Моторы mercury руководство по ремонту

Title	Download Link
Mercruiser and Mercury Racing (Sterndrive) Service Manual Index [PDF, ENG, 128 KB].pdf	Download
Mercury 115/135/150/175 OptiMax Service & Repair Manual [RAR, ENG, 13.2 MB].rar	Download
Mercury 115/135/150/175HP OptiMax (2000) Service manual [PDF, ENG, 14.6 MB].pdf	Download
Mercury 115/135/150/175HP OptiMax Service Repair Manual [RAR, ENG, 13.2 MB].rar	Download
Mercury 115/135/150HP OptiMax Operation and maintenance manual [PDF, RUS, 1.46 MB].pdf	Download

Mercruiser and Mercury Racing (Sterndrive) Service Manual Index [PDF, ENG, 128 KB].pdf

Mercury 115/135/150/175 OptiMax Service & Repair Manual [RAR, ENG, 13.2 MB].rar

Mercury 115/135/150/175HP OptiMax (2000) Service manual [PDF, ENG, 14.6 MB].pdf

Mercury 115/135/150/175HP OptiMax Service Repair Manual [RAR, ENG, 13.2 MB].rar

Mercury 115/135/150HP OptiMax Operation and maintenance manual [PDF, RUS, 1.46 MB].pdf

Mercury 135/150/170HP OptiMax Operation and maintenance manual [PDF, ENG, 2.47 MB].pdf

Mercury 135/150/175/200/225HP XR6/Magnum III/ EFI/ Pro Max/ Super Magnum Service Manual (1992) [PDF, ENG, 45.6 MB].pdf

Mercury 135/150/175HP Verado 4-stroke Operation and maintenance manual [PDF, RUS, 6.67 MB].pdf

Mercury 140/150/200HP Operation and maintenance manual [PDF, RUS, 3.43 MB].pdf

Mercury 15/20HP 4-stroke Operation and maintenance manual [PDF, RUS, 5.01 MB].pdf

Mercury 1971-1985 Service manual [PDF, ENG, 2.9 MB].pdf

Mercury 2/5/6HP 4-stroke (2004) Operation and Maintenance Manual [PDF, ENG, 939 KB].pdf

Mercury 2.4L 2.5L 3.0L V6 Technician Guide (1987-2001) [PDF, ENG, 3.34 MB].pdf

Mercury 2.5/3.3HP 2-stroke Owner’s manual [PDF, RUS, 701 KB].pdf

Mercury 2.5/3.3HP 4-stroke Owner’s manual [PDF, RUS, 4.2 MB].pdf

Mercury 200 OptiMax Jet Drive Service Manual (since 2001) [PDF, ENG, 16.3 MB].pdf

Mercury 200/225/250/275/300HP Verado 4-stroke Operation and maintenance manual [RAR, RUS, 8.3 MB].rar

Mercury 200/225/250/275HP Verado (2004) Service manual [PDF, ENG, 80.6 MB].pdf

Mercury 200/225/250HP OptiMax Operation and maintenance manual [RAR, RUS, 5.14 MB].rar

Mercury 200/225HP OptiMax DTS (2012) Operation and Maintenance Manual [PDF, ENG, 2.14 MB].pdf

Mercury 225/250HP 3.0 Litre Operation and maintenance manual [PDF, RUS, 1 MB].pdf

Mercury 25HP 4-stroke Operation and maintenance manual [PDF, ENG, 1.99 MB].pdf

Mercury 25HP 4-stroke Operation and maintenance manual [PDF, RUS, 1.42 MB].pdf

Mercury 30/40HP 2-stroke Operation and maintenance manual [PDF, RUS, 1.17 MB].pdf

Mercury 30/40HP 4-stroke Operation and maintenance manual [PDF, RUS, 1.17 MB].pdf

Mercury 300XS OptiMax Operation and maintenance manual [PDF, ENG, 4.18 MB].pdf

Mercury 4/5/6HP 4-stroke (2000) Service manual [PDF, ENG, 6.41 MB].pdf

Mercury 4/5/6HP 4-stroke Owner’s manual [PDF, RUS, 1.01 MB].pdf

Mercury 4/5HP 2-stroke Owner’s manual [PDF, RUS, 824 KB].pdf

Mercury 40/50/60HP 4-stroke Operation and maintenance manual [PDF, RUS, 1.06 MB].pdf

Mercury 40/50HP 2-stroke Operation and maintenance manual [PDF, RUS, 1.14 MB].pdf

Mercury 6/8/9,9/10/15HP (1986) Service manual [PDF, ENG, 2.49 MB].pdf

Mercury 6/8/9,9/10/15HP 2-stroke Owner’s manual [PDF, RUS, 1.04 MB].pdf

Mercury 60HP 2-stroke Operation and maintenance manual [PDF, RUS, 970 KB].pdf

Mercury 70/75/80/90/100/115HP (1987-1993) Service manual [PDF, ENG, 9.07 MB].pdf

Mercury 75/80/90/100/115HP 4-Stroke Operation and maintenance manual [RAR, RUS, 3.43 MB].rar

Mercury 75/90/115/125 OptiMax Operation and maintenance manual [RAR, ENG, 10.2 MB].rar

Mercury 75/90/115/125HP 2-stroke Operation and maintenance manual [PDF, RUS, 1.04 MB].pdf

Mercury 75/90/115HP 4-stroke Operation and maintenance manual [PDF, ENG, 2.54 MB].pdf

Mercury 75/90/115HP OptiMax Operation and maintenance manual [PDF, RUS, 8.21 MB].pdf

Mercury 8/9,9HP 4-stroke Operation and maintenance manual [PDF, ENG, 7.18 MB].pdf 

Mercury 8/9,9HP 4-stroke Owner’s manual [PDF, RUS, 1.33 MB].pdf

Mercury 9,9/15HP 4-stroke Operation and maintenance manual [PDF, RUS, 1.34 MB].pdf

Mercury Installation Manual — Outboard Power Trim Kit [PDF, ENG, 7 MB].pdf

Mercury Jet 25 HP Operation and maintenance manual [RAR, RUS, 9.14 MB].rar

Mercury Jet 65/80 Operation and maintenance manual [PDF, RUS, 3.86 MB].pdf

Mercury Jet20 Operation and maintenance manual [PDF, RUS, 3.81 MB].pdf

Mercury Marathon 30/40HP & Sea Pro 40HP Operation and maintenance manual [PDF, ENG, 5.31 MB].pdf

Mercury Marathon 6/8/9,9/10/15HP & Sea Pro 10/15HP Operating and Maintenance manual [PDF, ENG, 4.28 MB].pdf

Mercury Marathon 75/90/115/125HP & Sea Pro 75HP Operation and maintenance manual [PDF, RUS, 4.66 MB].pdf

Mercury Marathon Jet 40HP Operation and maintenance manual [PDF, RUS, 3.99 MB].pdf

Mercury Marathon/Sea Pro 20/25 HP Operation and maintenance manual [PDF, RUS, 9.5 MB].pdf

Mercury Marathon/Sea Pro 30/40HP Operation and maintenance manual [PDF, RUS, 8.75 MB].pdf

Mercury Marathon/Sea Pro 55/60HP Operation and maintenance manual [PDF, RUS, 9.79 MB].pdf

Mercury MerCruiser #31 5.0L/5.7L/6.2L MPI Gasoline Engine Service Manual [PDF, ENG, 19.1 MB].pdf

Mercury Outboard Motor Installation/Attachments Guide[PDF, ENG, 486 KB].pdf

Mercury Outboard Serial Number Guide [PDF, ENG, 158 KB].pdf

Mercury Outboards — Product Knowledge Handbook (January 2012) [PDF, ENG, 24.2 MB].pdf

