Mariner Mercury 105/140 JET Service Manual Download Page 273

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3D-0 - FUEL SYSTEMS

90-824052R3 JUNE 2002

Table of Contents

Page

Specifications

3D-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Tools

3D-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Detonation Controller/Air Temperature

Sensor/Throttle Position Sensor

3D-3

. . . . . . . . . .

Electronic Control Module (ECM) Assembly

3D-4

Fuel Management System

3D-6

. . . . . . . . . . . . . . . . .

Fuel Pump

3D-10

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Outboard Powerhead View

3D-12

. . . . . . . . . . . . . . .

Electronic Fuel Injection (EFl) System

3D-12

. . . . . .

Introduction

3D-12

. . . . . . . . . . . . . . . . . . . . . . . . . .

Using the Test Procedures

3D-12

. . . . . . . . . . . . .

EFI System Tests

3D-13

. . . . . . . . . . . . . . . . . . . . .

Safety Precautions

3D-13

. . . . . . . . . . . . . . . . . . . .

Fuel Injection System Function

3D-13

. . . . . . . . .

Preliminary Checks

3D-14

. . . . . . . . . . . . . . . . . . . . . .

Fuel Flow Diagram

3D-16

. . . . . . . . . . . . . . . . . . . . . .

Fuel Flow Component Description

3D-17

. . . . . . . . .

Wiring Diagram 150 EFI/175 EFI

150 Pro Max/Super Magnum

3D-19

. . . . . . . . . . .

Wiring Diagram 200 EFI/200 &

225 Pro Max/Super Magnum

3D-20

. . . . . . . . . . .

EFI Electrical Components (from Electrical

Component Diagram)

3D-21

. . . . . . . . . . . . . . .

EFI Fuel Management (Low Pressure

Fuel Route)

3D-23

. . . . . . . . . . . . . . . . . . . . . . . . . . .

EFI Fuel Management (High Pressure

Fuel Route)

3D-24

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Rail Electrical/Fuel Determination

3D-25

. . . . .

EFI System Test Procedures

3D-26

. . . . . . . . . . . . . .

Fuel Gauge Connection/Pressure Test

3D-26

. .

Vapor Separator Fuel Delivery Test

3D-27

. . . . .

Vapor Separator Float Test

3D-28

. . . . . . . . . . . . .

Water Separating Filter Flow Test

3D-28

. . . . . . .

Pulse Fuel Pump Delivery Test

3D-29

. . . . . . . . .

Final Filter Check and De-pressurizing EFI

System Procedures

3D-29

. . . . . . . . . . . . . . . . .

Pressure Regulator Test

3D-31

. . . . . . . . . . . . . . .

Electric Fuel Pump Voltage Test

3D-32

. . . . . . . .

Voltage Test Chart

3D-33

. . . . . . . . . . . . . . . . .

Injector Electrical Harness Test

3D-34

. . . . . . . . .

ECM Injector Driver Test

3D-34

. . . . . . . . . . . . . . .

Injector Fuel Delivery Test

3D-34

. . . . . . . . . . . . .

Injector Operation Test

3D-35

. . . . . . . . . . . . . . . .

Induction Manifold Leak Check

3D-36

. . . . . . . . .

Air Temperature Sensor Test

3D-37

. . . . . . . . . . .

Engine Head Temperature Sensor Test

3D-37

. .

Detonation Control System Test

(200 Models Only)

3D-38

. . . . . . . . . . . . . . . . . .

Detonation Sensor Check

3D-38

. . . . . . . . . . . . . .

Detonation Control Module Check

3D-39

. . . . . .

Page

Throttle Position Sensor Test

3D-39

. . . . . . . . . . .

Map Sensor Test

3D-40

. . . . . . . . . . . . . . . . . . . . .

Problem Diagnosis

3D-41

. . . . . . . . . . . . . . . . . . . .

Engine Head Temperature Sensor Removal 3D-44
EFI Induction Manifold Removal

3D-44

. . . . . . . . . . .

Water Separating Filter Assembly

Removal

3D-45

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Water Separating Filter Assembly

Installation

3D-45

. . . . . . . . . . . . . . . . . . . . . . . . .

Throttle Position Sensor and Temperature

Sensor Fuel Injector Harness
Disconnections

3D-46

. . . . . . . . . . . . . . . . . . . . .

Oil Reservoir Removal

3D-46

. . . . . . . . . . . . . . . .

Fuel Pressure Regulator Removal

3D-47

. . . . . .

Fuel Pressure Regulator Disassembly

3D-47

. . .

Fuel Pressure Regulator Reassembly

3D-47

. . .

Vapor Separator Removal

3D-48

. . . . . . . . . . . . .

Vapor Separator Disassembly

3D-49

. . . . . . . . . .

Vapor Separator Reassembly

3D-50

. . . . . . . . . .

Installing Vapor Separator Assembly to

Induction Manifold

3D-52

. . . . . . . . . . . . . . . . . .

Manifold Removal

3D-54

. . . . . . . . . . . . . . . . . . . .

EFI Induction Manifold Disassembly

3D-54

. . . . . . .

Air Temperature Sensor Removal

3D-55

. . . . . . .

Throttle Position Sensor Removal

3D-55

. . . . . . .

Fuel Rail Removal

3D-56

. . . . . . . . . . . . . . . . . . . .

Fuel Rail Disassembly

3D-57

. . . . . . . . . . . . . . . . .

Fuel Injector Removal and Disassembly

3D-57

Injector Harness Removal

3D-58

. . . . . . . . . . . . .

Throttle Linkage Removed

3D-59

. . . . . . . . . . . . .

EFI System Cleaning and Inspection

3D-59

. . . . . . .

Cleaning

3D-59

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection

3D-59

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Induction Manifold Assembly

3D-60

. . . . . . . . . . . . . .

Injector Harness Installation

3D-60

. . . . . . . . . . . .

Fuel Injector Assembly and Installation

3D-61

. .

Fuel Rail Assembly

3D-62

. . . . . . . . . . . . . . . . . . .

Fuel Rail Installation

3D-62

. . . . . . . . . . . . . . . . . .

Throttle Position Sensor Installation

3D-64

. . . . .

Air Temperature Sensor Installation

3D-64

. . . . .

EFI Induction Manifold Installation

3D-65

. . . . . . . . .

Oil Reservoir Installation

3D-66

. . . . . . . . . . . . . . .

Vapor Separator Installation

3D-67

. . . . . . . . . . . .

Throttle Position Sensor, Air Temperature

Sensor and Fuel Injector Harness
Connections

3D-68

. . . . . . . . . . . . . . . . . . . . . . .

ECM Installation

3D-69

. . . . . . . . . . . . . . . . . . . . . .

Engine Head Temperature Sensor

Installation

3D-70

. . . . . . . . . . . . . . . . . . . . . . . . .

3C - ELECTRONIC FUEL INJECTION

Summary of Contents for 105/140 JET

Page 1: ...200 200 EFI With Serial Numbers 0D082000 Through 0G960499 1992 Through 2000 150 200 225 Pro Max 150 200 225 Super Magnum With Serial Numbers 0D082000 Through 0T105314 SERVICE MANUAL MODELS 105 140 JE...

Page 2: ...method We have not under taken 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 th...

Page 3: ...d Before raising or removing and outboard engine from a boat the following precautions should be adhered to 1 Check that flywheel is secured to end of crank shaft with a locknut and lifting eye is thr...

Page 4: ...Starting System C Timing Synchronizing Adjusting D Wiring Diagrams Section 3 Fuel System A Fuel Pump B Carburetor C Fuel Injection 1995 and Prior D Fuel Injection 1996 and Up E Oil Injection F Emissio...

Page 5: ...1 A IMPORTANT INFORMATION SPECIFICATIONS...

Page 6: ...90 824052R3 JUNE 2002 1A 0 IMPORTANT INFORMATION Table of Contents Page Master Specifications 1A 1...

Page 7: ...t 135 150 Type Displacement Model 140 Jet XR6 MAGIII I75 200 150XRI 175XRI 200XRI Pro Max Super Magnum 150 200 225 Type Displacement V 6 Cylinder Two Cycle Loop Charged 121 9 cu in 1998cc V 6 Cylinder...

Page 8: ...ustment Positions Allowable Transom Thickness 75 20 60 5 2 3 8 in 6 03cm Maximum GEAR HOUSING Gear Ratio Models 135 150 Models XR6 MAGIII 150XRI Models XR6 MAGIII 4 1 4 dia Models 175 200 175XRI 200XR...

Page 9: ...tart Rope 175 Amperes 40 Amperes Min Reserve Cap Rating of 100 Min and CCA of 490 MCA of 630 Amperes IGNITION SYSTEM Type Spark Plug Type Except 225 ProMax and 225 Super Magnum Spark Plug Type 225 Pro...

Page 10: ...r Models All EFI Models Float Adjustment Float Level WMH Carburetor Jets Model 135 WMH 30 Main Jet Off Idle Jet Idle Air Jet Vent Jet Model 105 Jet 150 WMH 31 Main Jet Off Idle Jet Idle Air Jet Vent J...

Page 11: ...Model 105 Jet 150 WMV 2 2A Main Jet Idle Air Jet Vent Jet Model XR6 MAGIII WMV 3 3A Main Jet Idle Air Jet Vent Jet Model 175 WMV 4 4A Main Jet Idle Air Jet Vent Jet Model 140 Jet 200 WMV 5 5A Main Je...

Page 12: ...anking Speed WOT RPM 150 XRI Cranking Speed WOT RPM 140 Jet 200 Carb Models with Spark Advance Module Cranking Speed WOT RPM Models with Idle Stabilizer Module Cranking Speed WOT RPM Model 200XRI Cran...

Page 13: ...135 150 Model 140 Jet XR6 MAGIII 175 200 Model 150XRI 175XRI 200XRI Pro Max Super Magnum 150 200 225 Reserve Capacity Approx Time Output 1000 RPM for 3 Minutes with Pump Full Open Model 105 Jet 135 15...

Page 14: ...1 B IMPORTANT INFORMATION MAINTENANCE...

Page 15: ...ity 1B 5 Draining Gear Case 1B 5 Checking Lubricant Level and Refilling Gear Case 1B 5 Propeller Replacement 1B 6 Removal 1B 6 Installation 1B 6 Corrosion Control Anode 1B 7 Flushing Engine 1B 8 Flush...

Page 16: ...eck steering link rod fasteners for proper tightness 6 Check propeller blades for damage After Each Use 1 Flush out the outboard cooling system if operat ing in salt or polluted water 2 Wash off all s...

Page 17: ...ount 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 t...

Page 18: ...must be fully retracted into cable housing before lubricating cable If cable is lubricated while extended hydraulic lock of cable could occur With core of Ride Guide Steering cable transom end fully r...

Page 19: ...externally vented The outboard can be raised or lowered manually by loosening the manual release valve 3 to 4 turns The trim out angle of this outboard is not adjustable The trim system has an intern...

Page 20: ...normal gear wear An excessive amount of metal filings or larger particles chips may indicate abnormal wear and requires gear housing disassembly and component inspection 5 Note color of gear lubricant...

Page 21: ...peller shaft 51866 a b 51871 c d d e f a Thrust Hub Forward b Propeller Shaft c Continuity Washer If Equipped d Rear Thrust Hub e Tab Washer f Propeller Nut Installation WARNING When installing or rem...

Page 22: ...opeller nut Operation with a loose propeller could cause damage to the thrust hub and gear housing during acceleration deceleration or when shifting gears c d e c Locking Tab Washer Bend Tabs into Thr...

Page 23: ...uivalent tool on the gear housing from the FRONT side positioning the rubber cups over the water intake openings 2 Connect hose 1 2 in 12 7mm I D or larger between flushing attachment and water tap IM...

Page 24: ...bute the storage seal in the cylinders Rein stall spark plugs Electronic Fuel Injection EFI Models NOTE Make sure the fuel system has been pre pared for storage 1 Remove the spark plugs and inject a f...

Page 25: ...C 1 IMPORTANT INFORMATION GENERAL INFORMATION...

Page 26: ...her 1C 1 Boat 1C 2 Engine 1C 3 Following Complete Submersion 1C 4 Salt Water Submersion 1C 4 Submerged While Running 1C 4 Submerged Engine Fresh Water 1C 4 Propeller Selection 1C 5 Painting Procedures...

Page 27: ...ry weather In pointing out the consequences of weather effects an engine running on a hot humid summer day may lose as much as 14 of the horsepower it would produce on a dry brisk spring or fall day T...

Page 28: ...ause speed loss Clean surfaces when necessary d Gear Housing If unit is left in the water ma rine vegetation may accumulate over a peri od of time This growth MUST be removed from unit before operatio...

Page 29: ...of the blade sur face If allowed to continue eventual blade failure breakage will occur Engine DETONATION Detonation in a 2 cycle engine resembles the pinging heard in an automobile engine It can be...

Page 30: ...e eliminated by placing engine in a horizontal position with spark plug holes down and rotating flywheel 5 Pour alcohol into carburetor throats alcohol will absorbed water Again rotate flywheel 6 Turn...

Page 31: ...ilation 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...

Page 32: ...f 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...

Page 33: ...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 t...

Page 34: ...D 1 B A D C IMPORTANT INFORMATION OUTBOARD MOTOR INSTALLATION...

Page 35: ...6 Required Side Mount Remote Control or Ignition Key Switch Assembly 1D 7 Boats Equipped with Side Mount Remote Control 1D 7 Boats Equipped with Panel or Console Mount Remote Control 1D 7 Page Shift...

Page 36: ...powering a boat can result in serious injury death or boat damage Outboard Remote Control The remote control connected to the outboard must be equipped with a start in gear protection device This prev...

Page 37: ...ght of outboard generally will provide the following 1 Less steering torque 2 more top speed 3 greater boat stability but 4 will cause more prop break loose which may be particularly noticeable when p...

Page 38: ...g holes perpendicular to and thru the transom IMPORTANT If using Transom Drilling Fixture part number 91 98234A2 use drill guide holes marked A when drilling outboard mounting holes b a a Centerline o...

Page 39: ...ight preceding and position out board on boat transom to align mounting holes in transom bracket that will place the outboard nearest to the recommended mounting height CAUTION Marine sealer must be u...

Page 40: ...ecure steering cable to tilt tube with steering cable attaching nut c as shown Torque nut to 35 lb ft 41 0 N m 28160 c b a Steering Link Rod Installation IMPORTANT The steering link rod that connects...

Page 41: ...tall control cables to remote control and mount remote control BEFORE attaching control cables to engine Refer to installation instructions included with remote control Counter Left Hand Rotation Outb...

Page 42: ...on instructions included with the remote control 2 Before installing the shift cable to the engine lo cate the center point of the slack or lost motion that exists in the remote control and shift cabl...

Page 43: ...ould lock solidly in gear If not adjust barrel away from cable end guide Repeat steps a thru c d Return remote control handle to neutral The propeller should turn freely without drag If not adjust bar...

Page 44: ...Solenoid e Lead From Trim Sender f Lead From Temperature Sender g Harness Holder Located in Cowl Place Wiring Harness and Battery Cables into Holder Battery Connections CAUTION For dual outboard inst...

Page 45: ...must be run on a 50 1 gasoline oil mixture during the engine break in period Refer to engine break in proce dure in the Operation Maintenance Manual CAUTION If an electric fuel pump is to be used on...

Page 46: ...Oil Injection System 1 Fill remote oil tank with the recommended oil listed in the Operation and Maintenance Manual Tighten fill cap a a Fill Cap 2 Remove fill cap from the engine oil tank and fill t...

Page 47: ...r best all around performance from your outboard boat combination select a propeller that allows the engine to operate in the upper half of the recom mended full throttle RPM range with the boat norma...

Page 48: ...pin freely The boat can now spin out or go into a very tight maximum turn which if unexpected can result in occupants being thrown within the boat or out of the boat Consider the following lists caref...

Page 49: ...Do not attempt to turn boat when engine is trimmed extremely under or in a a Tilt Pin Checking Trim System Fluid Level 1 Tilt outboard to the full up position and engage the tilt support lever 2 Remov...

Page 50: ...A 2 ELECTRICAL IGNITION SYSTEM...

Page 51: ...tions 2A 18 Ignition Switch Bullet Connections 2A 19 Low Speed High Speed Spark Advance Module Description 2A 19 Tests For Proper Function of Low Speed High Speed Spark Advance Module 2A 19 Low Speed...

Page 52: ...E Trig ger Lead without YELLOW Sleeve and VIOLET Trigger Lead with YELLOW Sleeve 1100 1400 R x 100 Between VIOLET Trigger Lead without YELLOW Sleeve and BROWN Trigger Lead with YELLOW Sleeve 1100 1400...

Page 53: ...of individual cylinders Volt Ohm Multi Meter 91 62562 55218 NOTE Volt Ohm Multi Meter 91 62562 can be used to test ignition system voltages if used in conjunction with DVA ADAPTOR 91 89045 DVA Adapte...

Page 54: ...052R3 JUNE 2002 ELECTRICAL 2A 3 Test Harness 91 14443A1 Timing Light 91 99379 Crank Shaft Protector Cap 91 24161 Flywheel Puller 91 849154T1 55117 Flywheel Holder 91 52344 91 52344 54964 Heat Lamp 91...

Page 55: ...2A 4 ELECTRICAL 90 824052R3 JUNE 2002 Flywheel Starter Motor 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 15 7 25 Liquid Neoprene 92 25711 2 25 25 25 25 7 Loctite 271 92 809820...

Page 56: ...COVER ASSEMBLY 2 1 MARKER 3 2 SCREW 4 2 WASHER 5 1 PLUG 6 1 PLUG 7 1 NUT 120 163 8 1 WASHER 9 1 FLYWHEEL 10 1 STATOR 11 4 SCREW 50 5 5 12 4 WASHER 13 1 TRIGGER PLATE ASSEMBLY 14 1 STARTER MOTOR 15 2...

Page 57: ...Regulator 9 8 Dielectric Grease 92 823506 1 6 25 Liquid Neoprene 92 25711 2 25 6 33 1 2 3 4 5 6 7 10 11 12 13 10 10 14 15 14 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Loctite 680 92 809833 33 NOTE App...

Page 58: ...5 10 4 STA STRAP 11 2 COVER ignition coil 12 12 SCREW ignition coil cover 20 2 5 13 12 WASHER 14 14 NUT cover screw ground wire Drive Tight 15 6 GROUND WIRE 16 2 SCREW grounding wire 17 6 IGNITION COI...

Page 59: ...rter Solenoid 1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 28 29 30 31 32 33 34 35 6 10 17 14 17 23 22 25 Liquid Neoprene 92 25711 2 7 8 3 27 7 Loctite 271 92 809820 NOTE Apply L...

Page 60: ...150 175 14 20 NUT 20 2 5 15 1 CABLE ASSEMBLY 3 WHITE BLACK 150 175 15 1 CABLE ASSEMBLY 6 RED WHITE 16 2 WIRE 17 2 SCREW 35 4 0 18 1 CABLE ASSEMBLY BLACK 19 1 SCREW 1 2 40 4 5 20 3 SCREW 1 1 4 150 12...

Page 61: ...s the flywheel rotates the permanent magnets pass the capacitor charging coils producing AC voltage The AC voltage is conducted to the switch boxes where it is rectified and stored in a capacitor The...

Page 62: ...ded to engine 5 Check for disconnected wires and short and open circuits Checking for Loss of Spark The use of an inductive timing light while cranking or running the engine will show whether there is...

Page 63: ...mperature electrical components can be heated to without damage is 311 F 155 C 9 Repeat failures of the same electrical component could be caused by other electrical components If one circuit in a swi...

Page 64: ...s proceed with Step 1 D 1 D If Steps 1 A 1 B and 1 C check OK check ignition timing 1 If ignition timing DOES NOT check to specifica tion sudden and unexplained timing change check trigger advance lin...

Page 65: ...ATOR LOW SPEED TEST DVA RED DVA BLK 400 RPM 1000 RPM 3000 RPM BLUE GROUND 100 265 195 265 255 345 STATOR HIGH SPEED TEST DVA RED DVA BLK 400 RPM 1000 RPM 3000 RPM RED GROUND 25 50 120 160 230 320 1 If...

Page 66: ...T DVA RED DVA BLK 400 RPM 1000 RPM 3000 RPM GROUND WHT BLK 1 6 3 15 10 30 Ohm Test 1 Disconnect WHITE BLACK wire from switch box terminal 2 With ohmmeter set to 1K scale connect one ohm lead to WHT BL...

Page 67: ...5 10 30 1 Using meter only REVERSE LEAD POLARITY Connect leads as specified If using a meter with a built in DVA place selector switch in the DVA 400 VDC position Ignition System STATOR ASSEMBLY The s...

Page 68: ...ulty use Multi Meter DVA Tester 91 99750 or a voltmeter and Direct Voltage Adaptor 91 89045 to thoroughly check coil 1 Disconnect wires from the positive and nega tive coil terminals 2 Remove the spar...

Page 69: ...D IGNITION SWITCH SOLDERED CONNECTIONS 2 Set ohmmeter on R x 1 scale for the following tests 3 If meter readings are other than specified in the preceding tests verify that switch and not wiring is fa...

Page 70: ...start the engine and allow it to idle above 600 RPM Retard the ignition timing by slowly pulling forward on the spark advance lever The system is functioning correctly if a rapid spark advance as much...

Page 71: ...the timing to the normal idle timing TEST FOR PROPER FUNCTION OF IDLE STABILIZER IMPORTANT Due to the sensitivity characteris tics of individual modules and tachometer vari ances the engine RPM at wh...

Page 72: ...rd is shifted INTO GEAR shift switch circuit CLOSES BIAS VOLTAGE from each switch box is changed by a 6 8K 34K resistor located in the WHITE BLACK lead between the switch boxes and the shift switch Th...

Page 73: ...puller as shown CAUTION DO NOT hammer on end of puller center bolt to remove flywheel or damage may result to crankshaft or bearings DO NOT use heat to aid flywheel removal as excessive heat may seize...

Page 74: ...ng screws Torque screws to 50 Ib in 5 5 N m 2 Reconnect wires to proper terminals of voltage regulator rectifier and switch boxes Reconnect ground lead to ground Refer to wiring diagram following in t...

Page 75: ...Pull link rod out of lever 4 Remove 2 screws and lift outer switch box from inner switch box Retain round metal spacers 5 Disconnect all trigger leads from their respective terminals Cut sta strap and...

Page 76: ...must be grounded to engine before cranking engine or switch boxes will be damaged 5 Clean stator attaching screw threads with Loctite Primer T 92 59327 1 and apply Loctite 222 obtain locally Install...

Page 77: ...92 41669 Assemble boot over coil terminal SWITCH BOX ES REMOVAL AND INSTALLATION Switch Box es Removal 1 Remove 2 screws and lift switch boxes from engine Retain round metal spacers b a 51844 a Screws...

Page 78: ...c Outer Switch Box d Inner Switch Box a b 11652 a Wires with Yellow Sleeves Are Connected to Outer Switch Box b Switch Boxes MUST BE Grounded to Engine SPARK PLUG WIRE ROUTING PRODUCTION OUTBOARDS To...

Page 79: ...2A 28 ELECTRICAL 90 824052R3 JUNE 2002 SPARK PLUG WIRE ROUTING HIGH PERFORMANCE OUTBOARDS...

Page 80: ...B 2 51797 ELECTRICAL BATTERY CHARGING SYSTEM AND STARTING SYSTEM...

Page 81: ...t High Output 2B 6 Problem No Output 2B 6 Regulation Voltage Check 2B 6 Voltage Regulator Test 2B 7 Removal of Voltage Regulators 2B 7 Page Installation of Voltage Regulator Rectifier 2B 8 Incorporati...

