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75/90 FourStroke Starting Model Year 2000 Starting Serial Number 0G960500 Starting Model Year 2000 Starting S/N 0G960500 75/90 FourStroke 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. 90-858895R1 JANUARY 2001 Page i It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Mismatched or incorrect fasteners can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the same locations whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original. Cleanliness and Care of Outboard Motor A marine power product is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten thousands of an inch/mm. When any product component is serviced, care and cleanliness are important. Throughout this manual, it should be understood that proper cleaning, and protection of machined surfaces and friction areas is a part of the repair procedure. This is considered standard shop practice even if not specifically stated. Whenever components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed. Personnel should not work on or under an outboard which is suspended. Outboards should be attached to work stands, or lowered to ground as soon as possible. We reserve the right to make changes to this manual without prior notification. Refer to dealer service bulletins for other pertinent information concerning the products described in this manual. EXAMPLE: 90-826148R1 JANUARY 1996 Page 6A-7 Revision No. 1 Month of Printing Year of Printing Section Number Part of Section Letter Page Number Page ii 90-858895R1 JANUARY 2001 Service Manual Outline Section 1 - Important Information A - Specifications B - Maintenance C - General Information D - Outboard Motor Installation Section 2 - Electrical A - Ignition B - Charging & Starting System C - Timing, Synchronizing & Adjusting D - Wiring Diagrams Section 3 - Fuel System A - Fuel Pump B - Carburetor C - Emissions Section 4 - Powerhead A - Cylinder Head B - Cylinder Block/Crankcase C - Lubrication Section 5 - Mid-Section A - Clamp/Swivel Brackets & Drive Shaft Housing B - Power Trim Section 6 - Lower Unit A - Gear Housing Section 7 - Attachments/Control Linkage A - Throttle/Shift Linkage Section 8 - Color Diagrams Important Information Electrical Fuel System Powerhead Mid-Section Lower Unit Attachments/ Control Linkage Color Diagrams 90-858895R1 JANUARY 2001 Page iii SPECIFICATIONS IMPORTANT INFORMATION Section 1A - Specifications Table of Contents 1 A Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1 Propeller Information Charts . . . . . . . . . . . . . . . 1A-10 Specifications Models 75/90 (4-Stroke) Horsepower: Model 75 75 hp (55.9 Kw) @ 5000 rpm PERFORMANCE Model 90 Wide Open Throttle (WOT) RPM Range: 90 hp (67.1 Kw) @ 5500 rpm Model 75 4500 - 5500 Model 90 5000 - 6000 OUTBOARD WEIGHT Electric 75/90 ELPT 386 lb (175.1 kg) FUEL Recommended Gasoline Automotive Unleaded with a Minimum Pump Posted Octane Rating of 87 Oil Filter Oil Filter Wrench Engine Oil Capacity Engine Oil F° C° SAE 10W-30 SAE 25W-40 p/n 35-822626A2 p/n 91-802653 Either 5 Quarts or 5 Liters SAE 10W-30 viscosity oil is recommended for use in all temperatures. SAE 25W-40 viscosity oil may be used at temperatures above 40° F (4° C). OIL +20 +40 +60 +80 0 +100 –7 +4 +16 +27 –18 +38Use Quicksilver 4-Cycle Marine Oil with the proper viscosity for the expected temperature in your area (see range thermometer on left). If not available, use a premium quality 4-cycle engine oil certified to meet or exceed any one of the following American Petroleum Institute (API) service classifications SH, SG, SF, CF-4, CE, CD, CDll. 90-858895R1 JANUARY 2001 Page 1A-1 SPECIFICATIONS IGNITION SYSTEM Readings taken @ 68°F (20°C). Type Spark Plug: Type Gap Hex Size Torque Firing Order Ignition Timing: @ Idle (850 rpm) @ WOT (6000 rpm) Stator Output - Peak Voltage: @ 400 rpm (Cranking) @ 1500 rpm @ 3500 rpm Stator Coil Resistance Crank Position Sensor Output - Peak Voltage: (WHT/BLK - BLK) for Cylinders 1 & 4 (WHT/RED - BLK) for Cylinders 2 & 3 @ 400 rpm (Cranking) @ 1500 rpm @ 3500 rpm Crank Position Sensor Resistance (WHT/BLK - BLK) for Cylinders 1 & 4 (WHT/RED - BLK) for Cylinders 2 & 3 CDI Unit Output - Peak Voltage: (BLK/ORG - BLK) for Cylinders 1 & 4 (BLK/WHT - BLK) for Cylinders 2 & 3 @ 400 rpm (Cranking) @ 1500 rpm @ 3500 rpm Ignition Coil Resistance: Primary Secondary (Without Boots) High Tension Lead Resistance: Cylinder #1 Cylinder #2 Cylinder #3 Cylinder #4 Engine Protection Controls: Engine Speed Limiter Spark Cut-Out to Cylinders #1 or #4 #1 and #4 #1, #4, and #2 or #3 #1, #2, #3, and #4 Overheat/Low Oil Pressure Engine Speed Control (Spark Cut-Out to Cylinders #1 and #4) Water Temperature Sensor: 2000 Engine S/N OT178499 and Below Warning Horn/rpm Reduction Reset Temperature (Throttle Closed/Key off) 2001 Engine S/N OT178500 and Above Warning Horn/rpm Reduction Reset Temperature (Throttle Closed/Key Off) Microcomputer-Controlled CDI NGK LFR5A-11 0.043 in. (1.1 mm) 5/8 in. (16 mm) 18 lb-ft (25 Nm) 1-3-4-2 5° A.T.D.C 18° B.T.D.C 6 - 9 V (WHT – WHT) 12 - 18 V (WHT - WHT) 14 - 25 V (WHT - WHT) 0.32 - 0.48 W (WHT - WHT) 2.8 - 3.4 V 6.5 - 7.8 V 10.5 - 12.0 V 445 - 545 W 445 - 545 W 165 - 190 V 175 - 200 V 175 - 200 V 0.078 - 0.106 W (BLK - BLK/WHT) 3.5 - 4.7 kW (Between Towers) 4.5 - 10.7 kW 3.3 - 8.0 kW 3.7 - 8.9 kW 4.3 - 10.2 kW 6200 rpm 6250 rpm 6300 rpm 6350 rpm Gradually Lowers to 3000 rpm 140°F (60°C) 118°F (48°C) 194°F (90°F) 167°F (75°C) Page 1A-2 90-858895R1 JANUARY 2001 SPECIFICATIONS 2000 Engine Oil Pressure Switch: S/N OT178499 and BelowStamped P.15 Warning Horn/rpm Reduction Continuity Below 2.2 psi (15 kPa) Reset Pressure ECM [email protected] Closed Throttle/Key Off 2001 Engine Oil Pressure Switch: No Continuity Above 2.2 psi (15 kPa) S/N OT178500 and AboveStamped 1.5 IGNITION SYSTEM Readings taken @ 68°F (20°C). Warning Horn/rpm Reduction Reset Pressure ECM [email protected] Closed Throttle/Key Off Engine Water Temperature Sensor Resistance: Continuity Below 21.78 psi (150 kPa) No Continuity Above 21.78 psi (150 kPa) @ -4°F (-20°C) 15.5 kW @ 32°F (0°C) 5.79 kW @ 68°F (20°C) 2.45 kW @ 104°F (40°C) Throttle Position Sensor (TPS): 1.50 kW Input Voltage @ Idle (850 rpm) 5.0 ± 0.25 V (RED - ORG) Output [email protected] Idle (850 rpm) 0.68 - 0.82 V (PNK - ORG) CHARGING SYSTEM Readings taken @ 68°F (20°C). Alternator Type: Alternator Output Stator Coil Output - Peak Voltage: @ 400 rpm (Cranking) @ 1500 rpm @ 3500 rpm Stator Coil Resistance Rectifier/Regulator Output - Peak Voltage: @ 1000 rpm @ 1500 rpm @ 3500 rpm @ 6000 rpm Quicksilver Tachometer Setting Three Phase Stator Coil (12 Pole) 12.0 V; 20 Amps. (240 Watts) (Rectified/Regulated) 6 - 9 V (WHT – WHT) 12 - 18 V (WHT - WHT) 14 - 25 V (WHT - WHT) 0.32 - 0.48 W (WHT - WHT) 18 - 22 V (RED - BLK) 19 - 24 V (RED - BLK) 19 - 24 V (RED - BLK) 19 - 24 V (RED - BLK) “6P” or “4” STARTING SYSTEM Electric Start: Starter Type Model/Manufacturer Weight Output Rating Reduction Gear Ratio Brush: Length Minimum Length Commutator: Diameter Minimum Diameter Undercut Undercut Limit Ampere Draw Under: (Load) (No Load) Sliding Gear S114-828/Hitachi 7 lb, 11 oz (3.5 kg) 1.4 kW - 12 V 30 Seconds 7.85 (102:13) 0.610 in. (15.5 mm) 0.374 in. (9.5 mm) 1.113 in. (29.0 mm) 1.100 in. (28.0 mm) 0.020 in. (0.5 mm) 0.008 in. (0.2 mm) 165 Amps 80 Amps 90-858895R1 JANUARY 2001 Page 1A-3 SPECIFICATIONS Battery Rating Minimum Requirement 465 Marine Cranking Amps (MCA) BATTERY For operation below 32° F (0° C) or 350 Cold Cranking Amps (CCA) 1000 Marine Cranking Amps (MCA) or 775 Cold Cranking Amps (CCA) Ampere-Hours (Ah) 70 - 100 ENRICHMENT Auto Enrichener Resistance 15 - 25 Ohms (BLU - BLK) CONTROL SYSTEM Readings taken @ 68°F (20°C). FUEL SYSTEM Fuel Pump Type Fuel Pump: Discharge (@ 3000 rpm) Pressure (Maximum) Plunger Stroke Fuel Tank Capacity External (Plunger/Diaphragm) 17 gph (65 L/h) 7 psi (49 kPa) 0.23 - 0.36 in. (5.85 - 9.05 mm) Accessory CARBURETOR Number of Carburetors ID Mark 75 90 Venturi Size 75 90 Idle rpm (Neutral) Warm Engine Idle rpm (Forward Gear) Warm Engine Wide Open Throttle rpm (WOT) Range: Model 75 Model 90 Main Jet 75 90 Main Air Jet 75 90 Pilot Jet 75 90 Pilot Air Jet 75 90 Mid Range Jet 75 90 Pilot Screw 75 90 Float Height 4 67G 67F 0.945 in. (24 mm) 1.181 in. (30 mm) 850 ± 25 rpm 775 - 800 rpm 4500-5500 5000–6000 #112 #128 #115 #75 #45 #42 #85 #85 None #40 2-1/2 ± 1/2 2 ± 1/2 0.51 - 0.59 in. (13.0-15.0 mm) CYLINDER BLOCK Type Displacement Number of Cylinders In–Line, 4 Stroke – DOHC, 16 Valves 97.4 cid (1,596 cc) 4 Page 1A-4 90-858895R1 JANUARY 2001 SPECIFICATIONS STROKE Length 3.205 in. (81.4 mm) CYLINDER BORE Diameter Standard Oversize-0.010 in. (0.25 mm) Taper/Out of Round Maximum Bore Type 3.110 - 3.111 in. (79.000 - 79.020 mm) 3.120 - 3.121 in. (79.250 - 79.270 mm) 0.003 in. (0.08 mm) Cast Iron PISTON Piston Type Measure Point (H) O.D. at Skirt (H) Standard (D) Oversize-0.010 in. (0.25 mm) Pin Boss Inside Diameter Aluminum 0.51 in. (13 mm) 3.1073 - 3.1082 in. (78.928 - 78.949 mm) 3.1174 - 3.1182 in. (79.178 - 79.199 mm) 0.7090 - 0.7093 in. (18.008 - 18.015 mm) H D PISTON CLEARANCE Piston to Cylinder Clearance 0.0028 - .0031 in. (0.070 - 0.080 mm) Top Ring Dimension “B” B 0.046 - 0.047 in. (1.17 - 1.19 mm) Dimension “T” 0.114 - 0.115 in. (2.89 - 2.91 mm) End Gap (Installed) Side Clearance T 0.006 - 0.012 in. (0.15 - 0.30 mm) 0.001 - 0.003 in. (0.02 - 0.08 mm) Middle Ring Dimension “B” 0.058 - 0.059 in. (1.47 - 1.49 mm) RINGS Dimension “T” End Gap (Installed) B 0.118 - 0.126 in. (3.00 - 3.20 mm) 0.028 - 0.035 in. (0.70 - 0.90 mm) Side Clearance Bottom (Oil Ring) T 0.001 - 0.003 in. (0.03 - 0.07 mm) Dimension “B” 0.094 - 0.098 in. (2.38 - 2.48 mm) Dimension “T” 0.094 in. (2.40 mm) End Gap (Installed) Side Clearance B 0.008 - 0.028 in. (0.20 - 0.70 mm) 0.001 - 0.006 in. (0.03 - 0.15 mm) T COMPRESSION RATIO Compression Ratio Cylinder Compression (Minimum) 9.6:1 138 psi (950 kPa) PISTON PIN Piston Pin Outside Diameter 0.7083 - 0.7087 in. (17.997 - 18.000 mm) Small End Inside Diameter 0.7073 - 0.7081 in. (17.965 - 17.985 mm) Big End Inside Diameter 1.8514 - 1.8518 in. (47.025 - 47.035 mm) CONNECTING Oil Clearance (Big End) Big End Bearing Thickness 0.0009 - 0.0014 in. (0.023 - 0.035 mm) ROD Yellow 0.0590 - 0.0593 in. (1.499 -1.506 mm) Green 0.0593 - 0.0596 in. (1.506 - 1.513 mm) Blue 0.0596 - 0.0598 in. (1.513 - 1.520 mm) Red 0.0598 - 0.0601 in. (1.520 - 1.527 mm) 90-858895R1 JANUARY 2001 Page 1A-5 SPECIFICATIONS Crankshaft Journal Diameter 1.8892 - 1.8898 in. (47.985 - 48.000 mm) Minimum Diameter Crankshaft Pin 1.8887 in. (47.972 mm) Diameter 1.7316 - 1.7323 in. (43.982 - 44.000 mm) CRANKSHAFT Minimum Diameter 1.7311 in. (43.971 mm) Crankshaft Run-out 0.001 in. (0.03 mm) Crankcase Main Journal Inside Diameter 2.1269 - 2.1276 in. (54.023 - 54.042 mm) Crankshaft Journal Oil Clearance Upper Crankcase Main Journal Bearing Thickness 0.0009 - 0.0017 in. (0.024 - 0.044 mm) Green 0.1178 - 0.1181 in. (2.992 - 2.999 mm) Blue 0.1181 - 0.1183 in. (2.999 - 3.006 mm) CRANKCASE Red Lower Crankcase Main Journal Bearing Thickness 0.1183 - 0.1186 in. (3.006 - 3.013 mm) Yellow 0.1185 -0.1188 in. (3.010 - 3.017 mm) Green 0.1188 - 0.1191 in. (3.017- 3.024 mm) Blue 0.1191 - 0.1193 in. (3.024 - 3.031 mm) Red No. 3 Main Journal Bearing Thickness 0.1193 - 0.1196 in. (3.031 - 3.038 mm) Green 0.1178 - 0.1181 in. (2.992 - 2.999 mm) Blue 0.1181 - 0.1183 in. (2.999 - 3.006 mm) Red 0.1183 - 0.1186 in. (3.006 - 3.013 mm) Page 1A-6 90-858895R1 JANUARY 2001 SPECIFICATIONS Camshaft Dimensions Intake “A” 1.465 - 1.472 in. (37.22 - 37.38 mm) Exhaust “A” 1.453 - 1.459 in. (36.90 - 37.06 mm) Intake “B” A 1.178 - 1.184 in. (29.92 - 30.08 mm) Exhaust “B” Valve Lift 1.178 - 1.184 in. (29.92 - 30.08 mm) Intake 0.273 in. (6.94 mm) CAMSHAFT Exhaust Run-out Limit B 0.259 in. (6.58 mm) 0.0039 in. (0.1 mm) Camshaft Bearing Diameter “a” 0.9827 - 0.9835 in. (24.96 - 24.98 mm) Camshaft Bearing Oil Clearance 0.0008-0.0024 in.(0.020-0.061 mm) A Free Length “a” 2.094 in. (53.20 mm) Minimum Free Length 2.057 in. (52.25 mm) VALVE SPRING Tilt Limit “b” a b Less than 0.10 in. (2.6 mm) Warp Limit 0.004 in. (0.1 mm) CYLINDER HEAD Camshaft Bearing Inside Diameter a 0.984 - 0.985 in. (25.000 - 25.021 mm) Valve Lifter Bore Inside Diameter 1.102 - 1.103 in. (28.000 - 28.021 mm) 90-858895R1 JANUARY 2001 Page 1A-7 SPECIFICATIONS Valve/Valve Seat/Valve Guides: Valve Clearance (cold) Intake 0.007 - 0.009 in. (0.17 - 0.23 mm) Exhaust Valve Face Angle 0.011 - 0.014 in. (0.31 - 0.34 mm) Intake 120°, 91°, 110° Exhaust Valve Dimensions: “A” Head Diameter 140°, 91°, 110° Intake 1.142 - 1.150 in. (29.0 - 29.2 mm) Exhaust “B” Face Width 0.945 - 0.953 in. (24.0 - 24.20 mm) Intake 0.079 - 0.096 in. (2.00 - 2.43 mm) Exhaust “C” Seat Width 0.090 - 0.107 in. (2.28 - 2.71 mm) Intake 0.014 - 0.022 in. (0.35 - 0.55 mm) VALVES Exhaust “D” Margin Thickness 0.014 - 0.022 in. (0.35 - 0.55 mm) Intake 0.018 - 0.026 in. (0.45 - 0.65 mm) Exhaust Stem Outside Diameter 0.026 - 0.033 in. (0.65 - 0.85 mm) Intake 0.2352 - 0.2358 in. (5.975 - 5.990 mm) Exhaust Guide Inside Diameter 0.2346 - 0.2352 in. (5.960 - 5.975 mm) Intake 0.2364 - 0.2369 in. (6.005 - 6.018 mm) Exhaust Stem To Guide Clearance 0.2364 - 0.2369 in. (6.005 - 6.018 mm) Intake 0.0006 - 0.0017 in. (0.015 - 0.043 mm) Exhaust 0.0012 - 0.0023 in. (0.030 - 0.058 mm) Stem Run-out Limit (max.) 0.001 in. (0.03 mm) “A” “B” “C” “D” Valve Dimensions Head Diameter Face Width Seat Width Margin Thickness VALVE LIFTERS Valve Lifter Outside diameter Valve Lifter to Lifter Bore Clearance 1.1010 - 1.1016 in. (27.965 - 27.980 mm) 0.0008 - 0.0022 in. (0.020 -0.056 mm) VALVE SHIM Valve shim Thickness (in 0.025 mm increments) 0.0787 - 0.1299 in. (2.000 - 3.300 mm) THERMOSTAT Valve Opening Temperature Full Open Temperature Valve Lift (Minimum) 140° F (60° C) 158° F (70° C) 0.12 in. (3 mm) Page 1A-8 90-858895R1 JANUARY 2001 SPECIFICATIONS LUBRICATION SYSTEM Pump Type Oil Pump Drive Discharge at 212°F (100°C) with 10W-30 Oil at 1000 rpm Engine Oil Pressure (Warm Engine) @ 850 rpm Engine Oil Pan Capacity Relief Valve Opening Pressure Oil Pump: Non-Serviceable Trochoid with Relief Valve Drive shaft Spline 1.56 gph (5.9 L/h) 46.5 psi (320 kPa) Either 5 Qts. or 5 Liters 71 psi (490 kPa) Recommended Transom Height: Short Shaft 20 in. (51 cm) MID-SECTION Long Shaft Steering Pivot Range 25 in. (64 cm) 60° Full Tilt Up Angle 71° Allowable Transom Thickness (Max) 3 in. (76.2 mm) GEAR HOUSING BIGFOOT (2.07:1) Gear Ratio Gearcase Capacity Lubricant Type Forward Gear Number of Teeth Pinion Gear Number of Teeth Pinion Height Pinion Gear Locating Tool Flat Number Disc Number Forward Gear Backlash Backlash Indicating Tool Mark Number Water Pressure @ 1000 rpm @ 6000 rpm (WOT) 2.07:1 22.5 fl oz (665 mL) Quicksilver Gear Lube-Premium Blend 29 Spiral/Bevel 14 Spiral/Bevel 0.025 in. (0.64 mm) 91-12349A2 #2 #3 0.015-0.022 in. (0.38-0.55 mm) 91-19660--1 #1 5 psi (34.5 kPa) 20.5 psi (141.5 kPa) 90-858895R1 JANUARY 2001 Page 1A-9 SPECIFICATIONS Propeller Information Charts Mercury/Mariner 75 (4-Stroke) 2.07:1 Wide Open Throttle RPM : 4500-5500 Recommended Transom Heights : 20” Right Hand Rotation Standard Gear Reduction : 2.07:1 Diameter Pitch No. of Blades Material Approx. Gross Boat Wgt. (lbs) Approx. Boat Length Speed Range (mph) Propeller Part Number 13-1/2” 26” 3 Steel Up to 1400 Up to 16’ 47-64 48-16996A45 13-1/2” 24” 3 Steel Up to 1600 Up to 16’ 42-58 48-16994A45 12-1/2” 23” 3 Alum 1200-1700 15-17’ 40-55 48-77350A45 13-1/2” 22” 3 Steel 1300-1900 15-17’ 38-52 48-16992A45 12-3/4” 21” 3 Alum 1400-2000 15-17’ 35-49 48-77348A45 13-1/4” 20” 3 Steel 1500-2200 16-18’ 33-46 48-16990A45 13” 19” 3 Alum 1600-2400 16-18’ 31-43 48-77346A45 13” 18” 3 Steel 1800-2600 16-18’ 29-40 48-16988A45 13-1/4” 17” 3 Alum 1900-2900 17-19’ 27-37 48-77344A45 13-1/8” 16” 3 Steel 2100-3200 17-19’ 24-34 48-16986A45 13-1/4” 16” 3 Alum 2100-3200 17-19’ 24-34 48-854360A45 13-3/4” 15” 3 Alum 2300-3600 17-20’ 22-32 48-77342A45 13-3/8” 14” 3 Steel 2600-4100 19-21’ 20-29 48-17314A45 14” 13” 3 Alum 2900-4600 19-22’ 18-26 48-77340A45 14” 12” 3 Steel 3700+ pontoon 16-23 48-17312A45 14” 11” 3 Alum 4500+ pontoon/work 15-21 48-77338A45 14” 10” 3 Steel 5500+ houseboat/ work 1-18 48-17310A45 14” 10” 3 Alum 5500+ houseboat/ work 1-18 48-854342A45 Page 1A-10 90-858895R1 JANUARY 2001 SPECIFICATIONS Mercury/Mariner 90 (4-Stroke) 2.07:1 Wide Open Throttle RPM : 5000-6000 Recommended Transom Heights : 20” Right Hand Rotation Standard Gear Reduction : 2.07:1 Diameter Pitch No. of Blades Material Approx. Gross Boat Wgt. (lbs) Approx. Boat Length Speed Range (mph) Propeller Part Number 13-1/2” 26” 3 Steel Up to 1500 Up to 16’ 51-67 48-16996A45 13-1/2” 24” 3 Steel Up to 1800 Up to 17’ 45-60 48-16994A45 12-1/2” 23” 3 Alum 1300-1900 15-17’ 43-57 48-77350A45 13-1/2” 22” 3 Steel 1400-2100 15-17’ 40-54 48-16992A45 12-3/4” 21” 3 Alum 1600-2200 15-18’ 38-51 48-77348A45 13-1/4” 20” 3 Steel 1700-2400 16-18’ 36-48 48-16990A45 13” 19” 3 Alum 1800-2700 16-18’ 33-45 48-77346A45 13” 18” 3 Steel 2000-2900 17-19’ 31-42 48-16988A45 13-1/4” 17” 3 Alum 2200-3200 18-20’ 29-39 48-77344A45 13-1/8” 16” 3 Steel 2400-3600 19-21’ 26-36 48-16986A45 13-1/4” 16” 3 Alum 2400-3600 19-21’ 26-36 48-854360A45 13-3/4” 15” 3 Alum 2700-4000 19-22’ 24-33 48-77342A45 13-3/8” 14” 3 Steel 3000-4000 20-23’ 22-30 48-17314A45 14” 13” 3 Alum 3300-5100 21-24’ 20-28 48-77340A45 14” 12” 3 Steel 4000+ pontoon 17-24 48-17312A45 14” 11” 3 Alum 5000+ pontoon/work 15-21 48-77338A45 14” 10” 3 Steel 6500+ houseboat/ work 1-19 48-17310A45 14” 10” 3 Alum 6500+ houseboat/ work 1-19 48-854342A45 90-858895R1 JANUARY 2001 Page 1A-11 MAINTENANCE 1 B IMPORTANT INFORMATION Section 1B - Maintenance Table of Contents Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-1 Checking Power Trim Fluid . . . . . . . . . . . . . . . . 1B-10 Quicksilver Lubricant/Sealant . . . . . . . . . . . . . . . 1B-2 Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . 1B-11 Inspection And Maintenance Schedule . . . . . . . 1B-4 Oil Changing Procedure . . . . . . . . . . . . . . . . 1B-11 Before Each Use . . . . . . . . . . . . . . . . . . . . . . . 1B-4 Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . 1B-12 After Each Use . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5 Checking and Adding Engine Oil . . . . . . . . 1B-12 Every 100 Hours/Once yearly . . . . . . . . . . . . 1B-5 4-1/4 In. (108mm) Diameter Gear Case . . 1B-13 Every 300 Hours/Three Years . . . . . . . . . . . . 1B-5 Storage Preparation . . . . . . . . . . . . . . . . . . . . . . 1B-14 Every 400 Hours/Four Years . . . . . . . . . . . . . 1B-5 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-15 Before Periods of Storage . . . . . . . . . . . . . . . 1B-5 Protecting External Outboard Corrosion Control Anode . . . . . . . . . . . . . . . . . . . 1B-6 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-15 Spark Plug Inspection . . . . . . . . . . . . . . . . . . . . . . 1B-7 Protecting Internal Engine Components . . 1B-15 Battery Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 1B-7 Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-15 Fuse Replacement – Electric Start Models . . . . 1B-8 Positioning Outboard for Storage . . . . . . . . 1B-15 Timing Belt Inspection . . . . . . . . . . . . . . . . . . . . . 1B-8 Battery Storage . . . . . . . . . . . . . . . . . . . . . . . 1B-15 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9 Special Tools 1. Flushing Attachment P/N 44357A2 2. Crankcase Oil Pump P/N 90265A5 3. Oil Filter Wrench P/N 91-802653 90-858895R1 JANUARY 2001 Page 1B-1 MAINTENANCE Quicksilver Lubricant/Sealant 1. Quicksilver Anti-Corrosion Grease P/N 92-850735A1 2. 2-4-C Marine Lubricant with Teflon P/N 92-850736A1 3. Special Lubricant 101 P/N 92-13872A1 4. Quicksilver Power Trim and Steering Fluid P/N 92-90100A12 Page 1B-2 90-858895R1 JANUARY 2001 MAINTENANCE 5. Quicksilver 4-Stroke Outboard Oil P/N 92-828000A12 6. Gear Lube-Premium Blend P/N 92-850737A1 7. Quicksilver 4-Cycle Marine Engine Oil P/N 92-832111A1 4-CYCLE MARINE ENGINE OIL Premium Blend SAE 25W-40 NET 32 OZ (1 QT) 946 ml 90-858895R1 JANUARY 2001 Page 1B-3 MAINTENANCE Inspection And Maintenance Schedule To keep your outboard in the best operating condition, it is important that your outboard receive the periodic inspections and maintenance listed in the Inspection and Maintenance Schedule. We urge you to keep it maintained properly to ensure the safety of you and your passengers, and retain its dependability. WARNING Neglected inspection and maintenance service of your outboard, or attempting to perform maintenance or repair on your outboard if you are not familiar with the correct service and safety procedures, could cause personal injury, death, or product failure. Before Each Use 1. Check engine oil level. 2. Check that lanyard stop switch stops the engine. 3. Visually inspect the fuel system for deterioration or leaks. 4. Check outboard for tightness on transom. 5. Check steering system for binding or loose components. 6. Visually check steering link rod fasteners for proper tightness. 7. Check propeller blades for damage. Page 1B-4 90-858895R1 JANUARY 2001 MAINTENANCE After Each Use 1. Flush out the outboard cooling system if operating in salt or polluted water. 2. If operating in salt water, wash off all salt deposits and flush out the exhaust outlet of the propeller and gear case with fresh water. Every 100 Hours of Use or Once Yearly, Whichever Occurs First 1. Lubricate all lubrication points. Lubricate more frequently when used in salt water. 2. Change engine oil and replace the oil filter. The oil should be changed more often when the engine is operated under adverse conditions such as extended trolling. 3. Inspect thermostat visually for corrosion, broken spring, and to determine that the valve is completely closed at room temperature. If questionable, inspect thermostat as outlined in Section 4B “Thermostat”. 4. Inspect and clean spark plugs. 5. Check engine fuel filter for contaminants. 6. Adjust carburetor(s) (if required). 7. Check engine timing setup. 8. Check corrosion control anodes. Check more frequently when used in salt water. 9. Drain and replace gear case lubricant. 10. Lubricate splines on the drive shaft. 11. Check power trim fluid. 12. Inspect battery. 13. Check control cable adjustments. 14. Inspect timing belt. 15. Remove engine deposits with Quicksilver Power Tune Engine Cleaner. 16. Check tightness of bolts, nuts, and other fasteners. Every 300 Hours of Use or Three Years 1. Replace water pump impeller (more often if overheating occurs or reduced water pressure is noted). Every 400 Hours of Use or Four Years 1. Check and adjust valve clearance if necessary. Before Periods of Storage 1. Refer to Storage procedure (this section). 90-858895R1 JANUARY 2001 Page 1B-5 MAINTENANCE Page 1B-6 90-858895R1 JANUARY 2001 Corrosion Control Anode Your outboard has control anodes at different locations. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard metals. Each anode requires periodic inspection especially in salt water which will accelerate the erosion. To maintain this corrosion protection, always replace the anode before it is completely eroded. Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode. 1. The gear case has two corrosion control anodes. Another anode is installed on the bottom of the transom bracket assembly. b c a a - Bottom Anode b - Trim Tab c - Side Anodes 2. Three anodes are installed in the engine block. Remove anodes at locations shown. Install each anode with rubber seal and cover. Tighten bolts to specified torque. a b c a - Cover b - Anode c - Rubber Seal Anode Bolt Torque 70 lb-in. (8 Nm) MAINTENANCE Spark Plug Inspection Inspect spark plugs at the recommended intervals. 1. Remove the spark plug leads by twisting the rubber boots slightly and pull off. 2. Remove the spark plugs to inspect and clean. Replace spark plug if electrode is worn or the insulator is rough, cracked, broken, blistered or fouled. 3. Set the spark plug gap. See Specification Chart. 4. Before reinstalling spark plugs, clean away dirt on the spark plug seats. Install plugs finger tight, and tighten 1/4 turn or torque to 20 lb-ft (27 Nm). Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability. IMPORTANT: Read the safety and maintenance instructions which accompany your battery. 1. Turn off the engine before servicing the battery. 2. Add water as necessary to keep the battery full. 3. Make sure the battery is secure against movement. 4. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive and negative to negative. 5. Make sure the battery is equipped with a nonconductive shield to prevent accidental shorting of battery terminals. 90-858895R1 JANUARY 2001 Page 1B-7 MAINTENANCE Page 1B-8 90-858895R1 JANUARY 2001 Fuse Replacement – Electric Start Models The electric starting circuit is protected from overload fuses. 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 one of the same amperage rating. 1. Open the electrical cover and pull fuse with fuse puller. Look at the silver colored band inside the fuse. If band is broken replace the fuse. Replace fuse with a new one of the same amperage rating. a d b c a a - Fuse Puller b - Electrical Cover c - Fuses - 20 Amp. and 30 Amp. d - Blown Fuse Timing Belt Inspection 1. Inspect the timing belt and replace if any of the following conditions are found. a. Cracks in the back of the belt or in the base of the belt teeth. b. Excessive wear at the roots of the cogs. c. Rubber portion swollen by oil. d. Belt surfaces roughened. e. Signs of wear on edges or outer surfaces of belt. a a - Timing Belt MAINTENANCE Lubrication Points Lubricate Point 1 with Quicksilver Anti-Corrosion Grease or 2-4-C Marine Lubricant with Teflon 1. Propeller Shaft – Refer to Propeller Replacement for removal and installation of the propeller. Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft. 1 Lubricate Points 2 thru 5 with Quicksilver 2-4-C Marine Lubricant with Teflon or Special Lubricant 101. 2. Swivel Bracket – Lubricate through fitting. 3. Tilt Support Lever – Lubricate through fitting. 2 3 4. Tilt Tube-Lubricate through fitting. 4 90-858895R1 JANUARY 2001 Page 1B-9 MAINTENANCE 5. Steering Cable Grease Fitting (If equipped) – Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube. Lubricate through fitting. Lubricate Point 5 with light weight oil. a b 5 a-Steering Cable End b-Fitting WARNING The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant. Adding lubricant to steering cable when fully extended could cause steering cable to become hydraulically locked. A hydraulically locked steering cable will cause loss of steering control, possibly resulting in serious injury or death. Checking Power Trim Fluid 1. Tilt outboard to the full up position and engage the tilt support lock. a a-Tilt Support Lock 2. Remove fill cap and check fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver Power Trim & Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. a a-Fill Cap Page 1B-10 90-858895R1 JANUARY 2001 MAINTENANCE Changing Engine Oil Oil Changing Procedure Pump Method 1. Place the outboard in a vertical upright position. 2. Remove dipstick and slide adaptor tube/pump down dipstick tube. Pump out the engine oil into an appropriate container. a a-Crankcase Oil Pump Drain Plug Method 1. Tilt the outboard up to the trailer position. 2. Turn the steering on the outboard so that the drain hole is facing downward. Remove drain plug and drain engine oil into an appropriate container. Lubricate the seal on the drain plug with oil and reinstall. a a-Drain Hole 90-858895R1 JANUARY 2001 Page 1B-11 MAINTENANCE Page 1B-12 90-858895R1 JANUARY 2001 Changing Oil Filter 1. Place a rag or towel below the oil filter to absorb any spilled oil. 2. Unscrew old filter by turning the filter counterclockwise. 3. Clean the mounting base. Apply film of clean oil to filter gasket. Do not use grease. Screw new filter on until gasket contacts base, then tighten 3/4 to 1 turn. 91-802653 a a - Oil Filter Checking and Adding Engine Oil IMPORTANT: Do not overfill. Be sure that the outboard is upright (not tilted) when checking oil. 1. Remove the oil fill cap and add oil to to proper operating level. 2. Idle engine for five minutes and check for leaks. Stop engine and check oil level on dipstick. Oil must be between full mark and add mark. Add oil if necessary. b a c d a - Dipstick b - Oil Fill Cap c - Full Mark d - Add Mark Engine Oil Capacity 5 U.S. Quarts or (5.0 Liters) MAINTENANCE 4-1/4 In. (108mm) Diameter Gear Case When adding or changing gear case lubricant, visually check for the presence of water in the lubricant. If water is present, it may have settled to the bottom and will drain out prior to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance. If water is noticed, have the gear case checked by your dealer. Water in the lubricant may result in premature bearing failure or, in freezing temperatures, will turn to ice and damage the gear case. Whenever you remove the fill/drain plug, examine the magnetic end for metal particles. A small amount of metal filings or fine metal particles indicates normal gear wear. An excessive amount of metal filings or larger particles (chips) may indicate abnormal gear wear and should be checked by an authorized dealer. DRAINING GEAR CASE 1. Place outboard in a vertical operating position. 2. Place a drain pan below outboard. 3. Remove vent plugs and fill/drain plug, and drain lubricant. a b c a-Fill/drain Plug b-Rear Vent Plug c-Front Vent Plug Gear Case Lubricant Capacity 24 fl oz (710 ml) 90-858895R1 JANUARY 2001 Page 1B-13 MAINTENANCE CHECKING LUBRICANT LEVEL AND FILLING GEAR CASE 1. Place outboard in a vertical operating position. 2. Remove the front vent plug and rear vent plug. 3. Place lubricant tube into the fill hole and add lubricant until it appears at the front vent hole. At this time install the front vent plug and sealing washer. 4. Continue adding lubricant until it appears at the rear vent hole. 5. Stop adding lubricant. Install the rear vent plug and sealing washer before removing lubricant tube. 6. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer. a c d e b a-Front Vent Plug b-Rear Vent Plug c-Front Vent Hole d-Rear Vent Hole e-Fill/Drain Plug and Sealing Washer Storage Preparation The major consideration in preparing your outboard for storage is to protect it from rust, corrosion, and damage caused by freezing of trapped water. The following storage procedures should be followed to prepare your outboard for out-ofseason storage or prolonged storage (two months or longer). CAUTION Never start or run your outboard (even momentarily) without water circulating through the cooling water intake in the gear case to prevent damage to the water pump (running dry) or overheating of the engine. Page 1B-14 90-858895R1 JANUARY 2001 MAINTENANCE Fuel System IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a formation of acid during storage and can damage the fuel system. If the gasoline being 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 pump, and carburetor) with treated (stabilized) fuel to help prevent formation of varnish and gum. Proceed with following instructions. 1. Portable Fuel Tank – Pour the required amount of Quicksilver Gasoline Stabilizer (follow instructions on container) into fuel tank. Tip fuel tank back and forth to mix stabilizer with the fuel. 2. Permanently Installed Fuel Tank – Pour the required amount of Quicksilver Gasoline Stabilizer (follow instructions on container) into a separate container and mix with approximately one quart (one liter) of gasoline. Pour this mixture into fuel tank. 3. Place the outboard in water or connect flushing attachment for circulating cooling water. Run the engine for ten minutes to allow treated fuel to reach the carburetor. Protecting External Outboard Components 1. Lubricate all outboard components listed in the Inspection and Maintenance Schedule. 2. Touch up any paint nicks. 3. Spray Quicksilver Corrosion Guard on external metal surfaces (except corrosion control anodes). Protecting Internal Engine Components 1. Remove the spark plugs and inject a small amount of engine oil inside of each cylinder. 2. Rotate the flywheel manually several times to distribute the oil in the cylinders. Reinstall spark plugs. 3. Change the engine oil. Gear Case 1. Drain and refill the gear case lubricant (refer to maintenance procedure). Positioning Outboard for Storage Store outboard in an upright (vertical) position to allow water to drain out of outboard. CAUTION If outboard is stored tilted up in freezing temperature, trapped cooling water or rain water that may have entered the propeller exhaust outlet in the gear case could freeze and cause damage to the outboard. Battery Storage 1. Follow the battery manufacturer’s instructions for storage and recharging. 2. Remove the battery from the boat and check water level. Recharge if necessary. 3. Store the battery in a cool, dry place. 4. Periodically check the water level and recharge the battery during storage. 90-858895R1 JANUARY 2001 Page 1B-15 GENERAL INFORMATION IMPORTANT INFORMATION Section 1C - General Information Table of Contents 1 C Table of Contents . . . . . . . . . . . . . . . . . . . . . . . 1C-1 Propeller Removal/Installation . . . . . . . . . . . . 1C-13 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2 Standard Models . . . . . . . . . . . . . . . . . . . . . 1C-13 Serial Number Location . . . . . . . . . . . . . . . . . . 1C-2 Power Trim System . . . . . . . . . . . . . . . . . . . . . . 1C-15 Conditions Affecting Performance . . . . . . . . . 1C-3 General Information . . . . . . . . . . . . . . . . . . 1C-15 Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-3 Power Trim Operation . . . . . . . . . . . . . . . . . 1C-15 Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-4 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . 1C-17 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-5 Compression Check . . . . . . . . . . . . . . . . . . . . . 1C-18 Following Complete Submersion . . . . . . . . . . 1C-6 Cylinder Leakage Testing . . . . . . . . . . . . . . . . . 1C-19 Powerhead Front View . . . . . . . . . . . . . . . . . . . 1C-7 Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-20 Powerhead Starboard View . . . . . . . . . . . . . . . 1C-8 Water Pressure Measurement . . . . . . . . . . . . 1C-21 Powerhead Port View . . . . . . . . . . . . . . . . . . . . 1C-9 Painting Procedures . . . . . . . . . . . . . . . . . . . . . 1C-22 Powerhead Top View . . . . . . . . . . . . . . . . . . . . 1C-10 Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-22 Powerhead Aft View . . . . . . . . . . . . . . . . . . . . . 1C-11 Gear Housing . . . . . . . . . . . . . . . . . . . . . . . . 1C-22 Propeller Selection . . . . . . . . . . . . . . . . . . . . . . 1C-12 Decal Application/Removal . . . . . . . . . . . . . . . 1C-23 90-858895R1 JANUARY 2001 Page 1C-1 GENERAL INFORMATION Special Tools 1. Compression Gauge MT26J (Snap-on) Adaptor MT26J300 (Snap-on). 2. Water Pressure Gauge 91-79250A2. 3. Adapter P/N 22-86306. 4. Connector P/N 22-89772. Serial Number Location The Outboard serial number is located on the lower starboard side of the engine block. A serial number is also located on the starboard side of the swivel bracket. 19XX OGXXXXXX XXXX XX e d c b a a-Serial Number b-Model Year c-Model Description d-Year Manufactured e-Certified Europe Insignia Page 1C-2 90-858895R1 JANUARY 2001 GENERAL INFORMATION Conditions Affecting Performance Weather Rated hp Summer hp Horsepower Loss Due to Atmosphere Conditions Secondary Loss Due to Propeller Becoming To Large for Summer Horsepower RPM Drop Due to Weather ENGINE RPM Rated RPM It is a known fact that weather conditions exert a profound effect on power output of internal combustion engines. Therefore, established horsepower ratings refer to the power that the engine will produce at its rated rpm under a specific combination of weather conditions. Corporations internationally have settled on adoption of I.S.O. (International Standards Organization) engine test standards, as set forth in I.S.O. 3046 standardizing the computation of horsepower from data obtained on the dynamometer. All values are corrected to the power that the engine will produce at sea level, at 30% relative humidity, at 77° F (25° C) temperature, and a barometric pressure of 29.61 inches of mercury. Summer conditions of high temperature, low barometric pressure and high humidity all combine to reduce the engine power. This, in turn, is reflected in decreased boat speeds--as much as 2 or 3 miles-per-hour (3 or 5 Km per-hour) in some cases. (Refer to previous chart.) Nothing will regain this speed for the boater, but the coming of cool, dry weather. In pointing out the practical consequences of weather effects, an engine--running on a hot, humid summer day--may encounter a loss of as much as 14% of the horsepower it would produce on a dry, brisk spring or fall day. The horsepower that any internal combustion engine produces, depends upon the density of the air that it consumes, and in turn, this density is dependent upon the temperature of the air, its barometric pressure and water vapor (or humidity) content. Accompanying this weather-inspired loss of power is a second but more subtle loss. At rigging time in early spring, the engine was equipped with a propeller that allowed the engine to turn within its recommended rpm range at full throttle. With the coming of the summer weather and the consequent drop in available horsepower, this propeller will, in effect, become too large. Consequently, the engine operates at less than its recommended rpm. 90-858895R1 JANUARY 2001 Page 1C-3 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. Page 1C-4 90-858895R1 JANUARY 2001 GENERAL INFORMATION CAVITATION Cavitation is caused by water vapor bubbles forming either from a sharp edge or angle on the gear case or from an irregularity in the propeller blade itself. These vapor bubbles flow back and collapse when striking the surface of the propeller blade resulting in the erosion of the propeller blade surface. If allowed to continue, eventual blade failure (breakage) will occur. Engine DETONATION Detonation in a 4-cycle engine resembles the “pinging” heard in an automobile engine. It can be otherwise described as a tin-like “rattling” or “plinking” sound. Detonation is an explosion of an unburned portion of the fuel/air charge after the spark plug has fired. Detonation creates severe shock waves in the engine, and these shock waves often find or create a weakness: The dome of a piston, cylinder head/gasket, piston rings or piston ring lands, piston pin and roller bearings. A few of the most common causes of detonation in a marine 4-cycle application are as follows: • Over-advanced ignition timing. • Use of low octane gasoline. • Propeller pitch too high (engine rpm below recommended maximum range). • Lean fuel mixture at or near wide-open-throttle. • Spark plugs (heat range too hot - incorrect reach - cross-firing). • Inadequate engine cooling (deteriorated cooling system). • Combustion chamber/piston deposits (result in higher compression ratio). Detonation usually can be prevented if: 1. The engine is correctly set up. 2. Diligent maintenance is applied to combat the detonation causes. 51115 Damaged Piston Resulting from Detonation 90-858895R1 JANUARY 2001 Page 1C-5 GENERAL INFORMATION Following Complete Submersion SUBMERGED WHILE RUNNING (SPECIAL INSTRUCTIONS) When an engine is submerged while running, the possibility of internal engine damage is greatly increased. If, after engine is recovered and with spark plugs removed, engine fails to turn over freely when turning flywheel, the possibility of internal damage (bent connecting rod and/or bent crankshaft) exists. If this is the case, the powerhead must be disassembled. SALT WATER SUBMERSION (SPECIAL INSTRUCTIONS) Due to the corrosive effect of salt water on internal engine components, complete disassembly is necessary before any attempt is made to start the engine. FRESH WATER SUBMERSION (SPECIAL INSTRUCTIONS) 1. Recover engine as quickly as possible. 2. Remove cowling. 3. Flush exterior of outboard with fresh water to remove mud, weeds, etc. DO NOT attempt to start engine if sand has entered powerhead, as powerhead will be severely damaged. Disassemble powerhead if necessary to clean components. 4. Remove spark plugs and get as much water as possible out of powerhead. Most water can be eliminated by placing engine in a horizontal position (with spark plug holes down) and rotating flywheel. 5. Change engine oil and filter as outlined in Section 1B “Changing Engine Oil”. Run outboard for short time and check for presence of water in oil. If water present (milky appearance) drain and refill as previously mentioned. 6. Pour alcohol into carburetor throats (alcohol will absorbed water). Again rotate flywheel. 7. Turn engine over and pour alcohol into spark plug openings and rotate flywheel. 8. Turn engine over (place spark plug openings down) and pour engine oil into throat of carburetors while rotating flywheel to distribute oil throughout crankcase. 9. Again turn engine over and pour approximately one teaspoon of engine oil into each spark plug opening. Again rotate flywheel to distribute oil in cylinders. 10. Remove and clean carburetors and fuel pump assembly. 11. Dry all wiring and electrical components using compressed air. 12. Disassemble the engine starter motor and dry the brush contacts, armature and other corrodible parts. 13. Reinstall spark plugs, carburetors and fuel pump. 14. Attempt to start engine, using a fresh fuel source. If engine starts, it should be run for at least one hour to eliminate any water in engine. 15. If engine fails to start, determine cause (fuel, electrical or mechanical). Engine should be run within 2 hours after recovery of outboard from water, or serious internal damage may occur. If unable to start engine in this period, disassemble engine and clean all parts. Apply oil as soon as possible. Page 1C-6 90-858895R1 JANUARY 2001 GENERAL INFORMATION 90-858895R1 JANUARY 2001 Page 1C-7 Powerhead Front View a d e f b c g h 58645 i j a - Air Box b - Fuel Hose c - Remote Control Harness Opening d - Throttle Cable e - Battery Cables f - Shift Cable g - Speedometer Hose h - Remote Control and Engine Harness Connection i - Voltage Regulator/Rectifier j - ECM GENERAL INFORMATION Page 1C-8 90-858895R1 JANUARY 2001 Powerhead Starboard View 57882 9 b c d e f g h i j k n o p q a l 9 Loctite PST Pipe Sealant (92-809822) m a - Flywheel Cover b - Starter Motor c - Battery Ground Cable d - Oil Filter e - Dipstick f - 20 Amp Fuse g - 30 Amp Fuse h - Starter Relay i - Trim Relay (2) 1 Hidden j - Engine Harness Connector k - Batter Positive Cable l - Access Port, Water Pressure/ Temperature Sender Accessory m - Water Temperature Sensor n - Fuel Filter o - Pressure Control Valve Housing p - Ignition Coil Cylinders #2 & #3 q - Ignition Coil Cylinders #1 & #4 GENERAL INFORMATION 90-858895R1 JANUARY 2001 Page 1C-9 Powerhead Port View a b c e d f 58644 a - Enrichener (2) b - Throttle Valve Adjustment Screw (3) c - Intake Manifold Plug (4) d - Dashpot e - Shift Interrupt Switch f - Throttle Position Sensor (TPS) GENERAL INFORMATION Page 1C-10 90-858895R1 JANUARY 2001 Powerhead Top View 57870 a b c d e f c a - Camshaft Gear (2) b - Timing Belt c - Lifting Eye (2) d - Flywheel e - Timing Belt Tensioner f - Thermostat Housing GENERAL INFORMATION Powerhead Aft View a b c a-Spark Plug Cover b-Fuel Pump (2) c-Oil Fill Cap 90-858895R1 JANUARY 2001 Page 1C-11 GENERAL INFORMATION Propeller Selection For in-depth information on marine propellers and boat performance - written by marine engineers - see your Authorized Dealer for the illustrated “What You Should Know About Quicksilver Propellers... and Boat Performance Information” (Part No. 90-86144). For best all around performance from your outboard/boat combination, select a propeller that allows the engine to operate in the upper half of the recommended full throttle rpm range with the boat normally loaded (refer to Specifications). This rpm range allows for better acceleration while maintaining maximum boat speed. If changing conditions cause the rpm to drop below the recommended range (such as warmer, more humid weather, operation at higher elevations, increased boat load or a dirty boat bottom/gear case) a propeller change or cleaning may be required to maintain performance and ensure the outboard’s durability. Check full-throttle rpm using an accurate tachometer with the engine trimmed out to a balanced- steering condition (steering effort equal in both directions) without causing the propeller to “break loose”. Refer to “Quicksilver Accessory Guide” for a complete list of available propellers. 1. Select a propeller that will allow the engine to operate at or near the top of the recommended full throttle rpm range (listed in “Specifications,” preceding) with a normal load. Maximum engine speed (rpm) for propeller selection exists when boat speed is maximum and trim is minimum for that speed. (High rpm, caused by an excessive trim angle, should not be used in determining correct propeller.) Normally, there is a 150-350 rpm change between propeller pitches. 2. If full throttle operation is below the recommended range, the propeller MUST BE changed to one with a lower pitch to prevent loss of performance and possible engine damage. 3. After initial propeller installation, the following common conditions may require that the propeller be changed to a lower pitch: a. Warmer weather and great humidity will cause an rpm loss. b. Operating in a higher elevation causes an rpm loss. c. Operating with a damaged propeller or a dirty boat bottom or gear housing will cause an rpm loss. d. Operation with an increased load (additional passengers, equipment, pulling skiers, etc.). Page 1C-12 90-858895R1 JANUARY 2001 GENERAL INFORMATION Propeller Removal/Installation Standard Models WARNING If the propeller shaft is rotated while the engine is in gear, there is the possibility that the engine will crank over and start. To prevent this type of accidental engine starting and possible serious injury caused from being struck by a rotating propeller, always shift outboard to neutral position and remove spark plug leads when you are servicing the propeller. 1. Shift outboard to neutral position. N 2. Remove the spark plug leads to prevent engine from starting. 3. Straighten the bent tabs on the tab washer. a a-Tab Washer 90-858895R1 JANUARY 2001 Page 1C-13 GENERAL INFORMATION 4. Place a block of wood between gear case and propeller to hold propeller and remove propeller nut. 5. Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. 6. Coat the propeller shaft with Quicksilver Anti-Corrosion Grease or 2-4-C Marine Lubricant with Teflon. 95 2-4-C w/Teflon (92-850736A1) 95 IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft, especially in salt water, always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed. 7. Flo-Torque I Drive Hub Propellers de f c b a a-Thrust Washer b-Propeller c-Continuity Washer d-Thrust Hub e-Propeller Nut Retainer f-Propeller Nut Page 1C-14 90-858895R1 JANUARY 2001 GENERAL INFORMATION 8. Flo-Torque II Drive Hub Propellers ab c d ef a-Forward Thrust Hub b-Replaceable Drive Sleeve c-Propeller d-Rear Thrust Hub e-Propeller Nut Retainer f-Propeller Nut 9. Place a block of wood between gear case and propeller, and torque propeller nut to 55 lb-ft (75 Nm), aligning flat sides of the propeller nut with tabs on the tab washer. 