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Mercury 100 FourStroke, Service Manual

The Mercury 100 FourStroke delivers exceptional performance for any boating enthusiast. This user-friendly outboard engine guarantees smooth operation and superb fuel efficiency. For convenient access to product information and maintenance instructions, download the user manual for free from our website, making every boating experience a breeze.

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90-830234R3   DECEMBER 1997

FUEL SYSTEM - 3B-19

High Altitude Jet Chart

Factory installed main fuel jets are normally adequate for proper performance up to approximately 5000 feet
(1524m) above sea level. Between 2000 feet (609.6m) and 5000 feet (1524m) the reduction of the main fuel jet(s)
may result in improved performance and fuel economy. Above 5000 feet, however, it is recommended that main
jet size be reduced as shown per 1000 feet (304.8m) in the following chart. RETURN TO LOWER ELEVATION.
Carburetor jet changes must be reversed to avoid a lean fuel condition when used at low elevation.

Feet

Meter

1000

304.8

2000

609.6

3000

914.4

4000

1219.2

5000
1524

6000

1828.8

7000

2133.6

8000

2438.4

9000

2743.2

10000

3048

11000

3352.8

12000

3657.6

Jet Size

0.034

0.034

0.034 0.032

0.032

0.032

0.032

0.032

0.032

0.030

0.030

0.030

0.030

0.036

0.036

0.036 0.034

0.034

0.034

0.034

0.034

0.032

0.032

0.032

0.032

0.032

0.038

0.038

0.038 0.036

0.036

0.036

0.036

0.036

0.034

0.034

0.034

0.034

0.034

0.040

0.040

0.040 0.038

0.038

0.038

0.038

0.038

0.036

0.036

0.036

0.036

0.034

0.042

0.042

0.042 0.040

0.040

0.040

0.040

0.038

0.038

0.038

0.038

0.038

0.036

0.044

0.044

0.044 0.042

0.042

0.042

0.042

0.040

0.040

0.040

0.040

0.038

0.038

0.046

0.046

0.046 0.044

0.044

0.044

0.044

0.042

0.042

0.042

0.042

0.040

0.040

0.048

0.048

0.048 0.046

0.046

0.046

0.046

0.044

0.044

0.044

0.042

0.042

0.042

0.050

0.050

0.050 0.048

0.048

0.048

0.046

0.046

0.046

0.046

0.044

0.044

0.044

0.052

0.052

0.050 0.050

0.050

0.050

0.048

0.048

0.048

0.048

0.046

0.046

0.046

0.054

0.054

0.052 0.052

0.052

0.052

0.050

0.050

0.050

0.048

0.048

0.048

0.048

0.056

0.056

0.054 0.054

0.054

0.054

0.052

0.052

0.052

0.050

0.050

0.050

0.048

0.058

0.058

0.056 0.056

0.056

0.056

0.054

0.054

0.054

0.052

0.052

0.052

0.050

0.060

0.060

0.058 0.058

0.058

0.056

0.056

0.056

0.054

0.054

0.054

0.052

0.052

0.062

0.062

0.060 0.060

0.060

0.058

0.058

0.058

0.056

0.056

0.056

0.054

0.054

0.064

0.064

0.062 0.062

0.062

0.060

0.060

0.060

0.058

0.058

0.058

0.056

0.056

0.066

0.066

0.064 0.064

0.064

0.062

0.062

0.062

0.060

0.060

0.060

0.058

0.058

0.068

0.068

0.066 0.066

0.066

0.064

0.064

0.064

0.062

0.062

0.060

0.060

0.060

0.070

0.070

0.068 0.068

0.068

0.066

0.066

0.064

0.064

0.064

0.062

0.062

0.062

0.072

0.072

0.070 0.070

0.070

0.068

0.068

0.066

0.066

0.066

0.064

0.064

0.062

0.074

0.074

0.072 0.072

0.070

0.070

0.070

0.068

0.068

0.068

0.066

0.066

0.064

0.076

0.076

0.074 0.074

0.072

0.072

0.072

0.070

0.070

0.068

0.068

0.068

0.066

0.078

0.078

0.076 0.076

0.074

0.074

0.074

0.072

0.072

0.070

0.070

0.068

0.068

0.080

0.080

0.078 0.078

0.076

0.076

0.076

0.074

0.074

0.072

0.072

0.070

0.070

0.082

0.082

0.080 0.080

0.078

0.078

0.076

0.076

0.076

0.074

0.074

0.072

0.072

0.084

0.084

0.082 0.082

0.080

0.080

0.078

0.078

0.076

0.076

0.076

0.074

0.074

0.086

0.086

0.084 0.084

0.082

0.082

0.080

0.080

0.078

0.078

0.076

0.076

0.074

0.088

0.088

0.086 0.086

0.084

0.084

0.082

0.082

0.080

0.080

0.078

0.078

0.076

0.090

0.090

0.088 0.088

0.086

0.086

0.084

0.084

0.082

0.082

0.080

0.080

0.078

0.092

0.092

0.090 0.090

0.088

0.088

0.086

0.086

0.084

0.084

0.082

0.082

0.080

0.094

0.094

0.092 0.092

0.090

0.090

0.088

0.088

0.086

0.086

0.084

0.084

0.082

0.096

0.096

0.094 0.094

0.092

0.092

0.090

0.090

0.088

0.086

0.086

0.084

0.084

0.098

0.098

0.096 0.096

0.094

0.092

0.092

0.090

0.090

0.088

0.088

0.086

0.086

Summary of Contents for 100 FourStroke

Page 1: ...75 75 MARATHON 75 SEA PRO 90 100 115 125 65 80 JET United States 0D283222 and Above Belgium 09793577 and Above With Serial Numbers SERVICE MANUAL Printed in U S A 1997 Mercury Marine 90 830234R3 DECEMBER 1997 ...

Page 2: ...angered by the service procedure selected All information illustrations and specifications con tained in this manual are based on the latest product information available at the time of publication As re quired revisions to this manual will be sent to all deal ers contracted by us to sell and or service these prod ucts It should be kept in mind while working on the prod uct that the electrical sys...

Page 3: ...vice bulletins for other pertinent in formation concerning the products described in this manual Propeller Information For in depth information on marine propellers and boat performance see your Authorized Dealer for the illustrated What You Should Know About Quick silver Propellers and Boat Performance Informa tion 90 86144 How To Use This Manual The manual is divided into SECTIONS shown right wh...

Page 4: ...tion B Charging Starting System C Timing Synchronizing Adjusting D Wiring Diagrams Section 3 Fuel System A Fuel Pump B Carburetor C Oil Injection D Emissions Section 4 Powerhead Section 5 Mid Section A Clamp Swivel Brackets Drive Shaft Housing B Power Trim S N USA 0G360002 BEL 9934136 and Below C Power Trim S N USA 0G360003 BEL 9934137 and Above D Shock Absorber E Manual Tilt Section 6 Lower Unit ...

Page 5: ...1 A 52485 IMPORTANT INFORMATION SPECIFICATIONS ...

Page 6: ...1A 0 IMPORTANT INFORMATION 90 830234R3 DECEMBER 1997 Table of Contents Page Master Specifications 1A 1 ...

Page 7: ...in 88 773mm 3 510 in 89 154mm 3 525 in 89 535mm REEDS Reed Stand Open Max Reed Stop Max 0 020 in 0 50mm Not Adjustable TEMPERATURE SWITCH Temperature Normal 190 F 8 88 C 4 C 170 F 8 77 C 4 C Open No Continuity Closed Continuity Open No Continuity GEAR HOUSING Model 75 90 Gear Ratio Gearcase Capacity Forward Gear No of Teeth Type Pinion Gear No of Teeth Type Pinion Height Forward Gear Backlash Wate...

Page 8: ...Time W O T After Alarm Sounds Gasoline Oil Ratio Idle Gasoline Oil Ratio W O T Output 700 RPM for 15 Minutes with Pump Full Open 1 gallon 3 78 liters 6 Hours 1 qt 95 liters 1 Hour Approx 80 1 50 1 22cc Min 1 4 gal 5 3Liter 5 hrs 1 qt 0 95Liter 50 min 80 1 50 1 29cc Minimum STARTING SYSTEM Manual Start Commercial 75 Manual Start All Electric Models Electric Start Model 65 Jet 75 90 Starter Draw Und...

Page 9: ...A 09916721 4 Cyl Electric Red Stator Stamped 398 832075A3 Serial Number USA 0G404617 and Above Belgium 09916722 and Above Alternator Output 5250 RPM 10 Amperes 16 Amperes 14 Amperes 16 Amperes 16 Amperes 16 Amperes 16 Amperes IGNITION SYSTEM Model 65 Jet 75 90 Type Spark Plug Type NGK Spark Plug Gap Optional Inductor Plug Model 80 Jet 100 115 125 Type Spark Plug Type Spark Plug Gap Optional Induct...

Page 10: ...arb 1 Carb 2 Carb 3 WME 77 Carb 1 Carb 2 Carb 3 Model 75 Work WME 30 Carb 1 Carb 2 _ Carb 3 WME 47 48 76 Carb 1 Carb 2 Carb 3 WME 60 61 Carb 1 Carb 2 Carb 3 Model 65 Jet 90 WME 31 Carb 1 Carb 2 Carb 3 WME 49 62 Carb 1 Carb 2 Carb 3 WME 62 3A Carb 3 WME 78 Carb 1 Carb 2 Carb 3 050 052 050 052 052 052 052 054 052 054 052 054 054 054 054 054 050 052 050 054 054 054 054 054 054 062 064 062 062 064 062...

Page 11: ...Carb 3 WME 79 Carb 1 Carb 2 Carb 3 Carb 4 Model 115 WME 33 Carb 1 Carb 2 Carb 3 Carb 4 Model 80Jet 115 WME 40 Carb 1 Carb 2 Carb 3 Carb 4 WME 40 Carb 1A Carb 2A Carb 3A Carb 4A WME 51 Carb 1 Carb 2 Carb 3 Carb 4 WME 51 3A Carb 3 WME 80 Carb 1 Carb 2 Carb 3 Carb 4 046 048 052 052 048 050 048 052 050 048 050 050 052 052 056 056 060 066 068 068 070 060 070 070 074 062 062 060 064 062 060 064 062 064 ...

Page 12: ...Models 1994 1995 1996 1997 Model 65 Jet 75 90 Model 80 Jet 100 115 125 Maximum BTDC 1994 1995 Cranking Speed Model 75 Model 65 80 Jet 90 100 115 125 3000 RPM Model 75 Model 65 80 Jet 90 100 115 125 Maximum BTDC 1996 1997 Cranking Speed Model 75 Model 65 Jet 90 Model 80 Jet 100 115 125 3000 RPM Model 75 Model 65 Jet 90 Model 80 Jet 100 115 125 Firing Order 1994 1995 Model 65 Jet 75 90 Model 80 Jet ...

Page 13: ...1 C IMPORTANT INFORMATION GENERAL INFORMATION ...

Page 14: ...ion 1C 3 Submerged While Running 1C 3 Salt Water Submersion 1C 3 Fresh Water Submersion 1C 3 Propeller Selection 1C 4 Propeller Installation 1C 4 Power Trim System 1C 5 General Information 1C 5 Power Trim Operation 1C 5 Trim In Angle Adjustment 1C 6 Compression Check 1C 6 Painting Procedures 1C 7 Cleaning Painting Aluminum Propellers Gear Housings 1C 7 Decal Application 1C 8 Decal Removal 1C 8 Ins...

Page 15: ... of weath er effects an engine running on a hot humid sum mer day may encounter a loss of as much as 14 of the horsepower it would produce on a dry brisk spring or fall day The horsepower that any internal combustion engine produces depends upon the density of the air that it consumes and in turn this density is dependent upon the temperature of the air its barometric pressure and water vapor or h...

Page 16: ...se speed loss Clean surfaces when necessary WATER ABSORPTION It is imperative that all through hull fasteners be coated with a quality marine sealer at time of installa tion Water intrusion into the transom core and or in ner hull will result in additional boat weight reduced boat performance hull decay and eventual structur al failure CAVITATION Cavitation is caused by water vapor bubbles forming...

Page 17: ...nts 4 Remove spark plugs and get as much water as possible out of powerhead Most water can be eliminated by placing engine in a horizontal posi tion with spark plug holes down and rotating fly wheel 5 Pour alcohol into carburetor throats alcohol will absorbed water Again rotate flywheel 6 Turn engine over and pour alcohol into spark plug openings and rotate flywheel 7 Turn engine over place spark ...

Page 18: ...e trim angle should not be used in determining cor rect propeller Normally there is a 150 350 RPM change between propeller pitches 2 If full throttle operation is below the recom mended range the propeller MUST BE changed to one with a lower pitch to prevent loss of per formance and possible engine damage 3 After initial propeller installation the following common conditions may require that the p...

Page 19: ...ller handle in either direction may result Failure to keep a continuous firm grip on the steering wheel or tiller handle when this condition exists can result in loss of boat control as the outboard can turn freely The boat can now spin out or go into a very tight maximum turn which if unex pected can result in occupants being thrown within the boat or out of the boat Consider the following lists ...

Page 20: ...ARNING Avoid possible serious injury or death Adjust outboard to an intermediate trim position as soon as boat is on plane to avoid possible ejec tion due to boat spin out Do not attempt to turn boat when on plane if outboard is trimmed ex tremely in or down and there is a pull on the steer ing wheel or tiller handle a a Stainless Steel Tilt Pin P N 17 49930A1 Compression Check 1 Remove spark plug...

Page 21: ...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 22: ...roleum 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 wil...

Page 23: ...1 D IMPORTANT INFORMATION OUTBOARD INSTALLATION ...

Page 24: ...ide Steering Cable to the Outboard 1D 5 Steering Link Rod Installation 1D 5 Co Pilot Installation Tiller Handle models 1D 6 Remote Control Installation 1D 7 Required Side Mount Remote Control or Ignition Key Switch Assembly 1D 7 Boats Equipped with Side Mount Remote Control 1D 7 Boats Equipped with Panel Or Console Mount Remote Control 1D 7 Connecting Remote Wiring Harness to the Engine 1D 7 Shift...

Page 25: ...trol connected to your outboard must be equipped with a start in gear protection device This prevents the engine from starting when the out board is in gear WARNING Avoid serious injury or death from a sudden un expected acceleration when starting your en gine The design of this outboard requires that the remote control used with it must have a built in start in gear protection device Selecting Ac...

Page 26: ...eight of outboard generally will provide the following 1 Less steering torque 2 more top speed 3 greater boat stability but 4 will cause more prop break loose which may be particularly noticeable when planing off or with heavy load b These broken lines represent the extremes of known successful outboard mounting height dimensions c This line may be preferred to determine out board mounting height ...

Page 27: ...rilling any mounting holes carefully read Determining Recommended Out board Mounting Height preceding There is a 3 4 inch 19mm difference between outboard mounting holes in transom brackets WARNING DO NOT under any circumstances allow upper outboard mounting bolts to be closer than 1 inch 25 4mm from top of boat transom Upper mounting bolts must never be installed thru shims NOTE When drilling int...

Page 28: ...before securing out board to transom Refer to Steering Cable and Steering Link Rod Installation following Refer to Determining Recommended Outboard Mo tor Mounting Height preceding and position out board on boat transom to align mounting holes in transom bracket that will place the outboard nearest to the recommended mounting height CAUTION Marine sealer must be used on shanks bolts to make a wate...

Page 29: ...o tilt tube with steering cable attaching nut c as shown Torque nut to 35 lb ft 47 5 N m 95 2 4 C With Teflon 92 825407A12 95 a b 95 c Steering Link Rod Installation IMPORTANT The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt a Part Num ber 10 14000 and self locking nuts b c Part Number 11 34863 These locknuts must never be replace...

Page 30: ...g nylon insert locknuts f g Part Number 11 45592 These lock nuts must never be replaced with common nuts non locking as they will work loose and vibrate off freeing the link rod to disengage WARNING Disengagement of the co pilot link rod can result in the boat taking a full sudden sharp turn This potentially violent action can cause occupants to be thrown overboard exposing them to serious injury ...

Page 31: ...rning system a a Warning Horn Boats Equipped with Panel Or Console Mount Remote Control A Quicksilver Ignition Key Choke Assembly equipped with a warning horn must be used with this engine This warning horn is necessary for the en gine warning system a a Warning Horn Shift and Throttle Cable Installation To The Outboard Install the shift cable and throttle cable into the re mote control and mount ...

Page 32: ... end guide Repeat steps a thru d Throttle Cable Installation NOTE Attach Shift cable to engine prior to attaching throttle cable 1 Position the remote control handle into neutral detent 2 Position adjustment screw a against the stop 3 Adjust throttle cable barrel b so the barrel will be able to slip into the retainer when the cable end is on the mounting stud and there is a slight pre load against...

Page 33: ...ant Connecting Remote Wiring Harness To The Engine 1 Pull up the cowl seal a and remove the star board side rubber grommet b b a 2 Take hold of the engine connector c and install the remote wiring harness plug d Connect additional wire leads if equipped as shown NOTE The rubber grommet can to be lubricated to ease installation c d ...

Page 34: ...e terminal of each out boards cranking battery 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 engine to battery Connect red battery cable to positive terminal and black battery cable to negative battery terminal Set Up Instructions For Oil Injection System CAUTION Oil injected engines...

Page 35: ... and re tighten Reinstall the cowl cap FULL e b Bleeding Air From The Oil Injection System IMPORTANT If air exists in either the oil pump in let hose a or oil pump outlet hose b the air MUST BE bled from the hose s or engine dam age may occur BLEEDING AIR FROM THE OIL PUMP INLET HOSE 1 With the engine not running place a shop towel below the oil pump 2 Loosen bleed screw c four turns and allow oil...

Page 36: ...teering torque in many cases and can be adjusted within lim its to reduce any unequal steering effort NOTE Trim tab adjustment will have little effect re ducing steering torque if the outboard is installed with the anti ventilation plate approximately 2 inches 50mm or more above the boat bottom Operate your boat at normal cruising speed trimmed to desired position Turn your boat left and right and...

Page 37: ...A 2 53970 ELECTRICAL IGNITION ...

Page 38: ...mpere Stator 398 9873A21 USA 0D227200 and Above 75 90 Electric with 14 Ampere Stator 398 9873A24 USA 0G280044 thru 0G404505 Belgium 09879065 thru 09916672 2A 15 Page 4 Cylinder with 16 Ampere Stator 398 9710A33 USA 0G301751 and Above Belgium 09885528 thru 09916721 2A 15 ADI Ignition using a RED Stator with an Adapter Module 2A 17 RED Stator with Adaptor and Ignition Coils 2A 18 RED Stator DVA Test...

Page 39: ...90 830234R3 DECEMBER 1997 ELECTRICAL 2A 1 Special Tools 1 Flywheel Holder 91 52344 2 Flywheel Puller 91 73687A1 3 Volt Ohm DVA Meter 91 99750 4 Spark Gap Tester 91 63998A1 5 CDM Test Harness 84 825207A2 ...

Page 40: ...27499 BEL 9836632 BELOW IMPORTANT All eyelet electrical connections should be coated with LIQUID NEOPRENE after respec tive screw bolt or nut is tightened 1 2 3 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 4 Liquid Neoprene 92 25711 2 25 ...

Page 41: ...2 NUT 1 4 20 50 5 6 14 3 SCREW 13 5 18 3 15 1 HIGH TENSION CABLE 16 3 PROTECTOR 3 SPARK PLUG NGK BUHW 2 20 27 17 3 SPARK PLUG BELGIUM CANADA NGK BUZHW 2 20 27 3 SPARK PLUG BELGIUM CANADA NGK BUZHW 20 27 18 1 VOLTAGE REGULATOR 19 2 SCREW 70 7 9 20 1 HARNESS 21 3 IGNITION COIL ASSEMBLY 22 6 NUT 30 3 4 23 1 CABLE ignition coil BLACK 3 1 4 IN 24 1 RECTIFIER 25 2 SCREW 30 3 4 26 3 NUT 20 2 3 27 1 COVER...

Page 42: ...26999 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 33 21 22 23 24 25 26 27 28 29 30 31 32 34 35 Quicksilver Lubrication Sealant Application Points Liquid Neoprene 92 25711 2 25 IMPORTANT All eyelet electrical connections should be coated with LIQUID NEOPRENE after respective screw bolt or nut is tightened ...

Page 43: ...HER 5 16 IN 14 2 NUT 5 16 8 50 5 6 15 3 SCREW 13 5 18 3 16 1 HIGH TENSION CABLE 17 3 PROTECTOR 3 SPARK PLUG NGK BUHW 2 20 27 18 3 SPARK PLUG BELGIUM CANADA NGK BUZHW 2 20 27 3 SPARK PLUG BELGIUM CANADA NGK BUZHW 20 27 19 1 IGNITION PLATE 20 1 CABLE ignition coil BLACK 7 IN 20 1 CABLE ignition coil BLACK 3 1 4 IN 21 3 IGNITION COIL ASSEMBLY 22 6 NUT 30 3 4 23 1 RECTIFIER 24 2 SCREW 30 3 4 25 2 NUT ...

Page 44: ...000 BEL 9937000 UP IMPORTANT All eyelet electrical connections should be coated with LIQUID NEOPRENE after respec tive screw bolt or nut is tightened 5 16 30 29 31 21 22 24 28 35 33 26 27 20 19 1 34 8 2 4 3 13 11 6 7 14 15 32 17 9 6 6 12 18 23 36 30 9 10 25 10 Liquid Neoprene 92 25711 2 25 ...

Page 45: ...R 11 1 HARNESS Engine 12 1 FUSE ELECTRIC 13 1 HARNESS Ignition 14 1 BATTERY CABLE POSITIVE 15 1 BOOT 16 3 CDM 17 3 HI TENSION CABLE 18 3 BOOT 19 3 SPARK PLUG NGK BUHW 2 20 27 19 3 SPARK PLUG BELGIUM CANADA NGK BUZHW 20 27 20 6 SCREW M6 x 16 21 1 STARTER SOLENOID 22 2 BUSHING 23 2 GROMMET 24 2 NUT 8 32 ELECTRIC 25 1 CABLE 26 2 LOCKWASHER 5 16 IN 27 2 NUT 5 16 8 28 2 SCREW M6 x 25 29 1 VOLTAGE REGUL...

Page 46: ...999 BEL 9926999 BELOW 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 Liquid Neoprene 92 25711 2 18 25 IMPORTANT All eyelet electrical connections should be coated with LIQUID NEOPRENE after respec tive screw bolt or nut is tightened ...

Page 47: ...ROTECTOR 10 1 VOLTAGE REGULATOR 11 2 SCREW 70 7 9 12 4 IGNITION COIL ASSEMBLY 13 8 NUT 20 2 3 14 1 COVER 15 5 SCREW 20 2 3 16 5 WASHER 17 1 HARNESS 18 1 CABLE 6 1 2 IN 18 1 CABLE 4 3 4 IN 19 2 SCREW 30 3 4 20 3 NUT Use Where Applicable 20 2 3 21 1 TERMINAL BLOCK 22 4 SCREW 13 5 18 3 23 2 TERMINAL BLOCK 24 4 SCREW Drive Tight 25 1 ENGINE WIRING HARNESS 26 1 FUSE 20 AMP 27 1 BATTERY CABLE POSITIVE 2...

Page 48: ...G438000 BEL 9937000 UP IMPORTANT All eyelet electrical connections should be coated with LIQUID NEOPRENE after respec tive screw bolt or nut is tightened 34 5 16 30 29 31 21 22 24 33 26 27 20 19 1 34 8 2 4 3 13 11 6 7 14 15 32 26 17 6 6 6 33 11 22 35 7 7 27 Liquid Neoprene 92 25711 2 25 ...

Page 49: ... 12 1 HARNESS Ignition 13 1 BATTERY CABLE POSITIVE 14 1 BOOT 15 4 CDM S N USA 0G589999 BEL 9973099 BELOW 15 4 CDM S N USA 0G590000 BEL 9973100 UP 16 4 HI TENSION CABLE 17 4 BOOT 18 4 SPARK PLUG NGK BP8H N 10 20 27 18 4 SPARK PLUG NGK BPZ8H N 10 20 27 19 8 SCREW M6 x 16 20 1 STARTER SOLENOID 21 2 BUSHING 22 2 GROMMET 23 2 NUT 8 32 24 2 LOCKWASHER 5 16 IN 25 2 NUT 5 16 8 26 2 SCREW M6 x 25 27 1 WASH...

Page 50: ...agnets on the flywheel center hub IMPORTANT If the engine misfires runs rough or does not start the ignition system should be checked using a Multi Meter DVA Tester 91 99750 or a voltmeter capable of measuring 400 volts DC or higher and Direct Voltage Adap tor 91 89045 Test Procedures Direct Voltage Adapter DVA Tests WARNING DANGER HIGH VOLTAGE SHOCK HAZARD Do not touch ignition components and or ...

Page 51: ...g on flywheel hub for looseness and or a shift in position 2 If ignition checks to specification and engine does not run or runs poorly trouble exists with fuel system or engine mechanical 2 A Check switch box stop circuit See Test Chart 1 If reading is BELOW specifications proceed with Step 2 B 2 If reading is ABOVE specifications the Trigger or Switch Box is bad test trigger as outlined in this ...

Page 52: ... Yellow 3 Sw Box Terminal Ground 200 360 200 360 3 A 4 A Stator Low Speed 400 VDC Blue Sw Box Terminal Ground 200 300 200 330 3 A 4 A Stator High Speed 400 VDC Red Sw Box Terminal Ground 20 90 130 300 Sw Box 20 VDC or See Note 1 5 A Sw Box Bias 20 VDC or 40 VDC Ground White Black Sw Box Terminal 2 10 10 30 4 Cylinder with 16 Ampere Stator 398 9710A31 USA 0D283222 thru 0G301750 Belgium 09793577 thr...

Page 53: ...Note 1 5 A Sw Box Bias 20 VDC or 40 VDC Ground White Black Sw Box Terminal 2 10 10 30 10 30 4 Cylinder with 16 Ampere Stator 398 9710A33 USA 0G301751 and Above Belgium 09885528 thru 09916721 ADI Test Selector Sw DVA Leads Voltage 300 Voltage 1000 Voltage 4000 Test Seq Test Sw Position Red Black 300 RPM 1000 RPM 4000 RPM 1 A Coil Primary 400 VDC Coil Terminal Coil Terminal 110 140 250 300 215 265 2...

Page 54: ...trical components that are grounded directly to engine and all ground wires to see that they are grounded to engine 5 Check for disconnected wires and short and open circuits STATOR LOW AND HIGH SPEED OHM TEST NOTE Stator can be tested without removing from engine 1 Disconnect stator leads from switch box 2 Use an ohmmeter and perform the following tests IMPORTANT If stator is mounted on engine bl...

Page 55: ... is less than one 1 OHM If a reading resembling a short is obtained this would be acceptable Copper wire is an excellent conductor but it will have a noticeable difference in resistance from cold to hot temperatures Reasonable variations from these readings are acceptable 4 If meter readings are not as specified replace ignition coil TRIGGER TEST 1 Disconnect all trigger leads from switch box 2 Us...

Page 56: ... Test all wires disconnected R x 1 Ohms Positive Meter Lead Negative Meter Lead Scale Connect to White Green stator lead Connect to Green White stator lead 660 710 Connect to Yellow stator lead Connect to Yellow stator lead 0 165 0 181 Manual Start Engines Red Stator Resistance Test all wires disconnected R x 1 Ohms Positive Meter Lead Negative Meter Lead Scale Connect to White Green stator lead C...

Page 57: ...the switch box Connect the DVA meter between the BLUE WHITE adapter lead and ground Crank the engine manual or electric If the DVA reading is normal 190 to 260 volts the switch box is defective If either of the DVA readings is still low either the stator or the adaptor is defective Disconnect the GREEN WHITE and WHITE GREEN stator leads from the adapter Measure the resistance between the GREEN WHI...

Page 58: ...SCHARGE MOD ULES CDM where it is rectified DC and stored in a capacitor The stator voltage return path is through the ground wire of the other CDM and back through that CDM s charging coil wire to the capacitor charging coils N BLK N S S S S S S N N N N N S GRN WHT WHT GRN YEL YEL BRN BLK WHT _ _ _ WHT GRN PPL BRN BLK BLK YEL BRN BLK YEL BLK BLK YEL 2 3 PPL a b c d e f g h i j 1 Return Voltage CAP...

