MERCURY Outboard 40-50-60 4 Stroke Service Manual
MERCURY Outboard 40-50-60 4 Stroke Service Manual
MERCURY Outboard 40-50-60 4 Stroke Service Manual
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 in-
jury or death.
CAUTION
Hazards or unsafe practices which could result in minor personal injury or product
or property damage.
EXAMPLE:
Revision No. 1
Page Number
Page ii 90-883065 APRIL 2001
https://www.boat-manuals.com/
SPECIFICATIONS
IMPORTANT INFORMATION 1
Section 1A - Specifications A
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1 Propeller Information Charts . . . . . . . . . . . . . . 1A-8
Specifications
Battery Rating
Minimum Requirement 465 Marine Cranking Amps (MCA)
or 350 Cold Cranking Amps (CCA)
For operation below 32° F (0° C) 1000 Marine Cranking Amps (MCA) or
BATTERY 775 Cold Cranking Amps (CCA)
Ampere-Hours (Ah) Minimum
For operation above 32° F (0° C) 70
For operation below 32° F (0° C) 105
Fuel Pump Type Mechanical Water Cooled
(Plunger/Diaphragm)
FUEL
Fuel Pump:
SYSTEM
Pressure 3-6 psi
Fuel Tank Capacity Accessory
Fuel Injector System Batch (1 & 4) - (2 & 3)
Idle rpm (Out Of Gear) 725 ± 25 rpm
Idle rpm (In Forward Gear) 725 ± 25 rpm
FUEL INJECTION
Wide Open Throttle rpm (WOT)
Range 5500–6000
Fuel Pump Pressure - Electric 42-44 psi (290-303 kPa)
Type 4 Stroke Cycle – Over Head Camshaft
CYLINDER
Displacement 60.8 cu. in. (995 cc)
BLOCK
Number of Cylinders 4
STROKE Length 2.953 in. (75 mm)
Diameter
Standard 2.5591 in. (65 mm)
CYLINDER Oversize-0.010 in. (0.25 mm) 2.5689 in. (65.25 mm)
BORE Oversize-0.020 in. (0.50 mm) 2.5787 in. (65.5 mm)
Taper/Out of Round Maximum 0.003 in. (0.08 mm)
Bore Type Cast Iron
Piston Type Aluminum
O.D. at Skirt
PISTON Standard 2.5570 - 2.5578 in. (64.950 - 64.965 mm)
Oversize-0.010 in. (0.25 mm) 2.5669 - 2.5675 in. (65.2 - 65.215 mm)
Oversize-0.020 in. (0.50 mm) 2.5768 - 2.5774 in. (65.450 - 65.465 mm)
PISTON Piston to Cylinder Clearance 0.0014 - .0026 in. (0.035 - 0.065 mm)
CLEARANCE
Ring End Gap (Installed)
Top 0.006 - 0.012 in. (0.15 - 0.03 mm)
Middle 0.012 - 0.020 in. (0.30 - 0.50 mm)
RINGS Bottom (Oil Ring) 0.008 - 0.028 in. (0.20 - 0.70 mm)
Side Clearance:
Top 0.0008 - 0.0024 in. (0.02 - 0.06 mm)
Middle 0.0008 - 0.0024 in. (0.02 - 0.06 mm)
Compression Ratio 9.7:1
COMPRESSION Cylinder Compression* 180 - 210 psi (Peak)
RATIO (Electric Models Only, Cold Engine @
W.O.T.)
PISTON PIN Piston Pin Diameter 0.6285 - 0.6287 in. (15.965 - 15.970 mm)
CONNECTING Oil Clearance (Big End) 0.0008 - 0.0020 in. (0.020 - 0.052 mm)
ROD Small End Inside Diameter 0.6293 - 0.6298 in. (15.985 - 15.998 mm)
CAMSHAFT
b
b
b
b
aa
VALVE SPRING
Valve Dimensions
“C”
“B”
“D”
“A”
Head Diameter Face Width Seat Width Margin Thickness
cc
Transom Height:
Long Shaft 20 in. (51 cm)
Steering Pivot Range:
MID-SECTION Tiller 90°
Remote 60°
Full Tilt Up Angle 71°
Allowable Transom Thickness 2-3/4 in. (69.8 mm)
IMPORTANT INFORMATION 1
Section 1B - Maintenance B
Table of Contents
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-1 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-13
Quicksilver Lubricant/Sealant . . . . . . . . . . . . . . . 1B-2 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-13
Inspection And Maintenance Schedule . . . . . . . 1B-4 Fuel Line Inspection . . . . . . . . . . . . . . . . . . . 1B-13
Before Each Use . . . . . . . . . . . . . . . . . . . . . . . 1B-4 Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . 1B-14
After Each Use . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5 Oil Changing Procedure . . . . . . . . . . . . . . . . 1B-14
Every 100 Hours of Use or Once yearly, Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . 1B-15
Whichever occurs first . . . . . . . . . . . . . . . . . 1B-5 Checking and Adding Engine Oil . . . . . . . . 1B-15
Every 300 Hours of Use or Three Years . . . 1B-5 Changing Gear Case Lubricant . . . . . . . . . . . . 1B-16
Before Periods of Storage . . . . . . . . . . . . . . . 1B-5 3-1/4 In. (83mm) Diameter Gear Case . . . 1B-16
Flushing the Cooling System . . . . . . . . . . . . . . . . 1B-6 4-1/4 In. (108mm) Diameter Gear Case . . 1B-17
Steering Link Rod Fasteners . . . . . . . . . . . . . . . . 1B-7 Storage Preparation . . . . . . . . . . . . . . . . . . . . . . 1B-18
Corrosion Control Anode . . . . . . . . . . . . . . . . . . . 1B-8 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-19
Spark Plug Inspection and Replacement . . . . . 1B-8 Protecting External Outboard
Battery Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9 Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-19
Fuse Replacement – Electric Start Models . . . . 1B-9 Protecting Internal Engine Components . . 1B-19
Timing Belt Inspection . . . . . . . . . . . . . . . . . . . . 1B-10 Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-19
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . 1B-10 Positioning Outboard for Storage . . . . . . . . 1B-19
Checking Power Trim Fluid . . . . . . . . . . . . . . . . 1B-12 Battery Storage . . . . . . . . . . . . . . . . . . . . . . 1B-19
Special Tools
1. Crankcase Oil Pump P/N 90265A5
Quicksilver Lubricant/Sealant
1. Quicksilver Anti-Corrosion Grease P/N 92-850735A1
4-CYCLE
MARINE
ENGINE OIL
Premium Blend
SAE 25W-40
WARNING
Neglected inspection and maintenance service of your outboard or attempting to
perform maintenance or repair on your outboard if you are not familiar with the cor-
rect service and safety procedures could cause personal injury, death, or product
failure.
Before Each Use
1. Check engine oil level.
2. Check that lanyard stop switch stops the engine.
3. Visually inspect the fuel system for deterioration or leaks.
4. Check outboard for tightness on transom.
5. Check steering system for binding or loose components.
6. Visually check steering link rod fasteners for proper tightness.
7. Check propeller blades for damage.
WARNING
To avoid possible injury when flushing, remove the propeller. Refer to Propeller Re-
placement.
1. Place the outboard in either the operating position (vertical) or in a tilted position.
2. Remove propeller (refer to Propeller Replacement).
3. Thread a water hose into the rear fitting. Partially open the water tap (1/2 maximum).
Do not open the water tap all the way, as this allows a high pressure flow of water.
c
f
d
e
1. Assemble steering link rod to steering cable with two flat washers (d) and nylon insert
locknut (“b” – Part Number 11-34863). Tighten locknut (b) until it seats, then back nut
off 1/4 turn.
2. Assemble steering link rod to engine with special washer head bolt (“a” – Part Number
10-90041), locknut (“c” – Part Number 11-34863) and spacer (“e” – 12-71970). First
torque bolt (a) to 20 lb. ft. (27 N·m), then torque locknut (c) to 20 lb. ft. (27 N·m).
a
a - Bottom Anode
b - Trim Tab
c - Side Anodes (Big Foot Models Only)
WARNING
Avoid serious injury or death from fire or explosion caused by damaged spark plug
boots. Damaged spark plug boots can emit sparks. Sparks can ignite fuel vapors
under the engine cowl. To avoid damaging spark plug boots, do not use any sharp
object or metal tool such as pliers, screwdriver, etc. to remove spark plug boots.
1. Remove the spark plug leads by twisting the rubber boots slightly and pulling off.
2. Remove the spark plugs to inspect and clean. Replace spark plug if electrode is worn
or the insulator is rough, cracked, broken, blistered or fouled.
Battery Inspection
The battery should be inspected at periodic intervals to ensure proper engine starting capa-
bility.
IMPORTANT: Read the safety and maintenance instructions which accompany your
battery.
1. Turn off the engine before servicing the battery.
2. Add water as necessary to keep the battery full.
3. Make sure the battery is secure against movement.
4. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive
and negative to negative.
5. Make sure the battery is equipped with a nonconductive shield to prevent accidental
shorting of battery terminals.
a c
1 3
15
2 4
b d
a - Timing Belt
Lubrication Points
Lubricate Point 1 with Quicksilver or Mercury Precision Lubricants Anti-Corrosion
Grease or 2-4-C Marine Lubricant with Teflon.
1. Propeller Shaft – Refer to Propeller Replacement for removal and installation of the pro-
peller. Coat the entire propeller shaft with lubricant to prevent the propeller hub from cor-
roding and seizing to the shaft.
Lubricate Points 2 thru 6 with Quicksilver or Mercury Precision Lubricants 2-4-C Ma-
rine Lubricant with Teflon or Special Lubricant 101.
2. Swivel Bracket – Lubricate through fitting.
3. Tilt Support Lever – Lubricate through fitting.
4. Tilt Tube – Lubricate through fitting.
2 4
5. Steering Cable Grease Fitting (If equipped) – Rotate steering wheel to fully retract the
steering cable end into the outboard tilt tube. Lubricate through fitting.
Lubricate Points b with light weight oil.
6. This grease fitting is for lubricating the threaded rod for the co-pilot.
6
a
5
b
a - Steering Cable End
b - Pivot Points
WARNING
The end of the steering cable must be fully retracted into the outboard tilt tube be-
fore adding lubricant. Adding lubricant to steering cable when fully extended could
cause steering cable to become hydraulically locked. An hydraulically locked steer-
ing cable will cause loss of steering control, possibly resulting in serious injury or
death.
a - Fill Cap
Fuel System
WARNING
Avoid serious injury or death from gasoline fire or explosion. Carefully follow all
fuel system service instructions. Always stop the engine and DO NOT smoke or
allow open flames or sparks in the area while servicing any part of the fuel system.
Before servicing any part of the fuel system, stop engine and disconnect the battery. Drain
the fuel system completely. Use an approved container to collect and store fuel. Wipe up
any spillage immediately. Material used to contain spillage must be disposed of in an ap-
proved receptacle. Any fuel system service must be performed in a well ventilated area. In-
spect any completed service work for signs of fuel leakage.
Fuel Filter
IMPORTANT: Visually inspect for fuel leakage from the filter by squeezing the primer
bulb until firm, forcing fuel into the filter.
Check the fuel filter for water accumulation or sediment. If water is in the fuel, remove the
sight bowl and drain the water. If the filter appears to be contaminated, remove and replace.
a - Cover
b - Sight Bowl
c - Filter Element
d - O-Ring
REMOVAL
1. Read Fuel System servicing information and Warning on the previous page.
2. Pull out the filter assembly from mount. Hold onto the cover to prevent it from turning
and remove the sight bowl. Empty contents into an approved container.
3. Pull out the filter element and replace it if necessary.
INSTALLATION
4. Push the filter element into the cover.
5. Place the O-Ring seal into it’s proper position on the sight bowl and screw the sight bowl
hand tight into the cover.
6. Push filter assembly back into mount.
Fuel Line Inspection
Visually inspect the fuel line and primer bulb for cracks, swelling, leaks, hardness, or other
signs of deterioration or damage. If any of these conditions are found, the fuel line or primer
bulb must be replaced.
a - Drain Hole
91-802653Q1
a - Oil Filter
a
b
c
a - Dipstick
b - Oil Fill Cap
c - Full Mark
d - Add Mark
Engine Oil Capacity
3 U.S. Quarts or (3.0 Liters)
a - Fill/drain Plug
b - Vent Plug
CHECKING GEAR CASE LUBRICANT LEVEL AND REFILLING GEAR CASE
d
b
c
b
a
a - Fill/drain Plug
b - Rear Vent Plug
c - Front Vent Plug
c b
Storage Preparation
The major consideration in preparing your outboard for storage is to protect it from rust, cor-
rosion, and damage caused by freezing of trapped water.
The following storage procedures should be followed to prepare your outboard for out-of-
season storage or prolonged storage (two months or longer).
CAUTION
Never start or run your outboard (even momentarily) without water circulating
through the cooling water intake in the gear case to prevent damage to the water
pump (running dry) or overheating of the engine.
Fuel System
IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a forma-
tion of acid during storage and can damage the fuel system. If the gasoline being
used contains alcohol, it is advisable to drain as much of the remaining gasoline as
possible from the fuel tank, remote fuel line, and engine fuel system.
Fill the fuel tank and engine fuel system with treated (stabilized) fuel to help prevent forma-
tion of varnish and gum. Proceed with following instructions.
1. Portable Fuel Tank – Pour the required amount of Quicksilver Gasoline Stabilizer (follow
instructions on container) into fuel tank. Tip fuel tank back and forth to mix stabilizer with
the fuel.
2. Permanently Installed Fuel Tank – Pour the required amount of Quicksilver Gasoline
Stabilizer (follow instructions on container) into a separate container and mix with
approximately one quart (one liter) of gasoline. Pour this mixture into fuel tank.
3. Remove the fuel filter sight bowl (see “Fuel Filter” above) and empty contents in a suit-
able container. Add 3 cc (1/2 teaspoon) of gasoline stabilizer into the fuel filter sight bowl
and reinstall.
4. Place the outboard in water or connect flushing attachment for circulating cooling water.
Run the engine for 15 minutes to allow treated fuel to fill the engine fuel system.
Protecting External Outboard Components
1. Lubricate all outboard components listed in the Inspection and Maintenance Schedule.
2. Touch up any paint nicks.
3. Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal
surfaces (except corrosion control anodes).
Protecting Internal Engine Components
1. Remove the spark plugs and inject a small amount of engine oil inside of each cylinder.
2. Rotate the flywheel manually several times to distribute the oil in the cylinders. Reinstall
spark plugs.
3. Change the engine oil.
Gear Case
1. Drain and refill the gear case lubricant (refer to maintenance procedure).
Positioning Outboard for Storage
Store outboard in an upright (vertical) position to allow water to drain out of outboard.
CAUTION
If outboard is stored tilted up in freezing temperature, trapped cooling water or rain
water that may have entered the propeller exhaust outlet in the gear case could
freeze and cause damage to the outboard.
Battery Storage
1. Follow the battery manufacturer’s instructions for storage and recharging.
2. Remove the battery from the boat and check water level. Recharge if necessary.
3. Store the battery in a cool, dry place.
4. Periodically check the water level and recharge the battery during storage.
IMPORTANT INFORMATION 1
Section 1C - GENERAL INFORMATION C
Table of Contents
Serial Number Location . . . . . . . . . . . . . . . . . . 1C-2 Power Trim System . . . . . . . . . . . . . . . . . . . . . . 1C-16
Conditions Affecting Performance . . . . . . . . . 1C-2 General Information . . . . . . . . . . . . . . . . . . 1C-16
Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2 Power Trim Operation . . . . . . . . . . . . . . . . . 1C-16
Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-3 Trim “In” Angle Adjustment . . . . . . . . . . . . 1C-17
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-5 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . 1C-18
Following Complete Submersion . . . . . . . . . . 1C-6 Compression Check . . . . . . . . . . . . . . . . . . . . . 1C-19
Submerged While Running . . . . . . . . . . . . . . 1C-6 Cylinder Leakage Testing . . . . . . . . . . . . . . . . . 1C-20
Salt Water Submersion . . . . . . . . . . . . . . . 1C-6 Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-20
Fresh Water Submersion . . . . . . . . . . . . . 1C-6 Water Pressure Measurement . . . . . . . . . . . . 1C-21
Model 50/60 EFI (4-Stroke) Powerhead Views Painting Procedures . . . . . . . . . . . . . . . . . . . . . 1C-22
Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-8 Cleaning & Painting Aluminum Propellers & Gear
Starboard View . . . . . . . . . . . . . . . . . . . . . . 1C-9 Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-22
Port View . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-10 Decal Removal/Application . . . . . . . . . . . . . . . 1C-23
Top View . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-11 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-23
Aft View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-12 Instructions for “Wet” Application . . . . . . . 1C-23
Propeller Selection . . . . . . . . . . . . . . . . . . . . . . 1C-13
Propeller Removal/Installation . . . . . . . . . . . . 1C-14
3-1/4 In. (83mm) Diameter Gear Case . . 1C-14
4-1/4 In. (108mm) Diameter Gear Case . 1C-15
e
XX d
a - Serial Number
b - Model Year
c - Model Description
d - Year Manufactured
e - Certified Europe Insignia
Rated hp
Horsepower Loss
Due to Atmosphere
Conditions
Summer hp
Secondary Loss Due to
Propeller Becoming To
Large for Summer
Horsepower
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.
Corporations internationally have settled on adoption of I.S.O. (International Standards Or-
ganization) engine test standards, as set forth in I.S.O. 3046 standardizing the computation
of horsepower from data obtained on the dynamometer. All values are corrected to the pow-
er that the engine will produce at sea level, at 30% relative humidity, at a temperature of 77°
F (25° C) and a barometric pressure of 29.61 inches of mercury.
Summer conditions of high temperature, low barometric pressure and high humidity all com-
bine to reduce the engine power. This, in turn, is reflected in decreased boat speeds--as
much as 2 or 3 miles-per-hour (3 or 5 Km per-hour) in some cases. (Refer to previous chart.)
Nothing will regain this speed for the boater, but the coming of cool, dry weather.
In pointing out the practical consequences of weather effects, an engine--running on a hot,
humid summer day--may encounter a loss of as much as 14% of the horsepower it would
produce on a dry, brisk spring or fall day. The horsepower that any internal combustion en-
gine 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 rig-
ging 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, be-
come too large. Consequently, the engine operates at less than its recommended rpm.
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, how-
ever, can be regained by switching to a smaller pitch propeller that allows the engine to again
run at recommended rpm.
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 detona-
tion. This, of course, enhances overall reliability and durability of the engine.
Boat
WEIGHT DISTRIBUTION
1. Proper positioning of the weight inside the boat (persons and gear) has a significant ef-
fect on the boat’s 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).
c. Adjusting tilt pin to achieve best performance and handling.
(1.) Improves ease of planing off.
(2.) Generally improves rough water ride.
(3.) If excessive, can make the boat veer left and right (bow steer).
BOTTOM
For maximum speed, a boat bottom should be nearly a flat plane where it contacts the water
and particularly straight and smooth in fore-and-aft direction.
1. Hook: Exists when bottom is concave in fore-and-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.
2. Rocker: The reverse of hook and much less common. “Rocker” exists if bottom is con-
vex in fore-and-aft direction when viewed from the side, and boat has strong tendency
to porpoise.
3. Surface Roughness: Moss, barnacles, etc., on boat or corrosion of outboard’s gear
housing increase skin friction and cause speed loss. Clean surfaces when necessary.
WATER ABSORPTION
It is imperative that all through hull fasteners be coated with a quality marine sealer at time
of installation. Water intrusion into the transom core and/or inner hull will result in additional
boat weight (reduced boat performance), hull decay and eventual structural failure.
CAVITATION
Cavitation is caused by water vapor bubbles forming either from a sharp edge or angle on
the gear case, from an irregularity in the propeller blade itself or from improper engine instal-
lation (too high). These vapor bubbles flow back and collapse when striking the surface of
the propeller blade resulting in the erosion of the propeller blade surface. If allowed to contin-
ue, eventual blade failure (breakage) will occur.
Engine
DETONATION
Detonation in a 4-cycle engine resembles the “pinging” heard in an automobile engine. It
can be otherwise described as a tin-like “rattling” or “plinking” sound.
Detonation is an explosion of an unburned portion of the fuel/air charge after the spark plug
has fired. Detonation creates severe shock waves in the engine, and these shock waves
often find or create a weakness: The dome of a piston, cylinder head/gasket, piston rings
or piston ring lands, piston pin and bearings.
A few of the most common causes of detonation in a marine 4-cycle application are as
follows:
• Over-advanced ignition timing.
• Use of low octane gasoline.
• Propeller pitch too high (engine rpm below recommended maximum range).
• Lean fuel mixture at or near wide-open-throttle.
• Spark plugs (heat range too hot - incorrect reach - cross-firing).
• Inadequate engine cooling (deteriorated cooling system).
• Combustion chamber/piston deposits (result in higher compression ratio).
Detonation usually can be prevented if:
1. The engine is correctly set up.
2. Diligent maintenance is applied to combat the detonation causes.
51115
WARNING
Always release the fuel pressure in the high-pressure fuel line before servicing the
line or the vapor separator. If the fuel pressure is not released, pressurized fuel may
spray out.
c. Release fuel pressure. Refer to Releasing Fuel Pressure in the High Pressure
Fuel Line, Section 3C. Remove high-pressure fuel line from bottom of vapor separa-
tor fuel cooler and drain fuel/water into suitable container. Replace in-line fuel filter
of high-pressure fuel line and reconnect fuel line to connection on fuel cooler.
d. Remove fuel distribution manifold and empty contents into suitable container. In-
spect and clean fuel injectors. Reinstall fuel injectors/fuel distribution manifold.
e. Empty contents of water separating fuel filter into suitable container.
6. Change engine oil and filter as outlined in Section 1B “Changing Engine Oil”. Run
outboard for short time and check for presence of water in oil. If water present (milky
appearance) drain and refill as previously mentioned.
7. Pour alcohol into engine through throttle body (alcohol will absorb water). Again rotate
flywheel.
8. Turn engine over and pour alcohol into spark plug openings and rotate flywheel.
9. Turn engine over (place spark plug openings down) and pour engine oil into intake man-
ifold plug holes (plugs removed) while rotating flywheel to distribute oil throughout
crankcase.
10. 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.
11. Remove and clean intake manifold assembly and fuel pump assembly.
12. Dry all wiring and electrical components using compressed air.
13. Disassemble the engine starter motor and dry the brush contacts, armature and other
corrodible parts.
14. Reinstall spark plugs, intake manifold and fuel pump.
15. Attempt to start engine, using a fresh fuel source. If engine starts, it should be run for
at least one hour to eliminate any water in engine.
16. If engine fails to start, determine cause (fuel, electrical or mechanical). Engine should
be run within 2 hours after recovery of outboard from water, or serious internal damage
may occur. If unable to start engine in this period, disassemble engine and clean all
parts. Apply oil as soon as possible.
b
a
m c
f e
g
i
h 58811
a e
g
j
h
q
i
p
m l 58810
n
a - High Pressure Fuel Line from VST
b - Lifting Eye
c - Fuel Distribution Manifold
d - Engine Harness Connection to Remote Control Harness
e - 10 Pin SmartCraft Connection
f - Engine Harness Connections to ECM
g - Intake Manifold
h - Throttle Air By-Pass Hose
i - Idle Air Control (IAC)
j - Fuel Injectors
k - Shift Arm
l - Shift Linkage
m - Throttle Linkage
n - Tell-Tale
o - Throttle Lever
p - Throttle Cam
q - Fuel Filter
e
b
a
c f
g
h
m
n h
l
i
j
k
58812
g
f
58815
a - Cam Shaft Timing Gear
b - Timing Belt
c - Crank Position Sensor
d - Flywheel
e - Starter Motor
f - Remote Control and Engine Harness Connection
g - 10 Pin SmartCraft Connection
d
h
58814
a - Lifting Eye
b - Valve Cover
c - Crankcase Breather Hose
d - Oil Fill Plug
e - Bottom Cowl Latch
f - Fuel Pump (Water Cooled)
g - Main Power Relay
h - Trim Down Relay
i - Trim Up Relay
Propeller Selection
For in-depth information on marine propellers and boat performance - written by marine en-
gineers - see your Authorized Dealer for the illustrated “What You Should Know About
Quicksilver Propellers...and Boat Performance Information” (Part No. 90-86144).
For best all around performance from your outboard/boat combination, select a propeller
that allows the engine to operate in the upper half of the recommended full throttle rpm range
with the boat normally loaded (refer to Specifications). This rpm range allows for better ac-
celeration while maintaining maximum boat speed.
If changing conditions cause the rpm to drop below the recommended range (such as warm-
er, more humid weather, operation at higher elevations, increased boat load or a dirty boat
bottom/gear case) a propeller change or cleaning may be required to maintain performance
and ensure the outboard’s durability.
Check full-throttle rpm using an accurate tachometer with the engine trimmed out to a bal-
anced-steering condition (steering effort equal in both directions) without causing the pro-
peller to “break loose”.
Refer to “Quicksilver Accessory Guide” for a complete list of available propellers.
1. Select a propeller that will allow the engine to operate at or near the top of the recom-
mended full throttle rpm range (listed in “Specifications,” preceding) with a normal load.
Maximum engine speed (rpm) for propeller selection exists when boat speed is maxi-
mum and trim is minimum for that speed. (High rpm, caused by an excessive trim angle,
should not be used in determining correct propeller.) Normally, there is a 150-350 rpm
change between propeller pitches.
2. If full throttle operation is below the recommended range, the propeller MUST BE
changed to one with a lower pitch to prevent loss of performance and possible engine
damage.
3. After initial propeller installation, the following common conditions may require that the
propeller be changed to a lower pitch:
a. Warmer weather and great humidity will cause an rpm loss.
b. Operating in a higher elevation causes an rpm loss.
c. Operating with a damaged propeller or a dirty boat bottom or gear housing will cause
an rpm loss.
d. Operation with an increased load (additional passengers, equipment, pulling skiers,
etc.).
Propeller Removal/Installation
3-1/4 In. (83mm) Diameter Gear Case
WARNING
If the propeller shaft is rotated while the engine is in gear, there is the possibility that
the engine will crank over and start. To prevent this type of accidental engine start-
ing and possible serious injury caused from being struck by a rotating propeller,
always shift outboard to neutral position and remove spark plug leads when you
are servicing the propeller.
1. Shift outboard to neutral (N) position.
2. Remove the spark plug leads to prevent engine from starting.
a
3. Straighten the bent tabs (a) on the propeller nut retainer.
4. Place a block of wood between gear case and propeller to hold propeller and remove
propeller nut. Pull propeller straight off shaft.
5. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti-Corrosion
Grease or 2-4-C Marine Lubricant with Teflon.
IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller
shaft, especially in salt water, always apply a coat of the recommended lubricant to
the entire propeller shaft at the recommended maintenance intervals and also each
time the propeller is removed.
c e d
d f
a a
b c b
Flo-Torque I Drive Hub Propellers Flo-Torque II Drive Hub Propellers
6. Flo-Torque I Drive Hub Propellers – Install forward thrust hub (a), propeller (b), propeller
nut retainer (c) and propeller nut (d) onto the shaft.
7. Flo-Torque II Drive Hub Propellers – Install forward thrust hub (a), propeller (b), replace-
able drive sleeve (c), rear thrust hub (d), propeller nut retainer (e) and propeller nut (f)
onto the shaft.
8. Place propeller nut retainer over pins. Place a block of wood between gear case and
propeller and tighten propeller nut to 55 lb. ft. (75 N·m), aligning flat sides of the propeller
nut with tabs on the propeller nut retainer.
9. Secure propeller nut by bending tabs up and against the flats on the propeller nut.
10. Reinstall spark plug leads.
a
f c b d a
b
Flo-Torque I Drive Hub Propellers Flo-Torque II Drive Hub Propellers
6. Flo-Torq I Drive Hub Propellers – Install thrust washer (a), propeller (b), continuity wash-
er (c), thrust hub (d), propeller nut retainer (e), and propeller nut (f) onto the shaft.
7. Flo-Torq II Drive Hub Propellers – Install forward thrust hub (a), replaceable drive sleeve
(b), propeller (c), thrust hub (d), propeller nut retainer (e) and propeller nut (f) onto the
shaft.
8. Place a block of wood between gear case and propeller and torque propeller nut to 55
lb. ft. (75 N·m).
9. Secure propeller nut by bending three of the tabs into the thrust hub grooves.
10. Reinstall spark plug leads.
WARNING
Avoid possible serious injury or death. When the outboard is trimmed in or out be-
yond a neutral steering condition, a pull on the steering wheel or tiller handle in ei-
ther direction may result. Failure to keep a continuous firm grip on the steering
wheel or tiller handle when this condition exists can result in loss of boat control
as the outboard can turn freely. The boat can now “spin out” or go into a very tight
maximum turn which, if unexpected, can result in occupants being thrown within
the boat or out of the boat.
Consider the following lists carefully:
TRIMMING IN OR DOWN CAN:
1. Lower the bow.
2. Result in quicker planing off, especially with a heavy load or a stern heavy boat.
3. Generally improve the ride in choppy water.
4. Increase steering torque or pull to the right (with the normal right hand rotation propel-
ler).
5. In excess, lower the bow of some boats to a point where they begin to plow with their
bow in the water while on plane. This can result in an unexpected turn in either direction
called “bow steering” or “over steering” if any turn is attempted or if a significant wave
is encountered.
WARNING
Avoid possible serious injury or death. Adjust outboard to an intermediate trim po-
sition as soon as boat is on plane to avoid possible ejection due to boat spin-out.
Do not attempt to turn boat when on plane if outboard is trimmed extremely in or
down and there is a pull on the steering wheel or tiller handle.
TRIMMING OUT OR UP CAN:
1. Lift the bow higher out of the water.
2. Generally increase top speed.
3. Increase clearance over submerged objects or a shallow bottom.
4. Increase steering torque or pull to the left at a normal installation height (with the normal
right hand rotation propeller).
5. In excess, cause boat “porpoising” (bouncing) or propeller ventilation.
6. Cause engine overheating if any water intake holes are above the water line.
Trim “In” Angle Adjustment
Some outboard boats, particularly some bass boats, are built with a greater than normal
transom angle which will allow the outboard to be trimmed further “in” or “under”. This great-
er trim “under” capability is desirable to improve acceleration, reduce the angle and time
spent in a bow high boat, altitude during planing off, and in some cases, may be necessary
to plane off a boat with aft live wells, given the variety of available propellers and height
range of engine installations.
However, once on plane, the engine should be trimmed to a more intermediate position to
a avoid a bow-down planing condition called “plowing”. Plowing can cause “bow steering”
or “over steering” and inefficiently consumes horsepower. In this condition, if attempting a
turn or encountering a diagonal, moderate wake, a more abrupt turn than intended may re-
sult.
In rare circumstances, the owner may decide to limit the trim in. This can be accomplished
by repositioning the tilt stop pins into whatever adjustment holes in the transom brackets
is desired.
WARNING
Avoid possible serious injury or death. Adjust outboard to an intermediate trim po-
sition as soon as boat is on plane to avoid possible ejection due to boat spin-out.
Do not attempt to turn boat when on plane if outboard is trimmed extremely in or
down and there is a pull on the steering wheel or tiller handle.
