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SERVICE MANUAL MODELS United States 0G590000 and Above. . . . . . With Serial Numbers Mercury/Mariner 9.9/15 (4-Stroke) (323 cc) 9.9/15 Bigfoot (4-Stroke) (323 cc) Printed in U.S.A. W1998, Mercury Marine 90-856159R1 AUGUST 1998 Notice Throughout this publication, “Dangers”, “Warnings” and “Cautions” (accompanied by the International HAZARD Symbol ) are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. OBSERVE THEM CAREFULLY! These “Safety Alerts” alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus “Common Sense” operation, are major accident prevention measures. DANGER DANGER - Immediate hazards which WILL result in severe personal injury or death. WARNING WARNING - Hazards or unsafe practices which COULD result in severe personal injury or death. CAUTION Hazards or unsafe practices which could result in minor personal injury or product or property damage. Notice to Users of This Manual This service manual has been written and published by the Service Department of Mercury Marine to aid our dealers’ mechanics and company service personnel when servicing the products described herein. It is assumed that these personnel are familiar with the servicing procedures of these products, or like or similar products manufactured and marketed by Mercury Marine, that they have been trained in the recommended servicing procedures of these products which includes the use of mechanics’ common hand tools and the special Mercury Marine or recommended tools from other suppliers. We could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of the possible hazards and/or results of each method. We have not undertaken any such wide evaluation. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered by the service procedure selected. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service these products. It should be kept in mind, while working on the product, that the electrical system and ignition system are capable of violent and damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables should be disconnected at the battery. Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive internal damage when the engine is started. 90-856159R1 AUGUST 1998 Page i It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Mismatched or incorrect fasteners can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the same locations whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original. Cleanliness and Care of Outboard Motor A marine power product is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten thousands of an inch/mm. When any product component is serviced, care and cleanliness are important. Throughout this manual, it should be understood that proper cleaning, and protection of machined surfaces and friction areas is a part of the repair procedure. This is considered standard shop practice even if not specifically stated. Whenever components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed. Personnel should not work on or under an outboard which is suspended. Outboards should be attached to work stands, or lowered to ground as soon as possible. We reserve the right to make changes to this manual without prior notification. Refer to dealer service bulletins for other pertinent information concerning the products described in this manual. Page Numbering Two number groups appear at the bottom of each page. The example below is self-explanatory. EXAMPLE: 90-826148 R1 JANUARY 1996 Page 6A-7 Revision No. 1 Month of Printing Year of Printing Section Number Part of Section Letter Page Number Page ii 90-856159R1 AUGUST 1998 Service Manual Outline Section 1 - Important Information A - Specification B - Maintenance C - General Information D - Outboard Motor Installation Section 2 - Electrical A - Ignition B - Charging & Starting System C - Timing, Synchronizing & Adjusting D - Wiring Diagrams Section 3 - Fuel System A - Fuel Pump B - Carburetor C - Emissions Section 4 - Powerhead A - Cylinder Head B - Cylinder Block/Crankcase C - Oil Pump Section 5 - Mid-Section Section 6 - Lower Unit A - Gear Housing (Non-Bigfoot) B - Gear Housing (Bigfoot) Section 7 - Attachments/Control Linkage A - Throttle/Shift Linkage B - Tiller Handle Section 8 - Manual Starter Important Information Electrical Fuel System Powerhead Mid-Section Lower Unit Attachments/ Control Linkage Manual Starter 90-856159R1 AUGUST 1998 Page iii SPECIFICATIONS IMPORTANT INFORMATION Section 1A - Specifications Table of Contents 1 A Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1 Mercury/Mariner 9.9 (4 - Stroke) Bigfoot . . . 1A-7 Propeller Information Charts . . . . . . . . . . . . . . . . 1A-7 Mercury/Mariner 15 (4 - Stroke) Mercury/Mariner 9.9 (4 - Stroke) Non-Bigfoot . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-8 Non-Bigfoot . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-7 Mercury/Mariner 15 (4 - Stroke) Bigfoot . . . 1A-8 Specifications Models 9.9/15 (4-Stroke) HORSEPOWER (kW) 9.9 15 9.9 hp (7.4 Kw) 15 hp (11.2 Kw) OUTBOARD WEIGHT 9.9/15 ML 9.9/15 EL 9.9/15 EL Bigfoot 112 lb (50.8 kg) 116 lb (52.6 kg) 128 lb (58.0 kg) FUEL RECOMMENDED GASOLINE Automotive Unleaded with a Minimum Pump Posted Octane Rating of 87 FUEL SYSTEM Fuel Pump Type Fuel Pump: Pressure Plunger Stroke Fuel Tank Capacity External (Plunger/Diaphragm) 3-6 psi (21-41 kPa) 0.14 - 0.27 in. (3.52 - 6.58 mm) 3.0 US Gal. (12 L) OIL OIL FILTER OIL FILTER WRENCH OIL PAN CAPACITY ENGINE OIL +20 +40 +60 +80 F° C° 0 +100 –7 +4 +16 +27 –18 +38 SAE 10W-30 SAE 25W-40 p/n 35-822626A1 p/n 91-802653 Either 1 Quart or 1 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). Use Quicksilver 4-Cycle Marine Oil with the proper viscosity for the expected temperature in your area (see range thermometer on left). If not available, use a premium quality 4-cycle engine oil, certified to meet or exceed anyone of the following American Petroleum Institute (API) service classifications SH, SG, SF, CF-4, CE, CD, CDll. 90-856159R1 AUGUST 1998 Page 1A-1 SPECIFICATIONS IGNITION SYSTEM Readings taken @ 68°F (20°C). Type Spark Plug Type Gap Hex Firing Order Ignition Timing: Below 800 rpm @ 2800-3300 rpm Charge Coil Resistance Crank Position Sensor Resistance Ignition Coil Resistance: Capacitor Discharge Ignition NGK DPR6EA-9 0.035 in. (1.0 mm) 18 mm 1-2 5° B.T.D.C. 30° B.T.D.C. 270 - 410 W (BRN - BLU) 230 - 350 W (GRN/WHT - BLK) Primary Secondary (W/o Boots) ECM Engine Speed Limiter Spark Cut-Out Reduction (Percent ages of ignition spark are Cut-Out) ECM Low Oil Pressure Speed Control Oil Pressure Switch 0.16 - 0.24 W 3.9 - 5.9 k W 5850 rpm Approximately 2000 rpm Below 2.5 psi (17 kPa) Continuity CHARGING Output Output Alternator Type 6 AMP Manual (Standard) Alternator: Single Phase (6 Pole) 12 Volts-6 Amps. (Rectified) SYSTEM Readings taken @ 68°F (20°C). Battery Charging Resistance 10 AMP Electric (Standard) Alternator: Battery Charging Coil Resistance Quicksilver Tachometer Setting 0.48 - 0.72 Ohms (GRN-GRN) 12V-10 Amps. (Rectified/Regulated) 0.24 - 0.36 Ohms (GRN-GRN) “6C” or “2” STARTING SYSTEM Manual Start Electric Start: Starter Type Output Ampere Draw Under: (Load) (No Load) Battery Rating Minimum Requirement Recoil Starter Bendix 0.8 kW 106.0 Amps 21.1 Amps 465 Marine Cranking Amps (MCA) BATTERY Idle rpm (In Forward Gear) Wide Open Throttle rpm (WOT) For operation below 32° F (0° C) Idle rpm (Out Of Gear) 850 ± 50 rpm or 350 Cold Cranking Amps (CCA) 1000 Marine Cranking Amps (MCA) or 775 Cold Cranking Amps (CCA) 950 ± 50 rpm CARBURETOR Bodensee Model Range Standard Model Main Jet Size Standard Model Range 9.9 hp 5200-5700 4500-5500 #68 Pilot Jet Bodensee Model Main Jet Size 15 hp 9.9 hp 15 hp Pilot Jet Float Height #45 #104 #68 #103 #45 0.61 ± 0.04 in. (15.5 ± 1.0 mm) Page 1A-2 90-856159R1 AUGUST 1998 SPECIFICATIONS CYLINDER BLOCK STROKE Length Type Displacement Number of Cylinders 4 Stroke Cycle – Over Head Camshaft 19.7 cu. in. (323 cc) 2 2.323 in. (59 mm) CYLINDER BORE Diameter Standard Oversize-0.010 in. (0.25 mm) Oversize-0.020 in. (0.50 mm) Taper/Out of Round Maximum Bore Type 2.3228-2.3236 in. (59.00-59.02 mm) 2.3327-2.3335 in. (59.25-59.27 mm) 2.3425-2.3433 in. (59.50-59.52 mm) 0.003 in. (0.08 mm) Cast Iron PISTON Piston Type O.D. at Skirt Standard Oversize-0.010 in. (0.25mm) Oversize-0.020 in. (0.50mm) Aluminum 2.3209 - 2.3214 in. (58.950 - 58.965 mm) 2.3307 - 2.3313 in. (59.200 - 59.215 mm) 2.3406 - 2.3411 in. (59.450 - 59.465 mm) PISTON CLEARANCE Piston to Cylinder Clearance 0.0014 - 0.0026 in. (0.035 - 0.065 mm) RINGS Ring End Gap (Installed) Top Middle Bottom (Oil Ring) Side Clearance: Top Middle 0.006 - 0.012 in. (0.15 - 0.30 mm) 0.012 - 0.020 in. (0.30 - 0.50 mm) 0.008 - 0.028 in. (0.20 - 0.70 mm) 0.0016 - 0.0032 in. (0.04 - 0.08 mm) 0.0012 - 0.0028 in. (0.03 - 0.07 mm) COMPRESSION RATIO Compression Ratio Cylinder Compression (cold engine @ W.O.T.) 9.3:1 185 - 190 psi (Peak) CONNECTING ROD PISTON PIN Oil Clearance (Big End) Small End Inside Diameter Piston Pin Diameter 0.0008 - 0.0018 in. (0.021 - 0.045 mm) 0.5518 - 0.5523 in. (14.015 - 14.029 mm) 0.5510 - 0.5512 in. (13.996 - 14.000 mm) CRANKSHAFT Main Bearing Clearance Crankshaft Run-out 0.0004 - 0.0015 in. (0.011 - 0.039 mm) 0.0008 in. (0.02 mm) CAMSHAFT Camshaft Dimensions Intake “A” Exhaust “A” Intake “B” Exhaust “B” Run-out Limit Camshaft Bearing Diameter “a” Cylinder Head Upper “b” Oil Pump Housing Lower a b b a 0.941 - 0.945 in. (23.90 - 24.00 mm) 0.942 - 0.946 in. (23.92 - 24.02 mm) 0.785 - 0.789 in. (19.95 - 20.05 mm) 0.785 - 0.789 in. (19.95 - 20.05 mm) 0.0039 in. (0.1 mm) 0.6289 - 0.6293 in. (15.973 - 15.984 mm) 0.7077 - 0.7088 in. (17.975 - 17.991 mm) 90-856159R1 AUGUST 1998 Page 1A-3 SPECIFICATIONS TIMING BELT Deflection 0.39 in. (10 mm) Free Length “a” 1.354 in. (34.4 mm) Tilt Limit “b” Less than 0.043 in. (1.1 mm) a b VALVE SPRING Compressed Pressure (Installed) Intake Exhaust Dir. of Winding (Intake & Exhaust) VALVE GUIDES CYLINDER HEAD Valve Guide Inside Diameter Intake Valve Exhaust Valve Warp Limit * Lines indicate straight edge measurement Camshaft Bore Inside Diameter “a” a b Oil Pump Housing Bore Diameter “b” 23.1 - 25.4 lb (10.5 - 11.5 kg) 23.1 - 25.4 lb (10.5 - 11.5 kg) Right Hand 0.2165 - 0.2170 in. (5.500 - 5.512 mm) 0.2165 - 0.2170 in. (5.500 - 5.512 mm) 0.004 in. (0.1 mm) 0.7087 - 0.7094 in. (18.000 - 18.018 mm) 0.6299 - 0.63066 in. (16.000 - 16.0188 mm) Page 1A-4 90-856159R1 AUGUST 1998 SPECIFICATIONS Valve/Valve Seat/Valve Guides: Valve Clearance (cold) Intake 0.006 - 0.010 in. (0.15 - 0.25 mm) Exhaust Valve Dimensions: “A” Head Diameter 0.008 - 0.012 in. (0.20 - 0.30 mm) Intake 1.098 - 1.106 in. (27.9 - 28.1 mm) Exhaust “B” Face Width 0.862 - 0.870 in. (21.9 - 22.1 mm) Intake 0.079 - 0.124 in. (2.00 - 3.14 mm) Exhaust “C” Seat Width 0.079 - 0.124 in. (2.00 - 3.14 mm) Intake 0.024 - 0.031 in. (0.6 - 0.8 mm) Exhaust “D” Margin Thickness 0.024 - 0.031 in. (0.6 - 0.8 mm) VALVES Intake 0.020 - 0.035 in. (0.5 - 0.9 mm) Exhaust Stem Outside Diameter 0.020 - 0.035 in. (0.5 - 0.9 mm) Intake 0.2156 - 0.2161 in. (5.475 - 5.490 mm) Exhaust Guide Inside Diameter 0.2150 - 0.2156 in. (5.460 - 5.475 mm) Intake 0.2165 - 0.2170 in. (5.500 - 5.512 mm) Exhaust Stem To Guide Clearance 0.2165 - 0.2170 in. (5.500 - 5.512 mm) Intake 0.0004 - 0.0015 in. (0.010 - 0.037 mm) Exhaust 0.0010 - 0.0020 in. (0.025 - 0.052 mm) Stem Run-out Limit (max.) 0.0006 in. (0.016 mm) “A” “B” “C” “D” Valve Dimensions Head Diameter Face Width Seat Width Margin Thickness ROCKER SHAFT Outside Diameter 0.5095 - 0.5099 in. (12.941 - 12.951 mm) ROCKER ARM Inside Diameter of Bore 0.5118 - 0.5125 (13.000 - 13.018 mm) THERMOSTAT Valve Opening Temperature Full Open Temperature Valve Lift (Minimum) 136° F - 143° F (58° C - 62° C) 158° F (70° C) 0.12 in. (3 mm) 90-856159R1 AUGUST 1998 Page 1A-5 SPECIFICATIONS LUBRICATION SYSTEM Pump Type Engine Oil Pressure Oil Pressure Switch Oil Pump: Outer Rotor to Housing “a” Inner Rotor to Outer Rotor “b” Rotor to Housing “c” Relief Valve Opening Pressure a b Trochoid 30-40 psi at 3000 rpm (Warm Engine) Below 2.5 psi (17 kPa) Continuity 0.0024 - 0.0043 in. (0.06 - 0.11 mm) 0.0008 - 0.0059 in. (0.02 - 0.15 mm) 0.008 - 0.003 in. (0.02 - 0.07 mm) 55-64 psi (3.88-4.50 Kg/cm2) 388-450 kPa c Transom Height: Short Shaft 15 in. (38 cm) Long Shaft 20 in. (51 cm) MID-SECTION Steering Pivot Range 70° Tilt Pin Positions 5 + Shallow Water Full Tilt Up Angle 66° Allowable Transom Thickness 2-3/8 in. (60.3 mm) GEAR HOUSING NON-BIGFOOT (2.0:1) Gear Ratio Gearcase Capacity Lubricant Type Forward Gear Number of Teeth Pinion Gear Number of Teeth Pinion Height Forward Gear Backlash Reverse Gear Backlash Water Pressure @ Idle @ WOT 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 1/2 – 1-1/2 psi @ 950 rpm 5-7 psi @ 5000 rpm GEAR HOUSING BIGFOOT (2.42:1) Gear Ratio Gearcase Capacity Lubricant Type Forward Gear Number of Teeth Pinion Gear Number of Teeth Pinion Height 2.42:1 7.8 fl oz (230 mL) Quicksilver Gear Lube-Premium Blend 29 Spiral/Bevel 12 Spiral/Bevel 0.025 in. (0.64 mm) Forward Gear Backlash Water Pressure (With Thermostat) @ Idle @ WOT No Adjustment 1 - 4 psi @ 950 rpm 6 - 9 psi @ 5000 rpm Page 1A-6 90-856159R1 AUGUST 1998 SPECIFICATIONS Propeller Information Charts Mercury/Mariner 9.9 (4 - Stroke) Non-Bigfoot Wide Open Throttle rpm: 4500-5500 Recommended Transom Heights : 15”, 20” Right Hand Rotation Standard Gear Reduction : 2:1 Diameter Pitch No. of Blades Material Approx. Gross Boat Wgt. (lbs) Approx. Boat Length Speed Range (mph) Propeller Part Number 9” 10.5” 3 Alum Up to 800 Up to 16’ 17-24 48-828158A12 9” 9” 3 Alum 600-1000 15’-17’ 13-19 48-828156A12 9” 8” 3 Alum 700-1200 16’-19’ 10-16 48-828154A12 9.25” 7” 3 Alum 900-1600 16’-20’ 8-14 48-828152A12 9.75” 6.5” 3 Alum 1000-1800 sailboat/work 7-12 48-828150A12 9.75” 6” 4 Alum 1400 + pontoon/work 6-11 48-850204A12 9.75” 5.5” 3 Alum 1700 + work 1-10 48-828148A12 Mercury/Mariner 9.9 (4 - Stroke) Bigfoot Wide Open Throttle rpm: 4500-5500 Recommended Transom Heights : 20”, 25” Right Hand Rotation Standard Gear Reduction : 2.42:1 Diameter Pitch No. of Blades Material Approx. Gross Boat Wgt. (lbs) Approx. Boat Length Speed Range (mph) Propeller Part Number 10.25” 14.5” 3 Alum Up to 700 Up to 15’ 19-28 48-19642A40 10.38” 13” 3 Steel 500-900 13’-16’ 17-25 48-19644A5 10.38” 13” 3 Alum 500-900 13’-16’ 17-25 48-19640A40 10.38” 12” 3 Alum 600-1000 14’-17’ 15-23 48-19639A40 10.38” 11” 3 Alum 700-1100 15’-18’ 14-20 48-19638A40 10.38” 9.5” 3 Alum 1000 + pontoon/work 1-16 48-19636A10 90-856159R1 AUGUST 1998 Page 1A-7 SPECIFICATIONS Mercury/Mariner 15 (4 - Stroke) Non-Bigfoot Wide Open Throttle rpm: 4500-5500 Recommended Transom Heights : 15”, 20” Right Hand Rotation Standard Gear Reduction : 2:1 Diameter Pitch No. of Blades Material Approx. Gross Boat Wgt. (lbs) Approx. Boat Length Speed Range (mph) Propeller Part Number 9” 10.5” 3 Alum Up to 900 Up to 15’ 19-26 48-828158A12 9” 9” 3 Alum 800-1200 14’-16’ 15-22 48-828156A12 9” 8” 3 Alum 900-1500 15’-17’ 12-18 48-828154A12 9.25” 7” 3 Alum 1200-2000 15’-18’ 10-15 48-828152A12 9.75” 6.5” 3 Alum 1300-2300 sailboat/work 9-14 48-828150A12 9.75” 6” 4 Alum 1500 + pontoon/work 8-12 48-850204A12 9.75” 5.5” 3 Alum 1700 + work 1-11 48-828148A12 Mercury/Mariner 15 (4 - Stroke) Bigfoot Wide Open Throttle rpm: 4500-5500 Recommended Transom Heights : 20”, 25” Right Hand Rotation Standard Gear Reduction : 2.42:1 Diameter Pitch No. of Blades Material Approx. Gross Boat Wgt. (lbs) Approx. Boat Length Speed Range (mph) Propeller Part Number 10.25” 14.5” 3 Alum Up to 900 Up to 16’ 19-28 48-19642A40 10.38” 13” 3 Steel 600-1000 14’-17’ 17-25 48-19644A5 10.38” 13” 3 Alum 600-1000 14’-17’ 17-25 48-19640A40 10.38” 12” 3 Alum 700-1100 15’-18’ 15-23 48-19639A40 10.38” 11” 3 Alum 800-1300 15’-19’ 14-20 48-19638A40 10.38” 9.5” 3 Alum 1100 + pontoon/work 1-16 48-19636A10 Page 1A-8 90-856159R1 AUGUST 1998 MAINTENANCE IMPORTANT INFORMATION Section 1B - Maintenance Table of Contents 1 B Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-1 Timing Belt Inspection 1B-9. . . . . . . . . . . . . . . . . . . . . Quicksilver Lubricant/Sealant . . . . . . . . . . . . . . . 1B-2 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . 1B-10 Inspection And Maintenance Schedule . . . . . . . 1B-4 Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . 1B-12 Before Each Use . . . . . . . . . . . . . . . . . . . . . . . 1B-4 Oil Draining Procedure . . . . . . . . . . . . . . . . . 1B-12 After Each Use . . . . . . . . . . . . . . . . . . . . . . . . . 1B-4 Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . 1B-12 Every 100 Hours Of Use Or Once Yearly, Oil Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-13 Whichever Occurs First . . . . . . . . . . . . . . . . . 1B-4 Gear Case Lubrication . . . . . . . . . . . . . . . . . . . . 1B-13 Every 300 Hours of Use or Three Years . . . 1B-5 Draining Gear Case . . . . . . . . . . . . . . . . . . . 1B-13 Before Periods of Storage . . . . . . . . . . . . . . . 1B-5 Gear Case Lubricant Capacity . . . . . . . . . . 1B-13 Flushing The Cooling System . . . . . . . . . . . . . . . 1B-5 Checking Gear Case Lubricant Level and Standard Models . . . . . . . . . . . . . . . . . . . . . . . 1B-5 Refilling Gear Case . . . . . . . . . . . . . . . . . . . . 1B-14 Bigfoot Models . . . . . . . . . . . . . . . . . . . . . . . . . 1B-6 Storage Preparation . . . . . . . . . . . . . . . . . . . . . . 1B-15 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-7 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-15 Fuel Line Filter . . . . . . . . . . . . . . . . . . . . . . . . . 1B-7 Protecting External Outboard Fuel Line Inspection . . . . . . . . . . . . . . . . . . . . 1B-7 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-15 Corrosion Control Anode . . . . . . . . . . . . . . . . . . . 1B-8 Protecting Internal Engine Components 1B-15. . Spark Plug Inspection . . . . . . . . . . . . . . . . . . . . . . 1B-8 Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-15 Battery Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9 Positioning Outboard for Storage . . . . . . . . 1B-16 Fuse Replacement – Electric Start Models . . . . 1B-9 Battery Storage . . . . . . . . . . . . . . . . . . . . . . . 1B-16 Special Tools 1. Flushing Attachment Non-Bigfoot (P/N 12612A2). 2. Flushing Attachment Bigfoot (P/N 44357A2). 3. Oil Filter Wrench (P/N 91-802653). 55851 90-856159R1 AUGUST 1998 Page 1B-1 MAINTENANCE Quicksilver Lubricant/Sealant 1. Quicksilver Anti-Corrosion Grease P/N 92-850735A1 2. 2-4-C Marine Lubricant with Teflon P/N 92-850736A1 3. Special Lubricant 101 P/N 92-13872A1 4. Quicksilver Power Trim and Steering Fluid P/N 92-90100A12 Page 1B-2 90-856159R1 AUGUST 1998 MAINTENANCE 5. Quicksilver 4-Stroke Outboard Oil P/N 92-828000A12 6. Gear Lube-Premium Blend P/N 92-850737A1 90-856159R1 AUGUST 1998 Page 1B-3 MAINTENANCE Inspection And Maintenance Schedule To keep your outboard in the best operating condition, it is important that your outboard receive the periodic inspections and maintenance listed in the Inspection and Maintenance Schedule. We urge you to keep it maintained properly to ensure the safety of you and your passengers and retain its dependability. WARNING Neglected inspection and maintenance service of your outboard or attempting to perform maintenance or repair on your outboard if you are not familiar with the correct service and safety procedures could cause personal injury, death, or product failure. Before Each Use 1. Check engine oil level. 2. Check that lanyard stop switch stops the engine. 3. Visually inspect the fuel system for deterioration or leaks. 4. Check outboard for tightness on transom. 5. Check steering system for binding or loose components. 6. Visually check steering link rod fasteners for proper tightness. 7. Check propeller blades for damage. After Each Use 1. Flush out the outboard cooling system if operating in salt or polluted water. 2. Wash off all salt deposits and flush out the exhaust outlet of the propeller and gear case with fresh water if operating in salt water. Every 100 Hours Of Use Or Once Yearly, Whichever Occurs First 1. Lubricate all lubrication points. Lubricate more frequently when used in salt water. 2. Change engine oil and replace the oil filter. The oil should be changed more often when the engine is operated under adverse conditions such as extended trolling. 3. Inspect thermostat visually for corrosion, broken spring, and to determine that the valve is completely closed at room temperature. If questionable, inspect thermostat as outlined in Section 4B “Cleaning/Inspection/Repair-Thermostat”. 4. Inspect and clean spark plugs. 5. Check fuel line filter for contaminants. 6. Check corrosion control anodes. Check more frequently when used in salt water. 7. Drain and replace gear case lubricant. 8. Lubricate splines on the drive shaft. 9. Check and adjust valve clearance, if necessary. 10. Remote Control Models-Check control cable adjustments. 11. Inspect timing belt. 12. Check tightness of bolts, nuts, and other fasteners. Page 1B-4 90-856159R1 AUGUST 1998 MAINTENANCE Every 300 Hours of Use or Three Years 1. Replace water pump impeller (more often if overheating occurs or reduced water pressure is noted). Before Periods of Storage 1. Refer to Storage procedure (this section). Flushing The Cooling System Standard Models 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 Section 1C Propeller “Removal/Installation”). 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. a a-Flushing Attachment 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. a a-Excess Water Leaking From Cup 5. Check for a steady stream of water flowing out of the water pump indicator hole. Continue flushing the outboard for 3 to 5 minutes, carefully monitoring water supply at all times. 6. Stop the engine, turn off the water, and remove the flushing attachment. Reinstall the propeller. 90-856159R1 AUGUST 1998 Page 1B-5 MAINTENANCE Bigfoot Models 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 Section 1C Propeller “Removal/Installation”). Install the flushing attachment so the rubber cups fit tightly over the cooling water intake holes. a a-Flushing Attachments 2. Attach a water hose to the flushing attachment. Turn on the water and adjust the flow so water is leaking around the rubber cups to ensure the engine receives an adequate supply of cooling water. a a-Water Hose Connection 3. Start the engine and run it at idle speed in neutral shift position. 4. Adjust water flow (if necessary) so excess water continues leaking out from around the rubber cups to ensure the engine is receiving an adequate supply of cooling water. a a-Leaking Water Flow 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. Page 1B-6 90-856159R1 AUGUST 1998 MAINTENANCE Fuel System WARNING Avoid serious injury or death from gasoline fire or explosion. Carefully follow all fuel system service instructions. Always stop the engine and DO NOT smoke or allow open flames or sparks in the area while servicing any part of the fuel system. Before servicing any part of the fuel system, stop engine and disconnect the battery. Drain the fuel system completely. Use an approved container to collect and store fuel. Wipe up any spillage immediately. Material used to contain spillage must be disposed of in an approved receptacle. Any fuel system service must be performed in a well ventilated area. Inspect any completed service work for signs of fuel leakage. Fuel Line Filter 1. Inspect the fuel line filter. If the filter appears to be contaminated, remove and replace. a a-Fuel Line Filter IMPORTANT: Visually inspect for fuel leakage from the filter connections by squeez ing the primer bulb until firm, forcing fuel into the filter. Fuel Line Inspection Visually inspect the fuel line and primer bulb for cracks, swelling, leaks, hardness, or other signs of deterioration or damage. If any of these conditions is found, the fuel line or primer bulb must be replaced. 90-856159R1 AUGUST 1998 Page 1B-7 MAINTENANCE Corrosion Control Anode Your outboard has a corrosion control anode installed to the gear case. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard metals. 1. The anode on standard models and on Bigfoot models requires periodic inspection especially in salt water which will accelerate the erosion. To maintain this corrosion protection, always replace the anode before it is completely eroded. Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode. a b a-Standard Model Anode b-Bigfoot Model Anode Spark Plug Inspection Inspect spark plugs at the recommended intervals. 1. Remove the spark plug leads by twisting the rubber boots slightly and pull off. 2. Remove the spark plugs to inspect and clean. Replace spark plug if electrode is worn or the insulator is rough, cracked, broken, blistered or fouled. 3. Set the spark plug gap. See Specification Chart. 4. Before reinstalling spark plugs, clean away dirt on the spark plug seats. Install plugs finger tight, and tighten 1/4 turn or torque to 13 lb-ft (18 Nm). Page 1B-8 90-856159R1 AUGUST 1998 MAINTENANCE Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability. IMPORTANT: Read the safety and maintenance instructions which accompany your battery. 1. Turn off the engine before servicing the battery. 2. Add water as necessary to keep the battery full. 3. Make sure the battery is secure against movement. 4. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive and negative to negative. 5. Make sure the battery is equipped with a nonconductive shield to prevent accidental shorting of battery terminals. Fuse Replacement – Electric Start Models The electric starting circuit is protected from overload by an SFE 20 AMP fuse. If the fuse is blown, the electric starter motor will not operate. Try to locate and correct the cause of the overload. If the cause is not found, the fuse may blow again. Replace the fuse with a fuse of the same rating. Timing Belt Inspection 1. Inspect the timing belt and replace 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 0.39 in. (10 mm) or more when belt is pushed in with your finger. a a-Timing Belt 90-856159R1 AUGUST 1998 Page 1B-9 MAINTENANCE Page 1B-10 90-856159R1 AUGUST 1998 Lubrication Points Lubricate Points 1 thru 6 with Quicksilver 2-4-C Marine Lubricant with Teflon or Special Lubricant 101. 1. Steering Friction Adjustment Shaft (Tiller Handle Models) – Lubricate fitting. 2. Swivel Bracket – Lubricate fitting. 1 2 3. Transom Clamp Screws – Lubricate threads. 3 4. Tilt Tube – Lubricate fittings. 4 MAINTENANCE 90-856159R1 AUGUST 1998 Page 1B-11 5. Lubricate the throttle and shaft cables, moving components and pivot locations. 5 6. Steering Cable Grease Fitting (If Equipped) – Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube. Lubricate through fitting. Lubricate points 7 With Light Weight Oil 7. Steering Link Rod Pivot Points – Lubricate points. 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. 6 6 7 Lubricate Point 8 with Quicksilver Anti-Corrosion Grease or 2-4-C Marine Lubricant with Teflon. 8. 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. 8 MAINTENANCE Page 1B-12 90-856159R1 AUGUST 1998 Changing Engine Oil Engine Oil Capacity 1 US Quart (1.0 Liter) Oil Draining Procedure 1. Lock the outboard in the full tilt up position. 2. Position outboard so the drain hole is facing downward. 3. Remove drain plug and drain engine oil into an appropriate container. 4. After the initial oil has been drained, temporarily reinstall the drain plug. Disengage the tilt lock and lower the outboard. Wait a minute to allow the remaining oil that was trapped in the engine to return to the drain. Return outboard to the full tilt position and drain the remaining oil. 5. Lubricate the seal on the drain plug with oil and reinstall. a a- Drain Hole Changing Oil Filter 1. Place a rag or towel below the oil filter to absorb any spilled oil. 2. Unscrew old filter by turning the filter counterclockwise. 3. Clean the mounting base. Apply film of clean oil to filter gasket. Do not use grease. Screw new filter on until gasket contacts base, then tighten 3/4 to 1 turn. a 91-802653 a- Oil Filter MAINTENANCE Oil Filling IMPORTANT: Do not overfill. Be sure that the outboard is upright (not tilted) when checking oil. Remove the oil fill cap and refill with one US Quart (1 Liter) of oil. Reinstall the oil fill cap. Idle engine for five minutes and check for leaks. Stop engine and check oil level on dipstick. Add oil if necessary. 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 a drain pan below outboard. 3. Remove vent plug and fill/drain plug and drain lubricant. a b a-Fill/Drain Pan b-Vent Plug Gear Case Lubricant Capacity GEAR HOUSING Gearcase Capacity 6.8 fl oz (200 mL) GEAR HOUSING BIGFOOT Gearcase Capacity 7.8 fl oz (230 mL) 90-856159R1 AUGUST 1998 Page 1B-13 MAINTENANCE Checking Gear Case Lubricant Level and Refilling Gear Case 1. Place outboard in a vertical operating position. 2. Remove vent plug from vent hole. 3. Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole. b a a-Vent Hole b-Lubricant Tube 4. Stop adding lubricant. Install the vent plug and sealing washer before removing the lubricant tube. 5. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer. Page 1B-14 90-856159R1 AUGUST 1998 MAINTENANCE Storage Preparation The major consideration in preparing your outboard for storage is to protect it from rust, corrosion, and damage caused by freezing of trapped water. The following storage procedures should be followed to prepare your outboard for out-ofseason storage or prolonged storage (two months or longer). CAUTION Never start or run your outboard (even momentarily) without water circulating through the cooling water intake in the gear case to prevent damage to the water pump (running dry) or overheating of the engine. Fuel System IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a formation of acid during storage and can damage the fuel system. If the gasoline being use contains alcohol, it is advisable to drain as much of the remaining gasoline as possible from the fuel tank, remote fuel line, and engine fuel system. Fill the fuel system (tank, hoses, fuel pump, and carburetor) with treated (stabilized) fuel to help prevent formation of varnish and gum. Proceed with following instructions. 1. Portable Fuel Tank – Pour the required amount of Quicksilver Gasoline Stabilizer (follow instructions on container) into fuel tank. Tip fuel tank back and forth to mix stabilizer with the fuel. 2. Permanently Installed Fuel Tank – Pour the required amount of Quicksilver Gasoline Stabilizer (follow instructions on container) into a separate container and mix with approximately one quart (one liter) of gasoline. Pour this mixture into fuel tank. 3. Place the outboard in water or connect flushing attachment for circulating cooling water. Run the engine for ten minutes to allow treated fuel to reach the carburetor. Protecting External Outboard Components 1. Lubricate all outboard components listed in the Inspection and Maintenance Schedule. 2. Touch up any paint nicks. 3. Spray Quicksilver Corrosion Guard on external metal surfaces (except corrosion control anodes). Protecting Internal Engine Components 1. Remove the spark plugs and inject a small amount of engine oil inside of each cylinder. 2. Rotate the flywheel manually several times to distribute the oil in the cylinders. Reinstall spark plugs. 3. Change the engine oil. Gear Case 1. Drain and refill the gear case lubricant (refer to maintenance procedure). 90-856159R1 AUGUST 1998 Page 1B-15 MAINTENANCE Page 1B-16 90-856159R1 AUGUST 1998 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 positions shown below. a b c a- Upright b- Tiller Side Down c- Back Side Down If outboard is stored tilted up in freezing temperature, trapped cooling water or rain water that may have entered the propeller exhaust outlet in the gear case could freeze and cause damage to the outboard. Battery Storage 1. Follow the battery manufacturer’s instructions for storage and recharging. 2. Remove the battery from the boat and check water level. Recharge if necessary. 3. Store the battery in a cool, dry place. 4. Periodically check the water level and recharge the battery during storage. GENERAL INFORMATION IMPORTANT INFORMATION Section 1C - General Information Table of Contents 1 C Serial Number Location . . . . . . . . . . . . . . . . . . . . 1C-1 Conditions Affecting Performance . . . . . . . . . . . 1C-2 Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2 Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-4 Following Complete Submersion . . . . . . . . . . . . 1C-5 Submerged While Running (Special Instructions) . . . . . . . . . . . . . . . . . . . 1C-5 Salt Water Submersion (Special Instructions) . . . . . . . . . . . . . . . . . . . 1C-5 Fresh Water Submersion (Special Instructions) . . . . . . . . . . . . . . . . . . . 1C-5 Propeller Selection . . . . . . . . . . . . . . . . . . . . . . . . 1C-6 Propeller Removal/Installation . . . . . . . . . . . . . . 1C-7 Standard Models . . . . . . . . . . . . . . . . . . . . . . . 1C-7 Bigfoot Models . . . . . . . . . . . . . . . . . . . . . . . . . 1C-9 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . 1C-12 Compression Check . . . . . . . . . . . . . . . . . . . . . . 1C-12 Cylinder Leakage Testing . . . . . . . . . . . . . . . . . . 1C-13 Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-13 Painting Procedures . . . . . . . . . . . . . . . . . . . . . . 1C-14 Cleaning & Painting Aluminum Propellers & Gear Housings . . . . . . . . . . . . . . . . . . . . . . . . 1C-14 Decal Application. . . . . . . . . . . . . . . . . . . . . . . . . 1C-15 Decal Removal. . . . . . . . . . . . . . . . . . . . . . . . 1C-15 Instructions for “Wet” Application . . . . . . . . 