED Stator – 10 Pole/5 Pulse – 1999 and newer) Amperage output can be measured by installing a 10 ampere (minimum) amp meter in se ries between the rectifier and the battery or by clamping an inductive type amp meter (10 amp minimum) over the RED output lead from the rectifier to the battery. NOTE:Acceptable alternator amperage output should be within±10% of the amperes listed below. RPM AMPERES Idle 0 1000 0.75 2000 3.5 3000 4.5 4000 5.0 5000 5.5 6000 6.0 Battery Charging System Troubleshooting A fault in the battery charging system usually will cause the battery to become undercharged. Check battery electrolyte level, and charge battery. See “Electrolyte Level”, and “Charging a Discharged Battery”. If battery will NOT accept a satisfactory charge, replace battery. If battery accepts a satisfactory charge, determine the cause of the charging system problem as follows. 1. Check for correct battery polarity [RED cable to POSITIVE (+) battery terminal]. If polarity was incorrect, check for damaged rectifier. See “RECTIFIER TEST”. 2. Check for loose or corroded battery connections. 3. Visually inspect wiring between stator and battery for cuts, chafing; and disconnected, loose or corroded connection. 4. Excessive electrical load (from too many accessories) will cause battery to run down. If visual inspection determines that battery connections and wiring are OK, perform the following stator and rectifier tests. Alternator Test NOTE:Alternator can be tested without removing from engine. 1. Disconnect GRAY and YELLOW alternator leads from terminals on either rectifier, voltage regulator or isolator block. 2. Use an ohmmeter and perform tests as shown in following chart. 3. If meter readings are other than specified, replace alternator assembly. Test Leads Resistance Scale RED to YELLOW BLACK to GRAY 0.65* R x 1 RED to either GRAY or YELLOW BLACK to GROUND NO CONTINUITY R x 1000 NOTE:DC resistance of these windings generally is less than 1 ohm. A reading that resembles a short is acceptable. Page 2B-4 90-827242R1 MAY 1998 CHARGING AND STARTING SYSTEM Rectifier Test WARNING Disconnect battery leads from battery before testing rectifier. NOTE:Rectifier can be tested without removing from engine. 1. Disconnect all wires from terminals on rectifier. 2. Use an ohmmeter (R x 1000 scale) and perform the following test. Refer to drawing for rectifier terminal identification. d e b a c f 07300 Connect red meter lead to ground, black lead alternately to terminals “a” and “c”. Connect black meter lead to ground, red lead alternately to terminals “a” and “c”. Connect black meter lead to ground, red lead alternately to terminals “a” and “c”. Continuity Indicated No Continuity Indicated Continuity Indicated. Replace Rectifier. Continuity Indicated. Replace Rectifier. Continuity Indicated. Rectifier Tests O.K. Continuity Indicated. Replace Rectifier. No Continuity Indicated. Replace Rectifier. No Continuity Indicated. Replace Rectifier. No Continuity Indicated. Replace Rectifier. No Continuity Indicated. Rectifier tests O.K. Continuity Indicated Continuity Indicated No Continuity Indicated No Continuity Indicated Connect red meter lead to terminal “b”, black lead alternately to terminals “a” and “c”. Connect red meter lead to terminal “b”, black lead alternately to terminals “a” and “c”. Connect black meter lead to terminal “b”, red lead alternately to terminals “a” and “c”. Connect black meter lead to terminal “b”, red lead alternately to terminals “a” and “c”. 90-827242R1 MAY 1998 Page 2B-5 CHARGING AND STARTING SYSTEM Starting System STARTER MOTOR AMPERES DRAW STARTER MOTOR NO LOAD NORMAL PART NO. AMP. DRAW AMP. DRAW 50-90983A1 15 AMPS 55 AMPS Starter Motor Teeth 10 STARTING SYSTEM COMPONENTS The starting system consists of the following components. 1. Battery 2. Starter Solenoid 3. Neutral Start 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 in-line fuse in RED wire; see diagram SEC 2D, page 3. 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. IMPORTANT: Remote Control Electric Start Models have a 20 Ampere fuse located under the cowl next to the starter solenoid. This fuse protects the remote control harness. If this fuse is open, the starter will be inoperative. The cause of the blown fuse (a short) should be found and corrected. Page 2B-6 90-827242R1 MAY 1998 CHARGING AND STARTING SYSTEM Notes: 90-827242R1 MAY 1998 Page 2B-7 CHARGING AND STARTING SYSTEM Starting Circuit Troubleshooting Flow Chart To Rectifier 6 1 2 3 4 5 6 7 53056 Starter Motor Does Not Turn SAFETY WARNING: Disconnect BLACK (w/YELLOW sleeve) cable from starter solenoid test point 1 BEFORE making tests 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. There is an open circuit in the BLACK NEGATIVE (-) battery cable between the NEGATIVE (-) battery post and the power- head. • Check cable for loose or corroded connections. • Check cable for open. Continuity Indicated Proceed to TEST 2, on next page. No Continuity Indicated Page 2B-8 90-827242R1 MAY 1998 CHARGING AND STARTING SYSTEM a. Connect voltmeter between common engine ground and Test Point 2. b. Push start switch. * 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. Connect voltmeter between common engine ground and Test Point 3. b. Push Start Switch. Check BLACK ground wire for poor connection or open circuit. Reconnect ground wire to start- er solenoid; proceed to TEST 7. Neutral start switch is open, or YELLOW/RED wire is open between Test Points 4 and 3. a. Connect voltmeter between common engine ground and Test Point 4. b. Push Start Switch. 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 RED wire between 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. Push Start Switch. No voltage reading; De- fective starter solenoid. Should hear solenoid click; proceed to TEST 8. a. Reconnect BLACK (starter motor) cable to starter solenoid Test Point 1. b. Connect voltmeter between common engine ground and Test Point 7 c. Push Start Switch. No voltage reading; check BLACK 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 on lower engine cowl is open or BLACK or WHITE switch leads are disconnected or damaged. Proceed to TEST 7. 90-827242R1 MAY 1998 Page 2B-9 CHARGING AND STARTING SYSTEM COMMANDER 2000 Key Switch Test 1. Disconnect remote control wiring harness and instrument panel connector. 2. Set ohmmeter on R x 1 scale for the following tests: KEY POSITION OFF RUN START CHOKE* CONTINUITY SHOULD BE INDICATED AT THE FOLLOWING POINTS: BLK BLK/YEL RED YEL/RED PUR YEL/BLK *Key switch must be positioned to “RUN” or “START” and key pushed in to actuate choke for this test. 3. If meter readings are other than specified in the preceding tests, verify that switch and not wiring is faulty. If wiring checks ok, replace switch. Page 2B-10 90-827242R1 MAY 1998 CHARGING AND STARTING SYSTEM Emergency Stop Switch (Lanyard Type) IMPORTANT: Refer to Section 2D “Wiring Diagrams” for wiring connections. 1. Disconnect emergency stop switch leads from engine wiring. 2. Use an ohmmeter and perform the following tests. “RUN” “OFF” NO CONTINUITY CONTINUITY (8) (1 Ohm or Less) 23421 3. If meter readings are other than specified, replace emergency stop switch. Push Button Stop Switch IMPORTANT: Refer to Section 2D “Wiring Diagrams” for wiring connections. 1. Disconnect push button stop switch leads from engine wiring. 2. Use an ohmmeter and perform the following tests. CONTINUITY (I Ohm or Less) NO CONTINUITY (8) 23421 3. If meter readings are other than specified, replace push button stop switch. 90-827242R1 MAY 1998 Page 2B-11 CHARGING AND STARTING SYSTEM Electrical Component Removal and Installation e e a a b d c 25 25 25 25 Starter Solenoid Torque Specifications Tighten Securely 70 lb. in. (7.9 N·m) 15 lb. in. (1.7 N·m) 30 lb. in. (3.4 N·m) 25 lb. in. (2.8 N·m) Liquid Neoprene (92-25711--2) d e a b c 25 Page 2B-12 90-827242R1 MAY 1998 CHARGING AND STARTING SYSTEM Starter Motor Disassembly 1. Remove 2 thru bolts from starter. 2. Lightly tap on end of shaft and lower end cap with rubber mallet. Do not lose brush springs. 53235 a b c d a-Bolts b-Lower End Cap c-Washers d-Bolts 3. Tap on drive end cap to loosen. Remove end cap and armature from starter housing. 4. If removal of parts that are installed on armature is necessary, hold armature with Strap Wrench (91-24937A1) and remove locknut (and discard) from end of shaft. 5. Remove parts from shaft. 53228 53081 a b c d e f g h i j a-Strap Wrench (91-24937A1) b-Locknut (discard) c-Locknut d-Spacer e-Spring f-Drive Assembly g-Drive End Cap h-Armature Shaft i-Helix Threads j-Washer 90-827242R1 MAY 1998 Page 2B-13 CHARGING AND STARTING SYSTEM Cleaning and Inspection 1. If brushes are pitted, chipped or worn to less than 3/16 in. (4.8mm), replace brushes. IMPORTANT: DO NOT clean the starter drive assembly or armature shaft while starter motor is installed on outboard. The cleaning solution will drain dirt into motor housing. 2. If the motor drive assembly does not fully engage with flywheel, the drive assembly may be binding on the helix threads on the armature shaft due to dirt or wear. Locate cause of binding and correct before reassembling. 3. Clean drive components with cleaning solution and inspect parts for wear. 4. Clean commutator with No. 00 sandpaper. Remove any oil from commutator. If commutator surface is pitted , rough or worn unevenly, resurface on a lathe. 5. Resurface commutator on a lathe as follows: a. Use a lathe to turn down the commutator surface. DO NOT turn down the commutator surface excessively. b. Clean copper particles from slots between commutator bars. c. Sand the commutator lightly with No. 00 sand paper to remove burrs. Thoroughly clean the armature after resurfacing and sanding. Testing Motor Armature TESTING ARMATURE FOR SHORTS 1. Place armature in a growler and switch growler on. 2. Hold hack saw blade over armature core while rotating armature. 3. If saw blade vibrates, armature is shorted. Retest after cleaning between commutator bars. If saw blade still vibrates, replace armature. 01440 b a c a-Hack Saw Blade b-Armature Core c-Commutator Page 2B-14 90-827242R1 MAY 1998 CHARGING AND STARTING SYSTEM TESTING ARMATURE FOR GROUND 1. Use an ohmmeter (R x 100) to check for “no continuity” between commutator and armature core or commutator and shaft. 2. If continuity exists, armature is grounded and must be replaced. 01441 b ac a-Commutator b-Core c-Shaft Starter Motor Reassembly 1. Reinstall brush assembly. 53075 b e d c a a-Brush b-End Cap c-Fiber Washer d-Metal Washer e-Nut 90-827242R1 MAY 1998 Page 2B-15 CHARGING AND STARTING SYSTEM 2. Apply a drop of SAE 10W oil to to helix threads on armature shaft. DO NOT over lubricate. 3. Apply a drop of SAE 10W oil to bushings in drive end cap and lower end cap. DO NOT over lubricate. 4. Reinstall components on armature shaft. Use a new locknut and tighten securely. 53080 53228 b c d e f g h i a a-Helix Threads b-Locknut c-Spacer d-Spring e-Drive Assembly f-Drive End Cap g-Armature Shaft h-Helix Threads i-Washer 5. Position armature into starter frame so that commutator end of armature is at end of starter frame where permanent magnets are recessed 1-5/16 in. (33.3mm). Align marks as shown. 1-5/16 in. 53082 a b a-Alignment Marks b-Bottom Edge of Permanent Magnets Page 2B-16 90-827242R1 MAY 1998 CHARGING AND STARTING SYSTEM 6. Install springs and brushes into brush holders. Spread brushes and hold in place with a strip of spring steel. 7. Push in on drive end of shaft so that commutator will extend out of starter frame. 8. Install lower end cap onto starter frame. 53213 b c a 53083 e d f a-Brushes b-Spring Steel c-Commutator d-Alignment Mark; Must Align with Slot e-Slot f-Lower End Cap Starter Solenoid Test Test starter solenoid as follows: 1. Disconnect all leads from solenoid terminals. 2. Use an ohmmeter, set to (R x 1 scale) and connect between solenoid terminals 3 and 4. 3. Connect a 12-volt supply between solenoid terminals 1 and 2. Solenoid should click and meter should read zero ohms. 4. If meter does not read zero ohms (full continuity), replace solenoid. 14354 1 23 4 a b a-Ohmmeter Leads b-12-Volt Supply 90-827242R1 MAY 1998 Page 2B-17 CHARGING AND STARTING SYSTEM Flywheel Ring Gear Installation IMPORTANT: Before installing ring gear on flywheel, inspect gear and flywheel for paint runs which will prevent ring gear from laying flat against flywheel. 1. Inspect (and remove) any paint runs on ring gear and/or mounting surface on flywheel. 2. Place gear on flywheel with countersink side of mounting holes toward the outside. 3. Apply Loctite 271 to threads of 4 gear mounting screws and secure gear to flywheel. Torque screws to 100 lb. in. (11.3 N·m). 53240 a b c a-Ring Gear b-Flywheel c-Screws [Torque to 100 lb. in. (11.3 N·)] Neutral Start Switch (Electric Start Tiller Handle Shift Models) 1. Mount neutral start switch onto control platform with 2 bolts and plate. 2. Torque mounting bolts to 5 lb. in. (0.6 N·m). 53077 a bc a-Neutral Start Switch b-Plate c-Bolts [Torque to 5 lb in. (.6 N·m)] Page 2B-18 90-827242R1 MAY 1998 CHARGING AND STARTING SYSTEM 3. Route switch harness over block. Secure harness to stator harness with sta-strap. 4. Route harness behind rectifier. Attach BLACK lead to solenoid mount bolt. Attach Black lead with YELLOW sleeve to terminal 1 of starter solenoid. 53076 b c d a e a-Switch Harness b-BLACK Lead c-BLACK Lead with YELLOW Sleeve d-Terminal 1 e-Sta-strap Tiller Handle Start Button 1. The tiller handle start button assembly is secured to the tiller handle by 2 semi-loops which snap fit onto the tiller throttle shaft. To remove the button assembly, pry the assembly away from the tiller handle with a flat tip screw driver. 2. The starter button harness is routed into the lower cowl through the fuel connector access hole. 53216 d c b a a-Start Button Assembly b-Semi-Loops c-Harness d-Fuel Connector 90-827242R1 MAY 1998 Page 2B-19 CHARGING AND STARTING SYSTEM 3. The starter button harness is routed down the PORT side of lower engine to cowl. 4. The RED harness lead is connected to the POSITIVE (+) terminal of the rectifier. Torque attaching nut to 25 lb. in. (2.8 N·m). 5. The YELLOW/RED harness lead attaches to the #2 terminal of the starter terminal. Torque attaching nut to 15 lb. in. (1.7 N·m). 53215 b a a-RED Lead [Torque nut to 25 lb. in. (2.8 N·m)] b-YELLOW/RED Lead [Torque nut to 15 lb. in. (1.7 N·m)] Choke Solenoid Installation IMPORTANT: New gasket MUST be positioned as shown when being installed. 1. Install new gasket with solenoid plate assembly. 2. Secure assembly with 2 screws. Torque screws to 18 lb. in. (2.0 N·m). 53209 c b a a-Gasket b-Solenoid Plate c-Screws [Torque to 18 lb. in. (2.0 N·m)] Page 2B-20 90-827242R1 MAY 1998 CHARGING AND STARTING SYSTEM Battery Cables/Engine Wiring Harness (Remote Electric Start Models) 1. Slide battery cables through sleeve. 2. Thread battery cable/sleeve through wire retainer of engine wiring harness. Verify 1 in. (25.4mm) of sleeve remains to the outside of wire retainer. 1 in. (25.4mm) 5306553066 b a d e c a-Battery Cables b-Sleeve c-Sleeve d-Retainer e-Harness 3. Remove carburetor as outlined in Section 3. 4. Thread engine wiring harness first and then battery cable/sleeve through opening in bottom cowl. b c a a-Harness b-Battery Cable/Sleeve c-Opening 53210 90-827242R1 MAY 1998 Page 2B-21 CHARGING AND STARTING SYSTEM 5. Route engine wiring harness and battery cable/sleeve (under carburetor location) around to PORT side of cylinder block. 6. Push wire retainer into opening of bottom cowl and secure with clip a a-Clip 7. Secure harness and battery cable/sleeve with sta-strap just inside bottom cowl. 8. Reinstall carburetor as outlined in Sec 3A. 9. Secure fuse holder in J-clip. 53226 c b a a-Sta-strap b-Fuse Holder c-J-clip 10. Plug remote control harness connector into engine wiring harness connector and secure with harness connector retainer. 53064c b a a-Remote Control Harness b-Engine Harness c-Retainer Page 2B-22 90-827242R1 MAY 1998 CHARGING AND STARTING SYSTEM Battery Cables (Tiller Handle Push Button Electric Start Models) Installation 1. Fasten harness clamp to bottom cowl with nut, washer and bolt. 53069 ab d c a-Clamp b-Nut c-Washer d-Bolt 2. Slide battery cables through sleeve. 3. Slide harness clamp over battery cable sleeve and position cables into bottom cowl. 4. Position harness clamp onto clamp bracket in bottom cowl. Tighten clamp securely. 5. Slide battery cable grommet over battery cables and install grommet into opening in starboard bottom cowl. b a a-Clamp b-Bracket c-Grommet d-Cables c d 53149 53067 90-827242R1 MAY 1998 Page 2B-23 CHARGING AND STARTING SYSTEM Plug Harness (Battery Charging Kit) Installation 1. Install plug harness through fuel fitting opening in bottom cowl. 2. Route harness along PORT side of engine to rectifier. 53063 a a-Harness 3. Refer to Section 2D for wiring connections. Emergency Stop Switch (Lanyard Type) Installation 1. Route emergency stop switch wiring through opening in STARBOARD bottom cowl. 2. Secure stop switch into opening in bottom cowl using clip. 53055 a b 53054 a-Stop Switch b-Clip 3. Refer to Section 2D for wiring connections. Page 2B-24 90-827242R1 MAY 1998 TIMING, SYNCHRONIZING & ADJUSTING ELECTRICAL AND IGNITION Section 2C – Timing, Synchronizing & Adjusting Table of Contents 2 C Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1 Tiller Handle Shift Models . . . . . . . . . . . . . . . 2C-3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-2 Maximum Timing Adjustment . . . . . . . . . . . . 2C-4 Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-2 Idle Timing Adjustment . . . . . . . . . . . . . . . . . . 2C-4 Side Shift Models. . . . . . . . . . . . . . . . . . . . . . . 2C-2 Fast Idle Adjustment . . . . . . . . . . . . . . . . . . . . 2C-5 Specifications MAXIMUM TIMING 36° BTDC IDLE TIMING 6/8/9.9/10/15 8° BTDC ± 1° IDLE RPM IN FORWARD GEAR – 6 650 ± 75 8/9.9/15 725 ± 50 10 SEA PRO 850 ± 50 MARATHON 850 ± 50 XR10/MAG10 15 SEA PRO 725 ± 50 MARATHON 725 ± 50 FULL THROTTLE RPM 6 4000 – 5000 8 4500 – 5500 9.9/10/15 5000 – 6000 SPARK PLUG (1994) 6/8/9.9 NGK BP8H-N-10 10/15 SPARK PLUG GAP NGK BP8HS-15 6/8/9.9 0.040 IN. (1.0MM) 10/15 0.060 IN. (1.5MM) SPARK PLUG (1995 AND NEWER) 6/8 NGK BP8H-N-10 9.9/10/15 SPARK PLUG GAP NGK BP8HS-15 6/8 0.040 IN. (1.0MM) 9.9/10/15 0.060 IN. (1.5MM) NEUTRAL FAST IDLE 1500 – 2000 RPM 90-827242R1 MAY 1998 Page 2C-1 TIMING, SYNCHRONIZING & ADJUSTING Special Tools 1. DMT 2000 Service Tachometer 91-854009A1* 2. Timing Light 91-99379* *May be obtained locally. Adjustments 1. Place engine in water. Side Shift Models 1. Check tiller handle cable adjustment for full throttle movement in both “Forward”and “Reverse”gears. 2. Adjust jam nuts for proper travel and to eliminate any slack. a a a-Jam Nuts Page 2C-2 90-827242R1 MAY 1998 TIMING, SYNCHRONIZING & ADJUSTING Tiller Handle Shift Models 1. Rotate tiller handle twist grip to NEUTRAL. 2. Adjust “jam” nuts to remove slack from control cables while allowing full travel of throttle/ shift linkage. 53046 a a a-Jam Nuts TIMING POINTER LOCATION 40 30 20 10 a a-Timing Pointer 90-827242R1 MAY 1998 Page 2C-3 TIMING, SYNCHRONIZING & ADJUSTING Maximum Timing Adjustment 1. Connect timing light to no.1 (top) spark plug lead. 2. With engine in “Forward” gear, fully advance throttle to WOT position. 3. Adjust maximum spark advance screw to align the 36° BTDC timing mark on flywheel with timing pointer. Tighten jam nut if so equipped. 4. Adjust low speed mixture screw as described in the “Fuel System – Carburetor” section, under “Low Speed Mixture Adjustment”. a b a-Maximum Spark Advance Screw b-Jam Nut Idle Timing Adjustment 1. Push primer/fast idle knob completely in and rotate knob fully counterclockwise. 