manualshive.com logo in svg

Mariner 135 OPTIMAX, Service Manual, Page: 1 / 490

Share
Download
Mariner 135 OPTIMAX Service Manual Download Page 1

With Serial Numbers OG590000 and Above

SERVICE

MANUAL

MODELS

135 

•

 150 OPTIMAX

DIRECT FUEL INJECTION

With Serial Numbers

Printed in U.S.A.

1999, Mercury Marine

90-855347R1   JANUARY 1999

Summary of Contents for 135 OPTIMAX

Page 1: ...With Serial Numbers OG590000 and Above SERVICE MANUAL MODELS 135 150 OPTIMAX DIRECT FUEL INJECTION With Serial Numbers Printed in U S A 1999 Mercury Marine 90 855347R1 JANUARY 1999 ...

Page 2: ...ing procedures of these products which in cludes the use of mechanics common hand tools and the special Mercury Marine or recom mended tools from other suppliers We could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of the possible hazards and or results of each method We have not undertaken any such wide evaluation There...

Page 3: ... any product component is serviced care and cleanliness are important Throughout this manu al it should be understood that proper cleaning and protection of machined surfaces and friction areas is a part of the repair procedure This is considered standard shop practice even if not specifically stated Whenever components are removed for service they should be retained in order At the time of instal...

Page 4: ...General Information D Outboard Installation Section 2 Electrical A Ignition B Charging Starting System C Timing Synchronizing Adjusting D Wiring Diagrams Section 3 Fuel System A Fuel Pump B Direct Fuel Injection C Oil Injection D Emissions Section 4 Powerhead A Powerhead B Cooling Section 5 Mid Section A Clamp Swivel Brackets Drive Shaft Housing B Power Trim Section 6 Gear Housing A Right Hand Non...

Page 5: ...3 cu in 2508 cc 60 Vee STROKE Length All Models 2 65 in 67 3 mm CYLINDER BORE Diameter Std Diameter 0 015 in Oversize Taper Out of Round Wear Maximum Bore Type 3 501 in 88 925 mm 3 516 in 89 306 mm 0 003 in 0 076 mm Cast Iron CRANKSHAFT Maximum Runout 0 006 in 0 152 mm PISTON Piston Type Diameter Standard Diameter 0 015 in Oversize Aluminum 3 4925 in 0005 in 88 7095 mm 0 0127 mm 3 5075 in 0 0005 i...

Page 6: ... 0 711 mm 0 015 in 0 022 in 0 381 mm 0 558 mm 0 018 in 0 023 in 0 460 mm 0 584 mm 0 030 in to 0 050 in 0 076 mm to 0 127 mm 12 PSI Minimum 5500 RPM DIRECT INJECTION Injectors Quantity Injectors are Crank Angle Driven by ECM 2 Cylinder 4 Cylinder 6 Cylinder 1 Cylinder 3 Cylinder 5 Cylinder Fuel Line Pressure Injectors Air Pressure High Pressure Electric Fuel Pump Amperage Draw Low Pressure Electric...

Page 7: ...ug Type Spark Plug Gap Maximum Timing Idle Timing Throttle Position Sensor 1 Inner TPS Idle W O T Throttle Position Sensor 2 Outer TPS Idle W O T Crank Position Sensor Air Gap Digital Inductive NGK PZFR5F 11 NGK ZFR5F 11 or Champion RC12MC4 0 040 in 1 0 mm Not Adjustable Controlled by ECM Not Adjustable Controlled by ECM 3 70 4 90 VDC 0 30 1 80 VDC 0 10 1 50 VDC 3 20 4 90 VDC 0 025 in 0 040 in 0 6...

Page 8: ... Cooling System Using Cowl Flush Plug 1B 5 Flushing Cooling System Using Flushing Attachment 44357A2 1B 5 Fuel System 1B 6 Fuel Line Inspection 1B 6 Water Separating Fuel Filter 1B 6 Corrosion Control Anode 1B 7 Spark Plug Inspection 1B 7 Battery Inspection 1B 8 Fuse Replacement 1B 8 Compressor Air intake Filter 1B 9 Removal 1B 9 Installation 1B 9 Lubrication Points 1B 9 Checking Power Trim Fluid ...

Page 9: ...MAINTENANCE Page 1B 2 90 855347R1 JANUARY 1999 Special Tools 1 Grease Gun 91 37299A1 2 Flushing Attachment 44357A2 Quicksilver Lubricant Sealant 1 Gear Lubricant Premium Blend 92 19007A24 ...

Page 10: ...E 90 855347R1 JANUARY 1999 Page 1B 3 2 Anti Corrosion Grease 92 78376A6 3 2 4 C Marine Lubricant with Teflon 92 825407A12 4 SAE 30W Motor Oil Obtain Locally 5 Quicksilver Power Trim and Steering Fluid 91 90100A12 ...

Page 11: ...resh water if operating in salt water Every 100 Hours of Use or Once yearly Whichever occurs first 1 Lubricate all lubrication points Lubricate more frequently when used in salt water 2 Inspect and clean spark plugs 3 Replace water separating fuel filter 4 Replace compressor air intake filter 5 Check corrosion control anodes Check more frequently when used in salt water 6 Drain and replace gear ca...

Page 12: ...ushing Attachment 44357A2 or equivalent tool on the gear housing from the FRONT side positioning the rubber cups over the water intake openings 2 Connect hose 1 2 in 12 7mm I D or larger between flushing attachment and water tap IMPORTANT To prevent water pump damage do not start or run engine unless cooling water is flowing 3 With the outboard in the normal operating position vertical partially o...

Page 13: ...ork for sign of fuel leakage Fuel Line Inspection Visually inspect the fuel line and primer bulb for cracks swelling leaks hardness or other signs of deterioration or damage If any of these conditions is found the fuel line or primer bulb must be replaced Water Separating Fuel Filter NOTE The warning system will turn on when water in the fuel filter reaches the full level 1 This filter removes moi...

Page 14: ...e it is com pletely eroded Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode Spark Plug Inspection Inspect spark plugs at the recommended intervals 1 Remove the spark plug leads by twisting the rubber boots slightly and pull off Inspect spark plug boots and replace if cracked 2 Remove the spark plugs to inspect and clean Replace spark plug if ele...

Page 15: ... with a nonconductive shield to prevent accidental shorting of battery terminals Fuse Replacement IMPORTANT Always carry spare SFE 20 AMP fuses The electrical wiring circuits on the outboard are protected from overload by fuses in the wiring If a fuse is blown try to locate and correct the cause of the overload If the cause is not found the fuse may blow again 1 Open the fuse holder and look at th...

Page 16: ...ine without the air filter Removal 1 Remove flywheel cover from the engine Snap out the retainer a and remove filter b a b Installation Install filter b into the cover Secure filter into cover with retainer a Lubrication Points Lubricate Point 1 with Quicksilver Special Lubricant 101 1 Trim Rod Ball Ends Turn the ball ends to work the lubricant into the ball sockets 1 ...

Page 17: ... removal and installation of the propeller Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft 2 Lubricate Points 3 thru 6 with Quicksilver 2 4 C Marine Lubricant with Teflon or Special Lubricate 101 3 Swivel Bracket Lubricate through fitting 4 Tilt Support Lever Lubricate through fitting 3 4 5 Tilt Tube Lubricate through fitting 5 ...

Page 18: ...se steering cable to become hydraulically locked An hydraulically locked steering cable will cause loss of steering control possibly resulting in se rious injury or death Lubricate Points 7 With Light Weight Oil 7 Steering Link Rod Pivot Points Lubricate pivot points 7 6 b 6 a Checking Power Trim Fluid 8 Tilt outboard to the full up position and engage the tilt support lock 8 9 Remove fill cap and...

Page 19: ...ures will turn to ice and damage the gear case Whenever you remove the fill drain plug examine the magnetic end for metal particles A small amount of metal filings or fine metal particles indicates normal gear wear An ex cessive amount of metal filings or larger particles chips may indicate abnormal gear wear and should be checked by an authorized dealer DRAINING GEAR CASE NOTE Some models may hav...

Page 20: ...your outboard even momentarily without water circulating through all the cooling water intake holes in the gear case to prevent damage to the water pump running dry or overheating of the engine FUEL SYSTEM IMPORTANT Gasoline containing alcohol ethanol or methanol can cause a for mation of acid during storage and can damage the fuel system If the gasoline be ing used contains alcohol it is advisabl...

Page 21: ...present PROTECTING EXTERNAL OUTBOARD COMPONENTS 1 Lubricate all outboard components listed in the Inspection and Maintenance Schedule 2 Touch up any paint nicks See your dealer for touch up paint 3 Spray Quicksilver Corrosion Guard on external metal surfaces except corrosion con trol anodes GEAR CASE Drain and refill the gear case lubricant refer to maintenance procedure POSITIONING OUTBOARD FOR S...

Page 22: ...Starboard View 1C 10 Model 135 150 DFI Powerhead Port View 1C 11 Model 135 150 DFI Powerhead Top View 1C 12 Model 135 150 DFI Powerhead Aft View 1C 13 Painting Procedures 1C 14 Cleaning Painting Aluminum Propellers Gear Housings 1C 14 Decal Application 1C 15 Decal Removal 1C 15 Instructions for Wet Application 1C 15 Serial Number Location The engine serial number is located on the lower starboard ...

Page 23: ...the coming of cool dry weather In pointing out the consequences of weather effects an engine running on a hot humid summer day may lose as much as 14 of the horsepower it would produce on a dry brisk spring or fall day The horsepower that any internal combustion engine produces depends upon the density of the air that it consumes and this density is dependent upon the temperature of the air its ba...

Page 24: ... the boat veer back and forth bow steer BOTTOM 1 Boat Bottom For maximum speed a boat bottom should be nearly a flat plane where it contacts the water and particularly straight and smooth in fore and aft direction a Hook Exists when bottom is concave in fore and aft direction when viewed from the side When boat is planing hook causes more lift on bottom near transom and allows bow to drop thus gre...

Page 25: ...tion Rapid reduction in power will cause a sudden change of steering torque and may cause additional momentary boat instability 1 Will lift bow of boat generally increasing top speed 2 Transfers steering torque harder to left on single outboard installations below 23 in 584mm transom height 3 Increases clearance over submerged objects 4 In excess can cause porpoising and or ventilation 5 If trimme...

Page 26: ...rine sealer at time of installation Water intrusion into the transom core and or inner hull will result in addition al boat weight reduced boat performance hull decay and eventual structural failure CAVITATION Cavitation is caused by water vapor bubbles forming either from a sharp edge or angle on the gear case or from an irregularity in the propeller blade itself These vapor bubbles flow back and...

Page 27: ...r advanced ignition timing Use of low octane gasoline Propeller pitch too high engine RPM below recommended maximum range Lean fuel mixture at or near wide open throttle Spark plugs heat range too hot incorrect reach cross firing Inadequate engine cooling deteriorated cooling system Detonation usually can be prevented if 1 The engine is correctly set up 2 Diligent maintenance is applied to combat ...

Page 28: ...Recover engine from water as quickly as possible 2 Remove cowling 3 Clean the exterior of the outboard with fresh water 4 Dry all wiring and electrical components using compressed air 5 Drain water from fuel system as follows a Disconnect remote fuel hose from engine b Remove drain plug from vapor separator and drain fuel water Reinstall plug after draining c Remove the fuel hose from bottom of po...

Page 29: ...m with fuel Connect fuel hose and squeeze primer bulb until it feels firm b Turn the ignition key switch to the ON position c Within the first 10 seconds after the key switch has been turned on move the re mote control handle from neutral into forward gear 3 to 5 times This will automati cally start the priming process N F NOTE Audible click from the oil pump will tell you the pump is priming It m...

Page 30: ...arator 3 Vapor Separator Drain Plug 4 Air Temperature Sensor 5 Fuel Hose Outlet from Low Pressure Electric Fuel Pump 6 Fuel Return Hose from Fuel Cooler 7 Electric Fuel Pump Harness Connection 8 Electric Oil Pump Hidden 9 Digital Diagnostic Terminal Harness Connection 10 Crank Position Sensor Harness Connection 11 Starter Motor 12 Throttle Plate Assembly 13 Fuel Hose Out to Fuel Rails High Pressur...

Page 31: ... Oil Hose from Oil Reservoir to Oil Pump 7 Oil Pump 8 Main Power Relay 1998 Model 9 Trim DOWN Relay 10 Trim UP Relay 1998 Model 11 Temperature Sensor 12 Electronic Control Module 13 Starter Motor 14 Starter Solenoid 15 Oil Pump Fuse 16 Harness Fuse 20 Ampere 17 ECM Fuse 20 Ampere 18 Electric Fuel Pump Fuse 20 Ampere 19 Air Hose 20 Starboard Fuel Rail 21 Fuel Hose 22 5 Fuel Injector 23 3 Fuel Injec...

Page 32: ...essor 9 Temperature Sensor Air Compressor 10 2 Fuel Injector 11 4 Fuel Injector 12 6 Fuel Injector 13 Excess Air to Adaptor Plate 14 Water Inlet to Fuel Cooler from Adaptor Plate 15 Port Fuel Rail 16 Water Out to Poppet Valve 17 Excess Fuel Return to Fuel Cooler 18 Air Pressure Test Port 19 40 psi Check Valve 20 Fuel Cooler 21 Oil Reservoir 22 Neutral Shift Interrupt Switch 23 60 Ampere Alternator...

Page 33: ... 5 40 psi Check Valve 6 Fuel Return to Vapor Separator 7 Belt Tensioner 8 60 Ampere Alternator 9 Electric Fuel Pump 10 Throttle Plate Assembly 11 Crank Position Sensor 12 MAP Sensor Hose 13 Oil Return Hose from Air Compressor 14 Starter Motor 15 Oil Hose from Oil Pump to Air Compressor 16 Serial Number Plug 17 Fuel Pressure Test Valve 18 Air Hose 80 PSI to Fuel Rail 19 Check Valve 20 Air Compresso...

Page 34: ... Compressor 5 Air Pressure Out 80 psi 6 Fuel Pressure Test Valve 7 Check Valve 8 Excess Oil Return from Air Compressor 9 1 Fuel Injector 10 Starboard Fuel Rail 11 3 Fuel Injector 12 5 Fuel Injector 13 Tell Tale Outlet 14 Flush Plug 15 5 Ignition Coil 16 3 Ignition Coil 17 1 Ignition Coil 18 Water Inlet to Air Compressor 19 2 Ignition Coil 20 MAP Sensor 21 4 Ignition Coil 22 6 Ignition Coil 23 6 Fu...

Page 35: ...nded that the listed materials be purchased from a local Ditzler Automotive Finish Sup ply Outlet The minimum package quantity of each material shown following is sufficient to refinish several gear housings Procedure 1 Wash gear housing with a muriatic acid base cleaner to remove any type of marine growth and rinse with water if necessary 2 Wash gear housing with soap and water then rinse 3 Sand ...

Page 36: ...g old decal 3 Clean decal contact area with a 1 1 mixture of isopropyl alcohol and water 4 Thoroughly dry decal contact area and check for a completely cleaned surface Instructions for Wet Application NOTE The following decal installation instructions are provided for a Wet installation All decals should be applied wet TOOLS REQUIRED 1 Plastic Squeegee 2 Stick Pin 3 Dish Washing Liquid Detergent w...

Page 37: ...tion 4 Flood area where the decal will be positioned with wetting solution 5 Position pre wetted decal on wetted surface and slide into position 6 Starting at the center of the decal lightly squeegee out the air bubbles and wetting solution with overlapping strokes to the outer edge of the decal Continue going over the decal surface until all wrinkles are gone and adhesive bonds to the cowl surfac...

Page 38: ...oard 1D 8 Dual Outboard 1D 8 Shift Cable 1D 9 Counter Rotation Outboards 1D 9 Installation 1D 10 Throttle Cable 1D 12 Installation 1D 12 Front Clamp Reassembly 1D 13 Filling Fuel System 1D 14 Oil Injection Set Up 1D 14 Filling 1D 14 Priming the Oil Injection Pump 1D 15 Purging Air From the Engine Oil Tank 1D 16 Trim In Angle Adjustment 1D 16 Trim Tab Adjustment 1D 17 Models Without Power Steering ...

Page 39: ...ls 30 in 762 mm for XL models and 35 in 889 mm for XXL models Mounting the outboard higher may cause damage to the gear case components a This solid line is recommended to determine the outboard mounting height In creasing the height of outboard generally will provide the following 1 Less steer ing torque 2 more top speed 3 greater boat stability but 4 will cause more prop break loose which may be...

Page 40: ...engine mounting template located with the installation manual to boat transom IMPORTANT If using Transom Drilling Fixture part number 91 98234A2 use drill guide holes marked A when drilling outboard mounting holes b a a Centerline of Transom b Transom Drilling Fixture 91 98234A2 2 Mark and drill four 17 32 in 13 5mm mounting holes ...

Page 41: ...ing and Install outboard to the nearest recommended mounting height 2 Fasten outboard with provided mounting hardware shown d c b a b c a a 1 2 In Diameter Bolts 4 b Flat Washers 4 c Locknuts 4 d Marine Sealer Apply to Shanks of Bolts Not Threads Steering Cable STARBOARD SIDE ROUTED CABLE 1 Lubricate O ring seal and entire cable end 95 95 2 4 C With Teflon 92 825407A12 ...

Page 42: ...t Seats Then Back Nut Off 1 4 Turn IMPORTANT The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt a Part Number 10 14000 and self locking nuts b c Part Number 11 34863 These locknuts must never be replaced with common nuts non locking as they will work loose and vibrate off freeing the link rod to disengage WARNING Disengagement of a ...

Page 43: ...rement The remote control or key switch as sembly must be wired with a warning horn This warning horn is used with the en gine warning system Installation Note Open the front clamp assembly Remote Wiring Harness 1 Connect wiring Place harness into the holder GRN WHT BLU WHT BRN WHT TAN BLU WHT GRN WHT a a Power Trim Connections ...

Page 44: ...ng Gauge Harness Connect the harness extension to gauge and engine 1 2 3 4 5 6 a c b d f e a c b d a TAN BLACK b TAN WHITE c PINK LT BLUE to PINK LT BLUE d ORANGE e Connect PURPLE to 12 Volt Source or Adjacent Gauge f Sta Straps Fasten Wiring to Prevent Catching on Cowl ...

Page 45: ...99 Battery Cables Single Outboard a b c a RED Sleeve Positive b BLACK Sleeve Negative c Starting Battery Dual Outboard Connect a common ground cable wire size same as engine battery cables between NEGATIVE terminals on starting batteries d d Common Ground Cable ...

Page 46: ...tion instructions shipped with the control explain the procedure required to connect this control to a counter rotation out board IMPORTANT If the counter rotation outboard is rigged similar to a standard rota tion outboard OR if a standard rotation outboard is rigged similar to a counter rota tion outboard the reverse gear and bearing in the gear case must function as for ward gear THE REVERSE GE...

Page 47: ...o full speed position Slowly return the handle back to the neutral Place a mark a on the cable against the cable end guide b Move the remote control handle from neutral into reverse and advance the handle to full speed position Slowly return the handle back to the neutral Place a mark b on the cable against the cable end guide c Make a center mark c midway between marks a and b Align the cable end...

Page 48: ...djust cable barrel so it slips freely into the barrel holder 6 Secure shift cable with shift cable retainer b a a Cable Barrel b Shift Cable Retainer 7 Check shift cable adjustments as follows a With remote control in forward the propshaft should lock solidly in gear If it does not adjust cable barrel closer to cable end guide b Shift remote control into neutral The propshaft should turn freely wi...

Page 49: ...ol into neutral N 2 Attach throttle cable to the throttle lever Secure with latch a a Latch 3 Adjust the cable barrel so that the installed throttle cable will hold the idle stop screw against the stop a b a Cable Barrel Adjust To Hold Idle Stop Screw Against Stop b Idle Stop Screw 4 Check throttle cable adjustment as follows a Shift outboard into gear a few times to activate the throttle linkage ...

Page 50: ...p 5 Lock the barrel holder in place with the cable latch Front Clamp Reassembly IMPORTANT Sufficient slack must exist in engine wiring harness battery cables fuel hose and oil hoses routed between clamp and engine attachment point to re lieve stress and prevent hoses from being kinked or pinched 1 Place the clamp over the wiring hoses and control cables as shown ÇÇÇ ÇÇÇ ÇÇÇ ÉÉÉ ÉÉÉ ÉÉÉ ÇÇÇ ÇÇÇ ÇÇÇ...

Page 51: ...il it feels firm Turn the ignition key switch to the ON position for three seconds This operates the electric fuel pump Turn the ignition key switch back to the OFF position and squeeze the primer bulb again until it feels firm Turn the ignition key switch to the ON position again for three seconds Continue this procedure until the fuel line primer bulb stays firm Oil Injection Set Up Filling 1 Fi...

Page 52: ...tion Pump b Oil Supply Hose CAUTION To prevent damage to the fuel pumps fill the engine fuel system with fuel Other wise the fuel pumps will run without fuel during the priming process Prime the oil injection pump as follows 1 Fill the engine fuel system with fuel Connect fuel hose and squeeze primer bulb until it fells firm 2 Turn the ignition key switch to the ON position 3 Within the first 10 s...

Page 53: ...lls given the variety of available propellers and height range of engine installations However once on plane the engine should be trimmed to a more intermediate position to a avoid a bow down planing condition called plowing Plowing can cause bow steer ing or over steering and inefficiently consumes horsepower In this condition if attempt ing a turn or encountering a diagonal moderate wake a more ...

Page 54: ...your boat left and right and note the direction the boat turns more easily If adjustment is necessary loosen trim tab bolt until trim tab moves freely does not rub against locking ridges DO NOT strike tab to make adjustments Make small adjustments at a time If the boat turns more easily to the left move the trailing edge of trim tab to the left If the boat turns more easily to the right move the t...

Page 55: ...2A 12 DDT Functions 2A 13 DFI Troubleshooting Guide 2A 15 Ignition Components Removal and Installation 2A 18 Flywheel Cover Removal and Installation 2A 18 Electronic Control Module ECM 2A 19 Ignition Module Coil 2A 20 Crank Position Sensor 2A 21 Throttle Position Sensors TPS 2A 21 Specifications Ignition Coil Ohm Test Connect meter leads between primary terminal GRN Striped and ground BLACK termin...

Page 56: ...IGNITION Page 2A 2 90 855347R1 JANUARY 1999 Special Tools 1 Digital Diagnostic Terminal DDT 91 823686A2 2 Software Cartridge 91 822608 5 3 DDT Reference Manual 90 825159 3 4 Adaptor Harness 84 822560A5 ...

Page 57: ...IGNITION 90 855347R1 JANUARY 1999 Page 2A 3 5 Multi Meter DVA Tester 91 99750A1 6 Inductive Timing Light 91 99379 7 Spark Gap Tester 91 850439T 55117 ...

Page 58: ...5711 2 NOTE COAT ALL MULTI PIN ELECTRICAL CONNECTIONS EXCEPT POWER TRIM RELAYCONNECTORS WITH 6 DC 4 DIELECTRIC GREASE 92 823506 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 25 26 27 28 29 30 31 32 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 36 Liquid Neoprene 92 25711 2 6 Dielectric Grease 92 823506 1 25 ...

Page 59: ...3 RELAY 19 3 DECAL Trim Relay 20 3 BRACKET 21 3 BUSHING 22 3 GROMMET 23 2 SCREW M6 x 25 35 4 24 1 SCREW M6 x 35 35 4 25 1 BUSHING 26 2 STA STRAP 27 1 ENGINE HARNESS 28 1 HARNESS SERVICE ITEM 29 4 FUSE 30 1 BRACKET Fuse Holder 31 2 SCREW M4 x 8 32 1 ECU 135 33 1 ECU 150 34 1 PAD 35 3 SCREW M6 x 25 70 8 36 6 BUSHING 37 3 GROMMET 38 2 SCREW M6 x 14 100 11 5 39 1 CLIP 40 1 CLAMP 41 2 SCREW 10 16 x 3 8...

Page 60: ... the ECM When the ECM receives this signal the ECM will then open the ground circuit of the coil primary The magnetic field in the ignition coil primary will then collapse cutting across the coil sec ondary winding creating a high voltage charge 50 000 volts that is sent to the spark plug Ignition Component Description Electronic Control Module ECM The ECM requires 8 VDC minimum to operate If the ...

Page 61: ...used in conjunction with one another If one sensor should fail the dash mounted CHECK ENGINE light will light and the warning horn will sound RPM will be limited to 3000 rpm If both TPS s should fail rpm will be reduced to idle by the ECM TPS settings are not adjustable TPS settings can be monitored with the Digital Diagnostic Terminal through the ECM Charging System Alternator Battery charging sy...

Page 62: ...ming in the event of an over heat condition An ohms test of the temperature sensor would be as follows Insert digital or analog ohmmeter test leads into both TAN BLACK sensor leads With en gine at temperature F indicated ohm readings should be as indicated 10 0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 0 0 2 0 4 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 2 6 2 8 3 0 3 2 Resist...

Page 63: ... fuel air mix into cylinders Injectors are mounted between fuel rails and cylinder heads Direct Injector Ohm Test Injector Lead Disconnected Connect meter leads between each in jector terminal pin 1 1 6 Fuel Injectors 6 fuel injectors 1 per cylinder are used to provide fuel from the fuel rail to the direct injec tors The fuel injectors are mounted in the fuel rail Fuel Injector Ohm Test Injector L...

Page 64: ...nitiated through use of the DDT Any sensor or connection can be disconnected and reconnected while the engine is operating without damaging the ECM Disconnecting the crank position sensor will stop the engine IMPORTANT Any sensor that is disconnected while the engine is running will be recorded as a Fault in the ECM Fault History Use the DDT to view and clear the fault history when troubleshooting...

