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SERVICE MANUAL MODELS Mercury/Mariner 8/9.9 (4-Stroke) With Starting Serial Numbers United States . . . . . . 0H000058 Printed in U.S.A. W1996, Mercury Marine 90-827857R1 NOVEMBER 1996 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. 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. 90-827857R1 NOVEMBER 1996 i 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 serv- iced, 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 specif- ically stated. Whenever components are removed for service, they should be retained in order. At the time of instal- lation, they should be installed in the same locations and with the same mating surfaces as when re- moved. Before raising or removing and outboard engine from a boat, the following precautions should be adhered to: 1. Check that flywheel is secured to end of crank- shaft with a locknut and lifting eye is threaded into flywheel a minimum of 5 turns. 2. Connect a hoist of suitable strength to the lifting eye. In addition, 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 in- formation concerning the products described in this manual. Page Numbering Two number groups appear at the bottom of each page. The example below is self-explanatory. EXAMPLE: 90-826148 R1 JANUARY 1993 LOWER UNIT - 6A-7 Revision No. 1 Month of Printing Year of Printing Section Description Section Number Part of Section Letter Page Number 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 serv- iced, 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 specif- ically stated. Whenever components are removed for service, they should be retained in order. At the time of instal- lation, they should be installed in the same locations and with the same mating surfaces as when re- moved. Before raising or removing and outboard engine from a boat, the following precautions should be adhered to: 1. Check that flywheel is secured to end of crank- shaft with a locknut and lifting eye is threaded into flywheel a minimum of 5 turns. 2. Connect a hoist of suitable strength to the lifting eye. In addition, 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 in- formation concerning the products described in this manual. Page Numbering Two number groups appear at the bottom of each page. The example below is self-explanatory. EXAMPLE: 90-826148 R1 JANUARY 1993 LOWER UNIT - 6A-7 Revision No. 1 Month of Printing Year of Printing Section Description Section Number Part of Section Letter Page Number ii 90-827857R1 NOVEMBER 1996 Service Manual Outline Section 1 - Important Information A - Specifications B - Maintenance C - General Information D - Outboard 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 Section 4 - Powerhead A - Cylinder Head B - Cylinder Block/Crankcase Section 5 - Mid-Section Section 6 - Lower Unit Section 7 - Attachments/Control Linkage A - Throttle/Shift Linkage (Tiller Handle/Side Shift Models) B - Throttle/Shift Linkage (Removte Control Models) C - Tiller Handle Section 8 - Manual Starter Important Information Electrical Fuel System Powerhead Mid-Section Lower Unit Attachments/ Control Linkage Manual Starter 90-827857R1 NOVEMBER 1996 iii IMPORTANT INFORMATION A 1 SPECIFICATIONS Table of Contents Page General Specifications . . . . . . . . . . . . . . . . . . 1A-1 90-827857R1 NOVEMBER 1996 General Specifications Model 8/9.9 HORSEPOWER (KW) Model 8.0 (BODENSEE) Model 9.9 (BODENSEE) Model 9.9 8.0 (6.0) 9.9 (7.4) 9.9 (7.4) OUTBOARD WEIGHT Manual Start Electric Start 102 lbs. (46.3kg) 107 lbs. (48.5kg) FUEL Recommended Gasoline Automotive Unleaded with a minimum pump posted octane rating of 87 Engine Oil Capacity F° C° SAE 25W-40 SAE 10W-30 Either 1.0 quart (1.0 Liter) 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 chart above). If not available, use a premium quality 4 cycle engine oil, certified to meet or exceed anyone or combination of the following American Petroleum Institute (API) Service Classification SH, SG, SF, CF-4, CE, CD, CDII. IGNITION SYSTEM Type Spark Plug Type (NGK) Spark Plug Gap Firing Order Capacitor Discharge Ignition CR6HS 0.024 - 0.028 in. (0.6 - 0.7 mm) 1 - 2 BATTERY Battery Rating 465 Marine Cranking Amps (MCA) or 350 Cold Cranking Amps (CCA) STARTING SYSTEM Manual Start Electric Start Ampere Draw Under: (Load) (No Load) Recoil Start 12 Volt 41.5 Amperes 14.2 Amperes CHARGING SYSTEM Alternator Output Manual Start Model Electric Start Model 6 Amperes (Non Regulated Lighting Coil) 10 Amperes (Regulated) FUEL SYSTEM Fuel Pump Type Fuel Pump: Pressure Diaphragm Stroke Plunger Stroke Fuel Tank Capacity External (Plunger/Diaphragm) 3-6 PSI (20-41 kPa) 0.0945 in. (2.4 mm) 0.2283 in. (5.8 mm) 6.6 U.S. Gallons 90-827857R1 NOVEMBER 1996 IMPORTANT INFORMATION - 1A-1 Model 8/9.9 CARBURETOR SPECIFICATIONS Idle RPM Trolling RPM Wide Open Throttle (WOT) RPM 8.0/9.9 (BODENSEE) 9.9 Pilot Screw (Turns Out) 8.0/9.9 (BODENSEE) 9.9 Main Jet Size 8.0/9.9 (BODENSEE) 9.9 Pilot Jet Enrichener Jet Float Height* 950 ±50 RPM (Out Of Gear) 850 ±50 5000 - 5500 4500 - 5500 Not Adjustable 3 ±1 #82 #86 #48 .024 (0.61 mm) 1 ±0.04 in. (25.5 ±1 mm) TIMING Ignition Timing (Full Retarded) 850 ±50 RPM 5°±1° B.T.D.C. SPECIFICATIONS (Full Advanced) 2500-3000 RPM 35°±1° B.T.D.C. CYLINDER BLOCK Type Displacement Number of Cylinders 4 Stroke Cycle – Over Head Camshaft 14.16 cu. in. (232cc) 2 STROKE Length 1.67 in. (42.4mm) CYLINDER BORE Diameter (Std) Taper/Out of Round Maximum Bore Type Bore Wear Limit 2.323 in. (59.0mm) 0.003 in. (0.076mm) Steel 2.326 in. (59.1mm) PISTON Piston Type O.D. at Skirt (Standard) (Oversize) 0.010 (0.254mm) (Oversize) 0.020 (0.508mm) Aluminum 2.3209 - 2.3216 in. (58.950 - 58.965 mm) 2.333 in. (59.25 mm) 2.343 in. (59.50 mm) COMPRESSION/ RATIO Compression Ratio Cylinder Compression (cold engine) 9.3:1 Highest reading and lowest reading should not differ by more than 10% Top Main Bearing Journal 1.181 in. ±0.0001 in. (30.0 mm ±0.003 mm) Bottom Main Bearing Journal 1.181 in. ±0.0001 in. (30.0 mm ±0.003 mm) Connecting Rod Journal 1.102 in. ±0.0001 in. (28.0 mm ±0.003 mm) Crankshaft Width (Width of Thrust Sur4.87 - 4.88 in. (123.7 - 123.9 mm) CRANKSHAFT faces) “A” Runout Limit “B” 0.0008 in. (0.02 mm) Main Bearing Clearance B B 0.0002 - 0.0017 in. (0.005 - 0.0043 mm) A 1A-2 - IMPORTANT INFORMATION 90-827857R1 NOVEMBER 1996 Model 8/9.9 CONNECTING ROD Rod Clearance (Big End) 0.0008 - 0.0018 in. (0.021 - 0.045 mm) CYLINDER HEAD Warp Limit * * Lines indicate straight edge measurement 0.004 in. (0.1 mm) Ring End Gap (Installed) Top 0.006 - 0.012 in. (0.15 - 0.03 mm) Middle 0.006 - 0.012 in. (0.15 - 0.03 mm) Bottom (Oil Ring) 0.008 - 0.028 in. (0.20 - 0.70 mm) RINGS Wear Limit Side Clearance: 0.020 in. (0.50 mm) Top 0.002 - 0.003 in. (0.04 - 0.08 mm) Middle 0.001 - 0.003 in. (0.03 - 0.07 mm) Wear Limit 0.020 in. (0.50 mm) Valve/Valve Seat/Valve Guides: Valve Clearance (cold) Intake 0.0059 - 0.0079 in. (0.15 - 0.20 mm) Exhaust Valve Dimensions: 0.0079 - 0.0098 in. (0.20 - 0.25 mm) “A” Head Diameter Intake 1.020 - 1.028 in. (25.9 - 26.1 mm) Exhaust 0.862 - 0.870 in. (21.9 - 22.1 mm) “B” Face Width Intake 0.079 - 0.124 in. (2.00 - 3.14 mm) Exhaust 0.079 - 0.124 in. (2.00 - 3.14 mm) “C” Seat Width Intake 0.024 - 0.031 in. (0.6 - 0.8 mm) Exhaust 0.024 - 0.031 in. (0.6 - 0.8 mm) “D” Margin Thickness Intake 0.020 - 0.035 in. (0.5 - 0.9 mm) VALVES Exhaust 0.020 - 0.035 in. (0.5 - 0.9 mm) Stem Outside Diameter Intake 0.2156 - 0.2161 in. (5.475 - 5.490 mm) Exhaust 0.2150 - 0.2156 in. (5.460 - 5.475 mm) Guide Inside Diameter Intake 0.2165 - 0.2170 in. (5.500 - 5.512 mm) Exhaust 0.2165 - 0.2170 in. (5.500 - 5.512 mm) Stem To Guide Clearance Intake 0.0004 - 0.0015 in. (0.010 - 0.037 mm) Exhaust 0.0010 - 0.0020 in. (0.025 - 0.052 mm) Stem Runout Limit (max.) 0.0006 in. (0.016 mm) 90-827857R1 NOVEMBER 1996 IMPORTANT INFORMATION - 1A-3 Model 8/9.9 “A” “B” “C” “D” Valve Dimensions Head Diameter Face Width Seat Width Margin Thickness VALVE SPRING Set Length (Valve Closed) Intake Exhaust Compressed Pressure (Installed) Intake Exhaust Tilt Limit (Intake and Exhaust) Direction Of Winding (Intake and Exhaust) 0.960 in. (24.4 mm) 0.960 in. (24.4 mm) 19.8 - 22.0 lbs. (9.0 - 10.0 kg) 19.8 - 22.0 lbs. (9.0 - 10.0 kg) 0.043 in. (1.1 mm) Left Hand CAMSHAFT Camshaft Dimensions Intake “A” Intake “B” Exhaust “A” Exhaust “B” Camshaft Runout A B 0.966 - 0.970 in. (24.541 - 24.641 mm) 0.793 - 0.797 in. (20.137 - 20.237 mm) 0.968 - 0.972 in. (24.578 - 24.678 mm) 0.794 - 0.798 in. (20.178 - 20.278 mm) 0.004 in. (0.1mm) CAM BELT Cam Belt Type Belt Slack Cogged Belt 0 - 0.4 in. (0-10 mm) Model 8/9.9 “A” “B” “C” “D” Valve Dimensions Head Diameter Face Width Seat Width Margin Thickness VALVE SPRING Set Length (Valve Closed) Intake Exhaust Compressed Pressure (Installed) Intake Exhaust Tilt Limit (Intake and Exhaust) Direction Of Winding (Intake and Exhaust) 0.960 in. (24.4 mm) 0.960 in. (24.4 mm) 19.8 - 22.0 lbs. (9.0 - 10.0 kg) 19.8 - 22.0 lbs. (9.0 - 10.0 kg) 0.043 in. (1.1 mm) Left Hand CAMSHAFT Camshaft Dimensions Intake “A” Intake “B” Exhaust “A” Exhaust “B” Camshaft Runout A B 0.966 - 0.970 in. (24.541 - 24.641 mm) 0.793 - 0.797 in. (20.137 - 20.237 mm) 0.968 - 0.972 in. (24.578 - 24.678 mm) 0.794 - 0.798 in. (20.178 - 20.278 mm) 0.004 in. (0.1mm) CAM BELT Cam Belt Type Belt Slack Cogged Belt 0 - 0.4 in. (0-10 mm) 1A-4 - IMPORTANT INFORMATION 90-827857R1 NOVEMBER 1996 Model 8/9.9 LUBRICATION SYSTEM Pump Type Oil Filter Type Recommended Oil API Rating Engine Oil Pan Capacity Oil Pump: Outer Rotor to Housing “A” Inner Rotor to Outer Rotor “B” Rotor to Housing “C” Relief Valve Operating Pressure Torochoid Type Reusable Quicksilver SAE 10W-30, 25W-40 SH, SG, SF, CF-4, CE, CD, CDII 1 Quart (1 Liter) 0.0024 - 0.0043 in. (0.06 - 0.11 mm) 0.0008 - 0.0059 in. (0.02 - 0.15 mm) 0.0008 - 0.0028 in. (0.02 - 0.07 mm) 55 - 64 PSI (3.88 - 4.50 kg/cm2) 388- 450 kPa AB C Transom Height - Short Shaft 15 in. (38 cm) - Long Shaft 20 in. (51 cm) MID Steering Pivot Range 78° SECTION Tilt Pin Positions 3 + 3 Shallow Water Total Tilt Angle 78° Allowable Transom Thickness 2-3/8 in. (60.3mm) GEAR HOUSING Gear Ratio Gearcase Capacity Lubricant Type Forward Gear - No. of Teeth-Type Pinion Gear - No. of Teeth-Type Pinion Height Forward Gear Backlash Reverse Gear Backlash Water Pressure With Thermostat – @ W.O.T – @ Idle 2.0:1 6.8 fl. oz. (200 ml) Quicksilver Gear Lube Premium Blend 26 Spiral/Bevel 13 Spiral/Bevel Floating No Adjustment No Adjustment 5 - 7 PSI @ 5000 RPM 1/2 - 1-1/2 PSI @ 750 RPM 90-827857R1 NOVEMBER 1996 IMPORTANT INFORMATION - 1A-5 IMPORTANT INFORMATION B 1 MAINTENANCE Table of Contents Page Inspection And Maintenance Schedule . . . . . . 1B-1 Before Each Use . . . . . . . . . . . . . . . . . . . . . . 1B-1 After Each Use . . . . . . . . . . . . . . . . . . . . . . . . 1B-1 Every 100 Hours of Use or Once yearly, Whichever occurs first . . . . . . . . . . . . . . . . . . 1B-1 Every 300 Hours of Use or Three Years . . 1B-1 Before Periods of Storage . . . . . . . . . . . . . . 1B-1 Fuse Replacement-Electric Start Models . . . . 1B-1 Spark Plug Inspection. . . . . . . . . . . . . . . . . . . . . 1B-2 Timing Belt Inspection . . . . . . . . . . . . . . . . . . . . 1B-2 Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . 1B-2 Changing Engine Oil. . . . . . . . . . . . . . . . . . . . . . 1B-3 Oil Filter Change Intervals . . . . . . . . . . . . . . 1B-3 Engine Oil Capacity . . . . . . . . . . . . . . . . . . . . 1B-3 Oil Changing Procedure . . . . . . . . . . . . . . . . 1B-3 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-4 Fuel Line Filter . . . . . . . . . . . . . . . . . . . . . . . . 1B-4 Fuel Line Inspection . . . . . . . . . . . . . . . . . . . 1B-4 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . 1B-5 Gear Case Lubrication . . . . . . . . . . . . . . . . . . . . 1B-6 Draining Gear Case. . . . . . . . . . . . . . . . . . . . 1B-6 Gear Case Lubricant Capacity . . . . . . . . . . . 1B-6 Checking Lubricant Level And Refilling Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-6 Propeller Replacement. . . . . . . . . . . . . . . . . . . . 1B-7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-7 Corrosion Control Anode . . . . . . . . . . . . . . . . . . 1B-8 Flushing The Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8 Out-of-Season Outboard Storage . . . . . . . . . . 1B-9 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9 Protecting External Outboard Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9 Protecting Internal Engine Components . . 1B-9 Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9 Positioning outboard for storage . . . . . . . . . 1B-9 Out-of-season Battery Storage . . . . . . . . . 1B-10 90-827857R1 NOVEMBER 1996 Inspection And Maintenance Schedule Conduct a periodic, systematic inspection to uncover and correct a failure before it can cause injury, inconvenience or mechanical damage. 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. Remote Control Models – Visually check steering link rod fasteners for proper tightness. 7. Check propeller blades for damage. After Each Use 1. Flush out the outboard cooling system if operating in salt or polluted water. 2. Wash off all salt deposits and flush out the exhaust outlet of the propeller and gear case with fresh water if operating in salt water. 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 clean the oil filter. The oil should be changed more often when the engine is operated under adverse conditions such as extended trolling. 3. Inspect and clean spark plugs. 4. Check fuel line filter for contaminants. 5. Check corrosion control anodes. Check more frequently when used in salt water. 6. Check and adjust valve clearance, if necessary. 7. Drain and replace gear case lubricant. 8. Lubricate splines on the drive shaft. 9. Remote control models – Check control cable adjustments. 10. Inspect timing belt. 11. 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). 2. Replace oil filter. 3. Replace thermostat. Before Periods of Storage 1. Refer to Storage procedure (this section). Fuse Replacement-Electric Start Models IMPORTANT: Always carry spare SFE 20 AMP fuses. The electric starting circuit is protected from overload by a SFE 20 AMP fuse. If the fuse is blown, the electric starter motor will not operate. Try to locate and correct the cause of the overload. If the cause is not found, the fuse may blow again. Replace the fuse with a fuse of the same rating. 1. Replace with a new SFE 20 AMP fuse. a b a -Fuse b -Fuse Holder 90-827857R1 NOVEMBER 1996 IMPORTANT INFORMATION - 1B-1 Spark Plug Inspection Inspect spark plugs at the recommended intervals. 1. Remove the spark plug leads by twisting the rubber boots slightly and pull off. 2. Remove the spark plugs to inspect and clean. Replace spark plug if electrode is worn or the insulator is rough, cracked, broken, blistered or fouled. 3. Set the spark plug gap. See Specification Chart in Section 1A. 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 9 lb. ft. (12.3 N·m). 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. f. Stretching by .39 in. (10mm) or more when belt is pushed in with your finger. a b Checking Engine Oil IMPORTANT: Do not overfill. Be sure that the outboard is upright (not tilted) when checking oil. 1. Position the outboard vertical and remove the top cowl. 2. Remove the oil level dipstick. Wipe the dipstick clean and reinsert it all-the-way in. 3. Remove the dipstick and observe the oil level. If the oil level is near or below the lower oil level (a), remove the oil filler cap (c) and fill to (but not over) the upper oil level (b) with the recommended oil. Push the dipstick all the way back in when you’re through. 4. Reinstall the oil filler cap and tighten securely. c 1B-2 - IMPORTANT INFORMATION 90-827857R1 NOVEMBER 1996 Changing Engine Oil NOTE:The oil should be changed more often when the engine is operated under adverse conditions such as extended trolling. Oil Filter Change Intervals Clean the filter at each oil change. Replace the filter if it is damaged (cracked, torn, dented, etc.). Engine Oil Capacity One U.S. Quart (1 Liter). Oil Changing Procedure 1. Place the outboard in an vertical upright position. 2. Place a drain pan below outboard. 3. Loosen the drain plug access cover and remove cover. 4. Remove drain plug (a) and let the oil drain completely. 5. Remove the oil filter (b).Wash and clean the filter in solvent and dry it. Replace the filter if it is damaged (cracked, torn. dented, etc.). a b 6. Lubricate (with oil) the O-ring seals (c) on the oil filter, then install the filter. Torque the oil filter to 70 lbs. in. (8 N·m). 7. Lubricate (with oil) the O-ring seal on the drain plug (a), then reinstall the drain plug. Torque the drain plug to 70 lbs. in. (8 N·m). NOTE:The outboard can be tilted up for ease of filling. 8. Remove the oil fill cap (d) and refill with one U.S. Quart (1 Liter) of oil. Reinstall the oil fill cap. IMPORTANT: Do not overfill. Be sure that the outboard is upright (not tilted) when checking oil. 9. Start the engine and watch to make sure that there are no oil leaks. If there are oil leaks, stop the engine and find the cause. 10. Reinstall the drain plug access cover (e) with screw. d e c a 90-827857R1 NOVEMBER 1996 IMPORTANT INFORMATION - 1B-3 Fuel System WARNING Avoid serious injury or death from gasoline fire or explosion. Carefully follow all fuel system service instructions. Always stop the engine. DO NOT smoke or allow open flames or sparks in the area while servicing any part of the fuel system. NOTE:Before servicing any part of the fuel system, stop engine and disconnect the battery. Drain the fuel system completely. Use an approved container to collect and store fuel. Wipe up any spillage immediately. Material used to contain spillage must be disposed of in an approved receptacle. Any fuel system service must be performed in a well- ventilated area. Inspect any completed service work for sign of fuel leakage. Fuel Line Filter 1. Inspect the fuel line filter. If the filter appears to be contaminated, remove and replace. IMPORTANT: Visually inspect for fuel leakage from the filter connections by squeezing the primer bulb until firm, forcing fuel into the filter. a a -Fuel Filter Fuel Line Inspection 1. Visually inspect the fuel line and primer bulb for cracks, swelling, leaks, hardness, or other signs of deterioration or damage. If any of these conditions is found, the fuel line or primer bulb must be replaced. 1B-4 - IMPORTANT INFORMATION 90-827857R1 NOVEMBER 1996 Lubrication Points Lubricate Points 1 thru 6 with Quicksilver 2-4-C Marine Lubricant or Special Lubricate 101. 1. Tilt Tube – Lubricate fittings. 2. Transom Clamp Screws – Lubricate threads. 3. Swivel Bracket – Lubricate fitting. 4. Tilt Lock Pins – Apply lubricant to pins. Pin (a) is spring loaded. Make sure this pin is free to push in and out. 5. Lubricate along the entire tilt pin track on both transom brackets. 6. Lubricate the throttle and shaft cables, moving components and pivot locations. 1 2 3 4 6 5 4(a) WARNING The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant. Adding lubricant to steering cable when fully extended could cause steering cable to become hydraulically locked. An hydraulically locked steering cable will cause loss of steering control, possibly resulting in serious injury or death. Lubricate Point 7b with Quicksilver 2-4-C Marine Lubricant or Special Lubricate 101. 7. Steering Cable – Rotate steering wheel to fully retract the steering cable end (7a) into the outboard tilt tube. Lubricate through fitting (7b). Lubricate Point 8 With light weight oil. 8. Steering Link Rod Pivot Points – Lubricate points. 7b7a 8 Lubricate Point 9 with Quicksilver Anti-Corrosion Grease. 9. Propeller Shaft – Refer to Propeller Replacement for removal and installation of the propeller. Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding to the shaft. 9 90-827857R1 NOVEMBER 1996 IMPORTANT INFORMATION - 1B-5 Gear Case Lubrication When adding or changing gear case lubricant, visually check for the presence of water in the lubricant. If water is present, it may have settled to the bottom and will drain out prior to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance. If water is noticed, have the gear case checked by your dealer. Water in the lubricant may result in premature bearing failure or, in freezing temperatures, will turn to ice and damage the gear case. Whenever you remove the fill/drain plug, examine the magnetic end for metal particles. A small amount of metal filings or fine metal particles indicates normal gear wear. An excessive amount of metal filings or larger particles (chips) may indicate abnormal gear wear and should be checked by an authorized dealer. Draining Gear Case 1. Place outboard in a vertical operating position. 2. Place drain pan below outboard. 3. Remove fill/drain plug (a) and vent plug (b) and drain lubricant. b a Gear Case Lubricant Capacity Gear case lubricant capacity is approximately 6.8 fl. oz. (200 ml). Checking Lubricant Level And Refilling Gear Case 1. Place outboard in a vertical operating position. 2. Remove vent plug from vent hole (c). 3. Place lubricant tube (d) into the fill hole and add lubricant until it appears at the vent hole (c). 4. Stop adding lubricant. Install the vent plug (e) and sealing washer before removing the lubricant tube. 5. Remove lubricant tube and reinstall cleaned fill/ drain plug and sealing washer (f). d e c f 1B-6 - IMPORTANT INFORMATION 90-827857R1 NOVEMBER 1996 Propeller Replacement Removal 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 the outboard to neutral position. 2. Remove the spark plug leads to prevent engine from starting. 3. Place a block of wood between gear case and propeller to hold propeller and remove propeller nut. 4. Pull propeller straight off shaft. Installation 1. Coat the propeller shaft with Quicksilver Anti- Corrosion Grease. IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft, especially in salt water, always apply a coat of Quicksilver Anti-Corrosion Grease to the entire shaft at the recommended maintenance intervals and also each time the propeller is removed. 2. Flo-Torque I Drive Hub Propellers – Install forward thrust hub (a), propeller (b), rear thrust hub (c) and propeller nut (d) onto the shaft. cd ba 3. Flo-Torque II Drive Hub Propellers – Install forward thrust hub (a), replaceable drive sleeve (b) propeller (c), rear thrust hub (d) and propeller nut (e) onto the shaft. d e b ac 4. Place a block of wood between gear case and propeller and tighten propeller nut. 90-827857R1 NOVEMBER 1996 IMPORTANT INFORMATION - 1B-7 Corrosion Control Anode The anode (a) requires periodic inspection especially in salt water which will accelerate the erosion. To maintain this corrosion protection, always replace the anode before it is completely eroded. Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode. IMPORTANT: DO NOT paint or place protective coating on anode (or the contact surface on the drive) or corrosion protection is lost. a 5. Stop engine. Turn off water. Remove flushing attachment. Reinstall propeller. Flushing The Cooling System Flush the internal water passages of the outboard with fresh water after each use in salt, polluted, or muddy water. This will help prevent a buildup of deposits from clogging the internal water passages. Use a Quicksilver accessory (or equivalent) flushing attachment. WARNING To avoid possible injury when flushing, remove the propeller. Refer to Propeller Replacement. 1. Remove propeller (refer to Propeller Replacement). Install the flushing attachment so the rubber cup fits tightly over the cooling water intake. 2. Attach a water hose to the flushing attachment. Turn on the water and adjust the flow so water is leaking around the rubber cup to ensure the engine receives an adequate supply of cooling water. 3. Start the engine and run it at idle speed in neutral shift position. 4. Adjust water flow (if necessary) so excess water continues leaking out from around the rubber cup to ensure the engine is receiving an adequate supply of cooling water. 5. Check for a steady stream of water flowing out of the water pump indicator hole. Continue flushing the outboard for 3 to 5 minutes, carefully monitoring water supply at all times. 6. Stop the engine, turn off the water, and remove the flushing attachment. Reinstall the propeller. 1B-8 - IMPORTANT INFORMATION 90-827857R1 NOVEMBER 1996 Out-of-Season Outboard Storage WARNING As a safety precaution, when boat is in storage, remove positive (+) battery cable. This will eliminate possibility of accidental starting of engine and resultant overheating and damage to engine from lack of water. In preparing an outboard for out-of-season storage, 2 precautions must be considered: 1) The engine must be protected from physical damage and 2) the engine must be protected from rust, corrosion and dirt. Fuel System IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a formation of acid during storage and can damage the fuel system. If the gasoline being use contains alcohol, it is advisable to drain as much of the remaining gasoline as possible from the fuel tank, remote fuel line, and engine fuel system. Fill the fuel system (tank, hoses, fuel pump, and carburetor) with treated (stabilized) fuel to help prevent formation of varnish and gum. Proceed with following instructions. 1. Portable Fuel Tank – Pour the required amount of Quicksilver Gasoline Stabilizer (follow instructions on container) into fuel tank. Tip fuel tank back and forth to mix stabilizer with the fuel. 2. Permanently Installed Fuel Tank – Pour the required amount of Quicksilver Gasoline Stabilizer (follow instructions on container) into a separate container and mix with approximately one quart (one liter) of gasoline. Pour this mixture into fuel tank. 3. Place the outboard in water or connect flushing attachment for circulating cooling water. Run the engine for ten minutes to allow treated fuel to reach the carburetor. Protecting External Outboard Components 1. Lubricate all outboard components listed in the Inspection and Maintenance Schedule. NOTE:It is not necessary to spray storage seal into the throat of the carburetor on a four cycle outboard. 2. Touch up any paint nicks. 3. Clean outboard thoroughly, including all accessible powerhead parts, 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 1. To prevent problems which can be caused by oil entering the cylinders from the sump, store the outboard only in one of the three positioned shown below. 2. Position the outboard in one of the three following positions when placing in storage. Upright Tiller Side Down Back Side Down IMPORTANT: When storing outboard for the win- ter, be sure that all water drain holes in gear hous- ing are open and free so that all water will drain out. 90-827857R1 NOVEMBER 1996 IMPORTANT INFORMATION - 1B-9 Out-of-Season Battery Storage 1. Remove battery as soon as possible and remove all grease, sulfate and dirt from top surface. 2. Cover PLATES with distilled water, but not over 3/16 in. (5mm) above perforated baffles. 3. Cover terminal bolts well with grease. 4. Store battery in a COOL, DRY place in a dry carton or box. 5. Remove battery from storage every 60 days. Check water level and place on charge for 5 to 6 hours at 6 amperes. DO NOT fast charge. CAUTION A discharged battery can be damaged by freezing. 1B-10 - IMPORTANT INFORMATION 90-827857R1 NOVEMBER 1996 IMPORTANT INFORMATION 1 C GENERAL INFORMATION Table of Contents Page Serial Number Location . . . . . . . . . . . . . . . . . . . 1C-1 Conditions Affecting Performance . . . . . . . . . . 1C-1 Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-1 Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2 Weight Distribution . . . . . . . . . . . . . . . . . . 1C-2 Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2 Water Absorption . . . . . . . . . . . . . . . . . . . 1C-2 Cavitation . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2 Detonation . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2 Following Complete Submersion . . . . . . . . . . . 1C-3 Submerged While Running . . . . . . . . . . . . . 1C-3 Salt Water Submersion . . . . . . . . . . . . . . . . . 1C-3 Fresh Water Submersion . . . . . . . . . . . . . . . 1C-3 Propeller Selection . . . . . . . . . . . . . . . . . . . . . . . 1C-4 Compression Check . . . . . . . . . . . . . . . . . . . . . . 1C-5 Cylinder Leakage Testing . . . . . . . . . . . . . . . . . . 1C-5 Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-5 90-827857R1 NOVEMBER 1996 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. a b c d e a -Serial Number b -Model Year c -Model Description d -Year Manufactured e -Certified Europe Insignia Conditions Affecting Performance Weather 19XX OGXXXXXX XXXX XX It is a known fact that weather conditions exert a pro- found 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. 