Mercury Outboards Models 1966 thru 1972 Service Manual [PDF, ENG, 2.16 MB].pdf

Mercury SST120/S2000 Operation and maintenance manual [PDF, ENG, 440 KB].pdf

Mercury Verado V8, SeaPro V8 Operation and Maintenance Manual [PDF, ENG, 5.42 MB].pdf

Mercury XR2/XR2 SS Operation and maintenance manual [PDF, ENG, 703 KB].pdf

Ultimate Outboard Model Year Identification Guide [PDF, ENG, 983 KB].pdf

All Mercury outboard service manuals are in PDF formats, and contains:

• General Information & Specifications
• Electrical Wiring Diagrams
• Fuel System
• Power-head
• Mid-Section
• Gear Housing
• Attachments/Control Linkage
• Color Diagrams

Title	Download Link
Mercury Outboard Drive Parts [PDF, ENG, 2.73 MB].pdf	Download
Mercury Outboard Electrical Parts [PDF, ENG, 2.15 MB].pdf	Download
Mercury Outboard Fuel System Parts [PDF, ENG, 1.43 MB].pdf	Download

Service Manual Outline Section 1 — Important Information A — Specifications B — Maintenance C — General Information D — Outboard Installation Section 2 — Electrical A — Ignition B — Charging & Starting System C — Timing, Synchronizing & Adjusting D — Wiring Diagrams Section 3 — Fuel System A — Fuel Pump B — Carburetor C — Oil Injection D — Emissions Section 4 — Powerhead Section 5 — Mid-Section A — 40/50 Clamp/Swivel Brackets & Drive Shaft Housing B — 55/60 Clamp/Swivel Brackets & Drive Shaft Housing C — 40/50 Power Trim D — 55/60 Power Trim E — 40/50 Manual Tilt F — 55/60 Manual Tilt Section 6 — Lower Unit A — 40/50 Lower Unit B — 55/60 Lower Unit C — 60 Bigfoot D — Jet Drive Section 7 — Attachments/Control Linkage A — Throttle/Shift Linkage B — Tiller Handle Section 8 — Manual Starter

90-852572R02 NOVEMBER 2002

iii

Important Information

Electrical

Fuel System

Powerhead

Mid-Section

Lower Unit

Attachments/ Control Linkage

Manual Starter

1 2 3 4 5 6 7 8

who uses a service procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered by the service procedure selected.

Notice Throughout this publication, “Dangers”, “Warnings” and “Cautions” (accompanied by the International ) are used to alert the mechanic HAZARD Symbol to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. OBSERVE THEM CAREFULLY!

All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service these products.

These “Safety Alerts” alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus “Common Sense” operation, are major accident prevention measures.

It should be kept in mind, while working on the product, that the electrical system and ignition system are capable of violent and damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables should be disconnected at the battery.

DANGER DANGER — Immediate hazards which WILL result in severe personal injury or death.

Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive internal damage when the engine is started.

WARNING WARNING — Hazards or unsafe practices which COULD result in severe personal injury or death.

CAUTION

It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Mismatched or incorrect fasteners can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the same locations whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original.

Hazards or unsafe practices which could result in minor personal injury or product or property damage.

Notice to Users of This Manual This service manual has been written and published by the Service Department of Mercury Marine to aid our dealers’ mechanics and company service personnel when servicing the products described herein. It is assumed that these personnel are familiar with the servicing procedures of these products, or like or similar products manufactured and marketed by Mercury Marine, that they have been trained in the recommended servicing procedures of these products which includes the use of mechanics’ common hand tools and the special Mercury Marine or recommended tools from other suppliers. We could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of the possible hazards and/or results of each method. We have not undertaken any such wide evaluation. Therefore, anyone

90-852572R02 NOVEMBER 2002

i

In addition, personnel should not work on or under an outboard which is suspended. Outboards should be attached to work stands, or lowered to ground as soon as possible.

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

We reserve the right to make changes to this manual without prior notification. Refer to dealer service bulletins for other pertinent information concerning the products described in this manual.

Page Numbering

Whenever components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed.

Two number groups appear at the bottom of each page. The example below is self-explanatory.

Before raising or removing and outboard engine from a boat, the following precautions should be adhered to: 1. Check that flywheel is secured to end of crankshaft with a locknut and lifting eye is threaded into flywheel a minimum of 5 turns. 2. Connect a hoist of suitable strength to the lifting eye.

EXAMPLE:

90-826148R1 JANUARY 2002

LOWER UNIT — 6A-7

Revision No. 1

Section Description

Month of Printing

Section Number

Year of Printing

Part of Section Letter Page Number ii

90-852572R02 NOVEMBER 2002

iv

90-852572R02 NOVEMBER 2002

IMPORTANT INFORMATION

SPECIFICATIONS

1 A

Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . Mercury/Quicksilver Lubricants and Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . Propeller Information Charts . . . . . . . . . . . . . Mercury/Mariner 40 HP (3 Cyl.) . . . . . . . . . Mercury/Mariner 50 HP (3 Cyl.) . . . . . . . . . Mercury/Mariner 55 HP (3 Cyl.) . . . . . . . . . Mercury/Mariner 60 HP (3 Cyl.) . . . . . . . . . Mercury/Mariner 60 HP (3 Cyl.) Bigfoot . .

1A-0 — IMPORTANT INFORMATION

Page 1A-1 1A-4 1A-6 1A-6 1A-7 1A-8 1A-9 1A-10

90-852572R02 NOVEMBER 2002

Specifications Models 30/40 Jet/40/50/55/60 HORSEPOWER (kW)

Model 30 Jet Model 40 Jet Model 40 Model 50 Model 55 Model 60

Manual 30/40 Jet 40/50 ML 55 ML OUTBOARD WEIGHT Electric 40/50 ELPTO 40/50 ELO 60 ELPTO 60 ELO CYLINDER BLOCK STROKE

Type Displacement

30 (22.4) 40 (29.8) 40 (29.8) 50 (37.3) 55 (41.0) 60 (44.7) 233 lbs. (105.7 kg) 205 lbs. (93.0 kg) 220 lbs. (99.8 kg) 204 lbs. (92.5 kg) 200 lbs. (90.7 kg) 219 lbs. (99.3 kg) 215 lbs. (97.5 kg) 3 Cylinder-2 Cycle-Loop Charged 59 cu. in. (967 cc)

Length

2.796 in. (71.018 mm)

CYLINDER BORE

Diameter Taper/Out of Round Maximum Bore Type

2.993 in. (76.022 mm) 0.003 in. (0.076 mm) Cast Iron

PISTON

Type Standard Diameter 0.015 in. (0.381 mm) Oversize

Aluminum 2.988 in. (75.895 mm) 3.003 in. (76.276 mm)

REEDS

Reed Stand Open (Max.) Reed Stop (Max.) 40 50/55/60 Reed Thickness Recommended Gasoline Recommended Oil

FUEL SYSTEM

Break-in Gasoline/Oil Ratio Manual Start Models Electric Start Models After Break-in Gasoline/Oil Ratio Manual Start Models Electric Start Models Fuel Pressure @ Idle @ W.O.T.