Page 59: ...acitor charging coils NOTE 1 CDM stator voltage return path is through either CDM 2 or 3 The return path for CDM 2 and 3 is through CDM 1 if 1 stator wire is discon nected the engine will die the stator circuit is incom plete and the capacitors cannot be charged N BLK N S S S S S S N N N N N S GRN WHT WHT GRN YEL YEL BRN BLK WHT _ _ _ WHT GRN PPL BRN BLK BLK YEL BRN BLK YEL BLK BLK YEL 2 3 PPL a b...

Page 60: ...e pulse N S will activate the electron ic switch SCR inside the capacitor discharge mod ule CDM The switch discharges the capacitor volt age through the coil primary windings The return voltage pulse exits the CDM through the ground wire and returns through the trigger ground NOTE 4 cylinder models have 4 triggers N BLK N S S S S S S N N N N N S GRN WHT WHT GRN YEL YEL BRN BLK WHT _ _ _ WHT GRN PP...

Page 61: ...ry reach approximately 40 000 volts To complete the secondary voltage path the released voltage enters the ground circuit of CDM module N BLK N S S S S S S N N N N N S GRN WHT WHT GRN YEL YEL BRN BLK WHT _ _ _ WHT GRN PPL BRN BLK BLK YEL BRN BLK YEL BLK BLK YEL 2 3 PPL a b c d e f g h i j 1 Return Voltage CAPACITOR Source Voltage COIL SCR DIODE Trigger Voltage a Battery Charging Coils b Trigger Co...

Page 62: ...pacitor and possible failure if the SCR does not receive a trigger pulse N BLK N S S S S S S N N N N N S GRN WHT WHT GRN YEL YEL BRN BLK WHT _ _ _ WHT GRN PPL BRN BLK BLK YEL BRN BLK YEL BLK BLK YEL 2 3 PPL a b c d e f g h i j 1 Return Voltage CAPACITOR Source Voltage COIL SCR DIODE Trigger Voltage a Battery Charging Coils b Trigger Coils c Capacitor Charge Coils d CDM 1 e CDM 2 f CDM 3 g Rev Limi...

Page 63: ...und out the CDM capacitor charge The capacitor voltage flows through the BLACK YELLOW wires into the rev limiter and to engine ground through the BLACK wire N BLK N S S S S S S N N N N N S GRN WHT WHT GRN YEL YEL BRN BLK WHT _ _ _ WHT GRN PPL BRN BLK BLK YEL BRN BLK YEL BLK BLK YEL 2 3 PPL a b c d e f g h i j 1 Return Voltage CAPACITOR Source Voltage COIL SCR DIODE Trigger Voltage a Battery Chargi...

Page 64: ...nual stator 3 ignition charge coils and 9 auxiliary 3 for manual power coils wound in series that provide voltage to the CDM s and battery auxiliary circuits respectively FLYWHEEL Contains 6 magnets 12 pole around circumference Has one magnet on inner hub for trigger Outer mag nets are for battery charge coils and ignition charge coils NOTE Electric start model flywheel shown IMPORTANT Before repl...

Page 65: ...epair Re place Con nector Com ponents Step 3 3 Verify Ground from CDM connector to block 0 2 Ohms and below Step 4 Correct Ground Path Step 4 DVA Multimeter P N 91 99750 Test Harness P N 84 825207A2 4 Test all CDMs at Cranking with Spark Gap Tester Spark on All CDMs Will spark jump a 7 16 in 11 11 mm gap 7 16 in 11 11 mm gap If at least one CDM has spark continue with Chart 3 Continue with Chart 2...

Page 66: ... in CDM 1 would prevent CDMs 2 and 3 from sparking A shorted Stop Diode in CDM 2 or 3 would prevent CDM 1 from sparking 1 2 3 4 Cyl CDM 1 and 2 get their charging ground path through CDM 3 or 4 CDM 3 and 4 get their charging ground path through CDM 1 or 2 A shorted Stop Diode in CDM 1 or 2 would prevent CDMs 3 and 4 from sparking A shorted Stop Diode in CDM 3 or 4 would prevent CDM 1 and 2 from sp...

Page 67: ...Volt and above CDM disconnected 0 2 5 Volts CDM connected Step 5 2 3 4 Cyl Replace Trig ger Run Engine Verify Repair Step 6 6 Cyl Step 4 DVA Multimeter P N 91 99750 TPI CDM Test Harness 84 825207A2 4 V 6 Models Resistance Check Crank Position Sensor 900 1300 Ohms Step 5 Replace Crank Posi tion Sensor Run Engine Verify Repair Step 6 DVA Multimeter P N 91 99750 5 Test all CDMs at Cranking with Spark...

Page 68: ...Step 4 DVA Multimeter P N 91 99750 TPI CDM Test Harness 84 825207A2 4 V6 Models Resistance Check Crank Position Sensor 900 1300 Ohms Step 5 Replace Crank Posi tion Sensor Run Engine Verify Repair Step 6 DVA Multimeter P N 91 99750 5 Test all CDMs at Cranking with Spark Gap Tester Spark on All CDMs Will spark jump a 7 16 in 11 11 mm gap 7 16 in 11 11 mm gap Run Engine Verify Repair Step 6 Replace a...

Page 69: ... Yellow test harness lead Green D or Green test harness lead R x 100 Diode Reading No Continuity Return Ground Path Diode Reverse Bias Green D or Green test harness lead Ground Pin A or Black test harness lead R x 100 Diode Reading No Continuity Return Ground Path Diode Forward Bias Ground Pin A or Black test harness lead Green D or Green test harness lead R x 100 Diode Reading Continuity CDM Trig...

Page 70: ... the CDM mounted on the ignition plate for testing 1 Remove all spark plugs 2 Insert spark gap tool P N 91 63998A1 into each spark plug boot and attach alligator clips to a good engine ground 3 Disconnect remote fuel line from engine 4 Make sure all CDMs are plugged in 5 Test Stator and Trigger voltage to CDM a Install test harness 84 825207A2 between ignition harness and CDM b a c a Stator Trigge...

Page 71: ...arness Lead 100 300 If CDM Stop Circuit reading is below specifications replace that CDM Test each CDM Trigger Output Test Cranking Speed 2 DVA Scale Positive Meter Lead Negative Meter Lead DVA Reading White Test Harness Lead Black Test Harness Lead 0 2 5 0 If reading is below specifications replace trigger If reading is above specifications check CDM NOTE If voltage remains low after installing a...

Page 72: ...ck CDM NOTE If voltage remains low after installing a new trigger replace CDM Resistance Tests RED STATOR 1 Disconnect stator leads NOTE Resistance varies greatly with temperature Measurements should be taken with an ambient tem perature range of 65 to 85 degrees F Red Stator Resistance Test R x 10 Ohms Positive Meter Lead Negative Meter Lead R x 10 Ohms Scale Connect to White Green stator lead Co...

Page 73: ...preceding test verify that switch and not wiring is faulty If wiring checks OK replace switch Flywheel Removal and Installation REMOVAL 1 Remove flywheel cover from engine WARNING Engine could possibly start when turning fly wheel during removal and installation therefore disconnect and isolate spark plug leads from spark plugs to prevent engine from starting 2 Disconnect spark plug leads from spa...

Page 74: ...heel center bore with flywheel key and install flywheel onto crankshaft 4 Install washer and locknut 5 Hold flywheel with Flywheel Holder 91 52344 torque locknut to 100 lb ft 136 N m a 51123 a Flywheel Holder 91 52344 6 Install flywheel cover Stator Removal and Installation REMOVAL 1 Remove flywheel refer to Flywheel Removal 2 Remove screws a 53973 a Screws 3 Remove starter motor as outlined in Se...

Page 75: ...m on the underside of the stator where the stator harness exits the stator These stators MUST BE INSTALLED AS SHOWN RESPECTIVE LY OR PREMATURE STATOR FAILURE MAY OC CUR AS A RESULT OF STATOR INTERFERANCE WITH THE ENGINE BLOCK Small Rim Stator a Front of Engine b c d d d e d 51 Loctite 222 92 809818 51 54132 a Small Rim b Exhaust Cover Bolt c High Low Speed Winding Module of Stator d Stator Screws ...

Page 76: ... Screws Apply Loctite 222 to threads Torque screws to 60 lb in 6 8 N m e Stator Harness 1 Install stator as shown a b c d 51 Loctite 222 92 809818 51 53973 a Screws apply Loctite 222 on threads unless Patch Screw used and torque to 60 lbs in 6 6 N m b Stator c Stator Harness d Trigger Harness 2 Connect stator leads refer to wiring diagrams in Section 2D 3 Install sta strap 4 Install starter motor ...

Page 77: ... and stator refer to Flywheel and Stator removal preceding 2 Disconnect link arm and remove trigger b a 19459 a Link Arm b Trigger 3 Remove starter motor refer to Section 2B 4 Remove sta strap 5 Disconnect trigger leads from switch box and re move trigger 3 Cylinder Models b a c 53972 a Sta straps b Bullet Connectors Disconnect Trigger Leads c Trigger Harness 4 Cylinder Models a b c 53970 a Sta St...

Page 78: ...g diagrams in Section 2D 3 Install sta strap 4 Install starter motor refer to Section 2B 3 Cylinder Models b a c 53792 a Sta Straps b Bullet Connectors Connect Trigger Leads c Trigger Harness 4 Cylinder Models a b c 53970 a Sta Strap b Trigger Harness c Switch Box 5 Install stator refer to Stator Installation preced ing 6 Install flywheel refer to Flywheel Installation preceding ...

Page 79: ... 3 N m e Coil Tower Boots form a water tight seal between coil tower and spark plug lead using Quicksilver Insulating Compound Refer to wiring diagrams in Section 2D when con necting wires 4 Cylinder Models a e e e e b c c c d d d d d Liquid Neoprene 92 25711 2 53975 25 a Coils b Cover c Hex Nuts coat with Quicksilver Liquid Neoprene d Bolts torque to 20 lb in 2 3 N m e Coil Tower Boots form a wat...

Page 80: ...lts Torque to 40 lb in 4 5 N m b Bullet Connectors c Sta Strap d Switch Box 4 Cylinder Models d c c c b a 53970 a Switch Box b J Clip c Bolt Torque to 40 lb in 4 5 N m d Screw Secure coil ground wires under screw 3 Cylinder Models w CDM Ignition a b 55418 a CDM b Bolt Torque to 60 lb in 6 8 N m 4 Cylinder Models w CDM Ignition b a 55419 a CDM b Bolt Torque to 60 lb in 6 8 N m ...

Page 81: ...B 2 11669 ELECTRICAL CHARGING AND STARTING SYSTEM ...

Page 82: ...ooting 2B 6 Page 3 Cylinder 14 and 16 Ampere BLACK Stator Battery Charging Wiring Diagram 2B 9 4 Cylinder 14 and 16 Ampere BLACK Stator Battery Charging Wiring Diagram 2B 10 3 Cylinder Battery Charging Diagram with BLACK STATOR with Battery Isolator 2B 11 3 Cylinder Battery Charging Diagram with RED STATOR with Battery Isolator 2B 12 4 Cylinder Battery Charging Diagram with BLACK Stator with Batte...

Page 83: ...tor Stamped 398 9710A3 Serial Number USA 0D283222 0G280043 Belgium 09793577 09879064 3 Cyl Electric Black Stator Stamped 398 9873A24 Serial Number USA 0G280044 0G404505 Belgium 09879065 09916672 3 Cyl Electric Red Stator Stamped 398 832075A3 Serial Number USA 0G404506 and Above Belgium 09916673 and Above 4 Cyl Electric Black Stator Stamped 398 9710A31 Serial Number USA 0D283222 0G301750 Belgium 09...

Page 84: ...s 3 DO NOT reverse polarity of battery cables on bat tery terminals CAUTION If battery acid comes into contact with skin or eyes wash skin immediately with a mild soap Flush eyes with water immediately and see a doctor Operating Engine Without Battery If desired or in an emergency engines equipped with an alternator can be started and operated with out a battery either disconnected or removed if W...

Page 85: ...avity 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 battery is defective and should be replaced Electrolyte Level Check electrolyte level in battery regularly A battery in use in hot weather should be checked more fre quently because of more rapid loss of water If ...

Page 86: ...irable on terminals at all times re charge again as necessary and reinstall battery 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 with clear wat...

Page 87: ...table If stator is removed from engine connect test lead to black stator lead if provided 4 If meter readings are other than specified re place stator BLACK Stator 14 and 16 Ampere Alternator System Test 1 Check battery voltage at battery with engine run ning 2 If battery voltage is above 14 5 volts replace volt age regulator rectifier Check condition of battery as overcharging may damage battery ...

Page 88: ...crews to 30 lb in 3 4 N m 2 Attach two YELLOW wires to ALT YEL termi nals 3 Attach GREY wire to GREY TACH terminal RED Stator Battery Charging System Troubleshooting MODELS EQUIPPED WITH REGULATOR RED STATOR a b c d a Stator b Voltage Regulator Rectifier c Start Solenoid d 12V Battery The charging system may be damaged by 1 re versed battery cables 2 running the engine with bat tery cables disconn...

Page 89: ...ms If a reading resembling a short is obtained this would be acceptable ALTERNATOR SYSTEMS TEST RED STATOR 9 Ampere Manual Stator IMPORTANT Rectifier optional accessory must be functioning properly for accurate test results to be obtained 1 Remove RED lead from terminal of rectifier 2 Connect RED ammeter lead to rectifier ter minal and BLACK ammeter lead to RED recti fier lead 3 With engine runnin...

Page 90: ... from flywheel 9 With engine running at the indicated RPM s the ammeter should indicate the following approxi mate amperes RPM AMPERES 16 Ampere St t Idle 2 8 Stator 1000 9 3 2000 16 0 3000 17 0 4000 17 5 5000 17 5 10 A reading of 16 amperes at 2000 RPM indicates the charging system is functioning properly The battery is being discharged because of the excessive amperage draw on the system the dra...

Page 91: ...r Liquid Neoprene 92 25711 to avoid cor rosion 51000 YEL YEL BLK BLK RED RED YEL YEL GRY GRY YEL YEL RED RED BLK RED RED GRY a h g f e c d b BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN PUR PURPLE RED RED TAN TAN VIO VIOLET WHT WHITE YEL YELLOW a Stator b Terminal Block c To Tachometer d Voltage Regulator Rectifier e To Remote Control Harness f 20 Ampere Fuse g Battery Positive Terminal h Start...

Page 92: ...k silver Liquid Neoprene 92 25711 to avoid cor rosion 51001 YEL YEL RED RED YEL YEL GRY GRY YEL YEL RED RED GRY RED RED a h f g b c d e BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN PUR PURPLE RED RED TAN TAN VIO VIOLET WHT WHITE YEL YELLOW a Stator b Terminal Block c To Tachometer d Voltage Regulator Rectifier e To Remote Control Harness f 20 Ampere Fuse g Battery Positive Terminal h Starter So...

Page 93: ...n 51051 BLK GRY RED RED RED RED B1 B2 RED A BLK YEL YEL BLK YEL YEL GRY GRY YEL YEL RED RED a j b c d e f g i h k l BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN PUR PURPLE RED RED TAN TAN VIO VIOLET WHT WHITE YEL YELLOW a Stator b Terminal Block c To Tachometer d Voltage Regulator Rectifier e Battery Isolator f Auxiliary Battery g Start Battery h To Remote Control Harness i 20 Ampere Fuse j Sta...

Page 94: ...o avoid cor rosion 51051 RED RED RED RED B1 B2 RED A YEL YEL YEL YEL GRY GRY YEL YEL RED RED a b c d e f g i h j k BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN PUR PURPLE RED RED TAN TAN VIO VIOLET WHT WHITE YEL YELLOW a Stator b To Tachometer c Voltage Regulator Rectifier d Battery Isolator e Auxiliary Battery f Start Battery g To Remote Control Harness h 20 Ampere Fuse i Starter Solenoid j Sm...

Page 95: ... rosion 51050 YEL YEL RED YEL YEL GRY GRY YEL YEL RED RED GRY RED RED RED B1 B2 RED A a b c d e f g j h i k l BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN PUR PURPLE RED RED TAN TAN VIO VIOLET WHT WHITE YEL YELLOW a Stator b Terminal Block c To Tachometer d Voltage Regulator Rectifier e Battery Isolator f Auxiliary Battery g Start Battery h To Remote Control Harness i 20 Ampere Fuse j Starter S...

Page 96: ...o avoid cor rosion 51050 YEL YEL RED YEL YEL GRY GRY YEL YEL RED RED RED RED RED B1 B2 RED A a b c d e f g i h j k BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN PUR PURPLE RED RED TAN TAN VIO VIOLET WHT WHITE YEL YELLOW a Stator b To Tachometer c Voltage Regulator Rectifier d Battery Isolator e Auxiliary Battery f Start Battery g To Remote Control Harness h 20 Ampere Fuse i Starter Solenoid j Sm...

Page 97: ...lead alternately to terminals a and c No Continuity Indicated Connect BLACK meter lead to ground RED lead alternately to terminals a and c No Continuity Indicated Connect BLACK meter lead to terminal b RED lead alternately to terminals a and c Continuity Indicated Replace Rectifier Continuity Indicated Connect BLACK meter lead to terminal b RED lead alternately to terminals a and c No Continuity I...

Page 98: ...neutral start switch opens the start circuit when the shift control lever is not in neutral This prevents accidental starting when engine is in gear CAUTION The starter motor may be damaged if operated continuously DO NOT operate continuously for more than 30 seconds Allow a 2 minute cooling period between starting attempts Troubleshooting the Starting Circuit Before beginning the starting circuit...

Page 99: ...oting Flow Chart Starter Motor Does Not Turn SAFETY WARNING Disconnect BLACK starter motor cable from starter solenoid test point 1 BEFORE making tests 1 thru 7 to prevent unexpected engine cranking TEST 1 Use an ohmmeter R x 1 scale and connect meter leads between NEGATIVE battery post and common powerhead ground No continuity indicated there is an open circuit in the BLACK negative battery cable...

Page 100: ... Point 5 TEST 6 Connect voltmeter between common engine ground and Test Point 6 No voltage reading check RED wire between battery positive terminal and Test Point 6 TEST 7 a Connect voltmeter between common engine ground and Test Point 1 b Turn ignition key to Start position No voltage reading Defective starter solenoid 12 Volt Reading Check BLACK ground cable at starter for loose or cor roded con...

Page 101: ...ter clamps 6 Remove starter a b b c d 54159 a YELLOW Cable b Bolts 4 c BLACK Cable d Sta Strap 7 Remove 2 rubber collars and 2 rubber bumpers b a a 11645 a Rubber Collar b Rubber Bumpers Disassembly 1 Remove 2 thru bolts and commutator end cap taking care not to lose brush springs a a b 11646 a Thru Bolts b Commutator End Cap 2 Pull armature from starter frame 3 Remove locknut c b a 11659 a Hold A...

Page 102: ...ndercut is flat b Clean the commutator slots after undercut ting c Sand the commutator lightly with No 00 sandpaper to remove burrs then clean the commutator d Recheck the armature on a growler for shorts as specified in the following procedure Test ing 8 Open circuited armatures often can be repaired The most likely place for an open circuit is at the commutator bars as a result of long cranking ...

Page 103: ... brushes Meter must indicate full continuity or zero resistance If resistance is indi cated inspect lead to brush and lead to POSITIVE terminal solder connection If connection cannot be repaired brushes must be replaced a a 11673 a POSITIVE Brushes TESTING NEGATIVE BRUSHES FOR GROUND Set ohmmeter to R x 1 scale Place one lead of the ohmmeter on the NEGATIVE brush and the other lead on the end cap ...

Page 104: ...uity re place solenoid a a b 1 3 4 2 b 51809 a 12 Volt Supply b VOA Leads Brush Replacement STARTER REASSEMBLY 1 If brushes were removed replace as follows a Install POSITIVE brushes along with POS ITIVE terminal into commutator end cap c i b a h d d e f g 11660 a End Cap b POSITIVE Brushes c POSITIVE Terminal d Insulating Bushing e Washer f Split Washer g Hex Nut h Long Brush Lead i Push Lead int...

Page 105: ...cate bushing in drive end plate with a drop of SAE 10W oil 5 Position armature into starter frame 6 To prevent damage to brushes and springs when installing commutator end cap it is recom mended that a brush retaining tool be made as shown 90 Bend 2 2 1 11 16 3 3 4 1 2 1 3 4 b a a Brush Retainer Tool Layout Full Size b 18 Gauge Sheet Metal 7 Lubricate bushing located in commutator end cap with one...

Page 106: ...m c b a c 11646 a Alignment Marks b Alignment Marks c Bolts Torque to 70 lb in 7 9 N m INSTALLATION 1 Install 2 rubber collars and 2 rubber bumpers b a a 11645 a Rubber Collars b Rubber Bumpers 2 Install components as shown 3 Connect battery leads to battery k i h g b f e c d b a j b 54159 a Clamp upper b Bolts Torque to 14 5 lb ft 19 7 N m c Bolt and Lockwasher d BLACK Cable e Sta strap f Starter...

Page 107: ...90 830234R3 DECEMBER 1997 ELECTRICAL 2B 25 4 Reinstall electrical plate cover Torque bolts to 30 lb in 3 4 N m a a 53958 a Bolts Torque to 30 lb in 3 4 N m ...

Page 108: ...C 2 22480 ELECTRICAL TIMING SYNCHRONIZING ADJUSTING ...

Page 109: ...g Synchronizing Adjusting 3 Cylinder Models 2C 1 Specifications 2C 1 Special Tools 2C 1 Throttle Cable Installation 2C 4 Page Timing Synchronizing Adjusting 4 Cylinder Models 2C 5 Specifications 2C 5 Special Tools 2C 5 Idle Adjustment 2C 8 Throttle Cable Installation 2C 8 ...

Page 110: ...5000 5500 Idle RPM in FORWARD Gear 675 25 RPM Maximum Timing 3000 RPM 75 65JET 90 18 B T D C 20 B T D C Cranking Speed 75 65 JET 90 20 B T D C 22 B T D C Idle Timing 2 A T D C 6 B T D C Spark Plug NGK BUHW 2 Firing Order 1994 1995 Models 1996 97 98 Models 1 3 2 1 2 3 Special Tools 1 Service Tachometer 91 854008A1 2 Timing Light 91 99379 3 Spark Gap Tool 91 63998A1 May be obtained locally ...

Page 111: ...izing Screws 7 Hold throttle arm so that idle stop screw is against stop 8 Place roller of cam follower against throttle cam and adjust idle stop screw to align raised mark of throttle cam with center of cam follower roller Tighten locknut a Throttle Arm b Idle Stop Screw c Roller d Throttle Cam e Raised Mark f Lock Nut 9 Holding throttle arm at idle position adjust cam follower so that a clearanc...

Page 112: ...locknut 20442 a 2 8 BTDC 0 2 8 a Idle Timing Screw MAXIMUM TIMING 1 Hold control arm so that maximum spark ad vance screw is against stop 2 Crank engine with starter motor and adjust maxi mum spark advance screw to align the specified BTDC timing mark on flywheel with timing pointer due to the advance characteristic of this ignition system this cranking speed adjustment will auto matically be redu...

Page 113: ...PM to stabilize 2 With engine running at idle speed in water in Forward gear prop on turn low speed mixture screw IN clockwise until engine starts to bog down and misfire Back out 1 4 turn or more 3 Check for too lean mixture on acceleration 4 DO NOT adjust leaner than necessary to attain reasonable smooth idling When in doubt stay on the slightly rich side of the adjustment IDLE ADJUSTMENT 1 With...

Page 114: ... of oil pump body aligns with stamped mark of oil pump lever a b c a Link Rod b Stamped Mark of Oil Pump Body c Stamped Mark of Oil Pump Lever 2 Reinstall engine cowling Timing Synchronizing Adjusting 4 Cylinder Models Specifications Models 80 JET 100 115 125 Full Throttle RPM Range 4750 5250 Idle RPM in FORWARD Gear 675 25 Maximum Timing 1994 1995 Models 3000 RPM Cranking Speed 20 B T D C 22 B T ...

Page 115: ...crew securing cam follower 53433 0 005 0 020 a b c 0 13 0 51mm a Roller b Throttle Cam c Screw 10 Hold throttle arm against full throttle stop Adjust full throttle stop screw to allow throttle shutters to open fully To prevent throttle shutters to act as a stop screw in stop screw until there is a gap of 0 015 in 0 40mm between roller of cam follow er and throttle lever 53430 a b a Throttle Arm b ...

Page 116: ...ut engine running then final timing checks should be made with engine running due timing advance char acteristics of ignition system Maximum engine RPM required to check maximum timing advance is 3000 RPM 1 Insert Spark Gap Tool 91 63998A1 in no 1 top cylinder spark plug boot and attach alligator clip to good ground 2 Remove throttle cable barrel from barrel retainer IDLE TIMING ADJUSTMENT WARNING...

Page 117: ...For adjusting carburetor throttle linkage and synchronizing carburetors see section Timing Synchronizing Adjusting of this manual After service or replacement of carburetor turn low speed mixture screw adjustment in clockwise until it seats lightly then back off each carburetor to specifications 80 JET 100 115 125 1 1 2 turns This will permit engine start up LOW SPEED MIXTURE ADJUSTMENTS NOTE Only...

Page 118: ...Locknut Throttle Cable Installation 1 With end of throttle cable connected to throttle le ver hold throttle lever against idle stop Adjust throttle cable barrel to slip into barrel retainer on cable anchor bracket with a very light preload of throttle lever against idle stop Lock barrel in place IMPORTANT Excessive preload on throttle cable will cause difficulty when shifting from forward to neutr...

Page 119: ...D 2 ELECTRICAL WIRING DIAGRAMS ...

Page 120: ...3 1998 75 Electric Start Tiller Handle w Power Trim Wiring Diagram 2D 14 1998 75 90 Electric Start Wiring Diagram 2D 15 1998 75 90 Electric Start w Power Trim Wiring DiagraM 2D 16 1998 80 Jet 100 115 125 Wiring Diagram 2D 17 Page Power Trim System Wiring Diagram 3 Cylinder Models Using COMMANDER 2000 Side Mount Remote Control 2D 18 Power Trim System Wiring Diagram 3 Cylinder Models Using COMMANDER...

Page 121: ...RN GREEN PUR PURPLE RED RED TAN TAN VIO VIOLET WHT WHITE YEL YELLOW a Stator b Trigger c Starter d Starter Solenoid e 20 Ampere Fuse f 12 Volt Battery g Engine Harness h Low Oil Sensor i Warning Module j Temperature Switch k Enrichment Valve l Voltage Regulator m RPM Limiter n Switch Box o Ignition Coil 3 Cylinder p Ignition Coil 2 Cylinder q Ignition Coil 1 Cylinder r Terminal Block ...

Page 122: ...N PUR PURPLE RED RED TAN TAN VIO VIOLET WHT WHITE YEL YELLOW a Stator b Trigger c Starter d Starter Solenoid e 20 Ampere Fuse f 12 Volt Battery g Engine Harness h Low Oil Sensor i Warning Module j Temperature Switch k Enrichment Valve l Voltage Regulator Rectifier m RPM Limiter n Switch Box o Ignition Coil 3 Cylinder p Ignition Coil 2 Cylinder q Ignition Coil 1 Cylinder r Terminal Block ...

Page 123: ...REEN PUR PURPLE RED RED TAN TAN VIO VIOLET WHT WHITE YEL YELLOW a Stator b Trigger c Starter d Starter Solenoid e 20 Ampere Fuse f 12 Volt Battery g Engine Harness h Low Oil Switch i Warning Module j Temperature Switch k Terminal Block l Enrichment Valve m Voltage Regulator Rectifier n Switch Box o Ignition Coil 3 Cylinder p Ignition Coil 2 Cylinder q Ignition Coil 1 Cylinder ...