90-827857R1 NOVEMBER 1996 Corporations internationally have settled on adoption of I.S.O. (International Standards Organization) engine test standards, as set forth in I.S.O. 3046 standardizing the computation of horsepower from data obtained on the dynamometer, correcting all values to the power that the engine will produce at sea level, at 30% relative humidity at 77° F (25° C) temperature and a barometric pressure of 29.61 inches of mercury. Summer Conditions of high temperature, low barometric pressure and high humidity all combine to reduce the engine power. This, in turn, is reflected in decreased boat speeds--as much as 2 or 3 miles- per-hour (3 or 5 Km per-hour) in some cases. (Refer to previous chart.) Nothing will regain this speed for the boater, but the coming of cool, dry weather. In pointing out the practical consequences of weather effects, an engine--running on a hot, humid summer day--may encounter a loss of as much as 14% of the horsepower it would produce on a dry, brisk spring or fall day. The horsepower, that any internal combustion engine produces, depends upon the density of the air that it consumes and, in turn, this density is dependent upon the temperature of the air, its barometric pressure and water vapor (or humidity) content. Accompanying this weather-inspired loss of power is a second but more subtle loss. At rigging time in early spring, the engine was equipped with a propeller that allowed the engine to turn within its recommended RPM range at full throttle. With the coming of the summer weather and the consequent drop in available horsepower, this propeller will, in effect, become too large. Consequently, the engine operates at less than its recommended RPM. 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. IMPORTANT INFORMATION - 1C-1 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. CAVITATION Cavitation is caused by water vapor bubbles forming either from a sharp edge or angle on the gear case or from an irregularity in the propeller blade itself. These vapor bubbles flow back and collapse when striking the surface of the propeller blade resulting in the erosion of the propeller blade surface. If allowed to continue, eventual blade failure (breakage) will occur. Engine DETONATION Detonation in a 2-cycle engine resembles the “pinging” heard in an automobile engine. It can be otherwise described as a tin-like “rattling” or “plinking” sound. Detonation is an explosion of an unburned portion of the fuel/air charge after the spark plug has fired. Detonation creates severe shock waves in the engine, and these shock waves often find or create a weakness: The dome of a piston, cylinder head/gasket, piston rings or piston ring lands, piston pin and roller bearings. A few of the most common causes of detonation in a marine 2-cycle application are as follows: • Over-advanced ignition timing. • Use of low octane gasoline. • Propeller pitch too high (engine RPM below recommended maximum range). • Lean fuel mixture at or near wide-open-throttle. • Spark plugs (heat range too hot - incorrect reach -cross-firing). • Inadequate engine cooling (deteriorated cooling system). • Combustion chamber/piston deposits (result in higher compression ratio). 1C-2 - IMPORTANT INFORMATION 90-827857R1 NOVEMBER 1996 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 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 appereance) drain and refill as previoulsy mentioned. 6. Pour alcohol into carburetor throats (alcohol will absorb water). Again rotate flywheel. 7. Turn engine over and pour alcohol into spark plug openings and rotate flywheel. 8. Turn engine over (place spark plug openings down) and pour engine oil into throat of carburetors while rotating flywheel to distribute oil throughout crankcase. 9. Again turn engine over and pour approximately one teaspoon of engine oil into each spark plug opening. Again rotate flywheel to distribute oil in cylinders. 10. Remove and clean carburetors and fuel pump assembly. 11. Dry all wiring and electrical components using compressed air. 12. Disassemble the engine starter motor and dry the brush contacts, armature and other corrodible parts. 13. Reinstall spark plugs, carburetors and fuel pump. 14. Attempt to start engine, using a fresh fuel source. If engine starts, it should be run for at least one hour to eliminate any water in engine. 15. If engine fails to start, determine cause (fuel, electrical or mechanical). Engine should be run within 2 hours after recovery of outboard from water, or serious internal damage may occur. If unable to start engine in this period, disassemble engine and clean all parts. Apply oil as soon as possible. 90-827857R1 NOVEMBER 1996 IMPORTANT INFORMATION - 1C-3 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.). 1C-4 - IMPORTANT INFORMATION 90-827857R1 NOVEMBER 1996 Compression Check 1. Remove spark plugs. 2. Install compression gauge (a) in spark plug hole. 3. Hold throttle plate at W.O.T. 4. Crank the engine over until the compression reading peaks on the gauge. Record the reading. 5. Check and record compression of each cylinder. The highest and lowest reading recorded should not differ by more than 15% (See example test chart below). A reading below 120 psi might indicate a total engine wear problem. Example of compression test differences Maximum (psi) Minimum (psi) 180 162 150 127.5 6. Compression check is important because an engine with low or uneven compression cannot be tuned successfully to give peak performance. It is essential, therefore, that improper compression be corrected before proceeding with an engine tuneup. 7. Cylinder scoring: If powerhead shows any indication of overheating, such as discolored or scorched paint, visually inspect cylinders for scoring or other damage as outlined in Section 4 “Powerhead.” Cylinder Leakage Testing NOTE: Cylinder leakage testing*, along with compression testing, can help the mechanic pinpoint the source of a mechanical failure by gauging the amount of leakage in an engine cylinder. Refer to the manufactures tester instructions for proper testing procedures. * Courtesy of Snap-On-Tools Cylinder Leakage Tester (Snap-On-Tools MT324) NOTE: Spark plug hole is a 10 mm diameter. Use Snap-On -Tool MT26-17A adapter with valve core removed. Analysis Due to standard engine tolerances and engine wear, no cylinder will maintain a 0% of leakage. It is important only that cylinders have somewhat consistent reading between them. Differences of 15 to 30% indicate excessive leakage. Larger engines tend to have a larger percentage of cylinder leakage than smaller engines. If excessive leakage is present, first check that the piston is at top dead center of it’s compression stroke. Leakage will naturally occur if the exhaust or intake valve is open. To determine the cause of high percentage leaks, you must locate where the air is escaping from. Listen for air escaping thru the carburetor intake, adjacent spark plug holes, exhaust pipe, crankcase fill plug. Use the following table to aid in locating the source of cylinder leakage: Air Escaping From: Indicates Possible Defective: Carburetor Intake Valve Exhaust System Exhaust Valve Crankcase Fill Plug Piston or Rings Adjacent Cylinders Head Gasket 90-827857R1 NOVEMBER 1996 IMPORTANT INFORMATION - 1C-5 IMPORTANT INFORMATION D 1 OUTBOARD MOTOR INSTALLATION Table of Contents Page Mounting Outboard Motor on Transom . . . . . . 1D-1 Boat Transom Height Requirement . . . . . . 1D-1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-1 Fastening Security Line . . . . . . . . . . . . . . . . 1D-1 Ride-Guide Steering Cable Installation . . . . . . 1D-2 Lubrication/Sealant Application Points . . . . 1D-3 Shift and Throttle Cable Installation . . . . . . . . . 1D-4 Shift Cable Installation . . . . . . . . . . . . . . . . . 1D-4 Throttle Cable Installation . . . . . . . . . . . . . . . 1D-4 Remote Wiring Harness Connection . . . . . . . . 1D-5 90-827857R1 NOVEMBER 1996 Mounting Outboard Motor on Transom Boat Transom Height Requirement 1. Measure the transom height of your boat. The boat bottom should be aligned or be within 1 in. (25mm) above the anti-ventilation plate (a) of the outboard. 0–1in. (0–25mm) a Installation 1. Place outboard on center line of transom. 2. Tighten transom clamp handles. 3. To prevent loss of outboard overboard, fasten outboard by drilling two 5/16 in. (7.9 mm) holes through the transom using transom clamp holes as a template. Fasten with two bolts (a), flat washers (b) and locknuts (c). Use a marine waterproofing sealer in holes and around bolts to make the installation water tight. b c a Fastening Security Line 1. The primary purpose for installing a security line is to prevent loss of the outboard if the outboard becomes detached from the boat transom. An effective security line should be of a working strength of at least five times the weight of the outboard. The security line should be attached between the boat and outboard following one of these steps. Step1. The length of the security line should be short enough and affixed in a manner to prevent the outboard from rising up and disengaging off the boat transom. Step 2. The length of the security line should be long enough and affixed in a manner to permit a detached outboard to submerge completely behind the boat and stop running but not too short that could allow the outboard to continue running and propel itself back into the boat. WARNING If the length of security line being used is long enough to allow the outboard to disengage off the boat transom but is too short to not allow the outboard to submerge behind the boat and stop running, the outboard could continue running and propel itself back into the boat with the propeller rotating under power. This exposes the occupants to serious injury or death. 90-827857R1 NOVEMBER 1996 IMPORTANT INFORMATION - 1D-1 Ride-Guide Steering Cable Installation To the Outboard Install steering mount and steering wheel in accordance with installation instructions that accompany each. IMPORTANT: Steering cable must be correct length. Sharp bends on too-short of a cable result in “kinks;” too-long of a cable require unnecessary bends and/or loops. Both conditions place extra stress on the cable. 1. Refer to “Quicksilver Accessories Guide” to determine correct length of steering cable. IMPORTANT: Before installing steering cable into tilt tube, lubricate entire cable end with Quicksilver 2-4-C w/Teflon Marine Lubricant (92-825407A12). 2. Lubricate seal inside of outboard tilt tube and entire cable end (b) with Quicksilver 2-4-C w/teflon Marine Lubricant. 3. Insert steering cable end thru outboard tilt tube and secure steering cable to tilt tube with steering cable attaching nut as shown. Torque nut to 35 lb. ft. (47.5 N·m). b a 53400 a -Cable End b -Attaching Nut [Torque to 35 lb. ft. (47.5 N·m)]. 4. Place a mark on tilt tube 5/8 in. (15.9mm) from port end of tube. Slide plastic spacer, O-ring and cap over steering cable end, to tilt tube on engine. 5/8 in. (15.8mm) a b c d 53067 a -Mark b -Spacer c -O-ring d -Cap 5. Thread cap onto tilt tube up to mark. b a a -Cap b -Mark 1D-2 - IMPORTANT INFORMATION 90-827857R1 NOVEMBER 1996 -Steering Link Arm -Ball Joint (Flat End Facing Up) -Steering Bracket -Spacer [3/8 in. (9.5mm)] -Rubber Spacer -Flat Washer [13/16 in. (20.6mm)] -Locknut [Torque to 20 lb. ft. (27.1 N·m)] -Flat Washer [5/8 in. (15.9mm)] (2) -Spacer -Locknut. Tighten Until Nut Seats. Do Not Exceed 120 A 2-4-C w/Teflon (92-825407A12) Quicksilver Lubrication/Sealant Application Points A h i J a b c d e f g a -Steering Bracket b -Bolt (2) c -Flat Washer (2) d -Locknut (2) [Torque to 140 lb in. (15.8 N·m)] a b c d A A 53398 a 6. Secure steering bracket to engine. a -Steering Bracket 7. Secure steering link rod between engine steering bracket and steering cable end. -Steering Link Arm -Ball Joint (Flat End Facing Up) -Steering Bracket -Spacer [3/8 in. (9.5mm)] -Rubber Spacer -Flat Washer [13/16 in. (20.6mm)] -Locknut [Torque to 20 lb. ft. (27.1 N·m)] -Flat Washer [5/8 in. (15.9mm)] (2) -Spacer -Locknut. Tighten Until Nut Seats. Do Not Exceed 120 A 2-4-C w/Teflon (92-825407A12) Quicksilver Lubrication/Sealant Application Points A h i J a b c d e f g a -Steering Bracket b -Bolt (2) c -Flat Washer (2) d -Locknut (2) [Torque to 140 lb in. (15.8 N·m)] a b c d A A 53398 a 6. Secure steering bracket to engine. a -Steering Bracket 7. Secure steering link rod between engine steering bracket and steering cable end. a b c d e f g h i j lb. in. (13.6 N·m), Then Back Off 1/4-Turn 90-827857R1 NOVEMBER 1996 IMPORTANT INFORMATION - 1D-3 Shift and Throttle Cable Installation To The Outboard Install the shift cable and throttle cable into the remote control and mount the remote control following instructions which are provided the remote control. NOTE:Install the shift cable before the throttle cable. The shift cable is the first cable to move when the remote control handle is moved into gear. Shift Cable Installation 1. Position the remote control handle into neutral detent. 2. Remove the cable mounting cover (a). a 53396 3. Place the engine shift lever pin (a) into neutral position. The propeller shaft will rotate in either direction when in neutral position. 4. Install the shift cable onto the shift lever pin. lock in place with cable latch (b). 5. Adjust the barrel on the shift cable so that the barrel will fit in the cable holder with a slight pre-load toward reverse when installed. a b 53399 6. Check shift cable adjustments as follows: a. With remote control in forward the propshaft should lock solidly in gear. If it does not, adjust the cable barrel closer to the cable end guide. b. Shift remote control into neutral. The prop- shaft should turn freely without drag. If not, adjust the barrel away from the cable end guide. Repeat steps a and b. c. Shift remote control into reverse while turning propeller. The propshaft should lock solidly in gear. If not, adjust the barrel away from the cable end guide. Repeat steps a thru c. d. Return remote control handle to neutral. The propeller should turn freely without drag. If not, adjust the barrel closer to the cable end guide. Repeat steps a thru d. Throttle Cable Installation NOTE:Attach Shift cable to engine prior to attaching throttle cable. 1. Position the remote control handle into neutral detent. 2. Install the throttle cable onto the throttle lever pin (a). Lock in place with cable latch (b). 3. Move the throttle lever back-and-forth to locate the center of the loose free play in the carburetor linkage. Make sure the carburetor linkage is not binding in either direction. 4. Adjust the barrel on the throttle cable so that the barrel will fit in the cable holder while the throttle lever is centered within the free play of the carburetor linkage. b a 5. Reinstall the cable mounting cover. 1D-4 - IMPORTANT INFORMATION 90-827857R1 NOVEMBER 1996 b a d a -Remote Wiring Connector b -Outboard Wiring Harness Connector c -Retainer d -Quicksilver Dielectric Grease b a d a -Remote Wiring Connector b -Outboard Wiring Harness Connector c -Retainer d -Quicksilver Dielectric Grease Remote Wiring Harness Connection to Engine 1. Apply Quicksilver Dielectric Grease inside the connection. 2. Plug the remote wiring connector into the outboard wiring harness connector. Secure the connection together with retainer, as shown. c 90-827857R1 NOVEMBER 1996 IMPORTANT INFORMATION - 1D-5 ELECTRICAL A 2 IGNITION Table of Contents Page Theory of Operation . . . . . . . . . . . . . . . . . . . . . . 2A-1 Ignition Component Description . . . . . . . . . . . . 2A-1 Capacitor Discharge Unit (CDI) . . . . . . . . . . 2A-1 Trigger Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2 Stator Assembly . . . . . . . . . . . . . . . . . . . . . . . 2A-2 Flywheel Assembly . . . . . . . . . . . . . . . . . . . . 2A-2 Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2 Ignition Test Procedures . . . . . . . . . . . . . . . . . . . 2A-3 Direct Voltage Adapter (DVA) . . . . . . . . . . . 2A-3 Ignition Troubleshooting . . . . . . . . . . . . . . . . . . . 2A-4 Ignition Diagnostic Procedures . . . . . . . . . . . . . 2A-5 Suggested Testing Procedures . . . . . . . 2A-5 Recommended Test . . . . . . . . . . . . . . . . . . . . 2A-5 Testing Ignition Components . . . . . . . . . . . . . . . 2A-7 Resistance Tests . . . . . . . . . . . . . . . . . . . . . . 2A-7 Trigger Coil Test . . . . . . . . . . . . . . . . . . . . 2A-7 Stator Test (Ignition Charge Coil) . . . . . . 2A-7 Lighting Coil . . . . . . . . . . . . . . . . . . . . . . . . 2A-7 ElectroThermal Valve Coil . . . . . . . . . . . . 2A-7 Ignition Coil (Primary). . . . . . . . . . . . . . . . 2A-8 Spark Plug cap Removal . . . . . . . . . . . . . 2A-8 Spark Plug cap Resistor Test . . . . . . . . . 2A-8 Ignition Coil (Secondary) . . . . . . . . . . . . . 2A-8 Flywheel Removal and Installation . . . . . . . . . . 2A-9 Flywheel Removal . . . . . . . . . . . . . . . . . . . . . 2A-9 Flywheel Installation . . . . . . . . . . . . . . . . . . . 2A-9 Ignition Cover Removal and installation . . . . 2A-10 Wire Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-10 (CDI) Unit Removal and Installation . . . . . . . . 2A-10 Ignition Coil Removal and Installation . . . . . . 2A-11 Rectifier Removal and Installation . . . . . . . . . 2A-11 Stator Removal and Installation . . . . . . . . . . . 2A-12 Trigger Coil Removal and Installation . . . . . . 2A-13 90-827857R1 NOVEMBER 1996 Theory of Operation The ignition system uses CDI (Capacitor Discharge Ignition). This system provides quick voltage buildup and strong spark required for high power and high performance engines. The CDI ignition system does not incorporate mechanically operated points, therefor making this CDI unit virtually maintenance free. As the flywheel rotates, electrical power (alternating current) is produced by the capacitor charging coil. This power is rectified by diodes so that direct current voltage is utilized by the ignition system. When the silicone controlled rectifier (SCR) is off, the D.C. voltage is stored by the capacitor. As the flywheel rotates 360° from the point at which charging of the system began, the trigger coil produces voltage which is rectified and applied to the (SCR) gate. This gate signal then turns on the (SCR) and the stored voltage is shorted to ground thru the primary winding of the ignition coil. The voltage discharged to the primary winding of the ignition coil causes a surge of high voltage to be induced in the secondary winding of the ignition coil. This induced voltage of sufficient amplitude causes the spark plugs to fire. The voltage stored by the capacitor holds the (SCR) on until the ignition coil current is discharged. Then once the capacitor has discharged, the (SCR) turns off and the ignition cycle is repeated. Actuating the stop switch shorts the power being produced by the charge coil to ground. This prevents charging of the capacitor and thus stops spark plug firing. Ignition Component Description Capacitor Discharge Unit (CDI) a a -Ignition CDI Unit (Capacitor Discharge Ignition) Under normal operating conditions the CDI unit control the following: 1. Control ignition spark timing by monitoring the trigger pulses. 2. Maintains an idle timing of 5° BTDC. 3. Advances spark timing quickly to 35° BTDC under hard acceleration conditions. 4. Limits RPM of the engine to 2000 RPM in the event of low oil pressure conditions. NOTE:The CDI unit controls all timing operations. There is no timing adjustment required on this outboard engine. 90-827857R1 NOVEMBER 1996 ELECTRICAL - 2A-1 Trigger Coil a a -Trigger Coil A single wound coil with magnet core mounted to one side of the stator mounting base. The trigger is positioned on the outside of the flywheel assembly and is charged when a raised boss on the flywheel passes the trigger/magnet winding. A pulse voltage is then sent to an (SCR) switch within the CDI unit. The trigger is mounted in a fixed timing position. Stator Assembly a b a -Ignition Charge Coil b -Lighting System Coils and Electrothermal Valve Coils The stator assembly located under the flywheel contains the Ignition Charge Coils, Lighting System Coils and the Electrothermal Valve Coils. All of these coils make up the stator assembly. As the flywheel permanent magnets pass the respective stator coil windings, an AC pulse current is produced at each coil winding when magnet polarity changes. (South to North), (North to South) etc. Flywheel Assembly a b c a -Permanent Magnet b -Raised Boss (trigger actuation point) c -Flywheel The flywheel assembly contains one permanently charged magnet which is bonded and retained to the inner wall of the flywheel. This magnet is segmented with 3 positive and 3 negative poles. (6 pole) (3 positive pulses per revolution). Ignition Coil a a -Ignition Coil and High Tension Lead Assembly The primary (+) side of the ignition coil receives voltage discharged from a capacitor in the ignition (CDI) unit. The voltage is multiplied by the coil until it can jump the spark plug gap. The ignition coil will produce a high voltage current each crankshaft revolution, producing a spark at each cylinder at the same time (Waisted Spark Ignition). Ignition coil maximum output is approximately 40,000 volts. 2A-2 - ELECTRICAL 90-827857R1 NOVEMBER 1996 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 VDC test position should be used. NOTE: Test leads are not supplied with the Direct Voltage Adapter. Use test leads supplied with multi meter. Test procedures and specifications are provided for checking primary ignition voltage while the engine is running and/or being “cranked” with all harnesses connected. 90-827857R1 NOVEMBER 1996 ELECTRICAL - 2A-3 Ignition Troubleshooting WARNING DANGER - HIGH VOLTAGE/SHOCK HAZARD! Do not touch ignition components and/or metal test probes while engine is running and/or being “cranked”. STAY CLEAR OF SPARK PLUG LEADS. To assure personal safety, each individual spark plug lead should be grounded to engine. WARNING When testing or servicing the ignition system, high voltage is present. DO NOT TOUCH OR DISCONNECT any ignition parts while engine is running. Tool: Multimeter/DVA Tester 91-99750A1 Component Test Selector Sw. Position DVA Lead Red DVA Lead Black Voltage Read- ing(1) @300-3000 RPM Coil Primary 400 DVA* Coil (–) Black (B) Lead (2) ** Coil (+) Orange (O) Lead (2) ** 200-340 (1) Stator Charge Coil 400 DVA* Brown (Br) Lead (2) Ground 210-340 (1) (CDI) Unit Stop Circuit 20 DVA (CDI) Unit White (W) Lead (2) Ground 2-5 *If using a meter that requires a DVA adapter, place selector switch to the 400 VDC position. ** Reverse Polarity (1)Readings may vary at cranking speed or at idle speed. (2)Back probe the electrical lead bullet connector in order to make connection. Multimeter Ohm Checks Tested Part Multimeter Wires Connected To: Meter Scale Meter Reading Stator Charge Coil Red Black Blue (L) Brown (Br) R x 1 W 280-420 Trigger Coil Red Black White/Red (W/R) Black (B) R x 1 W 168-252 Ignition Coil Primary (with wires disconnected) Red Black Orange (O) Black (B) R x 1 W 0.08-0.22 Ignition Coil Secondary (test with coil leads disconnected and the high tension lead cap removed)*** Red Black High Tension Lead #1 High Tension Lead #2 k W 13-16 NOTE:Copper is an excellent conductor, however resistance may notably vary between low and high temperature. Therefore, reasonable differences can be accepted between resistance readings and specifications. The above readings are for a cold (room temperature) engine. Resistance will increase if the engine is warm. *** High tension lead cap contain a 5k ohm resister. Remove caps when making secondary ignition coil test. 2A-4 - ELECTRICAL 90-827857R1 NOVEMBER 1996 Trigger Stator (CDI) Unit a - stop circuit lead Ignition Coil Spark Plugs a - ignition coil b - (CDI) unit c - stator ground High Tension Lead Spark Plug a - ignition coil b - (CDI) unit c - stator sion) Weak Charge Coil (CDI) Unit Failure Spark Plug(s) Loss Of Oil Pressure: (CDI) Unit Trigger Stator (CDI) Unit a - stop circuit lead Ignition Coil Spark Plugs a - ignition coil b - (CDI) unit c - stator ground High Tension Lead Spark Plug a - ignition coil b - (CDI) unit c - stator sion) Weak Charge Coil (CDI) Unit Failure Spark Plug(s) Loss Of Oil Pressure: (CDI) Unit c. Disconnect and reconnect ignition harness Ignition Diagnostic connectors to verify proper continuity. Procedures SUGGESTED TESTING PROCEDURES TROUBLESHOOTING TIP: With engine running, use inductive timing light to check spark advance of NOTE: The following recommended tests and probeach cylinder as throttle is opened and closed. If tim able causes are not listed in any specific order. The ing advances and retards smoothly on each cylin technician should use this table as a guide to help der, ignition system is MOST LIKELY functioning isolate and test the specific problem/condition. properly. Always perform the DVA tests first (if applicable), then perform resistance test to validate suspected IMPORTANT: If outboard appears to have an igni component failure. tion system failure, it is recommended that before beginning in-depth troubleshooting: a. Ensure that the engine is mechanically sound *Recommended Test condition. (Fuel System, Cylinder Compres (1) DVA TEST (Direct Voltage Adapter) sion etc.). (2) OHM TEST (Resistance Testing) b. Check all engine ground leads for loose or (3) Replace Component and Retest corroded connections. (4) Mechanical Test/Repair PROBLEM/CONDITION Probable Cause *Perform Test No. No Spark Condition (Both Cylinders) 2 1-2 1-3 Stop Circuit Short to Ground: 2 b - lanyard stop switch 2 c - tiller handle stop button 2 d- remote control harness 2 2 3 Open Ground Condition: 2 3 2 No Spark Condition (One Cylinder) 2 Spark Plug Cap (Resistor) 2 3 Weak Spark Condition Ground Connection at: (Low Primary Voltage) 2 2 2 High Resistance To Ground at: a - stop /lanyard switch(water/corro 2 1-2 1-3 Ignition Coil/High Tension Lead(s) 2 3 Spark Plug Cap (Resistor) 2 Timing Fluctuates Note: It is considered normal for the timing to a - timing retards and fluctuates, rpm 4 fluctuate approximately 1° - 2° within the will drop below 2000 rpm designated timing window. Flywheel Key Sheared 4 3 90-827857R1 NOVEMBER 1996 ELECTRICAL - 2A-5 *Recommended Test (cont.) (1) DVA TEST (Direct Voltage Adapter) (2) OHM TEST (Resistance Testing) (3) Replace Component and Retest (4) Mechanical Test/Repair PROBLEM/CONDITION Probable Cause *Perform Test No. Timing Will Not Advance Low Oil Pressure: a - timing retards and fluctuates, rpm will remain below 2000 rpm 4 (CDI) Unit 1-3 Engine Misfires At High RPM Low Oil Pressure: a - timing retards and fluctuates, rpm will remain below 2000 rpm 4 Ignition Coil/High Tension Lead(s) 2 Spark Plug Cap(s) 5k W Resistor 2 Spark Plug(s) 3 (CDI) Unit Ground Connection: 1-3 a - (CDI) unit 2 b - ignition coil 2 c - stator 2 Engine Hard To Start Cold Debris In Carburetor Enrichener Circuit Weak Spark Condition Throttle Plate in Open Position 4 1 4 Engine Hard To Start Hot Weak Spark Condition Vapor Lock 4 1 Engine Will Not Run Over 2000 RPM Low Oil Pressure a - timing retards and fluctuates, rpm will remain below 2000 rpm 4 Stator 1-2 Ignition Coil/High Tension Lead(s) 2 (CDI) Unit 1-3 Spark Plug(s) 3 Engine Occasionally Misfires Charge Coil 1-2 (CDI) Unit 1-3 Ignition Coil/High Tension Lead(s) 2 Spark Plug Cap(s) 5k W Resistor 2 Spark Plug(s) Ground Connection at: 3 a - ignition coil 2 b - (CDI) unit 2 c - stator High Resistance To Ground at: 2 a - stop /lanyard switch(water/corrosion) 2 Engine Surges Over 5700 RPM While Boat Under Propped 4 Under Load Note: The engine (CDI) unit will retard timing and reduce RPM above 5700 RPM. Propeller Hub Spun 4 2A-6 - ELECTRICAL 90-827857R1 NOVEMBER 1996 Testing Ignition Components Resistance Tests When performing resistance tests, all component leads must be disconnected. Readings may very slightly due to temperature changes. Reading listed taken at 68° (20° C). TRIGGER COIL TEST METER TEST LEADS METER SCALE READING RED BLACK RX1 168-252WHITE/ RED (BLACK) STATOR TEST (IGNITION CHARGE COIL) LIGHTING COIL METER TEST LEADS METER SCALE READING RED BLACK RX1RX1 6 AMP 073 109 0.73-1.09GREEN GREEN GREEN GREEN RX1 10 AMP 0.91-1.37 WHITE/ GREEN BLACK RX1 10 AMP 0.96-1.44 ELECTROTHERMAL VALVE COIL METER TEST LEADS METER SCALE READING RED BLACK RX1RX1 024 050 0.24-0.50BLACK BLACK METER TEST LEADS METER SCALE READING RED BLACK RX1RX1 280 420 280-420BLUE BROWN 90-827857R1 NOVEMBER 1996 ELECTRICAL - 2A-7 Resistance Tests (cont.) IGNITION COIL (PRIMARY) METER TEST LEADS METER SCALE READING RED BLACK RX1RX1 008 022 0.08-0.22ORANGE BLACK NOTE: High tension cables must have spark plug cap removed before testing. Cap contains 5k ohm resistor. IMPORTANT: To remove spark plug cap from high tension leads, turn cap counterclockwise while applying slight outward pressure. DO NOT PULL HARD or lead may be damaged. To install cap, turn cap clockwise threading cap onto high tension lead. SPARK PLUG CAP REMOVAL SPARK PLUG CAP RESISTOR TEST METER TEST LEADS METER SCALE READING RED BLACK KW 4.90-5.10 NOTE:High tension cables must be installedinto spark plug cap before testing ignition coil secondary. IGNITION COIL (SECONDARY) METER TEST LEADS METER SCALE READING RED BLACK KWKW 13 16 13-16#1 CABLE #2 CABLE 2A-8 - ELECTRICAL 90-827857R1 NOVEMBER 1996 Flywheel Removal and Installation Flywheel Removal WARNING Engine could possibly start when turning flywheel during removal and installation. To prevent this type of accidental engine starting and possible serious injury, always remove spark plug leads from spark plugs. 