2. With engine running in “Forward” gear, reduce engine speed to idle. IMPORTANT: It may be necessary to adjust idle speed screw to obtain a reasonably stabilized idle. 3. Adjust idle timing adjustment screw to align the specified idle timing mark on flywheel with timing pointer. 4. Shift to “Neutral” gear and stop engine. a a-Idle Timing Adjustment Screw Page 2C-4 90-827242R1 MAY 1998 TIMING, SYNCHRONIZING & ADJUSTING Fast Idle Adjustment 1. Push primer/fast idle knob completely in and rotate knob fully COUNTERCLOCKWISE. 2. Shift outboard to NEUTRAL. 3. Adjust screw to remove all clearance between idle wire and trigger. 23970 b a a-Fast Idle Screw b-Idle Wire 4. Check fast idle by turning primer knob to full CLOCKWISE position. Fast idle speed should be 1500 – 2000 RPM. 90-827242R1 MAY 1998 Page 2C-5 WIRING DIAGRAMS ELECTRICAL AND IGNITION Section 2D – Wiring Diagrams Table of Contents 2 D Manual Start Ignition Wiring Diagram (BLACK Stator). . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-2 Electric Start Models with Tiller Handle Start Button (BLACK Stator) . . . . . . . . . . . . . . . . . . . . 2D-3 Electric Models Equipped with Remote Control (BLACK Stator). . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-4 Manual Start Ignition Wiring Diagram (RED Stator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-5 Manual Start Ignition Wiring Diagram (RED Stator) (Marathon and Sea Pro Models) . . . . . 2D-6 Electric Start Models with Tiller Handle Start Button (RED Stator). . . . . . . . . . . . . . . . . . . . . . . 2D-7 Electric Models Equipped with Remote Control (RED Stator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-8 Optional Electrical Accessories Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-9 Commander Remote Control (Electric Start) . 2D-10 Commander 2000 Remote Control (Manual) . 2D-11 Commander 2000 Remote Control (Electric Start). . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-12 Commander 3000 Panel Mount Control . . . . . 2D-13 90-827242R1 MAY 1998 Page 2D-1 WIRING DIAGRAMS Manual Start Ignition Wiring Diagram (BLACK Stator) BLK = BLACK c a b c d ef g BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW a-Stator b-Trigger c-Switch Box d-Ignition Coil Top Cylinder e-Ignition Coil Bottom Cylinder f-Stop Switch g-Emergency Stop Switch Page 2D-2 90-827242R1 MAY 1998 WIRING DIAGRAMS Electric Start Models with Tiller Handle Start Button (BLACK Stator) ma b c d e f g h i j k l m BLK = Black BRN = Brown GRY = Gray GRN = Green RED = Red WHT = White YEL = Yellow a-Stator h-Starter Motor b-Trigger i-Starter Solenoid c-Switch Box j-Neutral Start Switch d-Ignition Coil Top Cylinder k-Start Switch e-Ignition Coil Bottom Cylinder l-Stop Switch f-Alternator Stator m-Emergency Stop Switch g-Rectifier 90-827242R1 MAY 1998 Page 2D-3 WIRING DIAGRAMS Electric Models Equipped with Remote Control (BLACK Stator) BLK = BLACK j i a b c d e f g h k l BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW a-Stator g-Rectifier b-Trigger h-Starter Motor c-Switch Box i-Starter Solenoid d-Ignition Coil Top Cylinder j-Fuse Holder (20 Ampere Fuse) e-Ignition Coil Bottom Cylinder k-Choke Solenoid f-Alternator Stator l-Wiring Harness Page 2D-4 90-827242R1 MAY 1998 WIRING DIAGRAMS Manual Start Ignition Wiring Diagram (RED Stator) BLK/YEL WHT/GRN BRN/WHTBRN/YELGRN/WHTGRN/YEL GRN BLK BLK #2 #1 BLK/YEL BLK/YELBLK/YEL WHT/GRN BLK BLK BLK BLK BRN/WHTBRN/YELGRN/WHT a b c d e fg BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW a-Stator b-Trigger c-Switch Box d-Ignition Coil Bottom Cylinder e-Ignition Coil Top Cylinder f-Emergency Stop Switch g-Stop Switch 90-827242R1 MAY 1998 Page 2D-5 WIRING DIAGRAMS Page 2D-6 90-827242R1 MAY 1998 Manual Start Ignition Wiring Diagram (RED Stator) (Marathon and Sea Pro Models) BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW BRN/WHT BRN/YEL GRN/WHT WHT/GRN GRN/YEL GRN YEL GRY BLK BLK/YEL #2 #1 Z1 Z1 Z1 Z1 Z1 J2 J1 J3 J4 J7 J6 J5 GRN/WHT WHT/GRN BRN/YEL BRN/WHT BLK/YEL BLK/YEL BLK/YEL BLK BLK BLK BLK BLK a b c d g f a b c d e g h a - Stator b - Trigger c - Switch Box d - Ignition Coil Bottom Cylinder e - Ignition Coil Top Cylinder f - Stop Switch g - Emergency Stop Switch h - Alternator Stator WIRING DIAGRAMS 90-827242R1 MAY 1998 Page 2D-7 Electric Start Models with Tiller Handle Start Button (RED Stator) BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW BRN/WHT BRN/YEL WHT/GRN GRN/WHT BLK GRN/YEL GRN YEL GRY YEL BLK RED YEL/RED RED BLK/YEL BLK YEL/RED RED BLK – + BLK BLK RED #2 #1 Z1 Z1 Z1 Z1 Z1 J2 J1 J3 J4 J7 J6 J5 BLK BLK BLK BLK BLK BLK/YEL BLK/YEL BLK/YEL GRN/WHT WHT/GRN BRN/YEL BRN/WHT a b d e h i j m a b c d e g f i j k l m n a - Stator b - Trigger c - Switch Box d - Ignition Coil Bottom Cylinder e - Ignition Coil Top Cylinder f - Emergency Stop Switch g - Push Button Stop Switch h - Rectifier i - Alternator Stator j - Neutral Start Switch k - Push Button Start Switch l - Start Solenoid m - 12 VDC Battery n - Starter Motor WIRING DIAGRAMS Page 2D-8 90-827242R1 MAY 1998 Electric Models Equipped with Remote Control (RED Stator) BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW BRN/WHT BRN/YEL BLK/YEL WHT/GRN GRN/WHT GRN/YEL GRN YEL GRY YEL BLK RED RED – + #2 #1 BLK YEL/RED GRY YEL/RED GRY YEL/BLK YEL/BLK RED Z1 Z1 Z1 Z1 Z1 J2 J1 J3 J4 12345678 J5 J7 J6 BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK/YEL GRN/WHT WHT/GRN BRN/YEL BRN/WHT c d e f h i j k m a b d e g j k l a - Stator b - Trigger c - Switch Box d - Ignition Coil Bottom Cylinder e - Ignition Coil Top Cylinder f - Choke Solenoid g - Remote Control Harness h - Fuse Holder (20 Ampere Fuse) i - Rectifier j - Alternator Stator k - Starter Solenoid l - 12 VDC Battery m - Starter Motor WIRING DIAGRAMS Optional Electrical Accessories Wiring Diagrams Terminal Block Manual Start Model with Lighting Coil and Unregulated AC Voltage Rectifier Manual Start Model with Battery Charging Kit Voltage Regulator Manual Start Model with Voltage Regulator 90-827242R1 MAY 1998 Page 2D-9 WIRING DIAGRAMS Commander Remote Control (Electric Start) BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE b a b c d e YEL = YELLOW a-Ignition/Choke Switch b-Emergency Stop Switch c-Neutral Start Switch d-Tachometer/Accessories Harness Connector Page 2D-10 90-827242R1 MAY 1998 WIRING DIAGRAMS Commander 2000 Remote Control (Manual) BLK=BLACK YEL=YELLOW 23893 a b c a-RUN – OFF Switch b-Emergency Stop Switch c-Stop Switch Harness 90-827242R1 MAY 1998 Page 2D-11 WIRING DIAGRAMS Commander 2000 Remote Control (Electric Start) BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW 23890 c a b d e a-Ignition/Choke Switch b-Emergency Stop Switch c-Neutral Start Switch d-Tachometer/Accessories Harness Connector e-Wiring Harness Connector Page 2D-12 90-827242R1 MAY 1998 WIRING DIAGRAMS Commander 3000 Panel Mount Control Neutral Interlock Switch a b RED=RED YEL=YELLOW a-Neutral Interlock Switch b-Emergency Stop Switch 90-827242R1 MAY 1998 Page 2D-13 FUEL DELIVERY SYSTEM FUEL SYSTEM Section 3A – Fuel Delivery System Table of Contents Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1 WMC Carburetor Specifications . . . . . . . . . . . . . 3A-2 WMC Carburetor Specifications . . . . . . . . . . . . . 3A-3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-4 Carburetor Assembly (6.8) (9.9 - USA– S/N-0G112449/BEL–S/N-9831799 & Below) . . 3A-6 Carburetor Assembly (6.8) (9.9 - USA– S/N-0G112449/BEL–S/N-9831799 & Below) . . 3A-7 Carburetor Assembly (15) USA–S/N-0G112449/ BEL–S/N-9831799 & Below . . . . . . . . . . . . . . . . 3A-8 Carburetor Assembly (15) USA–S/N-0G112449/ BEL–S/N-9831799 & Below . . . . . . . . . . . . . . . . 3A-9 CARBURETOR ASSEMBLY USA–S/N-0G112450/ BEL–S/N-9831800 & Up . . . . . . . . . . . . . . . . . . 3A-10 Specifications Carburetor AssemblyUSA–S/N-0G112450/ BEL–S/N-9831800 & Up . . . . . . . . . . . . . . . . . . 3A-11 Fuel System Troubleshooting . . . . . . . . . . . . . . 3A-12 General Information . . . . . . . . . . . . . . . . . . . 3A-12 Carburetor Removal . . . . . . . . . . . . . . . . . . . . . . 3A-14 Carburetor Installation . . . . . . . . . . . . . . . . . . . . 3A-15 Carburetor Adjustments . . . . . . . . . . . . . . . . 3A-17 Rejetting Carburetors for High Altitude . . . 3A-21 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-22 Removal and Disassembly . . . . . . . . . . . . . 3A-22 Cleaning and Inspection . . . . . . . . . . . . . . . . 3A-22 Reassembly and Installation . . . . . . . . . . . . 3A-22 Primer System . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-23 Servicing Sight Bowl Fuel Filter . . . . . . . . . . . . 3A-24 3 A Models 6/8/9.9/10/15 CARBURETOR SPECIFICATIONS Type Idle RPM (In Gear) – 6 8 9.9/9.9 Sailpower 10 Sea Pro/Marathon XR10/MAG10 15 Wide Open Throttle RPM 6 8 9.9/9.9 Sailpower 10 Sea Pro/Marathon XR10/MAG10 15 15 Sea Pro/Marathon Idle Mixture Screw (Initial Setting) Float Setting (All Models) Main Jet – 6 8 9.9/9.9 Sailpower 10 Sea Pro/Marathon XR10/MAG10 15 15 Sea Pro/Marathon Center Bowl, Integral Fuel Pump 650 ± 75 725 ± 50 725 ± 50 850 ± 50 725 ± 50 725 ± 50 4000 – 5000 4500 – 5500 5000 – 6000 5000 – 6000 5000 – 6000 5000 – 6000 5000 – 6000 Refer to Page 3-20 for Specifics 1 in. (25.4mm) 1995-1999 .042 .046 .052 .064 .052 .066 .042 .046 .048 .052 .052 .072 1994 .072 90-827242R1 MAY 1998 Page 3A-1 FUEL DELIVERY SYSTEM WMC Carburetor Specifications 1994 MAIN JET MODEL CARB 0 – 5000 ft (0 – 1524m) 5000 – 7500 ft (1524 – 2286m) 7500 – 10000 ft (1524 – 3048m) FLOAT LEVEL IDLE MIX 6 WMC-20B .042 .040 .038 (25.4mm) 1 in. 1-3/8 ± 1/4 8 WMC-18B .046 .044 .042 (25.4mm) 1 in. 1 in.1 in. 1-3/8 ± 1/4 9.9 WMC-23 .052 .050 .048 (25.4mm) 1 in. 1-3/8 ± 1/4 XR10 Mag 10 WMC-23 .052 .050 .048 (25.4mm) 1 in. 1-3/8 ± 1/4 Seapro Marathon 10 WMC-42 .064 .062 .060 (25.4mm) 1 in. 1-3/8 ± 1/4 15 WMC-39 .064 .062 .060 (25.4mm) 1 in. 1-3/8 ± 1/4 1995 - 1996 MAIN JET MODEL CARB 0 – 5000 ft (0 – 1524m) 5000 – 7500 ft (1524 – 2286m) 7500 – 10000 ft (1524 – 3048m) FLOAT LEVEL IDLE MIX 6 WMC-20B .042 .040 .038 (25.4mm) 1 in. 1-3/8 ± 1/4 8 WMC-41 .046 .044 .042 (25.4mm) 1 in. 1-1/2 ± 1/4 9.9 WMC-47 .048 .046 .044 (25.4mm) 1 in. 1-1/2 ± 1/4 XR10 Mag 10 WMC-48 .052 .050 .048 (25.4mm) 1 in. 1-1/2 ± 1/4 Seapro Marathon 10 WMC-50 WMC-50A .052 .050 .048 (25.4mm) 1 in. 1-1/2 ± 1/4 15 WMC-49 .072 .068 .066 (25.4mm) 1 in. 1-1/2 ± 1/4 Page 3A-2 90-827242R1 MAY 1998 FUEL DELIVERY SYSTEM 1997WMC Carburetor Specifications MAIN JET MODEL CARB 0 – 5000 ft (0 – 1524m) 5000 – 7500 ft (1524 – 2286m) 7500 – 10000 ft (1524 – 3048m) FLOAT LEVEL IDLE MIX 6 WMC-20B .042 .040 .038 (25.4mm) 1 in. 1-3/8 ± 1/4 8 WMC-41 .046 .044 .042 (25.4mm) 1 in. 1 in.1 in. 1-1/2 ± 1/4 9.9 WMC-47 .048 .046 .044 (25.4mm) 1 in. 1-1/2 ± 1/4 XR10 Mag 10 Seapro Marathon 10 WMC-48 WMC-50A .052 .052 .050 .050 .048 .048 (25.4mm) 1 in. (25.4mm) 1 in. 1-1/2 ± 1/4 1-1/2 ± 1/4 15 WMC-49 .072 .068 .066 (25.4mm) 1 in. 1-1/2 ± 1/4 15 Sea Pro Marathon WMC-55 .072 .068 .066 (25.4mm) 1 in. 1-1/2 ± 1/4 1998 – 1999 MAIN JET MODEL CARB 0 – 5000 ft (0 – 1524m) 5000 – 7500 ft (1524 – 2286m) 7500 – 10000 ft (1524 – 3048m) FLOAT LEVEL IDLE MIX 6 WMC-57 .042 .040 .038 (25.4mm) 1 in. 1-1/4 ± 1/4 8 WMC-41A .046 .044 .042 (25.4mm) 1 in. 1-1/2 ± 1/4 9.9 WMC-47A .048 .046 .044 (25.4mm) 1 in. 1-1/2 ± 1/4 XR10 Mag 10 WMC-48A .052 .050 .048 (25.4mm) 1 in. 1-1/2 ± 1/4 Seapro Marathon 10 WMC-50B .052 .050 .048 (25.4mm) 1 in. 1-1/2 ± 1/4 15 WMC-49A .072 .068 .066 (25.4mm) 1 in. 1-1/2 ± 1/4 15 Sea Pro Marathon WMC-55A .072 .068 .066 (25.4mm) 1 in. 1-1/2 ± 1/4 90-827242R1 MAY 1998 Page 3A-3 FUEL DELIVERY SYSTEM Special Tools 1. Carburetor Scale Page 3A-4 90-827242R1 MAY 1998 FUEL DELIVERY SYSTEM Notes: 90-827242R1 MAY 1998 Page 3A-5 FUEL DELIVERY SYSTEM Carburetor Assembly (6.8) (9.9 - USA–S/N-0G112449/BEL–S/N-9831799 & Below)        43 44 45 35 34 33 29 36 37 38 42 39 27 251 25 24 25 17 16 18 24 25 22 22 22 2525 2 3 41 40 14 25 23 24 25 24 25 5 25 7 8 6 25 25 1915 24 25 4 9 10 13 32 31 28 30 11 24 25 24 25 25 25 21 24 25 46 47 20 Page 3A-6 90-827242R1 MAY 1998 FUEL DELIVERY SYSTEM Carburetor Assembly (6.8) (9.9 - USA–S/N-0G112449/BEL–S/N-9831799 & Below) REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 11 1 CARBURETOR (6/8) (WMC-41) 1 CARBURETOR (6/8) (WMC-41A) 1 CARBURETOR (6) (WMC-57) 1 CARBURETOR (9.9) (WMC-23) 22 1 THROTTLE VALVE (WMC-20B/57) 1 THROTTLE VALVE (WMC-41) 1 THROTTLE VALVE (WMC-23/41A) 33 1 SHAFT (WMC-20B/57) 1 SHAFT (WMC-41) 1 SHAFT (WMC-23/41A) (INCL. SCREW/SPRING) 4 1 FUEL BOWL 5 1 FLOAT 6 1 FLOAT PIN 7 1 SCREW 8 1 INLET NEEDLE VALVE 99 1 MAIN FUEL JET (.042) (6) 1 MAIN FUEL JET (.046) (8) 1 MAIN FUEL JET (.052) (9.9) 10 1 PLUG–jet retainer 33 3.7 11 1 COVER–diaphragm 12 1 COVER–diaphragm (WMC-57) 13 4 SCREW 14 1.6 14 1 FUEL PUMP KIT 15 5 SCREW–fuel pump 18 2.1 16 1 PLATE 17 1 GASKET–electric choke 18 2 SCREW 18 2.1 19 1 COVER–fuel pump (WMC-57) 20 1 COVER-fuel pump 21 1 PLUG 33 3.7 22 1 GASKET–carburetor (Use where applicable) 23 1 DIAPHRAGM 24 1 GASKET/DIAPHRAGM KIT 25 1 REPAIR PARTS KIT (WMC-20B) 26 1 REPAIR PARTS KIT (WMC-23/41/57) 27 1 IDLE WIRE 28 1 FAST IDLE LEVER 29 1 PRIMER BRACKET 30 1 PUSHNUT 31 1 SCREW 32 1 SPRING 33 2 SCREW (M5 x 8 x 12) 33 3.7 34 1 SCREW Tighten Securely 35 1 PRIMER LEVER 36 1 CAM BLOCK 37 1 RETAINING CLIP 38 1 CHOKE BEZEL 39 1 PRIMER KNOB 40 1 SCREW 41 1 NUT 42 1 DECAL (SLOW/FAST) 43 1 ELECTRIC CHOKE 44 1 COVER 45 1 PLUG 46 1 PRIMER/INJECTOR SERVICE KIT (See illustration for contents (indicated by star) 47 1 RESTRICTOR KIT (RESTRICTED 6) 90-827242R1 MAY 1998 Page 3A-7 FUEL DELIVERY SYSTEM Carburetor Assembly (15) USA–S/N-0G112449/BEL–S/N-9831799 & Below 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 15 16 15 16 15 16 15 16 15 16 16 16 16 16 16 16 15 16 16 16 16 15 16 15 16 38 39 Page 3A-8 90-827242R1 MAY 1998 FUEL DELIVERY SYSTEM Carburetor Assembly (15) USA–S/N-0G112449/BEL–S/N-9831799 & Below REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 CARBURETOR (WMC-39) 2 1 THROTTLE VALVE 3 1 THROTTLE SHAFT (INCLS. SCREW & SPRING) 4 1 FUEL BOWL 5 1 FLOAT 6 1 INLET NEEDLE VALVE 7 1 MAIN FUEL JET (.066) 8 1 PLUG–jet retainer 33 3.7 9 1 COVER–diaphragm 10 4 SCREW–diaphragm cover 14 1.7 11 1 FUEL PUMP KIT 12 5 SCREW–fuel pump cover 18 2.1 13 1 PLATE–cover 14 2 SCREW–cover plate 18 2.1 15 1 GASKET/DIAPHRAGM KIT 16 1 REPAIR PARTS KIT 17 1 COVER–fuel pump 18 1 PLUG 33 3.7 19 1 GASKET–carburetor 20 1 DIAPHRAGM 21 1 FAST IDLE LEVER 22 1 PRIMER BRACKET 23 1 PUSHNUT 24 1 SCREW 25 1 SPRING 26 2 SCREW (M5 x 8 x 12) 33 3.7 27 1 SCREW Tighten Securely 28 1 PRIMER LEVER 29 1 CAM BLOCK 30 1 RETAINING CLIP 31 1 CHOKE BEZEL 32 1 PRIMER KNOB 33 1 SCREW 34 1 NUT 35 1 DECAL (SLOW/FAST) 36 1 IDLE WIRE 37 1 ELECTRIC CHOKE 38 1 COVER 39 1 PLUG 90-827242R1 MAY 1998 Page 3A-9 FUEL DELIVERY SYSTEM CARBURETOR ASSEMBLY USA–S/N-0G112450/BEL–S/N-9831800 & Up NO TAG 1 2 3 4 5 67 8 9 10 11 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 22 22 12 22 23 22 23 22 23 22 23 22 23 22 23 22 23 23 Page 3A-10 90-827242R1 MAY 1998 FUEL DELIVERY SYSTEM Carburetor Assembly USA–S/N-0G112450/BEL–S/N-9831800 & Up REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 11 1 CARBURETOR (6) (WMC-57) 1 CARBURETOR (8) (WMC-41A) 1 CARBURETOR (9.9) (WMC-47A) 1 CARBURETOR (15) - (WMC-49A) 22 1 THROTTLE VALVE (6) (WMC-57) 1 THROTTLE VALVE (8) (WMC-41A) 1 THROTTLE VALVE (9.9) (WMC-47A) 1 THROTTLE VALE (15) - (WMC-49A) 3 1 SHAFT (6) (WMC-57) 1 SHAFT (8/9.9) (WMC-41A/47A) 1 SHAFT (15) - (WMC-49A) 4 1 FUEL BOWL 5 1 FLOAT 6 1 FLOAT PIN 7 1 SCREW 8 1 INLET NEEDLE VALVE 99 1 MAIN FUEL JET (.042) (6) 1 MAIN FUEL JET (.046) (8) 1 MAIN FUEL JET (.048) (9.9) 1 MAIN FUEL JET (.072) (15) 10 1 PLUG–jet retainer 33 3.7 1111 1 COVER–diaphragm (8) (WMC-41A) 1 COVER–diaphragm (6/9.9/15) (WMC-47A/49A/57) 12 4 SCREW 14 1.6 13 1 FUEL PUMP KIT 14 5 SCREW–fuel pump 18 2.1 15 1 PLATE 16 1 GASKET 17 2 SCREW 18 2.1 1818 1 COVER–fuel pump (6) (WMC-57) 1 COVER-fuel pump (8/9.9/15) (WMC-41A/47A/49A) 19 1 PLUG 33 3.7 20 1 GASKET–carburetor (RESTRICTED 6) 21 1 DIAPHRAGM 22 1 GASKET/DIAPHRAGM KIT 23 1 REPAIR PARTS KIT 24 1 IDLE WIRE 25 1 FAST IDLE LEVER 26 1 PRIMER BRACKET 27 1 PUSHNUT 28 1 SCREW (6-32 x 3/4) 29 1 SPRING 30 2 SCREW (M5 x 8 x 12) 33 3.7 31 1 SCREW (8-32 x 1/2) Tighten Securely 32 1 PRIMER LEVER 33 1 CAM BLOCK 34 1 RETAINING CLIP 35 1 CHOKE BEZEL 36 1 PRIMER KNOB 37 1 SCREW (M5 x 30) 38 1 NUT 39 1 DECAL - Bezel Choke 40 1 ELECTRIC CHOKE 41 1 RESTRICTOR PLATE (RESTRICTED 6) 90-827242R1 MAY 1998 Page 3A-11 FUEL DELIVERY SYSTEM Fuel System Troubleshooting General Information Problems that are thought to be caused by the fuel system may, in reality, be something completely different. Items, that are shown in the list on the right, could give the impression that there is a problem in the fuel system. 1. Propeller 2. Spark Plugs 3. Ignition Timing 4. Ignition Spark Voltage 5. Cylinder Compression 6. Reed Valves Typical symptoms and solutions in troubleshooting a fuel system are shown below: Problem: Engine Turns Over but Will Not Start or Starts Hard When Cold Problem: Engine Idles Rough and Stalls. Problem: Engine Runs Uneven or Surges. Problem: Engine Will Not Accelerate. Possible Cause Corrective Action Improper starting procedure used. Review starting procedure as outlined in “Operation and Maintenance Manual.” Fuel tank empty or too low. Improperly mixed fuel. Contaminants (water,dirt, etc.) in fuel. Check fuel in tank and replace or add whichever is necessary. Fuel tank air vent closed or restricted. Check air vent on fuel tank. Air vent must be open all-the-way and free from any contaminants. Pinched, cut, restricted fuel line or loose fuel line connection. Inspect all fuel lines and replace as needed. Tighten fuel line connections. Dirty or restricted fuel filter. Inspect and replace or clean all fuel filters. Choke solenoid or enrichment valve not operating. Inspect solenoid or valve and wiring. Replace as required. Needle and seat in carburetor that is either stuck open (flooding) or closed (no fuel). Refer to carburetor disassembly in this section. Improper carburetor jet, restricted jet or idle mixture screw out of adjustment. Refer to carburetor adjustments in this section. Improper float level. Refer to carburetor adjustments in this section. Low fuel pump pressure. Disassemble and inspect fuel pump components. Defective anti-siphon valve. Inspect valve and/or test engine without valve in fuel system. Page 3A-12 90-827242R1 MAY 1998 FUEL DELIVERY SYSTEM Possible Cause Corrective Action Improperly mixed fuel. Contaminants(water, dirt, etc.) in fuel. Check fuel in tank and replace if necessary. Carburetor loose on intake manifold. Check tightness of carburetor nuts. Reed block loose or gasket defective. Using a pressure oil can, apply 2-cycle oil around reed block housing/crankcase housing matching surfaces and carburetor base. If engine RPM changes, tighten bolts/nuts or replace gaskets as required. Improperly routed or restricted bleed hose(s). Refer to bleed hose routing in “Powerhead” section. Damaged fuel pump diaphragm. Disassemble and inspect fuel pump components. Carburetor mixing chamber cover leaking air. Tighten screws or replace gasket. Off idle holes plugged. Blow with compressed air. Main nozzle or idle nozzle air bleed holes plugged. Blow with compressed air. Damaged reeds. Refer to Section 4 for reed inspection. Fuel pick-up outlet tube in fuel tank cracked. Replace Wrong spark plug or improper spark plug gap Install correct plug or readjust gap. Improper spark timing. Reset timing to correct specifications. Enrichener diaphragm leaking Replace diaphragm Problem: Engine Floods Possible Cause Corrective Action Dirt or debris are preventing inlet needle from seating. Flush out inlet seat and clean inlet needle. Worn inlet needle. Replace Punctured float Replace. Incorrect float setting Reset float. Problem: Engine Runs Too Rich Possible Cause Corrective Action Fuel level too high. Reset float to correct level. Carburetor floods. See preceding “Engine Floods.” Idle nozzle air holes plugged. Blow out with compressed air. Restricted air flow. Inspect cowl air inlet and carburetor for obstructions. Main fuel jet loose. Retighten jet. 90-827242R1 MAY 1998 Page 3A-13 FUEL DELIVERY SYSTEM Problem: Fuel Blowback Out of Carburetor Problem: Unable to Reduce Engine RPM to Slow Idle Possible Cause Corrective Action Chipped or broken reeds on reed block. Replace reeds. Problem: Rough Idle Possible Cause Corrective Action Excessive preload on reeds. Replace reeds. Problem: Engine Runs Too Lean Possible Cause Corrective Action Carburetor is loose. Air leaks past mixing chamber cover. Tighten bolts securely. Tighten cover or replace gasket. Fuel level is too low. Reset float level. Clogged high speed jet. Inspect jet for varnish or debris and clean. Restricted fuel flow to carburetor. Check fuel lines and filter(s) for restricted flow. Incorrect high speed jet. Refer to main jet chart and replace with proper jet. Idle mixture set too lean. Adjust to run richer (turn idle mix screw counterclockwise). Air leakage into fuel system. Inspect fuel line connections, hose clamps, fuel pump and fuel outlet tube (located in fuel tank) for loose fittings. Anti-siphon valve restricting fuel flow. Inspect valve and/or test engine without valve in fuel system. Carburetor Removal 1. Loosen primer cam retaining screw. 