1992-2000.mercury Mariner Outboard 105-225 Service Manual Sprotetto PDF
1992-2000.mercury Mariner Outboard 105-225 Service Manual Sprotetto PDF
1992-2000.mercury Mariner Outboard 105-225 Service Manual Sprotetto PDF
!"#$%&"
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MODELS
105/140 JET • 135 • 150 • 175 •
200 • 225
1992 Through 2000
105/140 Jet • 135 • 150 •
150 XR6 •150 Magnum III • 150 EFI •
175 •175 EFI • 200 • 200 EFI
With Serial Numbers
0D082000 Through 0G960499
EXAMPLE:
Page Number
ii 90-824052R3 JUNE 2002
Service Manual Outline
Section 1 - Important Information
A - Specifications
B - Maintenance
Important
Information
1
C - General Information
D - Outboard Installation
Section 2 - Electrical
A - Ignition
Electrical
2
B - Charging & Starting System
C - Timing, Synchronizing & Adjusting
D - Wiring Diagrams
Section 3 - Fuel System
A - Fuel Pump
Fuel System
3
B - Carburetor
C - Fuel Injection 1995 and Prior
D - Fuel Injection 1996 and Up
E - Oil Injection
Powerhead
4
5
F - Emissions
Section 4 - Powerhead Mid-Section
A - Powerhead
B - Cooling
6
Section 5 - Mid-Section
A - Clamp/Swivel Brackets & Drive Shaft Housing Lower Unit
B - Power Trim
Section 6 - Lower Unit
A - Right Hand Rotation
B - Left Hand Rotation
C - 1.78:1 Ratio (4-1/4″ Dia.)
D - Right Hand Non-Ratcheting
Attachments/
Control Linkage
7
E - Left Hand Non-Ratcheting
F - Jet Outboards
Section 7 - Attachments/Control Linkage
SPECIFICATIONS
Table of Contents
Page
Master Specifications . . . . . . . . . . . . . . . . . . . . . 1A-1
Float Adjustment
Float Level Float Even with Bowl Edge w/Bowl
Inverted
Maximum BTDC
– Model 105 Jet/135/150
@ Cranking Speed 21° BTDC
@ WOT RPM 19° BTDC
– 150 XRI
@ Cranking Speed 15° BTDC
@ WOT RPM 16° BTDC
– Model 200XRI
@ Cranking Speed 16° BTDC
@ 5800 RPM 22° BTDC
NOTE: Timing specifications listed are for 1998 model year engines. Refer to timing decal on engine for previous
model year timing specifications.
MAINTENANCE
Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-1
Gear Case Lubricant Capacity . . . . . . . . . . . 1B-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-1
Quicksilver Lubricant/Sealant . . . . . . . . . . . 1B-1
Inspection and Maintenance Schedule . . . . . . 1B-1
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . 1B-2
Checking Power Trim Fluid . . . . . . . . . . . . . . . . 1B-4
Gear Case Lubrication . . . . . . . . . . . . . . . . . . . . 1B-5
Gear Case Lubricant Capacity . . . . . . . . . . . 1B-5
Draining Gear Case . . . . . . . . . . . . . . . . . . . . 1B-5
Checking Lubricant Level and Refilling
Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5
Propeller Replacement . . . . . . . . . . . . . . . . . . . . 1B-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-6
Corrosion Control Anode . . . . . . . . . . . . . . . . . . 1B-7
Flushing Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Flushing Cooling System with Engine NOT
Running (Using Cowl Flush Plug) . . . . . . . . 1B-8
Flushing Cooling System with Engine
Running (Using Flushing Attachment
44357A2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Protecting External Outboard
Components . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Protecting Internal Engine
Components . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9
Positioning Outboard for Storage . . . . . . 1B-9
Battery Storage . . . . . . . . . . . . . . . . . . . . . 1B-9
SAE 30W Motor Oil Obtain Locally 2. Inspect and clean spark plugs.
3. Check engine fuel filter for contaminants – Car-
buretor models.
4. Replace Water separating fuel filter – EFI mod-
els.
5. Check corrosion control anodes. Check more fre-
quently when used in salt water.
6. Drain and replace gear case lubricant.
7. Lubricate splines on the drive shaft.∗
8. Check power trim fluid.
9. Inspect battery.
10. Adjust carburetors (if required).∗
11. Check engine timing setup.∗
12. Check control cable adjustments.∗
13. Remove engine deposits with Quicksilver Power
Tune Engine Cleaner.
1. Portable Fuel Tank – Pour the required amount of 9 Propeller 2-4-C 100 Hours of Use or
Shaft w/Teflon Once in Season
Quicksilver Gasoline Stabilizer (follow instruc-
tions on container) into fuel tank. Tip fuel tank 10 Gear Hous- 2-4-C 100 Hours of Use or
ing Bearing w/Teflon Once in Season
back and forth to mix stabilizer with the fuel. Carrier and
Cover Nut
2. Permanently Installed Fuel Tank – Pour the re-
quired amount of Quicksilver Gasoline Stabilizer ◊ Gear Hous- Quicksilver 100 Hours of Use or
ing Premium Once in Season
(follow instructions on container) into a separate Blend Gear
container and mix with approximately one quart Lube
(one liter) of gasoline. Pour this mixture into fuel ° Engine Dri- 2-4-C Once in Once in
tank. veshaft w/Teflon Season Season
Splines
3. Place the outboard in water or connect flushing
attachment for circulating cooling water. Run the ◊ Refer to “Gear Housing Lubrication”
engine for ten minutes to allow treated fuel to fill
the fuel system. ° Refer to Gear Housing Removal and Installation”
(Section 6)
WARNING
Core of steering cable (transom end) must be
fully retracted into cable housing before
lubricating cable. If cable is lubricated while
extended, hydraulic lock of cable could occur.
With core of Ride-Guide Steering cable (transom
end) fully retracted, lubricate transom end of steering
1 - Throttle/Shift Linkage Pivot Point Lubrication cable thru grease fitting and exposed portion of cable
end with Quicksilver 2-4-C w/Teflon. Lubricate all
2 pivot points with SAE 30W engine oil.
7
6
52183
5 - Ride-Guide Steering Cable Grease Fitting
2 - Upper Shift Shaft Lubrication
6 - Tilt Tube Grease Fitting
7 - Steering Link Rod Pivot Point Lubrication
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1.87:1 22.5 fl. oz. (665ml) 5. Note color of gear lubricant. White or cream color
indicates presence of water in lubricant. Gear lu-
2.00:1 22.5 fl. oz. (665ml) bricant which has been drained from a gear case
recently in operation will have a yellowish color
2.30:1 22.5 fl. oz. (665ml) due to lubricant agitation/aeration. This is normal
and should not be confused with the presence of
water.
Draining Gear Case 6. Presence of water in gear lubricant indicates the
need for disassembly and inspection of oil seals,
WARNING seal surfaces, o-rings, water pump gaskets as
well as gear housing components for damage.
If gear housing is installed on outboard, to avoid
accidental starting, disconnect (and isolate)
spark plug leads from spark plugs before work-
ing near the propeller. Checking Lubricant Level and
Refilling Gear Case
CAUTION IMPORTANT: Never add lubricant to gear hous-
Do not use automotive grease in the gear hous- ing without first removing VENT screw, as
ing. Use only Quicksilver Gear Lubricant. trapped air will prevent housing from being filled.
Fill gear housing only when outboard is in oper-
1. Tilt outboard so that lubricant in gear housing will
ating position.
drain toward front of housing, out fill hole and into
clean container. 1. With outboard in vertical position, insert lubricant
tube into fill hole.
IMPORTANT: Inspect FILL and VENT screw seal-
ing washers for damage. Use new washers as 2. Slowly fill housing thru “FILL” hole with Quicksil-
needed. ver Gear Lubricant until lubricant flows out of
“VENT” hole and no air bubbles are visible.
2. Remove lubricant FILL screw and sealing
washer. Note amount of metal particles on 3. Install “VENT” screw into “VENT” hole.
magnetic fill screw. IMPORTANT: DO NOT lose more than one fluid
3. Remove VENT screw with sealing washer and al- ounce (30cc) of gear lubricant while reinstalling
low sufficient time for all lubricant to drain. “FILL” screw.
4. Remove grease tube (or hose) from “FILL” hole
and quickly install “FILL” screw into “FILL”
hole.
a
b
b
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WARNING
Removal When installing or removing propeller, verify re-
mote control is in NEUTRAL position and that key
WARNING switch is “OFF.” Place a block of wood between
Disconnect high tension leads from spark plugs the anti-ventilation plate and propeller to prevent
and remove spark plugs from engine before re- accidental engine starting and to protect hands
moving propeller from gear housing to prevent from propeller blades while removing propeller
accidental starting of outboard. nut.
1. Disconnect high tension leads from spark plugs 1. To aid in future removal of the propeller, coat the
and remove spark plugs from engine. propeller shaft splines with one of the following
Quicksilver lubricants:
2. Shift engine into neutral position. – Anti-Corrosion Grease
3. Tilt engine to full up position and engage tilt lock – 2-4-C w/Teflon
lever. – Special Lubricant 101
4. Bend tabs of propeller tab washer away from 2. Place forward thrust hub onto propeller shaft.
thrust hub (rear), then remove propeller locknut, 3. Align splines and slide propeller onto shaft.
tab washer, thrust hub (rear), propeller and thrust
hub (forward) from propeller shaft.
b b
51866
a
d 22750
f
a - Forward Thrust Hub
b - Propeller Shaft
c
d e
51871
a - Thrust Hub (Forward)
b - Propeller Shaft
c - Continuity Washer (If Equipped)
d - Rear Thrust Hub
e - Tab Washer
f - Propeller Nut
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CAUTION
If propeller moves fore-and-aft on the propeller
shaft, retighten the propeller nut. Operation with
a loose propeller could cause damage to the
thrust hub and gear housing during acceleration,
deceleration or when shifting gears.
e
a - Gear Case Anodes (2)
c b - Transom Bracket Anode
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NOTE: DO NOT have the engine running above idle IMPORTANT: Prevent engine overheating. If wa-
speed when flushing the cooling system using the ter flow is insufficient, stop engine and deter-
cowl flush plug as the water pump impeller will not mine cause before continuing.
receive sufficient water to prevent being damaged. b. Flush until discharge water is clear. In salt-
1. Remove the plug from fitting in the bottom water areas, run outboard 3 to 5 minutes.
cowl. c. Stop engine before turning off water.
6. Stop engine, turn water off and remove flushing
attachment from gear housing.
IMPORTANT: While and after flushing, keep out-
board in upright position until all water has
drained from drive shaft housing to prevent wa-
ter from entering the powerhead via drive shaft
housing and exhaust ports.
WARNING
When flushing, verify that area in vicinity of pro-
peller is clear and that no person is standing
nearby – to avoid possible injury. It is recom-
mended to remove propeller as a precautionary
measure.
1. Install Quicksilver Flushing Attachment 44357A2
(or equivalent tool) on the gear housing from the
FRONT side, positioning the rubber cups over
the water intake openings.
2. Connect hose [1/2 in.(12.7mm) I.D. or larger]
between flushing attachment and water tap.
IMPORTANT: To prevent water pump damage, do
not start or run engine unless cooling water is
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flowing.
GENERAL INFORMATION
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Table of Contents
Page
Serial Number Location . . . . . . . . . . . . . . . . . . . 1C-1
Conditions Affecting Performance . . . . . . . . . . 1C-1
Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-1
Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-3
Following Complete Submersion . . . . . . . . . . . 1C-4
Salt Water Submersion . . . . . . . . . . . . . . . . 1C-4
Submerged While Running . . . . . . . . . . . . . 1C-4
Submerged Engine (Fresh Water) . . . . . . . 1C-4
Propeller Selection . . . . . . . . . . . . . . . . . . . . . . . 1C-5
Painting Procedures . . . . . . . . . . . . . . . . . . . . . . 1C-5
Cleaning & Painting Aluminum Propellers
& Gear Housings . . . . . . . . . . . . . . . . . . . . . . 1C-5
Decal Application . . . . . . . . . . . . . . . . . . . . . . . . . 1C-6
Decal Removal . . . . . . . . . . . . . . . . . . . . . . . . 1C-6
Instructions for “Wet” Application . . . . . . . . 1C-6
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VENTILATION
Ventilation occurs when air is drawn from the water’s
surface (excessive trim out angle) or from the engine
exhaust flow (wrong propeller/propeller hardware
installed or gear case labyrinth seal worn) into the
propeller blades. These air bubbles strike the propel-
ler blade surface and cause erosion of the blade sur-
51115
face. If allowed to continue, eventual blade failure
(breakage) will occur. Damaged Piston Resulting from Detonation
Engine
DETONATION
Detonation in a 2-cycle engine resembles the
“pinging” heard in an automobile engine. It can be
otherwise described as a tin-like “rattling” or
“plinking” sound.
Detonation is an explosion of an unburned portion of
the fuel/air charge after the spark plug has fired.
Detonation creates severe shock waves in the
engine, and these shock waves often find or create
a weakness: The dome of a piston, cylinder
head/gasket, piston rings or piston ring lands, piston
pin and roller bearings.
A few of the most common causes of detonation in a
marine 2-cycle application are as follows:
a. Over-advanced ignition timing.
(1.) Use of low octane gasoline.
(2.) Propeller pitch too high (engine RPM be-
low recommended maximum range).
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GEAR HOUSINGS
The following procedures should be used in refinish-
ing gear housings. This procedure will provide the
most durable paint system available in the field. The
materials recommended are of high quality and
approximate marine requirements. The following
procedure will provide a repaint job that compares
with a properly applied factory paint finish. It is rec-
ommended that the listed materials be purchased
from a local Ditzler Automotive Finish Supply Outlet.
The minimum package quantity of each material
shown following is sufficient to refinish several gear
housings.
Procedure:
1. Wash gear housing with a muriatic acid base
cleaner to remove any type of marine growth,
and rinse with water, if necessary.
2. Wash gear housing with soap and water, then
rinse.
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A B
C D
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Table of Contents
Page Page
Notice to Installer and Owner . . . . . . . . . . . . . . 1D-1 Shift and Throttle Cable Installation to
Boat Horsepower Capacity . . . . . . . . . . . . . . . . 1D-1 the Outboard . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-7
Outboard Remote Control . . . . . . . . . . . . . . . . . 1D-1 Shift Cable Installation . . . . . . . . . . . . . . . . . 1D-7
Selecting Accessories For The Outboard . . . . 1D-1 Throttle Cable Installation . . . . . . . . . . . . . . . 1D-8
Selecting Steering Cables and Remote Remote Wiring Connections . . . . . . . . . . . . . . . 1D-9
Control Cables . . . . . . . . . . . . . . . . . . . . . . . . . 1D-1 Battery Connections . . . . . . . . . . . . . . . . . . . . . . 1D-9
Determining Recommended Outboard Fuel Connections . . . . . . . . . . . . . . . . . . . . . . . 1D-10
Mounting Height . . . . . . . . . . . . . . . . . . . . . . . 1D-2 Connecting Fuel Hose to Engine . . . . . . . . 1D-10
Locating Centerline of Boat Transom . . . . . . . 1D-3 Portable Fuel Tank . . . . . . . . . . . . . . . . . . . . 1D-10
Drilling Outboard Mounting Holes . . . . . . . . 1D-3 Permanent Fuel Tank . . . . . . . . . . . . . . . . . 1D-10
Applying Counter Rotation Decals . . . . . . . 1D-3 Fuel Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-10
Lifting Outboard . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-4 Set Up Instructions for Oil Injection System . 1D-10
Installing Outboard To Boat Transom . . . . . . . 1D-4 Installing Remote Oil Tank . . . . . . . . . . . . . 1D-10
Single Steering Cable and Steering Link Installing Oil Hoses To Engine . . . . . . . . . . 1D-11
Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . 1D-5 Filling the Oil Injection System . . . . . . . . . . 1D-11
Installing Ride Guide Cable to Outboard Bleeding Air from Oil Injection Pump and
Tilt Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-5 Oil Injection Outlet Hose . . . . . . . . . . . . . 1D-12
Steering Link Rod Installation . . . . . . . . . . . 1D-5 Adjusting Oil Injection Pump . . . . . . . . . . . 1D-12
Routing Location for Wiring and Hoses thru Propeller Selection . . . . . . . . . . . . . . . . . . . . . . 1D-12
Clamp in Bottom Cowl . . . . . . . . . . . . . . . . . . 1D-6 Propeller Installation . . . . . . . . . . . . . . . . . . . . . 1D-12
Remote Control Installation . . . . . . . . . . . . . . . . 1D-6 Power Trim System . . . . . . . . . . . . . . . . . . . . . . 1D-13
Counter (Left Hand) Rotation Outboards . . 1D-6 General Information . . . . . . . . . . . . . . . . . . . 1D-13
Required Side Mount Remote Control or Ignition Power Trim Operation . . . . . . . . . . . . . . . . . 1D-13
Key Switch Assembly . . . . . . . . . . . . . . . . . . . 1D-7 Trim “IN” Angle Adjustment . . . . . . . . . . . . 1D-14
Boats Equipped with Side Mount Checking Trim System Fluid Level . . . . . . 1D-14
Remote Control . . . . . . . . . . . . . . . . . . . . . 1D-7 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . 1D-14
Boats Equipped with Panel or Console
Mount Remote Control . . . . . . . . . . . . . . . 1D-7
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WARNING WARNING
WARNING – Hazards or unsafe practices which Avoid serious injury or death from a sudden
COULD result in severe personal injury or death. unexpected acceleration when starting the
engine. The design of this outboard requires that
CAUTION the remote control used with it must have a built
in start-in-gear protection device.
CAUTION – Hazards or unsafe practices which
could result in minor injury or product or
property damage.
Selecting Accessories For
The Outboard
Boat Horsepower Capacity Some accessories not manufactured or sold by Mer-
cury Marine are not designed to be safely used with
U.S. COAST GUARD CAPACITY these outboards or outboard operating system. Ac-
MAXIMUM HORSEPOWER XXX quire and read the installation, operation and mainte-
nance manuals for all selected accessories.
MAXIMUM PERSON
CAPACITY (POUNDS) XXX
MAXIMUM WEIGHT WARNING
CAPACITY XXX The misuse of acceptable accessories or the use
Do not overpower. Most boats will carry a required of unacceptable accessories can result in
capacity plate indicating the maximum acceptable serious injury, death or product failure.
power and load as determined by the manufacturer
following certain federal guidelines. If in doubt, con-
tact the boat manufacturer. Selecting Steering Cables
WARNING and Remote Control Cables
Using an outboard that exceeds the maximum Refer to “Quicksilver Accessories Guide” to deter-
horsepower limit of a boat can 1. cause loss of mine correct length of steering cables and remote
boat control 2. place too much weight at the control cables.
transom altering the designed flotation IMPORTANT: Steering cables and remote control
characteristics of the boat or 3. cause the boat to cables must be the correct length. Sharp bends
break apart particularly around the transom area. on too-short cables result in “kinks”; too-long
Overpowering a boat can result in serious injury, cables require unnecessary bends and/or loops.
death or boat damage. Both conditions place extra stress on the cables.
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26 in.
(660m
m)
25 in.
(635m
m)
24 in.
(609m
m) b
23 in.
(584m c
m)
e 22 in.
(560m
e m)
21 in.
(533m a
m)
20 in. d
(508m
m)
19 in.
(482m
m)
10 20 30 40 50 60 70 80
NOTE: Add 5 in. (127mm) for XL models and 10 in. d. This line may be preferred to determine out-
(254mm) for XXL models to listed outboard mounting board mounting height dimension for dual
height. outboard installation.
a. This solid line is recommended to determine e. Outboard mounting height (height of
the outboard mounting height. outboard transom brackets from bottom of
boat transom). For heights over 22 in.
IMPORTANT: Increasing the height of outboard
(560mm), a propeller, that is specifically
generally will provide the following: 1) Less
designed for surfacing operation, such as the
steering torque, 2) more top speed, 3) greater
“Laser” and “Mirage” series, usually are
boat stability, but, 4) will cause more prop “break
preferred.
loose” which may be particularly noticeable
when planing off or with heavy load. f. Maximum boat speed anticipated.
b. These broken lines represent the extremes of
known successful outboard mounting height
dimensions.
c. This line may be preferred to determine out-
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A B
b
a
C D
a - Centerline of Transom
NOTE: Dimensions “A” & “B” and “C” & “D” are equal
length. a
a b
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b CAUTION
Marine sealer must be used on shanks bolts to
make a water-tight installation.
a
IMPORTANT: DO NOT use an impact driver when
tightening transom bolts.
Apply marine sealer to shanks of mounting bolts (not
threads) and secure outboard to transom with 4 bolts,
flat washers and locknuts, as shown. Be sure that
installation is water-tight.
WARNING
Before operating, outboard(s) MUST BE
SECURED to boat transom with four 1/2 in.
50048 diameter bolts and locknuts, as follows: 2 bolts
a - Lifting Eye (91-75132) must be installed thru upper mounting holes and
b - Hoist 2 bolts thru lower mounting holes. Installation
must be water-tight and outboard should be
checked for tightness on the transom during
operation. Failure to bolt outboard to transom
(using 4 bolts and locknuts, as shown) may
result in damage to boat and/or loss of outboard
and possible injury to occupants of boat.
d
b
a
e
a - 1/2 in. Diameter Bolts (4) d - Flat Washers (4)
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WARNING
c After installation is complete (and before
b
operating outboard), check that boat will turn
right when steering wheel is turned right and that
boat will turn left when steering wheel is turned
left. Check steering thru full range (left and right)
and at all tilt angles to assure interference-free
a movement.
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28160
52188
a - Screws
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Boats Equipped with Panel or b. Move the remote control handle into reverse
and advance the handle to the full speed
Console Mount Remote Control position. Slowly return the handle back to the
A Quicksilver Ignition Key/Choke Assembly neutral detent position. Place a mark on the
equipped with a warning horn must be used with this shift cable against the cable end guide at
engine. This warning horn is necessary for the location (b).
engine warning system. c. Make a center mark (c) on the shift cable,
midway between marks (“a” and “b”). Align
a
the cable end guide against this center mark
(c) when installing cable to the engine.
a
a - Warning Horn b
c
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a c
d
g f
54074
9. Check shift cable adjustments as follows: d b
a. With remote control in forward, the propshaft 54075
should lock solidly in gear. If it does not, ad-
just cable barrel closer to cable end guide.
b. Shift remote control into neutral. The prop-
shaft should turn freely without drag. If not,
adjust barrel away from cable end guide. Re-
peat steps a and b.
c. Shift remote control into reverse while turning
propeller. The propshaft should lock solidly in
gear. If not, adjust barrel away from cable end
guide. Repeat steps a thru c.
d. Return remote control handle to neutral. The
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f
e
d
c
g
b
a
a - Remote Wiring Harness
b - Engine Wiring Harness Connector
c - Lead From Trim Solenoid (Down Solenoid)
d - Lead From Trim Solenoid (Up Solenoid)
e - Lead From Trim Sender
f - Lead From Temperature Sender
g - Harness Holder (Located in Cowl) - Place Wiring Harness
and Battery Cables into Holder
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CAUTION
If an electric fuel pump is to be used on engines
with oil injection, the fuel pressure at the engine
must not exceed 4 psi (27 kPa). If necessary, in-
stall a pressure regulator between electrical fuel
CARBURETOR MODELS pump and engine and set at 4 psi (27 kPa) maxi-
1. Connect fuel hose (a) to “T” fitting as shown. Se- mum.
cure with hose clamp (b).
2. Refer to page 7 for proper routing of fuel hose thru
Installing Remote Oil Tank
clamp in bottom cowl.
Minimum fuel line inside diameter (I.D.) is 5/16 in. during operation of the outboard.
(8mm), with separate fuel line/fuel tank pickup for NOTE: A Quicksilver Accessory oil hose extension
each engine. kit (41729A3) is available for the remote oil tank.
1D-10 - IMPORTANT INFORMATION 90-824052R3 JUNE 2002
Installing Oil Hoses To Engine Filling the Oil Injection System
1. Remove (and discard) the shipping cap from 1. Fill remote oil tank with the recommended oil
hose fitting (a). listed in the Operation and Maintenance Manual.
Tighten fill cap.
2. Connect oil hose (“b” with blue stripe) to fitting as
shown. Secure with sta-strap.
a
NOTE: Hose (c) is a vent hose and does not get
connected.
3. Remove (and discard) shipping cap from pulse
fitting (d).
4. Connect the second oil hose (e) to pulse fitting as
shown. Secure with sta-strap.
5. Refer to page 6 for proper routing of oil hoses thru
clamp in the bottom cowl. a - Fill Cap
b 2. Remove fill cap from the engine oil tank and fill
the tank with oil. Reinstall the fill cap.
3. Loosen the fill cap on the engine oil tank. Run the
engine until the all the air has been vented out of
a the tank and oil starts to flow out of the tank. Re-
tighten fill cap.
c
CAUTION
Be certain that the fill caps on the engine oil tank
and remote oil tank are installed tight. An air leak,
at one of the caps on the remote oil tank, will pre-
vent oil flow to the engine oil tank. A fill cap leak
on the engine oil tank will cause oil leakage.
d
b
54071
50047
a - Engine Oil Tank
b - Fill Cap
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a
c
b
50060
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a - Link Rod
b - Alignment Mark
c - Casting Mark g a b c d e f
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a - Tilt Pin
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2
A
IGNITION SYSTEM
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Table of Contents
Page Page
Ignition Specifications . . . . . . . . . . . . . . . . . . . . . 2A-1 Idle Stabilizer Modules . . . . . . . . . . . . . . . . 2A-20
40 Ampere Stator . . . . . . . . . . . . . . . . . . . . . . . . 2A-1 Idle Stabilizer Description . . . . . . . . . . . 2A-20
Trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1 Test for Proper Function of Idle
Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1 Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . 2A-20
DVA Specifications . . . . . . . . . . . . . . . . . . . . . . . 2A-1 Idle Stabilizer Shift System
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2 Description . . . . . . . . . . . . . . . . . . . . . . . . 2A-20
Flywheel/Starter Motor . . . . . . . . . . . . . . . . . . . . 2A-4 Test for Proper Function of Idle Stabilizer
Ignition Coil/Voltage Regulator . . . . . . . . . . . . . 2A-6 Shift System . . . . . . . . . . . . . . . . . . . . . 2A-21
Wiring Harness/Starter Solenoid . . . . . . . . . . . 2A-8 Troubleshooting Idle Stabilizer
Theory of Operation . . . . . . . . . . . . . . . . . . . . . 2A-10 Shift System . . . . . . . . . . . . . . . . . . . . . 2A-21
Description . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-10 Idle Stabilizer Module Removal . . . . . . 2A-21
Ignition Test Procedures . . . . . . . . . . . . . . . . . . 2A-11 Idle Stabilizer Module Installation . . . . 2A-21
Checking for Loss of Spark . . . . . . . . . . . . 2A-11 Ignition Components Removal and
Direct Voltage Adaptor (DVA) . . . . . . . . . . 2A-11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2A-22
Troubleshooting Tips . . . . . . . . . . . . . . . . . . 2A-12 Flywheel Removal And Installation . . . 2A-22
Ignition Troubleshooting . . . . . . . . . . . . . . . . . . 2A-13 Stator Assembly Removal and
Multimeter/DVA Tester 91-99750A1 . . . . . 2A-13 Installation . . . . . . . . . . . . . . . . . . . . . . 2A-23
Test Sequence . . . . . . . . . . . . . . . . . . . . . . . 2A-13 Trigger Plate Assembly Removal and
Stator Low Speed Test . . . . . . . . . . . . . . 2A-14 Installation . . . . . . . . . . . . . . . . . . . . . . 2A-24
Stator High Speed Test . . . . . . . . . . . . . 2A-14 Ignition Coil Removal and Installation . 2A-25
Bias Circuit Test . . . . . . . . . . . . . . . . . . . 2A-15 Switch Box(es) Removal and
Ignition System Test Chart . . . . . . . . . . . . . 2A-16 Installation . . . . . . . . . . . . . . . . . . . . . . 2A-26
40 Amp Charging System . . . . . . . . . . . 2A-16 Spark Plug Wire Routing
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . 2A-16 (Production Outboards) . . . . . . . . . . . 2A-27
Stator Assembly . . . . . . . . . . . . . . . . . . . 2A-16 Spark Plug Wire Routing
Stator Test . . . . . . . . . . . . . . . . . . . . . . . . 2A-16 (High Performance Outboards) . . . . 2A-28
40 Ampere Stator . . . . . . . . . . . . . . . . . . 2A-16
Trigger Assembly Test . . . . . . . . . . . . . . 2A-17
Ignition Coil Test . . . . . . . . . . . . . . . . . . . 2A-17
Mercury (Tilt) Stop Switch Test . . . . . . . 2A-17
Ignition (Key) Switch Test . . . . . . . . . . . 2A-18
Ignition Switch (Soldered Connections) 2A-18
Ignition Switch (Bullet Connections) . . 2A-19
Low Speed/High Speed Spark Advance
Module Description: . . . . . . . . . . . . . . 2A-19
Tests For Proper Function of Low Speed/
High Speed Spark Advance Module 2A-19
Low Speed Spark Advance Test . . . . . 2A-19
High Speed Spark Advance Test . . . . . 2A-19
Low Speed/High Speed Spark Advance
Module Removal . . . . . . . . . . . . . . . . . 2A-20
Low Speed/High Speed Spark Advance
Module Installation . . . . . . . . . . . . . . . 2A-20
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DVA Specifications
Test Selection DVA Lead DVA Lead Scale Reading Scale Reading Scale Reading
Sw. Position RED BLACK @ 400 RPM @ 1000 RPM @ 3000 RPM
Coil 400 VDC* Coil (+) Coil (-) 90 - 145 125 - 175 175 - 240
Primary Terminal Terminal
Sw. Box - 400 VDC* Black/Yellow Ground 200 - 300 225 - 400 225 - 400
Stop Circuit Sw. Box Termi-
nal
Stator 400 VDC* Blue Sw. Ground 100 - 265 195 - 265 255 - 345
Low Speed Box Terminal
Stator 400 VDC* Red Sw. Ground 25 - 50 120 - 160 230 - 320
High Speed Box Terminal
Sw. Box - 20VDC or [See Note 1] [See Note 1] 1-6 3 - 15 10 - 30
Bias 40VDC Ground White/Black
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55218
55218
Cylinder Timing Decal 91-853883-1
Decal can be used to help troubleshoot ignition
NOTE: There are 2 versions of the DVA adapter – 1
timing by determining the timing of individual
with studs and 1 with leads. Both are designed to be
cylinders.
used with Volt/Ohm Multi-Meter 91-62562 or any
volt/ohm meter that has a 400 vdc or higher scale.
Spark Gap Board 91-850439
55117
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91–52344
55117 http://SelfFixer.com
16 5
1
25
15 4 3
7
18 2
11
12
17 6 10
7
8
14 9
25
25
25
21 20
19
15
13
7 Loctite 271 (92-809820)
25 Liquid Neoprene (92-25711--2)
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33
6 3
1
7
10 14 4
8 5
14 10
16
10
15
18
25
11
19
12
20
17
21 13 22
6
25
26 23
27 24
28
29
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4
2
7
7
8
6
5
9
33
27
26
34 32 31
35
29
3
13 30
19
10 18 28
17
15 25
10
14 !
23 22
24
14
11
12
17
16
17 23
22
21
20
Stator
#2 Coil
Idle Stabilizer
Trigger
#4 Coil #1 Coil
Diode
Inner
Switch Box
#3 Coil
#6 Coil Ignition Key Switch
Mercury
(Tilt)
Switch
#5 Coil
Outer
Switch Box
51843
1. If voltage readings to coil(s) are BELOW specifi- BLK/YEL GROUND 200 - 300 225 - 400 225 - 400
cation, proceed with Step 2-A.
1. If reading is BELOW specification, proceed with
2. If voltage readings to coil(s) are WITHIN specifi- Step 2-B.
cation, proceed with Step 1-B.
2. If reading is ABOVE specification, either the trig-
1-B. Check coils for spark. [Connect Spark Gap ger or switch box is bad (test trigger as out- lined
Tester (91-63998A1) between coil high voltage in Outboard Service Manual; if trigger checks to
tower and spark plug.] specification replace switch box and repeat
1. If no spark or weak spark, COIL is bad. check).
2. If spark is OK, proceed with Step 1-C. 3. If reading is WITHIN specification, proceed with
Step 3-A.
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2. Remove ignition switch and mercury switch lead IMPORTANT: If engine is equipped with an Idle
wire(s) from switch box(es) [lead wire(s) are Speed Stabilizer and/or High Speed Spark Ad-
connected to ORANGE switch box terminal(s) on vance, disconnect and isolate both leads from
EARLY model engines -- BLACK/YELLOW switch box and repeat check to rule out possible
switch box terminal(s) on LATER model stabilizer/spark advance malfunction.
engines]. 2. If both the low speed and high speed readings are
NOTE: Be sure to disconnect ignition switch lead WITHIN specification, proceed with Step 4-A.
wire from both switch boxes.
CAUTION
3. With ignition switch and mercury switch lead
wire(s) ISOLATED (removed in preceding Step On V-6 models, OUTER switch box must be re-
2), repeat check in Step 2-A. moved from engine (which also loosens INNER
switch box) to gain access to INNER switch box.
a. If reading still is BELOW specification, pro- BEFORE checking stator input to INNER switch
ceed with Step 3-A. box, a GROUND LEAD MUST BE INSTALLED BE-
b. If reading now is WITHIN specification, either TWEEN BOTH switch boxes (INNER and OUTER)
the ignition switch, mercury switch, lanyard and engine to prevent possible damage to igni-
stop switch or wiring is bad. tion components and/or test equipment.
3-A. Check stator low speed and high speed in- 4-A. Check stator low speed and high speed
put to switch box. (See Test Chart, following.) input to OUTER switch box. (See Test Chart,
following.)
NOTE: This is INNER switch box.
51830
51838
STATOR LOW SPEED TEST
STATOR LOW SPEED TEST
DVA RED DVA BLK 400 RPM 1000 3000
DVA RED DVA BLK 400 RPM 1000 3000 RPM RPM
RPM RPM
BLU/WHT GROUND 100 - 265 195 - 265 255 - 345
BLUE GROUND 100 - 265 195 - 265 255 - 345
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DVA RED DVA BLK 400 RPM 1000 3000 DVA RED DVA BLK 400 RPM 1000 3000
RPM RPM RPM RPM
RED/WHT GROUND 25 - 50 120 - 160 230 - 320 GROUND WHT/BLK 1-6 3 - 15 10 - 30
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Coil 400 VDC* Coil (+) Coil (-) 90 - 145 125 - 175 175 - 240
Primary Terminal Terminal
Sw. Box - 400 VDC* Black/Yellow Ground 200 - 300 225 - 400 225 - 400
Stop Circuit Sw. Box Termi-
nal
Stator 400 VDC* Blue Sw. Ground 100 - 265 195 - 265 255 - 345
Low Speed Box Terminal
Stator 400 VDC* Red Sw. Ground 25 - 50 120 - 160 230 - 320
High Speed Box Terminal
Sw. Box - 20VDC or [See Note 1] [See Note 1] 1-6 3 - 15 10 - 30
Bias 40VDC Ground White/Black
Sw. Box Termi-
nal
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Idle Stabilizer
50707
IDLE STABILIZER DESCRIPTION a - Inner Switch Box
b - To Outer Switch Box
The idle stabilizer will electronically advance the igni- c - Resistor (6.8K)
tion timing by as much as 9° if the engine idle speed d - Shift Switch
falls below approximately 550 RPM. This timing ad-
vance raises the idle RPM to an acceptable level IDLE STABILIZER SHIFT SYSTEM
(550 RPM). When the idle stabilizer senses the idle DESCRIPTION
RPM has reached the acceptable level, it returns the
The idle stabilizer shift system advances ignition tim-
timing to the normal idle timing.
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51839
a - Flywheel
b - Flywheel Puller (91-849154T1)
c - Crankshaft Protector Cap (Hidden)
Flywheel Installation
IMPORTANT: Do not apply oil to crankshaft taper
or flywheel taper as flywheel will not seat
properly against crankshaft when torqued.
1. Reinstall flywheel on crankshaft. Secure flywheel
with flat washer and locknut. While holding
b flywheel with Flywheel Holder (91-52344), torque
flywheel nut to 120 Ib. ft. (163.0 N m).
51839
a - Flywheel Holder (91-52344)
b - Flywheel
3. Install a crankshaft protector cap on end of crank- a
shaft, then install Flywheel Puller (91-849154T1)
into flywheel.
CAUTION
Crankshaft damage may result if a protector cap
is not used between crankshaft and puller.
4. Remove flywheel by operating flywheel puller, as
shown. c
CAUTION b
DO NOT hammer on end of puller center bolt to
remove flywheel, or damage may result to
crankshaft or bearings. DO NOT use heat to aid
51839
a - Flywheel
b - Flywheel Holder (91-52344)
c - Torque Wrench-Torque Nut to 120 lb. ft. (163.0 N·m)
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CAUTION
Switch boxes must be grounded to engine before
cranking engine, or switch boxes will be
damaged.
a 4. Route stator wiring harness as shown. Secure
with sta-strap and clamp.
51797
a - Stator Attaching Screws 5. Reinstall flywheel, as outlined in “Flywheel
b - Stator Removal and Installation,” preceding.
a 51797
51797 a - Stator Attaching Screws with Lock washers (4)
a - Stator Assembly b - Stator Harness (Route as Shown; Wires with Yellow
Sleeves Connected to Outer Switch Box)
c - Sta-Strap
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51844
a - Trigger
b - Link Rod Swivel
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b b
51840
a - Spark Advance Lever a - ‘‘J” Clamp
b - Locknut b - Sta-Strap
c - Trigger Harness c - Trigger Wiring Harness (Routes as Shown-Wires with
Yellow Sleeve Are Connected to Outer Switch Box
3. Route trigger wiring harness as shown. Recon-
7. Reinstall flywheel as outlined in “Flywheel
nect wires to proper terminals of switch boxes.
Removal and Installation,” preceding.
Refer to wiring diagram, following in this section.
Wires with yellow identification sleeve must be
connected to outer switch box. IGNITION COIL REMOVAL AND INSTALLATION
4. Install switch boxes to engine with 2 screws and Ignition Coil Removal
2 round metal spacers. Refer to switch box(es) 1. Remove the spark plug (high tension) lead from
removal and installation (see “Table of the defective coil.
Contents”). Make sure that both switch boxes
2. Disconnect wires from (+) and (-) terminals on
are grounded to engine thru mounting screws
defective coil.
and spacers.
3. Remove 4 screws and nuts and lift coil cover
CAUTION along with coils from engine. Remove defective
coil from cover.
Switch boxes must be grounded to engine before
cranking engine, or switch boxes will be
damaged.
5. Clean stator attaching screw threads with Loctite
Primer T (92-59327--1 ) and apply Loctite 222 b
(obtain locally). Install stator assembly in position
on upper end cap and secure with attaching
screws. Torque screws to 50 Ib. in. (5.5 N m).
a
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51843
a - Screws
b - Cover
b
a
51843
a - Ground Wire [Between (–) Coil Terminal and Engine
Ground]
b - Ignition Coil
c - (+) Coil Terminal 51844
d - Coil Cover
a - Screws
b - Spacers
2. Reconnect switch box wire to (+) terminal of coil
and black ground wire to (–) terminal. 2. Disconnect wires from switch boxes.
3. Pull the boot back and insert spark plug lead into
coil. Caution must be taken to ensure a complete Switch Box(es) Installation
connection of lead into coil. Form a water tight
seal between coil tower and spark plug lead 1. Reconnect wires to proper terminals of switch
using Quicksilver Insulating Compound boxes. Secure a ground lead (if equipped) to
(92-41669). Assemble boot over coil terminal. each switch box using a screw. Refer to wiring
diagram, following in this section. Wires with
yellow identification sleeve must be connected to
outer switch box. Outer switch box fires cylinders
No. 2, 4 and 6.
2. Install switch boxes to engine with 2 screws and
2 round metal spacers, as shown. Make sure that
both switch boxes are grounded to engine thru
mounting screws, spacers, and ground leads (if
equipped).
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b
a
c
51844
a - Switch Box Mounting Screws (2)
b - Round Metal Spacer (2)
c - Outer Switch Box
d - Inner Switch Box 51840
Plug Wire Routing - Port Side
b
a
51841
11652
a - Wires with Yellow Sleeves Are Connected to Outer Switch
Plug Wire Routing - Starboard Side
Box
b - Switch Boxes MUST BE Grounded to Engine
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2
B
51797
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DFI #4* #2 #2 #2 #2 #2 #2 #2 #2 #2 #0 #0 #0
Models
* = Standard (original) Cable Length and wire gage size.
22532
Hydrometer measures percentage of sulfuric acid in Specific gravity of electrolyte varies not only with
battery electrolyte in terms of specific gravity. As a percentage of acid in liquid but also with temperature.
battery drops from a charged to a discharged As temperature increases, electrolyte expands, so
condition, acid leaves the solution and enters the that specific gravity is reduced. As temperature
plates, causing a decrease in specific gravity of drops, electrolyte contracts, so that specific gravity
electrolyte. An indication of concentration of increases. Unless these variations in specific gravity
electrolyte is obtained with a hydrometer. are taken into account, specific gravity obtained by
hydrometer may not give a true indication of acid in
When using a hydrometer, observe the following electrolyte.
points:
1. Hydrometer must be clean (inside and out) to
insure an accurate reading.
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CAUTION
During service, only distilled water should be
added to the battery, not electrolyte.
Liquid level in cells should never be allowed to drop
below top of plates, as portion of plates exposed to
air may be permanently damaged with a resulting
loss in performance.
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TROUBLESHOOTING 40 AMP
ALTERNATOR SYSTEM
WARNING
Before connecting or disconnecting any
electrical connection, battery cables MUST BE
REMOVED from battery to prevent possible
personal injury or damage to equipment.
IMPORTANT: The charging system may be
connected to one or more batteries during these
tests. However, these batteries MUST BE fully
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a
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51797
a - 4 Locknuts
b - 4 Spacers (HIDDEN)
a - Regulators
4. Position coil/solenoid plate over attaching studs.
b - Screws Place trim ground lead (BLACK) onto bottom
stud.
2. Disconnect 2 YELLOW leads, 2 RED leads and 5. Secure plate, regulators and trim ground lead to
GRAY tach lead (if connected) from respective powerhead with locknuts. Torque nuts to 80 lb. in.
bullet connectors. (9.0 N·m).
3. Remove voltage regulator/rectifier from
powerhead.
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c
d
f
g
a - Starter Solenoid
b - RED Leads – Engine Harness from Upper Regulator to
Start Solenoid
c - Disconnect (and discard) Engine Harness RED Leads to
Lower Regulator
d - Upper Regulator
e - Lower Regulator
f - Jumper Wire (from kit)
g - RED Pigtail Cable (from kit) to Auxiliary Battery “+”
Terminal
h - BLACK Cable (from kit) Route from Auxiliary Battery “–”
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b
h
j
c
h
i
e
g
2 a
6 1
3
e
2
6 1
5 4 c
e - 20 Ampere Fuse
f - Starter Solenoid (89-96054)
g - Battery
TEST 1
Use an ohmmeter (Rx1 scale) and connect meter leads
between NEGATIVE (-) battery post and common pow-
erhead ground.