1. Disconnect spark plug leads from spark plugs. 2. Remove flywheel cover by loosening thumb screw (a) and pull out lock pin (b). b a a -Thumb Screw b -Lock Pin 3. Hold flywheel from turning using flywheel holder (91-83163M). Remove nut and washer. a 53281 4. Remove flywheel using puller (91-83164M). a a -Flywheel Puller (91-83164M) Flywheel Installation 1. Place flywheel key into slot. 2. Install flywheel. 3. Hold flywheel from turning using flywheel holder (91-83163M). Apply oil to threads on crankshaft and tighten nut to the specified torque. b c a d 53278 a b c d -Flywheel Key -Washer -Nut -Apply Oil to Threads Flywheel Nut Torque 72 lb ft (100 N·m) a -Flywheel Holder (91-83163M) 90-827857R1 NOVEMBER 1996 ELECTRICAL - 2A-9 Ignition Cover Removal and Installation 1. Loosen screw and remove cover. c b a a -Ignition Cover b -Screw (Tighten Securely for Reassembly) c -Fuse Holder (Electric Start Models) Place into Retainer Wire Holder 1. Disconnect wires for removal of ignition components. Refer to Section 2 Part D Wiring Diagrams when reconnecting wires. 2. Assemble the wires connections into the slots in the wire holder for best fit. a 28370 a -Wire Holder - Assemble Wires in Holder for Best Fit (CDI) Unit Removal and Installation 1. Remove and install the (CDI) unit as shown. NOTE:Ignition coil was removed in picture to show proper wire routing. 2. Refer to Section 2 Part D for Wiring Diagrams. c b a a -(CDI) Unit b -Mounting Bolts (2) c -Ground Connection (CDI) Mounting Bolt Torque 70 lb in (8 N·m) 2A-10 - ELECTRICAL 90-827857R1 NOVEMBER 1996 Ignition Coil Removal and Installation 1. Remove and install ignition coil as shown. 2. Refer to Section 2 Part D for Wiring Diagrams. 28342 b a c a -Coil Assembly b -Mounting Plate c -Mounting Bolts (2) and Flat Washers (2) Rectifier Removal and Installation 1. Remove and install rectifier as shown. 2. Refer to Section 2 Part D for Wiring Diagrams. b a c 28370 a b c -Rectifier -Bolts (2) -Connect Black Ground Wire to Engine Ground Rectifier Mounting Bolt Torque 70 lb in (8 N·m) Ignition Coil Mounting Bolt Torque 70 lb in (8 N·m) 90-827857R1 NOVEMBER 1996 ELECTRICAL - 2A-11 2A-12 - ELECTRICAL 90-827857R1 NOVEMBER 1996 Stator Removal and Installation 1. Remove flywheel. Refer to Flywheel Removal. 2. Remove and install the stator as shown. NOTE: Switch Box was removed in picture to show proper wire routing. 3. Fasten the main wiring harness from the stator and trigger coil harness together with a sta strap. 4. Refer to Section 2D for Wiring Diagrams. 28338 b c a a - Stator b - Mounting Bolts (3) 1.00 in (25 mm) Long Apply Loctite 222 to Threads c - Sta-Strap Stator Bolt Torque 70 lb in (8 N·m) 5. Route stator wires (black) thru hole in the top flange and connect wires to the auto choke control. Secure wire connections inside the J-clamp. 28333 d e d - Route Stator Wires thru Hole e - Secure Wires in J-Clamp 90-827857R1 NOVEMBER 1996 ELECTRICAL - 2A-13 Trigger Coil Removal and Installation 1. Remove and install the trigger coil as shown. 2. Fasten trigger coil harness to stator harness with sta-strap. NOTE: Flywheel and Switch Box were removed in picture to show proper wire routing. 3. Set the air gap at 0.030 in. (0.77 mm) between the trigger and flywheel. 4. Refer to Section 2 Part D for Wiring Diagrams. 28338 b c a .030 in. (0.77 mm) d a - Trigger Coil b - Screw - Tighten Securely c - Sta-Strap d - Air Gap 0.030 in. (0.77 mm) ELECTRICAL B 2 CHARGING & STARTING SYSTEM Table of Contents Page Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1 Recommended Battery . . . . . . . . . . . . . . . . . 2B-1 Operating Engine Without Battery . . . . . . . . 2B-1 Specific Gravity Readings . . . . . . . . . . . . . . 2B-1 Specific Gravity Cell Comparison Test . 2B-2 Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Charging A Discharged Battery . . . . . . . . . . 2B-2 Winter Storage of Batteries . . . . . . . . . . . . . 2B-3 Charging System Troubleshooting . . . . . . . 2B-3 Battery Charging System . . . . . . . . . . . . . . . . . . 2B-4 6 Ampere Charging System Manual Start Models . . . . . . . . . . . . . . . . . . 2B-4 Description: . . . . . . . . . . . . . . . . . . . . . . . . 2B-4 Battery Charging System (cont.) . . . . . . . . . . . 2B-5 10 Ampere Charging System Electric Start Models . . . . . . . . . . . . . . . . . . 2B-5 Description: . . . . . . . . . . . . . . . . . . . . . . . . 2B-5 Optional Electrical Accessories Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-6 Stator Ohms Test (Alternator Lighting/Charging Coil) . . . . . . . 2B-7 Lighting Coil . . . . . . . . . . . . . . . . . . . . . . . . 2B-7 Alternator System Test (6 Ampere Stator) . . . . . . . . . . . . . . . . . . . . . 2B-7 Alternator System Test (10 Ampere Stator) . . . . . . . . . . . . . . . . . . . . 2B-7 Rectifier/Regulator Diode Test . . . . . . . . . . . 2B-8 Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9 Starter Motor Amperes Draw . . . . . . . . . . . . 2B-9 Starting system Components . . . . . . . . . 2B-9 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9 Troubleshooting the Starting Circuit . . . . . . 2B-9 Starter Relay Test . . . . . . . . . . . . . . . . . . . 2B-9 STARTER MOTOR ASSEMBLY . . . . . . . . . . . 2B-12 Starter Motor Removal . . . . . . . . . . . . . . . . . . . 2B-13 Starter Motor Disassembly . . . . . . . . . . . . . . . 2B-13 Cleaning and Inspection. . . . . . . . . . . . . . . . . . 2B-13 Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-14 Brush Holder . . . . . . . . . . . . . . . . . . . . . . 2B-14 Armature Inspection/Testing . . . . . . . . . 2B-14 Starter Motor Reassembly . . . . . . . . . . . . . . . . 2B-16 Starter Motor Installation . . . . . . . . . . . . . . . . . 2B-17 90-827857R1 NOVEMBER 1996 Battery Precautions When charging batteries, an explosive gas mixture forms in each cell. A portion of this gas escapes thru holes in vent plugs and may form an explosive atmosphere around battery if ventilation is poor. This explosive gas may remain in or around battery for several hours after it has been charged. Sparks or flames can ignite this gas and cause an internal explosion which may shatter the battery. The following precautions should be observed to prevent an explosion. 1. DO NOT smoke near batteries being charged or which have been charged very recently. 2. DO NOT break live circuits at terminals of batteries because a spark usually occurs at the point where a live circuit is broken. Always be careful when connecting or disconnecting cable clamps on chargers. Poor connections are a common cause of electrical arcs which cause explosions. 3. DO NOT reverse polarity of battery cables on battery terminals. CAUTION If battery acid comes into contact with skin or eyes, wash skin immediately with a mild soap. Flush eyes with water immediately and see a doctor. Recommended Battery A 12 volt battery with a “Cold Cranking Amperage” rating minimum of 350 amperes. 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 lighting coil leads (GREEN and GREEN/WHITE bullet connectors) from rectifier. a Specific Gravity Readings Use a hydrometer (a) to measure specific gravity of electrolyte in each cell. Hydrometer measures percentage of sulfuric acid in battery electrolyte in terms of specific gravity. As a battery drops from a charged to a discharged condition, acid leaves the solution and chemically combines with the plates, causing a decrease in specific gravity of electrolyte. An indication of concentration of electrolyte is obtained with a hydrometer. When using a hydrometer, observe the following points: 1. Hydrometer must be clean (inside and out) to insure an accurate reading. 2. Never take hydrometer readings immediately after water has been added. Water must be thoroughly mixed with electrolyte by charging for at least 15 minutes at a rate high enough to cause vigorous gassing. 3. If hydrometer has built-in thermometer, draw liquid in several times to ensure correct temperature before taking reading. 90-827857R1 NOVEMBER 1996 ELECTRICAL - 2B-1 4. Hold hydrometer vertically and draw in just enough liquid from battery cell so that float is free- floating. Hold hydrometer at eye level so that float is vertical and free of outer tube, then take reading at surface of liquid. Disregard curvature where liquid rises against float stem due to capillary action. 5. Avoid dropping electrolyte on boat or clothing, as it is extremely corrosive. Wash off immediately with baking soda solution. Specific gravity of electrolyte varies not only with percentage of acid in liquid but also with temperature.As temperature drops, electrolyte contracts, so that specific gravity increases. Unless these variations in specific gravity are taken into account, specific gravity obtained by hydrometer may not give a true indication of concentration of acid in electrolyte. A fully charged battery will have a specific gravity reading of approximately 1.270 at an electrolyte temperature of 80° F (27° C). If electrolyte temperature is above or below 80° F, additions or subtractions must be made in order to obtain a hydrometer reading corrected to 80° F standard. For every 10° F (3.3° C) above 80° F, add 4 specific gravity points (.004) to hydrometer reading. Example: A hydrometer reading of 1.260 at 110° F (43° C) would be 1.272 corrected to 80° F, indicating a fully charged battery. For every 10° below 80° F, subtract 4 points (.004) from the reading. Example: A hydrometer reading of 1.272 at 0° F (-18° C) would be 1.240 corrected to 80° F, indicating a partially charged battery. SPECIFIC GRAVITY CELL COMPARISON TEST This test may be used when an instrumental tester is not available. To perform this test, measure specific gravity of each cell, regardless of state of charge, and interpret results as follows: If specific gravity readings show a difference between highest and lowest cell of .050 (50 points) or more, battery is defective and should be replaced. Electrolyte Level Check electrolyte level in battery regularly. A battery in use in hot weather should be checked more frequently because of more rapid loss of water. If electrolyte level is found to be low, then distilled water should be added to each cell until liquid level rises approximately 3/16” (4.8mm) over plate. DO NOT OVERFILL, because this will cause loss of electrolyte and result in poor performance, short life and excessive corrosion. CAUTION During service, only distilled water should be added to the battery, not electrolyte. Charging A Discharged Battery The following basic rules apply to any battery charging situation: 1. Any battery may be charged at any rate (in amperes) as long as spilling of electrolyte (from violent gassing) does not occur and as long as electrolyte temperature does not exceed 125° F (52° C). If spewing of electrolyte occurs, or if electrolyte temperature exceeds 125° F, charging rate (in amperes) must be reduced or temporarily halted to avoid damage to the battery. 2. Battery is fully charged when, over a 2-hour period at a low charging rate (in amperes), all cells are gassing freely (not spewing liquid electrolyte), and no change in specific gravity occurs. Full charge specific gravity is 1.260-1.275, corrected for electrolyte temperature with electrolyte level at 3/16” (4.8mm) over plate. For most satisfactory charging, lower charging rates in amperes are recommended. 3. If, after prolonged charging, specific gravity of at least 1.230 on all cells cannot be reached, battery is not in optimum condition and will not provide optimum performance; however, it may continue to provide additional service, if it has performed satisfactorily in the past. 4. To check battery voltage while cranking engine with electric starter motor, place RED (+) lead of tester on POSITIVE (+) battery terminal and BLACK (–) lead of tester on NEGATIVE (–) battery terminal. If the voltage drops below 9-1/2 volts while cranking, the battery is weak and should be recharged or replaced. 2B-2 - ELECTRICAL 90-827857R1 NOVEMBER 1996 Winter Storage of Batteries Battery companies are not responsible for battery damage, either in winter storage or in dealer stock, if the following instructions are not observed: 1. Remove battery from its installation as soon as possible and remove all grease, sulfate and dirt from top surface by running water over top of battery. Be sure, however, that vent caps are tight beforehand, and blow off all excess water thoroughly with compressed air. Check water level, making sure that plates are covered. 2. When adding distilled water to battery, be extremely careful not to fill more than 3/16” (4.8mm) over plate inside battery. Battery solution or electrolyte expands from heat caused by charging. Overfilling battery will cause electrolyte to overflow (if filled beyond 3/16” over plate). 3. Grease terminal bolts well with Quicksilver 2-4-C Marine Lubricant, and store battery in COOLDRY place. Remove battery from storage every 30-45 days, check water level (add water if necessary), and put on charge for 5 or 6 hours at 6 amperes. DO NOT FAST CHARGE. 4. If specific gravity drops below 1.240, check battery for reason, and then recharge. When gravity reaches 1.260, discontinue charging. To check specific gravity, use a hydrometer, which can be purchased locally. 5. Repeat preceding charging procedure every 30-45 days, as long as battery is in storage. When ready to place battery back in service, remove excess grease from terminals (a small amount is desirable on terminals at all times), recharge again as necessary and re-install battery. WARNING Hydrogen and oxygen gases are produced during normal battery operation or charging. Sparks or flame can cause this mixture to ignite and explode, if they are brought near the battery. Sulfuric acid in battery can cause serious burns, if spilled on skin or in eyes. Flush or wash away immediately with clear water. Charging System Troubleshooting CAUTION The charging system may be damaged by: 1) reversed battery cables, 2) running the engine with battery cables disconnected and stator leads connected to rectifier, and 3) and open circuit, such as a broken wire or loose connection. A fault in the battery charging system usually will cause the battery to become undercharged. Check battery electrolyte level, and charge battery. See “Electrolyte Level”, and “Charging a Discharged Battery”. If battery will NOT accept a satisfactory charge, replace battery. If battery accepts a satisfactory charge, determine the cause of the charging system problem as follows. 1. Check for correct battery polarity [RED cable to POSITIVE (+) battery terminal]. If polarity was incorrect, check for damaged rectifier. See “RECTIFIER TEST”. 2. Check for loose or corroded battery connections. 3. Visually inspect wiring between stator and battery for cuts, chafing; and disconnected, loose or corroded connection. 4. Excessive electrical load (from too many accessories) will cause battery to run down. If visual inspection determines that battery connections and wiring are OK, perform the following stator and rectifier tests. 90-827857R1 NOVEMBER 1996 ELECTRICAL - 2B-3 Battery Charging System 6 Ampere Charging System Manual Start Models DESCRIPTION: The 6 ampere lighting coil is part of the stator assembly and is on all manual start model engines. The coil assembly is capable of producing and unregulated AC current. NOTE:The 6 ampere stator supplied with the manual start engine is designed to be used with a lighting regulator kit (optional) to provide AC voltage for running lights. An optional battery charging kit is also available. a b c d a -Stator Lighting Coil b -Stator Assembly c -Stator Lead d -Tachometer Signal Color Code W/R = WHITE/RED Br = BROWN L = BLUE B = BLACK W = WHITE P = PINK Y/R = YELLOW/RED G = GREEN O = ORANGE G/W = GREEN/WHITE R = RED B/Y = BLACK/YELLOW GRAY = GRAY TAN/BLU = TAN/BLUE TAN/WHT= TAN/WHITE PUR = PURPLE 2B-4 - ELECTRICAL 90-827857R1 NOVEMBER 1996 Battery Charging System (cont.) 10 Ampere Charging System Electric Start Models DESCRIPTION: The battery charging system components are the stator lighting coils, rectifier/regulator and battery. Alternating current (generated in stator lighting coils) flows to the rectifier/regulator, which changes the alternating current to a regulated direct current for charging the battery. Color Code W/R = WHITE/RED Br = BROWN L = BLUE B = BLACK W = WHITE P = PINK Y/R = YELLOW/RED G = GREEN O = ORANGE G/W = GREEN/WHITE R = RED B/Y = BLACK/YELLOW GRAY = GRAY TAN/BLU = TAN/BLUE TAN/WHT= TAN/WHITE PUR = PURPLE a -Stator Lighting Coil b -20 Ampere Fuse c -Starter Motor Assembly d -Battery e -Starter Solenoid f -Rectifier/Regulator g -Stator Assembly h -Tachometer Signal 90-827857R1 NOVEMBER 1996 ELECTRICAL - 2B-5 Optional Electrical Accessories Wiring Diagrams Manual Start Model with Battery Charging Kit Rectifier GG Manual Start Model with Lighting Coil and Unregulated AC Voltage GG AC Lighting Voltage Regulator GG Manual Start Model with Voltage Regulator 2B-6 - ELECTRICAL 90-827857R1 NOVEMBER 1996 Stator Ohms Test Stator Ohms Test (Alternator Lighting/Charging Coil) NOTE:Stator can be tested without removing from engine. 1. Disconnect the both green and the green/white (stator leads) bullet connectors from the rectifier/ regulator assembly. NOTE: On manual start models, equipped with lighting regulator or battery charging rectifier, remove both green lead bullet connectors. 2. Using and ohm meter and perform the following test. NOTE:When measuring the resistance of 10 ohms or less using an digital ohm meter, if the correct measurement cannot be obtained, place the meter selector to a lower resistance measurement. LIGHTING COIL G G B W/G METER TEST LEADS METER SCALE READING RED BLACK RX1RX1 6 AMP 073 109 0.73-1.09G G G G RX1 10 AMP 0.91-1.37 WHITE/ GREEN (W/G) BLACK (B) RX1 6/10 AMP 0.96-1.44 Alternator System Test (6 Ampere Stator) CAUTION When testing any charging system, the technician must use an amp meter capable of reading the maximum current output for the test being performed or higher. Failure to use a amp meter that can handle the specific current load could possibly damage the meter being used. IMPORTANT: Rectifier (optional accessory) must be functioning properly for accurate test results to be obtained. 1. Remove RED lead from (+) terminal of rectifier. 2. Connect RED (+) ammeter lead to rectifier (+) terminal and BLACK (–) ammeter lead to RED rectifier lead. 3. With engine running at the indicated RPM, the ammeter should indicate the following approximate amperes: 6 Ampere6 Ampere Stator RPM AMPERES Idle 1.0 1000 1.05 2000 4.61 3000 5.7 4000 5.91 4. If proper ampere readings are not obtained, replace stator. Alternator System Test (10 Ampere Stator) 1. Check battery voltage at battery with engine running. 2. If battery voltage is above 14.5-15.0 volts, replace voltage regulator/rectifier. Check condition of battery as overcharging may have damaged battery. 3. If battery voltage is below 14.5 volts, charge battery; refer to “CHARGING A DISCHARGED BATTERY”. If battery can NOT be satisfactorily charged, replace battery. 4. If battery accepts a satisfactory charge, check battery voltage while cranking engine; refer to “CHARGING A DISCHARGED BATTERY”. If cranking voltage is not acceptable, replace battery. 90-827857R1 NOVEMBER 1996 ELECTRICAL - 2B-7 5. If cranking voltage is acceptable, disconnect RED (fused) lead bullet connector between the positive (+) starter solenoid terminal and Red lead from rectifier/regulator. 6. Connect RED (+) ammeter lead to RED lead from fuse, and the BLACK (–) ammeter lead to the bullet from POSITIVE terminal from rectifier/regulator. 7. Secure starter wires away from flywheel. 8. With engine running at the indicated RPM’s, the ammeter should indicate the following appropriate amperes: 10 A 10 Ampere StatorStator RPM AMPERES Idle 2.4 1000 2.4 2000 6.7 3000 8.0 4000 8.3 9. A reading of 8-8.3 amperes at 4000 RPM indicates the charging system is functioning properly. 10. If ammeter reads less than required amperes @ 4000 RPM, test the stator; refer to “Stator Ohm Test”. If stator tests OK, replace rectifier/regulator. a b c d e f Rectifier/Regulator Diode Test Chart Red (+) Meter Lead To: Black Green/White Green White/Green Red Black 0.50 to 1.80 * 0.75 to 2.00 * Green/White 0.30 to 0.80 * 0.30 to 0.80 * Green 0.30 to 0.80 0.75 to 2.00 0.95 to 2.00 * White/Green * * * * Red 0.65 to 0.95 0.30 to 0.80 0.30 to 0.80 0.65 to 1.07 * Measured value is not affected by tester lead connection. Rectifier/Regulator Diode Test a -Voltage Regulator/Rectifier b -Ground Lead Eyelet (Black) c -Stator Lead Green d -Stator Lead (White/Green) e -Stator Lead (Green/White) f -Stator Lead (Red) IMPORTANT: When performing a diode test on the rectifier/regulator, use only a digital meter with the capability of selecting a diode inspection mode. NOTE: Due to differences in the manufacturing of ohmmeters, the internal polarity may vary from manufacture to manufacture. As a result, the test readings may be a direct reversal of the readings specified. If so, reverse the meter leads and perform the test again. A slight variance from the listed specification does not necessarily indicate a defective component. 2B-8 - ELECTRICAL 90-827857R1 NOVEMBER 1996 Starting System Starter Motor Amperes Draw Starter Motor No Load Ampere Draw* Normal Ampere Draw* Part No. 82599A1 14.2 41.5 Starter Motor Teeth 11 *Test must be taken with fully charged battery. STARTING SYSTEM COMPONENTS The starting system consists of the following components. 1. Battery 2. Starter Solenoid 3. Neutral Safety Switch 4. Starter Motor 5. Ignition Switch Description The function of the starting system is to crank the engine. The battery supplies electrical energy to crank the starter motor. When the ignition switch is turned to “START” position, the starter solenoid is activated and completes the starting circuit between the battery and starter. The neutral start switch opens the start circuit when the shift control lever is not in neutral. This prevents accidental starting when engine is in gear. CAUTION Troubleshooting the Starting Circuit Before beginning the starting circuit troubleshooting flow chart, following, check first for the following conditions: 1. Make sure that battery is fully charged. 2. Check that control lever is in “NEUTRAL” position. 3. Check terminals for corrosion and loose connections. 4. Check cables and wiring for frayed and worn insulation. 5. Check in-line fuse in RED wire; see diagram. STARTER RELAY TEST 1. Inspect starter relay for cracks, loose terminals or loose terminal lead connections. 2. Connect ohm meter between terminals of starter relay. 3. Connect the BLACK lead from relay to battery negative (–) terminal and momentarily connect the BROWN lead to the positive (+) terminal of battery. 4. Verify continuity between the starter relay terminals when 12 volts are applied. a b c 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. a -BROWN Lead b -Starter Relay c -BLACK Lead 90-827857R1 NOVEMBER 1996 ELECTRICAL - 2B-9 The following “STARTING CIRCUIT TROUBLESHOOTING FLOW CHART” is designed as an aid to troubleshooting the starting circuit. This flow chart will accurately locate any existing malfunction. Location of “TEST POINTS” (called out in the chart) are numbered in diagram below. To Rectifier/ Regulator 1 2 3 45 6 7 Y/R B B Starter Switch Neutral Start Switch Starter Motor Starter Solenoid NEUTRAL START SWITCH (LOCATED IN CONTROL HOUSING IF ENGINE IS EQUIPPED WITH REMOTE CONTROL) Battery Starting Circuit Troubleshooting Flow Chart Starter Motor Does Not Turn SAFETY WARNING: Disconnect BLACK (starter motor) cable from starter solenoid test point 1 BEFORE making tests 1-thru-7 to prevent unexpected engine cranking. TEST 1 Use an ohmmeter (R x 1 scale) and connect meter leads be- tween NEGATIVE (-) battery post and common powerhead ground. No continuity indicated; there is an open circuit in the BLACK NEGATIVE (-) battery cable between the NEGATIVE (-) battery post and the powerhead. • Check cable for loose or corroded connections. • Check cable for open. Continuity Indicated Proceed to TEST 2, on next page. 2B-10 - ELECTRICAL 90-827857R1 NOVEMBER 1996 a. Disconnect BLACK ground wire(s) from Test Point 2. b. Connect voltmeter between common engine ground and Test Point 2. c. Turn ignition key to “Start” position. * Battery Voltage TEST 2 TEST 3 TEST 4 TEST 5 TEST 6 TEST 7 TEST 8 12 Volt Reading* 12 Volt Reading 12 Volt Reading* 12 Volt Reading* 12 Volt Reading* 12 Volt Reading* 12 Volt Reading* No voltage reading; proceed to TEST 3. No voltage reading; proceed to TEST 4. No voltage reading; proceed to TEST 5. No voltage reading; proceed to TEST 6. a. Reconnect BLACK ground wire(s). b. Connect voltmeter between common engine ground and Test Point 3. c. Turn ignition key to “Start” position. Check BLACK ground wire for poor connection or open circuit. Reconnect ground wire to starter solenoid; proceed to TEST 7. Neutral start switch is open, or YELLOW/RED or BLACK wire is open between Test Points 4 and 3. a. Connect voltmeter between common engine ground and Test Point 4. b. Turn ignition key to “Start” position. Defective starter solenoid. Connect voltmeter between common engine ground and Test Point 5. Defective ignition switch. Connect voltmeter between common engine ground and Test Point 6. No voltage reading; check BLACK/WHITE wire between battery (+) positive terminal and Test Point 6. Check fuse in RED wire between test points 5 and 6. Check for open RED wire between test points 5 and 6. a. Connect voltmeter between common engine ground and Test Point 1. b. Turn ignition key to “Start” position. No voltage reading; De- fective starter solenoid. Should hear solenoid click; proceed to TEST 8. a. Reconnect BLACK (starter motor) cable to starter solenoid Test Point 1. b. Connect voltmeter between common engine ground and Test Point 7 c. Turn ignition key to “Start” position. No voltage reading; check BLACK cable for poor connection or open circuit. Check BLACK ground cable at starter for loose or corroded connection, or open circuit. If cable is O.K., check starter motor. Electric Start Tiller Handle Model Neutral start switch is open or BLACK leads are disconnected or damaged. a. Disconnect BLACK ground wire(s) from Test Point 2. b. Connect voltmeter between common engine ground and Test Point 2. c. Turn ignition key to “Start” position. * Battery Voltage TEST 2 TEST 3 TEST 4 TEST 5 TEST 6 TEST 7 TEST 8 12 Volt Reading* 12 Volt Reading 12 Volt Reading* 12 Volt Reading* 12 Volt Reading* 12 Volt Reading* 12 Volt Reading* No voltage reading; proceed to TEST 3. No voltage reading; proceed to TEST 4. No voltage reading; proceed to TEST 5. No voltage reading; proceed to TEST 6. a. Reconnect BLACK ground wire(s). b. Connect voltmeter between common engine ground and Test Point 3. c. Turn ignition key to “Start” position. Check BLACK ground wire for poor connection or open circuit. Reconnect ground wire to starter solenoid; proceed to TEST 7. Neutral start switch is open, or YELLOW/RED or BLACK wire is open between Test Points 4 and 3. a. Connect voltmeter between common engine ground and Test Point 4. b. Turn ignition key to “Start” position. Defective starter solenoid. Connect voltmeter between common engine ground and Test Point 5. Defective ignition switch. Connect voltmeter between common engine ground and Test Point 6. No voltage reading; check BLACK/WHITE wire between battery (+) positive terminal and Test Point 6. Check fuse in RED wire between test points 5 and 6. Check for open RED wire between test points 5 and 6. a. Connect voltmeter between common engine ground and Test Point 1. b. Turn ignition key to “Start” position. No voltage reading; De- fective starter solenoid. Should hear solenoid click; proceed to TEST 8. a. Reconnect BLACK (starter motor) cable to starter solenoid Test Point 1. b. Connect voltmeter between common engine ground and Test Point 7 c. Turn ignition key to “Start” position. No voltage reading; check BLACK cable for poor connection or open circuit. Check BLACK ground cable at starter for loose or corroded connection, or open circuit. If cable is O.K., check starter motor. Electric Start Tiller Handle Model Neutral start switch is open or BLACK leads are disconnected or damaged. 90-827857R1 NOVEMBER 1996 ELECTRICAL - 2B-11 STARTER MOTOR ASSEMBLY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1920 21 4 8 95 95 2-4-C With Teflon (92-825407A12) REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m – 1 STARTER MOTOR 1 1 RETAINER 2 1 GEAR 3 1 BRACKET 4 2 O-RING 5 1 WASHER KIT 6 1 ARMATURE 7 1 STATOR 8 2 SPRING 9 1 BRUSH 10 1 BRUSH HOLDER 11 1 BRUSH 12 1 BRACKET 13 2 BOLT 14 1 NUT 36 4.0 15 1 WASHER 16 1 SCREW 13 17.5 17 1 BATTERY CABLE 18 1 BRACKET 19 3 SCREW 13 17.5 20 3 WASHER 21 2 SCREW 13 17.5 2B-12 - ELECTRICAL 90-827857R1 NOVEMBER 1996 Starter Motor Removal CAUTION Disconnect the battery leads from the battery before removing starter. 