2. Remove retaining clip. 53072 b a a-Screw b-Retaining Clip Page 3A-14 90-827242R1 MAY 1998 FUEL DELIVERY SYSTEM 3. Push down on primer arm and pull primer knob, bezel and slide block out of bottom cowl. 4. Remove link wire from fast idle lever. 5. Disconnect fuel line from carburetor. 6. Remove carburetor mounting nuts. 7. Lift carburetor from engine. Remove bleed line from fitting in bottom of carburetor. 53071 a e dc b a-Primer Arm b-Primer Knob c-Bezel d-Slide Block e-Link Wire Carburetor Installation 1. Install primer assembly components and air intake cover (on models so equipped) to carburetor. 53065 53059 Model without Air Intake Cover Models Equipped with Air Intake Cover 90-827242R1 MAY 1998 Page 3A-15 FUEL DELIVERY SYSTEM 2. Reconnect bleed hose to fitting on carburetor and install carburetor and secure carburetor to engine with hex nuts. 3. Secure fuel line to carburetor with sta-strap. 4. Reconnect link wire to fast idle lever. 53073 a b a-Link Wire b-Fast Idle Lever 5. Push down on primer arm and insert primer knob, bezel and slide block into primer assembly. 6. Tighten screw to secure slide block in place. 7. Align notch in back side of bezel with tab on bottom cowl and secure bezel in place with retaining clip. 53072 53071 a b c d ef a-Primer Arm b-Primer Knob c-Bezel d-Slide Block e-Screw f-Retaining Clip Page 3A-16 90-827242R1 MAY 1998 FUEL DELIVERY SYSTEM Carburetor Adjustments 1. Place outboard in water. 2. Check tiller handle cable adjustment for full throttle movement in both “Forward” and “Reverse” gears. Adjust jam nuts for proper travel and to eliminate any slack. INITIAL CARBURETOR ADJUSTMENTS Idle Speed Screw (Models So Equipped) 1. Shift outboard to “Neutral” and place throttle twist grip to “Slow”. 2. Push primer/fast idle knob completely in and rotate knob fully counterclockwise. 3. Back idle speed screw (a) off of cam follower (b). 4. Turn idle speed screw inward (clockwise) until it “just touches” cam follower, then inward an additional 1/2 turn to slightly open throttle plate. PULL TO PRIME a b 90-827242R1 MAY 1998 Page 3A-17 FUEL DELIVERY SYSTEM NOTE:For Models NOT equipped with an idle speed screw: a. Loosen cam locking screw. b. Press cam follower down until it contacts throttle cam. c. Retighten cam locking screw. a c b a-Cam Locking Screw b-Cam Follower c-Throttle Cam LOW SPEED MIXTURE SCREW 1. Remove access plug (a) from carburetor air intake cover (b) (models so equipped). 2. Turn low speed mixture screw (c) slowly inward (clockwise) until it seats lightly, then back screw out (counterclockwise) 1–1/2 to 1–3/8 turns(turning mixture screw in tight will damage needle and seat). 3. Do not install access plug at this time. c a b Page 3A-18 90-827242R1 MAY 1998 FUEL DELIVERY SYSTEM IDLE WIRE ADJUSTMENT 1. Push primer/fast idle knob completely in and rotate fully counterclockwise. 2. Shift engine to “Neutral”. 3. Adjust screw (a) to remove all clearance between idle wire (b) and trigger. PULL TO PRIME b a 4. Check fast idle speed by turning primer knob to full clockwise position. Fast idle speed should be 1500 – 2000 RPM. IDLE ADJUSTMENT Low speed Mixture Adjustment 1. Start engine and allow to warm up (run for several minutes). Throttle engine back to idle for about one minute to allow RPM to stabilize. 2. Push primer/fast idle knob completely in and rotate knob fully counterclockwise. 3. With engine running at idling speed while in “Forward” gear, turn low speed mixture screw (a) counterclockwise until engine starts to “load up” or fire unevenly from over– rich mixture. 4. Slowly turn low speed mixture screw (a) clockwise until cylinders fire evenly and engine picks up speed. PULL TO PRIME a 5. Continue turning mixture screw clockwise until too lean a mixture is obtained and engine slows down and misfires. 6. Set low speed mixture screw halfway between rich and lean. 7. DO NOT adjust leaner than necessary to attain reasonably smooth idling. When in doubt, set mixture slightly richer rather than too lean. 90-827242R1 MAY 1998 Page 3A-19 FUEL DELIVERY SYSTEM 8. Check for freedom from 4–cycling between idle and 2000 RPM (in “Forward” gear). 9. Install access plug into opening in carburetor air intake cover. a a-Access Plug IDLE SPEED ADJUSTMENT (MODELS EQUIPPED WITH IDLE SCREW) 1. With engine running at idle in “Forward” gear, make sure primer/fast idle knob is pushed completely in and rotate fully counterclockwise to stop. 2. Adjust idle speed screw (b) to obtain recommended idle speed (see specifications.) b IDLE SPEED ADJUSTMENT (MODELS NOT EQUIPPED WITH AN IDLE SPEED SCREW) For models not equipped with an idle speed screw, the carburetor has been calibrated at the factory to maintain an idle speed of 650 ± 75 RPM in “Forward” gear. Page 3A-20 90-827242R1 MAY 1998 FUEL DELIVERY SYSTEM CARBURETOR FLOAT ADJUSTMENT Check float level by removing fuel bowl and checking level of float as shown. If necessary, adjust float level by bending float hinge. Measure From Bottom of Float Rejetting Carburetors for High Altitude The carburetor jet installed at the manufacturer is for engine operation at sea level through an elevation of 5000 feet (1254m) above sea level. If the engine is to be operated at an altitude higher than 5000 feet, it will be necessary to rejet the carburetor. Each time the engine is to be operated at a different elevation, refer to carburetor jet charts, following, and install the proper jet. JET ORIFICE SIZE/PART NUMBER CHART NOTE:Thread size for jets is 10-32. JET ORIFICE SIZE/PART NUMBER CHART Jet Orifice Size (Inch) Part Number Jet Orifice Size (Inch) Part Number .040 19266040 .058 1395-7831 .042 1399-5315 .060 1395-6487 .044 1395-7394 .062 1399-4217 .046 1399-5317 .064 1399-4216 .048 1395-6246 .066 1399-4215 .050 1395-6028 .068 1395-6029 .052 1395-6359 .070 1395-6030 .054 1399-5225 .072 1395-6207 .056 1399-5213 .074 1399-3794 .076 1399-3796 .094 1395-8423 .078 1395-6680 .096 1399-6249 .080 1395-6201 .098 1395-7335 .082 1399-3518 .084 1399-3517 .086 1395-5815 .088 1395-6202 .090 1395-6247 .092 1395-5733 90-827242R1 MAY 1998 Page 3A-21 FUEL DELIVERY SYSTEM Fuel Pump Removal and Disassembly IMPORTANT: Fuel pump check valve diaphragm and gasket should NOT be re-used once the fuel pump is disassembled. 1. Remove 5 screws securing fuel pump assembly to carburetor. 2. Separate fuel pump components. Cleaning and Inspection 1. Clean and dry all parts thoroughly. 2. Inspect pump body and base on carburetor for nicks, cracks or rough gasket surface. 3. Inspect pump check valve diaphragm. Diaphragm MUST BE flat and free from holes and imperfections. 4. Pump body surface below check valves MUST BE flat so that check valve will seat. Reassembly and Installation 1. Inspect all parts for serviceability. 2. Reassemble fuel pump. 3. Secure fuel pump assembly to carburetor with 5 screws. Torque screws to 18 lb. in. (3.2 N·m). h a b c d e f g hi j k a-Gasket b-Pump Body c-Spring d-Cap e-Gasket f-Diaphragm g-Pump Cover h-Lock Washer (5) i-Screw (5) [Torque screws to 18 lb. in. (3.2 N·m)] j-Maximum Spark Advance Screw k-Nut Page 3A-22 90-827242R1 MAY 1998 FUEL DELIVERY SYSTEM Primer System The primer system provides extra fuel to the outboard whenever the primer knob is pulled out. The primer system components should be inspected carefully for serviceability. The diaphragm and gaskets should be inspected for cuts or abrasions. Replace accordingly. The primer check ball and springs should be inspected for debris or varnish which restrict free movement. SYMPTOMS OF A DEFECTIVE PRIMER SYSTEM 1. Outboard is hard to start. a. Diaphragm is cut. b. Primer check ball is stuck in the closed position. c. Primer passage is plugged with debris or varnish. 2. Outboard smokes excessively at idle. a. Primer check ball is not seated due to debris, varnish or damaged check ball spring. a b c d e g h i j k f a-Seal b-Screw (4) [Torque to 14 lb. in. (1.6 N·m)] c-Cover d-Diaphragm e-Gasket f-Spring g-Primer Bowl h-Check Ball i-Spring j-Gasket k-Plug 90-827242R1 MAY 1998 Page 3A-23 FUEL DELIVERY SYSTEM Servicing Sight Bowl Fuel Filter WARNING Exercise extreme caution when cleaning fuel filter elements. Gasoline is extremely flammable and highly explosive under certain conditions. Always stop the engine and DO NOT smoke or allow open flames in the area while cleaning fuel filter elements. CAUTION DO NOT turn or cock fuel filter assembly when removing or installing. PULL STRAIGHT DOWN when removing assembly. PUSH STRAIGHT UP when installing assembly. Turning or cocking fuel filter may break fuel line connection on filter. The sight bowl fuel filter removes dirt and water from the fuel. Check the sight bowl frequently and clean the filter as required. 1. Verify that the sight bowl rubber sealing ring is properly positioned in the bowl. 2. Reinstall element in filter cover. 3. Thread sight bowl onto filter cover. 4. Tighten bowl securely by hand. 1 2 3 2 1 2 4 5 2 6 7 1-Fuel Line 2-Sta-strap (4) 3-Cover 4-Filter 5-Rubber Sealing Washer 6-Sight Bowl 7-Fuel Line Connector Page 3A-24 90-827242R1 MAY 1998 EMISSIONS FUEL SYSTEM Section 3B – Emissons Table of Contents Exhaust Emissions Standards . . . . . . . . . . . . . . 3B-1 Stratified vs. Homogenized Charge . . . . . . . . . . 3B-3 What Are Emissions? . . . . . . . . . . . . . . . . . . . 3B-1 Homogenized Charge . . . . . . . . . . . . . . . . . . . 3B-3 Hydrocarbons – HC . . . . . . . . . . . . . . . . . . . . . 3B-1 Stratified Charge . . . . . . . . . . . . . . . . . . . . . . . 3B-4 Carbon Monoxide – CO . . . . . . . . . . . . . . . . . 3B-1 Emissions Information . . . . . . . . . . . . . . . . . . . . . 3B-4 Oxides of Nitrogen - NOx . . . . . . . . . . . . . . . . 3B-2 Manufacturer’s Responsibility: . . . . . . . . . . . 3B-4 Controlling Emissions . . . . . . . . . . . . . . . . . . . 3B-2 Dealer Responsibility: . . . . . . . . . . . . . . . . . . . 3B-4 Stoichiometric (14.7:1) Air/Fuel Ratio . . . . . 3B-2 Owner Responsibility: . . . . . . . . . . . . . . . . . . . 3B-5 Outboard Hydrocarbon Emissions EPA Emission Regulations: . . . . . . . . . . . . . . 3B-5 Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-2 Decal Location: . . . . . . . . . . . . . . . . . . . . . . . . 3B-6 3 B Exhaust Emissions Standards Through the Environmental Protection Agency (EPA), the federal government has established exhaust emissions standards for all new marine engines sold in the U.S. What Are Emissions? Emissions are what comes out of the exhaust system in the exhaust gas when the engine is running. They are formed as a result of the process of combustion or incomplete combustion. To understand exhaust gas emissions, remember that both air and fuel are made of several elements. Air contains oxygen and nitrogen among other elements; gasolene contains mainly hydrogen and carbon. These four elements combine chemically during combustion. If combustion were complete, the mixture of air and gasoline would result in these emissions: water, carbon dioxide and nitrogen, which are not harmful to the environment. But combustion is not usually complete. Also, potentially harmful gases can be formed during and after combustion. All marine engines must reduce the emission of certain pollutants, or potentially harmful gases, in the exhaust to conform with levels legislated by the EPA. Emissions standards become more stringent each year. Standards are set primarily with regard to three emissions: hydrocarbons (HC), carbon monoxide (CO) and oxides of nitrogen (NOx). Hydrocarbons – HC Gasoline is a hydrocarbon fuel. The two elements of hydrogen and carbon are burned during combustion in combination with oxygen. But they are not totally consumed. Some pass through the combustion chamber and exit the exhaust system as unburned gases known as hydrocarbons. Carbon Monoxide – CO Carbon is one of the elements that make up the fuel burned in the engine along with oxygen during the combustion process. If the carbon in the gasoline could combine with enough oxygen (one carbon atom with two oxygen atoms), it would come out of the engine in the form of carbon dioxide (CO2). CO2 is a harmless gas. But carbon often combines with insufficient oxygen (one carbon atom with one oxygen atom). This forms carbon monoxide, CO. Carbon monoxide is the product of incomplete combustion and is a dangerous, potentially lethal gas. 90-827242R1 MAY 1998 Page 3B-1 EMISSIONS 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. 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 Page 3B-2 90-827242R1 MAY 1998 EMISSIONS Stratified vs. Homogenized Charge DFI engines use a stratified charge inside the combustion chamber to aid in reducing emissions. All other models use a homogenized charge. The difference between the two is: Homogenized Charge A homogenized charge has the fuel/air particles mixed evenly throughout the cylinder. This mixing occurs inside the carburetor venturi, reed blocks and crankcase. Additional mixing occurs as the fuel is forced through the transfer system into the cylinder. The homogenized charge is easy to ignite as the air/fuel ratio is approximately 14.7:1. 90-827242R1 MAY 1998 Page 3B-3 EMISSIONS Stratified Charge A stratified charge engine only pulls air through the transfer system. The fuel required for combustion is forced into the cylinder through an injector placed in the top of the cylinder (head). The injector sprays a fuel/air mixture in the form of a bubble into the cylinder. Surrounding this bubble is air supplied by the transfer system. As the bubble is ignited and burns, the surrounding air provides almost complete combustion before the exhaust port opens. A stratified charge is hard to ignite, the fuel/air bubble is not evenly mixed at 14.7:1 and not easily ignited. 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. Page 3B-4 90-827242R1 MAY 1998 EMISSIONS Adjustments must be kept within published factory specifications. Replacement or repair of any emission related component must be executed in a manner that maintains emission levels within the prescribed certification standards. Dealers are not to modify the engine in any manner that would alter the horsepower or allow emission levels to exceed their predetermined factory specifications. Exceptions include manufacturers prescribed changes, such as that for altitude adjustments. Owner Responsibility: The owner/operator is required to have engine maintenance performed to maintain emission levels within prescribed certification standards. The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications. Single engine exceptions may be allowed with permission from the EPA for racing and testing. EPA Emission Regulations: All new 1998 and later outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors. This certification is contingent on certain adjustments being set to factory standards. For this reason, the factory procedure for servicing the product must be strictly followed and, whenever practicable, returned to the original intent of the design. The responsibilities listed above are general and in no way a complete listing of the rules and regulations pertaining to the EPA laws on exhaust emissions for marine products. For more detailed information on this subject, you may contact the following locations: VIA U.S. POSTAL SERVICE: Office of Mobile Sources Engine Programs and Compliance Division Engine Compliance Programs Group (6403J) 401 M St. NW Washington, DC 20460 VIA EXPRESS or COURIER MAIL: Office of Mobile Sources Engine Programs and Compliance Division Engine Compliance Programs Group (6403J) 501 3rd St. NW Washington, DC 20001 EPA INTERNET WEB SITE: http:/www.epa.gov/omswww 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). 90-827242R1 MAY 1998 Page 3B-5 EMISSIONS jJAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC Emission Control Information 1998 PART # 37-855211 4 This engine conforms to 1998 Model Year U.S. EPA regulations for marine SI engines. This engine is certified to operate on regular 87 octane unleaded fuel (R+M)/2 Idle Speed (in gear): 725 RPM Timing: Idle: 8° BTDC WOT: 36° BTDC Spark Plug: NGK BP8HS-15 Gap: .060” Valve Clearance (Cold) mm Intake: N/A Exhaust: N/A Fuel/Oil Ratio: 50:1Engine Lubricants: 2-Cycle Outboard Oil NMMA/BIA Certified TC-W3 Refer to Owners Manual for required maintenance. Exhaust Emission Control Systems: None Family: WM9XM0016210 FEL: 243.11 GM/KW-HR 262 cc 9.9–15 HP 850 RPM (10W) a b c d e f g h j ik l m n a-Spark Ignition (SI) b-Model year of engine and production decal part number c-Type and octane of fuel used to establish emission levels d-Timing specifications when adjustable e-Spark plug gap in thousandths of an inch f-Recommended spark plug for best engine performance g-Engine Horsepower rating h-Cubic Centimeter i-Valve Clearance (Four Stroke engines only) j-Recommended oil/fuel ratio for best engine performance and minimal emis sions k-Month of production (Boxing month will punched) l-FEL: Represents (Mercury Marine) statement of the maximum emissions output for the engine family m-Family example: W M9X M 0016 2 1 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 n-Engine lubricants recommended by the manufacturer Decal Location: Model Production Part No. Service Part No. Location on Engine 1998 Merc/Mar 12,13 ci (6-8 H.P.) 37-855211 3 37-855577 3 Inside Rear Top Cowl 1998 Merc/Mar 12,16 ci (9.9-15 H.P.) 37-855211 4 37-855577 4 Inside Rear Top Cowl Page 3B-6 90-827242R1 MAY 1998 POWERHEAD POWERHEAD Section 4 Table of Contents Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Powerhead Torque Sequence . . . . . . . . . . . . . . . . . . . . 4-5 Cylinder Block and Covers . . . . . . . . . . . . . . . . . . . . . . 4-6 Crankshaft, Pistons and Flywheel . . . . . . . . . . . . . . . 4-10 Powerhead Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Powerhead Disassembly . . . . . . . . . . . . . . . . . . . . . . . 4-13 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Powerhead Cleaning and Inspection . . . . . . . . . . . . . 4-20 Cylinder Block and Crankcase Cover . . . . . . . . . 4-20 Exhaust Manifold and Exhaust Cover . . . . . . . . . 4-20 Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Specifications Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Pistons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 Reed Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 Bleed System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29 Thermostat (If Equipped) . . . . . . . . . . . . . . . . . . . . 4-30 Powerhead Reassembly . . . . . . . . . . . . . . . . . . . . . . . 4-30 4General Information . . . . . . . . . . . . . . . . . . . . . . . . 