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Mariner 100 Service Manual Download Page 3

Cleanliness and Care of
Outboard Motor

A marine power product is a combination of many ma-
chined, honed, polished and lapped surfaces with tol-
erances that are measured in the ten thousands of an
inch. When any product component is serviced, care
and cleanliness are important. Throughout this
manual, it should be understood that proper cleaning,
and protection of machined surfaces and friction
areas is a part of the repair procedure. This is consid-
ered standard shop practice even if not specifically
stated.

Whenever components are removed for service, they
should be retained in order. At the time of installation,
they should be installed in the same locations and
with the same mating surfaces as when removed.

Before raising or removing an outboard engine from a
boat, the following precautions should be adhered to:

1. Check that flywheel is secured to end of

crankshaft with a locknut and lifting eye is
threaded into flywheel a minimum of 5 turns.

2. Connect a hoist of suitable strength to the lifting

eye.

In addition, personnel should not work on or under an
engine which is suspended. Engines should be at-
tached to work stands, or lowered to ground as soon
as possible.

We reserve the right to make changes to this manual
without prior notification.

Refer to dealer service bulletins for other pertinent in-
formation concerning the products described in this
manual.

Service Manual Outline

1

-

General Information and Specifications

2

-

Electrical and Ignition

A

-

Ignition System

B

-

Battery, Charging System and
Starting System

C

-

Timing/Synchronizing and Adjusting

D

-

Wiring Diagrams

3

A

-

Fuel System and Carburetion

B

-

Oil Injection System

4

A

-

Powerhead (3-Cylinder Engines)

B

-

Powerhead (4-Cylinder Engines)

5

-

Lower Unit

A

-

Gear Housing

B

-

Mid Section

C

-

Shock Absorber

6

-

Power Trim

A

-

Design I (Side Fill Reservoir)

B

-

Design II (Aft Fill Reservoir)

C

-

Single Ram

7

-

Outboard Motor Installation/Attachments

A

-

Engine Attachments/Engine Installation

B

-

Tiller Handle and Co-Pilot

Summary of Contents for 100

Page 1: ...GIUM CANADA S N 0B209468 thru 0D283221 S N 09523034 thru 09793576 S N 0A731673 and Above MODELS 70 75 80 90 100 115 SERVICE MANUAL 1987 1993 70 75 75 Marathon 75XD 75 Seapro 80 90 1988 1993 100 115 4 Cylinder with Serial Numbers with Serial Numbers UNITED STATES Printed in U S A 1995 Brunswick Corporation 90 13645 2 1095 ...

Page 2: ...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 that neither his nor the product s safety will be endangered by the service procedure selected All information illustrations and specifications con tained in this manual are based on the latest product information...

Page 3: ... locknut and lifting eye is threaded into flywheel a minimum of 5 turns 2 Connect a hoist of suitable strength to the lifting eye In addition personnel should not work on or under an engine which is suspended Engines should be at tached to work stands or lowered to ground as soon as possible We reserve the right to make changes to this manual without prior notification Refer to dealer service bull...

Page 4: ...GENERAL INFORMATION AND SPECIFICATIONS 1 ...

Page 5: ...1 5 Connecting Engine Wiring Harness and Routing of Engine Battery Cables 1 6 Ride Guide Steering Cable and Pivot Points Lubrication 1 7 Following Complete Submersion 1 8 Salt Water Submersion Special Instructions 1 8 Submerged While Running Special Instructions 1 8 Submerged Engine Fresh Water Plus Special Instructions 1 8 Out of Season Outboard Storage 1 9 How Weather Affects Engine Performance ...

Page 6: ...commended Power Trim Fluid Quicksilver Power Trim Steering Fluid or Automotive Transmission Fluid ATF Type F FA or Dexron II Recommended Gasoline Regular Leaded Premium Low Lead and Lead Free automotive gaso lines with a minimum pump posted octane rating of 86 Recommended Oil Quicksilver TC WII or TC W3 2 Cycle Outboard Oil Engine Weight ELO ELOPT 260 lbs 280 lbs Fuel Tank Capacity 6 6 U S Gallons...

Page 7: ...ver Power Trim Steering Fluid or Automotive Transmission Fluid ATF Type F FA or Dexron II Recommended Gasoline Regular Leaded Premium Low Lead and Lead Free automotive gaso lines with a minimum pump posted octane rating of 86 Recommended Oil Quicksilver 2 Cycle Outboard Oil Engine Weight ELO ELOPT 340 lbs 360 lbs Fuel Tank Capacity 6 6 U S Gallons 5 Imp Gals 25 Liters Gear Housing Lubricant Capaci...

Page 8: ...oard side of front shield a Remove spring b from latch and open cowls 18291 a 18292 b Filling Oil Injection System Open starboard cowl refer to cowl removal on this page Some earlier outboards will have a cowl brack et to hold cowl open as shown Fill tank with recommended oil a a Oil Tank Tube ...

Page 9: ...RIM WARNING Operating some boats with outboard trimmed to the full in trim angle not using trim adjustment bolt a at planing speed will cause undesirable and or unsafe steering conditions Each boat MUST BE water tested for handling characteristics after outboard installation and after any trim adjust ments IMPORTANT Some boat motor combinations that do not use the trim adjustment bolt a and are tr...

Page 10: ...ng speeds will cause undesirable and or unsafe steering conditions Each boat should be tested for handling characteristics after any adjustment is made to the tilt angle DO NOT OPERATE motor with tilt lock pin removed Adjust tilt angle of motor on transom with tilt lock pin so that anti ventilation plate is about parallel and even with bottom of boat Speed sometimes may be im proved by tilting mot...

Page 11: ... c a b c Models with Power Trim Models without Power Trim a Wiring Harness b Neoprene Sheet c Sta Straps 1 Plug remote control harness connector into en gine harness connector then secure connector in place with retainer as shown 2 Wrap neoprene sheet around cable bundle and secure each end with a sta strap Secure to bracket with retainer IMPORTANT On Models without Power Trim the neoprene sheet m...

Page 12: ...W Engine Oil Every 60 Days Every 30 Days 10 Power Trim Pump Oil Level Quicksilver Power Trim and Steering Fluid Every 100 hours or once in season Same as Fresh Water Engine Crankshaft Splines to Drive Shaft Splines Quicksilver 2 4 C w Teflon Once in Season by Dealer 11 Accelerator Pump Stem Throttle Cam Quicksilver 2 4 C w Teflon Once in Season Every 60 Days 27868 7 8 20319 6 10 5 Ride Guide Steer...

Page 13: ... exists If this is the case the powerhead must be disas sembled Submerged Engine Fresh Water Plus Special Instructions 1 Recover engine as quickly as possible 2 Remove cowling 3 Flush outside of engine with fresh water to re move mud weeds etc DO NOT attempt to start engine if sand has entered powerhead as power head will be severely damaged Disassemble powerhead if necessary to clean components 4...

Page 14: ...ears to be contaminated re move and replace Refer to Section 3 Fuel System and Carburetion 6 Drain and refill lower unit with Quicksilver Gear Lube as explained in Gear Housing Lubrication see Table of Contents 7 Clean outboard thoroughly including all accessi ble powerhead parts and spray with Corrosion and Rust Preventive 8 Refer to lubrication chart in this section see Table of Contents and lub...

Page 15: ...erature low baro metric pressure and high humidity all combine to re duce the engine power This in turn is reflected in de creased boat speeds as much as 2 or 3 miles per hour 3 or 5 Km per hour in some cases Refer to previous chart Nothing will regain this speed for the boater but the coming of cool dry weather In pointing out the practical consequences of weather effects an engine running on a h...

Page 16: ...oves ease of planing off 2 Generally improves rough water ride 3 If excessive can make the boat veer left and right bow steer 2 Boat Bottom For maximum speed a boat bot tom should be nearly a flat plane where it contacts the water and particularly straight and smooth in fore and aft direction a Hook Exists when bottom is concave in fore and aft direction when viewed from the side When boat is plan...

Page 17: ...ct reach cross firing 6 Inadequate engine cooling deteriorated cooling system 7 Combustion chamber piston deposits result in higher compression ratio Detonation usually can be prevented provided that 1 the engine is correctly set up and 2 diligent mainte nance is applied to combat the detonation causes listed preceding 51115 Damaged Piston Resulting from Detonation Compression Check 1 Remove spark...

Page 18: ...IGNITION SYSTEM ELECTRICAL AND IGNITION A 2 ...

Page 19: ...Ampere Stators 2A 4 Ignition Coil Test 2A 5 Trigger Test 2A 5 Ignition Key Switch Test 2A 5 Commander 2000 Key Switch 2A 5 Commander Key Switch 2A 5 Ignition Components Removal and Installation 2A 6 Flywheel 2A 6 Removal 2A 6 Installation 2A 6 Stator 2A 7 Removal 2A 7 Installation 2A 7 Trigger 2A 8 Removal 2A 8 Installation 2A 8 Ignition Coils 3 Cylinder Models 2A 9 Ignition Coils 4 Cylinder Model...

Page 20: ...ion in relation to the permanent magnets on the flywheel center hub IMPORTANT If the engine misfires runs rough or does not start the ignition system should be checked using a Multi Meter DVA Tester 91 99750 or a voltmeter capable of measuring 400 volts DC or higher and Direct Voltage Adap tor 91 89045 Test Procedures Direct Voltage Adapter DVA Tests WARNING DANGER HIGH VOLTAGE SHOCK HAZARD Do not...

Page 21: ...anical 2 A Check switch box stop circuit See Test Chart 1 If reading is BELOW specifications proceed with Step 2 B 2 If reading is ABOVE specifications the Trigger or Switch Box is bad test trigger as outlined in this ser vice manual section if trigger checks OK replace switch box and repeat check 3 If reading is WITHIN specifications proceed with Step 3 A 2 B Check ignition switch wiring as follo...

Page 22: ...DVA 400 VDC position 3 Cylinder Stator 9 Ampere 398 9873A21 15 Ampere 398 9873A24 ADI Test Selector Sw DVA Leads Voltage Reading 1 Voltage Reading Seq Test Position Red Black g g 300 1000 RPM g g 1000 4000 RPM 1 A Coil Primary 400 VDC Coil Terminal Coil Terminal 145 250 210 240 2 A Sw Box Stop Circuit 400 VDC Black Yellow 3 Sw Box Terminal Ground 215 340 280 320 3 A 4 A Stator Low Speed 400 VDC Bl...

Page 23: ...em 2 Check that plug in connectors are fully engaged and terminals are free of corrosion 3 Make sure that wire connections are tight and free of corrosion 4 Check all electrical components that are grounded directly to engine and all ground wires to see that they are grounded to engine 5 Check for disconnected wires and short and open circuits STATOR TEST NOTE Stator can be tested without removing...

Page 24: ... 14 R x 100 Between White Trigger Lead and White Black Trigger Lead 1100 1400 11 14 R x 100 Between Violet Trigger Lead and White Black Trigger Lead 1100 1400 11 14 R x 100 NOTE Above readings are for a cold engine room temperature Resistance will increase slightly if en gine is warm 3 If meter readings are not as specified replace trigger TRIGGER TEST 4 CYLINDER 1 Disconnect all trigger leads fro...

Page 25: ...91 73687A1 into flywheel 5 Remove flywheel NOTE Neither heat or hammer should be used on fly wheel to aid in removal as damage to flywheel or elec trical components under flywheel may result 51124 a b a Flywheel Puller b Flywheel INSTALLATION WARNING Engine could possibly start when turning flywheel during installation therefore disconnect and isolate spark plug leads from spark plugs to prevent e...

Page 26: ...r leads from switch box and re move stator a 19453 a Sta Strap INSTALLATION 1 Install stator as shown 51124 a b a Screws apply Loctite Grade A on threads unless Patch Screw used and torque to 60 lbs in 6 6 N m b Stator 2 Connect stator leads refer to wiring diagrams in Section 2D 3 Install sta strap 4 Install starter motor refer to Section 2B a 19453 a Sta Strap 5 Install flywheel refer to Flywhee...

Page 27: ...move sta strap 5 Disconnect trigger leads from switch box and re move trigger a 19453 a Sta strap INSTALLATION 1 Install trigger and connect link arm 19459 a b a Trigger b Link Arm 2 Connect trigger leads to switch box refer to wiring diagrams in Section 2D 3 Install sta strap 4 Install starter motor refer to Section 2B a 19453 a Sta strap 5 Install stator refer to Stator Installation preceding 6 ...

Page 28: ... N m e Coil Tower Boots form a water tight seal between coil tower and spark plug lead using Quicksilver Insulating Compound Ignition Coils 4 Cylinder Models 1 Refer to wiring diagrams in Section 2D when con necting wires 25931 a c d b c e a Coils b Cover c Hex Nuts Torque to 30 lb in 3 4 N m coat with Quicksilver Liquid Neoprene d Bolts torque to 20 lb in 2 3 N m e Coil Tower Boots form a water t...

Page 29: ...NITION Switch Box 1 Refer to wiring diagrams in Section 2D when con necting wires f e a b d b c d 19454 a Switch Box b Bushings c J Clip d Bolt Torque to 40 lb in 4 5 N m e Screw Secure coil ground wires under screw f Coil Ground Wires BLACK ...

Page 30: ...11669 BATTERY CHARGING SYSTEM AND STARTING SYSTEM ELECTRICAL AND IGNITION B 2 ...

Page 31: ... Design 1 and 2 2B 8 Removal 2B 8 Installation 2B 8 3 Cylinder 16 and 24 Ampere Battery Charging Wiring Diagram 2B 9 3 Cylinder 16 Ampere Battery Charging Wiring Diagram with Small Voltage Regulator Rectifier 2B 10 4 Cylinder 16 and 24 Ampere Battery Charging Wiring Diagram 2B 11 4 Cylinder 16 Ampere Battery Charging Wiring Diagram with Small Voltage Regulator Rectifier 2B 12 3 Cylinder Battery Ch...

Page 32: ... circuits at terminals of batter ies because a spark usually occurs at the point where a live circuit is broken Always be careful when connecting or disconnecting cable clamps on chargers Poor connections are a common cause of electrical arcs which cause explosions 3 DO NOT reverse polarity of battery cables on bat tery terminals Recommended Battery The 2 cycle Outboard type engine requires a 12 v...

Page 33: ...ops electrolyte contracts so that spe cific gravity increases Unless these variations in spe cific gravity are taken into account specific gravity ob tained by hydrometer may not give a true indication of concentration of acid in electrolyte A fully charged battery will have a specific gravity reading of approximately 1 270 at an electrolyte temperature of 80 F 27 C If electrolyte tempera ture is ...

Page 34: ...9 1 2 volts while crank ing the battery is weak and should be recharged or replaced Winter Storage of Batteries Battery companies are not responsible for battery damage either in winter storage or in dealer stock if the following instructions are not observed 1 Remove battery from its installation as soon as possible and remove all grease sulfate and dirt from top surface by running water over top...

Page 35: ...l accessories to drop voltage to 13 5 volts or less 7 Run engine at 3000 RPM 8 Meter should read between 7 9 amperes 9 If meter reads 7 9 amperes this indicates the charging system is functioning properly and the battery is being discharged because the amper age draw on the system is greater than the amper age output of the system NOTE With engine running at the following RPM S the ammeter should ...

Page 36: ...fier tests Stator Ohms Test Alternator Coils Only NOTE Stator can be tested without removing from engine 1 Disconnect both YELLOW stator leads from ter minals on rectifier or terminal block 2 Use an ohmmeter and perform the following test IMPORTANT If stator is mounted on engine black stator lead if provided must be grounded to pow erhead when testing 3 Replace stator if readings are outside range...

Page 37: ...king voltage is not acceptable replace battery 5 If cranking voltage is acceptable disconnect RED harness wire from center terminal 6 Secure RED wire d on terminal c using hex nut 7 Connect RED ammeter lead to terminal c and BLACK ammeter lead to RED harness wire b 8 Secure wires away from flywheel IMPORTANT For accurate test results the voltage at battery with engine running in next step must be ...

Page 38: ...mperes test the stator refer to Stator Ohms Test Alternator Coils Only 18 Ampere Stator preceding If stator tests OK replace voltage regulator rectifier Optional 24 Amp Alternator System Test LARGE FINNED VOLTAGE REGULATOR RECTIFIER 1 Check battery voltage at battery with engine running 2 If battery voltage is above 14 5 volts replace volt age regulator rectifier a Check condition of bat tery as o...

Page 39: ...e ohm meter with the needle swinging in only ONE direction NO CONTINUITY should be observed when test leads are reversed If CONTINUITY is observed in BOTH directions or NO CONTINUITY is observed in either direction when leads are reversed diode is de fective and MUST BE REPLACED NOTE There is only one diode located in the tachom eter block It may be located either between the cen ter TACH terminal...

Page 40: ... connections are made coat all terminal connections using Quick silver Liquid Neoprene 92 25711 to avoid corro sion 50405 BLK BLACK BLU BLUE GRY GRAY RED RED YEL YELLOW a b c d e f g h a Stator b Terminal Block c ToTachometer d Voltage Regulator Rectifier e To Remote Control Harness f 20 Ampere Fuse g To Battery h Starter Solenoid ...

Page 41: ...all terminal connections using Quick silver Liquid Neoprene 92 25711 to avoid corro sion 51000 BLK BLACK BLU BLUE GRY GRAY RED RED YEL YELLOW YEL YEL BLK BLK RED RED YEL YEL GRY GRY YEL YEL RED RED BLK RED RED GRY a b c d e f g h a Stator b Terminal Block c ToTachometer d Votage Regulator Rectifier e To Remote Control Harness f 20 Ampere Fuse g Battery Positive Terminal h Starter Solenoid ...

Page 42: ...tions are made coat all terminal connections using Quick silver Liquid Neoprene 92 25711 to avoid corro sion 50406 BLK BLACK BLU BLUE GRY GRAY RED RED YEL YELLOW a b c d e f g h a Stator b Terminal Block c ToTachometer d Voltage Regulator Rectifier e To Remote Control Harness f 20 Ampere Fuse g Battery Positive Terminal h Starter Solenoid ...

Page 43: ... coat all terminal connections using Quick silver Liquid Neoprene 92 25711 to avoid corro sion 51001 BLK BLACK BLU BLUE GRY GRAY RED RED YEL YELLOW YEL YEL RED RED YEL YEL GRY GRY YEL YEL RED RED GRY RED RED a b c d e f g h a Stator b Terminal Block c ToTachometer d Voltage Regulator Rectifier e To Remote Control Harness f 20 Ampere Fuse g Battery Positive Terminal h Starter Solenoid ...

Page 44: ...GRY GRAY RED RED YEL YELLOW Start Battery Screw Size 10 16x3 8 P N 10 62568 User Supplied Red Lead 10 Gauge Minimum Diameter with Protective Abrasive Sleeve Installed Move Lead From Red Stud to Position Shown Move Red Lead From Start Solenoid to Position Shown a b c d e f g h i j a Stator b Terminal Block c To Tachometer d Voltage Regulator Rectifier e Battery Isolator f Auxiliary Battery g Start ...

Page 45: ...d Neoprene 92 25711 to avoid corro sion 51051 BLK GRY Large Red Output Lead RED RED RED RED B1 B2 RED A Small Red Sense Lead BLK YEL YEL BLK YEL YEL GRY GRY YEL YEL RED RED BLK BLACK BLU BLUE GRY GRAY RED RED YEL YELLOW a b c d e f g h i j a Stator b Terminal Block c To Tachometer d Voltage Regulator Rectifier e Battery Isolator f Auxiliary Battery g Start Battery h To Remote Control Harness i 20 ...

Page 46: ...0 16x3 8 P N 10 62568 User Supplied Red Lead 10 Gauge Minimum Diameter with Protective Abrasive Sleeve Installed Move Lead From Red Stud to Position Shown BLK BLACK BLU BLUE GRY GRAY RED RED YEL YELLOW Move Red Lead From Start Solenoid to Position Shown a b c d e f g h i j a Stator b Terminal Block c To Tachometer d Voltage Regulator Rectifier e Battery Isolator f Auxiliary Battery g Start Battery...