1. Disconnect the battery leads from the battery. 2. Disconnect the BLACK cable (w/RED sleeve). 3. Remove starter mounting bolts. 4. Remove ground cable. 5. Remove starter. b a c 28244 a -Black Cable (w/Red Sleeve) b -Mounting Bolts c -Ground Cable Starter Motor Disassembly 1. Using a screwdriver remove the following: • Circlip • Pinion Stopper • Pinion a b c a -Pinion b -Pinion Stopper c -Circlip (discard and use new circlip on assembly) 2. Remove through bolts and disassemble starter motor assembly. Cleaning and Inspection 1. Clean all motor parts. 2. Check pinion teeth for chips, cracks or excessive wear. 3. Replace the drive clutch spring and/or collar, if tension is not adequate, or if wear is excessive. 4. Check that the brush holder is not damaged or is not holding the brushes against the commutator. 5. Replace brushes that are pitted or worn to less than 0.35 - 0.49 in. (9.0 - 12.5 mm) in length. Refer to “BRUSH HOLDER”, following. 6. Replace rear or front cover for excessively worn bushings. 7. Check the armature (commutator) for wear, or being burnt. (A poor connection usually results in a burned commutator bar). 8. Re-surface and undercut a rough commutator. Refer to “Armature Inspection/Testing”. 90-827857R1 NOVEMBER 1996 ELECTRICAL - 2B-13 PINION 1. Check pinion teeth for chips, cracks or excessive wear. a a -Pinion Gear BRUSH HOLDER 1. Inspect brushes for wear. Replace brush holder if not within specifications. a a -Wear Limit - 0.35 - 0.49 in. (9.0 - 12.5 mm) 2. Ohm test the brush holder. The positive (+) brush should not show continuity to brush holder. Replace brush holder assembly if ohm test shows continuity. a b a -Positive (+) Brush Holder b -Brush Holder Assembly ARMATURE INSPECTION/TESTING 1. Inspect the commutator surface of the armature for burnt marks and dirt in commutator grooves. 2. Using a piece of #600 grit wet-or-dry sand paper, clean the surface of the commutator. a b a -Commutator b -Sand Paper (#600 Grit) 2B-14 - ELECTRICAL 90-827857R1 NOVEMBER 1996 3. Measure the armature shaft for deflection. If the armature has greater than 0.002 in. (0.05 mm) deflection, replace armature. a b c a -Armature b -V-Block c -Dial Indicator Gauge 4. Measure the commutator diameter. Replace if not within 1.14 - 1.18 in. (29.0 - 30.0 mm) diameter. MIN. a bb a -Commutator b -Commutator Diameter - 1.14 - 1.18 in. (29.0 - 30.0 mm) 5. Measure the mica undercut of the commutator. Clean out and undercut mica and build up of brush material to a depth of 0.003 - 0.008 in. (0.2 -0.8 mm). a b a -Commutator Depth b -File (or use commutator cutter) 6. After cleaning, ohm test each segment of the commutator as shown. If ohm test reading is other than listed, replace the armature. ARMATURE COIL CONTINUITY METER TEST LEADS METER SCALE READING RED BLACK X1X1 CONTINUITYSEGMENT SEGMENT 90-827857R1 NOVEMBER 1996 ELECTRICAL - 2B-15 a b c a -Commutator b -Lamination c -Shaft ARMATURE COIL CONTINUITY METER TEST LEADS METER SCALE READING RED BLACK X1 NO CONTINUITY SEGMENT LAMINATION SEGMENT SHAFT X1 NO CONTINUITY Starter Motor Reassembly 1. Install brush assembly into the rear cover as shown. a b c d e f g h i a -Screw b -Brush Spring c -Brush Holder d -Brush e -Rear Cover f -Bushing g -Washer h -Lock Washer i -Nut 2B-16 - ELECTRICAL 90-827857R1 NOVEMBER 1996 CAUTION Use care not to scratch the brushes when installing the armature on the rear cover. NOTE:Align the cut in the cover with the projection on the stator. 2. Assembly starter motor assembly aligning the housing marks as shown. a b c d e gh i J k 95 2-4-C w/Teflon (92-825407A12) 95 f a -Front Cover b -O-Ring c -Washer d -Washer e -Washer f -Armature g -Washer h -Through Bolt (2) i -Rear Cover j -O-Ring k -Stator IMPORTANT: Install new circlip when installing pinion onto shaft. NOTE: Make sure the circlip fits tightly into pinion stopper. 3. Install the pinion assembly onto starter shaft. a b c d a b c d a -Circlip b -Pinion Stopper c -Spring d -Pinion Starter Motor Installation 1. Secure starter motor to block. Torque mounting bolts to 13 lb. ft. (18 N·m). 2. Secure ground cable. Torque bolt to 13 lb. ft. (18 N·m). 3. Connect BLACK cable w/RED sleeve to starter stud. b a c 28244 a -Black Cable w/Red Sleeve b -Mounting Bolts -Torque to 13 lb. ft. (18 N·m) c -Black Ground Cable 90-827857R1 NOVEMBER 1996 ELECTRICAL - 2B-17 ELECTRICAL C 2 TIMING, SYNCHRONIZING & ADJUSTING Table of Contents Page Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1 Tiller Handle Cable Adjustment . . . . . . . . . . 2C-2 8.0/9.9 Hp Models W/Side Handle Shift And Single Adjustment Mark Platform . . . . . . 2C-2 8.0/9.9 Hp Models W/Side Handle Shift And Triple Adjustment Mark Platform . . . . . . 2C-2 8.0 Hp Model W/Tiller Handle Shift . . . . 2C-2 9.9 Hp Model W/Tiller Handle Shift . . . . 2C-2 Full Throttle Link Rod Adjustment . . . . . . . . 2C-3 Idle Speed – Initial Setting . . . . . . . . . . . . . . 2C-3 Tiller Handle Models . . . . . . . . . . . . . . . . . 2C-3 Remote Control Models . . . . . . . . . . . . . . 2C-4 Pilot Mixture Screw . . . . . . . . . . . . . . . . . . . . 2C-4 Float Level Adjustment . . . . . . . . . . . . . . . . . 2C-5 90-827857R1 NOVEMBER 1996 (Full Advanced) 2500-3000 RPM (Full Advanced) 2500-3000 RPM Specifications Idle RPM 950 ±50 RPM (Out Of Gear) Trolling RPM 850 ±50 Wide Open Throttle (WOT) RPM 8.0/9.9 (BODENSEE) 5000 - 5500 9.9 4500 - 5500 Pilot Screw (Turns Out) CARBURETOR 8.0/9.9 (BODENSEE) Not Adjustable SPECIFICATIONS 9.9 3 ±1 Main Jet Size 8.0/9.9 (BODENSEE) #82 9.9 #86 Pilot Jet #48 Enrichener Jet .024 (0.61 mm) Float Height* 1 ±0.04 in. (25.5 ±1 mm) Ignition Timing (Full Retarded) 5 °±1 ° B.T.D.C. 850 ±50 RPM SPECIFICATIONS TIMING 35 °±1 ° B.T.D.C. Type Capacitor Discharge Ignition Spark Plug Type (NGK) CR6HS IGNITION Spark Plug Gap 0.024 - 0.028 in. (0.6 - 0.7 mm) SYSTEM Firing Order 1 - 2 NOTE: The 9.9 Four-Stroke C.D.I. 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 as described within the following tests. If the ignition timing does not stay within the timing windows, replace the ignition C.D.I. unit and retest. (Refer to the Ignition Diagnostic Procedures tests in Section 2A.) NOTE: Timing/Synchronizing/Adjusting is the same for all models except where noted. NOTE: Check all electrical connections to ensure they are tight and secure (including battery connections on electric start models). 90-827857R1 NOVEMBER 1996 ELECTRICAL - 2C-1 2C-2 - ELECTRICAL 90-827857R1 NOVEMBER 1996 Tiller Handle Cable Adjustment 8.0 AND 9.9 HP MODELS WITH SIDE HANDLE SHIFT AND SINGLE ADJUSTMENT MARK PLATFORM 1. Position throttle grip to idle position. 2. Check the tiller handle cables for proper adjustment. Pointer on bell crank should line up with the adjustment mark shown. If necessary, adjust cables using jam nuts to remove any slack. (Do Not Over Tighten Cables). a b c a - Cable Bell Crank Pointer b - Adjustment Mark c - Jam Nuts 8.0 AND 9.9 HP MODELS WITH SIDE HANDLE SHIFT AND TRIPLE ADJUSTMENT MARK PLATFORM 1. Position throttle grip to idle position. 2. Check the tiller handle cables for proper adjustment. Pointer on bell crank should line up with the adjustment mark shown. If necessary, adjust cables using jam nuts to remove any slack. (Do Not Over Tighten Cables). a b c a - Cable Bell Crank Pointer b - Adjustment Mark c - Jam Nuts 8.0 HP MODEL WITH TILLER HANDLE SHIFT 1. Shift outboard into forward and position the throttle grip to full throttle. 2. Check the tiller handle cables for proper adjustment. Pointer on bell crank should line up with the front edge of the housing shown. If necessary, adjust cables using jam nuts to remove any slack. (Do Not Over Tighten Cables.) a b c a - Cable Bell Crank Pointer b - Front edge of Housing c - Jam Nuts 9.9 HP MODEL WITH TILLER HANDLE SHIFT 1. Shift outboard into forward and position the throttle grip to full throttle. 2. Check the tiller handle cables for proper adjustment. Pointer on bell crank should line up with the adjustment mark shown. If necessary, adjust cables using jam nuts to remove any slack. (Do Not Over Tighten Cables). a b c a - Cable Bell Crank Pointer b - Adjustment Mark c - Jam Nuts Full Throttle Link Rod Adjustment 1. Tiller Handle Models: Place outboard in the “full throttle” forward gear position. Remote Control Models: Disconnect the remote control cable from the throttle arm. Hold the throttle arm in “full throttle” position. a 53445 a -Throttle Arm 2. Adjust the throttle link rod to allow the throttle lever to just touch the wide open throttle stop. Tighten jam nut against adjustment nut. 28279 a bcd a -Adjustment Nut b -Jam Nut c -Throttle Link Rod d -Throttle Stop Idle Speed – Initial Setting NOTE: Before adjusting idle speed, make the full throttle link rod adjustment. See procedure preceding. TILLER HANDLE MODELS 1. Place throttle twist grip to neutral/idle position. 2. Back the idle speed screw off of the throttle lever so idle speed screw does not touch lever. a b a -Idle Speed Screw b -Throttle Lever 3. Check for link rod free play. There should be free play between throttle link rod and throttle cam stud. a b c Note: Side shift model shown a -Throttle Link Rod b -Throttle Link Rod Free-play c -Throttle Cam Stud 4. For an initial idle setting, turn idle speed screw “In” until the screw touches the throttle lever, then turn “In” one additional turn to slightly open the throttle plate. a a -Idle Speed Screw (1 Turn “In”) 90-827857R1 NOVEMBER 1996 ELECTRICAL - 2C-3 Idle Speed – Initial Setting (cont.) NOTE: Before adjusting idle speed, make the full throttle link rod adjustment. See procedure preceding. REMOTE CONTROL MODELS 1. Disconnect the remote control cable from the throttle arm. Position the throttle lever to idle position. 2. Back the idle speed screw off of the throttle lever so idle speed screw does not touch lever. a b a -Idle Speed Screw b -Throttle Lever 3. Check link rod free location. The throttle link rod should be centered in the throttle lever slot. a b c a -Throttle Link Rod b -Throttle Lever c -Centered Position 4. For an initial idle setting, turn idle speed screw “In” until the screw touches the throttle lever, then turn “In” one additional turn to slightly open the throttle plate. a a -Idle Speed Screw (1 Turn “In”) 2C-4 - ELECTRICAL Pilot Mixture Screw (NOT APPLICABLE TO BODENSEE MODELS) NOTE:The pilot mixture screw is set at the factory and normally should require no adjustment. 1. If adjustment to the pilot screw is required. adjust screw as follows: a. Turn pilot mixture screw in (clockwise) until LIGHTLY seated then back out to an initial setting of 3 ± 1 turns. b. Adjust pilot mixture screw for best performance. With engine running at slow/idle speed in “Forward” gear, turn mixture screw “In” (clockwise) until engine starts to loose R.P.M., then back out 1/4 turn. NOTE: When setting pilot mixture screw, DO NOT adjust leaner than necessary to attain reasonably smooth idling. Also allow time for engine to stabilize between adjustments. a b a -Pilot Screw Adjustment b -Carburetor 2. Readjust idle speed screw in “Forward” gear to specification. IMPORTANT: If the outboard is in test tank or in the water, check the throttle response from idle speed to wide open throttle. The engine should respond without hesitation. If the engine hesitates on acceleration, readjust pilot mixture screw. 90-827857R1 NOVEMBER 1996 Float Level Adjustment 1. With carburetor turned upside down and depth micrometer seated on inner ledge, check float level from top of float to float bowl flange as shown. Float Height – 1.00 ±0.04 in. (25.4 ±1.0mm) IMPORTANT: When checking float level, the float should be resting on the needle valve, but not compressing the needle valve. 2.If float level is not within specification, bend tab to adjust float height. a a -Float Adjustment Tab 1. Turn pilot mixture screw in (clockwise) until LIGHTLY seated then back out to an initial setting of 3 ± 1 turns. a b 28282 a -Pilot Screw Adjustment b -Carburetor With the outboard in water, or attached to flushette, connect fuel line to engine, squeeze bulb until firm, and check for carburetor flooding. IMPORTANT: (Electric Start Models Only) Check the neutral start micro switch for proper operation. Try to start the engine in the “Forward”, “Neutral”, and “Reverse” gear with the electric start button. The engine must start in “Neutral” Only. 90-827857R1 NOVEMBER 1996 ELECTRICAL - 2C-5 ELECTRICAL D 2 WIRING DIAGRAMS Table of Contents Page Manual Start Wiring Diagram . . . . . . . . . . . . . . 2D-1 Electric Start Wiring Diagram . . . . . . . . . . . . . . 2D-2 Battery Charging System . . . . . . . . . . . . . . . . . . 2D-3 6 Amp. Charging System-Manual Start . . . 2D-3 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-3 10 Amp. Charging System-Electric Start . . 2D-4 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-4 Commander Remote Control-Electric Start . . 2D-5 Commander 2000 Remote Control-Manual . . 2D-6 Commander 2000 Remote Control-Electric . . 2D-7 Commander 3000 Panel Mount Control . . . . . 2D-8 Remote Wiring Harness (To Engine) . . . . . . . . 2D-8 90-827857R1 NOVEMBER 1996 1 - Low Oil Light 2 - Trigger 3 - Stator 4 - Electrothermal Valve 5 - Low Oil Switch 6 - Secondary Coil 7 - Capacitor Discharge Module 8 - Emergency Stop Switch 9 - Stop Button 1 2 3 4 5 6 7 8 9 BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow LT = Light DRK = Dark 90-827857R1 NOVEMBER 1996 ELECTRICAL - 2D-1 Manual Start Wiring Diagram 1 2 3 4 5 7 9 10 11 6 1 - Electrothermal Valve 2 - Stator 3 - Trigger 4 - Voltage Regulator/Rectifier 5 - Oil Pressure Switch 6 - Secondary Coil 7 - Starter 8 - 20 Ampere Fuse 9 - Battery 10- Starter Solenoid 11- Capacitor Discharge Module 12- Oil Warning Diode 8 12 BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow LT = Light DRK = Dark 2D-2 - ELECTRICAL 90-827857R1 NOVEMBER 1996 Electric Start Wiring Diagram Battery Charging System 6 Ampere Charging System Manual Start Models Description: The 6 ampere lighting coil is part of the stator assembly and is on all manual start model engines. The coil assembly is capable of producing and unregulated AC current. NOTE:The 6 ampere stator supplied with the manual start engine is designed to be used with a lighting regulator kit (optional) to provide AC voltage for running lights. An optional battery charging kit is also available. a b c d a -Stator Lighting Coil b -Stator Assembly c -Stator Lead d -Tachometer Signal 90-827857R1 NOVEMBER 1996 ELECTRICAL - 2D-3 Battery Charging System (cont.) 10 Ampere Charging System Electric Start Models Description: The battery charging system components are the stator lighting coils, rectifier/regulator and battery. Alternating current (generated in stator lighting coils) flows to the rectifier/regulator, which changes the alternating current to a regulated direct current for charging the battery. Color Code W/R = WHITE/RED Br = BROWN L = BLUE B = BLACK W = WHITE P = PINK Y/R = YELLOW/RED G = GREEN O = ORANGE G/W = GREEN/WHITE R = RED B/Y = BLACK/YELLOW GRAY = GRAY TAN/BLU = TAN/BLUE TAN/WHT= TAN/WHITE PUR = PURPLE a -Stator Lighting Coil b -20 Ampere Fuse c -Starter Motor Assembly d -Battery e -Starter Solenoid f -Rectifier/Regulator g -Stator Assembly h -Tachometer Signal 2D-4 - ELECTRICAL 90-827857R1 NOVEMBER 1996 Commander Remote Control (Electric Start) BLK = Black BRN = Brown GRY = Ignition/Choke Switch Emergency Stop Switch Neutral Start Switch Tachometer/Accessories Harness Connector a e b c d ab c-Gray d- GRN = Green e -Wiring Harness Connector RED = Red WHT = White YEL = Yellow 90-827857R1 NOVEMBER 1996 ELECTRICAL - 2D-5 Commander 2000 Remote Control (Manual) b c a 23893 a -RUN-OFF Switch BLK=BLACK b -Emergency Stop Switch YEL=YELLOW c -Stop Switch Harness 2D-6 - ELECTRICAL 90-827857R1 NOVEMBER 1996 Commander 2000 Remote Control (Electric Start) b c d a e 23890 a b c d e -Ignition/Choke Switch -Emergency Stop Switch -Neutral Start Switch -Tachometer/Accessories Harness Connector -Wiring Harness Connector BLK BRN GRY GRN RED WHT YEL = = = = = = = Black Brown Gray Green Red White Yellow 90-827857R1 NOVEMBER 1996 ELECTRICAL - 2D-7 Neutral Interlock Switch YEL=YELLOW RED=RED a b Commander 3000 Panel Mount Control a -Neutral Interlock Switch b -Emergency Stop Switch Remote Wiring Harness Connection to Engine 1. Apply Quicksilver Dielectric Grease inside the connection. 2. Plug the remote wiring connector into the out- board wiring harness connector. Secure the con- nection together with retainer, as shown. b c a d a -Remote Wiring Connector b -Outboard Wiring Harness Connector c -Retainer d -Quicksilver Dielectric Grease Neutral Interlock Switch YEL=YELLOW RED=RED a b Commander 3000 Panel Mount Control a -Neutral Interlock Switch b -Emergency Stop Switch Remote Wiring Harness Connection to Engine 1. Apply Quicksilver Dielectric Grease inside the connection. 2. Plug the remote wiring connector into the out- board wiring harness connector. Secure the con- nection together with retainer, as shown. b c a d a -Remote Wiring Connector b -Outboard Wiring Harness Connector c -Retainer d -Quicksilver Dielectric Grease 2D-8 - ELECTRICAL 90-827857R1 NOVEMBER 1996 FUEL SYSTEM A 3 FUEL PUMP Table of Contents Page Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-2 Fuel Pump Removal . . . . . . . . . . . . . . . . . . . . . . 3A-4 Non-Bodensee . . . . . . . . . . . . . . . . . . . . . . . . 3A-4 Bodensee . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-4 Fuel Pump Disassembly . . . . . . . . . . . . . . . . . . 3A-4 Bodensee . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-4 Fuel Pump Reassembly . . . . . . . . . . . . . . . . . . . 3A-5 Bodensee . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-6 Fuel Pump Installation . . . . . . . . . . . . . . . . . . . . 3A-6 Non-Bodensee . . . . . . . . . . . . . . . . . . . . . . . . 3A-6 Bodensee . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-6 90-827857R1 NOVEMBER 1996 WARNING WARNING FIRE AND EXPLOSION HAZARD. Observe fire prevention rules, particularly NO SMOKING. Before servicing any part of the fuel system, disconnect electrical system at the battery. Drain the fuel system completely. Use an approved container to collect and store fuel. Wipe up any spillage immediately. Materials used to contain spillage must be disposed of in an approved receptacle. Any fuel system service must be performed in a well ventilated area. FUEL LEAKAGE FROM ANY PART OF THE FUEL SYSTEM CAN BE A FIRE AND EXPLOSION HAZARD WHICH CAN CAUSE SERIOUS BODILY INJURY OR DEATH. Careful periodic inspection of the entire fuel system is mandatory, particularly after engine storage. All fuel components, including fuel tanks, whether plastic, metal, or fiberglass, fuel lines, primer bulbs, fittings, swelling, and must be inspected for corrosion. Any sign of leakage or deterioration necessitates replacement before further engine operation. 90-827857R1 NOVEMBER 1996 FUEL SYSTEM - 3A-1 FUEL PUMP A=BODENSEE 3A-2 - FUEL SYSTEM 90-827857R1 NOVEMBER 1996 FUEL PUMP REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 11 1 FUEL PUMP 1 FUEL PUMP (BODENSEE) 2 1 CHECK VALVE 3 1 DIAPHRAGM 4 2 SCREW 5 1 DIAPHRAGM 6 4 SCREW 7 4 WASHER 8 1 SEAL BODENSEE SCREW9 2 10 1 TUBING (21 IN.) 11 AR STA-STRAP 12 1 STRAINER 13 1 HOSE 14 2 CLIP 15 2 SCREW (M6 x 30) 70 8.0 16 2 LOCKWASHER 17 2 WASHER 18 2 CLIP 19 1 HOSE 20 1 O-RING 21 1 CLIP 22 1 WASHER 23 1 SCREW (M6 x 12) 70 8.0 24 1 FUEL CONNECTOR 25 1 GROMMET–fuel connector 26 1 SCREW (M6 x 20) 70 8.0 27 1 TUBING (10 IN.) BODENSEE TUBING (10 IN.)28 1 90-827857R1 NOVEMBER 1996 FUEL SYSTEM - 3A-3 Fuel Pump Removal Non-Bodensee 1. Remove clamps, hoses, screws, and fuel pump. a b c d c a -Clamps (2) b -Hoses (2) c -Screws d -Fuel Pump Bodensee 1. Seperate fuel pump from cylinder head cover by removing clamps, hoses, and screws. a b c d a a -Clamps (4) b -Fuel Hoses (2) c -Screws (2) d -Water Hoses (2) Fuel Pump Disassembly 1. Remove screws and separate the pump cover from the pump body. ba c a -Screws b -Pump Cover c -Pump Body Bodensee 1. Remove two cooling jacket screws and separate cooling jacket from pump cover. a b c a -Pump Cover b -Cooling Jacket c -Cooling Jacket Screws (2) 2. Remove diaphragm by pushing plunger while holding the plate. Turn the diaphragm 90°. b a a -Plate b -Diaphragm 3A-4 - FUEL SYSTEM 90-827857R1 NOVEMBER 1996 3. Remove screws and plate from pump cover to inspect check valve. a b c a -Pump Cover b -Plate c -Screws 4. Inspect check valve, gasket, and diaphragm replace if damaged. a b c a -Check Valve b -Diaphragm c -Gasket Diaphragm 5.Inspect springs, replace if damaged. a b a -Spring b -Diaphragm Spring Fuel Pump Reassembly 1. Align the recess in the check valve and plate with the projection on the pump cover. a b a -Check Valve b -Plate 2. Secure plate to pump cover with screws. a b c a -Pump Cover b -Plate c -Screws 3. Assemble pump body, diaphragm spring, spring, and plunger. b c d a a -Diaphragm Spring b -Pump Body c -Spring d -Plunger 90-827857R1 NOVEMBER 1996 FUEL SYSTEM - 3A-5 4. Align the recess in the plunger with projection in pump body. 5. Install diaphragm by pushing in the plunger and holding plate, then turn the diaphragm 90o. b a a -Diaphragm b -Plate 6. Connect pump body to pump cover with screws. Bodensee 1. Connect cooling jacket and pump cover with two screws. a b c a -Pump Cover b -Cooling Jacket c -Cooling Jacket Screws (2) NOTE:After installing, check for smooth movement of plunger. 3A-6 - FUEL SYSTEM 2. Install O-ring. a a -O-ring NOTE:Always use a new O-ring. Fuel Pump Installation Non-Bodensee 1. Secure fuel pump with screws and reconnect hoses and clamps. c a b a -Screws (2) b -Fuel Hoses (2) c -Clamps (2) Bodensee 1. Connect fuel pump to cylinder head cover by installing clamps, hoses, and screws. a b c d a a -Clamps (4) b -Fuel Hoses (2) c -Screws (2) d -Water Hoses (2) 90-827857R1 NOVEMBER 1996 FUEL SYSTEM B 3 CARBURETOR Table of Contents Page Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-1 Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-2 Carburetor Adjustments . . . . . . . . . . . . . . . . . . . 3B-4 Pilot Mixture Screw . . . . . . . . . . . . . . . . . . . . 3B-4 Float Level Adjustment . . . . . . . . . . . . . . . . . 3B-4 Carburetor Removal . . . . . . . . . . . . . . . . . . . . . . 3B-5 Carburetor Disassembly . . . . . . . . . . . . . . . . . . . 3B-5 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-6 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-7 90-827857R1 NOVEMBER 1996 Specifications Specifications CARBURETOR SPECIFICATIONS Idle RPM Trolling RPM Wide Open Throttle (WOT) RPM 8.0/9.9 (BODENSEE) 9.9 Pilot Screw (Turns Out) 8.0/9.9 (BODENSEE) 9.9 Main Jet Size 8.0/9.9 (BODENSEE) 9.9 Pilot Jet Enrichener Jet Float Height 950 ± 50 RPM (Out Of Gear) 850 ± 50 5000 - 5500 4500 - 5500 Not Adjustable 3 ± 1 #82 #86 #48 .024 (0.61 mm) 1 ± 0.04 in. (25.5 ± 1 mm) Special Tools Description Part No. Carburetor Scale 91-36392 90-827857R1 NOVEMBER 1996 FUEL SYSTEM - 3B-1 CARBURETOR 1 2 3 4 5 6 7 8 10 11 12 13 14 15 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 3940 41 42 44 45 46 48 19 20 8 15 42 A 47 A=BODENSEE 3B-2 - FUEL SYSTEM 90-827857R1 NOVEMBER 1996 CARBURETOR REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m – 1 CARBURETOR – 1 CARBURETOR (BODENSEE) 1 2 SCREW 2 2 LOCKWASHER 3 1 STARTER SET 4 1 O-RING 5 1 PIPE 6 1 CLAMP 7 1 SEAL 8 1 SCREW–air adjusting 9 1 SCREW–air adjusting (BODENSEE) 10 1 SPRING 11 1 SCREW 12 1 SPRING–pilot adjusting 13 2 STUD 14 1 FLOAT PIN 15 1 ROD–accelerator pump 16 1 ROD–accelerator pump (BODENSEE) 17 1 NUT 18 1 SHAFT–choke 19 2 WASHER 20 2 CLIP 21 1 MAIN NOZZLE 22 1 MAIN JET (#86) 23 1 SCREW 19 1 MAIN NOZZLE MAIN JET (#82) BODENSEE20 1 24 1 VALVE–needle 25 1 JET–pilot 26 1 GASKET 27 1 PLUG–main nozzle 28 1 FLOAT 29 1 GASKET–float chamber 30 1 FILTER 31 1 JET–starter 32 1 VALVE–choke 33 1 SCREW 34 1 GASKET 35 1 SCREW–drain 36 1 O-RING 37 1 FLOAT BOWL 38 4 LOCKWASHER 39 4 SCREW 40 1 SPRING 41 1 DIAPHRAGM 42 1 COVER 43 1 COVER (BODENSEE) 44 1 SPRING 45 2 LOCKWASHER 46 2 SCREW 47 1 O RING (BODENSEE) 48 1 SEAL (BODENSEE) – 1 STOP–throttle 8 BODENSEE NUT–push– 1 90-827857R1 NOVEMBER 1996 FUEL SYSTEM - 3B-3 Carburetor Adjustments Pilot Mixture Screw (NOT APPLICABLE TO BODENSEE MODELS) NOTE:The pilot mixture screw is set at the factory and normally should require no adjustment. 1. If adjustment to the pilot screw is required, adjust screw as follows: a. Turn pilot mixture screw in (clockwise) until LIGHTLY seated then back out to an initial setting of 3 ± 1 turns. b. Adjust pilot mixture screw for best performance. With engine running at slow/idle speed in “Forward” gear, turn mixture screw “In” (clockwise) until engine starts to lose R.P.M., then back out 1/4 turn. NOTE: When setting pilot mixture screw, DO NOT adjust leaner than necessary to attain reasonably smooth idling. Also allow time for engine to stabilize between adjustments. a b 28282 a -Pilot Screw Adjustment b -Carburetor 2. Readjust idle speed screw in “Forward” gear to specification. IMPORTANT: If the outboard is in test tank or in the water, check the throttle response from idle speed to wide open throttle. The engine should respond without hesitation. If the engine hesitates on acceleration, readjust pilot mixture screw. Float Level Adjustment 1. With carburetor turned upside down and depth micrometer seated on inner ledge, check float level from top of float to float bowl flange as shown. Float Height – 1.00 ±0.04 in. (25.4 ±1.0mm) IMPORTANT: When checking float level, the float should be resting on the needle valve, but not compressing the needle valve. 2.If float level is not within specification, bend tab to adjust float height. a a -Float Adjustment Tab 3B-4 - FUEL SYSTEM 90-827857R1 NOVEMBER 1996 Carburetor Removal 1. Disconnect electrothermal valve leads, throttle link rod and fuel hose. a b c 28301 a -Electrothermal Valve Leads b -Throttle Link c -Fuel Hose 2. Remove gaskets, spacer, washers, and nuts. 28302 b a cd a -Spacer b -Gaskets (2) c -Washers d -Nuts Carburetor Disassembly 1. Remove screws, washer, clip, electrothermal valve, and float chamber. a a b e d c a -Screws b -Clip c -Washer d -Float Chamber e -Electrothermal Valve 2. Remove pin, float and needle valve. 28304 c a b a -Pin b -Float c -Needle Valve 90-827857R1 NOVEMBER 1996 FUEL SYSTEM - 3B-5 b c 3. Remove screws, cover, and diaphragm. a 28304 a -Screws b -Cover c -Diaphragm Inspection 1. Inspect carburetor body for cracks or damage and replace if necessary. 28305 NOTE:Use a petroleum based solvant for cleaning. Blow out all passages with compressed air. 2. Inspect pilot screw for bends or wear and replace if necessary. 28306 3. Inspect needle valve for grooves and replace if necesary. 28307 4. Inspect float for cracks or damage and replace if necessary. 28308 5. Inspect diaphragm for damage and replace if necessary. 28309 6. Inspect filter for contamination or damage. Clean or replace if necessary. 28310 3B-6 - FUEL SYSTEM 90-827857R1 NOVEMBER 1996 7. Inspect check valve for damage and replace if necessary. 28311 Electrothermal Valve 1. Inspect needle valve and piston valve. Replace if damaged or worn. 28312 b a a -Needle Valve b -Piston Valve 2.Measure the valve resistance. Replace if out of specification. 4.8 ~7.2 W at 20°C (68°F) 28313 3. Check piston valve height. • Connect 12V battery • Wait for several minutes • Check piston height Replace if no change. Assembly 1. Secure spring, diaphragm, and cover to float chamber with screws. a b c d e a -Float Chamber b -Spring c -Diaphragm d -Cover e -Screws 90-827857R1 NOVEMBER 1996 FUEL SYSTEM - 3B-7 2. Install pilot jet, O-ring, plug, and main nozzle. 28316 a b c d a -Main Nozzle b -Pilot Jet (Below seal cap) c -O-Ring d -Plug 3. Align the slit in the main nozzle with the screw hole in the carburetor. Install the screw and main jet. a b 28317 a -Nozzle Screw b -Main Jet 4. Install the needle valve into the float hinge. 28318 a b a -Needle Valve b -Float 5.Install pin into float hinge. Make any necessary float height adjustments as shown in “Carburetor Adjustments” section. 28319 a b a -Pin b -Float 3B-8 - FUEL SYSTEM 90-827857R1 NOVEMBER 1996 6. Install O-ring, drain screws, and gasket. a b c d 28320 a -O-ring b -Drain Screw c -Gasket d -Drain Screw 7. Install filter, check valve, and gasket. Secure float chamber to carburetor body with screws. 28321 a b c d e a -Filter b -Check Valve c -Gasket d -Float Chamber e -Screws 8. Install O-ring, electrothermal valve and plate. Secure with screws. 