If an adjustment is required, purchase a stainless steel tilt pin (P/N 17-49930A1) and insert
it through whatever pin hole is desired. The non-stainless steel shipping bolt should not be
used in this application other than on a temporary basis.
a - Trim Tab
Compression Check
CAUTION
Compression/Cylinder Leakage Tests Must be performed with the ignition/injection
system disabled. To do this, the lanyard stop switch MUST BE placed to the “OFF”
position.
IMPORTANT: Compression check should be done with throttle in WOT position.
1. Check valve clearance (refer to “Valve Clearance Adjustment” in section 4A), adjust
if out of specification.
2. Warm up the engine. Remove all spark plugs.
3. Lubricate threads in cylinder head and on compression gauge. Install compression
gauge in spark plug hole.
110
* Courtesy of Snap-On-Tools
Indicates Possible
Air Escaping From:
Defective:
Intake Manifold Intake Valve
Exhaust System Exhaust Valve
Crankcase Fill Plug Piston or Rings
Cylinder Head Gasket
22-89772 22
20
Painting Procedures
Cleaning & Painting Aluminum Propellers & Gear Housings
WARNING
Avoid serious injury from flying debris. Avoid serious injury from airborne par-
ticles. Use eye and breathing protection with proper ventilation.
PROPELLERS
1. Sand the entire area to be painted with 3M 120 Regalite Polycut or coarse Scotch-Brite,
disc or belts.
2. Feather edges of all broken paint edges. Try not to sand through the primer.
3. Clean the surface to be painted using PPG Industries DX330 Wax and Grease Remover
or equivalent (Xylene or M.E.K.).
4. If bare metal has been exposed, use Quicksilver’s Light Gray Primer.
5. Allow a minimum of 1 hour dry time and no more than 1 week before applying the finish
coat.
6. Apply the finish coat using Quicksilver’s EDP Propeller Black.
GEAR HOUSINGS
The following procedures should be used in refinishing gear housings. This procedure will
provide the most durable paint system available in the field. The materials recommended
are of high quality and approximate marine requirements. The following procedure will pro-
vide a repaint job that compares with a properly applied factory paint finish. It is recom-
mended that the listed materials be purchased from a local Ditzler Automotive Finish Supply
Outlet. The minimum package quantity of each material shown following is sufficient to refin-
ish several gear housings.
Procedure:
1. Wash gear housing with a muriatic acid base cleaner to remove any type of marine
growth, and rinse with water, if necessary.
2. Wash gear housing with soap and water, then rinse.
3. Sand blistered area with 3M 180 grit sandpaper or P180 Gold Film Disc to remove paint
blisters only. Feather edge all broken paint edges.
4. Clean gear housing thoroughly with (DX-330) wax and grease remover.
5. Spot repair surfaces where bare metal is exposed with (DX-503) alodine treatment.
IMPORTANT: Do not use any type of aerosol spray paints as the paint will not properly
adhere to the surface nor will the coating be sufficiently thick to resist future paint
blistering.
6. Mix epoxy chromate primer (DP-40) with equal part catalyst (DP-401) per manufactur-
ers instructions, allowing proper induction period for permeation of the epoxy primer and
catalyst.
7. Allow a minimum of one hour drying time and no more than one week before top coating
assemblies.
8. Use Ditzler Urethane DU9000 for Mercury Black, DU34334 for Mariner Grey, and
DU35466 for Force Charcoal, and DU33414M for Sea Ray White. Catalyze all four col-
ors with Ditzler DU5 catalyst mixed 1:1 ratio. Reduce with solvents per Ditzler label.
CAUTION
Be sure to comply with instructions on the label for ventilation and respirators. Us-
ing a spray gun, apply one half to one mil even film thickness. Let dry, flash off for
five minutes and apply another even coat of one half to one mil film thickness. This
urethane paint will dry to the touch in a matter of hours, but will remain sensitive
to scratches and abrasions for a few days.
9. The type of spray gun used will determine the proper reduction ratio of the paint.
IMPORTANT: Do not paint sacrificial zinc trim tab or zinc anode.
10. Cut out a cardboard “plug” for trim tab pocket to keep paint off of mating surface to main-
tain good continuity circuitry between trim tab and gear housing.
Decal Removal/Application
Removal
1. Mark decal location before removal to assure proper alignment of new decal.
2. Carefully soften decal and decal adhesive with a heat gun or heat blower while removing
old decal.
3. Clean decal contact area with a 1:1 mixture of isopropyl alcohol and water.
4. Thoroughly dry decal contact area and check for a completely cleaned surface.
Instructions for “Wet” Application
NOTE: The following decal installation instructions are provided for a “Wet” installation. All
decals should be applied wet.
TOOLS REQUIRED
1. Plastic Squeegee*
2. Stick Pin
3. Dish Washing Liquid/Detergent without ammonia** “Joy” and “Drift” are known to be
compatible for this process.
** Automotive Body Filler Squeegee
** Do not use a soap that contains petroleum based
solvents.
SERVICE TIP: Placement of decals using the “Wet” application will allow time to posi-
tion decal. Read entire installation instructions on this technique before proceeding.
TEMPERATURE
IMPORTANT: Installation of vinyl decals should not be attempted while in direct sun-
light. Air and surface temperature should be between 60°F (15°C) and 100°F (38°C)
for best application.
SURFACE PREPARATION
IMPORTANT: Do not use a soap or any petroleum based solvents to clean application
surface.
Clean entire application surface with mild dish washing liquid and water. Rinse surface thor-
oughly with clean water.
DECAL APPLICATION
1. Mix 1/2 ounce (16 ml) of dish washing liquid in one gallon (4 l) of cool water to use as
wetting solution.
NOTE: Leave protective masking, if present, on the face of decal until final steps of decal
installation. This will ensure that the vinyl decal keeps it’s shape during installation.
2. Place the decal face down on a clean work surface and remove the paper backing from
“adhesive side” of decal.
3. Using a spray bottle, flood the entire “adhesive side” of the decal with the pre-mixed wet-
ting solution.
4. Flood area where the decal will be positioned with wetting solution.
5. Position pre-wetted decal on wetted surface and slide into position.
6. Starting at the center of the decal, “lightly” squeegee out the air bubbles and wetting
solution with overlapping strokes to the outer edge of the decal. Continue going over the
decal surface until all wrinkles are gone and adhesive bonds to the cowl surface.
7. Wipe decal surface with soft paper towel or cloth.
8. Wait 10 - 15 minutes.
9. Starting at one corner, “carefully and slowly” pull the masking off the decal surface at
a 180° angle.
NOTE: To remove any remaining bubbles, pierce the decal at one end of the bubble with
stick pin and press out the entrapped air or wetting solution with your thumb (moving toward
the puncture).
IMPORTANT INFORMATION 1
Section 1D - Outboard Motor Installation D
Table of Contents
Electric Fuel Pump . . . . . . . . . . . . . . . . . . . . . . 1D-1 Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . 1D-7
Boat Horsepower Capacity . . . . . . . . . . . . . . . 1D-1 Battery Cable Connections . . . . . . . . . . . . . . . 1D-8
Start in Gear Protection . . . . . . . . . . . . . . . . . . 1D-2 Shift and Throttle Cable Installation . . . . . . . . 1D-9
Selecting Accessories For The Outboard . . . 1D-2 Trim-In Stop Adjustment
Installation Specifications . . . . . . . . . . . . . . . . . 1D-2 Power Trim Models . . . . . . . . . . . . . . . . . . . . . 1D-13
Lifting Outboard . . . . . . . . . . . . . . . . . . . . . . . . . 1D-3 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . 1D-13
Steering Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-3 Wiring for SmartCraft Gauges – EFI Models 1D-14
Steering Cable Seal . . . . . . . . . . . . . . . . . . . . . 1D-4 Typical SmartCraft Installation Configurations
Steering Link Rod . . . . . . . . . . . . . . . . . . . . . . . 1D-4 EFI Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-15
Installing Outboard Instrument/Lanyard Stop Switch Wiring Diagram
Thumb Screw Models . . . . . . . . . . . . . . . . . 1D-5 (Dual Outboard) . . . . . . . . . . . . . . . . . . . . . . . . 1D-16
Non Thumb Screw Models . . . . . . . . . . . . . 1D-6
Do not overpower or overload the boat. Most boats will carry a required capacity plate indi-
cating the maximum acceptable power and load as determined by the manufacturer follow-
ing certain federal guidelines. If in doubt, contact your dealer or the boat manufacturer.
WARNING
Using an outboard that exceeds the maximum horsepower limit of a boat can:
1. Cause loss of boat control
2. Place too much weight at the transom, altering the designed flotation characteris-
tics of the boat or,
3. Cause the boat to break apart, particularly around the transom area.
Overpowering a boat can result in serious injury, death, or boat damage.
WARNING
Avoid serious injury or death from a sudden unexpected acceleration when starting
your engine. The design of this outboard requires that the remote control used with
it must have a built in start-in-gear protection device.
Installation Specifications
a b
Lifting Outboard
Use lifting eye on engine.
Steering Cable
STARBOARD SIDE ROUTED CABLE
1. Lubricate the entire cable end.
95
a b c d
a - 1/4 in. (6.4 mm) Mark
b - Plastic Spacer
c - O-Ring Seal
d - Cap
b
d
f
e
a
a - Special Bolt (10-90041) Torque to 20 lb. ft. (27.1 N·m)
b - Nylon Insert Locknut (11-34863) Torque to 20 lb. ft. (27.1 N·m)
c - Spacer (12-71970)
d - Flat Washer (2)
e - Nylon Insert Locknut (11-34863) Tighten Locknut Until it Seats, Then Back Nut
Off 1/4 Turn
f - Use Middle Hole – Steer Outboard to the Side to Gain Hole Access
IMPORTANT: The steering link rod that connects the steering cable to the engine
must be fastened using special bolt (“a” - Part Number 10-90041) and self locking
nuts (“b” & “e” - Part Number 11-34863). These locknuts must never be replaced with
common nuts (non locking) as they will work loose and vibrate off, freeing the link
rod to disengage.
WARNING
Disengagement of a steering link rod can result in the boat taking a full, sudden,
sharp turn. This potentially violent action can cause occupants to be thrown over-
board exposing them to serious injury or death.
1. Center outboard on the transom. Install the outboard so that the anti-ventilation plate
is in line or within 1 in. (25 mm) below the bottom of the boat.
0 - 1 in.
(0 - 25mm)
a - Anti-Ventilation Plate
2. Fasten outboard with provided mounting hardware shown.
e
d
c
a
b
a - 1/2 in. Diameter Bolts (2) d - Marine Sealer - Apply to Shanks of
b - Flat Washers Bolts, Not Threads
c - Locknuts e - Thumb Screws - Tighten Securely
3. Install the outboard so that the anti-ventilation plate is in-line or within 1 in. (25 mm) be-
low the bottom of the boat.
0 - 1 in.
(0 - 25mm)
a - Anti-Ventilation Plate
4. Fasten outboard with provided mounting hardware shown.
d
d
c c
b b a
a
a - 1/2 in. Diameter Bolts (2)
b - Flat Washers
c - Locknuts
d - Marine Sealer - Apply to Shanks of Bolts, Not Threads
Wiring Harness
IMPORTANT: Warning Horn Requirement – The remote control or key switch assem-
bly must be wired with a warning horn. This warning horn is used with the engine
warning system.
1. Route wiring harness into bottom cowl.
a - Wiring Harness
2. Connect wiring. Push the wiring harness connectors together inside the rubber sleeve.
Push the retainer over the exposed ends of the connectors. This will hold the connectors
together.
c b
BRN/WHT
GRN/WHT
BLU/WHT
TAN
GRN/WHT
BLU/WHT
a
a - Power Trim Connections
b - Rubber Sleeve – Place Harness Connectors Inside
c - Retainer – Push Over Connector Ends
SINGLE OUTBOARD
(+)
(–) c
DUAL OUTBOARDS
Connect a common ground cable (wire size same as engine battery cables) between nega-
tive (–) terminals on starting batteries.
(–)
(–)
d - Ground Cable (Same Wire Size As Engine Battery Cable) – Connect Between
Negative (–) Terminals
a
a - Access Cover
3. Shift outboard into neutral.
4. Measure the distance (a) between pin and center of lower hole.
b c
a - Distance Between Pin And Center of Lower Hole
b - Pin
c - Lower Hole
5. Fit shift cable through rubber grommet.
7. While pushing in on the cable end, adjust the cable barrel (b) to attain the measured dis-
tance (a) taken in Step 3.
b
a - Adjust Cable Barrel To Attain The Measured Distance Taken In Step 3
b - Cable Barrel
8. Place cable barrel into the barrel holder. Fasten cable with retainer.
b a
3. Install throttle cable with retainer pin. Lock retainer pin in place.
4. Place throttle cable onto the throttle lever pin. Lock in place with retainer.
b
a - Throttle Cable
b - Retainer
5. Adjust cable barrel until the center of the roller lines up with the alignment mark on the
cam.
a - Cable Barrel
b - Alignment Mark
c - Roller
6. Fasten control cables with the cable latch.
a - Tilt Pin
NOTE: Trim tab adjustment will have little effect reducing steering torque if the anti-ventila-
tion plate is raised 2 inches (50mm) or more above the boat bottom.
System System
Monitor Tachometer
System Link
Gauge
Connection
Engine
System Link
Gauge
Connection
Engine
System Link
Gauge
Engine Connection
System System
Monitor Tachometer
Notes:
c b
BLK = Black g l
BLU = Blue
BRN = Brown BATT GND
GRY = Gray d
GRN = Green
SENDER
ORN = Orange
PNK = Pink
PUR = Purple a e
RED = Red
TAN = Tan
WHT = White
YEL = Yellow
LIT = Light
DRK = Dark
h n
PORT INSTALLATION
52716
IMPORTANT: On installations where gauge options will not be used, tape back and
isolate any unused wiring harness leads.
BATT GND
i SENDER
a
e
STARBOARD INSTALLATION
52654
ELECTRICAL
Section 2A - Ignition
Table of Contents
2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2 Ignition Troubleshooting . . . . . . . . . . . . . . . . . . 2A-8
A
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-3 Ignition Diagnostic Procedures . . . . . . . . . . . . 2A-8
Ignition Coil Mounting . . . . . . . . . . . . . . . . . . . . 2A-4 Testing Ignition Components . . . . . . . . . . . . . . 2A-9
Ignition Description . . . . . . . . . . . . . . . . . . . . . . 2A-6 Resistance Tests . . . . . . . . . . . . . . . . . . . . . 2A-9
Ignition Component Description . . . . . . . . . . . 2A-6 High Tension Lead Removal/Installation . 2A-9
Ignition Coils . . . . . . . . . . . . . . . . . . . . . . . . . 2A-6 High Tension Lead Resistance . . . . . . . . . 2A-10
Ignition Test Procedures . . . . . . . . . . . . . . . . . . 2A-7 Ignition Coil Removal and Installation . . . . . . 2A-11
Specifications
Type Capacitor Discharge Ignition
Spark Plug:
Type Champion RA8HC
Gap 0.040 in. (1.0 mm)
Hex Size 5/8 in. (16 mm)
Torque 150 lb-in. (17 Nm)
Hole Size 12 mm
Firing Order 1-3-4-2
Ignition Timing:
@Idle Controlled by ECM
@1500-1800 14° B.T.D.C
@ WOT (6000 rpm) 28° B.T.D.C
Stator Resistance 0.20 - 0.30 Ω (YEL-YEL)
Crank Position Sensor (CPS)
Resistance 300 - 350 Ω (RED - WHT)
Ignition Coil Resistance:
Internal Shielding 0 - 10.0 KΩ (Pin A - Mounting Bracket)
Electronic Spark Trigger (EST) 8.5 - 12KΩ (Pin B - Pin C)
Secondary 3.0 - 7.0 kΩ (Pin A - Coil Tower)
IGNITION High Tension Lead/Boot
SYSTEM Resistance 0.600 - 1.100 KΩ
Readings taken @ ECM Engine Speed Limiter
68°F (20°C). Fuel/Spark Cut-out on Cylinders
#2 and #3 6225 rpm
Fuel/Spark Cut-out on All
Cylinders 6350 rpm
ECM Overheat Speed Control Guardian System is activated. Power
limit will vary with level of overheat.
ECM Low Oil Pressure Speed Control Guardian System is activated. Engine
power is limited to 10% of maximum
(Approximately 2000 RPM)
MAT/ECT Temperature Sensor See Graph Section 3B - EFI
Manifold Absolute Pressure (MAP)
Sensor Resistance See Table Section 3B - EFI
Fuel Injector Resistance 10.0 - 13.5Ω
Main Power Relay 81-99 Ω (Pin 85 - Pin 86)
Idle Air Control (IAC) 24-30 Ω (Between Pins)
Throttle Position Sensor Typical
Range
Output Voltage @Idle 0.39-1.00 Volts
Output Voltage @WOT (6000) 3.66-4.80 Volts
Special Tools
1. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1
1
13
11 16 15
25
17
66
9
3 18 14 8
10
19
4
11 7
6
5
2 6 10
12
Ignition Description
When the ignition key switch is turned to the “RUN” position battery voltage is applied to both
the Electronic Control Module (ECM) through the purple wire, and the main power relay
through the red/purple wire. As the ECM receives the “RUN” signal it internally completes
the ground circuit of the main relay for a period of two seconds, energizing the ignition/injec-
tion systems for start-up. As the engine is cranked with the starter motor, the ECM receives
the run signal from the Crank Position Sensor (CPS) and completes the ground circuit to
the main relay for engine operation.
With the main relay closed (completed circuit) D.C. current from the battery/charging system
is transferred through the 20 ampere main relay fuse to the positive terminal of all ignition
coil primary windings. The negative terminals of the ignition coil primaries are connected
to the engine ground through the coils internal driver, which is triggered by the ECM. With
the coil drivers closed, an electric magnetic field is allowed to build up within the ignition coil.
As the flywheel rotates, the CPS senses the location of the 54 teeth on the flywheel and sup-
plies the trigger signal information to the ECM. The ECM utilizes the CPS information and
determines when to remove the trigger signal from the coil driver of each ignition coil. The
coil driver then opens the coil primary ground circuit which allows it’s magnetic field to rapidly
collapse across the coil secondary winding which induces a high voltage charge (50,000
volts) that fires the spark plug.
The negative terminals of the ignition coil primaries are connected to the engine ground
through the coils internal driver, which is triggered by the ECM. With the coil drivers closed,
an electric magnetic field is allowed to build up within the ignition coil.
As the flywheel rotates, the CPS senses the location of the 54 teeth on the flywheel and sup-
plies the trigger signal information to the ECM. The ECM utilizes the CPS information and
determines when to remove the trigger signal from the coil driver of each ignition coil. The
coil driver then opens the coil primary ground circuit which allows it’s magnetic field to rapidly
collapse across the coil secondary winding which induces a high voltage charge (50,000
volts) that fires the spark plug.
WARNING
When testing or servicing the ignition system, high voltage is present. 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 sys-
tem.
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 with Ignition Coils/Coil Mounting Plate not grounded.
CAUTION
To protect against meter and/or component damage, observe the following precau-
tions:
IMPORTANT: The metal housing of the ECM is isolation mounted and MUST NOT be
externally grounded. Should the housing become externally grounded, the engine
will not run until the ground is removed and battery cables are momentarily discon-
nected from the battery to re-set the ECM.
• ALL COMPONENTS MUST BE GROUNDED during tests. Running or “cranking” en-
gine with Ignition Coils/Coil Mounting Plate ungrounded may damage components.
Ignition Troubleshooting
Refer to Section 3B “Electronic Fuel Injection” - “Troubleshooting and Diagnostics”
for complete system troubleshooting/diagnostics procedures.
DC BA
b a
NOTE: Ohm readings may not be in range specified because of sensitivity of your multi-me-
ter. Meter should show almost full continuity or near zero resistance condition.
a - Coil End
b - Spark Plug End
METER TEST LEADS METER SCALE READING
(ANALOG) (
RED BLACK
RX100 0 600 - 1.100K
0.600 1 100K
COIL END PLUG END
DC BA
b
a
a - Pin A
b - Coil Tower
METER TEST LEADS METER SCALE READING
(ANALOG) (
RED BLACK
COIL TOWER PIN A RX1K 30-7
3.0 7.0
0
c
d
b
a
ELECTRICAL
Section 2B - Charging & Starting System
Table of Contents
2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1 Flywheel Removal/Installation . . . . . . . . . . . . . 2B-18
B
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-18
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-20
Electrical Components . . . . . . . . . . . . . . . . . . . 2B-6 Stator Removal/Installation . . . . . . . . . . . . . . . 2B-21
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-10 Voltage Regulator/Rectifier
Battery Charging System . . . . . . . . . . . . . . . . . 2B-11 Removal/Installation . . . . . . . . . . . . . . . . . . . . 2B-22
Description (20 Ampere) . . . . . . . . . . . . . . 2B-11 Starting System Components . . . . . . . . . . . . . 2B-23
Wiring Diagram (20 Ampere) . . . . . . . . . . . 2B-11 Description . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-23
Charging System Description . . . . . . . . . . . . . 2B-12 Troubleshooting the Starting Circuit . . . . . . . . 2B-23
Flywheel Assembly . . . . . . . . . . . . . . . . . . . 2B-12 Starter Solenoid Test . . . . . . . . . . . . . . . . . . 2B-24
Stator Assembly . . . . . . . . . . . . . . . . . . . . . . 2B-12 Starter Motor Servicing . . . . . . . . . . . . . . . . . . . 2B-27
Voltage Regulator/Rectifier Assembly . . . 2B-12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-27
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-13 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 2B-27
Battery Charging System Troubleshooting . . 2B-13 Cleaning and Inspection . . . . . . . . . . . . . . . 2B-29
Alternator System Test . . . . . . . . . . . . . . . . 2B-14 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-30
Stator Resistance Test - 20 Amp. Stator . 2B-15 Brush Replacement . . . . . . . . . . . . . . . . . . . 2B-32
Suppression Diode Tests . . . . . . . . . . . . . . 2B-15 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 2B-33
Regulator/Rectifier (P/N 854514-1) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-36
Diode Test . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-16
Specifications
Alternator Type: Single Phase (12 Pole)
CHARGING
20 Amp. Electric Alternator Output 12.6 V-20 Amps. (252 Watts)
SYSTEM
(Rectified/Regulated)
Readings taken @
Stator Resistance 0.20 - 0.30 Ohms (YEL-YEL)
68°F (20°C).
Quicksilver Tachometer Setting “6P” or “4”
Electric Start:
Starter Type Bendix
STARTING Output 1.1 kW
SYSTEM Ampere Draw Under:
(Load) 174.0 Amps
(No Load) 23.7 Amps
Battery Rating
Minimum Requirement 465 Marine Cranking Amps (MCA)
or 350 Cold Cranking Amps (CCA)
For operation below 32° F (0° C) 1000 Marine Cranking Amps (MCA) or
BATTERY 775 Cold Cranking Amps (CCA)
Ampere-Hours (Ah) Minimum
For operation above 32° F (0° C) 70
For operation below 32° F (0° C) 105
Special Tools
1. Flywheel Holder P/N 91-83163M
Notes:
FLYWHEEL
2 3
6
110
7 9 8
10
15
4
16
19
11
13
5
14
12
17
18
20
FLYWHEEL
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
1 1 FLYWHEEL COVER
2 4 SCREW (M6 X 25) 75 8.5
3 1 DECAL - EPA INFORMATION (SEE NOTE)
4 1 FLYWHEEL
5 1 DRIVEN GEAR
6 1 DECAL - WARNING SPINNING FLYWHEEL
7 1 DECAL - TIMING MARKS
8 1 DECAL - WARNING-NEUTRAL
9 1 NUT 115 155.9
10 1 WASHER
11 3 SCREW (M5 X 30) 85 9.6
12 1 STATOR
13 1 LOAD RING
14 1 DRIVE GEAR
15 1 SCREW (M10 X 40) 28 38
16 1 WASHER
17 1 KEY
18 1 KEY
19 1 TIMING BELT
20 1 STA-STRAP
NOTE: THE EPA LABEL HAS IMPORTANT INFORMATION REGARDING EPA EMISSION
REGULATIONS. REPLACE ANY MISSING OR UNREADABLE EPA LABEL.
ELECTRICAL COMPONENTS
6 Dielectric Grease (92-823506--1) 44
7 15
4 66
12
2 3 6
4 16 25
15
27
1
18
3 17
4
1 25
3
1 21
24 20
26 19
24
29
30 23
6 21
22
43
31
35 28 25
42
41 33
32
34
25 24
38
36
45
37
39 40
ELECTRICAL COMPONENTS
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
1 3 SCREW (M6 X 25) 45 5.1
2 1 PLATE
3 3 WASHER
4 3 GROMMET
1 ECM (50)
5 1 ECM (60)
3 ECM (40)
6 3 BUSHING
7 2 SCREW 45 5.1
8 1 BRACKET
9 1 RETAINER
10 1 RETAINER
11 1 PLATE
12 3 SCREW (M6 X 16) 75 8.5
13 1 J CLAMP
14 1 BRACE
15 2 SCREW (M6 X 14) 45 5.1
16 1 SOLENOID PLATE
17 1 SCREW (M6 X 14) 45 5.1
18 1 BRACKET
19 1 SOLENOID
20 1 CABLE
21 2 NUT 60 6.8
22 1 BATTERY CABLE (POSITIVE)
23 1 BOOT (RED)
24 1 ENGINE WIRING HARNESS
4 FUSE (20 AMP)
25
1 FUSE (15 AMP)
26 1 COVER
27 1 DIODE ADAPTOR CABLE
28 1 PLUG (MALE)
29 1 CRANK POSITION SENSOR
30 2 SCREW (M5 X 16) 45 5.1
31 1 VOLTAGE REGULATOR
32 1 BRACKET
33 1 FOAM PAD
34 2 SCREW (M6 X 40) 75 8.5
35 1 PRESSURE SWITCH 75 8.5
36 1 STARTER MOTOR (SEE BREAKDOWN ON STARTER MOTOR)
37 1 NUT (1/4-20) 60 6.8
38 1 BATTERY CABLE (NEGATIVE)
39 1 J CLIP
ELECTRICAL COMPONENTS
7 15
4 66
12
2 3 6
4 16 25
15
27
1
18
3 17
4
1 25
3
1 21
24 20
26 19
24
29
30 23
6 21
22
43
31
35 28 25
42
41 33
32
34
25 24
38
36
45
37
39 40
ELECTRICAL COMPONENTS
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
40 3 SCREW (M8 X 45) 21.7 29.4
41 2 SCREW (M6 X 25) 75 8.5
42 AR STA-STRAP
43 4 SPARK PLUG (RA8HC) 20 21.1
44 1 SCREW (M5 X 12) 45 5.1
45 1 EXTENSION HARNESS (HANDLE)
STARTER MOTOR
2
3
1 6
11
10
9
4 7
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
1 1 STARTER MOTOR
2 2 THRU BOLT 70 8.0
3 1 DRIVE KIT
4 1 ARMATURE
5 1 PINION
6 1 DRIVE CAP
7 1 COMMUTATOR CAP
8 1 BRUSH & SPRING KIT
9 1 BRUSH HOLDER
10 2 SCREW
11 1 DECAL-Warning-High voltage
YEL YEL b
e
RED
GRY RED
d
YEL BLK
RED
YEL
BLK
RED
f
c
a - Stator
b - Voltage Regulator/Rectifier
c - Connector
d - To Engine Ground
e - To Battery Positive (Red) Terminal
f - To Battery Negative (Black) Terminal
The flywheel assembly contains six permanently charged magnet segments which are
bonded and retained to the inner wall of the flywheel. Each magnet contains a north and a
south pole providing a 12 pole system.
Stator Assembly
58489
The stator assembly located under the flywheel contains the battery charge coils. As the
flywheel permanent magnets pass the respective stator coil windings, an AC pulse current
is produced at each coil winding when magnet polarity changes. (South to North), (North
to South) etc.
The voltage regulator converts the alternating current from the stator to direct current that
can be stored in the battery.
Battery
A 12 volt battery with a minimum rating of 465 marine cranking amps (MCA) or 350 cold
cranking amps (CCA). For operation below 32° F (0° C) a rating of 1000 Marine Cranking
Amps (MCA) or 775 Cold Cranking Amps (CCA) is recommended.
18
16
Alternator current (Amps)
14
12
10
0
0 1 2 3 4 5 6
RPM x 1000
9. A reading of 19.5 amperes at 5000 RPM indicates the charging system is functioning
properly.
10. If ammeter reads less than required amperes @ 5000 RPM, test the stator (refer to “Sta-
tor Resistance Test”). If stator tests OK, replace rectifier/regulator.
METER READING
METER TEST LEADS SCALE (
(ANALOG)
RED BLACK
YEL YEL RX1 0 20 - 0
0.20 0.30
30
NOTE: If using DMT 2000 turn the selector switch to . Allow the meter to auto-range.
Suppression Diode Tests
The suppression diode is located between the brown start solenoid lead, the yellow/red key
switch lead (within the engine harness) and connects to engine ground. The purpose of the
suppression diode is to eliminate the inductive spike created as the start solenoid is de-ener-
gized (key switch turned from START to RUN).
Symptoms of a failed suppression diode:
1. Open circuit - Longer crank times during engine start-up (3 seconds warm engine).
2. Short circuit - Blown fuse #3 (Main Power Relay/Accessory).
BLK
BRN YEL/RED
DIODE TEST
BLK RED YEL/RED BRN BLK
YEL/RED X 0V or SHORT 0.4 - 0.8V
BRN 0V or SHORT X 0.4 - 0.8V
BLK OUCH, OL, ∞ OUCH, OL, ∞ X
RESISTANCE TEST
BLK RED YEL/RED BRN BLK
YEL/RED X < 0.5 1 - 3M
GRY
YEL
YEL
RED
DIODE TEST:
1. Set Ohm meter to R X 10 scale.
2. Connect Red (+) meter lead to RED regulator lead.
3. Connect Black (–) meter lead to either YELLOW regulator lead.
TEST RESULTS:
100 - 400 OHMS
DIODE TEST:
1. Set Ohm meter to R X 1k scale.
2. Connect Black (–) meter lead to RED regulator lead.
3. Connect Red (+) meter lead to YELLOW regulator lead. Test. Then change Red (+) me-
ter lead to the other YELLOW regulator lead for 2ND test reading.
TEST RESULTS (1ST READING):
20,000 to ∞ OHMS
TEST RESULTS (2ND READING):
∞ OHMS (No needle movement)
SCR TEST:
1. Set Ohm meter to R X 1k scale.
2. Connect Red (+) meter lead to regulator case.
3. Connect Black (–) meter lead to one YELLOW regulator lead. Test. Connect Black (–)
meter lead to the other YELLOW lead.
TEST RESULTS (BOTH TESTS):
8,000 - 15,000 OHMS (8k - 15K)
DIGITAL METER
NOTE: Voltage regulator/rectifier specifications are given for informational purposes only.
Use the appropriate troubleshooting techniques previously mentioned to find the faulty
component in the charging system.
