Outboard Manual 70 75 80 90 100 115 PDF

SERVICE
MANUAL
MODELS
70 75 80 90 100 115
19871993 70 75 75 Marathon
75XD 75 Seapro 80 90 (3 Cylinder)
with Serial Numbers
19881993 100 115 (4 Cylinder)

with Serial Numbers
UNITED STATES S/N 0A996142 thru 0D283221 UNITED STATES S/N 0B209468 thru 0D283221
BELGIUM
S/N 09502135 thru 09793576 BELGIUM
S/N 09523034 thru 09793576
CANADA
S/N 0A722297 and Above
CANADA
S/N 0A731673 and Above
Printed in U.S.A.
1995, Brunswick Corporation
90-13645--2 1095
Notice
Notice to Users of This Manual
Throughout this publication, Dangers, Warnings

and Cautions (outlined in a border and accompanied by the International HAZARD Symbol
) are
used to alert the mechanic to special instructions concerning a particular service or operation that may be
hazardous if performed incorrectly or carelessly.
OBSERVE THEM CAREFULLY!
This service manual has been written and published

by the service department of Mercury Marine to aid
our dealers mechanics and company service personnel when servicing the products described herein.
These Safety Alerts alone cannot eliminate the

hazards that they signal. Strict compliance to these
special instructions when performing the service, plus
common sense operation, are major accident
prevention measures.
DANGER
DANGER Immediate hazards which WILL result
in severe personal injury or death.
WARNING
WARNING - Hazards or unsafe practices which
COULD result in severe personal injury or death.
CAUTION
CAUTION Hazards or unsafe practices which
could result in minor personal injury or product or
property damage.
It is assumed that these personnel are familiar with

the servicing procedures of these products, or like or
similar products manufactured and marketed by Mercury Marine, that they have been trained in the recommended servicing procedures of these products
which includes the use of mechanics common hand
tools and the special Mercury Marine or recommended tools from other suppliers.
We could not possibly know of and advise the service
trade of all conceivable procedures by which a service might be performed and of the possible hazards
and/or results of each method. We have not undertaken any such wide evaluation. Therefore, anyone
who uses a service procedure and/or tool, which is
not recommended by the manufacturer, first must
completely satisfy himself that neither his nor the
products safety will be endangered by the service
procedure selected.
All information, illustrations and specifications contained in this manual are based on the latest product
information available at the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service these products.
It should be kept in mind, while working on the
product, that the electrical system and ignition system
is capable of violent and damaging short circuits or
severe electrical shocks. When performing any work
where electrical terminals could possibly be
grounded or touched by the mechanic, the battery
cables should be disconnected at the battery.
Any time the intake or exhaust openings are exposed
during service they should be covered to protect
against accidental entrance of foreign material which
could enter the cylinders and cause extensive internal damage when the engine is started.
It is important to note that, during any maintenance
procedure, replacement fasteners must have the
same measurements and strength as those removed, whether metric or customary. Numbers on the
heads of the metric bolts and on surfaces of metric
nuts indicate their strength. Customary bolts use radial lines for this purpose, while most customary nuts
do not have strength markings. Mismatched or incorrect fasteners can result in damage or malfunction, or
possible personal injury. Therefore, fasteners removed should be saved for re-use in the same locations whenever possible. Where the fasteners are not
satisfactory for re-use care should be taken to select
a replacement that matches the original.
Cleanliness and Care of

Outboard Motor
Service Manual Outline

1
General Information and Specifications
A marine power product is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten thousands of an
inch. When any product component is serviced, care
and cleanliness are important. Throughout this
manual, it should be understood that proper cleaning,
and protection of machined surfaces and friction
areas is a part of the repair procedure. This is considered standard shop practice even if not specifically
stated.
Electrical and Ignition
Ignition System
Battery, Charging System and

Starting System
Timing/Synchronizing and Adjusting
Wiring Diagrams
Fuel System and Carburetion
Oil Injection System
Whenever components are removed for service, they

should be retained in order. At the time of installation,
they should be installed in the same locations and
with the same mating surfaces as when removed.
Powerhead (3-Cylinder Engines)
Powerhead (4-Cylinder Engines)
Lower Unit
Before raising or removing an outboard engine from a

boat, the following precautions should be adhered to:
Gear Housing
Mid Section
1. Check that flywheel is secured to end of

crankshaft with a locknut and lifting eye is
threaded into flywheel a minimum of 5 turns.
Shock Absorber
Power Trim
Design I (Side Fill Reservoir)
Design II (Aft Fill Reservoir)
Single Ram
Outboard Motor Installation/Attachments
Engine Attachments/Engine Installation
Tiller Handle and Co-Pilot
2. Connect a hoist of suitable strength to the lifting

eye.
In addition, personnel should not work on or under an
engine which is suspended. Engines should be attached to work stands, or lowered to ground as soon
as possible.
We reserve the right to make changes to this manual
without prior notification.
Refer to dealer service bulletins for other pertinent information concerning the products described in this
manual.
GENERAL INFORMATION
AND SPECIFICATIONS
Table Of Contents
Page
General Specification . . . . . . . . . . . . . . . . . . . . . .
Cowl Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling Oil Injection System . . . . . . . . . . . . . . . . . .
Power Trim General Information . . . . . . . . . . . . .
Trim In Angle Adjustment . . . . . . . . . . . . . . . . .
Models with Power Trim . . . . . . . . . . . . . . . .
Checking Trim System Fluid Level . . . . . . . . . . .
Tilt Angle Adjustment . . . . . . . . . . . . . . . . . . . . . .
Models without Power Trim . . . . . . . . . . . . . .
Connecting Engine Wiring Harness and
Routing of Engine Battery Cables . . . . . . . .
Ride-Guide Steering Cable and
Pivot Points Lubrication . . . . . . . . . . . . . . . . .
1-1
1-3
1-3
1-4
1-4
1-4
1-5
1-5
1-5
1-6
1-7
Page
Following Complete Submersion . . . . . . . . . . . . 1-8

Salt Water Submersion
(Special Instructions) . . . . . . . . . . . . . . . . 1-8
Submerged While Running
(Special Instructions) . . . . . . . . . . . . . . . . 1-8
Submerged Engine (Fresh Water)
(Plus Special Instructions) . . . . . . . . . . . 1-8
Out-of-Season Outboard Storage . . . . . . . . . . . 1-9
How Weather Affects Engine Performance . . 1-10
Conditions Affecting Operation . . . . . . . . . . . . . 1-11
Detonation: Causes and Prevention . . . . . . . . 1-12
Compression Check . . . . . . . . . . . . . . . . . . . . . . 1-12
90-13645-2 495
General Specification
NOTE: Other specification (torques, etc.) are listed in
the respective sections.
Horsepower
Idle RPM (in forward gear)
Model 70
Model 75
Model 80
Model 90
70 (52.2 kw)
75 (55.9 kw)
80 (59.6 kw)
90 (67.1 kw)
650 - 700
Full Throttle RPM Range
4750 - 5250
5000 - 5500
Piston Replacement
71.12 (1165.7cc)
Cylinder Bore
3.375 (85.7mm)
Stroke
2.65 (67.3mm)
Engine Type
3 Cylinder, 2 Cycle
Ignition Type
C.D. Breakerless
NGK-BUHW-2 or AC-V40 FFK or
Champion L78V
Recommended Spark Plug

Cylinder Firing Order
1-3-2
Recommended Power Trim Fluid
Quicksilver Power Trim & Steering Fluid or Automotive Transmission

Fluid (ATF) Type F, FA or Dexron II
Regular Leaded, Premium, Low-Lead and Lead-Free automotive gasolines with a minimum pump posted octane rating of 86
Recommended Gasoline
Recommended Oil
Engine Weight
Inductor Plugs: NGK-BUZHW-2 or

Champion QL78V
Quicksilver TC-WII or TC-W3 2-Cycle Outboard Oil
ELO
ELOPT
260 lbs.
280 lbs.
6.6 U.S. Gallons
(5 Imp. Gals.; 25 Liters)
Fuel Tank Capacity

Gear Housing Lubricant Capacity
22.5 fl. oz. (665.3ml)
Gasoline/Oil Ratio at Idle
80:1
Gasoline/Oil Ratio at W.O.T.
50:1
Gear Ratio
2.3:1
Oil Injection Tank Capacity

Tank Capacity
1 gal. (3.78 liter)
Maximum operation per tank

full of oil at W.O.T.
6 hours
Oil remaining when warning

buzzer sounds
1 qt. (.95 liter)
Operating time remaining at

wide open throttle when warning buzzer sounds
90-13645--2 1095
1 Hour
GENERAL INFORMATION AND SPECIFICATIONS
1-1
General Specification
(continued)
NOTE: Other specification (torques, etc.) are listed in
the respective sections.
Horsepower
Model 100
Model 115
100 (74.6 kw)
115 (85.8 kw)
Idle RPM (in forward gear)
650 - 700
4750 - 5250
Piston Replacement
105 (1720.9cc)
Cylinder Bore
3.375 (85.7mm)
Stroke
2.930 (74.4mm)
Engine Type
4 Cylinder, 2 Cycle
Ignition Type
C.D. Breakerless
NGK-BPH8H-N-10* Gap - 0.040 in. (1.0mm)
Inductor Plug NGK BPZ 8H-N-10* Gap - 0.040 in. (1.0mm)
NGK-BUHW
1-3-2-4
Recommended Spark Plug

Cylinder Firing Order
Recommended Power Trim Fluid
Quicksilver Power Trim & Steering Fluid or Automotive Transmission

Fluid (ATF) Type F, FA or Dexron II
Regular Leaded, Premium, Low-Lead and Lead-Free automotive gasolines with a minimum pump posted octane rating of 86
Recommended Gasoline
Recommended Oil
Engine Weight
Quicksilver 2-Cycle Outboard Oil
ELO
ELOPT
340 lbs.
360 lbs.
6.6 U.S. Gallons
(5 Imp. Gals.; 25 Liters)
Fuel Tank Capacity

Gear Housing Lubricant Capacity
22.5 fl. oz. (665.2ml)
Gasoline/Oil Ratio at Idle
80:1
Gasoline/Oil Ratio at W.O.T.
50:1
Gear Ratio
2.07:1
Oil Injection Tank Capacity

Tank Capacity
1.4 gal. (5.3 liters)
Maximum operation per tank

full of oil at W.O.T.
5 hours
Oil remaining when warning

buzzer sounds
1 qt. (.95 liter)
Operating time remaining at

wide open throttle when warning buzzer sounds
50 min. approx.
*Improves running quality between 1800 2000 RPM.
1-2
90-13645--2 1095
Cowl Removal
Filling Oil Injection System
Pull outward on starboard side of front shield (a).
Open starboard cowl (refer to cowl removal on this

page). Some earlier outboards will have a cowl bracket to hold cowl open as shown.
Remove spring (b) from latch and open cowls.
Fill tank with recommended oil.
18291
a - Oil Tank Tube
18292
90-13645--2 495
1-3
Power Trim System
Trim In Angle Adjustment
GENERAL INFORMATION
MODELS WITH POWER TRIM
The power trim system is filled at the manufacturer

and is ready for use.
Trim outboard through entire trailering range several
times to remove any air from the system.
The trim system is pressurized and is not externally
vented. The outboard can be raised or lowered manually by loosening the manual release valve four turns.
The trim out angle of this outboard is not adjustable.
The trim system has an internal valve which will
automatically stop the outward trim travel at 20 when
engine RPM is approximately 2000 RPM or higher;
outboard also has to be in water and in gear.
The outboard can be operated beyond the 20 trim
limit for operating outboard in shallow water if engine
RPM is kept below approximately 2000 RPM.
WARNING
Operating some boats with outboard trimmed to the
full in trim angle [not using trim adjustment bolt
(a)] at planing speed will cause undesirable and/or
unsafe steering conditions. Each boat MUST BE
water tested for handling characteristics after
outboard installation and after any trim adjustments.
IMPORTANT: Some boat/motor combinations,
that do not use the trim adjustment bolt (a) and are
trimmed to the full in trim angle, will not experience any undesirable and/or unsafe steering
conditions during planing speed. Thus, not using
trim adjustment bolt may be desired. However,
some boats with outboard trimmed to the full in
trim angle at planing speeds will cause undesirable and/or unsafe steering conditions. If these
steering conditions are experienced, under no
circumstances should the outboard be operated
without the trim adjustment bolt and without the
bolt adjusted in the proper holes to prevent unsafe handling characteristics.
Water test the boat not using the trim adjustment bolt.
If undesirable and/or unsafe steering conditions are
experienced (boat runs with nose down), install trim
adjustment bolt in proper hole to prevent unsafe handling characteristics.
23321
a - Fill Screw (System is Pressurized, DO NOT Open Unless
Outboard is Tilted to Full Up Position)
b - Manual Release Valve
a
22744
1-4
90-13645--2 495
Checking Trim System Fluid Level
Tilt Angle Adjustment
IMPORTANT: This trim system is pressurized.

Remove fill screw (b) when outboard is trimmed
to the full up position. Retighten fill screw
securely.
MODELS WITHOUT POWER TRIM
1. Trim outboard to full up position. Engage tilt lock

lever. Trim system fluid can only be checked when
outboard is in this position.
2. Remove fill screw and check fluid level. Fluid level
should be visible in fill tube.
3. If necessary, add Quicksilver Power Trim and
Steering Fluid; or Automatic Transmission Fluid
(ATF) Type F, FA or Dextron II.
WARNING
Operating some boats at minimum trim In at
planing speeds will cause undesirable and/or
unsafe steering conditions. Each boat should be
tested for handling characteristics after any
adjustment is made to the tilt angle.
DO NOT OPERATE motor with tilt lock pin removed.
Adjust tilt angle of motor on transom with tilt lock pin
so that anti-ventilation plate is about parallel and even
with bottom of boat. Speed sometimes may be improved by tilting motor out one tilt pin hole to raise bow
and reduce wetted surface. If motor is tilted in, boat
will ride bow down, wetting more of the bottom and reducing speed, which generally will improve operation
in rough water. Under ideal conditions, efficiency is
best with lower unit operating in level position. Operation with excessive tilt angle will reduce performance
noticeably and may induce ventilation. It is preferable
to level boat by proper loading rather than by extreme
adjustment of tilt angle.
20319
a - Tilt Lock Lever
b - Fill Screw
a
22744
a - Tilt Lock Pin
90-13645--2 495
1-5
Connecting Engine Wiring

Harness and Routing of
Engine Battery Cables
WARNING
Cables passing through cowl must be protected
from chafing or being cut, by using the neoprene
sheet as described in the following steps. Failure
to protect cables as described could result in
electrical system failure and/or possible injury to
occupants of boat.
1. Plug remote control harness connector into engine harness connector, then secure connector in
place with retainer as shown.
2. Wrap neoprene sheet around cable bundle and
secure each end with a sta-strap. Secure to
bracket with retainer.
IMPORTANT: On Models without Power Trim, the
neoprene sheet must be folded once and then
wrapped around cables as shown.
e
f
c
b
a
b
20290
a - Engine Connector
b - Retainer
c - Harness Connector
Models with Power Trim
d - Harness Retainer
e - Neoprene Sheet
f - Sta-Strap(s)
b
a
Models without Power Trim

a - Wiring Harness
b - Neoprene Sheet
c - Sta-Straps
1-6
90-13645--2 495
Lubrication Points
No.
Description
1 Ride-Guide
Steering Cable
2 Throttle-Shift
Linkage
3 Upper Shift Shaft
4 Tilt Tube
5 Swivel Pin
6 Tilt Lock Lever
7
8
9
10
---
11
Propeller Shaft
Gear Housing
Steering Link Rod
Pivot Points
Power Trim Pump
Oil Level
Engine Crankshaft
Splines to Drive
Shaft Splines
Accelerator Pump
Stem/Throttle Cam
Lubricant Used or
Maintenance
Fresh Water Frequency
Salt Water Frequency
Quicksilver
2-4-C
C
w/Teflon
E
Every
60 Days
D
E
Every
30 Days
D
Quicksilver
-2-4-C w/Teflon
Anti-Corrosion Grease
Once in Season
Every 60 Days
Quicksilver Gear Lube
Check and fill after 1st 10 days, then every 30 days

Drain and Refill after 1st 25 hours, then after every
100 hours, or once a year before storing.
SAE 30W Engine Oil
Every 60 Days
Every 30 Days
Quicksilver Power Trim

and Steering Fluid
Every 100 hours,

or once in season
Same as Fresh Water
Quicksilver
2-4-C w/Teflon
Quicksilver 2-4-C
w/Teflon
Once in Season by Dealer

Once in Season
Every 60 Days
Ride-Guide Steering Cable and Pivot

Points Lubrication
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.
8
7
27868
With core of Ride-Guide Steering cable (transom

end) fully retracted, lubricate transom end of steering
cable thru grease fitting and exposed portion of cable
end with Quicksilver 2-4-C w/Teflon. Lubricate all pivot points with SAE 30W engine oil.
5
1
6
10
9
4
20319
90-13645--2 495
50099
1-7
NOTE: 4 CYL. MODELS
Following Complete Submersion

Submerged engine treatment is divided into 3 distinct
problem areas. The most critical is submersion in salt
water; the second is submersion while running.
Salt Water Submersion (Special

Instructions)
Due to the corrosive effect of salt water on internal engine components, complete disassembly is necessary before any attempt is made to start the engine.
Submerged While Running (Special

Instructions)
11
22509B
11 Lubrication Points for Accelerator Pump Cam on 4 Cylinder
Models Only
When an engine is submerged while running, the

possibility of internal engine damage is greatly increased. If, after engine is recovered and with spark
plugs removed, engine fails to turn over freely when
turning flywheel, the possibility of internal damage
(bent connecting rod and/or bent crankshaft) exists.
If this is the case, the powerhead must be disassembled.
Submerged Engine (Fresh Water)

(Plus Special Instructions)
1. Recover engine as quickly as possible.
2. Remove cowling.
3. Flush outside of engine with fresh water to remove mud, weeds, etc. DO NOT attempt to start
engine if sand has entered powerhead, as powerhead will be severely damaged. Disassemble
powerhead if necessary to clean components.
4. Remove spark plugs and get as much water as
possible out of powerhead. Most water can be
eliminated by placing engine in a horizontal position (with spark plug holes down) and rotating flywheel.
5. Pour alcohol into carburetor throat (alcohol will
absorb water). Again rotate flywheel.
6. Turn engine over and pour alcohol into spark plug
openings and again rotate flywheel.
2
18298
2 Lubrication Points are indicated with Arrows
7. Turn engine over (place spark plug opening

down) and pour engine oil into throat of carburetors while rotating flywheel to distribute oil
throughout crankcase.
8. Again turn engine over and pour approximately
one teaspoon of engine oil into each spark plug
opening. Again rotate flywheel to distribute oil in
cylinders.
9. Remove and clean carburetors and fuel pump
assembly.
1-8
90-13645--2 495
10. Reinstall spark plugs, carburetors and fuel pump.

11. Attempt to start engine, using a fresh fuel source.
If engine starts, it should be run for at least one
hour to eliminate any water in engine.
12. If engine fails to start, determine cause (fuel, electrical or mechanical). DO NOT allow engine to remain idle for more than 2 hours, as serious internal damage will occur. If unable to start engine in
this period, disassemble engine and clean all
parts and apply oil as soon as possible.
Out-of-Season Outboard Storage

WARNING
As a safety precaution, when boat is in storage,
remove positive (+) battery cable. This will
eliminate possibility of accidental starting of
engine and resultant overheating and damage to
engine from lack of water.
In preparing an outboard for out-of-season storage,
2 precautions must be considered: 1) The engine
must be protected from physical damage and 2) the
engine must be protected from rust, corrosion and
dirt.
1. Remove cowling from engine.
2. Place outboard in water or install Quicksilver
Flushing Attachment over water intake by following instructions outlined in Flushing Cooling System (see Table of Contents).
3. Start engine and allow to warm up. Disconnect
fuel line. When engine starts to stall quickly spray
Quicksilver Storage Seal into each carburetor
throat. Continue to spray until engine dies from
lack of fuel.
4. Remove spark plugs and inject a 5 second spray
of Quicksilver Storage Seal around the inside of
each cylinder. Manually turn engine over several
times to distribute Storage Seal throughout cylinders. Reinstall spark plugs.
5. If engine fuel filter appears to be contaminated, remove and replace. Refer to Section 3 Fuel System
and Carburetion.
90-13645--2 495
6. Drain and refill lower unit with Quicksilver Gear

Lube, as explained in Gear Housing Lubrication
(see Table of Contents).
7. Clean outboard thoroughly, including all accessible powerhead parts, and spray with Corrosion
and Rust Preventive.
8. Refer to lubrication chart in this section (see
Table of Contents) and lubricate all lubrication
points.
9. Remove propeller. Apply Quicksilver Anti-Corrosion
Grease or 2-4-C w/Teflon to propeller shaft and reinstall propeller. Refer to Propeller Installation (see
Table of Contents).
10. If the water pickup is clogged, the speedometer
will be inoperative. Clean the pickup with a piece
of wire or blow out with compressed air. Before
blowing out with air, disconnect the tubing from
the speedometer.
11. To prevent freeze damage, drain the speedometer system of water completely before storage.
Remove tubing from speedometer fitting and
blow thru the tubing to remove water.
12. Store battery as outlined in Out-of-Season Battery Storage, following.
13. For out-of-season storage information on
Autoblend units, refer to Section 8 in this service
manual.
IMPORTANT: When storing outboard for the winter, be sure that all water drain holes in gear housing are open and free so that all water will drain
out. If a speedometer is installed in the boat, disconnect the pickup tube and allow it to drain. Reconnect the tube after draining. Trapped water
may freeze and expand, thus cracking gear housing and/or water pump housing. Check and refill
gear housing with Quicksilver Gear Lube before
storage to protect against possible water leakage
into gear housing which is caused by loose lubricant vent plug or loose grease fill plug. Inspect
gaskets under lubricant vent and fill plugs, replacing any damaged gaskets, before reinstalling
plugs.
1-9
Out-of-Season Battery Storage

1. Remove battery as soon as possible and remove
all grease, sulfate and dirt from top surface.
2. Cover PLATES with distilled water, but not over
3/16 in. (5mm) above perforated baffles.
3. Cover terminal bolts well with grease.
4. Store battery in a COOL, DRY place in a dry carton or box.
5. Remove battery from storage every 60 days.
Check water level and place on charge for 5 to 6
hours at 6 amperes. DO NOT fast charge.
CAUTION
A discharged battery can be damaged by freezing.
How Weather Affects Engine

Performance
Corporations internationally have settled on adoption

of I.S.O. (International Standards Organization)
engine test standards, as set forth in I.S.O. 3046
standardizing the computation of horsepower from
data obtained on the dynamometer, correcting all
values to the power that the engine will produce at
sea level, at 30% relative humidity at 77 F (25 C)
temperature and a barometric pressure of 29.61
inches of mercury.
Summer Conditions of high temperature, low barometric pressure and high humidity all combine to reduce the engine power. This, in turn, is reflected in decreased boat speeds--as much as 2 or 3 miles-perhour (3 or 5 Km per-hour) in some cases. (Refer to
previous chart.) Nothing will regain this speed for the
boater, but the coming of cool, dry weather.
In pointing out the practical consequences of weather
effects, an engine--running on a hot, humid summer
day--may encounter a loss of as much as 14% of the
horsepower it would produce on a dry, brisk spring or
fall day. The horsepower, that any internal combustion engine produces, depends upon the density of
the air that it consumes and, in turn, this density is dependent upon the temperature of the air, its barometric pressure and water vapor (or humidity) content.
Accompanying this weather-inspired loss of power is
a second but more subtle loss. At rigging time in early
spring, the engine was equipped with a propeller that
allowed the engine to turn within its recommended
RPM range at full throttle. With the coming of the summer weather and the consequent drop in available
horsepower, this propeller will, in effect, become too
large. Consequently, the engine operates at less than
its recommended RPM.
It is a known fact that weather conditions exert a profound effect on power output of internal combustion
engines. Therefore, established horsepower ratings
refer to the power that the engine will produce at its
rated RPM under a specific combination of weather
conditions.
1-10
Due to the horsepower/RPM characteristics of an engine, this will result in further loss of horsepower at the
propeller with another decrease in boat speed. This
secondary loss, however, can be regained by switching to a smaller pitch propeller that allows the engine
to again run at recommended RPM.
90-13645--2 495
For boaters to realize optimum engine performance

under changing weather conditions, it is essential that
the engine have the proper propeller to allow it to operate at or near the top end of the recommended maximum RPM range at wide-open-throttle with a normal
boat load.
Not only does this allow the engine to develop full
power, but equally important is the fact that the engine
also will be operating in an RPM range that discourages damaging detonation. This, of course, enhances overall reliability and durability of the engine.
Conditions Affecting Operation

1. Proper positioning of the weight inside the boat
(persons and gear) has a significant effect on the
boats performance, for example:
a. Shifting weight to the rear (stern)
(1.) Generally increases top speed.
(2.) If in excess, can cause the boat to porpoise.
(3.) Can make the bow bounce excessively in
choppy water.
(4.) Will increase the danger of the following wave splashing into the boat when coming
off plane.
b. Shifting weight to the front (bow)
(1.) Improves ease of planing off.
(3.) If excessive, can make the boat veer left

and right (bow steer).
2. Boat Bottom: For maximum speed, a boat bottom should be nearly a flat plane where it contacts
the water and particularly straight and smooth in
fore-and-aft direction.
a. Hook: Exists when bottom is concave in foreand-aft direction when viewed from the side.
When boat is planing, hook causes more lift
on bottom near transom and allows bow to
drop, thus greatly increasing wetted surface
and reducing boat speed. Hook frequently is
caused by supporting boat too far ahead of
transom while hauling on a trailer or during storage.
b. Rocker: The reverse of hook and much less
common. Rocker exists if bottom is convex in
fore-and-aft direction when viewed from the
side, and boat has strong tendency to porpoise.
c. Surface Roughness: Moss, barnacles, etc.,
on boat or corrosion of outboards gear housing
increase skin friction and cause speed loss.
Clean surfaces when necessary.
3. Gear Housing: If unit is left in the water, marine
vegetation may accumulate over a period of time
in certain types of water. This growth must be removed from unit before operation, as it may clog
the water inlet holes in the gear housing and
cause the engine to overheat.
(2.) Generally improves rough water ride.
90-13645--2 495
1-11
Detonation: Causes and Prevention
Compression Check
Detonation in a 2-cycle engine somewhat resembles

the pinging heard in an automobile engine. It can be
otherwise described as a tin-like rattling or plinking
sound.
1. Remove spark plugs.
Detonation generally is thought of as spontaneous ignition, but it is best described as a noisy explosion in
an unburned portion of the fuel/air charge after the
spark plug has fired. Detonation creates severe, untimely, shock waves in the engine, and these shock
waves often find or create a weakness: The dome of
a piston, piston rings or piston ring lands, piston pin
and roller bearings.
4. Crank engine thru at least 4 compression strokes

to obtain highest possible reading.
While there are many causes for detonation in a

2-cycle engine, emphasis is placed on those causes
which are most common in marine 2-cycle application. A few, which are not commonly understood, are:
6. Compression check is important because an engine with low or uneven compression cannot be
tuned successfully to give peak performance. It is
essential, therefore, that improper compression
be corrected before proceeding with an engine
tune-up.
1. Over-advanced ignition timing.

2. Use of low octane gasoline.
3. Propeller pitch too high (engine RPM below recommended maximum range).
4. Lean fuel mixture at or near wide-open-throttle.
5. Spark plugs (heat range too hot incorrect reach
cross-firing).
2. Install compression gauge in spark plug hole.

3. Hold throttle plates at W.O.T.
5. Check and record compression of each cylinder.

Variation of more than 15 psi (103.5 kPa) between
cylinders indicates that lower compression cylinder is in some way defective, such as worn or
sticking piston rings and/or scored piston and cylinder.
7. Cylinder scoring: If powerhead shows any indication of overheating, such as discolored or

scorched paint, visually inspect cylinders for scoring or other damage as outlined in Section 4
Powerhead.
6. Inadequate engine cooling (deteriorated cooling

system).
7. Combustion chamber/piston deposits (result in
higher compression ratio).
Detonation usually can be prevented, provided that
1) the engine is correctly set up and 2) diligent maintenance is applied to combat the detonation causes,
listed, preceding.
51115
Damaged Piston Resulting from Detonation
1-12
90-13645--2 495
ELECTRICAL AND
IGNITION
2
A
IGNITION SYSTEM
Table Of Contents
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . .
Direct Voltage Adapter (DVA) Tests . . . . . .
Troubleshooting Tips . . . . . . . . . . . . . . .
Test Sequence . . . . . . . . . . . . . . . . . . . . . . .
Ignition System Test Chart . . . . . . . . . . . . . . . . .
Stator Test . . . . . . . . . . . . . . . . . . . . . . . .
9/18/24 Ampere Stators . . . . . . . . . . . .
Ignition Coil Test . . . . . . . . . . . . . . . . . . .
Trigger Test . . . . . . . . . . . . . . . . . . . . . . .
Ignition (Key) Switch Test . . . . . . . . . . .
Commander 2000 Key Switch . . . . . . .
Commander Key Switch . . . . . . . . . . . .
Page
Page
2A-1
2A-1
2A-1
2A-1
2A-2
2A-3
2A-3
2A-4
2A-5
2A-5
2A-5
2A-5
2A-5
Ignition Components Removal and

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-6
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . 2A-6
Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . 2A-7
Trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . 2A-8
Ignition Coils (3 Cylinder Models) . . . . . . . 2A-9
Ignition Coils (4 Cylinder Models) . . . . . . . 2A-9
Switch Box . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-10
90-13645--2 1095
Description
Test Procedures
The outboard ignition system is alternator-driven with

distributor-less capacitor discharge. Major components of the ignition system are the flywheel, stator,
trigger, switch box, ignition coils and spark plugs.
Direct Voltage Adapter (DVA) Tests
The stator assembly is mounted stationary below the

flywheel and has 2 capacitor charging coils. The
flywheel is fitted with permanent magnets inside the
outer rim. As the flywheel rotates the permanent
magnets pass the capacitor charging coils. This
causes the capacitor charging coils to produce AC
voltage. The AC voltage then is conducted to the
switch box where it is rectified and stored in a
capacitor.
The trigger assembly (also mounted under the
flywheel) has 3 coils. The flywheel has a second set
of permanent magnets (located around the center
hub). As the flywheel rotates the second set of
magnets pass the trigger coils. This causes the
trigger coils to produce an AC voltage that is
conducted to an electric Silicon Controlled Rectifier
(SCR) in the switch box.
The switch discharges the capacitor voltage into the
ignition coil at the correct time and firing order
sequence.
Capacitor voltage is conducted to the primary side of
the ignition coil. The ignition coil multiplies this voltage
high enough to jump the gap at the spark plug.
The preceding sequence occurs once-per-enginerevolution for each cylinder.
Spark timing is changed (advanced/retarded) by
rotating the trigger assembly which changes each
trigger coil position in relation to the permanent
magnets on the flywheel center hub.
IMPORTANT: If the engine misfires, runs rough or
does not start, the ignition system should be
checked using a Multi-Meter/DVA Tester
(91-99750), or a voltmeter (capable of measuring
400 volts DC, or higher) and Direct Voltage Adaptor (91-89045).
WARNING
DANGER - HIGH VOLTAGE/SHOCK HAZARD! Do
not touch ignition components and/or metal test
probes while engine is running and/or being
cranked. STAY CLEAR OF SPARK PLUG
LEADS. To assure personal safety, each
individual spark plug lead should be grounded to
engine.
CAUTION
To protect against meter and/or component
damage, observe the following precautions:
400 VDC* test position (or higher) MUST BE
used for all tests.
INSURE the Positive (+) lead/terminal of DVA is
connected to the Positive (+) receptacle of
meter.
DO NOT CHANGE meter selector switch
position while engine is running and/or being
cranked.
Switch box MUST BE GROUNDED during tests.
Running or cranking engine with switch box
ungrounded may damage switch box.
*
If using a meter with a built-in DVA, the DVA/400 VDC test position should be used.
NOTE: Test leads are not supplied with the DVA. Use
test leads supplied with meter.
Test procedures and specifications are provided for
checking primary ignition voltage while the engine
is running and/or being cranked.
TROUBLESHOOTING TIPS:
1. Intermittent, weak, or no spark output at two

spark plugs usually indicates a bad TRIGGER.
2. Intermittent, weak, or no spark output at all three
spark plugs usually indicates a bad STATOR or
SWITCH BOX.
3. Intermittent, weak, or no spark at any one spark
plug usually indicates a bad SPARK PLUG,
COIL, or SWITCH BOX.
90-13645--2 1095
ELECTRICAL AND IGNITION
2A-1
Test Sequence
1-A) Check primary input voltage to coils. (See
Test Chart).
1. If voltage readings to coil(s) are BELOW specification, proceed with Step 2-A.
2. If voltage readings to coil(s) are WITHIN specifications, proceed with Step 1-B.
1-B) Check coils for spark. [Connect Spark Gap
Tester (91-63998A1) between coil high voltage
tower and spark plug.]
1. No spark or weak spark. COIL is bad.
2. Spark is OK, proceed with Step 1-C.
1-C) If Step 1-A and 1-B check OK, replace spark
plugs.
3. If reading is still BELOW specification, proceed

with Step 3-A.
4. If reading is WITHIN specification, either the
ignition switch, stop switch, or wiring is bad.
3-A) Check stator low speed and high speed input
to switch box. (See Test Chart).
1. If either the low speed or high speed reading to
switch box is BELOW specification, Stator or
Switch Box is bad (test stator as outlined in this
service manual section; if stator checks to specification replace switch box and repeat check).
2. If both the low speed and high speed reading are
WITHIN specification, replace switch box and repeat test.
If problem exists after replacing spark plugs, proceed

with Step 1-D.
1-D) If Steps 1-A, 1-B, and 1-C check OK, check
ignition timing.
1. If ignition timing does not check to specification
(or a sudden or unexplained timing change
occurs) check trigger advance linkage for loose
and/or broken parts and check trigger magnet
ring (on flywheel hub) for looseness and/or a shift
in position.
2. If ignition checks to specification and engine does
not run or runs poorly, trouble exists with fuel
system or engine mechanical.
2-A) Check switch box stop circuit. (See Test
Chart).
1. If reading is BELOW specifications, proceed with
Step 2-B.
2. If reading is ABOVE specifications, the Trigger or
Switch Box is bad (test trigger as outlined in this service manual section; if trigger checks OK, replace
switch box and repeat check).
3. If reading is WITHIN specifications, proceed with

Step 3-A.
2-B) Check ignition switch/wiring, as follows:
CAUTION
To prevent engine from starting, remove spark
plug leads from ALL spark plugs and ground
leads to engine.
1. Disconnect ignition switch and stop switch
leads from switch box and isolate the leads.
2. Repeat check in Step 2-A.
2A-2
90-13645--2 1095
Ignition System Test Chart

IMPORTANT: BEFORE attempting the ignition system checks, following, thoroughly read the preceding
pages of these instructions to become familiar with the proper Automatic Distributorless Ignition (ADI)
test sequence and procedures (particularly any Safety Warnings and Cautions). ALL tests are performed with lead wires connected terminals exposed. SWITCH BOX MUST BE GROUNDED (CASE TO
ENGINE BLOCK) FOR ALL TESTS IF NOT, SWITCH BOXES MAY BE DAMAGED.
3 Cylinder Stators 398-9710A13/14/28 and all 398-8778A Stators

4 Cylinder Stators 398-9710A15/31 and all 398-8778A Stators
ADI Test
Test
Seq.
1-A
Coil Primary
Sw. Box
2-A
Stop Circuit
3-A
Stator
4-A
Low Speed
3-A
Stator
4-A
High Speed
5-A
Sw Box
Sw.
Bias
Selector Sw.
Position
400 VDC*
400 VDC*
400 VDC*
400 VDC*
20 VDC or
40 VDC
DVA Leads
Coil () Terminal
Voltage
g Reading
g (1)
@ 300-1000 RPM
150-250
Voltage
g Reading
g
@ 1000-4000 RPM
180-280
Ground
200-360
200-360
Ground
200-300
200-330
Ground
20-90
130-300
White/Black
Sw. Box Terminal
2-10
10-30
Red
Black
Coil (+) Terminal

Black/Yellow (3)
Sw. Box Terminal
Blue Sw.
Box Terminal
Red Sw.
Box Terminal
[See Note (1)]
Ground
(1) Using meter only, REVERSE LEAD POLARITY; connect leads as specified.
* If using a meter with a built-in DVA, place selector switch in the DVA/400 VDC position.
3 Cylinder Stator 9 Ampere 398-9873A21 & 15 Ampere 398-9873A24

ADI Test
Test
Seq.
1-A
Coil Primary
Sw. Box
2-A
Stop Circuit
3-A
Stator
4-A
Low Speed
3-A
Stator
4-A
High Speed
5-A
Sw Box
Sw.
Bias
Selector Sw.
Position
400 VDC*
400 VDC*
400 VDC*
400 VDC*
20 VDC or
40 VDC
DVA Leads
Coil () Terminal
Voltage
g Reading
g (1)
@ 300-1000 RPM
145-250
Voltage
g Reading
g
@ 1000-4000 RPM
210-240
Ground
215-340
280-320
Ground
215-340
280-320
Ground
10-55
45-255
White/Black
Sw. Box Terminal
2-30
10-30
Voltage
g Reading
g
@ 1000-4000 RPM
215-265
Red
Black
Coil (+) Terminal

Black/Yellow (3)
Sw. Box Terminal
Blue Sw.
Box Terminal
Red Sw.
Box Terminal
[See Note (1)]
Ground
4 Cylinder Stator 16 Ampere 398-9710A33

ADI Test
Test
Seq.
1-A
Coil Primary
Sw. Box
2-A
Stop Circuit
3-A
Stator
4-A
Low Speed
3-A
Stator
4-A
High Speed
5-A
Sw. Box
Sw
Bias
Selector Sw.
Position
400 VDC*
400 VDC*
400 VDC*
400 VDC*
20 VDC or
40 VDC
DVA Leads
Red
Black
Coil (+) Terminal

Black/Yellow (3)
Sw. Box Terminal
Blue Sw.
Box Terminal
Red Sw.
Box Terminal
Coil () Terminal
Voltage
g Reading
g (1)
@ 300-1000 RPM
110-300
Ground
160-385
270-330
Ground
160-385
270-330
Ground
8-33
33-205
White/Black
Sw. Box Terminal
2-30
10-30
[See Note (1)]
Ground
90-13645--2 1095
2A-3
STATOR TEST
WARNING
When testing or servicing the ignition system,
high voltage is present, be extremely cautious!
DO NOT TOUCH OR DISCONNECT any ignition
parts while engine is running, while key switch is
on, or while battery cables are connected.
CAUTION
Failure to comply with the following items may
result in damage to the ignition system.
1. DO NOT reverse battery cable connections.
The battery negative cable is (-) ground.
2. DO NOT spark battery terminals with battery
cable connections to check polarity.
3. DO NOT disconnect battery cables while engine is running.
4. DO NOT crank engine when switch box is not
grounded to engine.
A process of elimination must be used when checking
the ignition system without a Multi-Meter/DVA Tester
(91-99750) or a voltmeter (capable of measuring 400
volts DC, or higher) and Direct Voltage Adaptor
(91-89045), as the switch box and ignition coils
cannot be thoroughly checked with conventional test
equipment.
All other components can be tested with an
ohmmeter. Before troubleshooting the ignition
system, check the following:
1. Make sure that electrical harness and ignition
switch are not the source of the problem.
2. Check that plug-in connectors are fully engaged
and terminals are free of corrosion.
NOTE: Stator can be tested without removing from

engine.
1. Disconnect stator leads from switch box.
2. Use an ohmmeter and perform the following tests.
IMPORTANT: If stator is mounted on engine, black
stator lead must be grounded to powerhead when
testing.
9/18/24 AMPERE STATORS (3 CYLINDER)
Test Leads
Between Blue Stator Lead
and Red Stator Lead (Low
Speed)
Between Red Stator Lead and
Engine Ground* (Hi-Speed)
Resistance
(OHMS)
Scale Reading
(x__________)
3600-4200
(90-140)
3.6-4.2
(R x 1000)
90-140
90-140
(R x 1)
9/18/24 AMPERE STATORS (4 CYLINDER)

Test Leads
Between Blue Stator Lead
and Blue/White Stator Lead
(Low Speed)
Between Red Stator Lead and
Red/White Stator Lead* (HiSpeed)
*
Resistance
(OHMS)
Scale Reading
(x__________)
6800-7600
(90-140)
6.8-7.6
(R x 1000)
90-140
90-140
(R x 1)
Connect test lead to black stator lead if stator is removed from

engine.
NOTE: Above readings are for a cold engine (room

temperature). Resistance will increase slightly, if engine is warm.
3. If meter readings are other than specified, replace
stator assembly.
3. Make sure that wire connections are tight and free

of corrosion.
4. Check all electrical components, that are
grounded directly to engine, and all ground wires
to see that they are grounded to engine.
5. Check for disconnected wires, and short and
open circuits.
2A-4
90-13645--2 1095
IGNITION COIL TEST

IMPORTANT: Ohmmeter tests can only detect certain faults in the ignition coil. Replace ignition
coil, if ohmmeter readings (listed in chart, following) are not as specified. If coil tests OK, and coil
is still suspected of being faulty, use Multi-Meter/
DVA Tester (91-99750) or a voltmeter (capable of
measuring 400 volts DC, or higher) and Direct
Voltage Adaptor (91-89045) to thoroughly check
coil.
1. Disconnect wires from coil terminals.
2. Pull spark plug lead out of coil tower.
3. Use an ohmmeter and perform the following tests.
Test Leads
Between (+) and
() Coil Terminals
Between Coil Tower and
() Coil Terminal
Resistance Scale Reading

(OHMS)
(x__________)
.02-.04*
.02-.04*
(R x 1)
800-1100**
8-11**
(R x 100)
Resistance
(OHMS)
Test Leads
Between Brown Trigger Lead
and Black Trigger Lead
Between White Trigger Lead
and Violet Trigger Lead
Scale Reading
(x__________)
7-10
(R x 100)
7-10
(R x 100)
700-1000
700-1000

3. If meter readings are not as specified, replace
trigger.
IGNITION (KEY) SWITCH TEST
1. Disconnect remote control wiring harness and
instrument panel connector.
NOTE: Wiring diagram for control boxes is located in
SECTION 2D.
2. Set ohmmeter on R x 1 scale for the following
tests:
COMMANDER 2000 KEY SWITCH
* The primary DC resistance of these coils generally is less than

one (1) OHM. If a reading resembling a short is obtained, this
would be acceptable.
** Copper wire is an excellent conductor, but it will have a noticeable difference in resistance from cold to hot temperatures.
Reasonable variations from these readings are acceptable.

ignition coil.
TRIGGER TEST (3 CYLINDER)
1. Disconnect all trigger leads from switch box.
2. Use an Ohmmeter and perform the following
tests.
23894
COMMANDER KEY SWITCH

BLK D
PUR D
RED D
YEL D
BLACK
PURPLE
RED
YELLOW
(PUR)
A
(BLK/YEL)
(RED)
Test Leads
Between Brown Trigger Lead
and White/Black Trigger Lead
Between White Trigger Lead
Between Violet Trigger Lead
Resistance
(OHMS)
1100-1400
1100-1400
1100-1400
Scale Reading
(x__________)
11-14
(R x 100)
11-14
(R x 100)
11-14
(R x 100)
KEY
POSITION
BLK
OFF
2. Use an Ohmmeter and perform the following

tests.
90-13645--2 1095
START
CHOKE*
*
(BLK)
(YEL/RED)
(YEL/BLK)
CONTINUITY SHOULD BE INDICATED

AT THE FOLLOWING POINTS:
RUN
1. Disconnect all trigger leads from switch box.
B
C

trigger.
TRIGGER TEST (4 CYLINDER)
BLK/YEL
RED YEL/RED
PUR YEL/BLK
Key switch must be positioned to RUN or START and key pushed

in to actuate choke, for this continuity test.
3. If meter readings are other than specified in the

preceding test, verify that switch and not wiring is
faulty. If wiring checks OK, replace switch.
2A-5
Ignition Components
Removal and Installation
INSTALLATION
Flywheel
Engine could possibly start when turning flywheel

during installation; therefore, disconnect (and
isolate) spark plug leads from spark plugs to
prevent engine from starting.
WARNING
REMOVAL
1. Remove flywheel cover from engine.
1. Disconnect spark plug leads from spark plugs.
WARNING
2. Place flywheel key into slot in crankshaft.
Engine could possibly start when turning flywheel

during removal and installation; therefore,
disconnect (and isolate) spark plug leads from
spark plugs to prevent engine from starting.
2. Disconnect spark plug leads from spark plugs.

3. While holding flywheel with Flywheel Holder
(91-52344), remove flywheel nut and washer.
51123
a - Flywheel Key
a
51123
a - Flywheel Holder (91-52344)
3. Align slot in flywheel center bore with flywheel key

and install flywheel onto crankshaft.
4. Install washer and locknut.
4. Install Crankshaft Protector Cap (91-24161) on

the end of crankshaft, then install Flywheel Puller
(91-73687A1) into flywheel.
5. Hold flywheel with Flywheel Holder (91-52344);

torque locknut to 120 lb. ft. (162.7 Nm).
5. Remove flywheel.
NOTE: Neither heat or hammer should be used on flywheel to aid in removal as damage to flywheel or electrical components under flywheel may result.
b
a
51123
a - Flywheel Holder (91-52344)
6. Install flywheel cover.

51124
a - Flywheel Puller
b - Flywheel
2A-6
90-13645--2 1095
Stator
INSTALLATION
REMOVAL
1. Install stator as shown.
1. Remove flywheel; refer to Flywheel Removal.

2. Remove screws.
51123
a - Screws
3. Remove starter motor as outlined in Section 2B.

4. Remove sta-strap.
a - Screws; apply Loctite Grade A on threads (unless Patch

Screw used) and torque to 60 lbs. in. (6.6 Nm)
b - Stator
2. Connect stator leads; refer to wiring diagrams in

Section 2D.
3. Install sta-strap.
5. Disconnect stator leads from switch box and remove stator.
4. Install starter motor; refer to Section 2B.
19453
19453
a - Sta-Strap
51124
a - Sta-Strap
5. Install flywheel; refer to Flywheel Installation,

preceding.
90-13645--2 1095
2A-7
Trigger
INSTALLATION
REMOVAL
1. Install trigger and connect link arm.
1. Remove flywheel and stator; refer to Flywheel

and Stator removal, preceding.
2. Disconnect link arm and remove trigger.
b
b
a
19459
a - Trigger
b - Link Arm
19459
a - Link Arm
b - Trigger
2. Connect trigger leads to switch box; refer to wiring

diagrams in Section 2D.
3. Install sta-strap.
3. Remove starter motor; refer to Section 2B.
4. Install starter motor; refer to Section 2B.
4. Remove sta-strap.
5. Disconnect trigger leads from switch box and remove trigger.
a
19453
a - Sta-strap
19453
a - Sta-strap
5. Install stator; refer to Stator Installation,

preceding.
6. Install flywheel; refer to Flywheel Installation,
preceding.
2A-8
90-13645--2 1095
Ignition Coils (3 Cylinder Models)
Ignition Coils (4 Cylinder Models)
1. Refer to wiring diagrams in Section 2D when connecting wires.
a
b
e
d
b
a - Coils
b - Cover
c - Hex Nuts; Torque to 30 lb. in. (3.4 Nm),coat with Quicksilver
Liquid Neoprene
d - Bolts; torque to 20 lb. in. (2.3 Nm)
e - Coil Tower Boots; form a water tight seal between coil tower
and spark plug lead using Quicksilver Insulating Compound
90-13645--2 1095
19455
25931
a - Coils
b - Cover
c - Hex Nuts; Torque to 30 lb. in. (3.4 Nm), coat with Quicksilver
Liquid Neoprene
d - Bolts; torque to 20 lb. in. (2.3 Nm)
e - Coil Tower Boots; form a water tight seal between coil tower
and spark plug lead using Quicksilver Insulating Compound
2A-9
Switch Box
b
d
c d
a
b
c
d
e
f
19454
Switch Box
Bushings
J-Clip
Bolt [Torque to 40 lb. in. (4.5 Nm)]
Screw (Secure coil ground wires under screw)
Coil Ground Wires (BLACK)
2A-10
90-13645--2 1095
ELECTRICAL AND
IGNITION
2
B
11669
BATTERY, CHARGING SYSTEM, AND

STARTING SYSTEM
Table of Contents
Page
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Battery . . . . . . . . . . . . . . . .
Operating Engine without Battery . . . . . . .
Specific Gravity Readings . . . . . . . . . . . . . .
Specific Gravity Cell
Comparison Test . . . . . . . . . . . . . . .
Electrolyte Level . . . . . . . . . . . . . . . . . . . . . .
Charging a Discharged Battery . . . . . . . . .
Winter Storage of Batteries . . . . . . . . . . . . .
Optional Voltage
Regulator Test . . . . . . . . . . . . . . . . . . . . . . . .
Battery Charging System
(9 Ampere Alternator) . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . .
Models Equipped with Rectifier . . . . . .
Models Equipped with Regulator . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . .
Stator Ohms Test
(Alternator Coils Only) . . . . . . . . . . . . . .
Standard Stator (Alternator Coils)
9 Amperes Output . . . . . . . . . . . . . . . . .
16 Amp Alternator System Test . . . . . . . . .
(Large Finned Voltage
Regulator/Rectifier) . . . . . . . . . . . . .
16 Ampere Alternator System Test . . . . . .
(Small Voltage Regulator/Rectifier) . . .
Optional 24 Amp Alternator System Test .
(Large Finned Voltage
Regulator/Rectifier) . . . . . . . . . . . . .
Tachometer Terminal Block (Design 1) . . .
Description . . . . . . . . . . . . . . . . . . . . . . .
Testing Tachometer Terminal Block
(Design 1) . . . . . . . . . . . . . . . . . . . . .
Tachometer Terminal Block (Design 2) . . .
Description . . . . . . . . . . . . . . . . . . . . . . .
Tachometer Terminal Block
(Design 1 and 2) . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . .
2B-1
2B-1
2B-1
2B-1
2B-2
2B-2
2B-2
2B-3
2B-3
2B-4
2B-4
2B-4
2B-4
2B-4
2B-5
2B-5
2B-6
2B-6
2B-6
2B-7
2B-7
2B-7
2B-7
2B-8
2B-8
2B-8
2B-8
2B-8
2B-8
2B-8
2B-8
Page
3 Cylinder 16 and 24 Ampere Battery

Charging Wiring Diagram . . . . . . . . . . .
3 Cylinder 16 Ampere Battery Charging
Wiring Diagram (with Small Voltage
Regulator/Rectifier) . . . . . . . . . . . . . . . .
Charging Wiring Diagram . . . . . . . . . . .
4 Cylinder 16 Ampere Battery Charging
Wiring Diagram (with Small Voltage
Regulator/Rectifier) . . . . . . . . . . . . . . . .
3 Cylinder Battery Charging Diagram
with Battery Isolator . . . . . . . . . . . . . . . .
with Battery Isolator (Small Voltage
Regulator) . . . . . . . . . . . . . . . . . . . . . . . .
with Battery Isolator . . . . . . . . . . . . . . . .
Regulator) . . . . . . . . . . . . . . . . . . . . . . . .
Rectifier Test . . . . . . . . . . . . . . . . . . . . . . . . .
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting System Components . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting the Starting Circuit . . . . .
Starting Circuit Troubleshooting
Flow Chart . . . . . . . . . . . . . . . . . . . . . . . .
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . .
Starter Cleaning, Inspection and Testing .
Cleaning and Inspection . . . . . . . . . . . .
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Armature Test for Shorts . . . . . . . . . . . .
Armature Test for Ground . . . . . . . . . . .
Checking Positive Brushes and
Terminal . . . . . . . . . . . . . . . . . . . . . . .
Testing Negative Brushes for
Ground . . . . . . . . . . . . . . . . . . . . . . .
Starter Solenoid Test . . . . . . . . . . . . . . .
Brush Replacement . . . . . . . . . . . . . . . . . . .
Starter Reassembly . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
2B-9
2B-10
2B-11
2B-12
2B-13
2B-14
2B-15
2B-16
2B-17
2B-18
2B-18
2B-18
2B-18
2B-19
2B-21
2B-21
2B-21
2B-22
2B-22
2B-22
2B-22
2B-22
2B-23
2B-23
2B-23
2B-24
2B-24
2B-26
90-13645--2 495
Battery
Recommended Battery
Precautions
The 2-cycle Outboard type engine requires a 12 volt

battery with a Cold Cranking Amperage rating for
cranking and a Reserve Capacity rating. The minimum should be a Cold Cranking Amperage of 350
amperes and a Reserve Capacity of 100 minutes for
engines outlined in this manual.
When charging batteries, an explosive gas mixture

forms in each cell. A portion of this gas escapes thru
holes in vent plugs and may form an explosive atmosphere around battery if ventilation is poor. This explosive gas may remain in or around battery for several hours after it has been charged. Sparks or flames
can ignite this gas and cause an internal explosion
which may shatter the battery.
The following precautions should be observed to prevent an explosion.
Operating Engine Without Battery

If desired (or in an emergency), engines equipped
with an alternator can be started and operated without a battery (either disconnected or removed) if
Warning, below, is followed.
1. DO NOT smoke near batteries being charged or

which have been charged very recently.
2. DO NOT break live circuits at terminals of batteries because a spark usually occurs at the point
where a live circuit is broken. Always be careful
when connecting or disconnecting cable clamps
on chargers. Poor connections are a common
cause of electrical arcs which cause explosions.
3. DO NOT reverse polarity of battery cables on battery terminals.
90-13645--2 495
2B-1
Specific Gravity Readings

Use a hydrometer to measure specific gravity of electrolyte in each cell.
5. Avoid dropping electrolyte on boat or clothing, as

it is extremely corrosive. Wash off immediately
with baking soda solution.
Specific gravity of electrolyte varies not only with percentage of acid in liquid but also with temperature. As
temperature drops, electrolyte contracts, so that specific gravity increases. Unless these variations in specific gravity are taken into account, specific gravity obtained by hydrometer may not give a true indication
of concentration of acid in electrolyte.
A fully charged battery will have a specific gravity
reading of approximately 1.270 at an electrolyte
temperature of 80 F (27 C). If electrolyte temperature is above or below 80 F, additions or subtractions
must be made in order to obtain a hydrometer reading
corrected to 80 F standard. For every 10 F (3.3 C)
above 80 F, add 4 specific gravity points (.004) to
hydrometer reading. Example: A hydrometer reading
of 1.260 at 110 F (43 C) would be 1.272 corrected
to 80 F, indicating a fully charged battery.
For every 10 below 80 F, subtract 4 points (.004)
from the reading. Example: A hydrometer reading of
1.272 at 0 F (18 C) would be 1.240 corrected to
80 F, indicating a partially charged battery.
22532
a - Hydrometer
Hydrometer measures percentage of sulphuric acid

in battery electrolyte in terms of specific gravity. As a
battery drops from a charged to a discharged condition, acid leaves the solution and chemically combines with the plates, causing a decrease in specific
gravity of electrolyte. An indication of concentration of
electrolyte is obtained with a hydrometer.
When using a hydrometer, observe the following
points:
1. Hydrometer must be clean (inside and out) to insure an accurate reading.
2. Never take hydrometer readings immediately after water has been added. Water must be thoroughly mixed with electrolyte by charging for at
least 15 minutes at a rate high enough to cause
vigorous gassing.
SPECIFIC GRAVITY CELL COMPARISON TEST

This test may be used when an instrumental tester is
not available. To perform this test, measure specific
gravity of each cell, regardless of state of charge, and
interpret results as follows: If specific gravity readings
show a difference between highest and lowest cell of
.050 (50 points) or more, battery is defective and
should be replaced.
Electrolyte Level
Check electrolyte level in battery regularly. A battery
in use in hot weather should be checked more frequently because of more rapid loss of water. If electrolyte level is found to be low, then distilled water should
be added to each cell until liquid level rises approximately 3/16 (4.8mm) over plate. DO NOT OVERFILL, because this will cause loss of electrolyte and
result in poor performance, short life and excessive
corrosion.
3. If hydrometer has built-in thermometer, draw liquid in several times to ensure correct temperature
before taking reading.
4. Hold hydrometer vertically and draw in just
enough liquid from battery cell so that float is freefloating. Hold hydrometer at eye level so that float
is vertical and free of outer tube, then take reading
at surface of liquid. Disregard curvature where liquid rises against float stem due to capillary action.
2B-2
90-13645--2 495
Charging a Discharged Battery

The following basic rules apply to any battery charging situation:
1. Any battery may be charged at any rate (in amperes) as long as spilling of electrolyte (from violent gassing) does not occur and as long as electrolyte temperature does not exceed 125 F
(52 C). If spewing of electrolyte occurs, or if electrolyte temperature exceeds 125 F, charging rate
(in amperes) must be reduced or temporarily
halted to avoid damage to the battery.
2. Battery is fully charged when, over a 2-hour period at a low charging rate (in amperes), all cells are
gassing freely (not spewing liquid electrolyte),
and no change in specific gravity occurs. Full
charge specific gravity is 1.260-1.275, corrected
for electrolyte temperature with electrolyte level at
3/16 (4.8mm) over plate. For most satisfactory
charging, lower charging rates in amperes are
recommended.
3. If, after prolonged charging, specific gravity of at
least 1.230 on all cells cannot be reached, battery
is not in optimum condition and will not provide optimum performance; however, it may continue to
provide additional service, if it has performed satisfactorily in the past.
4. To check battery voltage while cranking engine
with electric starter motor, place red (+) lead of
tester on positive (+) battery terminal and black ()
lead of tester on negative () battery terminal. If
the voltage drops below 9-1/2 volts while cranking, the battery is weak and should be recharged
or replaced.
1. Remove battery from its installation as soon as

possible and remove all grease, sulfate and dirt
from top surface by running water over top of battery. Be sure, however, that vent caps are tight beforehand, and blow off all excess water thoroughly with compressed air. Check water level, making
sure that plates are covered.
2. When adding distilled water to battery, be extremely careful not to fill more than 3/16 (4.8mm)
over plate inside battery. Battery solution or electrolyte expands from heat caused by charging.
Overfilling battery will cause electrolyte to overflow (if filled beyond 3/16 over plate).
3. Grease terminal bolts well with Quicksilver 2-4-C
w/teflon, and store battery in COOL-DRY place.
Remove battery from storage every 30-45 days,
check water level (add water if necessary), and
put on charge for 5 or 6 hours at 6 amperes. DO
NOT FAST CHARGE.
4. If specific gravity drops below 1.240, check battery for reason, and then recharge. When gravity
reaches 1.260, discontinue charging. To check
specific gravity, use a hydrometer, which can be
purchased locally.
5. Repeat preceding charging procedure every
30-45 days, as long as battery is in storage. When
ready to place battery back in service, remove excess grease from terminals (a small amount is desirable on terminals at all times), recharge again
as necessary and reinstall battery.
Winter Storage of Batteries

Battery companies are not responsible for battery
damage, either in winter storage or in dealer stock, if
the following instructions are not observed:
90-13645--2 495
2B-3
Optional Voltage
Regulator Test

(9 Ampere Alternator)
1. Check battery voltage at

battery with engine running.
Description
2. If battery voltage is above 14.5 volts, replace voltage regulator. Check condition of battery as overcharging may have damaged battery.
3. If battery voltage is below 14.5 volts, charge battery; refer to Charging a Discharged Battery,
preceding. If battery can NOT be satisfactorily
charged, replace battery.
The battery charging system components are the stator, rectifier, and battery. Alternating current (generated in stator alternator coils) flows to the rectifier,
which changes the alternating current to direct current for charging the battery.
MODELS EQUIPPED WITH RECTIFIER
4. If battery accepts a satisfactory charge, check

battery voltage while cranking engine; refer to
Charging a Discharged Battery, preceding. If
cranking voltage is not acceptable, replace battery.
5. If cranking voltage is acceptable, disconnect end

of RED wire (located between rectifier (+) terminal
and starter solenoid) from rectifier. Secure RED
wire (from voltage regulator) to rectifier (+) terminal with hex nut.
6. Connect RED (+) ammeter lead to (+) terminal of
rectifier and BLACK () ammeter lead to RED wire
(disconnected in last step).
IMPORTANT: For accurate test results the voltage
at battery with engine running, in next step, must
be 13.5 volts or less. It may be necessary to operate electrical accessories to drop voltage to 13.5
volts or less.
c
a - Stator
b - Rectifier
c - Battery
MODELS EQUIPPED WITH REGULATOR
7. Run engine at 3000 RPM.
8. Meter should read between 7 - 9 amperes.

9. If meter reads 7 - 9 amperes, this indicates the
charging system is functioning properly and the
battery is being discharged because the amperage draw on the system is greater than the amperage output of the system.
NOTE: With engine running at the following RPMS,

the ammeter should indicate the following approximate amperes:
RPM
IDLE
1000
2000
3000
AMPERES
1
4
8
9
a - Stator
b - Regulator
c - Battery
10. If the meter reads less than 7 amperes, test the

stator; refer to Standard Stator (Alternator Coils)
Amperes Output, following. If stator tests OK, replace voltage regulator.
2B-4
The charging system may be damaged by: 1) reversed battery cables, 2) running the engine with battery cables disconnected and stator leads connected
to rectifier, and 3) an open circuit, such as a broken
wire or loose connection.
90-13645--2 495
2. Use an ohmmeter and perform the following test.

