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Mercury 225 EFI, Service Manual

The Mercury 225 EFI is a high-performance outboard motor designed for optimal power and efficiency on the water. Ensure you have all the necessary information with the free Service Manual available for download on manualshive.com. This manual provides detailed instructions and maintenance tips to keep your motor running smoothly.

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POWERHEAD

90-884294   OCTOBER 2001

Page 4A-11

Exhaust Adaptor Plate

REF

TORQUE

REF.

NO.

QTY.

DESCRIPTION

lb-in

lb-ft

Nm.

1

1

EXHAUST PLATE

2

1

GASKET

3

1

GASKET (LOWER)

4

1

SEAL

5

1

CHECK VALVE FITTING

6

1

PIPE PLUG

7

2

DRAIN CHECK VALVE

8

4

DOWEL PIN

9

1

COVER

10

2

SCREW (M8 X 35)

150

17

11

1

CARRIER

12

1

GROMMET

13

1

POPPET

14

1

SPRING

15

1

RELIEF VALVE PLATE ASSEMBLY

16

2

GASKET

17

1

DIAPHRAGM

18

1

WASHER

19

1

SCREW (10-16 X 3/4 IN.)

25

3

20

6

SCREW (M8 X 35)

25

34

21

1

IDLE EXHAUST BOOT

22

2

CLAMP

23

1

FITTING – TELL TALE

24

1

PLUG

25

1

WASHER

26

1

FITTING

27

1

CHECK VALVE

28

1

O-RING

29

1

NUT

30

1

SHIFT LINK

31

1

SLIDE

32

1

NUT

33

1

BUSHING

34

1

UPPER SHIFT SHAFT

35

1

BUSHING

36

1

COUPLING

37

1

HOSE (INLET)

38

1

GROMMET SPLIT

39

2

WASHER

40

1

TUBING (3 IN.)

41

2

FITTING

Summary of Contents for 225 EFI

Page 1: ...ber 0T409000 Starting Model Year 2002 90 884294 OCTOBER 2001 3 0 Litre Work 225 250 EFI www mercurymarine com au Frankston Road P O Box 80 Dandenong Victoria 3175 Australia www mercurymarine com W6250...

Page 2: ...g 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...

Page 3: ...omponent 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 rep...

Page 4: ...al Information D Outboard Installation Section 2 Electrical A Ignition B Charging Starting System C Timing Synchronizing Adjusting D Wiring Diagrams Section 3 Fuel System A Fuel Pump B Fuel Injection...

Page 5: ...lbs 210 0 kg 479 0 lbs 217 3 kg CYLINDER BLOCK Model 3 Liter Work 225 EFI 250 EFI Type Displacement Thermostat V 6 Cylinder Two Cycle Loop Charged 185 9 cu in 3047 cc 120 F 48 8 C STROKE Length All Mo...

Page 6: ...d Starter Load No Load Minimum Brush Length Solenoid Driven Bendix Starter Draw Under Load Starter Load No Load Minimum Brush Length Battery Rating 165 Amperes 30 Amperes 0 25 in 25 4 mm 175 Amperes 6...

Page 7: ...dels Reserve Capacity Approx Time Oil Pump Output All Models Quicksilver or Mercury Precision Lubri cants NMMA BIA Certified TC W3 2 Cycle Outboard Oil 3 gal 11 4 Liter 6 0 hrs Approx 1 5 qt 1 45 Lite...

Page 8: ...92 12564 2 2 Cycle Premium Outboard Oil 1 Gallon 3 7 liter 92 802815A1 92 802815Q1 Perfect Seal 16 oz 0 45 kg can 92 34227 1 92 34227 1 Liquid Neoprene 8 oz 226 8 grams can 92 25711 3 92 25711 3 Cyan...

Page 9: ...802859A1 92 802859Q1 Loctite Quick Tite Obtain Locally Obtain Locally Isopropyl Alcohol Obtain Locally Obtain Locally Hot Glue Obtain Locally Obtain Locally Special Lubricant 101 8 oz 226 8 grams tub...

Page 10: ...1B 4 Flushing Engine 1B 5 Flushing Cooling System Using Cowl Flush Plug 1B 5 Flushing Cooling System Using Flushing Attachment 44357A2 1B 5 Fuel System 1B 6 Fuel Line Inspection 1B 6 Water Separating...

Page 11: ...ENANCE Page 1B 2 90 884294 OCTOBER 2001 Special Tools 1 Grease Gun 91 37299A1 2 Flushing Attachment 44357A2 Mercury Quicksilver Lubricants and Sealants NOTE See Section 1A for lubricants and sealants...

Page 12: ...ing in salt water Every 100 Hours of Use or Once Yearly Whichever Occurs First 1 Lubricate all lubrication points Lubricate more frequently when used in salt water 2 Inspect and clean spark plugs 3 Re...

Page 13: ...tc while applying water to side mounted water pick ups during powerhead flushing or engine testing to prevent possible engine overheat from air injestion 1 Install Flushing Attachment 44357Q2 or equiv...

Page 14: ...be disposed of in an ap proved receptacle Any fuel system service must be performed in a well ventilated area Inspect any completed service work for sign of fuel leakage Fuel Line Inspection Visually...

Page 15: ...e it is com pletely eroded Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode Spark Plug Inspection and Replacement Inspect spark plugs at the recomm...

Page 16: ...accidental shorting of battery terminals Fuse Replacement IMPORTANT Always carry spare SFE 15 and 20 AMP fuses The electrical wiring circuits on the outboard are protected from overload by fuses in th...

Page 17: ...cant with Teflon 2 Propeller Shaft Refer to Propeller Replacement for removal and installation of the propeller Coat the entire propeller shaft with lubricant to prevent the propeller hub from corrodi...

Page 18: ...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 Lubricate Points 7 With L...

Page 19: ...on the opposite side 1 Place outboard in a vertical operating position 2 Place drain pan below outboard 3 Remove vent plug and fill drain plug and drain lubricant 3 2 1 GEAR CASE LUBRICANT CAPACITY G...

Page 20: ...and forth to mix sta bilizer with the fuel 2 Permanently Installed Fuel Tank Pour the required amount of Fuel System Treat ment Stabilizer follow instructions on container into a separate container a...

Page 21: ...pped 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 in...

Page 22: ...9 Model 3 Liter Work 225 EFI 250 EFI Powerhead Port View 1C 10 Model 3 Liter Work 225 EFI 250 EFI Powerhead Top View 1C 11 Model 3 Liter Work 225 EFI 250 EFI Powerhead Aft View 1C 12 Painting Procedur...

Page 23: ...d produce on a dry brisk spring or fall day The horsepower that any internal combustion engine produces depends upon the density of the air that it consumes and this density is dependent upon the temp...

Page 24: ...boat speed Hook frequently is caused by supporting boat too far ahead of transom while hauling on a trailer or during storage b Rocker The reverse of hook and much less common Rocker exists if bottom...

Page 25: ...transom WATER ABSORPTION It is imperative that all through hull fasteners be coated with a quality marine sealer at time of installation Water intrusion into the transom core and or inner hull will r...

Page 26: ...ver advanced ignition timing Use of low octane gasoline Propeller pitch too high engine RPM below recommended maximum range Lean fuel mixture at or near wide open throttle Spark plugs heat range too h...

Page 27: ...ckly as possible 2 Remove cowling 3 Clean the exterior of the outboard with fresh water 4 Dry all wiring and electrical components using compressed air 5 Drain water from fuel system as follows a Disc...

Page 28: ...in tank if water is present 15 Attempt to start engine using a fresh fuel source If engine starts it should be run for at least one hour to eliminate any water in engine 16 If engine fails to start de...

Page 29: ...Pa 14 kPa to Fuel Rail 3 Fuel Pressure Test Point 4 Electric Fuel Pump inside VST 5 Vapor Separator Tank VST 6 Oil Input Hose to VST 7 Electric Fuel Pump Harness Connector 8 Fuel Regulator Vacuum Hose...

Page 30: ...Hose 9 Negative Battery Cable 10 Digital Speedometer Pressure Sensor 11 Trim Motor Bullet Connectors 12 Trim DOWN Relay 13 Trim UP Relay 14 Main Power Relay 15 Poppet Valve Assembly 16 Detonation Sens...

Page 31: ...re Alternator 11 Port Thermostat 120 F 48 8 C 12 2 Cylinder 13 Temperature Sender Analog Gauge 14 Temperature Sensor Digital 15 4 Cylinder 16 6 Cylinder 17 Powerhead Flush Hose 18 Thermostat Discharge...

Page 32: ...ulse Fuel Pump Vacuum Hose 8 Fuel Outlet Hose to Fuel Water Separator 9 Vapor Separator Vent Hose 10 Vapor Separator Tank VST 11 Fuel Hose to Fuel Rail 43 psi 2 psi 296 kPa 14 kPa 12 Throttle Plate Ad...

Page 33: ...5 Cylinder 9 Detonation Sensor Harness Connector 10 Starboard Thermostat Discharge Hose 11 Tell Tale Hose 12 5 Ignition Coil 13 3 Ignition Coil 14 1 Ignition Coil 15 Ignition Coil Harness Connector 1...

Page 34: ...clear coat finishes and buffing with a terry cloth type towel Abrasive type polishes should not be used as they will damage the cowl finish For deep scratches or for those that penetrate through the...

Page 35: ...y paints as the paint will not prop erly adhere to the surface nor will the coating be sufficiently thick to resist future paint blistering 6 Mix epoxy chromate primer DP 40 with equal part catalyst D...

Page 36: ...et TOOLS REQUIRED 1 Plastic Squeegee 2 Stick Pin 3 Dish Washing Liquid Detergent without ammonia DO NOT use a soap that con tains petroleum based solvents Automotive Body Filler Squeegee SERVICE TIP P...

Page 37: ...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 ou...

Page 38: ...Water Pressure Tubing Connection 1D 8 Shift Cable 1D 9 Counter Rotation Outboards 1D 9 Installation 1D 10 Throttle Cable 1D 12 Installation 1D 12 Front Clamp Reassembly 1D 13 Oil Injection Set Up 1D 1...

Page 39: ...s 30 in 762 mm for XL models and 35 in 889 mm for XXL models Mounting the outboard higher may cause damage to the gear case components a This solid line is recommended to determine the outboard mounti...

Page 40: ...ape engine mounting template located with the installation manual to boat transom IMPORTANT If using Transom Drilling Fixture 91 98234A2 use drill guide holes marked A when drilling outboard mounting...

Page 41: ...tall outboard to the nearest recommended mounting height 2 Fasten outboard with provided mounting hardware shown c a e b d a 1 2 in Diameter Bolts 4 b Flat Washers 4 c Locknuts 4 d Flat Washers 4 e Ma...

Page 42: ...Until it Seats Then Back Nut Off 1 4 Turn IMPORTANT The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt a Part Number 10 849838 and se...

Page 43: ...th the en gine warning system Installation Note Open the front clamp assembly 57841 Remote Wiring Harness 1 Connect wiring Place harness into the holder 59027 GRN WHT BLU WHT BRN WHT TAN BLU WHT GRN W...

Page 44: ...b c a RED Sleeve Positive b BLACK Sleeve Negative c Starting Battery DUAL OUTBOARD Connect a common ground cable wire size same as engine battery cables between NEGATIVE terminals on starting batteri...

Page 45: ...ure Tubing Connection If the boat is equipped with a water pressure gauge make the water connection to this tubing as shown a b c d e f g h i j k l a Remote Fuel Hose b Hose Clamp Secure Remote Fuel H...

Page 46: ...on instructions shipped with the control explain the procedure required to connect this control to a counter rotation out board IMPORTANT If the counter rotation outboard is rigged similar to a standa...

Page 47: ...on the cable against the cable end guide b Move the remote control handle from neutral into reverse and advance the handle to full speed position Slowly return the handle back to the neutral Place a...

Page 48: ...b Shift Cable Retainer c Locknut Tighten locknut then back off locknut 1 4 turn d Nylon Washer 7 Check shift cable adjustments as follows a With remote control in forward the propshaft should lock sol...

Page 49: ...ch throttle cable to the throttle lever Secure with washer and locknut a b a Nylon Washer b Locknut Tighten locknut then back off locknut 1 4 turn 3 Adjust the cable barrel so that the installed throt...

Page 50: ...ved without tearing but has some drag on it Readjust cable barrel if necessary IMPORTANT The idle stop screw must be touching the stop a b a Idle Stop Screw b Idle Stop 5 Lock the barrel holder in pla...

Page 51: ...rom moving around causing possible damage An acceptable means of restraining the tank would be the use of eye bolts and an elastic retaining strap about the mid section of the tank taking care that an...

Page 52: ...your dealer to get the latest gasoline and oil recommendations If Mercury Precision Premium Plus or Quicksilver Premium Plus Outboard Oil is not available you may substitute another brand of 2 Cycle o...

Page 53: ...and hoses using pressure is required on new or rebuilt power heads and any time maintenance is performed on the oiling system that allows air into the oil system There are three methods for priming th...

Page 54: ...ill remove any air that may be in the pump oil supply hose or internal passages a b a Oil Injection Pump b Oil Supply Hose CAUTION To prevent damage to the fuel pump fill the engine fuel system with f...

Page 55: ...ellers and height range of engine installations However once on plane the engine should be trimmed to a more intermediate position to avoid a bow down planing condition called plowing Plowing can caus...

Page 56: ...ur boat left and right and note the direction the boat turns more easily If adjustment is necessary loosen trim tab bolt until trim tab moves freely does not rub against locking ridges DO NOT strike t...

Page 57: ...Air Temperature Sensor 2A 21 Manifold Absolute Pressure MAP Sensor 2A 22 Ignition Troubleshooting and Fault Chart 2A 23 Ignition Coil Ohms Test 2A 27 Manifold Absolute Pressure MAP Sensor Ohms Test 2...

Page 58: ...tinuity EST PIN A No Continuity X 8500 12000 ohm No Continuity 29000 39000 ohm 11000 21000 ohm RED METER LEAD EST Low PIN B No Continuity 8500 12000 ohm X No Continuity 39000 49000 ohm 21000 31000 ohm...

Page 59: ...METER BLK ORG PIN A X 95000 105000 ohm 3900 4100 ohm RED METER LEAD YEL PIN B 95000 105000 ohm X 95000 105000 ohm PPL YEL PIN C 3900 4100 ohm 95000 105000 ohm X Crank Position Sensor Resistance Test...

Page 60: ...rature F indicated ohm readings should be as indicated 10 There should be no continuity between each connector pin and ground Temperature Sensor Specifications Fahrenheit Centigrade OHMS 257 125 340 2...

Page 61: ...Digital Tachometer Multimeter 91 854009A1 2 Cylinder Timing Decal 91 853883 1 NOTE Decal can be used to help troubleshoot ignition timing by determining the timing of individual cylinders 3 Digital Di...

Page 62: ...GNITION Page 2A 6 90 884294 OCTOBER 2001 5 DDT Reference Manual 90 881204 1 6 Adaptor Harness 84 822560A5 7 Spark Gap Tester 91 850439 55117 8 Timing Light 91 99379 9 Crank Shaft Protector Cap 91 2416...

Page 63: ...IGNITION 90 884294 OCTOBER 2001 Page 2A 7 10 Flywheel Puller 91 849154T1 55117 11 Flywheel Holder 91 52344 12 Heat Lamp 91 63209...

Page 64: ...IGNITION Page 2A 8 90 884294 OCTOBER 2001 Coil Plate Assembly...

Page 65: ...L 3 12 SCREW 100 11 3 4 6 HI TENSION CABLE 5 12 BOOT 6 6 SPARK PLUG NGK BPZ8HS10 20 27 7 1 COIL HARNESS 8 2 CABLE 9 3 SCREW M6 x 10 60 7 10 3 WASHER 11 4 GROMMET 12 4 WASHER 13 4 BUSHING 14 4 SCREW 31...

Page 66: ...IGNITION Page 2A 10 90 884294 OCTOBER 2001 Electrical Plate Assembly A...

Page 67: ...1 FUSE COVER 14 1 SCREW M6 x 14 15 1 J CLIP 16 1 GROUND WIRE BLACK 17 3 SCREW M6 x 12 100 11 3 18 1 TRIM HARNESS 19 1 HARNESS SMARTCRAFT 20 1 PLUG MALE 21 1 WASHER 22 2 CAP NUT 23 1 NUT 5 16 18 50 5 5...

Page 68: ...IGNITION Page 2A 12 90 884294 OCTOBER 2001 Electrical Plate Assembly A...

Page 69: ...R 2001 Page 2A 13 Electrical Plate Assembly REF TORQUE REF NO QTY DESCRIPTION lb in lb ft Nm 45 1 BATTERY CABLE 46 1 CONNECTOR 47 2 CONNECTOR 6 PIN PLUG 48 5 INSULATOR BOOT RED 49 2 CABLE YELLOW BLACK...

Page 70: ...the battery charging system is transferred through the 20 ampere main relay fuse to the positive terminal of all ignition coil primary windings The negative terminals of the ignition coil primaries ar...

Page 71: ...use may blow again 1 Open the fuse holder and look at the silver colored band inside the fuse If band is broken replace the fuse Replace fuse with a new fuse with the same rating 2 The fuses and circu...

Page 72: ...A or 630 Marine Cranking Amperes MCA Above 550 RPM all electrical power is provided by the alter nator Should engine rpm drop below 550 RPM the alternator is not capable of providing sufficient output...

Page 73: ...60A5 The ECM performs the following functions Calculates the precise fuel and ignition timing requirements based on engine speed throttle position manifold pressure and coolant temperature Controls fu...

Page 74: ...ank Position Sensor Crank Position Sensor Crank Position Sensor monitors 54 teeth on flywheel thus determining crankshaft posi tion and sends crankshaft position angle and engine speed signals to ECM...

Page 75: ...ine is started the Electronic Control Module ECM will sense that the Throttle Position Sensor TPS has failed The warning horn will sound check engine light will illuminate DDT will indicate failed TPS...

Page 76: ...t condition Should a temperature sensor fail the ECM will default to a temperature value of 32 F 0 C a b 59037 a Cylinder Temperature Sensor PORT b Cylinder Temperature Sensor STARBOARD Air Temperatur...

Page 77: ...rature F indicated ohm readings should be as indicated 10 There should be no continuity between each connector pin and ground Temperature Sensor Specifications Fahrenheit Centigrade OHMS 257 125 340 2...

Page 78: ...on For example if two engines indicate 15 psi when the key is turned ON and a third engine indicates 10 psi the third engine s MAP sensor would be suspect When the engines are started MAP sen sor read...

Page 79: ...ort and open circuits Symptom Cause Action 1 Engine cranks but won t start 1 0 Lanyard stop switch in wrong position Reset lanyard stop switch 1 1 Weak battery or bad starter motor battery voltage dro...

Page 80: ...02 mm from flywheel or for defective crank position sensor Defective ECM Power Supply Clean and inspect remote control male and female harness connec tors Sensor faulty Bad connection Air gap incorre...

Page 81: ...l and inspect 4 Engine idles fast rpm 700 or surges 4 1 Fuel leak Check for fuel entering induction manifold Fuel pump diaphragm leaking and or Vapor Separator flooding over 4 2 Improper set up Check...

Page 82: ...educed to idle only 8 1 TPS failed 8 2 Battery voltage below 9 5 volts See 2 2 Use DDT to monitor system 9 Loss of spark on 1 cylin der 9 1 Loose wire or pin in connec tors between ECM and coil pri ma...

Page 83: ...nuity 29000 39000 ohm 11000 21000 ohm RED METER LEAD EST Low PIN B No Continuity 8500 12000 ohm X No Continuity 39000 49000 ohm 21000 31000 ohm LEAD Secondary Low Pin C 850 1200 ohm No Continuity No C...

Page 84: ...00 105000 ohm X Idle Speed Control The ECM varies the timing and the fuel flow based on the throttle opening to maintain an idle speed of 650 rpm 50 rpm RPM Limit Circuit The rpm limit circuitry is co...

Page 85: ...ation continues fuel mixture is richened Use DDT to monitor Knock Volts Press Keys 1 3 1 59034 a a a Detonation Sensor 1 per cylinder head Detonation Circuit Test 1 Turn key switch to RUN position do...

Page 86: ...Flywheel Holder 91 52344 remove flywheel nut and washer 59071 b a a Flywheel Holder 91 52344 b Flywheel 4 Install Flywheel Puller 91 849154T1 into flywheel CAUTION Do not hammer on end of puller cent...