Page 65: ...hnicians diagnose and repair Mercury Marine 2 and 4 cycle engines Attach the diagnostic cable to the ECM diagnostic connector and plug in the software car tridge You will be able to monitor sensors and ECM data values including status switches The ECM program can help diagnose intermittent engine problems It will record the state of the engine sensors and switches for a period of time and then can...

Page 66: ...IGNITION Page 2A 12 90 855347R1 JANUARY 1999 Notes ...

Page 67: ...FF OFF TP1 LIM OFF OFF TP2 LIM OFF OFF RPM LIM OFF OFF OIL LIM OFF ON BAT LIM OFF OFF BLK LIM OFF OFF PWR LIM OFF OFF STATUS BREAK IN ENGINE IS IN BREAK IN MODE xxx MINUTES TO COMPLETION STATUS BREAK IN ENGINE HAS COMPLETED A FACTORY SCHED ULED BREAK IN or MISC ACTIVE HIST BATTERY PASS PASS PWR RLY PASS PASS PWR 1 V PASS PASS PWR 2 V PASS PASS HORN PASS PASS LAMP PASS PASS SENSOR ACTIVE HIST COOL ...

Page 68: ...s and then turn off Measure fuel pressure valve on starboard rail Fuel pres sure should be 10 1 psi greater than the air pressure 1 4 Low fuel pressure Check fuel pressure from low pres sure electric fuel pump 6 10 psi Check for fuel leaks If fuel pres sure leaks down faster than air pressure seals on fuel pump may be leaking Check air system pres sure see 1 2 1 5 Sheared Flywheel Key Remove flywh...

Page 69: ...YEL Check crank position sensor setting 0 015 in 0 040 in 0 38mm 1 01mm from flywheel or for defective crank position sensor Defective ECM Power Supply Clean and inspect remote control male and female harness connec tors 2 Engine cranks starts and stalls 2 0 Low air pressure in rail See 1 2 2 1 Low fuel pressure in rail See 1 2 and 1 3 2 2 Abnormally high friction in engine Check for scuffed pisto...

Page 70: ...ator or tracker diaphragm Measure fuel pressure Remove and inspect diaphragms a special tool is required for assembly 4 2 Fuel leak Check for fuel entering induction manifold or air compressor inlet Fuel pump diaphragm leaking and or Vapor Separator flooding over 4 3 Tracker Valve spring missing Inspect tracker valve for proper as sembly 4 4 Improper set up Check throttle cable cam roller adjustme...

Page 71: ...ge below 9 5 volts See 2 4 Use DDT or volt meter to check battery voltage 9 Loss of spark on 1 cylin der 9 1 Loose wire or pin in connectors between ECM and coil primary 9 2 Faulty ignition coil 9 3 Faulty spark plug 9 4 Faulty spark plug wire Note Due to the long spark dura tion of this ignition system the DDT may indicate the incorrect cyl inder as having an ignition fault Example If the DDT ind...

Page 72: ...itting d Holder Electronic Control Module ECM REMOVAL 1 Disconnect ECM harness connectors 2 Remove 3 bolts securing ECM a c b e f f g d a b c d e f f g a Electronic Control Module b Bracket Fuse Holder c Rubber Pad d Bolt 2 Torque to 80 lb in 9 N m e Bolt 3 Torque to 80 lb in 9 N m f Bushing g Rubber Grommet INSTALLATION 1 Secure ECM to powerhead with 3 bolts 2 Install rubber pad and bracket for t...

Page 73: ...ng bolts 56141 a c b d e f g h i j b a b c b d j i h g f e a Bolts 6 Torque to 80 lb in 9 Nm b Ignition Coils 6 c Spacer Place on Bolts between coils d Electrical Mounting Plate e Bolts 4 Torque to 235 lb in 27 Nm f Washer g Rubber Grommet h Bushing i Washer j Locknut 6 INSTALLATION 1 Fasten coils to electrical mounting plate as shown 2 Reinstall electrical mounting plate 3 Reconnect spark plug le...

Page 74: ... in 5 5 Nm INSTALLATION 1 Fasten sensor to bracket with bolt 2 Set air gap 0 025 in 0 040 in 0 635 mm 1 01 mm 3 Reconnect sensor harness Throttle Position Sensors TPS REMOVAL 1 Disconnect wiring harness 2 Remove screws securing sensors to bracket a b c d e a b c d e a Throttle Sensor Inside b Spacer c TPS Lever d Throttle Sensor Outside e Screw 3 Torque to 20 lb in 2 5 Nm INSTALLATION 1 Fasten sen...

Page 75: ... Tension Adjustment 2B 22 Starter System 2B 23 Starter Motor Amperes Draw 2B 23 Starter System Components 2B 23 Description 2B 23 Starter Motor 2B 24 Troubleshooting the Starter Circuit 2B 25 Starter Circuit Troubleshooting Flow Chart 2B 26 Starter Removal and Installation 2B 27 Removal 2B 27 Installation 2B 28 Disassembly 2B 28 Starter Cleaning Inspection and Testing 2B 30 Cleaning and Inspection...

Page 76: ...4 4 4 4 2 2 2 30 115 Hp 6 4 4 4 4 4 2 2 2 2 2 2 2 2 0 0 0 125 250 Hp ex cept DFI 6 6 4 4 4 4 4 4 2 2 2 2 2 2 2 DFI Models 4 2 2 2 2 2 2 2 2 2 0 0 0 Standard original Cable Length and wire gage size Replacement Parts WARNING Electrical ignition and fuel system components on your Mercury Mariner out board are designed and manufactured to comply with U S Coast Guard Rules and Regulations to minimize ...

Page 77: ...f battery acid comes in contact with skin or eyes wash skin immediately with a mild soap Flush eyes with water immediately and see a doctor When charging batteries an explosive gas mixture forms in each cell Part of this gas es capes through holes in vent plugs and may form an explosive atmosphere around battery if ventilation is poor This explosive gas may remain in or around battery for several ...

Page 78: ...riod at a low charging rate in amperes all cells are gassing freely not spewing liquid electrolyte and no change in specific gravity occurs Full charge specific gravity is 1 260 1 275 corrected for electrolyte temperature with electrolyte level at 3 16 in 4 8 mm over plate unless electrolyte loss has occurred from age or over filling in which case specific gravity reading will be lower For most sa...

Page 79: ...ch can be purchased locally 5 Repeat preceding charging procedure every 30 45 days as long as battery is in stor age for best possible maintenance during inactive periods to ensure a good service able battery in spring When ready to place battery back in service remove excess grease from terminals a small amount is desirable on terminals at all times recharge again as necessary and reinstall batte...

Page 80: ...e to flywheel or electrical components under flywheel may result 6 Remove flywheel Inspect flywheel for cracks or damage Installation IMPORTANT Do not apply grease to the flywheel taper or corresponding crank shaft splines The application of grease to these areas will result in flywheel hub breakage when tightening flywheel nut 1 Install flywheel 2 Install flywheel washer and nut 3 Hold flywheel w...

Page 81: ...CHARGING STARTING SYSTEM 90 855347R1 JANUARY 1999 Page 2B 7 Notes ...

Page 82: ...CHARGING STARTING SYSTEM Page 2B 8 90 855347R1 JANUARY 1999 Flywheel Alternator 1 2 12 14 23 27 16 4 15 20 17 21 25 26 3 22 19 24 18 14 7 8 9 10 11 13 6 5 5 7 9 4 4 20 5 7 ...

Page 83: ...x120 275 23 31 4 3 WASHER 5 3 MOUNT 6 1 BRACKET 7 3 WASHER 8 1 BRACKET 9 2 NUT 275 23 31 10 1 SCREW M10 x 55 275 23 31 11 1 CABLE 12 1 PIN 13 1 BRACKET 14 3 SCREW 5 16 18 x 1 IN 185 15 5 21 15 1 SPRING 16 1 BELT TENSIONER 17 1 STUD M10 x 85 18 1 NUT 180 15 20 19 1 BUSHING 20 2 WASHER 21 1 PULLEY 22 1 SCREW M10 x 35 300 25 34 23 1 BELT 24 1 FLYWHEEL 25 1 NUT 125 169 26 1 WASHER 27 1 PLUG ...

Page 84: ...ator system 1 Do not attempt to polarize the alternator 2 Do not short across or ground any of the terminals on the alternator except as specifi cally instructed 3 Never disconnect the alternator output lead regulator harness or battery cables when the alternator is being driven by the engine 4 Always remove NEGATIVE battery cable from battery before working on alternator system 5 When installing ...

Page 85: ...t the battery and regulates the field current to maintain alternator volt age for properly charging the battery Current output of the alternator does not require reg ulation as maximum current output is self limited by the design of the alternator As long as the voltage is regulated within the prescribed limits the alternator cannot produce ex cessive current A cutout relay in the voltage regulato...

Page 86: ...0 855347R1 JANUARY 1999 Alternator Assembly 51683 j i g f e h a b c d a b c d e f g h i j a Pulley Nut b Pulley c Spacer d Frame and Rotor Assembly e Brush Holder f Brush Cover g Regulator h Rectifier Diode Assembly i Insulator j End Cover ...

Page 87: ...and should not vary If proper reading is not obtained check for loose or dirty connections or dam aged wiring VOLTS DC AMPS OHMS 0 2 4 6 8 10 DCV ACV DVA 0 0 5 10 20 10 30 15 40 20 0 51015 2030 4060 100 200 56113 a a a Terminal B Sensing Circuit 1 Unplug RED and PURPLE lead connector from alternator 2 Connect POSITIVE voltmeter lead to RED lead and NEGATIVE voltmeter lead to ground 3 Voltmeter sho...

Page 88: ...o the following specifications 8 in 203 mm 13 16 in 20 6 mm 0 060 in 1 52 mm VOLTS DC AMPS OHMS 0 2 4 6 8 10 DCV ACV DVA 0 0 5 10 20 10 30 15 40 20 0 51015 2030 4060 100 200 56113 a a a Terminal B 4 Insert bent end of tool through end cover and ground TERMINAL F 56115 VOLTS DC AMPS OHMS 0 2 4 6 8 10 DCV ACV DVA 00 5 10 20 10 30 15 40 20 0 5 10 15 20 30 40 60 100 200 b a c 51683 a a b c a a Termina...

Page 89: ...E OUTPUT through end cover and ground TERMINAL F 56116 b e a d c a Terminal F b Tool c Jumper Wire to Engine Ground d Terminal B e Ammeter 4 Normal output is 60 amperes 2000 RPM If output is normal replace regulator If output is low a disassembly of the alternator is necessary to inspect and test individ ual components Repair Removal 1 Remove top cowling 2 Disconnect battery cables from battery 3 ...

Page 90: ... g Screws NOTE Proper regulator operation can be determined by VOLTAGE OUTPUT and CUR RENT OUTPUT previous If regulator does not meet specifications replace regulator Torque regulator screws to 17 lb in 2 Nm NOTE Brushes are replaced as an assembly Inspect assembly for stuck brushes or ex cessive brush wear Normal exposed brush length is 0 156 in 4 0 mm Minimum ex posed brush length is 0 059 in 1 ...

Page 91: ...SITIVE lead on each diode assembly NO CONTINUITY should be observed If continuity is observed in both tests or NO CONTINUITY is observed in both tests the rectifier assembly is defective and must be replaced Torque rectifier screws to 17 lb in 1 9 Nm 51679 b a c a b c a Positive Stud b Negative Ohm Lead c Positive Ohm Lead IMPORTANT Depending on the polarity of the ohmmeter reversed readings may b...

Page 92: ... condi tions exist rotor is not considered serviceable and alternator should be replaced 2 Measure the outer diameter of the slip rings using vernier calipers STANDARD DI AMETER 0 567 in 14 4 mm MINIMUM DIAMETER 0 551 in 14 mm If slip ring diameter is less than minimum rotor is not considered serviceable and alternator should be replaced 51680 51684 a a a Slip Rings 3 Inspect rotor for an open cir...

Page 93: ...or a short circuit between each stator lead and the stator frame If CONTINUITY exists stator is defective 51682 b a a b a Stator Leads b Frame 2 Inspect stator for open circuit Using an ohmmeter check for an open circuit between each of the stator leads If no continuity exists stator is defective 51682 a a a a a Stator Leads ...

Page 94: ...a b b a Rectifier Assembly b Stator Leads c Stator Leads d Screws Torque to 17 lb in 1 9 Nm 3 Secure regulator to alternator with 2 screws 1 in 25 4 mm long 1 screw 0 25 in 6 4 mm long and lockwashers DO NOT tighten screws at this time 4 Secure brush assembly with 2 screws 0 25 in 6 4 mm long and 0 312 in 8 0 mm long 51680 b c a d e f 51684 c a a b c a Regulator b Screws 1 in 25 4 mm c Screw 0 25 ...

Page 95: ...Torque nut to 36 lb in 4 Nm 51683 d c a b a b c d a Cover b Screw Torque to 23 lb in 2 5 Nm c Terminal Insulator d Nut Torque to 36 lb in 4 Nm Pulley 1 While holding rotor shaft remove pulley nut 2 Before reinstalling pulley verify spacer is installed on rotor shaft 51683 a d 51679 a c b a b c a Pulley b Rotor Shaft c Nut d Spacer 3 Torque pulley nut to 50 lb ft 68 Nm ...

Page 96: ... 35 lb ft 47 5 Nm 2 Install alternator belt in V groove of flywheel and alternator pulley 3 Reconnect electrical harness to alternator a 56117 b c a b c a Top Bolt Torque to 40 lb ft 54 Nm b Bottom Bolt Torque to 35 lb ft 47 5 Nm c Harnesses Alternator Belt Tension Adjustment Correct alternator belt tension is maintained by a belt tensioner assembly a 56142 a a Belt Tensioner Assembly ...

Page 97: ...s electricity to activate the starter motor When the ignition is turned to the START position the starter solenoid is energized and completes the starter circuit between the battery and starter The neutral start switch opens the starter circuit when the shift control lever is not in neu tral thus preventing accidental starting when the engine is in gear CAUTION The starter motor may be damaged if ...

Page 98: ...TY DESCRIPTION lb in lb ft Nm 1 1 STARTER MOTOR 2 1 DRIVE CAP 3 2 THRU BOLT 70 8 4 1 DRIVE KIT 5 1 PINION 6 1 ARMATURE 7 1 BRUSH SPRING KIT 8 1 BRUSH HOLDER 9 1 COMMUTATOR CAP 10 2 SCREW Drive Tight 11 1 LOCKWASHER 12 1 NUT 1 4 20 35 4 0 13 1 LOCKWASHER 14 1 NUT 1 4 20 35 4 0 15 3 SCREW 5 16 18 x 1 3 4 210 17 5 24 16 1 BATTERY CABLE NEGATIVE 17 1 DECAL Warning High Voltage 18 1 BOOT ...

Page 99: ...d 2 Check that control lever is in NEUTRAL position 3 Check terminals for corrosion and loose connections 4 Check cables and wiring for frayed and worn insulation 5 Check 20 amp fuse Location of Test Points called out in flow chart are numbered below Starter Circuit STARTER BATTERY STARTER SOLENOID 20 AMP FUSE IGNITION SWITCH NEUTRAL START SWITCH LOCATED IN CONTROL HOUSING TO ALTERNATOR 7 1 2 6 3 ...

Page 100: ... TEST 3 a Reconnect BLACK ground wire b Connect voltmeter between common engine ground and Test Point 3 c Turn ignition key to Start position 12 Volt Reading Check BLACK ground wire for poor connection or open circuit Reconnect ground wire to starter solenoid Proceed to TEST 7 12 Volt Reading Defective starter solenoid TEST 4 a Connect voltmeter between common engine ground and Test Point 4 b Turn...

Page 101: ...t 7 c Turn ignition key to Start position No voltage reading Check BLACK cable with YELLOW sleeve for poor connection or open circuit 12 Volt Reading If starter motor does not turn check starter motor Battery Voltage Starter Removal and Installation Removal CAUTION Disconnect battery leads from battery before removing starter 1 Disconnect BLACK ground cable from starter 2 Disconnect BLACK cable wi...

Page 102: ...LLOW sleeve to POSITIVE terminal on starter Torque nut to 60 lb in 7 Nm d c b 52135 a a b c d a Top Bolts Torque to 23 lb ft 31 Nm b Bottom Bolt Torque to 21 lb ft 28 5 Nm c BLACK Cable with YELLOW sleeve d Nut Torque to 60 lb in 7 Nm Disassembly 1 Remove starter as outlined in Starter Removal and Installation preceding 2 Remove 2 through bolts from starter 3 Tap commutator end cap to loosen and r...

Page 103: ... assembly b Remove 2 bolts securing NEGATIVE brushes and brush holder to end cap 11656 b c b d c a a b c c b d a Brush Holder b Positive Brushes c Negative Brushes d Positive Terminal 5 Remove armature with drive end cap from starter frame 6 Remove locknut and remove drive assembly from armature shaft 11658 e f g d c b a a 51711 b c d e f g h a a Hold Armature Shaft with Wrench on Hex Portion of D...

Page 104: ...ting c Sand the commutator lightly with No 00 sandpaper to remove burrs then clean the commutator d Recheck the armature on a growler for shorts as specified in the following proce dure Testing 8 Open circuited armatures often can be repaired The most likely place for an open cir cuit is at the commutator bars as a result of long cranking periods Long cranking peri ods overheat the starter motor s...

Page 105: ...een POSITIVE brushes Meter must indicate full continuity or zero resistance If resistance is indicated inspect lead to brush and lead to POSITIVE terminal solder connection If connection cannot be repaired brushes must be replaced a 51711 a a POSITIVE Brushes Testing Negative Brushes for Ground Set ohmmeter to R x1 scale Place one lead of the ohmmeter on the NEGATIVE brush and the other lead on th...

Page 106: ...r end cap 52131 a b c d e f c a b 51713 g h i a b c d e f a End Cap b POSITIVE Brushes c POSITIVE Terminal d Insulating Block e Insulating Washer f Hex Nut g POSITIVE Terminal h Long Brush Lead i Push Lead into Slot b Install NEGATIVE brushes along with brush holder 11656 a c b d a b d a b c a b d d a POSITIVE Brushes b NEGATIVE Brushes c Brush Holder d Bolts Fasten NEGATIVE Brushes and Holder ...

Page 107: ...te helix threads on armature shaft with a drop of SAE 10W oil 4 Lubricate bushing in drive end plate with a drop of SAE 10W oil 5 Position armature into starter frame 6 Lubricate bushing located in commutator end cap with one drop of SAE 10W oil DO NOT overlubricate 7 To prevent damage to brushes and springs when installing commutator end cap it is recommended that a brush retaining tool be made a...

Page 108: ...Install through bolts and torque to 70 lb in 8 Nm 52130 a 51713 a b a a Brush Retainer Tool b Alignment Marks Starter Solenoid Test 1 Disconnect all wires from solenoid 2 Connect ohmmeter R x1 scale between terminals 1 and 2 3 Connect a 12 volt power supply between terminals 3 and 4 Solenoid should click and meter should read 0 ohms full continuity 4 If meter does not read 0 ohms full continuity r...

Page 109: ...or the following tests 3 If meter readings are other than specified in the following tests verify that switch and not wiring is faulty If wiring checks ok replace switch IMPORTANT Key switch must be positioned to RUN or START and key pushed in to actuate choke for this test KEY POSITION OFF RUN START CHOKE CONTINUITY SHOULD BE INDICATED AT THE FOLLOWING POINTS BLK BLK YEL RED YEL RED PUR YEL BLK ...

Page 110: ...2C 6 Idle Speed 2C 6 Specifications FULL THROTTLE RPM RANGE 5000 5600 IDLE RPM IN FORWARD GEAR 550 25 MAXIMUM TIMING WIDE OPEN Not Adjustable Controlled by ECM IDLE TIMING Not Adjustable Controlled by ECM SPARK PLUG TYPE LIGHT DUTY HEAVY DUTY SPARK PLUG GAP NGK ZFR5F 11 Champion RC12MC4 NGK PZFR5F 11 Heavy Duty 0 040 in 1 0 mm FIRING ORDER 1 2 3 4 5 6 THROTTLE POSITION SENSOR 1 INNER TPS IDLE W O ...

Page 111: ...G SYNCHRONIZING ADJUSTING Page 2C 2 90 855347R1 JANUARY 1999 Special Tools 1 DMT 2000 Digital Tachometer Multi meter P N 91 854009A1 2 Digital Diagnostic Tool DDT 91 823686A2 3 Software Cartridge 91 822608 4 ...

Page 112: ...TIMING SYNCHRONIZING ADJUSTING 90 855347R1 JANUARY 1999 Page 2C 3 4 DDT Reference Manual 90 825159 2 5 ECM Harness 84 822560 5 6 Extension Cable 10 ft 3 05m 84 5003A1 ...

Page 113: ...er gauge measure the air gap between the crank position sensor and a tooth on the flywheel Gap should be 0 025 in 0 040 in 0 635 mm 1 02 mm IMPORTANT Crank Position Sensor must be perpendicular to flywheel tooth 3 Reinstall flywheel cover d c 56069 a c d b e a Air Gap 0 025 in 0 040 in 0 635 mm 1 02 mm b Crank Position Sensor c Flywheel Tooth d Bracket Screw Drive Tight e 0 010 in 0 254 mm or 0 02...

Page 114: ...m 3 Tighten roller arm screw to provide clearance of 0 005 in 0 005 in 0 127 mm 0 127 mm between roller and cam d a e 56061 a b c d e a Roller Arm Screw b Roller c Throttle Cam d Wide Open Throttle Stop Screw e Idle Stop Screw Maximum Throttle 1 Hold throttle arm against full throttle stop 2 Adjust full throttle stop screw located behind electric fuel pump to allow full throttle valve opening whil...

Page 115: ...etting Howev er should the throttle plate require adjustment use the throttle plate stop screw to set the throttle plate clearance 0 045 in 1 143 mm using a 56 drill a 56151 b a b a Throttle Plate Stop Screw b Throttle Plate Clearance Set 0 045 in 1 143mm Throttle Position Sensor TPS Adjustment The Throttle Position Sensors are not adjustable TPS settings can be monitored with the Digital Diagnost...

Page 116: ...am 2D 7 Instrument Lanyard Stop Switch Wiring Diagram Dual Outboard 2D 8 QSI Gauge Wiring Diagrams 2D 10 Tachometer Wiring Diagram 2D 10 Water Temperature Gauge 2D 11 Oil Level Gauge Wiring 2D 12 Engine Synchronizer Wiring Diagram 2D 14 Maintenance 2D 15 Multi Function Gauge 2D 16 Dip Switch Setting Testing 2D 16 Outboard Multi Function Gauge Setting 2D 17 Warning System Signals 2D 18 Warning Syst...

Page 117: ... g h i j k l m n a b c d e f g h i j k l m n a Tach Connector b Key Switch Assembly c Trim Switch d Trim Sender e Start Solenoid f To Battery g To Alternator h Trim Pump and Motor i DOWN Solenoid j UP Solenoid k Bottom Cowl Switch l 20 Ampere Fuse m Engine Harness n Remote Control Harness ...

Page 118: ... TRIM GAUGE TAN BLU TAN BLUE VISUAL WARNING KIT OPT Wire Color Where To a b c d Figure 1 Without Light Switch NOTE ANY INSTRUMENT WIRING HARNESS LEADS NOT USED MUST BE TAPED BACK TO THE HARNESS TAN WHT TAN BLK Speedometer Tachometer Temperature Oil Warning Panel Volt Meter 51819 To 12V e a b d c a b c d e Figure 2 With Light Switch a Tachometer Receptacle From Control Box or Ignition Choke Switch ...

Page 119: ... 855347R1 JANUARY 1999 Commander 3000 Classic Panel Remote Control BLK Black BLU Blue BRN Brown GRY Gray GRN Green ORN Orange PNK Pink PUR Purple RED Red Tan Tan WHT White YEL Yellow LIT Light DRK Dark a a Neutral Interlock Switch ...

Page 120: ...Y 1999 Page 2D 5 Commander 3000 Panel Remote Control RED PURPLE GREEN BLK Black BLU Blue BRN Brown GRY Gray GRN Green ORN Orange PNK Pink PUR Purple RED Red TAN Tan WHT White YEL Yellow LIT Light DRK Dark a a a Neutral Interlock Switch ...

Page 121: ...ch b Lanyard Stop Switch c Lead Not Used on Outboard Installations d Retainer e Tachometer f Trim Indicator Gauge Optional g Temperature Gauge h Remote Control i Power Trim Harness Connector j Connect Wires Together w Screw and Nut 2 Places Apply Liquid Neoprene to Connections and Slide Rubber Sleeve over each Connection k Lead to Optional Visual Warning Kit IMPORTANT On installations where gauge ...

Page 122: ...s Turned ON and OFF with Ignition Switch c Oil Level Gauge d BLACK Wire Connects to NEGATIVE Ground e To Ground f BLACK Wire From Gauge to Oil Clip Connector g LIGHT BLUE Sender Lead to Gauge h Wiring Harness LT BLU and BLACK i Screw 10 16 x 5 8 in j Spring k Oil Clip Connector l Adaptor Housing m Screw 10 16 x 1 4 in n Spring o Screw 10 16 x 5 8 in p BLACK Wire q Oil Level Sender Unit r Oil Pick ...

Page 123: ...N GRN GREEN GRY GRAY PUR PURPLE RED RED TAN TAN WHT WHITE YEL YELLOW 52205 g a e d k d b c l d f n n h o BATT GND SENDER PORT INSTALLATION a g d k d c b l d e f n n h o a Ignition Choke Switch b Lanyard Stop Switch c Lead not used on Outboard Installations d Retainer e Tachometer f Trim Indicator Gauge g Temperature Gauge h Remote Control ...

