Mariner 30 JET 40 (4 CYL) Service Manual Download

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7A-0 - OUTBOARD MOTOR INSTALLATION/ATTACHMENTS

90-814676R1 DECEMBER 1996

Table of Contents

Page

Installing Outboard Motor on Transom

7A-1

. . . . . .

Determining Recommended Outboard

Mounting Height

7A-1

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

Locate Centerline of Boat Transom

7A-1

. . . . . .

Drilling Outboard Mounting Holes

7A-2

. . . . . . . .

Lifting Outboard

7A-2

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

Securing Outboard to Boat Transom

7A-3

. . . . .

Securing Outboard to Boat Transom Using

Optional Outboard Mounting Kit (P/N
812432A1)

7A-3

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

Single Cable - Single Outboard Ride Guide Steer-

ing Attaching Kit (P/N 19608A3 and P/N
19609A2) Installation

7A-4

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

Component Removal - Tiller Handle

Models

7A-4

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

Steering Bracket Installation - Tiller Handle

Models

7A-4

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

19608A-3 Ride Guide Steering Attaching Kit

Installation – Steering Cable Routed for Star-
board Entry into Outboard Tilt Tube

7A-4

. . . .

Installing Ride Guide Cable to Outboard Tilt

Tube

7A-4

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

Installing Steering Link Rod

7A-5

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

19609A-2 Ride Guide Steering Attaching Kit

Installation - Steering Cable Routed for Port
Entry into Outboard Tilt Tube

7A-6

. . . . . . . . . .

Tilt Tube Reversal

7A-6

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

Installing Ride Guide Cable to Outboard Tilt

Tube

7A-6

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

Installing Steering Link Rod

7A-7

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

Maintenance Instructions

7A-7

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

Single Cable - Dual Outboard Ride Guide Steering

Kit (P/N 97933A4) Installation

7A-8

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

Installation Requirements

7A-8

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

Steering Cable Installation - Cable Routed

Down Starboard Side of Boat to Port
Outboard

7A-9

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

Installing Steering Link Rod

7A-9

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

Steering Cable Installation - Cable Routed

Down Port Side of Boat to Starboard
Outboard

7A-10

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

Tilt Tube Reversal

7A-10

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

Installing Steering Cable

7A-10

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

Installing Steering Link Rod

7A-11

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

Maintenance Instructions

7A-11

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

Steering Coupler Assembly

7A-12

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

Steering Coupler Installation

7A-13

. . . . . . . . . . .

Ride-Guide Steering Attachment Extension

Couplers

7A-14

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

Trim Tab Adjustment

7A-14

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

Dual Outboard

7A-14

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

Maintenance Instructions

7A-14

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

Page

Transom Mounted Ride Guide Attaching Kit

Installation (73770A1)

7A-15

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

Attaching Kit Installation

7A-15

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

Clevis Attaching Kit Installation

(P/N 70599A4)

7A-16

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

Installation Instructions

7A-16

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

Maintenance Instructions

7A-17

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

Steering Cable Installation

7A-18

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

Maintenance Instructions

7A-18

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

Selecting Steering Cable and Remote Control

Cables

7A-19

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

Remote Control Installation

7A-19

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

Shift Cable Installation and Adjustment to

Engine

7A-19

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

Throttle Cable Installation and Adjustment to

Engine

7A-20

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

Connecting Remote Control Wiring Harness

to Engine Wiring Harness
(Electric Start Models)

7A-21

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

Power Trim Wiring Connections (Models So

Equipped)

7A-22

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

Battery Connections

7A-22

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

Connecting Remote Control Stop Switch

Wiring to Engine Wiring
(Manual Start Models)

7A-23

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

Summary of Contents for 30 JET 40 (4 CYL)

Page 1: ...DELS United States 0C159200 and Above Belgium 9570305 and Above Canada 0A748269 and Above With Serial Numbers SERVICE MANUAL 30 JET 40 4 CYL Printed in U S A 1996 Mercury Marine 90 814676R1 DECEMBER 1996 ...

Page 2: ...ach method We have not under taken any such wide evaluation Therefore anyone who uses a service procedure and or tool which is not recommended by the manufacturer first must completely satisfy himself that neither his nor the products safety will be endangered by the service procedure selected All information illustrations and specifications con tained in this manual are based on the latest produc...

Page 3: ...repair procedure This is considered standard shop practice even if not specif ically stated Whenever components are removed for service they should be retained in order At the time of instal lation they should be installed in the same locations and with the same mating surfaces as when re moved Personnel should not work on or under an outboard which is suspended Outboards should be attached to wor...

Page 4: ...tem C Timing Synchronizing Adjustment D Wiring Diagrams Section 3 Fuel System Carburetion Section 4 Powerhead Section 5 Mid Section A Clamp Swivel Bracket Drive Shaft Housing B Power Trim Design I C Power Trim Design II D Power Trim Design III E Power Trim Design IV F Manual Tilt System Design I II III G Manual Tilt System Design IV Section 6 Lower Unit A Lower Unit B Jet Drive Section 7 Outboard ...

Page 5: ...1 50332 IMPORTANT INFORMATION GENERAL INFORMATION and SPECIFICATIONS ...

Page 6: ...ns 1 6 Boat Test Chart Example 1 7 Lubrication Points 1 8 Ride Guide Steering Cable and Pivot Points Lubrication 1 9 Gear Housing Lubrication 1 10 Salt Water Corrosion Gear Housing Bearing Carrier and Cover Nut 1 10 Periodic Inspection 1 11 Flushing Outboard Cooling System 1 11 Following Complete Submersion 1 12 Salt Water Submersion Special Instructions 1 12 Submerged While Running Special Instru...

Page 7: ... divided into SECTIONS shown right which represents major components and systems Some SECTIONS are further divided into PARTS Each PART has a title page A Table of Contents for the particular PART is printed on the back of the title page SECTIONS and PARTS are listed on the Service Manual Outline sheet which immediately follows the cover of this book Section Section Heading 1 2 3 4 5 6 7 8 Importa...

Page 8: ...tboard Weight ELPTO 192 lbs 87kg Carburetion 2 Carburetors Center Bowl Recommended Gasoline Any leaded or unleaded lead free gasoline with a minimum posted octane rating of 86 research octane number 90 Remote Fuel Tank Capacity U S Gallons Imperial Gallons Liters 6 6 5 5 25 Recommended Oil Quicksilver 2 Cycle Outboard Oil Gasoline Oil Ratio 50 1 Oil Tank Capacity 0 935 gal 3 54 Liters Maximum Oper...

Page 9: ...perating with a damaged propeller or a dirty boat bottom or gear housing will cause an RPM loss d Operation with an increased load additional passengers equipment pulling skiers etc Propeller Installation WARNING If the propeller shaft is rotated while the engine is in gear there is the possibility that the engine will crank over and start To prevent this type of accidental engine starting and pos...

Page 10: ...ng characteristics Water test the boat not using the trim adjustment pin If undesirable and or unsafe steering conditions are experienced boat runs with nose down install trim adjustment pin in proper hole to prevent unsafe han dling characteristics 50157 Power Trim System Models with Power Trim General Information The power trim system is filled at the manufacturer and is ready for use Trim outbo...

Page 11: ...nd aft position you can expect the following results Trimming Outboard Out Up Characteristics WARNING Excessive trim out also may reduce the stabil ity of some high speed hulls To correct instabili ty at high speed reduce the power GRADUALLY and trim the outboard In slightly before resum ing high speed operation Rapid reduction in power will cause a sudden change of steering torque and may cause a...

Page 12: ...cruising speed the outboard should be trimmed to obtain a balanced steering condition While trimming steering loads will vary and will pull in one direc tion until a balanced condition has been attained If the outboard is trimmed past the balanced steering condition the steering wheel tiller han dle then will have a tendency to pull in the oppo site direction Excessive trimming past the bal anced ...

Page 13: ...should be made to as sure a good average 6 Prop break loose sudden higher RPM if not excessive in some cases can be beneficial dur ing acceleration If undesirable break loose oc curs it can be decreased by trimming the out board further under If it remains excessive with all similar propellers the outboard must be low ered 7 It is suggested that all applicable data be re corded on a chart such as ...

Page 14: ...ut Quicksilver Special Lubricant 101 2 4 C Marine Lubricant After first 20 hours then once in season e r ousi Quic sil er Check and fill after first 10 days then every 30 days Check and fill after first 10 days then every 30 days Gear Housing Quicksilver Gear Lube Drain and refill after 1st 25 hours then after every 100 hours or once a year before storing Drain and refill after 1st 25 hours then a...

Page 15: ... while extended hy draulic lock of cable could occur With core of Ride Guide Steering cable transom end fully retracted lubricate transom end of steering cable thru grease fitting and exposed portion of cable end with Quicksilver 2 4 C Marine Lubricant Lubri cate all pivot points with SAE 30W engine oil 50334 5 6 7 5 Ride Guide Steering Grease Fitting 6 Tilt Tube Grease Fitting 7 Steering Link Rod...

Page 16: ...be confused with the presence of water 6 Presence of water in gear lubricant indicates the need for disassembly and inspection of oil seals seal surfaces O rings water pump gaskets as well as gear housing components for damage IMPORTANT Never add lubricant to gear hous ing without first removing VENT plug as trapped air will prevent housing from being filled Fill gear housing only when outboard is...

Page 17: ...oat propeller shaft with Quicksilver Spe cial Lubricant 101 Anti Corrosion Grease or 2 4 C Marine Lubricant 9 Inspect the outboard surface finish for damage or corrosion Thoroughly clean damaged or cor roded areas and apply matching paint Quicksil ver Spray Paints 10 Check trim tab and galvanic corrosion inhibitor for damage or for deterioration from salt water operation 11 Check remote controls a...

Page 18: ...ft exists If this is the case the powerhead must be disas sembled Submerged Engine Fresh Water Plus Special Instructions 1 Recover engine as quickly as possible 2 Remove cowling 3 Flush exterior of outboard with fresh water to re move mud weeds etc DO NOT attempt to start engine if sand has entered powerhead as power head will be severely damaged Disassemble powerhead if necessary to clean compone...

Page 19: ... 101 Anti Corrosion Grease or 2 4 C Marine Lubricant to propeller shaft and reinstall propeller Refer to Propeller Installation see Table of Contents 10 If the water pickup is clogged the speedometer will be inoperative Clean the pickup with a piece of wire or blow out with compressed air Before blowing out with air disconnect the tubing from the speedometer 11 To prevent freeze damage drain the s...

Page 20: ... or fall day The horsepower that any internal combustion engine produces depends upon the density of the air that it consumes and in turn this density is dependent upon the temperature of the air its barometric pressure and water vapor or humidity content Accompanying this weather inspired loss of power is a second but more subtle loss At rigging time in early spring the engine was equipped with a...

Page 21: ...hness Moss barnacles etc on boat or corrosion of outboard s gear hous ing increase skin friction and cause speed loss Clean surfaces when necessary 3 Gear Housing If unit is left in the water marine vegetation may accumulate over a period of time in certain types of water This growth must be re moved from unit before operation as it may clog the water inlet holes in the gear housing and cause the ...

Page 22: ...r Variation of more than 15 lbs per sq in 103 5 kPa between cylinders indicates that lower com pression cylinder is in some way defective such as worn or sticking piston rings and or scored pis ton and cylinder 6 Compression check is important because an en gine with low or uneven compression cannot be tuned successfully to give peak performance It is essential therefore that improper compres sion...

Page 23: ...sh gear housing with soap and water then rinse 3 Sand blistered area with 3M 180 grit sandpaper or P180 Gold Film Disc to remove paint blisters only Feather edge all broken paint edges 4 Clean gear housing thoroughly with DX 330 wax and grease remover 5 Spot repair surfaces where bare metal is ex posed with DX 503 alodine treatment IMPORTANT Do not use any type of aerosol spray paints as the paint...

Page 24: ...um based solvents to clean application surface Clean entire application surface with mild dish wash ing liquid and water Rinse surface thoroughly with clean water DECAL APPLICATION 1 Mix 1 2 ounce 16 ml of dish washing liquid in one gallon 4 l of cool water to use as wetting solu tion NOTE Leave protective masking if present on the face of decal until final steps of decal installation This will en...

Page 25: ...A 2 54637 ELECTRICAL AND IGNITION IGNITION SYSTEM ...

Page 26: ...0 Test For Spark 2A 12 Running Voltage Output Test 2A 12 Ignition Key Switch Test 2A 13 Mercury Tilt Stop Switch Test 2A 13 Flywheel Removal and Installation 2A 14 Flywheel Removal 2A 14 Manual Start Model 2A 14 Electric Start Model 2A 14 Flywheel Installation 2A 15 Ignition Components 2A 15 Stator Assembly Removal 2A 15 Black Stator Assembly Installation 2A 17 Red Stator Assembly Installation 2A ...

Page 27: ...ywheel likewise has a se cond set of magnets located around the hub As the flywheel rotates the second set of permanent mag nets passes the trigger coils This causes the trigger coils in turn to produce an AC voltage that is con ducted to an electronic switch SCR in the switch box The switch discharges the capacitor voltage into the ignition coil at the correct time and in firing order se quence C...

Page 28: ... Make sure that wire connections are tight and free of corrosion d Check all electrical components that are grounded directly to engine and all ground wires to see that they are grounded to engine e Check for disconnected wires and short and open circuits Checking for Loss of Spark The use of an inductive timing light while cranking or running the engine will show whether there is spark present or...

Page 29: ...VDC Ground 160 200 270 330 160 200 Voltage 1000 RPM 250 300 315 385 315 385 27 33 Switch Box Bias 20 VDC or 40 VDC Ground White Black Switch Box Terminal 2 10 10 30 10 30 Black Yellow Terminal Black Yellow Terminal If using a meter with a built in DVA place selector switch in the DVA 400 VDC position 90 814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION 2A 3 Ignition Troubleshooting Engines With Black...

Page 30: ...R 398 9710A33 398 9710A42 TEST RESULTS Good voltage output Go to STEP 3 Sta tor Low Speed and High Speed Test High voltage output The trigger or switch box is defective Go to Trigger Test and test trigger If trigger tests OK replace switch box and repeat step No voltage output or low voltage output Remove BLK YEL wires from switch box terminal and repeat test If voltage output is now OK either the...

Page 31: ...200 315 385 DCV ACV DVA Stator High Speed 400 VDC Red Sw Box Term Ground 25 90 140 310 Stator High Speed 400 VDC Red Sw Box Term Ground 8 10 165 205 27 33 TEST RESULTS If voltage output is low to either the stator low speed or stator high speed the stator or switch box is defective Go to stator test and test stator If stator tests OK replace switch box and repeat step If voltage output is good to ...

Page 32: ...to locate the problem Test Trigger Page 2A 10 Step 1 Primary Voltage At The Ignition Coils Test Refer to the troubleshooting steps on the following pages RED Stator DVA Test Test Selector Switch Posi tion RED DVA Lead BLACK DVA Lead Voltage 300 RPM Voltage 1000 RPM Voltage 4000 RPM Coil Primary 400 VDC Coil Terminal Coil Terminal 130 Volts Minimum 195 to 275 195 to 275 Stop Circuit 400 VDC Black Y...

Page 33: ... on two coils Go to Trigger Test Good voltage on all coils Go to Testing For Spark STEP 2 Stop Circuit Test DCV ACV DVA BLK YEL a b a Connect Test Lead To BLK YEL Wire Terminal On Switch Box b Connect Test Lead To Engine Ground 1 Use Multimeter DVA Tester 91 99750 Set switch position to 400 DVA 2 Crank engine and observe meter reading Voltage at 300 RPM cranking Voltage at 1000 4000 RPM Running 19...

Page 34: ...module Good voltage output Go to STEP 3 Switch Box BLU WHT Wire Circuit Test No voltage output or low voltage output Go to STEP 5 Stator Adapter Module and Switch Box Test STEP 4 Switch Box BLU WHT Wire Circuit Test DCV ACV DVA BLU WHT a b a Connect Test Lead To BLU WHT Wire Terminal On Switch Box b Connect Test Lead To Engine Ground 1 Use Multimeter DVA Tester 91 99750 Set switch position to 400 ...

Page 35: ...etween BLU WHT wire and engine ground 6 Crank engine and observe meter reading Voltage at 300 RPM cranking 190 to 260 Volts TEST RESULTS If voltage output is good on both wires the switch box is defective Voltage output is low on either wire continue with test 7 Disconnect the GRN WHT and WHT GRN sta tor leads from the adapter module DCV ACV DVA 8 Measure the resistance between the GRN WHT and WHT...

Page 36: ...d replace trigger Ignition Coil Test DCV ACV DVA DCV ACV DVA 1 Disconnect wires from coil terminals 2 Pull spark plug lead out of coil tower 3 Use a VOA meter and perform the following checks Test Leads To Ohm Scale Meter Reading Between and Coil Terminals R x 1 02 04 Ohms Between Coil Tower and Coil Terminal R x 100 800 1100 Ohms The primary DC resistance of these coils generally is less than one...

Page 37: ...r readings are other than specified replace stator Stator Test Black Stator 1 Disconnect all stator leads 2 Use a VOA meter and perform the following checks 9 AMP Stator Test Leads To Ohm Scale Ohm Reading Blue and Blue White R x 1000 5 7 8 0 Red and Red White R x 1 56 76 Blue and Engine Ground R X 1000 No Reading Red and Engine Ground R X 1000 No Reading YEL and YEL R x 1 5 1 0 16 AMP Stator 398 ...

Page 38: ...nders Go to Primary Volt age Test Engine Running Intermittent weak or no spark output on all cylin ders usually indicates a defective trigger Go to Trigger Test Intermittent weak or no spark output on any one cylinder indicates a bad ground defective igni tion coil defective spark plug lead or switch box Go to Ignition Coil Test Primary Voltage Test Engine Running a d b c a Plug into Meter b Attac...

Page 39: ...ontinuity test 3 If meter readings are other than specified in the preceding test verify that switch and not wiring is faulty If wiring checks OK replace switch Mercury Tilt Stop Switch Test 1 Remove mounting screw that secures mercury switch to outboard 2 Connect Ohmmeter R x 1 scale between black lead and black yellow lead or terminal stud on mercury switch 3 Test mercury switch as follows a Pos...

Page 40: ...gnition key is in the OFF posi tion When servicing manual start engines verify lanyard switch is in the OFF position MANUAL START MODEL 1 Remove 3 bolts securing rewind starter and re move rewind from outboard a a Rewind Starter 2 Use strap wrench to hold flywheel while removing flywheel nut and washer 54639 b a a Strap Wrench b Flywheel ELECTRIC START MODEL 1 Remove 3 bolts securing flywheel cove...

Page 41: ...flywheel and or electrical components located under fly wheel when outboard is initially started 1 Secure flywheel on crankshaft with flat washer and nut 2 On electric start type flywheel use flywheel hold er 91 52344 to hold flywheel while tightening flywheel nut On manual start type flywheel use strap wrench to hold flywheel while tightening fly wheel nut 3 Torque flywheel nut to 75 lb ft 101 7 ...

Page 42: ...rews which secure stator to upper cap 54644 b a a Screws b Stator 5 Remove 6 bolts securing electrical box access cover and remove cover 54645 b a a Bolts b Access Cover 6 Disconnect stator wiring from their respective ter minals and remove stator assembly from out board ...

Page 43: ...ctrical box through access holes under warning module 54647 a c b a Warning Module b Stator Wiring to Switch Box c Stator Wiring to Rectifier 4 Reconnect wires to proper terminals Refer to wiring diagrams Section 2D Torque terminal nuts to 30 lb in 3 4 N m 5 Reinstall electrical box access cover 6 Reinstall flywheel as outlined in FLYWHEELRE MOVAL AND INSTALLATION preceding 7 On manual start model...

Page 44: ...ll BLUE and BLUE WHITE cable adapters to BLUE and BLUE WHITE terminals on switch box Torque terminal nuts to 30 lb in 3 5 N m Install cap nuts on unused terminals 54953 c b a c a BLUE Cable Adapter b BLUE WHITE Cable Adapter c Cap Nuts 3 Install adapter module routing adapter wires through opening in upper right corner of electrical box Connect stator adapter module and switch box wires per approp...

Page 45: ...ing with sta straps 54957 a a a b c d e f f g h i a Sta Straps b Adapter Module Hidden c Adapter Module WHITE GREEN Lead d Adapter Module GREEN WHITE Lead e Stator YELLOW Leads f Caps g Adapter Module BLUE Lead h Adapter Module BLUE WHITE Lead i Adapter Module BLACK Lead Torque bolt to 40 lb in 4 5 N m ...

Page 46: ...raps b Adapter Module c Insulator Plug d Stator BLUE WHITE Lead not used e Adapter Module WHITE GREEN Lead f Adapter Module GREEN WHITE Lead g Stator YELLOW Leads h Terminal Block i Harness Extension Secure to Terminal Block w screws retained j Caps k Adapter Module BLUE Lead l Adapter Module BLUE WHITE Leads m Adapter Module BLACK Leads Torque bolt to 40 lb in 4 5 N m ...

Page 47: ...r off end cap and move to the side 5 Remove locknut that secures link rod swivel into spark arm Pull link rod swivel out of arm 54648 a b c d e f a Trigger Plate Assembly b Link Rod Swivel c Spark Arm d Lock Nut e Trigger Harness f Sta Straps 6 Remove 6 bolts from electrical box access cover and remove cover 54645 b a a Bolts b Access Cover 7 Disconnect trigger leads form their respective terminal...

Page 48: ...s Route as Shown 4 Reconnect trigger wires to proper terminals of switch box Refer to wiring diagram Section 2D Torque terminal nuts to 30 lb in 3 4 N m 54649 b a a Trigger Harness b Switch Box 5 Reinstall electrical box access cover and secure cover with 6 bolts 6 Reinstall stator as outlined in STATOR AS SEMBLY INSTALLATION previously 7 Reinstall flywheel as outlined in FLYWHEEL INSTALLATION pre...

Page 49: ...d e a Positive Lead b Negative Lead c High Tension Lead d Coil Tower Boot e Coil Ignition Coil Installation 1 Install spark plug high tension lead coil tower boot assembly retained onto new coil 2 Position secondary coil into electrical box 3 Reconnect positive and negative leads to their respective terminals on coil with 2 nuts Torque nuts to 30 lb in 3 4 N m 4 Reconnect spark plug boot to spark ...

Page 50: ...ch Box Switch Box Installation 1 Secure switch box to electrical component box with 4 bolts and their respective ground leads Torque bolts to 40 lb in 4 5 N m 2 Reconnect leads to switch box terminals Refer to WIRING DIAGRAM SECTION 2D Torque switch box terminal nuts to 30 lb in 3 4 N m 3 Reinstall electrical box access cover and secure cover with 6 bolts 4 Reinstall top cowl ...

Page 51: ...B 2 ELECTRICAL AND IGNITION BATTERY CHARGING SYSTEM and STARTING SYSTEM ...

Page 52: ...t Models Stator Output Test 2B 5 Electric Start Models With Rectifier 2B 5 Electric Start Models With Voltage Regulator Rectifier 2B 6 Rectifier Test 2B 7 Starter System 2B 8 Starter System Components 2B 8 Description 2B 8 Troubleshooting the Starter Circuit 2B 8 Starter Circuit Troubleshooting Flow Chart 2B 9 Starter Removal and Installation 2B 10 Removal 2B 10 Installation 2B 10 Bosch Starter 2B...

Page 53: ...or eyes wash skin immediately with a mild soap Flush eyes with water immediately and see a doc tor WARNING Hydrogen and oxygen gases are produced dur ing normal battery operation or charging Sparks or flame can cause this mixture to ignite and ex plode if they are brought near the battery Sulphuric acid in battery can cause serious burns if spilled on skin or in eyes Flush or wash away immediately...

Page 54: ...d be 1 240 corrected to 80 F indicating a partially charged battery SPECIFIC GRAVITY CELL COMPARISON TEST This test may be used when an instrumental tester is not available To perform this test measure specific gravity of each cell regardless of state of charge and interpret results as follows If specific gravity read ings show a difference between highest and lowest cell of 050 50 points or more ...

Page 55: ...lti Lube and store battery in COOL DRY place Remove battery from storage every 30 45 days check water level add water if necessary and put on charge for 5 or 6 hours at 6 amperes DO NOT FAST CHARGE 4 If specific gravity drops below 1 240 check bat tery for reason and recharge When gravity reaches 1 260 discontinue charging To check specific gravity use a hydrometer which can be purchased locally 5...

Page 56: ...Excessive electrical load from too many acces sories will cause battery to run down If visual inspection determines that battery connec tions and wiring is OK perform the following stator and rectifier test Stator Test Alternator Coils Only NOTE Stator can be tested without removing from engine 1 Disconnect both yellow stator leads 2 Use an ohmmeter and perform the following test 3 Replace stator ...

Page 57: ...ather as a power source for running lights However if a rectifier kit is installed on the engine to enable the stator to charge a battery the following approximate output can be checked at the listed RPM with an in series ammeter RPM AMPERES Manual Start Idle 0 Manual Start Stator 1000 0 2000 6 3000 9 ELECTRIC START MODELS WITH RECTIFIER a b a Rectifier b Red Lead IMPORTANT Rectifier must be funct...

Page 58: ...ct the two red leads coming from the voltage regulator rectifier 5 Connect the smaller diameter red lead to the terminal of a 9 volt transistor battery Connect the negative terminal of the 9 volt battery to en gine ground 6 Connect RED ammeter lead to larger diame ter RED lead and BLACK ammeter lead to POSITIVE on starter solenoid 7 With engine running at the indicated RPM the ammeter should indic...

