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Mercury FourStroke 2.5, Service Manual, Page: 1 / 205

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Mercury FourStroke 2.5 Service Manual Download Page 1

2.5/3.5

FourStroke

Serial Number 0R448033 and Above

90

-8M

00

65

42

1  

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O

VE

M

BE

R 2

01

2

2.5

/3.5

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ke

©2012, Mercury Marine.  All rights reserved.  Printed in U.S.A.

90-8M0065421   NOVEMBER 2012

www.mercurymarine.com.au

41-71 Bessemer Drive

Dandenong South, Victoria 3175 Australia

www.mercurymarine.com

P.O. Box 1939

Fond du Lac, WI 54936-1939 USA

www.marinepower.com

Parc Industriel de Petit-Rechain

B-4800 Verviers, Belgium

Summary of Contents for FourStroke 2.5

Page 1: ...rcury Marine All rights reserved Printed in U S A 90 8M0065421 NOVEMBER 2012 www mercurymarine com au 41 71 Bessemer Drive Dandenong South Victoria 3175 Australia www mercurymarine com P O Box 1939 Fo...

Page 2: ...el System A Carburetor and Fuel Pump B Emissions 4 Powerhead A Powerhead 5 Midsection A Clamp Swivel Bracket and Driveshaft Housing 6 Lower Unit A Gear Housing 7 Attachments A Shift Linkage B Tiller H...

Page 3: ...n the recommended service procedures of Mercury Marine Power Products including the use of mechanics common hand tools and the special Mercury Marine or recommended tools from other suppliers We could...

Page 4: ...ury Marine Power Product is a combination of many machined honed polished and lapped surfaces with tolerances measured in the ten thousands of an inch mm When any product component is serviced care an...

Page 5: ...Page iv...

Page 6: ...Specifications Table of Contents Model Specifications 1A 2 Ignition Specifications 1A 2 Carburetor Specifications 1A 3 Cooling System Specifications 1A 3 Cylinder Block Specifications 1A 4 Piston Spec...

Page 7: ...orward gear 1300 100 Fuel Automotive unleaded minimum 87 octane up to 10 ethanol Oil type All temperatures 10W 30 Alternate oil viscosity above 4 C 40 F 25W 40 Oil capacity 300 ml 10 0 fl oz Ignition...

Page 8: ...buretor Specifications 3 5 HP Venturi 13 mm 0 51 in Throttle bore 19 mm 0 75 in Main jet 68 Main nozzle I D 1 8 mm 0 07 in Slow jet 38 Idle air jet 115 Idle speed neutral 1400 50 RPM Idle speed forwar...

Page 9: ...36 mm 1 42 in Displacement 85 5 ml 5 22 in Number of cylinders 1 Rotation Clockwise Crankshaft Runout 0 05 mm 0 002 in Crankpin journal standard 19 98 mm 0 7866 in Crankpin journal service limit 19 95...

Page 10: ...standard Top 0 04 0 08 mm 0 0016 0 0031 in Middle 0 03 0 07 mm 0 0012 0 0028 in Bottom 0 05 0 15 mm 0 002 0 0059 in Piston ring side clearance service limit Top 0 10 mm 0 0039 in Middle 0 09 mm 0 0035...

Page 11: ...in Valve stem to valve guide clearance Intake 0 018 0 070 mm 0 0007 0 0028 in Exhaust 0 025 0 080 mm 0 0010 0 0031 in Valve seat angles First 30 Second 45 Third 60 Valve stem seal color Intake Black...

Page 12: ...Master Specifications 90 8M0065421 NOVEMBER 2012 Page 1A 7 Propellers Propellers Standard plastic 7 4 dia x 7 pitch Optional aluminum 7 4 dia x 5 7 pitch Optional plastic 7 4 dia x 5 7 pitch...

Page 13: ...Master Specifications Notes Page 1A 8 90 8M0065421 NOVEMBER 2012...

Page 14: ...ooling System 1B 3 Top Cowl Removal and Installation 1B 4 Removal 1B 4 Installation 1B 4 Engine Oil Recommendations 1B 4 Checking Engine Oil 1B 5 Changing Engine Oil 1B 5 Engine Oil Capacity 1B 5 Oil...

Page 15: ...e family description g Engine power kilowatts h Idle speed Owner Responsibility The owner operator is required to have routine engine maintenance performed to maintain emission levels within prescribe...

Page 16: ...of Storage Refer to Storage procedure See Storage section Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from t...

Page 17: ...for general all temperature use If SAE 25W 40 multi viscosity oil is preferred use Mercury MerCruiser 4 cycle engine oil or Quicksilver sterndrive and inboard 4 cycle engine oil Never use 4 cycle engi...

Page 18: ...ately 300 ml 10 fl oz Oil Changing Procedure 1 Place outboard in an upright not tilted position 2 Turn the outboard to gain access to the drain plug Remove drain plug and drain engine oil into an appr...

Page 19: ...spark plug to inspect Replace spark plug if electrode is worn or the insulator is rough cracked broken blistered or fouled 26946 3 Set the spark plug gap to specification 26947 Spark Plug Spark plug...

Page 20: ...eller Replacement WARNING Rotating propellers can cause serious injury or death Never operate the boat out of the water with a propeller installed Before installing or removing a propeller place the d...

Page 21: ...icant If water is present it may have settled to the bottom and will drain out prior to the lubricant or it may be mixed with the lubricant giving it a milky colored appearance If water is noticed hav...

Page 22: ...sher Tube Ref No Description Where Used Part No 82 Premium Gear Lubricant Gearcase 92 858058K01 4 Stop adding lubricant Use new sealing washer and install the vent plug before removing the lubricant t...

Page 23: ...er The following storage procedures should be followed to prepare your outboard for out of season storage or prolonged storage two months or longer NOTICE Without sufficient cooling water the engine t...

Page 24: ...otecting Internal Engine Components Remove the spark plug and inject a small amount of engine oil inside the cylinder Rotate the flywheel manually several times to distribute the oil in the cylinder R...

Page 25: ...Maintenance Notes Page 1B 12 90 8M0065421 NOVEMBER 2012...