4-30 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38 Powerhead Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-43 Set-Up and Test-Run Procedures . . . . . . . . . . . . . . . . 4-44 Break-In Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44 Model 6/8/9.9/10/15 HORSEPOWER Model 6 6 (4.5) (KW) Model 8 8 (5.9) Model 8 Sailmate 8 (5.9) Model 9.9 9.9 (7.4) Model 9.9 Sailpower 9.9 (7.4) XR10/MAG10 10.0 (7.5) Model Sea Pro/Marathon 10 10.0 (7.5) Model 15 15 (11.2) Model Sea Pro/Marathon 15 15 (11.2) STATIC THRUST Model 9.9 Sailpower W.O.T. in Forward – 207 Lbs. (920.7 N) W.O.T. in Reverse – 150 Lbs. (667.2 N) OUTBOARD Manual Start 6 73.0 lbs. (31.1kg) WEIGHT 8 73.0 lbs. (31.1kg) 9.9 74.5 lbs. (31.8kg) 9.9 Sailpower 79.0 lbs. (35.8kg) 10 Sea Pro/Marathon 74.5 lbs. (31.8kg) XR10/MAG10 74.5 lbs. (31.8kg) 15 75.0 lbs. (34.0kg) 15 Sea Pro/Marathon 82.5 lbs. (37.4kg) Electric Start 6 79.5 lbs. (36.1kg) 8 79.5 lbs. (36.1kg) 9.9 81.0 lbs. (36.7kg) 9.9 Sailpower 90.5 lbs. (41.0kg) XR10/MAG10 81.0 lbs. (36.7kg) 15 81.5 lbs. (36.9kg) 90-827242R1 MAY 1998 Page 4-1 POWERHEAD Model 6/8/9.9/10/15 CYLINDER BLOCK Type Displacement (1994 Model) 6 8 9.9 9.9 Sailpower 10 Sea Pro/Marathon XR10/MAG10 15 Displacement (1995 – 1999 Model) 6 8 9.9 9.9 Sailpower 10 Sea Pro/Marathon XR10/MAG10 15 15 Sea Pro/Marathon Two-Stoke Cycle – Cross Flow 12.8 cu. in. (209cc) 12.8 cu. in. (209cc) 12.8 cu. in. (209cc) 12.8 cu. in. (209cc) 16.0 cu. in. (262cc) 16.0 cu. in. (262cc) 16.0 cu. in. (262cc) 16.0 cu. in. (262cc) 16.0 cu. in. (262cc) 16.0 cu. in. (262cc) 16.0 cu. in. (262cc) 16.0 cu. in. (262cc) 16.0 cu. in. (262cc) 16.0 cu. in. (262cc) 16.0 cu. in. (262cc) STROKE Length 1.800 in. (45.7mm) CYLINDER BORE Diameter (Standard)(1994 Model) 6 8 8 Sailmate 9.9 9.9 Sailpower 10 Sea Pro/Marathon XR10/Mag10 15 Diameter (Standard)(1995 Model and Newer) 9.9 9.9 Sailpower 10 Sea Pro/Marathon XR10/Mag10 10 Sea Pro/Marathon 15 15 Sea Pro/Marathon Taper/Out of Round Maximum Bore Type 2.125 in. (53.975mm) 2.125 in. (53.975mm) 2.125 in. (53.975mm) 2.125 in. (53.975mm) 2.125 in. (53.975mm) 2.375 in. (60.325mm) 2.375 in. (60.325mm) 2.375 in. (60.325mm) 2.375 in. (60.325mm) 2.375 in. (60.325mm) 2.375 in. (60.325mm) 2.375 in. (60.325mm) 2.375 in. (60.325mm) 2.375 in. (60.325mm) 2.375 in. (60.325mm) 0.004 in. (0.1016mm) Cast Iron CRANKSHAFT Top Main Bearing Journal 0.7517 Center Main Bearing Journal 0.8108 Bottom Ball Bearing Journal 0.7880 Connecting Rod Journal 0.8125 Runout 0.003 in. (0.076mm) CONNECTING ROD Piston Pin End (I.D.) Crankpin End (I.D.) 0.8195 1.0635 Page 4-2 90-827242R1 MAY 1998 POWERHEAD Model 6/8/9.9/10/15 PISTON Piston Type Ring End Gap Aluminum 0.010 in. - 0.018 in. (0.25 mm - 0.46 mm) REEDS Reed Stand Open (Maximum) All Models Reed Stop Opening (Maximum) All Models 0.007 in. (0.178mm) 0.296 in. (7.54mm) Special Tools 1. Powerhead Stand 91-13662A1 a b a-Bushing 23-13653 b-Stand 91-13662 2. Piston Pin Tool 91-13663A1 3. Snap Ring Pliers 91-24283* 4. Torque Wrench (0-200 lb. ft.) 91-32610* 5. Universal Puller Plate 91-37241 90-827242R1 MAY 1998 Page 4-3 POWERHEAD 6. Torque Wrench (0-150 lb. in.) (91-66274)* *May be obtained locally. 7. Flywheel Puller 91-83164M 8. Compression Tester 91-29287 9. Flywheel Holder 91-52344 91–52344 54964 10. Strap Wrench 91-24937A1 11. Ring Expander 91-24697 Page 4-4 90-827242R1 MAY 1998 POWERHEAD Powerhead Torque Sequence EXHAUST COVER TORQUE SEQUENCE CYLINDER BLOCK COVER TORQUE SEQUENCE 60 lb. in. (6.8 N·m) 60 lb. in. (6.8 N·m) CRANKCASE COVER TORQUE SEQUENCE PISTON ROD BOLTS 100 lb. in. (11.3 N·m) 16.7 lb. ft. (22.6 N·m) 90-827242R1 MAY 1998 Page 4-5 POWERHEAD Cylinder Block and Covers 17 17 12 1 2 3 4 5 6 78 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 25 2526 27 53 54 55 17 12 Loctite Master Gasket (92-12564-2) 95 78 G. E. RTV Sealant 92-90113--2 Loctite 35 (92-59328-1) 2-4-C With Teflon (92-825407A12) Page 4-6 90-827242R1 MAY 1998 POWERHEAD Cylinder Block and Covers REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 CYLINDER BLOCK (6) 1 CYLINDER BLOCK (8) 1 CYLINDER BLOCK (9.9/15) 2 2 DOWEL PIN–cylinder block 3 2 STUD–carburetor 4 1 CHECK VALVE–bleed hose 5 1 HOSE–bleed (2-1/2 IN.) 6 2 STUD–cylinder block 7 6 SCREW–crankcase to cylinder block 200 16.5 22.6 8 1 GROOVE PIN (9.9/15) 9 2 NUT–cylinder block stud 100 11.3 10 1 GASKET–powerhead 11 1 PLUG-Serial Number 12 1 REED BLOCK 13 3 SCREW–reed block 14 2 NUT–carburetor stud 125 14.1 15 1 COVER–exhaust 16 11 SCREW–exhaust cover to cylinder block 60 6.8 17 1 GASKET–exhaust cover 18 1 BAFFLE PLATE 19 1 GASKET–baffle plate 20 3 SCREW–cover to cylinder block 60 6.8 21 1 FITTING 22 1 TUBING (7 IN.) 23 1 TUBING (5-1/4 IN.) 24 1 TEE 25 AR STA-STRAP 90-827242R1 MAY 1998 Page 4-7 POWERHEAD Cylinder Block and Covers 17 17 12 1 2 3 4 5 6 78 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 25 2526 27 53 54 55 17 12 Loctite Master Gasket (92-12564-2) 95 78 G. E. RTV Sealant 92-90113--2 Loctite 35 (92-59328-1) 2-4-C With Teflon (92-825407A12) Page 4-8 90-827242R1 MAY 1998 POWERHEAD Cylinder Block and Covers REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 26 1 GASKET 6/8 INTAKE COVER27 1 28 2 O-RING 9.9/15 INTAKE COVER29 1 30 1 HOSE–tell tale (6 IN.) 31 1 FITTING–tell tale hose - bottom cowl 32 1 COVER ASSEMBLY 33 1 GASKET 34 1 COVER–thermostat 35 1 GASKET 36 2 SCREW 60 6.8 37 1 THERMOSTAT (120 degrees) 9.9/15 GASKET–thermostat38 1 39 1 FITTING 40 6 SCREW–cover attaching 60 6.8 41 2 STUD-carb (RESTRICTED/NORWAY MODELS) 42 1 RECTIFIER SCREW (5/8) ELECTRIC NUT 43 2 Drive Tight 44 3 25 2.8 45 1 TERMINAL BLOCK SCREW (5/8 IN.) ALTERNATOR MODELS SCREW (3/8 IN.) 46 2 Drive Tight 47 2 Drive Tight 48 1 STARTER SOLENOID BATTERY CABLE (NEGATIVE) SCREW (M6 x 14) ELECTRIC NUT (10-32) BATTERY CABLE (POSITIVE) WIRE (YELLOW) NUT (1/4-20) 49 1 50 2 70 7.9 51 2 15 1.7 52 1 53 1 54 2 30 3.4 55 1 WIRE (RED)(15 ELECTRIC HANDLE) 90-827242R1 MAY 1998 Page 4-9 POWERHEAD Crankshaft, Pistons and Flywheel 7 14 14 95 14 14 14 14 14 14 95 95 95 95 2-4-C With Teflon (92-825407A12) 14 2 Cycle Outboard Oil (92-826666A24) 7 Loctite 271 (92-809820) 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 1 28 28 28 25 26 18 16 24 20 Page 4-10 90-827242R1 MAY 1998 POWERHEAD Crankshaft, Pistons and Flywheel REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 NUT 50 67.8 2 1 FLYWHEEL ASSEMBLY 3 1 RING GEAR–flywheel ELECTRIC SCREW (M5 x 13)4 4 65 7.3 5 1 CRANKSHAFT ASSEMBLY 6 1 SLEEVE 7 1 O RING 8 1 BALL BEARING–lower 9 1 WASHER 10 1 RETAINING RING 11 1 WASHER–lower 12 1 OIL SEAL–lower 13 1 KEY 14 1 ROLLER BEARING 15 1 OIL SEAL–upper 16 2 CONNECTING ROD ASSEMBLY 17 4 SCREW 100 11.3 18 3 ROLLER BEARING 19 48 NEEDLE BEARING–piston end 20 4 THRUST BEARING 2121 2 PISTON AND PIN ASSEMBLY (6/8) 2 PISTON AND PIN ASSEMBLY (9.9/15) 2222 1 PISTON RING-ASSEMBLY (6/8) 1 PISTON RING ASSEMBLY (9.9/15) 2323 2 PISTON RING-top (6/8) 2 PISTON RING-top (9.9/15) 24 4 LOCK RING 25 1 LINER–center main bearing (6/8) 26 1 BEARING (9.9/15) 27 1 SEAL–main bearing 28 1 ROLLER BEARING(9.9/15) 90-827242R1 MAY 1998 Page 4-11 POWERHEAD Powerhead Removal 1. Remove the following components/assemblies referring to the listed service manual sections: Component/Assembly Section Rewind Starter 8 Flywheel and Ignition/Electrical Components 2A/B Throttle/Shift Mechanism 7A/B/C Carburetor 3 2. Disconnect tell-tale hose from bottom cowl. 3. Remove 4 bolts and 2 nuts. 53204 53125 a b c a-Tell-tale Hose b-Bolts (2 each side) c-Nut (1 each side) 4. Rock powerhead to break gasket and lift powerhead from drive shaft housing. 5. Place powerhead on bench or powerhead stand (91-13662A1) mounted in vise. 53197 53203 a a a-Powerhead Stand (91-13662A1) Page 4-12 90-827242R1 MAY 1998 POWERHEAD Powerhead Disassembly Cylinder Block 1. Remove 3 bolts and remove intake manifold/reed block. 53191 b a b a-Bolts b-Intake Manifold/Reed Block IMPORTANT: Reed block can be inspected without disassembling. Refer to “Cleaning and Inspection”, following. If inspection of reed block indicates that replacement of a part is necessary, disassemble reed block as outlined. 2. If necessary, disassemble reed block as follows: a. Pull ends of rubber seal from holes in intake manifold/reed block. b. Remove 6 screws and separate reed stops and reeds. 1994 – 1996 Reed Blocks a d b 53202 a b c d a b b c c d d a-Rubber Seal b-Screws c-Reed Stop d-Reeds 90-827242R1 MAY 1998 Page 4-13 POWERHEAD 1997 and Newer Reed Blocks (Rubber Coated) NOTE:Individual components of 1997 and newer reed block assemblies are not sold separately. If individual component(s) are found to be not serviceable, entire reed block assembly must be replaced. 56956 aab c d a-Rubber Seal b-Screws c-Reed Stop d-Reeds 3. Remove 2 bolts and remove thermostat cover. 4. Remove thermostat (if equipped) 5. Remove 6 bolts and remove cylinder block cover. 5319353194 ba b c c d e a-Bolts (2) b-Cover c-Bolts d-Cover e-Thermostat (if equipped) Page 4-14 90-827242R1 MAY 1998 POWERHEAD 6. Remove 10 bolts and separate exhaust cover and exhaust manifold from cylinder block. NOTE:If engine is suspected of having been overheated or spark plugs are grayish colored (a sign of possible water intrusion), inspect exhaust manifold for warpage or for proper placement and integrity of gaskets which will allow water to enter cylinders through exhaust ports. 7. Remove 2 bolts and intake cover. NOTE:1995-1999 Model 9.9/15 powerheads have o-rings under intake cover instead of a gasket. This style intake cover with o-rings WILL NOT backfit prior models. 53198 53188 b a b c d e a-Bolts (10) b-Exhaust Cover c-Exhaust Manifold d-Bolts (2) e-Intake Cover 8. Remove 6 bolts which secure crankcase cover to cylinder block. 9. Use soft mallet to break seal between crankcase cover and cylinder block. 53192 a a a-Bolts (6) 90-827242R1 MAY 1998 Page 4-15 POWERHEAD 10. Lift crankcase cover from block. 53124 Crankshaft 1. Lift crankshaft assembly from cylinder block. 2. All Models Except 15 and 1995 9.9/10: Remove center main bearing halves and sleeve halves from crankshaft and/or cylinder block. 3. Remove upper crankshaft seal and bearing. 4. Remove lower crank shaft seal, stuffer washer and retaining ring. 53183 a b c d e f g 53273 a-Bearing Halves (Hidden) b-Sleeve Halves c-Crankshaft Seal (Upper) d-Bearing e-Crankshaft Seal (Lower) f-Stuffer Washer g-Retainer Page 4-16 90-827242R1 MAY 1998 POWERHEAD 5. Remove (and discard) coupling seal using: Snap On* Expanding Rod (CG 40-4) Snap On Collet (CG 40-15) Slide Hammer (91-34569A1) *Purchase from: Snap On Tools Corporation 2801 - 80th Street Kenosha, WI 53141-1410 CG 40-15 CG 40-4 53045 a b c d a-Coupling Seal b-Collet (CG 40-15) c-Expanding Rod (CG 40-4) d-Slide Hammer (91-34569A1) 6. Model 15 and 1995 9.9/10 Center Main Bearing Removal: a. Remove retaining ring from groove of center main bearing race. b. Remove center main bearing races and center main bearing halves. 5313353128 a b a-Retaining Ring b-Bearing Halves 90-827242R1 MAY 1998 Page 4-17 POWERHEAD 7. Remove sealing ring. CAUTION Eye protection MUST BE worn while removing piston pin lockrings. IMPORTANT: Identify upper (#1) and lower (#2) pistons and connecting rods. Store piston pin, piston pin needle bearings, locating washers, connecting rod bearings, rod caps and bolts together with corresponding piston and connecting rod for reassembly. 8. Remove (and discard) piston pin lockrings. 5313953129a b a-Sealing Ring b-Lockrings IMPORTANT: It is recommended that the piston and rod assembly be removed from the crankshaft before removing the piston pin to prevent possible bending of the connecting rod. 9. Remove rod bolts and remove piston and rod assembly from crankshaft. 10. While supporting piston, use Piston Pin Tool 91-13663 and soft faced mallet to drive piston pin from piston. 53142 52137 a a b c a-Rod Bolts b-Piston Pin Tool (91-13663) c-Piston Pin Page 4-18 90-827242R1 MAY 1998 POWERHEAD IMPORTANT: Piston pin needle bearings and locating washers will fall out when piston is removed from connecting rod. 11. Slide piston pin tool from piston and remove piston, needle bearings and locating washers. 12. Using Piston Ring Expander (91-24697), remove (and discard) piston rings. 53264 a b b c 53271 a-Needle Bearings b-Locating Washers c-Ring Expander (91-24697) IMPORTANT: DO NOT remove ball bearing from crank shaft unless replacement is necessary as removal process will damage bearing. Refer to “Cleaning and Inspection” following. 13. Remove lower crankshaft ball bearing using Universal Puller Plate (91-37241), suitable mandrel (to protect crank shaft while pressing) and press. 53135 91-27241 a b c a-Universal Puller Plate (91-27241) b-Ball Bearing c-Mandrel 90-827242R1 MAY 1998 Page 4-19 POWERHEAD Powerhead Cleaning and Inspection Cylinder Block and Crankcase Cover IMPORTANT: Crankcase cover and cylinder block are a matched, line-bored assembly and must be replaced as a set. 1. Thoroughly clean cylinder block and crankcase cover with Quicksilver Power Tune Engine Cleaner (91-92-15104A12). Verify that all sealant and old gaskets are removed from mating surfaces. Remove all carbon deposits from exhaust ports, decompression ports and cylinder dome. 2. Inspect cylinder block and crankcase cover for cracks or fractures. 3. Check gasket surfaces for nicks, deep grooves, cracks and distortion. 4. Inspect all water and fuel passages in cylinder block and crankcase cover for obstructions. 5. Verify that all fittings and plugs are tight. 53148 a a-Decompression Ports Exhaust Manifold and Exhaust Cover 1. Remove all carbon deposits and gasket material from exhaust manifold and cover. 2. Inspect for grooves, cracks or distortion that could cause leakage. Replace parts as required. Cylinder Bore NOTE:Cylinder sleeve is part of the cylinder block and cannot be replaced. MEASURING CYLINDER BORE 1. Inspect cylinder bores for scoring, scuffing or a transfer of aluminum from piston to cylinder wall. Scoring or scuffing, if NOT TOO SEVERE, can normally be removed by honing. If a transfer of aluminum has occurred, an acidic solution such as “TIDY BOWL CLEANER” should be applied to the areas of the cylinder bore where transfer of aluminum has occurred. After the acidic solution has removed the transferred aluminum, thoroughly flush the cylinder bore(s) to remove any remaining acid. Cylinder walls may now be honed to remove any glaze and to aid in the seating of new piston rings. 2. Measure ring traveled area of cylinder bore at 3 depths, (6 places) by positioning measuring instrument in-line with and at right angle (90°) to piston pin centerline. Page 4-20 90-827242R1 MAY 1998 POWERHEAD 3. If cylinder bore is tapered, egg shaped or out-of-round by more than 0.004 in. (0.1mm), replace cylinder block. TOP CENTER BOTTOM STANDARD CYLINDER BORE DIAMETER 1994 MODEL 6/8/9.9 2.125 IN. (53.98MM) 10/15 2.375 IN. (60.3MM) 1995 - 1999 MODEL 6/8 2.125 IN. (53.98MM) 9.9/10/15 2.375 IN. (60.3MM) HONING PROCEDURE a. When cylinders are to be honed, follow the hone manufacturer’s recommendations for use of the hone and cleaning and lubrication during honing. b. For best results, a continuous flow of honing oil should be pumped into the work area. If pumping oil is not practical, use an oil can. Apply oil generously and frequently on both stones and work area. CAUTION When honing cylinder block, remove hone frequently and check condition of cylinder walls. DO NOT hone any more than absolutely necessary, as hone can remove cylinder wall material rapidly. c. Start stroking at smallest diameter. Maintain firm stone pressure against cylinder wall to assure fast stock removal and accurate results. d. Localize stroking in the smallest diameter until drill speed is constant throughout length of bore. Expand stones, as necessary, to compensate for stock removal and stone wear. Stroke at a rate of 30 complete cycles per minute to produce best cross-hatch pattern. Use honing oil generously. e. Thoroughly clean cylinder bores with hot water and detergent. Scrub well with a stiff bristle brush and rinse thoroughly with hot water. A good cleaning is essential. If any of the abrasive material is allowed to remain in the cylinder bore, it will cause rapid wear of new piston rings and cylinder bore in addition to bearings. After cleaning, bores should be swabbed several times with engine oil and a clean cloth, then wiped with a clean, dry cloth. Cylinders should not be cleaned with kerosene or gasoline. Clean remainder of cylinder block to remove excess material spread during honing operation. 4. Hone all cylinder walls just enough to de-glaze walls. 90-827242R1 MAY 1998 Page 4-21 POWERHEAD 5. Measure cylinder bore diameter (with a snap gauge micrometer) at top, middle and bottom of each cylinder. Check for tapered, out-of-round (egg-shaped) and oversize bore. IMPORTANT: Ports must be deburred after honing. Crankshaft 1. Inspect crankshaft to drive shaft splines for wear. 2. Check crankshaft for straightness [runout – 0.003 in. (0.076mm)]. 3. Inspect crankshaft oil seal surfaces. Sealing surfaces must not be grooved, pitted or scratched. If top crankshaft sealing surface is severely worn, replace crankshaft. If bottom crankshaft sealing surface is worn, replace crankshaft coupling seal. 4. Check all crankshaft bearing surfaces for rust, water marks, chatter marks, uneven wear and/or overheating (blued). 5. If necessary, “clean up” crankshaft bearing surfaces with crocus cloth. 53131 a a-Crocus Cloth 6. Thoroughly clean crankshaft with solvent and dry with compressed air. 7. Recheck surfaces of crankshaft and replace crankshaft if surfaces can not be properly “cleaned up”. 8. If crankshaft will be reused, apply light oil to prevent rust. Seals It is recommended that all seals be replaced as a standard rebuilding procedure. 53200 a b a-Top Crankshaft Seal b-Bottom Crankshaft Seal Page 4-22 90-827242R1 MAY 1998 POWERHEAD Bearings BALL BEARINGS WARNING DO NOT spin-dry crankshaft ball bearings with compressed air. 1. Clean ball bearings with solvent and dry with compressed air. 2. Work inner bearing race in-and-out. There should not be excessive play. 3. Rotate bearing race. Bearing should have smooth action and no rust stains. If ball bearing sounds or feels rough or has “catches”, remove and discard bearing. Apply light oil to bearing after inspection to prevent rust. ROLLER BEARINGS 1. Clean roller bearing with solvent and dry with compressed air. 2. Inspect roller bearing for rust, fracturing, wear, galling or overheating (blued). Always replace bearings as a set if replacement is necessary. 3. Apply light oil to bearings after inspection to prevent rust. 53200 16 cu. in. Block 12.8 cu. in. Block 90-827242R1 MAY 1998 Page 4-23 POWERHEAD Connecting Rod 1. Check connecting rods for alignment by placing rods on a surface plate. If light can be seen under any portion of machined surfaces, if rod has a slight wobble on plate, or if a 0.002 in. (0.051mm) feeler gauge can be inserted between any machined surface and surface plate, rod is bent and must be discarded. a b c 53205 a-Feeler Gauge b-Surface Plate c-Even Downward Pressure 2. Overheating: Overheating is visible as a bluish bearing surface color that is caused by inadequate lubrication or excessive RPM. 3. Rust: Rust formation on bearing surfaces causes uneven pitting of surface(s). 4. Water Marks: When bearing surfaces are subjected to water contamination, a bearing surface “etching” occurs. This etching resembles the size of the bearing. a 51853 a-Pitting Page 4-24 90-827242R1 MAY 1998 POWERHEAD 5. Spalling: Spalling is the loss of bearing surface, and it resembles flaking or chipping. Spalling will be most evident on the thrust portion of the connecting rod in line with the “I” beam. General bearing surface deterioration could be caused by or accelerated by improper lubrication. 