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Mercury 15XD, Service Manual

The Mercury 15XD is a high-performance outboard motor that offers exceptional power and reliability. For complete maintenance and repairs, make sure to access the free Service Manual download available exclusively at manualshive.com. This comprehensive manual provides step-by-step instructions, diagrams, and troubleshooting tips to ensure optimal performance for your Mercury 15XD.

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MANUAL STARTER

Page 8-6

90-826883R2 JUNE 1998

2. Snap interlock link rod into lower lock lever.

b

56803

a

a -

Link Rod

b -

Lock Lever

CAUTION

Push filter straight up when installing. Turning or cocking filter may break fuel

line connection on filter.

3. Push ball of fuel filter into socket of rope guide. DO NOT turn or cock fuel filter.

53247

b

a

a -

Filter

b -

Guide

Summary of Contents for 15XD

Page 1: ...ions B Maintenance C General Information D Outboard Installation Section 2 Electrical A Ignition B Charging Starting System C Timing Synchronizing Adjusting D Wiring Diagrams Section 3 Fuel System A Carburetor Fuel Pump B Emissions Section 4 Powerhead Section 5 Mid Section Section 6 Lower Unit A Gear Housing B Jet Drive Section 7 Attachments Control Linkage A Throttle Shift Linkage B Tiller Handle...

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

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

Page 4: ...1 A SPECIFICATIONS 90 826883R2 JUNE 1998 Page 1A 1 IMPORTANT INFORMATION Section 1A Specifications Table of Contents Master Specifications 1A 2 ...

Page 5: ...ECTING ROD Piston Pin End I D Crankpin End I D 0 897 in 22 78 mm 1 196 in 30 38 mm PISTON Piston Type O D at Skirt Standard Ring End Gap Aluminum 2 5583 2 5593 64 98 65 00 0 011 0 025 28 mm 64 mm PISTON DIA Dimension A at Right Angle 90 to Pis ton Pin 0 50 in 12 7 mm 2 5583 in 0005 in 64 98 mm 0127 mm Using a micrometer measure dimension A at location shown Dimension A should be 2 5583 in 0005 for...

Page 6: ...som Height Short Shaft Long Shaft 15 in 38 cm 20 in 51 cm FUEL SYSTEM Fuel Pump Type Recommended Gasoline Fuel Tank Capacity Operating Fuel Oil Ratio Integral Automotive Unleaded with a Minimum Pump Posted Octane Rating of 87 6 6 U S Gallons 50 1 OIL Recommended Oil Pre Mix 50 1 NMMA TC W II or TC W III 2 Cycle Outboard Oil STARTING SYSTEM Manual Start Rope Length Electric Start Ampere Draw cranki...

Page 7: ... Speed Maximum BTDC Running Stator High Speed Winding Stator Low Speed Winding Diode Test Ignition Coil Resistance Primary Secondary w o Boots Trigger Capacitor Discharge Ignition NGK BP8H N 10 0 040 in 1 0 mm 18 mm 1 2 4 2 B T D C Not Adjustable 1400 RPM 250 RPM 25 1 5500 RPM 28 B T D C 3000 200 R P M Set up timing of 28 B T D C will be retarded to 25 B T D C 5500 R P M 100 180 Ω RED BLK 2900 350...

Page 8: ... Turn 1 1 4 1 4 Turn 1 0 in 25 4 mm 0 044 in 1 12 mm 0 076 in 1 93 mm 0 076 in 1 93 mm 0 080 in 2 03 mm 0 076 in 1 93 mm 0 044 in 1 12 mm 0 076 in 1 93 mm 0 080 in 2 03 mm TIMING SPECIFI CATIONS 20 Jet 19941 2 THRU 1998 20 25 19941 2 THRU 1996 Electronic Spark Advance Idle 750 50 RPM In Forward Gear Fast Idle Speed Maximum BTDC Running Setup Timing 20 25 1997 AND NEWER 20 Jet 1999 AND NEWER Mechan...

Page 9: ...uel Filter 1B 5 Corrosion Control Anode 1B 6 Spark Plug Inspection 1B 7 Battery Inspection 1B 7 Fuse Replacement Electric Start Remote Control Models 1B 8 Lubrication Points 1B 8 Gear Case Lubrication 1B 10 Gear Case Lubricant Capacity 1B 10 Draining Gear Case 1B 10 Draining Gear Case 1B 11 Checking Lubricant Level and Refilling Gear Case 1B 11 Storage Preparations 1B 12 Fuel System 1B 12 Protecti...

Page 10: ...6883R2 JUNE 1998 Quicksilver Lubricant Sealant 1 Quicksilver Anti Corrosion Grease P N 92 78376A6 2 2 4 C Marine Lubricant with Teflon P N 92 825407A12 3 SAE 30W Motor Oil P N 92 97959 4 Quicksilver Gear Lubricant P N 92 19007A24 ...

Page 11: ...ours of Use or Once Yearly Whichever Occurs First 1 Lubricate all lubrication points Lubricate more frequently when used in salt water 2 Inspect and clean spark plugs 3 Check fuel line filter for contaminants 4 Check carburetor adjustments if required 5 Check corrosion control anodes Check more frequently when used in salt water 6 Drain and replace gear case lubricant 7 Lubricate splines on the dr...

Page 12: ...ment 1 Remove propeller refer to Propeller Replacement Install the flushing attachment so the rubber cups fit tightly over the cooling water intake holes CAUTION Never start or run your outboard even momentarily without water circulating through the cooling water intake in the gear case to prevent damage to the water pump running dry or overheating of the engine 2 Attach a water hose to the flushi...

Page 13: ...f the fuel sys tem Before servicing any part of the fuel system stop engine and disconnect the battery Drain the fuel system completely Use an approved container to collect and store fuel Wipe up any spillage immediately Material used to contain spillage must be disposed of in an ap proved receptacle Any fuel system service must be performed in a well ventilated area Inspect any completed service ...

Page 14: ... sight bowl Corrosion Control Anode Your outboard has a corrosion control anode installed to the gear case An anode helps protect the outboard against galvanic corrosion bysacrificing itsmetal tobe slowlyeroded instead of the outboard metals The anode requires periodic inspection especially in salt water which will accelerate the erosion To maintain this corrosion protection always replace the ano...

Page 15: ...park plug seats Install plugs finger tight and tighten 1 4 turn or torque to 20 lb ft 27 1 N m Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting ca pability IMPORTANT Read the safety and maintenance instructions which accompany your battery 1 Turn off the engine before servicing the battery 2 Add water as necessary to keep the battery full 3 ...

Page 16: ...ate and correct the cause of the overload If the cause is not found the fuse may blow again Replace the fuse with a fuse of the same rating Replace with a new SFE 20 AMP fuse Lubrication Points Lubricate Points 1 thru 6 with Quicksilver 2 4 C Marine Lubricant with Teflon or Special Lubricant 101 1 Steering Friction Adjustment Shaft Tiller Handle Models Lubricate fitting 2 Swivel Bracket Lubricate ...

Page 17: ...nt to steering cable when fully extended could cause steering cable to become hydraulically locked An hydraulically locked steering cable will cause loss of steering control possibly resulting in se rious injury or death 6 Steering Cable Grease Fitting If Equipped Rotate steering wheel to fully retract the steering cable end a into the outboard tilt tube Lubricate through fitting b Lubricate point...

Page 18: ...heck for the presence of water in the lubricant If water is present it may have settled to the bottom and will drain out prior to the lubricant or it may be mixed with the lubricant giving it a milky colored appearance If water is noticed have the gear case checked by your dealer Water in the lubricant may result in premature bearingfailure or in freezingtemperatures willturn toice anddamage the g...

Page 19: ...and vent plug b and drain lubricant a b Checking Lubricant Level and Refilling Gear Case 1 Place outboard in a vertical operating position 2 Remove vent plug from vent hole a 3 Place lubricant tube into the fill hole b and add lubricant until it appears at the vent hole a a b 4 Stop adding lubricant Install the vent plug and sealing washer before removing the lubricant tube ...

Page 20: ... on container into a separate container and mix with ap proximately one quart one liter of gasoline Pour this mixture into fuel tank 3 Place the outboard in water or connect flushing attachment for circulating cooling wa ter Run the engine for ten minutes to allow treated fuel to fill the fuel system Protecting External Engine Components 1 Lubricate all outboard components listed in the Inspection...

Page 21: ...er to drain out of outboard CAUTION If outboard is stored tilted up in freezing temperature trapped cooling water or rain water that may have entered the propeller exhaust outlet in the gear case could freeze and cause damage to the outboard Battery Storage 1 Follow the battery manufacturers instructions for storage and recharging 2 Remove the battery from the boat and check water level Recharge i...

Page 22: ...bmersion Special Instructions 1C 5 Propeller Selection 1C 6 Propeller Removal Installation 1C 7 Compression Check 1C 9 Painting Procedures 1C 10 Cleaning Painting Aluminum Propellers Gear Housings 1C 10 Decal Application 1C 11 Decal Removal 1C 11 Instructions for Wet Application 1C 11 Serial Number Location The Outboard serial number is located on the lower starboard side of the engine block A ser...

Page 23: ...rn is reflected in decreased boat speeds as much as 2 or 3 miles per hour 3 or 5 Km per hour in some cases Refer to previous chart Nothing will regain this speed for the boater but the coming of cool dry weather In pointing out the practical consequences of weather effects an engine running on a hot humid summer day may encounter a loss of as much as 14 of the horsepower it would produce on a dry ...

Page 24: ...ill increase the danger of the following wave splashing into the boat when coming off plane b Shifting weight to the front bow 1 Improves ease of planing off 2 Generally improves rough water ride 3 If excessive can make the boat veer left and right bow steer BOTTOM For maximum speed a boat bottom should be nearly a flat plane where it contacts the water and particularly straight and smooth in fore...

Page 25: ...e after the spark plug has fired Detonation creates severe shock waves in the engine and these shock waves often find or create a weakness The dome of a piston cylinder head gasket piston rings or piston ring lands piston pin and roller bearings A few of the most common causes of detonation in a marine 2 cycle application are as follows Over advanced ignition timing Use of low octane gasoline Prop...

Page 26: ...or throats alcohol will absorbed water Again rotate fly wheel 6 Turn engine over and pour alcohol into spark plug openings and rotate flywheel 7 Turn engine over place spark plug openings down and pour engine oil into throat of carburetors while rotating flywheel to distribute oil throughout crankcase 8 Again turn engine over and pour approximately one teaspoon of engine oil into each spark plug o...

Page 27: ...uide for a complete list of available propellers 1 Select a propeller that will allow the engine to operate at or near the top of the recom mended full throttle RPM range listed in Specifications preceding with a normal load Maximum engine speed RPM for propeller selection exists when boat speed is maximum and trim is minimum for that speed High RPM caused by an excessive trim angle should not be ...

Page 28: ...used from being struck by a rotating pro peller always shift outboard to neutral position and remove spark plug leads when you are servicing the propeller 1 Shift outboard to neutral position N N 2 Remove the spark plug leads to prevent engine from starting 3 Place a block of wood between gear case and propeller to hold propeller and remove propeller nut 4 Pull propeller straight off shaft If prop...

Page 29: ...ler shaft at the recommended maintenance intervals and also each time the propeller is removed 6 Flo Torque I Drive Hub Propellers Install forward thrust hub propeller rear thrust hub and propeller nut onto the shaft a b c d a Forward Thrust Hub b Propeller c Rear Thrust Hub d Propeller Nut 7 Flo Torque II Drive Hub Propellers Install forward thrust hub replaceable drive sleeve propeller rear thru...

Page 30: ... not differ by more than 15 see example chart below A reading below 120 psi might indicate a total engine wear problem Example of compression test differences Maximum psi Minimum psi 180 162 150 127 5 6 Compression check is important because an engine with low or uneven compression cannot be tuned successfully to give peak performance It is essential therefore that improper compression be correcte...

Page 31: ...ed that the listed materials be purchased from a local Ditzler Automotive Finish Sup ply Outlet The minimum package quantity of each material shown following is sufficient to refinish several gear housings Procedure 1 Wash gear housing with a muriatic acid base cleaner to remove any type of marine growth and rinse with water if necessary 2 Wash gear housing with soap and water then rinse 3 Sand bl...

Page 32: ...old decal 3 Clean decal contact area with a 1 1 mixture of isopropyl alcohol and water 4 Thoroughly dry decal contact area and check for a completely cleaned surface Instructions for Wet Application NOTE The following decal installation instructions are provided for a Wet installation All decals should be applied wet TOOLS REQUIRED 1 Plastic Squeegee 2 Stick Pin 3 Dish Washing Liquid Detergent wit...

Page 33: ...on 4 Flood area where the decal will be positioned with wetting solution 5 Position pre wetted decal on wetted surface and slide into position 6 Starting at the center of the decal lightly squeegee out the air bubbles and wetting solution with overlapping strokes to the outer edge of the decal Continue going over the decal surface until all wrinkles are gone and adhesive bonds to the cowl surface ...

Page 34: ...11 Tilt Pin Adjustment 1D 11 Placing Tilt Pin in Lower Holes 1D 11 Placing Tilt Pin in Upper Holes 1D 12 Trim Tab Adjustment 1D 12 Notice to Installer and Owner This manual as well as safety labels posted on the outboard use the following safety alerts to draw your attention to special safety instructions that should be followed DANGER DANGER Immediate hazards which WILL result in severe personal ...

Page 35: ...it must have a built in start in gear protection device Selecting Accessories For The Outboard Genuine Mercury Marine Quicksilver Accessories have been specifically designed and tested for your outboard Mercury Marine Quicksilver accessories are available from Mercury Marine dealers Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or...

Page 36: ...a a Anti Ventilation Plate 2 Place outboard on center line of transom 3 Tighten transom clamp handles 4 To prevent loss of outboard overboard fasten outboard by drilling two 5 16 in 7 9 mm holes through the transom using transom clamp holes as a template Fasten with two bolts flat washers and locknuts Use a marine waterproofing sealer in holes and around bolts to make the installation water tight ...

Page 37: ...ate the entire cable end a a Quicksilver 2 4 C Marine Lubricant with Teflon 2 Insert steering cable end thru outboard 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 a b a Cable End b Attaching Nut Torque to 35 lb ft 47 5 N m Steering Cable Seal 3 Place a mark on tilt tube 5 8 in 15 9mm from port end of tube Slide plastic ...

Page 38: ...sengagement of a steering 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 or death 1 Assemble steering link rod to steering cable with two flat washers d and nylon insert locknut b Part Number 11 34863 Tighten locknut b until it seats then back nut off 1 4 turn 2 Assemble stee...

Page 39: ...e control NOTE Install the shift cable before 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 Move the remote control handle into full reverse position 2 Place the engine shift lever a into reverse position toward rear while rotating pro peller The propeller shaft will not rotate in either direction when in ...

Page 40: ...er to the engine shift lever 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 forward to wide open throttle position 2 Install the throttle cable a onto the throttle pin b lock in place with retainer latch c 3 Move throttle lever g until tab e contacts throttle stop f Adjust the barrel on the ...

Page 41: ...o the control cables and install control cables barrel holder and rubber seal into the cable holder as shown 7 Lock the barrel holder in place with the cable retainer latch a b a Rubber Seal b Cable Retainer Latch Remote Wiring Harness Connection to Engine 1 Remove wire retainer from the bottom cowl a a Wire Retainer ...

Page 42: ...r grommet as shown 3 Plug the remote wiring harness into the engine wiring harness connector 4 Secure the connection together using retainer a b c d a Rubber Grommet b Remote Wiring Harness c Engine Harness Connector d Retainer 5 Fasten the remote wiring harness and battery cables into the bottom cowl rubber grommet with retainer a a Retainer ...

Page 43: ...g batteries a a Ground Cable Same Wire Size As Engine Battery Cable Connect Between Negative Terminals Propeller Installation WARNING If the propeller shaft is rotated while the engine is in gear there is the possibility that the engine will crank over and start To prevent this type of accidental engine starting and possible serious injury caused from being struck by a rotating pro peller always s...

Page 44: ...ng Tilt Pin in Lower Holes 1 Lower the bow 2 Result in quicker planing off especially with a heavy load or a stern heavy boat 3 Generally improve the ride in choppy water 4 Increase steering torque or pull to the right with the normal right hand rotation propel ler 5 In excess lower the bow of some boats to a point at which they begin to plow with their bow in the water while on plane This can res...

Page 45: ...e water sur face The trim tab can help compensate for this steering torque and can be adjusted within limits to reduce any unequal steering effort NOTE Trim tab adjustment will have little effect reducing steering torque if the outboard is installed with the anti ventilation plate approximately 2 inches 50mm or more above the boat bottom Operate boat at normal cruising speed with the outboard set ...