Troubleshooting
A fault in the battery charging system usually will
cause the battery to become undercharged. Check
battery electrolyte level, and charge battery. See
Electrolyte Level, and Charging a Discharged
Battery.
IMPORTANT: If stator is mounted on engine, black

stator lead (if provided) must be grounded to powerhead when testing.
3. Replace stator if readings are outside ranges
shown.
Resistance
(Ohms)
Scale
Reading
)
(x
.6 1.1*
.6 1.1*
(R x 1)
No
Continuity
No
Continuity
(R x 1000)
.17 .19
.17 .19
(R x 1)
No
Continuity
No
Continuity
(R x 1000)
Between YELLOW
stator leads
.05 .15
.05 .15
(R x 1)
Between either
YELLOW stator lead
and engine ground**
No
Continuity
No
Continuity
(R x 1000)
If battery will NOT accept a satisfactory charge, replace battery.
Test Leads
If battery accepts a satisfactory charge, determine

the cause of the charging system problem as follows.
9 AMPERE STATOR
1. Check for correct battery polarity [RED cable to

positive (+) battery terminal]. If polarity was incorrect, check for damaged rectifier. See Rectifier
Test, following.
2. Check for loose or corroded battery connections.
3. Visually inspect wiring between stator and battery
for cuts, chafing; and disconnected, loose or corroded connection.
4. Excessive electrical load (from too many accessories) will cause battery to run down.
If visual inspection determines that battery connections and wiring are OK, perform the following stator
and rectifier tests.
Stator Ohms Test

(Alternator Coils Only)
NOTE: Stator can be tested without removing from
engine.
1. Disconnect both YELLOW (stator leads) from terminals on rectifier (or terminal block).
Between YELLOW
stator leads
Between either
YELLOW stator lead
and engine ground**
16 AMPERE STATOR
Between YELLOW
stator leads
Between either
YELLOW stator lead
and engine ground**
24 AMPERE STATOR
* DC resistance of these windings generally is less

than 1.5 ohms. If a reading (resembling a short) is
obtained, this would be acceptable.
** If stator is removed from engine, connect test lead
to black stator lead, if provided.
4. If meter readings are other than specified, replace
stator.
90-13645--2 495
2B-5
Standard Stator (Alternator Coils)

9 Amperes Output
IMPORTANT: Rectifier must be functioning properly for accurate test results to be obtained.
1. If engine is equipped with a voltage regulator,
disconnect voltage regulator leads at rectifier;
reinstall hex nut on rectifier terminal that has
yellow stator lead.
2. Remove red wire from (+) terminal of rectifier.
3. Connect RED (+) ammeter lead to rectifier (+) terminal and BLACK () ammeter lead to red rectifier
wire.
5. Meter should read 7 - 9 amperes; if not, replace
stator.
9. With engine running at the indicated RPMs, the

ammeter should indicate the following approximate amperes:
AMPERES
RPM
IDLE
2
1000
10
2000
17
3000
18
10. If ammeter indicates approximately 18 amperes
at 3000 RPM, this indicates the charging system
is functioning properly and the battery is being
discharged because the amperage draw on the
system is greater than the amperage output of the
system.
11. If ammeter reads less than 18 amperes, test the
stator; refer to Stator Ohms Test (Alternator Coils
Only) [18 Ampere Stator], preceding. If stator
tests OK, replace voltage regulator/rectifier.
16 Amp Alternator System Test
(LARGE FINNED VOLTAGE

REGULATOR/RECTIFIER)
1. Check battery voltage at battery with engine
running.
2. If battery voltage is above 14.5 volts, replace voltage regulator/rectifier. Check condition of battery
as overcharging may have damaged battery.
b
d
a - Voltage Regulator/Rectifier
b - RED Harness Wire
21619
c - Center Terminal
d - RED Sense Lead
NOTE: If one or more of the 3 terminals on the terminal block are shorted to ground, the battery charging
system output will be reduced.
5. If cranking voltage is acceptable, disconnect RED

harness wire from center terminal.
6. Secure RED wire (d) on terminal (c) using hex nut.
7. Connect RED (+) ammeter lead to terminal (c)
and BLACK () ammeter lead to RED harness
wire (b).
8. Secure wires away from flywheel.
volts or less.
26001
a - Terminal Block
2B-6
90-13645--2 495
16 Ampere Alternator System Test
Optional 24 Amp Alternator System Test
(SMALL VOLTAGE REGULATOR/RECTIFIER)
(LARGE FINNED VOLTAGE

REGULATOR/RECTIFIER)
1. Check battery voltage at battery with engine running.

2. If battery voltage is above 14.5 volts, replace voltage regulator/rectifier. Check condition of battery
as overcharging may damage battery.
5. If cranking voltage is acceptable, disconnect larger diameter Red wire from STARTER SOLENOID
terminal.
6. Remove smaller diameter RED wire (SENSE
LEAD) from STARTER SOLENOID terminal and
connect to the POSITIVE (+) terminal of a 9 VOLT
transistor battery. Ground the NEGATIVE () terminal of the 9 VOLT battery to the engine.
7. Connect RED (+) ammeter lead to larger diameter
RED wire, and BLACK () ammeter lead to POSITIVE terminal on STARTER SOLENOID.
9. With engine running at the indicated RPMs, the
ammeter should indicate the following approximate amperes:
RPM
IDLE
1000
2000
3000
AMPERES
2
10
17
18
10. A reading of 18 amperes at 3000 RPM indicates

the charging system is functioning properly. The
battery is discharging due to the amperage draw
on the system is greater than the amperage output of the engine charging system.
11. If ammeter reads less than 18 amperes, test the
stator; refer to Stator Ohms Test (Alternator Coils
Only), [18 Ampere Stator], preceding. If stator
tests OK, replace voltage regulator/rectifier.
1. Check battery voltage at battery with engine

running.
2. If battery voltage is above 14.5 volts, replace voltage regulator/rectifier (a). Check condition of battery as overcharging may have damaged battery.
5. If cranking voltage is acceptable, disconnect RED
harness wire (b) from terminal (c).
6. Secure RED wire (d) on terminal (c) using hex nut.
7. Connect RED (+) ammeter lead to terminal (c)
and BLACK () ammeter lead to RED harness
wire (b).
volts or less.
10. Meter should read 20 or more amperes.
11. If meter reads 20 or more amperes, this indicates
the charging system is functioning properly and
the battery is being discharged because the amperage draw on the system is greater than the amperage output of the system.
12. If meter reads less than 20 amperes, test the stator; refer to Optional 24 Amp Stator (Alternator
Coils) Amperes Output, following. If stator tests
OK, replace voltage regulator rectifier (a).
d
90-13645--2 495
21619
2B-7
Tachometer Terminal Block (Design 1)

DESCRIPTION
ALT YEL
Contains a diode which blocks high voltage AC

pulses (180 VAC) coming from the stator and allows
low voltage DC pulses (20-30 VDC) to pass through
to be counted by the tachometer. This terminal block
(with diode) is only used with large, finned type regulators. This block is BLACK in color.
GREY
TACH
ALT YEL
WARNING
HIGH VOLTAGE is present at the tachometer
blocks stator side terminals, while the outboard
is running. To avoid electrical shock, physical
contact should not be made on these terminals or
ANY IGNITION RELATED COMPONENT WHILE
THE OUTBOARD IS RUNNING.
IMPORTANT: The following ohm test is used to determine the proper functioning of the diode located in the tachometer block. If the diode is
OPEN (NO CONTINUITY IN EITHER DIRECTION),
the tachometer will be inoperative.
TESTING TACHOMETER TERMINAL BLOCK
(DESIGN 1)
With outboard NOT running, remove all leads from
block. Using an ohmmeter, test block as shown, following. Continuity should be observed on the ohmmeter with the needle swinging in only ONE direction.
NO CONTINUITY should be observed when test
leads are reversed. If CONTINUITY is observed in
BOTH directions or NO CONTINUITY is observed in
either direction when leads are reversed, diode is defective and MUST BE REPLACED.
NOTE: There is only one diode located in the tachometer block. It may be located either between the center (TACH) terminal and the top (ALT) terminal or between the center (TACH) terminal and the lower (ALT)
terminal.
50644
Tachometer Terminal Block (Design 2)

DESCRIPTION
This block is a junction point for stator and tachometer
signal wiring. It contains no electrical components.
This block is LIGHT GREY in color and is to be used
ONLY with small, non-finned voltage regulators. No
test is required for this terminal block.
Tachometer Terminal Block

(Design 1 and 2)
REMOVAL
1. Remove two YELLOW alternator wires from
block.
2. Remove GREY tachometer wire from block.
3. Remove two attaching screws and remove diode
block.
INSTALLATION
1. Secure diode block to powerhead with two
screws. Torque screws to 30 lb. in. (3.4 Nm).
2. Attach two YELLOW wires to ALT YEL
terminals.
3. Attach GREY wire to GREY TACH terminal.
ALT YEL
GREY
TACH
ALT YEL
50644
2B-8
90-13645--2 495

Charging Wiring Diagram
IMPORTANT: After electrical connections are
made, coat all terminal connections using Quicksilver Liquid Neoprene (92-25711), to avoid corrosion.
a
BLK
BLU
GRY
RED
YEL
BLACK
BLUE
GRAY
RED
YELLOW
g
c
f
d
e
50405
a
b
c
d
Stator
Terminal Block
ToTachometer
Voltage Regulator/Rectifier
90-13645--2 495
e
f
g
h
To Remote Control Harness

20 Ampere Fuse
To Battery
Starter Solenoid
2B-9
3 Cylinder 16 Ampere Battery

Charging Wiring Diagram (with Small
Voltage Regulator/Rectifier)
BLK
BLK
YEL
BLACK
BLUE
GRAY
RED
YELLOW
YEL
GRY
YEL
YEL
BLK
RED
RED
RED
RED
GRY
BLK
BLU
GRY
RED
YEL
d
e
GRY
YEL
YEL
RED
RED
51000
a
b
c
d
Stator
Terminal Block
ToTachometer
Votage Regulator/Rectifier
2B-10
e
f
g
h

20 Ampere Fuse
Battery (+) Positive Terminal
Starter Solenoid
90-13645--2 495

Charging Wiring Diagram
a
BLK
BLU
GRY
RED
YEL
BLACK
BLUE
GRAY
RED
YELLOW
g
c
f
d
e
50406
a
b
c
d
Stator
Terminal Block
ToTachometer
90-13645--2 495
e
f
g
h

20 Ampere Fuse
Starter Solenoid
2B-11
4 Cylinder 16 Ampere Battery

Charging Wiring Diagram (with Small
Voltage Regulator/Rectifier)
a
BLK
BLU
GRY
RED
YEL
BLACK
BLUE
GRAY
RED
YELLOW
YEL
YEL
YEL
GRY
YEL
RED
GRY
RED
RED
RED
d
e
GRY
YEL
YEL
RED
RED
51001
a
b
c
d
Stator
Terminal Block
ToTachometer
2B-12
e
f
g
h

20 Ampere Fuse
Starter Solenoid
90-13645--2 495

with Battery Isolator
a
BLK
BLU
GRY
RED
YEL
BLACK
BLUE
GRAY
RED
YELLOW
c
i
Move Red Lead From

Start Solenoid to
Position Shown
g
Start
Battery
User Supplied Red Lead

(10 Gauge Minimum Diameter
with Protective Abrasive Sleeve
Installed)
Move Lead From Red

Stud to Position Shown
Screw Size
#10-16x3/8
P/N 10-62568
50403
a
b
c
d
e
Stator
Terminal Block
To Tachometer
Battery Isolator
90-13645--2 495
f
g
h
i
j
Auxiliary Battery
Start Battery
20 Ampere Fuse
Starter Solenoid
2B-13

Regulator)
BLACK
BLUE
GRAY
RED
YELLOW
j
YEL
BLK
BLK
YEL
BLK
BLU
GRY
RED
YEL
b
GRY
RED
GRY
YEL
Small
Red
(Sense)Lead
YEL
BLK
RED
RED
RED
h
d
B1
A
RED
B2
Large Red
(Output) Lead
GRY
YEL
YEL
RED
RED
51051
a
b
c
d
e
Stator
Terminal Block
To Tachometer
Battery Isolator
2B-14
f
g
h
i
j
Auxiliary Battery
Start Battery
20 Ampere Fuse
Starter Solenoid
90-13645--2 495

with Battery Isolator
a
BLK
BLU
GRY
RED
YEL
BLACK
BLUE
GRAY
RED
YELLOW
Move Red Lead From

Start Solenoid to
Position Shown
g
e
User Supplied Red Lead
(10 Gauge Minimum Diameter
with Protective Abrasive Sleeve
Installed)
Move Lead From Red

Stud to Position Shown
Screw Size
#10-16x3/8
P/N 10-62568
50404
a
b
c
d
e
Stator
Terminal Block
To Tachometer
Battery Isolator
90-13645--2 495
f
g
h
i
j
Auxiliary Battery
Start Battery
20 Ampere Fuse
Starter Solenoid
2B-15

Regulator)
a
BLK
BLU
GRY
RED
YEL
BLACK
BLUE
GRAY
RED
YELLOW
YEL
YEL
b
RED
RED
YEL
GRY
Small
Red (Sense)
Lead
YEL
RED
RED
GRY
B1
RED
A
B2
Large Red
(Output) Lead
GRY
YEL
YEL
RED
RED
f
51050
a
b
c
d
e
Stator
Terminal Block
To Tachometer
Battery Isolator
2B-16
f
g
h
i
j
Auxiliary Battery
Start Battery
20 Ampere Fuse
Starter Solenoid
90-13645--2 495
Rectifier Test
WARNING
b
Disconnect battery leads from battery before

testing rectifier.
NOTE: Rectifier can be tested without removing from

engine.
1. Disconnect all wires from terminals on rectifier.

2. Use an ohmmeter (R x 1000 scale) and perform
the following test. Refer to illustration for rectifier
terminal identification.
07300
d - Stator Terminals
e - Positive Terminal
f - Ground
a - Terminal
b - Terminal
c - Terminal
Rectifier Test
Connect RED meter lead to ground,
BLACK lead alternately to terminals a
and c.
Continuity Indicated.
Connect BLACK meter lead to ground,
RED lead alternately to terminals a
and c.
No Continuity Indicated.
Connect BLACK meter lead to ground,
RED lead alternately to terminals a
and c.
Connect BLACK meter lead to terminal b,
RED lead alternately to terminals a and
c.
Replace Rectifier.
Replace Rectifier.
Connect RED meter lead to terminal b,
BLACK lead alternately to terminals a and
c.
Replace Rectifier.
Replace Rectifier.
Rectifier tests OK.
90-13645--2 495
Connect BLACK meter lead to terminal b,
RED lead alternately to terminals a and
c.
Replace Rectifier.
Connect RED meter lead to terminal b,
BLACK lead alternately to terminals a and
c.
Replace Rectifier.
Rectifier tests OK.
2B-17
Starting System
CAUTION
Starting System Components

The starting system consists of the following components:
1. Battery
The starter motor may be damaged if operated

continuously. DO NOT operate continuously for
more than 30 seconds. Allow a 2 minute cooling
period between starting attempts.
Troubleshooting the Starting Circuit
2. Starter Solenoid
4. Starter Motor
Before beginning the starting circuit troubleshooting

flow chart, following, check first for the following
conditions:
5. Ignition Switch
1. Make sure that battery is fully charged.
Description
2. Check that control lever is in neutral position.
The function of the starting system is to crank the engine. The battery supplies electrical energy to crank
the starter motor. When the ignition switch is turned
to Start position, the starter solenoid is activated
and completes the starting circuit between the battery
and starter.
3. Check terminals for corrosion and loose connections.
3. Neutral Start Switch
4. Check cables and wiring for frayed and worn insulation.

5. Check in-line fuse in red wire; see diagram.
The neutral start switch opens the start circuit when

the shift control lever is not in neutral. This prevents
accidental starting when engine is in gear.
2B-18
90-13645--2 495
Battery
Starter Solenoid
Starter
Starter Solenoid
Fuse Holder
(If Equipped)
(20 Amp Fuse)
Neutral Start Switch

(Located in Control Housing)
Ignition Switch
Starter Circuit
Starting Circuit Troubleshooting Flow Chart

Starter Motor Does Not Turn
SAFETY WARNING: Disconnect BLACK (starter motor)
cable from starter solenoid test point 1 BEFORE making
tests 1-thru-7 to prevent unexpected engine cranking.
TEST 1
Use an ohmmeter (R x 1 scale) and connect meter leads between
NEGATIVE () battery post and common powerhead ground.
No continuity indicated; there is an open circuit in the
BLACK negative () battery cable between the negative () battery post and the powerhead.
Continuity Indicated
Proceed to TEST 2, on next page
Check cable for loose or corroded connections.

Check cable for open.
90-13645--2 495
2B-19
No voltage reading;
proceed to TEST 3.
TEST 2
a - Disconnect BLACK ground wire(s) from Test Point 2.
b - Connect voltmeter between common engine ground and Test Point 2.
c - Turn ignition key to Start position.
TEST 3
a - Reconnect BLACK ground wire(s).
No voltage reading;
proceed to TEST 4.
12 Volt Reading*
Check BLACK ground wire for
poor connection or open circuit.
Reconnect ground wire to starter solenoid; proceed to TEST 7.
12 Volt Reading
Defective starter solenoid.
No voltage reading;
proceed to TEST 5.
TEST 4
a - Connect voltmeter between common
engine ground and Test Point 4.
b - Turn ignition key to Start position.
12 Volt Reading*
Neutral start switch is open,
or YELLOW/RED wire is
open between Test Points 4
and 3.
No voltage reading;
proceed to TEST 6.
TEST 5
Connect voltmeter between common
engine ground and Test Point 5.
12 Volt Reading*
Defective ignition switch.
TEST 6
Connect voltmeter between common engine ground and Test Point 6.
No voltage reading; check RED wire between battery (+) positive terminal and Test
Point 6.
12 Volt Reading*
Check fuse in RED wire between test points 5 and 6.
Check for open RED wire between test points 5 and
6.
TEST 7
a - Connect voltmeter between common engine ground and Test Point 1.
b - Turn ignition key to Start position.
No voltage reading;
Defective starter solenoid.
12 Volt Reading*
Should hear solenoid click; proceed to Test 8.
TEST 8
a - Reconnect BLACK (starter motor) cable to starter solenoid Test Point 1.
No voltage reading; check BLACK cable for
poor connection or open circuit.
*
2B-20
Battery Voltage
12 Volt Reading*
Check BLACK ground cable at starter for loose or corroded connection, or open circuit. If cable is OK, check
starter motor.
90-13645--2 495
Starter Motor
Disassembly
Removal
1. Remove 2 thru bolts and commutator end cap,

taking care not to lose brush springs.
CAUTION
Disconnect battery leads from battery before
removing starter.
1. Disconnect battery leads from battery.
2. Disconnect YELLOW cable.
b
11646
3. Remove 4 bolts and remove starter clamps.

4. Remove starter.
a - Thru Bolts
b - Commutator End Cap
5. Remove BLACK cable.
2. Pull armature from starter frame.

3. Remove locknut.
a b
c
11659
a - Hold Armature Shaft With Wrench on Hex Portion of Drive
Assembly
20412
a - YELLOW Cable
b - Bolts (4)
4. Remove components from armature.
c - Starter Clamps
d - BLACK Cable
a b
6. Remove 2 rubber collars and 2 rubber bumpers.
b
11645
a - Rubber Collar
90-13645--2 495
b - Spacer (If Equipped)
a
b
c
d
Locknut
Spacer
Spring
Drive Assembly
11658
e - Drive End Cap

f - Armature Shaft
g - Washer
2B-21
Starter Cleaning, Inspection and

Testing
11. Check the armature for ground. See the following

procedure (Testing).
CLEANING AND INSPECTION
Testing
1. Clean all starter motor parts.
ARMATURE TEST FOR SHORTS
2. Check pinion teeth for chips, cracks or excessive

wear.
Check armature for short circuits by placing on

growler and holding hack saw blade over armature
core while armature is rotated. If saw blade vibrates,
armature is shorted. Recheck after cleaning between
commutator bars. If saw blade still vibrates, replace
armature.
3. Replace the drive clutch spring and/or collar if tension is not adequate or if wear is excessive.
4. Inspect brush holder for damage or for failure to
hold brushes against commutator.
5. Replace brushes that are pitted or worn to less
than 1/4 (6.4mm) in length.
6. Inspect the armature conductor (commutator bar
junction) for a tight connection. A loose connection (excessive heat from prolonged cranking
melts solder joints) results in a burned commutator bar.
7. Resurface and undercut a rough commutator as
follows:
CAUTION
11669
Do not turn down the commutator excessively.

a. Resurface the commutator and undercut the insulation between the commutator bars 1/32
(0.8mm) to the full width of the insulation and so
that the undercut is flat.
ARMATURE TEST FOR GROUND
b. Clean the commutator slots after undercutting.
2. If meter indicates continuity,

grounded and must be replaced.
c. Sand the commutator lightly with No. 00 sandpaper to remove burrs, then clean the commutator.
1. Set ohmmeter to (R x 1 scale). Place one lead of

ohmmeter on armature core or shaft and other
lead on commutator.
armature
is
d. Recheck the armature on a growler for shorts

as specified in the following procedure (Testing).
8. Open-circuited armatures often can be repaired.
The most likely place for an open circuit is at the
commutator bars, as a result of long cranking periods. Long cranking periods overheat the starter
motor so that solder in the connections melts and
is thrown out. The resulting poor connections then
cause arcing and burning of the commutator bars.
9. Repair bars, that are not excessively burned, by
resoldering the leads in bars (using rosin flux solder) and turning down the commutator in a lathe
to remove burned material, then undercut the
mica.
11675
10. Clean out the copper or brush dust from slots between the commutator bars.
2B-22
90-13645--2 495
CHECKING POSITIVE BRUSHES AND

TERMINAL
STARTER SOLENOID TEST

1. Disconnect all wires from solenoid.
Set ohmmeter to (R x 1 scale). Connect meter leads

between POSITIVE brushes. Meter must indicate full
continuity or zero resistance. If resistance is indicated, inspect lead to brush and lead to POSITIVE
terminal solder connection. If connection cannot be
repaired, brushes must be replaced.
2. Use an ohmmeter (R x 1 scale) and connect meter

leads between solenoid terminals 1 and 2.
3. Connect a 12-volt power supply between solenoid terminals 3 and 4. Solenoid should click and
meter should read 0 ohms (full continuity).
4. If meter does not read 0 ohms (full continuity), replace solenoid.
11673
1. 3.
a - POSITIVE (+) Brushes
TESTING NEGATIVE BRUSHES FOR GROUND
Set ohmmeter to (R x 1 scale). Place one lead of the

ohmmeter on the NEGATIVE brush and the other
lead on the end cap (bare metal). If the meter indicates NO continuity, replace the NEGATIVE brush.
Repeat this procedure on the other NEGATIVE
brush.
4.
2.
51809
a - 12-Volt Supply
b - VOA Leads
b
a
11674
a - NEGATIVE () Brushes
b - End Cap
90-13645--2 495
2B-23
2. If removed, reinstall parts on armature shaft. Use

a new locknut and tighten securely on end of
shaft.
Brush Replacement
STARTER REASSEMBLY
1. If brushes were removed, replace as follows:
a. Install POSITIVE brushes (along with POSITIVE terminal) into commutator end cap.
a
b
i
h
a b
a
b
c
d
e
f
g
d
e
f
c
11660
a
b
c
d
e
End Cap
POSITIVE Brushes
POSITIVE Terminal
Insulating Bushing
Washer
f
g
h
i
11658
Locknut
Spacer
Spring
Drive Assembly
Drive End Cap
Armature Shaft
Washer
3. Lubricate helix threads on armature shaft with a

drop of SAE 10W oil.
4. Lubricate bushing in drive end plate with a drop of
SAE 10W oil.
Split Washer
Hex Nut
Long Brush Lead
Push Lead into Slot
b. Install NEGATIVE brushes (along with brush

holder).
a
b
11656
a
b
c
d
POSITIVE (+) Brushes

NEGATIVE () Brushes
Brush Holder
Bolts (Fasten NEGATIVE Brushes and Holder)
2B-24
90-13645--2 495
5. Position armature into starter frame.

6. To prevent damage to brushes and springs when
installing commutator end cap, it is recommended
that a brush retaining tool be made as shown:
7. Lubricate bushing (located in commutator end

cap) with one drop of SAE 10W oil. DO NOT over
lubricate.
8. Place springs and brushes into brush holder and
hold in place with brush retainer tool.
a
b
2
2
11661
90
Bend
1-11/16
a - Brush Retainer Tool

b - Bushing (DO NOT Over Lubricate)
9. Install armature into starter frame and align match

marks (a). Install commutator end cap onto starter
frame and align match marks (b). Remove brush
retainer tool. Install through bolts (c) and torque to
70 lb. in. (7.9 Nm).
1/2
3/4
1-3/4
Brush Retainer Tool Layout (Full Size)
b
18-Gauge Sheet Metal
Metric Scale
3
2
1-3/4
1-11/16
3/4
1/2
90-13645--2 495
= 76.2mm
= 50.8mm
= 44.5mm
= 42.9mm
= 19.1mm
= 12.7mm
11648
a - Alignment Marks
b - Alignment Marks
c - Bolts [Torque to 70 lb. in. (7.9 Nm)]
2B-25
Installation
2. Install components as shown.
1. Install 2 rubber collars and 2 rubber bumpers.
3. Connect battery leads to battery.
c b
e
b
11645
a - Rubber Collars
b - Rubber Bumpers
d
j
a
f
i
h
19452
a
b
c
d
e
f
g
h
i
j
k
l
2B-26
Starter
Rubber Mount, oil tank
Clamp, upper
BLACK Cable
Bolt and Lockwasher
Clamp, lower
J-Clip (If Equipped)
BLACK Negative (-) Battery Cable
Bolts [Torque to 14.5 lb. ft. (19.7 Nm)]
Fuse Holder (If Equipped)
YELLOW Cable [Torque to nut to 60 lb. in. (6.7 Nm)]
Fuse Holder (If Equipped)
90-13645--2 495
ELECTRICAL AND
IGNITION
2
22480
TIMING/SYNCHRONIZING/ADJUSTING
Table Of Contents
Page
Timing/Synchronizing/
Adjusting (3 Cylinder Models) . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Pointer Adjustment . . . . . . . . . . . . .
Carburetor Synchronization . . . . . . . . .
Carburetor/Oil Pump
Synchronization . . . . . . . . . . . . . . . .
Timing Adjustments . . . . . . . . . . . . . . . .
Idle Timing Adjustment . . . . . . . . . . . . .
Maximum Timing . . . . . . . . . . . . . . . . . .
Maximum Throttle . . . . . . . . . . . . . . . . .
Idle Adjustment . . . . . . . . . . . . . . . . . . . .
Throttle Cable Installation . . . . . . . . . . . . . .
2C-1
2C-1
2C-1
2C-1
2C-2
2C-3
2C-3
2C-3
2C-4
2C-4
2C-4
2C-5
Page
Adjusting (4 Cylinder Models) . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Pointer Alignment . . . . . . . . . . . . . .
Carburetor Synchronization . . . . . . . . .
Carburetor/Oil Pump
Synchronization . . . . . . . . . . . . . . . .
Timing Adjustments . . . . . . . . . . . . . . . .
Idle Timing Adjustment . . . . . . . . . . . . .
Maximum Timing . . . . . . . . . . . . . . . . . .
Carburetor Specifications . . . . . . . . . . . . . .
Initial Starting Adjustments . . . . . . . . . .
Low Speed Mixture Adjustments . . . . .
Idle Adjustment . . . . . . . . . . . . . . . . . . . . . . .
Throttle Cable Installation . . . . . . . . . . . . . .
2C-6
2C-6
2C-6
2C-6
2C-7
2C-8
2C-8
2C-8
2C-9
2C-10
2C-10
2C-10
2C-11
2C-11
90-13645--2 495
Adjusting (3 Cylinder Models)
Specifications
70, 75 and 80 Models
Serial Number and Above
U.S.
Belgium
Canada
B239242
9502135
A730007

Idle RPM (in FORWARD Gear)
Maximum Timing @ 5000 RPM
(@ Cranking Speed)
Idle Timing
Spark Plug
Firing Order
Mariner 75 Marathon/Merc 75XD

(@ Cranking Speed)
Idle Timing
Spark Plug
Firing Order
Special Tools
4750 - 5250
650 - 700
26 B.T.D.C.
(28 B.T.D.C.)
0 - 4 B.T.D.C.
NGK BUHW-2
1-3-2
Part No.
Description
*91-58222A1
Dial Indicator Gauge Kit
*91-59339
Service Tachometer
*91-99379
Timing Light
91-63998A1
Spark Gap Tool
* May be obtained locally.
Timing Pointer Adjustment
70, 75 and 80 Models

Serial Number and Below
U.S.
Belgium
Canada
4750 - 5250
650 - 700
16 B.T.D.C.
(18 B.T.D.C.)
0 - 4 B.T.D.C.
NGK BUHW-2
1-3-2
WARNING
Engine could start when turning flywheel to check
timing pointer alignment. Remove spark plugs
from engine to prevent engine from starting.
B239241
9502134
A730006

(@ Cranking Speed)
Idle Timing
Spark Plug
Firing Order
4750 - 5250
650 - 700
22 B.T.D.C.
(24 B.T.D.C.)
0 - 4 B.T.D.C.
NGK BUHW-2
1-3-2
1. Install Dial Indicator P/N 91-58222A1 into no. 1

(top) cylinder.
2. Turn flywheel clockwise until no. 1 (top) piston is
at top dead center (TDC). Set Dial Indicator to 0
(zero).
90 Models
(@ Cranking Speed)
Idle Timing
Spark Plug
Firing Order
5000 - 5500
650 - 700
26 B.T.D.C.
(28 B.T.D.C.)
0 - 4 B.T.D.C.
NGK BUHW-2
1-3-2
91-58222A1
19062
3. Turn flywheel counterclockwise until Dial Indicator needle reads approximately 0.550 (13.97mm)
BTDC, then turn flywheel clockwise so that
needle reads 0.491 in. (12.47 mm) BTDC exactly.
90-13645--2 1095
2C-1
4. Reposition timing pointer if necessary, so that timing pointer is aligned with 0.491 in. (12.47 mm)
timing mark on flywheel. Retighten attaching
screws.
c
a
b
20440
22480
a - Timing Pointer
b - Timing Mark
c - Attaching Screws
a - Set Screw
b - Synchronizing Screws
9. Hold throttle arm so that throttle stop screw is

against stop.
5. Remove Dial Indicator, and reinstall spark plug

and high tension spark plug lead of no. 1 (top)
cylinder only.
CARBURETOR SYNCHRONIZATION
10. Place roller of cam follower against throttle cam

and adjust throttle stop screw to align raised mark
of throttle cam with center of cam follower roller.
Tighten locknut.
1. Disconnect remote fuel line from engine.
2. Connect remote control electrical harness to

engine wiring harness.
3. Remove throttle cable barrel from barrel retainer.

4. Remove sound air box cover.
5. Loosen screw from throttle cam follower.
6. Loosen 4 synchronizing screws.

7. Look into throats of carburetors and make sure all
throttle shutters are completely closed. Tighten
synchronizing screws.
8. Recheck throttle shutters
necessary adjustments.
and
make
f
b
any
20428
a - Throttle Arm
b - Throttle Stop Screw
c - Roller
2C-2
d - Throttle Cam
e - Raised Mark
f - Lock Nut
90-13645--2 1095
11. Holding throttle arm against throttle stop screw,

adjust cam follower, so that a clearance of 0.005
in. - 0.020 in. (0.127 - 0.508 mm) exists between
roller of cam follower and throttle cam. Tighten set
screw securing cam follower.
0.005 0.020
TIMING ADJUSTMENTS
CAUTION
Engine is timed while cranking engine with starter
motor. To prevent engine from starting when
being cranked, all spark plugs must be removed,
except no. 1 (top) cylinder plug.
NOTE: If initial timing adjustments are made without

engine running, then final timing checks should be
made with engine running due to timing advance
characteristics of ignition system. Minimum engine
RPM required to check maximum timing advance is
3000 RPM.
a
c
IDLE TIMING ADJUSTMENT

1. Connect timing light to no. 1 (top) spark plug.
WARNING
52472
Before cranking engine, keep clear of propeller as

it may rotate.
a - Roller
b - Throttle Cam
c - Set Screw
2. Shift engine to Neutral.
CARBURETOR/OIL PUMP SYNCHRONIZATION

IMPORTANT: Some engines may have an additional stamped mark (d) which SHOULD NOT be
used.
1. While holding throttle arm at idle position, adjust
length of link rod so that stamped mark of oil pump
body aligns with stamped mark of oil pump lever.
IMPORTANT: To accurately time engine at cranking

speed, a fully charged battery must be used.
3. Holding throttle arm at idle position, crank engine

with starter motor and adjust idle timing screw to
align 2 BTDC timing mark of flywheel with timing
pointer. Tighten locknut.
2 BTDC
c
d
20442
22977
a - Link Rod
b - Mark of Oil Pump Body
90-13645--2 1095
c - Mark of Oil Pump Lever

d - Mark NOT Used
a - Idle Timing Screw

b - Locknut
2C-3
MAXIMUM TIMING
1. Hold control arm so that maximum spark advance
screw is against stop.
2. Install remaining spark plugs and high tension

spark plug leads.
2. Crank engine with starter motor and adjust maximum spark advance screw to align the specified
BTDC timing mark on flywheel with timing pointer
(due to the advance characteristic of this ignition
system, this cranking speed adjustment will automatically be reduced by 2 at an engine speed of
5000 RPM). Tighten locknut.
b c
a
20441
20443
a - Throttle Arm
b - Full Throttle Stop Screw
c - Locknut
IDLE ADJUSTMENT
a - Control Arm
b - Maximum Spark Advance Screw
c - Locknut

made with engine running due timing advance characteristics of ignition system. Minimum engine RPM
required to check maximum timing advance is 3000
RPM.
1. With engine in water, connect electrical harness

and fuel line to engine. Start engine and allow to
warm up.
MAXIMUM THROTTLE
1. Hold throttle arm against full throttle stop screw.
Adjust full throttle stop screw to allow throttle shutters to open fully, then turn stop screw in (clockwise) an additional 1/2 turn, to prevent throttle lever of center carburetor from acting as a stop.
Tighten locknut.
2C-4
90-13645--2 1095
2. Shift into Forward gear and adjust carburetor

low speed mixture screws properly (refer to Carburetor section).
Throttle Cable Installation

1. With end of throttle cable connected to throttle lever, hold throttle lever against idle stop. Adjust
throttle cable barrel to slip into barrel retainer on
cable anchor bracket with a very light preload of
throttle lever against idle stop. Lock barrel in
place.
IMPORTANT: Excessive preload on throttle cable
will cause difficulty when shifting from forward to
neutral. (Readjust throttle cable barrel, if necessary.)
2. Check preload on throttle cable by placing a thin
piece of paper between idle stop screw and idle
stop. Preload is correct when paper can be removed without tearing but has some drag on it.
(Readjust throttle cable barrel, if necessary.)
Lightly seated
1-1/2 turns out

3. Holding throttle arm (NO TAG) at idle position, adjust idle timing screw (NO TAG) to attain an engine idle RPM of 650-700 RPM in Forward gear.
Tighten locknut (NO TAG) and turn off engine.
2 BTDC
4
b
c
a
20442
a - Throttle Arm
b - Idle Timing Screw
c - Locknut
NOTE: On this type of engine, idle RPM is adjusted

exclusively with ignition timing.
90-13645--2 1095
2C-5
Adjusting (4 Cylinder Models)
Timing Pointer Alignment
Specifications
Engine could start when turning flywheel to check

timing pointer alignment. Remove all spark plugs
from engine to prevent engine from starting.
Models 100/115
(@ Cranking Speed)
Idle Timing
Spark Plug
4750 - 5250
650 - 700
23 B.T.D.C.
(25 B.T.D.C.)
2 - 4 B.T.D.C.
NGK
BP8H-N-10*
[0.040 in.
(1.0mm) gap]
WARNING
1. Remove aft cowl support bracket.

2. Install Dial Indicator 91-58222A1 into no. 1 (top)
cylinder.
3. Turn flywheel in a clockwise direction until no. 1
piston is a TDC, then set Dial Indicator at 0 (zero).
NGK
BPZ8H-N-10*
[0.040 in.
(1.0mm) gap]
NGK BUHW
1-3-2-4
Firing Order
*Improves running quality between 1800 2000 RPM
Special Tools
Part No.
Description
*91-58222A1
Dial Indicator Gauge Kit
*91-59339
Service Tachometer
*91-99379
Timing Light
* May be obtained locally.
91-58222A1
19062
4. Turn flywheel counterclockwise until Dial Indicator needle reads approximately 0.600 in. BTDC,
then turn flywheel clockwise, so that needle reads
0.554 in. BTDC exactly.
5. Reposition timing pointer, if necessary, so that
0.554 in. mark is aligned with groove in timing
pointer.
6. Remove Dial Indicator and reinstall spark plug
and spark plug lead on no. 1 cylinder.
a
22480
a - Timing Pointer
2C-6
90-13645--2 1095
CARBURETOR SYNCHRONIZATION
1. Remove sound box cover.
2. Loosen cam follower adjustment screw.

3. Loosen 6 synchronizing screws.
4. Look into throats of carburetors and make sure all
throttle shutters are completely closed.
a
c
5. Apply light down pressure on carburetor synchronizing shaft and tighten 6 synchronizing screws
from top to bottom.
6. Recheck throttle shutters and make any necessary adjustment.
7. Hold throttle arm so that the throttle stop screw is
against stop.
8. Place roller of cam follower against throttle cam
and adjust throttle stop screw to align raised mark
of throttle cam with center of cam follower roller.
Tighten locknut.
b
e
a
52483
a - Roller
b - Throttle Cam
c - Screw
10. Hold throttle arm against full throttle stop. Adjust

full throttle stop screw to allow throttle shutters to
open fully. To prevent throttle shutters to act as a
stop, screw in stop screw clockwise 1/2 turn and
tighten locknut.
b
a
g
d
23004
c
25498
a - Cam Follower Adjustment

Screw
b - Synchronizing Screws
c - Throttle Arm
d
e
f
g
a - Throttle Arm
b - Full Throttle Stop Screw
Idle Stop Screw

Roller
Throttle Cam
Locknut
9. Holding throttle arm at idle position, adjust cam

follower so that a clearance of 0.005 in. - 0.020 in.
(0.127mm - 0.508mm) exists between roller and
throttle cam. Tighten screw securing cam follower.
90-13645--2 1095
2C-7
11. Hold throttle cam in full throttle position. If necessary adjust acceleration pump adjusting bolts position so that a gap of 0.030 in. (0.762mm) exists
between throttle cam and top of acceleration
pump aluminum housing.
CARBURETOR/OIL PUMP SYNCHRONIZATION

IMPORTANT: Some engines may have an additional stamped mark (d) which SHOULD NOT be
used.
body aligns with stamped mark of oil pump lever.
2. Move throttle arm from idle to wide open throttle
while checking link rod for any interference with
hoses, cable ties, etc.
a
c
d
c
d
22509
a
b
c
d
Throttle Cam
Bolts
0.030 in. (0.762mm) Gap
Accelerator Pump
22977
a - Link Rod
b - Mark of Oil Pump Body
c - Mark of Oil Pump Lever

d - Mark NOT Used
TIMING ADJUSTMENTS
CAUTION
Engine can be timed while cranking engine with
starter motor. To prevent engine from starting
when being cranked, all spark plugs should be
removed.

RPM.
1. Insert Spark Gap Tool (91-63998A1) in no. 1 (top)
cylinder spark plug boot and attach alligator clip
to good ground.
2. Remove throttle cable barrel from barrel retainer.
IDLE TIMING ADJUSTMENT
WARNING
Before cranking engine, keep clear of propeller,
as it may rotate.
IMPORTANT: To accurately time engine at cranking speed, a fully charged battery must be used.
2C-8
90-13645--2 1095
1. Connect timing light to no. 1 (top) spark plug lead.
MAXIMUM TIMING
2. Shift engine into neutral.
1. Hold control arm against maximum advance stop.

Crank engine with starter motor and adjust maximum advance screw to align 25 BTDC mark on
flywheel with timing pointer (due to the advance
characteristics of ignition system, this cranking
speed adjustment will automatically be reduced
to 23 BTDC at engine speed of 5000 RPM).
Tighten locknut.
3. Holding throttle arm at idle position, crank engine

with starter motor and adjust idle timing screw to
align 2 degrees BTDC timing mark of flywheel with
timing pointer. Tighten locknut.

RPM.
c
a
b
b
a
23005
b - Locknut
23005
a - Control Arm
b - Maximum Advance Screw
c - Locknut
90-13645--2 1095
2C-9
Carburetor Specifications
Carburetor number stamped at TOP of carburetor mounting flange
NOTE: Early model engines may have identification stamped on face of air box mounting flange.
Carb Number
Location
Model HP
Main Jet*
Bowl* Vent Jet
WME-11, 20- 1
2
3
Top Carburetor
Top Center Carburetor
Bottom Center Carburetor
Bottom Carburetor
100
.054
None
WME-14, 21- 1
2
3
Top Carburetor
Bottom Center Carburetor
Bottom Carburetor
115
.076
None
* Standard jets listed are for operation of engine from 0-762 m (0-2500 ft.) of elevation (see jet size chart).
INITIAL STARTING ADJUSTMENTS
NOTE: For adjusting carburetor throttle linkage and

synchronizing carburetors, see section Timing/
Synchronizing/Adjusting of this manual.
4. DO NOT adjust leaner than necessary to attain

reasonable smooth idling. When in doubt, stay on
the slightly rich side of the adjustment.
After service or replacement of carburetor, turn low

speed mixture screw adjustment in (clockwise) until it
seats lightly, then back off (each carburetor) to specifications (100-1-3/4 turns or 115-1-1/2 turns). This will
permit engine start-up.
LOW SPEED MIXTURE ADJUSTMENTS
NOTE: Only the top two carburetors on four cylinder

models have an adjustable low speed mixture screw.
1. Start engine and allow to warm up (run for several
minutes). Throttle back to idle for about one minute to allow RPM to stabilize.
2. With engine running at idle speed (in water) in
Forward gear (prop on), turn low speed mixture
screw, IN (clockwise) until engine starts to bog
down and misfire. Back out 1/4 turn or more.
3. Check for too lean mixture on acceleration.
22990
a - Low Speed Mixture Screw
2C-10
90-13645--2 1095
Idle Adjustment
1. With engine in water, connect electrical harness

and fuel line to engine. Start engine and allow to
warm up.
1. With end of throttle cable connected to throttle lever, hold throttle lever against throttle stop. Adjust
throttle cable barrel to slip into barrel retainer on
cable anchor bracket with a very light preload of
throttle lever against throttle stop. Lock barrel in
place.
2. Properly adjust carburetor low speed mixture

screws. Refer to Carburetor Adjustments section 3A.
3. Holding throttle arm at idle position (throttle cable
barrel removed from barrel retainer), adjust idle
timing screw to attain an engine idle RPM of
650-700 RPM in Forward gear. Tighten locknut
and turn off engine.
IMPORTANT: Excessive preload on throttle cable

will cause difficulty when shifting from forward to
neutral. (Readjust throttle cable barrel, if necessary.)
piece of paper between throttle stop screw and
stop. Preload is correct when paper can be removed without tearing, but has some drag on it.
Readjust throttle cable barrel, if necessary.)
3. Reinstall sound box cover.
23005
b - Locknut
90-13645--2 1095
2C-11
ELECTRICAL AND
IGNITION
2
WIRING DIAGRAMS
Table Of Contents
Page
Engine Wiring Diagram (3 Cylinder

Models with Low Oil Warning Module) . . . . 2D-1
Models without Low Oil Warning Module) . 2D-2
Engine Wiring Diagram (3 Cylinder Models
with Small Voltage Regulator/Rectifier) . . . . 2D-3
Engine Wiring Diagram
(4 Cylinder Models) . . . . . . . . . . . . . . . . . . . . 2D-4
with Small Voltage Regulator/Rectifier) . . . . 2D-5
Power Trim System Wiring Diagram . . . . . . . . . . . . . .
(3 Cylinder Models using COMMANDER
2000 Side Mount Remote Control) . . . . . . . 2D-6
Power Trim System Wiring Diagram
Side Mount Remote Control) . . . . . . . . . . . . 2D-7
Page

2000 Side Mount Remote Control) . . . . . . . 2D-8
Tachometer (with Adjustable Dial) and
Trim Indicator Gauge Wiring Diagram . . . . . 2D-9
Key/Choke Switch Continuity Test
(COMMANDER 2000 Side Mount
Remote Control) . . . . . . . . . . . . . . . . . . . . . . 2D-10
COMMANDER 2000 Side Mount Remote Control
(Power Trim/Tilt Electric Start with
Warning Horn) Wiring Diagram . . . . . . . . . 2D-11
(Electric Start With Warning Horn)
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . 2D-12
COMMANDER Side Mount Remote Control
(Power Trim/Tilt Electric Start with Warning
Horn) Wiring Diagram . . . . . . . . . . . . . . . . . 2D-13
90-13645--2 495

Models With Low Oil Warning Module)
a
b
o
BLK
BLU
BRN
GRY
GRN
PUR
RED
TAN
VIO
WHT
YEL

BLACK
BLUE
BROWN
GRAY
GREEN
PURPLE
RED
TAN
VIOLET
WHITE
YELLOW
j
k
d
g
l
n
e
f
q
r
50388
a
b
c
d
e
f
g
h
i
Stator
Trigger
Switch Box
Ignition Coil Cylinder No. 1
Mercury (Tilt) Stop Switch
Starter Motor
Starter Solenoid
90-13645--2 495
j kl mnop-
Fuse Holder (20 Amp Fuse)
Battery
Wiring Harness Connector
Enrichment Valve
Terminal Block
Temperature Switch Opens [170F 8 (77C 8)]
Closes [190F 8 (88C 8)]
q - Low Oil Warning Module
r - Low Oil Sensor
2D-1

Models Without Low Oil Warning Module)
a
BLK
BLU
BRN
GRY
GRN
PUR
RED
TAN
VIO
WHT
YEL

BLACK
BLUE
BROWN
GRAY
GREEN
PURPLE
RED
TAN
VIOLET
WHITE
YELLOW
d
g
n
e
l
o
f
p
q
r
23888
a
b
c
d
e
f
g
h
i
Stator
Trigger
Switch Box
Starter Motor
Starter Solenoid
2D-2
j kl mnop-
Rectifier
Battery
Enrichment Valve
Terminal Block
Closes [190F 8 (88C 8)]
q - Test Button
r - Low Oil Sensor
90-13645--2 495

With Small Voltage Regulator/Rectifier)
a
h
BLK
BLU
BRN
GRY
GRN
PUR
RED
TAN
VIO
WHT
YEL

BLACK
BLUE
BROWN
GRAY
GREEN
PURPLE
RED
TAN
VIOLET
WHITE
YELLOW
j
k
d
g
m
l
o
f
p
q
51003
a
b
c
d
e
f
g
h
i
Stator
Trigger
Switch Box
Mercury Switch
Starter Motor
Starter Solenoid
90-13645--2 495
j kl mnopq-
20 Amp Fuse
Battery
Fuel Enrichment Valve
Terminal Block
Overheat Temperature Sensor
Warning Module
Low Oil Sensor (Float)
2D-3
Engine Wiring Diagram

(4 Cylinder Models)
a
c
j
o
l
h
d
k
BLK
BLU
BRN
GRY
GRN
PUR
RED
TAN
VIO
WHT
YEL
e
p o
f

BLACK
BLUE
BROWN
GRAY
GREEN
PURPLE
RED
TAN
VIOLET
WHITE
YELLOW
q
p
g
r
s
50389
a
b
c
d
e
f
g
h
i
j
Stator
Trigger
Switch Box
Starter Motor
Starter Solenoid
2D-4
kl mnopq-
Battery
Enrichment Valve
Terminal Block
Closes [190F 8 (88C 8)]
r - Low Oil Warning Module
s - Low Oil Sensor
90-13645--2 495

With Small Voltage Regulator/Rectifier)
j
b
c
j
o
BLK
BLU
BRN
GRY
GRN
PUR
RED
TAN
VIO
WHT
YEL

BLACK
BLUE
BROWN
GRAY
GREEN
PURPLE
RED
TAN
VIOLET
WHITE
YELLOW
d
m
k
e
o
n
p
o
g
q
r
51002
a
b
c
d
e
f
g
h
i
Stator
Trigger
Switch Box
Mercury Switch
Starter Motor
90-13645--2 495
j kl mnopqr -
Starter Solenoid
20 Amp Fuse
Battery
Fuel Enrichment Valve
Terminal Block
Overheat Sensor
Warning Module
Low Oil Sensor (Float)
2D-5
Power Trim System Wiring Diagram (3 Cylinder Models

Using COMMANDER 2000 Side Mount Remote Control)
BLK
BLU
GRN
RED
WHT

BLACK
BLUE
GREEN
RED
WHITE
b
c
d
e
f
g
23886
a
b
c
d
Power Trim Pump Motor

Trim Solenoid UP
Trim Solenoid DOWN
Engine Starter Motor Solenoid
2D-6
e
f
g
h
Red (+) Battery Cable

Engine Wiring Harness Connector
Remote Control Wiring Harness Connector
90-13645--2 495

Using COMMANDER Side Mount Remote Control)
BLK
BLU
GRN
PUR
RED
WHT

BLACK
BLUE
GREEN
PURPLE
RED
WHITE
a
e
f
1
g
2
g
23884
a
b
c
d

Trim Solenoid UP
Trim Solenoid DOWN
90-13645--2 495
e - Fuse Holder (20 Amp Fuse)

f - Red (+) Battery Cable
g - Wires from Remote Control
2D-7

Using COMMANDER 2000 Side Mount Remote Control)
BLK
BLU
GRN
RED
WHT

BLACK
BLUE
GREEN
RED
WHITE
d
a
f
23885
a
b
c
d

Trim Solenoid UP
Trim Solenoid DOWN
2D-8
e
f
g
h
Red (+) Battery Cable

Engine Wiring Harness Connector
Remote Control Wiring Harness Connector
90-13645--2 495
Tachometer (With Adjustable Dial) and

Trim Indicator Gauge Wiring Diagram
BLK
BRN
GRY
PUR
TAN
WHT
BATT

BLACK
BROWN
GRAY
PURPLE
TAN
WHITE
GND
SENDER
a - Tachometer
b - Position Dial to Point Toward 4
c - Trim Indicator Gauge (Optional)
90-13645--2 495
d - Tachometer/Accessories Harness Plug from Remote Control

e - Tachometer/Accessories Harness
2D-9
Key/Choke Switch Continuity Test

(COMMANDER 2000 Side Mount Remote Control)
BLK
PUR
RED
YEL
OFF
BLK/YEL BLK
RUN
RED PUR
START
RED PUR YEL/RED
PUSH (CHOKE)* RED YEL/BLK
*Key switch must be positioned to RUN
or START and key pushed in to actuate
choke, for this continuity test.
2D-10

BLACK
PURPLE
RED
YELLOW
23894
90-13645--2 495

(Power Trim/Tilt Electric Start With Warning Horn)
Wiring Diagram
d
e
f
a
b
BLK
BLU
BRN
GRY
GRN
PUR
RED
TAN
WHT
YEL

BLACK
BLUE
BROWN
GRAY
GREEN
PURPLE
RED
TAN
WHITE
YELLOW
23891
a
b
c
d
Ignition/Choke Switch
Emergency Stop Switch
Tachometer/Accessories Harness Connector
90-13645--2 495
e - Wiring Harness Connector

f - Warning Horn
g - Trim/Tilt Switch
2D-11

(Electric Start With Warning Horn) Wiring Diagram
BLK
BLU
BRN
GRY
GRN
PUR
RED
TAN
WHT
YEL

BLACK
BLUE
BROWN
GRAY
GREEN
PURPLE
RED
TAN
WHITE
YELLOW
d
e
a
b
23892
a - Ignition/Choke Switch
b - Emergency Stop Switch
c - Neutral Start Switch
2D-12
d - Tachometer/Accessories Harness Connector

e - Wiring Harness Connector
f - Warning Horn
90-13645--2 495
COMMANDER Side Mount Remote Control

(Power Trim/Tilt Electric Start With Warning
Horn) Wiring Diagram
BLK
BLU
BRN
GRN
GRY
PUR
RED
TAN
WHT
YEL
LIT
e
k

BLACK
BLUE
BROWN
GREEN
GRAY
PURPLE
RED
TAN
WHITE
YELLOW
LIGHT
h
i
l
d
f
c
j
a
b
c
d
e
f
Warning Horn
90-13645--2 495
24072
g
h
i
j
k
l
Trim/Tilt Switch
Wire Retainer
Control Handle
Trim Harness Bushing
Trim Harness Connector
Lead to Trim Indicator Gauge
2D-13
FUEL SYSTEM AND

CARBURETION
3
A
Table Of Contents
Page
Fuel Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information . . . . . . . . . . . . . . . . . . .
Fuel Pump Description/Operation . . . .
Checking For Restricted Fuel Flow
Caused By Anti-siphon Valves . . .
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Fuel Pump . . . . . . . . . . . .
Fuel Pump Components (Design 1) . . . . .
Fuel Pump Removal/Installation
(Design 1) . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Cleaning, Inspection,
Disassembly and Reassembly
(Design 1 and 2) . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Cleaning/Inspection . . . . . . .
Check Valve Reassembly . . . . . . . . . . . . . .
Carburetion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System Troubleshooting . . . . . . . . . . .
Checking for Restricted Fuel Flow
Caused by Anti-Siphon Valves . . . . . . .
Fuel System (Carburetor) . . . . . . . . . . . . . . . . .
Fuel System (Linkage) . . . . . . . . . . . . . . . . .
Carburetor Adjustments . . . . . . . . . . . . . . . .
Initial Starting Adjustment . . . . . . . . . . .
Low Speed Mixture Adjustment . . . . . .
Carburetor Float Adjustment . . . . . . . .
Specification Sheet - WME Carburetors . . . . .
Carburetor Fastener Torques: . . . . . . .
Settings . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Specifications . . . . . . . . . . .
Fuel Pump Pressure . . . . . . . . . . . . . . .
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . .
3A-1
3A-1
3A-1
3A-1
3A-1
3A-1
3A-2
3A-3
3A-3
3A-3
3A-4
3A-12
3A-12
3A-13
3A-14
3A-16
3A-17
3A-17
3A-17
3A-17
3A-18
3A-18
3A-18
3A-18
3A-18
3A-18
Page
Idle Speed Adjustment . . . . . . . . . . . . . 3A-19

Main (High Speed) Jet Adjustment . . . 3A-19
Rejetting Carburetors For High
Altitude Operation . . . . . . . . . . . . . . 3A-19
Jet Orifice Size/Part Number Chart . . . 3A-20
Carburetor Removal and
Disassembly . . . . . . . . . . . . . . . . . . . 3A-20
Carburetor Disassembly . . . . . . . . . . . . . . . 3A-21
Cleaning and Inspection . . . . . . . . . . . . 3A-22
Carburetor Reassembly . . . . . . . . . . . . . . . . 3A-22
Idle Air Screw . . . . . . . . . . . . . . . . . . . . . 3A-23
Enrichener System . . . . . . . . . . . . . . . . . . . . . . . 3A-24
Description for Three Cylinder Engines . . 3A-24
Enrichener Valve Hose Installation - Three
Cylinder Engines . . . . . . . . . . . . . . . . . . 3A-24
Description for Four Cylinder Engines . . . 3A-24
Enrichener Valve Hose Installation - Four
Cylinder Engines . . . . . . . . . . . . . . . . . . 3A-24
Enrichener Valve Test . . . . . . . . . . . . . . 3A-25
Acceleration Pump Circuit Operation Four Cylinder Engines . . . . . . . . . . . . . . 3A-26
Accelerator Pump Fuel Flow Circuit . . 3A-26
Acceleration Pump Fuel Flow Circuit for
Four Cylinder Engines . . . . . . . . . . . . . . 3A-27
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-28
Maintenance . . . . . . . . . . . . . . . . . . . . . . 3A-28
Fuel Tank Components . . . . . . . . . . . . . . . . 3A-28
Fuel Line and Primer Bulb Assembly . . . . 3A-29
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 3A-30
Fuel Line Clamp Removal and
Installation . . . . . . . . . . . . . . . . . . . . . 3A-30
90-13645--2 495
Fuel Pumps
General Information
FUEL PUMP DESCRIPTION/OPERATION
The fuel pump is a crankcase-pressure-operated, diaphragm-type pump. Crankcase pulsating pressure

(created by the up-and-down movement of piston) is
transferred to fuel pump by way of a passage (hole)
between crankcase and fuel pump.
When piston is in an upward motion, a vacuum is
created in the crankcase, thus pulling in a fuel/air mixture (from carburetor) into crankcase. This vacuum
also pulls in on the fuel pump diaphragm, thus the inlet check valve (in fuel pump) is opened and fuel (from
fuel tank) is drawn into fuel pump.
Downward motion of the piston forces the fuel/air mixture out of the crankcase into the cylinder. This motion
also forces out on the fuel pump diaphragm, which, in
turn, closes the inlet check valve (to keep fuel from returning to fuel tank) and opens the outlet check valve,
thus forcing fuel to the carburetors.
If, after using a separate fuel supply, it is found that

the anti-siphon valve is the cause of the problem,
there are 2 solutions to the problem; either (1) remove
the anti-siphon valve or (2) replace it with a solenoidoperated fuel shutoff valve.
Testing
Install clear fuel hose(s) between fuel pump and carburetor(s). Run engine, and inspect fuel passing thru
hose(s) for air bubbles. If air bubbles are found, see
Air Bubbles in Fuel Line, below. If air bubbles are
NOT found, see Lack of Fuel Pump Pressure, continued on next page.
Troubleshooting Fuel Pump

PROBLEM: AIR BUBBLES IN FUEL LINE
Possible Cause
Corrective Action
Low fuel in fuel tank.

Loose fuel line
connection.
Fuel pump fitting loose.
A hole or cut in fuel line.
CHECKING FOR RESTRICTED FUEL FLOW CAUSED

BY ANTI-SIPHON VALVES
While anti-siphon valves may be helpful from a safety

stand-point, they clog with debris, they may be too
small, or they may have too heavy a spring. Summarizing, the pressure drop across these valves can,
and often does, create operational problems and/or
powerhead damage by restricting fuel to the fuel
pump and carburetor(s). Some symptoms of restricted (lean) fuel flow, which could be caused by use
of an anti-siphon valve, are:
Fuel pump anchor

screw(s) loose.
Fuel pump gasket(s)
worn out.
PROBLEM: LACK OF FUEL PUMP PRESSURE

Possible Cause
Corrective Action
An anti-siphon valve.
Loss of fuel pump pressure

Loss of power
Air in fuel line.
High speed surging

Preignition/detonation (piston dome erosion)
Outboard cuts out or hesitates upon acceleration
Outboard runs rough
Outboard quits and cannot be restarted
Outboard will not start
Vapor lock
Since any type of anti-siphon device must be located
between the outboard fuel inlet and fuel tank outlet,
a simple method of checking [if such a device (or bad
fuel) is a problem source] is to operate the outboard
with a separate fuel supply which is known to be
good, such as a remote fuel tank.
90-13645--2 495
Fill tank with fuel.

Check and tighten all
connections.
Tighten fitting.
Check condition of all
fuel lines and replace
any found to be bad.
Tighten all screws
evenly and securely.
Rebuild fuel pump.
A dirty or clogged fuel

filter.
The fuel pickup in fuel
tank clogged or dirty.
Worn out fuel pump
diaphragm.
Defective (hole or crack)
check valve(s) in fuel
pump (unlikely).
Broken check valve
retainer.
Pulse hole plugged.
FUEL SYSTEM AND CARBURETION
Read Checking for

Restricted Fuel Flow,
Caused by Anti-Siphon
Valves preceding.
Air Bubbles in Fuel
Line, preceding.
Clean or replace fuel
filter.
Clean or replace pickup.
Rebuild fuel pump.
Rebuild fuel pump.
Rebuild fuel pump.