10. Secure propeller nut by bending three of the tabs into the thrust hub grooves. b a b a a b a-Thrust Hub Grooves b-Tabs Propeller Nut Torque 55 lb-ft (75 Nm) 11. Reinstall spark plug leads. Power Trim System General Information The power trim system is filled at the manufacturer and is ready for use. Trim outboard through entire trim and tilt range several times to remove any air from the system. The trim system is pressurized and is not externally vented. Power Trim Operation With most boats, operating around the middle of the “trim” range will give satisfactory results. However, to take full advantage of the trimming capability there may be times when you choose to trim your outboard all the way in or out. Along with an improvement in some performance aspects comes a greater responsibility for the operator, and this is being aware of some potential control hazards. The most significant control hazard is a pull or “torque” that can be felt on the steering wheel or tiller handle. This steering torque results from the outboard being trimmed so that the propeller shaft is not parallel to the water surface. 90-858895R1 JANUARY 2001 Page 1C-15 GENERAL INFORMATION WARNING Avoid possible serious injury or death. When the outboard is trimmed in or out beyond a neutral steering condition, a pull on the steering wheel or tiller handle in either direction may result. Failure to keep a continuous firm grip on the steering wheel or tiller handle when this condition exists can result in loss of boat control as the outboard can turn freely. The boat can now “spin out” or go into a very tight maximum turn which, if unexpected, can result in occupants being thrown within the boat or out of the boat. Consider the following lists carefully: TRIMMING IN OR DOWN CAN: 1. Lower the bow. 2. Result in quicker planing off, especially with a heavy load or a stern heavy boat. 3. Generally improve the ride in choppy water. 4. Increase steering torque or pull to the right (with the normal right hand rotation propeller). 5. In excess, lower the bow of some boats to a point where they begin to plow with their bow in the water while on plane. This can result in an unexpected turn in either direction called “bow steering” or “over steering” if any turn is attempted or if a significant wave is encountered. WARNING Avoid possible serious injury or death. Adjust outboard to an intermediate trim position as soon as boat is on plane to avoid possible ejection due to boat spin-out. Do not attempt to turn boat when on plane if outboard is trimmed extremely in or down and there is a pull on the steering wheel or tiller handle. TRIMMING OUT OR UP CAN: 1. Lift the bow higher out of the water. 2. Generally increase top speed. 3. Increase clearance over submerged objects or a shallow bottom. 4. Increase steering torque or pull to the left at a normal installation height (with the normal right hand rotation propeller). 5. In excess, cause boat “porpoising” (bouncing) or propeller ventilation. 6. Cause engine overheating if any water intake holes are above the water line. TRIM “IN” ANGLE ADJUSTMENT Some outboard boats, particularly some bass boats, are built with a greater than normal transom angle which will allow the outboard to be trimmed further “in” or “under”. This greater trim “under” capability is desirable to improve acceleration, reduce the angle and time spent in a bow high boat, altitude during planing off, and in some cases, may be necessary to plane off a boat with aft live wells, given the variety of available propellers and height range of engine installations. However, once on plane, the engine should be trimmed to a more intermediate position to a avoid a bow-down planing condition called “plowing”. Plowing can cause “bow steering” or “over steering” and inefficiently consumes horsepower. In this condition, if attempting a turn or encountering a diagonal, moderate wake, a more abrupt turn than intended may result. Page 1C-16 90-858895R1 JANUARY 2001 GENERAL INFORMATION In rare circumstances, the owner may decide to limit the trim in. This can be accomplished by repositioning the tilt stop pins into whatever adjustment holes in the transom brackets is desired. WARNING Avoid possible serious injury or death. Adjust outboard to an intermediate trim position as soon as boat is on plane to avoid possible ejection due to boat spin-out. Do not attempt to turn boat when on plane if outboard is trimmed extremely in or down and there is a pull on the steering wheel or tiller handle. If an adjustment is required, purchase a stainless steel tilt pin (P/N 17-49930A1) and insert it through whatever pin hole is desired. The non-stainless steel shipping bolt should not be used in this application other than on a temporary basis. a a-Optional Tilt Pin Trim Tab Adjustment Propeller steering torque will cause your boat to pull in one direction. This steering torque is a normal thing that results from your outboard not being trimmed so the propeller shaft is parallel to the water surface. The trim tab can help to compensate for this steering torque in many cases and can be adjusted within limits to reduce any unequal steering effort. NOTE:Trim tab adjustment will have little effect reducing steering torque if the outboard is installed with the anti-ventilation plate approximately 2 inches (50mm) or more above the boat bottom. Operate your boat at normal cruising speed, trimmed to desired position. Turn your boat left and right and note the direction the boat turns more easily. If adjustment is necessary, loosen trim tab bolt and make small adjustments at a time. If the boat turns more easily to the left, move the trailing edge of trim tab to the left. If the boat turns more easily to the right move the trailing edge of trim tab to the right. Retighten bolt and retest. a a-Trim Tab 90-858895R1 JANUARY 2001 Page 1C-17 GENERAL INFORMATION Page 1C-18 90-858895R1 JANUARY 2001 Compression Check CAUTION Before removing the spark plugs, use compressed air to blow away dirt accumulated in the spark plug well. NOTE: Use Snap-on compression gauge with adaptor. P/N MT26J-MT26J300. Spark plug size is 14 mm. IMPORTANT: Compression check should be done with throttle in WOT position. 1. Check valve clearance (refer to “Valve Clearance Adjustment” in section 4A), adjust if out of specification. 2. Warm up the engine. 3. Remove all spark plugs. 4. Lubricate threads in cylinder head and on compression gauge. Install compression gauge in spark plug hole. 110 4-Stroke Outboard Oil (92-828000A12) 110 110 a MT26J/MT26J300 b b a - Compression Gauge (MT26J - Snap-on) b - Adaptor (MT26J300 - Snap-on) 5. Hold throttle plate at W.O.T. 6. Crank the engine over until the compression reading peaks on the gauge. Record the reading. 7. Check and record compression of each cylinder. The highest and lowest reading recorded should not differ by more than 15% (see example chart below). A reading below 120 psi might indicate a total engine wear problem. Compression Pressure (Minimum) 135 psi (950 Kpa, 9.5 kg/cm2) Example of compression test differences: Maximum (psi) Minimum (psi) 180 162 150 127.5 GENERAL INFORMATION 8. Remove compression gauge. 9. Install spark plugs. NOTE:Compression check is important because an engine with low or uneven compression cannot be tuned successfully to give peak performance. It is essential, therefore, that improper compression be corrected before proceeding with an engine tuneup. Cylinder Leakage Testing NOTE:Cylinder leakage testing*, along with compression testing, can help the mechanic pinpoint the source of a mechanical failure by gauging the amount of leakage in an engine cylinder. Refer to the manufactures tester instructions for proper testing procedures. NOTE:Cylinders #1 and #4 TDC positions should show TDC mark on flywheel with timing marks (f). Cylinders #2 and #3 TDC positions should show TDC mark alone (g). #1 #2 #3 #4 a b c d e f g P/N MT324 a-TDC for Cylinder #1 b-TDC for Cylinder #2 c-TDC for Cylinder #3 d-TDC for Cylinder #4 e-Cylinder Leakage Tester (Snap-On-Tools MT324) f-Flywheel Position For Arrow Positions #1 & #4 g-Flywheel Position For Arrow Positions #2 & #3 NOTE: Spark plug hole is a 14 mm diameter. Use Snap-On Tool MT26J300 adapter with valve core removed. 90-858895R1 JANUARY 2001 Page 1C-19 GENERAL INFORMATION Analysis Due to standard engine tolerances and engine wear, no cylinder will maintain a 0% of leakage. It is important only that cylinders have somewhat consistent reading between them. Differences of 15 to 30% indicate excessive leakage. Larger engines tend to have a larger percentage of cylinder leakage than smaller engines. If excessive leakage is present, first check that the piston is at top dead center of its compression stroke. Leakage will naturally occur if the exhaust or intake valve is open. To determine the cause of high percentage leaks, you must locate where the air is escaping from. Listen for air escaping thru the carburetor intake, adjacent spark plug holes, exhaust pipe, and crankcase fill plug. Use the following table to aid in locating the source of cylinder leakage: Air Escaping From: Indicates Possible Defective: Carburetor Intake Valve Exhaust System Exhaust Valve Crankcase Fill Plug Piston or Rings Adjacent Cylinders Head Gasket Page 1C-20 90-858895R1 JANUARY 2001 GENERAL INFORMATION 90-858895R1 JANUARY 2001 Page 1C-21 Water Pressure Measurement 1. Warm up engine. 2. Remove plug. 3. Attach adaptor, hose fitting and water pressure gauge to cylinder block. NOTE: Water pressure measurements should be done on a warm engine with thermostat operating 140°F (60°C). 0 2 4 6 8 10 12 14 16 18 20 22 24 0 1 2 3 4 5 6 rpm x 1000 Pump Pressure (psi) Water Pump Pressure 91-79250A2 22-86306 a 22-89772 a - Plug GENERAL INFORMATION Painting Procedures WARNING Avoid serious injury from flying debris. Avoid serious injury from airborne particles. Use eye and breathing protection with proper ventilation. Propeller 1. Sand the entire area to be painted with 3M 120 Regalite Polycut or coarse Scotch-Brite, disc or belts. 2. Feather edges of all broken paint edges. Try not to sand through the primer. 3. Clean the surface to be painted using PPG Industries DX330 Wax and Grease Remover or equivalent (Xylene or M.E.K.). 4. If bare metal has been exposed, use Quicksilver’s Light Gray Primer. 5. Allow a minimum of 1 hour dry time and no more than 1 week before applying the finish coat. 6. Apply the finish coat using Quicksilver’s EDP Propeller Black. Gear Housing The following procedures should be used in refinishing gear housings. This procedure will provide the most durable paint system available in the field. The materials recommended are of high quality and approximate marine requirements. The following procedure will provide a repaint job that compares with a properly applied factory paint finish. It is recommended that the listed materials be purchased from a local Ditzler Automotive Finish Supply Outlet. The minimum package quantity of each material shown following is sufficient to refinish several gear housings. Procedure: 1. Wash gear housing with a muriatic acid base cleaner to remove any type of marine growth, and rinse with water, if necessary. 2. Wash gear housing with soap and water, then rinse. 3. Sand blistered area with 3M 180 grit sandpaper or P180 Gold Film Disc to remove paint blisters only. Feather edge all broken paint edges. 4. Clean gear housing thoroughly with (DX-330) wax and grease remover. 5. Spot repair surfaces where bare metal is exposed with (DX-503) alodine treatment. IMPORTANT: Do not use any type of aerosol spray paints as the paint will not properly adhere to the surface nor will the coating be sufficiently thick to resist future paint blistering. 6. Mix epoxy chromate primer (DP-40) with equal part catalyst (DP-401) per manufacturers instructions, allowing proper induction period for permeation of the epoxy primer and catalyst. 7. Allow a minimum of one hour drying time and no more than one week before top coating assemblies. 8. Use Ditzler Urethane DU9000 for Mercury Black, DU34334 for Mariner Grey, and DU35466 for Force Charcoal, and DU33414M for Sea Ray White. Catalyze all four colors with Ditzler DU5 catalyst mixed 1:1 ratio. Reduce with solvents per Ditzler label. Page 1C-22 90-858895R1 JANUARY 2001 GENERAL INFORMATION CAUTION Be sure to comply with instructions on the label for ventilation and respirators. Using a spray gun, apply one half to one mil even film thickness. Let dry, flash off for five minutes and apply another even coat of one half to one mil film thickness. This urethane paint will dry to the touch in a matter of hours, but will remain sensitive to scratches and abrasions for a few days. 9. The type of spray gun used will determine the proper reduction ratio of the paint. IMPORTANT: Do not paint sacrificial zinc trim tab or zinc anode. 10. Cut out a cardboard “plug” for trim tab pocket to keep paint off of mating surface to maintain good continuity circuitry between trim tab and gear housing. Decal Application/Removal DECAL REMOVAL 1. Mark decal location before removal to assure proper alignment of new decal. 2. Carefully soften decal and decal adhesive with a heat gun or heat blower while removing old decal. 3. Clean decal contact area with a 1:1 mixture of isopropyl alcohol and water. 4. Thoroughly dry decal contact area and check for a completely cleaned surface. INSTRUCTIONS FOR “WET” APPLICATION NOTE: The following decal installation instructions are provided for a “Wet” installation. All decals should be applied wet. TOOLS REQUIRED 1. Plastic Squeegee* 2. Stick Pin 3. Dish Washing Liquid/Detergent without ammonia** “Joy” and “Drift” are known to be compatible for this process. * Automotive Body Filler Squeegee ** Do not use a soap that contains petroleum based solvents. SERVICE TIP: Placement of decals using the “Wet” application will allow time to position decal. Read entire installation instructions on this technique before proceeding. TEMPERATURE IMPORTANT: Installation of vinyl decals should not be attempted while in direct sun light. Air and surface temperature should be between 60°F (15°C) and 100°F (38°C) for best application. SURFACE PREPARATION IMPORTANT: Do not use a soap or any petroleum based solvents to clean application surface. Clean entire application surface with mild dish washing liquid and water. Rinse surface thoroughly with clean water. 90-858895R1 JANUARY 2001 Page 1C-23 GENERAL INFORMATION DECAL APPLICATION 1. Mix 1/2 ounce (16 ml) of dish washing liquid in one gallon (4 l) of cool water to use as wetting solution. NOTE:Leave protective masking, if present, on the face of decal until final steps of decal installation. This will ensure that the vinyl decal keeps its shape during installation. 2. Place the decal face down on a clean work surface and remove the paper backing from “adhesive side” of decal. 3. Using a spray bottle, flood the entire “adhesive side” of the decal with the pre-mixed wetting solution. 4. Flood area where the decal will be positioned with wetting solution. 5. Position pre-wetted decal on wetted surface and slide into position. 6. Starting at the center of the decal, “lightly” squeegee out the air bubbles and wetting solution with overlapping strokes to the outer edge of the decal. Continue going over the decal surface until all wrinkles are gone and adhesive bonds to the cowl surface. 7. Wipe decal surface with soft paper towel or cloth. 8. Wait 10 - 15 minutes. 9. Starting at one corner, “carefully and slowly” pull the masking off the decal surface at a 180° angle. NOTE: To remove any remaining bubbles, pierce the decal at one end of the bubble with stick pin and press out the entrapped air or wetting solution with your thumb (moving toward the puncture). Page 1C-24 90-858895R1 JANUARY 2001 OUTBOARD MOTOR INSTALLATION IMPORTANT INFORMATION Section 1D - Outboard Motor Installation Table of Contents 1 D Electric Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . 1D-1 Boat Horsepower Capacity . . . . . . . . . . . . . . . . . 1D-1 Start in Gear Protection . . . . . . . . . . . . . . . . . . . . 1D-2 Selecting Accessories For The Outboard . . . . . 1D-2 Installation Specifications . . . . . . . . . . . . . . . . . . . 1D-2 Lifting Outboard. . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-3 Steering Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-3 Steering Cable Seal . . . . . . . . . . . . . . . . . . . . . . . 1D-4 Steering Link Rod . . . . . . . . . . . . . . . . . . . . . . . . . 1D-4 Installing Outboard – Thumb Screw Models . . . 1D-5 Installing Outboard – Non Thumb Screw Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-5 Electrical, Hoses, and Control Cables . . . . . . . . 1D-6 Front Cowl Grommet . . . . . . . . . . . . . . . . . . . . 1D-6 Remote Wiring Harness . . . . . . . . . . . . . . . . . 1D-7 Fuel Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-7 Speedometer (Optional) Water Pick-up . . . . 1D-8 Battery Cable Connections . . . . . . . . . . . . . . . . . 1D-9 Single Outboards . . . . . . . . . . . . . . . . . . . . . . . 1D-9 Dual Outboards . . . . . . . . . . . . . . . . . . . . . . . . 1D-9 Shift and Throttle Cable . . . . . . . . . . . . . . . . . . . 1D-10 Shift Cable Installation . . . . . . . . . . . . . . . . . 1D-10 Throttle Cable Installation . . . . . . . . . . . . . . 1D-12 Trim-In Stop Adjustment . . . . . . . . . . . . . . . . . . 1D-14 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . 1D-15 Electric Fuel Pump If an electric fuel pump is used, the fuel pressure must not exceed 4 psig at the engine. If necessary, install a pressure regulator to regulate the pressure. Boat Horsepower Capacity U.S. COAST GUARD CAPACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY (POUNDS) XXX MAXIMUM WEIGHT CAPACITY XXX Do not overpower or overload the boat. Most boats will carry a required capacity plate indicating the maximum acceptable power and load as determined by the manufacturer following certain federal guidelines. If in doubt, contact your dealer or the boat manufacturer. WARNING Using an outboard that exceeds the maximum horsepower limit of a boat can: 1. cause loss of boat control 2. place too much weight at the transom, altering the designed flotation characteristics of the boat or 3. cause the boat to break apart, particularly around the transom area. Overpowering a boat can result in serious injury, death, or boat damage. 90-858895R1 JANUARY 2001 Page 1D-1 OUTBOARD MOTOR INSTALLATION Start in Gear Protection The remote control connected to the outboard must be equipped with a start-in-gear protection device. This prevents the engine from starting in gear. WARNING Avoid serious injury or death from a sudden unexpected acceleration when starting your engine. The design of this outboard requires that the remote control used with it must have a built in start-in-gear protection device. Selecting Accessories For The Outboard Genuine Quicksilver Parts and Accessories have been specifically designed and tested for this outboard. Some accessories not manufactured or sold by Quicksilver are not designed to be safely used with this outboard or outboard operating system. Acquire and read the Installation, Operation, and Maintenance manuals for all selected accessories. Installation Specifications a b a Transom Opening “A” (Minimum) Single Engine (Remote) 19 in. (483 mm) Single Engine (Tiller) 30 in. (762 mm) Dual Engines 40 in. (1016 mm) Engine Center Line For Dual Engines “B” (Minimum) 26 in. (660 mm) Page 1D-2 90-858895R1 JANUARY 2001 OUTBOARD MOTOR INSTALLATION 90-858895R1 JANUARY 2001 Page 1D-3 Lifting Outboard 1. Use lifting eye on engine. Steering Cable STARBOARD SIDE ROUTED CABLE 1. Lubricate O-ring and the entire cable end with 2-4-C Lubricant with Teflon. 95 2-4-C w/Teflon (92-850736A1) 95 2. Insert steering cable into tilt tube. 3. Torque nut to 35 lb-ft (47.5 Nm). OUTBOARD MOTOR INSTALLATION Steering Cable Seal 1. Mark tilt tube 1/4 in. (6.4 mm) from end. Install seal components. 2. Thread cap to the mark. 1/4 in. (6.4mm) b da c a a-1/4 in. (6.4 mm) Mark b-Plastic Spacer c-O-Ring Seal d-Cap Steering Link Rod Installation Note NOTE:For ease of installation of special bolt (a) separate the front end of the bottom cowl. 1. Install steering link rod per illustration. a c d b a-Special Bolt (10-90041) Torque to 20 lb-ft (27.1 Nm) b-Nylon Insert Locknut (11-34863) Torque to 20 lb-ft (27.1 Nm) c-Flat Washers (2) d-Nylon Insert Locknut (11-34863) Tighten Locknut Until it Seats, Then Back Nut Off 1/4 Turn IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special bolt (“a” - Part Number 10-90041) and self locking nuts (“b” & “d” - Part Number 11-34863). These locknuts must never be replaced with common nuts (non locking) as they will work loose and vibrate off, freeing the link rod to disengage. WARNING Disengagement of a steering link rod can result in the boat taking a full, sudden, sharp turn. This potentially violent action can cause occupants to be thrown overboard exposing them to serious injury or death. Page 1D-4 90-858895R1 JANUARY 2001 OUTBOARD MOTOR INSTALLATION Installing Outboard – Thumb Screw Models WARNING Outboard must be fastened to boat transom one of two ways: 1. permanently fastened to transom with thumb screws, and mounting bolts (provided), or 2. secured to the transom using the optional outboard mounting kit (shown below). Should the outboard strike an underwater object or be steered into a sharp turn, failure to fasten outboard correctly to the boat transom with mounting bolts or optional mounting kit could result in outboard ejecting suddenly off boat transom causing serious injury, death, boat damage, or loss of outboard. Installing Outboard – Non Thumb Screw Models 1. Use transom drilling fixture (91-98234A2) or attach (tape) engine mounting template to boat transom. 2. Mark and drill four 17/32 in. (13.5 mm) mounting holes. 3. Install the outboard so that the anti-ventilation plate is in-line or within 1 in. (25 mm) below the bottom of the boat. 0 - 1 in. (0 - 25 mm) a a-Anti-Ventilation Plate 90-858895R1 JANUARY 2001 Page 1D-5 OUTBOARD MOTOR INSTALLATION 4. Fasten outboard with provided mounting hardware shown. c ab d a-1/2 in. Diameter Bolts (4) b-Flat Washers (4) c-Locknuts (4) d-Marine Sealer - Apply to Shanks of Bolts, Not Threads Electrical, Hoses, and Control Cables IMPORTANT: Warning Horn Requirement – The remote control or key switch assembly must be wired with a warning horn. This warning horn is used with the engine warning system. Front Cowl Grommet 1. Pull up the cowl seal and remove the cover from the bottom cowl. 2. Route the hoses, wiring and cables through the correct openings in the rubber grommet as shown. a b c d e fgh i a-Cover b-Rubber Grommet c-Fuel Hose Opening d-Remote Wiring Harness Opening e-Throttle Cable Opening f-Battery Cables Opening g-Shift Cable Opening h-Speedometer Tube i-Sta-Strap – Tie Around Grommet After Components are Installed Page 1D-6 90-858895R1 JANUARY 2001 OUTBOARD MOTOR INSTALLATION Remote Wiring Harness 1. Route wiring harness through the rubber grommet. Connect wiring. Push the retainer over the exposed ends of the connectors. This will hold the connectors together. BLU/WHTGRN/WHTBRN/WHTTAN BLU/WHTGRN/WHT a b a-Power Trim Connections b-Retainer – Push Over Connector Ends Fuel Hose PORTABLE FUEL TANK Select a suitable location in boat within engine fuel line length limitations and secure tank in place. PERMANENT FUEL TANK These should be installed in accordance with industry and federal safety standards which include recommendations applicable to grounding, anti-siphon protection, ventilation, etc. FUEL HOSE SIZE Minimum fuel line inside diameter (I.D.) is 5/16 in. (8mm), with separate fuel line/fuel tank pickup for each engine. FUEL HOSE CONNECTION Fasten remote fuel hose to fitting with hose clamp. 90-858895R1 JANUARY 2001 Page 1D-7 OUTBOARD MOTOR INSTALLATION Speedometer (Optional) Water Pick-up This outboard is equipped with a speedometer water pick-up located in the leading edge of the gear case. If this water pick-up is to be used, locate the hose coming out of the front grommet. Cut off the end of the hose fitting and make the connection. NOTE:If the speedometer water pick-up hose is not used, keep the hose routed out of the rubber grommet. a b c a-Fuel Hose b-Hose Clamp – Secure Remote Fuel Hose c-Water Pick-up Hose for Optional Speedometer Page 1D-8 90-858895R1 JANUARY 2001 OUTBOARD MOTOR INSTALLATION 90-858895R1 JANUARY 2001 Page 1D-9 Battery Cable Connections Single Outboards (+) (–) a b c a - Red Sleeve (Positive) b - Black Sleeve (Negative) c - Starting Battery Dual Outboards 1. Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. (–) (–) a a - Ground Cable (Same Wire Size As Engine Battery Cable) – Connect Between Negative (–) Terminals OUTBOARD MOTOR INSTALLATION Shift and Throttle Cable Install cables into the remote control following the instructions provided with the remote control. NOTE:Install the shift cable to the engine first. The shift cable is the first cable to move when the remote control handle is moved out of neutral. Shift Cable Installation 1. Position remote control into neutral. N 2. Shift outboard into neutral. 3. Measure the distance between pin and center of barrel pocket. a c b FNR a-Distance Between Pin And Center of Lower Hole b-Pin c-Barrel Pocket Page 1D-10 90-858895R1 JANUARY 2001 OUTBOARD MOTOR INSTALLATION 90-858895R1 JANUARY 2001 Page 1D-11 4. Push in on the shift cable end until resistance is felt. Adjust the cable barrel to attain distance (a) taken in Step 3. b a a - Adjust Cable Barrel To Attain The Measured Distance Taken In Step 3 b - Cable Barrel 5. Fit shift cable through rubber grommet. 6. Place cable barrel into pocket. Fasten cable with hairpin cotter. a b a - Place Barrel Into Barrel Pocket b - Hairpin Cotter 7. Check shift cable adjustments as follows: a. Shift remote control into forward. The propeller shaft should be locked in gear. If not, adjust the barrel closer to the cable end. b. Shift remote control into neutral. The propeller shaft should turn freely without drag. If not, adjust the barrel away from the cable end. Repeat steps a and b. c. Shift remote control into reverse while turning propeller. The propeller shaft should be locked in gear. If not, adjust the barrel away from the cable end. Repeat steps a thru c. d. Shift remote control back to neutral. The propeller shaft should turn freely without drag. If not, adjust the barrel closer to the cable end. Repeat steps a thru d. OUTBOARD MOTOR INSTALLATION Page 1D-12 90-858895R1 JANUARY 2001 Throttle Cable Installation Install cables into the remote control following the instructions provided with the remote control. 1. Position remote control into neutral. N 2. Install throttle cable to the throttle arm with hairpin cotter. 3. Adjust the cable barrel so that the installed throttle cable will hold the throttle arm against the idle stop. 4. Place cable barrel into retainer and install. 5. Fit throttle cable through the rubber grommet. 6. Lock the retainer in place with the cable latch. a b c d e f g a - Flat Washer b - Hairpin Cotter c - Barrel Retainer d - Throttle Arm e - Idle Stop f - Cable Latch g - Throttle Cable Opening OUTBOARD MOTOR INSTALLATION Check throttle cam adjustment as follows: 1. T.P.S. must be rotated clockwise to the extreme end of slot position as shown. 2. With the throttle arm against the idle stop, the pointer must line-up with the center of the throttle lever shaft. If not, unsnap the ball end connector and adjust to achieve correct adjustment. a b d e f g c a-T.P.S. b-Idle Stop c-Pointer d-Throttle Lever Shaft e-Ball End Socket Connector f-Throttle Cam g-Throttle Arm 90-858895R1 JANUARY 2001 Page 1D-13 OUTBOARD MOTOR INSTALLATION Trim-In Stop Adjustment Some outboard boats, particularly some bass boats, are built with a greater than normal transom angle which will allow the outboard to be trimmed further “in” or “under”. This greater trim “under” capability improves acceleration, reduces the angle and time spend in a bow high boat attitude during planing off, and in some cases, may be necessary to plane off a boat with aft live wells (given the variety of available propellers and height range of engine installations). However, once on plane, the engine should be trimmed to a more intermediate position to avoid a bow-down planing condition called “plowing”. Plowing can cause “bow steering” or “over steering” and inefficiently consumes horsepower. In this condition, if attempting a turn or encountering a diagonal, moderate wake, a more abrupt turn than intended may result. In rare circumstances, the owner may decide to limit the trim under. This can be accomplished by purchasing a stainless steel tilt pin (P/N 17-49930A1) and inserting it through whatever pin hole is desired. The non-stainless steel shipping bolt should not be used in this application other than on a temporary basis. WARNING Avoid possible serious injury or death. Adjust outboard to an intermediate trim position as soon as boat is on plane to avoid possible ejection due to boat spin-out. Do not attempt to turn boat when engine is trimmed extremely under or in. a a-Tilt Pin Page 1D-14 90-858895R1 JANUARY 2001 OUTBOARD MOTOR INSTALLATION Trim Tab Adjustment The trim tab can be adjusted within limits to help compensate for steering torque. Adjust trim tab as follows: 1. If boat tends to pull to the right, move the rear edge of the trim tab to the right. 2. If boat tends to pull to the left, move the rear edge of the trim tab to the left. NOTE:Trim tab adjustment will have little effect reducing steering torque if the anti-ventilation plate is raised 2 inches (50 mm) or more above the boat bottom. 90-858895R1 JANUARY 2001 Page 1D-15 IGNITION ELECTRICAL Section 2A - Ignition Table of Contents 2 A Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2 Recommended Tests . . . . . . . . . . . . . . . . . 2A-21 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-4 Ignition Component Voltage Tests . . . . . . . . . 2A-23 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-6 Rectifier/Regulator. . . . . . . . . . . . . . . . . . . 2A-23 Electrical Components . . . . . . . . . . . . . . . . . . . 2A-8 CDI Unit (Coil Primary) . . . . . . . . . . . . . . . . 2A-24 Ignition Components . . . . . . . . . . . . . . . . . . . . . 2A-10 Crank Position Sensor (CPS) . . . . . . . . . . 2A-25 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-12 Stator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-26 Theory of Operation . . . . . . . . . . . . . . . . . . . . . 2A-14 Throttle Position Sensor (TPS) Ignition Component Description . . . . . . . . . . . 2A-15 Tests/Adjustment . . . . . . . . . . . . . . . . . . . . . 2A-27 Capacitor Discharge Ignition (CDI) . . . . . . 2A-15 Ignition Spark Gap . . . . . . . . . . . . . . . . . . . . 2A-29 Start Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-15 Ignition Component Resistance Tests . . . . . . 2A-30 Warm-up Mode . . . . . . . . . . . . . . . . . . . . . . 2A-15 Stator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-30 Normal Operation . . . . . . . . . . . . . . . . . . . . 2A-15 Ignition Coil (Primary) . . . . . . . . . . . . . . . . . 2A-31 Shift Interrupt Switch . . . . . . . . . . . . . . . . . . 2A-16 Ignition Coil (secondary) . . . . . . . . . . . . . . . 2A-31 Protection Controls . . . . . . . . . . . . . . . . . . . 2A-16 Spark Plug Cap/Wire . . . . . . . . . . . . . . . . . 2A-32 Throttle Position Sensor (TPS) . . . . . . . . . 2A-17 Oil Pressure Switch . . . . . . . . . . . . . . . . . . . 2A-32 Engine Temperature Sensor . . . . . . . . . . . 2A-17 Engine Temperature Sensor . . . . . . . . . . . 2A-33 Flywheel Assembly . . . . . . . . . . . . . . . . . . . 2A-17 Flywheel Removal/Installation . . . . . . . . . . . . . 2A-34 Stator Assembly . . . . . . . . . . . . . . . . . . . . . . 2A-17 Stator Removal/Installation . . . . . . . . . . . . . . . 2A-37 Crankshaft Position Sensor (CPS) . . . . . . 2A-18 Timing Belt Removal/Installation . . . . . . . . . . 2A-38 Ignition Coils . . . . . . . . . . . . . . . . . . . . . . . . . 2A-18 Crank Position Sensor Removal/Installation 2A-40 Ignition Test Procedures . . . . . . . . . . . . . . . . . . 2A-19 Rectifier/Regulator Removal/Installation . . . . 2A-41 Direct Voltage Adapter (DVA) . . . . . . . . . . 2A-19 CDI Removal/Installation . . . . . . . . . . . . . . . . . 2A-43 Ignition Troubleshooting . . . . . . . . . . . . . . . . . . 2A-20 Ignition Coil Removal/Installation . . . . . . . . . . 2A-44 Ignition Diagnostic Procedures . . . . . . . . . . . . 2A-20 Temperature Sensor Removal/Installation . . 2A-45 90-858895R1 JANUARY 2001 Page 2A-1 IGNITION Specifications Type Microcomputer-Controlled CDI Spark Plug: Type NGK LFR5A-11 Gap 0.043 in. (1.1 mm) Hex Size 5/8 in. (16 mm) Torque 18 lb-ft (25 Nm) Firing Order 1-3-4-2 Ignition Timing: @ Idle (850 rpm) 5° A.T.D.C @ WOT (6000 rpm) 18° B.T.D.C Stator Output - Peak Voltage: @ 400 rpm (Cranking) 6 - 9 V (WHT – WHT) @ 1500 rpm 12 - 18 V (WHT - WHT) @ 3500 rpm 14 - 25 V (WHT - WHT) Stator Coil Resistance 0.32 - 0.48 W (WHT - WHT) Crank Position Sensor Output - Peak Voltage: (WHT/BLK - BLK) for Cylinders 1 & 4 (WHT/RED - BLK) for Cylinders 2 & 3 @ 400 rpm (Cranking) 2.8 - 3.4 V @ 1500 rpm 6.5 - 7.8 V @ 3500 rpm 10.5 - 12.0 V Crank Position Sensor Resistance IGNITION (WHT/BLK - BLK) for Cylinders 1 & 4 445 - 545 W SYSTEM (WHT/RED - BLK) for Cylinders 2 & 3 445 - 545 W Readings taken @ CDI Unit Output - Peak Voltage: 68°F (20°C). (BLK/ORG - BLK) for Cylinders 1 & 4 (BLK/WHT - BLK) for Cylinders 2 & 3 @ 400 rpm (Cranking) 165 - 190 V @ 1500 rpm 175 - 200 V @ 3500 rpm 175 - 200 V Ignition Coil Resistance: Primary 0.078 - 0.106 W (BLK - BLK/WHT) Secondary (Without Boots) 3.5 - 4.7 kW (Between Towers) High Tension Lead Resistance: Cylinder #1 4.5 - 10.7 kW Cylinder #2 3.3 - 8.0 kW Cylinder #3 3.7 - 8.9 kW Cylinder #4 4.3 - 10.2 kW Engine Protection Controls: Engine Speed Limiter Spark Cut-Out to Cylinders #1 or #4 6200 rpm #1 and #4 6250 rpm #1, #4, and #2 or #3 6300 rpm #1, #2, #3, and #4 6350 rpm Overheat/Low Oil Pressure Engine Speed Control (Spark Cut-Out to Cylinders #1 and #4) Gradually Lowers to 3000 rpm Page 2A-2 90-858895R1 JANUARY 2001 IGNITION IGNITION SYSTEM Readings taken @ 68°F (20°C). Water Temperature Sensor: 2000 Engine S/N OT178499 and Below Warning Horn/rpm Reduction Reset Temperature (Throttle Closed/Key off) 2001 Engine S/N OT178500 and Above Warning Horn/rpm Reduction Reset Temperature (Throttle Closed/Key Off) 2000 MY Engine Oil Pressure Switch: S/N 0T178499 and Below Warning Horn/rpm Reduction Reset Pressure (ECM reset @ Closed Throttle) 2001 MY Engine OIl Pressure Switch: S/N 0T178500 and Above Warning Horn/rpm Reduction Reset Pressure (ECM reset @ Closed Throttle) Engine Water Temperature Sensor Resistance: @ -4°F (-20°C) @ 32°F (0°C) @ 68°F (20°C) @ 104°F (40°C) Throttle Position Sensor (TPS): Input Voltage @ Idle (850 rpm) Output Voltage @ Idle (850 rpm) 140°F (60°C) 118°F (48°C) 194°F (90°F) 167°F (75°C) Stamped P.15 Continuity Below 2.2 psi (15 kPa) No Continuity Above 2.2 psi (15 kPa) Stamped P1.5 Continuity Below 21.78 psi (150 kPa) No Continuity Above 21.78 psi (150 kPa) 15.5 kW 5.79 kW 2.45 kW 1.50 kW 5.0 ± 0.25 V (RED - ORG) 0.68 ± 0.82 V (PNK - ORG) CHARGING SYSTEM Readings taken @ 68°F (20°C). Alternator Type: Alternator Output Stator Coil Output - Peak Voltage: @ 400 rpm (Cranking) @ 1500 rpm @ 3500 rpm Stator Coil Resistance Rectifier/Regulator Output - Peak Voltage: @ 1000 rpm @ 1500 rpm @ 3500 rpm @ 6000 rpm Quicksilver Tachometer Setting Three Phase Stator Coil (12 Pole) 12.0 V; 20 Amps. (240 Watts) (Rectified/Regulated) 6 - 9 V (WHT – WHT) 12 - 18 V (WHT - WHT) 14 - 25 V (WHT - WHT) 0.32 - 0.48 W (WHT - WHT) 18 - 22 V (RED - BLK) 19 - 24 V (RED - BLK) 19 - 24 V (RED - BLK) 19 - 24 V (RED - BLK) “6P” or “4” 90-858895R1 JANUARY 2001 Page 2A-3 IGNITION Special Tools 1. Flywheel Holder P/N 91-83163M 2. Flywheel Puller P/N 91-83164M 3. Timing Light P/N 91-99379 4. Direct Voltage Adapter P/N 91-89045 or P/N 91-89045--1 91-89045 91-89045-1 Page 2A-4 90-858895R1 JANUARY 2001 IGNITION 5. Spark Board P/N 91-850439 6. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1 7. Pick-Up Test Harness 91-804771 8. Charge Coil Test Harness 91-804772 9. Throttle Position Test Harness 91-804773 90-858895R1 JANUARY 2001 Page 2A-5 IGNITION Flywheel 1 10 11 12 14 15 19 20 21 8 2 3 4 13 110 6 7 5 8 9 16 17 18 15 110 4 Stroke Outboard Oil (92-828000A12) Page 2A-6 90-858895R1 JANUARY 2001 IGNITION Flywheel REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 FLYWHEEL COVER 2 1 DECAL-WARNING-SPINNING FLYWHEEL 3 1 DECAL-SERVICING REFERRAL 4 1 DECAL-ENGINE OIL/VALVE 5 1 DECAL-EMISSION 6 1 DECAL-Emergency 7 2 BOLT (M6 x 20 mm) 65 7.4 8 4 COLLAR 9 2 GROMMET 10 1 NUT (36 mm Hex) 140 190 11 1 PLATE WASHER 12 1 FLYWHEEL 13 1 DECAL-WARNING NEUTRAL 14 1 STATOR KIT 15 2 DOWEL PIN 16 4 SCREW 17 4 LOCKWASHER 18 4 WASHER 19 1 SCREW 20 1 TIMING PLATE 21 1 ROTOR 90-858895R1 JANUARY 2001 Page 2A-7 IGNITION Electrical Components 1 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1920 21 22 23 24 25 26 27 28 30 31 32 21 35 36 37 38 39 40 41 42 43 42 2 3 Dielectric Grease (92-823506--1)6 6 6 6 6 6 6 44 34 33 Page 2A-8 90-858895R1 JANUARY 2001 IGNITION Electrical Components REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 COVER 2 1 DECAL-START IN GEAR 3 1 DECAL-HIGH VOLTAGE 4 1 FUSE PULLER 5 1 WIRING HARNESS 6 2 FUSE (20A) 7 2 FUSE (30A) 8 1 STA-STRAP 9 1 BRACKET 10 3 SCREW (M6 x 16 mm) 70 8 11 1 RELAY BRACKET 12 2 SCREW (M6 x 16 mm) 70 8 13 1 BRACKET 14 1 RELAY 15 2 WASHER 16 2 NUT 17 2 BOOT 18 1 RELAY 19 3 WASHER 20 3 NUT 21 2 BOOT 22 1 RELAY 23 1 CABLE 24 1 CABLE 25 3 WASHER 26 3 NUT 27 1 COVER 28 5 SCREW (M6 x 20 mm) 70 8 29 1 HARNESS 30 1 BOLT (M6 x 20 mm) 70 8 31 1 LOCKWASHER 32 1 WASHER 33 1 PLATE 34 3 SCREW (M6 x 12 mm) 70 8 35 1 BATTERY CABLE (POSITIVE) 36 1 BATTERY CABLE (NEGATIVE) 37 1 NUT 120 10 13.5 38 1 SCREW (M8 x 12 mm) 120 10 13.5 39 CONNECTOR 40 1 HARNESS - Adaptor/Trim 41 1 HARNESS - Trim Motor Adaptor 42 2 NUT 20-25 2.3 43 1 HARNESS 44 1 RETAINER 90-858895R1 JANUARY 2001 Page 2A-9 IGNITION Ignition Components 11 13 14 16 17 12 1 5 2 8 6 9 4 7 9 10 16 17 15 10 3 Page 2A-10 90-858895R1 JANUARY 2001 IGNITION Ignition Components REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 RECTIFIER/REGULATOR 2 1 COVER 3 2 SCREW (M6 x 25 mm) 70 8 4 1 SCREW (M6 x 20 mm) 70 8 5 1 CDI UNIT 6 4 SCREW (M6 x 28 mm) 70 8 7 4 GROMMET 8 4 BUSHING 9 2 IGNITION COIL 10 4 SCREW (M6 x 30 mm) 70 8 11 1 CLAMP 12 1 SCREW (M6 x 12 mm) 70 8 13 1 SCREW (M6 x 20 mm) 70 8 14 1 HI-TENSION CABLE SET 15 1 BRACKET 16 2 CLAMP 17 2 CLAMP 90-858895R1 JANUARY 2001 Page 2A-11 IGNITION Sensors 1 23 4 5 6 7 8 9 10 11 12 13 14 15 16 1718 19 20 6 6 21 10 6 Dielectric Grease (92-823506--1) Page 2A-12 90-858895R1 JANUARY 2001 IGNITION Sensors REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 PLATE 2 2 SCREW (M6 x 16 mm) 70 8 3 1 THERMO SENSOR 4 1 RETAINER 5 1 GASKET 6 2 SCREW (M6 x 16 mm) 70 8 7 1 OIL PRESSURE SWITCH 8 1 CLAMP 9 1 CLAMP 10 2 STA-STRAP 11 2 SCREW (M5 x 10 mm) 15 2 12 1 THROTTLE SENSOR 13 1 LEVER 14 2 SCREW (M5 x 25 mm) 44 5 15 2 WASHER 16 1 BRACKET 17 2 GROMMET 18 2 COLLAR 19 1 STA-STRAP 20 1 HARNESS-TPS ADAPTOR 21 1 DECAL-Spark Plug 90-858895R1 JANUARY 2001 Page 2A-13 IGNITION Theory of Operation The ignition system uses a microcomputer-controlled CDI (Capacitor Discharge Ignition) system. This system provides quick voltage buildup and strong spark required for high power and high performance engines. The CDI ignition system does not incorporate mechanically operated points, therefore making this CDI unit virtually maintenance free. As the flywheel rotates, electrical power (alternating current) is produced by the stator coils. This power is rectified by diodes so that direct current voltage is utilized by the ignition system. When the ignition driver is off, the D.C. voltage is stored by the capacitor. Once capacitor voltage is charged to its potential, a gate signal is applied on the SCR and the residual current is dissipated through the capacitor charging coils. Ignition timing is regulated by the CDI which receives status input from three different signals. These signals include the crankshaft position, engine revolution and throttle position. The voltage discharged to the primary winding of the ignition coil causes a surge of high voltage to be induced in the secondary winding of the ignition coil. This induced voltage of sufficient amplitude causes the spark plugs to fire. a b c d e f g h a-Ignition Coils b-Engine Temperature Sensor c-Throttle Position Sensor (TPS) d-CDI Unit e-Crank Position Sensor (CPS) f-Stator Coil g-Crank Position Sensor (CPS) h-Oil Pressure Switch Page 2A-14 90-858895R1 JANUARY 2001 IGNITION Ignition Component Description Capacitor Discharge Ignition (CDI) Under normal operating conditions the microcomputer-controlled CDI system has three basic modes of operation: start, warm-up, and normal operation. Start Mode Ignition timing is fixed at 10° BTDC. The start mode cuts off when the engine is started and the engine speed is over 600 rpm. Warm-up Mode During this mode ignition timing is fixed at 10° BTDC and the engine speed is approximately 1100 rpm. There are four main situations (based on atmospheric temperatures) that this mode operates in. 1. Below 32°F (0°C), this mode lasts approximately 300 seconds. 2. From 32°F (0°C) - 68°F (20°C), this mode lasts approximately 180 seconds. 3. From 68°F (20°C) - 104°F (40°C), this mode lasts approximately 120 seconds. 4. Over 104°F (40°C), this mode does not operate. The warm-up mode will cut off if the engine speed exceeds 4000 rpm. Normal Operation This mode operates between 5° ATDC and 25° BTDC. The ignition timing is automatically adjusted by the microcomputer. The microcomputer receives three signals (i.e., crankshaft position, engine revolution, and throttle position) every 5ms (microseconds) and then adjusts the ignition timing accordingly. Two crank position sensors (CPS) send signals to the microcomputer which then determines the crankshaft position and engine revolution. The throttle position sensor (TPS) also sends signals to the microcomputer which then determines the throttle position. The microcomputer uses these three signals to determine the proper ignition timing. 90-858895R1 JANUARY 2001 Page 2A-15 IGNITION Shift Interrupt Switch As the remote control handle is shifted from forward gear to neutral (idle position) the switch will momentarily cut spark to cylinders number 1 and 4. This decreases the shift load and allows for easier shifting. NOTE:If switch activation occurs in the neutral position the engine will run rough. Reposition switch to the alternate (forward) set of mounting holes on the bracket. a b c a-Shift Interrupt Switch b-Bracket c-Alternate Mounting Holes Protection Controls This ignition system incorporates three protection controls that are described below. OVER REVOLUTION CONTROL Over 6200 rpm the ignition to either cylinder #1 or #4 is cut. At 6250 rpm the ignition to both cylinders #1 and #4 is cut. Over 6300 rpm the ignition to both cylinders #1 and #4 and either #2 or #3 is cut. Over 6350 rpm the ignition to all 4 cylinders is cut. OVERHEAT CONTROL IMPORTANT: The Temperature sensor remains the same for 2001 model year, but the location is changed from the lower exhaust cover to the upper portion of the cover. The switch is in a hotter position for 2001 model year. The CDI module (ECM) is changed to accommodate the higher temperature. When the engine speed is less than 2000 rpm this control mode is delayed 75 seconds after the engine is started. When the engine speed is 2000 rpm or more this control mode is delayed 24 seconds after the engine is started. When the cooling water reaches warning activation temperature, the overheat alarm (constant tone) will activate. Ignition to cylinders #1 and #4 will cut off and the engine speed will gradually reduce to approximately 3000 rpm. Once the cooling water decreases to reset temperature the alarm can be deactivated by bringing the remote control handle to neutral position and turning the ignition key to the off position (then back to the start position). 2000 Model Year S/N OT178499 and Below 2001 Model Year S/N OT178500 and Above ECM - P/N 804269 ECM - P/N 804269T1 Warning Activation Temp. 140°F (60°C) Warning Activation Temp. 194°F (90°C) Reset Temp. 118°F (48°C) Reset Temp. 167°F (75°C) Page 2A-16 90-858895R1 JANUARY 2001 IGNITION LOW OIL PRESSURE CONTROL Two seconds after staring the engine this mode does not operate. If the cooling water temperature is 104°F (40°C) or above, and the throttle is quickly closed so the engine speed drops below 1700 rpm, this mode will not operate for 9 minutes. When the oil pressure switch turns on (due to low oil pressure) this mode starts. The alarm (constant tone) will sound. Ignition to cylinders #1 and #4 will cut off and the engine speed will gradually reduce to approximately 3000 rpm. Once the oil pressure increases to an acceptable level (specified in table below), the alarm can be deactivated by bringing the remote control handle to neutral position and turning the ignition key to the off position (then back to the start position). 2000 Model Year S/N OT178499 and Below 2001 Model Year S/N OT178500 and Above P/N 87-804307 P/N 87-804307--1 Stamped P-.15 Stamped P-1.5 Warning Activates @ 2.2 psi (15kPa) and below Warning Activates @ 21.78 psi (150kPa) and below Throttle Position Sensor (TPS) If the TPS is faulty, the ignition timing will automatically be fixed at 10° BTDC. Engine Temperature Sensor If the engine temperature sensor is faulty, the ignition timing will automatically be fixed at 10° BTDC. Flywheel Assembly The flywheel assembly contains six permanently charged magnet segments which are bonded and retained to the inner wall of the flywheel. Each magnet contains a north and a south pole providing a 12 pole system. Stator Assembly The stator assembly located under the flywheel, contains coil windings which provides three-phase AC voltage, to power the ignition, electronic engine controls, and battery charging. As the flywheel permanent magnets pass the coil windings, an AC pulse current is produced at each coil winding as the magnet polarity changes (South to North), (North to South) etc. 90-858895R1 JANUARY 2001 Page 2A-17 IGNITION Crankshaft Position Sensor (CPS) 57673 a a-Crank Position Sensor (2) As the crankshaft rotates, the crank position sensors (CPS) (2) sense a passing tooth on the rotor (located on the crankshaft, under the cam belt drive gear). The CPS sends signals to the microcomputer which then determines both the crankshaft position and engine speed. Ignition Coils The primary (+) side of the ignition coil receives voltage discharged from a capacitor in the ignition (CDI) circuit located inside the ECM. The voltage is multiplied by the coil until it can jump the spark plug gap. The ignition coil will produce a high voltage current each crankshaft revolution, producing a spark at each cylinder at the same time (Waisted Spark Ignition). Ignition coil maximum output is approximately 40,000 volts. Page 2A-18 90-858895R1 JANUARY 2001 IGNITION Ignition Test Procedures Direct Voltage Adapter (DVA) WARNING DANGER – HIGH VOLTAGE/SHOCK HAZARD! Do not touch ignition components and/or metal test probes while engine is running and/or being “cranked”. STAY CLEAR OF SPARK PLUG LEADS. To assure personal safety, each individual spark plug lead should be grounded to engine. WARNING When testing or servicing the ignition system, high voltage is present. DO NOT TOUCH OR DISCONNECT any ignition parts while engine is running, while key switch is on or while battery cables are connected. CAUTION Failure to comply with the following items may result in damage to the ignition system. 