Page 124: ...ds 52206 i g a e j f m o STARBOARD INSTALLATION BATT GND SENDER g i j f m o a e i Synchronizer Gauge j Synchronizer Module k Lanyard Switch Isolation Diode l Y Harness m Power Trim Harness Connector n Connect Wires together with Screw and Nut 4 Places Apply Liquid Neo prene to Connections and slide Rubber Sleeve over each Connection o Lead to Visual Warning Kit ...

Page 125: ...h for instrument lighting 51106 a c d b a Connect to 12 Volt b 12 Volt Light Switch Wire c Position Light Bulb to the Switched Position d Connect to NEGATIVE Ground WIRING DIAGRAM B Use this wiring diagram when instrument lighting is wired directly to the ignition key switch Instrument lights are on when ignition key switch is turned on 51106 a b c a Connect to 12 Volt b Position Light Bulb to the...

Page 126: ...chometer Receptacle on Commander Side Mount Remote Control or TAN Lead coming from Accessory Ignition Choke Assembly WIRING DIAGRAM B Use this wiring diagram when instrument lighting is wired directly to the ignition key switch Instrument lights are on when ignition key is turned on 51105 SEND a b c d a Connect to 12 Volt b Position Light Bulb to the Unswitched Position c Connect to NEGATIVE Groun...

Page 127: ...n IMPORTANT Tape back and isolate any unused wiring harness leads 28086 a b a Lead from Temperature Sender b Engine Remote Control Harness Oil Level Gauge Wiring LIGHT BULB POSITION A Use this position when using a separate light switch for instrument lighting 51109 a b a 12 Volt Light Switch Wire b Position Light Bulb to the Switched Position ...

Page 128: ...sition when instrument lighting is wired directly to the ignition key switch In strument lights are on when ignition key switch is turned on 51112 a b a Position Light Bulb to the Unswitched Position b Sender SENDER WIRING 51108 a b a b a Connect to 12 Volt b Connect to NEGATIVE Ground ...

Page 129: ... a 12 Volt Light Switch Wire b Position Light Bulb to the Unswitched Position LIGHT BULB POSITION B Use this position when instrument lighting is wired directly to the ignition key switch In strument lights are on when ignition key switch is turned on 51106 a b a Position Light Bulb to the Switched Position b Sender Synchronizer wiring can be accomplished two different ways as an option to the use...

Page 130: ...le to point toward fast running engine GRY GRAY WHT WHITE BLK BLACK PUR PURPLE b c d 51107 a b c d a Tachometer Starboard Engine b Synchronizer Gauge c Tachometer Port Engine d Synchronizer Module Maintenance Clean gauge by washing with fresh water to remove sand and salt deposits Wipe off with a soft cloth moistened with water The gauge may be scored or damaged if wiped with abrasive material san...

Page 131: ...he Off position set the multi function gauge Dip Switch in test position as shown BLACK dot indicates switch position a b 52095 Open 1 2 3 4 a a b a Dip Switch shown in test position b Black Dot Switch in Open Position 2 Turn ignition switch to the Run position The multi function gauge now is in the dis play test mode The gauge Temp Batt Oil and Fuel red warning lights should be alter nately flash...

Page 132: ...itch 4 Open Open 1 2 3 4 Dip Switch 4 in Open Position For Dual Engine Single Fuel Tank Applications Switches 1 2 3 Must Be In Specified Model Position Warning System The outboard warning system incorporates warning light gauge a and warning horn b The warning horn is located inside the remote control or is part of the ignition key switch wiring harness a b b a b b When the key switch is turned to...

Page 133: ... Minutes Off Yes No No Oil Flow Continu ous Beep Yes Yes Yes Limits to 3000 RPM Oil Pump Electrical Failure Yes Yes Yes Limits to 3000 RPM Over Heat Continu ous Beep Yes Yes Limits to 3000 RPM Water In Fuel 4 Beep 2 Minutes Off Yes Over Speed Continu ous Beep Yes Activated at 5800 RPM Coolant Sensor Failure No Yes MAP Sensor Failure No Yes Air Temperature Sensor Failure No Yes Ignition Coil Failur...

Page 134: ...ank located beneath the top cowl along with the remote oil tank will have to be refilled The OIL light a will come on and the warning horn sounds a series of four short tones If you continue to operate the outboard the light will stay on and the horn will sound four short tones every two minutes The engine has to be shut off to reset the warning system NO OIL FLOW TO THE ELECTRIC OIL PUMP a b a b ...

Page 135: ...tor is not functioning correctly The CHECK ENGINE light a will turn on THROTTLE SENSOR NOT FUNCTIONING a a The system is activated if the throttle sensors are not functioning correctly The CHECK ENGINE light a will turn on and the warning horn will begin sounding WATER SEPARATING FUEL FILTER IS FULL OF WATER a The water level detection warning is activated when water in the water separating fuel f...

Page 136: ...le RPM Anytime the engine over speed system is activated the warning horn a begins to sound continuously The system will automatically reduce the engine speed to within the allow able limit NOTE Engine speed should never reach the maximum limit to activate the system unless the propeller is ventilating an incorrect propeller is being used or the propeller is faulty ...

Page 137: ...l b Ground Terminal c Speedometer d Tachometer e Tachometer Signal Terminal f Connect Wires Together with Screw and Hex Nut 3 Places Apply Quicksilver Liq uid Neoprene to Connections and Slide Rubber Sleeve Over Each Connection g Power Trim Connector h Horn i 8 Pin Harness Connector j Multi Function Gauge k Multi Function Adapter Har ness l To Fuel Sender Optional m To Oil Sender Optional n Two Wi...

Page 138: ... C A B C A B C C D B A B A C B A C B A C A B C BLK PPL GRY BLK ORG BLK ORG BLK BLK BLK BLK RED TAN BLK TAN BLK BLK GRN BRN 1 2 3 4 5 6 7 8 BLK YEL PPL TAN LT BLU BLK GRY YEL RED RED PPL DK BLU WHT A B 86 87 85 30 87a GRN WHT GRN RED BLK BLK 86 87 85 30 87a PPL RED RED WHT YEL PPL RED RED WHT RED WHT RED BLK RED BLU RED WHT RED YEL RED PPL B A B A B A B A 86 87 85 30 87a LT BLU WHT BLU RED BLK BLK ...

Page 139: ... A B C C D B A B A C B A C B A C A B C BLK PPL GRY BLK ORG BLK ORG BLK BLK BLK BLK RED TAN BLK TAN BLK BLK GRN BRN 1 2 3 4 5 6 7 8 BLK YEL PPL TAN LT BLU BLK GRY YEL RED RED PPL DK BLU WHT A B 86 87 85 30 87a GRN WHT GRN RED BLK BLK 86 87 85 30 87a PPL RED RED WHT YEL PPL RED RED WHT RED WHT RED BLK RED BLU RED WHT RED YEL RED PPL B A B A B A B A 86 87 85 30 87a LT BLU WHT BLU RED BLK BLK RED A B ...

Page 140: ...stricted Fuel Flow Caused by Anti Siphon Valves 3A 4 Testing Fuel Pump 3A 5 Fuel Pump Removal Disassembly 3A 6 Cleaning Inspection 3A 7 Reassembly lnstallation 3A 7 Specifications Fuel Pump Pressure W O T Maximum 10 psi Normal 8 10 psi Minimum 3 psi Fuel Pump Pressure Idle Normal 2 3 psi Minimum 1 psi NOTE Electric fuel pump pressure if used in conjunction with engine mechanical fuel pump must be ...

Page 141: ...FUEL PUMP Page 3A 2 90 855347R1 JANUARY 1999 Fuel Pump Loctite PST Pipe Sealant 92 809822 9 A TO VAPOR SEPARATOR FUEL INLET FITTING B REFER TO SERVICE BULLETIN 98 8 ...

Page 142: ... fuel pump is a crankcase pressure operated diaphragm type pump Crankcase pul sating pressure created by the up and down movement of piston is transferred to fuel pump by way of a passage hole between crankcase and fuel pump When piston is in an upward motion a vacuum is created in the crankcase thus pulling in a fuel air mixture from Vapor Separator Tank VST into crankcase This vacuum also pulls ...

Page 143: ... of power 3 High speed surging 4 Preignition detonation piston dome erosion 5 Outboard cuts out or hesitates upon acceleration 6 Outboard runs rough 7 Outboard quits and cannot be restarted 8 Outboard will not start 9 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 pro...

Page 144: ... gasket worn out Replace gasket Fuel pump gasket s worn out Rebuild fuel pump Problem Lack of Fuel Pump Pressure An anti siphon valve See Checking for Restricted Fuel Flow preced ing Air in fuel line See Air Bubbles in Fuel Line above A dirty or clogged fuel filter Clean or replace fuel filter The fuel pickup in fuel tank is clogged or dirty Clean or replace pickup Worn out fuel pump diaphragm Reb...

Page 145: ...p and vapor separator has been removed from illustration to provide improved visual clarity for location of mechanical fuel pump 1 Disconnect fuel hoses from fuel pump 2 Disconnect pulse hose 3 Remove two mounting screws 4 Remove fuel pump from engine a e 57298 c d b a Fuel hose from tank to fuel pump b Fuel hose from fuel pump to Water Separator c Pulse hose d Mounting screws e Fuel pump 5 Disass...

Page 146: ...ost springs for weakness or breakage 4 Inspect fuel pump housing pulse chamber and base for cracks or rough gasket sur face and replace if any are found 5 Inspect fitting on fuel pump housing for loosening or any signs of fuel or air leaks Re place or tighten fitting if a leak is found Reassembly lnstallation ASSEMBLY 1 Insert retainer thru plastic disc and rubber check valve 23601 a b c a Retaine...

Page 147: ...d in pump body break retainer rod from retainer by bending side ways 23601 a b a Rod b Retainer Cap 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 ...

Page 148: ...onto boost spring 50161 a b c a Boost Spring b Pump Body c Cap 6 Assemble remainder of components as shown and install retaining screws thru to align 7 Install pump onto engine Torque to 55 Ib in 6 Nm 8 Install hoses onto proper fittings and secure with sta straps 9 Run engine and check for leaks ...

Page 149: ...Management Assembly Removal 3B 22 Reed Block Assembly Removal 3B 25 Reed Block Assembly Installation 3B 25 Air Temperature Sensor Removal 3B 25 Air Temperature Sensor Installation 3B 26 Throttle Plate Assembly Removal 3B 26 Throttle Plate Assembly Installation 3B 26 Vapor Separator Disassembly 3B 26 Vapor Separator Reassembly 3B 28 Air Plenum Installation 3B 29 Low Pressure Electric Fuel Pump Inst...

Page 150: ... 1 3 0 3Ω Air Compressor Specifications Air Compressor Type Compressor Output Reciprocating Piston 1 to 1 ratio with engine RPM Idle 80 psi W O T 110 psi Cylinder Block Displacement 7 07 cu in 116 cc Cylinder Bore Diameter Standard Taper Out of Round Wear Maxi mum Bore Type 2 5591 in 65 0 mm 0 001 in 0 025 mm Cast Iron Stroke Length 1 374 in 34 9 mm Piston Piston Type Aluminum Piston Diameter Dime...

Page 151: ...uge 91 16850A1 to 160 psi gauge order upgrade 91 16850 1 57416 91 16850A2 a a Schrader Valve 22 84906 part of Schrader Valve Fuel Pressure Kit 849021A4 2 Duel Fuel Air Air Pressure Gauge 160 psi 91 852087A1 or A2 55295 3 Adaptors to convert pressure gauge 91 852078A1 to an A2 57341 4 Screw 5mm x 25mm 2 each 10 40073 25 5 Flat Washer 2 each 12 30164 ...

Page 152: ...347R1 JANUARY 1999 6 Seal Teflon Ring Installation Tool 91 851980 56015 7 Seal Teflon Ring Sizing Tool 91 851980 1 56014 8 DMT 2000 Digital Tachometer Multi meter P N 91 854009A1 9 Clamp Tool Kit 91 803146A2 57316 a a Clamp Tool 91 803146T ...

Page 153: ...DIRECT FUEL INJECTION 90 855347R1 JANUARY 1999 Page 3B 5 Notes ...

Page 154: ...99 Air Handler A OIL LINE TO COMPRESSOR B TO FITTING IN FLYWHEEL COVER C PRESS INTO TUBING Loctite Superbonder 454 GEL 96 10 25 12 2 30 3 26 8 1 2 30 5 6 A 35 96 4 29 27 36 28 9 13 16 19 20 21 22 23 17 17 17 18 24 7 33 33 31 32 B C 34 37 15 38 39 40 11 14 ...

Page 155: ...4 1 SLEEVE 15 4 SCREW M6 x 16 100 11 5 16 1 FUEL PUMP 17 4 CLAMP 18 1 HOSE 19 1 TUBING 18 IN 20 1 INSULATING SLEEVE 21 1 ELBOW 22 1 FITTING 23 1 O RING 24 1 GROMMET 25 1 ENCODER 26 1 SCREW 10 24 x 5 8 IN Drive Tight 27 1 WASHER 28 2 J CLAMP Upper Stbd 29 1 CLAMP Lower 30 12 SCREW 1 4 20 x 1 1 2 IN 175 15 20 31 1 TUBING 5 3 4 IN 32 1 CANISTER Vent 33 3 STA STRAP 34 1 CONNECTOR 35 1 PIN 36 1 DECAL E...

Page 156: ...DIRECT FUEL INJECTION Page 3B 8 90 855347R1 JANUARY 1999 Air Handler Components 1 4 2 3 5 6 7 8 13 14 15 16 9 10 17 19 20 21 22 23 25 26 27 15 14 13 9 9 10 18 24 A 11 12 16 A OIL LINE TO COMPRESSOR ...

Page 157: ...CREW 1 4 20 x 88 100 11 5 6 1 OIL PUMP 7 1 GASKET 8 1 BRACKET 9 3 FITTING 10 3 FITTING 11 1 ELBOW 12 1 FITTING STRAIGHT 13 6 BUSHING 14 6 GROMMET 15 6 SCREW 140 12 16 16 6 WASHER 17 1 AIR PLENUM KIT 18 1 ELBOW 19 1 ELBOW 236 O D 19 1 ELBOW 159 O D 20 1 GASKET 21 1 TEMPERATURE SENSOR 22 3 SCREW Drive Tight 23 3 LOCKWASHER 24 12 SCREW M4 x 16 Drive Tight 25 1 THROTTLE BODY KIT 26 1 O RING 27 4 SCREW...

Page 158: ...DIRECT FUEL INJECTION Page 3B 10 90 855347R1 JANUARY 1999 Vapor Separator Components 1 2 5 7 8 9 10 11 12 13 14 15 16 17 18 19 20 6 4 9 3 ...

Page 159: ...N lb in lb ft Nm 1 1 COVER KIT 2 1 FITTING Straight 3 1 ELBOW 4 1 SEAL 5 1 FITTING KIT Pump Outlet 6 1 O RING 7 7 SCREW 30 3 5 8 1 GASKET 9 1 FLOAT KIT 10 1 FLOAT PIN 11 1 NEEDLE VALVE 12 1 SCREW 10 1 0 13 1 FUEL PUMP KIT 14 1 SLEEVE 15 1 BOWL KIT 16 1 SEAL 17 1 PLUG KIT 18 2 ELBOW 19 1 FUEL FILTER ASSEMBLY 20 1 PROBE ...

Page 160: ... Oil Purchase Locally 54 2 3 1 4 5 7 9 10 11 16 17 18 19 20 21 22 23 24 25 26 27 28 8 9 9 9 9 9 10 12 13 14 14 14 14 14 15 20 14 20 90 54 6 29 29 14 30 54 A TO TELL TALE B TO STARBOARD FUEL RAIL C TO FUEL COOLER D TO TOP OF AIR HANDLER E QTY OF ONE 1 ON EACH SIDE OF COMPRESSOR FLANGE G TO VAPOR SEPARATOR ...

Page 161: ...5 1 HOSE 6 1 INSULATOR SLEEVE 16 IN 7 1 FUEL RAIL STARBOARD 8 6 INJECTOR 9 4 CLAMP 10 2 HOSE 16 IN 11 1 STUD 12 2 WASHER 13 1 NUT 25 34 14 8 STA STRAP 15 1 FUEL RAIL PORT 16 1 TUBING 22 1 2 IN 17 1 CHECK VALVE 18 1 TUBING 2 1 2 IN 19 1 TUBING 28 1 2 IN 20 2 CLAMP 21 1 TUBING 28 1 2 IN 22 4 SCREW M5 x 10 23 4 CLAMP 24 4 STUD 25 4 NUT 33 45 26 1 HOSE 30 IN W INSULATING SLEEVE 27 1 HOSE W INSULATING ...

Page 162: ...DIRECT FUEL INJECTION Page 3B 14 90 855347R1 JANUARY 1999 Fuel Rails 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1 4 4 4 5 5 5 12 13 5 21 22 22 22 ...

Page 163: ... starboard w out injectors 7 4 SCREW M5X16 70 8 8 1 COVER tracker valve 9 1 SPRING tracker valve 10 1 DIAPHRAGM tracker valve 11 1 O RING tracker cover 12 2 FITTING air fuel starboard 13 2 FITTING air fuel port 14 6 RETAINER injector DESIGN II 15 6 RETAINER injector DESIGN I 16 6 INJECTOR fuel 17 O RING KIT large 6 per kit 18 O RING KIT small 6 per kit 19 2 FITTING 20 1 RAIL port w out injectors 2...

Page 164: ...1999 Air Compressor Components 1 2 5 6 7 8 9 10 13 14 15 16 4 17 20 2122 19 ÇÇÇ ÇÇÇ ÇÇÇ ÇÇÇ 8 9 11 12 11 18 18 27 3 23 24 25 26 9 9 14 14 14 14 9 9 6 Dielectric Grease 92 823506 1 6 Loctite PST Pipe Sealant 92 809822 9 14 2 Cycle Outboard Oil 92 826666A24 ...

Page 165: ...CREW M6 x 20 100 11 5 5 O RING 6 O RING 7 CONNECTING ROD 8 PISTON ASSEMBLY 9 LOCK RING 10 REED PLATE ASSEMBLY 11 O RING 12 O RING 13 SEAL 14 COMPRESSOR HEAD 15 FITTING Straight 16 SCREW M8 x 35 240 20 27 17 ELBOW 18 ELBOW 19 FITTING Straight 20 TEMPERATURE SENSOR 21 RETAINER 22 SCREW M8 x 12 240 20 27 23 O RING 24 FITTING 25 PIPE PLUG 26 DECAL Important 27 GROMMET O RING KIT ...

Page 166: ...arings reed valves and a crankshaft The compressor is water cooled to lower the temperature of the air charge and is lubricated by oil from the engine oil pump assembly As the compressor piston moves downward inside the cylinder air is pulled through the filter reed valves and into the cylinder After the compressor piston changes direction the intake reeds close and the exhaust reeds open allowing...

Page 167: ...r re turns into the plenum and is ingested through the crankcase The ECM will change the discharge rate of the oil pump depending upon engine demand The ECM will also pulse the pump on initial start up to fill the oil passages eliminating the need to bleed the oil system The ECM provides additional oil for break in as determined by its internal clock The oil ratio varies with engine rpm and load E...

Page 168: ... shutters The crankshaft position sensor is different from the standard 3 0 liter sensor The crank position sensor serves two functions flywheel speed and position Testing Electric Fuel Pump Pressure Output Low Pressure Electric Fuel Pump IMPORTANT After completing fuel pressure tests reconnect and secure fuel outlet hose to fuel pump with full circle stainless clamps in Clamp Tool Kit 91 803146T ...

Page 169: ...Pressure Gauge Assembly 91 852087A1 A2 to starboard fuel rail pressure test valve NOTE After 15 seconds of cranking engine with starter motor fuel pressure gauge should indicate 89 2 psi 613 5 13 8 kPa 56146 d b a a Fuel Pressure Gauge Should Indicate 89 2 psi 613 5 13 8 kPa b Fuel Pressure Test Valve ...

Page 170: ...nts NOTE Use Fuel Air Pressure Gauge 91 16850 1 or 91 852087A1 A2 to de pressurize air hose first and then fuel hose 1 De pressurize fuel system b a a b a Starboard Fuel Rail b Fuel Pressure Port 2 Place suitable container underneath vapor separator drain plug and remove plug 3 Disconnect electric fuel pump harness connector 56049 a b 57317 a Drain Plug b Sensor Lead ...

Page 171: ... to fuel cooler Lower fuel hose goes to electric pump beside fuel water separator 6 Remove the fuel inlet hose from the pulse fuel pump 7 Remove the fuel outlet hose and fuel return hose from the vapor separator 8 Remove 3 mounting bolts and remove separator 56157 c c a b g g f e d 57317 a Harness Connector b Sta strap c Fuel Hoses d Fuel Inlet Hose e Fuel Outlet Hose f Fuel Return Hose g Mounting...

Page 172: ...m air management assembly 56068 b a c d b a 57317 a Throttle Link Rod b Throttle Position Sensor Link Rod c MAP Sensor Hose d Oil Return Hose 11 Disconnect oil hoses from oil pump 12 Remove and plug oil inlet hose to oil pump 13 Remove 12 bolts securing air management assembly to crankcase and remove as sembly 56144 b a 56140 b a a b c d a Oil Hoses b Oil Inlet Hose c Air Management d Bolts 12 eac...

Page 173: ...or plate to air plenum assembly 56144 b a a a a b a a a Screws 2 each b Bolts 3 each Reed Block Assembly Installation 1 Secure oil pump adaptor plate to air plenum with 3 bolts Torque bolts to 16 lb ft 22 0 Nm 2 Secure air plenum to reed plate with 2 screws Drive screws tight Air Temperature Sensor Removal Remove 3 screws securing sensor and remove sensor 56144 a b a b a Screws b Sensor ...

Page 174: ...be made Remove 4 bolts securing throttle plate assembly to air plenum and remove assembly 56068 b a a a b a a Bolts b Throttle Plate Assembly Throttle Plate Assembly Installation Secure throttle plate assembly to air plenum with 4 bolts Torque bolts to 100 lb in 11 5 Nm Vapor Separator Disassembly 1 Remove 7 screws securing separator cover and remove cover 2 Inspect seal in fuel pump chamber of se...

Page 175: ...uired 5 Inspect seal above fuel pump for cuts or abrasions Replace seal if necessary Apply 2 4 C w Teflon to seal lips 56058 56057 c b c b a d a Filter Screen b Harness Connector c Pump d Seal Seal shoulder faces OUT 6 Loosen screw securing float assembly and remove float Inspect float for deterioration or fuel retention Replace float as required 7 Remove phenolic sealing plate and inspect imbedde...

Page 176: ... screen for debris Re move screen and clean as required 5 Seat fuel pump and harness into separator cover being careful not to pinch harness 56057 c a g h i 56058 b e d a c f a b c d e a Sealing Plate b Float c Needle d Pivot Pin e Screw Torque to 10 lb in 1 0 N m f Seal Seal shoulder faces OUT g Harness h Filter i Fuel Pump 6 Apply 2 4 C w Teflon to lips of seal in separator tank 7 Install separa...

Page 177: ... a 1 2 3 4 5 6 7 8 9 10 11 12 b a b a Air Plenum b Bolts Torque to 100 lb in 11 5 Nm Low Pressure Electric Fuel Pump Installation NOTE If pump does not have a sleeve or grommet refer to Service Bulletin 98 8 1 Seat electric fuel pump w sleeve against grommet in pump bracket Secure pump to bracket with sta strap d a b c a Low Pressure Electric Fuel Pump b Sleeve c Grommet d Bracket ...

Page 178: ...ANT Only use tool 91 803146T or Snap On equivalent YA3080 to crimp full circle clamps Using a different tool could result in a crimp that is too loose or too tight Do not use screw type metal hose clamp as it may damage hose 3 Connect fuel hose from bottom of low pressure fuel pump to 90 elbow in bottom of vapor separator Secure hose with 16 2 mm full circle clamp 54 855697 using crimp ing tool 91...

Page 179: ... 57293 a Secure Fuel Hose with 15 3 mm Full Circle Clamp 54 856880 Vapor Separator Installation 1 Secure vapor separator to air plenum with 3 bolts Torque bolts to 45 lb in 5 0 Nm 2 Connect fuel inlet hose from pulse pump 3 Connect fuel outlet hose and fuel return hose to vapor separator a b e f d c 57317 a Mounting Bolts Torque to 45 lb in 5 0 Nm b Fuel Inlet Hose c Fuel Outlet Hose d Fuel Return...

Page 180: ...nsor Lead 5 Connect electric fuel pump harness 6 Connect vapor separator vent hose to air plenum 7 Secure air temperature sensor leads to fuel hose with sta strap 56157 c b a d a b c d a Electric Fuel Pump Harness Connector b Sta Strap c Top Fuel Hose Fuel return from fuel cooler d Bottom Fuel Hose Inlet from low pressure pump ...

Page 181: ...spring clip with flat tip screw driver while pulling on connector c b a 56118 c d e a a f g b b a Port Fuel Rail b Air Pressure Port c Spring Clip d Fuel Injector e Harness Connector f Fuel Pressure Port g Starboard Fuel Rail NOTE Always remove fuel air hose and fitting together by removing fitting retainer rather cutting clamps 3 Remove fuel inlet hose fuel outlet hose and air hose from fuel rail...