Page 59: ...alternately to terminals a and c No Continuity Indicated Connect black meter lead to terminal b red lead alternately to terminals a and c Continuity Indicated Connect red meter lead to terminal b black lead alternately to terminals a and c No Continuity Indicated Rectifier tests O K No Continuity Indicated Connect black meter lead to ground red lead alternately to terminals a and c No Continuity I...

Page 60: ...l starting when engine is in gear CAUTION The starter motor may be damaged seriously if operated continuously DO NOT operate continu ously for more than 30 seconds Allow a 2 minute cooling period between starting attempts Troubleshooting the Starter Circuit Before beginning the starter circuit troubleshooting flowchart following check first for the following conditions 1 Make sure that battery is ...

Page 61: ...ltmeter between common engine ground and Test Point 3 c Turn ignition key to Start position 12 Volt Reading Defective starter motor solenoid No voltage reading proceed to TEST 4 No voltage reading proceed to TEST 5 12 Volt Reading Neutral start switch is open or yellow red wire is open between Test Points 4 and 3 No voltage reading proceed to TEST 6 12 Volt Reading Defective ignition switch TEST 6...

Page 62: ... Lift starter motor from outboard 54652 g a b c d h e f a Black Positive Cable b Upper Mounting Bolts c Black Ground Cable d Upper Mounting Clamp e Bottom Mounting Bolts f Black Ground Cable from Battery g Black Ground Wire Starter Motor Solenoid Ground h Lower Mounting Clamp Installation 1 Install collars on starter motor if removed 2 Connect BLACK ground cable to starter using bolt and lockwashe...

Page 63: ...emove brushes as fol lows a Lift brush holder from end cap Remove hex nut and washers from positive terminal and remove positive brushes along with positive terminal as an assembly 11656 b a c d a b d a Brush Holder b Negative Brushes c Positive Brushes d Positive Terminal 5 Remove armature along with drive end cap from starter frame 6 If necessary remove parts from armature shaft by first removin...

Page 64: ...s as specified in the following proce dure Testing 9 Open circuited armatures often can be saved where an open circuit is obvious and repairable The most likely place for an open circuit is at the commutator bars as a result of excessively long cranking periods Long cranking periods over heat the starter motor so that solder in the con nections melts and is thrown out The resulting poor connection...

Page 65: ...d to brush and lead to positive termi nal solder connection If connection cannot be re paired brushes must be replace 11673 a a Positive Brushes Testing Negative Brushes for Ground Bosch Set VOA meter to R x 1 scale Place one lead of the VOA on the negative brush and the other lead on the end cap bare metal If the meter indicates NO conti nuity replace the negative brush Repeat this proce dure on ...

Page 66: ...onents 54656 e f a b c d a Insulating Bushing b Positive Terminal c Insulating Washer d Flat Washer e Lockwasher f Hex Nut Positive Brushes Installed a b c 11660 a Positive Terminal b Long Brush Lead c Push Lead into Slot b Install negative brushes along with brush holder Negative Brushes Installed 54655 a a b b c d d a Positive Brushes b Negative Brushes c Brush Holder d Bolts Fasten Negative Bru...

Page 67: ...f SAE 10W oil 5 Position armature into start frame so that com mutator end of armature is at end of starter frame where permanent magnets are recessed 1 25 4mm 6 Lubricate bushing located in commutator end cap with one drop of SAE 10W oil DO NOT over lubricate 7 To prevent damage to brushes and springs when installing commutator end cap it is recom mended that a brush retaining tool be made Brush ...

Page 68: ...ool Install thru bolts and torque to 70 lb in 7 9 N m 54657 a b a Alignment Marks b Align Mark with Positive Terminal Starter Solenoid Test Test starter solenoid as follows 1 Disconnect all leads from solenoid terminals 2 Using an ohmmeter R x 1 scale connect leads between solenoid terminals 1 and 2 as shown 3 Connect a 12 volt supply between solenoid ter minals 3 and 4 as shown Solenoid should cl...

Page 69: ...C 2 54663 ELECTRICAL AND IGNITION TIMING SYNCHRONIZING ADJUSTING ...

Page 70: ...stments 2C 1 Static Timing Outboard Not Running 2C 1 Electric Start Models 2C 1 Throttle Primary Pick Up Adjustment 2C 1 Maximum Timing Adjustment 2C 3 Throttle Secondary Pick Up Adjustment Outboard Not Running 2C 3 Full Throttle Stop Screw Adjustment Outboard Not Running 2C 4 Carburetor Adjustments 2C 5 Idle Mixture Screw Adjustment 2C 5 Idle RPM Adjustment 2C 5 ...

Page 71: ...nates possibility of outboard accidentally starting and also allows starter motor to turn outboards over faster thus pro viding more accurate timing readings 3 Install SPARK GAP TESTER 91 63998A1 be tween No 1 TOP spark plug lead and engine ground 4 Connect TIMING LIGHT 91 99379 to No 1 TOP spark plug lead IMPORTANT If carburetors were previously re moved it is recommended that they be synchro niz...

Page 72: ...oper idling RPM for the outboard while it is running 54659 a a Idle RPM Screw 3 Loosen throttle actuator plate retaining screws 54660 c a b d a Throttle Actuator Plate b Retaining Screws c Secondary Throttle Pick Up Screw d Top Carburetor 4 While holding throttle spark arm against IDLE RPM SCREW STOP rotate actuator plate until PRIMARY THROTTLE CAM just touches PRI MARY PICK UP ARM on carburetor c...

Page 73: ...DC at 5500 RPM Therefore it is recom mended that to be assured of maximum perfor mance from this outboard all timing adjust ments made at cranking speed should be verified with the outboard running 2 Remove timing light and SPARK GAP TESTER from 1 TOP spark plug lead 3 Reinstall spark plugs Torque spark plugs to 20 lb ft 27 1 N m 4 Reconnect spark plug high tension leads to spark plugs THROTTLE SE...

Page 74: ...ttle stop screw to allow full carbure tor shutter opening at wide open throttle Throttle shutters MUST NOT act as a throttle stop 010 015 0 254mm 0 381mm free play should exist between secondary pick up screw and car buretor cluster secondary lever If sufficient free play does not exist full throttle stop screw MUST BE adjusted 54664 a b c a Secondary Pick Up Screw b Carburetor Cluster Secondary L...

Page 75: ...onably smooth idling TOO LEAN a mixture is a major cause of hard starting IDLE RPM ADJUSTMENT 1 Place outboard in test tank or boat and outboard in water 2 Start outboard and allow to warm up for approxi mately five minutes 3 With outboard running shift into forward gear and adjust idle RPM as follows a Remove throttle cable barrel from barrel re tainer Adjust idle RPM screw to attain an idle spee...

Page 76: ...D 2 23891 ELECTRICAL AND IGNITION WIRING ...

Page 77: ...ram Model 40 Electric Start Tiller Handle with 16 Amp Black Stator 2D 8 Wiring Diagram Model 40 Electric Start Tiller Handle with 16 Amp Red Stator 2D 9 Wiring Diagram Model 40 Manual Start with Black Stator 2D 10 Wiring Diagram Model 40 Manual Start with Red Stator 2D 11 Power Trim Wiring Diagram 2D 12 Commander 2000 Side Mount Remote Control Power Trim Tilt Electric Start with Warning Horn Wirin...

Page 78: ...14 15 16 17 18 19 20 21 1 Stator 2 Trigger 3 Starter 4 Starter Solenoid 5 Voltage Regulator Rectifier 6 Battery 7 Engine Harness 8 Temperature Gauge Sender 9 Warning Module 10 Overheat Switch 11 Enrichment Valve 12 20 Ampere Fuse 13 Switch Box 14 Ignition Coil 1 Cylinder 15 Ignition Coil 2 Cylinder 16 Ignition Coil 3 Cylinder 17 Ignition Coil 4 Cylinder 18 Low Oil Sensor 19 RPM Limiter 20 To Femal...

Page 79: ...am Model 30 Jet with 16 Amp Red Stator 54944 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 16 Ampere Stator b Ground Connection c Switch Box d Stator Adaptor e Voltage Regulator ...

Page 80: ... 21 22 23 1 Stator 2 Trigger 3 Starter 4 Starter Solenoid 5 Battery 6 Engine Harness 7 Neutral Start Switch 8 Temperature Gauge Sender 9 RPM Limiter 10 Low Oil Sensor 11 Warning Module 12 Overheat Switch 13 Enrichment Valve 14 20 Ampere Fuse 15 Voltage Regulator Rectifier 16 Switch Box 17 Ignition Coil 1 Cylinder 18 Ignition Coil 2 Cylinder 19 Ignition Coil 3 Cylinder 20 Ignition Coil 4 Cylinder 2...

Page 81: ...90 814676R1 DECEMBER 1996 Wiring Diagram Model 30 Jet Tiller Handle with 16 Amp Red Stator 54946 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 ...

Page 82: ... GRY Gray GRN Green ORN Orange PNK Pink PUR Purple RED Red TAN Tan WHT White YEL Yellow LIT Light DRK Dark 50504 90 814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION 2D 5 Wiring Diagram Model 40 Electric Start with 9 Amp Black Stator ...

Page 83: ... LIT BLU LIGHT BLUE 52468 1 2 4 5 6 7 8 11 12 13 14 15 16 17 18 19 3 9 10 1 Stator 2 Trigger 3 Switch Box 4 Voltage Regulator 5 Starter 6 Starter Solenoid 7 Battery 8 To Bottom Cowl 9 To Tan Female Connector on Remote Control Harness Plug 10 Temperature Gauge Sender 11 Warning Module 12 Overheat Module 13 Low Oil Switch 14 Coil No 1 15 Coil No 2 16 Coil No 3 17 Coil No 4 18 20 Ampere Fuse 19 Fuel ...

Page 84: ...0 Electric Start with 16 Amp Red Stator 54947 a 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 b c d e a 16 Ampere Stator b Stator Adaptor c Voltage Regulator d Switch Box e Ground Connection ...

Page 85: ...467 1 2 3 4 5 6 7 8 9 8 10 11 12 13 19 18 14 15 16 17 20 21 1 Stator 2 Trigger 3 Switch Box 4 Voltage Regulator 5 Starter 6 Starter Solenoid 7 Battery 8 To Bottom Cowl 9 To Tan Female Connector on Remote Control Harness Plug 10 Temperature Gauge Sender 11 Warning Module 12 Overheat Switch 13 Low Oil Sensor 14 Coil No 1 15 Coil No 2 16 Coil No 3 17 Coil No 4 18 20 Ampere Fuse 19 Fuel Enrichment Val...

Page 86: ...ric Start Tiller Handle with 16 Amp Red Stator 54945 a 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 b c d e a 16 Ampere Stator b Stator Adaptor c Voltage Regulator d Switch Box e Ground Connection ...

Page 87: ...own GRY Gray GRN Green ORN Orange PNK Pink PUR Purple RED Red TAN Tan WHT White YEL Yellow LIT Light DRK Dark 50503 2D 10 ELECTRICAL AND IGNITION 90 814676R1 DECEMBER 1996 Wiring Diagram Model 40 Manual Start with Black Stator ...

Page 88: ...with Red Stator 54948 a 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 b c e f d g a Lighting Coil Stator b BLUE WHITE Lead Not Used c Plug d Terminal Block e Stator Adaptor f Switch Box g Ground Connection ...

Page 89: ...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 2D 12 ELECTRICAL AND IGNITION 90 814676R1 DECEMBER 1996 Power Trim Wiring Diagram ...

Page 90: ...891 a Ignition Choke Switch b Emergency Stop Switch c Neutral Start Switch d Tachometer Accessories Harness Connector e Wiring Harness Connector f Warning Horn g Trim Tilt Switch 90 814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION 2D 13 Commander 2000 Side Mount Remote Control Power Trim Tilt Electric Start with Warning Horn Wiring Diagram ...

Page 91: ...Light DRK Dark 23892 a Ignition Choke Switch b Emergency Stop Switch c Neutral Start Switch d Tachometer Accessories Harness Connector e Wiring Harness Connector f Warning Horn 2D 14 ELECTRICAL AND IGNITION 90 814676R1 DECEMBER 1996 Commander 2000 Side Mount Remote Control Electric Start with Warning Horn Wiring Diagram ...

Page 92: ...NK Pink PUR Purple RED Red TAN Tan WHT White YEL Yellow LIT Light DRK Dark 23893 a RUN OFF Switch b Emergency Stop Switch c Stop Switch Harness 90 814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION 2D 15 Commander 2000 Side Mount Remote Control Manual Wiring Diagram ...

Page 93: ...t DRK Dark 23894 OFF BLK YEL BLK RUN RED PUR START RED PUR YEL RED PUSH CHOKE RED YEL BLK Key switch must be positioned to RUN or START and key pushed in to actuate choke for this continuity test 2D 16 ELECTRICAL AND IGNITION 90 814676R1 DECEMBER 1996 Key Choke Switch Continuity Test Commander 2000 Side Mount Remote Control ...

Page 94: ...U 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 90 814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION 2D 17 Panel Mount Remote Control Wiring Diagram ...

Page 95: ...k 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 2D 18 ELECTRICAL AND IGNITION 90 814676R1 DECEMBER 1996 Remote Key Switch and Warning Horn ...

Page 96: ...3 FUEL SYSTEM AND CARBURETION ...

Page 97: ...3 13 Carburetor Adjustments 3 13 Initial Starting Adjustment 3 13 Idle Speed Adjustment 3 13 Idle Mixture Screw Adjustment 3 14 Float Adjustment 3 14 Float Level and Float Drop Adjustment 3 14 Float Level WMA7B Carburetor 3 14 Float Drop WMA7B Carburetor Only 3 15 Float Level WMA9 Carburetor 3 15 Float Drop WMA9 Carburetor Only 3 15 Main High Speed Jet Adjustment 3 15 Vent Jet 3 16 High Altitude J...

Page 98: ...PM In Forward Gear 500 600 Float Level Carb Model WMA7B Carb Model WMA9 1 4 in 1 64 in 6 4mm 0 4mm 11 16 in 1 64 in 16 3mm 0 4mm Float Drop Carb Model WMA7B Carb Model WMA9 1 32 in to 1 16 in 0 80mm to 1 6mm No Adjustment Special Tools Description Part No Carburetor Scale 91 36392 ...

Page 99: ... FUEL SYSTEM AND CARBURETION 90 814676R1 DECEMBER 1996 Fuel System Carburetor 1 Carburetor Body 2 Welch Plug 3 Plug 4 Throttle Shutter 5 Spring 6 Baffle 7 Float 8 Pivot Pin 9 Fuel Bowl 10 Gasket 11 Gasket 12 Needle 13 Main Jet 14 Vent Jet 15 Venturi 16 Screw 2 17 Gasket 18 Idle Mixture Screw 19 Spring 20 Gasket 21 Screw 4 22 Throttle Shaft 23 Nut 2 Upper Carburetor 24 Cover Plate 25 Throttle Lever...

Page 100: ... 3 3 Fuel System Fuel Pump 1 Pump Body 2 Rubber Disk 2 3 Plastic Disc 2 4 Retainer 2 5 Spring 6 Cap 7 Diaphragm 8 Gasket 9 Spring 10 Cap 11 Plate 12 Gasket 13 Gasket 14 Pump Base 15 Gasket 16 Bolt 40 mm 2 Bolt 50 mm 2 17 Pipe Plug 18 Pipe Plug 19 Hose 20 Fuel Connector 21 Bolt 1 1 2 in 22 Nut 23 Hose 24 Filter 25 Hose 26 Hose 2 27 Tee Fitting 28 Balance Tube 29 Sta Strap 30 Coupling 31 Screw 32 Ke...

Page 101: ...restricted lean fuel flow which could be caused by use of an anti siphon valve are 1 Loss of fuel pump pressure 2 Loss 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 ...

Page 102: ...ve Hole or Crack Check Valve s in Fuel Pump Rebuild Fuel Pump Broken Check Valve Re tainer Rebuild Fuel Pump Pulse Hole Plugged Remove Fuel Pump and Clean Out Hole Loose Pulse Hose Tighten Connection Boost Diaphragm Gasket Distorted or Out of Place Check Seal Between Mat ing Surfaces Where Rib Divides Pulse Chamber Gasket Must Align with Rib Check for Distorted Gasket Align or Replace Gasket if Ne...

Page 103: ...ETION 90 814676R1 DECEMBER 1996 4 Remove gasket from powerhead 52019 a a Gasket Fuel Pump Disassembly 1 Remove bolts and chamber plate 52019 a b a Bolts b Chamber Plate 2 Disassemble fuel pump as shown in Fuel Pump Exploded View ...

Page 104: ...E ANGLE 50569 90 814676R1 DECEMBER 1996 FUEL SYSTEM AND CARBURETION 3 7 Fuel Pump Exploded View Design 1 IMPORTANT Align all gasket and diaphragm aligning tabs with fuel pump aligning tabs during reassembly NOTE Respective diaphragms go against the mat ing surfaces of the fuel pump body and respective gaskets are between the diaphragms and end caps Gaskets should always be replaced on fuel pump re...

Page 105: ...gn 1 1 Insert retainer thru plastic disc and rubber check valve 23601 a Retainer b Plastic Disc c Rubber Check Valve 2 Install check valves and retainers into fuel pump body 23601 3 With retainer installed in pump body break re tainer rod from retainer by bending sideways 23601 a Retainer Rod b Retainer 4 Reinstall rod into retainer cap and use a hammer and punch to tap rod down into retainer unti...

Page 106: ...on Design 1 1 Install gasket on fuel pump base 52024 a b a Gasket b Base 2 Install pump and secure with screws Torque screws to 60 lb in 6 8 N m 52025 a a Screws Torque to 60 lb in 6 8 N m 3 Connect hoses as shown Secure hoses with sta straps 52014 b a a Inlet Hose b Outlet Hose ...

Page 107: ...0 FUEL SYSTEM AND CARBURETION 90 814676R1 DECEMBER 1996 Fuel Pump Exploded View Design 2 IMPORTANT Align all gasket and diaphragm aligning tabs with fuel pump aligning tabs during reassembly NOTE Respective diaphragms go against the mat ing surfaces of the fuel pump body and respective gaskets are between the diaphragms and end caps Gaskets should always be replaced on fuel pump reassembly ...

Page 108: ...h er damage Check Valve Reassembly Design 2 1 Insert retainer thru plastic disc and rubber check valve 51530 a Retainer b Plastic Disc c Check Valve 2 Install check valves and retainers into fuel pump body 51530 3 Break rod from retainer cap and reinstall rod into cap Using a hammer and punch tap rod down into retainer until flush with top of retainer 51530 a Rod b Retainer Cap Fuel Pump Installat...

Page 109: ... siphon valve restrict ing fuel flow Refer to Checking for re stricted Fuel Flow caused by Anti siphon Valves following See Checking for restricted Fuel Flow caused by Anti Siphon Valves page 3A 4 Problem Engine Floods Possible Cause Corrective Action Dirt or foreign particles are preventing inlet needle from seating Flush out inlet seat and clean inlet needle Worn inlet needle Replace Punctured f...

Page 110: ...ighten bolts securely Chamber cover leaking air Tighten or replace gasket Off idle holes plugged Blow out with compressed air Main nozzle or idle nozzle air bleed holes plugged Blow out with compressed air Improper main jet or re stricted jet Clean or replace with proper jet refer to Main Jet Chart Damaged reed s Inspect reeds as outlined in Section 4A A crack in the fuel pickup outlet tube locate...

Page 111: ...o lean a mixture is obtained engine slows down and mis fires 7 Set idle mixture screw at a point midway between TOO RICH and TOO LEAN When in doubt set slightly RICH rather than TOO LEAN 8 Do not adjust leaner than necessary to attain rea sonable smooth idling Too lean a setting is a ma jor cause of hard starting Float Adjustment 1 Remove carburetor as outlined in Carburetor Removal following 2 Re...

Page 112: ...om to casting FLOAT DROP WMA9 CARBURETOR ONLY Float drop is not adjustable on WMA9 carburetors Main High Speed Jet Adjustment The carburetor is equipped with a fixed high speed jet and normally no adjustment is required However extreme changes in weather temperature and hu midity and or elevation may result in a too lean or rich fuel mixture at wide open throttle which may re quire a change in the...

Page 113: ... the engine is to be op erated at a different elevation refer to the Carbure tor Jet Chart following and rejet carburetor for ele vation outboard will be operated at Carburetor Jet Orifice Sizes WMA7B Model Jet Type Standard Jet up to 2500 Size Part No 2500 5000 Size Part No 5000 7500 Size Part No 7500 and Up Size Part No 40 HP 4 Cyl Main Vent 057 098 1399 1457 1399 7335 055 096 1399 1655 1399 624...

Page 114: ...ine revolution When the key is released from the pushed in posi tion the valve will return closed The valve can be op erated manually if valve fails to operate electrically refer to Manual Operation of Enrichener Valve following Enrichener Hose Routed to Balance Tube 50571 Description The enrichener system using enrichener hose routed to balance tube is similar to the system using the enri chener ...

Page 115: ... fuel to the engine thru fittings located on each carburetor flange Equal fuel amounts are delivered while depressing primer bulb with engine stopped or running Enrichener Valve Manual Operation IMPORTANT Use of enrichener if motor is warm could result in engine flooding Squeeze primer bulb until bulb is firm Press button in on enrichener valve and hold approximately 5 sec onds Release button Star...

Page 116: ...valve DOES NOT click re place valve Check for open circuit in yellow black wire between key switch or choke button and terminal block Valve is O K Check hoses and fittings from valve to car buretors for leaks or obstructions Remove upper hose from fitting on enrichener valve If fuel flows from hose replace valve If not check hose and carbu retor fittings for leaks or obstructions 90 814676R1 DECEM...

Page 117: ...embly has 2 check valves Fuel inlet toward tank and a fuel outlet toward engine The fuel inlet valve allows fuel to fill primer bulb but closes to prevent fuel from returning to tank when bulb is squeezed The fuel outlet valve opens when primer bulb is squeezed to allow fuel flow to carbure tor but closes as bulb is released to prevent fuel from returning to primer bulb Fuel Line Clamp Removal and...

Page 118: ...ve 4 nuts securing carburetors to power head Disconnect fuel hose from fuel pump and primer hose 52022 a b d c a Nuts b Fuel Hose c Fuel Pump d Primer Hose Carburetor Disassembly Top Carburetor 1 Disconnect fuel hose and primer hose from car buretor 52012 a b a Fuel Hose b Primer Hose 2 Disconnect throttle linkage from throttle shaft 52020 a b a Throttle Linkage b Throttle Shaft ...

Page 119: ...MBER 1996 3 Remove 4 screws securing cover plate to carbu retor 52012 a b a Screws b Cover Plate 4 Remove cover plate and gasket 52018 a a Gasket 5 Remove primer fitting bowl and bowl gasket from carburetor 52012 a b c a Primer Fitting b Bowl c Gasket ...

Page 120: ...e identified below 52027 DESIGN 1 DESIGN 2 DESIGN 3 DESIGN 4 NOTCH 6 Remove pivot pin securing float to carburetor 52013 a b a Pivot Pin b Float 7 Remove float needle and baffle from carburetor 52013 a b c a Float b Needle c Baffle 8 Remove main nozzle and venturi from carbure tor 52015 a b a Main Nozzle b Venturi ...

Page 121: ...BER 1996 9 Remove main jet from carburetor 52016 WMA7B CARB a a Main Jet 52026 WMA9 CARB a a Main Jet 10 Remove vent jet from carburetor 52015 a a Vent Jet 11 Remove idle mixture screw and spring from car buretor 52015 a b a Idle Mixture Screw b Spring ...

Page 122: ... body and fuel bowl for cracks stripped threads plugged or restricted passages and passage plugs that show signs of leakage 2 Thoroughly clean all carburetor parts with a mild cleaning solution that will not damage rubber or plastic to remove dirt gum and varnish that may have accumulated 3 After washing parts blow parts dry with com pressed air Be sure to blow air thru all passages orifices and n...

Page 123: ... plate to throttle shaft Apply Loctite 271 to threads of screws Tighten secure ly 52023 a b a Throttle Shaft Plate b Screws 3 Install throttle return spring to throttle shaft 52016 a b a Throttle Return Spring b Throttle Shaft 4 Install idle mixture screw and spring in carbure tor Refer to Idle Mixture Screw Adjustment preceding 52015 a b a Idle Mixture Screw b Spring ...

Page 124: ... N m 52016 WMA7B CARB a a Main Jet Torque to 6 lb in 0 7 N m 52026 WMA9 CARB a a Main Jet Torque to 35 lb in 3 9 N m 7 Install venturi into carburetor Install main nozzle into carburetor Tighten securely 52015 a b a Venturi b Main Nozzle 8 Install float needle float and baffle plate Secure needle to float using retaining wire on float needle 52013 a b c a Float Needle b Float c Baffle Plate ...

Page 125: ...a Pivot Pin b Float c Post 11 Install float bowl using new bowl gasket and se cure to carburetor body using primer fitting Torque fitting to 33 lb in 3 7 N m See float bowl Primer Fitting Designs following 52012 c b a a Primer Fitting b Bowl c Gasket PRIMER FITTING DESIGNS 52027 DESIGN 1 DESIGN 2 DESIGN 3 DESIGN 4 NOTCH 12 Install gasket and cover to carburetor 52018 a a Gasket ...