Page 26: ...n 1C 7 Elevation and Climate 1C 7 Detonation 1C 7 Propeller Selection 1C 8 Following Complete Submersion 1C 8 Engine Submerged While Running Special Instructions 1C 8 Saltwater Submersion Special Inst...

Page 27: ...nder leakdown Component Identification 2 2 5 3 5 FourStroke Front View a Fuel cap vent b Fuel cap c Fuel tank d Recoil starter handle e Fuel pump f Stop switch with lanyard g Carry handle h Model deca...

Page 28: ...p d Throttle friction knob e Shift lever f Clamp handle g Clamp bracket h Choke cable i Oil fill cap j Oil level sight window k Fuel tank on off valve l Steering friction knob m Oil drain plug n Carbu...

Page 29: ...BER 2012 2 2 5 3 5 FourStroke Aft View a Fuel cap vent b Fuel cap c Fuel tank d Rear cowl latch e Water pump indicator hose f Steering friction knob g Spark plug boot h Throttle cables i Tiller handle...

Page 30: ...2012 Page 1C 5 2 2 5 3 5 FourStroke Port View a High tension lead b Spark plug c Fuel pump pulse hose d Water pump indicator hose e Steering friction knob f Tiller handle g Flywheel cover h Fuel pump...

Page 31: ...a dry brisk day The horsepower that any internal combustion engine produces depends upon the density of the air that it consumes The density of air is dependent upon the ambient air temperature the ba...

Page 32: ...ill result in additional boat weight reduced boat performance hull decay and eventual structural failure Cavitation Cavitation occurs when water flow cannot follow the contour of a fast moving underwa...

Page 33: ...ext lower pitch propeller When not pulling skiers do not operate at full throttle when using the lower pitch propeller Following Complete Submersion Engine Submerged While Running Special Instructions...

Page 34: ...tate flywheel so the timing marks on the flywheel and cylinder block are in alignment This will be the compression stroke for the cylinder 4 Complete the cylinder leak down test Refer to the manufactu...

Page 35: ...o airborne particles such as chemical vapors dust or spray can cause serious injury or death Ensure that the work area is properly ventilated and wear protective eyeware clothing and respirators NOTE...

Page 36: ...t scratching or damaging the decal and cowl 6 Use firm pressure on the squeegee with overlapping strokes 7 Remove the premask and application tape at a 180 angle to the decal 8 Puncture the air bubble...

Page 37: ...e Shine Microfiber Towel for the final decal squeegee With a firm hand pressure work the decal from the center out to the edge Ensure to pay attention to the edge of the decal during this final decal...

Page 38: ...nstallation Table of Contents Boat Horsepower Capacity 1D 2 Selecting Accessories for Your Outboard 1D 2 Installing the Outboard 1D 2 Boat Transom Height Requirement 1D 2 Installing the Outboard on th...

Page 39: ...ecting Accessories for Your Outboard Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for your outboard These accessories are available from Mercury Mari...

Page 40: ...3 Arrange the passengers and the load in the boat so the weight is distributed evenly a Tilt pin Engine Overspeed Protection System The system is activated if the engine speed should ever exceed the m...

Page 41: ...n long shaft 776 mm 30 6 in c Short shaft 434 mm 17 1 in long shaft 561 mm 22 1 in d 446 mm 17 6 in e 108 mm 4 3 in f 358 mm 14 1 in g 336 mm 13 2 in h 303 mm 11 9 in i 58 mm 2 3 in j 208 mm 8 2 in k...

Page 42: ...Specifications 2A 2 Flywheel and Ignition Components 2A 4 Ignition System Description 2A 6 Flywheel Removal and Installation 2A 6 Removal 2A 6 Installation 2A 7 Ignition Coil Replacement 2A 8 Removal...

Page 43: ...n Where Used Part No 66 Loctite 242 Threadlocker Recoil starter assembly mounting bolts Fuel tank mounting bolts 92 809821 Special Tools Flywheel Holder 91 83163M 8742 Holds and or turns the flywheel...

Page 44: ...Ignition Notes 90 8M0065421 NOVEMBER 2012 Page 2A 3...

Page 45: ...Ignition Page 2A 4 90 8M0065421 NOVEMBER 2012 Flywheel and Ignition Components 2 3 4 5 8 6 1 7 9 10 42489...

Page 46: ...2A 5 Flywheel and Ignition Components Ref No Qty Description Torque Nm lb in lb ft 1 1 Flywheel 2 1 Flywheel cover 3 3 Collar 4 1 Nut 45 33 5 1 Washer 6 1 Ignition coil 7 1 Spark plug lead 8 2 Bolt M...

Page 47: ...lug lead from the spark plug 2 Remove the fuel tank and recoil starter Refer to Section 8A Recoil Starter IMPORTANT Use an approved container to collect and store the fuel Wipe up any spillage immedia...

Page 48: ...wheel keyway with the key Install the flywheel onto the crankshaft Ensure the flywheel is fully seated on the crankshaft taper 3 Install the washer and flywheel nut 4 Use the flywheel holding tool to...

Page 49: ...anyard is positioned so that the engine cannot start Do not smoke or allow sources of spark or open flame in the area while servicing Keep the work area well ventilated and avoid prolonged exposure to...

Page 50: ...mounting bolts M6 x 20 2 b Ignition coil c J clamp d Spark plug lead e Tan wire connector Installation 1 Install the ignition coil onto the cylinder block 2 Install the two ignition coil mounting bol...

Page 51: ...connector Description Nm lb in lb ft Ignition coil mounting bolts M6 x 20 2 6 53 7 8 Apply Loctite 242 Threadlocker to the recoil starter assembly mounting bolts 9 Install the recoil starter and flyw...

Page 52: ...fuel line hose to the fuel tank with a hose clamp Ignition Coil Testing Secondary Resistance NOTE The readings listed are taken at 20 C 68 F with a digital ohmmeter Due to the number of different man...

Page 53: ...e of the following test procedures must be followed In a test tank with a cut down propeller On a boat secured to the trailer in the water with a cut down propeller 1 Attach the timing light to the sp...