BLK = Black
BLK GRY = Gray
RED = Red
YEL = Yellow
GRY
YEL
YEL
RED
DIODE TEST:
1. Set meter to .
2. Connect Black (–) meter lead to RED regulator lead.
3. Connect Red (+) meter lead to either YELLOW regulator lead.
TEST RESULTS:
0.4-0.8 V
DIODE TEST:
1. Set meter to .
2. Connect Red (+) meter lead to RED regulator lead.
3. Connect Black (–) meter lead to either YELLOW regulator lead.
TEST RESULTS (1ST READING):
∞ or OUCH or OL
SCR TEST:
1. Set meter to .
2. Connect Black (–) meter lead to regulator case.
3. Connect Red (+) meter lead to either YELLOW regulator lead.
TEST RESULTS (BOTH TESTS):
1.5 V - ∞ or OUCH or OL
Flywheel Removal/Installation
WARNING
Engine could possibly start when turning flywheel during removal and installation.
To prevent this type of accidental engine starting and possible serious injury, al-
ways remove spark plug leads from spark plugs.
Removal
1. Remove flywheel cover.
a - Flywheel Cover
b - Screw (4) M6 x 25
c
d
91-83163M
c
b
91-83164M
58815 58227
Installation
1. Place flywheel key into slot.
2. Install flywheel. Apply oil to threads on crankshaft.
3. Install washer and nut.
4. Hold flywheel using flywheel holder (91-83163M) and tighten nut to the specified torque.
d
110
c
a
b
91-83163M
58227
a - Key
b - Flywheel
c - Washer
d - Nut
e - Torque Wrench with 30mm socket
f - Flywheel Holder (91-83163M)
Stator Removal/Installation
NOTE: Remove flywheel as outlined in “Flywheel Removal and Installation” section of ser-
vice manual.
1. Disconnect stator wires. The 2 pin connector disconnects from voltage regulator.
2. Remove stator mounting screws.
3. Reverse steps for installation (refer to wiring diagram in Section 8 for correct stator wire
connections).
NOTE: Apply Loctite 222 to threads of stator mounting screws.
b
b
51
a - Voltage Regulator/Rectifier
b - Screw (2) M6 x 40
c - Connectors
CAUTION
The starter motor may be damaged if operated continuously. DO NOT operate con-
tinuously for more than 30 seconds. Allow a 2 minute cooling period between start-
ing attempts.
b
a - BROWN Lead
b - Starter Solenoid
c - BLACK Lead
d - Battery
YEL/RED
BRN
6
RED
BLK
BLK
STARTER
3
YEL/RED
RED/PUR
BLK
(with
RED SLEEVES) DIODE
BLK STARTER
(with SOLENOID
NEUTRAL
BLK
YEL SLEEVES)
1 START
SWITCH
7
4
5
2
BLK = Black
BLU = Blue
BRN = Brown
GRY = Gray
GRN = Green + – BLK
ORN = Orange IGNITION SWITCH
PNK = Pink
PUR = Purple BATTERY
RED = Red
TAN = Tan
WHT = White
YEL = Yellow
TEST 1
Use an ohmmeter (R x 1 scale) and connect meter leads be-
tween NEGATIVE (-) battery post and common powerhead
ground.
* Battery Voltage
TEST 2
a. Disconnect BLACK ground wire(s) from Test Point 2.
b. Connect voltmeter between common engine ground and Test Point 2.
No voltage reading; c. Turn ignition key to “Start” position.
proceed to TEST 3.
TEST 4
a. Connect voltmeter between common 12 Volt Reading*
engine ground and Test Point 4. Neutral start switch is open, or BROWN, or
No voltage reading; b. Turn ignition key to “Start” position. YEL/RED, or BLACK wire is open between
proceed to TEST 5. Test Points 4 and 3. Check diode adaptor if
equipped.
TEST 5
Connect voltmeter between common 12 Volt Reading*
No voltage reading; engine ground and Test Point 5. Defective ignition switch.
proceed to TEST 6.
TEST 6
Connect voltmeter between common engine ground and Test Point 6.
TEST 7
a. Connect voltmeter between common engine ground and Test Point 1.
b. Turn ignition key to “Start” position.
TEST 8
a. Reconnect BLACK (with YELLOW sleeve) (starter motor) cable to starter
solenoid Test Point 1.
b. Connect voltmeter between common engine ground and Test Point 7
c. Turn ignition key to “Start” position.
a 58813
Disassembly
1. Remove 2 thru bolts and commutator end cap, taking care not to lose brush springs.
a c
a c
b
a - Thru Bolts
b - Commutator End Cap
c - Brush Springs
2. Remove the nut, washer, spring, pinion stopper and pinion drive assembly. You may
need to lightly clamp the armature in a vise while removing the nut.
NOTE: DISPOSE OF NUT AFTER REMOVING IT AND USE A NEW ONE FOR REAS-
SEMBLY.
e
c
b
c d
58223
a - Nut d - Spring
b - Washer e - Pinion
c - Pinion Stopper
f g h
d c d
a b e
a - Nut e - Pinion
b - Washer f - Drive End Cap
c - Spring g - Armature Shaft
d - Pinion Stopper (2) h - Washer
CAUTION
Do not turn down the commutator excessively.
a. Re-surface the commutator and undercut the insulation between the commutator
bars 1/3 in. (0.8mm) to the full width of the insulation, make sure that the undercut
is flat.
b. Clean the commutator slots after undercutting.
c. De-burr the commutator lightly with No. 00 sandpaper, then clean the commutator.
d. Check the armature on a growler for shorts. See “TESTING”, following.
9. Open-circuited armatures often can be saved where an open circuit is obvious and re-
pairable. The most likely place for an open circuit is at the commutator bars. Long crank-
ing periods overheat the starter motor so that solder in the connections melts. The poor
connections cause arcing and burning of the commutator bars.
10. Repair bars, that are not too badly burned, by re-soldering the leads in bars (using rosin
flux solder) and turning down the commutator in a lathe to remove burned material, then
undercut the mica.
11. Clean out the copper or brush dust from slots between the commutator bars.
12. Check the armature for shorts and ground. See “TESTING”.
Testing
ARMATURE TEST FOR SHORTS
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. Re-
check after cleaning between commutator bars. If saw blade still vibrates, replace armature.
11673
a - Positive Brushes
b
a
Brush Replacement
IMPORTANT: Replace brushes that are pitted or worn to less than 1/4 in. (6.4mm) in
length.
e
c
f
g
b
a
a c b
b a
Reassembly
1. Lubricate helix threads and drive end cap bushing with SAE 10W oil.
2. Install the pinion, pinion stopper, spring, second pinion stopper, washer, and NEW nut
onto armature shaft.
3. Lightly clamp the armature in a vise and torque nut to specified torque.
f g h
d c d
a e
b
a - Nut
b - Washer
c - Spring
d - Pinion Stopper (2)
e - Pinion
f - Drive End Cap
g - Armature Shaft
h - Washer
Starter Shaft Nut Torque
22.5 lb.-ft. (30.5 N·m)
5. Place springs and brushes into brush holder and hold in place with brush retainer tool.
6. Lubricate bushing with one drop of SAE 10W oil. DO NOT over-lubricate.
7. Position armature into starter frame so that commutator end of armature is at end of
starter frame where permanent magnets are recessed 1 in. (25.4mm). Align marks (a)
as shown.
8. Install commutator end cap onto starter frame; align marks (b) as shown, and remove
brush retainer tool.
9. Install thru bolts (c) and torque to 70 lbs. in. (7.9 N·m).
c
c
Installation
1. Secure starter to block with (3) mounting screws. Tighten screws to specified torque.
Secure starter motor lead as shown.
a
a 58813
ELECTRICAL
Section 2C - Timing, Synchronizing, & Adjusting
Table of Contents
2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-2 Maximum Throttle . . . . . . . . . . . . . . . . . . . . 2C-6
C
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-3 Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-7
Throttle Link Setting . . . . . . . . . . . . . . . . . . . . . 2C-5 Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-8
Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-5 Throttle Position Sensor (TPS) . . . . . . . . . . . . 2C-8
Specifications
Type Capacitor Discharge Ignition
Spark Plug:
Type Champion RA8HC
Gap 0.040 in. (1.0 mm)
Hex Size 5/8 in. (16 mm)
Torque 150 lb-in. (17 Nm)
Hole Size 12 mm
Firing Order 1-3-4-2
Ignition Timing:
@Idle Controlled by ECM
@1500-1800 14° B.T.D.C
@ WOT (6000 rpm) 28° B.T.D.C
Stator Resistance 0.20 - 0.30 Ω (YEL-YEL)
Crank Position Sensor (CPS)
Resistance 300 - 350 Ω (RED - WHT)
Ignition Coil Resistance:
Internal Shielding 0 - 10.0 KΩ (Pin A - Mounting Bracket)
Electronic Spark Trigger (EST) 8.5 - 12KΩ (Pin B - Pin C)
Secondary 3.0 - 7.0 kΩ (Pin A - Coil Tower)
IGNITION High Tension Lead/Boot
SYSTEM Resistance 0.600 - 1.100 KΩ
Readings taken @ ECM Engine Speed Limiter
68°F (20°C). Fuel/Spark Cut-out on Cylinders
#2 and #3 6225 rpm
Fuel/Spark Cut-out on All
Cylinders 6350 rpm
ECM Overheat Speed Control Guardian System is activated. Power
limit will vary with level of overheat.
ECM Low Oil Pressure Speed Control Guardian System is activated. Engine
power is limited to 10% of maximum
(Approximately 2000 RPM)
MAT/ECT Temperature Sensor See Graph Section 3B - EFI
Manifold Absolute Pressure (MAP)
Sensor Resistance See Table Section 3B - EFI
Fuel Injector Resistance 10.0 - 13.5Ω
Main Power Relay 81-99 Ω (Pin 85 - Pin 86)
Idle Air Control (IAC) 24-30 Ω (Between Pins)
Throttle Position Sensor Typical
Range
Output Voltage @Idle 0.39-1.00 Volts
Output Voltage @WOT (6000) 3.66-4.80 Volts
NOTE: The 50/60 EFI (4-stroke) ECM unit electronically controls the ignition timing,
therefore making the ignition timing non–adjustable. When initially running the
outboard, use a timing light to verify that the ignition timing falls within the timing windows
(as outlined in this section).
Special Tools
1. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1
91-880118--2
90-881204--2
c e
f g
h
d
a
b
g
Maximum Throttle
1. With throttle cable(s) attached, advance throttle (remote control handle or throttle twist
grip) to wide open throttle position.
2. Throttle stop should lightly contact adjoining surface. To ensure the throttle shutter is
fully open, back the throttle stop screw out until there is a gap between the throttle stop
screw and adjoining surface (at WOT position). Keep turning the throttle stop screw “in”
until the throttle stop lightly contacts the adjoining surface.
a - Throttle Lever
b - Throttle Stop Screw
c - Throttle Stop
Timing
WARNING
To prevent personal injury or possible death, from loss of balance or stability while
servicing the motor, DO NOT attempt to check timing while boat is in motion. Failure
to follow one of the recommended servicing procedures may result in the person
falling overboard or causing personal injury from fall in boat.
WARNING
To prevent personal injury from spinning flywheel, Do Not attempt to remove fly-
wheel cover or place hands on top of cover when checking ignition timing.
Ignition timing is not adjustable. The Electronic Control Module unit electronically controls
the ignition timing.
When initially running the outboard, use a timing light to verify that the ignition timing falls
within the timing windows as described within the following tests.
IMPORTANT: When checking the timing with the engine running, one of the following
test procedures must be followed.
Check maximum timing per specification while running the outboard:
•IN A TEST TANK
•ON A DYNAMOMETER
•ON A BOAT SECURED ON A TRAILER “Backed in Water”
1. Attach timing light to #1 spark plug lead.
2 a
3 c
NOTE: Idle timing is controlled by the ECM and will vary for idle speed control. Checking
the ignition timing marks using a timing light will not be stable until 1500-1800 rpm.
2. Start the engine and place the outboard in “Forward” gear. Check timing at 1500 - 1800
rpm, timing should be 14° BTDC. If timing is not within specification refer to section 3B
EFI Troubleshooting and Diagnostics.
a
14 BTDC
15
a
28° BTDC
Idle Speed
Engine idle speed is maintained by the ECM and is therefore not adjustable. The parame-
ters affecting idle speed can be checked and monitored using the Digital Diagnostic Termi-
nal (DDT). Refer to section 3B - EFI Troubleshooting and Diagnostics.
Table of Contents
Electronic Fuel Injection System . . . . . . . . . . . 3A-2 Manifold Air Temperature (MAT) Sensor . 3A-7
Air Induction System . . . . . . . . . . . . . . . . . . 3A-2 Throttle Position Sensor (TPS) . . . . . . . . . 3A-8
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System Components . . . . . . . . . . . . . . . .
3A-3
3A-4
Oil Pressure Switch . . . . . . . . . . . . . . . . . . .
Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3A-8
3A-9
3
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-4 Idle Air Control (IAC) . . . . . . . . . . . . . . . . . . 3A-9 A
Vapor Separator . . . . . . . . . . . . . . . . . . . . . . 3A-5 Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . 3A-9
Fuel Pressure Regulator . . . . . . . . . . . . . . 3A-6 Main Power Relay . . . . . . . . . . . . . . . . . . . . . . . 3A-10
Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-6 Fuse Holder Assembly . . . . . . . . . . . . . . . . . . . 3A-10
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-7 Suppression Diode . . . . . . . . . . . . . . . . . . . . . . 3A-11
Crank Position Sensor (CPS) . . . . . . . . . . 3A-7 Electronic Control Module . . . . . . . . . . . . . . . . 3A-11
Engine Coolant Temperature Electronic Control Module Functions . . . . 3A-12
(ECT) Sensor . . . . . . . . . . . . . . . . . . . . . . . 3A-7 Outline of Control System . . . . . . . . . . . . . 3A-13
Manifold Absolute Pressure Control and Function . . . . . . . . . . . . . . . . . . 3A-14
(MAP) Sensor . . . . . . . . . . . . . . . . . . . . . . . 3A-7
f c
a - Intake Manifold
b - Throttle Body/Shutter
c - Throttle Position Sensor (TPS)
d - Idle Air Control (IAC)
e - Manifold Absolute Pressure (MAP) Sensor
f - Manifold Air Temperature (MAT) Sensor
Fuel System
The fuel system consists of a fuel line connector, a water separating fuel filter, a low-pres-
sure mechanical fuel pump, a high-pressure electric fuel pump, a fuel distribution manifold,
fuel injectors, a fuel cooler and a fuel pressure regulator. The low-pressure mechanical fuel
pump draws fuel from the fuel tank, through the fuel line connector and fuel filter, then deliv-
ers it to the high-pressure fuel pump within the vapor separator tank. High-pressure fuel is
circulated through the fuel cooler and supplied to the fuel distribution manifold and fuel in-
jectors to be sprayed into the intake manifold. Fuel not used by the fuel injectors (fuel not
entering the high-pressure fuel line to the fuel distribution manifold) circulates through the
fuel cooler, then flows through pressure regulator, and returns to the vapor separator tank.
h f
a e
c
b
d
a - Fuel From Filter/Tank
b - Fuel Outlet to VST
c - Water Inlet From VST Fuel Cooler
d - Water Outlet to Tell-tale
Vapor Separator
The vapor separator maintains a liquid fuel supply for the high pressure fuel pump located
in the vapor separator tank. Fuel delivered from the mechanical low-pressure fuel pump is
supplied to the top of the vapor separator and is controlled by the inlet needle/float assem-
bly. Pressurized fuel from the high-pressure pump circulates through the fuel cooler, to the
fuel distribution manifold and injectors. Excess fuel flows through the pressure regulator
back to the vapor separator tank.
e a
a
e
d b
d
c
f f
c
a - Vent to Atmosphere
b - High Pressure Fuel From Fuel Cooler
c - Excess Fuel Flows to VST
Fuel Cooler
A fuel cooler (heat exchanger) is attached to the vapor separator, and uses engine cooling
water to cool the high-pressure fuel supply to the fuel injectors as well as a return circuit to
the VST. Removing heat from the circulating high-pressure fuel prevents the formation of
fuel vapors.
Sensors
Sensors send input signals to the ECM regarding engine operating conditions.
Actuators
Actuators receive input signals from the ECM and perform functions, which control air-fuel
ratios, spark advance, and idle rpm.
Fuel Injector
The fuel injector is an electrically operated spring-loaded solenoid, which delivers a me-
tered amount of fuel into the intake manifold runner, just ahead of the intake valve. The
injectors are electrically charged as the key switch is set to the “RUN” position. The ECM
controls the injection by completing the ground circuit, lifting the solenoid, which allows
high-pressure fuel to flow. The ECM then opens the ground circuit allowing the spring to
close the injector and stop the fuel flow.
5
1 3
15
2 4
Suppression Diode
The suppression diode is located between the brown start solenoid lead and the yellow/red
key switch lead (within the engine harness), and connects to the engine ground. The pur-
pose of the suppression diode is to eliminate the inductive spike created as the start sole-
noid is de-energized (key switch turned from START to RUN).
The ECM requires 6 volts DC to operate. If the ECM should fail, the engine will stop run-
ning.
The inputs to the ECM can be monitored and tested by the Digital Diagnostic Terminal P/N
91-823686A2 and adapter harness 84-822560A5.
The ECM performs the following functions:
1. Calculates the precise fuel and ignition timing requirements based on engine speed,
throttle position, manifold pressure, manifold air temperature and engine coolant tem-
perature
2. Directly controls the ground circuit of fuel injectors, ignition coils, and idle air control
3. Indirectly controls the positive circuit of fuel injectors, ignition coils, and idle air control
through the main relay
4. Controls alarm horn and warning functions
5. Controls RPM limit function
6. Records engine running information
Throttle Position
Fuel Injectors
Sensor (TPS)
Ignition Timing 0 Engine load / Engine speed map Manifold Absolute Pressure (MAP) Sensor
Control Crank Position Sensor (CPS)
Manifold Air Temperature (MAT) Sensor
0 Ignition cutoff for decreased engine speed Crank Position Sensor (CPS)
Engine Coolant Temperature (ECT) Sensor
Oil Pressure Switch
ECM Sensors
Fuel system 0 Engine load / Engine speed map Manifold Absolute Pressure (MAP) Sensor
Manifold Air Temperature (MAT) Sensor
0 Fuel cutoff for decreased engine speed Crank Position Sensor (CPS)
Oil Pressure Switch
Engine Coolant Temperature (ECT) Sensor
Battery Voltage
0 Over-revolution prevention Crank Position Sensor (CPS)
ECM Sensors
IAC Control 0 Engine speed Crank Position Sensor (CPS)
Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . 3B-1 Troubleshooting Without the Digital
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-2 Diagnostic Terminal . . . . . . . . . . . . . . . . . . 3B-11
EFI System Diagnostic Procedures . . . . . . . .
Pressure Regulator Test . . . . . . . . . . . . . . .
3B-4
3B-4
Guardian Protection System . . . . . . . . . . . 3B-11
EFI System Troubleshooting Guide . . . . . . . . 3B-13
3
Mechanical Fuel Pump Test . . . . . . . . . . . . . . 3B-5 Component Resistance Tests . . . . . . . . . . . . . 3B-17 B
Checking for Restricted Fuel Flow Engine Coolant Temperature (ECT) Sensor
Caused by Anti-Siphon Valves . . . . . . . . . 3B-5 Manifold Air Temperature (MAT) Sensor . 3B-17
Vacuum (Lift) Test . . . . . . . . . . . . . . . . . . . . 3B-5 Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . 3B-18
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . 3B-8 Main Power Relay . . . . . . . . . . . . . . . . . . . . 3B-18
EFI System Troubleshooting . . . . . . . . . . . . . . 3B-10 Manifold Absolute Pressure
Using the Digital Diagnostical (MAP) Sensor . . . . . . . . . . . . . . . . . . . . . . . 3B-19
Terminal (DDT) . . . . . . . . . . . . . . . . . . . . . . 3B-10 Crank Position Sensor (CPS) . . . . . . . . . . 3B-19
Special Tools
1. Fuel Pressure Gauge 91-16850A7 or Fuel Pressure Gauge 91-852087A3.
91-16850A7
3. Cartridge 91-880118--2
b
91-16850A7
58821
7. To isolate the mechanical fuel pump from the rest of the fuel system:
a. Pinch off/restrict the fuel supply hose between the vacuum gauge and the fuel tank.
b. The mechanical fuel pump vacuum (lift) should be to specifications.
c. If vacuum reading for the pump is below specifications, the pump needs rebuilding.
d
a
b
57859
a - Extra Hose - To Inlet Fitting of Mechanical Fuel Pump
b - “TEE”-fitting
c - Vacuum Gauge
d - Fuel Supply Hose - From Fuel Tank
Pressure Test
Fuel system pressure/trouble shooting can be performed using piece of clear fuel hose 4
in. (10 cm) long, a pressure gauge, and a “TEE” fitting.
1. Conduct test with water to the engine cooling system using one of the following methods:
• In a test tank
• With boat/outboard lower unit in water
2. Disconnect fuel hose from outlet fitting of mechanical fuel pump.
3. Connect clear fuel hose onto the inlet fitting of pump.
4. Install “TEE” fitting onto clear fuel hose.
5. Connect pressure gauge and fuel outlet hose (to VST) onto “TEE” fitting.
6. Start engine and run at 1000 RPM, normal fuel system pressure should be to specifica-
tions.
7. To isolate the mechanical fuel pump from the rest of the fuel system:
a. Pinch off/restrict the fuel hose between the “TEE” fitting and the VST.
b. The mechanical fuel pump pressure should be to specifications.
c. If pressure reading for the pump is below specifications, the pump needs rebuild-
ing.
b a
NOTE: * Air bubbles may also be visible as fuel passes through the clear fuel (test) hose
installed between the mechanical fuel pump outlet fitting and the VST.
a c
d
b
The Quicksilver Digital Diagnostic Terminal (DDT) has been developed specifically to help
technicians diagnose and repair Mercury Marine 2 and 4 cycle engines.
Attach the diagnostic cable to the ECM diagnostic connector and plug in the software car-
tridge. You will be able to monitor sensors and ECM data values including status switches.
The ECM program can help diagnose intermittent engine problems. It will record the state
of the engine sensors and switches for a period of time and then can be played back to
review the recorded information.
Refer to the Digital Diagnostic Terminal Reference Manual for complete diagnostic proce-
dures.
IMPORTANT: In all instances check wiring harness integrity (especially ground connections) in boat and
on engine.
Condition Cause/Fault Warning Check
Mode
Engine cranks, Remote control to engine None Clean and inspect male and female
starts and stalls wiring harness connection is connections.
poor
Air in fuel system/lines None Crank and start engine several times.
Manifold Absolute Pressure 6 Beeps at See MAP sensor resistance chart -
(MAP) sensor key up or Section 3B “ELECTRONIC FUEL
failure INJECTION”.
Throttle Position Sensor 6 Beeps at Typical TPI range with DDT:
(TPS) key up or Idle 0.39-1.0 volts, WOT 3.66-4.80 volts.
failure
Idle Air Control (IAC) 3 Beeps 20 - 24 ohms
every 4 Between pin #20 (WHT/ORG) and pin
minutes #23 (RED/BLU) of starboard ECM con-
nector.
- or -
Between pin A and pin B of IAC.
ECM reference voltage to Intermittent 5 volts
MAP/TPS Beeps Between PUR/YEL pin of MAP sensor
wiring harness connector and engine
ground (key switch to “RUN”).
Fuel pressure at VST fitting None See fuel pressure test - Section 3B
“ELECTRONIC FUEL INJECTION”.
Flywheel misaligned None Remove flywheel and inspect flywheel key
and key way
Engine Idles Engine Coolant Temperature 3 Beeps See ECT sensor resistance chart -
Fast after warm- (ECT) sensor every 4 Section 3B “ELECTRONIC FUEL
up minutes INJECTION”.
(900-1100rpm)
Poor off idle or Fuel injector 3 Beeps 10.0 - 13.5 ohms
WOT running every 4 Between fuel injector pin #1 and pin #2.
quality minutes
- or -
Between (removed) fuse #2 (RED/BLU)
wire and port ECM connector:
Pin #17 (PNK/BRN) Fuel Injector #1
Pin #2 (PNK/RED) Fuel Injector #2
Pin #1 (PNK/ORG) Fuel Injector #3
Pin #18 (PNK/YEL) Fuel Injector #4
Ignition coil (EST) *** 3 Beeps See ignition coil resistance chart -
every 4 Section 2A “IGNITION”
minutes
Fuel pressure at VST fitting None See fuel pressure test - Section 3B
“ELECTRONIC FUEL INJECTION”.
Fuel filter plugged None Replace fuel filter
Improper spark plugs None Use recommended resistive spark plugs
Loose grounds None Check all ground connections.
Flywheel timing tooth pattern None Check tooth pattern for partially missing
or damaged teeth
Fouled spark plug(s) None Replace spark plug(s).
IMPORTANT: In all instances check wiring harness integrity (especially ground connections) in boat and
on engine.
Condition Cause/Fault Warning Check
Mode
Poor idle quality Crank Position Sensor None 300 - 350 ohms
(CPS) Between pin #5 (RED) and pin #6 (WHT)
of starboard ECM connector.
- or -
Between pin #1 (RED) and pin #2 (WHT)
of CPS connector.
Manifold Absolute Pressure 6 Beeps at See MAP sensor resistance chart -
(MAP) sensor key up or Section 3B “ELECTRONIC FUEL
failure INJECTION”.
Throttle Position Sensor 6 Beeps at Typical TPI range with DDT:
(TPS) key up or Idle 0.39-1.0 volts, WOT 3.66-4.80 volts.
failure
Engine Coolant Temperature 3 Beeps See ECT sensor resistance chart -
(ECT) sensor every 4 Section 3B “ELECTRONIC FUEL
minutes INJECTION”.
IMPORTANT: In all instances check wiring harness integrity (especially ground connections) in boat and
on engine.
Condition Cause/Fault Warning Check
Mode
Engine runs rich Fuel pressure regulator None 42 - 44 psi (290 – 303 kPa) at VST fitting
- Section 3B “ELECTRONIC FUEL
INJECTION”
Engine Coolant Temperature 3 Beeps See ECT sensor resistance chart -
(ECT) Sensor every 4 Section 3B Electronic Fuel Injection
minutes
Thermostat stuck open None Remove and inspect thermostat.
Section 4A “CYLINDER HEAD”
Speed Reduction Low oil pressure or GUARDIAN Check engine oil level and add oil as
Engine RPM grounded oil pressure switch Continuous needed.
Limited to 2000 lead Horn Above Remove oil pressure switch and install oil
10% Power pressure gauge, (warm engine) oil pres-
Setting sure should be:
Above 2.9 psi (20.0 kPa) at idle
30-40 psi. (207-278 kPa) at 3000 rpm.
See Oil Pressure Switch test -
Section 4B “Cylinder Block/Crankcase”.
Check for short between pin #7 (BLU) of
starboard ECM connector and open
connector of oil pressure switch.
Speed Reduction Engine Overheat GUARDIAN Engine Guardian System is activated.
Engine RPM Continuous Power limit will vary with level of overheat.
Limited Stop engine and check water intake for
obstruction.
Advancing throttle above idle may provide
additional cooling.
Battery Voltage GUARDIAN Engine Guardian System is activated.
Less Than 10v or More Continuous Engine power is limited to 75% of maxi-
Than 16v Horn Above mum.
75% Power
Setting
Engine Coolant Temperature GUARDIAN Engine Guardian System is activated.
(ECT) Sensor Failure Continuous Engine power is limited to 50% of maxi-
Horn Above mum. Engine overheat protection is com-
50% Power promised
Setting
270
255
240
Test Water Temperature ( F)
225
210
195
Temperature Sensor
180
165
150
135
120
105
90
75
60
45
30
15
0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32
Resistance (k)
Fuel Injector
b a
85 86
c a
a - Black/Orange
b - Yellow
c - Purple/Yellow
METER TEST LEADS METER SCALE READING
(ANALOG) (
RED BLACK
PIN A PIN B
95 - 105 K
PIN A PIN C RX1K 3.9 - 4.3 K
PIN B PIN C 95 - 105 K
Specifications
Fuel Pump Type Mechanical Water Cooled
(Plunger/Diaphragm)
FUEL
Fuel Pump:
SYSTEM
Pressure 3-6 psi
Fuel Tank Capacity Accessory
Fuel Injector System Batch (1 & 4) - (2 & 3)
Idle rpm (Out Of Gear) 725 ± 25 rpm
Idle rpm (In Forward Gear) 725 ± 25 rpm
FUEL INJECTION
Wide Open Throttle rpm (WOT)
Range 5500–6000
Fuel Pump Pressure - Electric 42-44 psi (290-303 kPa)
Special Tools
1. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1.
58816
57316
91-16850A7
INTAKE MANIFOLD
26
24
66 26
27
22
1 28
2 18
17
26
19 16 21
20
14
15
5
13
66
25 12 23
3 4
6
7
11
8
10
66 Loctite 242 (92-809821)
INTAKE MANIFOLD
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
1 1 INTAKE MANIFOLD
2 4 GASKET
3 1 SCREW 31 3.5
4 1 BRACKET
5 1 NUT 75 8.5
6 1 IDLE AIR CONTROL (IAC)
7 1 FUEL DISTRIBUTION MANIFOLD
8 4 INJECTOR
9 2 SCREW 31 3.5
10 4 SCREW 31 3.5
11 4 CLIP
12 1 HOSE
13 1 THROTTLE BODY
14 1 GASKET
15 2 SCREW 31 3.5
16 1 THROTTLE POSITION SENSOR (TPS)
17 2 SCREW 18 2
18 1 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
19 1 MANIFOLD AIR TEMPERATURE (MAT) SENSOR 12.5 1.4
20 1 O RING
21 1 SOUND ATTENUATOR
22 8 SCREW (M6 X 25) 75 8.5
1 RESTRICTOR (50)
23
1 RESTRICTOR (40)
24 1 BREATHER HOSE
25 1 SCREW (M6 X 30) 75 8.5
26 3 STA-STRAP
27 1 SCREW (10-16 X .625) Drive Tight
28 1 RETAINER
12 9
13 2
3 2
4 1
9 14 22
15
6 11
11
8
7
17 21
20 16
5 24
9 10 23
19
9
26
12
66 12
25 18
33
27
29
41
40 28
43
33 44 66
46
34
9
32 45
38
39
30
35
9
37
36 31
12 9
13 2
3 2
4 1
9 14 22
15
6 11
11
8
7
17 21
20 16
5 24
9 10 23
19
9
26
12
66 12
25 18
33
27
29
41
40 28
43
33 44 66
46
34
9
32 45
38
39
30
35
9
37
36 31
FUEL PUMP
21
20 22
23 19
13 A
B
24 13
18
15 10
25
11
13
14
13
8
13
17
13 9
13
1 2
16 13
12
C
A = TO VAPOR SEPARATOR COVER
B = TO VST COOLER
C = TO TELL TALE
3
3
4
3
5
3 3
66
1
3
6
7
3
66 Loctite 242 (92-809821)
FUEL PUMP
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
1 1 FUEL PUMP
2 4 SCREW
3 1 DIAPHRAGM/O-RING KIT
4 1 SPRING
5 4 NUT
6 1 SPRING
7 1 CAP
8 1 COWL DEFLECTOR
9 2 SCREW (M6 X 30) 75 8.5
10 1 TUBING (34 IN.)
11 1 TUBING (19 IN.)