Test 2
a. Disconnect BLACK ground wire(s) from Test Point 2.
No voltage reading: b. Connect voltmeter between common engine ground and Test Point 2.
proceed to TEST 3. c. Turn ignition key to “Start” position.
TEST 4
a. Connect voltmeter between common 12 Volt Reading*
No voltage reading: engine ground and Test Point 4. Neutral start switch is open or YELLOW/RED
Proceed to TEST 5 b. Turn ignition key to “Start” position. wire is open between Test Points 4 and 3.
TEST 5
No voltage reading: Connect voltmeter between common 12 Volt Reading*
Proceed to Test 6. engine ground and Test Point 5 Defective ignition switch.
TEST 6
Check for voltage between common engine ground and Test Point 6.
*Battery Voltage
TEST 8
a. Reconnect BLACK cable (with YELLOW sleeve) to starter solenoid Test
Point 1.
b. Connect voltmeter between common engine ground and Test Point 7.
c. Turn ignition key to “Start” position.
No voltage reading:
Check BLACK cable (with YELLOW
12 Volt Reading*
sleeve) for poor connection or open circuit. If starter motor does not turn, check starter motor.
*Battery Voltage
CAUTION
Disconnect battery leads from battery before
removing starter.
1. Disconnect BLACK ground cable from starter. e
2. Disconnect BLACK (with YELLOW sleeve) cable
from starter.
3. Remove 4 bolts and upper and lower starter b
clamps. Lift starter from engine. a
51840
f - Lower clamp
11645
a - Rubber Collar e
b - Spacer (If Equipped)
e
3. Install starter to engine with starter clamps.
Make sure that black ground cable is fastened,
b
along with lower mounting bolts. Torque bolts to
210 lb. in. (23.5 N·m).
c
d
4. Reconnect yellow cable to positive (+) terminal 11656
on starter. a - Brush Holder
b - POSITIVE Brushes
5. Reconnect black ground cable to terminal on c - NEGATIVE Brushes
starter. d - POSITIVE Terminal
e - Bolts (Fasten NEGATIVE Brushes and Holder)
DISASSEMBLY
5. Remove armature (with drive end cap) from
1. Remove starter as outlined in “Starter Removal
starter frame.
and Installation”.
6. Remove locknut and remove drive assembly
2. Remove 2 through bolts from starter.
from armature shaft.
a
b 11646
a
a - Through Bolts
b - Commutator End Cap
follows:
a - Hold Armature Shaft with Wrench on Hex Portion of Drive
Assembly
CAUTION
Do not turn down the commutator excessively.
a. Resurface the commutator and undercut the
insulation between the commutator bars
1/32 in. (0.8mm) to the full width of the insu- 11669
lation and so that the undercut is flat.
b. Clean the commutator slots after
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undercutting.
a b
11675
11674
a - NEGATIVE (–) Brushes
Checking Positive Brushes and Terminal b - End Cap
Set ohmmeter to (R x 1 scale). Connect meter leads
between POSITIVE brushes. Meter must indicate full
continuity or zero resistance. If resistance is indi-
cated, inspect lead to brush and lead to POSITIVE
terminal solder connection. If connection cannot be
repaired, brushes must be replaced.
11673
a - POSITIVE (+) Brushes
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b
i
d
d
d h
d
b a 11656
a - POSITIVE (+)Brushes
e b - NEGATIVE (-) Brushes
c c - Brush Holder
f d - Bolts (Fasten NEGATIVE Brushes and Holder)
11658
a - Locknut
b - Spacer
c - Spring
d - Drive Assembly
e - Drive End Cap
f - Armature Shaft
g - Washer
11661
a - Brush Retainer Tool
b - Bushing (DO NOT over lubricate)
c c
b
1 3a
4
a
2 b
51809
a - 12-VOLT Supply
b - VOA Leads
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2
C
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Table of Contents
Page Page
Timing/Synchronizing/Adjusting . . . . . . . . . . . . 2C-1 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-7
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1 Electronic Fuel Injection Models . . . . . . . . . 2C-7
Carbureted Models . . . . . . . . . . . . . . . . . . 2C-1 Timing Pointer Adjustment . . . . . . . . . . . 2C-7
Electronic Fuel Injection Models . . . . . . 2C-2 Throttle Cam Adjustment . . . . . . . . . . . . . 2C-8
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-2 Static Idle Timing Adjustment
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-3 (Cranking Engine with Starter) . . . . . . 2C-9
Carburetor Models . . . . . . . . . . . . . . . . . . . . . 2C-3 Static Maximum Timing Adjustment
Timing Pointer Adjustment . . . . . . . . . . . 2C-3 (Cranking Engine With Starter) . . . . 2C-10
Carburetor Synchronization . . . . . . . . . . 2C-3 Maximum Throttle . . . . . . . . . . . . . . . . . . 2C-10
Carburetor/Oil Pump Synchronization . . 2C-4 Maximum Timing Adjustment for
Timing Adjustments . . . . . . . . . . . . . . . . . 2C-5 225 Pro Max/Super Magnum . . . . . . . . 2C-10
Maximum Timing Adjustment . . . . . . . . . 2C-5 Throttle Position Sensor (TPS)
Primary Pickup Timing Adjustment . . . . 2C-6 Adjustment . . . . . . . . . . . . . . . . . . . . . 2C-11
Idle Speed Adjustment . . . . . . . . . . . . . . . 2C-6 Idle Timing (Engine Running) . . . . . . . . 2C-12
Idle Adjustment . . . . . . . . . . . . . . . . . . . . 2C-12
Throttle Valve/Oil Pump
Synchronization . . . . . . . . . . . . . . . . . . 2C-13
Throttle Cable Installation . . . . . . . . . . . 2C-13
Detonation Control (200 Model) . . . . . . 2C-14
Maximum Timing Adjustment
(Engine Running) . . . . . . . . . . . . . . . . 2C-14
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a
c
a
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c
.010 – .015
(0.25mm – 0.38mm)
b
a
a b
54389
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CAUTION CAUTION
Engine may be timed while cranking engine with Models equipped with Idle Stabilizer Shift Kit
starter motor. To prevent engine from starting Accessory (P/N 87-814281A1), excluding
when being cranked, all spark plugs must be re- Mercury XR6, Mariner Magnum llI and 175 require
moved. maximum timing at cranking speed in neutral to
be retarded 3° from specifications listed on page
1. Insert Spark Gap Tool (91-63998A1) into each
2C-1. Note, Stabilizer Shift Kit is standard on XR6,
spark plug boot and attach alligator clips to good
engine ground Magnum llI and 175 models and already has
retarded timing degrees calibrated into
2. Disconnect remote fuel line from engine. specifications listed on page 2C-1.
3. Connect remote control electrical harness to 1. Connect timing light to No 1 spark plug lead (TOP
engine wiring harness. STARBOARD BANK).
4. Remove throttle cable barrel from barrel retainer. 2. With engine in neutral, move throttle lever to
IMPORTANT: If trigger link rod was disassembled place maximum spark advance screw (a) against
verify that 11/16 in. (17.5mm) length is retained. stop. Crank engine with starter motor and adjust
maximum spark advance timing mark (see
11/16 in.
(17.5mm)
specifications on page 2C-1) with timing pointer.
Due to the spark advance/retardation
characteristics of this ignition system, this
cranking speed adjustment will increase (XR6,
Magnum llI and 175) or decrease (135,150 and
200) timing at 5000 RPM and above. Retighten
jam nut on adjustment screw.
a
5. Disconnect and isolate white/black lead (a)
(starboard side of engine) from 3 wire stabilizer
box at bullet connector (b).
a
b
WARNING
While cranking outboard, keep clear of propeller
as it may rotate.
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CAUTION
Engine idle RPM must NEVER EXCEED 750 RPM
in gear.
NOTE: All timing adjustments made to outboard
under cranking speed conditions should be verified 3. With end of throttle cable connected to throttle
with outboard running and adjustments made if lever, hold throttle lever against idle stop. Adjust
necessary. This is due to advance characteristics of throttle cable barrel to slip into barrel retainer on
individual ignition systems. cable anchor bracket with a very light preload of
throttle lever against idle stop. Lock barrel in
2. Remove timing light from No. 1 spark plug lead.
place.
3. Remove spark gap tools (91-63998A1) from
4. Check preload on throttle cable by placing a thin
each spark plug boot.
piece of paper between idle stop screw and idle
4. Install all spark plugs into cylinder heads. Torque stop. Preload is correct when paper can be
spark plugs to 20 Ib. ft. (27.0 N·m) and attach removed without tearing but has some drag on it.
spark plug leads to spark plugs. Readjust cable barrel, if necessary.
5. Reconnect WHITE/BLACK lead (a) (starboard IMPORTANT: Excessive preload on throttle cable
side of engine) from idle stabilizer at bullet will cause difficulty when shifting from forward
connector (b). to neutral. (Readjust throttle cable barrel, if
necessary.)
a
NOTE: Carburetors are equipped with idle mixture
adjustment screws. See carburetor specifications for
mixture screw adjustment.
b NOTE: If sufficient throttle cable barrel adjustment is
not available, check for correct installation of link rod
between the throttle lever and throttle cam. Each end
of this link rod must be threaded into its plastic barrel
until it bottoms against the throttle lever or throttle
cam casting, then turned out only far enough to
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c
d
Adjustments
WARNING
Engine could start when turning flywheel to
check timing pointer adjustment. Remove all
spark plugs from engine to prevent engine from 5. Remove dial indicator from cylinder.
starting.
1. Remove all spark plugs and install Dial Indicator
(91-58222A1 ) into No. 1 cylinder (top cylinder,
starboard bank).
2. Turn flywheel in a clockwise direction until No. 1
piston is at top dead center (TDC). Set dial indica-
tor at “O” (zero) and tighten indicator set screw.
3. Turn flywheel counterclockwise until dial
indicator needle is approximately 1/4 turn beyond
.462 in., then turn flywheel clockwise so that dial
indicator reads .462 in. (11.7mm) exactly.
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5
1
4
7
6
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CAUTION
Models equipped with Idle Stabilizer Shift Kit
Accessory (P/N 87-814281A1), excluding 175 EFI 3 1
models, require maximum timing (cranking
speed) to be retarded 3° from specifications
listed on page 2C-2. Note, Stabilizer Shift Kit is
standard on 175 EFI models and already has
retarded timing degrees calibrated into
specifications listed on page 2C-2.
Idle Stabilizer Shift System
b
c
d
50707
a - Inner Switch Box
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5
MAXIMUM TIMING ADJUSTMENT FOR 225 PRO
2
MAX/SUPER MAGNUM
IMPORTANT: Use this procedure for 225 Pro Max/
Super Magnum models only.
3 1 1. Connect timing light to No 1 spark plug lead (TOP
STARBOARD BANK).
MAXIMUM THROTTLE
IMPORTANT: Do not use this procedure for 225 WARNING
Pro Max/Super Magnum models. While cranking engine, keep clear of propeller, as
1. Hold throttle arm (1) against full throttle stop it may rotate.
screw (2). Adjust full throttle stop screw to allow 2. Start the engine and adjust the throttle arm (1) to
full throttle valve opening, while maintaining a maintain 3000 RPM (using a shop tachometer).
clearance between arm (3) of throttle shaft and
stop (4) on induction box. Tighten locknut (5). NOTE: Ensure that the maximum spark advance
screw (2) is resting against the stop (3).
2. Check for slight free play (roller lifter from cam)
between roller and cam at full throttle to prevent 3. Adjust the maximum spark advance screw to ob-
linkage from binding. Readjust full throttle stop tain 23! BTDC with the timing light.
screw, if necessary.
2 3
1
4. Tighten the locknut and recheck the timing. Re-
adjust if necessary.
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a
2
IDLE ADJUSTMENT
1. With outboard in water, start and allow to warm
51785 up.
a - Head Temperature Sensor Leads
2. Loosen cam follower screw, allowing free
IDLE TIMING (ENGINE RUNNING) movement of cam. Hold throttle arm against idle
stop. Adjust idle speed screw (1) by increasing or
1. WHITE/BLACK lead from idle stabilizer must be decreasing air valve opening to attain
disconnected. appropriate setting.
2. With engine in water, start engine and allow to
warm up.
3. Shift engine into “FORWARD” gear.
4. Hold throttle arm (1) against idle stop (throttle
cable barrel removed from barrel retainer).
Adjust idle timing screw (2) to attain appropriate 1
setting. Tighten locknut (3).
3 1
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2 3
1
3
3 2
3. Reconnect WHITE/BLUE lead to detonation
sensor (200 model).
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D
2
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Table of Contents
Page Page
Wiring Diagram 135/150 . . . . . . . . . . . . . . . . . . 2D-1 Commander 2000 Side Mount Remote
Wiring Diagram XR6/MAG III/175 . . . . . . . . . . . 2D-2 Control (Power Trim/Tilt Electric Start with
Wiring Diagram 200 . . . . . . . . . . . . . . . . . . . . . . 2D-3 Warning Horn) Wiring Diagram . . . . . . . . . . 2D-19
Wiring Diagram 200 Carb Serial # 0D077248 Oil Level Gauge Wiring Diagram . . . . . . . . . . 2D-20
thru Serial # 0D122746 . . . . . . . . . . . . . . . . . 2D-4 Visual Warning Wiring Diagram . . . . . . . . . . . 2D-21
Wiring Diagram 150/175 EFI . . . . . . . . . . . . . . . 2D-5 Instrument/Lanyard Stop Switch Wiring
Wiring Diagram 200 EFI . . . . . . . . . . . . . . . . . . . 2D-6 Diagram (Dual Outboard) . . . . . . . . . . . . . . . 2D-22
Wiring Diagram 200 Pro Max/Super Magnum Instrument/Lanyard Stop Switch Wiring
(Early Model with Detonation Module) . . . . . 2D-7 Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-24
Wiring Diagram 150/200/225 QSI Gauge Wiring Diagrams . . . . . . . . . . . . . . 2D-25
Pro Max/Super Magnum . . . . . . . . . . . . . . . . 2D-8 Tachometer Wiring Diagram . . . . . . . . . . . . 2D-25
Wiring Diagram105/140 Jet . . . . . . . . . . . . . . . . 2D-9 Water Temperature Gauge . . . . . . . . . . . . . 2D-25
Power Trim Wiring Diagram with Solenoids . 2D-10 Oil Level Gauge Wiring . . . . . . . . . . . . . . . . 2D-26
Power Trim Wiring Diagram with Relays . . . . 2D-11 Engine Synchronizer Wiring Diagram . . . . 2D-27
Instrument Wiring Connections . . . . . . . . . . . . 2D-12 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-27
Commander 3000 Classic Panel Remote Multi-Function Gauge . . . . . . . . . . . . . . . . . . . . 2D-28
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-13 Panel Mount Remote Control Wiring
Commander 3000 Panel Remote Control . . . 2D-14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-29
Commander Side Mount Remote Control Side Mount Remote Control Wiring
(Power Trim/Tilt Electric Start with Warning Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-30
Horn) Wiring Diagram . . . . . . . . . . . . . . . . . . 2D-18
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2D-0 - ELECTRICAL
2D - ELECTRICAL AND IGNITION 90-824052R3 JUNE 2002
Wiring Diagram 135/150
BLK = BLACK
BLU = BLUE 2
BRN = BROWN 1
GRY = GRAY
GRN = GREEN
PUR = PURPLE
RED = RED 24
TAN = TAN 3
VIO = VIOLET
WHT = WHITE
YEL = YELLOW
5 4
12
6 14 7
23
25
13
14
22
15
21
9
17
20 16
18 10
19
16 11
1 - 40 Ampere Stator 14- Terminal Block
2 - Starter 15- Water Temperature Switch
3 - Lubalert 16- Voltage Regulator
4 - Oil Tank Cap 17- Coil # 1
5 - Idle Stabilizer 18- Coil # 3
6 - Rotational Sensor 19- Coil # 5
7 - Enrichment Valve 20- Coil # 6
8 - Temperature Gauge Sender 21- Coil # 4
9 - Control Box Instrument Connector 22- Coil # 2
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5
4
12
6
14 7
8
23
13 27
14
15
22
21
9
17
16 10
18 11
20
19
16
1 - 40 Ampere Stator 17- Coil # 1
2 - Starter 18- Coil # 3
3 - Lubalert 19- Coil # 5
4 - Oil Tank Cap 20- Coil # 6
5 - Idle Stabilizer 21- Coil # 4
6 - Rotational Sensor 22- Coil # 2
7 - Enrichment Valve 23- Inner Switch Box
8 - Temperature Gauge Sender 24- Trigger
9 - Control Box Instrument Connector 25- Resister
10- Engine Harness 26- Shift Switch
11- 12V Battery 27- 20 Ampere Fuse
12- Starter Solenoid
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BLK = BLACK 2
BLU = BLUE 1
BRN = BROWN
GRY = GRAY
GRN = GREEN
PUR = PURPLE
3
RED = RED
TAN = TAN 24
VIO = VIOLET
WHT = WHITE
YEL = YELLOW 5
4
12
6
7
14
8
23
25
13
14
22
21 15
9
17
16 10
18
20
19
16 11
3
23
22
5 4
8
6
21
14 9
20
19 13
17
18 12
16
11
10
15
12 54963
23
1
2
24 3 4
5
6
21
25 7
22 10
8
26
27 20
17
28 9
19 11
29 16
12
30 18 13
14 15
54352
32 1
2 6
4 5
25 7
8
3
26 9
24 12
23 10
27
11
28 22
19
29
21 13
18
30
14
31 20 15
16 17
BLK = BLACK
BLU = BLUE
54353
BRN = BROWN
GRY = GRAY
GRN = GREEN
PUR = PURPLE
RED = RED
TAN = TAN
VIO = VIOLET
WHT = WHITE
YEL = YELLOW
32 1
2 6
TAN/BLU
4 5
25 7
8
3
26 9
24 12
23 10
27
11
28 22
19
29
21 13
18
30
14
31 20 15
16 17 BLK = BLACK
BLU = BLUE
BRN = BROWN
GRY = GRAY 54353
GRN = GREEN
PUR = PURPLE
RED = RED
TAN = TAN
VIO = VIOLET
WHT = WHITE
YEL = YELLOW
23
1 TAN/BLU
2
24 3 4
5
6
21
25 7
22 10
8
26
27 20
17
28 9
19 11
29 16
12
30 18 13
14 15
54352
8
17
9
18
12
16
22
15
19
23
14
20
24
21 14 11
10
f
i
52203
c
b
a
h
j i
h
d
g
a
b c
mercv6carb_1
Figure 2 To 12V
With Light Switch · · e
·I
h
d
g
a b
c
f
mercv6carb_2
51819
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
< F R >
RED
PURPLE
GREEN
a
BLK = Black
BLU = Blue
BRN = Brown
GRY = Gray
GRN = Green
ORN = Orange
PNK = Pink
PUR = Purple
RED = Red
TAN = Tan
WHT = White
YEL = Yellow
LIT = Light
DRK = Dark
RED
PURPLE
GREEN
a
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1 3
2 95
13
10 9
12 95
11
95
8 21
5 95
18
16
6
19
95
95
20 24
95
15
22
28 14 17 23
95
7
17
7 23
25
7
27
26
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h
BLK = Black
g BLU = Blue
BRN = Brown
GRY = Gray
GRN = Green
ORN = Orange
PNK = Pink
PUR = Purple
RED = Red
i Tan = Tan
WHT = White
YEL = Yellow
LIT = Light
DRK = Dark
f
e a d
c
k
l 24072
f - Warning Horn
g - Trim/Tilt Switch
h - Wire Retainer
i - Control Handle
d
a f
e
b
c
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
23891
a - Ignition/Choke Switch
b - Emergency Stop Switch
c - Neutral Start Switch
d - Tachometer/Accessories Harness Connector
e - Wiring Harness Connector
f - Warning Horn
g - Trim/Tilt Switch
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d f
c
g
q
r
p s h
o t
m
l
k i
2 3
4
6
5
14
7
7
8 9
11
10
12
8
10
10
8
13
d k d
c b
g
l
BLK=BLACK
BATT GND d
BLU=BLUE
SENDER
BRN=BROWN
GRN=GREEN
GRY=GRAY e
PUR=PURPLE a
RED=RED
TAN=TAN
WHT=WHITE
YEL=YELLOW
o
n
h
BATT GND
i
SENDER
a
e
j
f
k - Lanyard Switch (Isolation) Diode n - Connect Wires together with Screw and Nut (4 Places);
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BLK=BLACK
BLU=BLUE
BRN=BROWN
GRN=GREEN
GRY=GRAY d
PUR=PURPLE
RED=RED
TAN=TAN e
WHT=WHITE
YEL=YELLOW
c a
b
j
k
h
i
52204
a -
Ignition/Choke Switch
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
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j -
Connect Wires Together w/Screw and Nut (2 Places); Ap-
ply Liquid Neoprene to Connections and Slide Rubber
Sleeve over each Connection.
k - Lead to Optional Visual Warning Kit
WIRING DIAGRAM A
Tachometer Wiring Diagram Use this wiring diagram when using a separate light
Tachometer dial on back side of case must be set to switch for instrument lighting.
position number 4. b c
WIRING DIAGRAM A
Use this wiring diagram when using a separate light
switch for instrument lighting. d
a
b
c
a SEND
d
e
a - Connect to + 12 Volt
b - +12 Volt Light Switch Wire
c - Position Light Bulb to the Switched Position
d - Connect to NEGATIVE (–) Ground
e - Connect to TAN Lead located at the Tachometer Recep-
tacle on Commander Side Mount Remote Control or TAN
51106 Lead coming from Accessory Ignition/Choke Assembly.
a - Connect to + 12 Volt
b - +12 Volt Light Switch Wire WIRING DIAGRAM B
c - Position Light Bulb to the Switched Position
d - Connect to NEGATIVE (–) Ground Use this wiring diagram when instrument lighting is
wired directly to the ignition key switch. (Instrument
WIRING DIAGRAM B lights are on when ignition key is turned on.)
Use this wiring diagram when instrument lighting is b
wired directly to the ignition key switch. (Instrument
lights are on when ignition key switch is turned on.)
b c
a
a
c
SEND
d 51105
51106 a - Connect to +12 Volt
b - Position Light Bulb to the Unswitched Position
a - Connect to +12 Volt c - Connect to NEGATIVE (–) Ground
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b - Position Light Bulb to the Unswitched Position d - Connect to TAN Lead located at the Tachometer Recep-
c - Connect to NEGATIVE (–) Ground tacle on Commander Side Mount Remote Control or TAN
Lead coming from Accessory Ignition/Choke Assembly
b b
28086
a - Lead from Temperature Sender
b - Engine/Remote Control Harness
51112
a - Position Light Bulb to the Unswitched Position
Oil Level Gauge Wiring b - Sender
51109
a - +12 Volt Light Switch Wire
b - Position Light Bulb to the Switched Position
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51108
a - Connect to +12 Volt
b - Connect to NEGATIVE (–) Ground
GRY=GRAY
WHT=WHITE
BLK=BLACK d
PUR=PURPLE
SEND 51107
a - Tachometer Starboard Engine
b - Synchronizer Gauge
c - Tachometer Port Engine
d - Synchronizer Module
GRY=GRAY
WHT=WHITE
BLK=BLACK d
PUR=PURPLE 51107
Maintenance
Clean gauge by washing with fresh water to remove
51106 sand and salt deposits. Wipe off with a soft cloth
a - Position Light Bulb to the Switched Position moistened with water. The gauge may be scored or
b - Sender
damaged if wiped with abrasive material (sand,
Synchronizer wiring can be accomplished two saline or detergent compounds, etc.) or washed with
different ways as an option to the user. solvents such as trichloroethylene, turpentine, etc.
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a
Outboard Multi-Function Gauge
Setting
Model Dip Switch Setting
Test Display (All)
1 2 3 4
a Open
275 hp (3.4 Litre) Out-
1 2 3 4
boards
1 2 3 4 (single engine)
b
Open
Open 135-250 hp Outboards
52095 1 2 3 4
(single engine)
a - “Dip Switch” (shown in test position)
b - Black Dot - Switch in “Open” Position
s
k
l o
j n
p
m
t
q
BLK = Black
BLU = Blue
BRN = Brown
GRY = Gray
GRN = Green
ORN = Orange
PNK = Pink
PUR = Purple
RED = Red
TAN = Tan
25 Liquid Neoprene (92-25711--2)
WHT = White
YEL = Yellow
LIT = Light
DRK = Dark
t - To Engine
u - Neutral Safety Switch Lead
a b
g
e h
c d
j
f
r
o p
k m
i
n
25
s
l
q
BLK = Black
BLU = Blue
BRN = Brown
GRY = Gray
GRN = Green
ORN = Orange
PNK = Pink
PUR = Purple
25 Liquid Neoprene (92-25711--2) RED = Red
TAN = Tan
WHT = White
YEL = Yellow
LIT = Light
DRK = Dark
3
A
FUEL PUMP
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Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1
Fuel Pump Pressure @ W.O.T. . . . . . . . . . . 3A-1
Fuel Pump Pressure @ Idle . . . . . . . . . . . . . 3A-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-2
General Information . . . . . . . . . . . . . . . . . . . . 3A-4
Fuel Pump Description/Operation . . . . . 3A-4
Checking for Restricted Fuel Flow
Caused by Anti-Siphon Valves . . . . . . 3A-4
Testing Fuel Pump . . . . . . . . . . . . . . . . . . . . . 3A-5
Checking Fuel Pump Lift (Vacuum) . . . . . . . . . 3A-5
Vacuum Test Troubleshooting . . . . . . . . . . . 3A-6
Fuel Pump Removal/Disassembly . . . . . . . 3A-6
Cleaning/Inspection . . . . . . . . . . . . . . . . . . . . 3A-6
Reassembly/lnstallation . . . . . . . . . . . . . . . . 3A-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-7
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Special Tools
Fuel Pressure Gauge 91-16850
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!!
19
!* !
#
$ !'
$
!(
# % "
!&
"*
&
'
!(
!"
!# !$
( 19
!) !%
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Checking Fuel Pump Lift Fuel pump vacuum and air bubbles in the fuel supply
can be checked with a vacuum gauge, a t-fitting and
(Vacuum) a clear piece of fuel hose. Connect the clear hose
between the inlet fitting on the pulse driven fuel pump
The square fuel pump is designed to lift fuel and the vacuum gauge t-fitting, keeping the t-fitting
(vertically) about 60 in. (1524 mm) if there are no as close as possible to the pump. Connect the fuel
other restrictions in the system using a fuel hose that line from the fuel tank to the remaining connection on
is 5/16 in. (7.9 mm) minimum diameter. As the t-fitting.
restrictions are added, such as filters, fittings, valves,
etc., the amount of fuel pump lift decreases.
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b
a
a - Clear Hose b
b - T-fitting
c - Vacuum Gauge (obtain locally)
d
Vacuum Test Troubleshooting
This test is normally performed at an idle speed. As e
engine rpm increases, there will be a slight
increase in vacuum. The increase should not c
exceed specification. a
50161-1
Reassembly/lnstallation
50161-2
3. With retainer installed in pump body, break
ASSEMBLY
retainer rod from retainer by bending sideways.
1. Insert retainer thru plastic disc and rubber check
valve.
a
b
b
a
23601-2
a - Rod
23601-1 b - Retainer Cap
a - Retainer
b - Plastic Disc
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a
b
23601-3
a - Rod
b - Retainer Cap 50161-1
50161
a - Boost Spring
b - Pump Body
c - Cap
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3
B
54350
CARBURETORS
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Table of Contents
Page Page
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-1 WMV Carburetor Fuel Circuit Description . . . 3B-29
WMH 1,2,3,4,5,6,7,8,9,10,11 Carburetor Float Bowl Circuit . . . . . . . . . . . . . . . . . . . . . 3B-29
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-2 Idle Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-29
WMH 1,2,3,4,5,6,7,8,9,10,11 Carburetor Cold Start Circuit . . . . . . . . . . . . . . . . . . . . . 3B-30
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-4 Off-Idle Circuit . . . . . . . . . . . . . . . . . . . . . . . . 3B-30
WMH 1,2,3,4,5,6,7,8,9,10,11 Carburetor Main Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-31
Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-5 Back Draft Circuit . . . . . . . . . . . . . . . . . . . . . 3B-31
WMH 12,13,14,15,16,27 Carburetor Carburetor Placement and Jet Location for
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-6 Each Cylinder (WMV Carburetors) . . . . 3B-32
WMH 12,13,14,15,16,27 Carburetor High Altitude Recommendations . . . . . . . . 3B-33
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-8 High Altitude Jet Chart . . . . . . . . . . . . . . . . 3B-34
WMH 12,13,14,15,16,27 Carburetor Enrichener System Description . . . . . . . . . 3B-35
Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-9 Manual Operation of Enrichener Valve 3B-35
WMH 21,22,23,25,26,28 Carburetor Enrichener Valve Test . . . . . . . . . . . . . . 3B-36
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-10 Enrichener Valve Replacement . . . . . . 3B-36
WMH 21,22,23,25,26,28 Carburetor Removing Carburetor(s) from Engine . . . . . . 3B-37
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 3B-12 Carburetor Disassembly . . . . . . . . . . . . . . . . . . 3B-37
WMH 21,22,23,25,26,28 Carburetor Carburetor Jet Removal . . . . . . . . . . . . . . . 3B-37
Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-13 Fuel Bowl Removal and Disassembly . . . 3B-39
WMH 30,31,32,33,34,39 Carburetor Throttle Shaft Component Removal . . 3B-40
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-14 Carburetor Cleaning and Inspection . . . . . 3B-40
WMH 30,31,32,33,34,39 Carburetor Carburetor Reassembly . . . . . . . . . . . . . . . 3B-40
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 3B-16 Throttle Shaft Component Installation . . . 3B-40
WMH 30,31,32,33,34,39 Carburetor Fuel Bowl Reassembly . . . . . . . . . . . . . . . . 3B-41
Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-17 Carburetor Jet Installation . . . . . . . . . . . . . 3B-42
WMV 1/1A, 2/2A, 3/3A, 4/4A, 5/5A . . . . . . . . . 3B-18 Installing Carburetor(s) to Engine . . . . . . . 3B-43
WMV 1,2,3,4,5 Carburetor Specifications . . . 3B-22 Fuel Line and Primer Bulb Assembly . . . . . . . 3B-44
WMV 1,2,3,4,5 Carburetor Front View . . . . . . 3B-22 Maintenance . . . . . . . . . . . . . . . . . . . . . . 3B-44
Fuel System - Troubleshooting . . . . . . . . . . . . 3B-23 Fuel Line Clamp Removal and
General Information . . . . . . . . . . . . . . . . . . . 3B-23 Installation . . . . . . . . . . . . . . . . . . . . . . 3B-45
Reed Valve Leak Test . . . . . . . . . . . . . . . . . . . . 3B-25
Tools Needed for Test-- . . . . . . . . . . . . . 3B-25
Thermal Air Valve Circuit Description . . . . 3B-26
WMH Carburetor Fuel Circuit Description . . . 3B-26
Idle Circuit Description . . . . . . . . . . . . . . . . 3B-26
Idle Circuit Adjustments . . . . . . . . . . . . . 3B-26
Off-ldle Circuit Description . . . . . . . . . . . . . 3B-27
Back Draft Circuit Description . . . . . . . . . . 3B-27
High Speed Fuel Circuit Description . . . . . 3B-27
High Speed Fuel Circuit Adjustments . 3B-27
Carburetor Placement . . . . . . . . . . . . . . . . . 3B-28
Jet Location For Each Cylinder . . . . . . 3B-28
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10
8
4
13
12
11
1 6
5 7
3
2
14
15
16 17
18
19
25
24
21
26
27 20
22
23
24
25
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f
c d e
50756
a b
c c
d d
51861
a - Idle Air Jet
b - Back Draft Vent Jet
c - Progression Jet
d - Main Jet
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8
10
4
13
12
11
3
6
2 5 7
14
16 17 15
18
19
25
24
21
26
20
27
23
22
24
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25
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f
c d e
50756
a - Fuel Mixture Adjustment
b - Screw Cap (two)
c - Welch Plug (two)
d - Air Trim Screw (two) - Apply Loctite 271
e - Idle Air Bleed Jet
f - Thermal Air Valve Air Inlet
g - Emulsion Tube
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a b
c c
d d
51863
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10
4
13
12
8 11
3
6
2 5 7
14
16 17 15
18
19
25
24
21
26
20
27
23 22
24
25
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f
c d e
50756
a - Fuel Mixture Adjustment
b - Screw Cap (two)
c - Welch Plug (two)
d - Air Trim Screw (two) - Apply Loctite 271
e - Idle Air Bleed Jet
f - Thermal Air Valve Air Inlet
g - Emulsion Tube
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a b
c c
d d
51863
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8
10
13
12
11
6
3
2 7
1 5
14
16 17 15
18
19
25
21 24
26
20
27 22
23
24
25
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52154
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f
c d e
50756
a - Fuel Mixture Adjustment
b - Screw Cap (two)
c - Welch Plug (two)
d - Air Trim Screw (two) - Apply Loctite 271
e - Idle Air Bleed Jet
f - Thermal Air Valve Air Inlet
g - Emulsion Tube
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a b
c c
d d
51863
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c c
Problem: Engine Turns Over But Will Not Start Or Starts Hard When Cold.
Possible Cause Corrective Action
Improper starting procedure used. Check proper starting procedure, as outlined in “Op-
eration and Maintenance Manual.”
Fuel tank empty or too low. Improperly mixed fuel. Check fuel in fuel tank and replace or add whichever
Contaminants (water, dirt, etc.) in fuel is necessary.
Fuel tank air vent closed or restricted. Check air vent on fuel tank. Air vent must be open
all-the-way and free from any contaminants.
A pinched, cut or restricted fuel line. Also loose fuel Check all fuel lines and replace as needed. Check
line connection. and tighten all fuel line connections.
Dirty or restricted fuel filter. Check and replace or clean all fuel filters.
Low fuel pump pressure. Refer to Section 3A.
An anti-siphon valve. Refer to “Checking for Restricted Fuel Flow” in this
section.
Choke solenoid, or enrichment valve not operating. Check choke solenoid or valve, and electrical wiring
to solenoid or valve. Replace if necessary.
A needle and seat (in carburetor) that is either stuck Refer to “Carburetor Disassembly” in this section.
open or closed. Open=Flooding - Closed=Starving
Improper carburetor jets, restricted jet or idle mixture Refer to “Carburetor Adjustments” in this section.
screw out of adjustment.
Improper carburetor float level. Refer to “Carburetor Adjustments” in this section.
Problem: Engine Idles Rough and Stalls.
Problem: Engine Hesitates Upon Acceleration.
Problem: Engine Runs Uneven or Surges.
Possible Cause Corrective Action
Improperly mixed fuel. Contaminants (water, dirt, Check fuel in fuel tank and replace if necessary.
etc.) in fuel.
Fuel tank air vent closed or restricted. Check air vent on fuel tank. Air vent must be open
all-the-way and free from restrictions.
A pinched, cut or restricted fuel line. Also loose fuel Check all fuel lines and replace as needed. Check
line connection. and tighten all fuel line connections.
A dirty or restricted fuel filter. Check and replace or clean all fuel filters.
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Thermal relief valve not functioning. Stuck Open: Poor cold start characteristics.
Stuck Closed: Over rich at idle. Replace if neces-
sary.
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Fitting Location
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f c e
d
50756
a - Fuel Mixture Adjustment
b - Screw Cap (two)
c - Welch Plug (two)
d - Air Trim Screw (two) - Apply Loctite 271
e - Idle Air Bleed Jet
f - Thermal Air Valve Air Inlet
51863 g - Emulsion Tube
a - Thermal Air Valve
The idle circuit is independent of progression and
main circuits. The idle circuit consists of externally
The thermal air valve circuit functions as an air adjustable fuel mixture screws, idle air bleed jet, and
restrictor for the idle circuit which is controlled by a factory set air trim screws located beneath welch
thermal open/close valve monitoring engine plugs.
temperature. The valve is located on the starboard
cylinder head below no. 3 spark plug. When the
IDLE CIRCUIT ADJUSTMENTS
engine temperature is below 100° F (38° C) the
thermal air valve is closed. When a cold engine is a. Fuel mixture screws (2 per carb.) - When
running, the thermal air valve restricts air to the idle adjusting fuel mixture screws all screws must
circuit causing the fuel mixture to be richer. When the be turned the same amount and the same
engine warms sufficiently, the thermal valve opens direction for engine to operate efficiently at
allowing required fuel/air mixture for efficient idle speeds. DO NOT remove mixture screw
operation. caps to further richen or lean fuel flow.
Clockwise direction - leans mixture
Counterclockwise direction - richens mixture
NOTE: If caps are removed from mixture screws and
screws are removed for carburetor cleaning refer to
“IMPORTANT” preceding.
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c c e
f c
d
e
f
50756
a - Carburetor Body
b - Off-Idle Air Jet a a
c - Off-Idle Discharge Holes Front View
d - Throttle Shutter
b
50755
e - Off-Idle Tube
f - Back Draft Circuit Port (Port Bore Only) a - Fuel Bowl
b - Main Fuel Jet
The off-idle fuel flow circuit is controlled by an off-idle c - Main Discharge Tube
air jet located in each carburetor bore. Each venturi d - Float
has one off-idle tube and one off-idle air jet. The e - Main Discharge Tube Air Inlet
f - Cross Hole Vents
circuit functions at off-idle speeds until full throttle
operation occurs. The high speed fuel flow is controlled by the main
(high speed) jets and are located in the fuel bowl. A
fuel/air mixture is drawn from the fuel bowl thru the
main discharge tubes during full throttle operation.
becomes richer.
Middle
12-2 Cylinder
WMH Cylinder
#4 #3
Bottom
12-3 Cylinder
WMH Cylinder
#6 #5
51863
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l - Throttle Plate
m- Off-Idle Ports
n - Off-Idle Passage
a b
b
c
f c
h d d
i
g
Key Key
Air Air
Fuel e Fuel
g
e
f NOTE: Fuel Flow Not Shown For Clarity
a - From Open Thermal Air Valve a - Back Draft Port
b - Air Flow b - Back Draft Jet
c - Venturi c - Air Flow
d - Main Discharge Air Inlet Tube d - Main Discharge Tube
e - Cross Holes e - Fuel Bowl
f - Main Fuel Well f - Fuel Bowl Vent Passage
g - Main Fuel Jet g - Throttle Plate
h - Main Discharge Nozzle
i - Throttle Plate At partial throttle settings, the back draft circuit leans
out the mixture for increased fuel economy. The back
As the throttle plate rotates past the off-idle ports, the draft circuit uses the float bowl vent circuit and bowl
low pressure area extends to the main discharge vent jet to lean out the air/fuel mixture. The bowl vent
nozzle. In addition, the increased air flow through the jet limits the amount of air entering the float bowl vent
carburetor bore creates a low pressure area inside circuit. With the throttle plate positioned correctly, the
the venturi. These combined forces create a strong low pressure area is exposed to the back draft port
suction over the main discharge tube. Fuel flows: inside the carburetor bore. The float bowl vent circuit
1. Through the main fuel jet into the main fuel well. is connected by passages to the back draft port. The
low pressure area pulls air out of the bowl vent circuit.
2. Up the main discharge nozzle, Due to the size of the vent jet and the air loss through
3. Into the venturi. the back draft port, the air pressure on the fuel inside
the fuel bowl is lowered to below atmospheric pres-
Air is mixed with the fuel to make it lighter, air enters sure. Lower pressure on the fuel inside the float bowl,
the main fuel well through the main discharge air inlet lowers the amount of fuel being forced out of the main
tube. Cross holes are drilled in the main discharge discharge tube.
tube, allowing the air to mix with the fuel inside the
main well. As the throttle plate continues to open,
additional fuel is drawn out of the main discharge
tube, exposing additional cross holes. At full throttle,
the fuel mixture is controlled by the size of the main
fuel jet.
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TOP
Cylinder Cylinder
#2 #1
MIDDLE
Cylinder Cylinder
#4 #3
BOTTOM
Cylinder Cylinder
#6 #5
54349
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NOTE: Thread size for V-6 model carburetor main, idle air and back draft jets are 10-32
NOTE: Thread size for V-6 model carburetor progression jets are 8-32
Feet 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000
Meter 304.8 609.6 914.4 1219.2 1524 1828.8 2133.6 2438.4 2743.2 3048 3352.8 3657.6
Jet Size
0.034 0.034 0.034 0.032 0.032 0.032 0.032 0.032 0.032 0.030 0.030 0.030 0.030
0.036 0.036 0.036 0.034 0.034 0.034 0.034 0.034 0.032 0.032 0.032 0.032 0.032
0.038 0.038 0.038 0.036 0.036 0.036 0.036 0.036 0.034 0.034 0.034 0.034 0.034
0.040 0.040 0.040 0.038 0.038 0.038 0.038 0.038 0.036 0.036 0.036 0.036 0.034
0.042 0.042 0.042 0.040 0.040 0.040 0.040 0.038 0.038 0.038 0.038 0.038 0.036
0.044 0.044 0.044 0.042 0.042 0.042 0.042 0.040 0.040 0.040 0.040 0.038 0.038
0.046 0.046 0.046 0.044 0.044 0.044 0.044 0.042 0.042 0.042 0.042 0.040 0.040
0.048 0.048 0.048 0.046 0.046 0.046 0.046 0.044 0.044 0.044 0.042 0.042 0.042
0.050 0.050 0.050 0.048 0.048 0.048 0.046 0.046 0.046 0.046 0.044 0.044 0.044
0.052 0.052 0.050 0.050 0.050 0.050 0.048 0.048 0.048 0.048 0.046 0.046 0.046
0.054 0.054 0.052 0.052 0.052 0.052 0.050 0.050 0.050 0.048 0.048 0.048 0.048
0.056 0.056 0.054 0.054 0.054 0.054 0.052 0.052 0.052 0.050 0.050 0.050 0.048
0.058 0.058 0.056 0.056 0.056 0.056 0.054 0.054 0.054 0.052 0.052 0.052 0.050
0.060 0.060 0.058 0.058 0.058 0.056 0.056 0.056 0.054 0.054 0.054 0.052 0.052
0.062 0.062 0.060 0.060 0.060 0.058 0.058 0.058 0.056 0.056 0.056 0.054 0.054
0.064 0.064 0.062 0.062 0.062 0.060 0.060 0.060 0.058 0.058 0.058 0.056 0.056
0.066 0.066 0.064 0.064 0.064 0.062 0.062 0.062 0.060 0.060 0.060 0.058 0.058
0.068 0.068 0.066 0.066 0.066 0.064 0.064 0.064 0.062 0.062 0.060 0.060 0.060
0.070 0.070 0.068 0.068 0.068 0.066 0.066 0.064 0.064 0.064 0.062 0.062 0.062
0.072 0.072 0.070 0.070 0.070 0.068 0.068 0.066 0.066 0.066 0.064 0.064 0.062
0.074 0.074 0.072 0.072 0.070 0.070 0.070 0.068 0.068 0.068 0.066 0.066 0.064
0.076 0.076 0.074 0.074 0.072 0.072 0.072 0.070 0.070 0.068 0.068 0.068 0.066
0.078 0.078 0.076 0.076 0.074 0.074 0.074 0.072 0.072 0.070 0.070 0.068 0.068
0.080 0.080 0.078 0.078 0.076 0.076 0.076 0.074 0.074 0.072 0.072 0.070 0.070
0.082 0.082 0.080 0.080 0.078 0.078 0.076 0.076 0.076 0.074 0.074 0.072 0.072
0.084 0.084 0.082 0.082 0.080 0.080 0.078 0.078 0.076 0.076 0.076 0.074 0.074
0.086 0.086 0.084 0.084 0.082 0.082 0.080 0.080 0.078 0.078 0.076 0.076 0.074
0.088 0.088 0.086 0.086 0.084 0.084 0.082 0.082 0.080 0.080 0.078 0.078 0.076
0.090 0.090 0.088 0.088 0.086 0.086 0.084 0.084 0.082 0.082 0.080 0.080 0.078
0.092 0.092 0.090 0.090 0.088 0.088 0.086 0.086 0.084 0.084 0.082 0.082 0.080
0.094 0.094 0.092 0.092 0.090 0.090 0.088 0.088 0.086 0.086 0.084 0.084 0.082
0.096 0.096 0.094 0.094 0.092 0.092 0.090 0.090 0.088 0.086 0.086 0.084 0.084
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0.098 0.098 0.096 0.096 0.094 0.092 0.092 0.090 0.090 0.088 0.088 0.086 0.086
b
51862
a - Manual Primer Button
b - To Thermal Air Valve
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No Click Click
Check for battery voltage to yellow/black Squeeze primer bulb until bulb is firm.
wire at terminal block on engine when key Remove hose from fitting on bottom of
(or choke button) is pushed in enrichener valve. Place a container
under valve, then push key (or choke
button). Check for fuel flow from fitting.