6. Chatter Marks: Chatter marks are the result of a combination of low speed - low load -cold water temperature operation, aggravated by inadequate lubrication and/or improper fuel. Under these conditions, the crankshaft journal is hammered by the connecting rod. As ignition occurs in the cylinder, the piston pushes the connecting rod with tremendous force, and this force is transferred to the connecting rod journal. Since there is little or no load on the crankshaft, it bounces away from the connecting rod. The crankshaft then remains immobile for a split second until the piston travel causes the connecting rod to catch up to the waiting crankshaft journal, then hammers it. The repetition of this action causes a rough bearing surface(s) which resembles a tiny washboard. In some instances, the connecting rod crank pin bore becomes highly polished. During operation, the engine will emit a “whirr” and/or “chirp” sound when it is accelerated rapidly from idle speed to approximately 1500 RPM, then quickly returned to idle. If the preceding conditions are found, replace both the crankshaft and connecting rod(s). 5185351853 a b a-Spalling b-Chatter Marks Between Arrows 7. Uneven Wear: Uneven wear could be caused by a bent connecting rod. a 51853 a-Uneven Wear Between Arrows CAUTION Crocus cloth MUST BE USED to clean bearing surface at CRANKSHAFT END OF CONNECTING ROD. 320 grit Carborundum cloth MUST BE USED to clean bearing surface at PISTON PIN END OF CONNECTING ROD. VERIFY CAP TO ROD ALIGNMENT BEFORE TORQUING ROD BOLTS. DO NOT continue to clean connecting rod bearing surfaces after marks have been removed. 90-827242R1 MAY 1998 Page 4-25 POWERHEAD 8. To Drill Motor 51083 Crocus Cloth 320 Carborundum Cloth 100 lb. in. (11.3 N·m) NOTE: Wash rod to remove abrasive grit and applu light oil to bearing surfaces to prevent rust. Pistons IMPORTANT: If engine was submerged while engine was running, piston and/or con necting rod may be bent. If piston pin is bent, piston must be replaced. If piston pin is bent, connecting rod must be checked for straightness. 1. Inspect pistons for scoring and excessive piston skirt wear. 2. Check tightness of piston ring locating pins. Locating pins must be tight. 3. Thoroughly clean pistons. Carefully remove carbon deposits from pistons, with a soft wire brush or carbon remove solution. Do not burr or round off machined edges. Inspect piston ring grooves for wear and carbon accumulation. If necessary, scrape carbon from piston ring grooves being careful not to scratch sides of grooves. Refer to procedure following for cleaning piston ring grooves. Page 4-26 90-827242R1 MAY 1998 POWERHEAD CLEANING PISTON RING GROOVES Keystone (tapered) ring grooves CAUTION Care must be taken not to scratch the side surfaces of the ring groove. Scratching the side surface of the ring groove will damage the ring groove. 1. Use a bristle brush and carbon remover solution to remove carbon from side surfaces. 2. A tool can be made for cleaning the inner diameter of the tapered ring grooves. For the top ring groove, a tool can be made from a broken tapered piston ring with the side taper removed to enable the inside edge of the ring to reach the inner diameter of the groove. For the bottom ring groove, a tool can be made from a broken rectangular ring. Carefully scrape carbon from inner diameter of ring grooves. Care must be taken not to damage the grooves by scratching the side surfaces of the grooves. Piston with 1 half keystone (half tapered) and 1 rectangular ring. Enlarged View of Piston Ring Grooves MEASURING PISTON 1. Measure piston skirt at right angle (90°) to piston pin centerline. 0.10 in. (2.54mm) 56958 Standard Piston Diameter 1994 – 6/8/9.9 1994 – 10/15 2.123 in. (53.92mm) 2.373 in. (60.27mm) 1995 and newer – 6/8 1995 and newer – 9.9/10/15 2.123 in. (53.92mm) 2.373 in. (60.27mm) 90-827242R1 MAY 1998 Page 4-27 POWERHEAD PISTON CLEARANCE MINIMUM BORE MEASUREMENT – MAXIMUM PISTON MEASUREMENT = PISTON CLEARANCE PISTON CLEARANCE 0.002 IN. – 0.005 IN. (0.05MM – 0.13MM) Reed Block IMPORTANT: DO NOT remove reeds from reed block unless replacement is necessary. DO NOT turn used reeds over for reuse. Replace reeds in sets only. 1. Thoroughly clean reeds and reed block. 2. Check for wear (indentations), cracks or grooves on sealing surfaces of reed block that could cause leakage. 3. Check for chipped or broken reeds. 4. Inspect reed block seal for swelling or looseness. Replace seal if necessary. 5. Replace reeds as necessary. 6. After installing new reeds [having torqued screws to 20 lb. in. (2.3 N·m)], check new reeds as outlined in “Reed Opening” and “Reed Stop Opening” following. REED OPENING 1. Check reeds for preload and stand open conditions. Stand open should not exceed 0.007 in. (0.178mm). Replace reeds if necessary. 53280 a-Feeler Gauge b-Reed c-Seal a b cc Page 4-28 90-827242R1 MAY 1998 POWERHEAD REED STOP OPENING Reed stop opening can be checked by placing the appropriate sized drill bit between reeds and reed stops. Carefully bend reed stops if adjustment is necessary. 53278 ALL MODELS 19/64 IN. (7.6mm) Bleed System 1. Inspect bleed hoses for deterioration. Replace hoses as required. 2. Inspect bleed valve in lower crankcase cover for proper function. Valve should flow fuel only one way – from bottom of crankcase cover to top crankshaft bearing via bleed fitting at top of crankcase cover. If check ball in valve is stuck open or closed, replace check valve. Bleed fitting at base of carburetor drains excess fuel which puddles at base of reed block. a b a b a-Check Valve b-Bleed Fitting 90-827242R1 MAY 1998 Page 4-29 POWERHEAD Thermostat (If Equipped) 6/8/Work 10 No Thermostat 9.9/10/15 120°Thermostat Wash thermostat with clean water. Using a thermostat tester, similar to the one shown, test thermostat as follows: Open thermostat valve, then insert a thread between valve and thermostat body. Allow valve to close against thread. Suspend thermostat (from thread) and thermometer inside tester so that neither touches the container. Bottom of thermometer must be even with bottom of thermostat to obtain correct thermostat opening. Fill thermostat tester with water to cover thermostat. Plug tester into electrical outlet. Observe temperature at which thermostat begins to open. Thermostat will drop off thread when it starts to open. Thermostat must begin to open when temperature reaches 5°F (3• C) above designated stamping on bottom of thermostat. Continue to heat water until thermostat is completely open. Unplug tester unit. Replace thermostat, if it fails to open at the specified temperature, or if it does not fully open. Powerhead Reassembly General Information Before proceeding with powerhead reassembly, be sure that all parts to be reused have been carefully cleaned and thoroughly inspected, as outlined in “Cleaning and Inspection”. Parts, which have not been properly cleaned (or which are questionable), can severely damage an otherwise perfectly good powerhead within a few minutes of operation. All new powerhead gaskets must be installed during assembly. During reassembly, lubricate parts with Quicksilver 2-Cycle Outboard Oil whenever 2-cycle oil is specified, and Quicksilver 2-4-C w/Teflon Marine Lubricant whenever grease is specified. Page 4-30 90-827242R1 MAY 1998 POWERHEAD CAUTION Any GREASE used for bearings INSIDE the powerhead MUST BE gasoline soluble. Use only Quicksilver Needle Bearing Assembly Lubricant or 2-4-C w/Teflon Marine Lubricant. A torque wrench is essential for correct reassembly of powerhead. Do not attempt to reassemble powerhead without using a torque wrench. Crankshaft 1. Support crankshaft in press and install lower crankshaft ball bearing (open side of ball retainer facing crank) using powerhead stand (91-13662A1) with bearing sleeve. Bearing inner race must be firmly seated against crank shoulder. 2. Lubricate o-ring of new coupling seal with 2-4-C w/Teflon. Install seal using powerhead stand. 53150 53134 a b c d e a-Bearing b-Powerhead Stand (91-13662A1) c-Sleeve d-Seal e-Powerhead Stand 3. Install a new sealing ring. a 53130 a-Sealing Ring 90-827242R1 MAY 1998 Page 4-31 POWERHEAD NOTE:It is recommended that the piston pin and piston be installed on the connecting rod prior to installing the connecting rod on the crankshaft to avoid possible bending of the rod during piston pin installation. 4. Install piston onto connecting rod as follows: IMPORTANT: When replacing needle bearings, replace all needles as a set. DO NOT use old and new needles together. a. Lubricate sleeve of Piston Pin Tool (91-13663A1) with Needle Bearing Assembly Lubricant or 2-4-C w/Teflon Marine Lubricant. b. Hold lower locating washer and sleeve onto piston pin bore of connecting rod and install needle bearing set of 24. NOTE:If the tip of an awl can be inserted between the needle bearings, one or more needle is missing and must be replaced. 51228 53269 a b c a-Sleeve b-Locating Washer c-Needle Bearings (24) c. Install upper locating washer. a 53267 a-Locating Washer d. Slide piston onto connecting rod, centering piston pin bore over sleeve. Page 4-32 90-827242R1 MAY 1998 POWERHEAD e. Slide piston tool up thru piston pin bore and remove sleeve. f. Apply light oil to piston pin and place piston pin onto tool. 53277 53275 a b c d a-Sleeve b-Piston Pin Tool (91-13663A1) c-Piston Pin d-Piston Pin Tool (91-13663A1) g. Support bottom of piston and hold piston pin tool up against piston pin. h. Drive piston pin into piston pin bore (with a soft face mallet) until pin is flush with piston. i. Move piston pin tool to top of piston pin bore and center piston pin in piston. 5314353276 a b c a-Piston Pin Tool (91-13663A1) b-Piston Pin c-Piston Pin Tool (91-13663A1) 90-827242R1 MAY 1998 Page 4-33 53132 b 95 95 53279 a b b 53132 b 95 95 53279 a b b POWERHEAD 5. Install new lockrings into grooves in both ends of piston pin bore. 6. Install connecting rods onto crankshaft as follows: a. Apply 2-4-C w/Teflon Marine Lubricant to connecting rod big-end bearings. IMPORTANT: Replace roller bearing halves as a set. DO NOT use old and new halves together. b. Place both halves of connecting rod big-end roller bearing onto crank pin. a-Lockring b-Roller Bearing 95 2-4-C With Teflon (92-825407A12) IMPORTANT: Clean connecting rod bolts with solvent and dry with compressed air. Inspect threads for damage. If threads are not damaged, bolts may be reused. Apply light oil to threads prior to installation. Page 4-34 90-827242R1 MAY 1998 POWERHEAD c. Observe connecting rod/cap fracture line for correct alignment. Secure connecting rod (with v-notch of rod toward flywheel end of crankshaft) onto crankshaft with rod cap and bolts. Torque bolts to 100 lb. in. (11.3 N·m). d. Correct piston installation: 53138 53151 14 a b c d e f f g g a-Fracture Line b-Connecting Rod c-V-Notch (Toward Flywheel) d-Rod Cap e-Bolts [Torque to 100 lb. in. (11.3 N·m)] f-Intake Side g-Exhaust Side 14 2 Cycle Outboard Oil (92-826666A24) 90-827242R1 MAY 1998 Page 4-35 POWERHEAD 7. Install new piston rings using Piston Ring Expander (91-24697). Install RECTANGULAR ring first in bottom ring groove. Install HALF-KEYSTONE ring in top ring groove. Align piston rings with ring locating pins. 53268 a b c d a-Piston Ring Expander (91-24697) b-Rectangular Ring c-Half-Keystone Ring d-Locating Pin IMPORTANT: Chamfered side of retaining ring faces away from lower crankshaft ball bearing. 8. Install retaining ring, stuffer washer and lower crankshaft oil seal. 9. Install upper crankshaft roller bearing and oil seal. 53183 a b c d e a-Retaining Ring b-Stuffer Washer c-Lower Oil Seal d-Roller Bearing e-Upper Oil Seal IMPORTANT: When replacing roller bearing halves, replace both halves together. Page 4-36 90-827242R1 MAY 1998 POWERHEAD 10. Apply 2-4-C w/Teflon Marine Lubricant to center main bearing surface of crankshaft and install center main roller bearing halves. 53133 95 a a-Bearing Halves 95 2-4-C With Teflon (92-825407A12) 11. Model 10 and 1995 and newer Model 9.9: Position center main bearing race halves (retaining ring groove toward flywheel end of crankshaft) around center main roller bearing. Make sure fracture lines of race halves are correctly mated. 12. Secure center main bearing race halves together with retaining ring. Verify retaining ring bridges both fracture lines of bearing race. a b c d 53127 a-Bearing Race Halves b-Retaining Ring Groove c-Fracture Lines d-Retaining Ring 90-827242R1 MAY 1998 Page 4-37 POWERHEAD Cylinder Block 1. Lubricate piston rings, piston and cylinder wall with light oil. IMPORTANT: DO NOT seat crankshaft fully into block until center main sleeve and bearing half are installed. 2. Keeping crankshaft horizontal, guide pistons into cylinder bores. 3. 1994 Model 9.9 and all Model 6/8: Install 1/2 of center main bearing sleeve and bearing into cylinder block. 53272 a b a-Bearing Sleeve b-Bearing 4. 1994 Model 6/8/9.9 and 1995 Model 6/8: Install 2nd half of center main sleeve and bearing. a b c d e 53273 a-Alignment Boss d-Sleeve b-Notch e-Bearing c-Retaining Ring Page 4-38 90-827242R1 MAY 1998 POWERHEAD 5. Model 10/15 and 1995 and newer Model 9.9: Align hole in center main bearing race with pin of cylinder block. a b a-Hole b-Pin (Hidden) 6. Position alignment boss of upper crankshaft roller bearing into notch in cylinder block. 7. Firmly press retaining ring (bevel faces DOWN) into groove in cylinder block and gently seat crankshaft assembly into position. 8. Gently push seals inward to seat. 9. Check each piston ring for spring tension thru transfer and exhaust ports by pressing with a screwdriver. If no spring tension exists (ring fails to return to position), it is likely that the piston ring was broken during assembly [replace broken piston ring(s)]. Use caution not to burr piston rings while inspecting. 10. Clean crankcase sealing surfaces according to Loctite Master Gasket instructions. Apply a continuous bead of Loctite sealant along the inside of the mounting bolt holes of crankcase cover. 53124 a a 53144 a-Sealant IMPORTANT: For 1994 Model 9.9 and all Models 6/8, split line of center main bearing sleeve halves MUST ALIGN when crankcase cover is installed onto cylinder block. 90-827242R1 MAY 1998 Page 4-39 POWERHEAD 11. Place crankcase cover onto cylinder block and secure with 6 bolts. Torque bolts to 16.7 lb. ft. (22.7 N·m) in numbered torque sequence. 53192 1 2 34 56 a a a-Bolts [Torque to 16.7 lb. ft. (22.7 N·m)] 12. Rotate crankshaft several times to assure free operation. 13. If disassembled, assemble reed block as follows: a. Pull ends of rubber seal into holes in intake manifold/reed block. Trim off installation tabs from rubber seal and apply GM Silicone Sealer (92-91600-1) at each location where seal passes through manifold. NOTE:1997 and newer reed blocks are rubber coated and do not require sealant. b. Secure reeds and reed stops to intake manifold/reed block with 6 screws. Torque screws to 20 lb. in. (2.3 N·m). 53202 a b c d e a-Rubber Seal b-Apply Sealant (Each Side) c-Reeds d-Reed Stops e-Screws [Torque to 20 lb. in. (2.3 N·m)] Page 4-40 90-827242R1 MAY 1998 POWERHEAD 14. 1996 Models and prior: Apply 2-4-C w/Teflon (92-825407A12) to rubber seal (to prevent seal from moving out of position) and secure intake manifold/reed block (with new gasket) using 3 bolts. ALL Models: Torque bolts to 60 lb. in. (6.8 N·m). 53191 a b a-Bolts [Torque to 60 lb. in. (6.8 N·m)] b-Intake Manifold/Reed Block 15. 1994 Models: Secure intake cover (with new gasket) using 2 bolts. 1995 Models and newer: Inspect o-rings on intake cover for cuts or abrasions. Replace if necessary. Secure cover with 2 bolts. Torque bolts to 60 lb. in. (6.8 N·m). 53198 a b a-Bolts [Torque to 60 lb. in. (6.8 N·m)] b-Intake Cover 90-827242R1 MAY 1998 Page 4-41 POWERHEAD 16. Secure exhaust manifold and cover (with new gaskets) using 11 bolts. Torque bolts to 60 lb. in. (6.8 N·m) in torque sequence listed. 17. Secure cylinder block cover to block with 6 bolts. Torque bolts to 60 lb. in. (6.8 N·m) in sequence shown. Install thermostat, if equipped. 5319353188 1 2 3 4 56 7 8910 11 1 2 34 56 a a-Thermostat 18. Install thermostat cover. Torque bolts to 60 lb. in. (6.8 N·m). 53194 a b a-Cover b-Bolts [Torque to 60 lb. in. (6.8 N·m)] 19. Install the following components/assemblies referring to the listed service manual sections. Component/Assembly Section Carburetor 3 Throttle/Shift Mechanism 7A/B/C Electrical/Ignition Components and Flywheel 2A/B Rewind Starter 8 Page 4-42 90-827242R1 MAY 1998 POWERHEAD Powerhead Installation 1. Verify powerhead base surface and driveshaft housing mating surfaces are free of old gasket material. 2. Secure powerhead (with new gasket) onto driveshaft housing using 4 bolts and 2 nuts. Apply Loctite #35 (92-59328-1) to threads of bolts an torque bolts and nuts to 100 lb. in. (11.3 N·m). 3. Attach tell-tale hose to thermostat cover and fitting on bottom cowl. 53125 53204 b a b c d e a-Bolts (2 Each Side) [Torque to 100 lb. in. (11.3 N·m)] b-Nuts (1 Each Side) [Torque to 100 lb. in. (11.3 N·m)] c-Tell-Tale Hose d-Thermostat Cover e-Cowl Fitting 4. Secure end of shift shaft to yoke of horizontal shift shaft with lever. a b c d e f 53052 a-Shift Shaft b-Yoke c-Lever d-Apply 2-4-C w/Teflon e-Detent Spring f-Bolts [Torque to 25 lb. in. (2.8 N·m)] 90-827242R1 MAY 1998 Page 4-43 POWERHEAD Set-Up and Test-Run Procedures CAUTION When engine is started, IMMEDIATELY check for fuel leaks and water leaks. Check for water pump operation by water being discharged from tell-tale. 1. Following powerhead repairs, refer to Section 2C “Timing/Synchronizing/Adjusting” and perform set-up procedures. 2. While test running engine, check powerhead assembly for leaks and/or unusual noises. Make any repairs BEFORE returning engine to service. Break-In Procedure CAUTION To avoid possible engine damage, break-in procedure MUST BE completed BEFORE operating engine continuously at full throttle. Failure to break-in engine in properly will result in engine failure or shortened powerhead life. IMPORTANT: Advise the owner that the break-in procedure must be followed EXACTLY when returning an overhauled engine to service. 1. Mix gasoline and oil at the normal 50:1 ratio. 2. Operate engine at varied throttle settings for the first hour (1 hour). AVOID both wideopen- throttle operation and prolonged idle in cold water areas during this period. 3. After the first hour of operation, the engine is ready for normal operation and may be run at any speed. DO NOT EXCEED the full throttle RPM range listed in “Specifications”, preceding. Page 4-44 90-827242R1 MAY 1998 CLAMP/SWIVEL BRACKETS AND DRIVE SHAFT HOUSING MID-SECTION Section 5 – Clamp/Swivel Brackets and Drive Shaft Housing Table of Contents Clamp Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Drive Shaft Housing Disassembly/ Swivel Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Drive Shaft Housing . . . . . . . . . . . . . . . . . . . . . 