Remove fuel pump and
clean out hole.
3A-1
Troubleshooting Fuel Pump

(continued)
PROBLEM: LACK OF FUEL PUMP PRESSURE
Possible Cause
Corrective Action
Hole in pulse hose

(1 pulse hose).
Replace pulse hose.
Loose pulse hose.
Tighten connection.
Fuel Pump Components (Design 1)

NOTE: In fuel pump reassembly, remember that respective diaphragms go against the mating surfaces
of the fuel pump body, and respective gaskets are between the diaphragms and end caps. Gaskets should
always be replaced on fuel pump assembly.
Boost diaphragm gasket Check seal between

distorted or out of place. mating surfaces where
rib divides pulse
chamber gasket must
align with rib; check for
distorted gasket. Align
or replace gasket if
necessary.
a
f
h
i
j
b
q
g
k
l
s
r
m
n
o
p
c
abcdef ghi j kl mnopqr st -
3A-2
Fuel Pump Base

Fuel Pump Body
Chamber Plate
Gasket, Base
Fuel Filter Inline
Gasket, Pulse Chamber
Diaphragm, Fuel Pump
Retainer, Check Valve
Check Valve
Check Valve Rubber Disc
Main Compression Spring End Cap
Main Compression Spring
Boost Diaphragm
Boost Chamber Gasket
Boost Compression Spring End Cap
Boost Compression Spring
Retainer, Check Valve
Check Valve
Check Valve Rubber Disc
Check Valve Assembly
90-13645--2 495
Fuel Pump Removal/Installation

(Design 1)
Attach fuel lines (inlet and outlet).
Remove 4 hoses from fuel pump.
Attach pulse hose.
Remove 2 phillips-head screws -- lift off fuel pump.
Secure each hose connection with a sta-strap.
Attach oil injection hose.
Remove 2 hex-head bolts to disassemble fuel

pump.
d
b
a
a
20427
a - Fuel Pump
b - Screws (2 Each)
c - Bolts (2 Each)
Remove gasket from backside (fuel pump base) -replace gasket as necessary -- check gasket in
port area carefully.
c
a
b
c
d
Inlet Fuel Hose

Outlet Fuel Hose
Oil Injection Hose
Pulse Hose
Fuel Pump Cleaning,

Inspection, Disassembly and
Reassembly (Design 1 and 2)
a
Disassemble by removing 2 hex-head bolts;

remove/disassemble fuel pump parts.
Fuel Pump Cleaning/Inspection

Clean fuel pump housing, check valves, pulse chamber, and pump base in solvent, and dry all but check
valves with compressed air.
20417
a - Gasket
b - Port Area
Reinstall Fuel Pump (Design 1)

CAUTION
After reinstalling fuel pump, ALWAYS check all
fuel line connections for leaks, with engine
running.
Reinstall fuel pump to powerhead, as shown, with
2 phillips-head screws.
90-13645--2 495
Inspect each check valve (2 ea.), for cracks and/or

holes. Check each black rubber disc (2 ea.) to see
that the black coating is not coming off. Unless damaged while disassembled, replacement is seldom
necessary. Inspect the Check Valve Assembly on
Chamber Plate (check by both pressure and suction
to hose barb), to see that check ball is moving and
functioning (1-3 psi required).
Inspect fittings on fuel pump housing for looseness or
any signs of fuel or air leaks. Replace or tighten fitting
if leak is found, or replace chamber Plate Assembly.
3A-3
4. Reinstall rod into retainer cap and, use a small

hammer or hammer and punch to tap rod down
into retainer until flush with top of retainer.
Check Valve Reassembly

ASSEMBLY (DESIGN I)
1. Insert retainer thru plastic disc and rubber check

valve.
a
b
b
c
23601
a - Rod
b - Retainer Cap
23601
Check Valve Reassembly

ASSEMBLY (DESIGN II)
a - Retainer
b - Plastic Disc
c - Check Valve
1. Insert retainer thru plastic disc and rubber check

valve.
2. Install check valves and retainers into fuel pump

body.
a
c
b
51530
a - Retainer
b - Plastic Disc
c - Check Valve
24514
3. With retainer installed in pump body, break retainer rod from retainer by bending sideways.
a
b
23601
a - Retainer Rod
b - Retainer
3A-4
90-13645--2 495
2. Install check valves and retainers into fuel pump

body.
Step-by-Step Reassembly
IMPORTANT: ALWAYS REPLACE GASKETS.
STEP-BY-STEP FUEL PUMP REASSEMBLY
After reassembling check valve in fuel pump body,

using the following procedure will help insure proper
reassembly:
1. Insert two 3 in. minimum length 1/4 bolts (not the
fuel pump bolts) OR 1/4 dowels, through the
opposite large holes (6mm bolt holes) in the
chamber plate, as locating dowels, and turn plate
upside down so that the inner side is facing up.
2. Insert coil spring and cap in place.
3. Place Boost Chamber GASKET over dowels
(bolts) and lower onto Chamber Plate -- BE SURE
that gasket directional alignment is correct and
that V-tabs are aligned.
4. Place Boost DIAPHRAGM over dowels, and
lower to assembly.
51530
3. Reinstall rod into retainer cap and, use a small

hammer or hammer and punch to tap rod down
into retainer until flush with top of retainer.
5. Place Fuel Pump Body over dowels, and lower to

assembly.
6. Insert Coil Spring and Cap in pump body.
7. Place Fuel Pump DIAPHRAGM over dowels, and
lower to assembly.
8. Place Pulse Chamber GASKET over dowels, and
lower to assembly.
9. Place Fuel Pump Base over dowels, and lower to
assembly.
a
b
10. Grasp assembly firmly and clamp together with

hands--turn over, and insert the 5mm Fuel Pump
BOLTS (hex-head); After tightening, remove
dowels (1/4 bolts) used for locators.
11. Check that the directional alignment of all parts is
correct and that the V-Tabs are aligned.
a - Rod
b - Retainer Cap
90-13645--2 495
3A-5
70-75-80-90 (3 cyl.)
(Design 1)
a
Previous body with rubber check

valve retainers was colored black.
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50289
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Body (Opposite Side View)

Natural Body (Off White)
Rubber Valve
Cover (Opposite Side View)
Plastic Disc
Plastic Check Valve Retainer
Two Oil Passage Holes
Cast Aluminum Cover
One Tab
Two Tabs
3A-6
90-13645--2 495
100-115 (4 cyl.)
(Design 1)
a
Previous body with rubber check

valve retainers was colored black.
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50291
a
b
c
d
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Natural Body (Off White)
Rubber Valve
Plastic Disc
Two Oil Passage Holes
Cast Aluminum Cover
One Tab
Two Tabs
90-13645--2 495
3A-7
REASSEMBLY SEQUENCE (DESIGN 1)
j
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CAUTION
Observe position of both Pulse Chamber
DIAPHRAGM and GASKET. The two larger holes
allow oil injection output to enter the gas flow.
Failure to reinstall as shown WILL result in
extensive damage to engine.
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51119
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Chamber Plate (Step 1)

Boost Compression Spring & Cap (Step 2)
Boost Chamber Gasket (Step 3)
Boost Diaphragm (Step 4)
Fuel Pump Body (Step 5)
Main Compression Spring & Cap (Step 6)
Fuel Pump Diaphragm (Step 7)
Pulse Chamber Gasket (Step 8)
Fuel Pump Base (Step 9)
Fuel Pump to Powerhead Gasket - Shown for
Identification Purposes Only
Reinstalling Fuel Pump to Powerhead see preceding page
3A-8
90-13645--2 495
70-75-80-90 (3 cyl.)
(Design 2)
a
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51549
a
b
c
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Rubber Valve
Plastic Disc
Cast Aluminum Cover
Three Tabs
Three Tabs
90-13645--2 495
3A-9
100-115 (4 cyl.)
(Design 2)
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b
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51548

Rubber Valve
Plastic Disc
Cast Aluminum Cover
Body
Three Tabs
Three Tabs
3A-10
90-13645--2 495
MODEL 100, 115
Installation of Design 2 Fuel Pump

MODEL 70, 75, 80, 90
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51519
Clear Tube [5.5 in. (139.7mm)]

To Oil Pump Outlet
Check Valve
Hose [1.5 in. (38.1mm)]
Hose [2.5 in. (63.5mm)]
Fuel Line Connector
Y-Fitting
Hose [3 in. (76.2mm)]
Fuel Pump
90 Degree Elbow
Fuel Outlet to Filter
Hose [2.5 in. (63.5mm)]
To Pulse Fitting on Powerhead
abcdef ghi j kl mn-
51519
Clear Tube [8 in. (203.2mm)]

To Oil Pump Outlet
Check Valve
Hose [1.5 in. (38.1mm)]
Fuel Connector
Hose [1.5 in. (38.1mm)]
T-Fitting (EXISTING)
Y-Fitting
Hose [1.75 in. (44.5mm)]
Fuel Pump
Fuel Outlet to Filter
90 Degree Elbow
Hose [4 in. (101.6mm)]
To Pulse Fitting on Powerhead
MODEL 100, 115
MODEL 70, 75, 80, 90
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90-13645--2 495
51516
Fuel Pump
Pulse Hose
Inlet Hose
Outlet Hose (Replace with Molded Hose)
Elbow [Apply PERFECT SEAL (92-34227--1) to threads]
Check Valve
Y-Connector
Screws [Torque to 55 lb. in. (6.2 Nm)]
Clear Tubing [5.5 in. (139.7mm)]
Gasket (Cylinder Block to Fuel Pump) (HIDDEN)
a
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51516
a
b
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Fuel Pump
Pulse Hose
Inlet Hose
Outlet Hose
Elbow [Apply PERFECT SEAL (92-34227--1) to threads]
Check Valve
Y-Connector
Screws [Torque to 55 lb. in. (6.2 Nm)]
Clear Tubing [8 in. (203.2mm)]
Gasket (Cylinder Block to Fuel Pump) (HIDDEN)
3A-11
PROBLEM: ENGINE FLOODS
Carburetion
Possible Cause
Fuel System Troubleshooting
Corrective Action
Troubles, that are caused by items 1-thru-5, listed below, may give the impression that a problem exists in
the fuel system:
Dirt or foreign particles

are preventing inlet
needle from seating.
Worn inlet needle.
Flush out inlet seat and

clean inlet needle.
1. Spark plugs
Punctured float.
Replace.
2. Ignition spark voltage
Incorrect float setting.
Reset float.
Replace.
3. Cylinder compression
PROBLEM: ENGINE RUNS TOO LEAN
4. Reed valves
Possible Cause
5. Ignition timing
Troubleshooting Charts
PROBLEM 1: ENGINE TURNS OVER BUT WILL NOT
START OR STARTS HARD WHEN
COLD
Possible Cause
Improper starting
procedure.
Fuel tank empty;

improperly mixed fuel;
contaminants (water,
dirt, etc.) in fuel.
Corrective Action
Check procedure, as
outlined in Operation
and Maintenance
Manual.
Check fuel in fuel tank
and replace or add.
Fuel tank air vent closed Air vent must be open

or restricted.
and free from
contaminants.
A pinched or restricted
Check, and replace as
fuel line.
needed.
Dirty or restricted fuel
filter.
Check, replace or clean.
Enrichener valve not

operating.
Check enrichener
system. (Refer to
Enrichener System
following.)
An inlet needle (in

carburetor) that is stuck
open or closed. (A
needle stuck open, will
cause a flooding
condition. A needle stuck
closed, will prevent fuel
from entering carburetor.)
Remove, clean, or
replace.
Anti-Siphon valve
restricting fuel flow.
Refer to Checking for

Restricted Fuel Flow
caused by Anti-Siphon
Valves, following.
Corrective Action
Carburetor is loose. Air

leaks past mixing
chamber cover.
Fuel level too low.
Tighten bolts securely.

Tighten cover or replace
gasket.
Reset float level.
Clogged high speed jet.
Check and clean.
Restricted fuel flow to

carburetor.
Check fuel lines and

filter(s) for restricted
flow.
Refer to main jet chart
and replace with proper
jet.
Adjust to run richener.
Incorrect high speed jet.
Idle mixture set too

lean.
Air leakage into fuel
system.
Check fuel line

connections, hose
clamps, fuel pump, and
fuel outlet tube (located
in fuel tank) for loose
fittings.
Anti-Siphon valve

restricted fuel flow
caused by Anti-Siphon
valves.
PROBLEM: ENGINE RUNS TOO RICH

Possible Cause
Corrective Action
Fuel level too high.
Reset float to correct

level.
Carburetor floods.
See preceding Engine

Floods
Idle nozzle air holes

plugged.
Blow out with

compressed air.
Restricted air flow.
Check cowl air inlet and

carburetor for
obstructions.
Retighten Jet.
Main Fuel Jet loose.
See Checking for Restricted Fuel Flow caused

by Anti-Siphon Valves, page 3A-1.
3A-12
90-13645--2 495
PROBLEM 1: ENGINE IDLES ROUGH AND

STALLS
PROBLEM 2: ENGINE RUNS UNEVEN OR
SURGES
PROBLEM 3: ENGINE WILL NOT ACCELERATE
Possible Cause
Corrective Action
Fuel tank air vent closed Check - Air vent must

or restricted.
be open all-the-way and
free from restrictions.
A pinched, cut or
Check all fuel lines and
restricted fuel line; also replace as needed.
loose fuel line
Check and tighten all
connection.
fuel line connections.
A dirty or restricted fuel
filter.
Check, replace, or clean

all fuel filters.
Restricted filter in fuel

tank.
Clean by rinsing in
clean lead-free gasoline
or kerosene.
Check fuel and replace,
if necessary.
Improperly mixed fuel;

contaminants (water,
dirt, etc.) in fuel.
An inlet needle (in
Remove and replace
carburetor) that is either with new inlet needle.
stuck open or closed. (A
needle, that is stuck
open, will cause a
flooding condition. A
needle, that is stuck
closed, will prevent fuel
from entering
carburetor.)
Incorrect idle mixture
adjustment.
Re-adjust.
Damaged fuel pump

diaphragm.
Replace.
Carburetor is loose.
Tighten bolts securely.
Chamber cover leaking

air.
Tighten or replace
gasket.
Off idle holes plugged.
Blow out with

compressed air.
Main nozzle or idle

nozzle air bleed holes
plugged.
Improper main jet or
restricted jet.
Blow out with

compressed air.
Damaged reed(s).
A crack in the fuel
pick-up outlet tube
(located in fuel tank).
90-13645--2 495
A crack in the fuel outlet

tube (located in fuel
tank.)
Anti-Siphon valve
Replace.

Restricted Fuel Flow
Caused by Anti-Siphon
Valves, following.
PROBLEM: FUEL BLOW-BACK OUT OF

CARBURETOR
Possible Cause
Chipped/Broken
(reed-block) Reeds
Corrective Action
Replace Reeds.
PROBLEM: ROUGH IDLE

If related to reed-block, Replace Reeds.
indicates excessive
preload in reeds.
PROBLEM: CANT REDUCE ENGINE RPM TO
SLOW IDLE
Multiple Chipped Reeds.
Replace Reeds.
Checking for Restricted Fuel Flow

Caused by Anti-Siphon Valves
While anti-siphon valves are helpful from a safety
standpoint, they clog, they may be too small, or they
may have too heavy a spring. The pressure drop
across these valves can, create operational problems
and/or powerhead damage by restricting fuel. Some
symptoms of restricted (lean) fuel flow, are:
1. Loss of fuel pump pressure
2. Loss of power
3. High speed surging
4. Preignition/detonation (piston dome erosion)
Clean or replace with

proper jet (refer to Main
Jet Chart).
Inspect reeds as
outlined in Section 4A.
Replace.
5. Outboard cuts out or hesitates upon acceleration

6. Outboard runs rough
7. Outboard quits and cannot be restarted
8. Outboard will not start
9. Vapor lock
Any type of anti-siphon device must be located between the outboard fuel inlet and fuel tank outlet. A
method of checking [if such a device (or bad fuel) is
a problem source] is to operate the outboard with a
separate fuel supply which is known to be good.
If, it is found that the anti-siphon valve is the cause of
the problem, either 1) replace the anti-siphon valve or
2) replace it with a solenoid-operated fuel shutoff
valve.
3A-13
Fuel System (Carburetor)
25
Specifications
Float Setting 7/16 in (0.015 in.)

Float Weight 7 grams (0.4 grams)
Idle Adjustment Screw 1-1/2 turns (1/4)
(Set Halfway Between Lean and Rich)
16
18
13
22
109
24
51
20
5
14
15
23
IMPORTANT: DO NOT touch this

adjustment. This is preset by the
manufacturer, and is NOT for
field service. Conventional carb.
cleaners will not affect the sealant securing this adjustment.
21
9
1
2
10
8
4
11
12
19
Quicksilver Lubrication/Sealant
Application Points
51
109
3A-14
17
Loctite 222 (Obtain Locally)
Loctite Primer T (92-59327-1)
90-13645--2 495
Fuel System (Carburetor) (Continued)

TORQUE
REF. NO.
QUAN.
DESCRIPTION
Carburetor Body
Gasket
Retaining Ring
Fuel Bowl
Throttle Shaft (Upper/Bottom)
Throttle Shaft (Center)
Throttle Valve
Float
Float Shaft
10
Inlet Needle Valve
11
Plug
12
Gasket
13
Gasket
14
Gasket
15
16
17
lb. in.
lb. ft.
Nm
22
2.5
Screw
0.7
Screw
18
2.1
Screw
18
2.1
18
Cover Plate
19
Main Jet
14
1.6
20
Vent Jet
0.7
21
Gasket
22
Spring
23
Spring
24
Idle Mixture Screw
25
Screw
90-13645--2 495
3A-15
4 Cylinder Carburetor/Linkage Arrangement
Fuel System (Linkage)

3 Cylinder Carburetor/Linkage Arrangement
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Sta-Straps (4)
Fuel Liners (2)
Throttle Link
Throttle Arm
Throttle Link
Roller
Arm
Oil Injection Pump Link
Gasket
Gasket
3A-16
a
b
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Screw (6)
Washer (6)
Carburetor Link
Carburetor Link
Oil Injection Pump Link Rod
Roller
Throttle Shaft
Throttle Link
Throttle Link
Gasket
Gasket
90-13645--2 495
Carburetor Adjustments
CARBURETOR FLOAT ADJUSTMENT
INITIAL STARTING ADJUSTMENT
1. If installed, remove carburetor as outlined in

Carburetor Removal, following.
After service or replacement of carburetor, turn low

speed mixture screw adjustment in (CLOCKWISE)
until it seats LIGHTLY then back off (each
carburetor) the number of turns per model as
indicated, following:
70 H.P. --- 1-1/4
75 H.P. --- 1-1/2
80 H.P. --- 1-1/2
90 H.P. --- 1-1/2

100 H.P. --- 1-3/4
115 H.P. --- 1-1/2
2. Remove fuel bowl and gasket and check float

level as shown.
3. If necessary, adjust float level by bending metal
tab on float to which inlet needle is clipped.
11.1 mm
(7/16 in.)
a
b
This adjustment will permit engine startup.

LOW SPEED MIXTURE ADJUSTMENT
NOTE: Only the top two carburetors on four cylinder

models have adjustable idle mixture screws.
1. Start engine and allow to warm-up (run for several
minutes). Throttle back engine to idle for about
one minute to allow RPMs to stabilize.
2. With engine running at idle speed -- in water -- IN
FORWARD GEAR (prop on) -- turn low speed
mixture screw IN (clockwise) until engine starts to
bog down and misfire. Back out 1/4 turn or more.
a - Metal Tab
b - Inlet Needle
22990
a - Low Speed Mixture Screw
3. Check for too lean mixture on acceleration.

4. DO NOT adjust leaner than necessary to attain
reasonably smooth idling. When in doubt, stay on
the slightly rich side of the adjustment.
90-13645--2 495
3A-17
Specification Sheet - WME

Carburetors
Carburetor Number Stamped at TOP of carburetor
mounting flange.
NOTE: Early model engines may have identification

stamped on face of air box mounting flange.
Carburetor Number
Location
WME-9 - 1
2
3
WME-7 - 1
2
3
WME-10 -1
2
3
WME-8 - 1
2
3
WME-11 - 1
2
3
4
Top Carburetor
Center Carburetor
Bottom Carburetor
Top Carburetor
Center Carburetor
Bottom Carburetor
Top Carburetor
Center Carburetor
Bottom Carburetor
Top Carburetor
Center Carburetor
Bottom Carburetor
Top Carburetor
Bottom Carburetor
Bottom Carburetor
WME-14 -1
2
3
4
Top Carburetor
Bottom Carburetor
Bottom Carburetor
Model H.P.
Main Jet*
Bowl Vent Jet*
80
.064
.094
70
.072
.094
90
.072
.094
75
.068
.094
100
.054
NONE
115
.076
NONE
* Standard Jets listed are for operation of engine from 0-2500 ft. (0-762 M) of elevation.
See page 3A-12 (this section) for jet-size chart.
CARBURETOR FASTENER TORQUES:
FUEL PUMP SPECIFICATIONS:
Main Jet
14 lb. in. (1.6 Nm)
Main Jet Cap Plug
22 lb. in. (2.5 Nm)
Float Bowl
18 lb. in. (2.1 Nm)
Throttle Plate Screw 6 lb. in. (0.7 Nm)
(Loctite 609 used, OR:
RC-35 WITH PRIMER
OR:
Loctite 222 WITH PRIMER)
Cover Plate Screw
18 lb. in. (2.1 Nm)
Back Drag Jet
6 lb. in. (0.7 Nm)
Carb. (Air Box) Stud 100 lb. in. (11.3 Nm)
Nuts (6)
Fuel Pump Assembly Bolts

55 lb. in. (6.2 Nm)
Fuel Pump Mounting Screws 55 lb. in. (6.2 Nm)
SETTINGS:
Float Setting
7/16 (.015) See photo/diagram (this section), page 3A-18

Float Weight
7 grams (1 gr.)
(.4 gr./cc)
Idle Adjust Screw 1-1/2 turns (1/4 turn) (set halfway between lean and rich).
3A-18
FUEL PUMP PRESSURE:
Engine Side at W.O.T.
4-6 psi.
(depending on RPMs)
SEALANTS:
Fuel Pump Check Valve

Assembly
Loctite Pipe Sealant

w/teflon
Carb Throttle Plate Screw: Loctite 609 OR:

RC-35 WITH PRIMER
OR
Loctite 222 WITH PRIMER
90-13645--2 495
IDLE SPEED ADJUSTMENT
Adjust engine idle RPM as outlined in Section 2C

Timing/Synchronizing/Adjusting.
MAIN (HIGH SPEED) JET ADJUSTMENT
The carburetor is equipped with a fixed high speed jet

and normally no adjustment is required. However,
extreme changes in weather (temperature and
humidity) and/or elevation may result in a too lean or
rich fuel mixture at wide-open-throttle, which may
require a change in the high speed jet. A smaller size
main jet will lean the fuel mixture, and a larger size jet
will enrichen the fuel mixture.
Normally, for every 1000 feet (304.8m) of altitude increase, main jet size is reduced by 2%. However, this
does not always hold true for all situations; different
boat, motor, load and ambient air temperature conditions may require different jets I.E. going a jet size
richer than recommended for a particular altitude may
improve acceleration. It may also be noted that no noticeable improvement in engine performance was
achieved by changing the standard main jet at altitudes up to 5000 feet (1524m). Above 5000 feet,
however, changing jets did improve performance.
Several additional changes to improve engine
performance at higher altitudes are as follows:
1. Idle timing should be advanced 2-3 degrees at
5000 feet (1524m) and above.
2. Prop engine at the top of the recommended RPM
scale +/150 RPM.
3. Reset idle mixture screws for best idle. With standard idle mixture setting (sea level) considered to
be at the 12 oclock position, adjust the mixture
screw leaner for all models as follows:
20365
STANDARD HIGH SPEED JET CHART
5000 ft.
(1524m)
7500 ft.
(2286m)
10000 ft.
(3048m)
1 oclock
1 oclock
2 oclock
4. Change gear ratio:
Model
Carburetor
Number
Main Jet
Size (inch)
Bowl Vent
Jet (inch)
70
WME-7
.072
.094
75
WME-8, 17
.068
.094
80
WME-9
.064
.094
90
WME-10
WME-19
.072
.066
.094
.094
100
WME-11, 20
.054
NONE
Model
115
WME-14, 21
.076
NONE
REJETTING CARBURETORS FOR HIGH ALTITUDE

OPERATION
The carburetor jet installed at the factory is for engine

operation at sea level through an elevation of 5000
feet (1524m) above sea level. If the engine is to be operated at an altitude higher than 5000 feet (1524m),
then it will be necessary to rejet the carburetors. Refer
to the jet chart following for jet recommendations at
approximate altitudes.
90-13645--2 495
Above
5000 ft.
(1524m)
None
Available
Model
70, 75, 80, 90 Std. Ratio 2.33:1
100, 115 Std. Ratio 2.08:1
2.33:1
HIGH ALTITUDE JET CHART

Carb
Std. Jet
5000 ft.
(1524m)
7500 ft.
(2286m)
10000 ft.
(3048m)
70
WME-7
.072
.072
.070
.068
75
WME-8, 17
.068
.068
.066
.064
80
WME-9
.064
.064
.062
.060
90
WME-10
WME-19
.072
.066
.072
.066
.068
.062
.066
.060
100
WME-11, 20
.054
.054
.050
.048
115
WME-14, 21
.076
.076
.072
.068
3A-19
JET ORIFICE SIZE/PART NUMBER CHART
CARBURETOR REMOVAL AND DISASSEMBLY
NOTE: Thread size for jets is 10-32.
Carburetor Removal - remove the six nuts (on carb

studs), and lift off carburetor assembly. See Section
4A, this manual, for step-by-step procedure.
JET ORIFICE SIZE/PART NUMBER CHART

Jet
Orifice
Size
(Inches)
.040
.042
.044
.046
.048
.050
.052
.054
.056
.076
.078
.080
.082
.084
.086
.088
.090
.092
Part
Number
19266040
1399-5315
1395-7394
1399-5317
1395-6246
1395-6028
1395-6359
1399-5225
1399-5213
1399-3796
1395-6680
1395-6201
1399-3518
1399-3517
1395-5815
1395-6202
1395-6247
1395-5733
Jet
Orifice
Size
(Inch)
Part
Number
.058
.060
.062
.064
.066
.068
.070
.072
.074
.094
.096
.098
1395-7831
1395-6487
1399-4217
1399-4216
1399-4215
1395-6029
1395-6030
1395-6207
1399-3794
1395-8423
1399-6249
1395-7335
To Disassemble
S Remove fuel bowl.
a
51119
a - Fuel Bowl
S Remove float pin and remove float.

S Remove fuel bowl gasket.
a
c
51115
a - Float Pin
b - Float
c - Gasket
3A-20
90-13645--2 495
S Remove fuel inlet needle.
Carburetor Disassembly
S Remove stem gasket.
S Remove main jet plug and gasket.

S Remove main jet.
a
b
51116
a
51116
a - Fuel Inlet Needle

b - Stem Gasket
a - Main Jet Plug and Gasket

b - Main Jet
S Remove mixing chamber cover and gasket.

S Remove low speed mixture screw.
S Remove bowl vent jet (black drag) (3-Cylinder
Models only).
NOTE: It is not necessary to disassemble carburetor

beyond this point for cleaning. Examine throttle shaft
for wear and inspect for damaged throttle shutter
plate.
If removal of throttle shaft and/or throttle shutter plate
is necessary, remove 2 screws, which secure throttle
shutter plate to throttle shaft. Remove retaining clip
from end of throttle shaft, then pull shaft out of carburetor.
c
a
51116
a - Mixing Chamber Cover and Gasket
b - Idle Mixture Screw
c - Bowl Vent Jet
b
c
51117
a - Throttle Shaft
b - Screw (2)
c - Throttle Shaft Spring
90-13645--2 495
3A-21
1. Carefully inspect carburetor body and fuel bowl

for cracks, stripped threads, plugged or restricted
passages and passage plugs that show signs of
leakage.
S Install mixing chamber cover and gasket as

shown.
S Install low speed mixture screw.
S Install bowl vent jet (back drag) (3-Cylinder Models
only).
2. Thoroughly clean all carburetor parts with a mild

cleaning solution (that will not damage rubber or
plastic) to remove dirt, gum and varnish that may
have accumulated.
d
b
3. After washing parts, blow parts dry with compressed air. Be sure to blow air thru all passages,
orifices and nozzles.
4. Check float hinge in the float pin area for wear and
check float for leaks. Replace parts as necessary.
5. Examine inlet needle for wear. If worn, replace
with new inlet needle.
Carburetor Reassembly
S If removed, install throttle shaft throttle shutter
plate 2 screws (use specified LoctiteR), and
throttle shaft spring as shown. Install retaining clip
on other end of shaft.
51116
a
b
c
d
Mixing Chamber Cover and Gasket

Idle Mixture Screw
Bowl Vent Jet
Screw (2) Torque 18 lb. in. (2.1 Nm)
S Install main jet.

S Install main jet plug and gasket.
c
51117
a - Throttle Shaft
b - Screws (2)
c - Throttle Shaft Spring
S Spring tensions on stud.
51116
a - Main Jet [Torque 14 lb. in (1.6 Nm)]

b - Main Jet Plug and Gasket [Torque 22 lb. in. (2.5 Nm)]
b
51259
a - Spring
b - Stud
3A-22
90-13645--2 495
S Install stem gasket.
S Install float bowl.
S Install fuel bowl gasket.
51119
a - Stem Gasket
b - Fuel Bowl Gasket
NOTE: If spring clip on inlet needle was removed, or

if needle was replaced, be sure spring clip is
reattached.
S Attach spring clip on inlet needle to metal float tab
and place needle into its seat.
51116
a - Float Bowl
b - Screw (4) Torque 18 lb. in. (2.1 Nm)
IDLE AIR SCREW
Idle air screw is preset by the manufacturer and is

NOT for field service. If the idle air screw should become misadjusted, set air screw at 1/4 TURN OUT
from a LIGHTLY SEATED position.
51115
a - Spring Clip
b - Float Tab
S Install float into carburetor with float pin.
S Adjust float following Float Adjustment, Page

3A-18.
51620
a - Idle Air Screw
51115
a - Float
b - Float Pin
90-13645--2 495
3A-23
Enrichener System
Description for Four Cylinder Engines
Description for Three Cylinder

Engines
Enrichener valve receives fuel from a T-fitting between #1 and #2 carburetors. Valve is electrically
opened when ignition key is turned to the ON position and pushed in (and held in). Fuel is dispensed to
T-fittings on intake manifold of cylinders #2 and #4. Internal passages route fuel from cylinders #2 and #4
to cylinders #1 and #3. Valve returns to the closed
position when key (or choke button) is released. Valve
can be operated manually by PRESSING and HOLDING button located on top of valve.
Fuel flows from top carburetor float bowl to fuel enrichment valve. Valve is electrically opened when key
is turned to the ON position and pushed in (and held
in). Fuel is supplied to engine through fittings located
in the top, middle, and bottom carburetors. Valve returns to the closed position when key (or choke button) is released. Valve can be operated manually by
PRESSING and HOLDING button located at bottom
of valve.
Enrichener Valve Hose Installation Four Cylinder Engines
Enrichener Valve Hose Installation Three Cylinder Engines
Enrichener Valve
Manual Operation
Button
Connect to fitting on
SIDE of TOP carburetor
Electrical
Harness
Electrical
Harness
Enricher Valve
Manual Operation
Button
Connect to T-fitting
between #1 and #2
carburetors
23121
3A-24
90-13645--2 495
IMPORTANT: Use of enrichener if engine is warm

could result in engine flooding.
ENRICHENER VALVE TEST
Push key (or choke button) in.
Valve should click.
No Click
Click
Check for battery voltage to yellow/black wire

at terminal block on engine when key (or choke
button) is pushed in.
Squeeze primer bulb until bulb is firm. Remove

lower hose from fitting on enrichener valve.
Place a container under valve, then push key (or
choke button). Check for fuel flow from fitting.
Battery Voltage Indicated

Check for loose or corroded connection between
YELLOW/BLACK wire and black wire (under same screw at
terminal block).
Check that other BLACK wire at terminal block is properly
grounded.
Repair connection(s) as necessary, then push key (or choke
button) in. If enrichener valve DOES NOT click, replace valve.
No Voltage Indicated
Check for open in YELLOW/BLACK wire
between key switch (or choke button) and
terminal block.
Fuel Flow from Fitting

Valve is O.K. Check hoses and fittings from valve
to carburetors for leaks or obstructions.
No Fuel Flow from Fitting

Remove upper hose from fitting on enrichener valve. If
fuel flows from hose, replace valve. If not, check hose
and carburetor fitting for leaks or obstructions.
90-13645--2 495
3A-25
Acceleration Pump Circuit Operation Four Cylinder Engines

ACCELERATOR PUMP - Receives pressurized fuel
from T-fitting in fuel line between #1 and #2 carburetors. Pump is actuated by throttle cam. Pumps to two
check valve/injector nozzles in #3 and #4 cylinder
boost passages.
FUEL FILTER - 74 micron filter. Prevents debris from
plugging check valve/injector nozzles.
CHECK VALVE/INJECTOR NOZZLE - 2 assemblies,
one each for #3 and #4 cylinders. Fuel passes from
check valve thru .026 inch orifice (injector nozzle) and
into respective cylinder boost passage.
FLOW RESTRICTOR - Helps equalize pressure within the accelerator pump circuit while allowing air or
any vapor which has formed to pass through and be
vented at the carburetors.
FUEL CONNECTOR - Spring loaded shut off valve
which connects boat fuel tank with outboard fuel system.
IMPORTANT: The distance between the accelerator pump and the throttle cam determines the
amount of fuel the accelerator pump will discharge. If accelerator pump is moved or replaced,
refer to SECTION 2C for correct positioning of accelerator pump.
ACCELERATOR PUMP FUEL FLOW CIRCUIT
b
a
From T-Filtting between

#2 and #3 Carburetors
To #3 and #4 Cylinder Check

Valve/Injector Nozzles
To Fuel Pump
a
b
c
d
Accelerator Pump
Fuel Filter
Flow Restrictor
Fuel Connector
3A-26
90-13645--2 495
Acceleration Pump Fuel Flow Circuit

for Four Cylinder Engines
#1
CARB.
+5 .0 PSI
+4 .5 PSI
#2
CARB.
ACCELERATOR
PUMP
LARGE
FUEL
FILTER
+4.0 PSI
SMALL FUEL
FILTER
+5 .0 PSI
#3
CARB.
CYL. #3
FUEL
PUMP
CHECK VALVES
LOCATED IN
CYLINDER BLOCK
TRANSFER PORTS
(UNSEAT AT 1114 PSI
0 .5 PSI
#4
CARB.
+3 .5 PSI
CYL. #4
BRASS RESTRICTOR
(.014 I.D.) LOCATED
INSIDE FUEL LINE
FUEL
PRESSURE
DROP OCCURS
0 .4 PSI
FUEL
CONNECTORS
NOTE: Fuel pressure values are approximate.
90-13645--2 495
FUEL
TANK
3A-27
Fuel Tank
Fuel Tank Components
MAINTENANCE
l
m
The inside of the fuel tank should be cleaned once

each season. Dirt or water may have entered the fuel
tank during refilling. Clean the tank by flushing with
clean, lead-free gasoline or kerosene.
d
f
e
g
If a fuel restriction problem is encountered, the fuel

filter on end of outlet tube may be obstructed.
Remove cover and inspect filter for varnish, dirt or
deposits. Clean filter by rinsing in clean, lead-free
gasoline or kerosene.
c
b
j
k
b
c
51046
a
b
c
d
Fuel Tank Filter

Pick-Up Tube
Cover
Gasket
3A-28
abcdef ghi j kl m-
Fuel Tank Assembly (Plastic - 6.6 Gal.)

Filler Cap
Gasket, Filler Cap
Pick-Up Body Assembly
Adaptor
Window Assembly
Gasket, Pick-Up Body
Fuel Gauge Assembly
Screw, Fuel Gauge (2)
Hose
Filter
Screw, Pick-Up Body (6)
Washer, Pick-Up Body Screw (6)
90-13645--2 495
Fuel Line and Primer Bulb Assembly

f
h
i
j
k
n
g
i
a
abcdef ghi j kl mn-
Fuel Line Assembly

Primer Bulb Assembly
Check Valve, Inlet
Fittng, Outlet
Clamp, Primer Bulb to Check Valve (Large)
Clamp, Fuel Line to Check Valve (Small)
Connector, Fuel Tank (Outlet)
Connector, Engine (Inlet)
Clamp, Fuel Line to Connector
Bayonet Body Assembly (Fuel Tank End)
Stem, Bayonet Body
O-ring, Bayonet Body Stem
Spring, Bayonet Body Stem
Washer, Cupped - Body Spring
90-13645--2 495
3A-29
Maintenance
Periodically check fuel line and primer bulb for cracks,
breaks, restrictions or chafing. Check all fuel line connections for tightness. All fuel line connections must
be clamped securely.
2. To install fuel line clamps, grip hose clamp with

pliers and push down on hook with screwdriver
until hooks interlock.
Primer bulb assembly has 2 check valves: Fuel inlet

(toward tank) and a fuel outlet (toward engine).
The fuel inlet valve allows fuel to fill primer bulb but
closes to prevent fuel from returning to tank when
bulb is squeezed. The fuel outlet valve opens when
primer bulb is squeezed to allow fuel flow to carburetor, but closes as bulb is released to prevent fuel from
returning to primer bulb.
FUEL LINE CLAMP REMOVAL AND INSTALLATION
1. To remove fuel line clamps, grip clamp with pliers

and bend overlapping hook backwards.
51115
Installing Fuel Line Clamps
51115
Removing Fuel Line Clamps
3A-30
90-13645--2 495
OIL INJECTION
SYSTEM
3
B
Table Of Contents
Page
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose Connections . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump Drive System . . . . . . . . . . . . . . . . . . .
Filling Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carburetor/Oil Pump Synchronization . . . . . . .
Bleeding Air from Oil Injection System . . . . . .
Bleeding Air from Oil Pump Inlet Hose . . .
Bleeding Air from Oil Pump
Outlet Hose . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Oil Sensor Test . . . . . . . . . . . . . . . . . . . . . .
Warning Horn System . . . . . . . . . . . . . . . . . . . .
3B-1
3B-1
3B-1
3B-2
3B-2
3B-3
3B-3
3B-3
3B-3
3B-4
3B-4
Page
Models Equipped with Test Button

(3 Cylinder Only) . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . .
Warning Horn System Check . . . . . . . .
Models Not Equipped With Test Button
(3 and 4 Cylinder) . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . .
Warning Horn System
Wiring Diagram . . . . . . . . . . . . . . . .
Oil Injection System Troubleshooting Chart
(Models with Warning Module) . . . . . . . . . .
Troubleshooting the Oil
Injection System . . . . . . . . . . . . . . . . . . .
Troubleshooting Chart . . . . . . . . . . . . . . . . .
3B-4
3B-4
3B-4
3B-5
3B-5
3B-6
3B-7
3B-7
3B-7
90-13645--2 495
Description
Hose Connections
CAUTION
Be careful not to get dirt or other contamination in

tank, hoses or other components of the oil
injection system.
CAUTION
Engines with oil injection must be run on a fuel/oil
ratio of 50:1 in the fuel tank, in addition to the oil
supplied by the oil injection system, for the first 30
gallons of fuel. Refer to break-in procedure in the
Operation and Maintenance Manual.
a
a
CAUTION
If an electric fuel pump is to be used on engines
with oil injection, the fuel pressure at the engine
must not exceed 6 psig. If necessary, install a
pressure regulator between electric fuel pump
and engine and set at 6 psig maximum.
22511
a - Oil Hose Connections
Oil Pump Drive System
The major components of the oil injection system are

an oil tank, oil pump, and low oil warning system.
g
d
The oil tank is attached to the powerhead and holds

oil for delivery to the oil pump.
Oil is gravity fed to the oil pump via a hose.
The oil pump injects oil into the fuel at the fuel pump,
and is driven by the crankshaft.
A link rod is connected between the throttle linkage

and oil pump lever. When the throttle position is
changed, the link rod rotates the oil pump valve,
which changes the fuel/oil ratio from approximately
80:1 at idle speed, to 50:1 at wide-open-throttle.
f
b
c
The oil tank is equipped with a low oil sensor and a

magnetic float. When oil level in oil tank drops to
approximately 1 quart (.95 liter), the magnetized float
will complete the circuit between the low oil sensor
leads, causing the warning horn to sound.
IMPORTANT: Warning horn is also connected to
the powerhead temperature sensor. If the warning
horn sounds, either the oil level in oil tank is low,
or the powerhead is overheated.
A warning horn test button is located next to oil tank
fill cap. When ignition switch is in the Run position
and warning horn test button is depressed, the horn
should sound.
90-13645--2 1095
a
a
b
c
d
e
f
g
h
i
Crankshaft
Drive Key
Drive Gear
Apply Quicksilver 2-4-C w/Teflon on Both Areas
Driven Gear
O-Rings [.739 (18.77mm) I.D. x .809 (20.55mm) O.D.]
Spacer
Oil Pump
Bolts; Torque to 60 lb. in. (6.8 N.m)
OIL INJECTION SYSTEM
3B-1
Filling Oil Tank

1. Quicksilver 2-Cycle Outboard Oil is recommended for this oil injection system. In an emergency, when Quicksilver 2-Cycle Outboard Oil is
not available, substitute a high quality 2-cycle oil
that is intended for outboard use and meets BIA
rating TC-WII or TC-W3, shown on oil container.
BIA rating TC-W is the Boating Industry Associations designation for approved, 2-cycle watercooled outboard oils.
Carburetor/Oil Pump
Synchronization
body aligns with stamped mark of oil pump lever,
and lever is in closed position.
2. Check full travel of link rod that it does not interfere
with hoses, sta-straps, etc.
2. Remove fill cap from the oil tank and fill tank with
oil. Retighten the fill cap.
25955
a
b
a - Mark on Body
b - Mark, Fully Closed on Lever
c - Link Rod
a - Fill Cap
3B-2
90-13645--2 1095
Bleeding Air from Oil

Injection System
Oil Pump Test
IMPORTANT: If air exists in either oil pump hose

(inlet or outlet), the air MUST BE bled from the
hose(s) before operating engine.
Bleeding Air from Oil Pump Inlet Hose

1. With engine not running, place a shop towel below the oil pump. Loosen bleed screw three to four
turns and allow oil to flow from bleed hole until no
air bubbles are present in inlet hose. Torque bleed
screw to 25 lb. in. (2.8 Nm). This procedure also
allows oil pump to fill with oil.
NOTE: A graduated container is required to perform

this test.
1. Connect engine to remote fuel tank containing a
50:1 fuel/oil mixture (25:1 if during break-in
period).
2. Attach flush device to outboard or place outboard
in test tank.
3. Remove top cowling.
4. Disconnect oil outlet hose from fuel pump fitting.
5. Plug fuel pump fitting.
6. Remove link rod end from oil flow regulator.
7. Rotate oil pump regulator full counterclockwise
and hold it in this position, (wide-open pump position).
8. Attach an accurate service tachometer to engine.
9. Place end of hose into graduated container.
a
a
b
22988
a - Bleed Screw
b - Inlet Hose
Bleeding Air from

Oil Pump Outlet Hose
1. Purge air from outlet hose, by running engine at
idle speed, until no air bubbles are present in outlet hose.
c
d
a - Outlet Hose
b - Fuel Pump Fitting
22988
c - Link Rod End
d - Pump Regulator
10. Run engine at 700 RPM for 15 minutes.

11. 3 Cylinder:
pump # 42959/42959--1/42959--2 = 21 1.9cc
pump # 42959--3 = 25 2.3cc
4 Cylinder:
pump # 44345/44345--1/44345--2 = 28.6 2.6cc
pump # 44345--3 = 33.3 4cc
22988
NOTE: Pump output specifications are derived at 70

degrees room temperature. Cooler or warmer test
temperature will result in LESS oil pump discharge.
a - Outlet Hose
90-13645--2 1095
3B-3
Low Oil Sensor Test

NOTE: Low oil sensor is located in bottom of oil tank.
1. Disconnect low oil sensor leads (tan and black)
from terminal block.
2. Using an ohmmeter, perform both tests in chart,
following.
Oil Level in
Oil Tank
Test Leads
Between
Scale Reading
(x__________)
1/2 Full to Full
Low Oil Sensor Leads

(tan and black)
No Continuity*
(R x 1)
Empty
Low Oil Sensor Leads

(tan and black)
Continuity**
(R x 1)
* If continuity is indicated, check to see if float (located inside oil

tank) is stuck in place or if magnet (attached to bottom of float)
has come loose. If float checks O.K., replace sensor.
With the ignition switch in the Run position, electrical

current is routed thru the warning horn and supplied
to the powerhead temperature sensor, low oil sensor,
and warning horn test button. If the powerhead
overheats, the oil level in the oil tank drops below
approximately 1 quart (.95 liter), or the warning horn
test button is depressed, the electrical circuit
completed, and the warning horn will sound.
WARNING HORN SYSTEM CHECK
IMPORTANT: Warning horn will sound if powerhead is overheated or if oil level in oil tank has
dropped below approximately 1 quart (.95 liter).
1. Turn ignition key switch to Run position.
2. Depress test button. Warning horn will sound if
system is functioning properly.
3. Turn key switch to Off position.
** If continuity is NOT indicated, check to see if float (located

inside oil tank) is stuck in place. If float is NOT stuck in place,
replace sensor (bottom of oil tank remove screw and retract
sensor).
Warning Horn System

a
Models Equipped with Test Button

(3 Cylinder Only)
DESCRIPTION
Major components of the warning horn system are an

ignition switch, warning horn, low oil sensor,
powerhead temperature sensor, and warning horn
test button.
3B-4
25955
a - Test Button
90-13645--2 1095
Models Not Equipped With Test Button

(3 and 4 Cylinder)
DESCRIPTION
Self-test of the warning system is performed by

turning the ignition key to the RUN position. A
steady beep is indicative of an overheat condition. An
intermittent beep refers to a low oil condition. Both
overheat and low oil conditions are monitored by a
warning module mounted on the starboard side of the
engine block.
25939
a
a - Warning Module
a
c
b
h
f
51551
a - Powerhead Temperature Sensor
b - Warning Module
c - Terminal Block
90-13645--2 1095
d - Warning Horn
e - Ignition Switch
f - Engine Harness
g - Remote Control Harness

h - Low Oil Sensor
3B-5
WARNING HORN SYSTEM WIRING DIAGRAM
f
i
a
b
h
c
a
b
c
d
Ignition Switch
Powerhead Temperature Sensor
Battery
Wiring Harness Connectors
3B-6
e - Terminal Block
f - Warning Horn
g - Low Oil Sensor
h - Magnetic Float
i - Warning Horn Test Button (Some
Models)
90-13645--2 495
Oil Injection System

Troubleshooting Chart
(Models with Warning Module)
Troubleshooting the Oil Injection
System
If a problem occurs with the oil injection system and
the warning horn sounds in a pulsating manner, stop
engine and check if problem is caused by (1) low oil
level 1 quart remaining, (2) the oil injection pump,
or (3) a faulty warning module.
NOTE: There is a safety reserve of oil left in the reservoir after the low oil warning is sounded. There is
enough oil for approximately 50 minutes of full throttle
operation on four cylinder engines and approximately
1 hour of full throttle operation on three cylinder engines.
2. If there is more than 1 quart of oil in the reservoir,
then the problem may be in the oil injection pump.
DO NOT run engine on straight gas when a problem may be in the oil injection pump. Engine can
be run by connecting a remote fuel tank of 50:1
gas and oil mixture to engine.
1. Open the engine cowling and check oil level in engine reservoir. If oil level is approximately one
quart or less, the problem is low oil level. Add oil
to reservoir.
Troubleshooting Chart
PROBLEM: Warning horn does not sound when ignition key is turned to ON position.
POSSIBLE CAUSE
CORRECTIVE ACTION
Horn malfunction or open (TAN) wire between horn

and engine
Disconnect tan lead from main engine wiring harness

at terminal block on engine. Ground this tan lead to engine ground. Warning horn should sound. If not, check
tan wire between horn and engine for open circuit and
check horn.
Warning Module
Check if all warning module leads are connected to

harness leads. If so, warning module may be faulty.
Using incorrect side mount remote control or ignition/

choke assembly.
Refer to Quicksilver Accessory Guide for correct components
PROBLEM: Warning horn stays on when ignition key is turned to ON position.

POSSIBLE CAUSE
CORRECTIVE ACTION
Engine overheat sensor
If horn sounds a continuous beep, the engine overheat sensor may be faulty. Disconnect overheat sensor (BLACK Wire) and turn ignition key to ON position. If horn still sounds a continuous beep, the warning module is faulty. Replace module and retest. If
beep does not sound, then engine overheat sensor
is faulty. Replace and retest.
Warning Module
If horn continues to sound on intermittent beep, the

warning module is faulty or oil level is too low.
PROBLEM: Warning horn sounds when engine is running. Oil level in engine reservoir is full.
POSSIBLE CAUSE
Defective low oil sensor
Drive system of oil injection pump

Warning Module
90-13645--2 495
CORRECTIVE ACTION
Disconnect both low oil sensor leads (LIGHT BLUE)

from bullet connectors. Connect an ohmmeter between leads. There should be no continuity through
sensor. If continuity exists, sensor is faulty.
Refer to page 3B-3, Oil Pump Test to determine if oil
pump is operating properly.
Replace warning module.
3B-7
POWERHEAD
4
A
20032
3-CYLINDER ENGINES
Table Of Contents
Page
Throttle Lever And Linkage Wave Washer

Removal - Models 70-75-80-90-100 . . . . .
Crankshaft Assembly . . . . . . . . . . . . . . . . . . . . .
Powerhead Block and Cover Assemblies . . . .
Torque Specifications, Torque Sequences . . .
Tools for Powerhead Repair . . . . . . . . . . . . . . .
Sealants/Loctitesr Needed . . . . . . . . . .
General Information . . . . . . . . . . . . . . . . . . . . . .
Disassembly and Reassembly . . . . . . .
Powerhead Component Removal . . . . . . . . . .
Flywheel Removal . . . . . . . . . . . . . . . . . . . .
Powerhead Disassembly . . . . . . . . . . . . . . . . . .
Cleaning and Inspection . . . . . . . . . . . . . . . . . . .
Cylinder Block and Crankcase Cover . . . .
Honing Procedure . . . . . . . . . . . . . . . . .
Check Valves . . . . . . . . . . . . . . . . . . . . . . . . .
Design I
(Models with Check Valve Only) . .
Design 2 (Models with Check
Valve and Restrictor) . . . . . . . . . . . .
Bleed Check Valve/Restrictor Kit
(22-814204A1) . . . . . . . . . . . . . . . . .
Design 3 (Models with Check Valve
and Carrier) . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . .
Piston and Piston Rings . . . . . . . . . . . . . . .
Cleaning Piston Ring Grooves . . . . . . .
Measuring Piston Skirt . . . . . . . . . . . . .
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Rods . . . . . . . . . . . . . . . . . . . . .
4A-1
4A-2
4A-4
4A-6
4A-9
4A-9
4A-9
4A-9
4A-9
4A-11
4A-13
4A-17
4A-17
4A-18
4A-19
4A-19
4A-19
4A-19
4A-20
4A-20
4A-20
4A-21
4A-21
4A-22
4A-22
4A-23
Page
Cylinder Cover, Exhaust Divider Plate

and Exhaust Cover . . . . . . . . . . . . . . . . . . . .
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reed Blocks . . . . . . . . . . . . . . . . . . . . . . . . .
Backside - Reed Block Assembled . . .
Powerhead Reassembly and Installation . . . .
General Information . . . . . . . . . . . . . . . . . . .
End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Design 1 - Bottom Guided . . . . . . . . . .
Design 2 - Top Guided . . . . . . . . . . . . . .
Assembling Rod to Piston . . . . . . . . . . . . . .
Piston Ring Installation . . . . . . . . . . . . . . . .
Crankshaft Installation . . . . . . . . . . . . . . . . .
Installing Rods to crankshaft . . . . . . . .
Connecting Rod Cap Alignment . . . . . . . . .
Crankcase Cover to Block . . . . . . . . . . . . . .
Reattach Crankcase Cover . . . . . . . . .
Cylinder Block Cover . . . . . . . . . . . . . . . . . .
Cylinder Head Cover
Torque Sequence . . . . . . . . . . . . . .
Exhaust Plate Cover and Exhaust
Divider Plate . . . . . . . . . . . . . . . . . . . . . .
Exhaust Plate Cover Torque
Sequence . . . . . . . . . . . . . . . . . . . . .
Powerhead to Driveshaft Housing . . . . . . .
Reinstall Wiring Harness and
Components as a Unit . . . . . . . . . .
Electrical Components Installed . . . . .
Flywheel Installation . . . . . . . . . . . . . . . . . . .
Intake Manifold - Torque Sequence . .
Attach Rear Cowl Mounting Bracket . .
Attach Front Cowl Mounting Bracket .
4A-23
4A-24
4A-24
4A-24
4A-25
4A-25
4A-25
4A-26
4A-26
4A-27
4A-28
4A-29
4A-31
4A-32
4A-32
4A-33
4A-33
4A-34
4A-34
4A-34
4A-35
4A-36
4A-36
4A-37
4A-37
4A-38
4A-39
90-13645--2 495
c
e
d
c
b
f
e
d
a
b
c
d
e
Drive Gear
Adapter Assembly
O-rings
Oil Pump Assembly
Sta-Straps
a
m
Oil Pump Assembly
i
i
h
j
k
h
Remove
k
m
c
d
l
po n
a
q
t
s
a
b
c
d
e
f
g
h
i
j
Spark Advance Lever

Throttle Control Lever
Torsion Spring
Washer
Flanged Bushing
Nut
Wave Washer (Remove)
Swivel Bushings (2)
Nylon Caps (2)
Swivel Base
kl mnopqr st -
Spark Advance Rod

Stud
Link Arm
Swivel Bushing
Locknut
Washer
Throttle Cam
Return Spring
Stud
Wave Washer (Remove)
Control Arm Lever Assembly
90-13645--2 495
Remove
abcdef ghi j kl m-
Oil Tank
Oil Cap Assembly
Oil Tank Neck Bracket
Swivel Base
Swivel Bushing
Oil Tank Neck Boot
Oil Tank Base Boot
Oil Tank Base
Grommet
Bolt --[Torque to 160 lb. in. (18.1 Nm)]
Sta-Straps
Switch Assembly (Without Warning Module)
Switch Cover
Oil Tank Assembly

THROTTLE LEVER AND LINKAGE WAVE
WASHER REMOVAL - MODELS 70-75-80-90-100
When servicing 3 cylinder model 70-75-80-90 and 4
cylinder 100/115 HP outboards for any reason, remove
the wave washers from the swivel bushings. Removal
of the wave washers will prevent the swivels from
breaking during removal/installation. Future production
outboards will have the wave washers removed.
POWERHEAD
4A-1
Crankshaft Assembly
14
28
27
95
95
12
26
8
95
7
95
10
9
4
11
95
95
8
12
13
95
29
17
18
19
14
20
14
15
16
21
22
23
24
25
95
Application Points
4A-2
95
2-4-C With Teflon (92-825407A12)
14
2 Cycle Outboard Oil (92-13249A24)
95
POWERHEAD
90-13645--2 495
Crankshaft Assembly (Continued)

TORQUE
REF. NO.
QUAN.
DESCRIPTION
Crankshaft
Upper Main Bearing
O-Ring Seal
Key-Flywheel
Connecting Rod
Connecting Rod Cap
29
Piston Pin Needle Bearings
Needle Bearing Locating Rings
Piston
10
Piston Rings - 2 Each
11
Piston Pin
12
Piston Pin Retainer Rings - 2 Each
13
Rod Bearing Assembly
14
Center Main Bearings - (32 Each Main)
15
Retaining Ring - Center Mains
16
Bearing Race - (1 Set Each)
17
18
Crankshaft Sealing Rings, Metal

(2 Each Main)
Key-Gear
19
Gear
20
Lower Main Ball Bearing
21
Retaining Ring (If Equipped)
22
Seal Carrier Assembly
23
Crankshaft Seal
24
Wear - Sleeve
25
O-Ring Crankshaft Seal
26
Upper Main Bearing Seal
27
Flat Washer
28
Flywheel Nut
29
Rod Bolt
90-13645--2 395
lb. in.
lb. ft.
Nm
120
162.7
Apply Light Oil to

Threads and Bolt Face:
1st Torque - 15 lb. in. (1.7
Nm) Check Alignment
2nd Torque - 30 lb. ft.
(40.7 Nm)
Turn Bolt an Additional
90 after 2nd Torque is
Attained
POWERHEAD
4A-3
Powerhead Block and Cover Assemblies

5
6
7
4
10
3
11
1
9
12
14
17
95
13
75
15
95
95
16
Application Points
19
4A-4
95
2-4-C With Teflon (92-825407A12)
75
Loctite Master Gasket (92-12564-1)
19
Perfect Seal (92-34227-1)
POWERHEAD
90-13645--2 495
Powerhead Block and Cover Assemblies (Continued)

TORQUE
REF. NO.
QUAN.
DESCRIPTION
Cylinder Block
Exhaust Plate Cover
Exhaust Divider Plate
Exhaust Plate Gaskets
Thermostat/Poppet Valve Cover
Thermostat/Poppet Valve Cover Gasket
Thermostat
Poppet Valve Assembly
Temperature Sensor
10
Cylinder Cover
11
Cylinder Cover Gasket
12
Starter Hold-Down Brackets
13
Gasket--Powerhead to Driveshaft Housing
14
Shift Rail
15
Crankcase Cover
16
Crankcase End Cap (Lower)
17
Check Valves
90-13645--2 395
POWERHEAD
lb. in.
lb. ft.
Nm
4A-5
Torque Specifications, Torque Sequences

Flywheel Nut
120 lb. ft. (162.7 Nm)
Reed Block Assembly

80 lb. in. (9.0 Nm)
Connecting Rod Bolts

30 lb. ft. (40.7 Nm)
Check Alignment
Turn bolt 90 further after torque of
30 lb. ft. is reached
IMPORTANT: See page 4A-32
(this Section)
Intake Manifolds
18 lb. ft. (24.4 Nm)
(Each Manifold)
Stator Screws
60 lb. in. (6.8 Nm)
Add Loctite 271
to Threads Unless Patch
Screw is Used.
Spark Plugs
20 lb. ft. (27.1 Nm)
Starter Motor Hold-Down Bolts

14.5 lb. ft. (19.7 Nm)
Crankcase Cover Bolts

1st Torque Pattern (Large Bolts) = 25 lb. ft. (33.9 Nm)
2nd Torque Pattern (Small Bolts) = 18 lb. ft. (24.4 Nm)
3 Step Torque on Each Pattern
Crankcase End Cap Bolts (Lower)

18 lb. ft. (24.4 Nm)
Torque All Large Bolts First - Then Torque All Small Bolts.
4A-6
POWERHEAD
90-13645--2 495
Cylinder Block Cover

18 lb. ft. (24.4 Nm)
Electrical Component Plate

13.5 lb. ft. (18.3 Nm)
Loctite 271 Required.
Exhaust Cover (and Divider Plate)

18 lb. ft. (24.4 Nm)
We recommend that you read the sub-section on reassembly BEFORE proceeding. There are specifics
relating to this engine which are NOT applicable to prior engines.
90-13645--2 495
POWERHEAD
4A-7
TORQUE SPECIFICATIONS
Application (Listed in Reassembly Sequence)
Rod Cap Bolts
1st Torque
2nd Torque (after checking alignment)
Torque
15 lb. in. (1.7 Nm)
30 lb. ft. (40.7 Nm)
Recheck Alignment
NOTE: See page 4A-32
Crankcase End Cap Bolts (Lower)
18 lb. ft. (24.4 Nm)
Crankcase Cover
25 lb. ft. (33.9 Nm)

18 lb. ft. (24.4 Nm)
1st Torque Pattern (Large Bolts)

2nd Torque Pattern (Small Bolts)
18 lb. ft. (24.4 Nm)
Exhaust Cover (and Divider Plate) Bolts
18 lb. ft. (24.4 Nm)
Oil Injection Pump Bolts (or Plate Cover)
60 lb. in. (6.8 Nm)
Fuel Pump Screws
40 lb. in. (4.5 Nm)
Electrical Component Mounting Plate Bolts - Loctite 271 used

Stator Screws (Loctite 271 used unless Patch Screw used)
13.5 lb. ft. (18.3 Nm)

60 lb. in. (6.8 Nm)
Starter Motor Hold-Down Bolts
14.5 lb. ft. (19.7 Nm)
Flywheel
120 lb. ft. (162.7 Nm)
Intake Manifolds
18 lb. ft. (24.4 Nm)
Air Box Plate
100 lb. in. (11.3 Nm)
Cowl Mounting Bracket
150 lb. in. (16.9 Nm)
Powerhead to Driveshaft Housing
44 lb. ft. (59.7 Nm)

OTHER
Spark Plugs
20 lb. ft. (27.1 Nm)
Screw in Poppet Valve
No torque requirement tighten securely
Shift Rail Bolts
4A-8
150 lb. in. (16.9 Nm)
POWERHEAD
90-13645--2 495
Tools for Powerhead Repair

Part No.
Tool Description
91-52344
Flywheel Holder
91-24161
Protector Cap
91-73687A1
Flywheel Puller
91-90455
Lifting Eye
91-24697
Piston Ring Expander
91-74607A1
Piston Pin Tool
91-77109A1
Locking Installation Tool
91-812549
Powerhead Stand
Powerhead Component
Removal
1. Remove Front Cowl Bracket before removing
air box cover, by removing 2 bolts, cable retainer,
and fuel connector. Bushings normally remain in
brackets. Cowl and bracket seals/bushings stay
attached to respective locations. If seal replacement is necessary, remove old seals at time of replacement.
SEALANTS/LOCTITES NEEDED
Master Gasket Sealant Kit
Quicksilver No. 92-12564 1 (Loctite Kit)
Quicksilver Perfect Seal No. 4 (92-34227-1)
General Information
DISASSEMBLY AND REASSEMBLY
If complete disassembly is not necessary, start at
appropriate spot; start reassembly at point
disassembly stopped.
If major powerhead repairs are being done, remove
powerhead from lower unit. It is not necessary to
remove powerhead for:
a. Visual check for scoring or broken rings
(cylinder walls and pistons), by viewing through
exhaust ports.
b
a
a - Bolts
b - Cable Retainer
c - Fuel Connector
d - Bushings
2. Remove Air Box Cover by removing 8 screws.
b. Minor external repair (i.e. - ignition system, carburetors, reed blocks, thermostat checks, etc.).
20335
90-13645--2 495
POWERHEAD
4A-9
3. Remove 10mm bolt from lower oil tank support

(starboard side of engine, base).
4. Remove 2 (8mm) Bolts from upper oil tank neck
brace.
5. Remove Air Box by removing 6 nuts and pulling
off of carburetor studs.
6. Disconnect Oil Lines - Remove Oil Reservoir.
c
c
a
1-unit Removal Of Carburetor Assembly.

19546
10. Remove Intake Manifolds - see below.
19097
a - Oil Tank Support
b - Bolts (8mm)
c - Nuts (6)
7. Disconnect Throttle Linkage (c).