1. DO NOT reverse battery cable connections. The battery negative cable is (–) ground. 2. DO NOT “spark” battery terminals with battery cable connections to check polarity. 3. DO NOT disconnect battery cables while engine is running. 4. DO NOT crank engine with CDI or Ignition Coils not grounded. CAUTION To protect against meter and/or component damage, observe the following precautions: • 400 VDC* test position (or higher) MUST BE used for all tests. • INSURE the Positive (+) lead/terminal of DVA is connected to the Positive (+) receptacle of meter. • DO NOT CHANGE meter selector switch position while engine is running and/or being “cranked”. • ALL COMPONENTS MUST BE GROUNDED during tests. Running or “cranking” engine with CDI or Ignition Coils ungrounded may damage components. * If using a meter with a built-in DVA, the DVA/400 or DVA/500 VDC test position should be used. NOTE:If test leads are not supplied with the Direct Voltage Adapter.Use test leads supplied with multi meter. Test procedures and specifications are provided for checking primary ignition voltage while the engine is running and/or being “cranked” with all harnesses connected. 90-858895R1 JANUARY 2001 Page 2A-19 IGNITION Ignition Troubleshooting WARNING DANGER - HIGH VOLTAGE/SHOCK HAZARD! Do not touch ignition components and/or metal test probes while engine is running and/or being “cranked”. STAY CLEAR OF SPARK PLUG LEADS. To assure personal safety, each individual spark plug lead should be grounded to engine. WARNING When testing or servicing the ignition system, high voltage is present. DO NOT TOUCH OR DISCONNECT any ignition parts while engine is running. IMPORTANT: This ignition system requires proper battery voltage to obtain proper spark voltage. TOOL: MULTIMETER/DVA TESTER 91-99750A1 OR DMT 2000 MULTIMETER WITH DIRECT VOLTAGE ADAPTOR (91-89045). *If using a meter that requires a DVA adapter, place selector switch to the 400 VDC position. NOTE:Copper is an excellent conductor, however, resistance may vary between low and high temperature. Therefore, reasonable differences can be accepted between resistance readings and specifications. The above readings are for a cold (room temperature) engine. Resistance will increase if the engine is warm. Ignition Diagnostic Procedures TROUBLESHOOTING TIP: With engine running, use inductive timing light to check spark advance of each cylinder as throttle is opened and closed. If timing advances and retards on each cylinder, ignition system is MOST LIKELY functioning properly. IMPORTANT: If outboard appears to have an ignition system failure, it is recommended that before beginning in-depth troubleshooting: a. Ensure that the engine is in mechanically sound condition. (Fuel System, Cylinder Compression etc.). b. Check all engine ground leads for loose or corroded connections. c. Disconnect and reconnect ignition harness connectors to verify proper continuity. SUGGESTED TESTING PROCEDURES NOTE:The following recommended tests and probable causes are not listed in any specific order. The technician should use this table as a guide to help isolate and test the specific problem/condition. Always perform the DVA tests first (if applicable), then perform resistance test to validate suspected component failure. Page 2A-20 90-858895R1 JANUARY 2001 IGNITION Recommended Tests (1) DVA TEST (Direct Voltage Adapter) (2) OHM TEST (Resistance Testing) (3) Replace Component and Retest (4) Mechanical Test/Repair (5) Battery Voltage Check PROBLEM/CONDITION Probable Cause *Perform Test No. No Spark Condition (All Cylinders) Stator 1-2 (CDI) Stop Circuit Short to Ground: 3 a - stop circuit lead 2 b - lanyard stop switch 2 c - tiller handle stop button (if supplied) 2 d- remote control harness 2 Ignition Coil 2 a - primary Circuit Shorted to Ground 2 Spark Plugs Open Ground Condition: 3 a - ignition coil 2 b - stator ground 3 c - (CDI) 3 d - battery to CDI 5 No Spark Condition (One or two Cylinder) High Tension Lead (Resistance Lead) Spark Plug Cap (Resistor) Spark Plug 2 2 3 Weak Spark Condition Ground Connection at: a - Ignition Coil Primary Leads 2 b - Stator 2 c - (CDI) Primary Coil Supply Leads High Resistance To Ground at: 3 a - stop/lanyard switch (water/corrosion) 2 Weak Charge Coil 1-2 Ignition Coil/High Tension Lead(s) 1-3 Spark Plug(s) 2 Spark Plug Cap (Resistor) 3 Spark Plug Cap Leak 3 (CDI) Failure 3 Battery Voltage Condition 5 Timing Fluctuates NOTE:It is considered normal for the timing to fluctuate approximately 1° - 2° within the designated timing window. Loss Of Oil Pressure/Over Heating: a - timing retards and fluctuates, rpm will drop below 3000 rpm Flywheel Key Sheared (CDI) Unit 4 4 3 Timing Will Not Advance Low Oil Pressure/Engine Over Heating: a - timing retards and fluctuates, rpm will remain below 3000 rpm 4 (CDI) 3 90-858895R1 JANUARY 2001 Page 2A-21 IGNITION Recommended Tests (cont.) (1) DVA TEST (Direct Voltage Adapter) (2) OHM TEST (Resistance Testing) (3) Replace Component and Retest (4) Mechanical Test/Repair (5) Battery Voltage Check Engine Misfires At High RPM Low Oil Pressure/Engine Over Heating: a - timing retards and fluctuates, rpm will remain below 3000 rpm 4 Ignition Coil/High Tension Lead(s) 2 Spark Plug Cap(s) 2 Spark Plug(s) 3 (CDI) Unit Ground Connection: 3 a - (CDI) 3 b - ignition coil 2 Engine Hard To Start Cold Debris In Carburetor Enrichener Circuit Weak Spark Condition Throttle Plate in Open Position 4 1 4 Engine Hard To Start Hot Weak Spark Condition Vapor Lock Debris In Carburetor Enrichener Circuit 4 4 4 Engine Will Not Run Over 3000 RPM Low Oil Pressure/Engine Over Heating: a - timing retards and fluctuates, rpm will remain below 3000 rpm 4 Ignition Coil/High Tension Lead(s) 2 (CDI) 3 Spark Plug(s) 3 Engine Occasionally Misfires Ignition Coil/High Tension Lead(s) 2 Spark Plug Cap(s) 2 Spark Plug(s) Ground Connection at: 3 a - ignition coil 2 b - (CDI) High Resistance To Ground at: 3 a - stop/lanyard switch (water/corrosion) 2 (CDI) 3 Engine Surges Over Boat Under Propped 4 6200 RPM While Under Load NOTE:The engine (CDI) will retard timing and reduce rpm above 6200 rpm. Propeller Hub Spun 4 Page 2A-22 90-858895R1 JANUARY 2001 IGNITION 90-858895R1 JANUARY 2001 Page 2A-23 Ignition Component Voltage Tests IMPORTANT: Some of the test harness leads may have square dashed marks on them. Ignore these marks, they do not indicate the color of the test lead. The solid tracer line indicates the color of the lead. a b a - Square Dashed Marks b - Solid Tracer Line Rectifier/Regulator Output Peak Voltage 1. Connect the meter test leads to the leads illustrated below. Perform tests as specified in the chart below. • If the reading obtained is excessively below specification - check the stator coil output peak voltage. a b c d 91-854009A1 91-89045-1 a - BLACK Wire/Ground b - Red Lead c - Direct Voltage Adaptor (91-89045-1) d - DMT 2000 Multi - Meter (91-854009A1) NOTE:Use direct voltage adaptor and DMT 2000 digital multi-meter while performing test. METER TEST LEADS METER SCALE READING(V RED BLACK 18 - 22V @ 1000 RPM TEST HARNESS LEADS 19 24V @ 1500 RPM DC VOLTS - 19 - 24V @ 3500 RPM RED BLACK/GROUND 19 - 24V @ 6000 RPM IGNITION Page 2A-24 90-858895R1 JANUARY 2001 CDI Unit Peak Voltage (Coil Primary) 1. Plug in the test harness and perform tests as specified in the chart below. • If reading obtained is above specification on any of the tests - replace the ignition coil. • If reading obtained is below specification on any of the tests - measure the stator output peak voltage. Repeat this check two times. NOTE:Use direct voltage adaptor, DMT 2000 digital multi-meter and test harness 91-804771 while performing test. 91-804771 a b c 91-854009A1 91-89045-1 a - Direct Voltage Adaptor (91-89045-1) b - DMT 2000 Multi - Meter (91-854009A1) c - Test Harness (91-804771) METER TEST LEADS METER SCALE READING (V RED BLACK TEST HARNESS LEADS #2 AND #3 CYL. WHT/BLU #2 AND #3 CYL. WHT DC VOLTS 165-190 V @ 400 RPM (CRANKING) 170-200 V @1500 RPM #1 AND #4 CYL. WHT/GRN #1 AND #4 CYL. WHT 170 170-200 V @ 3500 RPM 58408 a b a b #2 AND #3 CYLINDER #1 AND #4 CYLINDER a - To Harness Connector b - To CDI Unit Connector IGNITION 90-858895R1 JANUARY 2001 Page 2A-25 Crank Position Sensor (CPS) Peak Voltage 1. Plug in the test harness and perform tests as specified in the chart below. • If reading obtained is above specification on any of the tests - replace the CDI unit. • If reading obtained is below specification on any of the tests - replace the crank position sensor. NOTE:Use direct voltage adaptor, DMT 2000 digital multi-meter and test harness 91-804771-while performing test. 91-804771 c 91-854009A1 91-89045-1 a b a - Direct Voltage Adaptor (91-89045-1) b - DMT 2000 Multi - Meter (91-854009A1) c - Test Harness (91-804771) METER TEST LEADS METER SCALE READING (V) RED BLACK TEST HARNESS LEADS #2 AND #3 CYL. WHT/YEL #2 AND #3 CYL. WHT DC VOLTS 2.8-3.4 V @ 400 RPM (CRANKING) 6.5 - 7.8 V @ 1500 RPM #1 AND #4 CYL. WHT/RED #1 AND #4 CYL. WHT 10.5 - 12.0 V @ 3500 RPM 58408 a b a b #2 AND #3 CYLINDER #1 AND #4 CYLINDER a - To Harness Connector b - To CDI Unit Connector IGNITION Page 2A-26 90-858895R1 JANUARY 2001 Stator Coil Peak Voltage 1. Plug in the test harness and perform tests as specified in the chart below. • If reading obtained is above specification on any of the tests - measure the CDI unit output peak voltage. • If reading obtained is below specification on any of the tests - replace the stator coil. 91-804772 a b c 91-854009A1 91-89045-1 a - Direct Voltage Adaptor (91-89045-1) b - DMT 2000 Multi - Meter (91-854009A1) c - Test Harness (91-804772) NOTE:Use direct voltage adaptor, DMT 2000 digital multi-meter and test harness 91-804772 while performing test. METER TEST LEADS METER SCALE READING(V RED BLACK TEST HARNESS LEADS 10-18 V @ 400 RPM (CRANKING) RED WHITE DC VOLTS 16 - 24 V @ 750 RPM ( IDLE) RED BLACK @ ) 16 - 24 V 1500 RPM 16 - 24 V @ 3500 RPM WHITE BLACK 58410 BLK RED BLK RED WHT RED WHT BLK BLK RED RED BLK RED WHT BLK a b a b a b a - Regulator/Rectifier Harness b - Stator Harness IGNITION Throttle Position Sensor Tests/Adjustment INPUT VOLTAGE 1. Plug the test harness in between the engine wiring harness and TPS adaptor harness. Perform tests as specified in the chart below. 2. If the reading obtained is out of specification - check the CDI unit. 91-804773 STATOR TPI a 91-854009A1 b c d e a-Engine Wiring Harness b-Test Harness (91-804773) c-TPS Adaptor Harness (part of engine wiring) d-Throttle Position Sensor e-DMT 2000 Multi - Meter (91-854009A1) METER TEST LEADS METER SCALE READING(V) RED BLACK DC VOLTS DC VOLTS 5.0 ± 0.25 V @ 850 RPM 5.0 ± 0.25 V @ 850 RPM TEST HARNESS LEADS RED ORANGE 58409 a b a-To Engine Wiring Harness b-To TPS Adaptor Harness 90-858895R1 JANUARY 2001 Page 2A-27 IGNITION THROTTLE POSITION SENSOR - OUTPUT VOLTAGE 1. Plug the test harness in between the engine wiring harness and TPS adaptor harness. Perform tests as specified in the chart below. 2. Start the engine, allow it to warm up for several minutes. 3. Measure the voltage at engine idle speed in forward gear. 4. If the reading obtained is out of specification - adjust the TPS position. 5. While slowly opening and closing the throttle valves, check if voltage changes gradually. 91-804773 STATOR TPI a 91-854009A1 b c d e a-Engine Wiring Harness b-Test Harness (91-804773) c-TPS Adaptor Harness (part of engine wiring) d-Throttle Position Sensor e-DMT 2000 Multi - Meter (91-854009A1) METER TEST LEADS METER SCALE READING(V) RED BLACK DC VOLTSDC VOLTS 0.68 0.82 @ 850 RPM0.68 - -- 0.82 @ 850 RPM TEST HARNESS LEADS PINK ORANGE 58409 a b a-To Engine Wiring Harness b-To TPS Adaptor Harness Page 2A-28 90-858895R1 JANUARY 2001 IGNITION THROTTLE POSITION SENSOR ADJUSTMENT 1. Start engine at idling speed. 2. Move the throttle control lever until it contacts the fully-closed stopper. 3. Loosen TPS mounting screws. 4. Rotate TPS fully clockwise (to end of slot position). 5. Tighten TPS mounting screws. a a-Screws (2) Ignition Spark Gap 1. Remove the spark plugs from the engine. Connect the spark plug cap to the spark gap tester (P/N 91-850439). 2. Set the spark gap length on the adjusting tool (Spark Gap 0.4 in. (11mm)). 3. Crank the engine and observe the ignition system spark through the discharge window. • Below specification - continue to check the CDI unit output. 90-858895R1 JANUARY 2001 Page 2A-29 IGNITION Ignition Component Resistance Tests When performing resistance tests, all component leads must be disconnected. Readings may very slightly due to temperature changes. NOTE:Readings listed taken at 68° F(20° C). NOTE:Use ohm meter and test harness91-804772while performing test. Stator Coil 1. Plug in the test harness and perform tests as specified in the chart below. IMPORTANT: Do not plug in both ends of the test harness. Only plug in the end that fits the connector coming out of the stator. 91-804772 METER TEST LEADS METER SCALE READING () RED BLACK RX1 0.32 - 0.48 TEST HARNESS LEADS RED WHITE RED BLACK WHITE BLACK 58410 BLKRED BLKREDWHTREDWHTBLKBLKREDREDBLK REDWHTBLK aa a a-To Stator Harness Page 2A-30 90-858895R1 JANUARY 2001 IGNITION Ignition Coil (Primary) METER TEST LEADS METER SCALE READING () RED BLACK RX1RX1 0 078 0 106 0.078 - 0.106BLK/WHT BLACK Ignition Coil (secondary) NOTE:Remove high tension spark plug leads/spark plug caps when performing this test. METER TEST LEADS METER SCALE READING () RED BLACK RX1KRX1K 35 473.5 - 4.7HIGH TENSION LEAD HIGH TENSION LEAD 90-858895R1 JANUARY 2001 Page 2A-31 IGNITION Spark Plug Cap/Wire • Out of specification - replace. METER TEST LEADS METER SCALE READING () RED BLACK RX1K #1 4.5 - 10.7 #2 3.3 - 8.0 #3 3.7 - 8.9 #4 4.3 - 10.2 WIRE END PLUG END Oil Pressure Switch • If the reading obtained is out of specification - replace. 2000 MY (S/N 0T178499 AND BELOW) Pressure switch stamped P.15 (point 15) METER TEST LEADS READING PRESSURE RED BLACK 2 2 i (15 kP ) d b l2.2 psi (15 kPa) and belowSWITCH END SWITCH EDGE 2001 MY (S/N 0T178500 AND ABOVE) Pressure switch stamped P1.5 (1 point 5) METER TEST LEADS READING PRESSURE RED BLACK Continuity and below 21 78 i (150 kP )21.78 psi (150 kPa)SWITCH END SWITCH EDGE Page 2A-32 90-858895R1 JANUARY 2001 IGNITION Engine Temperature Sensor 1. Place the engine cooling water temperature sensor in a container filled with water. 2. Place a thermometer in the water and slowly heat the water. 3. Measure the resistance when the specified temperature is reached. • Out of specification - replace. a BLK BLK/YEL a-Engine Temperature Sensor METER TEST LEADS METER SCALE READING () RED BLACK RX1K RX1KRX1K -4°F (-20°C) 15.5 °F(0°C)32 3232 F (0 C) 5 55 .79 7979 68°F (20°C) 2.45 104°F (40°C) 1.50 BLK/YEL BLK Temperature (  F) –10 5 20 35 50 65 80 95 110 125 140 155 170 185 200 215 230 245 260 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 Temperature Sensor Resistance (k) 90-858895R1 JANUARY 2001 Page 2A-33 IGNITION Flywheel Removal/Installation WARNING Engine could possibly start when turning flywheel during removal and installation. To prevent this type of accidental engine starting and possible serious injury, always remove spark plug leads from spark plugs. Removal 1. Remove flywheel cover. a 57601 a-Screw (2) Page 2A-34 90-858895R1 JANUARY 2001 IGNITION 90-858895R1 JANUARY 2001 Page 2A-35 2. Loosen flywheel nut. Hold flywheel using flywheel holder (91-83163M). 3. Remove nut and washer. 91-83163M b 57583 a c d a - Flywheel Holder (91-83163M) b - Breaker Bar with 36 mm Socket c - Nut (36 mm Hex) d - Washer 4. Loosen flywheel using puller (91-83164M). Remove flywheel and key. 91-83164M 57582 a b c a - Flywheel Puller (91-83164M) b - Flywheel c - Key IGNITION Page 2A-36 90-858895R1 JANUARY 2001 Installation 1. Place flywheel key into slot. 2. Install flywheel. 3. Install washer and nut. 4. Hold flywheel using flywheel holder (91-83163M) and tighten nut to the specified torque. 91-83163M c d f e b a 110 110 4-Stroke Outboard Oil (92-828000A12) a - Key b - Flywheel c - Washer d - Nut (36 mm Hex) e - Torque Wrench f - Flywheel Holder (91-83163M) Flywheel Nut Torque 140 lb-ft (190 Nm) IGNITION 90-858895R1 JANUARY 2001 Page 2A-37 Stator Removal/Installation 1. Remove flywheel. 2. Remove CDI cover screws. Remove CDI cover. 3. Disconnect stator coupler from CDI coupler. 4. Remove screw from j-clamp. 5. Remove stator mounting screws. 6. Reverse steps for installation. 57586 e 57588 d a c b a - CDI Cover Screws (3) M6 x 20 b - CDI Cover c - Stator Coupler d - J-clip e - Screws (3) M6 x 30 mm Stator Screw Torque 70 lb-in. (8 Nm) IGNITION Page 2A-38 90-858895R1 JANUARY 2001 Timing Belt Removal/Installation Removal 1. Remove flywheel (refer to flywheel removal section). 2. Remove stator (refer to stator removal on previous page). 3. Remove stator coil assembly base screws (4). 4. Remove timing belt tensioner spring. 5. Loosen timing belt tensioner bolt. 6. Remove timing belt. 57585 57550 a b c a - Stator Coil Base Screws (4) M6 x 28 b - Timing Belt Tensioner Spring c - Timing Belt Tensioner Bolt IGNITION Installation 1. Align marks on driven gears as shown. 2. Align mark on drive gear as shown. 3. Follow sequence in note below and install timing belt onto drive gear. Slide timing belt onto driven sprockets. 4. Install belt tensioner spring. 5. Tighten belt tensioner bolt. NOTE:Install timing belt with parts name up. NOTE:Install timing belt over drive gear first (1), then around driven gear (2) making sure belt is tight from drive gear to driven gear. Continue to keep belt tight while installing belt around other driven gear (3). Make sure timing marks are lined up on drive gear and driven gears, then place belt around belt tensioner (4). Install spring and tighten bolt. 57550 b c d a e1 23 4 a-Timing Mark on Driven Gears b-Timing Belt Tensioner Spring c-Timing Belt Tensioner Screw M10 x 45 d-Timing Mark on Drive Gear e-Parts Name Up On Timing Belt Belt Tensioner Bolt Torque 29 lb-ft (40 Nm) 90-858895R1 JANUARY 2001 Page 2A-39 IGNITION Page 2A-40 90-858895R1 JANUARY 2001 Crank Position Sensor Removal/Installation 1. Remove stator (refer to stator removal). 2. Remove stator coil assembly base screws. 3. Remove j-clip and screws (2 per sensor) from under side of stator coil base assembly. 4. Reverse steps for installation. d b c c 57585 a 57673 a - Stator Coil Base Screw (4) b - J-clip c - Crank Position Sensor Screw (4) d - Crank Position Sensor (2) IGNITION 90-858895R1 JANUARY 2001 Page 2A-41 Rectifier/Regulator Removal/Installation NOTE:Removal of intake silencer for ease of rectifier/regulator removal. 1. Remove TPI screws. 2. Remove intake silencer mounting screws. 57599 57594 b a c a - Intake Silencer Mounting Screws (8) b - TPI Mounting Screws (2) M5 x 25 c - Intake Silencer Side Mounting Screws (3) TPI Screw Torque 44 lb-in. (5 Nm) Intake Silencer Side Mounting Screw Torque 157 lb-in. (18 Nm) Intake Silencer Mounting Screw Torque 70 lb-in. (8 Nm) IGNITION 3. Remove rectifier/regulator mounting screws and ground wires. 4. Disconnect voltage regulator wires. 5. Disconnect coupler. 6. Reverse steps for installation (refer to wiring diagram section 2D for correct wire connections). a b c a-Mounting Screw (2) M6 x 25 b-Ground Wires c-Coupler Rectifier/Regulator Mounting Screw Torque 70 lb-in. (8 Nm) 57588 Page 2A-42 90-858895R1 JANUARY 2001 IGNITION CDI Removal/Installation 1. Remove and install CDI as shown. 57588 a b a-CDI Mounting Screw (4) M6 x 28 b-Harness Connections (3) CDI Mounting Screw Torque 70 lb-in. (8 Nm) 90-858895R1 JANUARY 2001 Page 2A-43 IGNITION Page 2A-44 90-858895R1 JANUARY 2001 Ignition Coil Removal/Installation 1. Remove spark plug cover. 2. Disconnect spark plug leads from spark plugs. 3. Disconnect wires (BLK and BLK/WHT). 4. Remove screw to remove ground wires. 5. Remove ignition coil mounting screws. 6. Reverse steps for installation. b a a a - Ignition Coil Mounting Screw (4) M6 x 30 b - Ground Screw M6 x 20 Ignition Coil Mounting Screw Torque 70 lb-in. (8 Nm) IGNITION Temperature Sensor Removal/Installation 1. Push down on wiring harness connector to remove from sensor. 2. Remove temperature sensor mounting screws and remove sensor from exhaust cover. 3. Reverse steps for installation. a b UP a-Temperature Sensor Mounting Screw (2) M6 x 16 b-Harness Connector Temperature Sensor Mounting Screw Torque 70 lb-in. (8 Nm) 90-858895R1 JANUARY 2001 Page 2A-45 CHARGING & STARTING SYSTEM ELECTRICAL Section 2B - Charging & Starting System Table of Contents 2 B Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Analog Meter . . . . . . . . . . . . . . . . . . . . . . . . 2B-10 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3 Digital Meter . . . . . . . . . . . . . . . . . . . . . . . . . 2B-11 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-4 Starting System Components . . . . . . . . . . . . . 2B-12 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-6 Description . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-12 Recommended Battery . . . . . . . . . . . . . . . . 2B-6 Troubleshooting the Starting Circuit . . . . . . . . 2B-12 Operating Engine Without Battery . . . . . . 2B-6 Starter Solenoid Test . . . . . . . . . . . . . . . . . . 2B-13 Battery Charging System Troubleshooting 2B-6 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-16 Battery Charging System . . . . . . . . . . . . . . . . . 2B-7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-16 Description (20 Ampere) . . . . . . . . . . . . . . 2B-7 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 2B-16 Wiring Diagram (20 Ampere) . . . . . . . . . . . 2B-7 Cleaning and Inspection . . . . . . . . . . . . . . . 2B-18 Alternator System Test . . . . . . . . . . . . . . . . . . . 2B-8 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-20 20 Ampere Stator . . . . . . . . . . . . . . . . . . . . 2B-8 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 2B-21 Stator Coil Resistance Test . . . . . . . . . . . . . . . 2B-9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-25 Rectifier/Regulator Diode Test . . . . . . . . . . . . 2B-10 90-858895R1 JANUARY 2001 Page 2B-1 CHARGING & STARTING SYSTEM Specifications CHARGING SYSTEM Readings taken @ 68°F (20°C). Alternator Type: Alternator Output Stator Coil Output-Peak Voltage: @ 400 rpm (Cranking) @ 1500 rpm @ 3500 rpm Stator Coil Resistance Battery Rectifier/Regulator Output-Peak Voltage: Three Phase Stator Coil (12 Pole) 12.0 V; 20 Amps. (240 Watts) (Rectified/Regulated) 6 - 9 V (WHT - WHT) 12 - 18 V (WHT - WHT) 14 - 25 V (WHT - WHT) 0.32 - 0.48 W (WHT - WHT) @ 1000 rpm @ 1500 rpm @ 3500 rpm @ 6000 rpm Quicksilver Tachometer Setting 18 - 22 V (RED - BLK) 19 - 24 V (RED - BLK) 19 - 24 V (RED - BLK) 19 - 24 V (RED - BLK) “6P” or “4” STARTING SYSTEM Electric Start: Starter Type Model/Manufacturer Weight Output Rating Reduction Gear Ratio Brush Length Minimum Length Commutator: Diameter Minimum Diameter Undercut Undercut Limit Ampere Draw Under: (Load) (No Load) Sliding Gear S114-828/Hitachi 7 lb, 11 oz (3.5 kg) 1.4 kW - 12 V 30 Seconds 7.85 (102:13) 0.610 in. (15.5 mm) 0.374 in. (9.5 mm) 1.113 in. (29.0 mm) 1.100 in. (28.0 mm) 0.020 in. (0.5 mm) 0.008 in. (0.2 mm) 165 Amps 80 Amps Battery Rating Minimum Requirement 465 Marine Cranking Amps (MCA) BATTERY For operation below 32° F (0° C) or 350 Cold Cranking Amps (CCA) 1000 Marine Cranking Amps (MCA) or 775 Cold Cranking Amps (CCA) Ampere-Hours (Ah) 70 - 100 Page 2B-2 90-858895R1 JANUARY 2001 CHARGING & STARTING SYSTEM Special Tools 1. Brush Holder P/N91-875216 90-858895R1 JANUARY 2001 Page 2B-3 CHARGING & STARTING SYSTEM Starter Motor 12 3 4 5 6 7 8 9 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 10 22 22 10 26 4-Stroke Outboard Oil (92-828000A12)110 95 2-4-C w/Teflon (92-850736A1) 110 95 95 Page 2B-4 90-858895R1 JANUARY 2001 CHARGING & STARTING SYSTEM Starter Motor REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm – 1 STARTER MOTOR 1 1 PINION STOP SET 2 1 PINION 3 1 COVER 4 2 BOLT (M6 x 52 mm) 70 8 5 1 LEVER KIT 6 1 STARTER RELAY 7 1 COVER 8 1 GEAR KIT 9 1 CLUTCH 10 1 WASHER KIT 11 1 BRACKET 12 1 RING GEAR 13 1 GASKET 14 1 BEARING 15 1 PINION SHAFT 16 3 IDLER GEAR 17 1 BRACKET 18 1 STATOR 19 1 ARMATURE 20 1 BRUSH HOLDER KIT 21 1 BRUSH SET 22 4 SPRING 23 1 BRACKET 24 2 SCREW (M4 x 16 mm) 25 2 THRU BOLT (M6 x 120 mm) 70 8 26 3 BOLT (M8 x 45 mm) 13 18 90-858895R1 JANUARY 2001 Page 2B-5 CHARGING & STARTING SYSTEM Battery Recommended Battery A 12 volt battery with a minimum rating of 465 marine cranking amps (MCA) or 350 cold cranking amps (CCA). For operation below 32° F (0° C) a rating of 1000 Marine Cranking Amps (MCA) or 775 Cold Cranking Amps (CCA) is recommended. Operating Engine Without Battery If desired (or in an emergency), engines equipped with an electric start and alternator can be started and operated without a battery (either disconnected or removed) if “WARNING”, below, is followed. WARNING Before operating engine with battery leads disconnected from battery, disconnect the three wire (stator harness plug) from rectifier. Battery Charging System Troubleshooting CAUTION The charging system may be damaged by: 1) reversed battery cables, 2) running the engine with battery cables disconnected and stator leads connected to rectifier, 3) an open circuit, such as a broken wire or loose connection. A fault in the battery charging system usually will cause the battery to become undercharged. Check battery electrolyte level, and charge battery. If battery will NOT accept a satisfactory charge, replace battery. If battery accepts a satisfactory charge, determine the cause of the charging system problem as follows. 1. Check for correct battery polarity [RED cable to POSITIVE (+) battery terminal]. If polarity was incorrect, check for damaged rectifier. See “RECTIFIER TEST”. 2. Check for loose or corroded battery connections. 3. Visually inspect wiring between stator and battery for cuts, chafing. and disconnected, loose or corroded connection. 4. Excessive electrical load (from too many accessories) will cause battery to run down. If visual inspection determines that battery connections and wiring are OK, perform the following stator and rectifier tests. Page 2B-6 90-858895R1 JANUARY 2001 CHARGING & STARTING SYSTEM Battery Charging System Description (20 Ampere) The battery charging system components are the stator coils, rectifier/regulator and battery. Alternating current (generated in the stator coils) flows to the rectifier/regulator, which changes the alternating current to a regulated direct current for charging the battery. Wiring Diagram (20 Ampere) 57625 a c b d BLK = BLU = BRN = GRY = GRN = ORG = PNK = PUR = RED = TAN = WHT = YEL = Black Blue Brown Gray Green Orange Pink Purple Red Tan White Yellow a-Rectifier/Regulator b-12V Battery c-Fuse-30A d-Stator Coil 90-858895R1 JANUARY 2001 Page 2B-7 CHARGING & STARTING SYSTEM Alternator System Test 20 Ampere Stator 1. Check battery voltage at battery with engine running. 2. If battery voltage is above 14.5-15.0 volts, replace voltage regulator/rectifier. Check condition of battery as overcharging may have damaged battery. 3. If battery voltage is below 14.5 volts, charge battery. If battery can NOT be satisfactorily charged, replace battery. 4. If battery accepts a satisfactory charge, check battery voltage while cranking engine. If cranking voltage is not acceptable, replace battery. 5. If cranking voltage is acceptable, disconnect the RED (voltage rectifier/regulator) wire bullet connector from the RED engine wiring harness. 6. Connect RED (+) ammeter lead to RED voltage rectifier/regulator wire and the BLACK (–) ammeter lead to the RED engine wiring harness. 7. Secure starter wires away from flywheel. 8. With engine running at the indicated rpm, the ammeter should indicate the following appropriate amperes: 24 22 20 18 16 14 12 10 8 6 4 2 0 RPM x 1000 9. A reading of 20 amperes at 6000 rpm indicates the charging system is functioning properly. 10. If ammeter reads less than required amperes @ 6000 rpm, test the stator (refer to “Stator Coil Resistance Test”). If stator tests OK, replace rectifier/regulator. Alternator current (Amps) 0123456 Page 2B-8 90-858895R1 JANUARY 2001 CHARGING & STARTING SYSTEM Stator Coil Resistance Test STATOR COIL 91-804772 METER TEST LEADS METER SCALE READING () RED BLACK RX1RX1 032 048 0.32 - 0.48WHT WHT 90-858895R1 JANUARY 2001 Page 2B-9 CHARGING & STARTING SYSTEM Rectifier/Regulator Diode Test Analog Meter NOTE:Voltage regulator/rectifier specifications are given for informational purposes only. Use the appropriate troubleshooting techniques previously mentioned to find the faulty component in the charging system. 1 2 3 GRN GRN/WHT BLK GRN/WHTGRN RED Blk = Black GRN/WHT = GREEN/WHITE Red = Red GRN = GREEN POSITIVE SIDE OF BRIDGE DIODE TEST 1: 1. Set Ohm meter to R X 10 scale. 2. Connect Red (+) meter lead to RED regulator lead. 3. Connect Black (–) meter lead to each of GREEN and GRN/WHT regulator leads. TEST RESULTS: 100 - 300 OHMS DIODE TEST 2: 1. Set Ohm meter to R X 1k scale. 2. Connect Black (–) meter lead to RED regulator lead. 3. Connect Red (+) meter lead to each of GREEN and GRN/WHT regulator leads. TEST RESULTS: 8 OHMS (No needle movement) GROUND SIDE OF BRIDGE DIODE TEST 3: 1. Set Ohm meter to R X 1k scale. 2. Connect Red (+) meter lead to BLACK ground wire. 3. Connect Black (–) meter lead to each of GREEN and GRN/WHT regulator leads. TEST RESULTS: 8 OHMS (No needle movement) DIODE TEST 4: 1. Set Ohm meter to R X 10 scale. 2. Connect BLACK (–) meter lead to BLACK ground lead. 3. Connect RED (+) meter lead to each of GREEN and GRN/WHT regulator leads. TEST RESULTS: 100 - 300 OHMS TACHOMETER CIRCUIT TEST: 1. Set Ohm meter to R X 1k scale. 2. Connect GRN/WHT bullet to GRN/WHT wire. TEST RESULTS: Should have continuity (0 OHMS). Page 2B-10 90-858895R1 JANUARY 2001 CHARGING & STARTING SYSTEM Digital Meter NOTE:Voltage regulator/rectifier specifications are given for informational purposes only, usethe appropriate troubleshooting techniques previously mentioned to find the faulty component in the charging system. 1 2 3 GRN GRN/WHT BLK GRN/WHTGRN RED Blk = Black GRN/WHT = GREEN/WHITE Red = Red GRN = GREEN POSITIVE SIDE OF BRIDGE DIODE TEST 1: 1. Set meter to . 2. Connect Red (+) meter lead to RED regulator lead. 3. Connect Black (–) meter lead to each of GREEN and GRN/WHT regulator leads. TEST RESULTS: No continuity - Ouch - OL DIODE TEST 2: . 1. Set meter to 2. Connect Black (–) meter lead to RED regulator lead. 3. Connect Red (+) meter lead to each of GREEN and GRN/WHT regulator leads. TEST RESULTS: 0.4 - 0.85 OHMS GROUND SIDE OF BRIDGE DIODE TEST 3: 1. Set meter to . 2. Connect Red (+) meter lead to BLACK ground wire. 3. Connect Black (–) meter lead to one GREEN regulator lead. Test. Connect Black (–) meter lead to each of other GREEN leads. TEST RESULTS: 0.4 - 0.85 OHMS DIODE TEST 4: 1. Set meter to . 2. Connect BLACK (–) meter lead to BLACK ground lead. 3. Connect RED (+) meter lead to each of 3 GREEN regulator leads. TEST RESULTS: No Continuity - Ouch - OL TACHOMETER CIRCUIT TEST: 1. Connect GRN/WHT to GRN/WHT lead. TEST RESULTS: Should have continuity (0 OHMS). 90-858895R1 JANUARY 2001 Page 2B-11 CHARGING & STARTING SYSTEM Starting System Components Description The function of the starting system is to crank the engine. The battery supplies electrical energy to crank the starter motor. When the ignition switch is turned to “START” position, the starter solenoid is activated and completes the starting circuit between the battery and starter. The neutral start switch opens the start circuit when the shift control lever is not in neutral. This prevents accidental starting when engine is in gear. The starting system consists of the following components. 1. Battery 2. Starter Solenoid 3. Neutral Safety Switch 4. Starter Motor 5. Ignition Switch CAUTION The starter motor may be damaged if operated continuously. DO NOT operate continuously for more than 30 seconds. Allow a 2 minute cooling period between starting attempts. Troubleshooting the Starting Circuit Before beginning the starting circuit troubleshooting flow chart, following, check first for the following conditions: 1. Make sure that battery is fully charged. 2. Check that control lever is in “NEUTRAL” position. 3. Check terminals for corrosion and loose connections. 4. Check cables and wiring for frayed and worn insulation. 5. Check 30 Amp fuse. Page 2B-12 90-858895R1 JANUARY 2001 CHARGING & STARTING SYSTEM Starter Solenoid Test 1. Inspect starter solenoid for cracks, loose terminals or loose terminal lead connections. 2. Connect ohm meter between relay (magnetic switch) terminals as shown. 3. Connect the starter motor body to the negative (–) battery terminal. 4. Connect the BLACK/WHITE lead to the positive (+) battery terminal. 5. Check that there is continuity between the relay (magnetic switch) terminals. 6. Check that there is no continuity after the BLACK/WHITE lead is removed. NOTE:The pinion gear should be pushed out while the magnet switch is ON. a b c a-Relay Terminals b-BLACK/WHITE Lead c-Battery The following “STARTING CIRCUIT TROUBLESHOOTING FLOW CHART” is designed as an aid to troubleshooting the starting circuit. This flow chart will accurately locate any existing malfunction. Location of “TEST POINTS” (called out in the chart) are numbered in diagram. 90-858895R1 JANUARY 2001 Page 2B-13 CHARGING & STARTING SYSTEM 63 2 3 7 13 43 53 Starter Ignition Switch Starter Solenoid BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORG = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow Starting Circuit Troubleshooting Flow Chart Starter Motor Does Not Turn SAFETY WARNING: Disconnect BLACK (starter motor) cable from starter solenoid test point 1 BEFORE making tests 1-thru-7 to prevent unexpected engine cranking. TEST 1 Use an ohmmeter (R x 1 scale) and connect meter leads be- tween NEGATIVE (–) battery post and common powerhead ground. No continuity indicated; there is an open circuit in the BLACK NEGATIVE (–) battery cable between the NEGATIVE (–) bat- tery post and the powerhead. • Check cable for loose or corroded connections. • Check cable for open. Continuity Indicated Proceed to TEST 2, on next page. Page 2B-14 90-858895R1 JANUARY 2001 CHARGING & STARTING SYSTEM a. Disconnect BLACK ground wire(s) from Test Point 2. b. Connect voltmeter between common engine ground and Test Point 2. c. Turn ignition key to “Start” position. 12 Volt Reading* Neutral start switch is open, or YELLOW/ RED or BLACK wire is open between Test Points 4 and 3. Electric Start Tiller Handle Model Neutral start switch is open or BLACK leads are disconnected or damaged. * Battery Voltage TEST 2 TEST 3 TEST 4 TEST 5 TEST 6 TEST 7 TEST 8 12 Volt Reading* 12 Volt Reading 12 Volt Reading* 12 Volt Reading* 12 Volt Reading* 12 Volt Reading* No voltage reading; proceed to TEST 3. No voltage reading; proceed to TEST 4. No voltage reading; proceed to TEST 5. No voltage reading; proceed to TEST 6. a. Reconnect BLACK ground wire(s). b. Connect voltmeter between common engine ground and Test Point 3. c. Turn ignition key to “Start” position. Check BLACK ground wire for poor connection or open circuit. Reconnect ground wire to start- er solenoid; proceed to TEST 7. a. Connect voltmeter between common engine ground and Test Point 4. b. Turn ignition key to “Start” position. Defective starter solenoid. Connect voltmeter between common engine ground and Test Point 5. Defective ignition switch. Connect voltmeter between common engine ground and Test Point 6. No voltage reading; check BLACK wire be- tween battery (+) positive terminal and Test Point 6. Check both fuses in RED wire between test points 5 and 6. Check for open RED wire between test points 5 and 6. a. Connect voltmeter between common engine ground and Test Point 1. b. Turn ignition key to “Start” position. No voltage reading; De- fective starter solenoid. Should hear solenoid click; proceed to TEST 8. a. Reconnect (starter motor) cable to starter solenoid Test Point 1. b. Connect voltmeter between common engine ground and Test Point 7 c. Turn ignition key to “Start” position. No voltage reading; check Yellow cable for poor connection or open circuit. Check BLACK ground cable at starter for loose or corroded connection, or open circuit. If cable is O.K., check starter motor. 90-858895R1 JANUARY 2001 Page 2B-15 CHARGING & STARTING SYSTEM Page 2B-16 90-858895R1 JANUARY 2001 Starter Motor Removal WARNING Always disconnect the battery and remove spark plug leads from spark plugs before working on motor. 1. Disconnect battery leads. Remove side cover. Disconnect red and black starter motor leads from starter. Disconnect BLACK and BLACK/WHITE wires from starter relay. 2. Remove 3 bolts. Remove starter. 57590 a c b 57620 d e a - Bolts (3) M8 x 45 mm b - Positive Starter Motor Lead (Battery) c - Negative Starter Motor Lead d - BLACK/WHITE e - BLACK Disassembly 1. Place starter in vise. 2. Rotate pinion gear clip opening towards front. Using a screwdriver push down on pinion gear. Using a hammer tap pinion gear stopper until pinion gear clip is protruded enough to pry out with a small screwdriver. 57637 a b a - Pinion Gear b - Pinion Gear Stopper CHARGING & STARTING SYSTEM 90-858895R1 JANUARY 2001 Page 2B-17 3. Loosen nut to disconnect spade connector on start solenoid from starter motor. 4. Remove 2 screws to separate start solenoid from starter motor. b a a - Spade Connector b - Bolts (2) M6 x 52 mm 5. Remove 2 thru bolts from commutator end cap to separate commutator from gear end. 6. Remove 2 screws from end cap to separate end cap from commutator. a b a a - Thru Bolts (2) M6 x 120 mm b - Commutator End Cap Screws (2) M4 x 14 mm CHARGING & STARTING SYSTEM 7. Pull commutator along with grommet and brush assembly from end cap. 8. Using a suitable punch, tap plate from brush holder assembly. 9. Pull brush assembly from commutator. 57621 a a-Plate 10. For pinion gear disassembly refer to exploded view. Cleaning and Inspection 1. Clean all motor parts. 2. Check pinion teeth for chips, cracks or excessive wear. 3. Replace the drive clutch spring and/or collar, if tension is not adequate, or if wear is excessive. 4. Check that the brush holder is not damaged or is not holding the brushes against the commutator. 5. Replace brushes that are pitted or worn to less than 0.374 in. (9.5 mm) in length. Refer to “BRUSH REPLACEMENT”, following. 6. Replace a damaged or excessively worn bushing in the end cap. 7. Check the armature conductor (commutator bar junction) for a firm connection. A poor connection usually results in a burned commutator bar. 8. Measure commutator undercut. • Out of specification - replace. a a-Undercut Commutator Undercut Limit 0.01 in. (0.2 mm) Page 2B-18 90-858895R1 JANUARY 2001 CHARGING & STARTING SYSTEM 9. Open-circuited armatures often can be saved where an open circuit is obvious and repairable. The most likely place for an open circuit is at the commutator bars. Long cranking periods overheat the starter motor so that solder in the connections melts. The poor connections cause arcing and burning of the commutator bars. 10. Armature inspection. • Clean with 600 grit sandpaper. 11. Measure commutator diameter. • Out of specification - replace. Commutator Diameter Limit 1.10 in. (28.0 mm) 12. Repair bars, that are not too badly burned, by re-soldering the leads in bars (using rosin flux solder) and turning down the commutator in a lathe to remove burned material, then undercut the mica. 13. Clean out the copper or brush dust from slots between the commutator bars. 14. Check the armature for shorts and ground. See “TESTING”. 90-858895R1 JANUARY 2001 Page 2B-19 CHARGING & STARTING SYSTEM Testing ARMATURE TEST FOR GROUND 1. Set ohmmeter to (R x 1 scale). 2. To test commutator segments place leads as shown. Should have continuity. If not replace armature. 3. To test armature core place leads as shown. Should have no continuity. If continuity exists, replace armature. 4. To test armature shaft place leads as shown. Should have no continuity. If continuity exists, replace armature. a b c a-Commutator Test c-Armature Shaft Test b-Armature Test BRUSH HOLDER INSPECTION 1. Measure brush length. If out of specification, replace brushes. Brush Length Limit 0.374 in. (9.5 mm) 2. Set ohmmeter to (R x 1 scale). NOTE:Only positive brushes 1 and 2 can be replaced. If negative brushes need replaced then the whole brush holder must be replaced. 3. Place leads on one positive brush and one negative brush. Should have no continuity. If continuity exists, replace brushes. Repeat this procedure on the other brushes. Should have no continuity. If continuity exists, replace brushes. a b 2 1 a-Negative (–) Brushes b-Positive (+) Brushes Page 2B-20 90-858895R1 JANUARY 2001 CHARGING & STARTING SYSTEM Reassembly 1. Using special tool (91-875216) slide brush assembly over tool as shown. Slide brush holder assembly onto commutator. 2. Replace plate onto armature end shaft by tapping with a hammer. 57635 d c 57647 b a 91-875216 a-Brush Holder Tool (91-875216) b-Brush Assembly c-Plate d-Threaded Holes 3. Slide armature assembly into end cap. 4. Secure armature assembly with 2 screws. NOTE:Make sure thrust plate is installed inside cover. NOTE:Make sure plate is aligned with threaded holes as shown above. Use punch to align holes. c a b 95 2-4-C w/Teflon (92-850736A1) 95 a-Thrust Plate b-End Cap c-Screws (2) M4 x 16 mm 5. Install armature stator cover over armature. 57900 a b a-Armature Stator Cover b-End Cap 90-858895R1 JANUARY 2001 Page 2B-21 CHARGING & STARTING SYSTEM 6. Install lever into pinion shaft as shown. 7. Insert pinion shaft into top cover making sure it is seated properly. 8. Install bracket cover as shown. b 57901 a c a-Lever b-Pinion Shaft c-Bracket Cover 9. Align marks and insert armature shaft assembly into top cover. 10. Secure with 2 thru bolts. Torque bolts to specified torque. b b 57636 a 57902 a-Alignment Marks b-Thru Bolts (2) M6 x 120 mm Starter Thru Bolt Torque 70 lb-in. (8 Nm) Page 2B-22 90-858895R1 JANUARY 2001 CHARGING & STARTING SYSTEM 11. Install starter relay to starter making sure grommet is in place and lever spring is in proper holes of dust cover plate. 12. Slide lever into starter relay assembly shaft hole while inserting spring below lever as shown. 13. Secure relay with 2 bolts. Torque to specified torque. a b g d f ec f 57626 a-Spring b-Dust Cover Plate Holes c-Screw M4 x 20 mm d-Grommet e-Lever f-Shaft Hole g-Relay Bolts (2) M6 x 52 mm Starter Relay Bolt Torque 70 lb-in. (8 Nm) 14. Connect spade connector on start solenoid. a b a-Spade Connector b-Nut Terminal Nut Torque 78 lb-in. (8.8 Nm) 90-858895R1 JANUARY 2001 Page 2B-23 CHARGING & STARTING SYSTEM 15. Lubricate helix threads and drive end cap bushing with SAE 10W oil. 16. Install the spring, pinion and pinion stopper onto starter shaft. 17. Place circlip into groove on shaft. 18. Press the pinion stopper over the circlip. IMPORTANT: Make sure the circlip fits tightly into pinion stopper. a b d c a b c d a-Circlip b-Pinion Stopper c-Pinion d-Spring Page 2B-24 90-858895R1 JANUARY 2001 CHARGING & STARTING SYSTEM 90-858895R1 JANUARY 2001 Page 2B-25 Installation 1. Secure starter to block with 3 screws. Secure NEGATIVE battery lead and POSITIVE battery lead as shown. 2. Connect BLACK and BLACK/WHITE leads from starter relay to starter solenoid. 57595 a b c d e f a - Starter b - Starter Motor Mounting Screw (3) M8 x 45 c - Negative Battery Lead d - Positive Battery Lead e - BLACK Lead f - BLACK/WHITE Lead Starter Motor Mounting Screw Torque 13 lb-ft (18 Nm) Negative Battery Terminal Screw Torque 120 lb-in. (13.5 Nm) Positive Battery Terminal Nut Torque 120 lb-in. (13.5 Nm) TIMING, SYNCHRONIZING, & ADJUSTING ELECTRICAL Section 2C - Timing, Synchronizing, & Adjusting Table of Contents 2 C Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1 Pilot Screw Adjustment . . . . . . . . . . . . . . . . 2C-6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-3 Carburetor Synchronization . . . . . . . . . . . . 2C-7 Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-4 Throttle Cam Adjustment . . . . . . . . . . . . . . 2C-9 Carburetor Adjustments . . . . . . . . . . . . . . . . . . 2C-5 Specifications IGNITION SYSTEM Readings taken @ 68°F (20°C). Type Spark Plug: Type Gap Hex Size Torque Firing Order Ignition Timing: @ Idle (850 rpm) @ WOT (6000 rpm) Stator Coil Output - Peak Voltage: @ 400 rpm (Cranking) @ 1500 rpm @ 3500 rpm Stator Coil Resistance Crank Position Sensor Output Peak Voltage: (WHT/BLK - BLK) for Cylinders 1 & 4 (WHT/RED - BLK) for Cylinders 2 & 3 @ 400 rpm (Cranking) @ 1500 rpm @ 3500 rpm Crank Position Sensor Resistance (WHT/BLK - BLK) for Cylinders 1 & 4 (WHT/RED - BLK) for Cylinders 2 & 3 CDI Unit Output - Peak Voltage: (BLK/ORN - BLK) for Cylinders 1 & 4 (BLK/WHT - BLK) for Cylinders 2 & 3 @ 400 rpm (Cranking) @ 1500 rpm @ 3500 rpm Ignition Coil Resistance: Primary Secondary (Without Boots) High Tension Lead Resistance: Cylinder #1 Cylinder #2 Cylinder #3 Cylinder #4 Microcomputer-Controlled CDI NGK LFR5A-11 0.043 in. (1.1 mm) 5/8 in. (16 mm) 18 lb-ft (25 Nm) 1-3-4-2 5° A.T.D.C 18° B.T.D.C 6 - 9 V (WHT – WHT) 12 - 18 V (WHT - WHT) 14 - 25 V (WHT - WHT) 0.32 - 0.48 W (WHT - WHT) 2.8 -3.4 V 6.5 - 7.8 V 10.5 - 12.0 V 445 - 545 W 445 - 545 W 165 -190 V 175 -200 V 175 - 200 V 0.078 - 0.106 W (BLK - BLK/WHT) 3.5 - 4.7 kW (Between Towers) 4.5 - 10.7 kW 3.3 - 8.0 kW 3.7 - 8.9 kW 4.3 - 10.2 kW 90-858895R1 JANUARY 2001 Page 2C-1 TIMING, SYNCHRONIZING, & ADJUSTING Specifications Engine Protection Controls: Engine Speed Limiter Spark Cut-Out to Cylinders #1 or #4 6200 rpm #1 and #4 6250 rpm #1, #4, and #2 or #3 6300 rpm #1, #2, #3, and #4 Overheat/Low Oil Pressure Engine Speed Control (Spark Cut-Out to 6350 rpm Cylinders #1 and #4) 2000 Engine S/N OT178499 and Below Gradually Lowers to 3000 rpm Warning Horn/rpm Reduction 140 °F (60 °C) Reset Temperature (Throttle Closed/Key off) 2001 Engine S/N OT178500 and Above 11 8 °F (48 °C) Warning Horn/rpm Reduction 194 °F (95 °F) IGNITION SYSTEM Readings taken @ 68°F (20°C). Reset Temperature (Throttle Closed/Key Off) 2000 MY Engine Oil Pressure Switch: S/N 0T178499 and Below Warning Horn/rpm Reduction 167 °F (79 °C) Stamped P.15 Continuity Below 2.2 psi (15 kPa) Reset Pressure (ECM reset @ Closed Throttle) 2001 MY Engine Oil Pressure Switch: No Continuity Above 2.2 psi (15 kPa) S/N 0T178500 and Above Stamped P1.5 Warning Horn/rpm Reduction Continuity Below 21.78 psi (150 kPa) Reset Pressure (ECM reset @ Closed Throttle) Engine Water Temperature Sensor Resistance: No Continuity Above 21.78 psi (150 kPa) @ -4°F (-20°C) 15.5 k W @ 32°F (0°C) 5.79 k W @ 68°F (20°C) 2 .45 k W @ 104°F (40°C) Throttle Position Sensor (TPS): 1.50 k W Input Voltage @ Idle (850 rpm) 5.0 ± 0.25 V (RED - ORG) Output [email protected] Idle (850 rpm) 0.68 - 0.82 V (PNK - ORG) NOTE:The 75/90 four stroke ECM unit electronically controls the ignition timing, therefore making the ignition timing non adjustable. When initially running the outboard, use a timing light to verify that the ignition timing falls within the timing windows. If the ignition timing does not stay within the timing windows, replace the ignition ECM unit and retest. Page 2C-2 90-858895R1 JANUARY 2001 TIMING, SYNCHRONIZING, & ADJUSTING Special Tools 1. New Style Vacuummate Carburetor Tuner P/N 91-809871-1 2. Old Style Mercury Filled Carburetor Tuner P/N 91-809641A1. Filters (4) P/N 35-18206. 3. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1 4. Timing Light P/N 91-99379 90-858895R1 JANUARY 2001 Page 2C-3 TIMING, SYNCHRONIZING, & ADJUSTING Timing WARNING To prevent personal injury or possible death, from loss of balance or stability while servicing the motor, DO NOT attempt to check timing while boat is in motion. Failure to follow one of the recommended servicing procedures may result in the person falling overboard or causing personal injury from fall in boat. WARNING To prevent personal injury from spinning flywheel, DO NOT attempt to remove flywheel cover or place hands on top of cover when checking ignition timing. Ignition timing is not adjustable. The CDI unit electronically controls the ignition timing. When initially running the outboard, use a timing light to verify that the ignition timing falls within the timing windows as described within the following tests. If the ignition timing does not stay within the timing windows, replace the ignition CDI unit and retest. (Refer to the Ignition Diagnostic Procedures tests in Section 2A.) IMPORTANT: When checking the timing with the engine running, one of the following test procedures must be followed. Check maximum timing per specification while running the outboard: • IN A TEST TANK (with a cut down propeller). • ON A DYNAMOMETER. • ON A BOAT SECURED ON A TRAILER “Backed in Water” (with a cut down propeller). 1. Attach timing light to #1 spark plug lead. 2. Place the outboard in “Forward” gear and check timing at idle “Retarded.” (If not within specification window, refer to Diagnostic Test Procedures Section 2A.) a b a-Timing Mark (Full Retarded) b-Pointer Page 2C-4 90-858895R1 JANUARY 2001 TIMING, SYNCHRONIZING, & ADJUSTING 3. Slowly increase the engine rpm while watching the ignition timing marks. The timing should increase to the maximum timing specification “Full Advance” at approximately 6000 RPM. (If not within specification window, refer to Diagnostic Test Procedures Section 2A.) a b a-Timing Mark (Full Advance) b-Pointer Carburetor Adjustments 1. Check engine idling speed, adjust if unstable (refer to “Pilot Screw Adjustment” and “Carburetor Synchronization” below). 2. Check vacuum pressure variation range, adjust if out of specification (refer to “Pilot Screw Adjustment” and “Carburetor Synchronization” below). Vacuum Variation Range Within 5 cm Hg NOTE:The carburetors are synchronized by adjusting the intake manifold vacuum on the carburetors. Use Carburetor Tuner (91-80964A1) to measure the vacuum. CAUTION Do not adjust the carburetors when they are operating properly, excess adjustments can cause poor engine performance. 90-858895R1 JANUARY 2001 Page 2C-5 TIMING, SYNCHRONIZING, & ADJUSTING Pilot Screw Adjustment PILOT SCREW ADJUSTMENT STEPS For EPA Engines: 1. Pilot screw is plugged for EPA specifications, making pilot screw non-adjustable. For Non-EPA Engines: 1. After warming up engine, turn in all of the pilot screws until they are lightly seated. 2. Turn out the pilot screw the specified number of turns. Pilot Screw Setting 75 Horsepower 21/2 ±1/2 turns out 90 Horsepower 2±1/2 turns out a b c a-Pilot Screw b-Lightly Seated Screw c-Properly Adjusted Screw 3. If the engine operates: a. Smooth: (1.) Do not make any further adjustments. b. Unstable: (1.) Turn each pilot screw in until the engine idle speed drops approximately 40 rpm, then back each screw out 3/4 of a turn. Page 2C-6 90-858895R1 JANUARY 2001 TIMING, SYNCHRONIZING, & ADJUSTING Carburetor Synchronization NOTE:The carburetors are synchronized by adjusting the intake manifold vacuum on the carburetors. Use Carburetor Tuner (91-809641A1) or Vacuummate Tuner (p/n 91-809871--1) to measure the vacuum. 1. Remove four plugs from the intake manifold. 2. Install intake manifold hose adaptor in each plug hole. Tighten securely. 3. Connect the Carburetor Tuner to the hose adaptors. 4. Install filters to prevent mercury being drawn into carburetors during an abrupt throttle change. NOTE:Intake manifold hose adaptors are provided with the Carburetor Tuner. a b #1 #2 #3 #4 #4 c a d #1 #2 #3 a-Intake Manifold Plugs (4) b-Intake Manifold Hose Adaptor (4) From Vacuummate Carb. Tuner c-Intake Manifold Hose Adaptor (4) From Mercury Filled Carb Tuner d-Vacuummate Carb. Tuner (91-809871--1) CAUTION Do not run engine at high rpm or abruptly change throttle position when using the old style liquid mercury filled carburetor tuner (p/n 91-809641). The possibility exists of drawing liquid mercury from the carburetor tuner into the engine during high rpm running or an abrupt throttle change. Installing filters (4) (p/n 35-18206) in each line will help to prevent liquid mercury from being drawn into carburetors during an accidental abrupt throttle change. 90-858895R1 JANUARY 2001 Page 2C-7 TIMING, SYNCHRONIZING, & ADJUSTING 5. With the outboard in water, start engine and allow to warm up. 6. Shift the outboard to neutral. 7. Connect a tachometer onto the spark plug lead of cylinder #1. 8. Adjust engine idling speed to 1000 rpm by turning the throttle stop screw on carburetor #4 in direction “a” or “b”. NOTE: Turning idle speed adjustment screw: • clockwise (direction “a”) willincreaseengine idling speed • counterclockwise(direction “b”) willdecreaseengine idling speed. a b c a-Engine Idling Speed Increases b-Engine Idling Speed Decreases c-Throttle Stop Screw 9. Measure the vacuum pressure of carburetor #4. It’s not important to be at any specific vacuum setting. 10. Turn the throttle valve adjusting screws so the vacuum pressure of carburetors #1, #2, and #3 are the same as carburetor #4. NOTE: Keep viewing the tachometer, as the engine rpm may fluctuate during adjustments. Keep adjusting the idle rpm screw in order to keep the engine speed at the 1000 rpm. Example If the vacuum reading of Cyl. #4 (base vacuum) is 30 cm, then adjust carburetor synchronization screws of cylinders #1, #2 and #3 to 30 cm. Cyl. # 1 32 cm 30 cm 28 cm 26 cm Cyl. Cyl. Cyl. # 2#3 # 4 11. Rev engine a few times and let engine idle for 15 seconds. Check that the vacuum values remain within 5 cm Hg (67 m bar, 1.97 in Hg) of each other. Re-adjust if necessary. Page 2C-8 90-858895R1 JANUARY 2001 TIMING, SYNCHRONIZING, & ADJUSTING 90-858895R1 JANUARY 2001 Page 2C-9 12. Once synchronization of carburetors has been achieved re-adjust idle speed back to specification Engine Idle Speed (out of gear) 850 ± 25 rpm 13. Stop engine, remove adaptors and reinstall plugs. Throttle Cam Adjustment Check carburetor pickup timing (using “Checking Steps” below, adjust if incorrectly set using “Adjustment Steps” below). CHECKING STEPS NOTE: Make sure TPS if fully rotated clockwise (to end of slot position). 1. Turn throttle control lever to the full retard position (throttle arm against throttle stop at idle). 2. Check that the pointer “b” on the throttle cam aligns with the center of the throttle lever shaft “c” as shown. a b c d e a - Throttle Arm Against Throttle Stop At Idle b - Throttle Cam Pointer c - Center of Throttle Lever Shaft d - Ball Connector e - Throttle Position Sensor (TPS) TIMING, SYNCHRONIZING, & ADJUSTING ADJUSTMENT STEPS 1. Unsnap ball connector from ball on cam. 2. Thread connector in or out to allow pointer on throttle cam to center on throttle lever shaft. NOTE:Threading ball connector clockwise will move pointer down, threading ball connector counterclockwise will move pointer up. a b a-Clockwise Moves Pointer Down b-Counterclockwise Moves Pointer Up Page 2C-10 90-858895R1 JANUARY 2001 WIRING DIAGRAMS ELECTRICAL Section 2D - Wiring Diagrams Table of Contents 2 D Commander 2000 Side Mount Without Light Switch . . . . . . . . . . . . . . . . . . 2D-8 Remote Control Wiring Diagram . . . . . . . . . . . 2D-2 With Light Switch . . . . . . . . . . . . . . . . . . . . . 2D-8 Commander 2000 Key Switch Test . . . . . . . . 2D-3 QSI Gauge Wiring Diagrams . . . . . . . . . . . . . . 2D-9 Commander 3000 Panel Mount Tachometer Wiring Diagram . . . . . . . . . . . 2D-9 Remote Control Wiring Diagram . . . . . . . . . . . 2D-4 Water Temperature Gauge . . . . . . . . . . . . 2D-10 Instrument/Lanyard Stop Switch Engine Synchronizer Wiring Diagram . . . 2D-11 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 2D-5 Remote Wiring Harness Instrument/Lanyard Stop Switch Connection to Engine . . . . . . . . . . . . . . . . . . . . 2D-13 Wiring Diagram (Dual Outboard) . . . . . . . . . . 2D-6 Power Trim Switch Wiring Diagram . . . . . . . . 2D-14 Instrument Wiring Connections . . . . . . . . . . . . 2D-8 90-858895R1 JANUARY 2001 Page 2D-1 WIRING DIAGRAMS Commander 2000 Side Mount Remote Control (Power Trim/Tilt Electric Start with Warning Horn) Wiring Diagram BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE RED = RED c f g a b d e TAN = TAN VIO = VIOLET WHT = WHITE YEL = YELLOW a-Ignition/Choke Switch b-Emergency Stop Switch c-Neutral Start Switch d-Tachometer/Accessories Harness Connector e-Wiring Harness Connector f-Warning Horn g-Trim/Tilt Switch Page 2D-2 90-858895R1 JANUARY 2001 WIRING DIAGRAMS Commander 2000 Key Switch Test 1. Disconnect remote control wiring harness and instrument panel connector. 2. Set ohmmeter on R x 1 scale for the following tests: BLK = Black PUR = Purple RED = Red YEL = Yellow 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. NOTE:If meter readings are other than specified in the preceding tests, verify that switch and not wiring is faulty. If wiring checks ok, replace switch. 90-858895R1 JANUARY 2001 Page 2D-3 WIRING DIAGRAMS Commander 3000 Panel Mount Control B A C S M M ÂÂÂÂÂÂÂÂÂYEL/RED RED YEL/RED YEL/RED YEL/RED PUR GRN BLU/WHT GRN/WHT RED BLK/YEL BLK BLK=BLACK BLU=BLUE BRN=BROWN GRN=GREEN GRY=GRAY PUR=PURPLE RED=RED TAN=TAN WHT=WHITE YEL=YELLOW a b c a-Lanyard stop switch leads must be soldered and covered with shrink tube for a water proof connection. If alternate method of connection is made, (use of electrical butt connector) verify connection is secure and sealed for moisture proof connection. b-Connect wires together with screw and hex nut (2 places); apply Quicksilver Liquid Neoprene to connections and slide heat shrink tubing over each connection. c-Key switch Page 2D-4 90-858895R1 JANUARY 2001 WIRING DIAGRAMS Instrument/Lanyard Stop Switch Wiring Diagram IMPORTANT: On installations where gauge options will not be used, tape back any unused wiring harness leads. 52715 BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow LIT = Light DRK = Dark c g d f e a b j h i j k a-Ignition/Choke Switch b-Lanyard Stop Switch c-Lead Not Used On Outboard Installations d-Retainer e-Tachometer f-Trim Indicator Gauge (Optional) g-Temperature Gauge h-Remote Control i-Power Trim Harness Connector j-Connect Wires Together with Screw and Hex Nut (2 Places); Apply Quicksilver Liquid Neoprene to Connections and Slide Rubber Sleeve over Each Connection k-Lead to Optional Visual Warning Kit 90-858895R1 JANUARY 2001 Page 2D-5 WIRING DIAGRAMS Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard) BLK = BLU = BRN = GRY = GRN = ORN = PNK = PUR = RED = TAN = WHT = YEL = LIT = DRK = a-Ignition/Choke Switch f-Trim Indicator Gauge b-Lanyard Stop Switch g-Temperature Gauge c-Lead Not Used on Outboard Installations h-Remote Control d-Retainer i-Synchronizer Gauge e-Tachometer j-Synchronizer Box 52716 Black Blue Brown Gray Green Orange Pink Purple Red Tan White Yellow Light Dark g d k d e BATT GND l c b d f a o h n n PORT INSTALLATION SENDER Page 2D-6 90-858895R1 JANUARY 2001 WIRING DIAGRAMS IMPORTANT: On installations where gauge options will not be used, tape back and isolate any unused wiring harness leads. j i a g m f e o BATT GND SENDER STARBOARD INSTALLATION k-Lanyard/Diode l-“Y” Harness m-Power Trim Harness Connector n-Connect Wires Together with Screw and Hex Nut (4 Places);Apply Quicksilver Liquid Neoprene to Connections and Slide Rubber Sleeve over Each Connection. o-Lead to Visual Warning Kit 90-858895R1 JANUARY 2001 Page 2D-7 WIRING DIAGRAMS Instrument Wiring Connections Without Light Switch NOTE: ANY INSTRUMENT WIRING HARNESS LEADS NOT USED MUST BE TAPED BACK TO THE HARNESS. Speedometer Tachometer Temperature/Oil Warning Panel Volt Meter TAN/WHTTAN/BLK 51820 a b c d a-Tachometer Receptacle-From Control Box or Ignition/Choke Switch b-Tachometer Wiring Harness c-Lead to Optional Visual Warning Kit (Taped Back to Harness) d-Cable Extension (For Two Function Warning Panel) e-Light Switch With Light Switch Wire Where To BLK=BLACK GROUND TAN/WHT=TAN/WHITE OIL LIGHT TAN/BLK=TAN/BLACK TEMPERATURE LIGHT TAN=TAN TEMPERATURE GAUGE PUR=PURPLE IGNITION 12 VOLT GRY=GRAY TACHOMETER BRN/WHT=BROWN/WHITE TRIM GAUGE TAN/BLU=TAN/BLUE VISUAL WARNING KIT (OPT.) TAN/WHTTAN/BLK Speedometer Tachometer Temperature/Oil Warning Panel Volt Meter 51819 To 12V a b d c e Page 2D-8 90-858895R1 JANUARY 2001 WIRING DIAGRAMS QSI Gauge Wiring Diagrams CLEANING GAUGES Clean gauge by washing with fresh water to remove sand and salt deposits. Wipe off with a soft cloth moistened with water. The gauge may be scored or damaged if wiped with abrasive material (sand, saline or detergent compounds, etc.) or washed with solvents such as trichloroethylene, turpentine, etc. Tachometer Wiring Diagram Tachometer dial on back side of case must be set to position number 4. WIRING DIAGRAM A Use this wiring diagram when using a separate light switch for instrument lighting. 51106 cb e d a a-PURPLE or WHITE - Connect to Positive (+) 12 Volt b-Light Switch Wire - 12 Volt c-Position Light Bulb to the Switched Position d-BLACK - Connect to Negative (–) Ground e-GRAY or BROWN Wire WIRING DIAGRAM B Use this wiring diagram when instrument lighting is wired directly to the ignition key switch. (Instrument lights are on when ignition key switch is turned on.) 51106 d c a b a-PURPLE or WHITE - Connect to Positive (+) 12 Volt b-Position Light Bulb to the Unswitched Position c-BLACK - Connect to Negative (–) Ground d-GRAY or BROWN Wire 90-858895R1 JANUARY 2001 Page 2D-9 WIRING DIAGRAMS Water Temperature Gauge WIRING DIAGRAM A Use this wiring diagram when using a separate light switch for instrument lighting. SEND c b e d a a-PURPLE - Connect to Positive (+) 12 Volt b-Light Switch Wire - 12 Volt c-Position Light Bulb to the Switched Position d-BLACK - Connect to Negative (–) Ground e-TAN - Connect to TAN lead located at the tachometer receptacle on Com mander Side Mount Remote Control or TAN lead coming from Accessary Ignition/ Choke Assembly. WIRING DIAGRAM B Use this wiring diagram when instrument lighting is wired directly to the ignition key switch. (Instrument lights are on when ignition key is turned on). 51105 SEND b d c a a-PURPLE - Connect to Positive (+) 12 Volt b-Position Light Bulb to the Unswitched Position c-BLACK - Connect to Negative (–) Ground d-TAN - Connect to TAN lead located at the tachometer receptacle on Commander Side Mount Remote Control or TAN lead coming from Accessary Ignition/ Choke Assembly. Page 2D-10 90-858895R1 JANUARY 2001 WIRING DIAGRAMS Route TAN lead on starboard side of engine to engine/remote control harness. Connect as shown. IMPORTANT: Tape back and isolate any unused wiring harness leads. 28086 a b a-Lead from Temperature Sender b-Engine/Remote Control Harness Engine Synchronizer Wiring Diagram LIGHT BULB POSITION A Use this position when using a separate light switch for instrument lighting. SEND 51105 a b a-Light Switch Wire - 12 Volt b-Position Light Bulb to the Unswitched Position LIGHT BULB POSITION B Use this position when instrument lighting is wired directly to the ignition key switch. (Instrument lights are on when ignition key switch is turned on). SEND 51106 a a-Position Light Bulb to the Switched Position 90-858895R1 JANUARY 2001 Page 2D-11 WIRING DIAGRAMS Synchronizer wiring can be accomplished two different ways as an option to the user. Wiring Diagram – Gauge needle to point toward slow running engine 52566 a b c d a-Tachometer - Starboard Engine b-Synchronizer Gauge c-Tachometer - Port Engine d-Synchronizer Box Wiring Diagram – Gauge needle to point toward fast running engine 52565 a b c d a-Tachometer - Starboard Engine b-Synchronizer Gauge c-Tachometer - Port Engine d-Synchronizer Box Page 2D-12 90-858895R1 JANUARY 2001 WIRING DIAGRAMS Remote Wiring Harness Connection to Engine 1. Route the remote control cable through the correct opening in the rubber grommet as shown. a b c d e fgh i a-Cover f-Battery Cable Opening b-Rubber Grommet g-Shift Cable Opening c-Fuel Hose Opening h-Speedometer Tube Opening d-Remote Wiring Harness Opening i-Sta-Strap - Tie Around Grommet e-Throttle Cable Opening After Components are Installed Remote Wiring Harness Route wiring harness through the rubber grommet. Connect wiring. Push the retainer over the exposed ends of the connectors. This will hold the connectors together. b BLU/WHTGRN/WHTBRN/WHTTAN BLU/WHTGRN/WHT a a-Power Trim Connections b-Retainer - Push Over Connector Ends 90-858895R1 JANUARY 2001 Page 2D-13 WIRING DIAGRAMS Power Trim Switch Wiring Diagram DN UP DN UP BLU/WHT GRN/WHT RED LT. BLU/WHT LT. GRN/WHT RED RED LT. GRN/WHT RED LT. BLU/WHT GRN = Green BLU = Blue RED = Red WHT = White a b RED a a-Trim Switch b-Starter Relay Page 2D-14 90-858895R1 JANUARY 2001 FUEL PUMP FUEL SYSTEM Section 3A - Fuel Pump Table of Contents Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-2 Fuel Pump Operation . . . . . . . . . . . . . . . . . . . . . . 3A-4 Fuel Line Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-5 Fuel Pump Removal . . . . . . . . . . . . . . . . . . . . . . . 3A-6 Specifications Fuel Pump Disassembly . . . . . . . . . . . . . . . . . . . 3A-6 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . . . 3A-8 Fuel Pump Reassembly . . . . . . . . . . . . . . . . . . . . 3A-9 Fuel Pump Installation . . . . . . . . . . . . . . . . . . . . 3A-11 Fuel Line Installation. . . . . . . . . . . . . . . . . . . . . . 3A-12 3 A Fuel Pump Type Fuel Pump: External (Plunger/Diaphragm) FUEL Discharge (@ 3000 rpm) 17 gph (65 L/h) SYSTEM Pressure (Maximum) 7 psi (49 kPa) Plunger Stroke 0.23 - 0.36 in. (5.85 - 9.05 mm) Fuel Tank Capacity Accessory 90-858895R1 JANUARY 2001 Page 3A-1 FUEL PUMP Fuel Pump 23 5 8 9 10 12 13 14 15 17 18 20 11 4 21 19 6 16 7 6 1 5 1 13 14 15 16 17 22 23 24 25 26 28 29 30 3124 24 24 24 24 33 34 24 27 32 7 7 Loctite 271 (92-809820) Page 3A-2 90-858895R1 JANUARY 2001 FUEL PUMP Fuel Pump REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 2 FUEL PUMP 2 4 SCREW (M5 x 35 mm) 25 3 3 1 GASKET 4 1 DIAPHRAGM 2 SCREW 6 2 CHECK VALVE 7 1 DIAPHRAGM 8 1 PIN 9 1 SPRING 4 NUT 11 1 SPRING 12 1 PLUNGER 13 4 SCREW (M6 x 30 mm) 70 8 14 2 O RING 2 WASHER 16 1 FUEL CHANGE LEVER 17 2 PIN 18 1 SHAFT 19 2 DOWEL PIN 1 FUEL PUMP BRACKET 21 2 SCREW (M7 x 48 mm) 150 17 22 1 FUEL FILTER 23 1 SLEEVE 75 8.5 24 8 STA-STRAP 1 TUBING (36 IN.) 26 1 CONNECTOR 27 1 CAP 28 1 TUBING (2 IN.) 29 1 TEE 1 TUBING (4-3/4 IN.) 31 1 TUBING (13-1/2 IN.) 32 1 CONDUIT (13 IN.) 33 1 CONDUIT (3-3/4 IN.) 34 1 CONDUIT (1-1/4 IN.) NOTE: TORQUE TOLERANCE +/– 10% 90-858895R1 JANUARY 2001 Page 3A-3 FUEL PUMP Fuel Pump Operation 1. The fuel pump is a diaphragm pump which is mechanically driven off of the camshaft. 2. If the engine runs out of fuel, or has a restriction preventing adequate fuel flow, the pump will make a “clicking” noise. WARNING FIRE AND EXPLOSION HAZARD. Observe fire prevention rules, particularly NO SMOKING. Before servicing any part of the fuel system, disconnect electrical system at the battery. Drain the fuel system completely. Use an approved container to collect and store fuel. Wipe up any spillage immediately. Materials used to contain spillage must be disposed of in an approved receptacle. Any fuel system service must be performed in a well ventilated area. FUEL LEAKAGE FROM ANY PART OF THE FUEL SYSTEM CAN BE A FIRE AND EXPLOSION HAZARD WHICH CAN CAUSE SERIOUS BODILY INJURY OR DEATH. Careful periodic inspection of the entire fuel system is mandatory, particularly after engine storage. All fuel components, including fuel tanks, (whether plastic, metal, or fiberglass), fuel lines, primer bulbs, fittings, and must be inspected for corrosion. Any sign of leakage or deterioration necessitates replacement before further engine operation. Page 3A-4 90-858895R1 JANUARY 2001 FUEL PUMP 90-858895R1 JANUARY 2001 Page 3A-5 Fuel Line Removal 1. Remove spark plug cover. b a b b a - Spark Plug Cover b - Screw (5) M6 x 16 2. Cut cable ties and disconnect fuel hoses. 3. Remove fuel filter and disassemble as shown. a b c d e c c f g h a - To Top Fuel Pump (Inlet) b - To Bottom Fuel Pump (Inlet) c - Conduit d - Cable Tie (8) e - Tee f - Filter g - Sleeve h - Connector FUEL PUMP Page 3A-6 90-858895R1 JANUARY 2001 Fuel Pump Removal 1. Remove spring clips and outlet fuel pump hoses. 2. Remove fuel pump mounting bolts and separate fuel pump from cylinder head. a b c c b d d a - Outlet Fuel Pump Hose b - Spring Clip (2) c - Mounting Screw (4) M6 x 30 d - O-Ring (2) Fuel Pump Disassembly 1. Remove screws to separate pump cover, cover seal, and diaphragm, from pump body. c d b a e f a - Screw (4) M5 x 35 b - Pump Cover c - Gasket d - Diaphragm e - Pump Body f - Nuts (4) FUEL PUMP 2. Separate pump body from pump base. a b a-Fuel Pump Body b-Fuel Pump Base 3. Rotate plunger to line up slots. b a 53615 a-Slots Offset b-Slots Aligned 4. Compress pump assembly to free spring load on pin. 5. Tilt assembly to allow pin to slide out. a a-Pin 90-858895R1 JANUARY 2001 Page 3A-7 FUEL PUMP Cleaning/Inspection/Repair 1. Inspect the check valves for damage. Replace if necessary. 2. Inspect springs for damage. Replace if necessary. 3. Inspect cover seal and diaphragm. Replace if damaged. ab a-Gasket b-Diaphragm 4. Inspect inline filter for leaks or contamination. Replace if necessary. 5. Inspect fuel pump change lever for wear. Replace if necessary. NOTE:Refer toSection 4A–Cylinder Headfor removal of cylinder head cover. a a-Fuel Pump Change Lever Page 3A-8 90-858895R1 JANUARY 2001 FUEL PUMP Fuel Pump Reassembly 1. Assemble springs, diaphragm, and plunger onto pump body. NOTE:Position tang on diaphragm as shown. a b c d e f a-Diaphragm d-Spring b-Diaphragm Spring e-Plunger c-Pump Body f-Diaphragm Tang Position 2. Line up slots and compress assembly. 3. Insert pin into hole. a b c a-Pump Body b-Slots c-Pin 90-858895R1 JANUARY 2001 Page 3A-9 FUEL PUMP 4. Rotate plunger 90° to offset slots. 53615 a b a-Slots Aligned b-Slots Offset 5. Assemble diaphragm, seal, and cover, to pump body. Secure assembly to pump base with screws and nuts. NOTE:Seal installs in one direction only. c d b a e f g 7 7 Loctite “271” (92-809820) a-Screws (4) M5 x 35 b-Cover c-Cover Seal d-Diaphragm e-Pump Body f-Pump Base g-Nuts (4) Fuel Pump Cover Screw Torque 25 lb-in. (3 Nm) Page 3A-10 90-858895R1 JANUARY 2001 FUEL PUMP 90-858895R1 JANUARY 2001 Page 3A-11 Fuel Pump Installation 1. Secure fuel pump to cylinder head. 2. Connect outlet fuel hoses and secure with spring clips. a a b b c d d a - O-Ring (2) b - Mounting Screw (4) M6 x 30 c - Outlet Fuel Hose d - Spring Clip (2) Fuel Pump Mounting Screw Torque 70 lb-in. (8 Nm) FUEL PUMP Page 3A-12 90-858895R1 JANUARY 2001 Fuel Line Installation 1. Connect fuel hoses and filter. Secure with cable ties. a b c d e c c f g h i j a - To Top Fuel Pump (Inlet) b - To Bottom Fuel Pump (Inlet) c - Conduit d - Cable Tie (8) e - Tee f - Filter g - Sleeve h - Connector i - Tubing (36 in.) j - Tubing (13.5 in.) FUEL PUMP 2. Install spark plug cover. b a a a a-Screw (5) M6 x 16 b-Spark Plug Cover Spark Plug Cover Screw Torque 65 lb-in. (7.5 Nm) 90-858895R1 JANUARY 2001 Page 3A-13 CARBURETOR FUEL SYSTEM Section 3B - Carburetor Table of Contents Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-2 Carburetor Specifications. . . . . . . . . . . . . . . . . . . 3B-2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-3 Intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-4 Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-6 Fuel & Vent Lines . . . . . . . . . . . . . . . . . . . . . . . . . 3B-8 Theory of Operations . . . . . . . . . . . . . . . . . . . . . 3B-10 Prime Start System . . . . . . . . . . . . . . . . . . . . 3B-10 Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-11 Carburetor Adjustments . . . . . . . . . . . . . . . . . . . 3B-12 Float Level . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-12 Idle Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-12 Intake Assembly Removal . . . . . . . . . . . . . . . . . 3B-13 Intake Disassembly. . . . . . . . . . . . . . . . . . . . . . . 3B-14 Auto Enrichener Removal/Disassembly . . . . . 3B-16 Carburetor Disassembly. . . . . . . . . . . . . . . . . . . 3B-17 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . . 3B-19 Carburetor. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-19 Auto Enrichener. . . . . . . . . . . . . . . . . . . . . . . 3B-20 Carburetor Reassembly . . . . . . . . . . . . . . . . . . . 3B-21 Auto Enrichener Assembly/Installation . . . . . . 3B-22 Intake Reassembly . . . . . . . . . . . . . . . . . . . . . . . 3B-24 Intake Assembly Installation . . . . . . . . . . . . . . . 3B-27 3 B 90-858895R1 JANUARY 2001 Page 3B-1 CARBURETOR Specifications Number of Carburetors ID Mark 4 75 67G 90 Venturi Size 67F 75 0.945 in. (24 mm) CARBURETOR 90 1.181 in. (30 mm) Idle rpm (Neutral) Warm Engine 850 ± 25 rpm Idle rpm (Forward Gear) Warm Engine Wide Open Throttle rpm (WOT) Range: 775 - 800 rpm Model 75 4500-5500 Model 90 5000–6000 Carburetor Specifications Carburetor Number Model Main Fuel- Jet Main AirJet Pilot Jet Pilot AirJet Float Setting Idle MIxture Pre-Set BCF68C10 75H.P. 4-Stroke #112 #115 #45 #85 0.51-0.59in (13-15 mm) 2-1/2 ± 1/2 BCF68C00 90H.P. 4-Stroke #128 #75 #42 #85 0.51-0.59in (13-15 mm) 2 ± 1/2 Page 3B-2 90-858895R1 JANUARY 2001 CARBURETOR Special Tools 1. Carburetor Scale P/N 91-36392. 2. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1. 90-858895R1 JANUARY 2001 Page 3B-3 1 2 6 8 9 10 11 12 13 15 18 19 20 7 14 17 3 4 5 5 18 11 18 11 CARBURETOR Intake 19 Page 3B-4 90-858895R1 JANUARY 2001 CARBURETOR Intake REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 INTAKE SILENCER 2 3 SCREW (M8 x 60 mm) 13 181 3 8 SCREW (M6 x 16 mm) 70 8 4 4 PLATE 5 8 O RING 6 4 O RING 7 8 SCREW (M6 x 115 mm) 70 8 8 4 INSULATOR 9 4 SEAL 10 1 MANIFOLD 11 2 PIN 12 1 GASKET 13 5 SCREW (M8 x 35 mm) 13 181 14 4 SCREW (M6 x 10 mm) 70 8 15 4 GASKET 16 1 BREATHER PIPE 17 1 STA-STRAP 18 2 CLAMP 19 2 SCREW (M6 x 12 mm) 70 8 20 1 CLIP 90-858895R1 JANUARY 2001 Page 3B-5 CARBURETOR Carburetor 2 4 5 6 8 9 1011 12 13 14 15 16 17 19 20 21 22 23 24 25 7 26 28 29 27 32 3334 38 39 40 41 43 44 42 45 46 1 32 33 35 38 39 1 30 31 18 35 36 37 3 Page 3B-6 90-858895R1 JANUARY 2001 CARBURETOR Carburetor REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 2 CARBURETOR (1/3) 2 1 CARBURETOR (2) 3 1 CARBURETOR (4) 4 12 SCREW (M4 x 10 mm) 5 4 PLAT 6 4 O RING 7 4 FILTER ELEMENT 8 3 SCREW (1/2/3) 9 3 SPRING (1/2/3) 10 4 SPRING 11 4 O RING 12 4 PILOT SCREW 13 4 PLUG 14 2 PRIME STARTER (1/3) 15 2 SCREW (1/3) (M4 x 10 mm) 16 2 STARTER LEVER PLATE (1/3) 17 2 STARTER HOUSING (1/3) 18 6 SCREW (1/3) (M5 x 16 mm) 19 2 O RING (1/3) 20 2 O RING (1/3) 21 2 O RING (1/3) 22 4 O RING (1/3) 23 3 SPRING (1/2/3) 24 4 O RING 25 4 NEEDLE VALVE SET 26 4 CLIP 27 4 FLOAT PIN 28 4 JET (#42) 29 4 CAP 30 4 NEEDLE JET 31 4 MAIN JET (#128) 32 4 FLOAT 33 4 FLOAT ARM PIN 34 4 SCREW (M4 x 8 mm) 35 4 GASKET 36 2 FLOAT BOWL (1/3) 37 16 SCREW (M4 x 14 mm) 38 4 DRAIN SCREW 39 4 O RING 40 2 FLOAT BOWL (2/4) 41 2 SCREW (4) 42 2 SPRING (4) 43 1 COLLAR (4) 44 1 BUSHING (4) 45 1 DIAPHRAGM (4) 46 2 SCREW (4) (M6 x14 mm) 70 8 90-858895R1 JANUARY 2001 Page 3B-7 CARBURETOR Fuel & Vent Lines 2 3 4 5 67 9 10 11 12 13 14 15 16 17 18 19 20 21 8 22 23 24 25 26 6 3 9 9 9 9 9 9 9 9 9 9 9 9 9 10 10 10 14 15 16 16 16 17 17 18 18 18 21 7 7 7 27 2830 31 29 1 Page 3B-8 90-858895R1 JANUARY 2001 CARBURETOR Fuel & Vent Lines REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 CHOKE ROD 2 1 STA-STRAP 3 2 HOSE 4 1 HARNESS 5 1 CHECK VALVE 6 2 HOSE 7 14 CONNECTOR 8 1 HOSE 9 18 CLAMP 10 4 HOSE 11 1 HOSE 12 1 HOSE 13 1 CLAMP 14 2 CLAMP 15 2 BOLT 16 4 TEE FITTING 17 3 HOSE 18 4 HOSE 19 1 CONNECTOR 20 1 HOSE 21 2 CLIP 22 2 HOSE 23 1 HOSE 24 2 HOSE 25 1 HOSE 26 1 HOSE 27 1 TUBING (1-3/4 IN.) 28 1 TEE FITTING 29 1 STA-STRAP 30 1 TUBING (22 IN.) 31 1 TUBE 90-858895R1 JANUARY 2001 Page 3B-9 CARBURETOR Theory of Operations Prime Start System This carburetor assembly uses the PrimeStart system for precise fuel delivery during start-up, at all temperatures. Two electrothermal valves are installed on the carburetor assembly. The upper electrothermal valve controls fuel flow for carburetors #1 and #2, and the lower valve controls fuel flow for carburetors #3 and #4. Before start-up, the electrothermal ram (needle) is retracted (the fuel enrichment valve is opened) according to the temperature, allowing a high percentage of fuel to flow form the flat chamber into the venturi during start-up. During start-up, the electrothermal ram (needle) is still retracted (the fuel enrichment valve is opened) according to the temperature, allowing a rich air/fuel mixture to be fed to the cylinders. After start-up, the current supplied form the electric power source and then flows to the electrothermal valves causing the wax in the valves to heat up. As the wax heats up the electrothermal ram (needle) begins to extend, partially closing the fuel enrichment valve, and reducing the flow of fuel from the float chamber into the venturi. After a few minutes, the electrothermal ram (needle) is fully extended, the fuel enrichment valve is fully closed, and enrichment ceases. d a b c e a-Electrothermal Valve b-Fuel Enrichment Valve c-Electrothermal Ram (needle) d-Carburetor #1 and #3 e-Carburetor #2 and #4 Air Fuel Air/Fuel Mixture Page 3B-10 90-858895R1 JANUARY 2001 CARBURETOR 90-858895R1 JANUARY 2001 Page 3B-11 Acceleration This carburetor assembly uses an accelerator pump to ensure that the proper amount of fuel reaches all of the carburetors during rapid throttle openings (preventing temporary lean conditions). As the throttle is opened, the throttle lever rotates and pushes the throttle lever link rod. The throttle lever link rod then pushes the diaphragm in the dashpot, forcing out the air. The air flows through the in-line, one-way valve, and then to all of the carburetors. This additional air flows into the carburetors and mixes with the fuel from the main jets. This air/fuel mixture is then injected into the venturi, ensuring that enough fuel reaches the engine. As the throttle is closed, the throttle lever rotates back and the throttle lever link rod returns, causing the diaphragm in the dashpot to move back, As the diaphragm moves back, suction causes the air from the venturi of carburetor #4 to flow through a one-way valve in the carburetors and back to the dashpot. The in-line, one-way valve prevents the air in the hoses from flowing back to the dashpot. Also, the diaphragm functions as a coasting enrichener during quick deceleration, preventing the engine form stalling. Carburetor #4 (Side View) Carburetor #4 (Cutaway View) a b c d e f g h i j Acceleration Deceleration a - Throttle Lever b - Throttle Lever Link Rod c - Diaphragm d - Dashpot e - In-Line, One-Way Valve f - To Carburetor #1 g - To Carburetor #2 h - To Carburetor #3 i - Main Jet j - One-Way Valve CARBURETOR Carburetor Adjustments Float Level 1. With carburetor turned upside down, and carb scale seated on inner edge, check float level from top of float to float bowl flange as shown. Adjust tab if out of specification. NOTE:Measure float level without gasket. NOTE:Bend tab to adjust float height. a a-Float Level b-Tab b Float Height 0.51-0.59 in. (13-15 mm) Idle Speed NOTE:Outboard should be completelywarmed upfor the idle speed adjustment. 1. With the outboard in forward gear, adjust idle speed screw to obtain the specified idle speed. NOTE: Turning idle speed adjustment screw; -clockwisewillincreaseengine idling speed. -counterclockwisewilldecreaseengine idling speed. a a-Idle Speed Screw Idle Speed (Forward Gear) 775-800 RPM Page 3B-12 90-858895R1 JANUARY 2001 CARBURETOR 90-858895R1 JANUARY 2001 Page 3B-13 Intake Assembly Removal NOTE: Refer to Section 7 for removal of the throttle lever/linkage assembly prior to removal of the intake assembly and carburetors. 1. Remove fuel pump hoses. 2. Disconnect auto enrichener wires and throttle position sensor (TPS) harness. a b a c a - Fuel Pump Hoses b - Auto Enrichener and TPS Connection c - Flat Blade Screwdriver Inserted into TPS Connector 3. Disconnect breather hose from intake silencer. 4. Remove intake assembly from engine. a b c e d a - Breather Hose b - Intake Silencer c - Screw (3) M8 x 60 d - Screw (5) M8 x 35 e - Gasket CARBURETOR Page 3B-14 90-858895R1 JANUARY 2001 Intake Disassembly 1. Remove intake silencer. a b c a - Intake Silencer b - Screw (8) M6x16 c - O-Ring (4) 2. Remove fuel and accelerator pump piping. NOTE: When removing fuel pump piping check hose for in-line fuel filters that may be stuck inside the hose. a b c a - Fuel Pump Piping b - Accelerator Pump Piping c - Remove Any Fuel Filters That May Be Stuck in Hose CARBURETOR 90-858895R1 JANUARY 2001 Page 3B-15 3. Remove link lever and accelerator pump. 4. Remove spacers and intake manifold. 5. Remove hose. a b c d e f g h i j k l a - Link Lever b - Screw (2) M6 x 14 mm c - Accelerator Pump d - Bolt (8) M6 x 115 mm e - Spacer (4) f - O-Ring (4) g - O-Ring (4) h - Spacer (4) i - O-Ring (4) j - Intake Manifold k - Hose (2) l - Carburetor Assembly CARBURETOR Page 3B-16 90-858895R1 JANUARY 2001 Auto Enrichener Removal/Disassembly 1. Cut cable tie and disconnect auto enrichener wires. a a - Cable Tie 2. Remove auto enrichener assembly. 3. Remove auto enrichener from valve housing. a b c e i f d g h j a - Screw (3) M5 x 16 b - Auto Enrichener Valve Assembly c - Screw-M4 x 10 d - Auto Enrichener Valve Retainer e - Auto Enrichener Valve f - O-Ring g - Auto Enrichener Valve Housing h - O-Ring (2) i - O-Ring j - O-Ring CARBURETOR Carburetor Disassembly 1. Remove top cover and pilot screw. a b c d e f g a-Screw (3) M4 x 10 e-Pilot Screw b-Carburetor Top Cover f-Spring c-Gasket g-O-Ring d-Blind Plug 90-858895R1 JANUARY 2001 Page 3B-17 CARBURETOR Page 3B-18 90-858895R1 JANUARY 2001 2. Remove float chamber and float. 3. Remove needle valve. 4. Remove main jet and main nozzle. 5. Remove pilot jet. a b c d e f g h i j k l m n o a - Screw (4) M4 x 14 b - Float Chamber c - Rubber Gasket d - Screw-M4 x 8 e - Float Pin f - Float g - Needle Valve h - Needle Valve Seat i - O-Ring j - Main Jet k - Main Nozzle l - Pilot Jet Plug m - Pilot Jet n - Drain Screw o - O-Ring CARBURETOR Cleaning/Inspection/Repair Carburetor 1. Inspect carburetor body. Replace if cracked or damaged. 2. Inspect inline filter for leaks or contamination. Replace if necessary. 3. Inspect o-rings and gaskets. Replace if cut or torn. 4. Inspect pilot screw. Replace if bent or worn. 5. Inspect main jet and pilot jet. Clean if they are contaminated. 6. Inspect needle valve. Replace if grooved wear is noticeable. 90-858895R1 JANUARY 2001 Page 3B-19 CARBURETOR 7. Inspect float. Replace if cracked or damaged. CAUTION Do not use steel wire for cleaning the jets as this may enlarge the jet diameters and seriously affect performance. Use a petroleum based solvent for cleaning and blow out all passages with compressed air. Auto Enrichener 1. Inspect needle and piston valve. Replace if worn or damaged. 2. Measure auto enrichener resistance. Replace if out of specification. Auto Enrichener Resistance 15-25 W @ 68°F (20°C) 3. Perform piston valve height test below. Piston Valve Height Test: a. Measure piston valve height (a). b. Connect to 12 V battery. c. Wait several minutes. d. Measure piston valve height. 4. Replace auto enrichener if no change was observed. a a-Piston Valve Height Measurement Page 3B-20 90-858895R1 JANUARY 2001 CARBURETOR 90-858895R1 JANUARY 2001 Page 3B-21 Carburetor Reassembly 1. Install pilot jet, main jet, and main nozzle. 2. Install needle valve, float chamber, and float. NOTE: Check float for smooth operation after installation. NOTE: When installing float into carburetor, place needle valve into needle valve seat. a b c d e f g h i j k l m n o d e g a - Screw (4) M4 x 14 b - Float Chamber c - Rubber Gasket d - Screw-M4x e - Float Pin f - Float g - Needle Valve h - Needle Valve Seat i - O-Ring j - Main Jet k - Main Nozzle l - Pilot Jet Plug m - Pilot Jet n - Drain Screw o - O-Ring CARBURETOR Page 3B-22 90-858895R1 JANUARY 2001 3. Install float chamber, pilot screw, and top cover. 4. Adjust pilot screw to specifications listed on page 3B-1. a b c d e f g a - Screw (3) M4 x 10 mm b - Carburetor Top Cover c - Gasket d - Blind Plug e - Pilot Screw f - Spring g - O-Ring Auto Enrichener Assembly/Installation 1. Assemble valve housing and auto enrichener. 2. Install auto enrichener assembly onto carburetors. a d b c e f g h i j a - O-Ring b - O-Ring c - O-Ring (2) d - Auto Enrichener Valve Housing e - O-Ring f - Auto Enrichener Valve g - Auto Enrichener Valve Retainer h - Screw-M4 x 10 i - Auto Enrichener Valve Assembly j - Screw (3) M5 x 16 CARBURETOR 3. Connect auto enrichener wires and secure with cable tie. NOTE: Refer to wiring diagram insection 2D for proper connections. a-Cable Tie a 90-858895R1 JANUARY 2001 Page 3B-23 CARBURETOR Page 3B-24 90-858895R1 JANUARY 2001 Intake Reassembly NOTE: Assemble carburetors in their original positions #1-#4. 1. Install hose, spacers and intake manifold. 2. Install link lever and accelerator pump. a b c e d f g h i j k l a - Carburetor Assembly b - Hose (2) c - Intake Manifold d - O-Ring (4) e - Spacer (4) f - O-Ring (4) g - O-Ring (4) h - Spacer (4) i - Bolt (8) M6 x 115 j - Accelerator Pump k - Screw (2) M6 x 10 l - Link Lever Carburetor Screw Torque (M6x115mm) 70 lb-in. (8 Nm) CARBURETOR 90-858895R1 JANUARY 2001 Page 3B-25 3. Install in-line fuel filters into 90° adapter. 4. Install fuel and accelerator pump line. Back View Front View b a c d a - Fuel Pump Line b - Accelerator Pump Line c - In-line Fuel Filter (4) d - 90° adapter CARBURETOR Page 3B-26 90-858895R1 JANUARY 2001 5. Install intake silencer. b c a a - O-Ring (4) b - Screw (8) M6 x 16 c - Intake Silencer Intake Silencer Screw Torque 70 lb-in. (8 Nm) CARBURETOR 90-858895R1 JANUARY 2001 Page 3B-27 Intake Assembly Installation 1. Install intake assembly onto engine. 2. Connect breather hose to intake silencer, secure with cable tie. a b c d e a - Gasket b - Screw (5) M8 x 35 c - Screw (3) M8 x 60 d - Intake Silencer e - Breather Hose Intake Manifold Screw Torque-M8x35mm 159 lb-in. (18 Nm) Intake Silencer Screw Torque-M8x60mm 159 lb-in. (18 Nm) CARBURETOR 3. Install fuel pump hoses, secure with hose clamps. 4. Connect auto enrichener wires, throttle position sensor (TPS) harness. a a b a-Fuel Pump Hoses b-Auto Enrichener and TPS Connection NOTE: Refer to Section 7 for installation of the throttle lever/linkage assembly. NOTE: Carburetor adjustments are required after rebuilding carburetors. Refer to Section 2C -Timing/Synchronizing/Adjusting for: -Pilot Screw Adjustments -Carburetor Synchronization -Throttle Cam Adjustment Page 3B-28 90-858895R1 JANUARY 2001 EMISSIONS FUEL SYSTEM Section 3C – Emissions Table of Contents Exhaust Emissions Standards . . . . . . . . . . . . . . 3C-2 What Are Emissions? . . . . . . . . . . . . . . . . . . . 3C-2 Hydrocarbons – HC. . . . . . . . . . . . . . . . . . . . . 3C-2 Carbon Monoxide – CO . . . . . . . . . . . . . . . . . 3C-2 Oxides of Nitrogen - NOx. . . . . . . . . . . . . . . . 3C-2 Controlling Emissions . . . . . . . . . . . . . . . . . . . 3C-2 Stoichiometric (14.7:1) Air/Fuel Ratio . . . . . 3C-3 Outboard Hydrocarbon Emissions Reductions . . . . . . . . . . . . . . . . . . . . . 3C-3 Stratified Vs Homogenized Charge . . . . . . . . . . 3C-4 Homogenized Charge . . . . . . . . . . . . . . . . . . . 3C-4 Stratified Charge . . . . . . . . . . . . . . . . . . . . . . . 3C-5 Emissions Information . . . . . . . . . . . . . . . . . . . . . 3C-6 Manufacturer’s Responsibility . . . . . . . . . . . . 3C-6 Dealer Responsibility . . . . . . . . . . . . . . . . . . . 3C-6 Owner Responsibility . . . . . . . . . . . . . . . . . . . 3C-6 EPA Emission Regulations . . . . . . . . . . . . . . 3C-7 Manufacturer’s Certification Label . . . . . . . . . . . 3C-8 Service Replacement Certification Label . . . . . 3C-9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-9 Date Code Identification. . . . . . . . . . . . . . . . . 3C-9 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-9 Decal Location . . . . . . . . . . . . . . . . . . . . . . . . . 3C-9 3 C 90-858895R1 JANUARY 2001 Page 3C-1 EMISSIONS Exhaust Emissions Standards Through the Environmental Protection Agency (EPA), the federal government has established exhaust emissions standards for all new marine engines sold in the U.S. What Are Emissions? Emissions are what comes out of the exhaust system in the exhaust gas when the engine is running. They are formed as a result of the process of combustion or incomplete combustion. To understand exhaust gas emissions, remember that both air and fuel are made of several elements. Air contains oxygen and nitrogen among other elements; gasoline contains mainly hydrogen and carbon. These four elements combine chemically during combustion. If combustion were complete, the mixture of air and gasoline would result in these emissions: water, carbon dioxide and nitrogen, which are not harmful to the environment. But combustion is not usually complete. Also, potentially harmful gases can be formed during and after combustion. All marine engines must reduce the emission of certain pollutants, or potentially harmful gases, in the exhaust to conform with levels legislated by the EPA. Emissions standards become more stringent each year. Standards are set primarily with regard to three emissions: hydrocarbons (HC), carbon monoxide (CO) and oxides of nitrogen (NOx). Hydrocarbons – HC Gasoline is a hydrocarbon fuel. The two elements of hydrogen and carbon are burned during combustion in combination with oxygen. But they are not totally consumed. Some pass through the combustion chamber and exit the exhaust system as unburned gases known as hydrocarbons. Carbon Monoxide – CO Carbon is one of the elements that make up the fuel burned in the engine along with oxygen during the combustion process. If the carbon in the gasoline could combine with enough oxygen (one carbon atom with two oxygen atoms), it would come out of the engine in the form of carbon dioxide (CO2). CO2 is a harmless gas. But carbon often combines with insufficient oxygen (one carbon atom with one oxygen atom). This forms carbon monoxide, CO. Carbon monoxide is the product of incomplete combustion and is a dangerous, potentially lethal gas. Oxides of Nitrogen - NOx NOx is a slightly different byproduct of combustion. Nitrogen is one of the elements that makes up the air going into the engine. Under extremely high temperatures it combines with oxygen to form oxides of nitrogen (NOx). This happens in the engine’s combustion chambers when temperatures are too high. NOx itself is not harmful, but when exposed to sunlight it combines with unburned hydrocarbons to create the visible air pollutant known as smog. Smog is a serious problem in California as well as many other heavily populated areas of the United States. Controlling Emissions There are two principle methods of reducing emissions from a two-stroke-cycle marine engine. The first method is to control the air/fuel ratio that goes into the combustion chamber. The second is to control the time when this air/fuel mixture enters the combustion chamber. Timing is important, to prevent any unburned mixture from escaping out of the exhaust port. Page 3C-2 90-858895R1 JANUARY 2001 EMISSIONS Stoichiometric (14.7:1) Air/Fuel Ratio In the search to control pollutants and reduce exhaust emissions, engineers have discovered that they can be reduced effectively if a gasoline engine operates at an air/fuel ratio of 14.7:1. The technical term for this ideal ratio is stoichiometric. An air/fuel ratio of 14.7:1 provides the best control of all three elements in the exhaust under almost all conditions. The HC and CO content of the exhaust gas is influenced significantly by the air/fuel ratio. At an air/fuel ratio leaner than 14.7:1, HC and CO levels are low, but with a ratio richer than 14.7:1 they rise rapidly. It would seem that controlling HC and CO by themselves might not be such a difficult task; the air/fuel ratio only needs to be kept leaner than 14.7:1. However, there is also NOx to consider. As the air/fuel ratio becomes leaner, combustion temperatures increase. Higher combustion temperatures raise the NOx content of the exhaust. But, enrichening the air/fuel ratio to decrease combustion temperatures and reduce NOx also increases HC and CO, as well as lowering fuel economy. So the solution to controlling NOx - as well as HC and CO - is to keep the air/fuel ratio as close to 14.7:1 as possible. OUTBOARD HYDROCARBON EMISSIONS REDUCTIONS 8 1/3%  PER YEAR OVER 9 MODEL YEARS 120 100 80 60 40 20 0 96 97 98 99200001 02 03 04 05 06 07 08 90-858895R1 JANUARY 2001 Page 3C-3 EMISSIONS STRATIFIED VS HOMOGENIZED CHARGE At certain operating conditions, DFI engines use a stratified charge inside the combustion chamber to aid in reducing emissions. All other models exclusively use a homogenized charge. The difference between the two is: Homogenized Charge A homogenized charge has the air/fuel particles mixed evenly throughout the cylinder. This mixing occurs inside the carburetor venturi, reed blocks, crankcase and/or combustion chamber. Additional mixing occurs as the fuel is forced through the transfer system into the cylinder. The homogenized charge has an air/fuel ratio of approximately 14.7:1 and is uniform throughout the cylinder. Page 3C-4 90-858895R1 JANUARY 2001 EMISSIONS Stratified Charge A stratified charge engine only pulls air through the transfer system. The fuel required for combustion is forced into the cylinder through an injector placed in the top of the cylinder (head). The injector sprays an air/fuel mixture in the form of a cloud into the cylinder. Surrounding this cloud is air supplied by the transfer system. As the cloud is ignited and burns, the surrounding air provides almost complete combustion before the exhaust port opens. A stratified charge engine concentrates a rich mixture in the vicinity of the spark plug (air/fuel ratio less than 14.7:1). Elsewhere, the mixture is very lean or is comprised of air only. 90-858895R1 JANUARY 2001 Page 3C-5 EMISSIONS Emissions Information Manufacturer’s Responsibility Beginning with 1998 model year engines, manufacturers of all marine propulsion engines must determine the exhaust emission levels for each engine horsepower family and certify these engines with the United States Environmental Protection Agency (EPA). A certification decal/emissions control information label, showing emission levels and engine specifications directly related to emissions, must be placed on each engine at the time of manufacture. Dealer Responsibility When performing service on all 1998 and later outboards that carry a certification, attention must be given to any adjustments that are made that affect emission levels. Adjustments must be kept within published factory specifications. Replacement or repair of any emission related component must be executed in a manner that maintains emission levels within the prescribed certification standards. Dealers are not to modify the engine in any manner that would alter the horsepower or allow emission levels to exceed their predetermined factory specifications. Exceptions include manufacturers prescribed changes, such as that for altitude adjustments. Owner Responsibility The owner/operator is required to have engine maintenance performed to maintain emission levels within prescribed certification standards. The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications. Exceptions: • Carburetor jets may be changed for high altitude use in accordance with factory recommendations. • Single engine exceptions may be allowed with permission from the EPA for racing and testing. Page 3C-6 90-858895R1 JANUARY 2001 EMISSIONS EPA Emission Regulations All new 1998 and later outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors. This certification is contingent on certain adjustments being set to factory standards. For this reason, the factory procedure for servicing the product must be strictly followed and, whenever practicable, the product returned to the original intent of the design. The responsibilities listed above are general and in no way a complete listing of the rules and regulations pertaining to the EPA laws on exhaust emissions for marine products. For more detailed information on this subject, you may contact the following locations: VIA U.S. POSTAL SERVICE: Office of Mobile Sources Engine Programs and Compliance Division Engine Compliance Programs Group (6403J) 401 M St. NW Washington, DC 20460 VIA EXPRESS or COURIER MAIL: Office of Mobile Sources Engine Programs and Compliance Division Engine Compliance Programs Group (6403J) 501 3rd St. NW Washington, DC 20001 EPA INTERNET WEB SITE: http:/www.epa.gov/omswww 90-858895R1 JANUARY 2001 Page 3C-7 EMISSIONS Manufacturer’s Certification Label The certification label must be placed on each engine at the time of manufacture and must be replaced in the same location if damaged or removed. Shown below is a typical certification label and is not representative of any one model. Label shown below is not to scale; (shown at twice the normal size). Gap: aEmission Control Information Refer to Owners Manual for required maintenance Family: YM9XM01.62G0 Idle Speed (in neutral): 900 RPM FEL: 16.00 GM/KW-HR 90 HP 1596 cc Timing (in degrees): Not Adjustable CDI Controlled Standard Spark Plug: Suppressor Spark Plug: NGK LFR5A-11 Valve Clearance (Cold) mm Intake: 0.17-0.23 Exhaust: 0.31-0.37 Gap: 0.043, (1.1 mm) This engine conforms to 1999 Model Year U.S. EPA regulations for Marine SI engines. b c d f g h i MAY 1999 e j a -Spark Ignition (SI) b -Idle Speed (In Gear) c -Cubic Centimeter d -Engine Horsepower rating e -Month and Year of Production f -Valve Clearance (Four Stroke engines only) g -Recommended spark plug for best engine performance h -Timing specifications when adjustable i -FEL: Represents (Mercury Marine) statement of the maximum emissions output for the engine family j -Family example Y M9X M1596 2 G 0 Model Year Y=2000 Regulation M=Marine Type of Product 0=General Outboard J=Sport Jet H=High Performance Manufacturer Mercury Marine Displacement Liter Technology Type Cycle Type C=2 Stroke Cubic Inch 1=Old G=4 Stroke 2=New 3=Sport Jet Page 3C-8 90-858895R1 JANUARY 2001 EMISSIONS Service Replacement Certification Label IMPORTANT: By federal law, it is required that all 1998 and newer Mercury Marine outboards have a visible and legible emission certification label. If this label is missing or damaged, replacement labels can be obtained from Mercury Marine. Removal Remove all remaining pieces of the damaged or illegible label. Do not install new label over the old label. Use a suitable solvent to remove any traces of the old label adhesive from the display location. Date Code Identification Cut and remove a “V” notch through the month of engine manufacture before installing the new label. The month of manufacture can be found on the old label. If the label is missing or the date code illegible, contact Mercury Marine Technical Service for assistance. JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC Emission Control Information 1999 PART # 37–859245 This engine conforms to 1999 Model Year U.S. EPA regulations for marine SI engines. Idle Speed (in neutral): 900 RPM Timing: Not Adjustable CDI Controlled Spark Plug: NGK LFR5A-11 Gap: 0.043” (1.1 mm) Valve Clearance (Cold) mm Intake: 0.17-0.23 Exhaust: 0.31-0.37 Family: YM9XM01.62G0 FEL: 16.00 GM/KW-HR 1596 cc 90 HP 4-Stroke Refer to Owners Manual for required maintenance a b a -“V” Notch b -Month of Manufacture Installation Install the label on a clean surface in the original factory location. Decal Location Model Production Part No. Service Part No. Location on Engine 2000 Merc/Mar 90 HP (4-Stroke) 37-859245 37-804656-00 Top of Flywheel Cover 90-858895R1 JANUARY 2001 Page 3C-9 CYLINDER HEAD POWERHEAD Section 4A - Cylinder Head Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-4 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-6 Intake/Exhaust Valves . . . . . . . . . . . . . . . . . . . . . 