Page 47: ... Liquid Neoprene 92 25711 to avoid corro sion 51050 Large Red Output Lead BLK BLACK BLU BLUE GRY GRAY RED RED YEL YELLOW YEL YEL RED YEL YEL GRY GRY YEL YEL RED RED GRY RED RED RED B1 B2 RED A Small Red Sense Lead a b c d e f g h i j a Stator b Terminal Block c To Tachometer d Voltage Regulator Rectifier e Battery Isolator f Auxiliary Battery g Start Battery h To Remote Control Harness i 20 Ampere...

Page 48: ...und RED lead alternately to terminals a and c No Continuity Indicated Connect BLACK meter lead to ground RED lead alternately to terminals a and c No Continuity Indicated Connect BLACK meter lead to terminal b RED lead alternately to terminals a and c Continuity Indicated Replace Rectifier No Continuity Indicated Replace Rectifier Continuity Indicated Connect RED meter lead to terminal b BLACK lea...

Page 49: ... neutral start switch opens the start circuit when the shift control lever is not in neutral This prevents accidental starting when engine is in gear The starter motor may be damaged if operated continuously DO NOT operate continuously for more than 30 seconds Allow a 2 minute cooling period between starting attempts CAUTION Troubleshooting the Starting Circuit Before beginning the starting circui...

Page 50: ...nect BLACK starter motor cable from starter solenoid test point 1 BEFORE making tests 1 thru 7 to prevent unexpected engine cranking TEST 1 Use an ohmmeter R x 1 scale and connect meter leads between NEGATIVE battery post and common powerhead ground No continuity indicated there is an open circuit in the BLACK negative battery cable between the nega tive battery post and the powerhead Check cable ...

Page 51: ... Point 5 TEST 6 Connect voltmeter between common engine ground and Test Point 6 No voltage reading check RED wire be tween battery positive terminal and Test Point 6 TEST 7 a Connect voltmeter between common engine ground and Test Point 1 b Turn ignition key to Start position No voltage reading Defective starter solenoid 12 Volt Reading Check BLACK ground cable at starter for loose or cor roded co...

Page 52: ...tarter Clamps d BLACK Cable 6 Remove 2 rubber collars and 2 rubber bumpers 11645 a b a a Rubber Collar b Spacer If Equipped Disassembly 1 Remove 2 thru bolts and commutator end cap taking care not to lose brush springs 11646 a b a a Thru Bolts b Commutator End Cap 2 Pull armature from starter frame 3 Remove locknut 11659 a a Hold Armature Shaft With Wrench on Hex Portion of Drive Assembly 4 Remove...

Page 53: ...ture on a growler for shorts as specified in the following procedure Test ing 8 Open circuited armatures often can be repaired The most likely place for an open circuit is at the commutator bars as a result of long cranking peri ods Long cranking periods overheat the starter motor so that solder in the connections melts and is thrown out The resulting poor connections then cause arcing and burning...

Page 54: ...cale Place one lead of the ohmmeter on the NEGATIVE brush and the other lead on the end cap bare metal If the meter indi cates NO continuity replace the NEGATIVE brush Repeat this procedure on the other NEGATIVE brush 11674 a b a NEGATIVE Brushes b End Cap STARTER SOLENOID TEST 1 Disconnect all wires from solenoid 2 Use an ohmmeter R x 1 scale and connect meter leads between solenoid terminals 1 a...

Page 55: ... Brush Lead i Push Lead into Slot b Install NEGATIVE brushes along with brush holder 11656 a b c d a d b a POSITIVE Brushes b NEGATIVE Brushes c Brush Holder d Bolts Fasten NEGATIVE Brushes and Holder 2 If removed reinstall parts on armature shaft Use a new locknut and tighten securely on end of shaft a b d e f g 11658 c a Locknut b Spacer c Spring d Drive Assembly e Drive End Cap f Armature Shaft...

Page 56: ...er Tool Layout Full Size 7 Lubricate bushing 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 a b a Brush Retainer Tool b Bushing DO NOT Over Lubricate 9 Install armature into starter frame and align match marks a Install commutator end cap onto starter frame and align mat...

Page 57: ...ents as shown 3 Connect battery leads to battery 19452 a b c d e f g h i j k l i a Starter b Rubber Mount oil tank c Clamp upper d BLACK Cable e Bolt and Lockwasher f Clamp lower g J Clip If Equipped h BLACK Negative Battery Cable i Bolts Torque to 14 5 lb ft 19 7 N m j Fuse Holder If Equipped k YELLOW Cable Torque to nut to 60 lb in 6 7 N m l Fuse Holder If Equipped ...

Page 58: ...22480 TIMING SYNCHRONIZING ADJUSTING ELECTRICAL AND IGNITION C 2 ...

Page 59: ... 2C 4 Maximum Throttle 2C 4 Idle Adjustment 2C 4 Throttle Cable Installation 2C 5 Timing Synchronizing Adjusting 4 Cylinder Models 2C 6 Specifications 2C 6 Special Tools 2C 6 Timing Pointer Alignment 2C 6 Carburetor Synchronization 2C 7 Carburetor Oil Pump Synchronization 2C 8 Timing Adjustments 2C 8 Idle Timing Adjustment 2C 8 Maximum Timing 2C 9 Carburetor Specifications 2C 10 Initial Starting A...

Page 60: ... T D C Idle Timing 0 4 B T D C Spark Plug NGK BUHW 2 Firing Order 1 3 2 Mariner 75 Marathon Merc 75XD Full Throttle RPM Range 4750 5250 Idle RPM in FORWARD Gear 650 700 Maximum Timing 5000 RPM Cranking Speed 16 B T D C 18 B T D C Idle Timing 0 4 B T D C Spark Plug NGK BUHW 2 Firing Order 1 3 2 Special Tools Part No Description 91 58222A1 Dial Indicator Gauge Kit 91 59339 Service Tachometer 91 9937...

Page 61: ...hrottle cable barrel from barrel retainer 4 Remove sound air box cover 5 Loosen screw from throttle cam follower 6 Loosen 4 synchronizing screws 7 Look into throats of carburetors and make sure all throttle shutters are completely closed Tighten synchronizing screws 8 Recheck throttle shutters and make any necessary adjustments 20440 a b b a Set Screw b Synchronizing Screws 9 Hold throttle arm so ...

Page 62: ...ine is timed while cranking engine with starter motor To prevent engine from starting when being cranked all spark plugs must be removed except no 1 top cylinder plug CAUTION NOTE If initial timing adjustments are made without engine running then final timing checks should be made with engine running due to timing advance characteristics of ignition system Minimum engine RPM required to check maxi...

Page 63: ...made without engine running then final timing checks should be made with engine running due timing advance char acteristics of ignition system Minimum engine RPM required to check maximum timing advance is 3000 RPM MAXIMUM THROTTLE 1 Hold throttle arm against full throttle stop screw Adjust full throttle stop screw to allow throttle shut ters to open fully then turn stop screw in clock wise an add...

Page 64: ...ely with ignition timing Throttle Cable Installation 1 With end of throttle cable connected to throttle le ver hold throttle lever against idle stop Adjust throttle cable barrel to slip into barrel retainer on cable anchor bracket with a very light preload of throttle lever against idle stop Lock barrel in place IMPORTANT Excessive preload on throttle cable will cause difficulty when shifting from...

Page 65: ...lly Timing Pointer Alignment WARNING Engine could start when turning flywheel to check timing pointer alignment Remove all spark plugs from engine to prevent engine from starting 1 Remove aft cowl support bracket 2 Install Dial Indicator 91 58222A1 into no 1 top cylinder 3 Turn flywheel in a clockwise direction until no 1 piston is a TDC then set Dial Indicator at 0 zero 19062 91 58222A1 4 Turn fl...

Page 66: ...st throttle stop screw to align raised mark of throttle cam with center of cam follower roller Tighten locknut 25498 a b c d e f g b b a Cam Follower Adjustment Screw b Synchronizing Screws c Throttle Arm d Idle Stop Screw e Roller f Throttle Cam g Locknut 9 Holding throttle arm at idle position adjust cam follower so that a clearance of 0 005 in 0 020 in 0 127mm 0 508mm exists between roller and ...

Page 67: ...nterference with hoses cable ties etc 22977 a b c d a Link Rod b Mark of Oil Pump Body c Mark of Oil Pump Lever d Mark NOT Used TIMING ADJUSTMENTS Engine can be timed while cranking engine with starter motor To prevent engine from starting when being cranked all spark plugs should be removed CAUTION NOTE If initial timing adjustments are made without engine running then final timing checks should ...

Page 68: ...stop Crank engine with starter motor and adjust maxi mum advance screw to align 25 BTDC mark on flywheel with timing pointer due to the advance characteristics of ignition system this cranking speed adjustment will automatically be reduced to 23 BTDC at engine speed of 5000 RPM Tighten locknut NOTE If initial timing adjustments are made without engine running then final timing checks should be mad...

Page 69: ...ynchronizing Adjusting of this manual After service or replacement of carburetor turn low speed mixture screw adjustment in clockwise until it seats lightly then back off each carburetor to speci fications 100 1 3 4 turns or 115 1 1 2 turns This will permit engine start up LOW SPEED MIXTURE ADJUSTMENTS NOTE Only the top two carburetors on four cylinder models have an adjustable low speed mixture s...

Page 70: ...cknut Throttle Cable Installation 1 With end of throttle cable connected to throttle le ver hold throttle lever against throttle stop Adjust throttle cable barrel to slip into barrel retainer on cable anchor bracket with a very light preload of throttle lever against throttle stop Lock barrel in place IMPORTANT Excessive preload on throttle cable will cause difficulty when shifting from forward to...

Page 71: ...WIRING DIAGRAMS ELECTRICAL AND IGNITION D 2 ...

Page 72: ...Remote Control 2D 6 Power Trim System Wiring Diagram 3 Cylinder Models using COMMANDER Side Mount Remote Control 2D 7 Power Trim System Wiring Diagram 4 Cylinder Models using COMMANDER 2000 Side Mount Remote Control 2D 8 Tachometer with Adjustable Dial and Trim Indicator Gauge Wiring Diagram 2D 9 Key Choke Switch Continuity Test COMMANDER 2000 Side Mount Remote Control 2D 10 COMMANDER 2000 Side Mo...

Page 73: ...i j k l m n o p q r o o a Stator b Trigger c Switch Box d Ignition Coil Cylinder No 1 e Ignition Coil Cylinder No 2 f Ignition Coil Cylinder No 3 g Mercury Tilt Stop Switch h Starter Motor i Starter Solenoid j Voltage Regulator Rectifier k Fuse Holder 20 Amp Fuse l Battery m Wiring Harness Connector n Enrichment Valve o Terminal Block p Temperature Switch Opens 170 F 8 77 C 8 Closes 190 F 8 88 C 8...

Page 74: ...W a b c d e f h i j k l m n o p q r g a Stator b Trigger c Switch Box d Ignition Coil Cylinder No 1 e Ignition Coil Cylinder No 2 f Ignition Coil Cylinder No 3 g Mercury Tilt Stop Switch h Starter Motor i Starter Solenoid j Rectifier k Fuse Holder 20 Amp Fuse l Battery m Wiring Harness Connector n Enrichment Valve o Terminal Block p Temperature Switch Opens 170 F 8 77 C 8 Closes 190 F 8 88 C 8 q T...

Page 75: ...VIO VIOLET WHT WHITE YEL YELLOW d f g j k q p o n e c a h i l m n b a Stator b Trigger c Switch Box d Ignition Coil Cylinder No 1 e Ignition Coil Cylinder No 2 f Ignition Coil Cylinder No 3 g Mercury Switch h Starter Motor i Starter Solenoid j Voltage Regulator Rectifier k 20 Amp Fuse l Battery m Fuel Enrichment Valve n Terminal Block o Overheat Temperature Sensor p Warning Module q Low Oil Sensor...

Page 76: ...ator b Trigger c Switch Box d Ignition Coil Cylinder No 1 e Ignition Coil Cylinder No 2 f Ignition Coil Cylinder No 3 g Ignition Coil Cylinder No 4 h Mercury Tilt Stop Switch i Starter Motor j Starter Solenoid k Voltage Regulator Rectifier l Fuse Holder 20 Amp Fuse m Battery n Wiring Harness Connector o Enrichment Valve p Terminal Block q Temperature Switch Opens 170 F 8 77 C 8 Closes 190 F 8 88 C...

Page 77: ...HT WHITE YEL YELLOW a b c h d e f g i j k l m n o p q r o o j a Stator b Trigger c Switch Box d Ignition Coil Cylinder No 1 e Ignition Coil Cylinder No 2 f Ignition Coil Cylinder No 3 g Ignition Coil Cylinder No 4 h Mercury Switch i Starter Motor j Starter Solenoid k Voltage Regulator Rectifier l 20 Amp Fuse m Battery n Fuel Enrichment Valve o Terminal Block p Overheat Sensor q Warning Module r Lo...

Page 78: ...00 Side Mount Remote Control 23886 BLK BLACK BLU BLUE GRN GREEN RED RED WHT WHITE a b c d e f g h a Power Trim Pump Motor b Trim Solenoid UP c Trim Solenoid DOWN d Engine Starter Motor Solenoid e Red Battery Cable f Fuse Holder 20 Amp Fuse g Engine Wiring Harness Connector h Remote Control Wiring Harness Connector ...

Page 79: ...Using COMMANDER Side Mount Remote Control 23884 BLK BLACK BLU BLUE GRN GREEN PUR PURPLE RED RED WHT WHITE a b c d e f g g 1 2 3 a Power Trim Pump Motor b Trim Solenoid UP c Trim Solenoid DOWN d Engine Starter Motor Solenoid e Fuse Holder 20 Amp Fuse f Red Battery Cable g Wires from Remote Control ...

Page 80: ...00 Side Mount Remote Control 23885 BLK BLACK BLU BLUE GRN GREEN RED RED WHT WHITE a b c d e f g h a Power Trim Pump Motor b Trim Solenoid UP c Trim Solenoid DOWN d Engine Starter Motor Solenoid e Red Battery Cable f Fuse Holder 20 Amp Fuse g Engine Wiring Harness Connector h Remote Control Wiring Harness Connector ...

Page 81: ... Indicator Gauge Wiring Diagram BLK BLACK BRN BROWN GRY GRAY PUR PURPLE TAN TAN WHT WHITE a b c d e BATT GND SENDER a Tachometer b Position Dial to Point Toward 4 c Trim Indicator Gauge Optional d Tachometer Accessories Harness Plug from Remote Control e Tachometer Accessories Harness ...

Page 82: ...y Test COMMANDER 2000 Side Mount Remote Control 23894 BLK BLACK PUR PURPLE RED RED YEL YELLOW OFF BLK YEL BLK RUN RED PUR START RED PUR YEL RED PUSH CHOKE RED YEL BLK Key switch must be positioned to RUN or START and key pushed in to actuate choke for this continuity test ...

Page 83: ...th Warning Horn Wiring Diagram 23891 BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN PUR PURPLE RED RED TAN TAN WHT WHITE YEL YELLOW a b c d e f g a Ignition Choke Switch b Emergency Stop Switch c Neutral Start Switch d Tachometer Accessories Harness Connector e Wiring Harness Connector f Warning Horn g Trim Tilt Switch ...

Page 84: ...With Warning Horn Wiring Diagram 23892 BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN PUR PURPLE RED RED TAN TAN WHT WHITE YEL YELLOW a b c d e f a Ignition Choke Switch b Emergency Stop Switch c Neutral Start Switch d Tachometer Accessories Harness Connector e Wiring Harness Connector f Warning Horn ...

Page 85: ... GREEN GRY GRAY PUR PURPLE RED RED TAN TAN WHT WHITE YEL YELLOW LIT LIGHT a b c d e f g h i j k l a Ignition Choke Switch b Emergency Stop Switch c Neutral Start Switch d Tachometer Accessories Harness Connector e Wiring Harness Connector f Warning Horn g Trim Tilt Switch h Wire Retainer i Control Handle j Trim Harness Bushing k Trim Harness Connector l Lead to Trim Indicator Gauge ...

Page 86: ...FUEL SYSTEM AND CARBURETION A 3 ...

Page 87: ...er Torques 3A 18 Settings 3A 18 Fuel Pump Specifications 3A 18 Fuel Pump Pressure 3A 18 Sealants 3A 18 Idle Speed Adjustment 3A 19 Main High Speed Jet Adjustment 3A 19 Rejetting Carburetors For High Altitude Operation 3A 19 Jet Orifice Size Part Number Chart 3A 20 Carburetor Removal and Disassembly 3A 20 Carburetor Disassembly 3A 21 Cleaning and Inspection 3A 22 Carburetor Reassembly 3A 22 Idle Ai...

Page 88: ... not start Vapor lock Since any type of anti siphon device must be located between the outboard fuel inlet and fuel tank outlet a simple method of checking if such a device or bad fuel is a problem source is to operate the outboard with a separate fuel supply which is known to be good such as a remote fuel tank If after using a separate fuel supply it is found that the anti siphon valve is the cau...

Page 89: ...ssembly remember that re spective diaphragms go against the mating surfaces of the fuel pump body and respective gaskets are be tween the diaphragms and end caps Gaskets should always be replaced on fuel pump assembly a b c d e g h i j k l m n o p q s t r f a Fuel Pump Base b Fuel Pump Body c Chamber Plate d Gasket Base e Fuel Filter Inline f Gasket Pulse Chamber g Diaphragm Fuel Pump h Retainer C...

Page 90: ...h a sta strap a b c d a Inlet Fuel Hose b Outlet Fuel Hose c Oil Injection Hose d Pulse Hose Fuel Pump Cleaning Inspection Disassembly and Reassembly Design 1 and 2 Disassemble by removing 2 hex head bolts remove disassemble fuel pump parts Fuel Pump Cleaning Inspection Clean fuel pump housing check valves pulse cham ber and pump base in solvent and dry all but check valves with compressed air Ins...

Page 91: ...24514 3 With retainer installed in pump body break retain er rod from retainer by bending sideways 23601 a b a Retainer Rod b Retainer 4 Reinstall rod into retainer cap and use a small hammer or hammer and punch to tap rod down into retainer until flush with top of retainer 23601 a b a Rod b Retainer Cap Check Valve Reassembly ASSEMBLY DESIGN II 1 Insert retainer thru plastic disc and rubber check...

Page 92: ...turn plate upside down so that the inner side is facing up 2 Insert coil spring and cap in place 3 Place Boost Chamber GASKET over dowels bolts and lower onto Chamber Plate BE SURE that gasket directional alignment is correct and that V tabs are aligned 4 Place Boost DIAPHRAGM over dowels and lower to assembly 5 Place Fuel Pump Body over dowels and lower to assembly 6 Insert Coil Spring and Cap in...

Page 93: ...ious body with rubber check valve retainers was colored black a b c d e f g h i j a Body Opposite Side View b Natural Body Off White c Rubber Valve d Cover Opposite Side View e Plastic Disc f Plastic Check Valve Retainer g Two Oil Passage Holes h Cast Aluminum Cover i One Tab j Two Tabs ...

Page 94: ...us body with rubber check valve retainers was colored black a b c d e f g h i j a Body Opposite Side View b Natural Body Off White c Rubber Valve d Cover Opposite Side View e Plastic Disc f Plastic Check Valve Retainer g Two Oil Passage Holes h Cast Aluminum Cover i One Tab j Two Tabs ...

Page 95: ... in extensive damage to engine CAUTION 51119 a b c d e f g h i j a Chamber Plate Step 1 b Boost Compression Spring Cap Step 2 c Boost Chamber Gasket Step 3 d Boost Diaphragm Step 4 e Fuel Pump Body Step 5 f Main Compression Spring Cap Step 6 g Fuel Pump Diaphragm Step 7 h Pulse Chamber Gasket Step 8 i Fuel Pump Base Step 9 j Fuel Pump to Powerhead Gasket Shown for Identification Purposes Only Rein...

Page 96: ...TEM AND CARBURETION 70 75 80 90 3 cyl Design 2 51549 a b c e f h d g a Body Opposite Side View b Rubber Valve c Plastic Disc d Cover Opposite Side View e Plastic Check Valve Retainer f Cast Aluminum Cover g Three Tabs h Three Tabs ...