5-6 5 A 90-827242R1 MAY 1998 Page 5-1 CLAMP/SWIVEL BRACKETS AND DRIVE SHAFT HOUSING Clamp Bracket 95 95 95 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1819 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 3637 38 39 40 41 42 31 32 12 21 14 9 3 15 17 18 19 95 2-4-C With Teflon (92-825407A12) Page 5-2 90-827242R1 MAY 1998 CLAMP/SWIVEL BRACKETS AND DRIVE SHAFT HOUSING Clamp Bracket REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 CLAMP BRACKET (BLACK-PORT) 2 1 CLAMP BRACKET (BLACK-STARBOARD) 3 2 THUMB SCREW ASSEMBLY 4 2 HANDLE 5 2 RIVET 6 2 WASHER–thumb screw 7 2 SCREW–washer attaching 65 7.3 8 1 SPACER 9 2 SCREW (M6 x 40) 60 6.8 10 1 DECAL (TILT) 11 1 SHUTTLE–tilt lock 1212 1 TILT TUBE (HANDLE MODELS) 1 TILT TUBE (RC MODELS) 13 1 CLIP–safety 14 2 NUT–tilt tube 120 10 13.6 15 2 WASHER–tilt tube 16 2 LEVER ASSEMBLY–tilt return 17 2 SCREW (M5 x 35) 18 2 SPRING 19 2 KNOB 20 1 STRAP–tilt stop - port side 21 2 SCREW–strap to clamp bracket 60 6.8 22 1 WAVE WASHER–tilt stop strap screw 23 2 BOLT–clamp bracket to transom (1/4-20 x 3-1/2) 24 2 WASHER–clamp bracket bolt 25 2 NUT–clamp bracket bolt 26 1 SPACER NUT SEAL O RING SPACER RC MODELS NUT WASHER (.625 O.D.) WASHER WASHER SCREW (M8 x 30) BRACKET NUT BALL JOINT TIE ROD SPACER 27 2 28 1 29 1 30 1 31 2 32 3 33 1 34 1 35 2 36 1 37 2 38 1 39 1 40 1 41 1 DECAL-Lower Tilt Limit 42 1 DECAL-Tilt Lock 90-827242R1 MAY 1998 Page 5-3 95 95 CLAMP/SWIVEL BRACKETS AND DRIVE SHAFT HOUSING Swivel Bracket 95 94 7 95 95 9595 95 94 Anti-Corrosion Grease (92-78376A6) 7 Loctite 271 (92-809820) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 2 2-4-C With Teflon (92-825407A12) Page 5-4 90-827242R1 MAY 1998 CLAMP/SWIVEL BRACKETS AND DRIVE SHAFT HOUSING Swivel Bracket REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 SWIVEL BRACKET (BLACK) 2 3 GREASE FITTING 3 1 BEARING 4 1 THRUST BEARING–upper 5 1 BUSHING–lower 6 1 SEAL 7 1 THRUST WASHER–lower 8 1 SPRING 9 1 BRACKET 10 1 PIN 11 1 HOOK–reverse lock 12 1 PIVOT PIN 13 1 RETAINING RING 14 1 WASHER 15 1 SPRING 16 1 CARRYING HANDLE (BLACK) 17 1 SPRING–reverse hook 18 2 E-RING 19 1 ROD 20 2 BRAKE DISC 21 1 SWIVEL HEAD PLATE 22 2 SCREW (M6 x 13) 70 7.9 23 1 BRAKE PLATE 24 1 WASHER 25 1 HANDLE 26 1 NUT 125 14.1 27 1 DECAL–co-pilot 28 1 DECAL-Serial Overlaminate 90-827242R1 MAY 1998 Page 5-5 CLAMP/SWIVEL BRACKETS AND DRIVE SHAFT HOUSING Drive Shaft Housing 17 95 95 2-4-C With Teflon (92-825407A12) Loctite 35 (92-59328-1) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 4 3 3 3 Page 5-6 90-827242R1 MAY 1998 CLAMP/SWIVEL BRACKETS AND DRIVE SHAFT HOUSING Drive Shaft Housing REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 11 1 HOUSING ASSEMBLY (BLACK-SHORT) 1 HOUSING ASSEMBLY (BLACK-LONG) 2 1 GASKET–drive shaft housing 3 4 MOUNT 4 2 COVER–mount (BLACK) 5 2 SCREW–mount cover (M6 x 80) 6 2 WASHER 7 2 NUT–cover screw 110 12.4 8 4 SCREW (M6 x 35) 100 11.3 9 1 SEAL–adaptor plate 1010 1 ADAPTOR PLATE (NO EXHAUST TUBE)(6/8/9.9) 1 ADAPTOR PLATE (WITH EXHAUST TUBE) (15) 11 1 EXHAUST TUBE (15) 1212 1 WATER TUBE (SHORT) 1 WATER TUBE (LONG) 13 1 SEAL–water tube 14 1 BEARING BLOCK (LONG) Drive Shaft Housing Disassembly/Reassembly Servicing components such as steering arm, drive shaft housing, exhaust assembly and swivel bracket will usually require powerhead and/or gear housing removal. Refer to SECTION 4 for powerhead removal and SECTION 6 for gear housing removal. NOTE:With powerhead removed, always inspect and remove any carbonbuildupinexhaust tube. The transom bracket, lower mount bracket, tilt tube and lower engine mounts can be serviced without powerhead/gear housing removal. However, OUTBOARD MUST BE SUPPORTED BEFORE SERVICING COMPONENTS. IMPORTANT: All gaskets should be replaced when removing powerhead and/or disassembling drive shaft housing. Corresponding gasket mating surfaces should be cleaned of any gasket material before installing new gaskets. 90-827242R1 MAY 1998 Page 5-7 GEAR HOUSING LOWER UNIT Section 6 – Gear Housing Table of Contents Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Gear Housing (Drive Shaft)(2.00:1 Gear Ratio) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Gear Housing (Propeller Shaft)(2.00:1 Gear Ratio) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Gearcase Removal . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Gearcase Disassembly . . . . . . . . . . . . . . . . . . . . . 6-9 Propeller Removal. . . . . . . . . . . . . . . . . . . . . . . 6-9 Draining and Inspecting Gear Lubricant . . . . 6-9 Bearing Carrier. . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Water Pump, Drive Shaft and Shift Shaft . . 6-13 Pinion Gear and Forward Gear . . . . . . . . . . . 6-17 Drive Shaft Bushing, Bearing and Lubrication Sleeve . . . . . . . . . . . . . . . . . . . . . 6-19 Aluminum Anode and Water Inlet . . . . . . . . . 6-21 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Drive Shaft Needle Bearing, Bushing and Lubrication Sleeve Installation . . . . . . . . . . . 6-21 Specifications Forward Gear Bearing Race Installation . . . 6-23 Forward Gear Reassembly . . . . . . . . . . . . . . 6-23 Bearing Carrier Reassembly . . . . . . . . . . . . . 6-24 Water Pump Base and Shift Shaft Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 Propeller Shaft Reassembly . . . . . . . . . . . . . 6-26 Forward Gear, Pinion Gear and Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . 6-27 Shift Shaft and Water Pump Base Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28 Water Pump Cover Reassembly . . . . . . . . . . 6-29 Impeller and Pump Cover Installation . . . . . 6-30 Propeller Shaft and Bearing Carrier Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 Aluminum Anode and Water Inlet Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 Propeller Installation . . . . . . . . . . . . . . . . . . . . 6-32 Filling Gear Housing with Lubricant . . . . . . . . . . 6-33 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33 6 GEAR HOUSING Gear Ratio Gearcase Capacity Lubricant Type Forward Gear - No. of Teeth-Type Pinion Gear - No. of Teeth-Type Pinion Height Forward Gear Backlash Reverse Gear Backlash Water Pressure With Thermostat – @ W.O.T – @ Idle W/O Thermostat – @ W.O.T – @ Idle 2.0:1 6.8 fl. oz. (200 ml) Quicksilver Gear Lube Premium Blend 26 Spiral/Bevel 13 Spiral/Bevel Floating No Adjustment No Adjustment 5 – 7 PSI @ 5000 RPM 1/2 – 1-1/2 PSI @ 750 RPM 5 – 7 PSI @ 5000 RPM 0 – 1 PSI @ 750 RPM NOTE: Telltale at IDLE may be intermittant on engines with thermostats installed. 90-827242R1 MAY 1998 Page 6-1 GEAR HOUSING Special Tools 1. Universal Puller Plate 91-37241 2. Puller Assembly 91-83165M and Puller Plate 91-29310 a a-Puller Plate 91-29310 3. Slide Hammer 91-345669A1 4. Bearing Carrier Tool 91-13664 5. Drive Shaft Bearing Removal Tool 91-824788A1 a a-Drive Shaft Bushing Removal Tool 23-824789 6. Drive Shaft Bushing Installation Tool 91-824790A1 a a-Drive Shaft Bearing Installation Tool 91-824791 Page 6-2 90-827242R1 MAY 1998 GEAR HOUSING 7. Mandrel 91-13658 8. Bushing Removal Tool 91-824787 9. Seal Installation Tool 91-824785A1 a a-Seal/Bushing Installation Tool 23-824786 10. Expanding Rod (SNAP ON P/N CG40-4)* 11. Collet (Jaws) (SNAP ON P/N CG40-15)* 12. Leakage Tester FT8950 *Purchase From: SNAP ON TOOLS Corporation 2801 - 80th Street Kenosha, Wi. 53141 - 1410 90-827242R1 MAY 1998 Page 6-3 GEAR HOUSING Gear Housing (Drive Shaft)(2.00:1 Gear Ratio) 95 87 87 7 95 7 95 95 7 95 85 95 2.60 IN./102MM TORPEDO DIA. 95 2-4-C With Teflon (92-825407A12) 87 Quicksilver Gear Lubricant (92-19007A24) 85 RTV 587 Silicone Sealer (92-809825) 7 Loctite 271 (92-809820) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 33 39 35 24 Page 6-4 90-827242R1 MAY 1998 GEAR HOUSING Gear Housing (Drive Shaft)(2.00:1 Gear Ratio) REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m – 1 GEAR HOUSING(BLACK-SHORT) – 1 GEAR HOUSING(BLACK-LONG) 1 1 GEAR HOUSING(BLACK-BASIC) 2 1 BUSHING–gear housing 3 1 DRAIN SCREW 4 1 SEALING WASHER 5 1 SLEEVE ASSEMBLY 6 1 SLEEVE 7 1 BUSHING 8 1 SCREW PLUG KIT 9 1 SEALING WASHER 10 1 SCREEN 11 1 SCREW 30 3.4 12 1 ANODE ASSEMBLY 13 1 SCREW 30 3.4 14 1 SEAL 15 1 PINION GEAR (13 TEETH) 16 1 WASHER–thrust 17 1 BEARING 18 1 WATER PUMP BASE 19 1 GASKET 20 1 SEAL 21 1 RETAINER 22 1 SCREW (10-16 x 1/2) Drive Tight 23 1 QUAD RING 24 2 OIL SEAL 25 1 GASKET 26 1 WATER TUBE 27 1 FACE PLATE 28 1 COVER ASSEMBLY 29 1 INSERT 30 1 SEAL 31 1 IMPELLER 32 1 KEY ASSEMBLY 33 2 WASHER 34 1 GUIDE 35 5 SCREW–water pump (M6 x 30) 50 5.6 36 1 CAM–shift 3737 1 SHIFT SHAFT (SHORT) 1 SHIFT SHAFT (LONG) 38 1 E-RING 39 2 GUIDE 40 1 SCREW (M5 x 25) 45 5.1 41 1 NUT–guide screw 45 5.1 4242 1 DRIVE SHAFT (SHORT) 1 DRIVE SHAFT (LONG) 43 1 THRUST WASHER 90-827242R1 MAY 1998 Page 6-5 GEAR HOUSING Gear Housing (Propeller Shaft)(2.00:1 Gear Ratio) 7 95 87 95 7 95 87 94 7 2.60 IN./102MM TORPEDO DIA. 1 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 6263 64 65 95 94 87 7 Loctite 271 (92-809820) Quicksilver Gear Lubricant (92-19007A24) Anti-Corrosion Grease (92-78376A6) 2-4-C With Teflon (92-825407A12) Page 6-6 90-827242R1 MAY 1998 GEAR HOUSING Gear Housing (Propeller Shaft)(2.00:1 Gear Ratio) REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m – 1 GEAR HOUSING(BLACK-SHORT) – 1 GEAR HOUSING(BLACK-LONG) 1 1 GEAR HOUSING (BLACK-BASIC) 44 1 ROLLER BEARING 45 1 CUP 46 1 FORWARD GEAR (26 TEETH) 47 1 BUSHING 48 1 CAM FOLLOWER 49 1 CLUTCH ASSEMBLY 50 1 CROSS PIN 51 1 SPRING 52 1 PROPELLER SHAFT 53 1 REVERSE GEAR (26 TEETH) 54 1 BEARING CARRIER 85 115.2 55 1 O-RING 56 1 BUSHING 57 1 OIL SEAL 58 1 OIL SEAL 59 1 SCREW (M8 x 50) 180 15 20.3 60 2 SCREW (M8 x 30) 180 15 20.3 61 1 PROPELLER (9-1/4 IN. x 7 IN.) 1 PROPELLER (9 IN. x 9 IN.) 1 PROPELLER (9-3/4 IN. x 6-1/2 IN.) 62 1 SPACER 63 1 PROPELLER NUT 100 11.3 64 1 THRUST HUB 65 1 HI-REVERSE THRUST CUP 90-827242R1 MAY 1998 Page 6-7 GEAR HOUSING Gearcase 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 outboard into FORWARD gear. 3. Tilt outboard to full “UP” position. 4. Remove shift shaft retainer. a 53049 a-Retainer 5. Remove reverse lock actuator. 6. Remove 3 bolts. 52998 53004 a b b a-Actuator b-Bolts (3) Page 6-8 90-827242R1 MAY 1998 GEAR HOUSING Gearcase Disassembly Propeller Removal WARNING If gear housing is NOT removed from drive shaft housing, remove (and isolate) spark plug leads from spark plugs to prevent outboard from accidentally starting while removing and installing propeller. 1. Place a block of wood between anti-ventilation plate and propeller to prevent propeller from turning and to protect hands while removing prop. 2. Remove nut, thrust hubs and propeller. 52547 a b c a-Wood b-Nut c-Thrust Hubs Draining and Inspecting Gear Lubricant 1. Remove both VENT and FILL screws with gaskets. 2. Inspect gear lubricant for metal particles. Presence of a small amount of fine metal particles (resembling powder) indicates normal wear. Presence of large particles (chips) or a large quantity of fine particles indicates need for gear housing disassembly and component inspection. 3. Note color of gear lubricant. White or cream color indicates presence of water in lubricant. NOTE:When draining gear case for the first time, lubricant may appear cream colored due to the mixing of assembly lubricant and gear lubricant. This is NOT an indication of water intrusion. If, during subsequent draining of gear case, lubricant appears cream colored or milky, water may be present. Gear case should be disassembled and all gaskets, seals and o-rings replaced. Inspect all components for water damage. 90-827242R1 MAY 1998 Page 6-9 GEAR HOUSING 4. Check drain pan for water separation from lubricant. Presence of water in gear lubricant indicates the need for disassembly and inspection of oil seals, seal surfaces and gear housing components. 53001 b a b a-Vent Screw b-Fill Screw Bearing Carrier 1. Remove bearing carrier (LEFT HAND thread) using Bearing Carrier Tool (91-13664). 91-13664 52993 91-13664 53017 2. Remove carrier and propeller shaft assembly from housing. NOTE:Cam follower is free to slide out of propeller shaft. 52994 a a-Cam Follower Page 6-10 90-827242R1 MAY 1998 GEAR HOUSING 3. Remove propeller shaft and REVERSE gear from bearing carrier. 4. Replace REVERSE gear if gear teeth or clutch teeth are chipped or worn. NOTE:When using a punch to remove carrier seals, be careful to not to scar carrier seal surface with punch. If carrier seal surface is damaged, replace carrier. 5. Using a suitable punch, remove both seals from bearing carrier. 5300252988 b a b c d e a-Gear Teeth b-Clutch Teeth c-Oil Seal d-Fish Line Cutter Seal e-Punch 6. Replace bearing carrier bushing if bushing or area on propeller shaft that bushing contacts is pitted or worn. Press bushing from carrier using Bushing Removal Tool (91-824787). 91-824787 53020 53026 a b a-Bushing b-Mandrel (91-824787) 90-827242R1 MAY 1998 Page 6-11 GEAR HOUSING Propeller Shaft 1. Inspect cam follower for wear. If cam follower is worn, replace follower and inspect shift cam for serviceability. Replace cam if worn. a a-Cam Follower 1. Remove groove pin from clutch/propeller shaft applying pressure to side of pin that is NOT grooved. Discard pin. 53013 b a b a-Punch b-Groove Pin (Discard) 2. Remove spring and sliding clutch. 53005 a b a-Spring b-Clutch 3. Replace clutch if jaws are rounded or chipped. Rounded jaws may be caused by the following: a. Improper shift cable adjustment. b. Engine idle speed too high while shifting. c. Shifting too slowly from NEUTRAL into FORWARD or REVERSE. 52990 Page 6-12 90-827242R1 MAY 1998 GEAR HOUSING 4. Inspect bushing surfaces of propeller shaft for pitting or wear. Replace shaft and corresponding bushing if wear or pitting is observed. 5. Replace shaft if any of the following exist: a. Splines are twisted or worn. b. Oil seal surface is grooved. c. Shaft has a noticeable “wobble” or is bent more than 0.006 in. (0.15mm). 52997aa a b c a-Bushing Surfaces b-Oil Seal Surface c-Measure Here for “Wobble” (When measuring shaft for wobble, use v-blocks and support at bushing surface) Water Pump, Drive Shaft and Shift Shaft 1. Remove 4 bolts from pump cover. 2. Remove cover, nylon washers (above and below impeller), impeller and drive key from drive shaft. 3. It is recommended that impeller be replaced whenever gear case is being serviced. NOTE:If impeller is not going to be replaced, DO NOT install impeller in reverse rotation to its original state as vanes have taken a set. Vanes will crack and break shortly after outboard is returned to service. 53023 a-Cover b-Nylon Washer c-Impeller d-Nylon Washer e-Key 53048 a b c d e 90-827242R1 MAY 1998 Page 6-13 GEAR HOUSING 4. Remove guide from cover. 5. Replace rubber seal if damaged. 6. Replace cover if inside is grooved. 7. Remove plate, gasket, quad-ring, bolt and washer. 8. Replace plate if grooved. 5301253032 a b c d e f a-Guide b-Seal c-Plate d-Gasket (Discard) e-Quad-Ring f-Bolt and Washer 9. Replace seal if damaged. 10. Remove water pump base and shift shaft from housing. 11. Remove gasket. 53014 a b c 53015 d a-Seal b-Pump Base c-Shift Shaft d-Gasket (Discard) Page 6-14 90-827242R1 MAY 1998 GEAR HOUSING 12. Inspect shift cam for wear. Replace if worn. 53034 a a-Shift Cam 13. Remove clip from shift shaft. Unthread shift cam. Remove shaft from water pump base. 53034 a b a-Clip b-Shift Cam 14. Remove screw and pull water tube from base. 53009 a b a-Screw b-Water Tube 15. Replace seal if damaged. Replace water tube if corroded. 53024 a b a-Seal b-Water Tube 90-827242R1 MAY 1998 Page 6-15 53036 b 53036 b GEAR HOUSING 16. Remove drive shaft from gear housing. NOTE:Thrust washers, pinion gear and forward gear assembly are free to fall from housing when drive shaft is removed. 52995 a b c d a-Thrust Washer (without oil groove) b-Thrust Washer (with oil groove – groove faces down) c-Pinion Gear d-Forward Gear Assembly 17. Inspect bearing/bushing surfaces of drive shaft for pitting or wear. If shaft is pitted or worn, replace shaft and corresponding bearing/bushing. 18. Replace drive shaft if the following exist: a. Splines are twisted or worn. b. Oil seal surface is grooved. 19. Using a screw driver or punch, carefully remove (and discard) seals from pump base. a c d a-Bushing Surface b-Bearing Surface c-Seal Surface d-Seals Page 6-16 90-827242R1 MAY 1998 GEAR HOUSING Pinion Gear and Forward Gear PINION GEAR 1. Inspect pinion gear teeth for breakage, rust, chipping or excessive wear (teeth are sharped edged). 2. If pinion gear teeth are damaged, inspect FORWARD and REVERSE gear for damage. 3. Replace gears as required. 52991 a a-Pinion Gear FORWARD GEAR 1. Inspect forward gear teeth for breakage, rust, chipping and excessive wear (teeth are sharped edged). 2. Inspect forward gear clutch jaws for wear. Rounded jaws indicate the following: a. Improper shift cable adjustment. b. Engine idle speed too high. c. Shifting too slowly. 52989 b a a-Gear Teeth b-Clutch Jaws 3. Inspect propeller shaft FORWARD gear bushing surface to determine condition of bushing. If surface is discolored (from lack of lubricant), pitted or worn, propeller shaft and bushing should be replaced. 52989 52997 a b a-Bushing b-Bushing Surface 90-827242R1 MAY 1998 Page 6-17 GEAR HOUSING 4. If necessary, press bushing from gear using Bushing Removal Tool 91-824787. 91-824787 53020 53035 a b a-Bushing b-Bushing Removal Tool (91-824787) IMPORTANT: If FORWARD gear tapered bearing or race requires replacement, replace bearing and race as a set. NOTE: DO NOT remove tapered bearing from FORWARD gear unless replacement is necessary as removal process will damage bearing. 5. Inspect FORWARD gear tapered bearing and race for rust, roughness or excessive wear (looseness). 6. If bearing is in serviceable condition, DO NOT remove bearing from gear as removal process will damage bearing. 7. If bearing must be replaced, remove bearing from gear using Universal Puller Plate (91-37241) and a suitable mandrel (5/8 in. socket) 53008 a b c a-Bearing b-Universal Puller Plate (91-37241) c-Mandrel (5/8 in. Socket) Page 6-18 90-827242R1 MAY 1998 GEAR HOUSING 8. Replace FORWARD gear race if it is rusted or damaged or if FORWARD gear tapered bearing must be replaced. Remove race from housing using Bearing Puller Assembly (91-83165M) and Puller Plate (91-29310). 52996 53031 a b c b c a-Race b-Bearing Puller Assembly (91-83165M) c-Puller Plate (91-29310) Drive Shaft Bushing, Bearing and Lubrication Sleeve 1. Inspect drive shaft bushing and bearing surface to determine condition of corresponding upper drive shaft bushing and lower drive shaft needle bearing. If drive shaft surface is rusted, pitted, discolored (blued – lack of lubrication) or worn; replace drive shaft and corresponding bushing/bearing. DO NOT remove bushing or bearing if replacement is not necessary. 53041 53036 b a c d a-Bushing Surface b-Bearing Surface c-Upper Drive Shaft Bushing d-Lower Drive Shaft Needle Bearing IMPORTANT: If upper drive shaft bushing or lower drive shaft needle bearing appear to be spinning in their respective bores, the gear housing should be replaced. 90-827242R1 MAY 1998 Page 6-19 GEAR HOUSING 2. To replace upper drive shaft bushing, use Snap On* Expanding Rod (CG 40-4) Snap On Collet (CG 40A6) Slide Hammer (91-34569A1) *Purchase from: Snap On Tools Corporation 2801 - 80th Street Kenosha, WI 53141-1410 53042 CG 40A6 CG 40-4 53045 a b c d a-Expanding Rod (CG 40-4) b-Collet (CG 40A6) c-Slide Hammer (91-34569A1) d-Bushing 3. To gain access to lower drive shaft needle bearing, remove lubrication sleeve. NOTE:When upper drive shaft bushing is installed, a burr may be formed preventing the removal of the lubrication sleeve. Use a knife to remove burr. 4. Remove needle bearing using Drive Shaft Bearing Removal Tool (91-824788A1). 91-824788A1 53029 5303953040 a b c d a-Lubrication Sleeve b-Needle Bearing c-Driver Rod d-Pilot Page 6-20 90-827242R1 MAY 1998 GEAR HOUSING Aluminum Anode and Water Inlet 1. Replace aluminum anode if more than 50% consumed. 2. Remove water inlet and check that holes are not obstructed. 53050 ab a-Aluminum Anode b-Water Inlet Reassembly Drive Shaft Needle Bearing, Bushing and Lubrication Sleeve Installation 1. Install lower drive shaft needle bearing (numbers/letters face down) using Drive Shaft Bushing Tool (91-824790A1). 91-824790A1 53044 53019 53030 a b c d e f a-Puller Bolt b-Flat Washer c-Wafer Bearing d-Pilot e-Needle Bearing f-Mandrel 90-827242R1 MAY 1998 Page 6-21 GEAR HOUSING 2. Install lubrication sleeve. 53040 a a-Sleeve 3. Install upper drive shaft bushing assembly using Drive Shaft Bushing Tool (91-824790A1). NOTE:The upper drive shaft bushing is pressed into a sleeve. If the bushing is not worn into the sleeve or the bushing is not spinning within the sleeve, the bushing alone may be replaced. Press the new bushing into the sleeve using a suitable mandrel. If the sleeve is damaged, the bushing/sleeve assembly must be replaced. 