12 1 TUBING (6 IN.)
13 AR STA STRAP
14 1 TUBING (8 IN.)
15 1 FUEL FILTER
16 1 TUBING (38 IN.)
17 1 FUEL CONNECTOR
18 1 BUSHING
19 1 GROMMET
20 1 WASHER
21 1 NUT (M6) 45 5.1
22 1 BRACKET
23 2 SCREW (M6 X 13) 75 8.5
24 1 CONDUIT (13 IN.)
25 1 CONDUIT (26 IN.)
FUEL LINES
FUEL LINES
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
1 1 CONDUIT (24 IN.)
2 1 FUEL LINE
3 1 FUEL FILTER
4 1 PROTECTIVE SLEEVE
5 1 FUEL LINE
Torque Sequence
3
4
1
2
5
6
b
91-16850A7
58821
a - Fuel Pressure Gauge
b - Pressure Relief Button
c - Drain Hose
Removal
4. Push in on the fuel injector harness connector retaining clip and unplug the harness
from each fuel injector. It is not necessary to remove the retaining clip from the connec-
tor.
5. Unplug the Idle Air Control (IAC) connector.
6. AFTER RELIEVING PRESSURE disconnect the high pressure fuel line from the fuel
distribution manifold by depressing the locking tab and pulling back on the fuel line.
7. Remove the flywheel cover.
f
g
e
b
d
c
58860
58817
a c
b
b d 58811
d
a
f
e
Installation
1. Install intake manifold assembly to engine. Make sure O-rings are in place. Tighten
screws (in sequence shown) to specified torque.
3
b
4
66
1
2
66 a
5
6
7
58817
66 Loctite 242 (92-809821)
3. Connect the following sensors: Manifold Absolute Pressure (MAP), Manifold Air Tem-
perature (MAT) Sensor, and Throttle Position Sensor (TPS).
4. Install MAP sensor retaining clip and tighten screw to specified torque.
5. Install crankcase breather hose into sound attenuator. Secure with sta-strap.
d
a
f
e
g
a - Manifold Absolute Pressure (MAP) Sensor
b - MAP Sensor Retaining Clip
c - Screw (10-16 x .625)
d - Manifold Air Temperature (MAT) Sensor
e - Throttle Position Sensor (TPS)
f - Crankcase Breather Hose
g - Sound Attenuator
6. Connect the fuel line to the fuel distribution manifold. Push on until locked into place.
7. Route injector harness as shown and plug-in the fuel injector and IAC connectors.
8. Install flywheel cover. Tighten screws to specified torque.
f
g
c d
58860
a c
b
b d 58811
b
a
b c
a d
a - IAC Mounting Screw
b - IAC Harness Connector
c - Throttle Air Bypass Hose
d - Idle Air Control (IAC) Valve
IAC Mounting Screw Torque
31 lb-in (3.5 Nm)
Fuel Injectors
WARNING
Always release the fuel pressure in the high-pressure fuel line before servicing the
line or the vapor separator. If the fuel pressure is not released, pressurized fuel
may spray out.
Removal
1. Remove fuel injector cap retaining clips and screws.
2. Push in on the harness connector retaining clip and unplug the harness from each fuel
injector.
3. Using service tool 91-883877A1, pry injector cap from the injector.
4. Remove fuel injectors from intake manifold.
b
d
91-883877A1
a - Fuel Injector (4)
b - Fuel Injector Cap (4)
c - Fuel Injector Cap Retaining Clip (4)
d - Screw (4)
e - Harness Connector Retaining Clip (4)
Installation
1. Install fuel injector cap by pushing it on the fuel injector until it bottoms out.
2. Lubricate O-rings and install fuel injectors into intake manifold.
3. Install fuel injector cap retaining screws and tighten to specified torque. Install fuel in-
jector cap retaining clips so that the locking teeth line up with the locking rib on the fuel
injector (as shown).
4. Connect the harness connectors to each fuel injector. Push the connector on until the
retaining clip locks in place.
f
g h
58823
b d
a - MAP Sensor
b - Retaining Clip
c - Screw
f e
d
91-883877A1
Installation
1. Install fuel distribution manifold and tighten mounting screws to specified torque.
2. Push fuel injector cap onto the fuel injector until the cap bottoms out on the injector.
3. Install fuel injector cap retaining screws and tighten securely. Install fuel injector cap
retaining clips so that the locking teeth line up with the locking rib on the fuel injector
(as shown).
4. Connect high pressure fuel line. Push on until locking tab snaps in place.
f
g e
91-883877A1
CAUTION
Overtightening the manifold air temperature (MAT) sensor can lead to failing the
plastic threads. Be sure to tighten to the specified torque.
1. Lubricate O-ring and screw in air temperature sensor. Tighten to specified torque.
2. Connect MAT sensor connector.
3. Install the intake manifold assembly. Refer to Intake Manifold Assembly Installa-
tion.
b
c
b
a
ECM Removal/Installation
Removal
1. Remove ECM harness connectors.
2. Remove the ECM mounting screws and washers. Remove the ECM from the mounting
plate.
Installation
1. Install ECM onto mounting bracket (position the j-clip as shown). Install screws and
washers. Tighten screws to specified torque.
2. Connect ECM harness connectors.
b
e
a c
b
b d 58811
58228
CAUTION
Over-tightening the coolant temperature sensor can lead to failing the plastic
threads. Be sure to tighten to the specified torque.
b c
58225
a - Harness Connector
b - Temperature Sensor
c - Exhaust Cover
e
c
a
g f
d
58814
Installation
1. Secure fuel pump and cowl deflector to cylinder head cover with screws. Tighten to
specified torque.
2. Connect fuel lines to pump and secure with new sta-straps.
c
h
a b
66
e
a
e
c d
b
g f
58814
66 Loctite 242 (92-809821)
Disassembly
IMPORTANT: Before separating fuel pump components mark each component with
an awl or marker. This will ensure the components are oriented correctly during
reassembly.
1. Remove screws to separate pump cover, cover seal, diaphragm and valve body from
pump base.
a
h
b
c
d
e
f
g
28378
a - Screws (4) e - Valve Body
b - Pump Cover f - Pump Base
c - Cover Seal g - Nuts (4)
d - Diaphragm h - I.D. Marks (Create These)
a b
53615
a - Slots Offset
b - Slots Aligned
53617
a - Pin
Cleaning/Inspection/Repair
1. Inspect springs for damage, replace if necessary.
b a
a - Cover Seal
b - Diaphragm
a
58831
a - Check Valve/Seal Assembly (2)
INSTALLATION
1. Fabricate an installation tool to the dimensions specified.
2. Lubricate the end of the seal and push the assembly into the valve body.
NOTE: Drill into the handle using a 5/64 in. (2mm) drill bit. Insert the peg into the drilled
hole until 0.312 in. (8mm) remains exposed.
a
58831
a - Check Valve/Seal Assembly (2)
b - Installation Tool (make yourself)
c - Valve Body
Assembly
1. Assemble springs, diaphragm, and plunger onto pump base.
a - Diaphragm
b - Diaphragm Spring
c - Pump Body
d - Spring
e - Plunger
c
b
a - Pump Body
b - Slots
c - Pin
4. Rotate plunger 90° to offset slots.
a b
53615
a - Slots Aligned
b - Slots Offset
5. Assemble valve body, diaphragm, seal, and cover to pump base. Be sure to line up
I.D. marks that were made before disassembly. Apply Loctite 242 to screws and se-
cure with nuts.
NOTE: Seal installs in one direction only.
a
h
b
c
d
e
f
g
66
66 Loctite 242 (92-809821)
28378
a - Screws (4) e - Valve Body
b - Pump Cover f - Pump Base
c - Cover Seal g - Nuts (4)
d - Diaphragm h - I.D. Marks
6. Inspect O-ring and replace if necessary. Install onto fuel pump assembly.
53620
a - O-ring
a b
c
h
g
d
e a
b
f
58812
Installation
1. Tighten drain valve and install VST to engine. Tighten mounting screws to specified
torque.
2. Connect fuel and water hoses as shown below. Secure with sta-straps.
3. Plug in high pressure fuel pump harness connector.
c
h
i
66
g
d
e a
b
f
Disassembly
1. Remove fuel cooler mounting screw.
2. If removal of fuel cooler is required (because of damaged/plugged hoses or fuel cooler
replacement), cut metal hose clamps and remove fuel hoses from VST cover. Remove
fuel cooler.
3. Remove VST cover screws and remove cover assembly.
c
d
e
c
4. Disconnect high pressure fuel pump connectors and remove high pressure fuel pump.
5. Inspect and clean high pressure fuel pump screen.
a - Connectors
b - High Pressure Fuel Pump
c - Screen
6. Loosen float pin retaining screw and remove float assembly.
7. Remove baffle plate (if desired).
8. Remove and inspect seat.
9. Inspect and clean VST float chamber.
g a
e
c
d
f
b
i
h
a - Float Pin Retaining Screw
b - Float
c - Float Shaft
d - Clip
e - Needle
f - Baffle Plate
g - VST Float Chamber
h - Seat
i - Gasket
Assembly
1. Apply Loctite 242 to screws and install baffle plate (if removed). Tighten screws to spe-
cified torque.
2. Install seat (with new gasket) and tighten.
3. Install float assembly as shown. Install float pin and tighten retaining screw to specified
torque.
a
66
f
e
c
d
b
h
g
66 Loctite 242 (92-809821)
a - Float Pin Retaining Screw e - Needle
b - Float f - Baffle Plate Screw (3)
c - Float Shaft g - Seat
d - Clip h - Gasket
Screw Torque
22 lb. in. (2.5 N·m)
4. Connect the high pressure fuel pump connectors. Push the nozzle into the rubber
grommet (lubricate with light oil if necessary). Make sure the alignment pin is positioned
properly and lines up with hole in the high pressure fuel pump.
a
c
a - Connectors
b - High Pressure Fuel Pump
c - Alignment Pin
g
e
g
d
h
a
i
91-803146T
a - Grommet
b - Gasket
c - VST Float Chamber
d - High Pressure Fuel Pump
e - VST Cover Assembly
f - VST Cover Screws (5)
g - Metal Hose Clamp (4)
h - Fuel Cooler Mounting Screw(1) M4 x 20
i - Fuel Cooler
Screw Torque
32 lb. in. (3.5 N·m)
Removal
1. Release fuel pressure. Refer to Releasing Fuel Pressure in the High Pressure Fuel
Line.
2. Remove fuel pressure regulator mounting screws and remove regulator from VST cover.
Installation
1. Lubricate o-rings with light lubricant and reassemble the pressure regulator to the VST
cover (twist while pushing in).
2. Apply Loctite 242 to mounting screws and tighten to specified torque.
a
d
b
66
c
f
a
a - Locking Tab
b - Fuel Filter
c - Fuel Line (to VST fuel cooler)
d - Fuel Line (to fuel distribution manifold)
e - Protective Sleeve
f - Conduit
g - Conduit
OUTBOARD HYDROCARBON
EMISSIONS REDUCTIONS
120
100
80
60
40
20
0
96 97 98 99 2000 01 02 03 04 05 06 07 08
Stratified Charge
A stratified charge engine only pulls air through the transfer system. The fuel required for
combustion is forced into the cylinder through an injector placed in the top of the cylinder
(head). The injector sprays a fuel/air mixture in the form of a bubble into the cylinder. Sur-
rounding this bubble is air supplied by the transfer system. As the bubble is ignited and
burns, the surrounding air provides almost complete combustion before the exhaust port
opens.
A stratified charge is hard to ignite, the fuel/air bubble is not evenly mixed at 14.7:1 and
not easily ignited.
Emissions Information
Manufacturer’s Responsibility:
Beginning with 1998 model year engines, manufacturers of all marine propulsion engines
must determine the exhaust emission levels for each engine horsepower family and certify
these engines with the United States Environmental Protection Agency (EPA). A certifica-
tion decal/emissions control information label, showing emission levels and engine speci-
fications directly related to emissions, must be placed on each engine at the time of
manufacture.
Dealer Responsibility:
When performing service on all 1998 and later outboards that carry a certification, atten-
tion must be given to any adjustments that are made that affect emission levels.
Adjustments must be kept within published factory specifications.
Replacement or repair of any emission related component must be executed in a manner
that maintains emission levels within the prescribed certification standards.
Dealers are not to modify the engine in any manner that would alter the horsepower or
allow emission levels to exceed their predetermined factory specifications.
Exceptions include manufacturers prescribed changes, such as that for altitude adjust-
ments.
Owner Responsibility:
The owner/operator is required to have engine maintenance performed to maintain emis-
sion levels within prescribed certification standards.
The owner/operator is not to modify the engine in any manner that would alter the horse-
power or allow emissions levels to exceed their predetermined factory specifications.
Exceptions:
• Carburetor jets may be changed for high altitude use in accordance with factory
recommendations.
• Single engine exceptions may be allowed with permission from the EPA for racing
and testing.
CERTIFICATION LABEL:
The certification label must be placed on each engine at the time of manufacture and must
be replaced in the same location if damaged or removed. Shown below is a typical certifi-
cation label and is not representative of any one model. Label shown below is not to scale;
(shown at twice the normal size).
EMISSION CONTROL
INFORMATION
THIS ENGINE CONFORMS TO 2002 CALIFORNIA AND U.S. EPA
EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES
REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE.
i IDLE SPEED (IN GEAR): 725 ± 25 RPM FAMILY: 2M9XM.9952G0 a
h 50 HP 995 cc FEL: 17.3 g/kW-hr b
g
TIMING (IN DEGREES): NOT ADJUSTABLE c
a-Family Example
b-FEL: Represents (Mercury Marine) statement of the maximum emissions output
for the engine family
c-Timing specifications when adjustable
d-Recommended spark plug for best engine performance
e-Valve Clearance (Four Stroke engines only)
f-Date of Manufacture
g-Cubic Centimeter
h-Engine Horsepower rating
i-Idle Speed (In Gear)
1 M9X M. 995 2 G 0
0=Unspecified
Model Year Regulation 3=Ultra Clean California
1=2001 M=Marine Technology type
1=Existing Rated Eng.
2=New Application
Manufacturer
3=Sport Jet C=2 Stroke
Mercury Marine
Displacement E=EFI Sport Jet
Liter G=4 Stroke
Cubic Inch H=Hi-Perf.
J=Sport Jet
Decal Location
Model Service Part No. Location on Engine
2001 Merc/Mar 995 cc 37-804655AO1 Flywheel/Rewind Cover
2002 Merc/Mar 995 cc 37-804655AO2 Flywheel/Rewind Cover
EMISSION CONTROL
INFORMATION
THIS ENGINE CONFORMS TO 2002 CALIFORNIA AND U.S. EPA
EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES
REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE.
IDLE SPEED (IN GEAR): 725 ± 25 RPM FAMILY: 2M9XM.9952G0
50 HP 995 cc FEL: 17.3 g/kW-hr
TIMING (IN DEGREES): NOT ADJUSTABLE
Spark Plug: NGK DPR6EA-9
Gap: 1.0 mm (0.035″)
a
a-“V” Notch
b-Month of Manufacture
Installation
Install the label on a clean surface in the original factory location.
Decal Location:
Model Service Part No. Location on Engine
2001 Merc/Mar 995 cc 37-804655AO1 Flywheel/Rewind Cover
2001 Merc/Mar 995 cc 37-804655AO2 Flywheel/Rewind Cover
POWERHEAD
Section 4A - Cylinder Head
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2 Valve Removal . . . . . . . . . . . . . . . . . . . . . . . 4A-26
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-4 Rocker Shaft and Rocker Arm . . . . . . . . . . 4A-27
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-6 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-28
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-8 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . 4A-30
Intake/Exhaust Valves . . . . . . . . . . . . . . . . . . . 4A-10 Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . 4A-30
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . 4A-12 Valve Guide Replacement . . . . . . . . . . . . . 4A-31
Valve Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-13 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
4A-13
4A-15
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . .
Valve Seat Reconditioning . . . . . . . . . . . . .
4A-33
4A-35
4
Valve Clearance Adjustment . . . . . . . . . . . . . . 4A-18 Valve Refacing Steps . . . . . . . . . . . . . . . . . 4A-36 A
Adjusting Valves . . . . . . . . . . . . . . . . . . . . . 4A-18 Cylinder Head Reassembly . . . . . . . . . . . . . . . 4A-37
Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-21 Valve Installation . . . . . . . . . . . . . . . . . . . . . 4A-37
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-21 Camshaft Oil Seal Installation . . . . . . . . . . 4A-38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-22 Camshaft Installation . . . . . . . . . . . . . . . . . 4A-39
Cylinder Head Removal . . . . . . . . . . . . . . . . . . 4A-23 Oil Pump Installation . . . . . . . . . . . . . . . . . . 4A-40
Cylinder Head Disassembly . . . . . . . . . . . . . . 4A-24 Rocker Arm Shaft Assembly . . . . . . . . . . . 4A-41
Rocker Arm Assembly Removal . . . . . . . . 4A-24 Rocker Arm Shaft Installation . . . . . . . . . . 4A-41
Oil Pump Removal . . . . . . . . . . . . . . . . . . . 4A-24 Cylinder Head Gasket . . . . . . . . . . . . . . . . . 4A-42
Camshaft Removal . . . . . . . . . . . . . . . . . . . 4A-25 Cylinder Head Installation . . . . . . . . . . . . . . . . 4A-43
Specifications
Camshaft Dimensions
Intake “A” 1.214 - 1.222 in. (30.83 - 31.03 mm)
Exhaust “A” A 1.214 - 1.222 in. (30.83 - 31.03 mm)
Intake “B” 1.020 - 1.028 in. (25.90 - 26.10 mm)
Exhaust “B” 1.020 - 1.028 in. (25.90 - 26.10 mm)
CAMSHAFT
b
b
b
b
aa
VALVE SPRING
Special Tools
1. Flywheel Holder P/N 91-83163M
Notes:
CYLINDER HEAD
12
22 24
19 20
21
17
18
A
22
15 9
14
11
3 4 1
110
10
6
8
23
7
16
CYLINDER HEAD
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
– 1 CYLINDER HEAD
1 1 CYLINDER HEAD
2 8 GUIDE 70 7.9
3 4 SCREW 70 7.9
4 4 WASHER
5 1 OIL SEAL
6 8 PIPE PLUG 14.7 19.9
7 1 O RING
8 1 COVER
9 1 BREATHER PIPE
10 1 BAFFLE PLATE
11 4 SCREW (M4 X 10) Drive Tight
12 1 ELBOW Drive Tight
13 1 GASKET
14 7 SCREW (M6 X 20) 70 7.9
15 10 SCREW (M9 X 95) 34 46.1
16 2 DOWEL PIN
17 1 PLUG
18 1 O RING
19 1 DECAL - SERVICING REFERRAL
20 1 DECAL - ENGINE OIL/VALVE CLEARANCE
21 1 HOSE (19 IN.)
22 2 STA-STRAP
23 5 SCREW (M6 X 25) 8.8 12
24 1 DECAL - HP ID
CAMSHAFT
10
5
3
4
6
2
66
CAMSHAFT
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
1 1 CAMSHAFT
2 1 OIL PUMP ASSEMBLY
3 1 O RING
4 1 O RING
5 1 O RING
6 1 O RING
7 2 SCREW (M6 x 16) 70 8
8 4 SCREW (M6 x 40) 70 8
9 1 DOWEL PIN
10 1 PIN
INTAKE/EXHAUST VALVE
5 6
4
3 9
8
1
8 15
9
7
12
16
6 17
5
4 14
11
13
10
2
14
12
11
INTAKE/EXHAUST VALVES
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
1 4 EXHAUST VALVE
2 4 INTAKE VALVE
3 8 SEAL-Valve Stem
4 8 VALVE SPRING-Outer
5 8 RETAINER
6 16 KEY
7 8 ROCKER ARM
8 8 SCREW
9 8 NUT 120 13.5
10 1 ROCKER SHAFT
11 2 PLUG
12 2 BRACKET
13 1 BRACKET
14 2 SPRING
15 5 SCREW (M8 x 23) 160 18
16 1 GASKET
17 1 PIN-Cam Thrust
Torque Sequence
Torque center bolts in sequence and in two steps, than torque the Cylinder Head and intake
manifold flange bolts.
8 7
8
3
3
3 4
4
1
2
1
1
5
2 6
2
5
7
4 6
9 10
58249
Valve Cover
Removal
1. Disconnect spark plug leads and remove spark plugs.
2. Remove flywheel cover.
3. Disconnect the crankcase breather hose and vent hose, fuel pump input/output hose
and fuel cooler in/out hoses.
IMPORTANT: The hose fittings on the fuel pump can break if you try twisting or pull-
ing off the hoses. Remove fuel pump hoses by slowly prying them off using a small
screwdriver.
4. Remove fuel pump from valve cover.
WARNING
Always release the fuel pressure in the high-pressure fuel line before servicing the
line or the vapor separator. If the fuel pressure is not released, pressurized fuel may
spray out.
5. Disconnect high pressure fuel line from fuel distribution manifold by depressing locking
tab. Refer to section 3C Releasing Fuel Pressure in the High Pressure Fuel Line.
6. Remove coil plate fasteners and swing the coil plate assembly to the side.
7. Loosen water separating fuel filter nut, pull the assembly from the mounting bracket and
place it out of the way.
8. Remove valve cover.
b
k
e a
i
c
j
d
f
58814
Installation
1. Install valve cover seal into groove.
2. If removed, reinstall baffle plate. Tighten screws securely.
a - Baffle Plate
b - Screw (4) M4x10
c - Cover Seal
k
l
e a
i
c
j
d l
f 58814
a - Flywheel Cover
b - Screw (4) - M6x25
Flywheel Cover Screw Torque
45 lb. in. (5.1 N·m)
WARNING
Engine could possibly start when turning flywheel during adjustment. To prevent
this type of accidental engine starting and possible serious injury, always remove
spark plug leads from spark plugs.
Adjusting Valves
1. Remove valve cover as outlined in “Valve Cover Removal”.
2. Measure valve clearance with a feeler gauge. Adjust if out of specification.
NOTE: When loosening lock nuts, hold the adjusting screw with a screw driver to prevent
it from moving.
a - Lock nut
b - Adjusting Screw
(b) (a)
58268
#1 (b)
#1 (a)
#2 (a)
#3 (b)
(b) (a) •
58268
#2 (b)
#3 (a)
#4 (b)
#4 (a)
Timing Belt
Removal
1. Remove flywheel and stator. Refer to section 2B Charging and Starting System.
2. Remove timing belt from driven gear and drive gear.
a - Timing Belt
Installation
Timing Belt Installation Notes:
• Protect the timing belt from water and oil.
• Use care not to scratch the belt.
• Do not use any metal device to help stretch the belt onto the driven gear.
1. Align marks on drive and driven gear with marks on cylinder block as shown.
2. Install timing belt onto drive gear as shown. Numbers/letters on belt should be readable
once belt is installed.
3. Install stator and flywheel. Refer to section 2B Charging & Starting System.
a
1
b
c c e
d
a
58818 58249
58249
58269
b
a - Oil Pump Assembly
b - Oil Pump Mounting Screw (4) M6x40
Camshaft Removal
1. Hold driven gear using tool (91-83163M) and remove screw and flat washer. Remove
driven gear.
2. Remove camshaft retaining pin. Slide camshaft/oil seal out of cylinder head.
NOTE: The cam can also be removed from the top without removing the cylinder head from
engine.
91-83163M
58287 58477
a - Driven Gear
b - Camshaft
c - Camshaft Retaining Pin with Seal
Valve Removal
VALVE COMPONENTS
e
d
c
b
a
a - Valve d - Spring Retainer
b - Valve Seal e - Valve Keepers
c - Valve Spring
REMOVING VALVES
1. Anytime a valve is removed, replace the valve seal.
2. Remove valves as shown.
91-809494A1
b
58256
2. Measure rocker arm inside diameter. Replace rocker arms if out of specification.
55804
Camshaft
Manual start models are equipped with a cam shaft featuring a compression release mecha-
nism. The compression relief mechanism releases a percentage of the cylinder compres-
sion during engine cranking which lowers the starter rope pull force.
At cranking speeds (RPM) the cam shaft decompression levers rest against the side of the
exhaust cam lobes, protruding out from the heal of the lobe. This protrusion contacts the
exhaust valve rocker arms during the compression stroke, slightly opening the exhaust
valve.
With the increase of centrifugal force at engine running speeds, the decompression levers
swing out of contact with the exhaust valve rocker arms, allowing the exhaust valves to oper-
ate normally (fully closed) during the compression stroke.
a 55805
b
4. Measure the camshaft bore diameters (a) and camshaft bearing diameters (b).
a a a a
b b b b
58255
Cylinder Head
1. Inspect the cylinder head for the following conditions:
• Mineral deposits/corrosion in water passage ways.
• Carbon deposits in combustion chamber (use round scraper to clean away depos-
its). Be careful not to scratch or remove material.
2. Inspect cylinder head for warpage. Replace cylinder head If out of specification.
58271
Valve Guides
NOTE: Inspect the valve guides for wear or damage. If valve guide wear is out of specifica-
tion, replace the valve guide.
Measure valve guide bore.
58257
55806
3. Install the new valve guide and circlip using a valve guide installer bushing along with
the valve guide remover.
a
b
55807
4. After installing the valve guide, ream the valve guide using a valve guide reamer to ob-
tain proper stem-to-guide clearance.
55808
Valves
1. Clean the carbon deposits from the valve. Discard any cracked, warped, or burned
valves.
2. Measure the valve stem to check for wear. Replace valves if not in specification.
55810
3. Check the valve face for pitting. Valves faces that are pitted must be refaced.
NOTE: Several different types of equipment are available for refacing valves. Follow the
equipment manufacturer’s instructions.
NOTE: After refacing valve seat or replacing the valve and valve guide, the valve seat and
valve face should be lapped.
4. Check the margin thickness of the valves after the valves have been ground. Any valve
with a margin thickness of less than the specification, should be replaced.
45 °
55809
Valve Springs
1. Check each spring under load on a spring tester. Replace any weak springs.
2. Check free length limit of each spring. Replace valve springs if not in specification.
55846
3. Check each spring on a flat surface using a square. Rotate spring and check space be-
tween the top coil and square. Replace valve springs if not in specification.
55797
If resurfacing the valve seats is required, resurface the valve seats to the specified angles
shown in chart.
c
b
a
55798
55799
Condition: The valve seat is in the middle of the valve face but it is too narrow.
55800
55801
Condition: Valve seat is too narrow and is located near the bottom edge of the valve face.
55802
e
d
c
b
a
a - Valve
b - Valve Seal
c - Valve Spring
d - Spring Retainer
e - Valve Keepers
INSTALLING VALVES
1. Always use new valve seals.
2. Apply engine oil to the valves and valve seats.
3. Install valves as shown.
NOTE: Valve springs are symmetrical and may be installed in either direction.
b
91-809494A1
58256
58261
a - Upper Camshaft Oil Seal
Camshaft Installation
1. Apply engine oil to the main journals (5 places) on the camshaft.
2. Slide camshaft into cylinder head (threaded end towards driven gear).
NOTE: Camshaft retaining pin groove must align with retaining pin hole in cylinder head.
3. Install camshaft retaining pin. Install seal over pin.
4. Place driven gear on camshaft so alignment pin is in hole. Hold gear with tool
(91-83163M) and fasten with washer and screw. Tighten screw to the specified torque.
5. Remove any oil from the camshaft lobes and apply Moly Grease to the lift portion of the
lobes. Obtain Moly Grease from a local source.
NOTE: Rotate camshaft after assembly to ensure it rotates smoothly.
f e
d c
a
b
58477
91-83163M
58287
58278
a - Camshaft d - Driven Gear
b - Camshaft Retaining Pin w/Seal e - Washer
c - Alignment Pin f - Screw M10x40
Driven Gear Screw Torque (f)
28 lb-ft (38 Nm)
b
a
a
a - O-Ring Seals
b - Pour Approximately 1 fl oz (30 ml) of Engine Oil into the Oil Pump Body
3. Align oil pump shaft with the camshaft and install the oil pump.
4. Fasten with 4 screws. Tighten screws to the specified torque.
58256
b
a c
58259
53739
a - Rocker Shaft
b - Rocker Arms
b
e
c d
58249
a - Rocker Arm Retainer (1)
b - Rocker Arm Retainer (2) Arrow Must Point Towards Driven Gear
c - Rocker Arm Retainer (2)
d - Mounting Screw (5) M8 x 23
e - Adjustment Screw Loose
Rocker Arm Shaft Mounting Bolt Torque
160 lb-in. (18 Nm)
58270
58249
3. Torque center bolts in sequence and in two steps, then torque the cylinder head and EFI
intake manifold screws.
4. Refer to “Timing Belt Installation” preceding, and install timing belt.
5. Refer to “Valve Clearance Adjustment” preceding, to perform valve clearance adjust-
ments.
6. Refer to “Valve Cover Installation” preceding, and install valve cover.
8 7
8
3
3
3 4
4
1
2
1
1
5
2 6
2
5
7
4 6
9 10
58249
POWERHEAD
Section 4B - Cylinder Block/Crankcase
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-1 Selecting New Main Bearings . . . . . . . . . . 4B-25
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-2 Main Bearing Installation . . . . . . . . . . . . . . 4B-26
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-4 Selecting New Connecting Rod Bearings 4B-27
Cylinder Block and Crankcase . . . . . . . . . . . . 4B-6 Installing Connecting Rod Bearings . . . . . 4B-27
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . 4B-8 Connecting Rod Installation . . . . . . . . . . . . 4B-28
Powerhead Removal . . . . . . . . . . . . . . . . . . . . 4B-9 Piston Ring Installation . . . . . . . . . . . . . . . . 4B-29
Removing Powerhead Components . . . . . . . 4B-12 Piston Installation . . . . . . . . . . . . . . . . . . . . 4B-30
Cylinder Block Disassembly . . . . . . . . . . . . . . 4B-13 Crankshaft Installation . . . . . . . . . . . . . . . . 4B-30
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . .
4B-17
4B-17
Crankcase Cover Installation . . . . . . . . . . .
Exhaust Cover Installation . . . . . . . . . . . . .