Page 82: ...DMT 2000 Digital Tachometer Multimeter 91 854009A1 Hydrometer obtain locally Ammeter obtain locally Battery Cable Size If standard original battery cables are replaced with longer cables the wire gaug...

Page 83: ...a charged to a discharged condition acid leaves the solution and enters the plates causing a decrease in specific gravity of electrolyte An indication of concentration of electrolyte is obtained with...

Page 84: ...should be added to the battery not electrolyte Liquid level in cells should never be allowed to drop below top of plates as portion of plates exposed to air may be permanently damaged with a resulting...

Page 85: ...receding charging procedure every 30 45 days as long as battery is in storage for best possible maintenance during inactive periods to ensure a good serviceable battery in spring When ready to place b...

Page 86: ...OILS ONLY NOTE Stator can be tested without removing from engine 1 Disconnect 2 short YELLOW and 2 long YEL LOW stator leads from bullet connectors at rear of engine above ignition coil plate 2 Use an...

Page 87: ...nnect 2 short YELLOW leads and 1 long YELLOW lead Repeat the test with the second long YELLOW lead connected Any output current indicates stator is shorted to ground Replace stator 4 If there is no ou...

Page 88: ...W lead Con nect POSITIVE ohm lead to case ground 8000 15000 R x 1K Tachometer Circuit Check Connect NEGATIVE ohm lead to case ground Connect POSITIVE ohm lead to GRAY lead 10000 50000 R x 1K NOTE Mete...

Page 89: ...Position regulators over attaching studs production models 2 Connect YELLOW RED and GRAY as required leads to their respective bullet connectors 3 Position spacers over attaching studs production mod...

Page 90: ...Liquid Neoprene 92 25711 to avoid corrosion 2 Using BATTERY ISOLATOR HARNESS KIT 84 815366A3 charging system can be wired to provide either 20 amps to auxiliary battery and 20 amps to cranking batter...

Page 91: ...2 25711 to avoid corrosion a b c d e f g h i k h j a Starter Solenoid b RED Lead to Starter Solenoid c Battery Isolator d Start Battery e Auxiliary Battery f RED pigtail Cable from kit to Battery Isol...

Page 92: ...arting when the 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 startin...

Page 93: ...t Point 3 c Turn ignition key to Start position 12 Volt Reading Check BLACK ground wire for poor connection or open circuit Reconnect ground wire to starter solenoid Proceed to TEST 7 No voltage readi...

Page 94: ...le with YELLOW sleeve for poor connection or open circuit 12 Volt Reading If starter motor does not turn check starter motor Battery Voltage ELECTRICAL 2B 13 90 824052R3 JUNE 2002 Starter Removal and...

Page 95: ...s from starter 11646 a b a Through Bolts b Commutator End Cap 3 Tap commutator end cap to loosen and remove from frame Do not lose brush springs 4 Brush replacement is recommended if brushes are pitte...

Page 96: ...ndercut is flat b Clean the commutator slots after undercutting c Sand the commutator lightly with No 00 sandpaper to remove burrs then clean the commutator d Recheck the armature on a growler for sho...

Page 97: ...brushes Meter must indicate full continuity or zero resistance If resistance is indi cated inspect lead to brush and lead to POSITIVE terminal solder connection If connection cannot be repaired brushe...

Page 98: ...Push Lead into Slot b Install NEGATIVE brushes along with brush holder 11656 a c b d a b d a POSITIVE Brushes b NEGATIVE Brushes c Brush Holder d Bolts Fasten NEGATIVE Brushes and Holder 2 If removed...

Page 99: ...hing located in commutator end cap with one drop of SAE 10W oil DO NOT over lubricate 8 Place springs and brushes into brush holder and hold in place with brush retainer tool 11661 b a a Brush Retaine...

Page 100: ...1 scale and connect meter leads between solenoid terminals 1 and 2 3 Connect a 12 volt power supply between sole noid terminals 3 and 4 Solenoid should click and meter should read 0 ohms full continui...

Page 101: ...C 2 ELECTRICAL TIMING SYNCHRONIZING ADJUSTING...

Page 102: ...C 6 Idle Speed Adjustment 2C 6 Page Adjustments 2C 7 Electronic Fuel Injection Models 2C 7 Timing Pointer Adjustment 2C 7 Throttle Cam Adjustment 2C 8 Static Idle Timing Adjustment Cranking Engine wit...

Page 103: ...Model 175 Carb Full Throttle RPM Range 5000 5600 Idle RPM in Forward Gear 600 700 Maximum Timing Cranking Speed 5000 RPM 20 BTDC 19 BTDC Idle Speed Pickup Timing 0 9 ATDC Spark Plug NGK BU8H Firing Or...

Page 104: ...725 Maximum Timing Cranking Speed 5800 RPM 16 BTDC 22 BTDC Idle Speed Pickup Timing 0 9 ATDC Spark Plug NGK BU8H Firing Order 1 2 3 4 5 6 Model 150 PRO MAX SUPER MAGNUM Full Throttle RPM Range 6200 6...

Page 105: ...ywheel clockwise so that dial indicator reads 462 in 11 7mm exactly 4 Reposition timing pointer a so that timing pointer is aligned with 462 in mark on timing decal Retighten pointer attaching screws...

Page 106: ...utters do not act as a throttle stop Allow 010 in 015 in 25mm 38mm clear ance between throttle shaft arm b and stop c at W O T Retighten jam nut on adjustment screw 010 015 0 25mm 0 38mm a b c 54389 C...

Page 107: ...at cranking speed a fully charged battery must be used MAXIMUM TIMING ADJUSTMENT CAUTION Models equipped with Idle Stabilizer Shift Kit Accessory P N 87 814281A1 excluding Mercury XR6 Mariner Magnum l...

Page 108: ...ve or below recommended RPM see specifications readjust primary pickup a screw to attain recommended engine speed Retighten jam nut a CAUTION Engine idle RPM must NEVER EXCEED 750 RPM in gear 3 With e...

Page 109: ...install Dial Indicator 91 58222A1 into No 1 cylinder top cylinder starboard bank 2 Turn flywheel in a clockwise direction until No 1 piston is at top dead center TDC Set dial indica tor at O zero and...

Page 110: ...11 16 in 1 Remove all spark plugs except No 1 cylinder top cylinder starboard bank plug 2 Disconnect remote fuel line from engine 3 Connect remote control electrical harness to engine wiring harness...

Page 111: ...EFI models and already has retarded timing degrees calibrated into specifications listed on page 2C 2 Idle Stabilizer Shift System 50707 a b c d a Inner Switch Box b To Outer Switch Box c Diode d Shif...

Page 112: ...ween arm 3 of throttle shaft and stop 4 on induction box Tighten locknut 5 2 Check for slight free play roller lifter from cam between roller and cam at full throttle to prevent linkage from binding R...

Page 113: ...to run too rich or too lean TPS can be readjusted Decreasing voltage yields leaner mixture Increasing voltage yields richer mix ture Allowable TPS range 200 300 volts 7 Tighten TPS screws holding corr...

Page 114: ...nto FORWARD gear 4 Hold throttle arm 1 against idle stop throttle cable barrel removed from barrel retainer Adjust idle timing screw 2 to attain appropriate setting Tighten locknut 3 2 3 1 5 Reconnect...

Page 115: ...e stop 2 Adjust throttle cable barrel to slip into barrel recess of control cable anchor bracket with a light preload of throttle lever against idle stop Lock barrel in place IMPORTANT Excessive prelo...

Page 116: ...l circuit is functioning MAXIMUM TIMING ADJUSTMENT ENGINE RUNNING 1 Disconnect WHITE BLUE lead 1 from detona tion sensor 2 200 model 2 1 2 Outboard running in gear advance throttle arm until maximum s...

Page 117: ...D 2 ELECTRICAL WIRING...

Page 118: ...rol 2D 13 Commander 3000 Panel Remote Control 2D 14 Commander Side Mount Remote Control Power Trim Tilt Electric Start with Warning Horn Wiring Diagram 2D 18 Page Commander 2000 Side Mount Remote Cont...

Page 119: ...24 14 25 1 40 Ampere Stator 2 Starter 3 Lubalert 4 Oil Tank Cap 5 Idle Stabilizer 6 Rotational Sensor 7 Enrichment Valve 8 Temperature Gauge Sender 9 Control Box Instrument Connector 10 Engine Harness...

Page 120: ...4 1 40 Ampere Stator 2 Starter 3 Lubalert 4 Oil Tank Cap 5 Idle Stabilizer 6 Rotational Sensor 7 Enrichment Valve 8 Temperature Gauge Sender 9 Control Box Instrument Connector 10 Engine Harness 11 12V...

Page 121: ...4 1 40 Ampere Stator 2 Starter 3 Warning Module 4 Oil Tank Cap 5 Idle Stabilizer 6 Rotational Sensor 7 Enrichment Valve 8 Temperature Gauge Sender 9 Control Box Instrument Connector 10 Engine Harness...

Page 122: ...tor 2 Starter 3 Warning Module 4 Oil Cap 5 Motion Sensor 6 Fuel Enrichment Valve 7 Temperature Gauge Sender 8 Starter Solenoid 9 20 Ampere Fuse 10 Engine Harness 11 Battery 12 Voltage Regulator 13 Wat...

Page 123: ...Solenoid 4 Starter Motor 5 Air Temperature Sensor 6 Electronic Control Unit 7 Fuel Pump 8 Injectors 9 12 Volt Battery 10 Rotational Sensor 11 Water Sensing Warning Module 12 Water Separating Filter 13...

Page 124: ...ing Module 5 Starter Solenoid 6 Starter Motor 7 Air Temperature Sensor 8 Electronic Control Unit 9 Fuel Pump 10 Injectors 11 12 Volt Battery 12 Rotational Sensor 13 Water Sensing Warning Module 14 Wat...

Page 125: ...ater Temperature Switch 4 Warning Module 5 Starter Solenoid 6 Starter Motor 7 Air Temperature Sensor 8 Electronic Control Unit 9 Fuel Pump 10 Injectors 11 12 Volt Battery 12 Rotational Sensor 13 Water...

Page 126: ...ule 3 Starter Solenoid 4 Starter Motor 5 Air Temperature Sensor 6 Electronic Control Unit 7 Fuel Pump 8 Injectors 9 12 Volt Battery 10 Rotational Sensor 11 Water Sensing Warning Module 12 Water Separa...

Page 127: ...15 16 17 18 19 21 24 23 22 20 1 Stator 2 Trigger 3 Starter 4 Warning Module 5 Idle Stabilizer 6 Low Oil Sensor 7 Rotational Sensor 8 Enrichment Valve 9 Temperature Gauge Sender 10 Engine Harness 11 Ba...

Page 128: ...2 Power Trim Wiring Diagram with Solenoids 52203 a b c d e f g h i j a Start Solenoid b Tach Connector c Key Switch Assembly d Trim Switch e 20 Ampere Fuse f Trim Sender g Bottom Cowl Switch h Pump an...

Page 129: ...s a b c d e f g h i j k l m n a Tach Connector b Key Switch Assembly c Trim Switch d Trim Sender e Start Solenoid f To Battery g To Alternator h Trim Pump and Motor i DOWN Solenoid j UP Solenoid k Bot...

Page 130: ...ads a Tachometer Receptacle From Control Box or Ignition Choke Switch b Tachometer Wiring Harness c Lead to Optional Visual Warning Kit Taped Back to Harness d Tachometer e Temperature Gauge f TAN Wir...

Page 131: ...D 13 Commander 3000 Classic Panel Remote Control F R RED PURPLE GREEN BLK Black BLU Blue BRN Brown GRY Gray GRN Green ORN Orange PNK Pink PUR Purple RED Red Tan Tan WHT White YEL Yellow LIT Light DRK...

Page 132: ...JUNE 2002 Commander 3000 Panel Remote Control RED PURPLE GREEN BLK Black BLU Blue BRN Brown GRY Gray GRN Green ORN Orange PNK Pink PUR Purple RED Red TAN Tan WHT White YEL Yellow LIT Light DRK Dark a...

Page 133: ...90 824052R3 JUNE 2002 ELECTRICAL 2D 15 Notes...

Page 134: ...1 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 17 23 95 95 95 95 95 7 7 95 95 95 7 Loctite 271 92 809820 95 2 4 C With Teflon 92 825407A12 2D 16 ELECTRICAL 90 824052R3 JUNE 2002 Commander 3000 3...

Page 135: ...als 6 1 SWITCH ASSY Neutral Start No Terminals 7 2 GROMMET 8 2 BALL Steel 9 1 RING Retaining 10 1 GEAR Shift 11 1 SPRING 12 1 SHAFT Throttle Only 13 1 PIN Shift Gear 14 2 SCREW 10 32 x 1 4 15 2 NUT 10...

Page 136: ...range PNK Pink PUR Purple RED Red Tan Tan WHT White YEL Yellow LIT Light DRK Dark 24072 a b c d e f g h i j k l a Ignition Choke Switch b Emergency Stop c Neutral Start Switch d Tachometer Accessories...

Page 137: ...iagram BLK Black BLU Blue BRN Brown GRY Gray GRN Green ORN Orange PNK Pink PUR Purple RED Red Tan Tan WHT White YEL Yellow LIT Light DRK Dark 23891 a d b f g c e a Ignition Choke Switch b Emergency St...

Page 138: ...nition Switch c Oil Level Gauge d BLACK Wire Connects to NEGATIVE Ground e To Ground f BLACK Wire From Gauge to Oil Clip Connector g LIGHT BLUE Sender Lead to Gauge h Wiring Harness LT BLU and BLACK i...

Page 139: ...cket Assembly 4 Connect to Trim Indicator Gauge Terminal I or POSITIVE 12 Volt Source that is turned ON and OFF with Ignition Switch 5 Connect to NEGATIVE ground 6 Float Tube Assembly 7 Screw Self Tap...

Page 140: ...Y GRAY PUR PURPLE RED RED TAN TAN WHT WHITE YEL YELLOW BATT GND SENDER PORT INSTALLATION 52205 g a e d k d b c l d f n n h o a Ignition Choke Switch b Lanyard Stop Switch c Lead not used on Outboard I...

Page 141: ...used wiring harness leads BATT GND SENDER STARBOARD INSTALLATION 52206 i g a e j f m o k Lanyard Switch Isolation Diode l Y Harness m Power Trim Harness Connector n Connect Wires together with Screw...

Page 142: ...b c j i k j h a Ignition Choke Switch b Lanyard Stop Switch c Lead Not Used on Outboard Installations d Retainer e Tachometer f Trim Indicator Gauge Optional g Temperature Gauge h Remote Control i Pow...

Page 143: ...IVE Ground Water Temperature Gauge WIRING DIAGRAM A Use this wiring diagram when using a separate light switch for instrument lighting SEND a b c d e a Connect to 12 Volt b 12 Volt Light Switch Wire c...

Page 144: ...HT BULB POSITION A Use this position when using a separate light switch for instrument lighting a b 51109 a 12 Volt Light Switch Wire b Position Light Bulb to the Switched Position LIGHT BULB POSITION...

Page 145: ...as an option to the user Wiring Diagram Gauge needle to point toward slow running engine GRY GRAY WHT WHITE BLK BLACK PUR PURPLE 51107 a b c d a Tachometer Starboard Engine b Synchronizer Gauge c Tac...

Page 146: ...tion 2 Turn ignition switch to the Run position The multi function gauge now is in the display test mode The gauge Temp Batt Oil and Fuel red warning lights should be alternately flashing On and Off t...

Page 147: ...ometer d Tachometer e Tachometer Signal Terminal f Connect Wires Together with Screw and Hex Nut 3 Places Apply Quicksilver Liquid Neoprene to Connections and Slide Rubber Sleeve Over Each Connection...

Page 148: ...Terminal c Speedometer d Tachometer e Tachometer Signal Terminal f Tachometer Receptacle g Side Mount Remote Control h 8 Pin Harness Connector i Multi Function Gauge j Multi Function Adapter Harness k...

Page 149: ...A 3 FUEL SYSTEMS FUEL PUMP...

Page 150: ...Tools 3A 1 Fuel Pump 3A 2 General Information 3A 4 Fuel Pump Description Operation 3A 4 Checking for Restricted Fuel Flow Caused by Anti Siphon Valves 3A 4 Testing Fuel Pump 3A 5 Checking Fuel Pump Li...

Page 151: ...kPa Normal 8 10 psi 55 69 kPa Minimum 3 psi 21 kPa Fuel Pump Pressure Idle Normal 2 3 psi 14 21 kPa Minimum 1 psi 7 kPa NOTE Electric fuel pump pressure if used in conjunction with engine mechanical...

Page 152: ...3A 2 FUEL SYSTEMS 90 824052R3 JUNE 2002 Fuel Pump 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 19 20 4 3 17 18 18 Perfect Seal 92 34227 1 19 19 19...

Page 153: ...1 DIAPHRAGM KIT 3 2 CHECK VALVE plastic 4 2 RETAINER 5 1 GASKET boost 6 1 CAP 7 1 SPRING 8 2 DIAPHRAGM 9 1 GASKET pulse 10 1 SPRING 11 1 CAP 12 1 GASKET base 13 1 BASE fuel pump 14 1 PLATE fuel pump 1...

Page 154: ...on valves may be helpful from a safety stand point they clog with debris they may be too small or they may have too heavy a spring Summarizing the pressure drop across these valves can and often does...

Page 155: ...n or replace pickup Worn out fuel pump diaphragm Rebuild fuel pump Worn out check valve s in fuel pump Rebuild fuel pump A leaky check valve gasket Rebuild fuel pump Pulse hole s plugged Remove fuel p...

Page 156: ...Restriction within the primer bulb Kinked or collapsed fuel hose Plugged water sepa rating fuel filter in the boat Restriction in fuel line thru hull fitting Restriction in fuel tank switching valves...

Page 157: ...using pulse chamber and base for cracks or rough gasket surface and replace if any are found 5 Inspect fitting on fuel pump housing for loosening or any signs of fuel or air leaks Replace or tighten f...

Page 158: ...601 3 a Rod b Retainer Cap 5 Place boost spring into pump body and place cap onto boost spring c a b 50161 a Boost Spring b Pump Body c Cap 6 Assemble remainder of components as shown and install reta...

Page 159: ...B 3 54350 FUEL SYSTEMS CARBURETORS...

Page 160: ...scription 3B 26 Idle Circuit Adjustments 3B 26 Off ldle Circuit Description 3B 27 Back Draft Circuit Description 3B 27 High Speed Fuel Circuit Description 3B 27 High Speed Fuel Circuit Adjustments 3B...

Page 161: ...90 824052R3 JUNE 2002 FUEL SYSTEMS 3B 1 Notes...

Page 162: ...1 2 3 4 5 6 7 8 10 11 12 13 14 15 16 17 18 19 9 20 21 22 24 25 26 27 23 24 25 3B 2 FUEL SYSTEMS 90 824052R3 JUNE 2002 WMH 1 2 3 4 5 6 7 8 9 10 11 Carburetor Assembly...

Page 163: ...JET idle air bleed 15 1 5 8 3 EMULSION TUBE 33 3 5 9 3 SPRING valve return 10 2 THROTTLE LEVER 11 3 SPACER 12 3 WASHER 13 3 NUT 50 5 5 14 3 GASKET fuel bowl 15 3 FLOAT 16 3 SCREW float pin 10 1 0 17 3...

Page 164: ...2 135 1 000 050 040 048 NONE WMH 9 1C 2C 3C 1991 150 1 312 062 070 046 096 WMH 10 1 2 3 1991 XR 4 MAG II 1 312 062 040 040 NONE WMH 11 1A 2A 3A 1991 175 1 312 064 070 048 080 Supercede WMH 4 and WMH 6...

Page 165: ...824052R3 JUNE 2002 FUEL SYSTEMS 3B 5 WMH 1 2 3 4 5 6 7 8 9 10 11 Carburetor Front View CYLINDERS 2 4 6 CYLINDERS 1 3 5 c a b c d d 51861 a Idle Air Jet b Back Draft Vent Jet c Progression Jet d Main J...

Page 166: ...3B 6 FUEL SYSTEMS 90 824052R3 JUNE 2002 WMH 12 13 14 15 16 27 Carburetor Assembly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 24 25 26 27 23 24 25...

Page 167: ...ET idle air bleed 15 1 5 8 3 EMULSION TUBE PLUG 33 3 5 9 3 SPRING valve return 10 2 THROTTLE LEVER 11 3 SPACER 12 3 WASHER 13 3 NUT 50 5 5 14 3 GASKET fuel bowl 15 3 FLOAT 16 3 SCREW float pin 10 1 0...

Page 168: ...2 200 1 312 066 050 058 090 WMH 27 1 2 3 1992 200 1 312 066 060 058 090 NOTE All idle mixture settings are 1 1 2 turns 1 4 turn from a lightly seated position IMPORTANT If welch plugs and air trim scr...

Page 169: ...90 824052R3 JUNE 2002 FUEL SYSTEMS 3B 9 WMH 12 13 14 15 16 27 Carburetor Front View CYLINDERS 2 4 6 CYLINDERS 1 3 5 c a b c d d 51863 a Idle Air Jet b Back Draft Vent Jet c Progression Jet d Main Jet...

Page 170: ...3B 10 FUEL SYSTEMS 90 824052R3 JUNE 2002 WMH 21 22 23 25 26 28 Carburetor Assembly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 21 20 25 24 26 27 23 24 25 22...

Page 171: ...le air bleed 15 1 5 8 3 EMULSION TUBE PLUG and GASKET 33 3 5 9 3 SPRING valve return 10 2 THROTTLE LEVER 11 3 SPACER 12 3 WASHER 13 3 NUT 50 5 5 14 3 GASKET fuel bowl 15 3 FLOAT 16 3 SCREW float pin 1...

Page 172: ...993 XR 4 MAG II 1 312 062 050 046 090 WMH 28 1 2 3 1993 135 1 312 062 070 056 NONE NOTE All idle mixture settings are 1 1 2 turns 1 4 turn from a lightly seated position IMPORTANT If welch plugs and a...

Page 173: ...90 824052R3 JUNE 2002 FUEL SYSTEMS 3B 13 WMH 21 22 23 25 26 28 Carburetor Front View CYLINDERS 2 4 6 CYLINDERS 1 3 5 c a b c d d 51863 a Idle Air Jet b Back Draft Vent Jet c Progression Jet d Main Jet...

Page 174: ...52154 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 24 25 25 26 27 3B 14 FUEL SYSTEMS 90 824052R3 JUNE 2002 WMH 30 31 32 33 34 39 Carburetor Assembly...

Page 175: ...le air bleed 15 1 5 8 3 EMULSION TUBE PLUG and GASKET 33 3 5 9 3 SPRING valve return 10 2 THROTTLE LEVER 11 3 SPACER 12 3 WASHER 13 3 NUT 50 5 5 14 3 GASKET fuel bowl 15 3 FLOAT 16 3 SCREW float pin 1...

Page 176: ...66 3 4 5 6 064 050 046 084 WMH 39 1 2 3 1994 1 2 1995 140 JET 200 1 312 1 2 066 3 4 5 6 064 050 046 084 NOTE All idle mixture settings are 1 1 2 turns 1 4 turn from a lightly seated position IMPORTANT...

Page 177: ...90 824052R3 JUNE 2002 FUEL SYSTEMS 3B 17 WMH 30 31 32 33 34 39 Carburetor Front View CYLINDERS 2 4 6 CYLINDERS 1 3 5 c a b c d d 51863 a Idle Air Jet b Back Draft Vent Jet c Progression Jet d Main Jet...

Page 178: ...3B 18 FUEL SYSTEMS 90 824052R3 JUNE 2002 WMV 1 1A 2 2A 3 3A 4 4A 5 5A 1 2 5 22 23 4 6 7 8 15 16 17 18 19 20 24 21 25 26 3 14 9 10 11 12 13...