4A-8 Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . 4A-10 Cylinder Head Bolts . . . . . . . . . . . . . . . . . . . 4A-10 Camshaft Caps Bolts . . . . . . . . . . . . . . . . . . 4A-10 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-11 Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . 4A-11 Preparing Cylinder Head for Removal . . . . . . . 4A-21 Cylinder Head Removal . . . . . . . . . . . . . . . . . . . 4A-23 Cylinder Head Disassembly . . . . . . . . . . . . . . . 4A-24 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . . 4A-26 Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-26 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-27 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-28 Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . 4A-29 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . 4A-30 Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . 4A-30 Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-33 Cylinder Head Reassembly . . . . . . . . . . . . . . . . 4A-34 Cylinder Head Installation . . . . . . . . . . . . . . . . . 4A-36 Following Cylinder Head Installation . . . . . . . . 4A-37 Timing Belt Installation . . . . . . . . . . . . . . . . . 4A-39 Extra Valve Clearance Work sheets . . . . . . . . . 4A-40 Measurement . . . . . . . . . . . . . . . . . . . . . . . . . 4A-40 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-40 4 A 90-858895R1 JANUARY 2001 Page 4A-1 CYLINDER HEAD Specifications Camshaft Dimensions Intake “A” 1.465 - 1.472 in. (37.22 - 37.38 mm) Exhaust “A” 1.453 - 1.459 in. (36.90 - 37.06 mm) Intake “B” A 1.178 - 1.184 in. (29.92 - 30.08 mm) Exhaust “B” Valve Lift 1.178 - 1.184 in. (29.92 - 30.08 mm) Intake 0.273 in. (6.94 mm) CAMSHAFT Exhaust Run-out Limit B 0.259 in. (6.58 mm) 0.0039 in. (0.1 mm) Camshaft Bearing Diameter “a” 0.9827 - 0.9835 in. (24.96 - 24.98 mm) Camshaft Bearing Oil Clearance 0.0008-0.0024 in.(0.020-0.061 mm) A Free Length “a” 2.094 in. (53.20 mm) Minimum Free Length 2.057 in. (52.25 mm) VALVE SPRING Tilt Limit “b” a b Less than 0.10 in. (2.6 mm) Warp Limit 0.004 in. (0.1 mm) CYLINDER HEAD Camshaft Bearing Inside Diameter a 0.984 - 0.985 in. (25.000 - 25.021 mm) Valve Lifter Bore Inside Diameter 1.102 - 1.103 in. (28.000 - 28.021 mm) Page 4A-2 90-858895R1 JANUARY 2001 CYLINDER HEAD Valve/Valve Seat/Valve Guides: Valve Clearance (cold) Intake 0.007 - 0.009 in. (0.17 - 0.23 mm) Exhaust Valve Face Angle 0.011 - 0.014 in. (0.31 - 0.34 mm) Intake 120°, 91°, 110° Exhaust Valve Dimensions: “A” Head Diameter 140°, 91°, 110° Intake 1.142 - 1.150 in. (29.0 - 29.2 mm) Exhaust “B” Face Width 0.945 - 0.953 in. (24.0 - 24.20 mm) Intake 0.079 - 0.096 in. (2.00 - 2.43 mm) Exhaust “C” Seat Width 0.090 - 0.107 in. (2.28 - 2.71 mm) Intake 0.014 - 0.022 in. (0.35 - 0.55 mm) VALVES Exhaust “D” Margin Thickness 0.014 - 0.022 in. (0.35 - 0.55 mm) Intake 0.018 - 0.026 in. (0.45 - 0.65 mm) Exhaust Stem Outside Diameter 0.026 - 0.033 in. (0.65 - 0.85 mm) Intake 0.2352 - 0.2358 in. (5.975 - 5.990 mm) Exhaust Guide Inside Diameter 0.2346 - 0.2352 in. (5.960 - 5.975 mm) Intake 0.2364 - 0.2369 in. (6.005 - 6.018 mm) Exhaust Stem To Guide Clearance 0.2364 - 0.2369 in. (6.005 - 6.018 mm) Intake 0.0006 - 0.0017 in. (0.015 - 0.043 mm) Exhaust 0.0012 - 0.0023 in. (0.030 - 0.058 mm) Stem Run-out Limit (max.) 0.001 in. (0.03 mm) “A” “B” “C” “D” Valve Dimensions Head Diameter Face Width Seat Width Margin Thickness VALVE LIFTERS Valve Lifter Outside diameter Valve Lifter to Lifter Bore Clearance 1.1010 - 1.1016 in. (27.965 - 27.980 mm) 0.0008 - 0.0022 in. (0.020 -0.056 mm) VALVE SHIM Valve shim Thickness (in 0.025 mm increments) 0.0787 - 0.1299 in. (2.000 - 3.300 mm) THERMOSTAT Valve Opening Temperature Full Open Temperature Valve Lift (Minimum) 140° F (60° C) 158° F (70° C) 0.12 in. (3 mm) 90-858895R1 JANUARY 2001 Page 4A-3 CYLINDER HEAD Special Tools 1. Flywheel Holder P/N 91-83163M 2. Valve Guide Remover/Installer P/N 91-804774 3. Valve Guide Reamer P/N 91-804775 4. Valve Spring Compressor P/N 91-809494A1 5. Valve Seat Cutter Kit (Obtain Locally). Page 4A-4 90-858895R1 JANUARY 2001 CYLINDER HEAD Notes: 90-858895R1 JANUARY 2001 Page 4A-5 CYLINDER HEAD 1 3 4 5 6 10 17 18 19 20 21 7 8 9 11 12 13 14 15 16 22 23 24 25 26 27 28 29 30 32 2 31 3 10 17 2 30 4-Stroke Outboard Oil (92-828000A12)110 110 110 110 110 110 109 GM Silicone Sealer (92-91600-1) 95 7 109 7 95 2-4-C w/Teflon (92-850736A1) 7 Loctite 271 (92-809820) Cylinder Head Page 4A-6 90-858895R1 JANUARY 2001 CYLINDER HEAD Cylinder Head REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 CYLINDER HEAD 2 16 GUIDE PIN 3 4 PLUG 4 4 SCREW (M7 x 48 mm) 150 17 5 4 DOWEL PIN 6 16 SCREW (M7 x 37 mm) 150 17 7 2 SCREW (M6 x 25 mm) 70 8 8 1 THERMOSTAT COVER 9 1 THERMOSTAT 140 degree F (60 degree C) 10 10 SCREW (M10 x 145 mm) T55 Torx 11 4 SPARK PLUG (NGK LFR5A-11) 18 25 12 4 SCREW (M8 x 25 mm) 13 18 13 2 SCREW (M6 X 20 mm) 70 8 14 2 COVER 15 2 GROMMET 16 2 ANODE 17 2 COLLAR 18 1 GASKET 19 4 SCREW 20 4 GASKET 21 5 SCREW (M8 x 55 mm) 21 28 22 1 GASKET 23 1 COVER KIT 24 1 COVER 25 8 SCREW (M4 x 8 mm) 18 2 26 1 NIPPLE 27 14 SCREW (M6 x 30 mm) 70 8 28 1 OIL PLUG 29 1 O RING 30 2 GROMMET 31 1 COVER 32 5 SCREW (M6 x 16) 65 7.5 NOTE: TORQUE TOLERANCE +/– 10% 90-858895R1 JANUARY 2001 Page 4A-7 CYLINDER HEAD Intake/Exhaust Valves 1 3 4 5 7 8 9 10 14 2 6 18 19 2022 23 21 24 3 6 7 8 8 8 9 10 13 15 16 17 110 110 4-stroke Outboard Oil (92-828000A12) 17 16 15 13 12 110 Page 4A-8 90-858895R1 JANUARY 2001 CYLINDER HEAD Intake/Exhaust Valves REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 8 INTAKE VALVE 2 8 EXHAUST VALVE 3 16 SEAT 4 8 SEAL 5 8 SEAL 6 16 VALVE SPRING 7 16 RETAINER 8 32 COTTER VALVE 9 16 VALVE LIFTER 10 AR ADJUSTING PAD (2.350) 1111 AR ADJUSTING PAD (2.375) AR ADJUSTING PAD (2.400) AR ADJUSTING PAD (2.425) AR ADJUSTING PAD (2.450) AR ADJUSTING PAD (2.475) AR ADJUSTING PAD (2.500) AR ADJUSTING PAD (2.525) AR ADJUSTING PAD (2.550) AR ADJUSTING PAD (2.575) AR ADJUSTING PAD (2.600) AR ADJUSTING PAD (2.625) AR ADJUSTING PAD (2.650) AR ADJUSTING PAD (2.675) AR ADJUSTING PAD (2.700) AR ADJUSTING PAD (2.725) AR ADJUSTING PAD (2.750) AR ADJUSTING PAD (2.775) AR ADJUSTING PAD (2.800) AR ADJUSTING PAD (2.825) AR ADJUSTING PAD (2.850) AR ADJUSTING PAD (2.875) AR ADJUSTING PAD (2.900) AR ADJUSTING PAD (2.925) AR ADJUSTING PAD (2.950) AR ADJUSTING PAD (2.975) 12 1 CAMSHAFT 13 2 DOWEL PIN 14 1 CAMSHAFT 15 2 OIL SEAL 16 2 DRIVEN GEAR 17 2 SCREW (M10 x 35 mm) 44 60 18 1 V-BELT 19 1 TENSIONER 20 1 SPRING 21 1 HOSE 22 1 SCREW (M10 x 45 mm) 29 40 23 1 NUT (M40) 46 mm Hex 195 265 24 1 DRIVE GEAR AR = As Required 90-858895R1 JANUARY 2001 Page 4A-9 CYLINDER HEAD Torque Sequence Cylinder Head Bolts 12 34 56 78 910 11 12 13 14 15 Cylinder Head Bolt Torque-M8 x 55 mm 1st 120 lb-in. (14 Nm) 2nd 20 lb-ft (28 Nm) Cylinder Head Bolt Torque-M10 x 145 mm 1st 132 lb-in. (15 Nm) 2nd 24 lb-ft (33 Nm) 3rd 90° 51 lb-ft (70 Nm)* *Torque value given for reference only. Camshaft Caps Bolts 1 2 8 4 6 7 3 1091920 5 11 12 17 18 13 14 15 16 Camshaft Cap Bolt Torque 1st 70 lb-in. (8 Nm) 2nd 144 lb-in. (17 Nm) Page 4A-10 90-858895R1 JANUARY 2001 CYLINDER HEAD Adjustments Valve Clearance WARNING Engine could possibly start when turning flywheel during adjustment. To prevent this type of accidental engine starting and possible serious injury, always remove spark plug leads from spark plugs. NOTE:Valve clearance adjustment should be made on a cold engine at room temperature. 1. Remove flywheel cover and spark plug cover. 2. Disconnect spark plug leads and fuel hoses. c d e e c c b a a-Screw (2) M6 x 20 b-Flywheel Cover c-Screw (5) M6 x 16 d-Spark Plug Cover e-Fuel Hoses 90-858895R1 JANUARY 2001 Page 4A-11 CYLINDER HEAD Page 4A-12 90-858895R1 JANUARY 2001 3. Align timing marks on driven cams. NOTE: Use flywheel holder (91-83163M) to rotate flywheel and align timing marks. 4. Loosen timing belt tensioner bolt and remove tensioner spring. a c b 91-83163M a - Timing Marks b - Timing Belt Tensioner Screw M10 x 45 c - Tensioner Spring 5. Remove timing belt and driven sprockets. 6. Remove cylinder head cover and spark plugs. a b d c e h g f a - Driven Sprocket Screw (2) M10 x 35 b - Washer (2) c - Driven Sprocket (2) d - Pin (2) e - Breather Hose f - Screw (14) M6 x 30 g - Cylinder Head Cover h - Rubber Gasket CYLINDER HEAD 90-858895R1 JANUARY 2001 Page 4A-13 7. Re-install driven sprockets and timing belt. NOTE: Make sure timing marks are still aligned. b a d c e a - Pin (2) b - Washer (2) c - Driven Sprocket (2) d - Driven Sprocket Screw (2) M10 x 35 e - Timing Marks Aligned Driven Sprocket Screw Torque 44 lb-ft (60 Nm) 8. Install tensioner spring and tighten timing belt tensioner. b a a - Timing Belt Tensioner Screw M10 x 45 b - Tensioner Spring Timing Belt Tensioner Screw Torque 29 lb-ft (40 Nm) CYLINDER HEAD Page 4A-14 90-858895R1 JANUARY 2001 9. Measure intake and exhaust valve clearance using the Valve Clearance Measurement Steps below. VALVE CLEARANCE MEASUREMENT STEPS: a. Turn flywheel clockwise until cylinder #1’s piston is at TDC. b. Measure and record the intake valve clearance for cylinders #1 and #2. c. Measure and record the exhaust valve clearance for cylinders #1 and #3. d. Turn the flywheel 360° clockwise. e. Measure and record the intake valve clearance for cylinders #3 and #4. f. Measure and record the exhaust valve clearance for cylinders #2 and #4. Intake cylinders #1 and #2 Intake cylinders #3 and #4 Exhaust cylinders #1 and #3 Exhaust cylinders #2 and #4 MEASUREMENT TABLE INTAKE (cold) 0.007-0.009 in. (0.17-0.23 mm) CYL. Clearance Old Pad New Pad New Clearance #1 #2 #3 #4 EXHAUST (cold) 0.012-0.014 in. (0.31-0.37 mm) CYL. Clearance Old Pad New Pad New Clearance #1 #2 #3 #4 #1 #2 #3 #4 Intake Exhaust CYLINDER HEAD 90-858895R1 JANUARY 2001 Page 4A-15 10. If adjustment of intake or exhaust valve clearance is necessary (out of specification) follow Changing Pad Thickness below. If no adjustment is necessary skip to step #11 on page 18. CHANGING PAD THICKNESS 1. Align timing marks on driven cams. 2. Loosen timing belt tensioner and remove tensioner spring. NOTE: Do not mix valve train parts (valve pads, camshaft caps, camshafts). Keep individual cylinder parts together. a c b a - Timing Marks b - Timing Belt Tensioner Screw M10 x 45 c - Tensioner Spring 3. Remove timing belt and driven sprockets. 4. Remove camshaft caps and camshafts. IMPORTANT: Remove camshaft cap bolts in reverse sequence (ex. #20 #1). b c a d e f g h i j 12 10 19 17 18 13 14 15 16 20 2 8 6 4 11 9 1 7 3 5 a - Driven Sprocket Screw (2) M10 x 35 b - Washer (2) c - Driven Sprocket (2) d - Pin (2) e - Screw (4) M7 x 48 f - Screw (16) M7 x 37 g - Camshaft Cap - Top (2) h - Camshaft Cap (8) i - Oil Seal (2) j - Camshaft (2) CYLINDER HEAD 5. Carefully pry up the valve pad and remove it. 6. Measure and record (in the Measurement Table) the thickness of the removed valve pad with a micrometer. a b c a-Valve Pad b-Screwdriver c-Measure Valve Pad Thickness With a Micrometer a. Select a proper replacement valve pad by calculating its thickness with the following formula. Removed Pad Thickness + Measured Valve Clearance – Specified Valve Clearance = New Pad Thickness NOTE:Measure the thickness of the new valve pads with a micrometer (thickness is not indicated on the pad). NOTE: Lubricate the valve pads withmolybdenum disulfide before installing. b. Insert the proper valve pad into the valve lifter. A A Molybdenum Disulfide Grease (Purchase Locally) Page 4A-16 90-858895R1 JANUARY 2001 CYLINDER HEAD 90-858895R1 JANUARY 2001 Page 4A-17 7. Install camshafts and camshaft caps IMPORTANT: Install camshaft cap bolts in the proper sequence and torque. 110 4-Stroke Outboard Oil (92-828000A12) a b c d e g f Intake Exhaust 12 10 19 17 18 13 14 15 16 20 2 8 6 4 11 9 1 7 3 5 h i a - Screw (4) M7 x 48 b - Camshaft Cap Top (2) c - Screw (16) M7 x 37 d - Camshaft Cap (8) e - Oil Seal (2) f - Camshaft - Intake g - Camshaft - Exhaust h - Pink Identification i - Exhaust Cam Tang Camshaft Cap Screw Torque 1st 70 lb-in. (8 Nm) 2nd 150 lb-in. (17 Nm) 8. Install driven sprockets and timing belt. b c a d a - Driven Sprocket Screw (2) M10 x 35 b - Washer (2) c - Driven Sprocket (2) d - Pin (2) Driven Sprocket Screw Torque 44 lb-ft (60 Nm) CYLINDER HEAD 9. Tighten timing belt tensioner and install tensioner spring. b a a-Timing Belt Tensioner Screw M10 x 45 b-Tensioner Spring Timing Belt Tensioner Screw Torque 29 lb-ft (40 Nm) 10. Re-check valve clearance using Valve Clearance Measurement Steps. NOTE: If any valve clearance is still out of specification, repeat all the valve clearance adjustment steps until the specified clearance is obtained. 11. Loosen timing belt tensioner screw and remove tensioner spring. 12. Remove driven sprockets and timing belt. Page 4A-18 90-858895R1 JANUARY 2001 CYLINDER HEAD 90-858895R1 JANUARY 2001 Page 4A-19 13. Install cylinder head cover and driven sprockets. a b c d e f g 109 h 109 GM Silicone Sealer (92-91600-1) 109 a - Rubber Gasket b - Cylinder Head Cover c - Screw (14) M6 x 30 d - Breather Hose e - Pin (2) f - Driven Sprocket (2) g - Washer (2) h - Driven Sprocket Screw (2) M10 x 35 Cylinder Head Cover Screw Torque 70 lb-in. (8 Nm) Driven Sprocket Screw Torque 44 lb-ft (60 Nm) CYLINDER HEAD 14. Install timing belt and spark plugs. 15. Install tensioner spring and tighten timing belt tensioner bolt. b a a-Timing Belt Tensioner Screw M10 x 45 b-Tensioner Spring Timing Belt Tensioner Screw Torque 29 lb-ft (40 Nm) 16. Connect fuel hoses and spark plug leads. 17. Install spark plug cover and flywheel cover. a a b c c c d e a-Fuel Hoses b-Spark Plug Cover c-Screw (5) M6 x 16 d-Flywheel Cover e-Screw (2) M6 x 20 Page 4A-20 90-858895R1 JANUARY 2001 CYLINDER HEAD 90-858895R1 JANUARY 2001 Page 4A-21 Preparing Cylinder Head for Removal 1. Remove flywheel cover and spark plug cap cover. 2. Disconnect fuel hoses and spark plug leads. c d e e c c b a a - Screw (2) M6 x 20 b - Flywheel Cover c - Screw (5) M6 x 16 d - Spark Plug Cover e - Fuel Hoses 3. Align timing marks on driven cams. 4. Loosen timing belt tensioner and remove tensioner spring. NOTE: Use flywheel holder (91-83163M) to rotate flywheel and align timing marks. a c b 91-83163M a - Timing Marks b - Timing Belt Tensioner Screw M10 x 45 c - Tensioner Spring CYLINDER HEAD Page 4A-22 90-858895R1 JANUARY 2001 5. Remove timing belt and driven sprockets. 6. Remove fuel pumps and cylinder head cover. a b c d e h g f e a - Driven Sprocket Screw (2) M10 x 35 b - Washer (2) c - Pin (2) d - Driven Sprocket (2) e - Breather Hose f - Screw (14) M6 x 30 g - Cylinder Head Cover h - Rubber Gasket 7. Remove camshaft caps and camshafts. NOTE: Do not mix valve train parts (valve pads, camshaft caps, camshafts). Keep individual cylinder parts together. IMPORTANT: Remove camshaft cap bolts in reverse sequence (ex. #20 #1). a b e c d f Intake Exhaust 12 10 19 17 18 13 14 15 16 20 2 8 6 4 11 9 1 7 3 5 a - Screw (4) M7 x 48 b - Camshaft Cap - Top (2) c - Screw (16) M7 x 37 d - Camshaft Cap (8) e - Oil Seal (2) f - Camshaft (2) CYLINDER HEAD 90-858895R1 JANUARY 2001 Page 4A-23 Cylinder Head Removal 1. Remove spark plugs and cylinder head assembly. 2. Remove gasket and discard dowel pins. IMPORTANT: Remove cylinder head bolts in reverse order of torque sequence (ex. #15 #1). NOTE: Use Torx socket driver T55 for removal/installation of cylinder head bolts. a b d c e f 1 2 4 3 5 6 8 7 9 10 11 12 13 14 15 a - Spark plugs b - Screw (10) M10 x145 c - Screw (5) M8 x 55 d - Cylinder Head Assembly e - Gasket (discard) f - Dowel Pins (2) CYLINDER HEAD Page 4A-24 90-858895R1 JANUARY 2001 Cylinder Head Disassembly 1. Remove thermostat and anodes. IMPORTANT: To prevent anode from falling into water jacket use the following procedure for anode removal: a. Remove anode cover screws “d”. b. Remove anode assembly from cylinder block. c. Remove anode center screw “e”. a b c d e f g d d e h a - Screw (2) M6 x 25 b - Thermostat Cover c - Thermostat d - Screw (4) M8 x 25 e - Screw (2) M6 x 20 f - Anode Cover (2) g - O-Ring (2) h - Anode (2) 2. Remove valve pad and valve lifter. NOTE: Keep valve pads and lifters organized to prevent them from being installed into the wrong location during cylinder head reassembly. a b c d e a - Pliers b - Valve Pad and Lifter c - Valve Pad d - Valve Lifter e - Lifter Position Fixture CYLINDER HEAD 3. Remove valve cotter, spring retainer, and spring. NOTE: Use valve spring compressor (p/n 91-809494A1) for removal of valves. Compress valve and remove valve cotters first. 4. Remove valve stem seal, spring seat, and valve guide* (see note below). 5. Remove valves (intake and exhaust). NOTE: *Do not remove valve guide unless it is out of specification, refer to“Cleaning/Inspection/ Repair” in this section for measurement and removal procedures. 91-809494A1 a-Valve Cotter b-Spring Retainer c-Valve Spring d-Valve Stem Seal a b c d e f g h e-Spring Seat f-Valve Guide g-Exhaust Valve h-Intake Valve 90-858895R1 JANUARY 2001 Page 4A-25 CYLINDER HEAD Cleaning/Inspection/Repair Camshaft 1. Measure camshaft lobe dimensions “a” and “b”. Replace the camshaft if out of specification. a b Cam Lobe Specifications aa Intake 1.465 - 1.472 in. (37.22 - 37.38 mm) Exhaust 1.453 - 1.459 in. (36.90 - 37.06 mm) bb Intake 1.178 - 1.184 in. (29.92 - 30.08 mm) Exhaust 1.178 - 1.184 in. (29.92 - 30.08 mm) 2. Measure camshaft journal diameter “a”. Replace the camshaft if out of specification. a Camshaft Journal Diameter “a” 0.9827 - 0.9835 in. (24.96 - 24.98 mm) Page 4A-26 90-858895R1 JANUARY 2001 CYLINDER HEAD 3. Measure camshaft cap inside diameter “b”. Replace cylinder head if out of specification. b b Camshaft Cap Inside Diameter “b” 0.984 - 0.985 in. (25.000 - 25.021 mm) Thermostat 1. Inspect thermostat. Replace if damaged or valve does not open. 2. Measure valve opening temperature and valve lift “a” using the “Measurement Test” below. Replace thermostat if out of specification. MEASUREMENT TEST 1. Tie a piece of thread (or other non-conductive material) onto the thermostat. 2. Suspend the thermostat in water. 3. Heat water slowly while observing the thermostat. a a-Valve Lift Distance Water Temperature Valve Lift Below 140° F (60° C) 0 in. (0 mm) Above 158° F (70° C) Minimum 0.12 in. (3 mm) 90-858895R1 JANUARY 2001 Page 4A-27 CYLINDER HEAD Valves 1. Inspect valve for damage/warpage. Replace if necessary. 2. Measure margin thickness “a”. Replace valve if out of specification. a Margin Thickness “a” Intake Valve 0.018 - 0.026 in. (0.45 - 0.65 mm) Exhaust Valve 0.026 - 0.033 in. (0.65 - 0.85 mm) 3. Measure the valve stem diameter “a”. Replace valves if out of specification. a Valve Stem Diameter “a” Intake Valve 0.2352 - 0.2358 in. (5.975 - 5.990 mm) Exhaust Valve 0.2346 - 0.2352 in. (5.960 - 5.975 mm) Page 4A-28 90-858895R1 JANUARY 2001 CYLINDER HEAD 4. Measure valve stem runout. Replace valves if out of specification. Valve Stem Runout Limit (Max.) Intake Valve Exhaust Valve 0.001 in. (0.03 mm) NOTE: Valve guides, valve seal, and valves should be replaced as a set. Valve Springs 1. Check free length limit “a” of each spring. Replace valve springs if out of specification. a Valve Spring Free Length 2.057 in. (52.25 mm) 2. Measure valve spring tilt “a”. Replace valve springs if out of specification. NOTE:Check each spring on a flat surface using a square. Rotate spring and check space between the top coil and square. a Valve Spring Tilt Specification “a” Less than 0.10 in. (2.6 mm) 90-858895R1 JANUARY 2001 Page 4A-29 CYLINDER HEAD Page 4A-30 90-858895R1 JANUARY 2001 Cylinder Head 1. Inspect the cylinder head for mineral deposits/corrosion in the water passage ways. Clean any deposits/corrosion observed. 2. Inspect the cylinder head for carbon deposits in combustion chamber (use round scraper to clean away deposits). Be careful not to scratch or remove material. 3. Measure cylinder head warpage. Replace cylinder head if out of specification. NOTE: Use a straight edge and a thickness gauge to inspect cylinder head for warpage. b a a - Straight Edge b - Thickness Gauge Cylinder Head Warpage Limit 0.004 in. (0.1 mm) Valve Guides 1. Measure the valve guide bore “a”. If valve guide wear is out of specification, replace the valve guide by following “Valve Guide Replacement” below. a Valve Guide Inside Diameter Intake Valve / Exhaust Valve 0.2364 - 0.2369 in. (6.005 - 6.018 mm) CYLINDER HEAD VALVE GUIDE REPLACEMENT NOTE:Heat the cylinder head in an oven to 390° F (200° C). This will help to ease guide removal and installation, and to maintain correct interference fit. 1. Remove the valve guide using a valve guide remover/installer. a 91-804774 a-Valve Guide Remover/Installer (91-804774) 2. Install the new valve guide to the specified position “a” using the valve guide remover/installer. NOTE:Before installing the valve guide, mark the installation depth “b” as shown. a b c 91-804774 a-Valve Guide Depth Position “a” b-Installation Depth Mark c-Valve Guide Remover/Installer (91-804774) Valve Guide Depth Position “a” 0.45 in. (11.5 mm) 90-858895R1 JANUARY 2001 Page 4A-31 CYLINDER HEAD 3. After installing the valve guide, bore the valve guide using a valve guide reamer to obtain proper stem-to-guide clearance. a 91-804775 a-Valve Guide Reamer (91-804775) Stem To Guide Clearance Intake 0.0006-0.0017 in. (0.015-0.043 mm) Exhaust 0.0012-0.0023 in. (0.030-0.058 mm) Page 4A-32 90-858895R1 JANUARY 2001 CYLINDER HEAD Valve Seats VALVE SEAT RECONDITIONING Clean the carbon deposits from the combustion chambers and valve seats and check for pitting. Several different types of equipment are available for reseating valve seats. Follow the equipment manufacturer’s instructions. Measure valve seat width “a”. Resurface the valve seat if not in specification. Reface valve seat. Use a 90° or 45° valve seat cutter. NOTE: When twisting cutter, keep an even downward pressure to prevent chatter marks. NOTE:After refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped. a Valve Seat Width Specification “a” Intake Valve/Exhaust Valve 0.014 - 0.022 in. (0.35 - 0.55 mm) NOTE:If resurfacing the valve seats is required, resurface the valve seats to the specified angles shown in chart following. a b Obtain Locally Valve Seat Area Valve Seat Cutter a 90° b 45° 90-858895R1 JANUARY 2001 Page 4A-33 CYLINDER HEAD Cylinder Head Reassembly 1. Install valves (intake and exhaust). 2. Install spring seat and valve stem seal. 3. Install spring and spring retainer. 4. Compress valve springs using valve spring compressor and install valve cotters onto their respective valves. 4-Stroke Outboard Oil (92-828000A12) 110 f a e d c b a-Valves (Intake And Exhaust) e-Spring Retainer f-Valve Cotter g-Valve Spring Compressor 91-809494A1 g 110 b-Spring Seat c-Valve Stem Seal d-Valve Spring 5. Install valve pad and valve lifter into their original locations. 110 4-Stroke Outboard Oil (92-828000A12) 110 a cb a-Valve Pad and Lifter b-Valve Pad c-Valve Lifter Page 4A-34 90-858895R1 JANUARY 2001 CYLINDER HEAD 6. Install anode and thermostat. IMPORTANT: To prevent anode from falling into water jacket use the “Anode Assembly” procedure for anode installation: Anode Assembly a. Install anode bolt “a” to secure anode to anode cover. b. Install anode assembly in cylinder block. c. Install anode cover bolts “e”. e f g h e e a b c d a 95 2-4-C w/Teflon (92-850736A1) 95 77 Loctite “271” (92-809820) a-Screw-(2) M6 x 20 e-Screw (4) M8 x 25 b-Anode Cover (2) f-Thermostat c-Anode (2) g-Thermostat Cover d-O-Ring (2) h-Screw (2) M6 x 25 Anode Screw Torque 70 lb-in. (8 Nm) Anode Cover Screw Torque 156 lb-in. (18 Nm) Thermostat Screw Torque 70 lb-in. (8 Nm) 90-858895R1 JANUARY 2001 Page 4A-35 CYLINDER HEAD Page 4A-36 90-858895R1 JANUARY 2001 Cylinder Head Installation 1. Install dowel pins and gasket (New). 2. Install cylinder head assembly and spark plugs. IMPORTANT: Install cylinder head bolts in torque sequence (ex. #1 #15) with proper torque. NOTE: Use Torx socket driver T55 for removal/installation of cylinder head bolts. f b a e c d 1 2 4 3 5 6 8 7 9 10 11 12 13 14 15 g h i 110 4-Stroke Outboard Oil (92-828000A12) 110 110 a - Dowel Pins (2) b - Gasket (New) c - Cylinder Head Assembly d - Bolt (5) M8 x 55 e - Bolt (10) M10 x 145 f - Spark plugs g - Cylinder Head h - Cylinder Block i - Specified Torque Cylinder Head Bolt Torque-M8 x 55 mm 1st 120 lb-in. (14 Nm) 2nd 20 lb-ft (28 Nm) Cylinder Head Bolt Torque-M10 x 145 mm 1st 132 lb-in. (15 Nm) 2nd 24 lb-ft (33 Nm) 3rd 90° 51 lb-ft (70 Nm)* *Torque value given for reference only. CYLINDER HEAD 90-858895R1 JANUARY 2001 Page 4A-37 Following Cylinder Head Installation 1. Install camshafts and camshaft caps. b c e d f 1 2 8 4 6 7 3 10 9 19 20 5 11 12 17 18 13 14 15 16 g 110 4-Stroke Outboard Oil (92-828000A12) 109 110 109 110 110 110 110 A A Molybdenum Disulfide Grease (Obtain Locally) h 109 GM Silicone Sealer (92-91600-1) i a a - Camshaft (2) b - Oil Seal (2) c - Camshaft Cap (2) d - Screw (4) M7 x 48 e - Camshaft Cap (8) f - Screw (16) M7 x 37 g - Exhaust Cam Tang h - Pink Identification i - Pistons Turned 90° Past TDC IMPORTANT: Install camshaft with tang and pink identifying mark on exhaust side of cylinder head. IMPORTANT: Before installing the intake and exhaust camshafts, turn the crankshaft 90° past TDC (either direction) to prevent bending of valves during cap installation. CYLINDER HEAD Page 4A-38 90-858895R1 JANUARY 2001 NOTE: Install the camshaft caps in the proper position and sequence as shown and with the stamped numbers facing upside down. Camshaft Cap Bolt Torque 1st 70 lb-in. (8 Nm) 2nd 144 lb-in. (17 Nm) 2. Install cylinder head cover and driven sprockets. a b g h c d e f 109 109 GM Silicone Sealer (92-91600-1) a - Rubber Gasket b - Cylinder Head Cover c - Screw (14) M6 x 30 d - Breather Hose e - Pin (2) f - Driven Sprocket (2) g - Washer (2) h - Driven Sprocket Screw (2) M10 x 35 Cylinder Head Cover Screw Torque 70 lb-in. (8 Nm) Driven Sprocket Screw Torque 43 lb-ft (60 Nm) CYLINDER HEAD 90-858895R1 JANUARY 2001 Page 4A-39 Timing Belt Installation 1. Align timing marks on driven cams. NOTE: Use flywheel holder (91-83163M) to rotate flywheel and align timing marks. 2. Align pointer with TDC mark on flywheel. 3. Install timing belt. 4. Install tensioner spring and secure timing belt tensioner bolt. a c b 91-83163M a - Timing Marks b - Timing Belt Tensioner Screw M10 x 45 c - Tensioner Spring Timing Belt Tensioner Screw Torque 29 lb-ft (40 Nm) 5. Connect fuel hoses and spark plug leads. NOTE: Secure fuel hoses with spring clips. 6. Install spark plug cap cover and flywheel cover. c c c a a b d e a - Fuel Hoses b - Spark Plug Cap Cover c - Bolts (5) M6 x 25 mm d - Flywheel Cover e - Bolts (2) M6 x 20 mm CYLINDER HEAD Extra Valve Clearance Work sheets NOTE:Photocopy this page for extra valve clearance measurement work sheets. Measurement 1. Turn flywheel clockwise until cylinder #1’s piston is at TDC. 2. Measure and record the intake valve clearance for cylinders #1 and #2. 3. Measure and record the exhaust valve clearance for cylinders #1 and #3. 4. Turn the flywheel 360° clockwise. 5. Measure and record the intake valve clearance for cylinders #3 and #4. 6. Measure and record the exhaust valve clearance for cylinders #2 and #4. Adjustment 1. If clearance is out of specification, remove and measure the pad. 2. Add or subtract to that measurement a number to put the valve back into specification. 3. Use that measurement to select a new pad. Removed Pad Thickness + Measured Valve Clearance – Specified Valve Clearance = New Pad Thickness Intake cylinders #1 and #2 Intake cylinders #3 and #4 Exhaust cylinders #1 and #3 Exhaust cylinders #2 and #4 MEASUREMENT TABLE INTAKE (cold) 0.007-0.009 in. (0.17-0.23 mm) CYL. Clearance Old Pad New Pad New Clearance #1#1 #2#2 #3#3 #4#4 EXHAUST (cold) 0.012-0.014 in. (0.31-0.37 mm) CYL. Clearance Old Pad New Pad New Clearance #1#1 #2#2 #3#3 #4#4 Page 4A-40 90-858895R1 JANUARY 2001 CYLINDER BLOCK/CRANKCASE POWERHEAD Section 4B - Cylinder Block/Crankcase Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-4 Cylinder Block And Crankcase . . . . . . . . . . . . . . 4B-6 Crankshaft, Pistons And Connecting Rods . . . . 4B-8 Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . 4B-10 Crankcase Cover Bolts. . . . . . . . . . . . . . . . . 4B-10 Exhaust Cover Screws . . . . . . . . . . . . . . . . . 4B-11 Powerhead Mounting Bolts/Nuts . . . . . . . . . 4B-11 Preparing Powerhead for Removal . . . . . . . . . 4B-12 Powerhead Removal . . . . . . . . . . . . . . . . . . . . . 4B-15 Removing Powerhead Components . . . . . . . . 4B-16 Ignition Components. . . . . . . . . . . . . . . . . . . 4B-16 Charging and Starting System Components . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-16 Fuel Components . . . . . . . . . . . . . . . . . . . . . 4B-16 Harness and Battery Cable Removal . . . . . 4B-16 Cylinder Head Removal . . . . . . . . . . . . . . . . 4B-16 Powerhead Disassembly . . . . . . . . . . . . . . . . . . 4B-17 Drive Sprocket Removal. . . . . . . . . . . . . . . . 4B-17 Exhaust Cover Removal . . . . . . . . . . . . . . . . 4B-18 Crankcase and Crankshaft Removal . . . . . 4B-20 Piston Ring Removal . . . . . . . . . . . . . . . . . . 4B-22 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . . 4B-23 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-23 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-24 Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-25 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-26 Crankcase and Bearings . . . . . . . . . . . . . . . 4B-26 Connecting Rod Oil Clearance . . . . . . . . . . 4B-31 Powerhead Assembly . . . . . . . . . . . . . . . . . . . . . 4B-35 Piston Ring/Piston Installation . . . . . . . . . . . 4B-35 Crankcase and Crankshaft Installation . . . 4B-36 Exhaust Cover Installation . . . . . . . . . . . . . . 4B-40 Drive Sprocket Installation . . . . . . . . . . . . . . 4B-42 Installing Powerhead Components . . . . . . . . . 4B-43 Cylinder Head Installation . . . . . . . . . . . . . . 4B-43 Harness and Battery Cable Removal . . . . . 4B-43 Fuel Components . . . . . . . . . . . . . . . . . . . . . 4B-43 Charging and Starting System Components . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-43 Ignition Components. . . . . . . . . . . . . . . . . . . 4B-43 Powerhead Installation . . . . . . . . . . . . . . . . . . . . 4B-44 Following Powerhead Installation . . . . . . . . . . . 4B-46 4 B 90-858895R1 JANUARY 2001 Page 4B-1 CYLINDER BLOCK/CRANKCASE Specifications CYLINDER BLOCK Type Displacement Number of Cylinders In–Line, 4 Stroke – DOHC, 16 Valves 97.4 cid (1,596 cc) 4 STROKE Length 3.205 in. (81.4 mm) CYLINDER BORE Diameter Standard Oversize-0.010 in. (0.25 mm) Taper/Out of Round Maximum Bore Type 3.110 - 3.111 in. (79.000 - 79.020 mm) 3.120 - 3.121 in. (79.250 - 79.270 mm) 0.003 in. (0.08 mm) Cast Iron PISTON Piston Type Measure Point (H) O.D. at Skirt (H) Standard (D) Oversize-0.010 in. (0.25 mm) Pin Boss Inside Diameter Aluminum 0.51 in. (13 mm) 3.1073 - 3.1082 in. (78.928 - 78.949 mm) 3.1174 - 3.1182 in. (79.178 - 79.199 mm) 0.7090 - 0.7093 in. (18.008 - 18.015 mm) H D PISTON CLEARANCE Piston to Cylinder Clearance 0.0028 - .0031 in. (0.070 - 0.080 mm) Top Ring Dimension “B” B 0.046 - 0.047 in. (1.17 - 1.19 mm) Dimension “T” 0.114 - 0.115 in. (2.89 - 2.91 mm) End Gap (Installed) Side Clearance T 0.006 - 0.012 in. (0.15 - 0.30 mm) 0.001 - 0.003 in. (0.02 - 0.08 mm) Middle Ring Dimension “B” 0.058 - 0.059 in. (1.47 - 1.49 mm) RINGS Dimension “T” End Gap (Installed) B 0.118 - 0.126 in. (3.00 - 3.20 mm) 0.028 - 0.035 in. (0.70 - 0.90 mm) Side Clearance Bottom (Oil Ring) T 0.001 - 0.003 in. (0.03 - 0.07 mm) Dimension “B” 0.094 - 0.098 in. (2.38 - 2.48 mm) Dimension “T” 0.094 in. (2.40 mm) End Gap (Installed) Side Clearance B 0.008 - 0.028 in. (0.20 - 0.70 mm) 0.001 - 0.006 in. (0.03 - 0.15 mm) T COMPRESSION RATIO Compression Ratio Cylinder Compression (Minimum) 9.6:1 138 psi (950 kPa) PISTON PIN Piston Pin Outside Diameter 0.7083 - 0.7087 in. (17.997 - 18.000 mm) Page 4B-2 90-858895R1 JANUARY 2001 CYLINDER BLOCK/CRANKCASE Small End Inside Diameter 0.7073 - 0.7081 in. (17.965 - 17.985 mm) Big End Inside Diameter 1.8514 - 1.8518 in. (47.025 - 47.035 mm) CONNECTING Oil Clearance (Big End) Big End Bearing Thickness 0.0009 - 0.0014 in. (0.023 - 0.035 mm) ROD Yellow 0.0590 - 0.0593 in. (1.499 -1.506 mm) Green 0.0593 - 0.0596 in. (1.506 - 1.513 mm) Blue 0.0596 - 0.0598 in. (1.513 - 1.520 mm) Red 0.0598 - 0.0601 in. (1.520 - 1.527 mm) Crankshaft Journal Diameter 1.8892 - 1.8898 in. (47.985 - 48.000 mm) Minimum Diameter Crankshaft Pin 1.8887 in. (47.972 mm) Diameter 1.7316 - 1.7323 in. (43.982 - 44.000 mm) CRANKSHAFT Minimum Diameter 1.7311 in. (43.971 mm) Crankshaft Run-out 0.001 in. (0.03 mm) Crankcase Main Journal Inside Diameter 2.1269 - 2.1276 in. (54.023 - 54.042 mm) Crankshaft Journal Oil Clearance Upper Crankcase Main Journal Bearing Thickness 0.0009 - 0.0017 in. (0.024 - 0.044 mm) Green 0.1178 - 0.1181 in. (2.992 - 2.999 mm) Blue 0.1181 - 0.1183 in. (2.999 - 3.006 mm) CRANKCASE Red Lower Crankcase Main Journal Bearing Thickness 0.1183 - 0.1186 in. (3.006 - 3.013 mm) Yellow 0.1185 -0.1188 in. (3.010 - 3.017 mm) Green 0.1188 - 0.1191 in. (3.017- 3.024 mm) Blue 0.1191 - 0.1193 in. (3.024 - 3.031 mm) Red No. 3 Main Journal Bearing Thickness 0.1193 - 0.1196 in. (3.031 - 3.038 mm) Green 0.1178 - 0.1181 in. (2.992 - 2.999 mm) Blue 0.1181 - 0.1183 in. (2.999 - 3.006 mm) Red 0.1183 - 0.1186 in. (3.006 - 3.013 mm) 90-858895R1 JANUARY 2001 Page 4B-3 CYLINDER BLOCK/CRANKCASE Special Tools 1. Oil Filter Wrench (P/N 91-802653) 2. Flywheel Holder (P/N 91-83163M) 3. Flywheel Puller (P/N 91-83164M) 4. Piston Ring Compressor (P/N FT2997) 5. Piston Ring Expander (P/N 91-24697) 6. Crankshaft Holder (P/N 91-804770A1) Page 4B-4 90-858895R1 JANUARY 2001 CYLINDER BLOCK/CRANKCASE Notes: 90-858895R1 JANUARY 2001 Page 4B-5 CYLINDER BLOCK/CRANKCASE Cylinder Block And Crankcase 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 20 21 22 23 24 25 26 27 28 29 30 31 32 33 13 19 34 35 36 37 38 40 2 16 17 39 41 42 43 44 110 110 110 4-Stroke Outboard Oil (92-828000A12) Page 4B-6 90-858895R1 JANUARY 2001 CYLINDER BLOCK/CRANKCASE Cylinder Block And Crankcase REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 CYLINDER BLOCK 2 10 DOWEL PIN 3 1 GASKET 4 10 SCREW (M8 x 55 mm) 1st Torque 2nd Torque 120 20 14 28 5 10 SCREW (M10 x 135 mm) 1st Torque 2nd Torque 1914 +60° 6 1 GROMMET 7 1 PLUG 8 1 GASKET 9 1 NIPPLE 10 1 OIL FILTER 11 1 O RING 12 1 BRACKET 13 2 SCREW (M6 x 13 mm) 70 8 14 1 STA-STRAP 15 1 BREATHER PIPE 16 2 CLAMP 17 2 SCREW (M6 x 12 mm) 70 8 18 1 CLIP 19 1 HOSE 20 2 STA-STRAP 21 1 ANODE 22 1 GROMMET 23 1 COVER 24 2 SCREW (M8 x 25 mm) 156 18 25 1 SCREW (M6 x 20 mm) 70 8 26 3 SCREW (M6 x 20 mm) 70 8 27 1 COVER 28 1 GASKET 29 1 SPRING 30 1 PRESSURE CONTROL VALVE 31 1 GROMMET 32 18 SCREW (M6 x 30 mm) 106 12 33 1 OUTER EXHAUST COVER 34 1 GASKET 35 1 CLIP 36 1 HOSE 37 1 STA-STRAP 38 2 LIFTING EYE 39 1 VALVE PLATE 40 4 SCREW (M6 x 20 mm) 70 8 41 6 STUD 42 6 WASHER 43 6 NUT 35 47.5 44 2 SCREW (M8 x 35 mm) 20 27 NOTE: TORQUE TOLERANCE +/– 10% 90-858895R1 JANUARY 2001 Page 4B-7 CYLINDER BLOCK/CRANKCASE Crankshaft, Pistons And Connecting Rods 10 9 5 3 1 5 6 7 4 2 8 4 4 4 5 5 5 11 12 110 110 110 110 110 110 110 110 4-Stroke Outboard Oil (92-828000A12) Page 4B-8 90-858895R1 JANUARY 2001 CYLINDER BLOCK/CRANKCASE Crankshaft, Pistons And Connecting Rods REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 CRANKSHAFT 2 1 OIL SEAL 3 1 OIL SEAL 4 4 BEARING (GREEN) 4 BEARING (BLUE) 4 BEARING (RED) 55 5 BEARING (YELLOW) 5 BEARING (GREEN) 5 BEARING (BLUE) 5 BEARING (RED) 6 1 BEARING (GREEN) 1 BEARING (BLUE) 1 BEARING (RED) 77 4 PISTON & CONNECTING ROD (STANDARD) AR PISTON & CONNECTING ROD (.25MM O/S) 8 2 BOLT 1st Torque 2nd Torque 70 8 +90° 99 8 BEARING (YELLOW) 8 BEARING (GREEN) 8 BEARING (BLUE) 8 BEARING (RED) 1010 4 PISTON RING SET (STANDARD) AR PISTON RING SET (.25MM O/S) 11 1 KEY 12 1 KEY 90-858895R1 JANUARY 2001 Page 4B-9 CYLINDER BLOCK/CRANKCASE Torque Sequence Crankcase Cover Bolts 121 34 5161 781 910 1112 1314 1516 18 19120 171 a b 60° 1st Torque 2nd Torque b a-Center Bolt (10) 1st Torque b-Center Bolt (10) 2nd Torque (60 Torque) Crankcase Cover Bolt Torque Outer Bolts Qty. 10Outer Bolts Qty. 10 (M8 x 55 mm) 1st Torque: 120 lb-in. (14 Nm) 2nd Torque: 20 lb-ft (28 Nm) Center Bolts Qty 10Center Bolts Qty. 10 (M10 x 135 mm) 1st Torque: 168 lb-in. (19 Nm) 2nd Torque: 60° 37 lb-ft (50 Nm)* *Torque value for reference only. Page 4B-10 90-858895R1 JANUARY 2001 CYLINDER BLOCK/CRANKCASE Exhaust Cover Screws 1 2 34 5 6 78 9 10 11 1213 14 15 16 17 18 Exhaust Cover Screw Torque 1st Torque: 53 lb-in. (6 Nm) 2nd Torque: 106 lb-in. (12 Nm) Powerhead Mounting Bolts/Nuts 12 3 4 5 678 Powerhead Mounting Nut Torque 35 lb-ft (47.5 Nm) Powerhead Mounting Bolt Torque 20 lb-ft (27 Nm) 90-858895R1 JANUARY 2001 Page 4B-11 CYLINDER BLOCK/CRANKCASE Page 4B-12 90-858895R1 JANUARY 2001 Preparing Powerhead for Removal 1. Remove top cowl. 2. Remove flywheel cover. b a a - Screw (2) M6 x 20 b - Flywheel Cover 3. Disconnect cowl switch power trim wires. b c a d a - Green/White b - Lt. Blue/White c - Red d - Cowl Switch CYLINDER BLOCK/CRANKCASE 90-858895R1 JANUARY 2001 Page 4B-13 4. Remove 2 screws from grommet cover to free grommet. 5. Remove 8 screws holding cowl halves together. a a d b c a - Cowl Screws (8) M6 x 40 b - Screws (2) M6 x 20 c - Cover d - Grommet CYLINDER BLOCK/CRANKCASE Page 4B-14 90-858895R1 JANUARY 2001 6. Remove dipstick and drain oil. 7. Remove drive shaft bushing coolant hose. 8. Remove carburetor vent hose from adaptor. 9. Disconnect power trim pump wires. b a d c e a - Dipstick b - Coolant Hose For Drive Shaft Bushing c - Carburetor Vent Hose (Hidden) d - Vent Hose Adaptor (Hidden) e - Power Trim Pump Wires CYLINDER BLOCK/CRANKCASE 90-858895R1 JANUARY 2001 Page 4B-15 Powerhead Removal 1. Remove nuts (6) and bolts (2) to free powerhead from drive shaft housing. c b a a - Nuts (6) b - Washers (6) c - Bolts (2) M8 x 35 2. Lift powerhead from driveshaft housing using flywheel puller/lifting eye (91-83164M). 3. Place powerhead on suitable stand. a 91-83164M a - Flywheel Puller/Lifting Eye (91-83164M) CYLINDER BLOCK/CRANKCASE Removing Powerhead Components Ignition Components 1. Refer to Section 2A for removal of the following ignition components. a. Flywheel - must use Crank Shaft Holder Tool (P/N 91-804770A1) b. Stator/pick-up coils c. Timing belt d. Ignition coils e. CDI unit f. Crank position sensor g. Temperature sensor Charging and Starting System Components 1. Refer to Section 2B for removal of the following ignition components. a. Starter motor/relay b. Voltage regulator/rectifier Fuel Components 1. Refer to Section 3A and 3B for removal of the following components. a. Fuel pumps b. Carburetor/Intake Assembly Harness and Battery Cable Removal 1. Remove battery and harness cable assembly. Cylinder Head Removal 1. See Section 4A for cylinder head removal. Page 4B-16 90-858895R1 JANUARY 2001 CYLINDER BLOCK/CRANKCASE Powerhead Disassembly Drive Sprocket Removal 1. Remove nut. NOTE:Use 46 mm socket with an internal depth of 76 mm (p/n 91-881847A1) to hold drive sprocket nut. Use crankshaft holder tool (P/N 91-804770A1) to hold crankshaft. a b c d 91-804770A1 91-881847A1 e f a-Drive Sprocket Nut b-Drive Sprocket c-Pick-up Coil Rotor d-Key e-46 mm, 76 mm Deep Socket (P/N 91-881847A1) f-Crankshaft Holder Tool (P/N 91-804770A1) 90-858895R1 JANUARY 2001 Page 4B-17 CYLINDER BLOCK/CRANKCASE Page 4B-18 90-858895R1 JANUARY 2001 Exhaust Cover Removal 1. Remove oil filter and oil return hose. 2. Remove water hose and exhaust cover and gasket. a b c d e f 91-802653 g g a - Oil Filter b - Oil Return Hose c - Water Hose d - Screw (18) M6 x 30 e - Exhaust Cover f - Gasket (Discard) g - Oil Filter Wrench (p/n 91-802653) CYLINDER BLOCK/CRANKCASE 90-858895R1 JANUARY 2001 Page 4B-19 3. Remove Pressure Control Valve (PCV) Cover. 4. Remove anode and engine temperature sensor. IMPORTANT: If removing anode from outboard with exhaust plate installed use the following procedure to prevent anode from falling into water jacket: ANODE REMOVAL PROCEDURE 1. Remove anode cover screw “h”. 2. Remove anode assembly from cylinder block. 3. Remove anode screw “k” to separate anode from anode cover. a c b d e f h g i j k l m n o p a - Screw (3) M6 x 20 b - PCV Cover c - Spring d - Pressure Control Valve (PCV) e - Grommet f - Gasket (Discard) g - Screw M6 x 12 h - Screw (2) M8 x 25 i - Anode Cover j - O-Ring k - Screw M6 x 20 l - Anode m - Screw (2) M6 x 16 n - Engine Temperature Sensor Retainer o - Engine Temperature Sensor p - Gasket (Discard) CYLINDER BLOCK/CRANKCASE Page 4B-20 90-858895R1 JANUARY 2001 Crankcase and Crankshaft Removal 1. Remove crankcase and connecting rod caps. IMPORTANT: Note locations of connecting rod caps for re-assembly. NOTE: Use torx E10 socket for removal of connecting rod bolts. a b c d e a - Screw (10) M8 x 55 b - Screw (10) M10 x 135 c - Crankcase d - Connecting Rod Bolt (Discard) (8) M8 x 38 e - Connecting Rod Cap (4) 2. Remove crankshaft and oil seals. a b c a - Crankshaft b - Upper Oil Seal c - Lower Oil Seal CYLINDER BLOCK/CRANKCASE 90-858895R1 JANUARY 2001 Page 4B-21 IMPORTANT: Do not interchange main bearings, re-install in their original locations. 3. Remove main bearing halves from the crankcase cover and cylinder block. a b a - Main Bearing Halves-Crankcase Cover (5) b - Main Bearing Halves-Cylinder Block (5) 4. Remove piston/connecting rod assembly. a a - Piston/Connecting Rod Assembly CYLINDER BLOCK/CRANKCASE Piston Ring Removal 1. Remove top and second ring. 2. Remove oil ring (bottom rail, top rail, and scraper). NOTE:Use piston ring expander tool (P/N 91-24697) to prevent rings from breaking. If reusing rings mark their location for re-installation. ab c d a-Top Ring b-Second Ring c-Oil Ring d-Piston 91-24697 Page 4B-22 90-858895R1 JANUARY 2001 CYLINDER BLOCK/CRANKCASE Cleaning/Inspection/Repair Cylinder MEASURING CYLINDER BORE 1. Measure the cylinder bore diameter at three locations in both X and Y axis. 2. If the cylinder bore is beyond the standard limits listed in the tables below, it will be necessary to re-bore the cylinder to accept the oversize piston. NOTE:Measure at three locations (L1, L2, and L3) in both X and Y axis (D1-6). L1=0.8 in. (20 mm) L2=2.8 in. (70 mm) L3=4.7 in. (120 mm) 3. Measure bore diameter with a cylinder gauge. Re-bore or replace if necessary. D1,2 D3,4 D5,6 L1 L2 L3 Cylinder Bore Specifications Bore Size Maximum Taper/Out-of-Round Standard Bore 3.110-3.111 in. (79.000-79.020 mm) 0.003 in. (0.08 mm) Oversize Bore-0.010 in. (0.25 mm) 3.120-3.121 in. (79.250-79.270 mm) 0.003 in. (0.08 mm) NOTE: Taper=(Maximum of D1 or D2)–(Minimum of D5 or D6) 90-858895R1 JANUARY 2001 Page 4B-23 CYLINDER BLOCK/CRANKCASE Piston 1. Inspect piston wall wear/damage. Replace piston/connecting rod assembly if necessary. 