Page 126: ... screws to 18 lb in 2 0 N m 52012 a b a Screws 14 Connect throttle linkage to carburetor throttle shaft 52020 a b a Throttle Linkage b Throttle Shaft 15 Connect fuel hose and primer hose to carburetor Secure fuel hose using sta strap 52012 a b a Fuel Hose b Primer Hose ...

Page 127: ... using new gas kets 52021 2 Secure carburetors to engine using 4 nuts Torque nuts to 110 lb in 12 4 N m 3 Connect fuel line and primer line Secure fuel line using sta strap 52022 a b d c a Nuts Torque to 110 lb in 12 4 N m b Fuel Line c Primer Line d Sta strap Reinstall oil tank Refer to Section 8 Oil Injection System ...

Page 128: ...4 54727 POWERHEAD ...

Page 129: ...assembly 4 16 End Cap Disassembly 4 21 Crankshaft Disassembly 4 22 Cleaning and Inspection 4 25 Cylinder Block and Crankcase Cover 4 25 Cylinder Bore Cleaning and Inspection 4 25 Honing Procedure 4 25 Cylinder Bore Size 4 26 Pistons 4 26 Measuring Piston Roundness 4 27 Reed Blocks 4 27 Connecting Rods 4 28 Cleaning Connecting Rods 4 30 Crankshaft 4 30 Ball Bearing 4 31 Powerhead Reassembly 4 31 Ge...

Page 130: ...Strap Wrench 91 24937A1 Protector Cap 91 24161 Flywheel Puller 91 73687A1 Lifting Eye 91 90455 Piston Ring Expander 91 24697 Piston Pin Tool 91 76160A2 Piston Ring Compres sor 91 31461A2 Bearing Puller 91 24100A1 Powerhead Stand 91 25821A1 Torque Wrench 0 200 lb ft 91 32610 Torque Wrench 0 150 lb in 91 66274 Compression Tester 91 29287 May be Obtained Locally General Information Powerhead Disassem...

Page 131: ... 814676R1 DECEMBER 1996 Throttle Control Linkage 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 10 6 7 33 34 35 4 95 2 4 C With Teflon 92 825407A12 95 95 95 95 95 95 ...

Page 132: ...2 IN Drive Tight but ac tuator must be free to pivot 10 2 WASHER 11 1 WAVE WASHER 12 1 PLATE 13 2 SCREW 1 2 IN 14 1 SCREW 1 IN 15 1 NUT 16 1 CAP 17 1 SCREW 7 8 IN 18 1 SPRING 19 1 NUT 20 1 SPARK ADVANCE LEVER 21 1 SCREW 1 3 4 IN Drive Tight 22 1 BUSHING 23 1 BUSHING 24 1 SPRING 25 1 WASHER 26 1 SCREW 1 3 4 IN 27 1 NUT 28 1 CAP 29 1 LINK ROD 30 1 PIVOT 31 1 SWIVEL BALL 32 1 SWIVEL BASE 33 1 SCREW 2...

Page 133: ...inder Block and Crankcase Assembly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 4 16 15 21 20 19 75 Loctite Master Gasket 92 12564 1 75 Perfect Seal 92 34227 1 19 19 19 7 33 33 Loctite 680 Obtain Locally 33 ...

Page 134: ...3 2 STUD 2 1 8 14 2 STUD 2 1 2 15 13 SCREW crankcase to cylinder block 1 1 2 210 17 5 23 7 15 3 SCREW crankcase to cylinder block 1 3 8 210 17 5 23 7 15 2 SCREW crankcase to cylinder block 2 7 8 210 17 5 23 7 16 17 WASHER crankcase screw 17 1 SCREW center main bearing locking 1 75 8 5 18 2 SCREW 3 4 DESIGN II 75 8 5 19 3 LOCKWASHER w LOCKWASHER 18 2 SCREW 5 8 DESIGN I 75 8 5 19 3 TAB WASHER w TAB ...

Page 135: ...Caps and Exhaust Cover 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 B A C 7 Loctite 271 Obtain Locally 14 2 Cycle Outboard Oil 92 13249A24 95 2 4 C With Teflon 92 825407A12 7 95 95 14 14 95 A DESIGN I B DESIGN II C DESIGN III ...

Page 136: ...nsfer port cover 5 8 65 7 3 15 1 GASKET cylinder block to baffle plate 16 1 PLATE baffle exhaust manifold 17 1 GASKET baffle plate to exhaust cover 18 1 COVER exhaust manifold 19 1 END CAP ASSEMBLY lower DESIGN I II 20 1 O RING lower end cap END CAP 21 2 OIL SEAL Design I End Cap SEE 21 1 OIL SEAL Design II End Cap BELOW 21 1 OIL SEAL Design II End Cap FOR S N 22 1 BALL BEARING lower end cap 19 1 ...

Page 137: ...ft Pistons and Connecting Rods 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 14 14 19 16 23 4 21 7 Loctite 271 Obtain Locally 14 2 Cycle Outboard Oil 92 13249A24 95 2 4 C With Teflon 92 825407A12 14 14 14 95 95 7 95 95 ...

Page 138: ...IN 030 O S 13 4 PISTON PISTON PIN STANDARD 13 AR PISTON PISTON PIN 015 O S DESIGN I 13 AR PISTON PISTON PIN 030 O S 14 8 LOCK RING piston pin 15 1 PISTON RING STANDARD 15 AR PISTON RING 015 O S DESIGN II 15 AR PISTON RING 030 O S 15 1 PISTON RING STANDARD 15 1 PISTON RING 015 O S DESIGN I 15 1 PISTON RING 030 O S 16 4 CONNECTING ROD AND CAP ASSEMBLY 17 8 SCREW cap to rod 200 16 6 22 5 18 108 NEEDL...

Page 139: ...N m EXHAUST COVER 16 5 lb ft 22 5 N m 1 1 9 5 1 4 8 7 3 2 6 10 12 11 10 6 3 2 9 15 14 13 8 5 1 4 7 16 12 8 4 1 7 11 15 14 10 6 3 2 5 9 13 17 POWERHEAD TO DRIVESHAFT HOUSING 12 5 lb ft 17 0 N m 4 10 POWERHEAD 90 814676R1 DECEMBER 1996 Powerhead Torque Sequence and Torque Speci fications ...

Page 140: ...cal harness connector Disconnect remote control trim control leads BLUE WHITE and GREEN WHITE if applicable 26835 a b a Harness Connector b Trim Control Leads 5 Remove shift and throttle cables from engine 50564C a b a Throttle Cable b Shift Cable 6 Remove POSITIVE LEAD from starter motor 7 Remove four bolts securing starter motor and re move retaining clamps and starter motor from powerhead 54652...

Page 141: ...rim Switch 10 Remove bolt securing fuel line connector to bot tom cowl 54669 b a a Bolt b Fuel Line Connector 11 Remove inlet hose from oil pump NOTE If oil tank contains oil inlet hose to oil pump must be plugged when disconnected to prevent oil leakage 53119 a b a Inlet Hose b Oil Pump 12 Remove black lead from grounding bolt at aft starboard corner of bottom cowl 13 Remove tell tale hose from b...

Page 142: ... a Bolts b Flywheel Cover 15 Remove four bolts securing trim cover to bottom cowl and remove cover 54671 b a a Bolts 2 Each Side b Trim Cover 16 Remove eight nuts securing powerhead to drive shaft housing 54672 a a Nuts 4 Each Side 17 Remove plastic cap from center of flywheel and thread Lifting Eye 91 75132 into flywheel Us ing hoist lift powerhead from driveshaft housing and install on Powerhead...

Page 143: ...lt securing fuel connector to bottom cowl 54674 b a a Bolt b Fuel Connector 6 Disconnect BLACK YELLOW stop leads at both bullet connectors 7 Remove three black leads from grounding bolt at aft starboard corner of bottom cowl 8 Remove tell tale hose from bottom cowl 54675 a b d c c e a Black Yellow Leads b Bullet Connectors c Black Leads d Bolt e Tell Tale Hose 9 Remove bolt and retaining clip from...

Page 144: ...to bottom cowl and remove cover 54671 b a a Bolts 2 Each Side b Trim Cover 13 Remove eight nuts securing powerhead to drive shaft housing 26815 a a Nuts 4 Each Side 14 Remove plastic cap from center of flywheel and thread lifting eye 91 75132 into flywheel Using hoist lift powerhead from driveshaft housing and install on powerhead stand 91 25821A1 or work bench 54678 a a Lifting Eye 91 75132 ...

Page 145: ...wo allen screws securing oil pump to crankcase cover Remove oil pump and driven gear NOTE If driven gear remains in crankcase cover it can be removed when crankcase cover is removed from cylinder block 54679 b a c a Allen Screws b Oil Pump c Driven Gear Hidden 3 Remove three bolts attaching throttle actuator assembly to crankcase cover 54680 b a a Bolts b Throttle Actuator Assembly 4 Remove bolt s...

Page 146: ...lock and crankcase cover 54682 b a a Bolts b Upper End Cap 54683 b a a Bolts b Lower End Cap 6 Bend back lock tabs on reed cage bolts and cen ter main bolt 54684 c b a a a Locking Tab Washer b Reed Cage Bolt c Center Main Bolt 7 Remove 17 bolts securing crankcase cover to block 54685 a a Crankcase Cover ...

Page 147: ...nder block 54686 b a a a a Pry Points b Crankcase Cover 9 Gently tap upper and lower end caps from crank shaft with rawhide mallet 54687 a a Upper End Cap 54688 a a Lower End Cap 10 Remove oil pump drive gear electric start mod els only from crankshaft Gear slides off crank shaft 54689 a a Oil Pump Drive Gear ...

Page 148: ... securing transfer cover to cyl inder block and remove cover 13 Remove balance tube and fittings from cylinder block 14 Remove bleed hose and bleed check valve from cylinder block 15 Remove tell tale hose and fitting from cylinder block NOTE Manual Start Models and some early Electric Start Models have fuel enrichment fitting in the bal ance tube 54691 c e b d f a a Screws b Transfer Cover c Balan...

Page 149: ...over Remove temperature switch from cylinder block 54692 b a a Cylinder Block Cover b Temperature Switch 17 Remove 15 bolts from exhaust manifold cover and remove manifold cover and baffle plate from cylinder block 50532 Exhaust Manifold Cover c b a a Exhaust Manifold Cover b Baffle Plate c Gaskets ...

Page 150: ...dden b Upper End Cap c O Ring d Punch 3 Inspect ball bearing located in the end cap as out lined in Cleaning and Inspection following IMPORTANT DO NOT remove ball bearing from end cap unless replacement is required IMPORTANT It is recommended that heat be ap plied carefully to end cap housing to aid in re moval of ball bearing 4 If inspection determines that replacement of ball bearing is required...

Page 151: ...l bearing 54695 a b a Lower End Cap b Ball Bearing Puller 91 24100A1 3 Drive oil seals from end cap with a suitable punch Discard oil seals Design 1 End Cap a a Oil Seals Design 2 End Cap a a Oil Seals Design 3 End Cap a a Oil Seals Crankshaft Disassembly WARNING Eye Protection must be worn while removing pis ton rings and piston pin lock rings from pistons 1 Remove piston rings from pistons with ...

Page 152: ...n the I beam and piston on inside of skirt 54698 a a Scribe Identification No on Connecting Rod and Inside of Piston Skirt 4 Place Piston Pin Tool 91 76160A2 into top of piston pin Support bottom of piston with hand and tap on end of piston pin tool with mallet push ing piston pin out of piston Remove piston from connecting rods 54699 b c a a Piston Pin Tool 91 76160A2 b Piston Pin c Support Pisto...

Page 153: ...dle bearings together if they are to be reused 54701 a c b d a Connecting Rod b Connecting Rod Cap c Connecting Rod Bolts d Needle Bearing 25 Required 7 Remove two screws and locknuts which secure both halves of reed block together Remove reed block from crankshaft 54702 a b a Screw and Nut One Each Side b Reed Block 8 Reassemble each reed block as it is removed to assure correct rematch of each a...

Page 154: ...pumped into the work area If pumping oil is not practical use an oil can Apply oil generously and frequently on both stones and work CAUTION When honing cylinder block remove hone fre quently and check condition of cylinder walls DO NOT hone any more than absolutely neces sary as hone can remove cylinder wall material rapidly c Localize stroking in the smallest diameter un til drill speed is const...

Page 155: ...t is important that piston rings be replaced IMPORTANT If engine was submerged while en gine 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 bent connecting rod must be checked for straightness refer to Connecting Rods fol lowing on how to check straightnes...

Page 156: ...ped or broken reeds 5 Check reeds to be sure that they are not pre loaded adhere tightly to reed block and that they are not standing open an excessive amount greater than 007 0 78mm 54706 a b a Feeler Gauge b Reed 6 Replace reeds as necessary IMPORTANT Replace reeds in sets only DO NOT turn used reed over for re use 7 Measuring from top of closed reed to inside of reed stop check reed stop openin...

Page 157: ...s If replacement of some bearings is required re place all bearings at that location 3 Inspect crankshaft end and piston pin end bear ing surfaces of connecting rod for the following a Rust Rust formation on bearing surfaces causes uneven pitting of surface s 51853 a a Pitting b Water Marks When bearing surfaces are subjected to water contamination a bearing surface etching occurs This etching re ...

Page 158: ... then hammers it The rep etition of this action causes a rough bearing surface s that resembles a tiny washboard In some instances the connecting rod crank pin bore becomes highly polished During op eration the engine will emit a whirr and or chirp sound when it is accelerated rapidly from idle speed to approximately 1500 RPM then quickly returned to idle If the preceding conditions are found repl...

Page 159: ...083 c Clean PISTON PIN END of connecting rod using same method as in Step b preceding using 320 grit carborundum cloth d Thoroughly wash connecting rods to remove abrasive grit Recheck bearing surfaces of connecting rods Replace any connecting rod s that cannot be properly cleaned up Lubricate bearing surfaces of connecting rods which will be re used with light oil to prevent rust Crankshaft 1 Ins...

Page 160: ...e ques tionable can severely damage an otherwise per fectly good powerhead within the first few minutes of operation All new powerhead gaskets MUST BE installed during reassembly During reassembly lubricate parts with Quicksilver Formula 50 D 2 Cycle Outboard Lubricant when light oil is specified or with Quicksilver Needle Bear ing Assembly Lubricant whenever grease is speci fied Quicksilver part ...

Page 161: ...t c Needle Bearings 56 Required 2 Install bearing race with needle bearings in place on crankshaft Secure both halves of race togeth er with snap ring 54711 Installing Main Bearing Race on Crankshaft 54712 b a a Snap Ring b Outer race Main Bearing Installed 3 Install main bearing support onto main bearing race Locating pin must enter hole in main bear ing race 54713 b a a Locating Pin Position in ...

Page 162: ...kshaft 54714 b a a Lubricate Inner Bore with Light Oil b Insert Locating Pins into Holes and Press Together 6 Secure both halves of reed block together with two screws and nuts Torque reed block screws to 55 lb in 6 2 N m 54702 a b a Torque Screws One Each Side to 55 lb in 6 2 N m b Reed Block CAUTION Clean connecting rod bolts with solvent and dry with compressed air to prevent damage to threads ...

Page 163: ...t alignment of the rod cap Correct Connecting Rod Cap Alignment g Tighten connecting rod bolts using 1 4 12 point socket evenly in three progressive steps until torqued to 200 lb in 22 5 N m h Check each connecting rod cap for correct alignment If not aligned a ridge can be seen or felt at the separating line as shown Correct any misalignment 7 Use a small diameter wire and try to spread needle be...

Page 164: ...ng rod Add needle bearings until race will accept no more 27 re quired 54717 a b c b a Sleeve b Locating Washer c Needle Bearings 27 Required 4 Place upper locating washer over sleeve on pis ton pin tool then slide piston pin tool out of sleeve sleeve and washers will hold needle bearings in position in connecting rod 5 Place piston on connecting rod Position piston pin bore directly over sleeve a...

Page 165: ...n Lockring One Each Side b Needle Nose Pliers 8 Install new piston rings on piston with Piston Ring Expander Tool 91 24697 Spread each ring just enough to slip over piston Check that piston rings rotate freely in ring grooves If ring does not rotate freely condition must be corrected Design 1 Design 2 9 Lubricate rings with light oil and align ring ends with locating pins in ring grooves 54719 a a...

Page 166: ...rine Lubricant b a c d a Design 1 Type Lower End Cap b O Ring Seal c Seal Carrier d Lubricate with 2 4 C Marine Lubricant SEAL CARRIER REPLACEMENT DESIGN 1 1 Thoroughly clean crankshaft splines with solvent and dry with compressed air 2 Drive seal carrier squarely into end of crankshaft using a block of wood to protect seal carrier Install seal carrier to the dimension shown 5 32 in 4mm a a Seal C...

Page 167: ...rine Lubricant to lips of oil seals 54722 b a a O Ring Seal b Mandrel Design 1 End Cap a a 26 41953 Oil Seal 2 Design 2 End Cap a b a 26 41953 Oil Seal 1 b 26 63742 Oil Seal 1 Design 3 End Cap a a 26 41953 Oil Seal 2 4 Press ball bearing into lower end cap with press block 54723 b a a Block b Arbor Press IMPORTANT If installing a Design 1 2 or 3 end cap on engine S N 0D040454 and below remove and ...

Page 168: ...align end of each piston ring with lo cating pin in ring groove CAUTION Piston rings MUST BE properly positioned with locating pin between piston ring end gaps Im properly positioned piston rings may break dur ing installation 54719 a a Piston Ring Locating Pin 3 Install ring compressors as follows a No 1 piston must be straight out from crank pin throw and at bottom of stroke Use straight ring co...

Page 169: ...R1 DECEMBER 1996 54724 b a b a Straight Compressors b Offset Compressors Ring Compressors Installed on Pistons Front View 54725 b a b a Straight Compressors b Offset Compressors Ring Compressors Installed on Pistons Rear View ...

Page 170: ...ile installing 54727 a a Keep Crankshaft Horizontal 6 Align centermain bearing and reed blocks with lo cating pins and push centermain bearing and reed blocks downward to seat them in cylinder block 54728 a a Align Centermain Bearing Support and Reed Blocks with Locating Pins and Push Downward to Seat 7 Check each piston ring for spring tension thru the exhaust ports by pressing with a screwdriver...

Page 171: ...54731 b a a Top End Cap Ball Bearing b Top Crankshaft Throw d If necessary add or remove shim s to attain correct end play Keep shim s thickness approximately the same within 005 0 127mm between upper and lower end caps to assure that crank pin throws are cen tered over cylinders 11 Loosen end cap bolts several turns and slide end caps away from cylinder block to allow crankcase cover to be instal...

Page 172: ...ssive steps 50545 Torque Sequence Intake Manifold 15 Install centermain bearing and reed block mount ing bolts with locking tabs Torque bolts to speci fied torque and bend locking tabs up and against flat of each bolt 54732 b c a c c a Reed Block Mounting Bolts 5 8 16mm Long Torque to 75 lb in 8 5 N m b Centermain Mounting Bolt 1 25mm Long Torque to 75 lb in 8 5 N m c Locking Tab Washers Bend as S...

Page 173: ...T fitting for the fuel enrichment hose in the balance tube Later electric start models will not have this T fitting 19 Apply pipe sealant obtain locally to bleed check valve threads and install bleed hose and check valve on cylinder block NOTE The bleed check valve allows excess crank case lubricant to flow one way from the bottom of the crankcase to the top end cap bearing to provide addi tional ...

Page 174: ... tell tale fitting and install fitting and hose 54735 a a 45 Tell Tale Fitting 21 Install transfer port cover and new gasket Apply Loctite Grade A to screw threads and torque screws to 65 lb in 7 3 N m a Transfer Port Cover b Gaskets c Screws 6 Each 22 Install cylinder cover and new gasket Torque bolts equally in three progressive steps to 100 lb in 11 3 N m a Cylinder Cover b Gasket c Bolt 10 Eac...

Page 175: ...s provided on cylinder cover which may be removed for installing a Water Pressure Gauge Kit or a Water Temperature Gauge Kit 54692 b a a Plug Remove for Installation of Water Pressure or Water Temperature Gauge Kit b Temperature Switch 24 On Electric Start Models Only refer to Section 8 Oil Injection for proper installation procedure of oil pump ...

Page 176: ... assembly to crankcase cover Secure actuator with three bolts Torque bolts to 150 lb in 16 9 N m 54680 b a a Bolts Torque to 150 lb in 16 9 N m b Throttle Actuator Assembly 27 Referring to Section 3 reinstall carburetors fuel pump and fuel enrichment components 28 Referring to Section 2A reinstall ignition compo nents and flywheel 29 On Electric Start Models reinstall starter motor referring to Se...

Page 177: ...Plate b Gasket c Driveshaft Splines 4 Thread LIFTING EYE 91 75132 into flywheel at least 5 full turns 5 Using suitable hoist install powerhead onto driveshaft housing NOTE It may be necessary to rotate flywheel slightly to engage crankshaft splines into driveshaft splines when lowering powerhead onto driveshaft housing IMPORTANT The forward starboard and port powerhead attaching nuts MUST BE start...

Page 178: ...nnect re mote control harness to engine harness 12 Refer to Section 2C for TIMING SYNCHRONIZ ING ADJUSTING procedure 13 Attach throttle and shift cables 14 Attach remote fuel hose to engine NOTE Gear Case lubricant level should be checked prior to operating outboard Refer to Section 5A for correct inspection and filling procedures If new bear ings and piston rings were installed in powerhead break...

Page 179: ...A 5 54738 MID SECTION CLAMP SWIVEL BRACKET AND DRIVE SHAFT HOUSING ...

Page 180: ...ubricants and Service Aids 5A 1 Transom Bracket Components 5A 2 Torque Specifications 5A 2 Quicksilver Lubricants and Service Aids 5A 2 Drive Shaft Housing Components 5A 3 Torque Specifications 5A 3 Quicksilver Lubricants and Service Aids 5A 3 Disassembly 5A 4 Reassembly 5A 4 Tilt Lock Lever Transom Bracket 5A 4 Drive Shaft Housing 5A 6 ...

Page 181: ...er 11 Washer Lower 12 Lock Nut 13 Washer 2 14 Oil Seal 2 Seal Lip Outward 15 Bushing Swivel Pin 2 16 Bushing Swivel Bracket 17 Swivel Bracket 18 Grease Fitting 19 Yoke 20 Retaining Ring Torque Specifications a 20 lb ft 27 N m b 40 lb ft 54 2 N m c Torque until it seats then back off 1 4 turn Quicksilver Lubricants and Service Aids A 2 4 C Marine Lubricant See Quicksilver Accessories Guide for part...

Page 182: ...t 4 20 Washer 4 21 Nut 4 22 Trim Adjustment Pin 23 Clamp 24 Washer 25 Bolt 26 Lower Mounting Bracket 27 Anode Plate 28 Washer 2 29 Bolt 2 Manual Tilt Models Only 30 Link 31 Bolt 32 Spring Washer 33 Tilt Lever 34 Grip Rubber 35 Washer Outboard Mounting Assembly 36 Bolt 2 37 T handle 2 38 Bolt 4 39 Washer 8 40 Bracket 8 41 Nut 4 Torque Specifications a 60 lb in 6 8 N m b 25 lb ft 33 9 N m Quicksilve...

Page 183: ...ng Tension 4 24 Nut 2 25 Screw 2 26 Ground Wire 27 Washer 2 28 Washer Rubber 2 29 Mount Rubber Lower 2 30 Washer 2 31 Nut 2 32 Exhaust Adaptor Plate 33 Seal 34 Bushing 35 Washer Nylon 36 Seal Rubber 37 Gasket 38 Housing 39 Screw 2 40 Gasket 41 Gasket 42 Shift Shaft Lever 43 Bushing 2 44 Shift LInk 45 Wave Washer 2 46 Nut 2 47 Washer 2 48 Slider 49 Retainer 50 Stud 51 Retaining Ring 52 Retainer 53 ...

Page 184: ...vicing components not re quiring powerhead gear housing removal WARNING Failure to support outboard as shown could re sult in personal injury and or damage to out board or boat Typical Outboard Shown 51078 a b c a Hoist b Rope c Lifting Eye P N 91 90455 NOTE Refer to parts views on pages 1 2 and 3 and disassemble mid section components as required Reassembly Tilt Lock Lever Transom Bracket 1 Apply...

Page 185: ...g fiber washers and lock nuts 51078 a b c c a Tilt Tube b Fiber Washer c Lock Nuts 5 Apply Quicksilver 2 4 C Marine Lubricant to steering arm shaft and install 51079 a b a a Steering Arm b Washer 6 Install and secure yoke and washer using snap ring 51079 a b c a Washer b Yoke c Snap Ring 7 Install lower mounting bracket to transom brack ets 51079 a b b b b a Lower Mounting Bracket b Bolt ...

Page 186: ... Drive Shaft Housing c Bolts d Lock Nuts Torque to 40 lb ft 54 2 N m e Washer f Rubber Mount g Washer 3 Secure lower mount assembly to drive shaft housing Secure drive shaft housing to yoke 54740 b c d a c a Lower Mount Assembly b Ground Cable c Bolt Torque to 150 lb in 17 N m d Lock Nut Torque to 60 lb ft 81 3 N m 4 Install exhaust plate assembly to drive shaft housing using new exhaust plate gas...

Page 187: ...mid section Refer to Section 6A 6 Install shift lever plate and bushing into mid sec tion as shown Shift lever plate must face forward while gearcase is in neutral position 54742 a a Shift Lever Plate 7 Install shift linkage to bottom cowl as shown 54634 c d a b a Shift Lever Plate b Shift Link c Slider d Retainer 8 Install power head refer to Section 4 ...