Page 87: ...2 Reinstall flywheel cover on engine Ignition Coil Removal WARNING Avoid serious injury or death from fire or explosion caused by damaged spark plug boots Damaged spark plug boots can emit sparks whi...

Page 88: ...spark plug lead to spark plug Electronic Control Module Removal 1 Disconnect 3 Control Module harness connectors 2 Remove 3 bolts securing module and remove module b a c 59026 a Harness Connectors b...

Page 89: ...Analog Temperature Sensor c Retainer d Retainer Screw e Digital Temperature Sensor f Port Sensor Harness g Starboard Sensor Har ness Engine Head Temperature Sensor Installation ANALOG TEMPERATURE SENS...

Page 90: ...o air plenum Torque sensor to 14 lb in 1 6 Nm 2 Reconnect sensor harness Manifold Absolute Pressure MAP Sensor Removal 1 Disconnect MAP harness 2 Remove bolt securing MAP retainer 3 Remove MAP sensor...

Page 91: ...Removal 1 Disconnect sensor harness 2 Remove screws securing sensor to engine 59070 b a a Crank Position Sensor b Harness Connector Crank Position Sensor Installation 1 Secure sensor to engine with 2...

Page 92: ...tor Belt Tension Adjustment 2B 20 Starter System 2B 21 Starter Motor Amperes Draw 2B 21 Starter System Components 2B 21 Description 2B 21 Starter Motor Centrifugal Bendix 2B 22 Troubleshooting the Sta...

Page 93: ...in Exposed Length 0 059 in 1 5 mm 13 5 to 15 1 Volts 0 15 mA Ign Switch Off 30 0 mA Ign Switch On STARTING SYSTEM Electric Start All Models Centrifugal Bendix Starter Draw Under Load Starter Load No L...

Page 94: ...er Multimeter 91 854009A1 a b a Volt Ohm Meter 91 99750A1 b DMT 2000 Digital Tachometer Multimeter 91 854009A1 2 Ammeter 60 Ampere minimum Obtain locally 3 Flywheel Holder 91 52344 54964 4 Protector C...

Page 95: ...e gage size Replacement Parts WARNING Electrical ignition and fuel system components on your Mercury Outboard are designed and manufactured to comply with U S Coast Guard Rules and Regula tions to min...

Page 96: ...or flame can cause this mixture to ignite and explode if they are brought near the vent openings Sulphuric acid in battery can cause serious burns if spilled on skin or in eyes Flush or wash away imm...

Page 97: ...o battery be extremely careful not to fill more than 3 16 in 4 8 mm above perforated baffles inside battery Battery solution or electrolyte ex pands from heat caused by charging Overfilling battery wi...

Page 98: ...ng flywheel with flywheel holder 91 52344 remove flywheel nut and washer 59071 a a Flywheel Holder 91 25344 4 Install a crankshaft Protector Cap 91 24161 on end of crankshaft then install Fly wheel Pu...

Page 99: ...01 Installation IMPORTANT Clean flywheel crankshaft taper with solvent and assemble dry 1 Install flywheel 2 Install flywheel washer and nut 3 Hold flywheel with Flywheel Holder 91 52344 Torque nut to...

Page 100: ...CHARGING STARTING SYSTEM 90 884294 OCTOBER 2001 Page 2B 9 Notes...

Page 101: ...CHARGING STARTING SYSTEM Page 2B 10 90 884294 OCTOBER 2001 Flywheel Alternator...

Page 102: ...1 BELT 10 1 FLYWHEEL 11 1 NUT 0 625 18 125 170 12 1 WASHER 13 1 PLUG 14 1 NUT 15 1 CABLE 16 1 WASHER 17 1 SCREW M10 x 50 40 54 18 1 SCREW M6 x 12 40 54 System Components The battery charging system c...

Page 103: ...gs wound 120 electrically out of phase on the inside of a laminated core The windings are connected together on one end while the other ends are connected to a full wave rectifier bridge The rectifier...

Page 104: ...tery must be at least 75 1 230 specific gravity of fully charged to obtain valid results in the following tests If not charge battery before testing system 3 Inspect entire alternator system wiring fo...

Page 105: ...ts Output Circuit 1 Connect POSITIVE voltmeter lead to alternator terminal B output terminal Con nect NEGATIVE lead to case ground on alternator 2 Shake alternator wiring harness Meter should indicate...

Page 106: ...lead connector from alternator 2 Connect POSITIVE voltmeter lead to RED lead and NEGATIVE voltmeter lead to ground 3 Voltmeter should indicate battery voltage If correct voltage is not present check...

Page 107: ...oltmeter to TERMINAL B of alternator and NEGATIVE lead of voltmeter to engine ground 2 Start engine and allow to warm up Increase engine RPM from idle to 2000 Normal voltage output should be 14 1 15 0...

Page 108: ...orrespond with graph below Example If engine is revolving at 2000 RPM current meter should be approximately 14 5 3 Amps 59066 a c b a Ammeter DMT 2000 Digital Tachometer Multimeter 91 854009A1 b Clamp...

Page 109: ...e Battery Open Circuit Defective Alternator Current Output is High Accessories turned on Defective Battery Internal Short Defective Alternator Repair Removal 1 Remove top cowling 2 Disconnect battery...

Page 110: ...olts Torque top bolt to 40 lb ft 54 Nm Torque bottom nut to 35 lb ft 47 5 Nm 2 Rotate belt tensioner and install alternator belt in groove of flywheel and alternator pulley a 59024 a Belt Tensioner Ro...

Page 111: ...HARGING STARTING SYSTEM Page 2B 20 90 884294 OCTOBER 2001 Alternator Belt Tension Adjustment Correct alternator belt tension is maintained by a belt tensioner assembly a 59024 a Belt Tensioner Assembl...

Page 112: ...5 in 25 4 mm Min 630 Marine Cranking Amps MCA or 490 Cold Cranking Amps CCA Starter System Components Battery Starter Solenoid Neutral Start Switch Starter Motor Ignition Switch Description Purpose to...

Page 113: ...CHARGING STARTING SYSTEM Page 2B 22 90 884294 OCTOBER 2001 Starter Motor Centrifugal Bendix Liquid Neoprene 25 25 25 25 95 95 2 4 C Marine Lubricant With Teflon...

Page 114: ...lb ft Nm 1 1 STARTER MOTOR 2 1 DRIVE KIT 3 1 DRIVE 4 1 DRIVE END PLATE 5 2 THRU BOLT 70 8 6 1 WASHER 7 1 ARMATURE 8 1 BRUSH SET 9 2 BRUSH HOLDER 10 2 SCREW 11 1 END CAP 12 2 COLLAR 13 2 RUBBER STOP 14...

Page 115: ...Battery is fully charged 2 Control lever is in NEUTRAL position 3 Check terminals for corrosion and loose connections 4 Check cables and wiring for frayed and worn insulation 5 Check 20 amp fuse NOTE...

Page 116: ...TEST 3 TEST 3 a Reconnect BLACK ground wire b Connect voltmeter between common engine ground and Test Point 3 c Turn ignition key to Start position 12 Volt Reading Check BLACK ground wire for poor co...

Page 117: ...oid 12 Volt Reading Should hear solenoid click proceed to TEST 8 TEST 8 a Reconnect BLACK cable with YELLOW sleeve to starter solenoid Test Point 1 b Connect voltmeter between common engine ground and...

Page 118: ...BLACK with YELLOW sleeve 12 volt cable c Upper Mount Bolts d Lower Mount Bolts e Upper Clamp f Lower Clamp Starter Installation Centrifugal Bendix 1 Slide rubber collars on starter 2 If the removed st...

Page 119: ...me Do not lose brush springs 4 Brush replacement is recommended if brushes are pitted chipped or worn to less than 0 25 in 6 4 mm If necessary remove brushes as follows a Remove hex nut and washers fr...

Page 120: ...d cap from starter frame 6 Remove locknut and remove drive assembly from armature shaft a a Hold armature shaft with wrench on hex portion of drive assembly 7 Remove parts from shaft 11658 f e a b c d...

Page 121: ...en the commutator bars 1 32 in 0 8mm to the full width of the insulation and so that the undercut is flat b Clean the commutator slots after undercutting c Sand the commutator lightly with No 00 sandp...

Page 122: ...core while armature is rotated If saw blade vibrates armature is shorted Re check after cleaning between commutator bars If saw blade still vibrates replace arma ture 11669 Armature Test for Ground 1...

Page 123: ...lead to brush and lead to POSITIVE terminal solder connection If connection cannot be repaired brushes must be replaced 11673 a a Positive Brushes Testing Negative Brushes for Ground Set ohmmeter to R...

Page 124: ...shes were removed replace as follows a Install POSITIVE brushes along with POSITIVE terminal into commutator end cap 11660 a c b d h i e f g d a End Cap b Positive Brushes c Positive Terminal d Insula...

Page 125: ...older 2 If removed reinstall parts on armature shaft Use a new locknut and tighten securely on end of shaft 11658 g f e a b c d a Locknut b Spacer c Spring d Drive Assembly e Drive End Cap f Armature...

Page 126: ...stalling commutator end cap it is recommended that a brush retaining tool be made as shown METRIC SCALE 3 2 1 3 4 1 11 16 3 4 1 2 76 2mm 50 8mm 44 5mm 42 9mm 19 1mm 12 7mm 18 Gauge Sheet Metal 7 Lubri...

Page 127: ...a b a Bushing Retainer Tool b Bushing do not over lubricate 9 Install armature into starter frame and align match marks a Install commutator end cap onto starter frame and align match marks b Remove b...

Page 128: ...hmmeter R x1 scale and connect meter leads between solenoid terminals 1 and 2 3 Connect a 12 volt power supply between solenoid terminals 3 and 4 Solenoid should click and meter should read 0 ohms ful...

Page 129: ...CHARGING STARTING SYSTEM Page 2B 38 90 884294 OCTOBER 2001 Starter Motor Solenoid Driven Bendix 58430 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 21 22 22 23 24 24 25...

Page 130: ...2 2 SCREWS 30 3 4 3 1 END CAP 4 1 BUSHING 5 1 BRUSH PLATE ASSEMBLY 6 1 ARMATURE 7 1 FIELD FRAME 8 1 SOLENOID 9 1 SHIELD 10 1 CUSHION 11 3 PLANETARY GEARS 12 1 PLUG 13 1 DISC 14 1 SHIFT FORK 15 1 GEAR...

Page 131: ...that control lever is in NEUTRAL position 3 Check terminals for corrosion and loose connections 4 Check cables and wiring for frayed and worn insulation 5 Check 20 amp fuse Location of Test Points ca...

Page 132: ...ohmmeter Rx1 scale and connect meter leads between NEGATIVE battery post and common power head ground TEST 4 a Reconnect BLACK ground wire b Connect voltmeter between common engine ground and Test Poi...

Page 133: ...ng Defective starter solenoid TEST 5 a Connect voltmeter between common engine ground and Test Point 5 b Turn ignition key to Start position 12 Volt Reading Neutral start switch is open or YELLOW RED...

Page 134: ...battery 2 Disconnect wires from starter solenoid terminals 3 Remove starter trunion mounting bolts and remove starter from engine 59038 b b a a Starter Solenoid b Mounting Bolts Starter Installation S...

Page 135: ...CK cables with RED sleeves to POSITIVE terminal on starter sole noid Torque nut to 55 lb in 6 Nm 59038 d a b e c a Top Bolts Torque to 23 lb ft 31 Nm b Bottom Bolts Torque to 21 lb ft 28 5 Nm c BLACK...

Page 136: ...end frame 58434 a b e d c a Brush Lead b Through Bolts c Starter Solenoid d Brush Plate Screws e End Frame 2 Remove armature and field frame from drive housing NOTE Permanent magnets inside field fram...

Page 137: ...using 58432 a b c a Shield b Cushion c Drive Housing 4 Remove 3 screws retaining starter solenoid Remove solenoid from drive housing 5 Remove snap ring and gear from starter shaft 58436 c a b d e a Dr...

Page 138: ...d e a Planetary Gear and Clutch Assembly b Drive Housing c Plug d Metal Disc e Solenoid Arm 8 Inspect drive housing needle bearing for roughness If bearing is worn or damaged bearing can be removed b...

Page 139: ...utch drive and gears Use clean rags and compressed air to clean components 1 Test over running clutch action of drive Pinion should turn freely in over running di rection and must not slip in cranking...

Page 140: ...olenoid Driven Bendix Starter 1 Install solenoid arm with planetary gear and clutch assembly into drive housing 58438 a b c a Solenoid Arm b Planetary Gear and Clutch Assembly c Drive Housing 2 Instal...

Page 141: ...e with 3 screws Torque screws to 40 lb in 4 5 N m 4 Install drive gear and secure with snap ring 5 Reinstall rubber bumpers on housing 58436 c a b e f d a Drive Housing b Starter Solenoid c Screw 3 To...

Page 142: ...with slot in field frame 9 Secure end plate to brush assembly with 2 screws Torque screws to 30 lb in 3 4 Nm NOTE Prior to installing field frame assembly into drive housing align slot in field frame...

Page 143: ...rame in drive housing 11 Install through bolts and brush lead Torque through bolts to 110 lb in 12 5 Nm Torque brush nut to 55 lb in 6 Nm 58434 e d b c f a a End Frame b Field Frame c Drive Housing d...

Page 144: ...the following tests 3 If meter readings are other than specified in the following tests verify that switch and not wiring is faulty If wiring checks ok replace switch IMPORTANT Key switch must be pos...

Page 145: ...FI MODELS Idle RPM All Models Wide Open Throttle WOT RPM All Models Float Adjustment Vapor Separator Float Level 625 50 5000 5800 Preset Factory IGNITION SYSTEM Type Spark Plug Type Spark Plug Gap Fir...

Page 146: ...ING ADJUSTING Page 2C 2 90 884294 OCTOBER 2001 Special Tools 1 Digital Diagnostic Terminal DDT 91 823686A2 2 Software Cartridge 91 880118A2 3 DDT Reference Manual 90 881204 1 4 Adaptor Harness 84 8225...

Page 147: ...nkage to approximate factory settings Throttle Cam Adjustment 1 Loosen cam follower screw using Snap On Tool TTXR25E allowing cam follower to move freely 2 Allow roller to rest on throttle cam Adjust...

Page 148: ...ng temperature Engine timing at idle should be between 0 to 6 BTDC with the engine at normal operating temperature Engine timing at 5000 rpm should be approximately 22 BTDC for all models Maximum Thro...

Page 149: ...oximately 700 in neutral and 625 in gear Throttle Cable Installation 1 With end of throttle cable connected to throttle lever hold throttle lever against idle stop Adjust throttle cable barrel to slip...

Page 150: ...t adjust throttle plate stop screw from factory setting However should the throttle plate require adjustment use the throttle plate stop screw to set the total throttle plate clearance 0 040 in 1 0 mm...

Page 151: ...ntrol Wiring Installation 2D 21 System Monitor V2 0 2D 22 Basic Operation 2D 22 Initial Power Up Or After Master Reset 2D 22 Standard Information Display Screens 2D 23 Display of Range and Depth Infor...

Page 152: ...h i j k l m n a b c d e f g h i j k l m n a Tach Connector b Key Switch Assembly c Trim Switch d Trim Sender e Start Solenoid f To Battery g To Alternator h Trim Pump and Motor i DOWN Solenoid j UP S...

Page 153: ...HT BROWN WHITE TRIM GAUGE TAN BLU TAN BLUE VISUAL WARNING KIT OPT Wire Color Where To a b a b c 58912 Figure 1 Without Light Switch NOTE ANY INSTRUMENT WIRING HARNESS LEADS NOT USED MUST BE TAPED BACK...

Page 154: ...BER 2001 Commander 3000 Classic Panel Remote Control F R RED PURPLE GREEN BLK Black BLU Blue BRN Brown GRY Gray GRN Green ORN Orange PNK Pink PUR Purple RED Red Tan Tan WHT White YEL Yellow LIT Light...

Page 155: ...2001 Page 2D 5 Commander 3000 Panel Remote Control RED PURPLE GREEN BLK Black BLU Blue BRN Brown GRY Gray GRN Green ORN Orange PNK Pink PUR Purple RED Red TAN Tan WHT White YEL Yellow LIT Light DRK Da...

Page 156: ...E GREEN WHITE BLK Black BLU Blue BRN Brown GRY Gray GRN Green ORN Orange PNK Pink PUR Purple RED Red TAN Tan WHT White YEL Yellow LIT Light DRK Dark a a 58629 BLUE WHITE c b d a Neutral Interlock Swit...

Page 157: ...b Lanyard Stop Switch c Lead Not Used on Outboard Installations d Retainer e Tachometer f Trim Indicator Gauge Optional g Temperature Gauge h Remote Control i Power Trim Harness Connector j Connect W...

Page 158: ...Turned ON and OFF with Ignition Switch c Oil Level Gauge d BLACK Wire Connects to NEGATIVE Ground e To Ground f BLACK Wire From Gauge to Oil Clip Connector g LIGHT BLUE Sender Lead to Gauge h Wiring H...

Page 159: ...WIRING DIAGRAMS 90 884294 OCTOBER 2001 Page 2D 9 Notes...

Page 160: ...GRN GREEN GRY GRAY PUR PURPLE RED RED TAN TAN WHT WHITE YEL YELLOW 52205 g a e d k d b c l d f n n h o BATT GND SENDER PORT INSTALLATION a g d k d c b l d e f n n h o a Ignition Choke Switch b Lanyard...

Page 161: ...s 52206 i g a e j f m o STARBOARD INSTALLATION BATT GND SENDER g i j f m o a e i Synchronizer Gauge j Synchronizer Module k Lanyard Switch Isolation Diode l Y Harness m Power Trim Harness Connector n...

Page 162: ...for instrument lighting 51106 a b c d a Connect to 12 Volt b 12 Volt Light Switch Wire c Position Light Bulb to the Switched Position d Connect to NEGATIVE Ground WIRING DIAGRAM B Use this wiring diag...

Page 163: ...ometer Receptacle on Commander Side Mount Remote Control or TAN Lead coming from Accessory Ignition Choke Assembly WIRING DIAGRAM B Use this wiring diagram when instrument lighting is wired directly t...

Page 164: ...IMPORTANT Tape back and isolate any unused wiring harness leads 28086 a b a Lead from Temperature Sender b Engine Remote Control Harness Oil Level Gauge Wiring LIGHT BULB POSITION A Use this position...

Page 165: ...tion when instrument lighting is wired directly to the ignition key switch In strument lights are on when ignition key switch is turned on 51112 a b a Position Light Bulb to the Unswitched Position b...

Page 166: ...ch for instrument lighting SEND 51105 a b a 12 Volt Light Switch Wire b Position Light Bulb to the Unswitched Position LIGHT BULB POSITION B Use this position when instrument lighting is wired directl...

Page 167: ...ronizer Module Wiring Diagram Gauge needle to point toward fast running engine GRY GRAY WHT WHITE BLK BLACK PUR PURPLE b c d 51107 a b c d a Tachometer Starboard Engine b Synchronizer Gauge c Tachomet...

Page 168: ...System Over Heat Continuous Beep Yes Yes Yes See Guardian System Water In Fuel 4 Beep 2 Minutes Off Yes No Over Speed Continuous Beep Yes Yes Yes See Guardian System Coolant Sensor Failure No Yes No N...

Page 169: ...n Warning Horn Function Sound Description Cooling System Problem Continuous Engine Guardian System is activated Power limit will very with level of overheat Shift out board into neutral and check for...

Page 170: ...ngine in power reduction The Guard ian system must be RESET before engine can resume full power Moving throttle lever back to idle resets the system Engine overspeed indi cates a condition that should...

Page 171: ...olt Terminal b Ground Terminal c Speedometer d Tachometer e Tachometer Signal Terminal f Connect Wires Together with Screw and Hex Nut 3 Places Apply Liquid Neo prene to Connections and Slide Rubber S...

Page 172: ...osition is displayed whenever the propulsion unit is trimmed Refer to Cal 1 Calibration Section for details Initial Power Up Or After Master Reset Unit will display software level then flash the word...

Page 173: ...entary 1 second screen displays the current System Monitor software version followed by a 4 second display showing hours of engine use Hrs NOTE NOT ALL SCREENS MAY APPLY TO YOUR ENGINE TYPE NOTE Scree...