Page 46: ... Component Description 2A 7 Trigger Coil 2A 7 Stator 2A 8 Flywheel 2A 8 Ignition Coil 2A 9 Ignition Switch Box 2A 9 Electronic Spark Advance 2A 11 Ignition Test Procedures 2A 12 Direct Voltage Adapter DVA 2A 12 Ignition Troubleshooting 2A 13 Ignition Diagnostic Procedures 2A 13 Ignition Troubleshooting 2A 15 Electronic Spark Advance 2A 15 Tool Multimeter DVA Tester 91 99750A1 2A 15 Ignition Troubl...

Page 47: ...dels Mechanical Spark Advance Idle 750 50 RPM In Forward Gear Fast Idle Speed Maximum BTDC Running Stator High Speed Winding Stator Low Speed Winding Diode Test Ignition Coil Resistance Primary Secondary w o Boots Trigger Capacitor Discharge Ignition NGK BP8H N 10 0 040 in 1 0 mm 18 mm 1 2 4 2 B T D C Not Adjustable 1400 RPM 250 RPM 25 1 5500 RPM 28 B T D C 3000 200 R P M Set up timing of 28 B T D...

Page 48: ...JUNE 1998 Page 2A 3 Special Tools 1 DMT 2000 Digital Tachometer Multi meter P N 91 854009A1 2 Flywheel Holder P N 90 24937A1 3 Flywheel Puller P N 91 83164M 4 Flywheel Holder 91 52344 54964 5 Spark Gap Board 91 850439 55117 ...

Page 49: ...IGNITION Page 2A 4 90 826883R2 JUNE 1998 Ignition Electrical Components Dielectric Grease 92 823506 1 6 7 Loctite 271 92 809820 Liquid Neoprene 92 25711 2 25 A ALTERNATOR VERSION ONLY ...

Page 50: ... 20 25 USA S N 0G437999 BELOW BEL S N 9926999 BELOW 10 1 SWITCH BOX 20 25 USA S N 0G438000 thru 0G589999 BEL S N 9927000 thru 9973099 10 1 SWITCH BOX 20 25 USA S N 0G590000 UP BEL S N 9973100 UP 11 2 SCREW M5 x 20 12 3 SCREW M5x 8x35 hex washer head Drive Tight 13 1 SCREW ground wire Drive Tight 14 1 CLIP 15 1 TRIGGER ASSEMBLY 16 1 TERMINAL BLOCK 17 2 SCREW terminal block 10 16x5 8 IN COMMERCIAL 1...

Page 51: ...located in the switch box As the flywheel continues to rotate the magnets in the center hub pass the trigger coil creating AC voltage This voltage turns on one of the two electronic switches SCR in the switch box A positive voltage pulse turns on the SCR switch associated with cylinder 1 a negative voltage pulse turns on the SCR switch associated with cylinder 2 The SCR switch discharges the store...

Page 52: ...R USA 0G438000 AND ABOVE BELGIUM 09927000 AND ABOVE 20 JET OUTBOARDS SERIAL NUMBER USA 0G760300 AND ABOVE BELGIUM 09017000 AND ABOVE The spark timing is changed advanced retarded by rotating the trigger coil which changes the trigger coil position in relation to the magnets in the center hub of the fly wheel The stop switch or ignition switch shorts the output of the stator to ground to stop the e...

Page 53: ... Low Speed Winding b High Speed Winding Flywheel b a c 57129 a b d e e a Center Hub Magnet b Outer Magnet c BLACK Stator Flywheel 2 Magnets d RED Stator Flywheel 4 Magnets e Spacers The flywheel assembly BLACK stator contains two outer magnets 8 Pole 4 Pulse and one center hub magnet The outer magnets are needed for battery charge coil and ignition charge coils The inner hub magnet is for trigger ...

Page 54: ...inter nal capacitor A voltage pulse from the trigger assembly in firing order turns on a respec tive SCR switch which discharges the capacitor stored voltage and sends it to the ignition coil The switch box contains an electrical circuit that controls the ignition spark timing The switch box senses the engine R P M by counting trigger pulses and adjusts the engine timing accordingly No idle timing...

Page 55: ...ds it to the ignition coil b a d e f g h c a 1 Coil Primary Lead Green Yellow b 2 Coil Primary Lead Green White c Ground Lead d Engine Stop Lead BLACK YELLOW e Trigger Lead BROWN YELLOW f Stator Lead BLACK WHITE High Speed g Trigger Lead BROWN WHITE h Stator Lead BLACK YELLOW Low Speed MECHANICAL AND ELECTRONIC SPARK ADVANCE RED STATOR The mechanical and electronic spark advance mechanism circuitr...

Page 56: ...98 Page 2A 11 Electronic Spark Advance Engine Speed RPM 0 5 10 15 20 25 30 1000 2000 3000 4000 5000 6000 7000 750 50 R P M Approx 3 5 B T D C 5800 R P M 25 B T D C 6200 RPM 15 B T D C Set Up Timing 28 B T D C 3000 200 RPM 5500 RPM ...

Page 57: ...y cable connections to check po larity 3 DO NOT disconnect battery cables while engine is running 4 DO NOT crank engine with CDI or Ignition Coils not grounded CAUTION To protect against meter and or component damage observe the following pre cautions 400 VDC test position or higher MUST BE used for all tests INSURE the Positive lead terminal of DVA is connected to the Positive re ceptacle of mete...

Page 58: ...fore beginning in depth troubleshooting a Ensure that the engine is mechanically sound condition Fuel System Cylinder Compression etc b Check all engine ground leads for loose or corroded connections c Disconnect and reconnect ignition harness connectors to verify proper continuity PROBLEM CORRECTION 1 No Spark or Weak Spark on Both Cylinders No Spark Trigger Stator Ignition Switch Box or Bad Grou...

Page 59: ...witch Box 7 Engine Misfires Low RPM but Runs Smooth High RPM Defective Harness or loose connections Defective Switch Box Defective Stator 8 Engine Starts Hard when Hot Defective Switch Box or Trigger 9 Engine Occasionally Misfires Replace Standard Spark Plug with Inductor Plug Bad Ground Connection from Switch Box to Block ...

Page 60: ... 300 3000 RPM Voltage Reading 3000 4000 RPM Test 1 Coil Primary 400 DVA Coil Terminal Coil Terminal 160 250 1 200 280 Test 2 Sw Box Stop Circuit 400 DVA Black Yellow Sw Box Terminal Ground 220 320 300 350 Test 3 Stator Low Speed 400 DVA Blue Sw 2 Box Terminal Ground 220 320 300 350 Test 4 Stator High Speed 400 DVA Red Sw 2 Box Terminal Ground 30 220 200 280 If using a meter that requires a DVA ada...

Page 61: ...le Stator BLACK YELLOW and BLACK WHITE wires discon nected from switch boxes R x 1 120 180 32 38 31 37 R x 100 R x 100 Trigger BROWN YELLOW and BROWN wires dis connected from switch boxes R x 100 6 5 8 5 RED BLACK BLACK WHITE GROUND RED BLACK BLACK YELLOW GROUND BLACK YELLOW BLACK WHITE BROWN YELLOW BROWN Tested Part Multimeter Connected To Scale Ignition Coils all wires dis connected R x 1 R x 10...

Page 62: ...nected R x 1 R x 1000 0 02 0 04 8 11 Resistance ohms RED BLACK Terminal Terminal Spark Plug Tower Terminal RED BLACK Tested Part Multimeter Wires Connected To Reading At 300 1000 RPM Selector Position Switch Box Primary Coil 400 VDC 125 320 Reading At 1000 4000 RPM Stop Circuit 400 VDC 200 320 RED BLACK Terminal Terminal RED BLACK BLACK YELLOW GROUND Switch Box 150 330 250 330 Stator Voltage RED B...

Page 63: ...st 2B 14 Emergency Stop Switch Lanyard Type 2B 15 Push Button Stop Switch 2B 15 Starter Motor 2B 16 Disassembly 2B 16 Cleaning and Inspection 2B 17 Testing Motor Armature 2B 18 Starter Motor Reassembly 2B 19 Starter Solenoid Test 2B 21 Flywheel Ring Gear 2B 22 Installation 2B 22 Neutral Start Switch Electric Start Tiller Handle Shift Models 2B 23 Tiller Handle Start Button 2B 24 Choke Solenoid 2B ...

Page 64: ...826883R2 JUNE 1998 Electric Start Components 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 A A B 14 2 Cycle Outboard Oil 92 13249A24 Liquid Neoprene 92 25711 2 14 25 25 25 25 A LOCAL ELECTRIC ONLY B SERVICE ONLY ...

Page 65: ...2 SCREW M6x1x25 hex head cap 40 4 5 11 2 NUT 8 32 Brass 25 2 8 12 1 NUT 1 4 20 30 3 4 13 1 INSULATOR solenoid 14 1 NUT 1 4 20 30 3 4 15 1 RETAINER harness connector 16 1 J CLIP 17 1 SCREW M6x30 hex head cap 140 12 0 15 8 18 1 WIRING HARNESS ASSEMBLY engine 19 1 FUSE 20 1 STARTER MOTOR ASSEMBLY 21 1 THRU BOLT 22 1 END CAP W BRUSHES 23 1 ARMATURE 24 1 DRIVE CAP 25 1 DRIVE 26 1 DRIVE KIT 27 2 SCREW M...

Page 66: ...ul when connecting or dis connecting cable clamps on chargers Poor connections are a commoncause of elec trical arcs which cause explosions 3 DO NOT reverse polarity of battery cables on battery 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 Recommended Battery A 12 volt battery with a...

Page 67: ...fic gravity are taken into account specific gravity obtained by hydrometer may not give a true indication of concentration of acid in electro lyte A fully charged battery will have a specific gravity reading of approximately 1 270 at an electrolyte temperature of 80 F 27 C If electrolyte temperature is above or below 80 F additions or subtractions must be made in order to obtain a hydrometer readi...

Page 68: ...battery damage either in winter storage or in dealer stock if the following instructions are not observed 1 Remove battery from its installation as soon as possible and remove all grease sul fate and dirt from top surface by running water over top of battery Be sure however that vent caps are tight beforehand and blow off all excess water thoroughly with com pressed air Check water level making su...

Page 69: ...M and note lamp brightness If lamps are considerably brighter than with leads connected to regulator the regulator is defective If lamps are NOT considerably brighter check the alternator refer to Alternator Test following Battery Charging System Description Thebatterychargingsystem componentsarethealternator rectifierandbattery Alternat ing current generated in alternator coils flows to the recti...

Page 70: ...s between the rectifier and the battery or by clamping an inductive type amp meter 10 amp minimum over the RED output lead from the rectifier to the battery BLACK Stator 2 Magnet Flywheel RPM AMPERES Approximate Idle 0 1000 0 2000 5 3000 2 2 4000 3 1 5000 3 8 6000 4 0 RED Stator 4 Magnet Flywheel RPM AMPERES Approximate Idle 0 1000 0 8 2000 4 1 3000 5 3 4000 5 8 5000 6 1 6000 6 3 ...

Page 71: ...lyinspect wiringbetween stator and batteryfor cuts chafing anddisconnected loose or corroded connection 4 Excessive electrical load from too many accessories will cause battery to run down If visual inspection determines that battery connections and wiring are OK perform the following stator and rectifier tests Alternator Test NOTE Alternator can be tested without removing from engine DC resistanc...

Page 72: ...inuity Indicated Replace Rectifier Continuity Indicated Replace Rectifier Continuity Indicated Rectifier Tests O K Continuity Indicated Replace Rectifier No Continuity Indicated Replace Rectifier No Continuity Indicated Replace Rectifier No Continuity Indicated Replace Rectifier No Continuity Indicated Rectifier tests O K Continuity Indicated Continuity Indicated No Continuity Indicated No Continu...

Page 73: ...ed 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 troubleshooting flow chart following check first for the following conditions 1 Make sure that battery is fully charged 2 Check that control lever is in NEUTRAL position 3 Check terminals for corros...

Page 74: ...EST 1 Use an ohmmeter R x 1 scale and connect meter leads between NEGATIVE battery post and common pow erhead ground There is an open circuit in the BLACKNEGATIVE bat tery cable between the NEGATIVE battery post and the powerhead Check cable for loose or corroded connections Check cable for open Continuity Indicated Proceed to TEST 2 on next page Starting Circuit Troubleshooting Flow Chart No Cont...

Page 75: ...Defective starter solenoid Connect voltmeter between common engine ground and Test Point 5 Defective ignition switch Connect voltmeter between common engine ground and Test Point 6 No voltage reading check RED wire be tween battery positive terminal and Test Point 6 Check fuse in RED wire between test points 5 and 6 Check for open RED wire between test points 5 and 6 a Connect voltmeter between co...

Page 76: ... scale for the following tests KEY POSITION OFF RUN START CHOKE CONTINUITY SHOULD BE INDICATED AT THE FOLLOWING POINTS BLK BLK YEL RED YEL RED PUR YEL BLK NOTE Key switch must be positioned to RUN or START and key pushed in to actuate choke for this test 3 If meter readings are other than specified in the preceding tests verify that switch and not wiring is faulty If wiring checks ok replace switc...

Page 77: ...following tests OFF CONTINUITY 1 Ohm or Less RUN NO CONTINUITY 23421 3 If meter readings are other than specified replace emergency stop switch Push Button Stop Switch IMPORTANT Refer to Section 2D Wiring Diagrams for wiring connections 1 Disconnect push button stop switch leads from engine wiring 2 Use an ohmmeter and perform the following tests 23421 CONTINUITY I Ohm or Less NO CONTINUITY 3 If m...

Page 78: ...ap with rubber mallet Do not loose brush springs 53235 a b c a Lower End Cap b Washers c Bolts 3 Tap on drive end cap to loosen Remove end cap and armature from starter housing 4 If removal of parts that are installed on armature is necessary hold armature with Strap Wrench 91 24937A1 and remove locknut and discard from end of shaft 53081 a b a Strap Wrench 91 24937A1 b Locknut discard ...

Page 79: ... fully engage with flywheel the drive assembly may be binding on the helix threads on the armature shaft due to dirt or wear Locate cause of binding and correct before reassembling 3 Clean drive components with cleaning solution and inspect parts for wear 4 Clean commutator with No 00 sandpaper Remove any oil from commutator If com mutator surface is pitted rough or worn unevenly resurface on a la...

Page 80: ... saw blade vibrates armature is shorted Retest after cleaning between commutator bars If saw blade still vibrates replace armature 01440 b a c a Hack Saw Blade b Armature Core c Commutator TESTING ARMATURE FOR GROUND 1 Use an ohmmeter R x 100 to check for no continuity between commutator and ar mature core or commutator and shaft 2 If continuity exists armature is grounded and must be replaced 014...

Page 81: ...op of SAE 10W oil to to helix threads on armature shaft DO NOT over lubri cate 53080 a a Helix Threads 3 Apply a drop of SAE 10W oil to bushings in drive end cap and lower end cap DO NOT over lubricate 4 Reinstall components on armature shaft Use a new locknut and tighten securely 53228 a b c d e f g h a Locknut b Spacer c Spring d Drive Assembly e Drive End Cap f Armature Shaft g Helix Threads h ...

Page 82: ...manent magnets are recessed 1 5 16 in 33 3mm Align marks as shown 1 5 16 in 53082 b a a Alignment Marks b Bottom Edge of Permanent Magnets 6 Install springs and brushes into brush holders Spread brushes and hold in place with a strip of spring steel 7 Push in on drive end of shaft so that commutator will extend out of starter frame 53213 b c a a Brushes b Spring Steel c Commutator ...

Page 83: ... Test Test starter solenoid as follows 1 Disconnect all leads from solenoid terminals 2 Use an ohmmeter set to R x 1 scale and connect between solenoid terminals 3 and 4 3 Connect a 12 volt supply between solenoid terminals 1 and 2 Solenoid should click and meter should read zero ohms 4 If meter does not read zero ohms full continuity replace solenoid 14354 4 1 b a 3 2 a Ohmmeter Leads b 12 Volt S...

Page 84: ...vent ring gear from laying flat against flywheel 1 Inspect and remove any paint runs on ring gear and or mounting surface on fly wheel 2 Place gear on flywheel with countersink side of mounting holes toward the outside 3 Apply Loctite 271 to threads of 4 gear mounting screws and secure gear to flywheel Torque screws to 100 lb in 11 3 N m 53240 a c b a Ring Gear b Flywheel c Screws Torque to 100 lb...

Page 85: ...lts to 5 lb in 0 6 N m 53077 a b c a Neutral Start Switch b Plate c Bolts Torque to 5 lb in 0 6 N m 3 Route switch harness over block Secure harness to stator harness with sta strap 4 Route harness behind rectifier Attach BLACK lead to solenoid mount bolt Attach Black lead with YELLOW sleeve to terminal 1 of starter solenoid 53076 b c d a e a Switch Harness b BLACK Lead c BLACK Lead with YELLOW Sl...