28322 a b c d a -O-ring b -Electrothermal Valve c -Plate d -Screws 9. Install spring, idle mixture screw (non-Bodensee models), and seal cap. a b c a -Spring b -Idle mixture Screw c -Seal Cap 90-827857R1 NOVEMBER 1996 FUEL SYSTEM - 3B-9 10. Screw in pilot mixture screw until it is lightly seated, then back out to an initial setting of 3 ± 1 turns. See idle adjustment procedure page 3A-1. (Not applicable to Bodensee models) 28324 11. Install rod, washer, and clip. 28325 a b c a -Rod b -Washer c -Clip 12. Connect throttle link and fuel hose. a b a -Throttle Link b -Fuel Hose 28326 13. Install gasket, spacer, washers, and nuts. 28327 a b cd a -Gaskets (2) b -Spacer c -Washers(2) d -Nuts(2) 14. Connect wire lead Wire Lead 28328 15. Install gasket, funnel and screws. c a b a -Gasket b -Funnel c -Screw 16. Adjust idle speed according to “Timing/Synchronizing/ Adjusting” in section 2C. 3B-10 - FUEL SYSTEM 90-827857R1 NOVEMBER 1996 POWERHEAD A 4 CYLINDER HEAD Table of Contents Page Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-3 Camshaft/Oil Pump. . . . . . . . . . . . . . . . . . . . . . . 4A-4 Intake/Exhaust Valve . . . . . . . . . . . . . . . . . . . . . 4A-6 Valve Clearance Adjustment . . . . . . . . . . . . . . . 4A-8 Checking Valve Clearance . . . . . . . . . . . . . . 4A-8 Adjusting Valves . . . . . . . . . . . . . . . . . . . . . . . 4A-9 Timing Belt Inspection . . . . . . . . . . . . . . . . . . . 4A-10 Timing Belt Removal . . . . . . . . . . . . . . . . . . . . . 4A-10 Timing Belt Installation . . . . . . . . . . . . . . . . . . . 4A-12 Cylinder Head Disassembly . . . . . . . . . . . . . . 4A-14 Cylinder Head Cover Removal . . . . . . . . . 4A-14 Cylinder Head Removal . . . . . . . . . . . . . . . 4A-14 Oil Pump Removal . . . . . . . . . . . . . . . . . . . . 4A-14 Rocker Arm Removal . . . . . . . . . . . . . . . . . 4A-15 Camshaft Removal . . . . . . . . . . . . . . . . . . . 4A-15 Anode Removal . . . . . . . . . . . . . . . . . . . . . . 4A-15 Exhaust Valve Removal . . . . . . . . . . . . . . . 4A-16 Exhaust Valve Components . . . . . . . . . 4A-16 Removing exhaust valves . . . . . . . . . . . 4A-16 Intake Valve Removal . . . . . . . . . . . . . . . . . 4A-16 Intake Valve Components . . . . . . . . . . . 4A-16 Removing intake valves . . . . . . . . . . . . . 4A-16 Cleaning and Inspection. . . . . . . . . . . . . . . . . . 4A-17 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-17 Rocker Shaft and Rocker Arm . . . . . . . . . . 4A-17 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-18 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . 4A-18 Page Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . 4A-19 Valve Guide Replacement . . . . . . . . . . . 4A-19 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-20 Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . 4A-20 Valves Seat Reconditioning . . . . . . . . . . . . 4A-21 Valve Refacing Steps . . . . . . . . . . . . . . . . . 4A-21 Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . 4A-22 Cylinder Head Reassembly . . . . . . . . . . . . . . . 4A-23 Exhaust Valve Installation . . . . . . . . . . . . . . 4A-23 Exhaust Valve Components . . . . . . . . . 4A-23 Installing exhaust valves . . . . . . . . . . . . 4A-23 Intake Valve Installation . . . . . . . . . . . . . . . 4A-23 Intake Valve Components . . . . . . . . . . . 4A-23 Installing intake valves . . . . . . . . . . . . . . 4A-23 Anode Assembly . . . . . . . . . . . . . . . . . . . . . 4A-24 Camshaft Oil Seal Installation . . . . . . . . . . 4A-24 Camshaft and Driven Gear Assembly . . . 4A-24 Rocker Arm Assembly . . . . . . . . . . . . . . . . . 4A-25 Oil Pump Assembly . . . . . . . . . . . . . . . . . . . 4A-26 Oil Pump Installation . . . . . . . . . . . . . . . . . . 4A-26 Cylinder Head Gasket . . . . . . . . . . . . . . . . . 4A-27 Cylinder Head Installation . . . . . . . . . . . . . . 4A-27 Cylinder Head Cover Installation . . . . . . . . 4A-28 Intake Manifold Assembly . . . . . . . . . . . . . . 4A-28 Oil Filter Assembly . . . . . . . . . . . . . . . . . . . . 4A-29 Oil Separator Installation . . . . . . . . . . . . . . 4A-29 90-827857R1 NOVEMBER 1996 Specifications VALVES Valve/Valve Seat/Valve Guides: Valve Clearance (cold) Intake 0.0059 - 0.0079 in. (0.15 - 0.20 mm) Exhaust Valve Dimensions: 0.0079 - 0.0098 in. (0.20 - 0.25 mm) “A” Head Diameter Intake 1.020 - 1.028 in. (25.9 - 26.1 mm) Exhaust 0.862 - 0.870 in. (21.9 - 22.1 mm) “B” Face Width Intake 0.079 - 0.124 in. (2.00 - 3.14 mm) Exhaust 0.079 - 0.124 in. (2.00 - 3.14 mm) “C” Seat Width Intake 0.024 - 0.031 in. (0.6 - 0.8 mm) Exhaust 0.024 - 0.031 in. (0.6 - 0.8 mm) “D” Margin Thickness Intake 0.020 - 0.035 in. (0.5 - 0.9 mm) Exhaust 0.020 - 0.035 in. (0.5 - 0.9 mm) Stem Outside Diameter Intake 0.2156 - 0.2161 in. (5.475 - 5.490 mm) Exhaust 0.2150 - 0.2156 in. (5.460 - 5.475 mm) Guide Inside Diameter Intake 0.2165 - 0.2170 in. (5.500 - 5.512 mm) Exhaust 0.2165 - 0.2170 in. (5.500 - 5.512 mm) Stem To Guide Clearance Intake 0.0004 - 0.0015 in. (0.010 - 0.037 mm) Exhaust 0.0010 - 0.0020 in. (0.025 - 0.052 mm) Stem Runout Limit (max.) 0.0006 in. (0.016 mm) “A” “B” “C” “D” Valve Dimensions Head Diameter Face Width Seat Width Margin Thickness 90-827857R1 NOVEMBER 1996 POWERHEAD - 4A-1 Specifications VALVE SPRING Set Length (Valve Closed) Intake Exhaust Compressed Pressure (Installed) Intake Exhaust Tilt Limit (Intake and Exhaust) Direction Of Winding (Intake and Exhaust) 0.960 in. (24.4 mm) 0.960 in. (24.4 mm) 19.8 - 22.0 lbs. (9.0 - 10.0 kg) 19.8 - 22.0 lbs. (9.0 - 10.0 kg) 0.043 in. (1.1 mm) Left Hand CAMSHAFT Camshaft Dimensions Intake “A” Intake “B” Exhaust “A” Exhaust “B” Camshaft Runout A B 0.966 - 0.970 in. (24.541 - 24.641 mm) 0.793 - 0.797 in. (20.137 - 20.237 mm) 0.968 - 0.972 in. (24.578 - 24.678 mm) 0.794 - 0.798 in. (20.178 - 20.278 mm) .004 in. (0.1 mm) CAM BELT Cam Belt Type Belt Slack Cogged Belt 0 - 0.4 in. (0-10 mm) OIL PUMP Oil Pump Dimensions: Outer Rotor to Housing “A” Inner Rotor to Outer Rotor “B” Rotor to Housing “C” Relief Valve Operating Pressure a c bb 0.0024 - 0.0043 in. (0.06 - 0.11 mm) 0.0008 - 0.0059 in. (0.02 - 0.15 mm) 0.0008 - 0.0028 in. (0.02 - 0.07 mm) 55.19 - 64.00 PSI (3.88 - 4.50 kg/cm2) 388- 450 kPa 4A-2 - POWERHEAD 90-827857R1 NOVEMBER 1996 Specifications CYLINDER HEAD Warp Limit * 0.004 in. (0.1 mm) * Lines indicate straight edge measurement Special Tools Description Part No. Flywheel Holder 91-83163M Valve Spring Compressor 91-80949A1 Valve Guide Remover 91-809495A1 Valve Guide Installer Bushing 91-809496A1 Valve Guide Reamer 91-809497A1 Valve Adjuster Wrench 91-809498A1 90-827857R1 NOVEMBER 1996 POWERHEAD - 4A-3 CAMSHAFT/OIL PUMP 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 2223 24 4 9 6 95 113 95 95 113 10 95 113 2-4-C With Teflon (92-825407A12) 4 Cycle Oil (92-828000A12) 4A-4 - POWERHEAD 90-827857R1 NOVEMBER 1996 CAMSHAFT/OIL PUMP REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 BELT 2 1 NUT 17 23.0 3 1 WASHER 4 2 WASHER 5 1 GEAR–drive 6 2 KEY 7 1 FILTER–oil/screen 70 8.0 8 1 HOUSING 9 2 O-RING 10 1 WASHER 11 1 BOLT 70 8.0 12 1 BOLT 70 8.0 13 1 BOLT 113 12.5 14 1 WASHER 15 1 GEAR–driven 16 1 WASHER 17 1 OIL SEAL 18 1 CAMSHAFT 19 1 OIL PUMP ASSEMBLY 20 1 O-RING 21 1 O-RING 22 2 O-RING 23 1 O-RING 24 3 BOLT 70 8.0 90-827857R1 NOVEMBER 1996 POWERHEAD - 4A-5 INTAKE/EXHAUST VALVE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 11 10 12 11 10 13 9 15 13 11 10 3 4 5 1 3 4 5 6 7 12 9 9 113 113 113 113 113 113 113 113 113 4 Cycle Oil (92-828000A12) 4A-6 - POWERHEAD 90-827857R1 NOVEMBER 1996 INTAKE/EXHAUST VALVE REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 2 VALVE–intake 2 2 VALVE–exhaust 3 4 WASHER 4 4 SEAL 5 4 SPRING–inner 6 2 RETAINER 7 4 COTTER PIN–valve 8 2 LIFTER–valve 9 4 ARM–rocker valve 10 4 SCREW–valve adjusting 11 4 NUT 70 8.0 12 3 SPRING 13 3 COLLAR 14 1 SPRING 15 2 SHAFT–rocker 16 2 RETAINER 90-827857R1 NOVEMBER 1996 POWERHEAD - 4A-7 Valve Clearance Adjustment • The valve clearance must be adjusted when the engine in cool to the touch. • Adjust the valve clearance when the corresponding piston is at the Top Dead Center (TDC) on compression stroke. Remove cylinder head cover. may occur. POSITION OF DRIVEN GEAR WHEN CHECKING VALVE CLEARANCE FOR NO. 1 (TOP) CYLINDER 1. Position the No. 1 piston (top) at Top Dead Center (TDC) on the compression stroke. 2. Rotate the driven gear clockwise to align the “1” mark on the driven gear with cylinder head mark. NOTE:Perform adjustment on following page. b a 12 28331 a -Driven Gear Mark b -Cylinder Head Mark POSITION OF DRIVEN GEAR WHEN CHECKING VALVE CLEARANCE FOR NO. 2 (BOTTOM) CYLINDER 1. Position the No. 2 piston (bottom) at Top Dead Center (TDC) on the compression stroke. 2. Rotate the driven gear clockwise 180° so the “2” mark on the driven gear aligns with cylinder head mark. 28337 Checking Valve Clearance IMPORTANT: The timing belt must be installed and gears in the correct position or valve damage NOTE:Perform adjustment on following page. b a 12 28331 a -Driven Gear Mark b -Cylinder Head Mark 4A-8 - POWERHEAD 90-827857R1 NOVEMBER 1996 CHECKING VALVE CLEARANCE Adjusting Valves 1. Position the driven gear for cylinder 1 or 2. See 1. Loosen the locknut. instructions preceding. 2. Measure the valve clearance using a feeler gauge. If out of specification, refer to Adjusting Valves. 28264 a -No. 1 Intake Valve b -No. 1 Exhaust Valve c -No. 2 Intake Valve d -No. 2 Exhaust Valve Valve Clearance “e” Specification Intake Valves 0.0059 - 0.0079 in. (0.15 - 0.20 mm) Exhaust Valves 0.0079 - 0.0098 in. (0.20 - 0.25 mm) 90-827857R1 NOVEMBER 1996 POWERHEAD - 4A-9 a b c d 2.Insert a feeler gauge (specification size) between the valve stem and valve adjusting screw. 3.Adjust the valve adjusting screw against the feel- er gauge using valve adjuster wrench until slight resistance is felt on the feeler gauge. b a a -Feeler Gaugeb -Valve Adjuster Wrench (91-809498A1) 4.Tighten the locknut with the feeler gauge in- serted. Torque on the locknut is 70 lb. in. (8 N·m). e e e -Valve Clearance 5. Recheck the valve clearance and readjust if necessary. Timing Belt inspection Replace timing belt if any of the following conditions are found. • Cracks in the back of the belt or in the base of the belt teeth. • Excessive wear at the roots of the cogs. • Rubber portion swollen by oil. • Belt surfaces roughened. • Signs of wear on edges or outer surfaces of belt. • Stretching by .40 in. (10mm) or more when belt is pushed in with your finger. 52951 Timing Belt Removal WARNING Engine could possibly start when turning flywheel during removal and installation. To prevent this type of accidental engine starting and possible serious injury, always remove spark plug leads from spark plugs. 1. Disconnect spark plug leads from spark plugs. 2. Remove flywheel cover by loosening thumb screw (a) and pull out lock pin (b). b a a -Thumb Screw b -Lock Pin 3. Hold flywheel from turning using flywheel holder (91-83163M). Remove nut and washer. a a -Flywheel Holder (91-83163M) 4.Remove flywheel using puller (91-83164M). a a -Flywheel Puller (91-83164M) 4A-10 - POWERHEAD 90-827857R1 NOVEMBER 1996 90-827857R1 NOVEMBER 1996 POWERHEAD - 4A-11 5. Remove the stator. 28338 b a a - Stator b - Stator Mounting Bolts 6. Remove the trigger base. 28340 b a b a - Trigger Base b - Mounting Screws (3) IMPORTANT: Align the timing marks before removing the timing belt. Otherwise, belt alignment may not be possible due to valves hitting piston. 7. Align the driven gear timing marks before removing the timing belt. 28331 1 2 a a - Timing Marks 8. Align the drive gear timing marks before removing the timing belt. 28371 a a - Timing Marks 9. Remove water hose from fitting and pull off the timing belt. 28333 a b a - Timing Belt b - Water Hose 4A-12 - POWERHEAD 90-827857R1 NOVEMBER 1996 Timing Belt Installation Timing Belt Installation Notes: • Protect the timing belt from water and oil. • Use care not to scratch the belt. • Do not use any metal device to help stretch the belt onto the driven gear. 1. Align drive gear mark with cylinder mark. NOTE: Turn the crankshaft clockwise. b a 28371 a - Drive Gear Mark b - Cylinder Mark 2. Align the driven gear mark with cylinder head mark. NOTE: Turn the driven gear clockwise. 28330 b a 1 2 a - Driven Gear Mark b - Cylinder Head Mark 3. Install timing belt as follows a. Align both gears with their alignment marks (Steps 1 and 2). Make sure that they don’t turn. b. Place the timing belt around the drive gear and around the driven gear. IMPORTANT: Make sure the Part Number on belt is not inverted. 4. Reconnect hose to fitting. 28333 a b 825657 c a - Timing Belt b - Water Hose c - Install so Part No. is Upright 5. Install the alignment pins for the trigger base. a 28372 a - Alignment Pins (2) 90-827857R1 NOVEMBER 1996 POWERHEAD - 4A-13 6. Reinstall trigger base with three screws. 28340 a b c a - Trigger Base b - Screw (1) 3/4 in. (20mm) Long - Tighten Securely c - Screw (2) 1 in. (25mm) Long - Tighten Securely 7. Reinstall stator with three bolts. b a 28338 a - Stator b - Mounting Bolts (3) 1.00 in (25 mm) Long Apply Loctite 222 to Threads Stator Bolt Torque 70 lb. in. (8 N·m) 8. Place flywheel key into slot. 9. Install flywheel. 10. Hold flywheel from turning using flywheel holder (91-83163M). Apply oil to threads on crankshaft and tighten nut to the specified torque. 53278 b c a d a - Flywheel Key b - Washer c - Nut d - Apply Oil to Threads Flywheel Nut Torque 72 lb. ft. (100 N·m) 4A-14 - POWERHEAD 90-827857R1 NOVEMBER 1996 Cylinder Head Disassembly Cylinder Head Cover Removal 1. Remove timing belt (See “Timing Belt Removal” in this section). 2. Remove the cylinder head cover and cover seal. a b c d a - Cover Seal b - Cylinder Head Cover c - Washer (4) d - Bolts (4) Cylinder Head Removal 1. Remove the eight cylinder head bolts from locations shown. 28264 a a a a a a a a a - Bolts (8) CAUTION When removing the cylinder head from the cylinder block, do not scratch the gasket contact surfaces. 2. Insert a screwdriver at the pry points between the cylinder head and block to separate. b a c a - Screwdriver b - Cylinder Head c - Block Oil Pump Removal 1. Loosen the rocker arm adjustment nuts and back out adjustment screws to relieve tension of valve assembly on cam. 2. Remove the oil pump assembly. 28262 a b a a a c a - Adjustment Screw b - Oil Pump Assembly c - Bolts (3) 90-827857R1 NOVEMBER 1996 POWERHEAD - 4A-15 Rocker Arm Removal 1. Remove the rocker arms by pulling the rocker arm shafts out using a M10 bolt as shown. b a 28263 a - Rocker Arm Shaft (2) b - M10 Bolt (Used as Removal Tool) Camshaft Removal 1. Hold driven gear using tool (91-83163M) and remove bolt and flat washer. Remove driven gear and camshaft. 28261 a b a - Driven Gear b - Camshaft Anode Removal 1. Check condition of the anode. Replace, if the anode shows signs of deterioration. 28260 a b c d a - Screw b - Anode c - O-ring d - Bolt Exhaust Valve Removal EXHAUST VALVE COMPONENTS ab- c- a bcdef Exhaust Valve Spring Seat Valve Seal d -Valve Spring e -Spring Retainer f -Valve Lifter REMOVING EXHAUST VALVES 1. Anytime a valve is removed, replace the valve seal. 2. Remove exhaust valves as shown. a b 28260 a -Use spring compressor tool (91-809494A1) to compress the springs for Removal b -Compress the Spring and Retainer and Push the Retainer off the valve stem Intake Valve Removal a -Intake Valve b -Spring Seat c -Valve Seal d -Valve Spring e -Spring Retainer f -Valve Keepers INTAKE VALVE COMPONENTS a b c d e f REMOVING INTAKE VALVES 1. Anytime a valve is removed, replace the valve seal. 2. Remove intake valves as shown. a b 28260 a -Use spring compressor tool (91-809494A1) to compress the springs for Removal b -Compress the Spring and Remove the Valve keepers. 4A-16 - POWERHEAD 90-827857R1 NOVEMBER 1996 Cleaning and Inspection Oil Pump NOTE:If the oil pump clearances does not fall within specifications, replace the oil pump assembly. 1. Check oil pump components for pitting and scratching. 2. Using a feeler gauge, measure the following oil pump clearances: • between outer rotor and pump housing (a) • between the inner rotor and outer rotor (b) • between the outer rotor and pump housing (c) a c bb Oil Pump Clearances a 0.002 - 0.0043 in. (0.06 - 0.11 mm) b 0.0008 - 0.0059 in. (0.02 - 0.15 mm) c 0.0008 - 0.0028 in. (0.02 - 0.07 mm) Rocker Shaft and Rocker Arm NOTE: Measure and inspect the rocker shaft and rocker arms for excessive wear. If any of the components fall out of specifications, replace. 1. Measure Rocker Shaft. Rocker Shaft Diameter 0.509 - 0.510 in. (12.94 -12.95 mm) 2. Inspect Rocker Arm and Adjustment Screw For Wear. 3. Check Rocker Arm For Free Play. (There should be no noticeable free play). 90-827857R1 NOVEMBER 1996 POWERHEAD - 4A-17 Camshaft 1. Inspect the camshaft for any of the following conditions. If not within specification, or excessive wear, replace the camshaft. • Cam Lobe Length • Cam Lobe Width • Heat Discoloration • Pitting • Scratching b a Cam Lobe Specifications a Intake 0.966 - 0.970 in. (24.541-24.641 mm) Exhaust 0.968 - 0.972 in. (24.578-24.678 mm) b Intake 0.793 - 0.797 in. (20.137-20.237 mm) Exhaust 0.794 - 0.798 in. (20.178-20.278 mm) Cylinder Head 1. Inspect the cylinder head for the following conditions: • Mineral Deposits/Corrosion in Water Passage Ways. • Carbon Deposits In Combustion Chamber (use round scraper to clean away deposits). Be careful not to scratch or remove material. 2. Inspect cylinder head for warpage. If not within specification, replace cylinder head. Cylinder Head Warpage Limit 0.004 in. (0.1 mm) 3. The cylinder head can be resurfaced using a surface plate and 400-600 grit wet sandpaper. Use a figure eight sanding pattern. 4A-18 - POWERHEAD 90-827857R1 NOVEMBER 1996 Valve Guides Valve Guides NOTE:Inspect the valve guides for wear/damage. If valve guide wear is out of specifications, replace the valve guide. Measure valve guide bore. Valve Guide Bore Specifications Intake Valve 0.2165 - 0.2170 in. (5 500 5 512 )(5.500 -5.512 mm)Exhaust Valve VALVE GUIDE REPLACEMENT 1. Heat the cylinder head in an oven to 390° F (200° C). This will help to ease guide removal and installation and to maintain correct interference fit. 2. Remove the valve guide using a valve guide remover. a 3. Install the new valve guide and circlip using a valve guide installer bushing along with the valve guide remover. b a a -Valve Guide Remover (91-809495A1) b -Valve Guide Installer Bushing (91-809496A1) 4. After installing the valve guide, ream the valve guide using a valve guide reamer to obtain proper stem-to-guide clearance. a a -Valve Guide Reamer (91-809497A1) a -Valve Guide Remover (91-809495A1) 90-827857R1 NOVEMBER 1996 POWERHEAD - 4A-19 Valves 1. Clean the carbon deposits from the valve. Discard any cracked, warped, or burned valves. 2. Measure the valve stem to check for wear. Replace if out of specification. a Valve Stem Diameter “a” Intake Valve 0.2156 - 0.2161 in. (5.475 - 5.490 mm) Exhaust Valve 0.2150 - 0.2156 in. (5.460 - 5.475 mm) 3. Check the valve face for pitting. Valves faces that are pitted must be refaced. NOTE: Several different types of equipment are available for refacing valves. Follow the equipment manufacturer’s instructions. IMPORTANT: Do not lap the valves. 4. Check the margin thickness of the valves after the valves have been ground. Any valve with a margin thickness of less than the specification should be replaced. 45 ° a Valve Springs Check each spring under load on a spring tester. Replace any weak spring. Valve Spring Compression Specification Compressed Length – 0.96 in. (24.4 mm) Compression Force – 19.8 -22.0 lb. ft. (90 - 100 N) Check each spring on a flat surface using a square. Rotate spring and check space between the top coil and square. If not in specification, replace spring. a Valve Spring Tilt Specification “a” Less than 0.043 in. (1.1 mm) Margin Thickness “a” Intake Valve 0.020 - 0.035 in. (0 5 0 9 mm) (0.5 -0.9 mm)Exhaust Valve 4A-20 - POWERHEAD 90-827857R1 NOVEMBER 1996 Valves 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). If not in specification, resurface the valve seat. a Valve Seat Width Specification “a” Intake Valve 0.024 - 0.031 in. (0 6 0 8 mm) (0.6 -0.8 mm)Exhaust Valve If resurfacing the valve seats is required, resurface the valve seats to the specified angles shown in chart. b c a Valve Refacing Steps Condition: The valve seat is centered on valve face but it is too wide. Valve Seat Cutter Set Desired Results Use LightlLightly 15° Cutter To reduce valve seat idthwidth60° Cutter Condition: The valve seat is in the middle of the valve face but it is too narrow. Valve Seat Cutter Set Desired Results Use Lightly 45° Cutter To achieve a uniform valve seat width Continued on next page Valve Seat Angle Specifications a 15° b 45° c 60° 90-827857R1 NOVEMBER 1996 POWERHEAD - 4A-21 Condition: Valve seat is to narrow and it is near valve margin. Valve Seat Cutter Set Desired Results Use Lightly 15° Cutter, First To center the seat and to achieve its Width 45° Cutter Condition: Valve seat is to narrow and is located near the bottom edge of the valve face. Valve Seat Cutter Set Desired Results Use Lightly 60° Cutter, First To Center the Seat and to increase its width 45° Cutter Oil Separator 1. Check reed valves for warpage. Replace if out of specification. b c d e a a b c f g h i J k l a -Reed Valve b -Flat Washer c -Screw d -Oil Separator e -Mounting Screws (2) f -Gasket g -Cover h -Screw (4) i -Gasket j -Breather k -Screw (4) l -Reed Valve Warpage Limit Reed Valve Warpage Limit “l” 0.008 in. (0.2 mm) 4A-22 - POWERHEAD 90-827857R1 NOVEMBER 1996 Cylinder Head Reassembly Exhaust Valve Installation EXHAUST VALVE COMPONENTS ab- cd -Valve Spring e -Spring Retainer f -Valve Lifter a bcdef Exhaust Valve Spring Seat Valve Seal INSTALLING EXHAUST VALVES 1. Always use new valve seals. 2. Coat valves and valve seats with oil. 3. Install exhaust valves as shown. a b 28260 a -Use spring compressor tool (91-809494A1) to compress the springs for installation b -Compress the Spring and Retainer and slide the Retainer onto the valve stem Intake Valve Installation a -Intake Valve b -Spring Seat c -Valve Seal d -Valve Spring e -Spring Retainer f -Valve Keeper INTAKE VALVE COMPONENTS a b c d e f INSTALLING INTAKE VALVES 1. Always use new valve seals. 2. Coat valves and valve seats with oil. 3. Install intake valves as shown. a b a -Use spring compressor tool (91-809494A1) to compress the springs for installation b -Compress the Spring and Retainer and install the valve keepers around the valve stem. You may have to tap lightly on end of valve to seat the keepers. 90-827857R1 NOVEMBER 1996 POWERHEAD - 4A-23 Anode Assembly 1. If removed, install anode. 28260 a -Screw b -Anode c -O-ring d -Anode Plug a b c d Anode Bolt Torque 13 lb. ft. (18 N·m) Camshaft Oil Seal Installation 1. If removed, install Oil Seal. Position seal so part number side in facing outward Camshaft and Driven Gear Assembly 1. Install camshaft and driven gear. Hold gear with tool 91-83163M when torquing bolt. b c d e f a a -Camshaft b -Drive Key c -Washer d -Driven Gear e -Washer f -Bolt Driven Gear Bolt Torque 113 lb. in. (13 N·m) 4A-24 - POWERHEAD 90-827857R1 NOVEMBER 1996 Rocker Arm Assembly 1. Coat all parts with oil. 2. Install rocker arms. NOTE: Leave all adjustments screws loose at this time. a b c d e f g b c d a c b d c f e 28262 Exhaust Intake a -Rocker Arm Shaft (Threaded End Facing Oil Pump) b -Collar (3) c -Rocker Arm (4) d -Spring (Short) (3) e -Adjustment Nut (4) f -Adjustment Screw (4) g -Spring (Long) 90-827857R1 NOVEMBER 1996 POWERHEAD - 4A-25 4A-26 - POWERHEAD 90-827857R1 NOVEMBER 1996 Oil Pump Assembly 1. Reassemble the oil pump assembly. 2. Lubricate the outer and inner rotors thoroughly with engine oil. b c d e a f g h 28265 e a - Oil Pump Housing b - Outer Rotor c - Inner Rotor d - Shaft e - O-Ring (2) f - O-Ring (1) g - Cover h - Screw (2) Oil Pump Installation 1. Place O-ring seals on the oil pump. 28266 2. Place O-ring on oil pump. 3. Align the slot in the oil pump shaft with the camshaft projection. 4. Fasten with 3 bolts. Torque to specification. 28262 b c d a a - Oil Pump Housing b - O-Ring c - Align Slot With Camshaft Projection d - Bolt (3) Oil Pump Mounting Bolt Torque 70 lb. in. (8 N·m) 90-827857R1 NOVEMBER 1996 POWERHEAD - 4A-27 Cylinder Head Gasket 1. Install cylinder head gasket, dowel pins, and Oring seal. b c a b a - Cylinder Head Gasket b - Dowel Pin (2) c - O-Ring Seal Cylinder Head Installation 1. Apply engine oil to the threads of each bolt and seat surface. 2. Fasten cylinder head with eight bolts. 28264 a a a b c b b c a - Bolts (3) 2.36 in. (60 mm) Long b - Bolts (3) 1.77 in. (45 mm) Long c - Bolts (2) 1.38 in. (35 mm) Long 3. Torque in sequence and in two steps. 1 2 3 5 6 8 7 4 28264 Cylinder Head Bolt Torque Center Bolts Qty. 6 (Larger Diameter M8) 1st: 11 lb. ft. (15 N·m) 2nd: 22 lb. ft. (30 N·m) Outer Flange Bolts Qty. 2 (Smaller Diameter M6) 1st: 53 lb. in. (6 N·m) 2nd: 106 lb. in. (12 N·m) 4. Install timing belt (refer to “Timing Belt Installation” in this section). 28333 a a - Timing Belt 5. Adjust valves. Refer to Section 4 Part B. b c b c Cylinder Head Cover Bolt Torque 70 lb. in. (8 N·m) Cylinder Head Cover Installation 1. Install cover as shown. a a -Cover Seal b -Cylinder Head Cover c -Bolt (4) 2. Torque bolts in sequence. 1 2 4 3 28336 Intake Manifold Assembly 1. If removed, Install intake manifold assembly to the cylinder head. b c d a e f g h f f g g i a -Intake Manifold b -Gasket c -Bracket d -“C”- Clamp e -Hose Clamp f -Bolt (3) 1.77 in. (45 mm) Long g -Flat Washer h -Hex Nut i -Threaded Stud Intake Manifold Fasteners Torque 70 lb. in. (8 N·m) 4A-28 - POWERHEAD 90-827857R1 NOVEMBER 1996 Oil Filter Assembly 1. If removed, install oil filter assembly as shown. b c d e f a c d a -Oil Filter Housing b -Oil Filter c -O-ring Seal (2) d -Flat Washer e -Bolt 1.97 in. (50 mm) Long f -Bolt 1.18 in. (30 mm) Long Oil Filter Housing Bolt Torque 70 lb. in. (8 N·m) Oil Separator Installation 1. Install oil separator and connect hoses. b a 28334 a -Oil Separator b -Screw (2) 90-827857R1 NOVEMBER 1996 POWERHEAD - 4A-29 POWERHEAD B 4 CYLINDER BLOCK/CRANKCASE Table of Contents Page Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-1 Cylinder Block And Crankcase . . . . . . . . . . . . . 4B-2 Crankshaft, Pistons And Connecting Rods . . . 4B-4 Crankcase and Main Bearing Selection . . . . . 4B-6 Powerhead Removal . . . . . . . . . . . . . . . . . . . . . 4B-7 Handle Rest Removal . . . . . . . . . . . . . . . . . . 4B-8 Neutral Interlock Cable (Manual Models) . . 4B-8 Battery Lead (Electric Start Models) . . . . . . 4B-8 Throttle Linkage Removal (Remote Models) . . . . . . . . . . . . . . . . . . . . . . 4B-9 Throttle Linkage Removal (Tiller Handle Models) . . . . . . . . . . . . . . . . . . 4B-9 Powerhead Disassembly . . . . . . . . . . . . . . . . . 4B-10 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-11 Piston connecting rod disassembly . 4B-11 Main bearing disassembly . . . . . . . . . . . 4B-11 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . 4B-12 Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . 4B-12 Measuring Cylinder Bore . . . . . . . . . . . . 4B-12 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-12 Measuring piston . . . . . . . . . . . . . . . . . . . 4B-12 Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-13 Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . 4B-13 Piston ring side clearance . . . . . . . . . . . 4B-13 Piston ring end gap clearance . . . . . . . 4B-13 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-14 Checking Main Bearing Clearance . . . . . . 4B-14 Checking Connecting Rod Oil Clearance 4B-15 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-15 Page Powerhead Reassembly . . . . . . . . . . . . . . . . . 4B-16 Main Bearing Selection . . . . . . . . . . . . . . . . 4B-16 Main Bearing Installation . . . . . . . . . . . . . . 4B-16 Piston Rings and Connecting Rod . . . . . . 4B-17 Piston Installation . . . . . . . . . . . . . . . . . . . . . 4B-17 Crankshaft Assembly . . . . . . . . . . . . . . . . . 4B-18 Crankshaft Cover . . . . . . . . . . . . . . . . . . . . . 4B-18 Exhaust Cover . . . . . . . . . . . . . . . . . . . . . . . 4B-19 Thermostat Housing . . . . . . . . . . . . . . . . . . 4B-19 Oil Pressure Switch . . . . . . . . . . . . . . . . . . . 4B-19 Drive Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-20 Cylinder Head Gasket . . . . . . . . . . . . . . . . . 4B-20 Cylinder Head Installation . . . . . . . . . . . . . . 4B-21 Electrical Mounting Plates . . . . . . . . . . . . . 4B-21 Cylinder Head Cover Installation . . . . . . . . 4B-22 Water Hose Routing . . . . . . . . . . . . . . . . . . 4B-22 Non-bodensee Models . . . . . . . . . . . . . . 4B-22 Bodensee Models . . . . . . . . . . . . . . . . . . 4B-22 Powerhead Installation . . . . . . . . . . . . . . . . . . . 4B-23 Throttle Linkage Installation (Electric Start Models) . . . . . . . . . . . . . . . . . 4B-24 Throttle Linkage Installation (Manual Start Models) . . . . . . . . . . . . . . . . . 4B-25 Neutral Interlock Cable (Manual Start Models) . . . . . . . . . . . . . . . . . 4B-25 Handle Rest Installation . . . . . . . . . . . . . . . 4B-25 Battery Lead (Electric Start Models) . . . . . 