Page 174: ...and 25 full trailer TRIM NOTE The System Monitor may be calibrated so that trim is displayed whenever the trim switch is used Refer to the Cal1 Calibrations Section for details ENGINE TEMPERATURE SCR...

Page 175: ...nd fuel remaining in the tank that is connected to the system The number displayed is an estimate of the dis tance you can travel on the remaining fuel at current boat speed Miles Range NOTE To activa...

Page 176: ...ay screen the warning horn and the Guardian Protection system The warning horn is located inside the remote control or is part of the ignition key switch wiring harness Alarms Warnings When a problem...

Page 177: ...d this may indicate a blockage in the cooling system or a water pump problem Operating the engine while over heated will cause engine damage If a steady stream of water is coming out of the water pump...

Page 178: ...servoir tank When the oil level gets close to empty the horn begins sound ing continuously and the Engine Guardian System will start limiting engine power The engine mounted oil reservoir tank along w...

Page 179: ...he Bell and Engine Icon will appear to inform the driver that an engine problem has occurred If the warning system senses that the problem could cause permanent engine damage the Engine Guardian Syste...

Page 180: ...tion functions 4 Press and hold and for 3 seconds to save changes and exit the Cal1 cal ibration screen Press the button to move to the next calibration screen NOTE Pressing the button while in this h...

Page 181: ...SAE standard English system or the Metric system Press the button to toggle between units Gal Ft Psi F Ltr M Bar C SAE English System Metric System Press the button to save and move to the next funct...

Page 182: ...n PITOT WATER PRESSURE SENSOR INPUT SETTING SPD1 OR SPD2 Select the PSI input of the Pitot water pressure sensor on the engine Press the button to select 1 100 PSI or 2 200 PSI The standard PSI input...

Page 183: ...entered tank 1 calibration 2 Press once more 3 You will see the word no and the gas tank icon Enter the capacity of tank 1 in gallons using the key NOTE The word no will not go away unless the gauge s...

Page 184: ...alibration 50 setting Gal Calibration 50 The 50 percent display alternates between percent of tank capacity and quantity of fuel to add based on total capacity entered in Cal2 Add fuel to total quanti...

Page 185: ...on page 34 and 35 if calibration of the second tank is desired Master Reset Command Master Reset You can return the gauge back to factory presets through the Master Reset command IMPORTANT Performing...

Page 186: ...speed during troll control and setting gauge calibrations Troll Control Allows the operator to set and control the idle speed of the engine for trol ling without using the throttle Engine Guardian Sy...

Page 187: ...h engines 5 Trim Synchronizer Dual Engines Only Displays the trim position of both engines Sim plifies keeping trim levels equal 6 Traveling Range The estimated traveling range is based on boat speed...

Page 188: ...in period of a new engine This screen will automatically disappear after the break in period is complete 2 Temperature Displays engine coolant temperature from Cold to Hot 3 Power Trim Angle Displays...

Page 189: ...set the speed in RPM and speedometer will set the speed in MPH Kph or KN You can shut off troll control anytime by pushing the MODE button when in the troll display screen or by moving the throttle If...

Page 190: ...Reduce troll speed 6 If you set troll control to a slower speed than the troll rpm can bring the boat to the TROLL SPEED TOO SLOW b message will appear Increase troll speed EXITING TROLL CONTROL There...

Page 191: ...shing alarm signal AL will appear in the upper right corner to indicate there still is a problem Engine Guardian System Monitors the critical sensors on the engine for any early indications of problem...

Page 192: ...wing it to cool back down will usually allow some additional low speed idle running time before the engine starts to overheat again The overheat problem must be corrected before you can resume normal...

Page 193: ...warning horn is not functioning correctly RESERVE OIL LOW 2 STROKE OUTBOARD ONLY d This message is displayed and the warning horn begins sounding a series of four beeps every two minutes to inform th...

Page 194: ...hometer and engine is not connected LOW FUEL LEVEL c This message serves as a warning that the fuel level in the fuel tank is critically low You should stop for fuel immediately to avoid running out L...

Page 195: ...l OIL TEMPERATURE c This overheat alarm message appears and the warning horn begins sounding continuously The Engine Guardian System will start limiting engine power OIL PRESSURE d This alarm message...

Page 196: ...hrough the calibration selections TACH CALIBRATION CAL 1 LEVEL 1 Press in the MODE and TROLL buttons and hold for approximately 7 seconds until you see the calibration1 Cal1 screen 2 Press MODE to adv...

Page 197: ...rd or Metric SPEED UNITS DOWN UP SAVE Lets you select speed units You can choose from MPH Miles Per Hour KN Nautical Miles Per Hour or KMH Kilometers Per Hour NO YES SAVE DEPTH SCREEN Do you want to t...

Page 198: ...ight into calibration level 2 EXTERNAL SENSORS EDIT SKIP This section lets you enable or disable the following external sensor inputs PITOT SENSOR NO YES SAVE Is the boat equipped with a pitot sensor...

Page 199: ...alues This mode does not factor in irregular tank shapes Second By following the tank calibration procedure following but without actually add ing fuel Calibrate fuel tank by pressing the dEFLt button...

Page 200: ...reads that value or below the shallow water alarm will sound EMPTY TANK THEN PRESS PLUS BUT TON DFLT SAVE SKIP You can choose to have an empty tank and hit SAVE or hit DFLT and a default value will b...

Page 201: ...AM DOWN UP SAVE Adjust the gauges internal clock to match your local time First set the hours then press MODE button to set the minutes DISPLAY UNITS DOWN UP SAVE Lets you change units of measurement...

Page 202: ...ut tons are used for setting engine speed during troll control and setting gauge calibrations Troll Control Allows the operator to set and control the idle speed of the engine for trol ling without us...

Page 203: ...rim position of both engines Simplifies keeping trim levels equal 6 Traveling Range The estimated traveling range is based on current fuel consump tion and fuel remaining in the tank The numbers displ...

Page 204: ...n period of a new engine This screen will automatically disappear after the break in period is complete 2 Power Trim Angle Water Pressure Displays trim angle of the outboard and cool ing system water...

Page 205: ...reen will revert back to the previous screen after 10 seconds of no activity Push the TROLL or TROLL button to reactivate the display screen When the troll control is engaged and you are out of the tr...

Page 206: ...horn will sound continuous ly and the Engine Guardian System will respond to the problem by limiting engine power Immediately reduce throttle speed to idle and refer to the warning mes sages on the f...

Page 207: ...the warning horn begins sounding continuous ly The Engine Guardian System will start limiting engine power If the engine overheats immediately reduce throttle speed to idle Shift outboard into neu tr...

Page 208: ...p indicator hole If no water is coming out of the water pump indicator hole or flow is intermittent stop en gine and check cooling water intake holes for obstruction If no obstruction is found this ma...

Page 209: ...ump has stopped functioning electrically No lubricating oil is being supplied to the engine Stop the engine as soon as possible The Engine Guardian system will start limiting the engine power NOTE The...

Page 210: ...uge Wiring UNIT MISMATCH c Multi Engines This message tells you that the tachometers are not calibrated alike For example this could happen if one tachometer readings are in English and the another is...

Page 211: ...GHTNESS YES NO SET ALL INSTRUMENTS Do you want the same brightness level for all SmartCraft gauges Press for yes Press MODE for no DOWN CALIBRATION UP SAVE CONTRAST Press or to adjust level Press MODE...

Page 212: ...Add the capacity of the fuel tank Press or to select Press MODE to save CALIBRATION EDIT SKIP CALIBRATING FUEL TANK CALIBRATION EMPTY TANK THEN PRESS PLUS BUTTON DFLT SAVE SKIP CALIBRATING 1 4 VALUE D...

Page 213: ...ss MODE to skip to the next display Press edit to calibrate the oil tank Pressing DFLT default during edit will return to original value setting Calibrate the oil tank as follows 1 Empty the oil tank...

Page 214: ...r Calibration Simple Calibration This calibration for setting lighting and setting the clock can be made while engine is running 1 Press in the MODE and TROLL buttons for calibration screen 2 Press MO...

Page 215: ...add UTC correction MODE to save Hour off set from universal time constant Press or to set the hour Press MODE to save Press or to set the minute Press MODE to save CALIBRATION EXTERNAL SENSORS EDIT S...

Page 216: ...CK TEST LEAD RANGE Trim Yellow Black Orange 2 7 vdc UP 0 6 vdc DOWN Fuel Sender Pink Black Black Orange 0 65 vdc FULL 2 92 vdc EMPTY Lake Temperature Tan Orange Black Orange 2 5 vdc room temp Voltage...

Page 217: ...20 21 22 23 24 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 1 2 1 2 1 2 1 2 1 2 1 2 A B A B C A B C A B C A B C D E F G H A B A B 1 2 3 4 5 6 7 8 A B A B A B...

Page 218: ...le 3A 2 Special Tools 3A 2 Notes 3A 3 Fuel Pump Assembly 3A 4 Fuel Pump Description Operation 3A 6 Checking for Restricted Fuel Flow Caused by Anti Siphon Valves 3A 6 Checking Fuel Pump Lift Vacuum 3A...

Page 219: ...ssure Idle Normal 2 3 psi 13 7 20 5 kPa Minimum 1 psi 6 8 kPa NOTE Electric fuel pump pressure if used in conjunction with engine mechanical fuel pump must be limited to no more than 4 psi 27 4 kPa Sp...

Page 220: ...FUEL PUMP 90 884294 OCTOBER 2001 Page 3A 3 Notes...

Page 221: ...FUEL PUMP Page 3A 4 90 884294 OCTOBER 2001 Fuel Pump Assembly A...

Page 222: ...CAP 9 1 DIAPHRAGM 10 1 GASKET BOOST 11 1 GASKET PULSE 12 1 GASKET 13 1 PLATE 14 1 FITTING 15 2 SCREW FUEL PUMP M5 x 40 55 6 0 16 2 SCREW PUMP TO CRANKCASE M6 x 50 55 6 0 17 1 BASE 18 1 ELBOW 19 AR ST...

Page 223: ...with debris they may be too small or they may have too heavy a spring Summarizing the pressure drop across these valves can and often does create operational problems and or power head damage by rest...

Page 224: ...uel pump vacuum and air bubbles in the fuel supply can be checked with a vacuum gauge a t fitting and a clear piece of fuel hose Connect the clear hose between the inlet fitting on the pulse driven fu...

Page 225: ...em Leak Test This test is done with the engine running and the tubing clamp removed The clear hose that was installed previously is used to view the fuel flow to the pulse pump No air bubbles seen in...

Page 226: ...used once fuel pump is disassembled 1 Disconnect fuel hoses from fuel pump 2 Disconnect pulse hose 3 Remove two mounting screws 4 Remove fuel pump from engine 59042 a b c d d a Fuel Inlet b Fuel hose...

Page 227: ...ning or any signs of fuel or air leaks Re place or tighten fitting if a leak is found Reassembly lnstallation ASSEMBLY NOTE The new repair kits contain check valves made of a plastic material impervio...

Page 228: ...58887 3 With retainer installed in pump body break retainer rod from retainer by bending side ways 23601 a b a Rod b Retainer Cap 4 Reinstall rod into retainer cap and use a small hammer or hammer and...

Page 229: ...c a Boost Spring b Pump Body c Cap 6 Assemble remainder of components as shown and install retaining screws through to align a 59040 a Reverse View of Pump Body INSTALLATION 1 Install pump onto engine...

Page 230: ...l Harness Test 3B 31 Injector Load Test 3B 32 Fuel Rail Assembly Leakage Test 3B 32 Air Temperature Sensor and Head Temperature Sensor Test 3B 33 Detonation Control System Test 200 Work Models Only 3B...

Page 231: ...ctors are Crank Angle Driven by ECM 1 Cylinder 2 Cylinder 3 Cylinder 4 Cylinder 5 Cylinder 6 Cylinder Line Pressure Injectors Injector Resistance Electric Fuel Pump Resistance Electric Fuel Pump Amper...

Page 232: ...3 OCTOBER 2001 Special Tools 1 Fuel Pressure Gauge 91 852087A3 a or Fuel Pressure Gauge 91 881834A1 b 55294 a b 58879 2 Digital Diagnostic Terminal DDT 91 823686T2 3 Software Cartridge 91 880118A2 4...

Page 233: ...OBER 2001 5 Adaptor Harness 84 822560A5 use with DDT 6 Remote Starter Switch 91 52024A1 7 DMT 2000 Digital Tachometer Multi meter 91 854009A1 8 Inductive Timing Light 91 99379 9 Spark Gap Tester 91 85...

Page 234: ...FUEL INJECTION 90 884294 Page 3B 5 OCTOBER 2001 11 Tamper Proof Torx Screw Set 91 881828 58685 Notes...

Page 235: ...FUEL INJECTION Page 3B 6 90 884294 OCTOBER 2001 Fuel Management System...

Page 236: ...0 9 13 1 BRACKET 14 1 MAP SENSOR 15 1 TEMPERATURE SENSOR 16 3 O RING 17 1 THROTTLE BODY 18 4 SCREW 100 11 3 19 1 O RING 20 1 THROTTLE ARM 21 1 ROLLER 22 1 RETAINING RING 23 1 SCREW M5 x 16 Drive Tight...

Page 237: ...FUEL INJECTION Page 3B 8 90 884294 OCTOBER 2001 Fuel Management System...

Page 238: ...CTOBER 2001 Fuel Management System REF TORQUE REF NO QTY DESCRIPTION lb in lb ft Nm 44 1 FUEL TUBE 45 2 O RING 46 1 ELBOW 47 1 SCREW 10 24 x 0 375 48 1 RETAINER 49 2 O RING 50 1 FUEL RAIL HARNESS 51 2...

Page 239: ...FUEL INJECTION Page 3B 10 90 884294 OCTOBER 2001 Vapor Separator Components...

Page 240: ...VALVE 8 1 CAP 9 1 CAP 10 1 PLUG 11 1 SEAL 12 1 GASKET 13 1 PRESSURE REGULATOR KIT 14 1 O RING KIT 15 1 WASHER RUBBER 16 2 SCREW 22 2 5 17 1 SCREW 22 2 5 18 1 GROUND WIRE 19 7 SCREW 30 3 5 20 1 FLOAT...

Page 241: ...erial prior to testing This will help in determining that each test is providing desired results EFI System Tests EFI Electrical System and ECM Check Fuel Gauge Connection Pressure Test Vapor Separato...

Page 242: ...ORTANT The following preliminary steps MUST BE FOLLOWED before at tempting EFI problem diagnosis Preliminary Checks Ignition Spark Check Purpose This test determines if the ignition system is deliveri...

Page 243: ...rections in solving simple prob lems in the EFI system Fresh Quality Fuel Using a remote fuel tank containing a major brand of premium unleaded gasoline test run the outboard to eliminate any problems...

Page 244: ...Fuel Injectors 6 d Pulse Fuel Pump e Fuel Water Separator f Water Sensor g From Fuel Tank h Vapor Separator i Electric Fuel Pump Filter j Electric Fuel Pump k Vapor Separator Float l Needle and Seat...

Page 245: ...and injectors Electric Fuel Pump Inside Vapor Separator j The electric fuel pump runs continuously while providing fuel in excess of engine de mands The excess fuel is circulated through the fuel rail...

Page 246: ...ins a fuel pump driver circuit that provides power to the electric fuel pump The fuel pump does not have its negative terminal BLACK RED wire grounded to the pump housing The fuel pump positive termin...

Page 247: ...will illu minate and the warning horn will sound RPM will be reduced by the ECM The TPS is not adjustable TPS settings can be monitored with the Digital Diagnostic Terminal Voltage change should be sm...

Page 248: ...fuel flow from vapor separator Fuel flows freely from vapor separator Follow High Pressure Fuel Route Flow Chart Inspect float system of vapor separator Perform Water Separating Fil ter Flow Test Low...

Page 249: ...ure above 45 psi 310 kPa Perform Final Filter Check Clogged or faulty fuel pressure regulator remove and replace Perform Electric Fuel Pump Volt age Test Final filter OK Final filter clogged Perform F...

Page 250: ...injector Perform Induction Manifold Disassembly and inspection Perform compression check on problem cylinder Low or no compression on cylinder Compression OK Inspect cylinder bore Refer to Section 4 f...

Page 251: ...Fuel pressure fluctuation i e 41 to 45 psi 283 to 310 kPa is com mon as the regulated pressure is a differential between fuel rail and manifold vacu um Purpose Checking fuel manifold pressure ensures...

Page 252: ...si 283 kPa fuel delivery to electric fuel pump fuel pump failure or other related problem exists Inspect final filter for debris If fuel pressure is above 45 psi 310 kPa go to fuel pressure regulator...

Page 253: ...prevent engine from starting 2 Remove fuel inlet hose from fuel water separator 59050 3 Turn ignition key switch to START and operate starter motor for 10 to 20 seconds Results Fuel should flow freel...

Page 254: ...re reassembly 59042 a b b a Pulse Fuel Pump b Attaching Screws Water Separating Filter Inspection Remove fuel water separator filter Inspect filter for debris Replace filter as required 1 Place emerge...

Page 255: ...s test will indicate if float is stuck in the up closed position NOTE If float is stuck down vapor separator will over flow causing a rich condition 1 Place emergency stop switch in OFF position to pr...

Page 256: ...c eliminates this component as a possible source of restriction in the system 1 De pressurize EFI fuel system by wrapping a clean cloth around pressure port valve and inserting tip of screwdriver into...

Page 257: ...ng cover 5 Remove vapor separator tank from cover 6 Pull downward to remove filter from fuel pump 59055 a a Inlet Filter 7 Inspect filter for debris or damage Results If filter is clogged with debris...

Page 258: ...sepa rator for debris If filter is clean perform amperage draw test on electric fuel pump If am perage draw is within specifications replace fuel pressure regulator Purpose This test will determine i...

Page 259: ...ack test lead to BLACK wire in the fuel pump connector positive test lead to positive wire RED BLUE of fuel pump con nector engine harness end 59029 a a Fuel Pump Harness Connector Positive test lead...

Page 260: ...will be heard each time an injector is activated If an injector does not respond to the load test an ohm test can be made on the harness and the injector s 59058 59058 a a Injector Harness Injector Re...

Page 261: ...erence Manual 90 881204 1 for test procedures Fuel Rail Assembly Leakage Test Purpose This test will determine if the supply tube or injector o rings are leaking or if an injector is stuck open 1 Remo...

Page 262: ...a Air Temperature Sensor b Head Temperature Sensor Disconnect temperature sensor harness and check continuity with digital or analog ohm meter test leads between both connector pins With engine at te...

Page 263: ...396 32 0 32654 14 10 55319 5 15 72940 Detonation Control System Test 200 Work Models Only 59034 a a a Knock Sensor Purpose Determines whether the detonation sensor and circuit located in the ECM is fu...

Page 264: ...minal DDT The Throttle Position Sensor is not adjustable 1 Place outboard in water connect Digital Diagnostic Terminal DDT to engine NOTE If throttle position sensor is not functioning 4 LED indicator...

Page 265: ...lts accuracy if below 1 volt Less than 10 millivolts i e 0 293 v to 0 285 v Replace any TPS that fails either test MAP Sensor Test 59025 a a MAP Sensor Purpose Determines whether the Manifold Absolute...

Page 266: ...w Low High Pressure Fuel Route Flow Charts and Fuel Rail Electrical Fuel Determination Flow Chart Perform Fuel Rail Leak Test Check for fuel coming out of va por separator vent hose Check cylinder hea...

Page 267: ...Stumbles At Off Idle Speeds Improper EFI Setup Failed Ignition Coil Failed Or Disconnected EFI Sensors Fuel Delivery Problem Manifold Fuel Leak R F I Problem Induction Manifold Air Leak MAP Sensor Fa...

Page 268: ...Ignition System Failure Pulse Fuel Pump Failure Electric Fuel Pump Failure ECM Failure Check battery connections un der charged battery or worn out battery Check EFI harness connector for improper co...

Page 269: ...emperature Sensor c Retainer d Retainer Screw e Digital Temperature Sensor f Port Sensor Harness g Starboard Sensor Har ness Engine Head Temperature Sensor Installation ANALOG TEMPERATURE SENSOR 1 Ins...

Page 270: ...prior to removal of fuel system components NOTE Use Fuel Air Pressure Gauge 91 881834A1 to de pressurize fuel system 1 De pressurize fuel system 91 881834A1 a b a Fuel Pressure Port b Fuel Pressure G...