2. Measure the piston at a point 0.51 in (13 mm) from the bottom. Replace piston/connecting rod assembly if out of specification. b a a-Piston Diameter b-0.51 in. (13 mm) Piston Diameter “a” Piston Size Diameter Standard 3.1074-3.1082 in. (78.928-78.949 mm) Oversize-0.010 in. (0.25 mm) 3.1174-3.1182 in. (79.178-79.199 mm) 3. Measure piston to cylinder clearance. If out of specification, examine piston and cylinder bore further to determine repair/replacement. a. Piston to Cylinder Clearance can be defined by: MBM–MPM=PCC where: MBM=Minimum Bore Measurement MPM=Maximum Piston Measurement PCC=Piston to Cylinder Clearance Piston to Cylinder Clearance 0.0028-0.0031 in. (0.070-0.080 mm) Page 4B-24 90-858895R1 JANUARY 2001 CYLINDER BLOCK/CRANKCASE Piston Rings PISTON RIND SIDE CLEARANCE 1. Measure piston ring side clearance. Replace piston rings as a set if out of specification. Piston Ring Side Clearance Top 0.001-0.003 in. (0.020-0.080 mm) Middle 0.001-0.003 in. (0.03-0.07 mm) Oil 0.001-0.006 in. (0.03-0.15 mm) PISTON RIND END GAP CLEARANCE 1. Measure piston ring end gap clearance. Replace piston rings as a set if out of specification. NOTE:Ring should be level for measurement, push ring into bore with crown of piston. NOTE:Measure end gap clearance at a depth of 0.8 in. (20 mm). a a-Measurement Depth Piston Ring End Gap Top 0.006 - 0.012 in. (0.15 - 0.30 mm) 2nd 0.028 - 0.035 in. (0.70 - 0.90 mm) Oil 0.008 - 0.028 in. (0.20 - 0.70 mm) 90-858895R1 JANUARY 2001 Page 4B-25 CYLINDER BLOCK/CRANKCASE Crankshaft 1. Thoroughly clean crankshaft and inspect bearing surfaces. Replace crankshaft if bearing surfaces are pitted, scored, or discolored. 2. Measure run-out. Replace crankshaft if out of specification. 3. Clean oil holes in crankshaft. Crankshaft Run-out 0.001 in. (0.03 mm) 4. Measure crankshaft journal diameter and crank pin diameter. Replace if out of specification. Crankshaft Journal Diameter Limit 1.8887 in. (47.972 mm) Crankpin Diameter Limit 1.7311 in. (43.971 mm) Crankcase and Bearings 1. Measure crankshaft main bearing clearance using the test below. Replace the upper and lower bearings as a set if out of specification (see Crankcase and Bearing Indication Marks). NOTE:Measure the main oil bearing clearance at room temperature 68° F (20° C). Main Bearing Clearance 0.0009 - 0.0017 in. (0.024 - 0.044 mm) Page 4B-26 90-858895R1 JANUARY 2001 CYLINDER BLOCK/CRANKCASE 90-858895R1 JANUARY 2001 Page 4B-27 CRANKSHAFT MAIN BEARING CLEARANCE MEASUREMENT IMPORTANT: Do not interchange the main bearings. Re-install in their original position. 1. Clean all the old sealing material from the split line on the crankcase cover and cylinder block. 2. Clean all the oil from the following areas: a. Main bearing surfaces on the cylinder block and crankcase cover. b. Main bearings. c. Crankshaft bearing surfaces. 3. Install main bearing halves into the cylinder block. 4. Install crankshaft. a a - Main Bearing Halves-Cylinder Block (5) 5. Place a piece of plastigauge onto each crankshaft bearing surface. NOTE: Do not put plastigauge over the oil hole on the bearing surface of the crankshaft. a a - Plastigauge CYLINDER BLOCK/CRANKCASE Page 4B-28 90-858895R1 JANUARY 2001 6. Install main bearing halves into the crankcase. a a - Main Bearing Halves-Crankcase (5) 7. Install crankcase onto cylinder block. 8. Apply oil to the cover bolts and torque cover bolts in sequence and in two steps. IMPORTANT: Do not move crankshaft until measurement has been completed. 110 4-Stroke Outboard Oil (92-828000A12) 1 2 4 3 5 6 8 7 9 10 11 12 14 13 15 16 18 19 20 17 a 110 110 b a - Bolt (10) M10x135mm b - Bolt (10) M8x55mm Crankcase Cover Bolt Torque Outer Bolts Qty. 10 1st Torque: 120 lb-in (14 Nm) (M8x55) 2nd Torque: 20 lb-ft (28 Nm) Center Bolts Qty 10 1st Torque: 168 lb-in. (19 Nm) Qty. (M10x135) 2nd Torque: 60° 37 lb-ft (50 Nm)* *Torque value for reference only. CYLINDER BLOCK/CRANKCASE SERVICE TIP 1. To obtain 60° rotation of crankcase cover bolts (after initial torque has been set) put a paint mark on corner point of the bolt head and a second paint mark one corner point clockwise on crankcase cover as shown. Rotate bolt until paint marks align. NOTE:When using this procedure for final assembly use different color paint on crankcase cover to avoid confusion with previous paint marks. a b a-Paint Mark On Bolt Head b-Paint Mark On Crankcase Cover MAIN BEARING CLEARANCE 1. Remove the bolts and crankcase. 2. Measure the width of the compressed plastigauge to check the main bearing clearance. Replace bearings if clearance is not within specification (see Selecting New Main Bearings following). a a-Compressed Plastigauge Main Bearing Clearance 0.0009 - 0.0017 in. (0.024 - 0.044 mm) 90-858895R1 JANUARY 2001 Page 4B-29 CYLINDER BLOCK/CRANKCASE SELECTING NEW MAIN BEARINGS 1. Subtract the crankshaft journal diameters (#1-#5) from the cylinder block journal diameters (#1-#5). 2. Select a suitable bearing from the table below according to the calculated values. NOTE:The cylinder block journal diameters (#1-#5) and the crankshaft journal diameters, (#1-#5) can be determined by the stamped value as described below. Crankshaft journal diameter=47.900+(stamped value/1000) Example: If the stamped value of position #1 reads 92 then using the previous formula would yield a crankshaft journal diameter of: 47.900+(92/1000)=47.992 Cylinder block journal diameter=54.000+(stamped value/1000) Example: If the stamped value of position #1 reads 32 then using the previous formula would yield a cylinder block journal diameter of: 54.000+(32/1000)=54.032 #1 #2 #3 #4 #5 #1 #2 #3 #4 #5 3. Refer to the following reference table to select the correct main bearings. Crankshaft Bearing Selection Table Cylinder Block journal diameters–crankshaft journal diameters (mm) Bearing (cylinder side) (with oil groove) Bearing (crankcase side) (w/o oil groove) 6.023-6.026 Green Yellow* 6.027-6.034 Blue Green* 6.035-6.042 Blue Blue 6.043-6.049 Red Blue* 6.050-6.058 Red Red Page 4B-30 90-858895R1 JANUARY 2001 CYLINDER BLOCK/CRANKCASE CAUTION The (*) mark indicates that the color of the upper and lower bearings are different. Install the main bearings in the middle of the cylinder block and crankcase journals so they do not block the oil holes. NOTE:Crankshaft bearing #3 is a thrust bearing. NOTE:If the difference between the cylinder block journal diameter and crankshaft journal diameter is more than the maximum value (6.058mm), replace the crankshaft, cylinder block, or both. Connecting Rod Oil Clearance 1. Measure the connecting rod oil clearance using the Connecting rod Oil Clearance Measurement steps below, replace the upper and lower bearings as a set, if out of specification. Connecting Rod Oil Clearance 0.0009 - 0.0014 in. (0.023 - 0.035 mm) CONNECTING ROD OIL CLEARANCE MEASUREMENT IMPORTANT: Mark the original connecting rod bolts to avoid confusion with new bolts. CAUTION The original connecting rod bolts are to be used for measurement and adjustment of the oil clearance only. Do not use the original connecting rod bolts for reassembly of the engine. NOTE:Clean all the oil from the connecting rod bearing surfaces and connecting rod journals on the crankshaft. CAUTION Install the bearings in their original positions. Incorrect oil clearance measurements can result in engine damage. 1. Install the upper half of the bearing into the connecting rod and the lower half of the bearing into the connecting rod cap. 2. Place a piece of Plastigauge onto the crank pin parallel to the crankshaft. a a-Plastigauge 90-858895R1 JANUARY 2001 Page 4B-31 CYLINDER BLOCK/CRANKCASE 3. Assemble the connecting rod onto their respective crankpins. IMPORTANT: Make sure the large flat side “a” on the connecting rod faces toward the flywheel side. NOTE:Do not move the crankshaft until the big end oil clearance measurement has been completed. b a a-Connecting Rod Cap-Flat side b-Connecting Rod/Piston Assembly 4. Apply engine oil onto the threads and seat of the original connecting rod bolts. 5. Tighten the original connecting rod bolts in alternating sequence and in two stages. Connecting Rod Bolt Torque 1st Torque: 70 lb-in. (8 Nm) 2nd Torque: 90° 6. Remove the connecting rod cap. 7. Measure the width of the compressed plastigauge on each crankpin to check the connecting rod oil clearance. Refer to Connecting Rod Oil Clearance Adjustment below if oil clearance is not within specification. a a-Compressed Plastigauge Connecting Rod Oil Clearance 0.0009 - 0.0014 in. (0.023 - 0.035 mm) Page 4B-32 90-858895R1 JANUARY 2001 CYLINDER BLOCK/CRANKCASE CONNECTING ROD OIL CLEARANCE ADJUSTMENT 1. Install new yellow bearings into the connecting rods and connecting rod caps. NOTE:Yellow bearings are used as a “reference” bearing to help determine clearance. 2. Place a piece of Plastigauge onto the crank pin parallel to the crankshaft. 3. Assemble the connecting rod caps onto their respective crankpins. IMPORTANT: Make sure the large flat side “a” on the connecting rod faces toward the flywheel side. NOTE:Do not move the crankshaft until the big end oil clearance measurement has been completed. b a a-Connecting Rod Cap-Flat side b-Connecting Rod/Piston Assembly 90-858895R1 JANUARY 2001 Page 4B-33 CYLINDER BLOCK/CRANKCASE 4. Apply engine oil onto the threads and seat of the original connecting rod bolts. 5. Tighten the original connecting rod bolts in alternating sequence and in two stages. Connecting Rod Bolt Torque 1st Torque: 70 lb-in. (8 Nm) 2nd Torque: 90° 6. Remove the connecting rod cap. 7. Measure the width of the compressed plastigauge on each crankpin to check the connecting rod oil clearance. 8. Select a suitable bearing from the table below according to the measurement values. a a-Compressed Plastigauge Connecting Rod Bearing Selection Table Measurement value with new yellow bearing using plastigauge (mm) Upper Bearing (Piston) Lower Bearing (Cap) 0.023-0.035 Yellow Yellow 0.036-0.042 Yellow Green* 0.043-0.049 Green Green 0.050-0.057 Green Blue* 0.058-0.065 Blue Blue 0.066-0.071 Blue Red* CAUTION The (*) mark indicates that the color of the upper and lower bearings are different. NOTE:If the measurement value is more than the maximum value (0.071 mm), replace the crankshaft, cylinder block, or both. Page 4B-34 90-858895R1 JANUARY 2001 CYLINDER BLOCK/CRANKCASE Powerhead Assembly Piston Ring/Piston Installation IMPORTANT: If re-using rings install in their original locations. IMPORTANT: Use caution when installing piston rings to avoid scratching piston. 1. Install the oil ring components as shown. Spread rings just enough to slip over piston. 2. Install the second and top compression rings (“T” side up). Spread rings just enough to slip over piston. 3. Offset the piston ring end gaps. 4-stroke Outboard Oil (92-828000A12)110 110 91-24697 a b c f e d 110 i j h g a-Oil Ring Spacer b-Bottom Rail c-Top Rail d-Second Compression Ring (“T” side up) e-Top Compression Ring (“T” side up) f-“T” Mark Should Face Piston Crown g-End Gap – Lower Oil Ring Rail h-End Gap – Upper Oil Ring Rail i-End Gap – Second Compression Ring j-End Gap – Top Compression Ring 90-858895R1 JANUARY 2001 Page 4B-35 CYLINDER BLOCK/CRANKCASE Page 4B-36 90-858895R1 JANUARY 2001 NOTE: Cylinder bores must be clean before installing pistons. Clean with light honing, as necessary. After honing, clean cylinder bores with water and detergent. After cleaning, swab cylinder bores several times with engine oil and a clean cloth, then wipe with a clean dry cloth. 4. Lubricate pistons, rings, and cylinder walls with engine oil. 5. Install piston/connecting rod assembly using piston ring compressor tool. NOTE: Install used pistons in their original locations (cylinders). Install piston with “UP” mark on piston crown facing toward the flywheel end of block. P/N FT2997 a a - Piston Ring Compressor (P/N FT2997) Crankcase and Crankshaft Installation IMPORTANT: Do not interchange main bearings, re-install in their original locations. NOTE: Apply oil to bearings before installing. NOTE: Bearing #3 is a thrust bearing. 1. Install main bearing halves on the crankcase cover and cylinder block. a 110 4-Stroke Outboard Oil (92-828000A12) 110 110 b c a - Main Bearing Halves-Crankcase Cover (5) b - Main Bearing Halves-Cylinder Block (with holes) (5) c - #3 Thrust Bearing CYLINDER BLOCK/CRANKCASE 90-858895R1 JANUARY 2001 Page 4B-37 2. Install crankshaft and oil seals. NOTE: Apply oil to seals before installation a b c 110 4-Stroke Outboard Oil (92-828000A12) 110 110 a - Crankshaft b - Upper Oil Seal c - Lower Oil Seal 3. Lubricate connecting rod journals with engine oil. NOTE: Apply oil to connecting rod bolts before installing. 4. Install connecting rod cap and new bolts onto their respective crankpins. 5. Tighten connecting rod bolts in alternating sequence and in two stages. NOTE: Use torx E10 socket for installation of connecting rod bolts. IMPORTANT: Assemble connecting rod caps in their original locations. 110 110 4-Stroke Outboard Oil (92-828000A12) a b a - Connecting Rod Cap (4) b - Connecting Rod Bolt (New) (8) M8 x 38 Connecting Rod Bolt Torque 1st Torque: 70 lb-in. (8 Nm) 2nd Torque: 90° CYLINDER BLOCK/CRANKCASE Page 4B-38 90-858895R1 JANUARY 2001 6. Clean off all oil from the contacting surfaces of the crankcase cover and cylinder block. IMPORTANT: Make sure the contacting surface of the crankcase cover and cylinder block are clean before applying gasket sealant. 7. Apply a smooth even coat of Loctite Master Gasket Sealant to the contacting surfaces on the crankcase cover. Use a small (paint type) roller to spread out the sealant for a smooth even coverage. Instructions in gasket sealant kit must be followed exactly. NOTE: Do not apply gasket sealant to the main bearings or the bolt holes. 8. Oil bolts and torque cover in sequence and in two steps. a c 12 Loctite Master Gasket “514” (92-12564-2) 12 b 1 2 4 3 5 6 8 7 9 10 11 12 14 13 15 16 18 19 20 17 d e 110 4-Stroke Outboard Oil (92-828000A12) 110 110 a - Crankcase b - Bolt (10) M8 x 55 c - Bolt (10) M10 x 135 d - Contact Surface of Crankcase e - Use Roller To Apply A Smooth Even Coat Crankcase Cover Bolt Torque Outer Bolts Qty. 10 1st Torque: 120 lb-in. (14 Nm) (M8 x 55 mm) 2nd Torque: 20 lb-ft (28 Nm) Center Bolts Qty 10 1st Torque: 168 lb-in. (19 Nm) Qty. (M10 x 135 mm) 2nd Torque: 60° 37 lb-ft (50 Nm)* *Torque value for reference only. CYLINDER BLOCK/CRANKCASE SERVICE TIP 1. To obtain 60° rotation of crankcase cover bolts (after initial torque has been set) put a paint mark on corner point of the bolt head and a second paint mark one corner point clockwise on crankcase cover as shown. Rotate bolt until paint marks align. NOTE:When using this procedure for final assembly use different color paint on crankcase cover to avoid confusion with previous paint marks. a b a-Paint Mark On Bolt Head b-Paint Mark On Crankcase Cover 90-858895R1 JANUARY 2001 Page 4B-39 CYLINDER BLOCK/CRANKCASE Page 4B-40 90-858895R1 JANUARY 2001 Exhaust Cover Installation 1. Install gasket, exhaust cover, and water hose. Torque exhaust cover in sequence. 2. Install oil filter and oil return hose. 91-802653 f a e b c d 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 g g a - Gasket (New) b - Exhaust Cover c - Screw (18) M6 x 30 d - Water Hose e - Oil Return Hose f - Oil Filter g - Oil Filter Wrench Exhaust Cover Screw Torque 1st Torque: 53 lb-in. (6 Nm) 2nd Torque: 106 lb-in. (12 Nm) 3. Install Pressure Control Valve (PCV) Cover. 4. Install anode and engine temperature sensor. IMPORTANT: To prevent anode from falling into water jacket use the following procedure for anode installation: CYLINDER BLOCK/CRANKCASE 90-858895R1 JANUARY 2001 Page 4B-41 ANODE INSTALLATION 1. Install anode bolt “h” securing cover to anode. 2. Install anode assembly onto cylinder block. 3. Install anode cover bolts “l”. i g 7 Loctite “271” (92-809820) 7 f a e b c d h j k l p m o n a - Gasket (New) b - Grommet c - Pressure Control Valve (PCV) d - Spring e - PCV Cover f - Screw (3) M6 x 20 g - Screw M6 x 12 h - Screw M6 x 20 i - Anode Cover j - Anode k - O-Ring l - Screw (2) M8 x 25 m - Gasket (New) n - Engine Temperature Sensor o - Engine Temp. Sensor Retainer p - Screw (2) M6 x 16 Anode Screw Torque 70 lb-in. (8 Nm) Anode Cover Screw Torque 156 lb-in. (18 Nm) Temperature Sensor Screw Torque 70 lb-in. (8 Nm) PCV Cover Screw Torque 70 lb-in. (8 Nm) CYLINDER BLOCK/CRANKCASE Drive Sprocket Installation 1. Install drive sprocket nut. NOTE:Use 46 mm, 76 mm deep socket to hold drive sprocket nut and crankshaft holder tool (P/N 91-804776A1) to hold crankshaft. d a c b e f 91-804770A1 91-881847A1 a-Key b-Pick-up Coil rotor c-Drive Sprocket d-Drive Sprocket Nut e-46 mm, 76 mm Deep Socket (91-881847A1) f-Crankshaft Holder Tool (P/N 91-804770A1) Drive Sprocket Nut Torque 195 lb-ft (265 Nm) Page 4B-42 90-858895R1 JANUARY 2001 CYLINDER BLOCK/CRANKCASE Installing Powerhead Components Cylinder Head 1. See Section 4A for cylinder head installation. Harness and Battery Cable 1. Install battery and harness cable assembly. Fuel Components 1. Refer to Section 3A and 3B for installation of the following components. a. Fuel pump b. Carburetor/Intake Assembly Charging and Starting System Components 1. Refer to Section 2B for installation of the following ignition components. a. Starter motor b. Voltage rectifier/regulator Ignition Components 1. Refer to Section 2A for installation of the following ignition components. a. Flywheel - must use Crank Shaft Holder Tool (P/N 91-804770A1) b. Stator/Pick-up coils c. Timing belt d. Ignition coils e. CDI unit f. Crank position sensor g. Temperature sensor 90-858895R1 JANUARY 2001 Page 4B-43 CYLINDER BLOCK/CRANKCASE Page 4B-44 90-858895R1 JANUARY 2001 Powerhead Installation NOTE: Carburetor vent hose should be attached as powerhead is being lowered onto drive shaft housing. Refer to Following Powerhead Installation for proper hose and adapter connections. 1. Lift powerhead using flywheel puller/lifting eye (91-83164M). 2. Install new powerhead gasket and dowel pins. 3. Place powerhead onto driveshaft housing. a 91-83164M b b c a - Flywheel Puller/Lifting Eye (91-83164M) b - Dowel Pins (2) c - Powerhead Gasket (New) CYLINDER BLOCK/CRANKCASE 90-858895R1 JANUARY 2001 Page 4B-45 4. Secure powerhead to drive shaft housing with nuts (6) and bolts (2). Torque in sequence. 1 2 3 4 5 6 7 8 b a c d a - Nut (6) b - Washer (6) c - Bolts (2) M8 x 35 d - Torque Sequence Powerhead Mounting Nut Torque 35 lb-ft (47.5 Nm) Powerhead Mounting Bolt Torque 20 lb-ft (27 Nm) CYLINDER BLOCK/CRANKCASE Page 4B-46 90-858895R1 JANUARY 2001 Following Powerhead Installation 1. Install carburetor vent hose on adaptor. NOTE: Carburetor vent hose should be attached to adapter just before powerhead is lowered onto drive shaft housing. 2. Install drive shaft bushing coolant hose. 3. Fill oil tank (refer to Section 1B-Maintenance) and install dipstick. 4. Connect power trim wires. d a c b e a - Vent Hose Adaptor (Hidden) b - Carburetor Vent Hose (Hidden) c - Coolant Hose For Drive Shaft Bushing d - Dipstick e - Power Trim Wires CYLINDER BLOCK/CRANKCASE 90-858895R1 JANUARY 2001 Page 4B-47 5. Install 8 screws holding cowl halves together. 6. Install grommet and grommet cover. a a b c d a - Cowl Screws (8) M6 x 40 b - Screws (2) M6 x 20 c - Grommet d - Cover Bottom Cowl Screw Torque 65 lb-in. (7.5 Nm) Grommet Cover Screw Torque 65 lb-in. (7.5 Nm) CYLINDER BLOCK/CRANKCASE Page 4B-48 90-858895R1 JANUARY 2001 7. Connect trim wires. b c a a - Green/White b - Lt. Blue/White c - Red 8. Install flywheel cover. 9. Install top cowl. a b a - Flywheel Cover b - Screw (2) M6 x 20 Flywheel Cover Screw Torque 65 lb-in. (7.5 Nm) LUBRICATION POWERHEAD Section 4C - Lubrication Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-1 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-2 Oil Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-4 Oil Pressure Measurement . . . . . . . . . . . . . . . . . 4C-5 Oil Pump Reference Drawing . . . . . . . . . . . . . . . 4C-6 Specifications Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . 4C-7 Oil Pickup Removal . . . . . . . . . . . . . . . . . . . . . . . . 4C-8 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . 4C-9 Oil Pickup Installation . . . . . . . . . . . . . . . . . . . . . 4C-10 Oil Pump Installation. . . . . . . . . . . . . . . . . . . . . . 4C-11 4 C Pump Type Trochoid with Relief Valve Oil Pump Drive Discharge at 212°F (100°C) with Drive shaft Spline 10W-30 Oil at 1000 rpm 1.56 gph (5.9 L/h) LUBRICATION Engine Oil Pressure (Warm Engine) SYSTEM @ 850 rpm 46.5 psi (320 kPa) Engine Oil Pan Capacity Either 5 Qts. or 5 Liters Relief Valve Opening Pressure 71 psi (490 kPa) Oil Pump: Non-Serviceable 90-858895R1 JANUARY 2001 Page 4C-1 1 2 3 4 5 10 11 12 13 14 3 16 17 18 6 7 9 8 15 19 95 10 91 91 Engine Coupler Grease (91-816391A4) 95 2-4-C w/Teflon (92-850736A1) LUBRICATION Page 4C-2 90-858895R1 JANUARY 2001 OIL PUMP LUBRICATION OIL PUMP REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 PIPE PLUG 2 1 PIPE PLUG 3 2 O RING 4 2 DOWEL PIN 5 1 MOUNT 6 2 BOLT (M12 X 175 mm) 55 75 7 2 WASHER 8 2 WASHER 9 2 NUT 55 75 10 8 SCREW (M8 x 50 mm) 25 34 11 1 OIL PUMP 12 6 BOLT (M6 x 45 mm) 85 9.5 13 1 SEAL 14 1 SHIFT LINKAGE BRACKET 15 2 DRIVE SCREW 16 3 SCREW (M6 x 20 mm) 80 9 17 1 RETAINER 18 1 LATCH 19 1 SEAL NOTE: TORQUE TOLERANCE +/– 10% 90-858895R1 JANUARY 2001 Page 4C-3 LUBRICATION LOW OIL PRESSURE PROTECTION Two seconds after starting the engine this mode does not operate. When the oil pressure switch turns on (oil pressure is 15 kPa (0.15 kg/cm2, 2.2 psi) or below), this mode starts. The buzzer will sound. Ignition to cylinders #1 and #4 will cut off and the engine speed will gradually lower to approximately 3,000 rpm. This mode will stop when the oil pressure is 15 kPa (0.15 kg/cm2, 2.2 psi or above and the throttle is fully closed. The buzzer will then stop. Oil Flow Chart Cylinder Page 4C-4 90-858895R1 JANUARY 2001 LUBRICATION Oil Pressure Measurement 1. Warm up engine. 2. Remove oil pressure switch. 3. Install oil pressure gauge. NOTE:Use a pressure gauge with a range of 0-10 kg/cm2and an adaptor with a 1/8” BSPT thread. a a-Oil Pressure Gauge 4. Measure the oil pressure at idle, if out of specification check oil pump, oil suction pipe, and oil strainer. Oil Pressure (@ Idle with warm engine-149 ° F (65 °C)) 46.5 psi (320 Kpa, 3.2 kg/cm2) 90-858895R1 JANUARY 2001 Page 4C-5 LUBRICATION Page 4C-6 90-858895R1 JANUARY 2001 Oil Pump Reference Drawing NOTE: The oil pump is non-serviceable, the assembly drawing below is strictly for reference purposes only. NOTE: If removing pump cover follow torque sequence for removal and installation. a 1 2 3 4 6 5 b a - Screw-(6) M6 x 10 b - Torque Sequence Oil Pump Screw Torque 70 lb-in. (8 Nm) LUBRICATION 90-858895R1 JANUARY 2001 Page 4C-7 Oil Pump Removal NOTE: Powerhead must be removed to gain access to oil pump, refer to section 4B Powerhead Removal. 1. Remove oil pump from adaptor plate. a b c d d a - Seal b - Oil Pump c - Screw (6) M8 x 45 d - O-Rings (2) LUBRICATION Page 4C-8 90-858895R1 JANUARY 2001 Oil Pickup Removal 1. Adapter plate must be removed to gain access to the oil sump and pick-up, refer to Section 5A for adaptor plate and oil sump removal. 2. Remove oil pick-up tube from adaptor plate. c e a d b a - Screw (4) M6 x 20 b - Oil Pick-Up Tube c - O-Ring d - Gasket e - Adaptor Plate LUBRICATION Cleaning and Inspection 1. Inspect pick up tube screen for debris, clean if necessary. a a-Pick-Up Tube Screen 2. Replace seals and gaskets. 3. Inspect oil pump, replace if gears are worn. NOTE:Pump should be replaced if there is a problem with oil pressure relief valve. 90-858895R1 JANUARY 2001 Page 4C-9 LUBRICATION Page 4C-10 90-858895R1 JANUARY 2001 Oil Pickup Installation 1. Install oil pick-up tube on adaptor plate, use proper torque sequence. 2. Refer to Section 5A for adaptor plate and oil sump installation. a b c d e 1 2 3 4 a - Adaptor Plate b - Gasket (New) c - O-Ring (New) d - Oil Pick-Up Tube e - Screw (4) M6 x 20 Oil Pick-up Tube Mounting Screw Torque 90 lb-in. (11.2 Nm) LUBRICATION 90-858895R1 JANUARY 2001 Page 4C-11 Oil Pump Installation NOTE: Make sure dowel pins are inserted before securing oil pump to adaptor plate. IMPORTANT: Oil pump must be primed before installation. Prime oil pump by filling inlet hole with 4-stroke outboard oil and rotating gear several revolutions. 1. Install O-Rings. 2. Apply spline grease to coupling. 3. Install pump and secure, torque bolts in sequence. a e b c d 110 4-Stroke Outboard Oil (92-828000A12) f 110 1 2 3 4 6 5 91 Engine Coupler Grease (91-816391A4) 91 a - Dowel Pins (2) b - O-Rings (2) c - Oil Pump d - Screw (6) M6 x 45 e - Seal f - Inlet Hole Oil Pump Mounting Screw Torque 85 lb-in. (9.5 Nm) CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING MID-SECTION Section 5A - Clamp/Swivel Brackets & Drive Shaft Housing Table of Contents Table of Contents . . . . . . . . . . . . . . . . . . . . . . . 5A-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-1 Swivel Bracket And Steering Arm . . . . . . . . . . 5A-2 Transom Bracket . . . . . . . . . . . . . . . . . . . . . . . . 5A-4 Exhaust Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-6 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-8 Specifications Drive Shaft Housing . . . . . . . . . . . . . . . . . . . . . 5A-10 Bottom Cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-12 Bottom Cowl Removal . . . . . . . . . . . . . . . . . . . 5A-14 Bottom Cowl Installation . . . . . . . . . . . . . . . . . . 5A-15 Adaptor Plate Removal . . . . . . . . . . . . . . . . . . 5A-16 Drive Shaft Bushing Removal . . . . . . . . . . . . . 5A-20 Adaptor Plate Reassembly . . . . . . . . . . . . . . . 5A-21 Recommended Transom Height: Short Shaft 20 in. (51 cm) MID-SECTION Long Shaft Steering Pivot Range 25 in. (64 cm) 60° Full Tilt Up Angle 71° Allowable Transom Thickness (Max) 3 in. (76.2 mm) 5 A Part No. Description 92-809820 Loctite “271” 92-88504 Loctite Pipe Sealant w/Teflon 92-850735A1 Anti-Corrosion Grease 92-850736A1 2-4-C w/Teflon 92-828000A12 4-Stroke Outboard Oil Special Tools 1. Drive Shaft Bushing Installer Tool (91-875215) 90-858895R1 JANUARY 2001 Page 5A-1 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Swivel Bracket And Steering Arm 12 3 4 5 6 7 8 9 1011 12 13 14 15 16 3 Quicksilver Lubrication/Sealant Application Points 95 95 95 95 95 95 95 TORQUE NUT TO 120 LB-IN. THEN BACK OFF 1/4 TURN TORQUE NUT TO 20 LB-FT (27.1 NM) 3 17 95 2-4-C w/Teflon (92-850736A1) Page 5A-2 90-858895R1 JANUARY 2001 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Swivel Bracket And Steering Arm REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 SWIVEL BRACKET 2 1 OIL SEAL (LOWER) 3 2 BUSHING 4 1 O-RING 5 1 SPACER 6 2 GREASE FITTING 40 4.5 7 2 BUSHING 8 2 SCREW (1/4-28 x 1/2 in.) 100 11.3 9 1 SWIVEL PIN/STEERING ARM 10 1 STEERING LINK ASSEMBLY 11 1 SCREW (3/8-28 x 1/2 in.) 20 27.1 12 2 NUT See Exploded View 13 2 WASHER 14 1 BOTTOM YOKE 15 1 RETAINING RING 16 1 THRUST WASHER 17 1 DECAL-Serial Overlaminate 90-858895R1 JANUARY 2001 Page 5A-3 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5A-4 90-858895R1 JANUARY 2001 Transom Bracket Quicksilver Lubrication/Sealant Application Points 87 95 7 7 1 3 2 4 6 5 7 8 9 10 11 12 13 14 15 17 16 18 19 20 21 22 23 24 25 14 21 20 20 20 21 21 7 Loctite “271” (92-809820) 87 Premium Gear Lubricant (92-850737A1) 95 2-4-C w/Teflon (92-850736A1) CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Transom Bracket REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 TRANSOM BRACKET (STARBOARD) 2 1 TRANSOM BRACKET (PORT) 3 1 GREASE FITTING (PORT) 40 4.5 44 1 TILT TUBE 1 TILT TUBE (SALTWATER) 5 55 1 NUT Tighten Nut until Bottomed on Shoulder of Tilt Tube 1 NUT (SALTWATER) Tighten Nut until Bottomed on Shoulder of Tilt Tube 6 1 O-RING 7 2 WAVE WASHER 88 1 NUT Drive Nut until Assembly is drawn together; but must be free to pivot 1 NUT (SALTWATER) Drive Nut until Assembly is drawn together; but must be free to pivot 9 4 BOLT (1/2-24 x 4.5 in.) 10 4 WASHER 11 4 NUT 12 1 SPRING 13 1 TILT LOCK LEVER 14 2 BUSHING 15 1 SPRING 16 1 KNOB 17 1 GROOVE PIN 18 1 PIN 19 1 ANCHOR BRACKET 20 6 SCREW (M10 x 30 mm) 30 40.7 21 6 WASHER 22 1 NUT 30 40.7 23 1 ANODE ASSEMBLY 24 2 SCREW (M6 x 25 mm) 60 6.8 25 2 WASHER 90-858895R1 JANUARY 2001 Page 5A-5 1 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21 22 23 24 16 25 26 3 3 3 27 28 29 3 3 2 95 2-4-C w/Teflon (92-850736A1) 95 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5A-6 90-858895R1 JANUARY 2001 Exhaust Plate CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Exhaust Plate REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 ADAPTOR PLATE ASSEMBLY 2 1 FITTING 15 2 3 7 DOWEL PIN 4 2 CHECK VALVE 5 1 GROMMET 6 1 GASKET 7 1 OIL SUMP 8 1 EXHAUST TUBE 9 4 SCREW (M6 x 60 mm) 100 11.5 10 1 GROMMET 11 1 WATER TUBE 12 1 SEAL (UPPER) 13 1 OIL PICK-UP TUBE 14 1 O RING 15 4 SCREW (M6 x 20 mm) 100 11.5 16 12 SCREW (M6 x 35 mm) 100 11.5 17 1 DIPSTICK 18 1 BUSHING 19 1 SHIFT SHAFT 20 1 SHIFT LINK 21 1 BUSHING 22 1 NUT Drive Tight; but Joint must be free to Pivot 23 1 SPACER 24 1 COUPLING 25 1 ROLLER 26 2 HAIRPIN COTTER 27 1 SEAL 28 1 DRAIN PLUG 210 17.5 24 29 1 GASKET 90-858895R1 JANUARY 2001 Page 5A-7 1 2 3 4 5 10 11 12 13 14 3 16 17 18 6 7 9 8 15 19 95 10 91 91 Engine Coupler Grease (91-816391A4) 95 2-4-C w/Teflon (92-850736A1) CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5A-8 90-858895R1 JANUARY 2001 Oil Pump CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Oil Pump REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 PIPE PLUG 2 1 PIPE PLUG 3 2 O RING 4 2 DOWEL PIN 5 1 MOUNT 6 2 BOLT (M12 x 175 mm) 7 2 WASHER 8 2 WASHER 9 2 NUT 55 75 10 8 SCREW (M8 x 50 mm) 25 39 11 1 OIL PUMP 12 6 SCREW (M6 x 45 mm) 85 9.6 13 1 SEAL 14 1 SHIFT LINKAGE BRACKET 15 2 DRIVE SCREW 16 3 SCREW (M6 x 20 mm) 80 9 17 1 RETAINER 18 1 LATCH 19 1 SEAL 90-858895R1 JANUARY 2001 Page 5A-9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 13 16 17 4 5 16 18 20 19 17 9 Loctite PST Pipe Sealant (92-809822) 9 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5A-10 90-858895R1 JANUARY 2001 Drive Shaft Housing CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Drive Shaft Housing REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 DRIVE SHAFT HOUSING ASSEMBLY 2 1 STUD (LONG) 3 4 STUD (LONG) 4 5 WASHER 5 5 NUT 40 54.2 6 1 SPEEDOMETER PICK-UP ASSEMBLY 7 1 CONNECTOR (90 Degrees) 8 1 CONNECTOR (STRAIGHT) 9 2 MOUNT 10 2 BOLT (M12 x 154 mm) 11 2 WASHER 12 2 NUT 50 68 13 2 GROUND WIRE ASSEMBLY 14 1 SCREW (1/4-20 x 3/8) Drive Tight 15 2 CLAMP 16 4 SCREW (M8 x 25 mm) 25 34 17 4 CAP 18 1 BUSHING 19 1 PIN-Alignment 20 1 ELBOW 90-858895R1 JANUARY 2001 Page 5A-11 1 2 3 4 5 6 7 8 9 10 12 17 18 19 20 21 22 23 24 25 21 11 16 11 26 13 14 15 11 11 11 A = TO REF. #20 ON DRIVE SHAFT HOUSING A 11 11 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5A-12 90-858895R1 JANUARY 2001 Bottom Cowl CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Bottom Cowl REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in lb-ft Nm. 1 1 BOTTOM COWL ASSEMBLY (PORT) 2 1 BOTTOM COWL ASSEMBLY (STARBOARD) 3 2 SEAL KIT 4 1 GROMMET 5 8 SCREW (M6 x 40 mm) 65 7.4 6 1 RETAINER 7 1 IDLE EXHAUST BOOT 8 1 GROMMET 9 1 TELLTALE FITTING 10 1 WASHER 11 6 STA-STRAP 12 1 HOSE (5 IN.) 13 1 HOSE (11 IN.) 14 1 HOSE (26 IN.) 15 1 TEE 16 2 SCREW (M6 x 20 mm) 65 7.4 17 1 COVER 18 1 SWITCH ASSEMBLY 19 1 SCREW (M6 x 75 mm) 20 1 FRONT HANDLE 21 2 BUSHING 22 1 O-RING 23 1 PAWL–front handle 24 1 WASHER 25 1 NUT 26 2 PLUG 90-858895R1 JANUARY 2001 Page 5A-13 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5A-14 90-858895R1 JANUARY 2001 Bottom Cowl Removal 1. Disconnect trim wires. 57865 b c a a - Green/White b - Lt. Blue/White c - Red 2. Remove 2 screws from grommet cover to free grommet. 3. Remove 8 screws holding cowl halves together. a a d b c a - Cowl Screws (8) M6 x 40 b - Screws (2) M6 x 20 c - Cover d - Grommet CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 90-858895R1 JANUARY 2001 Page 5A-15 Bottom Cowl Installation 1. Check for proper placement of boot and grommet between cowl halves. Verify trim wires are clear. 2. Place retainer between cowls. 3. Secure cowl halves together with screws. 4. Replace grommet, cover and screws. a a d b c e f g a - Cowl Screws (8) M6 x 40 b - Screws (2) M6 x 20 c - Cover d - Grommet e - Boot f - Grommet g - Retainer 5. Connect trim wires. 57865 b c a a - Green/White b - Lt. Blue/White c - Red CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5A-16 90-858895R1 JANUARY 2001 Adaptor Plate Removal 1. Remove the following components: • Remove powerhead, refer to section 4B. • Remove oil pump, refer to section 4C. • Remove lower unit, refer to section 6. 2. Remove gearcase first. 3. Disconnect shift link from shift shaft and remove shift shaft. 4. Remove wire grommet from adaptor plate. Pull power trim wire and speedometer hose out of grommet. 5. Pull water hose from adaptor plate. 57667 57668 a c e d b a - Shift Link b - Nut c - Power Trim Wire/Grommet/Speedometer Hose d - Water Hose (drive shaft bushing) e - Shift Shaft CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 90-858895R1 JANUARY 2001 Page 5A-17 6. Remove nuts and washers from lower mount bolts. NOTE: Note placement of ground straps on port side mounting bolt. 57666 b a a c a - Ground Strap (port side) b - Nut c - Lower Mount Bolts (2) M12 x 154 7. Remove nuts and washers from upper mount bolts. 57669 a a a b d c e a - Upper Mount Bolts (2) M12 x 154 b - Upper Mount c - Washers (2) d - Washers (2) e - Nuts (2) CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 8. Pull speedometer hose down thru swivel pin arm. 9. Separate drive shaft housing from transom bracket mount bolts by pulling backward. 57664 b c a a-Water Hose (drive shaft bushing) b-Speedometer hose c-Washers (2) 10. Remove drain plug on port side of driveshaft housing to drain remaining oil from sump. 57663 a a-Drain Plug Page 5A-18 90-858895R1 JANUARY 2001 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 90-858895R1 JANUARY 2001 Page 5A-19 11. Remove 4 screws from top/back of adaptor plate. 12. Remove adaptor plate from driveshaft housing. a a - Screw (4) M8 x 50 13. Remove 4 screws to remove exhaust tube. 14. Remove 12 screws to remove oil sump. c b b c b b a c c c c 57665 a - Exhaust Tube b - Exhaust Tube Screw (4) M6 x 60 c - Adaptor Plate Screw (12) M6 x 35 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5A-20 90-858895R1 JANUARY 2001 Drive Shaft Bushing Removal 1. Using a suitable punch, drive roll pin to inside of drive shaft housing. 2. Remove drive shaft bushing with suitable mandrel or socket. 57673 a b c a - Roll Pin b - Suitable Mandrel or Socket c - Water Hose CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 90-858895R1 JANUARY 2001 Page 5A-21 Adaptor Plate Reassembly NOTE: Use soapy water on drive shaft bushing for ease of installation. 1. Snap driveshaft bushing onto driveshaft bushing installer tool and install into housing until seated. 2. Insert roll pin into drive shaft housing until flush with outside of driveshaft housing. 57638 57639 91-875215 c a b a - Driveshaft Installer Tool (91-875215) b - Bushing c - Roll Pin 3. Place oil sump onto adaptor plate and secure with 12 screws. Install exhaust tube to oil sump and secure with 4 screws. Torque in sequence to specified torque. c 57665 c a 8 9 10 11 12 14 15 13 16 7 c b c 4 b 6 b 2 c b 1 5 3 c a - Exhaust Tube b - Exhaust Tube Screw (4) M6 x 60 c - Adaptor Plate Screw (12) M6 x 35 Exhaust and Adaptor Plate Screw Torque 100 lb-in. (11.5 Nm) CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5A-22 90-858895R1 JANUARY 2001 4. Align water tube/grommet while installing adaptor plate onto drive shaft housing. 5. Replace drain plug into housing and torque to specified torque. 57663 b 57904 a a - Water Tube/Grommet b - Drain Plug Drain Plug Torque 17.5 lb-ft (24 Nm) 6. Install 4 screws into adaptor plate (torque later). a a - Screws (4) M8 x 50 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 90-858895R1 JANUARY 2001 Page 5A-23 7. Replace drive shaft housing assembly to transom bracket. 8. Install speedometer hose up through swivel pin bracket. 57664 a b a - Speedometer Hose b - Washers (2) 9. Install nuts onto lower mount bolts. Torque to specified torque. NOTE: Note placement of ground straps on port side mounting bolt. 57666 b a a c a - Ground Strap (port side) b - Nut c - Lower Mount Bolt (2) M12 x 154 Lower Mount Bolt Torque 50 lb-ft (68 Nm) CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5A-24 90-858895R1 JANUARY 2001 10. Install nuts to upper mounting bolts. Tighten to specified torque. 11. Tighten adaptor plate screws (4) to specified torque. a 57669 a b a c e d f a - Upper Mount Bolt (2) M12 x 154 b - Adaptor Plate Screw (4) M8 x 50 c - Upper Mount d - Washer (2) e - Washer (2) f - Nut (2) Upper Mounting Bolt Torque 55 lb-ft (75 Nm) Adaptor Plate Screw Torque 25 lb-ft (34 Nm) CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 90-858895R1 JANUARY 2001 Page 5A-25 12. Install shift shaft. Make sure engine is in neutral. 57668 a a - Shift Shaft 13. Reconnect shift link to shift shaft. 14. Replace grommet. Pull power trim wire and speedometer hose up thru grommet in adaptor plate. 15. Pull water hose (drive shaft bushing) up thru adaptor plate. a b c d e a - Nut b - Shift Shaft c - Speedometer Hose d - Power Trim Wire e - Water Hose (drive shaft bushing) 16. Replace the following components: • Replace oil pump, refer to section 4C. • Replace lower unit, refer to section 6. • Replace powerhead, refer to section 4B. POWER TRIM MID-SECTION Section 5B - Power Trim Table of Contents Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-2 Quicksilver Lubricants and Service Aids . . . . . . 5B-2 Power Trim Components . . . . . . . . . . . . . . . . . . . 5B-4 Theory Of Operation. . . . . . . . . . . . . . . . . . . . . . . 5B-6 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-6 Trimming Characteristics . . . . . . . . . . . . . . . . 5B-6 Trailering Outboard . . . . . . . . . . . . . . . . . . . . . 5B-7 Tilting Outboard Up and Down Manually . . . 5B-7 Power Trim Flow Diagrams . . . . . . . . . . . . . . . . . 5B-8 Trim Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-8 Tilt Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-10 Maximum Tilt . . . . . . . . . . . . . . . . . . . . . . . . . 5B-12 Trim Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-14 Shock Function Up . . . . . . . . . . . . . . . . . . . . 5B-16 Shock Function Return . . . . . . . . . . . . . . . . . 5B-18 Manual Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-20 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-22 Preliminary Checks . . . . . . . . . . . . . . . . . . . . 5B-22 Hydraulic System Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-23 Troubleshooting the Power Trim Electrical System. . . . . . . . . . . . . . . . . . . . . . 5B-27 Power Trim System Removal . . . . . . . . . . . . . . 5B-29 Power Trim Disassembly . . . . . . . . . . . . . . . . . . 5B-32 Trim Motor Removal . . . . . . . . . . . . . . . . . . . 5B-32 Pump and Components Removal . . . . . . . . 5B-33 Manifold Removal . . . . . . . . . . . . . . . . . . . . . 5B-34 Shock Rod Removal . . . . . . . . . . . . . . . . . . . 5B-34 Shock Rod Disassembly . . . . . . . . . . . . . . . . . . 5B-35 Memory Piston Removal . . . . . . . . . . . . . . . 5B-38 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . . 5B-39 Trim Motor Electrical Tests . . . . . . . . . . . . . . 5B-39 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-40 O-Ring and Seal Placement . . . . . . . . . . . . 5B-40 O-ring Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-41 O-ring Description and Sizes. . . . . . . . . . . . . . . 5B-42 Power Trim Reassembly . . . . . . . . . . . . . . . . . . 5B-43 Shock Rod Reassembly . . . . . . . . . . . . . . . . 5B-43 Shock Rod Installation . . . . . . . . . . . . . . . . . 5B-45 Trim Limit Assembly Installation . . . . . . . . . 5B-46 Manual Release Valve Installation . . . . . . . 5B-47 Manifold Installation . . . . . . . . . . . . . . . . . . . 5B-47 Oil Pump Installation. . . . . . . . . . . . . . . . . . . 5B-48 Pressure Operated Assembly Installation . 5B-49 Reservoir/Motor Installation . . . . . . . . . . . . . 5B-50 Bleeding Power Trim Unit . . . . . . . . . . . . . . 5B-51 Installation of Power Trim System . . . . . . . . . . 