Page 179: ...WMV 3A 1 TOP CARBURETOR 1 CENTER CARBURETOR 175 WMV 4A 1 BOTTOM CARBURETOR 1 TOP CARBURETOR 1 CENTER CARBURETOR 200 WMV 5A 1 BOTTOM CARBURETOR 2 6 COVER 3 6 GASKET 4 12 SCREW 18 2 0 5 3 GASKET 2 JET...

Page 180: ...3B 20 FUEL SYSTEMS 90 824052R3 JUNE 2002 WMV 1 1A 2 2A 3 3A 4 4A 5 5A 1 2 5 22 23 4 6 7 8 15 16 17 18 19 20 24 21 25 26 3 14 9 10 11 12 13...

Page 181: ...5 2 JET idle air vent 028 Center Bottom 200 14 1 5 9 6 LIMITER CAP 10 6 IDLE MIXTURE SCREW SPRING 11 3 LEVER KIT 12 3 SPACER 13 3 SPRING 14 3 GASKET fuel bowl 15 3 FLOAT 16 3 FLOAT SHAFT 17 3 SCREW f...

Page 182: ...044 5 048 082 WMV 4 4A 1 2 3 1996 1998 175 1 312 078 1 2 3 4 6 030 5 034 086 WMV 5 5A 1 2 3 1996 1998 140 JET 200 1 312 1 2 082 3 4 5 6 080 1 2 052 3 4 6 028 5 032 096 NOTE All idle mixture settings...

Page 183: ...uel filter Check and replace or clean all fuel filters Low fuel pump pressure Refer to Section 3A An anti siphon valve Refer to Checking for Restricted Fuel Flow in this section Choke solenoid or enri...

Page 184: ...nt Refer to Carburetor Adjustments in this section Improper carburetor float level Refer to Carburetor Adjustments in this section Carburetor loose on reed block housing Tighten carburetor nuts secure...

Page 185: ...throttle cam from throttle linkage Refer to Carburetor Removal lnstallation for cam removal and installation 3 Remove and plug bleed hoses one at a time from crankcase cover and connect fuel pressure...

Page 186: ...umber of turns air screw is turned in until seated then remove Apply Loctite 271 and set air screws to the same position approx 1 1 4 turns Top View b a g f c d e 50756 a Fuel Mixture Adjustment b Scr...

Page 187: ...h carburetor bore Each venturi has one off idle tube and one off idle air jet The circuit functions at off idle speeds until full throttle operation occurs Back Draft Circuit Description Side View a 5...

Page 188: ...ACH CYLINDER 51863 Cylinder 2 Cylinder 4 Cylinder 6 Cylinder 1 Cylinder 3 Cylinder 5 Carburetor jets and adjustment screw installed in the starboard side of the carburetor supply fuel to the port cyli...

Page 189: ...he float bowl is at it s maximum level Fuel inside the bowl flows through the main fuel jet and fills the main fuel well Idle Circuit Top View k j i h a b d e f g c a Idle Discharge Ports b Off Idle D...

Page 190: ...discharged into the en gine Rotating the idle mixture screw will change the air fuel mixture at idle speeds Cold Start Circuit Air Fuel Key a b a Thermal Air Valve closed b Air Flow A cold engine wil...

Page 191: ...discharge tube exposing additional cross holes At full throttle the fuel mixture is controlled by the size of the main fuel jet Back Draft Circuit Air Fuel Key g a b c f e d NOTE Fuel Flow Not Shown...

Page 192: ...4052R3 JUNE 2002 Carburetor Placement and Jet Location for Each Cylinder WMV Carburetors Cylinder 2 Cylinder 4 Cylinder 6 TOP MIDDLE BOTTOM Cylinder 1 Cylinder 3 Cylinder 5 54349 A A A A Backdraft jet...

Page 193: ...ART 10 32 040 19266040 058 1395 7831 076 1399 3796 094 1395 8423 042 1399 5315 060 1395 6487 078 1395 6680 096 1399 6249 044 1395 7394 062 1399 4217 080 1395 6201 098 1395 7355 046 1399 5317 064 1399...

Page 194: ...4 0 054 0 054 0 052 0 052 0 052 0 050 0 050 0 050 0 048 0 058 0 058 0 056 0 056 0 056 0 056 0 054 0 054 0 054 0 052 0 052 0 052 0 050 0 060 0 060 0 058 0 058 0 058 0 056 0 056 0 056 0 054 0 054 0 054...

Page 195: ...in current is sent to the valve causing it to open which allows fuel to pass thru The fuel passes thru a hose and is supplied to the engine via fittings located on top of the middle and bottom carbure...

Page 196: ...e tween key switch or choke button and ter minal block Fuel Flow from Fitting Valve is O K Check hoses and fittings from valve to middle and bottom carburetors for leads or obstructions No Fuel Flow f...

Page 197: ...Linkage b Oil Pump Link Rod 5 Remove fuel hose fuel enrichener valve hose and thermal valve hose from carburetors 51844 a c b a Fuel Hose b Enrichment Valve Inlet Hose c Thermal Valve Hose 6 Carbureto...

Page 198: ...ts 2 c Off Idle Tube 2 2 Remove high speed fuel jet access plugs and main high speed fuel jet from carburetor c b a 51859 a Access Plug 2 b Gaskets 2 c Main Fuel Jets 2 3 Remove off idle air jets from...

Page 199: ...ion Tube Fuel Bowl Removal and Disassembly 1 Remove five screws securing fuel bowl and gasket to carburetor body 51862 a a Screws 2 Remove screw securing float assembly in place a c b 51863 a Screw b...

Page 200: ...ch has accumulated CAUTION DO NOT place floats inlet needles idle screw adjusting caps any rubber or plastic parts into carburetor cleaning solution If adjusting caps must be removed and reinstalled r...

Page 201: ...stall inlet needle into inlet needle seat as shown a b 51859 a Inlet Needle Seat b Inlet Needle 3 Install float with float pin to fuel bowl Secure in place with retained screw 51863 a c b a Screw b Fl...

Page 202: ...to carburetor body Secure in place with five retained screws b a c 51861 a Gasket b Fuel Bowl c Carburetor Body Carburetor Jet Installation 1 Install idle air jet and back draft vent jet if equipped...

Page 203: ...51859 a Access Plugs 2 b Gaskets 2 c Off Idle Tubes 2 Installing Carburetor s to Engine 1 Place new carburetor gaskets onto carburetor mounting studs on intake manifold 51844 c a b a Fuel Hose b Enri...

Page 204: ...ted above 3000 RPM with air box cover removed as outboard will run too lean and internal damage could result 8 Reinstall outboard cowling Fuel Line and Primer Bulb Assembly 3 2 7 4 2 6 2 2 5 3 2 1 501...

Page 205: ...CLAMP REMOVAL AND INSTALLATION 1 To remove fuel line clamps grip clamp with pliers and bend overlapping hook backward 51115 2 To install fuel line clamps grip hose clamp with pliers and push down on...

Page 206: ...C 3 FUEL SYSTEMS FUEL INJECTION SN 0G303045 AND BELOW...

Page 207: ...ation Control Module Check 3C 36 Throttle Position Sensor Test 3C 37 Map Sensor Test 3C 37 Problem Diagnosis 3C 37 Page Engine Head Temperature Sensor Removal 3C 40 EFI Induction Manifold Removal 3C 4...

Page 208: ...apor Separator Float Level Preset Factory Fuel Injectors All Models Quantity Inner Switch Box Controls 1 Primary Circuit 3 Primary Circuit 5 Primary Circuit 6 3 and 4 Injectors 5 and 6 Injectors 1 and...

Page 209: ...6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 25 Liquid Neoprene 92 25711 2 25 25 25 25 25 25 25 Dielectric Grease 92 823506 1 6 6 6 3C 2 FUEL SYSTEMS 90 824052R3 JUNE 2002 Electronic Control Module ECM...

Page 210: ...R 3 1 CLIP 4 2 MOUNT cowl mounting bracket 5 4 WASHER 6 4 NUT 45 5 0 7 1 CABLE ASSEMBLY 8 1 GROMMET 9 1 BUSHING 10 1 SCREW 45 5 0 11 1 LOCKWASHER 12 1 WASHER 13 1 WATER SENSOR MODULE ASSEMBLY 14 1 WIR...

Page 211: ...SYSTEMS 90 824052R3 JUNE 2002 Fuel Management System 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 14 17 18 19 20 21 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 41 42 43 44 45 46 47 48 49...

Page 212: ...O D 17 1 REGULATOR pressure 18 1 ELBOW KIT 19 1 GASKET pressure regulator 20 1 PLATE pressure regulator 21 AR SCREW 30 3 5 22 1 COVER KIT 23 6 SCREW cover to separator 24 6 LOCKWASHER cover screw 25 1...

Page 213: ...1 2 3 4 5 6 7 8 3C 6 FUEL SYSTEMS 90 824052R3 JUNE 2002 Fuel Management System...

Page 214: ...l Management System REF TORQUE REF NO QTY DESCRIPTION lb in lb ft N m 1 1 LINK LEVER KIT 2 1 STOP SCREW KIT 3 1 FUEL RAIL 4 1 FUEL PIPE JOINT KIT 18 2 0 5 1 SCREW KIT Fuel Rail 45 5 0 6 1 LINK DESIGN...

Page 215: ...3C 8 FUEL SYSTEMS 90 824052R3 JUNE 2002 Fuel Pump and Fuel Filter 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 26 27 28 29 30 31 32 33 31 35 34 28...

Page 216: ...3 1 GASKET base 14 1 BASE fuel pump 15 1 PLATE fuel pump 16 1 ELBOW 17 2 SCREW fuel pump 55 6 0 18 2 SCREW fuel pump to crankcase 55 6 0 19 1 HOSE pulse 20 1 ELBOW 21 1 TUBING 22 AR STA STRAP fuel tub...

Page 217: ...cks to be followed before proceeding with EFI tests diagrams fuel flow and electrical wiring component description from diagrams flow charts low pressure fuel delivery high pressure fuel delivery fuel...

Page 218: ...pills immediately CAUTION Depressurize fuel system prior to opening line connections or removing fuel system components DANGER Perform the tests in this section in a well ventilated area to avoid bein...

Page 219: ...ood spark to be present in the spark gap tester A steady blue spark should be present at each spark plug wire If a good spark is present problem may not be ignition related If good spark is not presen...

Page 220: ...supply clogged lines malfunctioning anti siphon valve etc and or marginal gasoline Low Battery Voltage Low battery voltage can cause EFI system to deliver fuel in an inconsistent manner Inspect batter...

Page 221: ...uel Inlet h Needle Float Device i Oil Supply Inlet j Water Separating Filter k Pulse Fuel Pump l Fuel Check Valve Vapor Separator m Vapor Separator n Fuel Filter o Electric Fuel Pump p Fuel Rail q Fin...

Page 222: ...itate upon acceleration ELECTRIC FUEL PUMP O The electric fuel pump is continually providing fuel in excess of engine demands The excess fuel circulates through the fuel rail back to the vapor separat...

Page 223: ...ion Sensor 2 Detonation Module 3 Engine Head Temperature Sensor 4 To Temperature Gauge 5 Air Temperature Sensor 6 Starter Solenoid 7 12 Volt Supply from Regulator 8 Electric Fuel Pump 9 Electronic Con...

Page 224: ...tion altering engine operation If no change occurs when drawing vacu um MAP sensor is not functioning properly MAP sensor can be tested with the EFI tester ENGINE HEAD TEMPERATURE SENSOR The Engine He...

Page 225: ...e tripled when engine head temperature is below 90 F 32 2 C to provide adequate fuel for quick start up When key is returned to the run position or engine head temperature is above 90 F 32 2 C pulse w...

Page 226: ...ssure Fuel Route Flow Chart Fuel flows from fresh fuel inlet hose Little or no flow from fresh fuel inlet hose Reconnect hose Inspect float system of vapor separator Perform Water Separating Filter Fl...

Page 227: ...e 3C 26 Clogged or faulty fuel pressure regulator remove and replace Perform Electric Fuel Pump Pro cedure B Test page 3C 28 Final filter OK Final filter clogged Perform Fuel Pressure Regula tor Test...

Page 228: ...Perform Injector Fuel Delivery Test page 3C 31 RPM increase occurs No RPM change Perform induction manifold dis assembly Inspect injector and filter Perform compression check on problem cylinder see s...

Page 229: ...TEP 1 Connect fuel pressure gauge to induction manifold pressure port 51796 STEP 2 Prime engine using fuel primer bulb STEP 3 Turn ignition key switch to On position OFF ON START STEP 4 Operate electr...

Page 230: ...ing If boat is not equipped with a emergency stop switch connect a jumper lead from the BLACK YELLOW terminal on the switch box to engine ground STEP 3 Turn ignition key switch to START and operate st...

Page 231: ...ating Filter Flow Test Water Separating Filter Flow Test Purpose This test will indicate if water separating filter is clogged Procedure STEP 1 Remove fuel inlet hose to water separating filter Put en...

Page 232: ...ter separating inlet hose Perform pulse fuel pump delivery test Pulse Fuel Pump Delivery Test Purpose This test will indicate pulse fuel pump is capable of supplying the low pressure fuel route with a...

Page 233: ...Procedure STEP 1 De pressurize EFI fuel system by wrapping a clean cloth around pressure port valve and inserting tip of screwdriver into valve depressing valve core Let fuel drain from valve 51796 a...

Page 234: ...248 kPa go to step 3 following OFF ON START STEP 3 Remove fuel pressure regulator but do not disconnect any hoses from regulator STEP 4 Put discharge end of regulator in clean container STEP 5 Turn i...

Page 235: ...3 Take a fuel pressure reading within 30 seconds 51796 CAUTION Do not close off fuel hose completely in step 4 or damage could result to hose or pump STEP 4 Partially close off fuel hose to pressure r...

Page 236: ...t the pump no or low fuel pressure will be developed Procedure STEP 1 Set volt meter to read bat tery voltage and connect black test lead to ground positive test lead to positive post of fuel pump NOT...

Page 237: ...or bad fuel pump 4 Engine being cranked terminal of fuel pump 2 volts or less Bad ECM or bad fuel pump 5 Engine running below approximately 2000 RPM terminal of fuel pump 2 volts or less for approxima...

Page 238: ...4 YELLOW Injectors Cylinders 5 and 6 1 2 3 4 50326 1 YELLOW 2 RED 3 DARK BLUE 4 WHITE Results If readings are 1 1 2 both injector circuits are complete Perform Injector Fuel Delivery Test If readings...

Page 239: ...are actually injecting fuel into the engine at a normal rate WARNING Do not start engine with induction manifold cover removed Disable ignition system prior to doing this test Procedure A STEP 1 Remov...

Page 240: ...ray pattern is equal on all injectors system is functioning normally Induction Manifold Leak Check Manifold Cover Removed Purpose Lack of good fuel pressure may be caused by an internal leak in the fu...

Page 241: ...ground Depress remote start switch pump will operate as long as switch is depressed WARNING Do not operate pump for more than 20 seconds continuously STEP 6 Look for leak points on induction man ifold...

Page 242: ...sistance reading may differ slightly from graph curve Results Resistance does not change inversely with temperature change Replace defective Engine Head Temperature Sensor Resistance changes inversely...

Page 243: ...ctable internal damage causing false readings to be transmitted to detonation module Detonation Control Module Check Purpose This check will determine if control module is correctly signaling ECM when...

Page 244: ...Ignition Tests Refer to Section 2A Electrical and Ignition Tests Refer to Section 2A Electrical and Ignition Tests Refer to Section 4A Power Head Perform Injector Fuel Delivery Test page 3C 31 Follow...

Page 245: ...coming out of vapor separator vent hose Refer to Injector Fuel Delivery Test page 3C 31 Engine Idles Ok But Stumbles At Off Idle Speeds Improper EFI Setup Failed Switch Box Failed or Disconnected EFI...

Page 246: ...ow Chart page 3C 20 Engine Stops for No Apparent Reason or Does Not Start Battery Undercharged EFI Harness Connections Ignition System Failure Pulse Fuel Pump Failure Electric Fuel Pump Failure ECM Fa...

Page 247: ...a b 51785 a Wires b Sensor EFI Induction Manifold Removal IMPORTANT Remove battery cables from bat tery before Induction Manifold Removal and Dis assembly 1 Disconnect ECM at harness connector a 51793...

Page 248: ...ve screws c filter base d and spacer block e d a b e c 51793 a Fuel Inlet Hose b Fuel Delivery Hose c Screws d Filter Base e Spacer Block Throttle Position Sensor Temperature Sensor Fuel Injector Harn...

Page 249: ...Nuts d Studs 2 Remove hose clamp and lift oil reservoir from engine Final Filter Assembly Removal CAUTION De pressurize EFI system prior to fuel filter removal Refer to page 3C 26 1 Remove screw from...

Page 250: ...electric fuel pump a c d e b a Positive Lead b Negative Lead c Inlet Hose d Rubber Blanket e Electric Fuel Pump Vapor Separator Removal 1 Disconnect fuel rail re circulation hose at manifold fitting...

Page 251: ...et Then remove regulator assembly 51792 a c b a a Screws b Plate c Regulator 2 Remove O ring 51719 a a O Ring 3 Remove screws and regulator fitting from regulator Then remove O ring from regulator c d...

Page 252: ...pivot pin a 51794 a Pivot Pin 3 Remove float a and needle b and if necessary remove needle from float Do not change angle of brass tab that the needle is attached to a b 51795 a Float b Needle 4 Remov...

Page 253: ...d Pressure Regulator e Vapor Separator Cover f Screw g Lock Washer h Flat Washer i Seat j Needle k Retainer l Pin m Float n Seal o Bracket p Check Valve q Fuel Check Valve r Bracket s Lock Washer t S...

Page 254: ...Cam c Oil Injection Link Rod d Injector Arm 3 Identify location of 3 ground wires for reassembly purposes 4 Remove12 screws securing manifold cover to manifold 5 Remove manifold cover 51795 a a a c b...

Page 255: ...n Manifold Disassembly 1 Remove manifold cover seal from manifold a b 51785 a Manifold Cover Seal b Manifold Air Temperature Sensor Removal 1 Remove screws and sensor a a b 51790 a Screws b Sensor 2 R...

Page 256: ...nsor screws a 51790 a Screws 2 Remove sensor and sleeve from throttle shaft 51788 a b c a Sensor b Sleeve c Throttle Shaft Fuel Rail Removal 1 Remove manifold vacuum hoses 2 Remove engine bleed hose 3...

Page 257: ...el rail from manifold Note fuel rail guides a c b 51788 c a Fuel Rail b Manifold c Guides Fuel Rail Disassembly 1 Remove tube support from fuel rail 2 Remove plugs from fuel rail 3 Remove tubes from t...

Page 258: ...re clamp from slot 2 Disconnect connector from injector 51792 b c a d a Clamp b Slot c Connector d Injector 3 Remove injector from manifold a 51789 a Injector 4 Place injector on clean work surface Re...

Page 259: ...screws and injector harness plate a b 51792 a Screws b Plate Throttle Linkage Removed b a b c 51786 a Throttle Cam b Bushings c Nut Tighten until snug against cam then back off 1 4 turn b c d e f g h...

Page 260: ...ose routing 4 Look at main connector between engine harness and ECM box for missing corroded or bent contact pins and socket Check for dislodged grommet in ECM where harness enters box 5 Look at all s...

Page 261: ...ld 2 Install O ring into groove on injector harness insert Install harness insert into manifold port a b c a O Ring b Groove c Insert 3 Install injector harness plate using screws Tighten securely a b...

Page 262: ...l injector into manifold a 51789 a Injector 3 Install wire clamp into slot on injector connector 4 Connect to injector 51792 d b c a a Clamp b Slot c Connector d Injector Fuel Rail Assembly 1 Install...

Page 263: ...35 Ib in 4 0 N m a a 51784 a Screws 4 3 Install O rings to manifold fitting Install fitting to manifold e 51791 b a a O Rings b Fitting 4 Install screws securing manifold fitting to manifold 5 Instal...

Page 264: ...e must guide sensor to throttle shaft a b c 51788 a Sleeve b Throttle Position Sensor c Throttle Shaft 3 Tighten screws after induction manifold installa tion and throttle position sensor adjustments...

Page 265: ...in induction manifold installation a a a Holes EFI Induction Manifold Installation 1 Install new gasket on induction manifold as shown Removing dotted line sections after manifold installation b a 517...

Page 266: ...remaining screws Install ground wires to proper location a c c b c 51795 a Manifold b Screws Torque to 90 lb in 10 0 N m c Ground Wires Cover Screw Torque Sequence IMPORTANT Before connecting oil pum...

Page 267: ...el rail re circulation hose to manifold fitting using hose clamp a a b c d a e f g 51786 a Screws Torque to 45 lb in 5 0 N m b Oil Inlet Hose c Bleed Hose d Vapor Separator Vacuum Hose e Regulator Vac...

Page 268: ...s b Pump Cap c Cover Plate d Screws 4 Final Filter Assembly Installation 1 Install fuel rail inlet hose and cap to manifold fitting 2 Install O ring to filter and cap as shown 3 Install final filter a...

Page 269: ...mounting bracket Secure reservoir using screws 51791 b d d d a c a Studs b Nuts c Bracket d Screws Throttle Position Sensor and Temperature Sensor Fuel Injector Harness Connections 1 Connect fuel inj...

Page 270: ...sembly Installation 1 Install spacer block to engine block 2 Install filter base secure with screws Tighten screws securely 3 Connect fuel inlet hose and fuel inlet hose to fittings a b c d c e 51793...

Page 271: ...at connector Install harness into harness bracket with connecting ring below or above bracket arms IMPORTANT DO NOT force connecting ring between bracket arms 51793 a b c a ECM Harness b Engine Harnes...

Page 272: ...D 3 55173 FUEL SYSTEMS FUEL INJECTION SN 0G303046 AND ABOVE...

Page 273: ...7 Detonation Control System Test 200 Models Only 3D 38 Detonation Sensor Check 3D 38 Detonation Control Module Check 3D 39 Page Throttle Position Sensor Test 3D 39 Map Sensor Test 3D 40 Problem Diagno...

Page 274: ...Float Adjustment Vapor Separator Float Level Preset Factory Fuel Injectors All Models Quantity Inner Switch Box Controls 1 Primary Circuit 3 Primary Circuit 5 Primary Circuit 6 3 and 4 Injectors 5 an...

Page 275: ...A1 For Mercury Mariner 150 thru 250 HP with Electronic Fuel Injection For Hi Performance 150 thru 300 HP PRO MAX SUPER MAGNUM models only Can be used to verify that the ECM is supplying operating volt...

Page 276: ...QTY DESCRIPTION lb in lb ft N m 1 1 DETONATION CONTROLLER ASSEMBLY 2 3 SCREW 30 3 5 3 3 WASHER 4 1 PLATE 5 1 CABLE ASSEMBLY 200 6 1 SCREW 7 3 BUSHING 8 1 OIL INJECTION WARNING MODULE 9 1 INDICATOR th...

Page 277: ...6 7 8 9 10 11 12 13 14 16 17 18 19 20 1 15 Dielectric Grease 92 823506 1 6 25 Liquid Neoprene 92 25711 2 6 25 25 25 6 25 25 25 3D 4 FUEL SYSTEMS 90 824052R3 JUNE 2002 Electronic Control Module ECM As...

Page 278: ...SEMBLY 200 2 2 SPACER 3 1 CLIP 4 2 MOUNT cowl mounting bracket 5 4 WASHER 6 4 NUT 45 5 0 7 1 CABLE ASSEMBLY 8 1 GROMMET 9 1 BUSHING 10 1 SCREW 1 4 20 x 1 45 5 0 11 1 LOCKWASHER 12 1 WASHER 13 1 WATER...