8. Remove main fuel hose (a), and fuel hose (b). Lift
carburetors off as 1-unit assembly (see next column).
a
b
c
19547
19093
a - Main Fuel Hose
b - Fuel Enrichment Hose
a - Intake Manifolds
c - Throttle Linkage
9. Remove Flywheel Cover by removing 3 wing

nuts.
4A-10
POWERHEAD
90-13645--2 495
11. The intake manifolds may be removed as 1-unit.
Flywheel Removal
CAUTION
DO NOT strike end of puller center bolt to remove
flywheel, or damage may result to crankshaft or
bearings.
1. Remove flywheel cover from powerhead.
2. While holding flywheel with Flywheel Holder
(91-52344), remove flywheel nut and washer.
19330
20344
12. Pry off each Reed-Block, as shown, using screwdriver.
CAUTION
Crankshaft damage may result if a protector cap
is not used between crankshaft and puller.
3. Install a crankshaft Protector Cap (91-24161) on
end of crankshaft, then install Flywheel Puller
(91-73687A1) into flywheel.
4. Install crankshaft Protector Cap (91-24161) on
the end of crankshaft, then install Flywheel Puller
(a) (91-73687A1) into flywheel (b).
NOTE: Neither heat nor hammer should be used on

flywheel to aid in removal as damage to flywheel or
electrical components under flywheel may result.
5. Remove flywheel.
b
19549
51124
90-13645--2 495
POWERHEAD
4A-11
6. Remove Rear Cowl Mounting Bracket from powerhead by removing 4 bolts.
8. Remove shift arm linkage at stud.
7. Remove Ignition Components, from powerhead,

including starter motor
S Stator Plate and Trigger
S Starter Motor
S Electrical Components Mounting Plate

S Plug Wires
S Temperature Sensor
S Solenoid
NOTE: Removal of wiring harness and components,

as a unit, is advisable to simplify reassembly.
19060
a - Shift Arm Linkage

b - Stud
9. Remove 8 bolts (3 each side, 2 backside) which

secure powerhead to driveshaft housing.
19070
20368
a - Bolts
10. nstall Lifting Eye (91-90455) onto flywheel.

Thread on at least 5 full turns.
11. Twist powerhead or move back and forth to break
gasket between powerhead and exhaust plate.
(Disconnect cable to Power Trim [3 wires])

Temporarily install flywheel with nut as shown.
12. Using a hoist, lift powerhead assembly from driveshaft housing.
20031
13. Place powerhead on bench.

20346
4A-12
POWERHEAD
90-13645--2 495
5. Remove thermostat housing and components.
Powerhead Disassembly
1. Remove fuel pump by removing 2 screws.
2. Remove oil injection pump by removing 2 bolts.

3. Remove hoses to fuel pump and oil injection
pump.
a
a
d
25907
a
b
c
d
Bolts
Thermostat Cover
Thermostat
Poppet Valve
6. Remove cylinder block cover.
b
19056
a - Screws
b - Bolts
4. Remove oil injection pump shaft and housing.
20039
NOTE: There are pry-slots on casting as shown by

screwdriver positions.
20041
7. Remove exhaust cover and divider plate.
20029
90-13645--2 495
POWERHEAD
4A-13
8. Remove 3 bolts from crankcase end cap (lower).
19314
13. Remove main roller bearing assemblies (2) from

crankshaft as follows;
S Remove retaining ring.
20020
S Remove race.
S Remove main roller bearings.
a - Bolts
b - End Cap
9. Remove crankcase bolts, and cover.
a
a
20032
10. Remove crankcase endcap (lower).
11. Remove oil seal and O-ring seal.
c
27649
a - Retaining Ring
b - Race
c - Main Roller Bearings
14. Remove 2 bolts, each rod cap, using a 3/8, 12

point socket.
a
20342
20341
a - Oil Seal
b - O-Ring
Some models may have a wear sleeve with an O-ring

seal. See page 4A-16.
12. Crankshaft may be removed as an assembly, or
by component parts.
IMPORTANT: If removed by components, rod
caps MUST be reassembled on the same rod - in
the dame direction. (Each mating surface is
slightly different), so rebolt cap to rod immediately, or mark rods and caps.
4A-14
IMPORTANT: Before disassembly, use a carbidetip scriber to mark caps and rods, to return pistons to proper cylinder.
15. Remove piston assembly from crankshaft; reattach caps to respective rods, as each is removed.
CAPS MUST BE INSTALLED IN SAME DIRECTION ON SAME ROD, or mating surfaces will not
seat properly.
19328
a - Bolts
POWERHEAD
90-13645--2 495
IMPORTANT: On some engines, BOTH the piston

rod and rod cap bolt holes are threaded. The rod
cap and rod must be aligned and held tight together when threading in rod cap bolts. Check mating
surfaces to be sure that they are tight together after bolt enters the threads in the piston rod.
18. Use piston ring expander (91-24697) to remove

piston rings. Always install new piston rings.
NOTE: Cylinders must be honed in order for new rings

to seat properly.
16. Remove main bearing sealing rings - 2 per center

main journal.
b
51081
a - Piston Ring Expander (P/N 91-24697)
b - Piston Rings
CAUTION
Eye protection MUST BE worn while removing
piston pin lockrings from piston.
51083
17. Using an awl, scribe identification number of connecting rod on inside of piston. Reassemble piston on same connecting rod.
19. Using an awl, remove piston pin lockrings (a) from

both ends of piston pin. Never re-use piston pin
lockpins. Hold shop cloth over lockring area when
snapping out lockrings.
a
a
51083
17770
20. Support piston and tap out piston pin (a), using
service tool (b) 91-74607A2, as shown.
a - Scribe Mark
51086
a - Piston Pin
b - Wrist Pin Tool (91-74607A2)
90-13645--2 495
POWERHEAD
4A-15
21. Remove piston pin needle bearings (29 per piston

pin) and locating washers ( 2 per piston) as
shown.
23. Press crankshaft out of bearing, as shown.
IMPORTANT: We recommend that you use new

needle bearings at reassembly for lasting repair.
However, if needle bearings must be re-used,
keep each set of bearings identified for reassembly on same connecting rod.
51088
a - Locating Washers
22. Inspect crankshaft bearing.

Only if removal is necessary, remove retaining ring ,
using a pair of snap-ring pliers.
20340
24. If oil pump drive gear replacement is necessary,

remove gear after pressing off main bearing
(slides-off shaft). Lower crankshaft seal carrier.
a
b
20037
a - Crankshaft Bearing
b - Retaining Ring
NOTE: There is NO main bearing retaining ring or retaining ring groove in the crankshaft on the following
outboards:
75/90--SERIAL NUMBER OC259434 and above.
a
51084
a - Oil Drive Gear
b - Key
4A-16
POWERHEAD
90-13645--2 495
Seal carrier is press-fitted into the spline end of crankshaft.
Cleaning and Inspection
NOTE: Seal should be replaced as a routine procedure without regard to appearance, to prevent water
leakage into crankshaft/driveshaft splines.
Cylinder Block and Crankcase Cover
1. Remove seal by prying out of carrier, using an awl.

2. Inspect seal carrier for damage or looseness.
IMPORTANT: Crankcase cover and cylinder block

are a matched, line-bored assembly and never
should be mismatched by using a different crankcase cover or cylinder block.
3. If replacement of carrier is necessary, use a pliers

to pull carrier from crankshaft, or tap gently off with
screwdriver and mallet.
a
b
20037
a - Seal Carrier
b - Seal
- OR Some models may be equipped with the following

sleeve (b), which retains an O-ring seal (c). The sleeve
is pushed over the crankshaft end until it bottoms-out
on a crank flange, leaving space for the O-ring between
the sleeve lip and the end of the crankshaft. Pop out the
O-ring with an awl - replace the O-ring seal.
IMPORTANT: The End Cap (lower) inside seal
rides on the wear sleeve (area a). If the outer
surface of the sleeve (in area a) is grooved or
corroded/pitted, replace by pulling off the sleeve
with pliers--it may be necessary to heat the sleeve
to release the Loctite sealant. Replace O-ring
AFTER wear-sleeve is installed on crankshaft.
To install the sleeve, apply Loctite 271 to the crankshaft; align sleeve squarely with crankshaft, place a
block of wood over end of sleeve, and tap lightly until
it bottoms-out. Wipe off excess sealant. The sleeve is
lightweight (31-gauge) stainless steel - DO NOT collapse the end contour or otherwise distort its shape.
Align squarely - Tap gently!
1. Inspect cylinder block and crankcase cover for

cracks or fractures.
2. Check gasket surfaces for nicks, deep grooves,
cracks and distortions that could cause compression leakages.
3. Check that all water passages in cylinder block
are not obstructed. Check locating pins in cylinder
block that they are tight.
4. Check crankcase cover fuel/bleed passages that
they are not obstructed. Verify that check valves
in crankcase cover are not damaged.
5. Thoroughly clean cylinder block and crankcase
cover. Verify that all sealant and old gaskets are
removed from matching surfaces. Clean all carbon deposits from exhaust ports.
6. Inspect spark plug holes for stripped or damaged
threads.
b
a
c
90-13645--2 495
CAUTION
If crankcase cover and cylinder block is to be
submerged in a very strong cleaning solution, it
will be necessary to remove the crankcase cover/
cylinder block bleed system from cover/cylinder
block to prevent damage to hoses and check
valves.
POWERHEAD
4A-17
CYLINDER BORE SIZE

Piston Size
Cylinder Block
Finish Hone
Standard Diameter
3.375 in.
(85.725mm)
.015 Oversize
3.390 in.
(86.106mm)
.030 Oversize
S Measure cylinder bore inside diameter (with an inside micrometer) of each cylinder, as shown below. Check for tapered, out-of-round (eggshaped) and oversize bore.
TOP
3.405 in.
(86.487mm)
S Inspect cylinder bores for scoring (a transfer of

aluminum from piston to cylinder wall). Cylinder
wall scoring usually can be cleaned up by honing
or reboring.
CENTER
CAUTION
When reboring cylinder block, remove hone
frequently and check condition of cylinder walls.
DO NOT hone any more than absolutely
necessary, as hone can remove cylinder wall
material rapidly.
HONING PROCEDURE
Follow hone manufacturers recommendations for
use of hone cleaning and lubrication during honing.
IMPORTANT: After honing, bores should be thoroughly cleaned with hot water and detergent.
Scrub well with stiff bristle brush and rinse with
hot water. If any abrasive material is allowed to remain in the cylinder bore, it will cause a rapid wear
of new piston rings and cylinder bore. After cleaning, bores should be swabbed several times with
2 cycle engine oil and a clean cloth. Wipe excess
oil with clean, dry cloth. Cylinders should not be
cleaned with kerosene or gasoline. Clean remainder of cylinder block.
S Hone all cylinder walls just enough to de-glaze.
4A-18
BOTTOM
S If a cylinder bore is tapered, out-of-round or worn

more than 0.003 in. (0.076mm) from standard
Cylinder Block Finish Hone diameter (refer to
chart), it will be necessary to rebore that cylinder(s)
to designated oversize bore and install oversize
piston(s) and piston rings during reassembly.
NOTE: The weight of an oversize piston is approximately the same as a standard size piston; therefore,
it is not necessary to rebore all cylinders in a block just
because one cylinder requires reboring.
IMPORTANT: Ports must be deburred after honing.
S After honing and thoroughly cleaning cylinder
bores, apply 2 cycle outboard oil to cylinder walls
to prevent rusting.
POWERHEAD
90-13645--2 495
Check Valves
DESIGN I (MODELS WITH CHECK VALVE ONLY)
Located in crankcase cover under center main
bearings.
These can be damaged by hot combustion blow-by
into crankcase.
To Check: Look through hole - if you see light, the nylon ball is bad - probably melted; REPLACE valve. If
you see no light, insert fine wire into check valve hole
to see if there is slight movement of the nylon ball; if
ball moves, valve is o.k. otherwise, replace check
valve.
This kit is for use in three cylinder 71 cubic inch 70, 75,
80 and 90 horsepower models and four cylinder 105
cubic inch 100 and 115 horsepower models.
NOTE: Three cylinder and four cylinder outboards

with starting serial number OC123214 and above
have these kits installed from factory.
Installation Instructions:
1. Referring to appropriate service manual, remove
powerhead from driveshaft housing.
2. Remove all assemblies as required to obtain access to crankcase cover.
3. Remove crankcase cover from cylinder block.
4. Using a 5/32 (3.9mm) punch, carefully tap bleed
check valves out of crankcase cover. (Tap check
valve towards crankshaft side of crankcase
cover.)
a - Check-Valve Body
b - Nylon Ball
c - Ball Retainer
IMPORTANT: If it is determined that the check

valves must be replaced or that restrictors are not
installed with the check valves, it is recommended that the Bleed Check Valve/Restrictor Kit
(22-814204A1) be installed.
DESIGN 2 (MODELS WITH CHECK VALVE AND
RESTRICTOR)
BLEED CHECK VALVE/RESTRICTOR KIT
(22-814204A1)
COMPONENTS CONTAINED IN KIT:
25703
a - Crankcase Cover
b - Bleed Check Valve
c - Punch (5/32- 3.9mm)
NOTE: Three cylinder models will require TWO bleed

check valves and TWO restrictors. Four cylinder models will require THREE bleed check valves and
THREE restrictors.
5. With FUNNEL SHAPE side of restrictor facing
crankshaft side of crankcase cover, carefully tap
restrictor into crankcase cover until seated.
a
a - Bleed Check Valve (3 Each)
b - Restrictor (3 Each)
90-13645--2 495
25704
6. With ONE HOLE side of bleed check valve facing

crankshaft, carefully tap check valve into crankcase cover until seated against restrictor. BE
CAREFUL NOT TO OVERSEAT CHECK VALVE
as check valve case may distort and valve will not
function properly.
POWERHEAD
4A-19
3. Push check valve out of carrier. If nylon ball within

check valve is stuck or carrier is charred, replace
check valve and/or carrier as required.
IMPORTANT: SINGLE HOLE side of check valve

MUST FACE CRANKCASE.
c
b
a
a
b
c
d
Crankcase Cover
Check Valve Assembly P/N 21-42657A1
Valve Restrictor P/N 22-814204
Install From Crankshaft Side
Check Valve/Restrictor Assembly

7. Verify check balls are free to move in check valve
case after installation. If check balls are not loose,
check valve case was damaged during installation and MUST BE replaced.
51131
a - Check Valve
b - Carrier
c - Single Hole
d - Double Hole
8. Reassemble powerhead per appropriate service

manual instructions and reinstall on driveshaft
housing.
INSTALLATION
DESIGN 3 (MODELS WITH CHECK VALVE AND

CARRIER)
2. Align carrier tab with slot in crankcase cover and

insert check valve/carrier assembly into cover.
1. Install check valve (if removed) inside of carrier

(single hole of valve faces tapered end of carrier).
NOTE: DESIGN 3 check valves may be replaced

without splitting crankcase halves.
REMOVAL
1. Remove carburetors and intake manifold/reed
block assemblies. Refer to page 4A-10/11 for
procedure.
2. Grasp carrier and remove carrier/check valve assembly from crankcase cover.
a
b
51621
a - Check Valve/Carrier Assembly
b - Slot
c - Crankcase Cover
51621
a - Carrier/Check Valve Assembly
4A-20
POWERHEAD
90-13645--2 495
3. Clean mating surfaces of crankcase cover and

intake manifold. Install new gaskets.
4. Install intake manifold/reed block assemblies to
crankcase cover. Refer to PAGE 4A-6 for torque
specification and tightening sequence.
CLEANING PISTON RING GROOVES

IMPORTANT: The piston rings are half-keystone
rings (tapered on the top side) - follow cleaning
and inspection carefully! Chromed ring is
installed on top.
5. Install carburetors. Torque carburetor (AIR BOX)

stud nuts to 100 lb. in. (11.3 Nm).
6. Carburetors MUST BE SYNCHRONIZED. Refer
to SECTION 2C for proper procedures.
7. Reinstall air box cover.
8. Reinstall top cowling.
Piston and Piston Rings
Enlarged View of
Piston Ring Grooves
IMPORTANT: If engine was submerged while

engine was running, piston pin and connecting
rod may be bent. If piston pin is bent, piston must
be replaced. Piston pins are not sold separately
because of matched fit into piston. If piston pin is
bent, connecting rod must be checked for
straightness (refer to Connecting Rods for
checking straightness).
S Inspect piston for scoring and excessive piston
skirt wear.
S Check tightness of piston ring locating pins.
Locating pins must be tight.
S Thoroughly clean pistons. Carefully remove
carbon deposits, with a soft wire brush or carbon
remover solution. DO NOT burr or round off
machined edges.
CAUTION
Care must be taken not to scratch the side
surfaces of ring groove. Scratching the side
surfaces of the ring groove will cause damage to
the ring groove.
S Inspect piston grooves for wear and carbon

accumulation. If necessary, scrape carbon from
piston ring grooves being careful not to scratch
sides of grooves. Refer to procedure for cleaning
piston ring grooves.
90-13645--2 495
POWERHEAD
4A-21
S Use a bristle brush and carbon remover solution to

remove carbon from side surfaces.
S A tool can be made for cleaning the inner diameter
of the tapered ring grooves. The tool can be made
from a broken tapered piston ring with the side taper removed to enable inside edge of the ring to
reach the inside diameter of the groove. Carefully
scrape the carbon from inner diameter of ring
grooves. Care must be taken not to damage the
grooves by scratching the surfaces of the grooves.
MEASURING PISTON SKIRT
Measure piston skirt at right angle (90_) to piston pin
centerline, 0.50 in. (12.7mm) up from bottom edge of
skirt.
Crankshaft
S Inspect crankshaft to drive shaft splines for wear.
(Replace crankshaft, if necessary.)
S Check crankshaft for straightness. Total maximum
runout for crankshaft is 0.006 (0.152mm). Replace
as necessary.
S Inspect crankshaft oil seal surfaces. Sealing surfaces must not be grooved, pitted or scratched.
(Replace as necessary.)
S Check all crankshaft bearing surfaces for rust, water marks, chatter marks, uneven wear and/or
overheating. (Refer to Connecting Rods.)
S If necessary, clean crankshaft surfaces with crocus cloth as shown.
.50 in.
(12.7mm)
PISTON
SIZE
PISTON SKIRT
DIAMETER
CYLINDER BORE
FINISH HONE
Standard
Piston
3.371 in.
(85.623mm)
3.375 in.
(85.725mm)
3.386 in.
(86.004mm)
3.390 in.
(86.106mm)
3.401 in.
(86.385mm)
3.405 in.
(86.487mm)
0.015 in.
(0.381mm)
Oversize
0.030 in.
(0.752mm)
Oversize
51089
S Thoroughly clean (with solvent) and dry crankshaft

and crankshaft ball bearings. Recheck surfaces of
crankshaft. Replace crankshaft if surfaces cannot
be properly cleaned up. If crankshaft will be reused, lubricate surfaces of crankshaft with light oil
to prevent rust. DO NOT lubricate crankshaft ball
bearings at this time.
WARNING
DO NOT spin-dry crankshaft ball bearing with
compressed air.
4A-22
POWERHEAD
90-13645--2 495
Connecting Rods
If necessary, clean connecting rod surfaces as follows:
S Attach end caps to connecting rods. Following
these directions, tighten rod cap attaching bolts to
specifications. Recheck alignment. Refer to
4A-32.
Cylinder Cover, Exhaust Divider Plate

and Exhaust Cover
S Thoroughly clean cylinder cover and gasket
surfaces.
S Inspect cylinder cover. Check for cracks which
could cause water leakage.
S Replace cylinder cover as necessary.
S Thoroughly clean gasket surfaces of exhaust divider plate and exhaust manifold cover.
CAUTION
Crocus cloth MUST BE USED to clean bearing
surface at crankshaft end of connecting rod. DO
NOT use any other type of abrasive cloth.
S Clean crankshaft end of connecting rod by using
crocus cloth placed in a slotted 3/8 in. (9.5mm) diameter shaft, as shown. Insert shaft in a drill press
and operate press at full speed while keeping connecting rod at a 90_ angle to slotted shaft.
S Inspect exhaust divider plate and exhaust

manifold cover for grooves, cracks or distortion
that could cause leakage. Replace parts as
necessary.
IMPORTANT: Clean connecting rod just enough to

clean bearing surfaces. DO NOT continue to clean
after marks are removed from bearing surfaces.
S Clean piston pin end of connecting rod, using
same method as above. Use 320 grit carborundum cloth instead of crocus cloth.
S Thoroughly wash connecting rods to remove abrasive grit. Recheck bearing surfaces of connecting
rods. Replace any connecting rod that cannot be
properly polished. Lubricate bearing surfaces of
connecting rods which will be reused with 2 cycle
engine oil to prevent rust.
c
a
b
a - Cylinder Cover
b - Divider Plate
c - Exhaust Cover
51083
90-13645--2 495
POWERHEAD
4A-23
Thermostat
Reed Blocks
Wash thermostat with clean water. Using a thermostat tester, similar to the one shown, test thermostat
as follows:
NOTE: Do not disassemble reed block unless necessary. It may be necessary to apply heat to bolt (e) to
soften LoctiteR before removal.
S Open thermostat valve, then insert a thread between valve and thermostat body. Allow valve to
close against thread.
S Suspend thermostat (from thread) and thermometer inside tester so that neither touches the container. Bottom of thermometer must be even with
bottom of thermostat to obtain correct thermostat
opening.
b
c
S Fill thermostat tester with water to cover

thermostat.
S Plug tester into electrical outlet.

S Observe temperature at which thermostat begins
to open. Thermostat will drop off thread when it
starts to open. Thermostat must begin to open
when temperature reaches 5_F (3_C) above designated stamping on bottom of thermostat.
S Continue to heat water until thermostat is completely open.
S Unplug tester unit.
S Replace thermostat, if it fails to open at the specified temperature, or if it does not fully open.
e
19331
a - Reed Block
b - Reed (3 Sets)
c - Retaining Washer
d - Tab Washer
e - Bolt
IMPORTANT: Do not flop (reverse) the reed for

additional use - replace reed when necessary.
BACKSIDE - REED BLOCK ASSEMBLED
19332
51087
4A-16
POWERHEAD
90-13645--2 495
There are 3 reed segments. Reed should lie flat.

There should be no preload (pressure between reed
and reed-block), but a slight preload is tolerable.
Powerhead Reassembly and

Installation
The maximum allowable opening between reed and

reed-block is 0.020 (in.). This must be checked with
a flat blade feeler gauge, as shown.
General Information
If the opening exceeds 0.020 (in.), or if the reed is

chipped, cracked, or otherwise damaged, replace.
Before proceeding with powerhead reassembly, be

sure that all parts to be reused have been carefully
cleaned and thoroughly inspected, as outlined in
Cleaning and Inspection. Parts, which have not
been properly cleaned (or which are questionable),
can severely damage an otherwise perfectly good
powerhead within a few minutes of operation. All
new powerhead gaskets must be installed during
assembly.
During reassembly, lubricate parts with Quicksilver
2-Cycle Outboard Oil whenever 2-cycle oil is specified
and Quicksilver 2-4-C W/Teflon whenever grease is
specified.
19337
CAUTION
Replace Locking Tab-Washer. DO NOT REUSE.
If reed block was disassembled, reassemble by locating reeds on pins with retaining washer . Use new tab
washer. Insert bolt, and torque to 80 lb. in. (9.0 Nm);
then, if necessary, continue the torque to align flat on
hex-head to locking tab - Do not exceed 100 lb. in.
(11.3 Nm) torque. Bend up tab to secure bolt position.
0.020 MAX.
A torque wrench is essential for correct reassembly of

powerhead. Do not attempt to reassemble powerhead without using a torque wrench.
EXAMPLE: If Exhaust Cover bolts require a torque of
220 lb. in. (24.9 Nm), (a) tighten all bolts to
73 lb. in. (8.2 Nm), following specified torque
sequence, (b) tighten all bolts to 146 lb. in. (16.6 Nm),
following torque sequence, then finally, (c) tighten all
bolts to 220 lb. in. (24.9 Nm), following torque
sequence.
End Cap
Clean thoroughly, including seal and O-ring seats; remove perfect seal residue and clean cap-to-head
mating surfaces.
Apply a thin bead of Loctite 271 to outer face on end
cap oil seal. Wipe off excess Loctite after installing.
Using suitable mandrel, press oil seal into cap until

fully seated. Remove any excess Loctite.
d
c
b
NOTE: Lip of seal goes in.
Lubricate oil seal lip with 2-4-C w/Teflon.

Lubricate O-ring seal with 2-4-C w/Teflon; install in
groove.
a - Reeds
b - Retaining Washer
c - Pins
90-13645--2 495
d - Bolt
e - Locking Tab
a
a - Outer Face
b - ORing
POWERHEAD
c
c - Seal Lip
d - Mating Surface
4A-25
IMPORTANT: There are two types of piston/rod assemblies available for the 3 cylinder powerheads:
Design 1 Bottom guided (centered in bore
by crankshaft)
Design 2 Top guided (centered in bore by
piston)
Top guided piston and rod assembly can be installed

in a powerhead with bottom guided piston and rod
assemblies.
DESIGN 1 - BOTTOM GUIDED
DESIGN 2 - TOP GUIDED
Bottom View of Piston
Bottom View of Piston
However, individual components cannot be intermixed I.E. Top guided piston cannot be used with
a bottom guided rod.
c
c
51536
51536
a - Ridged Washer
b - Smooth
c - Scalloped
4A-26
a - Flat Washer
b - Scalloped
c - Smooth
POWERHEAD
90-13645--2 495
Insert piston pin tool through piston in the direction

shown, pushing out sleeve.
CAUTION
Any GREASE used for bearings INSIDE the
Powerhead MUST BE gasoline soluble. Use only
Quicksilver Needle Bearing Assembly Lubricant
(92-42649A-1) or 2-4-C w/Teflon (92-825407A12). If
other lubricants are used inside the Powerhead,
damage to engine may occur.
a
b
Assembling Rod to Piston

Place clean needle bearings on a clean sheet of
paper and lubricate with Quicksilver Needle Bearing
Lubricant (92-42649A1) or 2-4-C w/Teflon
(92-825407A12).
NOTE: There are 29 needle bearings per piston.
CAUTION
Never intermix new needle bearings with used
needle bearings at the same connecting rod end.
Never intermix needle bearings on one
connecting rod with those of another connecting
rod. Should one (or more) piston pin needle
bearing of a connecting rod require replacement
(or should one or more be lost), replace all of that
connecting rods piston pin needle bearings.
51080
a - Sleeve
b - Piston Pin Tool (91-74607A2)
Place piston pin over end of tool, and tap into position
(driving tool out other side).
Place sleeve, which is part of Piston Pin Tool

(91-74607A1), into connecting rod and install needle
bearing around sleeve, as shown.
a
a
19537
a - Needle Bearings (29)
b - Sleeve [From Piston Pin Tool (91-74607A2)]
51086
Place locating washers on connecting rod; keeping locating washers in place, carefully place piston over end
of rod. Use disassembly marks for matching rod to piston and direction of insertion (which side of rod is UP).
a - Piston Pin
b - Piston Pin Tool
WARNING
Eye protection must be worn while installing
piston pin lockrings.
51083
a - Scribed Identification Number

b - Locating Washer
90-13645--2 495
POWERHEAD
4A-27
Install new piston pin lockrings (each side of piston)

using Lockring Tool (91-77109A1).
Make sure lockrings are properly seated in piston
grooves.
Piston Ring Installation

IMPORTANT: Piston ring side with letter or mark
must be facing up.
CAUTION
Do not reuse piston pin lockrings. Use only new
lockrings and make sure they are properly seated
in piston grooves.
Piston Ring
Piston rings are TAPERED top side, and flat (rectangular) on the bottom side (half-keystone rings).
Enlarged View of
Piston Ring Grooves
51086
a - Lockring Installation Tool (91-77109A1)
b - Lockring (2)
CAUTION
Care must be taken not to scratch the side
surfaces of ring groove. Scratching this area will
damage the ring groove.
1. Install piston ring in appropriate groove on piston
using Piston Ring Expander Tool. Spread rings
just enough to slip over piston.
2. Check piston rings to be sure they fit freely in
groove. Lubricate rings and cylinder wall with
2-cycle oil.
51086
NOTE: Shaft of Lockring Installation Tool

91-77109A1 must be modified (shortened) to 1.050
in. (26.7 mm).
1.050 in. (26.7 mm)
51081
a - Piston Ring Expander
b - Piston Rings
4A-28
POWERHEAD
90-13645--2 395
3. Align piston ring end gaps with ring locating pins

as shown. Check locating pins making sure they
are tight.
Check rings by viewing through exhaust ports while

depressing rings with a screwdriver. If no spring tension is there (ring fails to spring back), the ring is
probably broken and must be replaced, NOW, before
installing the crankshaft.
51228
a
20338
Crankshaft Installation
51082
a - Locating Pin
b - Piston Rings
4. Remove connecting rod cap from connecting rod

being installed.
5. Install each piston with UP identification facing
flywheel end. Pistons MUST be installed in this
direction.
UP
If Lower Bearing and Gear were removed from

crankshaft, reassemble using arbor press and
suitable mandrel for bearing; gear slides on.
(NOTE keyway and key in gear to crankshaft
assembly.)
Install main bearing retaining ring after pressing
main bearing tight against the oil gear.
NOTE: There is NO main bearing retaining ring or retaining ring groove in the crankshaft on the following
outboards:
75/90SERIAL NUMBER OC 259434 and above.
b
e
d
CAUTION
Pistons must be installed very carefully into
cylinders. Piston rings can not be inspected thru
exhaust ports.
6. Bottom end of cylinder bore has taper which
permits the insertion of the piston into block
without using a piston ring compressor. Place
piston carefully into cylinder.
d
c
51084
a - Lower Bearing
b - Gear
c - Retaining Ring
25949
d - Seal Carrier
e - Key
If Seal Carrier above was removed, replace by

placing a piece of wood on carrier and tapping
gently with a mallet, keeping carrier square during insertion, seal fully to crankshaft. See page
4A-17 -- (Powerhead Disassembly, this Section),
for wear-sleeve reinstallation, if so equipped.
51087
90-13645--2 495
POWERHEAD
4A-29
S Install 2 ring seals into slot between each center

main bearing and position ring seal end gaps 180_
apart.
Grease crankshaft journal with Needle Bearing Assembly Lubricant, to hold bearings in place. Position
bearings on journal, 32 each center main bearing.
20046
Attach bearing races with holes toward lower gear

end of crankshaft. Secure each main bearing race
with retaining ring.
ab
51083
20040
a - Main Bearing Race
b - Retaining Ring
c - Top Main Bearing
RING SEAL
2 Each Center
Main
To install top main bearing, lubricate needle bearing

with light oil, and slide bearing assembly, (holes
toward lower end), onto shaft.
CAUTION
Any GREASE used for bearings INSIDE the
Powerhead MUST BE gasoline soluble. Use only
Quicksilver Needle Bearing Assembly Lubricant
(92-42649A-1) or 2-4-C w/Teflon (92-825407A12). If
other lubricants are used inside the Powerhead,
damage to engine may occur.
4A-30
POWERHEAD
20040
90-13645--2 395
Position Cylinder Block and Piston Rods, as shown.

Note locating pins.
INSTALLING RODS TO CRANKSHAFT

Pull rod up to position shown.
Grease rod, bearing area, with Needle Bearing
Assembly Lubricant or 2-4-C w/Teflon - lay roller
bearings out on clean sheet of paper and grease
each bearing.
Place Bearing Cage in position.
Place Bearings in cage.
LOWER (Gear)
END
FLYWHEEL
END (Top)
20038
a - Locating Pins
Place crankshaft into cylinder block; align and seat

top and center main bearings so that locating pins on
block mate with holes in each bearing race.
20045
Grease crankshaft journal with Needle Bearing Assembly Lubricant or 2-4-C w/Teflon.
Pull-up rod into contact with crankshaft journal.
Place Bearing Cage on crankcase journal.
Place Bearings into cage.
Align bearing cages with rod-to-cap mating surfaces.
20336
20030
NOTE: Make sure that Rod Bolt Hole threads and

Rod Cap Bolt Hole threads are clean and oil free before reassembly.
Place Rod Cap carefully over cage and bearings,
and while holding cap tight to rod, and rod tight to
journal, insert bolt and lightly tighten, observing
cap-to-rod alignment. Install other bolt, rechecking
alignment.
90-13645--2 495
POWERHEAD
4A-31
IMPORTANT: On some engines, BOTH the piston

rod and rod cap bolt holes are threaded. The rod
cap and rod must be aligned and held tight
together when threading in bolt. Check that
mating surfaces are tight together after bolt
enters the threads in the piston rod.
S Replace lower crankshaft End Cap.

1. Coat mating surface with Perfect Seal. DO NOT
coat O-ring seal.
2. Bolt to block (2 bolts) - finger tighten - lightly.
20033
Connecting Rod Cap Alignment

1. Check each connecting rod for correct alignment
by carefully running fingernails up and down edge
of rod cap. If not aligned, a ridge can be seen or
felt at the separating line. Correct any misalignment.
Front View
Correct
Front View
Incorrect
19336
a - Mating Surface
b - O-ring Seal
Crankcase Cover to Block

LOCTITE
MASTER
GASKET
SEALANT,.
92-12564-1 is used; it comes as a kit, which includes
Primer and Sealant. Instructions contained in the kit
MUST BE FOLLOWED EXACTLY. (Clean both surfaces).
IMPORTANT: Extend sealer to edge on each center
main journal to prevent blow-by between cylinders.
Side View
Correct
Side View
Incorrect
Space
Side View
Incorrect
Ridge
Sealant Bead Pattern

indicated by bold line.
51224
2. When connecting rods are attached, and bolts

drawn down finger tight, torque rod-cap bolts to
15 lb. in. (1.7 Nm). Recheck alignment. Retorque
1/4 in. bolts to 15 lb. ft. (20.3 Nm) or 5/16 in.
bolts to 30 lb. ft. (40.7 Nm). Recheck alignment.
Turn each rod-cap bolt 90_ further after 30 lb. ft.
reading is acquired.
4A-32
POWERHEAD
90-13645--2 395
REATTACH CRANKCASE COVER
After the application of the Loctite Master Gasket

Sealing Kit, place crankcase cover onto block, and
align.
Align cover and gasket on block.
Recheck that bolt holes and bolts are clean to assure accurate torque.
Insert bolts - note 2 sizes and finger tighten.

Loctite End Cap Bolt and install in remaining (End
Cap to Cover) hole.
Torque Crankcase Cover Bolts.
IMPORTANT: This is a Double Torque Pattern.
10
8 12
a - Cover
b - Gasket
Install thermostat cover and components, as

follows:
1. Insert poppet valve (d) into valve seat (f).
2. Install cover gasket over poppet.

3. Insert thermostat (h) into well.
7 11
Torque large bolt sequence first.

1st Torque Pattern (#1-8) on Large Bolts 25 lb. ft. (33.9 Nm)
2nd Torque Pattern (#1-12) on Small Bolts - 18
lb. ft. (24.4 Nm)
Torque all (lower) end cap bolts (3 bolts) to
18 lb. ft. (24.4 Nm)
4. Align cover, with poppet spring (a) seated as

shown.
5. Depress cover, and insert bolts - finger tighten.
Note seating of thermostat gasket (h) and poppet
gasket diaphragm (c). These, and gasket g are replaceable when necessary.
NO TORQUE
REQUIREMENT
Reattach bleed line hose
NOTE: Inspect ALL hoses on reinstallation; replace

when necessary.
TIGHTEN
SECURELY IF
DISASSEMBLED
Note on Major Cover Gaskets: These are new

gaskets impregnated with a coating that causes the
gasket to retain torque. It is not necessary to use
sealant on gasket, or Loctite on bolts.
d
g
h
i
Position clips, align cover holes and insert bolts finger tighten (located under bolts #2 and 10).
Insert remaining cover bolts - finger tighten.
90-13645--2 495
POWERHEAD
4A-33
NOTE: Keep clips positioned, as shown, during

torque sequence.
EXHAUST PLATE COVER TORQUE SEQUENCE

All Cover Bolts: 18 lb. ft. (24.4 Nm)
CYLINDER HEAD COVER TORQUE SEQUENCE

All Cover Bolts: 18 lb. ft. (24.4 Nm)
22
13
17
18
10
11
19
15
23
24
20
14
16
12
21
Reinstall Oil Injection Pump Shaft and housing;

check O-rings - replace as necessary.
Exhaust Plate Cover and Exhaust

Divider Plate
IMPORTANT: Insure that gears engage properly

and that the O-rings are seated properly on reassembly, or an oil injection failure could occur, resulting in possible powerhead damage.
Assemble in order shown.

a. Exhaust Plate Gasket
b. Divider Plate
c. Exhaust Plate Gasket
20041
d. Exhaust Plate Cover
IMPORTANT: After reinstalling shaft and housing,

turn crankshaft - make sure oil pump shaft turns.
Reinstall Oil Injection Pump - 2 bolts. Torque to 60

lb. in. (6.8 Nm).
Reinstall Fuel Pump - 2 screws. Torque to
55 lb. in. (6.2 Nm).
Reattach fuel/oil line hoses and secure with staystraps.
Insert bolts (24) and finger tighten.

Torque bolts in sequence.
b
19056
a - Screws [Torque to 55 lb. in. (6.2 Nm)]
b - Bolts [Torque to 60 lb. in. (6.8 Nm)]
4A-34
POWERHEAD
90-13645--2 395
Powerhead to Driveshaft Housing

Temporarily install flywheel with nut, as shown.
Clean holes (threads) and bolts thoroughly, with Locquic Primer T (92-59327-1). Dry, apply Loctite 271 to
bolts, and install. There are 8 bolts (3 each side, 2
backside). Torque in 3 Steps to 45 lb. ft. (61.0 Nm).
20346
Install lifting eye (91-90455) onto flywheel. Thread

on at least 5 full turns.
After checking mating surfaces between powerhead and driveshaft housing for condition and
cleanliness, use hoist to lift powerhead, being
careful not to damage powerhead to driveshaft
housing gasket surface.
19070
Reattach shift arm linkage on stud.
Place new gasket over locating pins on driveshaft

housing-to-powerhead mating surface.
Apply a small amount of Quicksilver 2-4-C w/Teflon to driveshaft splines.
Recheck for correct installation of tip-seal in crankshaft seal carrier.
Use hoist to lower powerhead into driveshaft
housing, turning flywheel, if necessary, to align
crankshaft splines with driveshaft splines. Lower
so that powerhead is fully installed and aligned on
locating pins.
19544
a - Shift Arm Linkage

b - Stud
NOTE: For specific information on rewiring, see Section 4-D, Wiring Diagrams (this manual).
20031
90-13645--2 495
POWERHEAD
4A-35
ELECTRICAL COMPONENTS INSTALLED
REINSTALL WIRING HARNESS AND

COMPONENTS, AS A UNIT
S Reinstall Trigger Assembly and Stator Assembly.
(Refer to Section 2 - this manual.) Apply Loctite
271 to stator screws and torque to
60 lb. in. (6.8 Nm).
S Attach Electrical Component Mounting Plate.
Apply Loctite 271 to bolts and torque to
13.5 lb. ft. (18.3 Nm).
S Install Starter Motor as outlined in Section 2.
Torque to 14.5 lb. ft. (19.7 Nm).
S Attach Enrichener Valve and connect hose. See
Section 3B.
NOTE: See Section 2-D Wiring Diagrams.

S Attach Temperature Sensor (g), with 2 screws.
NOTE: Temperature sensor opens at 170_F 8_

(77_C 8_); closes at 190_F 8_ (88_C 8_)
20412
g
20368
S Attach Test Button, if so equipped.
a
20368
c
b
20414
a - Temperature Sensor
b - Temperature Sensor Wire
4A-36
POWERHEAD
25955
c - Spark Plug Wires
d - Horn Test Button
90-13645--2 395
Flywheel Installation
5. Install Carburetor Gaskets.
1. Reinstall Flywheel, washer and nut.
6. Reinstall Carburetors as Single-Unit Assembly.

Note manifold hose position and connection.
2. Torque Flywheel Nut to 120 lb. ft. (162.7 Nm).
20344
3. Reinstall Reed Block Housings, Intake Manifolds,

and Flywheel Cover Bracket.
INTAKE
MANIFOLD
GASKET
REED BLOCK
ASSEMBLY
19094
a - Manifold Hose
7. Reconnect main fuel line hose, and fuel enrichment hose. Secure fuel line a with sta-strap.
8. Reconnect throttle linkage.
INSTALL
INTAKE MANIFOLD
AS ONE UNIT
19574
INTAKE MANIFOLD - TORQUE SEQUENCE
1
3
19093
4. Torque each intake manifold, in sequence, to 18 lb.

ft. (24.4 Nm).
a - Main Fuel Hose

b - Fuel Enrichment Hose
c - Throttle Linkage
NOTE: Flywheel Cover Bracket uses longer bolts.

90-13645--2 495
POWERHEAD
4A-37
9. Reinstall Flywheel Cover. Tighten 3 wing-nuts securely.
14. Reinstall Air Box Cover and Gasket; tighten

screws securely.
10. Reinstall oil reservoir. Reconnect hoses and secure with sta-straps. See Section 3B for more details, if necessary.
See Oil Reservoir diagrams at beginning of this
section.
c
a
20335
ATTACH REAR COWL MOUNTING BRACKET

Bracket attaches with 4 bolts.
b
a - Oil Reservoir
b - Sta-straps
Note washer sequence (4 places).

19072
Torque bolts to 150 lb. in. (16.9 Nm).
c - Flywheel Cover
11. Install Gaskets - Air Box Plate to carburetor.

12. Reinstall Air Box Plate.
13. Torque bolts to 100 lb. in. (11.3 Nm).
a
20368
19097
4A-38
a - Bracket
b - Washer
POWERHEAD
90-13645--2 395
ATTACH FRONT COWL MOUNTING BRACKET

Front cowl mounting bracket is installed in location
a.
Install Mounting Bracket, as shown below. Grommets

c and g normally are left in place in the bracket on
disassembly. Bushing d inserts in grommet c.
Position wiring and secure with cable retainer (strap
casting).
Note sequence of washers, etc.
e
e
a
b
c
g
d
19072
e
a
b
c
d
e
f
g
h
90-13645--2 495
Washer
Washer
Grommet
Bushing
Screw
Retainer
Grommet
Seal
POWERHEAD
4A-39
LOWER UNIT
5
A
791-H
GEAR HOUSING
Table of Contents
Page
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Shaft and Water Pump Components . . .
Propeller Shaft Components . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Removal . . . . . . . . . . . . . . . . . . . .
Draining and Inspecting Gear Housing
Lubricant . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump (Design 1) . . . . . . . . . . . . . . . .
Water Pump (Design 2) . . . . . . . . . . . . . . . .
Bearing Carrier and Propeller Shaft . . . . .
Pinion Gear, Drive Shaft, and Forward
Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper Drive Shaft Bearing . . . . . . . . . . . . .
Oil Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Drive Shaft Bearing Race . . . . . . . .
Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . .
Forward Gear Bearing Race . . . . . . . . . . . .
Trim Tab Adjustment and Replacement . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Forward Gear Bearing Race . . . . . . . . . . . .
Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . .
5A-1
5A-2
5A-6
5A-8
5A-8
5A-8
5A-8
5A-9
5A-10
5A-11
5A-12
5A-15
5A-16
5A-17
5A-17
5A-18
5A-19
5A-19
5A-19
5A-19
5A-19
Page
Bearing Carrier Reassembly . . . . . . . . . . . .

Forward Gear Reassembly . . . . . . . . . . . . .
Propeller Shaft Reassembly . . . . . . . . . . . .
Drive Shaft Wear Sleeve Installation . . . . .
Lower Drive Shaft Bearing Race
Installation . . . . . . . . . . . . . . . . . . . . . . . .
Oil Sleeve Installation . . . . . . . . . . . . . . . . .
Upper Drive Shaft Bearing Installation . . .
Forward Gear, Lower Drive Shaft Bearing,
Pinion Gear, and Drive Shaft
Installation . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Gear Depth and Forward Gear
Backlash . . . . . . . . . . . . . . . . . . . . . . . . .
Determining Pinion Gear Depth . . . . . .
Determining Forward Gear Backlash .
Bearing Carrier and Propeller Shaft
Installation . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump Reassembly and
Installation . . . . . . . . . . . . . . . . . . . . . . . .
Gear Housing Pressure Test . . . . . . . . . . . .
Filling Gear Housing With Lubricant . . . . . . . .
Propeller Installation . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5A-20
5A-22
5A-23
5A-23
5A-24
5A-25
5A-25
5A-26
5A-26
5A-26
5A-28
5A-29
5A-30
5A-32
5A-32
5A-33
5A-33
90-13645--2 495
Notes:
90-13645--2 1095
LOWER UNIT
5A-1
Drive Shaft and Water Pump Components

7
30
31
32
33
36
37
29
7
95
95
28
27
26
25
34
24
45
46
23
95
35
22
21
95
47
38
40
39
20
41
19
95
18
42
3
43
4
16
15
17
14
44
13
12
11
5
6
Application Points
95
2-4-C With Teflon (92-825407A12)
5A-2
9
10
LOWER UNIT
90-13645--2 1095
Drive Shaft and Water Pump Components (Continued)

TORQUE
REF. NO.
QUAN.
DESCRIPTION
lb. in.
lb. ft.
Nm
Drive Shaft (Long)

Drive Shaft (X-Long)
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Shim
Bearing Race
Tapered Bearing
Washer
Screw
Washer
Screw
Washer
Screw (Magnetic)
Pinion Nut
Pinion Gear
Shift Cam (Letters Face Up)
Trim Tab
Washer
Trim Tab Bolt
Oiler Tube
Carrier
Needle Bearing (Numbers Face Up)
Gasket (Not used with nylon cover assy.)
Oil Seal (Lip Up)
Oil Seal (Lip Down)
Cover Assembly
Gasket
Face Plate
Gasket
90-13645--2 1095
LOWER UNIT
60
6.8
60
6.8
60
70
6.8
94.9
22
29.8
5A-3

7
30
31
36
32
33
37
29
7
95
95
28
27
26
25
34
24
45
46
23
95
22
21
47
39
38
40
95
20
41
19
7
95
42
18
3
43
4
16
15
17
44
13
14
12
11
5
6
Application Points
95
2-4-C With Teflon (92-825407A12)
5A-4
9
10
LOWER UNIT
90-13645--2 1095

TORQUE
REF. NO.
QUAN.
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
1
1
1
1
4
44
45
46
47
DESCRIPTION
1
1
2
1
1
1
1
1
Impeller Drive Key

Impeller
Water Pump Assembly
Water Tube Seal
Water Pump Bolt
Delete
Delete
Cover Screw
Delete
Wear Sleeve
Seal Ring
Bushing Screw
Oil Seal (Lip Up)
Shift Shaft Bushing
O-Ring
Shift Shaft E Ring
Shift Shaft (Long)
Shift Shaft (X-Long)
1
1
1
1
Gear Housing
Shift Shaft Adapter
Reverse Lock Cam
Washer
90-13645--2 1095
LOWER UNIT
lb. in.
lb. ft.
Nm
60
6.8
60
6.8
35
3.9
5A-5
Propeller Shaft Components

95
10
8
6
7
5
4
3
2
95
16
95
15
95
1
14
29
28
13
11
7
12
22 21
27
30
26
25
24
23
95
20
19
95
95
18
17
95
2-4-C With Teflon (92-825407A12)
5A-6
LOWER UNIT
90-13645--2 1095
Propeller Shaft Components (Continued)

TORQUE
REF. NO.
QUAN.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
90-13645--2 1095
DESCRIPTION
Gear Case
Shim
Bearing Race
Tapered Roller Bearing
Roller Bearing
Forward Gear
Cam Follower
Ball Bearing
Slide Cross Pin
Spring
Clutch
Clutch Cross Pin
Retainer Spring
Propeller Shaft
Reverse Gear
O-Ring
Thrust Bearing
Thrust Washer
Roller Bearing
Bearing Carrier
Washer
Nut (Design 2) or Bolt (Design 1)
Roller Bearing
Oil Seal (Lip In)
Oil Seal (Lip Out)
Thrust Washer
Propeller
Tab Washer
Propeller Nut
Stud
LOWER UNIT
lb. in.
lb. ft.
Nm
260
21.7
29.4
55
75
5A-7
6. Remove gear housing.
Special Tools
Part No.
91-46086A1
91-85716
91-34569A1
91-36569
91-37263
91-37323
91-56775
91-37241
91-83165M
91-31106
91-31108
91-37350
91-31229
11-24156
91-78473
91-58222A1
91-83155
91-12349A2
91-14308A1
91-14309A1
91-14310A1
91-14311A1
91-13945
91-13949
91-19660
*
Description
Puller Jaws
Puller Bolt
Slide Hammer
Mandrel*
Mandrel*
Driver Rod*
Drive Shaft Holding Tool
Universal Puller Plate
Bearing Puller Assembly
Mandrel
Oil Seal Driver
Mandrel
Threaded Rod*
Nut*
Backlash Indicator Tool (3 Cyl)
Dial Indicator
Dial Indicator Adaptor Kit
Pinion Gear Locating Tool
Bearing Race Tool
Bearing Installation Tool
Wear Sleeve Installation Tool
Bearing Preload Tool
Bearing Installation Tool
Oil Seal Driver
Backlash Indicator Tool (4 Cyl)
51552
a - Bolts (or Locknuts) and Washers
b - Locknut and Washer
Disassembly
Propeller Removal
WARNING
From Bearing Removal and Installation Kit (91-31229A5)
If gear housing is not removed from drive shaft

housing, before attempting to remove or install
the propeller, remove (and isolate) spark plug
leads from spark plugs to prevent engine from
starting accidentally.
1. Bend tabs of tab washer away from hub.
Removal
WARNING
a
To prevent accidental engine starting, remove

(and isolate) spark plug leads from spark plugs
before removing gear housing.
1. Remove (and isolate) spark plug leads from spark
plugs.
2. Shift engine into forward gear.
3. Tilt engine to full Up position.
4. Remove 4 bolts (or locknuts on 1995 Models) and
washers (two each side).
5. Remove locknut and washer.
51871
a - Tab Washer
b - Hub
5A-8
LOWER UNIT
90-13645--2 1095
2. Place a block of wood, as shown, to prevent propeller from rotating and to protect hands during
removal of nut.
3. Remove nut and pull components from shaft.
51552
a - Oil Level Screw
b - Fill/Drain Screw
c - Vent Screw
19183
a - Block of Wood
Draining and Inspecting Gear Housing

Lubricant
WARNING
If gear housing is installed on engine, to avoid
accidental starting, disconnect (and isolate)
spark plug leads from spark plugs before working
near the propeller.
1. With gear housing in normal running position,
place a clean pan under housing and remove the
two vent screws and one fill/drain screw (with
gaskets).
2. Inspect gear lubricant for metal particles (lubricant will have a metal flake appearance). Presence of fine metal particles (resembling powder)
on the drain plug bar magnet indicates normal
wear. The presence of metal chips on the drain
plug bar magnet indicates the need for gear housing disassembly and component inspection.
3. Note color of gear lubricant. White or cream color
MAY indicate presence of water in lubricant. Gear
lubricant which has been drained from a gear
case recently in operation will have a yellowish
color due to lubricant agitation/aeration. Gear
lube which is mixed with assembly lubricant (Special Lube 101 or 2-4-C w/Teflon will also be
creamy white in color. This is normal and should
not be confused with the presence of water. If water is supected to be present in gearcase, a pressure check of gearcase should be made (with no
lubricant in gearcase). Gearcase should hold 10
to 12 psi of pressure for 5 minutes without leaking
down. Pouring a portion of the gear lubricant into
a glass jar and allowing the lubricant to settle will
allow any water in the lube to separate and settle
to the bottom of the jar.
4. Presence of water in gear lubricant indicates the
need for disassembly and inspection of oil seals,
seal surfaces, O-rings, water pump gaskets as
well as gear housing components for damage. If
gearcase is rebuilt, gearcase should be pressure
checked before filling with lubricant.
90-13645--2 1095
LOWER UNIT
5A-9
7. Inspect impeller. Replace impeller if any of the

following conditions exist:
Water Pump (Design 1)

1. If water tube seal stayed on water tube (inside of
drive shaft housing) when gear housing was
removed, pull water tube seal from water tube.
2. Replace water tube seal, if damaged.
Impeller blade(s) are cracked, torn, or worn.

Impeller is glazed or melted (caused by operation without sufficient water supply).
Rubber portion of impeller is not bonded to
impeller hub.
3. Remove 4 bolts, washers, and isolators.

4. Remove cover.
8. Remove plate and gasket.

9. Replace plate if groove(s) (other than impeller
sealing bead groove) in plate are more than
0.030 (0.762mm) deep.
a
e
b
b
c
d
d
19212
a - Water Tube Seal
b - Bolts (4 each)
c - Washers (4 each)
d - Isolators (4 each)
e - Cover
19219
IMPORTANT: The circular groove formed by the

impeller sealing bead should be disregarded
when inspecting cover (Step 5) and plate (Step 9),
as the depth of the groove will not affect water
pump output.
a - Plate
b - Gasket
10. Remove bolts and washers.
5. Replace cover if thickness of steel at the discharge slots is 0.060 or less, or if groove(s) (other than impeller sealing bead groove) in cover roof
are more than 0.030 (0.762mm) deep.
6. Lift impeller, drive key, and gasket from drive
shaft.
b
19217
a - Bolts and Washers (6 each)
19220
a - Impeller
b - Drive Key
c - Gasket
5A-10
LOWER UNIT
90-13645--2 1095
11. Remove water pump base.
Water Pump (Design 2)

NOTE: Disassembly procedure for DESIGN 2 model
water pump is the same as for DESIGN 1 model water
pump, previous.
19226
a - Water Pump Base
12. Remove (and discard) seals.
IMPORTANT: Gear housing on 3 CYLINDER

MODELS 70, 75, 80, 90 and 4 CYLINDER MODELS
100 and 115 have been modified to accept a new
style plastic water pump base (P/N 19282A1). This
new base does not require gaskets as it has a silicone impregnated seal on the top and bottom. As
long as this silicone seal is not damaged i.e.,
cuts or abrasions it will retain its sealing capabilities. This new water pump base CANNOT BE
USED on older gear housings. The aluminum
water pump base (P/N 43055A2) is still available
for use with the older gear housings.
a
a
19195
a - Seals
26263
13. Remove gasket.
a - Water Pump Cover Gasket

b - Plastic Pump Base
c - Silicone Seal (Both Sides)
19218
a - Gasket
90-13645--2 1095
LOWER UNIT
5A-11
5. Lift reverse gear, thrust bearing and thrust washer from bearing carrier.

1. Drain lubricant from gear housing; refer to Draining and Inspecting Gear Housing Lubricant.
2. Remove bolts and washers or self locking nuts if
applicable.
6. Replace reverse gear if gear teeth or clutch teeth

on reverse gear are chipped or worn. If reverse
gear must be replaced, pinion gear and sliding
clutch should be inspected for damage.
7. Replace thrust bearing and thrust washer if
rusted, pitted or damaged.
a
a
b
c
a
51117
a - Bolt and Washers or Locknuts
3. With propeller shaft horizontal, pull carrier to

break seal with gear housing. Remove bearing
carrier/propeller shaft components as an assembly, taking care not to lose cam follower or 3 metal
balls in end of propeller shaft.
4. Remove propeller shaft from bearing carrier.
19202
a - Reverse Gear
b - Thrust Bearing
c - Thrust Washer
e
c
8. If bearing is rusted or does not roll freely, replace

bearing. Remove bearing using Slide Hammer
(91-34569A1).
d
a
b
c
d
e
51116
Bearing Carrier
Puller Jaws (91-46086A1)
Puller Bolt (91-85716)
Thrust Hub
Propeller Shaft
19205
a - Bearing
5A-12
LOWER UNIT
90-13645--2 1095
9. If bearing is rusted or does not roll freely, replace

bearing. Remove bearing and oil seals using
Mandrel* (91-36569) and Driver Rod* (91-37323).
Discard oil seals.
*
11. Remove spring.
From Bearing Removal and Installation Kit (91-31229A5).
51876
a - Spring
12. Apply constant pressure to cam follower to prevent cam follower assembly from ejecting from
propeller shaft while pushing cross pin out of
clutch dog.
51264
a - Bearing
b - Mandrel (91-26569)
c - Driver Rod (91-37323)
10. Remove (if not removed with bearing in Step 9)

propeller shaft seals and O-ring.
a
a
51800
a - Cross Pin
b - Cam Follower
51263
a - O-ring
90-13645--2 1095
LOWER UNIT
5A-13
13. Remove components from propeller shaft.
16. Check bearing surfaces of propeller shaft for pitting or wear. If shaft is worn or pitted, replace shaft
and corresponding bearing.
14. Replace cam follower if worn or pitted.

15. Replace sliding clutch if jaws are rounded or
chipped. Rounded jaws indicate one or more of
the following:
a. Splines are twisted or worn.
a. Improper shift cable adjustment.
b. Oil seal surface is grooved.
b. Engine idle speed too high while shifting.

c. Shifting from neutral to reverse (or forward) too
slowly.
a b
17. Replace propeller shaft if any of the following

exist:
c. Shaft has a noticeable wobble or is bent more

than 0.009 in. (0.228mm). Prop shaft trueness
should be measured with a dial indicator with
prop shaft on V-blocks.
f
a
b
c
d
e
f
Cam Follower
3 Metal Balls
Guide Block
Spring
Sliding Clutch
Jaws
5A-14
51265
a
51877
a - V-Blocks
b - Bearing Surfaces
c - Measure with Dial Indicator at this Point.
LOWER UNIT
90-13645--2 1095
Pinion Gear, Drive Shaft, and Forward

Gear
6. Replace bearing if it is rusted or does not roll freely; use a punch and hammer to remove bearing.
1. Hold drive shaft using Drive Shaft Holding Tool

(91-56775); remove (and discard) pinion nut.
2. Remove drive shaft, pinion gear, bearing and forward gear .
3. Replace pinion gear if it is chipped or worn.
4. Replace bearing and race if either are rusted or
damaged; or if bearing does not roll freely. To remove race, refer to Lower Drive Shaft Bearing
Race, following.
5. Replace forward gear if gear teeth or clutch teeth
are chipped or worn.
a
c
19203
a - Bearing
7. Replace forward gear bearing and race if either

are rusted or damaged; or if bearing does not roll
freely.
Remove
bearing
from
gear
using Universal Puller Plate (91-37241) and mandrel. To remove race, refer to Forward Gear Bearing Race, following.
a
e
b
51119
f
19175
a
b
c
d
e
f
a - Forward Gear Bearing

b - Universal Puller Plate (91-37241)
c - Mandrel
Drive Shaft Holding Tool (91-56775)

Pinion Nut
Drive Shaft
Pinion Gear
Bearing
Forward Gear
90-13645--2 1095
LOWER UNIT
5A-15
8. Replace drive shaft if splines are worn or twisted.
Upper Drive Shaft Bearing
9. If bearing surface is damaged, replace drive shaft

and corresponding bearing.
1. Replace upper drive shaft bearing and sleeve if

either are rust stained, or if bearing will not roll
freely. Remove bearing and then sleeve using
Puller Assembly (91-83165M) with suitable jaws.
IMPORTANT: Do not tighten vise against drive

shaft.
10. If wear sleeve is deeply grooved allowing water to
enter gear case, remove (and discard) sleeve using Universal Puller Plate (91-37241) and lead
hammer.
e
a
b
b
19177
a - Upper Drive Shaft Bearing
b - Sleeve
c - Puller Assembly (91-83165M)
c
a
19710
a
b
c
d
e
Splines
Bearing Surface
Wear Sleeve
Universal Puller Plate (91-37241)
Lead Hammer
11. Remove (and discard) rubber ring.
19152
a - Rubber Ring
5A-16
LOWER UNIT
90-13645--2 1095
IMPORTANT: Upper drive shaft bearing/sleeve

must be removed prior to oil sleeve removal. Refer to Upper Drive Shaft Bearing, preceding.

and oil sleeve do not have to be removed for lower
drive shaft bearing race removal.
Oil Sleeve
1. Remove oil sleeve (if necessary) using Puller Assembly (91-83165M) with suitable jaws.
IMPORTANT: Retain shim(s) for reassembly.
1. Remove race and shim(s) using bearing race tool

(91-14308A1).
c
a
a
19222
a - Oil Sleeve
b - Puller Assembly (91-83165M)
90-13645--2 1095
19171
a - Race
b - Shim(s)
c - Bearing Race Tool (91-14308A1)
LOWER UNIT
5A-17
4. Remove shift cam from housing.
Shift Shaft
1. Remove
spacer.
shift
shaft
coupler
and
nylon
5. Replace shift cam if worn.
51117
19221
a - Shift Shaft Coupler
b - Spacer
a - Shift Cam
6. Remove shift shaft bushing and clip from shift

shaft.
2. Remove bolts.
7. Replace shift shaft if splines are worn or shaft is

twisted.
8. Remove (and discard) O-ring.
a
d
e
b
19216
a - Bolts
19200
3. Remove shift shaft bushing and shift shaft.
a - Bushing
b - Clip
c - Shift Shaft
d - Splines
e - O-ring
9. Remove (and discard) seal.
a
19199
19225
a - Seal
a - Bushing
b - Shift Shaft
5A-18
LOWER UNIT
90-13645--2 1095
Reassembly
Forward Gear Bearing Race

IMPORTANT: Retain shim(s) for reassembly.
1. Remove race and shim(s)
Hammer (91-34569A1).
using
Forward Gear Bearing Race

Slide
1. Place shim(s) (retained from disassembly) into

housing. If shim(s) were lost, or a new gear housing is being assembled, start with 0.010
(0.254mm) shim(s).
2. Assemble components as shown; drive race into
housing by striking propeller shaft end with lead
hammer.
d
c
27653
a - Race
b - Shim(s)
c - Slide Hammer (91-34569A1)
Trim Tab Adjustment and Replacement

IMPORTANT: The trim tab is made of a special
alloy to aid in protecting the drive shaft housing
and gear housing from galvanic corrosion (corrosion and pitting of metal surfaces). Do not paint or
place protective coating on the trim tab, or trim
tab corrosion protection function will be lost.
1. Replace trim tab if 50% (or more) consumed.
Mark location of old trim tab on anti-ventilation
plate before removal; install new trim tab in same
location.
2. The trim tab provides a means to offset (balance)
some of the steering load that is caused by propeller torque at higher operating speeds. If at
higher speeds the boat turns more easily to the
left, loosen bolt, move the trim tab (trailing edge)
to the left (when viewed from behind); retighten
bolt. Turn trim tab (trailing edge) to the right if the
boat turns more easily to the right.
a - Shim(s)
b - Race, Apply Quicksilver
Needle Bearing Assembly
Lubricant on O.D.
c - Mandrel (91-31106)
19179
d - Disassembled Propeller
Shaft
e - Assembled Bearing
Carrier
Shift Shaft
1. Apply Loctite 271 on O.D. of new seal.
2. Press seal into shift shaft bushing until seal is
flush with surface.
3. Install new O-ring.
4. Apply 2-4-C with Teflon on O-ring and I.D. of seal.
a c
a - Trim Tab
b - Anti-Ventilation Plate
c - Retaining Bolt and Washer; Torque Bolt to 22 lbs. ft.
(29.8 Nm)
90-13645--2 1095
d
19172
a
b
c
d
b
19199
Seal
Bushing
Surface
O-ring
LOWER UNIT
5A-19
5. Assemble components as shown.
8. Apply Loctite 271 on bottom 1/2 of threads of

bolts; install bolts and torque to 60 lb. in. (6.8
Nm).
a
c
19200
a - Shift Shaft
b - E Clip
c - Shift Shaft Bushing
6. Install shift cam (numbers toward top of gear

housing); align hole in shift cam with hole.
19216
a - Bolts [Torque to 60 lb. in. (6.8 Nm)]
Bearing Carrier Reassembly

1. Lubricate O.D. of bearing and bearing carrier bore
with Quicksilver 2-4-C w/Teflon.
2. Protect lip on forward side of bearing carrier, using
bearing installation tool (91-13945).
3. Press propeller shaft needle bearing (number
side toward mandrel) into carrier, until bearing
bottoms out.
51117
a - Shift Cam (Numbers UP)
b - Hole
7. Install shift shaft assembly; insert splines into shift

cam.
b
a
b
21042
19227
a - Shift Shaft Assembly
b - Splines
5A-20
a - Bearing Installation Tool (91-13945)

b - Mandrel (91-37263)
c - Suitable Driver Rod
LOWER UNIT
90-13645--2 1095
4. Place smaller diameter seal on longer shoulder

of Oil Seal Driver (91-31108) with seal lip away
from shoulder.
5. Protect lip on front side of bearing carrier using
Bearing Installation Tool (91-13945). Apply
Loctite 271 on O.D. of seal. Press seal into carrier
until tool bottoms.
8. Install O-ring.
9. Lubricate O-ring with 2-4-C w/Teflon. Lubricate
seal lips with 2-4-C w/Teflon (92-825407A12). Lubricate outside diameter of bearing with a light
coating of 2-4-C w/Teflon.
10. Press bearing into carrier until tool bottoms.
a
d
21040
a - Seal
b - Oil Seal Driver (91-31108)
c - Bearing Installation Tool (91-13945)
6. Place larger diameter seal on shorter shoulder of

Oil Seal Driver (91-31108) with seal lip
toward shoulder.
7. Protect lip on front side of bearing carrier using
Bearing Installation Tool (91-13945). Apply
Loctite 271 on O.D. of new seal. Press seal into
carrier until tool bottoms.
19163
a - O-ring
b - Bearing, Numbered Side
Toward Tool
c - Seal Lips
d - Bearing Installation Tool
(91-13945)
11. Install thrust washer. Coat thrust washer with

Quicksilver Gear Lubricant (92-13783A24).
a
c
19167
21041
a - Seal
c - Bearing Installation Tool (91-13945)
90-13645--2 1095
a - Thrust Washer
LOWER UNIT
5A-21
12. Install thrust bearing . Coat thrust bearing with

Quicksilver Gear Lubricant (92-13783A24).
Forward Gear Reassembly

1. Press bearing onto gear (press only on inner race
of bearing).
a
b
51869
a - Mandrel (91-37350)
b - Bearing; Lubricate I.D. with Quicksilver 2-4-C w/Teflon
19168
a - Thrust Bearing
2. Apply 2-4-Cw/Teflon to bore in center of gear.