Page 124: ...EN PUR PURPLE RED RED TAN TAN VIO VIOLET WHT WHITE YEL YELLOW a Stator b Trigger c Starter d Starter Solenoid e 20 Ampere Fuse f 12 Volt Battery g Engine Harness h Low Oil Switch i Warning Module j Temperature Switch k Terminal Block l Enrichment Valve m Voltage Regulator Rectifier n Switch Box o Ignition Coil 3 Cylinder p Ignition Coil 2 Cylinder q Ignition Coil 1 Cylinder ...

Page 125: ... e f g h i j k BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN PUR PURPLE RED RED TAN TAN VIO VIOLET WHT WHITE YEL YELLOW a Stator b Trigger c Switch Box d Ignition Coil Cylinder 1 e Ignition Coil Cylinder 2 f Ignition Coil Cylinder 3 g Emergency Stop Switch h Stop Button i Warning Horn j Temperature Switch k RPM Limiter ...

Page 126: ... e f g h i j k BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN PUR PURPLE RED RED TAN TAN VIO VIOLET WHT WHITE YEL YELLOW a Stator b Trigger c Switch Box d Ignition Coil Cylinder 1 e Ignition Coil Cylinder 2 f Ignition Coil Cylinder 3 g Emergency Stop Switch h Stop Button i Warning Horn j Temperature Switch k RPM Limiter ...

Page 127: ...URPLE RED RED TAN TAN VIO VIOLET WHT WHITE YEL YELLOW a Stator b Trigger c Starter d Starter Solenoid e 12 Volt Battery f Engine Harness g Warning Module h Low Oil Sensor i Temperature Switch j Enrichment Valve k Voltage Regulator Rectifier l RPM Limiter m Ignition Coil 4 Cylinder n Ignition Coil 3 Cylinder o Ignition Coil 2 Cylinder p Ignition Coil 1 Cylinder q Switch Box r Terminal Block ...

Page 128: ...RPLE RED RED TAN TAN VIO VIOLET WHT WHITE YEL YELLOW WHT RED RED YEL GRY BRN BLK BLK YEL GRN WHT WHT GRN PPL YEL a Trigger b Stator c Remote Control d 20 Ampere Fuse e Starter f Starter Solenoid g 12 Volt Battery h Fuel Enrichment Solenoid i Head Temperature Switch j Oil Warning Module k Oil Level Switch l Engine Block m Electrical Plate n CDM 3 o CDM 2 p CDM 1 q Voltage Regulator ...

Page 129: ...rder a b c d e f g h i k l j BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN PUR PURPLE RED RED TAN TAN VIO VIOLET WHT WHITE YEL YELLOW a Trigger b Stator c Electrical Plate d Engine Block e Temperature Switch f Warning Horn g Push Button Stop Switch h Lanyard Stop Switch i RPM Limiter j CDM 3 k CDM 2 l CDM 1 ...

Page 130: ...ROWN GRY GRAY GRN GREEN PUR PURPLE RED RED TAN TAN VIO VIOLET WHT WHITE YEL YELLOW a Trigger b Stator c Remote Control d 20 Ampere Fuse e Starter f Starter Solenoid g 12 Volt Battery h Fuel Enrichment Solenoid i Head Temperature Switch j Oil Warning Module k Oil Level Switch l Engine Block m Electrical Plate n CDM 3 o CDM 2 p CDM 1 q Voltage Regulator ...

Page 131: ...N TAN VIO VIOLET WHT WHITE YEL YELLOW a Trigger b Stator c Remote Control d 20 Ampere Fuse e Trim Switch f To Remote Trim Switch g Down Relay h Up Relay i Starter j Trim Pump k Starter Solenoid l 12 Volt Battery m Fuel Enrichment Solenoid n Temperature Switch o Oil Warning Module p RPM Limiter Module q Oil Level Switch r Engine Block s Electrical Plate t CDM 4 u CDM 3 v CDM 2 w CDM 1 x Voltage Reg...

Page 132: ...W YEL ENDS LT BLU LT BLU TAN LT BLU TAN LT BLU BLK BLK BLK YEL BLK BLK BLK YEL BLK GRN WHT GRN WHT RED RED RED YEL RED BLK W YEL ENDS RED BLK TAN LT BLU TAN LT BLU PPL PPL PPL BRN BLK YEL BLK YEL BRN BLK YEL BRN BRN BLK YEL BLK YEL BLK BLK BLK PPL BRN BLK YEL BLK BLK TAN LT BLU a b c d e f g h i j k l m n o p q a Trigger b Stator c Engine Harness d 20 Ampere Fuse e Starter Motor f Starter Solenoid...

Page 133: ... GRN WHT WHT GRN GRN WHT BLK BLK BLK BRN BRN BLK YEL BLK YEL BLK YEL BLK BLK BLK YEL PPL DK BLU BLU WHT BLK DK BLU TAN LT BLU PPL TAN LT BLU BLK YEL BLK YEL TAN LT BLU TAN LT BLU PPL BLK YEL BLK YEL PPL PPL BLK BLK BLK BLK A B C D a b c d e f g h i j k l a Trigger b Stator c Electrical Plate d Block e Temperature Switch f Warning Horn g Push Button Stop Switch h Lanyard Stop Switch i Rev Limiter j...

Page 134: ...BRN BLK YEL BLK YEL BLK BLK BLK 1 2 3 4 5 6 7 8 PPL TAN LT BLU BLK YEL RED BLK YEL RED BLK BLK PPL TAN LT BLU YEL BLK GRY B S C M A M BLK YEL PPL YEL BLK YEL RED RED BLK BLK PPL PPL BLK YEL BLK YEL BLK YEL BLK YEL TAN LT BLU PPL PPL BLK BLK YEL BLK YEL TAN LT BLU PPL BLK BLK BLK BLK BLK PPL BLK YEL GRN WHT LT BLU WHT BLK YEL PPL GRN WHT LT BLU WHT WHT GRN GRN WHT WHT GRN GRN WHT GRN WHT BLK W YEL ...

Page 135: ... RED PPL RED RED PPL BLK W YEL ENDS LT BLU LT BLU TAN LT BLU TAN LT BLU BLK BLK BLK YEL BLK BLK BLK YEL BLK GRN WHT GRN WHT RED RED RED YEL RED BLK W YEL ENDS RED BLK TAN LT BLU TAN LT BLU PPL PPL PPL BRN BLK YEL BLK YEL BRN BLK YEL BRN BRN BLK YEL BLK YEL BLK BLK BLK BLK TAN LT BLU a b c d e f g h i j k l m n o p a Trigger b Stator c Engine Harness d 20 Ampere Fuse e Starter Motor f Starter Solen...

Page 136: ... GRN WHT BLK W YEL ENDS LT BLU LT BLU TAN LT BLU TAN LT BLU BLU GRN BLK BLK BLK YEL BLK BLK BLK YEL BLK RED RED RED YEL RED BLK W YEL ENDS RED RED RED BLK TAN LT BLU TAN LT BLU PPL PPL PPL BRN BLK YEL BLK YEL BRN BLK YEL BRN BRN BLK YEL BLK YEL BLK BLK BLK WHT GRN GRN WHT WHT GRN GRN WHT GRN WHT BLK TAN LT BLU a b c d e f g h i j k l m n o p q r s t u a Trigger b Stator c Engine Harness d 20 Amper...

Page 137: ...NDS LT BLU LT BLU TAN LT BLU TAN LT BLU BLU GRN BLK BLK BLK YEL BLK BLK BLK YEL BLK BLK BLK YEL BLU GRN WHT BLU BLU WHT GRN WHT GRN RED RED RED YEL RED BLK W YEL ENDS RED RED RED BLK TAN LT BLU TAN LT BLU PPL PPL PPL BLK YEL BLK BRN PPL BRN BLK YEL BLK YEL BRN BLK YEL BRN BRN BLK YEL BLK YEL BLK BLK BLK BLK BLK TAN LT BLU a b c d e f g h i j k l m n o p q r s t u v w a Trigger b Stator c Engine Ha...

Page 138: ...886 b c d e f g h a BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN PUR PURPLE RED RED TAN TAN VIO VIOLET WHT WHITE YEL YELLOW a Power Trim Pump Motor b Trim Solenoid UP c Trim Solenoid DOWN d Engine Starter Motor Solenoid e Red Battery Cable f Fuse Holder 20 Amp Fuse g Engine Wiring Harness Connector h Remote Control Wiring Harness Connector ...

Page 139: ...t Remote Control 23884 1 2 3 a b c e f d g g BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN PUR PURPLE RED RED TAN TAN VIO VIOLET WHT WHITE YEL YELLOW a Power Trim Pump Motor b Trim Solenoid UP c Trim Solenoid DOWN d Engine Starter Motor Solenoid e Fuse Holder 20 Amp Fuse f Red Battery Cable g Wires from Remote Control ...

Page 140: ... b c d e f g a h BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN PUR PURPLE RED RED TAN TAN VIO VIOLET WHT WHITE YEL YELLOW RED 8 a Power Trim Pump Motor b Trim Solenoid UP c Trim Solenoid DOWN d Engine Starter Motor Solenoid e Red Battery Cable f Fuse Holder 20 Amp Fuse g Engine Wiring Harness Connector h Remote Control Wiring Harness Connector ...

Page 141: ...iagram a b c d e BATT GND SENDER BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN PUR PURPLE RED RED TAN TAN VIO VIOLET WHT WHITE YEL YELLOW a Tachometer b Position Dial to Point Toward 4 c Trim Indicator Gauge Optional d Tachometer Accessories Harness Plug from Remote Control e Tachometer Accessories Harness ...

Page 142: ...emote Control 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 BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN PUR PURPLE RED RED TAN TAN VIO VIOLET WHT WHITE YEL YELLOW ...

Page 143: ...ing Horn Wiring Diagram 23891 g f c d e a b BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN PUR PURPLE RED RED TAN TAN VIO VIOLET WHT WHITE YEL YELLOW a Ignition Choke Switch b Emergency Stop Switch c Neutral Start Switch d Tachometer Accessories Harness Connector e Wiring Harness Connector f Warning Horn g Trim Tilt Switch ...

Page 144: ...arning Horn Wiring Diagram 23892 e d b a f c BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN PUR PURPLE RED RED TAN TAN VIO VIOLET WHT WHITE YEL YELLOW a Ignition Choke Switch b Emergency Stop Switch c Neutral Start Switch d Tachometer Accessories Harness Connector e Wiring Harness Connector f Warning Horn ...

Page 145: ...CK BLU BLUE BRN BROWN GRY GRAY GRN GREEN PUR PURPLE RED RED TAN TAN VIO VIOLET WHT WHITE YEL YELLOW a Ignition Choke Switch b Emergency Stop Switch c Neutral Start Switch d Tachometer Accessories Harness Connector e Wiring Harness Connector f Warning Horn g Trim Tilt Switch h Wire Retainer i Control Handle j Trim Harness Bushing k Trim Harness Connector l Lead to Trim Indicator Gauge ...

Page 146: ...A 3 53992 FUEL SYSTEM FUEL PUMP ...

Page 147: ... 3A 2 80 Jet 100 115 125 4 cyl 3A 3 Fuel Pump 65 Jet 75 90 3A 4 Fuel Pump 80 Jet 100 115 125 3A 8 Theory Of Operation 3A 10 Testing 3A 10 Troubleshooting Fuel Pump 3A 10 Removal 3A 11 Fuel Pump Cleaning Inspection 3A 11 Check Valve Reassembly 3A 11 Reassembly 3A 12 Installation of Fuel Pump 3A 13 ...

Page 148: ...90 830234R3 DECEMBER 1997 FUEL SYSTEM 3A 1 Notes ...

Page 149: ...0234R3 DECEMBER 1997 65 Jet 75 90 3 cyl 51549 a b c e f h d g a Body Opposite Side View b Rubber Valve c Plastic Disc d Cover Opposite Side View e Plastic Check Valve Retainer f Cast Aluminum Cover g Three Tabs h Three Tabs ...

Page 150: ...L SYSTEM 3A 3 80 Jet 100 115 125 4 cyl 51548 b c d e f g h i a a Body Opposite Side View b Rubber Valve c Plastic Disc d Cover Opposite Side View e Plastic Check Valve Retainer f Cast Aluminum Cover g Body h Three Tabs i Three Tabs ...

Page 151: ... 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 34 36 37 38 39 40 41 42 43 44 45 46 47 48 49 35 g h 49 4 3 5 19 19 19 19 37 37 40 39 50 51 52 53 54 55 33 c c d a d e f c b A TO OIL PUMP B TO CRANKCASE C TO CARBURETOR D TO TOP CARBURETOR E TO CENTER CARBURETOR F TO BOTTOM CARBURETOR G DESIGN I H DESIGN II ...

Page 152: ...SCREW pump to block M6 x 50 55 6 2 19 AR STA STRAP 20 1 TUBING 2 1 2 IN 21 1 NIPPLE 22 1 TUBING 2 IN 23 1 FUEL LINE OIL INJECTION 24 1 FUEL FILTER 25 1 TUBING 6 IN NON OIL INJECTED 26 1 MOLDED HOSE 27 1 PLUG OIL INJECTED 28 1 CHECK VALVE 29 1 FUEL CONNECTOR 1 O RING 30 1 SCREW M6 x 35 60 6 8 31 1 GROMMET 32 1 ENRICHER VALVE S N 0G437999 BEL 9926999 BELOW 33 1 ENRICHER VALVE S N 0G438000 BEL 992700...

Page 153: ...6 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 34 36 37 38 39 40 41 42 43 44 45 46 47 48 49 35 49 4 3 5 19 19 19 19 37 37 40 39 50 51 52 53 54 55 33 c h d e g c c f a b A TO OIL PUMP B TO CRANKCASE C TO CARBURETOR D TO TOP CARBURETOR E TO CENTER CARBURETOR F TO BOTTOM CARBURETOR G DESIGN I H DESIGN II ...

Page 154: ... INJECTED 41 1 SCREW DESIGN I Drive Tight 42 1 WASHER 37 2 TUBING 17 IN 39 1 FUEL FILTER 40 1 BRACKET 43 2 SCREW M6 x 14 NON OIL INJECTED Drive Tight 44 2 SCREW M6 x 30 DESIGN II Drive Tight 45 2 WASHER 46 2 BUSHING 47 2 GROMMET 48 1 PRIMER BULB 49 2 TEE FITTING 50 1 TUBING 6 IN 51 1 TUBING 9 1 2 IN MANUAL 52 1 TUBING 2 1 2 IN 53 1 TUBING 2 1 2 IN 54 1 TUBING 2 1 2 IN 55 1 TUBING 6 IN ...

Page 155: ...et 100 115 125 1 2 4 5 6 7 8 9 11 12 13 14 15 16 17 18 19 22 23 24 25 26 27 28 29 30 31 35 36 37 39 40 41 42 43 45 33 10 9 23 23 36 3 10 3 46 Perfect Seal 92 34227 1 19 19 34 32 32 20 21 38 44 d a b c A TO LOWER TEE B TO OIL PUMP C TO UPPER TEE D TO CRANKCASE ...

Page 156: ...G 8 1 2 IN 21 1 TUBING 2 IN 22 1 ELBOW 23 AR STA STRAP 24 1 FUEL FILTER 25 1 MOLDED HOSE 26 1 CHECK VALVE 27 1 CLAMP Use where applicable 28 1 CONNECTOR 29 1 FUEL CONNECTOR 1 O RING fuel connector 30 1 GROMMET 31 1 SCREW M6 x 35 60 6 8 32 2 TUBING 15 IN 33 1 TUBING 13 IN 34 1 TUBING 1 1 4 IN 35 1 FLOW RESTRICTOR 36 2 TEE FITTING 37 1 TUBING 4 1 2 IN 38 2 TUBING 2 1 2 IN 39 1 FUEL FILTER 40 1 ACCEL...

Page 157: ...e any type of anti siphon device must be located between the outboard fuel inlet and fuel tank outlet a simple method of checking if such a device or bad fuel is a problem source is to operate the outboard with a separate fuel supply which is known to be good such as a remote fuel tank If after using a separate fuel supply it is found that the anti siphon valve is the cause of the problem there ar...

Page 158: ...l pump housing check valves pulse cham ber and pump base in solvent and dry all but check valves with compressed air Inspect each check valve 2 ea for cracks and or holes Check each black rubber disc 2 ea to see that the black coating is not coming off Unless dam aged while disassembled replacement is seldom necessary Inspect the Check Valve Assembly on Chamber Plate check by both pressure and suc...

Page 159: ... that the inner side is facing up 2 Insert coil spring and cap in place 3 Place Boost Chamber GASKET over dowels bolts and lower onto Chamber Plate BE SURE that gasket directional alignment is correct and that V tabs are aligned 4 Place Boost DIAPHRAGM over dowels and low er to assembly 5 Place Fuel Pump Body over dowels and lower to assembly 6 Insert Coil Spring and Cap in pump body 7 Place Fuel ...

Page 160: ...L 92 34227 1 to threads f Check Valve g Screws Torque to 40 lb in 4 5 N m h Clear Tubing 5 5 in 139 7mm i Gasket Cylinder Block to Fuel Pump HIDDEN MODEL 80 JET 100 115 125 53992 a b h c f g d i e a Fuel Pump b Pulse Hose c Inlet Hose d Outlet Hose e Elbow Apply PERFECT SEAL 92 34227 1 to threads f Check Valve g Bolts Torque to 40 lb in 4 5 N m h Clear Tubing 8 in 203 2mm i Gasket Cylinder Block t...

Page 161: ...B 3 FUEL SYSTEM CARBURETOR ...

Page 162: ...0 Problem Engine Floods 3B 20 Problem Engine Runs Too Rich 3B 20 Problem Fuel Blow Back Out Of Carburetor 3B 20 Problem Rough Idle 3B 20 Problem Engine Turns Over But Will Not Start Or Starts Hard When Cold 3B 21 Problem Unable to Reduce Engine RPM to Slow Idle 3B 21 Problem Engine Runs Too Lean 3B 22 Problems Engine Idles Rough And Stalls Engine Runs Uneven Or Surges Engine Will Not Accelerate 3B...

Page 163: ...75 ELPTO 1994 29 1 2 3 0 050 in 0 052 in 0 050 in 1 2 1 1 4 1 1 4 75 MLH 1994 30 1 2 3 0 050 in 0 052 in 0 050 in 1 2 1 1 4 1 1 4 90 1994 31 1 2 3 0 062 in 0 064 in 0 062 in 1 2 1 1 2 1 1 2 100 1994 1995 S N 0G151655 and below 31 1 2 3 4 0 046 in 0 048 in 0 052 in 0 052 in 1 1 4 1 1 4 NA NA 100 1995 S N 0G151566 and above 7 6 94 32 1A 2A 3A 4A 0 046 in 0 050 in 0 054 in 0 056 in 1 1 4 1 1 4 NA NA ...

Page 164: ...1 2 1 1 2 1 1 2 75 MLH 1995 47 1 2 3 0 054 in 0 054 in 0 054 in 1 2 1 1 8 1 1 8 75 ELH 1995 48 1 2 3 0 054 in 0 054 in 0 054 in 1 2 1 1 4 1 1 4 65 Jet 90 1995 49 1 2 3 0 062 in 0 064 in 0 062 in 1 2 1 1 4 1 1 4 100 1996 1997 50 1 2 3 3A 4 0 048 in 0 050 in 0 048 in 0 050 in 0 052 in 1 1 2 1 1 2 NA NA NA 80 Jet 115 1996 1997 51 1 2 3 3A 4 0 062 in 0 062 in 0 060 in 0 062 in 0 064 in 1 1 2 1 1 2 NA ...

Page 165: ...1 2 3 0 054 in 0 054 in 0 054 in 1 1 8 1 1 8 1 1 8 75 ELH 1998 77 1 2 3 0 054 in 0 054 in 0 054 in 1 1 8 1 1 8 1 1 8 65 Jet 90 1998 78 1 2 3 0 062 in 0 064 in 0 064 in 1 1 4 1 1 4 1 1 4 100 1998 79 1 2 3 4 0 048 in 0 050 in 0 050 in 0 052 in 1 1 2 1 1 2 1 1 2 1 1 2 80 Jet 115 1998 80 1 2 3 4 0 060 in 0 064 in 0 062 in 0 064 in 1 1 2 1 1 2 1 1 2 1 1 2 125 1998 81 1 2 3 4 0 070 in 0 080 in 0 080 in ...

Page 166: ...6 7 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 8 7 92 A 7 Loctite 271 92 809820 92 Loctite 7649 Primer 92 809824 A DO NOT touch this adjustment This is preset by the manufacturer and is NOT for field service Conventional carb cleaners will not affect the sealant securing this adjustment ...

Page 167: ...7 48 49 5 3 RETAINING RING 6 3 FLOAT SHAFT 7 1 THROTTLE SHAFT CENTER 8 2 SCREW lever adjustment 9 6 SCREW 18 2 0 10 3 COVER PLATE 11 3 GASKET cover plate 12 3 SPRING idle needle 13 2 IDLE NEEDLE 14 3 JET 094 WME 29 6 0 7 15 2 THROTTLE SHAFT UPPER LOWER 16 3 SPRING throttle return 17 3 GASKET nozzle well 18 3 GASKET fuel bowl 19 3 INLET NEEDLE VALVE 20 3 FLOAT 1 FUEL BOWL UPPER WME 30 46 47 49 21 1...

Page 168: ...5 6 7 9 10 11 12 13 15 16 17 18 19 20 21 22 23 24 25 8 7 A 14 7 Loctite 271 92 809820 92 Loctite 7649 Primer 92 809824 92 A DO NOT touch this adjustment This is preset by the manufacturer and is NOT for field service Convention al carb cleaners will not affect the sealant securing this adjustment ...

Page 169: ... ELECTRIC WME 77 1 CARBURETOR BOTTOM NON OIL 1 CARBURETOR TOP 1 1 CARBURETOR CENTER 90 WME 78 1 CARBURETOR BOTTOM 1 CARBURETOR TOP 1 CARBURETOR CENTER 75 MANUAL WME 82 1 CARBURETOR BOTTOM 1 CARBURETOR TOP 1 CARBURETOR CENTER 75 ELECTRIC WME 83 1 CARBURETOR BOTTOM NON OIL 1 CARBURETOR TOP 1 CARBURETOR CENTER 90 WME 62 1 CARBURETOR BOTTOM 2 3 GASKET flange 3 6 SCREW throttle valve 6 0 7 4 3 THROTTLE...

Page 170: ...L SYSTEM 90 830234R3 DECEMBER 1997 Carburetor WME 59 60 61 62 75 76 77 78 82 83 1 2 3 4 5 6 7 9 10 11 12 13 15 16 17 18 19 20 21 22 23 24 25 8 7 A 14 7 Loctite 271 92 809820 92 Loctite 7649 Primer 92 809824 92 ...

Page 171: ...EDLE VALVE 20 3 FLOAT 1 FUEL BOWL UPPER WME 60 21 2 FUEL BOWL CENTER LOWER WME 60 3 FUEL BOWL WME 59 61 62 75 76 77 78 22 12 SCREW fuel bowl 18 2 0 23 3 PLUG KIT 22 2 5 24 3 SEAL drain plug 2 MAIN FUEL JET 052 TOP WME 59 1 MAIN FUEL JET 054 CENTER BOTTOM WME 59 3 MAIN FUEL JET 054 WME 60 61 76 77 2 MAIN FUEL JET 062 TOP WME 62 25 1 MAIN FUEL JET 064 CENTER BOTTOM WME 62 25 2 MAIN FUEL JET 044 Belg...

Page 172: ...9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 2 IMPORTANT DO NOT touch this adjustment This is preset by the manufacturer and is NOT for field service Conventional carb cleaners will not affect the sea lant securing this adjustment 7 92 7 Loctite 271 92 809820 92 Loctite 7649 Primer 92 809824 ...

Page 173: ...T NEEDLE VALVE 11 4 PLUG 12 4 SEAL drain plug 13 4 GASKET cover plate 14 4 GASKET flange 15 8 SCREW throttle valve 6 0 7 16 8 SCREW cover plate 18 2 1 17 16 SCREW fuel bowl 18 2 1 18 4 COVER PLATE 1 MAIN FUEL JET 046 WME 32 1 32A 1 14 1 6 1 MAIN FUEL JET 048 WME 32 2 14 1 6 1 MAIN FUEL JET 050 WME 33 1 32A 2 14 1 6 2 MAIN FUEL JET 0 52 WME 32 3 4 14 1 6 1 MAIN FUEL JET 054 WME 32A 3 14 1 6 19 2 MA...

Page 174: ...10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 IMPORTANT DO NOT touch this adjustment This is preset by the manufacturer and is NOT for field service Conventional carb cleaners will not affect the sea lant securing this adjustment 7 92 7 7 Loctite 271 92 809820 92 Loctite 7649 Primer 92 809824 ...

Page 175: ...R 1 1 CARBURETOR 1 CARBURETOR 100 WME 79 1 CARBURETOR 1 CARBURETOR 1 CARBURETOR 1 CARBURETOR 115 WME 80 1 CARBURETOR 1 CARBURETOR 1 CARBURETOR 1 CARBURETOR 125 WME 81 1 CARBURETOR 1 CARBURETOR 2 4 GASKET fuel bowl 3 4 RETAINING RING 4 4 FUEL BOWL 5 3 THROTTLE SHAFT WME 1 3 4 6 1 THROTTLE SHAFT WME 2 7 3 THROTTLE LEVER WME 1 3 4 8 4 THROTTLE VALVE WME 50 51 52 81 8 4 THROTTLE VALVE WME 79 80 9 4 FL...

Page 176: ...10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 IMPORTANT DO NOT touch this adjustment This is preset by the manufacturer and is NOT for field service Conventional carb cleaners will not affect the sea lant securing this adjustment 7 92 7 7 Loctite 271 92 809820 92 Loctite 7649 Primer 92 809824 ...

Page 177: ... 1 2 3 14 1 6 1 MAIN FUEL JET 070 WME 52 1 14 1 6 2 MAIN FUEL JET 080 WME 52 2 3 14 1 6 1 MAIN FUEL JET 082 WME 52 4 14 1 6 20 1 MAIN FUEL JET 048 WME 79 1 14 1 6 20 2 MAIN FUEL JET 050 WME 79 2 3 14 1 6 1 MAIN FUEL JET 052 WME 79 4 14 1 6 1 MAIN FUEL JET 060 WME 80 1 14 1 6 1 MAIN FUEL JET 064 WME 51 4 80 2 4 14 1 6 3 MAIN FUEL JET 062 WME 80 3 14 1 6 1 MAIN FUEL JET 070 WME 81 1 14 1 6 2 MAIN FU...

Page 178: ...ngement 54138 a b c c d 3 Cylinder Models a Oil Injection Pump Link b Throttle Link c Gasket d Fuel Enrichment Fitting 4 Cylinder Carburetor Linkage Arrangement 54137 4 Cylinder Models c c e d b a a Oil Injection Pump Link b Throttle Link c Gasket d Fuel Enrichment Fitting e Accelerator Pump Fitting ...

Page 179: ...ixture screw out 1 4 turn or more 53422 a a 54171 3 Cylinder Models 4 Cylinder Models a Low Speed Mixture Screw 3 Check for too lean mixture on acceleration 4 DO NOT adjust leaner than necessary to attain reasonably smooth idling When in doubt stay on the slightly rich side of the adjustment Idle Speed Adjustment 1 Adjust engine idle RPM as outlined in Section 2C Timing Synchronizing Adjusting Flo...

Page 180: ... Drain Plug c Idle Mixture Screw Jet Orifice Size Chart NOTE 10 32 Thread Size Jet Orifice Size inches Part Number 0 034 19266034 0 036 19266036 0 038 19266038 0 040 19266040 0 042 1399 5315 0 044 1395 7394 0 046 1399 5317 0 048 1395 6246 0 050 1395 6028 0 052 1395 6359 0 054 1399 5225 0 056 1399 5213 0 058 1395 7831 0 060 1395 6487 0 062 1399 4217 0 064 1399 4216 0 066 1399 4215 0 068 1395 6029 0...

Page 181: ... 0 050 0 050 0 050 0 048 0 048 0 048 0 048 0 056 0 056 0 054 0 054 0 054 0 054 0 052 0 052 0 052 0 050 0 050 0 050 0 048 0 058 0 058 0 056 0 056 0 056 0 056 0 054 0 054 0 054 0 052 0 052 0 052 0 050 0 060 0 060 0 058 0 058 0 058 0 056 0 056 0 056 0 054 0 054 0 054 0 052 0 052 0 062 0 062 0 060 0 060 0 060 0 058 0 058 0 058 0 056 0 056 0 056 0 054 0 054 0 064 0 064 0 062 0 062 0 062 0 060 0 060 0 0...