Repair connection(s) as necessary, then push key (or choke Fuel Flow from Fitting
button) in. If enrichment valve DOES NOT click, replace valve. Valve is O.K. Check hoses and fittings from
valve to middle and bottom carburetors for
leads or obstructions.
51844
a - Fuel Hose
b - Enrichment Valve Inlet Hose
c - Thermal Valve Hose
b Carburetor Disassembly
b
51861
a a - Off-Idle Jets (2)
51859
a - Access Plug (2) 4. Remove idle air jet and back draft vent jet (if
b - Gaskets (2) equipped) from carburetor.
c - Off-Idle Tube (2)
a b
2. Remove high speed fuel jet access plugs and
main (high speed) fuel jet from carburetor.
51861
51859
a - Access Plug (2)
b - Gaskets (2)
c - Main Fuel Jets (2)
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a
b
c
51863
a - Screw
b - Float Pin
c - Float
51862
a - Emulsion Tube 3. Remove needle and seat from fuel bowl.
a
Fuel Bowl Removal and Disassembly b
1. Remove five screws securing fuel bowl and
gasket to carburetor body.
51859
a - Needle
b - Seat with Gasket
51862
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CAUTION
DO NOT place floats, inlet needles, idle screw
adjusting caps, any rubber or plastic parts into
carburetor cleaning solution. If adjusting caps
must be removed and reinstalled, refer to ‘‘Idle
Circuit Adjustments” preceding.
a f
2. After soaking carburetor parts, rinse thoroughly
with water, then solvent. Blow parts dry with
compressed air. Be sure to blow thru all
d
passages, orifices and nozzles.
3. Check for float deterioration (saturation).
e g
4. Examine inlet needle and seat for wear. If worn,
replace with new inlet needle and seat assembly.
c b
Carburetor Reassembly
51863
IMPORTANT: Make certain that all parts are kept
a - Tab Washer clean during reassembly of carburetor.
b - Nut
c - Spacer
d - Throttle Spacer
e - Throttle Shaft Throttle Shaft Component
f - Screw
g - Throttle Link Installation
1. Install throttle shaft into carburetor body. Install
3. If necessary, remove four screws which secure throttle shutter plates to throttle shaft. Apply
two throttle shutter plates to throttle shaft. Loctite 271 to threads of screws and secure
Remove throttle shutter plates from throttle shaft, throttle shutters to throttle shaft.
then pull throttle shaft out of carburetor.
c
c a
a
b
b
51860
51860
a - Throttle Shaft
a - Throttle Shaft b - Throttle Shutter Plate
b - Throttle Shutter Plate c - Screws (use Loctite 271)
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c - Screws
b
a f
e g c
51863
a - Screw
b - Float Pin
c - Float
c b
51863
a - Tab Washer NOTE: Float height adjustment is the only adjust-
b - Nut ment made to adjust float setting.
c - Spacer
d - Throttle Lever 4. Adjust float height by turning fuel bowl
e - Throttle Shaft upside-down, then adjust float tab until float is
f - Screw level with edge of fuel bowl. Adjust float tab if
g - Throttle Link necessary.
b
a
b
c
51859
a - Inlet Needle Seat a - Float (Adjust by bending tab)
b - Inlet Needle b - Fuel Bowl (Upside-Down)
c - Float Level Even with Bowl Edge
d - Float Tab
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51861
51862 a - Idle Air Jet
b - Back Draft Jet
a - Emulsion Tube
6. Install gasket and fuel bowl to carburetor body 2. Install off-idle air jets to carburetor body.
Secure in place with five retained screws.
a
a
b
51861
a a - Off-Idle Jets
c
51861
a - Gasket
b - Fuel Bowl
c - Carburetor Body
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b b
c
b
a 51859
51844
a - Access Plugs (2)
b - Gaskets (2) a - Fuel Hose
c - Main Fuel Jets (2) b - Enrichener Valve Inlet Hose
c - Thermal Valve Hose
a
51859
a - Access Plugs (2)
b - Gaskets (2)
c - Off-Idle Tubes (2)
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2
6
a 7 2
2 4
3
1
2
3
5
2
51860
50165
a - Throttle Linkage
b - Oil Pump Link Rod 1 - Fitting (Fuel Line)
2 - Clamp
3 - Fuel Line
5. Re-synchronize carburetors following carburetor 4 - Primer Bulb
installation. Refer to “Timing/Synchronizing/ 5 - Check Valve (Black)
Adjusting” Section 2C. 6 - Check Valve (White)
7 - Fuel Line Connector (Engine End)
6. Attach bleed hose to back of air box.
7. Secure air box to carburetors with bolts. MAINTENANCE
IMPORTANT: Inspect all fuel hose connections, Periodically check fuel line and primer bulb for
and carburetor float bowl split lines for fuel leaks cracks, breaks, restrictions or chafing. Check all fuel
with outboard running. Also inspect each carbu- line connections for tightness. All fuel line connec-
retor throat, with outboard running at low RPM, tions must be clamped securely.
for fuel dribbling out of vent tube which would be Primer bulb assembly has 2 check valves: Fuel inlet
indicative of a float and/or needle and seat as- (toward tank) and a fuel outlet (toward engine).
sembly not functioning properly.
The fuel inlet valve allows fuel to fill primer bulb but
IMPORTANT: Outboard should not be operated closes to prevent fuel from returning to tank when
above 3000 RPM with air box cover removed as bulb is squeezed. The fuel outlet valve opens when
outboard will run too lean and internal damage primer bulb is squeezed to allow fuel flow to carbure-
could result. tor, but closes as bulb is released to prevent fuel from
8. Reinstall outboard cowling. returning to primer bulb. http://SelfFixer.com
51115
51115
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3
C
FUEL INJECTION
SN 0G303045 AND BELOW
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Table of Contents
Page Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-1 Engine Head Temperature Sensor Removal 3C-40
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-1 EFI Induction Manifold Removal . . . . . . . . . . . 3C-40
Electronic Control Module (ECM) Assembly . 3C-2 Water Separating Filter Assembly
Fuel Management System . . . . . . . . . . . . . . . . 3C-4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-41
Fuel Pump and Fuel Filter . . . . . . . . . . . . . . . . . 3C-8 Throttle Position Sensor/Temperature Sensor/
Outboard Powerhead View . . . . . . . . . . . . . . . 3C-10 Fuel Injector Harness Disconnections . 3C-41
Electronic Fuel Injection (EFl) System . . . . . . 3C-10 Oil Reservoir Removal . . . . . . . . . . . . . . . . 3C-42
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-10 Final Filter Assembly Removal . . . . . . . . . 3C-42
Using the Test Procedures . . . . . . . . . . . . . 3C-10 Electric Fuel Pump Removal . . . . . . . . . . . 3C-43
EFI System Tests . . . . . . . . . . . . . . . . . . . . . 3C-11 Vapor Separator Removal . . . . . . . . . . . . . 3C-43
Safety Precautions . . . . . . . . . . . . . . . . . . . . 3C-11 Vapor Separator Disassembly . . . . . . . . . . 3C-44
Fuel Injection System Function . . . . . . . . . 3C-11 Pressure Regulator Removal and
Preliminary Steps . . . . . . . . . . . . . . . . . . . . . . . 3C-12 Disassembly . . . . . . . . . . . . . . . . . . . . 3C-44
Ignition Spark Check . . . . . . . . . . . . . . . . . . 3C-12 Vapor Separator Float Removal . . . . . . 3C-44
Electronic Fuel Injection Set Up . . . . . . . . 3C-12 Vapor Separator Component Reassembly 3C-46
Fresh Quality Fuel . . . . . . . . . . . . . . . . . . . . 3C-13 Vapor Separator Float Installation . . . . . . . 3C-46
Low Battery Voltage . . . . . . . . . . . . . . . . . . . 3C-13 Manifold Removal . . . . . . . . . . . . . . . . . . . . 3C-47
Fuel Flow Diagram . . . . . . . . . . . . . . . . . . . . . . 3C-14 EFI Induction Manifold Disassembly . . . . . . . 3C-48
Fuel Flow Components . . . . . . . . . . . . . . . 3C-15 Air Temperature Sensor Removal . . . . . . . 3C-48
EFI Electrical Diagram . . . . . . . . . . . . . . . . . . . 3C-16 Throttle Position Sensor Removal . . . . . . . 3C-49
EFI Electrical Components . . . . . . . . . . . . . 3C-17 Fuel Rail Removal . . . . . . . . . . . . . . . . . . . . 3C-49
EFI Fuel Management Fuel Rail Disassembly . . . . . . . . . . . . . . . . . 3C-50
(Low Pressure Fuel Route) . . . . . . . . . . . . . 3C-19 Fuel Injector Removal and Disassembly . 3C-51
EFI Fuel Management Injector Harness Removal . . . . . . . . . . . . . 3C-52
(High Pressure Fuel Route) . . . . . . . . . . . . . 3C-20 Throttle Linkage Removed . . . . . . . . . . . . . 3C-52
Fuel Rail Electrical/Fuel Determination . . . . . 3C-21 EFI System Cleaning and Inspection . . . . . . . 3C-53
EFI System Test Procedures . . . . . . . . . . . . . . 3C-22 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-53
Fuel Gauge Connection/Pressure Test . . 3C-22 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-53
Vapor Separator Fuel Delivery Test . . . . . 3C-23 Induction Manifold Assembly . . . . . . . . . . . . . . 3C-54
Vapor Separator Float Test . . . . . . . . . . . . . 3C-23 Injector Harness Installation . . . . . . . . . . . . 3C-54
Water Separating Filter Flow Test . . . . . . . 3C-24 Fuel Injector Assembly and Installation . . 3C-55
Pulse Fuel Pump Delivery Test . . . . . . . . . 3C-25 Fuel Rail Assembly . . . . . . . . . . . . . . . . . . . 3C-55
Final Filter Check and De-pressurizing Fuel Rail Installation . . . . . . . . . . . . . . . . . . 3C-56
EFI System Procedures . . . . . . . . . . . . . 3C-26 Throttle Position Sensor Installation . . . . . 3C-57
Pressure Regulator Test . . . . . . . . . . . . . . . 3C-27 Air Temperature Sensor Installation . . . . . 3C-57
Electric Fuel Pump Test . . . . . . . . . . . . . . . 3C-28 EFI Induction Manifold Installation . . . . . . . . . 3C-58
Voltage Test Chart . . . . . . . . . . . . . . . . . 3C-30 Vapor Separator Installation . . . . . . . . . . . . 3C-60
Injector Electrical Harness Test . . . . . . . . . 3C-31 Electric Fuel Pump Installation . . . . . . . . . 3C-60
Injector Fuel Delivery Test . . . . . . . . . . . . . 3C-31 Final Filter Assembly Installation . . . . . . . . 3C-61
Injector Operation Test . . . . . . . . . . . . . . . . 3C-32 Oil Reservoir Installation . . . . . . . . . . . . . . . 3C-62
Induction Manifold Leak Check . . . . . . . . . 3C-33 Throttle Position Sensor and Temperature
Air Temperature Sensor Test . . . . . . . . . . . 3C-34 Sensor Fuel Injector Harness
Engine Head Temperature Sensor Test . . 3C-35 Connections . . . . . . . . . . . . . . . . . . . . . . . 3C-62
Detonation Control System Test Water Separating Filter Assembly
(200 Models Only) . . . . . . . . . . . . . . . . . . 3C-35 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3C-63
Detonation Sensor Check . . . . . . . . . . . . . . 3C-36 ECM Installation . . . . . . . . . . . . . . . . . . . . . . 3C-63
Detonation Control Module Check . . . . . . 3C-36 Engine Head Temperature Sensor
Throttle Position Sensor Test . . . . . . . . . . . 3C-37 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3C-64
Map Sensor Test . . . . . . . . . . . . . . . . . . . . . 3C-37
Problem Diagnosis . . . . . . . . . . . . . . . . . . . . 3C-37
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50 1 FUEL FILTER
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h
b e
a e a
d
c
c
d
51793
f a - Electronic Control Module (ECM)
51784
b - ECM Harness
a - Electric Fuel Pump c - Engine Harness
b - Fuel Pressure Regulator d - Throttle Position Sensor Harness
c - Vapor Separator e - Water Separating Filter
d - Engine Head Temperature Sensor
e - Lube Alert Module
f - Idle Stabilizer Module
g - Detonation Control Module (200)
h - Detonation Sensor (200) Electronic Fuel Injection
(EFl) System
Engine front view of EFI components.
a Introduction
The troubleshooting information provided here
consists of preliminary checks (checks to be followed
b before proceeding with EFI tests), diagrams (fuel
flow and electrical wiring), component description
(from diagrams), flow charts (low pressure fuel
c delivery, high pressure fuel delivery, fuel delivery vs.
electrical delivery), problem diagnosis, and a series
of test and check procedures that will help isolate
d problems associated with the fuel injection system.
Each test/check (listed) can be completed without
major fuel system disassembly.
ON
OFF START
STEP 5: Turn over engine using remote starter EFI set up procedures must be followed before tests
switch. on system are performed (refer to Section 2C).
Improper set up can result in poor engine
STEP 6: Look at spark gap tester viewing port for
performance (i.e. uncontrollable idle speeds, lean
presence of good quality spark. Com-
sneezing, low power during acceleration or engine
plete steps 1 through 6 on each spark
will simply not run.) Failure to properly set up the EFI
plug.
system can lead to misdirections in solving simple
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u t s a c
b d
e
v r f g
q
w
p
m h
l
n
x i
o
k j
10
19 12
8
11
18
17
BLK = Black
BLU = Blue
BRN = Brown
16 GRY = Gray
GRN = Green
ORN = Orange
PNK = Pink
PUR = Purple
RED = Red
TAN = Tan
13 WHT = White
15 YEL = Yellow
LIT = Light
14 DRK = Dark
1 - Detonation Sensor* 11- Throttle Position Sensor
2 - Detonation Module* 12- Fuel Injectors
3 - Engine Head Temperature Sensor 13- Injector Wiring Harness
4 - To Temperature Gauge 14- To Outer Switch Box
5 - Air Temperature Sensor 15- Inner Switch Box
6 - Starter Solenoid 16- #5 Ignition Coil
7 - 12 Volt Supply from Regulator 17- #3 Ignition Coil
8 - Electric Fuel Pump 18- #2 Ignition Coil
9 - Electronic Control Module 19- #1 Ignition Coil
10- Manifold Absolute Pressure Sensor *200 Models Only
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The air temperature sensor transmits manifold abso- NOTE: The higher the resistance the richer the fuel
lute air temperature, through full RPM range, to the flow. Refer to TPS Adjustment (Section 2C).
ECM. As air temperature increases “sensor” resis-
tance decreases causing the ECM to decrease fuel DETONATION CONTROL SYSTEM (200 MODEL)
flow (leaner mixture). Disconnecting the air temp The Detonation Control System consists of a
sensor (open circuit) will increase fuel flow (richen detonation control sensor located on the port side
mixture) by 10%. Bypassing air temp sensor (short in cylinder head and a detonation control module
circuit) will cause fuel flow to decrease 10%. mounted on the engine. The detonation control
The air temperature sensor circuit can be tested module has seven wires:
using the EFI tester. The air temperature sensor can • WHITE/BLUE - Connects to knock sensor,
be tested following air temperature sensor test on transmits knock signal to control module.
page 3C-34.
• GREEN - Connects to #2 primary wire. The
MANIFOLD ABSOLUTE PRESSURE (MAP) primary voltage signals the controller to monitor
SENSOR combustion “noise” during a window of time (See
Detonation System Function following).
The MAP sensor is a non-serviceable sensor
mounted in the ECM box. The MAP sensor is used • WHITE/BLACK - Two of these wires connect to
to sense changes in manifold absolute pressure and the switch boxes bias circuit terminals. A third
is connected to the intake manifold by the way of a wire is spliced in one bias circuit (inner switchbox)
vacuum hose. The MAP sensor is functioning and connects to the idle stabilizer module. (See
through the full RPM range and is continually signal- complete Engine Wiring Diagram - refer to
ing induction manifold pressure readings to the ECM. Section 2D).
The ECM in turn determines fuel flow as signals are • GRAY/WHITE - Connects to the ECM; signals
received. Drawing a vacuum on the MAP sensor ECM to enrich fuel mixture when knocking
hose will create a lean fuel condition altering engine occurs.
operation. If no change occurs when drawing vacu-
• PURPLE -12 Volt power supply.
um, MAP sensor is not functioning properly.
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c. Black wire has poor ground connection. WATER SENSING SYSTEM FUNCTION
d. Purple power wire becomes disconnected. 1. The filter separates the accumulated water from
NOTE: Disconnected Gray/White wire will not affect the fuel.
ignition timing and will not allow fuel enrichment. 2. A voltage is always present at sensing probe.
Other components associated with the ECM. When water reaches top of probe it completes
the circuit to ground.
12 Volt Battery -The 12 volt battery provides power
to the ECM even with the ignition switch in the “OFF” 3. The completed circuit activates the warning. The
position. warning has a 5-10 second delay, then the
module’s red light illuminates and warning horn
IMPORTANT: When disassembling EFI System intermittently sounds.
DISCONNECT BATTERY CABLES.
The system can be tested by disconnecting the TAN
Starter Solenoid - Provides 12 volt signal when key wire from sensor probe and holding to a good engine
is in the “start” position. In the “start” position, injector ground connection for 10 seconds.
pulse widths are tripled when engine head
temperature is below 90° F (32.2° C) to provide
adequate fuel for quick start up. When key is returned
to the run position or engine head temperature is
above 90° F (32.2° C), pulse widths return to normal
value.
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Pump does not run No or low fuel pressure Fuel pressure above 39 psi (269 kPa)
Follow High Pressure Fuel Perform Vapor Separator Fuel Follow High Pressure Fuel
Route Flow Chart. Delivery Test (page 3C-23). Route Flow Chart.
Results Results
No or little fuel flow from vapor Fuel flows freely from vapor
separator. Reconnect hose. separator. Reconnect hose.
Check in-line Filter
Results Results
Fuel flows from fresh fuel inlet Little or no flow from fresh fuel
hose. inlet hose. Reconnect hose.
Results Results
Low or no fuel flow from water sep- Fuel flows freely from water separat-
arating inlet hose. Reconnect hose. ing filter inlet hose. Reconnect hose.
Results Results
Fuel pressure above 39 psi (269 kPa) No or low fuel pressure Pump does not run
Clogged or faulty fuel pressure Perform Final Filter Check Perform Electric Fuel Pump “Pro-
regulator remove and replace. (page 3C-26). cedure B” Test (page 3C-28).
Results Results
Results Results
Results Results
Results Results
Results Results
Results Results
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IN-LINE
FILTER
51798
51798
Vapor Separator Float Test
Results: If fuel flow is present, fuel is being delivered Purpose: This test will indicate if float is stuck in the
to electric fuel pump. Go to high pressure flow up position.
chart.
NOTE: If float is stuck down vapor separator will over
If fuel flow is not present, proceed to step 2. flow causing a rich condition.
STEP 2: Place emergency stop switch in OFF Procedure: If float is suspected of sticking in the up
position to prevent engine from starting. If position:
boat is not equipped with a emergency
stop switch, connect a jumper lead from STEP 1: Remove fuel inlet hose from vapor
the BLACK/YELLOW terminal on the separator and put end of hose in clean
switch box to engine ground. container.
50346
Results: If fuel flow is present at hose, remove, dis-
assemble and inspect float assembly. See
STEP 2: Place emergency stop switch in OFF
vapor separator disassembly.
position to prevent engine from starting. If
If fuel flow is low or not present, perform Water boat is not equipped with a emergency
Separating Filter Flow Test. stop switch, connect a jumper lead from
the BLACK/YELLOW terminal on the
switch box to engine ground.
STEP 3: Turn ignition key switch to “START” and
operate starter motor for 10 to 20
seconds.
ON
OFF START
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50346
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50346
b
Final Filter Check and e
De-pressurizing EFI System f
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Procedures a - Filter Housing
b - Large O-ring
Purpose: Checking the final filter for obstructions, c - Filter Element
damage etc. eliminates this component as a d - Small O-ring
e - Filter Cap
possible source of restriction in the system. f - Lockwasher
Procedure: STEP 1: De-pressurize EFI fuel g - Screw
h - Cap
system by wrapping a clean cloth around
pressure port valve and inserting tip of
screwdriver into valve, depressing valve STEP 3: Look at filter for plugging, damage or
core. Let fuel drain from valve. other signs of unusual condition.
Results: Filter is clogged with debris. Clean with
carburetor cleaner and compressed air or
a replace. Recheck fuel pressure.
Filter is O.K. Pressure still below 36 psi (248 kPa).
Perform fuel pressure regulator test.
51796
a - Pressure Port may be located at this location on some
models.
NOTE: Induction manifold cover shown removed for STEP 5: Turn ignition key switch to “ON” position.
illustrative purposes only. ON
OFF START
Procedure: STEP 1: Connect pressure gauge to
EFI test port.
51796
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51796
CAUTION
When checking voltage at pump, DO NOT pry
boot covers off terminals with a metal object, as
each terminal is at 12 volts when engine is off.
Serious damage to electric fuel pump and/or
ECM box can result.
Purpose: If insufficient electrical power is available
at the pump, no or low fuel pressure will be
developed.
Procedure: STEP 1: Set volt meter to read bat-
tery voltage and connect black test lead
to ground, positive test lead to positive (+)
post of fuel pump.
NOTE: Positive test lead can be pierced through boot
cover for testing. Refer to voltage test chart (page
3C-30) for voltage readings.
Positive Test Terminal
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4 3
50326
(1) YELLOW
(2) RED
(3) DARK BLUE
(4) WHITE
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WARNING
Operation of EFI system with cover removed can
allow fuel to spray components. Be extremely
careful when operating the fuel system in this
condition.
Procedure: STEP 1: Remove induction manifold
cover using procedures outlined under
“Induction Manifold Removal.”
functioning normally.
WARNING
If a serious leak is present in the induction man-
ifold, fuel may spray out of bad seal. Have clean
up rags available to remove excess fuel from
components.
STEP 4: Place emergency stop switch in OFF
position to prevent engine from starting. If
boat is not equipped with a emergency
stop switch, connect a jumper lead from
the BLACK/YELLOW terminal on the
switch box to engine ground.
STEP 5: Connect remote starter Quicksilver Results: If no leaks are present, replace cover and
(91-52024A1) to negative terminal of gasket using normal length screws.
electric fuel pump and a good engine
ground. Depress remote start switch, If fuel leak is present between sealing surfaces,
pump will operate as long as switch is rebuild system using new O-rings.
depressed.
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a
b
51795
a - Probe
b - Connector
c - Positive Clip
51794
d - Ground Clip
Problem Diagnosis
Condition Possible Source Action
Engine Down On Power Or RPM. – Failed Switch Box Refer to Section 2A Electrical and
Ignition Tests.
– Vapor Separator Flooding Over, Check for fuel coming out of vapor
Engine Running Rich. separator vent hose.
– Vapor Separator Flooding Over. Check for fuel coming out of vapor
separator vent hose.
*R.F.I. Radio Frequency Interference. High voltage can alter signals ECM receives from sensors causing im-
proper fuel delivery. Route all sensor wires away from high voltage leads (i.e. spark plug leads)
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Sensor Removal
1. Remove screw and retaining plate.
51793
a - Connector
a
2. Remove screws (b) and ground wires (c).
3. Remove water sensing module (d).
4. Remove nuts (e) and screw (f).
51785
a - Screw
e
b - Retaining Plate
b f
a
c
51785
a - Wires d
b - Sensor 51793
b - Screws
c - Ground Wires
d - Water Sensing Module
EFI Induction Manifold e
f
- Nuts
- Screw
Removal
IMPORTANT: Remove battery cables from bat-
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g C
b
i
51793
b
a a
d
b
51793
a - Fuel Inlet Hose 51788
b - Fuel Delivery Hose a - Air Temperature Sensor
c - Screws b - Connectors
d - Filter Base
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e - Spacer Block
b a
51787
a - Fuel Injector Harness
b - 4 Pin Connector
51785
a - Screw
b - Final Filter
Oil Reservoir Removal
1. Remove screws, mounting bracket, nuts and 2. Remove final filter.
studs. 3. Remove O-rings from filter and cap.
4. Remove cap with inlet hose from manifold fitting.
d a
a
c
b
a
d e
a
b
51791
a - Screws
b - Bracket
c - Nuts
d - Studs 51786
a - Final Filter
2. Remove hose clamp and lift oil reservoir from b - O-Rings
engine. c - Filter
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d - Inlet Hose
e - Manifold Fitting
d a e
b c
d
a
51786 g g
a - Screws (4)
b - Cover Plate
c - Rubber Boots
d - Cap
f
g
51786
a - Re-circulation Hose
a b b - Manifold Fitting
c - Regulator Vacuum Hose
d - Bleed Hose
d e - Vapor Separator Vacuum Hose
f - Oil Inlet Hose
g - Screws
e
a - Positive Lead
b - Negative Lead
c - Inlet Hose
d - Rubber Blanket
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b d
c
a b
51794
c a - Screws
b - Regulator Fitting
c - Regulator
a d - O-ring
51792
a - Screws VAPOR SEPARATOR FLOAT REMOVAL
b - Plate
c - Regulator 1. Remove screws and cover.
2. Remove O-ring.
a
b
51719
51794
a - O-Ring a - Screws
b - Cover
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a b
a 51791
a - O-Ring
b - Housing
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a - Pivot Pin
a
51795
a - Float
b - Needle
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e
d b
u
f f
g g
h b
i
j
k
l
m
n
a
51795
o a - Float
b - Needle
p
2. Install new O-ring in housing.
q
a
s r
s
t t
a - Screw
b - Lock Washer
c - Plate and Grommet
d - Pressure Regulator
e - Vapor Separator Cover
f - Screw
g - Lock Washer
h - Flat Washer
i - Seat
j - Needle
k - Retainer
l - Pin
b
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m - Float
n - Seal a - O-Ring
o - Bracket b - Housing
p - Check Valve
q - Fuel Check Valve
r - Bracket
s - Lock Washer
t - Screw
u - O-Ring
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b b
a c
a
51794 a
a - Cover 51795
b - Screws
a - Ground Wires
b - Screws (12)
Manifold Removal c - Manifold Cover
1. Disconnect throttle link rod from throttle cam. 6. Disconnect bleed line hose from bleed shut off.
2. Disconnect oil injection link rod from injector arm. 7. Disconnect bleed line hoses from manifold
fittings.
d 8. Remove manifold assembly and place on clean
work surface.
c
a
b c
a
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a - Throttle Link Rod
b - Throttle Cam 51795
c - Oil Injection Link Rod
d - Injector Arm a - Bleed Hose
b - Bleed Shut Off
c - Bleed Hoses
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51790
a - Screws
b b - Sensor
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a - O-Ring
b - Sensor
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a
a c
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a - Vacuum Hoses
51790 b - Bleed Hose
c - Screws
a - Screws
d - Manifold Fitting
2. Remove sensor and sleeve from throttle shaft. 4. Remove manifold fitting and O-rings.
a
c
b a
51791
51788
a - Manifold Fitting
a - Sensor
b - O-Rings
b - Sleeve
c - Throttle Shaft
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a b
a c
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a - Tube Support
b - Fuel Rail
c - Tubes
51784 d - Plugs
a - Screws (4)
a
c
b
51788
a - Fuel Rail
b - Manifold
c - Guides
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a d
b a
b
51789
c a - Injector
51792 b - Seals
a - Clamp c - O-Ring
b - Slot d - Filter
c - Connector
d - Injector
51789
a - Injector
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a c
b
a b 51786
a - Throttle Cam
b - Bushings
c - Nut; Tighten until snug against cam, then back off 1/4 turn
b
a
51795 b l
a - Casing
b - Harness
c
k
2. Remove screws and injector harness plate. d
i
e
i
f
g j
i
h 51789
a - Fiber Washer
b - Bushing
c - Spring
d - Roller Cam Bracket
e - Bracket (Shutter Link)
b f - Lock Washer
g - Nut
h - Screw
a i - Flat Washer
51792 j - Cotter Key
k - Progressive Shutter Link
a - Screws
l - Bleed Shut Off
b - Plate
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Inspection
1. Look at entire system for signs of an obvious
problem such as poor condition of wire insulation,
leaking fitting, cracked or loose hoses and lines.
2. Look for fuel or oil leaks wherever these fluids are
used (i.e. fuel filter cap, fuel pump, vapor
separator cap, etc.).
3. Check for signs of tampering or abuse such as
modifications to wiring or 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 all sensors (throttle position, air
temperature and water temperature) connectors
and harnesses for bad connections or poor
insulation conditions such as fraying, stripping,
cracks or signs of abrasion wear. http://SelfFixer.com
a
b
51795
a - Casing
b - Harness
a - O-Ring
b - Groove
c - Insert
b
51792
a - Plate
b - Screws
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a d
c
b
d b
c
a 51792
a - Clamp
b - Slot
c - Connector
d - Injector
51789
a - Seals Fuel Rail Assembly
b - O-Ring
c - Filter 1. Install inspected O-rings to plugs. tube support
d - Injector and tubes.
2. Install tubes to tube support.
2. Install injector into manifold.
3. Install plugs to fuel rail.
4. Install tube support to fuel rail.
d
a a
c
51795
a - Tube Support
b - Fuel Rail
c - Tubes
d - Plugs
51789
a - Injector
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a e
c
b
51791
c a - O-Rings
b - Fitting
51789
a
a - Vacuum Hoses
b - Bleed Hose
c - Screws
d - Manifold Fitting
CAUTION
Use extreme care when installing induction
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51784
a - Screws (4)
manifold so as to eliminate any possibility for air
leaks.
b 51791
c a - O-Ring
b - Air Temperature Sensor
51788 a
a - Sleeve
b - Throttle Position Sensor
c - Throttle Shaft
b
3. Tighten screws after induction manifold installa-
tion and throttle position sensor adjustments are
completed.
51790
a - Screws
b - Air Temperature Sensor
51790
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a - Screws
b
51785
a - Cover Seal 51784
b - Manifold
a - Gasket
4. Install manifold cover to manifold and secure with b - Induction Manifold
M8 x 1.25 x 38mm long bolts through holes.
2. With induction manifold held in place, connect
NOTE: This will aid in induction manifold installation.
bleed line hoses to manifold fittings.
3. Connect bleed line hose to bleed shut off.
c
a
d
a a
51795
a - Holes
a - Bleed Hoses
b - Manifold Fittings
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c - Bleed Hose
d - Bleed Shut Off
b
b
a
c a
c
c 51811
c a - Link Rod
51795 b - Injector Arm
c - Throttle Link Rod
a - Manifold d - Throttle Cam
b - Screws [Torque to 90 lb. in. (10.0 N·m)]
c - Ground Wires
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f d
e
c
d e
a a
b
a
b c
a a - Electric Fuel Pump
b - Rubber Blanket
c - Inlet Hose
d - POSITIVE Lead (RED)
51786 e - NEGATIVE Lead (RED/BLUE)
a - Screws [Torque to 45 lb. in. (5.0 N·m)]
b - Oil Inlet Hose
c - Bleed Hose
d - Vapor Separator Vacuum Hose
e - Regulator Vacuum Hose
f - Recirculation Hose
g - Manifold Fitting
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a b
a d
a
e c
b
c
51786
a - Rubber Boots
51786
b - Pump Cap
c - Cover Plate a - Fuel Rail Inlet Hose
d - Screws (4) b - Cap
c - Manifold Fitting
d - O-Ring
e - Filter
51785
a - Screw
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b - Final Filter
a d
d
d b
51791
a - Studs
b - Nuts a
c - Bracket
d - Screws
51787
a - Injector Harness
b - 4 Pin Connector
b b
51788
a - Air Temperature Sensor
b - Connectors
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a
c d
b
c e
c
b
51787
a - Bracket 51793
b - Throttle Position Sensor
c - 3 Pin Connector a - Spacer Block
b - Filter Base
c - Screws
d - Fuel Outlet Hose
e - Fuel Inlet Hose
ECM Installation
1. Connect MAP sensor hose from ECM to manifold
fitting. Place ECM on manifold studs.
a
b
51793
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d b
a
e
51793
c 51785
a - Nuts a - Wires
b - Screw b - Sensor
c - Water Sensing Module
d - Screws
e - Ground Wires 2. Install retaining plate and screw.
b
c
b
51785
51793
a - Retainer
a - ECM Harness
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b - Screw
b - Engine Harness
c - Connector
3
D
55173
FUEL INJECTION
SN 0G303046 AND ABOVE
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Table of Contents
Page Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-1 Throttle Position Sensor Test . . . . . . . . . . . 3D-39
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-1 Map Sensor Test . . . . . . . . . . . . . . . . . . . . . 3D-40
Detonation Controller/Air Temperature Problem Diagnosis . . . . . . . . . . . . . . . . . . . . 3D-41
Sensor/Throttle Position Sensor . . . . . . . . . . 3D-3 Engine Head Temperature Sensor Removal 3D-44
Electronic Control Module (ECM) Assembly . 3D-4 EFI Induction Manifold Removal . . . . . . . . . . . 3D-44
Fuel Management System . . . . . . . . . . . . . . . . . 3D-6 Water Separating Filter Assembly
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-45
Outboard Powerhead View . . . . . . . . . . . . . . . 3D-12 Water Separating Filter Assembly
Electronic Fuel Injection (EFl) System . . . . . . 3D-12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3D-45
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-12 Throttle Position Sensor and Temperature
Using the Test Procedures . . . . . . . . . . . . . 3D-12 Sensor Fuel Injector Harness
EFI System Tests . . . . . . . . . . . . . . . . . . . . . 3D-13 Disconnections . . . . . . . . . . . . . . . . . . . . . 3D-46
Safety Precautions . . . . . . . . . . . . . . . . . . . . 3D-13 Oil Reservoir Removal . . . . . . . . . . . . . . . . 3D-46
Fuel Injection System Function . . . . . . . . . 3D-13 Fuel Pressure Regulator Removal . . . . . . 3D-47
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . 3D-14 Fuel Pressure Regulator Disassembly . . . 3D-47
Fuel Flow Diagram . . . . . . . . . . . . . . . . . . . . . . 3D-16 Fuel Pressure Regulator Reassembly . . . 3D-47
Fuel Flow Component Description . . . . . . . . . 3D-17 Vapor Separator Removal . . . . . . . . . . . . . 3D-48
Wiring Diagram 150 EFI/175 EFI Vapor Separator Disassembly . . . . . . . . . . 3D-49
150 Pro Max/Super Magnum . . . . . . . . . . . 3D-19 Vapor Separator Reassembly . . . . . . . . . . 3D-50
Wiring Diagram 200 EFI/200 & Installing Vapor Separator Assembly to
225 Pro Max/Super Magnum . . . . . . . . . . . 3D-20 Induction Manifold . . . . . . . . . . . . . . . . . . 3D-52
EFI Electrical Components (from Electrical Manifold Removal . . . . . . . . . . . . . . . . . . . . 3D-54
Component Diagram) . . . . . . . . . . . . . . . 3D-21 EFI Induction Manifold Disassembly . . . . . . . 3D-54
EFI Fuel Management (Low Pressure Air Temperature Sensor Removal . . . . . . . 3D-55
Fuel Route) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-23 Throttle Position Sensor Removal . . . . . . . 3D-55
EFI Fuel Management (High Pressure Fuel Rail Removal . . . . . . . . . . . . . . . . . . . . 3D-56
Fuel Route) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-24 Fuel Rail Disassembly . . . . . . . . . . . . . . . . . 3D-57
Fuel Rail Electrical/Fuel Determination . . . . . 3D-25 Fuel Injector Removal and Disassembly . 3D-57
EFI System Test Procedures . . . . . . . . . . . . . . 3D-26 Injector Harness Removal . . . . . . . . . . . . . 3D-58
Fuel Gauge Connection/Pressure Test . . 3D-26 Throttle Linkage Removed . . . . . . . . . . . . . 3D-59
Vapor Separator Fuel Delivery Test . . . . . 3D-27 EFI System Cleaning and Inspection . . . . . . . 3D-59
Vapor Separator Float Test . . . . . . . . . . . . . 3D-28 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-59
Water Separating Filter Flow Test . . . . . . . 3D-28 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-59
Pulse Fuel Pump Delivery Test . . . . . . . . . 3D-29 Induction Manifold Assembly . . . . . . . . . . . . . . 3D-60
Final Filter Check and De-pressurizing EFI Injector Harness Installation . . . . . . . . . . . . 3D-60
System Procedures . . . . . . . . . . . . . . . . . 3D-29 Fuel Injector Assembly and Installation . . 3D-61
Pressure Regulator Test . . . . . . . . . . . . . . . 3D-31 Fuel Rail Assembly . . . . . . . . . . . . . . . . . . . 3D-62
Electric Fuel Pump Voltage Test . . . . . . . . 3D-32 Fuel Rail Installation . . . . . . . . . . . . . . . . . . 3D-62
Voltage Test Chart . . . . . . . . . . . . . . . . . 3D-33 Throttle Position Sensor Installation . . . . . 3D-64
Injector Electrical Harness Test . . . . . . . . . 3D-34 Air Temperature Sensor Installation . . . . . 3D-64
ECM Injector Driver Test . . . . . . . . . . . . . . . 3D-34 EFI Induction Manifold Installation . . . . . . . . . 3D-65
Injector Fuel Delivery Test . . . . . . . . . . . . . 3D-34 Oil Reservoir Installation . . . . . . . . . . . . . . . 3D-66
Injector Operation Test . . . . . . . . . . . . . . . . 3D-35 Vapor Separator Installation . . . . . . . . . . . . 3D-67
Induction Manifold Leak Check . . . . . . . . . 3D-36 Throttle Position Sensor, Air Temperature
Air Temperature Sensor Test . . . . . . . . . . . 3D-37 Sensor and Fuel Injector Harness
Engine Head Temperature Sensor Test . . 3D-37 Connections . . . . . . . . . . . . . . . . . . . . . . . 3D-68
Detonation Control System Test ECM Installation . . . . . . . . . . . . . . . . . . . . . . 3D-69
(200 Models Only) . . . . . . . . . . . . . . . . . . 3D-38 Engine Head Temperature Sensor
Detonation Sensor Check . . . . . . . . . . . . . . 3D-38 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3D-70
Detonation Control Module Check . . . . . . 3D-39
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51796
55294
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a b
c f
d e
a - To Injector Manifold
b - To Engine Harness
c - RED
d - WHITE
e - BLUE
f - YELLOW
!#
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'
!(
!'
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(
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TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 DETONATION CONTROLLER ASSEMBLY
2 3 SCREW 30 3.5
3 3 WASHER
4 1 PLATE
5 1 CABLE ASSEMBLY 200
6 1 SCREW
7 3 BUSHING
8 1 OIL INJECTION WARNING MODULE
9 1 INDICATOR–throttle position
10 2 SCREW 20 2.0
11 2 LOCKWASHER
12 2 WASHER
13 1 SLEEVE
14 2 PLATE
15 1 AIR TEMPERATURE SENSOR ASSEMBLY
16 1 O-RING
17 3 SCREW Drive Tight
18 3 LOCKWASHER
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&
%
25
" '
"*
!)
25
6
!( #
6
25
)
(
!" !!
!*
!# 25
!'
25
!$ !& !%
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)
(
%
$
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'
" !
!)
"!
"*
$
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"! "!
!) !( ""
!' "#
!( "!
!) "#
"& "(
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!(
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19
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b d
e
b
c
d
55175
c f
a - Electronic Control Module (ECM)
b - ECM Harness
c - Engine Harness
55174
d - Throttle Position Sensor
e - Water Separating Filter
DANGER
Outboard motor fuels are extremely flammable.
Do not show open sparks or flames when
working near fuel systems.
WARNING
To avoid potential fire hazards, use extreme
caution when connecting and disconnecting fuel
line connections and test adaptors. Do not allow
fuel to spill on hot engine parts or on live
electrical connections.
CAUTION
Wipe up fuel spills immediately.
CAUTION
Depressurize fuel system prior to opening line
connections or removing fuel system
components.
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ON
OFF START
55174
5. Turn over engine using remote starter.
6. Look at spark gap tester viewing port for EFI set up procedures must be followed before tests
presence of good quality spark. Complete steps on system are performed (refer to Section 2C).
1 through 6 on each spark plug. Improper set up can result in poor engine
Results: IMPORTANT: The presence of a good performance (i.e. uncontrollable idle speeds, lean
spark will not necessarily indicate condi- sneezing, low power during acceleration or engine
tion of timing. Ignition timing may be off will simply not run.) Failure to properly set up the EFI
far enough to prevent the engine from system can lead to misdirections in solving simple
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starting, but still allow a good spark to be problems in the EFI system.
present in the spark gap tester.
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d
b h
e g
a i
q j
v o
r
a
p
a
s
n
m l
t
53646
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23
1
2
24 3 4
5
6
21
25 7
22 10
8
26
27 20
17
28 9
19 11
29 16
12
30 18 13
14 15
54352
32 1
2 6
4 5
25 7
8
3
26 9
24 12
23 10
27
11
28 22
19
29
21 13
18
30
14
54353
31 20 15
BLK = BLACK
16 17 BLU = BLUE
BRN = BROWN
GRY = GRAY
GRN = GREEN
PUR = PURPLE
RED = RED
TAN = TAN
VIO = VIOLET
WHT = WHITE
YEL = YELLOW
c. BLACK wire has poor ground connection. WATER SENSING SYSTEM FUNCTION
d. PURPLE power wire becomes disconnected. 1. The filter separates the accumulated water from
NOTE: Disconnected GRAY/WHITE wire will not the fuel.
affect ignition timing and will not allow fuel 2. A voltage is always present at sensing probe.
enrichment. When water reaches top of probe it completes
Other components associated with the ECM. the circuit to ground.