4B-32
4B-33
4
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-18 Drive Gear Installation . . . . . . . . . . . . . . . . 4B-34 B
Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-18 Installing Powerhead Components . . . . . . 4B-35
Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . 4B-19 Engine Wiring Harness and
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-20 Ignition/Electrical Component Installation 4B-35
Main Bearing Clearance . . . . . . . . . . . . . . . 4B-21 Ignition Components . . . . . . . . . . . . . . . . . . 4B-35
Connecting Rod Bearing Clearance . . . . . 4B-23 Charging/Starting System Components . 4B-35
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-24 Fuel Components . . . . . . . . . . . . . . . . . . . . 4B-35
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . 4B-24 Powerhead Installation . . . . . . . . . . . . . . . . . . . 4B-36
Cylinder Block Reassembly . . . . . . . . . . . . . . . 4B-25 Tiller Handle Models . . . . . . . . . . . . . . . . . . 4B-38
Specifications
Type 4 Stroke Cycle – Over Head Camshaft
CYLINDER
Displacement 60.8 cu. in. (995 cc)
BLOCK
Number of Cylinders 4
STROKE Length 2.953 in. (75 mm)
Diameter
Standard 2.5591 in. (65 mm)
CYLINDER Oversize-0.010 in. (0.25 mm) 2.5689 in. (65.25 mm)
BORE Oversize-0.020 in. (0.50 mm) 2.5787 in. (65.5 mm)
Taper/Out of Round Maximum 0.003 in. (0.08 mm)
Bore Type Cast Iron
Piston Type Aluminum
O.D. at Skirt
PISTON Standard 2.5570 - 2.5578 in. (64.950 - 64.965 mm)
Oversize-0.010 in. (0.25 mm) 2.5669 - 2.5675 in. (65.2 - 65.215 mm)
Oversize-0.020 in. (0.50 mm) 2.5768 - 2.5774 in. (65.450 - 65.465 mm)
PISTON Piston to Cylinder Clearance 0.0014 - .0026 in. (0.035 - 0.065 mm)
CLEARANCE
Ring End Gap (Installed)
Top 0.006 - 0.012 in. (0.15 - 0.03 mm)
Middle 0.012 - 0.020 in. (0.30 - 0.50 mm)
RINGS Bottom (Oil Ring) 0.008 - 0.028 in. (0.20 - 0.70 mm)
Side Clearance:
Top 0.0008 - 0.0024 in. (0.02 - 0.06 mm)
Middle 0.0008 - 0.0024 in. (0.02 - 0.06 mm)
Special Tools
1. Oil Filter Wrench (P/N 91-802653)
NOTES:
CRANKSHAFT
110
12
2
8
9
10
110 7
110 6
11
1 110
12
5 110
4
110
110
CRANKSHAFT
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
1 1 CRANKSHAFT
2 1 OIL SEAL
3 1 OIL SEAL
4 4 CONNECTING ROD
5 8 BOLT 150 12.5 17
8 BEARING (BROWN)
6 8 BEARING (BLACK)
8 BEARING (BLUE)
7 4 PISTON
8 4 PISTON RING (TOP)
9 4 PISTON RING (SECOND)
10 4 PISTON OIL RING
11 4 PISTON PIN
12 8 RETAINER
23
6
3 24
12
12
2
13
3 15 16
17
18
3
14
2 19
20
7
1 25
4 5 22
9 110
21
11
8 26
110
25
10
A
A – TO VST COOLER
Torque Sequence
11
9 10
8
7 19
20
4
3
15 5 6 16
2 11 1 2 12
5
14 4 3 13
6
9 18 17
10
12 7
8
3
4
1
2
5
6
Powerhead Removal
WARNING
The possibility exists that the engine could start when turning the flywheel. To avoid
possible serious injury, always disconnect the battery and remove spark plug leads
from spark plugs before working on motor.
1. On electric start models, disconnect the battery cables from the battery. Remove battery
cables from engine.
2. Disconnect the power trim wires (if so equipped).
3. Remove the bottom cowls.
a
b
a
58810
58479
a - Shift Guide Bracket
b - Screw (2) M6 x 25
8. Disconnect the crankcase vent hose.
9. Disconnect inlet hose from fuel pump.
IMPORTANT: The hose fittings on the fuel pump can break if you try twisting or pull-
ing off the hoses. Remove hoses by slowly prying off the hoses using a small screw-
driver.
a - Load Ring
b - Drive Gear
c - Woodruff Key
c
d
e
g 91-802653
a
f
h
a - Exhaust Cover
b - Gasket
c - Thermostat and Gasket
d - Gasket
e - Thermostat Cover
f - Oil Filter
g - Oil Filter Wrench
h - Exhaust Cover Screw (12) M6 x 35
58276
a - Crankcase Cover
b - Crankcase Cover Bolts (10) M6 x 35
c - Crankcase Cover Bolts (10) M8 x 82
5. With a rubber or plastic hammer, lightly strike the crankcase cover in order to separate
it from the block. If the cover will not separate, try prying it off with a screwdriver. Do not
damage the split line sealing surface when prying the cover off.
6. Use a 5/16 in. 12 point socket and remove connecting rod bolts.
7. Remove carbon ridge from the cylinder bore using a burr knife. Push out the pistons.
Keep each piston, connecting rod, and cap together as an assembly.
NOTE: Use piston ring expander tool to prevent rings from breaking. If reusing rings, mark
their location (piston #1, #2, #3, or #4) for correct installation.
NOTE: Each connecting rod and cap are a matched set. They must not be interchanged.
91-24697
d c
b a
53824
Inspection
Cylinder Bore
MEASURING CYLINDER BORE
1. Measure the cylinder bore diameter at three locations in both X and Y axis.
2. If the cylinder bore is beyond the standard limits listed in the tables below, it will be nec-
essary to re-bore the cylinder to accept the oversize piston.
NOTE: Measure at three locations (L1 , L2 , and L3 ) in both X and Y axis (D1-6 ).
L1 =0.8 in. (20 mm)
L2 =1.6 in. (40 mm)
L3 =2.4 in. (60 mm)
1. Inspect:
a. Water jacket for mineral deposits/corrosion, clean if necessary.
b. Inner surface for score marks, repair if necessary.
2. Measure bore diameter with a cylinder gauge, re-bore or replace if necessary.
L1
D1,2
L2
L3
D3,4
D5,6
55837
Piston
1. Inspect piston wall wear/damage, replace if necessary.
2. Measure the piston at a point 0.2 in (5.0 mm) from the bottom, replace if out of specifica-
tion.
a
b
3. Measure piston to cylinder clearance. If out of specification examine piston and cylinder
bore further to determine repair/replacement.
a. Piston to Cylinder Clearance can be defined by:
MBM–MPM=PCC where:
MBM=Minimum Bore Measurement
MPM=Maximum Piston Measurement
PCC=Piston to Cylinder Clearance
Piston Pin
1. Measure piston pin diameter. Replace piston pin if out of specification.
55839
1. Place the piston pin into the connecting rod and check for free play. There should be no
noticeable free play.
55840
2. Place the piston pin into the piston and check for free play. There should be no notice-
able free play.
55841
Piston Rings
PISTON RING SIDE CLEARANCE
1. Measure piston ring side clearance. Replace piston and/or piston rings if out of specifi-
cation.
55842
53747
a - Push Piston Rings into Cylinder 0.8 in. (20 mm) Deep. Push in the Rings Using
the Piston.
Piston Ring End Gap
Top 0.006 - 0.012 in. (0.15 - 0.30 mm)
2nd 0.012 - 0.020 in. (0.30 - 0.50 mm)
Oil 0.008 - 0.028 in. (0.20 - 0.70 mm)
Crankshaft
1. Thoroughly clean crankshaft and inspect bearing surfaces. Replace crankshaft if bear-
ing surfaces are pitted, scored, or discolored.
2. Measure Run-out. Replace crankshaft if out of specification.
Crankshaft Run-out
0.0018 in. (0.046 mm)
53811
53812
a - Plastigauge
NOTE: Do not put plastigauge over the oil hole on the bearing surface of the crankshaft.
6. Install crankcase cover. Apply oil to the cover bolts and torque cover bolts in sequence
and in two steps.
9 10
19 20
15 5 6 16
11 1 2 12
14 4 3 13
18 17
8 7
7. Remove the crankcase cover. Measure the compressed plastigauge to check the main
bearing clearance. Replace bearings if clearance is not in specification.
53751
8. If replacement of the main bearings is required, refer to Main Bearing Selection and
Installation in Cylinder Block Reassembly.
a
53751
a - Plastigauge
IMPORTANT: Do not rotate connecting rod when checking clearance.
3. Install the connecting rod to the respective journal. Tighten connecting rod bolts in se-
quence and in two steps to the specified torque.
a d
c
c
b
4. Remove the connecting rod cap. Measure the compressed plastigauge to check the
connecting rod oil clearance. Replace bearings if oil clearance is not in specification.
53810
Thermostat
1. Measure the lift of the thermostat at the operating water temperature listed.
55845
#1
#2
a
#3
A B C
#4
#1
#5 #2
#3
#4
b
#5
53819
a - Main Bearings
b - Locking Tab
c - Notch in Cylinder Block
A
B
C
53816
b 53815
110
c
d
110 4-stroke Outboard Oil (92-828000A12)
a - Connecting Rod
b - Piston
c - Piston Pin
d - Piston Pin Clip (2)
e - Piston Pin Clip End Gap
f - Pry Point
110 e
110
f
c
a
d
b
50°
g
UP
91-24697 h
i
j
110 4-stroke Outboard Oil (92-828000A12)
k
a - Oil Ring Spacer
b - Bottom Rail
c - Top Rail
d - Second Compression Ring (“T” side up)
e - Top Compression Ring (“T” side up)
f - “T” Mark Should Face Piston Crown
g - End Gap – Top Compression Ring
h - End Gap – Second Compression Ring
i - End Gap – Upper Oil Ring Rail
j - End Gap – Lower Oil Ring Rail
k - End Gap – Oil Ring Spacer
Piston Installation
NOTE: Cylinder bores must be clean before installing pistons. Clean with light honing, as
necessary. After honing, clean cylinder bores with water and detergent. After cleaning, swab
cylinder bores several times with engine oil and a clean cloth, then wipe with a clean dry
cloth.
1. Lubricate pistons, rings. and cylinder walls with engine oil.
2. Install piston/connecting rod assembly using piston ring compressor tool.
NOTE: Install used pistons in their original locations(cylinders). Install piston with “UP” mark
on piston crown facing toward the flywheel end of block.
ÎÎÎ
ÎÎÎ
ÎÎÎ
a
P/N FT2997
Crankshaft Installation
1. Lubricate the crankshaft bearing surfaces with engine oil.
a a a a a
53822
4. Install upper and lower oil seals on crankshaft. Position oil seal lips as shown.
5. If removed, install dowel pins
6. Carefully lower crankshaft into place.
IMPORTANT: Make sure the lower oil seal notch is positioned into the groove in the
crankcase.
c b
d
a
a
58273 53824
a a
53823
b a 12
9 10
19 20
15 5 6 16
11 1 2 12
14 4 3
13
18 17
8 7
f g b
11 c
d
8 e
7 4
3
a
2
h j
5
9 i
10
12 91-802653
53746
a - Exhaust Cover
b - Gasket
c - Thermostat
d - Gasket
e - Thermostat Cover
f - Oil Pressure Switch
g - Engine Coolant Temperature (ECT) Sensor
h - Oil Filter
i - Oil Filter Wrench
j - Exhaust Cover Screw (12) M6 x 35
Exhaust and Thermostat Cover Screw Torque
1st Torque: 53 lb-in. (6 Nm)
2nd Torque: 106 lb-in. (12 Nm)
a - Load Ring
b - Drive Gear
c - Drive Key
53740
Powerhead Installation
CAUTION
When lubricating the driveshaft splines do not allow any grease on top of the drive-
shaft. Grease on top of the driveshaft will force the shaft down when installing the
gearcase, causing the pinion gear to bind with the forward gear. This can result in
damage or failure of the gears.
1. Install powerhead and new base gasket. Tighten mounting bolts to specified torque.
IMPORTANT: If the crank shaft splines do not line up with the driveshaft splines, shift
the gearcase into forward, place a prop on the propshaft and rotate it counterclock-
wise. This will allow the splines to line up.
a
a - Powerhead Mounting Bolts (4 Each Side) M8 x 110
b - Hoist
c - Base Gasket
Powerhead Mounting Bolt Torque
33 lb-ft. (44.7 Nm)
2. Re-connect throttle/shift linkage and control cable anchor bracket. Torque fasteners to
specified torque.
Remote Control Model
a
58810
58479
a - Shift Guide Bracket b - Screw (2) M6 x 25
Shift Guide Bracket Mounting Screw Torque
70 lb-in. (8 Nm)
d
a
a
b
POWERHEAD
Section 4C - Lubrication
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-1 Cleaning and Inspection . . . . . . . . . . . . . . . . . . 4C-3
Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . 4C-2 Oil Pump Reassembly . . . . . . . . . . . . . . . . . . . 4C-4
Oil Pump Disassembly . . . . . . . . . . . . . . . . . . . 4C-2 Oil Pump Installation . . . . . . . . . . . . . . . . . . . . . 4C-5
Specifications
4
Pump Type Trochoid C
Engine Oil Pressure (Warm Engine)
@ 3000 rpm 30-40 psi (207-278 kPa)
Engine Oil Pan Capacity Either 3 Qts. or 3 Liters
Oil Pump:
Outer Rotor to Housing “a” 0.0045 - 0.009 in. (0.11 - 0.23 mm)
Inner Rotor to Outer Rotor “b” 0.005 in. (0.12 mm)
Rotor to Housing “c” 0.0015 - 0.003 in. (0.04 - 0.08 mm)
LUBRICATION a
SYSTEM bb
cc
a - Screw (2)
c a
a - Cover Seal
b - Outer Rotor
c - Inner Rotor
d - Shaft
e - Cross Pin
b
c
c a
a - Cover Seal
b - Outer Rotor
c - Inner Rotor
d - Shaft
e - Cross Pin
3. Fasten cover with two screws. Apply Loctite 222 to threads. Tighten screws to the speci-
fied torque.
a 51
a
a
58260
a - O-Ring Seals
b - 30 ml of Engine Oil
IMPORTANT: When the oil pump mounting surface gets close to the mating surface
of the cylinder head, do not twist/turn oil pump from side to side. The sharp edges
on the cylinder head will cut the oil pump sealing o-rings.
3. Align oil pump shaft with the camshaft and install the oil pump.
4. Fasten with 4 screws. Tighten screws to the specified torque.
e
d
c
b a
MID-SECTION
Section 5A - Clamp/Swivel Brackets & Drive Shaft Housing
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-1 Bottom Cowl Removal/Installation . . . . . . . . . 5A-14
Swivel Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-2 Adaptor Plate Removal . . . . . . . . . . . . . . . . . . 5A-15
Steering Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-4 Cleaning Oil Sump . . . . . . . . . . . . . . . . . . . 5A-19
Transom Bracket . . . . . . . . . . . . . . . . . . . . . . . . 5A-6 Adaptor Plate Inspection/Cleaning . . . . . . 5A-19
Adaptor Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-8 Adaptor Plate Reassembly . . . . . . . . . . . . . . . 5A-20
Driveshaft Housing . . . . . . . . . . . . . . . . . . . . . . 5A-10 Driveshaft Housing Reassembly . . . . . . . . . . . 5A-21
Bottom Cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-12
Specifications
Transom Height: 5
Long Shaft 20 in. (51 cm) A
Steering Pivot Range:
MID-SECTION Tiller 90°
Remote 60°
Full Tilt Up Angle 71°
Allowable Transom Thickness 2-3/4 in. (69.8 mm)
SWIVEL BRACKET
1
A
95 4
5
95
3
7
2
6
10 9
16
15
10
11
12
8
95 10 (HANDLE VERSION)
13
14
95
SWIVEL BRACKET
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
1 1 LINK ROD
2 1 SCREW (1-1/2 IN.) 20 27.0
3 1 WASHER ELECTRIC NON HANDLE
4 2 WASHER
5 2 NUT (.375-24) 120 13.5
6 1 PUCK
7 1 BUSHING
8 1 SWIVEL BRACKET
9 2 BEARING
10 2 GREASE FITTING (Qty. of 3 required on Handle Versions
11 1 DECAL-Co-Pilot (HANDLE)
12 1 DECAL-Serial Overlaminate
13 1 BUSHING (LOWER)
14 1 SEAL
1 SCREW (M8 x 10) (HANDLE)
15
1 SCREW (M8 x 25) NON-HANDLE
16 1 SEAL
STEERING ARM
1
2
5
3
8
5 6 9
4
95 10
11
95 12
19
20
95
21
22 13
94
23
18
24
15
25
14
27 26
17
STEERING ARM
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
1 2 NUT 50 5.7
2 1 STRAP
3 2 MOUNT
4 8 SCREW (M6 X 20) 130 14.7
5 2 BUMPER
6 1 RETAINING RING
7 1 STEERING ARM
8 1 BRACKET (NON-HANDLE)
9 1 TAB WASHER (NON-HANDLE)
10 2 SCREW (M10 X 30) 32 3.7
11 2 SCREW (M12 X 154) 50 67.8
12 1 SPACER
13 1 SWIVEL TUBE
14 1 GROUND STRAP
15 1 GROUND STRAP
16 2 SCREW (M10 X 105) 32.5 44
17 1 STRAP - LOWER MOUNT
18 3 SCREW (SELF-TAPPING) Drive Tight
19 1 NUT (.375-24) (HANDLE)
20 1 LEVER - CO-PILOT (HANDLE)
21 1 WASHER (HANDLE)
22 1 ROD (THREADED) (HANDLE)
23 1 BRACKET PLATE (HANDLE)
24 1 DISC (HANDLE)
25 1 PLATE (HANDLE)
26 1 DISC (HANDLE)
27 2 SCREW (HEX SHOULDER) (HANDLE) 70 7.9
TRANSOM BRACKET
9
8
7 10
95
5
21
11
4
2
3
11
6
25 17
26
27 95
16
95 18
20
21 31
12
19 1
23 13
15
28
24 14
33 32
22 29
30
TRANSOM BRACKET
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
1 1 TRANSOM BRACKET (PORT)
2 1 GREASE FITTING
3 1 GROOVE PIN
4 1 TRANSOM BRACKET (STARBOARD)
5 1 TILT LOCK LEVER
6 1 SPRING
7 1 NYLINER
8 1 SPRING
9 1 KNOB
10 1 GROOVE PIN
11 2 WASHER
12 1 ANCHOR BRACKET
13 1 ANODE ASSEMBLY
14 2 SCREW (M6 X 25) 60 6.8
15 2 WASHER
16 5 SCREW (30 MM) 25 33.9
17 1 SCREW (35 MM) 32.5 44
18 4 LOCKWASHER
19 2 NUT
20 1 TILT TUBE
Tighten nut to 32
21 2 NUT lb-ft and then back
off 1/4 turn.
22 1 SEAL KIT (NON-HANDLE)
23 1 O RING (NON-HANDLE)
24 1 SPACER (NON-HANDLE)
25 2 CLIP
26 1 C-WASHER
27 1 SCREW (10-16 X 5/8) Drive Tight
28 4 SCREW Drive Tight
29 4 WASHER Drive Tight
30 4 NUT
31 2 SCREW (M10 X 40)
32 2 WASHER
33 2 NUT
ADAPTOR PLATE
4
1
2
7
5 6
21 9
8 10
11
12
5
5
13
14
15
15 17
9 Loctite PST Pipe Sealant (92-809822)
20
110 4 Stroke Outboard Oil (92-828000A12)
18
110
20 16
19
ADAPTOR PLATE
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
1 1 DIPSTICK
2 1 DIPSTICK TUBE
3 1 SEAL
4 1 HEAT SHIELD
5 4 DOWEL PIN
6 1 ELBOW
7 2 STA-STRAP
8 1 SEAL-DRIVESHAFT
9 1 BUSHING
10 1 PLUG-OIL PASSAGE 24.3 33
11 1 ADAPTOR PLATE
12 1 PLUG
13 1 GASKET
14 1 O RING
15 3 SCREW (M6 X 20) 75 8.5
16 1 OIL PRESSURE RELIEF VALVE 34 3.8
17 1 PLATE-TOP OIL PICKUP
18 1 HOSE-OIL PICKUP
19 1 BAFFLE
20 2 CLAMP
21 1 SCREW (M6 X 55) 150 17
DRIVESHAFT HOUSING
1
15
5
7 6
4
3
24
25
18
14 8
19
26
20
23
10
22 12
11
21
13
16
17
DRIVESHAFT HOUSING
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
1 1 SEAL–water tube
2 1 EXHAUST PIPE
3 8 SCREW (M8x110) 33 44.7
4 5 SCREW (M8 x 45) 28 38
5 1 DRAIN PLUG 210 17.5 23.5
6 1 GASKET
7 2 BUMPER
8 1 GROMMET
1 STUD (M10 x 50) (NON-BIGFOOT) 12 16.3
9
1 STUD (M10 x 100) (BIGFOOT) 12 16.3
10 1 WASHER
11 1 NUT 40 54.5
12 1 WATER TUBE
13 1 GUIDE
14 1 BUMPER (LONG)
15 1 DRIVESHAFT HOUSING
16 1 PLATE
17 1 SCREW (M10 X 25) 26 35.3
18 1 SPEEDOMETER PICK UP
19 1 CONNECTOR
20 1 FITTING
21 1 SPACER
22 1 COUPLING
23 1 BUSHING
24 2 WASHER
25 2 NUT
26 1 STA-STRAP
BOTTOM COWL
1
7
9
12 10
14 6
13
15
13
8
14
16 5
3
19
3
11
17
18
4
2
BOTTOM COWL
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
1 1 BOTTOM COWL (LONG-PORT)
2 1 BOTTOM COWL (LONG-STBD.)
3 6 SCREW (M6 X 30) 60 6.8
4 1 WASHER
5 1 SEAL
6 1 WASHER
7 1 GASKET
8 1 SCREW (M6 X 60) 60 6.8
9 1 FITTING-TELLTALE
10 1 BOOT
11 1 STA-STRAP
12 1 LEVER-COWL LATCH
13 2 BUSHING
14 2 WAVE WASHER
15 1 LATCH HOOK
16 1 SCREW (M6 X 16) 60 6.8
17 1 GROMMET
18 1 SWITCH
19 1 GROMMET
a c
58471
58294
a - Shift Bracket Flat
b - Bushing Flat
c - Shift Shaft
4. Remove wire grommet from adaptor plate. Pull power trim wires out of grommet.
58293
c d a
58297
a - Nut (2)
b - Lower Mount Bolt (2) M10 x 105
c - Washer (2)
d - Ground Strap Bolt
f
e
c
a b
a
a
58295
a - Upper Mount Bolt (2) M12 x 154
b - Washer (2)
c - Bumper (2)
d - Mount (2)
e - Strap
f - Nut (2)
8. Separate drive shaft housing from transom bracket mount bolts by pulling backward.
b a
58483
a - Driveshaft Housing
b - Transom Bracket
9. Remove drain plug on port side of driveshaft housing to drain remaining oil from sump.
a - Drain Plug
10. Remove five (5) adaptor plate screws from aft/underside of driveshaft housing.
a a
58296
a - Screw (5) M8 x 45
11. Remove allen head screw on top of adaptor plate.
58480
58467
a - Oil Sump
Adaptor Plate Inspection/Cleaning
1. Disassemble, clean and inspect adaptor plate components as required.
2. Oil pick-up screen in baffle should be clean and free of damage.
3. Oil pick-up hose must be in good condition and clamped securely at either end.
4. Oil pressure relief valve must be clean and free to open and close without sticking.
b
d
c
e b
58488
a - Gasket
b - Dowel Pin (2)
c - Screw (3) M6 x 20
d - Oil Pressure Relief Valve/Deflector Cup Assembly
e - Oil Pick-up Hose
f - Baffle Screen
1. Place adaptor plate on to driveshaft housing, install five (5) screws on the aft/underside
of the driveshaft housing and tighten to specified torque.
a a
58296
a - Screw (5) M8 x 45
Adaptor Plate Screw Torque
33 lb-ft. (44.7 Nm)
2. Install allen head screw on top side of adaptor plate. Tighten to specified torque.
58480
c a
d 58297
58295
a - Upper Mount Bolt(2) M12 x 154
Driveshaft Housing Upper Bolt Torque
50 lb-ft. (68 Nm)
a - Drain Plug
Drain Plug Torque
17.5 lb-ft (24 Nm)
6. Slide the shift shaft through the bushing, into the driveshaft housing.
58294
a - Shift Shaft
b - Bushing
7. Rotate shift shaft so the flat on the shift shaft bracket lines up with the flat on the bushing.
58471
58487
9. Install grommet and pull power trim wires up thru adaptor plate grommet.
58293
MID-SECTION
Section 5B - Power Trim
Table of Contents
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-2 Power Trim Disassembly . . . . . . . . . . . . . . . . . 5B-30
Quicksilver Lubricants and Service Aids . . . . 5B-2 Trim Motor Removal . . . . . . . . . . . . . . . . . . 5B-31
Power Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-4 Pump and Components Removal . . . . . . . 5B-31
Theory Of Operation . . . . . . . . . . . . . . . . . . . . . 5B-6 Manifold Removal . . . . . . . . . . . . . . . . . . . . 5B-32
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-6 Shock Rod Removal . . . . . . . . . . . . . . . . . . 5B-33
Trimming Characteristics . . . . . . . . . . . . . . 5B-6 Shock Rod Disassembly . . . . . . . . . . . . . . . . . 5B-33
Trailering Outboard . . . . . . . . . . . . . . . . . . . 5B-7 Memory Piston Removal . . . . . . . . . . . . . . 5B-36
Tilting Outboard Up and Down Manually . 5B-7 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . 5B-37
Power Trim Flow Diagrams . . . . . . . . . . . . . . . 5B-8 Trim Motor Electrical Tests . . . . . . . . . . . . . 5B-37
Trim Up Circuit . . . . . . . . . . . . . . . . . . . . . . . 5B-8 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-38
Tilt Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-10 O-Ring and Seal Placement . . . . . . . . . . . 5B-38
Maximum Tilt . . . . . . . . . . . . . . . . . . . . . . . . 5B-12 O-ring Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-39
Down Circuit . . . . . . . . . . . . . . . . . . . . . . . . .
Shock Function Up . . . . . . . . . . . . . . . . . . .
5B-14
5B-16
Power Trim Reassembly . . . . . . . . . . . . . . . . .
Shock Rod Reassembly . . . . . . . . . . . . . . .
5B-41
5B-41
5
Shock Function Return . . . . . . . . . . . . . . . . 5B-18 Shock Rod Installation . . . . . . . . . . . . . . . . 5B-43 B
Manual Release . . . . . . . . . . . . . . . . . . . . . . 5B-20 Trim Limit Assembly Installation . . . . . . . . 5B-44
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 5B-22 Manual Release Valve Installation . . . . . . 5B-44
Preliminary Checks . . . . . . . . . . . . . . . . . . . 5B-22 Manifold Installation . . . . . . . . . . . . . . . . . . 5B-45
Hydraulic System Troubleshooting Oil Pump Installation . . . . . . . . . . . . . . . . . . 5B-46
Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . 5B-23 Pressure Operated Assembly Installation 5B-46
Troubleshooting the Power Trim Reservoir/Motor Installation . . . . . . . . . . . . 5B-47
Electrical System . . . . . . . . . . . . . . . . . . . . 5B-27 Bleeding Power Trim Unit . . . . . . . . . . . . . 5B-48
Power Trim System Removal . . . . . . . . . . . . . 5B-29 Installation of Power Trim System . . . . . . . . . 5B-48
Special Tools
1. Spanner Wrench P/N 91-74951
Notes:
Power Trim
17 A
19
2 B
4
12
16
8 9
D
5 E
13
6 15
6 C 11
11 11 7
6 6 11
11 11
17
11 14
10
18 15
11
D
66 Loctite 242 (92-809821)
NOTE: Lubricate all O-rings using Quicksilver Power Trim and Steering Fluid. If not avail-
able, use automotive (ATF) automatic transmission fluid.
NOTE: It is recommended that all O-rings be replaced when servicing tilt system.
Power Trim
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in. lb-ft Nm
– 1 POWER TRIM PUMP
1 1 SHOCK ROD KIT
2 1 MEMORY PISTON ASSEMBLY
3 1 O RING REBUILD KIT
4 2 O RING
5 1 CYLINDER ASSEMBLY
1 TRIM LIMIT VALVE KIT (NON-BIGFOOT)
6
1 TRIM LIMIT VALVE KIT (BIGFOOT)
7 1 PUMP ASSEMBLY
8 1 MOTOR KIT
9 1 RESERVOIR PLUG
10 1 MANUAL RELEASE ASSEMBLY
11 1 MANIFOLD KIT
12 1 SCREW KIT (MOTOR)
13 1 DRIVE SHAFT
14 1 FILTER KIT
15 1 P.O. CHECK ASSEMBLY KIT
16 1 CABLE
– 1 O RING KIT (COMPLETE TRIM)
17 2 GROOVE PIN
18 1 ANCHOR PIN
19 1 PIN
Theory Of Operation
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.
Adjustments
Trimming Characteristics
NOTE: Because varying hull designs react differently in various degrees of rough water, it
is recommended to experiment with trim positions to determine whether trimming “up” or
“down” will improve the ride in rough water.
When trimming your outboard from a mid-trim position (trim tab in neutral, straight fore-and-
aft, position), you can expect the following results:
TRIMMING OUTBOARD “UP” (“OUT”)
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 sud-
den change of steering torque and may cause additional momentary boat instabili-
ty.)
• Will lift bow of boat, generally increasing top speed.
• Transfers steering torque harder to left on installations below 23 in. transom height.
• Increases clearance over submerged objects.
• In excess, can cause porpoising and/or ventilation.
• In excess, can cause insufficient water supply to water pump resulting in serious water
pump and/or powerhead overheating damage.
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.
Operating “Up” circuit will actuate the “up” relay (located under engine cowl) and close the
electric motor circuit. The electric motor will drive the pump, thus forcing automatic transmis-
sion fluid through internal passageways into the “up” side of the trim cylinder.
The trim cylinder/trim rod 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.
WARNING
Excessive speed at minimum trim “In” may cause undesirable and/or unsafe steer-
ing conditions. Each boat should be tested for handling characteristics after any
adjustment is made to the tilt angle (tilt pin relocation).
• 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).
• Improves planing speed acceleration (by moving tilt pin 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, thus forcing automatic transmission fluid through internal pas-
sageways into the “down” side of the trim cylinder. The trim rod will move the engine down-
ward 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 cylinder rod will continue to tilt the outboard to a full up posi-
tion for trailering.
Tilting Outboard Up and Down Manually
WARNING
Before loosening the manual release valve, make sure all persons are clear of en-
gine, as engine will drop to full “down” position when valve is loosened.
With power trim installed, the outboard can be raised or lowered manually by opening the
manual release valve 3 to 4 turns (counterclockwise).
55170
TRIM UP CIRCUIT
a b
d
l
j
i k
v e
u h
m n Reservoir Oil
g f g
t
Í Í
Filtered Feed Oil
Í Í o
p
Return Oil
Trim Up
When the trim switch is activated in the up position, the electric motor (c) begins to rotate
the oil pump gears (j), the oil pump draws a small amount of oil through the filter (g) and
through the up circuit suction port (i). The oil pump gear (j) rotation forces oil into the pas-
sages for the up circuit. Oil, under pressure, will slide the shuttle valve (m) against the down
circuit pressure operated valve (f). The shuttle valve will mechanically open the down pres-
sure operated valve, allowing oil from the down cavity of the trim cylinder to flow into the oil
pump. This returning oil, from the down cavity, will supply most of the oil required for the up
circuit. Oil in the up circuit is blocked from returning into the reservoir by the ball inside the
down circuit suction port (k). The pressure of the oil will force the up circuit pressure oper-
ated valve (n) to open, allowing the oil to enter the passages inside the manifold (q) leading
to the trim cylinder (w) up cavity. Oil is blocked from all other passages by the closed manual
release valve (p). Oil under pressure will enter the trim cylinder below the memory piston
(t). With an increasing amount of oil entering the cylinder, the memory piston contacts the
shock piston (u) and forces the piston rod (a) up and out, raising the outboard motor. Oil on
the top of the shock piston exits through a passage running down along the side of the cylin-
der and enters the manifold passages. The oil is drawn back into the pump (j) through the
open down circuit pressure operated valve (f) and enters the pump as supply for the up cir-
cuit.