Page 182: ...on Dirt or debris are preventing inlet needle from seat ing Flush out inlet seat and clean inlet needle Worn inlet needle Replace Punctured float Replace Incorrect float setting Reset float Problem Engine Runs Too Rich Possible Cause Corrective Action Fuel level too high Reset float to correct level Carburetor floods See preceding Engine Floods Idle nozzle air holes plugged Blow out with compresse...

Page 183: ...ts in this section Improper float level Refer to carburetor adjustments in this section Low fuel pump pressure Refer to Section 3A Fuel Pump Defective anti siphon valve Refer to Section 3A Fuel Pump Needle and seat in carburetor that is either stuck open or closed Refer to carburetor adjustments in this section Improper float level Refer to carburetor adjustments in this section Carburetor loose o...

Page 184: ...cted Air vent must be open all the way and free from re strictions A pinched cut or restricted fuel line also loose fuel line connection Check all fuel lines and replace as needed Check and tighten all fuel line connections A dirty or restricted fuel filter Check replace or clean all fuel filters Restricted filter in fuel tank Clean by rinsing in clean lead free gasoline or kero sene Improperly mi...

Page 185: ...ce Use a petroleum based solvent for cleaning and blow out all passages with com pressed air 1 Inspect carburetor body Replace if cracked or damaged 2 Inspect float Replace if cracked or damaged 55883 3 Inspect idle mixture screw Replace if bent or damaged 53673 4 Inspect main jet Clean if contaminated 53672 5 Inspect inlet needle valve Replace if end is worn or grooved 28375 ...

Page 186: ... 1996 I D 0 156 1996 a 94 95 Models Connect to Fitting on Side of Carburetor 96 97 98 Models Connect to Fitting between Top and Middle Carburetors b Electrical Harness c Enrichener Valve Manual Operation Button Description for Four Cylinder Engines Enrichener valve receives fuel from a T fitting be tween 1 and 2 carburetors Valve is electrically opened when ignition key is turned to the ON posi ti...

Page 187: ...tage to YELLOW BLACK wire at terminal block on engine when key or choke button is pushed in Click Squeeze primer bulb until bulb is firm Remove lower hose from fitting on enrichener valve Place a container under valve then push key or choke button Check for fuel flow from fitting Battery Voltage Indicated Check for loose or corroded connection between YELLOW BLACK wire and black wire under same sc...

Page 188: ... cylinder boost passage FLOW RESTRICTOR Helps equalize pressure within the accelerator pump circuit while allowing air or any vapor which has formed to pass through and be vented at the carburetors FUEL CONNECTOR Spring loaded shut off valve which connects boat fuel tank with outboard fuel sys tem IMPORTANT The distance between the accelera tor pump and the throttle cam determines the amount of fu...

Page 189: ...ROP OCCURS 3 5 PSI BRASS RESTRICTOR 014 I D LOCATED INSIDE FUEL LINE CHECK VALVES LOCATED IN CYLINDER BLOCK TRANSFER PORTS UNSEAT AT 11 14 PSI LARGE FUEL FILTER 5 0 PSI 0 4 PSI 0 5 PSI 5 0 PSI FUEL PUMP FUEL TANK 4 0 PSI FUEL CONNECTORS 90 830234R3 DECEMBER 1997 FUEL SYSTEM 3B 27 Acceleration Pump Fuel Flow Circuit for Four Cylinder Engines ...

Page 190: ...C 3 FUEL SYSTEM OIL INJECTION ...

Page 191: ... 6 3 and 4 Cylinder Oil Flow Diagram 3C 7 Filling Oil Tank 3C 8 Carburetor Oil Pump Synchronization 3C 8 Bleeding Air from Oil Injection System 3C 9 Bleeding Air from Oil Pump Inlet Hose 3C 9 Bleeding Air from Oil Pump Outlet Hose 3C 9 Page Oil Pump Test 3C 9 Low Oil Sensor Test 3C 10 Warning Horn System 3C 10 Oil Injection System Troubleshooting Chart 3C 11 Models with Warning Module 3C 11 Troubl...

Page 192: ...90 830234R3 DECEMBER 1997 FUEL SYSTEM 3C 1 Notes ...

Page 193: ... 2 FUEL SYSTEM 90 830234R3 DECEMBER 1997 Oil Injection Components S N USA 0G301750 BEL 9885504 BELOW 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 8 A 26 A TO FUEL PUMP ...

Page 194: ...5 4 0 7 2 WASHER 8 1 GROOVE PIN 8 1 ROLL PIN 093 x 1 250 9 1 VENT ASSEMBLY 10 1 VALVE 11 1 SCREW 50 5 6 12 1 WASHER 13 1 GROMMET 14 1 BUSHING 15 1 BOOT 16 1 BASE 17 2 SCREW 15 20 3 18 1 SWITCH ASSEMBLY 19 1 SCREW Drive Tight 20 1 WASHER 21 1 DRIVEN GEAR 22 2 O RING 23 1 ADAPTOR ASSEMBLY 24 1 BUSHING 25 1 JOURNAL BUSHING 26 1 OIL PUMP 27 2 SCREW 60 6 8 28 1 TUBING 5 1 2 IN 29 1 TUBING 11 IN 30 AR S...

Page 195: ...3C 4 FUEL SYSTEM 90 830234R3 DECEMBER 1997 Oil Injection Components S N USA 0G301751 BEL 9885505 UP 3 4 5 1 2 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 19 a A TO FUEL PUMP ...

Page 196: ...ush Nut 6 1 VENT ASSEMBLY 7 1 VALVE 8 1 BRACKET 9 1 BOOT 10 2 SCREW M6X20 65 7 5 11 1 GROMMET 12 1 BUSHING 13 1 WASHER 14 1 SCREW M8X35 15 20 5 15 1 SWITCH ASSEMBLY 16 1 SCREW Drive Tight 17 1 WASHER 18 1 DRIVEN GEAR 19 2 O RING 20 1 ADAPTOR ASSEMBLY 21 1 BUSHING 22 1 JOURNAL BUSHING 23 1 OIL PUMP 24 2 SCREW 60 7 0 25 1 TUBING 5 1 2 IN 26 1 TUBING 11 IN 27 AR STA STRAP 8 IN 27 AR STA STRAP 5 1 2 I...

Page 197: ...the oil pump via a hose The oil pump injects oil into the fuel line prior to the fuel pump and is driven by the crankshaft A link rod is connected between the throttle linkage and oil pump lever When the throttle position is changed the link rod rotates the oil pump valve which changes the fuel oil ratio from approximately 80 1 at idle speed to 50 1 at wide open throttle The oil tank is equipped w...

Page 198: ...l m a Oil Tank Vent b Oil Tank c Low Oil Overheat Warning Module d Fuel Enrichment Valve Fuel Fitting e Accelerator Pump Fitting 4 Cylinder Models Only f Fuel Filter g To Crankcase Pulse Fitting h Fuel Pump i 2 psi 13 7kPa Check Valve j Oil Pump Bleed Valve k Oil Pump l Fuel Inlet Fitting m Low Oil Sensor ...

Page 199: ...e dipstick to check oil level 4 Hook the dipstick on the tank during filling a b a Dipstick b Hook 5 Slowly fill the oil tank with the specified oil DO NOT OVERFILL add only enough oil to bring the oil level up to the bottom of the fill neck NOTE The oil tank capacity for 3 cylinder models is 3 2 qt 3 0 liters and 4 cylinder models is 5 13 qt 4 9 liters 6 Install oil filler cap and re tighten Rein...

Page 200: ...d to perform this test 1 Connect engine to remote fuel tank containing a 50 1 fuel oil mixture 25 1 if during break in peri od 2 Attach flush device to outboard or place outboard in test tank 3 Remove top cowling 4 Disconnect oil outlet hose from fuel pump fitting 5 Plug fuel line fitting 6 Remove link rod end from oil flow regulator 7 Rotate oil pump regulator full counterclockwise and hold it in...

Page 201: ...ck in place replace sensor bottom of oil tank remove screw and retract sensor Warning Horn System DESCRIPTION Major components of the warning horn system are an ignition switch warning horn low oil sensor power head and temperature sensor With the ignition switch in the Run position electri cal current is routed thru the warning horn and sup plied to the powerhead temperature sensor and low oil se...

Page 202: ...tan lead from main engine wiring harness at termi nal block on engine Ground this tan lead to engine ground Warning horn should sound If not check tan wire between horn and engine for open circuit and check horn Warning Module Check if all warning module leads are connected to harness leads If so warning module may be faulty Using incorrect side mount remote control or ignition choke assembly Refe...

Page 203: ... 2 Refer to Owners Manual for required maintenance Exhaust Emission Control Systems None PART 37 855211 11 1848 cc Idle Speed in gear 675 RPM Timing Idle 4 ATDC 2 BTDC WOT 23 BTDC Gap 0 040 Spark Plug CHAMPION QL77CC 125 HP Fuel Oil Ratio 50 1 Oil Injection Variable Engine Lubricants Quicksilver Premium Plus TC W3 2 Cycle Outboard Oil Family WM9XM02 0210 FEL 145 00 GM KW HR Valve Clearance Cold mm...

Page 204: ...Ox 3D 1 Controlling Emissions 3D 1 Stoichiometric 14 7 1 Air Fuel Ratio 3D 1 Outboard Hydrocarbon Emissions Reductions 3D 2 Stratified vs Homogenized Charge 3D 3 Homogenized Charge 3D 3 Stratified Charge 3D 3 Emissions Information 3D 4 Manufacturer s Responsibility 3D 4 Dealer Responsibility 3D 4 Owner Responsibility 3D 4 EPA Emission Regulations 3D 4 Decal Location for 1998 Models 3D 6 ...

Page 205: ...engine in the form of carbon dioxide CO2 CO2 is a harmless gas But carbon often combines with insufficient oxygen one carbon atom with one oxy gen atom This forms carbon monoxide CO Car bon monoxide is the product of incomplete combus tion and is a dangerous potentially lethal gas Oxides of Nitrogen NOx NOx is a slightly different byproduct of combustion Nitrogen is one of the elements that makes ...

Page 206: ...hening the air fuel ratio to decrease combus tion temperatures and reduce NOx also increases HC and CO as well as lowering fuel economy So the solution to controlling NOx as well as HC and CO is to keep the air fuel ratio as close to 14 7 1 as pos sible OUTBOARD HYDROCARBON EMISSIONS REDUCTIONS 8 1 3 PER YEAR OVER 9 MODEL YEARS 0 20 40 60 80 100 120 96 97 98 99 2000 01 02 03 04 05 06 07 08 ...

Page 207: ...ystem into the cylinder The homogenized charge is easy to ignite as the air fuel ratio is approximately 14 7 1 Stratified Charge A stratified charge engine only pulls air through the transfer system The fuel required for combustion is forced into the cylinder through an injector placed in the top of the cylinder head The injector sprays a fuel air mixture in the form of a bubble into the cylin der...

Page 208: ... certification standards The owner operator is not to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined fac tory specifications Exceptions Carburetor jets may be changed for high altitude use in accordance with factory recommenda tions Single engine exceptions may be allowed with permission from the EPA for racing and testing EP...

Page 209: ...25 HP Fuel Oil Ratio 50 1 Oil Injection Variable Engine Lubricants Quicksilver Premium Plus TC W3 2 Cycle Outboard Oil Family WM9XM02 0210 FEL 145 00 GM KW HR Valve Clearance Cold mm Intake N A Exhaust N A a Spark Ignition SI b Model year of engine and production decal part number c Type and octane of fuel used to establish emission levels d Timing specifications when adjustable e Spark plug gap i...

Page 210: ...7 Decal Location for 1998 Models Model Production Part No Service Part No Location on Engine Merc Mar 85 C I 75 90 H P 37 855211 10 37 855577 10 Block Exhaust Cover Merc Mar 113 C I 100 115 125 H P 37 855211 11 37 855577 11 Block Exhaust Cover ...

Page 211: ...4 20032 POWERHEAD ...

Page 212: ...mation 4 47 End Cap 4 48 Assembling Rod to Piston 4 48 Piston Ring Installation 4 49 Crankshaft Installation 4 51 Connecting Rod Cap Alignment 4 54 Crankcase Cover to Block 4 55 Cylinder Block Cover 4 56 Exhaust Plate Cover and Exhaust Divider Plate 4 57 Intake Manifold and Reed Block Installation 4 59 Accelerator Pump Installation 4 Cylinder Models 4 60 3 Cylinder Bleed Hose Routing 4 61 4 Cylind...

Page 213: ...0 Type Displacement Model 80 Jet 100 115 125 Type Displacement In line 3 Cylinder 2 Cycle Loop Charged 84 6 cu in 1387cc In Line 4 Cylinder 2 Cycle Loop Charged 112 8 cu in 1848 8cc STROKE Length 2 93 in 74 42mm CYLINDER BORE Diameter Standard Taper Out of Round Maximum Bore Type 3 50 in 88 9mm 0 003 in 0 076mm Cast Iron PISTON Piston Type Standard 0 015 in 0 381mm Oversize 0 030 in 0 762mm Oversi...

Page 214: ...tand 91 812549 General Information DISASSEMBLY AND REASSEMBLY If complete disassembly is not necessary start at ap propriate spot start reassembly at point disassembly stopped If major powerhead repairs are being done remove powerhead from lower unit It is not necessary to re move powerhead for a Visual check for scoring or broken rings cyl inder walls and pistons by viewing through exhaust ports ...

Page 215: ...90 830234R3 DECEMBER 1997 POWERHEAD 4 3 Notes ...

Page 216: ...n 92 825407A12 14 2 Cycle Outboard Oil 92 13249A24 14 14 95 95 95 95 95 95 95 95 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 15 19 6 4 4 POWERHEAD 90 830234R3 DECEMBER 1997 Crankshaft Pistons and Connecting Rods 3 Cyl ...

Page 217: ...NG 11 2 ROLLER BEARING ASSEMBLY 3 PISTON ASSEMBLY STANDARD 12 AR PISTON ASSEMBLY 015 O S AR PISTON ASSEMBLY 030 O S 13 6 LOCK RING 1 PISTON RING ASSEMBLY STANDARD 14 AR PISTON RING ASSEMBLY 015 O S AR PISTON RING ASSEMBLY 030 O S 15 3 CONNECTING ROD ASSEMBLY 16 6 WASHER 17 87 NEEDLE BEARING 18 6 SCREW Apply Light Oil to Threads and Bolt Face 1st Torque 15 lb in 1 7 N m Recheck Alignment 2nd Torque...

Page 218: ...4 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 16 Loctite 35 92 59328 1 17 17 75 75 Loctite Master Gasket 92 12564 1 4 6 POWERHEAD 90 830234R3 DECEMBER 1997 Cylinder Block 3 cyl USA 0G127499 BEL 9836632 BELOW ...

Page 219: ...7 1 CARRIER ASSEMBLY 8 2 CHECK VALVE 9 3 DOWEL PIN BEARING RACE 10 1 DOWEL PIN 11 8 SCREW DESIGN I 25 33 9 12 8 STUD 13 8 WASHER DESIGN II 14 8 NUT 45 61 15 1 COVER BOTTOM 16 4 SCREW 12 5 16 9 17 1 COVER TOP 18 1 CARRIER Use where applicable 19 1 GROMMET 20 1 POPPET VALVE 21 1 SPRING 22 1 PLUG KIT 23 1 TUBING 19 IN 24 12 SCREW 18 24 4 25 1 COVER 26 1 GASKET NON OIL INJECTION 27 2 SCREW 60 6 8 28 2...

Page 220: ...4 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 16 17 75 Loctite 35 92 59328 1 17 75 Loctite Master Gasket 92 12564 1 4 8 POWERHEAD 90 830234R3 DECEMBER 1997 Cylinder Block 3 cyl USA 0G127499 BEL 9836632 BELOW ...

Page 221: ...VER 40 1 SCREW air vent hole 41 5 SCREW 35 MM 18 24 4 42 1 SCREW Drive Tight 43 1 WASHER 44 1 DIAPHRAGM 45 2 SCREW Drive Tight 46 1 WASHER 47 1 RETAINER 48 1 TEMPERATURE SENDER ELECTRIC 48 1 TEMPERATURE SENDER MANUAL 49 14 SCREW 18 24 4 50 4 CLAMP 51 1 BOOT 52 1 OIL WARNING MODULE 53 1 REV LIMITER NON OIL INJECTION 54 2 SCREW M6 x 1 x 50 80 9 0 54 2 SCREW M6 x 1 x 30 80 9 0 55 2 WASHER 56 1 HARNES...

Page 222: ...Loctite Master Gasket 92 12564 1 25 Liquid Neoprene 92 25711 2 75 7 Loctite 271 92 809820 4 10 POWERHEAD 90 830234R3 DECEMBER 1997 Cylinder Block 3 Cyl USA 0G127500 BEL 9836633 UP ...

Page 223: ...ECK VALVE PRESS IN 7 1 CARRIER ASSEMBLY 8 2 CHECK VALVE 9 3 DOWEL PIN BEARING RACE 10 1 DOWEL PIN 11 8 STUD M10 x 136 12 8 WASHER 13 8 NUT 45 61 14 1 COVER BOTTOM 15 4 SCREW M8 x 50 12 5 16 9 16 1 COVER TOP 17 1 CARRIER Use where applicable 18 1 GROMMET 19 1 POPPET VALVE 20 1 SPRING 21 1 PLUG KIT 22 12 SCREW M8 x 35 18 24 4 23 1 COVER 24 1 GASKET NON OIL INJECTION 25 2 SCREW M5 x 12 50 5 6 26 2 WA...

Page 224: ...Loctite Master Gasket 92 12564 1 25 Liquid Neoprene 92 25711 2 75 7 Loctite 271 92 809820 4 12 POWERHEAD 90 830234R3 DECEMBER 1997 Cylinder Block 3 Cyl USA 0G127500 BEL 9836633 UP ...

Page 225: ...RE SENDER DESIGN II 49 14 SCREW M8 x 35 18 24 4 50 2 CLAMP 51 1 BOOT 52 1 OIL WARNING MODULE USA S N 0G127500 thru 0G437999 BEL 9836633 thru 9926999 53 1 OIL WARNING MODULE USA S N 0G438000 thru 0G589999 BEL 9927000 thru 9973099 1 REV LIMITER ELECTRIC USA S N 0G127500 thru 0G437999 1 REV LIMITER MANUAL BEL S N9836633 thru 9926999 54 1 REV LIMITER ELECTRIC USA S N 0G438000 thru 0G589999 54 1 REV LI...

Page 226: ...4 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 4 1 19 35 33 Perfect Seal 92 34227 1 19 95 2 4 C With Teflon 92 825407A12 95 95 19 36 4 14 POWERHEAD 90 830234R3 DECEMBER 1997 Induction Manifold and Reed Block 3 Cyl ...

Page 227: ...END CAP ASSEMBLY 14 1 CHECK VALVE 15 1 OIL SEAL 16 1 O RING 17 3 SCREW M10 X 25 18 24 4 18 3 REED BLOCK ASSEMBLY 19 6 GASKET 20 3 REED SET 21 3 TAB WASHER 22 3 RETAINER 23 3 SCREW M6 x 16 80 9 0 24 1 BRACKET NON OIL INJECTION 24 1 BRACKET OIL INJECTION 25 2 WASHER 26 2 WING NUT Drive Tight 27 2 STUD 28 3 INDUCTION MANIFOLD 29 13 SCREW M8 x 35 18 24 4 30 2 SCREW M8 x 40 18 24 4 31 4 STUD M8 x 132 3...

Page 228: ...Oil 92 13249A24 14 14 95 95 95 95 95 95 95 95 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 6 12 16 95 2 4 C With Teflon 92 825407A12 4 16 POWERHEAD 90 830234R3 DECEMBER 1997 Crankshaft Pistons and Connecting Rods 4 Cyl ...

Page 229: ...MBLY STANDARD 9 AR PISTON ASSEMBLY 015 O S 9 AR PISTON ASSEMBLY 030 O S 10 8 LOCK RING 11 1 PISTON RING ASSEMBLY STANDARD 11 AR PISTON RING ASSEMBLY 015 O S 11 AR PISTON RING ASSEMBLY 030 O S 12 4 CONNECTING ROD ASSEMBLY 13 8 WASHER 14 116 NEEDLE BEARING 15 8 SCREW Apply Light Oil to Threads and Bolt Face 1st Torque 15 lb in 1 7 N m 2nd Torque 30 lb ft 40 7 N m Turn bolt an additional 90 after 2nd...

Page 230: ... 12564 1 Loctite 35 92 59328 1 17 Liquid Neoprene 92 25711 2 25 7 25 17 75 25 43 7 Loctite 271 92 809820 54 25 22 23 26 28 29 30 31 32 33 34 35 36 37 38 39 40 41 45 46 47 18 24 25 7 27 5 21 10 11 16 20 50 51 52 53 4 18 POWERHEAD 90 830234R3 DECEMBER 1997 Cylinder Block and Crankcase 80 Jet 100 115 125 ...

Page 231: ...0 25 33 9 3 4 DOWEL PIN BEARING RACE 4 1 DOWEL PIN 5 1 COVER TOP 6 1 COVER BOTTOM 7 4 SCREW M8 x 50 12 5 16 9 8 1 CARRIER 9 1 GROMMET 10 1 CARRIER ASSEMBLY 11 3 CHECK VALVE 12 2 CHECK VALVE 13 8 STUD M10 14 8 WASHER 15 8 NUT 45 61 16 1 CHECK VALVE PRESS IN 17 2 FITTING S N USA 0G301750 BEL 9885504 BELOW 18 1 PLUG KIT 19 1 TUBING S N USA 0G301750 BEL 9885504 BELOW 20 16 SCREW 8 x 35 18 24 4 21 1 BO...

Page 232: ...8 1 17 25 Liquid Neoprene 92 25711 2 27 43 7 Loctite 271 92 809820 54 26 28 29 30 32 33 34 35 36 37 38 39 40 41 8 9 22 31 23 2 3 4 10 11 16 17 19 20 49 19 19 5 6 7 12 13 14 15 21 42 44 51 52 53 17 25 7 25 17 25 75 4 20 POWERHEAD 90 830234R3 DECEMBER 1997 Cylinder Block and Crankcase 80 Jet 100 115 125 ...

Page 233: ... 1 GASKET 39 1 COVER 40 1 SCREW M8 x 35 18 24 4 40 4 SCREW M8 x 55 18 24 4 41 1 PIPE PLUG 42 1 OIL WARNING MODULE USA S N 0G437999 BEL 9926999 BELOW 43 1 OIL WARNING MODULE USA S N 0G438000 thru 0G589999 BEL 9927000 thru 9973099 44 2 SCREW M6 x 30 80 9 0 45 2 STUD 46 2 WASHER 47 2 WING NUT Drive Tight 48 2 FITTING TEE S N USA 0G301750 49 2 CHECK VALVE BEL 9885504 BELOW 50 1 REV LIMITER USA S N 0G5...

Page 234: ... 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 1 22 35 Loctite 35 92 59328 1 17 Perfect Seal 92 34227 1 19 95 2 4 C With Teflon 92 825407A12 95 19 95 40 4 22 POWERHEAD 90 830234R3 DECEMBER 1997 Induction Manifold and Reed Block 80 Jet 100 115 125 ...

Page 235: ... 1 GASKET 14 1 LOWER END CAP ASSEMBLY 15 1 CHECK VALVE 16 1 OIL SEAL 17 1 O RING 18 3 SCREW M10 x 25 150 16 9 19 1 TEE FITTING 20 2 HOSE 5 1 2 IN 21 2 FITTING STRAIGHT 22 2 INDUCTION MANIFOLD 23 1 BRACKET 24 12 SCREW M8 x 35 18 24 4 25 2 SCREW M8 X 40 12 5 16 9 26 2 STUD 27 2 WASHER 28 2 WING NUT Drive Tight 29 2 SCREW 4 cylinder 18 24 4 30 6 STUD 1 2 3 cylinder 31 2 GASKET 32 2 COVER 33 4 SCREW M...

Page 236: ... 4 C With Teflon 92 825407A12 95 95 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 8 10 9 23 4 24 POWERHEAD 90 830234R3 DECEMBER 1997 Throttle Lever and Linkage 65 Jet 75 90 Models ...

Page 237: ...7 1 SPARK ADVANCE LEVER 8 2 ADJUSTING SCREW 6 MM 9 2 JAM NUT 10 2 NYLON CAP 11 1 BUSHING 12 1 SCREW Tighten Securely But Arm Must Pivot Freely 13 1 WASHER 14 1 SPRING 15 1 PIN 16 1 WASHER 17 1 NUT Tighten Nut Secure ly Then Back Off Nut 1 4 Turn 18 1 SPARK ADVANCE ROD 19 2 SWIVEL BASE 20 2 SWIVEL BALL 21 1 THROTTLE ROD 22 1 SPRING 23 2 BUSHING 24 1 THROTTLE CAM 25 1 STUD 26 1 WASHER 27 1 NUT Drive...

Page 238: ...4 26 POWERHEAD 90 830234R3 DECEMBER 1997 Throttle Lever Models 80Jet 100 115 125 95 2 4 C With Teflon 92 825407A12 ...

Page 239: ...YLON CAP 9 1 SPARK ADVANCE LEVER 10 3 ADJUSTING SCREW M6 x 55 11 3 JAM NUT 12 3 NYLON CAP 13 1 SCREW M10 x 45 Tighten Screw Se curely But Arm Must Be Free To Pivot 14 1 BUSHING 15 1 SPRING 16 1 BUSHING 17 1 WASHER 18 1 PIN 19 1 WASHER 20 1 NUT Tighten Nut Securely Then Back Off 1 4 Turn 21 1 SPARK ADVANCE ROD 22 1 SWIVEL BALL 23 1 SWIVEL BASE 24 1 LINK 25 1 NUT Drive Tight But Joint Must be Free t...

Page 240: ...ical Component Plate 13 5 lb ft 18 3 N m Loctite 271 Required USA 438000 BEL 9937000 UP Electrical Component Plate 200 lb in 22 6 N m Loctite 271 Required We recommend that you read the sub section on reassembly BEFORE proceeding There are specifics relating to this engine which are NOT applicable to prior engines 7 Loctite 271 92 809820 7 7 Loctite 271 92 809820 7 ...

Page 241: ...ess a 53952 a Cowl Mounted Trim Switch Remove tell tale hose from exhaust cover a 53956 a Hose Remove 2 bolts securing aft end of lower cowling a 53953 a Bolts Remove bolt securing forward portion of lower cowling a 53954 a Bolt Loosen PORT nut securing front latch to bottom cowl and remove STARBOARD bottom cowl a b 53955 a Nut b Latch ...

Page 242: ...ical plate cover and remove cover a a 53958 a Bolts Remove 2 nuts securing GREEN and BLUE trim harness leads to solenoids Remove bolt secur ing BLACK trim harness lead a b c 53940 a GREEN Trim Lead b BLUE Trim Lead c BLACK Trim Lead Remove 2 screws and clamp which secure con trol box electrical harness to engine a b a 20290 a Screws b Clamp ...

Page 243: ...ead from driveshaft housing and install on powerhead stand a 25929 a Lift Eye 91 90455 Remove Air Box Cover by removing 6 screws a b b 3 Cylinder Models 53977 a Air Box Cover b Screws a b b 4 Cylinder Models 53976 a Air Box Cover b Screws Remove bolt from lower oil tank support star board side of engine base Remove bolt from upper oil tank support Remove 2 bolts securing voltage regulator Remove a...

Page 244: ... a Bolt Lower Oil Tank Support b Bolt Upper Oil Tank Support c Bolts Voltage Regulator d Nuts 6 Bolts 2 Disconnect Oil Pump Linkage Remove main fuel hose and fuel enrichment hose Lift carburetors off as 1 unit assembly a b c d 54131 a Main Fuel Hose b Fuel Enrichment Hose c Oil Pump Linkage d Accelerator Pump Hose 4 Cylinder Models Only Remove carburetors as an assembly a a 3 Cylinder Models 1994 ...