1C-15 Serial Number Location The Outboard serial number is located on the lower starboard side of the engine block. A serial number is also located on the starboard side of the swivel bracket. e a a-Serial Number b-Model Year c-Model Description d-Year Manufactured e-Certified Europe Insignia 19XX XX OGXXXXXX XXXX d c b 90-856159R1 AUGUST 1998 Page 1C-1 GENERAL INFORMATION Conditions Affecting Performance Weather ENGINE RPM Rated hp Summer hp Horsepower Loss Due to Atmosphere Conditions Secondary Loss Due to Propeller Becoming To Large for Summer Horsepower RPM Drop Due to Weather Rated RPM It is a known fact that weather conditions exert a profound effect on power output of internal combustion engines. Therefore, established horsepower ratings refer to the power that the engine will produce at its rated rpm under a specific combination of weather conditions. Corporations internationally have settled on adoption of I.S.O. (International Standards Organization) engine test standards, as set forth in I.S.O. 3046 standardizing the computation of horsepower from data obtained on the dynamometer, correcting all values to the power that the engine will produce at sea level, at 30% relative humidity at 77° F (25° C) temperature and a barometric pressure of 29.61 inches of mercury. Summer Conditions of high temperature, low barometric pressure and high humidity all combine to reduce the engine power. This, in turn, is reflected in decreased boat speeds--as much as 2 or 3 miles-per-hour (3 or 5 Km/h) in some cases. (Refer to previous chart.) Nothing will regain this speed for the boater, but the coming of cool, dry weather. In pointing out the practical consequences of weather effects, an engine--running on a hot, humid summer day--may encounter a loss of as much as 14% of the horsepower it would produce on a dry, brisk spring or fall day. The horsepower, that any internal combustion engine produces, depends upon the density of the air that it consumes and, in turn, this density is dependent upon the temperature of the air, its barometric pressure and water vapor (or humidity) content. Accompanying this weather-inspired loss of power is a second but more subtle loss. At rigging time in early spring, the engine was equipped with a propeller that allowed the engine to turn within its recommended rpm range at full throttle. With the coming of the summer weather and the consequent drop in available horsepower, this propeller will, in effect, become too large. Consequently, the engine operates at less than its recommended rpm. Page 1C-2 90-856159R1 AUGUST 1998 GENERAL INFORMATION Due to the horsepower/rpm characteristics of an engine, this will result in further loss of horsepower at the propeller with another decrease in boat speed. This secondary loss, however, can be regained by switching to a smaller pitch propeller that allows the engine to again run at recommended rpm. For boaters to realize optimum engine performance under changing weather conditions, it is essential that the engine have the proper propeller to allow it to operate at or near the top end of the recommended maximum rpm range at wide-open-throttle with a normal boat load. Not only does this allow the engine to develop full power, but equally important is the fact that the engine also will be operating in an rpm range that discourages damaging detonation. This, of course, enhances overall reliability and durability of the engine. Boat WEIGHT DISTRIBUTION 1. Proper positioning of the weight inside the boat (persons and gear) has a significant effect on the boat’s performance, for example: a. Shifting weight to the rear (stern) (1.) Generally increases top speed. (2.) If in excess, can cause the boat to porpoise. (3.) Can make the bow bounce excessively in choppy water. (4.) Will increase the danger of the following - wave splashing into the boat when coming off plane. b. Shifting weight to the front (bow) (1.) Improves ease of planing off. (2.) Generally improves rough water ride. (3.) If excessive, can make the boat veer left and right (bow steer). BOTTOM For maximum speed, a boat bottom should be nearly a flat plane where it contacts the water and particularly straight and smooth in fore-and-aft direction. 1. Hook: Exists when bottom is concave in fore-and-aft direction when viewed from the side. When boat is planing, “hook” causes more lift on bottom near transom and allows bow to drop, thus greatly increasing wetted surface and reducing boat speed. “Hook” frequently is caused by supporting boat too far ahead of transom while hauling on a trailer or during storage. 2. Rocker: The reverse of hook and much less common. “Rocker” exists if bottom is convex in fore-and-aft direction when viewed from the side, and boat has strong tendency to porpoise. 3. Surface Roughness: Moss, barnacles, etc., on boat or corrosion of outboard’s gear housing increase skin friction and cause speed loss. Clean surfaces when necessary. WATER ABSORPTION It is imperative that all through hull fasteners be coated with a quality marine sealer at time of installation. Water intrusion into the transom core and/or inner hull will result in additional boat weight (reduced boat performance), hull decay and eventual structural failure. 90-856159R1 AUGUST 1998 Page 1C-3 GENERAL INFORMATION CAVITATION Cavitation is caused by water vapor bubbles forming either from a sharp edge or angle on the gear case or from an irregularity in the propeller blade itself. These vapor bubbles flow back and collapse when striking the surface of the propeller blade resulting in the erosion of the propeller blade surface. If allowed to continue, eventual blade failure (breakage) will occur. Engine DETONATION Detonation in a 4-cycle engine resembles the “pinging” heard in an automobile engine. It can be otherwise described as a tin-like “rattling” or “plinking” sound. Detonation is an explosion of an unburned portion of the fuel/air charge after the spark plug has fired. Detonation creates severe shock waves in the engine, and these shock waves often find or create a weakness: The dome of a piston, cylinder head/gasket, piston rings or piston ring lands, piston pin and roller bearings. A few of the most common causes of detonation in a marine 4-cycle application are as follows: • Over-advanced ignition timing. • Use of low octane gasoline. • Propeller pitch too high (engine RPM below recommended maximum range). • Lean fuel mixture at or near wide-open-throttle. • Spark plugs (heat range too hot - incorrect reach - cross-firing). • Inadequate engine cooling (deteriorated cooling system). • Combustion chamber/piston deposits (result in higher compression ratio). Detonation usually can be prevented if: 1. The engine is correctly set up. 2. Diligent maintenance is applied to combat the detonation causes. 51115 Damaged Piston Resulting from Detonation Page 1C-4 90-856159R1 AUGUST 1998 GENERAL INFORMATION Following Complete Submersion Submerged While Running (Special Instructions) When an engine is submerged while running, the possibility of internal engine damage is greatly increased. If, after engine is recovered and with spark plugs removed, engine fails to turn over freely when turning flywheel, the possibility of internal damage (bent connecting rod and/or bent crankshaft) exists. If this is the case, the powerhead must be disassembled. Salt Water Submersion (Special Instructions) Due to the corrosive effect of salt water on internal engine components, complete disassembly is necessary before any attempt is made to start the engine. Fresh Water Submersion (Special Instructions) 1. Recover engine as quickly as possible. 2. Remove cowling. 3. Flush exterior of outboard with fresh water to remove mud, weeds, etc. DO NOT attempt to start engine if sand has entered powerhead, as powerhead will be severely damaged. Disassemble powerhead if necessary to clean components. 4. Remove spark plugs and get as much water as possible out of powerhead. Most water can be eliminated by placing engine in a horizontal position (with spark plug holes down) and rotating flywheel. 5. Change engine oil and filter as outlined in Section 1B “Changing Engine Oil”. Run outboard for short time and check for presence of water in oil, if water present (milky appearance) drain and refill as previously mentioned. 6. Pour alcohol into carburetor throats (alcohol will absorbed water). Again rotate flywheel. 7. Turn engine over and pour alcohol into spark plug openings and rotate flywheel. 8. Turn engine over (place spark plug openings down) and pour engine oil into throat of carburetors while rotating flywheel to distribute oil throughout crankcase. 9. Again turn engine over and pour approximately one teaspoon of engine oil into each spark plug opening. Again rotate flywheel to distribute oil in cylinders. 10. Remove and clean carburetors and fuel pump assembly. 11. Dry all wiring and electrical components using compressed air. 12. Disassemble the engine starter motor and dry the brush contacts, armature and other corrodible parts. 13. Reinstall spark plugs, carburetors and fuel pump. 14. Attempt to start engine, using a fresh fuel source. If engine starts, it should be run for at least one hour to eliminate any water in engine. 15. If engine fails to start, determine cause (fuel, electrical or mechanical). Engine should be run within 2 hours after recovery of outboard from water, or serious internal damage may occur. If unable to start engine in this period, disassemble engine and clean all parts. Apply oil as soon as possible. 90-856159R1 AUGUST 1998 Page 1C-5 GENERAL INFORMATION Propeller Selection For in-depth information on marine propellers and boat performance - written by marine engineers - see your Authorized Dealer for the illustrated “What You Should Know About Quicksilver Propellers... and Boat Performance Information” (Part No. 90-86144). For best all around performance from your outboard/boat combination, select a propeller that allows the engine to operate in the upper half of the recommended full throttle rpm range with the boat normally loaded (refer to Specifications). This rpm range allows for better acceleration while maintaining maximum boat speed. If changing conditions cause the rpm to drop below the recommended range (such as warmer, more humid weather, operation at higher elevations, increased boat load or a dirty boat bottom/gear case) a propeller change or cleaning may be required to maintain performance and ensure the outboard’s durability. Check full-throttle rpm using an accurate tachometer with the engine trimmed out to a balanced- steering condition (steering effort equal in both directions) without causing the propeller to “break loose”. Refer to “Quicksilver Accessory Guide” for a complete list of available propellers. 1. Select a propeller that will allow the engine to operate at or near the top of the recommended full throttle rpm range (listed in “Specifications,” preceding) with a normal load. Maximum engine speed (rpm) for propeller selection exists when boat speed is maximum and trim is minimum for that speed. (High rpm, caused by an excessive trim angle, should not be used in determining correct propeller.) Normally, there is a 150-350 rpm change between propeller pitches. 2. If full throttle operation is below the recommended range, the propeller MUST BE changed to one with a lower pitch to prevent loss of performance and possible engine damage. 3. After initial propeller installation, the following common conditions may require that the propeller be changed to a lower pitch: • Warmer weather and great humidity will cause an rpm loss. • Operating in a higher elevation causes an rpm loss. • Operating with a damaged propeller or a dirty boat bottom or gear housing will cause an rpm loss. • Operation with an increased load (additional passengers, equipment, pulling skiers, etc.). Page 1C-6 90-856159R1 AUGUST 1998 GENERAL INFORMATION Propeller Removal/Installation Standard Models WARNING If the propeller shaft is rotated while the engine is in gear, there is the possibility that the engine will crank over and start. To prevent this type of accidental engine starting and possible serious injury caused from being struck by a rotating propeller, always shift outboard to neutral position and remove spark plug leads when you are servicing the propeller. 1. Shift outboard to neutral position. N N 2. Remove the spark plug leads to prevent engine from starting. 3. Place a block of wood between gear case and propeller to hold propeller and remove propeller nut. 90-856159R1 AUGUST 1998 Page 1C-7 GENERAL INFORMATION 4. Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. 5. Coat the propeller shaft with Quicksilver Anti-Corrosion Grease or 2-4-C Marine Lubricant with Teflon. IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft, especially in salt water, always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed. 6. Flo-Torque I Drive Hub Propellers – Install forward thrust hub, propeller, rear thrust hub and propeller nut onto the shaft. d c b a a-Forward Thrust Hub b-Propeller c-Rear Thrust Hub d-Propeller Nut 7. Flo-Torque II Drive Hub Propellers – Install forward thrust hub, replaceable drive sleeve propeller, rear thrust hub and propeller nut onto the shaft. e d c b a a-Forward Thrust Hub b-Replaceable Drive Sleeve c-Propeller d-Rear Thrust Hub e-Propeller Nut Page 1C-8 90-856159R1 AUGUST 1998 GENERAL INFORMATION 8. Place a block of wood between gear case and propeller and tighten propeller nut. Bigfoot Models WARNING If the propeller shaft is rotated while the engine is in gear, there is the possibility that the engine will crank over and start. To prevent this type of accidental engine starting and possible serious injury caused from being struck by a rotating propeller, always shift outboard to neutral position and remove spark plug leads when you are servicing the propeller. 1. Shift outboard to neutral position. N N 2. Remove the spark plug leads to prevent engine from starting. 90-856159R1 AUGUST 1998 Page 1C-9 GENERAL INFORMATION 3. Place a block of wood between gear case and propeller to hold propeller and remove propeller nut. 4. Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. 5. Coat the propeller shaft with Quicksilver Anti-Corrosion Grease or 2-4-C Marine Lubricant with Teflon. IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft, especially in salt water, always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed. Page 1C-10 90-856159R1 AUGUST 1998 GENERAL INFORMATION 6. Flo-Torque I Drive Hub Propellers – Install forward thrust hub, propeller and propeller nut onto the shaft. c b a a-Forward Thrust Hub b-Propeller c-Propeller Nut 7. Flo-Torque II Drive Hub Propellers – Install forward thrust hub, propeller, replaceable drive sleeve, rear thrust hub and propeller nut onto the shaft. e d c b a a-Forward Thrust Hub b-Propeller c-Replaceable Drive Sleeve d-Rear Thrust Hub e-Propeller Nut 8. Place a block of wood between gear case and propeller and tighten propeller nut. 90-856159R1 AUGUST 1998 Page 1C-11 GENERAL INFORMATION Trim Tab Adjustment Propeller steering torque will cause your boat to pull in one direction. This steering torque is a normal thing that results from your outboard not being trimmed so the propeller shaft is parallel to the water surface. The trim tab can help to compensate for this steering torque in many cases and can be adjusted within limits to reduce any unequal steering effort. NOTE: Trim tab adjustment will have little effect reducing steering torque if the outboard is installed with the anti-ventilation plate approximately 2 inches (50mm) or more above the boat bottom. Operate your boat at normal cruising speed, trimmed to desired position. Turn your boat left and right and note the direction the boat turns more easily. If adjustment is necessary, loosen trim tab bolt and make small adjustments at a time. If the boat turns more easily to the left, move the trailing edge of trim tab to the left. If the boat turns more easily to the right move the trailing edge of trim tab to the right. Retighten bolt and retest. a a-Trim Tab Compression Check 1. Remove spark plugs. 2. Install compression gauge in spark plug hole. 3. Hold throttle plate at W.O.T. 4. Crank the engine over until the compression reading peaks on the gauge. Record the reading. 5. Check and record compression of each cylinder. The highest and lowest reading recorded should not differ by more than 15% (see example chart below). A reading below 120 psi might indicate a total engine wear problem. Example of compression test differences Maximum (psi) Minimum (psi) 180 162 150 127.5 6. Compression check is important because an engine with low or uneven compression cannot be tuned successfully to give peak performance. It is essential, therefore, that improper compression be corrected before proceeding with an engine tuneup. 7. Cylinder scoring: If powerhead shows any indication of overheating, such as discolored or scorched paint, visually inspect cylinders for scoring or other damage as outlined in Section 4 “Powerhead.” Page 1C-12 90-856159R1 AUGUST 1998 GENERAL INFORMATION Cylinder Leakage Testing NOTE:Cylinder leakage testing*, along with compression testing, can help the mechanic pinpoint the source of a mechanical failure by gauging the amount of leakage in an engine cylinder. Refer to the manufactures tester instructions for proper testing procedures. * Courtesy of Snap-On-Tools Cylinder Leakage Tester (Snap-On-Tools MT324) NOTE: Spark plug hole is a 12 mm diameter. Use Snap-On -Tool MT26-18 adapter with valve core removed. Analysis Due to standard engine tolerances and engine wear, no cylinder will maintain a 0% of leakage. It is important only that cylinders have somewhat consistent reading between them. Differences of 15 to 30% indicate excessive leakage. Larger engines tend to have a larger percentage of cylinder leakage than smaller engines. If excessive leakage is present, first check that the piston is at top dead center of 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 90-856159R1 AUGUST 1998 Page 1C-13 GENERAL INFORMATION Painting Procedures Cleaning & Painting Aluminum Propellers & Gear Housings WARNING Avoid serious injury from flying debris. Avoid serious injury from airborne particles. Use eye and breathing protection with proper ventilation. PROPELLERS 1. Sand the entire area to be painted with 3M 120 Regalite Polycut or coarse Scotch-Brite, disc or belts. 2. Feather edges of all broken paint edges. Try not to sand through the primer. 3. Clean the surface to be painted using PPG Industries DX330 Wax and Grease Remover or equivalent (Xylene or M.E.K.). 4. If bare metal has been exposed, use Quicksilver’s Light Gray Primer. 5. Allow a minimum of 1 hour dry time and no more than 1 week before applying the finish coat. 6. Apply the finish coat using Quicksilver’s EDP Propeller Black. GEAR HOUSINGS The following procedures should be used in refinishing gear housings. This procedure will provide the most durable paint system available in the field. The materials recommended are of high quality and approximate marine requirements. The following procedure will provide a repaint job that compares with a properly applied factory paint finish. It is recommended that the listed materials be purchased from a local Ditzler Automotive Finish Supply Outlet. The minimum package quantity of each material shown following is sufficient to refinish several gear housings. Procedure: 1. Wash gear housing with a muriatic acid base cleaner to remove any type of marine growth, and rinse with water, if necessary. 2. Wash gear housing with soap and water, then rinse. 3. Sand blistered area with 3M 180 grit sandpaper or P180 Gold Film Disc to remove paint blisters only. Feather edge all broken paint edges. 4. Clean gear housing thoroughly with (DX-330) wax and grease remover. 5. Spot repair surfaces where bare metal is exposed with (DX-503) alodine treatment. IMPORTANT: Do not use any type of aerosol spray paints as the paint will not properly adhere to the surface nor will the coating be sufficiently thick to resist future paint blistering. 6. Mix epoxy chromate primer (DP-40) with equal part catalyst (DP-401) per manufacturers instructions, allowing proper induction period for permeation of the epoxy primer and catalyst. 7. Allow a minimum of one hour drying time and no more than one week before top coating assemblies. 8. Use Ditzler Urethane DU9000 for Mercury Black, DU34334 for Mariner Grey, and DU35466 for Force Charcoal, and DU33414M for Sea Ray White. Catalyze all four colors with Ditzler DU5 catalyst mixed 1:1 ratio. Reduce with solvents per Ditzler label. Page 1C-14 90-856159R1 AUGUST 1998 GENERAL INFORMATION CAUTION Be sure to comply with instructions on the label for ventilation and respirators. Using a spray gun, apply one half to one mil even film thickness. Let dry, flash off for five minutes and apply another even coat of one half to one mil film thickness. This urethane paint will dry to the touch in a matter of hours, but will remain sensitive to scratches and abrasions for a few days. 9. The type of spray gun used will determine the proper reduction ratio of the paint. IMPORTANT: Do not paint sacrificial zinc trim tab or zinc anode. 10. Cut out a cardboard “plug” for trim tab pocket to keep paint off of mating surface to maintain good continuity circuitry between trim tab and gear housing. Decal Application Decal Removal 1. Mark decal location before removal to assure proper alignment of new decal. 2. Carefully soften decal and decal adhesive with a heat gun or heat blower while removing old decal. 3. Clean decal contact area with a 1:1 mixture of isopropyl alcohol and water. 4. Thoroughly dry decal contact area and check for a completely cleaned surface. Instructions for “Wet” Application NOTE: The following decal installation instructions are provided for a “Wet” installation. All decals should be applied wet. TOOLS REQUIRED 1. Plastic Squeegee* 2. Stick Pin 3. Dish Washing Liquid/Detergent without ammonia** “Joy” and “Drift” are known to be compatible for this process. * Automotive Body Filler Squeegee ** Do not use a soap that contains petroleum based solvents. SERVICE TIP: Placement of decals using the “Wet” application will allow time to position decal. Read entire installation instructions on this technique before proceeding. TEMPERATURE IMPORTANT: Installation of vinyl decals should not be attempted while in direct sunlight. Air and surface temperature should be between 60°F (15°C) and 100°F (38°C) for best application. SURFACE PREPARATION IMPORTANT: Do not use a soap or any petroleum based solvents to clean application surface. Clean entire application surface with mild dish washing liquid and water. Rinse surface thoroughly with clean water. 90-856159R1 AUGUST 1998 Page 1C-15 GENERAL INFORMATION DECAL APPLICATION 1. Mix 1/2 ounce (16 ml) of dish washing liquid in one gallon (4 l) of cool water to use as wetting solution. NOTE:Leave protective masking, if present, on the face of decal until final steps of decal installation. This will ensure that the vinyl decal keeps it’s shape during installation. 2. Place the decal face down on a clean work surface and remove the paper backing from “adhesive side” of decal. 3. Using a spray bottle, flood the entire “adhesive side” of the decal with the pre-mixed wetting solution. 4. Flood area where the decal will be positioned with wetting solution. 5. Position pre-wetted decal on wetted surface and slide into position. 6. Starting at the center of the decal, “lightly” squeegee out the air bubbles and wetting solution with overlapping strokes to the outer edge of the decal. Continue going over the decal surface until all wrinkles are gone and adhesive bonds to the cowl surface. 7. Wipe decal surface with soft paper towel or cloth. 8. Wait 10 - 15 minutes. 9. Starting at one corner, “carefully and slowly” pull the masking off the decal surface at a 180° angle. NOTE: To remove any remaining bubbles, pierce the decal at one end of the bubble with stick pin and press out the entrapped air or wetting solution with your thumb (moving toward the puncture). Page 1C-16 90-856159R1 AUGUST 1998 OUTBOARD MOTOR INSTALLATION IMPORTANT INFORMATION Section 1D - Outboard Motor Installation Table of Contents 1 D Boat Horsepower Capacity . . . . . . . . . . . . . . . . . 1D-1 Start in Gear Protection . . . . . . . . . . . . . . . . . . . . 1D-1 Selecting Accessories For The Outboard . . . . . 1D-2 Installing Outboard . . . . . . . . . . . . . . . . . . . . . . . . 1D-2 Steering Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-3 Steering Cable Seal . . . . . . . . . . . . . . . . . . . . . . . 1D-3 Steering Link Rod . . . . . . . . . . . . . . . . . . . . . . . . . 1D-4 Boat Horsepower Capacity Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-4 Remote Wiring Harness Connection to Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-4 Battery Cable Connections . . . . . . . . . . . . . . . . . 1D-5 Shift and Throttle Cable . . . . . . . . . . . . . . . . . . . . 1D-6 Shift Cable Installation . . . . . . . . . . . . . . . . . . 1D-6 Throttle Cable Installation . . . . . . . . . . . . . . . 1D-8 U.S. COAST GUARD CAPACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY (POUNDS) XXX MAXIMUM WEIGHT CAPACITY XXX Do not overpower or overload the boat. Most boats will carry a required capacity plate indicating the maximum acceptable power and load as determined by the manufacturer following certain federal guidelines. If in doubt, contact your dealer or the boat manufacturer. WARNING Using an outboard that exceeds the maximum horsepower limit of a boat can: 1. cause loss of boat control 2. place too much weight at the transom, altering the designed flotation characteristics of the boat or 3. cause the boat to break apart, particularly around the transom area. Overpowering a boat can result in serious injury, death, or boat damage. Start in Gear Protection The remote control connected to the outboard must be equipped with a start-in-gear protection device. This prevents the engine from starting in gear. WARNING Avoid serious injury or death from a sudden unexpected acceleration when starting your engine. The design of this outboard requires that the remote control used with it must have a built in start-in-gear protection device. 90-856159R1 AUGUST 1998 Page 1D-1 OUTBOARD MOTOR INSTALLATION Selecting Accessories For The Outboard Genuine Quicksilver Parts and Accessories have been specifically designed and tested for this outboard. Some accessories not manufactured or sold by Quicksilver are not designed to be safely used with this outboard or outboard operating system. Acquire and read the Installation, Operation, and Maintenance manuals for all selected accessories. Installing Outboard 1. Measure the transom height of your boat. The boat bottom should be aligned or be within 1 in. (25mm) above the anti-ventilation plate of the outboard. 0-1in. (0-25mm) a a-Anti-Ventilation Plate 2. Place outboard on center line of transom. 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, flat washers and locknuts. Use a marine waterproofing sealer in holes and around bolts to make the installation water tight. a c b a-Bolts (2) b-Flat Washers (2) c-Locknuts (2) Page 1D-2 90-856159R1 AUGUST 1998 OUTBOARD MOTOR INSTALLATION Steering Cable STARBOARD SIDE ROUTED CABLE 1. Lubricate the entire cable end. 95 95 2-4-C w/Teflon (92-850736A1) 2. Insert steering cable into tilt tube. Torque nut to 35 lb-ft (47.5 Nm). Steering Cable Seal 1. Mark tilt tube 1/4 in. (6.4 mm) from end. Install seal components. 1/4 in. (6.4 mm) a dcb a-1/4 in. (6.4 mm) Mark b-Plastic Spacer c-O-Ring Seal d-Cap 2. Thread cap to the mark. 90-856159R1 AUGUST 1998 Page 1D-3 OUTBOARD MOTOR INSTALLATION Steering Link Rod 1. Install steering link rod per illustration. c d b a a-Special Bolt (10-90041) Torque to 20 lb-ft (27.1 Nm) b-Nylon Insert Locknut (11-34863) Torque to 20 lb-ft (27.1 Nm) c-Flat Washer (2) d-Nylon Insert Locknut (11-34863) Tighten Locknut Until it Seats, Then Back Nut Off 1/4 Turn IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special bolt (“a” - Part Number 10-90041) and self locking nuts (“b” & “c” - Part Number 11-34863). These locknuts must never be replaced with common nuts (non locking) as they will work loose and vibrate off, freeing the link rod to disengage. WARNING Disengagement of a steering link rod can result in the boat taking a full, sudden, sharp turn. This potentially violent action can cause occupants to be thrown overboard exposing them to serious injury or death. Wiring Harness 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. 3. Secure the connection together with retainer, as shown. b a c a-Outboard Wiring Harness Connector b-Remote Wiring Connector c-Retainer Page 1D-4 90-856159R1 AUGUST 1998 OUTBOARD MOTOR INSTALLATION 90-856159R1 AUGUST 1998 Page 1D-5 Battery Cable Connections SINGLE OUTBOARD (+) (–) a b c a- Red Sleeve (Positive) b- Black Sleeve (Negative) c- Starting Battery DUAL OUTBOARD 1. Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. (–) (–) a a- Ground Cable (Same Wire Size As Engine Battery Cable – Connect Between Negative (–) Terminals OUTBOARD MOTOR INSTALLATION Page 1D-6 90-856159R1 AUGUST 1998 Shift and Throttle Cable Install cables into the remote control following the instructions provided with the remote control. NOTE: Install the shift cable to the engine first. The shift cable is the first cable to move when the remote control handle is moved out of neutral. Shift Cable Installation 1. Position remote control into forward gear. F 2. Remove cover. a a- Cover 3. Shift outboard into forward gear. a a- Rotate Shift Arm Forward OUTBOARD MOTOR INSTALLATION 4. Install cable to the shift lever. Secure with cable latch. 5. Adjust the cable barrel so that it fits into the anchor pocket. b a a-Cable Latch b-Cable Barrel 6. Check shift cable adjustment as follows: • Shift remote control into forward. The propeller shaft should be locked in gear. If not, adjust the barrel closer to the cable end. • Shift remote control into neutral. The propeller shaft should turn freely without drag. If not, adjust the barrel away from the cable end. Repeat steps a and b. • Shift remote control into reverse while turning propeller. The propeller shaft should be locked in gear. If not, adjust the barrel away from the cable end. Repeat steps a thru c. • Shift remote control back to neutral. The propeller shaft should turn freely without drag. If not, adjust the barrel closer to the cable end. Repeat steps a thru d. 90-856159R1 AUGUST 1998 Page 1D-7 OUTBOARD MOTOR INSTALLATION Page 1D-8 90-856159R1 AUGUST 1998 Throttle Cable Installation 1. Position remote control into neutral. N 2. Install throttle cable on pin. Lock in place with cable latch. 3. Adjust cable barrel until the link rod is centered in slot. a b c a- Shift Cable b- Cable Barrel c- Link Rod – Adjust Barrel so Link Rod is Centered in Slot IMPORTANT: After installation, move the remote control handle a few times from the neutral position to the wide-open-throttle position in forward gear. Move handle back to neutral and visually Check that the link rod is still centered. If necessary, readjust the barrel. 4. Reinstall cover. a a- Cover IGNITION ELECTRICAL Section 2A - Ignition Table of Contents 2 A Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-4 Electrical Components . . . . . . . . . . . . . . . . . . . . . 2A-6 Ignition Description . . . . . . . . . . . . . . . . . . . . . . . . 2A-8 Electronic Control Module (ECM) . . . . . . . . . 2A-8 Crank Position Sensor . . . . . . . . . . . . . . . . . . 2A-9 Ignition and Battery Charging Coils . . . . . . . 2A-9 Flywheel Assembly . . . . . . . . . . . . . . . . . . . . . 2A-9 Ignition Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-10 Ignition Test Procedures . . . . . . . . . . . . . . . . . . . 2A-10 Direct Voltage Adapter (DVA) . . . . . . . . . . . 2A-10 Ignition Troubleshooting . . . . . . . . . . . . . . . . . . . 2A-11 Tool: Multimeter/DVA Tester 91-99750A1 . 2A-12 Specifications Ignition Diagnostic Procedures . . . . . . . . . . . . . 2A-13 Recommended Test . . . . . . . . . . . . . . . . . . . 2A-13 Testing Ignition Components . . . . . . . . . . . . . . . 2A-15 Resistance Tests . . . . . . . . . . . . . . . . . . . . . . 2A-15 Flywheel Removal and Installation . . . . . . . . . . 2A-18 Flywheel Removal. . . . . . . . . . . . . . . . . . . . . 2A-18 Flywheel Installation . . . . . . . . . . . . . . . . . . . 2A-19 Timing Belt Removal and Installation . . . . . . . . 2A-20 Ignition Charge Coil Removal and Installation 2A-21 Ignition Coil Removal and Installation . . . . . . . 2A-22 Crank Position Sensor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-23 Rectifier/Regulator and ECM Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-24 IGNITION SYSTEM Readings taken @ 68°F (20°C). Type Spark Plug Type Gap Hex Firing Order Ignition Timing: Below 800 rpm @ 2800-3300 rpm Charge Coil Resistance Crank Position Sensor Resistance Ignition Coil Resistance: Capacitor Discharge Ignition NGK DPR6EA-9 0.035 in. (1.0 mm) 18 mm 1-2 5° B.T.D.C. 30° B.T.D.C. 270 - 410 W (BRN - BLU) 230 - 350 W (GRN/WHT - BLK) Primary Secondary (W/o Boots) ECM Engine Speed Limiter Spark Cut-Out Reduction (Percent ages of ignition spark are Cut-Out) ECM Low Oil Pressure Speed Control Oil Pressure Switch 0.16 - 0.24 W 3.9 - 5.9 kW 5850 rpm Approximately 2000 rpm Below 2.5 psi (17 kPa) Continuity Alternator Type 6 AMP Manual (Standard) Alternator: Single Phase (6 Pole) CHARGING Output 12 Volts-6 Amps. (Rectified) SYSTEM Readings taken @ Battery Charging Resistance 10 AMP Electric (Standard) Alternator: 0.48 - 0.72 Ohms (GRN-GRN) 68°F (20°C). Output 12V-10 Amps. (Rectified/Regulated) Battery Charging Coil Resistance 0.24 - 0.36 Ohms (GRN-GRN) Quicksilver Tachometer Setting “6C” or “2” 90-856159R1 AUGUST 1998 Page 2A-1 IGNITION Special Tools 1. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1 2. Flywheel Holder P/N 90-83163M 3. Flywheel Puller P/N 91-83164M Page 2A-2 90-856159R1 AUGUST 1998 IGNITION Notes: 90-856159R1 AUGUST 1998 Page 2A-3 IGNITION Flywheel 1 2 3 4 5 6 78 9 10 11 Page 2A-4 90-856159R1 AUGUST 1998 IGNITION Flywheel REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 NUT (M16) 80 110 2 1 WASHER 33 1 FLYWHEEL (MANUAL) 1 FLYWHEEL (ELECTRIC) 4 1 CHARGING COIL 5 2 BOLT (M6 x 25) 70 8 66 1 LIGHTING COIL (MANUAL) 1 LIGHTING COIL (ELECTRIC) 77 4 BOLT (M6 x 30) (MANUAL) 70 8 4 BOLT (M6 x 40) (ELECTRIC) 70 8 8 AR STA-STRAP 9 1 PULSER 10 2 BOLT (M6 x 16) 70 8 11 1 DECAL-Warning neutral 90-856159R1 AUGUST 1998 Page 2A-5 IGNITION Electrical Components 1 3 4 5 6 7 8 9 10 11 12 13 14 2 15 16 17 18 19 20 21 22 23 24 25 26 29 27 30 31 32 39 6 7 40 41 42 43 44 45 46 47 28 32 37 Loctite Pipe Sealant w/Teflon-567 (92-809822) 9 9 25 Liquid Neoprene (92-25711--2) 25 25 25 25 25 25 25 25 25 25 36 33 35 38 34 Page 2A-6 90-856159R1 AUGUST 1998 IGNITION Electrical Components REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 BRACKET (ELECTRIC) 1 1 BRACKET (MANUAL) 2 2 CLAMP 3 3 BOLT (M6 x 20) 70 8 4 1 BOLT (M6 x 25) 70 8 5 1 WASHER 6 4 GROMMET 7 4 COLLAR 8 1 RECTIFIER/REGULATOR 9 2 BOLT (M6 x 16) 70 8 10 1 CAP 11 1 CABLE (BROWN/WHITE) 12 1 CABLE 13 1 BRACKET 14 1 SOLENOID 15 2 WASHER 16 2 NUT (M6) 30 3.4 17 2 LOCKWASHER ELECTRIC 18 2 NUT (M6) 30 3.4 19 1 BOOT 20 1 LEAD WIRE 21 1 NUT (.250) 30 3.4 22 1 CABLE-Fuse 23 1 FUSE 24 1 CABLE-fuse 25 1 ENGINE WIRING HARNESS 26 1 RETAINER 27 1 BATTERY CABLE (POSITIVE) 28 1 BATTERY CABLE (NEGATIVE) 29 AR STA-STRAP 30 1 CABLE (HANDLE) 31 1 CDI UNIT 32 4 BOLT (M6 x 20) 70 8 33 1 IGNITION COIL 34 2 HIGH TENSION LEAD 35 2 GROMMET 36 1 OIL PRESSURE SWITCH 70 8 37 1 SCREW 18 2 38 1 LEAD WIRE 39 1 RECTIFIER/REGULATOR MANUAL 40 1 BOLT (M6 x 16) 70 8 41 1 SOLENOID COIL 42 1 BRACKET 43 1 HOOK WIRE ELECTRIC NON/HANDLE 44 2 SCREW (M5 x 8) 30 3.4 45 1 GROMMET 46 1 O RING 47 2 BOLT (M6 x 16) 70 8 90-856159R1 AUGUST 1998 Page 2A-7 IGNITION Ignition Description The ignition system uses CDI (Capacitor Discharge Ignition). This system provides quick voltage buildup and strong spark required for high power and high performance engines. The CDI ignition system does not incorporate mechanically operated points, therefor making this CDI unit virtually maintenance free. As the flywheel rotates, electrical power (alternating current) is produced by the capacitor charging coil. This power is rectified by diodes so that direct current voltage is utilized by the ignition system. When the ignition driver is off, the D.C. voltage is stored by the capacitor. Once capacitor voltage is charged to its potential, a gate signal is applied on the SCR and the residual current is dissipated through the capacitor charging coils. The electronic control module (ECM) activates the ignition driver in the ECM which allows the capacitor to discharge, causing the spark to occur. Ignition timing is regulated by the ECM which receives status input from a variety of sensors. These sensors include the crank position sensor, engine temperature and oil pressure sender. The voltage discharged to the primary winding of the ignition coil causes a surge of high voltage to be induced in the secondary winding of the ignition coil. This induced voltage of sufficient amplitude causes the spark plugs to fire. Ignition Component Description Electronic Control Module (ECM) Under normal operating conditions the ECM unit controls the following: 1. Controls ignition spark timing by monitoring the crank position sensor and the oil pressure sensor. 