Page 188: ...B 5 50158 MID SECTION POWER TRIM DESIGN 1 ...

Page 189: ...er Trim Tilt Electric Start with Warning Horn Wiring Diagram 5B 16 Power Trim System Wiring Diagram 5B 17 Troubleshooting the Down Circuit When Up Circuit is OK 5B 18 Troubleshooting the Up Circuit When Down Circuit Is OK 5B 19 Troubleshooting the Down and Up Circuits All Circuits Inoperative 5B 20 Page Power Trim System Removal 5B 21 Power Trim System Disassembly 5B 22 Trim Rod Removal 5B 22 Trim...

Page 190: ...and or powerhead overheating damage Make sure that water level is above gear housing water intake holes whenever engine is running Operating up circuit will actuate the up solenoid located under engine cowl and close the electric motor circuit The electric motor will drive the pump thus forcing automatic transmission fluid thru internal passageways into the up side of the trim cylinder The trim cy...

Page 191: ... trim adjustment pin a at planing speed will cause undesirable and or unsafe steering conditions Each boat must be water tested for handling characteristics after engine installation and after any trim adjust ments IMPORTANT Some boat motor combinations that doe not use the trim adjustment pin a and are trimmed to the full in trim angle will not ex perience any undesirable and or unsafe steering c...

Page 192: ... 33 Washer 4 34 O ring 2 364 in I D 35 Screw 36 Drive Shaft 37 Pump 38 O ring 176 in I D 2 39 Dowel Pin 40 Manifold 41 O ring 114 in I D 42 O ring 208 in I D 43 O ring 239 in I D 44 Relief Valve 45 E Clip 46 Wire Harness 47 Cap 48 Washer 49 Grommet 50 Screw 4 51 Screw 52 Reservoir Cap 53 O ring 2 364 in I D 54 Disk Foam Pad 55 Nut 2 56 End Cap 57 Washer 030 in Thick 2 58 Washer Thrust 59 Armature ...

Page 193: ...51638 5B 4 MID SECTION 90 814676R1 DECEMBER 1996 Power Trim Flow Diagrams Design 1 ...

Page 194: ...51637 90 814676R1 DECEMBER 1996 MID SECTION 5B 5 Design 1 ...

Page 195: ...51639 5B 6 MID SECTION 90 814676R1 DECEMBER 1996 Design 1 ...

Page 196: ...51640 90 814676R1 DECEMBER 1996 MID SECTION 5B 7 Design 1 ...

Page 197: ...51641 5B 8 MID SECTION 90 814676R1 DECEMBER 1996 Design 1 ...

Page 198: ...51642 90 814676R1 DECEMBER 1996 MID SECTION 5B 9 Design 1 ...

Page 199: ...51643 5B 10 MID SECTION 90 814676R1 DECEMBER 1996 Design 1 ...

Page 200: ... position or will not remain tilted for any extended period Outboard will not hold trim position when in reverse Determine if Power Trim pump motor operates when appro priate trim circuit is activated Pump motor operates Refer to Hydraulic System Troubleshooting Refer to Electrical System Troubleshooting Pump motor does not operate 90 814676R1 DECEMBER 1996 MID SECTION 5B 11 Troubleshooting Determ...

Page 201: ...se position 2 Check trim pump fluid level with outboard in full UP position and fill if necessary Refer to Fill and Purge the Power Trim System 3 Check for external leaks in Power Trim system Replace defective part s if leak is found 4 Outboard not holding tilted position falls to trim in position indicates debris or defective compo nents in trim valve assembly Clean or replace components as requi...

Page 202: ... O ring Leak Down Check Manual Release Valve 1 Debris or chips under O ring a 2 Flash from valve molding causing O ring a to not seal 3 Nicked O ring a a 51560 a O ring Leakage Past Ball and Seat Piston Assembly Unit will trim to full or near full DOWN position and then will begin to trim UP while trim switch is held in DOWN mode If trim switch is released outboard can be pushed by hand DOWN to th...

Page 203: ...efective O rings or components Inspect Oil Pump O rings located below oil pump O ring failure located below oil pump Replace O rings O rings appear to be OK Re place O rings Replace oil pump Inspect Manual Release Valve Outboard falls to full down position with manu al release valve closed Example a Outboard lowers more than one tilt pin hole in eight hours Example b Outboard lowers during acceler...

Page 204: ...eplace Manifold as a Unit Clean manifold reverse thrust valve without removing compo nents using engine cleaner and compressed air or replace Inspect Manual Release Valve Outboard will not hold tilted position in reverse and or trails out during high speed decelera tion Result Result Result Result Result Result DO NOT ADJUST OR REMOVE REVERSE THRUST VALVE THIS VALVE IS PRESET AT FACTORY FOR PRECIS...

Page 205: ...r f Warning Horn g Trim Tilt Switch 23891 BLK Black BLU Blue BRN Brown GRY Gray GRN Green PUR Purple RED Red TAN Tan WHT White YEL Yellow a b c d e f g 4 5 7 5B 16 MID SECTION 90 814676R1 DECEMBER 1996 Electrical System Troubleshooting COMMANDER 2000 Side Mount Remote Control Power Trim Tilt Electric Start with Warning Horn Wiring Diagram ...

Page 206: ...ngine Starter Motor Solenoid e Cowl Trim Switch f Fuse Holder 20 Amp Fuse g Engine Wiring Harness Connector h Remote Control Wiring Harness BLK Black BLU Blue GRN Green RED Red WHT White 50285 90 814676R1 DECEMBER 1996 MID SECTION 5B 17 Power Trim System Wiring Diagram ...

Page 207: ...t 3 and positive battery ter minal Connect Voltmeter red lead to Point 2 Connect Voltmeter red lead to Point 3 Connect Voltmeter red lead to Point 4 and black lead to ground Depress Down trim button If bat tery voltage is indicated wire is open between Points 4 and 1 Connect Voltmeter red lead to Point 1 and black lead to ground Depress the Down trim button Depress Down trim button Pump motor wiri...

Page 208: ...3 and positive battery ter minal Connect Voltmeter red lead to Point 6 Connect Voltmeter red lead to Point 3 Connect Voltmeter red lead to Point 7 and black lead to ground Depress Down 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 button Depress Up trim button Pump motor wiring is ...

Page 209: ...oltage at any instru ment using a Voltmeter Turn ignition switch to Run po sition DO NOT start engine Check for pinched or severed wires Check all trim harness connec tors for loose or corroded con nections Check trim switch Connect Voltmeter red lead to Point 3 and black lead to ground Battery voltage should be indi cated There is an open circuit in wire be tween Point 5 and Red terminal on the b...

Page 210: ...rness 2 Remove screw and clip securing wiring harness to clamp bracket 3 Use suitable tool to remove DRIVE DOWN up per dowel pin Retain dowel pin 51144 a a Dowel Pin 4 Use suitable punch to drive out upper pivot pin 51144 a a Pivot Pin 5 Use suitable punch to remove DRIVE UP lower dowel pin Retain dowel pin 51144 a a Dowel Pin 6 Use suitable punch to drive out lower pivot pin 51144 a a Pivot Pin ...

Page 211: ...1193 9 Remove O ring from fill cap 51194 Power Trim System Disassembly Trim Rod Removal 1 Secure power trim assembly in soft jawed vise 2 Open manual release valve three or four turns counterclockwise and position trim rod to full up position 3 Remove cylinder end cap assembly from cylinder using spanner wrench 1 4 in x 5 16 in long pegs 51194 a a Manual Release Valve ...

Page 212: ...ng b Memory Piston 7 Remove trim system from vise and empty fluid into appropriate container Trim Rod Disassembly 1 Place trim rod assembly on clean work surface 2 Remove screws securing plate to trim rod piston and O ring 3 Remove check ball components from trim rod piston 51143 b c a a Screw b Plate c O ring CAUTION When removing Trim Rod piston spanner wrench must have 1 4 in x 5 16 in long peg...

Page 213: ... 51146 a Trim Rod Piston b Spanner Wrench CAUTION Do not remove check ball components from trim rod piston Removal and reinstallation of check valve could result in improper operating pres sure and possible power trim system damage If check valve is defective replace trim rod piston 7 Remove inner O ring from piston b a c 51199 a Check Ball Components b O ring c Piston 8 Remove rod wiper inner O r...

Page 214: ... from reser voir assembly 51195 a b c a Cap b Washer c Grommet 3 Remove screws securing reservoir cap to reser voir 51193 a a a Screws 4 Remove motor and harness from reservoir 51196 Trim Motor Disassembly 1 Remove end cap from motor housing Note posi tion of washers on armature 51194 a b c d a End Cap b Motor Housing c Wave Washer 2 d Washer ...

Page 215: ... d Fiber Guard Brush Wires e Housing Reservoir Assembly Removal CAUTION DO NOT ADJUST OR REMOVE REVERSE THRUST VALVE THIS VALVE IS PRESET AT FAC TORY FOR PRECISE REVERSE THRUST PRES SURE AND DOES NOT REQUIRE ADJUSTMENT 1 Remove manual release valve from manifold DO NOT remove or adjust reverse thrust valve a b 51194 c a Manual Release Valve b Manifold c Reverse Thrust Valve 2 Remove E clip and O r...

Page 216: ... from oil pump 51194 a b a Drive Shaft b Oil Pump Oil Pump Removal IMPORTANT The oil pump is not rebuildable If oil pump is defective replace as an assembly 1 Remove screw oil pump and O rings from man ifold 51007 a a b c a O ring b Oil Pump c Screw Manifold Removal 1 While holding trim cylinder to manifold remove screws 51007 a b c a Trim Cylinder b Manifold c Screw ...

Page 217: ... filter 54745 a b a O rings b Filter Cleaning and Inspection of Trim Rod Components IMPORTANT Components must be dirt and lint free Slightest amount of debris in Power Trim system could cause system to malfunction CAUTION Do not remove check valve components from trim rod piston Removal and reinstallation of check valve could result in improper operating pressure and possible power trim system dam...

Page 218: ...ve to black results in motor up direction Positive to black negative to orange results in motor down direction Motor should run 3 If motor does not run disassemble motor and check components Thermal Overload Switch Test IMPORTANT If thermal overload switch has been activated pump motor cannot be tested for a minimum of one minute After this period switch should close reset itself and pump motor ma...

Page 219: ... mutator as shown If continuity is indicated armature is grounded and must be replaced 51195 CHECKING AND CLEANING COMMUTATOR If commutator a is worn it can be turned down on an armature conditioner tool or on a lathe Clean commutator with 00 sandpaper a Power Trim System Reassembly Manifold Installation IMPORTANT Filter must be installed in trim cylin der with ridge of filter housing facing out 5...

Page 220: ...nifold to trim cylinder 54748 4 Secure manifold to cylinder using screws torque to 100 lb in 11 2 N m 54746 b c a a Trim Cylinder b Manifold c Screw Oil Pump Installation 1 Secure power trim unit in soft jawed vise 2 Install lubricated O rings to manifold 3 Install oil pump to manifold and secure using screw torque to 90 lb in 10 2 N m 54747 b c a a O ring b Oil Pump c Screw ...

Page 221: ...aft b Washer c End Frame 2 Guide armature and end frame into housing as shown 51196 3 Align scribe mark on housing with mark on end frame 4 Install lubricated O ring to end frame 51194 a b a O ring b Scribe Mark 5 Install washers to armature shaft as shown 6 Install end cap to housing Torque nuts to 25 lb in 2 8 N m 51194 a b c d a End Cap b Motor Housing c Wave Washer d Washer ...

Page 222: ... Installation 1 Connect trim motor wires to harness 2 Insert motor into reservoir Motor must be seated properly prior to end cap installation 51196 3 Install end cap O ring and foam pad to cylinder 4 Torque screws to 13 lb ft 1 5 N m 51195 a b c a End Cap b O ring c Foam Pad 5 Install grommet washer and screw cap to cylin der end cap Tighten screw securely 51195 a b c a Grommet b Washer c Screw Ca...

Page 223: ...g 9 Secure reservoir to manifold using four screws Torque screws to 70 lb in 7 9 N m 51193 a a a Screw 10 Install lubricated O rings and E clip to manual release valve 51196 a b c a E Clip b O ring c Manual Release Valve 11 Insert manual release valve into manifold and tighten snuggly Back release valve out 3 or 4 turns allowing trim rod installation 51194 a b c a Manual Release Valve b Manifold c...

Page 224: ...6 a a End Cap 4 Apply Loctite Grade A 271 to threads of trim rod and install trim rod piston Tighten piston securely using spanner wrench 1 4 in x 5 16 in long peg b a a Trim Rod Piston b Spanner Wrench 5 Install lubricated O ring to trim rod piston 6 Install check ball components into its respective bore 7 Secure components in place using plate and screws Torque screws securely 51147 b c d e f a ...

Page 225: ...nstall lubricated O ring to memory piston and place into cylinder Push piston down to level of oil 51144 b a a O ring b Memory Piston IMPORTANT Memory piston must not come in contact with trim rod end cap during end cap trim rod installation 4 Install trim rod into cylinder 51196 5 Tighten end cap assembly to cylinder securely using spanner wrench 1 4 in x 5 16 in long pegs 51145 6 Tighten manual ...

Page 226: ...n position Connect posi tive lead to blue wire and negative lead to green wire and drive trim rod to the up position Re check fluid level add fluid if required and repeat cycle until fluid level remains at lower portion of threads 4 Install fill plug Power Trim Unit Installation 1 Apply Special Lubricant 101 92 13872A1 to lower pivot pin hole and pivot pin surface 2 Start lower pivot pin into pivo...

Page 227: ...drive upper pivot pin into swivel bracket and through trim ram until pivot pin is flushed with swivel bracket b c a 51148 a Pivot Pin b Swivel Bracket c Trim Ram 8 Drive upper dowel pin RETAINED into its re spective hole until seated a 51147 a Dowel Pin 9 Remove trim fluid fill screw Fluid level should be to bottom of threads Add Quicksilver Power Trim and Steering Fluid 92 90100A12 or Automatic T...

Page 228: ...C 5 50158 MID SECTION POWER TRIM DESIGN II ...

Page 229: ...ical System Troubleshooting 5C 16 COMMANDER 2000 Side Mount Remote Control Power Trim Tilt Electric Start with Warning Horn Wiring Diagram 5C 16 Power Trim System Wiring Diagram 5C 17 Troubleshooting the Down Circuit When Up Circuit is OK 5C 18 Troubleshooting the Up Circuit When Down Circuit Is OK 5C 19 Troubleshooting the Down and Up Circuits All Circuits Inoperative 5C 20 Page Power Trim System...

Page 230: ...or powerhead overheating damage Make sure that water level is above gear housing water intake holes whenever engine is running Operating Up circuit will actuate the up solenoid located under engine cowl and close the electric motor circuit The electric motor will drive the pump thus forcing automatic transmission fluid thru internal passageways into the up side of the trim ram The trim cylinder tr...

Page 231: ...g trim adjustment pin a at planing speed will cause undesirable and or unsafe steering conditions Each boat must be water tested for handling characteristics after engine installation and after any trim adjust ments IMPORTANT Some boat motor combinations that do not use the trim adjustment pin a and are trimmed to the full in trim angle will not experi ence any undesirable and or unsafe steering c...

Page 232: ...5 12 Spring 5 13 Retainer Plate 14 Screw 3 15 O ring 1 600 in I D 2 16 Memory Piston 17 Trim Rod Cylinder 18 Screw 2 19 O ring 208 in I D 2 20 O ring 114 in I D 21 Spool 22 O ring 301 in I D 3 23 Sleeve 24 Spring 25 Valve Seat 26 Valve 27 Spring 2 28 Ball 29 Dowel Pin 2 30 Manifold 31 O ring 114 in I D 32 O ring 208 in I D 33 O ring 239 in I D 34 Relief Valve 35 E Clip 36 Dowel Pin 37 O ring 176 i...

Page 233: ...51644 5C 4 MID SECTION 90 814676R1 DECEMBER 1996 Power Trim Flow Diagrams Design II ...

Page 234: ...51645 90 814676R1 DECEMBER 1996 MID SECTION 5C 5 Design II ...

Page 235: ...51646 5C 6 MID SECTION 90 814676R1 DECEMBER 1996 Design II ...

Page 236: ...51647 90 814676R1 DECEMBER 1996 MID SECTION 5C 7 Design II ...

Page 237: ...51648 5C 8 MID SECTION 90 814676R1 DECEMBER 1996 Design II ...

Page 238: ...51649 90 814676R1 DECEMBER 1996 MID SECTION 5C 9 Design II ...

Page 239: ...51650 5C 10 MID SECTION 90 814676R1 DECEMBER 1996 Design II ...

Page 240: ...position or will not remain tilted for any extended period Outboard will not hold trim position when in reverse Determine if Power Trim pump motor operates when appro priate trim circuit is activated Pump motor operates Refer to Hydraulic System Troubleshooting Refer to Electrical System Troubleshooting Pump motor does not operate 90 814676R1 DECEMBER 1996 MID SECTION 5C 11 Troubleshooting Determi...

Page 241: ...2 Check trim pump fluid level with outboard in full UP position and fill if necessary Refer to Bleeding Power Trim Unit 3 Check for external leaks in Power Trim system Replace defective part s if leak is found 4 Outboard not holding tilted position falls down to trim position indicates debris or defective com ponents in trim valve assembly Clean or replace components as required 5 Check manual rel...

Page 242: ... covered a c b 51560 a Valve and Seat b Pilot Valve O ring c O ring Leak Down Check Manual Release Valve 1 Debris or chips under O ring a 2 Flash from valve molding causing O ring a to not seal 3 Nicked O ring a a 51560 a O ring Leakage Past Ball and Seat Piston Assembly Unit will trim to full or near full DOWN position and then will begin to trim UP while trim switch is held in DOWN mode If trim ...

Page 243: ...efective O rings or components Inspect Oil Pump O rings located below oil pump O ring failure located below oil pump Replace O rings O rings appear to be OK Re place O rings Replace oil pump Inspect Manual Release Valve Outboard falls to full down position with manu al release valve closed Example a Outboard lowers more than one tilt pin hole in eight hours Example b Outboard lowers during acceler...

Page 244: ...g engine cleaner and com pressed air or replace Debris found in manifold reverse thrust valve components No debris found in manifold re verse thrust valve Replace Manifold as a Unit Clean manifold reverse thrust valve without removing compo nents using engine or cleaner and compressed air or replace Inspect Manual Release Valve Outboard will not hold tilted position in reverse and or trails out du...

Page 245: ...r f Warning Horn g Trim Tilt Switch 23891 BLK Black BLU Blue BRN Brown GRY Gray GRN Green PUR Purple RED Red TAN Tan WHT White YEL Yellow a b c d e f g 4 5 7 5C 16 MID SECTION 90 814676R1 DECEMBER 1996 Electrical System Troubleshooting COMMANDER 2000 Side Mount Remote Control Power Trim Tilt Electric Start with Warning Horn Wiring Diagram ...

Page 246: ... POWER TRIM MOTOR TO BATTERY WIRES FROM SIDE MOUNT REMOTE CONTROL HARNESS 1 8 2 6 3 STARTER SOLENOID BLK Black BLU Blue GRN Green RED Red WHT White 90 814676R1 DECEMBER 1996 MID SECTION 5C 17 Power Trim System Wiring Diagram ...

Page 247: ...circuit between Point 3 and positive battery ter minal Connect Voltmeter red lead to Point 2 Connect Voltmeter red lead to Point 3 Connect Voltmeter red lead to Point 4 and black lead to ground Depress Down trim button If bat tery voltage is indicated wire is open between Points 4 and 1 Connect Voltmeter red lead to Point 1 and black lead to ground Depress the Down trim button Depress Down trim bu...

Page 248: ...n circuit between Point 3 and positive battery ter minal Connect Voltmeter red lead to Point 6 Connect Voltmeter red lead to Point 3 Connect Voltmeter red lead to Point 7 and black lead to ground Depress Down 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 button Depress Up trim butt...

Page 249: ...con nections Check for voltage at any instru ment using a Voltmeter Turn ignition switch to Run po sition DO NOT start engine Check for pinched or severed wires Check all trim harness connec tors for loose or corroded con nections Check trim switch Connect Voltmeter red lead to Point 3 and black lead to ground Battery voltage should be indi cated There is an open circuit in wire be tween Point 5 a...

Page 250: ... harness 2 Remove screw and clip securing wiring harness to clamp bracket 3 Use suitable tool to remove DRIVE DOWN up per dowel pin Retain pin 51144 a a Dowel Pin 4 Use suitable punch to drive out upper pivot pin 51144 a a Pivot Pin 5 Use suitable punch to remove DRIVE UP lower dowel pin Retain dowel pin 51144 a a Dowel Pin 6 Use suitable punch to drive out lower pivot pin 51144 a a Pivot Pin ...

Page 251: ...OVE REVERSE THRUST VALVE THIS VALVE IS PRESET AT FAC TORY FOR PRECISE REVERSE THRUST PRES SURE AND DOES NOT REQUIRE ADJUSTMENT 1 Secure power trim assembly in soft jawed vise 2 Open manual release valve three or four turns counterclockwise and position trim rod to full up position 3 Remove cylinder end cap assembly from cylinder using trim cylinder spanner wrench 1 4 in x 5 16 in long pegs 51194 a...

Page 252: ...ng b Memory Piston 7 Remove trim system from vise and empty fluid into appropriate container Trim Rod Disassembly 1 Place trim rod assembly on clean work surface 2 Remove screws securing plate to trim rod piston and O ring 3 Remove check valve components from trim rod piston 51143 b c d a a Screw 3 b Plate c O ring d Piston CAUTION When removing Trim Rod piston spanner wrench must have 1 4 in x 5 ...

Page 253: ...146 51146 b a a Trim Rod Piston b Spanner Wrench CAUTION Do not remove check ball components from trim rod piston Removal and re installation of check valve could result in improper operating pres sure and possible power trim system damage If check valve is defective replace trim rod piston 7 Remove inner O ring from piston 51199 b a c a Check Ball Components b O ring c Piston 8 Remove rod wiper i...

Page 254: ...t from reser voir assembly 51195 a b c a Cap b Washer c Grommet 3 Remove screws securing reservoir cap to reser voir 51193 a a a Screws 4 4 Remove motor harness from reservoir 51196 Trim Motor Disassembly 1 Remove end cap from motor housing Note posi tion of washers on armature 51194 a b c d a End Cap b Motor Housing c Wave Washer 2 d Washer ...

Page 255: ...asher c Armature d Fiber Guard Liner e Housing Reservoir Assembly Removal CAUTION DO NOT ADJUST OR REMOVE REVERSE THRUST VALVE THIS VALVE IS PRESET AT FAC TORY FOR PRECISE REVERSE THRUST PRES SURE AND DOES NOT REQUIRE ADJUSTMENT 1 Remove manual release valve form manifold DO NOT remove or adjust reverse thrust valve a b 51194 a Manual Release Valve b Manifold 2 Remove E clip and O rings from manua...

Page 256: ...anifold 5 Remove drive shaft from oil pump 51194 a b a Drive Shaft b Oil Pump Oil Pump Manifold Removal 1 Remove screw oil pump O rings and check valve components from manifold 51007 a a b c e a d 51006 a O rings 3 b Oil Pump c Screw d Spring e Check Ball 2 Remove screws and manifold from cylinder 51007 a b c a Trim Cylinder b Manifold c Screw ...

Page 257: ...could cause system to malfunction CAUTION Do not remove check valve components a from trim rod piston Removal and re installation of check valve could result in improper operating pressure and possible power trim system dam age 51199 a Inspect check valve for debris clean debris form check valve if found If debris cannot be cleaned from check valve replace trim rod piston as an assembly Clean trim...

Page 258: ... overload switch has been activated pump motor cannot be tested for a minimum of one minute After this period switch should close reset itself and pump motor may be operated Perform the following check s only if switch does not reset itself MOTOR ASSEMBLED Connect Ohmmeter R x 1 scale leads as shown If switch is good full continuity zero ohms will be indi cated If full continuity is not indicated ...

Page 259: ...cated armature is grounded and must be replaced 51195 CHECKING AND CLEANING COMMUTATOR If commutator a is worn it can be turned down on an armature conditioner tool or on a lathe Clean commutator with 00 sandpaper a Power Trim System Reassembly Manifold Oil Pump Installation IMPORTANT Install spring check valve and O ring into manifold Position components in place using sleeve to seat in place 509...

Page 260: ...N m 3 Secure power trim unit in soft jawed vise 4 Install check valve components and O rings to manifold Secure oil pump to manifold using bolt Torque bolt to 90 lb in 10 2 N m 51007 51006 a a b c e a d a O rings 3 b Oil Pump c Screw d Spring e Check Ball Trim Motor Reassembly 1 Apply Quicksilver Marine Lubricant 2 4 C to ar mature shaft and insert into end frame 51195 a b c a Armature Shaft b Was...

Page 261: ...ated O ring to end frame 51194 a b a O ring b Scribe Mark 5 Install washers to armature shaft as shown 6 Install end cap to housing Torque nuts to 25 lb in 2 8 N m 51194 a b c d a End Cap b Motor Housing c Wave Washer d Washer IMPORTANT When installing motor wires black orange must rest in cavity of cylinder al lowing motor to seat properly 51194 a b a Manifold b Cavity ...

Page 262: ...nd cap O ring and foam pad to cylinder 4 Torque screws to 13 lb in 1 5 N m 51195 a b c a End Cap b O ring c Foam Pad 5 Install grommet washer and screw cap to cylin der end cap Tighten screw securely 51195 a b c a Screw Cap b Washer c Grommet 6 Place drive shaft into oil pump 7 Install lubricated O ring to base of reservoir 8 Carefully guide cylinder motor down onto drive shaft 51194 a b a Drive S...