Page 86: ...is routed into the lower cowl through the fuel connector access hole 53216 a c d b a Start Button Assembly b Semi Loops c Harness d Fuel Connector 3 The starter button harness is routed down the PORT side of lower engine to cowl 4 The RED harness lead is connected to the POSITIVE terminal of the rectifier Torque attaching nut to 25 lb in 2 8 N m 5 The YELLOW RED harness lead attaches to the 2 term...

Page 87: ...olenoid Installation IMPORTANT New gasket MUST be positioned as shown when being installed 1 Install new gasket with solenoid plate assembly 2 Secure assembly with 2 screws Torque screws to 18 lb in 2 0 N m 53209 a c b a Gasket b Solenoid Plate c Screws Torque to 18 lb in 2 0 N m ...

Page 88: ...ess Remote Electric Start Models 1 Slide battery cables through sleeve 53066 b a a Battery Cables b Sleeve 2 Thread battery cable sleeve through wire retainer of engine wiring harness Verify 1 in 25 4mm of sleeve remains to the outside of wire retainer 1 in 25 4mm 53065 a c b a Sleeve b Retainer c Harness ...

Page 89: ... outlined in Section 3 4 Thread engine wiring harness first and then battery cable sleeve through opening in bottom cowl 53210 b a c a Harness b Battery Cable Sleeve c Opening 5 Route engine wiring harness and battery cable sleeve under carburetor location around to PORT side of cylinder block ...

Page 90: ...ire retainer into opening of bottom cowl and secure with clip 53068 a a Clip 7 Secure harness and battery cable sleeve with sta strap just inside bottom cowl 8 Reinstall carburetor as outlined in Sec 3A 53226 a a Sta strap 9 Secure fuse holder in J clip a b a Fuse Holder b J clip ...

Page 91: ...gine wiring harness connector and se cure with harness connector retainer 53064 b a c a Remote Control Harness b Engine Harness c Retainer Battery Cables Tiller Handle Push Button Electric Start Models Installation 1 Fasten harness clamp to bottom cowl with nut washer and bolt 53069 b a c d a Clamp b Nut c Washer d Bolt ...

Page 92: ...rness clamp over battery cable sleeve and position cables into bottom cowl 4 Position harness clamp onto clamp bracket in bottom cowl Tighten clamp securely 53067 a b a Clamp b Bracket 5 Slide battery cable grommet over battery cables and install grommet into opening in starboard bottom cowl 53149 a b a Grommet b Cables ...

Page 93: ... 2 Route harness along PORT side of engine to rectifier 53063 a a Harness 3 Refer to Section 2D for wiring connections Emergency Stop Switch Lanyard Type Installation 1 Route emergency stop switch wiring through opening in STARBOARD bottom cowl 53054 a a Stop Switch 2 Secure stop switch into opening in bottom cowl using clip 53055 a a Clip 3 Refer to Section 2D for wiring connections ...

Page 94: ...ol Models 2C 10 Shift and Throttle Cable Installation to the Outboard 2C 13 Shift Cable Installation 2C 14 Throttle Cable Installation 2C 15 Starting Procedure 2C 16 Adjusting Idle Speed 2C 17 Specifications TIMING SPECIFI CATIONS 20 Jet 19941 2 THRU 1998 20 25 19941 2 THRU 1996 Electronic Spark Advance Idle 750 50 RPM In Forward Gear Fast Idle Speed Maximum BTDC Running Setup Timing 20 Jet 1999 A...

Page 95: ...TIMING SYNCHRONIZING ADJUSTING Page 2C 2 90 826883R2 JUNE 1998 Special Tools 1 DMT 2000 Service Tachometer 91 854009A1 2 Timing Light 91 99379 May be obtained locally ...

Page 96: ...cluding battery connections on electric start models 2 Shift outboard to Neutral on side shift model place throttle twist grip to Slow 3 Push choke primer all the way In On models equipped with a primer turn knob to full Counterclockwise position 4 Check the tiller handle cables for proper adjustment If necessary adjust cables and remove any slack 5 With the outboard placed in Neutral back the idl...

Page 97: ...n NOTE The throttle return spring on cam follower plate should just contact the fuel pump housing at wide open throttle position Do not allow the throttle spring to act as a throttle stop 7 Place throttle twist grip to Full Throttle position Verify that the throttle plate can achieve wide open throttle If adjustment is necessary adjust tiller cables or throttle link rod as shown Side Shift Models ...

Page 98: ...ions Chart 28195 a b a Access Plug b Idle Mixture Screw Behind Access Plug WARNING Keep clear of propeller while cranking and running the outboard motor 10 With the outboard in water connect fuel line to engine squeeze bulb until firm and check for carburetor flooding 11 Check choke operation making sure choke shutter opens and closes all the way IMPORTANT Local Electric Start Models Only Check th...

Page 99: ... the engine Immediately after the engine starts push the primer knob to Full In position and check for water at the tell tail and idle relief holes Allow the engine to warm up then turn the primer knob to the Full Counterclockwise position Tell tale pressure to be per General Specifications WARNING To prevent personal injury or possible death from loss of balance or stability while servicing the m...

Page 100: ... a Timing Mark b Side Shift Model Shown WARNING To prevent personal injury from spinning flywheel Do Not attempt to adjust the trigger link rod Maximum Timing Adjustment with engine running ADJUSTING SET UP TIMING With the engine OFF snap the trigger link rod socket off ball stud and Extend rod length to Advance timing Shorten rod length to Retard timing Snap link rod onto ball stud re start the e...

Page 101: ...crew out will advance timing Turning screw in will retard timing ADJUSTING IDLE TIMING 1 Loosen idle timing jam nut and turn idle timing adjustment screw in out to obtain speci fied timing NOTE Turning screw in will advance timing Turning screw out will retard timing NOTE Outboards equipped with a thermostat will have a Sporadic tell tail water dis charge Adjusting Idle Speed 1 Start the outboard ...

Page 102: ...4 Adjust carburetor for best performance after clearing the engine With engine running at idle speed in Forward gear turn mixture screw In clockwise until engine starts to loose R P M fire unevenly and or misfires Back out 1 4 turn or more See General Specifications for minimum and maximum adjustment 5 Check for too lean of mixture on acceleration Engine will hesitate or stall on accel eration Rea...

Page 103: ...ener 2 Check the primer enrichener circuit by pulling the primer enrichener knob to the full out position The engine speed should drop a minimum of 300 R P M and remain run ning for approximately five 5 seconds before stalling Timing Synchronizing Adjusting Remote Control Models 1 Check all electrical connections to ensure they are tight and secure including battery connections on electric start m...

Page 104: ...ll throttle lever to Full Aft position until the stop tab on the throttle arm contacts the stop tab on the shift platform 52798 a b c a Stop Tab b Shift Platform Stop Tab c Throttle Lever 4 Back the idle speed screw off of cam follower 52800 b a a Idle Speed Screw b Cam Follower ...

Page 105: ...htly open throttle plate a b c a Idle Speed Screw b Cam Follower c Throttle Cam NOTE The throttle return spring on cam follower plate should just contact the fuel pump housing at wide open throttle position If not adjust the throttle link rod Do not allow the throttle spring to act as a throttle stop 52912 a b a Contact Point spring to just contact fuel pump housing b Throttle Return Spring ...

Page 106: ...hrottle link rod if necessary 52799 a b c d a Throttle Stop b Throttle Lever c Return Spring do not allow to act as a throttle stop d Throttle Link Rod Shift and Throttle Cable Installation To The Outboard Install the shift cable and throttle cable into the remote control and mount the remote con trol following instructions which are provided with the remote control NOTE Install the shift cable be...

Page 107: ...e loading the shift cable f a b c d e a Shift Lever b Cable Retainer Cover c Shift Cable d Shift Lever Pin e Retainer Latch 6 Check shift cable adjustments as follows a With remote control shifted into forward the propeller shaft should lock solidly in gear If it does not adjust the cable barrel closer to the engine shift lever b Shift remote control into neutral The propeller shaft should turn fr...

Page 108: ...contacts throttle stop Adjust the barrel on the throttle cable so that the barrel will fit into the barrel holder 4 Slip the barrel into the barrel holder and place the barrel holder into the retaining pock et 5 Check the throttle cable adjustment as follows a Move the remote control handle back to neutral a few times and then return the handle back to forward wide open position b Recheck to make ...

Page 109: ... up when starting a cold engine Leave the lever in the down position until the engine starts 1 Turn ignition key to the START position If the engine is cold push In on key to enrich the engine If the engine fails to start in ten seconds return key to ON position wait 30 seconds and try again 2 If engine begins to stall re activate the choke enrichener until engine is running smoothly NOTE Starting...

Page 110: ... to warm up turn the primer knob to Full Counterclockwise position Tell tail pressure should be per General Specification Adjusting Idle Speed 1 Remove access plug from carburetor air intake cover 2 Turn idle mixture screw in clockwise until LIGHTLY seated then back out to an initial setting See Specifications Chart a b 52804 a Access Plug b Idle Mixture Screw Behind Access Plug WARNING Keep clear...

Page 111: ...rt Button Mechanical Advance Model 20 25 1998 2D 6 Electric Models Equipped with Remote Control Mechanical Advance Model 20 25 1998 2D 7 Manual Start Ignition Wiring Diagram RED Stator Model 20 Jet 20 25 1999 and NEWER 2D 8 Manual Start Wiring Diagram RED Stator Model 20 25 1999 and NEWER Work Model 2D 9 Electric Start Models with Tiller Handle Start Button RED Stator Model 20 25 1999 and NEWER 2D...

Page 112: ... 19941 2 THRU 1997 Model 20 Jet 19941 2 THRU 1998 a b c d h e f g i BLK BLACK BRN BROWN GRY GRAY GRN GREEN RED RED WHT WHITE YEL YELLOW a Charging Coils b Stator c Ignition Coil Top Cylinder d Ignition Coil Bottom Cylinder e Emergency Stop Switch f Stop Switch g Switch Box h Trigger i Terminal Block ...

Page 113: ...997 g a c b d e f h i j k l m n BLK BLACK BRN BROWN GRY GRAY GRN GREEN RED RED WHT WHITE YEL YELLOW a Stator b Trigger c Ignition Coil Top Cylinder d Ignition Coil Bottom Cylinder e Emergency Stop Switch f Stop Switch g Rectifier h Switch Box i Charging Coils j Starter Motor k Starter Solenoid l Start Button m 12 VDC Battery n Neutral Start Switch ...

Page 114: ...i f b g a c d e k l j h m BLK BLACK BRN BROWN GRY GRAY GRN GREEN RED RED WHT WHITE YEL YELLOW a Stator b Trigger c Ignition Coil Top Cylinder d Ignition Coil Bottom Cylinder e Rectifier f Switch Box g Charging Coils h Starter Motor i Starter Solenoid j Fuse Holder 20 Ampere Fuse k Remote Control Harness l 12 VDC Battery m Neutral Start Switch ...

Page 115: ...art Models Mechanical Advance Model 20 25 1998 a b c d e g f BLK BLACK BRN BROWN GRY GRAY GRN GREEN RED RED WHT WHITE YEL YELLOW a Stator b Trigger c Switch Box d Ignition Coil Top Cylinder e Ignition Coil Bottom Cylinder f Stop Switch g Emergency Stop Switch ...

Page 116: ... c d e f g h i j k l m n BLK Black BRN Brown GRY Gray GRN Green RED Red WHT White YEL Yellow a Charging Coils b Stator c Ignition Coil Top Cylinder d Ignition Coil Bottom Cylinder e Rectifier f Switch Box g Trigger h Starter Motor i Starter Solenoid j Emergency Stop Switch k Stop Switch l Start Switch m 12 VDC Battery n Neutral Start Switch ...

Page 117: ...CK BRN BROWN GRY GRAY GRN GREEN RED RED WHT WHITE YEL YELLOW a b c d e f g h k m i l j a Charging Coils b Stator c Ignition Coil Top Cylinder d Ignition Coil Bottom Cylinder e Rectifier f Switch Box g Trigger h Starter Motor i Starter Solenoid j Fuse Holder 20 Ampere Fuse k Remote Control Wiring Harness l 12 VDC Battery m Choke Solenoid ...

Page 118: ...EEN RED RED WHT WHITE YEL YELLOW BLK YEL WHT GRN BRN WHT BRN YEL GRN WHT GRN YEL GRN BLK BLK 2 1 Z1 Z1 Z1 Z1 Z1 J2 J1 J3 Z1 Z1 Z1 Z1 J4 J7 J6 J5 T4 T5 BLK YEL BLK YEL BLK YEL WHT GRN BLK BLK BLK BLK BRN WHT BRN YEL GRN WHT g f e d c b a a Stator b Trigger c Switch Box d Ignition Coil Bottom Cylinder e Ignition Coil Top Cylinder f Emergency Stop Switch g Stop Switch ...

Page 119: ...HITE YEL YELLOW BRN WHT BRN YEL GRN WHT WHT GRN GRN YEL GRN YEL GRY BLK BLK YEL 2 1 Z1 Z1 Z1 Z1 Z1 J2 J1 J3 J4 J7 J6 J5 GRN WHT WHT GRN BRN YEL BRN WHT BLK YEL BLK YEL BLK YEL BLK BLK BLK BLK BLK g f c b d e h i a a Stator b Trigger c Switch Box d Ignition Coil Bottom Cylinder e Ignition Coil Top Cylinder f Stop Switch g Emergency Stop Switch h Terminal Strip i Charging Coils ...

Page 120: ...K RED YEL RED RED BLK YEL BLK YEL RED RED BLK BLK BLK RED 2 1 Z1 Z1 Z1 Z1 Z1 J2 J1 J3 J4 J7 J6 J5 BLK BLK BLK BLK BLK BLK YEL BLK YEL BLK YEL GRN WHT WHT GRN BRN YEL BRN WHT c n a b d e f h g k i j l m a Stator b Trigger c Switch Box d Ignition Coil Bottom Cylinder e Ignition Coil Top Cylinder f Emergency Stop Switch g Push Button Stop Switch h Rectifier i Charging Coils j Neutral Start Switch k P...

Page 121: ...L BLK RED RED 2 1 BLK YEL RED GRY YEL RED GRY YEL BLK YEL BLK RED Z1 Z1 Z1 Z1 Z1 J2 J1 J3 J4 1 2 3 4 5 6 7 8 J5 J6 J7 BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK YEL GRN WHT WHT GRN BRN YEL BRN WHT m a b c d e f g h i j k l a Stator b Trigger c Switch Box d Ignition Coil Bottom Cylinder e Ignition Coil Top Cylinder f Choke Solenoid g Remote Control Harness h Fuse Holder 20 Ampere Fuse i Rectifier j Ch...

Page 122: ... Electrical Accessories Wiring Diagrams a b c d e f a Manual Start Model with Lighting Coil and Unregulated AC Voltage b Terminal Block c Manual Start Model with Battery Charging Kit d Rectifier e Manual Start Model with Voltage Regulator f Voltage Regulator ...

Page 123: ...r Remote Control Electric Start BLK BLACK BRN BROWN GRY GRAY GRN GREEN RED RED WHT WHITE YEL YELLOW d c b a e a Ignition Choke Switch b Emergency Stop Switch c Neutral Start Switch d Tachometer Accessories Harness Connector e Remote Control Harness Connector ...

Page 124: ...MS Page 2D 14 90 826883R2 JUNE 1998 Commander 2000 Remote Control Manual 23893 BLK BLACK BRN BROWN GRY GRAY GRN GREEN RED RED WHT WHITE YEL YELLOW a b c a RUN OFF Switch b Emergency Stop Switch c Stop Switch Harness ...

Page 125: ... 2000 Remote Control Electric Start BLK BLACK BRN BROWN GRY GRAY GRN GREEN RED RED WHT WHITE YEL YELLOW 23890 a b c d e a Ignition Choke Switch b Emergency Stop Switch c Neutral Start Switch d Tachometer Accessories Harness Connector e Wiring Harness Connector ...

Page 126: ...RING DIAGRAMS Page 2D 16 90 826883R2 JUNE 1998 Commander 3000 Panel Mount Control BLK BLACK BRN BROWN GRY GRAY GRN GREEN RED RED WHT WHITE YEL YELLOW b a a Neutral Interlock Switch b Emergency Stop Switch ...

Page 127: ...on 3A 22 Reassembly and Installation 3A 22 Primer System 3A 23 Symptoms of a defective primer system 3A 23 Servicing Sight Bowl Fuel Filter 3A 24 Specifications CARBURETOR SPECIFI CATIONS Idle RPM In Forward Gear Wide Open Throttle WOT RPM 20 25 Idle Mixture Screw Adjustment Preset Turns Out 20 20 Jet 25 25 Seapro 25 Marathon Float Level Main Jet Size 19941 2 thru 1996 20 WMC 44 25 20 Jet WMC 45 2...