Page 245: ...linder Models 54134 a Fuel Enrichment Fitting b Accelerator Pump Fitting Remove intake manifolds 3 Cylinder Models a 54136 a Intake Manifolds a a 4 Cylinder Models 54135 a Intake Manifolds Remove intake manifolds as an assembly 3 Cylinder Models 19330 ...

Page 246: ...th Flywheel Holder 91 52344 remove flywheel nut and washer 20344 Crankshaft damage may result if a protector cap is not used between crankshaft and puller Install a crankshaft Protector Cap 91 24161 on end of crankshaft then install Flywheel Puller 91 73687A1 into flywheel NOTE Neither heat nor hammer should be used on flywheel to aid in removal as damage to flywheel or electrical components under...

Page 247: ...ove check valves a 52478 a Check Valve 4 Cylinder Models Only Accelerator check valves can be tested for prop er performance as follows 1 Spray a small amount of WD 40 into barbed end of check valve 2 Blow out excess WD 40 with high pressure air 3 Apply suction to barbed end with small air vacu um hand pump 4 Apply suction until valve opens 22 28 inches of vacuum 5 Within 30 seconds after stopping...

Page 248: ...OTE There are pry slots on casting as shown by screwdriver positions Remove exhaust cover and divider plate 20029 Remove 3 bolts from crankcase end cap lower a 20020 a End Cap Bolts Remove crankcase bolts and cover 20032 Remove crankcase end cap lower Remove oil seal and O ring seal 20342 20341 a b a Oil Seal b O Ring Some models may have a wear sleeve with an O ring seal See page 4 39 ...

Page 249: ...p scriber to mark caps and rods to return pis tons to proper cylinder Remove piston assembly from crankshaft reat tach caps to respective rods as each is removed CAPS MUST BE INSTALLED IN SAME DIREC TION ON SAME ROD or mating surfaces will not seat properly a 19328 a Bolts IMPORTANT BOTH the piston rod and rod cap bolt holes are threaded The rod cap and rod must be aligned and held tight together ...

Page 250: ...in Never re use piston pin lockpins Hold shop cloth over lockring area when snapping out lockrings a 53986 a Lockrings Support piston and tap out piston pin using ser vice tool 91 74607A2 as shown a b 51086 a Piston Pin b Wrist Pin Tool 91 74607A2 Remove piston pin needle bearings 29 per pis ton pin and locating washers 2 per piston as shown IMPORTANT We recommend that you use new needle bearings ...

Page 251: ... replacement is necessary remove gear after pressing off main bearing slides off shaft Lower crankshaft seal carrier b a 51084 a Oil Drive Gear b Key Seal carrier is press fitted into the spline end of crankshaft NOTE Seal should be replaced as a routine proce dure without regard to appearance to prevent water leakage into crankshaft driveshaft splines Remove seal by prying out of carrier using an...

Page 252: ...b c a Wear Sleeve Surface b Carrier c O ring Cleaning and Inspection Cylinder Block and Crankcase Cover IMPORTANT Crankcase cover and cylinder block are a matched line bored assembly and never should be mismatched by using a different crankcase cover or cylinder block Inspect cylinder block and crankcase cover for cracks or fractures Check gasket surfaces for nicks deep grooves cracks and distorti...

Page 253: ... piston rings and cylinder bore After cleaning bores should be swabbed several times with 2 cycle engine oil and a clean cloth Wipe excess oil with clean dry cloth Cylinders should not be cleaned with kerosene or gasoline Clean remainder of cylinder block Hone all cylinder walls just enough to de glaze Measure cylinder bore inside diameter with an inside micrometer of each cylinder as shown below ...

Page 254: ...o cover a b c 51621 a Check Valve Carrier Assembly b Slot c Crankcase Cover Clean mating surfaces of crankcase cover and intake manifold Install new gaskets Install intake manifold reed block assemblies to crankcase cover Refer to PAGE 4 58 for torque specification and tightening sequence Install carburetors Torque carburetor AIR BOX stud nuts to 100 lb in 11 3 N m Carburetors MUST BE SYNCHRONIZED...

Page 255: ...g groove Scratching the side sur faces of the ring groove will cause damage to the ring groove Use a bristle brush and carbon remover solution to remove carbon from side surfaces A tool can be made for cleaning the inner diame ter of the tapered ring grooves The tool can be made from a broken tapered piston ring with the side taper removed to enable inside edge of the ring to reach the inside diam...

Page 256: ...ompressed air Connecting Rods If necessary clean connecting rod surfaces as follows Attach end caps to connecting rods Following these directions tighten rod cap attaching bolts to specifications Recheck alignment Refer to 4 53 Crocus cloth MUST BE USED to clean bearing surface at crankshaft end of connecting rod DO NOT use any other type of abrasive cloth Clean crankshaft end of connecting rod by...

Page 257: ...n test thermostat as follows Open thermostat valve then insert a thread be tween valve and thermostat body Allow valve to close against thread Suspend thermostat from thread and thermom eter inside tester so that neither touches the con tainer Bottom of thermometer must be even with bottom of thermostat to obtain correct thermostat opening Fill thermostat tester with water to cover thermostat Plug...

Page 258: ...d perform ohms test Compare to specifications If switch does not fall within specifications replace switch Reed Blocks NOTE Do not disassemble reed block unless neces sary It may be necessary to apply heat to bolt to soft en LoctiteR before removal a b c d e 19331 a Reed Block b Reed 3 Sets c Retaining Washer d Tab Washer e Bolt IMPORTANT Do not flop reverse the reed for additional use replace ree...

Page 259: ...d have been carefully cleaned and thoroughly inspected as outlined in Cleaning and Inspection Parts which have not been properly cleaned or which are questionable can severely damage an otherwise perfectly good powerhead within a few minutes of operation All new powerhead gaskets must be installed during assembly During reassembly lubricate parts with Quicksilver 2 Cycle Outboard Oil whenever 2 cy...

Page 260: ... Rod to Piston Place clean needle bearings on a clean sheet of paper and lubricate with Quicksilver 2 4 C w Teflon 92 825407A12 NOTE There are 29 needle bearings per piston Never intermix new needle bearings with used needle bearings at the same connecting rod end Never intermix needle bearings on one connect ing rod with those of another connecting rod Should one or more piston pin needle bearing...

Page 261: ...NG Eye protection must be worn while installing pis ton pin lockrings Install new piston pin lockrings each side of piston using Lockring Tool 91 77109A2 Make sure lockrings are properly seated in piston grooves Do not reuse piston pin lockrings Use only new lockrings and make sure they are properly seated in piston grooves b a 51086 a Lockring Installation Tool 91 77109A2 b Lockring 2 51086 Pisto...

Page 262: ...s just enough to slip over piston 2 Check piston rings to be sure they fit freely in groove Lubricate rings and cylinder wall with 2 cycle oil b a 14 2 Cycle Outboard Oil 92 826666A24 14 51081 a Piston Ring Expander b Piston Rings 3 Align piston ring end gaps with ring locating pins as shown Check locating pins making sure they are tight b a a b a 53988 a Locating Pin b Piston Rings 4 Remove conne...

Page 263: ...Bearing and Gear were removed from crankshaft reassemble using arbor press and suitable mandrel for bearing gear slides on NOTE keyway and key in gear to crankshaft as sembly Install main bearing retaining ring after pressing main bearing tight against the oil gear NOTE There is NO main bearing retaining ring or re taining ring groove in the crankshaft on the following outboards 75 90 100 115 125 ...

Page 264: ... damage to engine may occur Grease crankshaft journal with 2 4 C w Teflon to hold bearings in place Position bearings on journal 32 each center main bearing 95 2 4 C With Teflon 92 825407A12 20046 95 Attach bearing races with holes toward lower gear end of crankshaft Secure each main bearing race with retaining ring a b c 20040 a Main Bearing Race b Retaining Ring c Top Main Bearing To install top...

Page 265: ...s a a 3 Cylinder Models a 4 Cylinder Models b c 20038 20038 a Locating Pins b Lower Gear End c Flywheel End Top Place crankshaft into cylinder block align and seat top and center main bearings so that locating pins on block mate with holes in each bearing race 3 Cylinder Models 4 Cylinder Models 20336 51080 ...

Page 266: ... mating sur faces 95 2 4 C With Teflon 92 825407A12 20030 95 NOTE Apply light oil to connecting rod bolt face and threads prior to installation Place Rod Cap carefully over cage and bearings and while holding cap tight to rod and rod tight to journal insert bolt and lightly tighten observing cap to rod alignment Install other bolt recheck ing alignment 20033 Connecting Rod Cap Alignment 1 Check ea...

Page 267: ...Perfect Seal DO NOT coat O ring seal 2 Bolt to block 2 bolts finger tighten lightly a b 19336 a Mating Surface b O ring Seal Crankcase Cover to Block LOCTITE MASTER GASKET SEALANT 92 12564 1 is used it comes as a kit which includes Primer and Sealant Instructions contained in the kit MUST BE FOLLOWED EXACTLY Clean both sur faces IMPORTANT Extend sealer to edge on each center main journal to preven...

Page 268: ... cap bolts 3 bolts to 18 lb ft 24 4 N m Reattach bleed line hose NOTE Inspect ALL hoses on reinstallation replace when necessary Note on Major Cover Gaskets These are new gas kets impregnated with a coating that causes the gas ket to retain torque It is not necessary to use sealant on gasket or Loctite on bolts Cylinder Block Cover Align cover and gasket on block a b a Cover b Gasket Install therm...

Page 269: ... SEQUENCE All Cover Bolts 18 lb ft 24 4 N m 3 Cylinder Models 15 11 6 1 3 7 9 13 19 17 18 12 8 4 2 5 10 14 16 19 14 10 6 2 4 8 12 16 20 21 22 23 15 11 7 3 1 5 9 13 17 18 4 Cylinder Models 23014 Exhaust Plate Cover and Exhaust Divider Plate Assemble in order shown a Exhaust Plate Gasket b Divider Plate c Exhaust Plate Gasket d Exhaust Plate Cover 3 Cylinder Models 4 Cylinder Models a b c d a b c d ...

Page 270: ...sembly or an oil injection failure could occur re sulting in possible powerhead damage 20041 IMPORTANT After reinstalling shaft and hous ing turn crankshaft make sure oil pump shaft turns Reinstall Oil Injection Pump 2 bolts Torque to 60 lb in 6 8 N m Reinstall Fuel Pump 2 bolts Torque to 40 lb in 4 5 N m Reattach fuel oil line hoses and secure with sta straps 3 Cylinder Models a a b 53992 a Bolts...

Page 271: ...inkage b Stud NOTE For specific information on rewiring see Sec tion 2D Wiring Diagrams this manual Intake Manifold and Reed Block Installation Reinstall Reed Block Housings and Intake Manifolds 3 Cylinder Models a b c d 19574 a Gasket b Intake Manifold c Reed Block Assembly d Install Intake Manifold as One Unit INTAKE MANIFOLD TORQUE SEQUENCE 3 Cylinder Models 4 2 1 3 5 ...

Page 272: ...r Pump Installation 4 Cylinder Models Install accelerator pump check valves and hoses 4 Cylinder Models b a 25913 a Accelerator Pump Hoses b Check Valves Install accelerator pump with 2 bolts Torque bolts to 130 lb in 14 7 N m NOTE After powerhead reassembly is complete re fer to Section 2C for proper positioning of accelerator pump against throttle cam 4 Cylinder Models a b 25963 a Bolts Torque t...

Page 273: ...90 830234R3 DECEMBER 1997 POWERHEAD 4 61 3 Cylinder Bleed Hose Routing a b a Pressed In Check Valve b Threaded Check Valve ...

Page 274: ...4 62 POWERHEAD 90 830234R3 DECEMBER 1997 4 Cylinder Bleed Hose Routing 1995 and Prior 52478 a b a Pressed In Check Valve b Threaded Check Valve ...

Page 275: ...90 830234R3 DECEMBER 1997 POWERHEAD 4 63 4 Cylinder Bleed Hose Routing 1996 and Newer a b a Pressed In Check Valve b Threaded Check Valve ...

Page 276: ...4 64 POWERHEAD 90 830234R3 DECEMBER 1997 4 Cylinder Fuel Enrichment Accelerator Pump Hose Routing ...

Page 277: ...linder Harness Routing without Oil Reservoir Installed a b c d e f g h 54161 a Stator Harness b Trigger Harness c Voltage Regulator Harness d Fuel Enrichment Harness e NEGATIVE Battery Cable f Power Trim Harness g POSITIVE Battery Cable h Lower Cowl Trim Harness ...

Page 278: ...3 Cylinder Harness Routing with Oil Reservoir Installed a b c d e f g 54162 a Trigger Harness b Voltage Regulator Harness c NEGATIVE Battery Cable d Low Oil Warning Module Harness e POSITIVE Battery Cable f Power Trim Harness g Lower Cowl Power Trim Harness ...

Page 279: ...90 830234R3 DECEMBER 1997 POWERHEAD 4 67 3 Cylinder Manual Start Harness Routing a b c d a Stator Harness b Trigger Harness c RPM Limiter Harness d Overheat Sensor Lead ...

Page 280: ...ER 1997 1994 and Newer 4 Cylinder Harness Routing without Oil Reservoir Installed a b c d e f 54163 a Stator Harness b Trigger Harness c Fuel Enrichment Harness d Voltage Regulator Harness e NEGATIVE Battery Cable f Power Trim Harness ...

Page 281: ...ylinder Harness Routing with Oil Reservoir Installed a b d e f g h c 54164 a Stator Harness b Trigger Harness c Fuel Enrichment Harness d NEGATIVE Battery Cable e Voltage Regulator Harness f POSITIVE Battery Cable g Power Trim Harness h Low Oil Warning Harness ...

Page 282: ...odule inner c Ignition Plate Bolts 4 Each d RPM Limiter Oil Warning Module Bolts 2 Each Install Oil Warning module Inner and RPM Lim iter module Outer back to back Apply Loctite 271 to module bolt threads Torque bolts to 80 lb in 9 0 N m 4 Cylinder Models Only b a 54161 7 Loctite 271 92 809820 a Oil Warning Module Inner RPM Limiter Module Outer b Bolts Torque to 80 lb in 9 0 N m 3 Cylinder Models ...

Page 283: ...gger b Link Arm Connect trigger leads to switch box refer to wir ing diagrams in Section 2D Install sta strap Install starter motor refer to Section 2B b a c 3 Cylinder Models 53792 a Sta Straps b Bullet Connectors Connect Trigger Leads c Trigger Harness 4 Cylinder Models a b c 53970 a Sta Strap b Trigger Harness c Switch Box ...

Page 284: ...hese stators MUST BE INSTALLED AS SHOWN RESPECTIVELY OR PREMATURE STATOR FAILURE MAY OCCUR AS A RESULT OF STATOR INTERFERANCE WITH THE ENGINE BLOCK Small Rim Stator a b c b b b 54130 Front of Engine a Small Rim b Stator Screws Apply Loctite 271 to threads Torque screws to 60 lb in 6 8 N m c Stator Harness Large Rim Stator a c b b b b 54132 Front of Engine a Large Rim Stator b Stator Screws Apply L...

Page 285: ...ds refer to wiring diagrams in Section 2D Install sta strap Install starter motor refer to Section 2B 3 Cylinder Models a b c 53792 a Sta Straps b Switch Box Bullet Connectors c Stator Harness 4 Cylinder Models a b c 53790 a Sta Strap b Stator Harness c Switch Box Reinstall electrical plate cover Secure cover with 4 bolts 4 cyl models or 3 bolts 3 cyl models Torque bolts to 30 lb in 3 4 N m a a 53...

Page 286: ...sor b Retainer Screws 4 Cylinder Models a b 53993 a Temperature Sensor b Retainer Screws Carburetor Installation Install carburetor gaskets Reinstall carburetors as a single unit assembly Note manifold hose position and connection 3 Cylinder Models a 19094 a Manifold Hose a 4 Cylinder Models 25914 a Base Gaskets ...

Page 287: ...Carburetors b Top Carb Input Fuel Hose c Input Hose to Fuel Enrichment Valve d Input Hose to Accelerator Pump e Fuel Enrichment Valve f Accelerator Pump Reconnect main fuel line hose and fuel enrich ment hose Secure fuel line a with sta strap Reconnect throttle linkage 3 Cylinder Models a b c 19093 a Main Fuel Hose b Fuel Enrichment Hose 1996 Models will Connect Enrichment Hose to Fitting in Fuel ...

Page 288: ...cure flywheel with flat washer and locknut While holding fly wheel with Flywheel Holder 91 52344 torque flywheel nut to 120 lb ft 162 7 N m a 51123 a Flywheel Holder 91 52344 Install flywheel cover Oil Reservoir Installation Install oil tank assembly on powerhead Torque aft bottom oil tank bracket bolt to 15 lb ft 20 3 N m Connect 2 LIGHT BLUE leads from oil tank to oil warning module c a b 25939 ...

Page 289: ... Bolt Torque to 15 lb ft 20 3 N m Air Box Installation Install Gaskets Air Box Plate to carburetor Reinstall Air Box Plate Torque bolts and nuts to 100 lb in 11 3 N m 3 Cylinder Models c a b 53978 a Air Box Plate b Bolts Torque to 100 lb in 11 3 N m c Nuts Torque to 100 lb in 11 3 N m 4 Cylinder Models a b c 53979 a Air Box Plate b Bolts Torque to 100 lb in 11 3 N m c Nuts Torque to 100 lb in 11 3...

Page 290: ...ket surface Place new gasket over locating pins on driveshaft housing to powerhead mating surface Apply a small amount of Quicksilver 2 4 C w Teflon to driveshaft splines Recheck for correct installation of tip seal in crankshaft seal carrier Use hoist to lower powerhead into driveshaft housing turning flywheel if necessary to align crankshaft splines with driveshaft splines Lower so that powerhea...

Page 291: ...owl Mounted Trim Switch Reinstall tell tale hose to exhaust cover a 53956 a Hose Install 2 bolts securing aft end of lower cowling Torque bolts to 65 lb in 7 3 N m 53953 a a Bolts Install bolt securing forward portion of lower cowl Torque bolt to 65 lb in 7 3 N m a 53954 a Bolt Tighten PORT nut securing front latch to bottom cowl ...

Page 292: ...A 5 MID SECTION CLAMP SWIVEL BRACKETS DRIVE SHAFT HOUSING ...

Page 293: ...ket Manual Tilt Assist 65 Jet 75 90 5A 6 Swivel Bracket and Steering Arm 80 Jet 100 115 125 5A 8 Transom Bracket S N USA 0G589999 BEL 9973099 BELOW 5A 10 Page Transom Bracket S N USA 0G590000 BEL 9973100 UP 5A 12 Exhaust Plate 65 Jet 75 90 5A 14 Exhaust Plate 80 Jet 100 115 125 5A 16 Drive Shaft Housing 65 Jet 75 90 5A 18 Drive Shaft Housing 80 Jet 100 115 125 5A 20 Reference Views 5A 22 ...

Page 294: ...90 830234R3 DECEMBER 1997 MID SECTION 5A 1 Notes ...

Page 295: ...m 65 Jet 75 90 1 2 3 4 5 6 7 9 10 11 12 17 19 20 15 21 22 23 24 25 26 27 28 16 18 14 13 29 3 95 2 4 C With Teflon 92 825407A12 95 95 7 95 95 95 95 95 7 b 7 a 7 Loctite 271 92 809820 8 a Torque nut to 120 lb in 13 6 N m then back off 1 4 turn b Torque nut to 20 lb ft 27 0 N m ...

Page 296: ...3 8 x 24 x 1 1 8 20 27 0 11 2 NUT See Exploded View 12 2 WASHER 13 1 BUMPER top yoke X LONG LL 1 SWIVEL PIN STEERING ARM BLACK 14 1 SWIVEL PIN STEERING ARM GRAY 14 1 SWIVEL PIN STEERING ARM TRACKER GRAPHITE GRAY 15 1 THRUST WASHER 1 SHOCK BLACK NO 16 1 SHOCK GRAY STAMPING 16 1 SHOCK BLACK STAMPED 1 SHOCK GRAY A12 or A17 17 1 GROOVE PIN 18 1 SHAFT UPPER 1 BOTTOM YOKE BLACK 19 1 BOTTOM YOKE GRAY 19 ...

Page 297: ...22 23 24 25 26 27 28 18 27 26 87 Quicksilver Gear Lubricant 92 13783A24 95 2 4 C With Teflon 92 825407A12 87 95 7 7 7 Loctite 271 92 809820 2 15 4 5 5A 4 MID SECTION 90 830234R3 DECEMBER 1997 Transom Bracket Non Power Trim Power Trim 65 Jet 75 90 ...

Page 298: ... TILT TUBE 7 1 NUT Tighten Nut until Bot tomed on Shoulder of Tilt Tube 8 1 O RING 9 2 WAVE WASHER 10 1 NUT Drive Nut until As sembly is drawn to gether but must be free to pivot 11 4 BOLT 4 1 2 IN 12 4 WASHER 13 4 NUT 14 1 STOP 15 1 TILT LOCK LEVER NON POWER TRIM 16 1 TILT LOCK LEVER POWER TRIM 17 1 WAVE WASHER 18 2 BUSHING 19 1 KNOB 20 1 GROOVE PIN 21 1 SPRING 22 1 GROOVE PIN 23 1 BOLT ASSEMBLY ...

Page 299: ...87 Quicksilver Gear Lubricant 92 13783A24 95 2 4 C With Teflon 92 825407A12 7 Loctite 271 92 809820 5A 6 MID SECTION 90 830234R3 DECEMBER 1997 Transom Bracket Manual Tilt Assist 65 Jet 75 90 ...

Page 300: ... of Tilt Tube 8 1 O RING 9 2 WAVE WASHER 10 1 NUT Drive Nut until As sembly is drawn to gether but must be free to pivot 11 4 BOLT 4 1 2 IN 12 4 WASHER 13 4 NUT 14 1 SPRING 15 1 TILT LOCK LEVER 16 2 BUSHING 17 1 SPRING 18 1 KNOB 19 1 GROOVE PIN 20 1 PIN 21 1 NUT 22 1 LINK ROD 23 1 ARM 24 1 BUSHING 25 1 TILT LEVER 30 40 7 26 1 KNOB 27 1 MANUAL TILT ASSEMBLY 28 1 TILT SHAFT UPPER 29 1 ANCHOR PIN 30 ...

Page 301: ...t and Steering Arm 80 Jet 100 115 125 1 2 3 4 5 6 7 9 10 11 12 13 14 16 17 18 3 95 2 4 C With Teflon 92 825407A12 95 95 7 95 95 95 95 15 a b 7 Loctite 271 92 809820 8 a Torque nut to 120 lb in 13 6 N m then back off 1 4 turn b Torque nut to 20 lb ft 27 0 N m ...

Page 302: ...R 3 2 BUSHING 4 1 O RING 5 1 SPACER 6 2 GREASE FITTING 40 4 5 7 2 BUSHING 8 2 SCREW 100 11 3 1 SWIVEL PIN STEERING ARM BLACK 9 1 SWIVEL PIN STEERING ARM GRAY 9 1 SWIVEL PIN STEERING ARM TRACKER GRAPHITE GRAY 10 1 STEERING LINK ASSEMBLY 11 1 SCREW 20 27 0 12 2 NUT See Exploded View 13 2 WASHER 14 1 BUMPER X LONG 15 1 BUMPER X LONG 1 BOTTOM YOKE BLACK 16 1 BOTTOM YOKE GRAY 16 1 BOTTOM YOKE TRACKER G...

Page 303: ...13783A24 95 2 4 C With Teflon 92 825407A12 7 Loctite 271 92 809820 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 15 24 23 2 26 27 28 5A 10 MID SECTION 90 830234R3 DECEMBER 1997 Transom Bracket S N USA 0G589999 BEL 9973099 BELOW ...

Page 304: ...en Nut until Bot tom on Shoulder of Tilt Tube 6 1 O RING 7 2 WAVE WASHER 8 1 NUT Drive Nut Until As sembly is Drawn to gether But must free to pivot 9 4 BOLT 4 1 2 IN 10 4 WASHER 11 4 NUT 12 1 STOP 13 1 TILT LOCK LEVER 14 1 WAVE WASHER 15 2 BUSHING 16 1 KNOB 17 1 GROOVE PIN 18 1 SPRING 19 1 GROOVE PIN 20 1 BOLT ASSEMBLY 21 1 NUT 30 40 7 22 1 ANCHOR BRACKET 23 6 SCREW 30 40 7 24 6 WASHER 25 1 NUT 3...

Page 305: ...87 Quicksilver Gear Lubricant 92 13783A24 95 2 4 C With Teflon 92 825407A12 7 Loctite 271 92 809820 5A 12 MID SECTION 90 830234R3 DECEMBER 1997 Transom Bracket S N USA 0G590000 BEL 9973100 UP ...

Page 306: ...32 1 TILT TUBE 33 1 NUT Tighten Nut until Bot tomed on Shoulder of Tilt Tube 34 1 O RING 35 2 WAVE WASHER 36 1 NUT Drive Nut until As sembly is drawn to gether but must be free to pivot 37 4 BOLT 4 1 2 IN 38 4 WASHER 39 4 NUT 40 1 SPRING 41 1 TILT LOCK LEVER 42 2 BUSHING 43 1 SPRING 44 1 KNOB 45 1 GROOVE PIN 46 1 PIN 47 1 ANCHOR BRACKET BLACK 47 1 ANCHOR BRACKET GRAY 48 6 SCREW 30 40 7 49 6 WASHER...

Page 307: ...1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 23 24 25 26 27 28 29 30 31 7 22 7 Loctite 271 92 809820 5A 14 MID SECTION 90 830234R3 DECEMBER 1997 Exhaust Plate 65 Jet 75 90 ...

Page 308: ... 35 25 33 9 13 1 SEAL exhaust tube 14 1 GROMMET 1 WATER TUBE 13 1 4 IN 15 1 WATER TUBE 15 3 4 IN 15 1 WATER TUBE 18 1 4 IN 16 1 CLAMP 17 1 SEAL UPPER 18 2 SCREW M8 x 50 15 20 3 19 1 BRACKET ASSEMBLY LOWER 20 1 SEAL 21 1 GROMMET POWER TRIM S N 0G360002 BELOW 21 1 GROMMET NON POWER TRIM MANUAL TILT ASSIST 22 1 GROMMET POWER TRIM S N 0G360003 UP 23 3 SCREW M8 x 50 25 33 9 24 1 BUSHING 25 1 SHIFT SHAF...

Page 309: ...1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 23 24 25 26 27 28 29 30 7 22 7 Loctite 271 92 809820 5A 16 MID SECTION 90 830234R3 DECEMBER 1997 Exhaust Plate 80 Jet 100 115 125 ...

Page 310: ...74 6 10 1 GASKET 11 1 EXHAUST TUBE 12 6 SCREW 25 33 9 13 1 SEAL exhaust tube 14 1 GROMMET 15 1 WATER TUBE LONG 15 1 WATER TUBE X LONG 16 1 CLAMP 17 1 SEAL UPPER 18 2 SCREW M8 x 50 15 20 3 19 1 BRACKET ASSEMBLY LOWER BLACK 20 1 SEAL 21 1 GROMMET S 0G359967 BELOW 22 1 GROMMET S 0G359968 UP 23 3 SCREW M8 x 50 25 33 9 24 1 BUSHING 25 1 SHIFT SHAFT ASSEMBLY UPPER 26 1 SHIFT LINK 27 2 BUSHING 28 1 NUT D...

Page 311: ...octite 35 92 59328 1 17 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 6 5 30 15 95 95 95 95 17 17 5A 18 MID SECTION 90 830234R3 DECEMBER 1997 Drive Shaft Housing 65 Jet 75 90 ...

Page 312: ...ROD 13 1 SHAFT 14 1 COTTER PIN 15 2 BUSHING 16 1 SPRING 17 1 COTTER PIN NON 18 1 WASHER POWER TRIM 19 1 SPRING 20 1 YOKE 21 1 JAM NUT 22 1 CLEVIS PIN 23 1 COTTER PIN 24 2 MOUNT ELO ELHPTO SCATTO TYPHOON 24 2 MOUNT ALL OTHER MODELS 25 2 BOLT M12 x 1 75 x 154 26 2 COVER BLACK 27 4 SCREW 12 24 x 5 8 Drive Tight 28 2 WASHER 29 2 NUT 50 67 8 30 2 GROUND WIRE ASSEMBLY 31 1 SCREW 1 4 20 x 1 2 Drive Tight...