Page 263: ...p b O ring c Manual Release Valve 11 Insert manual release valve into manifold and tighten snuggly Back release valve out 3 or 4 turns allowing trim rod installation 51194 a b a Manual Release Valve b Manifold Trim Rod Reassembly 1 Install lubricated O rings and rod wiper to end cap 51145 b c a a Rod Wiper b Inner O ring c Outer O ring 2 Secure trim rod in soft jawed vise as shown 3 Slide end cap ...

Page 264: ...e using plate and screws Torque screws to 35 lb in 4 0 N m 51147 b c d e f a a Screw 3 b Plate c O ring d Ball 5 e Seat Spring 5 f Spring 5 Trim Rod Installation 1 Place trim cylinder in soft jawed vise 2 Fill trim cylinder three inches 76 2mm from top of cylinder using Quicksilver Power Trim and Steering Fluid or ATF Type F FA or Dexron II 3 Install lubricated O ring to memory piston and place in...

Page 265: ...in the closed position during power trim bleeding and operation 1 Secure power trim unit in soft jawed vise 2 Remove fill screw Add Quicksilver Power Trim and Steering Fluid 92 90100A12 or Automatic Transmission Fluid ATF Type F FA or Dexron II up to threads of reservoir Install cap 50241 3 Using a 12 volt power supply connect positive lead to green wire negative lead to blue wire and drive trim r...

Page 266: ...Pivot Pin b Lower Dowel Pin 3 Position trim cylinder assembly BOTTOM FIRST between clamp brackets and route trim pump electrical harness through access hole in starboard clamp bracket 51195 2 a 1 a Trim Cylinder Assembly 4 Using a suitable punch drive lower pivot pin into clamp bracket and trim cylinder assembly until pivot pin is flush with outside surface 51147 a a Lower Pivot Pin 5 Using a suit...

Page 267: ...vot pin into swivel bracket and through trim ram until pivot pin is flushed with swivel bracket 51148 b c a a Pivot Pin b Swivel Bracket c Trim Ram 8 Drive upper dowel pin a into its hole until seated 51147 a 9 Recheck fluid level 10 Power trim may now be operated to lower out board to desired position Trim system is self bleeding 11 Re connect spark plug leads to spark plugs 12 Re install top cow...

Page 268: ...D 5 51486 MID SECTION POWER TRIM DESIGN 3 ...

Page 269: ...Remote Control Power Trim Tilt Electric Start with Warning Horn Wiring Diagram 5D 9 Power Trim System Wiring Diagram 5D10 Troubleshooting the Down Circuit When Up Circuit is OK 5D 11 Troubleshooting the Up Circuit When Down Circuit Is OK 5D 12 Troubleshooting the Down and Up Circuits All Circuits Inoperative 5D 13 Page Power Trim System Removal 5D 14 Power Trim System Disassembly 5D 15 Trim Rod Re...

Page 270: ...excess can cause insufficient water supply to wa ter pump resulting in serious water pump and or pow erhead overheating damage WARNING Excessive engine trim angle will result in insuffi cient water supply to water pump causing water pump and or powerhead overheating damage Make sure that water level is above gear housing water intake holes whenever engine is running Operating Up circuit will actua...

Page 271: ...unterclockwise 52028 a a Manual Release Valve Trim In Angle Adjustment WARNING Operating some boats with engine trimmed to the full in trim angle not using trim adjustment bolt a at planing speed will cause undesirable and or unsafe steering conditions Each boat must be water tested for handling characteristics after engine installation and after any trim adjust ments IMPORTANT Some boat motor com...

Page 272: ...ECEMBER 1996 MID SECTION 5D 3 Power Trim System Components 1 Tilt Trim Cylinder 2 Reservoir Motor Housing 3 Piston Rod 4 Upper Pivot Shaft 5 Cross Pin 6 O ring 7 End Cap Seal 8 End Cap 9 O ring 10 O ring 11 Piston Assembly 12 O ring 13 O ring 14 Memory Piston 15 Lower Pivot Shaft 16 Cross Pin 17 Screw 2 18 Pump Assembly 19 Pilot Valve Assembly 20 O ring 21 Driveshaft 22 Washer 4 23 Screw 4 24 Fill...

Page 273: ...d trim po sition when in reverse Determine if Power Trim pump motor operates when appropriate trim circuit is activated Pump motor operates Refer to Hydraulic System Troubleshooting Refer to Electrical System Troubleshooting Pump motor does not operate Problem Chart 5D 4 MID SECTION 90 814676R1 DECEMBER 1996 Troubleshooting Determining if Problem is Electrical or Hydraulic When a problem is encoun...

Page 274: ...n 2 Check trim pump fluid level with outboard in full UP position and fill if necessary Refer to Fill and Purge the Power Trim System 3 Check for external leaks in Power Trim system Replace defective part s if leak is found 4 Outboard not holding tilted position falls to trim in position indicates debris or defective compo nents in trim valve assembly Clean or replace components as required 5 Chec...

Page 275: ...ed b a c 51560 a Valve and Seat b Pilot Valve O ring c O ring Leak Down Check Manual Release Valve 1 Debris or chips under O ring a 2 Flash from valve molding causing O ring a to not seal 3 Nicked O ring a 51560 a a O ring Leaks Past Ball and Seat Piston Assembly Unit will trim to full or near full down position and then will begin to trim up while trim switch is held in DOWN mode If trim switch i...

Page 276: ...rings appear to be OK Re place O rings Inspect Memory Piston O ring Inspect Manual Release Valve Outboard falls to full down position with manu al release valve closed Example a Outboard lowers more than one tilt bolt hole in eight hours Example b Outboard lowers during acceler ation Result Result Result Results Results All components appear to be OK Replace Manifold and Pump Assembly Results O ri...

Page 277: ...nd Inspect Manifold Reverse Thrust Valve Debris found in check valve com ponents Clean check valve components using engine cleaner and com pressed air or replace Inspect Manual Release Valve Outboard will not hold tilted position in reverse and or trails out during high speed decelera tion Results Results Results Results Replace Pump and Manifold Assembly 5D 8 MID SECTION 90 814676R1 DECEMBER 1996...

Page 278: ... Warning Horn g Trim Tilt Switch 23891 BLK Black BLU Blue BRN Brown GRY Gray GRN Green PUR Purple RED Red TAN Tan WHT White YEL Yellow a b c d e f g 4 5 7 UP DOWN 90 814676R1 DECEMBER 1996 MID SECTION 5D 9 Electrical System Troubleshooting COMMANDER 2000 Side Mount Remote Control Power Trim Tilt Electric Start with Warning Horn Wiring Diagram ...

Page 279: ...trol Harness 51507 Negative Trim Motor UP Trim Motor DOWN Positive Trim Switch to UP Relay Trim Switch to DOWN Relay 1 8 3 Start Solenoid To Battery BLK BLU GRN RED BLU WHT GRN WHT Black Blue Green Red Blue White Green White 5D 10 MID SECTION 90 814676R1 DECEMBER 1996 Power Trim System Wiring Diagram ...

Page 280: ...lying cur rent to Point 5 Down Relay is Defective Replace and retest Connect Voltmeter red lead to Point 4 and black lead to ground Depress Down trim button If bat tery voltage is indicated wire is open between Points 4 and 1 Connect Voltmeter red lead to Point 1 and black lead to ground Depress the Down trim button 90 814676R1 DECEMBER 1996 MID SECTION 5D 11 Troubleshooting the Down Circuit When ...

Page 281: ...pplying cur rent to Point 5 UP Relay is defective Replace and retest Connect Voltmeter red lead to Point 7 and black lead to ground Depress Down 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 button 5D 12 MID SECTION 90 814676R1 DECEMBER 1996 Troubleshooting the Up Circuit When Down...

Page 282: ...or voltage at any instru ment using a Voltmeter Turn ignition switch to Run po sition DO NOT start engine Check for pinched or severed wires Check all trim harness connec tors for loose or corroded con nections Check trim switch Connect Voltmeter red lead to Point 3 and black lead to ground Battery voltage should be indi cated There is an open circuit in wire be tween Point 5 and Red terminal on t...

Page 283: ...e sender if equipped 4 Use suitable tool to remove upper headed cross pin Retain pin Straight pin is hard to remove see item 5 a 51505 b a Cross Pin Design 1 Straight b Cross Pin Design 2 Headed 5 Drive out upper pivot pin This will shear cross pin a 50515 a Upper Pivot Pin Inspect cross pin hole and pivot pin hole for damage 6 Use suitable punch to remove DRIVE UP lower dowel pin Retain dowel pin...

Page 284: ... Power Trim System Disassembly Trim Rod Removal 1 Secure power trim assembly in soft jawed vise 2 Open manual release valve three turns maxi mum counterclockwise and position trim rod to full up position 3 Remove cylinder end cap assembly from cylinder using spanner wrench 1 4 in x 5 16 in long pegs 51194 a b c a Manual Release Valve b Manifold c Spanner Wrench P N 91 74951 4 Remove trim rod assem...

Page 285: ...ton 7 Remove trim system from vise and empty fluid into appropriate container Trim Rod Disassembly 1 Place trim rod assembly on clean work surface 2 Remove screws securing plate to trim rod piston and O ring 3 Remove check ball components from trim rod piston 51143 b c d a a Screw 3 b Plate c O ring d Piston CAUTION When removing Trim Rod piston spanner wrench must have 1 4 in x 5 16 in long pegs ...

Page 286: ...amp 51146 b c b Spanner Wrench c Trim Rod Piston CAUTION Do not remove check ball components a from trim rod piston Removal and re installation of check valve could result in improper operating pressure and possible power trim system dam age If check valve is defective replace trim rod piston 7 Remove inner O ring from piston 51199 b a c a Check Ball Components b O ring c Piston 8 Remove rod wiper...

Page 287: ...tor from reservoir 51484 Trim Motor Disassembly 1 Remove armature from motor frame Note posi tion of washers on armature 51486 a b c c a Armature b Motor Frame c Washer 1 each end of armature Reservoir Assembly Removal 1 Remove manual release valve from manifold a b a Manual Release Valve b Manifold 2 Remove E clip and O rings from manual re lease valve 51196 a b c a E Clip b O rings c Manual Rele...

Page 288: ...l 1 Remove screws and manifold from cylinder 51007 a b c a Trim Cylinder b Manifold c Screw 2 2 Remove check valve components from manifold IMPORTANT Sleeve d is chamfered on I D on end opposite drilled cross hole Install spool b with O ring installed from chamfered end of sleeve to avoid possibility of damaging O ring on spool d e c b a 51560 f g h a O ring 0 114 I D b Spool c O ring 0 301 I D 3 ...

Page 289: ...ing Quicksilver Power Trim and Steering Fluid or ATF Type F FA or Dexron II Motor and Electrical Tests Repair Trim Pump Motor Test WARNING Do not perform this test near flammables or ex plosives as a spark may occur when making connections 1 Disconnect green motor wire and blue motor wire from trim system wiring harness 2 Connect a 12 volt power supply to motor wires positive to blue negative to g...

Page 290: ... be replaced when in stalling Screw and Seal Kit 811226A1 in manifold 50999 b a c d a Spring b O ring c Sleeve d Valve Seat 1 Install check valve components into manifold d e c b a 51560 f g h a O ring 0 114 I D b Spool c O ring 0 301 I D 3 each d Sleeve e Spring f Valve Seat g Valve h Spring IMPORTANT Sleeve d is chamfered on I D on end opposite drilled cross hole Install spool e with O ring inst...

Page 291: ...nd install armature and motor frame into end cap As brushes contact commutator re lease brush tension spring from ends of brush housings returning springs to apply brush pres sure to commutator Install washer on each end of armature before installing armature into end cap see inset 51484 a d c b b a End Cap Bushing Lubricate with Quicksilver 2 4 C Lubricant b Brush 2 c Commutator d Brush Tension S...

Page 292: ... motor down onto drive shaft 51486 a b a Drive Shaft b O ring 5 Secure reservoir to manifold using four screws Torque screws to 70 lb in 7 7 N m 51193 a a a Screws 4 6 Install lubricated O rings and E clip to manual release valve 51196 a b c a E Clip b O ring c Manual Release Valve 7 Insert manual release valve into manifold and tighten snuggly Back release valve out 3 turns maximum allowing trim ...

Page 293: ...ap 4 Apply Loctite Grade A 271 to threads of trim rod and install rod piston Tighten piston securely us ing spanner wrench 1 4 in x 5 16 in long peg 51146 b a a Trim Rod Piston b Spanner Wrench 5 Install lubricated O ring to trim rod piston 6 Install check ball components into its respective bore 7 Secure components in place using plate and screws Torque screws to 35 lb in 4 0 N m 51147 b c d e f ...

Page 294: ...nstall lubricated O ring to memory piston and place into cylinder Push piston down to level of oil Memory piston must not contact end cap during trim rod end cap installation 51144 b a a O ring b Memory Piston 4 Install trim rod into cylinder 51196 5 Tighten end cap assembly to cylinder securely using spanner wrench 1 4 in x 5 16 in long pegs 51145 a a Spanner Wrench P N 91 74951 6 Tighten manual ...

Page 295: ...rim rod to the down position Connect posi tive lead to blue wire and negative lead to green wire and drive trim rod to the up position Re check fluid level add fluid as required and repeat cycle until fluid level remains at lower portion of threads Power Trim Unit Installation 1 Apply Special Lubricant 101 92 13872A1 to lower pivot pin bore and pivot pin surface 2 Start lower pivot pin into pivot ...

Page 296: ... bracket and trim cylinder assembly until pivot pin is flush with outside surface 51148 a Lower Dowel Pin 6 Apply Special Lubricant 92 13872A1 to surface of upper pivot pin pivot pin bore and trim ram bore NOTE Install trim ram with cross hole located as shown If trim ram is installed reversed the trim send er if installed will not operate 51515 a b b c Transom Side Cross Hole Engine Side d a Pivo...

Page 297: ...5 a Pivot Pin b Swivel Bracket c Trim Ram 8 Drive upper retaining pin a in until seated a 51505 9 Recheck fluid level 10 Power trim may now be operated to lower out board to desired position Trim system is self purging 11 Reconnect power trim leads to relays under igni tion cover 12 Reinstall spark plug leads to spark plugs 13 Reinstall cowls 14 Connect battery leads to battery terminals ...

Page 298: ...E 5 55331 MID SECTION POWER TRIM DESIGN 4 ...

Page 299: ...ooting the Power Trim Electrical System Wiring Diagram 5E 25 Troubleshooting the Power Trim Electrical System 5E 26 Power Trim System Removal 5E 27 Power Trim Disassembly 5E 28 Trim Motor Removal 5E 29 Pump and Components Removal 5E 29 Manifold Removal 5E 30 Shock Rod Removal 5E 30 Shock Rod Disassembly 5E 31 Memory Piston Removal 5E 33 Cleaning Inspection Repair 5E 34 Trim Motor Electrical Tests ...

Page 300: ...90 814676R1 DECEMBER 1996 MID SECTION 5E 1 Special Tools 1 Spanner Wrench P N 91 74951 2 Lock Ring Pliers P N 91 822778A3 3 Expanding Rod P N CG 41 11 4 Collet P N CG 41 14 ...

Page 301: ...18 19 17 20 21 22 23 24 25 26 4 4 16 A 95 7 95 D D C B E F 7 Loctite 271 92 809820 95 2 4 C With Teflon 92 825407A12 NOTE Lubricate all O rings using Quicksilver Power Trim and Steering Fluid If not available use automotive ATF automatic transmission fluid NOTE It is recommended that all o rings be replaced when servicing tilt system ...

Page 302: ...SE ASSEMBLY Drive Tight 11 1 MANIFOLD KIT 12 1 SCREW KIT MOTOR 80 9 0 13 1 DRIVE SHAFT 14 1 FILTER KIT 15 1 P O CHECK ASSEMBLY KIT 120 13 5 16 1 CABLE 1 O RING KIT COMPLETE TRIM 17 2 GROOVE PIN 18 1 ANCHOR PIN 19 1 PIN 20 1 BRACKET 21 1 HARNESS Trim 22 2 SCREW M6 x 25 23 2 RELAY 24 2 BRACKET 25 2 GROMMET 26 2 BUSHING A Torque cylinder cap to 45 lb ft 61 N m B Torque screws to 80 lb in 9 0 N m C To...

Page 303: ...head overheating damage Make sure that water level is above gear housing water intake holes whenever engine is running Operating Up circuit will actuate the up relay lo cated under engine cowl and close the electric motor circuit The electric motor will drive the pump thus forcing automatic transmission fluid through internal passageways into the up side of the trim cylinder The trim cylinder trim...

Page 304: ... is running While operating up circuit the cylinder rod will con tinue to tilt the outboard to a full up position for trail ering Tilting Outboard Up and Down Manually WARNING Before loosening the manual release valve make sure all persons are clear of engine as engine will drop to full down position when valve is loos ened With power trim installed the outboard can be raised or lowered manually b...

Page 305: ... n l g o p q r s POWER TRIM FLOW DIAGRAMS a Piston Rod b End Cap c Electric Motor d Reservoir Oil e Down Pressure Regulating Valve f Down Pressure Operated Valve g Filter 2 shown for clarity h Shock Return Valve i Up Circuit Suction Port j Oil Pump k Down Circuit Suction Port l Oil Fill Cap m Shuttle Valve n Up Pressure Operated Valve o Manifold Reverse Suction Valve p Manual Release Valve q Manif...

Page 306: ... Oil in the up circuit is blocked from return ing into the reservoir by the ball inside the down cir cuit suction port k The pressure of the oil will force the up circuit pressure operated valve n to open al lowing the oil to enter the passages inside the man ifold q leading to the trim cylinder w up cavity Oil is blocked from all other passages by the closed manual tilt valve p Oil under pressure...

Page 307: ...l g m n o p q r s t u v w c a Piston Rod b End Cap c Electric Motor d Reservoir Oil e Down Pressure Regulating Valve f Down Pressure Operated Valve g Filter 2 shown for clarity h Shock Return Valve i Up Circuit Suction Port j Oil Pump k Down Circuit Suction Port l Oil Fill Cap m Shuttle Valve n Up Pressure Operated Valve o Manifold Reverse Suction Valve p Manual Release Valve q Manifold r Tilt Rel...

Page 308: ... piston s to open the tilt pressure relief valve r This valve lowers the amount of pressure available to lift the outboard motor With the engine in forward gear and at high engine rpm the oil pres sure available will not be able to overcome the pro peller thrust limiting the trim range to below the pres sure relief orifice When the engine rpm s fall or if engine is not in forward gear the oil pres...

Page 309: ... j k l m n o p q r s t u v w a Piston Rod b End Cap c Electric Motor d Reservoir Oil e Down Pressure Regulating Valve f Down Pressure Operated Valve g Filter 2 shown for clarity h Shock Return Valve i Up Circuit Suction Port j Oil Pump k Down Circuit Suction Port l Oil Fill Cap m Shuttle Valve n Up Pressure Operated Valve o Manifold Reverse Suction Valve p Manual Release Valve q Manifold r Tilt Re...

Page 310: ...ravel and due to no rod movement the pressure inside of the trim cylin der w will increase to the pressure required to move the tilt relief piston s The tilt relief piston s pin opens the tilt relief valve r Up pressure flows into the trim relief passage and returns back into the res ervoir ...

Page 311: ... n m o p q r s g f e h v u t a Piston Rod b End Cap c Electric Motor d Reservoir Oil e Down Pressure Regulating Valve f Down Pressure Operated Valve g Filter 2 shown for clarity h Shock Return Valve i Up Circuit Suction Port j Oil Pump k Down Circuit Suction Port l Oil Fill Cap m Shuttle Valve n Up Pressure Operated Valve o Manifold Reverse Suction Valve p Manual Release Valve q Manifold r Tilt Re...

Page 312: ...suction port i Oil under pressure opens the down pressure operated valve f and enters the down passages inside of the man ifold q The manifold passage connects into the trim cylinder passage leading to the top of the cylinder The cavity inside the cylinder above the shock pis ton u is the down cavity As the down cavity fills with oil the piston rod a retracts into the cylinder lower ing the outboa...

Page 313: ... j k m n l g o p q r s a Piston Rod b End Cap c Electric Motor d Reservoir Oil e Down Pressure Regulating Valve f Down Pressure Operated Valve g Filter 2 shown for clarity h Shock Return Valve i Up Circuit Suction Port j Oil Pump k Down Circuit Suction Port l Oil Fill Cap m Shuttle Valve n Up Pressure Operated Valve o Manifold Reverse Suction Valve p Manual Release Valve q Manifold r Tilt Relief V...

Page 314: ...sure in creases inside the trim cylinder down cavity and con necting passages When the pressure increases to the level required the impact relief valves v located inside the shock piston u will open and allow the fluid to pass through the shock piston As the fluid passes through the piston the piston rod a will ex tend from the trim cylinder The memory piston t is held in position by vacuum create...

Page 315: ...f g k l g m n o p q r s a Piston Rod b End Cap c Electric Motor d Reservoir Oil e Down Pressure Regulating Valve f Down Pressure Operated Valve g Filter 2 shown for clarity h Shock Return Valve i Up Circuit Suction Port j Oil Pump k Down Circuit Suction Port l Oil Fill Cap m Shuttle Valve n Up Pressure Operated Valve o Manifold Reverse Suction Valve p Manual Release Valve q Manifold r Tilt Relief ...

Page 316: ...ory piston t and shock piston u to the level required to open the shock return valve h inside the shock piston allowing the oil to bleed back through the shock piston into the down cavity If re quired additional oil will enter the down cavity through the manifold reverse suction valve o This will return the engine back against the memory piston t and into the original running position ...

Page 317: ... i j k l m n g o p q r s e f g a Piston Rod b End Cap c Electric Motor d Reservoir Oil e Down Pressure Regulating Valve f Down Pressure Operated Valve g Filter 2 shown for clarity h Shock Return Valve i Up Circuit Suction Port j Oil Pump k Down Circuit Suction Port l Oil Fill Cap m Shuttle Valve n Up Pressure Operated Valve o Manifold Reverse Suction Valve p Manual Release Valve q Manifold r Tilt ...

Page 318: ...ith the valve backed out the internal pas sages inside the manifold are connected together These passages connect both the cylinder down and up cavities together along with the reservoir allow ing the engine to be raised or lowered Piston rod a movement will continue until the manual release valve p is closed locking the fluid inside of the cylin der and manifold ...

Page 319: ...ve removal Refer to instructions following if disassembly is re quired when servicing Follow preliminary checks before proceeding to trou bleshooting flow diagrams following Preliminary Checks IMPORTANT Operate Power Trim system after each check to see if problem has been corrected If problem has not been corrected proceed to next check 1 Check that manual release valve is tightened to full right ...

Page 320: ...omplete Remove and inspect pis ton rod assembly for de bris and or shock ball hang up Shock piston appears O K Clean and reinstall piston rod assembly Trim system holds reverse thrust Test ing complete Debris and or shock ball hang up identi fied Replace piston rod assembly Trim system holds reverse thrust Test ing complete Trim will not hold reverse thrust Remove PO check valve assembly inspect O...

Page 321: ...tion seat assembly Remove suction seat as sembly and inspect for debris and or damage Debris and or damage identified Trim system holds reverse thrust Test ing complete Trim will not hold reverse thrust Suction seat assembly ap pears O K Clean and rein stall suction seat assembly Trim system holds reverse thrust Test ing complete ...

Page 322: ...ef valving and inspect O rings and seals for debris and or damage Debris and or dam age identified Replace tilt relief valving Trim system does not leak down Test ing complete Trim system leaks down Tilt relief valving and O rings appear to be O K Clean and reinstall tilt relief valving Trim system does not leak down Test ing complete Remove PO check valve assembly inspect O rings and seals for da...

Page 323: ...place trim system continued Replace memory pis ton and shock piston O rings Inspect memory pis ton O ring and cylinder bore Cylinder bore appears smooth with no debris Cylinder bore appears rough and or debris found in cylinder Trim leaks down Trim system does not leak down Test ing complete ...

Page 324: ...UP RED PUR A B RED RED PUR DN UP LT GRN WHT LT BLU WHT RED RED GRN WHT BLU WHT RED DN UP GRN WHT BLU WHT Trim Switch Remote Control Mounted Trim Switch Panel Mounted Fuse Holder Solenoid Fuse Holder Down Relay Up Relay Cowl Switch RED GRN WHT or GRN BLU WHT or PUR 1 3 2 4 GRN 14 BLK RED BLK Battery LT GRN WHT LT BLU WHT Trim Pump Motor ...

Page 325: ...ut the Trim Switch DOWN does operate 1 Open wire between Wire Connection 2 and Solenoid 2 Faulty Cowl Switch 1 Check for an open connection or cut wire 2 Replace Trim Switch DOWN and Cowl Switch DOWN are both inoperative 1 Open wire between Wire Connection 3 and the Up Relay 2 Open BLK wire between ground and Down Relay 3 Open RED wire between Solenoid and Down Relay 4 Faulty Down Relay 1 Check fo...

Page 326: ... support with tilt lock pin 55464 a a Tilt Lock Pin 2 Disconnect the power trim wire harness and re move clamp 55264 a b a Power Trim Wire Harness Clamp b Harness 3 Remove the trilobe pin 4 Drive out the upper pivot pin a b a Trilobe Pin b Upper Pivot Pin 5 Remove the sacrificial anode a 55331 a Sacrificial Anode ...