Page 182: ...e a flat tip screw driver to hold direct injectors in cylinder head 56121 a b b a b b a Fuel Rail b Direct Injectors Fuel Rail Disassembly The starboard fuel rail contains 3 fuel injectors and a tracker valve The port fuel rail contains 3 fuel injectors 1 fuel fuel regulator and 1 air regulator NOTE Each fuel air inlet or outlet hose adaptor has 2 O ring seals These O rings should be inspected for...

Page 183: ...7418 a Screws b Pry Holes 3 Inspect fuel injector orifices for foreign debris O rings for cuts or abrasions and plastic components for heat damage Replace components as required 4 An ohm test of the fuel injector may be made by connecting test leads to injector termi nals Ohm reading should be 1 8 0 1 ohm VOLTS DC AMPS OHMS 0 2 4 6 8 10 DCV ACV DVA 0 0 5 10 20 10 30 15 40 20 0 5 10 15 20 30 40 60 ...

Page 184: ...ctor attaching screw threads 1 Insert fuel injector into fuel rail with connector pins facing inwards towards center of engine NOTE Turn injector back and forth slightly to seat injector O rings in fuel rail while secur ing injector with retainer and 2 screws Torque screws to 70 lb in 8 0 Nm 56125 c a b a Injector b Retainer c Screws Torque to 70 lb in 8 0 Nm ...

Page 185: ...f fuel vapor bubbles and minimizing the chances of vapor lock The fuel pressure regulator is calibrated to raise the fuel pressure to 10 psi above the air pressure The fuel regulator is mounted on the port fuel rail near the top This regulator relies on both air and spring pressure to control the fuel pressure Inside the regulator assembly is a 10 lb spring this spring holds the diaphragm against ...

Page 186: ...ATOR INSTALLATION NOTE Apply a light coat of 2 4 C w Teflon to diaphragm surface and O ring to aid in the retention of diaphragm and O ring on fuel rail during reassembly 1 Position diaphragm on fuel rail 2 Position O ring on fuel rail 3 Position spring and cup onto diaphragm NOTE Apply anti seize grease obtain locally or 2 4 C w Teflon to regulator attaching screw threads 4 Place cover over sprin...

Page 187: ...r pressure regulator is designed to limit the air pressure inside the rails to approximately 80 psi The air regulator uses a spring pressure to control the air pressure This spring 80 psi holds the diaphragm against the diaphragm seat The contact area blocks closes the air inlet passage from the excess air return passage As the air pressure rises below the diaphragm it must reach a pressure equal ...

Page 188: ...ng and cup onto fuel rail with fuel rail in horizontal position NOTE Apply anti seize grease obtain locally or 2 4 C w Teflon to regulator attaching screw threads NOTE Due to the stiffness of the regulator spring it is recommended that 2 longer screws 5mm x 25mm long 10 40073 25 and 2 flat washers 12 30164 be installed through cover first to begin compression This will allow 2 shorter screws 5mm x...

Page 189: ...ning and closing The tracker contains a spring on the air side of the diaphragm This spring positions the diaphragm against the diaphragm s seat when the engine is not running After the engine starts and the fuel and air pressure reach normal operating range the fuel pressure will compress the spring and the diaphragm will move slightly away from the seat to a neutral position At this point the pr...

Page 190: ... VALVE INSTALLATION NOTE Apply a light coat of 2 4 C w Teflon to tracker diaphragm and cover O ring to aid in their retention on fuel rail while reinstalling tracker valve to fuel rail NOTE Apply anti seize grease obtain locally or 2 4 C w Teflon to tracker valve attach ing screw threads 1 Position diaphragm spring and O ring onto fuel rail 2 Place cover over diaphragm spring O ring assembly and s...

Page 191: ...nections a Air Hose b Retainer c Allen Screws remove d Air Hose e Fuel Hose f Allen Screws Direct Injector Removal 1 Remove harness connectors from direct injectors 2 Remove direct injector from cylinder head 56138 a b a b a Direct Injector 3 each cylinder head b Harness Connector 3 Inspect injector teflon sealing ring white for signs of combustion blowby teflon ring will be streaked brownish blac...

Page 192: ... head d a a b c e e 91 851980 1 f a Teflon Sealing Ring b O ring c Teflon Seal d Seal Installation Tool 91 851980 e O ring f Teflon Ring Sizing Tool 91 851980 1 6 An ohm test of the direct injector may be made by connecting test leads to injector terminals Ohm reading should be 1 3 0 3 ohm 7 Carbon buildup on tip of direct injector may be removed by use of a brass wire hand brush 56017 a b b c VOL...

Page 193: ... Fuel Rail and Direct Injector Installation 1 Use Teflon Ring Sizing Tool 91 851980 1 to compress new teflon sealing rings prior to installation of injector into cylinder head 2 Carefully slide fuel rail over mounting studs and onto direct injectors IMPORTANT ALL fuel and air hoses attached to the fuel rails MUST be secured with stainless steel hose clamps 3 Secure each fuel rail with 2 nuts Torqu...

Page 194: ... Cylinder Block Displacement 7 07 cu in 116 cc Cylinder Bore Diameter Standard Taper Out of Round Wear Maxi mum Bore Type 2 5591 in 65 0 mm 0 001 in 0 025 mm Cast Iron Stroke Length 1 374 in 34 9 mm Piston Piston Type Aluminum Piston Diameter Dimen sion A at Right Angle 90 to Piston Pin 0 500 in 2 5578 0004 in 64 97 0 010 mm Piston Ring End Gap Top Ring Middle Ring Bottom Ring 0 0059 0 0098 in 0 1...

Page 195: ...ve vent hose from fitting on flywheel cover 3 Remove flywheel cover 4 Use 3 8 inch 9 5 mm drive on belt tensioner arm to relieve belt tension Remove belt b a 56142 a b a Belt Tensioner b 3 8 in 9 5 mm drive CAUTION If engine has been recently run air pressure outlet hose fittings may be extremely hot Allow components to cool off before beginning disassembly 5 Disconnect air pressure outlet hose ...

Page 196: ...sure Outlet Hose b Water outlet Hose tell tale 7 Disconnect air compressor oil inlet hose 8 Disconnect water inlet hose 9 Disconnect excess oil return hose 56147 a b c a b c a Air Compressor Oil Inlet Hose b Water Inlet Hose c Excess Oil Return Hose 10 Remove 4 bolts securing air compressor to outboard and remove compressor ...

Page 197: ...9 14 2 Cycle Outboard Oil 92 826666A24 NOTE End cap bearing and seal are not sold separately End cap must be replaced as an assembly NOTE Piston Installation use a metal hose clamp for piston ring compressor Stagger piston ring openings a Bolt Torque to 100 lb in 11 5 Nm b Bolt 4 each Torque to 100 lb in 11 5 Nm c End Cap Assembly Inspect bearing for roughness d O rings Inspect for cuts or abrasio...

Page 198: ... e Compressor Air Outlet f Compressor Water Inlet g Excess Oil Return h Compressor Oil Inlet i Fuel System Pressure Test Valve j Fuel Injector k Starboard Fuel Rail l High Pressure Fuel 89 2 psi 613 5 13 8 kPa m Tracker Valve n Fuel Inlet o Fuel Regulator 89 2 psi 613 5 13 8 kPa p Air Regulator 79 2 psi 544 0 13 8 kPa q Air 79 2 psi 544 0 13 8 kPa r Excess Air Return to Exhaust Adaptor Plate s Por...

Page 199: ... fuel rail has air pressure test valve NOTE After 15 seconds of cranking engine with starter motor air pressure gauge should indicate 79 2 psi 544 0 13 8 kPa and fuel pressure gauge should indicate 89 2 psi 613 5 13 8 kPa 56146 a b c d a b c d a Air Pressure Gauge Should Indicate 79 2 psi 544 0 13 8 kPa b Fuel Pressure Gauge Should Indicate 89 2 psi 613 5 13 8 kPa c Fuel Pressure Test Valve d Air ...

Page 200: ... no fuel output check va por separator remove drain plug for fuel 3 If no fuel present in vapor separator check fuel water separator for debris Check crankcase mounted fuel pump for output 4 Check high pressure pump amperage draw Normal draw is 6 9 amperes if draw is below 2 amperes check fuel pump filter base of pump for debris If filter is clean replace pump If am perage is above 9 amperes pump ...

Page 201: ...through hoses one hose for each cylinder The last oil discharge port discharges oil into the air compressor for lubrication Unused oil from the air compres sor returns to the plenum and is ingested through the crankcase The ECM is programmed to automatically increase the oil supply to the engine during the initial engine break in period The oil ratio is doubled during the first 120 minutes of oper...

Page 202: ...tem f h a b c d e g i a Remote Oil Tank b Engine Oil Reservoir c Oil Supply Hose to the Oil Pump d Oil Pump e Oil Supply Hoses to the Cylinders 6 f Oil Supply Hose to the Air Compressor g Air Compressor h Check Valve i Oil Return Hose from the Air Compressor ...

Page 203: ... starvation in the oil pump delivery hoses it is recom mended that check valve kit 21 858945A2 be installed as follows NOTE Refer to Service Bulletin 98 23 1 Remove flywheel cover Pull out vent hose a a Vent Hose 2 Remove 4 bolts securing bottom cowl halves and remove bottom cowling 55970 52352 55932 a a a a Bolt 3 Remove throttle cable from throttle arm a a Throttle Cable ...

Page 204: ...ANUARY 1999 4 Remove 3 bolts securing oil reservoir and lay reservoir off to one side a b a Bolts b Oil Reservoir 5 Remove throttle link arm and bolt securing throttle arm Remove throttle arm a b c a Throttle Link Arm b Bolt c Throttle Arm ...

Page 205: ... Belt Tensioner rotate counterclockwise c Aft Alternator Bolt d Alternator rotate forward NOTE It is recommended that a razor knife be used to make a small slit in the oil hoses to aid in removal Removing hoses without cutting them may result in the breakage of the oil fitting Trim cut portion off of oil hose before reinstalling hose 8 Remove oil hoses from fittings on 2 4 and 6 cylinders ...

Page 206: ...equate clear ance between the oil hose and the flywheel when the check valve assembly is installed 9 Trim off 2 cylinder oil hose to an appropriate length to provide clearance between hose and flywheel and install new check valve hose assembly Secure hose connec tions with sta straps 10 Install new check valve hose assemblies on cylinders 4 and 6 Secure all hose con nections with sta straps 57410 ...

Page 207: ...4 Nm 57409 b a c a Torque Bolt to 20 lb ft 27 Nm b Torque Bolts to 170 lb in 19 Nm c Torque bolt to 40 lb ft 54 Nm 14 Reinstall alternator air compressor belt 15 Remove Electronic Control Module ECM lay off to one side 16 Remove solenoid trim relay plate lay off to one side 17 Remove starter motor lay off to one side NOTE All check valve hose assemblies for cylinders 1 3 5 have a BLUE stripe band ...

Page 208: ...eck Valve Hose Assembly c 5 Cylinder Check Valve Hose Assembly 19 Reinstall starter motor Torque bolts to 17 5 lb ft 23 5 Nm 20 Reinstall starter solenoid trim relay plate Torque bolts to 150 lb in 17 Nm 21 Reinstall ECM Torque bolts to 70 lb in 8 Nm 57412 a b b c c c a Torque bolts to 17 5 lb ft 23 5 Nm b Torque bolts to 150 lb in 17 Nm c Torque bolts to 70 lb in 8 Nm 22 Reinstall bottom cowling ...

Page 209: ...ve with 3 125 in 79 4 mm length Hose Cyl 5 0 078 in 1 98 mm I D Check Valve with 3 125 in 79 4 mm length Hose Cyl 2 0 063 in 1 60 mm I D Check Valve with 1 250 in 31 7 mm length Hose Cyl 4 0 063 in 1 60 mm I D Check Valve with 1 250 in 31 7 mm length Hose Cyl 6 0 063 in 1 60 mm I D Check Valve with 1 250 in 31 7 mm length Hose Note All check valve I D measurements given are 0 002 in 0 050 mm c Fas...

Page 210: ...Washer 3 g Bolt 3 Torque to 16 lb ft 21 5 Nm h Sta Straps Fasten All Hose Ends INSTALLATION 1 Install pump as shown 2 Reconnect the oil hoses Refer to Oil Injection Hose Installation for correct location Fasten hoses to pump fittings with sta straps 3 Connect the wiring harness NOTE Replacement oil pump may have 2 pin electrical connection vs 4 pin with original oil pump The 2 pin connection will ...

Page 211: ...e tank a b c d e f g h i j d e g g k a Oil Reservoir b Fuel Cooler Design 1 c Bolt 1 Torque to 170 lb in 19 Nm d Washer 3 e Rubber Grommet 3 Insert into Holes f Low Oil Switch g Bushing 3 h Grommet 2 Insert into Hole i Bolt 2 Torque to 170 lb in 19 Nm j Sta Straps Fasten All Hose Ends k Fuel Cooler Design 2 INSTALLATION 1 Install oil reservoir as shown 2 Fasten the oil hoses with sta straps 3 Conn...

Page 212: ... 1 except the run history and fault history are erased from the ECM Refer to procedure in the Technician Reference Manual provided with the Digital Diagnos tic Software Cartridge Part No 91 822608 4 or 5 METHOD 3 DDT DIGITAL DIAGNOSTIC TERMINAL OIL PUMP PRIME This method fills the oil pump oil supply hose feeding pump and oil hoses going to the crankcase and air compressor Refer to procedure in th...

Page 213: ...e engine fuel system with fuel Other wise the fuel pumps will run without fuel during the priming process Prime the oil injection pump as follows 1 Fill the engine fuel system with fuel Connect fuel hose and squeeze primer bulb until it fells firm 2 Turn the ignition key switch to the ON position 3 Within the first 10 seconds after the key switch has been turned on move the remote control handle f...

Page 214: ... Remove shipping cap from fitting and connect hose a Fasten hose with sta strap a a Oil Hose Without Blue Stripe Filling the Oil Tanks 1 Fill remote oil tank with the recommended oil listed in the Operation and Maintenance Manual Tighten fill cap 2 Remove cap and fill engine oil tank with oil Reinstall the fill cap 3 Remove air from remote oil hose Refer to Purging Air from the Engine Oil Reservoi...

Page 215: ... along with the remote oil tank will have to be refilled refer to Filling the Oil tanks The warning system works as follows The OIL light a will come on and the warning horn sounds a series of four short tones If you continue to operate the outboard the light will stay on and the horn will sound four short tones every two minutes The engine has to be shut off to reset the warning system a OIL PUMP...

Page 216: ...emove filter and clean Replace tube Replace check valve Purge air from engine oil tank Refer to procedure Disconnect blue wires going to the low oil float switch in the engine oil reser voir Check switch for continuity Remove screw and pull out the oil float switch from the tank Check switch again for continuity Continuity Oil Float switch is faulty Re place switch Continuity Float in oil tank is ...

Page 217: ...ur elements combine chemically during combustion If combustion were complete the mixture of air and gasoline would result in these emissions water carbon dioxide and nitrogen which are not harmful to the environ ment However combustion is not usually complete Also potentially harmful gases can be formed during and after combustion All marine engines must reduce the emission of certain pollutants o...

Page 218: ...s and reduce exhaust emissions engineers have discov ered that they can be reduced effectively if a gasoline engine operates at an air fuel ratio of 14 7 1 the technical term for this ideal ratio is stoichiometric An air fuel ratio of 14 7 1 provides the best control of all three elements in the exhaust under almost all conditions The HC and CO content of the exhaust gas is influenced significantl...

Page 219: ...zed charge The difference between the two is Homogenized Charge A homogenized charge has the fuel air particles mixed evenly throughout the cylinder This mixing occurs inside the carburetor venturi reed blocks and crankcase Additional mixing occurs as the fuel is forced through the transfer system into the cylinder The homogenized charge is easy to ignite when the air fuel ratio is approximately 1...

Page 220: ...most complete combustion before the exhaust port opens A stratified charge is hard to ignite The fuel air bubble is not evenly mixed at 14 7 1 and is not easily ignited Emissions Information Manufacturer s Responsibility Beginning with 1998 model year engines manufacturers of all marine propulsion engines must determine the exhaust emission levels for each engine horsepower family and certi fy the...

Page 221: ... the horse power or allow emissions levels to exceed their predetermined factory specifications Single engine exceptions may be allowed with permission from the EPA for racing and testing EPA Emission Regulations All new 1998 and later outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for...

Page 222: ...ers Manual for required maintenance b c h i j e g f d a Spark Ignition SI b Cubic Centimeter c Model year of engine and production decal part number d Idle Speed In Gear e Timing specifications when adjustable f Recommended spark plug for best engine performance g Valve Clearance Four Stroke engines only h Engine Horsepower rating i Month of production Boxing month will punched j FEL Represents Me...

Page 223: ...the month of engine manufacture before installing the new label The month of manufacture can be found on the old label If the label is mis sing or the date code illegible contact Mercury Marine Technical Service for assistance JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC Emission Control Information 1998 PART 37 855211 27 This engine conforms to 1998 Model Year U S EPA regulations for marine ...

Page 224: ...s 4A 35 Powerhead Reassembly and Installation 4A 36 General 4A 36 Crankshaft Installation 4A 40 Piston and Connecting Rod Reassembly 4A 42 Piston and Piston Ring Combinations 4A 43 Piston Installation 4A 44 Crankcase Cover Installation 4A 46 Assembly of Reed Blocks to Intake Manifold 4A 48 Assembly of Exhaust Divider Plate to Block 4A 48 Reinstalling Engine Components 4A 51 Throttle Lever and Shif...

Page 225: ...on A at location shown Dimension A should be 3 4925 in 0005 for a STAN DARD size piston new Dimension A will be 0 001 0 0015 less if coating is worn off piston used REEDS Reed Stand 0pen Max 0 020 in 0 50 mm Special Tools 1 Lifting Eye 91 90455 2 Powerhead Stand 91 30591A1 3 Piston Ring Expander 91 24697 4 Lockring Removal Tool 91 52952A1 5 Piston Pin Tool 91 74607A1 6 Driver Head 91 55919 ...

Page 226: ...rs 91 24283 9 Lockring Installation Tool 91 77109A1 10 Piston Ring Compressor for 2 5 Litre 153 cu in 91 818773 11 Compression Tester 91 29287 Powerhead Repair Stand A powerhead repair stand may be purchased from Bob Kerr s Marine Tool Co P O Box 1135 Winter Garden FL 32787 Telephone 305 656 2089 ...

Page 227: ... BOTTOM OF BLOCK HEAD PORT OIL FITTING ORIENTATION 2 o clock Loctite PST Pipe Sealant 92 809822 9 12 Loctite 514 Master Gasket 92 12564 2 14 2 Cycle Outboard Oil 92 13249A24 Loctite RCA 680 Retaining Compound 92 809833 33 95 2 4 C w Teflon 92 825407A12 A TO AIR HANDLER B TO ON BOARD OIL TANK ...

Page 228: ...NTER 16 3 TUBING 24 1 2 IN 17 1 CONDUIT 7 IN 18 1 FITTING 19 1 TUBING 11 1 2 IN 20 1 CONNECTOR 21 6 STA STRAP 22 8 SCREW 3 8 16 x 3 1 4 37 50 23 6 SCREW 312 18 x 1 1 4 15 20 24 1 CAP 25 1 ADJUSTING SCREW 1 4 20 x 1 3 4 26 1 JAM NUT 27 1 UPPER END CAP 28 1 O RING 29 1 ROLLER BEARING 30 1 BEARING RACE 31 1 OIL SEAL 32 4 SCREW 5 16 18 x 1 205 17 23 33 1 LOWER END CAP 34 1 O RING 3 1 4 IN I D 35 2 OIL...

Page 229: ...43 44 45 46 47 18 10 32 35 36 10 10 6 7 D A B C 10 Permabond 105 Cyanacrylate Adhesive Purchase Locally 62 95 51 9 62 7 A TO FUEL COOLER WATER IN B TO FUEL COOLER WATER OUT FITTING C TO LOWER PORT FUEL RAIL SIDE FITTING D TO AIR COMPRESSOR LOWER WATER INLET FITTING 51 Loctite 222 92 809818 7 Loctite 271 92 809820 95 2 4 C With Teflon 92 825407A12 Loctite PST Pipe Sealant 92 809822 9 ...

Page 230: ...1 DIAPHRAGM 16 1 WATER DEFLECTOR 17 1 PLATE 18 2 GASKET 19 1 SPRING 20 1 WASHER 21 1 POPPET 22 1 GROMMET 23 1 CARRIER 24 1 GASKET 25 1 EXHAUST PATE 26 2 DOWEL PIN 27 1 SEAL 28 1 BRACKET 29 8 SCREW 10 16 x 1 2 IN 80 9 30 1 FITTING STRAIGHT BACK 31 1 ELBOW STARBOARD TOP HOLE 32 1 FITTING STRAIGHT STARBOARD BOTTOM HOLE 33 1 GROMMET 34 1 GROMMET 35 1 HOSE 25 IN 36 1 HOSE 37 4 WASHER 38 6 NUT 23 31 39 ...

Page 231: ...9 11 10 14 15 16 1 2 13 4 12 13 A 13 13 9 9 6 14 15 Back of Engine Water Fitting Orientation Looking Down at Top of Block Dielectric Grease 92 823506 1 6 Loctite PST Pipe Sealant 92 809822 9 14 2 Cycle Outboard Oil 92 13249A24 A TO STRAIGHT FITTING ON BACK OF EXHAUST PLATE ...

Page 232: ...D STARBOARD 2 2 GASKET 3 24 BOLT 2 IN 30 lb ft 40 7 N m then tighten additional 90 4 4 DOWEL PIN 5 2 GASKET 6 2 COVER 7 2 THERMOSTAT 143 degrees 8 4 SCREW M6 x 25 200 16 5 22 5 9 1 ELBOW STARBOARD 10 1 ELBOW PORT 11 1 HOSE 21 1 2 IN 12 1 HOSE 11 1 2 IN 13 5 STA STRAP 14 1 TEMPERATURE SENSOR STARBOARD 15 1 RETAINER 16 1 SCREW M8 x 12 200 16 5 22 5 ...

Page 233: ...ge 4A 10 90 855347R1 JANUARY 1999 Crankshaft Pistons and Connecting Rods 1 2 3 8 4 5 6 7 12 13 14 15 16 12 9 10 11 8 14 95 95 95 95 14 95 95 95 14 14 2 Cycle Outboard Oil 92 13249A24 95 2 4 C w Teflon 92 825407A12 ...

Page 234: ...2 RACE 9 3 PISTON STARBOARD 9 3 PISTON PORT 10 1 PISTON RING 11 12 LOCK RING 12 6 CONNECTING ROD ASSEMBLY 13 12 SCREW 1st Torque 15 lb in 2nd Torque 30 lb ft Turn Screw addition al 90 after 2nd torque 14 12 WASHER 15 6 ROLLER BEARING ASSEMBLY 16 174 NEEDLE BEARING piston end Torque Sequence CRANKCASE COVER BOLTS AND TORQUE SEQUENCE 1 2 3 4 5 6 7 8 a b a Add light oil to threads and bolt face 8 Bol...

Page 235: ...DIVIDER PLATE BOLTS 200 lb in 22 5 N m Apply Loctite 271 to threads 56167 1 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 18 19 10 CYLINDER HEAD BOLTS Add light oil to threads and bolt face 30 lb ft 41 N m then turn an additional 90 56168 1 2 3 4 5 6 7 8 9 10 11 12 ...

Page 236: ...ead will be required If major powerhead repairs are to be performed remove powerhead from drive shaft housing Removal of powerhead is not required for 1 inspection of cylinder walls and pis tons refer to Powerhead Removal and Disassembly following and remove cylinder heads and exhaust cover 2 minor repairs on components such as ignition system fuel injection reed blocks and cylinder heads and chec...

Page 237: ...r and wires as shown GRN WHT BLU WHT BRN WHT TAN BLU WHT GRN WHT a a Power Trim Connections 7 Remove sta strap which secures tell tale hose to fitting on lower cowl and remove hose from fitting 56141 a a Tell tale Hose 8 Disconnect warning gauge harness 1 2 3 45 6 a c b d a c b d e a TAN BLACK b TAN WHITE c PINK LT BLUE to PINK LT BLUE d ORANGE e Sta Straps ...

Page 238: ...1 Remove throttle cable 12 Remove locknut that secures shift cable latch assembly and remove latch flat wash er nylon wear plate spring and shift cable from control cable anchor bracket 13 Disconnect input fuel line c a b d a Throttle Cable b Shift Cable c Hose Clamp d Fuel Line 14 Remove 4 bolts securing bottom cowl halves and remove bottom cowling 55970 52352 55932 a a a a Bolt ...

Page 239: ...er hose from exhaust adaptor plate 56158 56159 d a b c a Fuel Cooler Outlet Water Hose b Fuel Cooler Inlet Water Hose c Air Hose d Thermostat Cover Hose 17 Remove 10 nuts and washers five each side from powerhead base 18 Remove plastic cap from center of flywheel and install LIFTING EYE 91 90455 into flywheel at least five full turns Using a hoist lift powerhead assembly from driveshaft housing 56...

Page 240: ... Tank Oil Pump Section 7 Shift Cable Latch Assembly Control Cable Anchor Bracket All ignition and electrical components should remain attached to electrical plate Plate with components can be removed as an assembly Powerhead Disassembly 1 Place powerhead in repair stand or on a bench 2 Remove thermostat covers thermostats and gaskets 3 Remove cylinder heads from engine block 56165 d e f 56163 a b ...

Page 241: ...seal 5 Referring to Section 3B remove air plenum reed block adaptor plate assembly from cylinder block d 56166 a c b a Exhaust Manifold Cover b Seal c Gasket d Reed Block Adaptor Plate Assembly 6 Inspect reeds as outlined in Cleaning and Inspection 56169 7 Remove bolts from end caps ...