5B-52 5 B 90-858895R1 JANUARY 2001 Page 5B-1 POWER TRIM Special Tools 1. Spanner Wrench P/N 91-74951 2. Lock-Ring Pliers P/N SRP-4 (Snap-On) 3. Expanding Rod P/N CG 41-11 (Snap- On) 4. Collet P/N CG 41-12 (Snap- On) 5. Heat Lamp P/N 91-63209 Address Snap-On Tools Company 2801 - 80th Street Kenosha, Wisconsin 53143 Phone 414.656.5200 Quicksilver Lubricants and Service Aids Part No. Description 92-90100A12 Power Trim Fluid 92-850736A1 2-4-C w/Teflon Page 5B-2 90-858895R1 JANUARY 2001 POWER TRIM Notes: 90-858895R1 JANUARY 2001 Page 5B-3 1 2 3 4 5 6 7 8 9 10 11 13 14 15 2 2 5 10 5 10 10 10 10 10 5 5 10 15 10 16 17 18 16 19 20 21 12 A E D C D B F POWER TRIM Page 5B-4 90-858895R1 JANUARY 2001 Power Trim Components NOTE: Lubricate all O-rings using Quicksilver Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. NOTE: It is recommended that all O-rings be replaced when servicing tilt system. POWER TRIM Power Trim Components REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm – 1 POWER TRIM PUMP 1 1 SHOCK ROD KIT 2 1 O RING REBUILD KIT 3 1 MEMORY PISTON ASSEMBLY 4 1 CYLINDER ASSEMBLY 5 1 TRIM LIMIT VALVE KIT 6 1 PUMP ASSEMBLY 7 1 MOTOR KIT 8 1 RESERVOIR PLUG 9 1 MANUAL RELEASE ASSEMBLY 10 1 MANIFOLD KIT 11 1 SCREW KIT (MOTOR) 12 1 CABLE 13 1 DRIVE SHAFT 14 1 FILTER KIT 15 1 P.O. CHECK ASSEMBLY KIT – 1 O RING KIT (COMPLETE TRIM) 16 2 GROOVE PIN 17 1 ANCHOR PIN 18 1 SHAFT 19 2 CLAMP 20 1 SCREW 21 1 C WASHER A -Torque cylinder cap to 45 lb-ft (61 Nm) B -Torque screws to 80 lb-in. (9.0 Nm) C -Torque screws to 70 lb-in. (7.9 Nm) D -Torque plugs to 120 lb-in. (13.5 Nm) E -Torque screws to 100 lb-in. (11 Nm) F -Torque shock piston to 90 lb-ft (122 Nm) 90-858895R1 JANUARY 2001 Page 5B-5 POWER TRIM Theory Of Operation The Power Trim system consists of an electric motor, pressurized fluid reservoir, pump and trim cylinder. The remote control (or trim panel) is equipped with a switch that is used for trimming the outboard “up” and “down”, and for tilting the outboard for shallow water operation (at slow speed) or for “trailering”. The outboard can be trimmed “up” or “down” while engine is under power or when engine is not running. Adjustments Trimming Characteristics NOTE: Because varying hull designs react differently in various degrees of rough water, it is recommended to experiment with trim positions to determine whether trimming “up” or “down” will improve the ride in rough water. When trimming your outboard from a mid-trim position (trim tab in neutral, straight fore-andaft, position), you can expect the following results: TRIMMING OUTBOARD “UP” (“OUT”) WARNING Excessive trim “out” may reduce the stability of some high speed hulls. To correct instability at high speed, reduce the power gradually and trim the motor “In” slightly before resuming high speed operation. (Rapid reduction in power will cause a sudden change of steering torque and may cause additional momentary boat instability.) • Will lift bow of boat, generally increasing top speed. • Transfers steering torque harder to left on installations below 23 in. transom height. • Increases clearance over submerged objects. • In excess, can cause porpoising and/or ventilation. • In excess, can cause insufficient water supply to water pump resulting in serious water pump and/or powerhead overheating damage. WARNING Excessive engine trim angle will result in insufficient water supply to water pump causing water pump and/or powerhead overheating damage. Make sure that water level is above gear housing water intake holes whenever engine is running. Operating “Up” circuit will actuate the “up” relay (located under engine cowl) and close the electric motor circuit. The electric motor will drive the pump, thus forcing automatic transmission fluid through internal passageways into the “up” side of the trim cylinder. The trim cylinder/trim rod will position the engine at the desired trim angle within the 20° maximum trim range. The power trim system is designed so the engine cannot be trimmed beyond the 20 maximum trim angle as long as engine rpm is above approximately 2000 rpm. The engine can be raised beyond the 20 maximum trim angle for shallow water operation, etc., by keeping the engine rpm below 2000 rpm. If engine rpm increases above 2000 rpm, the thrust created by the propeller (if deep enough in the water) will cause the trim system to automatically lower the engine back to the 20 maximum trim angle. Page 5B-6 90-858895R1 JANUARY 2001 POWER TRIM TRIMMING OUTBOARD “DOWN” (“IN”) WARNING Excessive speed at minimum trim “In” may cause undesirable and/or unsafe steering conditions. Each boat should be tested for handling characteristics after any adjustment is made to the tilt angle (tilt pin relocation). • Will help planing off, particularly with a heavy load. • Usually improves ride in choppy water. • In excess, can cause boat to veer to the left or right (bow steer). • Transfers steering torque harder to right (or less to the left). • Improves planing speed acceleration (by moving tilt pin one hole closer to transom). Operating “Down” circuit will actuate the “down” relay (located under engine cowl) and close the electric motor circuit (motor will run in opposite direction of the “Up” circuit). The electric motor will drive the pump, thus forcing automatic transmission fluid through internal passageways into the “down” side of the trim cylinder. The trim rod will move the engine downward to the desired angle. Trailering Outboard WARNING Excessive engine trim angle will result in insufficient water supply to water pump causing water pump and/or powerhead overheating damage. Make sure that water level is above gear housing water intake holes whenever engine is running. While operating “up” circuit, the cylinder rod will continue to tilt the outboard to a full up position for trailering. Tilting Outboard Up and Down Manually WARNING Before loosening the manual release valve, make sure all persons are clear of engine, as engine will drop to full “down” position when valve is loosened. With power trim installed, the outboard can be raised or lowered manually by opening the manual release valve 3 to 4 turns (counterclockwise). a a-Manual Release Valve 90-858895R1 JANUARY 2001 Page 5B-7 POWER TRIM Page 5B-8 90-858895R1 JANUARY 2001 Power Trim Flow Diagrams ÍÍ ÍÍ Reservoir Oil Filtered Feed Oil Oil Under Pressure Return Oil Up Pressure 1625 psi (3060 hp) 2800 psi (75125 hp) mininmum Tilt Relief Pressure 250400 psi (3060 hp) 500700 psi (4060 hp Bigfoot) 540990 psi (75125 hp) Impact Relief Pressure #22 8801110 psi (3060 hp) 12201420 psi (75125 hp) a b c d e g f h i j k l m o g p s r t u v w TRIM UP n q POWER TRIM Trim Up When the trim switch is activated in the up position, the electric motor (c) begins to rotate the oil pump gears (j). The oil pump draws a small amount of oil through the filter (g) and through the up circuit suction port (i). The oil pump gear (j) rotation forces oil into the passages for the up circuit. Oil, under pressure, will slide the shuttle valve (m) against the down circuit pressure operated valve (f). The shuttle valve will mechanically open the down pressure operated valve, allowing oil from the down cavity of the trim cylinder, to flow into the oil pump. This returning oil, from the down cavity, will supply most of the oil required for the up circuit. Oil in the up circuit is blocked from returning into the reservoir by the ball inside the down circuit suction port (k). The pressure of the oil will force the up circuit pressure operated valve (n) to open, allowing the oil to enter the passages inside the manifold (q) leading to the trim cylinder (w) up cavity. Oil is blocked from all other passages by the closed manual release valve (p). Oil under pressure will enter the trim cylinder below the memory piston (t). With an increasing amount of oil entering the cylinder, the memory piston contacts the shock piston (u) and forces the trim rod (a) up and out, raising the outboard motor. Oil on the top of the shock piston exits through a passage running down along the side of the cylinder and enters the manifold passages. The oil is drawn back into the pump (j) through the open down circuit pressure operated valve (f) and enters the pump as supply for the up circuit. a-Trim Rod b-End Cap c-Electric Motor d-Reservoir Oil e-Down Circuit Pressure Relief Valve f-Down Circuit Pressure Operated Valve g-Filter (2 shown for clarity) h-Shock Return Valve i-Up Circuit Suction Port j-Oil Pump Gears k-Down Circuit Suction Port l-Oil Fill Cap m-Shuttle Valve n-Up Circuit Pressure Operated Valve o-Manifold Reverse Suction Valve p-Manual Release Valve q-Manifold r-Tilt Relief Valve s-Tilt Relief Piston t-Memory Piston u-Shock Piston v-Impact Relief Valve w-Cylinder 90-858895R1 JANUARY 2001 Page 5B-9 POWER TRIM Page 5B-10 90-858895R1 JANUARY 2001 Tilt Up Tilt Relief Pressure 250400 psi (3060 hp) 500700 psi (4060 hp Bigfoot) 540990 psi (75125 hp) Up Pressure 1625 psi (3060 hp) 2800 psi (75125 hp) minimun Reservoir Oil Filtered Feed Oil Oil Under Pressure Return Oil ÍÍ ÍÍ Impact Relief Pressure #22 8801110 psi (3060 hp) 12201420 psi (75125 hp) a b c d w u v t h e f g s r p o g m n j k i l q POWER TRIM Tilt Up In the up mode, as the trim rod (a) extends from the cylinder (w), the memory piston (t) clears or uncovers the pressure relief passage. Oil from the up cavity will enter this passage and, if required, causes the tilt relief piston (s) to open the tilt relief valve (r). This valve lowers the amount of pressure available to lift the outboard motor. With the engine in forward gear, and at high engine rpm, the oil pressure available will not be able to overcome the propeller thrust, limiting the trim range to below the pressure relief orifice. When the engine rpm decreases, or if engine is not in forward gear, the oil pressure is available to extend the trim rod (a) up into the tilt range. a-Trim Rod b-End Cap c-Electric Motor d-Reservoir Oil e-Down Circuit Pressure Relief Valve f-Down Circuit Pressure Operated Valve g-Filter (2 shown for clarity) h-Shock Return Valve i-Up Circuit Suction Port j-Oil Pump Gears k-Down Circuit Suction Port l-Oil Fill Cap m-Shuttle Valve n-Up Circuit Pressure Operated Valve o-Manifold Reverse Suction Valve p-Manual Release Valve q-Manifold r-Tilt Relief Valve s-Tilt Relief Piston t-Memory Piston u-Shock Piston v-Impact Relief Valve w-Cylinder 90-858895R1 JANUARY 2001 Page 5B-11 POWER TRIM Page 5B-12 90-858895R1 JANUARY 2001 Maximum Tilt Up Pressure 1625 psi (3060 hp) 2800 psi (75125 hp) minimum ÍÍ ÍÍ Reservoir Oil Filtered Feed Oil Oil Under Pressure Return Oil Tilt Relief Pressure 250400 psi (3060 hp) 500700 psi (4060 hp Bigfoot) 540990 psi (75125 hp) Impact Relief Pressure #22 8801110 psi (3060 hp) 12201420 psi (75125 hp) a v t w b h c d e f g s r p o n g m i j k l u q POWER TRIM Maximum Tilt With the trim rod at maximum travel, and due to no rod movement, the pressure inside of the trim cylinder (w) will increase to the pressure required to move the tilt relief piston (s). The tilt relief piston’s “pin” opens the tilt relief valve (r). Up pressure flows allowing the oil to flow into the trim relief passage, and returns back into the reservoir. a-Trim Rod b-End Cap c-Electric Motor d-Reservoir Oil e-Down Circuit Pressure Relief Valve f-Down Circuit Pressure Operated Valve g-Filter (2 shown for clarity) h-Shock Return Valve i-Up Circuit Suction Port j-Oil Pump Gears k-Down Circuit Suction Port l-Oil Fill Cap m-Shuttle Valve n-Up Circuit Pressure Operated Valve o-Manifold Reverse Suction Valve p-Manual Release Valve q-Manifold r-Tilt Relief Valve s-Tilt Relief Piston t-Memory Piston u-Shock Piston v-Impact Relief Valve w-Cylinder 90-858895R1 JANUARY 2001 Page 5B-13 POWER TRIM Page 5B-14 90-858895R1 JANUARY 2001 Trim Down Up Pressure 1625 psi (3060 hp) 2800 psi (75125 hp) minimum ÍÍ ÍÍ Reservoir Oil Filtered Feed Oil Oil Under Pressure Return Oil Tilt Relief Pressure 250400 psi (3060 hp) 500700 psi (4060 hp Bigfoot) 540990 psi (75125 hp) Impact Relief Pressure #22 8801110 psi (3060 hp) 12201420 psi (75125 hp) a w b c d i j k l m n g o p s r h g f e t u v q POWER TRIM Trim Down When the trim switch is activated in the down position, the electric motor (c) will rotate the oil pump gears (j) in the opposite direction. With the oil pump gears rotating backwards, the flow of oil is reversed. Oil is drawn through the filter (g), through the down circuit suction port (k) and into the oil pump gears (j). As the pump forces pressurized oil into the down passages, oil will slide the shuttle valve (m) into the up circuit pressure operated valve (n). The shuttle valve will mechanically open the up circuit pressure operated valve, and allow oil from the up cavity of the trim cylinder (w) to return into the oil pump. This returning oil from the up cavity, will supply the oil required for the down circuit. The oil is blocked from returning into the reservoir by the ball (i) inside the up circuit suction port. Oil, under pressure, opens the down circuit pressure operated valve (f) and enters the down passages inside of the manifold (q). The manifold passage connects into the trim cylinder passage leading to the top of the cylinder. The cavity inside the cylinder above the shock piston (u), is the down cavity. As the down cavity fills with oil, the trim rod (a) retracts into the cylinder, lowering the outboard motor. Oil from the up cavity exits the cylinder, and is drawn back into the pump through the open up circuit pressure operated valve (n). When the trim rod reached full travel, the oil pressure inside the down circuit will rise until the down circuit pressure relief valve (e) opens, bypassing oil back into the reservoir. When the trim button is released and the oil pump stops supplying pressure, both of the pressure operated valves (f & n) will close; and, if open, the down circuit pressure relief valve (e) will close. The closed valves will lock the fluid on either side of the shock piston (u) & memory piston (t), holding the outboard motor in position. a-Trim Rod b-End Cap c-Electric Motor d-Reservoir Oil e-Down Circuit Pressure Relief Valve f-Down Circuit Pressure Operated Valve g-Filter (2 shown for clarity) h-Shock Return Valve i-Up Circuit Suction Port j-Oil Pump Gears k-Down Circuit Suction Port l-Oil Fill Cap m-Shuttle Valve n-Up Circuit Pressure Operated Valve o-Manifold Reverse Suction Valve p-Manual Release Valve q-Manifold r-Tilt Relief Valve s-Tilt Relief Piston t-Memory Piston u-Shock Piston v-Impact Relief Valve w-Cylinder 90-858895R1 JANUARY 2001 Page 5B-15 POWER TRIM Page 5B-16 90-858895R1 JANUARY 2001 Shock Function Up Up Pressure 1625 psi (3060 hp) 2800 psi (75125 hp) minimum ÍÍ ÍÍ Reservoir Oil Oil Under Pressure Return Oil Tilt Relief Pressure 250400 psi (3060 hp) 500700 psi (4060 hp Bigfoot) 540990 psi (75125 hp) Impact Relief Pressure #22 8801110 psi (3060 hp) 12201420 psi (75125 hp) a b c w v u t h d e f g i j k l n m g o p s r q POWER TRIM Shock Function Up Oil inside the down cavity is locked in a static position by the closed down circuit pressure operated valve (f), the manual release valve (p), and the manifold reverse suction valve (o). If the outboard strikes an underwater object while in forward gear, the trim rod (a) will try to rapidly extend from the cylinder (w), as the pressure increases inside the trim cylinder down cavity and connecting passages. When the pressure increases to the level required, the impact relief valves (v), located inside the shock piston (u), will open and allow the fluid to pass through the shock piston. As the fluid passes through the piston, the trim rod (a) will extend from the trim cylinder. The memory piston (t) is held in position by vacuum, created by the oil in the up cavity being locked in a static position. Therefore, oil passing through the shock piston is trapped between the memory piston (t) and shock piston (u). a-Trim Rod b-End Cap c-Electric Motor d-Reservoir Oil e-Down Circuit Pressure Relief Valve f-Down Circuit Pressure Operated Valve g-Filter (2 shown for clarity) h-Shock Return Valve i-Up Circuit Suction Port j-Oil Pump Gears k-Down Circuit Suction Port l-Oil Fill Cap m-Shuttle Valve n-Up Circuit Pressure Operated Valve o-Manifold Reverse Suction Valve p-Manual Release Valve q-Manifold r-Tilt Relief Valve s-Tilt Relief Piston t-Memory Piston u-Shock Piston v-Impact Relief Valve w-Cylinder 90-858895R1 JANUARY 2001 Page 5B-17 POWER TRIM Page 5B-18 90-858895R1 JANUARY 2001 Shock Function Return Up Pressure 1625 psi (3060 hp) 2800 psi (75125 hp) minimum ÍÍ ÍÍ Reservoir Oil Oil Under Pressure Return Oil Tilt Relief Pressure 250400 psi (3060 hp) 500700 psi (4060 hp Bigfoot) 540990 psi (75125 hp) Impact Relief Pressure #22 8801110 psi (3060 hp) 12201420 psi (75125 hp) a b c w v u t h d i j k l m n e f g g o p s r q POWER TRIM Shock Function Return After the engine clears the under water object, the weight of the engine will increase the oil pressure between the memory piston (t) and shock piston (u) to the level required to open the shock return valve (h), inside the shock piston. This allows the oil to bleed back through the shock piston into the down cavity. If required, additional oil will enter the down cavity through the manifold reverse suction valve (o). This will return the engine back against the memory piston (t) and into the original running position. a-Trim Rod b-End Cap c-Electric Motor d-Reservoir Oil e-Down Circuit Pressure Relief Valve f-Down Circuit Pressure Operated Valve g-Filter (2 shown for clarity) h-Shock Return Valve i-Up Circuit Suction Port j-Oil Pump Gears k-Down Circuit Suction Port l-Oil Fill Cap m-Shuttle Valve n-Up Circuit Pressure Operated Valve o-Manifold Reverse Suction Valve p-Manual Release Valve q-Manifold r-Tilt Relief Valve s-Tilt Relief Piston t-Memory Piston u-Shock Piston v-Impact Relief Valve w-Cylinder 90-858895R1 JANUARY 2001 Page 5B-19 POWER TRIM Page 5B-20 90-858895R1 JANUARY 2001 Manual Tilt ÍÍ ÍÍ Reservoir Oil Return Oil Filtered Oil Down Pressure 525880 psi Up Pressure 1625 psi (3060 hp) 2800 psi (75125 hp) minimum Tilt Relief Pressure 250400 psi (3060 hp) 500700 psi (4060 hp Bigfoot) 540990 psi (75125 hp) Impact Relief Pressure #22 8801110 psi (3060 hp) 12201420 psi (75125 hp) a b c w v u t h d i j k l m n g o p s r q e f g POWER TRIM Manual Tilt To manually tilt the outboard engine, the owner will need to back out the manual release valve (p) 3-4 turns. With the valve backed out, the internal passages inside the manifold are connected together. These passages connect both the cylinder down and up cavities together, along with the reservoir, allowing the engine to be raised or lowered. Trim rod (a) movement will continue until the manual release valve (p) is closed, locking the fluid inside of the cylinder and manifold. a-Trim Rod b-End Cap c-Electric Motor d-Reservoir Oil e-Down Circuit Pressure Relief Valve f-Down Circuit Pressure Operated Valve g-Filter (2 shown for clarity) h-Shock Return Valve i-Up Circuit Suction Port j-Oil Pump Gears k-Down Circuit Suction Port l-Oil Fill Cap m-Shuttle Valve n-Up Circuit Pressure Operated Valve o-Manifold Reverse Suction Valve p-Manual Release Valve q-Manifold r-Tilt Relief Valve s-Tilt Relief Piston t-Memory Piston u-Shock Piston v-Impact Relief Valve w-Cylinder 90-858895R1 JANUARY 2001 Page 5B-21 POWER TRIM Troubleshooting Support outboard with tilt lock pin when servicing power trim system. IMPORTANT: After debris or failed components have been found (during troubleshooting procedure), it is recommended that unit be disassembled completely and ALL O-rings be replaced. Check ball valve components and castings must be cleaned using engine cleaner and compressed air or replaced prior to re-assembly. IMPORTANT: Power trim system is pressurized. Outboard must be in the full “UP” position (trim rod fully extended) prior to fill/drain plug, or manual release valve removal. Refer to instructions following if disassembly is required when servicing. Follow preliminary checks before proceeding to troubleshooting flow diagrams (following). Preliminary Checks IMPORTANT: Operate Power Trim system after each check to see if problem has been corrected. If problem has not been corrected proceed to next check. 1. Check that manual release valve is tightened to full right (clockwise) position. 2. Check trim pump fluid level with outboard in full “UP” position and fill if necessary. Refer to “Bleeding Power Trim Unit”. 3. Check for external leaks in Power Trim system. Replace defective part(s) if leak is found. 4. Outboard not holding tilted position (falls down to trim position) indicates debris or defective components in trim assembly. Clean or replace components as required. Page 5B-22 90-858895R1 JANUARY 2001 POWER TRIM Hydraulic System Troubleshooting Flow Chart OUTBOARD WILL NOT HOLD TILTED POSITION DURING REVERSE AND/OR TRAILS OUT DURING HIGH SPEED DECELERATION. Inspect manual release valve.Manual release valve and O-ring damaged. Manual release valve and O-rings appear to be O.K. - Clean and reinstall manual release valve. Trim system holds re- verse thrust. Testing complete. Trim will not hold reverse thrust. Replace manual re- lease valve and O-rings. Trim system holds re- verse thrust. Testing complete. Remove and inspect pis- ton rod assembly for de- bris and/or shock ball hang up. Shock piston appears O.K. - Clean and reinstall piston rod assembly. Trim system holds re- verse thrust. Testing complete. Debris and/or shock ball hang up identi- fied. Replace piston rod assembly. Trim system holds re- verse thrust. Testing complete. Trim will not hold reverse thrust. Remove PO check valve assembly, inspect O-rings and seals for damage. Debris and/or dam- age identified. Replace PO check valve assembly. Trim system holds re- verse thrust. Testing complete. PO check valve appears O.K. - Clean and reinstall PO check valve assem- bly. Trim will not hold reverse thrust. Trim system holds reverse thrust. Test- ing complete. continued on next page 90-858895R1 JANUARY 2001 Page 5B-23 POWER TRIM Hydraulic System Troubleshooting Flow Chart continued Replace trim system. Replace suction seat assembly. Remove suction seat as- sembly and inspect for debris and/or damage. Debris and/or damage identified. Trim system holds reverse thrust. Test- ing complete. Trim will not hold reverse thrust. Suction seat assembly appears O.K. - Clean and reinstall suction seat assembly. Trim system holds reverse thrust. Test- ing complete. Page 5B-24 90-858895R1 JANUARY 2001 POWER TRIM Hydraulic System Troubleshooting Flow Chart TRIM SYSTEM LEAKS DOWN WITH MANUAL RELEASE VALVE CLOSED. Inspect manual release valve.Manual release valve and O-ring damaged. Replace manual re- lease valve and O-rings. Trim system does not leak down. Test- ing complete. Trim system leaks down. Manual release valve and O- rings appear to be O.K. - Clean and reinstall manual release valve. Trim system does not leak down. Test- ing complete. Remove tilt relief valving and inspect O-rings and seals for debris and/or damage. Debris and/or dam- age identified. Replace tilt relief valving. Trim system does not leak down. Test- ing complete. Trim system leaks down. Tilt relief valving and O-rings appear to be O.K. - Clean and reinstall tilt relief valving. Trim system does not leak down. Test- ing complete. Remove PO check valve assembly, inspect O- rings and seals for dam- age. Debris and/or dam- age identified. Replace PO check valve assembly. PO check valve appears O.K. - Clean and reinstall PO check valve assem- bly. continued on next page Trim system leaks down. Trim system does not leak down. Testing complete. Trim system does not leak down. Test- ing complete. 90-858895R1 JANUARY 2001 Page 5B-25 POWER TRIM Hydraulic System Troubleshooting Flow Chart continued Replace trim system. Replace memory pis- ton and shock piston O-rings. Inspect memory pis- ton O-ring and cylinder bore. Cylinder bore appears smooth with no debris. Cylinder bore appears rough and/or debris found in cylinder. Trim leaks down. Trim system does not leak down. Test- ing complete. Page 5B-26 90-858895R1 JANUARY 2001 POWER TRIM Troubleshooting the Power Trim Electrical System RED RED GRN BLK LT.GRN BLK DN UP AB RED RED DN UP LT.BLU/WHT GRN/WHT RED BLU/WHT GRN/WHT DN UP BLU/WHT GRN/WHT RED GRN/WHT or GRN BLU/WHT or PUR BLUE BLK LT.BLU BLK +– LT. BLU/WHT GRN/WHT RED/PUR a j kh e f d c b 1 2 3 4 i RED/PUR g RED GRN BLK BLU RED BLK GRN/WHT RED/PUR LT. BLU/WHT RED LT.GRN LT.BLU A B 30 (A) 20 (A) c a-Trim Switch (Remote Control Mounted) g-Up Relay b-Trim Switch (Panel Mounted) h-Down Relay c-Fuses (20A, 30A) i-Solenoid - Start d-Remote Control Wiring Plug Connector j-Trim Pump Motor e-Battery k-Cowl Switch f-Block Bolt 90-858895R1 JANUARY 2001 Page 5B-27 POWER TRIM Troubleshooting the Power Trim Electrical System Refer to wiring diagram on preceding page for location of wire connections. Problem Possible Cause Remedy Trim Switch “UP” is inoperative, but the Cowl Switch “UP” does operate. 1. Open wire between Wire Connection (1) and Trim Switch. 2. Faulty Trim Switch. 1. Check for an open connection or cut wire. 2. Replace. Cowl Switch “UP” is inoperative, but the Trim Switch “UP” does operate. 1. Open wire between Wire Connection (2) and Solenoid. 2. Faulty Cowl Switch. 1. Check for an open connection or cut wire. 2. Replace. Trim Switch “UP” and Cowl Switch “UP” are both inop1. Open wire between Wire Connection (1) and the “Up” Relay. 1. Check for an open connection. erative. 2. Open BLK wire between ground and “UP” Relay. 2. Check for an open connection. 3. Open RED wire between Solenoid and “UP” Relay. 3. Check for an open connection. 4. Faulty “UP” Relay. 4. Replace. Trim Switch “DOWN” is inoperative, but the Cowl Switch “DOWN” does operate. 1. Open wire between Wire Connection (3) and Trim Switch. 2. Faulty Trim Switch. 1. Check for an open connection or cut wire. 2. Replace. Cowl Switch “DOWN” is inoperative, but the Trim Switch “DOWN” does operate. 1. Open wire between Wire Connection (2) and Solenoid. 2. Faulty Cowl Switch. 1. Check for a open connection or cut wire. 2. Replace Trim Switch “DOWN” and Cowl Switch “DOWN” are 1. Open wire between Wire Connection (3) and the “UP” Relay. 1. Check for an open connection. both inoperative. 2. Open BLK wire between ground and “DOWN” Relay. 2. Check for an open connection. 3. Open RED wire between Solenoid and “DOWN” Relay. 3. Check for an open connection. 4. Faulty “DOWN” Relay 4. Replace. Trim Switch “UP” and “DOWN” are both inoperative, but the Cowl Switch does operate. 1. 20 AMP Fuse blown. 2. Faulty trim switch. 3. Wire is open between fuse holder and solenoid. 4. Wire is open between fuse holder and trim switch. 1. Replace fuse. Locate the cause of the blown fuse. Check electrical wiring for a shorted circuit. 2. Replace. 3. Check for a open connection or cut wire. 4. Check for a loose or corroded connection. Trim Switch and Cowl Switch are both inoperative. 1. One of the Trim Pump Motor wires is open between the motor and the Relays. 2. Faulty trim pump motor. 1. Check wire connections (4) for loose or corroded condition. 2. If voltage is present at connections (4) when the appropriate trim button is pressed, then motor is faulty. Replace motor. Trim system operates (motor runs) without pressing the switches. 1. The Trim or Cowl switch is shorted. 1. Replace. Page 5B-28 90-858895R1 JANUARY 2001 POWER TRIM 90-858895R1 JANUARY 2001 Page 5B-29 Power Trim System Removal 1. Tilt outboard to the full up position and support with tilt lock pin. 2. Disconnect the power trim wire harness and remove clamp. 55264 53949 a c b a - Tilt Lock Pin b - J-Clip c - Harness 3. Remove the trilobe pin. 4. Drive out the upper pivot pin. a b a - Trilobe Pin b - Upper Pivot Pin POWER TRIM 5. Use suitable punch to remove dowel pin. a a-Dowel Pin 6. Use suitable punch to drive out lower pivot pin. 7. Remove the sacrificial anode. a b a-Lower Pivot Pin b-Sacrificial Anode Page 5B-30 90-858895R1 JANUARY 2001 POWER TRIM 8. Tilt power trim assembly (top first) out from clamp bracket and remove assembly. 53944 90-858895R1 JANUARY 2001 Page 5B-31 POWER TRIM Page 5B-32 90-858895R1 JANUARY 2001 Power Trim Disassembly IMPORTANT: Power trim system is pressurized. Trim rod must be in the full “UP” position (fully extended) prior to fill/drain plug, or manual release valve removal. 1. Remove reservoir cap. 2. Remove manual release valve assembly to drain oil. 55263 b a a - Reservoir Cap b - Manual Release Valve Trim Motor Removal 1. Secure power trim assembly in a soft jaw vise. 2. Remove four (4) screws to remove motor/reservoir. Remove reservoir seal and coupler. e d c b a a - Screw (4) b - Reservoir c - Reservoir Seal d - Coupler e - Manifold Assembly POWER TRIM 90-858895R1 JANUARY 2001 Page 5B-33 Pump and Components Removal 1. Remove pressure operated plugs on pump. Remove spring and check valve/poppet (both sides). Use special tool CG 41-11 and special tool CG 41-14 with 5/16, end to remove spool. d b a c a b d e c a - Plug (2) b - Spring (2) c - Check Valve/Poppet (2) d - Seat (2) e - Spool IMPORTANT: Inspect poppet assembly for debris in the area shown. If debris is found on poppet replace poppet. 2. Remove three (3) screws to remove pump. Remove filter and filter seal under pump. Remove suction seat assembly. d c e f b a a - Debris Under Valve Tip b - Rubber Seat c - Screws (3) d - Filter Seal e - Filter f - Suction Seat Assembly POWER TRIM Manifold Removal 1. Remove two (2) screws to remove manifold from cylinder. 2. Remove tilt relief components. b c d e 51146 a-Screws (2) b-Spring c-Poppet d-Spool Housing e-Trim Limit Spool Shock Rod Removal 1. Unscrew end cap assembly from cylinder using spanner wrench [1/4 in. x 5/16 in. (6.4 mm x 8 mm) long pegs]. 2. Remove shock rod assembly from cylinder. a Page 5B-34 90-858895R1 JANUARY 2001 POWER TRIM Shock Rod Disassembly NOTE:The only serviceable items on the shock rod assembly are the O-rings and wiper ring. If shock rod requires any other repair, replace shock rod assembly. b b c a a-End Cap b-O-ring (2) c-Wiper Ring 1. Place shock rod assembly on clean work surface. 2. Remove three (3) screws and remove plate from shock rod piston. 51143 a b c a-Screw (3) b-Plate c-Shock Rod Piston 90-858895R1 JANUARY 2001 Page 5B-35 POWER TRIM 3. Remove check ball components from shock rod piston. 4. Remove O-ring from shock rod piston. 51147 d a b c a-Spring (5) b-Seat (5) c-Ball (5) d-O-ring CAUTION When removing shock piston, spanner wrench must have 1/4 in. x 5/16 in. long pegs to avoid damage to shock piston. 5. Place shock rod into soft jawed vise and apply heat to loosen piston using torch lamp (P/N 91-63209). 6. Loosen shock rod piston using spanner wrench [1/4 in. x 5/16 in. (6.4mm x 8mm) long pegs]. 7. Allow shock rod piston to cool. Remove from shock rod. 51146 51146 a b a-Spanner Wrench b-Shock Rod Piston Page 5B-36 90-858895R1 JANUARY 2001 POWER TRIM 8. Inspect check valve for debris; clean debris from check valve if found. If debris cannot be cleaned from check valve, replace shock piston as an assembly. 9. Clean shock and components with compressed air. 10. Remove inner O-ring from shock rod piston. 51199 a b a-Shock Piston b-O-ring 11. Remove cylinder end cap assembly from shock rod. 12. Inspect shock. If wiper (located in cap) has failed to keep rod clean, replace wiper. 13. Place end cap on clean work surface. 14. Remove rod wiper, inner O-ring, and outer O-ring. 51145 a b c a-Rod Wiper b-Inner O-ring c-Outer O-ring 90-858895R1 JANUARY 2001 Page 5B-37 POWER TRIM Memory Piston Removal 1. Remove memory piston from cylinder using one of two methods: a. Using lock ring pliers P/N SRP-4 (Snap-On) or suitable tool. SRP-4 (Snap-On) b. Blowing compressed air into manual release valve hole using air nozzle. WARNING Memory piston cup may be expelled at a high velocity when air pressure is applied. Failure to place cylinder as shown below could result in personal injury. NOTE: Point cylinder opening down and away. Use a shop rag or towel to avoid damage to the memory piston. 2. Remove O-ring from memory piston. 51144 d e 55466 a c b a-Adaptor/Air Hose b-Memory Piston Exit c-Shop Rag d-O-Ring e-Memory Piston Page 5B-38 90-858895R1 JANUARY 2001 POWER TRIM Cleaning/Inspection/Repair IMPORTANT: Components must be dirt and lint free. Slightest amount of debris in Power Trim system could cause system to malfunction. Clean shock rod and components with parts cleaner and dry with compressed air. It is recommended that all O-rings in trim system be replaced. Use O-Ring Kit 25-809880A1. Lubricate all O-rings with Quicksilver Power Trim Fluid (92-90100A12). If not available, use automotive (ATF) automatic transmission fluid. Trim Motor Electrical Tests 1. Connect a 12 volt supply to motor leads. If motor fails to run, replace pump motor. IMPORTANT: Trim Motor is not serviceable. If motor fails to run, replace motor assembly. 90-858895R1 JANUARY 2001 Page 5B-39 POWER TRIM Page 5B-40 90-858895R1 JANUARY 2001 Reassembly O-Ring and Seal Placement O-Rings and Seals are part of O-Ring Kit 25-809880A1 3 21 22 3 19 21 22 4 5 1 20 8 9 10 18 9 7 6 15 16 17 8 9 10 14 13 11 12 POWER TRIM 90-858895R1 JANUARY 2001 Page 5B-41 O-Ring Sizes O.D. I.D. Cutaway View of O-Ring Width O-RINGS SHOWN ARE ACTUAL SIZE 22 4 11 10 8 6 5 2211 1199 1166 20 15 18 17 12 33 11 2 2 99 7 13 1144 POWER TRIM O-Ring Description and Sizes O-Ring Description O-Ring I.D. O-Ring O.D. O-Ring Width 1 Wiper Ring 2 Cyl. Cap, Inner 0.671 in. (17.04 mm) 0.949 in. (24.10 mm) 0.139 in. (3.53 mm) 3 Cyl. Cap 1.864 in. (47.34 mm) 2.004 in. (50.90 mm) 0.07 in. (1.78 mm) 4 Shock Piston 1.6 in. (40.64 mm) 2.02 in. (53.086 mm) 0.21 in. (5.334 mm) 5 Piston Bolt 0.676 in. (17.17 mm) .816 in. (20.726 mm) 0.07 in. (1.78 mm) 6 Reservoir Plug 0.549 in. (13.94 mm) 0.755 in. (19.17 mm) 0.103 in. (2.616 mm) 7 Motor Seal 8 (2) P.O. Check Plug 0.489 in. (12.42 mm) 0.629 in. (15.97 mm) 0.07 in. (1.78 mm) 9 (3) Poppet Assy. 10 (2) P.O. Check Seat 0.364 in. (9.25 mm) 0.504 in. (12.80 mm) 0.07 in. (1.78 mm) 11 (2) Pump Port 0.145 in. (3.683 mm) 0.285 in. (7.239 mm) 0.07 in. (1.78 mm) 12 Suction Seat 0.239 in. (6.07 mm) 0.379 in. (9.626 mm) 0.07 in. (1.78 mm) 13 Filter Seal 14 Filter 15 Manual Release 0.114 in. (2.90 mm) 0.254 in. (6.451 mm) 0.07 in. (1.78 mm) 16 Manual Release 0.176 in. (4.47 mm) 0.316 in. (8.026 mm) 0.07 in. (1.78 mm) 17 Manual Release 0.239 in. (6.07 mm) 0.379 in. (9.626 mm) 0.07 in. (1.78 mm) 18 Spool 0.239 in. (6.07 mm) 0.379 in. (9.626 mm) 0.07 in. (1.78 mm) 19 (3) Spool Housing 0.301 in. (7.645 mm) 0.441 in. (11.20 mm) 0.07 in. (1.78 mm) 20 Trim Limit Spool 0.114 in. (2.895 mm) 0.254 in. (6.451 mm) 0.07 in. (1.78 mm) 21 (2) Manifold 0.208 in. (5.283 mm) 0.348 in. (8.839 mm) 0.07 in. (1.78 mm) 22 Memory Piston 1.6 in. (40.64 mm) 2.02 in. (53.086 mm) 0.21 in. (5.334 mm) Page 5B-42 90-858895R1 JANUARY 2001 POWER TRIM Power Trim Reassembly IMPORTANT: Lubricate all O-rings with Quicksilver Power Trim Fluid (92-90100A12). If not available, use automotive (ATF) automatic transmission fluid. Shock Rod Reassembly 1. Install lubricated O-rings to end cap. 2. Install rod wiper. 3. Install lubricated O-rings to shock piston. 51199 f d e a b c 51145 a-Rod Wiper b-Inner O-ring c-Outer O-ring d-Shock Piston e-O-ring f-O-ring 4. Clamp shock rod in soft jawed vise. 5. Position cylinder end cap onto rod as shown. 51146 90-858895R1 JANUARY 2001 Page 5B-43 POWER TRIM CAUTION When installing shock rod piston, spanner wrench must have 1/4 in. x 5/16 in. (6.4mm x 8mm) long pegs to avoid damage to shock rod piston. 6. Apply Loctite Grade “A” (271) to threads on shock rod. 7. Install shock rod piston. 8. Tighten shock rod piston securely using spanner wrench (1/4 in. x 5/16 in. long pegs). If a torquing type spanner tool is used to tighten shock piston, then torque to specified torque. 51146 b a a-Shock Rod Piston b-Spanner Wrench Shock Piston Torque 90 lb-ft (122 Nm) Page 5B-44 90-858895R1 JANUARY 2001 POWER TRIM 9. Remove shock rod assembly from vise. 10. Install ball, seat, and spring (five sets) to shock rod piston. 11. Secure components with plate. Torque screws to specified torque. 51147 e d c a b a-Screw (3) b-Plate c-Spring (5) d-Seat (5) e-Ball (5) Screw Torque 35 lb-in. (4 Nm) Shock Rod Installation 1. Place trim cylinder in soft jawed vice. 2. Install lubricated O-ring to memory piston and place into cylinder. Push memory piston all the way to bottom. 3. Fill cylinder three inches (76.2 mm) from top of cylinder using Quicksilver Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. 4. Install shock rod into cylinder until power trim fluid flows through oil blow off ball passage. Fill remaining cylinder to just below the cylinder threads. c a b a-Memory Piston b-O-ring c-Oil Blow Off Ball Passage 90-858895R1 JANUARY 2001 Page 5B-45 POWER TRIM CAUTION End cap must not make contact with shock rod piston when tightening. Shock rod piston must be positioned in cylinder deep enough to avoid contact. 5. Tighten end cap securely using spanner wrench [1/4 in. x 5/16 in. (6.4 mm x 8 mm) long pegs]. If a torquing type spanner tool is used to tighten end cap, then torque to specified torque. End Cap Torque 45 lb-ft (61 Nm) Trim Limit Assembly Installation 1. Lubricate all O-rings. Install spring, poppet, spool housing and trim limit spool into manifold. NOTE:There are three different size springs used in this manifold. The heavy spring is used on 75-125 hp outboards. The medium spring is used on 40-60 hp Bigfoot outboards. The light spring is used on 30-60 hp outboards. 51008 or a b c d or a-Spring b-Poppet c-Spool Housing d-Trim Limit Spool Page 5B-46 90-858895R1 JANUARY 2001 POWER TRIM 90-858895R1 JANUARY 2001 Page 5B-47 Manual Release Valve Installation 1. Install “E” clip (if removed) and lubricate O-rings on manual release valve. 2. Install manual release valve assembly into manifold. a b c a - Manifold b - Manual Release Valve c - E Clip Manifold Installation 1. Install dowel pin and two (2) lubricated O-rings into trim cylinder. b a a - O-Ring (2) b - Dowel Pin POWER TRIM Page 5B-48 90-858895R1 JANUARY 2001 2. Align the trim cylinder and pump/reservoir assembly together. 3. Install the two (2) long screws and torque to specified torque. 51146 a b c a - Trim Cylinder Assembly b - Reservoir/Manifold Assembly c - Screw (2) Screw Torque 100 lb-in. (11 Nm) Oil Pump Installation 1. Install spring, ball, lubricated O-ring and plastic seat to manifold. 2. Check to see that O-rings are placed on bottom of pump. 3. Install filter and filter seal under pump. Install pump onto manifold. Torque screws to specified torque. b a a - Screw (3) b - Suction Seat Assembly POWER TRIM 90-858895R1 JANUARY 2001 Page 5B-49 Screw Torque 70 lb-in. (7.7 Nm) Pressure Operated Assembly Installation IMPORTANT: Inspect poppet assembly for debris in the area shown. If debris is found on poppet, replace poppet. a b a - Debris Under Valve Tip b - Rubber Seat 1. Lubricate O-rings. 2. Install spool, seat with O-ring, check valve/poppet, spring and plug with O-ring into pump. Repeat for other side. Torque plugs to 120 lb-in. (13.5 Nm). d b a c a b d e c a - Plug (2) Torque to 120 lb-in. (13.5 Nm) b - Spring (2) c - Check Valve/Poppet (2) d - Seat (2) e - Spool POWER TRIM Page 5B-50 90-858895R1 JANUARY 2001 Reservoir/Motor Installation 1. Install coupler into top of pump. Make sure reservoir seal is in the reservoir groove and place reservoir onto pump/manifold assembly. Install ground strap under screw shown. Torque screws to 80 lb-in. (9 Nm). a b c d f e a - Screw (4) Torque to 80 lb-in. (9 Nm) b - Reservoir c - Reservoir Seal d - Coupler e - Manifold Assembly f - Ground Strap 2. Fill reservoir to bottom of fill hole using Quicksilver Power Trim Fluid (92-90100A12). If not available, use automotive (ATF) automatic transmission fluid. POWER TRIM Bleeding Power Trim Unit 1. Secure power trim unit in soft jawed vise. 2. Add power trim fluid until it is even with the bottom of the fill hole. Reinstall plug. 3. Close the manual release valve. (Turn full clockwise). 55263 a b a-Reservoir Plug/Fill Hole b-Manual Release Valve 4. Cycle system full up and down 3 times or until fluid level remains at proper level. Connect power trim wire to 12 volt source. . Up Direction . Down Blue + Positive Blue – Negative Green – Negative Green + Positive 5. Recheck fluid level with rod fully extended, add fluid if required and repeat cycle until fluid level stays even with the bottom of the fill hole. 90-858895R1 JANUARY 2001 Page 5B-51 POWER TRIM Installation of Power Trim System 1. Apply 2-4-C w/Teflon (92-825407A12) to lower pivot pin bore and pivot pin surface. 2. Position trim cylinder assembly (BOTTOM FIRST) between clamp brackets and route trim pump electrical harness through access hole in starboard clamp bracket. 3. Start lower pivot pin into pivot pin bore and position lower cross pin (RETAINED) in its respective hole. 4. Using a suitable punch, drive lower pivot pin into clamp bracket and trim cylinder assembly until pivot pin is flush with outside surface. 53965 95 95 2-4-C w/Teflon (92-850736A1) ab c a-Trim Cylinder Assembly b-Lower Pivot Pin c-Lower Cross Pin 5. Using a suitable punch, drive lower cross pin into its respective bore until seated. 6. Install sacrificial aluminum anode to reservoir bracket placing ground strap to anode, as shown. 53967 a b c a-Lower Cross Pin b-Sacrificial Anode c-Ground Strap Page 5B-52 90-858895R1 JANUARY 2001 POWER TRIM 7. Apply 2-4-C w/Teflon (92-825407A12) to surface of upper pivot pin, pivot pin bore and trim ram bore. NOTE:Install trim ram with cross hole located as shown. If trim ram is installed reversed, the trim sender (if installed) will not operate. 95 95 2-4-C w/Teflon (92-850736A1) 95 a b c d e f a-Pivot Pin b-Trim Ram Bore c-Install Trim Ram As Shown d-Engine Side e-Transom Side f-Cross Hole 90-858895R1 JANUARY 2001 Page 5B-53 POWER TRIM 8. Using a suitable mallet, drive upper pivot pin into swivel bracket and through trim ram until pivot pin is flush with swivel bracket. 53966 a b c a-Pivot Pin b-Swivel Bracket c-Trim Ram 9. Drive upper retaining pin in until seated. a a-Retaining Pin 52941 Page 5B-54 90-858895R1 JANUARY 2001 POWER TRIM 10. Secure trim harness with clamps. 55264 a a-Clamps 11. Recheck fluid level. 12. Power trim may now be operated to lower outboard to desired position. Trim system is self purging. 13. Reconnect power trim leads to relays under ignition cover. 14. Reinstall spark plug leads to spark plugs. 15. Reinstall cowls. 16. Connect battery leads to battery terminals. 90-858895R1 JANUARY 2001 Page 5B-55 GEAR HOUSING LOWER UNIT Section 6 - Gear Housing Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Quicksilver Lubricants and Service Aids . . . . 6-5 Gear Housing (Drive Shaft) (2.07:1 Gear Ratio) . . . . . . . . . . . . . . . . . . . . . . 6-6 Gear Housing (Propshaft) (2.07:1 Gear Ratio) . . . . . . . . . . . . . . . . . . . . . . 6-8 General Service Recommendations . . . . . . . 6-10 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Draining and Inspecting Gear Lubricant . . . . 6-11 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Bearing Carrier and Propeller Shaft . . . . . 6-16 Pinion Gear/Drive/Shaft/Forward Gear . . 6-21 Drive Shaft Upper Bearing . . . . . . . . . . . . . 6-24 Oil Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 Drive Shaft Lower Bearing Race . . . . . . . . 6-26 Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27 Forward Gear Bearing Race . . . . . . . . . . . 6-29 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30 Specifications Forward Gear Bearing Race . . . . . . . . . . . 6-30 Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30 Bearing Carrier Reassembly . . . . . . . . . . . 6-33 Forward Gear Reassembly . . . . . . . . . . . . 6-37 Propeller Shaft Reassembly . . . . . . . . . . . 6-39 Drive Shaft Wear Sleeve Installation . . . . 6-40 Drive Shaft Lower Bearing Race Installation . . . . . . . . . . . . . . . . . . . . . 6-42 Oil Sleeve Installation . . . . . . . . . . . . . . . . . 6-43 Drive Shaft Upper Bearing Installation . . . 6-43 Forward Gear, Drive Shaft Lower Bearing, Pinion Gear, and Drive Shaft Installation . 6-45 Pinion Gear Depth and Forward Gear Backlash . . . . . . . . . . . . . . . 6-46 Bearing Carrier and Propeller Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51 Water Pump Reassembly/Installation . . . 6-53 Gear Housing Pressure Test . . . . . . . . . . . 6-57 Filling Gear Housing With Lubricant . . . . . . . 6-58 Gearcase Installation . . . . . . . . . . . . . . . . . . . . 6-59 Trim Tab Adjustment/Replacement . . . . . 6-63 6 GEAR HOUSING BIGFOOT (2.07:1) Gear Ratio Gearcase Capacity Lubricant Type Forward Gear Number of Teeth Pinion Gear Number of Teeth Pinion Height Pinion Gear Locating Tool Flat Number Disc Number Forward Gear Backlash Backlash Indicating Tool Mark Number Water Pressure @ 1000 rpm @ 6000 rpm (WOT) Leak Test Pressure 2.07:1 24.0 fl oz (710 mL) Quicksilver Gear Lube-Premium Blend 29 Spiral/Bevel 14 Spiral/Bevel 0.025 in. (0.64 mm) 91-12349A2 #2 #3 0.015 - 0.022 in. (0.38 - 0.55 mm) 91-19660--1 #1 5 psi (34.5 kPa) 20.5 psi (141.5 kPa) 10-12 psi (69-83 kPa) for 5 Minutes 90-858895R1 JANUARY 2001 Page 6-1 GEAR HOUSING Special Tools 1. Pinion Gear Locating Tool (91-12349A2) 55079 Disc 3 Disc1 Disc 2 2. Bearing Installation Tool (91-13945) 3. Oil Seal Driver (91-13949) 4. Bearing Race Tool (91-14308A1) 5. Bearing Installation (91-14309A1) 6. Wear Sleeve Installation Tool (91-14310A1) Page 6-2 90-858895R1 JANUARY 2001 GEAR HOUSING 7. Bearing Preload Tool (91-14311A2) 8. Mandrel (91-15755)* 73815 9. Backlash Indicator Tool (91-19660--1) 2.07:1 Gear Ratio (14/29) 19660-1 10. Mandrel (91-31106) 11. Oil Seal Driver (91-31108) 12. Treaded Rod (91-31229) and Nut (91-24156)* 13. Slide Hammer (91-34569A1) 90-858895R1 JANUARY 2001 Page 6-3 GEAR HOUSING 14. Mandrel (91-36569)* 15. Universal Puller Plate (91-37241) 73652 16. Driver Rod (91-37323)* 74184 17. Mandrel (91-37350) 18. Puller Jaws (91-46086A1) 19. Driver Shaft Holding Tool (91-56775, 2-Stroke), (91-817070, 40/50 4-Stroke), (91-817070A1, 50/60 4- Stroke), (91-804776A1, 75/90 4-Stroke) 20. Dial Indicator (91-58222A1) Page 6-4 90-858895R1 JANUARY 2001 GEAR HOUSING 21. Backlash Indicator Tool (91-78473) 2.31:1 Gear Ratio (13/30) 22. Puller Bolt (91-85716) 23. Dial Indicator Adaptor Kit (91-83155) 24. Bearing Puller Assembly (91-83165M) 25. Bearing Installation Tool (91-856875A1) 56783 26. Bearing Installation Tool (91-877321A1) * From Bearing Removal and Installation Kit (91-31229A7) Quicksilver Lubricants and Service Aids Part No. Description 92-809820 Loctite “271” 92-90113--2 RTV Silicone Sealer 92-850737A1 Premium Blend Gear Lube 92-850735A1 Anti-Corrosion Grease 92-850736A1 2-4-C w/Teflon 90-858895R1 JANUARY 2001 Page 6-5 GEAR HOUSING GEAR HOUSING (DRIVE SHAFT)(2.31:1 GEAR RATIO) 7 95 7 95 87 7 7 95 95 7 7 4.25 IN./107.95MM TORPEDO DIA. BIGFOOT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 12 5 5 4 18 4 7 95 95 95 7 Loctite 271 (92-809820) 87 Premium Gear Lubricant (92-850737A1) 95 2-4-C With Teflon (92-850736A1) Page 6-6 90-858895R1 JANUARY 2001 GEAR HOUSING GEAR HOUSING (DRIVE SHAFT)(2.31:1 GEAR RATIO) REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in lb-ft Nm. – 1 GEAR HOUSING 1 1 GEAR HOUSING ASSEMBLY 2 1 DOWEL PIN (FRONT) 3 1 OILER TUBE 4 3 DRAIN SCREW 60 6.8 5 3 WASHER-Sealing 6 1 DOWEL PIN (REAR) 7 1 TRIM TAB 8 1 SCREW (.437-14 x 1.25) 22 29.8 9 1 WASHER 10 1 CARRIER 11 1 NEEDLE BEARING 12 2 ANODE 13 1 NUT 14 1 SCREW (M6 x 40) 60 6.8 15 1 PINION GEAR (13 TEETH) 16 1 NUT 70 95 17 1 SHIFT CAM 18 1 TAPERED ROLLER BEARING 19 AR SHIM ASSEMBLY (SIZES 006 THRU 048) 20 1 DRIVE SHAFT ASSEMBLY 21 1 WEAR SLEEVE ASSEMBLY 22 1 RING SEAL 23 1 COVER ASSEMBLY 24 1 GASKET 25 1 GASKET 26 1 OIL SEAL (LOWER) 27 1 OIL SEAL (UPPER) 28 1 GASKET 29 1 WATER PUMP ASSEMBLY 30 1 FACE PLATE 31 4 SCREW (M6x30) 60 6.8 32 1 SEAL 33 1 KEY 34 1 IMPELLER 35 6 SCREW 60 6.8 36 1 SHIFT SHAFT ASSEMBLY 37 1 E-RING 38 1 BUSHING ASSEMBLY 39 1 O-RING 40 1 OIL SEAL 41 2 SCREW (M6 x 1) 60 6.8 90-858895R1 JANUARY 2001 Page 6-7 GEAR HOUSING GEAR HOUSING (PROP SHAFT)(2.31:1 GEAR RATIO) 4.25 IN./107.95MM TORPEDO DIA. BIGFOOT50 4947 48 70 44 691 45 46 42 43 67 68 68 75 74 57 55 54 53 52 51 72 73 71 60 59 58 66 64 65 56 61 63 95 95 87 95 7 95 77 95 95 95 87 7 87 95 Loctite 271 (92-809820) Premium Gear Lubricant (92-850737A1) 2-4-C With Teflon (92-850736A1) Page 6-8 90-858895R1 JANUARY 2001 GEAR HOUSING GEAR HOUSING (PROP SHAFT)(2.31:1 GEAR RATIO) REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in lb-ft Nm. 1 1 GEAR HOUSING ASSEMBLY 42 1 TAPERED ROLLER BEARING ASSEMBLY 43 1 CUP 44 1 FORWARD GEAR (30 TEETH) 45 1 ROLLER BEARING 46 1 RETAINING RING 47 1 CAM FOLLOWER ASSEMBLY 48 3 BALL 49 1 SLIDE 50 1 SPRING 51 1 CLUTCH 52 1 CROSS PIN 53 1 SPRING 54 1 PROPELLER SHAFT 55 1 REVERSE GEAR (30 TEETH) 56 1 BEARING CARRIER ASSEMBLY 57 1 O-RING 58 1 ROLLER BEARING 59 1 OIL SEAL (INNER) 60 1 OIL SEAL (OUTER) 61 1 ROLLER BEARING 62 1 THRUST WASHER 63 1 THRUST BEARING 64 2 STUD 100 135 65 2 WASHER 66 2 NUT 22 29.8 67 AR SHIM ASSEMBLY (SIZES 006 THRU 038) 68 2 THREAD INSERT 69 1 DECAL 70 1 DECAL-PROP OPERATION 71 1 THRUST HUB ASSEMBLY PROPELLER NUT ASSEMBLY SERVICE ITEMS TAB WASHER 72 1 73 1 74 4 SCREW 40 54.2 75 4 WASHER 90-858895R1 JANUARY 2001 Page 6-9 GEAR HOUSING General Service Recommendations There may be more than one way to “disassemble” or “reassemble” a particular part(s), therefore, it is recommended that the entire procedure be read prior to repair. IMPORTANT: Read the following before attempting any repairs. In many cases, disassembly of a sub-assembly may not be necessary until cleaning and inspection reveals that disassembly is required for replacement of one or more components. Service procedure order in this section is a normal disassembly-reassembly sequence. Threaded parts are right hand (RH), unless otherwise indicated. When holding, pressing or driving is required, use soft metal vise jaw protectors or wood for protection of parts. Use a suitable mandrel (one that will contact only the bearing race) when pressing or driving bearings. When compressed air is used to dry a part, verify that no water is present in air line. Bearings All bearings must be cleaned and inspected. Clean bearings with solvent and dry with compressed air. Air should be directed at the bearing so that it passes through the bearing. DO NOT spin bearing with compressed air, as this may cause bearing to score from lack of lubrication. After cleaning, lubricate bearings with Premium Blend Gear Lubricant. DO NOT lubricate tapered bearing cups until after inspection. Inspect ball bearings for roughness, catches and bearing race side wear. Work inner bearing race in-and-out, while holding outer race, to check for side wear. When inspecting tapered bearings, determine condition of rollers and inner bearing race by inspecting bearing cup for pitting, scoring, grooves, uneven wear, imbedded particles and/or discoloration from over-heating. Always replace tapered bearing and race as a set. Inspect gear housing for bearing races that have spun in their respective bores. If race(s) have spun, gear housing must be replaced. Roller bearing condition is determined by inspecting the surface of the shaft that the roller bearing supports. Check shaft surface for pitting, scoring, grooving, imbedded particles, uneven wear and/or discoloration from overheating. The shaft and bearing must be replaced if such a condition exists. Seals As a normal procedure, all O-rings and oil seals should be replaced without regard to appearance. To prevent leakage around seals, apply Loctite 271 to outer diameter of all metal case seals. When using Loctite on seals or threads, surfaces must be clean and dry. Apply 2-4-C w/Teflon on all O-rings and on I.D. of oil seals. Apply 2-4-C w/Teflon to external surfaces of bearing carrier. Page 6-10 90-858895R1 JANUARY 2001 GEAR HOUSING Draining and Inspecting Gear Lubricant WARNING If gear housing is installed on engine, to avoid accidental starting, disconnect (and isolate) spark plug leads from spark plugs before working near the propeller. 1. With gear housing in normal running position, place a clean pan under housing and remove the two vent screws and one fill/drain screw (with gaskets). 53922 a bc a-Fill/Drain Screw b-Oil Level Screw c-Vent Screw 2. Inspect gear lubricant for metal particles (lubricant will have a “metal flake” appearance). Drain lube into a clean pan/container. Presence of fine metal particles (resembling powder) in the gear lube indicates normal wear. The presence of metal chips in the gear lube indicates the need for gear housing disassembly and component inspection. 3. Note color of gear lubricant. White or cream color MAY indicate presence of water in lubricant. Gear lubricant which has been drained from a gear case recently in operation will have a yellowish color due to lubricant agitation/aeration. Gear lube which is mixed with assembly lubricant (Special Lube 101 or 2-4-C w/Teflon) will also be creamy white in color. This is normal and should not be confused with the presence of water. If water is suspected to be present in gearcase, a pressure check of gearcase should be made (with no lubricant in gearcase). Gearcase should hold 10 to 12 psi of pressure for 5 minutes without leaking down. Pouring a portion of the gear lubricant into a glass jar and allowing the lubricant to settle will allow any water in the lube to separate and settle to the bottom of the jar. 4. Presence of water in gear lubricant indicates the need for disassembly and inspection of oil seals, seal surfaces, O-rings, water pump gaskets as well as gear housing components for damage. If gearcase is rebuilt, gearcase should be pressure checked before filling with lubricant. 90-858895R1 JANUARY 2001 Page 6-11 GEAR HOUSING Removal WARNING To prevent accidental engine starting, remove (and isolate) spark plug leads from spark plugs before removing gear housing. IMPORTANT: 90 hp (4-Stroke) models, when removing or installing gearcase carefully guide driveshaft through drive shaft bushing to avoid scoring bushing surface. 1. Remove (and isolate) spark plug leads from spark plugs. 2. Shift engine into forward gear. 3. Tilt engine to full “Up” position. 4. Remove 4 fasteners. 5. Remove locknut and washer. 