Tilt Circuit
a b
u v
h
d j l
i k
t
e
f Reservoir Oil
g m n
g
Í Í
Filtered Feed Oil
Í Í o
Return Oil
Tilt Up
In the up mode, as the piston rod (a) extends from the cylinder (w), the memory piston (t)
clears or uncovers the pressure relief passage. Oil from the up cavity will enter this passage
and, if required, causes the tilt relief piston (s) to open the tilt pressure relief valve (r). This
valve lowers the amount of pressure available to lift the outboard motor. With the engine in
forward gear, and at high engine rpm, the oil pressure available will not be able to overcome
the propeller thrust, limiting the trim range to below the pressure relief orifice. When the en-
gine rpm falls or if engine is not in forward gear, the oil pressure is available to extend the
piston rod (a) up into the tilt range.
Maximum Tilt
a b
v
u h
t
c
d j l
i k
e
f Reservoir Oil
m n
g g Filtered Feed Oil
Í Í
Í Í
Return Oil
Maximum Tilt
With the piston rod at maximum travel, and due to no rod movement, the pressure inside
of the trim cylinder (w) will increase to the pressure required to move the tilt relief piston (s).
The tilt relief piston’s “pin” opens the tilt relief valve (r). Up pressure flows into the trim relief
passage, and returns back into the reservoir.
Down Circuit
a b
d
i j l
k
u v f m n Reservoir Oil
h g
g
Í ÍÍ
Filtered Feed Oil
Í ÍÍ
t Return Oil
o
p Oil Under Pressure
Impact Relief Pressure #22
8801110 psi (3060 hp)
12201420 psi (75125 hp)
Down Mode
When the trim switch is activated in the down position, the electric motor (c) will rotate the
pump (j) in the opposite direction. With the oil pump gears rotating backwards, the flow of
oil is reversed. Oil is drawn through the filter (g), through the down circuit suction port (k)
and into the oil pump (j). The pump forces pressurized oil into the down passages. Oil will
slide the shuttle valve (m) into the up circuit pressure operated valve (n). The shuttle valve
will mechanically open the up circuit pressure operated valve and allow oil, from the up cav-
ity of the trim cylinder (w), to return into the oil pump. This returning oil, from the up cavity,
will supply the oil required for the down circuit. The oil is blocked from returning into the res-
ervoir by the ball (i) inside the up circuit suction port. Oil, under pressure, opens the down
circuit pressure operated valve (f) and enters the down passages inside of the manifold (q).
The manifold passage connects into the trim cylinder passage leading to the top of the cylin-
der. The cavity, inside the cylinder, above the shock piston (u) is the down cavity. As the
down cavity fills with oil, the piston rod (a) retracts into the cylinder, lowering the outboard
motor. Oil from the up cavity exits the cylinder and is drawn back into the pump through the
open up circuit pressure operated valve (n). When the piston rod reached full travel, the oil
pressure inside the down circuit will rise until the down pressure regulating valve (e) opens,
bypassing oil back into the reservoir. When the trim button is released, and the oil pump
stops supplying pressure, both of the pressure operated valves (f & n) will close, and if open,
the down pressure relief valve (e) will close. The closed valves will lock the fluid on either
side of the shock piston (u) & memory piston (t), holding the outboard motor in position.
Shock Function Up
a b
v
u h
d l
j
t i k
e
f Reservoir Oil
n
g m
Return Oil
g
Í Í p
o Impact Relief Pressure #22
8801110 psi (3060 hp)
12201420 psi (75125 hp)
Shock Function Up
Oil inside the down cavity is locked in a static position by the closed down circuit pressure
operated valve (f), the manual release valve (p) and the manifold reverse suction valve (o).
If the outboard strikes an underwater object while in forward gear, the piston rod (a) will try
to rapidly extend from the cylinder (w), and the pressure increases inside the trim cylinder
down cavity and connecting passages. When the pressure increases to the level required,
the impact relief valves (v), located inside the shock piston (u), will open and allow the fluid
to pass through it. As the fluid passes through the piston, the piston rod (a) will extend from
the trim cylinder. The memory piston (t) is held in position by vacuum, created by the oil in
the up cavity being locked in a static position. Therefore, oil passing through the shock pis-
ton is trapped between the memory piston (t) and shock piston (u).
a b
v
h
u
d l
t i j k
e
f Reservoir Oil
m n
Í
g Return Oil
g
Í Í Oil Under Pressure
Í Í o
p
Impact Relief Pressure #22
8801110 psi (3060 hp)
12201420 psi (75125 hp)
Manual Release
a b
Down
Pressure
525880 psi
v
h d
u l
i j k
t
e
f Reservoir Oil
m n
Return Oil
g
Í Í
g
Í Í
Filtered Oil
Manual Tilt
To manually tilt the outboard engine, the owner will need to back out the manual release
valve (p) 3-4 turns. With the valve backed out, the internal passages inside the manifold are
connected together. These passages connect both the cylinder down and up cavities to-
gether, along with the reservoir, allowing the engine to be raised or lowered. Piston rod (a)
movement will continue until the manual release valve (p) is closed, locking the fluid inside
of the cylinder and manifold.
Troubleshooting
Support outboard with tilt lock pin when servicing power trim system.
IMPORTANT: After debris or failed components have been found (during trouble-
shooting procedure), it is recommended that unit be disassembled completely and
ALL O-rings be replaced. Check ball valve components and castings must be
cleaned using engine cleaner and compressed air or replaced prior to re-assembly.
IMPORTANT: Power trim system is pressurized. Outboard must be in the full “UP” po-
sition (trim rod fully extended) prior to fill/drain plug, or manual release valve remov-
al.
Refer to instructions following if disassembly is required when servicing.
Follow preliminary checks before proceeding to troubleshooting flow diagrams (following).
Preliminary Checks
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 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 “Bleeding Power Trim Unit”.
3. Check for external leaks in Power Trim system. Replace defective part(s) if leak is found.
4. Outboard not holding tilted position (falls down to trim position) indicates debris or defec-
tive components in trim assembly. Clean or replace components as required.
Replace PO check
valve assembly. Trim system holds
reverse thrust. Test-
ing complete.
Trim will not hold
reverse thrust.
Trim system holds re-
verse thrust. Testing
complete.
continued on next page
Manual release valve Inspect manual release valve. Manual release valve and O-
and O-ring damaged. rings appear to be O.K. - Clean
and reinstall manual release
valve.
Replace tilt relief valve- Trim system leaks Trim system does
ing. down. not leak down. Test-
ing complete.
a DN
b DN
BLU/WHT
c
GRN/WHT
BLU/WHT or PUR
GRN/WHT or GRN
RED
1 3
RED/PUR
RED
n d
15 RED/PUR
RED 2
– + 2 4
GRN/WHT
f i
BLU/WHT
e
g
l
33
GRN/WHT GRN/WHT
GRN
14 BLK
RED GRN/WHT
BLK
m
44 11
h
UP
j
DN
k
Trim Switch “UP” is inopera- 1. Open wire between Wire Connection (1) 1. Check for an open connection or cut
tive, but the Cowl Switch and Trim Switch. wire.
“UP” does operate. 2. Faulty Trim Switch. 2. Replace.
Cowl Switch “UP” is inopera- 1. Open wire between Wire Connection (2) 1. Check for an open connection or cut
tive, but the Trim Switch “UP” and Solenoid. wire.
does operate. 2. Faulty Cowl Switch. 2. Replace.
Trim Switch “UP” and Cowl 1. Open wire between Wire Connection (1) 1. Check for an open connection.
Switch “UP” are both inop- and the “Up” Relay.
erative. 2. Open BLK wire between ground and 2. Check for an open connection.
“UP” Relay.
3. Open RED wire between Solenoid and 3. Check for an open connection.
“UP” Relay.
4. Faulty “UP” Relay. 4. Replace.
Trim Switch “DOWN” is inop- 1. Open wire between Wire Connection (3) 1. Check for an open connection or cut
erative, but the Cowl Switch and Trim Switch. wire.
“DOWN” does operate. 2. Faulty Trim Switch. 2. Replace.
Cowl Switch “DOWN” is inop- 1. Open wire between Wire Connection (2) 1. Check for a open connection or cut
erative, but the Trim Switch and Solenoid. wire.
“DOWN” does operate. 2. Faulty Cowl Switch. 2. Replace
Trim Switch “DOWN” and 1. Open wire between Wire Connection (3) 1. Check for an open connection.
Cowl Switch “DOWN” are and the “UP” Relay.
both inoperative. 2. Open BLK wire between ground and 2. Check for an open connection.
“DOWN” Relay.
3. Open RED wire between Solenoid and 3. Check for an open connection.
“DOWN” Relay.
4. Faulty “DOWN” Relay 4. Replace.
Trim Switch “UP” and 1. 20 AMP Fuse blown. 1. Replace fuse. Locate the cause of
“DOWN” are both inopera- the blown fuse. Check electrical wiring
tive, but the Cowl Switch for a shorted circuit.
does operate. 2. Faulty trim switch. 2. Replace.
3. Wire is open between fuse holder and 3. Check for a open connection or cut
solenoid. wire.
4. Wire is open between fuse holder and 4. Check for a loose or corroded con-
trim switch. nection.
Trim Switch and Cowl Switch 1. One of the Trim Pump Motor wires is 1. Check wire connections (4) for loose
are both inoperative. open between the motor and the Relays. or corroded condition.
2. Faulty trim pump motor. 2. If voltage is present at connections
(4) when the appropriate trim button is
pressed, then motor is faulty. Replace
motor.
Trim system operates (motor 1. The Trim or Cowl switch is shorted. 1. Replace.
runs) without pressing the
switches.
b
a
c
55264
55464
a
b
c
55331
a - Trilobe Pin
b - Upper Pivot Pin
c - Sacrificial Anode
6. Use suitable punch to remove (Drive Down) lower pin. Retain dowel pin.
7. Use suitable punch to drive out lower pivot pin.
a b 51144
51144
a - Dowel Pin
b - Lower Pivot Pin
55263
a - Reservoir Cap
b - Manual Release Valve
b
c
a - Screw (4)
b - Reservoir
c - Reservoir Seal
d - Coupler
e - Manifold Assembly
Pump and Components Removal
1. Remove pressure operated plugs on pump. Remove spring and check valve/poppet
(both sides). Use special tool CG 41-11 and special tool CG 41-14 with 5/16″ end to re-
move spool.
a
b
c
d
e
d
c
b
a
a - Plug (2)
b - Spring (2)
c - Check Valve/Poppet (2)
d - Seat (2)
e - Spool
IMPORTANT: Inspect poppet assembly for debris in the area shown. If debris is found
on poppet replace poppet.
2. Remove three (3) screws to remove pump. Remove filter and filter seal under pump.
Remove suction seat assembly.
a
d
b
Manifold Removal
1. Remove two (2) screws to remove manifold from cylinder.
2. Remove tilt relief components.
a
e
51146 51008
a - Screw (2)
b - Spring
c - Poppet
d - Spool Housing
e - Trim Limit Spool
b
b
a - End Cap
b - O-ring (2)
c - Wiper Ring
51143
a - Screw (3)
b - Plate
c - Shock Rod Piston
c
b
a
d
51147
a - Spring (5)
b - Seat (5)
c - Ball (5)
d - O-ring
CAUTION
When removing shock piston, spanner wrench must have 1/4 in. x 5/16 in. long pegs
to avoid damage to shock piston.
5. Place shock rod into soft jawed vise and apply heat to loosen piston using torch lamp
(P/N 91-63209).
6. Loosen shock rod piston using spanner wrench [1/4 in. x 5/16 in. (6.4mm x 8mm) long
pegs].
7. Allow shock rod piston to cool. Remove from shock rod.
a
b
51146
51146
a - Spanner Wrench
b - Shock Rod Piston
8. Inspect check valve for debris; clean debris from check valve if found. If debris cannot
be cleaned from check valve, replace shock piston as an assembly.
9. Clean shock and components with compressed air.
10. Remove inner o-ring from shock rod piston.
a b
51199
a - Shock Piston
b - O-ring
c
b
51145
a - Rod Wiper
b - Inner O-ring
c - Outer O-ring
51144
b. Blowing compressed air into manual release valve hole using air nozzle.
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.
NOTE: Point cylinder opening down and away. Use a shop rag or towel to avoid damage
to the memory piston.
2. Remove o-ring from memory piston.
a d
e
c
51144
55466
a - Adaptor/Air Hose
b - Memory Piston Exit
c - Shop Rag
d - O-Ring
e - Memory Piston
Cleaning/Inspection/Repair
IMPORTANT: Components must be dirt and lint free. Slightest amount of debris in
Power Trim system could cause system to malfunction.
Clean shock rod and components with parts cleaner and dry with compressed air.
It is recommended that all O-rings in trim system be replaced. Use O-Ring Kit 25-809880A1.
Lubricate all o-rings with Quicksilver Power Trim Fluid (92-90100A12). If not available, use
automotive (ATF) automatic transmission fluid.
Trim Motor Electrical Tests
1. Connect a 12 volt supply to motor leads. If motor fails to run, replace pump motor.
IMPORTANT: Trim Motor is not serviceable. If motor fails to run, replace motor assem-
bly.
Reassembly
O-Ring and Seal Placement
O-Rings and Seals are part of O-Ring Kit 25-809880A1.
22
33
22
20
8
9
19 10
21
21 11
12 13
14
18 9
15
10 16
9 17
8
O-ring Sizes
11 22
99
33
77
22 4
13
13
5
18 17 12 14
14
20 15
66
16
16
19
19 Cutaway View of O-Ring
8
8
Width
10 21
21
10
11
11 O-RINGS SHOWN ARE ACTUAL O.D. I.D.
SIZE
c
b
e f
51145
d 51199
a - Rod Wiper
b - Inner O-ring
c - Outer O-ring
d - Shock Piston
e - O-ring
f - O-ring
4. Clamp shock rod in soft jawed vise.
5. Position cylinder end cap onto rod as shown.
51146
CAUTION
When installing shock rod piston, spanner wrench must have 1/4 in. x 5/16 in.
(6.4mm x 8mm) long pegs to avoid damage to shock rod piston.
6. Apply Loctite Grade “A” (271) to threads on shock rod.
7. Install shock rod piston.
8. Tighten shock rod piston securely using spanner wrench (1/4 in. x 5/16 in. long pegs).
If a torquing type spanner tool is used to tighten shock piston, then torque to 90 lb-ft (122
Nm).
b a
51146
e
d
c
a
b 51147
b
c
a - Memory Piston
b - O-ring
c - Oil Blow Off Ball Passage
CAUTION
End cap must not make contact with shock rod piston when tightening. Shock rod
piston must be positioned in cylinder deep enough to avoid contact.
5. Tighten end cap securely using spanner wrench [1/4 in. x 5/16 in. (6.4mm x 8mm) long
pegs]. If a torquing type spanner tool is used to tighten end cap, then torque to 45 lb-ft
(61.0 Nm).
or or a
d
51008
a - Spring
b - Poppet
c - Spool Housing
d - Trim Limit Spool
b
a - Manifold
b - Manual Release Valve
c - E Clip
Manifold Installation
1. Install dowel pin and two (2) lubricated o-rings into trim cylinder.
a - O-Ring (2)
b - Dowel Pin
2. Align the trim cylinder and pump/reservoir assembly together.
3. Install the two (2) long screws and torque to 100 lb-in. (11 Nm).
c
b
51146
a
b
2. Install spool, seat with o-ring, check valve/poppet, spring and plug with o-ring into pump.
Repeat for other side. Torque plugs to 120 lb-in. (13.5 Nm).
a
b
c
d
e
d
c
b
a
a - Plug (2) Torque to 120 lb-in. (13.5 Nm)
b - Spring (2)
c - Check Valve/Poppet (2)
d - Seat (2)
e - Spool
Reservoir/Motor Installation
1. Install coupler into top of pump. Make sure reservoir seal is in the reservoir groove and
place reservoir onto pump/manifold assembly. Install ground strap under screw shown
Torque screws to 80 lb-in. (9 Nm).
55263
a 95
51148
a 95
b
51147
55467
5. Using a suitable punch, drive lower dowel pin into its hole until seated.
6. Apply 2-4-C Marine Lubricant to surface of upper pivot pin, pivot pin bore and trim ram
bore.
b
d
a
c
95
51148 51148
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 pivot pin into its hole until seated.
51148
55464
a - Pivot Pin
b - Swivel Bracket
c - Trim Ram
d - Trilobe Pin
9. Install sacrificial aluminum anode to reservoir bracket placing ground strap between
bracket and anode, as shown.
10. Route trim harness through clamp bracket and cowling.
b
a
c 55465
55264
a - Sacrificial Anode
b - Ground Strap
c - Bracket
d - Trim Harness
55264
a - Clamp
MID-SECTION
Section 5C - Manual Tilt Assist
Table of Contents
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-1 Memory Piston Removal . . . . . . . . . . . . . . 5C-24
Manual Tilt Components . . . . . . . . . . . . . . . . . 5C-2 Valve Block Disassembly . . . . . . . . . . . . . . . . . 5C-26
Manual Trim Flow Diagrams . . . . . . . . . . . . . . 5C-4 Reassembly - O-Ring and Seal Placement . 5C-27
Up Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-4 Actual O-Ring Sizes . . . . . . . . . . . . . . . . . . . . . 5C-28
Down Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 5C-6 O-ring Description and Sizes . . . . . . . . . . . . . . 5C-29
Slow Tilt Down Under High Thrust . . . . . . 5C-8 Manual Tilt System Cleaning and Inspection 5C-29
Under Water Strike (Valves Open) . . . . . . 5C-10 Manual Tilt System Reassembly . . . . . . . . . . 5C-29
Shock Function (Valve Closed) . . . . . . . . . 5C-12 Valve Block Installation . . . . . . . . . . . . . . . . 5C-32
Shock Function Return . . . . . . . . . . . . . . . . 5C-14 Shock Rod Reassembly . . . . . . . . . . . . . . . 5C-33
Hydraulic System Troubleshooting . . . . . . . . . 5C-16 Shock Rod Installation and Fluid
Manual Tilt System Removal . . . . . . . . . . . . . . 5C-18 Filling Procedure . . . . . . . . . . . . . . . . . . . . . 5C-35
Manual Tilt System Disassembly . . . . . . . . . . 5C-19 Filling Procedure Option Two Instructions
Accumulator Removal . . . . . . . . . . . . . . . . .
Shock Rod Removal . . . . . . . . . . . . . . . . . .
5C-20
5C-21
for Making Retaining Tool . . . . . . . . . . . . . . . .
Bleeding Manual Tilt System . . . . . . . . . . . . . .
5C-37
5C-38
5
Shock Rod Disassembly . . . . . . . . . . . . . . . . . 5C-21 Manual Tilt System Installation . . . . . . . . . . . . 5C-40 C
Valve Block Removal . . . . . . . . . . . . . . . . . 5C-24 Manual Release Valve Adjustment . . . . . . 5C-42
Special Tools
1. Spanner Wrench P/N 91-74951
1 12
f
95
2
4
7
b
e 11
8
6
7
5 d
6 11 8 11
13
8 9
11 8
11
12
9
95
8 10
c
7 Loctite 271 (92-809819)
95 2-4-C With Teflon (92-850736A1)
NOTE: Lubricate all O-rings using Quicksilver Power Trim and Steering Fluid. If not avail-
able, use automotive (ATF) automatic transmission fluid.
NOTE: It is recommended that all o-rings be replaced when servicing tilt system.
b
a
p
e
o
f
n
k
m
j i h g
l
Up Circuit
With the engine in the down position, the accumulator piston (d) will be at the top of the accu-
mulator (c) with the gas at maximum pressure. To raise the engine, the camshaft lever (f)
is rotated all the way down. The internal shaft connected to the camshaft lever will move the
push rods, opening the accumulator check valve (e), both fast transfer valves (h & j) and
the down circuit slow transfer valve (i). As the operator lifts the engine, oil, under pressure
inside the accumulator, will flow around both the slow transfer valve (i) and the down circuit
fast transfer valve (h). Oil flows into the bottom of the tilt cylinder forcing the memory piston
(m) into the shock piston (n) and then forcing the shock rod up and out. Oil above the shock
piston exits the cylinder (l) through an interconnecting passage along side of the cylinder
and returns into the manifold (g). Inside the manifold the oil flows past the groove in the
surge valve (k), through the up circuit fast transfer valve (j) and mixes with the oil flowing
from the accumulator into the up cavity. With the engine in the correct position, the camshaft
lever (f) is rotated up and the push rods allow the check valves (e, h, i, & j) to close. The
closed check valves prevent the oil from traveling between cavities and locks the engine into
position.
Down Circuit
b
a
p
e
f
n
m k
j i h g
l
Down Circuit
With the engine tilted up, the piston (inside the accumulator (d)) will be at the bottom of the
accumulator, (c) and the gas pressure low. To lower the engine, the camshaft lever (f) is ro-
tated down, the internal cam will cause the push rods to open the accumulator check valve
(e), both fast transfer valves (h & j) and the down circuit slow transfer valve (i). The operator
will have to press down on the engine cowl to overcome the pressure inside cylinder. Fluid
will flow out of the bottom of the cylinder, past both the down circuit fast transfer valve (h)
and down circuit slow transfer valve (i). Fluid will flow past the up circuit fast transfer valve
(j), surge valve (k) and through the interconnecting passage into the top of the cylinder (l).
Due to the shock rod (a), the tilt cylinder cavities differ in volume, the extra fluid from the up
cavity [forced into the accumulator (c)] will cause the internal accumulator piston (d) to com-
press the gas. With the engine in the correct position, the camshaft lever is rotated up and
the push rods allow the check valves (e, h, i, & j) to close.
b
a
p f
e
o
n
k
m
j i h g
l
b
a
f
n
k
m
j i h g
l
b
a
c
Accumulator
Gas Pressure
400 PSI
d
o
e
n
f
k
m
j i h g
l
b
a
o
e
n
f
k
m
j i h g
l
51143
a - Link Rod
b - Manual Release Lever
c - Accumulator
2. Check for external leaks in the manual tilt system. Replace defective part(s) if leak is
found.
IMPORTANT: If cut or damaged o-rings are found, inspect machined surfaces for
scoring, burrs or debris.
3. Check for discharged accumulator. 35 to 50 lb-ft (47-68 Nm) of pulling force must be at-
tained when tilting outboard from full “down” to full “up” position. If more than 50 lb-ft (68
Nm) of force is required, replace accumulator.
a
50431
a - Weight Scale
b - Valve Lever (open position)
WARNING
Service or installation of the tilt system may result in loss of pressure in the shock
cylinder. If the outboard is not in the full down position, such loss of pressure will
cause the engine to fall to the full down position with a potential for damaging en-
gine or causing personal injury. To avoid such injury support outboard in the up po-
sition using tilt lock lever.
WARNING
Manual tilt system is pressurized. Accumulator must be removed when shock rod
is in the full up position, prior to servicing, otherwise oil spray-back may occur.
b
d
51144
51143
a - Link Rod
b - Accumulator
c - Dowel Pin
d - Wood
4. Position tilt lock and remove piece of wood. Use suitable punch to drive out upper pivot
pin.
5. Use punch to remove (Drive Down) lower dowel pin. Retain dowel pin.
b c
51144 51144
a - Pivot Pin
b - Tilt Lock
c - Dowel Pin
b 1
a 51144
2
51144
a - Pivot Pin
b - Manual Tilt System
WARNING
This tilt system is pressurized. Remove accumulator only when shock rod is in full
up position.
Accumulator Removal
1. Place manual tilt system in soft jawed vise.
2. Position shock rod to full up position.
3. Open cam shaft valve (Down Position).
4. Loosen velocity valve enough to drip, wait until dripping stops.
5. When fluid stops dripping, loosen and remove accumulator.
6. If plunger can be compressed into accumulator by hand, accumulator is defective. Re-
place accumulator.
a
b
c
51143
51143
a - Accumulator
b - Cam Lever
c - Velocity Valve
d - Plunger
7. Once accumulator is removed, remove o-ring, conical spring, steel ball and plunger.
a
b
c
d
51145
a - Conical Spring
b - Steel Ball
c - Plunger
d - O-ring
91-74951
51145
a
a - End Cap
b - O-ring (2)
c - Wiper Ring
b
c
51143
a - Screw (3)
b - Plate
c - Shock Rod Piston
c
b
a
d 51147
a - Spring (5)
b - Seat (5)
c - Ball (5)
d - O-ring
CAUTION
When removing shock piston, spanner wrench must have 1/4 in. x 5/16 in. long pegs
to avoid damage to shock piston.
5. Place shock rod into soft jawed vise and apply heat to loosen piston using torch lamp
(P/N 91-63209).
6. Loosen shock rod piston using spanner wrench [1/4 in. x 5/16 in. (6.4mm x 8mm) long
pegs].
7. Allow shock rod piston to cool. Remove from shock rod.
a
b
91-74951
91-63209
a - Spanner Wrench
b - Shock Rod Piston
8. Inspect check valve for debris; clean debris from check valve if found. If debris cannot
be cleaned from check valve, replace shock piston as an assembly.
9. Clean shock and components with compressed air.
10. Remove inner O-ring.
b
a 51199
a - Shock Piston
b - O-ring
c
b
51147 51145
a - Rod Wiper
b - Inner O-ring
c - Outer O-ring
e
b
aa
51148
c
51146
a - Screw
b - Valve Block
c - Shock Rod Cylinder
d - O-ring (2)
e - Dowel Pin (2)
51144
91-822778A3
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.
NOTE: Point cylinder opening down and away. Use a shop rag or towel to avoid damage
to the memory piston. Fluid will blow out also.
2. Remove O-ring from memory piston.
a
d
51144
55466
a - Adaptor/Air Hose
b - Memory Piston Exit
c - Shop Rag
d - O-Ring
e - Memory Piston
c
d
e
f
a
b 51142
b c
a
14
7
9
6
11 12
10
13
NOTE: Lubricate all O-rings using Quicksilver Power Trim and Steering Fluid. If not avail-
able, use automotive (ATF) automatic transmission fluid.
NOTE: It is recommended that all o-rings be replaced when servicing tilt system.
2 9
14
4
5 10
Width
7 12
O.D. I.D.
8 (2)
f g
e
d
c
b
a
95
b
c
51145
a - Conical Spring
b - Steel Ball
c - Plunger
d - O-ring
a
b
c
d
a - Spool
b - Spring
c - O-ring
d - Velocity Valve - Torque to 75 lb-in. (8.5 Nm)
c
d
e 51142
a - Plunger
b - Spring (Large)
c - Ball
d - Spring (Small)
e - Plug
b
c
d
e
51142
a - Plunger (2)
b - Steel Ball (2)
c - Spring (2)
d - O-ring (2)
e - Screw Plug (2) Torque to 75 lb-in. (8.5 Nm)
b c
1
d
e
51148
51146
a - O-ring (2)
b - Dowel Pin (2)
c - Valve Block
d - Screw (2) Torque to 100 lb-in. (11 Nm)
e - Shock Rod Cylinder
c e
b f
51145
d 51199
a - Rod Wiper
b - Inner O-ring
c - Outer O-ring
d - Shock Piston
e - O-ring
f - O-ring
51146
CAUTION
When installing shock rod piston, spanner wrench must have1/4 in. x 5/16 in.
(6.4mm x8mm) long pegs to avoid damage to shock rod piston.
6. Apply Loctite Grade “A” (271) to threads on shock rod.
7. Install shock rod piston.
8. Tighten shock rod piston securely using spanner wrench [1/4 in. x 5/16 in. (6.4mm x
8mm) long pegs]. If a torquing type spanner tool is used to tighten shock piston, then
torque to 90 lb-ft (122 Nm).
a b
91-74951
7
a - Spanner Wrench
b - Shock Rod Piston - Torque to 90 lb-ft (122 Nm)
9. Install ball, seat, and spring (five sets) to shock rod piston.
10. Secure components with plate. Torque screws to 35 lb-in. (3.9 Nm).
11. Remove shock rod assembly from vise.
e
d
c
a
b 51147
51144
5. Fill top of cylinder again with fluid to top and install shock rod assembly on top memory
piston. Open cam lever (Down Position) and push shock rod assembly down to 1/8″ be-
low cylinder threads. Close cam lever (Up Position).
6. Fill top of shock rod assembly with fluid to top of cylinder. Open cam lever (Down Posi-
tion) and screw cylinder cap down.
7. Tighten end cap securely using spanner wrench [1/4 in. x 5/16 in. (6.4mm x 8mm) long
pegs]. If a torquing type spanner tool is used to tighten end cap, then torque the end cap
to 45 lb-ft (61.0 Nm). Close cam lever (Up Position).
51145
8. Open and close cam lever, watching for bubbles coming from accumulator check ball
hole. When bubbles stop, fill accumulator opening to top with fluid. Grease threads on
accumulator and opening with 2-4-C with Teflon. Start accumulator in threads and open
cam lever (Down Position). Torque accumulator to 35 lb–ft (47 Nm).
a b
51143
a - Accumulator
b - Cam Lever (Down Position)
NOTE: If filling procedure is done correctly, it should be hard to turn cylinder rod assembly
by hand.
3/16 in x 3 in.
(5 x 7.5 cm)
Steel Plate
10 in.
(25 cm)
1 in. 8 in.
(25mm) (20 cm)
3 in.
(76mm)
20 in.
(508mm)
2 in.
(50mm)
4 in.
(100 mm)
e b
c
a
d 50447
a - Retaining Tool
b - Tilt System
c - Container
d - Cam Lever
e - Accumulator Opening
3. Bleed unit by pushing rod down slowly (18-20 seconds per stroke) until stopped at base.
Wait until all air bubbles exit accumulator base.
50432
4. During up stroke, pull up on rod slowly 3 in. (76 mm) from base.
5. Wait until all air bubbles to exit accumulator base.
50433
6. Slowly cycle unit 5-8 times (round trip per cycle) using short strokes 3 in. (76 mm) from
base allowing bubbles to disappear during each stroke.
7. Allow unit to stand five minutes, then proceed to cycle unit 2-3 more times using short
strokes. No air bubbles should appear from accumulator port at this time.
8. With oil level well above accumulator port, slowly pull rod to full up position.
9. Install accumulator making sure air bubbles do not enter system.
10. Tighten accumulator snugly at this time.
50432
50432
11. With cam lever remaining open (facing down), remove tilt assembly from oil and secure
in soft jawed vise. Torque accumulator to 35 lb-ft (47 Nm).
50433
a
95
51148 1
51144
95 2-4-C w/Teflon (92-850736A1)
4. Using a suitable punch, drive lower pivot pin into clamp bracket and trim cylinder assem-
bly until pivot pin is flush with outside surface.
5. Using a punch, drive lower dowel pin in until seated.
a b
51147 51148
6. Apply 2-4-C Marine Lubricant to surface of upper pivot pin, pivot pin hole and shock rod
hole.