Page 54: ...rburetor Components 3A 4 Fuel Tank Components 3A 6 Carburetor Adjustments 3A 8 Pilot Idle Mixture Screw 3A 8 Idle Speed 3A 8 Fuel Pump Removal and Installation 3A 9 Removal 3A 9 Fuel Pump Hoses 3A 10...

Page 55: ...utral 1400 50 RPM Idle speed forward 1300 50 RPM Float level flange to float bottom 10 mm 0 39 in Pilot idle mixture screw 2 turn out Carburetor Specifications 3 5 HP Venturi 13 mm 0 51 in Throttle bo...

Page 56: ...Carburetor and Fuel Pump Notes 90 8M0065421 NOVEMBER 2012 Page 3A 3...

Page 57: ...retor and Fuel Pump Page 3A 4 90 8M0065421 NOVEMBER 2012 Carburetor Components 18 14 13 17 16 15 12 6 4 7 8 1 5 2 3 22 23 22 19 20 21 18 24 25 26 33 32 30 28 27 31 29 34 35 36 9 10 11 37 40 38 39 40 5...

Page 58: ...12 1 Float pin 13 1 Float bowl 14 1 Gasket 15 1 Drain screw M5 x 6 16 1 O ring 17 2 Screw M4 x 12 2 18 18 2 Hose 19 1 Intake manifold 20 1 Fitting 21 1 Intake manifold gasket 22 2 Carburetor gasket 2...

Page 59: ...Carburetor and Fuel Pump Page 3A 6 90 8M0065421 NOVEMBER 2012 Fuel Tank Components 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 17 19 51309...

Page 60: ...cription Torque Nm lb in lb ft 1 1 Fuel tank 2 1 Cover 3 3 Spacer 4 3 Washer 5 3 Bolt 6 53 6 1 Seal 7 1 Caution decal 8 1 Fuel cap 9 1 Gasket 10 1 Hook 11 1 Fuel hose to fuel pump inlet 12 2 Clip 13 1...

Page 61: ...or is rebuilt or cleaned 1 When removing Record the number of revolutions to lightly seat the pilot mixture screw 2 When installing Turn the pilot mixture screw in clockwise until lightly seated Then...

Page 62: ...el immediately WARNING Fuel leakage is a fire or explosion hazard which can cause serious injury or death Periodically inspect all fuel system components for leaks softening hardening swelling or corr...

Page 63: ...bracket d Pulse hose to intake manifold fitting e Fuel pump inlet hose from fuel shutoff valve f Fuel pump outlet hose to carburetor g Large hose clamp 2 h Hose clamp i Small hose clamp 2 Installatio...

Page 64: ...e the fuel tank vent after the engine has stopped a Fuel cap b Manual vent screw 3 Remove the fuel hose from the carburetor 4 Remove the three bolts and washers securing the fuel tank to the engine Re...

Page 65: ...uretor air silencer bolt M6 x 85 2 Installation 1 Connect the choke cable and the throttle linkage to the carburetor IMPORTANT The carburetor mounting gaskets must be oriented correctly with the intak...

Page 66: ...lt M6 x 85 2 d Flat washer 2 e Collar 2 f Choke cable g Air silencer h Carburetor i Vent hose 2 j Gasket 2 k Insulator l Intake manifold m Throttle linkage Description Nm lb in lb ft Carburetor air si...

Page 67: ...cription Nm lb in lb ft Throttle opener bolt 6 53 Choke cable holder bolt 6 53 8 Attach the fuel pump outlet hose to the carburetor inlet 9 Attach the fuel pump inlet hose to fuel shutoff valve Secure...

Page 68: ...the choke cable with the J clamp and the washer and bolt a J clamp b Washer and bolt securing choke cable c Fuel pump inlet hose d Fuel shutoff valve e Fuel shutoff valve knob f Fuel pump outlet hose...

Page 69: ...ten the bolts to the specified torque a Fuel tank b Bolts and washers Description Nm lb in lb ft Fuel tank bolts 6 53 Carburetor Disassembly 1 Remove the drain screw and drain the carburetor before di...

Page 70: ...ilot mixture screw a Remove the tamperproof plug b Count and record the number of revolutions to lightly seat the pilot mixture screw IMPORTANT This information will be used during carburetor assembly...

Page 71: ...hown Remove the float and the inlet needle a Knurled end of the float pin b Float c Inlet needle 6 Remove the rubber plug 7 Remove the main jet 8 Remove the main nozzle The nozzle should drop out If n...

Page 72: ...ssed air before installation a Main nozzle b Main jet c Pilot jet 2 Inspect the tip of the inlet needle and pilot mixture screw for wear a Inlet needle b Pilot mixture screw 3 Inspect the idle circuit...

Page 73: ...1 Install the inlet needle assembly onto the float arm 2 Install the float Push in the float pin in the direction of the arrow a Inlet needle assembly b Float c Knurled end of float pin 3 Check the fl...

Page 74: ...spring and screw 6 Turn the pilot mixture screw until it is seated Then back the screw out the same number of turns as measured during removal 7 Install a tamperproof plug Refer to the parts manual f...

Page 75: ...c Rubber plug 10 Install the carburetor drain screw 11 Install the O ring gasket onto the float bowl 12 Install the float bowl Tighten the screws to the specified torque a Float bowl b Screw M4 x 12 2...

Page 76: ...rolling Emissions 3B 2 Stoichiometric 14 7 1 Air Fuel Ratio 3B 2 Outboard Hydrocarbon Emissions Reduction 3B 3 Emissions Information 3B 3 Manufacturer s Responsibility 3B 3 Dealer Responsibility 3B 3...

Page 77: ...ygen one carbon atom with one oxygen atom This forms carbon monoxide CO Carbon monoxide is the product of incomplete combustion and is a dangerous potentially lethal gas Oxides of Nitrogen NOx NOx is...

Page 78: ...tandards Dealers are not to modify the engine in any manner that would alter the horsepower or allow emission levels to exceed their predetermined factory specifications Exceptions include manufacture...

Page 79: ...ended spark plug and gap Family Number The following is an illustration of a typical family number and is not a representation of any one model 1 Model year 3 2003 2 Manufacturer Mercury Marine 3 Regu...