Page 128: ...CARBURETOR FUEL PUMP Page 3A 2 90 826883R2 JUNE 1998 Carburetor 20 25 JET 20 CONTENTS OF PRIMER INJECTOR KIT PART NO 1395 9844A1 REFERENCE NO 26 ...

Page 129: ... BOWL 5 1 FLOAT 6 1 VALVE inlet needle 7 1 JET main fuel 044 20HP 7 1 JET main fuel 076 25HP JET 20 8 1 PLUG jet retainer 32 3 6 9 1 COVER diaphragm 10 4 SCREW diaphragm cover 14 1 6 11 1 BODY fuel pump 12 5 SCREW fuel pump cover 18 2 0 13 1 COVER fuel pump 14 1 COVER fuel pump JET 20 15 1 PLUG 32 3 6 16 1 GASKET DIAPHRAGM KIT 17 1 REPAIR PARTS KIT 18 1 PLATE cover MANUAL 19 1 ELECTRIC CHOKE ELECT...

Page 130: ...UMP Page 3A 4 90 826883R2 JUNE 1998 Carburetor Seapro Marathon 15 25 Super 15 1 2 3 4 5 6 7 8 9 10 11 12 15 16 17 18 19 20 21 22 23 24 25 26 17 16 17 16 17 17 17 17 17 17 16 17 16 17 17 16 17 17 17 17 17 17 27 28 13 14 ...

Page 131: ...1 JET main fuel 076 WMC 46 7 1 JET main fuel 080 WMC 46A 54 54A 1 JET main fuel 046 WMC 56 56A 8 1 PLUG jet retainer 32 3 6 9 1 CHOKE SHAFT 10 1 CHOKE LEVER 11 1 BODY fuel pump 12 5 SCREW fuel pump cover 18 2 0 13 1 COVER pump WMC 54 54A 56 56A 14 1 COVER fuel pump WMC 46 46A 15 1 CHOKE VALVE 16 1 GASKET DIAPHRAGM KIT 17 1 REPAIR PARTS KIT 18 1 PLATE cover 19 1 SCREW bowl drain 14 1 6 20 2 SCREW c...

Page 132: ... 44 20 044 None None 1 0 in 25 4 mm 1 1 2 Turns WMC 52 20 044 None None 1 0 in 25 4 mm 1 1 2 Turns WMC 53 WMC 53A 25 076 None None 1 0 in 25 4 mm 1 1 2 Turns WMC 54 Commercial 25 080 None None 1 0 in 25 4 mm 1 1 2 Turns Low Speed Mixture Screw Rich Lean a a Low Speed Mixture Screw Main Jet a a Main Jet High Altitude High Speed Jetting Altitude Main Jet 20 25 SeaPro Marathon 0 5000 ft 0 1524m 044 i...

Page 133: ...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 06...

Page 134: ...0 826883R2 JUNE 1998 Carburetor Float Adjustment 1 in 25 4 mm b a 17111 a Carburetor Scale 91 36392 b Measured from bottom of float 52646 a b c d e a Float b Float Hinge c Float Pin d Bend Float Arm Here to Adjust Float Level e Needle ...

Page 135: ...hrottle movement in both Forward and Reverse gears Adjust jam nuts for proper travel and to eliminate any slack 57049 a a a Jam Nuts INITIAL CARBURETOR ADJUSTMENTS Idle Speed Screw Models So Equipped 1 Shift outboard to Neutral and place throttle twist grip to Slow 2 Push primer fast idle knob completely in and rotate knob fully counterclockwise 57037 ...

Page 136: ...R2 JUNE 1998 3 Back idle speed screw off of cam follower 4 Turn idle speed screw inward clockwise until it just touches cam follower then inward an additional 1 2 turn to slightly open throttle plate a b 57070 a Idle Speed Screw b Cam Follower ...

Page 137: ...er models so equipped 57072 a b a Access Plug b Intake Cover 2 Turn low speed mixture screw slowly inward clockwise until it seats lightly then back screw out counterclockwise 1 1 2 to 1 3 8 turns turning mixture screw in tight will damage needle and seat 3 Do not install access plug at this time a 57071 a Low Speed Mixture Screw ...

Page 138: ...knob completely in and rotate fully counterclockwise 2 Shift engine to Neutral 57037 3 Adjust screw a to remove all clearance between idle wire b and trigger b a 57070 a Screw b Idle Wire 4 Check fast idle speed by turning primer knob to full clockwise position Fast idle speed should be 1500 2000 RPM ...

Page 139: ...arts to load up or fire unevenly from over rich mixture 4 Slowly turn low speed mixture screw clockwise until cylinders fire evenly and engine picks up speed a 57071 a Low Speed Mixture Screw 5 Continue turning mixture screw clockwise until too lean a mixture is obtained and en gine slows down and misfires 6 Set low speed mixture screw halfway between rich and lean 7 DO NOT adjust leaner than nece...

Page 140: ...pushed completely in and rotate fully counterclockwise to stop 2 Adjust idle speed screw a to obtain recommended idle speed see specifications a 57070 a Idle Speed Screw IDLE SPEED ADJUSTMENT MODELS NOT EQUIPPED WITH AN IDLE SPEED SCREW For models not equipped with an idle speed screw the carburetor has been calibrated at the factory to maintain an idle speed of 650 75 RPM in Forward gear ...

Page 141: ...Improperly mixed fuel Contaminants water dirt etc in fuel Check fuel in tank and replace or add whichever is necessary Fuel tank air vent closed or restricted Check air vent on fuel tank Air vent must be open all the way and free from any contaminants Pinched cut restricted fuel line or loose fuel line connection Inspect all fuel lines and replace as needed Tight en fuel line connections Dirty or ...

Page 142: ... mix ture screw out of adjustment Refer to carburetor adjustments in this section Improper float level Refer to carburetor adjustments in this section Carburetor loose on intake manifold Check tightness of carburetor nuts Reed block loose or gasket defective Using a pressure oil can apply 2 cycle oil around reed block housing crankcase housing matching surfaces and carburetor base If engine RPM ch...

Page 143: ...rective Action Chipped or broken reeds on reed block Replace reeds Problem Rough Idle Possible Cause Corrective Action Excessive preload on reeds Replace reeds Problem Engine Runs Too Lean Possible Cause Corrective Action Carburetor is loose Air leaks past mixing chamber cover Tighten bolts securely Tighten cover or replace gasket Fuel level is too low Reset float level Clogged high speed jet Insp...

Page 144: ... 2 Remove retaining clip 57069 b a a Screw b Retaining Clip 3 Push down on primer arm and pull primer knob bezel and slide block out of bottom cowl 4 Remove link wire from fast idle lever 5 Disconnect fuel line from carburetor 6 Remove carburetor mounting nuts 7 Lift carburetor from engine e a 57068 c d b a Primer Arm b Primer Knob c Bezel d Slide Block e Link Wire ...

Page 145: ...tion 1 Install carburetor with new gasket onto mounting studs Start attaching nuts but do not tighten 57067 b b a a Gasket b Nuts 2 Install primer assembly onto carburetor Position alignment hole on assembly over post on bottom of carburetor 57066 a b a Alignment Hole b Post ...

Page 146: ... 3 Install air cover onto carburetor and secure with 2 screws 4 Tighten carburetor attaching nuts 57075 b a a Screws b Nuts 5 Secure fuel line to carb with sta strap 6 Reconnect link wire to fast idle lever 57070 a b c a Fuel Line b Sta strap c Link Wire ...

Page 147: ... knob bezel and slide block into primer assembly c a d b 57068 a Primer Arm b Primer Knob c Bezel d Slide Block 8 Tighten screw to secure slide block in place 9 Align notch in back side of bezel with tab on bottom cowl and secure bezel in place with retaining clip b a 57069 a Screw b Retaining Clip ...

Page 148: ...rburetor for nicks cracks or rough gasket surface 3 Inspect pump check valve diaphragm Diaphragm MUST BE flat and free from holes and imperfections 4 Pump body surface below check valves MUST BE flat so that check valve will seat Reassembly and Installation 1 Inspect all parts for serviceability 2 Reassemble fuel pump 3 Secure fuel pump assembly to carburetor with 5 screws Torque screws to 18 lb i...

Page 149: ... and springs should be inspected for debris or varnish which restrict free movement SYMPTOMS OF A DEFECTIVE PRIMER SYSTEM 1 Outboard is hard to start a Diaphragm is cut b Primer check ball is stuck in the closed position c Primer passage is plugged with debris or varnish 2 Outboard smokes excessively at idle a Primer check ball is not seated due to debris varnish or damaged check ball spring a b c...

Page 150: ...installing PULL STRAIGHT DOWN when removing assembly PUSH STRAIGHT UP when instal ling assembly Turning or cocking fuel filter may break fuel line connection on fil ter The sight bowl fuel filter removes dirt and water from the fuel Check the sight bowl frequently and clean the filter as required 1 Verify that the sight bowl rubber sealing ring is properly positioned in the bowl 2 Reinstall elemen...

Page 151: ...ustion If combustion were complete the mixture of air and gasoline would result in these emissions water carbon dioxide and nitrogen which are not harmful to the environ ment But combustion is not usually complete Also potentially harmful gases can be formed during and after combustion All marine engines must reduce the emission of certain pollutants or potentially harmful gases in the exhaust to ...

Page 152: ...toichiometric 14 7 1 Air Fuel Ratio In the search to control pollutants and reduce exhaust emissions engineers have discov ered that they can be reduced effectively if a gasoline engine operates at an air fuel ratio of 14 7 1 The technical term for this ideal ratio is stoichiometric An air fuel ratio of 14 7 1 provides the best control of all three elements in the exhaust under almost all conditio...

Page 153: ...EMISSIONS 90 826883R2 JUNE 1998 Page 3B 3 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 154: ...zed charge The difference between the two is Homogenized Charge A homogenized charge has the fuel air particles mixed evenly throughout the cylinder This mixing occurs inside the carburetor venturi reed blocks and crankcase Additional mixing occurs as the fuel is forced through the transfer system into the cylinder The homogenized charge is easy to ignite as the air fuel ratio is approximately 14 ...

Page 155: ...most complete combustion before the exhaust port opens A stratified charge is hard to ignite the fuel air bubble is not evenly mixed at 14 7 1 and not easily ignited Emissions Information Manufacturer s Responsibility Beginning with 1998 model year engines manufacturers of all marine propulsion engines must determine the exhaust emission levels for each engine horsepower family and certi fy these ...

Page 156: ...tured by Mercury Marine are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors This certification is contingent on certain adjustments being set to factory standards For this reason the fac tory procedure for servicing the product must be strictly followed and whenever practic...

Page 157: ...n decal part number d Idle Speed In Gear e Timing specifications when adjustable f Recommended spark plug for best engine performance g Valve Clearance Four Stroke engines only h Engine Horsepower rating i Month of production Boxing month will punched j FEL Represents Mercury Marine statement of the maximum emissions out put for the engine family k Family example W M9X M 0024 2 1 0 Model Year W 19...

Page 158: ...inder Block 4 12 Crankshaft 4 17 Powerhead Cleaning and Inspection 4 22 Cylinder Block and Crankcase Cover 4 22 Exhaust Manifold and Exhaust Cover 4 23 Cylinder Bore 4 23 Crankshaft 4 26 Seals 4 27 Bearings 4 27 Connecting Rod 4 28 Pistons 4 31 Reed Block 4 32 Bleed System 4 33 Thermostat 4 34 Powerhead Reassembly 4 35 General Information 4 35 Crankshaft 4 35 Cylinder Block 4 46 Powerhead Installa...

Page 159: ...m 1 196 in 30 38 mm PISTON Piston Type O D at Skirt Standard Ring End Gap Aluminum 2 5583 2 5593 64 98 65 00 0 011 0 025 28 mm 64 mm PISTON DIA Dimension A at Right Angle 90 to Pis ton Pin 0 50 in 12 7 mm 2 5583 in 0005 in 64 98 mm 0127 mm Using a micrometer measure dimension A at location shown Dimension A should be 2 5583 in 0005 for a STANDARD size piston new Di mension A will be 0 001 0 0015 l...

Page 160: ...AD 90 826883R2 JUNE 1998 Page 4 3 Special Tools 1 Powerhead Stand 91 25821A1 2 Piston Pin Tool 91 76160A2 3 Piston Ring Expander 91 24697 4 Torque Wrench 0 200lb ft 91 32610 5 Torque Wrench 0 150lb in 91 66274 ...

Page 161: ...POWERHEAD Page 4 4 90 826883R2 JUNE 1998 6 Flywheel Puller 91 83164M a a Bolts 10mm 3 91 83191M 7 Compression Tester 91 29287 ...

Page 162: ... 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 1 A 9 10 7 Loctite 271 92 809820 Loctite PST Pipe Sealant 92 809822 9 12 Loctite Master Gasket 92 12564 2 95 2 4 C With Teflon 92 825407A12 7 7 7 95 7 9 7 SIDE SHIFT AND TILLER SHIFT ONLY ...

Page 163: ...UBING 13 1 4 IN 18 2 O RING 19 2 COVER 20 4 SCREW M5x 8x16 40 4 5 21 1 BALL threaded 40 4 5 22 6 SCREW M5x 8x16 40 4 5 23 2 COVER 24 2 O RING 25 1 GASKET 26 1 COVER CASTING 27 1 COVER ASSEMBLY 28 1 PIPE PLUG BRASS Drive Tight 29 5 SCREW 30 MM 140 12 0 15 8 30 1 FITTING 31 1 HOSE tell tale 8 IN 32 1 ELBOW Drive Tight 33 2 SCREW M6x1x40 140 12 0 15 8 34 1 COVER 35 1 GASKET 36 1 GASKET 37 1 THERMOSTA...

Page 164: ...ywheel 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 2 1 23 16 18 21 A 7 Loctite 271 92 809820 14 2 Cycle Outboard Oil 92 13249A24 95 2 4 C With Teflon 92 825407A12 95 95 95 14 95 14 14 95 A ELECTRIC START MODELS ONLY ...

Page 165: ... 15 1 ROLLER BEARING lower 16 2 CONNECTING ROD ASSEMBLY 17 4 SCREW 175 15 0 19 8 18 2 ROLLER BEARING ASSEMBLY 19 24 ROLLER Part of Ref 18 20 54 NEEDLE BEARING piston end 21 4 BEARING thrust 22 2 PISTON AND PIN ASSEMBLY 23 4 LOCK RING piston pin USA S N 0G202749 BELOW 24 1 PISTON RING BEL 09855586 BELOW 25 2 PISTON RING Part of Ref 24 22 2 PISTON AND PIN ASSEMBLY STD 22 2 PISTON AND PIN ASSEMBLY 03...

Page 166: ...AD 90 826883R2 JUNE 1998 Page 4 9 Torque Sequence 1 Exhaust Cover 140 lb in 15 8 N m 1 2 3 4 5 6 7 8 9 2 Crankcase Cover 30 0 lb ft 41 1 N m 6 1 2 3 4 5 3 Cylinder Block Cover 140 lb in 15 8 N m 1 2 3 4 5 6 7 ...

Page 167: ...es referring to the listed service manual sections Component Assembly Section Rewind Starter 8 Flywheel and Ignition Electrical Components 2A B Throttle Shift Mechanism 7A B C Carburetor 3A 2 Disconnect tell tale hose from bottom cowl a 57073 a Tell tale Hose 3 Remove 4 bolts a 57076 a Bolts 2 each side ...

Page 168: ... 6 bolts securing powerhead 57077 a a a Bolts 3 each side 5 Rock powerhead to break gasket and lift powerhead from drive shaft housing 6 Place powerhead on bench or powerhead stand 91 25821A1 mounted in vise 53197 53203 a a a Powerhead Stand 91 25821A1 ...

Page 169: ...pected without disassembling If inspection of reed block indicates that replacement of a part is necessary entire reed block as sembly must be replaced as individual parts are not sold separately 2 Inspect seal for cuts or abraisions If seal is damaged entire reed block assembly must be replaced 3 Inspect reeds for cracks or chips 57080 a b c a Seal b Reeds c Reed Valve Opening Maximum Opening 0 0...

Page 170: ...NE 1998 Page 4 13 4 Remove 2 bolts and remove thermostat cover 57081 a b a Bolts 2 b Cover 5 Remove thermostat if equipped 6 Remove 5 bolts and remove cylinder block cover 57082 c a b a a Bolts b Cover c Thermostat if equipped ...