7. Using a mallet, drive upper pivot pin into swivel bracket and through shock rod until pivot
pin is flush with swivel bracket.
a
c
e
f
b
d
95
51148
95 2-4-C w/Teflon (92-850736A1) 51148
a - Pivot Pin
b - Pivot Pin Bore
c - Shock Rod Bore
d - Pivot Pin
e - Swivel Bracket
f - Shock Rod
8. Drive upper dowel pin (a) into its hole until seated.
51147
a - Dowel Pin
9. Check manual release cam adjustment. Cam must open and close freely. Adjust link rod
as necessary.
b
51143
LOWER UNIT
Section 6A - Non-Bigfoot Gear Housing
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-1 Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . 6A-26
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2 Forward Gear Bearing Race . . . . . . . . . . . 6A-28
Quicksilver Lubricants and Service Aids . . . . 6A-5 Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . . 6A-28
Gear Housing (Drive Shaft - 1.83:1) . . . . . . . 6A-6 Reverse Gear . . . . . . . . . . . . . . . . . . . . . . . . 6A-31
Gear Housing (Prop Shaft - 1.83:1) . . . . . . . . 6A-8 Forward Gear . . . . . . . . . . . . . . . . . . . . . . . . 6A-32
General Service Recommendations . . . . . . . 6A-10 Lower Driveshaft Bearing Installation . . . 6A-33
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-10 Upper Driveshaft Bearing Installation . . . 6A-34
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-10 Forward Gear, Pinion Gear and
Draining and Inspecting Gear Lubricant . . . . 6A-11 Driveshaft Assembly Installation . . . . . . . 6A-35
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-12 Pinion Gear Location and
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-13 Forward Gear Backlash . . . . . . . . . . . . . . 6A-36
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . 6A-13 Determining Pinion Gear Location . . . . . . 6A-36
Bearing Carrier and Propeller Shaft . . . . . 6A-15 Determining Forward Gear Backlash . . . . 6A-39
Propeller Shaft Disassembly . . . . . . . . . . . . . . 6A-18 Bearing Carrier and
Pinion Gear, Driveshaft and Forward Gear . . 6A-20 Propeller Shaft Installation . . . . . . . . . . . . 6A-41
Upper Driveshaft Bearing . . . . . . . . . . . . . . . . . 6A-21 Water Pump Re-Assembly/Installation . . 6A-42
Lower Driveshaft Bearing . . . . . . . . . . . . . .
Forward Gear Bearing Race . . . . . . . . . . .
6A-22
6A-22
Gear Housing Pressure Test . . . . . . . . . . . . . .
Gear Housing Installation . . . . . . . . . . . . . . . . .
6A-47
6A-48
6
Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-23 Filling Gear Housing with Lubricant . . . . . . . . 6A-50 A
Gear Housing Reassembly . . . . . . . . . . . . . . . 6A-25 Trim Tab Adjustment and Replacement . . . . 6A-51
Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-25
Specifications
Special Tools
1. Bearing Preload Tool 91-14311A2
19660-1
3. Puller 91-27780
d
a
c
51043
91-817057A-1 Update Kit (Converts 91-14311A-1 Bearing Preload Kit Tool to a 91-14311A-2)
30 22
28 21
95
27 29 20
95 19
32 29
34
95
33
23
95 18
24
26 7
25
95 10
87 95
6
7
7
17
7 9
15
8 16
5
1 14 95
4
3
35
13
11
12
3 4
7
4
2
59
65
61
60
1
95 95
63 46
45
64 47
43
42 66
7 40
41 67
56 38
57
58 39
37
62
55
54
95 53 7
51
95
95 52
50
49
94 48
44
b
53922
a - Vent Plug
b - Fill/Drain Plug
2. Inspect gear lubricant for metal particles (lubricant will have a “metal flake” appearance).
Presence of fine metal particles (resembling powder) in the drain pan indicates normal
wear. The presence of metal chips in the drain pan 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 lu-
bricant. 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 suspected to be present in gearcase, a pressure check of gearcase should be made
(with no lubricant in gearcase). Gearcase should hold 10-12 psi of pressure for 5 min-
utes 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, bearings and bearing surfaces,
as well as gear housing components. If gearcase is rebuilt, gearcase should be pressure
checked before filling with lubricant.
Removal
WARNING
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 and washers, two from each side.
5. Remove trim tab.
6. Remove locknut and washer in trim tab recess.
7. Remove gear housing.
a c
53992
a - Trim Tab
b - Locknut and Washer
c - Bolts(4) M10 x 45 and Washers(4)
Disassembly
Water Pump
NOTE: 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.
1. Replace water tube seal, if damaged.
2. Remove 6 screws, washers, and isolators (Design 1).
3. Remove cover.
NOTE: Isolators from forward 2 screws are shorter than the other isolators. Retain these
for proper reassembly (Design 1).
NOTE: Design 1 included isolators on the water pump housing screws. Newer design ver-
sions did not use these isolators.
a
e
b
b
c
d
IMPORTANT: The circular groove formed by the impeller sealing bead should be dis-
regarded when inspecting cover and plate, as the depth of the groove will not affect
water pump output.
4. Replace cover if thickness of steel at the discharge slots is 0.060 in. (1.524 mm) or less,
or if groove(s) (other than impeller sealing bead groove) in cover roof are more than
0.030 in. (0.762 mm) deep.
5. Lift impeller, drive key, and gasket from drive shaft.
c b
19220
a - Impeller
b - Drive Key
c - Gasket
a - Plate
b - Gasket
Old Style Base
9. Remove water pump base by lifting gently as shown. Inspect carefully for cracks.
51206
55874
11. Remove (and discard) seals, if damaged. Secure the base to a bench top or lightly
clamp base in vise when removing seals.
51205
a - Seals
ÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉ
b
ÉÉÉÉÉÉÉ
a
51268
a - Seal
b - Plate
Bearing Carrier and Propeller Shaft
1. Remove fasteners.
a 51117
a - Fasteners
2. With propeller shaft horizontal, use bearing puller to remove carrier from gear housing.
Remove propeller shaft components as an assembly, taking care not to lose cam follow-
er.
b
e
c a 91-46086A1 Puller Jaws
91–58716 Puller Bolt
d 51116
a - Bearing Carrier
b - Puller Jaws (91-46086A1)
c - Puller Bolt (91-85716)
d - Thrust Hub
e - Propeller Shaft
3. Replace reverse gear if gear teeth or clutch teeth on reverse gear are chipped or worn.
If reverse gear must be replaced, pinion and sliding clutch should also be inspected for
damage.
4. If reverse gear bearing is rusted or does not roll freely, replace bearing. Remove bearing
and reverse gear using bearing puller.
a
91-27780
5. Remove ball bearing from reverse gear using Universal Puller Plate and mandrel.
a
d
91-37312 91-37241
b c
51269
a - Ball Bearing
b - Reverse Gear
c - Universal Puller Plate (91-37241)
d - Driver Head (91-37312)
6. If bearing is rusted or does not roll freely, replace bearing. Remove bearing and oil seals.
Discard oil seals.
91-37323
a
b 91-37312
51263
a - O-ring
d
b
c
a
a - Spring
b - Cam Follower
c - Apply Pressure as Shown
d - Punch
e - Cross Pin
a e c
b
d 51265
a - Cam Follower
b - Guide Block
c - Spring
d - Sliding Clutch
e - Jaws
4. Check bearing surfaces of propeller shaft. If shaft is worn/pitted, replace shaft and corre-
sponding bearing.
5. Replace propeller shaft if:
a. Splines are twisted or worn.
b. Bearing surfaces of propeller shaft are pitted or worn.
c. Oil seal surface is grooved in excess of 0.005 in. (0.12mm).
d. Shaft has a noticeable “wobble” or is bent more than 0.006 in. (.152 mm). Check with
a dial indicator and V-blocks.
c b
51139
a
a - V-Blocks
b - Bearing Surfaces
c - Check with Dial Indicator Here
e
a d
a - Pinion Nut
b - Driveshaft
c - Pinion Gear
d - Bearing
e - Forward Gear
6. Replace forward gear needle bearing if rusted or does not roll freely after cleaning in
solvent. Remove as shown.
a - Needle Bearing
7. Replace forward gear tapered roller bearing and race if either bearing or race are rusted
or damaged; or if bearing does not roll freely after cleaning in solvent. Remove bearing
from gear using Universal Puller Plate and Mandrel. To remove race, refer to “Forward
Gear Bearing Race”, following.
a c
91-37241
b
51119
a - Bearing/Race
b - Puller Plate (91-37241)
c - Mandrel
51271
a - Bearing
c
a
91-817058A1
51260
a - Bearing
b - Removal Tool (91-817058A1)
c - Bushing
91-27780
c b
a
a - Race
b - Shim(s)
c - Bearing Puller (91-27780)
Shift Shaft
1. Remove shift shaft coupler and spacer.
51271
a - Coupler
b - Spacer
2. Remove shift shaft bushing and shift shaft. Protect shift shaft to prevent spline damage.
51205
51117
NOTE: Remove any burrs or sharp edges on the shift shaft splines before removing the shift
shaft bushing.
4. Remove shift shaft bushing and “E” clip from shift shaft. Replace shift shaft if splines are
twisted or damaged on either end of shaft. Remove (and discard) O-ring if damaged.
d
b c
a
51264
51265
a - Seal
95
a
7
51270
7 Loctite 271 (92-809820)
95 2-4-C With Teflon (92-825407A12)
51264
95 2-4-C With Teflon (92-825407A12)
a - Shift Shaft
b - “E” Clip
c - Bushing
d - O-ring
5. Install shift cam; align hole in shift cam with shift shaft pilot bore.
a a
b c
51117
51268
95 e
b
95 2-4-C w/Teflon (92-850736A1)
a - Spring
b - Clutch (Align Hole with Slot in Prop Shaft)
c - Guide Block
d - Cam Follower (Hold in Place with 2-4-C w/Teflon)
e - Propshaft Shoulder
b
a 51268
a - Cross Pin
b - Cam Follower
c - Apply Pressure in This Direction
3. Install spring.
NOTE: Spring windings must lay flat in clutch groove. DO NOT allow spring coils to overlap
each other.
a
51265
a - Spring
d c a
b 4
91-817009 51265
Bearing Carrier
1. Lubricate O.D. of needle bearing with 2-4-C w/Teflon.
2. Install needle bearing.
Installation Note: Push against numbered end of bearing.
b
a
91-817011
95
51269
3. Apply Loctite 271 on O.D. of small diameter oil seal. Seal lip should face away from
shoulder on Installation Tool. Press seal in until Installer Tool bottoms out.
7 a
91-817007
58209
7 Loctite “271” (92-809819)
a - Small Diameter Seal
b - Installer Tool (91-817007)
4. Apply Loctite 271 on O.D. of larger diameter oil seal. Seal lip should face towards shoul-
der on installation tool. Press in until Installer tool bottoms out.
7
a 91-817007
51263
7 Loctite “271” (92-809819)
a - Large Diameter Seal
b - Installer Tool (91-817007)
Installation Note: If service tools are not available, the following reference dimensions ap-
ply for installing bearing and seals to proper depths.
.82 in. (20mm)
a
51275
a - Bearing
b
a
51275
Reverse Gear
1. Lubricate I.D. of bearing with 2-4-C w/Teflon. Use suitable mandrel and press onto gear
until bearing bottoms.
b
a
95
51205
95 2-4-C With Teflon (92-825407A12)
a - Bearing
b - Suitable Mandrel
2. Lubricate O.D. of bearing with 2-4-c w/Teflon. Use suitable mandrel and press reverse
gear/bearing assembly into bearing carrier until bearing bottoms out.
c
95
51264
95 2-4-C With Teflon (92-825407A12)
a - Reverse Gear and Bearing Assembly
b - Suitable Mandrel
c - Bearing Carrier
Forward Gear
1. Lubricate O.D. of bearing with 2-4-C w/Teflon. Press new propshaft bearing into gear
until Installer Tool bottoms.
Installation Note: Push against numbered end of bearing.
91-817005
95
2. Lubricate I.D. of bearing with 2-4-C w/Teflon. Use suitable mandrel and press tapered
roller bearing onto gear until bearing bottoms on gear.
b
95
a
51272
7.05 in.
7.07 in. ( )
179.0mm
179.5mm
b
95
c
91-817058A1
51260
95 2-4-C With Teflon (92-825407A12)
a - Needle Bearing (Lubricate O.D. Before Assembly)
b - Bearing Installer Tool (91-817058A1)
c - Reference (Bearing Depth)
95 a
51268
95 2-4-C With Teflon (92-825407A12)
Forward Gear, Pinion Gear, Upper Driveshaft Bearing Race, Retainer and
Driveshaft Installation
NOTE: If shim(s) were lost or are not reusable (damaged), start with approximately .015 in.
(0.361mm).
Install components in sequence shown.
g
91-43506
e
f
b
g a
51263
ASSEMBLY SEQUENCE
a - Forward Gear/Bearing: Apply Premium Blend Gear Lube to Bearing Rollers Be-
fore Installation
b - Pinion Gear
c - Driveshaft
d - Upper Driveshaft Bearing Race and Shim(s)
e - Upper Driveshaft Bearing Retainer. Tighten to Specified Torque using Tool
(91-43506)
f - Driveshaft Holding Tool
g - Pinion Nut (New) (See Note at “Pinion Gear Depth”, Following.) Recess in Nut
is Installed Toward Pinion Gear (See Inset).
Model Drive Shaft Holding Tool
40/50/60 (4-Stroke) 91-877840A1
55/60 (2-Stroke) 91-817070
h
3/4 in. (19mm) I.D.
i i
g
f
e
51270
c
a
19884
6. Insert Pinion Location Tool. Position access hole as shown. Insert feeler gauge between
gauging surface and pinion gear.
a b c d
91-817008A2
51265
7. The correct clearance between the gauging surface and the pinion gear is .025 in.
(0.64mm).
8. If clearance is more than .025 in. (0.64mm) remove shims from under the upper bearing
cup. If clearance is less than 0.25 in., add shims under the upper bearing race.
9. After final adjustment to pinion height, and forward gear backlash has been estab-
lished, apply Loctite 271 to threads and torque new pinion nut to specified torque.
NOTE: Clean driveshaft and pinion nut threads with Loctite Primer of suitable de-greaser
before applying Loctite.
51285
51263
7 Loctite “271” (92-809819)
a - Bearing Race
b - Shim(s)
c - Pinion Nut (Recessed Side Toward Pinion)
Pinion Nut Torque
50 lb-ft (67 Nm)
51119
c
a - Propeller Shaft*
b - Bearing Carrier* (Assembled)
c - Puller Jaws (91-46086A1)
d - Puller Bolt (91-58716)
Puller Bolt Torque
45 lb-in. (5.1 Nm)
d c
10. If backlash is less than the minimum reading, remove shim(s) from in front of the forward
gear bearing race. If backlash is more than the maximum reading, add shim(s) in front
of the forward gear bearing race. When final measurement has been made, apply Loc-
tite 271 to threads of pinion nut.
NOTE: By adding or subtracting .001 in. (0.025mm) shim, the backlash will change 0.001
in. (0.032mm).
a b
95 51271
a
b
51117
7
7 Loctite “271” (92-809819)
a - Bolts (2) M8x30
Bearing Carrier Bolt Torque
225 lb-in. / 18.8 lb-ft. (25.5 Nm)
7
91-817006
a
55876
7 Loctite 271 (92-809820)
a - Seal
b - Seal Installation Tool (91-817006)
3. Place seal on shorter shoulder side of tool. Seal spring should face the shoulder of the
tool during installation. Apply Loctite 271 to O.D. of seal.
4. Press into water pump base until tool bottoms.
b 91-817006
a
55877
a - Seal
b - Shorter Side of Tool
c - Seal Installation Tool (91-817006)
NOTE: If installation tool is not available, press seals in as shown to depths indicated.
55878
5. Install O-ring. Apply Quicksilver 2-4-C w/Teflon to o-ring,seal lips and gear housing bore.
6. Install water pump base into gear case.
95
55879
95 2-4-C w/Teflon (92-850736A1)
a - O-ring
b - Water Pump Base
c - Gear Case
7. If removed previously, re-install seal and filler plate.
ÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉ
b
a
ÉÉÉÉÉÉÉ
51268
a - Seal
b - Filler Plate
51293
a - Gasket
b - Face Plate
IMPORTANT: If the old impeller is re-used, install in the original (clockwise) direction
of rotation.
9. Install drive key and impeller.
51292
a - Drive Key
b - Impeller
10. Lubricate I.D. of cover with Quicksilver 2-4-C w/Teflon. Install gasket with bead facing up.
95
b
a
51290
11. Rotate driveshaft clockwise and push water pump housing down.
12. Apply Loctite 271 on threads and tighten screws to specified torque (in sequence
shown).
c d
d d
c
b b c 51275
1 3
4 2
51271
13. If water tube seal stayed on water tube (in driveshaft housing), pull seal from water tube.
14. Lubricate I.D. of water tube seal with Quicksilver 2-4-C w/Teflon and install.
51206
2. Pressurize housing to 10-12 PSI (69-83 kPa) and observe gauge for 5 minutes.
3. Rotate driveshaft, prop shaft and move shift rod while housing is pressurized to check
for leaks.
b
a
c
a - Shift Lever 40/50/60 EFI (4-Stroke)
b - Shift Lever 40/50/60 Carb (4-Stroke)
c - Shift Lever 60 Carb (2-Stroke)
2. Tilt engine to full “Up” position. Engage tilt lock lever.
3. Shift gear housing into neutral. Propeller shaft will rotate freely in either direction.
4. Install water tube seal, spacer and shift shaft coupler.
95
a c
51206
95 2-4-C w/Teflon (92-850736A1)
a - Water Tube Seal
b - Spacer
c - Shift Shaft Coupler
CAUTION
Do not lubricate top of driveshaft. Excess lubricant will not allow driveshaft to fully
engage crankshaft. Tightening the gear housing fasteners (if excess lubricant is on
top of driveshaft) will load the driveshaft/crankshaft and may damage either or both
powerhead and gear housing. Wipe the top of driveshaft free of lubricant.
5. Lightly apply Quicksilver 2-4-C w/Teflon onto the driveshaft splines.
6. Shift gear housing into forward gear. Gear housing will not engage when propeller shaft
is turned clockwise.
7. Position driveshaft into driveshaft housing. Move gear housing towards driveshaft hous-
ing while aligning shift shaft coupler, water tube seal and driveshaft splines.
NOTE: If the driveshaft splines will not align with the crankshaft splines, install a propeller
and turn the propeller shaft counterclockwise while pushing gear housing onto driveshaft
housing. It may also be necessary to move the shift block (on the powerhead) to align the
shift shaft splines for proper re-assembly.
8. Install 4 bolts and washers, (two each side). Apply Loctite 271 on bottom half of bolt
threads prior to installation.
9. Install locknut and washer.
10. Torque bolts and locknut to specified torque.
7 a
b
50551
WARNING
If gear housing is installed on outboard, 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.
1. Remove any gasket material from “Fill/Drain” and “Vent” plugs and gear housing. Install
new sealing washers on “Fill/Drain” and “Vent” plugs.
IMPORTANT: Never add lubricant without removing “Vent” plugs. Gear housing can-
not be filled because of trapped air. Fill gear housing when driveshaft is in a vertical
position.
2. Remove “Fill/Drain” plug and sealing washer.
3. Insert lubricant tube in “Fill/Drain” hole, then remove “Vent” plugs and sealing washer.
4. Fill until excess lubricant flows out of left “Vent” hole.
5. Replace left “Vent” plug and sealing washer and continue to fill until lubricant flows from
right “Vent” hole.
6. Replace right “Vent” plug and sealing washer.
7. Install “Fill/Drain” plug and sealing washer.
8. Torque screws to specified torque.
b
c
50558
a
a - “Fill/Drain” Plug
b - “Vent” Plug
c - “Vent” Plug
Screw Torque
58 lb-in. (6.5 Nm)
a
c
50553
a - Trim Tab
b - Anti-Ventilation Plate
c - Retaining Screw (M10x30) and Washer
Retaining Screw Torque
22 lb-ft (29.8 Nm)
LOWER UNIT
Section 6B - Bigfoot Gear Housing
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-1 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-31
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-2 Forward Gear Bearing Race . . . . . . . . . . . 6B-31
Quicksilver Lubricants and Service Aids . . . . 6B-6 Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-31
Gear Housing (Drive Shaft) 2.31:1 . . . . . . . . . 6B-7 Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . . 6B-34
Gear Housing (Prop Shaft) 2.31:1 . . . . . . . . . 6B-9 Forward Gear . . . . . . . . . . . . . . . . . . . . . . . . 6B-38
General Service Recommendations . . . . . . . 6B-11 Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . 6B-40
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-11 Drive Shaft Wear Sleeve . . . . . . . . . . . . . . 6B-41
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-11 Drive Shaft Lower Bearing Race . . . . . . . . 6B-43
Draining and Inspecting Gear Lubricant . . . . 6B-12 Oil Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-44
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-13 Drive Shaft Upper Bearing . . . . . . . . . . . . . 6B-44
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-14 Forward Gear, Drive Shaft Lower Bearing,
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . 6B-14 Pinion Gear, and Drive Shaft . . . . . . . . . . 6B-46
Bearing Carrier and Propeller Shaft . . . . . 6B-17 Pinion Gear Depth and
Pinion Gear, Drive Shaft, Forward Gear Backlash . . . . . . . . . . . . . . 6B-47
and Forward Gear . . . . . . . . . . . . . . . . . . . 6B-22 Bearing Carrier and Propeller Shaft . . . . . 6B-52
Upper Drive Shaft Bearing . . . . . . . . . . . . . 6B-25 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . 6B-54
Oil Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Drive Shaft Bearing Race . . . . . . . .
6B-26
6B-27
Gear Housing Pressure Test . . . . . . . . . . .
Filling Gear Housing With Lubricant . . . . . . .
6B-58
6B-59 6
Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-28 Gearcase Installation . . . . . . . . . . . . . . . . . . . . 6B-60 B
Forward Gear Bearing Race . . . . . . . . . . . 6B-30 Trim Tab Adjustment and Replacement . . 6B-65
Specifications
Gear Ratio 2.31:1
Gearcase Capacity 24.0 fl oz (710 mL)
Lubricant Type Quicksilver Gear Lube-Premium Blend
Forward Gear
Number of Teeth 30 Spiral/Bevel
Pinion Gear
Number of Teeth 13 Spiral/Bevel
Pinion Height 0.025 in. (0.64 mm)
GEAR HOUSING Pinion Gear Locating Tool 91-12349A2
BIGFOOT Flat Number #8
(2.31:1) Disc Number #3
Forward Gear Backlash 0.012 - 0.019 in. (0.30 - 0.48 mm)
Backlash Indicating Tool 91-78473
Mark Number #4
Water Pressure
@ 800 rpm 2-6 psi (14-41 kPa)
@ 6000 rpm (WOT) 12-25 psi (83-172 kPa)
Leak Test Pressure 10-12 psi (69-83 kPa)
for 5 Minutes
Special Tools
1. Pinion Gear Locating Tool (91-12349A2)
Disc 3 Disc1
Disc 2
55079
8. Mandrel (91-15755)*
73815
19660-1
73652
74184
19. Driver Shaft Holding Tool (91-56775, 2-Stroke), (91-56775, 40/50 4-Stroke,
747cc/935cc), (91-877840A1, 40/50/60 4-Stroke, 995cc), (91-804776A1, 75/90
4-Stroke)
56783
34 95
33
28
30
35 20
24
7
7 40 41
23
26 7
27 38
25 95 39
95
7 95
11
37
10
14 95 36
12
19
95
18
87
8 3
9
6
12
1
13
7 2
17
15
16 5
4
5
7 4
7 Loctite 271 (92-809820)
5
87 Premium Gear Lubricant (92-850737A1) 4
95 2-4-C With Teflon (92-850736A1)
95
4.25 IN./107.95MM
70 1
69 TORPEDO DIA.
50
BIGFOOT
44
48
49 47
45
46 42 87
43
67 68
95 75
57 68
95 95 74
55
72
54
73
53
52
51
7 7
65
66
64
95
87
71
60
59
58
56
95
61
95 63
Bearings
All bearings must be cleaned and inspected. Clean bearings with solvent and dry with com-
pressed air. Air should be directed at the bearing so that it passes through the bearing. DO
NOT spin bearing with compressed air, as this may cause bearing to score from lack of lu-
brication. After cleaning, lubricate bearings with Premium Blend Gear Lubricant. DO NOT
lubricate tapered bearing cups until after inspection.
Inspect ball bearings for roughness, catches and bearing race side wear. Work inner bear-
ing race in-and-out, while holding outer race, to check for side wear. When inspecting ta-
pered bearings, determine condition of rollers and inner bearing race by inspecting bearing
cup for pitting, scoring, grooves, uneven wear, imbedded particles and/or discoloration from
over-heating. Always replace tapered bearing and race as a set.
Inspect gear housing for bearing races that have spun in their respective bores. If race(s)
have spun, gear housing must be replaced.
Roller bearing condition is determined by inspecting the surface of the shaft that the roller
bearing supports. Check shaft surface for pitting, scoring, grooving, imbedded particles, un-
even wear and/or discoloration from overheating. The shaft and bearing must be replaced
if such a condition exists.
Seals
As a normal procedure, all O-rings and oil seals should be replaced without regard to ap-
pearance. To prevent leakage around seals, apply Loctite 271 to outer diameter of all metal
case seals. When using Loctite on seals or threads, surfaces must be clean and dry. Apply
2-4-C w/Teflon on all O-rings and on I.D. of oil seals. Apply 2-4-C w/Teflon to external sur-
faces of bearing carrier.
c b
53922
a - Fill/Drain Screw
b - Oil Level Screw
c - Vent Screw
2. Inspect gear lubricant for metal particles (lubricant will have a “metal flake” appearance).
Drain lube into a clean pan/container. Presence of fine metal particles (resembling pow-
der) in the gear lube indicates normal wear. The presence of metal chips in the gear lube
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 lu-
bricant. 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 suspected 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 min-
utes 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 compo-
nents for damage. If gearcase is rebuilt, gearcase should be pressure checked before
filling with lubricant.
Removal
WARNING
To prevent accidental engine starting, remove (and isolate) spark plug leads from
spark plugs before removing gear housing.
IMPORTANT: 90 hp (4-Stroke) models, when removing or installing gearcase care-
fully guide driveshaft through drive shaft bushing to avoid scoring bushing surface.
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 fasteners.
5. Remove locknut and washer.
6. Remove gear housing.
a
b
53992
Disassembly
Water Pump
NOTE: 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.
NOTE: Newer models will not have the isolators installed on the water pump.
1. Replace water tube seal, if damaged.
2. Remove 4 screws (2 on each side of water pump housing), washers, and isolators.
3. Remove cover.
a
c
19212
IMPORTANT: The circular groove formed by the impeller sealing bead should be dis-
regarded when inspecting cover (Step 4) and plate (Step 8), as the depth of the groove
will not affect water pump output.
4. Replace cover if thickness of steel at the discharge slots is 0.060 in. or less, or if
groove(s) (other than impeller sealing bead groove) in cover roof are more than 0.030
in. (0.762 mm) deep.
5. Lift impeller, drive key, and gasket from drive shaft.
c b
19220
a - Impeller
b - Drive Key
c - Gasket
19219
a - Plate
b - Gasket
c - Impeller Sealing Groove
19217
a - Screws and Washers (6 each)
10. Remove water pump base using flat screwdrivers to lightly pry up on base.
19226
a - Water Pump Base
11. Remove (and discard) seals (IT MAY BE BENEFICIAL TO CLAMP THE WATER PUMP
BASE IN A VISE WHILE REMOVING SEALS).
19195
a - Seals
19218
a - Gasket
a
51117
a - Fasteners
2. With propeller shaft horizontal, pull carrier (using tool shown) to break seal with gear
housing.
3. Remove bearing carrier/propeller shaft components as an assembly by pulling back on
the propshaft. Take care not to lose cam follower or 3 metal balls in end of propeller shaft.
4. Remove propeller shaft from bearing carrier.
b
e
c a
d 51116
a - Bearing Carrier
b - Puller Jaws (91-46086A1)
c - Puller Bolt (91-85716)
d - Thrust Hub
e - Propeller Shaft
5. Lift reverse gear, thrust bearing and thrust washer from bearing carrier. Replace thrust
bearing and thrust washer if rusted or damaged.
6. Replace reverse gear if gear teeth or clutch teeth on reverse gear are rounded or
chipped. If reverse gear must be replaced, pinion gear and sliding clutch should be in-
spected for damage.
19202
a - Reverse Gear
b - Thrust Bearing
c - Thrust Washer
7. If reverse gear radial bearing is rusted or does not roll freely, replace bearing. If the bear-
ing needs to be replaced remove it using Slide Hammer (91-34569A1).
a
91-34569A1
19205
a - Radial Bearing
8. If bearing is rusted or does not roll freely, replace bearing. If replacement is necessary,
remove bearing and oil seals using Mandrel* (91-36569) and Driver Rod* (91-37323).
Discard oil seals.
NOTE: *From Bearing Removal and Installation Kit (91-31229A7).
c
91-37323
91-36569
58205
a - Bearing
b - Mandrel (91-36569)
c - Driver Rod (91-37323)
9. Remove propeller shaft seals (if not removed with bearing in Step 9) and bearing carrier
O-ring.
51263
a - O-ring
51876
a - Spring
11. Apply constant pressure to cam follower in order to prevent it and internal components
from ejecting out of the propeller shaft during removal of the cross pin from the clutch.
51800
a
a - Cross Pin
b - Cam Follower
f c
a
b e d 51265
a - Cam Follower
b - Metal Balls (3)
c - Guide Block
d - Spring
e - Sliding Clutch
f - Jaws
c b b
a
51877
a - V-Blocks
b - Bearing Surfaces
c - Measure with Dial Indicator at This Point
2. Remove drive shaft, pinion gear, pinion bearing and forward gear.
3. Replace pinion gear if it is chipped or worn.
4. Replace pinion bearing and race if either are rusted, pitted 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
d
b
f
19175
a - Drive Shaft Holding Tool
b - Pinion Nut
c - Drive Shaft
d - Pinion Gear
e - Pinion Bearing
f - Forward Gear
6. Replace forward gear needle bearing if it is rusted or does not roll freely.
7. Use suitable tools (screwdriver and awl) to remove retaining ring. Use a punch and ham-
mer to remove bearing.
57905 b 19203
a - Retaining RIng
b - Forward Gear Needle Bearing
8. Replace forward gear bearing and race if either are rusted, pitted or damaged, or if bear-
ing 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,” follow-
ing.
a c
b 91-37241
51119
91-37241
d e
75/90/115
4-stroke
c
a 19710
a - Crankshaft/Driveshaft Splines
b - Oil Pump Drive Splines 75/90 4-Stroke Only
c - Bearing Surface
d - Wear Sleeve
e - Universal Puller Plate (91-37241)
f - Mallet
19152
a - Rubber Ring
OR
c
91-83165M
a
b 19177
IMPORTANT: Upper drive shaft bearing/sleeve must be removed prior to oil sleeve
removal. Refer to “Upper Drive Shaft Bearing,” preceding.
Oil Sleeve
1. Remove oil sleeve (if necessary) using Puller Assembly (91-83165M) with suitable jaws.
b
a
91-83165M
19222
a - Oil Sleeve
b - Puller Assembly (91-83165M)
IMPORTANT: Upper drive shaft bearing/sleeve and oil sleeve do not have to be re-
moved for lower drive shaft bearing race removal.
IMPORTANT: Retain shim(s) for reassembly.