Page 279: ...3D 6 FUEL SYSTEMS 90 824052R3 JUNE 2002 Fuel Management System 1 2 4 5 6 7 8 9 11 12 13 14 15 16 17 18 19 3 4 13 16 16 16 17 17 18 18 10 21 20...

Page 280: ...VER 2 1 HARNESS KIT 3 1 SEAL 4 1 O RING SEAL KIT 5 1 FUEL RAIL 6 1 FUEL INJECTOR 7 1 FILTER 8 1 RETAINING KIT 9 1 THROTTLE BODY 10 1 JOINT KIT 11 1 LINK 12 1 LINK LEVER KIT 13 1 STOP SCREW KIT 14 1 SC...

Page 281: ...ment System 1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 21 22 23 24 25 26 28 14 18 18 19 19 17 17 21 21 23 23 23 23 23 23 24 25 20 21 23 3 3 25 27 27 A B 29 A LARGE SCREW 5 MM TORGUE TO 30 LB IN 3 4...

Page 282: ...OCKWASHER 9 3 SCREW 45 5 0 10 1 DRAIN SCREW KIT 11 1 CHECK VALVE 12 1 FLOAT KIT 13 1 FLOAT VALVE KIT 14 1 SCREW KIT 15 1 COVER KIT 16 1 ELBOW KIT 17 1 ATTACHING KIT 30 3 5 18 1 PRESSURE REGULATOR KIT...

Page 283: ...3D 10 FUEL SYSTEMS 90 824052R3 JUNE 2002 Fuel Pump 4 3 1 2 5 6 7 8 9 10 11 12 13 14 15 16 18 19 21 4 3 5 20 19 19 19 22 23 27 23 24 25 26 29 28 A 17 Perfect Seal 92 34227 1 19 19 19 19 19...

Page 284: ...10 1 GASKET pulse 11 1 SPRING 12 1 CAP 13 1 GASKET base 14 1 BASE fuel pump 15 1 PLATE fuel pump 16 1 ELBOW 17 1 TUBING 6 IN 18 1 FUEL LINE 10 1 2 IN 19 AR STA STRAP 20 2 SCREW fuel pump to crankcase...

Page 285: ...e Water Separating Filter Electronic Fuel Injection EFl System Introduction The troubleshooting information provided here consists of preliminary checks checks to be followed before proceeding with E...

Page 286: ...lls immediately CAUTION Depressurize fuel system prior to opening line connections or removing fuel system components DANGER Perform the tests in this section in a well ventilated area to avoid being...

Page 287: ...e spark gap tester A steady blue spark should be present at each spark plug wire If a good spark is present problem may not be ignition related If good spark is not present problem may be ignition rel...

Page 288: ...supply clogged lines malfunctioning anti siphon valve etc and or marginal gasoline Low Battery Voltage Low battery voltage can cause EFI system to deliver fuel in an inconsistent manner Inspect batter...

Page 289: ...e e Fuel Pressure Regulator f To Starboard Bleed Junction Block g To Port Bleed Junction Block h Bleed System Filter Removed on later Models i Needle and Seat j Water Separator k Water Sensor l Pulse...

Page 290: ...r to eliminate contaminates and emptied into the vapor separator It mixes with fresh incoming fuel and is pumped to the fuel rail and fed through the injectors A 30 micron filter is installed in the b...

Page 291: ...contains the fuel rail injectors throttle position sensor and air temperature sensor A fuel rail pressure port is located on the fuel pressure regulator Fuel Pressure Regulator The fuel pressure regul...

Page 292: ...odule 3 Starter Solenoid 4 Starter Motor 5 Air Temperature Sensor 6 Electronic Control Unit 7 Fuel Pump 8 Injectors 9 12 Volt Battery 10 Rotational Sensor 11 Water Sensing Warning Module 12 Water Sepa...

Page 293: ...Switch 4 Warning Module 5 Starter Solenoid 6 Starter Motor 7 Air Temperature Sensor 8 Electronic Control Module 9 Fuel Pump 10 Injectors 11 12 Volt Battery 12 Rotational Sensor 13 Water Sensing Warni...

Page 294: ...ition altering engine operation If no change occurs when drawing vacuum MAP sensor is not functioning properly MAP sensor can be tested with the EFI tester ENGINE HEAD TEMPERATURE SENSOR The Engine He...

Page 295: ...e widths are tripled when engine head tempera ture is below 90 F 32 2 C to provide adequate fuel for quick start up When key is returned to the run po sition or engine head temperature is above 90 F 3...

Page 296: ...Pressure Fuel Route Flow Chart Fuel flows from fresh fuel inlet hose Little or no flow from fresh fuel inlet hose Reconnect hose Inspect float system of vapor separator Perform Water Separating Filter...

Page 297: ...ge 3D 29 Clogged or faulty fuel pressure regulator remove and replace Perform Electric Fuel Pump Volt age Test page 3D 31 Final filter OK Final filter clogged Perform Fuel Pressure Regula tor Test pag...

Page 298: ...55 60 Perform Injector Fuel Delivery Test page 3D 34 RPM increase occurs No RPM change Perform induction manifold dis assembly Inspect injector and filter Perform compression check on problem cylinde...

Page 299: ...Connect fuel pressure gauge to induction manifold pressure port 55180 a a Pressure Port 2 Prime engine using fuel primer bulb 3 Turn ignition key switch to On position OFF ON START 4 Operate electric...

Page 300: ...ing delivered to electric fuel pump Go to high pressure flow chart If fuel flow is not present proceed to step 2 2 Place emergency stop switch in OFF position to prevent engine from starting If boat i...

Page 301: ...arator disassembly If fuel flow is low or not present perform Water Separating Filter Flow Test Water Separating Filter Flow Test Purpose This test will indicate if water separating filter is clogged...

Page 302: ...pump section 3A IMPORTANT All fragments of failed pump must be located before re assembly No or low fuel flow from pulse pump inlet hose Check for restrictions holes or loose connections from fuel sup...

Page 303: ...d remove 9 screws securing cover 5 Remove vapor separator tank from cover 6 Rotate inlet filter counterclockwise and pull downward to remove filter from fuel pump 55205 a a Inlet Filter 7 Inspect filt...

Page 304: ...START 3 Remove fuel pressure regulator but do not disconnect any hoses from regulator 4 Put discharge end of regulator in clean container 5 Turn ignition key switch to ON position OFF ON START 6 Chec...

Page 305: ...ct black test lead to ground positive test lead to positive post of fuel pump NOTE Positive test lead can be pierced through boot cover for testing Refer to voltage test chart page 3D 33 for voltage r...

Page 306: ...is an open circuit in fuel pump 3 Ignition key in ON position and engine NOT running terminal of fuel pump 1 5 volt or less voltage should rise to 12 13 5 volts after approximately 30 seconds Bad ECM...

Page 307: ...mbly and inspection following ECM Injector Driver Test To verify that the ECM is operating the injector pairs connect test harness between manifold connector and engine harness Start engine Use DVA me...

Page 308: ...p seals crankcase split line seal or crankshaft sealing rings Remaining tests on EFI components may require some EFI disassembly See EFI System Disassembly following Injector Operation Test Manifold C...

Page 309: ...sent using EFI tester but not present while cranking perform switch box DVA tests Section 2A 1 3 5 switch box failure If fuel spray pattern is equal on all injectors system is functioning normally Ind...

Page 310: ...ength screws If fuel leak is present between sealing surfaces rebuild system using new O rings Air Temperature Sensor Test Purpose This test eliminates possibilities of improper fuel delivery related...

Page 311: ...System functioning properly detonation may be occurring See Detonation Sensor Module Checks following Detonation Sensor Check IMPORTANT When testing detonation control system keep all test leads away...

Page 312: ...ontrol unit is functioning properly no detonation occurring If voltage reading does not fall within range 0 30 to 0 70 volts DC at idle control module may be bad If voltage reading is above 0 01 volts...

Page 313: ...hile monitoring voltage reading Voltage read ing should increase and decrease smoothly 10 Set volt meter to 20 DC volts Maximum voltage reading at full throttle is approximately 7 46 volts 11 Remove t...

Page 314: ...Follow Low High Pressure Fuel Route Flow Charts and Fuel Rail Electrical Fuel Determination Flow Chart Perform Induction Manifold Leak Check page 3D 36 Perform Detonation Control Mod ule Check page 3D...

Page 315: ...Box Failed Or Disconnected EFI Sensors Fuel Delivery Problem Manifold Fuel Leak R F I Problem Stator High Speed Winding Induction Manifold Air Leak Refer to Section 2A Electrical and Ignition for prop...

Page 316: ...dercharged EFI Harness Connections Ignition System Failure Pulse Fuel Pump Failure Electric Fuel Pump Failure ECM Failure Check battery connections under charged battery or worn out bat tery Check EFI...

Page 317: ...g Plate c Wires d Sensor EFI Induction Manifold Removal IMPORTANT Remove battery cables from battery before Induction Manifold Removal and Disassembly 1 Disconnect ECM at harness connector a 55173 a C...

Page 318: ...ater Separating Filter Assembly Removal NOTE To inspect or replace water separator it is not necessary to remove inlet and outlet fuel lines or to unbolt bracket from manifold 1 Remove water sensor le...

Page 319: ...HAND TIGHTEN SEPARATOR DO NOT use strap wrench or other tool to tighten separator 3 Reconnect water sensor lead to bottom of separator 55185 a a Sealing Ring Throttle Position Sensor and Temperature S...

Page 320: ...lator Removal 1 Disconnect boat battery from engine harness 2 De pressurize EFI fuel system by wrapping a clean cloth around pressure port valve and inserting tip of screwdriver into valve depressing...

Page 321: ...rque to 45 lb in 5 0 N m Vapor Separator Removal 1 Disconnect boat battery from engine harness 2 De pressurize EFI fuel system by wrapping a clean cloth around pressure port valve and in serting tip o...

Page 322: ...l inlet hose to vapor separator 9 Remove 3 bolts securing separator to manifold assembly a b b b 55176 a Oil Inlet Hose b Bolts Vapor Separator Disassembly Remove 9 screws securing cover to vapor sepa...

Page 323: ...place O rings as required 53702 a a a a a a O rings VAPOR SEPARATOR FLOAT REMOVAL NOTE Inspect float for fuel absorbtion or deterioration DO NOT attempt to bend float arm to adjust float height Float...

Page 324: ...Float Needle Hidden c Float Drop Limit Bracket d Pivot Pin ELECTRIC FUEL PUMP INSTALLATION 1 Slide fuel pump into separator cover NOTE Fuel pump electrical studs are different diameters Pump will inst...

Page 325: ...Final Filter INSTALLING SEPARATOR COVER ASSEMBLY ONTO SEPARATOR TANK 1 Inspect separator tank sealing O ring for cuts or abraisions Replace O ring as required NOTE If O ring swells due to fuel and ai...

Page 326: ...for cuts or abraisions Replace O rings as required a 55215 a O rings 3 Secure adaptor plate to manifold with 2 screws Torque screws to 45 lb in 5 0 N m 55216 a a a Screws Torque to 45 lb in 5 0 N m 4...

Page 327: ...Washers Torque bolts to 45 lb in 5 0 N m Manifold Removal 1 Disconnect throttle link rod from throttle cam 2 Disconnect oil injection link rod from injector arm c b a d 55213 a Throttle Link Rod b Thr...

Page 328: ...and place on clean work surface 51795 a a Bleed Hoses EFI Induction Manifold Disassembly 1 Remove manifold cover seal from manifold a b 51785 a Manifold Cover Seal b Manifold Air Temperature Sensor R...

Page 329: ...ition sensor screws a 51790 a Screws 2 Remove sensor and sleeve from throttle shaft 51788 a b c a Sensor b Sleeve c Throttle Shaft Fuel Rail Removal 1 Remove manifold vacuum hoses 2 Remove engine blee...

Page 330: ...y 6 Lift fuel rail from manifold Note fuel rail guides a c b 51788 c a Fuel Rail b Manifold c Guides Fuel Rail Disassembly 1 Remove tube support from fuel rail 2 Remove plugs from fuel rail 3 Remove t...

Page 331: ...re clamp from slot 2 Disconnect connector from injector 51792 b c a d a Clamp b Slot c Connector d Injector 3 Remove injector from manifold a 51789 a Injector 4 Place injector on clean work surface Re...

Page 332: ...2 Remove screws and injector harness plate a b 51792 a Screws b Plate Throttle Linkage Removal b a b c 51786 a Throttle Cam b Bushings c Nut Tighten until snug against cam then back off 1 4 turn b c...

Page 333: ...se routing 4 Look at main connector between engine harness and ECM box for missing corroded or bent contact pins and socket Check for dislodged grommet in ECM where harness enters box 5 Look at all se...

Page 334: ...ld 2 Install O ring into groove on injector harness insert Install harness insert into manifold port a b c a O Ring b Groove c Insert 3 Install injector harness plate using screws Tighten securely a b...

Page 335: ...l injector into manifold a 51789 a Injector 3 Install wire clamp into slot on injector connector 4 Connect to injector 51792 d b c a a Clamp b Slot c Connector d Injector Fuel Rail Assembly 1 Install...

Page 336: ...4 b Early Models Only 3 Install O rings to manifold fitting Install fitting to manifold e 51791 b a a O Rings b Fitting 4 Install screws securing manifold fitting to manifold Torque screws to 45 lb i...

Page 337: ...Sleeve b Throttle Position Sensor c Throttle Shaft 3 Tighten screws after induction manifold installa tion and throttle position sensor adjustments are completed Torque screws to 20 lb in 2 0 N m a 5...

Page 338: ...bolts through holes NOTE This will aid in induction manifold installation a a a Holes EFI Induction Manifold Installation 1 Install new gasket on induction manifold as shown Removing dotted line secti...

Page 339: ...rque Sequence IMPORTANT Before connecting oil pump control rod verify pump quadrant is rotated to the clockwise of center 4 Connect oil injection link rod to injector arm 5 Connect throttle link rod t...

Page 340: ...ue to 45 lb in 5 0 N m b Spacers IMPORTANT If fuel outlet hose from electric fuel pump or fuel return hose from manifold to pressure regulator was disconnected stainless steel hose clamps MUST BE USED...

Page 341: ...EGATIVE lead to PORT terminal of fuel pump Torque POSITIVE nut to 6 lb in 0 7 N m and the NEGATIVE nut to 8 lb in 0 9 N m a b 55204 a RED Terminal Torque nut to 6 lb in 0 7 N m b BLACK RED Terminal To...

Page 342: ...ECM to manifold using nuts and screw Torque nuts and screw to 45 lb in 5 0 N m 3 Secure water sensing module and ground wires with screws Torque screws to 25 lb in 3 0 N m e d b a 55173 c a Nuts b Sc...

Page 343: ...T Engine Head Temperature Sensor must make clean contact with cylinder head for circuit to function properly 1 Connect wires and install sensor 2 Install retaining plate and screw Torque screw to 200...

Page 344: ...E 3 FUEL SYSTEMS OIL INJECTION...

Page 345: ...tructions for Oil Injection System 3E 5 Oil Injection Pump 3E 8 Oil Pump Removal 3E 8 Worm Bushing 3E 9 Worm Bushing Removal 3E 9 Worm Bushing Installation 3E 9 Oil Injection Pump Installation 3E 9 In...

Page 346: ...he vapor separator on EFI models The oil injection pump is driven by the crankshaft and is connected to the throttle linkage for metering the varied flow of oil per engine RPM The motion sensor will s...

Page 347: ...s of full throttle running after the remote tank is empty The warning horn will sound if the oil level in oil reservoir is low 10 MOTION SENSOR Senses the rotation of the oil injection pump drive syst...

Page 348: ...lue Stripe 5 Open 6 Vent Hose 7 4 PSI Check Valve 8 Low Oil Magnetic Float Sensor 9 Oil Reservoir 10 Motion Sensor 11 Oil Injection Pump 12 Warning Module 13 To Terminal Block 14 To 12 Volt Supply 15...

Page 349: ...l Pump Installed NOTE If magnet should fall out of the coupler using a directional compass locate end of magnet that attracts the North Arrow of the compass Insert this end of magnet into coupler firs...

Page 350: ...IL TANK 1 The remote oil tank should be installed in an area in the boat where there is access for refilling The tank should be restrained to keep it from moving around causing possible damage An acce...

Page 351: ...WII 2 Cycle Outboard Oil Quicksilver Certified TC W3 Outboard Oil is a higher grade oil that provides increased lu brication and extra resistance to carbon buildup when used with good or varying grade...

Page 352: ...h oil Bleeding Air from Oil Injection Pump Outlet Hose Any air bubbles in outlet hose in most cases will be purged out of the system during operation of the engine NOTE If air bubbles persist they can...

Page 353: ...mittent beep beep beep during operation this indicates a problem occurred in the oil injection system Refer to troubleshooting following to correct the problem 2 After engine has been run for a short...

Page 354: ...hrust Washer c Pocket 1 Inspect bushing O rings for cuts and abrasions Replace O rings if necessary a 51782 a O rings 2 Reinstall bushing seal assembly Oil Injection Pump Installation 1 Align oil pump...

Page 355: ...bearing bronze bushing and oil pump drive shaft be inspected for wear gauling or damage Replace parts as required 1 Align drive gear halves on crankshaft with retain ing screw access holes towards ce...

Page 356: ...odule 1 Open the cowling on engine and check oil level in engine reservoir tank If oil level is not to the top of tank the problem is low oil level There is a safety reserve of oil left in the reservo...

Page 357: ...ing horn should sound If not check TAN wire between horn and engine for open circuit and check horn Warning Module Verify all warning module leads are connected to harness leads If leads are connected...

Page 358: ...ct then the voltage to the warning module is correct Defective low oil sensor located in fill cap of engine oil reservoir DO NOT remove cap from oil reservoir Disconnect both low oil sensor leads from...

Page 359: ...ection pump Check drive system as follows 1 Use a 50 1 gas and oil mixture and start engine Verify engine has proper cooling water 2 Disconnect link rod connected between oil injec tion pump and carbu...

Page 360: ...link arm ATTACHED 8 2cc 10 in 3 MINUTES 1500 RPM with oil pump link arm DISCON NECTED 19 2cc 10 in 3 minutes Oil Warning Module REMOVAL 1 Disconnect PURPLE and TAN leads from termi nal block above ig...

Page 361: ...Pump d Oil Cap INSTALLATION 1 Apply Loctite 222 FT2962 2 to threads of 3 attaching bolts and secure oil reservoir to powerhead Torque bolts to 25 Ib in 3 0 N m 2 Install input oil hose to top of oil...

Page 362: ...0 Model Year U S EPA regulations for marine SI engines Idle Speed in gear 650 RPM Timing Idle 0 9 ATDC WOT 20 BTDC Spark Plug NGK BPZ8HS 10 Gap 0 040 in 1 0 mm Valve Clearance Cold mm Intake N A Exhau...

Page 363: ...ions 3F 1 Stoichiometric 14 7 1 Air Fuel Ratio 3F 1 Outboard Hydrocarbon Emissions Reductions 3F 2 Stratified vs Homogenized Charge 3F 3 Homogenized Charge 3F 3 Stratified Charge 3F 3 Emissions Inform...

Page 364: ...engine in the form of carbon dioxide CO2 CO2 is a harmless gas But carbon often combines with in sufficient oxygen one carbon atom with one oxygen atom This forms carbon monoxide CO Carbon monoxide i...

Page 365: ...ning 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...

Page 366: ...tem into the cylinder The homogenized charge is easy to ignite as the air fuel ratio is approximately 14 7 1 Stratified Charge A stratified charge engine only pulls air through the transfer system The...

Page 367: ...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 Exce...

Page 368: ...ugh the month of engine manufacture before installing the new label The month of manufacture can be found on the old label If the label is missing or the date code illegible contact Mercury Marine Tec...

Page 369: ...37 855211 12 37 855577 12 Air Cover Merc Mar 2 5 L 1998 V6 EFI Carb 150 200 H P 37 855211 13 37 855577 13 Vapor Separator EFI Air Cover Carb Merc Mar 2 5L Promax 150 225 H P 37 855211 28 37 855577 28...

Page 370: ...4 51804 A POWERHEAD...

Page 371: ...g 4 30 Connecting Rods 4 30 Thermostats 4 32 Powerhead Reassembly and Installation 4 33 General 4 33 Crankshaft Installation 4 36 Special Information 4 36 Page Piston and Connecting Rod Reassembly 4 3...

Page 372: ...ton 105 Jet 135 150 Dia Standard 3 115 in 002 in 79 121 mm 051 mm Dia 015 in Oversize 3 130 in 002 in 79 502 mm 051 mm Dia 030 in Oversize 3 145 in 002 in 79 883 mm 051 mm 140 Jet 175 XR6 Mag III 200...

Page 373: ...cial Tools Lifting Eye 91 90455 Flywheel Holder 91 52344 91 52344 54964 Protector Cap 91 24161 Flywheel Puller 91 849154T1 Powerhead Stand 91 30591A1 Piston Ring Expander 91 24697 Lockring Removal Too...

Page 374: ...tallation Tool 91 91 77109A1 Piston Ring Compressor for 2 Litre 122 cu in 91 65494 Piston Ring Compressor for 2 5 Litre 153 cu in 91 818773 Compression Tester 91 29287 54965 Powerhead Repair Stand A p...

Page 375: ...12 13 14 15 16 17 18 19 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 22 23 20 12 Loctite Master Gasket 92 12564 1 14 2 Cycle Outboard Oil 92 13249A24 95 2 4 C With Teflon 92 825407A12 51 12 95...

Page 376: ...2 IN HEX FLANGE 210 17 5 23 5 9 1 COVER LOWER 10 2 SCREW 2 IN HEX HEAD FLANGE 210 17 5 23 5 11 1 BUSHING 12 8 SCREW 3 1 4 IN 150 12 5 17 12 6 SCREW 1 1 4 IN 150 12 5 17 13 1 UPPER END CAP ASSEMBLY 14...

Page 377: ...Plate 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 42 43 12 A Loctite 262 Obtain Locally 86 9 51 86 7 39 51 Loctite 222 FT2962 2 7 Loc...

Page 378: ...1 SCREW 3 4 IN 25 3 0 14 1 WASHER 15 1 DIAPHRAGM 16 1 WATER DEFLECTOR 17 1 PLATE 18 1 SPRING 19 1 WASHER 20 1 POPPET 21 1 GROMMET 22 1 CARRIER 23 1 GASKET 24 1 EXHAUST PLATE 25 1 CONNECTOR STRAIGHT 2...

Page 379: ...Head 2 3 4 5 6 7 8 9 13 10 11 16 17 18 19 21 22 23 24 25 26 27 28 29 30 12 1 14 4 4 14 14 14 14 15 20 A B Dielectric Grease 92 823506 1 6 Loctite PST Pipe Sealant 92 809822 9 14 2 Cycle Outboard Oil 9...

Page 380: ...PIN 5 2 GASKET 6 2 COVER 7 2 THERMOSTAT 8 4 SCREW 1 IN 200 16 5 22 5 9 1 ELBOW 10 1 TEMPERATURE SENDER STBD 11 1 THERMAL AIR VALVE 12 1 HOSE 12 3 4 IN 13 1 FITTING 14 10 STA STRAP 15 1 HOSE 11 1 2 IN...

Page 381: ...kshaft Pistons and Connecting Rods 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 18 19 15 14 14 2 Cycle Outboard Oil 92 13249A24 95 2 4 C With Teflon 92 825407A12 95 95 95 92 7 95 95 14 14 14 7 Loctite 271 9...