Page 271: ...sure Regulator Vent Hose c VST Output Fuel Hose d VST Oil Input Hose e VST Electric Fuel Pump Harness Connector f Water Sensor Bullet Connector g Fuel Water Separator Input Fuel Hose 4 Remove ground l...

Page 272: ...rottle cam link rod and the Throttle Position Sensor link rod 59046 a b a Throttle Cam Link Rod b Throttle Position Sensor Link Rod 7 Disconnect the following hoses and connectors 59058 a b c a Air Te...

Page 273: ...8 Disconnect oil pump electrical harness oil pump inlet and outlet hoses 59039 a b c a Electrical Harness b Oil Outlet Hose c Oil Inlet Hose 9 Remove 12 bolts securing air management assembly to crank...

Page 274: ...Removal The fuel rail injector assembly is attached to the reed block assembly plate by 4 screws 59057 a b a Fuel Rail Injector Assembly b Reed Block Assembly 1 Remove 4 screws to securing fuel rail i...

Page 275: ...y a b a a d c e 59048 a Fuel Injectors 6 b Fuel Rail Fuel Inlet Pipe c O Rings d Fuel Rail e Reed Block Assembly 4 Individual fuel injectors and fuel inlet pipe can be removed from fuel rail by removi...

Page 276: ...rews to 27 lb in 3 0 Nm 2 Secure fuel inlet pipe to fuel rail with tamper proof screw Torque screw to 65 lb in 7 0 Nm a a a b 58792 a Fuel Injector Attaching Screws Torque to 27 lb in 3 0 Nm b Fuel In...

Page 277: ...FUEL INJECTION Page 3B 48 90 884294 OCTOBER 2001 4 Secure fuel rail assembly to reed block assembly plate with 4 screws Torque screws to 65 lb in 7 0 Nm a a 59054 a Screws Torque to 65 lb in 7 0 Nm...

Page 278: ...sket g Reed Block 6 each Reed Block Assembly Installation NOTE The gasket between the air plenum and the adaptor plate has a sealing bead which faces toward the air plenum during assembly Gaskets may...

Page 279: ...Carefully thread sensor into air plenum Torque sensor to 14 lb in 1 6 Nm 2 Reconnect sensor harness Manifold Absolute Pressure MAP Sensor Removal 1 Disconnect MAP sensor harness connector 2 Remove sen...

Page 280: ...Assembly Throttle Plate Assembly Installation Secure throttle plate assembly to air plenum with 4 bolts Torque bolts to 100 lb in 11 5 Nm Vapor Separator Disassembly 1 Remove 7 screws securing separat...

Page 281: ...ply 2 4 C Marine Lubricant with Teflon to seal lips d a b c 58786 a Filter Screen b Harness Connector c Pump d Seal Seal shoulder faces OUT 6 Loosen screw securing float assembly and remove float Insp...

Page 282: ...vot pin assembly to separator cover with screw Torque screw to 10 lb in 1 0 Nm 3 Apply 2 4 C Marine Lubricant with Teflon to lips of seal in separator cover 58787 b a c d 58783 e a Screw Torque to 10...

Page 283: ...cover to tank with 7 screws Torque screws to 30 lb in 3 5 Nm a a a a a a a 58784 a Screws Torque to 30 lb in 3 5 Nm Air Plenum Installation Secure plenum to crankcase with 12 bolts Torque bolts to 125...

Page 284: ...Torque bolts to 140 lb in 16 Nm 59047 a b b b a VST Ground Lead b Bolts Torque to 140 lb in 16 Nm 3 Reconnect the following hoses and connectors a e f g b c d 59051 a VST Vent Hose b Fuel Pressure Re...

Page 285: ...937A1 to remove water separa tor 91 24937A1 a b 59047 a Water Separator b Water Sensor Lead Water Separating Filter Assembly Installation IMPORTANT Apply a light coat of outboard oil to the rectangula...

Page 286: ...position sensor TPS harness connector 2 Remove sensor link rod 3 Remove 3 screws securing sensor a b c d 59046 a Sensor Harness Connector b Sensor Link Rod c Retaining Screws d Throttle Position Senso...

Page 287: ...il input hose to oil reservoir from check valve 4 Remove 3 screws and remove reservoir 59063 d e c a b a Bullet Connectors b Reservoir Hose c Oil Input Hose d Screws e Oil Reservoir Oil Reservoir Inst...

Page 288: ...emoval of fuel system components NOTE Use Fuel Air Pressure Gauge 91 881834A1 to de pressurize fuel system 1 De pressurize fuel system 91 881834A1 a 59053 a Fuel Pressure Port 2 Remove fuel regulator...

Page 289: ...for cuts and abraisions Replace as required 2 Inspect fuel filter for debris Clean with solvent as required 58789 a b a O Rings b Filter Fuel Pressure Regulator Reassembly 1 Reinstall fuel regulator i...

Page 290: ...r hose routing 4 Look at main connector between engine harness and ECM box for missing corroded or bent contact pins and socket Check for dislodged grommet in ECM where harness enters box 5 Look at al...

Page 291: ...ir Removal and Installation 3C 9 Priming the Oil Pump 3C 10 Priming Procedure Method 1 3C 11 Remote Oil Hose Connections 3C 12 Filling the Oil Tanks 3C 13 Purging Air From the Engine Oil Reservoir and...

Page 292: ...ng the first 120 minutes is 100 1 idle and 40 1 wide open throttle After the first 120 minutes the oil ratio changes to 120 1 idle and 50 1 wide open throttle Final Checks Before Operation of Engine M...

Page 293: ...OIL INJECTION 90 884294 OCTOBER 2001 Page 3C 3 Notes...

Page 294: ...OIL INJECTION Page 3C 4 90 884294 OCTOBER 2001 Oil Injection Components...

Page 295: ...R ASSEMBLY 2 1 DECAL RESERVOIR 3 1 SCREW 0 164 18 x 1 1 4 IN Drive Tight 4 1 WASHER 5 1 CAP ASSEMBLY 6 1 GASKET 7 1 SWITCH ASSEMBLY LOW OIL 8 3 SCREW M8 x 35 15 20 9 3 WASHER 10 3 GROMMET 11 3 BUSHING...

Page 296: ...SERVOIR e The oil reservoir feeds the oil pump and contains enough oil for 20 25 minutes of full throttle running after the remote tank is empty The warning horn will sound if the oil level in oil res...

Page 297: ...System e 58888 c d f b a g h i j a Remote Oil Tank b Oil Pick up Tube c Filter d 4 PSI Check Valve e Oil Reservoir f Low Oil Float Sensor Inside Reser voir g Vapor Separator Tank h Oil Inlet to Oil Pu...

Page 298: ...hree bolts and remove pump c d e a 59039 a b f g a Oil Pump b Bushing 3 c Rubber Grommet 3 Insert into Hole d Washer 3 e Bolt 3 Torque to 140 lb in 16 Nm f Wiring Harness g Sta Straps INSTALLATION 1 I...

Page 299: ...ad and remove tank a b c d e f g h i 59030 k l j a Oil Reservoir b Bushing 3 c Rubber Grommet 3 Insert into Holes d Decal e Bolt 3 Torque to 170 lb in 19 Nm f Washer 3 g Washer h Screw Drive Tight i L...

Page 300: ...sure is required on new or rebuilt power heads and any time maintenance is performed on the oiling system that allows air into the oil system There are three methods for priming the oil pump METHOD 1...

Page 301: ...Use Method 3 Oil drained from oil supply hose feeding pump Use Method 3 Oil pump removed Use Method 3 Oil injection hoses drained Use Method 3 Priming Procedure Method 1 METHOD 1 SHIFT SWITCH ACTIVATI...

Page 302: ...mp to complete the priming process Remote Oil Hose Connections NOTE Oil hose with BLUE stripe contains a directional filter which is designed to trap any debris in the oil before the oil reaches the e...

Page 303: ...ill cap 2 Remove cap and fill engine oil tank with oil Reinstall the fill cap 3 Remove air from remote oil hose Refer to Purging Air from the Engine Oil Reservoir and Remote Oil Hose b a c a b a Fill...

Page 304: ...ystem is activated Power limit will allow a fast idle The oil level is critically low in the engine mounted oil reservoir tank Re fill the engine mounted oil reservoir tank along with the remote oil t...

Page 305: ...leakage Remove filter and clean Replace tube Replace check valve Purge air from engine oil tank Refer to procedure Disconnect BLUE BLACK wires going to the low oil float switch in the engine oil reser...

Page 306: ...n and carbon These four elements combine chemically during combustion If combustion were complete the mixture of air and gasoline would result in these emissions water carbon dioxide and nitrogen whic...

Page 307: ...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 sto...

Page 308: ...ed 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 ree...

Page 309: ...haust port opens A stratified charge engine concentrates a rich mixture in the vicinity of the spark plug air fuel ratio is less than 14 7 1 Elsewhere the mixture is very lean or is comprised of air o...

Page 310: ...he horse power or allow emissions levels to exceed their predetermined factory specifications Single engine exceptions may be allowed with permission from the EPA for racing and testing EPA Emission R...

Page 311: ...PZ8HS 10 Gap 0 040 in 1 0 mm Valve Clearance Cold mm Intake N A Exhaust N A This engine conforms to 2002 Model Year U S EPA regulations for Marine SI engines b c d f g i JUN 2001 e j h a Spark Ignitio...

Page 312: ...e code illegible contact Mercury Marine Technical Service for assistance JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC Emission Control Information 2002 PART 37 804670 02 This engine conforms to 2...

Page 313: ...ure Relief Valve Components 4A 46 Cleaning and Inspection 4A 47 Cylinder Block and Crankcase Cover 4A 47 Special Service Information 4A 47 Cylinder Bores 4A 48 Pistons and Piston Rings 4A 49 Cylinder...

Page 314: ...mm Dia 0 015 in Oversize 3 516 in 89 306 mm Taper Out of Round Max 0 003 in 0 0762 mm Piston Dia Standard 3 494 in 001 in 88 748 mm 025 mm Dia 0 015 in Oversize 3 509 in 001 in 89 129 mm 025 mm IMPOR...

Page 315: ...4A 3 Special Tools 1 Lifting Eye 91 90455 2 Flywheel Holder 91 52344 91 52344 54964 3 Protector Cap 91 24161 4 Flywheel Puller 91 849154T1 55117 5 Powerhead Stand 812549T 6 Piston Ring Expander 91 246...

Page 316: ...nap Ring Pliers 91 24283 11 Lockring Installation Tool 91 91 79109A3 12 Piston Ring Compressor 91 818773 for 2 5 Liter 13 Compression Tester 91 29287 54965 Powerhead Repair Stand A powerhead repair st...

Page 317: ...POWERHEAD 90 884294 OCTOBER 2001 Page 4A 5 Notes...

Page 318: ...OWERHEAD Page 4A 6 90 884294 OCTOBER 2001 Cylinder Block Assembly Loctite PST Pipe Sealant 9 12 Loctite Master Gasket 14 2 Cycle Outboard Oil Loctite 680 33 95 2 4 C Marine Lubricant with Teflon 9 9 9...

Page 319: ...16 1 OIL LINE RETAINER 17 10 WASHER 18 10 NUT 50 69 19 1 SENSOR CRANK POSITION 20 2 SCREW M5 X 16 100 11 21 1 LOWER END CAP 22 1 O RING 23 2 OIL SEAL 24 4 SCREW M6 X 20 38 51 5 25 1 PLATE ASSEMBLY 26...

Page 320: ...OWERHEAD Page 4A 8 90 884294 OCTOBER 2001 Cylinder Block Assembly Loctite PST Pipe Sealant 9 12 Loctite Master Gasket 14 2 Cycle Outboard Oil Loctite 680 33 95 2 4 C Marine Lubricant with Teflon 9 9 9...

Page 321: ...2 O RING 45 2 SCREW M6 X 12 46 2 CLAMP 47 1 TPS LEVER 48 3 SCREW M6 X 25 55 6 49 3 BUSHING 50 3 GROMMET 51 3 WASHER 52 3 SCREW M6 x 25 35 4 53 1 THROTTLE POSITION SENSOR 54 1 SCREW 55 1 PIPE PLUG 56 1...

Page 322: ...e 4A 10 90 884294 OCTOBER 2001 Exhaust Adaptor Plate 3M Permabond 3MO8155 Obtain Locally 62 95 2 4 C Marine Lubricant with Teflon A TO BLOCK Loctite PST Pipe Sealant 92 809822 9 21 41 9 9 9 95 95 95 9...

Page 323: ...1 CARRIER 12 1 GROMMET 13 1 POPPET 14 1 SPRING 15 1 RELIEF VALVE PLATE ASSEMBLY 16 2 GASKET 17 1 DIAPHRAGM 18 1 WASHER 19 1 SCREW 10 16 X 3 4 IN 25 3 20 6 SCREW M8 X 35 25 34 21 1 IDLE EXHAUST BOOT 2...

Page 324: ...POWERHEAD Page 4A 12 90 884294 OCTOBER 2001 Crankshaft Pistons and Connecting Rods 14 2 Cycle Outboard Oil 95 2 4 C Marine Lubricant with Teflon 9 14...

Page 325: ...ODRUFF KEY 7 7 O RING 8 2 BEARING RACE 9 2 ROLLER BEARING 10 3 PISTON STARBOARD 10 3 PISTON PORT 11 12 LOCK RING 12 6 PISTON RING SET 13 6 PISTON RING LOWER 14 6 CONNECTING ROD ASSEMBLY 15 12 SCREW 1...

Page 326: ...POWERHEAD Page 4A 14 90 884294 OCTOBER 2001 Starboard Bleed System Routing 1 2 2 2 3 4 5 6 7 7 7 2 7...

Page 327: ...e 4A 15 Starboard Bleed System Routing REF TORQUE REF NO QTY DESCRIPTION lb in lb ft Nm 1 1 TUBING 15 1 2 IN 39 3 CM 2 3 CHECK VALVE 90 3 1 TUBING 16 1 2 IN 3 8 CM 4 1 TUBING 15 IN 38 1 CM 5 1 CLIP 6...

Page 328: ...POWERHEAD Page 4A 16 90 884294 OCTOBER 2001 Port Bleed System Routing 1 1 1 1 2 2 2 8 8 8 3 4 4 5 5 5 5 6 7 7 9 10 11 12...

Page 329: ...RQUE REF NO QTY DESCRIPTION lb in lb ft Nm 1 3 CHECK VALVE 2 2 PIPE PLUG 3 1 TUBING 20 5 IN 52 CM 4 1 CHECK VALVE 5 3 CHECK VALVE 90 DEGREE 6 1 TUBING 13 IN 33 CM 7 1 CHECK VALVE 8 2 PIPE PLUG 9 1 CLI...

Page 330: ...rque Sequence CRANKCASE COVER BOLTS 9 10 11 12 13 14 6 4 2 8 5 3 1 7 55986 a b 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 8 7 a Add light oil to threads and bolt face 8 Bolts 3 8 in 16 in 38 lb ft 5...

Page 331: ...OLTS Apply light oil to threads and bolt face 30 lb ft 40 7 N m and rotate 90 52132 20 16 12 7 6 9 13 17 19 15 11 8 5 10 14 18 1 3 4 2 POWERHEAD TO ADAPTOR PLATE ATTACHING NUT Torque nuts to 25 lb ft...

Page 332: ...was stopped Refer to Table of Contents preceding Usually complete disassembly of pow erhead will be required If major powerhead repairs are to be performed remove powerhead from drive shaft hous ing R...

Page 333: ...ft Housing 1 Disconnect battery cables from battery terminals 2 Remove top cowling 3 Remove two screws which secure remote control harness retainer and remove retainer 57841 a a b a Screws b Retainer...

Page 334: ...OCTOBER 2001 5 Disconnect and or remove the following 59026 a b c d e f a Remote Oil Tank Pressure Hose b Remote Control Harness c Power Trim Wires d Negative Battery Cable e Positive Battery Cable f...

Page 335: ...EAD 90 884294 OCTOBER 2001 Page 4A 23 6 Disconnect and or remove the following a 59030 b c d a Oil Supply Hose b Shift Lever Bracket Assembly c Water Pressure Hose GREY d Starboard Thermostat Discharg...

Page 336: ...0 884294 OCTOBER 2001 7 Disconnect the following 59028 a b c d a Water Pressure Sensor Hose GREY for Digital Gauges If not previously dis connected b Engine Flush Hose c Tell Tale Hose d Starboard The...

Page 337: ...emove throttle cable and shift cable from control cable anchor bracket a b a a Throttle Cable b Shift Cable 10 Disconnect input fuel line water pressure hose and speedometer hose a b c d a Input Fuel...

Page 338: ...h side from powerhead base 52373 a a a a a a Nuts and Washers 5 each side 12 Remove plastic cap from center of flywheel and install Lifting Eye 91 90455 into flywheel at least 5 full turns Using a hoi...

Page 339: ...ion 2 Starter Motor Electronic Control Module Ignition Coils Starter Solenoid Trim Relays Alternator Flywheel Section 3 Air Plenum Fuel Rail and Injectors Vapor Separator Assembly Pulse Fuel Pump Oil...

Page 340: ...ions or removing fuel sys tem components 1 Use Fuel Air Pressure Gauge 91 16850A7 or Fuel Pressure Gauge 91 881834A1 to de pressurize fuel system Direct fuel into suitable container 2 Remove VST drain...

Page 341: ...re Regulator Vent Hose c VST Output Fuel Hose d VST Oil Input Hose e VST Electric Fuel Pump Harness Connector f Water Sensor Bullet Connector g Fuel Water Separator Input Fuel Hose 4 Remove ground lea...

Page 342: ...ink rod and the Throttle Position Sensor link rod 59046 a b a Throttle Cam Link Rod b Throttle Position Sensor Link Rod Air Plenum Removal 1 Disconnect the following hoses and connectors 59058 c b a a...

Page 343: ...al harness oil pump inlet and outlet hoses and oil tank pres sure hose 59039 a b c d a Electrical Harness b Oil Outlet Hose c Oil Inlet Hose d Oil Tank Pressure Hose 3 Remove 12 bolts securing air man...

Page 344: ...c f a h a Temperature Gauge Bullet Connectors Hidden b Port Temperature Sensor Connector c Water Pressure Sensor Connector d Starboard Temperature Sensor Connector e Ignition Coil Harness Connector f...

Page 345: ...remove the following 59044 c d c d 59038 a b e f g h a Centrifugal Bendix Starter b Solenoid Driven Bendix Starter c Upper Mount Bolts d Lower Mount Bolts e BLACK ground cable f BLACK with YELLOW sle...

Page 346: ...4A 34 90 884294 OCTOBER 2001 Electrical Plate Removal Disconnect and or remove the following 59078 a b c d a Crank Position Sensor Connector b Trim Motor Bullet Connectors c ECM Screws 3 d Solenoid P...

Page 347: ...age 4A 35 Alternator Removal 58907 a b c d d d a Rotate Belt Tensioner with 3 8 in Drive and Remove Belt b Remove Alternator Output Lead and Harness Connector c Remove Ground Lead Screw d Remove 3 Bol...

Page 348: ...94 OCTOBER 2001 Powerhead Disassembly 1 Place powerhead in repair stand or on a bench 2 Remove thermostat covers and washers a b a Cover b Washer 3 Remove cylinder heads from engine block 52214 a b a...

Page 349: ...90 884294 OCTOBER 2001 Page 4A 37 4 Remove reed block housing from cylinder block 5 Inspect reeds as outlined in Cleaning and Inspection a b c d a Reed Block Housing b Reed Block c Adapter Plate d Ai...

Page 350: ...884294 OCTOBER 2001 LOWER END CAP 1 Remove lower end cap bolts 52325 a a a Crankcase Attaching End Cap Bolts 2 Remove bolts which secure crankcase cover to cylinder block 55977 a a Crankcase Cover 3 R...

Page 351: ...8 4 Use Powerhead Stand 91 30591A1 for rotating crankshaft to desired position for re moval of connecting rods 5 Using an awl or electric pencil scribe the cylinder identification number on each con n...

Page 352: ...onnecting Rod Bolts 7 Push piston out of cylinder block 8 After removal reassemble each piston and connecting rod assembly CAUTION Each connecting rod and end cap are a matched machined set and must n...

Page 353: ...ification number of connecting rod on inside of piston Reas semble piston on same connecting rod 55968 a a Scribe Identification Number 12 Using tool 91 52952A1 remove piston pin lockrings from both e...