Page 80: ...r Location of Engine Mercury Mariner 2 5 3 5 FourStroke If a replacement emission certification label is required contact the Mercury Marine Service Department Inside of bottom cowl Emission Control I...

Page 81: ...Emissions Notes Page 3B 6 90 8M0065421 NOVEMBER 2012...

Page 82: ...4A 20 Cylinder Block Disassembly 4A 21 Crankshaft Piston Disassembly 4A 22 Valve Lifter Rocker Arm Disassembly 4A 23 Cleaning Inspection Repair 4A 24 Flywheel 4A 24 Cylinder Bore Measurement 4A 25 Pis...

Page 83: ...5 45 5 47 mm 0 2146 0 2154 in Exhaust valve 5 44 5 46 mm 0 2142 0 2150 in Valve stem to valve guide clearance Intake 0 018 0 070 mm 0 0007 0 0028 in Exhaust 0 025 0 080 mm 0 0010 0 0031 in Valve seat...

Page 84: ...rd Top 0 04 0 08 mm 0 0016 0 0031 in Middle 0 03 0 07 mm 0 0012 0 0028 in Bottom 0 05 0 15 mm 0 002 0 0059 in Piston ring side clearance service limit Top 0 10 mm 0 0039 in Middle 0 09 mm 0 0035 in Bo...

Page 85: ...dard 0 015 0 041 mm 0 0006 0 0016 in Crankpin oil clearance service limit 0 060 mm 0 0024 in Lubricants Sealants Adhesives Tube Ref No Description Where Used Part No 12 Loctite Master Gasket Kit Cylin...

Page 86: ...ad 90 8M0065421 NOVEMBER 2012 Page 4A 5 Piston Ring Expander 91 24697 6255 Expands piston rings for removal and installation Bearing Puller Assembly 91 83165T 3610 Removes bearings races and bearing c...

Page 87: ...Powerhead Page 4A 6 90 8M0065421 NOVEMBER 2012 Camshaft and Valve Components 22493 1 10 11 12 13 10 11 14 15 16 3 5 6 7 8 9 9 8 7 6 4 2...

Page 88: ...scription Torque Nm lb in lb ft 1 1 Camshaft assembly 2 1 Intake valve 3 1 Exhaust valve 4 1 Intake seal black 5 1 Exhaust seal green 6 2 Seat 7 2 Spring 8 2 Retainer 9 4 Keeper 10 2 Lifter 11 2 Push...

Page 89: ...Powerhead Page 4A 8 90 8M0065421 NOVEMBER 2012 Crankshaft Piston and Connecting Rod Components 3 2 4 1 6 5 8 8 7 9 11 10 12 41756...

Page 90: ...nts Ref No Qty Description Torque Nm lb in lb ft 1 1 Crankshaft assembly 2 1 Ball bearing 3 1 Oil seal 4 1 Key 5 1 Connecting rod assembly 6 2 Screw First torque 6 53 Final torque 11 97 7 1 Piston pin...

Page 91: ...Powerhead Page 4A 10 90 8M0065421 NOVEMBER 2012 Oil Pan Components 17 16 17 13 15 14 19 18 19 20 12 1 3 4 5 6 6 3 7 8 10 11 9 9 6 6 6 2 22492...

Page 92: ...1 Oil level sight gauge 3 3 Dowel pin 4 1 Drain bolt 20 177 5 1 Washer 6 8 Bolt M6 x 35 11 97 7 1 Oil seal 8 1 O ring 9 2 Oil seal 10 1 Driveshaft seal housing 11 2 Bolt M6 x 20 6 53 12 1 Oil pan gas...

Page 93: ...Powerhead Page 4A 12 90 8M0065421 NOVEMBER 2012 Cylinder Block Components 50918 1 2 2 3 3 3 3 4 4 6 3 5 2 11 14 15 12 13 16 17 10 9 10 9 10 9 7 8 19 20 18 20 22 22 21 25 23 24 26 27 28 28 30 29 31 31...

Page 94: ...der head cover gasket 9 4 Bolt M6 x 16 6 53 10 4 Washer 11 1 Thermostat 12 1 Thermostat cap 13 1 Thermostat cap gasket 14 1 Clamp 15 2 Bolt M6 x 30 6 53 16 1 Spark plug 17 1 Slinger 18 1 Throttle cabl...

Page 95: ...d move the fuel tank to the side a Fuel tank b Bolt M6 x 25 and washer 3 Straighten the J clamp securing the throttle cables 4 Remove the two M6 x 30 bolts securing the thermostat housing bracket to t...

Page 96: ...8 Remove the gasket and thermostat a Thermostat b Gasket Inspection 1 Tie a piece of thread or other nonconductive material onto the thermostat 2 Suspend a thermometer in the water IMPORTANT Do not al...

Page 97: ...m 0 079 in Installation 1 Clean the gasket surfaces on the thermostat housing bracket and cylinder block 2 Install the thermostat 3 Install a new thermostat gasket 4 Install the thermostat housing bra...

Page 98: ...lanyard is positioned so that the engine cannot start Do not smoke or allow sources of spark or open flame in the area while servicing Keep the work area well ventilated and avoid prolonged exposure t...

Page 99: ...ver 3 Measure each valve clearance with a feeler gauge a Nut b Pivot c Push rod d Rocker arm e Intake valve f Exhaust valve Valve to Rocker Arm Clearance Intake 0 06 0 14 mm 0 0024 0 0055 in Exhaust 0...

Page 100: ...rottle cable as shown b Loosen the throttle cable jam nuts c Remove the throttle drum bolt d Remove the throttle cable ends from the throttle drum e Remove the throttle drum assembly and cable bracket...

Page 101: ...e d Fuel shutoff valve bracket e Bolt M6 x 20 with washer f Fuel tank outlet hose 4 Remove the hoses from the fuel pump Wipe up any spilled fuel immediately 5 Remove the two bolts securing the fuel pu...

Page 102: ...bolts securing the two cylinder block housings and separate the cylinder block housings 6 7 8 2 1 5 4 3 26589 2 Remove the camshaft gear assembly from the cylinder block 3 Remove the crankshaft conne...