53019 53030 53043 a b c de f 91-824790A1 a-Puller Bolt b-Flat Washer c-Wafer Bearing d-Pilot e-Bushing/Sleeve f-Mandrel Page 6-22 90-827242R1 MAY 1998 GEAR HOUSING Forward Gear Bearing Race Installation Install race into housing using Mandrel (91-13658) and Bearing Carrier Tool (91-13664). 52992 91-13664 53017 91-13658 53016 a b c a-Race b-Mandrel (91-13658) c-Bearing Carrier Tool (91-13664) Forward Gear Reassembly Install bushing and bearing using Mandrel (91-13658) and press. 91-13658 53018 53016 a b c a-Mandrel (91-13658) b-Bushing c-Bearing 90-827242R1 MAY 1998 Page 6-23 GEAR HOUSING Bearing Carrier Reassembly 1. Apply Quicksilver Gear Lubricant to bushing and press bushing into carrier using Mandrel (91-824785A1). 2. Apply Loctite 271 to O.D. of seal and with lip facing bushing, press seal into carrier using Mandrel (91-824785A1). 53027 91-824785A1 53022 7 Loctite 271 (92-809820) 7 53025 91-824785A1 53022 87 Quicksilver Gear Lubricant (92-19007A24) 87 a b c d ef a-Bushing b-Mandrel (91-824785A1) c-Mandrel (91-824785A1) d-Ring (used with mandrel) e-Seal (LIP FACES BUSHING) f-Bushing 3. Apply Loctite 271 to O.D. of fishline cutter seal. With ring removed from Mandrel (91-824785A1), press seal, with LIP FACING Mandrel, into carrier. Apply 2-4-C w/Teflon Marine Lubricant between lips of both seals. 4. Apply 2-4-C w/Teflon Marine Lubricant to o-ring and install o-ring on carrier. 53011 95 53028 91-824785A1 53022 a 95 2-4-C With Teflon (92-825407A12) 7 95 Loctite 271 (92-809820) a b c 7 a-Fishline Cutter Seal (LIP FACES MANDREL) b-Mandrel (without Ring – 91-824785A1) c-O-ring Page 6-24 90-827242R1 MAY 1998 GEAR HOUSING Water Pump Base and Shift Shaft Reassembly 1. Apply Loctite 271 to O.D. of seal. With lip of seal facing DOWN, push seal into base using Mandrel (91-13655). 2. Apply Loctite 271 to O.D. of seal. With seal lip facing UP, push seal into base using Mandrel (91-13655). Apply 2-4-C w/Teflon between lips of both seals. 91-13655 53021 53057 95 2-4-C With Teflon (92-825407A12) 7 95 529997 7 Loctite 271 (92-809820) a b c d a-Seal (Lip FACES DOWN) b-Mandrel (91-13655) c-Seal (Lip FACES UP) d-Mandrel (91-13655) 3. Install seal onto water tube. 4. Secure water tube to pump base with retainer and screw. 53009 53024 a b c d e a-Seal b-Pump Base c-Water Tube d-Retainer e-Screw 90-827242R1 MAY 1998 Page 6-25 GEAR HOUSING 5. Install shift shaft through pump base. 6. Install E-clip on shift shaft. Clip must be below pump base. 7. Thread shift cam onto shaft. 53034 a b a-E-clip b-Shift Cam Propeller Shaft Reassembly 1. Slide clutch onto propeller shaft. 53000ab c d a a-Sliding Clutch b-Short End (FORWARD Gear Side) c-Hole (must align with slot) d-Slot 2. Insert cam follower spring into shaft. 53005 a-Spring Page 6-26 90-827242R1 MAY 1998 GEAR HOUSING 3. Compress spring and install NEW groove pin. 53007 53038 a b c d e d a-Vise b-Screwdriver or small Punch c-Spring d-Groove Pin (Press in until Flush) e-Serrations 4. Apply 2-4-C w/Teflon to cam follower (flat side) and install follower into shaft. 53006a b a-Cam Follower b-Flat Side Forward Gear, Pinion Gear and Drive Shaft Installation 1. Install FORWARD gear assembly into forward gear race. 2. Install drive shaft through upper drive shaft bushing, oil sleeve and lower drive shaft needle bearing. 3. While lifting drive shaft slightly, install lower thrust washer (GROOVED SIDE FACES DOWN) and PINION gear. It may be necessary to rotate drive shaft slightly to engage pinion gear with splines of drive shaft and with forward gear teeth. 4. Install upper thrust washer above upper drive shaft bushing. 52995 a b c d e f g a-FORWARD Gear Assembly b-Drive Shaft Bushing c-Oil Sleeve d-Needle Bearing e-Lower Thrust Washer (GROOVED SIDE FACES DOWN) f-Pinion Gear g-Upper Thrust Washer 90-827242R1 MAY 1998 Page 6-27 GEAR HOUSING Shift Shaft and Water Pump Base Installation 1. Apply 2-4-C w/Teflon to I.D. of seal. 2. Install seal in housing with tapered end facing up. 3. Install base gasket with drain hole positioned as shown. 53015 53041 95 a b c d 95 2-4-C With Teflon (92-825407A12) a-Seal b-Tapered I.D. c-Base Gasket d-Hole IMPORTANT: Verify seal is not pushed out of position when water tube is installed. 4. Slide water pump base with shift shaft down drive shaft. Align water tube with seal in housing while seating water pump base. 53014 a b c d e a-Shift Shaft b-Shift Cam (POSITION AS SHOWN) c-Pump Base d-Water Tube e-Seal Page 6-28 90-827242R1 MAY 1998 GEAR HOUSING 5. Apply 2-4-C w/Teflon to I.D. and O.D. of shift shaft quad ring. Seat quad ring in pump base. 6. Apply Loctite 271 to bolt threads and secure pump base to housing with bolt and washer. Torque bolt to 50 lb. in. (5.6 N·m). 7. Install gasket and face plate. 53012 b 7 95 95 2-4-C With Teflon (92-825407A12) 7 Loctite 271 (92-809820) ab c d a-Quad Ring b-Bolt and Washer [Torque to 50 lb. in. (5.6 N·m)] c-Gasket d-Face Plate Water Pump Cover Reassembly 1. Apply 2-4-C w/Teflon to O.D. of seal and seal surface. 2. Install seal into cover. 3. Place water tube guide onto seal. 53032 95 2-4-C With Teflon (92-825407A12) 95 a b c a-Seal b-Seal Surface c-Guide 90-827242R1 MAY 1998 Page 6-29 GEAR HOUSING Impeller and Pump Cover Installation 1. Install neoprene washer. 2. Install drive key. Use 2-4-C w/Teflon to hold key to drive shaft. IMPORTANT: It is recommended that the impeller be replaced regardless of appearance. If impeller must be reused, it must be installed in the direction of original rotation. Installing impeller with vanes reversed from their previous “set” will result in vane breakage shortly after unit is returned to service. 3. Install new impeller and align with drive key. 4. Install neoprene washer. 5. Lubricate I.D. of water pump cover with 2-4-C w/Teflon. 6. Install cover on drive shaft and while pushing down on cover, rotate drive shaft CLOCKWISE and install cover over impeller. a-Neoprene Washer b-Drive Key c-Impeller d-Neoprene Washer e-Cover 7. Apply Loctite 271 to threads of bolts. Secure cover with bolts and torque to 50 lb. in. (5.6 N·m) per following numbered torque sequence. 53048 95 95 a bc d e 53023 77 7 1 2 3 4 5 95 7 Loctite 271 (92-809820) 2-4-C With Teflon (92-825407A12) Page 6-30 90-827242R1 MAY 1998 GEAR HOUSING Propeller Shaft and Bearing Carrier Installation 1. Install REVERSE gear into bearing carrier. 2. If not previously lubricated, apply 2-4-Cw/Teflon to o-ring. 3. Apply 2-4-C w/Teflon to bearing carrier threads and pilot diameter. 4. Slide bearing carrier onto propeller shaft and install entire assembly into gear housing. 5. Torque bearing carrier to 85 lb. ft. (115.2 N·m) using Bearing Carrier Tool (91-13664). 52994 95 95 a b c 91-13664 52993 LEFT HAND THREAD 95 2-4-C With Teflon (92-825407A12) a-Bearing Carrier Threads b-Propeller Shaft c-Pilot Diameter Aluminum Anode and Water Inlet Installation Secure anode and water inlet with screws. 53050 ab c a-Anode b-Water Inlet c-Screws 90-827242R1 MAY 1998 Page 6-31 GEAR HOUSING Propeller Installation WARNING If gear housing is NOT removed from drive shaft housing, BEFORE attempting to remove or install the propeller, remove (and isolate) spark plug leads from spark plugs to prevent engine from starting accidentally. 1. Apply Quicksilver Anti-Corrosion Grease to propeller shaft. 2. Install inner thrust hub. 3. Slide propeller onto shaft. 4. Install outer thrust hub. 5. Thread propeller nut onto shaft. a b d c 52547 a-Inner Thrust Hub b-Propeller c-Outer Thrust Hub d-Propeller Nut 6. Place a block of wood between propeller and anti-ventilation plate to prevent propeller from turning and to protect hands. Torque nut to 70 lb. in. (7.9 N·m). a b a-Outer Thrust Hub b-Nut Page 6-32 90-827242R1 MAY 1998 GEAR HOUSING Filling Gear Housing with Lubricant NOTE:Gear housing lubricant capacity – 6.8 oz. (200 ml). IMPORTANT: DO NOT use automotive grease in the gear housing. Use only Quicksilver Gear Lubricant (92-19007A24) 1. Remove any gasket material from “FILL” and “VENT” screws and housing. 2. Install new gaskets on “FILL” and “VENT” screws. IMPORTANT: Never apply lubricant to gear housing without first removing “VENT” screw or gear housing cannot be filled because of trapped air. Fill gear housing ONLY when housing is in a vertical position. 3. Slowly fill housing through “FILL” hole until lubricant flows out of “VENT” hole and no air bubbles are present. 4. Reinstall “VENT” screw. 5. Remove grease tube from “FILL” hole and quickly install “FILL” screw. 52998 a b a-Vent Screw b-Fill Screw Installation WARNING To prevent accidental engine starting, remove (and isolate) spark plug leads from spark plugs. BEFORE installing gear housing. 1. Remove (and isolate) spark plugs leads from spark plugs. 2. Place shift linkage on engine in FORWARD gear position. 3. Tilt engine to full “up” position. 4. Place gear housing in NEUTRAL. Propeller will rotate freely in either direction when gear housing is in NEUTRAL. 90-827242R1 MAY 1998 Page 6-33 GEAR HOUSING 5. Position shift shaft (a) as shown when measuring distance in Step 6. 6. Distance (b) between top of water pump base and center of hole (c) must be as specified below. Turn shift shaft clockwise to decrease distance (b) or counter clockwise to increase distance (b). 53051 a b c Drive Shaft Length Distance Short 16-1/2 in. (419mm) Long 22 in. (559mm) Extra Long 27-1/2 in. (698mm) 7. Place gear housing in FORWARD gear. Gear housing will ratchet when propeller shaft is turned clockwise. 8. Apply a 1/4 in. (6.4mm) diameter bead of RTV Sealer on water pump base. 53023 a a-RTV Sealer Page 6-34 90-827242R1 MAY 1998 GEAR HOUSING 9. Install gear housing as follows: a. Position gear housing so that drive shaft and shift shaft extend into drive shaft housing. b. Move gear housing toward drive shaft housing while keeping mating surfaces parallel. c. Guide shift shaft through hole in mid-section. d. Guide water tube into water tube guide. e. Rotate propeller counterclockwise while pushing upward on gear housing to align drive shaft splines with crankshaft splines. f. Guide end of shift shaft into shift coupling yoke under cowl. 53004 a a-Shift Shaft Hole 10. Secure detent spring to block with 2 bolts. Spring may have slotted holes. Install spring so that it is raised UP and at end of slot travel. Torque bolts to 25 lb. in. (2.8 N·m). 11. Secure end of shift shaft to yoke of horizontal shift shaft with coupler. Rotate coupler until it locks in place. 53052 d 95 2-4-C With Teflon (92-825407A12) 95 a b c d e f a-Shift Shaft b-Yoke c-Coupler d-Apply 2-4-C w/Teflon e-Detent Spring f-Bolts [Torque to 25 lb. in. (2.8 N·m)] 90-827242R1 MAY 1998 Page 6-35 GEAR HOUSING 12. Apply Loctite 271 to 3 bolts and torque to 15.0 lb. ft. (20.3 N·m). 52998 7 Loctite 271 (92-809820) 7 7a a a-Bolts [Torque to 15.0 lb. ft. (20.3 N·m)] 13. Check shift operation as follows: a. Place shift lever in FORWARD. Gear housing should ratchet when propeller shaft is turned clockwise and resistance should be felt when propeller is turned counterclockwise. b. Place shift lever in NEUTRAL. Resistance should NOT be felt when propeller shaft is rotated in either direction. c. Place shift lever in REVERSE. Resistance should be felt when propeller shaft is rotated in either direction. d. If shift operation is not as described, remove gear housing and recheck distance measurement in Step 6. 14. Place shift lever in NEUTRAL. 15. Install reverse lock actuator loosely on shift shaft. 16. Position reverse lock actuator so that it just contacts reverse lock hook; secure in this position. Torque actuator screw to 45 lb. in. (5.1 N·m). The outboard will now ONLY TILT UP IN FORWARD GEAR. If the operator wishes the outboard to tilt up in FORWARD and NEUTRAL, place shift lever in REVERSE. Install reverse lock actuator loosely on shift shaft. Position actuator so that 0.25 in. (6.4mm) clearance exists between reverse lock hook and actuator. Secure actuator in this position. Torque actuator screw to 45 lb. in. (5.1 N·m). 53004 a b c a-Reverse Lock Actuator b-Screw and Locknut [Torque to 45 lb. in. (5.1 N·m)] c-Reverse Lock Hook Page 6-36 90-827242R1 MAY 1998 THROTTLE/SHIFT LINKAGE (TILLER HANDLE SHIFT MODELS) ATTACHMENTS/CONTROL LINKAGE Section 7A – Throttle/Shift Linkage (Tiller Handle Shift Models) Table of Contents Throttle and Shift Linkage (Tiller Handle Shift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-2 Control Cables (Tiller Handle Shift) . . . . . . . . . . 7A-4 Removal/Installation . . . . . . . . . . . . . . . . . . . . 7A-4 Control Platform. . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-4 Removal/Disassembly . . . . . . . . . . . . . . . . . . 7A-4 Reassembly/Installation . . . . . . . . . . . . . . . . . 7A-5 Throttle Cam/Control Lever . . . . . . . . . . . . . . . . . 7A-8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-8 Throttle Cam/Control Lever . . . . . . . . . . . . . . . . . 7A-8 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-8 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-10 Neutral Interlock Control Lever . . . . . . . . . . . . . 7A-11 Reassembly/Installation . . . . . . . . . . . . . . . . 7A-11 Horizontal Shift Shaft . . . . . . . . . . . . . . . . . . . . . 7A-12 Reassembly/Installation . . . . . . . . . . . . . . . . 7A-12 7 A 90-827242R1 MAY 1998 Page 7A-1 THROTTLE/SHIFT LINKAGE (TILLER HANDLE SHIFT MODELS) Throttle and Shift Linkage (Tiller Handle Shift) 95 95 9595 95 95 95 2-4-C With Teflon (92-825407A12) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 11 5 Page 7A-2 90-827242R1 MAY 1998 THROTTLE/SHIFT LINKAGE (TILLER HANDLE SHIFT MODELS) Throttle and Shift Linkage REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 CONTROL PLATFORM 2 1 GEAR 3 1 GEAR 4 1 SCREW (M6 x 30) 5 2 WASHER 6 1 SPACER (SHORT) 7 2 NUT 60 6.8 8 1 PRIMARY LEVER 9 1 SCREW (M6 x 40) 10 1 SPACER (LONG) 11 2 SCREW (M6 x 16) 60 6.8 12 1 TIMING LINK 13 1 CONTROL LEVER 14 1 SCREW (M5 x 8 x 35) 15 1 ACTUATOR 16 1 LINK 17 1 SCREW (M6 x 40) 70 7.9 18 1 WASHER 19 1 BUSHING 20 1 SPRING 21 1 LOCKWASHER 22 1 SPRING 23 1 THROTTLE LINK 24 1 SOCKET 25 1 LEVER 26 1 BUSHING 27 1 SPRING 28 1 SCREW (M6 x 30) 70 7.9 29 1 WASHER 30 1 LEVER 31 1 LEVER 32 1 SHIFT SHAFT 33 1 SHIFT LINK 34 2 SCREW (M5 x 8 x 8) 25 2.8 35 1 SPRING 36 1 SWITCH ASSEMBLY SCREW (20MM) 15 ELECTRIC HANDLE PLATE 37 2 38 1 90-827242R1 MAY 1998 Page 7A-3 THROTTLE/SHIFT LINKAGE (TILLER HANDLE SHIFT MODELS) Control Cables (Tiller Handle Shift) Removal/Installation Refer to Section 7B for removal and installation instructions Control Platform Removal/Disassembly 1. Disconnect control cables from anchor bracket and pulley as outlined in Section 7B. 2. Disconnect throttle link rod from ball joint of primary throttle lever. 3. Disconnect shift link rod from ball joint of gear shift lever. 5317353166 e c aab c ad e f g h a-Cables e-Throttle Lever b-Bracket f-Shift Link Rod c-Pulley g-Gear Shift Lever d-Link Rod h-Shift Lever 4. Remove 3 bolts and control platform. 5. Remove nuts and flat washers. 5315953172 a a b c d a-Bolts b-Control Platform c-Nuts d-Flat Washers Page 7A-4 90-827242R1 MAY 1998 THROTTLE/SHIFT LINKAGE (TILLER HANDLE SHIFT MODELS) 6. Disassemble control platform. 53174a b c d e f g h i j j a-Nuts (2) [Torque to 60 lb. in. (6.8 N·m)] b-Flatwashers (2) c-Primary Throttle Lever d-Spacer (Long) e-Secondary Gear f-Spacer (Short) g-Gear Shift Lever h-Control Platform i-Bolts (2) j-Mount Bolts [Torque to 60 lb. in. (6.8 N·m)] Reassembly/Installation 1. Install short spacer and long spacer into recesses of control platform. 2. Lubricate spacers and area of platform traveled by gears with 2-4-C w/Teflon. 3. Install gear shift lever and secondary gear over spacers and lubricate gear teeth with 2-4-C w/Teflon. 53168 53167 a b c d e a-Short Spacer b-Long Spacer c-Platform d-Gear Shift Lever e-Secondary Gear 90-827242R1 MAY 1998 Page 7A-5 THROTTLE/SHIFT LINKAGE (TILLER HANDLE SHIFT MODELS) 4. Index primary throttle lever into secondary gear. 53190 a b a-Primary Throttle Lever b-Secondary Gear 5. Install bolts, washers and nuts. Torque nuts to 60 lb. in. (6.8 N·m). 53159 53175 a b c a-Nuts [Torque to 60 lb. in. (6.8 N·m)] b-Washers c-Bolts 6. Secure assembled control platform onto cylinder block using 3 bolts. Torque bolts to 60 lb. in. (6.8 N·m). a b b a-Platformb-Bolts [Torque to 60 lb. in. (6.8 N·m)] 53172 Page 7A-6 90-827242R1 MAY 1998 THROTTLE/SHIFT LINKAGE (TILLER HANDLE SHIFT MODELS) 7. Adjust shift link rod to a length of 5-1/8 in. (13.0cm) as measured between ball joint centerlines. 8. Connect shift link rod between joints of gear shift lever and shift shaft lever. 53173 aca b a a c a-Shift Link Rod [Adjust to length of 5-1/8 in. (13.0cm)] b-Shift Shaft Lever c-Gear Shift Lever 9. Adjust throttle link rod to a length of 4-7/8 in. (12.4cm) as measured between ball joint centerlines. 10. Connect throttle link rod between ball joints of primary throttle lever and throttle cam. 11. Connect control cables to pulley of secondary gears and anchor bracket as outlined in Section 7C. 53046 addbefa b f d e d c a-Throttle Link Rod [Adjust to length of 4-7/8 in. (12.4cm)] b-Primary Throttle Lever c-Throttle Cam d-Control Cables e-Pulley f-Anchor Bracket 90-827242R1 MAY 1998 Page 7A-7 THROTTLE/SHIFT LINKAGE (TILLER HANDLE SHIFT MODELS) Throttle Cam/Control Lever Removal 1. Refer to Section 7C for removal of throttle cables. 2. Remove bolt and flat washer securing cam/lever to powerhead. 53162 a b c a-Bolt b-Washer c-Cam/Lever Throttle Cam/Control Lever Reassembly 1. Assemble inner spring and outer spring together. 2. Position spring assembly over hub of throttle cam. 53177 53182 a b c cd d e f f a-Inner Spring b-Outer Spring c-Inner Spring Ends d-Outer Spring Ends e-Hub f-Tabs Page 7A-8 90-827242R1 MAY 1998 THROTTLE/SHIFT LINKAGE (TILLER HANDLE SHIFT MODELS) 3. Wind end of inner spring to position tab of cam between inner spring ends. Verify spring windings are firmly held around diameter of cam hub and that no windings are positioned on top of hub. 4. Lubricate bushing with 2-4-C w/Teflon and install bushing and wave washer. 53176 53178 a b c d e a-Inner Spring End b-Tab c-Cam Hub d-Bushing e-Wave Washer 5. Install control lever onto throttle cam assembly so that tab of control lever is positioned between ends of inner spring. 6. Hook longer spring end of outer spring behind peg of control lever. 5318053179 a b c c de a-Control Lever b-Tab c-Ends of Inner Spring d-Longer Spring End e-Peg 90-827242R1 MAY 1998 Page 7A-9 THROTTLE/SHIFT LINKAGE (TILLER HANDLE SHIFT MODELS) Installation 1. Secure throttle cam/control lever assembly onto mounting boss of crankcase cover with bolt. Torque bolt to 70 lb. in. (7.9 N·m). 2. Connect timing link between ball joints of control lever and trigger assembly. 53225 53162 a b cd e f a-Throttle Cam b-Control Lever c-Flat Washer d-Bolt [Torque bolt to 70 lb. in. (7.9 N·m)] e-Timing Link f-Control Lever 3. Adjust throttle link rod to a length of 4-7/8 in. (12.4cm) as measured between ball joint center lines. 4. Connect throttle link rod between ball joints of throttle cam and primary throttle lever. 53046 a b c a-Throttle Link Rod [Adjust to a length of 4-3/8 in. (11.1cm)] b-Throttle Cam c-Primary Throttle Lever Page 7A-10 90-827242R1 MAY 1998 THROTTLE/SHIFT LINKAGE (TILLER HANDLE SHIFT MODELS) THROTTLE CAM/CONTROL LEVER CROSS SECTIONAL VIEW a b c de f g a-Throttle Cam e-Springs b-Control Lever f-Flat Washer c-Bushing g-Bolt [Torque to 70 lb. in. (7.9 N·m)] d-Wave Washer Neutral Interlock Control Lever Reassembly/Installation 1. Lubricate bushing with 2-4-C w/Teflon and install bushing and spring. 2. Secure interlock lever components with bolt onto mounting boss of crankcase cover. 53171 53260 a b c d e f g a-Bushing b-Spring c-Interlock lever d-Spring Ends e-Flat washer f-Bolt [Torque to 70 lb. in. (7.9 N·m)] g-Neutral Interlock Wire (Install in top hole) 90-827242R1 MAY 1998 Page 7A-11 THROTTLE/SHIFT LINKAGE (TILLER HANDLE SHIFT MODELS) Horizontal Shift Shaft Reassembly/Installation 1. Install horizontal shift shaft/shift lever assembly into opening in STARBOARD side of crankcase cover. 