Page 171: ...aust Manifold NOTE If engine is suspected of having been overheated or spark plugs are grayish col ored a sign of possible water intrusion inspect exhaust manifold for warpage or for prop er placement and integrity of gaskets which will allow water to enter cylinders through ex haust ports 8 Remove 10 bolts and 4 transfer covers Starboard Side 57083 a a Transfer Covers ...

Page 172: ...POWERHEAD 90 826883R2 JUNE 1998 Page 4 15 9 Remove 4 bolts and 2 transfer covers Port Side 57085 a a Transfer Covers 10 Remove 6 bolts which secure crankcase cover to cylinder block 57090 a a a Bolts 6 ...

Page 173: ...POWERHEAD Page 4 16 90 826883R2 JUNE 1998 11 Use soft mallet to break seal between crankcase cover and cylinder block 57086 12 Lift crankcase cover from block 57087 ...

Page 174: ...8 Page 4 17 Crankshaft 1 Remove cylinder block from crankshaft assembly 57088 2 Slide upper and lower roller bearings and seals off of crankshaft Discard seals c 57089 a b b a Crankshaft Seal Upper b Bearing c Crankshaft Seal Lower ...

Page 175: ...IN BEARING REMOVAL 1 Remove retaining ring from groove of center main bearing race 57092 a a Retaining Ring 2 Remove center main bearing races and center main bearing halves Remove main bearing thrust washers a 57093 b a Bearing Halves b Thrust Washers ...

Page 176: ...bly 1 Using Piston Ring Expander 91 24697 remove and discard piston rings 57094 a a Ring Expander 91 24697 2 Remove and discard piston pin lockrings 57098 a a Lockrings discard IMPORTANT It is recommended that the piston and rod assembly be removed from the crankshaft before removing the piston pin to prevent possible bending of the connecting rod IMPORTANT It is recommended that new needle bearin...

Page 177: ... install them in their original location on the crankshaft 3 Remove and discard rod bolts and remove piston and rod assembly from crank shaft 57099 a a a Rod Bolts discard 4 While supporting piston use Piston Pin Tool 91 76160A2 and soft faced mallet to drive piston pin from piston b 57100 a a Piston Pin Tool 91 76160A2 b Piston Pin ...

Page 178: ...ton needle bearings and locating washers a b b 57101 a Needle Bearings b Locating Washers 6 Remove and discard coupling seal using Snap On Expanding Rod CG 40 4 Snap On Collet CG 40 A6 Slide Hammer 91 34569A1 Purchase from Snap On Tools Corporation 2801 80th Street Kenosha WI 53141 1410 CG 40 A6 CG 40 4 53045 57102 a b c d a Coupling Seal b Collet CG 40 15 c Expanding Rod CG 40 4 d Slide Hammer 91...

Page 179: ...l sealant and old gaskets are re moved from mating surfaces Remove all carbon deposits from exhaust ports de compression ports and cylinder dome 2 Inspect cylinder block and crankcase cover for cracks or fractures 3 Check gasket surfaces for nicks deep grooves cracks and distortion 4 Inspect all water and fuel passages in cylinder block and crankcase cover for obstruc tions 5 Verify that all fitti...

Page 180: ...aced 2 To determine if a groove or mark on the cylinder wall penetrates the chrome surfacing to the aluminum cylinder wall apply a small amount of diluted muriatic acid TIDY BOWL CLEANER to the groove or mark If the groove or mark begins to fizz the aluminum wall is exposed and the cylinder block and crankcase cover must be re placed 3 If a piston is scored and transferred aluminum to the cylinder...

Page 181: ...cidic solution has removed the transferred alu minum thoroughly wash the cylinder bore s with hot water and detergent to remove any remaining acid Cylinder walls may now be honed to remove any glaze and to aid in the seating of new piston rings 2 The cylinder block is Mercosil and if necessary can be rebored to 0 030 in 0 762 mm oversized 3 Check each cylinder bore for an out of round egged shaped...

Page 182: ... can re move cylinder wall material rapidly c Start stroking at smallest diameter Maintain firm stone pressure against cylinder wall to assure fast stock removal and accurate results d Localize stroking in the smallest diameter until drill speed is constant throughout length of bore Expand stones as necessary to compensate for stock removal and stone wear Stroke at a rate of 30 complete cycles per...

Page 183: ...e crankshaft If bottom crankshaft sealing surface is worn replace crankshaft coupling seal 4 Check all crankshaft bearing surfaces for rust water marks chatter marks uneven wear and or overheating blued 5 If necessary clean up crankshaft bearing surfaces with crocus cloth 57104 a a Crocus Cloth 6 Thoroughly clean crankshaft with solvent and dry with compressed air 7 Rechecksurfacesof crankshaft an...

Page 184: ... Crankshaft Seal Bearings ROLLER BEARINGS 1 Clean roller bearing with solvent and dry with compressed air 2 Inspect roller bearing for rust fracturing wear galling or overheating blued Always replace bearings as a set if replacement is necessary 3 Apply light oil to bearings after inspection to prevent rust NOTE Use 2 4 C with Teflon to hold bearings in place while reassembling roller bearings to ...

Page 185: ...or if a 0 002 in 0 051 mm feeler gauge can be inserted between any machined sur face and surface plate rod is bent and must be discarded 57126 a b c a Feeler Gauge b Surface Plate c Even Downward Pressure 2 Overheating Overheating is visible as a bluish bearing surface color that is caused by inadequate lubrication or excessive RPM 3 Rust Rust formation on bearing surfaces causes uneven pitting of...

Page 186: ...ft journal is hammered by the con necting rod As ignition occurs in the cylinder the piston pushes the connecting rod with tremendous force and this force is transferred to the connecting rod journal Since there is little or no load on the crankshaft it bounces away from the connecting rod The crankshaft then remains immobile for a split second until the piston travel causestheconnectingrodtocatch...

Page 187: ...NG ROD 320 grit Carborundum cloth MUST BE USED to clean bearing surface at PISTON PIN END OF CONNECTING ROD VERIFY CAP TO ROD ALIGNMENT BEFORE TORQUING ROD BOLTS DO NOT continue to clean connecting rod bearing surfaces after marks have been removed NOTE Wash rod to remove abrasive grit and apply light oil to bearing surfaces to prevent rust 100 lb in 11 3 N m a b c a To Drill Motor b Use 320 Carbo...

Page 188: ...tch sides of grooves Refer to procedure following for cleaning piston ring grooves CLEANING PISTON RING GROOVES Keystone tapered ring grooves CAUTION Care must be taken not to scratch the side surfaces of the ring groove Scratching the side surface of the ring groove will damage the ring groove 1 Use a bristle brush and carbon remover solution to remove carbon from sidesurfaces 2 A tool can be mad...

Page 189: ...except for inspection pur poses only DO NOT turn used reeds over for reuse If a reed block component is damaged the entire reed block assembly must be replaced Individual compo nents are not sold separately 1 Thoroughly clean reeds and reed block 2 Check for wear indentations cracks or grooves on sealing surfaces of reed block that could cause leakage 3 Check for chipped or broken reeds 4 Inspect ...

Page 190: ...is not adjustable Bleed System 1 Inspect bleed hoses for deterioration Replace hoses as required 2 Inspect bleed valves in lower crankcase cover for proper function Valve should flow fuel only one way from bottom of crankcase cover to intake transfer port cover side of each cylinder If check ball in valve is stuck open or closed replace check valve 5 2 4 3 1 1 90 Fitting 2 2 Bleed Check Valves 2 3...

Page 191: ...of thermometer must be even with bottom of ther mostat to obtain correct thermostat opening Fill thermostat tester with water to cover thermostat Plug tester into electrical outlet Observe temperature at which thermostat begins to open Thermostat will drop off thread when it starts to open Thermostat must begin to open when temperature reaches 5 F 3 C above designated stamping on bottom of thermos...

Page 192: ...enever 2 cycle oil is specified and Quicksilver 2 4 C w Teflon Marine Lubricant whenever grease is specified CAUTION Any GREASE used for bearings INSIDE the powerhead MUST BE gasoline solu ble Use only Quicksilver 2 4 C w Teflon Marine Lubricant or Quicksilver Needle Bearing Assembly Lubricant The use of any other grease may result in power head damage A torque wrench is essential for correct reas...

Page 193: ... well socket and ham mer carefully seat carrier onto crankshaft 57107 a b 7 Loctite 271 92 809820 7 a Carrier b 7 8 in deep well socket 2 Apply 2 4 C w Teflon to crankshaft roller bearings and thrust washers to hold compo nents in place on crankshaft while reassembling 3 Install roller bearings and thrust washers onto crankshaft 57108 95 2 4 C With Teflon 92 825407A12 a b 95 a Race Halves with Rol...

Page 194: ...ce halves retainer ring groove faces toward flywheel end of crankshaft 4 Reinstall bearing race halves Secure halves with retainer ring NOTE Install retainer ring so that ring bridges both fracture lines of bearing race 57109 b a a Race Halves b Retainer Ring ...

Page 195: ...ton pin and piston be installed on the connecting rod prior to installing the connecting rod on the crankshaft to avoid possible bending of the rod during piston pin installation IMPORTANT When replacing needle bearings replace all needles as a set Do not use old and new needles together 6 Install piston onto connecting rod as follows a Lubricate sleeve of Piston Pin Tool 91 76160A2 with 2 4 C w T...

Page 196: ...arings one or more needles are missing and must be replaced 57111 c Install upper locating washer a 57113 a Locating Washer d Slide piston onto connecting rod centering piston pin bore over sleeve e Slide piston tool up thru piston pin bore and remove sleeve 57114 b a a Sleeve b Piston Pin Tool 91 76160A2 ...

Page 197: ...2 Cycle Outboard Oil 92 826666A24 57115 14 b a a Piston Pin b Piston Pin Tool 91 76160A2 g Support bottom of piston and hold piston pin tool up against piston pin h Drive piston pin into piston pin bore with a soft face mallet until pin is flush with piston 57100 a b a Piston Pin Tool 91 76160A2 b Piston Pin ...

Page 198: ...UNE 1998 Page 4 41 i Move piston pin tool to top of piston pin bore and center piston pin in piston 57116 a a Piston Pin Tool 91 76160A2 7 Install new lockrings into grooves in both ends of piston pin bore 37117 a a Lockring ...

Page 199: ... roller bearing onto crank pin 95 2 4 C With Teflon 92 825407A12 95 a 95 a 57118 a Roller Bearing CAUTION The word UP cast on the outside of piston must be toward flywheel end of crankshaft when installing piston rod assembly onto crankshaft Failure to orient piston rod assembly correctly on crankshaft will result in piston rings catching in ports causing powerhead damage If UP is not present on t...

Page 200: ...l to threads prior to installation c Observe connecting rod cap fracture line for correct alignment Secure connect ing rod withv notch of rod towardflywheel endof crankshaft onto crankshaft with rod cap and bolts Torque bolts to 150 lb in 16 9 N m 14 2 Cycle Outboard Oil 92 826666A24 14 57119 b c a d e e a Fracture Line b Connecting Rod c V Notch Toward Flywheel d Rod Cap e Bolts Torque to 150 lb ...

Page 201: ...all new piston rings using Piston Ring Expander 91 24697 Install RECTANGU LAR ring first in bottom ring groove Install HALF KEYSTONE ring in top ring groove Align piston rings with each respective ring groove locating pin 57121 a b c d a Piston Ring Expander 91 24697 b Rectangular Ring c Half Keystone Ring d Locating Pin ...

Page 202: ... on bearings 11 Install new upper and lower crankshaft seals Both seal lips face down Apply 2 4 C w Teflon to seal lips 57089 a b 14 2 Cycle Outboard Oil 92 826666A24 95 2 4 C With Teflon 92 825407A12 95 95 14 14 57089 c d a Upper Crankshaft Seal b Upper Crankshaft Bearing Numbers letters face up out c Lower Crankshaft Bearing Numbers letters face down out d Lower Crankshaft Seal ...

Page 203: ...n hole in center main bearing race with pin of cylinder block 57122 a b c c a Hole b Pin Hidden c Align Pin In Slot 4 Position alignment boss of upper crankshaft roller bearing into notch in cylinder block 5 Gently push seals inward to seat 6 Check each piston ring for spring tension thru transfer and exhaust ports by pressing with a screwdriver If no spring tension exists ring fails to return to ...

Page 204: ...ions Apply a continuous bead of Loctite sealant along the inside of the mounting bolt holes of crankcase cover 57123 a a a Sealant 8 Place crankcase cover onto cylinder block and secure with 6 bolts Torque bolts to 30 0 lb ft 40 7 N m in numbered torque sequence 53192 1 2 a 3 4 5 6 a a Bolts Torque to 16 7 lb ft 22 7 N m ...

Page 205: ...Lubricate seal with 2 4 C w Teflon and install reed block onto cylinder block 95 2 4 C With Teflon 92 825407A12 57080 a b c 95 a Screws Torque to 25 lb in 2 8 N m b Seal c Reed Valve Opening Maximum Opening 0 007 in 0 178 mm 11 Secure carburetor adaptor plate with new gasket to cylinder block with 3 bolts Torque bolts to 80 lb in 9 0 N m 57079 a b a Adaptor Plate b Bolts Torque to 80 lb in 9 0 N m...

Page 206: ...all starboard transfer port covers with new seals Torque attaching bolts to 40 lb in 9 0 N m 57078 a b c a Upper Bleed Hose b Lower Bleed Hose c Transfer Port Covers 14 Install transfer port covers with new seals Torque attaching bolts to 40 lb in 4 5 N m 57085 a b b a Transfer Port Covers b Bolts Torque to 40 lb in 4 5 N m ...

Page 207: ...l cylinder block cover with thermostat and new gaskets Torque bolts to 140 lb in 15 8 N m in torque sequence shown NOTE If tell tale elbow fitting is removed replaced at thermostat cover apply Loctite PST Pipe Sealant to threads of elbow fitting prior to installation 57081 a b c 1 2 3 4 5 6 7 e Loctite PST Pipe Sealant 92 809822 9 d 9 a Cylinder Block Cover b Thermostat Under Cover c Gasket d Elbo...

Page 208: ...rhead with new gasket onto driveshaft housing NOTE It may be necessary to rotate propeller shaft slightly to align crankshaft splines with driveshaft splines 3 Secure powerhead to driveshaft with 6 bolts Torque bolts to 20 lb ft 27 1 N m 57077 a a a Bolts Torque to 20 lb ft 27 1 N m 4 Reinstall trim cover Torque bolts to 85 lb in 9 6 N N m a 57076 a Bolts Torque to 85 lb in 9 6 N m ...

Page 209: ...est running engine check powerhead assembly for leaks and or unusual noises Make any repairs BEFORE returning engine to service Break In Procedure CAUTION To avoid possible engine damage break in procedure MUST BE completed BE FORE operating engine continuously at full throttle Failure to break in engine in properly will result in engine failure or shortened powerhead life IMPORTANT Advise the own...

Page 210: ... 826883R2 JUNE 1998 Page 5 1 MIDSECTION Section 5 CLAMP and SWIVEL BRACKET Table of Contents Clamp Bracket Assembly 5A 2 Swivel Bracket Assembly 5A 4 Drive Shaft Housing Assembly 5A 6 Drive Shaft Housing Disassembly Reassembly 5A 7 ...

Page 211: ...AND SWIVEL BRACKET Page 5 2 90 826883R2 JUNE 1998 Clamp Bracket Assembly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 3 95 2 4 C With Teflon 92 825407A12 95 ...

Page 212: ...SCREW M6x1x40 140 12 0 15 8 11 1 HANDLE carrying 12 1 SPACER 13 1 WASHER tilt tube NYLON 14 1 TILT TUBE 15 1 WASHER tilt tube NYLON 16 1 DECAL co pilot 17 1 TILT PIN ASSEMBLY 18 1 SPRING 19 1 SCREW M6x1x40 140 12 0 15 8 20 1 NUT 7 8 14 120 10 0 13 6 21 1 CLIP safety 22 2 BOLT clamp bracket to transom 23 2 WASHER clamp bracket bolt 24 2 NUT clamp bracket bolt 25 1 NUT 1 4 28 65 7 3 26 1 SCREW 1 4 2...

Page 213: ... 11 12 13 14 15 16 17 18 19 20 21 23 24 25 26 27 28 29 30 31 32 33 35 34 36 37 38 39 40 41 42 43 44 45 46 NO TAG 47 48 49 50 A B B 7 Loctite 271 92 809820 94 Anti Corrosion Grease 92 78376A6 95 2 4 C With Teflon 92 825407A12 94 95 95 95 7 7 7 95 A REMOTE CONTROL MODELS ONLY B TILLER HANDLE MODELS ONLY ...