Page 103: ...r plate NOTE The lower bearing and gear are not serviceable a Connecting rod cap bolts b Upper bearing Universal Puller Plate 91 37241 4 Remove the piston pin clips and piston pin 5 Use a piston ring...

Page 104: ...et Clean the gasket surface on the cylinder head cover and the cylinder block a Cylinder head cover b Bolt and washer M6 x 16 4 4 Remove the rocker arm nut 5 Remove the rocker arm pivot and rocker arm...

Page 105: ...procedure 26675 8 Remove the valve keepers valve spring retainer spring and spring seat 9 Remove the intake and exhaust valves 10 Remove the intake and exhaust valve seals a Exhaust valve seal green b...

Page 106: ...with a cylinder bore gauge Determine the maximum taper out of round of the cylinder bore a 60 mm 2 36 in b 40 mm 1 575 in c 20 mm 0 787 in Cylinder Bore Maximum taper out of round 0 06 mm 0 00236 in...

Page 107: ...ement maximum piston diameter measurement piston to cylinder wall clearance Piston Pin 1 Measure the piston pin 3132 Piston Pin Inside diameter standard 14 0 mm 0 5512 in Inside diameter service 13 97...

Page 108: ...0 07 mm 0 0012 0 00276 in Bottom 0 05 0 15 mm 0 002 0 0059 in Piston Ring Side Clearance Service Limit Top 0 10 mm 0 0039 in Middle 0 09 mm 0 0035 in Bottom 0 17 mm 0 0067 in Piston Ring End Gap Clear...

Page 109: ...inside diameter of the connecting rod 26699 Connecting rod Wrist pin diameter standard 14 01 mm 0 5516 in Wrist pin diameter service 14 04 mm 0 5528 in Crankshaft Crankshaft Runout 1 Thoroughly clean...

Page 110: ...haft if the lower bearing is defective NOTE The lower crankshaft bearing is not serviceable Measuring Crankpin Oil Clearance 1 Clean the oil from the connecting rod bearing surface and connecting rod...

Page 111: ...Camshaft and Valves Camshaft 1 Measure the cam lobe at its maximum valve lift Replace the cam if any of the cam lobe dimensions are out of specification 21391 Cam Lobe Intake and exhaust 23 78 24 04 m...

Page 112: ...s and Push Rods 1 Replace the valve lifter if worn or corroded 2 Replace the push rod if worn or corroded 3 Inspect the push rod for straightness Replace if bent a Lifter b Push rod Valve Springs 1 Ch...

Page 113: ...eats Follow the equipment manufacturers instructions 3 Apply a thin even layer of mechanic s bluing dye Dykem onto the valve seat 4 Insert the valve into the valve guide and lap the valve slowly on th...

Page 114: ...10 If the valve seat contact area is too wide and situated in the center of the valve face use the 30 cutting tool to cut the top edge of the valve seat and the 60 cutting tool to cut the bottom edge...

Page 115: ...icate the piston pin with 4 Stroke 10W 30 Outboard Oil Install the piston pin and secure with a new piston pin clip IMPORTANT Ensure the UP on the connecting rod and piston are facing the same directi...

Page 116: ...ard Oil Piston rings 92 858045K01 Piston Crankshaft Installation 1 Lubricate the connecting rod connecting rod cap and the crankpin journal with 4 Stroke 10W 30 Outboard Oil 2 Assemble the connecting...

Page 117: ...o Description Where Used Part No 110 4 Stroke 10W 30 Outboard Oil Connecting rod connecting rod cap and the crankpin journal 92 858045K01 Description Nm lb in lb ft Connecting rod cap screw First 5 44...

Page 118: ...e box end wrench to compress the valve spring to install the valve keepers NOTE Hold the valves in place from the cylinder bore end during the assembly procedure a Keepers b Retainer c Spring d Seat e...

Page 119: ...ave entered the cylinder 6 Continue pushing until the crankshaft bearings fit into the cylinder block 7 Ensure the crankshaft bearing locating pins are positioned in the notch on the cylinder block 8...

Page 120: ...mshaft ends and lobes 92 858045K01 12 Loctite Master Gasket Kit Cylinder block mating surfaces 92 12564 2 15 Assemble the cylinder block housings 16 Secure the cylinder block housings with eight bolts...

Page 121: ...the driveshaft seals 92 802859A 1 Oil Pan Installation 1 Clean the gasket surface of the cylinder block and the oil pan 2 Ensure the dowel pins are installed in the cylinder block 3 Install a new oil...

Page 122: ...1 97 Driveshaft seal housing bolts M6 x 20 2 6 53 7 Attach the hoses to the fuel pump Secure the hoses with clamps 8 Attach the fuel pump pulse hose to the intake manifold fitting Secure the hose with...

Page 123: ...f Fuel tank outlet hose Description Nm lb in lb ft Bolt M6 x 20 with washer 6 53 Powerhead Installation 1 Install the fuel shutoff knob into the pan 41773 2 Clean the driveshaft housing powerhead mou...

Page 124: ...fer to Section 2A Ignition 12 Install the throttle drum and cable bracket 13 Install the throttle cables Refer to Section 7B Tiller Handle 14 Install the fuel pump pulse hose onto the fitting on the i...

Page 125: ...cable c Fuel hose to the fuel pump d Fuel shutoff valve e Fuel shutoff valve knob f Fuel hose from the fuel pump g Bracket 18 Route the fuel hoses as shown 49932 19 Install the fuel tank and recoil s...

Page 126: ...le of Contents Cowling Components 5A 4 Clamp Bracket Components 5A 6 Driveshaft Housing Components 5A 8 Clamp Bracket Removal and Installation 5A 10 Removal and Disassembly 5A 10 Reassembly and Instal...

Page 127: ...nts Sealants Adhesives Tube Ref No Description Where Used Part No 7 Loctite 271 Threadlocker Swivel bracket special flange head bolts 92 809819 95 2 4 C with PTFE Driveshaft housing between flanges sw...