3. Press bearing into gear until bearing bottoms out.
13. Install reverse gear.
NOTE: Do not apply pressing force AFTER bearing

bottoms out as bearing damage could result.
a
a
28062
19202
a - Mandrel
b - Bearing, Numbered Side Toward Mandrel
a - Reverse Gear
5A-22
LOWER UNIT
90-13645--2 1095
Propeller Shaft Reassembly

1. Install components
sequence shown.
c b
into
propeller
shaft
in
Drive Shaft Wear Sleeve Installation

1. Install new rubber ring.
2. Apply a light coat of Loctite 271 on outside
diameter of rubber ring.
a
19154
a - Spring
b - Guide Block
c - 3 Metal Balls*
d - Cam Follower*
19152
*Hold in Place With Quicksilver 2-4-C w/Teflon
a - Ring
2. Install cross pin.
3. Insert sleeve into holder*.
*Component of Wear Sleeve Installation Tool (91-14310A1).
a
b
51800
a - Apply Pressure in This Direction
b - Cross Pin
3. Install spring. DO NOT overlap springs.
19169
a
a - Sleeve
b - Holder
51876
a - Spring
90-13645--2 1095
LOWER UNIT
5A-23
4. Press sleeve onto drive shaft using Wear Sleeve

Installation Tool (91-14310A1); continue pressing
until surface contacts surface.

Installation
IMPORTANT: Lower drive shaft bearing cup can
be installed with or without upper drive shaft bearing/sleeve and oil sleeve installed.
1. Lubricate O.D. of bearing race with Quicksilver

2-4-C w/Teflon.
2. Install shim(s) and bearing race into housing.
NOTE: Verify shim(s) are not cocked when drawing
up race.
f
d
a
b
19166
a
b
c
d
Drive Shaft
Wear Sleeve Installation Tool
Surface
Surface
5. Remove excess Loctite from assembled shaft.
b
c
19150
a - Shim(s); Retained From Disassembly. If Shim(s) Were Lost

or a New Gear Housing is Being Assembled, Start With
0.025 (0.635mm) Shim(s)
b - Bearing Race
c - Mandrel*
d - Mandrel*
e - Threaded Rod** (91-31229)
f - Nut** (11-24156)
*From Bearing Installation Tool (91-14309A1)
**From Bearing Removal and Installation Kit (91-31229A5)
5A-24
LOWER UNIT
90-13645--2 1095
IMPORTANT: Oil sleeve must be installed prior to

upper drive bearing installation.
Oil Sleeve Installation

1. Install oil sleeve with tab positioned as shown.

can be installed with or without lower drive shaft
bearing cup installed.
3. Install bearing/sleeve into housing.
f
e
c
e
19173
a - Oil Sleeve
b - Tab
Upper Drive Shaft Bearing Installation

1. Lubricate I.D. of bearing holder and O.D. of
bearing with 2-4-C w/ Teflon.
19151
a
b
c
d
e
f
2. Press bearing into sleeve.
Bearing/Sleeve
Tapered End
Mandrel*
Mandrel*
Threaded Rod** (91-31229)
Nut** (11-24156)
*From Bearing Installation Tool (91-14309A1)

**From Bearing Removal and Installation Kit (91-31229A5)
d
c
a
b
19164
a
b
c
d
Bearing Sleeve
Tapered End
Bearing; Numbered Side Toward Mandrel
Mandrel; From Bearing Installation Tool (91-14309A1)
90-13645--2 1095
LOWER UNIT
5A-25
Forward Gear, Lower Drive Shaft

Bearing, Pinion Gear, and Drive Shaft
Installation
2. With gear housing positioned up right (drive shaft

vertical), install Bearing Preload Tool (91-14311A1)
over drive shaft in sequence shown.
1. Install components in sequence shown.
h
c
a
d
a
b
c
d
e
f
g
h
c
f
a
Adaptor: Bearing surfaces clean and free of nicks

Thrust Bearing: Oiled and able to move freely
Thrust Washer: Clean and free of nicks and bends
Spring
Nut: Threaded all-the-way onto bolt
Bolt: Held snug against spring
Sleeve: Holes in sleeve must align with set screws
Set Screw (2): Tightened against drive shaft, bolt should not
slide on drive shaft.
3. Measure distance (a) between top of nut (b) and

bottom of bolt head (c).
19175
a - Forward Gear/Bearing: Work Quicksilver gear lube into

bearing rollers.
b - Lower Drive Shaft Tapered Roller Bearing: Work Quicksilver
gear lube into bearing rollers.
c - Pinion Gear
d - Drive Shaft
e - Drive Shaft Holding Tool (91-56775)
f - Pinion Nut (New): Apply Loctite 271 to threads during final
assembly (after pinion gear depth and forward gear backlash
have been set), torque to 70 lb. ft. (95 Nm).
4. Increase distance (a) by 1 (25.4mm).

5. Rotate drive shaft 5 to 10 revolutions. This should
properly seat upper drive shaft tapered roller
bearing.
Pinion Gear Depth and Forward Gear

Backlash
a
c
DETERMINING PINION GEAR DEPTH
NOTE: Read entire procedure before attempting any

change in shim thickness.
IMPORTANT: Forward gear assembly must be
installed in gear housing when checking pinion
gear depth or an inaccurate measurement will be
obtained.
19884
1. Clean the gear housing bearing carrier shoulder

and diameter.
5A-26
LOWER UNIT
90-13645--2 1095
6. Assembly Pinion Gear Locating Tool (91-12349A2)

as shown; do not tighten collar retaining bolt at
this time.
10. Install the number 3 locating disc against bearing carrier shoulder in gear housing.
11. Position access hole as shown.
a
a
b
c
d
e
f
Arbor
Gauging Block; Install With Numbers Away From Split Collar
Bolt; Gauging Block Retaining
Split Collar
Bolt; Collar Retaining
Snap Ring
7. Insert tool into forward gear assembly; position

gauging block under pinion gear as shown.
24643
a - Locating Disc
b - Access Hole
12. Determine pinion gear depth by inserting a feeler

gauge thru access hole in locating disc.
13. The correct clearance between gauging block
and pinion gear is 0.025 (0.64mm).
14. If clearance is correct, leave Bearing Preload Tool
on drive shaft and proceed to Determining Forward Gear Backlash, following.
15. If clearance is incorrect, add (or subtract) shims
from above bearing race to lower (or raise) pinion
gear. When reinstalling pinion nut, apply Loctite
271 on threads of nut.
c
a
22067
a - Gauging Block
8. Remove tool, taking care not to change gauging

block position, and tighten collar retaining bolt.
9. Insert tool into forward gear assembly; position

proper numbered flat (from chart) of gauging
block under pinion gear.
24643
MODEL
GEAR RATIO
(PINION GEAR TEETH/
REVERSE GEAR TEETH)
USE
FLAT
NO.
75-thru-90
(3 Cylinder)
13/30
100/115/125
(4 Cylinder)
14/29
90-13645--2 1095
a
b
c
d
Feeler Gauge
Gauging Block
Pinion Gear
Bearing Race
LOWER UNIT
5A-27
DETERMINING FORWARD GEAR BACKLASH
NOTE: Read entire procedure before attempting any

change in shim thickness.
1. Obtain correct pinion gear depth; refer to Determining Pinion Gear Depth, preceding.
2. Install Bearing Preload Tool (91-14311A1) on
drive shaft; refer to Determining Pinion Gear
Depth, preceding.
c
a
b
c
d
51119
Propeller Shaft*
Bearing Carrier* (Assembled)
Puller Jaws (91-46086A1)
Puller Bolt (91-85716); Torque to 45 lbs. in.
(5.1 Nm)
*Refer to Bearing Carrier and Propeller Shaft Installation, following.
4. Rotate drive shaft 5 to 10 revolutions. This should

properly seat forward gear tapered roller bearing.
a
b
c
d
e
f
Threaded Rod (Obtain Locally)

Washers
Nuts
Dial Indicator Adaptor Kit (91-83155)
Dial Indicator (91-58222A1)
Backlash Indicator Tool
6. Position Dial Indicator on appropriate line (from

chart) marked on Backlash Indicator Tool.
MODEL
5A-28
51117
ALIGN POINTER OF
DIAL INDICATOR WITH MARK
75-thru-90
(3 Cylinder)
Backlash
Indicator
Tool (91-78473)
100/115/125
(4 Cylinder)
Backlash
Indicator
Tool (91-19660)
LOWER UNIT
90-13645--2 1095
7. Lightly turn drive shaft back-and-forth (no movement should be noticed at propeller shaft).
3. Lubricate o-ring (c) and areas (d) with 2-4-C w/

Teflon (92-825407A12).
8. Dial Indicator registers amount of backlash, which

must be between specification shown in chart.
4. Install bearing carrier and propeller shaft into

housing with the word TOP located on flange (e)
toward top of housing.
MODEL
DIAL
INDICATOR
MINIMUM
READING
MAXIMUM
75-thru-90
(3 Cylinder)
0.012 in.
(0.30mm)
0.019 in.
(.48mm)
100/115/125
(4 Cylinder)
0.015 in.
(0.38mm)
0.022 in.
(0.55mm)
9. If backlash is less than the minimum specification,

remove shim(s)* from in front of forward gear
bearing race to obtain correct backlash. When reinstalling pinion nut, apply Loctite 271 on threads
of nut.
10. If backlash is more than the maximum specification, add shim(s)* in front of forward gear bearing
race to obtain correct backlash. When reinstalling
pinion nut, apply Loctite 271 on threads of nut.
*
By adding or subtracting 0.001 (0.025mm) shim, the backlash will change approximately 0.001 (.025mm).

Installation
21044
1. Insert propeller shaft assembly into bearing

carrier.
a
b
2. Before installing bearing carrier assembly into

gear housing, obtain locally a 6 (152.4mm) long
by 1-1/4 1-1/2 (31.7 38.1mm) diameter
piece of PVC pipe. Install the PVC pipe (f) over the
prop shaft (a) and secure the pipe against the
bearing carrier assembly (b) with the propeller nut
(g) and tab washer (h). This will allow the reverse
gear to apply pressure to the reverse gear thrust
bearing to prevent the thrust bearing from being
inadvertently dislodged as the bearing carrier
assembly is installed in the gear housing.
a
b
f
g
19147
c
d
e
a - Washers
b - Bolts; Apply Loctite 271 on Threads and Torque to 21.7 lb. ft.
(29.4 Nm)
h
90-13645--2 1095
21043
NOTE: If nuts are used in place of bolts (b), torque

nuts to 21.7 lb. ft. (29.4 Nm).
LOWER UNIT
5A-29
8. Place seal on shorter shoulder side of Oil Seal

Driver (91-13949) with seal lip toward shoulder.
Water Pump Reassembly and

Installation
6. Place seal on longer shoulder side of Oil Seal
Driver (91-13949) with seal lip away from
shoulder.
7. Apply Loctite 271 on O.D. of seal; press seal into
water pump base until tool bottoms.
9. Apply Loctite 271 on O.D. of seal; press seal into

water pump base until tool bottoms.
10. Lubricate lip of each seal with Quicksilver 2-4-C w/
Teflon (92-825407A12).
LIP FACES TOWARD
GEAR CASE
- GLOSS BLACK
COLOR
TEFLON COATED LIP

- FLAT BROWNISH
BLACK COLOR
- LIP FACES TOWARD
POWER HEAD
a
SPRING - FACES
TOWARD
GEAR CASE
SPRING - FACES
TOWARD
POWER HEAD
b
b
b
b
a
51553
51553
a - Seal
a - Seal
11. Install gasket.
19218
a - Gasket
5A-30
LOWER UNIT
90-13645--2 1095
15. Lubricate I.D. of cover with Quicksilver 2-4C w/

Teflon (92-825407A12).
16. Rotate drive shaft clockwise and push cover
down over impeller.
17. Install cover.

18. If water tube seal stayed on water tube (inside of
drive shaft housing) when gear housing was removed, pull water tube seal from water tube.
19. Lubricate I.D. of water tube seal with Quicksilver
2-4-C w/Teflon (92-825407A12) and install as
shown.
19217
a - Water Pump Base

b - Bolts and Washers; Apply Loctite 271 on Threads and
Torque to 60 lb. in. (6.8 Nm).
13. Install gasket and plate.
c
d
b
c
b
a
19212
a
b
c
d
19219
a - Gasket
b - Plate
IMPORTANT: If the old impeller will be re-used,

impeller must be installed in original (clockwise)
direction of rotation.
Cover
Isolators (4) If Equipped
Washers (4)
Bolts (4); Apply Loctite 271 on Threads and Torque to
60 lb. in. (6.8 Nm).
e - Water Tube Seal
NOTE: It is recommended that the gearcase be pressure tested for leaks after reassembly and BEFORE
gear lube is added. Gearcase should hold 10 to 12 psi
for 5 minutes.
14. Install gasket, drive key and impeller.
c
b
a
19220
a - Gasket
b - Drive Key
c - Impeller
90-13645--2 1095
LOWER UNIT
5A-31
Gear Housing Pressure Test

1. Remove vent plug and install pressure test gauge
Filling Gear Housing With

Lubricant
NOTE: Gear housing lubricant capacity is 22.5 fl. oz.
(665.2ml).
WARNING
If gear housing is installed on engine, to avoid
accidental starting, disconnect (and isolate)
spark plug leads from spark plugs before working
near the propeller.
CAUTION
Do not use automotive grease in the gear housing.
Use only Quicksilver Gear Lube or Quicksilver
Super-Duty Lower Unit Lubricant.
2. Pressurized housing to 10 to 12 psi and observe
gauge for 5 minutes.
3. Rotate drive shaft,prop shaft and move shift shaft
while housing is pressurized to check for leaks.
1. Remove any gasket material from Fill and Vent

screws and gear housing.
2. Install new gaskets on Fill and Vent screws.
IMPORTANT: Never apply lubricant to gear housing without first removing Vent screws or gear
housing cannot be filled because of trapped air.
Fill gear housing only when housing is in a vertical position.
3. Remove lubricant Fill screw and gasket from
gear housing.
4. Insert lubricant tube into Fill hole, then remove
Vent screws and gaskets.
5. Fill gear housing with lubricant until excess starts
to flow out of one (first) Vent screw hole.
6. Replace this lubricant Vent screw and gasket
only and continue filling until excess starts to flow
out of second lubricant Vent screw hole.
4. If pressure drop is noted, immerse housing in water.

5. Re-pressurize to 10 to 12 psi and check for air
bubbles.
6. Replace leaking seals as necessary. Retest housing.

Note: Gearcase should hold 10 to 12 psi for 5 minutes.
7. Remove tester from housing and install vent plug.
51552
a - Vent Screw
b - Fill/Drain Screw
c - Oil Level Vent Screw
5A-32
LOWER UNIT
90-13645--2 1095
7. Replace second lubricant Vent screw and gasket.

IMPORTANT: Do not lose more than one fluid
ounce (30cc) of gear lubricant while reinstalling
FILL screw.
8. Remove lubricant tube from Fill hole; install Fill
screw and gasket.
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.
7. After first use, retighten propeller nut and again
secure with tab washer. Propeller should be
checked periodically for tightness, particularly if a
stainless steel propeller is used.
Propeller Installation
WARNING
If gear housing is not removed from drive shaft

housing, before attempting to remove or install
the propeller, remove (and isolate) spark plug
leads from spark plugs to prevent engine from
starting accidentally.
1. Apply a liberal coat of one of the following Quicksilver products on propeller shaft splines:
Special Lubricant 101 (P/N 92-13872A1)

51871
2-4-C w/Teflon (92-825407A12)
a - Tab Washer
b - Locknut
c - Grooves
Anti-Corrosion Grease (92-19007A24)

Installation
b
WARNING
a
Disconnect (and isolate) spark plug leads from

spark plugs before installing gear housing onto
drive shaft housing. Failure to follow this warning
could result in accidental engine starting and
possible injury.
1. Position shift block in forward gear position,
as shown.
51801
a - Thrust Hub; Flat Surface Toward Propeller
b - Propeller
3. Install tab washer and locknut.

4. Thread locknut onto propeller shaft until locknut is
recessed into tab washer.
5. Torque locknut to 55 lbs. ft. (75 Nm).
6. Bend 3 tabs of tab washer down into grooves to
secure locknut. If tab washer tabs do not align
with slots, continue to tighten locknut to obtain
alignment.
19879
a - Shift Block; Front of Block MUST Extend 1/8 (3.2mm) Past
Front of Rail.
b - Rail
2. Tilt engine to full up position and engage tilt lock

lever.
3. Shift gear housing into neutral position. Propeller
shaft will rotate freely in either direction.
90-13645--2 1095
LOWER UNIT
5A-33
4. Install water tube seal; lube I.D. of seal with Quicksilver 2-4-C w/Teflon (92-825407A12).
8. Install components as shown in appropriate

photo.
5. Apply a bead of RTV Sealer as shown.
a
b
19215
a - Water Tube Seal
b - RTV Sealer
19883
CAUTION
Do not use lubricant on top of drive shaft. Excess
lubricant, that is trapped in clearance space, will
not allow drive shaft to fully engage with
crankshaft. Subsequently, tightening the gear
housing fasteners (while lubricant is on top of
drive shaft) will load the drive shaft/crankshaft
and damage either or both the power head and
gear housing. Top of drive shaft is to be wiped free
of lubricant.
a - Nylon Spacer
b - Shift Shaft Coupler; Used on Models Equipped with Power
Trim
b
c
6. Apply a light coat of Quicksilver 2-4-C w/Teflon

onto drive shaft splines.
7. Apply a light coat of Quicksilver 2-4-C w/Teflon on
gear case shift shaft splines and upper shift shaft
splines. Do not use lubricant on ends of shift
shafts.
19221
a - Nylon Spacer
b - Shift Shaft Coupler; Used on Models NOT Equipped with
Power Trim
c - Flat; MUST BE Positioned Toward Front of Gear Housing.
9. Shift gear housing into forward gear position. In

forward gear the gear housing will ratchet when
propeller shaft is turned clockwise and resistance
will be felt when propeller shaft is rotated counterclockwise.
10. Apply Loctite Grade 271 on threads of gear housing retaining bolts.
5A-34
LOWER UNIT
90-13645--2 1095
NOTE: If, while performing Step 11, the drive shaft

splines will not align with the crankshaft splines, place
a propeller onto propeller shaft and turn it counterclockwise as the gear housing is being pushed toward drive shaft housing.
16. Check shift operation as follows:

a. Place shift lever in forward gear. Gear housing
should ratchet when propeller shaft is turned
clockwise and resistance should be felt when
propeller shaft is turned counterclockwise.
NOTE: During installation of gear housing, it may be

necessary to move the shift block (located under
cowl) slightly to align upper shift shaft splines with
shift shaft coupler splines.
b. Place shift lever in neutral. Propeller shaft

should rotate freely in either direction.
c. While rotating propeller shaft, place shift lever
in reverse gear. Resistance should be felt when
propeller shaft is rotated in either direction.
11. Position gear housing so that the driveshaft is protruding into drive shaft housing.
12. Move gear housing up toward drive shaft housing,
while aligning upper shift shaft splines with shift
shaft coupler splines, water tube with water tube
seal, and crank shaft splines with drive shaft
splines.
IMPORTANT: If shift operation is not as described,

preceding, the gear housing must be removed
and the cause corrected.
13. Install 4 bolts and washers (two each side).

14. Install locknut and washer.
15. Torque bolts and locknut (or nuts only if applicable) to 40 lbs. ft. (54 Nm).
51552
a - Bolts and Washers (4)
b - Locknut and Washer
90-13645--2 1095
LOWER UNIT
5A-35
LOWER UNIT
5
B
MID-SECTION
Table of Contents
Page
Page
Swivel Bracket Components . . . . . . . . . . . . . . . 5B-2

Transom Bracket Components . . . . . . . . . . . . . 5B-4
Exhaust Plate Components . . . . . . . . . . . . . . . . 5B-6
Drive Shaft Housing Components . . . . . . . . . . 5B-8

Drive Shaft Housing Components . . . . . . . . . . 5B-8
Reference Views . . . . . . . . . . . . . . . . . . . . . . . . 5B-10
90-13645--2 495
Notes:
90-13645--2 495
LOWER UNIT
5B-1
Swivel Bracket Components

13
12
95
15
11
10
14
18
17
23
16
9
8
95
22
5
4
95
95
95
7
95
95
2
19
95
20
21
Application Points
95
5B-2
2-4-C With Teflon (92-825407A12)

LOWER UNIT
90-13645--2 495
Swivel Bracket Components (Continued)

TORQUE
REF. NO.
QUAN.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
1
1
2
1
1
2
2
1
2
2
2
2
2
1
1
1
1
2
1
1
1
1
1
90-13645--2 495
DESCRIPTION
Swivel Bracket
Oil Seal (LIPS FACE DOWN)
Bushing
O-Ring (UPPER)
Spacer (UPPER)
Grease Fitting
Bushing
Swivel Pin and Steering Arm Assembly
Bolt
Rubber Mount (UPPER)
Washer
Washer
Nut
Steering Link Assembly
Bolt 1-1/4 in. (31.7mm) Long
Lock Nut
Lock Nut
Washer
Wave Washer
Bottom Yoke
Retaining Ring
Thrust Washer (ALUMINUM SIDE TOWARDS SWIVEL BRACKET)
Bumper
LOWER UNIT
lb. in.
lb. ft.
40
120
Nm
4.5
80
108.4
20
27.1
13.5
5B-3
Transom Bracket Components
17 18
95
13
15
3
14
87
16
14
12
4
7
1
19
22
28
23
2
27
21
95
20
26
20
22
24
25
23
9
10
11
Application Points
95
87
7
5B-4
LOWER UNIT
2-4-C With Teflon (92-825407A12)
Quicksilver Gear Lubricant (92-13783A24)

90-13645--2 495
Transom Bracket Components (Continued)

TORQUE
REF. NO.
QUAN.
1
2
3
4
5
1
1
1
1
1
6
7
8
1
2
1
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
4
4
4
1
1
2
1
1
1
1
1
1
1
6
6
1
2
2
1
1
90-13645--2 495
DESCRIPTION
Transom Bracket (STARBOARD)
Transom Bracket (PORT)
Grease Fitting (PORT TRANSOM BRACKET)
Tilt Tube
Nut (1-14); No Torque Requirement, Drive Nut Until Bottomed On
Shoulder Of Tilt Tube
O-Ring
Wave Washer
Nut (7/8-14); No Torque Requirement - Drive Nut Until Assembly Is
Drawn Together, But Must Be Free To Pivot
Bolt
Washer
Nut
Tilt Lock Lever
Wave Washer
Bushing
Knob
Roll Pin
Spring
Groove Pin
Bolt
Nut
Lower Shock Absorber Shaft
Bolt
Lockwasher
Anode
Bolt
Washer
Bracket
Groove Pin
LOWER UNIT
lb. in.
lb. ft.
40
4.5
30
60
Nm
40.7
6.8
5B-5
Exhaust Plate Components
Application Points
9
8
7
6
29
28
27
26
2
21
10
23
25
1
22
20
24
31
30
32
11
17
12
16
13
35
18
33
7
15
34
19
14
5B-6
LOWER UNIT
90-13645--2 495
Exhaust Plate Components (Continued)

TORQUE
REF. NO.
QUAN.
DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
1
3
1
1
4
2
2
2
2
3
1
1
2
1
1
1
1
2
1
1
1
3
1
1
1
1
1
1
1
30
31
32
33
34
35
1
1
1
1
1
1
Exhaust Plate
Dowel Pin
Lower Cowl Seal
Upper Mount
Bolt Upper Mount to Exhaust Plate
Bolt Upper Mount
Spacer Upper Mount Bolt
Washer Upper Mount Bolt
Nut Upper Mount Bolt
Bolt Exhaust Plate
Gasket Exhaust Plate
Exhaust Tube
Bolt Exhaust Tube to Plate
Seal Lower Exhaust Tube
Water Tube
Clamp Water Tube Seal
Seal Upper Water Tube
Bolt Water Tube Clamp
Grommet Water Tube
Bracket Lower Cowl
Seal Lower Cowl Bracket
Bolt Lower Cowl Bracket
Shift Shaft Bushing
Upper Shift Shaft
Shift Shaft Bushing
Shift Link
Wave Washer Shift Shaft
Washer Shift Nut;
Lock Nut Shift Shaft; No Torque Requirement - Drive Unit Tight, But
Joint Must Be Free To Pivot
Shift Shaft Spacer
Shift Shaft Coupling Non-Power Trim
Shift Shaft Coupling Power Trim
Water Tube Extension
O-Ring Extra Long Shaft Only
Seal Extra Long Shaft Only
90-13645--2 495
LOWER UNIT
lb. in.
lb. ft.
Nm
23
31.2
80
15
108.5
20.3
15
20.3
80
9.0
23
31.2
5B-7
Drive Shaft Housing Components
27
34
95
30
33
29
26
3
36
35
28
32
24
95
95
31
28
25
95
22
23
17
21
12
20
11
19
17
17
7
15
8
5
6
10
4
5
6
18
16
17
Application Points
5B-8
LOWER UNIT
95
2-4-C With Teflon (92-825407A12)
17
Loctite 35 (92-59328-1)
90-13645--2 495
Drive Shaft Housing Components (Continued)

TORQUE
REF. NO.
QUAN.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
1
1
2
4
5
5
1
1
1
1
2
2
2
2
2
2
1
1
2
4
4
2
4
24
25
26
27
28
29
30
31
32
33
34
35
36
1
1
1
1
2
1
1
1
1
1
1
1
1
90-13645--2 495
DESCRIPTION
Drive Shaft Housing
Drive Shaft Housing Stud
Dowel Pin
Gear Housing Stud
Washer
Nut
Plug Power Trim
Speedometer Pick Up Assembly
90 Degree Connector
Straight Connector
Lower Mount
Lower Mount Bolt
Washer (CHAMFER SIDE TOWARDS MOUNT)
Washer
Washer
Nut
Ground Strap
Ground Strap Bolt
Lower Mount Clamp
Nylon Nut
Clamp Bolt
Lower Mount, Cover
Cover Screws
NON POWER TRIM
Reverse Lock Hook
Push Rod
Shaft
Cotter Pin
Bushing
Spring
Cotter Pin
Washer
Push Rod Spring
Push Rod Yoke
Nut
Clevis Pin
Cotter Pin
LOWER UNIT
lb. in.
lb. ft.
Nm
40
54.5
50
67.8
13.8
18.7
Drive Tight
5B-9
Reference Views
a
a
d
g
21046
a
b
c
d
e
Steering Arm
Swivel Pin
Thrust Washer (Aluminum side towards swivel bracket)
Spacer (Upper)
O-Ring
21054
a
b
c
d
e
f
g
h
i
Swivel Pin/Steering Arm
Push Rod End

Nut
Push Rod Yoke
Cotter Pin
Clevis Pin
Reverse Lock Hook Shaft Arm
Reverse Lock Hook Shaft
Return Spring
Tilt Pin
Non Power Trim Reverse Lock Hook

(Shown From Above)
f e
e f
d
c b
21055
a
b
c
d
e
f
Swivel Pin
Retaining Ring
Yoke
Wave Washer
Bushing (Lower)
Oil Seal (Lips Face Down)
Lower Mount Point (Yoke)
b
a
21053
a
b
c
d
e
f
Push Rod Shaft

Spring
Push Rod Yoke
Clevis Pin
Reverse Lock Hook Shaft
Cotter Pin (2)
Non Power Trim Reverse Lock Hook

(Shown From Below)
5B-10
LOWER UNIT
90-13645--2 495
b c
c b
e
d
e
d
b
c
f
f
21048
a
b
c
d
e
f
Upper Mount
Nut (2) [Torque to 80 lb. ft. (108.5 Nm)]
Bolt (2)
Rubber Space (2)
Washer (2)
Bolt (4) [Torque to 23 lb. in. (31.2 Nm)]
a
b
c
d
e
f
Upper Mount
21050
Upper Shift Linkage

Steering Arm/Swivel Pin
Upper Mount Bolt
Swivel Bracket
Grease Fitting
Mid-Section Drive Shaft Housing
a
e
h
d
i
g
f
a
c
21051
21049
a - Upper Shift Linkage
a
b
c
d
e
f
g
h
i
Lower Mount Clamp

Ground Strap
Bolt (2) [Torque to 15 lb. ft. (20.3 Nm)]
Lower Mount Bolt
Washer
Washer
Nut [Torque to 50 lb. ft. (67.8 Nm)]
Ground Strap
Bolt
Lower Mount (Port Side Shown)
90-13645--2 495
LOWER UNIT
5B-11
LOWER UNIT
5
SHOCK ABSORBER
Table Of Contents
Page
Page
Engine Equipped with a Single

Shock Absorber . . . . . . . . . . . . . . . . . . . . . . 5C-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-1
Inspection and Repair . . . . . . . . . . . . . . . . . 5C-2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-3
90-13645--2 495
Engines Equipped with a

Single Shock Absorber
Removal
1. Tilt engine to full UP position and engage tilt lock
lever.
WARNING
Failure to support engine as shown could result in
personal injury and/or damage to engine or boat.
IMPORTANT: Support engine with tool as shown,
to prevent engine from tipping over center into
boat when retaining pin is removed.
SUPPORT TOOL
3/8
53983
a - Tilt Lock Lever

b - Support Tool
c - Retaining Clips
METRIC CONVERSION
17 = 43.18 cm
2-1/2 = 63.50 mm
3/8 = 9.50 mm
5/16 = 7.94 mm
DRILL HOLES FOR

RETAIN-ING CLIPS
17
2. To remove tilt pin when straight cross pin is

installed, use a punch and hammer to drive out tilt
pin (shearing cross pin) and remove halves of
sheared cross pin.
3. To remove tilt pin when headed cross pin is
installed, use diagonal cutters to pry cross pin out
of tilt pin. Push out tilt pin.
IMPORTANT: Cross pin should not be reused after
removal. Replace with a new pin.
a
b
3/8
2-1/2
Use a metal rod (5/16 diameter) to make support tool.
51505
a - Cross Pin (Design 1 - Straight)
b - Cross Pin (Design 2 - Headed)
90-13645--2 495
LOWER UNIT
5C-1
4. Support lower mount bracket and remove (6)

bolts.
Inspection and Repair

1. Inspect bushings and replace if worn.
17244
a - Bushings
a - Bolts (3 Each Side)

b - Lower Mount Bracket
5. Remove shock absorber from lower mount

bracket by driving out cross pin using a punch and
hammer.
CAUTION
The shock absorber is pressurized with gas. Do
not disassemble unless fluid is leaking from
shock absorber.
NOTE: A pressurized shock absorber makes tilting of

the engine easier than a non-pressurized shock
absorber.
If the shock absorber leaks fluid it can be rebuilt by
installing Shock Absorber Repair Kit (P/N
41760A2), however, the shock absorber will no
longer be pressurized and the force needed to tilt the
engine will be increased to that of a non-pressurized
shock absorber. Instructions are supplied with kit.
If the shock absorber leaks fluid and a pressurized

shock absorber is desired, replace shock absorber as
an assembly.
17257
a - Cross Pin
6. Push out retaining pin.
17258
b - Retaining Pin
5C-2
LOWER UNIT
90-13645--2 495
Installation
1. Remove anode plate. Lubricate retaining pin with
Quicksilver 2-4-C w/Teflon. Place shock absorber
into lower mount bracket, as shown, and install retaining pin so that groove aligns with hole.
3. Reinstall shock absorber assembly between

clamp brackets and secure shock assembly to
clamp brackets with 6 bolts and lockwashers (3
each clamp bracket). Torque bolts to 30 lb. ft.
(40.7 Nm).
d
b
a
a
17255
a
b
c
d
Anode Plate
Retaining Pin
Groove
Cross Pin Hole
17244
a - Bolts [Torque to 30 lb. ft. (40.7 Nm)]

b - Shock Asorber Assembly
2. Drive cross pin (flush) into lower mount bracket,

as shown and reinstall anode plate. Secure
anode with 2 bolts and washers. Torque bolts to
60 lb. in. (6.8 Nm).
4. Reinstall tilt pin through swivel bracket and shock

absorber eye.
5. Install new cross pin securing shock to tilt pin.
17256
a - Cross Pin
51505
a - Cross Pin
a
a - Bolts [Torque to 60 lb. in. (6.8 Nm)]
90-13645--2 495
LOWER UNIT
5C-3
POWER TRIM
17250
DESIGN I
(SIDE FILL RESERVOIR)
6
A
Table Of Contents
Page
Power Trim - General Information . . . . . . . . . .

Description . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trimming Characteristics . . . . . . . . . . . . . . .
Trimming Outboard UP (Out) . . . . . .
Trimming Outboard DOWN (In) . . . .
Trailering Outboard . . . . . . . . . . . . . . . . . . . .
Tilting Outboard Manually . . . . . . . . . . . . . .
Trim In Angle Adjustment . . . . . . . . . . . . .
Striker Plate Replacement . . . . . . . . . . . . .
Anode Plate . . . . . . . . . . . . . . . . . . . . . . . . . .
Trim Indicator Gauge . . . . . . . . . . . . . . . . . .
Fill, Check, and Purge Power Trim System . . . . . . . . . . . . . . . .
To Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bleeding Air From Power Trim System . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .
Determining if Problem is Electrical or
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . .
Trouble Chart . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic System Troubleshooting . . . . . . . . . .
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . .
Trim Indicator Gauge and Trim
Sender Wiring Diagrams . . . . . . . . . . . .
Side Mount Remote Control
Wiring Diagram . . . . . . . . . . . . . . . . . . . .
Electrical System
Troubleshooting . . . . . . . . . . . . . . . . . . . . . .
General Checks . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting the Trailer Circuit*
(When Up Circuit Is OK) . . . . . . . . . . .
Troubleshooting the Up and Trailer
Circuits* (Both Circuits Inoperative:
Down Circuit Is OK) . . . . . . . . . . . . . . .
Troubleshooting the Down, Up and
Trailer Circuits*
(All Circuits Inoperative) . . . . . . . . . . . .
Troubleshooting the Up Circuit*
(When Trailer Circuit Is OK) . . . . . . . .
Troubleshooting the Down, Up and
Trailer Circuits*
(All Circuits Inoperative) . . . . . . . . . . . .
Troubleshooting the Down Circuit
(When Up Circuit Is OK) . . . . . . . . . . .
(When Down Circuit Is OK) . . . . . . . .
Troubleshooting the Down and Up
Circuits* (All Circuits Inoperative) . . . .
Power Trim Assembly Removal and
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6A-1
6A-1
6A-1
6A-1
6A-1
6A-1
6A-2
6A-2
6A-3
6A-3
6A-3
6A-3
6A-3
6A-4
6A-5
6A-5
6A-5
6A-6
6A-7
6A-7
6A-8
6A-11
6A-11
6A-11
6A-11
6A-12
6A-12
6A-13
6A-14
6A-15
6A-16
6A-17
6A-17
Page
Support Tool . . . . . . . . . . . . . . . . . . . . . . 6A-17

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-19
Testing Power Trim System with Test
Gauge Kit (91-52915A3) . . . . . . . . . . . . 6A-20
UP Pressure Check . . . . . . . . . . . . . . . . . . 6A-21
DOWN Pressure Check . . . . . . . . . . . . . . 6A-22
Power Trim Components . . . . . . . . . . . . . . . . . . 6A-24
Hydraulic Repair . . . . . . . . . . . . . . . . . . . . . . 6A-26
Trim Rod Removal And Repair . . . . . . 6A-26
Cleaning And Inspection - Trim
Rods and Caps . . . . . . . . . . . . . . . . 6A-26
Trim Rod End Cap Seal . . . . . . . . . . . . . . . . 6A-27
Trim Rod Installation . . . . . . . . . . . . . . . 6A-27
Tilt Ram Components . . . . . . . . . . . . . . . . . . . . . 6A-28
Tilt Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-29
Disassembly . . . . . . . . . . . . . . . . . . . . . . 6A-29
Cleaning and Inspection . . . . . . . . . . . . 6A-31
Scraper Replacement . . . . . . . . . . . . . . 6A-31
Reassembly . . . . . . . . . . . . . . . . . . . . . . 6A-32
Installation . . . . . . . . . . . . . . . . . . . . . . . . 6A-33
Pump Replacement . . . . . . . . . . . . . . . . . . . . . . 6A-34
Operative Trim Motor . . . . . . . . . . . . . . . 6A-34
Inoperative Trim Motor . . . . . . . . . . . . . 6A-34
Motor and Electrical Tests/Repair . . . . . . . . . . . 6A-35
Thermal Overload Switch Test . . . . . . . . . . 6A-35
Motor Assembled . . . . . . . . . . . . . . . . . . 6A-35
Motor Disassembled . . . . . . . . . . . . . . . 6A-36
Trim Pump Motor Test . . . . . . . . . . . . . . . . . 6A-36
Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . 6A-36
Motor Disassembly . . . . . . . . . . . . . . . . . . . . 6A-36
Armature Tests . . . . . . . . . . . . . . . . . . . . . . . 6A-37
Test for Shorts . . . . . . . . . . . . . . . . . . . . . 6A-37
Test for Ground . . . . . . . . . . . . . . . . . . . . 6A-37
Checking and Cleaning Commutator . 6A-37
Field Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-37
Trim Sender (Optional Accessory) Test . . 6A-38
Trim Indicator Gauge (Optional Accessory)
Needle Adjustment . . . . . . . . . . . . . . . . . 6A-38
Motor Repair . . . . . . . . . . . . . . . . . . . . . . . . . 6A-38
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-38
Disassembly . . . . . . . . . . . . . . . . . . . . . . 6A-38
Cleaning AND Inspection . . . . . . . . . . . 6A-38
Square Motor Components . . . . . . . . . . . . . . . 6A-39
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-40
Brush Replacement . . . . . . . . . . . . . . . . . . . 6A-42
90-13645--2 495
The Up circuit actuates the up solenoid (under outboard cowl) and closes the motor circuit. The electric
motor drives the pump, forcing fluid thru passageways into the up side of the trim cylinders.
Power Trim - General

Information
Description
The Power Trim System consists of an electric motor,
pressurized fluid reservoir, pump, tilt cylinder, and two
trim rams.
The remote control (or trim panel) has switches that
trim the outboard Up or Down and tilt the engine for
Trailering. The outboard can be trimmed and tilted
under power or when the outboard is not running.
Trimming Characteristics
NOTE: Because hull designs react differently in
varying water conditions, varying the trim position will
often improve the ride and boat handling. When
trimming from a mid-trim position (with outboard trim
tab in a straight fore and aft position), expect the
following:
TRIMMING OUTBOARD UP (OUT):
WARNING
Excessive trim Out may reduce the stability of
some high speed hulls. To correct instability,
reduce the power gradually and trim the outboard
In slightly before resuming high speed
operation. A rapid reduction in power will result in
a sudden change of steering torque and may
cause additional boat instability.
Will lift boat bow, increasing top speed.
Increases gearcase clearance over submerged objects.

can
cause
porpoising
The outboard can be trimmed above the 20 degree

maximum trim angle (for shallow water operation,
etc.), by keeping the engine RPM below 2000. If the
RPM increases over 2000, propeller thrust (if propeller is deep enough) will result in the trim system to return the outboard to the 20 degree maximum trim position.
TRIMMING OUTBOARD DOWN (IN):
WARNING
Excessive speed at minimum trim In may result
in undesirable and/or unsafe steering conditions.
Test for handling characteristics after any
adjustment is made to the trim angle (and tilt pin
location).
Aids planing, particularly with heavy loads.
Improves ride in choppy water conditions.
Excess trim In can cause bow steer (boat veers to
left or right).
Transfers steering torque to starboard (right).
Improves acceleration to planing speed.
Transfers steering torque harder to port (left) on installations above 23 in. transom height.
Excess trim
ventilation.
The trim cylinders position the outboard at the desired

trim angle in the 20 degree maximum trim range. The
system will not allow the outboard to be trimmed
above the 20 degree trim range as long as the engine
RPM is above approximately 2000 RPM.
and/or
The Down circuit actuates the down solenoid (under engine cowl) and closes the motor circuit. The
electric motor drives the pump in the opposite direction as the up circuit, forcing fluid thru passageways
into the down side of the tilt ram. The tilt ram moves
the engine down to the desired position.
Trailering Outboard
WARNING
Excessive outboard trim angle will result in
insufficient water supply causing water pump
and/or powerhead overheating damage. Insure
water level is above water intake holes whenever
outboard is running.
The Up circuit first moves the trim cylinders; when

the trim cylinders extend fully, the tilt ram extends to
tilt the outboard to the full Up position for trailering.
Before the boat is trailered, the operator should check
for clearance between the outboard skeg and pavement to prevent damage to skeg from striking pavement.
If the outboard must be tilted for clearance between
skeg and pavement, a device such as a Transom
Saver should be installed to prevent stress to boat
transom from outboard weight while the boat/outboard are being trailered.
90-13645--2 495
POWER TRIM
6A-1
Tilting Outboard Manually
WARNING
WARNING
Before opening the manual release valve knob,

insure all persons are clear of outboard as
outboard will drop to full Down when valve is
opened.
The outboard can be raised or lowered manually by
opening the manual release valve 3 to 4 turns counterclockwise. Close manual release valve to hold outboard at the desired tilt position.
Fill Screw (System is

Pressurized, DO
NOT Open unless
Outboard is Tilted to
Full Up Position)
Boat operation with outboard trimmed to the full

In trim angle [not using the trim angle
adjustment bolt] at planing speed may result in
undesirable and/or unsafe steering conditions. A
water test for handling/steering conditions is
required after any trim angle adjustments.
IMPORTANT: Some boat/motor combinations not
using the trim angle adjustment bolt and trimmed
to the full In trim angle position may not exhibit
any undesirable and/or unsafe handling and/or
steering characteristics at planing speed. If so,
not using the trim angle adjustment bolt may be
advantageous to acceleration and planing. A water test is required to determine if these characteristics apply to a particular boat/motor combination.
Manual Release
Valve
a
23321
23321
6A-2
a - Trim Angle Adjustment Bolt
POWER TRIM
90-13645--2 495
Striker Plate Replacement
Trim Indicator Gauge
Visually inspect striker plates and replace if worn excessively.
A Quicksilver Trim Indicator Gauge accessory kit is

available for the power trim sender (if not previously
installed).
Fill, Check, and Purge - Power Trim

System
TO FILL:
IMPORTANT: This trim system is pressurized. Remove Fill plug only when outboard is tilted to
the full Up position or the trim/tilt rams are fully
extended. Retighten Fill plug before tilting outboard down or retracting tilt/trim rams.
Remove Fill plug and O-ring. System is full
when oil level is present at fill hole. Tighten Fill
plug securely
a
27930
a - Striker Plate (2)
b - Lockwasher
c - Locknut. Torque to 80 lb. in. (9.0 Nm)
Trim engine to full up position. Engage tilt lock lever.

Trim system fluid can only be checked when engine
is in this position.
Slowly remove fill screw and check fluid level. Fluid
level should be visible in fill tube.
Anode Plate
Anode plate is a self-sacrificing alloy plate that is consumed gradually by corrosion while providing protection to the midsection and power trim from galvanic
corrosion. Replace anode plate when it is 50% consumed.
If necessary, add Quicksilver Power Trim and Steering Fluid or Automatic Transmission Fluid (ATF) Type
F, FA or Dexron II to power trim system.
Reinstall fill screw; tighten screw securely.
27932
a - Anode Plate
IMPORTANT: Do not paint or place protective

coating on anode plate, or corrosion protection
function will be lost.
90-13645--2 495
20319
a - Tilt Lock Lever
b - Fill Screw
POWER TRIM
6A-3
Bleeding Air From Power Trim System

To determine if the Power Trim system contains air,
position engine so two trim rods are slightly extended.
Do not extend tilt ram. Push down on lower unit. If trim
rods retract into trim cylinders more than 1/8
(3.2mm), it will be necessary to bleed air from the
Power Trim system.
Bleed air from Power Trim system as follows:
IMPORTANT: This trim system is pressurized. Remove fill screw only when engine is trimmed to
the full up position. Retighten fill screw securely before trimming engine down.
Trim engine 3 or 4 times thru entire trim range; check

fluid level (fill if necessary) each time engine is
trimmed to the full up position. See Checking Fluid
Level and Filling, preceding.
20319
a - Fill Screw
6A-4
POWER TRIM
90-13645--2 495
Troubleshooting
Hydraulic
When a problem is encountered with the Power Trim
system, the first step is to determine whether the malfunction is in the electrical system or the hydraulic
system. Refer to the following chart to determine
which system is at fault.
Trouble Chart
Engine will not trim up or down.
Engine trims up, will not trim down.
Determine if Power Trim

pump motor operates when
appropriate trim circuit is
activated.
Engine trims down, will not trim up.

Pump motor operates.
Pump motor does not

operate.
Engine will not return completely to

down position or returns part way
with jerky motion.
Engine thumps when shifted.
Engine trails out when backing off

throttle at high speed.
Refer to Hydraulic System

Troubleshooting.
Engine will not hold a trimmed

position or will not remain tilted for
any extended period.
Refer to Electrical System

Troubleshooting.
Engine will not hold trim position

when in reverse.
90-13645--2 495
POWER TRIM
6A-5
Hydraulic System
Troubleshooting
IMPORTANT: Operate Power Trim system after
each check to see if problem has been corrected.
If problem has not been corrected, proceed to
next check.
1. Check that manual release valve knob is tightened to full right (clockwise) position.
2. Check trim pump fluid level and fill if necessary.
Refer to Filling and Bleeding the Power Trim System, preceding.
3. Check for external leaks in Power Trim system.
Replace defective part(s) if leak is found.
4. Check for air in Power Trim system and bleed if
necessary. Refer to Filling and Bleeding the Power Trim System, preceding.
CAUTION
Do not remove check valve from port trim rod.
Check valve is preset to operate at a specific
pressure. Removal and reinstallation of check
valve could result in improper operating pressure
and possible Power Trim system damage.
5. If engine will not hold a tilted (trailer) position
(leaks down to trim position) Remove port trim
rod assembly from Power Trim housing; refer to
Trim Rod Removal, following.
Inspect check valve (located in port trim rod) for
debris; clean debris from check valve if found. If
debris can not be cleaned from check valve, replace trim rod and check valve as an assembly.
Inspect trim rod O-ring and replace if damaged.
Reinstall trim rod in housing; refer to Trim Rod
Installation, following.
6A-6
6. Disconnect trim pump motor wires, and remove

starboard transom bracket from engine. Refer to
Removal instructions in Power Trim Assembly
Removal and Installation, following.
Slowly remove fill screw to bleed pressure from
reservoir.
Place a pan under manual release valve, and
slowly remove valve. Inspect the valve and Orings for damage.
If damaged component(s) are found, replace
component(s) and proceed to STEP 9.
If damaged component(s) are not found, reinstall
manual release valve and proceed to STEP 7.
7. Remove Power Trim assembly from engine; refer
to Removal instructions in Power Trim Assembly Removal and Installation, following.
Disassemble Power Trim assembly; refer to Trim
Rod, Tilt Ram, and Pump Replacement, following. Inspect O-rings for damage. Inspect
check valves for debris that could cause them to
remain open.
If O-rings are damaged or debris is found, replace
O-rings or clean debris from check valve(s), then
reassemble Power Trim assembly and proceed to
STEP 9.
If damaged O-ring(s) or debris are not found, proceed to STEP 8.
8. Replace pump assembly; refer to Pump Replacement, following.
9. Install Power Trim assembly and/or starboard
transom bracket, steering retaining nut (models
with thru-tilt tube steering) and motor wires; refer
to Installation instructions in Power Trim Assembly Removal and Installation, following.
POWER TRIM
90-13645--2 495
Wiring Diagram
Trim Indicator Gauge and Trim Sender
Wiring Diagrams
Wiring Diagram For boats equipped with Quicksilver
Commander Series side mount remote control.
8 PIN HARNESS
TRIM INDICATOR GAUGE
REMOTE CONTROL
Rubber Sleeve
(Slide over
Connection)
TRIM SENDER
ENGINE
GROUND
Connect Wires Together with

Screw and Hex Nut; Apply
Liquid Neoprene to Connection
TO ENGINE
Ignition/Choke and Main Harness Assembly.
8 PIN HARNESS

TRIM SENDER
BLK
(Provided with Ignition

Switch Harness)
IGNITION/CHOKE
SWITCH
Rubber Sleeve
(Slide over
Connection)
ENGINE
GROUND
Connect Wires Together with

Screw and Hex Nut; Apply
Liquid Neoprene to Connection
TO ENGINE
Commander 2000 Series side mount remote control.
12 PIN HARNESS
TRIM
SENDER
ENGINE
GROUND
REMOTE CONTROL
TO ENGINE

Ignition/Choke and Main Harness Assembly
12 PIN HARNESS
TRIM
SENDER
ENGINE
GROUND
IGNITION/CHOKE
SWITCH
POWER TRIM HARNESS
TO ENGINE
90-13645--2 495
POWER TRIM
22908
6A-7
Side Mount Remote Control

Wiring Diagram
d
e
a
b
BLK
BLU
BRN
GRY
GRN
PUR
RED
TAN
WHT
YEL
DBLACK
DBLUE
DBROWN
DGRAY
DGREEN
DPURPLE
DRED
DTAN
DWHITE
DYELLOW
23891
a
b
c
d
e
f
g
Warning Horn
Trim/Tilt Switch
6A-8
POWER TRIM
90-13645--2 495
90-13645--2 495
POWER TRIM
6A-9
Commander Side Mount Remote Control Wiring Diagram

(3 Cylinder Models Using COMMANDER
Side Mount Remote Control)
BLK
BLU
GRN
PUR
RED
WHT
DBLACK
DBLUE
DGREEN
DPURPLE
DRED
DWHITE
12
10
6
9
3
2
1
14
23884
2000 Side Mount Remote Control)
BLK
BLU
GRN
RED
WHT
DBLACK
DBLUE
DGREEN
DRED
DWHITE
12
10
6
2
3
9
1
14
23886
2000 Side Mount Remote Control)
BLK
BLU
GRN
RED
WHT
DBLACK
DBLUE
DGREEN
DRED
DWHITE
10
6
12
9
1
2
14
23885
6A-10
POWER TRIM
90-13645--2 495
Electrical System
Troubleshooting
2. Make certain all connections are tight and corrosion free.
General Checks
4. Make certain battery is fully charged.
Before troubleshooting the Power Trim electrical system, check the following:
Refer to the preceding wiring diagrams for connection

points when troubleshooting the electrical system.
(Connection points are specified by number.)
3. Check that plug-in connectors are fully engaged.
1. Check for disconnected wires.
Troubleshooting the Trailer Circuit* (When Up Circuit Is OK)

* Remote Control Equipped with Trailer Button
Use an Ohmmeter (R x 1 scale) and check

continuity of wire between Point 10 on Up
solenoid and Point 13 on trailer button. If no
continuity, wire is open.
If wire is OK, disconnect all battery leads

from battery and check continuity across
trailer button terminals with trailer button
depressed. If no continuity is indicated,
trailer button is faulty.
Troubleshooting the Up and Trailer Circuits* (Both Circuits Inoperative:

Down Circuit Is OK)
Connect Voltmeter red lead to Point 10 and
BLACK lead to ground.
Depress the trailer button.
No Voltage Indicated:
Battery Voltage Indicated:
There is an open circuit in wires

[BLUE-WHITE (or BLUE), PURPLE-WHITE
(or PURPLE)] between Up solenoid and
trim buttons.
Connect Voltmeter RED lead to Point

3.

D Connect Voltmeter RED lead to Point
6.
D Depress trailer button.
D Check for loose or corroded connection
at Point 9 or Point 3.
D Check RED lead between Point 9 and
Point 3 for open.

D Check Up solenoid terminals for loose or
corroded connections.
D Check BLACK ground wire (on Up solenoid)
for corrosion or open.
D Test Up solenoid. Refer to Motor and
Electrical Tests, following.
90-13645--2 495
Solenoid is defective.
POWER TRIM
6A-11

(When Trailer Circuit Is OK)
Use an Ohmmeter (R x 1 scale) and check

continuity of wire between Point 10 on Up
solenoid and Point 7 on trim button.
Continuity:
No Continuity:
Connect Voltmeter RED lead to Point

8 (push button trim switch) or Point 5
(toggle trim switch) and BLACK lead to
ground.
Wire is open between Point 10 and

Point 7.
D Connect Voltmeter red lead to Point 7.

D Depress Up trim button.
Wire is open between trailer button Point

11 and trim switch Point 8 (push button
trim switch) or Point 5 (toggle trim switch).
D Check for poor connection at Point 7.
D Trim switch is defective.
Troubleshooting the Down, Up and Trailer Circuits*

(All Circuits Inoperative)
Check two in-line fuses (under cowl) to see
if fuses are blown.
Blown Fuse:
Fuses Not Blown:
D Correct problem that caused fuse to blow.

D Replace fuse.
Connect Voltmeter red lead to Point 3

and black lead to ground. Battery voltage
should be indicated.
D Check battery leads and RED leads (between engine starter motor solenoid and
Point 3) for poor connections or open
circuits.
D Check battery charge.
D Connect Voltmeter RED lead to Point 10.

D Depress Trailer button and check for
battery voltage.
continued on next page . . .
6A-12
POWER TRIM
90-13645--2 495
Troubleshooting the Down, Up and Trailer Circuits*

continued from preceding page
D Check BLACK ground wires at solenoids

for poor connection or poor ground.
D Check BLACK motor lead for poor ground
at Point 12. If wire is grounded, the pump
motor is faulty. Refer to Motor and Electrical Tests/Repair, following.
Connect RED Voltmeter lead to

Point 11, and BLACK lead to ground.
Check that voltage is being supplied to

control by performing the following checks:
There is an open circuit in each wire

[GREEN-WHITE, BLUE-WHITE, and
PURPLE-WHITE (or PURPLE)] between
trim buttons and trim pump.
D DO NOT start engine.

D Turn ignition switch to Run position.
D Check for voltage at any instrument, using
a Voltmeter.
D Check all trim harness connectors for

loose or corroded connections.
D Check for pinched or severed wires.
RED wire is open between Point 14 and
terminal b on the back of the ignition
switch.

There is an open circuit in wire between
Point 11 and terminal b on the back of the
ignition switch.
D Check for loose or corroded connections.

D Check for open in wire.
90-13645--2 495
POWER TRIM
6A-13

(When Up Circuit Is OK)
Remote Controls With or Without Trailer Buttons
Connect Voltmeter RED lead to Point 1 and
BLACK lead to ground.
Depress the Down trim button.
Connect Voltmeter RED lead to Point 9.
Connect Voltmeter RED lead to

Point 4 and BLACK lead to
ground. Depress Down trim
button. If battery voltage is
indicated, wire is open between
Points 4 and 1.

D Depress Down trim button.
There is an open circuit between Point 9 and

positive (+) battery terminal.
D Check wires for open.

D Check Down solenoid terminals for
D Check BLACK ground wire (on Down
solenoid) for corrosion or open.
D Test Down solenoid. Refer to Motor and
Electrical Tests, see Index.
Connect Voltmeter RED lead to Point 5. If
battery voltage is indicated, trim switch is
faulty. If no battery voltage, check for loose
or corroded connection at Point 5 or open
circuit in wire supplying current to Point 5.
6A-14
POWER TRIM
90-13645--2 495

(When Down Circuit Is OK)
* Remote Control NOT Equipped with Trailer Button
Connect Voltmeter RED lead to Point 10

and BLACK lead to ground.
Depress the Up trim button.
Trim Switch is faulty or there is an open

circuit in wires [GREEN-WHITE,
BLUE-WHITE and PURPLE-WHITE (or
PURPLE)] between trim point 7 and trim
pump.

D Depress Up trim button.
D Check for loose or corroded connection at Point 9 or Point 3.

D Check RED lead between Point 9 and
Point 3 for open.

D Check Up solenoid terminals for loose or
corroded connections.
D Check BLACK ground wire (on Up solenoid) for corrosion or open.
D Test Up solenoid. Refer to Motor and
Electrical Tests/Repair, following.
90-13645--2 495
D Check trim switch.

D Check all trim harness connectors for
POWER TRIM
6A-15
Troubleshooting the Down and Up Circuits*

* Remote Control NOT Equipped with Trailer Button
Check two in-line fuses (under cowl) to see

if fuses are blown.
Blown Fuse:
Fuses Not Blown:
D Correct problem that caused fuse to blow.

D Replace fuse.
Connect Voltmeter red lead to Point 3,

and black lead to ground. Battery voltage
should be indicated.
D Check battery leads and RED leads

(between engine starter motor solenoid and Point 3) for poor connections
or open circuits.
D Check battery charge.
D Connect Voltmeter RED lead to Point

10 and black lead to ground.
D Depress Up trim button and check for
battery voltage.
Connect RED Voltmeter lead to Point 5,
D Check BLACK ground wires at solenoids

D Check BLACK motor lead for poor ground
at Point 12. If wire is grounded, the pump
motor is faulty. Refer to Motor and Electrical Tests/Repair, following.

control by performing the following checks:
Trim switch is faulty or there is an open circuit

in wires [GREEN-WHITE, BLUE-WHITE and
PURPLE-WHITE (or PURPLE)] between trim
buttons and trim pump.
D DO NOT start engine.