Page 214: ...se lock 21 1 SPRING REMOTE CONTROL MODELS 22 1 SPRING ALL OTHER MODELS 23 1 SPRING 24 1 RING retaining 25 1 PIN 26 1 TROLL BRACKET 27 1 SPRING 28 1 LEVER control 29 1 RING retaining 30 2 COVER lower mount 31 2 SCREW M8x100 390 32 5 44 1 32 1 SCREW M8x60 390 32 5 44 1 33 3 WASHER 34 3 NUT 390 32 5 44 1 35 1 BUMPER front 36 2 MOUNT lower 37 1 SWIVEL HEAD 38 2 SCREW upper mount M8x1 25x133 220 18 0 2...

Page 215: ...CLAMP AND SWIVEL BRACKET Page 5 6 90 826883R2 JUNE 1998 Drive Shaft Housing Assembly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 A 2 7 Loctite 271 92 809820 7 A SERVICE ONLY ...

Page 216: ...CREW cover 1 4 20x1 1 4 IN Drive Tight 17 6 SCREW drive shaft housing to block M8 x 70 20 27 1 18 6 WASHER drive shaft housing screw 19 4 SCREW M6x1x20 85 9 6 1 TRIM COVER BLACK 20 1 TRIM COVER GRAY 20 1 TRIM COVER TRACKER GRAPHITE GRAY Drive Shaft Housing Disassembly Reassembly Servicing components such as steering arm drive shaft housing exhaust assembly and swivel bracket will usually require p...

Page 217: ...ar 6A 25 Driveshaft 6A 25 Bearing Carrier 6A 26 Reassembly 6A 26 Drive Shaft Bearing and Seals 6A 26 Shift Shaft 6A 28 Forward Gear Installation 6A 29 Pinion and Driveshaft 6A 31 Propeller Shaft 6A 31 Bearing Carrier 6A 33 Bearing Carrier Propeller Shaft Installation 6A 34 Water Pump 6A 35 Gear Housing Installation 6A 36 Trim Tab Adjustment and Replacement 6A 41 Filling Gear Housing with Lubricant...

Page 218: ... 809819 Loctite 271 92 850736A1 2 4 C w Teflon 92 809824 Loctite Primer 7649 92 850737A1 Super Duty Gear Lubricant Special Tools 1 Universal Puller Plate 91 37241 2 Leakage Tester FT8950 3 Bearing Puller Installation Tool 91 31229A7 a Nut 11 24156 b Washer 2 12 34961 c Plate 91 29310 d Threaded Rod 91 31229 ...

Page 219: ...826883R2 JUNE 1998 Page 6A 3 e Mandrel 91 36571 4 Bearing Puller Tool 91 27780 5 Slide Hammer 91 34569A1 6 Bearing Carrier Tool 91 93843 1 91 93843 1 7 Bearing Cup Puller 91 44385 56812 8 Bushing Removal Tool 91 824787 ...

Page 220: ...ING Page 6A 4 90 826883R2 JUNE 1998 9 Driveshaft Seal Installation Tool 91 858775 10 Bearing Carrier Prop Shaft Seal Installation Tool 91 858776 11 Bearing Carrier Prop Shaft Bearing Installation Tool 91 858777 ...

Page 221: ...GEAR HOUSING 90 826883R2 JUNE 1998 Page 6A 5 Notes ...

Page 222: ... 29 30 34 35 36 37 38 39 40 41 42 43 44 31 32 33 17 92 87 95 7 2 4 C w Teflon 92 850736A1 Loctite 271 92 809819 Super Duty Gear Lubricant 92 850737A1 Loctite Primer 7649 92 809824 7 87 92 95 95 95 95 95 GEAR HOUSING Page 6A 6 90 826883R2 JUNE 1998 Gear Housing Drive Shaft ...

Page 223: ...tic 60 6 8 11 1 WASHER 12 1 SCREEN starboard 13 1 NUT M5 14 1 ROLLER BEARING ASSEMBLY 15 1 CUP 16 1 PINION GEAR 12 29 17 1 NUT 15 20 3 18 1 GASKET 19 1 FACE PLATE 20 1 WASHER 21 1 KEY 22 1 lMPELLER 23 1 WASHER 24 1 O RING 25 1 WATER PUMP ASSEMBLY 26 1 INSERT 27 1 SEAL 28 1 RING 29 4 BOLT M6 x 16 60 6 8 30 1 SHIFT SHAFT 31 1 NUT M6 Tighten Securely 32 1 COUPLER Tighten Securely 33 1 SHIFT SHAFT UPP...

Page 224: ... 63 64 65 68 69 70 1 66 67 87 95 7 2 4 C w Teflon 92 850736A1 Loctite 271 92 809819 Super Duty Gear Lubricant 92 850737A1 94 Anti Corrosion Grease 92 850735A1 7 87 87 87 94 95 95 95 GEAR HOUSING Page 6A 8 90 826883R2 JUNE 1998 Gear Housing Propeller Shaft ...

Page 225: ...ER BEARING 49 1 CUP 50 1 FORWARD GEAR 12 29 51 1 BUSHING 52 1 CAM FOLLOWER 53 1 SPRING 54 1 CLUTCH 55 1 CROSS PIN 56 1 SPRING 57 1 PROPELLER SHAFT 58 1 REVERSE GEAR 12 29 59 1 BEARING CARRIER ASSEMBLY 80 0 108 5 60 1 ROLLER BEARING 61 1 OIL SEAL INNER 62 1 OIL SEAL OUTER 63 1 O RING 64 1 PLATE 65 3 BOLT M5x16 65 7 2 66 4 BOLT M10 x 35 40 54 2 67 4 WASHER 68 1 THRUST HUB ASSEMBLY 69 1 PROPELLER 70 ...

Page 226: ...ck of lu brication After cleaning lubricate bearings with Quicksilver Gear Lubricant DO NOT lubri cate tapered bearing cups until after inspection Inspect all bearings for roughness catches and bearing race side wear Work inner bearing race in and out while holding outer race to check for side wear When inspecting tapered bearings determine condition of rollers and inner bearing race by inspecting...

Page 227: ... Washer b Drain Plug Washer 2 Inspect gear lubricant for metalparticles lubricant willhave a metal flake appearance Presence of fine metal particles resembling powder on the drain plug magnet indicates normal wear Metal chips on the magnet indicate the need for gear housing disassembly and component inspection 3 Note color of gear lubricant White or cream color indicates presence of water 4 Presen...

Page 228: ...oving gear housing 1 Tilt outboard to full UP position 9 9 15 Bigfoot 4 Stroke 2 Remove reverse hook guide assembly from lower shift shaft 3 Loosen jam nut and disconnect coupler Remove jam nut to allow removal of gearcase a b c a Reverse Hook Guide b Jam Nut c Coupler 20 25 2 Stroke 4 Unlatch and remove retainer to free shift shaft for removal of gearcase 57047 a a Retainer ...

Page 229: ...lide off shift shaft when gear case is removed Do not lose washer as washer is necessary for reassembly a 51187 a Flat Washer 5 Remove four screws and remove gear housing 56804 a a Screws 4 NOTE If water tube should pull out of driveshaft housing remove tube from water pump and insert tube back into driveshaft housing to aid in reassembly ...

Page 230: ...ing from gear housing 2 Remove bearing carrier using Special Tool 91 93843 1 LEFT HAND THREAD a b c d 91 93843 1 56805 d a Screws 3 b O Ring Retainer Plate c O Ring d Bearing Carrier 3 While holding onto propeller shaft and bearing carrier pull propeller shaft from propeller shaft cavity as shown NOTE Cam follower is free to slide out of propeller shaft 4 Remove reverse gear and bearing carrier fr...

Page 231: ...r in a vise Using a screwdriver pry out both seals from bearing carrier 57136 a a Oil Seals Propeller Shaft 1 Insert a thin blade screwdriver or awl under first coil from front of cross pin retainer spring 2 Rotate propeller shaft to unwind spring from sliding clutch a b a Awl b Cross Pin Retaining Ring 3 Insert flat end of cam follower into front end of propeller shaft 4 Position cam follower aga...

Page 232: ...aft a b c a Cam Follower b Spring c Clutch Water Pump 1 Slide centrifugal slinger off drive shaft 2 Remove four 4 screws securing water pump to gear housing as shown in illustration a b b a Centrifugal Slinger b Water Pump Mounting Screws 3 Remove cover nylon washers above and below impeller impeller and drive key from drive shaft 4 It is recommended that impeller be replaced whenever gear case is...

Page 233: ...t shaft from housing 56809 a b c d e 56810 f g h a Cover b Nylon Washer c Impeller d Nylon Washer e Key f Shift Shaft g Face Plate h Base Gasket NOTE Replace impeller if Impeller blades are cracked torn or worn Impeller is glazed or melted Rubber portion of impeller is not bonded to impeller hub ...

Page 234: ... inner f Washer g Spring h Washer i Roll Pin j Driver Pin k Shift Cam Drive Shaft and Pinion Gear 1 Clamp driveshaft in a soft jaw vise and remove pinion nut or bolt that secures pinion to driveshaft Pull driveshaft out of gear housing Remove pinion and tapered roller bear ing NOTE 9 9 15 Bigfoot 4 Stroke uses nut to secure pinion gear 20 25 2 Stroke uses bolt to secure pinion gear a b c a Pinion ...

Page 235: ...ler 91 27780 as shown remove the driveshaft oil seals from gear housing a b 91 27780 a Oil Seals b Water Pump Cartridge Puller 2 Using suitable mandrel drive upper drive shaft bearing through gearcase sleeve to the bottom of gearcase 3 Do not remove gearcase sleeve not shown a b a Upper Driveshaft Bearing b Mandrel ...

Page 236: ...3 Insert tapered end of rod 91 44385 into bearing cup puller and tap bearing cup out of driveshaft bore a c d e f g c 91 44385 b 56911 a b h a Bearing Cup b Bearing Cup Puller 91 44385 c Flat Washers 2 12 34961 d Hex Nut 0 625x18 11 24156 e Threaded Rod 0 625x18 16 Long 91 31229 f Plate 91 29310 g Hex Nut 0 625x18 11 24156 h Tapered Rod 91 44385 Forward Gear Race 1 Use slide hammer to remove forwa...

Page 237: ...ry ball bearings with compressed air 1 Clean bearing in solvent and dry with compressed air 2 Bearing should be free of rust stains 3 Attempt to work inner bearing race in and out There should not be excessive play 4 Lubricate ball bearing with Quicksilver Gear Lube Rotate inner bearing race Bearing should have smooth action If ball bearing sounds or feels rough or has catches remove and discard b...

Page 238: ...rom NEUTRAL into FORWARD or REVERSE 52990 Propeller shaft 1 Check propeller shaft for straightness 2 Inspect bushing bearingsurfaces of propeller shaft for pittingor wear Replace shaft and corresponding bushing bearing if wear or pitting is observed 3 Replace propeller shaft if any of the following exist Splines are twisted or worn Oil seal surface is grooved Shaft has a noticeable wobble or is be...

Page 239: ... 2 Inspect shift cam face for wear Replace if worn 53034 a b a Shift Cam b Shift Shaft Retainer Reverse And Forward Gear 1 Inspect gear teeth for pitting uneven wear scoring etc Replace gear if any damage is found 2 Inspect gear clutch jaws Replace gear if jaws are rounded or chipped b a 52989 a b a Gear Teeth b Clutch Teeth ...

Page 240: ...race requires replacement re place bearing and race as a set 53008 a b c 91 37241 a Bearing b Universal Puller Plate 91 37241 c Mandrel 5 8 in Socket 5 If inspection determines that replacement of forward gear bushing is required remove bushing from forward gear using one of two ways 6 Using a Punch Secure forward gear in a vise Be sure to use a soft jaw vise and do not clamp onto tapered bearing ...

Page 241: ...on Gear Driveshaft IMPORTANT If upper drive shaft bushing or lower drive shaft needle bearing race ap pear to be spinning in their respective bores the gear housing should be replaced 1 Replace drive shaft if the following exist Splines are twisted or worn Oil seal surface is grooved Bearing Bushing journal surfaces are pitted or worn Replace corresponding bearing as well 53036 c b a a Bearing Bus...

Page 242: ...el socket and ham mer 56811 b a a Bearing b Punch Reassembly Drive Shaft Bearing and Seals 1 Install upper driveshaft bearing into driveshaft bore of gear housing sleeve Apply a light coat of 2 4 C w Teflon to upper driveshaft bearing retainer bore as follows Place upper driveshaft bearing over bearing retainer bearing bore with lettered side of bearing face up Using a suitable mandrel press beari...

Page 243: ...Install new driveshaft oil seals into driveshaft bore of gear housing as follows Apply Loctite 271 to outer diameter of driveshaft oil seals With lip of seal facing down press the first oil seal into driveshaft bore until seal is just below the top of driveshaft bore With lip of seal facing up and using Installation tool 91 858775 press the second oil seal into driveshaft bore until seal is 3 16 4...

Page 244: ...E 1998 Shift Shaft 1 Install shift shaft assembly into gear housing assembly 56914 a j i h g f e d c b a k a Shift Shaft Assembly b Boot c Retainer d O ring outer e O ring inner f Washer g Spring h Washer i Roll Pin j Driver Pin k Shift Cam ...

Page 245: ...earing Installation Kit 91 31229A7 over tapered bearing race 5 Place propeller shaft into hole in center of mandrel 6 Install bearing carrier assembly over propeller shaft and thread it in 4 or 5 turns 7 Thread a suitable nut onto propeller shaft to protect propeller shaft threads DO NOT use propeller nut 8 Use a mallet to drive propeller shaft against mandrel until tapered bearing race is firmly ...

Page 246: ...ng 13 Position forward gear tapered bearing over gear 14 Press on inner race of bearing until bearing is firmly seated against forward gear 15 Apply a light coat of Gear Lube to bore in center of forward gear 16 Using a suitable mandrel press forward gear bushing into forward gear until bushing is flush with the back of gear a b c d e b 95 2 4 C w Teflon 92 850736A1 95 a Press b Mandrel c Bearing ...

Page 247: ...4 Secure pinion gear to driveshaft Apply Loctite 271 to pinion nut or bolt Refer to table for Fastener Type and Torque Model Fastener Type Torque 9 9 15 Bigfoot 4 Stroke Pinion Nut 15 lb ft 20 3 Nm 20 25 2 Stroke Pinion Bolt 13 3 lb ft 18 0 Nm 7 Loctite 271 92 809819 7 56913 a b c a Tapered Roller Bearing b Pinion Gear c Fastener Propeller Shaft 1 Position sliding clutch over propeller shaft splin...

Page 248: ...lutch between cam follower and spring 6 Apply a light coat of oil on cross pin and install cross pin into sliding clutch by pushing punch out of clutch with cross pin as shown Release pressure on cam follower and remove follower from propeller shaft a b c 95 2 4 C w Teflon 92 850736A1 95 a Punch b Cross Pin c Cam Follower 7 Install cross pin retainer spring a a Cross Pin Retainer Spring 8 Place a ...

Page 249: ...itable Mandrel b Propeller Shaft Bearing c Lettered end of Bearing 5 Apply Loctite Type 271 to outer diameter of inner propeller shaft seal Use installation tool 91 858776 to press inner seal into bearing carrier lip of seal is facing inward to a depth of 7 8 in 22 2 mm from end of bearing carrier housing 6 Apply 2 4 C w Teflon between seals 7 Apply Loctite Type 271 to outside diameter of the oute...

Page 250: ...and thread it into propeller shaft cavity as far as possible by hand LEFT HAND THREAD 3 Torque bearing carrier using Special Tool 91 93843 1 Torque to 80 lb ft 108 5 Nm 91 93843 1 56805 56806 b a a Reverse Gear b Bearing Carrier Assembly 4 Install O ring and O ring retainer plate on bearing carrier 5 Secure O ring retainer plate to bearing carrier with 3 screws NOTE Orientate O ring to prevent pin...

Page 251: ... vane set 5 Install nylon washer and set it flat against impeller 6 Install new O ring in water pump cover Install cover assembly over driveshaft and down against impeller a b c a Nylon Washer b Face Plate c Drive Key 7 While pushing down on water pump cover assembly rotate driveshaft clockwise to install impeller cover and seat cover against face plate 8 Align mounting holes in gasket face plate ...

Page 252: ...on the lower shift shaft from forward gear to neutral detent Propeller will rotate freely in either direction 4 Coat splines of drive shaft with 2 4 C w Teflon 5 Guide gear housing onto drive shaft housing to aligning the following Keep mating surfaces of gear housing drive shaft housing parallel NOTE It may be necessary to rotate the flywheel to aid engagement of drive shaft splines to crankshaft...