90-852572R02 NOVEMBER 2002

0.020 in. (0.50 mm) 0.090 in. (2.286 mm) Not Adjustable 0.010 in. (0.254 mm) Unleaded-87 Octane Minimum TC-WII or TC-W3 2 Cycle Outboard Oil Pre-mixed Gasoline and Oil 25:1 50:1 (In Fuel Tank) Pre-mixed Gasoline and Oil 50:1 Straight Gasoline 3.5 PSI (24 kPa) 6.0 PSI (41 kPa)

IMPORTANT INFORMATION — 1A-1

40/50 Gear Ratio Gearcase Capacity Lubricant Type Forward Gear Number of Teeth Pinion Gear Number of Teeth Pinion Height Forward Gear Backlash Water Pressure @ Idle @ W.O.T. Pressure Test 55/60 Gear Ratio Gearcase Capacity Lubricant Type Forward Gear Number of Teeth Pinion Gear Number of Teeth Pinion Height GEAR HOUSING Forward Gear Backlash Water Pressure @ Idle @ W.O.T. Pressure Test 60 Bigfoot Gear Ratio Gearcase Capacity Lubricant Type Forward Gear (2.31:1 Ratio) Number of Teeth Pinion Gear (2.31:1) Number of Teeth Forward Gear (2.33:1) Number of Teeth Pinion Gear (2.33:1) Number of Teeth Pinion Height Forward Gear Backlash Water Pressure @ Idle @ W.O.T. Pressure Test

1A-2 — IMPORTANT INFORMATION

1.83:1 14.9 fl. oz. (440 mL) Premium Gear Lubricant 22 Spiral/Bevel 12 Spiral/Bevel 0.025 in. (0.64 mm) No Adjustment 0.5-1.5 PSI (3-10 kPa) 5.0–7.0 PSI (35-48 kPa) 10-12 PSI (69-83 kPa) for 5 Minutes 1.64:1 11.5 fl. oz. (340 mL) Premium Gear Lubricant 23 14 0.025 in. (0.64 mm) Pinion Gear Locating Tool (91-817008A2) 0.013-0.019 in. (0.33-0.48 mm) 1–3 PSI (7-20 kPa) 7–12 PSI (48-83 kPa) 10-12 PSI (69-83 kPa) for 5 Minutes 2.3:1 22.5 fl. oz. (655 mL) Premium Gear Lubricant 30 13 28 12 0.025 in. (0.64 mm) 0.012 in.-0.019 in. (0.30 mm-0.48 mm) 10-15 PSI (69-103 kPa) @ 5250 RPM 2-7 PSI (14–48 kPa) 10-15 PSI (69-104 kPa) 10-12 PSI (69-83 kPa) for 5 Minutes

90-852572R02 NOVEMBER 2002

STARTING SYSTEM

Manual Start Electric Start Starter Draw (Under Load) Battery Rating Type Spark Plug Type

IGNITION SYSTEM Spark Plug Gap Firing Order

CHARGING SYSTEM

CARBURETOR

Alternator Output Electric Models Manual Models (Not Regulated) Stator Pole Pulse Idle RPM (In Forward Gear) 40 Jet Idle RPM (In Forward Gear) 40/50/55/60 Wide Open Throttle (W.O.T.) RPM Idle Mixture Screw Adjustment Preset (Turns Out) Float Adjustment Float Level Main Jet Model 40 (WME-53, 69) Model 50 (WME-68) Model 55 (WME-57) Model 60/40 Jet (WME-58) Recommended Oil

OIL INJECTION

Oil Tank Capacity/Approx. Time Reserve Capacity/Approx. Time Oil Output With Engine RPM of 1500 and Oil Pump @ W.O.T. Model 40 Model 50/60/40 Jet Idle

TIMING

TEMPERATURE SWITCH MANUAL STARTER ROPE

40/50/55/60 40 Jet Maximum Timing @ Cranking Speed -Model 40/50/60/40 Jet -Model 55/60 Seapro-Marathon @ 5000 RPM – Model 40/50/60/40 Jet – Model 55/60 Seapro-Marathon Temperature Normal 190°F ± 8° (88°C ± 4°C) 170°F ± 8° (77°C ± 4°C) Length

Recoil Starter 125 Amperes Min. Reserve Cap. Rating of 100 Min. and CCA of 350 Amperes Capacitor Discharge NGK BP8H-N-10 *NGK BPZ8H-N-10 0.040 in. (1.0mm) 1-2-3 Single Phase (12 Pole) 16 Amperes @ 2000 RPM 9 Amperes @ 3000 RPM 12 6 825 ± 100 675 ± 25 5000-5500 11/4 ± 1/4 9/

16

in. (14 mm)

0.044 in. 0.052 in. 0.058 in. 0.060 in. TC-WII or TC-W3 2 Cycle Outboard Oil 3.0 qts. (2.8 L) 7 hours 14.5 fl. oz. (0.43 L) 1/2 hour

15.0 ± 3.0 cc of oil in 10 minutes 22.0 ± 3.0 cc of oil in 10 minutes T.D.C. ± 2°/–0° 6°BTDC +1°/–0° 24° B.T.D.C. 18° B.T.D.C. 22° B.T.D.C. 16° B.T.D.C. Open — No Continuity Closed — Full Continuity Open — No Continuity 66 in. (1676 mm)

*Suppressor (resistor) spark plug

90-852572R02 NOVEMBER 2002

IMPORTANT INFORMATION — 1A-3

Mercury/Quicksilver Lubricants and Sealants Tube Ref. No.