Page 327: ... drive out lower pivot pin 51144 a a Lower Pivot Pin Power Trim Disassembly IMPORTANT Power trim system is pressurized Trim rod must be in the full UP position fully extended prior to fill drain plug or manual re lease valve removal 1 Remove reservoir cap 2 Remove manual release valve assembly to drain oil 55263 a b a Reservoir Cap b Manual Release Valve ...

Page 328: ...ler e Manifold Assembly Pump and Components Removal 1 Remove pressure operated plugs on pump Re move spring and check valve poppet both sides Use special tool CG 41 11 and special tool CG 41 14 with 5 16 end to remove spool a a b d c b c d e a Plug 2 b Spring 2 c Check Valve Poppet 2 d Seat 2 e Spool IMPORTANT Inspect poppet assembly for debris in the area shown If debris is found on poppet replac...

Page 329: ...al c Filter d Suction Seat Assembly Manifold Removal 1 Remove two 2 screws to remove manifold from cylinder 51146 a a Screw 2 2 Remove tilt relief components 51008 a b c d a Spring b Poppet c Spool Housing d Trim Limit Spool Shock Rod Removal 1 Unscrew end cap assembly from cylinder using spanner wrench 1 4 in x 5 16 in 6 4mm x 8mm long pegs 2 Remove shock rod assembly from cylinder ...

Page 330: ...ther repair replace shock rod assem bly a c b b a End Cap b O ring c Wiper Ring 1 Place shock rod assembly on clean work surface 2 Remove three 3 screws and remove plate from shock rod piston 51143 a b c a Screw 3 b Plate c Shock Rod Piston 3 Remove check ball components from shock rod piston 4 Remove o ring from shock rod piston 51147 a b c d a Spring 5 b Seat 5 c Ball 5 d O ring ...

Page 331: ...146 51146 a b a Spanner Wrench b Shock Rod Piston 8 Inspect check valve for debris clean debris from check valve if found If debris cannot be cleaned from check valve replace shock piston as an as sembly 9 Clean shock and components with compressed air 10 Remove inner o ring from shock rod piston 51199 a b a Shock Piston b O ring 11 Remove cylinder end cap assembly from shock rod 12 Inspect shock ...

Page 332: ...alve hole using adaptor P N 91 822778A3 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 NOTE Point cylinder opening down and away Use a shop rag or towel to avoid damage to the memory piston a 55466 a a b c a Adaptor Air Hose b Memory Piston Exit c Shop Rag 2 Remove o ring from memory...

Page 333: ...er and dry with compressed air It is recommended that all O rings in trim system be replaced Use O Ring Kit 25 827668A1 Lubricate all o rings with Quicksilver Power Trim Fluid 92 90100A12 If not available use automo tive ATF automatic transmission fluid Trim Motor Electrical Tests 1 Connect a 12 volt supply to motor leads If motor fails to run replace pump motor IMPORTANT Trim Motor is not service...

Page 334: ...90 814676R1 DECEMBER 1996 MID SECTION 5E 35 Reassembly O Ring and Seal Placement O Rings and Seals are part of O Ring Kit 25 809880A1 3 4 22 21 6 20 19 11 12 16 17 8 10 18 10 8 7 15 13 2 5 1 9 9 9 14 ...

Page 335: ...1 2 11 3 4 22 6 5 8 10 12 17 18 15 20 16 19 21 O D I D Cutaway View of O Ring Width O RINGS SHOWN ARE ACTUAL SIZE 9 7 13 14 5E 36 MID SECTION 90 814676R1 DECEMBER 1996 O ring Sizes ...

Page 336: ...P O Check Seat07328 0 364 in 9 25 mm 0 504 in 12 80 mm 0 07 in 1 78 mm 11 2 Pump Port 0 145 in 3 683 mm 0 285 in 7 239 mm 0 07 in 1 78 mm 12 Suction Seat 0 239 in 6 07 mm 0 379 in 9 626 mm 0 07 in 1 78 mm 13 Filter Seal12607 14 Filter12590 15 Manual Release406483 0 114 in 2 90 mm 0 254 in 6 451 mm 0 07 in 1 78 mm 16 Manual Release06226 0 176 in 4 47 mm 0 316 in 8 026 mm 0 07 in 1 78 mm 17 Manual R...

Page 337: ... c b a a Shock Piston b O ring c O ring 4 Clamp shock rod in soft jawed vise 5 Position cylinder end cap onto rod as shown 51146 CAUTION When installing shock rod piston spanner wrench must have1 4 in x 5 16 in 6 4mm x8mm long pegs to avoid damage to shock rod piston 6 Apply Loctite Grade A 271 to threads on shock rod 7 Install shock rod piston 8 Tighten shock rod piston securely using spanner wre...

Page 338: ...b O ring 3 Fill cylinder three inches 76 2mm from top of cylinder using Quicksilver Power Trim and Steer ing Fluid If not available use automotive ATF automatic transmission fluid 4 Install shock rod into cylinder until power trim fluid flows through oil blow off ball passage Fill re maining cylinder to just below the cylinder threads a a Oil Blow Off Ball Passage CAUTION End cap must not make con...

Page 339: ...gines 51008 or a b c d a Spring b Poppet c Spool Housing d Trim Limit Spool Manual Release Valve Installation 1 Install E clip if removed and lubricate O rings to manual release valve 2 Install manual release valve assembly into man ifold b a c a Manifold b Manual Release Valve c E Clip Manifold Installation 1 Install dowel pin and two 2 lubricated O rings into trim cylinder a b a O Rings 2 b Dowe...

Page 340: ... 100 lb in 11 N m Oil Pump Installation 1 Install spring ball lubricated O ring and plastic seat to manifold 2 Check to see that O rings are placed on bottom of pump 3 Install filter and filter seal under pump Install pump onto manifold Torque screws to 70 lb in 7 7 N m a b a Screws 3 Torque to 70 lb in 7 7 N m b Suction Seat Assembly ...

Page 341: ...c c d e b a Plugs 2 Torque to 120 lb in 13 5 N m b Springs 2 c Check Valve Poppet 2 d Seats 2 e Spool Reservoir Motor Installation 3 Install coupler into top of pump Make sure reser voir seal is in the reservoir groove and place res ervoir onto pump manifold assembly Install ground strap under screw shown Torque screws to 80 lb in 9 N m b d e a c f a Screw 4 Torque to 80 lb in 9 N m b Reservoir c ...

Page 342: ...sition Repeat for three times 5 Connect the positive lead to the green trim mo tor wire and the negative lead to the blue trim motor wire and drive the shock rod to the down position 6 Recheck fluid level add fluid if required and re peat cycle until fluid level stays even with the bot tom of the fill hole Installation of Power Trim System 1 Lubricate lower pivot pin mounting holes with 2 4 C Mari...

Page 343: ...r Pivot Pin 5 Using a suitable punch drive lower dowel pin into its hole until seated 51148 a a Lower Dowel Pin 6 Apply 2 4 C Marine Lubricant 92 90018A12 to surface of upper pivot pin pivot pin bore and trim ram bore 51148 a c b a Pivot Pin b Pivot Pin Bore c Trim Ram Bore 7 Using a suitable mallet drive upper pivot pin into swivel bracket and through trim ram until pivot pin is flush with swivel...

Page 344: ...be Pin 9 Install sacrificial aluminum anode to reservoir bracket placing ground strap between bracket and anode as shown 55465 a c b a Sacrificial Anode b Ground Strap c Bracket 10 Route trim harness through clamp bracket and cowling 55264 a a Trim Harness 11 Secure trim harness with clamp as shown a a Clamp ...

Page 345: ...F 5 MID SECTION MANUAL TILT SYSTEM DESIGN I II III ...

Page 346: ...Flow Diagrams Design 3 5F 13 Hydraulic System Troubleshooting 5F 18 Troubleshooting Flow Chart 5F 19 Manual Tilt System Removal 5F 21 Manual Tilt System Disassembly 5F 22 Accumulator Removal 5F 22 Shock Rod Removal 5F 23 Shock Rod Disassembly 5F 24 Valve Block Removal 5F 26 Valve Block Disassembly 5F 27 Manual Tilt System Cleaning and Inspection 5F 28 Manual Tilt System Reassembly 5F 28 Valve Bloc...

Page 347: ...emory Piston 21 Screw 2 22 O ring 208 in I D 2 23 Pipe Plug 24 Spring Large 25 Spring Small 26 Ball 27 Plunger 28 Screw Plug 2 29 Spring 2 30 O ring 2 31 Ball 2 32 Push Rod 2 33 Dowel Pin 34 Spool 35 Spring 36 O ring 301 in I D 37 Screw Plug 38 O ring 301 in I D 39 Cam Shaft 40 Insulator 41 Retainer Plate 42 Screw 43 O ring 2 114 in I D 44 Push Rod 45 Ball 46 Flat Spring 47 Screw Design One Only 4...

Page 348: ...ug 24 Spring Large 25 Spring Small 26 Ball 27 Plunger 28 Screw Plug 2 29 Spring 2 30 O ring 2 31 Ball 2 32 Push Rod 2 33 Dowel Pin 34 Spool 35 Spring 36 O ring 301 in I D 37 Screw Plug 38 O ring 301 in I D 39 Cam Shaft 40 Insulator 41 Retainer Plate 42 Screw 43 O ring 2 114 in I D 44 Push Rod 45 Ball 46 Flat Spring 47 Screw Quicksilver Lubricant Sealant Application Points Lubricate ALL O rings usi...

Page 349: ...90 814676R1 DECEMBER 1996 MID SECTION 5F 3 Manual Tilt Flow Diagrams Design 1 51651 ...

Page 350: ...5F 4 MID SECTION 90 814676R1 DECEMBER 1996 Design 1 51652 ...

Page 351: ...90 814676R1 DECEMBER 1996 MID SECTION 5F 5 Design 1 51653 ...

Page 352: ...5F 6 MID SECTION 90 814676R1 DECEMBER 1996 Design 1 51654 ...

Page 353: ...90 814676R1 DECEMBER 1996 MID SECTION 5F 7 Design 1 51655 ...

Page 354: ...5F 8 MID SECTION 90 814676R1 DECEMBER 1996 Manual Tilt Flow Diagrams Design 2 51656 ...

Page 355: ...90 814676R1 DECEMBER 1996 MID SECTION 5F 9 Design 2 51657 ...

Page 356: ...5F 10 MID SECTION 90 814676R1 DECEMBER 1996 Design 2 51658 ...

Page 357: ...90 814676R1 DECEMBER 1996 MID SECTION 5F 11 Design 2 51659 ...

Page 358: ...5F 12 MID SECTION 90 814676R1 DECEMBER 1996 Design 2 51660 ...

Page 359: ...90 814676R1 DECEMBER 1996 MID SECTION 5F 13 Manual Tilt Flow Diagrams Design 3 51661 ...

Page 360: ...5F 14 MID SECTION 90 814676R1 DECEMBER 1996 Design 3 51662 ...

Page 361: ...90 814676R1 DECEMBER 1996 MID SECTION 5F 15 Design 3 51663 ...

Page 362: ...5F 16 MID SECTION 90 814676R1 DECEMBER 1996 Design 3 51664 ...

Page 363: ...90 814676R1 DECEMBER 1996 MID SECTION 5F 17 Design 3 51665 ...

Page 364: ...board with tilt lock lever when servicing manual tilt system 1 Check manual release cam adjustment Cam must open and close freely Adjust cam link rod as necessary 51143 c a b a Link Rod b Manual Release Lever c Accumulator 2 Check for external leaks in the manual tilt system Replace defective part s if leak is found IMPORTANT If cut or damaged O rings are found inspect machined surfaces for scorin...

Page 365: ...ton O ring O ring defect Replace defective O ring O ring appears to be o k cylinder bore and memory piston are o k Replace O rings and proceed Inspect Transfer Valve No debris or defective components found Replace valve block Debris or defective components found in transfer valve Clean components using engine cleaner and compressed air or replace as necessary Results Results Results Results Tilt r...

Page 366: ... using engine clean er and compressed air or replace Inspect transfer valve s No debris or defective components found in transfer valve s Debris or defective components found in transfer valve s Inspect valve block Clean transfer valve s components using engine cleaner and compressed air or re place No debris found in valve block passages Debris found in valve block passages Replace defective valv...

Page 367: ...r damag ing engine or causing personal injury To avoid such injury support outboard in the up position using tilt lock lever WARNING Manual tilt system is pressurized Accumulator must be removed when shock rod is in the full up position prior to servicing otherwise oil spray back may occur 1 Support outboard in the up position using tilt lock lever 2 Remove link rod 51143 b a a Link Rod b Accumula...

Page 368: ...l Tilt System Manual Tilt System Disassembly NOTE Accumulator contains a high pressure nitro gen charge and is NOT SERVICEABLE Replace if necessary WARNING This tilt system is pressurized Remove accumu lator only when shock rod is in full up position Accumulator Removal 1 Place manual tilt system in soft jawed vise 2 Position shock rod to full up position 3 Remove accumulator 51143 b 1 2 a a Shock...

Page 369: ... compressed into accumulator by hand accumulator is defective Replace accu mulator 51143 a a Plunger 5 Remove O ring 51145 Shock Rod Removal 1 Remove cylinder end cap assembly using span ner wrench 1 4 in x 5 16 in long pegs 51145 2 Remove shock rod assembly 51143 ...

Page 370: ... Piston 5 Remove tilt system from vise and empty fluid into appropriate container Shock Rod Disassembly 1 Place shock rod assembly on clean work surface 2 Remove plate and O ring 3 Remove check ball components from shock rod piston 51143 b c d a a Screw 3 b Plate c O ring d Shock Rod Piston CAUTION When removing shock piston spanner wrench must have 1 4 in x 5 16 in long pegs to avoid damage to sh...

Page 371: ...heck ball components from shock rod piston Removal and reinstallation of check valve could result in improper operating pressure and possible manual tilt system dam age 7 Inspect check valve for debris clean debris from check valve if found If debris cannot be cleaned from check valve replace shock piston as an as sembly 8 Clean shock and components with compressed air 9 Remove inner O ring 51199 ...

Page 372: ...surface 13 Remove rod wiper inner O ring and outer O ring 51147 51145 b c a a Rod Wiper b Inner O ring c Outer O ring Valve Block Removal 1 Remove valve block from shock rod cylinder 51146 a b c a Screws 2 b Valve Block c Shock Rod Cylinder 2 Remove O rings 51148 a a O rings 2 ...

Page 373: ...y 2 Remove hydraulic oil transfer valve components 51143 a b a Transfer Valves 2 b Slow trim Valve Assembly Plug or Screw Plug 3 Remove surge valve assembly 51145 a a Surge Valve 4 Remove reservoir assembly 51142 b c a a Screw b Flat Spring c Ball 5 Remove cam assembly 51145 b a a Screw b Cam Assembly ...

Page 374: ...is in tilt system could cause system to malfunction Apply Quicksilver Power Trim and Steering Fluid or ATF Type F FA or Dexron II on all O rings during reassembly NOTE Refer to Manual Tilt System Components for proper O ring sizes Valve Block Reassembly IMPORTANT Cam shaft O ring must be lubri cated using Special Lubricant 101 prior to instal lation 1 Install lubricated O ring to cam shaft 2 Insta...

Page 375: ...components in valve block 9 Install plunger ball spring small spring large in valve block Slow Trim Valve Assembly 10 Apply Loctite Pipe Sealant with Teflon 592 to threads of pipe plug design one and two style valve block 11 Install pipe plug or plug into valve block Tighten pipe plug if equipped securely 51142 b c d e a f a Plunger b Ball c Spring Small d Spring Large e O ring f Plug Design 3 12 ...

Page 376: ... a O rings 2 2 Install valve block to shock rod cylinder Torque screws to 100 lb in 11 2 N m 51146 a b c a Screw 2 b Valve Block c Shock Rod Cylinder 3 Install lubricated O ring 51145 Shock Rod Reassembly 1 Install lubricated O rings 2 Install rod wiper 51145 b c a a Rod Wiper b Inner O ring c Outer O ring ...

Page 377: ...o shock rod piston 6 Apply Loctite Grade A 271 to threads on shock rod 7 Install shock rod piston 8 Tighten shock rod piston securely using spanner wrench 1 4 in x 5 16 in long pegs 51146 b a a Shock Rod Piston b Spanner Wrench 9 Remove shock rod assembly from vise 10 Install lubricated O ring to shock rod piston 11 Install ball seat and spring five sets to shock rod piston 12 Secure components wi...

Page 378: ...4 Install lubricated O ring to memory piston and in stall piston into cylinder three inches 76mm from top 51144 b a a O ring b Memory Piston 5 Refill cylinder to top and install shock rod assem bly into cylinder 51143 6 Refill cylinder to top CAUTION End cap must not make contact with shock rod piston when tightening Shock rod piston must be positioned in cylinder deep enough to avoid contact 7 Ti...

Page 379: ... min 10cm x 6 4mm minimum Channel Iron 10 in 25 cm 8 in 20 cm 1 in 25mm 3 in 76mm 5 in 125mm 1 1 4 in dia 30m 2 holes 7 16 in dia 11 mm 20 in 508mm 8 in 203mm 6 in 152mm 4 in 100 mm 2 in 50mm 3 8 in dia 2 holes 90 814676R1 DECEMBER 1996 MID SECTION 5F 33 Instructions for Making Retaining Tool ...

Page 380: ...d Steering Fluid or ATF Type F FA or Dexron II IMPORTANT Fluid level must remain above ac cumulator opening during bleeding process 50447 e b c d a a a Retaining Tool b Tilt System c Container d Cam Lever e Accumulator Opening 3 Bleed unit by pushing rod down slowly 18 20 se conds per stroke until stopped at base Wait until all air bubbles exit accumulator base 50432 4 During up stroke pull up on ...

Page 381: ...lator making sure air bubbles do not enter system 50432 10 Tighten accumulator snugly at this time 50432 11 With cam lever remaining open facing down re move tilt assembly from oil and secure in soft jawed vise Torque accumulator to 35 lb ft 47 N m 50433 Manual Tilt System Installation 1 Apply Special Lubricant 101 to lower pivot pin hole and pivot pin surface 2 Start lower pivot pin into pivot pi...

Page 382: ...il seated 51148 a Lower Dowel Pin 6 Apply 2 4 C Marine Lubricant 92 90018A12 to surface of upper pivot pin pivot pin hole and shock rod hole 51148 b c a 1 2 a Pivot Pin b Pivot Pin Bore c Shock Rod Bore 7 Using a mallet drive upper pivot pin into swivel bracket and through shock rod until pivot pin is flush with swivel bracket 51148 b c a a Pivot Pin b Swivel Bracket c Shock Rod 8 Drive upper dowe...

Page 383: ...G 5 MID SECTION MANUAL TILT SYSTEM DESIGN 4 ...

Page 384: ...e Block Removal 5G 22 Memory Piston Removal 5G 22 Valve Block Disassembly 5G 23 Actual O ring Sizes 5G 25 O ring Description and Sizes 5G 26 Manual Tilt System Cleaning and Inspection 5G 27 Page Manual Tilt System Reassembly 5G 27 Cam Shaft Reassembly 5G 27 Valve Body Check Reassembly 5G 27 Velocity Valve Reassembly 5G 27 Check Retainer Reassembly 5G 28 Valve Plug Reassembly 5G 28 Valve Block Inst...

Page 385: ...90 814676R1 DECEMBER 1996 MID SECTION 5G 1 Special Tools 1 Spanner Wrench P N 91 74951 2 Lock Ring Pliers P N 91 822778A3 ...

Page 386: ...8 11 8 12 13 A 4 4 7 95 7 Loctite 271 92 809820 95 2 4 C With Teflon 92 825407A12 95 D E C B F NOTE Lubricate all O rings using Quicksilver Power Trim and Steering Fluid If not available use automotive ATF automatic transmission fluid NOTE It is recommended that all O rings be replaced when servicing tilt system ...

Page 387: ...linder 4 2 O RING 5 1 CYLINDER ASSEMBLY 6 1 SCREW AND SEAL KIT 7 1 ACCUMULATOR ASSEMBLY 35 47 8 1 VALVE BODY ASSEMBLY 9 1 CAM KIT 10 1 VELOCITY VALVE KIT 75 8 5 11 1 CHECK SYSTEM REPAIR KIT 75 8 5 1 O RING KIT 12 2 PIN 13 2 GROOVE PIN A Torque cylinder cap to 45 lb ft 61 N m B Torque Accumulator to 35 lb ft 47 N m C Torque Velocity Valve to 75 lb in 8 5 N m D Torque Transfer Valve Plug to 75 lb in...

Page 388: ...m Up Circuit a Shock Rod b End Cap c Accumulator d Accumulator Piston e Accumulator Check Valve f Camshaft Lever g Manifold h Down Fast Transfer Valve i Down Slow Transfer Valve j Up Fast Transfer Valve k Surge Valve l Cylinder m Memory Piston n Shock Piston o Shock Return Valve p Impact Relief Valve ...

Page 389: ...r valve i and the down circuit fast transfer valve h Oil flows into the bottom of the tilt cylinder forcing the memory piston m into the shock piston n and then forcing the shock rod a up and out Oil above the shock piston exits the cylinder l through an intercon necting passage along side of the cylinder and re turns into the manifold g Inside the manifold the oil flows past the groove in the sur...

Page 390: ... a Shock Rod b End Cap c Accumulator d Accumulator Piston e Accumulator Check Valve f Camshaft Lever g Manifold h Down Fast Transfer Valve i Down Slow Transfer Valve j Up Fast Transfer Valve k Surge Valve l Cylinder m Memory Piston n Shock Piston o Shock Return Valve p Impact Relief Valve ...

Page 391: ...he engine cowl to overcome the pressure inside cylinder Fluid will flow out of the bottom of the cylinder past both the down fast transfer valve h and down slow transfer valve i Fluid will flow past the up fast transfer valve j surge valve k and through the interconnecting pas sage into the top of the cylinder l Due to the shock rod a the tilt cylinder cavities differ in volume the extra fluid fro...

Page 392: ... k p o n m a Shock Rod b End Cap c Accumulator d Accumulator Piston e Accumulator Check Valve f Camshaft Lever g Manifold h Down Fast Transfer Valve i Down Slow Transfer Valve j Up Fast Transfer Valve k Surge Valve l Cylinder m Memory Piston n Shock Piston o Shock Return Valve p Impact Relief Valve ...

Page 393: ...aft connected to the lever will open the down slow transfer valve i allowing oil under pressure into the cavity around the shaft The higher oil pressure will open the up fast transfer valve j allowing oil from the bottom of the cylinder to flow above the shock piston n while lowering the engine Additional oil will flow into the accumulator c as the internal pressure forces the accumulator check va...

Page 394: ...k l m n o a Shock Rod b End Cap c Accumulator d Accumulator Piston e Accumulator Check Valve f Camshaft Lever g Manifold h Down Fast Transfer Valve i Down Slow Transfer Valve j Up Fast Transfer Valve k Surge Valve l Cylinder m Memory Piston n Shock Piston o Shock Return Valve p Impact Relief Valve ...

Page 395: ...elow the surge valve k causing the valve to move closing the oil return passage back into the accumulator c Oil inside the up cavity is locked in a static position by the closed up fast transfer valve j the closed down slow trans fer valve i and down fast transfer valve h As the shock rod extends outward the pressure inside the up cavity will reach sufficient pressure to open the shock valve p whi...

Page 396: ... n m l j k i h g f e d c a Shock Rod b End Cap c Accumulator d Accumulator Piston e Accumulator Check Valve f Camshaft Lever g Manifold h Down Fast Transfer Valve i Down Slow Transfer Valve j Up Fast Transfer Valve k Surge Valve l Cylinder m Memory Piston n Shock Piston o Shock Return Valve p Impact Relief Valve ...

Page 397: ...losed down slow transfer valve i and closed down fast transfer valve h Fluid will attempt to exit the cylinder through the interconnecting passage back into the accumulator c The closed up fast transfer valve j will prevent the fluid return As the shock rod extends outward the pressure inside the up cavity will reach sufficient pressure to open the shock valve p which opens at 880 1110 psi Oil wil...

Page 398: ...m n o a Shock Rod b End Cap c Accumulator d Accumulator Piston e Accumulator Check Valve f Camshaft Lever g Manifold h Down Fast Transfer Valve i Down Slow Transfer Valve j Up Fast Transfer Valve k Surge Valve l Cylinder m Memory Piston n Shock Piston o Shock Return Valve p Impact Relief Valve ...

Page 399: ...5G 15 Shock Function Return After the drive clears the object the shock return valve o will allow the oil to flow from between the shock piston n and memory piston m onto the down cavity as the drive returns to its original running position ...

Page 400: ...board with tilt lock lever when servicing manual tilt system 1 Check manual release cam adjustment Cam must open and close freely Adjust cam link rod as necessary 51143 a c b a Link Rod b Manual Release Lever c Accumulator 2 Check for external leaks in the manual tilt system Replace defective part s if leak is found IMPORTANT If cut or damaged O rings are found inspect machined surfaces for scorin...

Page 401: ...ard in the up position using tilt lock lever WARNING Manual tilt system is pressurized Accumulator must be removed when shock rod is in the full up position prior to servicing otherwise oil spray back may occur 1 Support outboard in the up position using tilt lock lever 2 Remove link rod 51143 a b a Link Rod b Accumulator 3 Position piece of wood under transom bracket instead of tilt lock for acce...