6. Remove gear housing. 53992 b a a-Fasteners (2 Each Side) b-Locknut and Washer Page 6-12 90-858895R1 JANUARY 2001 GEAR HOUSING Disassembly Water Pump NOTE:If water tube seal stayed on water tube (inside of drive shaft housing) when gear housing was removed, pull water tube seal from water tube. NOTE:Newer models will not have the isolators installed on the water pump. 1. Replace water tube seal, if damaged. 2. Remove 4 screws (2 on each side of water pump housing), washers, and isolators. 3. Remove cover. 19212 a b c a-Water Tube Seal b-Screw, Washer, Isolator (4 each) c-Cover IMPORTANT: The circular groove formed by the impeller sealing bead should be disregarded when inspecting cover (Step 4) and plate (Step 8), as the depth of the groove will not affect water pump output. 4. Replace cover if thickness of steel at the discharge slots is 0.060 in. or less, or if groove(s) (other than impeller sealing bead groove) in cover roof are more than 0.030 in. (0.762 mm) deep. 5. Lift impeller, drive key, and gasket from drive shaft. a bc 19220 a-Impeller b-Drive Key c-Gasket 90-858895R1 JANUARY 2001 Page 6-13 GEAR HOUSING 6. Inspect impeller. Replace impeller if any of the following conditions exist: • Impeller blade(s) are cracked, torn, or worn. • Impeller is glazed or melted (caused by operation without sufficient water supply). • Rubber portion of impeller is not bonded to impeller hub. 7. Remove plate and gasket. 8. Replace plate if groove(s) (other than impeller sealing bead groove) in plate are more than 0.030 in. (0.762 mm) deep. 19219 a b c a-Plate b-Gasket c-Impeller Sealing Groove 9. Remove screws and washers. a 19217 a-Screws and Washers (6 each) Page 6-14 90-858895R1 JANUARY 2001 GEAR HOUSING 10. Remove water pump base using flat screwdrivers to lightly pry up on base. 19226 a a-Water Pump Base 11. Remove (and discard) seals (IT MAY BE BENEFICIAL TO CLAMP THE WATER PUMP BASE IN A VISE WHILE REMOVING SEALS). 19195 a a-Seals 12. Remove gasket. 19218 a a-Gasket 90-858895R1 JANUARY 2001 Page 6-15 GEAR HOUSING Bearing Carrier and Propeller Shaft 1. Remove fasteners. 51117 a a a-Fasteners 2. With propeller shaft horizontal, pull carrier (using tool shown) to break seal with gear housing. 3. Remove bearing carrier/propeller shaft components as an assembly by pulling back on the propshaft. Take care not to lose cam follower or 3 metal balls in end of propeller shaft. 4. Remove propeller shaft from bearing carrier. a b c d e a-Bearing Carrier b-Puller Jaws (91-46086A1) c-Puller Bolt (91-85716) d-Thrust Hub e-Propeller Shaft 51116 Page 6-16 90-858895R1 JANUARY 2001 GEAR HOUSING 5. Lift reverse gear, thrust bearing and thrust washer from bearing carrier. Replace thrust bearing and thrust washer if rusted or damaged. 6. Replace reverse gear if gear teeth or clutch teeth on reverse gear are rounded or chipped. If reverse gear must be replaced, pinion gear and sliding clutch should be inspected for damage. 19202 a b c a-Reverse Gear b-Thrust Bearing c-Thrust Washer 7. If reverse gear radial bearing is rusted or does not roll freely, replace bearing. If the bearing needs to be replaced remove it using Slide Hammer (91-34569A1). 91-34569A1 a 19205 a-Radial Bearing 90-858895R1 JANUARY 2001 Page 6-17 GEAR HOUSING 8. If bearing is rusted or does not roll freely, replace bearing. If replacement is necessary, remove bearing and oil seals using Mandrel* (91-36569) and Driver Rod* (91-37323). Discard oil seals. NOTE:*From Bearing Removal and Installation Kit (91-31229A7). a b c 91-37323 91-36569 58205 a-Bearing b-Mandrel (91-36569) c-Driver Rod (91-37323) 9. Remove propeller shaft seals (if not removed with bearing in Step 9) and bearing carrier O-ring. 51263 a a-O-ring Page 6-18 90-858895R1 JANUARY 2001 GEAR HOUSING 10. Remove spring. 51876 a a-Spring 11. Apply constant pressure to cam follower in order to prevent it and internal components from ejecting out of the propeller shaft during removal of the cross pin from the clutch. 51800 a b a-Cross Pin b-Cam Follower 90-858895R1 JANUARY 2001 Page 6-19 GEAR HOUSING 12. Remove components from propeller shaft. 13. Replace cam follower if worn or pitted. 14. Replace sliding clutch if jaws are rounded or chipped. Rounded jaws indicate one or more of the following: • Improper shift cable adjustment. • Engine idle speed too high while shifting. • Shifting from neutral to reverse (or forward) too slowly. 51265 a b c de f a-Cam Follower b-Metal Balls (3) c-Guide Block d-Spring e-Sliding Clutch f-Jaws 15. Replace propeller shaft if any of the following exist: • Splines are twisted or worn. • Bearing surfaces of propeller shaft are pitted or worn. • Oil seal surface is grooved. • Shaft has a noticeable “wobble” or is bent more than 0.009 in. (0.228 mm). Prop shaft trueness should be measured with a dial indicator with prop shaft on V-blocks. a bc b 51877 a-V-Blocks b-Bearing Surfaces c-Measure with Dial Indicator at This Point Page 6-20 90-858895R1 JANUARY 2001 GEAR HOUSING Pinion Gear, Drive Shaft, and Forward Gear 1. Hold drive shaft using Drive Shaft Holding Tool; remove (and discard) pinion nut. Model Drive Shaft Holding Tool 40/50 Bigfoot (4-Stroke) 91-56775 50/60 Bigfoot (4-Stroke) 91-817070A1 75/90/115 EFI (4-Stroke) 91-804776A1 60 Bigfoot (2-Stroke) 91-56775 75/90/100/115/125 (2-Stroke) 91-56775 2. Remove drive shaft, pinion gear, pinion bearing and forward gear. 3. Replace pinion gear if it is chipped or worn. 4. Replace pinion bearing and race if either are rusted, pitted or damaged; or if bearing does not roll freely. To remove race, refer to “Lower Drive Shaft Bearing Race,” following. 5. Replace forward gear if gear teeth or clutch teeth are chipped or worn. 19175 a b c d e f a-Drive Shaft Holding Tool b-Pinion Nut c-Drive Shaft d-Pinion Gear e-Pinion Bearing f-Forward Gear 90-858895R1 JANUARY 2001 Page 6-21 GEAR HOUSING Page 6-22 90-858895R1 JANUARY 2001 6. Replace forward gear needle bearing if it is rusted or does not roll freely. 7. Use suitable tools (screwdriver and awl) to remove retaining ring. Use a punch and hammer to remove bearing. 57905 19203 a b a - Retaining RIng b - Forward Gear Needle Bearing 8. Replace forward gear bearing and race if either are rusted, pitted or damaged, or if bearing does not roll freely. Remove bearing from gear using Universal Puller Plate (91-37241) and mandrel. To remove race, refer to “Forward Gear Bearing Race,” following. 51119 a b c 91-37241 a - Forward Gear Bearing b - Universal Puller Plate (91-37241) c - Mandrel GEAR HOUSING 9. Replace drive shaft if splines are worn or twisted. 10. If bearing surface is damaged, replace drive shaft and corresponding bearing. IMPORTANT: Do not tighten vise against drive shaft. 11. If wear sleeve is deeply grooved allowing water to enter gear case, remove (and discard) sleeve using Universal Puller Plate (91-37241) and mallet. 19710 c d f a 91-37241 e a b 75/90/115 4-stroke a-Crankshaft/Driveshaft Splines b-Oil Pump Drive Splines 75/90 4-Stroke Only c-Bearing Surface d-Wear Sleeve e-Universal Puller Plate (91-37241) f-Mallet 12. Remove (and discard) rubber ring. 19152 a a-Rubber Ring 90-858895R1 JANUARY 2001 Page 6-23 GEAR HOUSING Upper Drive Shaft Bearing 1. Replace upper drive shaft bearing and sleeve if either are rust stained, or if bearing will not roll freely. Remove bearing and then sleeve using Puller Assembly (91-83165M) with suitable jaws. 19177 OR a b 91-83165M c a-Upper Drive Shaft Bearing b-Sleeve c-Puller Assembly (91-83165M) IMPORTANT: Upper drive shaft bearing/sleeve must be removed prior to oil sleeve removal. Refer to “Upper Drive Shaft Bearing,” preceding. Page 6-24 90-858895R1 JANUARY 2001 GEAR HOUSING Oil Sleeve 1. Remove oil sleeve (if necessary) using Puller Assembly (91-83165M) with suitable jaws. 19222 a 91-83165M b a-Oil Sleeve b-Puller Assembly (91-83165M) 90-858895R1 JANUARY 2001 Page 6-25 GEAR HOUSING Lower Drive Shaft Bearing Race IMPORTANT: Upper drive shaft bearing/sleeve and oil sleeve do not have to be removed for lower drive shaft bearing race removal. IMPORTANT: Retain shim(s) for reassembly. 1. Remove bearing race and shim(s) using bearing race tool (91-14308A1). 19171 a b c 91-14308A1 a-Bearing Race b-Shim(s) c-Bearing Race Tool (91-14308A1) Page 6-26 90-858895R1 JANUARY 2001 GEAR HOUSING Shift Shaft 1. Remove shift shaft coupler and nylon spacer. 53925 a b 75 (2-Stroke) Tiller Model Shown a-Shift Shaft Coupler b-Spacer 2. Remove bolts. 53926 a a-Bolts NOTE:Remove rough edges from shift shaft splines before removing shift shaft bushing. 3. Remove shift shaft bushing and shift shaft. 53927 a b a-Bushing b-Shift Shaft 90-858895R1 JANUARY 2001 Page 6-27 GEAR HOUSING 4. Remove shift cam from housing. 5. Replace shift cam if worn. 51117 a 60 (2-Stroke) Bigfoot Shown a-Shift Cam 6. Remove shift shaft bushing and clip from shift shaft. 7. Replace shift shaft if splines are worn or shaft is twisted. 8. Remove (and discard) O-ring. 53928 a b c ded a-Bushing b-Clip c-Shift Shaft d-Splines e-O-ring 9. Remove (and discard) seal. (Lightly clamp the bushing in a vise when removing seal.) 53929 a a-Seal Page 6-28 90-858895R1 JANUARY 2001 GEAR HOUSING Forward Gear Bearing Race IMPORTANT: Retain shim(s) for reassembly. If shims are damaged, replace with new shims of equal thickness. 1. Remove race and shim(s) using Slide Hammer (91-34569A1). 27653 a b c 91-34569A1 a-Race b-Shim(s) c-Slide Hammer (91-34569A1) 90-858895R1 JANUARY 2001 Page 6-29 GEAR HOUSING Reassembly Forward Gear Bearing Race NOTE:Propshaft should be vertical when installing bearing race. 1. Place shim(s) (retained from disassembly) into housing. If shim(s) were lost, or a new gear housing is being assembled, start with 0.010 in. (0.254 mm) shim(s). 2. Assemble components as shown using mandrel (91-31106). Apply 2-4-C w/Teflon to O.D. of race. Drive race into housing by striking propeller shaft end with lead hammer. NOTE:Install a nut on the end of the propshaft to prevent damage to the propshaft threads while performing step 2. 19179 b de a c 91-31106 95 2-4-C w/Teflon (92-850736A1) 95 a-Shim(s) d-Disassembled Propeller Shaft b-Race e-Assembled Bearing Carrier c-Mandrel (91-31106) Shift Shaft 1. Apply Loctite 271 on O.D. of new seal. 2. Press seal into shift shaft bushing until seal is seated against shoulder. 3. Install new O-ring. 4. Apply 2-4-C with Teflon on O-ring and I.D. of seal. 53930 b c d 7 Loctite “271” (92-809820) 7 95 2-4-C w/Teflon (92-850736A1) 95 a a-Seal c-Surface b-Bushing d-O-ring Page 6-30 90-858895R1 JANUARY 2001 GEAR HOUSING 90-858895R1 JANUARY 2001 Page 6-31 5. Assemble components as shown. 53928 a b c a - Shift Shaft b - “E” Clip c - Shift Shaft Bushing 6. Install shift cam; align hole in shift cam with shift shaft pilot bore in gear housing. 60 Bigfoot, 75/90/100/115/125 (2-Stroke) 51117 a b a - Shift Cam (marked with “UP” and part number) b - Shift Shaft Pilot Bore 60 Bigfoot, 75/90/100/115/125 (2-Stroke) & 75/90/115EFI (4-Stroke) 51117 a b a - Shift Cam (marked with part number only) b - Shift Shaft Pilot Bore GEAR HOUSING 40/50 Bigfoot (4-Stroke), 50/60 Bigfoot(4-Stroke) 51117 850307 a b a-Shift Cam (Numbers Down) b-Shift Shaft Pilot Bore 7. Install shift shaft assembly; insert splines into shift cam. 53932 a b a-Shift Shaft Assembly b-Splines 8. Apply Loctite 271 to bottom half of threads on each screw. Install screws and tighten to specified torque. 53926 a 7 7 Loctite “271” (92-809820) a-Screw (2) Screw Torque 60 lb-in. (6.8 Nm) Page 6-32 90-858895R1 JANUARY 2001 GEAR HOUSING Bearing Carrier Reassembly 1. Lubricate O.D. of bearing and bearing carrier bore with Quicksilver 2-4-C w/Teflon. 2. Protect lip on forward side of bearing carrier, using bearing installation tool (91-13945). 3. Press propeller shaft needle bearing (number side toward mandrel 91-15755) into carrier, until bearing bottoms out. 95 21042 a b c 2-4-C w/Teflon (92-850736A1) 95 91-13945 91-15755 a-Bearing Installation Tool (91-13945) b-Mandrel (91-15755) c-Suitable Driver Rod 90-858895R1 JANUARY 2001 Page 6-33 GEAR HOUSING 4. Place smaller diameter seal on longer shoulder of Oil Seal Driver (91-31108) with seal lip away from shoulder. 5. Protect lip on front side of bearing carrier using Bearing Installation Tool (91-13945). Apply Loctite 271 on O.D. of seal. Press seal into carrier until tool bottoms. 21040 a b c 7 Loctite “271” (92-809820) 7 91-31108 91-13945 a-Seal b-Oil Seal Driver (91-31108) c-Bearing Installation Tool (91-13945) 6. Place larger diameter seal on shorter shoulder of Oil Seal Driver (91-31108) with seal lip toward shoulder. 7. Protect lip on front side of bearing carrier using Bearing Installation Tool (91-13945). Apply Loctite 271 on O.D. of new seal. Press seal into carrier until tool bottoms. 21041 a b c 91-31108 91-13945 7 Loctite “271” (92-809820) 77 a-Seal b-Oil Seal Driver (91-31108) c-Bearing Installation Tool (91-13945) Page 6-34 90-858895R1 JANUARY 2001 GEAR HOUSING 8. Install O-ring. Lubricate O-ring with 2-4-C w/Teflon. Lubricate seal lips with 2-4-C w/Teflon. 9. Lubricate outside diameter of reverse gear bearing and bearing carrier bore with a light coating of 2-4-C w/Teflon. 10. Press bearing into carrier until tool bottoms. 19163 a b c 95 95 91-13945 2-4-C w/Teflon (92-850736A1) a-O-ring b-Bearing, Numbered Side Toward Tool c-Bearing Installation Tool (91-13945) 11. Install thrust washer. Coat thrust washer with Premium Blend Gear Lubricant. 19167 a 87 Premium Blend Gear Lubricant (92-850737A1) 87 a-Thrust Washer 90-858895R1 JANUARY 2001 Page 6-35 GEAR HOUSING 12. Install thrust bearing. Coat thrust bearing with Premium Blend Gear Lubricant. 87 a 19168 87 Premium Blend Gear Lubricant (92-850737A1) a-Thrust Bearing 13. Apply Premium Blend Gear Lubricant to bearing surface of reverse gear and install reverse gear. 19202 a 87 87 b Premium Blend Gear Lubricant (92-850737A1) a-Reverse Gear b-Bearing Surface Page 6-36 90-858895R1 JANUARY 2001 GEAR HOUSING Forward Gear Reassembly 1. Apply Quicksilver 2-4-C w/Teflon grease to the I.D. of the bearing. Press bearing onto gear using suitable mandrel (press only on inner race of bearing). Because the gear hub is longer than the bearing, a tube type mandrel should be used to install the bearing. This will allow the bearing to bottom out on the gear. 51869 a b 95 2-4-C w/Teflon (92-850736A1) 95 a-Mandrel (91-37350) b-Bearing; Lubricate I.D. with Quicksilver 2-4-C w/Teflon 2. Inspect reverse gear end of clutch to determine the number of jaws. Refer to chart, following, for tool end selection. Model Installation End Bearing Position Tool Stamped 3 Jaw Reverse 91-856875A 1 3 0.155 in. (3.94mm) Clutch below surface 6 Jaw Reverse Clutch 91-856875A 1 6 Flush with surface FORWARD GEAR NEEDLE BEARING INSTALLATION 3 Jaw Reverse Clutch c a b a-Stamped “3” b-Numbered end of Needle Bearing c-3 Jaw Reverse Clutch 90-858895R1 JANUARY 2001 Page 6-37 GEAR HOUSING 6 Jaw Reverse Clutch 56784 c a b a b87 91-877321A1 a-Stamped “6” b-Numbered end of Needle Bearing c-6 Jaw Reverse Clutch 3. Apply Premium Blend Gear Lubricant to I.D. of forward gear, and O.D. of needle bearing. Press needle bearing into forward gear (using forward gear bearing installer tool) until tool bottoms out on gear. 87 Premium Blend Gear Lubricant (92-850737A1) a-Forward Gear Bearing Installer (91-877321A1) b-Needle Bearing, Numbered Side Toward Installer Tool 4. Install retaining ring into groove of forward gear by starting at one end of retaining ring and working it around until seated in groove. 57905 a b a-Retaining Ring b-Groove in Forward Gear Page 6-38 90-858895R1 JANUARY 2001 GEAR HOUSING Propeller Shaft Reassembly 1. Install components into propeller shaft in sequence shown. NOTE:When installing the clutch make sure the ratcheting clutch teeth (angled) are toward forward gear, and non-ratcheting (square on both sides) are toward reverse gear. 51265a b cd e gf Assembly Sequence a-Spring b-Guide Block c-Clutch d-3 Metal Balls e-Cam Follower f-Forward Clutch Teeth g-Reverse Clutch Teeth 2. Align the hole in the clutch with the hole in the guide block, install cross pin. a b 51800 a-Apply Pressure in This Direction b-Cross Pin 90-858895R1 JANUARY 2001 Page 6-39 GEAR HOUSING 3. Install spring. DO NOT allow spring coils to overlap each other. 51876 a a-Spring Drive Shaft Wear Sleeve Installation 1. Install new rubber ring. 2. Apply a light coat of Loctite 271 on outside diameter of rubber ring. a 7 Loctite “271” (92-809820) a-Ring 3. Insert sleeve into holder*. *Component of Wear Sleeve Installation Tool (91-14310A1). 19169 a b a 91-14310A1 19152 a-Sleeve b-Holder Page 6-40 90-858895R1 JANUARY 2001 GEAR HOUSING 4. Press sleeve onto drive shaft using Wear Sleeve Installation Tool (91-14310A1); continue pressing until the upper and lower part of the tool make surface to surface contact. 19166 a b b 91-14310A1 c d a-Drive Shaftb-Wear Sleeve Installation Tool (91-14310A1) c-Upper part of tool (Surface C) d-Lower part of tool (Surface D) 5. Remove excess Loctite from assembled shaft. 90-858895R1 JANUARY 2001 Page 6-41 GEAR HOUSING Lower Drive Shaft Bearing Race Installation 1. Lubricate O.D. of bearing race with Quicksilver 2-4-C w/Teflon. 2. Install shim(s) and bearing race into housing. If Shim(s) were lost or a new gear housing is being assembled, start with 0.025 in. (0.635 mm) shim(s). NOTE:Verify shim(s) are not cocked when drawing up race. Once shims and bearing cup are in place, position gearcase assembly so the driveshaft is vertical. This will aid in preventing the bearing cup from becoming cocked in the bore. a b c d f 95 2-4-C w/Teflon (92-850736A1) 95 91-14309A1 f d c e 58207 a-Shim(s) (Retained From Disassembly) b-Bearing Race c-Mandrel* (13780) d-Mandrel* (13781) e-Threaded Rod** (91-31229) f-Nut** (11-24156) *From Bearing Installation Tool (91-14309A1) **From Bearing Removal and Installation Kit (91-31229A7) Page 6-42 90-858895R1 JANUARY 2001 GEAR HOUSING Oil Sleeve Installation 1. Install oil sleeve with tab positioned as shown. 53934 a b a-Oil Sleeve b-Tab Drive Shaft Upper Bearing Installation 1. Lubricate I.D. of bearing sleeve and O.D. of bearing with 2-4-C w/Teflon. 2. Press bearing into sleeve using mandrel from bearing installation tool (91-14309A1). 19164 a b c d 95 2-4-C w/Teflon (92-850736A1) 91-1378195 a-Bearing Sleeve b-Tapered End c-Bearing; Numbered Side Toward Mandrel d-Mandrel* (91-13781) *From Bearing Installation Tool (91-14309A1) 90-858895R1 JANUARY 2001 Page 6-43 GEAR HOUSING 3. Install bearing/sleeve into housing. IMPORTANT: Oil sleeve must be installed prior to upper driveshaft bearing installation. IMPORTANT: Lower driveshaft bearing cup pilots the mandrel (13780) during installation of the upper driveshaft bearing/sleeve. Lower bearing cup must be installed prior to installing upper bearing/sleeve. 91-14309A1 a c b d e e f 58206 a-Bearing/Sleeve b-Tapered End Of Sleeve c-Mandrel* (13781) d-Mandrel* (13780) e-Threaded Rod** (91-31229) f-Nut** (11-24156) *From Bearing Installation Tool (91-14309A1) **From Bearing Removal and Installation Kit (91-31229A7) Page 6-44 90-858895R1 JANUARY 2001 GEAR HOUSING Forward Gear, Drive Shaft Lower Bearing, Pinion Gear, and Drive Shaft Installation 1. Install components per assembly sequence shown. 19175 a b c d e f d 87 Premium Gear Lubricant (92-850737A1) 7 Loctite “271” (92-809820) 7 87 Assembly Sequence: a-Forward Gear/Bearing: Work Premium Blend gear lube into bearing rollers. b-Lower Drive Shaft Tapered Roller Bearing: Work Premium Blend Gear Lube into bearing rollers. c-Pinion Gear d-Drive Shaft e-Drive Shaft Holding Tool f-Pinion Nut (New): Clean nut and driveshaft threads with Loctite Primer or suitable de-greaser. Apply Loctite 271 to threads (not necessary if using a new nut with drylock patch on threads) during final assembly (after pinion gear depth and forward gear backlash have been set), tighten to specified torque. Model Drive Shaft Holding Tool 40/50 Bigfoot (4-Stroke) 91-56775 50/60 Bigfoot (4-Stroke) 91-817070A1 75/90/115EFI (4-Stroke) 91-804776A1 60 Bigfoot/75/90/100/115/125 (2-Stroke) 91-56775 Pinion Nut Torque 70 lb-ft (95 Nm) 90-858895R1 JANUARY 2001 Page 6-45 GEAR HOUSING Pinion Gear Depth and Forward Gear Backlash DETERMINING PINION GEAR DEPTH NOTE:Read entire procedure before attempting any change in shim thickness. IMPORTANT: Forward gear assembly pilots the end of the pinion gauge and must be installed in gear housing when checking pinion gear depth. Without it an inaccurate measurement will be obtained. 1. Clean the gear housing bearing carrier shoulder and diameter. 2. With gear housing positioned up right (drive shaft vertical), install Bearing Preload Tool (91-14311A2) over drive shaft in sequence shown. a b c d e f g h h a-Adaptor: Bearing surfaces clean and free of nicks b-Thrust Bearing: Oiled and able to move freely c-Thrust Washer: Clean and free of nicks and bends d-Spring e-Nut: Threaded all-the-way onto bolt f-Bolt: Held snug against spring g-Sleeve: Holes in sleeve must align with set screws h-Set Screw (2): Tightened against drive shaft, bolt should not slide on drive shaft. 3. Measure distance between top of nut and bottom of bolt head. 4. Increase distance by 1 in. (25.4 mm). 5. Rotate drive shaft 5 to 10 revolutions. This should properly seat drive shaft tapered roller bearing. 19884 a b c a-1 in. (25.4 mm) c-Bolt Head b-Nut Page 6-46 90-858895R1 JANUARY 2001 GEAR HOUSING 6. Assemble Pinion Gear Locating Tool (91-12349A2) as shown; do not tighten collar retaining screw at this time. Install gauging block with numbers away from split collar. a b c d e f c a-Arbor d-Split Collar b-Gauging Block e-Collar Retaining Screw c-Screw (2) f-Snap Ring 7. Insert tool into forward gear assembly; position gauging block under pinion gear as shown. 22067 a a-Gauging Block 8. Remove tool, taking care not to change gauging block position, and tighten collar retaining bolt. 9. Insert tool into forward gear assembly; position proper numbered flat (from chart) of gauging block – under pinion gear. MODEL GEAR RATIO (PINION GEAR TEETH/REVERSE GEAR TEETH) USE FLAT NO. LOCATING DISC NO. 40/50 Bigfoot (4-stroke) 2.31:1 (13/30) 8 3 50/60 Bigfoot (4-stroke) 2.31:1 (13/30) 8 3 75/90/115EFI (4-stroke) 2.07:1 (14/29) 2 3 60 Bigfoot/60 Seapro 60 Marathon 2.31:1 (13/30) 8 3 75-thru-90 (3 Cylinder) 2.31:1 (13/30) 8 3 100/115/125 (4 Cylinder) 2.07:1 (14/29) 2 3 90-858895R1 JANUARY 2001 Page 6-47 GEAR HOUSING 10. Install locating disc against bearing carrier shoulder in gear housing. 11. Position access hole as shown. 24643 b a Disc 3 a-Locating Disc b-Access Hole 12. Determine pinion gear depth by inserting a feeler gauge thru access hole in locating disc. 13. The correct clearance between gauging block and pinion gear is 0.025 in. (0.64 mm). 14. If clearance is correct, leave Bearing Preload Tool on drive shaft and proceed to “Determining Forward Gear Backlash,” following. 15. If clearance is more than 0.025 in. (.064 mm) add shims behind the bearing race. If clearance is less than 0.025 in. (.064 mm) remove shims from behind the bearing race. When reinstalling pinion nut, apply Loctite 271 on threads of nut. NOTE:Clean driveshaft and pinion nut threads with Loctite Primer or suitable de-greaser before applying Loctite. 24643 a b c d 7 Loctite “271” (92-809820) 7 a-Feeler Gauge b-Gauging Block c-Pinion Gear d-Bearing Race Page 6-48 90-858895R1 JANUARY 2001 GEAR HOUSING DETERMINING FORWARD GEAR BACKLASH NOTE:Read entire procedure before attempting any change in shim thickness. 1. Obtain correct pinion gear depth; refer to “Determining Pinion Gear Depth,” preceding. 2. Install Bearing Preload Tool (91-14311A2) on drive shaft; refer to “Determining Pinion Gear Depth,” preceding. 3. Install components as shown. 4. While holding the driveshaft (to prevent from turning), torque the puller bolt to 45 lb-in. 5. Rotate driveshaft 5-10 revolutions. This should properly seat the forward gear tapered roller bearing. Repeat step 4. a bd c a-Propeller Shaft* b-Bearing Carrier* (Assembled) c-Puller Jaws (91-46086A1) d-Puller Bolt (91-85716) Puller Bolt Torque 45 lb-in. (5 Nm) 53936 *Refer to “Bearing Carrier and Propeller Shaft Installation,” following. 90-858895R1 JANUARY 2001 Page 6-49 GEAR HOUSING 6. Install components as shown. 51117 a b d e f c c a-Threaded Rod (Obtain Locally) b-Washers c-Nuts d-Dial Indicator Adaptor Kit (91-83155) e-Dial Indicator (91-58222A1) f-Backlash Indicator Tool 7. Position Dial Indicator on appropriate line (from chart below) marked on Backlash Indicator Tool. Make sure the dial indicator is perpendicular (^) to the indicator tool or an inaccurate reading will be obtained. MODEL BACKLASH INDICATOR TOOL ALIGN POINTER OF DIAL INDICATOR WITH MARK 40/50 Bigfoot (4-stroke) 91-78473 4 50/60 Bigfoot (4-stroke) 91-78473 4 75/90/115EFI (4-Stroke) 91-19660--1 1 60 Seapro/60 Marathon 60 Bigfoot 91-78473 4 75-thru-90 (3 Cylinder) 91-78473 4 100/115/125 (4 Cylinder) 91-19660--1 1 Page 6-50 90-858895R1 JANUARY 2001 GEAR HOUSING 8. Grasp the driveshaft pre-load tool bolt head and lightly turn drive shaft back-and-forth (no movement should be noticed at propeller shaft). 9. Dial Indicator registers amount of backlash, which must be between specification shown in chart. MODEL DIAL INDICATOR MINIMUM READING MAXIMUM 40/50 Bigfoot (4-Stroke) 0.012 in. (0.30 mm) 0.019 in. (.48 mm) 50/60 Bigfoot (4-Stroke) 0.012 in. (0.30 mm) 0.019 in. (.48 mm) 75/90/115EFI (4-Stroke) 0.013 in. (0.38 mm) 0.019 in. (.55 mm) 60 Bigfoot 0.012 in. (0.30 mm) 0.019 in. (.48 mm) 75-thru-90 (3 Cylinder) 0.012 in. (0.30 mm) 0.019 in. (.48 mm) 100/115/125 (4 Cylinder) 0.013 in. (0.38 mm) 0.019 in. (0.55 mm) 10. If backlash is less than the minimum specification, remove shim(s) from in front of forward gear bearing race. If backlash is more than the maximum specification, add shim(s) in front of forward gear bearing race. When reinstalling pinion nut, apply Loctite 271 on threads of nut. NOTE: By adding or subtracting 0.001 in. (0.025 mm) shim, the backlash will change approximately 0.001 in. Bearing Carrier and Propeller Shaft Installation 1. Insert propeller shaft assembly into bearing carrier. 2. Before installing bearing carrier assembly into gear housing, obtain locally a 6 in. (152.4 mm) long by 1-1/4 in. – 1-1/2 in. (31.7 – 38.1 mm) diameter piece of PVC pipe. Install the PVC pipe over the prop shaft and secure the pipe against the bearing carrier assembly with the propeller nut and tab washer. This holds the reverse gear and thrust bearing tight against the bearing carrier preventing possible bearing damage during installation. 21043 d a b c e a-Bearing Carrier Assembly b-PVC Pipe c-Propeller Nut d-Prop Shaft e-Tab Washer 90-858895R1 JANUARY 2001 Page 6-51 GEAR HOUSING 3. Generously lubricate O-ring, bearing carrier, and gear housing mating surfaces with 2-4-C w/Teflon. 4. Install bearing carrier and propeller shaft into housing with the word “TOP” (located on flange) toward top of housing. 21044 a b 95 95 2-4-C w/Teflon (92-850736A1) a-O-ring b-TOP NOTE:Use thick 0.090 in. (2.29mm) washers (12-855941) under fasteners if not previously installed. Washer Thickness Fastener Torque 0.090 in. (2.29mm) 22 lb-ft (29.8 Nm) 0.060 in. (1.53mm) 25 lb-ft (33.9 Nm) a b a-Washers b-Fasteners (If using Screws Apply Loctite 271 on Threads) Page 6-52 90-858895R1 JANUARY 2001 GEAR HOUSING Water Pump Reassembly and Installation 1. Place water pump base upper seal on longer shoulder side of Oil Seal Driver (91-13949) with seal lip away from shoulder. 2. Apply Loctite 271 on O.D. of seal; press seal into water pump base until tool bottoms. 51553 c 91-13949 7 b a d e 7 Loctite “271” (92-809820) a-Seal - Lip Faces UP (when water pump base is installed on gearcase) b-Spring - Faces UP (when water pump base is installed on gearcase) c-Oil Seal Driver (91-13949) d-Longer Shoulder Side of Oil Seal Driver e-Shorter Shoulder Side of Oil Seal Driver 90-858895R1 JANUARY 2001 Page 6-53 GEAR HOUSING 3. Place water pump base lower seal on shorter shoulder side of Oil Seal Driver (91-13949) with seal lip toward shoulder. 4. Apply Loctite 271 on O.D. of seal; press seal into water pump base until tool bottoms. 5. Lubricate lip of each seal with Quicksilver 2-4-C w/Teflon (92-850736A1). 51553 c 91-13949 7 Loctite “271” (92-809820)7 95 a b e d 95 2-4-C w/Teflon (92-850736A1) a-Seal - Lip Faces DOWN (when water pump base is installed on gearcase) b-Spring - Faces DOWN (when water pump base is installed on gearcase) c-Oil Seal Driver (91-13949) d-Longer Shoulder Side of Oil Seal Driver e-Shorter Shoulder Side of Oil Seal Driver 6. Install gasket. a 19218 a-Gasket Page 6-54 90-858895R1 JANUARY 2001 GEAR HOUSING IMPORTANT: To prevent cutting the seal lips remove any burrs or sharp edges from the driveshaft splines before installing water pump base assembly. 7. Install components as shown. Apply Loctite 271 on bottom half of screw threads and tighten to specified torque (in sequence shown). 19217 a 7 Loctite “271” (92-809820) 1 2 3 4 5 6 b a-Water Pump Base b-Screw (6) M6 x 1 and Washers(6) Screw Torque 60 lb-in. (6.8 Nm) 8. Install gasket and plate. 19219 a b a-Gasket b-Plate IMPORTANT: If the old impeller is re-used it must be installed in original (clockwise) direction of rotation. 9. Install gasket, drive key and impeller. 19220 a b c a-Gasket b-Drive Key c-Impeller 90-858895R1 JANUARY 2001 Page 6-55 GEAR HOUSING 10. Lubricate I.D. of cover with Quicksilver 2-4-C w/Teflon. 11. Rotate drive shaft clockwise and push impeller housing down (over impeller) until it contacts water pump base. 12. Apply Loctite 271 to bottom threads of cover screws. Install cover screws and tighten to specified torque. b b a 95 2-4-C w/Teflon (92-850736A1) 95 19212 a-Impeller Housing b-Screw (4) Screw Torque 60 lb-in. (6.8 Nm) NOTE:It is recommended that the gearcase be pressure tested for leaks after reassembly andBEFOREgear lube is added. Gearcase should hold 10-12 psi (69-83 kPa) for 5 minutes. Page 6-56 90-858895R1 JANUARY 2001 GEAR HOUSING Gear Housing Pressure Test 1. Remove vent plug and install pressure test gauge. 2. Pressurize housing to 10-12 psi (69-83 kPa)and observe gauge for 5 minutes. 3. Rotate drive shaft, prop shaft and shift shaft while housing is pressurized to check for leaks. 4. If pressure drop is noted, immerse housing in water. 5. Re-pressurize to 10-12 psi (69-83 kPa)and check for air bubbles. 6. Replace leaking seals as necessary. Retest housing. NOTE:Gearcase should hold 10-12 psi (69-83 kPa) for 5 minutes. 7. Remove tester from housing and install vent plug and sealing washer. 90-858895R1 JANUARY 2001 Page 6-57 GEAR HOUSING Filling Gear Housing With Lubricant NOTE:Gear housing lubricant capacity is 24 fl oz (710 mL). WARNING If gear housing is installed on engine, to avoid accidental starting, disconnect (and isolate) spark plug leads from spark plugs before working near the propeller. CAUTION Do not use automotive grease in the gear housing. Use only Quicksilver Premium Blend Gear Lube. 1. Remove any gasket material from “Fill/Drain” and “Vent” screws and gear housing. 2. Install new sealing washer on “Fill/Drain” and “Vent” screws. IMPORTANT: Never apply lubricant to gear housing without first removing “Vent” screws or gear housing cannot be filled because of trapped air. Fill gear housing only when driveshaft is in a vertical position. 3. Remove lubricant “Fill/Drain” screw and sealing washer from gear housing. 4. Insert lubricant tube into “Fill” hole, then remove “Vent” screws and sealing washer. 5. Fill gear housing with lubricant until excess starts to flow out of one (first) “Vent” screw hole. 6. Install this “Vent” screw and sealing washer only and continue filling until excess starts to flow out of second “Vent” screw hole. 7. Rotate driveshaft clockwise approximately 10 revolutions. Let gearcase sit for at least one minute to allow any trapped air to settle out, then top off lubricant level. 53922 a c b a-Vent Screw - Torque to 60 lb-in. (6.8 Nm) b-Fill/Drain Screw - Torque to 60 lb-in. (6.8 Nm) c-Oil Level Vent Screw - Torque to 60 lb-in. (6.8 Nm) 8. Replace second lubricant “Vent” screw and sealing washer. IMPORTANT: Do not lose more than one fluid ounce (30cc) of gear lubricant while reinstalling “FILL/DRAIN” screw. 9. Remove lubricant tube from Fill/Drain hole; install Fill/Drain screw and sealing washer. Page 6-58 90-858895R1 JANUARY 2001 GEAR HOUSING 90-858895R1 JANUARY 2001 Page 6-59 Gearcase Installation WARNING Disconnect (and isolate) spark plug leads from spark plugs before installing gear housing onto drive shaft housing. Failure to follow this warning could result in accidental engine starting and possible injury. 1. Position outboard shift linkage into forward gear position. Models 40-60 Bigfoot (4-Stroke) a Remote Control Model Shown a - Shift Lever Models 60 Bigfoot (2-Stroke) a a - Shift Block Models 75/90/100/115/125 (2-Stroke) 19879 a b a - Shift Block; Front of Block MUST Extend 1/8 in. (3.2 mm) Past Front of Rail. b - Rail GEAR HOUSING Models 75/90/115EFI (4-Stroke) a NRF a-Shift Block 2. Tilt engine to full up position and engage tilt lock lever. 3. Shift gear housing into neutral position. Propeller shaft will rotate freely in either direction. 4. Install water tube seal; apply 2-4-C w/Teflon to I.D. of seal. 5. Apply a bead of RTV Sealer as shown. NOTE:For ease of gear housing installation, install water tube seal (labyrinth end) onto water tube in drive shaft housing. Tapered end of water tube seal goes onto water pump. 53938 95 2-4-C w/Teflon (92-850736A1) 78 95 a b G. E. RTV Sealant 92-90113--2 78 a-Water Tube Seal b-RTV Sealer Page 6-60 90-858895R1 JANUARY 2001 GEAR HOUSING CAUTION Do not use lubricant on top of drive shaft. Excess lubricant, that is trapped in clearance space, will not allow drive shaft to fully engage with crankshaft. Subsequently, tightening the gear housing fasteners (while lubricant is on top of drive shaft) will load the drive shaft/crankshaft and damage either or both the power head and gear housing. Top of drive shaft is to be wiped free of lubricant. 6. Apply a light coat of Quicksilver 2-4-C w/Teflon onto drive shaft splines. 7. Apply a light coat of Quicksilver 2-4-C w/Teflon on gear case shift shaft splines and upper shift shaft splines. Do not use lubricant on ends of shift shafts. 8. Install components as shown in appropriate photo. ALL MODELS EXCEPT 75 (2-STROKE) W/MECHANICAL REVERSE LOCK a c b a-Nylon Spacer b-Shift Shaft Coupler c-Bushing 40-60 Bigfoot 4–Stroke Only 75 (2-STROKE) W/MECHANICAL REVERSE LOCK 53925 a b c a-Nylon Spacer b-Shift Shaft Coupler c-Flat; MUST BE Positioned Toward Front of Gear Housing 90-858895R1 JANUARY 2001 Page 6-61 GEAR HOUSING 9. Shift gear housing into forward gear position. In forward gear the gear housing will ratchet when propeller shaft is turned clockwise. Resistance will be felt when propeller shaft is rotated counterclockwise. 10. Apply Loctite Grade 271 on threads of gear housing retaining bolts. NOTE:During installation of gear housing, it may be necessary to move the shift block (located under cowl) slightly to align upper shift shaft splines with shift shaft coupler splines. NOTE:On 75/90 hp (4-Stroke)models. If, while performing Step 11, the drive shaft splines wil llnot align with the oil pump splines, place a propeller onto propeller shaft and turn it counterclockwiseas the gear housing is being pushed toward drive shaft housing. Continue rotating the propshaft until the driveshaft splines align with the crankshaft splines. IMPORTANT: 75/90 hp (4-Stroke) models, when removing or installing gearcase, carefully guide driveshaft through driveshaft bushing to avoid scoring bushing surface. 11. Position gear housing so that the driveshaft is protruding into driveshaft housing. 12. Move gear housing up toward driveshaft housing, while aligning upper shift shaft splines with shift shaft coupler splines, water tube with water tube seal, and crankshaft splines with driveshaft splines. 13. Install 4 fasteners and washers (two each side). Install locknut and washer. 14. Torque bolts and locknut (or nuts only if applicable) to specified torque. 53922 ab 7 Loctite “271” (92-809820) 7 a-Fasteners and Washers (2 Each Side) b-Locknut and Washer Bolt or Nut Torque 40 lb-ft (54 Nm) 15. Check shift operation as follows: • Place shift lever in forward gear. Gear housing should ratchet when propeller shaft is turned clockwise. Resistance should be felt when propeller shaft is turned counterclockwise. • Place shift lever in neutral. Propeller shaft should rotate freely in either direction. • While rotating propeller shaft, place shift lever in reverse gear. Resistance should be felt when propeller shaft is rotated in either direction. IMPORTANT: If shift operation is not as described above, the gear housing must be removed and the cause of the problem corrected. Page 6-62 90-858895R1 JANUARY 2001 GEAR HOUSING Trim Tab Adjustment and Replacement IMPORTANT: The trim tab is now painted and does NOT aid in protecting the drive shaft housing and gear housing from galvanic corrosion (corrosion and pitting of metal surfaces). Side anodes now provide protection. Do not paint or place protective coating on the side anodes, or corrosion protection function will be lost. TRIM TAB REPLACEMENT 1. Replace trim tab if damaged. Mark location of old trim tab on anti-ventilation plate before removal; install new trim tab in same location. TRIM TAB ADJUSTMENT NOTE:The trim tab provides a means to offset (balance) some of the steering load that is caused by propeller torque at higher operating speeds. NOTE:Loosen trim tab bolt sufficiently to allow trim tab to disengage from locking ridges in gear case before attempting to move tab. DO NOT strike trim tab with a hard object to make adjustments. 1. Shift engine control into NEUTRAL and turn ignition key to OFF position. 2. If at higher speeds the boat turns more easily to the left, loosen screw, move the trim tab (trailing edge) to the left (when viewed from behind). Tighten retaining screw to specified torque. 3. If the boat turns more easily to the right, loosen screw, move the trim tab (trailing edge) to the right (when viewed from behind) turn trim tab (trailing edge) to the right . Tighten retaining screw to specified torque. 53931ab c a-Trim Tab b-Anti-Ventilation Plate c-Retaining Screw and Washer Retaining Screw Torque 22 lb-ft (29.8 Nm) 90-858895R1 JANUARY 2001 Page 6-63 THROTTLE/SHIFT LINKAGE ATTACHMENTS/CONTROL LINKAGE Section 7 - Throttle/Shift Linkage Table of Contents Throttle Lever and Linkage . . . . . . . . . . . . . . . 7-2 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Throttle Position Sensor Adjustments . . . . . . 7-4 Throttle Lever and Linkage Assembly . . . . . . 7-8 Throttle Lever and Linkage Removal . . . . . . . 7-5 Throttle Lever and Linkage Installation . . . . . 7-10 Throttle Lever and Linkage Disassembly . . . 7-6 Shift Bracket Removal/Installation . . . . . . . . . 7-12 7 90-858895R1 JANUARY 2001 Page 7-1 THROTTLE/SHIFT LINKAGE THROTTLE LEVER AND LINKAGE 1 2 3 5 8 9 11 12 15 16 17 18 19 21 22 6 7 20 4 10 5 95 95 13 14 22 2-4-C w/Teflon (92-850736A1) Page 7-2 90-858895R1 JANUARY 2001 THROTTLE/SHIFT LINKAGE THROTTLE LEVER AND LINKAGE REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 SCREW (M6 x 12 mm) 70 8 2 1 WASHER 3 1 WAVE WASHER 4 1 PLATE 5 2 BUSHING 6 1 BRACKET 7 2 SCREW (M6 x 25 mm) 70 8 8 1 THROTTLE CONTROL LEVER 9 1 PIN (18.5 mm Long) 10 1 COLLAR 11 1 SPRING 12 1 CAM 13 1 WASHER 14 1 WAVE WASHER 15 1 WASHER 16 1 SCREW (M6 x 35 mm) 70 8 17 1 THROTTLE LEVER BRACKET 18 1 SCREW (M6 x 12 mm) 70 8 19 1 THROTTLE LINK 20 1 WASHER 21 1 WASHER 22 2 HAIRPIN COTTER NOTE: TORQUE TOLERANCE +/– 10% 90-858895R1 JANUARY 2001 Page 7-3 THROTTLE/SHIFT LINKAGE Throttle Position Sensor Adjustments 1. Move the throttle control lever until it contacts the fully-closed stopper (idle position). 2. Loosen TPS mounting screws. 3. Rotate TPS fully clockwise (to end of slot position). 4. Tighten TPS mounting screws. NOTE:Start engine at idle speed and measure the voltage between the PNK and ORN leads. Verify that TPS has been adjusted correctly. a a-Screw (2) TPS Output Voltage (PNK - ORN) 0.68 - 0.82 NOTE:Refer toSection 2Afor voltage measurement procedures on the throttle position sensor. Page 7-4 90-858895R1 JANUARY 2001 THROTTLE/SHIFT LINKAGE Throttle Lever and Linkage Removal 1. Disconnect throttle position sensor (TPS) plug. NOTE:To release connector from it’s mount, insert flat blade screwdriver next to connector and push down on screwdriver while pulling up on connector. c b a a-Throttle Position Sensor Connector b-Cable Tie c-Flat Blade Screwdriver 2. Remove throttle link from throttle cam. 3. Remove throttle lever/linkage assembly and/or throttle cam as needed. c c a b d e f g h a-Screw (2) M6 x 25 b-Screw M6 x 30 c-Washer (2) d-Wave Washer e-Bushing f-Throttle Cam g-Spring h-Throttle Link 90-858895R1 JANUARY 2001 Page 7-5 THROTTLE/SHIFT LINKAGE Page 7-6 90-858895R1 JANUARY 2001 Throttle Lever and Linkage Disassembly 1. Disassemble throttle lever/linkage assembly. a b c e d a - Throttle Link b - Washer c - Hairpin Cotter d - Screw M6 x 12 e - Throttle Lever Bracket 2. Remove throttle position sensor and bracket. a b c d e f g h i j a - Pin (18.5 mm Long) b - Lever c - Screw (2) M5 x 25 d - Washer (2) e - Grommet (2) f - Collar (2) g - Bracket h - Pin (16.5 mm Long) i - Screw (2) j - Throttle Position Sensor THROTTLE/SHIFT LINKAGE 3. Separate throttle control lever from bracket. a b c d e f g e a-Screw M6 x 12 b-Washer c-Wave Washer d-Plate e-Bushing (2) f-Bracket g-Throttle Control Lever Inspection 1. Inspect brackets, shaft, and cam. Replace if cracked or damaged. a b c d a-Bracket b-Throttle Control Lever c-Shaft d-Cam 90-858895R1 JANUARY 2001 Page 7-7 THROTTLE/SHIFT LINKAGE Throttle Lever and Linkage Assembly 1. Assemble throttle control lever and bracket. d a g f b e c c a-Throttle Control Lever b-Bracket c-Bushing (2) d-Plate e-Wave Washer f-Washer g-Screw M6 x 12 Page 7-8 90-858895R1 JANUARY 2001 THROTTLE/SHIFT LINKAGE 90-858895R1 JANUARY 2001 Page 7-9 2. Install throttle position sensor and bracket onto control lever assembly. e i a h b c f g d j a - Throttle Position Sensor b - Screw (2) M5 x 10 c - Bracket d - Collar (2) e - Grommet (2) f - Washer (2) g - Screw (2) M5 x 25 h - Lever i - Pin (18.5 mm Long) j - Pin (16.5 mm Long) 3. Assemble throttle lever/linkage assembly. a b d c e a - Throttle Lever Bracket b - Screw M6 x 12 c - Throttle Link d - Washer e - Hairpin Cotter THROTTLE/SHIFT LINKAGE Throttle Lever and Linkage Installation 1. Install cam over roller of cam follower and secure cam to boss on intake manifold. Tighten screw to specified torque. NOTE:Position longer end of spring in recess of cylinder block as shown. 2. Install throttle lever/linkage assembly and connect throttle link to throttle cam. ah g b c f d e f f b i a-Throttle Link b-Spring c-Cam d-Bushing e-Wave Washer f-Washer g-Throttle Cam Screw M6 x 35 h-Throttle Bracket Screw (2) M6 x 25 i-Recess for Spring Throttle Cam and Throttle Bracket Screw Torque 70 lb-in. (8 Nm) Page 7-10 90-858895R1 JANUARY 2001 THROTTLE/SHIFT LINKAGE 3. Connect throttle position sensor (TPS) leads. b a a-Throttle Position Sensor Connector b-Cable Tie NOTE: After reinstalling throttle linkage refer to section 2C-Timing, Synchronizing, and Adjusting for proper setup. 90-858895R1 JANUARY 2001 Page 7-11 THROTTLE/SHIFT LINKAGE Page 7-12 90-858895R1 JANUARY 2001 Shift Bracket Removal/Installation 1. Remove/install shift bracket as shown. a b b c f d g e a - Shift Linkage Bracket b - Screw (3) M6 x 20 c - Retainer d - Latch e - Shift Link f - Roller g - Cotter Pin (2) Shift Bracket Screw Torque 80 lb-in. (9 Nm) NOTE: Refer to section “1D-Outboard Installation” for proper installation of shift and throttle cables. COLOR DIAGRAMS COLOR DIAGRAMS Table of Contents 75/90 (4-Stroke) Wiring Diagram . . . . . . . . . . Page 8-3 75/90 (4-Stroke) Oil Flow Diagram . . . . . . . . . Page 8-7 75/90 (4-Stroke)Typical Remote 75/90 (4-Stroke) Water Flow Diagram . . . . . . Page 8-9 Control and Gauge Wiring. . . . . . . . . . . . . . . Page 8-5 8 90-858895R1 JANUARY 2001 Page 8-1 COLOR DIAGRAMS Notes: Page 8-2 90-858895R1 JANUARY 2001 COLOR DIAGRAMS 75/90 (4-STROKE) ENGINE WIRING DIAGRAM STARTING MODEL YEAR 2000 (STARTING SERIAL NUMBER G960500) 90-858895R1 JANUARY 2001 Page 8-3 1. Starter and Solenoid 2. 20 Amp Fuse 3. 30 Amp Fuse 4. Starter Relay 5. Power Trim Relay (UP) 6. Power Trim Relay (DOWN) 7. Voltage Regulator/Rectifier 8. Stator 9. Enrichener (top carburetors) 10. Enrichener (bottom carburetors) 11. Throttle Position Sensor (TPS) 12. Not Used 13. Engine Water Temperature Sensor 14. Oil Pressure Switch 15. Crankshaft Position Sensor (CPS) 16. Ignition Coil 1 & 4 17. Ignition Coil 2 & 3 18. To Ignition Coil Ground 19. Shift Interrupt Switch 20. ECM 21. To Oil Pressure Switch 22. To Throttle Position Sensor (TPS) 23. To Dash (key switch, trim switch, temperature gauge) 24. Remote Control Harness Connector 25. Adaptor Harness Used on S/N OT320117 and Above 26. Adaptor Harness Used on S/N OT320116 and Below 27. Green Wire is no Longer Used for Tach Signal - Does Not go Through to Harness Pin 28. Engine Harness Connector 29. Cowl Mounted Trim Switch 30. To Power Trim Pump 31. To 12 Volt Battery 14 20 A 30 A 58805 75/90 (4-Stroke) Engine Wiring 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 19 20 21 22 21 22 24 23 25 26 28 27 29 31 30 18 18 COLOR DIAGRAMS 75/90 (4-STROKE) TYPICAL REMOTE CONTROL AND GAUGE WIRING STARTING MODEL YEAR 2000 (STARTING SERIAL NUMBER G960500) 90-858895R1 JANUARY 2001 Page 8-5 1. MPC 4000 2. Neutral Lock Button 3. Trim Switch 4. Throttle Only Button 5. Lanyard Stop Switch 6. Lanyard stop switch leads must be soldered and covered with shrink tube for a water proof connection. If alternate method of connection is made (use of electrical butt connector) verify connection is secure and seal for moisture proof connection. 7. Trim Harness Connection 8. Connect wires together with screw and hex nut (2 places); apply Quicksilver Liquid Neoprene to connections and slide heat shrink tubing over each connection. 9. Key Switch 10. 5–Pin Tachometer Harness Connector 11. Warning Horn 12. Speedometer 13. Temperature Gauge 14. Trim Position Gauge 15. Tachometer 16. Light Switch Connection 17. To Warning Light ( if equipped) 18. To Trim Sender (if equipped) 19. To Engine Trim Harness Connections 20. To Temperature Sensor (if equipped) 21. Remote Control Harness Connection C D E A B 75/90 (4-Stroke) Typical Remote Control and Gauge Wiring 11 10 S I G IGN. CAL. SEND. GRD. LT. 5P 6P 2P 3P 8C 4P 4C 6C S I G 1 7 8 9 5 6 4 3 2 12 13 14 15 16 18 17 19 21 20 COLOR DIAGRAMS 75/90 (4-STROKE) OIL FLOW DIAGRAM STARTING MODEL YEAR 2000 (STARTING SERIAL NUMBER G960500) 90-858895R1 JANUARY 2001 Page 8-7 1. Sump 2. Oil Pick-up 3. Adapter Plate 4. Oil Pump and Pressure Regulator 5. Cylinder Block with oil passages 6. Oil Filter 7. Crankshaft with oil passages 8. Cylinder Head with oil passages 9. Camshafts 10. Oil drains from head to block 11. Oil in block drains through adapter plate back to the sump. 1 2 3 4 5 5 6 7 8 9 10 11 75/90 (4-Stroke) Oil Flow COLOR DIAGRAMS 75/90 (4-STROKE) WATER FLOW DIAGRAM STARTING MODEL YEAR 2000 (STARTING SERIAL NUMBER G960500) 90-858895R1 JANUARY 2001 Page 8-9 1. Water Inlet 2. Water Pump 3. Driveshaft Housing 4. Water Tube 5. Oil Sump 6. Adapter Plate 7. Cylinder Block 8. Cylinder Head 9. Thermostat 10. Water Jacket Cover and Pressure Relief Valve 11. Tee Fitting 12. Tell-Tale 13. Driveshaft Bushing 14. Exhaust/Cooling Water Outlet 1 2 3 4 5 6 7 8 9 10 11 12 14 13 75/90 (4-Stroke) Water Flow