Description

Mercury Part Number

Quicksilver Part Number

4

Needle Bearing Assy. Lubricant

92-802868A1

N/A

92-823506-1

92-823506-1

6

Dielectric Grease

7

Loctite 271 – Thread Locker

92-809819

92-809819

9

Loctite 567 PST Pipe Sealant

92-809822

92-809822

12

Loctite Master Gasket Kit

92-12564-2

92-12564-2

14

2 Cycle Premium Outboard Oil

92-802813A1

92-802813Q1

19

Perfect Seal

92-34227-1

92-34227-1

Liquid Neoprene

92-25711-3

92-25711-3

Bellows Adhesive

N/A

92-86166Q1

33

Loctite 680 Retaining Compound

92-809833

92-809833

34

Special Lubricant 101

92-802865A1

92-802865Q1

U-Joint and Gimbal Bearing Grease

92-802870A1

92-802870Q1

25 27

42

51

Loctite 222 Thread Locker

92-809818

92-809818

66

Loctite 242 Thread Locker

92-809821

92-809821

79

4 Cycle 25W40 Engine Oil

92-802837A1

92-802837Q1

82

Premium Gear Lubricant

92-802846A1

92-802846Q1

87

High Performance Gear Lube

92-802854A1

92-802854Q1

91

Engine Coupler Spline Grease

92-802869A1

92-802869Q1

94

Anti-Corrosion Grease

92-802867A1

92-802867Q1

95

2-4-C with Teflon

92-802859A1

92-802859Q1

4 Stroke 10W30 Outboard Oil

92-802833A1

92-802833Q1

Power Trim & Steering Fluid

92-802880A1

92-802880Q1

110

114

1A-4 — IMPORTANT INFORMATION

90-852572R02 NOVEMBER 2002

Mercury Part Number

Quicksilver Part Number

92-802824A1

92-802824Q1

RTV 587 Silicone Sealer

92-809825

92-809825

117

Loctite 7649 Primer N

92-809824

92-809824

119

Storage Seal Rust Inhibitor

92-802878-56

92-802878Q56

120

Corrosion Guard

92-802878 55

92-802878Q55

121

15W40 4-cycle Diesel Engine Oil

92-877695K1

92-877695Q1

122

Extended Life Antifreeze/Coolant

92-877770K1

92-877770K1

123

Marine Engine Coolant

NA

92-813054A2

124

Fuel System Treatment and Stabilizer Concentrate

92-802876A1

92-802876Q1

125

Heat Transfer Compound

92-805701 1

126

Liquid Gasket

92-808137

NA

127

T442 Sealant

92-862258

NA

Loctite 5900 Ultra Black RTV Silicone Sealant

92-809826

NA

128

129

Loctite Gasket Remover

92-809828 1

NA

130

Sealer Kit, Two Part Epoxy

NA

92-65150 1

131

Anti-seize Compound

92-881091K1

132

Torco MTF Gear Oil

92–849864–1

133

Optimol Longtime PD 2

92–848767

134

Dexron III Automatic Transmission Fluid

Obtain Locally

Obtain Locally

Loctite 592

Obtain Locally

Obtain Locally

Loctite Quick Tite

Obtain Locally

Obtain Locally

Isopropyl Alcohol

Obtain Locally

Obtain Locally

Hot Glue

Obtain Locally

Obtain Locally

Loctite 609

Obtain Locally

Obtain Locally

Loctite 405

Obtain Locally

Obtain Locally

Tube Ref. #

Description

115

Premium Plus 2 Cycle TC-W3 Outboard Oil

116

Chart continued on next page.

90-852572R02 NOVEMBER 2002

IMPORTANT INFORMATION — 1A-5

Mercury/Quicksilver Lubricants and Sealants (continued from previous page)

Description

Mercury Part Number

Quicksilver Part Number

Cyanacrylate Adhesive

Obtain Locally

Obtain Locally

3M Permabond #3M08155

Obtain Locally

Obtain Locally

Loctite 262

Obtain Locally

Obtain Locally

Loctite 290

Obtain Locally

Obtain Locally

Tube Ref. #

Propeller Information Charts Mercury/Mariner 40 HP (3 Cyl.) Wide Open Throttle RPM: 5000-5500 Recommended Transom Heights : 15”, 20” Right Hand Rotation Standard Gear Reduction : 1.83:1

Material

Approx. Gross Boat Wgt. (lbs)

Approx. Boat Length

Speed Range (mph)

Propeller Part Number

Diameter

Pitch

No. of Blades

10”

19”

3

Alum

Up to 900

Up to 14’

41-49

48-73146A40

10”

17”

3

Alum

Up to 900

Up to 14’

35-43

48-73144A40

10”

16”

3

SS

Up to 1200

Up to 15’

32-40

48-91818A5

10”

16”

3

Alum

Up to 1200

Up to 15’

32-40

48-73142A40

10-1/8”

15”

3

SS

1000-1500

13-15’

28-37

48-855862A5

10-1/8”

15”

3

Alum

1000-1500

13-15’

28-37

48-73140A40

10-3/8”

14”

3

Alum

1100-1700

14-16’

25-34

48-816706A40

10-1/4”

14”

3

SS

1100-1700

14-16’

25-34

48-855860A5

10-1/4”

14”

3

Alum

1100-1700

14-16’

25-34

48-73138A40

10-1/2”

13”

3

Alum

1300-2100

14-17’

21-31

48-816704A40

10-3/8”

13”

3

SS

1300-2100

14-17’

21-31

48-855858A5

10-3/8”

13”

3

Alum

1300-2100

14-17’

21-31

48-73136A40

10-3/4”

12”

3

Alum

1500-2500

15-19’

18-27

48-816702A40

10-5/8”

12”

3

SS

1500-2500

15-19’

18-27

48-855856A5

10-5/8”

12”

3

Alum

1500-2500

15-19’

18-27

48-73134A40

10-7/8”

11”

3

Alum

1800-3500

16-21’

14-24

48-85632A40

11-1/4”

10”

3

Alum

2000+

17’+

11-21

48-73132A40

11-5/8”

11”

3

SS

1800-3500

16-21’

14-24

48-823478A5

11-5/8”

10-1/2”

3

Alum

2000+

17’+

13-23

48-827312A10

12-1/4”

9”

3

Alum

2500+

18’+

8-17

48-87818A10

12-1/4”

9”

3

SS

2500+

18’+

8-17

48-97868A10

12-1/2”

8”

3

Alum

3000+

20’+

1-14

48-42738A10

1A-6 — IMPORTANT INFORMATION

90-852572R02 NOVEMBER 2002

Mercury/Mariner 50 HP (3 Cyl.) Wide Open Throttle RPM: 5000-5500 Recommended Transom Heights : 15”, 20”, 22-1/2” Right Hand Rotation Standard Gear Reduction : 1.83:1

Diameter

Pitch

No. of Blades

Material

Approx. Gross Boat Wgt. (lbs)

10”

19”

3

Alum

Up to 1100

Up to 14’

41-49

48-73146A40

10”

17”

3

Alum

Up to 1400

Up to 14’

35-43

48-73144A40

10”

16”

3

SS

1200-1500

Up to 15’

32-40

48-91818A5

10”

16”

3

Alum

1200-1500

Up to 15’

32-40

48-73142A40

10-1/8”

15”

3

SS

1300-1800

13-15’

28-37

48-855862A5

10-1/8”

15”

3

Alum

1300-1800

13-15’

28-37

48-73140A40

10-3/8”

14”

3

Alum

1400-2100

14-16’

25-34

48-816706A40

10-1/4”

14”

3

SS

1400-2100

14-16’

25-34

48-855860A5

10-1/4”

14”

3

Alum

1400-2100

14-16’

25-34

48-73138A40

10-1/2”

13”

3

Alum

1600-2600

14-17’

21-31

48-816704A40

10-3/8”

13”

3

SS

1600-2600

14-17’

21-31

48-855858A5

10-3/8”

13”

3

Alum

1600-2600

14-17’

21-31

48-73136A40

10-3/4”

12”

3

Alum

1900-3200

15-19’

18-27

48-816702A40

10-5/8”

12”

3

SS

1900-3200

15-19’

18-27

48-855856A5

10-5/8”

12”

3

Alum

1900-3200

15-19’

18-27

48-73134A40

10-7/8”

11”

3

Alum

2200-4300

16-21’

14-24

48-85632A40

11-1/4”

10”

3

Alum

2500+

17’+

11-21

48-73132A40

11-5/8”

11”

3

SS

2200-4300

16-21’

14-24

48-823478A5

11-5/8”

10-1/2”

3

Alum

2200+

17’+

13-23

48-827312A10

12-1/4”

9”

3

Alum

3000+

18’+

8-17

48-87818A10

12-1/4”

9”

3

SS

3000+

18’+

8-17

48-97868A10

12-1/2”

8”

3

Alum

3500+

20’+

1-14

48-42738A10

90-852572R02 NOVEMBER 2002

Approx. Boat Length

Speed Range (mph)

Propeller Part Number

IMPORTANT INFORMATION — 1A-7

Mercury/Mariner 55 HP (3 Cyl.) Wide Open Throttle RPM: 5000-5500 Recommended Transom Heights : 16-1/2”, 21”, 23-1/2” Right Hand Rotation Standard Gear Reduction : 2.3:1

Material

Approx. Gross Boat Wgt. (lbs)

Approx. Boat Length

Speed Range (mph)

Propeller Part Number

Diameter

Pitch

No. of Blades

12-3/4”

26”

5

SS

Up to 800

Up to 15’

48-54

48-815748A45

13-1/2”

26”

3

SS

Up to 800

Up to 15’

48-54

48-16996A30

12-3/4”

24”

5

SS

Up to1000

Up to 15’

46-52

48-815746A45

13-1/2”

24”

3

SS

Up to 1000

Up to 15’

46-52

48-16994A30

12-1/2”

23”