2. Maintains a normal idle timing of 5° BTDC. 3. Advances spark timing quickly to 30° BTDC under hard acceleration conditions. 4. Limits rpm of the engine in the event of a over speed condition (cavitation, no load on propeller, and/or under propped), as listed in the following steps: a. Soft Reduction: Ignition timing is gradually retarded to keep engine rpm below 5850. b. Spark Cut-Out Reduction: Percentages of ignition spark will be cut-out according to the degree of over speed rpm reached. 5. Low Oil Pressure Protection: Limits the engine rpm to 2000 if oil pressure drops below 2.5 psi (17 kPa). The ECM will turn on the Low Oil Pressure Warning lamp. NOTE:The ECM controls all timing operations. There are no timing adjustment required on this engine. Page 2A-8 90-856159R1 AUGUST 1998 IGNITION Crank Position Sensor Contains a permanent magnet and is positioned in front of the flywheel. The timed passing of the flywheel teeth through the sensor’s magnetic field enables the ECM to determine engine rpm and crankshaft angle. Ignition and Battery Charging Coils The coils located under the flywheel contains the Ignition charging coil and battery charging coils. As the flywheel permanent magnets pass the respective 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 The flywheel assembly contains six permanently charged magnet segments which are bonded and retained to the inner wall of the flywheel. Each magnet contains a north and a south pole providing a 12 pole system. 90-856159R1 AUGUST 1998 Page 2A-9 IGNITION Ignition Coil The primary (+) side of the ignition coil receives voltage discharged from a capacitor in the ignition (CDI) circuit located inside the ECM. The voltage is multiplied by the coil until it can jump the spark plug gap. The ignition coil will produce a high voltage current each crankshaft revolution, producing a spark at each cylinder at the same time (Waisted Spark Ignition). Ignition coil maximum output is approximately 40,000 volts. 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”. Page 2A-10 90-856159R1 AUGUST 1998 IGNITION • ALL COMPONENTS MUST BE GROUNDED during tests. Running or “cranking” engine with CDI or Ignition Coils ungrounded may damage components. * If using a meter with a built-in DVA, the DVA/400 or DVA/500 VDC test position should be used. NOTE:Test leads are not supplied with the Direct Voltage Adapter. Use test leads supplied with multi meter. Test procedures and specifications are provided for checking primary ignition voltage while the engine is running and/or being “cranked” with all harnesses connected. 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. 90-856159R1 AUGUST 1998 Page 2A-11 IGNITION Ignition Troubleshooting 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 - 280 (1) Ignition Charge Coil 400 DVA* Brown Ground 230 - 280 (1) Ignition Charge Coil 400 DVA* Blue Ground 20 - 45 (1) Stop Circuit 40 DVA Black/Yellow Ground 5 – 8 *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 Ignition Charge Coil Red Black Brown Blue R x 1 W 270 - 410 Battery Charge Coil (6 Amp.) Red Black Green Green R x 1 W 0.48-0.72 Battery Charge Coil (10 Amp.) Red Black Green Green R x 1 W 0.24-0.36 Crank Position Sensor Red Black White/Green Black R x 1 W 230 - 350 Ignition Coil Primary (with wires disconnected) Red Black Orange Black R x 1 W 0.16 - 0.24 Ignition Coil Secondary (test with coil leads disconnected and the high tension lead cap removed)*** Red Black High Tension Lead #1 High Tension Lead #2 k W 3.9 - 5.9 NOTE: Copper is an excellent conductor, however, resistance may notably vary between low and high temperature. Therefore, reasonable differences can be accepted between resistance readings and specifications. The above readings are for a cold (room temperature) engine. Resistance will increase if the engine is warm. *** High tension lead cap contain a 5k ohm resister. Remove caps when making secondary ignition coil test. Page 2A-12 90-856159R1 AUGUST 1998 IGNITION Ignition Diagnostic Procedures TROUBLESHOOTING TIP: With engine running, use inductive timing light to check spark advance of each cylinder as throttle is opened and closed. If timing advances and retards on each cylinder, ignition system is MOST LIKELY functioning properly. IMPORTANT: If outboard appears to have an ignition system failure, it is recommended that before beginning in-depth troubleshooting: • Ensure that the engine is mechanically sound condition. (Fuel System, Cylinder Compression etc.). • Check all engine ground leads for loose or corroded connections. • Disconnect and reconnect ignition harness connectors to verify proper continuity. SUGGESTED TESTING PROCEDURES NOTE:The following recommended tests and probable causes are not listed in any specific order. The technician should use this table as a guide to help isolate and test the specific problem/condition. Always perform the DVA tests first (if applicable), then perform resistance test to validate suspected component failure. *Recommended Test (1) DVA TEST (Direct Voltage Adapter) (2) OHM TEST (Resistance Testing) (3) Replace Component and Retest (4) Mechanical Test/Repair PROBLEM/CONDITION Probable Cause *Perform Test No. No Spark Condition (Both Cylinders) Crank Position Sensor 2 Stator 1-2 (ECM) Stop Circuit Short to Ground: 3 a - stop circuit lead 2 b - lanyard stop switch 2 c - tiller handle stop button (if supplied) 2 d - remote control harness 2 Ignition Coil 2 Primary Circuit Shorted to Ground 2 Spark Plugs Open Ground Condition: 3 a - ignition coil 2 b - stator ground 3 c - (ECM) 3 No Spark Condition (One Cylinder) High Tension Lead Spark Plug Cap (Resistor) Spark Plug 2 2 3 Engine Surges Over Boat Under Propped 4 5850 RPM While Under Load NOTE:The engine (ECM) will retard timing and reduce rpm above 5850 rpm. Propeller Hub Spun 4 Timing Fluctuates NOTE:It is considered normal for the timing to fluctuate approximately 1° - 2° within the designated timing window. Loss Of Oil Pressure: a - timing retards and fluctuates, rpm will drop below 2000 rpm Flywheel Key Sheared (ECM) Unit 4 4 3 90-856159R1 AUGUST 1998 Page 2A-13 IGNITION 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 (ECM) 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 (ECM) Unit Ground Connection: 3 a - (ECM) 3 b - Ignition coil 2 c - Ignition charge coil 2 Engine Will Not Run Over 2000 rpm Low Oil Pressure: a - timing retards and fluctuates, rpm will remain below 2000 rpm 4 Ignition Charge Coil 1-2 Ignition Coil/High Tension Lead(s) 2 (ECM) 3 Spark Plug(s) 3 Engine Occasionally Misfires Ignition Charge Coil 1-2 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 - (ECM) 3 c - Ignition Charge Coil High Resistance To Ground at: 2 a - stop/lanyard switch (water/corrosion) 2 (ECM) 3 Weak Spark Condition Ground Connection at: a - Ignition Coil Primary Leads 2 b - Ignition Charge Coil 2 c - (ECM) Primary Coil Supply Leads High Resistance To Ground at: 3 a - stop/lanyard switch (water/corrosion) 2 Weak Ignition Charge Coil 1-2 Ignition Coil/High Tension Lead(s) 1-3 Spark Plug(s) 2 Spark Plug Cap (Resistor) 3 Spark Plug Cap Leak 3 (ECM) Failure 3 Page 2A-14 90-856159R1 AUGUST 1998 IGNITION Testing Ignition Components Resistance Tests When performing resistance tests, all component leads must be disconnected. Readings may very slightly due to temperature changes. NOTE:Readings listed taken at 68° (20° C). IGNITION CHARGE COIL BLUBRN GRN-WHTGRNGRN DCV ACV DVA METER TEST LEADS METER SCALE READING () RED BLACK RX1RX1 270 410270 - 410BROWN BLUE SPARK PLUG CAP REMOVAL NOTE:High tension cables must have spark plug cap removed before testing. Cap contains 5k ohm resistor. IMPORTANT: To remove spark plug cap from high tension leads, turn cap counter clockwise while applying slight outward pressure. DO NOT PULL HARD or lead may be damaged. To install cap, turn cap clockwise threading cap onto high tension lead. 55852 90-856159R1 AUGUST 1998 Page 2A-15 IGNITION SPARK PLUG CAP RESISTOR TEST 55853 METER TEST LEADS METER SCALE READING () RED BLACK RX1KRX1K 35-523.5 -5.2WIRE END PLUG END IGNITION COIL (SECONDARY) #1 # 2 DCV ACV DVA METER TEST LEADS METER SCALE READING () RED BLACK RX1KRX1K 39 593.9 - 5.9#1 CABLE #2 CABLE Page 2A-16 90-856159R1 AUGUST 1998 IGNITION IGNITION COIL (PRIMARY) DCV ACV DVA METER TEST LEADS METER SCALE READING () RED BLACK RX1RX1 016 0240.16 - 0.24ORANGE BLACK CRANK POSITION SENSOR BLKWHT-GRN DCV ACV DVA METER TEST LEADS METER SCALE READING () RED BLACK RX1RX1 230 350230 - -- 350WHITE/GREEN BLACK 90-856159R1 AUGUST 1998 Page 2A-17 IGNITION Flywheel Removal and Installation WARNING Engine could possibly start when turning flywheel during removal and installation. To prevent this type of accidental engine starting and possible serious injury, always remove spark plug leads from spark plugs. Flywheel Removal 1. Disconnect spark plug leads from spark plugs. 2. Remove the two screws and rotate the front cover forward. a b a-Screws (2) b-Front Cover 3. Remove three bolts and then remove the flywheel cover. a b a-Bolts (3) b-Flywheel Cover Page 2A-18 90-856159R1 AUGUST 1998 IGNITION 90-856159R1 AUGUST 1998 Page 2A-19 4. Hold flywheel using flywheel holder. Remove nut (30 mm) and washer. b c a 91-83163M a- Flywheel Holder (P/N 91-83163M) b- Nut c- Washer 5. Loosen flywheel using flywheel puller. Remove Flywheel. b a 91-83164M a- Flywheel Puller (P/N 91-83164M) b- Flywheel Key Flywheel Installation 1. Place flywheel key into slot. 2. Install flywheel. 3. Hold flywheel using flywheel holder (91-83163M) and tighten nut to the specified torque. a c b a- Key b- Washer c- Nut Flywheel Nut Torque 80 lb-ft (110 Nm) IGNITION Page 2A-20 90-856159R1 AUGUST 1998 Timing Belt Removal and Installation CAUTION The valves may occur damage if the driven gear or drive gear are rotated when the timing belt is removed or incorrectly installed. IMPORTANT: To prevent valve damage If the timing marks are out of alignment, bring the timing marks into alignment as follows: 1. Rotate the drive gear timing mark 90° away from its alignment mark without going past the alignment mark. 2. Rotate the driven gear timing mark into alignment. 3. Rotate the drive gear timing mark into alignment, 4. Install timing belt with hands. 1 c b c a a- Drive Gear Timing Mark b- Driven Gear Timing Mark c- Alignment Marks IGNITION 90-856159R1 AUGUST 1998 Page 2A-21 Ignition Charge Coil Removal and Installation 1. Remove and install flywheel. Refer to Flywheel Removal and Installation. 2. Remove and install the charge coil as shown. 3. Refer to Section 2 Part D for wiring Diagrams. 4. Fasten wiring together with sta-strap. c b a a- Stator b- Bolts (2) – M6 × 25 c- Sta-Strap – Fasten Wiring Together Stator Bolt Torque 70 lb-in. (8 Nm) IGNITION Page 2A-22 90-856159R1 AUGUST 1998 Ignition Coil Removal and Installation 1. Remove and install ignition coil as shown. 2. Refer to Section 2 Part D for wiring Diagrams. 3. Fasten wiring together with sta-strap. a b c a- Ignition Coil b- Bolts (2) M6 × 20 c- Sta-Strap – Fasten Wiring Together Ignition Coil Mounting Bolt Torque 70 lb-in. (8 Nm) IGNITION Crank Position Sensor Removal and Installation 1. Electric Start Models – Remove and install flywheel. Refer to Flywheel Removal and Installation. 2. Remove and install trigger coil as shown. 3. Refer to Section 2 Part D for wiring Diagrams. 4. Fasten wiring together with sta-strap. a b c a-Trigger Coil b-Bolts (2) – M6 × 16 c-Sta-Straps – Fasten Wiring Together Trigger Coil Mounting Bolt Torque 70 lb-in. (8 Nm) 90-856159R1 AUGUST 1998 Page 2A-23 IGNITION Page 2A-24 90-856159R1 AUGUST 1998 Rectifier/Regulator and ECM Removal and Installation FRONT BRACKET REMOVAL 1. Remove the four bolts fastening the bracket. Gain access to the bottom two bolts through the front openings in the bottom cowl as shown. Tiller Handle Models a a- Bracket Remote Control Models a a- Bracket IGNITION FRONT BRACKET INSTALLATION 1. Route the wiring harness from the rectifier/regulator out the side above the lower mounting bolts. IMPORTANT: To prevent interference between the rectifier/regulator wiring harness and shift linkage, route the wiring harness out sideways above the lower mounting bolts as shown. 2. Install the front bracket with four bolts. 3. Refer to Section 2 Part D for wiring diagrams. b a b d e c a-Front Bracket b-Wiring Harness (Rectifier/Regulator) – Route Out Sideways Above Mounting Bolts c-Bolts (3) – M6 × 16 d-Bolt – (1) – M6 × 25 e-Washer Front Bracket Mounting Bolt Torque 70 lb-in. (8 Nm) 90-856159R1 AUGUST 1998 Page 2A-25 IGNITION Page 2A-26 90-856159R1 AUGUST 1998 RECTIFIER/REGULATOR 1. Remove and install rectifier/regulator to and from bracket as shown. 2. Refer to Section 2 Part D for wiring diagrams. 6 Amp Regulator c a b a- 6 Amp Regulator b- Bracket c- Bolt – M6 × 16 10 Amp Regulator 55864 a b c a- 10 Amp Regulator b- Bracket c- Bolt (2) – M6 × 16 Rectifier/Regulator Mounting Bolt Torque 70 lb-in. (8 Nm) IGNITION ECM 1. Remove and install the front bracket following instructions preceding. 2. Remove and install ECM as shown. IMPORTANT: Support ribs on mounting flanges must face in towards engine. 3. Refer to Section 2 Part D for wiring diagrams. c b a a-Support Ribs On The Mounting Flanges Must Face In Toward Engine b-ECM c-Bolt (2) – M6 × 20 ECM Mounting Bolt Torque 70 lb-in. (8 Nm) 90-856159R1 AUGUST 1998 Page 2A-27 CHARGING & STARTING SYSTEM ELECTRICAL Section 2B - Charging & Starting System Table of Contents 2 B Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Recommended Battery. . . . . . . . . . . . . . . . . . 2B-2 Battery Charging System Troubleshooting . 2B-2 Battery Charging System – Manual Start Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3 Battery Charging System – Electric Start Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-4 Battery Charging System Tests . . . . . . . . . . . . . . 2B-5 Testing The Battery Charging Coil . . . . . . . . 2B-5 Testing The Battery Charging System . . . . . 2B-6 Testing The Rectifier/Regulator (Diode Test) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-8 Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9 Specifications Starter Motor Amperes Draw . . . . . . . . . . . . . 2B-9 Starting System Components . . . . . . . . . . . . 2B-9 Troubleshooting the Starting Circuit . . . . . . . 2B-9 Starter Solenoid Test . . . . . . . . . . . . . . . . . . . 2B-10 Starting System Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-11 Starter Motor Components . . . . . . . . . . . . . . . . 2B-13 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-14 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-14 Cleaning and Inspection . . . . . . . . . . . . . . . . 2B-16 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-17 Brush Replacement. . . . . . . . . . . . . . . . . . . . 2B-19 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-20 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-23 Alternator Type 6 AMP Manual (Standard) Alternator: Single Phase (6 Pole) CHARGING Output 12 Volts-6 Amps. (Rectified) SYSTEM Readings taken @ Battery Charging Resistance 10 AMP Electric (Standard) Alternator: 0.48 - 0.72 Ohms (GRN-GRN) 68°F (20°C). Output 12V-10 Amps. (Rectified/Regulated) Battery Charging Coil Resistance 0.24 - 0.36 Ohms (GRN-GRN) Quicksilver Tachometer Setting “6C” or “2” STARTING SYSTEM Electric Start: Starter Type Output Ampere Draw Under: (Load) (No Load) Bendix 0.8 kW 106.0 Amps 21.1 Amps Battery Rating Minimum Requirement 465 Marine Cranking Amps (MCA) BATTERY or 350 Cold Cranking Amps (CCA) For operation below 32° F (0° C) 1000 Marine Cranking Amps (MCA) or 775 Cold Cranking Amps (CCA) 90-856159R1 AUGUST 1998 Page 2B-1 CHARGING & STARTING SYSTEM Special Tools 1. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1 Battery Recommended Battery A 12 volt battery with a minimum rating of 465 marine cranking amps (MCA) or 350 cold cranking amps (CCA). For operation below 32° F (0° C) a rating of 1000 Marine Cranking Amps (MCA) or 775 Cold Cranking Amps (CCA) is recommended. Battery Charging System Troubleshooting CAUTION The charging system may be damaged by: 1) reversed battery cables, 2) running the engine with battery cables disconnected and stator leads connected to rectifier, and 3) 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. Page 2B-2 90-856159R1 AUGUST 1998 CHARGING & STARTING SYSTEM Battery Charging System – Manual Start Models Manual start models are equipped with a 6 Amp battery charging system. If battery charging is required, order Quicksilver Battery Charging Harness Kit (856558A1). This kit contains the wiring harness for the battery connection. An optional Quicksilver high output 10 Amp alternator kit (856557A1) is also available for manual start models. Description: The battery charging system components are the battery charging coil, rectifier/regulator and battery. Alternating current (generated in charging coils) flows to the rectifier/regulator, which changes the alternating current to a regulated direct current for charging the battery. a-Battery Charging Coil b-Rectifier/Regulator c-Battery Color Code Blk = Black Blu = Blue Brn = Brown Gry = Gray Grn = Green Orn = Orange Pnk = Pink Pur = Purple Red = Red Tan = Tan Wht = White Yel = Yellow GRN-WHT GRN RED BLK GRN GRN GRN GRN-WHT GRN RED + – 6 AMP Battery Charging System WHT-GRN GRN-WHT GRN RED RED BLK GRN-WHT GRN GRN RED Optional 10 AMP Battery Charging System + – b d c a b d c a d-Optional Harness Kit (856558A1) 90-856159R1 AUGUST 1998 Page 2B-3 CHARGING & STARTING SYSTEM Battery Charging System – Electric Start Models Description: The battery charging system components are the stator lighting coils, rectifier/regulator and battery. Alternating current (generated in charging coil) flows to the rectifier/regulator, which changes the alternating current to a regulated direct current for charging the battery. Blk = Black Blu = Blue Brn = Brown Gry = GrayGrn = Green Orn = OrangePnk = Pink Pur = PurpleRed = Red Tan = Tan WHT-GRN GRN-WHT GRN RED REDBLK RED BLK W/RED SLEEVE RED + – GRN-WHT GRN GRN RED b a c d e Wht = White Yel = Yellow a-Battery Charging Coil b-Rectifier/Regulator c-Battery d-20 Ampere Fuse e-Starter Solenoid Page 2B-4 90-856159R1 AUGUST 1998 CHARGING & STARTING SYSTEM Battery Charging System Tests Testing The Battery Charging Coil NOTE:Charging coil can be tested without removing from engine. 1. Disconnect the charging coil leads. 2. Use an 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. BLUBRN GRN-WHTGRNGRN DCV ACV DVA 6 Amp Charging Coil METER TEST LEADS METER SCALE READING () RED BLACK RX1RX1 048 072 0.48 - 0.72GRN GRN 10 Amp Charging Coil METER TEST LEADS METER SCALE READING () RED BLACK RX1RX1 024 036 0.24 - 0.36GRN/WHT GRN 90-856159R1 AUGUST 1998 Page 2B-5 CHARGING & STARTING SYSTEM Testing The Battery Charging System 6 AMP BATTERY CHARGING COIL 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/Regulator must be functioning properly for accurate test results to be obtained. 1. Disconnect the red lead from rectifier/regulator. 2. Connect RED (+) ammeter lead to the rectifier/regulator RED wire and BLACK (–) ammeter lead to the disconnected lead. 3. With engine running at the indicated RPM, the ammeter should indicate the following approximate amperes: DCV ACV DVA RED BLK 6 Amp6 Amp Charging Coilgg RPM AMPERES 1000 2.0 2000 4.1 3000 5.0 4000 5.3 5000 5.5 4. If proper ampere readings are not obtained, replace battery charging coil. Page 2B-6 90-856159R1 AUGUST 1998 CHARGING & STARTING SYSTEM 10 AMP BATTERY CHARGING COIL 1. Check battery voltage at battery with engine running. 2. If battery voltage is above 14.5-15.0 volts, replace voltage rectifier/regulator. Check condition of battery as overcharging may have damaged battery. 3. If battery voltage is below 14.5 volts, charge battery; refer to “CHARGING A DISCHARGED BATTERY”. If battery can NOT be satisfactorily charged, replace battery. 4. If battery accepts a satisfactory charge, check battery voltage while cranking engine; refer to “CHARGING A DISCHARGED BATTERY”. If cranking voltage is not acceptable, replace battery. 5. If cranking voltage is acceptable, disconnect 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. DCV ACV DVA RED RED 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 Amp Charging Coil Charging Coil RPM AMPERES 1000 1.0 2000 5.8 3000 8.0 4000 8.8 5000 9.1 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 battery charging coil; refer to “Ohm Testing The Battery Charging Coil”. If stator tests OK, replace rectifier/ regulator. 90-856159R1 AUGUST 1998 Page 2B-7 CHARGING & STARTING SYSTEM Testing The Rectifier/Regulator (Diode Test) 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. 6 AMP 10 AMP WHT-GRN RED BLK GRN-WHT GRN RED BLK GRN-WHT GRN GRN-WHT GRN RED 6 AMP RECTIFIER/REGULATOR DIODE TEST – DIGITAL METER ( SCALE) Red (+) Meter Lead To: Black Green/White Green Red Red Red Green/White 0.30 to 0.80 – OUCH or 8OUCH Green 0.30 to 0.80 OUCH – OUCH Red 0.65 to 2.0 0.30 to 0.80 0.30 to 0.80 – OUCH = OL = Full Meter Deflection 10 AMP RECTIFIER/REGULATOR DIODE TEST - DIGITAL METER ( SCALE) Red (+) Meter Lead To: Black Green/White Green White/Green Red Black – 1.0 to OUCH 1.0 to OUCH 1.2 to OUCH OUCH Green/White 0.30 to 0.80 – 1.2 to OUCH 0.30 to 0.80 OUCH Green 0.30 to 0.80 1.2 to OUCH – 1.5 to OUCH OUCH White/Green OUCH OUCH OUCH – OUCH Red 0.65 to 1.2 0.30 to 0.80 0.30 to 0.80 0.65 to 1.3 – OUCH = OL = Full Meter Deflection Page 2B-8 90-856159R1 AUGUST 1998 CHARGING & STARTING SYSTEM Starting System Starter Motor Amperes Draw Starter Motor No Load Ampere Draw* Normal Ampere Draw* Part No. 50-852570 14.2 41.5 Starter Motor Teeth 9 *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 The starter motor may be damaged if operated continuously. DO NOT operate continuously for more than 30 seconds. Allow a 2 minute cooling period between starting attempts. Troubleshooting the Starting Circuit Before beginning the starting circuit troubleshooting flow chart, following, check first for the following conditions: 1. Make sure that battery is fully charged. 2. Check that control lever is in “NEUTRAL” position. 3. Check terminals for corrosion and loose connections. 4. Check cables and wiring for frayed and worn insulation. 5. Check in-line fuse in RED wire; see diagram. 90-856159R1 AUGUST 1998 Page 2B-9 CHARGING & STARTING SYSTEM Starter Solenoid Test 1. Disconnect all wires from solenoid. 2. Connect ohmmeter (R × 1 scale) between terminals 1 and 2. 3. Connect a 12 volt power supply between terminals 3 and 4. Solenoid should click and meter should read 0 ohms (full continuity). 4. If meter does not read 0 ohms (full continuity), replace solenoid. DCV ACV DVA 1 24 3 Page 2B-10 90-856159R1 AUGUST 1998 CHARGING & STARTING SYSTEM Starting System Troubleshooting Flow Chart The following “STARTING CIRCUIT TROUBLESHOOTING FLOW CHART” is designed as an aid to troubleshooting the starting circuit. This flow chart will accurately locate any existing malfunction. Location of “TEST POINTS” (called out in the chart) are numbered in diagram below. a-Battery b-Starter Solenoid c-20 Ampere Fuse d-Key Switch e-Start Button f-Neutral Start Switch g-Starter Motor Color Code Blk = Black Blu = Blue Brn = Brown Gry = Gray Grn = Green Orn = Orange Pnk = Pink Pur = Purple Red = Red Tan = Tan Wht = White Yel = Yellow + – Blk Blk Red Blk Brn + – Blk Blk Blk Yel/Red Red Yel/Red Blk/Yel Yel/Red Blk/Yel Remote Control Models Tiller Handle Models Yel/Red Red Blk Red Red Red Blk Brn a c 7 g c 1 5 7 g a e 41 f2 b f 4d 3 6 b 2 3 6 1 51 Starter Motor Does Not Turn SAFETY WARNING: Disconnect BLACK (starter motor) cable from starter solenoid test point 1 BEFORE making tests 1-thru-7 to prevent unexpected engine cranking. TEST 1 Use an ohmmeter (R x 1 scale) and connect meter leads be- tween NEGATIVE (-) battery post and common powerhead ground. No continuity indicated; there is an open circuit in the BLACK NEGATIVE (-) battery cable between the NEGATIVE (-) battery post and the powerhead. • Check cable for loose or corroded connections. • Check cable for open. Continuity Indicated Proceed to TEST 2, on next page. 90-856159R1 AUGUST 1998 Page 2B-11 CHARGING & STARTING SYSTEM a. Disconnect BLACK ground wire from Test Point 2. b. Connect voltmeter between common engine ground and Black ground wire. c. Turn ignition key to “Start” or push-in the start button. * 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. b. Connect voltmeter between common engine ground and Test Point 3. c. Turn ignition key to “Start” or push-in the start button. 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 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” or push-in the start button. Defective starter solenoid. Connect voltmeter between common engine ground and Test Point 5. Defective ignition switch or start button. Connect voltmeter between common engine ground and Test Point 6. No voltage reading; check BLACK wire be- tween battery (+) positive terminal and Test Point 6. Check fuse in RED wire between test points 5 and 6. Check for open RED wire between test points 5 and 6. a. Connect voltmeter between common engine ground and Test Point 1. b. Turn ignition key to “Start” position or push-in the start button. No voltage reading; De- fective starter solenoid. Should hear solenoid click; proceed to TEST 8. a. Reconnect Black (starter motor) cable to starter solenoid. b. Connect voltmeter between common engine ground and Test Point 7 c. Turn ignition key to “Start” position or push-in the start button. 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. Page 2B-12 90-856159R1 AUGUST 1998 CHARGING & STARTING SYSTEM Starter Motor Components 95 3 4 5 6 7 8 9 10 11 12 1 10 2 1 95 2-4-C w/Teflon (92-850736A1) REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 3 BOLT (M8 x 45) 15 20.3 2 1 WASHER (BOTTOM) 3 1 STARTER MOTOR 4 2 THRU BOLT 70 8 5 1 DRIVE KIT 6 1 DRIVE ASSEMBLY 7 1 DRIVE CAP 8 1 ARMATURE 9 1 COMMUTATOR CAP 10 1 BRUSH & SPRING KIT 11 1 BRUSH HOLDER 12 2 SCREW 30 3.4 90-856159R1 AUGUST 1998 Page 2B-13 CHARGING & STARTING SYSTEM Starter Motor Removal WARNING Always disconnect the battery and remove spark plug leads from spark plugs before working on motor. 1. Disconnect battery leads from battery. 2. Remove flywheel cover. 3. Remove the rubber plug. 4. Remove 3 bolts. Remove starter. 56688 a b a-Bolts (3) b-Rubber Plug Disassembly 1. Scribe alignment marks on the end caps and frame for correct reassembly. a a-Alignment Marks Page 2B-14 90-856159R1 AUGUST 1998 CHARGING & STARTING SYSTEM 2. Remove 2 thru-bolts from the starter motor. 3. Tap the commutator end cap to loosen it and then remove the end cap. a b a-Thru Bolts b-Commutator End Cap 4. Tap the drive end cap to loosen it and pull armature from the frame. b a a-Drive End Cap b-Frame 5. If removal of the pinion is necessary, pull-off the rubber cap and push down the pinion stopper and remove the circlip. b a a-Pinion Stopper b-Circlip (discard and use new circlip on assembly) 6. Remove remaining components from the armature shaft. a b c a-Pinion Stopper b-Spring c-Retainer – Rubber Cap 90-856159R1 AUGUST 1998 Page 2B-15 CHARGING & STARTING SYSTEM Cleaning and Inspection 1. Clean all motor parts. 2. Check pinion teeth for chips, cracks or excessive wear. 3. Replace the drive clutch spring and/or collar, if tension is not adequate, or if wear is excessive. 4. Check that the brush holder is not damaged or is not holding the brushes against the commutator. 5. Replace brushes that are pitted or worn to less than 1/4 in. (6.4 mm) in length. Refer to “BRUSH REPLACEMENT”, following. 1/4 in. (6.3 mm) 6. Replace a damaged or excessively worn bushing in the end cap. 7. Check the armature conductor (commutator bar junction) for a firm connection. A poor connection usually results in a burned commutator bar. 8. Re-surface and undercut a rough commutator, as follows: • Re-surface the commutator and undercut the insulation between the commutator bars .03 in. (0.8mm) to the full width of the insulation, make sure that the undercut is flat. • Clean the commutator slots after undercutting. • De-burr the commutator lightly with No. 00 sandpaper, then clean the commutator. • Check the armature on a growler for shorts. See “TESTING”, following. 9. Open-circuited armatures often can be saved where and open circuit is obvious and repairable. The most likely place for an open circuit is at the commutator bars. Long cranking periods overheat the starter motor so that solder in the connections melts. The poor connections cause arcing and burning of the commutator bars. 10. Repair bars, that are not too badly burned, by re-soldering the leads in bars (using rosin flux solder) and turning down the commutator in a lathe to remove burned material, then undercut the mica. 11. Clean out the copper or brush dust from slots between the commutator bars. 12. Check the armature for shorts and ground. See “TESTING”. Page 2B-16 90-856159R1 AUGUST 1998 CHARGING & STARTING SYSTEM Testing ARMATURE TEST FOR SHORTS Check armature for short circuits by placing on growler and holding hack saw blade over armature core while armature is rotated. If saw blade vibrates, armature is shorted. Recheck after cleaning between commutator bars. If saw blade still vibrates, replace armature. ARMATURE TEST FOR GROUND 1. Set ohmmeter to (R x 1 scale). Place one lead of ohmmeter on armature core (or shaft) and other lead on commutator, as shown. 2. If meter indicates continuity, armature is grounded and must be replaced. 11675 90-856159R1 AUGUST 1998 Page 2B-17 CHARGING & STARTING SYSTEM CHECKING POSITIVE BRUSHES AND TERMINALS 1. Connect ohmmeter (R x 1 scale) leads between positive brushes. 2. Ohmmeter must indicate full continuity (zero resistance). If resistance is indicated, check lead to positive terminal solder connection. If connection cannot be repaired, brushes must be replaced. Refer to “BRUSH REPLACEMENT”. a 11673 a-Positive Brushes TESTING NEGATIVE BRUSHES FOR GROUND Set ohmmeter to (R x 1 scale). Place one lead of ohmmeter on the negative brush and the other lead on the end cap (bare metal). If the meter indicates NO continuity, replace the negative brush. Repeat this procedure on the other negative brush. a b a-Negative (-) Brushes b-End Cap Page 2B-18 90-856159R1 AUGUST 1998 CHARGING & STARTING SYSTEM Brush Replacement 11660 ab c d e f g a-Positive (+) Terminal b-Long Brush Lead c-Push Lead Into Slot d-Insulating Washer e-Flat Washer f-Lock Washer g-Nut 11656 a bc d d b a a-Positive (+) Brushes b-Negative (–) Brushes c-Brush Holder d-Bolts (Fasten Negative Brushes and Holder) 90-856159R1 AUGUST 1998 Page 2B-19 CHARGING & STARTING SYSTEM Reassembly 1. Lubricate helix threads and drive end cap bushing with SAE 10W oil. 2. Install the pinion, spring, and pinion stopper onto starter shaft. 3. Place circlip into groove on shaft. 4. Press the pinion stopper over the circlip. IMPORTANT: Install new circlip for reassembly. NOTE:Make sure the circlip fits tightly into pinion stopper. a b c d e b c d e f a-Rubber Cap b-Circlip c-Pinion Stopper d-Spring e-Retainer – Rubber Cap (Spring Should Set Inside) f-Pinion Page 2B-20 90-856159R1 AUGUST 1998 CHARGING & STARTING SYSTEM 5. Construct a brush retainer tool as shown. 18-Gauge Sheet Metal METRIC SCALE 3” 2” 1-3/4” 1-11/16” 3/4” 1/2” = 76.2mm = 50.8mm = 44.5mm = 42.9mm = 19.1mm = 12.7mm 90-856159R1 AUGUST 1998 Page 2B-21 CHARGING & STARTING SYSTEM 6. Lubricate bushing with one drop of SAE 10W oil. DO NOT over-lubricate. 7. Position armature into frame so that commutator end of armature is at end of frame where permanent magnets are recessed 1-1/16 in. (27.0 mm). Align marks as shown. 11661 a b a-Brush Retainer Tool b-Bushing 8. Install commutator end cap onto starter frame; align marks as shown, and remove brush retainer tool. 9. Install thru bolts and torque to 70 lb–in. (7.8 Nm). 52659 1-1/16 in. (27.0 mm) a b c c b a-Frame Magnets Recessed 1-1/16 in. (27.0 mm) b-Alignment Marks c-Thru Bolts - Torque to 70 lb-in. (7.8 Nm) Page 2B-22 90-856159R1 AUGUST 1998 CHARGING & STARTING SYSTEM Installation 1. Secure starter to block with 3 bolts. Torque bolts to 15 lb-ft (20.3 Nm). Secure battery cable along with upper bolt. 2. Reinstall the rubber plug. 56688 a b c a-Bolts (3) M8 × 45 - Torque to 15 lb-ft (20.3 Nm) b-Battery Cable c-Rubber Plug 90-856159R1 AUGUST 1998 Page 2B-23 TIMING, SYNCHRONIZING & ADJUSTING ELECTRICAL Section 2C - Timing, Synchronizing & Adjusting Table of Contents 2 C Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1 Checking Ignition Timing . . . . . . . . . . . . . . . . 2C-2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1 Specifications IGNITION SYSTEM Readings taken @ 68°F (20°C). Type Spark Plug Type Gap Hex Firing Order Ignition Timing: Below 800 rpm @ 2800-3300 rpm Charge Coil Resistance Crank Position Sensor Resistance Ignition Coil Resistance: Capacitor Discharge Ignition NGK DPR6EA-9 0.035 in. (1.0 mm) 18 mm 1-2 5° B.T.D.C. 30° B.T.D.C. 270 - 410 W (BRN - BLU) 230 - 350 W (GRN/WHT - BLK) Primary Secondary (W/o Boots) ECM Engine Speed Limiter Spark Cut-Out Reduction (Percent ages of ignition spark are Cut-Out) ECM Low Oil Pressure Speed Control Oil Pressure Switch 0.16 - 0.24 W 3.9 - 5.9 kW 5850 rpm Approximately 2000 rpm Below 2.5 psi (17 kPa) Continuity Special Tools 1. Timing Light P/N 91-99379 90-856159R1 AUGUST 1998 Page 2C-1 TIMING, SYNCHRONIZING & ADJUSTING 2. DMT 2000 Digital Tachometer Multi-meter P/N 91-854007A1 Checking Ignition Timing NOTE:The ignition ECM unit electronically controls the ignition timing, therefore making the ignition timing non adjustable. When initially running the outboard, use a timing light to verify that the ignition timing falls within the timing ranges as described within the following tests. If the ignition timing does not stay within the timing ranges, refer to the Ignition Diagnostic Procedures tests in Section 2A. 1. Connect timing light to no.1 spark plug lead. 2. With outboard in water, start engine and allow to warm up. 3. Set engine speed at idle speed. Visually check the timing pointer to verify it is within the required timing range on the flywheel. If not, refer to Diagnostic Test Procedure in Section 2A. 5 30 5 a a-Idle Speed (Full Retarded) Timing Range Page 2C-2 90-856159R1 AUGUST 1998 TIMING, SYNCHRONIZING & ADJUSTING 4. Slowly increase engine speed more than 3000 rpm. Visually check the timing pointer to verify the ignition timing advances to the full advanced range. If not, refer to Diagnostic Test Procedure in Section 2A. 5 30 5 30 a a-Full Advanced Timing Range 90-856159R1 AUGUST 1998 Page 2C-3 WIRING DIAGRAMS ELECTRICAL Section 2D - Wiring Diagrams Table of Contents 2 D Electric Start Tiller Handle Models Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-2 Electric Start Remote Control Models Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-3 Manual Start Models Wiring Diagram . . . . . . . . 