12 Volt Battery - The 12 volt battery provides power 3. The completed circuit activates the warning. The
to the ECM even with the ignition switch in the “OFF” warning has a 5-10 second delay, then the
position. module’s red light illuminates and warning horn
intermittently sounds.
IMPORTANT: When disassembling EFI System
DISCONNECT BATTERY CABLES. The system can be tested by disconnecting the TAN
wire from sensor probe and holding to a good engine
Starter Solenoid - Provides 12 volt signal when key ground connection for 10 seconds.
is in the “start” position. In the “start” position, injector
pulse widths are tripled when engine head tempera-
ture is below 90° F (32.2° C) to provide adequate fuel
for quick start up. When key is returned to the run po-
sition or engine head temperature is above 90° F
(32.2° C), pulse widths return to normal value.
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Pump does not run No or low fuel pressure Fuel pressure above 36 psi (248 kPa)
Follow High Pressure Fuel Perform Vapor Separator Fuel Follow High Pressure Fuel
Route Flow Chart. Delivery Test (page 3D-27). Route Flow Chart.
Results Results
No or little fuel flow from vapor Fuel flows freely from vapor
separator. Reconnect hose. separator. Reconnect hose.
Check in-line Filter
Results Results
Fuel flows from fresh fuel inlet Little or no flow from fresh fuel
hose. inlet hose. Reconnect hose.
Results Results
Low or no fuel flow from water sep- Fuel flows freely from water separat-
arating inlet hose. Reconnect hose. ing filter inlet hose. Reconnect hose.
Results Results
Fuel pressure above 36 psi (248 kPa) No or low fuel pressure Pump does not run
Clogged or faulty fuel pressure Perform Final Filter Check Perform Electric Fuel Pump Volt-
regulator remove and replace. (page 3D-29). age Test (page 3D-31).
Results Results
Results Results
Results Results
Results Results
Results Results
Results Results
55177
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55178
55188
55179
a - Pressure Port
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55187
55177 55205
a - Inlet Filter
3. Remove 3 bolts securing vapor separator
assembly to manifold. 7. Inspect filter for debris or damage.
Results: If filter is clogged with debris, clean filter
a with solvent and compressed air or replace
a filter. Reassemble vapor separator to
manifold and recheck fuel pressure. If
pressure is still below 34 psi (234 kPa),
perform fuel pressure regulator test.
a
55176
a - Bolts
VOLTS 0 2
15
4 6 8 20
40
10
Serious damage to electric fuel pump and/or DC AMPS
a
DCV ACV
DVA
55192
a - NEGATIVE (–) Terminal
55191
a - POSITIVE (+) Terminal
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55194
(1) YELLOW
(2) RED
(3) DARK BLUE
(4) WHITE
Results: If readings are 1.1 ± .2 both injector circuits
are complete. Perform Injector Fuel Delivery
Test.
If readings are 2.2 ± .2 one injector does not have a
complete circuit. Perform induction manifold
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a
a
50342
a - Bleed Line Fittings (Inject fuel at this location)
WARNING
6. Look at injector spray pattern using an explosive
Do not start engine with induction manifold
proof flashlight.
cover removed. Disable ignition system prior to
doing this test.
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55197
5. Connect remote starter Quicksilver 2. Connect digital meter set at “20K scale” (from EFI
(91-52024A1) to NEGATIVE terminal of electric Tester P/N 91-11001A2) to leads of sensor.
fuel pump and a good engine ground. Depress 3. Place sensor in ice water while monitoring meter
remote start switch, pump will operate as long as reading. Use graph (below) for reference.
switch is depressed.
NOTE: Temperature/resistance reading may differ
slightly from graph curve.
WARNING
Do not operate pump for more than 20 seconds
2. Start engine, allow to warm up. Advance throttle 3. Start and operate engine at idle speed.
(between 3000-3500 RPM in gear). NOTE: 4. Check meter reading. A typical reading of 0.075
Timing advancement. to 0.120 volts AC should be present.
Results: Timing advances from 19° to 25° BTDC NOTE: As RPM increases, volt readings will in-
system functioning properly. crease.
Timing advance from 19° to 25° but retards while Results: If voltage reading is not within 0.075 to
maintaining a steady throttle position. System 0.120 volts AC replace detonation sensor.
functioning properly detonation may be occurring. Torque sensor to 144 Ib. in. (16.0 N·m).
See Detonation Sensor/Module Checks (following).
If voltage reading is within 0.075 to 0.120 volts AC
perform check on detonation control module.
IMPORTANT: Handle detonation sensor with care
when testing or replacing. Rough handling could
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51795
a - Probe
b - Connector
c - Positive Clip
d - Ground Clip
55198
– Vapor Separator Flooding Over, Check for fuel coming out of vapor
Engine Running Rich. separator vent hose.
– Vapor Separator Flooding Over. Check for fuel coming out of vapor
separator vent hose.
*R.F.I. Radio Frequency Interference. High voltage can alter signals ECM receives from sensors causing im-
proper fuel delivery. Route all sensor wires away from high voltage leads (i.e. spark plug leads) http://SelfFixer.com
Sensor Removal
1. Remove screw and retaining plate.
2. Disconnect wires and remove sensor.
b
c 55173
a - Connector
a
a. Remove screws (b) and ground wires (c).
b. Remove water sensing module (d).
c. Remove nuts (e) and screw (f).
55196
e
a - Screw
b - Retaining Plate
c - Wires
d - Sensor
d
55173
b - Screws
c - Ground Wires
d - Water Sensing Module
e - Nuts
f - Screw
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c 55199
a - ECM
b - MAP Sensor Hose
b
c - Manifold Fitting
55182
a - Water Separator
b - Water Sensor Lead
55184
a - Strap Wrench (91-24937A1)
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51787
a - Throttle Position Sensor
b - 3 Pin Connector
55185 c - Bracket
a - Sealing Ring
2. Disconnect air temperature sensor at
connectors.
55195
a - Air Temperature Sensor
b - Connectors
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a
55193
a - Fuel Injector Harness
b - 4 Pin Connector
55179
a - Pressure Port
Oil Reservoir Removal
1. Remove 3 screws. 3. Remove return fuel line from pressure regulator.
4. Remove regulator hose from regulator.
a
5. Remove 2 screws securing regulator to separa-
tor and remove regulator.
a
b
a
55201
a - Screws
55204
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b a
a 55179
b
a
b c
b - Screw (2) [Torque to 45 lb. in. (5.0 N·m)] a - Return Fuel Line
b - Regulator Hose
c - Screws
a
a
55177 a a a a 55209
a - Fuel Inlet Hose a - Screws (3 screws are hidden on back side)
8. Disconnect and plug oil inlet hose to vapor FINAL FILTER REMOVAL
separator.
Rotate final filter counterclockwise and pull down.
9. Remove 3 bolts securing separator to manifold
assembly.
b
b
55205
b a - Final Filter
a b - Electric Fuel Pump
55176
a - Oil Inlet Hose
b - Bolts
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a
a
d
c
b
55206
a - Nuts
b - Pump
b
2. Inspect pump O-rings for cuts or abraisions. a 55207
Replace O-rings as required. a - Float
b - Float Arm
a c - Float Needle (Hidden)
a a d - Pivot Pin
53702
a - O-rings
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b c
b
c a
a 55207
a - Float
b - Float Needle (Hidden)
c - Float Drop Limit Bracket
d - Pivot Pin
a - Electric Pump
b - POSITIVE (+) Stud (Small Diameter)
c - NEGATIVE (–) Stud (Large Diameter)
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a
a
c
b
53701
a - O-ring
55209
a a
55217
a - O-rings
55216
a - Screws [Torque to 45 lb. in. (5.0 N·m)]
2. Install fuel tubes into manifold. Inspect adaptor
plate O-rings for cuts or abraisions. Replace
O-rings as required. 4. Reconnect engine bleed hose (with filter) to fitting
on vapor separator.
5. Reconnect vapor separator over flow hose
between separator and manifold.
6. Reconnect pressure regulator hose to top fitting
a on regulator.
c b
55215
a - O-rings
55204
a - Bleed Hose
b - Separator Over Flow Hose
c - Pressure Regulator Hose
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d
a c
a
a
a
55176 55213
a - Bolts and Washers [Torque bolts to 45 lb. in. (5.0 N·m)] a - Throttle Link Rod
b - Throttle Cam
c - Oil Injection Link Rod
d - Injector Arm
a
c
55210
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a - Ground Wires
b - Screws (12)
c - Manifold Cover
51790
51795 a - Screws
b - Sensor
a - Bleed Hoses
51791
a - O-Ring
b - Sensor
51785
a - Manifold Cover Seal
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b - Manifold
a
a b
51789
a - Vacuum Hoses
51790 b - Screws
c - Manifold Fitting
a - Screws
a
c
a
b
51791
a - Manifold Fitting
51788
b - O-Rings
a - Sensor
b - Sleeve
c - Throttle Shaft
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a
b
a c
51795
a - Tube Support
b - Fuel Rail
c - Tubes
b 51784 d - Plugs
a - Screws (4)
b - Early Models Only
a
c
b
51788
a - Fuel Rail
b - Manifold
c - Guides
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a d
a
b
b
51789
c a - Injector
51792 b - Seals
a - Clamp c - O-Ring
b - Slot d - Filter
c - Connector
d - Injector
51789
a - Injector
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a c
b
a b 51786
a - Throttle Cam
b - Bushings
c - Nut; Tighten until snug against cam, then back off 1/4 turn
b
a
51795 b
a - Casing
b - Harness
c
k
2. Remove screws and injector harness plate. d
i
e
i
f
g j
i
h 51789
a - Fiber Washer
b - Bushing
c - Spring
d - Roller Cam Bracket
e - Bracket (Shutter Link)
b f - Lock Washer
g - Nut
h - Screw
a i - Flat Washer
51792 j - Cotter Key
k - Progressive Shutter Link
a - Screws
b - Plate
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Inspection
1. Look at entire system for signs of an obvious
problem such as poor condition of wire insulation,
leaking fitting, cracked or loose hoses and lines.
2. Look for fuel or oil leaks wherever these fluids are
used (i.e. fuel filter cap, fuel pump, vapor
separator cap, etc.).
3. Check for signs of tampering or abuse such as
modifications to wiring or 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 all sensors (throttle position, air tempera-
ture and water temperature) connectors and har-
nesses for bad connections or poor insulation
conditions such as fraying, stripping, cracks or
signs of abrasion wear. http://SelfFixer.com
a
b
51795
a - Casing
b - Harness
a - O-Ring
b - Groove
c - Insert
b
51792
a - Plate
b - Screws
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a d
c
b
d b
c
a 51792
a - Clamp
b - Slot
c - Connector
d - Injector
51789
a - Seals Fuel Rail Assembly
b - O-Ring
c - Filter 1. Install inspected O-rings to plugs. tube support
d - Injector and tubes.
2. Install tubes to tube support.
2. Install injector into manifold.
3. Install plugs to fuel rail.
4. Install tube support to fuel rail.
d
a c
a
51795
a - Tube Support
b - Fuel Rail
c - Tubes
d - Plugs
51789
a - Injector
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a e
c
b
51791
c a - O-Rings
b - Fitting
a 51789
a - Vacuum Hoses
b - Screws [Torque screws to 45 lb. in. (5.0 N·m)]
c - Manifold Fitting
CAUTION
Use extreme care when installing induction man-
b 51784
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b 51791
c a - O-Ring
b - Air Temperature Sensor
a
51788
b
a - Sleeve
b - Throttle Position Sensor
c - Throttle Shaft
a
3. Tighten screws after induction manifold installa-
tion and throttle position sensor adjustments are c
completed. Torque screws to 20 lb. in. (2.0 N·m).
a - Screws
b - Air Temperature Sensor
c - Harness
d - Bracket
51790
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a - Screws
a b
b
51785
a - Cover Seal
b - Manifold
c 51784
4. Install manifold cover to manifold and secure with a - Gasket
b - Induction Manifold
M8 x 1.25 x 38mm long bolts through holes. c - Early Models Only
NOTE: This will aid in induction manifold installation.
2. With induction manifold held in place, connect
bleed line hoses to manifold fittings.
a
51795
d
c
b
c a
c
a
c
55213
a - Throttle Link Rod
55210 b - Throttle Cam
a - Manifold c - Oil Injection Link Rod
b - Screws [Torque to 90 lb. in. (10.0 N·m)] d - Oil Injection Arm
c - Ground Wires
c a c
55201
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a - Studs
b - Nuts
c - Screws [Torque 25 lb. in. (3.0 N·m)]
b a
55204
a - Over Flow Hose
b - Bleed Hose
c - Pressure Regulator Hose
d - Fuel Outlet Hose
a e - Fuel Return Hose
a
b 55203
a - Screws [Torque to 45 lb. in. (5.0 N·m)]
b - Spacers
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c
a
55203
a - Fuel Inlet Hose 51787
b - Oil Inlet Hose a - Injector Harness
c - Throttle Link Arm b - 4 Pin Connector
9. Connect RED (POSITIVE) lead to STARBOARD 2. Connect air temperature sensor leads to bullet
terminal of electric fuel pump and BLACK/RED connectors. Position sensor leads behind har-
(NEGATIVE) lead to PORT terminal of fuel pump. ness clamp.
Torque POSITIVE nut to 6 lb. in. (0.7 N·m) and the
NEGATIVE nut to 8 lb. in. (0.9 N·m).
a
a
b
b
55204
a - RED (+) Terminal [Torque nut to 6 lb. in. (0.7 N·m)] 55203
b - BLACK/RED (–) Terminal [Torque nut to 8 lb. in. (0.9 N·m)]
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b
e d
c
51787
a - Throttle Position Sensor 55173
b - 3 Pin Connector a - Nuts
b - Screw
c - Water Sensing Module
ECM Installation d - Screws
e - Ground Wires
1. Connect MAP sensor hose from ECM to manifold
fitting. Place ECM on manifold studs. 4. Connect ECM harness to engine harness at con-
nector. Install harness into harness bracket with
connecting ring below or above bracket arms.
c
IMPORTANT: DO NOT force connecting ring
between bracket arms.
a
c a
b
55175
55199
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a - ECM Harness
a - MAP Sensor Hose
b - Engine Harness
b - Fitting
c - Bracket
c - ECM
d
a
c
55196
a - Wires
b - Sensor
c - Retainer
d - Screw [Torque to 200 lb. in. (22.5 N·m)]
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3
E
OIL INJECTION
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Table of Contents
Page
Operation of the Oil Injection System . . . . . . . 3E-1
Oil Injection Components . . . . . . . . . . . . . . . . . . 3E-2
Oil Injection Flow System . . . . . . . . . . . . . . . . . . 3E-3
Pump Drive Assembly . . . . . . . . . . . . . . . . . . . . 3E-4
Pump Drive System . . . . . . . . . . . . . . . . . . . . . . 3E-4
Set Up Instructions for Oil Injection
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E-5
Oil Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . 3E-8
Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . 3E-8
Worm Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E-9
Worm Bushing Removal . . . . . . . . . . . . . . . . 3E-9
Worm Bushing Installation . . . . . . . . . . . . . . 3E-9
Oil Injection Pump Installation . . . . . . . . . . . 3E-9
Installing Drive Gear (for Oil Injection Pump)
Onto Crankshaft . . . . . . . . . . . . . . . . . . . . 3E-10
Motion Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 3E-10
Oil Injection System Troubleshooting
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E-11
Oil Pump Volume (Flow) Test . . . . . . . . . . . . . 3E-15
Oil Warning Module . . . . . . . . . . . . . . . . . . . 3E-15
Engine Mounted Oil Reservoir . . . . . . . . . . 3E-15
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(See Page 3 for Location) Injection pump is driven off the crankshaft. See
illustration on page 3.
! REMOTE OIL TANK The oil injection pump is a variable metering
pump. At idle the pump will meter the oil at
Holds 3 gallons (11.5 liters) of oil. approximately 100 to 1 gasoline to oil ratio and at
NOTE: Some boats may be equipped with optional WOT, 50 to 1 ratio.
1.8 gallon (7.0 liters) oil tank.
The tank is pressurized by air from crankcase 12 WARNING MODULE
pressure thus forcing oil up the outlet hose to the • Sounds the warning horn briefly when key switch
oil reservoir on engine. is turned on, to indicate that the system is
operational.
OIL PICK UP TUBE • While engine is running, the module continuously
A filter screen is located in end of tube to prevent monitors the rotation of the drive system for the
dirt or other particles from entering the system. oil injection pump by picking up pulses from the
motion sensor. If drive system becomes inopera-
6 VENT HOSE tive, the module will sound the warning horn.
• If oil level drops in the engine oil reservoir, the low
Hose is only used to keep check valve clean.
oil (float) sensor will signal the module to sound
Other end of hose is not connected.
the warning horn.
9 OIL RESERVOIR
The oil reservoir feeds the oil pump and contains
enough oil for at least 30 minutes of full throttle
running after the remote tank is empty. The
warning horn will sound if the oil level in oil
reservoir is low.
10 MOTION SENSOR
Senses the rotation of the oil injection pump drive
system. If the drive system for the injection pump
becomes inoperative, the sensor will signal the
warning module to sound the warning horn.
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7 9
TAN/BLUE
13
10
14
15
6
16 11
12
5 17
4
18
19
20
3
22
23 21
24
1
2
c
d
e
b
f
a - Oil Pump
b - Retaining Bolts (2)
c - O-ring
d - Magnet
e - Coupler
f - Driven Gear
g - Oil Pump (Installed)
NOTE: If magnet should fall out of the coupler, using a directional compass, locate end of magnet that attracts
the North Arrow of the compass. Insert this end of magnet into coupler first.
a b
h
g
f - Driven Gear
g - Bushing
h - Drive Gear
CAUTION
Be careful not to get dirt or other contamination
in tanks, hoses or other components of the oil
injection system during installation.
CAUTION
Oil injected engines additionally, must be run on
a 50:1 gasoline/oil mixture in the fuel tank for the
first 30 gallons of fuel. Refer to engine break-in
procedures in the Operation & Maintenance
Manual.
CAUTION
If an electric fuel pump is to be used on engines
with oil injection, the fuel pressure at the engine
must not exceed 4 psi (27 kPa). If necessary,
install a pressure regulator between electrical 22750
fuel pump and engine and set at 4 psi (27 kPa) Quick Disconnect Type Hose Connection
maximum.
54071
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c b
a - Bleed Screw
50047 b - Outlet Hose
c - Link Rod
a - Engine Reservoir Tank d - Pump Arm
b - Fill Cap
ADJUSTING OIL INJECTION PUMP
BLEEDING AIR FROM OIL INJECTION PUMP
AND OIL INJECTION OUTLET HOSE When carburetor linkage is at idle position, alignment
mark on oil injection arm should be in-line with mark
Bleeding Air from Oil Injection Pump on casting as shown. If necessary, adjust link rod.
With engine not running, place a shop towel below
the oil injection pump. Loosen bleed screw three to
four turns and allow oil to flow from bleed hole. Re-
tighten bleed screw. This procedure allows the pump
to fill with oil.
Bleeding Air from Oil Injection Pump Outlet Hose
Any air bubbles in outlet hose, in most cases, will be
purged out of the system during operation of the a
engine.
b
NOTE: If air bubbles persist, they can be purged out c
of the hose by removing link rod and rotating the
pump arm full clockwise while operating engine at
1000 to 1500 RPM: If necessary, gently pinch the fuel
line between the remote fuel line connector and the
oil injection pump “Tee” fitting. This will cause the fuel
pump to provide a partial vacuum which will aid in
removal of the air. Reinstall link rod. a - Link Rod
b - Alignment Mark
c - Casting Mark
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warning system.
a 51782
a - O-rings
51782
a - Worm Shaft
b - Coupler
CAUTION
Gear tooth mismatch at split line must not exceed
0.020 in. (0.50mm) or gear failure will result.
c
51892
a - Retaining Nut
b - Allen Screw
c - Center Main Bearing (Hidden)
50755
Motion Sensor
Testing Procedure--Refer to “Oil Injection System
Trouble Shooting Chart,” following:
Removal--Remove screw securing sensor to oil
pump. Disconnect WHITE and BLUE/WHITE leads
from WARNING MODULE. Remove BLACK LEAD
from engine ground. Remove MOTION SENSOR
from powerhead.
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Problem: Warning Horn does NOT sound when Ignition Key is turned to “ON” Position
Problem: Warning Horn stays ON when Ignition Key is turned to “ON” Position
Problem: Warning Horn sounds when Engine is Running and Oil Level in Engine Reservoir is Full
Drive system of the oil injection pump Check drive system as follows:
1. Use a 50:1 gas and oil mixture and start engine.
Verify engine has proper cooling water.
2. Disconnect link rod connected between oil injec-
tion pump and carburetor linkage.
3. Disconnect outlet hose of oil injection pump and
observe if injection pump is pumping oil. If pump is
not pumping oil, the drive system to the pump is
faulty.
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d
54388
b
51892
a - Oil Pump Output Hose (Clear)
a - Oil Warning Module
b - Tee Fitting
b - Bolts
c - Link Arm
d - Input Fuel Line
e - Oil Pump INSTALLATION
1. Apply Loctite 222 (FT2962-2) to bolt threads and
Two different capacity oil pumps are utilized on V-6 secure oil warning module to powerhead with 3
outboards. bolts. Torque bolts to 25 Ib. in. (3.0 N·m).
Flow specifications are as follows: 2. Refer to Section 2D, “WIRING DIAGRAMS” for
135 /150 2.0 L Models: proper connection of module wiring harness.
51893
a - Bolts
b - Input Oil Hose from boat mounted oil tank
c - Input Hose (Clear) to Oil Pump
d - Oil Cap
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3
F
Emission Control 2507 2000
Information cc PART # 37–804669-00
This engine conforms to 2000 Model Year Idle Speed (in gear): 650 RPM
U.S. EPA regulations for marine SI engines.
Refer to Owners Manual Timing: Idle – 0 – 9° ATDC
for required maintenance WOT – 20° BTDC
Family: WM9XM02.51C0 Spark Plug: NGK BPZ8HS-10
Gap: 0.040 in. (1.0 mm)
150 HP
JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC
EMISSIONS
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Table of Contents
Page
Exhaust Emissions Standards . . . . . . . . . . . . . 3F-1
What Are Emissions . . . . . . . . . . . . . . . . . . . 3F-1
Hydrocarbons - HC . . . . . . . . . . . . . . . . . . . . 3F-1
Carbon Monoxide - CO . . . . . . . . . . . . . . . . . 3F-1
Oxides of Nitrogen - NOx . . . . . . . . . . . . . . . 3F-1
Controlling Emissions . . . . . . . . . . . . . . . . . . 3F-1
Stoichiometric (14.7:1) Air/Fuel Ratio . . . . . 3F-1
Outboard Hydrocarbon Emissions
Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F-2
Stratified vs Homogenized Charge . . . . . . . . . 3F-3
Homogenized Charge . . . . . . . . . . . . . . . . . . 3F-3
Stratified Charge . . . . . . . . . . . . . . . . . . . . . . 3F-3
Emissions Information . . . . . . . . . . . . . . . . . . . . 3F-4
Manufacturer’s Responsibility . . . . . . . . . . . 3F-4
Dealer Responsibility . . . . . . . . . . . . . . . . . . . 3F-4
Owner Responsibility . . . . . . . . . . . . . . . . . . . 3F-4
EPA Emission Regulations . . . . . . . . . . . . . . 3F-4
Service Replacement Certification Label . . 3F-5
Decal Location for 1998 Models . . . . . . . . . 3F-6
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OUTBOARD HYDROCARBON
EMISSIONS REDUCTIONS
8 1/3% ! PER YEAR OVER 9 MODEL YEARS
120
100
80
60
40
20
0
96 97 98 99 2000 01 02 03 04 05 06 07 08
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Owner Responsibility:
The owner/operator is required to have engine
maintenance performed to maintain emission levels
within prescribed certification standards.
The owner/operator is not to modify the engine in any
manner that would alter the horsepower or allow
emissions levels to exceed their predetermined
factory specifications.
Exceptions:
• Carburetor jets may be changed for high altitude
use in accordance with factory
recommendations.
• Single engine exceptions may be allowed with
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Removal
Remove all remaining pieces of the damaged or illegible label. Do not install new label over
the old label. Use a suitable solvent to remove any traces of the old label adhesive from the
display location.
This engine conforms to 2000 Model Year Idle Speed (in gear): 650 RPM
U.S. EPA regulations for marine SI engines.
Refer to Owners Manual Timing: Idle – 0 – 9° ATDC
for required maintenance WOT – 20° BTDC
Family: WM9XM02.51C0 Spark Plug: NGK BPZ8HS-10
Gap: 0.040 in. (1.0 mm)
150 HP
b JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC
a - “V” Notch
b - Month of Manufacture
Installation
Install the label on a clean surface in the original factory location.
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51804
A
4
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Table of Contents
Page Page
Powerhead Specifications . . . . . . . . . . . . . . . . . . 4-1 Piston and Connecting Rod Reassembly . 4-37
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Piston and Piston Ring Combinations . . . . 4-39
Powerhead Repair Stand . . . . . . . . . . . . . . . . 4-3 Piston Installation (Standard and High
Cylinder Block and End Caps . . . . . . . . . . . . . . . 4-4 Performance Models) . . . . . . . . . . . . . . . . 4-40
Exhaust Manifold and Exhaust Plate . . . . . . . . . 4-6 Crankcase Cover Installation (Standard and
Reed Block and Cylinder Head . . . . . . . . . . . . . . 4-8 High Performance Models) . . . . . . . . . . . . 4-42
Crankshaft, Pistons and Connecting Rods . . . 4-10 Assembly of Reed Blocks to Intake Manifold
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . 4-12 (Standard and High Performance
General Information . . . . . . . . . . . . . . . . . . . . . . 4-13 Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Powerhead Removal from Driveshaft Assembly of Exhaust Divider Plate to Block
Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 (Standard and High Performance
Removing Engine Components . . . . . . . 4-17 Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Powerhead Disassembly . . . . . . . . . . . . . . . . . . 4-18 Cylinder Head Installation (Standard and
Water Pressure Relief Valve Components . 4-24 High Performance Models) . . . . . . . . . 4-44
Torque Specifications . . . . . . . . . . . . . . . . . . 4-24 Bleed Line Routing (Carbureted Models) . . . . 4-45
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . 4-25 Front View . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
Cylinder Block and Crankcase Cover . . . . . 4-25 Port Side View . . . . . . . . . . . . . . . . . . . . . . 4-45
Special Service Information . . . . . . . . . . . . . 4-25 Starboard Side View . . . . . . . . . . . . . . . . . 4-45
Cylinder Bores . . . . . . . . . . . . . . . . . . . . . . . . 4-25 Bleed Line Routing (Fuel Injected Models) . . . 4-45
Honing Procedure . . . . . . . . . . . . . . . . . . . 4-25 Front View . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
Pistons and Piston Rings . . . . . . . . . . . . . . . 4-27 Port Side View . . . . . . . . . . . . . . . . . . . . . . 4-46
Cleaning Piston Ring Grooves . . . . . . . . 4-27 Starboard Side View . . . . . . . . . . . . . . . . . 4-46
Measuring Piston Roundness . . . . . . . . . 4-28 Reinstalling Engine Components . . . . . . . . . . . 4-46
Cylinder Heads and Exhaust Divider Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 Throttle Lever and Shift Shaft . . . . . . . . . . . . . . 4-48
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29 Powerhead Installation on Driveshaft
Crankshaft (and End Cap) Bearings . . . . . . 4-29 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Reed Block Assembly . . . . . . . . . . . . . . . . . . 4-30 Break-ln Procedure . . . . . . . . . . . . . . . . . . . . . . . 4-57
Reed Block Housing . . . . . . . . . . . . . . . . . . . 4-30 Break-in Fuel Mixture . . . . . . . . . . . . . . . . . . 4-57
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . 4-30 Gasoline/Oil Mixing Ratio Chart . . . . . . . 4-57
Thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32 Engine Break-in Procedure
Powerhead Reassembly and Installation . . . . 4-33 (All Models) . . . . . . . . . . . . . . . . . . . . . . 4-57
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Crankshaft Installation . . . . . . . . . . . . . . . . . . 4-36
Special Information . . . . . . . . . . . . . . . . . . 4-36
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91–52344
54964
Protector Cap 91-24161
Piston Pin Tool 91-74607A1
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54965
"" "!
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12 Loctite Master Gasket (92-12564-1) #% 14
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95 2-4-C With Teflon (92-825407A12)
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9 Loctite PST Pipe Sealant (92-809822)
14 2 Cycle Outboard Oil (92-13249A24) ")
A = TO TELL-TALE HOSE
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B = TO ADAPTOR PLATE
!" !!
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92 Loctite 7649 Primer (92-809824)
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2 3 4
3
7 8
Bolts (5/16 in. - 18)
180 lb. in. (20.3 N·m)
5 11 12
6
EXHAUST DIVIDER PLATE BOLTS
200 lb. in. (22.6 N·m)
Apply Loctite 271 to threads
19 18
20 15
13 14
10
9
6
5
3
1
2
4
7
8
11
12
16 17
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c
Powerhead Removal from b
Driveshaft Housing
a e
1. Disconnect battery cables from battery terminals.
2. Disconnect fuel tank hose from outboard.
f
3. Remove top cowling.
4. Remove two screws which secure remote control d
harness retainer and remove retainer.
1994-1995 Standard Models –
51851
a - Control Harness
b - Powerhead Harness
a c - Trim 12 Volt Power Supply (RED)
d - Trim Up Lead (BLUE/WHITE)
e - Trim Down Lead (GREEN/WHITE)
f - Overheat Lead (TAN)
b
51854
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a - Screws
b - Retainer
b a
c b c
55007
a - Blue Trim Lead
51809 b - Green Trim Lead
a - Blue Trim Lead c - Black Trim Lead (Hidden – Attaches to relay mounting
b - Green Trim Lead plate)
c - Black Trim Lead
1996 Standard Models – Disconnect trim relay 1996 High Performance Models –
harnesses from each relay.
b
a
b
a
55006
54938 a - UP Trim Relay
b - DOWN Trim Relay
a - UP Trim Relay
b - DOWN Trim Relay
9. Slide outboard shift lever into neutral position.
10. Remove throttle cable.
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a
h
a
c
f
g
d a
e 51847
51853 a - Bolts
a - Lock Nut
b - Shift Cable Latch
c - Flat Washer (Hidden)
d - Nylon Wear Plate
e - Spring (Hidden)
f - Shift Cable
g - Anchor Bracket
h - Throttle Cable
51846
a - Bolts
b a
51803
a - Sta-Strap
b - Fuel Line
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a
52354
a - Bolts
b
55005
a 51851
a - Water Hose
54896 b - Fitting
a - Bolts
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a
b
55004
a - Hose
b - Fittings – Fittings must be turned to allow clearance for
bottom pan
51804
16. All Models – Remove 10 nuts and 10 washers (5 REMOVING ENGINE COMPONENTS
each side) from powerhead base.
Remove the following engine components:
Section 2 Starter Motor
Starter Motor
*Ignition Switch Boxes
*Ignition Coil
*Starter Solenoid
Voltage regulator/rectifier
Flywheel
*Stator Assembly
a a *Trigger Assembly
a *Low speed/high speed spark advance module
*Idle Stabilizer
Section 3
a Air Silencer
Carburetors and Linkage
a Fuel Pump
*Fuel Enrichment Valve
Fuel Injection Assembly
*Warning Module
51846 On-Board Oil Tank
a - Nuts and Washers (5 Each Side) Oil Pump
Section 7
Shift Cable Latch Assembly
Control Cable Anchor Bracket
*All ignition and electrical components should
remain attached to electrical plate. Plate with
components can be removed as an assembly.
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b
c
a
51852
a - Thermostat Cover 51852
b - Thermostat
c - Gasket a - Exhaust Manifold Cover
b - Seal
c - Gasket
3. Remove cylinder heads from engine block.
5. Remove reed block housing from cylinder block.
a
51847
a - Cylinder Head 51845
b - Gasket
c - Engine Block a - Reed Block Housing
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a 51849
a - Crankcase Attaching End Cap Bolts
51845
a - Pry Points
b - Crankcase Cover
a 51854
51848
CAUTION
Each connecting rod and end cap are a matched
machined set and must never be mismatched.
51849
51849
Inspection,” following.
51083
51081 a - Lockring
IMPORTANT: Warming the piston dome using a
8. Using an awl, scribe identification number of con-
torch lamp will ease removal and installation of
necting rod on inside of piston (1). Reassemble
piston pin.
piston on same connecting rod.
10. Support piston and tap out piston pin using
service tool (91-76159A1) as shown.
b
a
1
51853
a - Piston Pin
b - Piston Pin Tool (91-76159A1)
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a 51853
a - O-Ring
a b - Seal
CAUTION
Safety glasses should be worn when removing or
installing crankshaft sealing rings.
IMPORTANT: DO NOT remove oil pump drive
gear on crankshaft unless gear is damaged; i.e.
cracked, gear teeth chipped or fretting, or exces-
sive looseness. Refer to “Section 3E” for proper
oil drive gear installation procedures.
51848
a - Upper End Cap
b - Lower End Cap
51847
a - Sealing Rings
b - Oil Pump Drive Gear
b
a
51850
a - Retaining Ring
a a
b
c
51850
d
a - Bearing Race Halves
b - Roller Bearings
12
11
10
13
9
3
4
6
7 5
3 8
1
2
50803
b
Torque Specifications
a a - 150 lb. in. (17.0 N·m)
b - 25 lb. in. (3.0 N·m)
1 - Cover
2 - Bolt
3 - Gasket
4 - Relief Valve Plate
5 - Diaphragm
6 - Water Deflector
7 - Washer
8 - Screw
9 - Spring
10- Poppet Valve
11- Carrier
12- Grommet
13- Washer
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Cylinder Bores
1. Inspect cylinder bores for scoring, scuffing or a
transfer of aluminum from piston to cylinder wall.
Scoring or scuffing, if NOT TOO SEVERE, can
normally be removed by honing. If a transfer of
aluminum has occurred, an acidic solution such
as “TIDY BOWL CLEANER” should be applied to
the areas of the cylinder bore where transfer of
aluminum has occurred. After the acidic solution
has removed the transferred aluminum, thor-
oughly flush the cylinder bore(s) to remove any
remaining acid. Cylinder walls may now be
honed to remove any glaze and to aid in the seat-
ing of new piston rings.
HONING PROCEDURE
CAUTION a. When cylinders are to be honed, follow the
It crankcase cover or cylinder block is to be hone manufacturer’s recommendations for
submerged in a very strong cleaning solution, it use of the hone and cleaning and lubrication
will be necessary to remove the crankcase during honing.
cover/cylinder block bleed system from
b. For best results, a continuous flow of honing
crankcase cover/cylinder block to prevent oil should be pumped into the work area. If
damage to hoses and check valves.
pumping oil is not practical, use an oil can.
1. Thoroughly clean cylinder block and crankcase Apply oil generously and frequently on both
cover. Be sure that all sealant and old gaskets are stones and work area.
removed from matching surfaces. Be sure that
carbon deposits are removed from exhaust ports. CAUTION
2. Inspect cylinder block and crankcase cover for When honing cylinder block, remove hone
cracks or fractures. frequently and check condition of cylinder walls.
3. Check gasket surfaces for nicks, deep grooves, DO NOT hone any more than absolutely
cracks and distortion that could cause compres- necessary, as hone can remove cylinder wall
sion leakages. material rapidly.
4. Check all water and oil passages in cylinder block c. Start stroking at smallest diameter. Maintain
and crankcase cover to be sure that they are not firm stone pressure against cylinder wall to
obstructed and that plugs are in place and tight. assure fast stock removal and accurate
results.
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51846
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CAUTION
Care must be taken not to scratch the side
surfaces of the ring groove. Scratching the side
surface of the ring groove will damage the ring
groove.
1. Use a bristle brush and carbon remover solution
to remove carbon from side surfaces.
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a 1/2 in.
(12.7mm)
a
29/32
in. b
(23mm)
Lower Ball
a b Bearing
CAUTION
DO NOT intermix halves of upper and lower
crank- shaft center main roller bearings. Replace
bearings in pairs only.
4. Thoroughly inspect center main roller bearings.
51847 Replace bearings if they are rusted, fractured,
a - Crankshaft Journals worn, galled or badly discolored.
b - Crocus Cloth
c - Work Cloth “Back-and-Forth” Center main
Roller Bearing
WARNING
DO NOT spin-dry crankshaft ball bearing with
compressed air.
6. Thoroughly clean (with solvent) and dry 5. Clean (with solvent) and dry crankshaft roller
crankshaft and crankshaft ball bearing. Recheck bearing that is installed in upper end cap. Lubri-
surfaces of crankshaft. Replace crankshaft, if cate bearing with light oil.
surfaces cannot be properly “cleaned up.” If 6. Thoroughly inspect upper end cap roller bearing.
crankshaft will be re-used, lubricate surfaces of If roller bearing is rusted, fractured, worn, galled,
crankshaft with light oil to prevent rust. DO NOT badly discolored or loose inside of end cap
lubricate crankshaft ball bearing at this time. replace end cap and roller bearing as an
assembly.
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Upper Roller
Bearing
Connecting Rods
1. Check connecting rods for alignment by placing
rods on a surface plate. If light can be seen under
any portion of machined surfaces, if rod has a
slight wobble on plate, or if a 0.002 in. (0.051mm)
feeler gauge can be inserted between any
machined surface and surface plate, rod is bent
and must be discarded.
51851
2. Overheating: Overheating is visible as a bluish
Allowable reed opening is 0.020 in. (0.51mm) or less. bearing surface color that is caused by inade-
Replace reeds if either reed is standing open more quate lubrication or excessive RPM.
than 0.020 in. (0.51mm).
3. Rust: Rust formation on bearing surfaces
causes uneven pitting of surface(s).
Reed Block Housing
1. Check rubber bleed hoses. Replace any hose
that is cracked, cut or deteriorating.
2. Check operation of bleed system check valves in
reed block housing. If valves are working
properly, air can be drawn thru check valves “one
way” only. If air can pass thru a check valve both
ways, valve is not working properly and must be
replaced. a
51853
a - Pitting
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51853
a
5. Spalling: Spalling is the loss of bearing surface, 51853
and it resembles flaking or chipping. Spalling will a - Chatter Marks Between Arrows
be most evident on the thrust portion of the
connecting rod in line with the “I” beam. General 7. Uneven Wear: Uneven wear could be caused by
bearing surface deterioration could be caused by a bent connecting rod.
or accelerated by improper lubrication.
a a
51853
51853
a - Uneven Wear Between Arrows
a - Spalling
some instances, the connecting rod crank pin operation press at high speed while keeping
bore becomes highly polished. During operation, connecting rod at a 90° angle to slotted shaft.
Thermostats
1. Inspect thermostat covers and cylinder head
covers (thermostat opening) for cracks and
corrosion damage that could cause leakage.
Replace parts as necessary.
2. Remove and discard gasket from each
thermostat.
3. Wash thermostats with clean water. 51087
4. Using a thermostat tester, similar to the one
shown, test each thermostat as follows:
a. Open thermostat valve, then insert a thread
between valve and thermostat body. Allow
valve to close against thread.
b. Suspend thermostat (from thread) and ther-
mometer inside tester so that neither touches
the container. Bottom of thermometer must
be even with bottom of thermostat to obtain
correct temperature of thermostat opening.
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d
General
Before proceeding with powerhead reassembly, be
sure that all parts to be re-used have been carefully
cleaned and thoroughly inspected, as outlined in
“Cleaning and Inspection,” preceding. Parts, which c
have not been properly cleaned (or which are
questionable), can severely damage an otherwise
perfectly good powerhead within the first few minutes
a b
of operation. All new powerhead gaskets MUST BE
installed during reassembly.
During reassembly, lubricate parts with Quicksilver
2-Cycle Outboard Lubricant whenever “light oil” is
specified. Quicksilver part numbers of lubricants,
sealers and locking compounds and tools are listed 51852
in “Powerhead General Information,” preceding. a - Crankshaft
b - Crankshaft Ball Bearing
A torque wrench is essential for correct reassembly c - Suitable Mandrel
of powerhead. DO NOT attempt to reassemble d - Press
powerhead without using a torque wrench. Attaching
bolts for covers, housings and cylinder heads MUST 2. Reinstall retaining ring using a suitable pair of
BE torqued by tightening bolts in 3 progressive steps Snap Ring Pliers.
(following specified torque sequence) until specified
torque is reached (see “Example,” following).
a
EXAMPLE: If cylinder head attaching bolts require a
torque of 40 Ib. ft. (54.0 N·m), a) tighten all bolts to
10 Ib. ft. (13.5 N·m), following specified torque
sequence, b) tighten all bolts to 20 Ib. ft. (27.0 N·m),
following torque sequence, then finally c) tighten all
bolts to 40 Ib. ft. (54.0 N·m), following torque
sequence.
51854
a - Retaining Ring
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a b
51854
51849
a
51849
a - O-ring
a
10. Install oil seal into upper end cap as follows:
a. Apply a thin bead of Loctite 271 (obtain
locally) to outer diameter of upper end cap oil
a seal.
b. Use a suitable mandrel, press oil seal into
upper end cap (lip facing down) until
bottomed out on lip of end cap. Remove any
excess Loctite.
c. Lubricate oil seal lip with Quicksilver 2-4-C w/
Teflon (92-825407A12).
51847
a - Center main Bearing Races d. Lubricate O-ring seal surface on end cap with
Quicksilver 2-4-C w/Teflon (92-825407A12).
Install O-ring on end cap.
9. Install oil seals into lower end cap as follows:
a. Apply a thin bead of Loctite 271 (obtain
locally) to outer diameter on 2 lower end cap a
oil seals (a).
b. Using driver head (91-55919) press one oil
seal (lip facing down) into lower end cap until
firmly seated. Remove any excess Loctite.
c. Press second oil seal (lip facing down) until b
firmly seated on first oil seal. Remove any
excess Loctite. a - Oil Seal
b - Lip of End Cap
d. Lubricate oil seal lips with Quicksilver 2-4-C
w/Teflon (92-825407A12).
e. Lubricate O-ring seal surface on end cap with
2 cycle oil. Install o-ring over lower end cap.
a
a - Oil Seal
a
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51849
a - O-ring
51848
a - Upper End Cap
b - Lower End Cap
51848
a - Dowel Pins
dowel pin.
51080
a - Piston Pin Tool (91-74607A1)
b - Sleeve
51086
a - Piston Pin
b - Piston Pin Tool
b a
51086
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a
.093 in.
.063 in.
b
.056 in.
a b
.056 in.
51081
a - Piston Ring Expander
a b - Dot Side “Up” on Piston Ring
b
6. Rotate each piston ring so end of ring is aligned
with locating pin as shown.