Page 382: ...T STANDARD AR PISTON PORT 015 O S 135 150 AR PISTON PORT 030 O S 1 PISTON RING STANDARD 12 AR PISTON RING 015 O S AR PISTON RING 030 O S 13 12 LOCK RING 14 6 PISTON PIN 3 PISTON STARBOARD STANDARD 11...

Page 383: ...3 8 in 16 in 38 lb ft 51 5 N m Bolts 5 16 in 18 180 lb in 20 3 N m 1 2 3 4 5 6 7 8 EXHAUST DIVIDER PLATE BOLTS 200 lb in 22 6 N m Apply Loctite 271 to threads 19 20 10 6 3 2 7 11 16 17 12 8 4 1 5 9 1...

Page 384: ...refer to Powerhead Removal and Disassembly following and remove cylinder heads and exhaust cover 2 minor repairs on components such as ignition system carburetors reed blocks and cylinder heads and ch...

Page 385: ...Lead c Black Trim Lead 1996 Standard Models Disconnect trim relay harnesses from each relay 54938 a b a UP Trim Relay b DOWN Trim Relay 1994 1995 High Performance Models 55007 b a c a Blue Trim Lead b...

Page 386: ...anchor bracket g e b a h c d f 51853 a Lock Nut b Shift Cable Latch c Flat Washer Hidden d Nylon Wear Plate e Spring Hidden f Shift Cable g Anchor Bracket h Throttle Cable 12 Disconnect input fuel lin...

Page 387: ...lts 54896 a a Bolts All High Performance Models 55005 b c a a Bottom Pan The bottom pan does not have to be removed to remove the powerhead b Skirt c Bolts Washers Nuts 8 each 14 All Standard Models R...

Page 388: ...a hoist lift powerhead assembly from driveshaft housing 51804 REMOVING ENGINE COMPONENTS Remove the following engine components Section 2 Starter Motor Starter Motor Ignition Switch Boxes Ignition Coi...

Page 389: ...rmostats and gaskets b a c 51852 a Thermostat Cover b Thermostat c Gasket 3 Remove cylinder heads from engine block a c 51847 b a Cylinder Head b Gasket c Engine Block 4 Remove exhaust manifold cover...

Page 390: ...from end caps UPPER END CAP a 51854 a a Crankcase Attaching End Cap Bolts LOWER END CAP a 51849 a a Crankcase Attaching End Cap Bolts 1 Remove bolts which secure crankcase cover to cylinder block 2 Pr...

Page 391: ...assemble connecting rods in same cylinder 51849 3 Use a 5 16 in 12 point socket to remove connecting rod bolts then remove rod cap roller bearings and bearing cage from connecting rod a 51850 a Connec...

Page 392: ...1 1 9 Using tool 91 52952A1 remove piston pin lockrings from both ends of piston pin Never re use piston pin lockrings a 51083 a Lockring IMPORTANT Warming the piston dome using a torch lamp will ease...

Page 393: ...cap as out lined in Cleaning and Inspection NOTE If roller bearing is damaged replace upper end cap and roller bearings as an assembly b a 51853 a O Ring b Seal 16 Remove crankshaft and place in powe...

Page 394: ...kshaft ball bearing as outlined in Clean ing and Inspection following IMPORTANT DO NOT remove crankshaft ball bearing unless replacement is required 19 Remove lower ball bearing from crankshaft as fol...

Page 395: ...ter pressure relief valve components as shown 50803 2 3 7 5 4 3 13 11 12 10 9 6 8 1 a b Torque Specifications a 150 lb in 17 0 N m b 25 lb in 3 0 N m 1 Cover 2 Bolt 3 Gasket 4 Relief Valve Plate 5 Dia...

Page 396: ...nkshaft do not line up with existing grooves in cylinder block If installing a new crankshaft refer to crankshaft installation Powerhead Reassembly section to determine if powerhead can be used Cylind...

Page 397: ...crometer of each cylinder as shown below Check for tapered out of round egg shaped and oversize bore 51846 135 and 150 carbureted Models Models Cylinder Block Finish Hone 135 and 150 with a Stan dard...

Page 398: ...groove Pistons may have two keystone ring grooves or one keystone ring groove and one rectangular ring groove as shown Rectangular ring grooves A broken rectangular piston ring can be used as a tool f...

Page 399: ...following Piston Dimension A Standard Piston 3 494 in 0 001 in 015 in Oversize Piston 3 509 in 0 001 in 2 Using a micrometer measure dimension B at location shown Dimension B should be within 0 008 i...

Page 400: ...aning crankshaft grasp outer race of crankshaft ball bearing installed on lower end of crankshaft and attempt to work race back and forth There should not be excessive play 2 Lubricate ball bearing wi...

Page 401: ...Check operation of bleed system check valves in reed block housing If valves are working properly air can be drawn thru check valves one way only If air can pass thru a check valve both ways valve is...

Page 402: ...causes the connecting rod to catch up to the waiting crankshaft journal then hammers it The repetition of this action causes a rough bearing surface s which resembles a tiny washboard In some instance...

Page 403: ...r 4 Using a thermostat tester similar to the one shown test each thermostat as follows a Open thermostat valve then insert a thread between valve and thermostat body Allow valve to close against threa...

Page 404: ...orque wrench is essential for correct reassembly of powerhead DO NOT attempt to reassemble powerhead without using a torque wrench Attaching bolts for covers housings and cylinder heads MUST BE torque...

Page 405: ...rings into groove 51849 5 Lubricate center main crankshaft roller bearings and races with light oil a b 51854 a Install so LARGER of the 3 holes is toward DRIVE SHAFT end of crankshaft b Verify retain...

Page 406: ...on first oil seal Remove any excess Loctite d Lubricate oil seal lips with Quicksilver 2 4 C w Teflon 92 825407A12 e Lubricate O ring seal surface on end cap with 2 cycle oil Install o ring over lower...

Page 407: ...veral times to check if sealing rings are binding against crankshaft You will feel a drag on the crankshaft If sealing rings are binding recheck grooves for burrs If this does not correct the problem...

Page 408: ...ssy 91 74607A1 3 Place locating washers on connecting rod IMPORTANT Position connecting rod part number facing towards flywheel Carefully position piston over end of rod Make sure locating washers rem...

Page 409: ...4A 38 POWERHEAD 90 824052R3 JUNE 2002 7 Make sure lockrings are properly seated in piston grooves b a 51086 a Lockring Installation Tool 91 77109A1 b Lockring a 51086 a Lockring Installation Tool...

Page 410: ...tone tapered ring on top and one rectangular ring on bottom 093 in 063 in a b c a Keystone tapered Piston Ring b Rectangular Piston Ring c Enlarged View of Piston Ring Grooves 153 CU IN 2508cc MODELS...

Page 411: ...and install piston rings dot side up on each piston Spread rings just enough to slip over piston 4 Check piston rings to be sure that they fit freely in ring groove 5 Lubricate piston rings and cylind...

Page 412: ...re Run a pencil lightly over ground area If pencil stops at fracture point loosen bolts retighten and check again NOTE If you still feel the fracture point discard the rod 12 Tighten connecting rod bo...

Page 413: ...trips b Edge of Cover 3 Apply a thin even coat of Loctite Master Gasket 203 on mating surfaces of crankcase cover and cylinder block a a a Loctite Master Gasket 92 12564 1 4 Place crankcase cover in p...

Page 414: ...ite 271 obtain locally to bolt threads and torque bolts to 16 5 Ib ft 22 5 N m d b c a 50805 a Divider Seal b Exhaust Divider Plate c Gasket d Attaching Bolt 5 Torque exhaust divider plate bolts in fo...

Page 415: ...r head below 1 spark plug a b c f g h k i j e d a Thermostat 143 F 61 7 C b Gasket c Thermostat Cover d Bolt Torque to 16 5 lb ft 22 5 N m e 90 Elbow f Hose g Sta Strap h Temperature Sensor i Retainer...

Page 416: ...IDE VIEW 50802 STARBOARD SIDE VIEW 50801 Bleed Line Routing Fuel Injected Models FRONT VIEW 50935 a b b a To Vapor Separator Thru Bleed Shut Off Valve 0G303045 and Below Direct to Vapor Separator 0G30...

Page 417: ...46 and Above b To Bottom of EFI Manifold if Equipped Reinstalling Engine Components Reinstall the following engine components Section 2 Starter Motor Ignition Switch Boxes Ignition Coil Starter Soleno...

Page 418: ...90 824052R3 JUNE 2002 POWERHEAD 4A 47 Notes...

Page 419: ...d Shift Shaft 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 47 46 48 49 50 51 52 53 45 A B 46 46 95 2 4 C With Teflon 92 82...

Page 420: ...4 0 10 1 LINK ROD 11 1 NUT 12 1 BALL JOINT 13 1 PIVOT 14 1 SPRING 15 1 BUSHING 16 1 THROTTLE CONTROL LEVER 17 1 SCREW 1 3 4 IN 18 1 BUSHING 19 1 SCREW 2 1 8 IN 20 1 NUT 1 4 20 21 1 CAP 22 1 LATCH 23...

Page 421: ...d Shift Shaft 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 47 46 48 49 50 51 52 53 45 A B 46 46 7 95 95 95 95 95 95 95 95...

Page 422: ...43 1 LINK ROD ASSEMBLY 44 1 SHIFT SHAFT ASSEMBLY LONG 44 1 SHIFT SHAFT ASSEMBLY X LONG USE WITH REF 46 45 1 SHIFT SHAFT LEVER UPPER WITH TAB SEE BUBBLE A 46 1 BUSHING 44 1 SHIFT SHAFT ASSEMBLY LONG 44...

Page 423: ...ing into crankshaft 4 Apply a small amount of 2 4 C w Teflon Marine Lubricant 92 90018A12 onto driveshaft splines 5 Use hoist to lower powerhead onto driveshaft housing It may be necessary to turn fly...

Page 424: ...e hose to fitting 51851 a b a Hose b Fittings Fittings must be turned to allow clearance for bottom pan 11 1994 1995 Standard Models Install four bolts which secure bottom cowl halves together a a 518...

Page 425: ...s 54896 a a Bolts 12 Reconnect input fuel line b a 51803 a Sta Strap b Fuel Line 13 1994 1995 Standard Models Connect BLUE GREEN and BLACK trim harness leads to trim solenoids Install trim harness to...

Page 426: ...Reconnect remote control harness to powerhead harness connector and wires as shown d c f b a e 51851 a Control Harness b Powerhead Harness c Trim 12 Volt Power Supply RED d Trim Up Lead BLUE WHITE e...

Page 427: ...t the bleed hose going to the vapor separator be disconnected prior to the bleed hose in line filter Place disconnected bleed hose in a refuse container 2 With engine on flush attachment or with boat...

Page 428: ...ith the gasoline NOTE At the end of the break in period visually check to see if the oil level in the oil injection tank has dropped Oil usage indicates the oil injection system is functioning correct...

Page 429: ...4 51804 B POWERHEAD COOLING...

Page 430: ...stat 4B 1 Water Pressure 4B 1 Temperature Sensor 4B 1 Special Tools 4B 1 Temperature Sensor 4B 2 Water Flow 4B 3 Description 4B 3 Water Flow Diagram 4B 5 Troubleshooting 4B 7 Thermostat Test 4B 7 Wate...

Page 431: ...Poppet Valve Opening 4 9 PSI 27 4 61 6 kPa W O T 12 0 PSI 82 1 kPa Minimum Temperature Sensor Temperature Sensor s Between Black and each TAN BLK wire No Continuity Between each lead and ground No Co...

Page 432: ...ngs from both air and head temperature sensors NOTE Temperature sensor in starboard cylinder head on EFI models activates a warning horn when engine temperature exceeds 240 F 8 F 115 6 C 13 3 C Warnin...

Page 433: ...ing upon en gine temperature When the thermostats are open water passes through the cylinder heads and exits to the drive shaft housing At higher RPM above 1500 RPM the poppet valve will control the w...

Page 434: ...4B 4 POWERHEAD 90 824052R3 JUNE 2002 Notes...

Page 435: ...ng temperature run cold and will run rough at idle 5 Primary Water Discharge into Driveshaft Housing 6 Water passing through thermostats dump into the adaptor plate then discharges down the exhaust 7...

Page 436: ...90 824052R3 JUNE 2002 4B 6 POWERHEAD...

Page 437: ...er Bottom of thermometer must be even with bottom of thermostat to obtain correct temperature of thermostat opening c Fill thermostat tester with water to cover thermostat d Plug tester into electrica...

Page 438: ...le gauge may be connected to this line to register water pressure WARNING Shut off engine and refer to troubleshooting chart if water pressure is not within specification DO NOT exceed 3000 RPM in neu...

Page 439: ...ad should be disregarded when inspecting cover and plate The depth of the groove will not affect water pump output 5 Replace cover if plastic is melted from excessive heat lack of water Replace stainl...

Page 440: ...ugged or restricted Severe internal leak Defective poppet valve seal Poppet valve flutter water pres sure drop does not stabilize prior to 2500 RPM 4 9 PSI 27 4 61 6 kPa be tween 1000 2200 RPM Wrong p...

Page 441: ...A 5 MID SECTION CLAMP SWIVEL BRACKET AND DRIVESHAFT HOUSING...

Page 442: ...and Steering Arm 5A 2 Transom Brackets S N 0G589999 Below 5A 4 Transom Brackets S N 0G590000 Up 5A 6 Drive Shaft Housing and Exhaust Tube 5A 8 Drive Shaft Housing and Dyna Float Suspension 5A 10 Remov...

Page 443: ...90 824052R3 JUNE 2002 MID SECTION 5A 1 Notes...

Page 444: ...TION 90 824052R3 JUNE 2002 Swivel Bracket and Steering Arm 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 3 95 95 95 95 95 2 4 C With Teflon 92 825407A12 A B 95 95 7 7 Loctite 27...

Page 445: ...HER 9 2 SCREW 10 2 MOUNT 135 150 175LONG JET 10 2 MOUNT ALL OTHER MODELS 11 2 WASHER 12 2 WASHER 13 2 NUT 50 68 0 14 1 STEERING LINK ASSEMBLY 15 1 SCREW 240 20 27 0 16 2 NUT 17 2 WASHER 18 1 SWIVEL PI...

Page 446: ...1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 15 95 2 4 C With Teflon 92 825407A12 95 95 95 95 95 95 95 5A 4 MID SECTION 90 824052R3 JUNE 2002 Transom Brackets S N 0G589999 BELOW...

Page 447: ...KET STARBOARD 2 1 TRANSOM BRACKET PORT 3 1 GREASE FITTING PORT 85 7 0 9 5 4 1 JAM NUT 5 1 TILT TUBE 6 1 NUT 1 14 45 61 7 1 O RING 8 2 WAVE WASHER 9 1 NUT 7 8 14 45 61 10 4 BOLT 11 4 WASHER 12 4 NUT 13...

Page 448: ...5A 6 MID SECTION 90 824052R3 JUNE 2002 Transom Brackets S N 0G590000 UP 95 95 95 95 95 95 2 4 C With Teflon 92 825407A12 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 14 95...

Page 449: ...STARBOARD 1 1 TRANSOM BRACKET GRAY 2 1 TRANSOM BRACKET BLACK PORT 2 1 TRANSOM BRACKET GRAY 3 1 GREASE FITTING PORT 85 7 0 9 5 4 1 TILT TUBE 5 1 NUT 1 IN 14 45 61 0 6 1 O RING 7 2 WAVE WASHER 8 1 NUT...

Page 450: ...21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 95 95 7 95 2 4 C With Teflon 92 825407A12 33 19 Perfect Seal 92 34227 1 19 7 Loctite 271 92 809820 Loctite 680 92 809833 33 5A 8 MID SECTION 90 82405...

Page 451: ...W 1 1 4 156 13 17 5 14 2 COVER 15 4 SCREW 5 8 25 3 0 16 4 NUT 156 13 17 5 17 1 WASHER 18 1 NUT 55 74 5 19 4 WASHER 20 4 NUT 240 20 27 0 21 1 IDLE EXHAUST BOOT 22 1 PLUG 23 1 GASKET 24 1 SEAL LOWER 25...

Page 452: ...sing After bolts are removed lift exhaust extension plate off drive shaft housing 3 Remove screws which secure lower mount covers to drive shaft housing then remove covers a e f b d c 51858 a Shift Sh...

Page 453: ...Remove bolts then remove diffuser b a 51857 a Water Tube b Exhaust Diffuser 8 Pull exhaust tube out of drive shaft housing a b 51850 a Exhaust Tube b Drive Shaft Housing 9 Remove all gasket and gaske...

Page 454: ...ng with tapered side of seal facing up b a 51856 a Exhaust Tube Seal b Driveshaft Housing 3 Push exhaust tube boots onto tabs on each side of exhaust tube 4 Position exhaust tube in drive shaft housin...

Page 455: ...olts 14 Insert a mounting bolt thru the short end of each lower mount 15 Position a mount on each lower side of driveshaft housing 16 Install a flat washer over each lower mounting bolt 17 Position a...

Page 456: ...ount covers and secure each cover with 2 screws 51855 a b a Cover One Each Side b Screws Two for Each Cover 24 Install exhaust extension plate on driveshaft housing with shift shaft assembly Secure ex...

Page 457: ...B 5 MID SECTION POWER TRIM SQUARE MOTOR AND ROUND MOTOR DESIGN...

Page 458: ...11 Troubleshooting the Down Circuit 5B 11 Troubleshooting the Up Circuit 5B 12 Troubleshooting the Down and Up Circuits All Circuits Inoperative 5B 13 Power Trim Assembly Removal and Installation 5B 1...

Page 459: ...ial Tools 1 Alignment Tool 91 11230 17238 2 Trim Rod Removal Tool 91 44486A1 51337 3 Trim Rod Guide Removal Tool 91 44487A1 51337 4 Power Trim Test Gauge Kit 91 52915A6 73835 5 Adaptor Fitting 91 8227...

Page 460: ...11 12 13 14 15 16 17 19 20 21 22 23 24 25 26 27 28 29 30 31 32 5 5 6 6 6 6 5 13 13 13 13 13 13 13 9 3 6 18 33 34 35 94 7 109 94 Anti Corrosion Grease 92 78376A6 109 GM Silicone Sealer 92 91600 1 36 37...

Page 461: ...E ASSEMBLY 12 1 E RING 13 1 O RING KIT 14 1 PUMP 15 1 PLUG ASSEMBLY 16 4 SCREW 17 4 WASHER 18 1 COVER 19 1 DRIVE SHAFT 20 1 TRIM MOTOR Breakdown on Power Trim Motor 21 2 SCREW LONG 80 9 21 2 SCREW SHO...

Page 462: ...5B 4 MID SECTION 90 824052R3 JUNE 2002 Power Trim Motor 1 2 3 3 REF TORQUE REF NO QTY DESCRIPTION lb in lb ft N m 1 POWER TRIM MOTOR 1 1 BRUSH AND SEAL KIT 2 1 ARMATURE KIT 3 1 END FRAME Complete...

Page 463: ...e trim cylinders The trim cylinders position the outboard at the desired trim angle in the 20 degree maximum trim range The system will not allow the outboard to be trimmed above the 20 degree trim ra...

Page 464: ...may result in undesirable and or unsafe steering conditions A water test for handling steering conditions is required after any trim angle adjustments IMPORTANT Some boat motor combinations not using...

Page 465: ...trim and tilt rams fully to depressurize system Remove fill plug and O ring System is full when oil level is present at filler hole Tighten fill plug securely NOTE Automatic Transmission Fluid ATF Ty...

Page 466: ...Trim motor runs trim system does not move up or down 1 2 5 10 B Does not trim full down Up trim OK 2 3 4 C Does not trim full up Down trim OK 1 6 D Partial or Jerky down up 1 3 E Thump noise when shif...

Page 467: ...tor will not run in the UP direction it could be either the UP relay is not making contact to 12 volts OR the DOWN relay is not making contact to ground The opposite is true if the system will not run...

Page 468: ...5B 10 MID SECTION 90 824052R3 JUNE 2002 Power Trim System with Relays and 2 Wire Trim Motor BLK Black BLU Blue GRN Green RED Red WHT White DOWN Relay UP Relay 53794 1 2 3 4 5 6 7 8 9 10...

Page 469: ...onnect Voltmeter red lead to Point 5 If battery voltage is indi cated trim switch is faulty If no battery voltage check for loose or corroded connection at Point 5 or open circuit in wire supply ing c...

Page 470: ...ective There is an open circuit be tween Point 9 and positive battery terminal Connect Voltmeter red lead to Point 6 Connect Voltmeter red lead to Point 9 Connect Voltmeter red lead to Point 7 and bla...

Page 471: ...ulty Refer to Motor and Electrical Tests Repair following Check for open circuit in wire Check for loose or corroded connections Check for voltage at any instru ment using a Voltmeter Turn ignition sw...

Page 472: ...c Retaining Clips IMPORTANT Support outboard as shown above to prevent engine from tipping when power trim retaining pin is removed SUPPORT TOOL 3 8 in diameter metal rod a used shift shaft works well...

Page 473: ...51354 a a a Filler Cap b Retaining Nut 5 Remove outboard transom mounting bolts and loosen tilt tube nut until nut is flush with end of tilt tube thread 6 Remove 3 screws and washers and move star bo...

Page 474: ...E If ram extends too far retract ram by connecting GREEN wire to POSITIVE 4 Install Upper Swivel Pin with slotted end to left port side of engine b a c 51375 c a b a Screw 6 Torque to 40 lb ft 54 0 N...

Page 475: ...ply Quicksilver Liquid Neoprene 91 25511 2 on all electrical connections WARNING Electrical wires passing through cowl openings must be protected from chafing or being cut Follow the recommended proce...

Page 476: ...rass fitting into test adaptor securely using teflon tape on threads f e d c b a 54457 g a Test Adaptor 91 822778A2 b O ring Installation Tool c Small O ring Install 1st d Medium O ring Install 2nd e...

Page 477: ...test gauge hose and adapter 15 Reinstall Manual Release Valve and secure valve with circlip 16 Retighten Fill plug NOTE If pressure is less than 1300 PSI 91 kg cm2 troubleshoot system per instruction...

Page 478: ...se e Hose Not Used f OPEN Valve g CLOSE Valve 6 Reinstall fill plug 7 Disengage tilt lock lever 8 Open valve f and close valve g 9 Run trim DOWN Minimum pressure should be 500 P S I 35 kg cm2 10 Tilt...

Page 479: ...pull trim rod from cylinder 27933 a a a Trim Rod Removal Tool 91 44486A1 CLEANING AND INSPECTION TRIM RODS AND CAPS CAUTION Do not remove check valve a Check valve is preset to operate at a specific...

Page 480: ...tighten caps securely 51353 a c a c b b a Trim Rods b Cylinder End Caps c Rod End Rollers lubricate with Quicksilver Anti Corrosion Grease or Special Lubricant 101 Tilt Ram REMOVAL TILT ROD ASSEMBLY...

Page 481: ...a Cross Pin Remove as shown b Lower Swivel Pin Remove as shown Disassembly 1 Secure tilt ram in a soft jawed vise Remove tilt rod and cap a c 51364 51337 91 74951 b a Cap Turn Counterclockwise to Remo...

Page 482: ...ffer also and must be used only on the cylinder the piston was removed from 3 Remove washer check valve assemblies and piston NOTE Check valve held in by roll pin can be cleaned but not removed 51363...

Page 483: ...nal parts for damage or wear Clean and replace parts as necessary 2 Inspect tilt rod for scratches Replace scraper seal in rod end cap if tilt rod is scratched or worn 3 Slight scratches or tool marks...

Page 484: ...Cap 5 Install components on rod 51340 51363 e a d c b c a Piston b O ring c Check Valve Assembly 7 d Washer e Bolt or Locknut Tighten securely 6 Clamp cylinder in a soft jawed vise and install tilt r...