Page 313: ...Loctite 35 92 59328 1 17 1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 17 18 19 20 21 22 5 6 16 17 17 8 5A 20 MID SECTION 90 830234R3 DECEMBER 1997 Drive Shaft Housing 80 Jet 100 115 125 ...

Page 314: ... 2 DOWEL PIN 4 4 STUD LONG 4 4 STUD X LONG 5 5 WASHER 6 5 NUT 40 54 2 7 1 SPACER drive shaft housing X LONG 7 1 SPACER drive shaft housing 8 1 DOWEL PIN W HOLE 8 DOWEL PIN 9 1 SPEEDOMETER PICK UP ASSEMBLY 10 1 CONNECTOR 90 Degrees 11 1 CONNECTOR STRAIGHT 12 2 MOUNT 13 2 BOLT 14 2 WASHER 15 2 NUT 50 67 8 16 2 GROUND WIRE ASSEMBLY 17 1 SCREW Drive Tight 18 2 CLAMP 19 4 NUT 20 4 SCREW M8 x 25 13 5 18...

Page 315: ...ace Down e Bushing f Swivel Bracket g O ring h Spacer i Yoke j Retaining Ring 21054 b d e a c f h i g Non Power Trim Reverse Lock Hook Shown From Above a Push Rod End b Nut c Push Rod Yoke d Cotter Pin e Clevis Pin f Reverse Lock Hook Shaft Arm g Reverse Lock Hook Shaft h Return Spring i Tilt Pin 21053 c a b f e f d Non Power Trim Reverse Lock Hook Shown From Below a Push Rod Shaft b Spring c Push...

Page 316: ...per Shift Linkage a f b c d e 95 2 4 C With Teflon 92 825407A12 95 21050 a Upper Shift Linkage b Steering Arm Swivel Pin c Upper Mount Bolt d Swivel Bracket e Grease Fitting f Mid Section Drive Shaft Housing Lower Mount Port Side Shown g h i c b c a e d f 21051 a Lower Mount Clamp b Ground Strap c Bolt 2 Torque to 15 lb ft 20 3 N m d Lower Mount Bolt e Washer f Washer g Nut Torque to 50 lb ft 67 8...

Page 317: ...5 51485 B MID SECTION POWER TRIM S N USA 0G360002 BEL 9934136 BELOW ...

Page 318: ...Electrical System Troubleshooting 5B 15 COMMANDER 2000 Side Mount Remote Control Power Trim Tilt Electric Start with Warning Horn Wiring Diagram 5B 15 Power Trim System Wiring Diagram 5B 16 Troubleshooting the Down Circuit When Up Circuit is OK 5B 17 Troubleshooting the Up Circuit When Down Circuit Is OK 5B 17 Troubleshooting the Down and Up Circuits All Circuits Inoperative 5B 18 Page Power Trim ...

Page 319: ...90 830234R3 DECEMBER 1997 MID SECTION 5B 1 Special Tools 1 Torch Lamp 91 63209 2 Spanner Wrench 91 74951 3 Multi Meter DVA Tester 91 99750 ...

Page 320: ...5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 2930 31 32 33 2 2 3 3 4 20 4 6 12 15 16 11 15 16 15 18 11 12 15 16 11 15 11 15 11 12 7 11 14 34 25 110 110 110 25 Liquid Neoprene 92 25711 2 110 Power Trim and Steering Fluid 92 90100A12 NOTE Lubricate all O rings and seals with Power Trim and Steering Fluid ...

Page 321: ...4 7 9 1 SCREW KIT 70 7 9 10 1 DRIVE SHAFT 11 1 SEAL KIT W CASE BOLTS 13 1 5 12 1 RESERVOIR 13 1 PLUG KIT Drive Tight 14 1 RELIEF VALVE KIT 15 1 FRAME AND FIELD KIT 13 1 5 16 1 ARMATURE KIT 17 1 BRUSH SPRING KIT 18 1 BRUSH CARD KIT 19 1 ANCHOR PIN 20 2 GROOVE PIN 21 1 SHAFT 22 1 TRIM HARNESS ASSEMBLY 23 2 SCREW Drive Tight 24 2 C WASHER 25 2 CLAMP 26 2 SOLENOID 27 4 BUSHING 28 4 GROMMET 29 4 SCREW ...

Page 322: ... the up relay lo cated under engine cowl and close the electric motor circuit The electric motor drives the pump forcing fluid thru internal passageways into the up side of the trim cylinder The trim cylinder trim ram will position the engine at the desired trim angle within the 20 maximum trim range The Power Trim system is designed so the en gine cannot be trimmed beyond the 20 maximum trim angl...

Page 323: ...g 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 bolt and are trimmed to the full in trim angle will not experi ence any undesirable and or unsafe steering conditions during planing speed Thus not us ing trim adjustment bolt may be desired How...

Page 324: ...up will not trim down Outboard trims down will not trim up Outboard will not return completely to down position or returns part way with jerky motion Outboard thumps when shifted Outboard trails out when backing off throttle at high speed Outboard will not hold a trimmed po sition or will not remain tilted for any extended period Outboard will not hold trim position when in reverse Determine if Po...

Page 325: ...rd must be in the full UP position cylinder fully extended prior to fill screw or manual release valve removal Refer to instructions following if disassembly is re quired Follow preliminary checks before proceeding to trou bleshooting flow diagrams following Date Code Location Date codes are placed on power trim assemblies at date of manufacture These date codes are designed to quickly identify as...

Page 326: ...en stem Install new re lease valve and test system 6 Check for nicked deteriorated or misplaced O rings throughout trim system Leak Down Check Pump and Manifold Assembly The 1993 and 1994 models listed with power trim date codes 13011 through 23288 ONLY may experi ence a very slow trim rate one minute or more with the outboard drifting back down as soon as the UP trim button is released This failu...

Page 327: ...n check for debris be tween the valve seat and valve b a 52792 a Chip under Valve Tip b Rubber Seat 6 Inspect for nicked deteriorated or misplaced O ring d a b c 51560 a Valve and Seat b O ring c O ring d Scribe Mark Reassembly 1 Install the spool into sleeve from the chamfered end end opposite the cross hole 2 Insert spool into sleeve until end is flush with the chamfered end of the sleeve Insert...

Page 328: ...ssembly and remove the memory piston 2 Cut a small groove 0 020 0 040 in 0 5 1 0mm deep across the top face of the memory piston The groove will allow oil passage when the shock piston and memory piston are in contact The groove can be made with a hacksaw or triangular file NOTE Power trim assemblies with Date Code 14183 and ABOVE have a groove in the shock piston to allow fluid passage The memory...

Page 329: ...overed b c a 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 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 swit...

Page 330: ... trim that will not trim or tilt up or down may have a pump manifold assembly with a broken rocker arm 1 Replace broken rocker with improved rocker arm assembly 823180 b a a Rocker Arm b Rocker Arm Assembly Previous Rocker Arm Design Improved Rocker Design 51742 51742 2 Clearance between the side of the rocker arm and each pin is 0 001 to 0 010 in 0 025 0 25mm 3 Torque bolt to 125 140 lb in 14 1 1...

Page 331: ...ace O rings and proceed Inspect O rings on Pilot Relief Valve located in manifold assembly O ring failure Replace O rings O rings appear to be OK Replace O rings Inspect Memory Piston O ring Inspect Manual Release Valve Outboard falls to full down position with manual release valve closed Example a Outboard lowers more than one tilt bolt hole in eight hours Example b Outboard lowers during acceler...

Page 332: ...eed No debris or defective components found Inspect Manifold Reverse Thrust Valve Debris found in check valve components 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 deceleration Result Result Result Result Replace Pump and Manifold Assembly Inspect...

Page 333: ...th Warning Horn Wiring Diagram 23891 4 5 7 g f d a b e c BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN PUR PURPLE RED RED TAN TAN VIO VIOLET WHT WHITE YEL YELLOW h i a Ignition Choke Switch b Emergency Stop Switch c Neutral Start Switch d Tachometer Accessories Harness Connector e Wiring Harness Connector f Warning Horn g Trim Tilt Switch h Up i Down ...

Page 334: ...AN TAN VIO VIOLET WHT WHITE YEL YELLOW a Cowl Trim Switch b To Ignition Switch c UP Solenoid d DOWN Solenoid e To Battery f Starter Solenoid g Power Trim Motor h 20 Ampere Fuse i Engine Harness j Remote Control Harness BLK BLACK Negative BLU BLUE Trim Motor UP GRN GREEN Trim Motor DOWN RED RED Positive BLU WHT BLUE WHITE Trim Switch to UP Relay GRN WHT GREEN WHITE Trim Switch to DOWN Relay ...

Page 335: ...ire supplying current to Point 5 Connect Voltmeter red lead to Point 1 and black lead to ground Depress the Down trim button Troubleshooting the Up Circuit When Down Circuit Is OK Remote Control NOT Equipped with Trailer Button Battery Voltage Indicated UP Solenoid is defective Replace and retest No Voltage Indicated Connect Voltmeter red lead to Point 7 and black lead to ground Depress Down trim ...

Page 336: ...te blue white be tween trim buttons and trim pump Check trim switch Check all trim harness connectors for loose or corroded connections Check for pinched or severed wires Battery Voltage Indicated There is an open circuit in wire between Point 5 and Red terminal on the back of the ignition switch No Voltage Indicated Check that voltage is being supplied to control by performing the following check...

Page 337: ...th outboard in the full tilt UP position support outboard with tilt lock lever when servicing trim system 1 Remove top cowl 2 Disconnect bullet connectors in cowl mounted trim switch harness a 53952 a Cowl Mounted Trim Switch 3 Remove tell tale hose from exhaust cover a 53956 a Hose ...

Page 338: ...ortion of lower cowling a 53954 a Bolt 6 Loosen PORT nut securing front latch to bottom cowl and remove STARBOARD bottom cowl a b 53955 a Nut b Latch 7 Remove 4 bolts securing electrical plate cover and remove cover a a 53958 a Bolts 8 Remove 2 bolts and J clips securing trim motor harness to starboard clamp bracket a b 53957 a Bolts b J clips ...

Page 339: ...d to the full UP position and engage tilt lock lever to support outboard while servicing power trim system a 53949 a Tilt Lock Lever 11 Remove 2 nuts securing GREEN and BLUE trim harness leads to solenoids Remove bolt secur ing BLACK trim harness lead a b c 53940 a GREEN Trim Lead b BLUE Trim Lead c BLACK Trim Lead 12 Remove trim gauge sender if equipped ...

Page 340: ...ool to remove upper headed cross pin Retain pin Straight pin is hard to remove see item 15 a b 52941 a Cross Pin Design 1 Straight b Cross Pin Design 2 Headed 15 If necessary drive out upper pivot pin This will shear cross pin a 53949 a Upper Pivot Pin Inspect cross pin hole and pivot pin hole for damage 16 Use suitable punch to remove lower cross pin Retain cross pin a 53950 a Cross Pin ...

Page 341: ...Use suitable punch to drive out lower pivot pin a 53951 a Pivot Pin 18 Tilt power trim assembly top first out from clamp bracket and remove assembly 53944 19 Remove fill screw and drain unit a 53945 a Fill Screw 20 Remove O ring from fill cap 51194 ...

Page 342: ...ve cylinder end cap assembly from cylinder using spanner wrench 1 4 in x 5 16 in long pegs a b c 51194 a Manual Release Valve b Manifold c Spanner Wrench P N 91 74951 4 Remove trim rod assembly from cylinder 51196 5 Remove memory piston from cylinder using lock ring pliers Craftsman P N 4735 or suitable tool a 51193 a Lock ring pliers 6 Remove O ring from memory piston a b 51196 a O ring b Memory ...

Page 343: ...avoid damage to trim piston 4 Place trim rod into soft jawed vise and apply heat to shock piston using torch lamp 91 63209 5 Loosen trim rod piston using spanner wrench 1 4 in x 5 16 in long pegs 6 Allow trim rod piston to cool Remove from trim rod a 51146 a Torch Lamp a b 51146 a Spanner Wrench b Trim Rod Piston CAUTION Do not remove check ball components from trim rod piston Removal and re insta...

Page 344: ...ng and outer O ring a b c 51147 51145 a Rod Wiper b Inner O ring c Outer O ring Trim Motor Removal 1 Secure power trim assembly in soft jawed vise 2 Remove screws securing motor to reservoir and remove motor a a 53946 a Screws 4 3 Remove motor from reservoir a 53947 a Motor ...

Page 345: ...63 a Armature b Motor Frame c Washer 1 each end of armature Reservoir Assembly Removal 1 Remove manual release valve from manifold a b 53943 a Manual Release Valve b Manifold 2 Remove E clip and O rings from manual re lease valve a c b 51196 a E Clip b O rings c Manual Release Valve 3 Remove 4 screws securing reservoir to manifold a a 53959 a Screws 4 ...

Page 346: ...rew 2 2 Remove check valve components from manifold IMPORTANT Sleeve f is chamfered on I D on end opposite drilled cross hole Install spool g with O ring installed from chamfered end of sleeve to avoid possibility of damaging O ring on spool a b b c d d d e f g h 53961 a Manifold and Pump b Spring 2 c Check Valve d O ring 4 e Seat f Sleeve g Spool h Chamfered End 3 Remove O rings from cylinder a 5...

Page 347: ...m and Steering Fluid or ATF Type F FA or Dexron III 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 mo tor wire from trim system wiring harness 2 Connect a 12 volt power supply to motor wires POSITIVE to BLUE NEGATIVE to GREEN re sults in motor ...

Page 348: ...a Growler follow Growler man ufacturer s test instructions Indication of a short re quires replacement of armature TEST FOR GROUND Use an Ohmmeter R x 1 scale Place one lead on Ohmmeter on armature shaft and other lead on com mutator as shown If continuity is indicated armature is grounded and must be replaced 51359 CHECKING AND CLEANING COMMUTATOR If commutator is worn it can be turned down on an...

Page 349: ...readings are not obtained check for Defective Armature Dirty or Worn Brushes Dirty or Worn Commutator If defective components are found repair or replace component s and retest Motor Repair REMOVAL NOTE Power trim system does not have to be re moved from outboard to repair replace motor DISASSEMBLY Refer to Motor Disassembly on page 5B 28 to disassemble motor from pump CLEANING AND INSPECTION Insp...

Page 350: ...d of brush holder slot is 1 16 in 1 6mm or less Check distance with armature a 51350 a 1 16 in 1 6mm 2 To replace brush card remove metal connectors a a 51351 a Metal Connectors 3 Install new brush card 4 Crimp new metal connectors onto wires IMPORTANT If metal connectors are not insu lated with shrink tube bend metal connectors away from motor housing to prevent shorts ...

Page 351: ... Reassembly Manifold Installation IMPORTANT Install spring check valve and O ring into manifold Position components in place using sleeve to seat in place 50999 1 Install check valve components into pump manifold IMPORTANT Sleeve f is chamfered on I D on end opposite drilled cross hole Install spool g with O ring installed from chamfered end of sleeve to avoid possibility of damaging O ring on spo...

Page 352: ...in 11 5 N m 3 Secure power trim unit in soft jawed vise Reservoir Installation 1 Inspect O ring on bottom of reservoir for cuts or abrasions Replace as required a 53960 a O ring 2 With O ring aligned in groove in bottom of reser voir install reservoir on manifold 3 Secure reservoir to manifold with 4 bolts and washers Torque bolts to 70 lb in 8 0 N m a a 53959 a Bolts and Washers Torque to 70 lb i...

Page 353: ...nd cap screws to 13 lb in 1 5 N m a b b 53946 a End Cap b Screws 4 Torque to 13 lb in 1 5 N m 3 Place drive shaft into oil pump 4 Install lubricated O ring to base of reservoir 5 Install lubricated O rings and E clip to manual release valve a c b 51196 a E Clip b O ring c Manual Release Valve 6 Insert manual release valve into manifold and tighten snuggly Back release valve out 3 turns maximum all...

Page 354: ...3 Slide end cap onto trim rod a 51146 a End Cap 4 Apply Loctite 271 92 809820 to threads of trim rod and install rod piston Tighten piston securely using spanner wrench 1 4 in x 5 16 in long peg 51146 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 d e f a c b 51147 a Screw 3 b Plate c O ring d Ball 5 e Seat...

Page 355: ...I 3 Install lubricated O ring to memory piston and place into cylinder Push piston down to level of oil b a 51144 Memory piston must not contact end cap dur ing trim rod end cap installation a O ring b Memory Piston 4 Install trim rod into cylinder 51196 5 Tighten end cap assembly to cylinder securely using spanner wrench 1 4 in x 5 16 in long pegs c 51145 c Spanner Wrench 91 74951 6 Tighten manua...

Page 356: ...rive trim rod to the DOWN position Connect POSITIVE lead to BLUE wire and NEG ATIVE lead to GREEN wire and drive trim rod to the UP position Recheck fluid level add fluid as required and repeat cycle until fluid level remains at lower portion of threads Power Trim Unit Installation 1 Apply 2 4 C w Teflon 92 825407A12 to lower pivot pin bore and pivot pin surface 2 Position trim cylinder assembly B...

Page 357: ...n into its respective bore until seated a 53967 a Lower Cross Pin 6 Apply 2 4 C w Teflon 92 825407A12 to surface of upper pivot pin pivot pin bore and trim ram bore NOTE Install trim ram with cross hole located as shown If trim ram is installed reversed the trim send er if installed will not operate a b c d e f 53966 95 2 4 C With Teflon 92 825407A12 95 95 a Pivot Pin b Trim Ram Bore c Install Tri...

Page 358: ...ot Pin b Swivel Bracket c Trim Ram 8 Drive upper retaining pin in until seated a 52941 a Retaining Pin 9 Recheck fluid level 10 Power trim may now be operated to lower out board to desired position Trim system is self purging 11 Reconnect power trim leads to relays under igni tion cover 12 Reinstall spark plug leads to spark plugs 13 Reinstall cowls 14 Connect battery leads to battery terminals ...

Page 359: ...C 5 55331 MID SECTION POWER TRIM S N USA 0G360003 BEL 9934137 UP ...

Page 360: ...ower Trim Electrical System 5C 27 Page Power Trim System Removal 5C 29 Power Trim Disassembly 5C 30 Trim Motor Removal 5C 31 Pump and Components Removal 5C 31 Manifold Removal 5C 32 Shock Rod Removal 5C 32 Shock Rod Disassembly 5C 33 Memory Piston Removal 5C 35 Cleaning Inspection Repair 5C 36 Trim Motor Electrical Tests 5C 36 Reassembly 5C 37 O Ring and Seal Placement 5C 37 O Ring Sizes 5C 38 O R...

Page 361: ...90 830234R3 DECEMBER 1997 MID SECTION 5C 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 362: ...1 12 13 14 2 2 5 10 5 10 10 10 10 10 5 5 10 14 10 15 16 17 18 20 21 22 19 26 27 28 29 15 19 23 24 19 22 20 21 25 2 25 Liquid Neoprene 92 25711 2 110 Power Trim and Steering Fluid 92 90100A12 25 110 95 2 4 C With Teflon 92 825407A12 7 Loctite 271 92 809820 95 95 7 NOTE Lubricate all o rings and seals with Power Trim and Steering Fluid ...

Page 363: ...MANUAL RELEASE ASSEMBLY 10 1 MANIFOLD KIT 100 11 3 11 1 SCREW KIT MOTOR 80 9 0 12 1 DRIVE SHAFT 13 1 FILTER KIT 14 1 P O CHECK ASSEMBLY KIT 1 O RING KIT COMPLETE TRIM 15 2 GROOVE PIN 16 1 ANCHOR PIN 17 1 SHAFT 18 2 SCREW M6 x 25 USA 0G437999 BEL 9926999 BELOW 35 4 0 19 2 RELAY 20 2 BUSHING 21 2 GROMMET 22 2 BRACKET 23 1 HARNESS ASSEMBLY USA 0G437999 BEL 9926999 BELOW 24 1 HARNESS ASSEMBLY USA 0G43...

Page 364: ...5C 4 MID SECTION 90 830234R3 DECEMBER 1997 Notes ...

Page 365: ...eservoir pump and trim cylinder The remote control or trim panel is equipped with a switch that is used for trimming the outboard up and down and for tilting the outboard for shallow water operation at slow speed or for trailering The out board can be trimmed up or down while engine is under power or when engine is not running ...

Page 366: ...P a b w c u v t h d e f g i 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...

Page 367: ... 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 368: ... i j k 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 T...

Page 369: ...f 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 pressure avail able will not be able to overcome the propeller thrust limiting the trim range to below the pressure relief ori fice When the engine rpm s fall or if engine is not in forward gear the oil pres...

Page 370: ... h g i 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 T...

Page 371: ...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 372: ... k l g 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 T...

Page 373: ...uit suction port 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 outb...

Page 374: ...f g i 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 Rel...

Page 375: ...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 376: ...j i e 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 R...

Page 377: ...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 378: ... t h d 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...

Page 379: ...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 380: ...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 rod will position the engine at the desired trim angle within the 20 maximum trim range The Power Trim system is designed so the en gine cannot be trimmed beyond the 20 maximum trim angle as long as engine RPM is ab...

Page 381: ...e is running While operating up circuit the cylinder rod will continue to tilt the outboard to a full up position for trailering 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 by...

Page 382: ...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 383: ...complete 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 Testing complete Debris and or shock ball hang up identi fied Replace piston rod assembly Trim system holds reverse thrust Testing complete Trim will not hold reverse thrust Remove PO check valve assembly inspect O ...

Page 384: ...ction seat assembly Remove suction seat as sembly and inspect for debris and or damage Debris and or damage identified Trim system holds reverse thrust Testing complete Trim will not hold reverse thrust Suction seat assembly appears O K Clean and reinstall suction seat as sembly Trim system holds reverse thrust Testing complete ...

Page 385: ...ief 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 Testing 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 Testing complete Remove PO check valve assembly inspect O rings and seals for dam...

Page 386: ...lace 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 ap pears rough and or debris found in cylin der Trim leaks down Trim system does not leak down Testing complete ...

Page 387: ...WHT BLU WHT RED DN UP GRN WHT BLU WHT RED GRN WHT or GRN BLU WHT or PUR 1 3 2 4 GRN 14 BLK RED BLK LT GRN WHT LT BLU WHT a Trim Switch Remote Control Mounted b Trim Switch Panel Mounted c Fuse Holder d Solenoid e Cowl Switch f Trim Pump Motor g Up Relay h Down Relay i Battery a b c c d e f g h i BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN PUR PURPLE RED RED TAN TAN VIO VIOLET WHT WHITE YEL YEL...

Page 388: ... the Trim Switch DOWN does operate 1 Open wire between Wire Connection 2 and Solenoid 2 Faulty Cowl Switch 1 Check for a 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 for a...

Page 389: ... support with tilt lock pin a 55464 a Tilt Lock Pin 2 Disconnect the power trim wire harness and re move clamp a b 55264 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 390: ... drive out lower pivot pin a 51144 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 a b 55263 a Reservoir Cap b Manual Release Valve ...

Page 391: ...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 re pla...

Page 392: ...al c Filter d Suction Seat Assembly Manifold Removal 1 Remove two 2 screws to remove manifold from cylinder a 51146 a Screw 2 2 Remove tilt relief components a b c d 51008 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 393: ... rod piston a b c 51143 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 a b c d 51147 a Spring 5 b Seat 5 c Ball 5 d O ring CAUTION When removing shock piston spanner wrench must have 1 4 in x 5 16 in long pegs to avoid damage to shock piston 5 Place shock rod into soft jawed vise and apply heat to loosen piston using ...

Page 394: ...piston as an as sembly 9 Clean shock and components with compressed air 10 Remove inner O ring from shock rod piston a b 51199 a Shock Piston b O ring 11 Remove cylinder end cap assembly from shock rod 12 Inspect shock If wiper located in cap has failed to keep rod clean replace wiper 13 Place end cap on clean work surface 14 Remove rod wiper inner O ring and outer O ring b a c 51145 a Rod Wiper b...

Page 395: ...valve 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 a a b c 55466 a Adaptor Air Hose b Memory Piston Exit c Shop Rag 2 Remove O ring from memor...

Page 396: ...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 397: ...90 830234R3 DECEMBER 1997 MID SECTION 5C 37 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 398: ...5C 38 MID SECTION 90 830234R3 DECEMBER 1997 O Ring Sizes 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 ...

Page 399: ...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 400: ... 51199 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 have 1 4 in x 5 16 in 6 4mm x 8mm long pegs to avoid damage to shock rod piston 6 Apply Loctite Grade 271 to threads on shock rod 7 Install shock rod piston 8 Tighten shock rod piston securely using spanner wre...

Page 401: ... 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 cont...

Page 402: ...gines or a b c d 51008 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 Ring 2 b Dowel...

Page 403: ... 100 lb in 11 3 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 9 N m a b a Screw 3 Torque to 70 lb in 7 9 N m b Suction Seat Assembly ...

Page 404: ... c d e b a Plug 2 Torque to 120 lb in 13 6 N m b Spring 2 c Check Valve Poppet 2 d Seat 2 e Spool Reservoir Motor Installation 1 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 0 N m b d e a c f a Screw 4 Torque to 80 lb in 9 0 N m b Reservoir c ...

Page 405: ...tion Repeat for three times 5 Connect the positive lead to the GREEN trim motor 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 w Teflo...

Page 406: ...ower Pivot Pin 5 Using a suitable punch drive lower dowel pin into its hole until seated a 51148 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 a c b 51148 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 flushed with s...

Page 407: ...be Pin 9 Install sacrificial aluminum anode to reservoir bracket placing ground strap between bracket and anode as shown a c b 55465 a Sacrificial Anode b Ground Strap c Bracket 10 Route trim harness through clamp bracket and cowling a 55264 a Trim Harness 11 Secure trim harness with clamp as shown a a Clamp ...

Page 408: ...5 D MID SECTION SHOCK ABSORBER ...

Page 409: ...5D 0 MID SECTION 90 830234R3 DECEMBER 1997 Table of Contents Page Removal 5D 1 Inspection and Repair 5D 2 Installation 5D 3 ...

Page 410: ...m T Fitting between SUPPORT TOOL Use a metal rod 5 16 diameter to make support tool a a Drill Holes for Retaining Clips b c c a 53983 a Tilt Lock Lever b Support Tool c Retaining Clips 2 To remove tilt pin when straight cross pin is installed use a punch and hammer to drive out tilt pin shearing cross pin and remove halves of sheared cross pin 3 To remove tilt pin when headed cross pin is installe...

Page 411: ...er is pressurized with gas Do not disassemble unless fluid is leaking from shock absorber NOTE A pressurized shock absorber makes tilting of the engine easier than a non pressurized shock absorber If the shock absorber leaks fluid it can be rebuilt by installing Shock Absorber Repair Kit P N 41760A2 however the shock absorber will no long er be pressurized and the force needed to tilt the en gine ...

Page 412: ...lower mount bracket as shown and reinstall anode plate Secure anode with 2 bolts and washers Torque bolts to 60 lb in 6 8 N m a 17256 a Cross Pin a 17258 a Bolts Torque to 60 lb in 6 8 N m 3 Reinstall shock absorber assembly between clamp brackets and secure shock assembly to clamp brackets with 6 bolts and lockwashers 3 each clamp bracket Torque bolts to 30 lb ft 40 7 N m b a 17244 a Bolts Torque...

Page 413: ...5 E MID SECTION MANUAL TILT ...

Page 414: ...E 16 Manual Tilt System Removal 5E 17 Manual Tilt System Disassembly 5E 18 Accumulator Removal 5E 18 Shock Rod Removal 5E 19 Page Shock Rod Disassembly 5E 20 Valve Block Removal 5E 22 Memory Piston Removal 5E 22 Valve Block Disassembly 5E 23 Reassembly O Ring and Seal Placement 5E 24 Actual O Ring Sizes 5E 25 O Ring Description and Sizes 5E 26 Manual Tilt System Cleaning and Inspection 5E 27 Manua...