7. Install Piston Ring Compressor.
8. Remove screws and connecting rod cap from
piston rod assembly being installed.
c
d 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 the port
side of engine and the word “UP” facing toward top
51852
of engine.
a - Piston Ring
b - Dots (Faces Up) Pistons with the letter “S” must be installed in the
c - Feeler Gauge starboard side of engine and the word “UP” toward
d - Ring End Gap top of engine.
UP UP
b CYL 4 CYL 3
P S
a - Dot or Letter
b - Piston Ring
UP UP
3. Use Piston Ring Expander (91-24697) and install CYL 6
P
CYL 5
S
piston rings (dot side up) on each piston. Spread
rings just enough to slip over piston.
4. Check piston rings to be sure that they fit freely
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in ring groove.
50802
51850
10. Apply Quicksilver Needle Bearing Assembly a - Connecting Rod Screws
Lubricant to bearing surface of connecting rod
and install bearing assembly, as shown. 13. Rotate crankshaft several times (using power-
11. Place connecting rod cap on connecting rod. head stand) to assure free operation (no binds
Apply light oil to threads and face of connecting and catching).
rod bolts. Thread connecting rod bolts finger-tight Connecting Rod Cap Alignment
while checking for correct alignment of the rod Check each connecting rod cap for correct
cap as shown. alignment. If not aligned, a ridge can be seen or felt
IMPORTANT: Connecting rod and connecting at the separating line as shown below. Correct any
rod caps are matched halves. Do not torque misalignment.
screws before completing the following Side View
procedure. Side View Incorrect-Cap
Correct on Backwards
• Run a pencil lightly over ground area.
• If pencil stops at fracture point, loosen bolts,
retighten, and check again.
NOTE: If you still feel the fracture point, discard the
rod.
a
a
a - Loctite Master Gasket (92-12564-1)
c
4
1
a b
3 2
51852
a - Gasket Strips 5 6
b - Edge of Cover
a - Upper End Cap Bolts – Torque to 150 lb. in. (17.0 N·m)
b - Lower End Cap Bolts – Torque to 80 lb. in. (9.0 N·m)
3. Apply a thin, even coat of Loctite Master Gasket c - Add Light Oil to Threads and Bolt Face – 8 Bolts
(3/8 in.-18) Torque to 38 lb. ft. (51.5 N·m)
#203 on mating surfaces of crankcase cover and
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50803
1 - Cover
2 - Bolt - 150 lb. in. (17.0 N·m)
3 - Gasket
d 4 - Relief Valve Plate
5 - Diaphragm
b 6 - Water Deflector
7 - Washer
c 8 - Screw - 25 lb. in. (3.0 N·m)
a
9 - Spring
50805 10- Poppet Valve
a - Divider Seal 11- Grommet
b - Exhaust Divider Plate 12- Carrier
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6 5
2 1
3 4
7 8
11 12
51852
j
i
k
51846
b - Overheat Temperature Sensor
(Carbureted Models)
FRONT VIEW
50801
50802
b b 50935
a - To Vapor Separator Thru Bleed Shut-Off Valve (0G303045
and Below) – Direct to Vapor Separator (0G303046 and
Above)
b - To Bottom of EFI Manifold if Equipped
NOTE: Filter removed S/N 0G654636 and above.
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b 50935
a - To Vapor Separator Thru Bleed Shut-Off Valve (0G303045
and Below) – Direct to Vapor Separator (0G303046 and
Above)
b - To Bottom of EFI Manifold if Equipped
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A B
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51851
a - Water Hose
51804 b - Fitting
a - Lifting Eye (91-90455)
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a
b
51851
a - Hose
b - Fittings – Fittings must be turned to allow clearance for 51846
bottom pan a - Bolts
All High Performance Models –
11. 1994 - 1995 Standard Models – Install four bolts
which secure bottom cowl halves together.
a
a b
51847
a - Bolts 55005
a - Bottom Pan
b - Skirt
c - Bolts, Washers, Nuts (8 each)
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a
52354
a - Bolts b a
51803
a - Sta-Strap
b - Fuel Line
a
13. 1994 - 1995 Standard Models – Connect BLUE,
GREEN and BLACK trim harness leads to trim
solenoids. Install trim harness to J-clip on
52352 exhaust cover.
a - Bolts
c b
51809
a a - Blue Trim Lead
b - Green Trim Lead
c - Black Trim Lead
54896
a - Bolts
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c
b
a
e
b d
a
51851
a - Control Harness
54938 b - Powerhead Harness
a - UP Trim Relay c - Trim 12 Volt Power Supply (RED)
b - DOWN Trim Relay d - Trim Up Lead (BLUE/WHITE)
e - Trim Down Lead (GREEN/WHITE)
1994 -1997 High Performance Models – f - Overheat Lead (TAN)
a
a
b
55173
a - UP Trim Relay
b - DOWN Trim Relay
51854
a - Screws
b - Retainer
b c
a
h
c
b
f a
g
e
d 51853
a - Lock Nut
b - Shift Cable Latch
c - Flat Washer (Hidden) 50345
d - Nylon Wear Plate
a - Vapor Separator
e - Spring (Hidden)
b - Bleed Hose In-Line Filter
f - Shift Cable
c - Bleed Hose
g - Anchor Bracket
h - Throttle Cable
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4
B
51804
COOLING
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Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-1
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-1
Water Pressure . . . . . . . . . . . . . . . . . . . . . . . 4B-1
Temperature Sensor . . . . . . . . . . . . . . . . . . 4B-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-1
Temperature Sensor . . . . . . . . . . . . . . . . . . 4B-2
Water Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-3
Water Flow Diagram . . . . . . . . . . . . . . . . . . 4B-5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 4B-7
Thermostat Test . . . . . . . . . . . . . . . . . . . . . . 4B-7
Water Pressure Check . . . . . . . . . . . . . . . . 4B-8
Water Pump Cleaning and Inspection . . . 4B-9
Problem Diagnosis . . . . . . . . . . . . . . . . . . . 4B-10
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Water Pressure
Idle 1.0 – 3.0 PSI
(6.8 – 20.5 kPa)
Poppet Valve Opening 4 – 9 PSI
(27.4 – 61.6 kPa)
W.O.T. 12.0 PSI (82.1 kPa)
Minimum
Temperature Sensor
Temperature Sensor(s)
Between Black and No
each TAN/BLK wire. Continuity
Between each lead and No
ground Continuity
56725
Special Tools
1. DMT 2000 Digital Tachometer Multimeter P/N
91-854009A1
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165
150
135
120
105
90
75
60
45
30
15
0
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 3.2
Resistance (k!)
Carburetor Models – Temperature sensor in star- Temperature sensor in port cylinder head provides
board cylinder head activates a warning horn when signal for optional temperature gauge.
engine temperature exceeds 240° F ± 8° F (115.6°C
± –13.3°C). Warning horn will deactivate when en-
gine temperature drops below 210° F ± 15° F (98.9°C
± –9.4°C).
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$ '
)
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!"
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!! 58063
&
( 1. Cylinder Head Cover – Removed from head for illustration, normally part of head casting.
2. Thermostat (2) 143° F (61.7° C) – If stuck closed, engine will over heat at low speed. If stuck open, engine will
not warm up at idle speed.
# 3. Check Valve for powerhead flush.
4. Poppet Valve – Controls water flow at high RPM.
! NOTE: If poppet valve is stuck open at low RPM, the engine will not reach proper operating temperature (run cold) and
will run rough at idle.
5. Primary Water Discharge into Driveshaft Housing.
6. Water passing through thermostats dump into the adaptor plate, then discharges down the exhaust.
"
7. Water Dump Holes for Exhaust Cooling (2 each) 1/8 in. (3.175 mm) – if holes are plugged, tuner pipe will melt
and bearing carrier prop shaft seals will be damaged.
8. Tell-Tale Outlet
9. Water Tube
10. Wall of Water – If water level height is insufficient, water pump may draw in air resulting in an overheated engine.
11. Excess water from wall of water around exhaust bucket exits around anodes.
12. Water Inlet
13. Water exiting exhaust discharge.
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90-824052R3 JUNE 2002
POWERHEAD - 4B-5
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90-824052R3 JUNE 2002
4B-6 - POWERHEAD
Troubleshooting NOTE: BE SURE that water in thermostat tester is
allowed to cool sufficiently [below 110°F (43.3° C)]
before testing the other thermostat.
Thermostat Test
1. Inspect thermostat covers and cylinder head
covers (thermostat opening) for cracks and
corrosion damage that could cause leakage.
Replace parts as necessary.
2. Remove and discard gasket from each
thermostat.
3. Wash thermostats with clean water.
4. Using a thermostat tester, similar to the one
shown, test each thermostat as follows:
a. Open thermostat valve, then insert a thread
between valve and thermostat body. Allow
valve to close against thread.
51087
b. Suspend thermostat (from thread) and ther-
mometer inside tester so that neither touches IMPORTANT: DO NOT operate engine without
the container. Bottom of thermometer must thermostats installed.
be even with bottom of thermostat to obtain
correct temperature of thermostat opening.
c. Fill thermostat tester with water to cover
thermostat.
d. Plug tester into electrical outlet.
e. Observe temperature at which thermostat
begins to open. (Thermostat will drop off
thread, that was installed in Step “a”, when it
starts to open.) Thermostat must begin to
open when temperature reaches 140°-145° F
(60°-63° C).
f. Continue to heat water until thermostat is
completely open.
g. Unplug thermostat tester.
h. Replace thermostat, if it fails to open at the
specified temperature, or if it does not fully
open.
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WARNING
Shut off engine and refer to troubleshooting
chart if water pressure is not within specification.
DO NOT exceed 3000 RPM in neutral.Engine
could start when turning flywheel to check timing
pointer adjustment. Remove all spark plugs from
engine to prevent engine from starting.
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a b
d
57408
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Pressure above 5 psi (34.2kPa) 1.0 – 3.0 PSI (6.8 – 20.5 kPa) •Plugged poppet by-pass pas-
@ idle sage or tell-tale
Pressure does not drop between 4 – 9 PSI (27.4 – 61.6 kPa) be- •Wrong poppet valve spring
1000 – 2500 RPM indicating pop- tween 1000 – 2200 RPM •Low output water pump
pet valve has opened •Inlet restriction
•Poppet valve vent hole plugged
or restricted
•Severe internal leak
•Defective poppet valve seal
Poppet valve flutter/water pres- 4 – 9 PSI (27.4 – 61.6 kPa) be- •Wrong poppet valve spring
sure drop does not stabilize prior tween 1000 – 2200 RPM •Low output water pump
to 2500 RPM •Inlet restriction
•Broken diaphragm in poppet
valve
•Severe internal leak
•Defective poppet valve seal
Pressure is below minimum speci- 12 PSI (54.9 – 68.5kPa) •Inlet restriction
fication @ W.O.T. •Engine mounted too high on
transom
•Engine trimmed out too far
•Configuration of boat bottom in-
terfering with adequate flow of wa-
ter to coolant inlets
•Severe internal leak
•Low output water pump
Pressure higher than normal @ Maximum pressure – 23 PSI •Outlet water passages restricted.
W.O.T., but engine still indicates (157.4 kPa) •Steam pocket has formed at top
overheat condition of powerhead due to lack of cool-
ing water
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5
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"* 95 2-4-C With Teflon (92-825407A12)
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A – Torque nut to 120 lb. in. (13.5 N·m) and then BACK OFF 1/4 turn.
B – Torque nut to 20 lb. ft. (27.0 N·m)
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19 Perfect Seal (92-34227-1)
33
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Dyna-Float Suspension
Refer to “Powerhead Removal” Section to d
d
Remove Powerhead. Refer to “Lower Unit
Removal” in This Section to Remove Lower Unit. c g
f
Removal and Disassembly
1. Remove shift shaft from driveshaft housing by e
pulling straight up on shaft.
2. Remove 5 bolts which secure exhaust extension
plate to drive shaft housing. After bolts are b
removed, lift exhaust extension plate off drive a
shaft housing.
3. Remove screws, which secure lower mount 51858
covers to drive shaft housing, then remove a - Shift Shaft Assembly
covers. b - Bushing
c - Lock Nut
d - Washer (2)
c e - Bushing (Hidden)
a f - Spring
g - Guide Block
b
d
e
51858
a - Shift Shaft Linkage
b - Exhaust Extension Plate
c - Exhaust Plate to Drive Shaft Housing Bolts
d - Driveshaft Housing Plate 51857
e - Lower Mount Cover (One Each Side) a - Upper Mount Nuts
f - Mounting Bracket Bolts
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b b
51850 51850
a - Drive Shaft Housing Plate a - Exhaust Tube
b - Drive Shaft Housing b - Drive Shaft Housing
6. Remove water tube from driveshaft housing 9. Remove all gasket and gasket material from
plate. driveshaft housing and related components.
7. Exhaust diffuser is secured to housing plate with 10. Remove bolts, which secure lower mount
6 bolts. Remove bolts, then remove diffuser. retainers to drive shaft housing, and remove
retainers.
b
11. Remove rubber caps from lower mount bolts.
51857
a - Water Tube
b - Exhaust Diffuser
51855
a - Bolts
b - Lower Mount Retainer (One Each Side)
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b
b
a
51855
a - Lower Mount Nuts
b - Lower Mount
51856 51857
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c b a
a
b
d
b c
d c
d 51855
a - Lower Mount
b - Nut [Torque to 50 lb. ft. (67.5 N·m)]
51857 c - Rubber Cap
d - Ground Strap (only one side)
a - Water Tube Seal (Plastic End)
b - Dyna-Float Mounts
c - Rubber Washers NOTE: If ground strap on lower mount is burned off,
d - Metal Washer inspect ground lead for trim motor for tightness
and/or continuity.
13. Install a ground strap onto one of the lower mount
mounting bolts.
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b
f
a
b
d
b
51855 e
a - Lower Mount Retainer
b - Bolts [Torque to 160 lb. in. (18.0 N·m)] 51858
c - Ground Strap a - Shift Shaft Linkage
b - Exhaust Extension Plate
c - Exhaust Plate to Driveshaft Housing Bolts, Torque to
23. Install lower mount covers and secure each 25 Ib. ft. (34.0 N·m)
cover with 2 screws. d - Drive Shaft Housing Plate
e - Lower Mount Cover (One Each Side)
f - Mounting Bracket Bolts, Torque to 40 Ib. ft. (54.0 N·m)
51855
a - Cover (One Each Side)
b - Screws (Two for Each Cover)
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5
B
POWER TRIM
SQUARE MOTOR AND
ROUND MOTOR DESIGN http://SelfFixer.com
Table of Contents
Page Page
Power Trim Specifications . . . . . . . . . . . . . . . . . 5B-1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-16
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-1 Testing Power Trim System With Test
Power Trim Components . . . . . . . . . . . . . . . . . . 5B-2 Gauge Kit (91-52915A6) . . . . . . . . . . . . . . . 5B-17
Power Trim Motor . . . . . . . . . . . . . . . . . . . . . . . . 5B-4 “UP” Pressure Check . . . . . . . . . . . . . . . . . 5B-17
Power Trim - General Information . . . . . . . . . . 5B-5 “DOWN” Pressure Check . . . . . . . . . . . . . . 5B-19
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-5 Hydraulic Repair . . . . . . . . . . . . . . . . . . . . . . 5B-21
Trimming Characteristics . . . . . . . . . . . . . . . 5B-5 Trim Rod End Cap Seal . . . . . . . . . . . . . . 5B-22
Trailering Outboard . . . . . . . . . . . . . . . . . . . . 5B-5 Tilt Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-22
Tilting Outboard Manually . . . . . . . . . . . . . . . 5B-6 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 5B-23
Trim “In” Angle Adjustment . . . . . . . . . . . . . . 5B-6 Scraper Seal Replacement . . . . . . . . . . . . 5B-25
Striker Plate Replacement . . . . . . . . . . . . . . 5B-6 Motor and Electrical Tests/Repair . . . . . . . . . . 5B-27
Anode Plate . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-7 Trim Pump Motor Test . . . . . . . . . . . . . . . . . 5B-27
Trim Indicator Gauge . . . . . . . . . . . . . . . . . . . 5B-7 Motor Disassembly . . . . . . . . . . . . . . . . . . . 5B-28
Check, Fill and Purge - Armature Tests . . . . . . . . . . . . . . . . . . . . . . . 5B-28
Power Trim System . . . . . . . . . . . . . . . . . . . . 5B-7 Motor Repair . . . . . . . . . . . . . . . . . . . . . . . . . 5B-29
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 5B-8 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 5B-32
Power Trim System with Relays and 2 Wire Reassembly - Motor and Pump . . . . . . . . . 5B-33
Trim Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-10 Priming Power Trim System . . . . . . . . . . . . 5B-34
Electrical System Troubleshooting . . . . . . . . . 5B-11 Trim Sender Test . . . . . . . . . . . . . . . . . . . . . 5B-34
General Checks . . . . . . . . . . . . . . . . . . . . . . 5B-11 Trim Indicator Gauge Needle Adjustment 5B-35
Troubleshooting the “Down Circuit” . . . . . . . . 5B-11 Trim Indicator Wiring Diagrams . . . . . . . . . . . 5B-36
Troubleshooting the “Up” Circuit . . . . . . . . . . . 5B-12
Troubleshooting the “Down” and “Up” Circuits
(All Circuits Inoperative) . . . . . . . . . . . . . . . . . . 5B-13
Power Trim Assembly Removal and
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-14
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Test Reading
Trim “UP” 1300 PSI (91kg/cm2)
Maximum Pressure
Trim “DOWN” 500 PSI (35kg/cm2) 54458
Minimum Pressure 6. Spanner Wrench 91-74951
Special Tools
1. Alignment Tool 91-11230
17238
2. Trim Rod Removal Tool 91-44486A1 51337
7. Multi-Meter DVA Tester 91-99750A1 or
DMT 2000 Digital Tachometer Multi-meter
91-854009A1
51337
3. Trim Rod Guide Removal Tool 91-44487A1
51337
4. Power Trim Test Gauge Kit 91-52915A6
a
73835
b
109
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13 13
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10 13
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9
13
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11
26 13
25
1 12
2
3
31 7
30
27
24
29 13
28
TORQUE
REF
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 END FRAME (Complete)
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The remote control (or trim panel) has switches that The outboard can be trimmed above the 20 degree
trim the outboard “Up” or “Down” and tilt the engine maximum trim angle (for shallow water operation,
for “Trailering”. The outboard can be trimmed and etc.), by keeping the engine RPM below 2000. If the
tilted under power or when the outboard is not RPM increases over 2000, propeller thrust (if
running. propeller is deep enough) will cause the trim system
to return the outboard to the 20 degree maximum trim
position.
Trimming Characteristics
WARNING
NOTE: Because hull designs react differently in
varying water conditions, varying the trim position will Excessive speed at minimum trim “In” may result
often improve the ride and boat handling. When in undesirable and/or unsafe steering condi-
trimming from a mid-trim position (with outboard trim tions. Test for handling characteristics after any
tab in a straight fore and aft position), expect the adjustment is made to the trim angle (and tilt pin
following: location).
TRIMMING OUTBOARD “UP” (OUT): Aids planing, particularly with heavy loads.
Improves ride in choppy water conditions.
WARNING Excess trim “In” can cause “bow steer” (boat veers to
Excessive trim “Out” may reduce the stability of left or right).
some high speed hulls. To correct instability, Transfers steering torque to starboard (right).
reduce the power gradually and trim the
outboard “In” slightly before resuming high Improves acceleration to planing speed.
speed operation. A rapid reduction in power will The “Down” circuit actuates the down solenoid
result in a sudden change of steering torque and (under engine cowl) and closes the motor circuit. The
may cause additional boat instability. electric motor drives the pump in the opposite
Will lift boat bow, increasing top speed. direction as the up circuit, forcing fluid thru
passageways into the “down” side of the tilt ram. The
Transfers steering torque harder to port (left) on tilt ram moves the engine down to the desired
installations below 23 in. (584.2 mm) transom height. position.
Increases gearcase clearance over submerged
objects. Trailering Outboard
Excess trim can cause “porpoising” and/or
The “Up” circuit first moves the trim cylinders; when
ventilation.
the trim cylinders extend fully, the tilt ram extends to
tilt the outboard to the full up position for trailering.
WARNING
Before the boat is trailered, the operator should
Excessive outboard trim angle will result in check for clearance between the outboard skeg and
insufficient water supply causing water pump pavement to prevent damage to skeg from striking
and/or powerhead overheating damage. Insure pavement.
water level is above water intake holes whenever
If the outboard must be tilted for clearance between
outboard is running.
skeg and pavement, a device such as a “Transom
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a 51353
a 51353 a - Trim Angle Adjustment Bolt
27930
a - Striker Plate (2)
b - Lockwasher
c - Locknut. Torque to 80 lb. in. (9 Nm)
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51368
a - Tilt Lock Lever
TO FILL:
IMPORTANT: This trim system is pressurized.
Remove “Fill” plug only when outboard is tilted
a 27932 to the full “Up” position or the trim/tilt rams are
a - Anode Plate fully extended. Retighten “Fill” plug before tilting
outboard down or retracting tilt/trim rams.
IMPORTANT: Do not paint or place protective Remove “Fill” plug and O-ring. System is full
coating on anode plate, or corrosion protection when oil level is present at fill hole. Tighten “Fill”
function will be lost. plug securely.
CAUTION
Tilt outboard to full “Up” position and engage tilt
lock lever before checking fluid level. System is
pressurized. Extend trim and tilt rams fully to 51344
depressurize system. a - Fill Plug and O-ring
Remove fill plug and O-ring. System is full when oil (remove to fill system, tighten securely)
b - Oil Can (fill system with Quicksilver Power
level is present at filler hole. Tighten fill plug securely. 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
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7
External Mounted Hydraulic
System 4
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"
5
51491
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'
(
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53794
UP Relay DOWN Relay
BLK = Black
BLU = Blue
#$ GRN = Green
RED = Red
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WHT = White
No Voltage Indicated:
Battery Voltage Indicated: Connect Voltmeter red lead to
Connect Voltmeter red lead to Point 4 and black lead to ground.
Point 3. Depress “Down” trim button. If
battery voltage is indicated, wire
is open between Points 4 and 1.
No Voltage Indicated:
Relay good: Connect Voltmeter red lead to
Point 5. If battery voltage is indi-
•Pump motor wiring is defec-
cated, trim switch is faulty. If no
tive.
battery voltage, check for loose
•Pump motor is defective. or corroded connection at Point
5 or open circuit in wire supply-
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No Voltage Indicated:
Battery Voltage Indicated: Connect Voltmeter red lead to
Connect Voltmeter red lead to Point 7 and black lead to ground.
Point 9. Depress “Up” trim button. If bat-
tery voltage is indicated, wire is
open between Points 7 and 8.
No Voltage Indicated:
Red wire is open between Point Battery Voltage Indicated:
3 and red terminal on back of
the ignition switch. There is an open circuit in wire
between Point 5 and Red ter-
•Check for loose or corroded
minal on the back of the ignition
connections.
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switch.
•Check for open circuit in wire.
Removal
1. Remove clamps on transom bracket to free
power trim wiring.
2. Raise outboard to full “Up” position and engage
tilt lock lever.
b c
a
51346
c
a - Tilt Lock Lever
b - Support Tool
c - Retaining Clips
aa a
2”
1/4”
a - Drill holes for retaining clips
b 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 re-
50605 moving power trim wires from solenoids.
a - Clamps 3. Disconnect power trim wires at solenoids (BLUE,
b - Tilt Lock Lever GREEN, and BLACK) or if relay style, disconnect
(BLUE and GREEN) bullet connector harness.
WARNING 4. Open filler cap and release any remaining
pressure in the system.
Failure to support outboard as shown could
result in personal injury and/or damage to
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outboard or boat.
51375
51339
cd
51375
a a - Transom Mount Bolts (2)
51354 b - Tilt Tube Nut (flush with end of thread)
c - Screws (3)
d - Washers (3)
a - Filler Cap
b - Retaining Nut IMPORTANT: Cross pin (a) should not be reused.
Replace with new cross pin.
5. Remove outboard transom mounting bolts, and
loosen tilt tube nut until nut is flush with end of tilt
tube thread.
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a b
51375
b
a
51339 c
a - Cross Pin
b - Upper Swivel Pin
c - Port Transom Bracket Screws and Washers (3). Remove a - Screw (6) Torque to 40 lb. ft. (54.0 N·m)
to Release Trim System from Outboard. b - Lockwasher (6) Install one per screw
c - Tilt Tube Nut
d - Upper Swivel Pin
Installation e - Slotted end
f - Cross hole (in line with slotted end)
1. Paint any exposed metal surfaces to prevent
corrosion. IMPORTANT: Cross pin should not be reused.
Install a new pin.
2. Apply Loctite 271 to screws. Install trim system,
starboard transom bracket, and tilt tube nut. 5. Position slot on end of swivel shaft in line with
hole in tilt ram end. Insert a punch into tilt ram hole
3. Use a 12 volt power source to extend tilt ram up to align cross hole in upper swivel shaft. Tap new
to align upper swivel shaft hole and end of ram. cross pin in until flush.
Connect trim motor wires [BLUE wire to POS-
ITIVE (+), BLACK wire to NEGATIVE (–)]. If ram a
extends too far, retract ram by connecting
GREEN wire to POSITIVE (+).
c b
4. Install Upper Swivel Pin with slotted end to left
(port) side of engine.
56921 56922
a - Conduit Tubing
54458
5. Thread hose from Test Gauge Kit (91-52915A6) into brass fitting on adaptor.
a d
c b 54459
a - Brass Fitting
b - Test Gauge Assembly
c - Tilt Pin (Position in Hole Shown)
d - Hose
e - Hose (Not Used)
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f a e d c b
!""!#
a - Test Adaptor (91-822778A3)
b - O-ring Installation Tool
c - Small O-ring (Install 1st)
d - Medium O-ring (Install 2nd)
e - Large O-ring (Install Last)
f - Brass Fitting
g - Apply Teflon Tape
a b
51374
10. Run trim “UP”. The minimum pressure should be
1300 P.S.I. (91 kg/cm2).
11. Run trim “DOWN” to release pressure and
remove spare tilt pin or bolts and nuts.
12. Tilt outboard full “UP” and engage tilt lock lever.
13. Slowly remove “Fill” plug to bleed pressure.
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54458
5. Thread hose from Test Gauge Kit (91-52915A6) into brass fitting on adaptor.
e
a d
g
b
c f 54459
a - Brass Fitting
b - Test Gauge Assembly
c - Tilt Pin (Position in Hole Shown)
d - Hose
e - Hose (Not Used)
f - OPEN Valve
g - CLOSE Valve
6. Reinstall fill plug. NOTE: If pressure is less than 500 PSI (35 kg/cm 2),
troubleshoot system per instructions on Page 5B-11.
7. Disengage tilt lock lever.
8. Open valve (f) and close valve (g).
9. Run trim “DOWN”. Minimum pressure should be
500 P.S.I. (35 kg/cm2).
10. Tilt outboard full “UP” and engage tilt lock lever.
11. Slowly remove “Fill” plug to bleed pressure.
12. Remove test gauge hose and adaptor.
13. Reinstall manual release valve and secure valve
with circlip.
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51337
51352 b
a - Trim Rod Cylinder Cap
b - Turn Counterclockwise to Remove
c - Removal Tool (91-44487A1)
d - Spanner Wrench (91-74951)
c 57886
a - Check Valve
b - Check Valve Screen
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51343
a - Seal (remove as shown)
2. Install new seal with seal lip up.
TRIM ROD INSTALLATION b
b
IMPORTANT: Components must be free of dirt
and lint. Any debris in the system can cause sys-
51353
tem to malfunction.
a - Trim Rods
NOTE: Install trim rod with check valve in the port b - Cylinder End Caps
(left) cylinder. c - Rod End Rollers (lubricate with Quicksilver Anti-Corrosion
Grease or Special Lubricant 101)
Tilt Ram
REMOVAL - TILT ROD ASSEMBLY ONLY
NOTE: Tilt Rod Assembly can be removed from cylinder without removing entire power trim system from
outboard.
TILT RAM COMPONENTS
1 - Housing - Tilt
Ram 7
2 - O-ring* (5) 6
3 - Memory Piston** 2
4 - Washer
5 - Piston Assembly
2
6 - End Cap 5
7 - Oil Seal
3
8 - Bolt (Design 1) 2 2
2
9 - Nut (Design 2) 1
4
10 - Tilt Rod 10
(Design 1)
11 - Tilt Rod 9
(Design 2) 8
11
51372
*O-ring Repair Kit Available, P.N. 811607A1 (Includes item 7, Oil Seal)
**Memory piston (3) for tilt rods (10 and 11) are different and must be used with correct tilt rod/cylinder assembly.
Memory piston for Design 1 tilt rod is flat, Design 2 is dished to clear nut and thread.
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51364
a - Cap (Turn Counterclockwise to Remove)
b - Spanner Wrench (91-74951)
c - Tilt Rod - Pull to Remove
a
b
a
51355
a - Cross Pin (Remove as shown)
b - Lower Swivel Pin (Remove as shown)
51378
Disassembly
1. Secure tilt ram in a soft jawed vise. Remove tilt
rod and cap.
51340
a - Bolt (Design 1) or Stud/Nut (Design 2)
b - O-Ring
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c
DO NOT REMOVE 51361
a - End Cap
b - Allen Plug
c - Hole In Shaft
51363
a - Washer 6. Lubricate shaft with Quicksilver Power Trim and
b - Check Valve Assembly (7) Steering Fluid. Insert shaft into cylinder.
c - Piston
51342
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e
c
51365
b
a - Cap
WARNING b - O-ring (2)
c - Scraper Seal
Memory Piston Cup may be expelled at a high d - Washer
velocity when air pressure is applied. Failure to e - Retaining Ring
place cylinder as shown below could result in
personal injury. REASSEMBLY
8. Place cylinder as shown. Hold down on cylinder IMPORTANT: Components must be clean for
and inject air into shaft opening. reassembly. Any debris in the system can cause
the system to malfunction.
c NOTE: Refer to “Tilt Ram Components” for proper
O-ring sizes.
1. Apply Quicksilver Power Trim and Steering Fluid
on O-rings prior to reassembly.
2. Install O-ring on Memory Piston Cup and install
in cylinder.
b
a
51353
a - Shop Cloth
b - Solid Surface b
c - Air Nozzle a 51372
a - O-ring
9. Remove shaft after Memory Piston Cup has been b - Memory Piston Cup (Design 1 shown)
expelled. Replace allen plug removed in Step 5
and tighten securely.
b
f
51340
a - Piston
b - O-ring
c - Check Valve Assembly (7)
d - Washer
e - Bolt or Locknut. (Tighten securely)
51376
a - End Cap 6. Clamp cylinder in a soft jawed vise and install tilt
b - O-ring (2) rod assembly. Use spanner wrench and tighten
c - Scraper seal end cap securely.
d - Washer
e - Retaining Ring c
f - End Cap 91-74951
51337
51341
a - Cylinder
b - Tilt Rod Assembly
c - End Cap (Tighten Securely.) Use Spanner Wrench.
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a
a
b
51356
a - Pin (Drive Against Knurled End)
51369
a - Alignment Tool (91-11230)
b - Shaft
Motor and Electrical
2. Align tilt ram and housing using alignment tool. Tests/Repair
3. Install shaft.
c
b
51352
a - Alignment Tool (91-11230)
b - Shaft
c - Groove
d - Hole [Groove (c) will Align with this Hole]
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53779
a - Frame
b - Armature
c - End Cap
Armature Tests
53774 TEST FOR SHORTS
2. If motor does not run, disassemble and check Check armature on a Growler per the Growler
components. manufacturer’s instructions. Replace armature if a
short is indicated.
a a
53774
a - Screw (2)
53786
Motor Repair
REMOVAL
NOTE: Power Trim System does not have to be
removed from outboard to repair/replace motor.
DISASSEMBLY
Refer to “Motor Disassembly” on page 5B-28 to
disassemble motor from pump.
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d
53779
a - Frame
b - Armature
c - Shim
d - Brush Card Assembly
e - O-rings
BRUSH REPLACEMENT
1. Brush replacement is required if brushes are 4. Remove 2 screws securing brush card to end
pitted, chipped, or if distance (a) between the cap.
brush pigtail and end of brush holder slot is 1/16
in. (1.6 mm) or less. Check distance with
armature installed. a c
a - Spade Terminal
b - Crimped Brush Lead
c - Screws
c d
b e
53783
53778
a - Brush Card
b - Metal Connector
c - Spade Connector
d - Screws and Lockwashers
e - O-ring
53785
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a
53781
a - Thermoswitch
53779
Reassembly
IMPORTANT: Components must be clean. Any
debris in power trim system can cause system to
malfunction.
53784
a - Armature
b - Shim
c - End Cap Assembly
d - Armature (Spread brushes to install armature into end cap)
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i e
f i
g
d
c
a b
53784
53776
a - Vise Grip Pliers
a b - Armature Shaft
c - O-ring
d - End Cap
53783 e - Harness Retainer
f - Retainer Hole
g - O-ring
a - O-rings
h - Frame Assembly
i - Screws
IMPORTANT: Attach Vise Grip pliers to
armature shaft before installing frame assembly.
The Vise Grip pliers will prevent the armature Reassembly - Motor and Pump
from being drawn out of the brush card assembly
NOTE: Drive shaft is a loose part and may fall out of
by the frame magnets while installing the frame
position.
assembly.
1. Install pump onto power trim manifold. Insure
3. Install Vise Grip pliers on armature shaft.
O-rings are in proper locations. Secure with two
4. Carefully install frame assembly over armature. (2) screws. Torque screws to 80 lb. in. (9 N·m).
5. Position harness retainer hole over tab in end
cap.
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c d
a a
b
b
c 53782
c c
51433
a - Pump (Flat Towards Starboard Transom Bracket)
b - Flat - Faces Starboard Transom Bracket)
c - O-rings (4)
d - Drive Shaft (Install in Center Hole in Pump)
1
22744
a - Trim Sender
a b - Screws, Loosen to Rotate Sender
c - Turn Sender Counterclockwise to raise needle reading
d - Turn Sender Clockwise to Lower Needle Reading
22908 e - Tilt lock lever
a - Trim sender
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a b c
d
e
d
e
22908
a - Trim Indicator
b - Remote Control
c - Trim Sender
d - Engine Ground
e - To Engine
f - Ignition Switch
g - Power Trim Harness
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6
A
LUBRICANT CAPACITY
REVERSE GEAR BACKLASH
Special Tools
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73658
Gear Housing Cover Nut Tool 91-61069
73605
70615
Bearing Carrier Removal Tool 91-46086A1 and
Puller Bolt 91-85716
73599
73655
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74187
Puller Rod 91-31229 and Nut 91-24156
74190
Mandrel 91-38628
73651
Forward Gear Bearing Tool 91-86943
74193
Driver Rod 91–37323
74184
Universal Puller Plate 91-37241 http://SelfFixer.com
73652
73429
Bearing Retainer Tool 91-43506
55079 73600
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g
f
e
d
Slotted Cross Pin Tool 91-86642-1
a - Adaptor (N.S.S.)
b - Bearing (N.S.S.)
c - Washer (N.S.S.) Threaded Cross Pin Tool 91-86642-2
d - Spring (24-14111)
e - Bolt (10-12580)
f - Nut (11-13953)
g - Set Screw (10-12575)
h - Sleeve (23-13946)
Mandrel 91-92788
Mandrel 91-15755
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73815
41 29
95 95
43
18
44
95
95
38
27
28
39 26
7 37 25
24
32 95
95
7
36 95
35 109 4
7
34
33
33 10 23
3
13 7
12
22
1647–
9147–C1 9
33
8
21 2
20
12 6
14 33
5
11
15
7
7 Loctite 271 (92-809820) 16
1
19 Perfect Seal (92-34227-1) 17
33 Loctite 680 (92-809833)
92 20
92 Loctite 7649 Primer (92-809824)
19
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48 1 WASHER
49 1 NUT 50 5.5
50 1 SLEEVE
1647– 77
9147–C1
80
79 81
94
B C
95
52
!
95
65 63
85
86
84 83 87
64
62
61
63
95
82 57
76 58
A 75
73 60
87 59 55
72 95
56
54
95
71
53
7 70 87
51
69
95
68 87
66
67
74
7 Loctite 271 (92-809820) 95
95
87 Super Duty Gear Lubricant (92-13783A24)
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36 25
26
24
37 7
95
22 95
35 23
95
30
7 21
34
95 109
20
33
32 13 Note
31
7 11
9 12 9
8
10 7 33
95 18
33
5 19
7 Loctite 271 (92-809820) 6
14
9 Loctite PST Pipe Sealant (92-809822)
19 Perfect Seal (92-34227-1) 15 92 1
3 16
109 GM Silicone Sealer (92-91600-1) 7
33 Loctite 680 (92-809833) 2
92 Loctite 7649 Primer (92-809824) 19
4
95 2-4-C With Teflon (92-825407A12) 17
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Note – This plug acts as a water diverter. The screw slot in the plug head MUST BE ALIGNED FORE
AND AFT with the gearcase for cooling water to be routed properly.
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84
94
85
87 86
95
1
50
95
79 60
80 81 63
82 87
62
61
59
60
78 95
57
77 58
76 87 56
71
55 52
72 95
95 70 54
53
95 69
87 51
7 68 49
66
73 67 87
74
64
65
75
7 Loctite 271 (92-809820) 95
95
87 Super Duty Gear Lubricant (92-13783A24)
94 Anti-Corrosion Grease (92-78376A6)
95 2-4-C With Teflon (92-825407A12)
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49 44
41
45 95
46
48
47
47
39 30
19 29
40 28
95
42 95
18
43
95
95
37
27 26
38 25
36 24
7
23
31
95
95
7
35 95
34 109 4
7 33
33
32 10
22
3
13 7
12
9
33
8
21 2
20
12 6
14 33
5
11
7 Loctite 271 (92-809820) 15
7
19 Perfect Seal (92-34227-1) 16
1
33 Loctite 680 (92-809833) 17
81
85
94
84 83
95
50
1
95
79 63 61
80
78
77 87
62
60
59
61
95
76 57
75 58
74
72 87 56
55 52
95
71 70 54
53
95 69
51
7
68 49
95
67
66 87
64
65
73
7 Loctite 271 (92-809820) 95
39 28
19
40
95 27
44 95
43 26
95
37 24
23
38
95
25 21
36 22 95
7
31
95
7
35
95 20
34 32
33
7
Note
7
13 10 9 8 9
12 109
11
33
33 11
12 18
14
19
6
95 5
15
7 Loctite 271 (92-809820)
9 Loctite PST Pipe Sealant (92-809822) 16 1
19 Perfect Seal (92-34227-1) 3 17
7
33 Loctite 680 (92-809833)
2
92
92 Loctite 7649 Primer (92-809824)
95 2-4-C With Teflon (92-825407A12) 4
109 GM Silicone Sealer (92-91600-1)
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Note – This plug acts as a water diverter. The screw slot in the plug head MUST BE ALIGNED FORE
AND AFT with the gearcase for cooling water to be routed properly.
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39 28
19
95
40
95 27
44
43 26
95
37 24
23
38 7
95
25 21
36 22 95
31
95
7
35
95 20
34 32
33
7
7
13 10 9 8 9
12 109
11
33
33 11
12 18
14
19
6
95 5
15
16 1
7 Loctite 271 (92-809820) 3 17
9 Loctite PST Pipe Sealant (92-809822) 7
19 Perfect Seal (92-34227-1) 2
92
33 Loctite 680 (92-809833)
4
92 Loctite 7649 Primer (92-809824)
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84
88
94
85
87 86
95
1
51
95
82
83 81 64 61
80
87
63
62
60
61
79 95
58
78
59
77 87
73 57
72 56 53
71 95 55
54
95 70
52
7
69 50
95 67
74 68 87
75
65
66
76
95
7 Loctite 271 (92-809820) 95
51866
d
f
d e
51871
a - Thrust Hub (Forward)
b - Propeller Shaft
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a
51871
b
a
a a - “Fill” Screw (Sport Master Gear Case has Drain/Fill Screw
Located in the Bearing Carrier)
b - “Vent” Screw
51879
a - Front Mounting Locknut 3. Inspect gear lubricant for metal particles.
b - Side Mounting Locknut (One Each Side) Presence of a small amount of fine metal
particles (resembling powder) indicates normal
DRAINING AND INSPECTING GEAR wear. Presence of larger particles (or a large
HOUSING LUBRICANT quantity of fine particles) indicates need for
1. Place gear housing in a suitable holding fixture or gear housing disassembly, and component
vise with the drive shaft in a vertical position. inspection.
4. Note the color of gear lubricant. White or cream
color indicates presence of water in lubricant.
Check drain pan for water separation from
lubricant. Presence of water in gear lubricant
indicates the need for disassembly, and
inspection of oil seals, seal surfaces, O-rings and
gear housing components.
NOTE: Gear lubricant drained from a recently run
gear case will be a light chocolate brown in color due
to agitation/aeration. Oil which is stabilized will be a
clear yellow brown in color.
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51874 a 51874
a - Pads
b. Drill two 3/16″ (4.8mm) diameter holes thru
the top of water pump cover (but not thru 11. Remove (and discard) O-ring from O-ring groove
insert). Drive insert out of cover with a punch on water pump base.
and hammer.
12. Using a screwdriver, pry oil seals out of water
pump base from gear housing side of base.
51865
a - Punch a
b - Tab of Tab Washer
b
4. Remove gear housing cover nut with Cover Nut
Tool (91-61069).
c 51867
a - Long Puller Jaws (91-46086A1)
b - Puller Bolt (91-85716)
51866 c - Thrust Hub
a - Cover Nut Tool (91-61069)
IMPORTANT: Prior to removal of shift shaft from
5. After cover nut has been removed, remove lock gear housing, recheck that gear housing is in
tab washer from gear housing. neutral position.
51885
a - Tab Washer
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b
Shift Shaft
d
CLEANING AND INSPECTION
1. Clean shift shaft and bushing with solvent and dry
with compressed air.
2. Check shift shaft splines on both ends for wear
and/or corrosion damage.
3. Inspect shift shaft for groove(s) at shift shaft
51867 bushing seal surface.
a - Shift Shaft Bushing 4. Inspect shift shaft bushing for corrosion damage.
b - Shift Shaft
c - “E” Ring (If Equipped) 5. Inspect shift shaft bushing oil seal for wear and/or
d - Retaining Ring (If Equipped) cuts.
NOTE: Oil seal in shift shaft bushing should be
replaced as a normal repair procedure.
CAUTION 6. Check “E” clip and retaining ring (if equipped) for
Propeller shaft, cam follower and shift cam, in damage. Replace if damaged.
most cases, will come out of gear housing by
simply pulling outward on propeller shaft. DO DISASSEMBLY
NOT FORCE shaft sideways or ATTEMPT TO
1. Remove (and discard) shift shaft bushing oil seal
PULL with a slide hammer or any mechanical
by prying it out or driving it out with a punch and
puller.
hammer.
8. Remove propeller shaft, cam follower and shift
2. Remove “E” clip and retaining ring if inspection
cam by pulling shaft straight out of gear housing.
determines that replacement of shift shaft is
(DO NOT JERK propeller shaft.) If propeller shaft
required.
will not come out, proceed with Step “a” or “b”,
following:
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CAUTION
DO NOT spin bearings dry with compressed air,
as this could cause bearing to score.