2D-4 Electric Start Tiller Handle Models Wiring Locations . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-5 Electric Start Remote Control Models Wiring Locations . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-6 Manual Start Models Wiring Locations . . . . . . . 2D-7 90-856159R1 AUGUST 1998 Page 2D-1 WIRING DIAGRAMS Electric Start Tiller Handle Models Wiring Diagram PNK BLUBRN BLUBRNBLKBLKYEL-RED WHT PNK BLK PNK ORG BLKBLK ORG WHT-GRNGRN-WHTGRN RED REDBLK RED RED BLK W/RED SLEEVE BLKBLK W/RED SLEEVE PNKYEL-REDBLK W/BRN SLEEVEBRN BLK BLK-YEL BLK-YEL BLK BLK-YEL RED + – WHT-GRNWHT-GRN BLK W/YEL SLEEVEBLK YEL-RED YEL-REDREDBLKBLKBLK-YELGRN-WHTGRNGRNRED BLK = BlackBLU = BlueBRN = BrownGRY = GrayGRN = GreenORN = OrangePNK = PinkPUR = PurpleRED = RedTAN = TanWHT = WhiteYEL = Yellow a c d f h i j p l m k b o e n g a-Crank Position Sensor b-Ignition Charge Coil c-Oil Pressure Switch d-Ignition Coil e-Push Button Start Switch f-Rectifier/Regulator g-Push Button Stop Switch h-Start Solenoid i-12 V Battery j-20 Amp Fuse k-Battery Charging Coils l-Neutral Start Switch m-Lanyard Stop Switch n-Oil Lamp o-ECM p-Starter Page 2D-2 90-856159R1 AUGUST 1998 WIRING DIAGRAMS Electric Start Remote Control Models Wiring Diagram PNK BLUBRN BLUBRNBLKWHT-GRNWHT-GRNBLK YEL-REDWHTPNKBLK PNK ORG BLKBLK ORG BLK-YEL PPL BLKGRYYEL-BLKYEL-RED RED BLU WHT-GRNGRN-WHTGRN RED REDBLK GRN-WHTGRNGRN BRN-WHT BRN RED RED BLK W/RED ENDS BLKBLK W/RED SLEEVE TAN-WHTTAN-BLK BLK RED YEL-RED YEL-BLK GRY BLK BLK-YEL PPL BRN-WHT BLK 12345678 C + – RED BLK = BlackBLU = BlueBRN = BrownGRY = GrayGRN = GreenORN = OrangePNK = PinkPUR = PurpleRED = RedTAN = TanWHT = WhiteYEL = Yellow a f h i k l j c d e n b m g a-Crank Position Sensor b-Ignition Charge Coil c-Battery Charging Coils d-Oil Pressure Switch e-Ignition Coil f-Rectifier/Regulator g-Remote Control Connector h-Start Solenoid i-12 V Battery j-20 Amp Fuse k-Starter l-Electric Choke m-Oil Lamp n-ECM 90-856159R1 AUGUST 1998 Page 2D-3 WIRING DIAGRAMS Manual Start Models Wiring Diagram a-Crank Position Sensor b-Ignition Charge Coil c-Oil Pressure Switch d-Ignition Coil e-Battery Charging Coils f-Rectifier/ Regulator BLK = BlackBLU = BlueBRN = BrownGRY = GrayGRN = GreenORN = OrangePNK = PinkPUR = PurpleRED = RedTAN = TanWHT = WhiteYEL = Yellow PNK BLUBRN BLUBRNBLKWHT-GRNWHT-GRNBLKYEL-RED WHT PNK BLK PNK ORG BLKBLK ORG GRN-WHTGRN REDBLK GRNGRNGRN PNKYEL-RED BLK BLK-YELBLK BLK-YEL BLY-YEL BLKBLK BLK—YELGRN-WHTGRN a d f h c b j e i g g-Push Button Stop Switch h-Lanyard Stop Switch i-Oil Lamp j-ECM Page 2D-4 90-856159R1 AUGUST 1998 BLK BLK RED BLK W/RED SLEEVE BLK W/RED ENDS YEL-RED PNK ORN BLK BLU BRN BLK WHT-GRN BLK WHT-GRN GRN-WHT GRN WHT-GRN YEL-RED YEL-RED BLK-YEL BLK-YEL BLK BLK BLK BLK BKK-YEL WHT RED PNK PNK RED RED BLK BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow GRN-WHT GRN RED BLK W/YEL SLEEVE BLK W/BRN SLEEVE BRN BLK a b c d e f p p i o l m n k h g g g j WIRING DIAGRAMS 90-856159R1 AUGUST 1998 Page 2D-5 Electric Start Tiller Handle Models Wiring Locations a- Crank Position Sensor b- Ignition Charge Coil c- Battery Charging Coils d- Push Button Stop Switch e- Push Button Start Switch f - Oil Pressure Switch g- Sta-Strap – Fasten Wires Together h- Lanyard Stop Switch i - Rectifier/Regulator j - Ignition Coil k- Neutral Start Switch l - Start Solenoid m- 20 Amp Fuse n- Starter o- Oil Lamp p- ECM BLK BLK BLK BLK RED RED BLU GRN RED RED BLK WHT-GRN BLK WHT PNK BRN-WHT WHT-GRN BLK-YEL YEL-BLK GRN-WHT GRN WHT-GRN YEL-RED GRY BLK W/RED SLEEVE BLK W/RED ENDS TAN-BLY PNK ORN BLK BLU BRN BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow BLK BLK BRN TAN-WHT GRN-WHT PUR YEL-RED f h l a b n g k m n c e i j d d d WIRING DIAGRAMS Page 2D-6 90-856159R1 AUGUST 1998 Electric Start Remote Control Models Wiring Locations a- Battery Charging Coils b- Crank Position Sensor c- Ignition Charge Coil d- Sta-Strap – Fasten Wires Together e- Oil Pressure Switch f - Remote Control Connecter g- Rectifier/Regulator h- Oil Lamp Harness i - Start Solenoid j - Ignition Coil k- 20 Amp Fuse l - Electric Choke m- Starter n- ECM WIRING DIAGRAMS Manual Start Models Wiring Locations a-Crank Position Sensor b-Sta-Strap – Fasten Wires Together c-Ignition Charge Coil GRNGRN PNK ORN BLKBLU BRN BLK WHT-GRN BLK WHT-GRN YEL-RED YEL-RED BLK-YEL BLK-YEL BLK BLK BLK BLKBLK-YEL BLK-YEL PNK PNK RED GRN-WHT GRN GRN GRN-WHT BLK WHT BLK GRNBLK = BlackBLU = BlueBRN = BrownGRY = GrayGRN = GreenORN = OrangePNK = PinkPUR = PurpleRED = RedTAN = TanWHT = WhiteYEL = Yellow ik k e a j d fg h c b bb d-Lanyard Stop Switch e-Battery Charging Coils f-Push Button Stop Switch g-Oil Pressure Switch h-Ignition Coil i-Rectifier/ Regulator j-Oil Lamp k-ECM 90-856159R1 AUGUST 1998 Page 2D-7 FUEL PUMP FUEL SYSTEM Section 3A – Fuel Pump Table of Contents Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . . . 3A-6 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-2 Fuel Pump Reassembly. . . . . . . . . . . . . . . . . . . . 3A-7 Fuel Pump Removal . . . . . . . . . . . . . . . . . . . . . . . 3A-4 Fuel Pump Installation . . . . . . . . . . . . . . . . . . . . . 3A-9 Fuel Pump Disassembly . . . . . . . . . . . . . . . . . . . 3A-5 Specifications 3 A FUEL SYSTEM Fuel Pump Type Fuel Pump: Pressure Plunger Stroke Fuel Tank Capacity External (Plunger/Diaphragm) 3-6 psi (21-41 kPa) 0.14 - 0.27 in. (3.52 - 6.58 mm) 3.0 US Gal. (12 L) 90-856159R1 AUGUST 1998 Page 3A-1 FUEL PUMP Fuel Pump A 1 13 14 15 16 17 18 19 20 2 3 4 5 6 7 8 910 11 12 13 18 310 B 110 110 4-Stroke Outboard Oil (92-828000A12) A = TO CARB B = TO FUEL CONNECTOR Page 3A-2 90-856159R1 AUGUST 1998 FUEL PUMP Fuel Pump REF REFREF . NO. QTY. DESCRIPTION TORQUE lb–in. lb-ft Nm 1 1 FUEL PUMP 2 1 BODY 3 2 CHECK VALVE 4 1 DIAPHRAGM 5 1 SPRING 6 1 PLUNGER 7 1 SPRING 8 4 SCREW (M4x30) 13.3 1.5 9 1 DIAPHRAGM 10 2 SCREW (M3x5) Drive Tight 11 2 NUT (M5) 12 1 PIN 13 2 CLIP 14 1 HOSE 15 1 FILTER 16 2 SCREW (M6 x 100) 70 8 17 1 O RING 18 2 CLIP 19 1 HOSE 20 1 CLAMP 90-856159R1 AUGUST 1998 Page 3A-3 FUEL PUMP Page 3A-4 90-856159R1 AUGUST 1998 Fuel Pump Removal 1. Separate inlet and outlet fuel hoses from fuel pump. 2. Remove fuel pump screws. b c h a e d f g i a-Inlet Fuel Hose b-Outlet Fuel Hose c-Hose Clamps d-Screws (2)-M6x25 e-Fuel Filter f-Fuel Connector g-Bolt M6x25 h-J-Clip i-O-Ring FUEL PUMP Fuel Pump Disassembly 1. Remove bolts, separate cover, pump body and pump base. a c d b e a-Screws (4)-M4x30 b-Nuts (4)-M4 c-Cover d-Pump Body e-Pump Base 2. Remove diaphragm, gasket, screws and check valves from pump body. a b c d e ab a-Screws (2) b-Check Valves (2) c-Diaphragm d-Gasket e-Pump Body 3. Rotate plunger on body to align slots. 4. Compress plunger to free spring load on pin. 5. Remove pin. NOTE: Tilt/shake pump base while compressing plunger to remove pin. 53617 a b c a-Pump Base Slot b-Plunger Slot c-Pin 90-856159R1 AUGUST 1998 Page 3A-5 FUEL PUMP 6. Remove diaphragm, plunger, springs and o-ring. a b c d e f a-Diaphragm b-Spring-Diaphragm c-Pin d-Pump Base e-Spring-Plunger f-Plunger Cleaning/Inspection/Repair 1. Inspect fuel filter for cracks/clogs, replace if necessary. 2. Inspect the check valves for damage, replace if necessary. 3. Inspect springs for damage, replace if necessary. 4. Inspect diaphragms for damage, replace if necessary. Page 3A-6 90-856159R1 AUGUST 1998 FUEL PUMP Fuel Pump Reassembly 1. Install diaphragm, plunger, springs and o-ring. a b c d e f a-Diaphragm b-Spring-Diaphragm c-Pin d-Pump Base e-Spring-Plunger f-Plunger 2. Rotate plunger on body to align slots. 3. Compress plunger and install pin. a b c a-Pump Base Slot b-Plunger Slot c-Pin 53617 90-856159R1 AUGUST 1998 Page 3A-7 FUEL PUMP 4. Rotate plunger/diaphragm to align tabs of diaphragm with notches in pump base. 5. Assemble fuel pump to body. e b c d a ab a-Screws (2) b-Check Valves (2) c-Diaphragm d-Gasket e-Pump Body 6. Assemble cover, pump body and pump base. Secure assembly with nuts and bolts. a b cd e f a-Screws (4)-M4x30 b-Nuts (4)-M4 c-Cover d-Pump Body e-Pump Base f-Notch (Opposite of Hose Fitting) Fuel Pump Cover Screws 13.3 lb-in. (1.5 Nm) Page 3A-8 90-856159R1 AUGUST 1998 FUEL PUMP 90-856159R1 AUGUST 1998 Page 3A-9 Fuel Pump Installation 1. Install fuel pump screws. 2. Connect inlet and outlet fuel hoses onto fuel pump, secure with clamps. NOTE: Position filter with arrow pointing toward fuel pump as shown. NOTE: Never reuse fuel pump O-ring. a b c d e f g h i j a-Inlet Fuel Hose b-Outlet Fuel Hose c-Hose Clamps d-Screws (2)-M6x25 e-Fuel Filter f-Fuel Connector g-Bolt M6x25 h-J-Clip i-Notch (Aligns with Pin on Cylinder Head Cover) j-O-Ring (New) Fuel Pump Mounting Screws 70 lb-in. (8 Nm) CARBURETOR FUEL SYSTEM Section 3B – Carburetor Table of Contents Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-1 Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-2 Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-3 Intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-4 Intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-5 Carburetor Adjustments . . . . . . . . . . . . . . . . . . . . 3B-6 Idle Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-6 Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-6 Specifications Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-9 Carburetor Removal . . . . . . . . . . . . . . . . . . . . . . 3B-11 Carburetor Disassembly. . . . . . . . . . . . . . . . . . . 3B-13 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . . 3B-15 Carburetor Reassembly . . . . . . . . . . . . . . . . . . . 3B-16 Float Height Measurement. . . . . . . . . . . . . . 3B-18 Carburetor Installation . . . . . . . . . . . . . . . . . . . . 3B-19 Electric Choke Models Installation . . . . . . . 3B-19 3 B Idle rpm (Out Of Gear) 950 ± 50 rpm Idle rpm (In Forward Gear) Wide Open Throttle rpm (WOT) 850 ± 50 rpm Standard Model Range 4500–5500 Bodensee Model Range Standard Model Main Jet Size 5200-5700 CARBURETOR 9.9 hp #68 15 hp #104 Pilot Jet Bodensee Model Main Jet Size #45 9.9 hp #68 15 hp #103 Pilot Jet #45 Float Height 0.61 ± 0.04 in. (15.5 ± 1.0 mm) Special Tools 1. Carburetor Scale P/N 91-36392 55847 90-856159R1 AUGUST 1998 Page 3B-1 CARBURETOR Carburetor 2 3 4 5 6 7 8 9 10 11 12 1314 15 16 17 18 19 20 21 23 25 33 34 1 35 22 24 31 32 27 28 26 30 29 Page 3B-2 90-856159R1 AUGUST 1998 CARBURETOR Carburetor REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 11 1 CARBURETOR (15) 1 CARBURETOR (9.9) 1 CARBURETOR (9.9 BODENSEE) 1 CARBURETOR (15 BODENSEE) 2 2 SCREW (M4x10) 17.7 2 3 1 COVER 4 1 GASKET 5 1 THROTTLE SCREW 6 1 SPRING-Pilot Adjusting 7 1 SCREW (M4x5) Drive Tight 8 1 PLATE 9 1 SCREW (M3x5) Drive Tight 10 1 PILOT JET (#45) 10.6 1.2 11 1 PLUG 17.7 2 12 1 MAIN NOZZLE (15) 17.7 2 1 MAIN NOZZLE (15 BODENSEE) 17.7 2 1 MAIN NOZZLE (ALL 9.9) 17.7 2 13 1 O RING 14 1 MAIN JET (#104) (15) 10.6 1.2 1 MAIN JET (#103) (15 BODENSEE) 10.6 1.2 1 MAIN JET (#68) (ALL 9.9) 10.6 1.2 15 1 SCREW (M4x5) 17.7 2 16 1 NEEDLE VALVE 17 1 FLOAT 18 1 FLOAT PIN 19 1 GASKET 20 1 FILTER 2121 1 FLOAT BOWL ASSEMBLY (15) 1 FLOAT BOWL ASSEMBLY (9.9) 22 1 RETAINING RING 23 1 CAP 24 1 SEAL 25 1 DIAPHRAGM 15 26 1 SPRING 27 1 COVER 28 3 SCREW (M4x8) 17.7 2 29 1 DRAIN SCREW (M4x5) 17.7 2 30 1 GASKET 31 1 DRAIN SCREW (M5x6) 34 4.5 32 1 GASKET Not Included W/ 9.9 Bowl 33 4 SCREW (M4x12) 17.7 2 34 1 CHECK VALVE (15) 35 1 SEAL (BODENSEE) 90-856159R1 AUGUST 1998 Page 3B-3 CARBURETOR Intake 4 1 3 5 6 7 8 9 10 11 12 13 2 3 6 110 110 4-Stroke Outboard Oil (92-828000A12) Page 3B-4 90-856159R1 AUGUST 1998 CARBURETOR Intake REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 INTAKE MANIFOLD 2 1 GASKET 3 2 DOWEL PIN 4 4 BOLT (M6 x 40) 70 8 5 1 INSULATOR 6 2 GASKET 7 1 O RING 8 1 SILENCER 9 DECAL-Warning, High Voltage 10 1 PLATE 11 2 COLLAR 12 2 BOLT (M6 x 100) 88 10 13 1 HOSE 90-856159R1 AUGUST 1998 Page 3B-5 CARBURETOR Carburetor Adjustments Idle Speed NOTE:Before adjusting the idle speed make sure the throttle link rod has been properly adjusted. 1. Measure the idle speed using the procedure below, adjust if necessary: • Start engine and allow it to warm up. • Attach a tachometer to the spark plug lead of cylinder #1. • Measure idle rpm with outboard in neutral. • Turn throttle stop screw in direction A or B until the specified idle speed is obtained. NOTE:Turning throttle stop screw in (a) will increase idle speed while turning screw out (b) will decrease speed. Idle rpm (Out Of Gear) 950 ± 50 RPM a b Linkage REMOTE CONTROL MODELS 1. Connect throttle linkage and secure with screw. NOTE: Linkage should extend 0.28 in. (7 mm) beyond barrel. Over-tightening screw may damage throttle linkage. c a b a-Throttle Linkage b-0.28 in. (7 mm) Length c-Screw Page 3B-6 90-856159R1 AUGUST 1998 CARBURETOR 90-856159R1 AUGUST 1998 Page 3B-7 TILLER HANDLE MODELS (SIDE SHIFT SHOWN) 1. Turn idle speed screw counterclockwise until screw is not touching throttle shaft arm. a b a-Idle Speed Screw b-Throttle Shaft Arm 2. Install throttle linkage on pulley and throttle barrel. c b a a a-Throttle Linkage b-Throttle Barrel c-Pulley 3. Check to make sure throttle linkage is has free movement between throttle barrel and pulley. NOTE: The throttle arm should remain stationary while checking for free movement of throttle linkage. a b c a-Throttle Barrel b-Pulley c-Throttle Arm CARBURETOR 4. Move throttle linkage forward until linkage comes to rest on the pulley boss. a b a-Throttle Linkage b-Pulley Boss 5. Tighten screw on throttle barrel to secure linkage. NOTE: Over-tightening screw may damage throttle linkage. NOTE: Check linkage for free movement on pulley. Verify throttle shaft arm in not sticking and returns to idle position. a b a-Screw b-Linkage 6. Verify throttle arm does not hit the full throttle stop at wide open throttle. Gap between stop and throttle arm should be no more than 0.1 in. (2.54 mm). c a b a-Throttle Stop b-Throttle Arm c-Approximately 0.1 in. (2.54 mm) Gap Page 3B-8 90-856159R1 AUGUST 1998 CARBURETOR 7. Turn idle speed screw in (clockwise) until it touches the throttle shaft arm, then turn an additional 1/2 turn for initial setting. a b a-Idle Speed Screw b-Throttle Shaft Arm Choke 1. Route choke cable through cable bracket and install retaining ring. a b a-Choke Cable b-Retaining Ring 2. Set the choke cable to the off position (cable fully pushed in). a a-Choke Cable 90-856159R1 AUGUST 1998 Page 3B-9 CARBURETOR 3. Set choke shutter to the off position (shutter lever rotated fully counterclockwise). 4. Thread the ball socket end on shaft until ball socket aligns with ball on carburetor. Snap socket onto ball. NOTE:Verify choke goes to full choke with cable pulled out and returns to off position with cable pushed in. ab c a-Threaded Ball Socket b-Ball c-Shutter Lever Page 3B-10 90-856159R1 AUGUST 1998 CARBURETOR 90-856159R1 AUGUST 1998 Page 3B-11 Carburetor Removal 1. Remove throttle linkage from carburetor barrel. a b a-Barrel b-Throttle Link 2. Remove choke linkage (tiller handle models only). a a-Choke Linkage 3. Remove j-clips. 4. Disconnect breather hose from air intake and breather cover. c a b d a-J-Clips (2) b-Breather Hose c-Air Intake d-Breather Cover CARBURETOR Page 3B-12 90-856159R1 AUGUST 1998 5. Remove bolts. 6. Separate intake/carburetor assembly from powerhead. 56601 a b c a-Bolts M8x40 (4) b-Dowel Pin (2) c-Gasket-Manifold (Discard) 7. Remove air intake bolts. 8. Separate intake/manifold components from carburetor assembly. 56601 i h e d c b a f g g a-Bolts-Air Intake M6x76 (2) b-Spacers (2) c-Plate d-Air Intake e-O-Ring (Discard) f-Carburetor Assembly g-Gasket (2) (Discard) h-Insulator i-Manifold CARBURETOR 90-856159R1 AUGUST 1998 Page 3B-13 Carburetor Disassembly 1. Remove drain screw. NOTE: Use an acceptable container to hold gas when draining float bowl. 2. Remove float bowl. 3. Remove cover. a b c d e f g h i a-Drain Screw-M5x6 b-Gasket-Drain Screw c-Screws (4)-M4x12 d-Float Bowl e-Valve f-Gasket-Float Bowl g-Screw(2)-M4x10 h-Cover i-Gasket 4. Remove float assembly. a b c d a-Screw-M4x5 b-Pin c-Needle Valve d-Float Assembly CARBURETOR 5. Remove jets and nozzle. a b c d e f g a-Main Nozzle b-O-Ring c-Main Jet d-Pilot Jet e-Seal Cap f-Plate g-Screw-M3x5 6. Remove diaphragm and filter. g h j k f d i a b c e a-Filter b-Screw-M4x5 c-Gasket-Drain Screw d-Screws (3)-M4x8 e-Base f-Spring g-Ring h-Cap i-Diaphragm j-Plunger k-O-Rings (2) Page 3B-14 90-856159R1 AUGUST 1998 CARBURETOR Cleaning/Inspection/Repair 1. Inspect carburetor body for cracks/damage/contamination. Replace/clean as necessary. NOTE:Use a petroleum based solvent for cleaning. Blow out all passages with compressed air, never use a wire. 2. Inspect jets and nozzle for contamination. Replace if necessary. b d a c a-Main Jet c-Valve b-Pilot Jet d-Main Nozzle 3. Inspect needle valve for wear. Replace if necessary. NOTE:Check tip of needle valve for wear. 4. Inspect float for cracks/damage. Replace if necessary. 5. Inspect diaphragm, o-rings and gaskets for damage. Replace if necessary. 6. Inspect filter for contamination/damage. Clean/replace if necessary. 90-856159R1 AUGUST 1998 Page 3B-15 CARBURETOR Carburetor Reassembly 1. Install diaphragm and filter. f e d b k a c g h i j a-O-Rings (2) g-Base b-Plunger h-Screws (3)-M4x8 c-Diaphragm i-Gasket-Drain Screw d-Cap j-Screw-M4x5 e-Ring k-Filter f-Spring 2. Install jets and nozzle. a b c d e f g a-Plate e-Main Nozzle b-Screw-M3x5 f-O-Ring c-Pilot Jet g-Main Jet d-Seal Cap Page 3B-16 90-856159R1 AUGUST 1998 CARBURETOR 3. Install needle valve onto float hinge. 56677 b c a a-Float b-Needle Valve c-Pin 4. Install float assembly. 56676 a b c a-Float b-Pin-M4x5 c-Screw 90-856159R1 AUGUST 1998 Page 3B-17 CARBURETOR Float Height Measurement 1. Measure float height as shown, if out of specification replace. 56675 P/N 91-36392 Carburetor Float Height 0.61 ± 0.04 in. (15.5 ± 1.0 mm) or 36/64 in. - 41/64 in. 2. Install drain screw, float bowl and cover. c b a e i d h g f a-Gasket b-Cover c-Screw (2)-M4x10 d-Valve e-Gasket-Float Bowl f-Float Bowl g-Screws (4)-M4x12 h-Gasket-Drain Screw i-Drain Screw-M5x6 Page 3B-18 90-856159R1 AUGUST 1998 CARBURETOR 90-856159R1 AUGUST 1998 Page 3B-19 Carburetor Installation Electric Choke Models Installation 1. Assemble solenoid components as shown. a b c d e f a-Grommet b-O-ring c-Hook d-Solenoid e-Bracket f-Screws M5x8 - Torque to 30 lb-in. (3.4 Nm) 2. Install solenoid to carburetor assembly. Push grommet over pin and secure spring to carburetor with O-ring. 56750 a b c a-Solenoid Assembly b-Grommet c-O-ring 3. Secure solenoid bracket to powerhead with two (2) bolts M6x16. Connect BLUE to YELLOW/ BLACK and BLACK lead to BLACK lead from remote control. 56751 a b a-Bolts M6x16 (2) - Torque to 70 lb-in. (8 Nm) b-Solenoid Bracket CARBURETOR 1. Assemble intake/manifold components to carburetor assembly. 2. Secure air intake with bolts. a b c b d e h f g i 56601 a-Manifold b-Gasket (2) (New) c-Insulator d-Carburetor Assembly e-O-Ring (New) f-Plate g-Spacers h-Air Intake i-Bolts (2)-M6x 100 Carburetor Mounting Bolts 88 lb-in. (10 Nm) Page 3B-20 90-856159R1 AUGUST 1998 CARBURETOR 90-856159R1 AUGUST 1998 Page 3B-21 3. Install intake/carburetor assembly onto powerhead. 56601 a b c d a-Gasket-Manifold (New) b-Dowel Pin (2) c-Intake/Carburetor Assembly d-Bolts (4) M6x40 Manifold Mounting Bolts 70 lb-in. (8 Nm) 4. Install j-clips. 5. Connect breather hose to air intake and route hose through j-clips. a b a-J-Clips (2) b-Breather Hose EMISSIONS FUEL SYSTEM Section 3C – Emissions Table of Contents Exhaust Emissions Standards . . . . . . . . . . . . . . 3C-2 What Are Emissions? . . . . . . . . . . . . . . . . . . . 3C-2 Hydrocarbons – HC. . . . . . . . . . . . . . . . . . . . . 3C-2 Carbon Monoxide – CO . . . . . . . . . . . . . . . . . 3C-2 Oxides of Nitrogen - NOx. . . . . . . . . . . . . . . . 3C-2 Controlling Emissions . . . . . . . . . . . . . . . . . . . 3C-2 Stoichiometric (14.7:1) Air/Fuel Ratio . . . . . 3C-3 Outboard Hydrocarbon Emissions Reductions . . . . . . . . . . . . . . . . . . . . . 3C-3 8 1/3% # Per Year Over 9 Model Years . . . . 3C-3 Stratified Vs Homogenized Charge . . . . . . . . . . 3C-4 Homogenized Charge . . . . . . . . . . . . . . . . . . . 3C-4 Stratified Charge . . . . . . . . . . . . . . . . . . . . . . . 3C-5 Emissions Information . . . . . . . . . . . . . . . . . . . . . 3C-6 Manufacturer’s Responsibility: . . . . . . . . . . . 3C-6 Dealer Responsibility: . . . . . . . . . . . . . . . . . . . 3C-6 Owner Responsibility: . . . . . . . . . . . . . . . . . . . 3C-6 EPA Emission Regulations: . . . . . . . . . . . . . . 3C-7 Decal Location for 1998 Models: . . . . . . . . . 3C-8 3 C 90-856159R1 AUGUST 1998 Page 3C-1 EMISSIONS Exhaust Emissions Standards Through the Environmental Protection Agency (EPA), the federal government has established exhaust emissions standards for all new marine engines sold in the U.S. What Are Emissions? Emissions are what comes out of the exhaust system in the exhaust gas when the engine is running. They are formed as a result of the process of combustion or incomplete combustion. To understand exhaust gas emissions, remember that both air and fuel are made of several elements. Air contains oxygen and nitrogen among other elements; gasolene contains mainly hydrogen and carbon. These four elements combine chemically during combustion. If combustion were complete, the mixture of air and gasoline would result in these emissions: water, carbon dioxide and nitrogen, which are not harmful to the environment. But combustion is not usually complete. Also, potentially harmful gases can be formed during and after combustion. All marine engines must reduce the emission of certain pollutants, or potentially harmful gases, in the exhaust to conform with levels legislated by the EPA. Emissions standards become more stringent each year. Standards are set primarily with regard to three emissions: hydrocarbons (HC), carbon monoxide (CO) and oxides of nitrogen (NOx). Hydrocarbons – HC Gasoline is a hydrocarbon fuel. The two elements of hydrogen and carbon are burned during combustion in combination with oxygen. But they are not totally consumed. Some pass through the combustion chamber and exit the exhaust system as unburned gases known as hydrocarbons. Carbon Monoxide – CO Carbon is one of the elements that make up the fuel burned in the engine along with oxygen during the combustion process. If the carbon in the gasoline could combine with enough oxygen (one carbon atom with two oxygen atoms), it would come out of the engine in the form of carbon dioxide (CO2). CO2 is a harmless gas. But carbon often combines with insufficient oxygen (one carbon atom with one oxygen atom). This forms carbon monoxide, CO. Carbon monoxide is the product of incomplete combustion and is a dangerous, potentially lethal gas. Oxides of Nitrogen - NOx NOx is a slightly different byproduct of combustion. Nitrogen is one of the elements that makes up the air going into the engine. Under extremely high temperatures it combines with oxygen to form oxides of nitrogen (NOx). This happens in the engine’s combustion chambers when temperatures are too high. NOx itself is not harmful, but when exposed to sunlight it combines with unburned hydrocarbons to create the visible air pollutant known as smog. Smog is a serious problem in California as well as many other heavily populated areas of the United States. Controlling Emissions There are two principle methods of reducing emissions from a two-stroke-cycle marine engine. The first method is to control the air/fuel ratio that goes into the combustion chamber. The second is to control the time when this air/fuel mixture enters the combustion chamber. Timing is important, to prevent any unburned mixture from escaping out of the exhaust port. Page 3C-2 90-856159R1 AUGUST 1998 EMISSIONS Stoichiometric (14.7:1) Air/Fuel Ratio In the search to control pollutants and reduce exhaust emissions, engineers have discovered that they can be reduced effectively if a gasoline engine operates at an air/fuel ratio of 14.7:1. The technical term for this ideal ratio is stoichiometric. An air/fuel ratio of 14.7:1 provides the best control of all three elements in the exhaust under almost all conditions. The HC and CO content of the exhaust gas is influenced significantly by the air/fuel ratio. At an air/fuel ratio leaner than 14.7:1, HC and CO levels are low, but with a ratio richer than 14.7:1 they rise rapidly. It would seem that controlling HC and CO by themselves might not be such a difficult task; the air/fuel ratio only needs to be kept leaner than 14.7:1. However, there is also NOx to consider. As the air/fuel ratio becomes leaner, combustion temperatures increase. Higher combustion temperatures raise the NOx content of the exhaust. But, enrichening the air/fuel ratio to decrease combustion temperatures and reduce NOx also increases HC and CO, as well as lowering fuel economy. So the solution to controlling NOx - as well as HC and CO - is to keep the air/fuel ratio as close to 14.7:1 as possible. OUTBOARD HYDROCARBON EMISSIONS REDUCTIONS 8 1/3%  PER YEAR OVER 9 MODEL YEARS 120 100 80 60 40 20 0 96 97 98 99200001 02 03 04 05 06 07 08 90-856159R1 AUGUST 1998 Page 3C-3 EMISSIONS STRATIFIED VS HOMOGENIZED CHARGE DFI engines use a stratified charge inside the combustion chamber to aid in reducing emissions. All other models use a homogenized charge. The difference between the two is: Homogenized Charge A homogenized charge has the fuel/air particles mixed evenly throughout the cylinder. This mixing occurs inside the carburetor venturi, reed blocks and crankcase. Additional mixing occurs as the fuel is forced through the transfer system into the cylinder. The homogenized charge is easy to ignite as the air/fuel ratio is approximately 14.7:1. Page 3C-4 90-856159R1 AUGUST 1998 EMISSIONS Stratified Charge A stratified charge engine only pulls air through the transfer system. The fuel required for combustion is forced into the cylinder through an injector placed in the top of the cylinder (head). The injector sprays a fuel/air mixture in the form of a bubble into the cylinder. Surrounding this bubble is air supplied by the transfer system. As the bubble is ignited and burns, the surrounding air provides almost complete combustion before the exhaust port opens. A stratified charge is hard to ignite, the fuel/air bubble is not evenly mixed at 14.7:1 and not easily ignited. 90-856159R1 AUGUST 1998 Page 3C-5 EMISSIONS Emissions Information Manufacturer’s Responsibility: Beginning with 1998 model year engines, manufacturers of all marine propulsion engines must determine the exhaust emission levels for each engine horsepower family and certify these engines with the United States Environmental Protection Agency (EPA). A certification decal/emissions control information label, showing emission levels and engine specifications directly related to emissions, must be placed on each engine at the time of manufacture. Dealer Responsibility: When performing service on all 1998 and later outboards that carry a certification, attention must be given to any adjustments that are made that affect emission levels. Adjustments must be kept within published factory specifications. Replacement or repair of any emission related component must be executed in a manner that maintains emission levels within the prescribed certification standards. Dealers are not to modify the engine in any manner that would alter the horsepower or allow emission levels to exceed their predetermined factory specifications. Exceptions include manufacturers prescribed changes, such as that for altitude adjustments. Owner Responsibility: The owner/operator is required to have engine maintenance performed to maintain emission levels within prescribed certification standards. The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications. Exceptions: • Carburetor jets may be changed for high altitude use in accordance with factory recommendations. • Single engine exceptions may be allowed with permission from the EPA for racing and testing. Page 3C-6 90-856159R1 AUGUST 1998 EMISSIONS EPA Emission Regulations: All new 1998 and later outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors. This certification is contingent on certain adjustments being set to factory standards. For this reason, the factory procedure for servicing the product must be strictly followed and, whenever practicable, returned to the original intent of the design. The responsibilities listed above are general and in no way a complete listing of the rules and regulations pertaining to the EPA laws on exhaust emissions for marine products. For more detailed information on this subject, you may contact the following locations: VIA U.S. POSTAL SERVICE: Office of Mobile Sources Engine Programs and Compliance Division Engine Compliance Programs Group (6403J) 401 M St. NW Washington, DC 20460 VIA EXPRESS or COURIER MAIL: Office of Mobile Sources Engine Programs and Compliance Division Engine Compliance Programs Group (6403J) 501 3rd St. NW Washington, DC 20001 EPA INTERNET WEB SITE: http:/www.epa.gov/omswww 90-856159R1 AUGUST 1998 Page 3C-7 EMISSIONS CERTIFICATION LABEL: The certification label must be placed on each engine at the time of manufacture and must be replaced in the same location if damaged or removed. Shown below is a typical certification label and is not representative of any one model. Label shown below is not to scale; (shown at twice the normal size). JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC Emission Control Information 1999 PART # 37–855211 22 This engine conforms to 1999 Model Year U.S. EPA regulations for marine SI engines. Idle Speed (in gear): 850 RPM Timing: Not Adjustable Standard Spark Plug: NGK DPR6EA-9 Gap: .035, Valve Clearance (Cold) mm Intake: 0.15-0.25 Exhaust: 0.20-0.30 Refer to Owners Manual for required maintenance. Family: WM9XM.747220 FEL: 32.20 GM/KW-HR 323 cc 9.9-15 HP 4-Stroke e ba k j i d f g h c a-Spark Ignition (SI) b-Cubic Centimeter c-Model year of engine and production decal part number d-Idle Speed (In Gear) e-Timing specifications when adjustable f-Recommended spark plug for best engine performance g-Valve Clearance (Four Stroke engines only) h-Engine Horsepower rating i-Month of production (Boxing month will punched) j-FEL: Represents (Mercury Marine) statement of the maximum emissions output for the engine family k-Family example W M9X M. 747 2 2 0 Model Year Regulation Application Unspecified W=1998 M=Marine 1=PWC X=1999 2=OB Manufacturer Displacement Technology type Mercury Marine Liter 1=Existing Cubic Inch 2=New Decal Location for 1998 Models: Model Production Part No. Service Part No. Location on Engine 1998 Merc/Mar 323 cc (15 hp) 37-855211 22 37-855577 22 Inside Top Cowl 1999 Merc/Mar 323 cc (9.9/15 hp) 37-856984 4 37-856985 4 Top of Cam Gear Cover Page 3C-8 90-856159R1 AUGUST 1998 CYLINDER HEAD POWERHEAD Section 4A – Cylinder Head Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-4 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-6 Intake/Exhaust Valves . . . . . . . . . . . . . . . . . . . . . 4A-8 Oil Pump/Camshaft. . . . . . . . . . . . . . . . . . . . . . . 4A-10 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-12 Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . 4A-12 Preparing Cylinder Head for Removal . . . . . . . 4A-14 Cylinder Head Removal . . . . . . . . . . . . . . . . . . . 4A-15 Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . . 4A-16 Cylinder Head Disassembly . . . . . . . . . . . . . . . 4A-16 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . . 4A-19 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . 4A-19 Specifications Cylinder Head Resurfacing . . . . . . . . . . . . . 4A-20 Rocker Arm and Rocker Arm Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-21 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-22 Valve Guide inspection . . . . . . . . . . . . . . . . . 4A-23 Valve Guide Replacement . . . . . . . . . . . . . . 4A-23 Valve Seat Reconditioning . . . . . . . . . . . . . . 4A-24 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-27 Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . 4A-29 Cylinder Head Reassembly. . . . . . . . . . . . . . . . 4A-30 Oil Pump Installation. . . . . . . . . . . . . . . . . . . . . . 4A-32 Cylinder Head Installation . . . . . . . . . . . . . . . . . 4A-33 Following Cylinder Head Installation . . . . . . . . 4A-35 4 A CRANKSHAFT Main Bearing Clearance Crankshaft Run-out 0.0004 - 0.0015 in. (0.011 - 0.039 mm) 0.0008 in. (0.02 mm) Camshaft Dimensions Intake “A” 0.941 - 0.945 in. (23.90 - 24.00 mm) Exhaust “A” A 0.942 - 0.946 in. (23.92 - 24.02 mm) Intake “B” 0.785 - 0.789 in. (19.95 - 20.05 mm) Exhaust “B” 0.785 - 0.789 in. (19.95 - 20.05 mm) Run-out Limit Camshaft Bearing Diameter B 0.0039 in. (0.1 mm) “a” Cylinder Head Upper 0.6289 - 0.6293 in. CAMSHAFT (15.973 - 15.984 mm) “b” Oil Pump Housing Lower 0.7077 - 0.7088 in. (17.975 - 17.991 mm) b a TIMING BELT Deflection 0.39 in. (10 mm) 90-856159R1 AUGUST 1998 Page 4A-1 CYLINDER HEAD Free Length “a” Tilt Limit “b” b 1.354 in. (34.4 mm) Less than 0.043 in. (1.1 mm) VALVE SPRING a Compressed Pressure (Installed) Intake Exhaust Dir. of Winding (Intake & Exhaust) 23.1 - 25.4 lb (10.5 - 11.5 kg) 23.1 - 25.4 lb (10.5 - 11.5 kg) Right Hand VALVE GUIDES Valve Guide Inside Diameter Intake Valve Exhaust Valve 0.2165 - 0.2170 in. (5.500 - 5.512 mm) 0.2165 - 0.2170 in. (5.500 - 5.512 mm) Warp Limit 0.004 in. (0.1 mm) * Lines indicate straight edge measurement CYLINDER HEAD Camshaft Bore Inside Diameter “a” a 0.7087 - 0.7094 in. (18.000 - 18.018 mm) Oil Pump Housing Bore Diameter “b” b 0.6299 - 0.63066 in. (16.000 - 16.0188 mm) Page 4A-2 90-856159R1 AUGUST 1998 CYLINDER HEAD Valve/Valve Seat/Valve Guides: Valve Clearance (cold) Intake 0.006 - 0.010 in. (0.15 - 0.25 mm) Exhaust Valve Dimensions: “A” Head Diameter 0.008 - 0.012 in. (0.20 - 0.30 mm) Intake 1.098 - 1.106 in. (27.9 - 28.1 mm) Exhaust “B” Face Width 0.862 - 0.870 in. (21.9 - 22.1 mm) Intake 0.079 - 0.124 in. (2.00 - 3.14 mm) Exhaust “C” Seat Width 0.079 - 0.124 in. (2.00 - 3.14 mm) Intake 0.024 - 0.031 in. (0.6 - 0.8 mm) Exhaust 0.024 - 0.031 in. (0.6 - 0.8 mm) CYLINDER HEAD “D” Margin Thickness Intake 0.020 - 0.035 in. (0.5 - 0.9 mm) VALVES Exhaust Stem Outside Diameter 0.020 - 0.035 in. (0.5 - 0.9 mm) Intake 0.2156 - 0.2161 in. (5.475 - 5.490 mm) Exhaust Guide Inside Diameter 0.2150 - 0.2156 in. (5.460 - 5.475 mm) Intake 0.2165 - 0.2170 in. (5.500 - 5.512 mm) Exhaust Stem To Guide Clearance 0.2165 - 0.2170 in. (5.500 - 5.512 mm) Intake 0.0004 - 0.0015 in. (0.010 - 0.037 mm) Exhaust 0.0010 - 0.0020 in. (0.025 - 0.052 mm) Stem Run-out Limit (max.) 0.0006 in. (0.016 mm) “A” “B” “C” “D” Valve Dimensions Head Diameter Face Width Seat Width Margin Thickness ROCKER SHAFT Outside Diameter 0.5095 - 0.5099 in. (12.941 - 12.951 mm) ROCKER ARM Inside Diameter of Bore 0.5118 - 0.5125 in. (13.000 - 13.018 mm) 90-856159R1 AUGUST 1998 Page 4A-3 CYLINDER HEAD Special Tools 1. Flywheel Holder (P/N 91-83163M). 