Page 242: ...Crankcase Attaching End Cap Bolts LOWER END CAP 51849 a a Crankcase Attaching End Cap Bolts 1 Remove bolts which secure crankcase cover to cylinder block 2 Pry crankcase cover off cylinder block using pry bars in locations shown 51845 a b a a Pry Points b Crankcase Cover ...

Page 243: ...ric pencil scribe the cylinder identification number on each con necting rod as shown Reassemble connecting rods in same cylinder 51849 Ä Ä 3 Use a 5 16 in 12 point socket to remove connecting rod bolts then remove rod cap roller bearings and bearing cage from connecting rod 51850 a a Connecting Rod Bolts 4 Push piston out of cylinder block 5 After removal reassemble each piston and connecting rod...

Page 244: ...piston rings Always install new pis ton rings 56155 56153 8 Using an awl scribe identification number of connecting rod on inside of piston a Reassemble piston on same connecting rod 9 Using tool 91 52952A1 remove piston pin lockrings from both ends of piston pin Never re use piston pin lockrings 51083 56154 b a a Scribe Identification Number b Lockring IMPORTANT Warming the piston dome using a to...

Page 245: ...entified for reassembly on same connecting rod 51088 51853 b a c a Piston Pin b Piston Pin Tool 91 76159A1 c Needle Bearing Locating Washers 12 Remove upper end cap and lower end cap from crankshaft 13 Remove and discard O ring seals from each end cap 14 Remove oil seal s from end of each end cap by driving seal out with a punch and ham mer 15 Inspect roller bearing in upper end cap as outlined in...

Page 246: ... Usually crankshaft sealing rings do not require replacement unless broken CAUTION Safety glasses should be worn when removing or installing crankshaft sealing rings 17 Remove retaining ring as shown 51850 a b a Sealing Rings b Retaining Ring 18 Remove bearing race halves and roller bearings from crankshaft IMPORTANT Keep same bearing races and roller bearings together 51850 a a b a Bearing Race H...

Page 247: ...g unless replacement is re quired 19 Remove lower ball bearing from crankshaft as follows a Remove retaining ring using a pair of snap ring pliers a b c 51854 a Crankshaft Ball Bearing b Pliers c Retaining Ring b Press crankshaft out of lower ball bearing as shown 51081 a b c d a Press b Powerhead Stand 91 30591A1 c Crankshaft Ball Bearing d Universal Puller Plate 91 37241 ...

Page 248: ...emove water pressure relief valve components as shown a b 1 2 3 4 5 6 7 8 9 10 11 12 13 3 50803 1 Cover 2 Bolt 3 Gasket 4 Relief Valve Plate 5 Diaphragm 6 Water Deflector 7 Washer 8 Screw 9 Spring 10 Poppet Valve 11 Grommet 12 Carrier 13 Washer Torque Specifications a 150 lb in 17 N m b 25 lb in 3 N m ...

Page 249: ...m matching surfaces Be sure that carbon deposits are re moved from exhaust ports 2 Inspect cylinder block and crankcase cover for cracks or fractures 3 Check gasket surfaces for nicks deep grooves cracks and distortion that could cause compression leakages 4 Check all water and oil passages in cylinder block and crankcase cover to be sure that they are not obstructed and that plugs are in place an...

Page 250: ...move hone frequently and check condition of cyl inder walls DO NOT hone any more than absolutely necessary as hone can re move cylinder wall material rapidly c Start stroking at smallest diameter Maintain firm stone pressure against cylinder wall to assure fast stock removal and accurate results d Localize stroking in the smallest diameter until drill speed is constant throughout length of bore Ex...

Page 251: ...ylinder requires re boring 5 After honing and thoroughly cleaning cylinder bores apply light oil to cylinder walls to prevent rusting Pistons and Piston Rings IMPORTANT If engine was submerged while engine was running piston pin and or connecting rod may be bent If piston pin is bent piston must be replaced Piston pins are not sold separately because of matched fit into piston If piston pin is ben...

Page 252: ...arbon from side surfaces 2 A tool can be made for cleaning the inner diameter of the tapered ring grooves The tool can be made from a broken tapered piston ring with the side taper removed to enable the inside edge of the ring to reach the inner diameter of the groove Carefully scrape carbon from inner diameter of ring grooves Care must be taken not to damage the grooves by scratching the side sur...

Page 253: ...ead warpage should not exceed 0 004 in 0 1 mm over the ENTIRE length of the cylinder head If measured warpage as determined on a sur face block exceeds 0 004 in 0 1 mm or a discontinuity of up to 0 004 in 0 1 mm exists in a narrow portion of the cylinder head s surface length then the cylinder head may be re surfaced up to 0 010 in 0 25 mm 2 Replace cylinder head s as necessary 3 Thoroughly clean ...

Page 254: ...s time Crankshaft and End Cap Bearings 1 After cleaning crankshaft grasp outer race of crankshaft ball bearing installed on low er end of crankshaft and attempt to work race back and forth There should not be excessive play 2 Lubricate ball bearing with light oil Rotate outer bearing race Bearing should have smooth action and no rust stains If ball bearing sounds or feels rough or has catches remo...

Page 255: ...e end cap and roller bearing as an assembly Upper Roller Bearing Reed Block Assembly IMPORTANT DO NOT remove reeds from reed blocks unless replacement is nec essary DO NOT turn used reeds over for re use Replace reeds in sets only 1 Thoroughly clean gasket surfaces of reed blocks and reed block housing Check for deep grooves cracks and distortion that could cause leakage Replace parts as nec essar...

Page 256: ... gauge can be inserted between any machined sur face and surface plate rod is bent and must be discarded 2 Overheating Overheating is visible as a bluish bearing surface color that is caused by inadequate lubrication or excessive RPM 3 Rust Rust formation on bearing surfaces causes uneven pitting of surface s 51853 a a Pitting 4 Water Marks When bearing surfaces are subjected to water contaminatio...

Page 257: ...in bore becomes highly polished During operation the engine will emit a whirr and or chirp sound when it is accelerated rapidly from idle speed to approximately 1500 RPM then quickly re turned to idle If the preceding conditions are found replace both the crankshaft and connecting rod s a 51853 a a Chatter Marks Between Arrows 7 Uneven Wear Uneven wear could be caused by a bent connecting rod a 51...

Page 258: ...nd discard gasket from each thermostat 3 Wash thermostats with clean water 4 Using a thermostat tester similar to the one shown test each thermostat as follows a Open thermostat valve then insert a thread between valve and thermostat body Allow valve to close against thread b Suspend thermostat from thread and thermometer inside tester so that neither touches the container Bottom of thermometer mu...

Page 259: ...ver light oil is specified Quicksilver part numbers of lubricants sealers and locking compounds and tools are listed in Powerhead General Information preceding A torque wrench is essential for correct reassembly of powerhead DO NOT attempt to reassemble powerhead without using a torque wrench Attaching bolts for covers hous ings and cylinder heads MUST BE torqued by tightening bolts in 3 progressi...

Page 260: ... 90 855347R1 JANUARY 1999 Page 4A 37 2 Reinstall retaining ring using a suitable pair of Snap Ring Pliers 51854 51852 a b c d e a Crankshaft b Crankshaft Ball Bearing c Suitable Mandrel d Press e Retaining Ring ...

Page 261: ... 24697 and install crankshaft sealing rings into groove 51849 51854 a a Crankshaft Sealing Rings 5 Lubricate center main crankshaft roller bearings and races with light oil 51854 a b 14 2 Cycle Outboard Oil 92 826666A24 14 a Install so LARGER of the 3 holes is toward DRIVE SHAFT end of crankshaft b Verify retaining ring bridges the separating lines of the bearing race ...

Page 262: ...end cap as follows a Apply a thin bead of Loctite 271 to outer diameter on 2 lower end cap oil seals a b Using driver head 91 55919 press one oil seal lip facing down into lower end cap until firmly seated Remove any excess Loctite c Press second oil seal lip facing down until firmly seated on first oil seal Remove any excess Loctite d Lubricate oil seal lips with Quicksilver 2 4 C w Teflon 92 825...

Page 263: ...Into Cylinder Block Check the crankshaft sealing ring mating surfaces in the cylinder block and crankcase cover for wear grooves that were caused by the crankshaft sealing rings from the previous crankshaft If wear grooves are present the sealing rings on the new crankshaft will have to fit into the grooves without binding the crankshaft Before installing crankshaft remove any burrs that may exist...

Page 264: ...bearing race with dowel pin 5 Gently push crankshaft down into position making sure that the dowel pins are lined up with the holes in center main bearings and crankshaft seal rings are in place 6 Lubricate crankshaft ends oil seal areas with light oil then install upper and lower end caps a and b Secure end caps to cylinder block with attaching bolts DO NOT tighten end cap bolts at this time 5184...

Page 265: ...und sleeve as shown 3 Place locating washers on connecting rod IMPORTANT Position connecting rod part number facing towards flywheel Carefully position piston over end of rod Make sure locating washers remain in place 51851 b 51851 b a a Sleeve Part of Tool Assy 91 74607A1 b Locating Washers 4 Insert piston pin tool 91 74607A1 and push sleeve out of piston Keep piston pin tool in piston 5 Use a ma...

Page 266: ...ated in piston grooves 51086 51086 a a b a Lockring Installation Tool 91 77109A1 b Lockring Piston and Piston Ring Combinations 153 CU IN 2508 cc MODELS All 153 cu in 2508 cc models have two half keystone half tapered rings Pistons with two half keystone half tapered rings 0 056 in 1 4 mm 0 056 in 1 4 mm a b a Half Keystone half tapered Piston Ring b Enlarged View of Piston Ring Grooves ...

Page 267: ... until rings within tolerance are found IMPORTANT Piston ring side with dot or letter must be facing up 51852 b a c d e f a Piston Ring b Dots Faces Up c Feeler Gauge d Ring End Gap e Dot or Letter f Piston Ring 3 Use Piston Ring Expander 91 24697 and install piston rings dot side up on each piston Spread rings just enough to slip over piston 4 Check piston rings to be sure that they fit freely in...

Page 268: ...tboard Oil 92 826666A24 10 Apply Quicksilver 2 4 C w Teflon to bearing surface of connecting rod and install bear ing assembly as shown 11 Place connecting rod cap on connecting rod Apply light oil to threads and face of con necting rod bolts Thread connecting rod bolts finger tight while checking for correct alignment of the rod cap as shown IMPORTANT Connecting rod and connecting rod caps are ma...

Page 269: ...ct Cap on Backwards ÄÄ ÄÄ ÄÄ ÄÄ End View Incorrect Not Aligned 14 Verify that no piston rings were broken during installation by pressing in on each piston ring thru exhaust port using a screwdriver If no spring tension exists ring fails to re turn to position it s likely ring is broken and must be replaced 51852 a a Screwdriver Crankcase Cover Installation 1 Thoroughly remove all oil from mating ...

Page 270: ...has been drawn down to cylinder block Tighten eight bolts a evenly in three progressive steps following torque sequence 5 Install remaining crankcase cover flange bolts 6 Tighten end cap bolts to specified torque 8 7 4 2 6 5 3 1 51846 b c d e 12 Loctite Master Gasket 92 12564 2 12 a a Loctite Master Gasket 92 12564 2 b Upper End Cap Bolts Torque to 150 lb in 17 N m c Lower End Cap Bolts Torque to ...

Page 271: ...tall exhaust divider plate with gasket 3 Clean bolt threads with Loctite 7649 Primer 92 809824 4 Apply Loctite 271 to bolt threads and torque bolts to 16 5 Ib ft 22 Nm 5 Torque exhaust divider plate bolts in following sequence Torque bolts to 16 5 lb ft 22 N m Add Loctite 271 to threads 56167 1 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 18 19 10 50805 a b c d a Divider Seal b Exhaust Divider Plate c Gas...

Page 272: ... relief valve components as shown Torque bolts to specifications 2 1 3 8 5 4 9 10 11 12 7 6 3 13 50803 1 Cover 2 Bolt 150 lb in 17 N m 3 Gasket 4 Relief Valve Plate 5 Diaphragm 6 Water Deflector 7 Washer 8 Screw 25 lb in 3 N m 9 Spring 10 Poppet Valve 11 Grommet 12 Carrier 13 Washer ...

Page 273: ...cylinder head below 1 spark plug 56168 1 2 3 4 5 6 7 8 9 10 11 12 a b b b b c c d e f g h i j k l a Elbow Starboard b Sta strap c Hose d Elbow Port e Bolt Torque to 30 lb ft 41 N m and then turn 90 f Bolt Torque to 17 lb ft 23 0 N m g Cover h Gasket i Thermostat 143 j Temperature Sensor Starboard k Bolt Torque to 17 lb ft 23 0 N m l Retainer NOTE The temperature sender provides continuous temperat...

Page 274: ...to port thermostat hose a with sta straps b to prevent hose from being cut by alternator air compressor belt a b Reinstalling Engine Components Reinstall the following engine components Section 2 Starter Motor Electronic Control Module Ignition Coil Starter Solenoid Alternator Flywheel Section 3 Direct Fuel Injection Fuel Pump On Board Oil Tank Oil Pump Section 7 Shift Cable Latch Assembly Control...

Page 275: ...ARY 1999 Throttle Lever and Shift Shaft 16 17 14 18 19 1 2 3 6 7 8 9 11 10 12 13 15 36 23 24 25 26 27 28 29 30 31 32 33 34 39 38 40 41 43 44 42 35 37 15 21 22 20 95 95 95 4 5 95 2 4 C w Teflon 92 825407A12 A A Tighten and back off 1 2 turn ...

Page 276: ...M6 x 40 45 5 15 2 SWIVEL BUSHING 16 1 THREADED BALL Drive Tight 17 1 LINK 18 1 ROLLER 19 1 THROTTLE ROLLER 20 1 SCREW M5 x 16 Drive Tight 21 1 WASHER 22 1 STAR WASHER 23 1 ANCHOR BRACKET 24 1 LATCH 25 2 SCREW Drive 26 1 CAP 27 1 WEAR PLATE 28 1 LATCH 29 1 WASHER 30 1 NUT 31 3 SCREW 312 18 x 7 8 160 18 32 1 GUIDE BLOCK 33 1 SPRING 34 1 LINK ROD ASSEMBLY 35 1 SHIFT SHAFT ASSEMBLY 36 1 ROLL PIN 37 1 ...

Page 277: ...4 Cw Teflon Marine Lubricant 92 90018A12 onto drive shaft splines 5 Use hoist to lower powerhead onto driveshaft housing It may be necessary to turn flywheel aligning crankshaft splines with driveshaft splines so that powerhead will be fully installed 6 Install 10 flat washers and10 locknuts which secure powerhead to exhaust extension plate driveshaft housing Torque locknuts in 3 progressive steps...

Page 278: ...ostat cover hose to exhaust adaptor plate 56158 d 56159 a b c a Fuel Cooler Outlet Water Hose b Fuel Cooler Inlet Water Hose c Air Hose d Thermostat Cover Hose 11 Install 4 bolts securing bottom cowl halves and install bottom cowling 55970 52352 55932 a a a a Bolt ...

Page 279: ...13 Reconnect BLUE and GREEN trim harness leads to trim solenoids a c a b a b a Hose Clamp b Fuel Line c Trim Solenoids 14 Reconnect remote control harness to powerhead harness connector and wires as shown GRN WHT BLU WHT BRN WHT TAN BLU WHT GRN WHT a a a Power Trim Connections ...

Page 280: ...t exist in engine wiring harness battery cables fuel hose and oil hoses routed between clamp and engine attachment point to re lieve stress and prevent hoses from being kinked or pinched 1 Place the clamp over the wiring hoses and control cables as shown ÇÇÇ ÇÇÇ ÇÇÇ ÉÉÉ ÉÉÉ ÉÉÉ ÇÇÇ ÇÇÇ ÇÇÇ ÇÇÇ ÇÇÇ ÇÇÇ ÇÇ ÇÇ ÉÉ ÉÉ ÇÇ ÇÇ a b c d e f g a Battery Cables b Remote Wiring Harness c Warning Gauge Wiring H...

Page 281: ...edure FUEL REQUIREMENTS Do not use pre mixed gas and oil in this engine Use straight gasoline during engine break in and after engine break in The ECM is programmed to signal the oil pump to pro vide additional oil 50 1 ratio during the first 120 minutes of operation The ECM will moni tor this period through its own internal clock At the end of this period the ECM will signal the oil pump to go to...

Page 282: ...ostat Test 4B 7 Water Pressure Check 4B 8 Water Pump Cleaning and Inspection 4B 9 Problem Diagnosis 4B 10 Specifications Water Pressure Idle 1 0 3 0 PSI 6 8 20 5 kPa Poppet Valve Opening 4 9 PSI 27 4 61 6 kPa W O T 12 0 PSI 82 1 kPa Minimum Thermostat 120 F 48 9 C Temperature Sensor Location Starboard Cylinder Head Horn Activation Speed Reduction 3000 RPM 221 F 105 C Compressor Horn Activation 221...

Page 283: ...COOLING Page 4B 2 90 855347R1 JANUARY 1999 Special Tools 1 Volt Ohm Meter 91 99750A1 2 Water Pressure Gauge 91 79250A2 56725 ...

Page 284: ...essor temperature sensor and cylinder head temperature sensors are the same part number The ECM has been programmed to activate a warning circuit at different temperatures depending upon sensor location NOTE The Digital Diagnostic Terminal DDT can be used to monitor temperature read ings from all three temperature sensors 2 5 Liter Optimax DFI Water Flow Description Cooling water enters the coolin...

Page 285: ...e driveshaft housing Water dumped into the drive shaft housing builds up a wall of water around the exhaust tube This performs 2 functions Helps silence the exhaust Prevents air from being drawn into the pump Water exits the engine in 3 locations Excess water from the wall of water exits around anodes on the gear housing Water that passes through the air compressor exits out the tell tail Water ex...

Page 286: ...alve is stuck open at low RPM the engine will not reach proper operating temperature run cold and will run rough at idle 7 Fuel Cooler If internal leak occurs fuel will be forced into cooling system 8 Water Outlet from Air Compressor Connects to tell tale outlet on bottom cowl 9 Water Dump Holes Exhaust Cooling 2 each 1 8 in 3 175 mm If holes are plugged tuner pipe will melt and bearing carrier pr...

Page 287: ...ing temperature run cold and will run rough at idle 7 Fuel Cooler If internal leak occurs fuel will be forced into cooling system 8 Water Outlet from Air Compressor Connects to fuel cooler and then to tell tale outlet on bottom cowl 9 Water Dump Holes Exhaust Cooling 2 each 1 8 in 3 175 mm If holes are plugged tuner pipe will melt and bearing carrier prop shaft seals will be damaged 10 Water Tube ...

Page 288: ...ainer Bottom of thermometer must be even with bottom of thermo stat to obtain correct temperature of thermostat opening c Fill thermostat tester with water to cover thermostat d Plug tester into electrical outlet e Observe temperature at which thermostat begins to open Thermostat will drop off thread that was installed in Step a when it starts to open Thermostat must begin to open when temperature...

Page 289: ... 52582 9 56141 Loctite Pipe Sealant w Teflon 592 9 g b d c a e f a Tee Fitting 22 64706 b Fitting 22 63651 c Tubing d Compression Nut 22 63670 e Compressor Water Inlet Hose Cut and splice in this location f Sta straps g Compressor Water Inlet Hose WARNING Shut off engine and refer to troubleshooting chart if water pressure is not within specification DO NOT exceed 3000 RPM in neutral Idle 1 0 3 0 ...

Page 290: ...g bead should be dis regarded when inspecting cover and plate The depth of the groove will not affect wa ter pump output 5 Replace cover if plastic is melted from excessive heat lack of water Replace stainless insert and or face plate if grooves other than impeller sealing bead groove are more than 0 010 in 0 254 mm deep 57408 a b c d a Water Pump Face Plate b Sealing Groove disregard c Water Pump...

Page 291: ...t hole plugged or restricted Severe internal leak Defective poppet valve seal Poppet valve flutter water pres sure drop does not stabilize prior to 2500 RPM 4 9 PSI 27 4 61 6 kPa be tween 1000 2200 RPM Wrong poppet valve spring Low output water pump Inlet restriction Broken diaphragm in poppet valve Severe internal leak Defective poppet valve seal Pressure is below minimum spec ification W O T 12 ...

Page 292: ...TION Section 5A Clamp Swivel Brackets Drive Shaft Housing Table of Contents Swivel Bracket and Steering Arm 5A 2 Transom Brackets 5A 4 Drive Shaft Housing and Exhaust Tube 5A 6 Drive Shaft Housing and Dyna Float Suspension 5A 8 Removal and Disassembly 5A 8 Reassembly and Installation 5A 11 ...

Page 293: ...age 5A 2 90 855347R1 JANUARY 1999 Swivel Bracket and Steering Arm 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 3 27 29 28 30 95 95 95 7 95 95 95 B 7 Loctite 271 Adhesive Sealant 92 809819 95 2 4 C w Teflon 92 825407A12 A ...

Page 294: ...0 2 MOUNT 11 2 WASHER 12 2 WASHER 13 2 NUT 50 68 14 1 STEERING LINK ASSEMBLY 15 1 SCREW 3 8 24 x 1 1 4 IN 20 27 16 2 NUT See Note 17 2 WASHER 18 1 SWIVEL PIN AND STEERING ARM BLACK 19 1 BOTTOM YOKE BLACK 20 1 RETAINING RING 21 1 BUMPER 22 2 SCREW 1 4 28 x 1 2 IN 100 11 5 23 1 TRIM SENDER ASSEMBLY 24 2 SCREW 15 1 7 25 2 LOCKWASHER 26 2 WASHER 27 2 STRIKER PLATE 28 2 LOCKWASHER 29 2 NUT 23 31 30 1 D...

Page 295: ...CLAMP SWIVEL BRACKETS DRIVE SHAFT HOUSING Page 5A 4 90 855347R1 JANUARY 1999 Transom Brackets 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 18 14 14 95 95 95 95 95 95 95 2 4 C w Teflon 92 825407A12 ...

Page 296: ...N lb in lb ft Nm 1 1 TRANSOM BRACKET STARBOARD BLACK 2 1 TRANSOM BRACKET PORT BLACK 3 1 GREASE FITTING PORT 80 9 4 1 TILT TUBE 5 1 NUT 1 IN 14 45 61 6 1 O RING 7 2 WAVE WASHER 8 1 NUT 7 8 14 45 61 9 4 BOLT 10 4 WASHER 11 4 NUT 12 1 TILT LOCK LEVER ASSEMBLY 13 1 SPRING 14 2 BUSHING 15 1 SPRING 16 1 KNOB 17 1 GROOVE PIN 18 1 PIN ...

Page 297: ...18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 38 P80 Rubber Lubricant Purchase Locally 23 7 96 36 Loctite Superbonder 454 Gel Purchase Locally 96 33 95 95 36 62 Permabond 105 Cyanacrylate Adhesive Purchase Locally 62 37 Soap Purchase Locally 23 Loctite RCA 680 Retaining Compound 92 809833 33 95 2 4 C w Teflon 92 825407A12 7 Loctite 271 92 809820 ...

Page 298: ... 2 WASHER 11 2 NUT 50 68 12 2 CLAMP 13 4 SCREW 5 16 18 x 1 1 4 IN 22 30 14 2 COVER BLACK 15 4 SCREW 12 24 x 5 8 IN 17 1 9 16 4 NUT 25 34 17 1 WASHER 18 1 NUT 57 77 19 4 WASHER 20 4 NUT 23 31 21 1 IDLE EXHAUST BOOT 22 1 PLUG 23 1 GASKET 24 1 SEAL LOWER 25 1 EXHAUST TUBE 26 1 SEAL UPPER 27 1 EXHAUST EXTENSION 150 27 1 EXHAUST EXTENSION 135 28 1 WATER TUBE LONG 28 1 WATER TUBE X LONG 29 1 GASKET 30 1...

Page 299: ... driveshaft housing by pulling straight up on shaft 2 Remove 5 bolts which secure exhaust extension plate to drive shaft housing After bolts are removed lift exhaust extension plate off drive shaft housing 3 Remove screws which secure lower mount covers to drive shaft housing then re move covers 51858 a b c d e f a Shift Shaft Linkage b Exhaust Extension Plate c Exhaust Plate to Drive Shaft Housin...

Page 300: ...ASSEMBLY a b c d d e f g a Shift Shaft Assembly b Bushing c Lock Nut d Washer 2 e Bushing Hidden f Spring g Guide Block 1 Remove upper mount nuts and flat washers a a a Upper Mount Nuts 2 Lift driveshaft housing plate off housing a b 51850 a b a Drive Shaft Housing Plate b Drive Shaft Housing ...

Page 301: ... diffuser 5 Pull exhaust tube out of drive shaft housing 51850 51857 c d a b a Water Tube b Exhaust Diffuser c Exhaust Tube d Drive Shaft Housing 6 Remove all gasket material from driveshaft housing and related components 7 Remove bolts which secure lower mount retainers to drive shaft housing and remove retainers 8 Remove rubber caps from lower mount bolts 51855 a b a Bolts b Lower Mount Retainer...

Page 302: ...et by pulling alternately from top to bot tom on housing 11 Remove upper and lower mounts by lifting them out of driveshaft housing Reassembly and Installation 1 Apply a thin coat of 2 4 C w Teflon Marine Lubricant onto inside portion of exhaust tube seal 2 Install exhaust tube seal into driveshaft housing with tapered side of seal facing up 51856 a b a Exhaust Tube Seal b Driveshaft Housing ...