Page 97: ...M AND CARBURETION 100 115 4 cyl Design 2 51548 b c d e f g h i a a Body Opposite Side View b Rubber Valve c Plastic Disc d Cover Opposite Side View e Plastic Check Valve Retainer f Cast Aluminum Cover g Body h Three Tabs i Three Tabs ...

Page 98: ...1 to threads f Check Valve g Y Connector h Screws Torque to 55 lb in 6 2 N m i Clear Tubing 5 5 in 139 7mm j Gasket Cylinder Block to Fuel Pump HIDDEN MODEL 100 115 51519 a b c d e f g h i j k l n m f a Clear Tube 8 in 203 2mm b To Oil Pump Outlet c Check Valve d Hose 1 5 in 38 1mm e Fuel Connector f Hose 1 5 in 38 1mm g T Fitting EXISTING h Y Fitting i Hose 1 75 in 44 5mm j Fuel Pump k Fuel Outle...

Page 99: ... Fuel Flow caused by Anti Siphon Valves following See Checking for Restricted Fuel Flow caused by Anti Siphon Valves page 3A 1 PROBLEM ENGINE FLOODS Possible Cause Corrective Action Dirt or foreign particles are preventing inlet needle from seating Flush out inlet seat and clean inlet needle Worn inlet needle Replace Punctured float Replace Incorrect float setting Reset float PROBLEM ENGINE RUNS T...

Page 100: ...in Section 4A A crack in the fuel pick up outlet tube located in fuel tank Replace A crack in the fuel outlet tube located in fuel tank Replace Anti Siphon valve restricting fuel flow Refer to Checking for Restricted Fuel Flow Caused by Anti Siphon Valves following PROBLEM FUEL BLOW BACK OUT OF CARBURETOR Possible Cause Corrective Action Chipped Broken reed block Reeds Replace Reeds PROBLEM ROUGH ...

Page 101: ...leaners will not affect the sea lant securing this adjustment 1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 3 Specifications Float Setting 7 16 in 0 015 in Float Weight 7 grams 0 4 grams Idle Adjustment Screw 1 1 2 turns 1 4 Set Halfway Between Lean and Rich Quicksilver Lubrication Sealant Application Points 51 109 51 Loctite 222 Obtain Locally Loctite Primer T 92 59327 1 109 25 ...

Page 102: ...ng 4 1 Fuel Bowl 5 1 Throttle Shaft Upper Bottom 6 1 Throttle Shaft Center 7 1 Throttle Valve 8 1 Float 9 1 Float Shaft 10 1 Inlet Needle Valve 11 1 Plug 22 2 5 12 1 Gasket 13 1 Gasket 14 1 Gasket 15 2 Screw 6 0 7 16 2 Screw 18 2 1 17 2 Screw 18 2 1 18 1 Cover Plate 19 1 Main Jet 14 1 6 20 1 Vent Jet 6 0 7 21 1 Gasket 22 1 Spring 23 1 Spring 24 1 Idle Mixture Screw 25 1 Screw ...

Page 103: ...uel Liners 2 c Throttle Link d Throttle Arm e Throttle Link f Roller g Arm h Oil Injection Pump Link i Gasket j Gasket 4 Cylinder Carburetor Linkage Arrangement a b c d e f g g g g h i j k a Screw 6 b Washer 6 c Carburetor Link d Carburetor Link e Oil Injection Pump Link Rod f Roller g Throttle Shaft h Throttle Link i Throttle Link j Gasket k Gasket ...

Page 104: ...veral minutes Throttle back engine to idle for about one minute to allow RPMs to stabilize 2 With engine running at idle speed in water IN FORWARD GEAR prop on turn low speed mixture screw IN clockwise until engine starts to bog down and misfire Back out 1 4 turn or more 22990 a a Low Speed Mixture Screw 3 Check for too lean mixture on acceleration 4 DO NOT adjust leaner than necessary to attain r...

Page 105: ...115 076 NONE Standard Jets listed are for operation of engine from 0 2500 ft 0 762 M of elevation See page 3A 12 this section for jet size chart CARBURETOR FASTENER TORQUES Main Jet 14 lb in 1 6 N m Main Jet Cap Plug 22 lb in 2 5 N m Float Bowl 18 lb in 2 1 N m Throttle Plate Screw 6 lb in 0 7 N m Loctite 609 used OR RC 35 WITH PRIMER OR Loctite 222 WITH PRIMER Cover Plate Screw 18 lb in 2 1 N m B...

Page 106: ...1000 feet 304 8m of altitude in crease main jet size is reduced by 2 However this does not always hold true for all situations different boat motor load and ambient air temperature condi tions may require different jets I E going a jet size richer than recommended for a particular altitude may improve acceleration It may also be noted that no no ticeable improvement in engine performance was achie...

Page 107: ...399 3796 1395 6680 1395 6201 1399 3518 1399 3517 1395 5815 1395 6202 1395 6247 1395 5733 058 060 062 064 066 068 070 072 074 094 096 098 1395 7831 1395 6487 1399 4217 1399 4216 1399 4215 1395 6029 1395 6030 1395 6207 1399 3794 1395 8423 1399 6249 1395 7335 CARBURETOR REMOVAL AND DISASSEMBLY Carburetor Removal remove the six nuts on carb studs and lift off carburetor assembly See Section 4A this ma...

Page 108: ...or Disassembly S Remove main jet plug and gasket S Remove main jet 51116 a b a Main Jet Plug and Gasket b Main Jet NOTE It is not necessary to disassemble carburetor beyond this point for cleaning Examine throttle shaft for wear and inspect for damaged throttle shutter plate If removal of throttle shaft and or throttle shutter plate is necessary remove 2 screws which secure throttle shutter plate ...

Page 109: ...s necessary 5 Examine inlet needle for wear If worn replace with new inlet needle Carburetor Reassembly S If removed install throttle shaft throttle shutter plate 2 screws use specified LoctiteR and throttle shaft spring as shown Install retaining clip on other end of shaft 51117 a b c a Throttle Shaft b Screws 2 c Throttle Shaft Spring S Spring tensions on stud 51259 a b a Spring b Stud S Install...

Page 110: ...ab and place needle into its seat 51115 a b a Spring Clip b Float Tab S Install float into carburetor with float pin S Adjust float following Float Adjustment Page 3A 18 51115 a b a Float b Float Pin S Install float bowl 51116 a b b a Float Bowl b Screw 4 Torque 18 lb in 2 1 N m IDLE AIR SCREW Idle air screw is preset by the manufacturer and is NOT for field service If the idle air screw should be...

Page 111: ...r Valve Manual Operation Button Electrical Harness Connect to fitting on SIDE of TOP carburetor Description for Four Cylinder Engines Enrichener valve receives fuel from a T fitting be tween 1 and 2 carburetors Valve is electrically opened when ignition key is turned to the ON posi tion and pushed in and held in Fuel is dispensed to T fittings on intake manifold of cylinders 2 and 4 In ternal pass...

Page 112: ...ttery voltage to yellow black wire atterminalblockonenginewhenkey orchoke button is pushed in Click Squeeze primer bulb until bulb is firm Remove lower hose from fitting on enrichener valve Placeacontainerundervalve thenpushkey or choke button Check for fuel flow from fitting Battery Voltage Indicated Check for loose or corroded connection between YELLOW BLACK wire and black wire under same screw ...

Page 113: ...e cylinder boost passage FLOW RESTRICTOR Helps equalize pressure with in the accelerator pump circuit while allowing air or any vapor which has formed to pass through and be vented at the carburetors FUEL CONNECTOR Spring loaded shut off valve which connects boat fuel tank with outboard fuel sys tem IMPORTANT The distance between the accelera tor pump and the throttle cam determines the amount of ...

Page 114: ...proximate 1 CARB 2 CARB 3 CARB 4 CARB 4 5 PSI CYL 3 CYL 4 SMALL FUEL FILTER ACCELERATOR PUMP FUEL PRESSURE DROP OCCURS 3 5 PSI BRASS RESTRICTOR 014 I D LOCATED INSIDE FUEL LINE CHECK VALVES LOCATED IN CYLINDER BLOCK TRANSFER PORTS UNSEAT AT 11 14 PSI LARGE FUEL FILTER 5 0 PSI 0 4 PSI 0 5 PSI 5 0 PSI FUEL PUMP FUEL TANK 4 0 PSI FUEL CONNECTORS ...

Page 115: ... end of outlet tube may be obstructed Remove cover and inspect filter for varnish dirt or deposits Clean filter by rinsing in clean lead free gasoline or kerosene 51046 a b c d a Fuel Tank Filter b Pick Up Tube c Cover d Gasket Fuel Tank Components a b c d e f g h i j k l m a Fuel Tank Assembly Plastic 6 6 Gal b Filler Cap c Gasket Filler Cap d Pick Up Body Assembly e Adaptor f Window Assembly g G...

Page 116: ... Assembly c Check Valve Inlet d Fittng Outlet e Clamp Primer Bulb to Check Valve Large f Clamp Fuel Line to Check Valve Small g Connector Fuel Tank Outlet h Connector Engine Inlet i Clamp Fuel Line to Connector j Bayonet Body Assembly Fuel Tank End k Stem Bayonet Body l O ring Bayonet Body Stem m Spring Bayonet Body Stem n Washer Cupped Body Spring ...

Page 117: ... to fill primer bulb but closes to prevent fuel from returning to tank when bulb is squeezed The fuel outlet valve opens when primer bulb is squeezed to allow fuel flow to carbure tor but closes as bulb is released to prevent fuel from returning to primer bulb FUEL LINE CLAMP REMOVAL AND INSTALLATION 1 To remove fuel line clamps grip clamp with pliers and bend overlapping hook backwards 51115 Remo...

Page 118: ...OIL INJECTION SYSTEM B 3 ...

Page 119: ...Air from Oil Pump Outlet Hose 3B 3 Oil Pump Test 3B 3 Low Oil Sensor Test 3B 4 Warning Horn System 3B 4 Models Equipped with Test Button 3 Cylinder Only 3B 4 Description 3B 4 Warning Horn System Check 3B 4 Models Not Equipped With Test Button 3 and 4 Cylinder 3B 5 Description 3B 5 Warning Horn System Wiring Diagram 3B 6 Oil Injection System Troubleshooting Chart Models with Warning Module 3B 7 Tro...

Page 120: ...iven by the crankshaft A link rod is connected between the throttle linkage and oil pump lever When the throttle position is changed the link rod rotates the oil pump valve which changes the fuel oil ratio from approximately 80 1 at idle speed to 50 1 at wide open throttle The oil tank is equipped with a low oil sensor and a magnetic float When oil level in oil tank drops to approximately 1 quart ...

Page 121: ... the Boating Industry Associa tion s designation for approved 2 cycle water cooled outboard oils 2 Remove fill cap from the oil tank and fill tank with oil Retighten the fill cap 25955 a a Fill Cap Carburetor Oil Pump Synchronization 1 While holding throttle arm at idle position adjust length of link rod so that stamped mark of oil pump body aligns with stamped mark of oil pump lever and lever is ...

Page 122: ... container is required to perform this test 1 Connect engine to remote fuel tank containing a 50 1 fuel oil mixture 25 1 if during break in period 2 Attach flush device to outboard or place outboard in test tank 3 Remove top cowling 4 Disconnect oil outlet hose from fuel pump fitting 5 Plug fuel pump fitting 6 Remove link rod end from oil flow regulator 7 Rotate oil pump regulator full countercloc...

Page 123: ...and retract sensor Warning Horn System Models Equipped with Test Button 3 Cylinder Only DESCRIPTION Major components of the warning horn system are an ignition switch warning horn low oil sensor powerhead temperature sensor and warning horn test button With the ignition switch in the Run position electrical current is routed thru the warning horn and supplied to the powerhead temperature sensor lo...

Page 124: ... is indicative of an overheat condition An intermittent beep refers to a low oil condition Both overheat and low oil conditions are monitored by a warning module mounted on the starboard side of the engine block 25939 a a Warning Module 51551 a b c d e f g h a Powerhead Temperature Sensor b Warning Module c Terminal Block d Warning Horn e Ignition Switch f Engine Harness g Remote Control Harness h...

Page 125: ...ARNING HORN SYSTEM WIRING DIAGRAM f i h g c d b a e a Ignition Switch b Powerhead Temperature Sensor c Battery d Wiring Harness Connectors e Terminal Block f Warning Horn g Low Oil Sensor h Magnetic Float i Warning Horn Test Button Some Models ...

Page 126: ... lead from main engine wiring harness at terminal block on engine Ground this tan lead to en gine ground Warning horn should sound If not check tan wire between horn and engine for open circuit and check horn Warning Module Check if all warning module leads are connected to harness leads If so warning module may be faulty Using incorrect side mount remote control or ignition choke assembly Refer t...

Page 127: ...20032 3 CYLINDER ENGINES POWERHEAD A 4 ...

Page 128: ... Ring Grooves 4A 21 Measuring Piston Skirt 4A 22 Crankshaft 4A 22 Connecting Rods 4A 23 Cylinder Cover Exhaust Divider Plate and Exhaust Cover 4A 23 Thermostat 4A 24 Reed Blocks 4A 24 Backside Reed Block Assembled 4A 24 Powerhead Reassembly and Installation 4A 25 General Information 4A 25 End Cap 4A 25 Design 1 Bottom Guided 4A 26 Design 2 Top Guided 4A 26 Assembling Rod to Piston 4A 27 Piston Rin...

Page 129: ...rol Arm Lever Assembly a b c d e f g h i j k l m a Oil Tank b Oil Cap Assembly c Oil Tank Neck Bracket d Swivel Base e Swivel Bushing f Oil Tank Neck Boot g Oil Tank Base Boot h Oil Tank Base i Grommet j Bolt Torque to 160 lb in 18 1 N m k Sta Straps l Switch Assembly Without Warning Module m Switch Cover Oil Tank Assembly THROTTLE LEVER AND LINKAGE WAVE WASHER REMOVAL MODELS 70 75 80 90 100 When ...

Page 130: ...ssembly 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 12 8 Quicksilver Lubrication Sealant Application Points 95 2 4 C With Teflon 92 825407A12 14 2 Cycle Outboard Oil 92 13249A24 14 14 95 95 95 95 95 95 95 95 95 29 ...

Page 131: ... Assembly 14 1 Center Main Bearings 32 Each Main 15 2 Retaining Ring Center Mains 16 1 Bearing Race 1 Set Each 17 1 Crankshaft Sealing Rings Metal 2 Each Main 18 1 Key Gear 19 1 Gear 20 1 Lower Main Ball Bearing 21 1 Retaining Ring If Equipped 22 1 Seal Carrier Assembly 23 1 Crankshaft Seal 24 1 Wear Sleeve 25 1 O Ring Crankshaft Seal 26 1 Upper Main Bearing Seal 27 1 Flat Washer 28 1 Flywheel Nut...

Page 132: ...head Block and Cover Assemblies 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Quicksilver Lubrication Sealant Application Points 95 2 4 C With Teflon 92 825407A12 75 Loctite Master Gasket 92 12564 1 Perfect Seal 92 34227 1 19 19 95 95 75 95 ...

Page 133: ...vider Plate 4 2 Exhaust Plate Gaskets 5 1 Thermostat Poppet Valve Cover 6 1 Thermostat Poppet Valve Cover Gasket 7 1 Thermostat 8 1 Poppet Valve Assembly 9 1 Temperature Sensor 10 1 Cylinder Cover 11 1 Cylinder Cover Gasket 12 1 Starter Hold Down Brackets 13 1 Gasket Powerhead to Driveshaft Housing 14 1 Shift Rail 15 1 Crankcase Cover 16 1 Crankcase End Cap Lower 17 2 Check Valves ...

Page 134: ...nd Cap Bolts Lower 18 lb ft 24 4 N m Reed Block Assembly 80 lb in 9 0 N m Connecting Rod Bolts 30 lb ft 40 7 N m Check Alignment Turn bolt 90 further after torque of 30 lb ft is reached IMPORTANT See page 4A 32 this Section Intake Manifolds 18 lb ft 24 4 N m Each Manifold Crankcase Cover Bolts 1st Torque Pattern Large Bolts 25 lb ft 33 9 N m 2nd Torque Pattern Small Bolts 18 lb ft 24 4 N m 3 Step ...

Page 135: ...ust Cover and Divider Plate 18 lb ft 24 4 N m Electrical Component Plate 13 5 lb ft 18 3 N m Loctite 271 Required We recommend that you read the sub section on reassembly BEFORE proceeding There are specifics relating to this engine which are NOT applicable to prior engines ...

Page 136: ...nd Divider Plate Bolts 18 lb ft 24 4 N m Oil Injection Pump Bolts or Plate Cover 60 lb in 6 8 N m Fuel Pump Screws 40 lb in 4 5 N m Electrical Component Mounting Plate Bolts Loctite 271 used 13 5 lb ft 18 3 N m Stator Screws Loctite 271 used unless Patch Screw used 60 lb in 6 8 N m Starter Motor Hold Down Bolts 14 5 lb ft 19 7 N m Flywheel 120 lb ft 162 7 N m Intake Manifolds 18 lb ft 24 4 N m Air...

Page 137: ...sembly at point disassembly stopped If major powerhead repairs are being done remove powerhead from lower unit It is not necessary to remove powerhead for a Visual check for scoring or broken rings cylinder walls and pistons by viewing through exhaust ports b Minor external repair i e ignition system car buretors reed blocks thermostat checks etc Powerhead Component Removal 1 Remove Front Cowl Bra...

Page 138: ...t Oil Lines Remove Oil Reservoir 19097 a b c c a Oil Tank Support b Bolts 8mm c Nuts 6 7 Disconnect Throttle Linkage c 8 Remove main fuel hose a and fuel hose b Lift carburetors off as 1 unit assembly see next col umn 19093 a b c a Main Fuel Hose b Fuel Enrichment Hose c Throttle Linkage 9 Remove Flywheel Cover by removing 3 wing nuts 19546 1 unit Removal Of Carburetor Assembly 10 Remove Intake Ma...

Page 139: ...1 52344 remove flywheel nut and washer 20344 Crankshaft damage may result if a protector cap is not used between crankshaft and puller CAUTION 3 Install a crankshaft Protector Cap 91 24161 on end of crankshaft then install Flywheel Puller 91 73687A1 into flywheel 4 Install crankshaft Protector Cap 91 24161 on the end of crankshaft then install Flywheel Puller a 91 73687A1 into flywheel b NOTE Neit...

Page 140: ...e to simplify reassembly 20368 a a Bolts Disconnect cable to Power Trim 3 wires Temporarily install flywheel with nut as shown 20346 8 Remove shift arm linkage at stud 19060 a b a Shift Arm Linkage b Stud 9 Remove 8 bolts 3 each side 2 backside which secure powerhead to driveshaft housing 19070 10 nstall Lifting Eye 91 90455 onto flywheel Thread on at least 5 full turns 11 Twist powerhead or move ...

Page 141: ...p and oil injection pump 19056 a b a Screws b Bolts 4 Remove oil injection pump shaft and housing 20041 5 Remove thermostat housing and components 25907 a b c d a Bolts b Thermostat Cover c Thermostat d Poppet Valve 6 Remove cylinder block cover 20039 NOTE There are pry slots on casting as shown by screwdriver positions 7 Remove exhaust cover and divider plate 20029 ...

Page 142: ...n Each mating surface is slightly different so rebolt cap to rod immediate ly or mark rods and caps 19314 13 Remove main roller bearing assemblies 2 from crankshaft as follows S Remove retaining ring S Remove race S Remove main roller bearings 27649 a b c a c a Retaining Ring b Race c Main Roller Bearings 14 Remove 2 bolts each rod cap using a 3 8 12 point socket IMPORTANT Before disassembly use a...