Page 415: ...90 830234R3 DECEMBER 1997 MID SECTION 5E 1 Special Tools 1 Spanner Wrench P N 91 74951 2 Lock Ring Pliers P N 91 822778A3 ...

Page 416: ...5E 2 MID SECTION 90 830234R3 DECEMBER 1997 Manual Tilt Assist Components 1 2 3 4 5 6 7 8 9 10 2 2 5 7 10 10 7 7 10 7 10 8 7 7 Loctite 271 92 809820 ...

Page 417: ...SCRIPTION lb in lb ft N m 1 TRIM PUMP ASSEMBLY 1 1 SHOCK ROD ASSEMBLY 2 1 O RING REBUILD KIT Cylinder 3 1 MEMORY PISTON ASSEMBLY 4 1 CYLINDER ASSEMBLY 5 1 SCREW AND SEAL KIT 6 1 ACCUMULATOR ASSEMBLY 7 1 VALVE BODY ASSEMBLY 8 1 CAM KIT 9 1 VELOCITY VALVE KIT 10 1 CHECK SYSTEM REPAIR KIT 1 O RING KIT ...

Page 418: ... l 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 419: ...fer 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 up and out Oil above the shock piston exits the cylinder l through an interconnect ing passage along side of the cylinder and returns into the manifold g Inside the manifold the oil flows past the groove in the surg...

Page 420: ... 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 421: ...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 422: ... 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 423: ...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 424: ...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 425: ...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 426: ... 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 427: ...closed 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 wi...

Page 428: ...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 429: ...E 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 it s original running position ...

Page 430: ...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 a c b 51143 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 431: ...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 a b 51143 a Link Rod b Accumulator 3 Position piece of wood under transom bracket instead of tilt lock for acce...

Page 432: ...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 433: ...lace accumulator a 51143 a Plunger 7 Once accumulator is removed remove O ring conical spring steel ball and plunger a b c d 51145 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 434: ...uires any other 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 a b c 51143 a Screw 3 b Plate c Shock Rod Piston 3 Remove check ball components from shock rod piston 4 Remove O ring a b c d 51147 a Spring 5 b Seat 5 c Ball 5 d O ring ...

Page 435: ...k rod a b 51146 51146 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 a b 51199 a Shock Piston b O ring 11 Remove cylinder end cap assembly from shock rod 12 Inspect shock If wiper locat...

Page 436: ...m cylinder using one of two methods a Using lock ring pliers a Craftsman P N 4735 or Snap on P N SRP4 a 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 dam...

Page 437: ...tainer plug and components 2 Remove hydraulic oil transfer valve plugs and components 51142 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 438: ... 809820 95 2 4 C With Teflon 92 825407A12 1 2 5 4 14 6 9 8 7 10 3 12 11 13 7 95 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 439: ...90 830234R3 DECEMBER 1997 MID SECTION 5E 25 Actual O Ring Sizes 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 ...

Page 440: ...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 441: ...matic 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 e f g 95 2 4 C W...

Page 442: ...icated O ring and screw plug Torque screw plugs to 75 lb in 8 5 N m e d c b a 51142 a Plunger 2 b Steel Ball 2 c Spring 2 d O ring 2 e Screw Plug 2 Torque to 75 lb in 8 5 N m Valve Block Installation 1 Install lubricated O rings and dowel pins 1 a b 51148 a O ring 2 b Dowel Pin 2 2 Install valve block to shock rod cylinder Insert screws to shock rod cylinder and torque to 100 lb in 11 3 N m a c b ...

Page 443: ...onto rod as shown 51146 CAUTION When installing shock rod piston spanner wrench must have 1 4 in x 5 16 in 6 4mm x 8mm long pegs to avoid damage to shock rod piston 6 Apply Loctite Grade 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 pisto...

Page 444: ... jawed vice 2 With manifold cam lever closed Up Position fill cylinder and manifold to top with Quicksilver Power trim and steering fluid or ATF automatic transmission fluid Let bubbles disperse 3 Install lubricated O ring to memory piston 4 Using lock ring pliers Craftsman P N 4735 or Snap on P N SRP4 set memory piston in top of cylinder then open cam lever Down Position and push memory piston do...

Page 445: ... 61 0 N m Close cam lever up Position 51145 8 Open and close cam lever watching for bubbles coming from accumulator check ball hole When bubbles stop fill accumulator opening to top with fluid Grease threads on accumulator and open ing with 2 4 C with Teflon Start accumulator in threads and open cam lever Down Position Torque accumulator to 35 lb ft 47 5 N m b a 95 2 4 C With Teflon 92 825407A12 9...

Page 446: ...etaining Tool 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 a b c d e a c a Plate Obtain Locally b Threaded Rod 3 8in x 13in 9 5mm x 330 2mm c Plate Obtain Locally d Hole 3 8in 9 5mm Diameter e Hole 3 8in 9 5mm Diameter ...

Page 447: ...f not available use automotive ATF automatic transmission fluid IMPORTANT Fluid level must remain above ac cumulator opening during bleeding process c a a b e d 50447 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 s...

Page 448: ...umulator 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 remove tilt assembly from oil and secure in soft jawed vise Torque accumulator to 35 lb ft 47 5 N m 50433 ...

Page 449: ... its hole a b 95 2 4 C With Teflon 92 825407A12 95 51148 a Lower Pivot Pin b Lower Dowel Pin 3 Reinstall manual tilt system bottom first Recon nect release valve link rod 2 1 a 51144 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 a 51147 a Lower Pivot Pin 5 Using a punch drive lower dow...

Page 450: ...n is flush with swivel 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 posit...

Page 451: ...A 6 791 H LOWER UNIT GEAR HOUSING ...

Page 452: ...djustment and Replacement 6A 17 Page Reassembly 6A 18 Forward Gear Bearing Race 6A 18 Shift Shaft 6A 18 Bearing Carrier Reassembly 6A 19 Forward Gear Reassembly 6A 21 Propeller Shaft Reassembly 6A 22 Drive Shaft Wear Sleeve Installation 6A 22 Lower Drive Shaft Bearing Race Installation 6A 23 Oil Sleeve Installation 6A 24 Upper Drive Shaft Bearing Installation 6A 24 Forward Gear Lower Drive Shaft B...

Page 453: ... 0 48mm Backlash Indicator Tool 91 78473 Mark 4 2 0 4 0 psi 14 28 kPa 10 0 15 0 psi 69 103 kPa MODEL 100 115 125 Gear Ratio Gearcase Capacity Lubricant Type Forward Gear Number of Teeth Pinion Gear Number of Teeth Pinion Height Forward Gear Backlash Water Pressure 750 RPM Idle 6000 RPM WOT 2 07 1 22 5 fl oz 655ml Quicksilver Gear Lube Premium Blend 29 Spiral Bevel 14 Spiral Bevel 0 025 in 0 64mm P...

Page 454: ...tallation Tool 91 13945 3 Oil Seal Driver 91 13949 4 Bearing Race Tool 91 14308A1 5 Bearing Installation 91 14309A1 6 Wear Sleeve Installation Tool 91 14310A1 7 Bearing Preload Tool 91 14311A2 8 Mandrel 91 15755 73815 9 Backlash Indicator Tool 91 19660 1 4 cyl 19660 1 10 Mandrel 91 31106 11 Oil Seal Driver 91 31108 ...

Page 455: ...river Rod 91 37323 74184 17 Mandrel 91 37350 18 Puller Jaws 91 46086A1 19 Driver Shaft Holding Tool 91 56775 20 Dial Indicator 91 58222A1 21 Backlash Indicator Tool 91 78473 3 cyl 22 Puller Bolt 91 85716 23 Dial Indicator Adaptor Kit 91 83155 24 Bearing Puller Assembly 91 83165M 25 Bearing Installation Tool 91 855875 56783 From Bearing Removal and Installation Kit 91 31229A7 ...

Page 456: ...1 32 33 34 35 36 37 38 39 40 41 3 5 5 13 95 2 4 C With Teflon 92 825407A12 95 95 95 95 7 7 7 7 87 7 7 Loctite 271 92 809820 92 92 Loctite 7649 Primer 92 809824 95 95 7 7 1 7 87 Quicksilver Gear Lubricant 92 19007A24 6A 4 LOWER UNIT 90 830234R3 DECEMBER 1997 Gear Housing Drive Shaft ...

Page 457: ...NION GEAR 17 1 NUT 70 95 0 18 1 SHIFT CAM 19 1 TAPERED ROLLER BEARING 20 1 SHIM ASSEMBLY 1 DRIVE SHAFT ASSEMBLY LONG 32 IN 21 1 DRIVE SHAFT ASSEMBLY LL 34 1 2 IN 1 DRIVE SHAFT ASSEMBLY X LONG 37 IN 22 1 WEAR SLEEVE ASSEMBLY 23 1 COVER ASSEMBLY 24 1 GASKET 25 1 OIL SEAL LOWER 26 1 OIL SEAL UPPER 27 1 GASKET 28 1 GASKET 29 1 WATER PUMP ASSEMBLY 30 1 FACE PLATE 31 4 SCREW M6 x 30 60 6 8 32 1 SEAL 33 ...

Page 458: ... Anti Corrosion Grease 92 78376A6 7 Loctite 271 92 809820 87 Quicksilver Gear Lubricant 92 19007A24 95 2 4 C With Teflon 92 825407A12 6A 6 LOWER UNIT 90 830234R3 DECEMBER 1997 Gear Housing Propeller Shaft ...

Page 459: ...G 49 1 CLUTCH 50 1 CROSS PIN 51 1 SPRING 52 1 PROPELLER SHAFT 53 1 REVERSE GEAR 54 1 BEARING CARRIER ASSEMBLY 55 1 O RING 56 1 ROLLER BEARING 57 1 OIL SEAL INNER 58 1 OIL SEAL OUTER 59 1 ROLLER BEARING 60 1 THRUST WASHER 61 1 THRUST BEARING 62 2 STUD M8 x 48 100 135 63 2 WASHER DESIGN II 64 2 NUT 25 34 0 65 2 SCREW DESIGN I 25 34 0 66 2 WASHER 67 1 THRUST HUB ASSEMBLY THESE PARTS ARE NOT 68 1 PROP...

Page 460: ...er Removal WARNING To prevent accidental engine starting remove and isolate spark plug leads from spark plugs before removing gear housing 1 Remove and isolate spark plug leads from spark plugs 2 Shift engine into forward gear 3 Tilt engine to full Up position 4 Remove fasteners 5 Remove locknut and washer 6 Remove gear housing a b 53992 a Fasteners 2 each side b Locknut and Washer Disassembly Dra...

Page 461: ...out leaking down Pouring a portion of the gear lubricant into a glass jar and allowing the lubricant to settle will allow any water in the lube to separate and settle to the bottom of the jar 4 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 If gearcase is rebui...

Page 462: ... Rubber portion of impeller is not bonded to impel ler hub 8 Remove plate and gasket 9 Replace plate if groove s other than impeller sealing bead groove in plate are more than 0 030 in 0 76mm deep b a c 19219 a Plate b Gasket c Impeller Sealing Groove 10 Remove bolts and washers a 19217 a Bolts and Washers 6 each 11 Remove water pump base a 19226 a Water Pump Base 12 Remove and discard seals a 191...

Page 463: ...6 a Bearing Carrier b Puller Jaws 91 46086A1 c Puller Bolt 91 85716 d Thrust Hub e Propeller Shaft 4 Lift reverse gear thrust bearing and thrust wash er from bearing carrier 5 Replace reverse gear if gear teeth or clutch teeth on reverse gear are chipped or worn If reverse gear must be replaced pinion gear and sliding clutch should be inspected for damage 6 Replace thrust bearing and thrust washer...

Page 464: ...229A7 a c b 51264 a Bearing b Mandrel 91 26569 c Driver Rod 91 37323 9 Remove if not removed with bearing in Step 8 propeller shaft seals and bearing carrier O ring a 51263 a O ring 10 Remove spring a 51876 a Spring 11 Apply constant pressure to cam follower to pre vent cam follower assembly from ejecting from propeller shaft while pushing cross pin out of clutch dog a b 51800 a Cross Pin b Cam Fo...

Page 465: ...or is bent more than 0 009 in 0 23mm Prop shaft trueness should be measured with a dial indi cator with prop shaft on V blocks b b c a 51877 a V Blocks b Bearing Surfaces c Measure with Dial Indicator at This Point Pinion Gear Drive Shaft and Forward Gear Model Drive Shaft Holding Tool 50 Bigfoot 4 Stroke 91 56775 60 Bigfoot 91 817070 75 90 100 115 125 91 56775 1 Hold drive shaft using Drive Shaft...

Page 466: ...earing Race following c b a 51119 a Forward Gear Bearing b Universal Puller Plate 91 37241 c Mandrel 8 Replace drive shaft if splines are worn or twisted 9 If bearing surface is damaged replace drive shaft and corresponding bearing IMPORTANT Do not tighten vise against drive shaft 10 If wear sleeve is deeply grooved allowing water to enter gear case remove and discard sleeve using Universal Puller...

Page 467: ...7 a Upper Drive Shaft Bearing b Sleeve c Puller Assembly 91 83165M IMPORTANT Upper drive shaft bearing sleeve must be removed prior to oil sleeve removal Re fer to Upper Drive Shaft Bearing preceding Oil Sleeve 1 Remove oil sleeve if necessary using Puller As sembly 91 83165M with suitable jaws a b 19222 a Oil Sleeve b Puller Assembly 91 83165M IMPORTANT Upper drive shaft bearing sleeve and oil sl...

Page 468: ...e tool 91 14308A1 b c a 19171 a Race b Shim s c Bearing Race Tool 91 14308A1 Shift Shaft 1 Remove shift shaft coupler and nylon spacer b a 53925 a Shift Shaft Coupler b Spacer 2 Remove bolts a 53926 a Bolts NOTE Gearcase should be in FORWARD for easi est removal of shift shaft 3 Remove shift shaft bushing and shift shaft b a 53927 a Bushing b Shift Shaft ...

Page 469: ...ment IMPORTANT The trim tab is now painted and does NOT aid in protecting the drive shaft hous ing and gear housing from galvanic corrosion corrosion and pitting of metal surfaces Side anodes now provide protection Do not paint or place protective coating on the side anodes or corrosion protection function will be lost 1 Replace trim tab if damaged Mark location of old trim tab on anti ventilation...

Page 470: ...sembled Bearing Carrier Shift Shaft 1 Apply Loctite 271 on O D of new seal 2 Press seal into shift shaft bushing until seal is seated against shoulder 3 Install new O ring 4 Apply 2 4 C with Teflon on O ring and I D of seal d b c a 7 Loctite 271 92 809820 7 53930 a Seal Lip faces UP b Bushing c Surface d O ring 5 Assemble components as shown a b c 53928 a Shift Shaft b E Clip c Shift Shaft Bushing...

Page 471: ...4 0 N m a 7 Loctite 271 92 809820 7 53926 a Bolts Torque to 35 lb in 4 0 N m Bearing Carrier Reassembly 1 Lubricate O D of bearing and bearing carrier bore with Quicksilver 2 4 C w Teflon 2 Protect lip on forward side of bearing carrier us ing Bearing Installation Tool 91 13945 3 Press propeller shaft needle bearing number side toward mandrel into carrier until bearing bottoms out c b a 95 2 4 C W...

Page 472: ...aring carrier using Bearing Installation Tool 91 13945 Apply Loc tite 271 on O D of new seal Press seal into carri er until tool bottoms b c a a 7 7 Loctite 271 92 809820 21041 a Seal b Oil Seal Driver 91 31108 c Bearing Installation Tool 91 13945 8 Install O ring 9 Lubricate O ring with 2 4 C w Teflon Lubricate seal lips with 2 4 C w Teflon Lubricate outside diameter of bearing and bearing carrie...

Page 473: ...ress tapered bearing onto gear press only on inner race of bearing a b 51869 87 Quicksilver Gear Lubricant 92 19007A24 87 a Mandrel 91 37350 b Bearing Lubricate I D with Quicksilver Gear Lubricant 2 Inspect reverse gear end of clutch to determine the number of jaws Refer to chart following for tool end selection Model Installation Tool End Stamped Bearing Position 3 Jaw Re verse Clutch 91 856875 3...

Page 474: ...Quicksilver Gear Lubricant 92 19007A24 87 a Forward Gear Bearing Installer 91 856875 b Needle Bearing Numbered Side Toward Installer Tool Propeller Shaft Reassembly 1 Install components into propeller shaft in se quence shown b d c a 19154 a Spring b Guide Block c 3 Metal Balls d Cam Follower Hold in Place With Quicksilver 2 4 C w Teflon 2 Install cross pin b a 51800 a Apply Pressure in This Direc...

Page 475: ...ctite 271 92 809820 a Ring 3 Insert sleeve into holder Component of Wear Sleeve Installation Tool 91 14310A1 b a a 19169 a Sleeve b Holder 4 Press sleeve onto drive shaft using Wear Sleeve Installation Tool 91 14310A1 continue press ing until surface contacts surface b c b d a 19166 a Drive Shaft b Wear Sleeve Installation Tool c Surface d Surface 5 Remove excess Loctite from assembled shaft ...

Page 476: ...re Lost or a New Gear Housing is Being Assembled Start With 0 025 in 0 635mm Shim s b Bearing Race c Mandrel 91 13780 d Mandrel 91 13781 e Threaded Rod 91 31229 f Nut 11 24156 From Bearing Installation Tool 91 14309A1 From Bearing Removal and Installation Kit 91 31229A7 Oil Sleeve Installation 1 Install oil sleeve with tab positioned as shown b a 53934 a Oil Sleeve b Tab Upper Drive Shaft Bearing ...

Page 477: ...d Installation Kit 91 31229A7 Forward Gear Lower Drive Shaft Bearing Pinion Gear and Drive Shaft Installation Model Drive Shaft Holding Tool 50 Bigfoot 4 Stroke 91 56775 60 Bigfoot 91 817070 75 90 100 115 125 91 56775 1 Install components in sequence shown d e d b c f a 19175 7 Loctite 271 92 809820 7 a Forward Gear Bearing Work Quicksilver gear lube into bearing rollers b Lower Drive Shaft Tapere...

Page 478: ...oad Tool 91 14311A2 over drive shaft in sequence shown g h h e f c b a d a Adaptor Bearing surfaces clean and free of nicks b Thrust Bearing Oiled and able to move freely c Thrust Washer Clean and free of nicks and bends d Spring e Nut Threaded all the way onto bolt f Bolt Held snug against spring g Sleeve Holes in sleeve must align with set screws h Set Screw 2 Tightened against drive shaft bolt ...

Page 479: ...shown a 22067 a Gauging Block 8 Remove tool taking care not to change gauging block position and tighten collar retaining bolt 9 Insert tool into forward gear assembly position proper numbered flat from chart of gauging block under pinion gear MODEL GEAR RATIO PINION GEAR TEETH REVERSE GEAR TEETH USE FLAT NO 50 Bigfoot 4 stroke 13 30 8 60 Bigfoot 60 Sea pro 60 Marathon 13 30 8 75 thru 90 3 Cylinde...

Page 480: ...4643 7 Loctite 271 92 809820 7 a Feeler Gauge b Gauging Block c Pinion Gear d Bearing Race DETERMINING FORWARD GEAR BACKLASH NOTE Read entire procedure before attempting any change in shim thickness 1 Obtain correct pinion gear depth refer to Deter mining Pinion Gear Depth preceding 2 Install Bearing Preload Tool 91 14311A2 on drive shaft refer to Determining Pinion Gear Depth preceding 3 Install ...

Page 481: ... be noticed at propeller shaft 8 Dial Indicator registers amount of backlash which must be between specification shown in chart MODEL DIAL INDICATOR MINIMUM READING MAXIMUM 50 Bigfoot 4 Stroke 0 012 in 0 30mm 0 019 in 48mm 60 Bigfoot 0 012 in 0 30mm 0 019 in 48mm 75 thru 90 3 Cylinder 0 012 in 0 30mm 0 019 in 48mm 100 115 125 4 Cylinder 0 015 in 0 38mm 0 022 in 0 55mm 9 If backlash is less than th...

Page 482: ...g from being inadvertently dislodged as the bearing carrier as sembly is installed in the gear housing 21043 a b c d e a Bearing Carrier Assembly b PVC Pipe c Tab Washer d Prop Shaft e Propeller Nut 3 Lubricate O ring and mating surfaces with 2 4 C w Teflon 4 Install bearing carrier and propeller shaft into housing with the word TOP located on flange to ward top of housing a b c 95 95 95 2 4 C Wit...

Page 483: ...a Seal Teflon Coated Lip Flat Brownish Color Lip faces toward Power Head b Spring Faces Toward Power Head c Oil Seal Driver 91 13949 3 Place seal on shorter shoulder side of Oil Seal Driver 91 13949 with seal lip toward shoulder 4 Apply Loctite 271 on O D of seal press seal into water pump base until tool bottoms 5 Lubricate lip of each seal with Quicksilver 2 4 C w Teflon a b c c 7 95 51553 7 Loc...

Page 484: ... I D of cover with Quicksilver 2 4 C w Teflon 11 Rotate drive shaft clockwise and push cover down over impeller 12 Install cover 13 If water tube seal stayed on water tube inside of drive shaft housing when gear housing was re moved pull water tube seal from water tube 14 Lubricate I D of water tube seal with Quicksilver 2 4 C w Teflon and install as shown a b c 7 95 95 7 Loctite 271 92 809820 95 ...

Page 485: ...ousing With Lubricant NOTE Gear housing lubricant capacity is 22 5 fl oz 665 2ml WARNING If gear housing is installed on engine to avoid ac cidental starting disconnect and isolate spark plug leads from spark plugs before working near the propeller CAUTION Do not use automotive grease in the gear hous ing Use only Quicksilver Gear Lube or Quicksil ver Super Duty Lower Unit Lubricant 1 Remove any g...

Page 486: ...le reinstalling FILL screw 7 Remove lubricant tube from Fill hole install Fill screw and gasket Torque Fill screw to 60 lb in 6 8 N m Gearcase Installation WARNING Disconnect and isolate spark plug leads from spark plugs before installing gear housing onto drive shaft housing Failure to follow this warn ing could result in accidental engine starting and possible injury 1 Position outboard shift li...

Page 487: ...ft and damage either or both the power head and gear housing Top of drive shaft is to be wiped free of lubricant 6 Apply a light coat of Quicksilver 2 4 C w Teflon onto drive shaft splines 7 Apply a light coat of Quicksilver 2 4 C w Teflon on gear case shift shaft splines and upper shift shaft splines Do not use lubricant on ends of shift shafts 8 Install components as shown in appropriate photo P...

Page 488: ...ld ratchet when propeller shaft 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 lever in reverse gear Resistance should be felt when propeller shaft is rotated in either direction IMPORTANT If shift operation is not ...

Page 489: ...6 B LOWER UNIT JET DRIVE ...

Page 490: ...Drive Shaft Bearing 6B 11 Impeller Removal and Installation 6B 11 Steering Pull Adjustment 6B 13 Impeller Clearance Adjustment 6B 13 Page Worn Dull Impeller 6B 13 Flushing the Cooling System 6B 13 Liner Replacement 6B 14 Jet Drive Removal 6B 14 Bearing Carrier Removal 6B 15 Bearing Carrier Disassembly 6B 16 Bearing Carrier Reassembly 6B 17 Installing Lower Seals 6B 17 Installing Upper Seals 6B 17 ...

Page 491: ...90 830234R3 DECEMBER 1997 LOWER UNIT 6B 1 Notes ...

Page 492: ...6B 2 LOWER UNIT 90 830234R3 DECEMBER 1997 65 Jet Drive 3 cylinder 1 2 3 4 5 6 10 11 12 13 14 15 16 19 20 21 22 23 24 25 26 27 28 29 6 19 95 2 4 C With Teflon 92 825407A12 95 4 4 7 8 9 17 18 ...

Page 493: ... LINER S N 0G582705 UP 9 1 DRIVESHAFT 10 1 SLEEVE 11 1 NUT Drive Tight 12 1 KEY 13 8 SHIM impeller 14 1 TAB WASHER 15 6 SCREW 312 18 x 1 160 18 1 16 4 SCREW 1 4 20 x 875 S N 0G582704 BELOW 70 7 9 16 4 SCREW 1 4 20 x 875 S N 0G582705 UP 144 12 16 5 17 6 STUD 312 x 18 x 1 81 144 12 16 5 18 6 NUT S N 0G582705 UP 144 12 16 6 19 2 PIN dowel 20 2 SCREW 1 4 20 x 625 70 7 9 21 1 SCREW 312 18 x 1 25 160 18...

Page 494: ...6B 4 LOWER UNIT 90 830234R3 DECEMBER 1997 80 Jet Drive 4 cylinder 1 2 3 4 5 6 10 11 12 13 14 15 16 19 20 21 22 23 24 25 26 27 28 29 6 19 95 2 4 C With Teflon 92 825407A12 95 4 4 8 9 7 7 7 17 18 ...

Page 495: ... 1 DRIVESHAFT 7 1 HOUSING intake 8 1 LINER S N 0G582705 UP 9 1 DRIVESHAFT 10 1 SLEEVE 11 1 NUT Drive Tight 12 1 KEY 13 8 SHIM impeller 14 1 TAB WASHER 15 6 SCREW 312 18 x 1 160 18 1 16 4 SCREW 1 4 20 x 875 S N 0G582704 BELOW 70 7 9 16 4 SCREW 312 x 18 x 1 IN S N 0G582705 UP 144 12 16 5 17 6 STUD 312 x 18 x 1 81 144 12 16 6 18 6 NUT S N 0G582705 UP 144 12 16 5 19 2 PIN dowel 20 2 SCREW 1 4 20 x 625...

Page 496: ... Neoprene 92 25711 2 7 95 25 25 25 7 Loctite 271 92 809820 REF TORQUE REF NO QTY DESCRIPTION lb in lb ft N m 1 1 REV LIMITER 2 1 HARNESS adaptor rev Limiter 3 1 HARNESS adaptor 4 2 SCREW M6 x 50 70 7 9 5 1 GREASE KIT 6 1 GASKET 7 1 GASKET 8 1 WATER PUMP ASSEMBLY 9 1 FACE PLATE 10 4 SCREW M6 x 1 x 30 60 6 8 11 1 SEAL 12 1 KEY 13 1 IMPELLER ...

Page 497: ...s considerably more depth than one which is planing on the surface of the water It is important therefore to use sufficient horsepower and not to overload your boat beyond its ability to plane See the following table Engine Horsepower Selection 0 20 40 60 80 100 120 140 160 180 200 220 500 6 8 1000 12 14 16 2000 22 24 26 28 18 3000 32 34 36 HP Gross Weight Lbs The following table is based on exper...

Page 498: ...n air and cause cavitation cavitation will cause the engine to overspeed in spurts and reduce thrust This condition should be avoided by proper height set ting 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 Make a horizontal line a on the tran...

Page 499: ...in order to provide a scooping angle on the water intake Tilting the outboard out beyond a vertical position reduces the scoop angle and can cause im peller slippage and cavitation If the angle of the boat transom does not allow the drive shaft to be posi tioned vertical a Wedge kit should be installed behind the transom brackets to increase the tilt in angle NOTE Slight cavitation in sharp turns ...

Page 500: ...y or death 1 Attach shift cable a to the shift cam b with flat washer and locknut as shown Tighten locknut against the flat washer then back off the locknut 1 4 turn 2 Place remote control handle into full forward position 3 Adjust the brass barrel c on the shift cable so that roller d is at the full end of travel bottom in the shift cam when the remote control is in full forward 4 Attach the bras...

Page 501: ...he vent hose a onto the grease fitting after greasing After 30 hours of operation pump in extra grease to purge out any moisture Visually inspecting the purged grease at this time will give you an indication of conditions inside the bearing housing A gradual increase in moisture content indicates seal wear If the grease begins to turn dark dirty gray the drive shaft bearing and seals should be ins...

Page 502: ...en the impeller 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 side ways a small amount in order to center the liner 03 in 8mm 3 After setting the impeller height tighten the im peller nut snug with a wrench Secure impeller nut by bending tab...