Page 485: ...2 Align tilt ram and housing using alignment tool 3 Install shaft 51352 a c b 51348 a a Alignment Tool 91 11230 b Shaft c Groove d Hole Groove c will Align with this Hole 4 Drive pin in until flush 51...

Page 486: ...53774 a a a Screw 2 2 Remove frame and armature from end cap Use care not to drop armature 53779 a b c c a Frame b Armature c End Cap Armature Tests TEST FOR SHORTS Check armature on a Growler per the...

Page 487: ...Wires 0 Rx1 BLACK Motor Wire and Frame Motor Housing No Continuity Rx1 BLUE Motor Wire and Frame No Continuity Rx1 If specified readings are not obtained check for defective armature dirty or worn br...

Page 488: ...embly e O rings BRUSH REPLACEMENT 1 Brush replacement is required if brushes are pitted chipped or if distance a between the brush pigtail and end of brush holder slot is 1 16 in 1 6 mm or less Check...

Page 489: ...Card b Metal Connector c Spade Connector d Screws and Lockwashers e O ring END CAP INSPECTION 1 Inspect seal and O ring for cuts and abraisions If replacement is required install BRUSH and SEAL KIT 82...

Page 490: ...tch will reset itself within 1 minute 53781 a a Thermoswitch Reassembly IMPORTANT Components must be clean Any debris in power trim system can cause system to malfunction 1 Install armature into end c...

Page 491: ...pliers on armature shaft 4 Carefully install frame assembly over armature 5 Position harness retainer hole over tab in end cap 6 Secure frame assembly to end cap with 2 screws 53776 i g c b a d i f h...

Page 492: ...e wiring refer to Wiring Diagrams in this service manual NOTE Verify motor and drive shaft are aligned 53782 a b 53777 c c a Motor b O ring c Screw 2 Tighten securely 4 Complete reassembly of Power Tr...

Page 493: ...f needle does not move trim sender is defective 22908 1 a a Trim sender Trim Indicator Gauge Needle Adjustment 1 Turn ignition key to RUN position 2 Tilt outboard to full IN position Needle of trim in...

Page 494: ...s equipped with Quicksilver Commander Series side mount remote control Wiring Diagram For boats equipped with Quicksilver Ignition Choke and Main Harness Assembly a b c a f g c e d e d a Trim Indicato...

Page 495: ...A 6 LOWER UNIT E Z SHIFT GEAR HOUSING STANDARD ROTATION...

Page 496: ...ring Carrier 6A 31 Disassembly Bearing Carrier 6A 31 Propeller Shaft 6A 32 Inspection 6A 32 Balance Wheels 6A 32 Disassembly 6A 33 Page Clutch Actuator Rod 6A 34 Cleaning Inspection 6A 34 Disassembly...

Page 497: ...Disc 2 and Flat 7 REVERSE GEAR BACKLASH Gear Case Reverse Gear Backlash All Ratios 0 030 in to 0 050 in 0 762mm to 1 27mm FORWARD GEAR BACKLASH Gear Case Ratio Backlash Inches mm Dial Indicator Pointe...

Page 498: ...3605 Bearing Carrier Removal Tool 91 46086A1 and Puller Bolt 91 85716 73599 Slide Hammer Puller 91 34569A1 73655 Bearing Removal and Installation Kit 91 31229A5 This kit contains the following tools P...

Page 499: ...1 31229 and Nut 91 24156 Puller Plate 91 29310 74190 Mandrel 91 38628 74193 Driver Rod 91 37323 74184 Universal Puller Plate 91 37241 73652 Cross Pin Tool 91 86642 Driveshaft Holding Tool 91 34377A1 5...

Page 500: ...JUNE 2002 Bearing Driver Cup 91 87120 Pinion Locating Gear Tool 91 12349A2 or 91 74776 55079 Backlash Indicator Rod 91 19660 Backlash Indicator Rod 91 78473 Dial Indicator 91 58222A1 73429 Bearing Re...

Page 501: ...S S c Washer N S S d Spring 24 14111 e Bolt 10 12580 f Nut 11 13953 g Set Screw 10 12575 h Sleeve 23 13946 Mandrel 91 92788 Dial Indicator Holder 91 89897 Mandrel 91 15755 73815 Seal Driver 91 816294...

Page 502: ...0 21 22 23 24 25 26 27 28 29 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 1647 9147 C1 12 20 46 30 3 4 95 2 4 C With Teflon 92 825407A12 109 GM Silicone Sealer 92 91600 1 7 92 33 33 33...

Page 503: ...R NOT USED W HIGH ALTITUDE 17 1 NUT Included With Forward Gear Set 17 1 NUT HIGH ALTITUDE 18 AR SHIM SET 19 1 SCREW drain fill MAGNETIC 55 6 0 20 2 WASHER 21 1 SCREW vent 55 6 0 22 1 STA STRAP 23 1 SH...

Page 504: ...2 53 57 59 60 58 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 1 55 54 56 1647 9147 C1 63 87 Super Duty Gear Lubricant 92 13783A24 94 Anti Corrosion Grease 92 78376A6 9...

Page 505: ...PELLER SHAFT 1 REVERSE GEAR XR6 MAG III 175 200 1 87 1 15 28 66 1 REVERSE GEAR 135 150 2 0 1 14 28 1 REVERSE GEAR HIGH ALTITUDE PART OF 43 16294A2 67 1 THRUST SPACER NOT USED W HIGH ALTITUDE 68 1 THRU...

Page 506: ...9 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 43 109 GM Silicone Sealer 92 91600 1 95 2 4 C With Teflon 92 825407A12 Perfect Seal 92 34227 1 19 19 95 95 95 9...

Page 507: ...ER 20 1 SHIFT SHAFT 21 1 E RING Use where applicable 22 1 BUSHING ASSEMBLY 50 68 23 1 O RING 24 1 OIL SEAL 25 1 WASHER rubber 26 1 DRIVE SHAFT 27 AR SHIM ASSEMBLY 28 1 ROLLER BEARING ASSEMBLY 29 1 RET...

Page 508: ...Models 1 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 95 2 4 C With Teflon 92 825407A12 94 Anti Corrosion Grease 92 78376A6 87...

Page 509: ...LLER BEARING 59 1 CLUTCH 60 2 DETENT PIN 61 1 CROSS PIN 62 2 SPRING 63 1 PROPELLER SHAFT 64 1 REVERSE GEAR 65 1 THRUST RING 66 1 BALL BEARING 67 1 THRUST RING 68 1 O RING 69 1 BEARING CARRIER ASSEMBLY...

Page 510: ...14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 12 20 47 30 3 4 95 2 4 C With Teflon 92 825407A12 109 GM Silicone Sealer 92 91600 1 7 92 33 33...

Page 511: ...15 1 WASHER 16 1 PINION NUT Included With Forward Gear Set 85 115 17 AR SHIM SET 18 1 SCREW drain MAGNETIC 55 6 0 19 2 WASHER 20 1 SCREW grease filler 55 6 0 21 1 SHIFT SHAFT 22 1 O RING 23 1 BUSHING...

Page 512: ...r Magnum Models 87 Super Duty Gear Lubricant 92 13783A24 94 Anti Corrosion Grease 92 78376A6 95 2 4 C With Teflon 92 825407A12 1 49 50 51 52 53 54 55 56 57 58 59 60 61 61 62 63 64 65 66 67 68 69 70 71...

Page 513: ...1 GEAR SET 58 2 ROLLER BEARING 59 1 CLUTCH 60 1 CROSS PIN 61 2 DETENT PIN 62 2 SPRING 63 1 PROPELLER SHAFT 64 1 REVERSE GEAR 65 1 THRUST SPACER NOT USED W HIGH ALTITUDE 66 1 THRUST RING 67 1 BALL BEA...

Page 514: ...37 38 39 40 41 43 44 45 46 47 48 49 11 42 12 13 14 45 11 12 26 27 2 3 4 6 15 17 16 7 Loctite 271 92 809820 Perfect Seal 92 34227 1 19 Loctite 680 92 809833 33 95 2 4 C With Teflon 92 825407A12 109 GM...

Page 515: ...UD 7 16 x 2 1 16 IN 11 2 STUD 7 16 x 7 06 IN 3 STUD 7 16 x 7 69 IN X LONG 1 STUD 7 16 x 8 1 8 IN 12 2 ANODE 13 1 SCREW 14 1 NUT 60 5 0 7 0 15 1 PINION GEAR Part of 43 13742A2 or 43 44102A5 16 1 WASHER...

Page 516: ...36 37 38 39 40 41 43 44 45 46 47 48 49 11 42 12 13 14 45 11 12 26 27 2 3 4 6 15 17 16 7 Loctite 271 92 809820 Perfect Seal 92 34227 1 19 Loctite 680 92 809833 33 95 2 4 C With Teflon 92 825407A12 109...

Page 517: ...ITH TORQUE TAB BASIC 1 1 GEAR HOUSING WITHOUT TORQUE TAB 31 1 WATER PUMP BASE ASSEMBLY 32 1 GASKET 33 1 O RING 34 1 OIL SEAL 35 1 OIL SEAL 36 1 GASKET LOWER 37 1 GASKET UPPER 38 1 FACE PLATE 39 1 WATE...

Page 518: ...51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 1 61 87 Super Duty Gear Lubricant 92 13783A24 94 Anti Corrosion Grease 92 78376A6 95...

Page 519: ...WARD GEAR SET Includes Pinion 59 1 ROLLER BEARING 60 1 RATCHET 61 2 DETENT PIN 62 1 CROSS PIN 63 2 SPRING 64 1 PROPELLER SHAFT 65 1 REVERSE GEAR 66 1 THRUST RING 67 1 BALL BEARING 68 1 THRUST RING 69...

Page 520: ...rom 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 be...

Page 521: ...lock lever 4 Bend tabs of propeller tab washer away from thrust hub rear then remove propeller locknut tab washer thrust hub rear propeller and thrust hub forward from propeller shaft a b 51866 c d d...

Page 522: ...gear housing and remove Fill and Vent screws from gear housing b a 51871 a a Fill Screw Sport Master Gear Case has Drain Fill Screw Located in the Bearing Carrier b Vent Screw 3 Inspect gear lubricant...

Page 523: ...by operation without sufficient water supply Replace impeller if any of these conditions exist IMPORTANT It is recommended that all seals and gaskets be replaced as a normal repair procedure to assure...

Page 524: ...late and both gaskets one above and below face plate from water pump base 10 Using 2 pry bars positioned and padded as shown lift water pump base up and off drive shaft 51874 a a Pads 11 Remove and di...

Page 525: ...ring carrier is removed from gear housing extreme care MUST BE taken not to apply any side force on propeller shaft Side force on propeller shaft may break the neck of the clutch actuator rod 6 Use lo...

Page 526: ...tate shift shaft to neutral position Remove shift shaft then remove propeller shaft as instructed in Step 8 immediately preceding b Push propeller shaft back into place against forward gear Slide bear...

Page 527: ...O ring from between bearing carrier and thrust washer 2 If inspection of reverse gear or reverse gear bearing determines that replacement of gear or bearing is required remove gear and bearing as fol...

Page 528: ...dle bearing if any of the above conditions are found Bearing carrier needle bearing contacts propeller shaft just in front of oil seal surface Forward gear bearing contacts propeller shaft in front of...

Page 529: ...ring 3 Remove the second cross pin retainer spring from sliding clutch in the same way as in Step 2 CAUTION Detent pins are free and can fall out of sliding clutch Care MUST BE taken not to lose pins...

Page 530: ...6 are for the Hi Performance gear cases with two 2 springs 4 Measure distance from each end of elongated slot to the near side of cross pin tool The measurement taken must be equal within 1 64 0 016 0...

Page 531: ...a of gear housing where flex handle will make contact to prevent damage to gear housing 4 Use a socket and flex handle on Driveshaft Holding Tool to loosen pinion nut Remove pinion nut and Drive Shaft...

Page 532: ...haft in a vise DO NOT tighten vise jaws against shaft b Strike shaft with a lead hammer take care not to drop shaft 51866 12 Sport Master Gear Case Both upper and lower tapered roller bearings can be...

Page 533: ...splines for pitting grooves scoring uneven wear and or discolor ation from overheating Replace driveshaft and driveshaft needle bearing if any of the preceding conditions are found 4 Inspect drive sha...

Page 534: ...1 Clean forward gear and bearings with solvent and dry with compressed air 2 Inspect gear teeth for pitting grooves scoring uneven wear and for discoloration from over heating Replace gear if any of t...

Page 535: ...e d c b a 51869 a Mandrel b Bearing c Pilot d Plate e Puller Rod f Hold Bearing Carrier REASSEMBLY 1 Place reverse gear on a press with gear teeth facing down IMPORTANT The reverse gear thrust washer...

Page 536: ...until seal driver bottoms against bearing carrier c b a 51872 a Oil Seal Lip of Seal Down b Oil Seal Driver c Seated 12 Place second seal on short shoulder side of seal driver with lip of seal toward...

Page 537: ...g toward shoulder Press bearing into forward gear until bearing tool bottoms against gear a b 51873 a Forward Gear Bearing Tool 91 86943 b Numbered Side of Needle Bearing 7 Place second needle bearing...

Page 538: ...bearing Sport Master only Apply High Pressure Grease such as Chicago Manufacturing and Distributing Lube 3 to the I D of both bearings 2 Thread a used pinion nut onto end of drive shaft Leave approxim...

Page 539: ...engage driveshaft splines with pinion gear splines Continue to insert driveshaft into gear housing until driveshaft tapered bearing is against bearing race NOTE It is recommended that after final pin...

Page 540: ...LE Torque Master and Sportmaster to 85 lb ft 115 N m a b a c c d a Driveshaft Holding Tool 91 34377A1 b Torque Wrench Torque Nut to 75 lb ft 101 5 N m CLE Torque Master Sportmaster Torque Nut to 85 lb...

Page 541: ...ign sleeve holes to allow set screws to pass thru 5 Measure distance a and increase that distance by 1 25 4mm by turning bottom nut away from top nut a 1 in 25 4mm a b 51870 a Adaptor b Ledge 6 Turn d...

Page 542: ...t into position in gear hous ing DO NOT place shift cam on propeller shaft 2 Place bearing carrier into gear housing and thread cover nut tightly against bearing carrier It is not necessary to torque...

Page 543: ...Gear Backlash Although reverse gear backlash is not adjustable it may be checked as follows 1 Propeller shaft and bearing carrier must be com pletely assembled and installed in gearcase 2 Install shif...

Page 544: ...to gear case It is not necessary to reinstall the pinion gear for this procedure 6 Install the upper drive shaft bearing cup and install and torque the upper bearing retainer to 100 lb ft 135 5 N m 51...

Page 545: ...N m NOTE If forward gear backlash has not yet been determined do not use a new pinion nut until final assembly 14 Apply 271 Loctite to a NEW pinion nut and install the pinion gear washer and nut using...

Page 546: ...r must rest against flat side 5 If measurements X and Y taken in Step 4 are not equal to within 1 64 remove retaining pin and re shim compression spring to obtain the measurement needed If shims are r...

Page 547: ...ross pin must be flush on both ends with sliding clutch b a 51864 a Cross Pin Tool 91 86642 b Cross Pin NOTE Pro Max and Super Magnum models use a slotted cross pin 91 86642 1 and Cross Pin Handle 91...

Page 548: ...into cam pocket of cam follower with numbered side of cam facing up b a c 51864 a Cam Pocket b Cam Follower c Shift Cam 10 With shift cam positioned as shown insert propeller shaft thru forward gear...

Page 549: ...r as possible by hand then install bearing carrier key 18 Place tab washer against bearing carrier 19 Apply Quicksilver 2 4 C w Teflon Marine Lubricant to threads of cover nut and install cover nut in...

Page 550: ...housing a 51870 a Divider Block 4 Install a new water pump base gasket and install water pump base a b c 51866 a Water Pump Base b Gasket c Hole MUST be positioned as shown 5 Install the following in...

Page 551: ...eshaft in a clockwise direction viewed from top while pushing down on pump cover to ease impeller entry into cover 13 Install water pump cover retainer washers nuts and bolt CAUTION DO NOT over torque...

Page 552: ...housing up toward driveshaft housing while aligning shift shaft splines and water tube with water tube guide in water pump cover 9 Place flat washers onto studs located on either side of driveshaft ho...

Page 553: ...Place continuity washer if equipped onto shoulder of rear thrust hub 5 Place rear thrust hub tab washer and propeller nut on propeller shaft 6 Thread propeller nut onto propeller shaft until nut is re...

Page 554: ......

Page 555: ...B 6 LOWER UNIT COUNTER ROTATING LEFT HAND GEAR CASE...

Page 556: ...apter 6B 31 Disassembly Cleaning Inspection 6B 31 Pinion Gear and Driveshaft 6B 32 Removal 6B 32 Cleaning Inspection 6B 34 Reverse Gear 6B 35 Removal and Disassembly 6B 35 Cleaning and Inspection 6B 3...

Page 557: ...eth 0 018 0 027 0 46 0 69 1 Sport Master 1 87 1 15 28 teeth 0 021 0 026 0 53 0 66 1 All 2 00 1 15 30 teeth 0 015 0 022 0 38 0 56 2 LUBRICANT CAPACITY Gearcase Lubricant Capacity All Ratios 21 0 fl oz...

Page 558: ...1 31229 and Nut 91 24156 Puller Plate 91 29310 74190 Mandrel 91 38628 74193 Driver Rod 91 37323 74184 Universal Puller Plate 91 37241 73652 Cross Pin Tool 91 86642 Driveshaft Holding Tool 91 34377A1 5...

Page 559: ...02 LOWER UNIT 6B 3 Bearing Driver Cup 91 87120 Pinion Locating Gear Tool 91 12349A2 or 91 74776 55079 Backlash Indicator Rod 91 78473 Dial Indicator 91 58222A1 73429 Bearing Retainer Tool 91 43506 736...

Page 560: ...r N S S d Spring 24 14111 e Bolt 10 12580 f Nut 11 13953 g Set Screw 10 12575 h Sleeve 23 13946 Propeller Shaft 44 93003 and Load Washer a 12 37429 51876 a Bearing Cup Driver 91 34379 73659 Bearing In...

Page 561: ...IT 6B 5 Retainer 91 18604 Shaft 91 18605 Screw 10 18602 Seal Driver 91 816294 Slotted Cross Pin Tool 91 86642 1 Threaded Cross Pin Tool 91 86642 2 Mandrel 91 15755 73815 Mandrel 91 31106 Propeller Sha...

Page 562: ...1 22 23 24 25 26 27 28 29 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 1647 9147 C1 12 20 46 30 3 4 95 2 4 C With Teflon 92 825407A12 109 GM Silicone Sealer 92 91600 1 95 95 95 7 92 33...

Page 563: ...t of 43 18572A1 or 43 18475A1 16 1 WASHER 17 1 NUT 75 102 18 AR SHIM SET 19 1 SCREW drain MAGNETIC 55 6 0 20 2 WASHER 21 1 SCREW grease filler 55 6 0 22 1 STA STRAP 23 1 SHIFT SHAFT 24 1 O RING 25 1 B...

Page 564: ...57 58 59 60 64 61 63 62 74 65 66 67 68 69 71 72 73 70 75 76 77 78 80 79 81 82 83 84 85 86 87 88 89 90 91 1 1647 9147 C1 62 73 72 87 Super Duty Gear Lubricant 92 13783A24 94 Anti Corrosion Grease 92 7...

Page 565: ...NG CUP 58 1 BALL BEARING 59 1 REVERSE GEAR PART OF 43 18572A1 or 43 18475A1 60 1 ROLLER BEARING 61 1 CLUTCH 62 2 DETENT PIN 63 1 CROSS PIN 64 2 SPRING 65 1 FORWARD GEAR 135 150 65 1 FORWARD GEAR 175 2...

Page 566: ...6 57 58 59 60 64 61 63 62 74 65 66 67 68 69 71 72 73 70 75 76 77 78 80 79 81 82 83 84 85 86 87 88 89 90 91 1 1647 9147 C1 62 73 72 94 Anti Corrosion Grease 92 78376A6 95 2 4 C With Teflon 92 825407A12...

Page 567: ...1 ROLLER BEARING 72 2 THRUST WASHER 73 2 THRUST BEARING 74 1 PROPELLER SHAFT 75 1 BEARING CARRIER ASSEMBLY 76 1 ROLLER BEARING 77 1 OIL SEAL INSIDE 78 1 OIL SEAL OUTSIDE 79 1 KEY 80 1 TAB WASHER 81 1...

Page 568: ...4 35 36 37 38 39 40 41 42 43 44 45 46 47 49 48 45 11 26 27 12 14 7 Loctite 271 92 809820 Perfect Seal 92 34227 1 19 87 Super Duty Gear Lubricant 92 13783A24 95 2 4 C With Teflon 92 825407A12 Loctite 6...

Page 569: ...16 IN 11 2 STUD 7 16 x 7 06 IN 3 STUD 7 16 x 7 69 IN X LONG 1 STUD 7 16 x 8 1 8 IN 12 2 ANODE 13 1 SCREW 14 1 NUT 60 5 0 7 0 15 1 PINION GEAR Part of 43 15845A2 or 43 817515A2 16 1 WASHER 17 1 PINION...

Page 570: ...34 35 36 37 38 39 40 41 42 43 44 45 46 47 49 48 45 11 26 27 12 14 7 Loctite 271 92 809820 Perfect Seal 92 34227 1 19 87 Super Duty Gear Lubricant 92 13783A24 95 2 4 C With Teflon 92 825407A12 Loctite...

Page 571: ...ft N m 1 1 GEAR HOUSING BASIC 31 1 WATER PUMP BASE ASSEMBLY 32 1 GASKET 33 1 O RING 34 1 OIL SEAL 35 1 OIL SEAL 36 1 GASKET LOWER 37 1 GASKET UPPER 38 1 FACE PLATE 39 1 WATER PUMP BODY ASSEMBLY 40 1...

Page 572: ...54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 61 71 1 87 Super Duty Gear Lubricant 92 13783A24 94 Anti Corrosion Grease 92 78376A6 9...

Page 573: ...58 1 REVERSE GEAR Part of 43 15845A2 1 87 1 GEAR RATIO 58 1 REVERSE GEAR 2 1 GEAR RATIO 59 1 ROLLER BEARING 60 1 RATCHET 61 2 DETENT PIN 62 1 CROSS PIN 63 2 SPRING 64 1 FORWARD GEAR SET AR SPACER SHI...

Page 574: ...54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 61 71 1 87 Super Duty Gear Lubricant 92 13783A24 94 Anti Corrosion Grease 92 78376A6 9...

Page 575: ...PROPELLER SHAFT 73 1 BEARING CARRIER 74 1 ROLLER BEARING 75 2 OIL SEAL 76 1 SNAP RING 77 1 MAGNETIC DRAIN SCREW 55 6 0 78 1 SEALING WASHER 79 1 KEY 80 1 TAB WASHER 81 1 COVER NUT 250 339 82 1 THRUST...

Page 576: ...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 roughn...

Page 577: ...ar housing 2 Shift engine into NEUTRAL position 3 Tilt engine to full up position and engage tilt lock lever 4 Bend tabs of propeller tab washer away from thrust hub rear then remove propeller locknut...

Page 578: ...riveshaft in a vertical position as shown 2 Position a clean drain pan under gear housing and remove Fill and Vent screws from gear housing 3 Inspect gear lubricant for metal particles Presence of a s...

Page 579: ...by operation without sufficient water supply Replace impeller if any of these conditions exist IMPORTANT It is recommended that all seals and gaskets be replaced as a normal repair procedure to assur...