Page 143: ...mble pis ton on same connecting rod 17770 a a Scribe Mark 18 Use piston ring expander 91 24697 to remove piston rings Always install new piston rings NOTE Cylinders must be honed in order for new rings to seat properly 51081 a b a Piston Ring Expander P N 91 24697 b Piston Rings Eye protection MUST BE worn while removing piston pin lockrings from piston CAUTION 19 Using an awl remove piston pin lo...

Page 144: ...ing Washers 22 Inspect crankshaft bearing Only if removal is necessary remove retaining ring using a pair of snap ring pliers 20037 a b a Crankshaft Bearing b Retaining Ring NOTE There is NO main bearing retaining ring or re taining ring groove in the crankshaft on the following outboards 75 90 SERIAL NUMBER OC259434 and above 23 Press crankshaft out of bearing as shown 20340 24 If oil pump drive ...

Page 145: ...ly with crankshaft place a block of wood over end of sleeve and tap lightly until it bottoms out Wipe off excess sealant The sleeve is lightweight 31 gauge stainless steel DO NOT col lapse the end contour or otherwise distort its shape Align squarely Tap gently a b c Cleaning and Inspection Cylinder Block and Crankcase Cover IMPORTANT Crankcase cover and cylinder block are a matched line bored ass...

Page 146: ...and cylinder bore After clean ing bores should be swabbed several times with 2 cycle engine oil and a clean cloth Wipe excess oil with clean dry cloth Cylinders should not be cleaned with kerosene or gasoline Clean remain der of cylinder block S Hone all cylinder walls just enough to de glaze S Measure cylinder bore inside diameter with an in side micrometer of each cylinder as shown be low Check ...

Page 147: ...odels and four cylinder 105 cubic inch 100 and 115 horsepower models NOTE Three cylinder and four cylinder outboards with starting serial number OC123214 and above have these kits installed from factory Installation Instructions 1 Referring to appropriate service manual remove powerhead from driveshaft housing 2 Remove all assemblies as required to obtain ac cess to crankcase cover 3 Remove crankc...

Page 148: ... halves REMOVAL 1 Remove carburetors and intake manifold reed block assemblies Refer to page 4A 10 11 for procedure 2 Grasp carrier and remove carrier check valve as sembly from crankcase cover 51621 a a Carrier Check Valve Assembly 3 Push check valve out of carrier If nylon ball within check valve is stuck or carrier is charred replace check valve and or carrier as required IMPORTANT SINGLE HOLE ...

Page 149: ...checked for straightness refer to Connecting Rods for checking straightness S Inspect piston for scoring and excessive piston skirt wear S Check tightness of piston ring locating pins Locating pins must be tight S Thoroughly clean pistons Carefully remove carbon deposits with a soft wire brush or carbon remover solution DO NOT burr or round off machined edges S Inspect piston grooves for wear and ...

Page 150: ... 004mm 3 390 in 86 106mm 0 030 in 0 752mm Oversize 3 401 in 86 385mm 3 405 in 86 487mm Crankshaft S Inspect crankshaft to drive shaft splines for wear Replace crankshaft if necessary S Check crankshaft for straightness Total maximum runout for crankshaft is 0 006 0 152mm Replace as necessary S Inspect crankshaft oil seal surfaces Sealing sur faces must not be grooved pitted or scratched Replace as...

Page 151: ...are removed from bearing surfaces S Clean piston pin end of connecting rod using same method as above Use 320 grit carborun dum cloth instead of crocus cloth S Thoroughly wash connecting rods to remove abra sive grit Recheck bearing surfaces of connecting rods Replace any connecting rod that cannot be properly polished Lubricate bearing surfaces of connecting rods which will be reused with 2 cycle...

Page 152: ... S Observe temperature at which thermostat begins to open Thermostat will drop off thread when it starts to open Thermostat must begin to open when temperature reaches 5_ F 3_ C above des ignated stamping on bottom of thermostat S Continue to heat water until thermostat is com pletely open S Unplug tester unit S Replace thermostat if it fails to open at the speci fied temperature or if it does not...

Page 153: ...operly cleaned or which are questionable can severely damage an otherwise perfectly good powerhead within a few minutes of operation All new powerhead gaskets must be installed during assembly During reassembly lubricate parts with Quicksilver 2 Cycle Outboard Oil whenever 2 cycle oil is specified and Quicksilver 2 4 C W Teflon whenever grease is specified A torque wrench is essential for correct ...

Page 154: ... by piston DESIGN 1 BOTTOM GUIDED Bottom View of Piston 51536 a b c a Ridged Washer b Smooth c Scalloped Top guided piston and rod assembly can be installed in a powerhead with bottom guided piston and rod assemblies However individual components cannot be inter mixed I E Top guided piston cannot be used with a bottom guided rod DESIGN 2 TOP GUIDED Bottom View of Piston 51536 a b c a Flat Washer b...

Page 155: ... connecting rod require replacement or should one or more be lost replace all of that connecting rod s piston pin needle bearings CAUTION Place sleeve which is part of Piston Pin Tool 91 74607A1 into connecting rod and install needle bearing around sleeve as shown 19537 a b a Needle Bearings 29 b Sleeve From Piston Pin Tool 91 74607A2 Place locating washers on connecting rod keeping lo cating wash...

Page 156: ... 1 050 in 26 7 mm Piston Ring Installation IMPORTANT Piston ring side with letter or mark must be facing up Piston Ring Piston rings are TAPERED top side and flat rectan gular on the bottom side half keystone rings Enlarged View of Piston Ring Grooves Care must be taken not to scratch the side surfaces of ring groove Scratching this area will damage the ring groove CAUTION 1 Install piston ring in...

Page 157: ...ring ten sion is there ring fails to spring back the ring is probably broken and must be replaced NOW before installing the crankshaft 20338 Crankshaft Installation If Lower Bearing and Gear were removed from crankshaft reassemble using arbor press and suitable mandrel for bearing gear slides on NOTE keyway and key in gear to crankshaft assembly Install main bearing retaining ring after pressing m...

Page 158: ...her lubricants are used inside the Powerhead damage to engine may occur CAUTION Grease crankshaft journal with Needle Bearing As sembly Lubricant to hold bearings in place Position bearings on journal 32 each center main bearing 20046 Attach bearing races with holes toward lower gear end of crankshaft Secure each main bearing race with retaining ring 20040 a b c a Main Bearing Race b Retaining Rin...

Page 159: ...ean sheet of paper and grease each bearing Place Bearing Cage in position Place Bearings in cage 20045 Grease crankshaft journal with Needle Bearing As sembly Lubricant or 2 4 C w Teflon Pull up rod into contact with crankshaft journal Place Bearing Cage on crankcase journal Place Bearings into cage Align bearing cages with rod to cap mating surfaces 20030 NOTE Make sure that Rod Bolt Hole threads...

Page 160: ... 51224 2 When connecting rods are attached and bolts drawn down finger tight torque rod cap bolts to 15 lb in 1 7 N m Recheck alignment Retorque 1 4 in bolts to 15 lb ft 20 3 N m or 5 16 in bolts to 30 lb ft 40 7 N m Recheck alignment Turn each rod cap bolt 90_ further after 30 lb ft reading is acquired S Replace lower crankshaft End Cap 1 Coat mating surface with Perfect Seal DO NOT coat O ring s...

Page 161: ...spect ALL hoses on reinstallation replace when necessary Note on Major Cover Gaskets These are new gaskets impregnated with a coating that causes the gasket to retain torque It is not necessary to use sealant on gasket or Loctite on bolts Cylinder Block Cover Align cover and gasket on block a b a Cover b Gasket Install thermostat cover and components as follows 1 Insert poppet valve d into valve s...

Page 162: ... 14 10 13 9 6 5 1 2 4 8 7 3 11 15 16 19 21 20 12 Reinstall Oil Injection Pump Shaft and housing check O rings replace as necessary IMPORTANT Insure that gears engage properly and that the O rings are seated properly on reas sembly or an oil injection failure could occur re sulting in possible powerhead damage 20041 IMPORTANT After reinstalling shaft and housing turn crankshaft make sure oil pump s...

Page 163: ...t of Quicksilver 2 4 C w Te flon to driveshaft splines Recheck for correct installation of tip seal in crank shaft seal carrier Use hoist to lower powerhead into driveshaft housing turning flywheel if necessary to align crankshaft splines with driveshaft splines Lower so that powerhead is fully installed and aligned on locating pins 20031 Clean holes threads and bolts thoroughly with Loc quic Prim...

Page 164: ... to 13 5 lb ft 18 3 N m S Install Starter Motor as outlined in Section 2 Torque to 14 5 lb ft 19 7 N m S Attach Enrichener Valve and connect hose See Section 3B NOTE See Section 2 D Wiring Diagrams S Attach Temperature Sensor g with 2 screws NOTE Temperature sensor opens at 170_F 8_ 77_C 8_ closes at 190_F 8_ 88_C 8_ g 20368 S Attach Test Button if so equipped ELECTRICAL COMPONENTS INSTALLED 20412...

Page 165: ...Y 19574 INTAKE MANIFOLD TORQUE SEQUENCE 4 2 1 3 5 4 Torque each intake manifold in sequence to 18 lb ft 24 4 N m NOTE Flywheel Cover Bracket uses longer bolts 5 Install Carburetor Gaskets 6 Reinstall Carburetors as Single Unit Assembly Note manifold hose position and connection 19094 a a Manifold Hose 7 Reconnect main fuel line hose and fuel enrich ment hose Secure fuel line a with sta strap 8 Rec...

Page 166: ... at beginning of this section 19072 a b c b a Oil Reservoir b Sta straps c Flywheel Cover 11 Install Gaskets Air Box Plate to carburetor 12 Reinstall Air Box Plate 13 Torque bolts to 100 lb in 11 3 N m 19097 14 Reinstall Air Box Cover and Gasket tighten screws securely 20335 ATTACH REAR COWL MOUNTING BRACKET Bracket attaches with 4 bolts Note washer sequence 4 places Torque bolts to 150 lb in 16 9...

Page 167: ... Install Mounting Bracket as shown below Grommets c and g normally are left in place in the bracket on disassembly Bushing d inserts in grommet c Position wiring and secure with cable retainer strap casting Note sequence of washers etc a b c d e f g e e e a Washer b Washer c Grommet d Bushing e Screw f Retainer g Grommet h Seal ...

Page 168: ...791 H GEAR HOUSING LOWER UNIT A 5 ...

Page 169: ... 19 Reassembly 5A 19 Forward Gear Bearing Race 5A 19 Shift Shaft 5A 19 Bearing Carrier Reassembly 5A 20 Forward Gear Reassembly 5A 22 Propeller Shaft Reassembly 5A 23 Drive Shaft Wear Sleeve Installation 5A 23 Lower Drive Shaft Bearing Race Installation 5A 24 Oil Sleeve Installation 5A 25 Upper Drive Shaft Bearing Installation 5A 25 Forward Gear Lower Drive Shaft Bearing Pinion Gear and Drive Shaf...

Page 170: ...5A 1 90 13645 2 1095 LOWER UNIT Notes ...

Page 171: ...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 7 Loctite 271 Obtain Locally 7 7 7 7 7 Quicksilver Lubrication Sealant Application Points 7 95 2 4 C With Teflon 92 825407A12 95 95 95 95 95 45 46 47 ...

Page 172: ...er 6 1 Screw 60 6 8 7 1 Washer 8 1 Screw 60 6 8 9 1 Washer 10 1 Screw Magnetic 60 6 8 11 1 Pinion Nut 70 94 9 12 1 Pinion Gear 13 1 Shift Cam Letters Face Up 14 1 Trim Tab 15 1 Washer 16 1 Trim Tab Bolt 22 29 8 17 1 Oiler Tube 18 1 Carrier 19 1 Needle Bearing Numbers Face Up 20 1 Gasket Not used with nylon cover assy 21 1 Oil Seal Lip Up 22 1 Oil Seal Lip Down 23 1 Cover Assembly 24 1 Gasket 25 1 ...

Page 173: ...inued Quicksilver Lubrication Sealant Application Points 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 34 36 37 38 39 40 41 42 43 44 7 Loctite 271 Obtain Locally 7 7 7 7 7 7 95 95 95 95 95 95 2 4 C With Teflon 92 825407A12 31 32 33 45 46 47 ...

Page 174: ... Pump Assembly 30 1 Water Tube Seal 31 4 Water Pump Bolt 60 6 8 32 Delete 33 Delete 34 6 Cover Screw 60 6 8 35 Delete 36 1 Wear Sleeve 37 1 Seal Ring 38 2 Bushing Screw 35 3 9 39 1 Oil Seal Lip Up 40 1 Shift Shaft Bushing 41 1 O Ring 42 1 Shift Shaft E Ring 43 1 Shift Shaft Long 1 Shift Shaft X Long 44 1 Gear Housing 45 1 Shift Shaft Adapter 46 1 Reverse Lock Cam 47 1 Washer ...

Page 175: ...95 5A 6 LOWER UNIT Propeller Shaft Components 1 2 3 4 5 6 7 8 9 10 16 28 29 7 7 11 12 13 14 15 17 18 19 20 21 22 23 24 25 26 27 30 95 2 4 C With Teflon 92 825407A12 7 Loctite 271 Obtain Locally 95 95 95 95 95 95 95 ...

Page 176: ... Ball Bearing 9 1 Slide Cross Pin 10 1 Spring 11 1 Clutch 12 1 Clutch Cross Pin 13 1 Retainer Spring 14 1 Propeller Shaft 15 1 Reverse Gear 16 1 O Ring 17 1 Thrust Bearing 18 1 Thrust Washer 19 1 Roller Bearing 20 1 Bearing Carrier 21 1 Washer 22 1 Nut Design 2 or Bolt Design 1 260 21 7 29 4 23 1 Roller Bearing 24 1 Oil Seal Lip In 25 1 Oil Seal Lip Out 26 1 Thrust Washer 27 1 Propeller 28 1 Tab W...

Page 177: ...lation Tool 91 13949 Oil Seal Driver 91 19660 Backlash Indicator Tool 4 Cyl From Bearing Removal and Installation Kit 91 31229A5 Removal WARNING To prevent accidental engine starting remove and isolate spark plug leads from spark plugs before removing gear housing 1 Remove and isolate spark plug leads from spark plugs 2 Shift engine into forward gear 3 Tilt engine to full Up position 4 Remove 4 bo...

Page 178: ...ing disassembly and component inspection 3 Note color of gear lubricant White or cream color MAY indicate presence of water in lubricant Gear lubricant which has been drained from a gear case recently in operation will have a yellowish color due to lubricant agitation aeration Gear lube which is mixed with assembly lubricant Spe cial Lube 101 or 2 4 C w Teflon will also be creamy white in color Th...

Page 179: ... output 5 Replace cover if thickness of steel at the dis charge slots is 0 060 or less or if groove s oth er than impeller sealing bead groove in cover roof are more than 0 030 0 762mm deep 6 Lift impeller drive key and gasket from drive shaft a b c 19220 a Impeller b Drive Key c Gasket 7 Inspect impeller Replace impeller if any of the following conditions exist Impeller blade s are cracked torn o...

Page 180: ...CYLINDER MODELS 100 and 115 have been modified to accept a new style plastic water pump base P N 19282A1 This new base does not require gaskets as it has a sili cone impregnated seal on the top and bottom As long as this silicone seal is not damaged i e cuts or abrasions it will retain its sealing capa bilities This new water pump base CANNOT BE USED on older gear housings The aluminum water pump ...

Page 181: ...er shaft 4 Remove propeller shaft from bearing carrier 51116 a d b e c a Bearing Carrier b Puller Jaws 91 46086A1 c Puller Bolt 91 85716 d Thrust Hub e Propeller Shaft 5 Lift reverse gear thrust bearing and thrust wash er from bearing carrier 6 Replace reverse gear if gear teeth or clutch teeth on reverse gear are chipped or worn If reverse gear must be replaced pinion gear and sliding clutch shou...

Page 182: ...d Installation Kit 91 31229A5 51264 a b c a Bearing b Mandrel 91 26569 c Driver Rod 91 37323 10 Remove if not removed with bearing in Step 9 propeller shaft seals and O ring 51263 a a O ring 11 Remove spring 51876 a a Spring 12 Apply constant pressure to cam follower to pre vent cam follower assembly from ejecting from propeller shaft while pushing cross pin out of clutch dog 51800 a b a Cross Pin...

Page 183: ...f f a Cam Follower b 3 Metal Balls c Guide Block d Spring e Sliding Clutch f Jaws 16 Check bearing surfaces of propeller shaft for pit ting or wear If shaft is worn or pitted replace shaft and corresponding bearing 17 Replace propeller shaft if any of the following exist a Splines are twisted or worn b Oil seal surface is grooved c Shaft has a noticeable wobble or is bent more than 0 009 in 0 228m...

Page 184: ... Replace forward gear if gear teeth or clutch teeth are chipped or worn 19175 a b c d e f a Drive Shaft Holding Tool 91 56775 b Pinion Nut c Drive Shaft d Pinion Gear e Bearing f Forward Gear 6 Replace bearing if it is rusted or does not roll free ly use a punch and hammer to remove bearing 19203 a a Bearing 7 Replace forward gear bearing and race if either are rusted or damaged or if bearing does...

Page 185: ...us ing Universal Puller Plate 91 37241 and lead hammer 19710 a b c d a e a Splines b Bearing Surface c Wear Sleeve d Universal Puller Plate 91 37241 e Lead Hammer 11 Remove and discard rubber ring 19152 a a Rubber Ring Upper Drive Shaft Bearing 1 Replace upper drive shaft bearing and sleeve if either are rust stained or if bearing will not roll freely Remove bearing and then sleeve using Puller As...

Page 186: ...ng Puller As sembly 91 83165M with suitable jaws 19222 a b a Oil Sleeve b Puller Assembly 91 83165M IMPORTANT Upper drive shaft bearing sleeve and oil sleeve do not have to be removed for lower drive shaft bearing race removal Lower Drive Shaft Bearing Race IMPORTANT Retain shim s for reassembly 1 Remove race and shim s using bearing race tool 91 14308A1 19171 a b c a Race b Shim s c Bearing Race ...

Page 187: ...hing and shift shaft 19225 a b a Bushing b Shift Shaft 4 Remove shift cam from housing 5 Replace shift cam if worn 51117 a a Shift Cam 6 Remove shift shaft bushing and clip from shift shaft 7 Replace shift shaft if splines are worn or shaft is twisted 8 Remove and discard O ring 19200 a b c d d e a Bushing b Clip c Shift Shaft d Splines e O ring 9 Remove and discard seal 19199 a a Seal ...

Page 188: ...speeds the boat turns more easily to the left loosen bolt move the trim tab trailing edge to the left when viewed from behind retighten bolt Turn trim tab trailing edge to the right if the boat turns more easily to the right 19172 a b c a Trim Tab b Anti Ventilation Plate c Retaining Bolt and Washer Torque Bolt to 22 lbs ft 29 8 N m Reassembly Forward Gear Bearing Race 1 Place shim s retained from...

Page 189: ... Splines 8 Apply Loctite 271 on bottom 1 2 of threads of bolts install bolts and torque to 60 lb in 6 8 N m 19216 a a Bolts Torque to 60 lb in 6 8 N m Bearing Carrier Reassembly 1 Lubricate O D of bearing and bearing carrier bore with Quicksilver 2 4 C w Teflon 2 Protect lip on forward side of bearing carrier using bearing installation tool 91 13945 3 Press propeller shaft needle bearing number si...

Page 190: ...tect lip on front side of bearing carrier using Bearing Installation Tool 91 13945 Apply Loctite 271 on O D of new seal Press seal into carrier until tool bottoms 21041 a b c a a Seal b Oil Seal Driver 91 31108 c Bearing Installation Tool 91 13945 8 Install O ring 9 Lubricate O ring with 2 4 C w Teflon Lubricate seal lips with 2 4 C w Teflon 92 825407A12 Lu bricate outside diameter of bearing with...

Page 191: ...r Reassembly 1 Press bearing onto gear press only on inner race of bearing 51869 a b a Mandrel 91 37350 b Bearing Lubricate I D with Quicksilver 2 4 C w Teflon 2 Apply 2 4 Cw Teflon to bore in center of gear 3 Press bearing into gear until bearing bottoms out NOTE Do not apply pressing force AFTER bearing bottoms out as bearing damage could result 28062 a b a Mandrel b Bearing Numbered Side Toward...