Page 253: ... to 40 lb ft 54 2 Nm 7 Thread retained jam nut onto lower shift to expose five 5 threads above the nut 8 Reconnect shift shaft coupling and tighten jam nut against coupler 9 Shift to forward gear 10 Assemble reverse hook guide around lower shift shaft and tighten bolt nut to allow ad justment 57141 a b c d a Jam Nut b Coupling c Reverse Hook Guide d Lower Shift Shaft ...

Page 254: ...ink Rod d Reverse Lock Hook 13 Lower outboard to the normal operating position 14 Check reverse lock operation as follows Forward Gear Reverse lock fully released Outboard will tilt up Neutral Reverse lock engaged Outboard will not tilt up Reverse Gear Reverse lock fully engaged Outboard will not tilt up 15 Shift outboard into reverse and verify that free play exists between lower loop of reverse ...

Page 255: ... is in forward gear NOTE It is not necessary to grease the drive shaft splines prior to installation of gear hous ing assembly Splines receive internal engine lubrication during normal engine operation 20 Position gear housing so that drive shaft and shift shaft extend up into drive shaft hous ing 21 Move gear housing up toward drive shaft housing while keeping machined surfaces par allel 22 Guide...

Page 256: ...et when propeller shaft is turned clockwise and resistance should be felt when propeller is turned coun terclockwise Place shift lever in NEUTRAL Resistance should NOT be felt when propeller shaft is rotated in either direction Place shift lever in REVERSE Resistance should be felt when propeller shaft is rotated in either direction If shift operation is not as described recheck the coupler instal...

Page 257: ...ab in same location 1 Check trim tab position 2 Operate boat at the speed at which it would normally be operated 3 If the boat pulls to the right starboard the trailing edge of trim tab must be moved to the right If the boat pulls to the left port the trailing edge of trim tab must be moved to the left 4 If necessary adjust trim tab 5 Shift engine control into NEUTRAL and turn ignition key to OFF ...

Page 258: ...d lubricant until it appears at the vent hole b a a Vent Hole b Lubricant Tube 4 Install the vent plug and sealing washer before removing the lubricant tube 5 Remove lubricant tube and reinstall cleaned fill drain plug and sealing washer a b a Vent Plug b Fill Plug 6 Apply a liberal coat of 2 4 C w Teflon 92 825407A12 to propeller shaft splines 95 2 4 C w Teflon 92 850736A1 7 Install thrust hub ca...

Page 259: ...Rod Adjustment 6B 15 Adjusting Shift Link Rod 6B 15 Lubricating the Drive Shaft Bearing 6B 16 Impeller Removal and Installation 6B 17 Steering Pull Adjustment 6B 20 Impeller Clearance Adjustment 6B 20 Worn Dull Impeller 6B 21 Liner Replacement 6B 22 Jet Drive Removal and Installation 6B 23 Removal 6B 23 Installation 6B 23 Water Pump Removal and Installation 6B 24 Removal 6B 24 Installation 6B 24 B...

Page 260: ...JET DRIVE Page 6B 2 90 826883R2 JUNE 1998 Jet Pump Assembly S N 0G157845 Below 95 2 4 C With Teflon 92 825407A12 95 7 7 Loctite 271 92 809820 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 6 6 ...

Page 261: ...BLY GRAY 1 1 HOUSING pump 2 1 HOSE lube 3 1 IMPELLER 4 1 HOUSING intake 5 1 LINER 6 1 DRIVESHAFT 7 1 SLEEVE 8 1 NUT 9 1 ADAPTOR 10 1 BASE pump 11 4 SCREW 10 32 x 1 35 4 0 12 1 SCREW 375 16 x 1 1 4 23 0 31 2 13 4 SCREW 312 18 x 2 160 13 0 18 1 14 4 SCREW 15 1 KEY impeller 16 8 SHIM impeller 17 1 TAB WASHER 18 6 SCREW 250 20 x 3 4 96 8 0 10 8 19 2 SCREW 10 24 x 5 8 30 3 4 ...

Page 262: ...QUE REF NO QTY DESCRIPTION lb in lb ft N m 1 1 COTTER PIN 2 1 ROD END 3 1 BUSHING 4 2 WASHER 5 2 NUT 1 4 28 6 1 SHIFT ROD 7 2 NUT 8 1 ROD END 9 1 SPACER 10 1 SCREW 1 4 20 x 3 4 11 1 WASHER 12 2 WASHER 13 1 BUSHING 14 1 LEVER ASSEMBLY 15 1 SCREW 16 1 KNOB 17 1 SCREW 312 18 x 1 2 18 1 SPRING 19 1 SHAFT 20 1 SCREW 1 4 20 x 1 1 4 21 1 LEVER MOUNT ...

Page 263: ...2 809820 REF TORQUE REF NO QTY DESCRIPTION lb in lb ft N m 1 1 FACE PLATE 2 1 WASHER impeller 3 1 KEY Impeller Drive 4 1 IMPELLER 5 1 WASHER impeller 6 1 O RING water pump 7 1 WATER PUMP ASSEMBLY 8 1 INSERT 9 1 SEAL water tube 10 1 RING driveshaft rubber 11 4 SCREW M6 x 16 70 5 8 7 9 11 4 SCREW M5 x 16 70 5 8 7 9 12 4 BUSHING Use with M5 X 16 REF 11 ...

Page 264: ...JET DRIVE Page 6B 6 90 826883R2 JUNE 1998 Jet Pump Assembly S N 0G157846 Up 95 2 4 C With Teflon 92 825407A12 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 18 19 20 6 95 7 14 7 7 7 7 Loctite 271 92 809820 ...

Page 265: ...IMPELLER 4 1 HOUSING intake 5 1 LINER 6 1 DRIVESHAFT 7 1 SLEEVE 8 1 NUT Drive Tight 9 1 ADAPTOR 10 1 BASE pump 11 4 SCREW 10 32 x 1 30 2 5 3 4 12 1 SCREW 375 16 x 1 1 4 265 22 29 9 13 4 SCREW 312 18 x 2 155 12 9 17 5 14 4 WASHER 15 4 SCREW M10 x 35 300 25 33 9 16 1 KEY impeller 17 8 SHIM impeller 18 1 TAB WASHER 19 6 SCREW 250 20 x 3 4 70 5 8 7 9 20 2 SCREW 10 24 x 5 8 30 2 5 3 4 ...

Page 266: ...JET DRIVE Page 6B 8 90 826883R2 JUNE 1998 Jet Linkage S N 0G157846 Up 7 1 2 4 5 6 7 8 9 10 11 12 13 14 15 8 7 6 9 3 7 Loctite 271 92 809820 ...

Page 267: ... lb ft N m 1 1 NUT 2 1 LOCKWASHER 3 1 SHIFT HANDLE Use without Ref 4 3 1 SHIFT HANDLE Use with Ref 4 4 1 SPACER sleeve 5 1 ROD END 6 2 SPRING 7 2 WASHER 8 2 COTTER PIN 9 2 NUT 70 5 8 7 9 10 1 SHIFT LEVER 11 1 SCREW 10 32 x 3 4 12 1 SCREW 10 32 x 2 1 2 30 2 5 3 4 13 1 SHIFT ROD 14 1 ROD END 15 1 TILT LATCH ROD ...

Page 268: ... speed requires considerably more depth than one which is plan ing 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 The following table is based on experience obtained with sled type boats using outboard jets The gross weights shown includes the outboard boat people and all the gear ...

Page 269: ...boat transom B A D C a a Centerline of Transom Outboard Mounting Height Theinitialoutboardmountingheight settingwill workgood for most applications however because of different boat hulls designs the setting should be rechecked by test running the boat Refer to Water Testing Installing the outboard too high on the transom will allow the water intake to suck in air and cause cavitation Cavitation w...

Page 270: ...long the bottom of the boat with the horizontal line made in Step 1 and measure the distance between the horizontal line and top front edge of the water intake housing a b a Straight Edge b Top Front Edge of Water Intake Housing 5 Raise The outboard up on the transom the distance measured in Step 4 Use a straight edgeand recheckthe mountingheight Thetop edgeof thewater intakehous ing should be lin...

Page 271: ... to the transom at this height Water Testing Checking for Cavitation Making the initial outboard height setting should be close to the optimum setting for the outboard However because of the hull design of some boats obstructions or imperfec tions in the hull ahead of the water intake may require this setting to change in order to prevent cavitation at running speeds When operating the boat the ou...

Page 272: ...30 thru 140 The purpose of these fins is to ram more water into the intake and shield the for ward sides of the intake from the entrance of air This kit will help reduce cavitation when running with the wind in a chop a a Intake Fin Kit Water Intake Fin Kit Part No 1186 for jet models 45 thru 140 and Part No 1185 for jet mod el 30 is available from Specialty Mfg Co 2035 Edison Ave San Leandro CA 9...

Page 273: ... Checking Shift Link Rod Adjustment Check the shift link rod a adjustment in forward shift position The correct adjustment will position the shift cam b far enough on the roller c in order to lock the the reverse gate d into forward position You should not be able to forcibly push up the reverse gate toward neutral Pull on the reverse gate by hand to verify this Adjusting Shift Link Rod 1 Place th...

Page 274: ...0 hours of operation pump in extra grease to purge out any moisture Lubricating Procedure Pull vent hose off the grease fitting Pump in grease through the grease fitting until excess grease starts to exit the vent hose a b a Vent Hose b Grease Exiting Vent Hose Reconnect the vent hose onto the grease fitting after greasing After 30 hours of operation pump in extra grease to purge out any moisture ...

Page 275: ...ater intake housing that is fastened with six screws 4 Straighten the bent tabs on the impeller nut retainer and remove the impeller nut 5 Pull impeller straight off the shaft If the impeller is tight use a hammer and block of wood to rotate the impeller clockwise on the shaft until the keyway is directly above the flat on the shaft This will free the jammed key and allow removal a b a Tab b Nut ...

Page 276: ...flats on the nut remove the nut and turn the retainer over and re tighten the nut again a b f c d e a Plastic Sleeve b Impeller c Shear Key d Shims e Nut Retainer f Impeller Nut 2 Temporarily reinstall the water intake housing in order to check for impeller clearance The clearance between the impeller and liner should be 0 030 in 0 8 mm Shim washers can be transferred to either side of the impelle...

Page 277: ...4 Reinstall the water intake housing with six bolts Check clearance around the impeller to make sure the water intake housing is centered and not rubbing against the liner Torque mounting bolts to 100 lb in 11 3 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 moun...

Page 278: ... ance between the impeller edge and liner Operating the jet drive in waters that con tain sand and gravel can cause wear to the impeller blades and the clearance will start to exceed 0 030 in 0 8 mm As the blades wear shims a located in the stack outside of the impeller can be transferred behind the impeller This will move the im peller further down into the tapered liner to reduce the clearance 2...

Page 279: ...noticeable performance loss especially on acceleration 2 difficultly getting the boat on plane or 3 an increase in engine RPM at wide open throttle Check the impeller blades occasion ally for damage Use a flat file to resharpen the leading edges as shown a b c d a Do not sharpen or alter the top side lifting angle b Leading Edge c Sharpen to 1 32 in 0 8mm radius by removing material from bottom si...

Page 280: ...ough the intake grate NOTE Apply grease to the liner mounting bolt threads before assembly 3 Position the liner into the water intake housing Line up one of the liner bolts and lightly thread it in It may be necessary to tap or press the liner into the water intake housing to locate the liner for installation of the remaining bolts Torque bolts to 100 lbs in 11 3 N m 4 Grind off the ends of any bo...

Page 281: ...tionpreced ing 2 Disconnect the shift linkage Remove 5 bolts shown securing jet drive to drive shaft housing and remove jet drive Installation 1 Install jet drive with bolts shown b a a 7 Loctite 271 92 809820 7 7 a Bolts 4 Apply Loctite 271 to Threads and Torque to 25 lb ft 34 0 N m b Bolt 1 Apply Loctite 271 to Threads and Torque to 23 0 lb ft 31 0 N m ...

Page 282: ...service NOTE Apply a light coat of 2 4 C w Teflon to inside of pump cover to ease installation of cover over impeller 1 Reassemble water pump assembly as shown Rotate drive shaft CLOCKWISE while pressing water pump body down over impeller c 95 95 2 4 C With Teflon 92 825407A12 b a d h e f g i k j l m a Bolt and flat washer 4 Apply Loctite 271 to threads b Bushing 4 Used on earlier type water pumps...

Page 283: ...o 30 lb in 3 4 N m Installing Drive Shaft Bearing Single Bearing System Small Diameter Bearing 1 If removed install the bearing thrust ring a into the groove on the drive shaft 2 Install collar b onto the drive shaft Install thrust washer c gray Teflon coating side facing the ball bearing Press the new ball bearing d onto the drive shaft pressing against the inner race only Press collar b over the...

Page 284: ...groove on the drive shaft 2 Install collar onto the drive shaft Press the new ball bearing onto the drive shaft pressing against the inner race only Press collar over the thrust ring a locking it in its groove Install snap ring into drive shaft groove below the bearing a b c d b c d a a Bearing Thrust Ring b Collar c Ball Bearing d Snap Ring ...

Page 285: ... bearing carrier a onto the drive shaft Square up the inner bore with the ball bearing s and push the bearing carrier down until it bottoms out against the bear ing It may be necessary to lightly tap bearing carrier onto the bearing s using a rub ber hammer NOTE Only a light pressing force is needed to press on the bearing carrier It may be nec essary to lightly tap the bearing carrier onto the be...

Page 286: ...Install the upper seal housing b being careful not to damage the O ring seals as they pass the snap ring groove Only finger pressure should be necessary to push in the housing 5 Install the beveled snap ring a beveled side facing up into the ring groove Make sure the snap ring is fully seated into groove 6 Install the bearing carrier into the jet drive and fill with grease using a grease gun If us...

Page 287: ... Cables Tiller Handle Shift 7A 4 Removal Installation 7A 4 Control Platform 7A 4 Removal Disassembly 7A 4 Reassembly Installation 7A 7 Throttle Cam Control Lever 7A 10 Removal 7A 10 Throttle Cam Control Lever 7A 10 Reassembly 7A 10 Installation 7A 12 Neutral Interlock Control Lever 7A 13 Reassembly Installation 7A 13 Horizontal Shift Shaft 7A 14 Removal 7A 14 Installation 7A 15 ...

Page 288: ... 1998 Throttle and Shift Linkage Tiller Handle Shift 1 2 3 17 18 19 4 5 6 7 8 9 10 11 12 13 14 15 16 20 21 22 23 32 33 34 35 36 37 38 39 40 41 42 43 44 15 A 36 37 24 25 26 27 28 29 30 31 45 46 95 2 4 C With Teflon 92 825407A12 95 A LOCAL ELECTRIC ONLY ...

Page 289: ...EL 9926999 BELOW 20 1 THROTTLE CAM ASSEMBLY S 21 1 LEVER gear shift USA 0G286099 BELOW 22 1 PRIMARY LEVER BEL 9881099 BELOW 23 1 WASHER 62x 255x 03 Use w Ref 20 20 1 THROTTLE CAM ASSEMBLY S N 21 1 LEVER gear shift USA 0G286100 thru 0G437999 22 1 PRIMARY LEVER BEL 9881100 thru 9926999 23 1 WASHER Use w Ref 20 24 1 WASHER 25 1 WAVE WASHER 26 1 THROTTLE CAM S N 27 1 SPRING USA 0G438000 UP 28 1 SPARK ...

Page 290: ...Section 7B for removal and installation instructions Control Platform Removal Disassembly 1 Disconnect control cables from anchor bracket and pulley as outlined in Section 7B 2 Disconnect throttle link rod from ball joint of primary throttle lever a a b e c d 57031 a Cables b Bracket c Pulley d Link Rod e Throttle Lever ...

Page 291: ...6883R2 JUNE 1998 Page 7A 5 3 Disconnect shift link rod from ball joint of gear shift lever 57033 a c b a Shift Link Rod b Gear Shift Lever c Shift Lever 4 Remove 3 bolts and control platform 57034 a a b a Bolts b Control Platform ...

Page 292: ... a a Nuts b Flat Washers 6 Disassemble control platform 53174 b c d e a f e e g h i j a Bolts 2 Torque to 120 lb in 13 6 N m b Flatwashers 2 c Primary Gear d Bushing Long e Mount Bolts Torque to 120 lb in 13 6 N m f Control Platform g Bushing Short h Detent Spring i Detent Ball j Secondary Gear ...

Page 293: ...m traveled by gears with 2 4 C w Teflon c b 57038 95 2 4 C With Teflon 92 825407A12 95 a a Short Bushing b Long Bushing c Platform 4 Install secondary gear over short bushing and detent ball and spring as shown 5 Secure secondary gear with bolt and flat washer Torque bolt to 120 lb in 13 6 N m 6 Lubricate gear teeth with 2 4 C w Teflon b a 57039 95 2 4 C With Teflon 92 825407A12 95 a Secondary Gea...