Page 402: ...gh pressure nitro gen charge and is NOT SERVICEABLE Replace if necessary WARNING This tilt system is pressurized Remove accumu lator only when shock rod is in full up position Accumulator Removal 1 Place manual tilt system in soft jawed vise 2 Position shock rod to full up position 3 Open cam shaft valve Down Position 4 Loosen surge valve enough to drip wait until dripping stops 5 When fluid stops...

Page 403: ...ace accu mulator 51143 a a Plunger 7 Once accumulator is removed remove O ring conical spring steel ball and plunger 51145 a b c d a Conical Spring b Steel Ball c Plunger d O ring Shock Rod Removal 1 Unscrew cylinder end cap assembly using span ner wrench 1 4 in x 5 16 in long pegs 51145 2 Remove shock rod assembly from cylinder ...

Page 404: ...es any other repair replace shock rod assem bly a c b b a End Cap b O rings 2 c Wiper Ring 1 Place shock rod assembly on clean work surface 2 Remove three 3 screws and remove plate from shock rod piston 51143 a b c a Screw 3 b Plate c Shock Rod Piston 3 Remove check ball components from shock rod piston 4 Remove O ring 51147 a b c d a Springs 5 b Seats 5 c Balls 5 d O ring ...

Page 405: ... rod 51146 51146 a b a Spanner Wrench b Shock Rod Piston 8 Inspect check valve for debris clean debris from check valve if found If debris cannot be cleaned from check valve replace shock piston as an as sembly 9 Clean shock and components with compressed air 10 Remove inner O ring 51199 a b a Shock Piston b O ring 11 Remove cylinder end cap assembly from shock rod 12 Inspect shock If wiper locate...

Page 406: ...from cylinder using one of two methods a Using lock ring pliers Craftsman P N 4735 or Snap on P N SRP4 51144 b Blowing compressed air into center O ring hole 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 NOTE Point cylinder opening down and away Use a shop rag or towel to avoid dama...

Page 407: ...iner plug and components 2 Remove hydraulic oil transfer valve plugs and components 51142 a b a Transfer Valve Plug Assembly 2 b Check Retainer Plug or Screw Assembly 3 Remove surge valve assembly a b c d a Spool b Spring c O ring d Screw Plug 4 Remove screw and remove cam assembly a b c d e a Spacer Retainer Clip b Retainer Clip c Screw d Shaft Seal e Cam ...

Page 408: ... SEAL PLACEMENT 1 2 5 4 14 6 9 8 7 10 3 12 11 13 NOTE Lubricate all O rings using Quicksilver Power Trim and Steering Fluid If not available use automotive ATF automatic transmission fluid NOTE It is recommended that all O rings be replaced when servicing tilt system ...

Page 409: ...1 2 11 13 3 4 14 6 2 5 8 2 10 O D I D Cutaway View of O Ring Width O RINGS SHOWN ARE ACTUAL SIZE 9 7 12 90 814676R1 DECEMBER 1996 MID SECTION 5G 25 Actual O ring Sizes ...

Page 410: ...in 17 17 mm 816 in 20 726 mm 0 07 in 1 78 mm 6 2 Manifold Split Line405387 0 208 in 5 283 mm 0 348 in 8 839 mm 0 07 in 1 78 mm 7 Slow Valve 401627 0 114 in 2 90 mm 0 254 in 6 451 mm 0 07 in 1 78 mm 8 2 Plug 404463 0 489 in 12 42 mm 0 629 in 15 97 mm 0 07 in 1 78 mm 9 Accumulator 412175 2 114 in 53 69 mm 2 254 in 57 25 mm 0 07 in 1 78 mm 10 Lip Seal 412574 11 Cam Shaft 402664 0 301 in 7 645 mm 0 44...

Page 411: ...omotive ATF automatic transmission fluid CAM SHAFT REASSEMBLY IMPORTANT Cam shaft O ring must be lubri cated using 2 4 C with Teflon 92 825407A12 1 Install lubricated O ring and back up seal to cam 2 Install shaft seal in valve block with lips facing out 3 Install cam shaft assembly in valve block 4 Secure cam shaft in place using insulator retain er plate and screw Tighten screw securely a b c d ...

Page 412: ...ated O ring and screw plug Torque screw plugs to 75 lb in 8 5 N m 51142 e d c b a a Plungers 2 b Steel Balls 2 c Springs 2 d O rings 2 e Screw Plugs 2 Torque to 75 lb in 8 5 N m Valve Block Installation 1 Install lubricated O rings and dowel pins 51148 1 a b a O rings 2 b Dowel Pins 2 2 Install valve block to shock rod cylinder Insert screws to shock rod cylinder and torque to 100 lb in 11 N m 511...

Page 413: ...8mm long pegs to avoid damage to shock rod piston 6 Apply Loctite Grade A 271 to threads on shock rod 7 Install shock rod piston 8 Tighten shock rod piston securely using spanner wrench 1 4 in x 5 16 in 6 4mm x 8mm long pegs If a torquing type spanner tool is used to tighten shock piston then torque to 90 lb ft 122 N m 51146 b a a Spanner Wrench b Shock Rod Piston Torque to 90 lb ft 122 N m 9 Inst...

Page 414: ...tall shock rod assembly on top memory piston Open cam lever Down Position and push shock rod assembly down to 1 8 below cylinder threads Close cam lever Up Position 6 Fill top of shock rod assembly with fluid to top of cylinder Open cam lever Down Position and screw cylinder cap down 7 Tighten end cap securely using spanner wrench 1 4 in x 5 16 in 6 4mm x 8mm long pegs If a torquing type spanner t...

Page 415: ...in x 1 4 in min 10cm x 6 4mm minimum Channel Iron 10 in 25 cm 8 in 20 cm 1 in 25mm 3 in 76mm 5 in 125mm 1 1 4 in dia 30m 20 in 508mm 8 in 203mm 6 in 152mm 4 in 100 mm 2 in 50mm 3 8 in dia 2 holes 90 814676R1 DECEMBER 1996 MID SECTION 5G 31 Filling Procedure Option Two Instructions for Making Retaining Tool ...

Page 416: ...If not available use automotive ATF automatic transmission fluid IMPORTANT Fluid level must remain above ac cumulator opening during bleeding process 50447 c a a b e d a Retaining Tool b Tilt System c Container d Cam Lever e Accumulator Opening 3 Bleed unit by pushing rod down slowly 18 20 se conds per stroke until stopped at base Wait until all air bubbles exit accumulator base 50432 4 During up ...

Page 417: ...cumulator port at this time 8 With oil level well above accumulator port slowly pull rod to full up position 9 Install accumulator making sure air bubbles do not enter system 50432 10 Tighten accumulator snugly at this time 50432 11 With cam lever remaining open facing down re move tilt assembly from oil and secure in soft jawed vise Torque accumulator to 35 lb ft 47 N m 50433 ...

Page 418: ...in retained in its hole 51148 a b a Lower Pivot Pin b Lower Dowel Pin 3 Reinstall manual tilt system bottom first Recon nect release valve link rod 51144 2 1 a a Manual Tilt System 4 Using a suitable punch drive lower pivot pin into clamp bracket and trim cylinder assembly until pivot pin is flush with outside surface 51147 a a Lower Pivot Pin 5 Using a punch drive lower dowel pin in until seated ...

Page 419: ...bracket a b c 51148 a Pivot Pin b Swivel Bracket c Shock Rod 8 Drive upper dowel pin a into its hole until seated a 51147 a Dowel Pin 9 Check manual release cam adjustment Cam must open and close freely Adjust link rod as necessary Manual Release Valve Adjustment 1 With outboard in full up position place tilt lock lever forward 2 Lift cam lever with link rod to full up position 51143 a c b a Tilt ...

Page 420: ...A 6 50508 LOWER UNIT GEAR HOUSING ...

Page 421: ...Removal 6A 13 Cleaning and Inspection 6A 13 Gear Housing Bearing Carrier Castings 6A 13 Bearings 6A 13 Ball Roller Bearings 6A 13 Needle Bearing 6A 14 Propeller Shaft 6A 14 Forward Reverse an Pinion Gears 6A 14 Sliding Clutch 6A 15 Cam Follower 6A 15 Water Pump Components 6A 15 Drive Shaft 6A 15 Shift Shaft 6A 16 Page Gear Housing Reassembly 6A 16 Drive Shaft Needle Bearing Installation 6A 16 Shif...

Page 422: ...Indicator Adaptor 91 83155 Backlash Indicator Rod 91 78473 Puller Bolt 91 85716 Mandrel 91 37312 Mandrel 91 37311 Mandrel 91 38628 Mandrel 91 36569 Driver Rod 91 37323 Mandrel 91 31361 Mandrel 91 86290 From Bearing Puller Installation Kit P N 91 31229A5 Quicksilver Lubricants and Service Aids Description Part No Special Lubricant 101 92 13872A1 Loctite Grade A 271 92 32609 1 Needle Bearing Assembl...

Page 423: ...Body 27 Seal 28 Washer Nylon 29 Washer 30 Nut 31 Centrifugal Slinger Rubber 32 Seal Rubber 33 Vent Screw 34 Fill Screw 35 Gasket 2 36 Lubrication Sleeve 37 Shim s 38 Tapered Bearing 39 Drive Shaft 40 Spring 41 Pin 42 Shift Shaft 43 E Clip 44 O ring 45 Bushing 46 Oil Seal Torque Specifications a 50 lb ft 67 8 N m b 17 lb ft 23 N m c 60 lb in 6 8 N m d 30 lb in 3 4 N m Lubrication Sealant Applicatio...

Page 424: ...g 17 O ring 18 Bearing Carrier 19 Needle Bearing 20 Oil Seal 21 Oil Seal 22 Alignment Key 23 Tab Washer 24 Cover Nut 25 Trim Tab 26 Bolt 27 Washer 28 Locknut 29 Washer 30 Locknut 31 Thrust Hub 32 Locking Washer Torque Specifications a 100 lb ft 135 6 N m b 60 lb ft 81 4 N m c 55 lb ft 74 6 N m d 20 lb ft 27 1 N m Lubrication Sealant Application Points A 2 4 C Marine Lubricant P N 92 90018A12 B Spe...

Page 425: ...sket a and fill drain screw and gasket b 26473 b a Trim Tab Propeller Removal 1 Place reference mark on trim tab a and anti ventilation plate b to allow trim tab to be rein stalled at the same angle 2 Remove nylon plug from drive shaft housing and remove bolt securing trim tab to gear housing 54749 a b WARNING If gear housing is not removed before attempting to remove or install the propeller remo...

Page 426: ...e Sleeve c Rear Thrust Hub d Propeller Nut Retainer e Propeller Nut Gear Housing Removal WARNING To prevent outboard from accidentally starting remove and isolate spark plug leads from spark plugs prior to removing gear housing 1 Remove and isolate spark plug leads 2 Shift outboard into forward gear 3 Tilt outboard to full UP position 4 Remove four lock nuts a securing gear housing to drive shaft ...

Page 427: ... due to improved lower end cap design 51188 4 Remove seal a and plate b from gear housing 54752 b a Water Pump Removal 1 Remove centrifugal slinger a and three lock nuts and washers b 54753 b a 2 Remove water pump body 3 Inspect body for cracks distortion or melting Re place if necessary 54754 b c a a Water Pump Body b Screwdrivers c Shop Cloths ...

Page 428: ...replaced If impeller must be reused DO NOT install in re verse to original rotation or premature impeller failure will occur Original rotation is clockwise 6 Remove impeller a and drive key b from drive shaft If necessary use a punch and hammer to drive impeller upward off drive shaft In extreme instances the impeller center hub must be split with chisel Take care not to damage drive shaft 54757 b...

Page 429: ...oths c Screwdrivers 11 Remove and discard seals a and O ring b 54760 b a Bearing Carrier and Propeller Shaft Removal IMPORTANT For proper retention between hous ing and cover nut it is recommended that PLAS TIC cover nut NOT be reused Replace as re quired 1 Bend lock tab a away from cover nut slot 54761 a 2 Remove cover nut using cover nut tool 54762 a a a Cover Nut Tool 91 91947 ...

Page 430: ...r shaft from gear housing 54764 5 Remove spring a from sliding clutch 54765 a 6 Remove cross pin 7 Remove remaining components from propeller shaft 54766 b c d a a Punch b Cross Pin c Sliding Clutch d Cam Follower 8 Inspect cam follower for pitting scoring or rough surface replace cam follower AND shift cam if damage to cam follower has occurred 9 Remove reverse gear using puller 54767 a a Puller ...

Page 431: ...ng in Bearing Carrier 11 Inspect bearing a If bearing is rusted or does not roll freely replace bearing 54770 b a a Bearing b Mandrel 91 24273 Drive Shaft and Pinion Gear Removal 1 Place gear housing assembly in to padded vise as shown 2 Remove pinion nut 3 Remove drive shaft from gear housing 54771 b c d a a Forward Gear b Drive Shaft c Pinion Gear d Pinion Nut Hidden Flat Side Away from Pinion G...

Page 432: ...aged replace bearing and race as an assembly 54772 b c a a Universal Puller Plate 91 37241 b Press c Tapered Bearing 6 Remove bearing race using slide hammer 54773 b c a a Race b Shim s c Slide Hammer 91 34569A1 Lubrication Sleeve Removal 1 Remove lubrication sleeve using puller 54774 b a a Puller 91 27780 b Lubrication Sleeve ...

Page 433: ... a Universal Puller Plate 91 37241 b Mandrel 36569 c Bearing d Press 3 Remove race using slide hammer 54776 b c a a Slide Hammer 91 34569 b Bearing Race c Shim s 4 Replace bearing a if it is rusted or does not roll freely Use punch and hammer to remove bear ing 19203 Shift Shaft Removal 1 Remove shift shaft bushing 2 Remove shift shaft b and shift cam c from gear housing 54777 b c a a a Shift Shaf...

Page 434: ... and Inspection Gear Housing Bearing Carrier Castings 1 Thoroughly clean gear housing bearing carrier castings Be sure all old gasket material is re moved from mating surfaces and that carbon de posits have been removed from exhaust pas sages 2 Inspect castings for cracks or fractures 3 Check sealing surfaces for nicks deep grooves and distortion which could cause leaks 4 Check water passages for ...

Page 435: ...n galled discolored or if area of shaft that bearing contact is worn or pitted 54782 Propeller Shaft 1 Replace propeller shaft if any of the following conditions exist a Splines are twisted or worn b Oil Seal surfaces are deeply grooved allow ing water to enter gear housing c Sliding clutch slot worn d Bearing surface is pitted worn rusted or contain imbedded metal particles 54783 b c d a a 2 Chec...

Page 436: ...follower if end of follower shows signs of wear 54786 Water Pump Components 1 Inspect impeller Replace impeller if any of the following conditions exist Impeller blade s are cracked torn or worn Impeller is glazed or melted caused by operation without sufficient water supply Rubber portion of impeller is not bonded to impel ler hub 54787 Drive Shaft 1 Inspect drive shaft Replace drive shaft if any...

Page 437: ...nto housing until approxi mately even with drive shaft cavity 54780 b a a a Mandrel 91 37312 b Needle Bearing Numbered Side Up Shift Shaft Bushing Reassembly and Installation 1 Press new oil seal a into bushing with lip of seal away from threaded end of bushing Install new O ring b 2 Lubricate lip of seal and O ring with Quicksilver 2 4 C Marine Lubricant 54779 b a 3 Assemble shift shaft 4 Apply Q...

Page 438: ...lubrication sleeve into gear housing NOTE Lip of lubrication sleeve must be below drive shaft bearing race shim shoulder If lip is above shoulder the drive shaft needle bearing may not be seated deep enough 54791 a a Tab Position Towards Front of Gearcase Forward Gear and Bearing Reassembly 1 Press needle bearing numbered side toward mandrel into gear until dimensions c is ob tained 54792 d b c a ...

Page 439: ...r c Wood Bearing Carrier Reassembly IMPORTANT Do not force bearing into carrier or damage may occur to bearing 1 Press needle bearing into bearing carrier until bearing edge is just below bearing carrier seal edge 54794 b c a a a Mandrel 91 37321 b Needle Bearing c Seal Edge 2 Press bearing onto reverse gear until seated 54795 b c d a c a Thrust Washer Beveled Side Toward Gear b Bearing c Mandrel ...

Page 440: ...everse Gear c Ball Bearing d Flush e Wood Forward Gear Race Installation 1 Install shim s 2 carefully drive bearing race into gear housing un til seated as shown 54797 b c d a a a Mandrel 91 31361 b Shim s c Bearing Race d Lead Hammer Drive Shaft Reassembly and Installation 1 Press tapered bearing onto drive shaft until inner bearing race bottoms on shoulder 54798 b c d a a Power Head End of Drive...

Page 441: ...4 Rotate drive shaft several times with down pres sure applied to seat drive shaft tapered bearing 5 With down pressure applied determine pinion gear depth by inserting a feeler gauge through access hole in shimming tool 6 The correct clearance between pinion gear and shimming tool is 025 in 0 64mm 7 If clearance is incorrect add or subtract shim s under drive shaft tapered bearing race to raise o...

Page 442: ...embly Lubricant on flat side a of cam follower b and install cam follower 54803 b a 5 Install cross pin b a a Apply Pressure in this Direction b Cross Pin 6 Install spring a 54805 a 7 Place propeller shaft into forward gear 54764 Bearing Carrier Installation 1 Install O ring a 2 Apply 2 4 C Marine Lubricant on O ring a and seal lips b 3 Coat surfaces c with Special Lubricant 101 54806 b c a ...

Page 443: ...n between hous ing and cover nut it is recommended that PLAS TIC cover nut NOT be reused Replace as re quired 6 Apply Quicksilver Special Lubricant 101 onto threaded area of gear housing b 54808 b 7 Install cover nut a with the word OFF visible Torque cover nut to 100 lb ft 136 N m using cover nut tool 91 91947 b 8 Bend one of lock tabs c into slot in cover nut 9 Bend remaining tabs towards front ...

Page 444: ...ve shaft back and forth no move ment should be noticed at propeller shaft 7 Dial indicator registers amount of backlash Backlash should be between 007 in and 010 in 0 178mm to 0 254mm 8 If backlash is less than minimum specification remove shim s from front of forward gear bear ing race to obtain correct backlash When rein stalling pinion nut apply Loctite 271 on threads of nut 9 If backlash is mo...

Page 445: ... and install insert a making sure locating tab b enters hole in body Wipe off excess lubricant 54814 b a 5 Install seal and washer Apply Quicksilver 2 4 C Marine Lubricant to I D of insert and seal 54755 b a c a Cupped Nylon Washer Cupped Side Towards Seal b Seal c Insert 6 Install components as shown 54758 b a c d a Water Pump Base b Gasket c Face Place d Gasket ...

Page 446: ...de diameter ot the water pump body with Quicksilver 2 4 C Marine Lubricant 9 Rotate drive shaft clockwise while pushing water pump body down over impeller b a a Water Pump Body b Turn Drive Shaft Clockwise 10 Install locking nuts and washers a and centrifu gal slinger b 54753 b a Gear Housing Installation WARNING When installing gear housing remove and iso late spark plug leads from spark plugs to...

Page 447: ... water tube a into drive shaft housing and insert into seal located at bottom of exhaust plate 54816 a NOTE If drive shaft splines will not align with crank shaft splines while performing step 10 turn propel ler shaft while gear housing is being pushed toward drive shaft housing 9 Position gear housing so that the drive shaft is protruding into drive shaft housing 10 Move gear housing up toward dr...

Page 448: ...b Vent Screw with Gasket Propeller Trim Tab Installation WARNING Remove and isolate spark plug leads from spark plugs when installing propeller 1 Remove and isolate spark plug leads from spark plugs 2 Apply a thin coat of lubricant to propeller shaft splines with Quicksilver 2 4 C Marine Lubricant 3 Install components as shown Flo Torq I Drive Hub Propellers a c b a Forward Thrust Hub b Propeller ...

Page 449: ... is turned clockwise and resistance should be felt when propeller shaft is turned counter clockwise b Place shift lever in neutral Propeller shaft should rotate freely in either direction c While rotating propeller shaft place shift le ver in reverse gear Resistance should be felt when propeller shaft is rotated in either direc tion IMPORTANT If shift operation is not as de scribed preceding the g...

Page 450: ...JET DRIVE LOWER UNIT B 6 ...

Page 451: ...ng 6B 8 Impeller Removal and Installation 6B 8 Steering Pull Adjustment 6B 10 Impeller Clearance Adjustment 6B 10 Worn Dull Impeller 6B 10 Liner Replacement 6B 11 Jet Drive Removal and Installation 6B 11 Water Pump Removal and Installation 6B 12 Bearing Carrier Removal and Installation 6B 12 Bearing Carrier Disassembly 6B 13 Bearing Carrier Reassembly 6B 13 Installing Lower Seals 6B 13 Installing ...

Page 452: ...LOWER UNIT 6B 1 90 814676R1 DECEMBER 1996 Notes ...

Page 453: ...95 2 4 C With Teflon 92 825407A12 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 19 6 95 6B 2 LOWER UNIT 90 814676R1 DECEMBER 1996 Jet Pump Assembly ...

Page 454: ...rive 7 1 NUT 8 1 SLEEVE shaft 9 1 KEY 10 8 SHIM 11 1 TAB WASHER 12 6 SCREW 1 4 20 x 75 96 8 10 8 13 4 SCREW 1 4 20 x 875 70 7 9 14 2 SCREW 1 4 20 x 625 70 7 9 15 1 SCREW 312 18 x 1 25 16 1 BRACKET 17 1 NUT 160 13 3 18 1 18 2 STUD 19 2 PIN dowel 20 1 RING SUPPORT water pump 21 1 GASKET water pump base 22 3 STUD 1 4 x 2 5 8 23 1 SCREW 3 8 16 x 3 22 5 30 5 24 1 WASHER 25 2 WASHER 26 2 NUT 60 81 3 ...

Page 455: ...T 90 814676R1 DECEMBER 1996 Selecting A Boat That Is Best Suited For Jet Power To obtain the best performance from the jet drive the boat should have the following features 1 The boat should be as light as possible 2 The boat should have hull and transom that is de signed for use with a jet drive 3 The boat should be at least 13 feet in length Engine Horsepower Selection A boat operating at slow s...

Page 456: ... allow the water intake to suck in air and cause ca vitation Cavitation will cause the engine to over speed in spurts and reduce thrust This condition should be avoided by proper height setting Installing the outboard too low on the transom will allow excessive drag SETTING OUTBOARD MOUNTING HEIGHT ON BOATS WITH V BOTTOM HULLS 1 Measure the width of the leading edge on the wa ter intake housing Ma...

Page 457: ...rd the boat in order to provide a scooping angle on the water intake Tilting the outboard out beyond a vertical posi tion reduces the scoop angle and can cause impeller slippage and cavitation If the angle of the boat tran som does not allow the drive shaft to be positioned vertically a Wedge kit should be installed behind the transom brackets to increase the tilt in angle NOTE Slight cavitation i...

Page 458: ... ry or death 1 Attach shift cable to the shift cam with flat washer and locknut as shown Tighten locknut against the flat washer then back off the locknut 1 4 turn 2 Place remote control handle into full forward posi tion 3 Adjust the brass barrel on the shift cable so that roller is at the full end of travel bottom in the shift cam when the remote control is in full forward 4 Attach the brass bar...

Page 459: ...t hose Reconnect the vent hose onto the grease fitting after greasing After 30 hours of operation pump in extra grease to purge out any moisture Visually inspecting the purged grease at this time will give you an indication of conditions inside the bearing housing A gradual in crease in moisture content indicates seal wear If the grease begins to turn dark or dirty gray the drive shaft bearing and...

Page 460: ...peller and liner should be 0 030 in 0 8 mm Shim washers can be trans ferred to either side of the impeller to raise or low er the impeller to the correct clearance setting The water intake housing can be shifted sideways a small amount in order to center the liner 03 in 8mm 3 After setting the impeller height tighten the impel ler nut snug with a wrench Secure impeller nut by bending tabs against ...

Page 461: ...d the impeller This will move the impeller further down into the tapered liner to reduce the clearance 2 Check the impeller clearance by sliding a feeler gauge through the intake grate and measure the clearance between the impeller edge and liner If adjustment is required refer to Impeller Removal and Installation 03 in 8mm a a Shims Worn Dull Impeller leading edge Do not sharpen or alter the top ...

Page 462: ... It may be necessary to tap or press the liner into the water intake housing to locate the liner for installation of the remaining bolts Torque bolts to 100 lbs in 11 2 N m 4 Grind off the ends of any bolts that may extend be yond the inner liner surface Jet Drive Removal and Installation REMOVAL 1 Remove 2 locknuts and bolt securing jet drive to drive shaft housing and remove jet drive INSTALLATI...

Page 463: ...nter bore below the water pump 2 Reassemble water pump assembly as shown Rotate drive shaft CLOCKWISE while pressing water pump body down over impeller c d e g i g f b a j k h g 95 2 4 C With Teflon 92 825407A12 95 95 a Locknut and Flat Washer 3 Torque to 30 lb in 3 4N m b Water Tube Seal and Washer c Rubber Ring d Water Pump Body Assembly e Impeller f Key g Gasket h Plate i Base j Metal Ring k Se...

Page 464: ... d Upper Seal Housing e Snap Ring f Thrust Ring Bearing Carrier Reassembly Installing Lower Seals Install seals into bearing carrier as follows 1 Install O ring seals into the top seats of the three passage holes 2 Install spiral retaining ring into the inner ring groove 3 Spread a film of grease around the inside bore of the seal surface before pressing in the seals 4 Press in the garter spring s...