Page 192: ...ilver 2 4 C w Teflon 2 Install cross pin 51800 b a a Apply Pressure in This Direction b Cross Pin 3 Install spring DO NOT overlap springs 51876 a a Spring Drive Shaft Wear Sleeve Installation 1 Install new rubber ring 2 Apply a light coat of Loctite 271 on outside diameter of rubber ring 19152 a a Ring 3 Insert sleeve into holder Component of Wear Sleeve Installation Tool 91 14310A1 19169 a b b a ...

Page 193: ... be installed with or without upper drive shaft bear ing sleeve and oil sleeve installed 1 Lubricate O D of bearing race with Quicksilver 2 4 C w Teflon 2 Install shim s and bearing race into housing NOTE Verify shim s are not cocked when drawing up race 19150 a b c d e f f d e c a Shim s Retained From Disassembly If Shim s Were Lost or a New Gear Housing is Being Assembled Start With 0 025 0 635m...

Page 194: ...ng Numbered Side Toward Mandrel d Mandrel From Bearing Installation Tool 91 14309A1 IMPORTANT Oil sleeve must be installed prior to upper drive bearing installation IMPORTANT Upper drive shaft bearing sleeve can be installed with or without lower drive shaft bearing cup installed 3 Install bearing sleeve into housing 19151 a b c d e f f c e d a Bearing Sleeve b Tapered End c Mandrel d Mandrel e Th...

Page 195: ...gear assembly must be installed in gear housing when checking pinion gear depth or an inaccurate measurement will be obtained 1 Clean the gear housing bearing carrier shoulder and diameter 2 With gear housing positioned up right drive shaft vertical install Bearing Preload Tool 91 14311A1 over drive shaft in sequence shown a b c d e f g h h a Adaptor Bearing surfaces clean and free of nicks b Thru...

Page 196: ... MODEL GEAR RATIO PINION GEAR TEETH REVERSE GEAR TEETH USE FLAT NO 75 thru 90 3 Cylinder 13 30 8 100 115 125 4 Cylinder 14 29 2 10 Install the number 3 locating disc against bear ing carrier shoulder in gear housing 11 Position access hole as shown 24643 a b a Locating Disc b Access Hole 12 Determine pinion gear depth by inserting a feeler gauge thru access hole in locating disc 13 The correct cle...

Page 197: ... Bolt 91 85716 Torque to 45 lbs in 5 1 N m Refer to Bearing Carrier and Propeller Shaft Installation follow ing 4 Rotate drive shaft 5 to 10 revolutions This should properly seat forward gear tapered roller bearing 5 Install components as shown 51117 a b c d e f c a Threaded Rod Obtain Locally b Washers c Nuts d Dial Indicator Adaptor Kit 91 83155 e Dial Indicator 91 58222A1 f Backlash Indicator T...

Page 198: ...ately 0 001 025mm Bearing Carrier and Propeller Shaft Installation 1 Insert propeller shaft assembly into bearing carrier 2 Before installing bearing carrier assembly into gear housing obtain locally a 6 152 4mm long by 1 1 4 1 1 2 31 7 38 1mm diameter piece of PVC pipe Install the PVC pipe f over the prop shaft a and secure the pipe against the bearing carrier assembly b with the propeller nut g ...

Page 199: ... TOWARD POWER HEAD SPRING FACES TOWARD POWER HEAD a b b 51553 a a Seal b Oil Seal Driver 91 13949 8 Place seal on shorter shoulder side of Oil Seal Driver 91 13949 with seal lip toward shoulder 9 Apply Loctite 271 on O D of seal press seal into water pump base until tool bottoms 10 Lubricate lip of each seal with Quicksilver 2 4 C w Teflon 92 825407A12 LIP FACES TOWARD GEAR CASE GLOSS BLACK COLOR ...

Page 200: ... 4 C w Teflon 92 825407A12 16 Rotate drive shaft clockwise and push cover down over impeller 17 Install cover 18 If water tube seal stayed on water tube inside of drive shaft housing when gear housing was re moved pull water tube seal from water tube 19 Lubricate I D of water tube seal with Quicksilver 2 4 C w Teflon 92 825407A12 and install as shown 19212 a b c d c d b e a Cover b Isolators 4 If ...

Page 201: ...lug leads from spark plugs before working near the propeller Do not use automotive grease in the gear housing Use only Quicksilver Gear Lube or Quicksilver Super Duty Lower Unit Lubricant CAUTION 1 Remove any gasket material from Fill and Vent screws and gear housing 2 Install new gaskets on Fill and Vent screws IMPORTANT Never apply lubricant to gear hous ing without first removing Vent screws or...

Page 202: ...Bend 3 tabs of tab washer down into grooves to secure locknut If tab washer tabs do not align with slots continue to tighten locknut to obtain alignment Do not misinterpret propeller 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 CAUTION 7 After first use retig...

Page 203: ...6 Apply a light coat of Quicksilver 2 4 C w Teflon onto drive shaft splines 7 Apply a light coat of Quicksilver 2 4 C w Teflon on gear case shift shaft splines and upper shift shaft splines Do not use lubricant on ends of shift shafts 8 Install components as shown in appropriate photo 19883 a b a Nylon Spacer b Shift Shaft Coupler Used on Models Equipped with Power Trim 19221 a b c a Nylon Spacer ...

Page 204: ...ines water tube with water tube seal and crank shaft splines with drive shaft splines 13 Install 4 bolts and washers two each side 14 Install locknut and washer 15 Torque bolts and locknut or nuts only if applica ble to 40 lbs ft 54 N m 51552 a b a Bolts and Washers 4 b Locknut and Washer 16 Check shift operation as follows a Place shift lever in forward gear Gear housing should ratchet when prope...

Page 205: ...MID SECTION LOWER UNIT B 5 ...

Page 206: ... Table of Contents Page Page Swivel Bracket Components 5B 2 Transom Bracket Components 5B 4 Exhaust Plate Components 5B 6 Drive Shaft Housing Components 5B 8 Drive Shaft Housing Components 5B 8 Reference Views 5B 10 ...

Page 207: ...5B 1 90 13645 2 495 LOWER UNIT Notes ...

Page 208: ...2 495 LOWER UNIT Swivel Bracket Components 3 4 5 6 7 8 9 10 11 12 13 15 1 20 22 21 17 16 14 3 2 6 Quicksilver Lubrication Sealant Application Points 19 18 23 95 2 4 C With Teflon 92 825407A12 95 95 95 95 95 95 95 95 ...

Page 209: ...er UPPER 6 2 Grease Fitting 40 4 5 7 2 Bushing 8 1 Swivel Pin and Steering Arm Assembly 9 2 Bolt 10 2 Rubber Mount UPPER 11 2 Washer 12 2 Washer 13 2 Nut 80 108 4 14 1 Steering Link Assembly 15 1 Bolt 1 1 4 in 31 7mm Long 16 1 Lock Nut 20 27 1 17 1 Lock Nut 120 13 5 18 2 Washer 19 1 Wave Washer 20 1 Bottom Yoke 21 1 Retaining Ring 22 1 Thrust Washer ALUMINUM SIDE TOWARDS SWIVEL BRACKET 23 1 Bumper...

Page 210: ...s 1 2 4 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 14 6 5 20 22 23 87 Quicksilver Gear Lubricant 92 13783A24 87 Quicksilver Lubrication Sealant Application Points 28 3 95 2 4 C With Teflon 92 825407A12 95 95 7 Loctite 271 Obtain Locally 7 7 ...

Page 211: ...rive Nut Until Bottomed On Shoulder Of Tilt Tube 6 1 O Ring 7 2 Wave Washer 8 1 Nut 7 8 14 No Torque Requirement Drive Nut Until Assembly Is Drawn Together But Must Be Free To Pivot 9 4 Bolt 10 4 Washer 11 4 Nut 12 1 Tilt Lock Lever 13 1 Wave Washer 14 2 Bushing 15 1 Knob 16 1 Roll Pin 17 1 Spring 18 1 Groove Pin 19 1 Bolt 20 1 Nut 21 1 Lower Shock Absorber Shaft 22 6 Bolt 30 40 7 23 6 Lockwasher ...

Page 212: ...95 LOWER UNIT Exhaust Plate Components 1 2 3 4 5 6 7 8 9 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 10 2 7 Loctite 271 Obtain Locally Quicksilver Lubrication Sealant Application Points 7 ...

Page 213: ...ower Exhaust Tube 15 1 Water Tube 16 1 Clamp Water Tube Seal 17 1 Seal Upper Water Tube 18 2 Bolt Water Tube Clamp 80 9 0 19 1 Grommet Water Tube 20 1 Bracket Lower Cowl 21 1 Seal Lower Cowl Bracket 22 3 Bolt Lower Cowl Bracket 23 31 2 23 1 Shift Shaft Bushing 24 1 Upper Shift Shaft 25 1 Shift Shaft Bushing 26 1 Shift Link 27 1 Wave Washer Shift Shaft 28 1 Washer Shift Nut 29 1 Lock Nut Shift Shaf...

Page 214: ...using Components 1 2 4 5 6 7 8 9 10 11 12 15 16 17 18 20 21 22 23 24 25 26 28 29 31 32 33 34 35 36 27 28 17 5 6 Quicksilver Lubrication Sealant Application Points 3 30 19 95 2 4 C With Teflon 92 825407A12 95 95 95 95 17 17 Loctite 35 92 59328 1 17 ...

Page 215: ...10 1 Straight Connector 11 2 Lower Mount 12 2 Lower Mount Bolt 13 2 Washer CHAMFER SIDE TOWARDS MOUNT 14 2 Washer 15 2 Washer 16 2 Nut 50 67 8 17 1 Ground Strap 18 1 Ground Strap Bolt 19 2 Lower Mount Clamp 20 4 Nylon Nut 21 4 Clamp Bolt 13 8 18 7 22 2 Lower Mount Cover 23 4 Cover Screws Drive Tight NON POWER TRIM 24 1 Reverse Lock Hook 25 1 Push Rod 26 1 Shaft 27 1 Cotter Pin 28 2 Bushing 29 1 Sp...

Page 216: ...Washer e Bushing Lower f Oil Seal Lips Face Down Lower Mount Point Yoke 21054 a c b d e f g h i a Push Rod End b Nut c Push Rod Yoke d Cotter Pin e Clevis Pin f Reverse Lock Hook Shaft Arm g Reverse Lock Hook Shaft h Return Spring i Tilt Pin Non Power Trim Reverse Lock Hook Shown From Above 21053 a b c e f f d a Push Rod Shaft b Spring c Push Rod Yoke d Clevis Pin e Reverse Lock Hook Shaft f Cotte...

Page 217: ...1049 a a Upper Shift Linkage 21050 a b c d e f a Upper Shift Linkage b Steering Arm Swivel Pin c Upper Mount Bolt d Swivel Bracket e Grease Fitting f Mid Section Drive Shaft Housing 21051 a b c d e f g h i c a Lower Mount Clamp b Ground Strap c Bolt 2 Torque to 15 lb ft 20 3 N m d Lower Mount Bolt e Washer f Washer g Nut Torque to 50 lb ft 67 8 N m h Ground Strap i Bolt Lower Mount Port Side Shown...

Page 218: ...SHOCK ABSORBER LOWER UNIT C 5 ...

Page 219: ...90 13645 2 495 Table Of Contents Page Page Engine Equipped with a Single Shock Absorber 5C 1 Removal 5C 1 Inspection and Repair 5C 2 Installation 5C 3 ...

Page 220: ...C CONVERSION 17 43 18 cm 2 1 2 63 50 mm 3 8 9 50 mm 5 16 7 94 mm Use a metal rod 5 16 diameter to make support tool 17 3 8 3 8 2 1 2 b c c a 53983 a Tilt Lock Lever b Support Tool c Retaining Clips 2 To remove tilt pin when straight cross pin is installed use a punch and hammer to drive out tilt pin shearing cross pin and remove halves of sheared cross pin 3 To remove tilt pin when headed cross pi...

Page 221: ...ized with gas Do not disassemble unless fluid is leaking from shock absorber CAUTION NOTE A pressurized shock absorber makes tilting of the engine easier than a non pressurized shock absorber If the shock absorber leaks fluid it can be rebuilt by installing Shock Absorber Repair Kit P N 41760A2 however the shock absorber will no longer be pressurized and the force needed to tilt the engine will be...

Page 222: ...s shown and reinstall anode plate Secure anode with 2 bolts and washers Torque bolts to 60 lb in 6 8 N m 17256 a a Cross Pin a a Bolts Torque to 60 lb in 6 8 N m 3 Reinstall shock absorber assembly between clamp brackets and secure shock assembly to clamp brackets with 6 bolts and lockwashers 3 each clamp bracket Torque bolts to 30 lb ft 40 7 N m 17244 b a a Bolts Torque to 30 lb ft 40 7 N m b Sho...

Page 223: ...17250 DESIGN I SIDE FILL RESERVOIR POWER TRIM A 6 ...

Page 224: ...hen Up Circuit Is OK 6A 14 Troubleshooting the Up Circuit When Down Circuit Is OK 6A 15 Troubleshooting the Down and Up Circuits All Circuits Inoperative 6A 16 Power Trim Assembly Removal and Installation 6A 17 Removal 6A 17 Support Tool 6A 17 Installation 6A 19 Testing Power Trim System with Test Gauge Kit 91 52915A3 6A 20 UP Pressure Check 6A 21 DOWN Pressure Check 6A 22 Power Trim Components 6A...

Page 225: ...im 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 range as long as the engine RPM is above approximately 2000 RPM The outboard can be trimmed above the 20 degree maximum trim angle for shallow water operation etc by keeping the engine RPM below 2000 If the RPM increases over...

Page 226: ... Boat operation with outboard trimmed to the full In trim angle not using the trim angle adjustment bolt at planing speed 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 the trim angle adjustment bolt and trimmed to the full In trim angle position ...

Page 227: ...m sender if not previously installed Fill Check and Purge Power Trim System TO FILL IMPORTANT This trim system is pressurized Re move Fill plug only when outboard is tilted to the full Up position or the trim tilt rams are fully extended Retighten Fill plug before tilting out board down or retracting tilt trim rams Remove Fill plug and O ring System is full when oil level is present at fill hole T...

Page 228: ... it will be necessary to bleed air from the Power Trim system Bleed air from Power Trim system as follows IMPORTANT This trim system is pressurized Re move fill screw only when engine is trimmed to the full up position Retighten fill screw secure ly before trimming engine down Trim engine 3 or 4 times thru entire trim range check fluid level fill if necessary each time engine is trimmed to the ful...

Page 229: ...ilted for any extended period Engine will not return completely to down position or returns part way with jerky motion Engine will not trim up or down Engine trims up will not trim down Engine trims down will not trim up Engine thumps when shifted Engine trails out when backing off throttle at high speed Engine will not hold trim position when in reverse Determine if Power Trim pump motor operates...

Page 230: ...m rod O ring and replace if damaged Reinstall trim rod in housing refer to Trim Rod Installation following 6 Disconnect trim pump motor wires and remove starboard transom bracket from engine Refer to Removal instructions in Power Trim Assembly Removal and Installation following Slowly remove fill screw to bleed pressure from reservoir Place a pan under manual release valve and slowly remove valve ...

Page 231: ... and Hex Nut Apply Liquid Neoprene to Connection TRIM INDICATOR GAUGE 8 PIN HARNESS BLK TRIM SENDER IGNITION CHOKE SWITCH Wiring Diagram For boats equipped with Quicksilver Ignition Choke and Main Harness Assembly ENGINE GROUND Wiring Diagram For boats equipped with Quicksilver Commander 2000 Series side mount remote control TRIM INDICATOR GAUGE 12 PIN HARNESS REMOTE CONTROL ENGINE GROUND TRIM SEN...

Page 232: ... e f g BLK DBLACK BLU DBLUE BRN DBROWN GRY DGRAY GRN DGREEN PUR DPURPLE RED DRED TAN DTAN WHT DWHITE YEL DYELLOW a Ignition Choke Switch b Emergency Stop Switch c Neutral Start Switch d Tachometer Accessories Harness Connector e Wiring Harness Connector f Warning Horn g Trim Tilt Switch ...

Page 233: ...6A 9 POWER TRIM 90 13645 2 495 Commander Side Mount Remote Control Wiring Diagram ...

Page 234: ...ED DRED WHT DWHITE Power Trim System Wiring Diagram 3 Cylinder Models Using COMMANDER Side Mount Remote Control Power Trim System Wiring Diagram 3 Cylinder Models Using COMMANDER 2000 Side Mount Remote Control Power Trim System Wiring Diagram 4 Cylinder Models Using COMMANDER 2000 Side Mount Remote Control 23885 23886 23884 10 6 9 3 12 2 1 14 10 6 9 12 2 1 14 3 3 12 9 14 10 6 1 2 ...

Page 235: ...iler button Battery Voltage Indicated D Check Up solenoid terminals for loose or corroded connections D Check BLACK ground wire on Up solenoid for corrosion or open D Test Up solenoid Refer to Motor and Electrical Tests following Remote Control Equipped with Trailer Button If wire is OK disconnect all battery leads from battery and check continuity across trailer button terminals with trailer butt...

Page 236: ...r Circuit Is OK Use an Ohmmeter R x 1 scale and check continuity of wire between Point 10 on Up solenoid and Point 7 on trim button No Continuity Wire is open between Point 10 and Point 7 Battery Voltage Indicated D Check for poor connection at Point 7 No Voltage Indicated Wire is open between trailer button Point 11 and trim switch Point 8 push button trimswitch orPoint5 toggletrimswitch No Volta...

Page 237: ...oltage is being supplied to control by performing the following checks D DO NOT start engine D Turn ignition switch to Run position D Check for voltage at any instrument using a Voltmeter No Voltage Indicated RED wire is open between Point 14 and terminal b on the back of the ignition switch D Check for loose or corroded connections D Check for open in wire Battery Voltage Indicated There is an op...

Page 238: ...button If battery voltage is indicated wire is open between Points 4 and 1 Battery Voltage Indicated D ConnectVoltmeterREDleadtoPoint2 D Depress Down trim button No Voltage Indicated Connect Voltmeter RED lead to Point 5 If battery voltage is indicated trim switch is faulty If no battery voltage check for loose or corroded connection at Point 5 or open circuit in wire supplying current to Point 5 ...

Page 239: ...Up trim button No Voltage Indicated Trim Switch is faulty or there is an open circuit in wires GREEN WHITE BLUE WHITEandPURPLE WHITE or PURPLE betweentrimpoint7andtrim pump D Check trim switch D Check all trim harness connectors for loose or corroded connections D Check for pinched or severed wires Battery Voltage Indicated D Connect VoltmeterRED lead to Point 6 D Depress Up trim button Battery Vo...

Page 240: ...mbuttonandcheckfor battery voltage Battery Voltage Indicated D Check BLACK ground wires at solenoids for poor connection or poor ground D CheckBLACKmotorleadforpoorground at Point 12 If wire is grounded the pump motor is faulty Refer to Motor and Elec trical Tests Repair following No Voltage Indicated RedwireisopenbetweenPoint14andRED terminal on back of the ignition switch D Check for loose or co...

Page 241: ...age tilt lock lever WARNING Failure to support outboard as shown could result in personal injury and or damage to outboard or boat 20319 a a Tilt Lock Lever 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 a 14 2 1 4 a a Drill Holes for Retaining Clips METRIC CONVER...

Page 242: ...4 Open filler cap and release any remaining pres sure in the system 20319 a a Filler Cap IMPORTANT Outboards equipped with thru the tilt tube steering remove steering link arm from end of steering cable and cable retaining nut from tilt tube 51354 a a Retaining Nut 5 Remove outboard transom mounting bolts and loosen tilt tube nut until nut is flush with end of tilt tube thread 51375 a a b a Transo...