4B-25 90-827857R1 NOVEMBER 1996 Specifications CYLINDER BLOCK Type Displacement Number of Cylinders 4 Stoke Cycle – Over Head Camshaft 14.16 cu. in. (232cc) 2 CYLINDER Diameter (Std) 2.323 in. (59.0mm) BORE Taper/Out of Round Maximum Bore Type Bore Wear Limit 0.003 in. (0.076mm) Steel 2.326 in. (59.1mm) PISTON Piston Type O.D. at Skirt (Standard) (Oversize) 0.010 (0.254mm) (Oversize) 0.020 (0.508mm) Aluminum 2.3209 - 2.3216 in. (58.950 - 58.965 mm) 2.333 in. (59.25 mm) 2.343 in. (59.50 mm) COMPRESSION/ RATIO Compression Ratio Cylinder Compression (cold engine) 9.3:1 170 -190 lbs./in2 (Peak) CRANKSHAFT Top Main Bearing Journal 1.181 in. ± 0.0001 in. (30.0 mm ± 0.003 mm) Bottom Main Bearing Journal 1.181 in. ± 0.0001 in. (30.0 mm ± 0.003 mm) Connecting Rod Journal 1.102 in. ± 0.0001 in. (28.0 mm ± 0.003 mm) Crankshaft Width (Width of Thrust Surfaces) “A” 4.87 - 4.88 in. (123.7 - 123.9 mm) Runout Limit “B” 0.0008 in. (0.02 mm) Main Bearing Clearance B B 0.0002 - 0.0017 in. (0.005 - 0.0043 mm) A CONNECTING ROD Rod Clearance (Big End) 0.0008 - 0.0018 in. (0.021 - 0.045 mm) RINGS Ring End Gap (Installed) Top 0.006 - 0.012 in. (0.15 - 0.03 mm) Middle 0.006 - 0.012 in. (0.15 - 0.03 mm) Bottom (Oil Ring) 0.008 - 0.028 in. (0.20 - 0.70 mm) Wear Limit Side Clearance: 0.020 in. (0.50 mm) Top 0.002 - 0.003 in. (0.04 - 0.08 mm) Middle 0.001 - 0l003 in. (0.03 - 0.07 mm) Wear Limit 0.020 in. (0.50 mm) 90-827857R1 NOVEMBER 1996 POWERHEAD - 4B-1 Cylinder Block And Crankcase 12 113 Loctite Master Gasket (92-12564-2) 4 Cycle Oil (92-828000A12) A=BODENSEE 4B-2 - POWERHEAD 90-827857R1 NOVEMBER 1996 Cylinder Block And Crankcase REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 CRANKCASE ASSEMBLY 2 4 PIN–dowel 3 4 BOLT 22 30.0 4 6 BOLT 106 12.0 1 GASKET–cylinder block 6 1 GASKET–inner exhaust cover 7 1 COVER–inner exhaust 8 1 GASKET–outer exhaust cover 9 2 BOLT 106 12.0 1 COVER–outer exhaust 11 1 COVER–outer exhaust (BODENSEE) (SEE NOTE) 12 1 FITTING (BODENSEE) 13 5 BOLT 14 1 O-RING 1 THERMOSTAT 16 1 GASKET–cover 17 1 COVER–thermostat 18 2 BOLT 106 12.0 19 1 PIPE 1 HOSE (16 IN.) 21 1 GASKET–cylinder head 22 1 CYLINDER HEAD ASSEMBLY 23 4 GUIDE 24 4 CIRCLIP 2 FITTING 26 2 BOLT 70 8.0 27 2 SPARK PLUG 20 27.0 28 1 PLUG 13 18.0 29 1 O-RING 1 ANODE 31 1 SCREW 32 3 BOLT 22 30.0 33 3 BOLT 22 30.0 34 1 SEAL 2 GROMMET 36 1 COVER–cylinder head 37 1 PIPE–breather 38 1 NIPPLE 39 4 BOLT 70 8.0 1 O-RING 41 1 PLUG–oil 42 1 DIPSTICK 43 1 HOSE 44 1 CONNECTOR-T 1 HOSE (2 IN.) 46 2 HOSE (1-1/2 IN.) 47 1 CONNECTOR (NON BODENSEE) 45 1 TEE (BODENSEE) 48 1 HOSE 49 1 HOSE (10 IN.) (NON BODENSEE) 1 HOSE 51 1 FITTING NOTE: THE POWERHEAD LISTED DOES NOT INCLUDE THE BODENSEE OUTER EXHAUST COVER. 90-827857R1 NOVEMBER 1996 POWERHEAD - 4B-3 Crankshaft, Pistons And Connecting Rods 1 2 3 4 5 6 7 8 9 10 11 12 9 4 4 4 2 113 113 113 113 95 113 113 113 113 95 95 113 2-4-C With Teflon (92-825407A12) 4 Cycle Oil (92-828000A12) 4B-4 - POWERHEAD 90-827857R1 NOVEMBER 1996 Crankshaft, Pistons And Connecting Rods REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 SEAL–oil 2 2 BEARING–thrust 3 1 CRANKSHAFT 4 AR BEARING–main (BROWN) AR BEARING–main (BLACK) AR BEARING–main (BLUE) 5 1 SEAL–oil 6 4 BOLT 106 12.0 7 4 WASHER 8 2 CONNECTING ROD 9 4 CIRCLIP 10 2 PISTON PIN 11 2 PISTON (STANDARD) PISTON (.010 OVERSIZE) SEE NOTE PISTON (.020 OVERSIZE) AR AR 12 2 RING–Piston (STANDARD) AR RING–Piston (.010 OVERSIZE) AR RING–Piston (.020 OVERSIZE) NOTE: PISTON DOES NOT INCLUDE RINGS, PIN AND CLIP 90-827857R1 NOVEMBER 1996 POWERHEAD - 4B-5 Crankcase and Main Bearing Selection a a Combination of Crankcase and Bearing Crankcase: b b Mark a Housing Size A 1.3005 in. – 1.3008 in. (33.032mm – 33.040mm) B 1.3002 in. – 1.3005 in. (33.024mm – 33.032mm) C 1.2998 in. – 1.3002 in. (33.016mm – 33.024mm) Bearing: Indication b Bearing Size Blue 0.0594 in. – 0.0595 in. (1.508mm – 1.512mm) Black 0.0592 in. – 0.0594 in. (1.504mm – 1.508mm) Brown 0.0591 in. – 0.0592 in. (1.500mm – 1.504mm) Combination: Combine the Crankcase and Bearing by the following chart. Crankcase Mark Bearing Color A Blue B Black C Brown 4B-6 - POWERHEAD 90-827857R1 NOVEMBER 1996 Powerhead Removal 1. Remove terminal cover. Disconnect the oil lamp and stop switch leads (see section 2D “Wiring Diagrams” for correct leads). 2. Remove dipstick and drain oil from engine. 28345 b 28346 a -Blow-by Hose b -Fuel Line a a –Dipstick 3.Remove fuel line and blow-by hose. a 4. Disconnect water hoses. NON-BODENSEE MODELS BODENSEE MODELS a -Non-Bodensee Disconnections b -Bodensee Disconnections 90-827857R1 NOVEMBER 1996 POWERHEAD - 4B-7 Handle Rest Removal 1. To prevent the rope from being pulled into the starter pull out the starter rope and make a knot. 28347 2. Remove hinge pin and handle rest bolt. a b 28287 a -Hinge Pin b -Handle Rest Bolt c -Thumb Screw d -Flywheel Cover Neutral Interlock Cable (Manual Start Models) 1. Loosen lock nut and disconnect neutral interlock cable. 28351 a b a -Lock Nut b -Neutral Interlock Cable Battery Lead (Electric Start Models) 1.Disconnect battery lead. Disconnect the battery lead to both the starter motor and starter relay. 28244 a a -Battery Lead 4B-8 - POWERHEAD 90-827857R1 NOVEMBER 1996 Throttle Linkage Removal (Remote Control Models) 1. Unsnap throttle link from remote slide. 53445 a b a -Throttle Link b -Remote Slide Throttle Linkage Removal (Tiller Handle Models) 1. Un-clip throttle linkage from cable pulley stud. 53402 a b a -Throttle Linkage b -Cable Pulley Stud 2. Remove screws and trim covers. 28349 b a a -Screw b -Trim Cover 3. Remove mounting bolts. 28350 a -Mounting Bolts 90-827857R1 NOVEMBER 1996 POWERHEAD - 4B-9 Powerhead Disassembly 1. Remove flywheel and electrical components. Refer to Section 2 Part A. 2. Remove timing belt. Refer to Section 4 Part A. 3. Remove the drive gear components. a b c d c a -Nut b -Lock Washer c -Washer (2) d -Drive Gear 4. Remove exhaust covers and gaskets. a b c d a -Outer Exhaust Cover b -Gasket c -Inner Exhaust Cover d -Gasket 5. Remove crankcase cover bolts from locations shown. a a -Bolts (10) 6. Insert a screwdriver at the pry points between the crankcase cover and block to separate. b a c 28272 a b c -Screwdriver -Crankcase Cover -Block 7. Remove the crankshaft assembly along with connecting rods and pistons. 4B-10 - POWERHEAD 90-827857R1 NOVEMBER 1996 Crankshaft PISTON CONNECTING ROD DISASSEMBLY 1. Remove Circlips with a needle nose pliers. NOTE: Each connecting rod and cap (b) are a matched set. They must not be interchanged. 2. Mark the top side of the connecting rods. 3. Scribe the cylinder number (1 or 2) on inside of each piston and connecting rod (c) to insure reassembly of piston to same connecting rod and cylinder. b c a a -Remove Circlips with a needle nose pliers b -Connecting Rod and Cap are a Matched Set. Don’t Interchange c -Scribe the Cylinder Number (1 or 2) on Inside of Each Piston and Connecting Rod MAIN BEARING DISASSEMBLY 1. Do not interchange the main bearings. They must be installed in their original position. 2. Disassemble crankshaft as shown. a a a a a -Main Bearings – Do Not Interchange. Reinstall in Original Position 90-827857R1 NOVEMBER 1996 POWERHEAD - 4B-11 Cleaning/Inspection/Repair Cylinder Bore MEASURING CYLINDER BORE 1. Measure the cylinder bore diameter “d” at three locations in both X and Y axis. 2. If the cylinder bore is beyond the limits listed in the tables below, it will be necessary to rebore the cylinder to accept the next oversize piston. X Y d d d Piston MEASURING PISTON 1. Measure the piston at a point 0.4 in (10 mm) from the bottom. b a a -Piston Diameter b -0.4 in. (10 mm) Cylinder Bore Specifications Diameter (Standard) 2.323 - 2.324 in. (59.00 - 59.02 mm) Bore Wear Limit 2.326 in. (59.1 mm) Taper or Out-of-Round Maximum Limit 0.003 in. (0.08 mm) Diameter 0.010 in. (0.254mm) Oversize 2.333 - 2.334 in. (59.254 - 59.274 mm) Bore Wear Limit 2.336 in. (59.354mm) Taper or Out-of-Round Maximum Limit 0.003 in. (0.08 mm) Diameter 0.020 in. (0.508mm) Oversize 2.343 - 2.344 in. (59.508 - 59.508 mm) Bore Wear Limit 2.346 in. (59.608 mm) Taper or Out-of-Round Maximum Limit 0.003 in. (0.08 mm) Piston Diameter “a” Standard 2.3209 - 2.3216 in. (58.950 - 58.965 mm) (Oversize) 0.010 in. (0.254 mm) 2.333 in. (59.25 mm) (Oversize) 0.020 in. (0.508 mm) 2.343 in. (59.50 mm) Piston Clearance to Cylinder Clearance 0.0014 - 0.0026 in. (0.035 - 0.065 mm) Minimum bore measurement – maximum piston measurement = piston clearance to cylinder clearance 4B-12 - POWERHEAD 90-827857R1 NOVEMBER 1996 Piston Pin Piston Pin 1. Measure piston pin diameter. Out of specification, replace. Piston Pin Diameter 0.5510 - 0.5512 in. (13.996 - 14.000 mm) 2. Place the piston pin into the connecting rod and check for free play. There should be no noticeable free play. 3. Place the piston pin into the piston and check for free play. There should be no noticeable free play. Piston Rings PISTON RING SIDE CLEARANCE 1. Measure piston ring side clearance. Out of specification, replace piston and or piston rings. Piston Ring Side Clearance Top 0.002 - 0.003 in. (0.04 - 0.08 mm) 2nd 0.001 - 0.003 in. (0.03 - 0.08 mm) PISTON RING END GAP CLEARANCE 1. Measure piston ring end gap clearance. Out of specification, replace. a a -Push Piston Rings into Cylinder 0.8 in. (20 mm) Deep. Push in the Rings Using the Piston. Piston Ring End Gap Top 0.006 - 0.012 in. (0.15 - 0.30 mm) 2nd 0.006 - 0.012 in. (0.15 - 0.30 mm) Oil 0.008 - 0.028 in. (0.20 - 0.70 mm) 90-827857R1 NOVEMBER 1996 POWERHEAD - 4B-13 Crankshaft 1. Thoroughly clean crankshaft and inspect bearing surfaces. Replace crankshaft in bearing surfaces are pitted, scored, or discolored. 2. Measure crankshaft main bearing journals, connecting rod journals, and crankshaft width (see specifications). Replace crankshaft if out of specifications. 3. Measure Runout. Out of specification, replace. Crankshaft Runout 0.0008 in. (0.02 mm) Checking Main Bearing Clearance IMPORTANT: Do not interchange the main bearings. They must be installed in their original position. 1. Clean all the oil from the crankshaft bearing surfaces and main bearings. NOTE:Refer to instructions in Cylinder Block Reassembly for selecting and installing main bearings. 2. Install main bearings. 3. Place crankshaft into cylinder block. 4. Place a piece of plastigauge onto the crankshaft bearing surface. 5. Install crankcase cover. Apply oil to the cover bolts and torque cover bolts in sequence and in two steps. 1 2 10 9 5 6 8 7 3 4 Crankcase Cover Bolt Torque Center Bolts Qty. 4 (Larger Diameter M8) 1st: 11 lb. ft. (15 N·m) 2nd: 22 lb. ft. (30 N·m) Outer Bolts Qty. 6 (Smaller Diameter M6) 1st: 53 lb. in. (6 N·m) 2nd: 106 lb. in. (12 N·m) 6. Remove the crankcase cover and measure the compressed plastigauge to check the main bearing clearance. Out of specification, replace the main bearings. Main Bearing Clearance 0.0002 - 0.0017 in. (0.005 - 0.043 mm) 7. If replacement of the main bearings is required, refer to Main Bearing Selection and Installation in Cylinder Block Reassembly. 4B-14 - POWERHEAD 90-827857R1 NOVEMBER 1996 Checking Connecting Rod Oil Clearance 1. Clean all the oil from the connecting rod and bearing surface on the crankshaft. Check for pitting, scoring and discoloration. 2. Install the connecting rod to the respective crank pin. 3. Place a piece of plastigauge on the crank pin. IMPORTANT: Do not rotate connecting rod and/or crankshaft when measuring clearance. 4. Install the connecting rod cap. Torque bolts in sequence and in two steps. 5. Remove the connecting rod cap and measure the compressed plastigauge to check the connecting rod oil clearance. Out of specification, replace. Connecting Rod Oil Clearance 0.0008 - 0.0018 in. (0.021 - 0.045 mm) Thermostat 1. Push open the thermostat valve and place a piece of thread into the valve. 2. Suspend thermostat in water. Heat water slowly while observing thermometer. Connecting Rod Bolt Torque 1st: 53 lb. in. (6 N·m) 2nd: 106 lb. in. (12 N·m) Water Temperature Valve Lift 136° -144° F (58° - 62° C) 0 in. (0 mm) Above 158° F (70° C) Minimum 0.12 in. (3 mm) 90-827857R1 NOVEMBER 1996 POWERHEAD - 4B-15 Powerhead Reassembly Main Bearing Selection 1. Locate the upper and lower crankcase code letters on the crankcase cover. 2. Refer to the following reference chart to select the correct main bearings. 3. Use the color coded main bearings that match the crank case code letter. Crankcase Code Main Bearing Code Letter A Blue B Black C Brown b a a b a -Crankcase Code Letter Location b -Color Location on Main Bearings Main Bearing Installation IMPORTANT: Do not interchange the main bearings. They must be installed in their original position. 1. Clean all the oil from the main bearing surfaces on the cylinder block and cylinder cover. 2. Install main bearings. make sure the locking lug on each bearing fits into the locking notch. 28268 a a a a b 28267 a -Main Bearings b -Fit the Locking Lugs on Main Bearings into the Notches 4B-16 - POWERHEAD 90-827857R1 NOVEMBER 1996 Piston Rings and Connecting Rod 1. Install the oil ring as shown. b a a -Oil Ring b -Side Ring (2) 2. Install the second and top piston rings as shown. Align the end gaps with the locating pins in the ring grooves. UP b a a -Top Piston Ring b -Second Piston Ring 3. Lubricate piston pin with oil and assemble the piston to the connecting rod. Always use new Circlips. b a a c a -Circlip b -Piston Pin c -Side Marked 6G8-03 is Installed Towards “UP” on Piston 90-827857R1 NOVEMBER 1996 Piston Installation IMPORTANT: Position the “UP” mark on the piston toward the flywheel side. 1. Align ring end gap on the top and second piston rings with the locating pins in the ring groove. 2. Align ring end gap on the oil ring and oil ring side rails as shown. b a b a -Oil Ring End Gap b -Oil Ring Side Rails End Gap 3. Lubricate pistons, piston rings, and cylinder walls with oil. NOTE:The bottom of the cylinder bore has a taper which allows the insertion of the piston and rings without using a ring compressor. IMPORTANT: Make sure pistons are oriented towards up. 4. Align all the piston ring end gaps as shown above and carefully fit each piston into the cylinder using the tapered cylinder wall to compress the rings. 28270 a a -Installation of Number “1” Piston and Rod Assembly POWERHEAD - 4B-17 4B-18 - POWERHEAD 90-827857R1 NOVEMBER 1996 Crankshaft Assembly 1. Lubricate the thrust bearings and crankshaft with oil. 2. Place a thrust bearing (oil grooves on the crank side) on each end of the crankshaft. Place crankshaft into the cylinder block. 3. Position the tabs on the thrust bearings into the notches in the cylinder block. 28271 b a a c a - Thrust Bearings (Oil Grooves Towards Crank) b - Oil Grooves c - Tabs -Position Into Notches 4. Assemble the connecting rods to the crankshaft. 5. Align the casting rib on the cap with the same casting rib on the connecting rod. 6. Apply oil to connecting rod bolts and torque bolts in sequence and in two steps. 28276 Connecting Rod Bolt Torque 1st: 53 lb. in. (6 N·m) 2nd: 106 lb. in. (12 N·m) Crankshaft Cover 1. Install dowel pins into cylinder block. 2. Lubricate inside of oil seals with 2-4-C w/Teflon. 3. Install upper and lower oil seals. Install oil seals so numbers are facing out. 28275 b a c a a - Dowel Pin (2) b - Upper Oil Seal c - Lower Oil Seal NOTE: Make sure the contacting surface of the crankcase cover and cylinder block are clean before applying gasket sealant. 4. Apply Loctite Master Gasket Sealant to block surface. Instructions in kit must be followed exactly. IMPORTANT: Make sure sealant is applied so that it does not overflow into the main bearings. a 28275 a - Apply Loctite Master Gasket Sealant a b c d 6 2 3 e f a -Outer Exhaust Cover b -Gasket c -Inner Exhaust Cover d -Gasket e -Bolt - Bottom (2) .98 in. (25mm) Long f -Bolt (5) 1.18 (30 mm) Long ab c d 6 2 3 e f a -Outer Exhaust Cover b -Gasket c -Inner Exhaust Cover d -Gasket e -Bolt - Bottom (2) .98 in. (25mm) Long f -Bolt (5) 1.18 (30 mm) Long 5. Install crankshaft cover. 6. Apply oil to threads of bolts and torque bolts in sequence and two steps. 1 9 10 5 6 8 7 3 4 a -Center Bolts (4) 1.74 in. (45 mm) Long b -Outer Bolts (6) .98 in. (25 mm) Long 2 b a Crankcase Cover Bolt Torque Center Bolts Qty. 4 (Larger Diameter M8) 1st: 11 lb. ft. (15 N·m) 2nd: 22 lb. ft. (30 N·m) Outer Bolts Qty. 6 (Smaller Diameter M6)) 1st: 53 lb. in. (6 N·m) 2nd: 106 lb. in. (12 N·m) Exhaust Cover 1. Install exhaust covers as shown with new gaskets as shown. 2. Torque bolts in sequence and in two steps. 7 4 1 5 Exhaust Cover Bolt Torque 1st: 53 lb. in. (6 N·m) 2nd: 106 lb. in. (12 N·m) Thermostat Housing 1. Install Thermostat. Always use a new gasket. d c b e a a -Thermostat b -Gasket (Always Use A New Gasket) c -Thermostat Cover d -Bolt (2) e -By-Pass Hose Thermostat Bolt Torque 70 lb. in. (8 N·m) Oil Pressure Switch 1. If removed, install oil pressure switch. Apply sealant to threads of switch and tighten securely. 2. If removed, install oil pressure switch wire. Secure wire with bolt, torque to 17 lb. in. (2 N·m). a 9 9 Loctite PST Pipe Sealant (92-809822) a -Oil Pressure Switch 90-827857R1 NOVEMBER 1996 POWERHEAD - 4B-19 4B-20 - POWERHEAD 90-827857R1 NOVEMBER 1996 Drive Gear 1. Install drive gear components. d b c b TOP a 28261 a - Drive Key b - Timing Belt Guide Plate (Install With the Curved Side Towards Drive Gear) c - Drive Gear (Side Marked “TOP” Should Face Up) d - The Projections on the Drive Gear Should Fit into the Holes in the Guide Plates 2. Insert the tab on the lock washer into the opening with the “TOP” Mark. a 28273 a - Lock Washer 3. Tighten drive gear nut to the specified torque. 4. After tightening the nut, bend the lock washer against the nut. b a a - Drive Gear Nut b - Bend Lock Washer Against Nut Drive Gear Nut Torque 17 lb. ft. (23 N·m) Cylinder Head Gasket 1. Install cylinder head gasket, dowel pins, and Oring seal. b c a b a - Cylinder Head Gasket b - Dowel Pin (2) c - O-Ring Seal 90-827857R1 NOVEMBER 1996 POWERHEAD - 4B-21 Cylinder Head Installation 1. Apply engine oil to the threads of each mounting bolt and seat surface. 2. Fasten cylinder head with eight bolts. 28264 a a a b c b b c a - Bolts -M8 (3) 2.36 in. (60 mm) Long b - Bolts - M8 (3) 1.77 in. (45 mm) Long c - Bolts -M6 (2) 1.38 in. (35 mm) Long 3. Torque bolts in sequence and in two steps. 1 2 3 5 6 8 7 4 28264 Cylinder Head Bolt Torque Center Bolts Qty. 6 (Larger Diameter M8) 1st: 11 lb. ft. (15 N·m) 2nd: 22 lb. ft. (30 N·m) Outer Flange Bolts Qty. 2 (Smaller Diameter M6) 1st: 53 lb. in. (6 N·m) 2nd: 106 lb. in. (12 N·m) 4. Refer to Section 4 Part A for timing belt installation. 28333 a a - Timing Belt Electrical Mounting Plates Install electrical mounting plates as shown. 28243 b a a - Switch Box/Coil Mounting Plate b - Rectifier Mounting Plate (Electric Start Models) b c b c Cylinder Head Cover Installation 1. Adjust valves. Refer to Section 4 Part A. 2. Install cover as shown. a a -Cover Seal b -Cylinder Head Cover c -Bolt (4) 3. Torque bolts in sequence. 1 2 4 3 28336 Cylinder Head Cover Bolt Torque 70 lb. in. (8 N·m) Water Hose Routing Route and connect water hoses as shown. NON-BODENSEE MODELS c a b BODENSEE MODELS a -Connects to Water Pump Indicator (Discharge) Fitting b -Connects to Port Side Fitting in Bottom Cowl c -Connects to Starboard Side Fitting in Bottom Cowl d -Fuel Pump 4B-22 - POWERHEAD 90-827857R1 NOVEMBER 1996 Powerhead Installation 1. Remove all old gasket material from power head base and matching drive shaft housing surface. 2. Install powerhead gasket, dowel pin, O-ring, damper and seal. b d a b c e 28351 a -Gasket b -Dowel Pin c -O-Ring d -Damper e -Seal 3. Install powerhead and secure to drive shaft housing. Torque bolts to 15 lb. ft. (21 N.·m). 28350 NOTE:If crankshaft splines do not line up with drive shaft splines, turn the flywheel a little so that they can mesh. 4. Install trim covers and screws. 28349 b a a -Screw b -Trim Cover 5. Install dipstick. a 28345 a -Dipstick 90-827857R1 NOVEMBER 1996 POWERHEAD - 4B-23 6. Connect water hoses. NON-BODENSEE MODELS 53374 BODENSEE MODELS 53374 a -Non-Bodensee Connections b -Bodensee Connections 7. Connect fuel line and blow-by hose. b a a -Blow-by Hose b -Fuel Line Throttle Linkage Installation (Electric Start Models) 1. Snap throttle link into remote slide. 53445 a b a -Throttle Link b -Remote Slide 4B-24 - POWERHEAD 90-827857R1 NOVEMBER 1996 Throttle Linkage Installation (Manual Start Models) 1. Clip throttle linkage onto cable pulley stud. 53402 a b a -Throttle Linkage b -Cable Pulley Stud Neutral Interlock Cable (Manual Start Models) 1. Install stop wire and lock nut and adjust the neutral interlock cable length (see section 8 for proper adjustment). a b 28351 a -Neutral Interlock Cable b -Lock Nut Handle Rest Installation 1. Install hinge pin and handle rest bolt. a b a -Hinge Pin b -Handle Rest Bolt 2. Untie the knot and let rope wind around the starter. Battery Lead (Electric Start Models) 1. Install battery lead. Connect the battery lead to both the starter motor and starter relay. 28244 a a -Battery Lead NOTE:Check for proper neutral start protection at start up. 2.Install Electrical leads, Terminal Cover, and Screw. Refer to Section 2D “Electrical and Igni- tion” for proper connections. 90-827857R1 NOVEMBER 1996 POWERHEAD - 4B-25 MID-SECTION 5 Table of Contents Page DriveshaftHousing ........................ 5-2 SwivelBracket ............................ 5-4 SwivelHeadAndSteeringHandle ........... 5-6 ClampBracket ............................ 5-8 Drive Shaft Housing Disassembly/Reassembly ................ 5-10 90-827857R1 NOVEMBER 1996 Notes: 90-827857R1 NOVEMBER 1996 MID-SECTION -5-1 DRIVESHAFT HOUSING 1 2 34 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 30 31 32 33 34 35 36 38 40 41 43 44 45 47 48 49 50 51 52 53 54 55 56 57 54 35 38 40 44 45 8 A 66 Loctite 242 (92-809821) 66 66 A=REF. #10 INVERTED DRIVESHAFT HOUSING 1 2 34 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 30 31 32 33 34 35 36 38 40 41 43 44 45 47 48 49 50 51 52 53 54 55 56 57 54 35 38 40 44 45 8 A 66 Loctite 242 (92-809821) 66 66 A=REF. #10 INVERTED 5-2 -MID-SECTION 90-827857R1 NOVEMBER 1996 90-827857R1 NOVEMBER 1996 MID-SECTION -5-3 DRIVESHAFT HOUSING REF. TORQUE REF. NO. QTY. DESCRIPTION lb. in. lb. ft. N·m 1 1 SEAL--rubber 2 1 SEAL 3 1 DAMPER 4 1 O-RING 9 BOLT 90 10.0 6 2 SCREW (M6 x 20) 70 8.0 7 2 WASHER 8 2 PIN--dowel 9 1 SEAL--oil 1 EXHAUST GUIDE 11 1 SEAL 12 2 SEAL--oil 13 1 HOUSING--seal 14 1 SEAL 1 GUIDE 16 1 SCREW 36 4.0 17 1 STRAINER 18 1 BOLT 70 8.0 19 1 O-RING 1 RELIEF VALVE 70 8.0 21 1 GASKET--oil pan22 1 SEAL 23 1 OIL PAN 24 1 O-RING 1 DRAIN PLUG 70 8.0 26 1 DAMPER 27 1 SEAL 28 1 WATER TUBE (SHORT) 29 1 WATER TUBE (LONG) 1 GASKET 31 1 EXHAUST MANIFOLD 32 4 BOLT 80 9.0 33 1 COVER 34 1 GASKET 2 PIN--dowel 36 1 HOUSING ASSEMBLY (SHORT) BLACK 1 HOUSING ASSEMBLY (LONG) 37 1 HOUSING ASSEMBLY (SHORT) GRAY37 1 HOUSING ASSEMBLY (LONG) 38 1 COVER (PORT) BLACK 1 COVER (STARBOARD) 39 1 COVER (PORT) GRAY39 1 COVER (STARBOARD) 2 SCREW (Self-Tapping) Tighten Securely 41 1 COVER-oil drain (BLACK) 42 1 COVER-oil drain (GRAY) 43 6 SCREW (M8 x 40) 15 20.5 44 2 MOUNT 2 COVER--mount (BLACK) 46 2 COVER--mount (GRAY) 47 2 SCREW--mount cover 48 2 LOCKWASHER 49 2 NUT--cover screw 105 11.5 1 PIPE 51 1 PIPE 52 2 WASHER 53 2 BUSHING 54 2 NUT 30 3.5 1 SEAL 56 1 SCREW (M5 x 10) Tighten Securely57 1 FUNNEL--oil drain 90-827857R1 NOVEMBER 1996 MID-SECTION -5-3 DRIVESHAFT HOUSING REF. TORQUE REF. NO. QTY. DESCRIPTION lb. in. lb. ft. N·m 1 1 SEAL--rubber 2 1 SEAL 3 1 DAMPER 4 1 O-RING 9 BOLT 90 10.0 6 2 SCREW (M6 x 20) 70 8.0 7 2 WASHER 8 2 PIN--dowel 9 1 SEAL--oil 1 EXHAUST GUIDE 11 1 SEAL 12 2 SEAL--oil 13 1 HOUSING--seal 14 1 SEAL 1 GUIDE 16 1 SCREW 36 4.0 17 1 STRAINER 18 1 BOLT 70 8.0 19 1 O-RING 1 RELIEF VALVE 70 8.0 21 1 GASKET--oil pan22 1 SEAL 23 1 OIL PAN 24 1 O-RING 1 DRAIN PLUG 70 8.0 26 1 DAMPER 27 1 SEAL 28 1 WATER TUBE (SHORT) 29 1 WATER TUBE (LONG) 1 GASKET 31 1 EXHAUST MANIFOLD 32 4 BOLT 80 9.0 33 1 COVER 34 1 GASKET 2 PIN--dowel 36 1 HOUSING ASSEMBLY (SHORT) BLACK 1 HOUSING ASSEMBLY (LONG) 37 1 HOUSING ASSEMBLY (SHORT) GRAY37 1 HOUSING ASSEMBLY (LONG) 38 1 COVER (PORT) BLACK 1 COVER (STARBOARD) 39 1 COVER (PORT) GRAY39 1 COVER (STARBOARD) 2 SCREW (Self-Tapping) Tighten Securely 41 1 COVER-oil drain (BLACK) 42 1 COVER-oil drain (GRAY) 43 6 SCREW (M8 x 40) 15 20.5 44 2 MOUNT 2 COVER--mount (BLACK) 46 2 COVER--mount (GRAY) 47 2 SCREW--mount cover 48 2 LOCKWASHER 49 2 NUT--cover screw 105 11.5 1 PIPE 51 1 PIPE 52 2 WASHER 53 2 BUSHING 54 2 NUT 30 3.5 1 SEAL 56 1 SCREW (M5 x 10) Tighten Securely57 1 FUNNEL--oil drain SWIVEL BRACKET 1 2 3 4 5 6 7 8 9 10 11 13 12 16 17 18 19 20 21 22 23 24 25 26 27 2 15 94 Anti-Corrosion Grease (92-78376A6) 7 Loctite 271 (92-809820) 95 2-4-C With Teflon (92-825407A12) 95 95 95 95 95 7 94 95 14 5-4 -MID-SECTION 90-827857R1 NOVEMBER 1996 90-827857R1 NOVEMBER 1996 MID-SECTION -5-5 SWIVEL BRACKET REF. TORQUE REF. NO. QTY. DESCRIPTION lb. in. lb. ft. N·m 1 1 SWIVEL BRACKET (BLACK) 1 1 SWIVEL BRACKET (GRAY) 2 4 GREASE FITTING 3 1 BEARING 4 1 THRUST BEARING--upper 5 1 BUSHING-lower 6 1 SEAL 7 1 THRUST WASHER-lower 8 1 SPRING 9 1 BRACKET 10 1 PIN 11 1 HOOK--reverse lock 12 1 WASHER--pivot pin 13 1 PIVOT PIN DESIGN I 14 1 PIVOT PIN DESIGN II 15 1 RETAINING RING 16 1 SPRING 17 1 CARRYING HANDLE (BLACK) 17 1 CARRYING HANDLE (GRAY) 18 1 SPRING--reverse hook 19 2 E-RING 20 1 ROD 21 2 BRAKE DISC 22 1 SWIVEL HEAD PLATE 23 2 SCREW 70 8.0 24 1 BRAKE PLATE 25 1 WASHER 26 1 HANDLE 27 1 NUT 125 14.0 --1 DECAL--co-pilot 90-827857R1 NOVEMBER 1996 MID-SECTION -5-5 SWIVEL BRACKET REF. TORQUE REF. NO. QTY. DESCRIPTION lb. in. lb. ft. N·m 1 1 SWIVEL BRACKET (BLACK) 1 1 SWIVEL BRACKET (GRAY) 2 4 GREASE FITTING 3 1 BEARING 4 1 THRUST BEARING--upper 5 1 BUSHING-lower 6 1 SEAL 7 1 THRUST WASHER-lower 8 1 SPRING 9 1 BRACKET 10 1 PIN 11 1 HOOK--reverse lock 12 1 WASHER--pivot pin 13 1 PIVOT PIN DESIGN I 14 1 PIVOT PIN DESIGN II 15 1 RETAINING RING 16 1 SPRING 17 1 CARRYING HANDLE (BLACK) 17 1 CARRYING HANDLE (GRAY) 18 1 SPRING--reverse hook 19 2 E-RING 20 1 ROD 21 2 BRAKE DISC 22 1 SWIVEL HEAD PLATE 23 2 SCREW 70 8.0 24 1 BRAKE PLATE 25 1 WASHER 26 1 HANDLE 27 1 NUT 125 14.0 --1 DECAL--co-pilot SWIVEL HEAD AND STEERING HANDLE 66 Loctite 242 (92-809821) 95 2-4-C With Teflon (92-825407A12) 5-6 -MID-SECTION 90-827857R1 NOVEMBER 1996 10 12 3 4 5 6 7 8 11 12 13 14 15 16 18 19 21 22 23 24 25 26 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 37 40 2 5 95 95 66 95 90-827857R1 NOVEMBER 1996 MID-SECTION -5-7 SWIVEL HEAD AND STEERING HANDLE REF. TORQUE REF. NO. QTY. DESCRIPTION lb. in. lb. ft. N·m 1 1 SWIVEL HEAD (BLACK) 1 1 SWIVEL HEAD (GRAY) 2 2 BUSHING 3 1 PLATE 4 2 SCREW (M5 x .8 x 16) 50 5.5 5 2 WASHER 6 1 WAVE WASHER 7 1 WASHER --1 TILLER HANDLE--complete (BLACK) SIDE SHIFT --1 TILLER HANDLE--complete (GRAY) --1 TILLER HANDLE--complete (BLACK) 9.9 --1 TILLER HANDLE--complete (GRAY) HANDLE SHIFT --1 TILLER HANDLE--complete (BLACK) 8 BODENSEE --1 TILLER HANDLE--complete (GRAY) HANDLE SHIFT 8 1 STEERING HANDLE ARM (BLACK) 9 1 STEERING HANDLE ARM (GRAY) 10 1 RETAINER 11 1 SCREW (M5 x .8 x 16) 35 4.0 12 1 COVER KIT 13 1 PULLEY 14 1 PULLEY CASE (Part of Ref. #11) 15 1 SCREW (10-16) 20 2.5 16 2 THROTTLE CABLE (SIDE SHIFT) 17 2 THROTTLE CABLE (HANDLE SHIFT) 18 1 SLEEVE 19 1 DECAL (SIDE SHIFT) 20 1 DECAL (HANDLE SHIFT) 21 1 GRIP 22 1 STOP SWITCH 23 1 THROTTLE FRICTION KNOB Finger Tight 24 1 THROTTLE FRICTION LOCK 25 1 SCREW (M6 x 1 x 25) As Required 26 1 THROTTLE HANDLE (SIDE SHIFT) 27 1 THROTTLE HANDLE (HANDLE SHIFT) (9.9)27 1 THROTTLE HANDLE (HANDLE SHIFT) (8 BODENSEE) 28 1 TILLER TUBE 29 1 SPRING 30 2 WASHER 31 2 STUD 32 2 SCREW (M6 x 12 70 8.0 33 2 WASHER 34 1 PLATE 35 1 SEAL 36 1 MOUNT 37 2 CLAMP 38 2 SCREW (M8 x 30) 13 17.5 39 2 WASHER 40 2 SEAL 41 1 BRACKET 42 2 DAMPER 43 2 NUT 18 24.5 --1 STOP--throttle handle (SIDE SHIFT --8 BODENSEE) 90-827857R1 NOVEMBER 1996 MID-SECTION -5-7 SWIVEL HEAD AND STEERING HANDLE REF. TORQUE REF. NO. QTY. DESCRIPTION lb. in. lb. ft. N·m 1 1 SWIVEL HEAD (BLACK) 1 1 SWIVEL HEAD (GRAY) 2 2 BUSHING 3 1 PLATE 4 2 SCREW (M5 x .8 x 16) 50 5.5 5 2 WASHER 6 1 WAVE WASHER 7 1 WASHER --1 TILLER HANDLE--complete (BLACK) SIDE SHIFT --1 TILLER HANDLE--complete (GRAY) --1 TILLER HANDLE--complete (BLACK) 9.9 --1 TILLER HANDLE--complete (GRAY) HANDLE SHIFT --1 TILLER HANDLE--complete (BLACK) 8 BODENSEE --1 TILLER HANDLE--complete (GRAY) HANDLE SHIFT 8 1 STEERING HANDLE ARM (BLACK) 9 1 STEERING HANDLE ARM (GRAY) 10 1 RETAINER 11 1 SCREW (M5 x .8 x 16) 35 4.0 12 1 COVER KIT 13 1 PULLEY 14 1 PULLEY CASE (Part of Ref. #11) 15 1 SCREW (10-16) 20 2.5 16 2 THROTTLE CABLE (SIDE SHIFT) 17 2 THROTTLE CABLE (HANDLE SHIFT) 18 1 SLEEVE 19 1 DECAL (SIDE SHIFT) 20 1 DECAL (HANDLE SHIFT) 21 1 GRIP 22 1 STOP SWITCH 23 1 THROTTLE FRICTION KNOB Finger Tight 24 1 THROTTLE FRICTION LOCK 25 1 SCREW (M6 x 1 x 25) As Required 26 1 THROTTLE HANDLE (SIDE SHIFT) 27 1 THROTTLE HANDLE (HANDLE SHIFT) (9.9)27 1 THROTTLE HANDLE (HANDLE SHIFT) (8 BODENSEE) 28 1 TILLER TUBE 29 1 SPRING 30 2 WASHER 31 2 STUD 32 2 SCREW (M6 x 12 70 8.0 33 2 WASHER 34 1 PLATE 35 1 SEAL 36 1 MOUNT 37 2 CLAMP 38 2 SCREW (M8 x 30) 13 17.5 39 2 WASHER 40 2 SEAL 41 1 BRACKET 42 2 DAMPER 43 2 NUT 18 24.5 --1 STOP--throttle handle (SIDE SHIFT --8 BODENSEE) CLAMP BRACKET 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 14 14 32 34 13 12 7 16 66 Loctite 242 (92-809821) 95 2-4-C With Teflon (92-825407A12) 32 66 66 95 95 95 95 A B 5-8 -MID-SECTION 90-827857R1 NOVEMBER 1996 90-827857R1 NOVEMBER 1996 MID-SECTION -5-9 CLAMP BRACKET REF. TORQUE REF. NO. QTY. DESCRIPTION lb. in. lb. ft. N·m 1 1 CLAMP BRACKET (PORT -BLACK) 1 1 CLAMP BRACKET (PORT -GRAY) 2 1 CLAMP BRACKET (STBD. -BLACK) 2 1 CLAMP BRACKET (STBD. -GRAY) 3 2 THUMB SCREW ASSEMBLY 4 2 WASHER--thumb screw 5 2 SCREW--washer attaching 65 7.5 6 1 SPACER 7 2 SCREW 60 7.0 8 1 DECAL (TILT) 9 1 SHUTTLE--tilt lock 10 1 TILT TUBE (MANUAL) 11 1 CLIP--safety 12 2 NUT--tilt tube 100 11.0 13 2 WASHER--tilt tube 14 2 LEVER ASSEMBLY--tilt return 15 1 STRAP--tilt stop -port side 16 2 SCREW--strap to clamp bracket 60 7.0 17 1 WAVE WASHER--tilt stop strap screw 18 2 BOLT--clamp bracket to transom 19 2 WASHER--clamp bracket bolt 20 2 NUT--clamp bracket bolt Tighten Securely 21 1 TILT TUBE 22 2 NUT 100 11.0 23 1 SPACER 24 2 SCREW 25 2 WASHER 26 1 BRACKET 27 2 NUT 140 16.0 28 1 TIE ROD ELECTRIC 29 1 BALL JOINT 30 1 WASHER (.39 x .546 x .1) 31 1 WASHER (.97 x .56 x .19) 32 3 WASHER (.390 x .625 x .062) 33 1 SPACER 34 2 NUT (.375-24) 35 1 SEAL KIT A --Torque nut to 20 lb. ft. (27.0 N·m) B --Tighten until nut seats. DO NOT exceed 120 lb. in. (13.5 N·m), then back off 1/4 turn. 90-827857R1 NOVEMBER 1996 MID-SECTION -5-9 CLAMP BRACKET REF. TORQUE REF. NO. QTY. DESCRIPTION lb. in. lb. ft. N·m 1 1 CLAMP BRACKET (PORT -BLACK) 1 1 CLAMP BRACKET (PORT -GRAY) 2 1 CLAMP BRACKET (STBD. -BLACK) 2 1 CLAMP BRACKET (STBD. -GRAY) 3 2 THUMB SCREW ASSEMBLY 4 2 WASHER--thumb screw 5 2 SCREW--washer attaching 65 7.5 6 1 SPACER 7 2 SCREW 60 7.0 8 1 DECAL (TILT) 9 1 SHUTTLE--tilt lock 10 1 TILT TUBE (MANUAL) 11 1 CLIP--safety 12 2 NUT--tilt tube 100 11.0 13 2 WASHER--tilt tube 14 2 LEVER ASSEMBLY--tilt return 15 1 STRAP--tilt stop -port side 16 2 SCREW--strap to clamp bracket 60 7.0 17 1 WAVE WASHER--tilt stop strap screw 18 2 BOLT--clamp bracket to transom 19 2 WASHER--clamp bracket bolt 20 2 NUT--clamp bracket bolt Tighten Securely 21 1 TILT TUBE 22 2 NUT 100 11.0 23 1 SPACER 24 2 SCREW 25 2 WASHER 26 1 BRACKET 27 2 NUT 140 16.0 28 1 TIE ROD ELECTRIC 29 1 BALL JOINT 30 1 WASHER (.39 x .546 x .1) 31 1 WASHER (.97 x .56 x .19) 32 3 WASHER (.390 x .625 x .062) 33 1 SPACER 34 2 NUT (.375-24) 35 1 SEAL KIT A --Torque nut to 20 lb. ft. (27.0 N·m) B --Tighten until nut seats. DO NOT exceed 120 lb. in. (13.5 N·m), then back off 1/4 turn. Drive Shaft Housing Disassembly/Reassembly Servicing components such as steering arm, drive shaft housing, exhaust assembly and swivel bracket will usually require powerhead and/or gear housing removal. Refer to SECTION 4 for powerhead removal and SECTION 6 for gear housing removal. The transom bracket, lower mount bracket, tilt tube and lower engine mounts can be serviced without powerhead/gear housing removal. However, OUTBOARD MUST BE SUPPORTED BEFORE SERVICING COMPONENTS. IMPORTANT: All gaskets should be replaced when removing powerhead and/or disassembling drive shaft housing. Corresponding gasket mating surfaces should be cleaned of any gasket material before installing new gaskets. 