Page 503: ... the impeller edge and liner If adjustment is required refer to Impeller Removal and Installation 03 in 8mm a a Shims Worn Dull Impeller Enlarged View a b c a Sharpen to a 1 32 in 8mm radius by removing material from bottom side only b Leading edge c Do Not sharpen or alter the top side lifting angle The intake of gravel through the pump can round off and wear the leading edges on the impeller Som...

Page 504: ... to tap or press the liner into the water intake housing to locate the liner for installation of the remaining bolts Torque bolts to 120 lbs in 13 6 N m 4 Grind off the ends of any bolts that may extend beyond the inner liner surface Jet Drive Removal 1 Shift outboard to NEUTRAL N position and dis connect the shift linkage 2 Remove spark plug leads to prevent engine from starting 3 Remove the wate...

Page 505: ...b 54165 a Bolts 4 b Bolt 1 Bearing Carrier Removal NOTE Water pump assembly must be removed be fore bearing carrier can be removed 1 Remove 4 bolts 2 each side securing water pump assembly and remove water pump a b c d e f g h i a 54166 a Bolts 2 each side b Seal c Housing d Impeller e Key f Gasket g Plate h Gasket i Spacer ...

Page 506: ... bump the impel ler end of the drive shaft against a wooden block causing the bearing carrier to slide down off the bearings 4 Press the ball bearings c off the drive shaft Leave the bearing thrust ring e located in the drive shaft groove above the upper ball bearing unless damaged 5 Remove the seals and spiral retaining rings from the bearing carrier and the upper seal housing d 6 Clean all parts...

Page 507: ...tched ends of the retaining ring must straddle this vent hole a a b d c e a O rings b Retaining Ring c Spring Seal d Retaining Ring e Outer Seal Installing Upper Seals 1 Install spiral retaining ring a into the inner ring groove of the upper seal housing 2 Spread a film of grease around the inside bore of the seal surface before pressing in the seals 3 Press in the garter spring seal b against the...

Page 508: ...Lubricate the seals and inside bore of the bearing carrier a 2 Place the drive shaft b impeller end facing up into a vise 3 Heat the bearing carrier a until it feels warm to the touch 4 Place the bearing carrier a onto the drive shaft Square up the inner bore with the ball bearings and push the bearing carrier down until it bot toms out against the bearing It may be neces sary to lightly tap beari...

Page 509: ...ld be necessary to push in the housing 4 Install the beveled snap ring a beveled side facing up into the ring groove Make sure the snap ring is fully seated into groove Bearing Carrier Installation 1 Install the bearing carrier into the jet drive Se cure carrier in drive with 4 bolts Torque bolts to 70 lb in 7 9 N m Fill carrier with grease using the grease gun supplied with the jet drive If using...

Page 510: ...ES UP and impel ler key IMPORTANT If impeller being installed has been previously used and vanes have taken a set DO NOT INSTALL THE IMPELLER WITH THE VANES REVERSED FROM THEIR PREVIOUS SET AS VANE BREAKAGE WILL OCCUR SHORTLY AFTER UNIT IS RETURNED TO SERVICE 3 Install impeller NOTE Apply a light coat of 2 4 C w Teflon to inside of pump cover to ease installation of cover over im peller 4 Install ...

Page 511: ...m a a Bolt and Washer Torque to 22 5 lb ft 30 5 N m 5 Grease the drive shaft shear key and impeller bore Place the plastic sleeve a inside the im peller b and install impeller shear key c shims d nut retainer e and impeller nut f Turn the nut tight on the shaft to remove any play between the impeller and shaft If the tabs on the retainer do not line up with the flats on the nut remove the nut and ...

Page 512: ...arance around the impeller to make sure the water intake housing is centered and not rubbing against the liner Torque mounting bolts to 120 lbs in 13 5 N m NOTE If the outboard is used in salt water apply Quicksilver Anti Corrosion Grease around the entire mounting flange on the water intake housing and also to the threads on the six mounting bolts 94 Anti Corrosion Grease 92 78376A6 94 9 Refer to...

Page 513: ...A 7 50099 ATTACHMENTS CONTROL LINKAGE THROTTLE SHIFT LINKAGE ...

Page 514: ...xtension Couplers 7A 14 Transom Mounted Ride Guide Attaching Kit Installation 73770A1 7A 14 Attaching Kit Installation 7A 14 Maintenance Instructions 7A 16 Page Ride Guide Steering Cable Attaching Kit Installation 92876A3 7A 17 Dual Cable Single Outboard 7A 17 Super Ride Guide Steering Kit Installation 7A 17 Mounting Bracket Installation 7A 18 Steering Cable Mounting Tube Installation 7A 18 Instal...

Page 515: ...n 92 825407A12 95 51890 a Seal IMPORTANT Before installing steering cable into tilt tube lubricate seal and entire cable end with Quicksilver 2 4 C w Teflon 3 Insert steering cable end thru engine tilt tube and secure steering cable to tilt tube with steering cable attaching nut as shown Torque nut to 35 lb ft 47 5 N m 4 Install rubber bumper on inside of locking sleeve then install locking sleeve...

Page 516: ...ORTANT The distance from each engine s centerline to the side of transom opening must be a minimum of 16 40 6cm This kit contains all necessary parts to connect both engines to Ride Guide Steering cables for 22 1 2 57 2cm thru 24 1 2 62 2cm refer to Figure 14 page 7A 14 for additional extension couplers Cable Routing Types Use 1 or 2 following to route steering cables 1 Parallel cable routing Cabl...

Page 517: ...Left Rotary Steering Right b Steering Cables Install so that Both Cables Will Push and pull Together Figure 1 Super Ride Guide Steering Kits Installed WARNING Before using engine after installation of cables check to see that boat will turn right when steer ing wheel is turned right and that boat will turn left when wheel is turned left Do this check at all tilt angles and thru full range of turn ...

Page 518: ...h Quicksilver 2 4 C w Teflon c Insert ends of steering cables thru engine tilt tube and cable mounting tube Figure 4 Thread steering cable attaching nuts onto tubes hand tight a b d c b c 16977 a Steering Cables Routed Down Starboard Side b See Figure 7 for Correct Parts Sequence c See Figure 8 for Correct Parts Sequence d Seal Figure 4 Steering Cables and Steering Link Rods Installed NOTE Torque ...

Page 519: ... pivot bolt holes in steering eyes is the same distance as between centers of threaded pivot holes in engine steering arms Ex posed steering eye threads should be equal at both ends of coupler and must not extend out of coupler more than 2 3 4 70mm WARNING Both steering eyes must be threaded into cou pler 3 4 19mm minimum Thread length of steering eye is 3 1 2 89mm so exposed thread must not exten...

Page 520: ...nd of steering cable when adding tension to steering system to remove slack Failure to adjust tube this way may result in hard steering if one engine is tilted up while operating boat Steering System Tension Adjustment Parallel Routed Steering Cables IMPORTANT After this Ride Guide Attachment Kit is installed there must be proper tension in the steering system Not enough tension will cause slack p...

Page 521: ...taching nuts Figure 13 to 35 lbs ft 47 5 N m 4 Install rubber bumpers on inside of locking sleeves then install a locking sleeve over each steering cable attaching nut and secure with cot ter pin Spread ends of cotter pin Be sure to install cotter pin so that it is located in between at taching nut and grease fitting Figure 13 e a d b c 51890 a Steering Cable Attaching Nut Torque to 35 lbs ft 47 5...

Page 522: ... as shown in Figure 2 Be sure that long er threaded end of tube is toward steering cable attaching nut side of engine 3 Temporarily adjust tube so that longer threaded end of tube is aligned with outward edge of tran som bracket DO NOT tighten adjustment nuts at this time c b a 50130 a Tube Mounting Bracket b Nuts c Locking Retainers Bend Ends Up and Against Flat on Bolts Figure 1 Tube Mounting Br...

Page 523: ...ring cable mounting tube 5 8 16mm from end of tube Figure 4 b a c d e 50180 a 5 8 from End of Tube b Place Mark on Tube Here c Nylon Spacer d O ring e Cap Figure 4 Seal Installation Sequence a 50180 a Mark Made in Step 5a Figure 5 Steering Cable Seal Installed b Slide plastic spacer O ring and cap from kit over steering cable Figure 4 c Thread cap onto steering cable mounting tube up to mark made ...

Page 524: ...n Figure 7 Tight en self locking nut until it seats DO NOT exceed 120 lbs in 13 6 N m then back nut off 1 4 turn Steering Eyes and Coupler Installation 1 Position engines so that they are facing straight forward Distance between centers of threaded pivot bolt holes in engine steering arms must be equal to distance between propeller shaft cen ters 2 Lubricate inside of rubber sleeves Figure 8 and s...

Page 525: ... coupler to top side front holes of steering arm with pivot bolts and locknuts as shown in Figures 6 and 9 IMPORTANT With steering eyes and coupler installed and before tightening pivot bolts check engine alignment Distance between pivot bolts centers and distance between propeller shaft centers must be equal for proper steering If ad justment is necessary remove pivot bolt from one steering eye a...

Page 526: ...just Nuts Torque to 35 lbs ft 47 5 N m b Tab Lockwashers Bend Against Flat on Each Nut Figure 11 Adjustment Nuts Secured with Lock tabs d c b a e 51888 a Steering Cable Attaching Nut Torque to 35 lbs in 47 5 N m b Locking Sleeve Provided with Ride Guide Steering Cables c Cotter Pin d Grease Fitting e Cable Guide Tube Figure 12 Steering Cables Fastened to Tubes 50101 Figure 13 Attachment Kit Instal...

Page 527: ... replace plastic caps 5 Operate boat per Check trim tab position as fol lows preceding to check trim tab setting Read just trim tabs if necessary Maintenance Instructions Maintenance inspection is owner s responsibility and must be performed at intervals specified following Normal Service Every 50 hrs of operation or 60 days whichever comes first Severe Service Every 25 hrs of operation or 30 days...

Page 528: ...Coupler and 12 in 30 5cm Coupler Connected together with coupler link rod a b c d e a 18 in 45 7cm Coupler 97932 3 b 15 in 38 1cm Coupler 97932 2 c 12 in 30 5cm Coupler 97932 1 d 9 in 22 9cm Coupler 97932 4 e Coupler Link Rod 98181A1 51890 a a b c a Couplers Connected Together b Lockwashers c Coupler Link Rod Torque to 20 lbs ft 27 0 N m into End of Each Coupler Figure 14 Couplers Connected Togeth...

Page 529: ...to steering cable tube Place tab washer over Ride Guide yoke then insert cable tube thru tab washer and yoke Install second cable tube jam nut onto cable tube but do not tighten at this time Figure 3 5 Position transom attaching kit on transom as fol lows a Determine centerline of outboard then mea sure 15 in 38 1cm over from this centerline and draw a vertical line on transom Figure 1 b Position ...

Page 530: ...h Ride Guide cable to outboard steering arm using the proper Clevis Kit Installation instructions for clevis are with Clevis Kit 4 Adjust 2 large jam nuts on cable tube of attaching kit so that steering wheel is in normal straight driving position with outboard in straight running position Torque each jam nut to 35 lbs ft 47 5 N m then bend a side of tab washer against flat of each jam nut Figure ...

Page 531: ...ies Guide to de termine correct length of steering cables and remote control cables IMPORTANT Steering cables and remote control cables MUST BE THE CORRECT LENGTH sharp bends on too short cables result in kinks too long cables require unnecessary bends and or loops Both conditions place extra stress on the cables CAUTION With this kit installed the upper outboard mounting bolts MUST BE installed s...

Page 532: ...Cable Mounting Tube b Tab Washer c Adjustment Nut Steering Cable Mounting Tube Installation IMPORTANT Spacers b must be installed be tween outboard swivel bracket and mounting bracket for steering cable mounting tube to pro vide proper spacing between steering cables Secure mounting bracket for steering cable mount ing tube on to swivel bracket of outboard b e d d c a 51891 a Mounting Bracket for ...

Page 533: ...unting tube with Quicksilver 2 4 C w Teflon Verify rubber O ring seal located in out board tilt tube is lubricated a 95 2 4 C With Teflon 92 825407A12 51890 95 a Seal Insert steering cable ends thru outboard tilt tube and cable mounting tube Thread steering cable attach ing nuts on to tubes hand tight Torque steering cable attaching nuts only after final steering adjustments have been made a d b c...

Page 534: ...upler and nylon insert locknut Tighten locknut un til it seats DO NOT exceed 120 Ib in 13 6 N m of torque then back nut off 1 4 turn Lubricate ball joint in steering link rod with 2 4 C w Teflon Secure link rod to outboard steering arm us ing special washer head bolt 10 14000 provided and nylon insert locknut as shown Torque special bolt to 20 Ib ft 27 0 N m then torque locknut to 20 Ib ft 27 0 N ...

Page 535: ...her against a flat on each nut b c c a 51887 a Steering Cable Mounting Tube b Adjustment Nuts Torque to 35 lb ft 47 5 N m c Tab Lock Washer Bend Against Flat on Each Adjustment Nut Tighten steering cable attaching nuts of each steer ing cable to a torque of 35 Ib ft 47 5 N m Install rubber bumpers a on inside of each locking sleeve b a b 51889 Install locking sleeves over steering cable attaching ...

Page 536: ...icate transom end of steering cables thru grease fittings with 2 4 C w Teflon Lubricate exposed portion of cable ends with 2 4 C w Teflon 4 Lubricate pivot point of steering link rod and ball joint of link rod steering coupler with 2 4 C w Teflon 5 Inspection and lubrication of steering head assembly rotary or straight rack should be performed once each year by your Authorized Dealer or whenever s...

Page 537: ...e Control A Quicksilver Ignition Key Choke Assembly equipped with a warning horn must be used with this engine This warning horn is necessary for the en gine warning system a a Warning Horn Connecting Remote Wiring Harness To The Engine 1 Pull up the cowl seal a and remove the star board side rubber grommet b b a 2 Take hold of the engine connector c and install the remote wiring harness plug d Co...

Page 538: ... the throttle cable The shift cable is the first cable to move when the remote control handle is moved into gear Shift Cable Installation 1 Pull up the cowl seal and remove the port side rubber grommet a a 2 Position the remote control and outboard into neutral 3 Slide shift actuator b toward the rear of engine reverse gear until resistance is felt Measure distance c between mounting stud and barr...

Page 539: ...Position the remote control handle into neutral detent 2 Position adjustment screw a against the stop 3 Adjust throttle cable barrel b so the barrel will be able to slip into the retainer when the cable end is on the mounting stud and there is a slight pre load against the stop 4 Check preload on throttle cable by placing a thin piece of paper between adjustment screw and stop Preload is correct w...

Page 540: ...torque 2 more top speed 3 greater boat stability but 4 will cause more prop break loose which may be particularly noticeable when planing off or with load b These broken lines represent the extremes of known suc cessful outboard mounting height dimensions c This line may be preferred to determine outboard mounting height dimension if maximum speed is the only objective d This line may be preferred...

Page 541: ...st has a minimum lift capacity of at least 500 lbs 227 kg BEFORE lifting engine 1 Remove cowling from engine and plastic cap from center of flywheel Thread lifting eye into fly wheel hub a minimum of 5 turns Replace plastic cap after installation 2 Connect hoist minimum lift capacity of 500 lbs 227 kg to lifting eye Lift engine and place on boat transom b a 25929 a Lifting Eye C 91 75132 b Hoist I...

Page 542: ...ocknut 4 Req WARNING Before operating motor s MUST BE SECURED to boat transom with four 1 2 diameter bolts and locknuts as follows 2 bolts must be installed thru upper mounting holes and 2 bolts thru lower mounting holes as shown in step 5 Installation must be water tight and engine should be checked for tightness on the transom during op eration Failure to bolt engine to transom using 4 bolts and...

Page 543: ...7 B ATTACHMENTS CONTROL LINKAGE TILLER HANDLE ...

Page 544: ...s 7B 2 Co Pilot 7B 6 Tiller Arm Shift Lever Removal 7B 7 Tiller Handle Disassembly 7B 10 Tiller Arm Reassembly 7B 13 Tiller Handle Shaft Bracket Installation 7B 16 Shift Link Rod Installation and Adjustment to Engine 7B 20 Throttle Cable Installation and Adjustment to Engine 7B 21 Co Pilot Installation 7B 21 ...

Page 545: ...90 830234R3 DECEMBER 1997 ATTACHMENTS CONTROL LINKAGE 7B 1 Notes ...

Page 546: ...7B 2 ATTACHMENTS CONTROL LINKAGE 90 830234R3 DECEMBER 1997 Steering Handle Components 95 2 4 C With Teflon 92 825407A12 Soapy Water Solution Obtain Locally 7 Loctite 271 92 809820 ...

Page 547: ...CREW 3 5 IN Drive Tight 7 4 SCREW 1 2 IN Drive Tight 8 1 CLAMP 9 2 SCREW M5 x 40 40 4 5 10 1 NUT Hand Tighten 11 1 THROTTLE HANDLE STOP SWITCH KIT 12 1 STOP SWITCH 13 1 THROTTLE TUBE 14 1 SCREW 10 16 x 3 8 IN Hand Tighten 15 1 GRIP 16 2 CLIP 17 1 NUT 40 54 2 18 1 CONDUIT 19 1 GUIDE TUBE 20 1 BARREL 21 1 SET SCREW 9 1 0 22 1 CABLE 23 1 GUIDE 24 1 ANCHOR 25 2 SET SCREW Drive Tight 26 1 SCREW 27 1 CA...

Page 548: ...4R3 DECEMBER 1997 Steering Handle Components 1 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 21 95 2 4 C With Teflon 92 825407A12 95 95 7 10 7 Loctite 271 92 809820 ...

Page 549: ...P SWITCH ASSEMBLY 17 1 LANYARD 18 1 RETAINER 19 1 SCREW M8 x 1 25 x 50 110 12 4 20 1 TAB WASHER 21 2 BUSHING 22 1 SHIFT LEVER BLACK 22 1 SHIFT LEVER GRAY 23 1 WASHER 24 1 STUD 3 8 24 x 1 1 8 25 1 KNOB 26 1 SHIFT ROD 27 1 ROD END 28 1 BUSHING 29 1 WASHER 30 1 COTTER PIN 31 1 DETENT ASSEMBLY 32 1 TRIM SWITCH POWER TRIM 33 1 NUT Drive Tight 34 1 STOP HARNESS 35 1 CABLE MANUAL 36 1 PLUG 37 1 HORN 38 1...

Page 550: ... DESCRIPTION lb in lb ft N m 1 CO PILOT REPLACEMENT ROD LENGTH 1 1 PILOT ROD is 12 5 8 IN 1 CO PILOT REPLACEMENT ROD LENGTH 1 1 PILOT ROD is 14 5 8 IN 2 1 NUT ASSEMBLY 3 1 SCREW 4 1 KNOB PRONG 5 1 ROD 6 1 BUSHING 7 2 WASHER 8 2 NUT Tighten Until Nut Seats Do Not Exceed 120 lb in 13 6 N m then back off 1 4 turn ...

Page 551: ...51620 a Locking Nut b Washer c Shift Cable d Throttle Cable e Latch f Anchor Bracket 4 Remove cotter key washer bushing and shift link rod from shift lever a b c d 51624 a Cotter Key b Washer c Bushing d Shift Link Rod 5 Remove access cover from underneath tiller handle bracket a b 51626 a Access Cover b Screws 6 Disconnect key switch lanyard stop switch and tiller stop switch leads at bullet conn...

Page 552: ...om bracket a b c d e a 51626 a Nuts b Key Switch c Trim Switch d Clip e Lanyard Stop Switch 8 Remove harness retainer from outboard Remove grommet from tiller bracket a b 51624 a Harness Retainer b Grommet 9 Remove electrical panel access cover Disconnect switch harness from engine harness plug Disconnect PURPLE bullet connector a b c d 51621 a Access Cover b Bolts c Switch Harness d PURPLE Lead ...

Page 553: ...itch trim switch and their har nesses from tiller bracket 12 Remove plug from tiller handle bracket a 51608 a Plug 13 Remove bolt and nut hidden from tiller handle bracket a b 51625 a Bolt b Nut Hidden 14 Remove tiller handle 2 nylon bushings stainless bushing and 2 flat washers from bracket a b c b d e 51606 a Tiller Handle b Nylon Bushings 2 c Stainless Steel Bushing d Flat Washers 2 e Bolt ...

Page 554: ...ever 16 Remove spring and detent pin from bracket a b 51621 a Spring b Detent Pin 17 Bend tabs on tab washers away from nuts secur ing bracket to steering arm Remove nuts tab washers and bracket from steering arm a b c 51621 a Tab Washer b Nut c Steering Arm Tiller Handle Disassembly 1 Using a flat tip screwdriver carefully pry push rubber grip off tiller handle a b 51603 a Grip b Tiller Handle ...

Page 555: ...ch harness and remove screw from harness J clip a b 51603 a Ties b Screw 4 Remove stop switch and twist grip from tiller handle 51603 5 Remove throttle cable anchor screws and re move cable guide a b a 51602 a Anchor Screws b Throttle Cable Guide 6 Remove allen screw from brass barrel and re move barrel a b 51602 a Allen Screw b Brass Barrel ...

Page 556: ...le 9 Remove cover plate and gasket from tiller handle 10 Remove bolt from throttle friction assembly a b c d e c 51604 a Cover Plate b Gasket below plate c Screws d Throttle Friction Assembly e Bolt 11 Remove throttle arm gear assembly and friction device from tiller handle Slide gear cover and friction device off of throttle arm a b c d 51604 a Throttle Arm b Gear Assembly c Friction Device d Gea...

Page 557: ...arm with new drift pin a b 51602 a Gear b Drift Pin 2 Apply a light coat of 2 4 C w Teflon to gear teeth and inside of gear cover 3 Slide cover and friction device onto throttle arm a b c d 95 2 4 C With Teflon 92 825407A12 51604 95 a Throttle Arm b Gear c Throttle Friction Device d Cover 4 Install throttle arm assembly into tiller arm 5 Torque friction device attaching bolt to 40 lb in 4 5 N m a ...

Page 558: ...8 Insert throttle cable CURVED END FACING UP into tiller handle gear assembly while rotating til ler arm COUNTERCLOCKWISE a 51604 a Gear Drift Pin FACES UP 9 Retract throttle cable into gear assembly until approximately 17 in 43 cm extends from the til ler arm a 51604 a Cable Extends 17 in 43 cm 10 Slide stainless steel conduit over throttle cable and thread into tiller arm until lightly seated Ro...

Page 559: ...s Guide hole should face up a b c b 51602 a Cable Guide b Screws 2 c Hole faces up 13 Position throttle arm slot to face stop harness exit hole in tiller handle Route stop switch harness through twist grip into throttle arm and out through side of tiller handle a b c d e 51602 a Slot b Exit Hole c Harness d Twist Grip e Stop Switch 14 Secure twist grip to throttle arm with attaching screw a 51603 ...

Page 560: ...oapy water solution to rubber grip will ease installation a b 51603 a Ridges b Grooves under handle Tiller Handle Shaft Bracket Installation 1 Slide bracket over steering arm studs Secure bracket to arm with retained nuts and NEW tab washers Torque nuts to 40 lb ft 54 0 N m Bend locking tabs against flats of nuts a b c 51621 a Tab Washer b Nut c Steering Arm 2 Install retained spring and detent pi...

Page 561: ...with bolt and NEW tab washer Align tab washer with slot in bracket Torque bolt to 110 lb in 12 4 N m a b 51620 a Bolt b Tab Washer 5 Install two nylon bushings into tiller handle Install stainless bushing into bracket Install tiller handle to bracket using bolt and two washers a b c d e 51622 a Nylon Bushings b Stainless Bushing c Bolt d Washer Thin e Washer Thick 6 Secure bolt in place with nut T...

Page 562: ...ss retainer a b c d 51624 a Harness Retainer b Switch Harness c Tiller Bracket d Grommet 9 Reinstall lanyard stop switch in bracket and se cure with clip a b c d e a 51626 a Nuts b Key Switch c Lanyard Stop Switch d Trim Switch e Clip 10 Reconnect key switch trim switch and remote stop switch leads at bullet connectors Secure harness BLACK ground lead and tiller handle re mote stop switch ground l...

Page 563: ...onnector a b 51623 a Switch Harness Plug b PURPLE Bullet Connector 13 Reconnect trim switch leads to trim solenoids a b 51622 a BLUE WHITE Lead b GREEN WHITE Lead 14 Reinstall electrical panel access cover and secure with screws Torque screws to 30 lb in 3 4 N m a b 51621 a Panel b Screws Torque to 30 lb in 3 4 N m 15 Reconnect shift link rod to shift lever using bush ing washer and cotter key a b...

Page 564: ...he nylon washer then back off the locknut 1 4 turn 6 Check shift link rod adjustment as follows a Place engine shift lever in F Forward posi tion Propeller should not rotate in a COUN TERCLOCKWISE direction If propeller does rotate COUNTERCLOCKWISE length of shift link rod must be reduced and Step a repeated b Place engine shift lever in N Neutral posi tion Propeller should rotate freely without d...

Page 565: ...d of throttle lever against idle stop Apply small amount of Loctite 271 to threads of allen screw and tighten until snug then an additional 1 8 turn Lock barrel in place with barrel retainer c d 51620 c Barrel Receptacle d Barrel Retainer 5 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 te...

Page 566: ...tion loosen to decrease friction WARNING If wing nut is tightened it may not be possible to steer the outboard in an emergency a b c d e f g h i g 51626 95 2 4 C With Teflon 92 825407A12 95 95 a Steering Friction Device b Wing Nut c Pilot Rod d Spacer Hidden Place in hole of steering handle assem bly e Steering Handle Assembly f Link Rod Short bend of link rod to steering handle g Flat Washer 2 h ...

Page 567: ...51605 8 MANUAL STARTER ...

Page 568: ...R 90 830234R3 DECEMBER 1997 Table of Contents Page Notes 8A 1 Starter Assembly Manual 8A 2 Rewind Starter Disassembly 8A 4 Cleaning and Inspection 8A 5 Rewind Starter Reassembly 8A 5 Adjusting Rewind Spring Tension 8A 6 ...

Page 569: ...90 830234R3 DECEMBER 1997 MANUAL STARTER 8A 1 Notes ...

Page 570: ...97 Starter Assembly Manual 1 2 3 4 5 6 7 8 10 9 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 8 10 11 12 13 14 15 16 16 15 17 13 9 9 14 2 Cycle Outboard Oil 92 826666A24 95 2 4 C With Teflon 92 825407A12 95 14 ...

Page 571: ...NTERLOCK CABLE 19 1 SCREW 10 16 x 5 8 Drive Tight 20 1 WASHER 21 1 COTTER PIN 22 1 SCREW Drive Tight 23 1 PUSH NUT DESIGN I 24 1 WASHER DESIGN II 25 1 COTTER PIN 1 STARTER HOUSING S N 0G242650 BELOW 1 STARTER HOUSING S N 0G242651 UP 26 1 SPRING 27 1 INTERLOCK LEVER S N 0G242650 BELOW 27 1 INTERLOCK LEVER S N 0G242651 UP 28 1 CAM 29 1 RETAINER 30 3 SCREW 10 16 x 1 31 1 FELT PAD DESIGN I 32 1 WASHER...

Page 572: ...pe 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 b a c c c c 51606 a Retaining Clip b Screw c Bolts 4 4 Remove cam retainer a b a 51605 a Screws 2 b Retainer 5 Remove cam and spring a b 51605 a Cam b Spring 6 Remove starter sheave a b 51605 a Starter Sheave b Screw 7 Spring is ...

Page 573: ...pring for wear or damage 5 Inspect starter rope for wear 6 Replace components as necessary Rewind Starter Reassembly WARNING When reassembling rewind starter SAFETY GLASSES must be worn in case rewind spring uncoils out of the housing 1 Install spring cover assembly into sheave a 51607 a Spring Assembly 2 Install starter sheave to housing and secure in place with screw Torque to 135 lb in 15 3 N m...

Page 574: ... housing Never back off sheave less than one full turn 2 Route starter rope thru rope guide in housing Tie a slip knot in rope approximately 12 in 305 mm from end of rope 51605 NOTE Check operation of rewind and rewind ten sion before outboard installation 3 Install rewind starter to engine 4 Pull starter rope thru bracket handle and rope retainer Secure rope retainer with knot in rope b c c c c d...

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