Page 354: ...973A1 as shown 55957 b a a Piston Pin b Piston Pin Tool 91 92973A1 14 Remove piston pin needle bearings 34 per piston and locating washers 2 per piston as shown IMPORTANT It is recommend that new need...

Page 355: ...eal from end cap 17 Remove oil seals from end cap by driving seals out with a punch and hammer 51849 b a a O ring b Seal 18 Inspect roller bearing in upper end cap as outlined in Cleaning and Inspecti...

Page 356: ...lly crankshaft sealing rings do not require replacement unless broken CAUTION Safety glasses should be worn when removing or installing crankshaft sealing rings 20 Remove retaining ring as shown 58991...

Page 357: ...replacement is re quired 22 Remove lower ball bearing from crankshaft as follows a Remove retaining ring using a pair of snap ring pliers 55983 b a a c a Crankshaft Ball Bearing b Pliers c Retaining...

Page 358: ...sure relief valve components for debris or damage Re place components as required 1 2 3 4 5 6 7 8 9 10 11 12 13 1 Exhaust Plate 2 Carrier 3 Grommet 4 Poppet Relief Valve 5 Spring 6 Gasket 7 Inner Plat...

Page 359: ...matching surfaces Be sure that carbon deposits are re moved from exhaust ports 2 Inspect cylinder block and crankcase cover for cracks or fractures 3 Check gasket surfaces for nicks deep grooves crack...

Page 360: ...block remove hone frequently and check condition of cylin der walls DO NOT hone any more than absolutely necessary as hone can remove cylinder wall material rapidly c Start stroking at smallest diame...

Page 361: ...a block just because one cylinder requires re boring 5 After honing and thoroughly cleaning cylinder bores apply light oil to cylinder walls to prevent rusting Pistons and Piston Rings IMPORTANT If en...

Page 362: ...m inner diameter of ring grooves Care must be taken not to damage the grooves by scratching the side surfaces of the grooves Piston with two half keystone half tapered rings Enlarged View of Piston Ri...

Page 363: ...kshaft 1 Inspect crankshaft to drive shaft splines for wear Replace crankshaft if necessary 2 Check crankshaft for straightness Maximum runout is 0 002 in 0 0508 mm Replace as necessary 3 Inspect cran...

Page 364: ...ing Refer to Powerhead Removal and Disassembly Crank shaft Removal and Disassembly a 52326 a Lower Crankshaft Ball Bearing 3 Thoroughly clean with solvent and dry crankshaft center main roller bearing...

Page 365: ...ed System 1 Check rubber bleed hoses Replace any hose that is cracked cut or deteriorating 2 Check operation of lower end cap check valve If valve is working properly air can be drawn through check va...

Page 366: ...nal is hammered by the connect ing rod As ignition occurs in the cylinder the piston pushes the connecting rod with tre mendous force and this force is transferred to the connecting rod journal Since...

Page 367: ...ON PIN END of connecting rod using same method as in Step b pre ceding but using 320 grit carborundum cloth instead of crocus cloth d Thoroughly wash connecting rods to remove abrasive grit Recheck be...

Page 368: ...an severely damage an otherwise perfectly good powerhead within the first few minutes of op eration All new powerhead gaskets MUST BE installed during reassembly During reassembly lubricate parts with...

Page 369: ...d Press e Retaining Ring 3 If removed spread new crankshaft sealing rings just enough to slide over crankshaft journal 4 Use Piston Ring Expander 91 24697 and install crankshaft sealing rings into gr...

Page 370: ...als into lower end cap as follows a Apply a thin bead of Loctite 271 to outer diameter on 2 lower end cap oil seals b Use suitable mandrel to press one oil seal lip facing down into lower end cap unti...

Page 371: ...Into Cylinder Block Check the crankshaft sealing ring mating surfaces in the cylinder block and crankcase cover for wear grooves that were caused by the crankshaft sealing rings from the previous cran...

Page 372: ...raight up 4 Align hole in each center main bearing race with dowel pin 5 Gently push crankshaft down into position making sure that the dowel pins are lined up with the holes in center main bearings a...

Page 373: ...sleeve as shown 3 Place locating washers on connecting rod IMPORTANT Position connecting rod part number facing towards flywheel Carefully position piston over end of rod Make sure locating washers re...

Page 374: ...7 Make sure lockrings are properly seated in piston grooves b a 51086 a b 55963 a a Lockring Installation Tool 91 93004A2 b Lockring Piston and Piston Ring Combinations Pistons with two half keystone...

Page 375: ...und IMPORTANT Piston ring side with dot or letter must be facing up a a c d b 52317 e f a Piston Ring b Dots Faces Up c Feeler Gauge d Ring End Gap e Dot or Letter f Piston Ring IMPORTANT 3 Liter Work...

Page 376: ...alled IMPORTANT Piston must be correctly installed and positioned as shown Pistons marked with the word UP and with the letter P or S on top of piston Pistons with the letter P must be installed in th...

Page 377: ...and connecting rod caps are matched halves Do not torque screws before completing the following procedure Run a pencil lightly over ground area If pencil stops at fracture point loosen bolts retighten...

Page 378: ...ach connecting rod cap for correct alignment If not aligned a ridge can be seen or felt at the separating line as shown below Correct any misalignment 52381 a b c d a Side View Incorrect Cap on Backwa...

Page 379: ...Thoroughly remove all oil from mating surfaces of crankcase cover and cylinder block with Loctite 7649 Primer 55984 a b b a Crankcase Cover b Remove all Oil 2 Apply a thin even coat of Loctite Master...

Page 380: ...lock Tighten eight bolts evenly in three progressive steps following torque sequence 4 Install remaining crankcase cover flange bolts 5 Tighten end cap bolts to specified torque 55986 52132 52132 1 7...

Page 381: ...Adaptor Plate a b c d e f g NOTE Air plenum gasket is beaded on 1 side Bead side of the gasket faces the air plenum a Torque to 90 lb in 10 Nm b Reed Block 6 c Cylinder Block Cover d Adaptor Plate e A...

Page 382: ...lve components as shown Torque bolts to specifications 7 5 13 11 12 9 8 1 2 3 4 5 7 8 9 10 11 12 13 3 50803 6 1 Cover 2 Bolt 150 lb in 17 Nm 3 Gasket 4 Relief Valve Plate 5 Diaphragm 6 Water Deflector...

Page 383: ...mber 812851C13 The 225 EFI and 250 EFI cylinder heads can be identified by the casting number 812851C15 1 Install each cylinder head to engine block with thermostat pocket UP Apply light oil to cylind...

Page 384: ...Sensor Port Over heat b Temperature Sensor Analog Tem perature Gauge c Bolt Torque to 17 lb ft 23 Nm d Port Thermostat e Starboard Thermostat f Temperature Sensor Starboard Overheat NOTE The temperat...

Page 385: ...POWERHEAD 90 884294 OCTOBER 2001 Page 4A 73 Notes...

Page 386: ...POWERHEAD Page 4A 74 90 884294 OCTOBER 2001 Throttle Lever and Shift Platform Assembly 95 95 2 4 C Marine Lubricant with Teflon...

Page 387: ...2 1 SCREW M8 x 35 21 28 3 1 WASHER 4 1 BUSHING 5 2 SCREW M6 x 55 6 2 NUT 7 2 CAP 8 1 PIN INSERT 9 1 NUT 50 5 5 10 1 SWIVEL BUSHING 11 1 LINK 12 1 ANCHOR BRACKET 13 1 LATCH 14 2 SCREW DRIVE 15 2 CUP 1...

Page 388: ...ce of powerhead 3 Place a new gasket around powerhead studs and into position on base of powerhead IMPORTANT DO NOT apply lubricant to top of driveshaft as this will prevent drive shaft from fully eng...

Page 389: ...erhead to exhaust extension plate driveshaft housing Torque locknuts in 3 progressive steps until secured 7 Disconnect hoist from Lifting Eye and remove Lifting Eye from flywheel 8 Reinstall plastic c...

Page 390: ...OCTOBER 2001 9 Reconnect and or reinstall the following 59026 a b c d e f a Remote Oil Tank Pressure Hose b Remote Control Harness c Power Trim Wires d Negative Battery Cable e Positive Battery Cable...

Page 391: ...POWERHEAD 90 884294 OCTOBER 2001 Page 4A 79 10 Reinstall the following a 59030 b c d a Oil Supply Hose b Shift Lever Bracket Assembly c Water Pressure Hose GREY d Starboard Thermostat Discharge Hose...

Page 392: ...EAD Page 4A 80 90 884294 OCTOBER 2001 11 Reconnect the following 59028 a b c d a Water Pressure Sensor Hose GREY for Digital Gauges b Engine Flush Hose c Tell Tale Hose d Starboard Thermostat Discharg...

Page 393: ...ottom cowls a a 59075 a b a Screws b Access Cover to Lower Screw 13 Reconnect input fuel line water pressure hose and speedometer hose a b c d a Input Fuel Hose b Water Pressure Hose GRAY Ana log Gaug...

Page 394: ...shipped with the control explain the procedure required to connect this control to a counter rotation outboard IMPORTANT If the counter rotation outboard is rigged similar to a standard rotation outb...

Page 395: ...able against the cable end guide b Move the remote control handle from neutral into reverse and advance the handle to full speed position Slowly return the handle back to the neutral Place a mark b on...

Page 396: ...e Retainer c Locknut Tighten locknut then back off locknut 1 4 turn d Nylon Washer 7 Check shift cable adjustments as follows a With remote control in forward the propshaft should lock solidly in gear...

Page 397: ...le cable to the throttle lever Secure with washer and locknut a b a Nylon Washer b Locknut Tighten locknut then back off locknut 1 4 turn 3 Adjust the cable barrel so that the installed throttle cable...

Page 398: ...ring but has some drag on it Readjust cable barrel if necessary IMPORTANT The idle stop screw must be touching the stop a b a Idle Stop Screw b Idle Stop 5 Lock the barrel holder in place with the cab...

Page 399: ...break in Break In Procedure FIRST HOUR Avoid continuous operation at idle speed for more then ten minutes Run the engine the majority of time between 3000 and 4500 RPM approximately three quarter thr...

Page 400: ...e 4B 2 Thermostat 4B 2 Digital Port and Starboard Temperature Sensor 4B 3 Analog Temperature Sensor 4B 4 Special Tools 4B 5 Water Flow 4B 6 Description 4B 6 Water Flow Diagram 4B 7 Notes 4B 8 Troubles...

Page 401: ...Pressure Idle 1 5 4 5 PSI 10 3 30 8 kPa Poppet Valve Opening 6 0 7 0 PSI 41 3 48 2 kPa W O T 8 10 PSI 54 8 68 5 kPa Minimum a b c a Analog Temperature Sensor EFI Models and optional gauge sender b Dig...

Page 402: ...indicated ohm readings should be as indicated 10 There should be no continuity between each connector pin and ground Temperature Sensor Specifications Fahrenheit Centigrade OHMS 257 125 340 248 120 3...

Page 403: ...meter test leads into both TAN BLACK sensor leads With en gine at temperature F indicated ohm readings should be as indicated 10 0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 0 0...

Page 404: ...COOLING 90 884294 OCTOBER 2001 Page 4B 5 Special Tools 1 DMT 2000 Digital Tachometer Multimeter P N 91 854009A1 2 Water Pressure Gauge 91 79250A2 56725...

Page 405: ...ending upon engine tem perature When the thermostats are open water passes through the cylinder heads and exits to the drive shaft housing At higher RPM above 1500 RPM the poppet valve will control th...

Page 406: ...closed engine will overheat at low speed If stuck open engine will not warm up at idle speed 9 Poppet Valve Controls water flow at high RPM If poppet valve is stuck open at low rpm the engine will not...

Page 407: ...COOLING Page 4B 8 90 883728 JULY 2001 Notes...

Page 408: ...ner Bottom of thermometer must be even with bottom of thermo stat to obtain correct temperature of thermostat opening c Fill thermostat tester with water to cover thermostat d Plug tester into electri...

Page 409: ...olored is provided that exits at the front of the lower cowl A dash style gauge may be connected to this line to register water pressure WARNING Shut off engine and refer to troubleshooting chart if w...

Page 410: ...ades are in this condition IMPORTANT The circular groove formed by the impeller sealing bead should be dis regarded when inspecting cover and plate The depth of the groove will not affect wa ter pump...

Page 411: ...on Poppet valve vent hole plugged or restricted Severe internal leak Defective poppet valve seal Poppet valve flutter water pres sure drop does not stabilize prior to 2500 RPM Wrong poppet valve sprin...

Page 412: ...ON Section 5A Clamp Swivel Brackets Drive Shaft Housing Table of Contents Swivel Bracket and Steering Arm 5A 2 Transom Brackets 5A 4 Drive Shaft Housing and Exhaust Tube 5A 6 Drive Shaft Housing and D...

Page 413: ...Page 5A 2 90 884294 OCTOBER 2001 Swivel Bracket and Steering Arm 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 3 6 31 7 95 2 4 C Marine Lubricant with Teflon 95 9...

Page 414: ...R PLATE 12 2 LOCKWASHER 13 2 NUT 25 34 14 2 SCREW 1 4 28 x 1 2 IN 100 11 5 15 1 DECAL Serial Overlaminate 16 1 TRIM SENDER 17 2 SCREW 10 24 x 3 4 IN 15 1 7 18 2 LOCKWASHER 19 2 WASHER 20 1 SWIVEL PIN...

Page 415: ...CLAMP SWIVEL BRACKETS DRIVE SHAFT HOUSING Page 5A 4 90 884294 OCTOBER 2001 Transom Brackets 95 95 95 95 95 95 2 4 C Marine Lubricant with Teflon 1 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 18 19 15 10...

Page 416: ...lb in lb ft Nm 1 1 TRANSOM BRACKET STARBOARD 2 1 TRANSOM BRACKET PORT 3 1 GREASE FITTING PORT 80 9 4 1 TILT TUBE 5 1 NUT 1 IN 14 45 61 6 1 O RING 7 2 WAVE WASHER 8 1 NUT 7 8 14 45 61 9 4 BOLT 10 4 WAS...

Page 417: ...90 884294 OCTOBER 2001 Drive Shaft Housing and Exhaust Tube 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 20 21 23 24 25 11 23 26 19 33 95 7 95 9 27 22 28 29 30 31 5 5 95 2 4 C Marine Lubricant with T...

Page 418: ...WASHER 6 4 NUT M12 x 1 75 55 74 5 7 1 PLUG 8 2 SCREW M14 x 2 x 178 9 2 GROUND WIRE 10 2 WASHER 11 2 WASHER 12 2 MOUNT 13 2 WASHER 14 2 NUT 90 122 15 2 CLAMP 16 4 SCREW M8 x 35 20 27 0 17 1 LOCKWASHER...

Page 419: ...Unit Removal in this section to remove lower unit Removal and Disassembly 1 Remove shift shaft from driveshaft housing by pulling straight up on shaft 2 Remove power trim wiring harness from exhaust...

Page 420: ...b d c d c b a Shift Shaft Assembly b Bushing 3 c Lock Nut 2 d Washer 2 1 Remove upper mount nuts and flat washers 2 Pull mount bolts through mounts and remove mounts 58004 a a Upper Mount Nuts 3 Remo...

Page 421: ...ssure on rear of adaptor plate use a mallet and a piece of hardwood against the adaptor plate to loosen gasket adhesion a a Adaptor Plate 5 Remove 2 bolts securing water tube to adaptor plate and remo...

Page 422: ...move exhaust tube c a b a Hardwood b Adaptor Plate c Exhaust Tube 7 Remove all gasket material from driveshaft housing and related components 8 Remove screw which secure lower mount cover to drive sha...

Page 423: ...on housing 12 Remove upper and lower mounts by lifting them out of drive shaft housing Reassembly and Installation 1 Apply a thin coat of 2 4 C Marine Lubricant with Teflon onto inside portion of exh...

Page 424: ...to plate with 6 bolts Torque bolts to 21 Ib ft 28 5 Nm 4 Secure tube to adaptor plate with 2 bolts Torque bolts to 80 lb in 9 Nm c b a a Exhaust Tube b Gasket c Water Tube 5 Position adaptor plate on...

Page 425: ...f each lower mount 13 Position a mount on each lower side of drive shaft housing 14 Install a flat washer over each lower mounting bolt 15 Start upper mounting bolts in upper mounts and align lower mo...

Page 426: ...r b Bolts Torque to 20 lb ft 27 Nm c Ground Strap d Cover e Screw 1 for each cover 21 Install upper mount cover on adaptor plate Secure cover with 3 bolts Torque bolts to 20 lb ft 27 Nm 22 Route power...

Page 427: ...All Circuits Inoperative 5B 27 Power Trim Assembly Removal and Installation 5B 28 Removal 5B 28 Installation 5B 31 Testing Power Trim System With Test Gauge Kit 91 52915A6 5B 33 UP Pressure Check 5B 3...

Page 428: ...84294 OCTOBER 2001 Special Tools 1 Alignment Tool 91 11230 17238 2 Trim Rod Removal Tool 91 44486A1 51337 3 Trim Rod Guide Removal Tool 91 44487A1 51337 4 Power Trim Test Gauge Kit 91 52915A6 73835 5...

Page 429: ...tor Fitting 91 82278A2 and 91 82278A3 54458 7 Spanner Wrench 91 74951 51337 8 Multi Meter DVA Tester 91 99750A1 or DMT 2000 Digital Tachometer Multi meter 91 854009A1 a b a Multi Meter DVA Tester 91 9...

Page 430: ...Power Trim Components Oildyne 1 2 3 4 5 1 6 7 7 8 9 10 11 9 9 9 9 11 11 12 13 13 13 13 13 14 14 14 14 14 14 15 15 16 17 17 18 18 19 20 20 21 21 22 23 24 24 25 25 25 25 25 25 25 25 25 25 25 25 25 11 25...

Page 431: ...s Ref 26 45 61 13 1 O RING KIT Includes Ref 26 14 1 SHOCK ROD KIT 95 129 15 1 MEMORY PISTON 16 1 CHECK VALVE REPAIR KIT Includes Ref 26 17 1 STARBOARD TRIM ROD 18 1 PORT TRIM ROD 19 2 END CAP TRIM ROD...

Page 432: ...DESIGN II Page 5B 6 90 884294 OCTOBER 2001 Power Trim Motor Oildyne 1 2 3 58446 58449 REF TORQUE REF NO QTY DESCRIPTION lb in lb ft N m 1 POWER TRIM MOTOR 1 1 BRUSH AND SEAL KIT 2 1 ARMATURE KIT 3 1...

Page 433: ...dditional boat instability Will lift boat bow increasing top speed Transfers steering torque harder to port left on installations below 23 in 584 2 mm tran som height Increases gearcase clearance over...

Page 434: ...down to the desired position Trailering Outboard The Up circuit first moves the trim cylinders when the trim cylinders extend fully the tilt ram extends to tilt the outboard to the full up position fo...

Page 435: ...t using the trim angle adjustment pin and trimmed to the full In trim angle position may not exhibit any undesirable and or unsafe handling and or steering characteristics at planing speed If so not u...

Page 436: ...function will be lost Trim Indicator Gauge A Trim Indicator Gauge accessory kit is available for the power trim sender if not pre viously installed Check Fill and Purge Power Trim System TO CHECK CAUT...

Page 437: ...ove to fill system tighten securely b Fill system with Power Trim and Steering Fluid c Tilt Lock Lever engage to support engine in Up position TO PURGE IMPORTANT Fill plug and O ring must be tightened...

Page 438: ...from returning into the reservoir by the closed down suction check valve 4 Oil under pressure slides the shuttle spool 5 to the left against the down circuit pressure operated valve 6 The shuttle spoo...

Page 439: ...h Pressure b Low Pressure 1 Electric Motor 2 Oil Pump Gears 3 Up Circuit Suction Check Valve 4 Down Circuit Suction Check Valve 5 Shuttle Spool 6 Down Circuit Pressure Operated Valve 7 Tilt Cylinder 8...

Page 440: ...ams When the engine thrust falls low engine rpms the check ball in the trim relief valve closes al lowing oil flow to extend the tilt cylinder ram into the tilt range Over Trim At High Thrust As the o...

Page 441: ...84294 OCTOBER 2001 Page 5B 15 Tilt Circuit a b 3 7 1 2 1 4 5 6 a High Pressure b Low Pressure 1 Trim Cylinders 2 Trim Relief Valve 3 Port Trim ram 4 Tilt Cylinder 5 Pump Gears 6 Up Circuit Suction Che...