Page 303: ...iffuser gasket and exhaust diffuser onto plate then secure both to plate with 6 bolts Clean bolts with Loctite 7649 Primer and then apply Loctite 271 to bolt threads Torque bolts to 60 Ib in 7 0 Nm 51857 c d 51856 a b b a Exhaust Tube b Exhaust Tube Boots c Exhaust Diffuser Gasket d Exhaust Diffuser 7 Apply a small amount of 2 4 C w Teflon Marine Lubricant onto water tube seal 8 Install water tube...

Page 304: ...mount bolts 14 Insert a mounting bolt thru the short end of each lower mount 15 Position a mount on each lower side of driveshaft housing 16 Install a flat washer over each lower mounting bolt 17 Position a bumper on steering arm between mounting bolts 18 Start upper mounting bolts in upper mounts and align lower mounting bolts with holes in swivel pin yoke Slide driveshaft housing up against yoke...

Page 305: ...iner f Bolts Torque to 160 lb in 18 0 Nm g Ground Strap 23 Install lower mount covers and secure each cover with 2 screws 24 Install exhaust extension plate on driveshaft housing with shift shaft assembly Secure extension plate to drive shaft housing with 5 bolts 51858 c d e f g h 51855 a b a Cover One Each Side b Screws Two for Each Cover c Shift Shaft Linkage d Exhaust Extension Plate e Exhaust ...

Page 306: ... 16 Troubleshooting the Down and Up Circuits All Circuits Inoperative 5B 17 Power Trim Assembly Removal and Installation 5B 18 Removal 5B 18 Installation 5B 21 Testing Power Trim System With Test Gauge Kit 91 52915A6 5B 23 UP Pressure Check 5B 23 DOWN Pressure Check 5B 26 Hydraulic Repair 5B 28 Trim Rod End Cap Seal 5B 29 Tilt Ram 5B 30 Disassembly 5B 31 Scraper Seal Replacement 5B 34 Motor and El...

Page 307: ...Page 5B 2 90 855347R1 JANUARY 1999 Special Tools 1 Alignment Tool 91 11230 17238 2 Trim Rod Removal Tool 91 44486A1 51337 3 Trim Rod Guide Removal Tool 91 44487A1 51337 4 Power Trim Test Gauge Kit 91 52915A6 73835 ...

Page 308: ... Fitting 91 82278A2 and 91 82278A3 54458 6 Spanner Wrench 91 74951 51337 7 Multi Meter DVA Tester 91 99750A1 or DMT 2000 Digital Tachometer Multi meter 91 854009A1 a b a Multi Meter DVA Tester 91 99750A1 b DMT 2000 Digital Tachometer Multi meter 91 854009A1 ...

Page 309: ... 10 11 12 13 14 15 16 17 19 20 21 22 23 24 25 26 27 28 29 30 31 32 5 5 6 6 6 6 5 13 13 13 13 13 13 13 9 3 6 18 33 34 35 94 7 109 94 Anti Corrosion Grease 92 78376A6 109 GM Silicone Sealer 92 91600 1 36 37 13 13 13 7 Loctite 271 92 809820 Power Trim Steering Fluid 92 90100A12 110 38 110 ...

Page 310: ... VALVE ASSEMBLY 12 1 E RING 13 1 O RING KIT 14 1 PUMP 15 1 PLUG ASSEMBLY 16 4 SCREW 17 4 WASHER 18 1 COVER 19 1 DRIVE SHAFT 20 1 TRIM MOTOR Breakdown on Power Trim Motor 21 2 SCREW LONG 80 9 21 2 SCREW SHORT 80 9 22 1 SHAFT ASSEMBLY 23 2 PIPE PLUG 24 1 GROOVE PIN 25 1 GROOVE PIN 26 1 SHAFT 27 1 ANODE ASSEMBLY 28 2 SCREW M6 x 1 x 25 70 8 29 2 WASHER 30 6 SCREW M10 x 1 5 x 30 45 61 31 6 WASHER 32 1 ...

Page 311: ...POWER TRIM Page 5B 6 90 855347R1 JANUARY 1999 Power Trim Motor 1 2 3 3 REF TORQUE REF NO QTY DESCRIPTION lb in lb ft N m 1 POWER TRIM MOTOR 1 1 BRUSH AND SEAL KIT 2 1 ARMATURE KIT 3 1 END FRAME Complete ...

Page 312: ...onal boat instability Will lift boat bow increasing top speed Transfers steering torque harder to port left on installations below 23 in 584 2 mm tran som height Increases gearcase clearance over submerged objects Excess trim can cause porpoising and or ventilation WARNING Excessive outboard trim angle will result in insufficient water supply causing water pump and or powerhead overheating damage ...

Page 313: ...to the desired position Trailering Outboard The Up circuit first moves the trim cylinders when the trim cylinders extend fully the tilt ram extends to tilt the outboard to the full up position for trailering Before the boat is trailered the operator should check for clearance between the outboard skeg and pavement to prevent damage to skeg from striking pavement If the outboard must be tilted for ...

Page 314: ... using the trim angle adjustment pin and trimmed to the full In trim angle position may not exhibit any undesirable and or unsafe handling and or steering characteristics at planing speed If so not using the trim angle adjustment bolt may be advantageous to acceleration and planing A water test is required to determine if these characteristics apply to a par ticular boat motor combination 51353 a ...

Page 315: ... will be lost Trim Indicator Gauge A Quicksilver Trim Indicator Gauge accessory kit is available for the power trim sender if not previously installed Check Fill and Purge Power Trim System TO CHECK CAUTION Tilt outboard to full Up position and engage tilt lock lever before checking fluid level System is pressurized Extend trim and tilt rams fully to depressurize sys tem Remove fill plug and O rin...

Page 316: ...m tighten securely b Oil Can fill system with Quicksilver Power Trim and Steering Fluid c Tilt Lock Lever engage to support engine in Up position TO PURGE IMPORTANT Fill plug and O ring must be tightened securely before purging sys tem IMPORTANT Run Trim System in short jogs until pump is primed and trim sys tem moves If trim motor is run without priming pump driveshaft failure could re sult Cycle...

Page 317: ... 2 3 6 7 F Does not trim under load 5 8 9 10 G Does not hold trim position under 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 PROBL...

Page 318: ...otor will not run in the UP direction it could be either the UP relay is not making contact to 12 volts OR the DOWN relay is not making contact to ground The opposite is true if the system will not run DOWN When the system is not energized both relays should connect the heavy motor leads to ground To test which relay is faulty if the trim system does not operate in one direction 1 Disconnect the h...

Page 319: ...POWER TRIM Page 5B 14 90 855347R1 JANUARY 1999 Power Trim System with Relays and 2 Wire Trim Motor BLK Black BLU Blue GRN Green RED Red WHT White DOWN Relay UP Relay 53794 1 2 3 4 5 6 7 8 9 10 ...

Page 320: ...Indicated Connect Voltmeter red lead to Point 5 If battery voltage is indi cated trim switch is faulty If no battery voltage check for loose or corroded connection at Point 5 or open circuit in wire supply ing current to Point 5 Relay Switch is defective There is an open circuit be tween Point 3 and positive battery terminal Connect Voltmeter red lead to Point 2 Connect Voltmeter red lead to Point...

Page 321: ...h is defective There is an open circuit be tween Point 9 and positive battery terminal Connect Voltmeter red lead to Point 6 Connect Voltmeter red lead to Point 9 Connect Voltmeter red lead to Point 7 and black lead to ground Depress Up trim button If bat tery voltage is indicated wire is open between Points 7 and 8 Connect Voltmeter red lead to Point 8 and black lead to ground Depress the Up trim...

Page 322: ...tor is faulty Refer to Motor and Electrical Tests Repair following Check for open in wire Check for loose or corroded connections 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 Check all trim harness con nectors for loose or corroded connections Check trim switch Connect Voltmeter red lead to Point ...

Page 323: ...o full Up position and engage tilt lock lever 50605 b 51377 a a a Clamps b Tilt Lock Lever WARNING Failure to support outboard as shown could result in personal injury and or dam age to outboard or boat 51346 b c c a 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 ...

Page 324: ...ry cables at battery before removing power trim wires from sole noids 3 Disconnect power trim wires at solenoids BLUE GREEN and BLACK or if relay style disconnect BLUE and GREEN bullet connector harness 4 Open filler cap and release any remaining pressure in the system IMPORTANT Outboards equipped with thru the tilt tube steering remove steer ing link arm from end of steering cable and cable retai...

Page 325: ...51375 c d a b a a Transom Mount Bolts 2 b Tilt Tube Nut flush with end of thread c Screws 3 d Washers 3 IMPORTANT Cross pin a should not be reused Replace with new cross pin 7 Drive out cross pin push out upper swivel pin and remove 3 screws and washers retaining trim system Remove system from outboard a b c 51339 a Cross Pin b Upper Swivel Pin c Port Transom Bracket Screws and Washers 3 Remove to...

Page 326: ... POS ITIVE 4 Install Upper Swivel Pin with slotted end to left port side of engine d e f 51375 a b c a Screw 6 Torque to 40 lb ft 54 0 N m b Lockwasher 6 Install one per screw c Tilt Tube Nut d Upper Swivel Pin e Slotted end f Cross hole in line with slotted end IMPORTANT Cross pin should not be reused Install a new pin 5 Position slot on end of swivel shaft in line with hole in tilt ram end Inser...

Page 327: ...1 56922 a a Conduit Tubing 7 Apply marine sealer to shanks of mount bolts and install transom mount bolts IMPORTANT Do not use an impact driver to tighten transom mount bolts Apply marine sealer to threads of mount bolts Secure with flat washers and locknuts Be sure installation is watertight 8 Tighten tilt tube nut securely IMPORTANT Outboards equipped with thru the tilt tube steering Tighten ste...

Page 328: ...tery is fully charged before performing tests 1 Tilt outboard to full Up position and engage tilt lock lever 2 Slowly remove Fill plug to bleed pressure from reservoir 3 Remove circlip securing manual release valve and unscrew release valve from trim assembly NOTE A small amount of trim fluid may drip from manual release valve hole Place a suit able container under trim assembly to collect any lea...

Page 329: ...al release valve hole a 54458 a Test Adaptor 91 822778A2 5 Thread hose from Test Gauge Kit 91 52915A6 into brass fitting on adaptor a b c d e 54459 a Brass Fitting b Test Gauge Assembly c Tilt Pin Position in Hole Shown d Hose e Hose Not Used 6 Reinstall fill plug 7 Disengage tilt lock lever ...

Page 330: ...rackets and swivel bracket in the hole shown a 54460 a Tilt Pin Hole Install Spare Tilt Pin or Hardened Bolts and Nuts 9 Open valve a and close valve b a b 51374 10 Run trim UP The minimum pressure should be 1300 P S I 91 kg cm2 11 Run trim DOWN to release pressure and remove spare tilt pin or bolts and nuts 12 Tilt outboard full UP and engage tilt lock lever 13 Slowly remove Fill plug to bleed pr...

Page 331: ...ease valve hole Place a suit able container under trim assembly to collect any leakage NOTE Assemble test adaptor by using O ring installation tool to position small O ring onto adaptor 1st then install medium O ring and lastly large O ring Thread brass fitting into test adaptor securely using teflon tape on threads 3 f a e d c b g a Test Adaptor 91 822778A3 b O ring Installation Tool c Small O ri...

Page 332: ...6 Reinstall fill plug 7 Disengage tilt lock lever 8 Open valve f and close valve g 9 Run trim DOWN Minimum pressure should be 500 P S I 35 kg cm2 10 Tilt outboard full UP and engage tilt lock lever 11 Slowly remove Fill plug to bleed pressure 12 Remove test gauge hose and adaptor 13 Reinstall manual release valve and secure valve with circlip 14 Retighten Fill plug NOTE If pressure is less than 50...

Page 333: ...ill plug to bleed reservoir pressure 3 Turn Manual Release Valve 3 to 4 turns counterclockwise to bleed remaining pres sure 4 Remove trim rod cylinder caps NOTE Place a clean pan under trim system to catch fluid c d a b b 51337 51353 a Trim Rod Cylinder Cap b Turn Counterclockwise to Remove c Removal Tool 91 44487A1 d Spanner Wrench 91 74951 5 Install trim rod removal tool and pull trim rod from c...

Page 334: ... be removed replace trim rod assembly Clean trim rod with parts cleaner and dry with compressed air 51352 a b a Check Valve b Check Valve Screen Trim Rod End Cap Seal 1 Inspect trim cap end seal and replace if damaged or if seal does not keep trim rod clean a 51343 a Seal remove as shown 2 Install new seal with seal lip up TRIM ROD INSTALLATION IMPORTANT Components must be free of dirt and lint An...

Page 335: ... be removed from cylinder without removing entire power trim system from outboard TILT RAM COMPONENTS 51372 1 2 3 4 2 2 5 2 2 6 7 8 9 11 10 1 Housing Tilt Ram 2 O ring 5 3 Memory Piston 4 Washer 5 Piston Assembly 6 End Cap 7 Oil Seal 8 Bolt Design 1 9 Nut Design 2 10 Tilt Rod Design 1 11 Tilt Rod Design 2 O ring Repair Kit Available P N 811607A1 Includes item 7 Oil Seal Memory piston 3 for tilt ro...

Page 336: ...zed prior to tilt ram removal 1 Remove cross pin 2 Remove lower swivel pin 51355 51366 a b a Cross Pin Remove as shown b Lower Swivel Pin Remove as shown Disassembly 1 Secure tilt ram in a soft jawed vise Remove tilt rod and cap 51364 51337 91 74951 a b c a Cap Turn Counterclockwise to Remove b Spanner Wrench 91 74951 c Tilt Rod Pull to Remove ...

Page 337: ...lt rod assembly re places either tilt rod assembly Either design will fit as a replace cylinder assem bly complete Design 2 will NOT fit a cylinder originally using a Design 1 tilt rod assembly Memory Pistons for Design 1 and 2 differ also and must be used only on the cylin der the piston was removed from 3 Remove washer check valve assemblies and piston NOTE Check valve held in by roll pin can be...

Page 338: ...376 a b c a End Cap b Allen Plug c Hole In Shaft 6 Lubricate shaft with Quicksilver Power Trim and Steering Fluid Insert shaft into cylinder 51342 7 Tap shaft into cylinder until shaft is positioned as shown 51365 WARNING Memory Piston Cup may be expelled at a high velocity when air pressure is applied Failure to place cylinder as shown below could result in personal injury ...

Page 339: ...ved 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 0 005 in 0 1 mm deep in cylinder are accept able Scraper Seal Replacement 1 Remove components from end cap a b ...

Page 340: ...efer to Tilt Ram Components for proper O ring sizes 1 Apply Quicksilver Power Trim and Steering Fluid on O rings prior to reassembly 2 Install O ring on Memory Piston Cup and install in cylinder 51372 a b a O ring b Memory Piston Cup Design 1 shown 3 Assemble end cap 4 Install end cap 51376 f a b b c d e a End Cap b O ring 2 c Scraper seal d Washer e Retaining Ring f End Cap ...

Page 341: ...iston 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 spanner wrench and tighten end cap securely 51341 51337 91 74951 a b c a Cylinder b Tilt Rod Assembly c End Cap Tighten Securely Use Spanner Wrench ...

Page 342: ...se Quicksilver Power Trim and Steer ing Fluid 51369 a b a Alignment Tool 91 11230 b Shaft 2 Align tilt ram and housing using alignment tool 3 Install shaft 51352 51348 b c d a a Alignment Tool 91 11230 b Shaft c Groove d Hole Groove c will Align with this Hole 4 Drive pin in until flush 51356 a a Pin Drive Against Knurled End ...

Page 343: ...hile making electrical connections 1 Connect a 12 volt power supply to motor wires one motor lead to POSITIVE bat tery terminal and the other motor lead to the NEGATIVE battery terminal Motor should run Reverse motor leads between battery terminals Motor should run 53774 2 If motor does not run disassemble and check components Motor Disassembly 1 Remove 2 screws 53774 a a a Screw 2 ...

Page 344: ...Armature c End Cap Armature Tests TEST FOR SHORTS Check armature on a Growler per the Growler manufacturer s instructions Replace ar mature if a short is indicated TEST FOR GROUND 1 Use an Ohmmeter Rx1 scale Connect one lead on armature shaft and other lead on commutator If continuity is indicated armature is grounded Replace armature 53786 ...

Page 345: ...istance Ohms Scale Reading x____________ BLUE and BLACK Motor Wires 0 Rx1 BLACK Motor Wire and Frame Motor Housing No Continuity Rx1 BLUE Motor Wire and Frame No Continuity Rx1 If specified readings are not obtained check for defective armature dirty or worn brushes dirty or worn commutator If defective components are found repair or replace component s and retest Motor Repair REMOVAL NOTE Power T...

Page 346: ...n inspect and test motor components Refer to Brush Replacement Armature Test and Field Tests for inspection and test procedures 53779 a b c d e a Frame b Armature c Shim d Brush Card Assembly e O rings BRUSH REPLACEMENT 1 Brush replacement is required if brushes are pitted chipped or if distance a be tween the brush pigtail and end of brush holder slot is 1 16 in or less Check distance with armatu...

Page 347: ... Install new brush card BRUSH and SEAL KIT 828714A1 6 Crimp metal connector onto motor lead and new brush lead 7 Connect spade connector motor lead to brush card connector 8 Secure brush card to end cap with 2 screws and lockwashers 9 Inspect O ring for cuts and abrasions Replace O ring as required BRUSH and SEAL KIT 828714A1 53778 a b c d e a Brush Card b Metal Connector c Spade Connector d Screw...

Page 348: ...4A1 2 Inspect bushing for wear If bushing appears to be excessively worn grooves scratches etc install END FRAME ASSEMBLY COMPLETE 828715A1 53785 c 53783 a b a Seal Apply 2 4 C w Teflon to seal lips b O ring c Bushing 3 If trim motor is overheated a thermoswitch located under brush card will open Nor mally this switch will reset itself within 1 minute 53781 a a Thermoswitch ...

Page 349: ...ean Any debris in power trim system can cause system to malfunction 1 Install armature into end cap brush card assembly 53779 53784 a b c d a Armature b Shim c End Cap Assembly d Armature Spread brushes to install armature into end cap 2 Install O rings in end cap 53784 53783 a a a O rings ...

Page 350: ...ard assembly by the frame magnets while installing the frame assembly 3 Install Vise Grip pliers on armature shaft 4 Carefully install frame assembly over armature 5 Position harness retainer hole over tab in end cap 6 Secure frame assembly to end cap with 2 screws 53776 a b c d e g h i i f a Vise Grip Pliers b Armature Shaft c O ring d End Cap e Harness Retainer f Retainer Hole g O ring h Frame A...

Page 351: ...rews to 80 lb in 9 N m IMPORTANT Install pump with location flat facing towards starboard transom bracket 51433 a b c d c a Pump Flat Towards Starboard Transom Bracket b Flat Faces Starboard Transom Bracket c O rings 4 d Drive Shaft Install in Center Hole in Pump 2 Fill pump with Quicksilver Power Trim and Steering Fluid prior to installing motor 3 Install motor secure with two 2 screws Route wiri...

Page 352: ...Purge on page 5B 10 IMPORTANT Run Trim System in short jogs until pump motor primes and trim system moves If trim motor is run without priming pump drive shaft failure could result Trim Sender Test 1 Check trim sender black lead for proper ground 2 Trim outboard to full DOWN position 3 Place ignition switch to ON position 4 Disconnect BRN WHT trim sender wire from trim sender harness 5 Connect Ohm...

Page 353: ...ld be in full IN position 3 If not tilt outboard to full OUT position to gain access to trim sender and engage tilt lock lever 4 Loosen trim sender screws and reposition trim sender 5 Tighten trim sender screws a b c d e 22744 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 ...

Page 354: ... boats equipped with Quicksilver Commander Series side mount remote control Wiring Diagram For boats equipped with Quicksilver Ignition Choke and Main Harness Assembly a b c e d a f g c e d a Trim Indicator b Remote Control c Trim Sender d Engine Ground e To Engine f Ignition Switch g Power Trim Harness ...

Page 355: ...Bearing Race 6A 31 Driveshaft and Pinion Gear 6A 32 Pinion Gear Depth Forward Gear Backlash Reverse Gear Backlash 6A 34 Clutch Actuator Rod 6A 38 Shift Shaft Bushing 6A 38 Propeller Shaft 6A 39 Water Pump 6A 42 Gear Lubricant Filling Instructions 6A 45 Installing Gear Housing to Driveshaft Housing 6A 45 Propeller Installation 6A 46 Gear Housing Specifications Standard Rotation Ratio Pinion Depth F...

Page 356: ... Bearing Carrier Removal Tool 91 46086A1 and Puller Bolt 91 85716 4 Slide Hammer Puller 91 34569A1 5 Bearing Removal and Installation Kit 91 31229A5 This kit contains the following tools Pilot 91 36571 Puller Rod 91 31229 Nut 11 24156 Puller Plate 91 29310 Mandrel 91 38628 and Driver Rod 91 37323 6 Pilot 91 36571 7 Puller Rod 91 31229 and Nut 91 24156 ...

Page 357: ...el 91 38628 10 Driver Rod 91 37323 11 Universal Puller Plate 91 37241 12 Cross Pin Tool 91 86642 13 Driveshaft Holding Tool 91 34377A1or 91 90094 14 Oil Seal Driver 91 31108 15 Forward Gear Bearing Tool 91 86943 16 Bearing Driver Cup 91 31106 17 Pinion Locating Gear Tool 91 12349A2 or 91 74776 ...

Page 358: ...cator 91 58222A1 20 Bearing Retainer Tool 91 43506 21 Bearing Preload Tool 91 14311A1 1 2 3 4 5 6 7 8 1 Adaptor N S S 2 Bearing N S S 3 Washer N S S 4 Spring 24 14111 5 Bolt 10 12580 6 Nut 11 13953 7 Set Screw 10 12575 8 Sleeve 23 13946 22 Mandrel 91 92788 23 Mandrel 91 15755 24 Dial Indicator Holder 91 89897 ...

Page 359: ...RIGHT HAND NON RATCHETING 90 855347R1 JANUARY 1999 Page 6A 5 Notes ...

Page 360: ...6 27 29 30 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 11 20 10 45 28 31 23 95 95 7 95 95 95 98 33 109 7 95 95 7 95 19 95 109 9 95 Soap Purchase Locally 23 4 75 IN 120 65MM TORPEDO DIA 7 Loctite 271 92 809820 Perfect Seal 92 34227 1 19 Loctite 680 92 809833 33 95 2 4 C With Teflon 92 825407A12 GM Silicone Sealer 92 91600 1 109 4 5 6 18 21 19 ...

Page 361: ...EAR 2 1 14 TEETH 135 Also part of 43 828176A2 14 1 WASHER 15 1 NUT 75 101 16 AR SHIM SET 17 1 SCREW drain MAGNETIC 60 7 18 1 SCREW grease filler 60 7 19 2 WASHER 20 1 STA STRAP 21 1 SHIFT SHAFT 22 1 O RING 23 1 BUSHING ASSEMBLY 50 5 5 24 1 OIL SEAL 25 1 WASHER rubber 26 1 DRIVE SHAFT LONG 26 1 DRIVE SHAFT X LONG 27 1 ROLLER BEARING 28 1 CUP 29 1 RETAINER 100 135 30 1 WATER PUMP BASE 31 1 RETAINER ...

Page 362: ...A 8 90 855347R1 JANUARY 1999 Gear Housing Prop Shaft Standard Rotation 87 Super Duty Gear Lubricant 92 13783A24 4 75 IN 120 65MM TORPEDO DIA 7 Loctite 271 92 809820 94 Anti Corrosion Grease 92 78376A6 95 2 4 C With Teflon 92 825407A12 ...

Page 363: ...ET 55 1 TAPERED ROLLER BEARING 56 1 CUP 57 1 NEEDLE BEARING 58 1 CLUTCH 59 1 CROSS PIN 60 1 DETENT PIN 61 1 SPRING 62 1 PROPELLER SHAFT 63 1 REVERSE GEAR 1 87 1 15 28 150 63 1 REVERSE GEAR 2 1 14 28 135 64 1 THRUST SPACER 65 1 THRUST RING 66 1 BALL BEARING 67 1 O RING 68 1 BEARING CARRIER ASSEMBLY 69 1 ROLLER BEARING 70 1 OIL SEAL INSIDE 71 1 OIL SEAL OUTSIDE 72 1 KEY 73 1 TAB WASHER 74 1 COVER 21...

Page 364: ... passes thru the bearing DO NOT spin bearing with compressed air as this may cause bearing to score from lack of lubrication After cleaning lubricate bearings with Quicksilver Gear Lubricant DO NOT lubricate tapered bearing cups until after inspection Inspect all bearings for roughness catches and bearing race side wear Work inner bear ing race in and out while holding outer race to check for side...

Page 365: ...ft MUST BE removed from gear housing BEFORE propeller shaft can be removed from gear housing 2 Shift engine into neutral position 3 Tilt engine to full up position and engage tilt lock lever 4 Bend tabs of propeller tab washer away from thrust hub rear then remove propeller locknut tab washer thrust hub rear propeller and thrust hub forward from propel ler shaft 51871 51866 a b c d d e f a Thrust ...

Page 366: ...one nut before oppo site side is loosened sufficiently or driveshaft housing could be damaged 10 Pull gear housing away from driveshaft housing as far as the loosened nuts in Step 9 will allow then remove loosened nuts DO NOT allow gear housing to fall as it now is free 11 Pull gear housing from driveshaft housing 51879 a b a Front Mounting Locknut b Side Mounting Locknut One Each Side Draining an...