1. Remove bearing race and shim(s) using bearing race tool (91-14308A1).
91-14308A1
19171
a - Bearing Race
b - Shim(s)
c - Bearing Race Tool (91-14308A1)
Shift Shaft
1. Remove shift shaft coupler and nylon spacer.
53925
2. Remove bolts.
53926
a - Bolts
NOTE: Remove rough edges from shift shaft splines before removing shift shaft bushing.
3. Remove shift shaft bushing and shift shaft.
a b
53927
a - Bushing
b - Shift Shaft
a
51117
53928
a - Bushing
b - Clip
c - Shift Shaft
d - Splines
e - O-ring
9. Remove (and discard) seal. (Lightly clamp the bushing in a vise when removing seal.)
a
53929
a - Seal
91-34569A1
b c
27653
a - Race
b - Shim(s)
c - Slide Hammer (91-34569A1)
Reassembly
Forward Gear Bearing Race
NOTE: Propshaft should be vertical when installing bearing race.
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 in. (0.254 mm) shim(s).
2. Assemble components as shown using mandrel (91-31106). Apply 2-4-C w/Teflon to
O.D. of race. Drive race into housing by striking propeller shaft end with lead hammer.
NOTE: Install a nut on the end of the propshaft to prevent damage to the propshaft threads
while performing step 2.
e d
91-31106
95
Shift Shaft
1. Apply Loctite 271 on O.D. of new seal.
2. Press seal into shift shaft bushing until seal is seated against shoulder.
3. Install new O-ring.
4. Apply 2-4-C with Teflon on O-ring and I.D. of seal.
c a
7
d b
53930
7 Loctite “271” (92-809820)
95
95 2-4-C w/Teflon (92-850736A1)
a - Seal c - Surface
b - Bushing d - O-ring
c 53928
a - Shift Shaft
b - “E” Clip
c - Shift Shaft Bushing
6. Install shift cam; align hole in shift cam with shift shaft pilot bore in gear housing.
60 Bigfoot, 75/90/100/115/125 (2-Stroke)
51117
51117
850307
51117
b
53932
53926
95
91-15755
91-13945
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). Ap-
ply Loctite 271 on O.D. of seal. Press seal into carrier until tool bottoms.
a 7
91-31108
91-13945
7 Loctite “271” (92-809820) 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). Ap-
ply Loctite 271 on O.D. of new seal. Press seal into carrier until tool bottoms.
a
b
7 7
91-31108
91-13945
21041
7 Loctite “271” (92-809820)
a - Seal
b - Oil Seal Driver (91-31108)
c - Bearing Installation Tool (91-13945)
8. Install O-ring. Lubricate O-ring with 2-4-C w/Teflon. Lubricate seal lips with 2-4-C
w/Teflon.
9. Lubricate outside diameter of reverse gear bearing and bearing carrier bore with a light
coating of 2-4-C w/Teflon.
10. Press bearing into carrier until tool bottoms.
95
c
a
91-13945
19163
95 2-4-C w/Teflon (92-850736A1)
a - O-ring
b - Bearing, Numbered Side Toward Tool
c - Bearing Installation Tool (91-13945)
11. Install thrust washer. Coat thrust washer with Premium Blend Gear Lubricant.
87
19167
87 Premium Blend Gear Lubricant (92-850737A1)
a - Thrust Washer
12. Install thrust bearing. Coat thrust bearing with Premium Blend Gear Lubricant.
87
19168
87 Premium Blend Gear Lubricant (92-850737A1)
a - Thrust Bearing
13. Apply Premium Blend Gear Lubricant to bearing surface of reverse gear and install re-
verse gear.
87
19202
95
a
51869
95 2-4-C w/Teflon (92-850736A1)
a - Mandrel (91-37350)
b - Bearing; Lubricate I.D. with Quicksilver 2-4-C w/Teflon
2. Inspect reverse gear end of clutch to determine the number of jaws. Refer to chart, fol-
lowing, for tool end selection.
c b
56783
a - Stamped “3”
b - Numbered end of Needle Bearing
c - 3 Jaw Reverse Clutch
c
a 56784
a - Stamped “6”
b - Numbered end of Needle Bearing
c - 6 Jaw Reverse Clutch
3. Apply Premium Blend Gear Lubricant to I.D. of forward gear, and O.D. of needle bearing.
Press needle bearing into forward gear (using forward gear bearing installer tool) until
tool bottoms out on gear.
a
87
b
91-877321A1
4. Install retaining ring into groove of forward gear by starting at one end of retaining ring
and working it around until seated in groove.
a
57905
a - Retaining Ring
b - Groove in Forward Gear
e f g
b
d c a 51265
Assembly Sequence
a - Spring
b - Guide Block
c - Clutch
d - 3 Metal Balls
e - Cam Follower
f - Forward Clutch Teeth
g - Reverse Clutch Teeth
2. Align the hole in the clutch with the hole in the guide block, install cross pin.
b
a
51800
a - Apply Pressure in This Direction
b - Cross Pin
51876
a - Spring
19152
a
a
91-14310A1
19169
a - Sleeve
b - Holder
4. Press sleeve onto drive shaft using Wear Sleeve Installation Tool (91-14310A1); contin-
ue pressing until the upper and lower part of the tool make surface to surface contact.
91-14310A1
a
b d
19166
a - Drive Shaft
b - Wear Sleeve Installation Tool (91-14310A1)
c - Upper part of tool (Surface C)
d - Lower part of tool (Surface D)
f e
a
91-14309A1
b
95
c
95 2-4-C w/Teflon (92-850736A1) 58207
53934
a - Oil Sleeve
b - Tab
d
95 c 91-13781
a
b
19164
95 2-4-C w/Teflon (92-850736A1)
a - Bearing Sleeve
b - Tapered End
c - Bearing; Numbered Side Toward Mandrel
d - Mandrel* (91-13781)
*From Bearing Installation Tool (91-14309A1)
f
c
a
e
91-14309A1
58206
a - Bearing/Sleeve
b - Tapered End Of Sleeve
c - Mandrel* (13781)
d - Mandrel* (13780)
e - Threaded Rod** (91-31229)
f - Nut** (11-24156)
*From Bearing Installation Tool (91-14309A1)
**From Bearing Removal and Installation Kit (91-31229A7)
Forward Gear, Drive Shaft Lower Bearing, Pinion Gear, and Drive Shaft
Installation
1. Install components per assembly sequence shown.
e
d
b
87
c
f
a
7
19175
7 Loctite “271” (92-809820)
87 Premium Gear Lubricant (92-850737A1)
Assembly Sequence:
a - Forward Gear/Bearing: Apply Premium Blend gear lube to bearing rollers.
b - Drive Shaft Lower Tapered Roller Bearing: Apply Premium Blend Gear Lube to
bearing rollers.
c - Pinion Gear
d - Drive Shaft
e - Drive Shaft Holding Tool
f - Pinion Nut (New): Clean nut and driveshaft threads with Loctite Primer or suit-
able de-greaser. Apply Loctite 271 to threads (not necessary if using a new
nut with drylock patch on threads) during final assembly (after pinion gear
depth and forward gear backlash have been set), tighten to specified torque.
Model Drive Shaft Holding Tool
40/50 Bigfoot (4-Stroke, 747cc/935cc) 91-56775
40/50/60 Bigfoot (4-Stroke, 995cc) 91-877840A1
75/90/115EFI (4-Stroke) 91-804776A1
60 Bigfoot/75/90/100/115/125
91-56775
(2-Stroke)
g
h h
e c
f b
a
d
a
c
19884
a - 1 in. (25.4 mm) c - Bolt Head
b - Nut
6. Assemble Pinion Gear Locating Tool (91-12349A2) as shown; do not tighten collar retain-
ing screw at this time. Install gauging block with numbers away from split collar.
b d e
f
a c
22067
a - Gauging Block
8. Remove tool, taking care not to change gauging block position, and tighten collar retain-
ing bolt.
9. Insert tool into forward gear assembly; position proper numbered flat (from chart) of
gauging block – under pinion gear.
10. Install locating disc against bearing carrier shoulder in gear housing.
11. Position access hole as shown.
Disc 3
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 in. (0.64 mm).
14. If clearance is correct, leave Bearing Preload Tool on drive shaft and proceed to “Deter-
mining Forward Gear Backlash,” following.
15. If clearance is more than 0.025 in. (.064 mm) add shims behind the bearing race. If clear-
ance is less than 0.025 in. (.064 mm) remove shims from behind the bearing race. When
reinstalling pinion nut, apply Loctite 271 on threads of nut.
NOTE: Clean driveshaft and pinion nut threads with Loctite Primer or suitable de-greaser
before applying Loctite.
c
a
7 b
24643
a b
d
c
53936
a - Propeller Shaft*
b - Bearing Carrier* (Assembled)
c - Puller Jaws (91-46086A1)
d - Puller Bolt (91-85716)
Puller Bolt Torque
45 lb-in. (5 Nm)
d c
b c
51117
a - Threaded Rod (Obtain Locally)
b - Washers
c - Nuts
d - Dial Indicator Adaptor Kit (91-83155)
e - Dial Indicator (91-58222A1)
f - Backlash Indicator Tool
7. Position Dial Indicator on appropriate line (from chart below) marked on Backlash Indi-
cator Tool. Make sure the dial indicator is perpendicular (⊥) to the indicator tool or an
inaccurate reading will be obtained.
8. Grasp the driveshaft pre-load tool bolt head and lightly turn drive shaft back-and-forth
(no movement should be noticed at propeller shaft).
9. Dial Indicator registers amount of backlash, which must be between specification shown
in chart.
DIAL INDICATOR READING
MODEL MINIMUM MAXIMUM
0.012 in. 0.019 in.
40/50 Bigfoot (4-Stroke, 747cc/935cc) (0.30 mm) (.48 mm)
0.012 in. 0.019 in.
40/50/60 Bigfoot (4-Stroke, 995cc) (0.30 mm) (.48 mm)
0.013 in. 0.019 in.
75/90/115EFI (4-Stroke)
(0.38 mm) (.55 mm)
0.012 in. 0.019 in.
60 Bigfoot
(0.30 mm) (.48 mm)
75-thru-90 0.012 in. 0.019 in.
(3 Cylinder) (0.30 mm) (.48 mm)
100/115/125 0.013 in. 0.019 in.
(4 Cylinder) (0.38 mm) (0.55 mm)
10. If backlash is less than the minimum specification, remove shim(s) from in front of for-
ward gear bearing race. If backlash is more than the maximum specification, add
shim(s) in front of forward gear bearing race. When reinstalling pinion nut, apply Loctite
271 on threads of nut.
NOTE: By adding or subtracting 0.001 in. (0.025 mm) shim, the backlash will change
approximately 0.001 in.
e 21043
a - Bearing Carrier Assembly
b - PVC Pipe
c - Propeller Nut
d - Prop Shaft
e - Tab Washer
3. Generously lubricate O-ring, bearing carrier, and gear housing mating surfaces with
2-4-C w/Teflon.
4. Install bearing carrier and propeller shaft into housing with the word “TOP” (located on
flange) toward top of housing.
a
b
95
21044
95 2-4-C w/Teflon (92-850736A1)
a - O-ring b - TOP
NOTE: Use thick 0.090 in. (2.29mm) washers (12-855941) under fasteners if not previously
installed.
b
a
a - Washers
b - Fasteners (If using Screws Apply Loctite 271 on Threads)
91-13949
7
b
3. Place water pump base lower seal on shorter shoulder side of Oil Seal Driver (91-13949)
with seal lip toward shoulder.
4. Apply Loctite 271 on O.D. of seal; press seal into water pump base until tool bottoms.
5. Lubricate lip of each seal with Quicksilver 2-4-C w/Teflon (92-850736A1).
91-13949
95
7
b
7 Loctite “271” (92-809820)
95 2-4-C w/Teflon (92-850736A1) 51553
a - Seal - Lip Faces DOWN (when water pump base is installed on gearcase)
b - Spring - Faces DOWN (when water pump base is installed on gearcase)
c - Oil Seal Driver (91-13949)
d - Longer Shoulder Side of Oil Seal Driver
e - Shorter Shoulder Side of Oil Seal Driver
6. Install gasket.
19218
a - Gasket
IMPORTANT: To prevent cutting the seal lips remove any burrs or sharp edges from the dri-
veshaft splines before installing water pump base assembly.
7. Install components as shown. Apply Loctite 271 on bottom half of screw threads and
tighten to specified torque (in sequence shown).
a 3 1 5
b
2
6
4
7 Loctite “271” (92-809820) 19217
19219
a - Gasket
b - Plate
b
a
19220
a - Gasket
b - Drive Key
c - Impeller
95 a b
a - Impeller Housing
b - Screw (4) M 6 x 30
Screw Torque
60 lb-in. (6.8 Nm)
NOTE: It is recommended that the gearcase be pressure tested for leaks after reassembly
and BEFORE gear lube is added. Gearcase should hold 10-12 psi (69-83 kPa) for 5 min-
utes.
2. Pressurize housing to 10-12 psi (69-83 kPa) and observe gauge for 5 minutes.
3. Rotate drive shaft, prop shaft and shift shaft while housing is pressurized to check for
leaks.
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 Premium
Blend Gear Lube.
1. Remove any gasket material from “Fill/Drain” and “Vent” screws and gear housing.
2. Install new sealing washer on “Fill/Drain” 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 driveshaft is in a vertical position.
3. Remove lubricant “Fill/Drain” screw and sealing washer from gear housing.
4. Insert lubricant tube into “Fill” hole, then remove “Vent” screws and sealing washer.
5. Fill gear housing with lubricant until excess starts to flow out of one (first) “Vent” screw
hole.
6. Install this “Vent” screw and sealing washer only and continue filling until excess starts
to flow out of second “Vent” screw hole.
7. Rotate driveshaft clockwise approximately 10 revolutions. Let gearcase sit for at least
one minute to allow any trapped air to settle out, then top off lubricant level.
a c
b
53922
Gearcase Installation
WARNING
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 acci-
dental engine starting and possible injury.
1. Position outboard shift linkage into forward gear position.
a
Remote Control Model Shown
a - Shift Lever
a
a - Shift Block
19879
a - Shift Block; Front of Block MUST Extend 1/8 in. (3.2 mm) Past Front of Rail.
b - Rail
F N R
a
a - Shift Block
NOTE: For ease of gear housing installation, install water tube seal (labyrinth end) onto
water tube in drive shaft housing. Tapered end of water tube seal goes onto water pump.
95
78
b
53938
78 G. E. RTV Sealant 92-90113--2
95 2-4-C w/Teflon (92-850736A1)
a - Water Tube Seal
b - RTV Sealer
CAUTION
Do not use lubricant on top of drive shaft. Excess lubricant, that is trapped in clear-
ance 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.
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.
8. Install components as shown in appropriate photo.
a - Nylon Spacer
b - Shift Shaft Coupler
c - Bushing 40-60 Bigfoot 4–Stroke Only
a b
53925
a - Nylon Spacer
b - Shift Shaft Coupler
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 ratch-
et when propeller shaft is turned clockwise. Resistance will be felt when propeller shaft
is rotated counterclockwise.
10. Apply Loctite Grade 271 on threads of gear housing retaining bolts.
NOTE: During installation of gear housing, it may be necessary to move the shift block (lo-
cated under cowl) slightly to align upper shift shaft splines with shift shaft coupler splines.
NOTE: On 75/90 hp (4-Stroke) models. If, while performing Step 11, the drive shaft splines
will not align with the oil pump splines, place a propeller onto propeller shaft and turn it coun-
terclockwise as the gear housing is being pushed toward drive shaft housing. Continue ro-
tating the propshaft until the driveshaft splines align with the crankshaft splines.
IMPORTANT: 75/90 hp (4-Stroke) models, when removing or installing gearcase,
carefully guide driveshaft through driveshaft bushing to avoid scoring bushing sur-
face.
11. Position gear housing so that the driveshaft is protruding into driveshaft housing.
12. Move gear housing up toward driveshaft housing, while aligning upper shift shaft splines
with shift shaft coupler splines, water tube with water tube seal, and crankshaft splines
with driveshaft splines.
13. Install 4 fasteners and washers (two each side). Install locknut and washer.
14. Torque bolts and locknut (or nuts only if applicable) to specified torque.
7
b a
53922
7 Loctite “271” (92-809820)
a - Fasteners and Washers (2 Each Side)
b - Locknut and Washer
Bolt or Nut Torque
40 lb-ft (54 Nm)
b a 53931
a - Trim Tab
b - Anti-Ventilation Plate
c - Retaining Screw and Washer
Retaining Screw Torque
22 lb-ft (29.8 Nm)
ATTACHMENTS/CONTROL LINKAGE
Section 7A - Throttle/Shift Linkage
Table of Contents
Linkage (Remote) . . . . . . . . . . . . . . . . . . . . . . . 7A-2 Throttle Link Adjustment . . . . . . . . . . . . . . . . . 7A-6
Linkage (Handle) . . . . . . . . . . . . . . . . . . . . . . . . 7A-4 Maximum Throttle . . . . . . . . . . . . . . . . . . . . . . . 7A-7
7
A
LINKAGE (REMOTE)
7 20
9 15 18
19
27 10
12 16 18
5
8 13
2
66 11 95
1 17
12 95
3
29 28 26 95
21
4 14
17
6 23
25
30
22
24
LINKAGE (REMOTE)
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
1 1 SCREW (M8 X 70) 100 11.3
2 1 SCREW (M6 X 55)
3 1 NUT
4 1 CAP
5 1 THROTTLE LEVER
6 1 RETAINER
7 1 BUSHING
8 1 RETAINER
9 1 SHIFT LEVER
10 1 BRACKET
11 1 LATCH
12 2 SCREW (M6 X 16) 75 8.5
13 2 SLEEVE
14 1 SHIFT ROD
15 1 GUIDE - SHIFT ROD
16 1 SHIFT LINK
17 2 NYLINER
18 2 WASHER
19 1 NUT 75 8.5
20 1 COTTER PIN
21 1 SHIFT SHAFT LEVER
22 1 BUSHING
23 1 LINK
24 1 SOCKET 75 8.5
25 1 BUSHING
26 1 THROTTLE CAM
27 2 SCREW (M6 X 40) 75 8.5
28 1 THROTTLE ARM
29 1 BUSHING
30 1 SCREW (10-16 X .625) Drive Tight
LINKAGE (HANDLE)
30 5
2
29
6
1
7
3
31 4
32
8 95
23
28
33
13
14 17
24
10 12 15
18
18 16
17
95
18
95
9 19
20
11
22
27
26
25
95 21
LINKAGE (HANDLE)
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
1 1 SCREW (M8 X 70) 100 11.3
2 1 SCREW (M6 X 55)
3 1 NUT
4 1 CAP
5 1 THROTTLE LEVER
6 1 BRACKET (HANDLE)
7 2 SCREW (M6 X 20) 75 8.5
8 1 BUSHING
9 2 SCREW (M6 X 25) 75 8.5
10 1 SHIFT GUIDE
11 1 SCREW (M5 X 12) 45 5.1
12 1 SHIFT SLIDE
13 1 SHIFT DETENT
14 1 SPRING
15 1 SHIFT ROD
16 1 COTTER PIN
17 2 NUT 75 8.5
18 3 WASHER
19 1 SHIFT LINK
20 1 NYLINER
21 1 SHIFT SHAFT LEVER
22 1 BUSHING
23 1 THROTTLE LINK
24 1 SOCKET 75 8.5
25 1 SWITCH
26 1 PLATE-SWITCH
27 2 SCREW (M3 X 20) 20 2.3
28 1 BUSHING
29 1 THROTTLE CAM
30 2 SCREW (M6 X 40) 75 8.5
31 1 THROTTLE ARM
32 1 BUSHING
33 1 SCREW (10-16 X .625) Drive Tight
c e
f g
h
d
a
b
g
Maximum Throttle
1. With throttle cable(s) attached, advance throttle (remote control handle or throttle twist
grip) to wide open throttle position.
2. Throttle stop should lightly contact adjoining surface. To ensure the throttle shutter is
fully open, back the throttle stop screw out until there is a gap between the throttle stop
screw and adjoining surface (at WOT position). Keep turning the throttle stop screw “in”
until the throttle stop lightly contacts the adjoining surface.
a - Throttle Lever
b - Throttle Stop Screw
c - Throttle Stop
ATTACHMENTS/CONTROL LINKAGE
Section 7B - Tiller Handle
Table of Contents
Tiller Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-2 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . 7B-8
Tiller Handle Assembly Removal . . . . . . . . . . 7B-4 Tiller Handle Reassembly . . . . . . . . . . . . . . . . 7B-9
Tiller Handle Disassembly . . . . . . . . . . . . . . . . 7B-6 Tiller Handle Installation . . . . . . . . . . . . . . . . . . 7B-14
7
B
TILLER HANDLE
1
2
3
6
4
5 8
95
7
9
10
95
31 11
30
29
26 28
35 27 12
13
14
24
15
16
25 33 17
36 32
34
37
38
95 23
18 19
22
20
21
95 2-4-C With Teflon (92-825407A12)
TILLER HANDLE
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
1 1 COVER KIT
2 1 PULLEY
3 1 CASE
4 1 SCREW (10-16 x 1/2 IN. Self Tapping) 20 2.3
5 1 THROTTLE CABLE (30-1/2 IN.)
6 1 THROTTLE CABLE (41-1/2 IN.)
7 1 SLEEVE
8 2 SCREW (M8 x 25) 135 15.3
9 1 COVER
10 1 BUSHING
11 1 ARM–Steering Handle
12 1 RETAINER
13 1 SCREW (M5 x 16) 35 3.9
14 1 SCREW (M6 x 25)
15 1 LOCK–Throttle
16 1 SPRING
17 1 KNOB–Throttle
18 1 TILLER TUBE
19 1 DECAL
20 1 HANDLE–Throttle
21 1 GRIP
22 1 SWITCH (STOP)
23 2 CLIP
24 1 SWITCH (STOP)
25 1 RETAINER
26 1 BRACKET–Tiller
27 1 WAVE WASHER
28 1 BUSHING
29 1 WASHER
30 1 CONDUIT
31 1 CABLE TIE
32 1 DECAL-Shift (F-N-R)
33 1 LANYARD SWITCH
34 1 SCREW (M8 x 35) 100 11.3
35 1 SHIFT HANDLE
36 1 BUSHING
37 1 TAB WASHER
38 2 SCREW (M10 x 90) 35 47.5
a - Screws-M6x30 (6)
b - Screw-M6x60
a - Shift Handle
b - Bushing
c - Screw-M8x35
3. Loosen the jam nuts and disconnect the throttle cables from the throttle lever.
b
58829
a - Throttle Cable (Long)
b - Throttle Cable (Short)
a
BLK BLK
BLK/YEL
BLK/YEL BLK/YEL
BLK BLK
b
54272
a - Disconnect Tiller Handle Wires
b - Screws-M10x90 (2)
c - Tab Washer
a - Clips (2)
b - Side Cover
3. Pull the tiller arm, along with the throttle cables and wiring, from the tiller bracket.
a - Tiller Arm
b - Throttle Cables/Wiring
c - Tiller Bracket
a
b
a - Retainer
b - Throttle Friction Knob Assembly
c - Tiller Tube Assembly
6. Use a flat tip screwdriver to pry/push the rubber grip off the handle.
b c
b - Tiller Tube
c - Handle
a - Cover
b - Throttle Cables
c - Pulley
Cleaning/Inspection/Repair
1. Inspect throttle cables for bending/damage and replace if necessary.
a
a - Short Throttle Cable (30-1/2 in.) Place in Top Groove
b - Long Throttle Cable (40-1/2 in.) Place in Bottom Groove
c - Pulley
2. Place pulley and cables into case.
3. Install cover with screw.
c
b
4. Match tiller tube end with slots in the handle. Pull the tube end into the handle until it
bottoms out.
5. Install the throttle friction knob components on tiller tube.
b
a
g c
f
e
d
c
a - Tiller Tube e - Lock
b - Handle f - Spring
c - Slots In Handle g - Knob
d - Screw M6x25
6. Check to make sure tiller tube is recessed in the end of the handle 7/8 in. (22.2mm).
a
a - Stop Switch
9. Align the grooves inside the rubber grip with the ridges on the handle. Push the rubber
grip onto the handle.
NOTE: Applying a soap/water solution to the inside of the rubber grip will ease installation.
a b
a - Rubber Grip
b - Handle
c
d
b
a - Pulley Assembly
b - Throttle Lock Knob
c - Retainer
d - Screw-M5x16
95
c
b
a
d
95
16. Pull the throttle cables and wiring into the bracket.
a - Tiller Bracket
17. Push the arm into the tiller bracket. Secure the arm by installing the cover and screws.
Tighten screws to specified torque.
c b a
a - Arm
b - Cover
c - Screw (2) M8 x 25
CAUTION
Wiring passing through the hand grip opening must be protected from chaffing or
being cut, by using the wiring conduit described in the following steps. Failure to
protect wiring as described could result in electrical system failure.
18. Place the throttle cables through the hand grip opening as shown.
19. Place all wiring inside the wiring conduit.
20. Route the wiring through the hand grip opening and position the wiring conduit inside
the opening so that at least 1/2 in. (12.7mm) extends past each end of the opening.
21. Push the wiring and throttle cables down into the handle grip and hold in place with two
clips.
b a
e
d
c
a - Tiller Handle
b - Tab Washer
c - Screw (2) M10 x 90
Tiller Handle Mounting Screw Torque
35 lb. ft. (47.5 N·m)
a - Cable Tie
BLK
BLK
j
BLK
BLK
l
BLK
BLK BLK
BRN
BLK_YEL RED
GRY
o
+ –
TAN_LTBLU
PPL
YEL_RED
BLK i
m
n YEL_RED
BLK
TAN_LTBLU
YEL_RED
BLK_YEL
BLK_YEL
BLK
GRY
PPL
BLK_YEL
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 c BLK = Black
d BLU = Blue
BLK_YEL
YEL_BLK
PPL
BLK
YEL_RED
TAN
RED
BRN = Brown
GRY = Gray
GRN = Green
PPL
ORN = Orange
BLK_YEL
BLK_YEL
PPL
BLK PNK = Pink
YEL_RED PUR = Purple
BLK_YEL
RED RED = Red
TAN = Tan
b YEL_BLK
PPL + e WHT = White
–
TAN
YEL = Yellow
LIT = Light
BLK
BLK_YEL
BLK f DRK = Dark
BLK_YEL
BLK_YEL BLK_YEL
BLK BLK g
h
a
a - Ground Harness below Starter Motor M6x16 h - Push Button Stop Switch
screw i - Battery
b - Harness Extension j - Starter Motor
c - Harness Connection k - Voltage Regulator/Rectifier
d - Key Switch Assembly Transom Mount l - Start Solenoid
e - Key Switch m - Neutral Start Switch
f - Horn n - ECM
g - Lanyard Stop Switch o - In-line Diode
e
b
58829
a - Throttle Lever
b - Anchor of Shorter Throttle Cable
c - Jam Nut
d - Anchor of Longer Throttle Cable
e - Jam Nut
10. Rotate throttle grip to the wide open throttle position. The throttle stop screw should be
contacting the plate. If there is a gap between the throttle stop screw and plate, loosen
the jam nut on the shorter throttle cable, turn the adjustment nut clockwise. Tighten the
jam nut finger tight, rotate the throttle grip to full throttle. Keep adjusting until the throttle
stop screw lightly contacts the plate.
NOTE: No free-play should exist in throttle grip handle once the throttle stop screw has hit
the plate. If this condition exists, re-adjust jam nuts on appropriate throttle cable.
a
b
58830
a - Throttle Stop Screw Hitting Plate
b - No Free play should exist in throttle grip handle past full throttle once throttle
stop screw has hit plate. If this condition exists re-adjust jam nuts.
IMPORTANT: After installation, cycle the throttle grip a few times from the idle posi-
tion to the wide-open-throttle position. Make sure the throttle stop is still contacting
the plate. If it is not, re-adjust the jam nuts.
11. Install lower cowl.
a
b
12. Cables, wires, and shift rod should be routed through grommet as shown. Seat grommet
between cowl halves.
f
d a
c b
e
a - Fuel Connector d - Shift Rod
b - Battery Cables e - Tiller Handle Harness Wires
c - Throttle Cables f - Remote Key Harness
13. Assemble the shift rod into the shift handle by sliding the rod into the hole.
a
a - Shift Rod
b - Shift Handle
14. Install shift handle assembly, bushing, and screw. Tighten screw to specified torque.
95
c
b
a - Handle Assembly
b - Screw M8 x 35
c - Bushing
COLOR DIAGRAMS
Table of Contents
40/50/60 EFI (4-Stroke) Tiller Handle Electric 40/50/60 EFI (4-Stroke)
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . Page 8-3 Fuel Flow Diagram . . . . . . . . . . . . . . . . . . . . . Page 8-9
40/50/60 EFI (4-Stroke) Remote Control Electric 40/50/60 EFI (4-Stroke)
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . Page 8-5 Oil Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . Page 8-11
40/50/60 EFI (4-Stroke) Typical SmartCraft 40/50/60 EFI (4-Stroke)
(CAN) Installation Wiring Diagram . . . . . . . . Page 8-7 Water Flow Diagram . . . . . . . . . . . . . . . . . . . . Page 8-13
Notes:
https://www.boat-manuals.com/
10 11 12 13
24 25
3 22
5
20
9
6 7
15 17
8 14
23 23
4 21
16 18
19
1 2 3 4
1 26
1 9 17 1
2
3
4
5
2 6
7
8
9
10
11
12
13
14
15
27
16 30
17
18
19
20
21
22
29 28
23
8 16 24 24
1 9 17 1
2
3
4
5
6
7 39
8
9
10
11
12
40
13
14
15
16
17
38 18
19
41
20
21
22
23 31 46
8 16 24 24
32
1 2 3 4 43 42
45
33
44 59080
34 35 36 37
https://www.boat-manuals.com/
COLOR DIAGRAMS
https://www.boat-manuals.com/
10 11 12 13
24 25
3 22
5
20
9
6 7
15 17
8 14
23 23
4 21
16 18
19
1 2 3 4
1 26
1 9 17 1
2
3
4
5
2 6
7
8
9
10
11
12
13
14
15
27
16
17
18
19
20
21 29 28
22
23
30
8 16 24 24
1 9 17 1
2
3
4
5
38 6
7
8
9
10
11
12
13
14
15
16
17
18
19 31
20
21
22
23
8 16 24 24
1 2 3 4
32
33
34 59079
35 36 37
https://www.boat-manuals.com/
COLOR DIAGRAMS
https://www.boat-manuals.com/
2 3
5 5
1
4 4
22
4
20
21
19 10
9
8
20 11
18 17
16
15 14 C B
12
D E A
13
59083
https://www.boat-manuals.com/
COLOR DIAGRAMS
https://www.boat-manuals.com/
9 4
7
9
6
10
4
1 2
10
12
11
13
59082
https://www.boat-manuals.com/
COLOR DIAGRAMS
https://www.boat-manuals.com/
3 2 1
4
7
14
5
6
13
11
9
12
14
9
14
10
59081
https://www.boat-manuals.com/
COLOR DIAGRAMS
https://www.boat-manuals.com/
7
13
6 3
2
1
5
11
58906
10
12
https://www.boat-manuals.com/