Page 442: ...under pressure then moves the shuttle spool 6 to the right mechanically opening the up pressure operated valve 7 allowing oil from the bottom of the trim 8 and tilt cylinders 9 to supply oil to the tr...

Page 443: ...ressure b Low Pressure 1 Pump Gears 2 Down Circuit Suction Check Valve 3 Down Pressure Regu lating valve 4 Reservoir 5 Up Circuit Suction Check Valve 6 Shuttle Spool 7 Up Circuit Pressure Operated Val...

Page 444: ...y as the outboard returns to its normal running position Propel ler thrust and the weight of the outboard provides the return motion for the engine Shock System When a submerged object is hit with gre...

Page 445: ...Trail Over and Shock Absorber a 1 2 5 3 4 6 7 8 a High Pressure 1 Up Circuit Pressure Operated Valve 2 Down Circuit Pressure Operated Valve 3 Manual Tilt Valve 4 Tilt Cylinder 5 Shock Piston 6 Memory...

Page 446: ...n side cavities When trimming the outboard in either the up or down position with the manual tilt valve open or leaking little or no movement will occur Oil pressure from the pump 4 will move to both...

Page 447: ...CTOBER 2001 Page 5B 21 Manual Tilt a 1 2 3 4 3 6 5 7 8 a Low Pressure 1 Manual Release Valve 2 Tilt Cylinder 3 Reservoir 4 Pump 5 Up Pressure Operated Valve 6 Down Pressure Oper ated Valve 7 Trim Reli...

Page 448: ...position under load 5 6 7 H Trail out when backing off from high speed 3 4 I Leaks down and does not hold trim 5 6 7 J Trim motor working hard and trims slow up and down 8 9 K Trims up very slow 1 2 5...

Page 449: ...ections If the motor will not run in the UP direction it could be either the UP relay is not making contact to 12 volts OR the DOWN relay is not making contact to ground The opposite is true if the sy...

Page 450: ...POWER TRIM DESIGN II Page 5B 24 90 884294 OCTOBER 2001 Power Trim System with Relays and 2 Wire Trim Motor BLK Black BLU Blue GRN Green RED Red WHT White DOWN Relay UP Relay 53794 1 2 3 4 5 6 7 8 9 10...

Page 451: ...ge Indicated Connect Voltmeter red lead to Point 5 If battery voltage is indi cated trim switch is faulty If no battery voltage check for loose or corroded connection at Point 5 or open circuit in wir...

Page 452: ...itch is defective There is an open circuit be tween Point 9 and positive battery terminal Connect Voltmeter red lead to Point 6 Connect Voltmeter red lead to Point 9 Connect Voltmeter red lead to Poin...

Page 453: ...motor is faulty Refer to Motor and Electrical Tests Repair following Check for open in wire Check for loose or corroded connections Check for voltage at any instru ment using a Voltmeter Turn ignitio...

Page 454: ...t to free power trim wiring 2 Raise outboard to full Up position and engage tilt lock lever 3 Remove trim indicator 50605 a b 58448 a a a Clamps b Tilt Lock Lever WARNING Failure to support outboard a...

Page 455: ...METRIC CONVERSION 14 in 35 56 cm 2 in 50 8 mm 3 8 in 9 5 mm 1 4 in 6 35 mm CAUTION Disconnect battery cables at battery before removing power trim wires from sole noids 4 Disconnect BLUE and GREEN bul...

Page 456: ...ashers in port clamp bracket 58452 b b a a 58444 c a Cross Pin b Upper Swivel Pin c Port Transom Bracket Bolts and Washers 3 Remove to release Trim System from Outboard 7 Remove 3 bolts and washers an...

Page 457: ...tends too far retract ram by connecting GREEN wire to POS ITIVE and BLUE wire to NEGATIVE 4 Install Upper Swivel Pin with slotted end to left port side of engine b a c d e f a b c 58453 a Screw 6 Torq...

Page 458: ...n transom mount bolts Apply marine sealer to threads of mount bolts Secure with flat washers and locknuts Be sure installation is watertight 8 Tighten tilt tube nut securely IMPORTANT Outboards equipp...

Page 459: ...manual release valve and unscrew release valve from trim assembly NOTE A small amount of trim fluid may drip from manual release valve hole Place a suit able container under trim assembly to collect a...

Page 460: ...Thread hose from Test Gauge Kit 91 52915A6 into brass fitting on adaptor 54459 e b d c a a b c d e a Brass Fitting b Test Gauge Assembly c Tilt Pin Position in Hole Shown d Hose e Hose Not Used 6 Rein...

Page 461: ...ets and swivel bracket in the hole shown a 54460 a a Tilt Pin Hole Install Spare Tilt Pin or Hardened Bolts and Nuts 10 Open valve a and close valve b 51374 a b a b 11 Run trim UP The minimum pressure...

Page 462: ...ase valve hole Place a suit able container under trim assembly to collect any leakage NOTE Assemble test adaptor by using O ring installation tool to position small O ring onto adaptor 1st then instal...

Page 463: ...e 6 Reinstall fill plug 7 Run trim UP 8 Disengage tilt lock lever 9 Open valve f and close valve g 10 Run trim DOWN Minimum pressure should be 600 P S I 42 kg cm2 11 Tilt outboard full UP and engage t...

Page 464: ...Fill plug to bleed reservoir pressure 3 Turn Manual Release Valve 3 to 4 turns counterclockwise to bleed remaining pres sure 4 Remove trim rod cylinder caps NOTE Place a clean pan under trim system t...

Page 465: ...limits the amount of total trim by 2 A maximum of 5 reducers may be installed on each trim rod 1 Inspect check valve and check valve screen for debris if debris cannot be removed replace trim rod ass...

Page 466: ...rod with check valve in the port left cylinder 1 Apply ATF Dexron III or Power Trim and Steering Fluid on all O rings and seals before installation 2 Install trim rods and caps Use installation tool 9...

Page 467: ...r trim system from outboard TILT RAM COMPONENTS 1 2 2 3 4 3 3 5 6 3 7 8 9 10 11 12 13 1 Tilt Cylinder Rod 2 Scraper Seal 3 O ring 4 Cylinder Cap 5 Return Ball 6 Shock Piston 7 Shock Balls 8 Spring Kee...

Page 468: ...d prior to tilt ram removal 1 Remove cross pin 2 Remove lower swivel pin 51355 a 51366 a b a a Cross Pin Remove as shown b Lower Swivel Pin Remove as shown Disassembly 1 Secure tilt ram in a soft jawe...

Page 469: ...ign 2 tilt rod assembly Design 1 or Design 2 cylinder assemblies complete can be used as re placements Design 2 will NOT fit a cylinder originally using a Design 1 tilt rod assembly Memory Pistons for...

Page 470: ...end cap from tilt rod 51376 a a a End Cap Memory Piston Removal 1 Remove memory piston from cylinder using Snap On lock ring pliers SRP 4 or similar tool 2 Remove o ring from memory piston SRP 4 Snap...

Page 471: ...m deep in cylinder are accept able IMPORTANT Components must be dirt and lint free Slightest amount of debris in Power Trim system could cause system to malfunction 4 Clean shock rod and components wi...

Page 472: ...ply ATF Dexron III or Power Trim and Steering Fluid on O rings prior to reassembly 2 Install O ring on Memory Piston Cup and install in cylinder 3 Inspect and replace as required 3 O rings in the bott...

Page 473: ...ng c Check Valve Assembly 7 d Washer e Locknut Torque to 95 lb ft 129 N m 8 Clamp cylinder in a soft jawed vise and install tilt rod assembly Use spanner wrench and tighten end cap securely Torque end...

Page 474: ...se ATF Dexron III or Power Trim and Steering Fluid a b a Alignment Tool 91 11230 b Shaft 2 Align tilt ram and housing using alignment tool 3 Install shaft 51348 a a 58603 d c a b a Alignment Tool 91 1...

Page 475: ...the full up position fully extended prior to fill drain plug or manual release valve removal 1 Remove reservoir cap to drain oil 2 Remove manual release valve to drain any remaining oil 58604 a b a Re...

Page 476: ...ce O ring as required 58605 a a O Ring Trim Motor Removal 1 Secure power trim assembly in a soft jaw vise 2 Remove 2 screws securing motor and remove motor Remove motor O ring yellow and coupler 3 Ins...

Page 477: ...e to internal components of the pump requires pump assembly replacement 2 Inspect filter O ring assemblies on bottom of oil pump Replace as required 58608 58609 b a a Screws b Filter O ring Assemblies...

Page 478: ...bris in the area shown If debris is found on poppet replace poppet Inspect o rings on both seats and spool for cuts or abraisions Replace o rings as required 58607 b c a d e e e e e a a f f g g h h a...

Page 479: ...while making electrical connections 1 Connect a 12 volt power supply to motor wires one motor lead to POSITIVE bat tery terminal and the other motor lead to the NEGATIVE battery terminal Motor should...

Page 480: ...an b Armature c End Cap Armature Tests TEST FOR SHORTS Check armature on a Growler per the Growler manufacturer s instructions Replace ar mature if a short is indicated TEST FOR GROUND 1 Use an Ohmmet...

Page 481: ...otor Wire and Frame No Continuity Rx1 If specified readings are not obtained check for defective armature dirty or worn brushes dirty or worn commutator If defective components are found repair or rep...

Page 482: ...t and test motor components Refer to Brush Replace ment Armature Test and Field Tests for inspection and test procedures 53779 a b c d e a b c d e a Can b Armature c Shim d Motor End Frame Assembly e...

Page 483: ...hing appears to be excessively worn grooves scratches etc replace END FRAME ASSEMBLY COMPLETE 53785 c 53783 a b a b a Seal Apply 2 4 C Marine Lubricant with Teflon to seal lips b O ring c Bushing 3 If...

Page 484: ...Any debris in power trim system can cause system to malfunction 1 Install armature into end cap brush card assembly 53779 a b c 53784 d a b c d a Armature b Shim c End Cap Assembly d Armature Spread...

Page 485: ...d assembly by the frame magnets while installing the frame assembly 3 Install Vise Grip pliers on armature shaft 4 Carefully install can over armature 5 Position harness retainer hole over tab in end...

Page 486: ...8609 a b a Oil Pump b Screws 3 Torque to 60 lb in 7 N m IMPORTANT Install pump with location flat facing towards starboard transom bracket 2 Fill pump with ATF Dexron III or Power Trim and Steering Fl...

Page 487: ...Verify cover O ring is in place and in serviceable condition Secure cover with 4 screws Torque screws to 60 lb in 7 Nm 58605 a 58606 b c c a O Ring b Reservoir Cover c Screws Torque to 60 lb in 7 Nm 5...

Page 488: ...or is run without priming pump drive shaft failure could result Analog Trim Sender Test 1 Check trim sender black lead for proper ground 2 Trim outboard to full DOWN position 3 Place ignition switch t...

Page 489: ...position to gain access to trim sender and engage tilt lock lever 4 Loosen trim sender screws and reposition trim sender 5 Tighten trim sender screws c b a d a b c d e 22744 a Trim Sender b Screws Lo...

Page 490: ...voltage indicates a defective ECU If ECU reference voltage is correct but voltage at trim sender is low or not existent inspect send er wiring and connections Voltage at trim sender should rise and f...

Page 491: ...ts equipped with Quicksilver Commander Series side mount remote control Wiring Diagram For boats equipped with Quicksilver Ignition Choke and Main Harness Assembly a b c a f g c a b c e d a f g c e d...

Page 492: ...bly 6A 50 Drive Shaft and Pinion Gear 6A 51 Gear Location Backlashes Checking and Adjustment 6A 54 Drive Shaft Bearing Preload Tool 6A 54 Pinion Gear Location 6A 55 Bearing Carrier Assembly 6A 58 Forw...

Page 493: ...oval Tool 91 46086A1 and Puller Bolt 91 85716 3 Slide Hammer Puller 91 34569A1 4 Bearing Removal and Installation Kit 91 31229A5 This kit contains the following tools Pilot 91 36571 Puller Rod 91 3122...

Page 494: ...91 29310 8 Mandrel 91 38628 9 Driver Rod 91 37323 10 Universal Puller Plate 91 37241 11 Driveshaft Holding Tool 91 56775 12 Oil Seal Driver 91 31108 13 Forward Gear Bearing Tool 91 877321A1 14 Bearin...

Page 495: ...17 Dial Indicator 91 58222A1 18 Bearing Retainer Tool 91 43506 19 Bearing Preload Tool 91 14311A2 1 2 3 4 5 6 8 7 9 1 Plate 44307 2 Adaptor N S S 3 Bearing N S S 4 Washer N S S 5 Spring 24 14111 6 Bo...

Page 496: ...IGHT HAND NON RATCHETING 90 884294 OCTOBER 2001 Page 6A 5 23 Leakage Tester FT8950 24 Oil Seal Driver 91 817569 25 Water Pump Alignment Pins 91 821571A1 26 Bearing Adaptor Installation Tool 91 18605A2...

Page 497: ...d Rotation 1 2 3 13 4 5 6 7 8 9 10 11 12 14 16 17 18 19 20 21 22 23 24 28 29 30 32 37 38 39 40 41 42 43 44 45 46 5 9 95 95 95 7 92 95 95 95 95 95 95 31 4 75 IN 120 65MM TORPEDO DIA 26 15 10 11 7 27 25...

Page 498: ...OVER 15 1 GASKET 16 1 PINION GEAR 1 75 1 12 21 Part of 43 859321A3 17 1 WASHER 18 1 NUT 70 95 19 1 OIL SEAL 20 1 O RING 21 2 SCREW M6 x 16 60 7 22 1 RUBBER WASHER 23 1 SHIFT SHAFT LOWER 1 DRIVE SHAFT...

Page 499: ...rop Shaft Standard Rotation 48 50 54 55 53 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 49 51 52 1 95 95 95 94 95 87 95 95 95 87 87 87 4 75 IN 120 65MM TORPEDO DIA Anti Corrosion Grease 94...

Page 500: ...ORWARD PINION GEAR SET 1 75 1 12 21 54 AR SHIM SET 55 1 TAPERED ROLLER BEARING 56 1 CUP 57 1 RETAINING RING 58 1 ROLLER BEARING 59 1 SPRING 60 1 SLIDING CLUTCH 61 1 DETENT PIN 62 1 CROSS PIN 63 1 PROP...

Page 501: ...ause bearing to score from lack of lubrication After cleaning lubricate bearings with Pre mium Gear Lubricant DO NOT lubricate tapered bearing cups until after inspection Inspect all bearings for roug...

Page 502: ...her away from thrust hub rear then remove propeller locknut tab washer thrust hub rear propeller and thrust hub forward from propel ler shaft 5 Mark gear housing and trim tab so that trim tab can be r...

Page 503: ...e side mounting locknuts Do not attempt to remove one nut before oppo site side is loosened sufficiently or gear housing could be damaged a 52374 a Side Mounting Locknuts 2 each side 9 Pull gear housi...

Page 504: ...l amount of fine metal particles resembling powder indicates normal wear Presence of larger particles or a large quantity of fine particles indicates need for gear housing disassembly and component in...

Page 505: ...ssembly and the water pump screws 57944 a c b a Water Seal b Water Tube Coupling c Water Pump Screws 4 2 Carefully slide the water pump straight up off of the drive shaft It may be necessary to encour...

Page 506: ...essary replace the worn or damaged components especially the two O rings on the inside one at the top and one at the bottom 70613 a b b a Water Tube Adaptor b O rings 2 IMPORTANT The circular groove f...

Page 507: ...a Impeller b Hub IMPORTANT When completing gear housing repairs that require removal of water pump impeller it is recommended that the impeller be replaced If it is necessary however to re use impell...

Page 508: ...T DISASSEMBLY NOTE Complete the instructions in this section only if the assembly components have been found to be defective and are in need of repair or replacement 1 Remove the o ring 70501 a b a O...

Page 509: ...second seal lip faces up Apply 2 4 C Marine Lubricant with Teflon to seal lips and between seals Press seal into carrier with suitable mandrel Second seal should be pressed in flush with carrier surfa...

Page 510: ...retainer threads when using the following pro cedure for removing the retainer a If the retainer is corroded in place drill 4 holes in the retainer and fracture the re tainer with a chisel Pry the rem...

Page 511: ...that all seals and O rings be replaced as a normal repair procedure to assure effective repair 1 Clean bearing carrier with solvent and dry with compressed air 2 Inspect the bearing carrier for signs...

Page 512: ...ted conditions exist DISASSEMBLY BEARING CARRIER 1 Remove and discard O ring from between bearing carrier and thrust washer 2 If inspection of reverse gear or reverse gear bearing determines that repl...

Page 513: ...3351 a b c a Universal Puller Plate 91 37241 b Thrust Washer c Bearing 6 Using a suitable mandrel and the universal puller plate to support the bearing press the bearing from the reverse gear as shown...

Page 514: ...d worn unevenly discolored from overheating or has em bedded particles 7 Perform the following step a or b as necessary a If Replacing the Needle Bearing and Seals Remove the needle bearing and seals...

Page 515: ...careful not to spin the bearing 2 Lubricate the bore that the needle bearing is pressed into with Premium Gear Lubri cant 3 Assemble the needle bearing with the numbered end of the bearing towards the...

Page 516: ...of Loctite 271 to the outer diameter of the second seal 9 Assemble the second seal with the lips of the seal facing the driver shoulder onto the short end of the driver 10 Press the oil seal with the...

Page 517: ...346 a b c d a Pilot Washer 91 36571 b Ball Bearing c Thrust Hub d Reverse Gear 14 Lubricate the bore that the bearing is pressed into with Premium Gear Lubricant 15 Press the bearing carrier onto the...

Page 518: ...e pinion nut adapter with the MR slot facing the pinion gear into the gear housing It may be necessary to slightly lift and rotate the drive shaft to align the pinion gear nut into the pinion nut adap...

Page 519: ...otect shaft splines with soft material f Completely unscrew the drive shaft bearing retainer g Completely unscrew the pinion nut by rotating the drive shaft or the propeller shaft in a counterclockwis...

Page 520: ...ting surface Use a mallet and care fully tap gear housing away from drive shaft CAUTION Do not strike gear housing hard with mallet or allow gear housing to fall 57951 a b a Wood Block b Drive Shaft i...

Page 521: ...ompressed air being careful not to spin the bearings 2 The condition of the drive shaft bearing cup is an indication of the condition of the ta pered roller bearing on the drive shaft Replace the bear...

Page 522: ...ered roller bearing to the drive shaft with the large O D of the bearing facing the pinion gear end of the drive shaft 3 Thread a used pinion nut onto end of drive shaft Leave approximately 1 16 2mm o...

Page 523: ...d 58016 a Propeller Shaft Assembly b Shift Spool c Shift Crank d Thrust Washer Reverse Gear 2 Remove the forward gear bearing cup and shims Measure and make note of the shim thickness If the shims are...

Page 524: ...c d e f a Spring b Cross Pin c Shift Spool Assembly d Forward Gear Assembly e Sliding Clutch f Detent Pin hidden PROPELLER SHAFT ASSEMBLY Component Inspection 1 Clean all the parts with a suitable sol...

Page 525: ...ect reverse gear thrust washer surface for wear or taper If surface is worn or ta pered propeller shaft must be replaced 23355 a a Thrust Washer Surface 7 Inspect the propeller shaft for a bent condit...

Page 526: ...OMPONENT INSPECTION 1 Clean the forward gear assembly and the forward gear bearing cup with a suitable solvent and dry with compressed air Be careful not to spin the bearings 2 Inspect the gear for pi...

Page 527: ...overheating or has embedded particles replace the forward gear bearing cup and remove and replace the tapered roller bearings as outlined in the next section FORWARD GEAR ASSEMBLY Component Disassemb...

Page 528: ...move bearing 57905 a b 19203 a Retaining RIng b Bearing FORWARD GEAR ASSEMBLY Component Reassembly NOTE Complete the instructions in this section only if the assembly components have been disassembled...

Page 529: ...will be necessary to replace the com plete shift spool assembly Individual parts are not available for the assembly 3 Inspect the shift spool for wear in the area where the shift crank comes into cont...

Page 530: ...in a vice being careful not to damage the spool 4 Unscrew the retainer SHIFT SPOOL REASSEMBLY 1 Place the shift spool onto the shift spool shaft 2 Screw the castle nut down until it touches the washe...

Page 531: ...ropeller shaft and through the shift spool shaft hole 5 Install detent pin in 3rd hole in clutch 6 Assemble the cross pin retaining spring over the propeller end of the propeller shaft and wind it aro...