Page 294: ...orque bolt to 120 lb in 13 6 N m 9 Lubricate gear teeth with 2 4 C w Teflon 57040 a b 95 95 2 4 C With Teflon 92 825407A12 a Primary Gear b Bolt and Flat Washer Torque to 120 lb in 13 6 N m 10 Secure assembled control platform onto cylinder block using 3 bolts Torque bolts to 120 lb in 13 6 N m 57034 a b b a Platform b Bolts Torque to 120 lb in 13 6 N m ...

Page 295: ...ver b c a 57033 a Shift Link Rod Adjust to length of 5 1 2 in 13 9 cm b Shift Shaft Lever c Secondary Lever 13 Adjust throttle link rod to a length of 5 1 4 in 13 3 cm as measured between ball joint centerlines 14 Connect throttle link rod between ball joints of primary gear and throttle cam a b c d e f a Throttle Link Rod Adjust to length of 5 1 4 in 13 3 cm b Primary Gear c Throttle Cam d Pulley...

Page 296: ...r to Section 7B for removal of throttle cables 2 Remove bolt and flat washer securing cam lever to powerhead c a b 57041 a Bolt b Washer c Cam Lever Throttle Cam Control Lever Reassembly 1 Position spring over hub of throttle cam Spring ends must straddle tab a b b c 57042 a Hub b Spring Ends c Tab ...

Page 297: ... C w Teflon and install bushing and wave washer 57050 a b 95 2 4 C With Teflon 92 825407A12 95 a Bushing b Wave Washer 3 Install control lever onto throttle cam assembly so that tabof controllever ispositioned between ends of spring c c b a 57043 a Control Lever b Tab c Ends of Spring ...

Page 298: ...control lever and trigger assembly 57041 a b c d e a Throttle Cam b Control Lever c Flat Washer d Bolt Torque bolt to 120 lb in 13 6 N m e Timing Link 3 Adjust throttle link rod to a length of 5 1 4 in 13 3cm as measured between ball joint center lines 4 Connect throttle link rod between ball joints of throttle cam and primary throttle lever 57031 a b c a Throttle Link Rod Adjust to a length of 5 ...

Page 299: ...ion 1 Lubricate bushing with 2 4 C w Teflon and install bushing 57045 a 95 2 4 C With Teflon 92 825407A12 95 a Bushing 2 Secure interlock lever components with bolt onto mounting boss of crankcase cover 57044 a b c d a Interlock lever b Flat washer c Bolt Torque to 120 lb in 13 6 N m d Neutral Interlock Wire ...

Page 300: ... 90 826883R2 JUNE 1998 Horizontal Shift Shaft Removal 1 Remove nut securing access cover to port side of bottom cowl Remove cover 57035 b a a Nut b Access Cover 2 Lift up and remove lever securing horizontal shift shaft 56915 a a Lever ...

Page 301: ... 7A 15 3 Pull out and remove horizontal shift shaft a 57046 a Horizontal Shift Shaft Installation 1 Install horizontal shift shaft shift lever assembly into opening in STARBOARD side of crankcase cover a 57046 b a Horizontal Shift Shaft b Shift Lever ...

Page 302: ...ntal shift shaft with lever 57047 a a Lever 3 Reinstall access cover and secure with nut and bolt Torque nut to 50 lb in 5 6 N m 57035 b a a Access Cover b Nut Torque to 50 lb in 5 6 N m 4 Refer to Control Platform Throttle Cam Control Lever previous and reinstall plat form shift link and throttle cam ...

Page 303: ...1998 Page 7B 1 CONTROLS Section 7B Tiller Handle Table of Contents Tiller Handle Assembly 7B 2 Control Cables 7B 4 Removal 7B 4 Tiller Handle Removal Disassembly 7B 5 Removal 7B 5 Installation 7B 7 Control Cables 7B 10 Installation 7B 10 ...

Page 304: ...HANDLE Page 7B 2 90 826883R2 JUNE 1998 Tiller Handle Assembly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 7 Loctite 271 92 809820 95 2 4 C With Teflon 92 825407A12 95 95 7 95 ...

Page 305: ...VE throttle cable 8 1 ARM steering handle BLACK 8 1 ARM steering handle GRAY 9 2 SCREW M5x1x16 80 9 0 9 2 SCREW M6x1x20 10 1 SCREW M5x 5x16 50 5 6 11 1 KNOB throttle friction As Required 12 1 SPRING 13 1 LOCK throttle friction 14 1 SCREW M6x1x25 15 1 TILLER TUBE 16 1 DECAL TILLER HANDLE SHIFT 16 1 DECAL SIDE SHIFT 17 1 THROTTLE HANDLE TILLER HANDLE SHIFT 17 1 THROTTLE HANDLE SIDE SHIFT 18 1 GRIP t...

Page 306: ...ottle cam and primary throttle lever 57031 a b c a Link Rod b Throttle Cam c Primary Throttle Lever 3 Loosen jam nuts which secure control cables to anchor bracket 4 Unwrap and remove control cables from pulley of primary gear NOTE If not replacing control cables mark top cable with a piece of tape to aid in reas sembly a 57032 a b a Jam Nuts b Primary Gear ...

Page 307: ...HANDLE 90 826883R2 JUNE 1998 Page 7B 5 5 Remove nut securing access cover and remove cover 57035 a b a Nut b Access Cover 6 Disconnect stop button wires BLACK YELLOW and BLACK 57036 a b a BLACK YELLOW b BLACK ...

Page 308: ...e 2 bolts securing tiller handle to anchor bracket and remove tiller handle as sembly 57037 a a Bolts 2 Remove bushing flatwashers 2 wave washer and tiller handle washer Remove re tainer and bolt 53248 a b c d e f b a Bushing b Flat Washer 2 c Wave Washer d Tiller Handle Washer e Retainer f Bolt ...

Page 309: ...lley case 53256 b a a Tiller Tube b Pulley Case 4 Remove pulley case assembly from tiller handle and remove cover bolt 53262 a b a Pulley Case Assembly b Cover Bolt 5 Remove cover and lift pulley assembly from case Replace cables as required 53257 a b a Cover b Pulley Assembly ...

Page 310: ... wraps and locks in bottom groove 2 Place pulley and cable assembly into pulley case 53257 a b c a Pulley b Top Cable c Bottom Cable 3 Install pulley cover and secure cover with bolt 53262 a b a Cover b Bolt Drive Tight 4 Install pulley assembly into tiller handle and slide tiller tube into pulley 53256 a b a Pulley Assembly b Tiller Tube ...

Page 311: ...sembly 53248 d e b a c f g h f a Retainer b Bolt Torque to 50 lb in 5 6 N m c Tiller Washer d Tab e Slot f Plain Washer g Wave Washer h Flanged Bushing 7 Slide tiller handle assembly into anchor bracket 8 Route stop button harness through fuel connector opening in bottom cowl 9 Route control cables through opening in bottom cowl 10 Align tabs of inner and outer flanged bushings with slots in ancho...

Page 312: ...9 0 N m 57037 b a a Plate b Bolts Torque to 80 lb in 9 0 N m Control Cables Installation 1 Rotate tiller handle twist grip to REVERSE gear position 2 Route extended cable over top of primary gear pulley and secure cable into inner groove of pulley Place cable jacket into top notch of cable anchor bracket 57048 b a c d a Extended Cable b Inner Groove c Cable Jacket d Top Notch ...

Page 313: ... 5 Rotate tiller handle twist grip to NEUTRAL 6 Rotate tiller handle twist grip to SLOW position 7 Adjust jam nuts to remove slack from throttle cables while allowing full travel of throttle linkage carburetor throttle shutter 57049 a b c d e a Cable b Outer Groove c Cable Jacket d Lower Notch e Jam Nuts 8 Reinstall access cover Secure cover with nut and bolt Torque nut to 50 lb in 5 6 N m 57035 b...

Page 314: ...kage Side Shift 7C 2 Throttle Cables Side Shift Models 7C 4 Removal Installation 7C 4 Throttle Cam Control Lever 7C 4 Removal 7C 4 Throttle Cam Control Lever 7C 5 Reassembly 7C 5 Installation 7C 6 Neutral Interlock Control Lever 7C 8 Reassembly Installation 7C 8 Horizontal Shift Shaft 7C 9 Reassembly Installation 7C 9 ...

Page 315: ...IDE SHIFT Page 7C 2 90 826883R2 JUNE 1998 Throttle And Shift Linkage Side Shift 17 18 19 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 27 16 28 20 29 27 28 21 22 23 24 25 26 95 2 4 C With Teflon 92 825407A12 95 95 ...

Page 316: ...1 LEVER horizontal shift shaft PORT 11 1 SHIFT SHAFT HORIZONTAL 12 1 SHIFT HANDLE 13 1 SCREW M5 x 20 50 5 6 14 1 WASHER 15 1 THROTTLE CAM 16 1 WASHER 17 1 SPARK ADJUST LINK 20 JET 18 2 SOCKET 19 1 NUT 20 1 ANCHOR BRACKET cable 15 1 THROTTLE CAM 20 25 16 1 WASHER 17 1 SPARK ADJUST LINK S N 18 2 SOCKET USA 0G437999 BELOW 19 1 NUT BEL 9926999 BELOW 20 1 ANCHOR BRACKET cable 20 1 ANCHOR BRACKET cable ...

Page 317: ...stallation Refer to Section 7B for removal and installation instructions Throttle Cam Control Lever Removal 1 Refer to Section 7B for removal of throttle cables 2 Remove bolt and flat washer securing cam lever to powerhead 57065 a b c d a Throttle Cam b Control Lever c Flat Washer d Bolt ...

Page 318: ...l Lever Reassembly 1 Position spring assembly over hub of throttle cam 57042 a a c b a Inner Spring Ends b Hub c Tab 2 Lubricate bushing with 2 4 C w Teflon and install bushing and wave washer 57042 b a 95 2 4 C With Teflon 92 825407A12 95 a Bushing b Wave Washer ...

Page 319: ... Control Lever b Tab c Ends of Inner Spring Installation 1 Secure throttle cam control lever assembly onto mounting boss of crankcase cover with bolt Torque bolt to 120 lb in 13 6 N m 2 Connect timing link between ball joints of control lever and trigger assembly 57065 a b c d e a Throttle Cam b Control Lever c Flat Washer d Bolt Torque bolt to 120 lb in 13 6 N m e Timing Link ...

Page 320: ...0 826883R2 JUNE 1998 Page 7C 7 3 Connect throttle cables to throttle cam and throttle cable anchor bracket as outlined in Throttle Cable Installation preceding 57063 a c b a Throttle Cables b Throttle Cam c Bracket ...

Page 321: ...Lubricate bushing with 2 4 C w Teflon and install bushing 57045 a 95 2 4 C With Teflon 92 825407A12 95 a Bushing 2 Secure interlock lever components with bolt onto mounting boss of crankcase cover 57064 d a b c a Interlock Lever b Flat Washer c Bolt Torque to 120 lb in 13 6 N m d Neutral Interlock Wire ...

Page 322: ...Installation 1 Install horizontal shift shaft shift lever assembly into opening in STARBOARD side of crankcase cover 57046 b a a Horizontal Shift Shaft b Shift Lever 2 Secure horizontal shift shaft to shift rod with lever 57047 b a c a Lever b Horizontal Shift Shaft c Shift Rod ...

Page 323: ... 3 Install rubber grommet into opening in starboard side of bottom cowl 4 Secure shift handle onto end of horizontal shift shaft with screw and flat washer Torque screw to 50 lb in 5 6 N m 57061 d c b a a Grommet b Shift Handle c Screw d Washer ...

Page 324: ...nual Starter Table of Contents Specifications 8 1 Starter Assembly Manual 8 2 Rewind Starter Assembly 8 4 Removal 8 4 Installation 8 5 Starter Rope Replacement 8 7 Disassembly 8 11 Cleaning and Inspection 8 12 Reassembly 8 12 Specifications STARTING SYSTEM Manual Start Rope Length Recoil 66 in 1676 mm ...

Page 325: ...er Assembly Manual Cyanacrylate Adhesive purchase locally 26 95 2 4 C With Teflon 92 825407A12 1 4 5 6 7 8 9 2 10 11 12 13 14 15 16 17 18 19 20 31 27 28 21 22 23 24 29 30 32 25 29 30 31 32 A B 26 95 3 26 26 95 95 A 30 lb in 3 5 N m B 110 lb in 12 5 N m ...

Page 326: ...NDLE ASSEMBLY starter rope 14 1 RETAINER 15 1 BUSHING rope 16 1 SUPPORT starter handle 17 2 SCREW support to starter housing M5x35MM 18 4 SPACER support screw 19 1 SUPPORT 20 2 NUT support screw 30 3 4 21 1 LEVER lock LOWER 22 1 ROLL PIN lock lever 23 1 SPRING upper lock lever 24 1 LEVER lock UPPER 25 1 BUSHING 26 3 SCREW M6 x 35 NON SEAPRO MARATHON USA 0G BEL UP 110 12 4 26 2 SCREW M6 x 20 NON SE...

Page 327: ...n removing Remove fuel filter by pulling straight down Turning or cocking fuel filter may break fuel line connec tion on filter 1 Pry fuel filter from starter rope guide DO NOT turn or cock filter pull straight down 53246 b a 56800 a Filter b Guide 2 Unsnap interlock link rod from lower lock lever b 56803 a a Link Rod b Lock Lever ...

Page 328: ...r from engine b a a a a Bolts b Rewind Starter Installation 1 Secure rewind starter to engine with 3 bolts Apply Loctite 242 to threads of 3 mount ing bolts Torque bolts to 110 lb in 12 4 N m b a a a 66 Loctite 242 92 809821 66 66 66 a Bolts Torque to 110 lb in 12 4 N m b Rewind Starter ...

Page 329: ... lower lock lever b 56803 a a Link Rod b Lock Lever CAUTION Push filter straight up when installing Turning or cocking filter may break fuel line connection on filter 3 Push ball of fuel filter into socket of rope guide DO NOT turn or cock fuel filter 53247 b a a Filter b Guide ...

Page 330: ...er sheave 3 Pull starter rope handle out from rewind starter about 1 ft 30 5cm and tie a knot at this point to prevent rope from being pulled back into rewind starter NOTE 1999 Model and newer have a redesigned rope guide support which must be re moved before replacing starter rope 57051 a b a Interlock b Rope Guide Support 1999 Model and Newer 4 Remove rope retainer from starter handle and rope 5...

Page 331: ... rope Place knot into recess of rope retainer Install rope retainer into starter handle 53233 a b c a Handle b Knot c Retainer CAUTION Starter sheave must be firmly held against spring tension to prevent spring from unwinding 6 Pull starter rope from rewind starter until rope is fully unwound from starter sheave b a 57052 a Rope b Sheave ...

Page 332: ...nd pull all remaining rope from sheave c a b 57053 a Sheave b Knot c Recess 8 Turn sheave COUNTERCLOCKWISE until stop indicating spring is wound tight 9 Slowly turn sheave CLOCKWISE with spring tension until knot recess is aligned with rope hole in starter housing a c b 57054 a Sheave b Knot Recess c Rope Hole ...

Page 333: ...ing and starter sheave Pull end of rope out of knot recess b c a 57056 a Rope b Holes c Knot Recess 11 Tie a knot into end of rope and pull knot back into knot recess 57057 a b a Knot b Knot Recess 12 Allow starter rope to be slowly rewound onto starter sheave 13 Reinstall rope guide support if applicable ...

Page 334: ...rope as outlined previously 2 With rope removed allow sheave to slowly unwind to release spring tension 3 Remove bolt securing cam and sheave to housing 57055 a b a Bolt b Sheave 4 Gently lift starter sheave from housing 5 Rewind spring assembly may be replaced as required DO NOT remove spring from retainer Spring and retainer are replaced as an assembly 57058 a b a Sheave b Rewind Spring ...

Page 335: ...age Replace as necessary 4 Inspect starter sheave and housing for nicks grooves cracks and distortion especial ly in area of rope travel Replace assembly if necessary 5 Inspect starter rope for wear and replace if necessary Reassembly 1 Apply 2 4 C w Teflon 92 825407A12 to rewind spring and cam tension spring 2 Install rewind spring assembly into recoil housing positioning end of spring in notch 5...

Page 336: ...o 70 lb in 7 9 N m 57055 a 95 2 4 C With Teflon 92 825407A12 b 95 95 a Cam b Bolt NOTE If after tightening cam retaining bolt sheave does not move freely sheave is not aligned properly with recoil spring retainer Remove cam retainer bolt and check align ment of sheave with spring retainer 5 Apply 2 4 C w Teflon to edge of cam that contacts both pawls 6 Install starter rope as outlined previously 7...

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