2. Bearing carrier propeller shaft needle bearing
condition is determined by propeller shaft
bearing surface condition. (See “Propeller Shaft
Inspection.”)
a 51874
3. Inspect reverse gear to pinion gear wear pattern a - Universal Puller Plate
(should be even and smooth). If not, replace b - Mandrel
reverse gear and pinion gear.
d. If reverse gear bearing has remained in
4. Check clutch jaws on reverse gear for damage. bearing carrier, use slide hammer to remove
Replace reverse gear, if damage is found on bearing in the same methods as was used to
clutch jaws. remove reverse gear (Step “b”).
5. Apply light oil to reverse gear bearing. Rotate 3. Propeller shaft oil seals can be removed by (a)
reverse gear bearing while checking bearing for using a pry bar, or (b) pressing seals out when
rough spots and/or catches. Push in and pull out propeller shaft needle bearing is pressed out of
on reverse gear to check for bearing side wear. bearing carrier.
Replace bearing if any of the listed conditions
exist.
a
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 replacement of gear or
bearing is required, remove gear and bearing as
follows:
a. Position bearing carrier in a soft jaw vise.
b. Use Slide Hammer (91-34569A1) and
remove reverse gear.
51868
a - Pry Bar
a
c
b
51872
c a - Balance Wheels
b - Bearing Surfaces
c - Watch for “Wobble”
51871
a - Propeller Shaft Needle Bearing Position propeller shaft needle bearing surfaces on
b - Mandrel “vee” blocks. Mount a dial indicator at front edge of
c - Oil Seals (Seals and snap ring Must be removed prior to propeller splines. Rotate propeller shaft. Dial
pressing out bearing on CLE, Sport Master and Torque indicator movement of more than .006” (.152mm) (or
Master gearcases)
noticeable “wobble”) is reason for replacement.
b b
Propeller Shaft
INSPECTION
1. Clean propeller shaft assembly with solvent and a
dry with compressed air. c
2. Inspect bearing carrier oil seal surfaces for
grooves. Run fingernail across seal surface to 51872
check for groove. Replace shaft if groove is a - “Vee” Blocks
b - Bearing Surfaces
found. c - Measure with Dial Indicator at this Point
3. Visually check bearing surfaces of propeller shaft
for pitting, grooves, scoring, uneven wear or 6. Inspect sliding clutch. Check reverse gear and
discoloration (bluish color) from overheating. forward gear clutch “jaws.” Rounded “jaws”
Replace shaft and corresponding needle bearing indicate one or more of the following:
if any of the above conditions are found. (Bearing
carrier needle bearing contacts propeller shaft a. Improper shift cable adjustment.
just in front of oil seal surface. Forward gear b. Improper shift habits of operator(s) (shift from
bearing contacts propeller shaft in front of sliding NEUTRAL to REVERSE gear too slowly).
clutch splines.)
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c 51864
51865
a - Clutch “Jaws” a - Detent Pins
b - Cross Pin
c - Sliding Clutch
7. Check condition of cam follower. If it shows wear
(pitting, scoring or rough surface), replace cam
5. Push cross pin out of sliding clutch and propeller
follower and shift cam.
shaft with Cross Pin Tool (91-86642).
DISASSEMBLY
1. Remove shift cam from cam follower. a
2. Insert a thin blade screwdriver or awl under first
coil of cross pin retainer spring and rotate
propeller shaft to unwind spring from sliding
clutch. DO NOT over-stretch spring.
b
b
51864
a - Cross Pin Tool (91-86642)
b - Cross Pin
a - Cross Pin
b - Cross Pin Tang
c - Cross Pin Tool 91-86642-2
a b c 51864
a - Cam Follower g
b - Clutch Actuator Rod
c - Propeller Shaft f
51870
a - Wooden Block
b - Soft Jaw Vise Covers
51866
c Forward Gear
Gear Housing
51873
d a - Thrust Washer
b - Mandrel
d - Plate
e - Puller Rod
f - Hold
a
a
c
51872
a - Mandrel (91-15755)
51872
9. CLE, Sport Master and Torque Master Gear a - Oil Seal (Lip of Seal Up)
b - Oil Seal Driver
Cases Only - Install snap ring to retain bearing. c - Seated
10. Apply Loctite 271 to outer diameter of propeller
shaft oil seals. 13. Wipe off excess Loctite.
11. Place one seal on longer shoulder side of Oil Seal 14. Apply a light coat of Quicksilver Super Duty Gear
Driver (91-31108) with lip of seal away from Lubricant onto the outside diameter of reverse
shoulder. Press seal into bearing carrier until seal gear ball bearing.
driver bottoms against bearing carrier.
15. Place bearing carrier over reverse gear and bear-
ing assembly. Press bearing carrier onto bearing.
b
c a
51872
a - Oil Seal (Lip of Seal Down)
b - Oil Seal Driver
c - Seated 51870
a - Mandrel
b - Seated
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Forward Gear
REASSEMBLY
1. Place forward gear on a press with gear teeth
down. a b
2. Apply a light coat of Quicksilver Super Duty Gear
Lubricant onto the inside diameter of forward
gear tapered bearing.
3. Position forward gear tapered bearing over gear.
4. Press bearing onto gear until firmly seated. (Be
sure to press only on inner race of bearing and
that bearing is firm against the gear.)
a 51873
a - Forward Gear Bearing Tool (91-86943)
b - Numbered Side of Needle Bearing
INSTALLATION
1. Place shim(s) (retained from disassembly) into
gear housing. If shim(s) were lost or a new gear
51869 housing is being used, start with approximately
a - Mandrel 0.010″ (0.254mm).
b - Wooden Block
2. Apply a light coat of Quicksilver Super Duty Gear
5. Apply a light coat of Quicksilver Super Duty Gear Lubricant to forward gear bearing race bore in
Lubricant to bore in center of forward gear. gear housing.
3. Position tapered bearing race squarely over
bearing bore in front portion of gear housing.
4. Place Bearing Driver Cup (91-87120) over
tapered bearing race.
NOTE: A used propeller shaft is recommended for
use in Step 5. If it is necessary, however, to use the
propeller shaft that will be installed in gear housing,
the propeller shaft must be disassembled. (Refer to
“Propeller Shaft Disassembly,” preceding.)
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c
b
a
51867
a - Tapered Bearing Race
c
b - Bearing Driver Cup (91-87120) d
c - Shim(s)
e 51867
a - Drive Shaft (rotate to engage splines with pinion gear)
b - Forward Gear Assembly
c - Pinion Gear
b d - Washer (located above pinion nut)
e - Pinion Nut [apply Loctite 271 on threads and install with
flat side away from pinion gear]
51726
10. Place shim(s) (retained from disassembly) into
gear housing. If shim(s) were lost or are not
a - Late Model Gearcase Without Lubrication Sleeve reusable (damaged), start with approximately
b - 3/8″ (9.5mm) Oil Flow Passage 0.010″ (0.254mm).
NOTE: Sport Master Only, Lower bearing race
6. Sport Master gear case only: Do not install cannot be installed until pinion gear height is set.
driveshaft lower bearing cup until pinion height is
determined.
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c
d b a
c a
b c
a d
51880
a - Driveshaft Holding Tool (91-34377A1)
b - Torque Wrench; Torque Nut to 75 lb. ft. (101.5 N·m).
CLE, Torque Master & Sportmaster Torque Nut to
e 85 lb. ft. (115 N.m)
c - Socket
d - Breaker Bar
g
g
e a
b
1 in. (25.4mm)
a
a - Adaptor
b - Bearing
c - Washer
d - Spring
e - Nut; Thread Nut ALL-the-Way Onto Bolt
f - Bolt a
g - Set Screw
h - Sleeve; Holes in Sleeve Must Align with Set Screw
c
a
e
c 51867
a - Propeller Shaft (DO NOT install shift cam)
b - Bearing Carrier (assembled)
b c - Cover Nut (Tighten; DO NOT torque)
d d - Bearing Carrier Removal Tool (91-46086A1)
e - Puller Bolt (91-85716); Torque to 45 lb. in. (5.0 N·m)
is not necessary to torque cover nut against c - Backlash Indicator Tool (91-78473)
d - Dial Indicator Holder (91-89897)
bearing carrier.) e - Dial Indicator (91-58222A1)
11. If backlash is MORE than the specified 7. Gently rock driveshaft. Dial indicator should
MAXIMUM, add shim(s) in front of forward gear show backlash of 0.030″-0.060″ (0.762mm-
bearing race to obtain correct backlash. When 01.54mm).
reinstalling pinion nut, apply Loctite 271 on If backlash is not as indicated, gear case is not
threads of nut. properly assembled or parts are excessively worn
NOTE: By adding or subtracting 0.001″ (0.025mm) and must be replaced before returning gear case to
shim, the backlash will change approximately 0.001″ service.
(0.025mm).
DRIVE SHAFT END PLAY (SPORT MASTER
REVERSE GEAR ONLY)
a c
d
c b
a 51880
NOTE: Do not install any shims below lower bearing 7. Install the adjustable nut part of the pre-load tool
cup at initial installation. (with the set screws) onto the driveshaft to use as
4. Apply High Pressure Grease (such as Chicago a surface for checking driveshaft end play. Tight-
Manufacturing and Distributing Lube #3) to the en set screws and position a dial indicator so that
O.D. of the driveshaft lower bearing cup and dial indicator arm touches the top surface of the
install cup into the gear case. upper nut.
d
c 51543
a - Spring
b - Clutch Actuator
c - Washer
d - Clutch Cross Pin
e - Locating Pin
Propeller Shaft
e
d REASSEMBLY/INSTALLATION
X
Y 1. Insert clutch actuator rod part way into end of
a - Shim Washer propeller shaft, then install cam follower onto the
b - Compression Spring end of rod and push rod the rest of the way into
c - Cross Pin Tool 91-86642 propeller shaft. Align cross pin slot in actuator rod
d - Clutch Actuator Rod
e - Retaining Pin (Shim washer must rest against flat side)
with cross pin slot in propeller shaft.
a
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b 51864
a - Compression Springs
b - Cam Follower
b
c
a
d
51864
a - The Line of “Sight”
b - Forward Retaining Spring (Wound Counterclockwise a
b
around Clutch) 51864
c - Rear Retaining Spring (Wound Clockwise around Clutch)
a - Shift Cam (Position as Shown)
d - Tang End of Spring
b - Gear Housing
c 51864
a - Cam Pocket
b - Cam Follower
c - Shift Cam
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b a
b
d c
51867 51871
a - Shift Shaft Bushing a - O-ring
b - Shift Shaft b - Cover Nut Tool
c - “E” Ring (If Equipped) c - Torque Wrench
d - Round Retaining Ring (If Equipped)
21. Bend one lock tab of tab washer into cover nut
13. Lubricate O-ring on bearing carrier with (only one will align).
Quicksilver 2-4-C w/Teflon Marine Lubricant. 22. Bend remaining tabs of tab washer toward front
14. Apply a light coat of Quicksilver 2-4-C w/Teflon of gear housing.
Marine Lubricant to outside diameter of bearing 23. Use Shift Shaft Bushing Tool (91-31107) and
carrier (where carrier contacts gear housing). torque shift shaft bushing to 50 Ib. ft. (67.5 N·m).
NOTE: When performing Step 16, rotate driveshaft
clockwise (viewed from top) to mesh pinion gear with
reverse gear.
NOTE: DO NOT reinstall thrust spacer onto propeller
shaft if installing high altitude 2.3:1 gear set.
a
15. Install thrust spacer onto propeller shaft.
16. Position bearing carrier over propeller shaft and
slide it into gear housing. (Be sure to align bear-
ing carrier keyway with gear housing keyway.)
b
17. Push bearing carrier in as far as possible by
hand, then install bearing carrier key.
18. Place tab washer against bearing carrier.
19. Apply Quicksilver 2-4-C w/Teflon Marine 51882
Lubricant to threads of cover nut and install cover a - Shift Shaft Bushing Tool (91-31107)
nut in gear housing (verify that the word “OFF” b - Shift Shaft Bushing
and arrow are visible).
Water Pump
CAUTION
Before torquing bearing carrier cover nut, gear REASSEMBLY/INSTALLATION
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case should either be mounted in a stand 1. Install oil seals into water pump base, as follows:
specifically designed for holding gear cases or
a. Place water pump base on a press.
c b
b
51869
c
a - Mandrel
b - Oil Seal (Smaller OD)
c - O-ring Groove
51868
a - Gasket (Water Pump Base to Face Plate)
b - Face Plate
c - Gasket (Face Plate to Water Pump Cover)
c
51866
a - Continuity Washer (if Equipped)
b - Rear Thrust Hub
c - Tab Washer
d - Propeller Nut
b
51866
a - Forward Thrust Hub
b - Propeller Shaft
6
B
COUNTER ROTATING
(LEFT HAND) GEAR CASE
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Table of Contents
Page Page
Gear Housing Specifications Reassembly and Installation of Counter
(Counter Rotation) . . . . . . . . . . . . . . . . . . . . . . 6B-1 Rotation Gear Housing . . . . . . . . . . . . . . . . . 6B-36
Pinion Depth . . . . . . . . . . . . . . . . . . . . . . . 6B-1 Driveshaft Needle Bearing . . . . . . . . . . . . . 6B-36
Reverse Gear Backlash . . . . . . . . . . . . . . 6B-1 Reassembly/Installation . . . . . . . . . . . . . 6B-36
Forward Gear Backlash . . . . . . . . . . . . . . 6B-1 Bearing Carrier, Forward Gear and
Lubricant Capacity . . . . . . . . . . . . . . . . . . 6B-1 Bearing Adaptor . . . . . . . . . . . . . . . . . . . . 6B-37
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-1 Reassembly . . . . . . . . . . . . . . . . . . . . . . . 6B-37
Gear Housing (Driveshaft)(Counter Rotation) Propeller Shaft Needle Roller Bearing
(S/N-0G437999 & BELOW) . . . . . . . . . . . . . . 6B-6 and Oil Seal Installation . . . . . . . . . . . 6B-37
Gear Housing (Prop Shaft)(Counter Rotation) Reverse Gear and Bearing Cup
(S/N-0G437999 & BELOW) . . . . . . . . . . . . . . 6B-8 Adaptor Reassembly . . . . . . . . . . . . . 6B-38
Gear Housing (Driveshaft)(Counter Rotation) Driveshaft and Pinion Gear . . . . . . . . . . . . 6B-39
(Sportmaster) . . . . . . . . . . . . . . . . . . . . . . . . . 6B-12 Reassembly/Installation . . . . . . . . . . . . . 6B-39
Gear Housing (Prop Shaft)(Counter Rotation) Pinion Gear Depth . . . . . . . . . . . . . . . . . . . . 6B-41
(Sportmaster) . . . . . . . . . . . . . . . . . . . . . . . . . 6B-16 Determining Pinion Gear Depth . . . . . . 6B-41
General Service Recommendations . . . . . . . 6B-20 Setting/Checking Driveshaft End Play
Removal, Disassembly, Cleaning and (Sport Master Only) . . . . . . . . . . . . . . 6B-42
Inspection of Counter Rotation (Left Hand) Reverse Gear . . . . . . . . . . . . . . . . . . . . . . . . 6B-44
Gear Housing . . . . . . . . . . . . . . . . . . . . . . . . . 6B-21 Determining Reverse Gear Backlash . 6B-44
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-21 Forward Gear . . . . . . . . . . . . . . . . . . . . . . . . 6B-45
Draining and Inspecting Gear Determining Forward Gear Backlash . 6B-45
Housing Lubricant . . . . . . . . . . . . . . . . 6B-22 Propeller Shaft/Forward Gear Bearing
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . 6B-23 Adapter/Bearing Carrier . . . . . . . . . . . . . 6B-47
Cleaning and Inspection . . . . . . . . . . . . 6B-23 Reassembly . . . . . . . . . . . . . . . . . . . . . . . 6B-47
Removal and Disassembly . . . . . . . . . . 6B-23 Clutch Actuator Rod . . . . . . . . . . . . . . . . . . 6B-50
Bearing Carrier and Propeller Shaft Reassembly/Shimming . . . . . . . . . . . . . 6B-50
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-24 Shift Shaft Bushing . . . . . . . . . . . . . . . . . . . 6B-51
Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-27 Reassembly . . . . . . . . . . . . . . . . . . . . . . . 6B-51
Cleaning and Inspection . . . . . . . . . . . . 6B-27 Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . 6B-51
Disassembly . . . . . . . . . . . . . . . . . . . . . . 6B-27 Reassembly/Installation . . . . . . . . . . . . . 6B-51
Cleaning/Inspection - Bearing Carrier . 6B-27 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . 6B-55
Disassembly- Bearing Carrier . . . . . . . . 6B-27 Reassembly/Installation . . . . . . . . . . . . . 6B-55
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . 6B-28 Gear Lubricant Filling Instructions . . . . . . . 6B-57
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 6B-28 Installing Gear Housing to Drive
Disassembly . . . . . . . . . . . . . . . . . . . . . . 6B-28 Shaft Housing . . . . . . . . . . . . . . . . . . . . . . 6B-57
Clutch Actuator Rod . . . . . . . . . . . . . . . . . . 6B-30 Propeller Installation . . . . . . . . . . . . . . . . . . 6B-58
Cleaning and Inspection . . . . . . . . . . . . 6B-30
Disassembly . . . . . . . . . . . . . . . . . . . . . . 6B-30
Forward Gear and Bearing Adapter . . . . . 6B-31
Disassembly/Cleaning/Inspection . . . . 6B-31
Pinion Gear and Driveshaft . . . . . . . . . . . . 6B-32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-32
Cleaning/Inspection . . . . . . . . . . . . . . . . 6B-34
Reverse Gear . . . . . . . . . . . . . . . . . . . . . . . . 6B-35
Removal and Disassembly . . . . . . . . . . 6B-35
Cleaning and Inspection . . . . . . . . . . . . 6B-35
Gear Housing . . . . . . . . . . . . . . . . . . . . . . . . 6B-36
Cleaning and Inspection . . . . . . . . . . . . 6B-36
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6B-0 - LOWER
6B - LOWER UNIT
UNIT 90-824052R3 JUNE 2002
Gear Housing Specifications Gear Housing Cover Nut Tool 91-61069
(Counter Rotation)
PINION DEPTH
Special Tools
Shift Shaft Bushing Tool 91-31107
73658
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70615
74187
Puller Rod 91-31229 and Nut 91-24156
73652
Cross Pin Tool 91-86642
74190
Mandrel 91-38628
55079
Oil Seal Driver 91-31108
74193
Driver Rod 91-37323
73651
Forward Gear Bearing Tool 91-86943
74184
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73429
Bearing Retainer Tool 91-43506
73600
Mandrel 91-92788
55079
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a 51876
Bearing Cup Driver 91-34379
g
f
e 73659
c
b
a - Adaptor (N.S.S.)
b - Bearing (N.S.S.)
c - Washer (N.S.S.)
d - Spring (24-14111)
e - Bolt (10-12580) Reverse Gear Installation Kit 91-18605A1 includes
f - Nut (11-13953) Pilot 91-18603; Retainer 91-18604; Shaft 91-18605
g - Set Screw (10-12575) and Screw 10-18602.
h - Sleeve (23-13946)
Pilot 91-18603
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Screw 10-18602
73815
Mandrel 91-31106
Slotted Cross Pin Tool 91-86642-1 Propeller Shaft Bearing Installer 91-816292
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7 Loctite 271 (92-809820)
9 Loctite PST Pipe Sealant (92-809822) 16 1
3 17
19 Perfect Seal (92-34227-1)
92
33 Loctite 680 (92-809833) 2
7
87 Super Duty Gear Lubricant (92-13783A24)
92 Loctite 7649 Primer (92-809824) 4
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Note: This plug acts as a water diverter. The screw slot in the plug head MUST BE ALIGNED FORE
AND AFT with the gearcase for cooling water to be routed properly.
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7 Loctite 271 (92-809820)
9 Loctite PST Pipe Sealant (92-809822) 16 1
3 17
19 Perfect Seal (92-34227-1)
92
33 Loctite 680 (92-809833) 2
7
87 Super Duty Gear Lubricant (92-13783A24)
92 Loctite 7649 Primer (92-809824) 4
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87 Super Duty Gear Lubricant (92-13783A24)
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87 Super Duty Gear Lubricant (92-13783A24)
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BEARINGS
Upon disassembly of gear housing, all bearings must
be cleaned and inspected. Clean bearings with
solvent and dry with compressed air. Air should be
directed at the bearing so that it passes thru the
bearing. DO NOT spin bearing with compressed air,
as this may cause bearing to score from lack of
lubrication. After cleaning, lubricate bearings with
Quicksilver Gear Lubricant. DO NOT lubricate
tapered bearing cups until after inspection.
Inspect all bearings for roughness, catches and
bearing race side wear. Work inner bearing race
in-and-out, while holding outer race, to check for side
wear. When inspecting tapered bearings, determine
condition of rollers and inner bearing race by
inspecting bearing cup for pitting, scoring, grooves,
uneven wear, imbedded particles and/or
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WARNING a
Disconnect high tension leads from spark plugs
and remove spark plugs from engine before
removing gear housing from driveshaft housing.
1. Disconnect high tension leads from spark plugs
and remove spark plugs from engine.
CAUTION
Gear housing MUST BE in NEUTRAL position
and shift shaft MUST BE removed from gear b
housing BEFORE propeller shaft can be
removed from gear housing.
2. Shift engine into NEUTRAL position. 51912
d 51916
a - Thrust Hub (Forward)
b - Propeller Shaft
c - Continuity Washer (If Equipped)
d - Rear Thrust Hub
e - Tab Washer
f - Propeller Nut
b
a
51873
a
a - Front Mounting Locknut 51871
b - Side Mounting Locknut (One Each Side)
a
51874
a - Pads
CAUTION
Gear housing MUST BE in neutral position, and
shift shaft MUST BE removed from gear housing
before propeller shaft can be removed from gear
a housing.
1. Place gear housing in a suitable holding fixture
with propeller shaft in a horizontal position.
2. Use Shift Shaft Bushing Tool (91-31107) to
unthread shift shaft bushing. (DO NOT remove
bushing from shift shaft at this time.)
51873 a
a - Drill Two Holes at These Locations
b
a
c 51867
a - Long Puller Jaws (91-46086A1)
b - Puller Bolt (91-85716)
c - Thrust Hub
a
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51885
a - Tab Washer
c
51877
DISASSEMBLY
1. Remove (and discard) shift shaft bushing oil seal
by prying it out or driving it out with a punch and 51886
hammer.
a - Thrust Bearing
2. Remove “E” clip and retaining ring if inspection b - Thrust Washer (Not Used In Sport Master Gear Case)
determines that replacement is required (if c - Bearing Carrier
equipped).
2. If thrust bearing, thrust washer or thrust bearing
CLEANING/INSPECTION - BEARING CARRIER surface on propeller shaft shows signs of rust,
pitting or blueing from lack of lubricant,
IMPORTANT: It is recommended that all seals and component(s) should be discarded.
O-rings be replaced (as a normal repair proce-
dure) to assure effective repair. 3. Remove bearing carrier oil seals.
NOTE: High Performance models have a retaining
CAUTION ring between the 2nd seal and the needle bearing.
DO NOT spin bearings dry with compressed air, This retaining ring must be removed before the
as this could cause bearing to score. needle bearing can be removed from the bearing
carrier.
1. Clean bearing carrier assembly with solvent and
dry with compressed air.
a
2. Bearing carrier propeller shaft needle bearing
condition is determined by propeller shaft
bearing surface condition. (See “Propeller
Shaft Inspection.”)
d
51878
a - Pry Bar
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b - Oil Seals
c - Bearing Carrier
d - Bearing Carrier Needle Bearing
c c
a
a
51885
a - Needle Bearing
b - Push Rod
c - Mandrel 51877
a - Balance Wheels
b - Bearing Surfaces
Propeller Shaft c - Watch for “Wobble”
51875
a - Cross Pin Retainer Spring
a
c
c b
a - Cross Pin
b - Cross Pin Tang
c - Cross Pin Tool 91-86642-2
a b
51875 a
51875
a - Cross Pin
a - Sliding Clutch
b - Punch
b - Reverse Gear Clutch Jaws
c - Forward Gear Clutch Jaws
g
f
b
51913 a - Spring Locating Pin
a - Forward Gear b - Shim Washer
b - Bearing Adaptor Assembly c - Compression Spring
d - Elongated Slot
e - Cross Pin Tool (91-86642)
f - Clutch Actuator Rod
Clutch Actuator Rod g - Shim Washer Must Lie Flat on Spring Locating Pin
CLEANING AND INSPECTION NOTE: “A” and “B” Measurements Must Be Equal
within 1/64″ [.016″ (0.4mm)].
CAUTION
Care MUST BE taken when handling clutch DISASSEMBLY
actuator rod. The locating pin is free and will fall IMPORTANT: Keep a record of shim amounts and
out, allowing compression springs and shims to location during disassembly of clutch actuator
fall out. rod to aid in reassembly.
1. Push locating pin out of clutch actuator rod.
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b a
c
a c
d b
51864
a - Locating Pin
b - Shim Washer(s)
c - Compression Springs
d - Clutch Actuator Rod
d
3. Refer to Step 6 in “Clutch Actuator Rod
lnspection” for spring length requirements.
e
DISASSEMBLY/CLEANING/INSPECTION f
51878
1. Remove forward gear from bearing adapter. a - Forward Gear
b - Forward Gear Clutch Teeth
2. Inspect forward gear clutch teeth for signs of c - Forward Gear Teeth
wear. If clutch teeth are worn, sliding clutch d - Forward Gear Hub
should be replaced also. e - Thrust Bearing
f - Spacer Shim
3. Inspect forward gear teeth for full tooth contact,
chips, pits and signs of rust. If forward gear teeth
are damaged, pinion gear must be inspected and
replaced if necessary.
4. Inspect forward gear hub for signs of pitting, rust,
scoring or discoloration (blueing) due to lack of
lubricant.
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51883
a - Thrust Washer b
b - O-Ring 51883
a - Forward Gear Bearing
7. Remove thrust bearing and thrust washer (not b - Bearing Adaptor
used on Sport Master gear cases) from bearing
adaptor. Thrust roller bearing should be
inspected for pitting, rust or signs of discoloration Pinion Gear and Driveshaft
(blueing) due to lack of lubricant. If thrust roller
bearing must be replaced, the bearing surfaces REMOVAL
on the thrust washer and propeller shaft where 1. Remove bearing retainer using Bearing Retainer
the thrust roller bearing rides should also be Tool (91-43506).
inspected for signs of wear.
b
c
a
b a
51865
51885
a - Bearing Retainer
a - Thrust Bearing b - Bearing Retainer Tool (91-43506)
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CAUTION b
DO NOT strike gear housing hard with the mallet
or allow gear housing to fall.
51865
a - Slide Hammer
b - Lubrication Sleeve (if equipped)
51878
a - Wooden Block
b - Soft Jaw Vise Covers
b
7. Reach into gear housing and remove pinion gear.
8. After driveshaft is removed from gear case,
remove and retain shim(s) that were located
under upper tapered driveshaft bearing.
NOTE: Sport Master gear cases do not use a lubrica-
tion sleeve.
51866
51869
a - Mandrel (91-37263)
b - Pilot* (91-36571)
b c - Driver Rod* (91-37323)
*From Bearing Removal and Installation Kit (91-31229A5)
a d
b a
c
51880
a - Installation Tool
b - Forward Gear Bearing
c - Bearing Adaptor
51881
PROPELLER SHAFT NEEDLE ROLLER a - Inner Seal
b - Mandrel (91-31108)
BEARING AND OIL SEAL INSTALLATION c - Bearing Carrier
1. Using mandrel 91-15755, press bearing carrier d - Mandrel Shoulder
needle bearing (number side up) into bearing 4. With seal lip facing towards mandrel, press outer
carrier until mandrel shoulder contacts bearing seal (a) using short end of mandrel (b)
carrier. (91-31108) into bearing carrier (c) until mandrel
NOTE: Sport Master models use Mandrel shoulder (d) bottoms out on bearing carrier.
91-816292 to install bearing carrier needle bearing.
Install snap ring above needle bearing to retain
bearing. b
a a d
d
c
c
b
51881
51881
a - Outer Seal
a - Mandrel (91-15755) b - Mandrel (91-31108)
b - Bearing Carrier Needle Bearing c - Bearing Carrier
c - Bearing Carrier d - Mandrel Shoulder
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d - Shoulder
5. Lubricate both seal lips with 2-4-C w/Teflon
2. Apply Loctite 271 (92-32609-1) to outside
Marine Lubricant (92-90018A12).
diameter of oil seals.
90-824052R3 JUNE 2002 LOWER UNIT - 6B-37
REVERSE GEAR AND BEARING CUP 3. With reverse gear teeth facing down, use a suit-
ADAPTOR REASSEMBLY able mandrel which contacts the INNER RACE
DIAMETER of the reverse gear ball bearing, to
1. With reverse gear teeth facing down, use
press bearing and adapter onto reverse gear until
mandrel (91-86943) to press propeller shaft
the bearing seats against gear shoulder.
needle bearing (NUMBERS/LETTERS UP) into
reverse gear until short shoulder on mandrel
bottoms on reverse gear. b
b
d
c
51883
d
a - Reverse Gear Teeth a
b - Mandrel (91-86943) 51879
c - Propeller Shaft Needle Bearing
a - Reverse Gear Teeth
d - Shoulder
b - Mandrel
c - Inner Race Diameter
NOTE: If gear housing has been replaced or inspec- d - Shoulder
tion determines that reverse gear bearing adapter
4. With Driver Tool (91-18605) installed in reverse
must be replaced, assemble and install as follows:
gear assembly, place entire assembly into gear
2. Place reverse gear ball bearing (NUMBER/ case.
LETTERS UP) on top of mandrel 91-31106.
Using suitable mandrel, press bearing cup
adapter onto reverse gear bearing. The purpose
of mandrel 91-31106 is to ensure that reverse
gear ball bearing is fully seated into bearing cup
adapter.
a
b
a
51876
a - Driver Tool (91-18605)
c b - Reverse Gear Assembly
e b b
c
c
51884 d
a - Pilot Ring (91-18603)
b - Driver Tool (91-18605)
c - Inner Ledge
d - Retainer (91-18604) e
e - Screw (10-18602)
a c
51870
a - Lubrication Sleeve b
b - Tab (MUST align with slot)
c - Slot a
51880
c g
g
b a
a
e
c
d
d c
DETERMINING PINION GEAR DEPTH 3. Align adaptor on driveshaft bearing pocket ledge.
NOTE: Read entire procedure before attempting any 4. With tool installed over driveshaft, tighten both
change in shim thickness. set screws securely, making certain to align
IMPORTANT: Reverse gear assembly must be sleeve holes to allow set screws to pass thru.
installed in gear housing when checking pinion
gear depth or an inaccurate measurement will be
obtained.
1. Clean gear housing bearing carrier shoulder.
2. Install Bearing Preload Tool (91-14311A1) over
driveshaft in sequence shown.
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c
a
b
1 in. (25.4mm)
d
24643
a - Pinion Gear Shimming Tool (91-74776 or 91-12349A2)
a b - Feeler Gauge
c - Obtain 0.025″ (0.64mm) Clearance between Shimming
Tool and Pinion Gear
d - Add or Subtract Shim(s) Here
b
NOTE: Bearing Preload Tool (91-14311A1) should
remain installed on driveshaft after setting pinion
gear depth as it is required to properly check forward
51870 gear and reverse gear backlash. However, if
a - Adaptor rebuilder wants to set driveshaft end play next, the
b - Ledge
preload tool will need to be removed.
6. Turn driveshaft clockwise 2 or more turns to seat SETTING/CHECKING DRIVESHAFT END PLAY
driveshaft bearings. (SPORT MASTER ONLY)
7. Insert Pinion Gear Locating Tool* (91-74776) into 1. With pinion height set in previous step, remove
gear housing until it bottoms out on bearing the preload tool from the driveshaft.
carrier shoulder.
2. Remove the upper bearing cup retainer with tool
*Pinion Gear Locating Tool (91-12349A2) can be 91-43506, and remove cup [leave upper cup
used. Use flat #7 and disc #2. Follow instructions shim(s) in place].
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c d
a
b
a 51880
c
a - Shim(s)
b - Upper Bearing Race
c - Bearing Retainer (Word “OFF” must be visible)
b Torque to 100 lb. ft. (135.5 N·m)
d - Bearing Retainer Tool (91-43506)
a - Driveshaft Holding Tool (91-34377A1)
b - Breaker Bar
c - Socket 7. Install the adjustable nut part of the pre-load tool
(with the set screws) onto the driveshaft to use as
NOTE: Do not install any shims below lower bearing a surface for checking driveshaft end play.
cup at initial installation. Tighten set screws and position a dial indicator so
that dial indicator arm touches the top surface of
4. Apply High Pressure Grease (such as Chicago the upper nut.
Manufacturing and Distributing Lube #3) to the
O.D. of the driveshaft lower bearing cup and
install cup into the gear case.
5. Reinstall driveshaft assembly into gear case. It is c
not necessary to reinstall the pinion gear for this
procedure. a
c d
b
a
a
e
c
51884
a - Driver Tool (91-18605)
a - Driveshaft Housing b - Pilot Ring (91-18603)
b - Lower Driveshaft Bearing Cup
c - Inner Ledge
c - Location of Driveshaft End Play Shims
d - Retainer (91-18604)
e - Screw (91-18602) [Torque to 45 lb. in. (5.0 N·m)]
12. Clean threads of driveshaft and apply Loctite
#271. 5. Thread stud adapter [from Bearing Preload Tool
(91-14311A1)] all the way onto stud.
13. Apply gear oil to all bearing surfaces and install
driveshaft assembly, upper bearing cup and 6. Install: Backlash Indicator Tool (91-78473)
retainer into the gear case. Tighten upper cup Dial Indicator Holder (91-89897)
retainer to a torque of 100 lb. ft. (135.5 N·m). Dial Indicator (91-58222A1)
NOTE: If reverse gear backlash has not yet been 7. Position dial indicator pointer on line marked “1”
determined, do not use a new pinion nut until final on Backlash Indicator Tool, if gear ratio is 1.87:1
assembly. (15 teeth on pinion gear), or on line marked “2” on
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e c
a
b c
a 51876
a - Load Washer (12-37429)
b - Shoulder
c - Propeller Shaft (44-93003)
a d
f h c
e a
g
c e j k
b i 51882
a - Prop Nut 51880
b - Flat Washer a - Stud Adaptor (from 91-44307A1)
c - PVC Pipe [5″ x 2″ (127mm x 50.8mm)] b - Stud
d - Cover Nut c - Backlash Indicator Tool (91-78473)
e - Tab Washer d - Dial Indicator Holder (91-89897)
f - Bearing Carrier e - Dial Indicator (91-58222A1)
g - Prop Shaft f - Dial Indicator Pointer
h - Bearing Adaptor
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i - Shim
j - Forward Gear
k - Load Washer
a c
51886
51882 a
a - Shim
c
Propeller Shaft/Forward Gear
Bearing Adapter/Bearing Carrier
REASSEMBLY
NOTE: Applying a light coat of 2-4-C w/Teflon Marine
Lubricant (92-90018A12) to the surfaces of both
thrust washers and thrust bearings will aid in keeping
them in place during assembly of bearing carrier into Top illustration: Production Gear Cases.
gear case. Bottom illustration: Sport Master gear cases.
1. Install thrust bearing and thrust washer into a - Thrust Bearing
b - Thrust Washer (Not Used in Sport Master Gear Cases)
bearing carrier.
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c - Bearing Carrier
a
c
b
b
51882 a
a - Propeller Shaft
b - Bearing Carrier
CAUTION
On Sport Master gear cases, the thrust bearing 51913
installed in the following step must be installed
with the bearing rollers against the flange of the
prop shaft or sever damage will occur.
a
c
b
a
a
b
51886
a - Thrust Bearing
51885 b - Thrust Washer
a - Forward Gear Bearing Adaptor
b - Bearing Carrier
c
51885
a - Thrust Washer
b - O-Ring
c - Bearing Adaptor
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a
c
d b
51864
b
Clutch Actuator Rod Sub-Assembly Sequence
a - Retaining Pin
b - Shim Washer(s)
c - Compression Springs
d - Clutch Actuator Rod
51878
a - Shoulder
b - Shim e
b c
a d c
8. Install forward gear onto bearing adaptor.
g
f
a
REASSEMBLY/INSTALLATION
1. Position sliding clutch onto propeller shaft. The
“GROOVED RINGS” on the Sport Master gear
cases should be installed with the grooves
toward the front of the gear housing. On all other
gear cases, the grooves are for manufacturing
purposes only and may be positioned towards
either gear. Cross pin hole and detent holes in
sliding clutch must line up with cross pin slot and
Clutch Actuator Rod with One Additional Shim detent notches in propeller shaft.
Washer Added to Front End a d f
b
c e g
51913
a - Sliding Clutch
b - Propeller Shaft
Clutch Actuator Rod with One Additional Shim c - Grooved Rings (Toward Front of Gear Case for Hi-Perfor-
Washer Added to Each End mance Applications)
d - Cross Pin Hole
e - Detent Holes
f - Cross Pin Slot
g - Detent Notches
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51875
a - Cam Follower
b - Clutch Actuator Rod a
c - Propeller Shaft
d - Cross Pin Slot
e - Clutch/Propeller Shaft
c b
3. Insert Cross Pin Tool (91-86642) through sliding
clutch, propeller shaft and actuator. The cross pin
a - Cross Pin
tool must pass between the compression b - Cross Pin Tang
springs. c - Cross Pin Tool 91-86642-2
4. Insert cross pin through sliding clutch, propeller
shaft and actuator rod forcing cross pin tool out. 5. Verify that flat sides of cross pin are toward
compression springs. Cross pin must be flush on
both ends with sliding clutch.
b 6. Apply a small amount of 2-4-C w/Teflon Marine
Lubricant (92-90018A12) to the rounded end of
each detent pin. Position a detent pin in each
detent pin hole of sliding clutch with rounded end
of pins toward propeller shaft.
a
c
51875
a - Cross Pin Tool
b - Cross Pin
a b
51879
a - Detent Pin
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b
a
a - Cross Pin Tang a
b - Spring (One on Each Side of Cross Pin Tang)
b
51864
a - Shift Cam (Position as Shown)
8. Place gear housing in a soft jaw vise with the b - Gear Housing
driveshaft in a vertical position.
9. Coat cam pocket of cam follower with 2-4-C 13. Rotate driveshaft to verify PINION GEAR and
w/Teflon Marine Lubricant. FORWARD GEAR are meshing properly and
propeller shaft/bearing carrier assembly are fully
seated in gear housing.
IMPORTANT: Do Not rotate the PROPSHAFT until
the shift shaft is installed or shift cam will
become dislocated.
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51885
b a - Tab Washer
51867 CAUTION
a - Shift Shaft Bushing Before torquing bearing carrier cover nut, gear
b - Shift Shaft
case should either be mounted in a stand specifi-
c - “E” Ring (if equipped)
d - Round Retaining Ring (if equipped) cally designed for holding gear cases or bolted to
a driveshaft housing to avoid possible damage to
the gear case.
14. Apply a light coat of 2-4-C w/Teflon to the threads
of the shift shaft bushing. 19. Using Cover Nut Tool (91-61069), torque cover
nut to 210 Ib. ft. (284.5 N·m) for production
15. Insert shift shaft down shift shaft hole in gear
models and 250 lb. ft. (339.0 N·m) for high
housing and into shift cam. It may be necessary
performance Pro Max and Super Magnum
to rotate shift shaft back-and-forth slightly in
models.
order for splines of shift shaft to match up with
splines of shift cam. Thread bushing into position,
but do not tighten down at this time.
16. Verify bearing carrier key way is aligned with gear
housing key way and install bearing carrier key. a b
51911
a - Cover Nut Tool (91-61069)
b - Cover Nut
20. Bend one lock tab of tab washer into cover nut
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c
b
b 51869
a - Mandrel
b - Oil Seal (Smaller OD)
c - O-Ring Groove
51882
a - Shift Shaft Bushing Tool (91-31107) 3. Install divider block if removed. Use RTV Sealer
b - Shift Shaft Bushing to seal seams between divider block and gear
housing.
Water Pump
REASSEMBLY/INSTALLATION
1. Install oil seals into water pump base, as follows:
a. Place water pump base on a press.
b. Just before installing each seal apply Loctite
a
271 on outside diameter of oil seal.
c. With a suitable mandrel, press the smaller
diameter oil seal into pump base with lip of oil
seal toward impeller side of base.
d. With a suitable mandrel, press the larger 51878
diameter oil seal into pump base with lip of oil a - Divider Block
seal toward gear housing side of base.
e. Wipe any excess Loctite from oil seals and
water pump base.
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CAUTION
A visual inspection of impeller drive key MUST
BE made to determine that drive key is on flat of
driveshaft after impeller is installed. If key has
moved off flat of driveshaft, repeat Steps 6 and 7.
a 7. Slide impeller down driveshaft to impeller drive
b 51866
key. Align drive key with key way in the center hub
of impeller, and slide impeller over drive key.
a - Water Pump Base
b - Gasket 8. If removed, install new water pump insert into
c - Hole (MUST be positioned as shown) pump cover as follows:
a. Apply Quicksilver Perfect Seal to water pump
5. Install the following in order: Pump base to face
insert area of pump cover.
plate gasket, face plate to pump cover gasket.
Gaskets and face plate are indexed by dowel pin b. Install water pump insert into pump cover,
location and must be installed correctly. being sure that tab on insert enters recess in
pump cover.
c. Wipe any excess Quicksilver Perfect Seal
from insert and cover.
b NOTE: If 2 holes were drilled in top of water pump
cover to aid in removal of insert, fill holes with RTV
c Sealer or equivalent. Allow to cure 24 hours prior to
operating engine.
9. Install water tube seal into pump cover. Plastic
side of seal goes into cover first.
10. Reinstall water tube guide into water pump cover.
11. Apply a light coat of Quicksilver 2-4-C w/Teflon
a
Marine Lubricant to inside of water pump insert.
12. Position assembled water pump cover over
driveshaft and lower over water pump studs.
51868 Rotate driveshaft in a clockwise direction (viewed
a - Gasket (Water Pump Base to Face Plate) from top), while pushing down on pump cover to
b - Face Plate
c - Gasket (Face Plate to Water Pump Cover) ease impeller entry into cover.
13. Install water pump cover retainer washers, nuts
6. Place impeller drive key on flat of driveshaft. and bolt.
Hold key on driveshaft with a small amount of
Quicksilver 2-4-C w/Teflon Marine Lubricant CAUTION
(92-90018A12). DO NOT over-torque nuts and bolt, as this could
cause cover to crack during operation.
14. Torque water pump nuts to 50 Ib. in. (5.5 N·m),
and water pump bolt to 35 Ib. in. (4.0 N·m).
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WARNING
Disconnect high tension leads from spark plugs
b
and remove spark plugs from engine before
installing gear housing onto driveshaft housing.
1. Tilt engine to full up position and engage the tilt
lock lever.