2. Valve Spring Compressor (P/N 91-809494A1). 55822 3. Valve Guide Remover (P/N 91-809495A1). 4. Valve Guide Installer Bushing (P/N 91-809496A1). 5. Valve Guide Reamer (P/N 91-809497A1). 6. Valve Seat Cutter Kit (Obtain Locally). 55848 Page 4A-4 90-856159R1 AUGUST 1998 CYLINDER HEAD Notes: 90-856159R1 AUGUST 1998 Page 4A-5 110 1 2 3 4 5 6 7 8 10 11 12 14 15 6 110 1 2 3 4 5 6 7 8 10 11 12 14 15 6 CYLINDER HEAD Cylinder Head 9 13 110 4-Stroke Outboard Oil (92-828000A12) Page 4A-6 90-856159R1 AUGUST 1998 CYLINDER HEAD Cylinder Head REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 CYLINDER HEAD 2 4 INTAKE GUIDE 3 4 CLIP 4 3 PIPE PLUG 5 6 BOLT (M8 x 7) 22 30 6 2 DOWEL PIN 7 3 BOLT (M6 x 25) 104 8.7 11.8 8 1 GASKET 9 1 COVER 10 1 SEAL 11 4 BOLT (M6 x 20) 70 8 12 2 SPARK PLUG 13 18 13 1 OIL PLUG Hand Tighten 14 1 O RING 15 1 DECAL-Recomm. Eng. Oil/Valve Cle. 90-856159R1 AUGUST 1998 Page 4A-7 CYLINDER HEAD Intake/Exhaust Valves 9 10 6 8 5 4 913 10 7 12 3 8 1 14 13 8 11 9 10 12 13 8 6 9 10 6 12 5 74 2 3 11 Page 4A-8 90-856159R1 AUGUST 1998 CYLINDER HEAD Intake/Exhaust Valves REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 2 INTAKE VALVE 2 2 EXHAUST VALVE 3 4 SEAT-Valve Spring 4 4 VALVE SPRING 5 4 RETAINER-Valve Spring 6 8 KEY 7 4 SEAL-Valve Stem 8 4 ROCKER ARM ASSEMBLY 9 4 SCREW 10 4 NUT 124 10.3 14 11 2 ROCKER SHAFT 12 3 COLLAR 13 3 SPRING 14 1 SPRING 90-856159R1 AUGUST 1998 Page 4A-9 CYLINDER HEAD 7Oil Pump/Camshaft 1 3 4 5 6 7 8 9 10 11 12 13 14 15 2 110 110 4-Stroke Outboard Oil (92-828000A12) Page 4A-10 90-856159R1 AUGUST 1998 CYLINDER HEAD Oil Pump/Camshaft REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 CAMSHAFT 2 1 O RING 3 1 GASKET 4 3 BOLT (M6 x 35) 70 8 5 1 KEY 6 1 OIL SEAL 7 1 WASHER 8 1 DRIVEN GEAR 9 1 WASHER 10 1 BOLT (M6 x 16) 115 9.6 13 11 1 OIL PUMP 12 1 DRIVE GEAR 13 1 WASHER 14 1 NUT (M28) 29.5 40 15 1 TIMING BELT 90-856159R1 AUGUST 1998 Page 4A-11 CYLINDER HEAD Adjustments Valve Clearance IMPORTANT: The timing belt must be installed and gears in the correct position or valve damage may occur. 1. Remove components: • Flywheel cover/manual starter depending on electric/manual start version. • Driven gear cover. • Disconnect inlet and outlet fuel pump hoses. • Cylinder head cover. a b a-Fuel Hosesb-Cylinder Head Cover 2. Measure valve clearance with a feeler gauge. Adjust if out of specification. Valve Clearance (Cold) Intake 0.006 - 0.010 in. (0.15 - 0.25 mm) Exhaust 0.008 - 0.012 in. (0.20 - 0.30 mm) b c d a a-Lock nut b-Adjusting Screw c-Intake Valve Clearance d-Exhaust Valve Clearance Page 4A-12 90-856159R1 AUGUST 1998 CYLINDER HEAD NOTE:When loosening lock nuts, hold the adjusting screw with a screw driver to prevent it from moving. 3. Perform the following adjustment steps: • Turn the driven gear and align the “1 or D” mark on the driven gear with the “D” mark on the cylinder block. • Adjust the intake and exhaust valve clearance for cylinder #1. • Turn the driven gear 180° (crank shaft 360°) and align the “2 or D” mark on the driven gear with the “D” on the cylinder block. • Adjust the intake and exhaust valve clearance for cylinder #2. a b c d a-Cylinder Block “D” Mark b-Driven Gear c-Driven Gear “1 or D” Mark d-Driven Gear “2 or D” Mark 4. Tighten the lock nuts. NOTE:When tightening lock nuts, hold the adjusting screw with a screw driver to prevent it from moving. Lock Nut Torque 10.3 lb-ft (14 Nm) 90-856159R1 AUGUST 1998 Page 4A-13 CYLINDER HEAD 5. Install components: • Cylinder head cover. • Connect inlet and outlet fuel pump hoses. • Driven gear cover. • Flywheel cover/manual starter depending on electric/manual start version. a b a-Fuel Hoses b-Cylinder Head Cover Preparing Cylinder Head for Removal 1. Remove driven gear cover. 56555 a a-Cover 2. Refer to Section 2A for removal of the following components: • Flywheel • Stator assembly • Timing belt • CDI • Ignition coil 3. Refer to Section 3A for removal of the following components: • Fuel pump 4. Refer to Section 3B for removal of the following components: • Intake manifold Page 4A-14 90-856159R1 AUGUST 1998 CYLINDER HEAD 90-856159R1 AUGUST 1998 Page 4A-15 Cylinder Head Removal 1. Remove spark plugs. 2. Remove cylinder head cover. NOTE: Rubber gasket is not reusable, please discard. a b c d a-Spark Plugs b-Bolts-Cylinder Head Cover M6x20 (4) c-Cylinder Head Cover d-Rubber Gasket (Discard) 3. Remove cylinder head. NOTE: Cylinder head gasket is not reusable. a b c d e a-Bolts-Cylinder Head M8x78 (6) b-Bolts-Cylinder Head M6x25 (3) c-Cylinder Head Assembly d-Gasket-Cylinder Head (Discard) e-Dowel Pins CYLINDER HEAD Oil Pump Removal 1. Remove oil pump. NOTE:O-ring is not reusable. a b c d a-Bolt-Oil Pump b-Oil Pump Assembly c-O-Ring (Discard) d-Gasket Cylinder Head Disassembly IMPORTANT: Note the location of valve train components for reassembly in their original location. 1. Loosen lock nuts and valve adjusting screws. a b a-Lock nuts (4) b-Valve Adjusting Screws (4) Page 4A-16 90-856159R1 AUGUST 1998 CYLINDER HEAD 90-856159R1 AUGUST 1998 Page 4A-17 2. Shake cylinder head to remove rocker shafts. 56561 a a-Rocker Shafts 3. Remove springs, collars and rocker arms. a b c d a-Spring #1 b-Collar (3) c-Spring #2 (3) d-Rocker Arms (4) 4. Remove camshaft. 56564 a a-Camshaft CYLINDER HEAD 5. Remove oil seal. a a-Seal 6. Compress springs using valve spring compressor. 91-809494A1 a a-Valve Spring Compressor P/N 91-809494A1 Page 4A-18 90-856159R1 AUGUST 1998 CYLINDER HEAD 7. Remove keepers, upper seats, springs, seals, lower seats, and intake/exhaust valves. NOTE:Seals are not reusable. a b c d e g f a-Keepers (8) b-Valve Spring Seats-Upper (4) c-Valve Springs (4) d-Valves-Intake (2) e-Valves-Exhaust (2) f-Valve Spring Seats-Lower (4) g-Valve Seals (4) (Discard) Cleaning/Inspection/Repair Cylinder Head 1. Inspect the cylinder head for: • Mineral deposits/corrosion in the water passage ways, clean with brush/round scraper. • Carbon deposits in combustion chamber, clean with round scraper. 56569 90-856159R1 AUGUST 1998 Page 4A-19 CYLINDER HEAD 2. Use a straight edge and a thickness gauge to inspect cylinder head for warpage. Replace or resurface (using procedure below) if out of specification. 56568 Cylinder Head Warpage Limit 0.004 in. (0.1 mm) Cylinder Head Resurfacing 1. Place 400-600 grit wet sandpaper on flat surface. 2. Resurface the head using a figure eight motion until within the specifications. NOTE:Rotate the head several times during the resurfacing procedure to avoid removing to much material from one side. 56567 Page 4A-20 90-856159R1 AUGUST 1998 CYLINDER HEAD Rocker Arm and Rocker Arm Shaft Inspection 1. Measure rocker arm inside diameter and rocker arm shaft outside diameter. Replace if out of specification. a b a-Rocker Arm Inside Diameter b-Rocker Arm Shaft Outside Diameter Rocker Arm Inside Diameter 0.5118 - 0.5125 in. (13.000 - 13.018 mm) Rocker Arm Shaft Outside Diameter 0.5095 - 0.5099 in. (12.941 - 12.951 mm) 90-856159R1 AUGUST 1998 Page 4A-21 CYLINDER HEAD Camshaft 1. Inspect the camshaft for pitting, heat discoloration, scratches and for the following measurements. Replace camshaft if worn or not within specification. 2. Measure the cam lobe length (a) and width (b). 55805 a a b b Cam Lobe Specifications aa Intake 0.941 - 0.945 in. (23.90 - 24.00 mm) Exhaust 0.942 - 0.946 in. (23.92 - 24.02 mm) bb Intake 0.785 - 0.789 in. (19.95 - 20.05 mm) Exhaust 0.785 - 0.789 in. (19.95 - 20.05 mm) 3. Measure the diameter of the camshaft bearing surfaces on the cylinder head side (upper) (a) and oil pump housing side (b). b a Camshaft Bearing Diameter Cylinder Head Surface (a) 0.6289 - 0.6293 in. (15.973 - 15.984 mm) Oil Pump Housing Surface (b) 0.7077 - 0.7088 in. (17.975 - 17.991 mm) Page 4A-22 90-856159R1 AUGUST 1998 CYLINDER HEAD Valve Guide inspection 1. Measure the valve guide bore. If valve guide wear is out of specification, replace the valve guide. 55794 a a-Valve Guide Bore Valve Guide Inside Diameter Intake Valve 0.2165 - 0.2170 in.0.2165 0.2170 in. (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. 55806 91-809495A1 a a-Valve Guide Remover (91-809495A1) 3. Install the new valve guide and circlip using a valve guide installer bushing along with the valve guide remover. 55807 91-809496A1 91-809495A1 a b a-Valve Guide Remover (91-809495A1) b-Valve Guide Installer Bushing (91-809496A1) 90-856159R1 AUGUST 1998 Page 4A-23 CYLINDER HEAD 4. After installing the valve guide, ream the valve guide using a valve guide reamer to obtain proper stem-to-guide clearance. 55808 91-809497A1 a a-Valve Guide Reamer (91-809497A1) Valve Seat Reconditioning 1. Clean the carbon deposits from the combustion chambers and valve seats and check for pitting. NOTE:Several different types of equipment are available for reseating valve seats. Follow the equipment manufacturer’s instructions. 2. Measure valve seat width. Resurface the valve seat if not in specification. 55799 a a-Valve Seat Width Valve Seat Width Specification “a” Intake Valve 0.024 - 0.031 in.0.024 0.031 in. (0.6 - 0.8 mm)Exhaust Valve Reface valve seat, use a 60°, 45°, 15° valve seat cutter. Page 4A-24 90-856159R1 AUGUST 1998 CYLINDER HEAD NOTE: When twisting cutter, keep an even downward pressure to prevent chatter marks. 55795 NOTE:If resurfacing the valve seats is required, resurface the valve seats to the specified angles shown in chart. 55798 a c b Valve Seat Angle Specifications a 15 ° b 45 ° c 60 ° 90-856159R1 AUGUST 1998 Page 4A-25 CYLINDER HEAD VALVE SEAT POSITIONS AND CORRECTIONS Condition: The valve seat is centered on valve face but it is too wide. 55799 Valve Seat Cutter Set Desired Results UseUse Lightly 15° Cutter To reduce valve seat To reduce valve seat width60° Cutter Condition: The valve seat is in the middle of the valve face but it is too narrow. 55800 Valve Seat Cutter Set Desired Results UseUse 45° Cutter To achieve a uniform valve seat To achieve a uniform valve seat width Condition: Valve seat is too narrow and it is near valve margin. 55801 Valve Seat Cutter Set Desired Results UseUse 15° Cutter, First To center the seat and to achieve its To center the seat and to achieve its width45° Cutter Page 4A-26 90-856159R1 AUGUST 1998 CYLINDER HEAD Condition: Valve seat is too narrow and is located near the bottom edge of the valve face. 55802 Valve Seat Cutter Set Desired Results UseUse 60° Cutter, First To center the seat and to increase To center the seat and to increase its width45° Cutter CORRECT VALVE SEAT POSITION 55800 Valve Seat Width Specification “a” Intake Valve 0.024 - 0.031 in.0.024 0.031 in. (0.6 - 0.8 mm)Exhaust Valve Valves 1. Clean the carbon deposits from the valve. Discard any cracked, warped, or burned valves. 2. Measure the valve stem diameter to check for wear. Replace valves if not within specification. a a-Valve Stem Diameter 55810 90-856159R1 AUGUST 1998 Page 4A-27 CYLINDER HEAD Valve Stem Diameter Intake Valve 0.2156 - 0.2161 in. (5.475 - 5.490 mm) Exhaust Valve 0.2150 - 0.2156 in. (5.460 - 5.475 mm) 3. Check the valve face for pitting. Valves faces that are pitted must be replaced or 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 (a) of the valves after the valves have been ground. Any valve with a margin thickness of less than the specification, should be replaced. 55809 45 ° a Margin Thickness “a” Intake Valve 0.020 - 0.035 in.0.020 0.035 in. (0.5 - 0.9 mm)Exhaust Valve 5. Measure valve stem runout, replace if out of specification. 55811 Valve Stem Runout Limit (Max.) Intake Valve Exhaust Valve 0.0006 in. (0.016 mm) Page 4A-28 90-856159R1 AUGUST 1998 CYLINDER HEAD Valve Springs 1. Check each spring under load on a spring tester. Replace any weak springs. 55796 2. Check free length limit of each spring. Replace if out of specification. 55846 Valve Spring Free Length Limit 1.354 in. (34.4 mm) 3. Check each spring on a flat surface using a square. Rotate spring and check space between the top coil and square. Replace if out of specification. 55797 a Valve Spring Tilt Specification “a” Less than 0.043 in. (1.1 mm) 90-856159R1 AUGUST 1998 Page 4A-29 CYLINDER HEAD Cylinder Head Reassembly IMPORTANT: Reassemble valve train components for in there original location. 1. Install valves, lower seats, springs, seals, upper seats, and keepers. NOTE:Compress springs using valve spring compressor, insert keepers, and release valve spring compressor. ab c d e g f 110 110 110 110 4-Stroke Outboard Oil (92-828000A12) a-Keepers (8) b-Valve Spring Seats-Upper (4) c-Valve Springs (4) d-Valves-Intake (2) e-Valves-Exhaust (2) f-Valve Spring Seats-Lower (4) g-Valve Seals (4) (New) 91-809494A1 a a-Valve Spring Compressor P/N 91-809494A1 Page 4A-30 90-856159R1 AUGUST 1998 CYLINDER HEAD 90-856159R1 AUGUST 1998 Page 4A-31 2. Install oil seal. a 110 110 4-Stroke Outboard Oil (92-828000A12) a-Oil Seal 3. Install camshaft. 56564 a 110 4-Stroke Outboard Oil (92-828000A12) 110 a-Camshaft 4. Install springs, collars, rocker arms. a b c d b a-Spring #1 b-Rocker Arms (4) c-Collar (3) d-Spring #2 (3) CYLINDER HEAD 5. Insert rocker shafts until fully seated. a a-Rocker Shafts Oil Pump Installation 1. Install oil pump using new gasket and O-Ring. a b c d a-Gasket (New) b-O-Ring (New) c-Oil Pump Assembly d-Bolt-Oil Pump Oil Pump Bolt Torque 70 lb-in. (8 Nm) Page 4A-32 90-856159R1 AUGUST 1998 CYLINDER HEAD Cylinder Head Installation 1. Install cylinder head with new gasket. NOTE:Cylinder head should be torqued in sequence shown. a b c d e a-Dowel Pins (2) b-Gasket-Cylinder Head (New) c-Cylinder Head Assembly d-Bolts-Cylinder Head M6x25 (3) e-Bolts-Cylinder Head M8x78 (6) Cylinder Head Bolt Torque (M6x25) 8.7 lb-ft (11.8 Nm) Cylinder Head Bolt Torque (M8x78) 22 lb-ft (30 Nm) 90-856159R1 AUGUST 1998 Page 4A-33 CYLINDER HEAD 2. Perform valve clearance adjustment at the beginning of this section. 3. Install cylinder head cover with new gasket. NOTE:Cylinder head cover should be torqued in sequence shown. 4. Install spark plugs. a b c d a-Rubber Gasket (New) b-Cylinder Head Cover c-Bolts-Cylinder Head Cover M6x20 (4) d-Spark Plugs Cylinder Head Cover Bolt Torque 70 lb-in. (8 Nm) Spark Plug Torque 13 lb-ft (18 Nm) Page 4A-34 90-856159R1 AUGUST 1998 CYLINDER HEAD Following Cylinder Head Installation 1. Refer to Section 3B for installation of the following components: • Intake manifold 2. Refer to Section 3A for installation of the following components: • Fuel pump 3. Refer to Section 2A for installation of the following components: • Flywheel • Stator assembly • Timing belt • CDI • Ignition coil 4. Install driven gear cover. 56555 a a-Cover 90-856159R1 AUGUST 1998 Page 4A-35 CYLINDER BLOCK/CRANKCASE POWERHEAD Section 4B – Cylinder Block/Crankcase Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-4 Cylinder Block And Covers . . . . . . . . . . . . . . . . . 4B-6 Preparing Powerhead for Removal . . . . . . . . . . 4B-8 Remote Control Models . . . . . . . . . . . . . . . . . 4B-8 Tiller Handle Models . . . . . . . . . . . . . . . . . . . . 4B-8 Electric Start Models . . . . . . . . . . . . . . . . . . . . 4B-9 Manual Start Models . . . . . . . . . . . . . . . . . . . . 4B-9 Powerhead Removal . . . . . . . . . . . . . . . . . . . . . 4B-10 Preparing Powerhead for Disassembly . . . . . . 4B-11 Powerhead Disassembly . . . . . . . . . . . . . . . . . . 4B-12 Thermostat, Exhaust, and Breather Cover Removal . . . . . . . . . . . . . . . . . . . . . . . 4B-12 Anode Removal . . . . . . . . . . . . . . . . . . . . . . . 4B-13 Crankcase and Crankshaft Removal . . . . . 4B-14 Piston Disassembly . . . . . . . . . . . . . . . . . . . . 4B-15 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . . 4B-15 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-15 Drive Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-15 Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-16 Anode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-16 Oil Pressure Switch. . . . . . . . . . . . . . . . . . . . 4B-16 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-17 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-18 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-19 Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-20 Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-20 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-21 Crankcase and Bearing . . . . . . . . . . . . . . . . 4B-22 Connecting Rod Oil Clearance . . . . . . . . . . 4B-25 Powerhead Reassembly . . . . . . . . . . . . . . . . . . 4B-27 Piston Ring Installation . . . . . . . . . . . . . . . . . 4B-27 Piston Installation . . . . . . . . . . . . . . . . . . . . . 4B-28 Crankcase and Crankshaft Installation . . . 4B-29 Anode Installation . . . . . . . . . . . . . . . . . . . . . 4B-32 Thermostat, Exhaust, and Breather Cover Installation. . . . . . . . . . . . . . . . . . . . . . 4B-33 Following Powerhead Assembly . . . . . . . . . . . . 4B-36 Timing Belt Installation . . . . . . . . . . . . . . . . . 4B-36 Electrical Component Installation . . . . . . . . 4B-37 Carburetor Installation . . . . . . . . . . . . . . . . . 4B-37 Powerhead Installation . . . . . . . . . . . . . . . . . . . . 4B-37 Following Powerhead Installation . . . . . . . . . . . 4B-39 Electric Start Models . . . . . . . . . . . . . . . . . . . 4B-40 Manual Start Models. . . . . . . . . . . . . . . . . . . 4B-40 All Models (If Equipped) . . . . . . . . . . . . . . . . 4B-40 Driveshaft Housing Covers . . . . . . . . . . . . . 4B-40 4 B 90-856159R1 AUGUST 1998 Page 4B-1 CYLINDER BLOCK/CRANKCASE Specifications CYLINDER BLOCK Type Displacement Number of Cylinders 4 Stroke Cycle – Over Head Camshaft 19.7 cu. in. (323cc) 2 STROKE Length 2.323 in. (59 mm) CYLINDER BORE Diameter Standard Oversize-0.010 in. (0.25 mm) Oversize-0.020 in. (0.50 mm) Taper/Out of Round Maximum Bore Type 2.3228–2.3236 in. (59.00-59.02 mm) 2.3327-2.3335 in. (59.25-59.27 mm) 2.3425-2.3433 in. (59.50-59.52 mm) 0.003 in. (0.08 mm) Cast Iron PISTON Piston Type O.D. at Skirt Standard Oversize-0.010 in. (0.25 mm) Oversize-0.020 in. (0.50 mm) Aluminum 2.3209 - 2.3214 in. (58.950 - 58.965 mm) 2.3307 - 2.3313 in. (59.200 - 59.215 mm) 2.3406 - 2.3411 in. (59.450 - 59.465 mm) PISTON CLEARANCE Piston to Cylinder Clearance 0.0014 - 0.0026 in. (0.035 - 0.065 mm) RINGS Ring End Gap (Installed) Top Middle Bottom (Oil Ring) Side Clearance: Top Middle 0.006 - 0.012 in. (0.15 - 0.30 mm) 0.012 - 0.020 in. (0.30 - 0.50 mm) 0.008 - 0.028 in. (0.20 - 0.70 mm) 0.0016 - 0.0032 in. (0.04 - 0.08 mm) 0.0012 - 0.0028 in. (0.03 - 0.07 mm) COMPRESSION RATIO Compression Ratio Cylinder Compression (cold engine @ W.O.T.) 9.3:1 185 - 190 psi (Peak) PISTON PIN Piston Pin Diameter 0.5510 - 0.5512 in. (13.996 - 14.000 mm) CONNECTING ROD Oil Clearance (Big End) Small End Inside Diameter 0.0008 - 0.0018 in. (0.021 - 0.045 mm) 0.5518 - 0.5523 in. (14.015 - 14.029 mm) CRANKSHAFT Main Bearing Clearance Crankshaft Run-out 0.0004 - 0.0015 in. (0.011 - 0.039 mm) 0.0008 in. (0.02 mm) Page 4B-2 90-856159R1 AUGUST 1998 CYLINDER BLOCK/CRANKCASE Special Tools 1. Oil Filter Wrench (P/N 91-802653). 55851 2. Flywheel Holder (P/N 91-83163M) 3. Flywheel Puller (P/N 91-83164M) 56570 4. Piston Ring Compressor (P/N FT2997) 5. Powerhead Stand (P/N 83190M) 56571 90-856159R1 AUGUST 1998 Page 4B-3 CYLINDER BLOCK/CRANKCASE Crankshaft 11 9 4 1 2 3 4 5 6 7 8 10 12 13 14 15 13 Page 4B-4 90-856159R1 AUGUST 1998 CYLINDER BLOCK/CRANKCASE Crankshaft REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 CRANKSHAFT 2 1 OIL SEAL 3 1 OIL SEAL 4 AR BEARING (BROWN) AR BEARING (BLACK) AR BEARING (BLUE) 5 2 CONNECTING ROD 6 4 BOLT (M7 x 38) 16.2 22 7 4 WASHER 8 2 PISTON 9 2 PISTON RING 10 2 PISTON RING 11 2 OIL RING 12 2 PISTON PIN 13 4 SNAP RING 14 1 KEY 15 1 KEY 90-856159R1 AUGUST 1998 Page 4B-5 CYLINDER BLOCK/CRANKCASE Page 4B-6 90-856159R1 AUGUST 1998 Cylinder Block And Covers 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 21 26 27 28 30 29 22 23 24 32 31 34 36 33 35 37 39 40 41 22 39 42 43 45 2 12 1 A 25 12 Loctite Master Gasket “514” (92-12564-2) 110 4-Stroke Outboard Oil (92-828000A12) 12 110 110 110 19 20 38 44 A= TO TELL-TALE CYLINDER BLOCK/CRANKCASE Cylinder Block And Covers REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 CYLINDER BLOCK 2 2 DOWEL PIN 3 4 BOLT (M8 x 20) 22 30 4 6 BOLT (M6 x 14) 104 9 12.2 5 1 PIPE PLUG 6 1 GASKET 7 1 EXHAUST COVER 8 1 FITTING 9 1 THERMOSTAT (60C/140F) 10 1 COVER-Thermostat 11 1 GASKET 12 7 BOLT (M6 x 30) 104 9 12.2 13 1 HOSE 14 1 STA-STRAP 15 1 TUBING (16 IN.) 16 1 OIL FILTER 156 13 18 17 1 UNION PIPE (M20) 29 40 18 1 PLUG-Serial Number 19 1 BREATHER COVER 20 1 SEAL 21 3 BOLT (M6 x 20) 70 8 22 2 GASKET 23 1 PLATE-Oil Deflection 24 6 BOLT (M8 x 35) 22 30 25 6 WASHER 26 1 ANODE 27 1 GROMMET 28 1 COVER 29 1 BOLT (M5 x 12) 44 5 30 1 PLATE 31 1 BOLT (M6 x 20) 70 8 32 1 CHOKE CABLE 33 1 NUT (.375-24) Drive Tight 34 1 BRACKET HANDLE 35 1 RETAINING RING 36 2 BOLT (M6 x 13) 70 8 37 1 BALL SOCKET 38 1 DIPSTICK 39 2 STA-STRAP 40 1 PIPE JOINT 41 1 HOSE 42 1 OIL SCREEN 43 1 CLAMP 44 1 CLAMP 45 1 GROMMET 90-856159R1 AUGUST 1998 Page 4B-7 CYLINDER BLOCK/CRANKCASE Page 4B-8 90-856159R1 AUGUST 1998 Preparing Powerhead for Removal 1. Drain engine oil (refer to “Changing Engine Oil” in Section 1B). Remote Control Models 1. Disconnect shift lever. a b a-Shift Lever b-Shift Link Rod 2. Disconnect throttle linkage. a a-Throttle Linkage Tiller Handle Models 1. Disconnect throttle linkage. a a-Throttle Linkage CYLINDER BLOCK/CRANKCASE 90-856159R1 AUGUST 1998 Page 4B-9 2. Disconnect choke linkage. Remove two (2) bolts and remove choke bracket. a b c a-Choke Linkage b-Bolts (2)-M6x13 c-Choke Bracket Electric Start Models 1. Remove battery cables at the starter motor side. 2. Remove flywheel cover. Manual Start Models 1. Remove starter rewind, refer to Section 8 “Manual Starter”. All Models (If So Equipped) 1. Disconnect the following leads, refer to the wiring diagrams in Section 2D. • Engine stop switch leads. • Neutral start switch lead. • Fuse lead. • Oil light leads. 2. Remove inlet fuel hose from fuel pump. a a-Fuel Hose (Inlet) CYLINDER BLOCK/CRANKCASE 3. Remove tell–tale water hose. a a-Water Hose Powerhead Removal 1. Remove driveshaft housing covers (4 bolts and nuts). NOTE:To aid in removal of bolts, a small straight screwdriver should be placed in nut pocket to prevent turning of nuts. 56919 a b a-Driveshaft Housing Covers b-Bolts (4), Nuts (4) Page 4B-10 90-856159R1 AUGUST 1998 CYLINDER BLOCK/CRANKCASE 90-856159R1 AUGUST 1998 Page 4B-11 2. Remove dipstick. 3. Remove powerhead bolts. Place powerhead on powerhead stand. 4. Remove powerhead gasket and dowel pins. 5. Cut sta-straps securing oil strainer assembly to powerhead. Remove oil strainer assembly 6. Separate oil strainer assembly as needed. NOTE: Do not re-use powerhead gasket. a b c d f d e c a-Dipstick b-Bolts (6)-M8x45 c-Dowel Pins (2) d-Powerhead Gaskets (2) (New) e-Oil Deflection Plate f-Oil Strainer Assembly Preparing Powerhead for Disassembly 1. Refer to Section 2A for removal of the following components. • Rectifier/regulator • CDI and flywheel pickup • Ignition coil 2. Remove carburetor unit and breather hose. Refer to “Carburetor Removal” in Section 3B. 3. Remove cylinder head. Refer to “Cylinder Head Removal” in Section 4A. CYLINDER BLOCK/CRANKCASE Page 4B-12 90-856159R1 AUGUST 1998 Powerhead Disassembly 1. Remove oil filter (if necessary). NOTE: Slide boot off of oil pressure switch. 2. Remove oil pressure switch. a b f d e c a-Oil Filter b-Oil Filter Plug c-Boot d-Screw w/Washer e-Oil Pressure Switch Lead f-Oil Pressure Switch Thermostat, Exhaust, and Breather Cover Removal 1. Remove thermostat cover, gasket, and thermostat. 2. Remove exhaust cover and gasket. b a e f g h d c a-Bolts (2)-M6x30 b-Thermostat Cover c-Gasket-Thermostat Cover (Discard) d-Thermostat e-Bolts (5)-M6x30 f-Washers (7) g-Exhaust Cover h-Gasket-Exhaust Cover (Discard) CYLINDER BLOCK/CRANKCASE 90-856159R1 AUGUST 1998 Page 4B-13 3. Remove breather cover and gasket. 56592 a b c d e c a-Bolts (3) - M6x20 b-Washers (3) c-J-Clips (2) d-Breather Cover e-Gasket-Breather Cover (Discard) Anode Removal 1. Remove plate, cover, and anode. 56592 f e d c b a a-Bolt-M6x20 b-Plate c-Bolt-M5x12 d-Anode Cover e-Anode f-Rubber Packing CYLINDER BLOCK/CRANKCASE Crankcase and Crankshaft Removal 1. Remove crankcase cover and dowel pins. a c d b a-Bolts-M8x20 (4) b-Bolts-M6x14 (6) c-Crankcase Cover d-Dowel Pins (2) 2. Remove connecting rod bolts and caps. 3. Remove crankshaft, oil seals, and main bearings. 4. Remove carbon ridge from the cylinder bore using a burr knife. Pistons should be taken out through the cylinder head side of block. IMPORTANT: Note locations of connecting rod bolts, caps, rods, and pistons for reassembly. NOTE:Do not interchange main bearings, re-install in there original location. a b c d e f f d f a-Bolts-M7x38 (4) b-Connecting Rod Caps (2) c-Crankshaft d-Oil Seals (2) e-Connecting Rod/Piston Assembly f-Main Bearings (4) Page 4B-14 90-856159R1 AUGUST 1998 CYLINDER BLOCK/CRANKCASE Piston Disassembly NOTE: Disassemble each piston separately, make sure components are not mixed. 1. Remove piston pin clip and piston pin. Separate connecting rod from piston. 2. Remove top ring and second. NOTE:If re-using rings mark their location (piston #1 or piston #2) for correct installation. 3. Remove oil ring (bottom rail, top rail, and scraper). NOTE:Scraper separates between red and blue marks. a b a c d e f g a-Piston Pin Clips (2) b-Piston Pin c-Connecting Rod d-Top Ring e-Second Ring f-Oil Ring g-Piston Cleaning/Inspection/Repair Flywheel 1. Inspect flywheel teeth, replace if worn or damaged. Drive Gear 1. Inspect drive gear, replace if worn or damaged. 90-856159R1 AUGUST 1998 Page 4B-15 CYLINDER BLOCK/CRANKCASE Timing Belt 1. Inspect timing belt, replace if worn/stretched/damaged. Anode 1. Replace water jacket anode if partially consumed. 56592 abcdef a-Bolt-M6x20 b-Plate c-Bolt-M5x12 d-Anode Cover e-Anode f-Rubber Packing Oil Pressure Switch 1. Check continuity of switch. 55845 Oil Pressure Switch Continuity Check Below 2.5 psi (17 kPa) Continuity Above 2.5 psi (17 kPa) No Continuity Page 4B-16 90-856159R1 AUGUST 1998 CYLINDER BLOCK/CRANKCASE Thermostat 1. Inspect thermostat, replace if stuck or damaged. 56573 2. Use Measurement Test below to measure: • Valve opening temperature. • Valve lift. MEASUREMENT TEST 1. Tie a piece of thread (or other non-conductive material) onto the thermostat. 2. Suspend the thermostat in water. 3. Heat water slowly while observing the thermostat. 56575 56574 Water Temperature Valve Lift Below 140° F (60° C) 0 in. (0 mm) Above 158° F (70° C) Minimum 0.12 in. (3 mm) 90-856159R1 AUGUST 1998 Page 4B-17 CYLINDER BLOCK/CRANKCASE Cylinder 1. Inspect: • Water jacket for mineral deposits/corrosion, clean if necessary. • Inner surface for score marks, repair if necessary. 2. Measure bore diameter with a cylinder gauge, re-bore or replace if necessary. NOTE:Measure at three locations (L1, L2, and L3) in both X and Y axis (D1-6). L1=0.8 in. (20 mm) L2=1.6 in. (40 mm) L3=2.4 in. (60 mm) 55837 D1,2 D3,4 D5,6 L1 L2 L3 Cylinder Bore Specifications Standard Bore Maximum Taper/Out-of-Round 2.3228–2.3236 in. (59.00-59.02 mm) 0.003 in. (0.08 mm) Oversize Bore 0.10 in. (0.25 mm) Maximum Taper/Out-of-Round 2.3327-2.3335 in. (59.25-59.27 mm) 0.003 in. (0.08 mm) Oversize Bore 0.20 in. (0.50 mm) Maximum Taper/Out-of-Round 2.3425-2.3433 in. (59.50-59.52 mm) 0.003 in. (0.08 mm) NOTE: Taper=(Maximum of D1 or D2)–(Minimum of D5 or D6) Page 4B-18 90-856159R1 AUGUST 1998 CYLINDER BLOCK/CRANKCASE Piston 1. Inspect piston wall wear/damage, replace if necessary. 2. Measure the piston at a point 0.2 in (5.0 mm) from the bottom, replace if out of specification. b 55838 a a-Piston Diameter b-0.2 in. (5.0 mm) Piston Diameter “a” Diameter (Standard) 2.3209 - 2.3214 in. (58.950 - 58.965 mm) Diameter (Oversize) 0.010 in. (0.50 mm) 2.3307 - 2.3313 in. (59.200 - 59.215 mm) Diameter (Oversize) 0.020 in. (0.50 mm) 2.3406 - 2.3411 in. (59.450 - 59.465 mm) Piston to Cylinder Clearance 0.0014 - 0.0026 in. (0.035 - 0.065 mm) Minimum bore measurement – maximum piston measurement = piston to cylinder clearance 90-856159R1 AUGUST 1998 Page 4B-19 CYLINDER BLOCK/CRANKCASE Piston Pin 1. Measure piston pin diameter. Replace piston pin if out of specification. 55839 Piston Pin Diameter 0.5510 - 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. Replace the pin and/or connecting rod as necessary. 55840 3. Place the piston pin into the piston and check for free play. There should be no noticeable free play. Replace the pin and/or piston as necessary. 55841 Piston Rings PISTON RING SIDE CLEARANCE 1. Measure piston ring side clearance. Replace piston and or piston rings if out of specification. 55842 Piston Ring Side Clearance Top 0.0016 - 0.0032 in. (0.04 - 0.08 mm) Middle 0.0012 - 0.0028 in. (0.03 - 0.07 mm) Page 4B-20 90-856159R1 AUGUST 1998 CYLINDER BLOCK/CRANKCASE PISTON RING END GAP CLEARANCE 1. Measure piston ring end gap clearance. Replace piston ring if out of specification. NOTE:Ring should be level for measurement, push ring into bore with crown of piston a a-0.8 mm (20 mm) Depth Piston Ring End Gap Top 0.006 - 0.012 in. (0.15 - 0.30 mm) 2nd 0.012 - 0.020 in. (0.30 - 0.50 mm) Oil 0.008 - 0.028 in. (0.20 - 0.70 mm) Crankshaft 1. Thoroughly clean crankshaft and inspect bearing surfaces. Replace crankshaft if bearing surfaces are pitted, scored, or discolored. 2. Measure run-out. Replace crankshaft if out of specification. 57576 Crankshaft Run-out 0.0008 in. (0.02 mm) 90-856159R1 AUGUST 1998 Page 4B-21 CYLINDER BLOCK/CRANKCASE Crankcase and Bearing 1. Measure crankshaft main bearing clearance using the test below, replace the bearings as a set if out of specification (see Crankcase and Bearing Indication Marks). Main Bearing Clearance 0.0004 - 0.0015 in. (0.011 - 0.039 mm) CRANKSHAFT MAIN BEARING CLEARANCE MEASUREMENT IMPORTANT: Do not interchange the main bearings. Reinstall in their original position. 1. Clean all the old sealing material from the split line on the crankcase cover and cylinder block. 2. Clean all the oil from the following areas: • Main bearing surfaces on the cylinder block and crankcase cover. • Main bearings. • Crankshaft bearing surfaces. 3. Install half of the main bearings and crankshaft into the cylinder block. NOTE:Align each bearing projection with the notch in the cylinder body. 57578 a b cd a-Cylinder Block b-Crankshaft c-Main Bearing Halves d-Notch in Cylinder Body 4. Place a piece of plastigauge onto each crankshaft bearing surface. NOTE:Do not put plastigauge over the oil hole on the bearing surface of the crankshaft. 57579 a a-Plastigauge Page 4B-22 90-856159R1 AUGUST 1998 CYLINDER BLOCK/CRANKCASE 5. Install the other bearing halves into the crankcase. NOTE:Align each bearing projection with the notch in the crankcase. 57580 a a-Crankcase Bearing Halves 6. Install crankcase onto cylinder block. 7. Apply oil to the cover bolts and torque cover bolts in sequence and in two steps. IMPORTANT: Do not move crankshaft until measurement has been completed. 57581 2 4 5363 783 93 103 1 3 Crankcase Cover Bolt Torque Center Bolts Qty. 4 (Larger Diameter M8) 1st: 11 lb-ft (15 Nm) 2nd: 22 lb-ft (30 Nm) Outer Bolts Qty. 6 (Smaller Diameter M6) 1st: 53 lb-in. (6 Nm) 2nd: 104 lb-in. (12.2 Nm) 90-856159R1 AUGUST 1998 Page 4B-23 CYLINDER BLOCK/CRANKCASE 8. Remove the bolts and crankcase. 9. Measure the compressed plastigauge to check the main bearing clearance. Replace bearings if clearance is not within specification. 57577 a a-Compressed Plastigauge SELECTING NEW MAIN BEARINGS 1. Locate the main bearing code letters on the crankcase. a b a a-Main Bearing Code Letters b-Bearing Color 2. Refer to the following reference chart to select the correct main bearings. 3. Use the color coded main bearings that match the main bearing code letter. CRANKCASE AND BEARING INDICATION MARKS Main Bearing Code Letter Main Bearing Color Code A Blue B Black C Brown Page 4B-24 90-856159R1 AUGUST 1998 CYLINDER BLOCK/CRANKCASE Connecting Rod Oil Clearance 1. Measure the connecting rod oil clearance using the measurement steps below, replace the connecting rod as a set if out of specification. Connecting Rod Oil Clearance 0.0008 - 0.0018 in. (0.021 - 0.045 mm) CONNECTING ROD OIL CLEARANCE MEASUREMENT IMPORTANT: Do not interchange used connecting rod bearings. Reinstall bearings in their original position. 1. Clean all the oil from the connecting rod bearing surfaces and connecting rod journals on the crankshaft. 2. Install the connecting rod to the crankshaft. IMPORTANT: Reinstall connecting rods in their original positions (top and bottom). Make sure the “66M-00” mark on the connecting rod faces towards the driveshaft end of the crankshaft. 57583 a b a-Connecting Rod b-Driveshaft End of Crankshaft 3. Place a piece of plastigauge on the crankpin journals. a a-Plastigauge 57584 90-856159R1 AUGUST 1998 Page 4B-25 CYLINDER BLOCK/CRANKCASE 4. Assemble the connecting rod caps onto their respective crankpins. NOTE:Make sure “Flat” sides of cap and rod are together. 56589 a b a-“Flat” Side of Cap b-“Flat” Side of Connecting Rod 5. Tighten connecting rod bolts in alternating sequence and in two stages. IMPORTANT: Do not rotate connecting rod when checking clearance. Connecting Rod Bolt Torque 1st: 7.2 lb-ft (10 Nm) 2nd: 16.2 lb-ft (22 Nm) 6. Remove the connecting rod cap. 7. Measure the width of the compressed plastigauge on each crankpin to check the connecting rod oil clearance. Replace connecting rod as a set if oil clearance is not within specification. 57582 a a-Compressed Plastigauge Page 4B-26 90-856159R1 AUGUST 1998 CYLINDER BLOCK/CRANKCASE Powerhead Reassembly Piston Ring Installation IMPORTANT: Use caution when installing piston rings to avoid scratching piston. 1. Install oil ring, second ring, and top ring. NOTE:“N” should face crown of piston. 