5-10 -MID-SECTION 90-827857R1 NOVEMBER 1996 LOWER UNIT 6 Table of Contents Page Gear Housing Specifications. . . . . . . . . . . . . . . . 6-1 Special Tools Required For Disassembly And Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Forward/Reverse Gear Backlash and Pinion Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Gear Housing (Drive Shaft) . . . . . . . . . . . . . . . . . 6-2 Gear Housing (Propeller Shaft) . . . . . . . . . . . . . 6-4 Gearcase Removal . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Gearcase Disassembly . . . . . . . . . . . . . . . . . . . . 6-6 Propeller Removal . . . . . . . . . . . . . . . . . . . . . . 6-6 Draining and Inspecting Gear Lubricant . . . . 6-7 Bearing Carrier. . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Water Pump, Drive Shaft and Shift Shaft . . 6-10 Pinion Gear and Forward Gear . . . . . . . . . . 6-14 Pinion Gear . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Forward Gear . . . . . . . . . . . . . . . . . . . . . . 6-14 Drive Shaft Bushing, Bearing and Lubrication Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 Aluminum Anode and Water Inlet . . . . . . . . 6-17 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Drive Shaft Needle Bearing, Bushing and Lubrication Sleeve Installation . . . . . . . . . . . 6-18 Forward Gear Bearing Race Installation . . 6-19 Forward Gear Reassembly . . . . . . . . . . . . . 6-19 Bearing Carrier Reassembly . . . . . . . . . . . . 6-19 Water Pump Base and Shift Shaft Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Propeller Shaft Reassembly. . . . . . . . . . . . . 6-21 Forward Gear, Pinion Gear and Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Shift Shaft and Water Pump Base Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Water Pump Cover Reassembly . . . . . . . . . 6-24 Impeller and Pump Cover Installation . . . . . 6-24 Propeller Shaft and Bearing Carrier Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 Aluminum Anode and Water Inlet Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26 Propeller Installation . . . . . . . . . . . . . . . . . . . 6-26 Filling Gear Housing with Lubricant . . . . . . . . . 6-27 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27 90-827857R1 NOVEMBER 1996 Gear Housing Specifications Special Tools Required For Disassembly And Reassembly DESCRIPTION PART NO. Universal Puller Plate 91-37241 Puller Assembly 91-83165M Slide Hammer 91-34569A1 Bearing Carrier Tool 91-13664 Drive Shaft Bearing Removal Tool 91-824788A1 Drive Shaft Bushing Installation Tool 91-824790A1 Mandrel 91-13658 Bushing Removal Tool 91-824787 Seal Installation Tool 91-824785A1 Puller Plate 91-29310 Drive Shaft Bushing Removal Tool 23-824789 Seal/Bushing Installation Tool 23-824786 Drive Shaft Bearing Installation Tool 91-824791 Expanding Rod SNAP ON* P/N CG40-4 Collet (Jaws) SNAP ON* P/N CG40A6 Leakage Tester FT8950 *Purchase From: SNAP ON TOOLS Corporation 2801 - 80th Street Kenosha, WI 53141-1410 Forward/Reverse Gear Backlash and Pinion Depth Pinion Depth . . . . . . . . . . . . . Not Adjustable Forward Gear Backlash . . . Not Adjustable Reverse Gear Backlash . . . Not Adjustable Gear Ratio . . . . . . . . . . . . . . . 2.00:1 Lubricant Capacity . . . . . . . 6.8 fl. oz. (200 ml) NOTE:Before filling gear case, apply 10-15 PSI of air pressure at the VENT hole. Pressure should not drop for 15 seconds while alternately applying a 2-3 pound force to the top of the shift shaft in the fore and aft direction. Fwd. Gear (No. of Teeth-Type) . . 26 Spiral/Bevel Rev. Gear (No. of Teeth-Type) . . 26 Spiral/Bevel Pinion Gear (No. of Teeth-Type) 13 Spiral/Bevel Water Pressure With Thermostat – @ W. O. T . . . 4–5 PSI @ 5500 RPM – @ Idle . . . . . . . 0–1/2 PSI @ 750 RPM 90-827857R1 NOVEMBER 1996 LOWER UNIT - 6-1 Gear Housing (Drive Shaft) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 38 39 4042 43 44 45 47 41 33 31 31 24 42 7 Loctite 271 (92-809820) 85 RTV Silicone Sealer (92-91601-1) 87 Super Duty Gear Lubricant (92-13783A24) 95 2-4-C With Teflon (92-825407A12) 95 87 87 85 7 95 7 95 95 7 6-2 - LOWER UNIT 90-827857R1 NOVEMBER 1996 Gear Housing (Drive Shaft) REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m – 1 GEAR HOUSING–complete (SHORT) BLACK GEAR HOUSING–complete (LONG)– 1 – 1 GEAR HOUSING–complete (SHORT) GRAY GEAR HOUSING–complete (LONG)– 1 1 1 GEAR HOUSING (BLACK) 1 1 GEAR HOUSING (GRAY) 2 1 BUSHING–gear housing 3 1 DRAIN SCREW 60 7.0 4 1 SEALING WASHER 5 1 SLEEVE ASSEMBLY 6 1 SLEEVE 7 1 BUSHING 8 1 SCREW PLUG KIT 60 7.0 9 1 SEALING WASHER 10 1 SCREEN 11 1 SCREW 30 3.5 12 1 ANODE ASSEMBLY 13 1 SCREW 30 3.5 14 1 SEAL 15 1 PINION GEAR 16 1 WASHER–thrust 17 1 BEARING 18 1 WATER PUMP BASE 19 1 GASKET 20 1 SEAL 21 1 RETAINER 22 1 SCREW Drive Tight 23 1 QUAD RING 24 2 OIL SEAL 25 1 GASKET 26 1 WATER TUBE 27 1 FACE PLATE 28 1 COVER ASSEMBLY 29 1 SEAL 30 1 IMPELLER 31 1 KEY ASSEMBLY 32 1 GUIDE 33 5 SCREW–water pump 50 5.5 34 1 WASHER 35 1 CAM–shift 36 1 SHIFT SHAFT (SHORT) LOWER SHIFT SHAFT (LONG)37 1 38 1 NUT 70 8.0 39 1 COUPLER 40 1 SHIFT SHAFT (UPPER) 41 1 E-RING 42 2 GUIDE 43 1 SCREW 45 5.0 44 1 NUT–guide screw 45 1 DRIVE SHAFT (SHORT) 46 1 DRIVE SHAFT (LONG) 47 1 THRUST WASHER 90-827857R1 NOVEMBER 1996 LOWER UNIT - 6-3 Gear Housing (Propeller Shaft) 7 87 94 95 Loctite 271 (92-809820) Super Duty Gear Lubricant (92-13783A24) Anti-Corrosion Grease (92-78376A6) 2-4-C With Teflon (92-825407A12) 48 49 50 51 52 53 54 55 56 57 5859 60 61 62 63 65 66 68 69 1 64 95 87 7 95 95 7 87 94 87 7 67 1.0 in. (25.4mm) 1-11/64 in. (29.8mm) 66 67 Actual Size Actual Size 6-4 - LOWER UNIT 90-827857R1 NOVEMBER 1996 Gear Housing (Propeller Shaft) REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m – 1 GEAR HOUSING–complete (SHORT) BLACK GEAR HOUSING–complete (LONG) GEAR HOUSING–complete (SHORT) GRAY GEAR HOUSING–complete (LONG) – 1 – 1 – 1 11 1 GEAR HOUSING (BLACK) 1 GEAR HOUSING (GRAY) 48 1 ROLLER BEARING 49 1 FORWARD GEAR 50 1 BUSHING 51 1 CAM FOLLOWER 52 1 CLUTCH ASSEMBLY 53 1 CROSS PIN 54 1 SPRING 55 1 PROPELLER SHAFT 56 1 REVERSE GEAR 57 1 BEARING CARRIER 85 115.0 58 1 O-RING 59 1 BUSHING 60 1 OIL SEAL 61 1 OIL SEAL 62 1 SCREW 15 20.5 63 2 SCREW 15 20.5 6464 1 PROPELLER (9 x 10-1/2) PROPELLER (9 x 9) PROPELLER (9 x 8) USE W/REF. #64 PROPELLER (9-1/4 x 7) PROPELLER (9-3/4 x 6-1/2) PROPELLER (9-3/4 x 5-1/2) 1 1 1 1 1 1 PROPELLER (9 x 10-1/2) PROPELLER (9 x 9) PROPELLER (9 x 8) USE W/REF. #65 PROPELLER (9-1/4 x 7) PROPELLER (9-3/4 x 6-1/2) PROPELLER (9-3/4 x 5-1/2) 1 1 1 1 1 65 1 PROPELLER NUT 100 11.5 66 1 THRUST HUB (Refer to Illustration) 67 1 THRUST HUB (Refer to Illustration) 68 1 SPACER 69 1 REVERSE THRUST CUP 90-827857R1 NOVEMBER 1996 LOWER UNIT - 6-5 Gearcase Removal WARNING To prevent accidental engine starting, remove (and isolate) spark plug leads from spark plugs BEFORE removing gear housing. 1. Remove (and isolate) spark plug leads from spark plugs. 2. Tilt outboard to full “UP” position. 3. Loosen jam nut and disconnect coupler. 28277 a b a -Jam Nut b -Coupler 4. Remove 3 bolts. 52998 a a a -Bolts (3) Gearcase Disassembly Propeller Removal WARNING If gear housing is NOT removed from drive shaft housing, remove (and isolate) spark plug leads from spark plugs to prevent outboard from accidentally starting while removing and installing propeller. 1. Place a block of wood between anti-ventilation plate and propeller to prevent propeller from turning and to protect hands while removing prop. a a -Wood 6-6 - LOWER UNIT 90-827857R1 NOVEMBER 1996 2. Remove nut, thrust hubs and propeller. 52547 a b a -Nut b -Thrust Hubs Draining and Inspecting Gear Lubricant 1. Remove both VENT and FILL screws with gaskets. 2. Inspect gear lubricant for metal particles. Presence of a small amount of fine metal particles (resembling powder) indicates normal wear. Presence of large particles (chips) or a large quantity of fine particles indicates need for gear housing disassembly and component inspection. 3. Note color of gear lubricant. White or cream color indicates presence of water in lubricant. NOTE: When draining gear case for the first time, lubricant may appear cream colored due to the mixing of assembly lubricant and gear lubricant. This is NOT an indication of water intrusion. If, during subsequent draining of gear case, lubricant appears cream colored or milky, water may be present. Gear case should be disassembled and all gaskets, seals and o-rings replaced. Inspect all components for water damage. 4. Check drain pan for water separation from lubricant. Presence of water in gear lubricant indicates the need for disassembly and inspection of oil seals, seal surfaces and gear housing components. 53001 a b a -Vent Screw b -Fill Screw 90-827857R1 NOVEMBER 1996 LOWER UNIT - 6-7 Bearing Carrier 1. Remove bearing carrier (LEFT HAND thread) using Bearing Carrier Tool (91-13664). 91-13664 52993 91-13664 53017 2. Remove carrier and propeller shaft assembly from housing. NOTE:Cam follower is free to slide out of propeller shaft. 52994 a a -Cam Follower 3. Remove propeller shaft and REVERSE gear from bearing carrier. 4. Replace REVERSE gear if gear teeth or clutch teeth are chipped or worn. a b 52988 a -Gear Teeth b -Clutch Teeth NOTE:When using a punch to remove carrier seals, be careful not to scar carrier seal surface with punch. If carrier seal surface is damaged, replace carrier. 5. Using a suitable punch, remove both seals from bearing carrier. a b c 53002 a -Oil Seal b -Fish Line Cutter Seal c -Punch 6-8 - LOWER UNIT 90-827857R1 NOVEMBER 1996 6. Replace bearing carrier bushing if bushing or area on propeller shaft that bushing contacts is pitted or worn. Press bushing from carrier using Bushing Removal Tool (91-824787). a b 91-824787 53020 53026 a -Bushingb -Mandrel (91-824787) Propeller Shaft 1. Inspect cam follower for wear. If cam follower is worn, replace follower and inspect shift cam for serviceability. Replace cam if worn. a a -Cam Follower 2. Remove groove pin from clutch/propeller shaft applying pressure to side of pin that is NOT grooved. Discard pin. a b a -Punchb -Groove Pin (Discard) 3.Remove spring and sliding clutch. a b a -Spring b -Clutch 90-827857R1 NOVEMBER 1996 LOWER UNIT - 6-9 4. Replace clutch if jaws are rounded or chipped. Rounded jaws may be caused by the following: a. Improper shift cable adjustment or linkage. b. Engine idle speed too high while shifting. c. Shifting too slowly from NEUTRAL into FORWARD or REVERSE. 52990 5. Inspect bushing surfaces of propeller shaft for pitting or wear. Replace shaft and corresponding bushing if wear or pitting is observed. 6. Replace shaft if any of the following exist: a. Splines are twisted or worn. b. Oil seal surface is grooved. c. Shaft has a noticeable “wobble” or is bent more than 0.006 in. (0.15mm). cba 52997a a -Bushing Surfaces b -Oil Seal Surface c -Measure Here for “Wobble” (When measuring shaft for wobble, use v-blocks and support at bushing surface) Water Pump, Drive Shaft and Shift Shaft 1. Remove 4 bolts from pump cover. 53023 2. Remove cover, nylon washers (above and below impeller), impeller and drive key from drive shaft. 3. It is recommended that impeller be replaced whenever gear case is being serviced. NOTE: If impeller is not going to be replaced, DO NOT install impeller in reverse rotation to its original state as vanes have taken a set. Vanes will crack and break shortly after outboard is returned to service. a b c d e 53048 a -Cover b -Nylon Washer c -Impeller d -Nylon Washer e -Key 6-10 - LOWER UNIT 90-827857R1 NOVEMBER 1996 4. Remove guide from cover. 5. Replace rubber seal if damaged. 6. Replace cover if inside is grooved. a b 53032 a -Guide b -Seal 7. Remove plate, gasket, quad-ring, bolt and washer. 8. Replace plate if grooved. d c a b a -Plate b -Gasket (Discard) c -Quad-Ring d -Bolt and Washer 53012 9. Replace seal if damaged. 10. Remove water pump base and shift shaft from housing. 53014 a b c a -Seal b -Pump Base c -Shift Shaft 11. Remove gasket. a 53015 a -Gasket (Discard) 90-827857R1 NOVEMBER 1996 LOWER UNIT - 6-11 12. Inspect shift cam for wear. Replace if worn. a 53034 a -Shift Cam 13. Remove clip from shift shaft. Unthread shift cam. Remove shaft from water pump base. a b 53034 a -Clip b -Shift Cam 14. Remove screw and pull water tube from base. b a a -Screw b -Water Tube 15. Replace seal if damaged. Replace water tube if corroded. a b a -Seal b -Water Tube 6-12 - LOWER UNIT 90-827857R1 NOVEMBER 1996 16. Remove drive shaft from gear housing. NOTE: Thrust washers, pinion gear and forward gear assembly are free to fall from housing when drive shaft is removed. 52995 a b c d a -Thrust Washer (without oil groove) b -Thrust Washer (with oil groove – groove faces down) c -Pinion Gear d -Forward Gear Assembly 17. Inspect bearing/bushing surfaces of drive shaft for pitting or wear. If shaft is pitted or worn, replace shaft and corresponding bearing/bushing. 18. Replace drive shaft if the following exist: a. Splines are twisted or worn. b. Oil seal surface is grooved. ab 53036 c a -Bushing Surface b -Bearing Surface c -Seal Surface 19. Using a screwdriver or punch, carefully remove (and discard) seals from pump base. a a -Seals 90-827857R1 NOVEMBER 1996 LOWER UNIT - 6-13 Pinion Gear and Forward Gear PINION GEAR 1. Inspect pinion gear teeth for breakage, rust, chipping or excessive wear. 2. If pinion gear teeth are damaged, inspect FORWARD and REVERSE gear for damage. 3. Replace gears as required. a 52991 a -Pinion Gear FORWARD GEAR 1. Inspect forward gear teeth for breakage, rust, chipping and excessive wear. 2. Inspect forward gear clutch jaws for wear. Rounded jaws indicate the following: a. Improper shift cable adjustment or linkage. b. Engine idle speed too high. c. Shifting too slowly. b a 52989 a -Gear Teeth b -Clutch Teeth 3. Inspect propeller shaft FORWARD gear bushing surface to determine condition of bushing. If surface is discolored (from lack of lubricant), pitted or worn, propeller shaft and bushing should be replaced. a b 52989 52997 a -Bushing b -Bushing Surface 6-14 - LOWER UNIT 90-827857R1 NOVEMBER 1996 4. If necessary, press bushing from gear using Bushing Removal Tool 91-824787. a b 91-824787 53020 53035 a -Bushingb -Bushing Removal Tool (91-824787) IMPORTANT: If FORWARD gear tapered bearing or race requires replacement, replace bearing and race as a set. NOTE:DO NOT remove tapered bearing from FORWARD gear unless replacement is necessary as removal process will damage bearing. 5. Inspect FORWARD gear tapered bearing and race for rust, roughness or excessive wear (looseness). 6. If bearing is in serviceable condition, DO NOT remove bearing from gear as removal process will damage bearing. 7. If bearing must be replaced, remove bearing from gear using Universal Puller Plate (91-37241) and a suitable mandrel (5/8 in. socket) a c b 53008 a -Bearingb -Universal Puller Plate (91-37241) c -Mandrel (5/8 in. Socket) 90-827857R1 NOVEMBER 1996 LOWER UNIT - 6-15 8. Replace FORWARD gear race if it is rusted or damaged or if FORWARD gear tapered bearing must be replaced. Remove race from housing using Bearing Puller Assembly (91-83165M) and Puller Plate (91-29310). cb a 52996 53031 b c a -Race b -Bearing Puller Assembly (91-83165M) c -Puller Plate (91-29310) Drive Shaft Bushing, Bearing and Lubrication Sleeve 1. Inspect drive shaft bushing and bearing surface to determine condition of corresponding upper drive shaft bushing and lower drive shaft needle bearing. If drive shaft surface is rusted, pitted, discolored (blued – lack of lubrication) or worn; replace drive shaft and corresponding bushing/ bearing. DO NOT remove bushing or bearing if replacement is not necessary. ab 53036 a -Bushing Surface b -Bearing Surface a b a -Upper Drive Shaft Bushing b -Lower Drive Shaft Needle Bearing IMPORTANT: If upper drive shaft bushing or lower drive shaft needle bearing appear to be spinning in their respective bores, the gear housing should be replaced. 6-16 - LOWER UNIT 90-827857R1 NOVEMBER 1996 2. To replace upper drive shaft bushing, use Snap On* Expanding Rod (CG 40-4) Snap On Collet (CG 40A6) Slide Hammer (91-34569A1) *Purchase from: Snap On Tools Corporation 2801 - 80th Street Kenosha, WI 53141-1410 c d a b 53042 CG 40A6 CG 40-4 53045 a -Expanding Rod (CG 40-4) b -Collet (CG 40A6) c -Slide Hammer (91-34569A1) d -Bushing 3. To gain access to lower drive shaft needle bearing, remove lubrication sleeve. NOTE:When upper drive shaft bushing is installed, a burr may be formed preventing the removal of the lubrication sleeve. Use a knife to remove burr. 53040 a a -Lubrication Sleeve 4. Remove needle bearing using Drive Shaft Bearing Removal Tool (91-824788A1). ab- c -Pilot c a b 91-824788A1 53029 Needle Bearing Driver Rod Aluminum Anode and Water Inlet 1. Replace aluminum anode if more than 50% consumed. 2. Remove water inlet and check that holes are not obstructed. ab a -Aluminum Anode b -Water Inlet 90-827857R1 NOVEMBER 1996 LOWER UNIT - 6-17 Reassembly Drive Shaft Needle Bearing, Bushing and Lubrication Sleeve Installation 1. Install lower drive shaft needle bearing (numbers/ letters face down) using Drive Shaft Bushing Tool (91-824790A1). 91-824790A1 53044 53019 53030 a b c d e f a -Puller Bolt b -Flat Washer c -Wafer Bearing d -Pilot e -Needle Bearing f -Mandrel 2. Install lubrication sleeve. a 53040 3. Install upper drive shaft bushing assembly using Drive Shaft Bushing Tool (91-824790A1). NOTE:The upper drive shaft bushing is pressed into a sleeve. If the bushing is not worn into the sleeve or the bushing is not spinning within the sleeve, the bushing alone may be replaced. Press the new bushing into the sleeve using a suitable mandrel. If the sleeve is damaged, the bushing/sleeve assembly must be replaced. a b 91-824790A1 53019 53030 c de f 53043 a -Puller Bolt b -Flat Washer c -Wafer Bearing d -Pilot e -Bushing/Sleeve f -Mandrel a -Sleeve 6-18 - LOWER UNIT 90-827857R1 NOVEMBER 1996 Forward Gear Bearing Race Bearing Carrier Reassembly Installation 1. Apply Quicksilver Gear Lubricant to bushing and press bushing into carrier using Mandrel Install race into housing using Mandrel (91-13658) (91-824785A1). and Bearing Carrier Tool (91-13664). 91-13664 c b a 52992 53017 91-13658 53016 a -Race b -Mandrel (91-13658) c -Bearing Carrier Tool (91-13664) Forward Gear Reassembly Install bushing and bearing using Mandrel (91-13658) and press. c ba 91-13658 53018 53016 a -Mandrel (91-13658) b -Bushing c -Bearing 53025 a b 91-824785A1 53022 a -Bushingb -Mandrel (91-824785A1) 2.Apply Loctite 271 to O.D. of seal and with lip fac- ing bushing, press seal into carrier using Mandrel (91-824785A1). d c b a 53027 91-824785A1 53022 a -Mandrel (91-824785A1) b -Ring (used with mandrel) c -Seal (LIP FACES BUSHING) d -Bushing 90-827857R1 NOVEMBER 1996 LOWER UNIT - 6-19 3. Apply Loctite 271 to O.D. of fishline cutter seal. Water Pump Base and Shift Shaft With ring removed from Mandrel (91-824785A1), Reassembly press seal, with LIP FACING Mandrel, into carrier. Apply Special Lubricant 101 between lips of 1. Apply Loctite 271 to O.D. of seal. With lip of seal both seals. facing DOWN, push seal into base using Mandrel (91-13655). a b 53028 91-824785A1 53022 a -Fishline Cutter Seal (LIP FACES MANDREL) b -Mandrel (without Ring – 91-824785A1) 4.Apply Special Lubricant 101 to o-ring and install O-ring on carrier. 52999 b 91-13655 53021 a a -Seal (Lip FACES DOWN) b -Mandrel (91-13655) 2.Apply Loctite 271 to O.D. of seal. With seal lip fac- ing UP, push seal into base using Mandrel (91-13655). Apply Special Lubricant 101 be- tween lips of both seals. a 53011 a -O-ring a91-13655 53021 b 53057 a -Seal (Lip FACES UP) b -Mandrel (91-13655) 6-20 - LOWER UNIT 90-827857R1 NOVEMBER 1996 a a 3. Install seal onto water tube. a 53024 a -Seal 4. Secure water tube to pump base with retainer and screw. b a 53009 c d a -Pump Base b -Water Tube c -Retainer d -Screw 5. Install shift shaft through pump base. 6. Install E-clip on shift shaft. Clip must be below pump base. 7. Thread shift cam onto shaft. a b 53034 a -E-clip b -Shift Cam Propeller Shaft Reassembly 1. Slide clutch onto propeller shaft. c d b a -Sliding Clutch b -Short End (FORWARD Gear Side) c -Hole (must align with slot) d -Slot 2. Insert cam follower spring into shaft. a a -Spring 90-827857R1 NOVEMBER 1996 LOWER UNIT - 6-21 3. Compress spring and install NEW groove pin. 53038 c d e d b a 53007 a -Vise b -Screwdriver or small Punch c -Spring d -Groove Pin (Press in until Flush) e -Serrations 4. Apply 2-4-C w/Teflon to cam follower (flat side) and install follower into shaft. a b 53006 a -Cam Follower b -Flat Side Forward Gear, Pinion Gear and Drive Shaft Installation 1. Install FORWARD gear assembly into forward gear race. 2. Install drive shaft through upper drive shaft bushing, oil sleeve and lower drive shaft needle bearing. 3. While lifting drive shaft slightly, install lower thrust washer (GROOVED SIDE FACES DOWN) and PINION gear. It may be necessary to rotate drive shaft slightly to engage pinion gear with splines of drive shaft and with forward gear teeth. 4. Install upper thrust washer above upper drive shaft bushing. g f a e d c b 52995 a -FORWARD Gear Assembly b -Drive Shaft Bushing c -Oil Sleeve d -Needle Bearing e -Lower Thrust Washer (GROOVED SIDE FACES DOWN) f -Pinion Gear g -Upper Thrust Washer 6-22 - LOWER UNIT 90-827857R1 NOVEMBER 1996 Shift Shaft and Water Pump Base Installation 1. Apply Special Lubricant 101 to I.D. of seal. 2. Install seal in housing with tapered end facing up. a b 53041 a -Seal b -Tapered I.D. 3.Install base gasket with drain hole positioned as shown. a b 53015 a -Base Gasket b -Hole IMPORTANT: Verify seal is not pushed out of position when water tube is installed. 4. Slide water pump base with shift shaft down drive shaft. Align water tube with seal in housing while seating water pump base. 53014 a b c d e a -Shift Shaft b -Shift Cam (POSITION AS SHOWN) c -Pump Base d -Water Tube e -Seal 5. Apply Special Lubricant 101 to I.D. and O.D. of shift shaft quad ring. Seat quad ring in pump base. 6. Apply Loctite 271 to bolt threads and secure pump base to housing with bolt and washer. Torque bolt to 50 lb. in. (5.6 N·m). 7. Install gasket and face plate. d c ab 53012 a -Quad Ring b -Bolt and Washer [Torque to 50 lb. in. (5.6 N·m)] c -Gasket d -Face Plate 90-827857R1 NOVEMBER 1996 LOWER UNIT - 6-23 Water Pump Cover Reassembly 1. Apply Special Lubricant 101 to O.D. of seal and seal surface. 2. Install seal into cover. 3. Place water tube guide onto seal. a b c 53032 a -Seal b -Seal Surface c -Guide Impeller and Pump Cover Installation 1. Install neoprene washer. 2. Install drive key. Use 2-4-C w/Teflon to hold key to drive shaft. IMPORTANT: It is recommended that the impeller be replaced regardless of appearance. If impeller must be reused, it must be installed in the direction of original rotation. Installing impeller with vanes reversed from their previous “set” will result in vane breakage shortly after unit is returned to service. 3. Install new impeller and align with drive key. 4. Install neoprene washer. 5. Lubricate I.D. of water pump cover with 2-4-C w/ Teflon. 6. Install cover on drive shaft and while pushing down on cover, rotate drive shaft CLOCKWISE and install cover over impeller. a bc d e 53048 a -Neoprene Washer b -Drive Key c -Impeller d -Neoprene Washer e -Cover 6-24 - LOWER UNIT 90-827857R1 NOVEMBER 1996 7. Apply Loctite 271 to threads of bolts. Secure cover with bolts and torque to 50 lb. in. (5.6 N·m) per following numbered torque sequence. 53023 1 2 3 4 5 Propeller Shaft and Bearing Carrier Installation 1. Install REVERSE gear into bearing carrier. 2. If not previously lubricated, apply Special Lubricant 101 to O-ring. 3. Apply Special Lubricant 101 to bearing carrier threads and pilot diameter. 4. Slide bearing carrier onto propeller shaft and install entire assembly into gear housing. a b 52994 c a -Bearing Carrier Threads b -Propeller Shaft c -Pilot Diameter 5. Torque bearing carrier to 85 lb. ft. (115.2 N·m) using Bearing Carrier Tool (91-13664). 91-13664 52993 LEFT HAND THREAD Aluminum Anode and Water Inlet Installation Secure anode and water inlet with screws. ab 53050 c a -Anode b -Water Inlet c -Screws 90-827857R1 NOVEMBER 1996 LOWER UNIT - 6-25 Propeller Installation WARNING If gear housing is NOT removed from drive shaft housing, BEFORE attempting to remove or install the propeller, remove (and isolate) spark plug leads from spark plugs to prevent engine from starting accidentally. 1. Apply Quicksilver Anti-Corrosion Grease to propeller shaft. 2. Install inner thrust hub. 3. Slide propeller onto shaft. 4. Install outer thrust hub. 5. Thread propeller nut onto shaft. 52547 b c a d a -Inner Thrust Hub b -Propeller c -Outer Thrust Hub d -Propeller Nut 6. Place a block of wood between propeller and anti-ventilation plate to prevent propeller from turning and to protect hands. Torque nut to 70 lb. in. (7.9 N·m). a b a -Outer Thrust Hub b -Nut 6-26 - LOWER UNIT 90-827857R1 NOVEMBER 1996 Filling Gear Housing with Lubricant NOTE: Gear housing lubricant capacity – 6.8 oz. (205 ml). IMPORTANT: DO NOT use automotive grease in the gear housing. Use only Quicksilver Gear Lubricant (92-19007A24). 1. Remove any gasket material from “FILL” and “VENT” screws and housing. 2. Install new gaskets on “FILL” and “VENT” screws. IMPORTANT: Never apply lubricant to gear housing without first removing “VENT” screw or gear housing cannot be filled because of trapped air. Fill gear housing ONLY when housing is in a vertical position. 3. Slowly fill housing through “FILL” hole until lubricant flows out of “VENT” hole and no air bubbles are present. 4. Reinstall “VENT” screw. 5. Remove grease tube from “FILL” hole and quickly install “FILL” screw. a b 52998 a -Vent Screw b -Fill Screw Installation WARNING To prevent accidental engine starting, remove (and isolate) spark plug leads from spark plugs. BEFORE installing gear housing. 