Page 580: ...th gaskets one above and below face plate from water pump base 10 Using 2 pry bars positioned and padded as shown lift water pump base up and off driveshaft 51874 a a Pads 11 Remove and discard O ring...

Page 581: ...me care MUST BE taken not to apply any side force on propeller shaft Side force on propeller shaft may break the neck of the clutch actuator rod 6 Use long Puller Jaws 91 46086A1 and Puller Bolt 91 85...

Page 582: ...liding clutch forward gear assembly bear ing adaptor thrust washer and thrust bearings will be removed from gearcase with propeller shaft 51877 9 If propeller shaft will not come out proceed with Step...

Page 583: ...effective repair CAUTION DO NOT spin bearings dry with compressed air as this could cause bearing to score 1 Clean bearing carrier assembly with solvent and dry with compressed air 2 Bearing carrier p...

Page 584: ...ont of oil seal surface Reverse gear bearing contacts propeller shaft in front of sliding clutch splines 4 Inspect propeller shaft splines for wear and or corrosion damage 5 Check propeller shaft for...

Page 585: ...l 91 86642 2 to remove cross pin Turn tool CLOCKWISE to remove threaded cross pin c b a a a Cross Pin b Cross Pin Tang c Cross Pin Tool 91 86642 2 6 Pull sliding clutch off propeller shaft 7 Inspect s...

Page 586: ...nd forth in elongated slot This will release any initial set from springs 4 Measure distance from each end of elongated slot to the near side of cross pin tool The mea surement taken must be equal wit...

Page 587: ...d gear clutch teeth for signs of wear If clutch teeth are worn sliding clutch should be replaced also 3 Inspect forward gear teeth for full tooth contact chips pits and signs of rust If forward gear t...

Page 588: ...and propeller shaft where the thrust roller bearing rides should also be inspected for signs of wear c b a 51885 a Thrust Bearing b Thrust Washer Not Used on Sport Master Gear Cases c Bearing Adaptor...

Page 589: ...r allow gear housing to fall 51878 a b a Wooden Block b Soft Jaw Vise Covers 7 Reach into gear housing and remove pinion gear 8 After driveshaft is removed from gear case remove and retain shim s that...

Page 590: ...ith Both Upper and Lower Bearings 13 Remove 18 loose needles from outer race of driveshaft needle bearing 14 If inspection of driveshaft needle bearing surface determines that replacement of needle be...

Page 591: ...they have been removed a c b a Slide Hammer b Two Jaw Puller c Reverse Gear Bearing Assembly 2 If inspection determines that replacement of reverse gear ball bearing is required then a Install Univers...

Page 592: ...aring race has turned in the gear housing gear housing must be replaced Loose fitting needle bearing will move out of position and cause repeated failures NOTE Driveshaft needle bearing must be instal...

Page 593: ...earing a b d c 51881 a Mandrel 91 15755 b Bearing Carrier Needle Bearing c Bearing Carrier d Shoulder 2 Apply Loctite 271 92 32609 1 to outside diameter of oil seals 3 With seal lip facing towards bea...

Page 594: ...6 is to ensure that reverse gear ball bearing is fully seated into bearing cup adapter a b d c 51911 a Mandrel b Bearing Cup Adapter c Reverse Gear Ball Bearing d Mandrel 91 31106 3 With reverse gear...

Page 595: ...end of driveshaft Leave approximately 1 16 2mm of nut threads exposed Driveshaft threads MUST NOT extend beyond nut or thread damage could result while pressing 3 Place bearing over driveshaft Sport M...

Page 596: ...ue to insert driveshaft into gear housing until driveshaft tapered bearing is against bearing race 9 Place a small amount of Loctite 271 onto threads of pinion gear nut and install flat washer and nut...

Page 597: ...him thickness IMPORTANT Reverse gear assembly must be installed in gear housing when checking pinion gear depth or an inaccurate measurement will be obtained 1 Clean gear housing bearing carrier shoul...

Page 598: ...Forward Gear Backlash following 11 If clearance is not correct add or subtract shims at location shown to raise or lower pinion gear When reinstalling pinion nut apply Loctite 271 on threads of nut an...

Page 599: ...t assembly into gear case It is not necessary to reinstall the pinion gear for this procedure 6 Install the upper driveshaft bearing cup and install and torque the upper bearing retainer to 100 lb ft...

Page 600: ...not yet been determined do not use a new pinion nut until final assembly 14 Apply 271 Loctite to a NEW pinion nut and install the pinion gear washer and nut using procedures detailed earlier in this...

Page 601: ...e replaced before returning gear case to service 10 Remove Driver Tool Pilot Ring Retainer and Screw from gear case Forward Gear DETERMINING FORWARD GEAR BACKLASH NOTE Propeller Shaft 44 93003 is for...

Page 602: ...to hold the propeller shaft from moving when measuring backlash NOTE Bearing Preload Tool 91 44307A1 should still be installed from having previously been used to determine pinion gear depth and reve...

Page 603: ...der PVC pipe forward gear assembly bearing adaptor bearing carrier and test propeller shaft can all be removed from the gear case Propeller Shaft Forward Gear Bearing Adapter Bearing Carrier REASSEMBL...

Page 604: ...g rollers against the flange of the prop shaft or sever damage will occur 3 Install thrust bearing and thrust washer onto propeller shaft Sport Master Gear Cases Install thrust bearing onto propeller...

Page 605: ...daptor into bearing carrier a b 51885 a Forward Gear Bearing Adaptor b Bearing Carrier 5 Install thrust washer and O ring onto bearing adaptor Lubricate O ring with 2 4 C w Teflon Marine Lubricant 92...

Page 606: ...Actuator Rod Sub Assembly Sequence a Retaining Pin b Shim Washer s c Compression Springs d Clutch Actuator Rod a b c d e c f g Clutch Actuator Rod Assembly a Retaining Pin b Shim Washer c Compression...

Page 607: ...ng with lip of seal up 4 Wipe any excess Loctite from oil seal and bushing 5 Place rubber washer against oil seal 6 Install O ring over threads and up against shoulder of bushing 7 Lubricate O ring an...

Page 608: ...port Master models use a slotted cross pin 91 86642 1 and Cross Pin Handle 91 86642 2 to assemble clutch onto propshaft Turn handle COUNTERCLOCKWISE to install cross pin and thread pin into sliding cl...

Page 609: ...ach other b a a Cross Pin Tang b Spring One on Each Side of Cross Pin Tang 8 Place gear housing in a soft jaw vise with the driveshaft in a vertical position 9 Coat cam pocket of cam follower with 2 4...

Page 610: ...s aligned with gear housing key way and install bearing carrier key 17 Place tab washer against bearing carrier 51885 a a Tab Washer IMPORTANT Ensure that the V shaped tab on cover nut tab washer loca...

Page 611: ...eter of oil seal c With a suitable mandrel press the smaller diameter oil seal into pump base with lip of oil seal toward impeller side of base d With a suitable mandrel press the larger diameter oil...

Page 612: ...7 7 Slide impeller down driveshaft to impeller drive key Align drive key with key way in the center hub of impeller and slide impeller over drive key 8 If removed install new water pump insert into pu...

Page 613: ...housing 1 Tilt engine to full up position and engage the tilt lock lever 2 Apply a light coat of Quicksilver 2 4 C w Teflon Marine Lubricant onto driveshaft splines CAUTION DO NOT allow lubricant on t...

Page 614: ...anti cavitation plate Torque to listing in Torque Specifications preceding 15 Install special flat washer and nut on stud at leading edge of driveshaft housing Torque to listing in Torque Specificati...

Page 615: ...osen nut to align tabs CAUTION DO NOT misinterpret propeller shaft movement with propeller movement If propeller and propeller shaft together move forward and aft this is normal however propeller shou...

Page 616: ...C 6 LOWER UNIT MERCURY XR6 MARINER MAGNUM III GEAR HOUSING...

Page 617: ...pection 6C 17 Shift Shaft Bushing and Cam 6C 18 Shift Shaft Removal 6C 18 Shift Shaft Bushing CamCleaning and Inspection 6C 18 Shift Shaft and Bushing Disassembly 6C 18 Gear Housing 6C 18 Cleaning and...

Page 618: ...r on line mark 1 0 030 in to 0 050 in 0 762mm to 1 27mm Gearcase Lubricant Capacity 1 78 1 Ratio 21 0 fl oz 621 0ml Special Tools Pinion Gear Locating Tool 91 12349A2 Pilot 91 36571 74187 Bearing Prel...

Page 619: ...s kit contains the following tools Pilot 91 36571 Puller Rod 91 31229 Nut 11 24156 Puller Plate 91 29310 Mandrel 91 38628 and Driver Rod 91 37323 70615 Mandrel 91 38628 74193 Driver Rod 91 37323 74184...

Page 620: ...9 Slide Hammer Puller 91 34569A1 73655 Universal Puller Plate 91 37241 73652 Bearing Retainer Tool 91 43506 73600 Bearing Carrier Removal Tool 91 46086A1 and Puller Bolt 91 85716 73599 Dial Indicator...

Page 621: ...h Teflon 92 825407A12 1 14 10 4 14 11 5 2 38 39 40 41 42 43 16 17 18 12 7 3 8 6 9 13 15 20 21 22 23 19 24 26 25 31 30 28 27 33 34 29 37 32 33 36 35 Perfect Seal 92 34227 1 19 95 95 95 95 95 95 95 95 9...

Page 622: ...N GEAR 14 2 WASHER 15 1 NUT Included With Forward Gear Set 80 108 5 16 AR SHIM SET 17 1 ROLLER BEARING 18 2 RETAINER 100 135 5 19 1 WATER PUMP BASE 20 1 GASKET 21 1 O RING 22 1 OIL SEAL 23 1 OIL SEAL...

Page 623: ...Super Duty Gear Lubricant 92 13783A24 94 Anti Corrosion Grease 92 78376A6 95 2 4 C With Teflon 92 825407A12 1 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 62 60 61 63 64 65 66 67 68 69 70 71 72 73...

Page 624: ...ERED ROLLER BEARING 49 1 FORWARD GEAR 50 1 ROLLER BEARING 51 1 CLUTCH 52 1 CROSS PIN 53 1 SPRING 54 1 PROPELLER SHAFT 55 1 REVERSE GEAR 56 1 THRUST WASHER 57 1 O RING 58 1 BEARING CARRIER ASSEMBLY 59...

Page 625: ...his may cause bearing to score from lack of lubrication After cleaning lubricate bearings with Quicksilver Gear Lube DO NOT lubricate tapered bearing cups until after inspection Inspect all bearings f...

Page 626: ...haft housing Using a 12 point socket un thread bolt that secures anodic plate gear housing and remove tab It is not necessary to remove bolt at this time 6 Once anodic plate is removed remove bolt fro...

Page 627: ...for metal particles A small amount of metal fuzz on magnet is normal A large amount of metal fuzz or the presence of metal chips on the mag net indicate the need for complete disassembly and inspecti...

Page 628: ...t water pump cover and insert as outlined in Cleaning and Inspection following 51874 6 If inspection of water pump insert determines that replacement is required follow Step a or b immediately followi...

Page 629: ...TANT When completing gear housing re pairs that require removal of water pump impel ler it is recommended that the impeller be re placed It it is necessary however to re use impeller DO NOT install in...

Page 630: ...Propeller Shaft Cleaning and Inspection following 4 Inspect the reverse gear to pinion gear wear pattern If it is not even and smooth replace the reverse gear and pinion gear 5 Check clutch jaws on r...

Page 631: ...onding needle bearing if any of the above conditions are found Bearing carrier needle bearing contacts propeller shaft just in front of oil seal surface Forward gear bearing contacts propeller shaft i...

Page 632: ...utch DO NOT over stretch spring 4 Push against cam follower Use a punch or awl to push cross pin out of sliding clutch 5 Release pressure against cam follower 6 Tip propeller shaft to allow cam follow...

Page 633: ...spin while drying 2 Inspect pinion gear for pitting grooves scoring uneven wear and or discoloration from overheating Replace pinion gear if any of the above conditions are found 3 Inspect driveshaft...

Page 634: ...ehind bearing race a b 51865 a Slide Hammer b Tapered Bearing Race 3 If inspection determines that replacement of propeller shaft needle bearing in forward gear is required refer to Cleaning and Inspe...

Page 635: ...nd or corrosion damage on upper and lower splines 4 Inspect shift shaft bushing for corrosion damage 5 Inspect shift shaft bushing oil seal for wear or cuts NOTE If shift shaft bushing is equipped wit...

Page 636: ...surface refer to CLEANING and INSPECTION following determines that replacement of needle bearing is required remove bearing from gear housing following 2 Remove forward gear from gear housing 3 Using...

Page 637: ...g gear housing MUST BE REPLACED as reinstalling new bearing in old housing will result in repeat bearing failure Reassembly and Installation Driveshaft Needle Bearing INSTALLATION EARLY MODEL 50737 EA...

Page 638: ...must be replaced Loose fitting needle bearing will move out of position and cause repeated failures 1 Apply a thin coat of Quicksilver 2 4 C w Teflon Marine Lubricant to driveshaft needle bearing bor...

Page 639: ...e of cam reverse ramp must be toward left side of gear housing fill screw hole side 10 Place lower shift shaft short spline end into shift shaft cavity Rotate shift shaft to engage splines into spline...

Page 640: ...ust washer has a tapered outside diameter so that one side is larger than the other The smaller diameter of washer must be toward bearing carrier b Place thrust washer onto bearing carrier with the sm...

Page 641: ...r Cup 91 31106 over tapered bearing race NOTE A used propeller shaft is recommended for use in Step 11 11 Place propeller shaft into hole in center of bearing driver cup NOTE The bearing carrier is us...

Page 642: ...ring onto shaft until seated 5 Remove used pinion nut from driveshaft a b c d e 50064 a Used Pinion Nut b Driveshaft c Tapered Bearing d Old Bearing Inner Race e Universal Puller Plate 91 37241 6 Inst...

Page 643: ...ing any change in shim thickness IMPORTANT Forward gear assembly must be installed in gear housing when checking pinion gear depth or an inaccurate measurement will be obtained 1 Clean the gear housin...

Page 644: ...is correct leave Bearing Preload Tool on driveshaft and proceed to Determining Forward Gear Backlash following 11 If clearance is not correct add or subtract shims at location shown to raise or lower...

Page 645: ...earing Preload Tool 91 14311A1 on driveshaft refer to Determining Pinion Gear Depth preceding 3 Install components as shown a d e c 51867 b a Propeller Shaft Horizontal Position b Bearing Carrier Asse...

Page 646: ...b washer toward front of gear housing NOTE Reverse gear backlash is not adjustable However reverse gear backlash which should be 0 030 0 048 0 76mm 1 21 mm can be mea sured to determine proper assembl...

Page 647: ...er pump base 4 Lubricate O ring and oil seals with 2 4 C w Teflon Marine Lubricant 92 90018A12 5 Install a new water pump base gasket and install water pump base a d b c 51866 a Water Pump Base b Gask...

Page 648: ...otate driveshaft in a clockwise direction viewed from top while pushing down on pump cover to ease impeller entry into cover 14 Install water pump cover retainer washers nuts and bolt CAUTION DO NOT o...

Page 649: ...ated on either side of driveshaft housing Start nut on these studs and tighten finger tight 10 Start bolt at rear of gear housing inside anodic plate recess DO NOT tighten bolt at this time 11 Recheck...

Page 650: ...ut in tab washer groove 5 Thread propeller nut onto propeller shaft 6 After propeller nut is recessed into tab washer tighten nut securely minimum of 55 Ib ft 74 5 N m torque 7 Bend 3 of the tabs of t...

Page 651: ...D 6 LOWER UNIT E Z SHIFT GEAR HOUSING NON RATCHETING STANDARD ROTATION STARTING S N 0G438000...

Page 652: ...ing and Inspection 6D 20 Pinion Gear and Driveshaft 6D 20 Removal 6D 20 Cleaning and Inspection 6D 21 Forward Gear 6D 22 Removal and Disassembly 6D 22 Cleaning and Inspection 6D 22 Gear Housing 6D 23...

Page 653: ...n to 0 050 in 0 762mm to 1 27mm 2 3 1 13 30 teeth 0 025 in 0 635mm With Tool 91 12349A2 using Disc 2 and Flat 7 0 018 in to 0 023 in 0 46mm to 0 58mm Pointer on line mark 4 0 030 in to 0 050 in 0 762m...

Page 654: ...1 31229 and Nut 91 24156 Puller Plate 91 29310 74190 Mandrel 91 38628 74193 Driver Rod 91 37323 74184 Universal Puller Plate 91 37241 73652 Cross Pin Tool 91 86642 Driveshaft Holding Tool 91 34377A1 5...

Page 655: ...JUNE 2002 LOWER UNIT 6D 3 Bearing Driver Cup 91 31106 Pinion Locating Gear Tool 91 12349A2 or 91 74776 55079 Backlash Indicator Rod 91 78473 Dial Indicator 91 58222A1 73429 Bearing Retainer Tool 91 4...

Page 656: ...Preload Tool 91 14311A1 a b c d e f g h a Adaptor N S S b Bearing N S S c Washer N S S d Spring 24 14111 e Bolt 10 12580 f Nut 11 13953 g Set Screw 10 12575 h Sleeve 23 13946 Mandrel 91 92788 Dial Ind...

Page 657: ...90 824052R3 JUNE 2002 LOWER UNIT 6D 5 Notes...

Page 658: ...15 16 17 18 19 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 11 20 10 19 43 95 2 4 C With Teflon 92 825407A12 109 GM Silicone Sealer 92 91600 1 7 92 33 33 95 95 95 9...

Page 659: ...ASHER 15 1 NUT Included With Forward Gear Set 75 102 16 AR SHIM SET 17 1 SCREW drain MAGNETIC 55 6 0 18 1 SCREW grease filler 55 6 0 19 2 WASHER 20 1 STA STRAP 21 1 SHIFT SHAFT 22 1 O RING 23 1 BUSHIN...

Page 660: ...00 UP 1 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 81 A B 87 Super Duty Gear Lubricant 92 13783A24 94 Anti Corrosion Grease 92 78376A6 95 2 4...

Page 661: ...LER SHAFT 60 1 REVERSE GEAR XR6 MAG III 175 200 1 87 1 15 28 60 1 REVERSE GEAR 135 150 2 0 1 14 28 61 1 THRUST SPACER 62 1 THRUST RING 63 1 BALL BEARING 64 1 O RING 65 1 BEARING CARRIER ASSEMBLY 66 1...

Page 662: ...om 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 bea...

Page 663: ...lock lever 4 Bend tabs of propeller tab washer away from thrust hub rear then remove propeller locknut tab washer thrust hub rear propeller and thrust hub forward from propeller shaft a b 51866 c d d...

Page 664: ...on 2 Position a clean drain pan under gear housing and remove Fill and Vent screws from gear housing b a 51871 a Fill Screw b Vent Screw 3 Inspect gear lubricant for metal particles Presence of a smal...

Page 665: ...appearance caused by operation without sufficient water supply Replace impeller if any of these conditions exist IMPORTANT It is recommended that all seals and gaskets be replaced as a normal repair...

Page 666: ...rom water pump base 10 Using 2 pry bars positioned and padded as shown lift water pump base up and off driveshaft 51874 a a Pads 11 Remove and discard O ring from O ring groove on water pump base 12 U...

Page 667: ...er is removed from gear housing extreme care MUST BE taken not to apply any side force on propeller shaft Side force on propeller shaft may break the neck of the clutch actuator rod 6 Use long Puller...

Page 668: ...in Step 8 immediately preceding b Push propeller shaft back into place against forward gear Slide bearing carrier back into gear housing to support propeller shaft Place gear housing on its left side...

Page 669: ...ing from between bear ing carrier and thrust washer 2 If inspection of reverse gear or reverse gear bearing determines that replacement of gear or bearing is required remove gear and bearing as follow...

Page 670: ...ng carrier needle bearing contacts propeller shaft just in front of oil seal surface Forward gear bearing contacts propeller shaft in front of sliding clutch splines 4 Inspect propeller shaft splines...

Page 671: ...coil of cross pin retainer spring and rotate propeller shaft to unwind spring from sliding clutch DO NOT over stretch spring b a 51864 a Awl b Cross Pin Retainer Spring CAUTION Detent pin is free and...

Page 672: ...handle to hold pinion nut Pad area of gear housing where flex handle will make contact to prevent damage to gear housing 4 Use a socket and flex handle on Driveshaft Holding Tool to loosen pinion nut...

Page 673: ...1869 a Mandrel 91 37263 b Pilot 91 36571 c Driver Rod 91 37323 From Bearing Removal and Installation Kit 91 31229A5 CLEANING AND INSPECTION 1 Clean driveshaft tapered bearing and race and pinion gear...

Page 674: ...241 between forward gear and tapered bearing b Place forward gear bearing and puller plate on a press and press gear out of bearing with a suitable mandrel b a 51870 a Universal Puller Plate b Mandrel...

Page 675: ...lation Standard Rotation Driveshaft Needle Bearing REASSEMBLY INSTALLATION CAUTION If driveshaft needle bearing failure has occurred and original bearing race has turned in the gear housing gear housi...

Page 676: ...and that bearing is firm against gear b a 51873 a Thrust Washer b Mandrel 6 Apply a light coat of Quicksilver Super Duty Gear Lubricant onto outside diameter of propeller shaft needle bearing 7 Place...

Page 677: ...ween bearing carrier and thrust washer 16 Lubricate oil seals and O ring with Quicksilver 2 4 C w Teflon Marine Lubricant Forward Gear REASSEMBLY 1 Place forward gear on a press with gear teeth down 2...

Page 678: ...bore in front portion of gear housing 4 Place Bearing Driver Cup 91 87120 over tapered bearing race NOTE A used propeller shaft is recommended for use in Step 5 If it is necessary however to use the p...

Page 679: ...w drive shaft bore with teeth of pinion gear meshed with teeth of forward gear 6 Insert driveshaft into driveshaft bore while holding pinion gear Rotate driveshaft to align and engage driveshaft splin...

Page 680: ...e Nut to 75 lb ft 101 5 N m c Socket d Breaker Bar IMPORTANT Wipe any excess Loctite from pinion nut and pinion gear Pinion Gear Depth Forward Gear Backlash Reverse Gear Backlash DETERMINING PINION GE...

Page 681: ...e Bearing Preload Tool on driveshaft and proceed to Determining Forward Gear Backlash following 11 If clearance is not correct add or subtract shims at location shown to raise or lower pinion gear Whe...

Page 682: ...eeth on pinion gear or on line marked 4 if gear ratio is 2 3 1 13 teeth on pinion gear 51880 d e a b c a Thread Stud Adaptor from 91 14311A1 b Stud c Backlash Indicator Tool 91 78473 d Dial Indicator...

Page 683: ...veshaft Dial indicator should show backlash of 0 030 0 050 0 762mm 01 27mm If backlash is not as indicated gear case is not properly assembled or parts are excessively worn and must be replaced before...

Page 684: ...Hole d Detent Hole Behind Finger and Thumb e Detent Notch One on Each Side f Cross Pin Slot 3 Insert cross pin thru sliding clutch propeller shaft and actuator rod forcing cross pin tool out a 51864...

Page 685: ...ilver 2 4 C w Teflon Marine Lubricant to threads of shift shaft bushing Thread bushing into position but do not tighten down at this time a b 51867 a Shift Shaft Bushing b Shift Shaft 13 Lubricate O r...

Page 686: ...ater pump base on a press b Just before installing each seal apply Loctite 271 on outside diameter of oil seal c With a suitable mandrel press the smaller diameter oil seal into pump base with lip of...