56586 f edca b 110 110 4-Stroke Outboard Oil (92-828000A12) a-Expander b-Bottom Rail c-Top Rail d-Second Ring e-Top Ring f-“N” Mark Should Face Piston Crown 2. Offset the piston ring end gaps. UP 50° a b c d e a-End Gap – Top Compression Ring b-End Gap – Second Compression Ring c-End Gap – Upper Oil Ring Rail d-End Gap – Lower Oil Ring Rail e-End Gap – Oil Ring Spacer 90-856159R1 AUGUST 1998 Page 4B-27 CYLINDER BLOCK/CRANKCASE Piston Installation 1. Assemble connecting rod to piston, secure with piston pin and new piston pin clip. IMPORTANT: Reinstall connecting rods in their original positions (top and bottom). Make sure the “Y” mark on the connecting rod is facing up when installed. NOTE:Cylinder bores must be clean before installing pistons. Clean with light honing, as necessary. After honing, clean cylinder bores with water and detergent. After cleaning, swab cylinder bores several times with engine oil and a clean cloth, then wipe with a clean dry cloth. 56588 b c b a 110 110 4-Stroke Outboard Oil (92-828000A12) a-Connecting Rod b-Piston Pin Clip (2)-New c-Piston Pin 2. Install piston/connecting rod assembly using piston ring compressor tool. NOTE:Install used pistons into same cylinder from which they were removed. NOTE:Install piston with “UP” mark on piston crown facing toward the flywheel side. 56591 P/N FT2997 a b a-Piston Ring Compressor (P/N FT2997) b-Flywheel End Page 4B-28 90-856159R1 AUGUST 1998 CYLINDER BLOCK/CRANKCASE Crankcase and Crankshaft Installation 1. Install crankshaft main bearings. NOTE:Align the projection of the bearings with the notch in the cylinder body and crankcase. Apply oil to bearings before installing. 110 110 a a 4-stroke Outboard Oil (92-828000A12) a-Main Bearings 2. Install upper and lower oil seal NOTE:Install oil seal with manufacturers marks/numbers facing outward. Apply oil to seals before installing. 110 110 110 4-Stroke Outboard Oil (92-828000A12) a b a-Upper Oil Seal b-Lower Oil Seal 3. Install crankshaft. 56265 90-856159R1 AUGUST 1998 Page 4B-29 CYLINDER BLOCK/CRANKCASE IMPORTANT: Assemble connecting rod bolts, caps, rods, and pistons in their original locations. 4. Install connecting rod cap and bolts onto their respective crankpins. NOTE:Apply oil to connecting rod bolts before installing. 5. Tighten connecting rod bolts in alternating sequence and in two stages. 56266 110 110 a b 4-Stroke Outboard Oil (92-828000A12) a-Connecting Rod Caps (2) b-Bolts (4) Connecting Rod Bolt Torque 1st: 7.2 lb-ft (10 Nm) 2nd: 16.2 lb-ft (22 Nm) 6. Apply gasket maker to contact surface of crankcase, use roller and follow instructions contained in gasket maker kit. NOTE:Verify that contact surfaces of crankcase and cylinder block are clean before applying gasket maker. 57580 Loctite Master Gasket “514” (92-12564-2)12 12 Page 4B-30 90-856159R1 AUGUST 1998 CYLINDER BLOCK/CRANKCASE 7. Install dowel pins and crankcase cover. Oil bolts and torque cover in sequence and in two steps. 110 4-Stroke Outboard Oil (92-828000A12) 110 a b c d 12 34 56 78 910 a-Dowel Pins (2) b-Crankcase Cover c-Bolts-M8x20 (4) d-Bolts-M6x14 (6) Crankcase Cover Bolt Torque Center Bolts Qty. 4 (Larger Diameter M8) 1st: 11 lb-ft (15 Nm) 2nd: 22 lb-ft (30 Nm) Outer Bolts Qty. 6 (Smaller Diameter M6) 1st: 53 lb-in. (6 Nm) 2nd: 104 lb-in. (12.9 Nm) 90-856159R1 AUGUST 1998 Page 4B-31 CYLINDER BLOCK/CRANKCASE Anode Installation 1. Install anode, cover, and plate. 56592 110 4-Stroke Outboard Oil (92-828000A12) 110 b a c d e f a-Rubber Packing b-Anode c-Anode Cover d-Bolt-M5x12 e-Plate f-Bolt-M6x20 Anode Cover Bolt Torque-M5x12 44 lb-in. (5 Nm) Plate Bolt Torque-M6x20 70 lb-in. (8 Nm) Page 4B-32 90-856159R1 AUGUST 1998 CYLINDER BLOCK/CRANKCASE Thermostat, Exhaust, and Breather Cover Installation 1. Install new gasket and breather cover. a c b d e c a-Gasket (New) b-Breather Cover c-J-Clips (2) d-Washers (3) e-Bolts (3) - M6x20 56592 Breather Cover Bolt Torque 70 lb-in. (8 Nm) 90-856159R1 AUGUST 1998 Page 4B-33 CYLINDER BLOCK/CRANKCASE 2. Install new exhaust cover gasket and exhaust cover. 3. Install thermostat, new gasket, and thermostat cover. NOTE: Torque exhaust and thermostat covers in sequence. a b c d e f g h 12 3 4 56 7 a-Gasket (New) b-Exhaust Cover c-Washers (7) d-Bolts (5)-M6x30 e-Thermostat f-Gasket (New) g-Thermostat Cover h-Bolts (2)-M6x30 Exhaust and Thermostat Cover Bolt Torque 70 lb-in. (8 Nm) Page 4B-34 90-856159R1 AUGUST 1998 CYLINDER BLOCK/CRANKCASE 4. Install oil pressure switch. NOTE:Slide boot over oil pressure switch after switch and screw have been fully tightened. 5. Install oil filter plug (if removed) and oil filter. Loctite Pipe Sealant w/Teflon-567 (92-809822) 9 9 a b c d e f a-Oil Pressure Switch b-Oil Pressure Switch Lead c-Screw w/Washer d-Boot e-Oil Filter Plug f-Oil Filter Oil Pressure Switch Torque 70 lb-in. (8 Nm) Oil Pressure Switch Lead Bolt Torque 18 lb-in. (2 Nm) Oil Filter Plug Torque 29 lb-ft (40 Nm) Oil Filter Torque 13 lb-ft (18 Nm) 90-856159R1 AUGUST 1998 Page 4B-35 CYLINDER BLOCK/CRANKCASE Following Powerhead Assembly Timing Belt Installation 1. Install cylinder head (if removed). Refer to “Cylinder Head Installation” in section 4A. 2. Install drive gear and driven gear. 110 4-Stroke Outboard Oil (92-828000A12) 110 ab c d e fg h i j a-Key-Drive Gear b-Drive Gear c-Washer (Should Curl Upwards as Shown in insert) d-Nut M28 e-Washer-Driven Gear f-Key-Driven Gear g-Driven Gear h-Washer Driven Gear i-Bolt-M6x16 j-Timing Belt (Manufacturing Part Name Upright) Drive Gear Nut Torque 29.5 lb-ft (40 Nm) Driven Gear Bolt Torque 115 lb-in. (13 Nm) 3. For timing belt installation refer to “Timing Belt Removal and Installation” in Section 2A. Page 4B-36 90-856159R1 AUGUST 1998 CYLINDER BLOCK/CRANKCASE Electrical Component Installation 1. Refer to Section 2 for installation and wiring of the following components. • Rectifier/regulator • Stator • CDI • Ignition coil • Flywheel Pickup Carburetor Installation 1. Refer to section 3 for installation of the carburetor unit and breather hose. 2. Starter motor (if equipped). Powerhead Installation 1. Secure oil strainer assembly (if removed) to powerhead with sta-straps. IMPORTANT: Position oil pick-up hose so natural bend is towards the front and carburetor side of engine. a b c d e a-Front View of Engine b-Side View of Engine c-Carburetor Side d-Oil Filter Side e-Oil Pick-up Hose 90-856159R1 AUGUST 1998 Page 4B-37 CYLINDER BLOCK/CRANKCASE Page 4B-38 90-856159R1 AUGUST 1998 2. Install powerhead gasket and dowel pins. NOTE: Do not re-use powerhead gaskets (2). 3. Place powerhead onto drive shaft housing secure powerhead with bolts. Torque powerhead bolts in sequence. NOTE: Powerhead bolts should be clean and dry prior to installation. 4. Install dipstick. a b c d e f g b 1 2 3 4 5 6 a-Oil Strainer Assembly b-Powerhead Gaskets (2) (New) c-Oil Deflection Plate d-Dowel Pins (2) e-Bolts (6)-M8x45 f-Washers (6) g-Dipstick Powerhead Bolt Torque 1st: 11 lb-ft (15 Nm) 2nd: 22 lb-ft (30 Nm) 5. Install cover. CYLINDER BLOCK/CRANKCASE 90-856159R1 AUGUST 1998 Page 4B-39 Following Powerhead Installation 1. Install inlet fuel hose onto fuel pump. a a-Fuel Hose (Inlet) 2. Install tell–tale water hose. a a-Water Hose 3. Fill engine with oil (refer to “Changing Engine Oil” in Section 1B). 4. Connect throttle linkage (refer to section 3B “Carburetor Adjustments” for correct installation and setup of linkages). 5. Install bracket (if equipped). a b a-Bracket b-Bolts-M6x13 Choke Bracket Bolt Torque 70 lb-in. (8 Nm) CYLINDER BLOCK/CRANKCASE Electric Start Models 1. Install battery cables at the starter motor side. 2. Install flywheel cover. Manual Start Models 1. Install starter rewind, refer to Section 8 “Manual Starter”. All Models (If Equipped) 1. Connect the following leads, refer to the wiring diagrams in section 2D. • Engine stop switch leads. • Neutral start switch lead. • Fuse lead. • Oil light leads. Driveshaft Housings Covers 1. Install driveshaft housing covers (4 bolts and nuts). 56919 a b a-Driveshaft Housing Covers b-Bolts (4), Nuts (4) Driveshaft Housing Cover Bolt Torque 30 lb-in. (3.4 Nm) Page 4B-40 90-856159R1 AUGUST 1998 OIL PUMP POWERHEAD Section 4C – Oil Pump Table of Contents Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-1 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . . . 4C-3 Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . 4C-2 Oil Pump Reassembly . . . . . . . . . . . . . . . . . . . . . 4C-4 Oil Pump Disassembly . . . . . . . . . . . . . . . . . . . . . 4C-2 Oil Pump Installation. . . . . . . . . . . . . . . . . . . . . . . 4C-4 Specifications Pump Type Trochoid Engine Oil Pressure 30-40 psi at 3000 rpm (Warm Engine) Engine Oil Pan Capacity Either 1 Qts. or 1 Liters Oil Pump: Outer Rotor to Housing “a” 0.0024 - 0.0043 in. (0.06 - 0.11 mm) Inner Rotor to Outer Rotor “b” 0.0008 - 0.0059 in. (0.02 - 0.15 mm) Rotor to Housing “c” Relief Valve Opening Pressure 0.008 - 0.003 in. (0.02 - 0.07 mm) 55-64 psi (3.88-4.50 Kg/cm2) a 388-450 kPa LUBRICATION SYSTEM b c 4 C 90-856159R1 AUGUST 1998 Page 4C-1 OIL PUMP Oil Pump Removal 1. Refer to “Oil Pump Removal” in Section 4A. Oil Pump Disassembly 1. Remove screws, gaskets, rotors, and pin. NOTE:Rubber gasket is not reusable, please discard. a b c d f g h e a-Screw- M6x20 b-Oil Pump Cover c-Gasket-Oil Pump (Discard) d-Inner Rotor e-Outer Rotor f-Pin g-Shaft h-Oil Pump Housing Page 4C-2 90-856159R1 AUGUST 1998 OIL PUMP Cleaning/Inspection/Repair 1. Inspect oil pump components for pitting/scratches. Replace if necessary. 2. Using a feeler gauge, measure the following oil pump clearances. Replace if worn or out of specification. • Between outer rotor and pump housing. • Between the inner rotor and outer rotor. • Between the outer rotor and pump housing. 55803 a bc a-Outer rotor and Pump Housing b-Inner Rotor and Outer Rotor c-Outer Rotor and Pump Housing Oil Pump Clearances a 0.0024 - 0.0043 in. (0.06 - 0.11 mm) b 0.0008 - 0.0059 in. (0.02 - 0.15 mm) c 0.008 - 0.003 in. (0.02 - 0.07 mm) 90-856159R1 AUGUST 1998 Page 4C-3 OIL PUMP Oil Pump Reassembly 1. Install pin, rotors, gasket (new), and screws. NOTE:Rubber gasket is not reusable, please discard. 95 2-4-C w/Teflon (92-850736A1) 95 95 a b c d e f g h a-Oil Pump Housing b-Shaft c-Pin d-Inner Rotor e-Outer Rotor f-Gasket-Oil Pump (New) g-Oil Pump Cover h-Screw (2) M6x20 Oil Pump Cover Screw Torque 39 lb-in. (4 Nm) Oil Pump Installation 1. Refer to “Oil Pump Installation” in Section 4A. Page 4C-4 90-856159R1 AUGUST 1998 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING MID-SECTION Section 5 – Clamp/Swivel Brackets & Drive Shaft Housing Table of Contents Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Drive Shaft Housing Assembly . . . . . . . . . . . . . . . 5-6 Clamp Bracket Assembly . . . . . . . . . . . . . . . . . . . . 5-2 Removal/Installation of Clamp Bracket Swivel Bracket Assembly . . . . . . . . . . . . . . . . . . . . 5-4 Assembly and Mounts . . . . . . . . . . . . . . . . . . . . . . 5-8 Specifications MID-SECTION Transom Height: Short Shaft Long Shaft Steering Pivot Range Tilt Pin Positions Full Tilt Up Angle Allowable Transom Thickness 15-7/8 in. (40.3 cm) 21-3/8 in. (54.3 cm) 70° 5 + Shallow Water 66° 2-3/8 in. (60.3 mm) 5 90-856159R1 AUGUST 1998 Page 5-1 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Clamp Bracket Assembly 95 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 1920 21 22 23 24 25 26 27 28 29 30 31 323334 35 3 17 95 2-4-C w/Teflon (92-850736A1) Page 5-2 90-856159R1 AUGUST 1998 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Clamp Bracket Assembly REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 11 1 CLAMP BRACKET (STARBOARD)(BLACK) 1 CLAMP BRACKET (STARBOARD)(GRAY) 22 1 CLAMP BRACKET (PORT)(BLACK) 1 CLAMP BRACKET (PORT)(GRAY) 3 2 THUMB SCREW ASSEMBLY 4 2 RIVET 5 2 HANDLE 6 2 BOLT 140 11.7 15.8 7 2 WASHER–thumb screw 8 1 NUT (.250) 65 7.3 9 1 NUT (.875) 120 10.0 13.6 10 1 SCREW (M6 x 40) 140 11.7 15.8 11 1 HANDLE–carrying 12 1 SPACER 13 1 WASHER–tilt tube (NYLON) 14 1 TILT TUBE 15 1 WASHER–tilt tube (NYLON) 16 1 DECAL–co-pilot (HANDLE MODELS) 17 1 TILT PIN ASSEMBLY 18 1 SPRING 19 1 SCREW (M6 x 40) 140 11.7 15.8 20 1 NUT (.875) 120 10.0 13.6 21 1 CLIP–safety 22 2 BOLT (.312 x 3.50) 23 2 WASHER 24 2 NUT(.312) 25 1 NUT (.250) 65 7.3 26 1 SCREW (.250 x 1.00) 65 7.3 27 1 LEVER–tilt stop - starboard side 28 1 NUT (.250) 65 7.3 29 1 SPRING–tilt stop lever screw 30 1 SCREW (.250 x 1.75) 65 7.3 31 1 SCREW (.250 x 1.75) 65 7.3 32 1 WAVE WASHER–tilt stop strap screw 33 1 NUT (.250) 65 7.3 34 1 STRAP–tilt stop - port side 35 1 BOLT (.250 x 1.00) 65 7.3 90-856159R1 AUGUST 1998 Page 5-3 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5-4 90-856159R1 AUGUST 1998 Swivel Bracket Assembly 1 2 3 4 5 6 7 8 9 27 30 31 34 41 42 43 44 47 29 30 48 49 45 50 46 44 35 51 7 7 95 7 36 37 38 36 A-TIGHTEN NUT UNTIL IT SEATS AND THEN BACK OFF 1/4 TURN. 39 40 95 2-4-C w/Teflon (92-850736A1) 94 Anti-Corrosion Grease (92-850735A1) 94 95 95 95 95 7 Loctite “271” (92-809819) 10 11 12 14 15 16 17 13 18 19 20 21 22 23 26 25 24 28 32 29 33 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Swivel Bracket Assembly REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 SWIVEL BRACKET (BLACK) 2 1 GREASE FITTING 35 4 3 2 GREASE FITTING 35 4 4 1 GREASE FITTING 35 4 5 1 BUSHING 6 1 O-RING 7 1 BUSHING 8 1 BUSHING 9 1 WASHER 10 1 ROD 11 2 BRAKE DISC 12 1 SWIVEL HEAD PLATE HANDLE 13 2 BOLT (M6 x 13) 140 11.7 15.8 14 1 BRACKET PLATE 15 1 WASHER 16 1 HANDLE 17 1 NUT (.375) 125 10.4 14.1 18 1 REVERSE LOCK HOOK 19 1 SPRING 20 1 SPRING 21 1 RETAINING RING 22 1 PIN 23 1 TROLL BRACKET HANDLE 24 1 SPRING 25 1 CONTROL LEVER 26 1 RETAINING RING 27 1 BOLT (.375 x 1.250) 20 27.1 28 1 STEERING LINK 29 2 WASHER ELECTRIC - NON-HANDLE 30 2 NUT (.375) See Note A 31 1 BRACKET (BLACK) 32 2 SCREW (M10 x 25) 32.5 44 33 2 LOCKWASHER 34 1 SWIVEL HEAD ASSEMBLY (BLACK) 35 1 REVERSE LOCK SHAFT 36 2 GUIDE 37 1 SCREW (M5 x 25) 38 1 NUT 39 OPT REVERSE LOCK LINK ROD KIT MAY BE USED IN PLACE BOLT (M5 x 6) OF REF. #3540 2 41 2 STUD (M10 x 1.5) Drive Tight 42 2 WASHER 43 2 NUT (M10) 32.5 44 44 2 MOUNT 45 1 COVER (STARBOARD) (BLACK) 46 1 COVER (PORT)(BLACK) 47 2 BOLT (M8 x 100) 32.5 44 48 1 BOLT (M8 x 60) 32.5 44 49 3 WASHER 50 3 NUT (M8) 32.5 44 51 1 DECAL-Serial Overlaminate 90-856159R1 AUGUST 1998 Page 5-5 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5-6 90-856159R1 AUGUST 1998 Drive Shaft Housing Assembly 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 4 2 3 23 24 25 26 27 28 21 29 30 7 Loctite “271” (92-809819) 7 7 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Drive Shaft Housing Assembly REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 11 1 DRIVESHAFT HOUSING (SHORT & BIGFOOT)(BLACK) 1 DRIVESHAFT HOUSING (SHORT & BIGFOOT)(GRAY) 1 DRIVESHAFT HOUSING (LONG)(BLACK) 1 DRIVESHAFT HOUSING (LONG)(GRAY) 22 2 MOUNT-Upper 2 MOUNT-Upper (BIGFOOT) 3 4 SCREW (M8 x .98) 15 20.3 4 1 SEAL 5 1 GASKET 6 1 DRAIN PLUG 17.5 23.7 7 1 COVER 8 1 GASKET 9 8 SCREW (M6 x 16) 70 8 10 1 SEAL 11 1 WATER TUBE (SHORT) 1 WATER TUBE (LONG) 1 WATER TUBE (BIGFOOT) 12 1 SEAL 13 1 OIL SEAL 14 1 SEAL 15 1 BRACKET 16 1 SLEEVE 1717 1 COVER (PORT)(BLACK) 1 COVER (PORT)(GRAY) 1818 1 COVER (STARBOARD)(BLACK) 1 COVER (STARBOARD)(GRAY) 19 4 SCREW (M6 x 55) 30 3.4 20 4 NUT 21 2 BUMPER 22 1 GROMMET 2323 1 ADAPTOR (BLACK) 1 ADAPTOR (GRAY) 24 1 BUSHING BIGFOOT 25 1 BOLT (M8 x 50) 15 20.3 26 2 BOLT (M8 x 30) 15 20.3 27 1 RELIEF VALVE ASSEMBLY 125 10.4 14.1 28 1 O RING 29 2 DOWEL PIN 30 1 PIPE PLUG 90-856159R1 AUGUST 1998 Page 5-7 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Driveshaft Housing Cover Removal/Installation 1. Remove driveshaft housing covers (4 screws and nuts). NOTE:To aid in removal of screws, a small straight screwdriver should be placed in nut pocket to prevent turning of nuts. 56919 a b a-Driveshaft Housing Covers b-Screws (4), Nuts (4) 2. Install driveshaft housing covers (4 screws and nuts). Driveshaft Housing Cover Bolt Torque 30 lb-in. (3.4 Nm) Upper Motor Mount Replacement NOTE:Change one mount at a time. 1. Remove driveshaft housing covers. 2. Remove two (2) bolts (M8x.98) from upper mount. 3. Remove nut and washer from swivel head stud. 36917 a b c a-Nut and Washer b-Bolts (2) c-Upper Mount Page 5-8 90-856159R1 AUGUST 1998 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 4. Slide a piece of rubber hose over a screwdriver to prevent paint damage on outboard components. Pry up on lower cowl pan. Slide mount off of stud. 56916 a b a-Rubber Padded Bar b-Mount 5. Pry up on lower cowl pan to slide new mount over stud just enough to pass over top lip on lower cowl pan. Remove pry bar. Push down on top of outboard (to seat mount). Mount should align into place. a a-Lip on Lower Cowl Pan 56918 90-856159R1 AUGUST 1998 Page 5-9 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5-10 90-856159R1 AUGUST 1998 6. First replace two (2) bolts (M8x.98) into mount and then replace washer and nut. 7. Torque two (2) bolts to 15 lb-ft (20.3 Nm). 8. Torque nut to 32.5 lb-ft (44 Nm). 9. Re-install driveshaft housing covers. 36917 a b a-Nut and Washer - Torque to 32.5 lb-ft (44 Nm) b-Bolts (2) Torque to 15 lb-ft (20.3 Nm) Removal/Installation of Clamp Bracket Assembly 1. Shift outboard into reverse. 2. Remove driveshaft housing covers. 3. Lay outboard on backside. 4. Disconnect shift shaft. 5. Remove upper mount bolts and nuts. 6. Remove lower mount covers. 56681 a b c d e f a-Covers-Lower Mount (2) b-Bolts-Lower Mount M8x100 (2) c-Bolt-Lower Mount M8x60 d-Bolts-Upper Mount M8x.98 (4) e-Nuts-Upper Mount (2) f-Shift Shaft CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 90-856159R1 AUGUST 1998 Page 5-11 7. Remove upper mounts while lifting clamp bracket/swivel arm assembly from drive shaft housing. 56680 a a-Upper Mounts 8. Remove clamp bracket/swivel arm assembly from outboard by freeing upper shift shaft from reverse hook lock. 56679 a b a-Upper Shift Shaft b-Reverse Hook Lock 9. Reverse steps for installation. Refer to exploded views for correct torques. CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5-12 90-856159R1 AUGUST 1998 Reverse Lock Link Rod Installation (2 Piece Design) Reverse Lock Link Rod Up-Grade (Refer to Mercury/Mariner Service Bulletin No. 98-13) 57141 a b c a-Upper Reverse Lock Link Rod - Early design (actuated by a cross pin) making contact with lower cowl. b-Reverse Lock Link Rod Kit (p/n 858338A3) - Current design, actuated by reverse hook guide. c-Reverse Hook Guide Pre-Assembly 1. Assemble reverse lock link rod to align flats of looped end link and hooked end link with threaded holes of link rod coupling. Ends of link rods should butt together. 57153 b d c d a c a d b a-Looped End Link b-Hooked End Link c-Coupling d-Flats CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 2. Apply Loctite 271 to threads of both coupling bolts. IMPORTANT: Secure coupling in a vice when tightening the first bolt to prevent bending of the link rod. 3. Secure coupling to looped end link rod (only) using first bolt. 4. Tighten bolt on flat of looped end link rod to a torque of 50 lb. in. (5.7 N·m). 5. Apply a mark on hooked end link to indicate full engagement into the coupling. 6. Temporally remove hooked end link rod from coupling and start second bolt into front coupling hole. Do not tighten at this time. IMPORTANT: Make sure second bolt doesn’t protrude into coupler bore at this time. a bc d e 57152 a d f e b c 7 Loctite “271” (92-809819) 7 a-Looped End Link d-Bolt -Tighten to a torque of 50 lb. in. (5.7 N·m) b-Hooked End Link e-Second Bolt -DO NOT tighten at this time. c-Coupling f-Engagement Mark 7. Shift to reverse. 8. Lift up on reverse lock hook and tilt outboard to full up position. Secure with tilt lock lever. 9. Remove and discard both link rod pieces. 10. Disconnect vertical shift shaft coupling and remove/retain “jam” nut. b a c a-Vertical Shift Shaft b-Coupling c-Jam Nut 90-856159R1 AUGUST 1998 Page 5-13 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5-14 90-856159R1 AUGUST 1998 11. Install hooked end reverse link rod: • Up through slot in swivel bracket and opening in swivel head. a c b a-Hooked End Reverse Link Rod b-Swivel Bracket c-Reverse Lock Hook • With top leg of 90 bend pointing aft, secure lower hooked end of link rod onto clip of reverse lock hook. b c 57157 a a-Hooked End Reverse Link Rod b-Lower Hooked End c-Reverse Lock Hook Clip CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 90-856159R1 AUGUST 1998 Page 5-15 12. Install looped end link rod with coupling behind starboard upper mount arm. b a a-Looped End Reverse Link Rod b-Upper Mount Arm 13. Join link rod halves at coupler. Make sure end of hooked link rod is fully engaged into coupler (up to mark). 14. Tighten bolt on flat of hooked end link rod to a torque of 50 lb. in. (5.7 N·m). NOTE: Lift up on reverse lock hooks to gain additional access to coupling bolts. a c b d a-Coupler b-Engagement Mark c-Hooked End Reverse Link Rod d-Bolt - Torque to 50 lb. in. (5.7 N·m) CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Page 5-16 90-856159R1 AUGUST 1998 15. Position lower loop of looped end link rod over end of the lower shift shaft. 16. Thread (retained) “jam” nut onto lower shift to expose five (5) threads above the nut. 57138 a c b a-Looped End Reverse Link Rod b-Lower Shift Shaft c-Jam Nut 17. Place shift handle (tiller models) or shift lever (remote control models) into neutral. 18. Place gear housing into neutral by pulling up on shift shaft to neutral detent. (Propeller will rotate freely in either direction). 19. Reconnect shift shaft coupling and tighten “jam” nut against coupler. 57139 a b a-Coupling b-Jam Nut CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 20. Shift to forward gear. 21. Assemble supplied reverse hook guide around lower shift shaft and tighten bolt/nut to allow adjustment. 22. Lift and hold reverse lock hook in the full up position. 23. Slide reverse hook guide up shift shaft to make contact with loop of reverse lock link rod. DO NOT bend link rod. Tighten guide bolt/nut to a torque of 50 lb. in. (5.7 N·m). a b c d a-Reverse Hook Guide b-Bolt/Nut - Torque to 50 lb. in. (5.7 N·m) c-Reverse Lock Hook Link Rod d-Reverse Lock Hook 24. Lower outboard to the normal operating position. 25. Check reverse lock operation as follows: • Forward Gear – Reverse lock fully released. Outboard will tilt up. • Neutral – Reverse lock engaged. Outboard will not tilt up. • Reverse Gear – Reverse lock fully engaged. Outboard will not tilt up. 26. Shift outboard into reverse and verify that free play exists between lower loop of reverse lock link rod and shift shaft coupling “jam”. 27. If no free play exists, inspect link rod/coupling for proper assembly. 90-856159R1 AUGUST 1998 Page 5-17 NON BIGFOOT GEAR HOUSING LOWER UNIT Section 6A – Non-Bigfoot Gear Housing Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2 Gear Housing (Drive Shaft) . . . . . . . . . . . . . . . . . 6A-4 Gear Housing (Propeller Shaft) . . . . . . . . . . . . . . 6A-6 General Service Recommendations . . . . . . . . . 6A-8 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-8 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-8 Draining and Inspecting Gear Lubricant . . . . . . 6A-9 Gear Housing Removal . . . . . . . . . . . . . . . . . . . 6A-10 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-11 Bearing Carrier. . . . . . . . . . . . . . . . . . . . . . . . 6A-11 Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . 6A-13 Water Pump, Drive Shaft and Shift Shaft . 6A-15 Pinion Gear and Forward Gear . . . . . . . . . . 6A-20 Drive Shaft Bushing, Bearing and Lubrication Sleeve. . . . . . . . . . . . . . . . . . . . . 6A-23 Aluminum Anode and Water Inlet . . . . . . . . 6A-25 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-26 Drive Shaft Needle Bearing, Bushing and Lubrication Sleeve Installation . . . . . . . 6A-26 Specifications Forward Gear Bearing Race Installation . . 6A-28 Forward Gear Reassembly . . . . . . . . . . . . . 6A-28 Bearing Carrier Reassembly . . . . . . . . . . . . 6A-29 Water Pump Base and Shift Shaft Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-31 Propeller Shaft Reassembly . . . . . . . . . . . . 6A-33 Forward Gear, Pinion Gear and Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . 6A-34 Shift Shaft and Water Pump Base Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-35 Water Pump Cover Reassembly . . . . . . . . . 6A-37 Impeller and Pump Cover Installation . . . . 6A-38 Propeller Shaft and Bearing Carrier Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-39 Aluminum Anode and Water Inlet Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-40 Filling Gear Housing with Lubricant . . . . . . . . . 6A-40 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-41 6 A Gear Ratio 2.0:1 Gearcase Capacity Lubricant Type 6.8 fl oz (200 mL) Quicksilver Gear Lube-Premium Blend Forward Gear Number of Teeth 26 Spiral/Bevel GEAR HOUSING (2.0:1) Pinion Gear Number of Teeth Pinion Height Forward Gear Backlash 13 Spiral/Bevel Floating No Adjustment Reverse Gear Backlash No Adjustment Water Pressure @ 950 rpm (Idle) @ 5000 rpm (WOT) 1/2 – 1-1/2 psi (3.5-10 kPa) 5-7 psi (34-48 kPa) 90-856159R1 AUGUST 1998 Page 6A-1 NON BIGFOOT GEAR HOUSING Special Tools 1. Universal Puller Plate-P/N 91-37241. 2. Puller Assembly P/N 91-83165M. 3. Slide Hammer P/N 91-34569A1. 4. Bearing Carrier Tool P/N 91-13664. 5. Drive Shaft Bearing Removal Tool P/N 91-824788A1. 6. Drive Shaft Bushing Installation Tool P/N 91-824790A1. 7. Mandrel P/N 91-13658. Page 6A-2 90-856159R1 AUGUST 1998 NON BIGFOOT GEAR HOUSING 8. Bushing Removal Tool P/N 91-824787. 9. Seal Installation Tool P/N 91-824785A1. 10. Puller Plate P/N 91-29310. 11. Expanding Rod (Obtain from Snap-On P/N CG40-4). 12. Collet (Jaws) (Obtain from Snap-On P/N CG40A6). 13. Leakage Tester-P/N FT8950. 90-856159R1 AUGUST 1998 Page 6A-3 NON BIGFOOT GEAR HOUSING Gear Housing (Drive Shaft) 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 28 34 35 38 39 40 41 42 43 44 29 7 Loctite “271” (92-809819) 85 RTV Silicone Sealer (92-91601-1) 87 Super Duty Gear Lubricant (92-850737A1) 7 7 7 85 87 87 95 95 95 95 14 18 19 20 21 22 23 24 25 26 27 30 31 32 36 37 33 24 35 33 95 2-4-C w/Teflon (92-850736A1) Page 6A-4 90-856159R1 AUGUST 1998 NON BIGFOOT GEAR HOUSING Gear Housing (Drive Shaft) REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm – 1 GEAR HOUSING (SHORT - BLACK) – 1 GEAR HOUSING (SHORT - GRAY) – 1 GEAR HOUSING (LONG - BLACK) – 1 GEAR HOUSING (LONG - GRAY) 11 1 GEAR HOUSING (BASIC - BLACK) 1 GEAR HOUSING (BASIC - GRAY) 2 1 BUSHING–gear housing 3 1 DRAIN SCREW 60 6.8 4 1 SEALING WASHER 5 1 SLEEVE ASSEMBLY 6 1 SLEEVE 7 1 BUSHING 8 1 SCREW PLUG KIT 60 6.8 9 1 SEALING WASHER 10 1 SCREEN 11 1 SCREW (.250 x .875) 30 3.4 12 1 ANODE ASSEMBLY 13 1 SCREW (.250 x .875) 30 3.4 14 1 SEAL 15 1 PINION GEAR (13-26) 16 1 WASHER–thrust 17 1 BEARING 18 1 WATER PUMP BASE 19 1 GASKET 20 1 SEAL 21 1 RETAINER 22 1 SCREW (#10 x .50) Drive Tight 23 1 QUAD RING 24 2 OIL SEAL 25 1 GASKET 26 1 WATER TUBE 27 1 FACE PLATE 28 1 COVER ASSEMBLY 29 1 INSERT 30 1 SEAL 31 1 IMPELLER 32 1 KEY ASSEMBLY 33 2 WASHER 34 1 GUIDE 35 5 BOLT (M6 x 30) 50 5.6 36 1 WASHER 37 1 CAM–shift 3838 1 SHIFT SHAFT (SHORT) 1 SHIFT SHAFT (LONG) 39 1 NUT (M6) Tighten Securely 40 1 COUPLER Tighten Securely 41 1 SHIFT SHAFT (UPPER) 42 1 E-RING 4343 1 DRIVE SHAFT (SHORT) 1 DRIVE SHAFT (LONG) 44 1 THRUST WASHER 90-856159R1 AUGUST 1998 Page 6A-5 NON BIGFOOT GEAR HOUSING Gear Housing (Propeller Shaft) 1 45 47 48 49 50 51 52 53 54 55 5657 58 59 60 61 62 63 64 65 46 7 7 7 87 95 95 95 94 87 87 7 87 95 94 Loctite “271” (92-809819) Super Duty Gear Lubricant (92-850737A1) Anti-Corrosion Grease (92-850735A1) 2-4-C w/Teflon (92-850736A1) Page 6A-6 90-856159R1 AUGUST 1998 NON BIGFOOT GEAR HOUSING Gear Housing (Propeller Shaft) REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm – 1 GEAR HOUSING (SHORT - BLACK) – 1 GEAR HOUSING (SHORT - GRAY) – 1 GEAR HOUSING (LONG - BLACK) – 1 GEAR HOUSING (LONG - GRAY) 11 1 GEAR HOUSING (BASIC - BLACK) 1 GEAR HOUSING (BASIC - GRAY) 45 1 ROLLER BEARING 46 1 CUP 47 1 FORWARD GEAR (13-26) 48 1 BUSHING 49 1 CAM FOLLOWER 50 1 CLUTCH ASSEMBLY 51 1 CROSS PIN 52 1 SPRING 53 1 PROPELLER SHAFT 54 1 REVERSE GEAR (13-26) 55 1 BEARING CARRIER 85 115.0 56 1 O-RING 57 1 BUSHING 58 1 OIL SEAL 59 1 OIL SEAL 60 1 BOLT (M8 x 50) 15 20.3 61 2 BOLT (M8 x 30) 15 20.3 62 1 PROPELLER 63 1 PROPELLER NUT 100 8.3 11.3 64 1 THRUST HUB 65 1 SPACER 90-856159R1 AUGUST 1998 Page 6A-7 NON BIGFOOT GEAR HOUSING General Service Recommendations There may be more than one way to “disassemble” or “reassemble” a particular part(s), therefore, it is recommended that the entire procedure be read prior to repair. IMPORTANT: Read the following before attempting any repairs. In many cases, disassembly of a sub-assembly may not be necessary until cleaning and inspection reveals that disassembly is required for replacement of one or more components. Service procedure order in this section is a normal disassembly-reassembly sequence. Threaded parts are right hand (RH), unless otherwise indicated. When holding, pressing or driving is required, use soft metal vise jaw protectors or wood for protection of parts. Use a suitable mandrel (one that will contact only the bearing race) when pressing or driving bearings. Whenever compressed air is used to dry a part, verify that no water is present in air line. Bearings All bearings must be cleaned and inspected. Clean bearings with solvent and dry with compressed air. Air should be directed at the bearing so that it passes through the bearing. DO NOT spin bearing with compressed air as this may cause bearing to score from lack of lubrication. After cleaning, lubricate bearings with Quicksilver Gear Lubricant. DO NOT lubricate tapered bearing cups until after inspection. Inspect all bearings for roughness, catches and bearing race side wear. Work inner bearing race in-and-out, while holding outer race, to check for side wear. When inspecting tapered bearings, determine condition of rollers and inner bearing race by inspecting bearing cup for pitting, scoring, grooves, uneven wear, imbedded particles and/or discoloration from over-heating. Always replace tapered bearing and race as a set. Inspect gear housing for bearing races that have spun in their respective bores. If race(s) have spun, gear housing must be replaced. Roller bearing condition is determined by inspecting the surface of the shaft that the roller bearing supports. Check shaft surface for pitting scoring, grooving, imbedded particles, uneven wear and/or discoloration from overheating. The shaft and bearing must be replaced if such a condition exists. Seals As a normal procedure, all O-rings and oil seals SHOULD BE REPLACED without regard to appearance. To prevent leakage around seals, apply Loctite 271 to outer diameter of all metal case seals. When using Loctite on seals or threads, surfaces must be clean and dry. Apply 2-4-C w/Teflon on all O-rings and on I.D. of oil seals. Apply 2-4-C w/Teflon to bearing carrier threads and pilot diameters. Page 6A-8 90-856159R1 AUGUST 1998 NON BIGFOOT GEAR HOUSING Draining and Inspecting Gear Lubricant WARNING If gear housing is installed on outboard, disconnect (and isolate) spark plug leads from spark plugs before working near the propeller. 1. 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. Pressure check gear case prior to disassembly. 53001 a b a-Vent Screw b-Fill Screw 90-856159R1 AUGUST 1998 Page 6A-9 NON BIGFOOT GEAR HOUSING Page 6A-10 90-856159R1 AUGUST 1998 Gear Housing Removal WARNING To prevent accidental engine starting, remove (and isolate) spark plug leads from spark plugs BEFORE removing gear housing. 1. Tilt outboard to full “UP” position. 2. Remove reverse hook guide assembly from lower shift shaft. 3. Loosen jam nut and disconnect coupler. Remove jam nut to allow removal of gearcase. a b c a-Reverse Hook Guide b-Jam Nut c-Coupler 4. Remove 3 bolts. 52998 a a a-Bolts (3) NON BIGFOOT GEAR HOUSING Disassembly IMPORTANT: It is recommended that, during complete disassembly of gear housing, all O-rings and oil seals be replaced, regardless of their appearance. Bearing Carrier 1. Remove bearing carrier (LEFT HAND thread) using Bearing Carrier Tool (91-13664). 52993 91-13664 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. 90-856159R1 AUGUST 1998 Page 6A-11 NON BIGFOOT GEAR HOUSING 4. Replace REVERSE gear if gear teeth or clutch teeth are chipped or worn. 52988 a b a-Gear Teeth b-Clutch Teeth NOTE:When using a screwdriver to remove carrier seals, be careful not to scar carrier seal surface. If carrier seal surface is damaged, replace carrier. 5. Using a screwdriver, remove both seals from bearing carrier. 57136 a a-Oil Seals 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). 53026 a b a-Bushingb-Mandrel (91-824787) 91-824787 Page 6A-12 90-856159R1 AUGUST 1998 NON BIGFOOT GEAR HOUSING Propeller Shaft 1. Inspect cam follower for wear. If cam follower is worn, replace follower and inspect shift cam for serviceability. Replace cam if worn. a a-Cam Follower 2. Remove groove pin from clutch/propeller shaft applying pressure to side of pin that is NOT grooved. Discard pin. 53013 a b a-Punch b-Groove Pin (Discard) 3. Remove spring and sliding clutch. a b 53005 a-Spring b-Clutch 90-856159R1 AUGUST 1998 Page 6A-13 NON BIGFOOT GEAR HOUSING 4. Replace clutch if jaws are rounded or chipped. Rounded jaws may be caused by the following: • Improper shift cable adjustment or linkage. • Engine idle speed too high while shifting. • 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: • Splines are twisted or worn. • Oil seal surface is grooved. • Shaft has a noticeable “wobble” or is bent more than 0.006 in. (0.15mm). a b ca 52997 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) Page 6A-14 90-856159R1 AUGUST 1998 NON BIGFOOT GEAR HOUSING Water Pump, Drive Shaft and Shift Shaft 1. Remove four (4) bolts from pump cover. 53023 a a a-Bolts (4) 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. 53048 a bc d e a-Cover b-Nylon Washer c-Impeller d-Nylon Washer e-Key 90-856159R1 AUGUST 1998 Page 6A-15 NON BIGFOOT GEAR HOUSING 4. Remove guide from cover. 5. Replace rubber seal if damaged. 6. Replace cover if inside is grooved. 53032 a b a-Guide b-Seal 7. Remove plate, gasket, quad-ring seal, bolt and washer. 8. Replace plate if grooved. 53012 a b c d a-Plate b-Gasket (Discard) c-Quad-Ring Seal d-Bolt and Washer 9. Replace quad ring seal if damaged. Page 6A-16 90-856159R1 AUGUST 1998 NON BIGFOOT GEAR HOUSING 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. 53015 a a-Gasket (Discard) 12. Inspect shift cam for wear. Replace if worn. 53034 a a-Shift Cam 90-856159R1 AUGUST 1998 Page 6A-17 NON BIGFOOT GEAR HOUSING 13. Remove clip from shift shaft. Unthread shift cam. Remove shaft from water pump base. 53034 a b a-Clip b-Shift Cam 14. Remove screw and pull water tube from base. 53009 a b a-Screw b-Water Tube 15. Replace seal if damaged. Replace water tube if corroded/eroded. 53024 a b a-Seal b-Water Tube Page 6A-18 90-856159R1 AUGUST 1998 NON BIGFOOT GEAR HOUSING 16. Remove drive shaft from gear housing. NOTE:Thrust washers, pinion gear and forward gear assembly are free to fall from housing when drive shaft is removed. 