1. Remove (and isolate) spark plugs leads from spark plugs. 2. Apply a 1/4 in. (6.4mm) diameter bead of RTV Sealer on water pump base. 53023 a a -RTV Sealer 3.Place gear housing into forward gear. (Pull shift shaft all-the-way up. 4.Turn the shift shaft in (clockwise) until it bottoms out, than back out the shift shaft two turns until the bend in the shaft is positioned as shown. 53051 a b a -Shift Shaft (Pull all-the-Way Up) for Forward Gear b -Position Bend Towards Back of Gear Housing 90-827857R1 NOVEMBER 1996 LOWER UNIT - 6-27 5. Install gear housing as follows: a. Apply a light coat of 2-4-C w/Teflon Marine Lubricant onto the drive shaft splines. b. Insert the drive shaft into the opening in the upper part of the mid section. c. Insert the shift shaft through the rubber seal in the mid section. d. Insert the water tube into the water tube guide. NOTE: It may be helpful to slide the water tube guide onto the water tube and then reconnect the water tube guide onto the water pump. e. Rotate propeller counterclockwise while pushing upward on gear housing to align drive shaft splines with crankshaft splines. f. Place the gear housing into neutral by pushing down the shift shaft into the neutral detent position (propeller will rotate freely in either direction). g. Place the shift lever into neutral position. Connect the coupler to the shift shaft (making sure the coupler does not push the shift shaft down while making connection). Secure coupler with jam nut. a b 28277 a -Jam Nut b -Coupler 6. Install 3 bolts and torque to 15.0 lb. ft. (20.3 N·m). 52998 a a a -Bolts [Torque to 15.0 lb. ft. (20.3 N·m)] 7. Check shift operation as follows: a. Place shift lever in FORWARD. Gear housing should ratchet when propeller shaft is turned clockwise and resistance should be felt when propeller is turned counterclockwise. b. Place shift lever in NEUTRAL. Resistance should NOT be felt when propeller shaft is rotated in either direction. c. Place shift lever in REVERSE. Resistance should be felt when propeller shaft is rotated in either direction. d. If shift operation is not as described, recheck the coupler installation procedure. 6-28 - LOWER UNIT 90-827857R1 NOVEMBER 1996 A 7 ATTACHMENTS/CONTROL LINKAGE THROTTLE/SHIFT LINKAGE (TILLER HANDLE SHIFT & SIDE SHIFT MODELS) Table of Contents Page Throttle Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-2 Tiller Handle Shift Models . . . . . . . . . . . . . . . . . 7A-4 Control Cables . . . . . . . . . . . . . . . . . . . . . . . . 7A-4 Removal/Installation . . . . . . . . . . . . . . . . . 7A-4 Control Platform . . . . . . . . . . . . . . . . . . . . . . . 7A-4 Removal/Disassembly . . . . . . . . . . . . . . . 7A-4 Reassembly/Installation . . . . . . . . . . . . . . 7A-5 Side Shift Models . . . . . . . . . . . . . . . . . . . . . . . . 7A-7 Throttle Cables . . . . . . . . . . . . . . . . . . . . . . . . 7A-7 Removal/Installation . . . . . . . . . . . . . . . . . 7A-7 Control Platform . . . . . . . . . . . . . . . . . . . . . . . 7A-7 Removal/Disassembly . . . . . . . . . . . . . . . 7A-7 Reassembly/Installation . . . . . . . . . . . . . . 7A-8 90-827857R1 NOVEMBER 1996 Notes: 90-827857R1 NOVEMBER 1996 ATTACHMENTS/CONTROL LINKAGE - 7A-1 THROTTLE LINKAGE (MANUAL) 7A-2 - ATTACHMENTS/CONTROL LINKAGE 90-827857R1 NOVEMBER 1996 THROTTLE LINKAGE (MANUAL) REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 SHIFT HANDLE GROMMET SIDE SHIFT SCREW (M5 x 12) 2 1 3 1 50 5.5 4 1 STRAP 2 SCREW (M6 X 16) 70 8.0 6 1 SCREW (M6 x 20) 70 8.0 7 1 WASHER 8 1 LINK–sliding 9 1 LINK–joint 1 NUT Tighten Securely 11 1 THROTTLE LINK 12 1 LINK–joint 13 1 PULLEY 14 1 BUSHING (SIDE SHIFT) 1 NUT Tighten Securely 16 1 SPRING 17 1 SPRING 18 1 PLATE 19 2 SCREW (M5 x 12) 36 4.0 1 SCREW (M5 x 35) 36 4.0 21 1 INTERLOCK LEVER 22 1 HORIZONTAL SHIFT SHAFT 23 2 SCREW (M6 x 20) (SIDE SHIFT) 70 8.0 24 1 CONTROL PLATFORM 1 BUSHING (SIDE SHIFT) 26 1 PLUG GEAR–driven COVER HANDLE SHIFT SCREW (M6 x 20) GEAR–driver 27 1 28 1 29 5 70 8.0 1 90-827857R1 NOVEMBER 1996 ATTACHMENTS/CONTROL LINKAGE - 7A-3 7A-4 - ATTACHMENTS/CONTROL LINKAGE 90-827857R1 NOVEMBER 1996 Tiller Handle Shift Models Control Cables REMOVAL/INSTALLATION Refer to Section 7C for removal and installation instructions. Control Platform Removal/Disassembly 1. Remove bolt securing fuel connector to lower cowl. Pull connector forward to gain access to handle rest bracket bolt. Remove 3 bolts securing handle rest bracket to frame. 28288 a b c a - Fuel Connector Bolt b - Handle Rest Bracket Bolts c - Handle Rest Bracket 2. Remove horizontal shaft retainer plate and 2 bolts. 3. Remove leaf spring plate and 2 bolts. Note location of fuel hose. 54470 a c b d e f a - Leaf Spring Plate b - Bolts c - Retainer Plate d - Bolt e - Sta-Strap f - Fuel Hose 4. Remove bolt and interlock lever. 28291 b a a - Bolt b - Interlock Lever 90-827857R1 NOVEMBER 1996 ATTACHMENTS/CONTROL LINKAGE - 7A-5 5. Remove 2 bolts securing bracket/shaft assembly. 6. Remove assembly. a a - Bracket/Shaft Assembly 7. Remove cover from control platform. a b a - 3 Bolts-M6x20 b - Cover 8. Remove throttle cable pulley, primary gear, and secondary gear from control platform as shown. a b c d e f a - Bolt-M6x20 b - Pulley c - Control Platform d - Primary Gear e - Secondary Gear f - Nylon Insert Nut Reassembly/Installation 1. Secure throttle cable pulley, primary gear, and secondary gear to control platform as shown. Torque bolt enough to firmly secure pulley and fully engage nylon nut. Do not over tighten. a b c d e f a - Bolt-M6x20 b - Pulley c - Control Platform d - Primary Gear e - Secondary Gear f - Nylon Insert Nut 2. Secure cover to control platform. Torque bolts to 70 lb in. (8.0 N·m). a b a - 3 Bolts-M6x20 b - Cover 7A-6 - ATTACHMENTS/CONTROL LINKAGE 90-827857R1 NOVEMBER 1996 3. Install throttle cable bracket onto horizontal shift shaft and secure bracket/shaft assembly to bottom cowl with 2 bolts, retained (fuel line should be routed underneath horizontal shaft). Torque bolts to 70 lb. in. (8.0 N·m). a a - Bracket/Shaft Assembly 4. Secure vertical shift rod to horizontal shift shaft with interlock lever and bolt. Torque bolt to 36 lb. in. (4.0 N·m). 53591 a a - Bolt 5. Reinstall detent plate and secure with 2 bolts. Torque bolts to 36 lb. in. (4.0 N·m). 6. Reinstall horizontal shaft retainer plate and bolts. Torque bolt to 70 lb. in. (8.0 N·m). 7. Secure fuel line to bolt mount with sta-strap, if original sta-strap was removed. Note position of fuel line. 54470 a c b d e f a - Leaf Spring b - Bolts [Torque to 36 lb. in. (4.0 N·m)] c - Retainer Plate d - Bolt [Torque to 70 lb. in. (8.0 N·m)] e - Sta-Strap f - Fuel Line 8. Install 3 bolts securing handle rest bracket to frame. Install bolt securing fuel connector to lower cowl. Torque bolts to 70 lb. in. (8.0 N·m). 28288 a b c a - Fuel Connector Bolt b - Handle Rest Bracket Bolts c - Handle Rest Bracket 90-827857R1 NOVEMBER 1996 ATTACHMENTS/CONTROL LINKAGE - 7A-7 Side Shift Models Throttle Cables REMOVAL/INSTALLATION Refer to Section 7C for removal and installation instructions. Control Platform REMOVAL/DISASSEMBLY 1. Remove bolt securing fuel connector to lower cowl. Pull connector forward to gain access to handle rest bracket bolt. Remove 3 bolts securing handle rest bracket to frame. 28288 a b c a - Fuel Connector Bolt b - Handle Rest Bracket Bolts c - Handle Rest Bracket 2. Remove 2 bolts securing cable bracket. Remove bolts holding leaf spring and retainer plate. 28294 c a b a - Cable Bracket Bolts b - Leaf Spring Bolts c - Retainer Bolts 3. Remove bolt securing interlock lever to horizontal shift shaft. 28291 a b c a - Neutral Interlock Cable b - Interlock Lever c - Bolt 4. Remove pulley/horizontal shift shaft assembly. 5. Disassemble the control platform as shown in the exploded view in this section page NO TAG. 7A-8 - ATTACHMENTS/CONTROL LINKAGE 90-827857R1 NOVEMBER 1996 REASSEMBLY/INSTALLATION 1. Reassemble the control platform as shown in the exploded view in this section page NO TAG. 2. Install pulley/horizontal shift shaft assembly. 3. Install bolt securing interlock lever to horizontal shift shaft. Torque bolt to 36 lb. in. (4.0 N·m). 28291 a b c a - Neutral Interlock Cable b - Interlock Lever c - Bolt 4. Install 2 bolts securing cable bracket. Install bolts holding leaf spring and retainer plate. Torque bolts to 70 lb. in. (8.0 N·m). 28294 c a b a - Cable Bracket Bolts b - Leaf Spring Bolts c - Retainer Plate Bolts 5. Install 3 bolts securing handle rest bracket to frame. Install bolt securing fuel connector to lower cowl. 28288 c b a a - Handle Rest Bracket b - Handle Rest Bracket Bolts c - Fuel Connector Bolt ATTACHMENTS/CONTROL LINKAGE B 7 THROTTLE/SHIFT LINKAGE (REMOTE CONTROL MODELS) Table of Contents Page Throttle Linkage (Electric-Remote Control) . . 7B-2 Remote Platform . . . . . . . . . . . . . . . . . . . . . . . . . 7B-4 Removal/Disassembly. . . . . . . . . . . . . . . . . . 7B-4 All Models. . . . . . . . . . . . . . . . . . . . . . . . . . 7B-4 Models With Throttle Arm Spring . . . . . . 7B-5 Models W/ Throttle Arm Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-6 Reassembly/Installation . . . . . . . . . . . . . . . . 7B-6 Models With Throttle Arm Spring . . . . . . 7B-6 Models W/ Throttle Arm Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-7 All Models. . . . . . . . . . . . . . . . . . . . . . . . . . 7B-8 90-827857R1 NOVEMBER 1996 Notes: 90-827857R1 NOVEMBER 1996 ATTACHMENTS/CONTROL LINKAGE - 7B-1 THROTTLE LINKAGE (ELECTRIC-REMOTE CONTROL) THROTTLE LINKAGE (ELECTRIC-REMOTE CONTROL) 7B-2 -ATTACHMENTS/CONTROL LINKAGE 90-827857R1 NOVEMBER 1996 THROTTLE LINKAGE (ELECTRIC-REMOTE CONTROL) REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 PLUG 2 1 STRAP 3 2 SCREW (M6 X 16) 70 8.0 4 1 SHIFT ARM 1 NUT–push 6 1 RETAINER 7 1 SCREW (M5 x 12) 50 5.5 8 1 SCREW (M6 x 20) 70 8.0 9 1 LINK 1 LINK–joint 11 1 NUT 12 1 THROTTLE LINK 13 1 LINK–joint 14 1 PLATE 1 SCREW (M6 X 16) 70 8.0 16 1 SLIDE 17 1 SPRING (DESIGN I - ORDER 826028A2) 18 1 THROTTLE ARM 19 1 RETAINER 1 NUT–push 21 1 E CLIP 22 1 SHIFT SHAFT 23 1 INTERLOCK LEVER 24 1 SCREW (M5 x 35) 36 4.0 1 SCREW 26 1 LOCKWASHER 27 1 WASHER 28 1 COVER 29 2 SCREW (M6 x 20) 70 8.0 1 PLATFORM 31 1 SEAL 32 2 SCREW (M5 x 12) 36 4.0 33 1 PLATE 34 1 SPRING 1 SPRING 90-827857R1 NOVEMBER 1996 ATTACHMENTS/CONTROL LINKAGE - 7B-3 7B-4 - ATTACHMENTS/CONTROL LINKAGE 90-827857R1 NOVEMBER 1996 Remote Platform Removal/Disassembly ALL MODELS 1. Remove starter solenoid retaining bolt (if equipped) and lay solenoid and bracket off to one side. 2. Remove fuel connector retaining bolt. 53548 c a b a - Bolt b - Bolt c - Solenoid 3. Remove 3 bolts securing flywheel cover support. Remove support. 53549 b b a a - Bolts b - Support 4. Remove 4 bolts securing horizontal shift shaft. 53550 a b a - Retainer Plate Bolts b - Leaf Spring Bolts 5. Remove 3 bolts securing throttle/shift cable platform. 6. Remove bolt (c) securing shift lever to horizontal shift shaft. 7. Remove throttle link rod from throttle lever. a a c b d 53556 a - Bolts (3) b - Throttle/Shift Cable Platform c - Bolt d - Throttle Link Rod 90-827857R1 NOVEMBER 1996 ATTACHMENTS/CONTROL LINKAGE - 7B-5 8. Remove bolt securing shift rod retainer to horizontal shift shaft. Remove horizontal shift shaft/ control platform assembly. a c b a - Bolt b - Horizontal Shift Shaft c - Control Platform 9. Remove horizontal shift shaft from control platform. 30019 a a - Horizontal Shift Shaft 10. Remove plate from shift arm cylinder. 30014 a b c a - Plate b - Bolt c - Shift Arm Cylinder MODELS WITH THROTTLE ARM SPRING 1. Remove remote shift arm and remote throttle arm from platform. 2. Remove smaller hook end of spring from slide. 30015 b c a a - Slide b - Throttle Arm c - Spring MODELS WITH THROTTLE ARM RETAINING RING 1. Remove retaining ring. ab 54467 a -Throttle Slide b -Retaining Ring 2. Remove throttle slide from slot in throttle lever. ab 54466 a -Throttle Slide b -Throttle Lever 3. Remove remote cable retainer and push nut from throttle lever stem. NOTE: Remove push nut only if necessary, push nut removal will damage throttle lever and push nut requiring replacement. a b c 54468 a -Remote Cable Retainer b -Push Nut c -Throttle Lever Stem Reassembly/Installation MODELS WITH THROTTLE ARM SPRING 1. Insert slide into throttle arm slot. Connect smaller hook end of spring onto slide. 30015 b c a a -Slide b -Throttle Arm c -Spring 2. Assemble remote shift arm and remote throttle arm to platform. 3. Lightly secure plate to platform with bolt. Hook remaining end of spring over bushing. a b c d e 30013 a -Plate b -Spring Hook c -Platform d -Bushing e -Bolt 7B-6 - ATTACHMENTS/CONTROL LINKAGE 90-827857R1 NOVEMBER 1996 90-827857R1 NOVEMBER 1996 ATTACHMENTS/CONTROL LINKAGE - 7B-7 4. Rotate plate clockwise onto shift arm extension and tighten bolt completely. 30014 a b c a - Plate b - Bolt c - Throttle Arm Extension MODELS WITH THROTTLE ARM RETAINING RING 1. Assemble remote cable retainer and push nut onto throttle lever stem. 54468 a b c a - Remote Cable Retainer b - Push Nut c - Throttle Lever Stem 2. Insert throttle slide into slot in throttle lever. 54466 a b a - Throttle Slide b - Throttle Lever 3. Secure throttle slide with retaining ring. 54467 b a a - Throttle Slide b - Retaining Ring 4. Insert shift arm into platform hole. Slide throttle arm over shift arm cylinder. 53564 a b c a - Remote Platform b - Shift Arm c - Throttle Arm 7B-8 - ATTACHMENTS/CONTROL LINKAGE 90-827857R1 NOVEMBER 1996 5. Lightly secure plate to platform with bolt. 30013 a b c d a - Plate b - Platform c - Bushing d - Bolt-M6x16 6. Rotate plate onto shift arm cylinder and tighten bolt completely. 30014 a b c a - Plate b - Bolt c - Shift Arm Cylinder ALL MODELS 7. Secure shift arm to horizontal shift shaft with bolt. Do not tighten bolt completely until platform assembly is installed. 30019 a b c a - Shift Arm b - Horizontal Shift Shaft c - Bolt (M5x12) 8. Secure platform assembly to frame. Torque bolts to 70 lb. in. (8.0 N·m). 28290 a a a b a - Bolts (M6x20) b - Platform 90-827857R1 NOVEMBER 1996 ATTACHMENTS/CONTROL LINKAGE - 7B-9 9. Screw throttle link into adjusting nut. Clip 90° end of throttle link into throttle slide. b 54521 a c a - Throttle Link b - Adjusting Nut c - Throttle Slide 10. Secure horizontal shift shaft with leaf spring and retainer plate bolts. Torque bolts to 70 lb. in. (8.0 N·m). 11. Align interlock lever pin with vertical shift shaft. Secure interlock lever to horizontal shift shaft with bolt. Torque bolt 36 lb. in. (4.0 N·m). b c d e a f a - Retainer Plate Bolts b - Vertical Shift Shaft c - Interlock Lever d - Horizontal Shift Shaft e - Interlock Lever Bolt f - Leaf Spring Bolts 12. Tighten horizontal shift shaft bolt completely. Torque bolt to 50 lb. in. (5.6 N·m). 30019 a a - Horizontal Shift Shaft Bolt ATTACHMENTS/CONTROL LINKAGE C 7 TILLER HANDLE Table of Contents Page Swivel Head And Tiller Handle . . . . . . . . . . . . . 7C-1 Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-3 Tiller Shift Models-Control Cables . . . . . . . . 7C-3 Side Shift Models-Throttle Cables . . . . . . . . 7C-3 Tiller Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-5 Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . 7C-6 Tiller Shift Models-Control Cables . . . . . . . . 7C-6 Side Shift Models-Throttle Cables . . . . . . . . 7C-6 90-827857R1 NOVEMBER 1996 Notes: 90-827857R1 NOVEMBER 1996 ATTACHMENTS/CONTROL LINKAGE - 7C-1 SWIVEL HEAD AND STEERING HANDLE 14 12 3 4 5 6 7 8 10 11 12 13 15 16 18 19 21 22 23 24 25 26 28 29 30 31 32 33 34 3536 37 38 39 40 41 42 43 37 40 2 5 95 95 66 95 66 95 Loctite 242 (92-809821) 2-4-C With Teflon (92-825407A12) 7C-2 - ATTACHMENTS/CONTROL LINKAGE 90-827857R1 NOVEMBER 1996 SWIVEL HEAD AND STEERING HANDLE REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 11 1 SWIVEL HEAD (BLACK) 1 SWIVEL HEAD (GRAY) 2 2 BUSHING 3 1 PLATE 4 2 SCREW (M5 x .8 x 16) 50 5.5 5 2 WASHER 6 1 WAVE WASHER 7 1 WASHER – 1 TILLER HANDLE–complete (BLACK) SIDE SHIFT TILLER HANDLE–complete (GRAY)– 1 – 1 TILLER HANDLE–complete (BLACK) 9.9 TILLER HANDLE–complete (GRAY) HANDLE SHIFT– 1 – 1 TILLER HANDLE–complete (BLACK) 8 BODENSEE TILLER HANDLE–complete (GRAY) HANDLE SHIFT– 1 88 1 STEERING HANDLE ARM (BLACK) 1 STEERING HANDLE ARM (GRAY) 9 1 RETAINER 10 1 SCREW (M5 x .8 x 16) 35 4.0 11 1 COVER KIT 12 1 PULLEY 13 1 PULLEY CASE (Part of Ref. #11) 14 1 SCREW (10-16) 20 2.5 1515 2 THROTTLE CABLE (SIDE SHIFT) 2 THROTTLE CABLE (HANDLE SHIFT) 16 1 SLEEVE 1717 1 DECAL (SIDE SHIFT) 1 DECAL (HANDLE SHIFT) 18 1 GRIP 19 1 STOP SWITCH 20 1 THROTTLE FRICTION KNOB Finger Tight 21 1 THROTTLE FRICTION LOCK 22 1 SCREW (M6 x 1 x 25) As Required 23 1 THROTTLE HANDLE (SIDE SHIFT) 1 THROTTLE HANDLE (HANDLE SHIFT) (9.9) 1 THROTTLE HANDLE (HANDLE SHIFT) (8 BODENSEE) 24 1 TILLER TUBE 25 1 SPRING 26 2 WASHER 27 2 STUD 28 2 SCREW (M6 x 12 70 8.0 29 2 WASHER 30 1 PLATE 31 1 SEAL 32 1 MOUNT 33 2 CLAMP 34 2 SCREW (M8 x 30) 13 17.5 35 2 WASHER 36 2 SEAL 37 1 BRACKET 38 2 DAMPER 39 2 NUT 18 24.5 – 1 STOP–throttle handle (SIDE SHIFT – 8 BODENSEE) 90-827857R1 NOVEMBER 1996 ATTACHMENTS/CONTROL LINKAGE - 7C-3 Cable Removal Tiller Shift Models-Control Cables 1. Loosen jam nuts which secure throttle cables to bracket and remove cables from pulley. c a a b a -Jam Nuts b -Bracket c -Pulley Side Shift Models-Throttle Cables 1. Loosen jam nuts which secure throttle cables to bracket and remove cables from pulley. a a 53402 b c Note:Single adjustment mark platform shown. a -Jam Nuts b -Pulley c -Bracket Tiller Handle Removal 1. Disconnect black and black/yellow stop button wires. 2. Remove 2 bolts securing tiller handle to anchor bracket and remove tiller handle assembly. 53155 a 53155 a -Bolts Disassembly 1. Remove bushing, flat washers (2), wave washer and tiller handle washer. Remove retainer and bolt. e d c f a b 53248 b a -Bushing b -Flat Washer (2) c -Wave Washer d -Tiller Handle Washer e -Retainer f -Bolt 7C-4 - ATTACHMENTS/CONTROL LINKAGE 90-827857R1 NOVEMBER 1996 2. Slide tiller tube out of pulley case. a b 53256 a -Tiller Tube b -Pulley Case 3. Remove pulley case assembly from tiller handle and remove cover bolt. a b 53262 a -Pulley Case Assembly b -Cover Bolt 4. Remove cover and lift pulley assembly from case. Replace cables as required. b 53257 a a -Cover b -Pulley Assembly Reassembly 1. Wrap cables around pulley. Top cable wraps and locks in top groove. Bottom cable wraps and locks in bottom groove. 2. Place pulley and cable assembly into pulley case. c ba 53257 a -Pulley b -Top Cable c -Bottom Cable 3. Install pulley cover and secure cover with bolt. Torque bolt to 20 lb. in. (2.3 N·m). a b 53262 a -Cover b -Bolt [Torque to 20 lb. in. (2.3 N·m)] 4. Install pulley assembly into tiller handle and slide tiller tube into pulley. a b 53256 a -Pulley Assembly b -Tiller Tube 90-827857R1 NOVEMBER 1996 ATTACHMENTS/CONTROL LINKAGE - 7C-5 h g f e d c f a b 5. Secure tiller tube in handle with retainer and bolt. Torque bolt to 35 lb. in. (3.9 N·m). 6. Install tiller washer (tab aligns with slot in handle), plain washer, wave washer, plain washer and flanged bushing over cable/harness assembly. 53248 a -Retainer b -Bolt [Torque to 35 lb. in. (3.9 N·m)] c -Tiller washer d-Tab e -Slot f -Plain Washer g -Wave Washer h -Flanged Bushing 7C-6 - ATTACHMENTS/CONTROL LINKAGE Installation 1. Slide tiller handle assembly into anchor bracket. 2. Route stop button harness through fuel connector opening in bottom cowl. 3. Route control cables through opening in bottom cowl. 4. Align tabs of inner and outer flanged bushings with slots in anchor bracket. a -Stop Button Harness b -Control Cables c -Tabs 5. Pull on cable ends to remove slack and secure tiller handle to anchor bracket with plate and 2 bolts. Torque bolts to 50 lb. in. (5.6 N·m). a b c c a 53155 b a -Plateb -Bolts [Torque to 50 lb. in. (5.6 N·m)] 6.Connect black and black/yellow stop button wires. 90-827857R1 NOVEMBER 1996 90-827857R1 NOVEMBER 1996 ATTACHMENTS/CONTROL LINKAGE - 7C-7 Cable Installation Tiller Shift Models-Control Cables 1. Rotate tiller handle twist grip into “FORWARD” gear and then to “FAST” position (full throttle/ ccw). 2. Secure longest cable into inner groove on top side of throttle cam pulley. 53402 a b a - Pulley b - Throttle Cable 3. Secure remaining cable into outer groove on bottom side of pulley. Place cable jackets into notches on anchor bracket. 53402 a b c d a - Pulley b - Throttle Cable c - Cable Jacket d - Lower Notch 4. Refer to Section 2C “Timing, Synchronizing, and Adjusting” for proper control cable adjustment. Side Shift Models-Throttle Cables 1. Rotate tiller handle twist grip to “FAST” position (full throttle/ccw). 2. Secure longest cable into inner groove on top side of throttle cam pulley. 53402 a b a - Pulley b - Throttle Cable 3. Secure remaining cable into outer groove on bottom side of pulley. Place cable jackets into notches on anchor bracket. 53402 a b c d a - Pulley b - Throttle Cable c - Cable Jacket d - Lower Notch 4. Refer to Section 2C “Timing, Synchronizing, and Adjusting” for proper throttle cable adjustment. MANUAL STARTER 8 Table of Contents Page Starter Assembly (Manual) . . . . . . . . . . . . . . . . . 8-2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Pinion Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Drum Removal . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Spiral Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Spiral Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Stopper Assembly . . . . . . . . . . . . . . . . . . . . . . 8-7 Stopper Arm Assembly . . . . . . . . . . . . . . . . . . 8-8 Installing Starter Rope. . . . . . . . . . . . . . . . . . . 8-8 Drum Installation . . . . . . . . . . . . . . . . . . . . . . . 8-9 Pinion Installation. . . . . . . . . . . . . . . . . . . . . . . 8-9 Adjusting Spring Tension . . . . . . . . . . . . . . . 8-10 Plate Assembly. . . . . . . . . . . . . . . . . . . . . . . . 8-10 Rewind Starter Installation . . . . . . . . . . . . . . 8-11 90-827857R1 NOVEMBER 1996 Notes: 90-827857R1 NOVEMBER 1996 MANUAL STARTER - 8-1 Starter Assembly (Manual) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1617 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 8 9 9 8 66 95 66 95 95 66 95 95 95 66 95 Loctite 242 (92-809821) 2-4-C With Teflon (92-825407A12) 8-2 - MANUAL STARTER 90-827857R1 NOVEMBER 1996 Starter Assembly (Manual) REFREF. .. NO. QTY. DESCRIPTION TORQUE lb. in. lb. ft. N·m 1 1 STARTER ASSEMBLY 2 1 HOUSING 3 1 THRUST WASHER 4 1 STARTER ROPE 1 SPRING–starter 6 1 DRUM–sheave 7 1 COVER–starter housing 8 6 LOCKWASHER 9 6 BOLT 43 5.0 1 STOPPER 11 1 SPRING 12 1 LINK 13 1 WASHER 14 1 COTTER PIN 1 PLATE–drive 16 1 DAMPER 17 1 COVER 18 1 SPRING–drive plate 19 1 WASHER–Thrust 1 ROLLER–rope 21 1 BUSHING 22 1 LOCKWASHER 23 1 LOCKWASHER 24 1 BOLT 70 8.0 1 PULLEY 26 1 PIN 27 1 BUSHING 28 1 WASHER–drive pawl 29 1 NUT 13 17.5 1 BOLT 13 17.5 31 1 SPRING–return 32 1 ARM 33 1 WASHER 34 1 HANDLE 3 BOLT (M8 x 30) 13 17.5 36 3 WASHER 37 1 STEERING CABLE 38 2 BOLT (M5 x 12) 43 5.0 39 1 STAY 1 STAY 90-827857R1 NOVEMBER 1996 MANUAL STARTER - 8-3 8-4 - MANUAL STARTER 90-827857R1 NOVEMBER 1996 Removal 1. Before removing the starter grip, pull out the starter rope and make a knot in the rope to prevent the rope from being pulled into the starter. a 28358 a - Knot 2. Remove the retainer, untie the knot at the end of the rope, and remove the starter grip. a b c 53233 a - Retainer b - Knot c - Starter Grip 3. Remove three mounting bolts. 28339 a a - Mounting Bolts (3) Disassembly WARNING Wear safety glasses for eye protection when disassembling the rewind starter. The spiral spring could jump out and uncoil causing injury. Pinion Gear 1. Loosen jam nut and remove top bolt (a). 2. Push out the cross pin and remove pinion. b a c a - Top Bolt b - Jam Nut c - Cross Pin 90-827857R1 NOVEMBER 1996 MANUAL STARTER - 8-5 Drum Removal IMPORTANT: The spring tension on the drum must be relieved before removal of the drum. 1. Relieve the spring tension on the drum by untieing the knot in the starter rope and slowly releasing the starter rope, allowing the starter rope to wind fully onto the drum. 28362 a a - Allow the Starter Rope to Wind Slowly onto to Drum 2. Remove cover. a b c a - Cover b - Lock Washer (3) c - Bolt (3) 3. Turn the drum counterclockwise a few turns. This will help disengage the spiral spring from the drum. 28355 a a - Turn Drum Counterclockwise a few Turns 4. Slowly start to slide out the drum and observe if the spiral spring is staying engaged to the drum. If so, refer to next step. 28360 b a a - Observe if Spring is Staying Engaged to Drum. b - Drum 5. If the spiral spring is staying engaged to the drum, insert a slotted screwdriver thru the hole in the drum and push down the spring. 28363 b a 28355 a -If Necessary, Insert a Screwdriver into Hole to Push Down (Disengage) the Spiral Spring b -Drum Spiral Spring WARNING Wear safety glasses and gloves for eye and hand protection when removing the spiral spring. As the spiral spring uncoils it could cause injury. Hold the starter housing facing downward and away from you. Insert a screwdriver into the shaft opening and push the spiral spring out. a b a -Spiral Spring b -Thrust Washer 8-6 - MANUAL STARTER 90-827857R1 NOVEMBER 1996 Reassembly WARNING Wear safety glasses and gloves for eye and hand protection when reassembling the rewind starter. The spiral spring could jump out and uncoil causing injury. Spiral Spring 1. Lubricate the spiral spring with 2-4-C w/Teflon grease. 2. Install the thrust washer. 3. Install the spiral spring as follows: a. Installing New Spring: When installing a new spiral spring, do not cut the wire holding the spring together until after the installation. b. Reusing Existing Spring: When reusing the spiral spring, set the leading end first in the housing and then fit one turn each time. Use care that the spring does not jump out. b a 28365 a -Thrust Washer b -Spiral Spring Stopper Assembly 1. If removed, lubricate the shaft on the stopper. 2. Install stopper components as shown. b c d a e a -Stopper b -Spring c -Link d -Washer e -Cotter Pin 3. Install the spring on the link as shown. b a a -Straight End of Spring b -Bent End of Spring 90-827857R1 NOVEMBER 1996 MANUAL STARTER - 8-7 8-8 - MANUAL STARTER 90-827857R1 NOVEMBER 1996 Stopper Arm Assembly 1. If removed, install stopper arm assembly. b c d e a a - Spring b - Stopper Arm c - Washer d - Lock Washer e - Bolt 2. Place the looped end of the spring over the pin and insert the straight end into the hole in the arm. 28367 b a a - Place looped End of Spring Over Pin b - Insert straight End of Spring into Hole Installing Starter Rope 1. Make a knot in one end of the rope. 2. Pass the rope through the hole in the drum and wind it approximately 7 turns around the sheave. 28353 3. Place excess rope into notch. 28354 a a - Place Excess Rope into Notch Drum Installation 1. Lubricate the drum shaft with 2-4-C w/Teflon. 2. Place the starter rope into the drum notch. 3. Slide the drum into the housing. 28364 4. Rotating the drum clockwise will help engage the spiral spring with the drum. 28355 a a -Rotating the Drum Clockwise Will Help Engage the Spiral Spring. Pinion Installation 1. Lubricate inside of pinion with 2-4-C w/Teflon. 2. Assemble pinion as shown. 3. After the cross pin is installed, tighten the top bolt against the cross pin and secure by tightening the jam nut against the flat washer. a b c d e f g a -Top Bolt (Apply Loctite 242 on Threads) b -Jam Nut c -Flat Washer d -Bushing e -Friction Spring f -Cross Pin g -Flat Washer 90-827857R1 NOVEMBER 1996 MANUAL STARTER - 8-9 Adjusting Spring Tension NOTE: Have the pinion installed before adjusting spring tension. This will prevent the drum from disengaging off the spiral spring. 1. Locate the end of the starter rope and pull it out of the drum. Guide it around the pulley and tie a knot at the end of the rope. b a 28356 a -Pulley b -Place a Knot in End of Rope 2. Pull out Approximately 12 in. (300 mm) of starter rope from the drum. 3. Form a loop with the with rope. Place the rope in the drum notch and preload the spring tension by rotating the drum clockwise three turns. 28357 a a -With Rope in Notch, Rotate Drum Clockwise Three Turns 4. Install cover on the rewind housing. b c a a -Cover b -Lock Washer c -Bolt Plate Assembly 1. Assemble the damper and cover onto the plate. b c a a -Rubber Damper - Position Inside Radius with Radius on Plate b -Plate c -Cover 8-10 - MANUAL STARTER 90-827857R1 NOVEMBER 1996 2. Place the plate assembly inside the loop of the friction spring and fasten with two bolts. 28369 b a a -Plate Assembly (Place Inside of Friction Spring) b -Bolts and Lock Washers Rewind Starter Installation 1. Reinstall rewind starter with three bolts. 28339 2. Install the shift interlock cable to stopper arm. Set the shift lever to neutral. Adjust and tighten the adjustment nuts so the arrows marks align with each other. b a a -Adjustment Nuts b -Align Arrows 3.Install starter grip by passing the rope through the front panel and starter grip. Make a knot in the end of the rope. Place knot into retainer and install. 90-827857R1 NOVEMBER 1996 MANUAL STARTER - 8-11