Page 367: ...TE Gear lubricant drained from a recently run gear case will be a light chocolate brown in color due to agitation aeration Oil which is stabilized will be a clear yellow brown in color Water Pump CLEANING AND INSPECTION 1 Clean all water pump parts with solvent and dry with compressed air 2 Inspect water pump cover and base for cracks and distortion from overheating 3 Inspect face plate and water ...

Page 368: ...all washers which secure water pump cover to gear housing 4 Using 2 pry bars lift water pump cover up and off driveshaft 51874 51874 a b c a Water Tube Guide b Water Tube Seal c Nuts Bolt and Washers To Be Removed 5 Inspect water pump cover and insert as outlined in Cleaning and Inspection pre vious 6 If inspection of water pump insert determines that replacement is required follow Step a or b imm...

Page 369: ...ler upward on driveshaft In extreme cases it may be necessary to split hub of impeller with a hammer and chisel 8 Once impeller is removed remove impeller drive key from driveshaft 9 Remove water pump face plate and both gaskets one above and below face plate from water pump base 10 Using 2 pry bars positioned and padded as shown lift water pump base up and off driveshaft 51874 a a Pads 11 Remove ...

Page 370: ...ng from shift shaft at this time IMPORTANT Prior to removal of shift shaft from gear housing recheck that gear housing is in NEUTRAL position 3 Bend cover nut lock tab out of cover nut recess 51865 b c 51874 a a Shift Shaft Bushing Tool 91 31107 b Punch c Tab of Tab Washer 4 Remove gear housing cover nut with Cover Nut Tool 91 61069 51866 a a Cover Nut Tool 91 61069 5 After cover nut has been remo...

Page 371: ...out of gear housing by simply pulling outward on propeller shaft DO NOT FORCE shaft side ways or ATTEMPT TO PULL with a slide hammer or any mechanical puller 8 Remove propeller shaft cam follower and shift cam by pulling shaft straight out of gear housing DO NOT JERK propeller shaft If propeller shaft will not come out proceed with Step a or b following a Push propeller shaft back into place again...

Page 372: ...ing carrier with solvent and dry with compressed air CAUTION DO NOT spin bearings dry with compressed air as this could cause bearing to score 2 Bearing carrier propeller shaft needle bearing condition is determined by propeller shaft bearing surface condition See Propeller Shaft Inspection 3 Inspect reverse gear to pinion gear wear pattern should be even and smooth If not replace reverse gear and...

Page 373: ... in the same methods as was used to remove reverse gear Step b 3 Propeller shaft oil seals can be removed by a using a pry bar or b pressing seals out when propeller shaft needle bearing is pressed out of bearing carrier 4 If inspection of propeller shaft needle bearing determines that replacement of bearing is required use Universal Bearing Removal and Installation Tool 91 31229A1 to press bearin...

Page 374: ...t of oil seal surface Forward gear bearing contacts propeller shaft in front of sliding clutch splines 4 Inspect propeller shaft splines for wear and or corrosion damage 5 Check propeller shaft for straightness Use either method following BALANCE WHEELS Place propeller shaft on balance wheels Rotate propeller shaft and observe propeller end of shaft for wobble Replace shaft if any wobble is observ...

Page 375: ... cam follower If it shows wear pitting scoring or rough surface replace cam follower and shift cam DISASSEMBLY 1 Remove shift cam from cam follower 2 Insert a thin blade screwdriver or awl under first coil of cross pin retainer spring and rotate propeller shaft to unwind spring from sliding clutch DO NOT over stretch spring CAUTION Detent pin is free and can fall out of sliding clutch Care MUST BE...

Page 376: ...eller shaft lift rod out of cam follower Clutch Actuator Rod CLEANING AND INSPECTION 1 Clean clutch actuator rod in solvent and dry with compressed air 2 Inspect actuator components for wear or damage Replace components as required Pinion Gear and Driveshaft REMOVAL 1 Remove bearing retainer using Bearing Retainer Tool 91 43506 51865 a b a Bearing Retainer b Bearing Retainer Tool 91 43506 2 Place ...

Page 377: ... gear assembly 8 After driveshaft is removed from gear case remove and retain shim s that were lo cated under upper tapered driveshaft bearing 9 If inspection determines that replacement of driveshaft tapered bearing is required remove bearing from driveshaft as follows a Position driveshaft in a vise DO NOT tighten vise jaws against shaft b Strike shaft with a lead hammer take care not to drop sh...

Page 378: ... uneven wear and or discoloration from overheating Replace pinion gear if any of the above conditions are found 3 Inspect driveshaft needle bearing surface area just above pinion gear splines for pit ting grooves scoring uneven wear and or discoloration from overheating Replace driveshaft and driveshaft needle bearing if any of the preceding conditions are found 4 Inspect driveshaft to crankshaft ...

Page 379: ... replaced as a set as follows a Install Universal Puller Plate 91 37241 between forward gear and tapered bear ing b Place forward gear bearing and puller plate on a press and press gear out of bear ing with a suitable mandrel c Use Slide Hammer 91 34569A1 to remove forward gear tapered bearing race 51865 51870 c d a b a Universal Puller Plate b Mandrel c Slide Hammer d Tapered Bearing Race d After...

Page 380: ...ard gear inspect propeller shaft forward gear needle bearing surface as outlined in Propeller Shaft Inspection Gear Housing CLEANING AND INSPECTION 1 Clean gear housing with solvent and dry with compressed air 2 Check gear housing carefully for impact damage 3 Check for loose fitting bearing cups and needle bearings 4 Inspect bearing carrier cover nut retainer threads in gear housing for corrosion...

Page 381: ...ion Kit 91 31229A5 51869 a b c d e f a Mandrel b Bearing c Pilot d Plate e Puller Rod f Hold Bearing Carrier REASSEMBLY 1 Place reverse gear on a press with gear teeth facing down IMPORTANT The reverse gear thrust washer has a tapered outside diameter so that one side is larger than the other The larger outside diameter of washer must be toward reverse gear 2 Place thrust washer over gear with the...

Page 382: ...propeller shaft needle bearing into aft end of bearing carrier with numbered side toward aft end 8 Use Mandrel 91 15755 and press needle bearing into bearing carrier 51872 51873 a b c a Thrust Washer b Mandrel c Mandrel 91 15755 9 Apply Loctite 271 to outer diameter of propeller shaft oil seals 10 Place one seal on longer shoulder side of Oil Seal Driver 91 31108 with lip of seal away from shoulde...

Page 383: ... Oil Seal Driver c Seated 12 Wipe off excess Loctite 13 Apply a light coat of Quicksilver Super Duty Gear Lubricant onto the outside diameter of reverse gear ball bearing 14 Place bearing carrier over reverse gear and bearing assembly Press bearing carrier onto bearing 51870 a b a Mandrel b Seated 15 Place O ring over bearing carrier and position it between bearing carrier and thrust washer 16 Lub...

Page 384: ...st the gear 51869 a b a Mandrel b Wooden Block 5 Apply a light coat of Quicksilver Super Duty Gear Lubricant to bore in center of forward gear 6 Place one forward gear needle bearing on longer shoulder side of Forward Gear Bear ing Tool 91 86943 with numbered side of bearing toward shoulder Press bearing into forward gear until bearing tool bottoms against gear 51873 a b a Forward Gear Bearing Too...

Page 385: ...stalled in gear housing the propeller shaft must be disassembled Refer to Propeller Shaft Disassembly preceding 5 Place propeller shaft into hole in center of bearing driver cup 6 Install bearing carrier assembly over propeller shaft and lower it into gear housing Bearing carrier acts as a pilot to assure proper bearing race alignment 7 Thread a nut onto propeller shaft to protect propeller shaft ...

Page 386: ...Puller Plate 5 Position pinion gear in gear housing below driveshaft bore with teeth of pinion gear meshed with teeth of reverse gear 6 Insert driveshaft into driveshaft bore while holding pinion gear Rotate driveshaft to align and engage driveshaft splines with pinion gear splines Continue to insert drive shaft into gear housing until driveshaft tapered bearing is against bearing race NOTE It is ...

Page 387: ... s g Bearing Race h Bearing Retainer Word OFF must be visible Torque to 100 lb ft 135 5 Nm i Bearing Retainer Tool 91 43506 10 Use a socket and flex handle to hold pinion nut pad area where flex handle will con tact gear housing while torquing nut 11 Place Driveshaft Holding Tool 91 34377A1 or 91 90094 over crankshaft end of driveshaft Torque pinion nut to 75 lb ft 101 5 Nm a b a c c d a Driveshaf...

Page 388: ...ear housing bearing carrier shoulder 2 Install Bearing Preload Tool 91 14311A1 over driveshaft in sequence shown NOTE Bearing Preload Tool 91 44307A1 may also be used Follow instructions pro vided with tool for proper installation a b c d e f g h g a Adaptor b Bearing c Washer d Spring e Nut thread nut all the way onto bolt f Bolt g Set Screw h Sleeve Holes in sleeve must align with set screw 3 Al...

Page 389: ...ions supplied with tool 8 Determine pinion gear depth by inserting a feeler gauge thru access slot in pinion gear shimming tool 9 Clearance between shimming tool and pinion gear should be 0 025 in 0 64 mm 10 If clearance is correct leave Bearing Preload Tool on driveshaft for Determining For ward Gear Backlash following 11 If clearance is not correct add or subtract shims at location shown to rais...

Page 390: ...over nut tightly against bearing carrier It is not necessary to torque cover nut against bearing carrier 3 Attach Bearing Carrier Removal Tool 91 46086A1 and Puller Bolt 91 85716 onto gear housing 4 Torque puller bolt against propeller shaft to 45 Ib in 5 Nm Turn driveshaft 10 revolu tions with the load applied to propeller shaft This will seat forward gear bearing 51867 a b c d e a Propeller Shaf...

Page 391: ...io and 0 018 in to 0 023 in 0 46 mm to 0 58 mm for the 2 3 1 gear ratio 10 If backlash is LESS than the specified minimum REMOVE shim s from in front of for ward gear bearing race to obtain correct backlash When reinstalling pinion nut apply Loctite 271 on threads of nut 11 If backlash is MORE than the specified MAXIMUM add shim s in front of forward gear bearing race to obtain correct backlash Wh...

Page 392: ...placed before returning gear case to service Clutch Actuator Rod REASSEMBLY 1 Place a small amount of Quicksilver 2 4 C w Teflon Lubricant on actuator rod and install cam follower a b a Actuator Rod b Cam Follower Shift Shaft Bushing REASSEMBLY 1 Position shift shaft bushing on a press with threaded side down 2 Apply Loctite 271 to outside diameter of oil seal 3 Press oil seal into shift shaft bus...

Page 393: ...sliding clutch must line up with cross pin slot and detent notches on propeller shaft 51864 51864 c d e f g h a b a Cam Follower b Propeller Shaft c Sliding Clutch d Grooved Rings e Cross Pin Hole f Detent Hole Behind Finger and Thumb g Detent Notch One on Each Side h Cross Pin Slot 3 Insert cross pin thru sliding clutch propeller shaft and actuator rod forcing cross pin tool out 4 Apply a small a...

Page 394: ...g clutch 7 Place gear housing in a soft jaw vise with the driveshaft in a vertical position 8 Coat cam pocket of cam follower with 2 4 C w Teflon Marine Lubricant 9 Place shift cam into cam pocket of cam follower with numbered side of cam facing up 10 With shift cam positioned as shown insert propeller shaft thru forward gear until shaft bottoms out 51864 d e 55095 a b c a Cam Pocket b Cam Followe...

Page 395: ...me 51867 a b a Shift Shaft Bushing b Shift Shaft 13 Lubricate O ring on bearing carrier with Quicksilver 2 4 C w Teflon Marine Lubricant 14 Apply a light coat of Quicksilver 2 4 C w Teflon Marine Lubricant to outside diameter of bearing carrier where carrier contacts gear housing NOTE When performing Step 15 rotate driveshaft clockwise viewed from top to mesh pinion gear with reverse gear 15 Posit...

Page 396: ...NSTALLATION 1 Install oil seals into water pump base as follows a Place water pump base on a press b Just before installing each seal apply Loctite 271 on outside diameter of oil seal c With a suitable mandrel press the smaller diameter oil seal into pump base with lip of oil seal toward impeller side of base d With a suitable mandrel press the larger diameter oil seal into pump base with lip of o...

Page 397: ...b c a Gasket Water Pump Base to Face Plate b Face Plate c Gasket Face Plate to Water Pump Cover 6 Place impeller drive key on flat of driveshaft Hold key on driveshaft with a small amount of Quicksilver 2 4 C w Teflon Marine Lubricant IMPORTANT When completing gear housing repair that requires removal of water pump impeller it is recommended that the impeller be replaced If it is necessary however...

Page 398: ...ng engine 9 Install water tube seal into pump cover being sure that plastic side of seal goes into cover first 10 Reinstall water tube guide into water pump cover 11 Apply a light coat of Quicksilver 2 4 C w Teflon Marine Lubricant inside of water pump insert 12 Position assembled water pump cover over driveshaft and lower over water pump studs Rotate driveshaft in a clockwise direction viewed fro...

Page 399: ...installing gear housing onto driveshaft housing 1 Tilt engine to full up position and engage the tilt lock lever 2 Apply a light coat of Quicksilver 2 4 C w Teflon Marine Lubricant onto driveshaft splines CAUTION DO NOT allow lubricant on top of driveshaft Excess lubricant that is trapped in clearance space will not allow driveshaft to fully engage with crankshaft Subse quently tightening the gear...

Page 400: ...kwise c Place guide block anchor pin into reverse gear position Rotate flywheel clockwise viewed from top propeller shaft should rotate counterclockwise IMPORTANT lf shifting operation is not as described preceding the gear housing must be removed and the cause corrected 14 Install washers and nuts onto studs located on bottom center of anti cavitation plate Torque to listing in Torque Specificati...

Page 401: ...f 55 Ib ft 74 5 Nm torque 8 Bend 3 of the tabs of tab washer down in grooves of rear thrust hub to secure propeller nut If tab washer tabs do not align with slots continue to tighten propeller nut to ob tain alignment DO NOT loosen nut to align tabs CAUTION DO NOT misinterpret propeller shaft movement with propeller movement If pro peller and propeller shaft together move forward and aft this is n...

Page 402: ...Needle Bearing 6B 31 Bearing Carrier Forward Gear and Bearing Adaptor 6B 32 Reverse Gear Bearing Adaptor Assembly 6B 35 Driveshaft and Pinion Gear 6B 37 Pinion Gear Depth 6B 39 Reverse Gear 6B 41 Forward Gear 6B 42 Propeller Shaft Forward Gear Bearing Adapter Bearing Carrier 6B 45 Water Pump 6B 52 Gear Lubricant Filling Instructions 6B 55 Installing Gear Housing to Driveshaft Housing 6B 55 Propell...

Page 403: ... Bearing Carrier Removal Tool 91 46086A1 and Puller Bolt 91 85716 4 Slide Hammer Puller 91 34569A1 5 Bearing Removal and Installation Kit 91 31229A5 This kit contains the following tools Pilot 91 36571 Puller Rod 91 31229 Nut 11 24156 Puller Plate 91 29310 Mandrel 91 38628 and Driver Rod 91 37323 6 Pilot 91 36571 7 Puller Rod 91 31229 and Nut 91 24156 ...

Page 404: ...1 38628 10 Driver Rod 91 37323 11 Universal Puller Plate 91 37241 12 Driveshaft Holding Tool 91 34377A1 or91 90094 13 Oil Seal Driver 91 31108 14 Forward Gear Bearing Tool 91 86943 15 Pinion Locating Gear Tool 91 12349A2 or 91 74776 16 Backlash Indicator Rod 91 78473 17 Dial Indicator 91 58222A1 ...

Page 405: ...91 15755 21 Dial Indicator Holder 91 89897 22 Bearing Preload Tool 91 14311A1 1 2 3 4 5 6 7 8 1 Adaptor N S S 2 Bearing N S S 3 Washer N S S 4 Spring 24 14111 5 Bolt 10 12580 6 Nut 11 13953 7 Set Screw 10 12575 8 Sleeve 23 13946 23 Propeller Shaft 44 93003 and Load Washer i 12 37429 24 Forward Gear Installation Tool 91 815850 ...

Page 406: ...855347R1 JANUARY 1999 Page 6B 5 25 Reverse Gear Installation Kit 91 18605A1 includes Pilot 91 18603 Retainer 91 18604 Shaft 91 18605 and Screw 10 18602 a b c d a Pilot 91 18603 b Shaft 91 18605 c Retainer 91 18604 d Screw 10 18602 ...

Page 407: ... 95 Soap Purchase Locally 23 4 75 IN 120 65 MM TORPEDO DIA 7 Loctite 271 92 809820 Perfect Seal 92 34227 1 19 Loctite 680 92 809833 33 95 2 4 C With Teflon 92 825407A12 109 GM Silicone Sealer 92 91600 1 1 2 3 4 5 6 7 8 9 10 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 45 46 47 48 49 50 7 19 ...

Page 408: ... part of 43 828703A1 14 1 WASHER 15 1 NUT 75 101 16 AR SHIM SET 17 1 SCREW drain MAGNETIC 60 7 18 1 SCREW grease filler 60 7 19 2 WASHER 20 1 STA STRAP 21 1 SHIFT SHAFT 22 1 O RING 23 1 BUSHING ASSEMBLY 50 5 5 24 1 OIL SEAL 25 1 WASHER rubber 26 1 DRIVE SHAFT 27 1 ROLLER BEARING 28 1 CUP 29 1 RETAINER 100 11 5 30 1 WATER PUMP BASE 31 1 RETAINER 32 1 GASKET 33 1 O RING 34 1 OIL SEAL 35 1 OIL SEAL 3...

Page 409: ... 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 74 73 72 95 87 87 95 87 87 87 87 94 95 87 7 95 95 95 87 87 4 75 IN 120 65 MM TORPEDO DIA 7 Loctite 271 92 809820 94 Anti Corrosion Grease 92 78376A6 95 2 4 C With Teflon 92 825407A12 87 Quicksilver Gear Lubricant 92 19007A24 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 ...

Page 410: ...59 1 REVERSE GEAR 1 87 1 15 28 150 59 1 REVERSE GEAR 2 1 14 28 135 60 1 ROLLER BEARING 61 1 SPRING 62 1 SLIDING CLUTCH 63 1 CROSS PIN 64 1 DETENT PIN 65 1 PROPELLER SHAFT 66 1 FORWARD GEAR 1 87 1 15 28 150 66 1 FORWARD GEAR 2 1 14 28 135 AR SPACER SHIM 206 IN AR SPACER SHIM 208 IN AR SPACER SHIM 210 IN AR SPACER SHIM 212 IN AR SPACER SHIM 214 IN AR SPACER SHIM 216 IN 67 AR SPACER SHIM 218 IN AR SP...

Page 411: ...3 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 74 73 72 95 87 87 95 87 87 87 87 94 95 87 7 95 95 95 87 87 4 75 IN 120 65 MM TORPEDO DIA 7 Loctite 271 92 809820 87 Quicksilver Gear Lubricant 92 19007A24 94 Anti Corrosion Grease 92 78376A6 95 2 4 C With Teflon 92 825407A12 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 ...

Page 412: ...mpting any repairs In many cases disassembly of a sub assembly may not be necessary until cleaning and inspection reveals that disassembly is required for replacement of one or more compo nents Service procedure order in this section is a normal disassembly reassembly sequence It is suggested that the sequence be followed without deviation to assure proper repairs When performing partial repairs f...

Page 413: ...Keep a record of all shim amounts and location during disassembly to aid in reassembly Be sure to follow shimming instructions during reassembly as gears must be installed to correct depth and have the correct amount of backlash to avoid noisy operation and pre mature gear failure SEALS As a normal procedure all O rings and oil seals SHOULD BE REPLACED without regard to appearance To prevent leaka...

Page 414: ...inuity Washer If Equipped d Rear Thrust Hub e Tab Washer f Propeller Nut 5 Mark gear housing and trim tab so that trim tab can be reinstalled in the same position Remove plastic cap at rear edge of driveshaft housing Remove bolt that secures trim tab and remove tab from gear housing 6 Once trim tab is removed remove bolt from inside of trim tab cavity 7 Remove 2 locknuts from bottom middle of anti...

Page 415: ...y be located on the starboard side of gearcase on later models 2 Position a clean drain pan under gear housing and remove Fill and Vent screws from gear housing 3 Inspect gear lubricant for metal particles Presence of a small amount of fine metal particles resembling powder indicates normal wear Presence of larger particles or a large quantity of fine particles indicates need for gear housing disa...

Page 416: ... impeller hub 6 Inspect impeller for glazed or melted appearance caused by operation without suffi cient water supply Replace impeller if any of these conditions exist IMPORTANT It is recommended that all seals and gaskets be replaced as a normal repair procedure to assure effective repair REMOVAL AND DISASSEMBLY 1 Slide rubber centrifugal slinger up and off driveshaft 2 Remove water tube guide an...

Page 417: ...from driveshaft It may be necessary to use a punch and hammer to drive impeller upward on driveshaft In extreme cases it may be necessary to split hub of impeller with a hammer and chisel 8 Once impeller is removed remove impeller drive key from driveshaft 9 Remove water pump face plate and both gaskets one above and below face plate from water pump base 10 Using 2 pry bars positioned and padded a...

Page 418: ...aft in a horizon tal position 2 Use Shift Shaft Bushing Tool 91 31107 to unthread shift shaft bushing DO NOT re move bushing from shift shaft at this time 3 Bend retainer nut lock tab out of retainer nut recess 51865 c d 51882 a b a Shift Shaft Bushing Tool 91 31107 b Shift Shaft Bushing c Punch d Tab of Tab Washer 4 Remove gear housing retainer nut with Retainer Nut Tool 91 61069 5 After retainer...

Page 419: ... carrier alignment key will come out with it 51867 a b c a Long Puller Jaws 91 46086A1 b Puller Bolt 91 85716 c Thrust Hub IMPORTANT Prior to removal of shift shaft from gear housing recheck that gear housing is in neutral position 7 With gear housing in neutral pull shift shaft out of gear housing If necessary use a pliers to pull shift shaft out of gear housing If pliers are used to pull shift s...

Page 420: ...tall shift shaft and rotate shift shaft to neu tral position Remove shift shaft then remove propeller shaft as instructed in Step 8 immediately preceding b Push propeller shaft back into place against reverse gear Slide bearing carrier back into gear housing to support propeller shaft Place gear hous ing on its left side viewed from rear and strike upper leading end of gear housing with a rubber m...

Page 421: ...essed air 2 Bearing carrier propeller shaft needle bearing condition is determined by propeller shaft bearing surface condition See Propeller Shaft Inspection DISASSEMBLY BEARING CARRIER 1 Remove thrust bearing and thrust washer from bearing carrier 2 If thrust bearing thrust washer or thrust bearing surface on propeller shaft shows signs of rust pitting or blueing from lack of lubricant component...

Page 422: ...for pitting grooves scoring uneven wear or discoloration bluish color from overheating Replace shaft and correspond ing needle bearing if any of the above conditions are found Bearing carrier needle bearing contacts propeller shaft just in front of oil seal surface Reverse gear bearing contacts propeller shaft in front of sliding clutch splines 4 Inspect propeller shaft splines for wear and or cor...

Page 423: ...ft cam from cam follower 2 Insert a thin blade screwdriver or awl under first coil of cross pin retainer spring and rotate propeller shaft to unwind spring from sliding clutch DO NOT overstretch spring 51875 a a Cross Pin Retainer Spring CAUTION Detent pin is free and can fall out of sliding clutch Care MUST BE taken not to lose pin 3 Detent pin is free and can be removed from sliding clutch at th...

Page 424: ...Clutch Jaws c Forward Gear Clutch Jaws 7 Pull cam follower and clutch actuator rod out of propeller shaft DO NOT force cam follower up or down or side to side when pulling from propeller shaft 8 Once cam follower and clutch actuator rod are removed from propeller shaft lift rod out of cam follower 9 Check condition of cam follower If it shows wear pitting scoring or rough surface replace cam follo...

Page 425: ...lutch teeth are worn sliding clutch should be replaced also 3 Inspect forward gear teeth for full tooth contact chips pits and signs of rust If forward gear teeth are damaged pinion gear must be inspected and replaced if necessary 4 Inspect forward gear hub for signs of pitting rust scoring or discoloration blueing due to lack of lubricant 5 Remove thrust bearing and spacer shim Inspect thrust bea...

Page 426: ...nt If thrust roller bearing must be replaced the bearing surfaces on the thrust washer and propeller shaft where the thrust roller bearing rides should also be in spected for signs of wear 55090 c d e 55089 a b a Thrust Washer b O Ring hidden c Thrust Bearing d Thrust Washer e Bearing Adaptor 8 The forward gear bearing should be carefully inspected for smoothness of movement pits rust or signs of ...

Page 427: ...prevent damage to gear housing 4 Use a socket and flex handle on Driveshaft Holding Tool to loosen pinion nut Remove pinion nut and Driveshaft Holding Tool 5 Remove gear housing from vise and reposition it as shown Be sure to use soft jaw vise covers and clamp as close as possible to water pump studs 6 Place a block of wood on gear housing mating surface Use a mallet and carefully tap gear housing...

Page 428: ...re not to drop shaft 51866 10 Remove 18 loose needles from outer race of driveshaft needle bearing 11 If inspection of driveshaft needle bearing surface determines that replacement of needle bearing is required the 18 loose needle bearings previously removed must be reinstalled in bearing race to provide surface for mandrel to drive against NOTE Reverse gear must be removed first before removing d...