D Turn ignition switch to Run position.
D Check for voltage at any instrument, using a Voltmeter.
D Check trim switch.

D Check all trim harness connectors for loose
or corroded connections.
Red wire is open between Point 14 and RED
terminal on back of the ignition switch.

Point 5 and RED terminal on the back of the
ignition switch.

D Check for open in wire.
6A-16
POWER TRIM
90-13645--2 495
Power Trim Assembly

WARNING
Failure to support outboard as shown could result
in personal injury and/or damage to outboard or
boat.
Removal
1. Remove clamps on transom bracket to free power
trim wiring.
a
a
20290
a - Harness Retainer
b - Clamp
c - Sta-Strap(s)
20319
2. Raise outboard to full Up position and engage tilt

lock lever.
a - Tilt Lock Lever
IMPORTANT: Support outboard as shown above

to prevent engine from tipping when power trim
retaining pin is removed.
SUPPORT TOOL
3/8 in. diameter metal rod (a used shift shaft works

well).
14
2
a
1/4
a - Drill Holes for Retaining Clips
METRIC CONVERSION
14 =
2 =
3/8=
1/4=
90-13645--2 495
POWER TRIM
35.56cm
50.8mm
9.5mm
6.35mm
6A-17
IMPORTANT: Outboards equipped with thru-thetilt-tube steering - remove steering link arm from
end of steering cable and cable retaining nut from
tilt tube.
c
b
51346
a - Tilt Lock Lever

b - Support Tool
c - Retaining Clips
51354
a - Retaining Nut
CAUTION
Disconnect battery cables at battery before
removing power trim wires from solenoids.
5. Remove outboard transom mounting bolts, and

loosen tilt tube nut until nut is flush with end of tilt
tube thread.
3. Disconnect power trim wires at solenoids (BLUE,

GREEN, and BLACK).
4. Open filler cap and release any remaining pressure in the system.
a
20319
a - Filler Cap
6A-18
51375
a - Transom Mount Bolts (2)

b - Tilt Tube Nut (flush with end of thread)
POWER TRIM
90-13645--2 495
6. Remove 3 screws and washers and move

starboard transom bracket so that manual
release valve will clear bracket when power trim
is removed.
Installation
1. Paint any exposed metal surfaces to prevent
corrosion.
2. Apply Loctite 271 to screws. Install trim system,
starboard transom bracket, and tilt tube nut.
c
a
b
a - Screws (3)
b - Washers (3)
c - Manual Release Valve
51375
IMPORTANT: Cross pin (a) should not be reused.

Replace with new cross pin.
7. Drive out cross pin, push out upper swivel pin, and
remove 3 screws and washers retaining trim system. Remove system from outboard.
a
b
51375
a - Screw (6) Torque to 45 lb. ft. (61.0 Nm)

b - Flatwasher (6) Install one per screw
3. Use a 12 volt power source to extend tilt ram up

to align upper swivel shaft hole and end of ram.
Connect trim motor wires (BLUE wire to POSITIVE (+), BLACK wire to NEGATIVE (-). If ram extends too far, retract ram by connecting GREEN
wire to POSITIVE (+).
4. Install Upper Swivel Pin with slotted end to left
(port) side of engine.
b
51339
a - Cross Pin
b - Upper Swivel Pin
90-13645--2 495
a - Upper Swivel Pin

b - Slotted End
c - Cross Hole (in line with slotted end)
IMPORTANT: Cross pin should not be reused.

Install a new pin.
POWER TRIM
6A-19
5. Position slot on end of swivel shaft in line with hole

in tilt ram end. Insert a punch into tilt ram hole to
align cross hole in upper swivel shaft. Tap new
cross pin in until flush.
9. Apply Quicksilver Liquid Neoprene (91-25511--2)

on all electrical connections.
b
c
a
a
b
a
b
c
d
Upper Swivel Shaft (Slot is in line with cross hole)

Chamfered End of Hole (Faces away from transom)
Cross Pin (Tri-lobe Design)
Tilt Ram End
20290
b - Clamp
WARNING
6. Connect trim motor wires to solenoids. Refer to

Wiring Diagrams in this manual. Route trim wires
as specified in this manual.
7. Apply marine sealer to shanks of mount bolts and
install transom mount bolts.
IMPORTANT: Do not use an impact driver to tighten transom mount bolts.
Apply marine sealer to threads of mount bolts. Secure
with flat washers and locknuts. Be sure installation is
watertight.
8. Tighten tilt tube nut securely.
IMPORTANT: Outboards equipped with thru-thetilt-tube steering: Tighten steering cable retaining
nut securely to tilt tube.
Electrical wires passing through cowl openings

must be protected from chafing or being cut.
Follow the recommended procedures outlined in
Section 1 of this Manual. Failure to protect wires
as described could result in electrical system
failure and/or injury to occupants of boat.
Testing Power Trim System With Test

Gauge Kit (91-52915A3)
IMPORTANT: This test will not locate problems in
the trim system. The test will show if the system
is correct after a repair. If minimum pressures are
not obtainable, the trim system requires additional repair.
Use Adapter Fitting (22-11243) to connect test gauge
to trim system.
3/8-24 UNF
1/16-27 NPSF
51354
a - Steering Cable Retaining Nut
6A-20
POWER TRIM
90-13645--2 495
5. Install components.
UP Pressure Check
IMPORTANT: Insure battery is fully charged before performing tests.
1. Tilt outboard to full Up position and engage tilt
lock lever.
2. Slowly remove Fill plug to bleed pressure from

reservoir.
3. Turn Manual Release Valve 3 to 4 turns (counterclockwise) to bleed any remaining pressure.
4. Remove allen plug.
e
a
b
c
d
17259
a
b
c
d
e
17250
Adaptor Fitting (22-11243)

Test Gauge Assembly
Tilt Pin (Position in Hole Shown)
Hose (Route Hose Behind Tilt Pin, as Shown)
Hose (Not Used for This Check)
6. Disengage tilt lock lever.
a - Allen Plug
90-13645--2 495
POWER TRIM
6A-21
11. Run trim UP. The minimum pressure should be

1300 P.S.I. (91 kg/cm2).
CAUTION
Failure to install spare tilt pin (or hardened bolts
and nuts) in hole shown could result in transom
bracket failure and possible injury.
12. Run trim DOWN to release pressure and remove spare tilt pin or bolts and nuts.
7. Move outboard In until hole in swivel bracket

ear aligns with the third tilt hole in transom bracket. Lock engine in trim range by installing a 3/8 in.
(9.5mm) diameter tilt pin or two 3/8 in. (9.5mm)
hardened bolts and nuts thru the transom brackets and swivel bracket in the hole shown.
14. Slowly remove Fill plug to bleed pressure.
13. Tilt outboard full UP and engage tilt lock lever.

15. Open Manual Release Valve 3 to 4 turns to bleed
any remaining pressure.
16. Remove test gauge hose and adapter, and install
allen plug.
NOTE: If pressure is less than 1300 PSI (91 kg/cm2),

troubleshoot system per instructions on page 6A-6.
DOWN Pressure Check

1. Repeat steps 1 through 4 from preceding UP
pressure check, removing allen plug as shown.
a
18456
a - Tilt Pin Hole
(Install Spare Tilt Pin or Hardened Bolts and Nuts)
8. Install Fill plug.

9. Close Manual Release Valve (clockwise).
10. Open valve (a) and close valve (b).
51367
a - Allen Plug
51374
a - Open Valve
b - Close Valve
6A-22
POWER TRIM
90-13645--2 495
3. Open valve (d) and close valve (e).

4. Install fill plug.
6. Run trim DOWN. Minimum pressure should be
500 P.S.I. (35 kg/cm2).

9. Open Manual Release Valve 3 to 4 turns to release any remaining pressure.

10. Remove test gauge hose and adapter fitting.
Install allen plug.
b
d
51360
11. Fill Power Trim system and purge system; refer to

Fill, Check, and Purge preceding.

troubleshoot system per instructions on Page 6A-6.
a - Adapter Fitting (22-11243)

b - Hose (route hose so it will not be pinched when outboard is
trimmed DOWN)
c - Test Gauge Assembly
d - Valve Open
e - Valve Close
f - Hose (not used for this test)
90-13645--2 495
POWER TRIM
6A-23
Power Trim Components
31
30
110
25
24
23
22
94
18
33
29
28
27
25
35
21
45
46
47
26
32
17
40
2
6
19
5
4
16
9
39
1
20
15
14
36
34 38
37
44
41
42
43
8
42
11
12
44
10
11
12
13
Application Points
94
110

Power Trim and Steering Fluid (92-90100A12)
25
Liquid Neoprene (92-25711--2)

TORQUE
REF. NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
6A-24
DESCRIPTION
Housing
Allen Plug
Manual Release Valve
O-ring [.239 (6.07mm) I.D.]
O-ring [.208 (5.28mm) I.D.]
O-ring [.114 (2.90mm) I.D.]
O-ring [.989 (25.12mm) I.D.]
Shaft
Trim Rod Assembly, Starboard
Anode Plate
Washer
Bolt
Striker Plate, Trim Rod
Lockwasher
Nut
POWER TRIM
lb. in.
lb. ft.
Nm
70
7.9
80
9.0
90-13645--2 495
Power Trim Components (Continued)

TORQUE
REF. NO.
16
17
18
19
D20
21
D22
D23
24
D25
D26
27
28
29
D30
31
JD32
33
34
35
36
37
38
39
40
J41
J42
J43
44
45
46
47
DESCRIPTION
Tilt Cylinder Assembly
Cross Pin
Retaining Pin
Pin
O-ring [1.248I (31.70mm) I.D.]
Trim Rod Assembly w/Check Valve, Port
O-ring [.612I (15.54mm) I.D.]
O-ring [1.475I (37.47mm) I.D.]
Cap, Trim Cylinder
Seal
O-ring (2.864I I.D.)
Washer
Bolt
Reservoir Cover
O-ring [.583I (14.81mm) I.D.]
Fill Screw
O-ring [2.739I (69.57mm) I.D.]
(If Equipped)
Square Motor Assembly
Square Ring, used when end frame cap
has groove
Gasket, used when end frame cap does
NOT have groove
Bolt
Allen Bolt
Lockwasher
End Frame Cap
O-ring (or Flat Ring)
O-ring [2.739I (69.57mm) I.D.]
O-ring [2.614I (66.40mm) I.D.]
Flat Ring
Pump Assembly
Screen (If Equipped)
Washer (If Equipped)
Screw (If Equipped)
lb. in.
70
70
lb. ft.
Nm
7.9
7.9
J Contents of Pump Seal Kit (P/N 12663)

D Contents of Power Trim O-ring Kit (P/N 25-48462A1)
* It is recommended O-ring be installed even if pump was not originally equipped with this O-ring.
90-13645--2 495
POWER TRIM
6A-25
5. Install trim rod removal tool and pull trim rod from
cylinder.
Hydraulic Repair
TRIM ROD REMOVAL AND REPAIR
NOTE: Power Trim does not have to be removed from

outboard to remove trim rods.
1. Tilt outboard to full UP position and engage tilt
lock lever.
2. Slowly remove Fill plug to bleed reservoir
pressure.
3. Turn Manual Release Valve 3 to 4 turns (counterclockwise) to bleed remaining pressure.
4. Remove trim rod cylinder caps.
NOTE: Place a clean pan under trim system to catch

fluid.
27933
a - Trim Rod Removal Tool (91-44486A1)
CLEANING AND INSPECTION - TRIM RODS AND

CAPS
CAUTION
a
b
Do not remove check valve (a). Check valve is

preset to operate at a specific pressure. Removal
and installation of check valve could result in
improper operating pressure and possible
system damage.
NOTE: Check valve is in port side trim rod only.
51353
a - Trim Rod Cylinder Cap
b - Turn Counterclockwise to Remove
1. Inspect check valve and check valve screen for

debris; if debris cannot be removed, replace trim
rod assembly. Clean trim rod with parts cleaner
and dry with compressed air.
b
a
a
b
51337
a - Removal Tool (91-44487A1)
b - Spanner Wrench (91-74951)
6A-26
51352
a - Check Valve
b - Check Valve Screen
POWER TRIM
90-13645--2 495
Trim Rod End Cap Seal

1. Inspect trim cap end seal and replace if damaged
or if seal does not keep trim rod clean.
1. Apply Quicksilver Power Trim and Steering Fluid

on all O-rings and seals before installation.
2. Install trim rods and caps. Use Installation Tool
(91-44487A1) or Spanner Wrench (91-74951) to
tighten caps securely.
51343
a - Seal (Remove as shown)
2. Install new seal with seal lip up.

TRIM ROD INSTALLATION
IMPORTANT: Components must be free of dirt and

lint. Any debris in the system can cause system
to malfunction.
NOTE: Install trim rod with check valve in the port (left)
cylinder.
b
51353
a - Trim Rods
b - Cylinder End Caps
c - Rod End Rollers (lubricate with Quicksilver Anti-Corrosion Grease or
2-4-C w/Teflon)
90-13645--2 495
POWER TRIM
6A-27
Tilt Ram Components
3
2
1
14
13
12
11
10
9
8
16
2
7
6
5
17
15
18
TORQUE
REF. NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
QUAN.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
DESCRIPTION
lb. in.
lb. ft.
Nm
Housing, Tilt Ram

O-ring (1.957 I.D.)
Cup
O-ring (.307 I.D.)
Rod End
O-ring (.661 I.D.)
Washer
Piston
O-ring (2.067 I.D.)
Cap
O-ring (.854 I.D.)
Scraper
Washer
Retaining Ring
Roll Pin
Rod
Contents of Tilt Cylinder O-ring Kit (P/N 25-41478A1)
6A-28
POWER TRIM
90-13645--2 495
DISASSEMBLY
Tilt Ram
1. Secure tilt ram (at its base) in a soft jawed vise.
REMOVAL
Using Spanner Wrench, loosen cap by turning

cap in direction.
1. Remove Power Trim assembly from engine, refer

to Removal instructions in Power Trim Assembly Removal and Installation, preceding.
Remove ram from vise, and pour fluid from ram.

Pull rod assembly out of ram.

reservoir.
From a full closed (clockwise) position, slowly
open manual release valve 3 to 4 turns (counterclockwise) to bleed remaining pressure from
Power Trim system.
91-74951
a
d
Remove pin by driving pin in direction shown.

51337
51364
51366
a - Pin
2. Remove shaft by driving shaft in direction shown.
a
b
c
d
Spanner Wrench
Cap
Turn in Counterclockwise Direction
Rod Assembly
a
51355
a - Shaft
90-13645--2 495
POWER TRIM
6A-29
2. Clamp tilt rod in a soft jawed vise, as shown.
4. Slide cap off from rod.
Remove o-ring.
Heat rod with Torch Lamp (91-63209 or
91-74042).
Using spanner wrench (91-74951), remove rod
end by turning rod end in direction shown.
c
a
91-749
51
HEAT THIS AREA
51376
a - Cap
5. Remove roll pin using a punch and hammer.

51337
Remove check valve assembly.
51340
a - O-ring
b - Rod End
c - Turn in Counterclockwise Direction
3. Lift washer and piston from rod; do not let check

valve assemblies fall.
Remove check valve assemblies.
a - Roll Pin
b - Check Valve Assembly
6. Remove allen plug from shaft.
IMPORTANT: Remove plug from same side as

holes in shaft.
Lubricate shaft with Automatic Transmission Fluid

(ATF) Type A or AF.
a
b
DO NOT REMOVE
51361
51363
a - Allen Plug
a - Washer
b - Piston
c - Valve Assemblies
6A-30
POWER TRIM
90-13645--2 495
7. Insert shaft into housing, as shown.
51342
Tap shaft into housing until shaft is positioned as

shown.
51353
a - Shop Cloth
b - Solid Work Bench (or Floor)
c - Air Nozzle

Inspect O-rings, and replace if damaged.
Clean components with parts cleaner and dry with
compressed air.
Inspect tilt rod. If scraper (located in cap) has failed to
keep rod clean, replace scraper; refer to instructions,
following.
51365
SCRAPER REPLACEMENT
Use a screwdriver to remove components from cap.
DANGER
Cup will be expelled from housing at a high
velocity when air pressure is applied. Failure to
place housing as shown could result in severe
personal injury or death.
e
d
c
8. Place housing, as shown.
Hold down on housing and inject air into shaft

opening, as shown.
Reinstall allen plug into shaft.
a
b
a
b
c
d
e
90-13645--2 495
Cap
O-ring (2)
Scraper Seal
Washer
Retaining Ring
POWER TRIM
6A-31
REASSEMBLY
4. Install components, as shown.
IMPORTANT: Components must be dirt and lint

free. Slightest amount of debris in Power Trim
system could cause system to malfunction.
1. Apply Automatic Transmission Fluid (ATF) Type A

(Dexron II) on O-rings during reassembly.
NOTE: Refer to Tilt Ram Components for proper

O-ring sizes.
Install O-rings.
2. Insert cup into housing.
a
a
b
c
d
Piston
Roll Pin
O-ring
5. Install O-rings in locations shown.
51372
a - O-ring
b - Memory Piston Cup (Design 1 shown)
3. Assemble cap, as shown.
b
e
a - Rod End
b - O-rings
d
c
6. Install end cap.
b
a
b
51376
a
b
c
d
e
End Cap
O-ring (2)
Scraper Seal
Washer
Retaining Ring
6A-32
NOTE: Some tilt rams have one check valve spring

that is a lighter duty than the other six springs.
7. Install components onto rod, as shown.
POWER TRIM
90-13645--2 495
Screw rod end into rod. Tighten rod end securely

using Spanner Wrench.
INSTALLATION
1. Lubricate alignment tool and shaft with Quicksilver Power Trim and Steering Fluid or Automatic
Transmission Fluid (ATF) Type F, FA or Dexron II.
b
b
c
51369
a - Alignment Tool (91-11230)
b - Shaft
2. Align tilt ram with Power Trim housing by inserting

alignment tool in direction shown.
17222
a
b
c
d
e
Rod End
Washer
Piston
Rod
Check Valve Assemblies (7)
8. Clamp housing in a soft jawed vise.

Install rod assembly into housing.
Tighten cap securely using Spanner Wrench
(91-74951).
51348
a - Alignment Tool
91-74951
3. Install shaft into housing, as shown.
Groove will align with hole when shaft is properly

installed.
51337
a
c
51341
a - Housing
b - Rod Assembly
c - Cap
90-13645--2 495
51352
a - Shaft
b - Groove
c - Hole
POWER TRIM
6A-33
4. Install pin. Drive pin in until flush.
Tighten manual release valve to full right (clockwise).
Install Power Trim assembly on engine, refer to

Installation instructions in Power Trim Assembly Removal and Installation, preceding.
Operate trim motor in Up direction by connecting

trim motor wires to a 12-volt battery [BLUE wire to
POSITIVE (+) terminal and BLACK wire to
NEGATIVE () terminal].
reservoir.
From a full closed (clockwise) position, slowly turn
manual release valve counterclockwise four turns to
bleed remaining pressure from system.
Remove 2 bolts and lockwashers.

Lift motor and pump assembly from housing.
INOPERATIVE TRIM MOTOR
reservoir.
51356
a - Pin (Drive Against Knurled End)
Pump Replacement
From a full closed (clockwise) position, slowly turn

manual release valve counterclockwise four turns to
bleed remaining pressure from system.
Remove 2 bolts and lockwashers.
IMPORTANT: The pump is not rebuildable. If pump

is defective, replace as an assembly.
Using 2 screwdrivers, pry up on motor at slots.
NOTE: Power Trim assembly does not have to be removed from engine to replace pump.
1. Disconnect trim pump motor wires, and remove
starboard transom bracket from engine; refer to
Removal instructions in Power Trim Assembly
Removal and Installation, preceding.
Unseat motor and pump assembly from housing

as follows:
OPERATIVE TRIM MOTOR
Loosen 2 bolts until 1/4 (6mm) of each bolt is exposed. Do not remove bolts.
a
1/4
18461
1/4
b - Bolts
c - Slots
18458
a - Bolts
6A-34
POWER TRIM
90-13645--2 495
2. Remove screws and clamp.

Remove screws.
Lift motor from end cap, taking care not to drop
armature.
Motor and Electrical

Tests/Repair
Thermal Overload Switch Test
IMPORTANT: If trim pump has just been operated,
do not run pump for approximately one minute before testing thermal overload switch. After this
period of time the switch should close (reset itself) and pump again may be operated. Perform
the following check(s) only if switch does not reset itself.
MOTOR ASSEMBLED
Connect Ohmmeter (R x 1 scale) leads as shown. If
switch is good, full continuity (zero ohms) will be indicated. If full continuity is not indicated, disassemble
motor and recheck switch per instructions, following.
d
e
b
a
b
c
d
e
51345
Screw (3)
Clamp
Screw (4)
Gasket
Grommet
3. Remove bolts.
NOTE: Some motors use 2 bolts to secure end frame

cap.
Lift end cap from pump.

Follow Reassembly and Installation instructions in Motor Repair, following.
18459
a - Motor Wire (BLUE)

b - Motor Wire (BLACK)
18469
a - Bolts
b - End Cap
c - Pump
90-13645--2 495
POWER TRIM
6A-35
MOTOR DISASSEMBLED
Connect Ohmmeter (R x 1 scale) leads as shown. If
switch is good, full continuity (zero ohms) will be
indicated.
3. Connect a 12-volt power supply to terminals 3 and

4. Solenoid should click and meter should read
zero (0) ohms (full continuity).
If full continuity is not indicated, clean switch contact

surfaces, using an ignition point file.
1
2
4
d
a
b
51338
3
c
18473
c - Test Leads
d - Switch Contact Surface
4. If meter does not read zero (0) ohms, replace

solenoid.
Motor Disassembly
Recheck switch; if full continuity is not indicated, replace brush card. Switch is supplied on brush card.
Trim Pump Motor Test
WARNING
Do not perform this test near flammables (or
explosives), as a spark may occur when making
connections.
1. Disconnect BLUE (motor) wire and BLACK (motor) wire at solenoids.
2. Connect a 12-volt supply to motor wires [POSITIVE (+) wire to BLUE (motor) wire, and NEGATIVE () wire to BLACK (motor) wire]. Motor
should run.
d
e
3. If motor does not run, disassemble motor and

check components. Refer to Motor Repair,
following.
Solenoid Test
WARNING
Do not perform this test near flammable materials,
as a spark may occur while making electrical
connections.
a
b
c
d
e
51345
Screw (4)
Screw (3)
Clamp
Gasket
Grommet
1. Disconnect all wires from solenoid terminals.

2. Set an Ohmmeter to R x 1 scale and connect meter leads to solenoid terminals 1 and 2.
6A-36
POWER TRIM
90-13645--2 495
2. Lift motor from end cap. Use care not to drop

armature.
CHECKING AND CLEANING COMMUTATOR

1. If commutator is worn, it may be turned on an armature conditioner or a lathe.
2. Clean commutator with OO sandpaper.
b
a - Commutator
Field Tests
IMPORTANT: Commutator end of armature must
be installed in brushes when performing the following tests.
Ohmmeter
Leads Between
51349
a - End Cap
b - Armature
Armature Tests
TEST FOR SHORTS
Check armature on a Growler per the Growler manufacturers instructions. Replace armature if a short is
indicated.
TEST FOR GROUND
1. Use an Ohmmeter (R x 1 scale). Connect one
lead on armature shaft and other lead on commutator. If continuity is indicated, armature is
grounded. Replace armature.
Resistance
(Ohms)
Scale Reading*
(x
Green and Blue

Motor Wires
Full Continuity
(R x 1)
Green and Black

Motor Wires
Full Continuity
(R x 1)
Blue and Black

Motor Wires
Full Continuity
(R x 1)
Black Motor Wire,

and Frame (Motor
Housing)
No
Continuity
No Continuity
(R x 1)
Green Motor Wire,

and Frame
No
Continuity
No Continuity
(R x 1)
Blue Motor Wire,

and Frame
No
Continuity
No Continuity
(R x 1)
*If specified readings are not obtained, check for:

defective armature
dirty or worn brushes
dirty or worn commutator
If defective components are found, repair or
replace component(s) and retest.
51359
90-13645--2 495
POWER TRIM
6A-37
Trim Sender (Optional Accessory) Test

Check trim sender BLACK lead for proper ground.
Trim engine to full Down position.
Place ignition switch in Off position.
Connect Ohmmeter (R x 1 scale) leads between
engine ground and Point 1.
Depress Up trim button. Ohmmeter needle should
move as the engine is trimmed up. If needle does not
move, the trim sender is defective.
Trim Indicator Gauge (Optional

Accessory) Needle Adjustment
Trim engine to full Down position. If trim indicator
needle is not at the bottom of the green arc on the
gauge face, tilt engine up to gain access to the trim
sender. Loosen screws and reposition trim sender, as
shown. Trim engine to full Down position and recheck needle position.
BRN/WHT
BLK
c
b
BRN/WHT
a - Trim Sender
b - Connect with Screw and Hex Nut (Coat with Liquid
Neoprene)
c - Rubber Sleeve (Slide Over Connection)
22744
a
b
c
d
e
Trim Sender
Screws, Loosen to Rotate Sender
Turn Sender Counterclockwise to Raise Needle Reading
Turn Sender Clockwise to Lower Needle Reading
Tilt Lock Lever
Motor Repair
REMOVAL
NOTE: Power Trim assembly does not have to be removed from engine to repair motor.
Remove motor and pump as an assembly; refer to
Pump Replacement, preceding.
DISASSEMBLY
Refer to Pump Replacement, preceding, for proper
disassembly procedure.
Inspect O-rings, and replace if damaged.
Clean, inspect and test motor components; refer to
Brush Replacement, Armature Test, and Field
Tests, preceding.
6A-38
POWER TRIM
90-13645--2 495
Square Motor Components
4
1
25
20
5
6
7
2
3
27
10
25
8
11
9
27
12
13
14
10
15
Application Points
25
27
Bellows Adhesive (92-86166)
16
9
18
17
19
25
TORQUE
REF. NO.
QUAN.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
4
4
4
3
1
1
1
1
2
2
3
2
4
1
1
1
1
2 or 3
1
1
90-13645-2 495
DESCRIPTION
Thru Bolt
Nylon Washer (If Equipped)
O-ring
Self-Tapping Screw
Retainer, metal
Nylon Isolator (If Equipped)
Seal, rubber
End Frame Cap, upper
Square Ring, used when end frame cap has groove
Gasket, used when end frame cap does not have groove
Connector, metal
Sleeve
Brush Spring
Brush Card
Field and Frame Assembly
Thrust Washer
Armature
Bolt
End Frame Cap, lower
Clamp
POWER TRIM
lb. in.
lb. ft.
Nm
13
1.5
13
1.5
70
7.9
6A-39
Reassembly
IMPORTANT: Components must be dirt and lint
free. Slightest amount of debris in Power Trim
system could cause system to malfunction.
3. Install a flat ring (if equipped) into groove in each

end cap.
NOTE: Verify rings are not twisted after installation.
1. Install O-rings and flat ring(s).

Apply Quicksilver Power Trim and Steering Fluid
or Automatic Transmission Fluid (ATF) Type F, FA
or Dexron II on lip of seal.
e
b
c
d
c
18465
18452
a
b
c
d
e
a - Flat Ring (If Equipped)
O-ring (or Flat Ring)

O-ring [2.739 (69.57mm) I.D.]
O-ring [2.614 (66.40mm) I.D.]
Flat Ring
Seal
Glue a rubber gasket (if equipped) onto each end

cap using Quicksilver Bellows Adhesive.
2. Apply Loctite 271 on bolts, and install end frame

cap.
a
b
18462
18469
a - Rubber Gasket
a - Bolts
b - End Cap
NOTE: Some motors use 2 bolts to secure end frame

cap.
6A-40
POWER TRIM
90-13645--2 495
4. Install armature into pump.
6. Spread brushes; position brushes as shown.
Rotate armature to align hex shaft with pump.
Install thrust washer (if equipped).
a
b
18464
a - Armature
b - Pump
18457
5. Install field and frame assembly onto pump as

shown.
a - Brushes
b - Thrust Washer
7. Install end cap and screws.
d
e
b
c
18454
a - Thermal Overload Switch
b - Rocker Arm
90-13645--2 495
a
b
c
d
e
51345
Screw (4)
Screw (3)
Clamp
Gasket
Grommet
POWER TRIM
6A-41
8. Install O-ring [2.739 (69.57mm) I.D.]. It is recommended O-ring be installed even if pump did not
originally have O-ring.
Insert pump and motor assembly into Power Trim
housing, with rocker arm positioned as shown.
Brush Replacement (Square Motor)

1. Brush replacement is recommended if brushes
are pitted, chipped, or if distance (a) between the
brush pigtail and end of brush holder slot is 1/16
or less. Check the distance with armature
installed, as shown.
b
18453
a - O-ring
b - Rocker Arm
9. Apply Quicksilver Perfect Seal on threads of 2

bolts.
Secure motor using 2 bolts and lockwashers.
Waterproof Power Trim system by applying
Quicksilver Liquid Neoprene on seam.
18457
a - Distance =1/16 in. (1.6mm)
a
b
a
b
18461
a - Bolts
b - Lockwashers
c - Seam
10. Install starboard transom bracket, steering retaining nut (models with thru-tilt tube steering), and
motor wires; refer to Installation instructions in
Power Trim Assembly Removal and Installation,
preceding.
6A-42
POWER TRIM
90-13645--2 495
2. To replace brush card, remove plastic insulators.
3. Remove metal connectors by separating the slit

in connectors using a side cutter, as shown.
a
a
18463
18466
a - Insulators
a - Metal Connectors
Install new brush card.

Crimp metal connectors on connections.
Use heat shrink tubing to insulate connections.
90-13645--2 495
POWER TRIM
6A-43
POWER TRIM
51344
DESIGN II
(AFT FILL RESERVOIR)
6
B
Table Of Contents
Page
Power Trim System . . . . . . . . . . . . . . . . . . . . . . .

Specifications . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . .
Quicksilver Lubricants and Service Aids . .
Power Trim Components . . . . . . . . . . . . . . . . . .
Information . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trimming Outboard UP (Out) . . . . . .
Trimming Outboard DOWN (In) . . . .
Tilting Outboard Manually . . . . . . . . . . . . . .
Striker Plate Replacement . . . . . . . . . . . . .
Anode Plate . . . . . . . . . . . . . . . . . . . . . . . . . .
Trim Indicator Gauge . . . . . . . . . . . . . . . . . .
Fill, Check, and Purge - Power
Trim System . . . . . . . . . . . . . . . . . . . . . .
To Purge . . . . . . . . . . . . . . . . . . . . . . . . .
To Check . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic System
Hydraulic System Troubleshooting . . .
Electrical System Troubleshooting . . .
Power trim System Wiring Diagram
(V-6 Models) . . . . . . . . . . . . . . . . . . .
Side Mount Remote Control Wiring Diagram
(Test Points for Electrical
Troubleshooting) . . . . . . . . . . . . . . . . . . . . . .
Electrical System
General Checks . . . . . . . . . . . . . . . . . . .
(When Up Circuit is OK) . . . . . . . . . . .
Troubleshooting the Up Circuit
(When Down Circuit is OK) . . . . . . . .
Circuits (All Circuits Inoperative) . . . . .
Power Trim Assembly
Removal and Installation . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Support Tool . . . . . . . . . . . . . . . . . . . . . .
6B-1
6B-1
6B-1
6B-1
6B-2
6B-4
6B-4
6B-4
6B-4
6B-4
6B-4
6B-5
6B-5
6B-6
6B-6
6B-6
6B-6
6B-7
6B-7
6B-7
6B-8
6B-8
6B-9
6B-9
6B-10
6B-11
6B-11
6B-11
6B-12
6B-13
6B-14
6B-14
6B-14
Page
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
UP Pressure Check . . . . . . . . . . . . . . . . . .
DOWN Pressure Check . . . . . . . . . . . . . .
Hydraulic Repair . . . . . . . . . . . . . . . . . . . . . .
Trim Rod Removal and Repair . . . . . .
Cleaning And Inspection Trim Rods and Caps . . . . . . . . . . . .
Trim Rod End Cap Seal . . . . . . . . . . . . . . . .
Trim Rod Installation . . . . . . . . . . . . . . .
Tilt Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal - Tilt Rod Assembly Only . . .
Tilt Ram Components . . . . . . . . . . . . . .
Tilt Ram Removal - Power Trim
System Removed from
Outboard . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . .
Scraper Seal Replacement . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . .
Tilt Ram Assembly Installation . . . . . . .
Motor And Pump Replacement . . . . . .
Motor and Electrical Tests/Repair . . . . . . . . . . .
Trim Pump Motor Test . . . . . . . . . . . . . . . . .
Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Disassembly . . . . . . . . . . . . . . . .
Armature Tests . . . . . . . . . . . . . . . . . . . . . . .
Test For Shorts . . . . . . . . . . . . . . . . . . . .
Test For Ground . . . . . . . . . . . . . . . . . . .
Checking And Cleaning
Commutator . . . . . . . . . . . . . . . . . . .
Field Tests . . . . . . . . . . . . . . . . . . . . . . . .
Motor Repair . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . .
Brush Replacement . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly - Motor and Pump . . . . . . . . .
Priming Power Trim System . . . . . . . . . . . .
Trim Sender (Optional Accessory) Test . .
Trim Indicator Gauge Needle
Adjustment . . . . . . . . . . . . . . . . . . . . . . .
Trim Indicator Wiring Diagrams . . . . . . . . . . . .
6B-16
6B-18
6B-19
6B-20
6B-20
6B-20
6B-21
6B-21
6B-22
6B-22
6B-22
6B-23
6B-23
6B-25
6B-25
6B-26
6B-27
6B-28
6B-29
6B-29
6B-29
6B-29
6B-30
6B-30
6B-30
6B-30
6B-30
6B-31
6B-31
6B-31
6B-31
6B-32
6B-33
6B-34
6B-34
6B-34
6B-35
6B-35
90-13645--2 495
Power Trim System

Specifications
Test
Readings
Trim UP
1300 PSI (91 kg/cm2)

Maximum Pressure
Trim DOWN
500 PSI (35 kg/cm2)

Minimum Pressure
Special Tools
Part No.
Description
91-11230
Alignment Tool
91-44486A1
Trim Rod Removal Tool
91-44487A1
Trim Rod Guide Removal Tool
91-52915A3
Power Trim Test Gauge Kit
91-11243
Adaptor Fitting
91-74951
Spanner Wrench
91-99750
Multi-Meter DVA Tester
Quicksilver Lubricants and Service

Aids
Part No.
Description
91-90100A12
Power Trim and Steering Fluid
Obtain Locally
Loctite 271
91-25711-1
Liquid Neoprene
91-78376A6
90-13645--2 495
POWER TRIM
6B-1
Power Trim Components

NOTE: All O-rings - Lubricate with Power Trim
and Steering Fluid.
7
35
34
6
7 6
23
38
22
37
36
8
4
5
25
17
18
18
25
15
16
110
24
18
94
18
19
10
11
18
10
18
18
12
26
13
18
1
14
2
40
32
31
33
30
6B-2
25
Liquid Neoprene (92-25711-1)
27
18
29
28
20
39
110
94

POWER TRIM
21
90-13645--2 1095
Power Trim Components (Continued)

REF. NO.
1
2
3
4
5
6
7
8
9
10
10
11
12
13
14
15
16
17
18
19
20
21
22
QUAN.
1
9
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
1
1
1
1
2
1
23
23
24
25
26
27
28
29
30
31
32
33
34
35
35
35
36
37
38
39
40
2
2
1
1
1
1
2
2
2
2
2
1
1
1
1
1
2
2
2
6
6
90-13645--2 1095
DESCRIPTION
TORQUE
lb. in. lb. ft.
Nm
Manifold
Pipe Plug
Tilt Cylinder Assembly
Piston Rod (Bolt Type) Design 1
Piston Rod (Nut Type) Design 2
Guide Kit
O-ring Repair Kit (811607A1)
Check Valve Kit
Guide Assembly
Piston and Rod Assembly (Port)
Piston and Rod Assembly (Starboard)
Trim Filter Assembly
Groove Pin
Valve Assembly
E-ring
Screw
Washer
Cover
O-ring Kit (811612A1)
Plug Assembly
Shaft Assembly
Plug Pipe
Trim Motor
Screw (Long)
Screw (Short)
Pump
Driveshaft
Shaft
Anode Assembly
Screw
Washer
Striker Plate
Lockwasher
Nut
Groove Pin
Control Harness, Power Trim
Cable (6-3/8 Red)
Cable (24 Red)
Cable (2-3/4 Red)
Clip, Pump Wire
C-Washer, Clip Screw
Screw, Clip to Transom Bracket
Screw, Manifold
Flatwasher, Manifold Screw
POWER TRIM
70
70
7.9
7.9
60
6.8
80
9.0
30
40.7
6B-3
The Up circuit actuates the up solenoid (under outboard cowl) and closes the motor circuit. The electric
motor drives the pump, forcing fluid thru passageways into the up side of the trim cylinders.

Information
Description
The Power Trim System consists of an electric motor,
pressurized fluid reservoir, pump, tilt cylinder, and two
trim rams.
The remote control (or trim panel) has switches that
trim the outboard Up or Down and tilt the engine for
Trailering. The outboard can be trimmed and tilted
under power or when the outboard is not running.
NOTE: Because hull designs react differently in
varying water conditions, varying the trim position will
often improve the ride and boat handling. When
trimming from a mid-trim position (with outboard trim
tab in a straight fore and aft position), expect the
following:
TRIMMING OUTBOARD UP (OUT):
WARNING
Excessive Trim Out may reduce the stability of
some high speed hulls. To correct instability,
reduce the power gradually and trim the outboard
In slightly before resuming high speed
operation. A rapid reduction in power will result in
a sudden change of steering torque and may
cause additional boat instability.
Will lift boat bow, increasing top speed.
Transfers steering torque harder to port (left) on installations above 23 in. transom height.
Increases gearcase clearance over submerged
objects.
Excess trim
ventilation.
can
cause
porpoising
and/or
The outboard can be trimmed above the 20 degree

maximum trim angle (for shallow water operation,
etc.), by keeping the engine RPM below 2000. If the
RPM increases over 2000, propeller thrust (if propeller is deep enough) will result in the trim system to return the outboard to the 20 degree maximum trim
position.
TRIMMING OUTBOARD DOWN (IN):
WARNING
Excessive speed at minimum trim In may result
in undesirable and/or unsafe steering conditions.
Test for handling characteristics after any
adjustment is made to the trim angle (and tilt pin
location).
Aids planing, particularly with heavy loads.
Improves ride in choppy water conditions.
Excess trim In can cause bow steer (boat veers to
left or right).
Transfers steering torque to starboard (right).
Improves acceleration to planing speed.
The Down circuit actuates the down solenoid (under engine cowl) and closes the motor circuit. The
electric motor drives the pump in the opposite direction as the up circuit, forcing fluid thru passageways
into the down side of the tilt ram. The tilt ram moves
the engine down to the desired position.
Trailering Outboard
WARNING
Excessive outboard trim angle will result in
insufficient water supply causing water pump
and/or powerhead overheating damage. Insure
water level is above water intake holes whenever
outboard is running.
6B-4
The trim cylinders position the outboard at the desired

trim angle in the 20 degree maximum trim range. The
system will not allow the outboard to be trimmed
above the 20 degree trim range as long as the engine
RPM is above approximately 2000 RPM.
The Up circuit first moves the trim cylinders; when

the trim cylinders extend fully, the tilt ram extends to
tilt the outboard to the full Up position for trailering.
POWER TRIM
90-13645--2 495
Before the boat is trailered, the operator should check

for clearance between the outboard skeg and pavement to prevent damage to skeg from striking pavement.
If the outboard must be tilted for clearance between
skeg and pavement, a device such as a Transom
Saver should be installed to prevent stress to boat
transom from outboard weight while the boat/outboard are being trailered.
Tilting Outboard Manually

WARNING
Before opening the manual release valve knob,
insure all persons are clear of outboard as
outboard will drop to full Down when valve is
opened.
The outboard can be raised or lowered manually by
opening the manual release valve 3 to 4 turns counterclockwise. Close manual release valve to hold outboard at the desired tilt position.

WARNING
Boat operation with outboard trimmed to the full
In trim angle [not using the trim angle
adjustment bolt (a)] at planing speed may result in
undesirable and/or unsafe steering conditions. A
water test for handling/steering conditions is
required after any trim angle adjustments.
IMPORTANT: Some boat/motor combinations not
using the trim angle adjustment pin (a) and
trimmed to the full In trim angle position may
not exhibit any undesirable and/or unsafe handling and/or steering characteristics at planing
speed. If so, not using the trim angle adjustment
bolt (a) may be advantageous to acceleration and
planing. A water test is required to determine if
these characteristics apply to a particular boat/
motor combination.
a
51353
51353
a - Trim Angle Adjustment Bolt
a - Manual Release Valve
90-13645--2 495
POWER TRIM
6B-5
Striker Plate Replacement
Trim Indicator Gauge
Visually inspect striker plates (a) and replace if worn

excessively.
A Quicksilver Trim Indicator Gauge accessory kit is

available for the power trim sender (if not previously
installed).
Fill, Check, and Purge - Power Trim

System
c
b
IMPORTANT: This trim system is pressurized. Remove Fill plug only when outboard is tilted to
the full Up position or the trim/tilt rams are fully
extended. Retighten Fill plug before tilting outboard down or retracting tilt/trim rams.
Remove Fill plug and O-ring. System is full
when oil level is present at fill hole. Tighten Fill
plug securely.
a
27930
a - Striker Plate (2)
b - Lockwasher
c - Locknut - Torque to 80 lb. in. (9.0 Nm)
Anode Plate
Anode plate (a) is a self-sacrificing alloy plate that is
consumed gradually by corrosion while providing protection to the midsection and power trim from galvanic
corrosion. Replace anode plate when it is 50% consumed.
51344
a - Fill Plug and O-ring (remove to fill system, tighten securely)
b - Oil Can (fill system with Quicksilver Power Trim and Steering
Fluid)
NOTE: Automatic Transmission Fluid (ATF) Type F,

FA, or Dexron II may be used.
27932
a - Anode Plate
IMPORTANT: Do not paint or place protective

coating on anode plate, or corrosion protection
function will be lost.
6B-6
POWER TRIM
90-13645--2 495
TO PURGE:
IMPORTANT: Fill plug and O-ring must be tightened securely before purging system.
Hydraulic System
Troubleshooting
IMPORTANT: Run Trim System in short jogs until pump is primed and trim system moves. If trim
motor is run without priming pump, driveshaft
failure could result.
IMPORTANT: Operate Power Trim System after

each check to see if problem is corrected. If problem has not been corrected, proceed to next
check.
Cycle outboard through entire trim/tilt range 4 times.

Check fluid level after purging system.
1. Check that Manual Release Valve knob is tightened to full right (clockwise) position.
Push down on outboard when trim rams are slightly

extended. If rams retract more than 1/8 in. (3.2 mm),
air is present in system. Cycle system again and
check fluid level.
2. Check trim pump fluid level and fill if necessary.

(Refer to Fill, Check, and Purge - Power Trim
System) preceding.
TO CHECK:
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
depressurize system.
3. Check for external leaks in the system. Replace

defective parts if leak is found.
4. Check for air in the system and purge if necessary. (Refer to Fill, Check, and Purge - Power
Trim System) preceding.
NOTE: When troubleshooting the hydraulic system,

cleanliness, and inspection of sealing surfaces,
seals, O-rings, and moving parts is important. The internal pressures required for proper operation of the
Power Trim System require these parts to be in excellent condition. Replace any parts that may be suspect
of failure.
51368
a - Tilt Lock Lever (engage to support engine in Up position)
Remove fill plug and O-ring. System is full when oil

level is present at filler hole. Tighten fill plug securely.
90-13645--2 495
POWER TRIM
6B-7
Troubleshooting
IMPORTANT: Determine if Electrical or Hydraulic problem exists.
HYDRAULIC SYSTEM TROUBLESHOOTING
IMPORTANT: Make one correction at a time. Check operation of trim system before proceeding to the next check.
CONDITION OF TRIM SYSTEM
PROBLEM
A. Trim motor runs; trim system does not move up or down.
1, 2, 5, 10
B. Does not trim full down. Up trim OK.
2, 3, 4
C. Does not trim full up. Down trim OK.
1, 6
D. Partial or Jerky down/up.
E. Thump noise when shifting.
2, 3, 6, 7
F. Does not trim under load.
8, 9
G. Does not hold trim position under load.
2, 5, 6
H. Trail out when backing off from high speed.
3, 4
I. Leaks down and does not hold trim.
2, 5, 7
J. Trim motor working hard and trims slow up and down.
8, 9
K. Trims up very slow.
1, 2, 8, 9
L. Starts to trim up from full down position when IN trim button is depressed.
3, 4
M. Trim position will not hold in reverse.
3, 4
PROBLEM
1. Low oil Level.
2. Pump Assembly faulty.
3. Tilt ram piston ball not seated (displaced, dirt, nickel seat).
4. Tilt ram piston O-ring leaking or cut.
5. Manual release valve leaking (check condition of O-rings) (Valve not fully closed.)
6. Lower check valve not seating in port side trim ram.
7. Upper check valve not seating in port side trim ram.
8. Check condition of battery.
9. Replace motor assembly.
10. Broken motor/pump driveshaft.
10
3
7
4
5
6
6B-8
POWER TRIM
51491
90-13645--2 495
ELECTRICAL SYSTEM TROUBLESHOOTING

CONDITION OF TRIM SYSTEM
A. Trim motor does not run when trim button is depressed.
B. Trim system trims opposite of buttons.
C. Cowl mounted trim buttons do not activate trim system.
PROBLEM
1, 2, 4, 5, 6, 7
3
2, 4, 5, 6
PROBLEM
1. Battery low or discharged.

2. Open circuit in trim wiring.
3. Wiring reversed in remote control.
4. Wire harness corroded through.
5. Internal motor problem (brushed, shorted armature).
6. Blown fuse(s).
7. Trim Solenoids Failed
NOTE: Refer to following pages to troubleshoot Power Trim Electrical System.

POWER TRIM SYSTEM WIRING DIAGRAM
3
10
12
1
11
BLK
BLU
GRN
RED
WHT
=
=
=
=
=
Black
Blue
Green
Red
White
51306
90-13645--2 495
POWER TRIM
6B-9
Side Mount Remote Control Wiring

Diagram (Test Points for Electrical
Troubleshooting)
5
23891
6B-10
POWER TRIM
90-13645--2 495
Electrical System
Troubleshooting
2. Make certain all conditions are tight and corrosion

free.
GENERAL CHECKS
4. Make certain battery is fully charged.
Before troubleshooting the Power Trim electrical system, check the following:
Refer to the preceding four wiring diagrams for

connection points when troubleshooting the electrical
systems (Connection points are specified by
number).
3. Check that plug-in connectors are fully engaged.
1. Check for disconnected wires.

(When Up Circuit is OK)

and BLACK lead to ground. Depress
Down trim button. If battery voltage is
indicatied, wire is open between Points
4 and 1.

Depress Down trim button.
There is an open circuit between Point 9

and positive (+) battery terminal.
Check for loose or corroded connections.
Check wires for open.
Check Down solenoid terminals for

Check BLACK ground wire (on
Down solenoid) for corrosion or
open.
Test Down solenoid. Refer to Motor
and Electrical Tests, see Index.
90-13645--2 495
If battery voltage is indicated, trim
switch is faulty. If no battery voltage,
check for loose or corroded connection
at Point 5 or open circuit in wire supplying current to Point 5.
POWER TRIM
6B-11
Troubleshooting the Up Circuit

(When Down Circuit is OK)
There is an open circuit in wires (BLUEWHITE, PURPLE-WHITE, or PURPLE)
between Up solenoid and trim switch.

Check for loose or corroded connection at Point 9 or Point 3.

Check RED lead between Point 9
and Point 3 for open.
6B-12
Depress Up trim button.
Check Up solenoid terminals for

Check BLACK ground wire (on Up
solenoid) for corrosion or open.
Test Up solenoid. Refer to Motor and
Electrical Tests/Repair, following.
POWER TRIM
90-13645--2 495

Circuits (All Circuits Inoperative)
Check in-line fuses (under cowl) to
see if fuses are blown.
Blown Fuse:
Fuse Not Blown:
Correct problem that caused fuse

to blow.

Point 3 and BLACK lead to ground.
Battery voltage should be indicated.
Replace fuse.
Check battery leads and RED leads
(between engine starter motor solenoid
and Point 3) for poor connections or
open circuits.

Point 10.
Depress Up trim button and

check for battery voltage.
Check battery charge.

Check BLACK ground wires at solenoids
Connect RED Voltmeter lead to
Point 5, and BLACK lead to ground.
Check BLACK motor lead for poor

ground at Point 11. If wire is grounded,
the pump motor is faulty. Refer to Motor
and Electrical Tests/Repair, following.
Check that voltage is being supplied

to control by performing the following
checks:
DO NOT start engine.
Trim switch is faulty or there is an open circuit

in wires [GREEN-WHITE, BLUE-WHITE AND
PURPLE-WHITE (OR PURPLE)] between trim
buttons and trim pump.
Turn ignition switch to Run position.
Check for voltage at any instrument, using a Voltmeter.
Check trim switch.

Check all trim harness connectors for loose
or corroded connections.
Check for pinched or severed wires.
RED wire is open between Point 12 and red


Point 5 and RED lead terminal on the
back of the ignition switch.
Check for loose or corroded connections.
Check for open in wire.
90-13645--2 495
POWER TRIM
6B-13
Power Trim Assembly

WARNING
Failure to support outboard as shown could result
in personal injury and/or damage to outboard or
boat.
Removal
1. Remove clamps on transom bracket to free power
trim wiring.
51377
a - Clamps
2. Raise outboard to full Up position and engage tilt

lock lever.
51346
a - Tilt Lock Lever

b - Support Tool
c - Retaining Clips
IMPORTANT: Support outboard as shown above

to prevent engine from tipping when power trim
retaining pin is removed.
SUPPORT TOOL
3/8 in. diameter metal rod (a used shift shaft works
well).
14
1/4
a - Drill Holes for Retaining Clips

50605
a - Tilt Lock Lever
6B-14
METRIC CONVERSION
14 in. = 35.56 cm
3/8 in. = 9.50 mm
POWER TRIM
2 in. = 50.80 mm
1/4 in. = 6.35 mm
90-13645--2 495
CAUTION
Disconnect battery cables at battery before
removing power trim wires from solenoids.
5. Remove outboard transom mounting bolts, and

loosen tilt tube nut until nut is flush with end of tilt
tube thread.
3. Disconnect power trim wires at solenoids (BLUE,

GREEN, and BLACK).
4. Open filler cap and release any remaining pressure in the system.
a
a
51375
51339
a - Filler Cap
IMPORTANT: Outboards equipped with thru-thetilt-tube steering - remove steering link arm from
end of steering cable and cable retaining nut from
tilt tube.
a - Transom Mount Bolts (2)

b - Tilt Tube Nut (flush with end of thread)
6. Remove 3 screws and washers and move starboard transom bracket.
a
b
51375
a - Screws (3)
b - Washers (3)
51354
a - Retaining Nut
90-13645--2 495
POWER TRIM
6B-15
IMPORTANT: Cross pin (a) should not be reused.

Replace with new cross pin.
7. Drive out cross pin, push out upper swivel pin, and
remove 3 screws and washers retaining trim system. Remove system from outboard.
Installation
1. Paint any exposed metal surfaces to prevent
corrosion.
2. Apply Loctite 271 to screws. Install trim system,
starboard transom bracket, and tilt tube nut.
c
a
b
51339
a - Cross Pin
b - Upper Swivel Pin
c - Port Transom Bracket Screws and Washers (3) - Remove to
release trim system from outboard.
51375
a - Screw (6) - Torque to 45 lb. ft. (61.0 Nm)
b - Flatwasher (6) - Install one per screw
c - Tilt Tube Nut
3. Use a 12 volt power source to extend tilt ram up

to align upper swivel shaft hole and end of ram.
Connect trim motor wires (BLUE wire to positive
(+), BLACK wire to negative (-). If ram extends too
far, retract ram by connecting GREEN wire to positive (+).
4. Install Upper Swivel Pin with slotted end to left
(port) side of engine.
a - Upper Swivel Pin

b - Slotted End
c - Cross Hole (in line with slotted end)
IMPORTANT: Cross pin should not be reused. Install a new pin.
6B-16
POWER TRIM
90-13645--2 495
5. Position slot on end of swivel shaft in line with hole

in tilt ram end. Insert a punch into tilt ram hole to
align cross hole in upper swivel shaft. Tap new
cross pin in until flush.
a
c
WARNING
Electrical wires passing through cowl openings
must be protected from chafing or being cut.
Follow the recommended procedures outlined in
Section 1 of this Manual. Failure to protect wires
as described could result in electrical system
failure and/or injury to occupants of boat.
Testing Power Trim System With Test Gauge Kit
(91-52915A3)
IMPORTANT: This test will not locate problems in
the trim system. The test will show if the system
is correct after a repair. If minimum pressures are
not obtainable, the trim system requires additional repair.
d
a
b
c
d
Upper Swivel Shaft (Slot is in line with cross hole)

Chamfered End of Hole (Faces away from transom)
Retaining Pin
Tilt Ram End
Use Adapter Fitting (22-11243) to connect test gauge

to trim system.
6. Connect trim motor wires to solenoids. Refer to

Wiring Diagrams in this manual. Route trim wires
as specified in this manual.
7. Apply marine sealer to shanks of mount bolts and
install transom mount bolts.
3/8-24 UNF
1/16-27 NPSF
IMPORTANT: Do not use an impact driver to tighten transom mount bolts.

Apply marine sealer to threads of mount bolts. Secure
with flat washers and locknuts. Be sure installation is
watertight.
8. Tighten tilt tube nut securely.
IMPORTANT: Outboards equipped with thru-thetilt-tube steering: Tighten steering cable retaining
nut securely to tilt tube.
51354
a - Steering Cable Retaining Nut
9. Apply Quicksilver Liquid Neoprene (91-25511--2)

on all electrical connections.
90-13645--2 495
POWER TRIM
6B-17
6. Disengage tilt lock lever.
UP Pressure Check
IMPORTANT: Insure battery is fully charged before performing tests.
1. Tilt outboard to full Up position and engage tilt
lock lever.
2. Slowly remove Fill plug to bleed pressure from
reservoir.
3. Turn Manual Release Valve 3 to 4 turns (counterclockwise) to bleed any remaining pressure.
CAUTION
Failure to install spare tilt pin (or hardened bolts
and nuts) in hole shown could result in transom
bracket failure and possible injury.
7. Move outboard In until hole in swivel bracket
ear aligns with the third tilt hole in transom bracket. Lock engine in trim range by installing a 3/8 in.
(9.5 mm) diameter tilt pin or two 3/8 in. (9.5 mm)
hardened bolts and nuts thru the transom brackets and swivel bracket in the hole shown.
51353
a - Allen Plug
51374
a - Tilt Pin Hole (Install spare tilt pin or hardened bolts and nuts.)
8. Install Fill plug.

10. Open valve (a) and close valve (b).
b
a
d
51374
51374
a
b
c
d
e
Adapter Fitting (22-11243)

Test Gauge Assembly
Tilt Pin (Position in hole shown)
Hose
Hose (not used for this check)
6B-18
a - Open valve
b - Close valve
POWER TRIM
90-13645--2 495
11. Run trim UP. The minimum pressure should be

1300 P.S.I. (91 kg/cm2).
12. Run trim DOWN to release pressure and remove spare tilt pin or bolts and nuts.

15. Open Manual Release Valve 3 to 4 turns to bleed
any remaining pressure.
16. Remove test gauge hose and adapter, and install

allen plug.

troubleshoot system per instructions on page 6B-7.
DOWN Pressure Check
1. Repeat steps 1 through 4 from preceding UP

pressure check, removing allen plug as shown.
51360
a - Adapter Fitting (22-11243)
b - Hose (route hose so it will not be pinched when outboard is
trimmed DOWN)
c - Test Gauge Assembly
d - Valve
e - Valve
f - Hose (not used for this test)
3. Open valve (d) and close valve (e).

4. Install fill plug.
6. Run trim DOWN. Minimum pressure should be
500 P.S.I. (35 kg/cm2).

51367
a - Allen Plug
9. Open Manual Release Valve 3 to 4 turns to release any remaining pressure.

10. Remove test gauge hose and adapter fitting. Install allen plug.
11. Fill Power Trim system and purge system; refer to
Fill, Check, and Purge preceding.

troubleshoot system per instructions on page 6B-7.
90-13645--2 495
POWER TRIM
6B-19
5. Install trim rod removal tool and pull trim rod from
cylinder.
Hydraulic Repair
TRIM ROD REMOVAL AND REPAIR
NOTE: Power Trim does not have to be removed from

outboard to remove trim rods.
1. Tilt outboard to full UP position and engage tilt
lock lever.
2. Slowly remove Fill plug to bleed reservoir
pressure.
3. Turn Manual Release Valve 3 to 4 turns (counterclockwise) to bleed remaining pressure.
4. Remove trim rod cylinder caps.
NOTE: Place a clean pan under trim system to catch

fluid.
27933
a - Trim Rod Removal Tool (91-44486A1)
CLEANING AND INSPECTION - TRIM RODS AND

CAPS
CAUTION
b
Do not remove check valve (a). Check valve is

preset to operate at a specific pressure. Removal
and installation of check valve could result in
improper operating pressure and possible
system damage.
NOTE: Check valve is in port side trim rod only.

51353
a - Trim Rod Cylinder Cap
b - Turn Counterclockwise to Remove
b
a
51337
a - Removal Tool (91-44487A1)
6B-20
POWER TRIM
90-13645--2 495
1. Inspect check valve and check valve screen for

debris; if debris cannot be removed, replace trim
rod assembly. Clean trim rod with parts cleaner
Trim Rod End Cap Seal

1. Inspect trim cap end seal and replace if damaged
or if seal does not keep trim rod clean.
51343
a - Seal (Remove as shown)
2. Install new seal with seal lip up.

TRIM ROD INSTALLATION
IMPORTANT: Components must be free of dirt and

lint. Any debris in the system can cause system
to malfunction.
b
a - Check Valve
b - Check Valve Screen
51352
NOTE: Install trim rod with check valve in the port (left)
cylinder.
on all O-rings and seals before installation.
2. Install trim rods and caps. Use installation tool
(91-44487A1) or spanner wrench (91-74951) to
tighten caps securely.
b
51353
a - Trim Rods
b - Cylinder End Caps
c - Rod End Rollers (Lubricate with Quicksilver Anti-Corrosion
Grease or 2-4-C w/Teflon)
90-13645--2 495
POWER TRIM
6B-21
TILT RAM COMPONENTS
Tilt Ram
REMOVAL - TILT ROD ASSEMBLY ONLY
NOTE: Tilt Rod Assembly can be removed from

cylinder without removing entire power trim system
from outboard. Refer to page 6A-13 to remove upper
swivel pin.
b
a
CAUTION
Insure Power Trim System Is Depressurized Prior
To Tilt Rod Removal.
1. Use spanner wrench (91-74951) to loosen tilt ram

end cap.
f
b
b
e
b
b
d
51337
k
b
a
b
c
d
e
f
g
h
i
j
k
91-74951
51337
i
51372
Housing - Tilt Ram

O-ring* (5)
Memory Piston**
Washer
Piston Assembly
End Cap
Oil Seal
Bolt (Design 1)
Nut (Design 2)
Tilt Rod (Design 1)
Tilt Rod (Design 2)
* O-ring Repair Kit Available, P/N 811607A1 (Includes item g, Oil

Seal)
** Memory piston (c) for tilt rods (j and k) 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.
51364
a - End Cap
b - Spanner Wrench (91-74951) (Turn counterclockwise)
c - Tilt Rod - Pull to remove.
NOTE: Place a clean pan under tilt ram to catch fluid.
6B-22
POWER TRIM
90-13645--2 495
TILT RAM REMOVAL - POWER TRIM SYSTEM

REMOVED FROM OUTBOARD
CAUTION
Insure Trim System Is Depressurized Prior To Tilt
Ram Removal.
Disassembly
1. Secure tilt ram in a soft jawed vise. Remove tilt rod
and cap.
91-74951
1. Remove cross pin.
a
51337
51364
51366
a - Cross Pin (Remove as shown)
2. Remove lower swivel pin.
a - Cap (Turn counterclockwise to remove)

c - Tilt Rod - Pull to remove
2. Clamp tilt rod in a soft jawed vise. Remove bolt or

nut as applicable to disassemble rod assembly.
Remove O-ring.
51355
a - Lower Swivel Pin (Remove as shown)
51378
51340
a - Bolt (Design 1) or Stud/Nut (Design 2)
b - O-ring
90-13645--2 495
POWER TRIM
6B-23
IMPORTANT: Note Design 1 and 2 previous.

Design 1 tilt rod assembly replaces either tilt rod
assembly Either design will fit as a (replace)
cylinder assembly complete.
Design 2 will NOT fit a cylinder originally using a
Design 1 tilt rod assembly.
Memory Pistons for Design 1 and 2 differ also and
must be used only on the cylinder the piston was
removed from.
4. Remove end cap from tilt rod.
3. Remove washer, check valve assemblies, and

piston.
NOTE: Check valve held in by roll pin can be cleaned

but not removed.
51376
a - End Cap

IMPORTANT: Remove plug from same side as
holes in shaft.
c
DO NOT REMOVE
51361
a - Allen Plug
b - Hole in Shaft
51363
a - Washer
b - Check Valve Assembly (7)
c - Piston
6. Lubricate shaft with Quicksilver Power Trim and

Steering Fluid. Insert shaft into cylinder.
51342
6B-24
POWER TRIM
90-13645--2 495
7. Tap shaft into cylinder until shaft is positioned as

shown.