3

Alum

700-1100

Up to 15’

45-51

48-77350A45

12-3/4”

22”

5

SS

700-1100

Up to 15’

43-49

48-815744A45

13-1/2”

22”

3

SS

700-1100

Up to 15’

43-59

48-16992A30

12-3/4”

21”

3

Alum

800-1200

13-16’

40-47

48-77348A45

12-3/4”

20”

5

SS

800-1200

13-16’

38-45

48-816612A45

13-1/2”

20”

3

SS

800-1200

13-17’

38-45

48-16990A30

13”

19”

3

Alum

1000-1400

14-17’

35-42

48-77346A45

13”

18”

3

SS

1000-1400

14-17’

33-40

48-16988A30

13-1/4”

17”

3

Alum

1200-1700

15-18’

31-38

48-77344A45

13-1/8”

16”

3

SS

1200-1700

15-18’

29-36

48-16986A30

13-3/4”

15”

3

Alum

1500-2100

16-19’

26-33

48-77342A45

13-3/8”

14”

3

SS

1500-2100

16-19’

23-31

48-17314A30

14”

13”

3

Alum

1900-2500

17’+

20-28

48-77340A45

14”

12”

3

SS

1900-2500

17’+

17-26

48-17312A30

14”

11”

3

Alum

2200+

18’+

1-22

48-77338A45

14”

10”

3

SS

2400+

19’+

1-20

48-17310A30

1A-8 — IMPORTANT INFORMATION

90-852572R02 NOVEMBER 2002

Mercury/Mariner 60 HP (3 Cyl.) Wide Open Throttle RPM: 5000-5500 Recommended Transom Heights : 15”, 20” Right Hand Rotation Standard Gear Reduction : 1.64:1

Material

Approx. Gross Boat Wgt. (lbs)

Approx. Boat Length

Speed Range (mph)

Propeller Part Number

Diameter

Pitch

No. of Blades

10”

19”

3

Alum

Up to 800

Up to 14’

48-55

48-73146A40

10”

17”

3

Alum

Up to 1000

Up to 15’

44-51

48-73144A40

10”

16”

3

SS

700-1100

Up to 15’

41-48

48-91818A5

10”

16”

3

Alum

700-1100

Up to 15’

41-48

48-73142A40

10-1/8”

15”

3

SS

800-1200

13-15’

38-45

48-855862A5

10-1/8”

15”

3

Alum

800-1200

13-15’

38-45

48-73140A40

10-1/4”

14”

3

SS

900-1500

14-16’

35-41

48-816706A40

10-3/8”

14”

3

Alum

900-1500

14-16’

35-41

48-855860A5

10-3/8”

13”

3

SS

1200-1800

15-17’

32-38

48-73138A40

10-1/2”

13”

3

Alum

1200-1800

15-17’

32-38

48-816704A40

10-5/8”

12”

3

SS

1500-2100

16-18’

28-34

48-855858A5

10-3/4”

12”

3

Alum

1500-2100

16-18’

28-34

48-73136A40

10-7/8”

11”

3

Alum

1800-2400

16-18’

24-30

48-816702A40

11-5/8”

11”

3

SS

Workboat

16’+

24-30

48-855856A5

12”

10-1/2”

3

Alum

2000-2600

17’+

22-28

48-73134A40

11-5/8”

10-1/2”

3

Alum

2000-2600

17’+

22-28

48-85632A40

11-1/4”

10”

3

Alum

2100-2600

17’+

20-26

48-73132A40

12-1/4”

9”

3

SS

2400+

18’+

14-22

48-823478A5

12-1/4”

9”

3

Alum

2400+

18’+

14-22

48-827312A10

12-1/2”

8”

3

Alum

2800+

19’+

1-18

48-87818A10

90-852572R02 NOVEMBER 2002

IMPORTANT INFORMATION — 1A-9

Mercury/Mariner 60 HP (3 Cyl.) Bigfoot Wide Open Throttle RPM: 5000-5500 Recommended Transom Heights : 15”, 20”, 22-1/2” Right Hand Rotation Standard Gear Reduction : 2.31:1

Diameter

Pitch

No. of Blades

Material

Approx. Gross Boat Wgt. (lbs)

13”

18”

3

SS

Up to 1100

Up to 14’

41-49

48-16988A45

13-1/4”

17”

3

Alum

Up to 1400

Up to 14’

35-43

48-77344A45

13-1/8”

16”

3

SS

1200-1500

Up to 15’

32-40

48-16986A45

13-3/4”

15”

3

Alum

1200-1500

Up to 15’

32-40

48-77342A45

13-3/8”

14”

3

SS

1300-1800

13-15’

28-37

48-17314A45

14”

13”

3

Alum

1300-1800

13-15’

28-37

48-77340A45

14”

12”

3

SS

1400-2100

14-16’

25-34

48-17312A45

14”

11”

3

Alum

1400-2100

14-16’

25-34

48-77338A45

14”

10”

3

Alum

1400-2100

14-16’

25-34

48-854342A45

14”

9”

3

Alum

1600-2600

14-17’

21-31

48-854340A45

1A-10 — IMPORTANT INFORMATION

Approx. Boat Length

Speed Range (mph)

Propeller Part Number

90-852572R02 NOVEMBER 2002

IMPORTANT INFORMATION

MAINTENANCE

1 B

Table of Contents Page Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-1 Gear Case Lubricant Capacity . . . . . . . . . 1B-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-1 Inspection and Maintenance Schedule . . . . 1B-2 Before Each Use . . . . . . . . . . . . . . . . . . . . 1B-2 After Each Use . . . . . . . . . . . . . . . . . . . . . . 1B-2 Every 100 Hours of Use or Once Yearly, Whichever Occurs First . . . . . . . . . . . . . . . 1B-2 Every 300 Hours of Use or Three Years 1B-2 Before Periods of Storage . . . . . . . . . . . . 1B-2 Flushing The Cooling System . . . . . . . . . . . . 1B-3 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-3 Corrosion Control Anode . . . . . . . . . . . . . . . . 1B-4 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . 1B-5 Checking Power Trim Fluid . . . . . . . . . . . . . . 1B-7 60 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-7 40/50 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-7 Gear Case Lubrication . . . . . . . . . . . . . . . . . . 1B-8 Draining Gear Case . . . . . . . . . . . . . . . . . . 1B-8 Checking Lubricant Level and Filling Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9 Storage Preparations . . . . . . . . . . . . . . . . . . . 1B-9 Protecting External Outboard Components . . . . . . . . . . . . . . . . . . . . . . . . 1B-9 Protecting Internal Engine Components 1B-9 Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-10 Positioning Outboard for Storage . . . . . . 1B-10 Battery Storage . . . . . . . . . . . . . . . . . . . . . 1B-10

1B-0- IMPORTANT INFORMATION

90-852572R02 NOVEMBER 2002

Specifications Gear Case Lubricant Capacity Gear Case Ratio

Capacity

1.83:1 1.64 :1 2.3:1

14.9 fl. oz. (440 mL) 11.5 fl. oz. (340 mL) 22.5 fl. oz. (655 mL)

Special Tools 1. Flushing Attachment (44357A2)

50551

90-852572R02 NOVEMBER 2002

IMPORTANT INFORMATION — 1B-1

Inspection and Maintenance Schedule

Every 100 Hours of Use or Once Yearly, Whichever Occurs First 1. Lubricate all lubrication points. Lubricate more frequently when used in salt water.