Page 128: ...Clamp Swivel Bracket and Driveshaft Housing Notes 90 8M0065421 NOVEMBER 2012 Page 5A 3...

Page 129: ...Clamp Swivel Bracket and Driveshaft Housing Page 5A 4 90 8M0065421 NOVEMBER 2012 Cowling Components 22482 1 3 4 6 5 2 11 10 9 8 7 21 19 20 12 13 14 15 16 17 18 22...

Page 130: ...owl 2 1 Cowl seal 3 1 Tilt handle 4 4 Washer 5 4 Lockwasher 6 4 Nut 6 53 7 1 Bottom cowl 8 1 Spark plug decal 9 1 Cowl latch 10 1 Collar 11 1 Bolt 6 53 12 4 Bolt 6 53 13 4 Washer 14 4 Collar 15 1 Fuel...

Page 131: ...amp Swivel Bracket and Driveshaft Housing Page 5A 6 90 8M0065421 NOVEMBER 2012 Clamp Bracket Components 22490 10 11 2 3 12 9 8 5 1 6 7 15 26 28 16 24 23 25 27 30 29 14 21 22 20 18 17 19 6 8 9 1 13 4 3...

Page 132: ...1 Nut M8 9 80 6 2 Washer 7 1 Rod 8 2 Nut 6 53 9 2 Washer 10 1 Thrust support 11 1 Damper 12 1 Thrust rod 13 1 Knob 14 1 Tilt pin 15 1 O ring 16 1 Swivel bracket cap 17 1 Stopper 18 1 Steering stop lev...

Page 133: ...Clamp Swivel Bracket and Driveshaft Housing Page 5A 8 90 8M0065421 NOVEMBER 2012 Driveshaft Housing Components 22488 3 3 4 5 2 7 6 8 9 10 12 20 15 11 14 13 17 16 19 18 1...

Page 134: ...orque Nm lb in lb ft 1 1 Driveshaft housing 2 1 Plug 3 2 Dowel pin 4 1 Driveshaft housing gasket 5 7 Bolt 6 53 6 1 Flush plug 15 132 7 1 Gasket 8 1 Steering bracket 9 2 Bolt 15 132 10 1 Hose 11 1 Grom...

Page 135: ...cknut 3 Remove the nut and washer from each end of the spacer rod 4 Remove the tilt pin from the starboard clamp bracket 5 Remove the thrust support and damper a Port clamp bracket b Spacer rod c Tilt...

Page 136: ...s to the specified torque a Port clamp bracket b Spacer rod c Tilt pin d Nut and washer 2 each e Thrust support and damper f Starboard clamp bracket Description Nm lb in lb ft Spacer rod nut 2 6 53 7...

Page 137: ...racket locknut 9 80 Swivel Bracket Removal Installation NOTE The swivel bracket may be removed and disassembled with or without prior removal of the clamp brackets Removal 1 Remove the four special bo...

Page 138: ...and split plastic bushing a Thrust plate b Rubber bushing c Split plastic bushing d Tab e Front swivel bracket Steering Co Pilot Components a Swivel bracket cap b Pocket for split plastic bushing tab...

Page 139: ...ing towards the front of the engine 3 Lubricate the thrust plate and plastic bushing with 2 4 C with PTFE a Thrust plate b Plastic bushing c Split in plastic bushing d Lower flange e Driveshaft housin...

Page 140: ...housing a Thrust plate b Rubber bushing c Split plastic bushing d Tab e Swivel bracket 7 Attach the swivel bracket cap to the swivel bracket NOTE The split plastic bushing tabs fit into the cast pocke...

Page 141: ...Page 5A 16 90 8M0065421 NOVEMBER 2012 Tube Ref No Description Where Used Part No 7 Loctite 271 Threadlocker Swivel bracket special flange head bolts 92 809819 Description Nm lb in lb ft Swivel bracke...

Page 142: ...A 13 Water Pump 6A 13 Bearing Carrier and Propeller Shaft 6A 15 Propeller Shaft Disassembly 6A 17 Driveshaft Pinion Gear and Forward Gear 6A 18 Upper Driveshaft Bearing 6A 19 Lower Driveshaft Bearing...

Page 143: ...ubricant Outside diameter of lower bearing race Outside diameter of forward gear bearing Forward gear bronze bearing Inside diameter of the upper driveshaft bearing Gear housing cavity 92 858058K01 87...

Page 144: ...moval and Installation Kit 91 31229A7 2966 Installs and removes the bearings in all gearcases 91 31229A7 Tool assembly includes the following components 11 24156 Hex Nut 12 34961 Washer 91 15755T Bear...

Page 145: ...Gear Housing Page 6A 4 90 8M0065421 NOVEMBER 2012 Gear Housing Driveshaft 3 4 6 5 26 2 3 4 1 26 25 24 22 23 20 21 19 18 17 16 15 12 13 14 7 1 8 10 11 9 42491...

Page 146: ...ket 5 1 Anode 6 1 Bolt M6 x 16 5 6 50 7 1 Pinion gear 8 1 Spacer 9 1 Driveshaft 10 1 Ball bearing 11 1 Key 12 1 Water pump base 13 1 Oil seal 14 1 Water pump base gasket 15 2 Roll pin 16 1 Gasket 17 1...

Page 147: ...Gear Housing Page 6A 6 90 8M0065421 NOVEMBER 2012 Gear Housing Propeller Shaft 22478 11 12 13 10 14 9 16 17 15 8 7 6 5 4 3 2 1...

Page 148: ...b in lb ft 1 1 Gear housing 2 1 Ball bearing 3 AR Shim 0 1 0 15 4 1 Forward gear 5 1 Cam follower 6 1 Spring 7 1 Clutch 8 1 Propeller shaft 9 1 Bearing carrier assembly 10 1 Bearing carrier 11 1 Ball...

Page 149: ...Gear Housing Page 6A 8 90 8M0065421 NOVEMBER 2012 Shift Linkage Components 22474 12 11 18 18 16 17 15 8 13 14 9 10 7 6 5 4 2 3 1...