Page 243: ... 1 Paint any exposed metal surfaces to prevent corrosion 2 Apply Loctite 271 to screws Install trim system starboard transom bracket and tilt tube nut 51375 a b a Screw 6 Torque to 45 lb ft 61 0 N m b Flatwasher 6 Install one per screw 3 Use a 12 volt power source to extend tilt ram up to align upper swivel shaft hole and end of ram Connect trim motor wires BLUE wire to POS ITIVE BLACK wire to NEG...

Page 244: ...ertight 8 Tighten tilt tube nut securely IMPORTANT Outboards equipped with thru the tilt tube steering Tighten steering cable retaining nut securely to tilt tube 51354 a a Steering Cable Retaining Nut 9 Apply Quicksilver Liquid Neoprene 91 25511 2 on all electrical connections 20290 a b a Harness Retainer b Clamp WARNING Electrical wires passing through cowl openings must be protected from chafing...

Page 245: ... Fill plug to bleed pressure from reservoir 3 Turn Manual Release Valve 3 to 4 turns counter clockwise to bleed any remaining pressure 4 Remove allen plug 17250 a a Allen Plug 5 Install components 17259 a b c d e a Adaptor Fitting 22 11243 b Test Gauge Assembly c Tilt Pin Position in Hole Shown d Hose Route Hose Behind Tilt Pin as Shown e Hose Not Used for This Check 6 Disengage tilt lock lever ...

Page 246: ...Install Fill plug 9 Close Manual Release Valve clockwise 10 Open valve a and close valve b 51374 a b a Open Valve b Close Valve 11 Run trim UP The minimum pressure should be 1300 P S I 91 kg cm2 12 Run trim DOWN to release pressure and re move spare tilt pin or bolts and nuts 13 Tilt outboard full UP and engage tilt lock lever 14 Slowly remove Fill plug to bleed pressure 15 Open Manual Release Val...

Page 247: ...e Manual Release Valve clockwise 6 Run trim DOWN Minimum pressure should be 500 P S I 35 kg cm2 7 Tilt outboard full UP and engage tilt lock lever 8 Slowly remove Fill plug to bleed pressure 9 Open Manual Release Valve 3 to 4 turns to re lease any remaining pressure 10 Remove test gauge hose and adapter fitting Install allen plug 11 Fill Power Trim system and purge system refer to Fill Check and P...

Page 248: ...rosion Grease 92 78376A6 Power Trim and Steering Fluid 92 90100A12 Liquid Neoprene 92 25711 2 94 25 110 7 Loctite 271 Obtain Locally 7 25 26 110 TORQUE REF NO DESCRIPTION lb in lb ft N m 1 Housing 2 Allen Plug 3 Manual Release Valve 4 O ring 239 6 07mm I D 5 O ring 208 5 28mm I D 6 O ring 114 2 90mm I D 7 O ring 989 25 12mm I D 8 Shaft 9 Trim Rod Assembly Starboard 10 Anode Plate 11 Washer 12 Bolt...

Page 249: ...1 Fill Screw JD32 O ring 2 739I 69 57mm I D If Equipped 33 Square Motor Assembly 34 Square Ring used when end frame cap has groove 35 Gasket used when end frame cap does NOT have groove 36 Bolt 70 7 9 37 Allen Bolt 70 7 9 38 Lockwasher 39 End Frame Cap 40 O ring or Flat Ring J41 O ring 2 739I 69 57mm I D J42 O ring 2 614I 66 40mm I D J43 Flat Ring 44 Pump Assembly 45 Screen If Equipped 46 Washer I...

Page 250: ...clockwise to Remove 51337 a b a Removal Tool 91 44487A1 b Spanner Wrench 91 74951 5 Install trim rod removal tool and pull trim rod from cylinder 27933 a a Trim Rod Removal Tool 91 44486A1 CLEANING AND INSPECTION TRIM RODS AND CAPS Do not remove check valve a Check valve is preset to operate at a specific pressure Removal and installation of check valve could result in improper operating pressure ...

Page 251: ...t and lint Any debris in the system can cause system to malfunction NOTE Install trim rod with check valve in the port left cylinder 1 Apply Quicksilver Power Trim and Steering Fluid on all O rings and seals before installation 2 Install trim rods and caps Use Installation Tool 91 44487A1 or Spanner Wrench 91 74951 to tighten caps securely 51353 a a b b c c a Trim Rods b Cylinder End Caps c Rod En...

Page 252: ... m 1 1 Housing Tilt Ram 2 1 O ring 1 957 I D 3 1 Cup 4 1 O ring 307 I D 5 1 Rod End 6 1 O ring 661 I D 7 1 Washer 8 1 Piston 9 1 O ring 2 067 I D 10 1 Cap 11 1 O ring 854 I D 12 1 Scraper 13 1 Washer 14 1 Retaining Ring 15 1 Check Valve Assembly 16 1 Check Valve Assembly 17 1 Roll Pin 18 1 Rod Contents of Tilt Cylinder O ring Kit P N 25 41478A1 ...

Page 253: ... 3 to 4 turns counter clockwise to bleed remaining pressure from Power Trim system Remove pin by driving pin in direction shown 51366 a a Pin 2 Remove shaft by driving shaft in direction shown 51355 a a Shaft DISASSEMBLY 1 Secure tilt ram at its base in a soft jawed vise Using Spanner Wrench loosen cap by turning cap in direction Remove ram from vise and pour fluid from ram Pull rod assembly out o...

Page 254: ...erclockwise Direction 3 Lift washer and piston from rod do not let check valve assemblies fall Remove check valve assemblies 51363 a b c a Washer b Piston c Valve Assemblies 4 Slide cap off from rod 51376 a a Cap 5 Remove roll pin using a punch and hammer Remove check valve assembly a b a Roll Pin b Check Valve Assembly 6 Remove allen plug from shaft IMPORTANT Remove plug from same side as holes i...

Page 255: ...down on housing and inject air into shaft opening as shown Reinstall allen plug into shaft 51353 a b c a Shop Cloth b Solid Work Bench or Floor c Air Nozzle CLEANING AND INSPECTION Inspect O rings and replace if damaged Clean components with parts cleaner and dry with compressed air Inspect tilt rod If scraper located in cap has failed to keep rod clean replace scraper refer to instructions follow...

Page 256: ...sizes Install O rings 2 Insert cup into housing a b 51372 a a O ring b Memory Piston Cup Design 1 shown 3 Assemble cap as shown c a b d e b a End Cap b O ring 2 c Scraper Seal d Washer e Retaining Ring 4 Install components as shown a b c d a Piston b Roll Pin c Check Valve Assembly d O ring 5 Install O rings in locations shown a b a Rod End b O rings 6 Install end cap 51376 NOTE Some tilt rams hav...

Page 257: ...341 a b c 51337 91 74951 a Housing b Rod Assembly c Cap INSTALLATION 1 Lubricate alignment tool and shaft with Quicksil ver Power Trim and Steering Fluid or Automatic Transmission Fluid ATF Type F FA or Dexron II 51369 a b a Alignment Tool 91 11230 b Shaft 2 Align tilt ram with Power Trim housing by inserting alignment tool in direction shown 51348 a a Alignment Tool 3 Install shaft into housing a...

Page 258: ...until 1 4 6mm of each bolt is ex posed Do not remove bolts 18458 a a 1 4 1 4 a Bolts Tighten manual release valve to full right clockwise Operate trim motor in Up direction by connecting trim motor wires to a 12 volt battery BLUE wire to POSITIVE terminal and BLACK wire to NEGATIVE terminal Slowly remove fill screw to bleed pressure from reservoir From a full closed clockwise position slowly turn ...

Page 259: ...ectrical Tests Repair Thermal Overload Switch Test IMPORTANT If trim pump has just been operated do not run pump for approximately one minute be fore testing thermal overload switch After this period of time the switch should close reset it self and pump again may be operated Perform the following check s only if switch does not re set itself MOTOR ASSEMBLED Connect Ohmmeter R x 1 scale leads as s...

Page 260: ...ds 2 Connect a 12 volt supply to motor wires POS ITIVE wire to BLUE motor wire and NEG ATIVE wire to BLACK motor wire Motor should run 3 If motor does not run disassemble motor and check components Refer to Motor Repair following Solenoid Test WARNING Do not perform this test near flammable materials as a spark may occur while making electrical connections 1 Disconnect all wires from solenoid term...

Page 261: ...2 Clean commutator with OO sandpaper a a Commutator Field Tests IMPORTANT Commutator end of armature must be installed in brushes when performing the fol lowing tests Ohmmeter Leads Between Resistance Ohms Scale Reading x Green and Blue Motor Wires 0 Full Continuity R x 1 Green and Black Motor Wires 0 Full Continuity R x 1 Blue and Black Motor Wires 0 Full Continuity R x 1 Black Motor Wire and Fra...

Page 262: ...r needle is not at the bottom of the green arc on the gauge face tilt engine up to gain access to the trim sender Loosen screws and reposition trim sender as shown Trim engine to full Down position and re check needle position 22744 a b c d e a Trim Sender b Screws Loosen to Rotate Sender c Turn Sender Counterclockwise to Raise Needle Reading d Turn Sender Clockwise to Lower Needle Reading e Tilt ...

Page 263: ... N m 1 4 Thru Bolt 13 1 5 2 4 Nylon Washer If Equipped 3 4 O ring 4 3 Self Tapping Screw 13 1 5 5 1 Retainer metal 6 1 Nylon Isolator If Equipped 7 1 Seal rubber 8 1 End Frame Cap upper 9 2 Square Ring used when end frame cap has groove 10 2 Gasket used when end frame cap does not have groove 11 3 Connector metal 12 2 Sleeve 13 4 Brush Spring 14 1 Brush Card 15 1 Field and Frame Assembly 16 1 Thru...

Page 264: ... lip of seal 18452 a b c d e c a O ring or Flat Ring b O ring 2 739 69 57mm I D c O ring 2 614 66 40mm I D d Flat Ring e Seal 2 Apply Loctite 271 on bolts and install end frame cap 18469 a b a Bolts b End Cap NOTE Some motors use 2 bolts to secure end frame cap 3 Install a flat ring if equipped into groove in each end cap NOTE Verify rings are not twisted after installation 18465 a a Flat Ring If ...

Page 265: ...re b Pump 5 Install field and frame assembly onto pump as shown 18454 a b a Thermal Overload Switch b Rocker Arm 6 Spread brushes position brushes as shown Install thrust washer if equipped 18457 a b a a Brushes b Thrust Washer 7 Install end cap and screws e d c b a 51345 a a b a Screw 4 b Screw 3 c Clamp d Gasket e Grommet ...

Page 266: ...ower Trim system by applying Quicksilver Liquid Neoprene on seam 18461 a b c b a a Bolts b Lockwashers c Seam 10 Install starboard transom bracket steering retain ing nut models with thru tilt tube steering and motor wires refer to Installation instructions in Power Trim Assembly Removal and Installation preceding Brush Replacement Square Motor 1 Brush replacement is recommended if brushes are pit...

Page 267: ...tic insulators 18463 a a a Insulators 3 Remove metal connectors by separating the slit in connectors using a side cutter as shown 18466 a a a a Metal Connectors Install new brush card Crimp metal connectors on connections Use heat shrink tubing to insulate connections ...

Page 268: ...DESIGN II AFT FILL RESERVOIR POWER TRIM B 6 51344 ...

Page 269: ...ing the Down and Up Circuits All Circuits Inoperative 6B 13 Power Trim Assembly Removal and Installation 6B 14 Removal 6B 14 Support Tool 6B 14 Installation 6B 16 UP Pressure Check 6B 18 DOWN Pressure Check 6B 19 Hydraulic Repair 6B 20 Trim Rod Removal and Repair 6B 20 Cleaning And Inspection Trim Rods and Caps 6B 20 Trim Rod End Cap Seal 6B 21 Trim Rod Installation 6B 21 Tilt Ram 6B 22 Removal Ti...

Page 270: ...91 11230 Alignment Tool 91 44486A1 Trim Rod Removal Tool 91 44487A1 Trim Rod Guide Removal Tool 91 52915A3 Power Trim Test Gauge Kit 91 11243 Adaptor Fitting 91 74951 Spanner Wrench 91 99750 Multi Meter DVA Tester Quicksilver Lubricants and Service Aids Part No Description 91 90100A12 Power Trim and Steering Fluid Obtain Locally Loctite 271 91 25711 1 Liquid Neoprene 91 78376A6 Anti Corrosion Grea...

Page 271: ...ing Fluid 1 2 11 12 13 14 15 16 18 20 21 25 29 30 32 35 4 5 24 34 Liquid Neoprene 92 25711 1 Power Trim and Steering Fluid 92 90100A12 94 Anti Corrosion Grease 92 19007A24 10 23 17 26 28 27 9 94 7 25 7 7 3 6 22 3 6 7 8 7 38 37 36 18 18 18 39 40 33 18 10 18 31 6 18 19 18 7 Loctite 271 Obtain Locally 110 25 110 ...

Page 272: ...bly 12 1 Groove Pin 13 1 Valve Assembly 14 1 E ring 15 4 Screw 16 4 Washer 17 1 Cover 18 1 O ring Kit 811612A1 19 1 Plug Assembly 20 1 Shaft Assembly 21 2 Plug Pipe 22 1 Trim Motor 23 2 Screw Long 70 7 9 23 2 Screw Short 70 7 9 24 1 Pump 25 1 Driveshaft 26 1 Shaft 27 1 Anode Assembly 28 2 Screw 60 6 8 29 2 Washer 30 2 Striker Plate 31 2 Lockwasher 32 2 Nut 80 9 0 33 1 Groove Pin 34 1 Control Harne...

Page 273: ...uit actuates the up solenoid under out board cowl and closes the motor circuit The electric motor drives the pump forcing fluid thru passage ways into the up side of the 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 range as long as the engine RPM is...

Page 274: ...clockwise Close manual release valve to hold out board at the desired tilt position 51353 a a Manual Release Valve Trim In Angle Adjustment WARNING Boat operation with outboard trimmed to the full In trim angle not using the trim angle adjustment bolt a at planing speed may result in undesirable and or unsafe steering conditions A water test for handling steering conditions is required after any t...

Page 275: ...tion will be lost Trim Indicator Gauge A Quicksilver Trim Indicator Gauge accessory kit is available for the power trim sender if not previously installed Fill Check and Purge Power Trim System IMPORTANT This trim system is pressurized Re move Fill plug only when outboard is tilted to the full Up position or the trim tilt rams are fully extended Retighten Fill plug before tilting out board down or...

Page 276: ...emove fill plug and O ring System is full when oil level is present at filler hole Tighten fill plug securely Hydraulic System Troubleshooting IMPORTANT Operate Power Trim System after each check to see if problem is corrected If prob lem has not been corrected proceed to next check 1 Check that Manual Release Valve knob is tight ened to full right clockwise position 2 Check trim pump fluid level ...

Page 277: ...r load 2 5 6 H Trail out when backing off from high speed 3 4 I Leaks down and does not hold trim 2 5 7 J Trim motor working hard and trims slow up and down 8 9 K Trims up very slow 1 2 8 9 L Starts to trim up from full down position when IN trim button is depressed 3 4 M Trim position will not hold in reverse 3 4 PROBLEM 1 Low oil Level 2 Pump Assembly faulty 3 Tilt ram piston ball not seated dis...

Page 278: ...do not activate trim system 2 4 5 6 PROBLEM 1 Battery low or discharged 2 Open circuit in trim wiring 3 Wiring reversed in remote control 4 Wire harness corroded through 5 Internal motor problem brushed shorted armature 6 Blown fuse s 7 Trim Solenoids Failed NOTE Refer to following pages to troubleshoot Power Trim Electrical System POWER TRIM SYSTEM WIRING DIAGRAM 51306 BLK Black BLU Blue GRN Gree...

Page 279: ...6B 10 90 13645 2 495 POWER TRIM Side Mount Remote Control Wiring Diagram Test Points for Electrical Troubleshooting 23891 5 4 7 ...

Page 280: ...s defective Connect Voltmeter RED lead to Point 2 Connect Voltmeter RED lead to Point 9 ConnectVoltmeterREDleadtoPoint4 and BLACK lead to ground Depress Down trim button If battery voltage is indicatied wireisopenbetweenPoints 4 and 1 Depress the Down trim button Depress Down trim button Check Down solenoid terminals for loose or corroded connections Check BLACK ground wire on Down solenoid for co...

Page 281: ... 3 There is an open circuit in wires BLUE WHITE PURPLE WHITE orPURPLE between Up solenoid and trim switch Depress the Up trim button Depress Up trim button Check Up solenoid terminals for loose or corroded connections Check BLACK ground wire on Up solenoid for corrosion or open Check for loose or corroded connec tion at Point 9 or Point 3 Check RED lead between Point 9 and Point 3 for open Test Up...

Page 282: ...t Point 11 If wire is grounded the pump motor is faulty Refer to Motor and Electrical Tests Repair following Check for open in wire Checkforlooseorcorrodedconnections Check for voltage at any instru ment using a Voltmeter Turn ignition switch to Run position DO NOT start engine Check for pinched or severed wires Checkalltrimharnessconnectorsforloose or corroded connections Check trim switch Connec...

Page 283: ...re to support outboard as shown could result in personal injury and or damage to outboard or boat 51346 a b c c a Tilt Lock Lever b Support Tool 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 14 2 1 4 a a a Drill Holes for Retaining Clips METRIC ...

Page 284: ...ler Cap IMPORTANT Outboards equipped with thru the tilt tube steering remove steering link arm from end of steering cable and cable retaining nut from tilt tube 51354 a a Retaining Nut 5 Remove outboard transom mounting bolts and loosen tilt tube nut until nut is flush with end of tilt tube thread 51375 b a a Transom Mount Bolts 2 b Tilt Tube Nut flush with end of thread 6 Remove 3 screws and wash...

Page 285: ...y Loctite 271 to screws Install trim system starboard transom bracket and tilt tube nut 51375 a b c a Screw 6 Torque to 45 lb ft 61 0 N m b Flatwasher 6 Install one per screw c Tilt Tube Nut 3 Use a 12 volt power source to extend tilt ram up to align upper swivel shaft hole and end of ram Connect trim motor wires BLUE wire to positive BLACK wire to negative If ram extends too far retract ram by co...

Page 286: ...ation is watertight 8 Tighten tilt tube nut securely IMPORTANT Outboards equipped with thru the tilt tube steering Tighten steering cable retaining nut securely to tilt tube 51354 a a Steering Cable Retaining Nut 9 Apply 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 ...

Page 287: ...ose e Hose not used for this check 6 Disengage tilt lock lever Failure to install spare tilt pin or hardened bolts and nuts in hole shown could result in transom bracket failure and possible injury CAUTION 7 Move outboard In until hole in swivel bracket ear aligns with the third tilt hole in transom brack et Lock engine in trim range by installing a 3 8 in 9 5 mm diameter tilt pin or two 3 8 in 9 ...

Page 288: ...g as shown 51367 a a Allen Plug 2 Install components 51360 a b c d e f a Adapter Fitting 22 11243 b Hose route hose so it will not be pinched when outboard is trimmed DOWN c Test Gauge Assembly d Valve e Valve f Hose not used for this test 3 Open valve d and close valve e 4 Install fill plug 5 Close Manual Release Valve clockwise 6 Run trim DOWN Minimum pressure should be 500 P S I 35 kg cm2 7 Til...

Page 289: ...ps NOTE Place a clean pan under trim system to catch fluid 51353 a b b a Trim Rod Cylinder Cap b Turn Counterclockwise to Remove 51337 a b a Removal Tool 91 44487A1 b Spanner Wrench 91 74951 5 Install trim rod removal tool and pull trim rod from cylinder a 27933 a Trim Rod Removal Tool 91 44486A1 CLEANING AND INSPECTION TRIM RODS AND CAPS Do not remove check valve a Check valve is preset to operat...

Page 290: ...e as shown 2 Install new seal with seal lip up TRIM ROD INSTALLATION IMPORTANT Components must be free of dirt and lint Any debris in the system can cause system to malfunction NOTE Install trim rod with check valve in the port left cylinder 1 Apply Quicksilver Power Trim and Steering Fluid on all O rings and seals before installation 2 Install trim rods and caps Use installation tool 91 44487A1 o...