Page 687: ...peat Steps 6 and 7 7 Slide impeller down driveshaft to impeller drive key Align drive key with keyway in the center hub of impeller and slide impeller over drive key 8 If removed install new water pum...

Page 688: ...lt engine to full up position and engage the tilt lock lever 2 Apply a light coat of Quicksilver 2 4 C w Teflon Marine Lubricant onto driveshaft splines CAUTION DO NOT allow lubricant on top of drives...

Page 689: ...ifications preceding 15 Install special flat washer and nut on stud at lead ing edge of driveshaft housing Torque to listing in Torque Specifications preceding 16 Torque bolt started in Step 10 to lis...

Page 690: ...opeller shaft movement with propeller movement If propeller and propeller shaft together move forward and aft this is normal however propeller should not move forward and aft on propeller shaft 9 Afte...

Page 691: ...E 6 LOWER UNIT E Z SHIFT COUNTER ROTATING GEAR HOUSING NON RATCHETING LEFT HAND ROTATION STARTING S N 0G438000...

Page 692: ...ction 6E 22 Pinion Gear and Driveshaft 6E 23 Removal 6E 23 Cleaning and Inspection 6E 25 Reverse Gear 6E 25 Removal and Disassembly 6E 25 Cleaning and Inspection 6E 26 Gear Housing 6E 27 Cleaning and...

Page 693: ...ing Disc 2 and Flat 7 0 015 in to 0 022 in 0 38mm to 0 56mm Pointer on line mark 2 0 030 in to 0 050 in 0 762mm to 1 27mm Gearcase Lubricant Capacity All Ratios 21 0 fl oz 650 0ml Special Tools Shift...

Page 694: ...Puller Rod 91 31229 and Nut 91 24156 Puller Plate 91 29310 74190 Mandrel 91 38628 74193 Driver Rod 91 37323 74184 Universal Puller Plate 91 37241 73652 Driveshaft Holding Tool 91 34377A1 55079 Oil Sea...

Page 695: ...Locating Gear Tool 91 12349A2 or 91 74776 55079 Backlash Indicator Rod 91 78473 Dial Indicator 91 58222A1 73429 Bearing Retainer Tool 91 43506 73600 Mandrel 91 92788 Dial Indicator Holder 91 89897 Fo...

Page 696: ...e Bolt 10 12580 f Nut 11 13953 g Set Screw 10 12575 h Sleeve 23 13946 Propeller Shaft 44 93003 and Load Washer a 12 37429 51876 a Reverse Gear Installation Kit 91 18605A1 includes Pilot 91 18603 Reta...

Page 697: ...90 824052R3 JUNE 2002 LOWER UNIT 6E 5 Notes...

Page 698: ...14 15 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 34 35 36 37 38 39 40 41 42 44 45 46 47 7 16 43 19 10 43 7 Loctite 271 92 809820 Loctite 680 92 809833 33 95 2 4 C With Teflon 92 825407A12 109 GM Si...

Page 699: ...15 1 NUT Included With Forward Gear Set 75 102 16 AR SHIM SET 17 1 SCREW drain MAGNETIC 55 6 0 18 1 SCREW grease filler 55 6 0 19 2 WASHER 20 1 STA STRAP 21 1 SHIFT SHAFT 22 1 O RING 23 1 BUSHING ASS...

Page 700: ...1 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 71 70 69 7 Loctite 271 92 809820 95 2 4 C With Teflon 92 825407A12 87 Super Duty...

Page 701: ...ER 55 1 THRUST BEARING 56 1 REVERSE GEAR 135 150 56 1 REVERSE GEAR 175 200 57 1 ROLLER BEARING 58 1 SPRING 59 1 SLIDING CLUTCH 60 1 CROSS PIN 61 1 DETENT PIN 62 1 PROPELLER SHAFT 63 1 FORWARD GEAR 135...

Page 702: ...52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 71 70 69 7 Loctite 271 92 809820 95 2 4 C With Teflon 92 825407A12 87 Super Duty G...

Page 703: ...UST WASHER 70 2 THRUST BEARING 71 2 THRUST RACE 72 2 KEEPER 73 1 O RING 74 1 BEARING CARRIER ASSEMBLY 75 1 ROLLER BEARING 76 1 OIL SEAL INSIDE 77 1 OIL SEAL OUTSIDE 78 1 TAB WASHER 79 1 KEY 80 1 COVER...

Page 704: ...ng 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 c...

Page 705: ...ar housing 2 Shift engine into NEUTRAL position 3 Tilt engine to full up position and engage tilt lock lever 4 Bend tabs of propeller tab washer away from thrust hub rear then remove propeller locknut...

Page 706: ...able holding fixture or vise with the driveshaft in a vertical position as shown 2 Position a clean drain pan under gear housing and remove Fill and Vent screws from gear housing 3 Inspect gear lubric...

Page 707: ...appearance caused by operation without sufficient water supply Replace impeller if any of these conditions exist IMPORTANT It is recommended that all seals and gaskets be replaced as a normal repair...

Page 708: ...h gaskets one above and below face plate from water pump base 10 Using 2 pry bars positioned and padded as shown lift water pump base up and off driveshaft 51874 a a Pads 11 Remove and discard O ring...

Page 709: ...me care MUST BE taken not to apply any side force on propeller shaft Side force on propeller shaft may break the neck of the clutch actuator rod 6 Use long Puller Jaws 91 46086A1 and Puller Bolt 91 85...

Page 710: ...assembly bear ing adaptor thrust washer and thrust bearings will be removed from gearcase with propeller shaft 51877 9 If propeller shaft will not come out proceed with Step a or b following a Push pr...

Page 711: ...sure effective repair CAUTION DO NOT spin bearings dry with compressed air as this could cause bearing to score 1 Clean bearing carrier assembly with solvent and dry with compressed air 2 Bearing carr...

Page 712: ...aring contacts propeller shaft in front of sliding clutch splines 4 Inspect propeller shaft splines for wear and or corrosion damage 5 Check propeller shaft for straightness Use either method followin...

Page 713: ...one or more of the following a Improper shift cable adjustment b Improper shift habits of operator s shift from neutral to reverse gear or forward gear too slowly c Engine idle speed too high while sh...

Page 714: ...ard gear from bearing adapter 2 Inspect forward gear clutch teeth for signs of wear If clutch teeth are worn sliding clutch should be replaced also 3 Inspect forward gear teeth for full tooth contact...

Page 715: ...bearing surfaces on the thrust washer and propeller shaft where the thrust roller bearing rides should also be inspected for signs of wear c b a 55090 a Thrust Bearing b Thrust Washer c Bearing Adapto...

Page 716: ...d on gear housing mating surface Use a mallet and carefully tap gear housing away from driveshaft CAUTION DO NOT strike gear housing hard with the mallet or allow gear housing to fall 51878 a b a Wood...

Page 717: ...t needle bearing surface area just above pinion gear splines for pitting grooves scoring uneven wear and or discolor ation from overheating Replace driveshaft and driveshaft needle bearing if any of t...

Page 718: ...grooves scoring uneven wear and for discoloration from over heating Replace gear if any of these conditions are found 3 Check clutch jaws on reverse gear for damage Replace reverse gear if damage is...

Page 719: ...ON If driveshaft needle bearing failure has occurred and original bearing race has turned in the gear housing gear housing must be replaced Loose fitting needle bearing will move out of position and c...

Page 720: ...755 b Bearing Carrier Needle Bearing c Bearing Carrier d Shoulder 2 Apply Loctite 271 92 809820 to outside diameter of oil seals 3 With seal lip facing towards bearing press inner seal a using long en...

Page 721: ...identical There are two ways to distinguish between the reverse and forward gears The reverse gear has a shorter hub and it has a smaller inner diameter needle bearing bore 50885 d a b c a Reverse Ge...

Page 722: ...ring Adaptor b Shims 4 Position the reverse gear without the thrust race or thrust bearing into the gear housing and into the adaptor a 55100 a Reverse Gear 5 Install PILOT RING 91 18603 over DRIVER T...

Page 723: ...ed Driveshaft threads MUST NOT extend beyond nut or thread damage could result while pressing 3 Place bearing over driveshaft 4 Using an old driveshaft bearing inner race or other suitable mandrel whi...

Page 724: ...Bar IMPORTANT Wipe any excess Loctite from pinion nut and pinion gear Pinion Gear Depth DETERMINING PINION GEAR DEPTH NOTE Read entire procedure before attempting any change in shim thickness IMPORTAN...

Page 725: ...shimming tool 9 Clearance between shimming tool and pinion gear should be 0 025 0 64mm 10 If clearance is correct leave Bearing Preload Tool on driveshaft for Determining Forward Gear Backlash followi...

Page 726: ...tor Tool if gear ratio is 1 87 1 15 teeth on pinion gear or on line marked 2 on Backlash Indicator Tool if gear ratio is 2 1 14 teeth on pinion gear 8 Lightly turn driveshaft back and forth no movemen...

Page 727: ...washer and nut 51882 a d f h c b e i j k g a Prop Nut b Flat Washer c PVC Pipe 5 x 2 127mm x 50 8mm d Cover Nut e Tab Washer f Bearing Carrier g Prop Shaft h Bearing Adaptor i Shim j Forward Gear k Lo...

Page 728: ...HP models with 1 87 1 Ratio 0 018 to 0 027 0 46mm 0 69mm backlash 135 and 150 HP models with 2 00 1 Ratio 0 015 to 0 022 0 38mm 0 56mm backlash 12 If backlash is less than the specifications then a la...

Page 729: ...r 2 4 C w Teflon Lubricant on actuator rod and install cam follower b a a Actuator Rod b Cam Follower 3 Slide clutch actuator assembly into propeller shaft Align cross pin slot in actuator rod with cr...

Page 730: ...t cam into cam pocket of cam follower with numbered side of cam facing up b a c 55095 a Cam Pocket b Cam Follower c Shift Cam 10 Slide propeller shaft assembly into reverse gear assembly b a 55096 a S...

Page 731: ...t Forward Gear Installation Tool 91 815850 into forward gear bearing adaptor assembly a b 55221 a Forward Gear Installation Tool 91 815850 b Forward Gear Bearing Adaptor Assembly 16 Install tool with...

Page 732: ...its STEPPED SIDE DOWN toward the small thrust bearing a b 55109 a Thrust Collar b Thrust Bearing 20 Pull up slightly on the propeller shaft to gain access to the groove on the shaft for the keepers I...

Page 733: ...ce inside of the bearing carrier a b 50779 a Thrust Race b Bearing Carrier Race Surface 24 Apply Quicksilver 2 4 C w Teflon Marine Lubricant to bearing carrier O ring Install O ring onto bearing adapt...

Page 734: ...gear case should either be mounted in a stand specifically designed for holding gear cases or bolted to a driveshaft housing to avoid possible damage to the gear case 31 Using Cover Nut Tool 91 61069...

Page 735: ...if removed Use RTV Sealer to seal seams between divider block and gear housing a 51878 a Divider Block 4 Install a new water pump base gasket and install water pump base c a b 51866 a Water Pump Base...

Page 736: ...to aid in removal of insert fill holes with RTV Sealer or equivalent Allow to cure 24 hours prior to operating engine 9 Install water tube seal into pump cover Plastic side of seal goes into cover fi...

Page 737: ...es DO NOT allow lubricant on top of shift shaft 4 Apply a thin bead of G E Silicone Sealer 92 90113 2 against the top of divider block 5 Insert trim tab bolt into hole in rear of gear hous ing to driv...

Page 738: ...r installing nut 1 To aid in future removal of the propeller liberally coat the propeller shaft splines with one of the following Quicksilver products Anti Corrosion Grease 92 78376A6 Special Lubrican...

Page 739: ...opeller nut and again secure with tab washer Steps 7 and 8 preced ing Propeller should be checked periodically for tightness particularly if a stainless steel propeller is used 51916 a c d b a Continu...

Page 740: ...6 F JET OUTBOARDS...

Page 741: ...Shift Cable Installation Jet 105 and 140 6F 8 Lubricating the Driveshaft Bearing 6F 9 Impeller Removal and Installation 6F 9 Steering Pull Adjustment 6F 11 Impeller Clearance Adjustment 6F 11 Worn Du...

Page 742: ...90 824052R3 JUNE 2002 JET OUTBOARDS 6F 1 Notes...

Page 743: ...6F 2 JET OUTBOARDS 90 824052R3 JUNE 2002 Jet Pump Assembly 1 2 3 4 6 7 8 9 10 11 12 13 14 17 18 19 20 21 22 23 24 25 26 27 7 21 95 2 4 C With Teflon 92 825407A12 95 5 4 4 15 16...

Page 744: ...W 4 1 HOUSING Intake S N 0G605662 UP 4 1 HOUSING Intake S N 0G605661 BELOW 5 1 LINER S N 0G605662 UP 6 1 LINER S N 0G605661 BELOW 7 1 SHAFT Drive S N 0G605662 UP 7 1 SHAFT Drive S N 0G605661 BELOW 8 1...

Page 745: ...ft N m 1 3 SCREW 190 32 x 1 62 30 3 5 2 3 WASHER 3 3 BUSHING 4 1 PLATE 5 1 REV LIMITER 6 1 HARNESS Adaptor rev limiter 7 1 GREASE KIT 8 1 WATER PUMP BASE 9 1 GASKET 10 1 OIL SEAL 11 1 OIL SEAL 12 1 GA...

Page 746: ...iderably more depth than one which is planing on the surface of the water It is important therefore to use sufficient horsepower and not to overload your boat beyond its ability to plane See the follo...

Page 747: ...allow the water intake to suck in air and cause cavitation cavitation will cause the engine to overspeed in spurts and reduce thrust This condition should be avoided by proper height setting Installi...

Page 748: ...n order to provide a scooping angle on the water intake Tilting the outboard out beyond a vertical position reduces the scoop angle and can cause impeller slippage and cavitation If the angle of the b...

Page 749: ...jury or death 1 Attach shift cable a to the shift cam b with flat washer and locknut as shown Tighten locknut against the flat washer then back off the locknut 1 4 turn 2 Place remote control handle i...

Page 750: ...nt hose a onto the grease fitting after greasing After 30 hours of operation pump in extra grease to purge out any moisture Visually inspecting the purged grease at this time will give you an indicati...

Page 751: ...ld be 0 030 in 0 8 mm Shim washers can be transferred to either side of the impeller to raise or lower the impeller to the correct clearance setting The water intake housing can be shifted side ways a...

Page 752: ...tween the impeller edge and liner If adjustment is required refer to Impeller Removal and Installation 03 in 8mm a a Shims Worn Dull Impeller leading edge Do Not sharpen or alter the top side lifting...

Page 753: ...e liner into the water intake housing Line up one of the liner bolts and lightly thread it in It may be necessary to tap or press the liner into the water intake housing to locate the liner for instal...

Page 754: ...p cover Rotate driveshaft CLOCK WISE while pressing cover down over impeller 95 2 4 C With Teflon 92 825407A12 95 h e g c j k i f d a b l m a Bolt and Flat Washer Apply Loctite 271 to threads Torque t...

Page 755: ...g Bearing Carrier Reassembly Installing Seals Install seals into bearing carrier as follows 1 Install O ring seals a into the top seats of the three passage holes 2 Install spiral retaining ring b int...

Page 756: ...hole drilled in the ring groove 5 Press in the outer seal against the retaining ring as shown 6 Grease all the seal lips 7 Grease the two O ring seals e and install then into the outer ring grooves IM...

Page 757: ...a until it feels warm to the touch 4 Place the bearing carrier a onto the driveshaft Square up the inner bore with the ball bearings and push the bearing carrier down until it bottoms out against the...

Page 758: ...up 3 Install the upper seal housing b being careful not to damage the O ring seals as they pass the snap ring groove Only finger pressure should be necessary to push in the housing 4 Install the beve...

Page 759: ...7 ATTACHMENTS CONTROL LINKAGE...

Page 760: ...Super RideGuide Steering Kit Installation 7 20 Steering Cable Installation Starboard Outboard 7 20 Steering Cable Installation Port Outboard 7 21 Steering Link Rod Installation 7 22 Page Steering Arm...

Page 761: ...ing the height of outboard generally will provide the following 1 Less steering torque 2 more top speed 3 greater boat stability but 4 will cause more prop break loose which may be particularly notice...

Page 762: ...64cm IMPORTANT The optimum height for each application will need to be determined by individual boat testing Some generalities may apply when increasing the transom height More top speed Greater boat...

Page 763: ...multiple production model V 6 product the following is recommended A minimum of 26 inches 660mm centerline to centerline width is recommended On high performance engines Pro Max Super Magnum models a...

Page 764: ...wling from outboard and plastic cap from center of flywheel Thread lifting eye a into flywheel hub a minimum of 5 turns Replace plastic cap after installation Connect hoist minimum lift capacity of 50...

Page 765: ...on IMPORTANT DO NOT use an impact driver when tightening transom bolts Apply marine sealer to shanks of mounting bolts not threads and secure outboard to transom with 4 bolts flat washers and locknuts...

Page 766: ...le Cable Single Production Outboard Refer to Quicksilver Accessories Guide to determine correct length of steering cable and remote control cables IMPORTANT Steering cable and remote control cables mu...

Page 767: ...right and that boat will turn left when steering wheel is turned left Check steering thru full range left and right and at all tilt angles to assure interference free movement Maintenance Instructions...

Page 768: ...wn in illustration could result in interference between steering cable nut and ends of mounting bolts when outboard is tilted up CAUTION Marine sealer must be used on shanks bolts to make a water tigh...

Page 769: ...bolts from turning out Install steering cable mounting tube into mounting bracket with 2 adjusting nuts and 2 locking tab washers Verify longer threaded end of tube is toward starboard side of boat Te...

Page 770: ...s to coupler Failure to adhere to this requirement could result in steering system failure Slide coupler a onto steering cable ends and secure each steering cable to coupler with bolt b and locknut c...

Page 771: ...oo much tension will cause steering cables to bind Perform the following steps to adjust for correct tension Loosen adjustment nuts and pull steering cable mounting tube by hand away from end of steer...

Page 772: ...r area is considered Severe Service 1 Carefully check steering system components for wear Replace worn parts 2 Check steering system fasteners to be sure that they are torqued to correct specification...

Page 773: ...ering cables 1 Parallel cable routing Cables routed together down starboard side of boat Refer to Parallel Routed Steering Cables and Attaching Kit Installation immediately following 2 Opposite side c...

Page 774: ...ent up and against flats on each bolt that secures mounting bracket for steering cable mounting tube to outboard swivel bracket to prevent bolts from turning out Install steering cable mounting tube i...

Page 775: ...TALLATION PORT OUTBOARD IMPORTANT Lubricate inside of port outboard s tilt tube and rubber O ring seal located inside tilt tube with 2 4 C w Teflon before installing steering cable Lubricate inside of...

Page 776: ...urn c Special Washer Head Bolt 10 14000 Torque to 20 lb ft 27 0 N m d Nylon Insert Locknut Torque to 20 lb ft 27 0 N m e Steering Link Rod f Steering Cable End Lubricate holes in ends of steering cabl...

Page 777: ...g arm extensions MUST BE equal to distance between propeller shaft centerlines Lubricate inside of rubber sleeves with 2 4 C w Teflon and slide sleeves on steering coupler Work rubber bushings onto th...

Page 778: ...n or out to correct alignment Torque special washer head bolts to 20 Ib ft 27 0 N m then torque locknuts to 20 Ib ft 27 0 N m WARNING Both steering eyes MUST BE threaded into coupler 3 4 in 19mm minim...

Page 779: ...necessary a b c d 51887 a Steering Cable Mounting Tube b Adjustment Nuts c Adjust Tube in This Direction to Remove Slack from Steer ing System d Adjust Tube in This Direction to Reduce Tension from S...

Page 780: ...and Against Flats on Each Bolt WARNING Locking retainer corner tabs MUST BE bent up and against flats on each bolt that secures mounting bracket for steering cable mounting tube to prevent bolts from...

Page 781: ...IMPORTANT Lubricate inside of port outboard s tilt tube and rubber O ring seal located inside tilt tube with 2 4 C w Teflon before installing steering cable Lubricate inside of port outboard s tilt tu...

Page 782: ...sert locknuts Tighten locknuts until they seat DO NOT exceed 120 lb in 13 5 N m of torque then back nut off 1 4 turn Lubricate ball joints in steering link rods with SAE 30W Motor Oil Secure link rods...

Page 783: ...g arm extensions MUST BE equal to distance between propeller shaft centerlines Lubricate inside of rubber sleeves with 2 4 C w Teflon and slide sleeves on steering coupler Work rubber bushings onto th...

Page 784: ...n or out to correct alignment Torque special washer head bolts to 20 Ib ft 27 0 N m then torque locknuts to 20 Ib ft 27 0 N m WARNING Both steering eyes MUST BE threaded into coupler 3 4 in 19 mm mini...

Page 785: ...nting Tube b Adjustment Nuts c Adjust Tube in This Direction to Remove Slack from Steering System d Adjust Tube in This Direction to Reduce Tension from Steering System After steering system tension i...

Page 786: ...2 If necessary adjust trim tab as follows a Shift outboard into NEUTRAL and make sure ignition key is at OFF position b Remove plastic cap from rear of driveshaft housing and loosen bolt and trim tab...

Page 787: ...ice 1 Carefully check steering system components for wear Replace worn parts 2 Check steering system fasteners to be sure that they are torqued to correct specifications NOTE RideGuide Steering Cables...

Page 788: ...o Centerline of Outboard f Pivot Attaching Locknut Torque to 20 lb ft 27 0 N m g Outboard Steering Arm h Clevis Kit i RideGuide Cable Attaching Locknut Torque to 10 lb ft 13 6 N m j Bolt 3 8 in x 2 1...

Page 789: ...kit positioned as outlined preceding use 3 holes in transom bracket as a guide and drill three 11 32 in 8 7mm holes thru transom 7 Use a marine type sealer on three 5 16 in x 3 1 4 in 7 9 mm x 82 6 m...

Page 790: ...ied preceding to be sure that they are torqued to correct specifications Figures 1 2 and 3 Clevis Attaching Kit Installation A 70599A2 NOTE This kit is used to attach RideGuide cable to outboard steer...

Page 791: ...ress on the cables Failure of remote control cables at high speeds could result in possible serious injury or death IMPORTANT Install control cables to remote control and mount remote control BEFORE a...

Page 792: ...bles thru clamp in bottom cowl at locations shown 1995 Models and Older Production Outboards d b c a 51889 a Remote Control Harness b Engine Harness c Harness Retainer d Wiring Clamp f d e g 50103 d W...

Page 793: ...f a Remote Control Wiring Harness b Engine Wiring Harness c RED Trim 12 Volt Power Supply d BLUE WHITE Trim UP Lead e GREEN WHITE Trim DOWN Lead f TAN Overheat Warning Lead g J Clamp Remote Control I...

Page 794: ...th shift cable retainer d g f 54074 d 9 Check shift cable adjustments as follows WARNING Remove spark leads from spark plugs to prevent accidental starting while working on engine NOTE Turn propeller...

Page 795: ...IMPORTANT Excessive pre load on throttle cable will cause difficulty when shifting from FORWARD to NEUTRAL Readjust throttle cable barrel if necessary a c d b 54075 Battery Connections CAUTION For du...

Page 796: ...efer to page 7 32 for proper routing of fuel hose thru clamp in bottom cowl a b a Fuel Hose b Hose Clamp PRODUCTION CARBURETOR MODELS 1 Connect fuel hose to T fitting as shown Secure with hose clamp 2...

Page 797: ...be mounted vertically with the electrical connections on top or sideways with the connections on either end DO NOT MOUNT PUMP VERTICALLY WITH THE ELECTRICAL CONNECTIONS ON THE BOTTOM 1 Install in lin...

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Mariner Mercury 105/140 JET, Service Manual

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