1. Inspect all internal parts for damage or wear.
Clean and replace parts as necessary.
2. Inspect tilt rod for scratches. Replace scraper seal
in rod end cap if tilt rod is scratched or worn.
3. Slight scratches or tool marks less than 0.005 in.
(0.1 mm) deep in cylinder are acceptable.
Scraper Seal Replacement

1. Remove components from end cap.
e
d
51365
c
b
WARNING
Memory Piston Cup may be expelled at a high
velocity when air pressure is applied. Failure to
place cylinder as shown below could result in
personal injury.
8. Place cylinder as shown. Hold down on cylinder

and inject air into shaft opening.
b
c
a
b
c
d
e
Cap
O-ring (2)
Scraper Seal
Washer
Retaining Ring
51353
a - Shop Cloth
b - Solid Surface
c - Air Nozzle
9. Remove shaft after Memory Piston Cup has been

expelled. Replace allen plug removed in Step 5
and tighten securely.
90-13645--2 495
POWER TRIM
6B-25
REASSEMBLY
4. Install end cap.
IMPORTANT: Components must be clean for reassembly. Any debris in the system can cause the
system to malfunction.
NOTE: Refer to Tilt Ram Components for proper

O-ring sizes.
on O-rings prior to reassembly.
2. Install O-ring on Memory Piston Cup and install in
cylinder.
51376
a - End Cap
5. Install components on rod.
d
c
b
a
a
b
51363
51372
a - O-ring
b - Memory Piston Cup
51340
3. Assemble end cap.
d
b
a
b
c
d
e
Piston
O-ring
Check Valve Assembly (7)
Washer
Bolt or Locknut (Tighten securely)
6. Clamp cylinder in a soft jawed vise and install tilt

rod assembly. Use spanner wrench and tighten
end cap securely.
c
91-74951
b
a
b
c
d
e
End Cap
O-ring (2)
Scraper Seal
Washer
Retaining Ring
51337
51341
a - Cylinder
b - Tilt Rod Assembly
c - End Cap (Tighten securely) - Use spanner wrench
6B-26
POWER TRIM
90-13645--2 495
TILT RAM ASSEMBLY INSTALLATION
4. Drive pin in until flush.
1. Lubricate alignment tool (91-11230) and shaft.

Use Quicksilver Power Trim and Steering Fluid.
b
a
51369
b - Shaft
2. Align tilt ram and housing using alignment tool.
51356
a - Pin (Drive against knurled end)
5. Install Power Trim Assembly on outboard. Refer

to Installation instructions on pages 6B-16 and
6B-17.
51348
3. Install shaft.
51352
a - Shaft
b - Groove
c - Hole [groove (b) will align with this hole]
90-13645--2 495
POWER TRIM
6B-27
MOTOR AND PUMP REPLACEMENT
3. Remove two screws to remove pump.
IMPORTANT: The pump is not rebuildable. If pump

is defective, replace as an assembly.
NOTE: Power Trim System does not have to be removed from outboard to replace pump or motor.
1. Tilt outboard to full UP position. Depressurize
power trim system, and loosen starboard transom
bracket as outlined in Removal and Installation on page 6B-14.
2. Remove 2 screws to remove motor from system.
NOTE: Driveshaft is a loose part and may fall out of

motor when motor is removed.
51433
a - Pump
b - Screw (2)
c
a
51433
a - Motor
b - Screw (2)
c - Driveshaft
6B-28
POWER TRIM
90-13645--2 495
MOTOR DISASSEMBLY

Tests/Repair
a b
WARNING
a
b

connections.
1. Connect a 12 volt power supply to motor wires
[positive (+) to blue wire and negative (-) to black
wire]. Motor should run. Disconnect blue wire and
connect green wire to positive (+) terminal of power supply. Motor should run.
c
d
e
2. If motor does not run, disassemble and check

components.
Solenoid Test
51345
WARNING
connections.
1. Disconnect all wires from solenoid terminals.
2. Set an Ohmmeter to Rx1 scale and connect meter
leads to solenoid terminals 1 and 2.
a
b
c
d
e
Screw (4)
Screw (3)
Clamp
Grommet
Gasket
2. Lift motor from end cap. Use care not to drop

armature.
3. Connect a 12 volt power supply to terminals 3 and

4. Solenoid should click and meter should read
zero (0) ohms (full continuity).
a
b
1
2
4
18457
51338
4. If meter does not read zero (0) ohms, replace

solenoid.
90-13645--2 495
a - End Cap
b - Armature
POWER TRIM
6B-29
Armature Tests
FIELD TESTS
TEST FOR SHORTS
IMPORTANT: Commutator end of armature must

be installed in brushes when performing the following tests.
Check armature on a Growler per the Growler manufacturers instructions. Replace armature if a short is
indicated.
TEST FOR GROUND
1. Use an Ohmmeter (R x 1 scale). Connect one
lead on armature shaft and other lead on commutator. If continuity is indicated, armature is
grounded. Replace armature.
Ohmmeter
Leads Between
Resistance
(Ohms)
Scale Reading*
(x
)
Green and Blue Motor

Wires
Full Continuity
(R x 1)
Green and Black Motor

Wires
Full Continuity
(R x 1)
Blue and Black Motor

Wires
Full Continuity
(R x 1)
Black Motor Wire, and

Frame (Motor Housing)
No
Continuity
Full Continuity
(R x 1)
Green Motor Wire, and

Frame
No
Continuity
Full Continuity
(R x 1)
Blue Motor Wire, and

Frame
No
Continuity
Full Continuity
(R x 1)
* If specified readings are not obtained, check for:

defective armature
dirty or worn brushes
dirty or worn commutator
If defective components are found, repair or replace
component(s) and retest.
51359

1. If commutator is worn it may be turned on an
armature conditioner or a lathe.
2. Clean commutator with 00 sandpaper.
a - Commutator
6B-30
POWER TRIM
90-13645--2 495
Motor Repair
REMOVAL
Inspect O-rings and replace if necessary. Clean, inspect, and test motor components. Refer to Brush
Replacement, Armature Test, and Field Tests
for inspection and test procedures.
NOTE: Power Trim System does not have to be

removed from outboard to repair/replace motor.
DISASSEMBLY
a
d
Refer to Motor Disassembly on page 6B-29 to

disassemble motor from pump.
a
d
a
c
d
a
a
b
c
d
c
c
51371
Power Trim Motor
a
b
c
d
e
90-13645--2 495
Frame and Field Kit

Brush Card Kit
End Frame Kit
Seal Kit
Armature Kit
POWER TRIM
6B-31
BRUSH REPLACEMENT
1. Brush replacement is required if brushes are pitted,
chipped, or if distance (a) between the brush pigtail
and end of brush holder slot is 1/16 in. or less.
Check distance with armature installed.
a
a
a
18466
a - Metal Connectors
4. Install new brush card.

18457
a - 1/16 in.
6. Insulate connections with heat shrink tubing.
2. To replace brush card, remove insulators.
5. Crimp new metal connectors onto wires.
51350
a - Insulators
3. Remove metal connectors.
6B-32
POWER TRIM
90-13645--2 495
Reassembly
IMPORTANT: Components must be clean. Any debris in power trim system can cause system to
malfunction.
3. Install screws and clamp. Tighten screws

securely.
1. Install armature in motor housing.
b
b
a
b
a
b
51357
c
d
e
51349
a - Motor Housing
b - Armature (Spread brushes to insert commutator)
2. Install square-rings in end caps being careful that

square ring is not twisted.
51345
a
b
c
d
e
Screw (4) - Contains flat washer and O-ring

Screw (3)
Clamp
Gasket
Grommet
18465
a - Square-rings
90-13645--2 495
POWER TRIM
6B-33
Reassembly - Motor and Pump

NOTE: Driveshaft is a loose part and may fall out of
position.
1. Install pump onto power trim manifold. Insure

O-rings are in proper locations. Secure with two
(2) screws. Torque screws to 70 lb. in. (7.9 Nm).
IMPORTANT: Install pump with location flat facing
towards starboard transom bracket.
51433
a - Motor
b - O-ring
c - Screw (2) - Torque screws to 70 lb. in. (7.9 Nm)
4. Complete reassembly of Power Trim System as

outlined in Installation on page 6B-15 and
6B-16.
b
c
Priming Power Trim System

1. Fill system with Quicksilver Power Trim and Steering Fluid or Automatic Transmission Fluid (ATF)
Type F or FA. Refer to Fill, Check, and Purge
on page 6B-5.
IMPORTANT: Run Trim System in short jogs
until pump motor primes and trim system moves.
If trim motor is run without priming pump,
driveshaft failure could result.
51433
a
b
c
d
Pump (Flat towards starboard transom bracket)

Flat (Faces starboard transom bracket)
O-rings (4)
Driveshaft (Install in center hole in pump)
1. Check trim sender black lead for proper ground.

2. Trim outboard to full DOWN position.
2. Fill pump with Quicksilver Power Trim and Steering Fluid prior to installing motor.
3. Install motor, secure with two (2) screws. Route
wiring; refer to Wiring Diagrams in this service
manual. Torque screws to 70 lb. in. (7.9 Nm).
NOTE: Insure motor and driveshaft are aligned.
6B-34
Trim Sender (Optional Accessory) Test
3. Place ignition switch to ON position.

4. Connect Ohmmeter (R x 1 scale) leads between
outboard ground and Point 1.
5. Depress UP button. Ohmmeter needle should
move as the outboard is trimmed up. If needle
does not move, trim sender is defective.
POWER TRIM
90-13645--2 495
5. Tighten trim sender screws.
d
b
22908
a - Trim Sender
b - Connect with screw and hex nut (coat with liquid
neoprene).
c - Rubber Sleeve (Slide over connection)
Trim Indicator Gauge Needle

Adjustment
1. Turn ignition key to RUN position.
2. Tilt outboard to full IN position. Needle of trim indicator gauge should be in full IN position.
3. If not, tilt outboard to full OUT position to gain access to trim sender and engage tilt lock lever.
4. Loosen trim sender screws and reposition trim
sender.
22744
a
b
c
d
e
Trim Sender
Screws, loosen to rotate sender
Turn sender counterclockwise to raise needle reading.
Turn sender clockwise to lower needle reading.
Tilt Lock Lever
Trim Indicator Wiring

Diagrams
Wiring Diagram - For boats equipped with Quicksilver
Commander Series Side Mount Remote Control.
TRIM INDICATOR
TRIM
SENDER
REMOTE CONTROL
ENGINE
GROUND
TO ENGINE
Wiring Diagram - For boats equipped with Quicksilver

Ignition/Choke and Main Harness Assembly.
TRIM
SENDER
TRIM INDICATOR
IGNITION/
CHOKE
SWITCH
ENGINE
GROUND
POWER TRIM
HARNESS
TO ENGINE
22908
90-13645--2 495
POWER TRIM
6B-35
POWER TRIM
6
C
51485
SINGLE RAM
Table Of Contents
Page
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quicksilver Lubricants and Service Aids . . . . .
Power Trim - General Information . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trimming Outboard Up (Out) . . . . .
Trimming Outboard Down (In) . . . .
Tilting Outboard Up and Down Manually .
Power Trim System Components . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .
Determining if Problem is Electrical
or Hydraulic . . . . . . . . . . . . . . . . . . . . . . .
Problem Chart . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic System Troubleshooting . . . . . .
Date Code Location . . . . . . . . . . . . . . . . . . .
Preliminary Checks . . . . . . . . . . . . . . . . . . .
Leak Down Check - Pump and Manifold
Assembly . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Trim Partial Leak Down at
Maximum Trim . . . . . . . . . . . . . . . . . . . .
Leak Down Check Pilot Valve Assembly . . . . . . . . . . . . . . .
Leak Down Check Manual Release Valve . . . . . . . . . . . . . .
Leaks Past Ball and Seat Piston Assembly . . . . . . . . . . . . . . . . . . .
Power Trim Rocker Arm . . . . . . . . . . . . . . .
Troubleshooting Flow Diagram . . . . . . . . . .
Electrical System Troubleshooting . . . . . . .
6C-1
6C-1
6C-1
6C-1
6C-1
6C-1
6C-1
6C-2
6C-2
6C-2
6C-4
6C-6
6C-6
6C-6
6C-7
6C-7
6C-7
6C-8
6C-9
6C-10
6C-11
6C-11
6C-11
6C-12
6C-13
6C-15
Page
COMMANDER 2000 Side Mount

Remote Control (Power Trim/Tilt
Electric Start with Warning Horn)
Wiring Diagram . . . . . . . . . . . . . . . . . . . .
Power Trim System Wiring Diagram . . . . .
Troubleshooting the Down Circuit*
(When Up Circuit is OK) . . . . . . . . . . .
(When Down Circuit Is OK) . . . . . . . .
Circuits (All Circuits Inoperative) . . . . .
Power Trim System Removal . . . . . . . . . . . . . .
Power Trim System Disassembly . . . . . . . . . . .
Trim Rod Removal . . . . . . . . . . . . . . . . . . . .
Trim Rod Disassembly . . . . . . . . . . . . . . . . .
Trim Motor Removal . . . . . . . . . . . . . . . . .
Trim Motor Disassembly . . . . . . . . . . . . . .
Reservoir Assembly Removal . . . . . . . . . .
Manifold Removal . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection of Trim
Rod Components . . . . . . . . . . . . . . . . . . . . .
Motor and Electrical Tests/Repair . . . . . . . . . . .
Trim Pump Motor Test . . . . . . . . . . . . . . . . .
Armature Tests . . . . . . . . . . . . . . . . . . . . . . .
Test for Shorts . . . . . . . . . . . . . . . . . . . . .
Test for Ground . . . . . . . . . . . . . . . . . . . .
Checking and Cleaning Commutator .
Power Trim System Reassembly . . . . . . . . . . .
Manifold Installation . . . . . . . . . . . . . . . . . . .
Trim Motor Reassembly . . . . . . . . . . . . . . . .
Reservoir Installation . . . . . . . . . . . . . . . . . .
Trim Rod Reassembly . . . . . . . . . . . . . . . . .
Trim Rod Installation . . . . . . . . . . . . . . . . . .
Purging Power Trim Unit . . . . . . . . . . . . . . . . . .
Power Trim Unit Installation . . . . . . . . . . . .
6C-15
6C-16
6C-17
6C-17
6C-18
6C-19
6C-20
6C-20
6C-21
6C-23
6C-23
6C-23
6C-24
6C-25
6C-25
6C-25
6C-25
6C-25
6C-25
6C-26
6C-26
6C-26
6C-27
6C-28
6C-29
6C-30
6C-31
6C-31
90-13645--2 495
Increases clearance over submerged objects.
Special Tools
In excess, can cause porpoising and/or ventilation.

Part No.
Description
91-63209
Torch Lamp
91-74951
Spanner Wrench
91-99750
Multi-Meter DVA Tester
In excess, can cause insufficient water supply to water pump resulting in serious water pump and/or powerhead overheating damage.
WARNING
Quicksilver Lubricants and

Service Aids
Part No.
Description
91-90100A12
Power Trim and Steering Fluid
Obtain Locally
Loctite 271
91-25711-1
Liquid Neoprene
91-78376A6
Excessive engine trim angle will result in

insufficient water supply to water pump causing
water pump and/or powerhead overheating
damage. Make sure that water level is above gear
housing water intake holes whenever engine is
running.
Operating Up circuit will actuate the up relay (located under engine cowl) and close the electric motor
circuit. The electric motor drives the pump, forcing
fluid thru internal passageways into the up side of
the trim cylinder.

Information
Description
The Power Trim system consists of an electric motor,
pressurized fluid reservoir, pump and trim cylinder.
The remote control (or trim panel) is equipped with a
switch that is used for trimming the outboard up and
down, and for tilting the outboard for shallow water
operation (at slow speed) or for trailering. The outboard can be trimmed up or down while engine is
under power or when engine is not running.
The trim cylinder/trim ram will position the engine at

the desired trim angle within the 20 maximum trim
range. The Power Trim system is designed so the engine cannot be trimmed beyond the 20 maximum
trim angle as long as engine RPM is above approximately 2000 RPM.
The engine can be raised beyond the 20 maximum
trim angle for shallow water operation, etc., by keeping the engine RPM below 2000 RPM. If engine RPM
increases above 2000 RPM, the thrust created by the
propeller (if deep enough in the water) will cause the
trim system to automatically lower the engine back to
the 20 maximum trim angle.
When trimming outboard from a mid-trim position

(trim tab in neutral, straight fore-and-aft position), you
can expect the following results:
TRIMMING OUTBOARD DOWN (IN)
TRIMMING OUTBOARD UP (OUT)
Excessive speed at minimum trim In may cause

undesirable and/or unsafe steering conditions.
Each boat should be tested for handling
characteristics after any adjustment is made to
the tilt angle (tilt bolt relocation).
WARNING
Excessive trim out may reduce the stability of
some high speed hulls. To correct instability at
high speed, reduce the power gradually and trim
the motor In slightly before resuming high
speed operation. (Rapid reduction in power will
cause a sudden change of steering torque and
may cause additional momentary boat instability.)
Will lift bow of boat, usually increasing top speed.
Transfers steering torque harder to port (left) on installations below 23 in. transom height.
90-13645--2 495
WARNING
Will help planing off, particularly with a heavy load.

Usually improves ride in choppy water.
In excess, can cause boat to veer to the left or right
(bow steer).
Transfers steering torque harder to right (or less to the
left).
POWER-TRIM
6C-1
Improves planing speed acceleration (by moving tilt

bolt one hole closer to transom).
Operating Down circuit will actuate the down relay
(located under engine cowl) and close the electric
motor circuit (motor will run in opposite direction of the
Up circuit). The electric motor will drive the pump,
forcing fluid thru internal passageways into the
down side of the tilt ram. The tilt ram will move the
engine down to the desired angle.
Trailering Outboard
WARNING
Excessive engine trim angle will result in
insufficient water supply to water pump causing
water pump and/or powerhead overheating
damage. Make sure that water level is above gear
housing water intake holes whenever engine is
running.
While operating up circuit, the ram will continue to tilt
outboard to full up position for trailering.
Tilting Outboard Up and Down

Manually
WARNING
Before opening the manual release valve, make
sure all persons are clear of engine as engine will
drop to full down position when valve is
opened.

WARNING
Operating some boats with engine trimmed to the
full in trim angle [not using trim adjustment bolt]
at planing speed will cause undesirable and/or
unsafe steering conditions. Each boat must be
water tested for handling characteristics after
engine installation and after any trim
adjustments.
IMPORTANT: Some boat/motor combinations,
that do not use the trim adjustment bolt and are
trimmed to the full in trim angle, will not experience any undesirable and/or unsafe steering conditions during planing speed. Thus, not using trim
adjustment bolt may be desired. However, some
boats with engine trimmed to the full in trim
angle at planing speed will cause undesirable
and/or unsafe steering conditions. If these steering conditions are experienced, under no circumstances should the engine be operated without
the trim adjustment bolt and without the bolt adjusted in the proper holes to prevent unsafe handling characteristics.
Water test the boat not using the trim adjustment bolt.
If undesirable and/or unsafe steering conditions are
experienced (boat runs with nose down), install trim
adjustment bolt in proper hole to prevent unsafe handling characteristics.
With power trim installed, the outboard can be raised

or lowered manually by opening the manual release
valve 3 turns maximum (counterclockwise).
51432
6C-2
POWER-TRIM
90-13645--2 495
Notes:
90-13645--2 495
POWER-TRIM
6C-3
Power Trim System Components

110
31
5
3
32
26
110
6
7
8
9
10
23
22
24
29
25
27
17
11
12
30
20
28
27
21
16
13
14
15
19
110
44
36
38
37
35
38
18
36
43
42
33
35
37
39
33
40
41
34
25
NOTE: Lubricate all

O-rings and seals with
110
Application Points
110
6C-4
25
POWER-TRIM
90-13645--2 495
Power Trim System Components (Continued)

TORQUE
REF. NO.
QUAN.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
4
4
1
1
1
2
1
1
1
2
4
2
1
2
2
2
2
1
2
2
1
3
1
90-13645--2 495
DESCRIPTION
Tilt/Trim Cylinder
Reservoir/Motor Housing
Piston Rod
Upper Pivot Shaft
Cross Pin
O-ring
Seal-End Cap
End Cap
O-ring
O-ring
Piston Assembly
O-ring
O-ring
Memory Piston
Lower Pivot Shaft
Cross Pin
Screw
Pump Assembly
Pilot Valve Assembly
O-ring
Driveshaft
Washer
Screw
Fill Screw
O-ring
Motor Frame
Thrust Washer
Armature
Ring
Seal
Screw
Screw
Relay
Wiring Harness
Relay Mount
Rubber Mount
Screw
Spacer
Anode
Washer
Screw
Manual Release Valve
O-rings
E-Clip
POWER-TRIM
lb. in.
lb. ft.
Nm
35
4.0
100
11.3
70
7.9
13
13
1.5
1.5
35
4.0
70
8.0
6C-5
Troubleshooting
Hydraulic
When a problem is encountered with the Power Trim
system, the first step is to determine whether the malfunction is in the electrical system or the hydraulic
system. Refer to the following chart to determine
which system is at fault.
Problem Chart
Outboard will not trim up or down.
Outboard trims up, will not trim down.
Determine if Power Trim pump motor

operates when appropriate trim
circuit is activated.
Outboard trims down, will not trim up.
Outboard will not return completely to

down position or returns part way
with jerky motion.
Pump motor operates.
Pump motor does not operate.
Outboard thumps when shifted.

Refer to Hydraulic System
Troubleshooting.
Refer to Electrical System

Troubleshooting.
Outboard trails out when backing off

throttle at high speed.
Outboard will not hold a trimmed
position or will not remain tilted for
any extended period
Outboard will not hold trim position

when in reverse.
6C-6
POWER-TRIM
90-13645--2 495
Hydraulic System Troubleshooting
Preliminary Checks
Support outboard with tilt lock lever when servicing

power trim system.
Operate Power Trim System after each check to

see if problem is corrected. If not, proceed with
the next check.
After debris or failed components have been

found (during troubleshooting procedures) disassemble unit completely and replace all O-rings.
Check ball valve components and castings must
be cleaned using engine cleaner and compressed
air or replaced prior to reassembly.
Power trim system is pressurized. Outboard must
be in the full UP position (cylinder fully extended) prior to fill screw or manual release valve
removal.
Refer to instructions following if disassembly is
required.
Follow preliminary checks before proceeding to troubleshooting flow diagrams (following).
Date Code Location

Date codes are placed on power trim assemblies at
date of manufacture. These date codes are designed
to quickly identify assemblies which may be affected
by service bulletins pertaining to specific problems.
Note date code on trim assembly and compare to
date code listed on service bulletins before making repairs.
1. Check that manual release valve is tightened to

full right (clockwise) position.
2. Check trim pump fluid level with outboard in full
UP position and fill if necessary. Refer to Fill and
Purge the Power Trim System.
3. Check for external leaks in Power Trim system.
Replace defective part(s) if leak is found.
4. Outboard not holding tilted position (falls to trim in
position) indicates debris or defective components in trim valve assembly. Clean or replace
components as required.
5. Check manual release valve for broken stem and
one O-ring remaining in the release valve passage. (Separate the manifold assembly from the
cylinder to dislodge broken stem.) Install new release valve and test system.
6. Check for nicked, deteriorated, or misplaced
O-rings throughout trim system.
a
c
b
a - Label on Top Cover of Motor
b - Motor Reservoir Flange
c - Embossed into the CAUTION Decal on Trim/Tilt Cylinder
90-13645--2 495
POWER-TRIM
6C-7
2. The spool is considered stuck when the pin end

is protruding out past the end of the sleeve.
Leak Down Check - Pump and

Manifold Assembly
The 1993 and 1994 models listed with power trim date
codes 13011 through 23288 ONLY may experience
a very slow trim rate (one minute or more) with the outboard drifting back down as soon as the UP trim button is released. This failure usually occurs when the
unit is new or after 3 or 4 weeks of non use. The cause
may be a stuck spool inside the sleeve due to an oversize or a hard o-ring on the spool (SERVICE BULLETIN No. 93-22A).
SPOOL STUCK
52790
a - Spool Pin
NOTE: Scribe pump housing and manifold before disassembly.

1. Remove tilt cylinder from the manifold and replace pilot valve assembly.
SPOOL NOT STUCK
52791
a
50999
a - Sleeve with Spool Inside
Pilot Valve and Seat Removal

a
b
c
d
e
6C-8
Pilot Valve
Valve Seat
Return Spring
Sleeve
Spool
POWER-TRIM
90-13645--2 495
3. A leak path is created between the UP side of the

cylinder and the reservoir when the spool sticks
holding the pilot valve open.
6. Inspect for nicked, deteriorated, or misplaced

O-ring .
d
a
a
b
c
d
e
f
b c
Cylinder/Manifold Mating Surface

O-ring
Spool
Return Spring
Valve Seat
Pilot Valve Held Open (away from valve seat)
4. Power trim units with date code 23289 and higher

have improved o-rings and improved surface finish on the inside of the sleeve to correct the problem.
5. To correct a slow leak down, check for debris between the valve seat and valve.
c
a
b
c
d
51560
Valve and Seat

O-ring
O-ring
Scribe Mark
Reassembly
1. Install the spool into sleeve from the chamfered
end (end opposite the cross hole).
2. Insert spool into sleeve until end is flush with the
chamfered end of the sleeve. Inserting the spool
too far into the sleeve may allow the spool o-ring
to contact the sharp edges of the sleeve cross
hole and damage the o-ring.
a
b
3. After reassembly, insert driveshaft and check

pump rotor resistance to turning - housing halves
can shift/turn during reassembly. Align scribe
marks carefully.
52792
a - Chip under Valve Tip
b - Rubber Seat
90-13645--2 495
POWER-TRIM
6C-9
3. Remove all burrs and filings from the memory piston.
Power Trim Partial Leak Down at

Maximum Trim
Power Trim Date Code 14182 and Below Service
Bulletin No. 94-13.
4. Reassemble the trim/tilt ram assembly using new

o-rings and seals.
Some units, when trimmed to the maximum 20 degree limit, will leak down approximately 5 degrees
and then hold. The leak will ONLY occur while the
boat is under power. The cause for the 5 degree leak
down is the lack of a fluid passage between the shock
piston and the memory piston.
1. Disassemble the tilt ram assembly and remove
the memory piston.
2. Cut a small groove 0.020 0.040 in. (0.5
1.0mm) deep across the top face of the memory
piston. The groove will allow oil passage when the
shock piston and memory piston are in contact.
The groove can be made with a hacksaw or triangular file.
NOTE: Power trim assemblies with Date Code
14183 and ABOVE have a groove in the shock
piston to allow fluid passage. The memory piston
remains the same and does not have a groove
across the face.
a - Shock Piston
b - Memory Piston
c - 0.020 0.040 in. (0.5 1.0mm) Groove
6C-10
POWER-TRIM
90-13645--2 495
Leak Down Check - Pilot Valve

Assembly
Leaks Past Ball and Seat - Piston

Assembly
1. Debris or chips between valve and seat (a), usually imbedded in rubber valve seat.
Unit will trim to full or near full down position and then
will begin to trim up while trim switch is held in
DOWN mode.
2. Pilot valve installed from non-chamfered end of

spool, results in nicked or damaged O-ring (b).
3. Nicked or deteriorated O-ring (c).
A leak path is created between the UP side of the cylinder and the reservoir. The trim system will leak down
until the trim port in cylinder is covered.
If trim switch is released, outboard can be pushed (by

hand) down to the point where trim UP started.
1. Inspect balls and seats in piston assembly for debris or damage. Repair or replace balls/seats.
c
a
b
a
51560
51143
a - Valve and Seat

b - Pilot Valve O-ring
c - O-ring
a - Ball and Seat. Check all for debris or damage.
Leak Down Check - Manual Release

Valve
1. Debris or chips under O-ring (a).
2. Flash from valve molding causing O-ring (a) to not
seal.
3. Nicked O-ring (a).
51560
a - O-ring
90-13645--2 495
POWER-TRIM
6C-11
Power Trim Rocker Arm

Power Trim Date Code 14182 and Below. Refer to
Service Bulletin No. 92-12.
2. Clearance between the side of the rocker arm and

each pin is 0.001 to 0.010 in. (0.025 0.25mm).
3. Torque bolt to 125 140 lb. in. (14.1 15.8 Nm).
Outboard in the trim position will not trim up or down

OR pump motor will lock up (not turn) in either direction.
Outboard in the tilt position will not tilt up or down OR
pump motor will run slow in either direction.
a
d
Single ram power trim that will not trim or tilt up or

down may have a pump/manifold assembly with a
broken rocker arm.
1. Replace broken rocken with improved rocker arm

assembly 823180A1.
a
51560
a - Clearance Between Each Pin and Rocker Arm 0.001
to 0.010 in. (0.025 0.25mm)
b - Pump Pins
c - Rocker Arm
d - Bolt [Torque to 125 140 lb. in. (14.1 15.8 Nm)]
a - Rocker Arm
b - Rocker Arm Assembly
Previous Rocker Arm Design
Improved Rocker Design
6C-12
51742
51742
POWER-TRIM
90-13645--2 495
Troubleshooting Flow Diagram

Outboard falls to full down position
with manual release valve closed.
Example a: Outboard lowers more
than one tilt bolt hole in eight hours.
Example b: Outboard
during acceleration.
lowers
Inspect Manual Release Valve.

Result
Result
Manual release valve and/or

O-ring damage.
Manual release valve and O-rings

appear to be OK. Replace O-rings.
Replace defective valve and O-rings.

Result
O-rings appear to be OK. Cylinder

bore and memory piston are OK.
Replace O-rings and proceed.
Inspect O-rings on Pilot Relief Valve

(located in manifold assembly).
Result
Result
O-ring failure.
O-rings appear to be OK.

Replace O-rings.
Replace O-rings.
Inspect Memory Piston O-ring.
90-13645--2 495
Result
Result
All components appear to be OK.
O-ring or Cylinder
Bore Defective.
Replace Manifold and

Pump Assembly.
Replace O-ring or Components.
POWER-TRIM
6C-13
Troubleshooting Flow Diagram

Outboard will not hold tilted position
in reverse and/or trails out during
high speed deceleration.
Inspect Manual Release Valve.
Result
Result
Manual release valve and/or

O-ring damage.
Manual release valve and O-rings

appear to be OK. Replace O-rings
and proceed.
Replace defective valve and O-rings.
Inspect Trim Rod Piston Check Valve.

Result
Result
No debris or defective
components found.
Debris found in check

valve components.
Inspect Manifold Reverse

Thrust Valve.
Clean check valve components using engine cleaner and

compressed air or replace.
Replace Pump and Manifold Assembly.
6C-14
POWER-TRIM
90-13645--2 495
Electrical System Troubleshooting

COMMANDER 2000 Side Mount
Remote Control (Power Trim/Tilt
Electric Start with Warning Horn)
Wiring Diagram
UP
DOWN
d
e
BLK
BLU
BRN
GRY
GRN
PUR
RED
TAN
WHT
YEL

f
b
BLACK
BLUE
BROWN
GRAY
GREEN
PURPLE
RED
TAN
WHITE
YELLOW
23891
a
b
c
d
e
f
g
Warning Horn
Trim/Tilt Switch
90-13645--2 495
POWER-TRIM
6C-15

BLK
BLU
GRN
RED
BLU/WHT
GRN/WHT

BLACK
BLUE
GREEN
RED
BLUE/WHITE
GREEN/WHITE
Negative ()
Trim Motor (UP)
Trim Motor (DOWN)
Positive (+)
Trim Switch to UP Relay
Trim Switch to DOWN Relay
8
Wiring From
Side Mount
Remote Control
Harness
Power
Trim
Motor
Engine Harness
Fuse
Rectifier
Start Solenoid
To Battery
UP
DOWN
Trim Relays
51507
6C-16
POWER-TRIM
90-13645--2 495
Troubleshooting the Down Circuit*

(When Up Circuit is OK)
*Remote Control Not Equipped with Trailer Button

and black lead to ground.
black lead to ground. Depress Down trim
button. If battery voltage is indicated, wire
is open between Points 4 and 1.

Down Relay is Defective. Replace
and retest.
Connect Voltmeter red lead to Point 5. If battery voltage is indicated, trim switch is faulty. If no battery
voltage, check for loose or corroded connection at
Point 5 or open circuit in wire supplying current to
Point 5.

(When Down Circuit Is OK)
*Remote Control NOT Equipped with Trailer Button

and black lead to ground.
UP Relay is defective. Replace

and retest.

black lead to ground. Depress Down
trim button. If battery voltage is indicated,
wire is open between Points 7 and 8.
Connect Voltmeter red lead to Point 5. If battery voltage is
indicated, trim switch is faulty. If no battery voltage, check
for loose or corroded connection at Point 5 or open circuit
in wire supplying current to Point 5.
90-13645--2 495
POWER-TRIM
6C-17
Troubleshooting the Down and Up Circuits (All Circuits Inoperative)*

*Remote Control NOT Equipped with Trailer Button
Check in-line fuse (under cowl) to see if fuse is blown
Blown Fuse:
Fuse Not Blown:
S Correct problem that

caused fuse to blow.
Connect Voltmeter red lead to Point

3 and black lead to ground, Battery
voltage should be indicated.
S Replace fuse.
S Check battery leads for poor

connections or open circuits.
S Connect Voltmeter red lead to

Point 8 and black lead to ground.
S Check battery charge.
S Depress Up trim button and

check for battery voltage.

S Check black ground wires for poor

connection or poor ground.
Connect red Voltmeter lead to

Point 5, and black lead to ground.
S Pump motor is faulty. Refer to Motor

and Electrical Tests/Repair, following.

control by performing the following
checks:
Trim switch is faulty or there is an open

circuit in wires (green-white, blue-white)
between trim buttons and trim pump.
S DO NOT start engine.
S Check trim switch.
S Turn ignition switch to Run position.
S Check all trim harness connectors

for loose or corroded connections.
S Check for voltage at any instrument,

using a Voltmeter.
S Check for pinched or severed wires.
Red wire is open between Point 3 and red
S Check for loose or corroded connections.
S Check for open circuit in wire.
6C-18

Point 5 and Red terminal on the back of
the ignition switch.
POWER-TRIM
90-13645--2 495
Power Trim System Removal
6. Use suitable punch to remove lower cross pin.

Retain cross pin.
Support outboard with tilt lock lever when servicing

power trim system.
1. Disconnect power trim harness from outboard wiring harness.
2. Remove screw and clip securing wiring harness
to clamp bracket.
3. Remove trim gauge sender (if equipped).
4. Use suitable tool to remove upper headed cross
pin. Retain pin. Straight pin is hard to remove (see
item 5).
a
b
51506
a - Cross Pin
7. Use suitable punch to drive out lower pivot pin.
51505
a - Cross Pin (Design 1 - Straight)
b - Cross Pin (Design 2 - Headed)
5. Drive out upper pivot pin. This will shear cross pin.
51485
a - Pivot Pin
50515
a - Upper Pivot Pin
Inspect cross pin hole and pivot pin hole for damage.
90-13645--2 495
POWER-TRIM
6C-19
8. Tilt power trim assembly (top first) out from clamp

bracket and remove assembly.
Power Trim System

Disassembly
Trim Rod Removal
1. Secure power trim assembly in soft jawed vise.
2. Open manual release valve three turns maximum (counterclockwise) and position trim rod to
full up position.
3. Remove cylinder end cap assembly from cylinder
using spanner wrench (1/4 in. x 5/16 in. long
pegs).
51506
NOTICE: Trim ram should be fully extended BEFORE

removing fill screw as system is under pressure (and
will spray out fluid) if fill screw is removed with ram retracted.
9. Remove fill screw and drain unit.
51194
b - Manifold
c - Spanner Wrench (P/N 91-74951)
4. Remove trim rod assembly from cylinder.
51505
a - Fill Screw
10. Remove O-ring from fill cap.
51194
6C-20
POWER-TRIM
51196
90-13645--2 495
5. Remove memory piston from cylinder using lockring pliers (Craftsman P/N 4735) or suitable tool.
Trim Rod Disassembly

1. Place trim rod assembly on clean work surface.
2. Remove screws securing plate to trim rod piston
and O-ring.
3. Remove check ball components from trim rod
piston.
d
b
LOCK-RING PLIERS
a - Screw (3)
b - Plate
51143
c - O-ring
d - Piston
CAUTION
51193
6. Remove O-ring from memory piston.
When removing Trim Rod piston, spanner wrench

must have 1/4 in. x 5/16 in. long pegs to avoid
damage to trim piston.
4. Place trim rod into soft jawed vise and apply heat
to shock piston using torch lamp (91-63209).
5. Loosen trim rod piston using spanner wrench
(1/4 in. x 5/16 in. long pegs).
6. Allow trim rod piston to cool. Remove from trim
rod.
51196
a - O-ring
b - Memory Piston
51146
1. Place trim rod assembly on clean work surface.

2. Remove trim system from vise and empty fluid
into appropriate container.
90-13645--2 495
a - Torch Lamp
POWER-TRIM
6C-21
8. Remove rod wiper, inner O-ring and outer O-ring.
b
c
51147
51146
b - Spanner Wrench
c - Trim Rod Piston
CAUTION
Do not remove check ball components (a) from
trim rod piston. Removal and re-installation of
check valve could result in improper operating
pressure and possible power trim system
damage. If check valve is defective, replace trim
rod piston.
c
51145
a - Rod Wiper
b - Inner O-ring
c - Outer O-ring
7. Remove inner O-ring from piston.
b
51199
a - Check Ball Components
b - O-ring
c - Piston
6C-22
POWER-TRIM
90-13645--2 495
Trim Motor Removal
Trim Motor Disassembly
1. Secure power trim assembly in soft jawed vise.
1. Remove armature from motor frame. Note position of washers on armature.
2. Remove screws securing end cap to reservoir

and remove end cap.
b
c
51486
a - Armature
b - Motor Frame
c - Washer (1 each end of armature)
Reservoir Assembly Removal

1. Remove manual release valve from manifold.
51486
a - Screws (4)
3. Remove motor from reservoir.
b
b - Manifold
2. Remove E clip and O-rings from manual release

valve.
a
c
51484
90-13645--2 495
51196
a - E Clip
b - O-rings
POWER-TRIM
6C-23
3. Remove four screws securing reservoir to manifold.
Manifold Removal
1. Remove screws and manifold from cylinder.
c
a
a
51193
a - Screws (4)
51007
a - Trim Cylinder
b - Manifold
c - Screw (2)
4. Remove reservoir from manifold.

5. Remove drive shaft from oil pump.
2. Remove check valve components from manifold.

IMPORTANT: Sleeve (d) is chamfered on I.D. on
end opposite drilled cross hole. Install spool (e)
(with O-ring installed) from chamfered end of
sleeve to avoid possibility of damaging O-ring on
spool.
e
c
d
a
b
c
51560
51486
a - Reservoir
b - Driver Shaft
c - Oil Pump
6C-24
a
b
c
d
e
Manifold and Pump

O-ring (3)
Spring
Sleeve
Spool
POWER-TRIM
90-13645--2 495
3. Remove O-rings from cylinder.

Tests/Repair
WARNING
Do not perform this test near flammables (or
explosives), as a spark may occur when making
connections.
1. Disconnect GREEN (motor) wire and BLUE (motor) wire from trim system wiring harness.
51008
a - O-rings
Cleaning and Inspection of

Trim Rod Components
2. Connect a 12 volt power supply to motor wires

(POSITIVE to BLUE; NEGATIVE to GREEN results in motor up direction. POSITIVE to GREEN;
NEGATIVE to BLUE results in motor down direction). Motor should run.
3. If motor does not run, disassemble motor and
check components.
CAUTION
Armature Tests
Do not remove check ball components (a) from

trim rod piston. Removal and re-installation of
check valve could result in improper operating
pressure and possible power trim system
damage.
TEST FOR SHORTS
Check armature on a Growler (follow Growler manufacturers test instructions). Indication of a short requires replacement of armature.
TEST FOR GROUND
Use an Ohmmeter (R x 1 scale). Place one lead on

Ohmmeter on armature shaft and other lead on commutator, as shown. If continuity is indicated, armature
is grounded and must be replaced.
51199
a - Check Ball Components
Inspect check valve for debris; clean debris form

check valve if found. If debris cannot be cleaned from
check valve, replace trim rod piston as an assembly.
Clean trim rod and components with parts cleaner
It is recommended that all O-rings in trim system be
replaced.
51195
Inspect trim rod. If scraper (located in cap) has failed

to keep rod clean, replace scraper.
Lubricate all O-rings using Quicksilver Power Trim
and Steering Fluid or; (ATF) Type F, FA or Dexron II.
90-13645--2 495
POWER-TRIM
6C-25
If commutator is worn it can be turned down on an armature conditioner tool or on a lathe.

Clean commutator with 00 sandpaper.
1. Install check valve components into pump manifold.

IMPORTANT: Sleeve (d) is chamfered on I.D. on
end opposite drilled cross hole. Install spool (e)
(with O-ring installed) from chamfered end of
sleeve to avoid possibility of damaging O-ring on
spool.
e
c
b
d
a - Commutator
Power Trim System

Reassembly
Manifold Installation
IMPORTANT: Install spring, check valve and
O-ring into manifold. Position components in
place using sleeve to seat in place.
51560
a
b
c
d
e
Manifold and Pump

O-ring (3)
Spring
Sleeve
Spool
2. Install O-rings on cylinder and secure manifold

assembly to cylinder using screws. Torque screws
to 100 lb. in. (11.3 Nm).
50999
a
51486
a - O-ring (2)
6C-26
POWER-TRIM
90-13645--2 495
2. Lubricate end cap bushing with Quicksilver 2-4-C

Lubricant and install armature and motor frame
into end cap. As brushes contact commutator, release brush tension spring from ends of brush
housings (returning springs to apply brush pressure to commutator). Install washer on each end
of armature before installing armature into end
cap (see inset).
51007
b - Screws [100 lb. in. (11.3 Nm)]
3. Secure power trim unit in soft jawed vise.
Trim Motor Reassembly
1. Place brush tension springs on outer ends of

brush housings to release tension on brushes.
51484
b
a
b
c
d
End Cap Bushing. Lubricate with Quicksilver 2-4-C w/Teflon

Brush (2)
Commutator
Brush Tension Spring (2)
3. Guide armature and motor frame into reservoir

housing as shown.
b
a
51485
a - Brush Tension Spring (2)

b - Brush Housing (2)
c - Brush (2)
c
d
b
a
b
c
d
90-13645--2 495
51485
End Cap
Motor Housing
Armature and Motor Frame
Washer (One Each End of Armature)
POWER-TRIM
6C-27
5. Secure reservoir to manifold using four screws.

Torque screws to 70 lb. in. (7.9 Nm).
Reservoir Installation
1. Torque end cap screws to 13 lb in. (1.5 Nm).
c
a
a
51193
a - Screw
6. Install lubricated O-rings and E clip to manual release valve.

51486
a - End Cap
b - O-ring
c - Screws (4)
2. Place drive shaft into oil pump.

3. Install lubricated O-ring to base of reservoir.
4. Carefully guide (with motor) down onto drive
shaft.
a
c
51196
a - E Clip
b - O-ring
7. Insert manual release valve into manifold and

tighten snuggly. Back release valve out 3 turns
maximum allowing trim rod installation.
b
a
b
a
51194
51486

b - Manifold
a - Drive Shaft
b - O-ring
6C-28
POWER-TRIM
90-13645--2 495
Trim Rod Reassembly

1. Install lubricated O-rings and rod wiper to end
cap.
4. Apply Loctite 271 (Obtain Locally) to threads of

trim rod and install rod piston. Tighten piston securely using spanner wrench (1/4 in. x 5/16 in.
long peg).
c
b
51145
a - Rod Wiper
b - Inner O-ring
c - Outer O-ring
2. Secure trim rod in soft jawed vise as shown.
51146
3. Slide end cap onto trim rod.
a - Trim Rod Piston

b - Spanner Wrench
5. Install lubricated O-ring to trim rod piston.
6. Install check ball components into its respective

bore.
f
a
51146
a - End Cap
51147
a
b
c
d
e
f
90-13645--2 495
Screw (3)
Plate
O-ring
Ball (5)
Seat, Spring (5)
Spring (5)
POWER-TRIM
6C-29
4. Install trim rod into cylinder.
Trim Rod Installation

1. Place trim cylinder in soft jawed vise.
2. Fill trim cylinder three inches (76.2mm) from top
of cylinder using Quicksilver Power Trim and
Steering Fluid or; (ATF) Type F, FA or Dexron II.
3. Install lubricated O-ring to memory piston and
place into cylinder. Push piston down to level of
oil.
b
a
51196
5. Tighten end cap assembly to cylinder securely using spanner wrench (1/4 in. x 5/16 in. long pegs).
51144
Memory piston must not contact end cap during

trim rod/end cap installation.
a - O-ring
b - Memory Piston
51145
a - Spanner Wrench (91-74951)
6. Tighten manual release valve snuggly following

end cap installation.
6C-30
POWER-TRIM
90-13645--2 495
Purging Power Trim Unit
Power Trim Unit Installation
Manual release valve must be in full closed position during power trim purging and operation.
1. Apply 2-4-C w/Teflon (92-825407A12) to lower

pivot pin bore and pivot pin surface.
1. Secure power trim unit in soft jawed vise.
2. Position trim cylinder assembly (BOTTOM

FIRST) between clamp brackets and route trim
pump electrical harness through access hole in
starboard clamp bracket.
2. Remove fill cap. Add Quicksilver Power Trim and

Steering Fluid (92-90100A12) or Automatic
Transmission Fluid (ATF) Type F, FA or Dexron II
up to threads of reservoir. Install cap.
3. Start lower pivot pin into pivot pin bore and position lower cross pin (RETAINED) in its respective
hole.
51432
a - Fill Cap
3. Using a 12 volt power supply connect POSITIVE

lead to GREEN wire, NEGATIVE lead to BLUE
wire and drive trim rod to the DOWN position.
Connect POSITIVE lead to BLUE wire and NEGATIVE lead to GREEN wire and drive trim rod to
the UP position. Recheck fluid level, add fluid as
required and repeat cycle until fluid level remains
at lower portion of threads.
90-13645--2 495
a
b
51515
a - Trim Cylinder Assembly

b - Lower Pivot Pin
c - Lower Cross Pin
POWER-TRIM
6C-31
4. Using a suitable punch, drive lower pivot pin into

clamp bracket and trim cylinder assembly until
pivot pin is flush with outside surface.
6. Apply 2-4-C w/Teflon (92-825407A12) to surface

of upper pivot pin, pivot pin bore and trim ram
bore.
NOTE: Install trim ram with cross hole located as

shown .If trim ram is installed reversed, the trim sender (if installed) will not operate.
51515
Cross Hole
51515
a - Lower Pivot Pin
5. Using a suitable punch, drive lower cross pin into

its respective bore until seated.
Transom Side
Engine Side
a
b
c
d
Pivot Pin
Pivot Pin Bore
Trim Ram Bore
Install Trim Ram As Shown
a
51515
a - Lower Cross Pin
6C-32
POWER-TRIM
90-13645--2 495
7. Using a suitable mallet, drive upper pivot pin into

swivel bracket and through trim ram until pivot pin
is flush with swivel bracket.
8. Drive upper retaining pin in until seated.
c
b
51505
a - Retaining Pin
51515
a - Pivot Pin
b - Swivel Bracket
c - Trim Ram
9. Recheck fluid level.

10. Power trim may now be operated to lower outboard to desired position. Trim system is self
purging.
11. Reconnect power trim leads to relays under ignition cover.
12. Reinstall spark plug leads to spark plugs.
13. Reinstall cowls.
14. Connect battery leads to battery terminals.
90-13645--2 495
POWER-TRIM
6C-33
ENGINE ATTACHMENTS/
ENGINE INSTALLATION
7
A
50099
Table Of Contents
Page
Steering Cable and Steering Link Rod

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ride-Guide Attachment
Dual Front Installation (92876A2) . . . . . . .
Installation and Maintenance . . . . . . . . . . .
Cable Routing Types . . . . . . . . . . . . . . . . . .
Parallel Routed Steering Cables and
Attaching Kit Installation . . . . . . . . . . . . . . .
Super Ride-Guide Steering Kit
Installation . . . . . . . . . . . . . . . . . . . . . . . .
Installing Steering Cables and Steering
Link Rods to Engines . . . . . . . . . . . . . . .
Steering Eyes and Coupler Installation . . .
Steering System Tension Adjustment
(Parallel Routed Steering Cables) . . . .
Opposite Side Routed Steering Cables and
Super Ride-Guide Steering
Kit Installation . . . . . . . . . . . . . . . . . . . . .
Installing Steering Cables and Steering
Link Rods to Engines . . . . . . . . . . . . . . .
Steering Eyes and Coupler Installation . . .
Steering System Tension Adjustment . . . .
Trim Tab Installation . . . . . . . . . . . . . . . . . . . . . .
Trim Tab Adjustment . . . . . . . . . . . . . . . . . .
Maintenance Instructions . . . . . . . . . . . . . .
Ride Guide Steering Attachment
Extension Couplers . . . . . . . . . . . . . . . .
Transom Mounted Ride-Guide Attaching
Kit Installation (73770A1) . . . . . . . . . . . . . .
7A-1
7A-2
7A-2
7A-2
7A-3
7A-3
7A-3
7A-5
7A-6
7A-8
7A-8
7A-8
7A-10
7A-11
7A-12
7A-13
7A-13
7A-14
7A-14
7A-14
Page
Steering Cable Installation . . . . . . . . . .

Ride-Guide Steering Cable/Attaching Kit
Installation (92876A3) . . . . . . . . . . . . . . . . .
Dual Cable - Single Outboard . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Bracket Installation . . . . . . . . . . .
Steering Cable Mounting Tube
Installation . . . . . . . . . . . . . . . . . . . . . . . .
Coupler Installation . . . . . . . . . . . . . . . .
Installing Steering Cables . . . . . . . . . . . . . .
Coupler Installation . . . . . . . . . . . . . . . . . . . .
Installing Link Rod . . . . . . . . . . . . . . . . . . . .
Steering System Tension
Adjustment . . . . . . . . . . . . . . . . . . . .
Remote Control Installation . . . . . . . . . . . . . . . .
Shift Cable Installation and Adjustment
to Engine . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Cable Installation and
Adjustment to Engine . . . . . . . . . . . . . .
Connecting Engine Wiring Harness
and Routing of Engine Cables . . . . . . .
Installing Outboard Motor on Transom . . . . . .
Determining Recommended Outboard
Mounting Height . . . . . . . . . . . . . . . . . . .
Locate Centerline of Boat Transom . . . . . .
Drilling Outboard Mounting Holes . . . . . . .
Lifting Engine . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Engine to Transom . . . . . . . . . . .
7A-16
7A-16
7A-17
7A-17
7A-17
7A-18
7A-18
7A-18
7A-19
7A-20
7A-20
7A-20
7A-21
7A-22
7A-22
7A-23
7A-24
7A-25
7A-25
7A-25
7A-26
7A-26
7A-26
90-13645--2 495
Steering Cable and Steering

Link Rod Installation
CAUTION
Control cables must be the correct length when
installed. Cables that are too long may bind or
kink putting extra stress on cables.
4. Install rubber bumper on inside of locking sleeve,

then install locking sleeve over steering cable attaching nut ) and secure with cotter pin . Spread
ends of cotter pin. Be sure to install cotter pin so
that it is located in-between attaching nut and
grease fitting , as shown.
c
e
1. Install steering mount and steering wheel in

accordance with installation instructions that
accompany each.
2. Lubricate seal inside of engine tilt tube and entire
steering cable end with Quicksilver 2-4-C
w/Teflon.
d b
a
50130
a - Cable Nut
b - Locking Sleeve
c - Cotter Key
d - Grease Fitting
e - Steering Cable
51890
a - Seal
IMPORTANT: Before installing steering cable into

tilt tube, lubricate seal and entire cable end with
Quicksilver 2-4-C w/Teflon.
3. Insert steering cable end thru engine tilt tube and
secure steering cable to tilt tube with steering
cable attaching nut as shown. Torque nut to
35 lbs. ft. (47.5 Nm).
90-13645--2 495
ENGINE ATTACHMENTS
7A-1
Cable Routing Types
CAUTION
Steering link must be installed in rear hole in
engine steering arm. Failure to install in rear hole
may cause damage to steering system.
5. Lubricate hole in end of steering cable with Quicksilver 2-4-C w/Teflon and assemble steering link
rod to steering cable with 2 flat washers and locknut as shown. Torque locknut to 120 lbs. in. (13.5
Nm) maximum and back off 1/4- turn.
6. Lubricate ball joint in steering link rod with 30W oil
and assemble to rear hole in engine steering arm
with pivot bolt and locknut. Torque pivot bolt, then
locknut to 20 lbs. ft. (27.1 Nm).
c
a
Use 1 or 2, following, to route steering cables:

1. Parallel cable routing: Cables routed together
down starboard side of boat. Refer to Parallel
Routed Steering Cables and Attaching Kit Installation, immediately following.
2. Opposite side cable routing: One cable routed
down starboard side of boat and one cable routed
down port side of boat. Refer to Opposite Side
Routed Steering Cables and Attaching Kit Installation, page 7A-8.
CAUTION
With this kit installed, the upper (engine)
mounting bolts must be installed so that hex head
end of bolts is on the inside of boat transom, as
illustrated below. Failure to install upper
mounting bolts, as shown in illustration, could
result in interference between outer steering
cable locking sleeve and ends of mounting bolts
when engine is tilted up.
b
50099
a
b
c
d
Install Upper Bolts so

that Hex Head End of
Bolts Are on the
Inside of Boat
Transom
Flat Washers (2)

Locknut
Pivot Bolt
Locknut
Ride-Guide Attachment
Dual Front Installation
(92876A2)
WARNING
Quicksilver Super Ride-Guide Steering (Dual
Cables) must be used with this attaching kit.
Failure to adhere to this requirement could result
in steering system failure.
Installation and Maintenance

IMPORTANT: The distance from each engines
centerline to the side of transom opening must be
a minimum of 16 (40.6cm).
This kit contains all necessary parts to connect
both engines to Ride-Guide Steering cables for
22-1/2 thru 24-1/2, refer to Figure 14, page 7A-14
for additional extension couplers.
7A-2
ENGINE ATTACHMENTS
90-13645--2 495
Parallel Routed Steering

Cables and Attaching Kit
Installation
WARNING
(Both Steering Cables Routed Together Down

Starboard Side of Boat)
Before using engine after installation of cables,

check to see that boat will turn right when steering
wheel is turned right and that boat will turn left
when wheel is turned left. Do this check at all tilt
angles and thru full range of turn angles.

Installation
Installing Steering Cables and

Steering Link Rods to Engines
IMPORTANT: It may be necessary to install steering cable into tilt tube of starboard engine before
mounting engine.
1. Install tube mounting bracket (Figure 2) to starboard mounted engine with 2 locking retainers
and 4 bolts. Torque bolts to 100 lbs. in. (11.3 Nm)
and bend end of locking retainers up and against
flat on each bolt, as shown in Figure 2.
Both gear racks or rotary steering heads must be

installed so that both steering cables will be
routed together on the same side of the boat and
will push-and-pull together.
1. Install Super Ride-Guide Steering Kit in accordance with instructions included with Super RideGuide Kit.
WARNING
Locking retainer ends must be bent up and
against flat on each bolt, that secures mounting
bracket to engine, to prevent bolts from turning
out.
2. Make sure that both gear racks or rotary steering

heads are installed so that both steering cables
are routed together and will push-and-pull together (Figure 1).
b
16958
a - Tube Mounting Bracket

b - Bolts
c - Locking Retainers (Bend Ends Up and Against
Flat on Bolts.)
b
a - Straight Rack (Left); Rotary Steering (Right)
b - Steering Cables (Install so that Both Cables Will
Push-and-pull Together.)
Figure 2. Tube Mounting Bracket Installed
Figure 1. Super Ride-Guide Steering Kits Installed
90-13645--2 495
ENGINE ATTACHMENTS
7A-3
2. Install steering cable mounting tube into mounting

bracket with 2 adjustment nuts and tab lock washers, as shown in Figure 3. Be sure that longer
threaded end of tube is toward steering cable attaching nut side of engine.
NOTE: Torque steering cables attaching nuts and

install locking sleeve after final tension adjustment.
5. Install steering cable seal to steering cable
mounting tube, as follows:
a. Place a mark on steering cable mounting tube
5/8 (15.8mm) from end of tube (Figure 5).
3. Temporarily adjust tube so that longer threaded

end of tube is extended out the same distance as
engine tilt tube. Do not tighten adjustment nuts at
this time.
16959
a - Steering Cable Mounting Tube

b - Tab Lock Washers
c - Adjustment Nuts (Rounded Edge Facing Out)
Figure 3. Steering Cable Mounting Tube Installed

4. Install steering cables, as follows:
IMPORTANT: Before installing steering cables, lubricate inside of port mounted engine tilt tube and
inside of steering cable mounting tube with
Quicksilver 2-4-C w/Teflon. Verify that rubber Oring seal (located in engine tilt tube) also is lubricated.
a
b
c
d
e
50180
5/8 from End of Tube

Place Mark on Tube Here.
Nylon Spacer
O-ring
Cap
Figure 5. Seal Installation Sequence

b. Slide nylon spacer, O-ring and cap (from kit)
over steering cable (Figure 5).
c. Thread cap onto steering cable mounting tube
up to mark (made on tube in Step a (Figure 6).
a. Lubricate inside of (port) engine tilt tube with

Quicksilver 2-4-C w/Teflon. Make sure that rubber O-ring seal (located in engine tilt tube) also
is lubricated.
b. Lubricate inside of steering cable mounting
tube with Quicksilver 2-4-C w/Teflon.
c. Insert ends of steering cables thru engine tilt
tube and cable mounting tube (Figure 4).
Thread steering cable attaching nuts onto
tubes hand-tight.
a
a
b
c
d
50180
a - Mark Made in Step 5a
Figure 6. Steering Cable Seal Installed
Steering Cables Routed Down Starboard Side

See Figure 7 for Correct Parts Sequence
See Figure 8 for Correct Parts Sequence
Seal
16977
6. Install link rods (Figure 4) to engine steering arms.