Before Each Use

2. Inspect and clean spark plugs.

1. Check that lanyard stop switch stops the engine.

3. Check engine fuel filter for contaminants.

2. Visually inspect the fuel system for deterioration or leaks.

4. Adjust carburetor(s) (if required).∗

3. Check outboard for tightness on transom.

5. Check engine timing setup.∗

4. Check steering system for binding or loose components.

6. Check corrosion control anodes. Check more frequently when used in salt water.

5. Remote Control Models – Visually check steering link rod fasteners for proper tightness.

7. Drain and replace gear case lubricant.

6. Check propeller blades for damage.

9. Check power trim fluid.

8. Lubricate splines on the drive shaft. 10. Inspect battery.

After Each Use

11. Check control cable adjustments. ∗

1. Flush out the outboard cooling system if operating in salt or polluted water.

12. Remove engine deposits with Power Tune Engine Cleaner.

2. Wash off all salt deposits and flush out the exhaust outlet of the propeller and gear case with fresh water if operating in salt water.

13. Check tightness of bolts, nuts, and other fasteners. * These items should be serviced by an authorized dealer.

Every 300 Hours of Use or Three Years 1. Replace water pump impeller (more often if overheating occurs or reduced water pressure is noted).

Before Periods of Storage Refer to Storage Procedure.

1B-2- IMPORTANT INFORMATION

90-852572R02 NOVEMBER 2002

Flushing The Cooling System Flush the internal water passages of the outboard with fresh water after each use in salt, polluted, or muddy water. This will help prevent a buildup of deposits from clogging the internal water passages. Use Flushing Attachment (44357A2) (or equivalent) flushing attachment.

3. Start the engine and run it at idle speed in neutral shift position. 4. Adjust water flow (if necessary) so excess water continues leaking out from around the rubber cups to ensure the engine is receiving an adequate supply of cooling water. 5. Check for a steady stream of water flowing out of the water pump indicator hole. Continue flushing the outboard for 3 to 5 minutes, carefully monitoring water supply at all times.

WARNING To avoid possible injury when flushing, remove the propeller. Refer to Propeller Replacement. 1. Remove propeller (refer to Propeller Replacement). Install the flushing attachment so the rubber cups fit tightly over the cooling water intake holes.

6. Stop the engine, turn off the water, and remove the flushing attachment. Reinstall the propeller.

Fuel System 2. Attach a water hose to the flushing attachment. Turn on the water and adjust the flow so water is leaking around the rubber cups to ensure the engine receives an adequate supply of cooling water.

IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a formation 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 system (tank, hoses, fuel pump, and carburetors) with treated (stabilized) fuel to help prevent formation of varnish and gum. Proceed with following instructions. 1. Portable Fuel Tank – Pour the required amount of 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 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.

90-852572R02 NOVEMBER 2002

IMPORTANT INFORMATION — 1B-3

3. Place the outboard in water or connect flushing attachment for circulating cooling water. Run the engine for ten minutes to allow treated fuel to reach the carburetors.

Corrosion Control Anode 1. Your outboard has two corrosion control anodes. One of the anodes is the trim tab installed on the gear case and the other is installed on the bottom of the transom bracket assembly. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard metals.

a

b a — Trim Tab Anode b — Transom Bracket Anode

NOTE: Each anode requires periodic inspection especially in salt water which will accelerate the erosion. To maintain this corrosion protection, always replace the anode before it is completely eroded. Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode.

1B-4- IMPORTANT INFORMATION

90-852572R02 NOVEMBER 2002

Lubrication Points ITEM NO. 1 2

DESCRIPTION Throttle/Shift linkage Pivot Points Shift Handle (Tiller Handle Models)

TYPE OF LUBRICANT

Swivel Pin

4

Ride Guide Steering Cable

5

Tilt Tube/Co-Pilot

6

Steering Link Rod Pivot Points

SAE 30W Motor Oil

7

Propeller Shaft

Anti-Corrosion Grease or 2-4-C with Teflon

8

Starter Motor Pinion Gear

SAE 30W Motor Oil

9 *

Gear Housing Bearing Carrier

2-4-C with Teflon

Gear Housing

Premium Gear Lubricant

Engine Crankshaft Splines to Drive Shaft Splines

2-4-C with Teflon

◊ ∆

SALT WATER FREQUENCY

2-4-C with Teflon 100 Hours of Use or Once Per Season

3

10

FRESH WATER FREQUENCY

* Refer to lubrication instructions outlined in “Salt Water Corrosion — Gear Housing Bearing Carrier and Cover Nut” of this section (see “Table of Contents”).

100 Hours of Use or Once Per Season

Once Per Season ◊ Refer to “Gear Housing Lubrication” of this section (see “Table of Contents”). ∆ Refer to “Gear Housing Removal and Installation”.

1 1

1 — Throttle/Shift Linkage Pivot Points

90-852572R02 NOVEMBER 2002

IMPORTANT INFORMATION — 1B-5

2

2

5 5

5

5 — Tilt Tube/Co-Pilot 2 — Shift Handle (Tiller Handle Models)

3

6 6 — Steering Link Rod Pivot Points 3 — Swivel Pin

4

4 — Ride Guide Steering Cable

4

7

7 — Propeller Shaft

1B-6- IMPORTANT INFORMATION

90-852572R02 NOVEMBER 2002

a

8

50157 51118

8 — Starter Motor Pinion Gear

a — Tilt Lock Lever

2. Remove fill screw and check fluid level. Fluid level should be to bottom of threads in fill hole. 3. If necessary, add Power Trim & Steering Fluid or; Automatic Transmission Fluid (ATF) Type F, FA or Dexron II fluid to trim system. 4. Reinstall fill screw.

40/50 HP 1. Tilt outboard to the full up position and engage the tilt support lock.

10 9

2. Remove fill cap and check fluid level. The fluid level should be even with the bottom of the fill hole. Add Power Trim & Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid.

50558

9 — Gear Housing Bearing Carrier 10- Gear Housing

a

Checking Power Trim Fluid IMPORTANT: This trim system is pressurized. Remove fill screw when outboard is trimmed to the full “up” position. Retighten fill screw securely.

b

60 HP 1. Trim outboard to full “up” position. Engage tilt lock lever. Trim system fluid can only be checked when outboard is in this position.

a — Tilt Support Lock b — Fill Cap 90-852572R02 NOVEMBER 2002

IMPORTANT INFORMATION — 1B-7

Gear Case Lubrication When adding or changing gear case lubricant, visually check for the presence of water in the lubricant. If water is present, it may have settled to the bottom and will drain out prior to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance. If water is noticed, have the gear case checked by your dealer.Water in the lubricant may result in premature bearing failure or, in freezing temperatures, will turn to ice and damage the gear case.

a

Whenever you remove the fill/drain plug, examine the magnetic end for metal particles. A small amount of metal filings or fine metal particles indicates normal gear wear. An excessive amount of metal filings or larger particles (chips) may indicate abnormal gear wear and should be checked by an authorized dealer.

WARNING If gear housing is installed on outboard, 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 Premium Gear Lubricant.

Draining Gear Case 1. Tilt outboard so that lubricant in gear housing will drain toward front of housing, out fill hole and into clean container. IMPORTANT: Inspect FILL and VENT plug washers for damage. Use new washers as needed. 2. Remove lubricant Fill plug and washer. Note amount of metal particles on magnetic Fill plug. Remove all magnetic particles from Fill plug.

b

a — Lubricant Vent Plug/Washer b — Lubricant Fill Plug/Washer

4. Inspect gear lubricant for metal particles (lubricant will have a “metal flake” appearance). Presence of fine metal particles (resembling powder) on the magnetic fill plug indicates normal wear. The presence of metal chips on the magnetic fill plug indicates the need for gear housing disassembly and components inspection. 5. Note color of gear lubricant. White or cream color indicates presence of water in lubricant. Gear lubricant which has been drained from a gear housing recently in operation, will have a yellowish color due to lubricant agitation/aeration. This is normal and should not be confused with the presence of water. 6. Presence of water in gear lubricant indicates the need for disassembly and inspection of oil seals, seal surfaces, O-rings, water pump gaskets, as well as, gear housing components for damage.