Page 532: ...aft bushing screws and remove the shift shaft and bushing by pulling both straight out of gear housing 57934 a a Shift Shaft Bushing Screws 2 Remove the shift crank from the inside of the gear housing...

Page 533: ...all components with a suitable solvent and dry thoroughly with compressed air a Inspect the shift shaft bushing for cracking damage or excessive wear b Inspect the oil seal inside the bushing the sle...

Page 534: ...the bushing and the lip of the oil seal with 2 4 C Marine Lubricant with Teflon 2 If the speedometer connector was removed and or replaced lightly coat the threads of the connector with Perfect Seal A...

Page 535: ...needles and race as a set if the drive shaft is pitted grooved scored worn unevenly discolored from overheating or has embedded particles IMPORTANT All the needle bearings 18 MUST BE in place inside...

Page 536: ...threads in the gear housing for corrosion and or stripped threads Damage or corrosion to the threads requires replacement of the gear housing 5 Inspect bearing race cup contact areas for evidence of...

Page 537: ...g sleeve in place onto the driver head with the lettered and numbered side of the bearing oriented upward 3 Insert the driver with the bearing assembly into position by way of the propeller shaft bore...

Page 538: ...ed and it was determined that it needs to be adjusted see Checking Forward Gear Backlash adding or subtracting 0 001 in 0 03mm shims will change the gear backlash by the same amount Example 1 if backl...

Page 539: ...void cocking it in the bore while pressing it in 50791 87 Premium Gear Lubricant 87 a b c d a Hex Head Screw b Bearing Cup Installation Tool 91 18605A1 c Driver Cup 91 31106 d Shims Shift Shaft Assemb...

Page 540: ...h 2 4 C Marine Lubricant with Teflon Secure shift shaft bushing with 2 screws Torque screws to 60 lb in 7 Nm 57933 a b a Shift Shaft Assembly b Screws Torque to 60 lb in 7 Nm NOTE If the pinion bearin...

Page 541: ...shaft from reverse to neutral while installing shaft 58016 c b a a Shift Actuating Spool b Shift Crank c Propeller Shaft Assembly 2 Operate the shift shaft to ensure that it has been properly installe...

Page 542: ...none of the above listed parts were replaced reinstall the same shims or same amount of shims 1 Place the upper tapered bearing shim s into the drive shaft housing bore 70620 a a Shim s NOTE For ease...

Page 543: ...housing 5 Insert the drive shaft into the gear housing drive shaft bore It may be necessary to rotate the drive shaft to engage the drive shaft splines into the pinion gear splines 6 Start the pinion...

Page 544: ...e pinion nut to 75 lb ft 102 Nm by turning the drive shaft using the drive shaft nut wrench and torque wrench 57950 b c a a Pinion Nut Adapter 91 61067A2 b Drive Shaft Nut Wrench 91 56775 c Bearing Ca...

Page 545: ...omponents from the Bearing Preload Tool Kit 91 14311A2 over the drive shaft in the order shown 70496 a b c d e f g d a Top Nut with Threaded Pipe b Nut c Spring d Thrust Washer 2 Required 12 18448 e T...

Page 546: ...eight IF Pinion Height Tool 91 56048 is used 1 Place the pinion gear shimming tool into the gear housing NOTE Take the following measurements at 3 locations rotating the drive shaft 120 de grees betwe...

Page 547: ...shaking it Add or subtract shims beneath the cup to obtain the proper average pinion gear height Reinstall the cup and retainer Retorque retainer to 100 lb ft 135 Nm Reinstall the bearing preload tool...

Page 548: ...a Bearing Retainer Tool 91 43506 6 Push down on drive shaft and check clearance between pinion gear and pinion gear shimming tool shoulder Clearance should be 0 020 in 0 024 in 0 51 mm 0 61 mm a b a P...

Page 549: ...HECKING BACKLASHES NOTE If backlashes have already been checked and they are to specification proceed with Bearing Carrier Assembly Final Installation section 1 Place the bearing carrier assembly into...

Page 550: ...e V notch in bearing carrier 70714 a b a Tab Washer b V Tab 4 Lubricate the bearing carrier retainer threads with 2 4 C Marine Lubricant with Teflon Start the retainer into the gear housing threads an...

Page 551: ...een set up see Drive Shaft Bearing Preload Tool Installation section 2 Install a dial indicator and align the dial indicator pointer so that it is perpendicular to and touching the I mark on the dial...

Page 552: ...tain correct backlash When reinstalling pinion nut apply Loctite 271 to threads of nut 6 If backlash is MORE than the specified MAXIMUM add shim s in front of forward gear bearing race to obtain corre...

Page 553: ...eel the backlash between the gears no movement should be noticed at the propeller shaft a Observe the dial indicator and record the reading b Loosen the indicator tool and rotate the drive shaft 90 de...

Page 554: ...w the bottom nut up as close as possible to the top nut 1 Remove the dial indicator and its supporting tooling 2 Screw the bottom nut of the bearing preload tool until it is as close as possible to to...

Page 555: ...ill the space between the carrier oil seals with 2 4 C Marine Lubricant with Teflon 2 Place the bearing carrier assembly into the gear housing It may be necessary to turn the drive shaft to align the...

Page 556: ...arrier 70714 a b a Tab Washer b V Tab 5 Fill the bearing carrier retainer nut threads and corresponding gear housing threads with 2 4 C Marine Lubricant with Teflon Start the retainer into the gear ho...

Page 557: ...ing carrier retainer to 210 lb ft 285 Nm If one tab does not align up in space between two of the notches continue to tighten retainer until alignment is achieved DO NOT loosen retainer to achieve ali...

Page 558: ...the gear case 70501 a b c a Oil Seal Carrier b Oil Seal Lips c O ring Water Pump Assembly Installation NOTE The gaskets face plate hole pattern is not symmetrical If the holes of the gaskets face plat...

Page 559: ...ler onto the drive shaft and down over the key 57938 95 2 4 C Marine Lubricant With Teflon 95 a b a Water Pump Impeller b Water Pump Impeller Key 4 Install the 2 water pump locating pins through the g...

Page 560: ...ng assembly to the water pump ensuring that the O rings are not damaged during assembly IMPORTANT If seal installed above pump housing is not at the proper height air will be drawn into the pump resul...

Page 561: ...ling gear housing onto driveshaft housing 1 Tilt engine to full up position and engage the tilt lock lever 2 Apply a light coat of 2 4 C Marine Lubricant with Teflon onto driveshaft splines CAUTION DO...

Page 562: ...k wise b Place guide block anchor pin into NEUTRAL position Propeller shaft should ro tate freely clockwise counterclockwise c Place guide block anchor pin into REVERSE gear position Rotate flywheel c...

Page 563: ...washer down in grooves of rear thrust hub to secure propeller nut If tab washer tabs do not align with slots continue to tighten propeller nut to ob tain alignment DO NOT loosen nut to align tabs a 51...

Page 564: ...e secured to yoke with sta strap 2 Route speedometer tube from swivel tube around lower yoke and push into junction After insertion of speedometer tubes into junction pull on each tube to verify that...

Page 565: ...6B 61 Drive Shaft and Pinion Gear 6B 62 Gear Location Backlashes Checking and Adjustment 6B 65 Pinion Gear Location 6B 66 Reverse Gear Backlash 6B 70 Forward Gear Bearing Carrier Assembly 6B 72 Forwa...

Page 566: ...1 Special Tools 1 Propeller Shaft 44 93003 and Load Washer 12 37429 2 Bellville Washer 12 54048 3 Needle Bearing Driver 91 15755 4 Oil Seal Driver 91 31108 5 Universal Puller Plate 91 37241 6 Bearing...

Page 567: ...Shaft Nut Wrench 91 56775 9 Bearing Carrier Retainer Wrench 91 61069 10 Torque Wrench lb in 91 66274 11 Backlash Indicator Rod 91 78473 12 Puller Bolt 91 85716 and Puller Jaws 91 46086A1 13 Dial Indi...

Page 568: ...Page 6B 4 90 884294 OCTOBER 2001 15 Forward Gear Installation Tool 91 815850 16 Puller Jaws 91 816242 17 Guide Plate 91 816243 18 Bearing Driver 91 816244 19 Oil Seal Driver 91 817569 20 Water Pump Al...

Page 569: ...himming Tool 91 12349A2 22 Bearing Preload Tool 91 14311A2 1 2 3 4 5 6 8 7 9 1 Plate 44307 2 Adaptor N S S 3 Bearing N S S 4 Washer N S S 5 Spring 24 14111 6 Bolt 10 12580 7 Nut 11 13953 8 Set Screw 1...

Page 570: ...ead 91 36569 Driver Head Rod 91 37323 Nut 11 24156 Pilot Washer 91 36571 Pilot Plate 91 29310 Puller Driver Head 91 38628 Mandrel 91 30366 Plate 91 29310 Driver Head 91 32325 Puller Shaft 91 31229 Was...

Page 571: ...LEFT HAND NON RATCHETING 90 884294 OCTOBER 2001 Page 6B 7 28 Pinion Nut Adaptor 91 61067A3 29 Drive Shaft Adaptor 91 61077 30 Leakage Tester FT8950...

Page 572: ...otation 1 2 3 4 13 5 6 7 8 9 10 11 12 14 16 17 18 25 19 20 21 22 23 24 28 33 34 35 36 39 41 44 46 45 38 43 37 42 40 5 9 95 95 95 95 7 7 92 7 95 95 95 95 95 47 15 4 75 IN 120 65MM TORPEDO DIA 10 11 27...

Page 573: ...GASKET 16 1 PINION GEAR 1 75 1 12 21 PART OF 43 828695A1 17 1 WASHER 18 1 NUT 70 95 19 1 OIL SEAL 20 1 O RING 21 2 SCREW M6 x 16 60 7 22 1 RUBBER WASHER 23 1 SHIFT SHAFT LOWER 24 1 DRIVE SHAFT X LONG...

Page 574: ...er Rotation 1 49 50 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 51 52 53 74 73 72 95 87 87 95 95 95 95 95 95 87 87 94 87 87 87 4 75 IN 120 65MM TORPEDO...

Page 575: ...PROPELLER SHAFT 66 1 FORWARD GEAR 1 75 1 12 21 AR SPACER SHIM 206 IN AR SPACER SHIM 208 IN AR SPACER SHIM 210 IN AR SPACER SHIM 212 IN AR SPACER SHIM 214 IN AR SPACER SHIM 216 IN 67 AR SPACER SHIM 21...

Page 576: ...se bearing to score from lack of lubrication After cleaning lubricate bearings with Pre mium Gear Lubricant DO NOT lubricate tapered bearing cups until after inspection Inspect all bearings for roughn...

Page 577: ...ler tab washer away from thrust hub rear then remove propeller locknut tab washer thrust hub rear propeller and thrust hub forward from propel ler shaft 5 Mark gear housing and trim tab so that trim t...

Page 578: ...osen the side mounting locknuts DO NOT attempt to remove one nut before oppo site side is loosened sufficiently or gear housing could be damaged a a Side Mounting Locknuts 9 Pull gear housing away fro...

Page 579: ...resembling powder indicates normal wear Presence of larger particles or a large quantity of fine particles indicates need for gear housing disassembly and component inspection 4 Note the color of gear...

Page 580: ...ile observing the dial indicator If the deflection is more than 0 009 in 0 23 mm a bent propeller shaft is indicated 2 Measure propeller shaft endplay If it is in excess of 0 093 in 2 36mm disassemble...

Page 581: ...sembly and the water pump screws 57944 b a c a Water Seal b Water Tube Coupling c Water Pump Screws 4 2 Carefully slide the water pump straight up off of the drive shaft It may be necessary to encoura...

Page 582: ...essary replace the worn or damaged components especially the two O rings on the inside one at the top and one at the bottom 70613 a b b a Water Tube Adaptor b O rings 2 IMPORTANT The circular groove f...

Page 583: ...a Impeller b Hub IMPORTANT When completing gear housing repairs that require removal of water pump impeller it is recommended that the impeller be replaced If it is necessary however to re use impell...

Page 584: ...DISASSEMBLY NOTE Complete the instructions in this section only if the assembly components have been found to be defective and are in need of repair or replacement 1 Remove the o ring 70501 a b a O r...

Page 585: ...second seal lip faces up Apply 2 4 C Marine Lubricant with Teflon to seal lips and between seals Press seal into carrier with suitable mandrel Second seal should be pressed in flush with carrier surfa...

Page 586: ...etainer threads when using the following pro cedure for removing the retainer a If the retainer is corroded in place drill 4 holes in the retainer and fracture the re tainer with a chisel Pry the rema...

Page 587: ...CLOSE TO BOSSES IN CARRIER NOTE If the bearing carrier is seized in the gear housing it may be necessary to use heat to loosen the carrier 50786 b a a Puller Jaws 91 46086A1 b Puller Bolt 91 85716 4...

Page 588: ...LEFT HAND NON RATCHETING Page 6B 24 90 884294 OCTOBER 2001 5 Remove the aft thrust bearing 50786 a a Thrust Bearing 6 Remove the aft thrust collar 50787 a a Thrust Collar...

Page 589: ...OCTOBER 2001 Page 6B 25 7 Lift up on the propeller shaft and push down on the forward thrust collar to remove the two keepers 50778 50826 a b a b a Thrust Collar b Keepers 2 8 Remove the forward thru...

Page 590: ...50786 a b a Wire Tool b Forward Gear Bearing Adaptor 11 Shift gear case into forward gear NOTE The thrust race has a tight fit in the gear housing bore Use the Forward Gear In stallation Tool 91 81585...

Page 591: ...emove the O ring from inside the gear housing 13 Remove the forward gear thrust race and the thrust bearing between the gear and the race 14 Remove the forward gear shim 50783 a b c d a Forward Gear I...

Page 592: ...er for signs of excessive corrosion especially in the area where the bearing carrier touches the gear housing If excessive corrosion is evident replace the carrier 50818 a b a Bearing Carrier b Mating...

Page 593: ...ws of the gear for damage Surfaces must not be chipped or rounded off Replace the forward and the pinion gear if any are found 23355 a b a Reverse Gear Teeth b Clutch Jaws 7 Inspect the thrust bearing...

Page 594: ...eplace needle bearing in the bearing carrier if the prop shaft is pitted grooved scored worn unevenly discolored from overheating or has em bedded particles 1 Perform the following step a or b as nece...

Page 595: ...emium Gear Lubri cant 3 Assemble the needle bearing with the numbered end of the bearing towards the driv er shoulder onto the driver 4 Press the needle bearing into the bearing carrier until the driv...

Page 596: ...ring Carrier 8 Apply a thin film of Loctite 271 to the outer diameter of the second seal 9 Assemble the second seal with the lips seal facing the driver shoulder onto the short end of the driver 10 Pr...

Page 597: ...aring surfaces on the forward gear in the areas that the bearings of the bearing adaptor and the thrust bearing rides is an indication of the condi tion of the respective bearings Replace the bearing...

Page 598: ...the holes of the adaptor and apply pressure to the center of the tool so that the pressure is equal on both of the pins Discard the bearing 50874 b a c c d a Forward Gear Bearing Adaptor b Bearing Rem...

Page 599: ...be necessary to slightly lift and rotate the drive shaft to align the pinion gear nut into the pinion nut adapter slot c Install the bearing carrier into the gear housing backwards to support the pro...

Page 600: ...kwise Protect shaft splines with soft material f Completely unscrew the drive shaft bearing retainer g Completely unscrew the pinion nut by rotating the drive shaft or the propeller shaft in a counter...

Page 601: ...de to dislodge the pinion gear 50884 a c b a Propeller Shaft b Pinion Gear c Wire Tool NOTE If pinion gear is seized onto the driveshaft place gearcase in vise using soft jaw vise covers Place a block...

Page 602: ...shaft in one operation Using the bottom bearing cup removed from the gearcase place the cup on top of a vise leaving the vise jaws open enough to allow the drive shaft to slide through 2 Place the dri...

Page 603: ...pped or broken teeth hairline fractures and excessive or uneven wear Replace the pinion gear and the forward gear if any defects are found 6 Inspect driveshaft for groove s where water pump base oil s...

Page 604: ...housing to allow the shift spool to disengage from the shift crank lower the propeller shaft out of the gear housing NOTE The rollers of the reverse gear bearing adaptor may become dislodged while re...

Page 605: ...DISASSEMBLY IMPORTANT When accomplishing the next step all of the parts are free to come apart Work closely over a work bench to ensure that the parts are not dropped or damaged and to avoid personal...

Page 606: ...CTOBER 2001 2 Remove detent pin 3 Remove the cross pin that goes through the clutch dog Remove the reverse gear and slide the clutch off of the propeller shaft 58012 a b 58018 d c e a Detent Pin b Cro...

Page 607: ...bearing and the needles of the forward gear needle bearing roll Re place the propeller shaft if it is pitted grooved scored worn unevenly discolored from overheating or has embedded particles 50698 c...

Page 608: ...dial indicator movement If the indicator in the dial moves more than 0 009 in 0 23mm replace the propeller shaft Reverse Gear Assembly COMPONENT INSPECTION 1 Clean the reverse gear assembly with a su...

Page 609: ...scored worn unevenly discolored from overheating or has embedded particles replace the propeller shaft and remove and replace the needle bearing in the reverse gear as outlined in the next section 506...

Page 610: ...MPORTANT The appearance of the forward and reverse gear is almost identical The forward gear has a shorter hub and is slightly smaller in diameter 50885 REVERSE FORWARD 3 75 9 5cm 4 10 2cm a a Shorter...

Page 611: ...eplace the complete shift spool assembly Individual parts are not available for the assembly 3 Inspect the shift spool for wear in the area where the shift crank comes into contact 23356 a b a Contact...

Page 612: ...all components with a suitable solvent and dry them with compressed air 2 Inspect each component for wear or damage If any components are worn beyond repair damaged or broken it will be necessary to r...

Page 613: ...is not aligned at the hole in the shaft back off the castle nut until the next available slot in the nut is aligned with the hole in the shaft 4 Insert a new cotter pin and bend ends in opposite direc...

Page 614: ...ry it using compressed air NOTE The condition of the bearing surfaces on the reverse gear in the areas that the bearings of the bearing adaptor and the thrust bearing rides is an indication of the con...

Page 615: ...tor using a suitable mandrel b Discard the bearing 2 Assemble the adaptor as follows a Lubricate the bore that the needle bearing is to be pressed into with 2 4 C Marine Lubricant with Teflon b Positi...

Page 616: ...aft bushing screws and remove the shift shaft and bushing by pulling them straight out of gear housing 57934 a a Shift Shaft Bushing Screws 2 Remove the shift crank from the inside of the gear housing...

Page 617: ...all components with a suitable solvent and dry thoroughly with compressed air a Inspect the shift shaft bushing for cracking damage or excessive wear b Inspect the oil seal inside the bushing the slee...

Page 618: ...the bushing and the lip of the oil seal with 2 4 C Marine Lubricant with Teflon 2 If the speedometer connector was removed and or replaced lightly coat the threads of the connector with Perfect Seal A...

Page 619: ...needles and race as a set if the drive shaft is pitted grooved scored worn unevenly discolored from overheating or has embedded particles IMPORTANT All the needle bearings 18 MUST BE in place inside b...

Page 620: ...threads in the gear housing for corrosion and or stripped threads Damage or corrosion to the threads requires replacement of the gear housing 5 Inspect bearing race cup contact areas for evidence of b...

Page 621: ...sleeve in place onto the driver head with the lettered and numbered side of the bearing oriented upward 3 Insert the driver with the bearing assembly into position by way of the propeller shaft bore...

Page 622: ...ng bearing race or gear housing were replaced install 0 008 in 0 51 mm of shims 1 Lubricate the bore into which the reverse gear bearing adaptor is to be installed with 2 4 C Marine Lubricant with Tef...

Page 623: ...straight as possible to avoid cocking it in the bore while pressing it in a Lubricate the threads of the installation tool with 2 4 C Marine Lubricant with Teflon b Turn the hex head screw of the ins...

Page 624: ...t port side of the gear housing 50314 a b a Shift Crank b Locating Pin 2 Install the shift shaft assembly into the gear housing as shown Engage the splined end of the shift shaft with the shift crank...

Page 625: ...cant with Teflon 95 a b a Rollers 18 b Roller Bearing Outer Race Gear Location Backlashes Checking and Adjustment Reverse Gear INSTALLATION FOR CHECKING BACKLASH ONLY 1 Lubricate the large reverse gea...