Fasten each link rod to steering arm onto top side
rear hole with pivot bolt and locknut, as shown in
Figure 7. Torque each pivot bolt to 20 lbs. ft.
(27.1 Nm), then thread locknut onto pivot bolt
and torque nut to 20 lbs. ft. (27.1 Nm).
Figure 4. Steering Cables and Steering Link

Rods Installed
7A-4
ENGINE ATTACHMENTS
90-13645--2 495
Steering Eyes and Coupler Installation
1. Position engines so that they are facing straight

forward. (Distance between centers of threaded
pivot bolt holes in engine steering arms must be
equal to distance between propeller shaft
centers.)
c
a
2. Lubricate inside of rubber sleeves (Figure 9) and

slide onto coupler.
e
a
b
c
d
e
3. Slide rubber bushings (Figure 9) onto steering

eyes.
Engine Steering Arm

Steering Link Rod
Steering Eye and Coupler
Pivot Bolts - Torque to 20 lbs. ft. (27.1 Nm)
Locknuts - Torque to 20 lbs. ft. (27.1 Nm)
Figure 7. Steering Link Rod and Steering Eye

with Coupler Installed on Engine
Steering Arm
7. Lubricate hole(s) in end of steering cable(s) with
Quicksilver 2-4-C w/Teflon and assemble steering
link rod(s) to steering cable end, as shown in Figure 8. Tighten self-locking nut until it seats [DO
NOT exceed 120 lbs. in. (13.5 Nm)], then back
nut off 1/4-turn.
Steering Link Rod

Flat Washer (5/8 O.D.)
Steering Cable End
Locknut; Tighten Until it Seats [DO NOT Exceed 120 lbs. in.
(13.5 Nm)], then Back Nut Off 1/4-Turn.
Figure 8. Steering Link

Steering Cable
Rod
Both steering eyes must be threaded into coupler

3/4 (19mm) minimum. Thread length of steering
eye is 3-1/2 (89mm), so exposed thread must not
extend out of coupler more than 2-3/4. Failure to
adhere to this requirement could result in steering
system failure.
6. Assemble steering eyes and coupler to top side,

front holes of steering arm with pivot bolts and
locknuts, as shown in Figures 7 and 10.
d
-
WARNING
5. Lubricate steering eye threads, pivot bolts, and

ball joints with Quicksilver Anti-Corrosion Grease
(92-78376-12) before assembling.
a
b
c
d
4. Thread steering eyes (Figures 9 and 10) into coupler and adjust steering eyes so that distance between centers of pivot bolt holes in steering eyes
is the same distance as between centers of
threaded pivot holes in engine steering arms. Exposed steering eye threads should be equal at
both ends of coupler and must not extend out of
coupler more than 2-3/4 (70mm).
Assembled
on
IMPORTANT: With steering eyes and coupler

installed and before tightening pivot bolts, check
engine alignment. Distance between pivot bolts
centers and distance between propeller shaft
centers must be equal for proper steering. If adjustment is necessary, remove pivot bolt from one
steering eye and turn eye in or out to correct alignment. Both steering eyes MUST BE threaded into
coupler 3/4 (19mm) minimum.
7. Torque pivot bolts to 20 lbs. ft. (27.1 Nm), then
thread self-locking nut (Figure 7) onto bolts and
torque nuts to 20 lbs. ft. (27.1 Nm).
WARNING
Both steering eyes MUST BE threaded into
coupler 3/4 minimum, and jam nut (Figure 9) must
be secured against coupler to prevent coupler
from turning. Torque jam nut to 20 lbs. ft.
90-13645--2 495
ENGINE ATTACHMENTS
7A-5
50061
a
b
c
d
e
Rubber Bushing
Rubber Sleeve
Jam Nut; Torque to 20 lbs. ft. (27.1 Nm)
Coupler
Steering Eye
Figure 9. Coupler Assembled
e
f
d
a
b
c
d
e
f
g

Engine Steering Arm
Coupler
Steering Eye
Rubber Sleeves
Rubber Bushings
Pivot Bolt and Locknut

(Parallel Routed Steering Cables)
Figure 10. Coupler Parts Sequence

8. Secure coupler with jam nut, as shown in Figures
9 and 10, and torque to 20 lbs. ft. (27.1 Nm).
9. Position rubber bushings as shown above.
10. Slide both rubber sleeves over exposed threads
on each steering eye (Figure 10).
WARNING
Tension adjustment steering cable mounting
tube must be adjusted away from end of steering
cable when adding tension to steering system (to
remove slack). Failure to adjust tube this way may
result in hard steering, if one engine is tilted up
while operating boat.
7A-6
IMPORTANT: After this Ride-Guide Attachment

Kit is installed, there must be proper tension in the
steering system. Not enough tension will cause
slack (play) in steering system. Too much tension
will cause steering cables to bind. Perform Step
1, following, to adjust for correct tension.
1. Loosen adjustment nuts and push steering cable
mounting tube (by-hand) toward end of steering
cable (to remove slack in steering system). Tighten adjustment nuts and check system for slack
(play) or too much tightness. If steering system is
too tight, readjust tube away from end of steering
cable (Figure 11) or, if too much slack (play) exists
in system, readjust tube toward end of steering
cable (Figure 11). Tighten nuts and readjust, if
necessary.
ENGINE ATTACHMENTS
90-13645--2 495
3. Secure each steering cable attaching nut to tubes

by torquing steering cable attaching nuts (Figure 13) to 35 lbs. ft. (47.5 Nm).
51887

b - Adjustment Nuts
c - Adjust Tube in This Direction to Remove Slack from Steering
System
d - Adjust Tube in This Direction to Reduce Tightness from
Steering System
4. Install rubber bumpers on inside of locking

sleeves, then install a locking sleeve over each
steering cable attaching nut and secure with cotter pin. Spread ends of cotter pin. Be sure to install
cotter pin so that it is located in-between attaching
nut and grease fitting (Figure 13).
Figure 11. Steering System Tension Adjustment

(Parallel Routed Steering Cables)
2. After steering system tension is adjusted correctly, torque adjustment nuts (Figure 12) to 35 lbs. ft.
(47.5 Nm) and bend a tab lockwasher against a
flat on each nut.
a
b
c
a
b
c
d
e
d
51890
Steering Cable Attaching Nut -Torque to 35 lbs. ft. (47.5 Nm)

Grease Fitting
Cotter Pin
Locking Sleeve
Cable Mounting Tube
Figure 13. Steering Cables Fastened to Tubes
51887
5. Install new trim tabs as outlined in Trim Tab Installation, following.
a - Adjustment Nuts - Torque to 35 lbs. ft. (47.5 Nm)

b - Tab Lockwasher (Bend Against Flat on Each Nut.)
Figure 12. Adjustment Nuts Secured with Locktabs

50098
Figure 14. Attachment Kit Installation Complete
WARNING
After installation is complete (and before
operating engine), 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) at all
tilt angles to assure interference-free movement.
90-13645--2 495
ENGINE ATTACHMENTS
7A-7
Figure 1. Tube Mounting Bracket Installed
Opposite Side Routed

Steering Cables and
Attaching Kit Installation
(ONE CABLE ROUTED DOWN STARBOARD SIDE

OF BOAT AND ONE CABLE ROUTED DOWN
PORT SIDE OF BOAT)
IMPORTANT: Steering cable must be installed into
tilt tube of port engine before engine is
mounted.
Super Ride-Guide Steering

Kit Installation
Install Super Ride-Guide Steering Kit in accordance

with instructions included with Super Ride-Guide Kit.
Installing Steering Cables and

Steering Link Rods to Engines
1. Install tube mounting bracket to (starboard)
mounted engine with 2 locking retainers and 4
bolts. Torque bolts to 100 lbs. in. (11.3 Nm) and
bend end of locking retainers up against flat on
each bolt, as shown in Figure 1.
WARNING
Locking retainer ends must be bent up and
against flat on each bolt, that secures tube
mounting bracket to engine, to prevent bolts from
turning out.
2. Install steering cable mounting tube into mounting
bracket with 2 adjustment nuts and tab lockwashers, as shown in Figure 2. Be sure that longer
threaded end of tube is toward steering cable attaching nut side of engine.
a
b
c
d
51891
Mounting Bracket for Steering Cable Mounting Tube

J Clip - Supplied with Outboard
Locking Retainers (2)
Bolts (4) - 5/8 in. (16mm) Long - Torque to 100 lb. in.
(11.3 Nm), then Bend Corner Tabs of Locking Retainers Up
and Against Flats on Each Bolt
Figure 2. Steering Cable Mounting Tube Installed

4. Install steering cables, as follows:
IMPORTANT: Lubricate inside of (port mounted)
engine tilt tube and inside of steering cable
mounting tube with Quicksilver 2-4-C w/Teflon.
Make sure that rubber O-ring seal (located in engine tilt tube) is lubricated.
a. Lubricate inside of (port) engine tilt tube with
Quicksilver 2-4-C w/Teflon. Make sure that rubber O-ring seal (located in engine tilt tube) is lubricated.
b. Lubricate inside of steering cable mounting
tube with Quicksilver 2-4-C w/Teflon.
3. Temporarily adjust tube so that longer, threaded

end of tube is aligned with outward edge of transom bracket. DO NOT tighten adjustment nuts at
this time.
50130
a - Tube Mounting Bracket

b - Bolts
c - Locking Retainers (Bend Ends Up and Against
Flat on Bolts.)
7A-8
ENGINE ATTACHMENTS
90-13645--2 495
c. Insert ends of steering cables thru engine tilt

tube and cable mounting tube (Figure 3).
Thread steering cable attaching nuts hand-tight
onto tubes.
e a
50180
50101
a - Flat Washer (2 Each Link Rod)

b - Nylon Insert Locknut - Torque Until it Seats [DO NOT Exceed
120 lb. in. (13.5 Nm) of Torque], then Back Off 1/4-Turn
c - Special Washer Head Bolt (10-14000) - Torque to 20 lb. ft.
(27.1 Nm)
d - Nylon Insert Locknut - Torque to 20 lb. ft. (27.1 Nm)
e - Steering Link Rod
f - Steering Cable End
Figure 3. Steering Cables and Link Rod Installed
NOTE: Torque steering cables attaching nuts and

install locking sleeves after final tension adjustment.
5. Install steering cable seal to steering cable
mounting tube, as follows:
a - Mark Made in Step 5a
Figure 5. Steering Cable Seal Installed

b. Slide plastic spacer, O-ring and cap (from kit)
over steering cable (Figure 4).
c. Thread cap onto steering cable mounting tube
up to mark (made on tube in Step a (Figure 5).
6. Install link rods (supplied with engines) to engine
steering arms (Figure 3). Fasten each link rod to
steering arm onto topside rear hole with pivot bolt
and locknut, as shown in Figure 6. Torque each
pivot bolt to 20 lbs. ft. (27.1 Nm), then thread locknut onto pivot bolt and torque nut to 20 lbs. ft.
(27.1 Nm).
a. Place a mark on steering cable mounting tube

5/8 (16mm) from end of tube (Figure 4).
d
b
b
50180
a
b
c
d
e
5/8 from End of Tube

Place Mark on Tube Here.
Nylon Spacer
O-ring
Cap
a
b
c
d
e
Engine Steering Arm

Steering Link Rod
Steering Eye and Coupler
Pivot Bolts - Torque to 20 lbs. ft. (27.1 Nm)
Locknuts - Torque to 20 lbs. ft. (27.1 Nm)
Figure 6. Steering Link Rod and Steering Eye with

Coupler Installed on Engine Steering
Arm
Figure 4. Seal Installation Sequence
90-13645--2 495
ENGINE ATTACHMENTS
7A-9
Steering Eyes and Coupler Installation
1. Position engines so that they are facing straight

forward. (Distance between centers of threaded
pivot bolt holes in engine steering arms must be
equal to distance between propeller shaft
centers.)
2. Lubricate inside of rubber sleeves (Figure 8) and

slide onto coupler.
3. Slide rubber bushings (Figure 8) onto steering
eyes.
ac
d
a
b
c
d
Steering Link Rod

Flat Washer (5/8 O.D.)
Steering Cable End
Locknut; Tighten Until it Seats [DO NOT Exceed 120 lbs. in.
(13.5 Nm)], then Back Nut Off 1/4-Turn.
Figure 7. Steering Link Rod Assembled on

Steering Cable
7. Lubricate hole(s) in end of steering cable(s) with
Multi-purpose Lubricant and assemble steering
link rod(s) to steering cable end, as shown in Figure 7. Tighten self-locking nut until it seats [DO
NOT exceed 120 lbs. in. (13.5 Nm)], then back
nut off 1/4-turn.
7A-10
50061
a
b
c
d
e
Rubber Bushing
Rubber Sleeve
Coupler
Steering Eye
Figure 8. Coupler Assembled
ENGINE ATTACHMENTS
90-13645--2 495
e
f
b
d
a
b
c
d
e
f
g

Engine Steering Arm
Coupler
Steering Eye
Rubber Sleeves
Rubber Bushing
Pivot Bolt and Locknut; Torque to 20 lbs. ft. (27.1 Nm)
Figure 9. Coupler Parts Sequence

4. Thread steering eyes (Figures 8 and 9) into coupler and adjust steering eyes so that distance between centers of pivot holes in steering eyes is the
same distance as between centers of threaded
pivot holes in engine steering arms. Exposed
steering eye threads should be equal at both ends
of coupler and must not extend out of coupler
more than 2-3/4 (70mm).
7. Torque pivot bolts to 20 lbs. ft. (27.1 Nm), then

thread self-locking nut onto bolts and torque nuts
to 20 lbs. ft. (27.1 Nm).
WARNING
Both steering eyes MUST BE threaded into coupler
3/4 minimum, and jam nut (Figures 8 and 9) must
be secured against coupler to prevent coupler from
turning. Torque jam nut to 20 lbs. ft. (13.5 Nm).
8. Secure coupler with jam nut, as shown in Figure 9.
Torque to 20 lbs. ft. (27.1 Nm).
9. Position rubber bushings as shown above.
10. Slide both rubber sleeves over exposed threads
on each steering eye (Figure 9).
WARNING
WARNING
Both steering eyes must be threaded into coupler
3/4 (19mm) minimum. Thread length of steering
eye is 3-1/2 (89mm), so exposed thread must not
extend out of coupler more than 2-3/4 (69.8mm).
5. Lubricate steering eye threads, pivot bolts and
ball joints with Quicksilver Corrosion Grease
(92-78376-12) or Corrosion Guard (92-78379-12)
before assembling.
6. Assemble steering eyes and coupler to top side
front holes of steering arm with pivot bolts and
locknuts, as shown in Figures 6 and 9.
IMPORTANT: With steering eyes and coupler
installed and before tightening pivot bolts, check
engine alignment. Distance between pivot bolts
centers and distance between propeller shaft
centers must be equal for proper steering. If adjustment is necessary, remove pivot bolt from one
steering eye and turn eye in or out to correct alignment. Both steering eyes MUST BE threaded into
coupler 3/4 (19mm) minimum.
90-13645--2 495
Tension adjustment steering cable mounting

tube must be adjusted away from end of steering
cable when adding tension to steering system (to
remove slack). Failure to adjust tube this way may
result in hard steering, if one engine is tilted up
while operating boat.

OPPOSITE SIDE ROUTED STEERING CABLES
IMPORTANT: After this Ride-Guide Attachment
Kit is installed, there must be proper tension in the
steering system. Not enough tension will cause
slack (play) in steering system. Too much tension
will cause steering cables to bind. Perform Step
1, following, to adjust for correct tension.
1. Loosen adjustment nuts and pull steering cable
mounting tube (by hand) away from end of steering cable (to remove slack in steering system).
Tighten adjustment nuts and check system for
slack (play) or too much tightness. If steering system is too tight, readjust tube toward end of steering cable (Figure 10) or, if too much slack (play)
exists in system, readjust tube away from end of
steering cable (Figure 10). Tighten nuts and readjust, if necessary.
ENGINE ATTACHMENTS
7A-11
50101
Figure 13. Attachment Kit Installation Complete
51887

b - Adjustment Nuts
System
d - Adjust Tube in This Direction to Reduce Tightness from
Steering System
Figure 10. Steering System Tension Adjustment

(Opposite Side Routed Steering Cables)
2. After steering system tension is adjusted correctly, torque adjustment nuts (Figure 11) to 35 lbs. ft.
(47.5 Nm) and bend a tab lockwasher against a
flat on each nut.
3. Secure each steering cable attaching nut to tubes
by torquing steering cable attaching nuts
(Figure 12) to 35 lbs. ft. (47.5 Nm).
4. Install rubber bumpers on inside of locking
sleeves, then install a locking sleeve over each
steering cable attaching nut and secure with cotter pin. Spread ends of cotter pin. Be sure to install
cotter pin so that it is located in-between attaching
nut and grease fitting (Figure 12).
5. Install new trim tabs as outlined in Trim Tab Installation, following.
WARNING
51887
a - Adjust Nuts; Torque to 35 lbs. ft. (47.5 Nm)

b - Tab Lockwashers (Bend Against Flat on Each Nut.)
Figure 11. Adjustment Nuts Secured with Locktabs
After installation is complete (and before

operating engine), check that boat will turn right
Trim Tab Installation

IMPORTANT: With dual engine installation, existing trim tabs MUST BE replaced with new trim
tabs (supplied with kit).
1. Install new trim tabs as follows:
a. Shift engine controls into neutral and turn ignition keys to Off position.
b. Remove plastic cap from rear of both drive shaft
housings, loosen bolt, that secures trim tab to
gear housing, and remove both trim tabs from
gear housing.
a
a
b
c
d
e
51888
Steering Cable Attaching Nut;Torque to 35 lbs. in. (47.5 Nm)

Locking Sleeve (Provided with Ride-Guide Steering Cables)
Cotter Pin
Grease Fitting
Cable Guide Tube
c. Install special trim tabs (supplied with kit) to

both gear housings, using existing bolts. Tighten bolts securely. Initial trim tab setting should
be straight to rear of engine. Replace plastic
caps on drive shaft housing.
Figure 12. Steering Cables Fastened to Tubes
7A-12
ENGINE ATTACHMENTS
90-13645--2 495
2. Check trim tab position as follows:

a. Operate boat at normal cruise throttle setting
and adjust trim to optimum setting. Turn steering wheel to left and right, noting in which direction wheel turns more easily.
b. If wheel turns more easily to left, then the trailing edge of trim tab must be turned to left (when
viewing motor from behind). Reverse procedure if boat turns more easily to right.
Trim Tab Adjustment

1. Shift engine controls into neutral and turn ignition
keys to Off position.
IMPORTANT: Trim tabs MUST BE set in the same
position on both engines.
2. Remove plastic cap from rear of drive shaft housing and loosen bolt and trim tab.
3. Position trailing edge of trim tab to left (viewing
motor from behind), if steering wheel turns more
easily to left. Position trailing edge of trim tab to
right (viewing motor from behind), if steering
wheel turns more easily to right.
4. Tighten both trim tab bolts securely and replace
plastic caps.
5. Operate boat per Check trim tab position as follows, preceeding, to check trim tab setting.
Readjust trim tabs, if necessary.
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 of cable could occur.
3. With core of Ride-Guide steering cables (transom
end) fully retracted, lubricate transom end of
steering cables thru grease fittings (Figure 12)
with Quicksilver 2-4-C w/Teflon. Lubricate exposed portion of cable end with 2-4-C w/Teflon.
4. Lubricate pivot points and ball joints in link rods
and coupler steering eyes with Quicksilver AntiCorrosion Grease or Corrosion Guard.
5. Inspection and lubrication of steering head 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 effort has increased. Lubricate with Quicksilver 2-4-C w/Teflon.
WARNING
When 2 couplers are connected together with
coupler link rod, a lockwasher must be used on
each side of coupler link rod, and link rod must be
torqued to 20 lbs. ft. (27.1 Nm) into end of each
coupler.
Maintenance Instructions
Maintenance inspection is owners responsibility and
must be performed at intervals specified, following:
Normal Service Every 50 hrs. of operation or 60
days (whichever comes first)
*Severe Service Every 25 hrs. of operation or 30
* Operation in a salt water area is considered Severe Service.
1. Carefully check steering system components for

wear. Replace worn parts.
2. Check steering system fasteners to be sure that
they are torqued to correct specifications.
NOTE: Ride-Guide steering cables are lubricated at

the factory and require no additional lubrication at initial installation.
90-13645--2 495
ENGINE ATTACHMENTS
7A-13
Ride Guide Steering Attachment

Extension Couplers
Outboard Center
Line Distance
22-1/2 in. thru
24-1/2 in. (57.2cm
thru 62.2cm)
23-1/2 in. thru
27-1/2 in. (59.7cm
thru 69.9cm)
26-1/2 in. thru
30-1/2 in. (67.3cm
thru 75.5cm)
30 in. thru 34 in.
(76.3cm thru
86.4cm)
Required Coupler(s)
Between Steering Eyes
(Shown Below)
12 in. (30.5cm) Coupler
c
(Supplied with this kit)
9 in. (22.9cm) Coupler and

(Connected together with
coupler link rod)
33 in. thru 37 in.

12 in. (30.5cm) Coupler and
83.8cm thru 94.0cm 12 in. (30.5cm) Coupler
(Connected together with
coupler link rod)
51890
a - Couplers Connected Together

b - Lockwashers
c - Coupler Link Rod - Torque to 20 lbs. ft. (27.1 Nm) into End
of Each Coupler.
Couplers Connected Together with Coupler

Link Rod
Transom Mounted
Ride-Guide Attaching Kit
Installation (73770A1)
Attaching Kit Installation
e
a
b
c
d
e
18 in. (45.7cm) Coupler (97932-3)

15 in. (38.1cm) Coupler (97932-2)
12 in. (30.5cm) Coupler (97932-1)
9 in. (22.9cm) Coupler (97932-4)
Coupler Link Rod (98181A1)
Figure 14.
7A-14
ENGINE ATTACHMENTS
90-13645--2 495
1. Lubricate both holes in pivot block (Figure 1) with

Quicksilver 2-4-C w/Teflon.
2. Place pivot block on pivot spacer and secure to
transom bracket with 3/8 in. x 2-1/2 in. (9.5mm x
63.5mm) bolt, flat washer and locknut, as shown
in Figure 1. Torque locknut to 20 lbs. ft. (27.1 Nm).
f
k
d
c
g
j
a
b
c
d
e
Ride-Guide Cable
Ride-Guide Yoke
Pivot Block
Pivot Spacer
15 in. (38.1cm) (Centerline of Attaching Kit Pivot to Centerline
of Outboard)
f - Pivot Attaching Locknut - Torque to 20 lbs. ft. (27.1 Nm)
g - Outboard Steering Arm

h - Clevis Kit
i - Ride-Guide Cable Attaching Locknut - Torque to 10 lbs. ft.
(13.5 Nm)
j - Bolt - 3/8 in. x 2-1/2 in. (9.5mm x 63.5mm)
k - Flat Washer
l - Transom Bracket
Figure 1
3. Place Ride-Guide yoke on pivot block and secure
with 7/16 in. x 1-3/4 in. (11.1mm x 44.5mm) bolt
and locknut, as shown in Figures 1 and 2. Torque
locknut to 10 lbs. ft. (13.5 Nm), then back off
1/4-turn.
f
g
d
4. Install one cable tube jam nut onto steering cable

tube. Place tab washer over Ride-Guide yoke,
then insert cable tube thru tab washer and yoke.
Install second cable tube jam nut onto cable tube
but do not tighten at this time (Figure 3).
b
c
5. Position transom attaching kit on transom as

follows:
a. Determine centerline of outboard, then measure 15 in. (38.1cm) over from this centerline
and draw a vertical line on transom (Figure 1).
b. Position attaching kit on transom so that
transom bracket is centered on the 15 in.
(38.1cm) (Figure 1) at a height where the
center of Ride-Guide yoke is even with, or
not more than 1/2 in. (12.7mm) above top
edge of transom (Figure 3).
e
a
b
c
d
Transom Backing Plate

Bolt - 5/16 in. x 3-1/4 in. (7.9mm x 82.5mm)
Locknut - Torque to 10 lbs. ft. (13.5 Nm)
Ride-Guide Yoke Attaching Locknut - Torque to 10 lbs. ft.
(13.5 Nm) 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 - Ride-Guide Yoke
Figure 2
90-13645--2 495
ENGINE ATTACHMENTS
7A-15
a f
k
c
f
b
g
d
a - Ride-Guide Yoke
b - 0 in. to 1/2 in. (0mm to 12.8mm) (Center of Ride-Guide Yoke
to Top of Transom)
c - Top of Transom
d - Transom Bracket
e - Cable Tube Jam Nuts - Torque to 35 lbs. ft. (47.4 Nm)
f - Tab Washer
g - After Jam Nuts are Torqued to Specification, Bend Locking

Tabs against Nuts.
h - Cable Guide Tube
i - Ride-Guide Cable Attaching Nut - Torque to 35 lbs. ft.
(47.4 Nm)
j - Clevis Kit
k - Clevis Attaching Locknut - Torque to 20 lbs. ft. (27.1 Nm)
Figure 3
NOTE: When drilling thru transom, be sure that holes

are drilled perpendicular to transom.
6. With attaching kit positioned as outlined preceding, use 3 holes in transom bracket as a guide and
drill three 11/32 in. (8.7mm) holes thru transom.
5. Torque Ride-Guide cable attaching nut (which secures cable to guide tube) to 35 lbs. ft. (47.4 Nm)
(Figure 3). Install locking sleeve over cable attaching nut and secure with cotter pin. Spread
ends of cotter pin.
7. Use a marine-type sealer on three 5/16 in. x

3-1/4 in. (7.9mm x 82.6mm) bolts. Secure attaching kit to transom, using transom backing plate, 3
bolts (with sealer) and 3 locknuts, installed as
shown in Figure 2. Torque locknuts to 10 Ibs. ft.
(13.5 Nm).
NOTE: Some Ride-Guide steering cables may not be

equipped with locking sleeve and cotter pin. If cable
being installed does not have these parts, disregard
instructions to install them.
STEERING CABLE INSTALLATION
After installation is completed (and before

operating outboard), check that boat will turn right
1. Lubricate steering cable end with Quicksilver

2-4-C w/Teflon.
2. Install steering cable thru steering cable tube and
secure to cable tube with cable attaching nut
(Figure 3). Do not tighten cable attaching nut at
this time.
WARNING
3. Attach Ride-Guide cable to outboard steering

arm, using the proper Clevis Kit. Installation
instructions for clevis are with Clevis Kit.
Lubrication and maintenance inspection is owners

responsibility and must be performed at intervals specified, following:
4. Adjust 2 large jam nuts on cable tube of attaching

kit, so that steering wheel is in normal straightdriving position with outboard in straight-running
position. Torque each jam nut to 35 lbs. ft. (47.4
Nm), then bend a side of tab washer against flat
of each jam nut (Figure 3).

7A-16

ENGINE ATTACHMENTS
90-13645--2 495
CAUTION
Core of steering cable must be fully retracted into
cable housing when lubricating cable. If cable is
lubricated while extended, hydraulic lock of cable
could occur.
1. Lubricate outboard end of Ride-Guide steering
cable (thru grease fitting next to cable attaching
nut) with Quicksilver 2-4-C w/Teflon.
NOTE: Ride-Guide steering cable is lubricated at the

factory and requires no additional lubrication at initial
installation.
CAUTION
With this kit installed, the upper (outboard)
mounting bolts MUST BE installed so that hex
head end of bolts is on the inside of boat transom,
as illustrated. Failure to install upper mounting
bolts, as shown in illustration, could result in
interference between outer steering cable locking
sleeve and ends of mounting bolts when outboard
is tilted up.
2. Lubricate all steering system pivot points (and exposed portion of steering cable core) with Quicksilver 2-4-C w/Teflon. Lubricate at intervals specified preceding.
wear (at intervals specified, preceding). Replace
worn parts.
4. Check steering system fasteners (at intervals
specified, preceding) to be sure that they are
torqued to correct specifications. (Figures 1, 2
and 3).
Ride-Guide Steering
Cable/Attaching Kit
Installation (92876A3)
Install upper bolts so that hex head end of bolts is on

the inside of boat transom.

Installation
IMPORTANT: Both gear racks or rotary steering
heads must be installed so that both steering
cables will be routed together on the same side of
the boat and will push-and-pull together.
Dual Cable - Single Outboard

WARNING
Quicksilver Super Ride-Guide Steering (dual
cables) MUST BE USED with this attaching kit.
Refer to Quicksilver Accessories Guide to determine correct length of steering cables and remote
control cables.
1. Install Super Ride-Guide Steering Kit in accordance with instructions included with Super RideGuide Kit.
2. Make sure that both gear racks or rotary steering
heads are installed so that both steering cables
are routed together down starboard side of boat
and will push-and-pull together.
IMPORTANT: Steering cables and remote control

cables MUST BE THE CORRECT LENGTH, sharp
bends on too-short cables result in kinks;
too-long cables require unnecessary bends and/
or loops. Both conditions place extra stress on
the cables.
b
a - Straight Rack (Left); Rotary Steering (Right)
b - Steering Cables (Install so that Both Cables Will
Push-and-pull Together.)
90-13645--2 495
ENGINE ATTACHMENTS
7A-17
Mounting Bracket Installation

IMPORTANT: Spacers (d) must be installed between
engine and mounting bracket.
1. Install mounting bracket (a) to engine with 2

spacers (d), 2 locking retainers (b) and 4 bolts (c).
Torque bolts to 100 lb. in. (11.3 Nm) and bend
end of locking retainers up and against flat on
each bolt, as shown.

Installation
IMPORTANT: Spacers (b) must be installed between outboard swivel bracket and mounting
bracket for steering cable mounting tube to provide proper spacing between steering cables.
Secure mounting bracket for steering cable mounting
tube on to swivel bracket of outboard.
WARNING
The locking retainer ends must be bent up and
against flat on each bolt, that secures mounting
bracket engine, to prevent bolts from turning out.
d
c
16958
2. Install steering cable mounting tube (a) into

mounting bracket with 2 adjustment nuts (c) and
locking tab washer (b), as shown. Be sure that
longer, threaded end of tube is toward steering
cable attaching nut side of engine.
3. Temporarily adjust tube so that longer, threaded
end of tube is extended out the same distance as
engine tilt tube. Do not tighten adjustment nuts at
this time.
a
b
c
d
e
a
51891
Mounting Bracket for Steering Cable Mounting Tube

Spacer (2)
J Clip (Supplied with Outboard.)
Locking Retainer (2)
Bolts (4) - 7/8 in. (22.2mm) Long - Torque to 100 lb. in.
(11.3 Nm), then Bend Corner Tabs of Locking Retainers Up
and Against Flats on Each Bolt.
WARNING
Locking retainer corner tabs, MUST BE bent up
and against flats on each bolt that secures
mounting bracket for steering cable mounting
tube to outboard swivel bracket, to prevent bolts
from turning out.
COUPLER INSTALLATION
7A-18
16959
Install steering cable mounting tube into mounting

bracket with 2 adjusting nuts and 2 locking tab washers. Verify longer threaded end of tube is toward starboard side of boat.
ENGINE ATTACHMENTS
90-13645--2 495
Temporarily adjust tube so that longer threaded end

of tube extends out the same distance as the outboard tilt tube. Do not tighten adjustment nuts at this
time.
Torque steering cable attaching nuts only after final

steering adjustments have been made.
c
c
51891
51891
a - Steering Cable Mounting Tube (End of Tube with Longer

Threads Toward Starboard Side of Boat)
b - Mounting Bracket
c - Locking Tab Washers (2)
d - Adjustment Nuts (Flats of Nuts Facing Toward Locking Tab
Washer)
a
b
c
d
Steering Cable Ends

Outboard Tilt Tube
Cable Mounting Tube
Cable Attaching Nuts
Place a mark on steering cable mounting tube 5/8 in.

(16mm) from end of mounting tube. Slide plastic
spacer, O-ring and cap over steering cable.
5/8(16mm)
Installing Steering Cables

IMPORTANT: Lubricate inside of outboard tilt
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
steering cables.
Lubricate inside of outboard tilt tube and inside of

steering cable mounting tube with Quicksilver 2-4-C
w/Teflon. Verify rubber O-ring seal (located in outboard tilt tube) is lubricated.
e
51890
a
b
c
d
e
c d
a
-
Mark
Steering Cable Tube
Spacer
O-ring
Cap
Thread cap (e) onto steering cable mounting tube, up

to mark (a).
51890
a - Seal
Insert steering cable ends thru outboard tilt tube and

cable mounting tube. Thread steering cable attaching
nuts on to tubes hand tight.
90-13645--2 495
ENGINE ATTACHMENTS
e
51890
7A-19
Coupler Installation
WARNING
Locknuts must be used with bolts to secure
steering cables to coupler. Failure to adhere to
this requirement could result in steering system
failure.
Lubricate ball joint in steering link rod with SAE 30W

Motor Oil. Secure link rod to outboard steering arm,
using special washer head bolt (10-14000) provided
and nylon insert locknut as shown. Torque special
bolt to 20 Ib. ft. (27.1 Nm), then torque locknut to
20 Ib. ft. (27.1 Nm).
Slide coupler onto steering cable ends and secure

each steering cable to coupler with bolt and locknut
as shown. Tighten to a torque of 20 Ib. ft. (27.1 Nm).
b
c
c
a
c
51790
51888
a - Coupler
b - Bolt
c - Locknut
Installing Link Rod
a
b
c
d
Steering Coupler
Steering Link Rod
Flat Washer (2)
Nylon Insert Locknut - Torque until it seats [DO NOT exceed
120 lb. in. (13.5 Nm) of torque], then back nut off 1/4 turn.
e - Special Washer Head Bolt (10-14000) - Torque to 20 lb. ft.
(27.1 Nm)
STEERING SYSTEM TENSION ADJUSTMENT
WARNING
Steering link rod MUST BE secured between
outboard steering arm and steering coupler,
using special washer head bolt (10-14000) and
two nylon insert locknuts (11-34863), as shown.
Both special washer head bolt and nylon insert
locknuts MUST BE tightened as specified.
IMPORTANT: After this dual steering cable attachment kit is installed, there must be proper tension
in forward mounted steering cable for this attachment kit to operate properly. Not enough tension
will cause slack (or play) in steering system. Too
much tension will cause steering cables to bind.
Perform the following steps to adjust for correct
tension.
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 Nm) of
torque], then back nut off 1/4 turn.
7A-20
ENGINE ATTACHMENTS
90-13645--2 495
Loosen adjustment nuts and pull steering cable

mounting tube (by hand) away from end of steering
cable (to remove slack in steering system). Tighten
adjustment nuts against mounting bracket and check
system for slack (play). If steering system is too tight,
readjust tube toward end of steering cable or, if too
much slack (play) exists in system, readjust tube
away from end of steering cable. Tighten nuts against
mounting bracket and readjust, if necessary.
Install rubber bumpers (a) on inside of each locking

sleeve (b).
a
a
51889
Install locking sleeves over steering cable attaching

nuts and secure with cotter pins. Spread ends of cotter pins. Be sure to install cotter pin so that it is located
in between attaching nut and grease fitting.
f
d
c
a
c
16961

b - Adjustment Nuts
System.
d - Adjust Tube in This Direction to Reduce Tension from
Steering System.
e
a
After steering system tension is adjusted correctly,

tighten adjustment nuts against mounting bracket, to
a torque of 35 Ib. ft. (47.4 Nm) and bend a tab lock
washer against a flat on each nut.
b
d b
d
51890
51452
51887

b - Adjustment Nuts; Torque to 35 lb. ft. (47.4 Nm)
c - Tab Lock Washer (Bend Against Flat on Each Adjustment
Nut)
Tighten steering cable attaching nuts of each steering

cable to a torque of 35 Ib. ft. (47.4 Nm).
a
b
c
d
e
f
Steering Cable Attaching Nut - Torque to 35 lb. ft. (47.4 Nm)

Locking Sleeve (If So Equipped)
Cotter Pin
Grease Fitting
Outboard Tilt Tube
WARNING
After installation is complete (and before operating
outboard(s), 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) at all tilt
angles to assure interference-free movement.
Maintenance inspection is owners responsibility and
must be performed at intervals specified, following:
90-13645--2 495
ENGINE ATTACHMENTS
7A-21

Remote Control Installation

Shift Cable Installation and

Adjustment to Engine

wear. Replace worn parts.
2. Check steering system fasteners to be sure that
they are torqued to correct specifications.
Ride-Guide steering cables are lubricated at the factory and require no additional lubrication at initial
installation.
WARNING
Core of each steering cable (transom end) must
be fully retracted into cable housing before
lubricating cable. If cable is lubricated while
extended, hydraulic lock could occur.
IMPORTANT: Install control cables to remote control and mount remote control BEFORE attaching
control cables to engine.
NOTE: Attach shift cable to engine first. Shift cable is

the first cable to move when remote control handle is
advanced from neutral position toward in-gear
position.
If remote control has a neutral lock release, secure
the release in the depressed position using a piece of
tape, as shown. Now you can locate the true neutral
detent.
3. With core of Ride-Guide steering cable (transom

end) fully retracted, lubricate transom end of
steering cables thru grease fittings with 2-4-C w/
Teflon. Lubricate exposed portion of cable ends
with 2-4-C w/Teflon.
4. Lubricate pivot point of steering link rod and ball
joint of link rod/steering coupler with SAE 30W
Motor Oil.
5. Inspection and lubrication of steering head
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
effort has increased. Lubricate with 2-4-C
w/Teflon.
22752
NOTE: Rotate remote control handle back and forth.

You will feel three detent positions; center detent is
neutral.
1. Position remote control handle in neutral detent.
2. Manually shift engine into neutral (propeller will
rotate freely).
d
c
b
a
a
b
c
d
50135
Grease Fitting
Cable Ends
Pivot Point
Ball Joint
7A-22
ENGINE ATTACHMENTS
90-13645--2 495
3. Adjust cable barrel to attain the same length between cable barrel and hole in end of cable guide
as exists between barrel retainer and shift actuator stud, with a slight preload toward reverse.

Adjustment to Engine
4. Place end of shift cable on shift actuator stud then

place plastic washer on stud and secure with locknut.
2. Attach end of throttle cable to stud on throttle lever

and secure with locknut as shown. Be sure to first
put on the cable end, then the plastic washer and
finally the locknut. Snug up the locknut and then
back off 1/4-turn.
5. If used, remove tape from control handle.
1. Shift remote control into neutral.
6. Check shift cable adjustment as follows:

a. Shift remote control into forward gear. Now,
check prop shaft. The shaft should not be able
to turn counterclockwise. If it does, adjust cable
barrel closer to cable end guide.
b. Shift remote control into neutral. The prop

shaft now should turn freely without drag. If not,
adjust cable barrel away from cable end guide.
Repeat steps a and b.
c. Shift remote control into reverse as the prop

shaft is rotated by hand. The prop shaft
should not be able to turn in either direction. If
it does, adjust cable barrel away from cable end
guide. Repeat steps a thru c.
d. Shift remote control into neutral. The prop
shaft should turn freely without drag. If not, adjust cable barrel closer to cable end guide. Repeat steps a thru d.
22888
a - Locknut
b - Plastic Washer
3. Hold engine throttle lever against idle stop. Adjust

brass barrel so that there will be a slight preload
of throttle lever against the idle stop. Lock brass
barrels in place with barrel retainer.
4. Proper preload on throttle cable can be checked
by placing a piece of paper between idle stop
screw and idle stop. Preload is correct when the
paper can be removed without tearing but has
some drag on it. If necessary, readjust brass
barrel.
e
a
b
a
b
c
d
e
22888
Cable Barrel
Barrel Retainer
Shift Actuator Stud
Plastic Washer
Locknut
18432
a - Barrel Retainer
90-13645--2 495
ENGINE ATTACHMENTS
7A-23
Connecting Engine Wiring Harness

and Routing of Engine Cables
2. Wrap neoprene sheet around cable bundle and

secure each end with a sta-strap. Secure to
bracket with retainer.
WARNING
Wiring passing through cowl must be protected

from damage by using a neoprene sheet as
shown. Failure to protect wiring could cause
chafing or cuts in wiring resulting in electrical
system failure and/or possible bodily injury.
d
f
c
b
b
a
b
c
d
e
f
c
b
e
20290
Engine Connector
Retainer
Harness Connector
Harness Retainer
Neoprene Sheet
Sta-Strap(s)
Models without Power Trim

a - Wiring Harness
b - Neoprene Sheet
c - Sta-Straps
1. Plug remote control harness connector into engine harness connector, then secure connector in
place with retainer as shown.
IMPORTANT: On Models without Power Trim, the
neoprene sheet must be folded once and then
wrapped around cables as shown.
7A-24
ENGINE ATTACHMENTS
90-13645--2 495
Installing Outboard Motor on

Transom
Determining Recommended Outboard
Mounting Height
a - This solid line is recommended to determine the outboard

mounting height dimension. Use transom mounting bolt
holes that will position outboard nearest to the
recommended height. After engine break-in (if necessary),
raise or lower outboard one position at a time to attain best
performance. See Important immediately following.
b-
e
c
cd-
e-
IMPORTANT: Increasing the height of outboard generally

will provide the following: 1) Less steering torque, 2) more
top speed, 3) greater boat stability, but, 4) will cause more
prop break loose which may be particularly noticeable
when planing off or with load.
These broken lines represent the extremes of known
successful outboard mounting height dimensions.
This line may be preferred to determine outboard mounting
height dimension, if maximum speed is the only objective.
This line may be preferred to determine outboard mounting
height dimension for dual outboard installation.
Outboard mounting height (height of outboard transom
bracket from bottom of boat transom). For heights over 22 in.
(560mm), a propeller, that is specifically designed for
surfacing operation, such as the Chopper series, usually is
preferred.
Locate Centerline of Boat Transom

Locate (and mark with pencil) vertical centerline (a) of
boat transom, as shown.
Boat Speed (MPH) Maximum Speed Anticipated
a
d
e
NOTE: Dimensions b and c and d and e are
equal length.
IMPORTANT: Add 5 in. (12.7cm) to Mounting

Height for XL Models.
90-13645--2 495
ENGINE ATTACHMENTS
7A-25
Drilling Outboard Mounting Holes

IMPORTANT: Before drilling any mounting holes,
carefully read Determining Recommended Outboard Motor Mounting Height, preceding. There
is a 3/4 in. (19mm) difference between outboard
mounting holes in transom bracket.
WARNING
DO NOT, under any circumstances, allow upper
outboard mounting bolts to be closer than 1 in.
(25.4mm) from top of boat transom. Upper
mounting bolts must never be installed thru
shims.
IMPORTANT: If using Transom Drill Fixture
(91-98234A2), use drill guide holes marked A
when drilling outboard mounting holes.
Lifting Engine
WARNING
Make sure that lifting eye is threaded into flywheel
a minimum of 5 turns and that hoist has a
minimum lift capacity of at least 500 lbs. (227 kg)
BEFORE lifting engine.
1. Remove cowling from engine and plastic cap from
center of flywheel. Thread lifting eye into flywheel
hub a minimum of 5 turns. Replace plastic cap after installation.
2. Connect hoist [minimum lift capacity of 500 lbs.
(227 kg)] to lifting eye. Lift engine and place on
boat transom.
25929
a - Lifting Eye (C-91-75132)
b - Hoist
Installing Engine to Transom

CAUTION
Marine sealer must be used on shanks of
mounting bolts to make a water-tight installation.
NOTE: Because of clearance on some boats it will be

necessary to install steering cable on engine before
installing engine to transom. Refer to page 1 of this
instruction.
IMPORTANT: DO NOT use an impact driver when
tightening transom mounting bolts.
1. Determine engine mounting height dimension
from graph (STEP 1) and use engine mounting
holes that will position engine nearest to recommended height.
7A-26
ENGINE ATTACHMENTS
90-13645--2 495
2. Apply marine sealer to shanks of mounting bolts

(not threads) and secure engine to transom with
4 bolts, flat washers and locknuts, as shown. Be
sure that installation is water-tight.
a
b
c
c
WARNING
Before operating, motor(s) MUST BE SECURED to
boat transom with four 1/2 diameter bolts and
locknuts, as follows: 2 bolts must be installed thru
upper mounting holes and 2 bolts thru lower
mounting holes, as shown in step 5. Installation
must be water-tight, and engine should be
checked for tightness on the transom during
operation. Failure to bolt engine to transom (using
4 bolts and locknuts, as shown in step 5) may
result in damage to boat and/or loss of motor and
possible injury to occupants of boat.
a - Mounting Bolt - 4-1/2 in. (11.4mm) long (4 Reqd.)

b - Flat Washer (4 Reqd.)
c - Locknut (4 Reqd.)
90-13645--2 495
ENGINE ATTACHMENTS
7A-27
OUTBOARD MOTOR
INSTALLATION/
ATTACHMENTS
7
B
TILLER HANDLE AND CO-PILOT
Table Of Contents
Page
Tiller Arm Components . . . . . . . . . . . . . . . . . . . . 7B-2

Tiller Arm Bracket Assembly . . . . . . . . . . . . . . . 7B-4
Co-Pilot Components . . . . . . . . . . . . . . . . . . . . . 7B-6
Tiller Arm/Shift Lever Removal . . . . . . . . . . . . . 7B-7
Tiller Handle Disassembly . . . . . . . . . . . . . . . . . 7B-10
Tiller Arm Reassembly . . . . . . . . . . . . . . . . . . . .

Tiller Handle/Shaft Bracket Installation . . . . . .
Shift Link Rod Installation and
Adjustment to Engine . . . . . . . . . . . . . . . . . .
Adjustment to Engine . . . . . . . . . . . . . . . . . .
Co-Pilot Installation . . . . . . . . . . . . . . . . . . . . . . .
7B-13
7B-16
7B-20
7B-20
7B-21
90-13645--2 495
Notes:
90-13645--2 495
OUTBOARD MOTOR INSTALLATION/ATTACHMENTS
7B-1
Tiller Arm Components
21
26
25
29
28
27
22
110
17
30
110
24
7
33
24
23
18
20
110
16
15
30
19
31
10
11
110
32
12
110
13
14
3
4
5
8
7
Application Points
110
8
9
2-4-C W/Teflon (92-825407A12)

Soapy Water Solution (Obtain Locally)
7B-2

90-13645--2 495
Tiller Arm Components (Continued)

TORQUE
REF. NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
QUAN.
1
1
1
1
1
4
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
90-13645--2 495
DESCRIPTION
Steering Arm
Throttle Tube
Housing
Gasket
Plate
Screw
Throttle Clamp
Screw
Nut
Throttle Handle
Screw
Stop Switch Harness
Stop Switch
Grip
Clip
Screw
Conduit
Guide Tube
Barrel
Set Screw
Cable
Cable Guide
Anchor
Set Screw
Bolt
Cap
Washer
Washer
Spacer
Bushing
Nut
Gear Assembly
Grease Fitting
lb. in.
lb. ft.
Nm
Drive Tight
40
4.5
Drive Tight
1.0
Drive Tight
40
4.5
7B-3
Tiller Arm Bracket Assembly

24
22
23
21
95
25
4
7
95
19
18
20
26
27
37
18
95
12
38
13
8
39
9
17
16
15
14
29
10
11
17
36
35
28
30
31
34
33
32
Application Points
7B-4
95
2-4-C With Teflon (92-825407A12)
90-13645--2 495
Tiller Arm Bracket Assembly (Continued)

TORQUE
REF. NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
QUAN.
1
2
1
2
2
1
1
1
1
1
6
1
1
1
1
1
3
2
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
1
1
1
90-13645--2 495
DESCRIPTION
Bracket Assembly
Stud
Spacer
Tab Washer
Nut
Grommet
Harness Assembly
Key Switch
Nut
Cover
Screw
Plug
Stop Switch Assembly
Lanyard
Retainer
Bolt
Tab Washer
Bushing
Shift Lever
Washer
Stud
Shift Knob
Shift Rod
Rod End
Bushing
Washer
Cotter Pin
Bracket
Switch Bracket
Screw
Nut
Bolt
Washer
Nut
Bolt
Detent Assembly
Trim Switch
Nut
lb. in.
lb. ft.
Nm
35
47.4
Drive Tight
110
12.4
Drive Tight
Drive Tight
15
20.3
7B-5
Co-Pilot Components
8
7
6
95
2
3
4
1
95
7
8
95
2-4-C With Teflon (92-825407A12)
TORQUE
REF. NO.
1
2
3
4
5
6
7
8
7B-6
QUAN.
1
1
1
1
1
1
2
2
DESCRIPTION
Pilot Rod
Friction Assembly
Bolt
Wing Nut
Steering Link Rod
Bushing
Washer
Nut -- Tighten until it seats; do not exceed 120 lb. in. (13.6 Nm), then
back off 1/4 turn.
lb. in.
120
lb. ft.
Nm
13.6
90-13645--2 495
5. Remove access cover from underneath tiller

handle bracket.
Tiller Arm/Shift Lever

Removal
1. Remove BATTERY CABLES from BATTERY.
2. Remove outboard cowling.
3. Remove nuts securing shift link rod and throttle
cable to engine. Release latch and remove shift
link rod and throttle cable from anchor bracket.
a
f
a
51626
a - Access Cover
b - Screws
b
c
a
b
c
d
e
f
51620
Locking Nut
Washer
Shift Cable
Throttle Cable
Latch
Anchor Bracket
6. Disconnect key switch, lanyard stop switch and tiller stop switch leads at bullet connectors.
Remove screw securing key switch and tiller stop
switch ground leads.
4. Remove cotter key, washer, bushing and shift link

rod from shift lever.
a
c
51626
a - Bullet Connectors
b - Screw
b
a
51624
a
b
c
d
Cotter Key
Washer
Bushing
Shift Link Rod
90-13645--2 495
7B-7
7. Remove nuts securing key switch and trim switch

to tiller handle bracket.
9. Remove electrical panel access cover.

Disconnect switch harness from engine harness
plug.
Remove clip securing lanyard stop switch and remove switch from bracket.
Disconnect PURPLE bullet connector.
a
e
a
c
d
a
b
c
d
e
51626
Nuts
Key Switch
Trim Switch
Clip
Lanyard Stop Switch
d
a
b
c
d
8. Remove harness retainer from outboard.

Remove grommet from tiller bracket.
51621
Access Cover
Bolts
Switch Harness
PURPLE Lead
51624
b - Grommet
7B-8
90-13645--2 495
10. Disconnect BLUE/WHITE and GREEN/WHITE

trim leads from trim solenoids.
13. Remove bolt and nut (hidden) from tiller handle

bracket.
a
b
a
51625
51622
a - BLUE/WHITE Lead
b - GREEN/WHITE Lead
a - Bolt
b - Nut (Hidden)
14. Remove tiller handle, 2 nylon bushings, stainless

bushing and 2 flat washers from bracket.
11. Remove key switch, trim switch and their harnesses from tiller bracket.
12. Remove plug from tiller handle bracket.
d
e
b
a
b
51606
a
51608
a
b
c
d
e
Tiller Handle
Nylon Bushings (2)
Stainless Steel Bushing
Flat Washers (2)
Bolt
a - Plug
90-13645--2 495
7B-9
15. Bend tab washer away from bolt securing shift lever and remove bolt and lever from bracket.
17. Bend tabs on tab washers away from nuts securing bracket to steering arm. Remove nuts, tab
washers and bracket from steering arm.
b
a
b
c
51622
a - Tab Washer
b - Bolt
c - Shift Lever
c
51621
16. Remove spring and detent pin from bracket.
a - Tab Washer
b - Nut
c - Steering Arm
Tiller Handle Disassembly

1. Using a flat tip screwdriver, carefully pry/push rubber grip off tiller handle.
51621
a - Spring
b - Detent Pin
a
51603
a - Grip
b - Tiller Handle
7B-10
90-13645--2 495
2. Remove screw from twist grip.
5. Remove throttle cable anchor screws and remove

cable guide.
a
b
51603
a - Screw
3. Cut sta-strap securing stop switch harness and

remove screw from harness J-clip.
a
a
51602
a - Anchor Screws
b - Throttle Cable Guide
6. Remove allen screw from brass barrel and

remove barrel.
b
a
51603
a - Ties
b - Screw
4. Remove stop switch and twist grip from tiller

handle.
b
51602
a - Allen Screw
b - Brass Barrel
51603
90-13645--2 495
7B-11
7. Unscrew (counterclockwise) stainless conduit

from tiller handle.
9. Remove cover plate and gasket from tiller handle.

10. Remove bolt from throttle friction assembly.
a
b
e
51603
a - Conduit
8. Pull throttle cable from tiller handle.
a
b
c
d
e
51604
Cover Plate
Gasket (below plate)
Screws
Throttle Friction Assembly
Bolt
11. Remove throttle arm, gear assembly and friction

device from tiller handle. Slide gear cover and friction device off of throttle arm.
a
b
51604
a
b
c
d
Throttle Arm
Gear Assembly
Friction Device
Gear Cover
51604
a - Throttle Cable
7B-12
90-13645--2 495
12. Drive out drift pin and remove throttle gear from
throttle arm.
3. Slide cover and friction device onto throttle arm.
b
51604
a
51602
a
b
c
d
Throttle Arm
Gear
Throttle Friction Device
Cover
4. Install throttle arm assembly into tiller arm.
a - Gear
b - Drift Pin
5. Torque friction device attaching bolt to 40 lb. in.

(4.5 Nm).
Tiller Arm Reassembly

1. Reinstall throttle gear on throttle arm and secure
gear to arm with new drift pin.
a
51604
a - Bolt [Torque to 40 lb. in. (4.5 Nm)]
a
51602
a - Gear
b - Drift Pin
2. Apply a light coat of2-4-C w/Teflon to gear teeth

and inside of gear cover.
90-13645--2 495
7B-13
6. Install gasket and cover plate over gear

assembly. DO NOT OVERTIGHTEN attaching
screws.
9. Retract throttle cable into gear assembly until

approximately 17 in. (43 cm) extends from the tiller arm.
a
b
a
51604
51604
a - Cover Plate
b - Gasket (below cover)
c - Screws
a - Cable [Extends 17 in. (43 cm)]
7. Rotate throttle arm so that twist grip attaching

screw hole faces DOWN and gear drift pin faces
UP.
10. Slide stainless steel conduit over throttle cable

and thread into tiller arm until lightly seated. Rotate conduit COUNTERCLOCKWISE ONE FULL
TURN from a lightly seated position.
8. Insert throttle cable (CURVED END FACING UP)

into tiller handle gear assembly while rotating tiller
arm COUNTERCLOCKWISE.
51604
a - Stainless Steel Conduit
51604
a - Gear Drift Pin (FACES UP)
7B-14
90-13645--2 495
11. Slide brass barrel over throttle cable tube. Secure

barrel to tube with allen screw approximately
3.5 in. (89 mm) from stainless conduit. DO NOT
OVERTIGHTEN screw as tubing may be crushed
binding throttle cable. Position barrel to face towards tiller handle.
13. Position throttle arm slot to face stop harness exit

hole in tiller handle. Route stop switch harness
through twist grip, into throttle arm, and out
through side of tiller handle.
c
51602
a
b
c
d
e
b
c
Slot
Exit Hole
Harness
Twist Grip
Stop Switch
14. Secure twist grip to throttle arm with attaching

screw.
a
51607
a
b
c
d
Brass Barrel
Tube
Allen Screw
Tiller Handle
51603
12. Install throttle cable guide onto throttle cable. Secure guide to cable with anchor and two screws.
Guide hole should face up.
b b
a - Screw
15. Sta-strap harness to throttle arm.
CAUTION
Allow enough slack in harness (rotate throttle grip
in both directions) before securing harness to
handle assembly with J-clip.
16. Attach harness to tiller arm with J-clip allowing
enough slack in harness for full throttle rotation.
c
51602
a - Cable Guide
b - Screws (2)
c - Hole (faces up)
90-13645--2 495
7B-15
17. Attach sta-strap to end of harness sleeve.
Tiller Handle/Shaft Bracket

Installation
1. Slide bracket over steering arm studs. Secure
bracket to arm with retained nuts and NEW tab
washers.
Torque nuts to 35 lb. ft. (47.5 Nm).
Bend locking tabs against flats of nuts.
a
b
51603
a - Sta-strap
b - J-clip
18. Install rubber twist grip by aligning ridges on plastic twist grip with grooves inside of rubber grip.
NOTE: Applying a soapy water solution to rubber grip

will ease installation.
a
51621
a - Tab Washer
b - Nut
c - Steering Arm
a
51603
a - Ridges
b - Grooves (under handle)
2. Install retained spring and detent pin into tiller

handle bracket.
b
a
51621
a - Spring
b - Detent Pin
7B-16
90-13645--2 495
3. Insert bushings and thrust washer into shift lever.

Install shift lever onto bracket.
5. Install two nylon bushings into tiller handle.

Install stainless bushing into bracket.
Install tiller handle to bracket using bolt and two

washers.
e
c
d
a
51620
a
b
c
d
Bushings
Thrust Washer
Shift Lever
Bracket
4. Secure shift lever to bracket with bolt and NEW

tab washer. Align tab washer with slot in bracket.
Torque bolt to 110 lb. in. (12.4 Nm).
51622
a
b
c
d
e
Nylon Bushings
Stainless Bushing
Bolt
Washer (Thin)
Washer (Thick)
6. Secure bolt in place with nut. Torque nut to 40 lb. ft.

(54.2 Nm).
51623
a - Nut
51620
a - Bolt
b - Tab Washer
90-13645--2 495
7B-17
7. Reinstall plug.
9. Reinstall lanyard stop switch in bracket and secure with clip.
a
c
a
e
51608
a - Plug
8. Route key switch and trim switch harness through

tiller bracket. Secure both switches to bracket with
respective nuts.
Install grommet in harness access hole.
Secure harness with harness retainer.
a
b
c
d
e
51626
Nuts
Key Switch
Lanyard Stop Switch
Trim Switch
Clip
10. Reconnect key switch, trim switch and remote

stop switch leads at bullet connectors. Secure
harness BLACK ground lead and tiller handle remote stop switch ground lead to bracket with selftapping screw.
a
b
b
d
c
51624
a
b
c
d
Harness Retainer
Switch Harness
Tiller Bracket
Grommet
7B-18
51626
a - Bullet Connectors
b - Screw
90-13645--2 495
11. Secure access cover to tiller bracket with five

screws. DO NOT OVERTIGHTEN SCREWS.
14. Reinstall electrical panel access cover and

secure with screws. Torque screws to 30 lb. in.
(3.4 Nm).
b
b
a
51626
a - Access Cover
b - Screws
12. Connect switch harness plug to engine harness

plug.
Reconnect PURPLE bullet connector.
51621
a - Panel
b - Screws - Torque to 30 lb. in. (3.4 Nm)
15. Reconnect shift link rod to shift lever using bushing, washer and cotter key.
51623
a - Switch Harness Plug

b - PURPLE Bullet Connector
13. Reconnect trim switch leads to trim solenoids.
a
b
d
c
51624
a
b
c
d
Shift Link Rod

Bushing
Washer
Cotter Key
51622
a - BLUE/WHITE Lead
b - GREEN/WHITE Lead
90-13645--2 495
7B-19
Shift Link Rod Installation

and Adjustment to Engine

and Adjustment to Engine
1. Position shift lever handle into neutral detent.
IMPORTANT: Turn throttle cable conduit

clockwise until bottomed on tiller handle then
back off one turn before reconnecting throttle
cable to engine.
2. Manually shift outboard into neutral (propeller will

rotate freely).
3. Adjust shift link rod end to slip over shift actuator
bolt with slight preload adjustment toward reverse.
4. Place hole in end of shift link rod end over stud of
shift actuator and secure with lock nut and washer. Tighten until snug then back off 1/4 turn.
1. Rotate throttle twist grip fully clockwise to stop

IDLE position.
2. Back out set screw from throttle cable barrel until
2 or 3 threads of set screw are exposed.
b
a
b
51077
a - Set Screw
b - Throttle Cable Barrel
3. Place end of throttle cable guide over peg of

throttle lever and secure with locknut and washer.
Tighten until snug then back off 1/4 turn.
CAUTION
51622
DO NOT exceed 1/4 turn on set screw after it has

bottomed-out.
a - Shift Link Rod End

b - Shift Actuator Stud
c - Lock Nut
5. Check shift link rod adjustment as follows:

a. Place engine shift lever in F (Forward) position. Propeller should not rotate in a COUNTERCLOCKWISE direction. If propeller does
rotate COUNTERCLOCKWISE, length of shift
link rod must be reduced and Step a repeated.
b. Place engine shift lever in N (Neutral) position.
Propeller should rotate freely without drag. If
not, length of shift link rod must be increased
and Steps a and b repeated
4. Holding engine throttle lever against idle stop, adjust throttle cable barrel to slip into upper hole of
barrel receptacle, with a very light preload of
throttle lever against idle stop. Apply small
amount of Loctite 271 to threads of allen screw
and tighten until snug, then an additional 1/8 turn.
Lock barrel in place with barrel retainer.
c. While rotating propeller, place engine shift lever

in R (Reverse) position. If propeller can be rotated in either direction, length of shift link rod
must be increased and Steps a thru c repeated.
d. Place engine shift lever in N (Neutral) position.
Propeller should turn freely without drag. If not,
length of shift link rod must be decreased and
Steps a thru d repeated.
c
51620
c - Barrel Receptacle
d - Barrel Retainer
7B-20
90-13645--2 495

piece of paper between idle stop screw and idle
stop. Preload is correct when paper can be removed without tearing, but has some drag on it.
Readjust cable barrel, if necessary.
3. Loosen wing nut on friction device and insert pilot

rod thru friction device and into tilt tube.
4. Lubricate both ends of link rod with Quicksilver
2-4-C w/Teflon.
6. Reinstall outboard cowling.
5. Secure link rod between steering handle assembly and pilot rod end as shown.
7. Reconnect POSITIVE (+) and NEGATIVE ()

cables to battery.
6. Adjust wing nut on friction device to provide desired steering control.
Co-Pilot Installation
IMPORTANT: Tighten wing nut to increase friction; loosen to decrease friction.
WARNING
Co-Pilot Assembly (supplied) MUST BE installed
on tiller handle models.
WARNING
If wing nut is tightened, it may not be possible to
steer the outboard in an emergency.
1. Remove and discard shipping bracket components, if installed.
h
e
g
g
b
i
e
a
b
c
d
e
2. Thread friction device onto starboard end of tile

tube, until securely tightened and position wing
nut toward front of outboard as shown.
d
51626
51623
Bolt
Nut
Shipping Bracket
Washer
Nut
a
b
c
d
e
f
g
h
i
Steering Friction Device

Wing Nut
Pilot Rod
Spacer (Hidden) - Place in hole of steering handle assembly.
Steering Handle Assembly
Link Rod - Short bend of link rod to steering handle.
Flat Washer (2)
Locknut - Torque to 120 lb. in. (13.6 Nm)
Locknut - Tighten until it seats DO NOT exceed 120 lb. in.
(13.6 Nm), then back off 1/4 Turn.
51624
a - Friction Device
90-13645--2 495
7B-21

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SERVICE

19881993 100 115 (4 Cylinder)

1995, Brunswick Corporation

Notice to Users of This Manual

Throughout this publication, Dangers, Warnings

This service manual has been written and published

These Safety Alerts alone cannot eliminate the

It is assumed that these personnel are familiar with

Cleanliness and Care of

Service Manual Outline

General Information and Specifications

Electrical and Ignition

Battery, Charging System and

Timing/Synchronizing and Adjusting

Fuel System and Carburetion

Oil Injection System

Whenever components are removed for service, they

Powerhead (3-Cylinder Engines)

Powerhead (4-Cylinder Engines)

Before raising or removing an outboard engine from a

1. Check that flywheel is secured to end of

Design I (Side Fill Reservoir)

Design II (Aft Fill Reservoir)

Outboard Motor Installation/Attachments

Engine Attachments/Engine Installation

Tiller Handle and Co-Pilot

2. Connect a hoist of suitable strength to the lifting

Following Complete Submersion . . . . . . . . . . . . 1-8

Full Throttle RPM Range

Recommended Spark Plug

Recommended Power Trim Fluid

Quicksilver Power Trim & Steering Fluid or Automotive Transmission

Inductor Plugs: NGK-BUZHW-2 or

Quicksilver TC-WII or TC-W3 2-Cycle Outboard Oil

Fuel Tank Capacity

22.5 fl. oz. (665.3ml)

Gasoline/Oil Ratio at Idle

Gasoline/Oil Ratio at W.O.T.

Oil Injection Tank Capacity

1 gal. (3.78 liter)

Maximum operation per tank

Oil remaining when warning

1 qt. (.95 liter)

Operating time remaining at

GENERAL INFORMATION AND SPECIFICATIONS

100 (74.6 kw)

115 (85.8 kw)

Idle RPM (in forward gear)

Full Throttle RPM Range

Recommended Spark Plug

Quicksilver Power Trim & Steering Fluid or Automotive Transmission

Quicksilver 2-Cycle Outboard Oil

Fuel Tank Capacity

22.5 fl. oz. (665.2ml)

Gasoline/Oil Ratio at Idle

Gasoline/Oil Ratio at W.O.T.

Oil Injection Tank Capacity

1.4 gal. (5.3 liters)

Maximum operation per tank