3. Remove Vent plug and washer and allow all lubricant to drain.

1B-8- IMPORTANT INFORMATION

90-852572R02 NOVEMBER 2002

Checking Lubricant Level and Filling Gear Case IMPORTANT: Never add lubricant to gear housing

without first removing VENT plug, as trapped air will prevent housing from being filled. Fill gear housing only when outboard is in operating position.

NOTE: Refer to “Specifications,” for gear housing lubricant capacity. 1. With outboard in operating position, insert lubricant tube into fill hole. 2. Fill gear housing until excess lubricant flows from VENT hole.

b

Storage Preparations The major consideration in preparing your outboard for storage is to protect it from rust, corrosion, 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 all the cooling water intake holes in the gear case to prevent damage to the water pump (running dry) or overheating of the engine.

Protecting External Outboard Components 1. Lubricate all outboard components listed in the Inspection and Maintenance Schedule. 2. Touch up any paint nicks. See your dealer for touch-up paint. 3. Spray Corrosion Guard on engine exterior, electrical components, and other metal surfaces (except corrosion control anodes).

a

a — Lubricant/Fill Hole b — Vent Hole

Protecting Internal Engine Components

3. Install VENT plug and washer.

NOTE: Before performing the following steps, make sure the fuel system has been prepared for storage. Refer to Fuel System.

4. Install FILL plug and washer.

1. Place the outboard in water or connect flushing attachment for circulating cooling water. Start the engine and let it run in neutral to warm up.

a

2. With engine running at fast idle, stop the fuel flow by disconnecting the remote fuel line. When engine begins to stall, quickly spray Storage Seal into carburetor until engine stops from lack of fuel. 3. Remove the spark plugs and inject a five second spray of Storage Seal around the inside of each cylinder.

b

4. Rotate the flywheel manually several times to distribute the storage seal in the cylinders. Reinstall spark plugs.

a — Vent Plug/Washer b — Fill Plug/Washer

90-852572R02 NOVEMBER 2002

IMPORTANT INFORMATION — 1B-9

Gear Case 1. Drain and refill the gear case lubricant (refer to maintenance procedure).

Positioning Outboard for Storage 1. 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 manufacturers 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.

1B-10- IMPORTANT INFORMATION

90-852572R02 NOVEMBER 2002

IMPORTANT INFORMATION

GENERAL INFORMATION

1 C

Table of Contents Serial Number Location . . . . . . . . . . . . . . . . . Conditions Affecting Performance . . . . . . . . Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Following Complete Submersion . . . . . . . . . Salt Water Submersion (Special Instructions) . . . . . . . . . . . . . . . . . . Submerged While Running (Special Instructions) . . . . . . . . . . . . . . . . . . Submerged Engine (Fresh Water) (Plus Special Instructions) . . . . . . . . . . . . . Propeller Selection . . . . . . . . . . . . . . . . . . . . . Propeller Removal/Installation . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .

1C-0 — IMPORTANT INFORMATION

Page 1C-1 1C-1 1C-1 1C-2 1C-3 1C-3 1C-3 1C-3 1C-4 1C-4 1C-5 1C-5 1C-5

90-852572R02 NOVEMBER 2002

Serial Number Location The Outboard serial number is located on the lower starboard side of the engine block. A serial number is also located on the starboard side of the swivel bracket.

a OGXXXXXX 19XX XXXX

e

b c

d XX

a b c d e

—

Serial Number Model Year Model Description Year Manufactured Certified Europe Insignia

Conditions Affecting Performance Weather

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

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. 90-852572R02 NOVEMBER 2002

Not only does this allow the engine to develop full power, but equally important is the fact that the engine also will be operating in an RPM range that discourages damaging detonation. This, of course, enhances overall reliability and durability of the engine.

IMPORTANT INFORMATION — 1C-1

Boat

TRIM

WEIGHT DISTRIBUTION

TRIMMING OUTBOARD “OUT” (“UP”)

1. Proper positioning of the weight inside the boat

(persons and gear) has a significant effect 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 por-

poise. (3.) Can make the bow bounce excessively in

choppy water. (4.) Will increase the danger of waves splash-

ing into the boat when coming off plane. b. Shifting weight to the front (bow) (1.) Improves ease of planing off.

WARNING Excessive trim “out” also may reduce the stability of some high speed hulls. To correct instability at high speed, reduce the power GRADUALLY and trim the outboard “in” slightly before resuming high speed operation. (Rapid reduction in power will cause a sudden change of steering torque and may cause additional momentary boat instability.) 1. Will lift bow of boat, generally increasing top speed. 2. Transfers steering torque harder to left on single outboard installations below 23 in. (584mm) transom height.

(2.) Generally improves rough water ride.

3. Increases clearance over submerged objects.

(3.) If excessive, can make the boat veer left

4. In excess, can cause porpoising and/or ventilation.

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 foreand-aft direction when viewed from the side. When boat is planing, “hook” causes more lift on bottom near transom and allows bow to drop, thus greatly increasing wetted surface and reducing boat speed. “Hook” frequently is caused by supporting boat too far ahead of transom while hauling on a trailer or during storage. 2. Rocker: The reverse of hook and much less common. “Rocker” exists if bottom is convex in fore-and-aft direction when viewed from the side, and boat has strong tendency to porpoise. 3. Surface Roughness: Moss, barnacles, etc., on boat or corrosion of outboard’s gear housing increase skin friction and causes speed loss. Clean surfaces when necessary.

5. If trimmed out beyond the water pickup, reduced water supply can cause overheating resulting in engine damage. TRIMMING OUTBOARD “IN” (“DOWN”)

WARNING Excessive speed at minimum trim “in” may cause undesirable and/or unsafe steering conditions. Each boat should be tested for handling characteristics after any adjustment is made to the angle (trim adjustment bolt relocation.) 1. Will help planing off, particularly with a heavy load. 2. Usually improves ride in choppy water. 3. In excess, can cause boat to veer to the left or right (bow steer). 4. Transfers steering torque harder to right (or less to the left) on single outboard installations. 5. Improves planing speed acceleration (by moving trim adjustment bolt one hole closer to transom). WATER ABSORPTION It is imperative that all through the 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.

1C-2 — IMPORTANT INFORMATION

90-852572R02 NOVEMBER 2002

CAVITATION

Detonation usually can be prevented if:

Cavitation is caused by water vapor bubbles forming either from a sharp edge or angle on the gear case or from an irregularity in the propeller blade itself. 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 continue, eventual blade failure (breakage) will occur.

1. The engine is correctly set up. 2. Diligent maintenance is applied to combat the detonation causes.

Engine DETONATION Detonation in a 2-cycle engine resembles the “pinging” heard in an automobile engine. It can be otherwise described as a tin-like “rattling” or “plinking” sound. Detonation is an explosion of an unburned portion of the fuel/air charge after the spark plug has fired. Detonation creates severe shock waves in the engine, and these shock waves often find or create a weakness. The dome of a piston, cylinder head/gasket, piston rings or piston ring lands, piston pin and roller bearings. A few of the most common causes of detonation in a marine 2-cycle application are as follows: •

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).