Page 429: ...o crankshaft splines for wear Replace driveshaft if wear is exces sive 5 Inspect tapered bearing race for pitting grooves scoring uneven wear and discolor ation from overheating Replace tapered bearing and race as a set if any of the pre ceding conditions are found 6 Inspect driveshaft for groove s where water pump base oil seals contact shaft Re place driveshaft if groove s are found Reverse Gear...

Page 430: ... Gear Bearing Adaptor d Bolt 91 31229 e Nut 91 11 24156 f Guide Plate 91 816243 g Washer 91 34961 h Puller Head from Slide Hammer Puller Kit 91 34569A1 i Jaws 91 816242 CLEANING AND INSPECTION CAUTION DO NOT spin bearings dry with compressed air as this could cause bearing to score 1 Clean reverse gear and bearing with solvent and dry with compressed air DO NOT spin the bearing 2 Inspect gear teet...

Page 431: ...rings or the bearing surface of the pro peller shaft is pitted grooved worn unevenly discolored from overheating or has em bedded particles replace the propeller shaft and needle bearing in the reverse gear a a Reverse Gear Needle Bearing Contact Area 5 If reverse gear needle bearing is found to be damaged place reverse gear in a press and use mandrel 91 63569 to press bearing out of gear 50778 a ...

Page 432: ...ed prior to installation of reverse gear 1 Apply a thin coat of Quicksilver 2 4 C w Teflon Lubricant to driveshaft needle bearing bore in gear housing 2 By way of propeller shaft cavity place needle bearing in driveshaft bore with num bered side of bearing facing up driveshaft bore 3 Install and seat needle bearing with the following tools Puller Rod 91 31229 Nut 91 24156 Pilot 91 36571 Plate 91 2...

Page 433: ...or a b c a Suitable Mandrel b Forward Gear Bearing c Bearing Adaptor PROPELLER SHAFT NEEDLE ROLLER BEARING AND OIL SEAL INSTALLATION 1 Using mandrel 91 15755 press bearing carrier needle bearing number side up into bearing carrier until mandrel shoulder contacts bearing carrier 51881 a b c d a Mandrel 91 15755 b Bearing Carrier Needle Bearing c Bearing Carrier d Shoulder 2 Apply Loctite 271 92 809...

Page 434: ...g carrier 51881 a b c d a Inner Seal b Mandrel 91 31108 c Bearing Carrier d Mandrel Shoulder 4 With seal lip facing towards mandrel press outer seal using short end of mandrel 91 31108 into bearing carrier until mandrel shoulder bottoms out on bearing carrier 51881 a b c d a Outer Seal b Mandrel 91 31108 c Bearing Carrier d Mandrel Shoulder 5 Lubricate both seal lips with 2 4 C w Teflon Marine Lub...

Page 435: ...ows 2 Place reverse gear roller bearing NUMBER LETTERS UP in press Using suitable mandrel press bearing cup adapter onto reverse gear bearing e f g 51883 a b c d a Reverse Gear Teeth b Mandrel 91 86943 c Propeller Shaft Needle Bearing d Shoulder e Mandrel f Bearing Cup Adapter g Reverse Gear Roller Bearing IMPORTANT The appearance of the forward and reverse gear is almost identical There are two w...

Page 436: ...sh adding 0 001 in 0 025 mm shims will reduce the gear backlash by approximately 0 001 in 0 025 mm Subtracting 0 001 in 0 025 mm shims will increase backlash by approximately the same amount Example 1 if backlash is too high Backlash checks subtract middle of specification You get add this quantity of shims 0 045 in 0 025 in 0 020 in 1 14 mm 0 64 mm 0 51 mm Example 2 if backlash is too low Backlas...

Page 437: ...ATS in gearcase DO NOT OVER SEAT the adaptor as the reverse gear bearing will be damaged As bearing adaptor begins to seat the effort required to turn screw will increase considerably 55100 a b c d e f a Reverse Gear b Pilot Ring 91 18603 c Driver Tool 91 18605 d Inner Ledge e Retainer 91 18604 f Screw 10 18602 6 After reverse bearing adaptor is seated remove screw retainer driver tool pilot ring ...

Page 438: ...until seated 50064 a b c d e a Used Pinion Nut b Driveshaft c Tapered Bearing d Old Bearing Inner Race e Universal Puller Plate 5 Position pinion gear in gear housing below driveshaft bore with teeth of pinion gear meshed with teeth of reverse gear 6 Insert driveshaft into driveshaft bore while holding pinion gear Rotate driveshaft to align and engage driveshaft splines with pinion gear splines Co...

Page 439: ...ol 91 43506 10 Use a socket and breaker bar to hold pinion nut pad area where flex handle will con tact gear housing while torquing nut 11 Place Driveshaft Holding Tool 91 34377A1 over crankshaft end of driveshaft Torque pinion nut to 75 Ib ft 101 5 Nm a b a c c d a Driveshaft Holding Tool 91 34377A1 b Torque Wrench Torque Nut to 75 lb ft 101 5 Nm c Socket d Breaker Bar IMPORTANT Wipe any excess L...

Page 440: ...er shoulder 2 Install Bearing Preload Tool 91 14311A1 over driveshaft in sequence shown NOTE Bearing Preload Tool 91 44307A1 may also be used Follow instructions pro vided with tool for proper installation a b c d e f g h g a Adaptor b Bearing c Washer d Spring e Nut thread nut all the way onto bolt f Bolt g Set Screw h Sleeve holes in sleeve must align with set screws 3 Align adaptor on driveshaf...

Page 441: ...ied with tool 8 Determine pinion gear depth by inserting a feeler gauge thru access slot in pinion gear shimming tool 9 Clearance between shimming tool and pinion gear should be 0 025 in 0 64 mm 10 If clearance is correct leave Bearing Preload Tool on driveshaft for Determining Forward Gear Backlash following 11 If clearance is not correct add or subtract shims at location shown to raise or lower ...

Page 442: ...ead Retainer 91 18604 into gear case cover nut threads 4 Torque Screw 91 18602 to 45 Ib in 5 Nm against driver tool 51884 a b c d e a Driver Tool 91 18605 b Pilot Ring 91 18603 c Inner Ledge d Retainer 91 18604 e Screw 91 18602 Torque to 45 lb in 5 Nm 5 Thread stud adapter from Bearing Preload Tool 91 14311A1 all the way onto stud 6 Install Backlash Indicator Tool 91 78473 Dial Indicator Holder 91...

Page 443: ...ter NOTE If reverse gear backlash is not within specifications then gear case is not properly assembled or component s within gear case are excessively worn and must be replaced before returning gear case to service 10 Remove Driver Tool Pilot Ring Retainer and Screw from gear case Forward Gear DETERMINING FORWARD GEAR BACKLASH 1 Install a load washer 12 37429 over a 44 93003 propeller shaft so th...

Page 444: ... 135 5 N m to seat forward gear assembly in gear case NOTE Drill a 3 8 in 22 2 mm diameter hole through the side PROPELLER NUT END of a 5 in x 2 in 127 mm x 50 8 mm long piece of PVC pipe A screwdriver may be inserted thru pipe into propeller shaft splines to prevent PVC pipe from turning while tightening re taining nut 6 Install a 5 in x 2 in 127 mm x 50 8 mm long piece of PVC pipe obtain locally...

Page 445: ...gs and thus provide the most accurate backlash readings 9 If not previously installed a Thread stud adaptor from bearing preload tool 91 44307A1 all the way onto stud b Install Backlash Indicator Tool 91 78473 Dial Indicator Holder 91 89897 Dial Indicator 91 58222A1 10 Position dial indicator pointer on line marked 1 on BACKLASH INDICATOR TOOL if gear ratio is 1 87 1 15 teeth on pinion gear or on ...

Page 446: ...ool Dial Indi cator Backlash Indicator Tool Dial Indicator Holder PVC pipe forward gear assem bly bearing adaptor bearing carrier and test propeller shaft can all be removed from the gear case Propeller Shaft Forward Gear Bearing Adapter Bearing Carrier REASSEMBLY 1 Position sliding clutch onto propeller shaft GROOVED RINGS are for manufactur ing purposes only and may be positioned towards either ...

Page 447: ...h propeller shaft 51875 a b c d e a Cam Follower b Clutch Actuator Rod c Propeller Shaft d Cross Pin Slot e Clutch Propeller Shaft 4 Insert cross pin through sliding clutch propeller shaft and actuator rod forcing cross pin tool out 51875 a a Cross Pin 5 Apply a small amount of 2 4 C w Teflon Marine Lubricant 92 90018A12 to the rounded end of detent pin Position detent pin in detent pin hole of sl...

Page 448: ...Teflon Marine Lubricant 92 90018A12 9 Place shift cam into cam pocket of cam follower with numbered side of cam facing up 10 Slide propeller shaft assembly into reverse gear assembly 55096 55095 d e a b c a Cam Pocket b Cam Follower c Shift Cam d Shift Cam Position as Shown e Gear Housing 11 Apply a light coat of 2 4 C w Teflon to the threads of the shift shaft bushing 12 Insert shift shaft down s...

Page 449: ...c d a 55220 50782 a Shim b Bearing Adaptor c Thrust Washer d Thrust Bearing 15 Insert Forward Gear Installation Tool 91 815850 into forward gear bearing adaptor assembly 16 Install tool with adaptor assembly over propeller shaft and into gear housing Applying downward pressure to bearing adaptor remove installation tool from assembly 55202 55221 a b c a Forward Gear Installation Tool 91 815850 b F...

Page 450: ...ust race 55108 55107 a b a Thrust Race b Thrust Bearing 19 Install thrust collar with its STEPPED SIDE DOWN toward the small thrust bearing 20 Pull up slightly on the propeller shaft to gain access to the groove on the shaft for the keepers Install the 2 keepers into the groove and lower the propeller shaft 55110 55109 c d e a b a Thrust Collar b Thrust Bearing c Propeller Shaft d Keepers 2 e Thru...

Page 451: ...the second thrust collar 55112 a b c a Thrust Collar b Thrust Bearing c Thrust Collar 23 Apply Quicksilver Super Duty Gear Lubricant to to second small thrust bearing race and install race to the surface inside of the bearing carrier 24 Apply Quicksilver 2 4 C w Teflon Marine Lubricant to bearing carrier O ring Install O ring onto bearing adaptor 55113 50779 a b c a Thrust Race b Bearing Carrier R...

Page 452: ... keyway and install bearing carrier key 29 Place tab washer against bearing carrier 51885 55114 a b a Bearing Carrier b Tab Washer 30 Apply 2 4 C w Teflon to threads of cover nut and install cover nut in gear housing Verify that the word OFF and arrow are visible NOTE Before torquing bearing carrier cover nut gear case should either be mounted in a stand specifically designed for holding gear case...

Page 453: ...llows a Place water pump base on a press b Just before installing each seal apply Loctite 271 on outside diameter of oil seal c With a suitable mandrel press the smaller diameter oil seal into pump base with lip of oil seal toward impeller side of base d With a suitable mandrel press the larger diameter oil seal into pump base with lip of oil seal toward gear housing side of base e Wipe any excess...

Page 454: ... face plate are indexed by dowel pin location and must be in stalled correctly b c a 51868 a b c a Gasket Water Pump Base to Face Plate b Face Plate c Gasket Face Plate to Water Pump Cover 6 Place impeller drive key on flat of driveshaft Hold key on driveshaft with a small amount of Quicksilver 2 4 C w Teflon Marine Lubricant 92 90018A12 IMPORTANT When completing gear housing repair that requires ...

Page 455: ...ter pump cover to aid in removal of insert fill holes with RTV Sealer or equivalent Allow to cure 24 hours prior to operating engine 9 Install water tube seal into pump cover Plastic side of seal goes into cover first 10 Reinstall water tube guide into water pump cover 11 Apply a light coat of Quicksilver 2 4 C w Teflon Marine Lubricant to inside of water pump insert 12 Position assembled water pu...

Page 456: ... and remove spark plugs from engine before installing gear housing onto driveshaft housing 1 Tilt engine to full up position and engage the tilt lock lever 2 Apply a light coat of Quicksilver 2 4 C w Teflon Marine Lubricant onto driveshaft splines CAUTION DO NOT allow lubricant on top of driveshaft Excess lubricant that is trapped in clearance space will not allow driveshaft to fully engage with c...

Page 457: ...ywheel clockwise viewed from top propeller shaft should rotate clock wise b Place guide block anchor pin into NEUTRAL position Propeller shaft should ro tate freely clockwise counterclockwise c Place guide block anchor pin into REVERSE gear position Rotate flywheel clock wise viewed from top propeller shaft should rotate counterclockwise IMPORTANT If shifting operation is not as described precedin...

Page 458: ...r shaft until nut is recessed into tab washer 7 After propeller nut is recessed into tab washer tighten nut securely minimum of 55 Ib ft 74 5 Nm torque 8 Bend 3 of the tabs of tab washer down in grooves of rear thrust hub to secure propeller nut If tab washer tabs do not align with slots continue to tighten propeller nut to ob tain alignment DO NOT loosen nut to align tabs CAUTION DO NOT misinterp...

Page 459: ...allation 7 28 Maintenance Instructions 7 31 Clevis Attaching Kit Installation A 70599A2 7 32 Installation Instructions 7 32 Maintenance Instructions 7 32 Ride Guide Steering Cable Attaching Kit Installation 92876A1 Single Cable Refer to Quicksilver Accessories Guide to determine correct length of steering cable and remote control cables IMPORTANT Steering cable and remote control cables must be th...

Page 460: ...nylon insert locknut c Part Number 11 34863 First torque bolt a to 20 lb ft 27 Nm then torque locknut c to 20 lb ft 27 Nm High Performance Outboards An access hole is provided through the bottom cowl to ease installation of the link rod connecting bolt Remove the BACK plug for installa tion and reinstall after installation a b d c WARNING After installation is complete and before operating outboar...

Page 461: ...assembled or if steering effort has increased Lubricate with 2 4 C w Teflon 28169 a a b c d a a c b d Ride Guide Steering Cable Attaching Kit Installation 92876A3 Dual Cable Single Outboard WARNING Quicksilver Super Ride Guide Steering dual cables MUST BE USED with this at taching kit Failure to adhere to this requirement could result in steering system failure Refer to Quicksilver Accessories Gui...

Page 462: ...x head end of bolts is on the inside of boat transom Super Ride Guide Steering Kit Installation IMPORTANT Both gear racks or rotary steering heads must be installed so that both steering cables will be routed together on the same side of the boat and will push and pull together 1 Install Super Ride Guide Steering Kit in accordance with instructions included with Super Ride Guide Kit 2 Make sure th...

Page 463: ...inst Flats on Each Bolt WARNING Locking retainer corner tabs MUST BE bent up and against flats on each bolt that secures mounting bracket for steering cable mounting tube to outboard swivel bracket to prevent bolts from turning out Install steering cable mounting tube into mounting bracket with 2 adjusting nuts and 2 locking tab washers Verify longer threaded end of tube is toward starboard side o...

Page 464: ...r 2 4 C w Teflon Verify rubber O ring seal a located in outboard tilt tube is lubricated a 51890 a Insert steering cable ends a thru outboard tilt tube b and cable mounting tube c Thread steering cable attaching nuts d on to tubes hand tight NOTE Torque steering cable attaching nuts only after final steering adjustments have been made 51891 a b d c Place a mark a on steering cable mounting tube b ...

Page 465: ...BE tightened as specified Lubricate hole in steering coupler with Quicksilver 2 4 C w Teflon Assemble steering link rod to steering coupler using 2 flat washers one each side of coupler and nylon insert locknut Tighten locknut until it seats DO NOT exceed 120 Ib in 13 5 Nm 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 outbo...

Page 466: ...oo tight read just tube toward end of steering cable or if too much slack play exists in system readjust tube away from end of steering cable Tighten nuts against mounting bracket and read just if necessary 51887 b a c d a Steering Cable Mounting Tube b Adjustment Nuts c Adjust Tube in This Direction to Remove Slack from Steering System d Adjust Tube in This Direction to Reduce Tension from Steeri...

Page 467: ...em components for wear Replace worn parts 2 Check steering system fasteners to be sure that they are torqued to correct specifica tions NOTE Ride Guide Steering Cables are lubricated at the factory and require no additional lubrication at initial installation WARNING Core of each steering cable transom end must be fully retracted into cable hous ing before lubricating cable If cable is lubricated ...

Page 468: ...ts to connect both outboards to Ride Guide Steering Cables for 23 1 2 in thru 27 1 2 in 597 mm thru 699 mm outboard centerline spacing If outboard centerline distance is other then specified refer to end of this instruction man ual for optional extension couplers DETERMINE ROUTING OF STEERING CABLES Use 1 or 2 following to route steering cables 1 Parallel cable routing Cables routed together down ...

Page 469: ...ions included with Super Ride Guide Kit 2 Make sure that both gear racks or rotary steering heads are installed so that both steering cables are routed together and will push and pull together a b b a a Straight Rack Left Rotary Steering Right b Steering Cables Install so that Both Cables Will Push and Pull Together STEERING CABLE INSTALLATION STARBOARD OUTBOARD IMPORTANT Mounting bracket for stee...

Page 470: ...same dis tance as the outboard tilt tube Do not tighten adjustment nuts at this time 51891 a b c d a Steering Cable Mounting Tube End of Tube with Longer Threads Toward Starboard Side of Boat b Mounting Bracket c Locking Tab Washers 2 d Adjustment Nuts Flats of Nuts Facing Toward Locking Tab Washer IMPORTANT Lubricate inside of steering cable mounting tube with 2 4 C w Teflon before installing ste...

Page 471: ...LE INSTALLATION PORT OUTBOARD IMPORTANT Lubricate inside of port outboard s tilt tube and rubber O ring seal lo cated inside tilt tube with 2 4 C w Teflon before installing steering cable Lubricate inside of port outboard s tilt tube and rubber O ring seal a with 2 4 C w Teflon 51890 a Insert steering cable end b thru tilt tube c of port outboard and thread steering cable attaching nut d onto tilt...

Page 472: ... Off 1 4 Turn c Special Washer Head Bolt 10 14000 Torque to 20 lb ft 27 Nm d Nylon Insert Locknut Torque to 20 lb ft 27 Nm e Steering Link Rod f Steering Cable End Lubricate holes in ends of steering cables with Quicksilver 2 4 C w Teflon Marine Lubri cant Assemble steering link rods to steering cable ends of each outboard using flat washers and nylon insert locknuts Tighten locknuts until they se...

Page 473: ...ing arm extensions MUST BE equal to distance between propeller shaft centerlines Lubricate inside of rubber sleeves with 2 4 C w Teflon and slide sleeves on steering cou pler Work rubber bushings onto threaded ends of steering eyes Thread jam nut on starboard steering eye Thread steering eyes equally into coupler so that distance between hole centers of steer ing eye ball joints is equal to distan...

Page 474: ...eye and turn eye in or out to correct alignment Torque special washer head bolts to 20 Ib ft 27 Nm then torque locknuts to 20 Ib ft 27 Nm WARNING Both steering eyes MUST BE threaded into coupler 3 4 in 19 mm minimum and jam nut must be tightened against coupler to prevent coupler from turning Torque jam nut to 20 Ib ft 27 N m Tighten jam nut against coupler Torque jam nut to 20 Ib ft 27 Nm Spray Q...

Page 475: ...m is too tight read just tube toward end of steering cable or if too much slack play exists in system readjust tube away from end of steering cable Tighten nuts against mounting bracket and read just if necessary 51887 b a c d a Steering Cable Mounting Tube b Adjustment Nuts c Adjust Tube in This Direction to Remove Slack from Steering System d Adjust Tube in This Direction to Reduce Tension from ...

Page 476: ...cordance with instructions included with Super Ride Guide Kit STEERING CABLE INSTALLATION STARBOARD OUTBOARD IMPORTANT Mounting bracket for steering cable mounting tube MUST BE secured to outboard swivel bracket using 5 8 in 16 mm long bolts supplied with this dual cable dual outboard attaching kit Secure mounting bracket for steering cable mounting tube onto swivel bracket of star board outboard ...

Page 477: ...TANT Lubricate inside of steering mounting tube with 2 4 C w Teflon 92 825407A12 before installing steering cable Lubricate inside of steering cable mounting tube starboard outboard with 2 4 C w Teflon Insert steering cable end a steering cable routed down port side of boat thru cable mounting tube b and thread steering cable attaching nut c onto tube hand tight NOTE Torque steering cable attachin...

Page 478: ...ng cable attaching nut d onto tilt tube hand tight NOTE Torque steering cable attaching nut only after final steering adjustments have been made 51887 b c d STEERING LINK ROD INSTALLATION WARNING Steering link rods MUST BE secured between outboard steering arm and steering cable end using special washer head bolt 10 14000 and two nylon insert lock nuts 11 34863 as shown Both special washer head bo...

Page 479: ...rt locknuts as shown Torque special bolts to 20 lb ft 27 Nm then torque locknuts to 20 Ib ft 27 Nm 50061 28165 a b f e a c e d a a b c d e f b f d c e a Flat Washer 2 Each Link Rod b Nylon Insert Locknut Torque Until it Seats DO NOT Exceed 120 lb in 13 5 Nm of Torque Then Back Off 1 4 Turn c Special Washer Head Bolt 10 14000 Torque to 20 lb ft 27 Nm d Nylon Insert Locknut Torque to 20 lb ft 27 Nm ...

Page 480: ...ing arm extensions MUST BE equal to distance between propeller shaft centerlines Lubricate inside of rubber sleeves with 2 4 C w Teflon and slide sleeves on steering cou pler Work rubber bushings onto threaded ends of steering eyes Thread jam nut on starboard steering eye Thread steering eyes equally into coupler so that distance between hole centers of steer ing eye ball joints is equal to distan...

Page 481: ... and turn eye in or out to correct alignment Torque special washer head bolts to 20 Ib ft 27 Nm then torque locknuts to 20 Ib ft 27 Nm WARNING Both steering eyes MUST BE threaded into coupler 3 4 in 19 mm minimum and jam nut must be tightened against coupler to prevent coupler from turning Torque jam nut to 20 Ib ft 27 Nm Tighten jam nut against coupler Torque jam nut to 20 Ib ft 27 Nm Spray Quick...

Page 482: ...Cable Mounting Tube b Adjustment Nuts c Adjust Tube in This Direction to Remove Slack from Steering System d Adjust Tube in This Direction to Reduce Tension from Steering System After steering system tension is adjusted correctly tighten adjustment nuts against mounting bracket to a torque of 35 Ib ft 47 5 Nm and bend a tab lock washer against a flat on each nut 51887 c c a b a Steering Cable Moun...

Page 483: ...sary adjust trim tab as follows a Shift outboard into NEUTRAL and make sure ignition key is at OFF position b Remove plastic cap from rear of driveshaft housing and loosen bolt and trim tab IMPORTANT Trim tabs MUST BE set in the same position on both outboards c If boat pulls to the right adjust trailing edges of both trim tabs to the right If boat pulls to the left adjust trailing edges of both t...

Page 484: ...tion 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 specifica tions NOTE Ride Guide Steering Cables are lubricated at the factory and require no additional lubrication at initial installation WARNING Core of each steering cable transom end must b...

Page 485: ...Authorized Dealer or whenever steering mount and or steering head are disassembled or if steering effort has increased Lu bricate with 2 4 C w Teflon 28168 a a b c d a a b c d Lubrication Points for Parallel Cable Routing Installations 28175 a a a a b c d b c d Lubrication Points for Opposite Side Cable Routing Installations a Grease Fittings b Cable Ends c Pivot Points d Ball Joints ...

Page 486: ...x 2 1 2 in 9 5 mm x 63 5 mm bolt flat washer and locknut as shown in Figure 1 Torque locknut to 20 Ib ft 27 Nm a b c d e f g h i j k l Figure 1 a Ride Guide Cable b Ride Guide Yoke c Pivot Block d Pivot Spacer e 15 in 381 mm Centerline of Attaching Kit Pivot to Centerline of Outboard f Pivot Attaching Locknut Torque to 20 lb ft 27 Nm g Outboard Steering Arm h Clevis Kit i Ride Guide Cable Attachin...

Page 487: ...Yoke Attaching Locknut Torque to 10 lb ft 13 5 Nm Then Back Off 1 4 Turn e 2 3 8 in 60 3 mm Maximum Transom Thickness f Bolt 7 16 in x 1 3 4 in 11 1 mm x 44 5 mm g Ride Guide Yoke 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...

Page 488: ...es in transom bracket as a guide and drill three 11 32 in 8 7 mm holes thru transom 7 Use a marine type sealer on three 5 16 in x 3 1 4in 7 9mm x 82 6mm bolts Secure attaching kit to transom using transom backing plate 3 bolts with sealer and 3 lock nuts installed as shown in Figure 2 Torque lock nuts to 10 Ib ft 13 5 Nm STEERING CABLE INSTALLATION 1 Lubricate steering cable end with Quicksilver 2...

Page 489: ...area is considered Severe Service CAUTION Core of steering cable must be fully retracted into cable housing when lubricating cable If cable is lubricated while extended hydraulic lock of cable could occur 1 Lubricate outboard end of Ride Guide steering cable thru grease fitting if equipped next to cable attaching nut with Quicksilver 2 4 C w Teflon NOTE Ride Guide steering cable is lubricated at t...

Page 490: ...ngine Steering Arm j Clevis to Engine Locknut Torque to 20 lb ft 27 Nm 3 Lubricate spacer supplied with this kit with 2 4 C w Teflon 4 Attach clevis to top of outboard steering arm with a 3 8 in x 1 1 4 in 9 5 mm x 31 8 mm bolt thin washer spacer thick washer thick washer must be installed between clevis and steering arm and locknut as shown Torque bolt item e to 20 Ib ft 27 Nm then torque locknut...

Reviews:

No comments