2. Apply 2-4-C w/Teflon to detent of yoke and install yoke onto shift shaft. cd53187 aba b c d 53147 a-Horizontal Shift Shaft b-Shift Lever c-Yoke d-Detent 3. Secure detent spring to block with 2 bolts. Spring may have slotted holes. Install spring so that it is raised UP and at end of slot travel. Torque bolts to 25 lb. in. (2.8 N·m). 4. Secure end of shift shaft to yoke of horizontal shift shaft with lever. 53052 cdabfea b c d e f a-Shift Shaft b-Yoke c-Lever d-Apply 2-4-C w/Teflon e-Detent Spring f-Bolts [Torque to 25 lb. in. (2.8 N·m)] 5. Refer to Control Platform/Throttle Cam/Control Lever previous and reinstall platform, shift link and throttle cam. Page 7A-12 90-827242R1 MAY 1998 THROTTLE SHIFT LINKAGE (SIDE SHIFT MODELS) ATTACHMENTS/CONTROL LINKAGE Section 7B – Throttle Shift Linkage (Side Shift Models) Table of Contents Throttle and Shift Linkage (Side Shift) . . . . . . . . 7B-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-6 Throttle Cables (Side Shift Models) . . . . . . . . . . 7B-4 Neutral Interlock Control Lever . . . . . . . . . . . . . . 7B-8 Removal/Installation . . . . . . . . . . . . . . . . . . . . 7B-4 Reassembly/Installation . . . . . . . . . . . . . . . . . 7B-8 Throttle Cam/Control Lever . . . . . . . . . . . . . . . . . 7B-4 Horizontal Shift Shaft . . . . . . . . . . . . . . . . . . . . . . 7B-8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-4 Reassembly/Installation . . . . . . . . . . . . . . . . . 7B-8 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-4 7 B 90-827242R1 MAY 1998 Page 7B-1 THROTTLE SHIFT LINKAGE (SIDE SHIFT MODELS) Throttle and Shift Linkage (Side Shift) 95 2-4-C With Teflon (92-825407A12) 95 95 95 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Page 7B-2 90-827242R1 MAY 1998 THROTTLE SHIFT LINKAGE (SIDE SHIFT MODELS) Throttle and Shift Linkage (Side Shift) REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 CABLE BRACKET 2 2 SCREW 60 6.8 3 1 SCREW 35 4.0 4 1 WASHER 5 1 SHIFT HANDLE 6 1 GROMMET 7 1 SHIFT SHAFT 8 1 LEVER 9 1 LEVER 10 1 SPRING 11 2 SCREW (M5 x 8 x 8) 25 2.8 12 1 TIMING LINK 13 1 CONTROL LEVER 14 1 SCREW (M5 x 8 x 35) 15 1 LOCKWASHER 16 1 SPRING 17 1 SPRING 18 1 ACTUATOR 19 1 BUSHING 20 1 WASHER 21 1 SCREW 70 7.9 22 1 LINK 23 1 LEVER 24 1 SPRING 25 1 SCREW 70 7.9 26 1 WASHER 27 1 BUSHING 90-827242R1 MAY 1998 Page 7B-3 THROTTLE SHIFT LINKAGE (SIDE SHIFT MODELS) Throttle Cables (Side Shift Models) Removal/Installation Refer to Section 7C for removal and installation instructions Throttle Cam/Control Lever Removal 1. Refer to Section 7C for removal of throttle cables. 2. Remove bolt and flat washer securing cam/lever to powerhead. 53185 a b c d a-Throttle Cam b-Control Lever c-Flat Washer d-Bolt [Torque bolt to 70 lb. in. (7.9 N·m)] Reassembly 1. Assemble inner spring and outer spring together. 53182 a b a-Inner Spring b-Outer Spring Page 7B-4 90-827242R1 MAY 1998 THROTTLE SHIFT LINKAGE (SIDE SHIFT MODELS) 2. Position spring assembly over hub of throttle cam. 3. Wind end of inner spring to position tab of cam between inner spring ends. Verify spring windings are firmly held around diameter of cam hub and that no windings are positioned on top of hub. 53178 53177 d a b c ab d d e f g a-Inner Spring Ends b-Outer Spring Ends c-Hub d-Tabs e-Inner Spring End f-Tab g-Cam Hub 4. Lubricate bushing with 2-4-C w/Teflon and install bushing and wave washer. 5. Install control lever onto throttle cam assembly so that tab of control lever is positioned between ends of inner spring. 5317953176 a b c de e a-Bushing b-Wave Washer c-Control Lever d-Tab e-Ends of Inner Spring 90-827242R1 MAY 1998 Page 7B-5 THROTTLE SHIFT LINKAGE (SIDE SHIFT MODELS) 6. Hook longer spring end of outer spring behind peg of control lever. 53180 a b a-Longer Spring End b-Peg Installation 1. Secure throttle cam/control lever assembly onto mounting boss of crankcase cover with bolt. Torque bolt to 70 lb. in. (7.9 N·m). 2. Connect timing link between ball joints of control lever and trigger assembly. 53185 a b c d 53225 e f a-Throttle Cam b-Control Lever c-Flat Washer d-Bolt [Torque bolt to 70 lb. in. (7.9 N·m)] e-Timing Link f-Control Lever Page 7B-6 90-827242R1 MAY 1998 THROTTLE SHIFT LINKAGE (SIDE SHIFT MODELS) 3. Connect throttle cables to throttle cam and throttle cable anchor bracket as outlined in “Throttle Cable” – “Installation”, preceding. 53189 a bc a-Throttle Cables b-Throttle Cam c-Bracket THROTTLE CAM/CONTROL LEVER CROSS SECTIONAL VIEW a b c de f g a-Throttle Cam b-Control Lever c-Bushing d-Wave Washer e-Springs f-Flat Washer g-Bolt [Torque to 70 lb. in. (7.9 N·m)] 90-827242R1 MAY 1998 Page 7B-7 THROTTLE SHIFT LINKAGE (SIDE SHIFT MODELS) Neutral Interlock Control Lever Reassembly/Installation 1. Lubricate bushing with 2-4-C w/Teflon and install bushing and spring. a-Bushing b-Spring 2. Secure interlock lever components with bolt onto mounting boss of crankcase cover. 53171 53260 a b c d e f g c-Interlock lever d-Spring Ends e-Flat washer f-Bolt [Torque to 70 lb. in. (7.9 N·m)] g-Neutral Interlock Wire (Install in top hole) Horizontal Shift Shaft Reassembly/Installation 1. Install horizontal shift shaft/shift lever assembly into opening in STARBOARD side of crankcase cover. 2. Apply 2-4-C w/Teflon to detent of yoke and install yoke onto shift shaft. 53187 a b c d a-Horizontal Shift Shaft b-Shift Lever c-Yoke d-Detent Page 7B-8 90-827242R1 MAY 1998 THROTTLE SHIFT LINKAGE (SIDE SHIFT MODELS) 3. Install rubber grommet into opening in starboard side of bottom cowl. 4. Secure shift handle onto end of horizontal shift shaft with screw and flat washer. Torque screw to 35 lb. in. (4.0 N·m). a b c d 53181 a-Grommet b-Shift Handle c-Screw d-Washer 5. Secure detent spring to block with 2 bolts. Spring may have slotted holes. Install spring so that it is raised UP and at end of slot travel. Torque bolts to 25 lb. in. (2.8 N·m). 6. Secure end of shift shaft to yoke of horizontal shift shaft with coupler. 53052 a b c d e f a-Shift Shaft b-Yoke c-Coupler d-Apply 2-4-C w/Teflon e-Detent Spring f-Bolts [Torque to 25 lb. in. (2.8 N·m)] 90-827242R1 MAY 1998 Page 7B-9 TILLER HANDLE ATTACHMENTS/ CONTROL LINKAGE Section 7C – Tiller Handle Table of Contents Swivel Head and Steering Handle . . . . . . . . . . . 7C-2 Control Cables (Tiller Handle Shift Models) . . . 7C-4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-4 Throttle Cables (Side Shift Models) . . . . . . . . . . 7C-5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-5 Tiller Handle Removal/Disassembly . . . . . . . . . 7C-6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-6 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-7 Control Cables (Tiller Handle Shift Models) . . . 7C-9 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-9 Throttle Cable (Side Shift Models) . . . . . . . . . . 7C-11 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-11 7 C 90-827242R1 MAY 1998 Page 7C-1 TILLER HANDLE Swivel Head and Steering Handle 1012162395 95 95 95 95 95 2-4-C With Teflon (92-825407A12) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 2 6 Page 7C-2 90-827242R1 MAY 1998 TILLER HANDLE Swivel Head and Steering Handle REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 SWIVEL HEAD (BLACK) 2 2 BUSHING 3 1 PLATE 4 1 GREASE FITTING 5 2 SCREW (M5 x 1 x 16) 70 7.9 6 2 WASHER 7 1 WAVE WASHER 8 1 WASHER 9 1 STEERING HANDLE ARM (BLACK) 10 1 RETAINER 11 1 SCREW (M5 x .8 x 16) 35 4.0 12 1 COVER KIT 13 1 PULLEY 14 1 PULLEY CASE 15 1 SCREW (10-16 x 1/2) 20 2.3 16 2 THROTTLE CABLE 17 1 SLEEVE 18 1 DECAL 19 1 GRIP 20 1 STOP SWITCH 21 1 THROTTLE FRICTION KNOB Finger Tight 22 1 THROTTLE FRICTION LOCK As Required 23 1 SCREW (M6 x 1 x 25) 24 1 THROTTLE HANDLE 25 1 TILLER TUBE 26 1 SPRING 27 1 START/STOP SWITCH HOUSING ELECTRIC HANDLE CLIP 28 1 29 1 90-827242R1 MAY 1998 Page 7C-3 TILLER HANDLE Control Cables (Tiller Handle Shift Models) Removal 1. Place tiller handle twist grip in NEUTRAL position 2. Remove throttle link rod from throttle cam and primary throttle lever. 53046 a b c a-Link Rod b-Throttle Cam c-Primary Throttle Lever 3. Loosen jam nuts which secure control cables to anchor bracket. 4. Unwrap and remove control cables from pulley of secondary gear. NOTE:If not replacing control cables, mark top cable with a piece of tape to aid in reassembly. 5. Disconnect stop button wires – BLACK/YELLOW and BLACK. 53162 a a b d c a-Jam Nuts b-Secondary Gear c-BLACK/YELLOW d-BLACK Page 7C-4 90-827242R1 MAY 1998 TILLER HANDLE Throttle Cables (Side Shift Models) Removal 1. Loosen jam nuts which secure throttle cables to anchor bracket and remove cables from pulley of throttle cam. NOTE:If not replacing throttle cables, mark top cable with a piece of tape to aid in reassembly. 53186 c ab c a d a-Jam Nuts b-Throttle Cables c-Anchor Bracket d-Throttle Cam 2. Disconnect stop button wires – BLACK/YELLOW and BLACK. 53156 a b a-BLACK/YELLOW b-BLACK 90-827242R1 MAY 1998 Page 7C-5 TILLER HANDLE Tiller Handle Removal/Disassembly Removal 1. Remove 2 bolts securing tiller handle to anchor bracket and remove tiller handle assembly. 53155 a a-Bolts 2. Remove bushing, flatwashers (2). wave washer and tiller handle washer. Remove retainer and bolt. 3. Slide tiller tube out of pulley case. a b c b d e f g h 53256 53248 a-Bushing b-Flat Washer (2) c-Wave Washer d-Tiller Handle Washer e-Retainer f-Bolt g-Tiller Tube h-Pulley Case Page 7C-6 90-827242R1 MAY 1998 TILLER HANDLE 4. Remove pulley case assembly from tiller handle and remove cover bolt. 5. Remove cover and lift pulley assembly from case. Replace cables as required. 5325753262 a b c d a-Pulley Case Assembly b-Cover Bolt c-Cover d-Pulley Assembly Installation 1. Wrap cables around pulley. Top cable wraps and locks in top groove. Bottom cable wraps and locks in bottom groove. 2. Place pulley and cable assembly into pulley case. 3. Install pulley cover and secure cover with bolt. Torque bolt to 20 lb. in. (2.3 N·m). 5326253257 a b c d e a-Pulley b-Top Cable c-Bottom Cable d-Cover e-Bolt [Torque to 20 lb. in. (2.3 N·m)] 4. Install pulley assembly into tiller handle and slide tiller tube into pulley. a b a-Pulley Assembly b-Tiller Tube 53256 90-827242R1 MAY 1998 Page 7C-7 TILLER HANDLE 5. Secure tiller tube in handle with retainer and bolt. Torque bolt to 35 lb. in. (4.0 N·m). 6. Install tiller washer (tab aligns with slot in handle), plain washer, wave washer, plain washer and flanged bushing over cable/harness assembly. 53248 a-Retainer e-Slot b-Bolt [Torque to 35 lb. in. (4.0 N·m)] f-Plain Washer c-Tiller washer g-Wave Washer d-Tab h-Flanged Bushing 7. Slide tiller handle assembly into anchor bracket. d e h f g f c a b 8. Route stop button harness through fuel connector opening in bottom cowl. 9. Route control cables through opening in bottom cowl. 10. Align tabs of inner and outer flanged bushings with slots in anchor bracket. 11. Pull on cable ends to remove slack and secure tiller handle to anchor bracket with plate and 2 bolts. Torque bolts to 70 lb. in. (7.9 N·m). 5315553169 a b c d e a-Stop Button Harness b-Control Cables c-Tabs d-Plate e-Bolts [Torque to 70 lb. in. (7.9 N·m)] Page 7C-8 90-827242R1 MAY 1998 TILLER HANDLE Control Cables (Tiller Handle Shift Models) Installation 1. Rotate tiller handle twist grip to REVERSE gear position. 2. Route extended cable over top of secondary gear pulley and secure cable into inner groove of pulley. Place cable jacket into inner notch of cable anchor bracket. 53164 a b c d a-Extended Cable b-Inner Groove c-Cable Jacket d-Inner Notch 3. Rotate tiller handle to FORWARD gear position. 4. Route remaining cable below secondary gear pulley and secure cable into outer groove of pulley. Place cable jacket into lower notch of cable anchor bracket. 53165 a b cd a-Cable b-Outer Groove c-Cable Jacket d-Lower Notch 90-827242R1 MAY 1998 Page 7C-9 TILLER HANDLE 5. Position tab washers to lock control cables to holes of cable anchor bracket. a b ba a-Tab Washers b-Hole 6. Rotate tiller handle twist grip to NEUTRAL. 7. Adjust jam nuts to remove slack from control cables while allowing full travel of throttle/ shift linkage. a a b b 53165 a-Jam Nuts b-Cables 8. After cables are adjusted, verify FORWARD, NEUTRAL and REVERSE gears can be selected while smoothly advancing and retarding throttle. If throttle/shift operation is not correct, inspect for pinched or kinked cables, misaligned linkage or loose attaching bolts. NOTE:It may be necessary to rotate propeller shaft in order to select REVERSE gear. Page 7C-10 90-827242R1 MAY 1998 TILLER HANDLE Throttle Cable (Side Shift Models) Installation 1. Rotate tiller handle twist grip to FAST position. 2. Place gear shift lever into FORWARD gear. 3. Secure extended cable into groove in top side of throttle cam pulley. Place cable jacket into upper notch of cable anchor bracket. 53190 a bc d a-Extended Cable b-Pulley c-Cable Jacket d-Notch 4. Rotate tiller handle twist grip to SLOW position. 5. Secure remaining cable into groove in bottom side of pulley. Place cable jacket into lower notch of anchor bracket. 6. Secure throttle cables into notches of cable anchor bracket. 7. Rotate tiller handle twist grip to SLOW position. 8. Adjust jam nuts to remove slack from throttle cables while allowing full travel of throttle linkage/carburetor throttle shutter. a b c d e e a-Cable b-Pulley c-Cable Jacket d-Notch e-Jam Nuts 53186 53186 90-827242R1 MAY 1998 Page 7C-11 MANUAL STARTER MANUAL STARTER Section 8 Table of Contents Manual Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Starter Rope Replacement . . . . . . . . . . . . . . . . . . 8-6 Rewind Starter Assembly . . . . . . . . . . . . . . . . . . . . 8-4 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . 8-9 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 8 90-827242R1 MAY 1998 Page 8-1 MANUAL STARTER Manual Starter 95 95 95 95 952-4-C With Teflon (92-825407A12) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 15 Page 8-2 90-827242R1 MAY 1998 MANUAL STARTER Manual Starter REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m – 1 RECOIL STARTER ASSEMBLY 1 1 STARTER HOUSING 2 1 BUSHING 3 1 RETAINING RING 4 1 SPRING 5 1 STARTER PULLEY 6 1 ROPE–starter 7 2 SPRING 8 2 CAM 9 2 RETAINING RING 10 1 SPRING 11 1 CAM 12 1 SCREW 135 11.5 15.3 13 1 FELT PAD 14 1 REST 15 4 SPACER–rest screw 16 1 SUPPORT 17 2 SCREW–rest to starter housing (M5 x 35) 18 2 NUT–rest screw 30 3.4 19 1 LEVER–lock (UPPER) 20 1 WASHER–upper lock lever 21 1 LEVER–lock (LOWER) 22 1 SCREW–lower lock lever (10-16 x 1/2) 30 3.4 23 3 SCREW–starter housing attaching (M6 x 20) 70 7.9 24 1 HANDLE ASSEMBLY 25 1 RETAINER 26 1 DECAL-Servicing Referral 27 1 DECAL-Warning-High Voltage 28 1 DECAL-Emergency Starting Procedure 90-827242R1 MAY 1998 Page 8-3 MANUAL STARTER Rewind Starter Assembly Removal CAUTION DO NOT turn or cock fuel filter assembly when removing. Remove fuel filter by pulling straight down. Turning or cocking fuel filter may break fuel line connection on filter. 1. Pry fuel filter from starter rope guide. DO NOT turn or cock filter; pull straight down. 2. Unsnap interlock link rod from lower lock lever. 5323453246 a b c d a-Filter b-Guide c-Link Rod d-Lock Lever 3. Remove 3 bolts and lift rewind starter from engine. 53242 a a a b a-Bolts b-Rewind Starter Page 8-4 90-827242R1 MAY 1998 MANUAL STARTER Installation 1. Secure rewind starter to engine with 3 bolts. Torque bolts to 70 lb. in. (7.9 N·m). 2. Snap interlock link rod into lower lock lever. 53234 53242 a a a b c d a-Bolts [Torque to 70 lb. in. (7.9 N·m)] b-Rewind Starter c-Link Rod d-Lock lever CAUTION Push filter straight up when installing. Turning or cocking filter may break fuel line connection on filter. 3. Push ball of fuel filter into socket of rope guide. DO NOT turn or cock fuel filter. 53247 aab a-Filter b-Guide 90-827242R1 MAY 1998 Page 8-5 MANUAL STARTER Starter Rope Replacement 1. Remove rewind starter from engine, as outlined previously. NOTE:If starter is broken, remove all remaining rope from sheave. 2. Disengage starter interlock from starter sheave. 3. Pull starter rope handle out from rewind starter about 1 ft. (30.5cm) and tie a knot at this point to prevent rope from being pulled back into rewind starter. 4. Remove rope retainer from starter handle and rope. 53233 53223 a b c a-Interlock b-Starter Handle c-Retainer 5. Install starter handle on new rope [cut to a length of 62 in. (157.5cm)]. Tie a knot into end of rope. Place knot into recess of rope retainer. Install rope retainer into starter handle. CAUTION Starter sheave must be firmly held against spring tension to prevent spring from unwinding. 6. Pull starter rope from rewind starter until rope is fully unwound from starter sheave. 53221 53233 a b c de a-Handle b-Knot c-Retainer d-Rope e-Sheave Page 8-6 90-827242R1 MAY 1998 MANUAL STARTER 7. While holding sheave in this position, lift knot from recess and pull all remaining rope from sheave. 8. Turn sheave COUNTERCLOCKWISE until stop, indicating spring is wound tight. 9. Slowly turn sheave CLOCKWISE (with spring tension) until knot recess is aligned with rope hole in starter housing. 53218 53245 a b c d e f a-Sheave b-Knot c-Recess d-Sheave e-Knot Recess f-Rope Hole 10. Push end of new rope through rope holes in starter housing and starter sheave. Pull end of rope out of knot recess. 11. Tie a knot into end of rope and pull knot back into knot recess. 5321953222 a b c d e a-Rope b-Holes c-Knot Recess d-Knot e-Knot Recess 12. Allow starter rope to be slowly rewound onto starter sheave. 90-827242R1 MAY 1998 Page 8-7 MANUAL STARTER Disassembly WARNING When disassembling rewind starter, SAFETY GLASSES MUST BE WORN in case spring should uncoil out of housing. 1. Remove starter rope as outlined previously. 2. With rope removed, allow sheave to slowly unwind to release spring tension. 3. Remove bolt securing cam and sheave to housing. 52220 a b a-Bolt b-Sheave 4. Gently lift starter sheave from housing. 5. Rewind spring assembly may be replaced as required. DO NOT remove spring from retainer. Spring and retainer are replaced as an assembly. 53241 a b a-Sheave b-Rewind Spring Page 8-8 90-827242R1 MAY 1998 MANUAL STARTER Cleaning and Inspection 1. Clean rewind spring assembly with solvent and dry with compressed air. 2. Inspect rewind spring (without removing spring from retainer) for kinks, burrs or breakage. Replace assembly if necessary. 3. Inspect cam tension spring for damage. Replace as necessary. 4. Inspect starter sheave and housing for nicks, grooves, cracks and distortion especially in area of rope travel. Replace assembly if necessary. 5. Inspect starter rope for wear and replace if necessary. Reassembly 1. Apply 2-4-C w/Teflon (92-825407A12) to rewind spring and cam tension spring. 2. Install rewind spring assembly into recoil housing positioning end of spring in notch. 53160 53161 a bc a-Rewind Spring b-Notch c-Cam Tension Spring 3. Install starter sheave into housing aligning notches in sheave with appropriate locations on recoil spring retainer. 53241 a b c c c a-Sheave b-Retainer c-Alignment Notches 90-827242R1 MAY 1998 Page 8-9 MANUAL STARTER NOTE: If sheave will not seat fully over recoil spring assembly, inspect spring retainer, through lock lever access hole in housing, for proper alignment with sheave. 53217 a b c a-Spring Retainer b-Lock Lever Access Hole c-Sheave 4. Secure cam to housing with bolt. Torque bolt to 70 lb. in. (7.9 N·m). 52220a b a-Cam b-Bolt NOTE: If, after tightening cam retaining bolt, sheave does not move freely, sheave is not aligned properly with recoil spring retainer. Remove cam retainer bolt and check alignment of sheave with spring retainer. 5. Install starter rope as outlined previously. 6. Install rewind starter as outlined previously. Page 8-10 90-827242R1 MAY 1998