Page 291: ...Spanner Wrench 91 74951 Turn counterclockwise c Tilt Rod Pull to remove NOTE Place a clean pan under tilt ram to catch fluid TILT RAM COMPONENTS 51372 a b c d e f g h i j k b b b b a Housing Tilt Ram b O ring 5 c Memory Piston d Washer e Piston Assembly f End Cap g Oil Seal h Bolt Design 1 i Nut Design 2 j Tilt Rod Design 1 k Tilt Rod Design 2 O ring Repair Kit Available P N 811607A1 Includes item...

Page 292: ...ower swivel pin 51355 a a Lower Swivel Pin Remove as shown Disassembly 1 Secure tilt ram in a soft jawed vise Remove tilt rod and cap 51364 51337 91 74951 a b c a Cap Turn counterclockwise to remove b Spanner Wrench 91 74951 c Tilt Rod Pull to remove 2 Clamp tilt rod in a soft jawed vise Remove bolt or nut as applicable to disassemble rod assembly Remove O ring 51378 51340 a b a Bolt Design 1 or S...

Page 293: ...lso 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 a b c a Washer b Check Valve Assembly 7 c Piston 4 Remove end cap from tilt rod 51376 a a End Cap 5 Remove allen plug IMPORTANT Remove plug from same side as holes in shaft 51361 DO NOT REMOVE a b a Allen P...

Page 294: ... Solid Surface c Air Nozzle 9 Remove shaft after Memory Piston Cup has been expelled Replace allen plug removed in Step 5 and tighten securely CLEANING AND INSPECTION 1 Inspect all internal 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 less than 0 0...

Page 295: ...ll in cylinder a b 51372 a a O ring b Memory Piston Cup 3 Assemble end cap a b c d e b a End Cap b O ring 2 c Scraper Seal d Washer e Retaining Ring 4 Install end cap 51376 a a End Cap 5 Install components on rod 51340 51363 a b c d e 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 rod assembly Use span...

Page 296: ...lignment Tool 91 11230 b Shaft 2 Align tilt ram and housing using alignment tool 51348 a a Alignment Tool 91 11230 3 Install shaft 51352 a b c a Shaft b Groove c Hole groove b will align with this hole 4 Drive pin in until flush 51356 a a Pin Drive against knurled end 5 Install Power Trim Assembly on outboard Refer to Installation instructions on pages 6B 16 and 6B 17 ...

Page 297: ...eplace pump or motor 1 Tilt outboard to full UP position Depressurize power trim system and loosen starboard transom bracket as outlined in Removal and Installa tion on page 6B 14 2 Remove 2 screws to remove motor from system NOTE Driveshaft is a loose part and may fall out of motor when motor is removed 51433 a b c b a Motor b Screw 2 c Driveshaft 3 Remove two screws to remove pump 51433 a b a Pu...

Page 298: ...mponents Solenoid Test WARNING Do not perform this test near flammable materials as a spark may occur while making electrical connections 1 Disconnect all wires from solenoid terminals 2 Set an Ohmmeter to Rx1 scale and connect meter leads to solenoid terminals 1 and 2 3 Connect a 12 volt power supply to terminals 3 and 4 Solenoid should click and meter should read zero 0 ohms full continuity 5133...

Page 299: ...ator FIELD TESTS IMPORTANT Commutator end of armature must be installed in brushes when performing the fol lowing tests Ohmmeter Leads Between Resistance Ohms Scale Reading x Green and Blue Motor Wires 0 Full Continuity R x 1 Green and Black Motor Wires 0 Full Continuity R x 1 Blue and Black Motor Wires 0 Full Continuity R x 1 Black Motor Wire and Frame Motor Housing No Continuity Full Continuity ...

Page 300: ...on page 6B 29 to disassemble motor from pump CLEANING AND INSPECTION Inspect O rings and replace if necessary Clean in spect and test motor components Refer to Brush Replacement Armature Test and Field Tests for inspection and test procedures 51371 a a a a b b c c c d d d d e c a d a Power Trim Motor a Frame and Field Kit b Brush Card Kit c End Frame Kit d Seal Kit e Armature Kit ...

Page 301: ... pigtail and end of brush holder slot is 1 16 in or less Check distance with armature installed 18457 a a 1 16 in 2 To replace brush card remove insulators 51350 a a a Insulators 3 Remove metal connectors a a 18466 a a Metal Connectors 4 Install new brush card 5 Crimp new metal connectors onto wires 6 Insulate connections with heat shrink tubing ...

Page 302: ...re in motor housing 51349 a b a Motor Housing b Armature Spread brushes to insert commutator 2 Install square rings in end caps being careful that square ring is not twisted a 18465 a Square rings 3 Install screws and clamp Tighten screws securely 51357 51345 a b c d e a a b a a b a Screw 4 Contains flat washer and O ring b Screw 3 c Clamp d Gasket e Grommet ...

Page 303: ...m NOTE Insure motor and driveshaft are aligned 51433 a b c c a Motor b O ring c Screw 2 Torque screws to 70 lb in 7 9 N m 4 Complete reassembly of Power Trim System as outlined in Installation on page 6B 15 and 6B 16 Priming Power Trim System 1 Fill system with Quicksilver Power Trim and Steer ing Fluid or Automatic Transmission Fluid ATF Type F or FA Refer to Fill Check and Purge on page 6B 5 IMP...

Page 304: ...n trim sender screws and reposition trim sender 5 Tighten trim sender screws 22744 a b c d e a Trim Sender b Screws loosen to rotate sender c Turn sender counterclockwise to raise needle reading d Turn sender clockwise to lower needle reading e Tilt Lock Lever Trim Indicator Wiring Diagrams Wiring Diagram For boats equipped with Quicksilver Commander Series Side Mount Remote Control Wiring Diagram...

Page 305: ...SINGLE RAM POWER TRIM C 6 51485 ...

Page 306: ... Electrical System Troubleshooting 6C 15 COMMANDER 2000 Side Mount Remote Control Power Trim Tilt Electric Start with Warning Horn Wiring Diagram 6C 15 Power Trim System Wiring Diagram 6C 16 Troubleshooting the Down Circuit When Up Circuit is OK 6C 17 Troubleshooting the Up Circuit When Down Circuit Is OK 6C 17 Troubleshooting the Down and Up Circuits All Circuits Inoperative 6C 18 Power Trim Syst...

Page 307: ...cause porpoising and or ventilation In excess can cause insufficient water supply to wa ter pump resulting in serious water pump and or pow erhead overheating damage WARNING Excessive engine trim angle will result in insufficient water supply to water pump causing water pump and or powerhead overheating damage Make sure that water level is above gear housing water intake holes whenever engine is r...

Page 308: ...y opening the manual release valve 3 turns maximum counterclockwise 51432 a a Manual Release Valve Trim In Angle Adjustment WARNING Operating some boats with engine trimmed to the full in trim angle not using trim adjustment bolt at planing speed will cause undesirable and or unsafe steering conditions Each boat must be water tested for handling characteristics after engine installation and after ...

Page 309: ...6C 3 90 13645 2 495 POWER TRIM Notes ...

Page 310: ...0 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 NOTE Lubricate all O rings and seals with 38 37 33 27 36 35 Power Trim and Steering Fluid 92 90100A12 Liquid Neoprene 92 25711 2 110 Quicksilver Lubrication Sealant Application Points 110 110 110 7 25 7 Loctite 271 Obtain Locally 110 25 ...

Page 311: ...ring 13 1 O ring 14 1 Memory Piston 15 1 Lower Pivot Shaft 16 1 Cross Pin 17 2 Screw 100 11 3 18 1 Pump Assembly 19 1 Pilot Valve Assembly 20 1 O ring 21 1 Driveshaft 22 4 Washer 23 4 Screw 70 7 9 24 1 Fill Screw 25 1 O ring 26 1 Motor Frame 27 2 Thrust Washer 28 1 Armature 29 1 Ring 30 1 Seal 31 2 Screw 13 1 5 32 4 Screw 13 1 5 33 2 Relay 34 1 Wiring Harness 35 2 Relay Mount 36 2 Rubber Mount 37 ...

Page 312: ...ll not trim down Outboard trims down will not trim up Outboard will not return completely to down position or returns part way with jerky motion Outboard thumps when shifted Outboard trails out when backing off throttle at high speed Outboard will not hold a trimmed position or will not remain tilted for any extended period Outboard will not hold trim position when in reverse Determine if Power Tr...

Page 313: ...lems Note date code on trim assembly and compare to date code listed on service bulletins before making re pairs a b c a Label on Top Cover of Motor b Motor Reservoir Flange c Embossed into the CAUTION Decal on Trim Tilt Cylinder Preliminary Checks Operate Power Trim System after each check to see if problem is corrected If not proceed with the next check 1 Check that manual release valve is tight...

Page 314: ...4 weeks of non use The cause may be a stuck spool inside the sleeve due to an over size or a hard o ring on the spool SERVICE BULLE TIN No 93 22A NOTE Scribe pump housing and manifold before dis assembly 1 Remove tilt cylinder from the manifold and re place pilot valve assembly 50999 a a Sleeve with Spool Inside 2 The spool is considered stuck when the pin end is protruding out past the end of the...

Page 315: ...k for debris be tween the valve seat and valve 52792 a b a Chip under Valve Tip b Rubber Seat 6 Inspect for nicked deteriorated or misplaced O ring 51560 a b c d a Valve and Seat b O ring c O ring d Scribe Mark Reassembly 1 Install the spool into sleeve from the chamfered end end opposite the cross hole 2 Insert spool into sleeve until end is flush with the chamfered end of the sleeve Inserting th...

Page 316: ... and remove the memory piston 2 Cut a small groove 0 020 0 040 in 0 5 1 0mm deep across the top face of the memory piston The groove will allow oil passage when the shock piston and memory piston are in contact The groove can be made with a hacksaw or trian gular file NOTE Power trim assemblies with Date Code 14183 and ABOVE have a groove in the shock piston to allow fluid passage The memory pisto...

Page 317: ... 51560 a b c a Valve and Seat b Pilot Valve O ring c O ring Leak Down Check Manual Release Valve 1 Debris or chips under O ring a 2 Flash from valve molding causing O ring a to not seal 3 Nicked O ring a 51560 a a O ring Leaks Past Ball and Seat Piston Assembly Unit will trim to full or near full down position and then will begin to trim up while trim switch is held in DOWN mode If trim switch is ...

Page 318: ...that will not trim or tilt up or down may have a pump manifold assembly with a broken rocker arm 1 Replace broken rocken with improved rocker arm assembly 823180A1 a b a Rocker Arm b Rocker Arm Assembly Previous Rocker Arm Design Improved Rocker Design 51742 51742 2 Clearance between the side of the rocker arm and each pin is 0 001 to 0 010 in 0 025 0 25mm 3 Torque bolt to 125 140 lb in 14 1 15 8 ...

Page 319: ...rings and proceed Inspect O rings on Pilot Relief Valve located in manifold assembly O ring failure Replace O rings O rings appear to be OK Replace O rings Inspect Memory Piston O ring Inspect Manual Release Valve Outboard falls to full down position with manual release valve closed Example a Outboard lowers more than one tilt bolt hole in eight hours Example b Outboard lowers during acceleration ...

Page 320: ...debris or defective components found Inspect Manifold Reverse Thrust Valve Debris found in check valve components Clean check valve compo nents using engine cleaner and compressed air or replace Inspect Manual Release Valve Outboard will not hold tilted position in reverse and or trails out during high speed deceleration Result Result Result Result Replace Pump and Manifold Assembly Inspect Trim R...

Page 321: ... with Warning Horn Wiring Diagram 23891 4 5 7 UP DOWN a c d e f g b BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN PUR PURPLE RED RED TAN TAN WHT WHITE YEL YELLOW a Ignition Choke Switch b Emergency Stop Switch c Neutral Start Switch d Tachometer Accessories Harness Connector e Wiring Harness Connector f Warning Horn g Trim Tilt Switch ...

Page 322: ... Trim Relays UP DOWN Power Trim Motor Wiring From Side Mount Remote Control Harness 51507 1 8 3 Start Solenoid To Battery BLK BLACK Negative BLU BLUE Trim Motor UP GRN GREEN Trim Motor DOWN RED RED Positive BLU WHT BLUE WHITE Trim Switch to UP Relay GRN WHT GREEN WHITE Trim Switch to DOWN Relay ...

Page 323: ...upplying current to Point 5 Connect Voltmeter red lead to Point 1 and black lead to ground Depress the Down trim button Troubleshooting the Up Circuit When Down Circuit Is OK Remote Control NOT Equipped with Trailer Button Battery Voltage Indicated UP Relay is defective Replace and retest No Voltage Indicated Connect Voltmeter red lead to Point 7 and black lead to ground Depress Down trim button I...

Page 324: ...ite between trim buttons and trim pump S Check trim switch S Check all trim harness connectors for loose or corroded connections S Check for pinched or severed wires Battery Voltage Indicated There is an open circuit in wire between Point 5 and Red terminal on the back of the ignition switch No Voltage Indicated Check that voltage is being supplied to control by performing the following checks S D...

Page 325: ...ender if equipped 4 Use suitable tool to remove upper headed cross pin Retain pin Straight pin is hard to remove see item 5 51505 a b a Cross Pin Design 1 Straight b Cross Pin Design 2 Headed 5 Drive out upper pivot pin This will shear cross pin 50515 a a Upper Pivot Pin Inspect cross pin hole and pivot pin hole for damage 6 Use suitable punch to remove lower cross pin Retain cross pin 51506 a a C...

Page 326: ...crew and drain unit 51505 a a Fill Screw 10 Remove O ring from fill cap 51194 Power Trim System Disassembly Trim Rod Removal 1 Secure power trim assembly in soft jawed vise 2 Open manual release valve three turns maxi mum counterclockwise and position trim rod to full up position 3 Remove cylinder end cap assembly from cylinder using spanner wrench 1 4 in x 5 16 in long pegs 51194 a b c a Manual R...

Page 327: ...ace trim rod assembly on clean work surface 2 Remove screws securing plate to trim rod piston and O ring 3 Remove check ball components from trim rod piston 51143 a b c d a Screw 3 b Plate c O ring d Piston When removing Trim Rod piston spanner wrench must have 1 4 in x 5 16 in long pegs to avoid damage to trim piston CAUTION 4 Place trim rod into soft jawed vise and apply heat to shock piston usi...

Page 328: ...ation of check valve could result in improper operating pressure and possible power trim system damage If check valve is defective replace trim rod piston CAUTION 7 Remove inner O ring from piston 51199 a b c a Check Ball Components b O ring c Piston 8 Remove rod wiper inner O ring and outer O ring 51145 51147 a b c a Rod Wiper b Inner O ring c Outer O ring ...

Page 329: ...rom reservoir 51484 Trim Motor Disassembly 1 Remove armature from motor frame Note posi tion of washers on armature 51486 a b c c a Armature b Motor Frame c Washer 1 each end of armature Reservoir Assembly Removal 1 Remove manual release valve from manifold a b a Manual Release Valve b Manifold 2 Remove E clip and O rings from manual release valve 51196 a c b a E Clip b O rings c Manual Release Va...

Page 330: ...p Manifold Removal 1 Remove screws and manifold from cylinder 51007 c b a a Trim Cylinder b Manifold c Screw 2 2 Remove check valve components from manifold IMPORTANT Sleeve d is chamfered on I D on end opposite drilled cross hole Install spool e with O ring installed from chamfered end of sleeve to avoid possibility of damaging O ring on spool 51560 e a b d b b c a Manifold and Pump b O ring 3 c ...

Page 331: ...s using Quicksilver Power Trim and Steering Fluid or ATF Type F FA or Dexron II Motor and Electrical Tests Repair Trim Pump Motor Test WARNING Do not perform this test near flammables or explosives as a spark may occur when making connections 1 Disconnect GREEN motor wire and BLUE mo tor wire from trim system wiring harness 2 Connect a 12 volt power supply to motor wires POSITIVE to BLUE NEGATIVE ...

Page 332: ...osition components in place using sleeve to seat in place 50999 1 Install check valve components into pump man ifold IMPORTANT Sleeve d is chamfered on I D on end opposite drilled cross hole Install spool e with O ring installed from chamfered end of sleeve to avoid possibility of damaging O ring on spool 51560 e a b d b b c a Manifold and Pump b O ring 3 c Spring d Sleeve e Spool 2 Install O ring...

Page 333: ...tall armature and motor frame into end cap As brushes contact commutator re lease brush tension spring from ends of brush housings returning springs to apply brush pres sure to commutator Install washer on each end of armature before installing armature into end cap see inset 51484 d a b c b a End Cap Bushing Lubricate with Quicksilver 2 4 C w Teflon b Brush 2 c Commutator d Brush Tension Spring 2...

Page 334: ...r down onto drive shaft 51486 b a a Drive Shaft b O ring 5 Secure reservoir to manifold using four screws Torque screws to 70 lb in 7 9 N m 51193 a a a Screw 6 Install lubricated O rings and E clip to manual re lease valve 51196 a b c a E Clip b O ring c Manual Release Valve 7 Insert manual release valve into manifold and tighten snuggly Back release valve out 3 turns maximum allowing trim rod ins...

Page 335: ... cap onto trim rod 51146 a a End Cap 4 Apply Loctite 271 Obtain Locally to threads of trim rod and install rod piston Tighten piston se curely using spanner wrench 1 4 in x 5 16 in long peg 51146 b a a Trim Rod Piston b Spanner Wrench 5 Install lubricated O ring to trim rod piston 6 Install check ball components into its respective bore 51147 f e d c b a a Screw 3 b Plate c O ring d Ball 5 e Seat ...

Page 336: ...l lubricated O ring to memory piston and place into cylinder Push piston down to level of oil 51144 b a Memory piston must not contact end cap during trim rod end cap installation a O ring b Memory Piston 4 Install trim rod into cylinder 51196 5 Tighten end cap assembly to cylinder securely us ing spanner wrench 1 4 in x 5 16 in long pegs 51145 a a Spanner Wrench 91 74951 6 Tighten manual release ...

Page 337: ...rim rod to the DOWN position Connect POSITIVE lead to BLUE wire and NEG ATIVE lead to GREEN wire and drive trim rod to the UP position Recheck fluid level add fluid as required and repeat cycle until fluid level remains at lower portion of threads Power Trim Unit Installation 1 Apply 2 4 C w Teflon 92 825407A12 to lower pivot pin bore and pivot pin surface 2 Position trim cylinder assembly BOTTOM ...

Page 338: ... cross pin into its respective bore until seated 51515 a a Lower Cross Pin 6 Apply 2 4 C w Teflon 92 825407A12 to surface of upper pivot pin pivot pin bore and trim ram bore NOTE Install trim ram with cross hole located as shown If trim ram is installed reversed the trim send er if installed will not operate 51515 Transom Side Cross Hole Engine Side d c b a b a Pivot Pin b Pivot Pin Bore c Trim Ra...

Page 339: ... b Swivel Bracket c Trim Ram 8 Drive upper retaining pin in until seated 51505 a a Retaining Pin 9 Recheck fluid level 10 Power trim may now be operated to lower out board to desired position Trim system is self purging 11 Reconnect power trim leads to relays under igni tion cover 12 Reinstall spark plug leads to spark plugs 13 Reinstall cowls 14 Connect battery leads to battery terminals ...

Page 340: ...50099 ENGINE ATTACHMENTS ENGINE INSTALLATION 7 A ...

Page 341: ...de Steering Attachment Extension Couplers 7A 14 Transom Mounted Ride Guide Attaching Kit Installation 73770A1 7A 14 Attaching Kit Installation 7A 14 Steering Cable Installation 7A 16 Maintenance Instructions 7A 16 Ride Guide Steering Cable Attaching Kit Installation 92876A3 7A 17 Dual Cable Single Outboard 7A 17 Super Ride Guide Steering Kit Installation 7A 17 Mounting Bracket Installation 7A 18 S...