CAUTION
DO NOT allow lubricant on top of driveshaft.
Excess lubricant, that is trapped in clearance
space, will not allow driveshaft to fully engage
with crankshaft. Subsequently, tightening the
d
gear housing nuts (while excess lubricant is on
top of driveshaft) will load the
51874
driveshaft/crankshaft and damage either or both
a - Centrifugal Slinger
the powerhead and gear housing. Top of
b - Water Tube Guide
c - Water Tube Seal driveshaft is to be wiped free of lubricant.
d - Nuts, Bolts and Washers
3. Apply a light coat of Quicksilver 2-4-C w/Teflon
Marine Lubricant onto shift shaft splines. (DO
NOT allow lubricant on top of shift shaft.)
Gear Lubricant Filling Instructions
4. Apply a thin bead of G.E. Silicone Sealer
1. Remove any gasket material from “Fill” and (obtained locally) against the top of divider block.
“Vent” screws and gear housing.
5. Insert trim tab bolt into hole in rear of gear
2. Install new gaskets on “Fill” and ”Vent” screws. housing to driveshaft housing machined surface.
IMPORTANT: Never apply lubricant to gear 6. Shift gear housing into forward gear and place
housing without first removing “Vent” screw, or guide block anchor pin into forward gear position.
gear housing cannot be filled because of trapped
air. Fill gear housing ONLY when housing is in a
vertical position.
3. Slowly fill housing thru “Fill” hole with Quicksilver
Super Duty Lower Unit Lubricant until lubricant
flows out of “Vent” hole and no air bubbles are
visible. a
4. Install “Vent” screw into “Vent” hole. 51900
IMPORTANT: DO NOT lose more than one fluid a - Guide Block Anchor Pin
ounce (30cc) of gear lubricant while reinstalling
“Fill” screw. 7. Position gear housing so that the driveshaft is
protruding into driveshaft housing.
5. Remove grease tube (or hose) from “Fill” hole
and quickly install “Fill” screw into “Fill” hole. NOTE: If, while performing Step 8, the driveshaft
splines will not align with crankshaft splines, place a
propeller onto propeller shaft and turn it
counterclockwise as the gear housing is being
pushed toward driveshaft housing.
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CAUTION
DO NOT misinterpret propeller shaft movement
with propeller movement. If propeller and
propeller shaft together move forward-and-aft,
this is normal; however, propeller should not
move forward-and-aft on propeller shaft.
9. After first use, retighten propeller nut and again
secure with tab washer (Steps 7 and 8,
preceding). Propeller should be checked
periodically for tightness, particularly if a
stainless steel propeller is used.
b 51916
a - Continuity Washer (If Equipped)
b - Rear Thrust Hub
c - Tab Washer
d - Propeller Nut
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6
C
(1.78:1 Ratio) h
Ratio Pinion Forward Reverse
Depth Gear Gear
Backlash Backlash g
1.78:1 0.025 in. 0.016 in. to 0.030 in. to
(14/25 (0.635mm) 0.019 in. 0.050 in.
f
teeth) With Tool (0.41mm (0.762mm e
91-12349A to to
2 Using 0.48mm) 1.27mm)
Disc #1 Pointer on d
and Flat line mark
#1 #1
c
Gearcase Lubricant Capacity
b
1.78:1 Ratio 21.0 fl. oz. (621.0ml)
a
a - Adaptor (N.S.S.)
Special Tools b - Bearing (N.S.S.)
c - Washer (N.S.S.)
Pinion Gear Locating Tool 91-12349A2 d - Spring (24-14111)
e - Bolt (10-12580)
f - Nut (11-13953)
g - Set Screw (10-12575)
h - Sleeve (23-13946)
Pilot 91-36571
74187
Puller Plate 91-29310
74190
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74184
Mandrel 91-31106
70615
73658
74193
Oil Seal Driver 91-31108
73651
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55079
73599
Slide Hammer Puller 91-34569A1
Dial Indicator 91-58222A1
73655
Universal Puller Plate 91-37241
73429
Cover Nut Tool 91-73688
73652
Bearing Retainer Tool 91-43506
51866
Dial Indicator Holder 91-89897
73600
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29
34 33
36 95
33
35
18
27
19
28 17 95
95
30
16
31
95
25
43
12
26 42
7
95 24 41
40 95
19
39
23
95
7 22 38
21 2
20
6 3
95
8
7 5
95 33 11
14
9 33
4
13
15 1
7 Loctite 271 (92-809820)
19 Perfect Seal (92-34227-1)
33 Loctite 680 (92-809833) 7 92
14
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1
69
95
66 71
72
46
45 70
49 44
87
50
48
95
60
47
95
87
59 57
62 56
58 55
87
68 94
67
54
95
53
61
73
64 52
63 51
95
7 Loctite 271 (92-809820)
85 RTV Silicone Sealer (92-91601-1)
87 Super Duty Gear Lubricant (92-13783A24)
94 Anti-Corrosion Grease (92-78376A6)
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d e
c 51866
a - Bolt Location (Secures Anodic Plate)
51871 b - Bolt (Inside Anodic Plate Cavity)
c - Locknuts and Washers
a
CAUTION
DO NOT attempt to remove one of the side
mounting locknuts before opposite side locknut
is loosened sufficiently, or driveshaft housing
could be damaged.
9. Loosen the side mounting locknuts. (DO NOT
attempt to remove one nut before opposite side
nut is loosened sufficiently.)
b 10. Pull gear housing away from driveshaft housing
as far as the loosened nuts (in Step 9) will allow,
a - Thrust Hub then remove loosened nuts. (DO NOT allow gear
b - Propeller Shaft housing to fall, as it is now free.)
c - Propeller Hub
d - Tab Washer
e - Propeller Nut
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a b
51873
a - Front Mounting Locknut
b - Side Mounting Locknut (One Each Side)
b
51874
b. Drill two 3/16″ (4.8mm) diameter holes thru
the top of water pump cover (but not thru
insert) at locations shown. Drive insert out of
c cover with a punch and hammer.
a
d
51874 a
a - Centrifugal Slinger (If equipped)
b - Water Tube Guide
c - Water Tube Seal
d - Nuts, Bolt and Washers to be Removed
51873
a - Drill 2 Holes at These Locations
b a
51865
a - Punch
b - Tab of Tab Washer
c 51867
a - Long Puller Jaws
b - Puller Bolt (91-85716)
c - Thrust Hub
b
a
c
a
51877
a - Balance Wheels
c b - Bearing Surfaces
c - Watch for “Wobble”
51884
a - Propeller Shaft Needle Bearing
“Vee” Blocks and Dial Indicator
b - Mandrel Position propeller shaft needle bearing surfaces on
c - Oil Seals
“Vee” blocks. Mount a dial indicator at front edge of
propeller splines. Rotate propeller shaft. Dial
PROPELLER SHAFT CLEANING AND indicator movement of more than 0.006″ (0.152mm)
INSPECTION (or noticeable “wobble”) is reason for replacement.
NOTE: Cam follower and 3 metal balls (in end of
propeller shaft) are free and will fall out. Care should
be taken not to lose cam follower or 3 balls. b b
1. Clean propeller shaft assembly with solvent and
dry with compressed air.
2. Inspect bearing carrier oil seal surfaces for
grooves. Run fingernail across seal surface to
check for grooves. Replace shaft, if a groove is c a
found.
3. Visually check bearing surfaces of propeller shaft 51877
for pitting, grooves, scoring, uneven wear or a - “Vee” Blocks
discoloration (bluish color) from overheating. b - Bearing Surfaces
Replace shaft and corresponding needle bearing c - Measure with Dial Indicator at This Point
if any of the above conditions are found. (Bearing a
carrier needle bearing contacts propeller shaft
just in front of oil seal surface. Forward gear
bearing contacts propeller shaft in front of sliding
clutch splines).
4. Inspect propeller shaft splines for wear and/or
corrosion damage.
5. Check propeller shaft for straightness. Use either
method, following:
51876
a - Clutch “Dogs”
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a
51875
a - Bearing Retainer
b - Bearing Retainer Tool (91-43506)
51800
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51866
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Gear Housing
a CLEANING AND INSPECTION
1. Clean gear housing with solvent and dry with
compressed air.
2. Check gear housing carefully for impact damage.
3. Check for loose fitting bearing cups and needle
bearings.
4. Inspect bearing carrier cover nut retainer threads
in gear housing for corrosion damage and/or
51800 stripped threads.
a - Shift Shaft Bushing Tool (91-31107)
a b c
51882
50737 a - Suitable Mandrel
b - Pilot* (91-36571)
EARLY MODEL c - Driver Rod* (91-37323)
*From Bearing Removal and Installation Kit (91-31229A5)
50737
LATE MODEL
50737
EARLY MODEL
c
NOTE: New gear housings have a driveshaft needle
bearing already installed.
b CAUTION
If driveshaft needle bearing failure has occurred,
and original bearing race has turned in the gear
housing, gear housing must be replaced. Loose
fitting needle bearing will move out of position
and cause repeated failure.
1. Position driveshaft needle bearing over driver
head (from Bearing Removal and Installation Kit
91-31229A1) with numbered side of bearing
toward shoulder of driver head.
a
2. Thread driver rod from kit into driver head.
3. Lubricate needle bearing area of driveshaft
51869 cavity with a thin coat of Quicksilver 2-4-C
a - Mandrel (91-37263) w/Teflon Marine Lubricant.
b - Pilot* (91-36571)
c - Driver Rod* (91-37323) 4. Position rod, driver head and bearing into gear
housing driveshaft cavity.
*From Bearing Removal and Installation Kit (91-31229A5)
5. Place pilot washer (from kit) over driver rod and
slide it down into driveshaft bearing cavity.
IMPORTANT: Discard driveshaft needle bearing
after removal (bearing cannot be reused).
IMPORTANT: If DRIVESHAFT NEEDLE BEARING
RACE has spun in bore in gear housing, gear
housing MUST BE REPLACED as reinstalling
new bearing in old housing will result in repeat
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bearing failure.
f
51882
a - Mandrel (91-37263)
b - Pilot Washer (91-36571)
c - Driver Rod (91-37323)
e
d
Driveshaft Needle Bearing
b
a 51869
a - Mandrel (91-38628)
b - Bearing
c - Pilot (91-36571)
50737 d - Plate (91-29310)
e - Puller Rod (91-31229)
LATE MODEL f - Hold
CAUTION
If driveshaft needle bearing failure has occurred,
and original bearing race has turned in the gear
housing, gear housing must be replaced. Loose
fitting needle bearing will move out of position
and cause repeated failures.
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51880
51883 a - Mandrel
a - Longer Side
12. Place shift shaft bushing over shift shaft and start
threads of bushing into gear housing by hand.
6C-22 - LOWER UNIT 90-824052R3 JUNE 2002
5. Place one seal on longer shoulder side of Oil Seal 8. Assemble bearing carrier, as follows:
Driver (91-31108) with lip of seal away from
a. Install O-ring onto groove on bearing carrier.
shoulder. Press seal into bearing carrier until seal
driver bottoms against bearing carrier. IMPORTANT: The reverse gear thrust washer has
a tapered outside diameter so that one side is
b larger than the other. The smaller diameter of
washer must be toward bearing carrier.
51882
a - Oil Seal (Lip of Seal Down)
b - Oil Seal Driver (91-31108)
c - Seated
b 51885
a - O-ring Groove
a REASSEMBLY
1. Place forward gear on a press with gear teeth
down.
2. Apply Super Duty Gear Lubricant onto the inside
diameter of forward gear tapered bearing.
51876 3. Position forward gear tapered bearing over gear,
a - Oil Seal (Lip of Seal Up) as shown.
b - Oil Seal Driver
c - Seated 4. Press bearing onto gear until firmly seated. (Be
sure to press only on inner race of bearing that
bearing is firm against the gear.)
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28062 c
a - Forward Gear Needle Bearing Installation Tool 51879
(91-818149) a - Tapered Bearing Race
b - Bearing Driver Cup (91-31106)
c - Shims
7. Place shim(s) (retained from disassembly) into
gear housing. If shim(s) were lost, or are not 15. Remove nut from propeller shaft, then remove
reusable (damaged), start with approximately bearing carrier and propeller shaft from gear
0.010″ (0.254mm). housing. Lift bearing driver cup out of gear
housing.
8. Apply a light coat of Quicksilver Super Duty Gear
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Lubricant to forward gear bearing race bore in 16. Apply a light coat of oil on tapered bearing race.
gear housing. Place forward gear assembly into forward
bearing race.
b a
c
d
e
50064
a - Used Pinion Nut
b - Driveshaft
c - Tapered Bearing
d - Old Bearing Inner Race c
e - Universal Puller Plate (91-37241) d
b
51883
a - Driveshaft (Rotate to Engage Splines with Pinion Gear)
b - Forward Gear Assembly
c - Pinion Gear
d - Pinion Nut (Apply Loctite 271 on Threads and Install with
Flat Side Away from Pinion Gear)
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b
g
a g
51880
a - Shim(s)
b - Bearing Race
c - Bearing Retainer (Word “OFF” Must Be Visible); Torque to
100 lb. ft. (135.5 N·m)
d - Bearing Retainer Tool (91-43506)
e
d
c
b a
c
a
b
a - Adaptor
b - Bearing
c c - Washer
d - Spring
e - Nut; Thread Nut All-The-Way onto Bolt
f - Bolt
g - Set Screw
d h - Sleeve; Holes in Sleeve Must Align With Set Screw
a - Driveshaft Holding Tool (91-34377A1)
b - Torque Wrench; Torque Nut to 80 lb. ft. (108.5 N·m) 3. Align adaptor on driveshaft bearing pocket ledge.
c - Socket
d - Breaker Bar 4. With tool installed over driveshaft tighten both set
screws securely, making certain to align sleeve
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a
c
a
b
d
1 in. (25.4mm) c
24643
REASSEMBLY
a - Adaptor
1. Position sliding clutch over clutch splines with
b - Ledge
cross pin hole aligned with cross pin slot in
propeller shaft.
6. Turn driveshaft clockwise 2 or more turns to seat
driveshaft bearings. 2. Insert spring into end of propeller shaft.
7. Insert Pinion Gear Locating Tool 91-12349A2 3. Insert guide block (stepped end) into front end of
into gear housing until it bottoms-out on bearing propeller shaft with cross pin hole aligned with
carrier shoulder. Use Disc #1 and Flat #1. Follow cross pin hole in sliding clutch.
instructions provided with tool. CAM FOLLOWER COMPONENTS
8. Determine pinion gear depth by inserting a feeler
gauge thru access slot in pinion gear shimming
tool.
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b c
e
c 51867
a - Propeller Shaft (Horizontal Position)
b - Bearing Carrier (Assembled and Bearing Carrier Key
Installed)
c - Cover Nut (Tighten; DO NOT Torque)
d - Bearing Carrier Removal Tool (91-46086A1)
e - Puller Bolt (91-85716); Torque to 45 lbs. in. (5.0 N·m)
INSTALLATION
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e 15. Bend one lock tab of tab washer into cover nut
d (only one will align).
16. Bend remaining tabs of tab washer toward front
of gear housing.
NOTE: Reverse gear backlash is not adjustable.
c However, reverse gear backlash which should be
0.030″ - 0.048″ (0.76mm - 1.21 mm) can be mea-
sured to determine proper assembly of gearcase as
follows:
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c
c
b
51869
a - Mandrel
b - Oil Seal (Smaller OD)
c - O-ring Groove
a
3. Install O-ring into O-ring groove of water pump
base.
51868
4. Lubricate O-ring and oil seals with 2-4-C w/Teflon a - Gasket (Water Pump Base to Face Plate)
Marine Lubricant (92-90018A12). b - Face Plate
c - Gasket (Face Plate to Water Pump Cover)
d
Installing Gear Housing to Driveshaft
51874 Housing
a - Centrifugal Slinger
b - Water Tube Guide WARNING
c - Water Tube Seal
d - Nuts, Bolts and Washers Disconnect high tension leads from spark plugs
and remove spark plugs from engine before
10. Install water tube seal into pump cover. Verify that installing gear housing onto driveshaft housing.
plastic side of seal goes into cover first. 1. Tilt outboard to full up position and engage the tilt
11. Reinstall water tube guide into water pump cover. lock lever.
2. Apply a light coat of Quicksilver 2-4-C w/Teflon
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a
e
51866
b c - Propeller Hub
d - Tab Washer
e - Propeller Nut
51801
a - Thrust Hub
b - Propeller Shaft
6
D
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(Standard Rotation)
Ratio Pinion Forward Reverse
Depth Gear Gear
Backlash Backlash
1.87:1 0.025 in. 0.018 in. to 0.030 in. to
(15/28 (0.635mm) 0.027 in. 0.050 in.
teeth) With Tool (0.460mm (0.762mm
91-12349A2 to to
using Disc 0.686mm) 1.27mm) 73605
#2 and Flat Pointer on
#7 line mark Bearing Carrier Removal Tool 91-46086A1 and
#1 Puller Bolt 91-85716
2.0:1 0.025 in. 0.015 in. to 0.030 in. to
(15/30 (0.635mm) 0.022 in. 0.050 in.
teeth) With Tool (0.38mm (0.762mm
91-12349A2 to to
using Disc 0.56mm) 1.27mm)
#2 and Flat Pointer on
#7 line mark
#2
2.3:1 0.025 in. 0.018 in. to 0.030 in. to
(13/30 (0.635mm) 0.023 in. 0.050 in.
73599
teeth) With Tool (0.46mm (0.762mm
91-12349A2 to to Slide Hammer Puller 91-34569A1
using Disc 0.58mm) 1.27mm)
#2 and Flat Pointer on
#7 line mark
#4
73658
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70615
74187
Puller Rod 91-31229 and Nut 91-24156
73652
Cross Pin Tool 91-86642
74190
Mandrel 91-38628
55079
74193
Driver Rod 91-37323
73651
Forward Gear Bearing Tool 91-86943
74184
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73429
Bearing Retainer Tool 91-43506
55079 73600
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g
f
e
Dial Indicator Holder 91-89897
d
a
Mandrel 91-15755
a - Adaptor (N.S.S.)
b - Bearing (N.S.S.)
c - Washer (N.S.S.)
d - Spring (24-14111)
e - Bolt (10-12580)
f - Nut (11-13953)
g - Set Screw (10-12575)
h - Sleeve (23-13946) 73815
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95
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51866
a - Bolt (Secures Trim Tab)
b b - Bolt (Inside Trim Tab Cavity)
51866 c - Locknuts and Washers
d
f
d e
51871
a - Thrust Hub (Forward)
b - Propeller Shaft
c - Continuity Washer (If Equipped)
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a
51871
a - “Fill” Screw
b b - “Vent” Screw
a 51874
51874 a - Pads
b. Drill two 3/16″ (4.8mm) diameter holes thru 11. Remove (and discard) O-ring from O-ring groove
the top of water pump cover (but not thru on water pump base.
insert). Drive insert out of cover with a punch
and hammer. 12. Using a screwdriver, pry oil seals out of water
pump base from gear housing side of base.
a CAUTION
Gear housing MUST BE in NEUTRAL position,
and shift shaft MUST BE removed from gear
housing before propeller shaft can be removed
from gear housing.
1. Place gear housing in a suitable holding fixture
with propeller shaft in a horizontal position.
2. Use Shift Shaft Bushing Tool (91-31107) to
unthread shift shaft bushing. (DO NOT remove
bushing from shift shaft at this time.)
51873
a - Drill Two Holes at These Locations
NEUTRAL position.
CAUTION
Once bearing carrier is removed from gear
housing, extreme care MUST BE taken not to
apply any side force on propeller shaft. Side
force on propeller shaft may break the neck of the
clutch actuator rod.
6. Use long Puller Jaws (91-46086A1) and Puller
b a Bolt (91-85716) to remove bearing carrier. (Use
propeller thrust hub to maintain outward pressure
51865 on puller jaws.)
a - Punch NOTE: When bearing carrier is removed from gear
b - Tab of Tab Washer
housing, the bearing carrier alignment key will come
out with it.
4. Remove gear housing cover nut with Cover Nut
Tool (91-61069).
a
b
51866
a - Cover Nut Tool (91-61069)
c 51867
a - Long Puller Jaws (91-46086A1)
b - Puller Bolt (91-85716)
c - Thrust Hub
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Shift Shaft
DISASSEMBLY
CAUTION
1. Remove (and discard) shift shaft bushing oil seal
Propeller shaft, cam follower and shift cam, in
by prying it out or driving it out with a punch and
most cases, will come out of gear housing by
hammer.
simply pulling outward on propeller shaft. DO
NOT FORCE shaft sideways or ATTEMPT TO
PULL with a slide hammer or any mechanical CLEANING/INSPECTION - BEARING CARRIER
puller. IMPORTANT: It is recommended that all seals and
8. Remove propeller shaft, cam follower and shift O-rings be replaced (as a normal repair
cam by pulling shaft straight out of gear housing. procedure) to assure effective repair.
(DO NOT JERK propeller shaft.) If propeller shaft 1. Clean bearing carrier assembly with solvent and
will not come out, proceed with Step “a” or “b”, dry with compressed air.
following:
a. Push propeller shaft back into place against CAUTION
the forward gear. Visually inspect location of DO NOT spin bearings dry with compressed air,
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shift cam by looking down shift shaft hole as this could cause bearing to score.
(illuminated with a flashlight). If splined hole
51868
51868
a - Pry Bar
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a
c
b
51872
c a - Balance Wheels
b - Bearing Surfaces
c - Watch for “Wobble”
51871
a - Propeller Shaft Needle Bearing Position propeller shaft needle bearing surfaces on
b - Mandrel “vee” blocks. Mount a dial indicator at front edge of
c - Oil Seals propeller splines. Rotate propeller shaft. Dial
indicator movement of more than 0.006” (.152mm)
(or noticeable “wobble”) is reason for replacement.
Propeller Shaft b b
INSPECTION
1. Clean propeller shaft assembly with solvent and
dry with compressed air. a
c
2. Inspect bearing carrier oil seal surfaces for
grooves. Run fingernail across seal surface to
check for groove. Replace shaft if groove is 51872
found. a - “Vee” Blocks
b - Bearing Surfaces
3. Visually check bearing surfaces of propeller shaft c - Measure with Dial Indicator at this Point
for pitting, grooves, scoring, uneven wear or
discoloration (bluish color) from overheating. 6. Inspect sliding clutch. Check reverse gear and
Replace shaft and corresponding needle bearing forward gear clutch “jaws.” Rounded “jaws”
if any of the above conditions are found. (Bearing indicate one or more of the following:
carrier needle bearing contacts propeller shaft
just in front of oil seal surface. Forward gear a. Improper shift cable adjustment.
bearing contacts propeller shaft in front of sliding b. Improper shift habits of operator(s) (shift from
clutch splines.) NEUTRAL to REVERSE gear too slowly).
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a
b
a
51865
a - Clutch “Jaws”
b
51864
a - Cross Pin Tool (91-86642)
b - Cross Pin
a
51864
a - Awl
b - Cross Pin Retainer Spring
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REMOVAL
1. Remove bearing retainer using Bearing Retainer 51870
Tool (91-43506). a - Wooden Block
b - Soft Jaw Vise Covers
51866
b
10. Remove 18 loose needles from outer race of
driveshaft needle bearing.
11. If inspection of driveshaft needle bearing surface
determines that replacement of needle bearing is a
required, the 18 loose needle bearings
previously removed must be reinstalled in
bearing race to provide surface for mandrel to
51869
drive against.
a - Mandrel (91-37263)
NOTE: FORWARD gear must be removed first b - Pilot* (91-36571)
BEFORE removing driveshaft needle bearing. c - Driver Rod* (91-37323)
Forward Gear
a
51869
a - Mandrel
b - Bearing
c - Pilot
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d - Plate
e - Puller Rod
f - Hold
51873 a
a - Thrust Washer
b - Mandrel
51869
a a - Mandrel
b - Wooden Block
51870
a - Mandrel
b - Seated
51873
a - Forward Gear Bearing Tool (91-86943)
b - Numbered Side of Needle Bearing
e 51867
a - Driveshaft (rotate to engage splines with pinion gear)
a b - Forward Gear Assembly
c - Pinion Gear
d - Washer (located above pinion nut)
e - Pinion Nut (apply Loctite 271 on threads and install with
flat side away from pinion gear.)
b
c
d
e
a h
51880
a - Shim(s)
b - Bearing Race g
c - Bearing Retainer (Word “OFF” must be visible) g
Torque to 100 lb. ft. (135.5 N·m)
d - Bearing Retainer Tool (91-43506)
c c
b a
b
a
a
a - Adaptor
b - Bearing
c - Washer
d - Spring
c e - Nut; Thread Nut ALL-the-Way Onto Bolt
f - Bolt
g - Set Screw
h - Sleeve; Holes in Sleeve Must Align with Set Screw
d
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a
c
a
b
d
1 in. (25.4mm)
24643
a a - Pinion Gear Tool (91-74776 or 91-12349A2)
b - Feeler Gauge
c - Obtain 0.025″ (0.64mm) Clearance between Shimming
Tool and Pinion Gear
d - Add or Subtract Shim(s) Here
b
NOTE: Bearing Preload Tool (91-14311A1) should
remain installed on driveshaft after setting pinion
a - Adaptor
b - Ledge
gear depth as it is required to properly check forward
gear and reverse gear backlash.
6. Turn driveshaft clockwise 2 or more turns to seat DETERMINING FORWARD GEAR BACKLASH
driveshaft bearings.
IMPORTANT: Bearing carrier must be assembled
7. Insert Pinion Gear Locating Tool* (91-74776) into to provide a pilot for propeller shaft.
gear housing until it bottoms out on bearing
carrier shoulder. 1. Insert propeller shaft into position in gear hous-
ing. (DO NOT place shift cam on propeller shaft.)
*Pinion Gear Locating Tool (91-12349A2) can be
used. Use flat #7 and disc #2. Follow instructions 2. Place bearing carrier into gear housing and
supplied with tool. thread cover nut tightly against bearing carrier. (It
is not necessary to torque cover nut against
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bearing carrier.)
c
e a
b
51880
a - Thread Stud Adaptor (from 91-14311A1)
b - Stud
c - Backlash Indicator Tool (91-78473)
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REASSEMBLY
1. Position shift shaft bushing on a press with
b a threaded side down.
2. Apply Loctite 271 to outside diameter of oil seal.
3. Press oil seal into shift shaft bushing with lip of
seal up.
4. Wipe any excess Loctite from oil seal and
c bushing.
5. Place rubber washer against oil seal.
51866
6. Install O-ring over threads and up against
a - Pipe [6 in. x 1.5 in. (152.4mm x 38.1mm)]
shoulder of bushing.
b - Propeller Nut 7. Lubricate O-ring and oil seal with Quicksilver
c - Tab Washer
2-4-C w/Teflon Marine Lubricant.
a 51864
b 51864
a - Cross Pin
a - Cam Follower
b - Propeller Shaft
4. Apply a small amount of 2-4-C w/Teflon Marine
Lubricant on detent pin. Position a detent pin in
2. On PRODUCTION MODEL GEAR CASES, detent pin hole of sliding clutch with rounded end
position sliding clutch onto propeller shaft with of pin toward propeller shaft.
GROOVED RINGS (ON SLIDING CLUTCH)
TOWARD PROPELLER END OF PROPELLER a
SHAFT. Cross pin hole and detent holes (in b
sliding clutch) must line up with cross pin slot and
detent notches on propeller shaft.
b f
e
c
d c 51864
a - Detent Pin
b - Cross Pin
c - Sliding Clutch
a
51864
5. Install cross pin retaining spring onto sliding
clutch as follows:
a - Sliding Clutch
b - Grooved Rings IMPORTANT: DO NOT over-stretch retaining
c - Cross Pin Hole spring when installing onto sliding clutch.
d - Detent Hole (Behind Finger and Thumb)
e - Detent Notch (One on Each Side) 6. Spirally wrap spring into groove on sliding clutch.
f - Cross Pin Slot 7. Place gear housing in a soft jaw vise with the
driveshaft in a vertical position.
8. Coat cam pocket of cam follower with 2-4-C
w/Teflon Marine Lubricant.
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c 51864
a - Cam Pocket
b - Cam Follower
c - Shift Cam
b
10. With shift cam positioned as shown, insert
propeller shaft thru forward gear until shaft
bottoms out.
51867
a - Shift Shaft Bushing
b - Shift Shaft
a
b
c a
c
b
51871 51869
a - O-ring a - Mandrel
b - Cover Nut Tool b - Oil Seal (Smaller OD)
c - Torque Wrench c - O-ring Groove
20. Bend one lock tab of tab washer into cover nut 3. Install divider block if removed. Use RTV Sealer
(only one will align). to seal seams between divider block and gear
housing.
21. Bend remaining tabs of tab washer toward front
of gear housing.
22. Use Shift Shaft Bushing Tool (91-31107) and
torque shift shaft bushing to 30 Ib. ft. (40.5 N·m).
Water Pump
REASSEMBLY/INSTALLATION
a
1. Install oil seals into water pump base, as follows:
a. Place water pump base on a press.
b. Just before installing each seal apply Loctite
271 on outside diameter of oil seal.
c. With a suitable mandrel, press the smaller
diameter oil seal into pump base with lip of oil 51870
seal toward impeller side of base. a - Divider Block
d. With a suitable mandrel, press the larger
diameter oil seal into pump base with lip of oil
seal toward gear housing side of base.
e. Wipe any excess Loctite from oil seals and
water pump base.
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CAUTION
A visual inspection of impeller drive key MUST
BE made to determine that drive key is on flat of
driveshaft after impeller is installed. If key has
moved off flat of driveshaft, repeat Steps 6 and 7.
7. Slide impeller down driveshaft to impeller drive
a b key. Align drive key with keyway in the center hub
51866
of impeller, and slide impeller over drive key.
a - Water Pump Base
b - Gasket 8. If removed, install new water pump insert into
c - Hole (MUST be positioned as shown) pump cover as follows:
a. Apply Perfect Seal to water pump insert area
5. Install the following in order: Pump base to face
of pump cover.
plate gasket, face plate gasket and face plate to
pump cover gasket. Gaskets and face plate are b. Install water pump insert into pump cover.
indexed by dowel pin location and must be Verify that tab on insert enters recess in pump
installed correctly. cover.
c. Wipe any excess Perfect Seal from insert and
cover.
b NOTE: If 2 holes were drilled in top of water pump
cover to aid in removal of insert, fill holes with RTV
c Sealer or equivalent. Allow to cure, 24 hours prior to
operating engine.
9. Install water tube seal into pump cover, being
sure that plastic side of seal goes into cover first.
10. Reinstall water tube guide into water pump cover.
11. Apply a light coat of Quicksilver 2-4-C w/Teflon
Marine Lubricant inside of water pump insert.
a
12. Position assembled water pump cover over
driveshaft and lower over water pump studs.
Rotate driveshaft in a clockwise direction (viewed
51868 from top), while pushing down on pump cover to
a - Gasket (Water Pump Base to Face Plate) ease impeller entry into cover.
b - Face Plate
c - Gasket (Face Plate to Water Pump Cover) 13. Install water pump cover retainer washers, nuts
and bolt.
6. Place impeller drive key on flat of driveshaft. Hold
key on driveshaft with a small amount of CAUTION
Quicksilver 2-4-C w/Teflon Marine Lubricant. DO NOT over-torque nuts and bolt, as this could
cause cover to crack during operation.
14. Torque water pump nuts to 50 Ib. in. (5.5 N·m),
and water pump bolt to 35 Ib. in. (4.0 N·m).
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WARNING
Disconnect high tension leads from spark plugs
a and remove spark plugs from engine before
installing gear housing onto driveshaft housing.
1. Tilt engine to full up position and engage the tilt
lock lever.
2. Apply a light coat of Quicksilver 2-4-C w/Teflon
b Marine Lubricant onto driveshaft splines.
CAUTION
DO NOT allow lubricant on top of driveshaft.
Excess lubricant, that is trapped in clearance
space, will not allow driveshaft to fully engage
with crankshaft. Subsequently, tightening the
c gear housing nuts (while excess lubricant is on
top of driveshaft) will load the
51874
driveshaft/crankshaft and damage either or both
a - Water Tube Guide
the powerhead and gear housing. Top of
b - Water Tube Seal
c - Nuts, Bolts and Washers driveshaft is to be wiped free of lubricant.
3. Apply a light coat of Quicksilver 2-4-C w/Teflon
Marine Lubricant onto shift shaft splines. (DO
Gear Lubricant Filling Instructions NOT allow lubricant on top of shift shaft.)
1. Remove any gasket material from “Fill” and 4. Apply a thin bead of G.E. Silicone Sealer
“Vent” screws and gear housing. (obtained locally) against the top of divider block.
2. Install new gaskets on “Fill” and “Vent” screws. 5. Insert trim tab bolt into hole in rear of gear
housing to driveshaft housing machined surface.
IMPORTANT: Never apply lubricant to gear
housing without first removing “Vent” screw, or 6. Shift gear housing into forward gear and place
gear housing cannot be filled because of trapped guide block anchor pin into forward gear position.
air. Fill gear housing ONLY when housing is in a
vertical position.
3. Slowly fill housing thru “Fill” hole with Quicksilver
Super Duty Lower Unit Lubricant until lubricant
flows out of “Vent” hole and no air bubbles are
visible.
4. Install “Vent” screw into “Vent” hole. a
51900
IMPORTANT: DO NOT lose more than one fluid
a - Guide Block Anchor Pin
ounce (30cc) of gear lubricant while reinstalling
“Fill” screw.
7. Position gear housing so that the driveshaft is
5. Remove grease tube (or hose) from “Fill” hole protruding into driveshaft housing.
and quickly install “Fill” screw into “Fill” hole.
NOTE: If, while performing Step 8, the driveshaft
splines will not align with crankshaft splines, place
a propeller onto propeller shaft and turn it
counterclockwise as the gear housing is being
pushed toward driveshaft housing.
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CAUTION
DO NOT misinterpret propeller shaft movement
with propeller movement. If propeller and
propeller shaft together move forward-and-aft,
this is normal; however, propeller should not
move forward-and-aft on propeller shaft.
9. After first use, retighten propeller nut and again
secure with tab washer (Steps 7 and 8,
preceding). Propeller should be checked
periodically for tightness, particularly if a
stainless steel propeller is used.
d
a b
c
51866
a - Continuity Washer (if Equipped)
b - Rear Thrust Hub
c - Tab Washer
d - Propeller Nut
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6
E
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(Counter Rotation)
Ratio Pinion Forward Reverse
Depth Gear Gear
Backlash Backlash
1.87:1 0.025 in. 0.018 in. to 0.030 in. to
(15/28 (0.635mm) 0.027 in. 0.050 in.
teeth) With Tool (0.460mm (0.762mm
91-12349A2 to to
using 0.686mm) 1.27mm) 73605
Disc #2 and Pointer on
Flat #7 line mark Bearing Carrier Removal Tool 91-46086A1 and
#1 Puller Bolt 91-85716
2.0:1 0.025 in. 0.015 in. to 0.030 in. to
(15/30 (0.635mm) 0.022 in. 0.050 in.
teeth) With Tool (0.38mm (0.762mm
91-12349A2 to to
using 0.56mm) 1.27mm)
Disc #2 and Pointer on
Flat #7 line mark
#2
Special Tools
Shift Shaft Bushing Tool 91-31107
73655
73658
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70615
74187
74190 55079
73651
74184
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73600
Mandrel 91-92788
55079
73429
72486
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g
f
e
d
Shaft 91-18605
a
Screw 10-18602
a - Adaptor (N.S.S.)
b - Bearing (N.S.S.)
c - Washer (N.S.S.)
d - Spring (24-14111)
e - Bolt (10-12580)
f - Nut (11-13953)
g - Set Screw (10-12575)
h - Sleeve (23-13946) Mandrel 91-15755
a 51876
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BEARINGS
Upon disassembly of gear housing, all bearings must
be cleaned and inspected. Clean bearings with
solvent and dry with compressed air. Air should be
directed at the bearing so that it passes thru the
bearing. DO NOT spin bearing with compressed air,
as this may cause bearing to score from lack of
lubrication. After cleaning, lubricate bearings with
Quicksilver Gear Lubricant. DO NOT lubricate
tapered bearing cups until after inspection.
Inspect all bearings for roughness, catches and
bearing race side wear. Work inner bearing race
in-and-out, while holding outer race, to check for side
wear. When inspecting tapered bearings, determine
condition of rollers and inner bearing race by
inspecting bearing cup for pitting, scoring, grooves,
uneven wear, imbedded particles and/or
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WARNING a
Disconnect high tension leads from spark plugs
and remove spark plugs from engine before
removing gear housing from driveshaft housing.
1. Disconnect high tension leads from spark plugs
and remove spark plugs from engine.
CAUTION
Gear housing MUST BE in NEUTRAL position
and shift shaft MUST BE removed from gear b
housing BEFORE propeller shaft can be
removed from gear housing.
2. Shift engine into NEUTRAL position. 51912
d 51916
a - Thrust Hub (Forward)
b - Propeller Shaft
c - Continuity Washer (If Equipped)
d - Rear Thrust Hub
e - Tab Washer
f - Propeller Nut
b
a
a
51873
a - Front Mounting Locknut 51871
b - Side Mounting Locknut (One Each Side) a - “Fill” Screw
b - “Vent” Screw
10. Pull gear housing away from driveshaft housing
as far as the loosened nuts (in Step 9) will allow,
then remove loosened nuts. (DO NOT allow gear
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a
51874
a - Pads
REMOVAL
CAUTION
Gear housing MUST BE in neutral position, and
shift shaft MUST BE removed from gear housing
a before propeller shaft can be removed from gear
housing.
1. Place gear housing in a suitable holding fixture
with propeller shaft in a horizontal position.
2. Use Shift Shaft Bushing Tool (91-31107) to
un-thread shift shaft bushing. (DO NOT remove
bushing from shift shaft at this time.)
51873
a - Drill Two Holes at These Locations
a
b
a
c 51867
a - Long Puller Jaws (91-46086A1)
b - Puller Bolt (91-85716)
c - Thrust Hub
a
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51885
a - Tab Washer
51877
d
51878
a - Pry Bar
b - Oil Seals
c - Bearing Carrier
d - Bearing Carrier Needle Bearing
c
a c
51885
a - Needle Bearing
b - Push Rod a
c - Mandrel
51877
Propeller Shaft a - Balance Wheels
b - Bearing Surfaces
c - Watch for “Wobble”
INSPECTION
1. Clean propeller shaft assembly with solvent and “Vee” Blocks and Dial Indicator
dry with compressed air.
Position propeller shaft needle bearing surfaces on
2. Inspect bearing carrier oil seal surfaces for “vee” blocks. Mount a dial indicator at front edge of
grooves. Run fingernail across seal surface to propeller splines. Rotate propeller shaft. Dial
check for groove. Replace shaft if groove is indicator movement of more than 0.006″ (0.152mm)
found. (or noticeable “wobble”) is reason for replacement.
3. Visually check bearing surfaces of propeller shaft
for pitting, grooves, scoring, uneven wear or DISASSEMBLY
discoloration (bluish color) from overheating. 1. Remove shift cam from cam follower.
Replace shaft and corresponding needle bearing
if any of the above conditions are found. (Bearing 2. Insert a thin blade screwdriver or awl under first
carrier needle bearing contacts propeller shaft coil of cross pin retainer spring and rotate
just in front of oil seal surface. Reverse gear propeller shaft to unwind spring from sliding
bearing contacts propeller shaft in front of sliding clutch. DO NOT overstretch spring.
clutch splines.) a
4. Inspect propeller shaft splines for wear and/or
corrosion damage.
5. Check propeller shaft for straightness. Use either
method, following:
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51875
a - Cross Pin Retainer Spring
c
c
b
b a
51875
51879 a - Sliding Clutch
a - Detent Pin b - Reverse Gear Clutch Jaws
b - Cross Pin c - Forward Gear Clutch Jaws
c - Sliding Clutch
7. Pull cam follower and clutch actuator rod out of
4. Push cross pin out of sliding clutch and propeller propeller shaft. DO NOT force cam follower
shaft with a punch. up-or-down or side-to-side when pulling from
propeller shaft.
8. Once cam follower and clutch actuator rod are
removed from propeller shaft, lift rod out of cam
follower.
b
a a b
51884
51875 a - Cam Follower
a - Cross Pin b - Clutch Actuator Rod
b - Punch
9. Check condition of cam follower. If it shows wear
5. Pull sliding clutch off propeller shaft. (pitting, scoring or rough surface), replace cam
follower and shift cam.
6. Inspect sliding clutch. Check reverse gear clutch
“jaws” and forward gear clutch “jaws.” Rounded
“jaws” indicate one or more of the following:
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g
51878
a - Forward Gear
b - Forward Gear Clutch Teeth
c - Forward Gear Teeth
d - Forward Gear Hub
e - Thrust Bearing
f - Thrust Washer
g - Spacer Shim
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55089
a - Thrust Washer
b - O-Ring (hidden)
REMOVAL
1. Remove bearing retainer using Bearing Retainer
Tool (91-43506).
b
a
a
b 51865
a - Bearing Retainer
b - Bearing Retainer Tool (91-43506)
55090
a - Thrust Bearing
b - Thrust Washer
c - Bearing Adaptor
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CAUTION
DO NOT strike gear housing hard with the mallet
or allow gear housing to fall. 51866
b a
51878
a - Wooden Block
b - Soft Jaw Vise Covers
51869
a - Mandrel (91-37263) a
b - Pilot* (91-36571)
c - Driver Rod* (91-37323)
*From Bearing Removal and Installation Kit (91-31229A5)
a
c
50882
a - Thrust Bearing
b - Thrust Washer b
c - Reverse Gear Bearing Adaptor
f - Jaws (91-816242)
a - Reverse Gear Needle Bearing Contact Area
f
Gear Housing
a
Reassembly and Installation 51869
of Counter Rotation Gear a
b
- Mandrel
- Bearing
Housing c
d
- Pilot
- Plate
e - Puller Rod
f - Hold
Driveshaft Needle Bearing
REASSEMBLY/INSTALLATION
CAUTION
If driveshaft needle bearing failure has occurred,
and original bearing race has turned in the gear
housing, gear housing must be replaced. Loose
fitting needle bearing will move out of position
and cause repeated failures.
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a
b c
b
a
d
a d
c
b
c
51881
a - Mandrel (91-15755)
b - Bearing Carrier Needle Bearing
51881
c - Bearing Carrier
d - Shoulder a - Outer Seal
b - Mandrel (91-31108)
c - Bearing Carrier
2. Apply Loctite 271 (92-809820) to outside d - Mandrel Shoulder
diameter of oil seals.
5. Lubricate both seal lips with 2-4-C w/Teflon
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b
d
c a b
50885
a - Reverse Gear
b - Forward Gear
c - Shorter Length Hub
a d - Smaller Diameter Bearing Bore
51883
a - Reverse Gear Teeth Reverse Gear Bearing Adaptor
b - Mandrel (91-86943)
c - Propeller Shaft Needle Bearing
Assembly
d - Shoulder
INSTALLATION
NOTE: If gear housing has been replaced or NOTE: If the reverse gear, reverse gear adaptor,
inspection determines that reverse gear bearing large thrust bearing, or bearing race in the gear
adapter must be replaced, assemble and install as housing were not replaced, install the same shim(s)
(or the same thickness of shim(s) that were taken out
follows:
when adaptor was removed. If the reverse gear,
2. Place reverse gear roller bearing (NUMBER/ reverse gear adaptor, large thrust bearing, bearing
LETTERS UP) in press. Using suitable mandrel, race, or gear housing were replaced, install 0.008 in.
press bearing cup adapter onto reverse gear (0.51 mm) of shims.
bearing.