52995 a b c d a-Thrust Washer (without oil groove) b-Thrust Washer (with oil groove – groove faces down) c-Pinion Gear d-Forward Gear Assembly 17. Inspect bearing/bushing surfaces of drive shaft for pitting or wear. If shaft is pitted or worn, replace shaft and corresponding bearing/bushing. 18. Replace drive shaft if the following exist: • Splines are twisted or worn. • Oil seal surface is grooved. 53036ab c a-Bearing Surface b-Bearing Surface c-Seal Surface 90-856159R1 AUGUST 1998 Page 6A-19 NON BIGFOOT GEAR HOUSING 19. Using a screwdriver or punch, carefully remove (and discard) seals from pump base. 53010 a a-Seals 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. 52991 a a-Pinion Gear Page 6A-20 90-856159R1 AUGUST 1998 NON BIGFOOT GEAR HOUSING 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: • Improper shift cable adjustment or linkage. • Engine idle speed too high. • Shifting too slowly. 52989 a b 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. 52989 52997 a b a-Bushing b-Bushing Surface 4. If necessary, press bushing from gear using Bushing Removal Tool 91-824787. 91-824787 53035 a b a-Bushing b-Bushing Removal Tool (91-824787) 90-856159R1 AUGUST 1998 Page 6A-21 NON BIGFOOT GEAR HOUSING IMPORTANT: If FORWARD gear tapered bearing or race requires replacement, replace bearing and race as a set. NOTE: DO NOT remove tapered bearing from FORWARD gear unless replacement is necessary as removal process will damage bearing. 5. Inspect FORWARD gear tapered bearing and race for rust, roughness or excessive wear (looseness). 6. If bearing is in serviceable condition, DO NOT remove bearing from gear as removal process will damage bearing. 7. If bearing must be replaced, remove bearing from gear using Universal Puller Plate (91-37241) and a suitable mandrel (5/8 in. socket). 53008 a b c a-Bearing b-Universal Puller Plate (91-37241) c-Mandrel (5/8 in. Socket) 8. Replace FORWARD gear race if it is rusted or damaged or if FORWARD gear tapered bearing must be replaced. Remove race from housing using Bearing Puller Assembly (91-83165M) and Puller Plate (91-29310). 52996 53031 a cb b c 91-83165M a-Race b-Bearing Puller Assembly (91-83165M) c-Puller Plate (91-29310) Page 6A-22 90-856159R1 AUGUST 1998 NON BIGFOOT GEAR HOUSING 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. 53036 ab 53041 c d a-Bushing Surface b-Bearing Surface c-Upper Drive Shaft Bushing d-Lower Drive Shaft Needle Bearing IMPORTANT: If upper drive shaft bushing or lower drive shaft needle bearing appear to be spinning in their respective bores, the gear housing should be replaced. 2. To replace upper drive shaft bushing, use Snap On* Expanding Rod (CG 40-4) Snap On Collet (CG 40A6) Slide Hammer (91-34569A1) *Purchase from: Snap On Tools Corporation 2801 - 80th Street Kenosha, WI 53141-1410 53042 CG 40A6 CG 40-4 53045 a b c d 91-34569A1 a-Expanding Rod (CG 40-4) b-Collet (CG 40A6) c-Slide Hammer (91-34569A1) d-Bushing 90-856159R1 AUGUST 1998 Page 6A-23 NON BIGFOOT GEAR HOUSING 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). 91-824788A1 53029 53039 a b c a-Needle Bearing b-Driver Rod c-Pilot Page 6A-24 90-856159R1 AUGUST 1998 NON BIGFOOT GEAR HOUSING Aluminum Anode and Water Inlet 1. Replace aluminum anode if more than 50% consumed. 2. Remove water inlet and check that holes are not obstructed. 53050 b a a-Aluminum Anode b-Water Inlet 90-856159R1 AUGUST 1998 Page 6A-25 NON BIGFOOT GEAR HOUSING 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 ab c d e f a-Puller Bolt b-Flat Washer c-Wafer Bearing d-Pilot e-Needle Bearing f-Mandrel 2. Install lubrication sleeve. 53040 a a-Sleeve Page 6A-26 90-856159R1 AUGUST 1998 NON BIGFOOT GEAR HOUSING 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. 91-824790A1 ab c d f e a-Puller Bolt b-Flat Washer c-Wafer Bearing d-Pilot e-Bushing/Sleeve f-Mandrel 90-856159R1 AUGUST 1998 Page 6A-27 NON BIGFOOT GEAR HOUSING Forward Gear Bearing Race Installation Install race into housing using Mandrel (91-13658) and Bearing Carrier Tool (91-13664). 52992 91-13664 53017 91-13658 53016 a b c a-Race b-Mandrel (91-13658) c-Bearing Carrier Tool (91-13664) Forward Gear Reassembly Install bushing and bearing using Mandrel (91-13658) and press. 91-13658 53018 53016 a b c a-Mandrel (91-13658) b-Bushing c-Bearing Page 6A-28 90-856159R1 AUGUST 1998 NON BIGFOOT GEAR HOUSING Bearing Carrier Reassembly 1. Apply Quicksilver Gear Lubricant to bushing and press bushing into carrier using Mandrel (91-824785A1). 53025 91-824785A1 53022 a b Super Duty Gear Lubricant (92-850737A1) 87 87 a-Bushing b-Mandrel (91-824785A1) 2. Apply Loctite 271 to O.D. of seal and with lip facing bushing, press seal into carrier using Mandrel (91-824785A1). 53027 91-824785A1 53022 d c b a 7 Loctite “271” (92-809819) 7 a-Mandrel (91-824785A1) b-Ring (used with mandrel) c-Seal (LIP FACES BUSHING) d-Bushing 90-856159R1 AUGUST 1998 Page 6A-29 NON BIGFOOT GEAR HOUSING 3. Apply Loctite 271 to O.D. of fishline cutter seal. With ring removed from Mandrel (91-824785A1), press seal, with LIP FACING Mandrel, into carrier. Apply Special Lubricant 101 between lips of both seals. 53028 91-824785A1 53022 a b 7 Loctite “271” (92-809819) 7 a-Fish Line Cutter Seal (LIP FACES MANDREL) b-Mandrel (without Ring – 91-824785A1) 4. Apply 2-4-C w/Teflon to O-ring and threads of bearing carrier. Install O-ring on carrier. 53011 a 2-4-C w/Teflon (92-850736A1) 95 95 a-O-ring Page 6A-30 90-856159R1 AUGUST 1998 NON BIGFOOT GEAR HOUSING Water Pump Base and Shift Shaft Reassembly 1. Apply Loctite 271 to O.D. of seal. With lip of seal facing DOWN, push seal into base using Mandrel (91-13655). 52999 91-13655 53021 a b 7 Loctite “271” (92-809819) 7 a-Seal (Lip FACES DOWN) b-Mandrel (91-13655) 2. Apply Loctite 271 to O.D. of seal. With seal lip facing UP, push seal into base using Mandrel (91-13655). Apply 2-4-C w/Teflon between lips of both seals. 91-13655 53021 53057 a b 7 Loctite “271” (92-809819) 7 a-Seal (Lip FACES UP) b-Mandrel (91-13655) 90-856159R1 AUGUST 1998 Page 6A-31 NON BIGFOOT GEAR HOUSING 3. Install seal onto water tube. 53024 a a-Seal 4. Secure water tube to pump base with retainer and screw. 53009 a b 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 as shown. a b 53034 a-E-clip b-Shift Cam Page 6A-32 90-856159R1 AUGUST 1998 NON BIGFOOT GEAR HOUSING Propeller Shaft Reassembly 1. Slide clutch onto propeller shaft. 53000 a b c d a-Sliding Clutch b-Short End (FORWARD Gear Side) c-Hole (must align with slot) d-Slot 2. Insert cam follower spring into shaft. 53005 a a-Spring 3. Compress spring and install NEW groove pin. 53007 53038 c ed b ad 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. 53006 ba 2-4-C w/Teflon (92-850736A1) 95 95 a-Cam Follower b-Flat Side 90-856159R1 AUGUST 1998 Page 6A-33 NON BIGFOOT GEAR HOUSING Forward Gear, Pinion Gear and Drive Shaft Installation 1. Install FORWARD gear assembly into forward gear race. 2. Install drive shaft through upper drive shaft bushing, oil sleeve and lower drive shaft needle bearing. 3. While lifting drive shaft slightly, install lower thrust washer (GROOVED SIDE FACES DOWN) and PINION gear. It may be necessary to rotate drive shaft slightly to engage pinion gear with splines of drive shaft and with forward gear teeth. 4. Install upper thrust washer above upper drive shaft bushing. 52995 a b c d e f g a-FORWARD Gear Assembly b-Drive Shaft Bushing c-Oil Sleeve d-Needle Bearing e-Lower Thrust Washer (GROOVED SIDE FACES DOWN) f-Pinion Gear g-Upper Thrust Washer Page 6A-34 90-856159R1 AUGUST 1998 NON BIGFOOT GEAR HOUSING Shift Shaft and Water Pump Base Installation 1. Apply 2-4-C w/Teflon to I.D. of seal. 2. Install seal in housing with tapered end facing up. NOTE:Align rubber tab on seal to hole in tube cavity. 95 57137 95 a b c d 2-4-C w/Teflon (92-850736A1) a-Rubber Tab b-Tapered I.D. c-Seal d-Hole in Cavity 3. Install base gasket with drain hole positioned as shown. 53015 a b a-Base Gasket b-Hole 90-856159R1 AUGUST 1998 Page 6A-35 NON BIGFOOT GEAR HOUSING 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 2-4-C w/Teflon to I.D. and O.D. of shift shaft quad ring. Seat quad ring in pump base. 6. Apply Loctite 271 to bolt threads and secure pump base to housing with bolt and washer. Torque bolt to 50 lb-in. (5.6 Nm). 7. Install gasket and face plate. 53012 b c d 7 Loctite “271” (92-809819) 95 a 7 95 2-4-C w/Teflon (92-850736A1) a-Quad Ring b-Bolt and Washer [Torque to 50 lb-in. (5.6 Nm)] c-Gasket d-Face Plate Page 6A-36 90-856159R1 AUGUST 1998 NON BIGFOOT GEAR HOUSING Water Pump Cover Reassembly 1. Apply 2–4-C w/Teflon to O.D. of seal and seal surface. 2. Install seal into cover. 3. Place water tube guide onto seal. 53032 a b c 95 95 2-4-C w/Teflon (92-850736A1) a-Seal b-Seal Surface c-Guide 90-856159R1 AUGUST 1998 Page 6A-37 NON BIGFOOT GEAR HOUSING Impeller and Pump Cover Installation 1. Install lower 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 upper 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. 53048 a b c d e a-Lower Neoprene Washer b-Drive Key c-Impeller d-Upper Neoprene Washer e-Cover 7. Apply Loctite 271 to threads of bolts. Secure cover with bolts and torque to 50 lb-in. (5.6 Nm) per following numbered torque sequence. 53023 1 2 3 4 5 7 Loctite “271” (92-809819) 7 Page 6A-38 90-856159R1 AUGUST 1998 NON BIGFOOT GEAR HOUSING Propeller Shaft and Bearing Carrier Installation 1. Install REVERSE gear into bearing carrier. 2. If not previously lubricated, apply 2-4-C w/Teflon to O-ring. 3. Apply 2-4-C w/Teflon to bearing carrier threads and pilot diameter. 4. Slide bearing carrier onto propeller shaft and install entire assembly into gear housing. 52994 a bc 95 95 2-4-C w/Teflon (92-850736A1) a-Bearing Carrier Threads b-Propeller Shaft c-Pilot Diameter 5. Torque bearing carrier (LEFT HAND THREAD) to 85 lb-ft (115.2 Nm) using Bearing Carrier Tool (91-13664). 91-13664 52993 a a-Bearing Carrier Tool (91-13664) 90-856159R1 AUGUST 1998 Page 6A-39 NON BIGFOOT GEAR HOUSING Aluminum Anode and Water Inlet Installation Secure anode and water inlet with screws. 53050 ab c a-Anode b-Water Inlet c-Screws 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 and gasket. 5. Remove grease tube from “FILL” hole and quickly install “FILL” screw and gasket. 52998 a b a-Vent Screw b-Fill Screw Page 6A-40 90-856159R1 AUGUST 1998 NON BIGFOOT GEAR HOUSING 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. (6.4 mm) diameter bead of RTV Sealer on water pump base. a 85 53023 85 RTV Silicone Sealer (92-91601-1) 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 90-856159R1 AUGUST 1998 Page 6A-41 NON BIGFOOT GEAR HOUSING Page 6A-42 90-856159R1 AUGUST 1998 IMPORTANT: If water tube has been removed, follow installation procedure in Section 5. Water tube location is critical for proper alignment to water pump. 5. Tilt outboard to full “UP” position. 6. Place shift handle (tiller models) or shift lever (remote control models) into neutral. 7. Place gear housing into neutral by pushing down on the lower shift shaft (from forward gear) to neutral detent. (Propeller will rotate freely in either direction). 8. Coat splines of drive shaft with 2-4-C w/Teflon. 9. Guide gear housing onto drive shaft housing to aligning the following: • Keep mating surfaces of gear housing/drive shaft housing parallel. NOTE: It may be necessary to rotate the flywheel to aid engagement of drive shaft splines to crankshaft splines. • Insert drive shaft into the opening in the upper part of the drive shaft housing to align with crankshaft splines. • Guide lower shift shaft thru rubber seal/opening in lower drive shaft housing and up thru loop of reverse lock link rod. • Position water tube guide onto water tube. 57138 a c b a-Reverse Lock Link Rod b-Lower Shift Shaft c-Jam Nut NON BIGFOOT GEAR HOUSING 90-856159R1 AUGUST 1998 Page 6A-43 10. Install 3 bolts and torque to 15.0 lb-ft. (20.3 Nm). 52998 a a a-Bolts [Torque to 15.0 lb-ft. (20.3 Nm)] 11. Thread (retained) “jam” nut onto lower shift to expose five (5) threads above the nut. 12. Reconnect shift shaft coupling and tighten “jam” nut against coupler. 13. Shift to forward gear. 14. Assemble reverse hook guide around lower shift shaft and tighten bolt/nut to allow adjustment. 57141 a b c d a-Jam Nut b-Coupling c-Reverse Hook Guide d-Lower Shift Shaft NON BIGFOOT GEAR HOUSING 15. Lift and hold reverse lock hook in the full up position. 16. Slide reverse hook guide up shift shaft to make contact with loop of reverse lock link rod. DO NOT bend link rod. Tighten guide bolt/nut to a torque of 50 lb-in. (5.7 Nm). a b c d a-Reverse Hook Guide b-Bolt/Nut - Torque to 50 lb-in. (5.7 Nm) c-Reverse Lock Hook Link Rod d-Reverse Lock Hook 17. Lower outboard to the normal operating position. 18. Check reverse lock operation as follows: • Forward Gear - Reverse lock fully released. Outboard will tilt up. • Neutral - Reverse lock engaged. Outboard will not tilt up. • Reverse Gear - Reverse lock fully engaged. Outboard will not tilt up. 19. Shift outboard into reverse and verify that free play exists between lower loop of reverse lock link rod and shift shaft coupling “jam”. 20. If no free play exists, turn coupling up shift shaft a maximum of 1-1/2 turns and re-tighten jam nut against coupling. Page 6A-44 90-856159R1 AUGUST 1998 NON BIGFOOT GEAR HOUSING 21. Check shift operation as follows: • 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. • Place shift lever in NEUTRAL. Resistance should NOT be felt when propeller shaft is rotated in either direction. • Place shift lever in REVERSE. Resistance should be felt when propeller shaft is rotated in either direction. • If shift operation is not as described, recheck the coupler installation procedure. 90-856159R1 AUGUST 1998 Page 6A-45 BIG FOOT LOWER UNIT Section 6B – Big Foot Table of Contents Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-1 Quicksilver Lubricants and Service Aids . . . . . . 6B-2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-2 Gear Housing (Drive Shaft) . . . . . . . . . . . . . . . . . 6B-6 Gear Housing (Propeller Shaft). . . . . . . . . . . . . . 6B-8 General Service Recommendations . . . . . . . . 6B-10 Draining and Inspecting Gear Lubricant . . . . . 6B-11 Gear Housing Removal . . . . . . . . . . . . . . . . . . . 6B-12 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-14 Bearing Carrier. . . . . . . . . . . . . . . . . . . . . . . . 6B-14 Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . 6B-15 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-16 Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-18 Drive Shaft and Pinion Gear . . . . . . . . . . . . 6B-18 Upper Drive Shaft and Bearing/Seals . . . . 6B-19 Lower Drive Shaft Bearing/Cup . . . . . . . . . . 6B-20 Forward Gear Race. . . . . . . . . . . . . . . . . . . . 6B-20 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . 6B-21 Gear Housing/Bearing Carrier Castings . . 6B-21 Ball Bearings . . . . . . . . . . . . . . . . . . . . . . . . . 6B-21 Needle Bearing . . . . . . . . . . . . . . . . . . . . . . . 6B-21 Specifications Cam Follower . . . . . . . . . . . . . . . . . . . . . . . . . 6B-22 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-22 Propeller shaft . . . . . . . . . . . . . . . . . . . . . . . . 6B-22 Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-23 Reverse And Forward Gear . . . . . . . . . . . . . 6B-23 Pinion Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-25 Driveshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-25 Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . . . 6B-26 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-26 Drive Shaft Bearing and Seals . . . . . . . . . . 6B-26 Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-28 Forward Gear Installation . . . . . . . . . . . . . . . 6B-29 Pinion and Driveshaft . . . . . . . . . . . . . . . . . . 6B-31 Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . 6B-31 Bearing Carrier. . . . . . . . . . . . . . . . . . . . . . . . 6B-33 Bearing Carrier/Propeller Shaft Installation 6B-34 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-35 Gear Housing Installation. . . . . . . . . . . . . . . 6B-36 Trim Tab Adjustment and Replacement . . . 6B-41 Filling Gear Housing with Lubricant . . . . . . . . . 6B-42 6 B Gear Ratio 2.42:1 Gearcase Capacity Lubricant Type 7.8 fl oz (230 mL) Quicksilver Gear Lube-Premium Blend Forward Gear GEAR HOUSING BIGFOOT (2.42:1) Number of Teeth Pinion Gear Number of Teeth Pinion Height 29 Spiral/Bevel 12 Spiral/Bevel No Adjustment Forward Gear Backlash No Adjustment Water Pressure (With Thermostat) @ 950 rpm (Idle) 1 - 4 psi (7-28 kPa) @ 5000 rpm (WOT) 6 - 9 psi (41-62 kPa) NOTE:Before filling gear case, apply 10-12 psi of air pressure at the vent hole. Pressure should not drop for 5 minutes while alternately applying a 2-3 pound force to the top of the shift shaft in the fore and aft direction. 90-856159R1 AUGUST 1998 Page 6B-1 BIG FOOT Quicksilver Lubricants and Service Aids Part No. Description 92-809819 Loctite “271” 92-850736A1 2-4-C w/Teflon 92-809824 Loctite Primer “7649” 92-850737A1 Super Duty Gear Lubricant Special Tools 1. Universal Puller Plate 91-37241 2. Leakage Tester FT8950 3. Bearing Puller & Installation Tool 91-31229A7 a. Nut 11-24156 b. Washer (2) 12-34961 c. Plate 91-29310 d. Threaded Rod 91-31229 Page 6B-2 90-856159R1 AUGUST 1998 BIG FOOT e. Mandrel 91-36571 4. Bearing Puller Tool 91-27780 5. Slide Hammer 91-34569A1 6. Bearing Carrier Tool 91-93843--1 91-93843--1 7. Bearing Cup Puller 91-44385 56812 8. Bushing Removal Tool 91-824787 90-856159R1 AUGUST 1998 Page 6B-3 BIG FOOT 9. Driveshaft Seal Installation Tool 91-858775 10. Bearing Carrier Prop Shaft Seal Installation Tool 91-858776 11. Bearing Carrier Prop Shaft Bearing Installation Tool 91-858777 Page 6B-4 90-856159R1 AUGUST 1998 BIG FOOT Notes: 90-856159R1 AUGUST 1998 Page 6B-5 BIG FOOT Gear Housing (Drive Shaft) 31 32 33 17 92 87 95 7 2-4-C w/Teflon (92-850736A1) Loctite “271” (92-809819) Super Duty Gear Lubricant (92-850737A1) Loctite Primer “7649” (92-809824) 7 87 92 95 95 95 95 95 1 2 3 4 5 6 7 8 9 1011 12 13 14 15 16 18 19 20 21 22 23 24 25 26 27 28 29 30 34 35 36 37 38 39 40 41 42 43 44 Page 6B-6 90-856159R1 AUGUST 1998 BIG FOOT Gear Housing (Drive Shaft) REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 GEAR HOUSING ASSEMBLY 2 1 SLEEVE 3 2 SEAL–gear housing 4 1 ROLLER BEARING–upper 5 2 DOWEL PIN (.187 x .53) 6 1 SCREW (.375 x.25) 60 6.8 7 1 WASHER–sealing 8 1 SCREEN–water inlet-port 9 1 SCREW (M5 x 40) 25 2.8 10 1 DRAIN SCREW–magnetic 60 6.8 11 1 WASHER 12 1 SCREEN–starboard 13 1 NUT (M5) 14 1 ROLLER BEARING ASSEMBLY 15 1 CUP 16 1 PINION GEAR (12-29) 17 1 NUT 15 20.3 18 1 GASKET 19 1 FACE PLATE 20 1 WASHER 21 1 KEY 22 1 lMPELLER 23 1 WASHER 24 1 O-RING 25 1 WATER PUMP ASSEMBLY 26 1 INSERT 27 1 SEAL 28 1 RING 29 4 BOLT (M6 x 16) 60 6.8 30 1 SHIFT SHAFT 31 1 NUT (M6) Tighten Securely 32 1 COUPLER Tighten Securely 33 1 SHIFT SHAFT (UPPER) 34 1 DRIVE SHAFT 35 1 BOOT 36 1 RETAINER 37 1 O-RING 38 1 O-RING 39 1 WASHER 40 1 SPRING 41 1 WASHER 42 1 ROLL PIN 43 1 SHIFT CAM 44 1 DRIVE PIN 90-856159R1 AUGUST 1998 Page 6B-7 BIG FOOT Gear Housing (Propeller Shaft) 66 67 87 95 7 2-4-C w/Teflon (92-850736A1) Loctite “271” (92-809819) Super Duty Gear Lubricant (92-850737A1) 94 Anti-Corrosion Grease (92-850735A1) 7 87 87 87 94 95 95 95 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 6263 64 65 68 69 70 1 Page 6B-8 90-856159R1 AUGUST 1998 BIG FOOT Gear Housing (Propeller Shaft) REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 GEAR HOUSING ASSEMBLY 45 1 TRIM TAB 46 1 BOLT (M8x30) 17.1 23.2 47 1 WASHER 48 1 TAPERED ROLLER BEARING 49 1 CUP 50 1 FORWARD GEAR (12-29) 51 1 BUSHING 52 1 CAM FOLLOWER 53 1 SPRING 54 1 CLUTCH 55 1 CROSS PIN 56 1 SPRING 57 1 PROPELLER SHAFT 58 1 REVERSE GEAR (12-29) 59 1 BEARING CARRIER ASSEMBLY 80.0 108.5 60 1 ROLLER BEARING 61 1 OIL SEAL (INNER) 62 1 OIL SEAL (OUTER) 63 1 O-RING 64 1 PLATE 65 3 BOLT (M5x16) 65 7.2 66 4 BOLT (M10 x 35) 40 54.2 67 4 WASHER 68 1 THRUST HUB ASSEMBLY 69 1 PROPELLER 70 1 PROP NUT 16.7 22.6 90-856159R1 AUGUST 1998 Page 6B-9 BIG FOOT General Service Recommendations There may be more than one way to “disassemble” or “reassemble” a particular part(s), therefore, it is recommended that the entire procedure be read prior to repair. IMPORTANT: Read the following before attempting any repairs. In many cases, disassembly of a sub-assembly may not be necessary until cleaning and inspection reveals that disassembly is required for replacement of one or more components. Service procedure order in this section is a normal disassembly-reassembly sequence. Threaded parts are right hand (RH), unless otherwise indicated. When holding, pressing or driving is required, use soft metal vise jaw protectors or wood for protection of parts. Use a suitable mandrel (one that will contact only the bearing race) when pressing or driving bearings. Whenever compressed air is used to dry a part, verify that no water is present in air line. BEARINGS All bearings must be cleaned and inspected. Clean bearings with solvent and dry with compressed air. Air should be directed at the bearing so that it passes through the bearing. DO NOT spin bearing with compressed air as this may cause bearing to score from lack of lubrication. After cleaning, lubricate bearings with Quicksilver Gear Lubricant. DO NOT lubricate tapered bearing cups until after inspection. Inspect all bearings for roughness, catches and bearing race side wear. Work inner bearing race in-and-out, while holding outer race, to check for side wear. When inspecting tapered bearings, determine condition of rollers and inner bearing race by inspecting bearing cup for pitting, scoring, grooves, uneven wear, imbedded particles and/or discoloration from over-heating. Always replace tapered bearing and race as a set. Inspect gear housing for bearing races that have spun in their respective bores. If race(s) have spun, gear housing must be replaced. Roller bearing condition is determined by inspecting the surface of the shaft that the roller bearing supports. Check shaft surface for pitting scoring, grooving, imbedded particles, uneven wear and/or discoloration from overheating. The shaft and bearing must be replaced if such a condition exists. SEALS As a normal procedure, all O-rings and oil seals SHOULD BE REPLACED without regard to appearance. To prevent leakage around seals, apply Loctite 271 to outer diameter of all metal case seals. When using Loctite on seals or threads, surfaces must be clean and dry. Apply 2-4-C w/Teflon on all O-rings and on I.D. of oil seals. Apply 2-4-C w/Teflon to bearing carrier threads and pilot diameters. Page 6B-10 90-856159R1 AUGUST 1998 BIG FOOT Draining and Inspecting Gear Lubricant WARNING If gear housing is installed on outboard, disconnect (and isolate) spark plug leads from spark plugs before working near the propeller. 1. With gear housing in normal running position, place a clean pan under housing and remove vent plug and fill/drain plug (with gaskets). b a a-Vent Plug/Washer b-Drain Plug/Washer 2. Inspect gear lubricant for metal particles (lubricant will have a “metal flake” appearance). Presence of fine metal particles (resembling powder) on the drain plug magnet indicates normal wear. Metal chips on the magnet indicate the need for gear housing disassembly and component inspection. 3. Note color of gear lubricant. White or cream color indicates presence of water. 4. Presence of water indicates the need for disassembly and inspection of oil seals, O- rings, gaskets and components for damage. Pressure check prior to disassembly to determine leak area. 90-856159R1 AUGUST 1998 Page 6B-11 BIG FOOT Page 6B-12 90-856159R1 AUGUST 1998 Gear Housing Removal WARNING To prevent accidental engine starting, remove (and isolate) spark plug leads from spark plugs BEFORE removing gear housing. 1. Tilt outboard to full “UP” position. 9.9/15 Bigfoot (4 Stroke) 2. Remove reverse hook guide assembly from lower shift shaft. 3. Loosen jam nut and disconnect coupler. Remove jam nut to allow removal of gearcase. a b c a-Reverse Hook Guide b-Jam Nut c-Coupler 20/25 (2 Stroke) 4. Unlatch and remove retainer to free shift shaft for removal of gearcase. 57047 a a-Retainer BIG FOOT NOTE:A flat washer is located on the shift shaft near the top of the shaft. This washer may slide off shift shaft when gear case is removed. Do not lose washer as washer is necessary for reassembly. a51 187 a-Flat Washer 5. Remove four screws and remove gear housing. 56804 a a-Screws (4) NOTE:If water tube should pull out of driveshaft housing, remove tube from water pump and insert tube back into driveshaft housing to aid in reassembly. 90-856159R1 AUGUST 1998 Page 6B-13 BIG FOOT Page 6B-14 90-856159R1 AUGUST 1998 Disassembly IMPORTANT: It is recommended that, during complete disassembly of gear housing, all O-rings and oil seals be replaced, regardless of their appearance. Bearing Carrier 1. Remove 3 screws which secure the O-ring retainer plate and O-ring to the bearing carrier. Remove the O-ring retainer plate and O-ring from gear housing. 2. Remove bearing carrier using Special Tool 91-93843--1 (LEFT HAND THREAD). a b c d 91-93843--1 56805 d a-Screws (3) b-O-Ring Retainer Plate c-O-Ring d-Bearing Carrier 3. While holding onto propeller shaft and bearing carrier, pull propeller shaft from propeller shaft cavity, as shown. NOTE: Cam follower is free to slide out of propeller shaft. 4. Remove reverse gear and bearing carrier from propeller shaft. 5. Separate reverse gear from bearing carrier. 56806 a b c d a-Cam Follower b-Propeller Shaft Assembly c-Reverse Gear d-Bearing Carrier BIG FOOT NOTE:When using a screwdriver to remove carrier seals, be careful not to scar carrier seal surface. If carrier seal surface is damaged, replace carrier. 6. Secure bearing carrier in a vise. Using a screwdriver, pry out both seals from bearing carrier. 57136 a a-Oil Seals Propeller Shaft 1. Insert a thin blade screwdriver or awl under first coil (from front) of cross-pin retainer spring. 2. Rotate propeller shaft to unwind spring from sliding clutch. a b a-Awl b-Cross Pin Retaining Ring 3. Insert flat end of cam follower into front end of propeller shaft. 4. Position cam follower against a solid surface. 90-856159R1 AUGUST 1998 Page 6B-15 BIG FOOT WARNING Use caution when removing cam follower. As the cross-pin is remove the cam follower can shoot out of the propeller shaft as a high speed projectile. 5. Push against cam follower. Use a punch or awl to push cross-pin out of sliding clutch. 6. Release pressure against cam follower. a b a-Cam Follower b-Cross Pin 7. Remove cam follower, spring and sliding clutch from propeller shaft. a b c a-Cam Follower b-Spring c-Clutch Water Pump 1. Slide centrifugal slinger off drive shaft. 2. Remove four (4) screws securing water pump to gear housing as shown in illustration. a b b a-Centrifugal Slinger b-Water Pump Mounting Screws 3. Remove cover, nylon washers (above and below impeller), impeller and drive key from drive shaft. 4. 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. Page 6B-16 90-856159R1 AUGUST 1998 BIG FOOT 90-856159R1 AUGUST 1998 Page 6B-17 5. Remove face plate and base gasket. 6. Remove shift shaft from housing. 56809 a b c d e 56810 f g h a-Cover b-Nylon Washer c-Impeller d-Nylon Washer e-Key f-Shift Shaft g-Face Plate h-Base Gasket NOTE: Replace impeller if: • Impeller blades are cracked, torn or worn. • Impeller is glazed or melted. • Rubber portion of impeller is not bonded to impeller hub. BIG FOOT Shift Shaft 1. Pull shift shaft assembly from gear housing. 2. Remove and replace outer O-ring from shift shaft retainer. a-Shift Shaft g-Spring b-Boot h-Washer c-Retainer i-Roll Pin d-O-ring (outer) j-Driver Pin e-O-ring (inner) k-Shift Cam f-Washer k j i h g f e d c b a Drive Shaft and Pinion Gear 1. Clamp driveshaft in a soft jaw vise and remove pinion nut or bolt that secures pinion to driveshaft. Pull driveshaft out of gear housing. Remove pinion and tapered roller bearing. NOTE: 9.9/15 Bigfoot (4 Stroke) uses nut to secure pinion gear. 20/25 (2 Stroke) uses bolt to secure pinion gear. a b c a-Pinion Nut/Bolt b-Pinion c-Tapered Roller Bearing Page 6B-18 90-856159R1 AUGUST 1998 BIG FOOT Upper Drive Shaft and Bearing/Seals 1. Using Water Pump Cartridge Puller (91-27780), as shown, remove the driveshaft oil seals from gear housing. a b 91-27780 a-Oil Seals b-Water Pump Cartridge Puller 2. Using suitable mandrel drive upper drive shaft bearing through gearcase sleeve to the bottom of gearcase. 3. Do not remove gearcase sleeve (not shown). a b a-Upper Driveshaft Bearing b-Mandrel 90-856159R1 AUGUST 1998 Page 6B-19 BIG FOOT Lower Drive Shaft Bearing/Cup 1. Fasten bearing cup puller on a threaded rod as shown. 2. Tighten hex nut and draw the bearing cup puller up into bearing cup until lip on tool snaps over the top side of bearing cage. Remove threaded rod assembly. 3. Insert tapered end of rod (91-44385) into bearing cup puller and tap bearing cup out of driveshaft bore. a c d e fg c 91-44385 b 56911 a b h a-Bearing Cup b-Bearing Cup Puller (91-44385) c-Flat Washers 2 (12-34961) d-Hex Nut 0.625x18 (11-24156) e-Threaded Rod 0.625x18-16 Long (91-31229) f-Plate (91-29310) g-Hex Nut 0.625x18 (11-24156) h-Tapered Rod (91-44385) Forward Gear Race 1. Use slide hammer to remove forward gear tapered bearing race as shown. ab a-Slide Hammer b-Tapered Bearing Race 91-34569A1 Page 6B-20 90-856159R1 AUGUST 1998 BIG FOOT Cleaning and Inspection Gear Housing/Bearing Carrier Castings 1. Thoroughly clean gear housing/bearing carrier castings. Be sure all old gasket material is removed from mating surfaces and that carbon deposits have been removed from exhaust passages. 2. Inspect castings for cracks or fractures. 3. Check sealing surfaces for nicks, deep grooves and distortion which could cause leaks. 4. Check water passages for obstructions. Ball Bearings CAUTION DO NOT spin-dry ball bearings with compressed air. 1. Clean bearing in solvent and dry with compressed air. 2. Bearing should be free of rust stains. 3. Attempt to work inner bearing race in-and-out. There should not be excessive play. 4. Lubricate ball bearing with Quicksilver Gear Lube. Rotate inner bearing race. Bearing should have smooth action. If ball bearing sounds or feels rough or has catches, remove and discard bearing. Refer to “Bearing Carrier” following. 56430 Needle Bearing 1. Clean needle bearings in solvent and dry with compressed air. 2. Replace bearing if needles are rusted, fractured, worn, galled badly, discolored, or if area of shaft that bearing contacts is worn or pitted. Refer to “Drive Shaft” following. 56431 90-856159R1 AUGUST 1998 Page 6B-21 BIG FOOT Cam Follower 1. Inspect cam follower for wear or galling. If wear is present, inspect corresponding shift cam for wear. Replace if worn. 52822 Clutch 1. Replace clutch if jaws are rounded or chipped. Rounded jaws may be caused by the following: • Improper shift cable adjustment or linkage. • Engine idle speed too high while shifting. • Shifting too slowly from NEUTRAL into FORWARD or REVERSE. 52990 Propeller shaft 1. Check propeller shaft for straightness. 2. Inspect bushing/bearing surfaces of propeller shaft for pitting or wear. Replace shaft and corresponding bushing/bearing if wear or pitting is observed. 3. Replace propeller shaft if any of the following exist: • Splines are twisted or worn. • Oil seal surface is grooved. • Shaft has a noticeable “wobble” or is bent more than 0.006 in. (0.15 mm). 56807 c ba a a-Bushing/Bearing Surfaces b-Oil Seal Surface c-Measure Here for “Wobble” (When measuring shaft for wobble, use v-blocks and support at bushing surface) Page 6B-22 90-856159R1 AUGUST 1998 BIG FOOT Shift Shaft 1. Inspect shift shaft retainer for cracks and replace if necessary. 2. Inspect shift cam face for wear. Replace if worn. 53034 a b a-Shift Cam b-Shift Shaft Retainer Reverse And Forward Gear 1. Inspect gear teeth for pitting, uneven wear, scoring, etc. Replace gear if any damage is found. 2. Inspect gear clutch jaws. Replace gear if jaws are rounded or chipped. b a a-Gear Teeth b-Clutch Teeth 52989 a b 90-856159R1 AUGUST 1998 Page 6B-23 BIG FOOT 3. Inspect FORWARD gear tapered bearing and race for rust, roughness, pitting, spalling or excessive wear (looseness). NOTE: DO NOT remove tapered bearing from FORWARD gear unless replacement is necessary as removal process will damage bearing. 4. If bearing must be replaced, remove bearing from gear using Universal Puller Plate (91-37241) and a suitable mandrel (5/8 in. socket). IMPORTANT: If FORWARD gear tapered bearing or race requires replacement, replace bearing and race as a set. 53008 a b c 91-37241 a-Bearing b-Universal Puller Plate (91-37241) c-Mandrel (5/8 in. Socket) 5. If inspection determines that replacement of forward gear bushing is required, remove bushing from forward gear using one of two ways. 6. Using a Punch: Secure forward gear in a vise. Be sure to use a soft jaw vise and do not clamp onto tapered bearing. Use a punch and hammer, remove bushing from the clutch jaw (teeth) side of gear. 7. Using a Press: Press bushing from gear using Bushing Removal Tool 91-824787. b c d a 91-824787 c e a a-Forward Gear d-Punch b-Vise Protector e-Bushing Removal Tool (91-824787) c-Bushing Page 6B-24 90-856159R1 AUGUST 1998 BIG FOOT 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. 52991 a a-Pinion Gear Driveshaft IMPORTANT: If upper drive shaft bushing or lower drive shaft needle bearing race appear to be spinning in their respective bores, the gear housing should be replaced. 1. Replace drive shaft if the following exist: • Splines are twisted or worn. • Oil seal surface is grooved. • Bearing/Bushing journal surfaces are pitted or worn. Replace corresponding bearing as well. 53036 c ba a-Bearing/Bushing Surface b-Bearing/Bushing Surface c-Seal Surface 90-856159R1 AUGUST 1998 Page 6B-25 BIG FOOT Bearing Carrier 1. If inspection of bearing area on propeller shaft determines that replacement of bearing inside of bearing carrier is required, remove bearing from bearing carrier. 2. Secure bearing carrier in a vise, DO NOT clamp onto threaded portion of bearing carrier. 3. Remove bearing from bearing carrier with a punch or suitable mandrel/socket and hammer. 56811 b a a-Bearing b-Punch Reassembly Drive Shaft Bearing and Seals 1. Install upper driveshaft bearing into driveshaft bore of gear housing sleeve. Apply a light coat of 2-4-C w/Teflon to upper driveshaft bearing retainer bore as follows: • Place upper driveshaft bearing over bearing retainer bearing bore with lettered side of bearing face up. • Using a suitable mandrel, press bearing into gear housing sleeve until the bearing is just below the oil hole to a depth of 1.00 in. (25.4 mm) as shown. 