Page 150: ...orque Nm lb in lb ft 1 1 Shift lever 2 1 Spring 3 1 Detent ball 4 1 Washer 5 2 O ring 6 1 Shift shaft lever 7 1 Screw M5 x 12 4 35 8 1 Upper shift shaft 9 1 Washer 10 1 Cotter pin 11 1 Joint 12 1 Bolt...

Page 151: ...ect the gear housing for bearing races that have spun in their respective bores If the race has spun the gear housing must be replaced Roller bearing condition is determined by inspecting the bearing...

Page 152: ...been properly completed a Oil level screw with gasket b Oil fill screw with gasket Propeller Removal WARNING Rotating propellers can cause serious injury or death Never operate the boat out of the wat...

Page 153: ...moving the keys from the ignition if equipped and engaging the lanyard stop switch to prevent the engine from starting 2 Place the gear shift lever in the neutral position 3 Tilt the engine to the ful...

Page 154: ...he impeller if The impeller blades are cracked torn or worn The impeller is glazed or melted caused by insufficient water supply The rubber portion of the impeller is not bonded to the impeller hub a...

Page 155: ...pump base to prevent the driveshaft from disconnecting from the pinion gear If the driveshaft separates from the pinion gear the gear housing must be disassembled to realign the driveshaft with the p...

Page 156: ...al surface If the surface is damaged replace the water pump base 9 Apply 2 4 C with PTFE to the new seal lips Press the new seal into the pump base with a 16 mm 11 16 in socket a Seal b Socket Tube Re...

Page 157: ...rier b Propeller shaft 3 Inspect the carrier ball bearing for serviceability If the bearing is rusted or does not roll freely replace the bearing If the bearing must be replaced use a slide hammer wit...

Page 158: ...spect the O ring for cuts or abrasions Replace the O ring as required a O ring Propeller Shaft Disassembly 1 Remove the cam follower and inspect both ends for wear If the cam follower is worn or pitte...

Page 159: ...dial indicator and V blocks a V blocks b Bearing surfaces c Check with dial indicator here Dial Indicator 91 58222A1 Driveshaft Pinion Gear and Forward Gear 1 Remove the driveshaft and spacer from the...

Page 160: ...orward gear teeth and pinion gear teeth for chips or excessive wear a Forward gear b Clutch teeth c Shim d Bronze bearing e Pinion gear Upper Driveshaft Bearing 1 Inspect the upper driveshaft ball bea...

Page 161: ...g and the lower driveshaft bearing are removed from the gear housing inspect the gear housing for signs of the bearing race spinning in their respective bores This usually occurs as a result of bearin...

Page 162: ...ter of the lower bearing race with Premium Gear Lubricant Place the bearing into the driveshaft bore number side faces up Using a 3 4 in socket carefully tap the bearing check alignment frequently int...

Page 163: ...iption Where Used Part No 82 Premium Gear Lubricant Outside diameter of forward gear bearing 92 858058K01 Bearing Removal and Installation Kit 91 31229A7 Forward Gear 1 Lubricate the forward gear bron...

Page 164: ...Place the crankshaft end of the driveshaft on a padded surface Place the upper driveshaft bearing on the pinion end of the driveshaft Using the fabricated driver tool tap the bearing down the drivesh...

Page 165: ...es a Driveshaft b Pinion gear Bearing Carrier Assembly 1 Apply 2 4 C with PTFE to the new seal lips Press the new seal flat side down into the carrier with a 13 16 in socket a Seal flat side down b So...

Page 166: ...ng 92 802859A 1 Bearing Removal and Installation Kit 91 31229A7 4 Install the carrier O ring Apply 2 4 C with PTFE to the O ring surface a O ring Tube Ref No Description Where Used Part No 95 2 4 C wi...

Page 167: ...pected for wear If no freeplay exists either the forward gear or forward gear bearing are not seated properly in the gear housing or the lower driveshaft bearing above the pinion gear is positioned to...

Page 168: ...Apply a light coat of 2 4 C with PTFE to the shift shaft to lubricate the O ring in the pump housing 3 Apply a light coat of 2 4 C with PTFE to the inside of the pump cover insert Slide the pump cove...

Page 169: ...emium or High Performance Gear Lubricant in the gear housing WARNING Rotating propellers can cause serious injury or death Never operate the boat out of the water with a propeller installed Before ins...

Page 170: ...ignition if equipped and engaging the lanyard stop switch to prevent the engine from starting 1 Place the gear shift lever in the neutral position 2 Tilt the engine to the full up position 3 Shift the...

Page 171: ...turn freely If the propeller shaft does not turn freely in neutral loosen the clamping bolt and verify the shift lever and gear housing are both in neutral Tighten the bolt Install the access cover a...

Page 172: ...can cause serious injury or death Never operate the boat out of the water with a propeller installed Before installing or removing a propeller place the drive unit in neutral and engage the lanyard s...

Page 173: ...Gear Housing Notes Page 6A 32 90 8M0065421 NOVEMBER 2012...

Page 174: ...65421 NOVEMBER 2012 Page 7A 1 7 A Attachments Section 7A Shift Linkage Table of Contents Shift Linkage Components 7A 4 Shift Linkage Removal and Installation 7A 6 Shift Linkage Removal 7A 6 Shift Link...

Page 175: ...Shift Linkage Page 7A 2 90 8M0065421 NOVEMBER 2012 Lubricants Sealants Adhesives Tube Ref No Description Where Used Part No 95 2 4 C with PTFE Shift lever shaft and O rings 92 802859A 1...

Page 176: ...Shift Linkage Notes 90 8M0065421 NOVEMBER 2012 Page 7A 3...

Page 177: ...Shift Linkage Page 7A 4 90 8M0065421 NOVEMBER 2012 Shift Linkage Components 22474 12 11 18 18 16 17 15 8 13 14 9 10 7 6 5 4 2 3 1...

Page 178: ...Torque Nm lb in lb ft 1 1 Shift lever 2 1 Spring 3 1 Detent ball 4 1 Washer 5 2 O ring 6 1 Shift shaft lever 7 1 Screw M5 x 12 4 35 8 1 Upper shift shaft 9 1 Washer 10 1 Cotter pin 11 1 Joint 12 1 Bol...