NOTE: If backlash has already been checked and it
has determined that it needs to be adjusted, (see
Checking Reverse Gear Backlash), adding 0.001 in.
(0.025 mm) shims will reduce the gear backlash by
approximately 0.001 in. (0.025 mm). Subtracting
.001 in. (0.025 mm) shims will increase backlash by
approximately the same amount.
a
c
a - Mandrel
b - Bearing Cup Adapter
c - Reverse Gear Roller Bearing
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(subtract) middle
of .025 in. (0.64 mm)
specification:
You get: .020 in. (0.51 mm)
d a
e b
c
55099
c - Inner Ledge
d - Retainer (91-18604)
e - Screw (10-18602)
c a
55101
a - Thrust Bearing
b - Thrust Washer b
c - Bearing Adaptor
c
7. Reinstall reverse gear into bearing adaptor. d
e
50064
a - Used Pinion Nut
a b - Driveshaft
c - Tapered Bearing
cb d - Old Bearing Inner Race
e - Universal Puller Plate
c
c
b a
b
a a
a - Adaptor
b - Bearing
c - Washer
d - Spring
e - Nut; Thread Nut All-The-Way Onto Bolt
f - Bolt
c g - Set Screw
h - Sleeve; Holes in Sleeve Must Align With Set Screws
c
a
b
1 in. (25.4mm) d
a 24643
a - Pinion Gear Shimming Tool (91-74776 or 91-12349A2)
b - Feeler Gauge
c - Obtain 0.025″ (0.64mm) Clearance between Shimming
Tool and Pinion Gear
d - Add or Subtract Shim(s) Here
b
NOTE: Bearing Preload Tool (91-14311A1) should
remain installed on driveshaft after setting pinion
gear depth as it is required to properly check forward
gear and reverse gear backlash.
a - Adaptor
b - Ledge
d
b
51880
c 55088
a
a - Load Washer (12-37429)
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b - Shoulder
c - Propeller Shaft (44-93003)
e c
a d
f h
g
c e j k
a b i 51882
a - Prop Nut
f d b - Flat Washer
b 55103
a - Bearing Carrier c - PVC Pipe [5″ x 2″ (127mm x 50.8mm)]
b - Bearing Adaptor d - Cover Nut
c - Thrust Washer e - Tab Washer
d - Thrust Bearing f - Bearing Carrier
e - Forward Gear g - Prop Shaft
f - Shim (PLACE IN GEARCASE FIRST) h - Bearing Adaptor
i - Shim
j - Forward Gear
3. Position shim against shoulder in gear case. k - Load Washer
d
f
c 51882
e a a - Shim
51880
a - Stud Adaptor (from 91-44307A1)
b - Stud
c - Backlash Indicator Tool (91-78473)
d - Dial Indicator Holder (91-89897)
e - Dial Indicator (91-58222A1)
f - Dial Indicator Pointer
b a
e g
c 51913
a - Sliding Clutch
b - Propeller Shaft
c - Grooved Rings
d - Cross Pin Hole
e - Detent Hole
f - Cross Pin Slot
g - Detent Notches
51875
a - Cross Pin
2. Place a small amount of Quicksilver 2-4-C
w/Teflon Lubricant on actuator rod and install
cam follower. 5. Apply a small amount of 2-4-C w/Teflon Marine
Lubricant (92-90018A12) to the rounded end of
b a detent pin. Position detent pin in detent pin hole
of sliding clutch with rounded end of pin toward
propeller shaft.
b
a - Actuator Rod a
b - Cam Follower
51879
a - Detent Pin
b - Detent Pin Hole
c - Sliding Clutch
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a b
b
c 51867
55095 a - Shift Shaft Bushing
b - Shift Shaft
a - Cam Pocket
b - Cam Follower
c - Shift Cam 13. Install appropriate spacer shim into the gear
housing.
10. Slide propeller shaft assembly into reverse gear
assembly.
b a
55096
a - Shift Cam (Position as Shown)
b - Gear Housing
50782
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a - Shim
b
a
55220
a - Bearing Adaptor
b - Thrust Washer
c - Thrust Bearing
55221
a - Forward Gear Installation Tool (91-815850)
b - Forward Gear/Bearing Adaptor Assembly
55107
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a - Thrust Race
a c
55108
a - Thrust Bearing 55110
a - Propeller Shaft
b - Keepers (2)
19. Install thrust collar with its STEPPED SIDE c - Thrust Collar
DOWN toward the small thrust bearing.
21. Install second thrust collar with its stepped side
UP.
a
b
55109
a - Thrust Collar
b - Thrust Bearing
a - Thrust Collar
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55113
55112 a - O-ring
a - Thrust Bearing
b - Thrust Collar 25. Apply Quicksilver 2-4-C w/Teflon Marine
Lubricant to:
23. Apply Quicksilver Super Duty Gear Lubricant to
a. Outer diameter of bearing carrier which
to second small thrust bearing race and install
contacts gear case.
race to the surface inside of the bearing carrier.
b. Space between carrier oil seals.
26. Apply Quicksilver Super Duty Gear Lubricant to
bearing carrier needle bearing.
27. Install bearing carrier into gear housing.
b
50779
a - Thrust Race
b - Bearing Carrier Race Surface
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55114
a - Bearing Carrier
51885
a - Tab Washer 51882
a - Shift Shaft Bushing Tool (91-31107)
30. Apply 2-4-C w/Teflon to threads of cover nut and b - Shift Shaft Bushing
install cover nut in gear housing. Verify that the
word “OFF” and arrow are visible.
NOTE: Before torquing bearing carrier cover nut,
gear case should either be mounted in a stand
specifically designed for holding gear cases or bolted
to a driveshaft housing to avoid possible damage to
the gear case.
31. Using Cover Nut Tool (91-61069), torque cover
nut to 210 Ib. ft. (284.5 N·m).
a b
51911
a - Cover Nut Tool (91-61069)
b - Cover Nut
32. Bend one lock tab of tab washer into cover nut
(only one will align).
33. Bend remaining tabs of tab washer toward front
of gear housing.
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a
b
c
b
51869
a - Mandrel
b - Oil Seal (Smaller OD)
c - O-Ring Groove a
3. Install divider block if removed. Use RTV Sealer
to seal seams between divider block and gear
housing. 51868
a - Gasket (Water Pump Base to Face Plate)
b - Face Plate
c - Gasket (Face Plate to Water Pump Cover)
51874
a - Water Tube Guide
b - Water Tube Seal
c - Nuts, Bolts and Washers
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2. Apply a light coat of Quicksilver 2-4-C w/Teflon IMPORTANT: Do not force gear case up into place
Marine Lubricant onto driveshaft splines. with attaching nuts.
12. Evenly tighten 2 nuts which were started in Step
CAUTION 9. Torque to listing in “Torque Specifications,”
preceding.
DO NOT allow lubricant on top of driveshaft.
Excess lubricant, that is trapped in clearance 13. After 2 nuts (located on either side of driveshaft
space, will not allow driveshaft to fully engage housing) are tightened, check shift operation as
with crankshaft. Subsequently, tightening the follows:
gear housing nuts (while excess lubricant is on a. Place guide block anchor pin into forward
top of driveshaft) will load the driveshaft/ gear position while turning prop shaft. Rotate
crankshaft and damage either or both the flywheel clockwise (viewed from top);
powerhead and gear housing. Top of driveshaft propeller shaft should rotate clockwise.
is to be wiped free of lubricant.
b. Place guide block anchor pin into NEUTRAL
3. Apply a light coat of Quicksilver 2-4-C w/Teflon position. Propeller shaft should rotate freely
Marine Lubricant onto shift shaft splines. (DO clockwise/counterclockwise.
NOT allow lubricant on top of shift shaft.)
c. Place guide block anchor pin into REVERSE
4. Apply a thin bead of G.E. Silicone Sealer gear position. Rotate flywheel clockwise
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(92-90113--2) against the top of divider block. (viewed from top); propeller shaft should
rotate counterclockwise.
1. To aid in future removal of the propeller, liberally 7. After propeller nut is recessed into tab washer,
coat the propeller shaft splines with one of the tighten nut securely [minimum of 55 Ib. ft. (74.5
following Quicksilver products: N·m) torque].
-- Anti-Corrosion Grease (92-78376A6) 8. Bend 3 of the tabs of tab washer down in grooves
-- Special Lubricant 101 (92-13872A1) of rear thrust hub to secure propeller nut. (If tab
-- 2-4-C Marine Lubricant (92-90018A12) washer tabs do not align with slots, continue to
-- Perfect Seal (92-34227--1) tighten propeller nut to obtain alignment. DO
2. Place forward thrust hub over propeller shaft with NOT loosen nut to align tabs.)
shoulder side toward propeller.
CAUTION
DO NOT misinterpret propeller shaft movement
with propeller movement. If propeller and
propeller shaft together move forward-and-aft,
this is normal; however, propeller should not
move forward-and-aft on propeller shaft.
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b 51916
a - Continuity Washer (If Equipped)
b - Rear Thrust Hub
c - Tab Washer
d - Propeller Nut
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F
6
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Table of Contents
Page
105/140 Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-2
Jet Components . . . . . . . . . . . . . . . . . . . . . . . . . 6F-4
Selecting a Boat that is best suited for
Jet Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-5
Engine Horsepower Selection . . . . . . . . . . . . . . 6F-5
Transom Height of the Boat . . . . . . . . . . . . . . . . 6F-6
Locate Centerline of the Outboard . . . . . . . . . . 6F-6
Outboard Mounting Height . . . . . . . . . . . . . . . . . 6F-6
Water Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-7
Checking for Cavitation . . . . . . . . . . . . . . . . . 6F-7
Shift Cable Installation Jet 105 and 140 . . . . . 6F-8
Lubricating the Driveshaft Bearing . . . . . . . . . . 6F-9
Impeller Removal and Installation . . . . . . . . . . 6F-9
Steering Pull Adjustment . . . . . . . . . . . . . . . . . 6F-11
Impeller Clearance Adjustment . . . . . . . . . . . . 6F-11
Worn (Dull) Impeller . . . . . . . . . . . . . . . . . . . . . 6F-11
Flushing the Cooling System . . . . . . . . . . . . . . 6F-11
Liner Replacement . . . . . . . . . . . . . . . . . . . . . . 6F-12
Jet Drive Removal and Installation . . . . . . . . . 6F-12
Bearing Carrier Disassembly . . . . . . . . . . . . . . 6F-14
Bearing Carrier Reassembly . . . . . . . . . . . . . . 6F-14
Installing Seals . . . . . . . . . . . . . . . . . . . . . . . 6F-14
Installing Upper Seals . . . . . . . . . . . . . . . . . 6F-15
Installing Driveshaft Bearing(s) . . . . . . . . . 6F-15
Installing Driveshaft . . . . . . . . . . . . . . . . . . . 6F-16
Installing Upper Seal Housing . . . . . . . . . . 6F-17
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TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 3 SCREW (.190-32 x 1.62) 30 3.5
2 3 WASHER
3 3 BUSHING
4 1 PLATE
5 1 REV LIMITER
6 1 HARNESS–Adaptor-rev limiter
7 1 GREASE KIT
8 1 WATER PUMP BASE
9 1 GASKET
10 1 OIL SEAL
11 1 OIL SEAL
12 1 GASKET–lower
13 1 GASKET–upper
14 1 FACE PLATE
15 1 WATER PUMP BODY ASSEMBLY
16 1 INSERT
17 1 SEAL–rubber
18 1 lMPELLER
19 1 KEY
20 1 SCREW (2-1/4 IN.) 50 5.5
21 2 WASHER
22 2 NUT 50 5.5
23 1 WASHER
24 1 SLEEVE
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200
180
160
140
120
HP
100
80
60
40
20
0
500 6 8 1000 12 14 16 18 2000 22 24 26 28 3000 32 34 36
a - Centerline of Transom
a
5. Fasten outboard to the transom at this height. a - Intake Fin Kit
d
b a - Shift Cable
b - Shift Cam
c - Barrel
d - Roller
IMPORTANT: It is important that you do not use 1. Shift outboard to NEUTRAL (N) position.
a general-all-purpose grease for this bearing. 2. Remove spark plug leads to prevent engine from
The lubricant we recommend is a water resistant starting.
grease of the proper consistency for this applica-
3. Remove the water intake housing that is fastened
tion. If you use a substitute grease, be sure that
with six screws.
it is water resistant and of the same consistency.
Frequency of lubrication - We recommend
lubricating the driveshaft bearing after each day’s
use and after every 10 hours of operation. After every
30 hours of operation, pump in extra grease to purge
out any moisture.
a a
a - Tabs
Enlarged
leading View
edge
a
Sharpen to a 1/32 in. (0.8mm) radius by
a - Exhaust Fins removing material from bottom side only
Impeller Clearance The intake of gravel through the pump can round off
Adjustment and wear the leading edges on the impeller. Some
conditions you may experience from a worn impeller
1. The impeller should be adjusted so there is are (1) a noticeable performance loss, especially on
approximately 0.030 in. (0.8mm) clearance acceleration, (2) difficulty getting the boat on plane,
between the impeller edge and liner. Operating or (3) an increase in engine RPM at wide open
the jet drive in waters that contain sand and throttle. Check the impeller blades occasionally for
gravel can cause wear to the impeller blades, and damage. Use a flat file to resharpen the leading
the clearance will start to exceed 0.030 in. edges as shown.
(0.8mm). As the blades wear, shims (a) located
in the stack outside of the impeller can be
transferred behind the impeller. This will move
the impeller further down into the tapered liner to
Flushing the Cooling System
reduce the clearance. Use Quicksilver accessory hose coupling Part
Number 24789A1.
2. Check the impeller clearance by sliding a feeler
gauge through the intake grate and measure the 1. Remove plug and gasket (a) and thread-in hose
clearance between the impeller edge and liner. If coupling (b).
adjustment is required, refer to Impeller Removal 2. Attach a water hose to the hose coupling. Turn on
and Installation. the water gently, start the engine, and run it at idle
speed only.
3. Check for a steady stream of water flowing out of
the water pump indicator hole. Continue flushing
the outboard for 3 to 5 minutes; adjust water
pressure if needed.
a
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INSTALLATION
1. Install jet drive with bolt and locknuts shown.
Torque.
a
b b
a - Plug and Gasket
b - Hose Coupling
Liner Replacement
f
95
g
h
i
k
l
j - Face Plate
k - Lower Gasket
l - Pump Base
m - Gasket
4. Remove snap ring (e). Press the ball bearing(s) 3. Spread a film of grease around the inside bore of
(c) off the driveshaft. the seal surface before pressing in the seals.
5. Remove the seals and spiral retaining rings from 4. Press in the garter spring seal (c) against the
the bearing carrier and the upper seal housing inner retaining ring as shown. Fill the garter
(d). spring cavity in the seal with grease.
6. Clean all parts thoroughly and remove any burrs. 5. Install spiral retaining ring (d) into the outer ring
groove. Align the notched ends of the retaining
d a ring to straddle the small vent hole drilled in the
ring groove.
6. Press in the outer seal (e) against the retaining
ring as shown.
7. Grease all the seal lips.
a
c
b
e
a - Snap Ring
b - Bearing Carrier
c - Ball Bearing
d - Upper Seal Housing
e - Snap Ring
b
c
d e
IMPORTANT: The
notched ends of the
retaining ring must
straddle this vent hole.
a - O-rings
b - Retaining Ring
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c - Spring Seal
d - Retaining Ring
e - Outer Seal
2. Spread a film of grease around the inside bore of 1. If removed, install the bearing thrust ring (a) into
the seal surface before pressing in the seals. the groove on the driveshaft.
3. Press in the garter spring seal (b) against the 2. Press new ball bearings (b) onto the driveshaft,
inner retaining ring as shown. Fill the garter pressing against the inner races only. press
spring cavity in the seal with grease. bearings against the thrust ring , locking it in its
groove. Install snap ring (c) into driveshaft below
4. Install spiral retaining ring (c) into the outer ring the lower bearing.
groove. Align the notched ends of the retaining
ring to straddle the small vent hole drilled in the a
ring groove.
5. Press in the outer seal against the retaining ring
as shown. b a
6. Grease all the seal lips.
7. Grease the two O-ring seals (e) and install then
into the outer ring grooves. b
b c
c
c d
a b
IMPORTANT: The
notched ends of the
retaining ring must
straddle this vent hole.
a - Retaining Ring
b - Spring Seal
c - Retaining Ring
d - Outer Seal
e - O-rings
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a - Bearing Carrier
b - Driveshaft
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Table of Contents
Page Page
Installing Production Outboards . . . . . . . . . . . . . 7-1 Steering Arm Extension Bracket
Installing High Performance Outboards - Installation . . . . . . . . . . . . . . . . . . . . . . . 7-23
Pro Max/Super Magnum Models . . . . . . . . . . 7-2 Steering Coupler Assembly and
Installing Outboard on Transom . . . . . . . . . . 7-3 Installation . . . . . . . . . . . . . . . . . . . . . . . 7-23
Lifting Outboard . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Steering System Tension Adjustment
RideGuide Steering Cable/Attaching Kit (Parallel Routed Steering Cables) . . . 7-25
Installation (92876A1) . . . . . . . . . . . . . . . . . . . . 7-6 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . 7-26
Single Cable - Single High Performance Dual Outboard - Counter Rotation
Outboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Installation . . . . . . . . . . . . . . . . . . . . . . . 7-26
Single Cable - Single Production Outboard . 7-6 Dual Outboard - Non Counter Rotation
Maintenance Instructions . . . . . . . . . . . . . . . . 7-7 Installation . . . . . . . . . . . . . . . . . . . . . . . 7-26
RideGuide Steering Cable/Attaching Kit RideGuide Steering Attachment
Installation (92876A3) . . . . . . . . . . . . . . . . . . . . 7-8 Extension Couplers . . . . . . . . . . . . . . . . . . 7-26
Dual Cable - Single Outboard . . . . . . . . . . . . 7-8 Maintenance Instructions . . . . . . . . . . . . . . . 7-27
Super RideGuide Steering Kit Installation . . 7-8 Transom Mounted RideGuide Attaching
Steering Cable Mounting Tube Installation . 7-9 Kit Installation (73770A1) . . . . . . . . . . . . . . . . 7-28
Installing Steering Cables . . . . . . . . . . . . . . . . 7-9 Attaching Kit Installation . . . . . . . . . . . . . . . . 7-28
Coupler Installation . . . . . . . . . . . . . . . . . . . . 7-10 Steering Cable Installation . . . . . . . . . . . 7-29
Installing Link Rod . . . . . . . . . . . . . . . . . . . . . 7-10 Maintenance Instructions . . . . . . . . . . . . . . . 7-30
Steering System Tension Adjustment . . 7-11 Clevis Attaching Kit Installation (A-70599A2) . 7-30
Maintenance Instructions . . . . . . . . . . . . . . . 7-12 Installation Instructions . . . . . . . . . . . . . . . . . 7-30
RideGuide Steering Cable/ Attaching Kit Maintenance Instructions . . . . . . . . . . . . . . . 7-31
Installation (92876A6) . . . . . . . . . . . . . . . . . . . 7-13 Remote Control Installation . . . . . . . . . . . . . . . . 7-31
Dual Cable - Dual Outboard . . . . . . . . . . . . . 7-13 Required Side Mount Remote Control or
Installation Requirements . . . . . . . . . . . . . . . 7-13 Ignition Key Switch Assembly . . . . . . . . . . . . 7-31
Determine Routing of Steering Cables . 7-13 Boats Equipped with Side Mount
Parallel Routed Steering Cables and Remote Control . . . . . . . . . . . . . . . . . . . . . 7-31
Attaching Kit Installation . . . . . . . . . . . . . . 7-13 Boats equipped with Panel or Console
Super RideGuide Steering Kit Mount Remote Control . . . . . . . . . . . . . . . 7-31
Installation . . . . . . . . . . . . . . . . . . . . . . . 7-13 Connecting Engine Wiring Harness Engine
Steering Cable Installation Battery Cables and Trim Wires . . . . . . . . 7-31
Starboard Outboard . . . . . . . . . . . . . . . 7-14 Routing Location for Wiring and Hoses thru
Steering Cable Installation - Clamp in Bottom Cowl . . . . . . . . . . . . . . . . . . 7-32
Port Outboard . . . . . . . . . . . . . . . . . . . . 7-15 Remote Control Installation . . . . . . . . . . . . . . . . 7-33
Steering Link Rod Installation . . . . . . . . . 7-16 Shift Cable Adjustment and Installation
Steering Arm Extension Bracket to the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Installation . . . . . . . . . . . . . . . . . . . . . . . 7-17 Throttle Cable Adjustment and Installation
Steering Coupler Assembly and to the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Installation . . . . . . . . . . . . . . . . . . . . . . . 7-17 Battery Connections . . . . . . . . . . . . . . . . . . . . . . 7-35
Steering System Tension Adjustment Fuel Connections . . . . . . . . . . . . . . . . . . . . . . . . 7-36
(Parallel Routed Steering Cables) . . . 7-19 Connecting Fuel Hose to Engine . . . . . . . . . 7-36
Opposite Side Routed Steering Production EFI Models . . . . . . . . . . . . . . . 7-36
Cables and Attaching Kit Installation . . . 7-20 Production Carburetor Models . . . . . . . . 7-36
Super RideGuide Steering Kit High Performance Models - Pro Max/
Installation . . . . . . . . . . . . . . . . . . . . . . . 7-20 Super Magnum . . . . . . . . . . . . . . . . . . . 7-36
Steering Cable Installation - Starboard Auxiliary Fuel Pump . . . . . . . . . . . . . . . . . 7-37
Outboard . . . . . . . . . . . . . . . . . . . . . . . . 7-20 Portable Fuel Tank . . . . . . . . . . . . . . . . . . 7-37
Steering Cable Installation - Port Permanent Fuel Tank . . . . . . . . . . . . . . . . 7-37
Outboard . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Steering Link Rod Installation . . . . . . . . . 7-22
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26 in.
(660m
m)
25 in.
(635m
m)
24 in.
(609m
m) b
23 in.
(584m c
m)
e 22 in.
(560m
e m)
21 in.
(533m a
m)
20 in. d
(508m
m)
19 in.
(482m
m)
10 20 30 40 50 60 70 80
NOTE: Add 5 in. (127mm) for XL models and 10 in. c. This line may be preferred to determine out-
(254mm) for XXL models to listed outboard mounting board mounting height dimension, if maxi-
height. mum speed is the only objective.
a. This solid line is recommended to determine d. This line may be preferred to determine out-
the outboard mounting height. board mounting height dimension for dual
outboard installation.
IMPORTANT: Increasing the height of outboard
generally will provide the following: 1) Less e. Outboard mounting height (height of
steering torque, 2) more top speed, 3) greater outboard transom brackets from bottom of
boat stability, but, 4) will cause more prop “break boat transom). For heights over 22 in.
loose” which may be particularly noticeable (560mm), a propeller, that is specifically
when planing off or with heavy load. designed for surfacing operation, such as the
“Laser”, “Mirage”, “Trophy” and “Tempest”
b. These broken lines represent the extremes of
series, usually are preferred.
known successful outboard mounting height
dimensions. f. Maximum boat speed anticipated.
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CAUTION
Prevent engine damage. If outboard is mounted
too high, engine damage could occur due to a
lack of water flow and pressure; this particularly
evident on 4-1/4 in. XR and Torque Master gear-
cases.
NOTE: Only propellers designed for surface type
applications should be used with Pro Max and Super
a
Magnum outboards.
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A B
a b
C D
a - Centerline of Transom
NOTE: Dimensions “A” & “B” and “C” & “D” are equal
length.
a
DRILLING OUTBOARD MOUNTING HOLES
a - Centerline of Transom
IMPORTANT: Before drilling any mounting holes, b - Transom Drilling Fixture (91-98234A2)
carefully read “Determining Recommended
Outboard Mounting Height,” preceding. There is IMPORTANT: During installation of dual or
a 3/4 in. (19 mm) difference between outboard multiple production model V-6 product, the
mounting holes in transom brackets. following is recommended. A minimum of 26
inches (660mm) centerline to centerline width is
WARNING recommended. On high performance engines -
DO NOT, under any circumstances, allow upper Pro Max/Super Magnum models - a minimum of
outboard mounting bolts to be closer than 1 in. 20.5 (521mm) centerline to centerline width is
(25.4 mm) from top of boat transom. Upper recommended. This is required to alleviate
mounting bolts must never be installed thru cowling interference during lock to lock turns if
shims. one outboard would be in the full tilt position,
while the other outboard(s) are in the vertical
NOTE: When drilling into a fiberglass boat, place running position.
masking tape directly onto boat where mounting
holes will be drilled to help prevent fiberglass from 1. Secure (tape) “Outboard Mounting Template”
chipping. (located in “Outboard Installation Manual”) to
the outside of the boat transom.
2. Align “Top of Boat Transom Line” on template
with top edge of (real) boat transom, not shims.
3. Single Outboard Installation: Align vertical
centerline of template with centerline of transom.
4. Dual Outboard Installation: Align vertical center-
line of template with each outboards (one at a
time) selected centerline on boat transom. Refer
to caution, preceding.
5. Use a 17/32 in. (13.5 mm) diameter drill bit and
drill 4 mounting holes perpendicular to and thru
transom at marked holes’ centers on template.
6. Align “Top of Boat Transom Line” of template
with top edge of (real) boat transom, not shim(s).
7. Single Outboard Installations: Align vertical
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Lifting Outboard
WARNING
Make sure that lifting eye is threaded into
flywheel a minimum of 5 turns and that hoist has a - Counter Rotation Decal (Left-Hand Rotation Outboard)
a minimum lift capacity of at least 500 lbs. (227 b - Counter Rotation Decal (Right-Hand Rotation Outboard)
kg.) BEFORE lifting outboard.
Remove cowling from outboard and plastic cap from
center of flywheel. Thread lifting eye (a) into flywheel
hub a minimum of 5 turns. Replace plastic cap after
installation. Connect hoist [minimum lift capacity of
500 Ibs. (227 kg)] to lifting eye (a). Lift outboard and
place on boat transom.
50048
a - Lifting Eye (91-90455)
b - Hoist
CAUTION
Marine sealer must be used on shanks bolts to
make a water-tight installation.
IMPORTANT: DO NOT use an impact driver when
tightening transom bolts.
Apply marine sealer to shanks of mounting bolts (not
threads) and secure outboard to transom with 4 bolts, d
flat washers and locknuts, as shown. Be sure that b
installation is water-tight.
a
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CAUTION c b
It is recommended that boats capable of going
over 50 MPH be equipped with dual cable
steering and adjusted so that there is a minimum
of steering backlash. The more steering
backlash that exists, the more difficult it is to
control a high performance boat, particularly if
the hull has chine walking tendencies.
a
WARNING
Quicksilver RideGuide Outboard power Steering
is limited to 200 H.P. engines and CANNOT BE
USED ON ENGINES OVER 200 H.P. External
hydraulic steering systems are available from
aftermarket suppliers. 28160
installation.
Disengagement of a steering link rod can result 1. Carefully check steering system components for
in the boat taking a full, sudden, sharp turn. This wear. Replace worn parts.
potentially violent action can cause occupants to 2. Check steering system fasteners to be sure that
be thrown overboard exposing them to serious they are torqued to correct specifications.
injury or death.
NOTE: RideGuide Steering Cables are lubricated at
1. Assemble steering link rod to steering cable with the factory and require no additional lubrication at
two flat washers (d) and nylon insert locknut (“b” initial installation.
- Part Number 11-34863). Tighten locknut (b)
until it seats, then back nut off 1/4 turn. WARNING
2. Production Outboards - Assemble steering link Core of each steering cable (transom end) must
rod to engine with special washer head bolt (“a” be fully retracted into cable housing before lubri-
- Part Number 10-14000) and nylon insert locknut cating cable. If cable is lubricated while ex-
(“c” - Part Number 11-34863). First torque bolt (a) tended, hydraulic lock of cable could occur.
to 20 lb. ft. (27.0 N·m), then torque locknut (c) to
20 lb. ft. (27.0 N·m). 3. With core of RideGuide Steering Cable (transom
High Performance Outboards - An access hole end) fully retracted, lubricate transom end of
is provided through the bottom cowl to ease steering cables thru grease fittings (a) with 2-4-C
installation of the link rod connecting bolt. w/Teflon (92-825407A12). Lubricate exposed
Remove the BACK plug for installation and portion of cable end (b) with 2-4-C w/Teflon.
reinstall after installation. 4. Lubricate pivot point (c) of steering link rod and
ball joint (d) of link rod with SAE 30 Weight Oil.
a
5. Inspection and lubrication of steering head
d assembly (rotary or straight rack) should be
performed once each year (by your Authorized
Dealer) or whenever steering mount and/or
steering head are disassembled, or if steering
b effort has increased. Lubricate with 2-4-C
w/Teflon.
d
c
WARNING
After installation is complete (and before
operating outboard), check that boat will turn
right when steering wheel is turned right and that a c
boat will turn left when steering wheel is turned a b
28169
left. Check steering thru full range (left and right)
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WARNING
Quicksilver Super RideGuide Steering (dual
cables) MUST BE USED with this attaching kit.
Failure to adhere to this requirement could result
in steering system failure.
Refer to “Quicksilver Accessories Guide” to
determine correct length of steering cables and
remote control cables.
IMPORTANT: Steering cables and remote control
cables MUST BE THE CORRECT LENGTH, sharp
bends on too-short cables result in “kinks”;
too-long cables require unnecessary bends and/
or loops. Both conditions place extra stress on Super RideGuide Steering Kit
the cables and will reduce the performance of the
steering system. Installation
IMPORTANT: Both gear racks or rotary steering
CAUTION heads must be installed so that both steering
With this kit installed, the upper (outboard) cables will be routed together on the same side
mounting bolts MUST BE installed so that hex of the boat and will push-and-pull together.
head end of bolts is on the inside of boat 1. Install Super RideGuide Steering Kit in
transom, as illustrated. Failure to install upper accordance with instructions included with Super
mounting bolts, as shown in illustration, could RideGuide Kit.
result in interference between steering cable nut
and ends of mounting bolts when outboard is 2. Make sure that both gear racks or rotary steering
tilted up. heads are installed so that both steering cables
are routed together down starboard side of boat
CAUTION and will push-and-pull together.
a
b b c
a - Gear Rack
b - Steering Cables
c - Rotary Steering Heads
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b d
b
a
c
a
d c 51891
a - Steering Cable Mounting Tube (End of Tube with Longer
Threads Toward Starboard Side of Boat)
b - Mounting Bracket
c c - Locking Tab Washers (2)
d - Adjustment Nuts (Flats of Nuts Facing Toward Locking Tab
28163 Washer)
a - Mounting Bracket for Steering Cable Mounting Tube
b - Spacer (2) – Used on Earlier Models
c - Locking Retainer (2) Installing Steering Cables
d - Bolts (4) - 7/8 in. (22mm) Long - Torque to 100 lb. in.
(11.5N·m), then Bend Corner Tabs of Locking Retainers Up IMPORTANT: Lubricate inside of outboard tilt
and Against Flats on Each Bolt tube, inside of steering cable mounting tube and
rubber O-ring seal (located in outboard tilt tube)
with Quicksilver 2-4-C w/Teflon before installing
WARNING steering cables.
Locking retainer corner tabs, MUST BE bent up
Lubricate inside of outboard tilt tube and inside of
and against flats on each bolt that secures
steering cable mounting tube with Quicksilver 2-4-C
mounting bracket for steering cable mounting
w/Teflon. Verify rubber O-ring seal (a) (located in
tube to outboard swivel bracket to prevent bolts
outboard tilt tube) is lubricated.
from turning out.
51890
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c
51891
5/8″(16mm)
a 51888
b
Installing Link Rod
WARNING
Steering link rod MUST BE secured between
outboard steering arm and steering coupler,
a c d e using special washer head bolt (10-14000) and
51890
two nylon insert locknuts (11-34863), as shown.
Both special washer head bolt and nylon insert
locknuts MUST BE tightened as specified.
Thread cap (e) onto steering cable mounting tube, up
to mark (a). Lubricate hole in steering coupler, with Quicksilver
2-4-C w/Teflon. Assemble steering link rod to
steering coupler, using 2 flat washers (one each side
of coupler) and nylon insert locknut. Tighten locknut
until it seats [DO NOT exceed 120 Ib. in. (13.5 N·m)
of torque], then back nut off 1/4 turn.
a
e
51890
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c a d
f 51887
a - Steering Cable Mounting Tube
a b - Adjustment Nuts
d 28172 c - Adjust Tube in This Direction to Remove Slack from
a -
Steering Coupler Steering System
b -
Steering Link Rod d - Adjust Tube in This Direction to Reduce Tension from
c -
Flat Washer (2) Steering System
d -
Nylon Insert Locknut - Torque until it seats [DO NOT
exceed 120 lb. in. (13.5 N·m) of torque], then back nut off
1/4 turn
After steering system tension is adjusted correctly,
e - Special Washer Head Bolt (10-14000) - Torque to 20 lb. ft. tighten adjustment nuts against mounting bracket, to
(27.0 N·m) a torque of 35 Ib. ft. (47.5 N·m) and bend a tab lock
f - Nylon Insert Locknut - Torque to 20 lb. ft. (27.0 N·m) washer against flat on each adjustment nut.
c
c a
51887
a - Steering Cable Mounting Tube
b - Adjustment Nuts; Torque to 35 lb. ft. (47.5 N·m)
c - Tab Lock Washer (Bend Against Flat on Each Adjustment
Nut)
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Maintenance Instructions
Maintenance inspection is owner’s responsibility and a a
must be performed at intervals specified, following: 28170
WARNING
Core of each steering cable (transom end) must
be fully retracted into cable housing before
lubricating cable. If cable is lubricated while
extended, hydraulic lock could occur.
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c
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b
51887
b
b
a d d c
c e
51890 51887
a e
51890
51890
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d
50061
c c
e e
a a
b b
f f
d d
28166
f a
a
b
a - Flat Washer (2 Each Link Rod) Lubricate holes in ends of steering cables, with
b - Nylon Insert Locknut - Torque Until it Seats [DO NOT Quicksilver 2-4-C w/Teflon Marine Lubricant.
Exceed 120 lb. in. (13.5 N·m) of Torque], Then Back Off
1/4 Turn Assemble steering link rods to steering cable ends of
c - Special Washer Head Bolt (10-14000) - Torque to 20 lb. ft. each outboard, using flat washers and nylon insert
. (27.0 N·m) locknuts. Tighten locknuts until they seat [DO NOT
d - Nylon Insert Locknut - Torque to 20 lb. ft. (27.0 N·m) exceed 120 Ib. in. (13.5 N·m) of torque], then back
e - Steering Link Rod
f - Steering Cable End
nut off 1/4 turn.
Lubricate ball joints in steering link rods with SAE
30W Motor Oil. Secure link rods to outboard steering
arms, using special washer head bolts (10-14000)
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50061
WARNING a - Coupler
Locking retainer corner tabs MUST BE bent up b - Rubber Sleeve
c - Steering Eye
and against flats on each bolt that secures d - Rubber Bushing
extension bracket to outboard steering arm to e - Jam Nut
prevent bolts from turning out.
WARNING
Both steering eyes must be threaded into
coupler 3/4 in. (19 mm) minimum. Thread length
of steering eye is 3-1/2 in. (89 mm), so exposed
thread must not extend out of coupler more than
2-3/4 in. (70 mm). Failure to adhere to this
requirement could result in steering system
failure.
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f a f
28167
g g
d b d
c
h h
f
f c e a 50061
f
c
g h
50061
c - Steering Eye g - Nylon Insert Locknut - Torque to 20 lb. ft. (27.0 N·m)
d - Rubber Bushing h - Steering Arm Extension Bracket
e - Jam Nut - Torque (Against Coupler) to 20 lb. ft.
(27.0 N·m)
c d
51887
a - Steering Cable Mounting Tube
b - Adjustment Nuts
c - Adjust Tube in This Direction to Remove Slack from Steer
ing System
d - Adjust Tube in This Direction to Reduce Tension from
Steering System
c c a 51887
a - Steering Cable Mounting Tube
b - Adjustment Nuts Torque to 35 lb. ft. (47.5 N·m)
c - Tab Lock Washer (Bend Against Flat on Each Adjustment
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Nut)
a
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b c
51887
a
a
e d c b
51890
51890
a 51888 d b
c
51887
e c c
e
a
a
d d
f f b
b 28165
e
f a
a
b
a - Flat Washer (2 Each Link Rod)
b - Nylon Insert Locknut - Torque Until it Seats [DO NOT
Exceed 120 lb. in. (13.5 N·m) of Torque], Then Back Off
1/4 Turn
c - Special Washer Head Bolt (10-14000) - Torque to 20
lb. ft. (27.0 N·m)
d - Nylon Insert Locknut - Torque to 20 lb. ft. (27.0 N·m)
e - Steering Link Rod
f - Steering Cable End
d
d c d e b a b d c
a
50061
a - Coupler
c c b - Rubber Sleeve
c - Steering Eye
d - Rubber Bushing
e - Jam Nut
WARNING
51889 Both steering eyes must be threaded into
a - Steering Arm (Port Outboard Shown) coupler 3/4 in. (19 mm) minimum. Thread length
b - Extension Bracket of steering eye is 3-1/2 in. (89 mm), so exposed
c - Locking Retainer (2 Each Bracket) thread must not extend out of coupler more than
d - Bolts (2 Each Bracket) 1-1/4 in. (31.8 mm) Long - Torque to
2-3/4 in. (70 mm). Failure to adhere to this
23 lb. ft. (31.5 N·m), Then Bend Corner Tabs of Locking
Retainers Up Against Flats on Each Bolt requirement could result in steering system
failure.
WARNING
Locking retainer corner tabs, MUST BE bent up
and against flats on each bolt that secures
extension bracket to outboard steering arm, to
prevent bolts from turning out.
f f
a
28174
g g
d b d
c
h h
f
f c e a 50061
f
c
g h
50061
DUAL OUTBOARD - NON COUNTER ROTATION 30 in. thru 34 in. 9″ (229mm) Coupler and 12″
INSTALLATION (763mm thru 864mm) (305mm) Coupler (Connected
together with coupler link rod)
1. Check trim tab position as follows:
IMPORTANT: Initial trim tab setting for both 33 in. thru 37 in. 12″ (305mm) Coupler and
outboards should be straight to rear of outboard, 12″ (305mm) Coupler (Con-
so that tabs are aligned with gear housing center nected together with coupler
link rod)
line. Refer to “If necessary, adjust trim tab as
follows,” following.
a. Operate boat at normal cruise throttle setting
and adjust trim to optimum setting.
b. If boat pulls to the right (starboard), trailing
edge of trim tab must be moved to the right
(when viewing outboard from behind). If boat
pulls to the left (port), trailing edge of trim tab
must be moved to the left.
2. If necessary, adjust trim 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 set in the same
position on both outboards.
c. If boat pulls to the right, adjust trailing edges
of both trim tabs to the right. If boat pulls to the
left, adjust trailing edges of both trim tabs to
the left.
d. Tighten both trim tab bolts securely and
replace plastic caps.
e. Operate boat per “Check trim tab position
as follows,” preceding, to check trim tab
setting. Readjust trim tabs, if necessary.
d d
a c c
a a b
a b 28168
Lubrication Points for Parallel Cable Routing Installations
d
d
c
c
b a a a a b
Lubrication Points for Opposite Side Cable Routing Installations 28175
a b i h
f
k c g
d
l
j
e
Figure 1
a - RideGuide Cable 3. Place RideGuide yoke on pivot block and secure
b - RideGuide Yoke with 7/16 in. x 1-3/4 in. (11.1mm x 44.5mm) bolt
c - Pivot Block
d - Pivot Spacer and locknut, as shown in Figures 1 and 2. Torque
e - 15 in. (381mm) (Centerline of Attaching Kit Pivot to locknut to 10 Ib. ft. (13.5 N·m), then back off
Centerline of Outboard) 1/4-turn.
f - Pivot Attaching Locknut [Torque to 20 lb. ft. (27.0 N·m)]
g - Outboard Steering Arm g f
h - “Clevis Kit”
i - RideGuide Cable Attaching Locknut [Torque to 10 lb. ft.
(13.6 N·m)] d
j - Bolt [3/8 in. x 2-1/2 in. (9.5mm x 63.5mm)]
k - Flat Washer
l - Transom Bracket a
b
c
e
Figure 2
a -
Transom Backing Plate
b -
Bolt [5/16 in. x 3-1/4 in. (7.9mm x 82.5)]
c -
Locknut [Torque to 10 lb. ft. (13.5 N·m)]
d -
RideGuide Yoke Attaching Locknut [Torque to 10 lb. ft.
(13.5 N·m)] Then Back Off 1/4-Turn
e - 2-3/8 in. (60.3mm) Maximum Transom Thickness
f - Bolt [7/16 in. x 1-3/4 in. (11.1mm x 44.5mm)]
g - RideGuide Yoke
f h j
e a e
f
i
k
c
g
b
d
Figure 3
b
c a - Clamp (2 Halves)
b - Battery Cables
c - Engine Wiring Harness Adaptor
a d - Fuel Line
e - Oil Hose
f - Throttle Cable
g - Shift Cable
h - Accessory (Knock Out)
52188
e g a - Screws
50103
d - Wiring Clamp (2 Halves)
e - Remote Control Wiring Harness/Key Switch Wiring
Harness Opening
f - Battery Cable Openings
g - Oil Hose Openings
d
c Shift Cable Adjustment and
b
a Installation to the Engine
1. Install the shift cable to the remote control. Refer
to installation instructions included with the
remote control.
2. Before installing the shift cable to the engine,
locate the center point of the slack or lost motion
that exists in the remote control and shift cable as
follows.
NOTE: On counter rotation outboards, the location of
marks “a” and “b” below on the shift cable will be
a - Lead From Trim Solenoid (Down Solenoid/Relay) reversed.
b - Lead From Trim Solenoid (Up Solenoid/Relay)
c - Lead From Trim Sender a. Move the remote control handle into forward
d - Lead From Temperature Sender and advance the handle to the full speed
position. Slowly return the handle back to the
3. Place the remote control harness and battery neutral detent position. Place a mark on the
cables behind the “J” clamp. shift cable against the cable end guide at
location (a).
g
f 54074
d b
54075
FUEL LINE
Minimum fuel line inside diameter (I.D.) is 5/16 in.
(8mm), with separate fuel line/fuel tank pickup for
each engine.
40653
b
a
c
d 40654
a - Bottom Cowl
b b - Fuel Inlet Connection on Cowl
c - Bayonet Locking Device for Fuel Connection
a - Fuel Hose d - Fuel Line Connector from Fuel Tank
b - Hose Clamp
a - Fuel Tank
b - Auxiliary Electric Fuel Pump