1.00 in. (25.4 mm) b a c a a-Upper Driveshaft Bearing b-Mandrel c-Oil Hole Page 6B-26 90-856159R1 AUGUST 1998 BIG FOOT 2. Install lower driveshaft bearing cup into driveshaft bore of gear housing as follows: • Assemble bearing cup as shown. • Draw bearing cup up to shoulder of gearcase housing using cup puller (91-44385) as shown a b c c d e f 91-44385 11-24156 12-34961 91-29310 f 91-44385 a-Bearing Cup d-Threaded Rod 0.625x18-16 in. long (91-31229) b-Bearing Cup Puller (91-44385) e-Plate (91-29310) c-Flat Washers 2 (12-34961) f-Hex Nut 0.625x18 (2) (11-24156) 3. Install new driveshaft oil seals into driveshaft bore of gear housing as follows: • Apply Loctite “271” to outer diameter of driveshaft oil seals. • With lip of seal facing down, press the first oil seal into driveshaft bore until seal is just below the top of driveshaft bore. • With lip of seal facing up, and using Installation tool 91-858775, press the second oil seal into driveshaft bore until seal is 3/16” (4.7 mm) below top of driveshaft bore. • Wipe off excess Loctite. a b 7 Loctite “271” (92-809819) 7 7 d e 3/16, (4.7 mm) 91-858775 c f a-Upper Driveshaft Bearing b-Mandrel c-Seals (2) d-Oil Seal with Lip of Seal Facing Up e-Oil Seal with Lip of Seal Facing Down f-Installation Tool (91-858775) 90-856159R1 AUGUST 1998 Page 6B-27 BIG FOOT Shift Shaft 1. Install shift shaft assembly into gear housing assembly. 56914 a j i h gf e d c b a k a-Shift Shaft Assembly b-Boot c-Retainer d-O-ring (outer) e-O-ring (inner) f-Washer g-Spring h-Washer i-Roll Pin j-Driver Pin k-Shift Cam Page 6B-28 90-856159R1 AUGUST 1998 BIG FOOT Forward Gear Installation 1. Install forward gear bearing race into gear housing. 2. Apply a light coat of Super Duty Gear Lubricant to forward gear bearing race bore in propeller shaft cavity. 3. Position tapered bearing race squarely over bearing bore in front portion of propeller shaft cavity. 4. Place mandrel (91-36571) from Bearing Installation Kit (91-31229A7) over tapered bearing race. 5. Place propeller shaft into hole in center of mandrel. 6. Install bearing carrier assembly over propeller shaft and thread it in 4 or 5 turns. 7. Thread a suitable nut onto propeller shaft to protect propeller shaft threads. (DO NOT use propeller nut.) 8. Use a mallet to drive propeller shaft against mandrel until tapered bearing race is firmly seated in bearing race bore. a c d 91-36571 b 87 Super Duty Gear Lubricant (92-850737A1) 87 a-Forward Gear Bearing Race b-Mandrel (91-36571) c-Propeller Shaft d-Bearing Carrier 90-856159R1 AUGUST 1998 Page 6B-29 BIG FOOT 9. Remove nut from propeller shaft, then remove bearing carrier, propeller shaft and mandrel from propeller shaft cavity. 10. Apply a light coat of oil on tapered bearing race. 11. Place forward gear on a press with gear teeth down. 12. Apply a light coat of oil to I.D. of forward gear tapered bearing. 13. Position forward gear tapered bearing over gear. 14. Press on inner race of bearing until bearing is firmly seated against forward gear. 15. Apply a light coat of Gear Lube to bore in center of forward gear. 16. Using a suitable mandrel, press forward gear bushing into forward gear until bushing is flush with the back of gear. a b c d e b 95 2-4-C w/Teflon (92-850736A1) 95 a-Press b-Mandrel c-Bearing d-Forward Gear e-Bushing 17. Apply a light coat of oil on forward gear tapered bearing, then position forward gear assembly in gear housing. Page 6B-30 90-856159R1 AUGUST 1998 BIG FOOT Pinion and Driveshaft 1. Place lower drive shaft tapered roller bearing into bearing cup. 2. Place pinion gear into gear housing with teeth of pinion meshed with teeth of forward gear. 3. Insert driveshaft into gear housing while holding pinion in place with other hand. Rotate driveshaft back and forth to align splines on driveshaft with splines in pinion gear. 4. Secure pinion gear to driveshaft. Apply Loctite “271” to pinion nut or bolt. Refer to table for “Fastener Type” and “Torque”. Model Fastener Type Torque 9.9/15 Bigfoot (4-Stroke) Pinion Nut 15 lb-ft (20.3 Nm) 20/25 (2-Stroke) Pinion Bolt 13.3 lb-ft (18.0 Nm) 7 Loctite “271” (92-809819) 7 56913 a b c a-Tapered Roller Bearing b-Pinion Gear c-Fastener Propeller Shaft 1. Position sliding clutch over propeller shaft spline with cross-pin holes aligned with slots in propeller shaft. a b c a-Short End b-Cross Pin Hole c-Slot 2. Apply a small amount of light oil onto sliding clutch spring and insert spring into propeller shaft. 90-856159R1 AUGUST 1998 Page 6B-31 BIG FOOT 3. Insert flat end of cam follower into propeller shaft. a b a-Spring b-Flat End of Cam Follower 4. Place cam follower against a solid object and push against cam follower to compress spring. 5. Insert a punch thru the cross-pin holes in sliding clutch (between cam follower and spring). 6. Apply a light coat of oil on cross-pin and install cross-pin into sliding clutch by pushing punch out of clutch with cross-pin, as shown. (Release pressure on cam follower and remove follower from propeller shaft.) a b c 2-4-C w/Teflon (92-850736A1) 95 95 a-Punch b-Cross Pin c-Cam Follower 7. Install cross-pin retainer spring. a a-Cross Pin Retainer Spring 8. Place a dab of 2-4-C w/Teflon into end of propeller shaft and install cam follower (flat end first). Page 6B-32 90-856159R1 AUGUST 1998 BIG FOOT Bearing Carrier 1. Apply a small amount of oil into bearing bore in bearing carrier. 2. Position bearing carrier on a press (with the threaded side down). 3. Place propeller shaft bearing into aft end of bearing carrier with lettered end of bearing up. 4. Use installation tool (91-858777) to press bearing into bearing carrier until the installation tool bottoms out, or using a suitable mandrel press bearing to depth of 1-9/64 in. (28.9 mm) from end of bearing carrier housing. a b c 91-858777 1-9/64 in. (28.9 mm) a-Suitable Mandrel b-Propeller Shaft Bearing c-Lettered end of Bearing 5. Apply Loctite Type “271” to outer diameter of inner propeller shaft seal. Use installation tool (91-858776) to press inner seal into bearing carrier (lip of seal is facing inward) to a depth of 7/8 in. (22.2 mm) from end of bearing carrier housing. 6. Apply 2-4-C w/Teflon between seals. 7. Apply Loctite Type “271” to outside diameter of the outer propeller shaft seal. Rotate installation tool and press outer seal into bearing carrier (lip of seal is facing outward) to a depth of 13/32 in. (10.3 mm) from end of bearing carrier housing. 7 95 91-858776 Loctite “271” (92-809819) 7 2-4-C w/Teflon (92-850736A1) 13/32 in. (10.3 mm) 7/8 in. (22.2 mm) 7 95 a b a-Inner Propeller Shaft Seal b-Outer Propeller Shaft Seal 90-856159R1 AUGUST 1998 Page 6B-33 BIG FOOT Page 6B-34 90-856159R1 AUGUST 1998 Bearing Carrier/Propeller Shaft Installation 1. Apply a small amount of 2-4-C w/Teflon between lips of propeller shaft oil seals. Apply 2-4-C w/Teflon to threads, O-ring groove and pilot diameter. 2. Slide reverse gear into bearing carrier assembly. Slide bearing carrier assembly over propeller shaft and thread it into propeller shaft cavity as-far-as possible by hand (LEFT HAND THREAD). 3. Torque bearing carrier using Special Tool 91-93843--1. Torque to 80 lb-ft (108.5 Nm). 91-93843--1 56806 56805 a b a-Reverse Gear b-Bearing Carrier Assembly 4. Install O-ring and O-ring retainer plate on bearing carrier. 5. Secure O-ring retainer plate to bearing carrier with 3 screws. NOTE: Orientate O-ring to prevent “pinching it”. 6. Torque screws to 65 lb-in. (7.2 Nm). a b c b a d a-O-Ring b-O-Ring Retainer Plate c-Screws (3) Torque to 65 lb-in. (7.2 Nm) d-Bearing Carrier BIG FOOT Water Pump 1. Slide a new face plate gasket and face plate over driveshaft and position them on gear housing. 2. Install nylon washer over driveshaft and set it flat against face plate. 3. Place impeller drive key on flat of driveshaft. 4. Slide new impeller over driveshaft. Align impeller keyway with drive key, then push impeller over drive key and against face plate. If reusing impeller (not recommended) note orientation of vane set. 5. Install nylon washer and set it flat against impeller. 6. Install new O-ring in water pump cover. Install cover assembly over driveshaft and down against impeller. a b c a-Nylon Washer b-Face Plate c-Drive Key 7. While pushing down on water pump cover assembly, rotate driveshaft clockwise to install impeller cover and seat cover against face plate. 8. Align mounting holes in gasket, face plate and water pump cover with mounting holes in gear housing. Install four (4) screws applying Loctite “271” and torque to 60 lb-in. (6.8 Nm). 9. Slide centrifugal slinger down drive shaft. a b b Loctite “271” (92-809819) 7 7 a-Centrifugal Slinger b-Screws (4) Torque to 60 lb-in. (6.8 Nm). 90-856159R1 AUGUST 1998 Page 6B-35 BIG FOOT Page 6B-36 90-856159R1 AUGUST 1998 Gear Housing Installation 9.9/15 Bigfoot (4 - Stroke) WARNING To prevent accidental engine starting remove (and isolate) spark plug leads from spark plugs before installing gear housing IMPORTANT: If water tube has been removed, follow installation procedure in Section 5. Water tube location is critical for proper alignment to water pump. 1. Tilt outboard to full “UP” position. 2. Place shift handle (tiller models) or shift lever (remote control models) into neutral. 3. Place gear housing into neutral by pushing down on the lower shift shaft (from forward gear) to neutral detent. (Propeller will rotate freely in either direction). 4. Coat splines of drive shaft with 2-4-C w/Teflon. 5. Guide gear housing onto drive shaft housing to aligning the following: • Keep mating surfaces of gear housing/drive shaft housing parallel. NOTE: It may be necessary to rotate the flywheel to aid engagement of drive shaft splines to crankshaft splines. • Insert drive shaft into the opening in the upper part of the drive shaft housing to align with crankshaft splines. • Guide lower shift shaft thru rubber seal/opening in lower drive shaft housing and up thru loop of reverse lock link rod. • Position water tube guide onto water tube. 57138 a c b a-Reverse Lock Link Rod b-Lower Shift Shaft c-Jam Nut BIG FOOT 90-856159R1 AUGUST 1998 Page 6B-37 6. Secure gear housing to drive shaft house with four (4) screws. Torque screws to 40 lb-ft (54.2 Nm). 56804 a a-Screws (4) Torque to 40 lb-ft (54.2 Nm) 7. Thread (retained) “jam” nut onto lower shift to expose five (5) threads above the nut. 8. Reconnect shift shaft coupling and tighten “jam” nut against coupler. 9. Shift to forward gear. 10. Assemble reverse hook guide around lower shift shaft and tighten bolt/nut to allow adjustment. 57141 a b c d a-Jam Nut b-Coupling c-Reverse Hook Guide d-Lower Shift Shaft BIG FOOT 11. Lift and hold reverse lock hook in the full up position. 12. Slide reverse hook guide up shift shaft to make contact with loop of reverse lock link rod. DO NOT bend link rod. Tighten guide bolt/nut to a torque of 50 lb-in. (5.7 Nm). a b c d a-Reverse Hook Guide b-Bolt/Nut - Torque to 50 lb-in. (5.7 Nm) c-Reverse Lock Hook Link Rod d-Reverse Lock Hook 13. Lower outboard to the normal operating position. 14. Check reverse lock operation as follows: • Forward Gear - Reverse lock fully released. Outboard will tilt up. • Neutral - Reverse lock engaged. Outboard will not tilt up. • Reverse Gear - Reverse lock fully engaged. Outboard will not tilt up. 15. Shift outboard into reverse and verify that free play exists between lower loop of reverse lock link rod and shift shaft coupling “jam”. 16. If no free play exists, turn coupling up shift shaft a maximum of 1-1/2 turns and re-tighten jam nut against coupling. Page 6B-38 90-856159R1 AUGUST 1998 BIG FOOT 20/25 (2 Stroke) 17. While turning drive shaft in a clockwise direction, pull up lightly on shift shaft until gear housing is in forward gear (propeller shaft turns clockwise). 18. Install flat washer (retained) onto shift shaft. a 51187 a-Washer IMPORTANT: Verify water tube (inside drive shaft housing) is connected to the water tube seal in the adaptor plate. 19. Position twist grip on tiller handle so that outboard is in forward gear. NOTE:It is not necessary to grease the drive shaft splines prior to installation of gear housing assembly. Splines receive internal engine lubrication during normal engine operation. 20. Position gear housing so that drive shaft and shift shaft extend up into drive shaft housing. 21. Move gear housing up toward drive shaft housing while keeping machined surfaces parallel. 22. Guide shift shaft thru loop in the reverse lock rod. 23. Guide water tube into rubber seal in water pump cover. 24. Guide drive shaft into crankshaft. NOTE:It may be necessary to rotate the flywheel to aid engagement of drive shaft splines to crank shaft splines. 90-856159R1 AUGUST 1998 Page 6B-39 BIG FOOT 25. Secure shift rod to horizontal shift shaft with retainer. 57047 a a-Retainer 26. Check shift operation as follows: • 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. • Place shift lever in NEUTRAL. Resistance should NOT be felt when propeller shaft is rotated in either direction. • Place shift lever in REVERSE. Resistance should be felt when propeller shaft is rotated in either direction. • If shift operation is not as described, recheck the coupler installation procedure. Page 6B-40 90-856159R1 AUGUST 1998 BIG FOOT Trim Tab Adjustment and Replacement IMPORTANT: The trim tab made of a special alloy to aid in protecting the drive shaft housing and gear housing from galvanic corrosion (corrosion and pitting of metal surfaces). Do not paint or place protective coating on the trim tab, or trim tab corrosion protection function will be lost. Replace trim tab if 50% (or more) corroded. Mark location of old trim tab on anti-ventilation place before removal; install new trim tab in same location. 1. Check trim tab position. 2. Operate boat at the speed at which it would normally be operated. 3. If the boat pulls to the right (starboard), the trailing edge of trim tab must be moved to the right. If the boat pulls to the left (port). the trailing edge of trim tab must be moved to the left. 4. If necessary, adjust trim tab. 5. Shift engine control into NEUTRAL and turn ignition key to “OFF” position. NOTE:Loosen trim tab bolt sufficiently to allow trim tab to disengage from locking ridges in gear case before attempting to move tab. DO NOT strike trim tab with a hard object to make adjustments. 6. Repeat steps 2-4 as required to reduce steering torque. 56813 a b a-Trim Tab b-Retaining Bolt 90-856159R1 AUGUST 1998 Page 6B-41 BIG FOOT Filling Gear Housing with Lubricant 1. Place outboard in a vertical operating position. 2. Remove vent plug from vent hole. 3. Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole. b a a-Vent Hole b-Lubricant Tube 4. Install the vent plug and sealing washer before removing the lubricant tube. 5. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer. a b a-Vent Plug b-Fill Plug 6. Apply a liberal coat of 2-4-C w/Teflon (92-825407A12) to propeller shaft splines. 95 2-4-C w/Teflon (92-850736A1) 7. Install thrust hub cap on thrust hub. Page 6B-42 90-856159R1 AUGUST 1998 THROTTLE/SHIFT LINKAGE ATTACHMENTS/CONTROL LINKAGE Section 7A – Throttle/Shift Linkage Table of Contents Throttle/Shift Linkage (Handle Models) Throttle/Shift Linkage (Non-Handle Models) . . 7A-6 (Side Shift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-2 Throttle/Shift Linkage (Handle Models) (Front Shift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-4 7 A 90-856159R1 AUGUST 1998 Page 7A-1 THROTTLE/SHIFT LINKAGE Page 7A-2 90-856159R1 AUGUST 1998 Throttle/Shift Linkage (Handle Models) (Side Shift) 1 2 22 4 5 6 7 8 10 12 13 16 15 17 18 19 20 21 23 9 14 24 25 26 27 28 29 30 31 12 33 32 3 95 2-4-C w/Teflon (92-850736A1) 95 95 11 31 THROTTLE/SHIFT LINKAGE Throttle/Shift Linkage (Handle Models) (Side Shift) REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 SHIFT HANDLE 2 1 GROMMET 3 1 BOLT (M5 x 12) 36 4 4 1 BOLT (M6 x 20) 15 1.7 5 1 WASHER 6 1 PULLEY ASSEMBLY 7 1 BUSHING 8 1 NUT (M6) 15 1.7 9 1 THROTTLE LINK 10 1 CONTROL PLATFORM 11 1 BUSHING 12 2 BOLT (M6 x 20) 70 8 1313 1 HORIZONTAL SHIFT SHAFT (BIGFOOT) 1 HORIZONTAL SHIFT SHAFT (NON BIGFOOT) 1414 1 INTERLOCK LEVER (BIGFOOT) 1 INTERLOCK LEVER (NON BIGFOOT) 15 1 BOLT (M5 x 35) 20 2.3 16 1 SPRING 17 1 SPRING 18 1 PLATE 19 2 BOLT (M5 x 12) 36 4 20 1 STRAP 21 2 BOLT (M6 x 20) 70 8 2222 1 COVER (MANUAL) 1 COVER (ELECTRIC) 23 2 BOLT (M6 x 20) Drive Flush 24 1 STOP SWITCH 25 1 RETAINER 26 1 LANYARD STOP SWITCH 27 3 CABLE TIE (8 IN.) 28 1 WIRE (MANUAL) 29 1 BRACKET 30 1 BOLT (M5 x 12) 36 4 31 1 SWITCH 32 1 PLATE ELECTRIC 33 2 SCREW (M3.5 x 20) 20 2.3 90-856159R1 AUGUST 1998 Page 7A-3 1 4 22 4 5 6 7 8 10 11 12 13 15 16 17 18 19 20 21 9 14 24 25 26 27 28 29 31 30 33 32 2 4 14 15 16 17 18 19 21 20 14 3 95 2-4-C w/Teflon (92-850736A1) 95 95 THROTTLE/SHIFT LINKAGE Page 7A-4 90-856159R1 AUGUST 1998 Throttle/Shift Linkage (Handle Models) (Front Shift) THROTTLE/SHIFT LINKAGE Throttle/Shift Linkage (Handle Models) (Front Shift) REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 SCREW (M6 x 20) 2 1 COVER 3 1 DECAL-F,N,R 4 3 SCREW (M6 x 20) 5 1 THROTTLE CABLE BRACKET 6 1 BOLT (M6 x 20) 15 1.7 7 1 WASHER 8 1 PULLEY ASSEMBLY 9 1 BUSHING 10 1 NUT (M6) 15 1.7 11 1 THROTTLE LINK 12 1 SHIFT PLATFORM 13 1 SEAL 14 2 RETAINING RING 15 1 WAVE WASHER 16 1 RETAINING RING 17 1 SHIFT HANDLE 18 1 SHAFT 19 1 SHIFT LINK 20 1 SHIFT LEVER 21 1 SCREW (M5 x 12) 2222 1 HORIZONTAL SHIFT SHAFT (BIGFOOT) 1 HORIZONTAL SHIFT SHAFT (NON BIGFOOT) 2323 1 INTERLOCK LEVER (BIGFOOT) 1 INTERLOCK LEVER (NON BIGFOOT) 24 1 BOLT (M6 x 35) 25 1 SPRING 26 1 SPRING 27 1 PLATE 28 2 BOLT (M5 x 12) 36 4 29 1 STRAP 30 2 BOLT (M6 x 20) 70 8 31 1 SEAL 32 1 STOP SWITCH 33 1 RETAINER 34 1 LANYARD STOP SWITCH 35 3 CABLE TIE (8 IN.) 36 1 WIRE (MANUAL) 37 1 BRACKET 38 1 BOLT (M5 x 12) 36 4 39 1 SWITCH 40 1 PLATE ELECTRIC 41 2 SCREW (M3.5 x 20) 20 2.3 90-856159R1 AUGUST 1998 Page 7A-5 THROTTLE/SHIFT LINKAGE Page 7A-6 90-856159R1 AUGUST 1998 Throttle/Shift Linkage (Non-Handle Models) 1 2 3 4 5 6 7 8 10 9 11 12 13 14 15 16 17 18 19 20 21 22 23 24 26 25 28 27 29 30 31 32 33 34 35 36 37 95 2-4-C w/Teflon (92-850736A1) 95 THROTTLE/SHIFT LINKAGE Throttle/Shift Linkage (Non-Handle Models) REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 PLUG 2 1 STRAP 3 2 BOLT (M6 x 16) 70 8 4 2 BOLT (M5 x 12) 36 4 5 1 PLATE 6 1 SPRING 7 1 SPRING 88 1 HORIZONTAL SHIFT SHAFT (BIGFOOT) 1 HORIZONTAL SHIFT SHAFT (NON BIGFOOT) 99 1 INTERLOCK LEVER (BIGFOOT) 1 INTERLOCK LEVER (NON BIGFOOT) 10 1 BOLT (M5 x 35) 20 2.3 11 1 REMOTE CONTROL PLATFORM 12 3 BOLT (M6 x 20) 70 8 13 1 COVER 14 1 SCREW (M6 x 20) 30 3.4 15 1 SHIFT SHAFT LEVER 16 1 BOLT (M5 x 12) 36 4 17 1 SHIFT LINK ASSEMBLY 18 1 SOCKET 19 1 NUT (#10) Drive Tight 20 1 SEAL 21 1 SHIFT LEVER 22 1 BUSHING 23 1 BOLT (M6 x 20) 70 8 24 1 RETAINER 25 1 PUSH NUT 26 1 THROTTLE LEVER 27 1 RETAINER 28 1 PUSH NUT 29 1 BOLT (M6 x 45) 70 8 30 1 BUSHING 31 1 SLIDE 32 1 THROTTLE LINK 33 1 RETAINING RING 34 1 GROMMET 35 1 PLUG-Choke Cable 36 1 CLAMP ELECTRIC 37 1 BOLT (M5 x 12) 44 5 90-856159R1 AUGUST 1998 Page 7A-7 TILLER HANDLE ATTACHMENTS/CONTROL LINKAGE Section 7B – Tiller Handle Table of Contents Tiller Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-2 Throttle Cable/Linkage Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-4 Throttle Cables. . . . . . . . . . . . . . . . . . . . . . . . . 7B-4 Side Shift Models. . . . . . . . . . . . . . . . . . . . . . . 7B-4 Throttle Cables. . . . . . . . . . . . . . . . . . . . . . . . . 7B-6 Front Shift Models . . . . . . . . . . . . . . . . . . . . . . 7B-6 Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-8 Preparing Tiller Handle Assembly for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-11 Tiller Handle Assembly Removal . . . . . . . . . . . 7B-11 Tiller Handle Disassembly . . . . . . . . . . . . . . . . . 7B-11 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . . 7B-15 Tiller Handle Reassembly . . . . . . . . . . . . . . . . . 7B-16 Tiller Handle Installation . . . . . . . . . . . . . . . . . . . 7B-20 Following Tiller Handle Installation . . . . . . . . . . 7B-20 7 B 90-856159R1 AUGUST 1998 Page 7B-1 TILLER HANDLE Tiller Handle 3 1 2 45 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 2526 27 2829 5 6 20 21 30 95 95 95 95 2-4-C w/Teflon (92-850736A1) Page 7B-2 90-856159R1 AUGUST 1998 TILLER HANDLE Tiller Handle REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm – 1 TILLER HANDLE ASSEMBLY (BLACK) – 1 TILLER HANDLE ASSEMBLY (GRAY) 1 1 COVER 2 1 PULLEY 3 1 CASE 4 1 SCREW (10-16 x 1/2) Drive Tight 5 2 THROTTLE CABLE 6 1 SLEEVE 7 1 STEERING HANDLE ARM 8 2 BOLT (M5 x 16) 70 8 9 1 BOLT (M5 x 16) 50 5.6 10 1 KNOB-Throttle Friction 11 1 SPRING 12 1 LOCK-Throttle Friction 13 1 BOLT (M6 x 25) Hand Tight 14 1 TILLER TUBE 15 1 DECAL 16 1 THROTTLE HANDLE 17 1 GRIP 18 1 STOP SWITCH 19 1 RETAINER 20 2 BUSHING 21 2 WASHER 22 1 WAVE WASHER 23 1 WASHER 24 1 BRACKET-Steering Arm 25 2 BOLT (M10 X 80) 32.5 44 26 1 PLATE 27 1 SWITCH HOUSING 28 1 CLIP ELECTRIC HANDLE 29 1 SWITCH 30 1 DECAL-Start 90-856159R1 AUGUST 1998 Page 7B-3 TILLER HANDLE Throttle Cable/Linkage Installation and Adjustment Throttle Cables SIDE SHIFT MODELS 1. Rotate the tiller twist grip to full counterclockwise position. a a-Wide Open Throttle Position 2. Rotate pulley to align the pointer with the match mark on the bracket as shown below. b a a-Pulley Pointer b-Match Mark Page 7B-4 90-856159R1 AUGUST 1998 TILLER HANDLE 3. Install longest cable barrel into anchor “a”. 4. Wrap longest cable into inner groove around top side of pulley. Place cable jacket into upper anchor bracket. a c b a-Anchor “a” b-Cable Jacket c-Upper Anchor Bracket 5. Rotate tiller twist grip to full clockwise (idle) position. 6. Install remaining barrel into anchor “b”. 7. Place remaining cable into outer groove, wrap around to bottom side of pulley. Place cable jacket into lower anchor bracket. a b c d a-Remaining Cable b-Anchor “b” c-Cable Jacket d-Lower Anchor Bracket 90-856159R1 AUGUST 1998 Page 7B-5 TILLER HANDLE 8. Position locking tab washer into respective tab slot and hole. a c b a a-Locking Tabs b-Tab Slot c-Tab Hole 9. Rotate throttle twist grip back to full counterclockwise (wide open throttle) position. 10. Adjust cable lengths using jam nuts to bring match marks into alignment, make adjustments to lower cable first. 11. Remove slack in upper cable by adjusting upper jam nuts. DO NOT OVERTIGHTEN. a b a-Upper Jam Nuts b-Lower Jam Nuts 12. Rotate tiller throttle handle from idle to wide open throttle to idle again. Verify match marks are in alignment [± 1/8,(3.175mm)]. Readjust jam nuts if marks are not aligned. FRONT SHIFT MODELS 1. Rotate the tiller twist grip to full counterclockwise position. a a-Wide Open Throttle Position Page 7B-6 90-856159R1 AUGUST 1998 TILLER HANDLE 90-856159R1 AUGUST 1998 Page 7B-7 2. Rotate pulley to align the pointer with the match mark on the bracket as shown below. 56971 a b a- Pulley Pointer b- Match Mark 3. Install longest cable/barrel into anchor “a”. 4. Wrap longest cable into inner groove around top side of pulley. Place cable jacket into upper anchor bracket. 56972 a b c a- Anchor “a” b- Cable Jacket c- Upper Anchor Bracket 5. Install remaining barrel into anchor “b”. 6. Place remaining cable into outer groove, wrap around to bottom side of pulley. Place cable jacket into lower anchor bracket. 56973 a b c d a- Remaining Cable b- Anchor “b” c- Cable Jacket d- Lower Anchor Bracket TILLER HANDLE Page 7B-8 90-856159R1 AUGUST 1998 7. Position locking tab washers into respective tab slot and hole. 8. Adjust cable lengths using jam nuts to bring match marks into alignment, make adjustments to lower cable first. 9. Remove slack in upper cable by adjusting upper jam nuts. DO NOT OVERTIGHTEN. 56974 57013 a a b b b c d a- Locking Tab Washers b- Tab Hole c- Upper Jam Nuts d- Lower Jam Nuts Linkage 1. Turn idle speed screw counterclockwise until screw is not touching throttle shaft arm. a b a- Idle Speed Screw b- Throttle Shaft Arm TILLER HANDLE 90-856159R1 AUGUST 1998 Page 7B-9 2. Install throttle linkage on pulley and throttle barrel. a b 56974 c a a- Throttle Linkage b- Throttle Barrel c- Pulley 3. Check to make sure throttle linkage has free movement between throttle barrel and pulley. NOTE: The throttle arm should remain stationary while checking for free movement of throttle linkage. a b c a- Throttle Barrel b- Pulley c- Throttle Arm 4. Move throttle linkage forward until linkage comes to rest on the pulley boss. a b a- Throttle Linkage b- Pulley Boss TILLER HANDLE 5. Tighten screw on throttle barrel to secure linkage. NOTE: Over-tightening screw may damage throttle linkage. NOTE: Check linkage for free movement on pulley. Verify throttle shaft arm in not sticking and returns to idle position. a b a-Screw b-Linkage 6. Verify throttle arm does not hit the full throttle stop at wide open throttle. Gap between stop and throttle arm should be no more than 0.1 in. (2.54 mm). ab c a-Throttle Stop b-Throttle Arm c-Approximately 0.1 in. (2.54 mm) Gap 7. Turn idle speed screw in (clockwise) until it touches the throttle shaft arm, then turn an additional 1/2 turn for initial setting. a b a-Idle Speed Screw b-Throttle Shaft Arm Page 7B-10 90-856159R1 AUGUST 1998 TILLER HANDLE Preparing Tiller Handle Assembly for Removal 1. Disconnect push button start and stop wires. See “Wiring Diagrams” Section 2D. 2. Disconnect throttle cables from pulley. Tiller Handle Assembly Removal 1. Remove tiller handle assembly with 2 bolts. 56755a a-Bolts-M10x80 (2) Tiller Handle Disassembly 1. Remove steering handle arm from steering arm bracket. a b c d a-Bolts (2)-M5x16 b-Plate c-Steering Arm Handle d-Steering Arm Bracket 90-856159R1 AUGUST 1998 Page 7B-11 TILLER HANDLE 2. Remove bushing and washers. a b c d b 53592 a-Bushing b-Flat Washer (2) c-Wave Washer d-Tiller Handle Washer 3. Remove engine start switch from tiller tube (if equipped). NOTE:Pry engine start switch off of tiller tube. a a-Engine Start Switch Page 7B-12 90-856159R1 AUGUST 1998 TILLER HANDLE 4. Remove rubber handle grip. NOTE:Use a flat tip screwdriver to pry/push the rubber grip off the handle. a a-Rubber Grip 5. Remove tiller tube retainer. a b a-Bolt M5x16 b-Retainer 6. Slide tiller tube out of pulley case. Remove from steering handle arm. NOTE: Tiller tube assembly should clear end of steering handle arm. 56695 a b c a-Tiller Tube Assembly b-Steering Handle Arm c-Tiller Tube Assembly Clearing End of Steering Handle Arm 90-856159R1 AUGUST 1998 Page 7B-13 TILLER HANDLE 7. Remove throttle friction assembly from tiller tube. a b a-Throttle Friction Assembly b-Tiller Tube 8. Remove handle from tiller tube. a b a-Handle b-Tiller Tube 9. Remove stop button from tiller tube. ab a-Stop Button b-Tiller Tube 10. Remove pulley case assembly from steering handle arm. a b a-Steering Handle Arm b-Pulley Case Assembly Page 7B-14 90-856159R1 AUGUST 1998 TILLER HANDLE 11. Remove cover and pulley assembly from case. b a c d e f a-Screw (10-16x1/2) b-Cover c-Pulley d-Case e-Sleeve f-Throttle Cables Cleaning/Inspection/Repair 1. Inspect throttle cables for bending/damage and replace if necessary. 2. Inspect steering handle arm for cracks/damage and replace if necessary. 90-856159R1 AUGUST 1998 Page 7B-15 TILLER HANDLE Tiller Handle Reassembly 1. Install sleeve over throttle cables. 2. Install throttle cables onto pulley. a b c d b c a-Sleeve b-Throttle Cables c-Barrel d-Pulley 3. Install pulley assembly into case. Install cover onto case and tighten screw until fully secure. NOTE:Cable jackets should be secured in case. a b c d e b a-Pulley Assembly b-Cable Jackets Secured in Case c-Case d-Cover e-Screw (10-16x1/2)-Drive Tight Page 7B-16 90-856159R1 AUGUST 1998 TILLER HANDLE 4. Install pulley case assembly into steering handle arm. a b a-Pulley Case Assembly b-Steering Handle Arm 5. Install throttle handle on tiller tube. a b a-Throttle Handle b-Tiller Tube 6. Install stop button. NOTE:Feed stop button wires through tiller tube. a b a-Stop Button b-Tiller Tube 7. Install throttle friction assembly. a b c d e f a-Throttle Friction Assembly b-Tiller Tube c-Lock d-Bolt-M6X25 e-Spring f-Knob 90-856159R1 AUGUST 1998 Page 7B-17 TILLER HANDLE 8. Install tiller tube assembly onto steering handle arm. NOTE: Feed stop button wires through pulley case assembly. Insert tiller tube until fully seated in pulley case assembly. Align throttle friction lock with slot in steering arm. 56695 a b c d a-Tiller Tube Assembly b-Steering Handle Arm c-Pulley Case Assembly d-Throttle Friction Assembly 9. Install tiller tube retainer. Tighten bolt to specific torque. a b a-Retainer b-Bolt M5x16 Tiller Tube Retainer Bolt Torque 50 lb-in. (5.6 Nm) 10. Install rubber handle grip. a a-Rubber Handle Grip 11. Install engine start button (if equipped). Page 7B-18 90-856159R1 AUGUST 1998 TILLER HANDLE a a-Engine Start Button 12. Install bushing and washers. 53592 a b c d b a-Bushing b-Flat Washer (2) c-Wave Washer d-Tiller Handle Washer 13. Install steering handle arm assembly into steering arm bracket. a b c d a-Steering Arm Bracket b-Steering Arm Handle Assembly c-Plate d-Bolts (2)-M5x16 Steering Arm Bolt Torque 50 lb-in. (5.6 Nm) 90-856159R1 AUGUST 1998 Page 7B-19 TILLER HANDLE Tiller Handle Installation 1. Secure tiller handle to steering arm with 2 bolts, plate and bushing (align bushing with slot in steering arm). Torque bolts to 70 lb-in. (8.0 Nm). 56755a a-Bolts-M10x80 (2) Steering Arm Bracket Bolt Torque 32.5 lb-ft (44 Nm) Following Tiller Handle Installation 1. Connect push button start (if equipped) and stop wires. See “Wiring Diagrams” Section 2D. 2. Connect throttle cables to pulley. Refer to “Throttle Cable/Linkage Installation and Adjustment” in this section. Page 7B-20 90-856159R1 AUGUST 1998 MANUAL STARTER MANUAL STARTER Section 8 Table of Contents Starter Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Neutral Interlock Adjustment. . . . . . . . . . . . . . 8-6 Manual Starter Removal. . . . . . . . . . . . . . . . . . 8-4 Manual Rewind Disassembly . . . . . . . . . . . . . 8-7 Manual Starter Installation. . . . . . . . . . . . . . . . 8-5 Manual Rewind Reassembly. . . . . . . . . . . . . . 8-9 8 90-856159R1 AUGUST 1998 Page 8-1 MANUAL STARTER Page 8-2 90-856159R1 AUGUST 1998 Starter Assembly 1 2 3 4 7 24 27 28 29 30 31 33 34 35 32 9 23 5 36 8 11 19 22 26 1 6 37 7 Loctite “271” (92-809819) 95 2-4-C w/Teflon (92-850736A1) 95 95 7 25 26 10 12 13 14 15 16 17 18 20 21 MANUAL STARTER Starter Assembly REF REFREF . NO. QTY. DESCRIPTION TORQUE lb-in. lb-ft Nm 1 1 HANDLE REST 2 1 SEAL 3 1 HANDLE 4 1 RETAINER HANDLE MODELS 5 1 PILOT LAMP 6 1 NUT 7 2 SCREW (M6 x 16) 30 3.4 – 1 RECOIL ASSEMBLY 8 1 HOUSING 9 3 COLLAR 10 1 STARTER SHEAVE 11 1 DRIVE PAWL 12 1 SPRING 13 1 DRIVE PLATE 14 1 DRIVE PAWL SPRING 15 1 SPRING 16 1 RETURN SPRING MANUAL 17 1 CIRCLIP 18 1 BOLT 52 5.9 19 1 COLLAR 20 1 STARTER ROPE 21 1 STOPPER 22 1 RETURN SPRING 23 1 SPRING 24 3 BOLT (M6 x 20) 70 8 25 1 BOLT (M6 x 90) 30 3.4 26 2 WASHER 27 1 NUT (M6) 30 3.4 28 1 PLUG-Warning Light (ELECTRIC NON-HANDLE) 29 1 PLUG (ELECTRIC NON-HANDLE) 30 1 STARTER HOUSING 31 3 COLLAR ELECTRIC 32 1 DECAL-Caution-Start In Gear 33 1 DECAL-Emergency Start Procedure 34 1 COVER 35 2 GROMMET 36 1 DECAL-Servicing Referral 37 1 DECAL-EPA Information 90-856159R1 AUGUST 1998 Page 8-3 MANUAL STARTER Page 8-4 90-856159R1 AUGUST 1998 Manual Starter Removal 1. Remove the two screws and rotate the handle rest forward. a a-Handle Rest 2. Remove three bolts and than remove the manual starter. a a-Manual Starter 3. Disengage the neutral interlock cable. MANUAL STARTER 90-856159R1 AUGUST 1998 Page 8-5 Manual Starter Installation 1. Install manual starter with three bolts. a a-Bolt (3) - M6x20 Cover Mounting Bolt Torque 70 lb-in. (8 Nm) 2. Fasten handle rest with two screws. aa a-Screw (2) – M6× 16 Handle Rest Mounting Screw Torque 30 lb-in. (3.4 Nm) 3. Reinstall the neutral interlock components. Refer to adjustment following. IMPORTANT: Check the operation of the neutral interlock. The starter rope must not pull out when the shift handle is in forward or reverse position. MANUAL STARTER Page 8-6 90-856159R1 AUGUST 1998 Neutral Interlock Adjustment 1. Place shift lever in neutral position. 2. The slide on the end of the cable should line-up with the the neutral start mark on the cover as shown. 3. If adjustment is required, remove the cable and rotate the cable to obtain the correct adjustment. IMPORTANT: Check the operation of the neutral interlock. The starter rope must not pull out when the shift handle is in forward or reverse position. aa b c a-Slide b-Neutral Start Mark c-Rotate Cable For Adjustment MANUAL STARTER 90-856159R1 AUGUST 1998 Page 8-7 Manual Rewind Disassembly WARNING Safety glasses should be worn to prevent eye injury caused by the rewind spring uncoiling out out of the housing. 1. Rotate the sheave counterclockwise until you can loop up the starter rope. 2. Place the looped rope in the cutaway and turn the sheave clockwise until rewind spring is fully unwound. 3. Remove the bolt, drive plate and spring. a b a-Drive Plate b-Spring MANUAL STARTER Page 8-8 90-856159R1 AUGUST 1998 4. Rotate the starter sheave clockwise until the rewind spring disengages from the sheave. 5. Gently lift the starter sheave from the housing. 6. If the rewind spring requires removal, remove it by allowing it out one turn of winding each time. a a-Starter Sheave 7. Pull out the retainer from the handle and untie the knot. a a-Retainer MANUAL STARTER Manual Rewind Reassembly STARTER ROPE REPLACEMENT NOTE:Starter rope length: When replacing the starter, cut the length to 71 in. (1.500 mm). 1. Push the starter rope through the rope hole in the starter sheave. Pull end of rope out of the knot recess. 2. Tie a knot into the end of the rope and pull the knot back into the recess. 3. Wind the rope counterclockwise around the sheave. a a-Knot Recess SHEAVE INSTALLATION CAUTION Wear safety glasses for eye protection in case spring should uncoil out of housing. 1. If the rewind spring was removed, place outer hook of the rewind spring in the slot and wind spring counterclockwise into housing. 90-856159R1 AUGUST 1998 Page 8-9 MANUAL STARTER 2. Insert the starter rope through the rope guide. 3. Install the starter sheave. Engage the tab on the back side of the sheave into the hook on the rewind spring. Lubricate the rewind spring with Quicksilver 2-4-C w/Teflon. 95 95 a c b 2-4-C w/Teflon (92-850736A1) a-Starter Sheave b-Rope Guide c-Engage Tab With The Hook On The Rewind Spring Page 8-10 90-856159R1 AUGUST 1998 MANUAL STARTER 4. Spread the spring onto the drive plate. 5. Insert the spring through the wire loop as shown. 6. Fasten the sheave and drive plate to the housing. Apply Loctite “271” to bolt threads and tighten to specified torque. 7. Lubricate the drive plate with Quicksilver 2-4-C w/Teflon 7 Loctite “271” (92-809819) 7 95 a bd c 95 2-4-C w/Teflon (92-850736A1) a-Spring – Spread Onto The Drive Plate b-Drive Plate c-Insert Spring Through Wire Loop d-Bolt Drive Plate Mounting Bolt Torque 52 lb-in. (5.9 Nm) 8. Tie a knot into end of rope. Place knot into retainer and install retainer into handle. 90-856159R1 AUGUST 1998 Page 8-11 MANUAL STARTER Page 8-12 90-856159R1 AUGUST 1998 STOPPER INSTALLATION 1. If removed, install stopper as shown. b a c a-Stopper b-Spring c-Assemble Spring As Shown ADJUSTING REWIND SPRING TENSION 1. Form a loop in the rope. place rope in the cutout and pre-load the spring tension by rotating the drum counterclockwise three turns.