Page 626: ...he upper tapered roller bearing NOTE If the original shims were retained or measurement known and none of the above listed parts were replaced reinstall the same shims or same amount of shims 1 Place...

Page 627: ...plines into the pinion gear splines 5 Temporarily install the propeller shaft without the sliding clutch installed into reverse gear 6 Insert the pinion nut adaptor with the nut into the gear housing...

Page 628: ...to 70 lb ft 95 Nm by turning the drive shaft using the drive shaft nut wrench and torque wrench 57950 b c a a Pinion Nut Adapter 91 61067A2 b Drive Shaft Nut Wrench 91 56775 c Bearing Carrier installe...

Page 629: ...earing Preload Tool Kit 91 14311A1 over the drive shaft in the order shown 70496 a b c d e f g d a Top Nut with Threaded Pipe b Nut c Spring d Thrust Washer 2 Required 12 18448 e Thrust Bearing f Thru...

Page 630: ...3 locations rotating the drive shaft 120 de grees between each reading always rotate the drive shaft in a clockwise direction 2 Insert the thickest feeler gauge that fits snugly between one tooth of t...

Page 631: ...shaking it Add or subtract shims beneath the cup to obtain the proper average pinion gear height Reinstall the cup and retainer Retorque retainer to 100 lb ft 135 Nm Reinstall the bearing preload tool...

Page 632: ...bearing preload tool screw the bottom nut up as close as possible to the top nut 1 Remove the dial indicator and its supporting tooling 2 Screw the bottom nut of the bearing preload tool until it is a...

Page 633: ...a Bearing Retainer Tool 91 43506 6 Push down on drive shaft and check clearance between pinion gear and pinion gear shimming tool shoulder Clearance should be 0 020 in 0 024 in 0 51 mm 0 61 mm a b a P...

Page 634: ...m NOTE If the bearing preload tool has not already been set up see Drive Shaft Bearing Preload Tool Installation section first NOTE The reverse gear bearing adaptor installation tool is used to apply...

Page 635: ...2A1 e Indicator Pointer f Backlash Indicator Rod 91 53459 for 1 75 1 ratio Backlash Indicator Rod 91 78473 for 1 87 1 ratio 3 Take the backlash readings by lightly turning the drive shaft back and for...

Page 636: ...1 79 mm 1 27 mm 0 50 mm Example 2 if backlash is too low Backlash checks middle of specification subtract You get 050 in 020 in 030 in 1 27 mm 0 50 mm 0 76 mm add this quantity of shims subtract this...

Page 637: ...ing and thrust race onto forward gear bearing adaptor 55220 87 87 Premium Gear Lubricant a b c a Bearing Adaptor b Thrust Washer c Thrust Bearing 3 Insert Forward Gear Installation Tool 91 815850 into...

Page 638: ...tool with adaptor assembly over propeller shaft and into gear housing Applying downward pressure to bearing adaptor remove installation tool from assembly 55431 a b a Forward Gear Bearing Adaptor b L...

Page 639: ...gear housing Install the tab washer with the external tab inserted into the hole in the gear housing 50779 a c b a Gear Housing Tab Washer Alignment Hole not seen b V Shaped Notch in Bearing Carrier c...

Page 640: ...ricant with Teflon Start the retainer into the gear housing threads and screw it down fully by hand 50881 95 2 4 C Marine Lubricant with Teflon 95 a a Bearing Carrier Retainer 9 Torque the bearing car...

Page 641: ...all a 5 x 2 127mm x 50 8mm long piece of PVC pipe obtain locally over propel ler shaft and secure it against the bearing carrier with a flat washer and nut 51882 a b c d f e g h i j k a Prop Nut b Fla...

Page 642: ...least one full revolution and comes to 0 on the dial indicator scale 3 Take the backlash readings by lightly turning the drive shaft back and forth a Observe the dial indicator and record the reading...

Page 643: ...gear installation tool into the forward gear and remove the forward gear thrust bearing and thrust race 4 Remove the spacer shim 5 Complete the instruction found in section Forward Gear Bearing Carri...

Page 644: ...tch on the propeller shaft being sure to align cross pin holes in the clutch with the slot in the propeller shaft Make sure that the sliding clutch is placed on the propeller shaft with the grooved en...

Page 645: ...Shift Spool Assembly f Detent Pin 6 Assemble the cross pin retaining spring over the propeller shaft and wind it around the clutch over the cross pin hole Be careful not to distort the spring while a...

Page 646: ...e the shift crank toward the aft end of the gear housing until it touches against the bearing adaptor and hold it in this position 50885 a b a Shift Crank b Bearing Adaptor IMPORTANT Be careful when i...

Page 647: ...lower it into the gear housing 50888 b a c a Shift Actuating Spool b Shift Crank c Propeller Shaft Assembly 4 With the propeller shaft assembly tilted to the port side of the gear housing continue to...

Page 648: ...aft to ensure that it has been properly installed The sliding clutch should move forward when the shift shaft is turned clockwise and should move aft when the shift shaft is turned counterclockwise 7...

Page 649: ...he pinion gear nut with the flat side of the nut away from the pinion gear 4 Place the pinion gear with the washer glued to it into the gear housing 5 Insert the drive shaft into the gear housing driv...

Page 650: ...drive shaft using the drive shaft nut wrench and torque wrench with the appropriate socket to 70 lb ft 95 Nm 57950 c a b a Pinion Nut Adaptor 91 61067A2 b Drive Shaft Nut Wrench 91 56775 c Bearing Car...

Page 651: ...lation 1 Install appropriate spacer shim into the gear housing 50782 a a Shim 2 Apply Premium Gear Lubricant to thrust bearing and install thrust bearing and thrust race onto forward gear bearing adap...

Page 652: ...ar bearing adaptor assembly 55221 a b a Forward Gear Installation Tool 91 815850 b Forward Gear Bearing Adaptor Assembly 4 Install tool with adaptor assembly over propeller shaft and into gear housing...

Page 653: ...the small thrust race on top of the bearing adaptor 50880 a b c a Thrust Race b Forward Gear Bearing Adaptor c Forward Gear 6 Lubricate the small thrust bearing with Premium Gear Lubricant and instal...

Page 654: ...d the small thrust bearing 50784 a b a Thrust Collar b Small Thrust Bearing 8 Pull up slightly on the propeller shaft to gain access to the groove on the shaft for the keepers Assemble the two keepers...

Page 655: ...LEFT HAND NON RATCHETING 90 884294 OCTOBER 2001 Page 6B 91 50778 a b a Thrust Collar b Keepers 9 Install the second thrust collar with its STEPPED SIDE UP 50787 b a a Propeller Shaft b Thrust Collar...

Page 656: ...install it to the top of the thrust collar 50786 87 Premium Gear Lubricant 87 a b a Thrust Bearing b Thrust Collar 11 Lubricate the second small thrust bearing race with Premium Gear Lubricant Assembl...

Page 657: ...bearing carrier for installation as follows a Lubricate the outer diameter of the bearing carrier with 2 4 C Marine Lubricant with Teflon b Fill the space between the carrier oil seals with 2 4 C Mar...

Page 658: ...in the gear housing and then install the tab washer with the external tab inserted into the hole in the gear housing 70713 a c b a Gear Case Alignment Hole b V Shaped Notch in Bearing Carrier c Alignm...

Page 659: ...eflon 95 a a Bearing Carrier Retainer IMPORTANT Before torquing bearing carrier retainer gear case must be bolted to drive shaft housing or securely fastened in a gear case holding fixture to avoid po...

Page 660: ...Notches d Alignment Tabs Bend Inward Oil Seal Carrier Assembly Installation NOTE Apply hand pressure only to install the oil seal carrier into position Do not hammer it into position 1 Lubricate the...

Page 661: ...58011 a b c a Small Hole gasket b Face Plate c Large Hole Gasket GRAY sealing ring faces up 2 Place a small amount of 2 4 C Marine Lubricant with Teflon on the flat surface of the impeller key and in...

Page 662: ...eflon b a c 95 a Water Pump Body b Water Pump Alignment Pins 91 821571A1 c Drive Shaft turn clockwise while installing water pump body 6 Hand start two 2 fasteners into the water pump assembly and rem...

Page 663: ...575A2 or water pump kit 817275A3 press seal down over drive shaft DO NOT GREASE DRIVE SHAFT until tool seats against pump housing 57945 a b a Tool b Seal If tool is not available lightly press seal ag...

Page 664: ...ng to Driveshaft Housing WARNING Disconnect high tension leads from spark plugs and remove spark plugs from engine before installing gear housing onto driveshaft housing 1 Tilt engine to full up posit...

Page 665: ...is in FORWARD IMPORTANT Do not force gear case up into place with attaching nuts 12 Evenly tighten 2 nuts which were started in Step 9 Torque to 55 lb ft 75 Nm 13 After 2 nuts located on either side o...

Page 666: ...ar thrust hub 5 Place rear thrust hub tab washer and propeller nut on propeller shaft 6 Thread propeller nut onto propeller shaft until nut is recessed into tab washer 7 After propeller nut is recesse...

Page 667: ...e secured to yoke with sta strap 2 Route speedometer tube from swivel tube around lower yoke and push into junction After insertion of speedometer tubes into junction pull on each tube to verify that...

Page 668: ...ntenance Instructions 7 31 Clevis Attaching Kit Installation A 70599A5 7 32 Installation Instructions 7 32 Maintenance Instructions 7 32 Ride Guide Steering Cable Attaching Kit Installation 92876A10 S...

Page 669: ...insert locknut c Part Number 11 826709113 First torque bolt a to 20 lb ft 27 Nm then torque locknut c to 20 lb ft 27 N m High Performance Outboards An access hole is provided through the bottom cowl...

Page 670: ...ng head are disassembled or if steering effort has increased Lu bricate with 2 4 C Marine Lubricant with Teflon d c b a a 57834 Ride Guide Steering Cable Attaching Kit Installation 92876A8 Dual Cable...

Page 671: ...ad end of bolts is on the inside of boat transom Super Ride Guide Steering Kit Installation IMPORTANT Both gear racks or rotary steering heads must be installed so that both steering cables will be ro...

Page 672: ...Flats on Each Bolt WARNING Locking retainer corner tabs MUST BE bent up and against flats on each bolt that secures mounting bracket for steering cable mounting tube to outboard swivel bracket to pre...

Page 673: ...Lubricant with Teflon Verify rubber O ring seal a located in outboard tilt tube is lubricated 51890 a Insert steering cable ends a through outboard tilt tube b and cable mounting tube c Thread steeri...

Page 674: ...d as specified Lubricate hole in steering coupler with 2 4 C Marine Lubricant with Teflon Assemble steering link rod to steering coupler using 2 flat washers one each side of coupler and nylon insert...

Page 675: ...ack play exists in system readjust tube away from end of steering cable Tighten nuts against mounting bracket and read just if necessary 51887 b a c d a Steering Cable Mounting Tube b Adjustment Nuts...

Page 676: ...ica tions NOTE Ride Guide Steering Cables are lubricated at the factory and require no additional lubrication at initial installation WARNING Core of each steering cable transom end must be fully retr...

Page 677: ...Steering Cables for 23 1 2 in thru 27 1 2 in 597 mm thru 699 mm outboard centerline spacing If outboard centerline distance is other then specified refer to end of this instruction man ual for optiona...

Page 678: ...uted together and will push and pull together a b b a a Straight Rack Left Rotary Steering Right b Steering Cables Install so that Both Cables Will Push and Pull Together STEERING CABLE INSTALLATION S...

Page 679: ...Toward Starboard Side of Boat b Mounting Bracket c Locking Tab Washers 2 d Adjustment Nuts Flats of Nuts Facing Toward Locking Tab Washer IMPORTANT Lubricate inside of steering cable mounting tube wi...

Page 680: ...BOARD IMPORTANT Lubricate inside of port outboard s tilt tube and rubber O ring seal lo cated inside tilt tube with 2 4 C Marine Lubricant with Teflon before installing steering cable Lubricate inside...

Page 681: ...f 1 4 Turn c Special Washer Head Bolt 10 849838 Torque to 20 lb ft 27 Nm d Nylon Insert Locknut Torque to 20 lb ft 27 Nm e Steering Link Rod f Steering Cable End Lubricate holes in ends of steering ca...

Page 682: ...nsions MUST BE equal to distance between propeller shaft centerlines Lubricate inside of rubber sleeves with 2 4 C Marine Lubricant with Teflon and slide sleeves on steering coupler Work rubber bushin...

Page 683: ...e steering eye and turn eye in or out to correct alignment Torque special washer head bolts to 20 Ib ft 27 Nm then torque locknuts to 20 Ib ft 27 Nm WARNING Both steering eyes MUST BE threaded into co...

Page 684: ...s too tight read just tube toward end of steering cable or if too much slack play exists in system readjust tube away from end of steering cable Tighten nuts against mounting bracket and read just if...

Page 685: ...rdance with instructions included with Super Ride Guide Kit STEERING CABLE INSTALLATION STARBOARD OUTBOARD IMPORTANT Mounting bracket for steering cable mounting tube MUST BE secured to outboard swive...

Page 686: ...ide of steering mounting tube with 2 4 C Marine Lubri cant with Teflon before installing steering cable Lubricate inside of steering cable mounting tube starboard outboard with 2 4 C Marine Lubricant...

Page 687: ...Marine Lubricant with Teflon 51890 a Insert steering cable end b steering cable routed down starboard side of boat through tilt tube c of port outboard and thread steering cable attaching nut d onto t...

Page 688: ...nk rods with SAE 30W Motor Oil obtain locally Secure link rods to outboard steering arms using special washer head bolts 10 849838 pro vided and nylon insert locknuts as shown Torque special bolts to...

Page 689: ...nsions MUST BE equal to distance between propeller shaft centerlines Lubricate inside of rubber sleeves with 2 4 C Marine Lubricant with Teflon and slide sleeves on steering coupler Work rubber bushin...

Page 690: ...eering eye and turn eye in or out to correct alignment Torque special washer head bolts to 20 Ib ft 27 Nm then torque locknuts to 20 Ib ft 27 Nm WARNING Both steering eyes MUST BE threaded into couple...

Page 691: ...ble Mounting Tube b Adjustment Nuts c Adjust Tube in This Direction to Remove Slack from Steering System d Adjust Tube in This Direction to Reduce Tension from Steering System After steering system te...

Page 692: ...tab as follows a Shift outboard into NEUTRAL and make sure ignition key is at OFF position b Remove plastic cap from rear of driveshaft housing and loosen bolt and trim tab IMPORTANT Trim tabs MUST BE...

Page 693: ...considered Severe Service 1 Carefully check steering system components for wear Replace worn parts 2 Check steering system fasteners to be sure that they are torqued to correct specifica tions NOTE Ri...

Page 694: ...ealer or whenever steering mount and or steering head are disassembled or if steering effort has increased Lu bricate with 2 4 C Marine Lubricant with Teflon 28168 a b c d a a b c d a Lubrication Poin...

Page 695: ...n x 2 1 2 in 9 5 mm x 63 5 mm bolt flat washer and locknut as shown in Figure 1 Torque locknut to 20 Ib ft 27 Nm a b c d e f g h i j k l Figure 1 a Ride Guide Cable b Ride Guide Yoke c Pivot Block d P...

Page 696: ...de Yoke Attaching Locknut Torque to 10 lb ft 13 5 Nm Then Back Off 1 4 Turn e 2 3 8 in 60 3 mm Maximum Transom Thickness f Bolt 7 16 in x 1 3 4 in 11 1 mm x 44 5 mm g Ride Guide Yoke 4 Install one cab...

Page 697: ...ing use 3 holes in transom bracket as a guide and drill three 11 32 in 8 7 mm holes thru transom 7 Use a marine type sealer on three 5 16 in x 3 1 4in 7 9mm x 82 6mm bolts Secure attaching kit to tran...

Page 698: ...nsidered Severe Service CAUTION Core of steering cable must be fully retracted into cable housing when lubricating cable If cable is lubricated while extended hydraulic lock of cable could occur 1 Lub...

Page 699: ...gine Steering Arm j Clevis to Engine Locknut Torque to 20 lb ft 27 Nm 3 Lubricate spacer supplied with this kit with 2 4 C Marine Lubricant with Teflon 4 Attach clevis to top of outboard steering arm...

Page 700: ...edometer Installation with System Link Gauges 2002 Model Year Page 8 5 Typical SmartCraft System Monitor Tachometer Installation with System Link Gauges 2002 Model Year Page 8 7 Typical SmartCraft Dua...

Page 701: ...COLOR DIAGRAMS Page 8 2 90 884294 OCTOBER 2001 Notes...

Page 702: ...COLOR DIAGRAMS Page 8 3 90 884294 OCTOBER 2001 225 250 3 0 LITRE WORK EFI WIRING DIAGRAM 2002 MODEL YEAR...

Page 703: ...pere Fuse 21 Fuel System Oil Pump 20 Ampere Fuse 22 Main Power Relay Remote Control Harness Power Trim Circuit 20 Ampere Fuse 23 Ignition Coils 20 Ampere Fuse 24 Low Oil Switch 25 Starter Solenoid 26...

Page 704: ...22 23 24 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 1 2 3 4 5 6 1 9 17 8 24 1 11 12 22 32 1 9 17 8 24 1 2 3 4 5 6 7 8 16 16 21 1 3 5 2 4 6 59138 1 2 3 4 5...

Page 705: ...COLOR DIAGRAMS Page 8 5 90 884294 OCTOBER 2001 TYPICAL SMARTCRAFT SYSTEM TACHOMETER SYSTEM SPEEDOMETER INSTALLATION WITH SYSTEM LINK GAUGES 2002 MODEL YEAR...

Page 706: ...14 Connections for GPS 15 System Tachometer 16 Connections for Auxiliary Warning Horn for Depth Sensor 17 System Link Series Connection 18 2 1 4 in System Link Gauges Fuel Temperature Trim etc 19 Syst...

Page 707: ...C D E A B 59265 1 2 3 4 6 7 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 5...

Page 708: ...COLOR DIAGRAMS Page 8 7 90 884294 OCTOBER 2001 TYPICAL SMARTCRAFT SYSTEM MONITOR TACHOMETER INSTALLATION WITH SYSTEM LINK GAUGES 2002 MODEL YEAR...

Page 709: ...istor End of CAN Harness 13 Either System Monitor or System Tachometer is Used If System Tachometer is Used Tachometer Link Gauge is not Used 14 System Link Series Connection 15 3 1 4 in System Link G...

Page 710: ...C D E A B 59266 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16 17 18 19 20 21 22 23 24 25 26 27 28 29 14 15 14 14 12 10...

Page 711: ...COLOR DIAGRAMS Page 8 9 90 884294 OCTOBER 2001 TYPICAL SMARTCRAFT DUAL OUTBOARD INSTALLATION 2002 MODEL YEAR...

Page 712: ...Area Network CAN Connection from System Speedometer to Junction Box 28 10 Pin Control Area Network CAN Connection from System Tachometer Starboard Outboard to Junction Box 29 10 Pin Control Area Netwo...

Page 713: ...59276 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 18 19 20 29 30 32 33 34 35 36 37 21 22 23 24 26 27 28 38 39 40 41 42 43 44 45 46 47 48 49 50 51 14 15 23 25 31 52...

Page 714: ...COLOR DIAGRAMS Page 8 11 90 884294 OCTOBER 2001 225 250 3 0 LITRE WORK EFI OIL FUEL FLOW DIAGRAM 2002 MODEL YEAR...

Page 715: ...e in Outlet Hose from Oil Tank 10 Outboard Oil Tank 11 Oil Inlet Hose to Electronic Oil Pump 12 Electronic Oil Pump 13 Oil Outlet Hose from Oil Pump to VST 14 Oil is Mixed with Gas in VST 15 Gas Oil M...

Page 716: ...58847 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...

Page 717: ...COLOR DIAGRAMS Page 8 13 90 884294 OCTOBER 2001 225 250 3 0 LITRE WORK EFI WATER FLOW DIAGRAM 2002 MODEL YEAR...

Page 718: ...61 7 C If stuck closed engine will overheat at low speed If stuck open engine will not warm up at idle speed 9 Poppet Valve Controls water flow at high RPM If poppet valve is stuck open at low RPM the...

Page 719: ...7 7 14 59162 1 17 16 2 3 4 5 6 8 8 9 1 16 12 13 14 15 10 11 11 17 1 1...

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