Page 342: ...l IMPORTANT Before installing steering cable into tilt tube lubricate seal and entire cable end with Quicksilver 2 4 C w Teflon 3 Insert steering cable end thru engine tilt tube and secure steering cable to tilt tube with steering cable attaching nut as shown Torque nut to 35 lbs ft 47 5 N m 4 Install rubber bumper on inside of locking sleeve then install locking sleeve over steering cable at tach...

Page 343: ...m each engine s centerline to the side of transom opening must be a minimum of 16 40 6cm This kit contains all necessary parts to connect both engines to Ride Guide Steering cables for 22 1 2 thru 24 1 2 refer to Figure 14 page 7A 14 for additional extension couplers Cable Routing Types Use 1 or 2 following to route steering cables 1 Parallel cable routing Cables routed together down starboard sid...

Page 344: ... Left Rotary Steering Right b Steering Cables Install so that Both Cables Will Push and pull Together Figure 1 Super Ride Guide Steering Kits Installed WARNING Before using engine after installation of cables check to see that boat will turn right when steering wheel is turned right and that boat will turn left when wheel is turned left Do this check at all tilt angles and thru full range of turn ...

Page 345: ...lver 2 4 C w Teflon c Insert ends of steering cables thru engine tilt tube and cable mounting tube Figure 4 Thread steering cable attaching nuts onto tubes hand tight a 16977 b b c c d a Steering Cables Routed Down Starboard Side b See Figure 7 for Correct Parts Sequence c See Figure 8 for Correct Parts Sequence d Seal Figure 4 Steering Cables and Steering Link Rods Installed NOTE Torque steering ...

Page 346: ...ering eyes is the same distance as between centers of threaded pivot holes in engine steering arms Ex posed steering eye threads should be equal at both ends of coupler and must not extend out of coupler more than 2 3 4 70mm WARNING Both steering eyes must be threaded into coupler 3 4 19mm minimum Thread length of steering eye is 3 1 2 89mm so exposed thread must not extend out of coupler more tha...

Page 347: ... steering system to remove slack Failure to adjust tube this way may result in hard steering if one engine is tilted up while operating boat Steering System Tension Adjustment Parallel Routed Steering Cables IMPORTANT After this Ride Guide Attachment Kit is installed there must be proper tension in the steering system Not enough tension will cause slack play in steering system Too much tension wil...

Page 348: ...s Fig ure 13 to 35 lbs ft 47 5 N m 4 Install rubber bumpers on inside of locking sleeves then install a locking sleeve over each steering cable attaching nut and secure with cot ter pin Spread ends of cotter pin Be sure to install cotter pin so that it is located in between attaching nut and grease fitting Figure 13 51890 a b c d e a Steering Cable Attaching Nut Torque to 35 lbs ft 47 5 N m b Grea...

Page 349: ... Figure 2 Be sure that longer threaded end of tube is toward steering cable at taching nut side of engine 3 Temporarily adjust tube so that longer threaded end of tube is aligned with outward edge of tran som bracket DO NOT tighten adjustment nuts at this time a b c 50130 a Tube Mounting Bracket b Bolts c Locking Retainers Bend Ends Up and Against Flat on Bolts Figure 1 Tube Mounting Bracket Insta...

Page 350: ...mounting tube 5 8 16mm from end of tube Figure 4 50180 a b c d e a 5 8 from End of Tube b Place Mark on Tube Here c Nylon Spacer d O ring e Cap Figure 4 Seal Installation Sequence 50180 a a Mark Made in Step 5a Figure 5 Steering Cable Seal Installed b Slide plastic spacer O ring and cap from kit over steering cable Figure 4 c Thread cap onto steering cable mounting tube up to mark made on tube in ...

Page 351: ...g ure 7 Tighten self locking nut until it seats DO NOT exceed 120 lbs in 13 5 N m then back nut off 1 4 turn Steering Eyes and Coupler Installation 1 Position engines so that they are facing straight forward Distance between centers of threaded pivot bolt holes in engine steering arms must be equal to distance between propeller shaft centers 2 Lubricate inside of rubber sleeves Figure 8 and slide ...

Page 352: ...ye in or out to correct align ment Both steering eyes MUST BE threaded into coupler 3 4 19mm minimum 7 Torque pivot bolts to 20 lbs ft 27 1 N m then thread self locking nut onto bolts and torque nuts to 20 lbs ft 27 1 N m WARNING Both steering eyes MUST BE threaded into coupler 3 4 minimum and jam nut Figures 8 and 9 must be secured against coupler to prevent coupler from turning Torque jam nut to...

Page 353: ...ber bumpers on inside of locking sleeves then install a locking sleeve over each steering cable attaching nut and secure with cot ter pin Spread ends of cotter pin Be sure to install cotter pin so that it is located in between attaching nut and grease fitting Figure 12 5 Install new trim tabs as outlined in Trim Tab Instal lation following WARNING After installation is complete and before operatin...

Page 354: ... comes first Severe Service Every 25 hrs of operation or 30 days whichever comes first Operation in a salt water 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 specifications NOTE Ride Guide steering cables are lubricated at the factory and require no additional...

Page 355: ...m Coupler and 12 in 30 5cm Coupler Connected together with coupler link rod 33 in thru 37 in 83 8cm thru 94 0cm 12 in 30 5cm Coupler and 12 in 30 5cm Coupler Connected together with coupler link rod a b c d e a 18 in 45 7cm Coupler 97932 3 b 15 in 38 1cm Coupler 97932 2 c 12 in 30 5cm Coupler 97932 1 d 9 in 22 9cm Coupler 97932 4 e Coupler Link Rod 98181A1 Figure 14 51890 a b c a a Couplers Connec...

Page 356: ...es 1 and 2 Torque locknut to 10 lbs ft 13 5 N m then back off 1 4 turn 4 Install one cable tube jam nut onto steering cable tube Place tab washer over Ride Guide yoke then insert cable tube thru tab washer and yoke Install second cable tube jam nut onto cable tube but do not tighten at this time Figure 3 5 Position transom attaching kit on transom as follows a Determine centerline of outboard then...

Page 357: ...de cable to outboard steering arm using the proper Clevis Kit Installation instructions for clevis are with Clevis Kit 4 Adjust 2 large jam nuts on cable tube of attaching kit so that steering wheel is in normal straight driving position with outboard in straight running position Torque each jam nut to 35 lbs ft 47 4 N m then bend a side of tab washer against flat of each jam nut Figure 3 5 Torque...

Page 358: ...e to deter mine correct length of steering cables and remote control cables IMPORTANT Steering cables and remote control cables MUST BE THE CORRECT LENGTH sharp bends on too short cables result in kinks too long cables require unnecessary bends and or loops Both conditions place extra stress on the cables With this kit installed the upper outboard mounting bolts MUST BE installed so that hex head ...

Page 359: ...tube Do not tighten adjustment nuts at this time 16959 a b c Steering Cable Mounting Tube Installation IMPORTANT Spacers b must be installed be tween outboard swivel bracket and mounting bracket for steering cable mounting tube to pro vide proper spacing between steering cables Secure mounting bracket for steering cable mounting tube on to swivel bracket of outboard 51891 a b c d e d a Mounting Br...

Page 360: ...ng steering cables Lubricate inside of outboard tilt tube and inside of steering cable mounting tube with Quicksilver 2 4 C w Teflon Verify rubber O ring seal located in out board tilt tube is lubricated 51890 a a Seal Insert steering cable ends thru outboard tilt tube and cable mounting tube Thread steering cable attaching nuts on to tubes hand tight Torque steering cable attaching nuts only afte...

Page 361: ...e of cou pler and nylon insert locknut Tighten locknut until it seats DO NOT exceed 120 Ib in 13 5 N m of torque then back nut off 1 4 turn Lubricate ball joint in steering link rod with SAE 30W Motor Oil Secure link rod to outboard steering arm using special washer head bolt 10 14000 provided and nylon insert locknut as shown Torque special bolt to 20 Ib ft 27 1 N m then torque locknut to 20 Ib f...

Page 362: ...e b Adjustment Nuts Torque to 35 lb ft 47 4 N m c Tab Lock Washer Bend Against Flat on Each Adjustment Nut Tighten steering cable attaching nuts of each steering cable to a torque of 35 Ib ft 47 4 N m Install rubber bumpers a on inside of each locking sleeve b a b 51889 Install locking sleeves over steering cable attaching nuts and secure with cotter pins Spread ends of cot ter pins Be sure to ins...

Page 363: ...od and ball joint of link rod steering coupler with SAE 30W Motor Oil 5 Inspection and lubrication of steering head assembly rotary or straight rack should be performed once each year by your Authorized Dealer or whenever steering mount and or steering head are disassembled or if steering effort has increased Lubricate with 2 4 C w Teflon 50135 a b d c a Grease Fitting b Cable Ends c Pivot Point d...

Page 364: ... barrel away from cable end guide Repeat steps a thru c d Shift remote control into neutral The prop shaft should turn freely without drag If not ad just cable barrel closer to cable end guide Re peat steps a thru d 22888 a b c d e a Cable Barrel b Barrel Retainer c Shift Actuator Stud d Plastic Washer e Locknut Throttle Cable Installation and Adjustment to Engine 1 Shift remote control into neutr...

Page 365: ...hout Power Trim a b c a b c a Wiring Harness b Neoprene Sheet c Sta Straps 1 Plug remote control harness connector into en gine harness connector then secure connector in place with retainer as shown IMPORTANT On Models without Power Trim the neoprene sheet must be folded once and then wrapped around cables as shown 2 Wrap neoprene sheet around cable bundle and secure each end with a sta strap Sec...

Page 366: ...top speed 3 greater boat stability but 4 will cause more prop break loose which may be particularly noticeable when planing off or with load b These broken lines represent the extremes of known successful outboard mounting height dimensions c This line may be preferred to determine outboard mounting height dimension if maximum speed is the only objective d This line may be preferred to determine o...

Page 367: ...inimum lift capacity of at least 500 lbs 227 kg BEFORE lifting engine 1 Remove cowling from engine and plastic cap from center of flywheel Thread lifting eye into flywheel hub a minimum of 5 turns Replace plastic cap af ter installation 2 Connect hoist minimum lift capacity of 500 lbs 227 kg to lifting eye Lift engine and place on boat transom 25929 a b a Lifting Eye C 91 75132 b Hoist Installing ...

Page 368: ... Req d WARNING Before operating motor s MUST BE SECURED to boat transom with four 1 2 diameter bolts and locknuts as follows 2 bolts must be installed thru upper mounting holes and 2 bolts thru lower mounting holes as shown in step 5 Installation must be water tight and engine should be checked for tightness on the transom during operation Failure to bolt engine to transom using 4 bolts and locknu...

Page 369: ...TILLER HANDLE AND CO PILOT OUTBOARD MOTOR INSTALLATION ATTACHMENTS 7 B ...

Page 370: ...t Components 7B 6 Tiller Arm Shift Lever Removal 7B 7 Tiller Handle Disassembly 7B 10 Tiller Arm Reassembly 7B 13 Tiller Handle Shaft Bracket Installation 7B 16 Shift Link Rod Installation and Adjustment to Engine 7B 20 Throttle Cable Installation and Adjustment to Engine 7B 20 Co Pilot Installation 7B 21 ...

Page 371: ...7B 1 90 13645 2 495 OUTBOARD MOTOR INSTALLATION ATTACHMENTS Notes ...

Page 372: ...ponents 1 32 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 26 27 28 29 30 Soapy Water Solution Obtain Locally 2 8 24 25 30 31 110 110 110 110 110 2 4 C W Teflon 92 825407A12 110 33 7 Loctite 271 Obtain Locally 7 Quicksilver Lubrication Sealant Application Points ...

Page 373: ...ve Tight 7 1 Throttle Clamp 8 2 Screw 40 4 5 9 1 Nut 10 1 Throttle Handle 11 1 Screw Drive Tight 12 1 Stop Switch Harness 13 1 Stop Switch 14 1 Grip 15 1 Clip 16 1 Screw 17 1 Conduit 18 1 Guide Tube 19 1 Barrel 20 1 Set Screw 9 1 0 21 1 Cable 22 1 Cable Guide 23 1 Anchor 24 2 Set Screw Drive Tight 25 1 Bolt 26 1 Cap 27 1 Washer 28 1 Washer 29 1 Spacer 30 1 Bushing 31 1 Nut 40 4 5 32 1 Gear Assembl...

Page 374: ...ller Arm Bracket Assembly 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 17 18 95 2 4 C With Teflon 92 825407A12 95 95 95 Quicksilver Lubrication Sealant Application Points 7 Loctite 271 Obtain Locally 7 ...

Page 375: ...Nut 10 1 Cover 11 6 Screw Drive Tight 12 1 Plug 13 1 Stop Switch Assembly 14 1 Lanyard 15 1 Retainer 16 1 Bolt 110 12 4 17 3 Tab Washer 18 2 Bushing 19 1 Shift Lever 20 1 Washer 21 1 Stud 22 1 Shift Knob 23 1 Shift Rod 24 1 Rod End 25 1 Bushing 26 1 Washer 27 1 Cotter Pin 28 1 Neutral Start Switch 29 1 Bracket 30 1 Switch Bracket 31 2 Screw 32 2 Nut Drive Tight 33 2 Bolt 34 2 Washer 35 2 Nut Drive...

Page 376: ...7 8 7 8 95 95 95 2 4 C With Teflon 92 825407A12 TORQUE REF NO QUAN DESCRIPTION lb in lb ft N m 1 1 Pilot Rod 2 1 Friction Assembly 3 1 Bolt 4 1 Wing Nut 5 1 Steering Link Rod 6 1 Bushing 7 2 Washer 8 2 Nut Tighten until it seats do not exceed 120 lb in 13 6 N m then back off 1 4 turn 120 13 6 ...

Page 377: ...d e f a Locking Nut b Washer c Shift Cable d Throttle Cable e Latch f Anchor Bracket 4 Remove cotter key washer bushing and shift link rod from shift lever 51624 a b c d a Cotter Key b Washer c Bushing d Shift Link Rod 5 Remove access cover from underneath tiller handle bracket 51626 a b a Access Cover b Screws 6 Disconnect key switch lanyard stop switch and til ler stop switch leads at bullet con...

Page 378: ...om bracket 51626 a b c d e a a Nuts b Key Switch c Trim Switch d Clip e Lanyard Stop Switch 8 Remove harness retainer from outboard Remove grommet from tiller bracket 51624 a b a Harness Retainer b Grommet 9 Remove electrical panel access cover Disconnect switch harness from engine harness plug Disconnect PURPLE bullet connector a b c 51621 d a Access Cover b Bolts c Switch Harness d PURPLE Lead ...

Page 379: ...witch trim switch and their har nesses from tiller bracket 12 Remove plug from tiller handle bracket 51608 a a Plug 13 Remove bolt and nut hidden from tiller handle bracket 51625 a b a Bolt b Nut Hidden 14 Remove tiller handle 2 nylon bushings stainless bushing and 2 flat washers from bracket 51606 a b c b d e a Tiller Handle b Nylon Bushings 2 c Stainless Steel Bushing d Flat Washers 2 e Bolt ...

Page 380: ...ever 16 Remove spring and detent pin from bracket 51621 a b a Spring b Detent Pin 17 Bend tabs on tab washers away from nuts secur ing bracket to steering arm Remove nuts tab washers and bracket from steering arm 51621 a b c a Tab Washer b Nut c Steering Arm Tiller Handle Disassembly 1 Using a flat tip screwdriver carefully pry push rub ber grip off tiller handle 51603 a b a Grip b Tiller Handle ...

Page 381: ...tch harness and remove screw from harness J clip 51603 a b a Ties b Screw 4 Remove stop switch and twist grip from tiller handle 51603 5 Remove throttle cable anchor screws and remove cable guide 51602 a b a a Anchor Screws b Throttle Cable Guide 6 Remove allen screw from brass barrel and remove barrel 51602 a b a Allen Screw b Brass Barrel ...

Page 382: ...le 9 Remove cover plate and gasket from tiller handle 10 Remove bolt from throttle friction assembly 51604 a b c d e c a Cover Plate b Gasket below plate c Screws d Throttle Friction Assembly e Bolt 11 Remove throttle arm gear assembly and friction device from tiller handle Slide gear cover and fric tion device off of throttle arm 51604 a b c d a Throttle Arm b Gear Assembly c Friction Device d Ge...

Page 383: ... and secure gear to arm with new drift pin b a 51602 a Gear b Drift Pin 2 Apply a light coat of2 4 C w Teflon to gear teeth and inside of gear cover 3 Slide cover and friction device onto throttle arm d c b a 51604 a Throttle Arm b Gear c Throttle Friction Device d Cover 4 Install throttle arm assembly into tiller arm 5 Torque friction device attaching bolt to 40 lb in 4 5 N m 51604 a a Bolt Torqu...

Page 384: ... 8 Insert throttle cable CURVED END FACING UP into tiller handle gear assembly while rotating tiller arm COUNTERCLOCKWISE 51604 a a Gear Drift Pin FACES UP 9 Retract throttle cable into gear assembly until approximately 17 in 43 cm extends from the til ler arm 51604 a a Cable Extends 17 in 43 cm 10 Slide stainless steel conduit over throttle cable and thread into tiller arm until lightly seated Ro...

Page 385: ...ews Guide hole should face up 51602 a b c b a Cable Guide b Screws 2 c Hole faces up 13 Position throttle arm slot to face stop harness exit hole in tiller handle Route stop switch harness through twist grip into throttle arm and out through side of tiller handle 51602 a b c d e a Slot b Exit Hole c Harness d Twist Grip e Stop Switch 14 Secure twist grip to throttle arm with attaching screw 51603 ...

Page 386: ...soapy water solution to rubber grip will ease installation 51603 a b a Ridges b Grooves under handle Tiller Handle Shaft Bracket Installation 1 Slide bracket over steering arm studs Secure bracket to arm with retained nuts and NEW tab washers Torque nuts to 35 lb ft 47 5 N m Bend locking tabs against flats of nuts 51621 a b c a Tab Washer b Nut c Steering Arm 2 Install retained spring and detent p...

Page 387: ... with bolt and NEW tab washer Align tab washer with slot in bracket Torque bolt to 110 lb in 12 4 N m 51620 a b a Bolt b Tab Washer 5 Install two nylon bushings into tiller handle Install stainless bushing into bracket Install tiller handle to bracket using bolt and two washers 51622 a b c d e a Nylon Bushings b Stainless Bushing c Bolt d Washer Thin e Washer Thick 6 Secure bolt in place with nut ...

Page 388: ...ess retainer 51624 a b c d a Harness Retainer b Switch Harness c Tiller Bracket d Grommet 9 Reinstall lanyard stop switch in bracket and se cure with clip 51626 a b c d e a a Nuts b Key Switch c Lanyard Stop Switch d Trim Switch e Clip 10 Reconnect key switch trim switch and remote stop switch leads at bullet connectors Secure harness BLACK ground lead and tiller handle re mote stop switch ground ...

Page 389: ...onnector 51623 a b a Switch Harness Plug b PURPLE Bullet Connector 13 Reconnect trim switch leads to trim solenoids 51622 a b a BLUE WHITE Lead b GREEN WHITE Lead 14 Reinstall electrical panel access cover and secure with screws Torque screws to 30 lb in 3 4 N m 51621 a b a Panel b Screws Torque to 30 lb in 3 4 N m 15 Reconnect shift link rod to shift lever using bush ing washer and cotter key 516...

Page 390: ...e ro tated in either direction length of shift link rod must be increased and Steps a thru c re peated d Place engine shift lever in N Neutral position Propeller should turn freely without drag If not length of shift link rod must be decreased and Steps a thru d repeated Throttle Cable Installation and Adjustment to Engine IMPORTANT Turn throttle cable conduit clockwise until bottomed on tiller ha...

Page 391: ...ard front of outboard as shown 51624 a a Friction Device 3 Loosen wing nut on friction device and insert pilot rod thru friction device and into tilt tube 4 Lubricate both ends of link rod with Quicksilver 2 4 C w Teflon 5 Secure link rod between steering handle assem bly and pilot rod end as shown 6 Adjust wing nut on friction device to provide de sired steering control IMPORTANT Tighten wing nut...

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