Page 179: ...aining the shift lever 3 Remove the shift lever from the driveshaft housing 4 Remove the cotter pin from the upper shift shaft 5 Remove the shift shaft lever from the upper shift shaft a Shift lever b...

Page 180: ...shaft housing 4 Install a washer onto the shift lever 5 Install the shift shaft lever onto the shift lever Secure with the screw Tighten the screw to the specified torque 6 Install the upper shift sha...

Page 181: ...Shift Linkage Page 7A 8 90 8M0065421 NOVEMBER 2012 8 Install the powerhead Refer to Section 4A Powerhead Installation...

Page 182: ...ion 7B Tiller Handle Table of Contents Tiller Handle Components 7B 4 Tiller Handle Removal 7B 6 Tiller Handle Disassembly 7B 7 Tiller Handle Reassembly 7B 7 Tiller Handle Installation 7B 9 Throttle Ca...

Page 183: ...Tiller Handle Page 7B 2 90 8M0065421 NOVEMBER 2012 Lubricants Sealants Adhesives Tube Ref No Description Where Used Part No 66 Loctite 242 Threadlocker Fuel tank mounting bolts 92 809821...

Page 184: ...Tiller Handle Notes 90 8M0065421 NOVEMBER 2012 Page 7B 3...

Page 185: ...Tiller Handle Page 7B 4 90 8M0065421 NOVEMBER 2012 Tiller Handle Components 22485 5 12 7 6 9 10 8 11 2 13 3 4 1 15 14 18 24 17 17 19 20 21 22 23 25 25 16...

Page 186: ...Drive tight 6 1 Bracket 7 1 Screw Drive tight 8 1 Throttle shaft friction device 9 1 Throttle friction knob As required 10 1 Spring 11 1 Bolt 12 1 Throttle shaft 13 1 Throttle decal 14 2 Rubber isolat...

Page 187: ...immediately Materials used to contain spillage must be disposed of in an approved receptacle Any fuel system service must be performed in a well ventilated area 3 Remove the three bolts and washers se...

Page 188: ...om the pulley on the throttle shaft 6 Remove the throttle shaft from the tiller handle a Tiller handle screw b Grip c Friction knob d Throttle shaft e Screw f Bracket g Pulley h Acceleration throttle...

Page 189: ...er a Tiller handle cover slot b Throttle cable deceleration c Throttle cable acceleration 5 Install the throttle cable ends in the throttle shaft drum a Throttle shaft b Drum c Throttle cable decelera...

Page 190: ...nd washers Tighten the bolts to the specified torque a Tiller handle mounting bolt and washer M8 x 35 2 b Steering bracket Description Nm lb in lb ft Steering bracket mounting bolt M8 x 35 2 15 132 2...

Page 191: ...nstall the sleeve around the throttle cables Secure the sleeve with the J clamp a Sleeve b J clamp 6 Install the fuel tank assembly Attach the fuel line to the fuel tank and secure it with a hose clam...

Page 192: ...mounting bolts M6 x 25 3 6 53 8 Install the top cowl Throttle Cable Adjustment Deceleration Cable 1 Rotate the grip to the START position 2 Loosen the jam nuts on both throttle cables 3 Pull the choke...

Page 193: ...0 mm 0 020 0 040 in Acceleration Cable 1 Rotate the grip to the WOT position 2 Loosen the acceleration cable jam nuts 3 Pull the outer cable jacket in the direction of the arrow 4 Tighten the acceler...

Page 194: ...Section 8A Recoil Starter Table of Contents Recoil Starter Components 8A 4 Recoil Starter Removal 8A 6 Recoil Starter Spring Replacement 8A 7 Removal 8A 7 Reassembly 8A 8 Recoil Starter Rope Replaceme...

Page 195: ...r Page 8A 2 90 8M0065421 NOVEMBER 2012 Lubricants Sealants Adhesives Tube Ref No Description Where Used Part No 66 Loctite 242 Threadlocker Recoil starter assembly mounting bolts Fuel tank mounting bo...

Page 196: ...Recoil Starter Notes 90 8M0065421 NOVEMBER 2012 Page 8A 3...

Page 197: ...Recoil Starter Page 8A 4 90 8M0065421 NOVEMBER 2012 Recoil Starter Components 22484 1 8 12 9 10 11 2 3 6 5 7 4 4 13 14 15 13 14...

Page 198: ...escription Torque Nm lb in lb ft 1 1 Recoil starter assembly 2 1 Spring 3 1 Reel 4 2 Ratchet pawl 5 1 Friction plate 6 1 Screw Drive tight 7 1 Friction spring 8 1 Rope 9 1 Starter handle 10 1 Rope anc...

Page 199: ...he top cowl 2 Remove the three bolts and washers securing the fuel tank to the engine 3 Drain the fuel tank IMPORTANT Use an approved container to collect and store the fuel Wipe up any spillage immed...

Page 200: ...uncoil Removal 1 Pull the starter rope until it is fully unwound from the reel Hold the reel in this position 2 Untie or cut the knot from the rope Remove the rope from the recoil starter assembly a...

Page 201: ...from the reel spring cavity Reassembly 1 Install the hook on the end of the spring into the reel 2 Rewind the spring in a counterclockwise direction into the reel spring cavity a Spring hook engaged...

Page 202: ...the rope and handle into the housing 10 Pull the starter handle out to ensure that the ratchet pawls engage a Ratchet pawls engaged 11 If the ratchet pawls do not engage loosen the friction plate scr...

Page 203: ...ter rope 2 Thread the rope through the rope anchor plate rope anchor and the handle NOTE The ridge on the anchor plate faces the handle a Handle b Rope anchor c Ridge side of rope anchor plate d Knot...

Page 204: ...assembly mounting bolts 4 Attach the recoil starter assembly onto the flywheel cover and secure with three bolts and washers 5 Tighten the bolts to the specified torque a Recoil starter assembly b Bo...

Page 205: ...olonged exposure to vapors Always check for leaks before attempting to start the engine and wipe up any spilled fuel immediately 7 Apply Loctite 242 Threadlocker to the fuel tank mounting bolts Instal...

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