Page 465: ...s Installing Drive Shaft Ball Bearing 1 If removed install the bearing thrust ring into the groove on the drive shaft 2 Install collar onto the drive shaft Press the new ball bearing onto the drive shaft pressing against the inner race only Press collar over the thrust ring locking it in its groove Install snap ring into drive shaft groove below the bearing c d a b a b c d Installing Drive Shaft 1...

Page 466: ... of the seal housing 6 Install the thrust washer against the ball bearing 7 Install spacer and the upper seal housing being careful not to damage the O ring seals as they pass the snap ring groove Only finger pressure should be necessary to push in the housing 8 Install the beveled snap ring beveled side facing up into the ring groove Make sure the snap ring is fully seated into groove ...

Page 467: ... lows a Locate the centerlines for the hole following the dimensions given in the illustration below Use a center punch to mark center of hole b Drill a 1 4 in pilot hole and then a 9 16 in hole angling up into the bottom cowl Side View Front View 5 8 in 16 mm 1 2 in 12 mm 2 Install the shift cable to the jet drive Use the exist ing mounting hardware supplied with the out board Adjust shift cable ...

Page 468: ...that the set screw is facing out and the slot is facing up 9 Slide shift cable into retainer until brass tube ex tends out 3 3 4 in 95 mm Secure the retainer at this position by tightening the set screw until its snug then add an additional 1 8 turn 10 Install the Allen head screw and tighten securely 3 3 4 in 95 mm a c b d a Shift Cable Retainer b Set Screw c Lock Washer d Allen Head Screw Tighte...

Page 469: ...Multipur pose Lubricant with Teflon b Shift Slider c Spacer 23 32 in Long d Bolt 1 3 4 in Long 16 Refer to the parts provided with your tiller handle kit and install the neutral start switch to the retain er Do not tighten screws at this time a c b d a Retainer b Neutral Start Switch c Screw 2 Do Not Tighten At This Time d Locknut 2 17 Install retainer with two screws a c b a Retainer b Screw 2 Pr...

Page 470: ... the boat This action may result in serious inju ry or death 1 Place shift lever into full forward position 2 Adjust the brass barrel on the shift cable so that roller is at the full end of travel bottom in the shift cam when the shift lever is in forward 3 Attach the brass barrel to the bracket with bolt and locknut Tighten the bolt until it seats against the barrel then back off the bolt 1 4 tur...

Page 471: ...7 A 50331 OUTBOARD MOTOR INSTALLATION ATTACHMENTS OUTBOARD MOTOR INSTALLATION ATTACHMENTS ...

Page 472: ...it P N 97933A4 Installation 7A 8 Installation Requirements 7A 8 Steering Cable Installation Cable Routed Down Starboard Side of Boat to Port Outboard 7A 9 Installing Steering Link Rod 7A 9 Steering Cable Installation Cable Routed Down Port Side of Boat to Starboard Outboard 7A 10 Tilt Tube Reversal 7A 10 Installing Steering Cable 7A 10 Installing Steering Link Rod 7A 11 Maintenance Instructions 7A...

Page 473: ... Start Models Remove plastic cap from center of flywheel Thread lifting ring a 91 90455 into flywheel hub a minimum of 5 turns Replace plastic cap after installation 2 Manual Start Models Use lifting harness b 91 64400A2 a b Installing Outboard On Boat Transom Models Without Transom Clamp Handles b c a a Mounting Bolts 4 b Flat Washers 4 c Locknuts 4 WARNING DO NOT under any circumstances allow up...

Page 474: ...ts 4 h Flat Washers 4 i Locknuts 4 CAUTION Marine sealer must be used on shanks of mount ing bolts to make a water tight installation Installing Outboard On Boat Transom Models With Transom Clamp Handles a Transom Clamp Handles WARNING DO NOT under any circumstances allow the cupped washers on the ends of the transom clamp screws to be closer than 1 inch 25 4mm from top of real boat transom not sh...

Page 475: ... sharp turn Failure to fasten outboard correctly to the boat transom with mounting bolts or optional mounting kit could re sult in outboard ejecting suddenly off boat tran som causing serious injury death boat damage or loss of outboard FASTENING OUTBOARD TO THE BOAT TRANSOM IMPORTANT Read the preceding WARNING be fore installing outboard Use a 17 32 inch 13 5mm diameter drill bit and drill two up...

Page 476: ...ring Cable Routed for Starboard Entry into Outboard Tilt Tube Refer to Quicksilver Accessories Guide to deter mine correct length of steering cable and remote con trol cables IMPORTANT Steering cable and remote control cables must be the correct length sharp bends on too short cables result in kinks too long cable require unnecessary bends and or loops Both conditions place extra stress on the cab...

Page 477: ... locknut Tighten locknut until it seats DO NOT exceed 120 lb in 14 N m of torque then back nut off 1 4 turn Lubricate ball joint in steering link rod with SAE 30W Motor Oil Secure link rod to outboard steering arm using special washer head bolt P N 10 14000 pro vided and nylon insert locknut as shown Torque spe cial bolt 20 lb ft 27 N m then torque locknut to 20 lb ft 27 N m 50579 50182 50056 a Fl...

Page 478: ...d remote control cables must be the correct length sharp bends on too short cables result in kinks too long cables require unnecessary bends and or loops Both conditions place extra stress on the cables Install steering mount and steering wheel in accor dance with installation instructions that accompany each Installing Ride Guide Cable to Outboard Tilt Tube IMPORTANT Before installing steering ca...

Page 479: ...lb ft 27 N m e Steering Link Rod WARNING After installation is complete and before operat ing outboard check that boat will turn to right when steering wheel is turned right and that boat will turn left when steering wheel is turned left Check steering thru full range left and right at all tilt angles to assure interference free movement Maintenance Instructions Maintenance inspection is the owner...

Page 480: ...ening or gun nel MUST BE a minimum of 16 in 406mm This kit contains all necessary parts to connect both outboards to Ride Guide Steering Cable for 21 in 533mm MINIMUM thru 22 1 2 in 572mm If out board centerline distance is other then specified re fer to Ride Guide Steering Attachment Extension Couplers following Ride Guide steering cable can be routed on either side of boat If steering cable is r...

Page 481: ...10 14000 and two nylon insert locknuts P N 11 34863 as shown Both special washer head bolt and nylon insert locknuts MUST BE tight ened as specified Lubricate hole in end of steering cable with Quicksil ver 2 4 C Marine Lubricant Assemble steering link rod to steering cable end using 2 flat washers and nylon insert locknut Tighten locknut until it seats DO NOT exceed 120 lb in 14 N m of torque the...

Page 482: ...emote control cables must be the correct length sharp bends on too short cables result in kinks too long cables require unnecessary bends and or loops Both conditions place extra stress on the cables Install steering mount and steering wheel in accor dance with installation instructions that accompany each Installing Steering Cable IMPORTANT Before installing steering cable into tilt tube lubricat...

Page 483: ...P N 10 14000 Torque to 20 lb ft 27 1 N m d Nylon Insert Locknut Torque to 20 lb ft 27 N m e Steering Link Rod WARNING After installation is complete and before operat ing outboard check that boat will turn to right when steering wheel is turned right and that boat will turn left when steering wheel is turned left Check steering thru full range left and right at all tilt angles to assure interferen...

Page 484: ...teering system failure Assemble steering coupler between outboard steer ing brackets as shown on the following pages IMPORTANT With assembled steering coupler installed and before tightening special washer head bolts locknuts check outboard alignment Distance between hole centers of steering eye ball joints MUST BE equal to distance between propeller shaft center lines for proper steering If adjus...

Page 485: ...embly Connection Hole 40 Model c Steering Link Supplied on Outboard d Washer Supplied with Steering Link e Ride Guide Cable f Steering Bracket Supplied in Kit g Special Washer Head Bolt Supplied in Kit 3 8 x 1 5 8 P N 10 90041 Torque to 20 lb ft 27 1 N m h Special Washer P N 12 71970 i Lock Nut Two Supplied in Kit and with Steering Link P N 11 34863 Torque to 20 lb ft 27 1 N m j Special Washer Hea...

Page 486: ...o the right If boat pulls to the left adjust trailing edges of both trim tabs to the left d Tighten both trim tab bolts securely and re place plastic caps e Operate boat per Check Trim Tab Position as Follows preceding to check trim tab set ting Readjust trim tabs if necessary Maintenance Instructions Maintenance inspection is the owner s responsibility and must be performed at intervals specified...

Page 487: ...e with 7 16 in x 1 3 4 in bolt and locknut as shown in Figures 1 and 2 Torque locknut to 10 lb ft 13 6 N m then back off 1 4 turn 4 Install one cable tube jam nut onto steering cable tube Place tab washer over Ride Guide yoke then insert cable tube thru tab washer and yoke Install second cable tube jam nut onto cable tube but do not tighten at this time Figure 3 5 Position transom attaching kit on...

Page 488: ...orque to 35 lb ft 41 5 N m j Clevis Kit k Clevis Attaching Locknut Torque to 20 lb ft 27 1 N m Figure 3 Installing Attaching Kit Clevis Attaching Kit Installation P N 70599A4 NOTE This kit is used to attach Ride Guide cable to outboard steering arm ONLY when Transom Mounted Ride Guide Attaching Kit is being used If Ride Guide cable is installed thru outboard tilt tube then Steering Link Rod must b...

Page 489: ...knut Clevis to Engine Steering Bracket Torque to 240 lb in 27 N m g Steering Bracket Maintenance Instructions Lubrication and maintenance inspection is owner s responsibility and must be performed at intervals as specified following Normal Service Every 50 hours of operation or 60 days whichever comes first Severe Service Every 25 hours of operation or 30 days whichever comes first Operation in sa...

Page 490: ...and that boat will turn left when steering wheel is turned left Check steering thru full range left and right at all tilt angles to assure interference free movement 50568 a Ride Guide Cable b Ride Guide Yoke c Pivot Block d Pivot Spacer e 15 in Centerline of Attaching Kit Pivot to Centerline of Engine f Pivot Attaching Locknut Torque to 20 lb ft 27 1 N m g Engine Steering Arm h Clevis Kit i Ride ...

Page 491: ...control and mount remote control BEFORE at taching control cables to engine Install throttle and shift cables to remote control and mount remote control as outlined in the installation instructions which accompany the remote control NOTE It will be necessary to lift control cable rubber grommet out of opening in bottom cowl so that con trol cables can be routed thru grommet and into bot tom cowl 5...

Page 492: ...aft is rotated by hand The prop shaft should not be able to turn clockwise If it does adjust cable barrel away from cable end guide Repeat steps a thru c d Shift remote control into neutral The prop shaft should turn freely without drag If not adjust cable barrel closer to cable end guide Repeat steps a thru d Throttle Cable Installation and Adjustment to Engine 1 Shift remote control into neutral...

Page 493: ...bilge water Route the remote control wiring harness a into bot tom cowl thru control cable grommet Route harness behind oil tank to engine harness connector located on starboard side of engine 919 H a Plug remote control wiring harness into engine har ness connector b and push connection into retainer 50566 b CAUTION Remote control wiring harness or key switch wir ing harness must be routed betwee...

Page 494: ... Connections Models So Equipped Make bullet connector wiring connection between remote control wiring harness key switch wiring har ness and engine wiring IMPORTANT Tape back and isolate any unused wiring harness leads Battery Connections CAUTION Failure to observe correct polarity when con necting battery cables to battery will result in damage to the charging system 1 Connect battery cables from...

Page 495: ...ness in the bottom cowl and disconnect the black yellow wire that goes to the switch box 2 Route the remote control wiring harness e into the bottom cowl thru the wiring grommet Con nect the Y harness f P N 84 11149A1 sup plied with remote control between the remote control wiring harness and the disconnected black yellow wire connections as shown Engine Ground BLK YEL BLK BLK YEL BLK YEL BLK YEL ...

Page 496: ...B 7 50505 OUTBOARD MOTOR INSTALLATION ATTACHMENTS TILLER HANDLE AND CO PILOT ...

Page 497: ...Quicksilver Lubricants and Service Aids 7B 1 Tiller Handle Throttle Cable Replacement 7B 2 Tiller Handle Installation 7B 5 Shift Link Rod Installation 7B 6 Throttle Cable Installation 7B 6 Lanyard Stop Switch Wiring 7B 8 Neutral Start Switch Wiring 7B 9 Battery Connections 7B 10 Co Pilot Installation Instructions 7B 11 Shift Interlock Adjustment 7B 12 ...

Page 498: ...Rod End 26 Detent 27 Screw 2 28 Bushing 29 Washer 30 Screw 31 Washer 32 Bracket 33 Washer 34 Bushing 2 35 Spacer 36 Washer 37 Wave Washer 2 38 Washer 39 Locknut 40 Spacer 41 Stud 2 42 Tab Washer 2 43 Nut 2 44 Retainer 45 Stop Switch 46 C Washer 47 Clamp 48 Lanyard Electric Start Models 49 Switch Assembly 50 Screw 2 51 Set Screw 2 52 Actuator Torque Specifications a 30 lb in 3 3 N m b 33 lb ft 45 N...

Page 499: ...tle twist grip 3 Loosen screws a securing cable guide b to throttle cable c 54819 b c a 4 Remove conduit a and throttle cable from tiller handle 54820 a 5 Install throttle cable a Position drive rod flat surface parallel to work surface 54821 a a Drive Rod b Rotate drive rod either direction 1 8 turn to attain drive rod flat surface of 45 54822 1 8 Turn 45 Angle ...

Page 500: ...erclockwise 1 8 turn 45 until flat surface becomes parallel with work surface 54823 1 8 Turn e Rotate drive rod counterclockwise 1 4 turn 90 until flat surface becomes parallel with work surface 54823 1 4 Turn f Measure distance between tiller handle port and end of throttle cable A measurement of 18 in 457mm must be attained for throttle shutter plates to open and close properly 54824 ...

Page 501: ...825 IMPORTANT If 18 in 457mm measurement is not attained following throttle cable installation repeat steps a g 54826 6 Install washer nut and end cap to throttle grip Tighten nut snuggly allowing grip to turn freely 7 Install conduit a to tiller handle Turn conduit in until bottomed out on tiller handle then back off one turn 54820 a 8 Reinstall cable guide to throttle cable 54819 b c a a Screws ...

Page 502: ...thru opening in the bottom cowl 50505 2 Route shift link rod a around port side of out board and position through lower opening in rub ber grommet b 54827 b a 3 Secure tiller handle assembly to studs of out board steering arm using tab washers a and locknuts b Torque locknuts to 33 lb ft 45 N m and bend tab washers against hex of locknuts 54828 b a a ...

Page 503: ...rward position Propeller should not rotate in a COUNTERCLOCKWISE direction If propel ler does rotate COUNTERCLOCKWISE length of shift link rod must be reduced and Step a repeated b Place outboard shift lever in N Neutral position Propeller should rotate freely with out drag If not length of shift link rod must be increased and Steps a and b repeated c While rotating propeller place outboard shift ...

Page 504: ...opening in rubber grommet b 54832 b c d e 4 Position barrel receptacle a into receptacle guide b 54833 b a 5 Place end of throttle cable c on peg of throttle lever d 54834 c d 6 Secure throttle cable c with latch e 54835 c e 7 Apply a drop of Loctite 271 onto exposed threads of throttle cable barrel set screw DO NOT tight en set screw at this time CAUTION DO NOT exceed 1 4 turn on set screw after ...

Page 505: ...receptacle using barrel retainer c 54837 c 10 Check preload on throttle cable by placing a thin piece of paper between idle stop screw and idle stop Preload is correct when paper can be re moved without tearing but has some drag on it Readjust throttle cable barrel if necessary Lanyard Stop Switch Wiring 1 Route Lanyard Stop Switch and Neutral Start Switch wiring through bushing as shown Secure wi...

Page 506: ...lanyard stop switch leads with sta strap a 54840 a Neutral Start Switch Wiring NOTE Electric Start Models 1 Remove ground lead f from solenoid terminal e 54840 e f 2 Connect ground lead f and ground lead d from Neutral Start Switch to switch box ground g Connect remaining Neutral Start Switch wire h to solenoid terminal e 50221 d Ground Lead Large Ring Terminal from Neutral Start Switch e Solenoid...

Page 507: ...y cable to battery will result in damage to the charging system 1 A battery with a minimum reserve capacity rating of 100 minutes minimum cold cranking rating of 350 amperes is recommended 2 House battery in a battery box and secure in a favorable position in boat 3 Connect battery cables to battery by connecting BLACK lead to negative terminal and con necting RED lead to positive terminal on bat ...

Page 508: ...et with spacer flat washer and locknut Torque lock nut to 120 lb in 13 6 N m 6 Secure link rod to pilot rod with flat washer and locknut Tighten locknut until it seats DO NOT exceed 120 lb in 13 6 N m then back off 1 4 turn 7 Adjust wing nut on friction device to provide de sired steering control IMPORTANT Tighten wing nut b to increase friction loosen to decrease friction WARNING If the wing nut ...

Page 509: ... engine is not running as shifting mecha nism could be damaged 1 Shift outboard into neutral position 2 Loosen cable attaching screw a to allow cable movement 54842 a 3 Interlock actuator b must align with rise of inter lock cam c while shift lever is in the neutral posi tion 4 Tighten cable attaching screw securely 54843 b c 54844 b c b Interlock Actuator c Interlock Cam ...

Page 510: ...C 7 54845 OUTBOARD MOTOR INSTALLATION ATTACHMENTS REWIND STARTER ...

Page 511: ... Components 7C 1 Torque Specifications 7C 1 Quicksilver Lubricants and Service Aids 7C 1 Rewind Starter Disassembly 7C 2 Cleaning and Inspection 7C 3 Rewind Starter Reassembly 7C 4 Installing Used Rewind Spring 7C 4 Installing New Rewind Spring 7C 4 Rope Installation 7C 5 Adjusting Rewind Spring Tension 7C 7 ...

Page 512: ...her 17 Lever 18 Wave Washer 19 Sheave Shaft 20 Starter Rope 21 Handle and Retainer 22 Cable 23 Screw 24 Washer 25 Washer 26 Screw 27 Spring 28 Cam 29 Screw 30 Actuator 31 Cotter Pin 32 Screw 33 Spring 34 Bushing 35 Retaining Ring 36 Rest Assembly 37 Seal 38 Primer Bulb 39 Tubing 40 Stop Switch Assembly 41 Boot Assembly 42 Cotter Pin 2 Torque Specifications a 100 lb in 11 N m Quicksilver Lubricants...

Page 513: ...rope and release starter rope to allow rewind spring to unwind 2 Remove retaining clip and attaching screw which secures shift interlock cable to starter housing 3 Remove rewind starter from engine 54842 a b c a Shift Interlock Cable b Cable Attaching Screw c Retaining Clip 4 Bend lock tabs a away from nut b 5 Remove nut b left hand thread turn clockwise to remove while supporting rewind assembly ...

Page 514: ...h a mallet This will cause rewind spring to drop out of sheave 54849 Cleaning and Inspection 1 Clean components in solvent and dry with com pressed air 2 Inspect rewind spring for kinks burrs corrosion or breakage 3 Inspect starter sheave rope guide and starter housing for nicks grooves cracks wear or dis tortion especially area of rope travel 4 Inspect bushing starter drive pawl and spring for we...

Page 515: ...o guide rewind spring into recess Proceed cautiously do not allow spring to get out of control 5 Remove sheave from vise and remove sheave shaft and bushing 54850 b c d e f g a c a Sheave Shaft b Bushing c Sheave d Flat Washers Allowing Enough Clearance for Sheave to Rotate Above Vise e Hook Spring in Notch f Turn Sheave Clockwise while Feeding Spring into recess g Vise with Soft Jaw Protectors 54...

Page 516: ... onto sheave when viewed from rewind spring side of sheave 54853 b a 4 Lubricate shoulder on sheave shaft a with low temperature grease and install lever as shown 54854 a 5 Lubricate all components with low temperature grease a Sheave Shaft b Lever c Wave Washer d Flat Washer e Sheave f Spring Bushing g Shaft Bushing h Rewind Spring i Spring Retainer Plate 6 Assemble sheave components as shown 548...

Page 517: ...heave shaft Use a thin shaft screwdriver to engage tab into in ner loop of rewind spring 54856 a 9 Spring retainer plate installed 54857 10 Push starter rope thru rope guide a then place sheave assembly into rewind housing 54858 a 11 Place new locking tab washer b cupped side facing down on sheave shaft 12 Thread nut c left hand thread finger tight on shaft 54859 b c ...

Page 518: ...ining nut b 54860 b a a Hold Retainer Nut and Turn Sheave Shaft 2 Full Turns to Add Proper Tension to Rewind Spring b Sheave Shaft Retaining Nut Left hand Thread Turn Counterclockwise to Tighten NOTE Check operation of rewind starter before bending tabs against nut 6 Check rewind operation as follows a Slowly pull starter rope outward Pawl must move to engage position as the lever begins to turn b...

Page 519: ... to 100 lb in 11 N m 9 Install and adjust shift interlock cable as outlined in Shift Interlock Adjustment Section 7B 54844 b c a a Interlock Actuator b Interlock Cam c Interlock Cable 10 Pull starter rope thru cowl panel and install han dle and rope retainer 11 Reinstall removed cowling 54862 b c d a a Starter Rope b Handle c Retainer d Knot ...

Page 520: ...8 50444 OIL INJECTION SYSTEM ...

Page 521: ...5 Bleeding Air from Oil Pump Outlet Hose 8 5 Operation of the Oil Injection System 8 6 Check Operation of the Oil Injection System Engine Running 8 6 Required Side Mount Remote Control or Ignition Key Switch Assembly to be Used with Engines Equipped with Oil Injection 8 6 Boats Equipped with a Side Mount Remote Control 8 6 Boats Equipped with Panel or Console Mount Remote Control 8 6 Oil Injection...

Page 522: ...ft It is a constant ratio oil pump and provides a mixture of 50 1 3 Check Valve Vent Provides air to oil reservoir for proper venting of reservoir Check valve prevents oil from leaking out of reservoir where outboard is tilted forward 4 2 PSI Check Valve This valve prevents gasoline from being forced into the oil line 5 Low Oil Float Sensor When oil level in oil reservoir drops until approxi matel...

Page 523: ...50444 8 2 OIL INJECTION SYSTEM 90 814676R1 DECEMBER 1996 Oil Injection Flow System ...

Page 524: ...Pump Drive System 50448 50448 50448 90 814676R1 DECEMBER 1996 OIL INJECTION SYSTEM 8 3 Pump Drive Assembly ...

Page 525: ...o Powerhead Assembly 1 Bolt 2 Each 2 Oil Pump 3 O ring Large 4 O ring Small 5 Bearing 6 Driven Gear Torque Specifications a 45 lb in 5 1 N m Quicksilver Lubrication Sealant Application Points A Loctite Grade A 92 32609 1 B Needle Bearing Assembly Lubricant 92 42649A 1 ...

Page 526: ...BIA ratings TC W or TC WII shown on oil container BIA ratings TC W and TC WII are the Boating Industry Association s designation for approved 2 cycle water cooled outboard oils Remove fill cap from the oil tank and fill tank with oil Retighten the fill cap 50330 a Fill Cap Bleeding Air from Oil Injection System CAUTION If air exists in either oil pump hose inlet or out let the air MUST BE bled fro...

Page 527: ...intermittent Check Operation of the Oil Injection System Engine Running 1 Operate engine following the break in procedure outlined in the Operation and Maintenance Manual If warning horn should sound an inter mittent beep beep beep during operation this indicates a problem occurred in the oil injec tion system Refer to troubleshooting following to correct the problem Required Side Mount Remote Con...

Page 528: ... to ground tan blue warning module lead to engine ground Warning horn should sound If not check tan blue wiring between engine and warning horn for open circuit and check horn Warning Module Check if all warning module leads are connected to harness leads If so warning module may be faulty Using incorrect side mount remote control or igni tion choke assembly See info on page 8 6 Problem Warning Ho...

Page 529: ...haft throw 54864 b c d a a Gear b Chamfer c Key d 4 Crankshaft Throw 5 Refer to Section 4A Powerhead for proper reas sembly of powerhead components Oil Pump Volume Flow Test NOTE The following specifications are determined with the outboard running off a remote fuel supply with pre mix fuel The oil pump output hose must be disconnected from the input fuel line TEE fitting and directed into a gradu...

Page 530: ...rom electrical access cover and remove cover 54645 b a a Bolts b Cover 5 Disconnect warning module PURPLE TAN and both BLUE leads from their respective bullet con nectors Remove warning module BLACK ground lead from the upper right switch box mounting bolt 6 Remove 2 bolts which secure warning module to electrical box and remove module 54866 b a a Switch Box Mounting Bolt remove Black Lead b Warni...

Page 531: ...e to electrical box with 2 bolts Torque bolts to 40 lb in 4 5 N m 54867 b a a Warning Module b Bolts Torque to 40 lb in 4 5 N m 3 Reinstall electrical box access cover 4 Reinstall top cowling 5 Reconnect engine battery cables to battery Engine Mounted Oil Reservoir Removal 1 Disconnect engine battery cables from battery 2 Verify ignition key is in the OFF position 3 Remove top cowl 4 Remove 3 bolt...

Page 532: ...res ervoir Secure hose with STA STRAP 2 Insert oil level sensor into bottom of oil reservoir Secure sensor with screw 3 Position oil reservoir upright with bottom of reser voir seated in support pocket in engine tray 54869 b a a Oil reservoir b Support Pocket 4 Reinstall flywheel cover while aligning oil fill cap and sealing O ring on oil reservoir Torque fly wheel cover bolts to 100 lb in 11 3 N ...

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