90-852572R02 NOVEMBER 2002

51115

Damaged Piston Resulting from Detonation

Following Complete Submersion Salt Water Submersion (Special Instructions) Due to the corrosive effect of salt water on internal engine components, complete disassembly is necessary before any attempt is made to start the engine.

Submerged While Running (Special Instructions) When an engine is submerged while running, the possibility of internal engine damage is greatly increased. If, after engine is recovered and with spark plugs removed, engine fails to turn over freely when turning flywheel, the possibility of internal damage (bent connecting rod and/or bent crankshaft) exists. If this is the case, the powerhead must be disassembled.

IMPORTANT INFORMATION — 1C-3

Submerged Engine (Fresh Water) (Plus Special Instructions) 1. Recover engine as quickly as possible. 2. Remove cowling. 3. Flush exterior of outboard with fresh water to remove mud, weeds, etc. DO NOT attempt to start engine if sand has entered powerhead, as powerhead will be severely damaged. Disassemble powerhead if necessary to clean components. 4. Remove spark plugs and get as much water as possible out of powerhead. Most water can be eliminated by placing engine in a horizontal position (with spark plug holes down) and rotating flywheel. 5. Pour alcohol into carburetor throats (alcohol will absorbed water). Again rotate flywheel. 6. Turn engine over and pour alcohol into spark plug openings and rotate flywheel. 7. Turn engine over (place spark plug openings down) and pour engine oil into throat of carburetors while rotating flywheel to distribute oil throughout crankcase. 8. Again turn engine over and pour approximately one teaspoon of engine oil into each spark plug opening. Again rotate flywheel to distribute oil in cylinders. 9. Remove and clean carburetors and fuel pump assembly. 10. Dry all wiring and electrical components using compressed air. 11. Disassemble the engine starter motor and dry the brush contacts, armature and other corrodible parts. 12. Reinstall spark plugs, carburetors and fuel pump. 13. 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. 14. 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.

1C-4 — IMPORTANT INFORMATION

Propeller Selection For in-depth information on marine propellers and boat performance — written by marine engineers — see your Authorized Dealer for the illustrated “What You Should Know About Mercury/Quicksilver Propellers… and Boat Performance Information” (Part No. 90-86144-92). 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 acceleration while maintaining maximum boat speed. If changing conditions cause the RPM to drop below the recommended range (such as warmer, 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 balanced-steering condition (steering effort equal in both directions) without causing the propeller to “break loose”. Refer to “Mercury/Quicksilver Accessory Guide” for a complete list of available propellers. 1. Select a propeller that will allow the engine to op-

erate at or near the top of the recommended full throttle RPM range (listed in “Specifications,” preceding) with a normal load. Maximum engine speed (RPM) for propeller selection exists when boat speed is maximum 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 recom-

mended range, the propeller MUST BE changed to one with a lower pitch to prevent loss of performance and possible engine damage.

90-852572R02 NOVEMBER 2002

3. After initial propeller installation, the following

common conditions may require that the propeller be changed to a lower pitch:

4. Place a block of wood between gear case and propeller to hold propeller and remove propeller nut.

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

5. Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer.

Removal 1. Shift outboard to neutral (N) position. 2. Remove the spark plug leads to prevent engine from starting. 3. Straighten the bent tabs on the propeller nut retainer.

Installation 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 starting 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.

CAUTION If the propeller moves forward-and-aft on the propeller shaft (is loose), re-tighten the propeller nut. Operation with a loose propeller could cause damage to the thrust hub and gear housing during acceleration, deceleration or when shifting gears. IMPORTANT: To assure that the propeller remains

secure on the shaft during the season, periodically check propeller shaft nut for tightness.

90-852572R02 NOVEMBER 2002

IMPORTANT INFORMATION — 1C-5

1. To aid in future removal of the propeller, liberally coat the propeller shaft spline with one of the following Mercury/Quicksilver lubricants: •

Anti-Corrosion Grease

•

2-4-C with Teflon

6. After first use, bend the tab straight, re-tighten propeller nut and again bend tab washer to secure nut. Check propeller periodically for tightness.

2. Place forward thrust hub on propeller shaft. 3. Flo-Torque I Drive Hub Propellers – Install forward thrust hub, propeller, propeller nut retainer and propeller nut onto the shaft.

d c

b a a b c d

—

Forward Thrust Hub Propeller Propeller Nut Retainer Propeller Nut

4. Flo-Torque II Drive Hub Propellers – Install forward thrust hub, propeller, replaceable drive sleeve, rear thrust hub, propeller nut retainer and propeller nut onto the shaft.

d

f e

c a b c d e f

—

b

a

Forward Thrust Hub Propeller Replaceable Drive Sleeve Rear Thrust Hub Propeller Nut Retainer Propeller Nut

5. 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.

a

b

b

a

a — Pins b — Tabs

1C-6 — IMPORTANT INFORMATION

90-852572R02 NOVEMBER 2002

IMPORTANT INFORMATION

OUTBOARD MOTOR INSTALLATION

1 D

Table of Contents Page Lifting Outboard . . . . . . . . . . . . . . . . . . . . . . . . 1D-1 Steering Link Rod . . . . . . . . . . . . . . . . . . . . . . 1D-1 Installing Outboard 40-50 HP . . . . . . . . . . . . 1D-2 40-50 Hp – Non-Thumb Screw Models . 1D-2 40-50 HP – Thumb Screw Models . . . . . 1D-3 Installing Outboard 55-60 HP . . . . . . . . . . . . 1D-4 55-60 HP — Non-Thumb Screw Models . 1D-4 55-60 HP – Thumb Screw Models . . . . . 1D-5 Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . 1D-6 Battery Cable Connections . . . . . . . . . . . . . . 1D-6 Shift and Throttle Cable 40 and 50 Hp Models . . . . . . . . . . . . . . . . . . . 1D-7 40-50 Hp – Shift Cable Installation . . . . . 1D-7 40-50 Hp – Throttle Cable Installation . . 1D-8 Shift and Throttle Cable 60 HP Models . . . . . . . . . . . . . . . . . . . . . . . . . 1D-9 60 HP – Shift Cable Installation . . . . . . . . 1D-9 60 HP – Throttle Cable Installation . . . . . 1D-10 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . 1D-11

1D-0 — IMPORTANT INFORMATION

90-852572R02 NOVEMBER 2002

Lifting Outboard

Steering Link Rod

Electric Start Models – Remove plastic cap from flywheel hub. Thread lifting ring into flywheel a minimum of 5 turns. Replace plastic cap after installation.

1. Install steering link rod per illustration. 40-60 HP 60 Hp 40-50 Hp

f

b

d e

c

a Manual Start Models – Use lifting eye.

a — Special Bolt (10-856680) Torque to 20 lb. ft.(27.1 N·m) b — Nylon Insert Locknut (11-826709113) Torque to 20 lb. ft.(27.1 N·m) c — Spacer (12-71970) d — Flat Washer (2) e Nylon Insert Locknut (11-826709113) Tighten Locknut Until it Seats, Then Back Nut Off 1/4 Turn f — Use Correct Hole

IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special bolt (“a” — Part Number 10-856680) and self locking nuts (“b” & “e” Part Number 11-826709113). 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 overboard exposing them to serious injury or death.

90-852572R02 NOVEMBER 2002

IMPORTANT INFORMATION — 1D-1

Installing Outboard 40-50 HP

5. Drill four mounting holes using a 17/32 in. (13.5 mm) drill bit.

40-50 Hp – Non-Thumb Screw Models a

a — Non-Thumb Screw

6. Position outboard so the anti-ventilation plate is within 1 in. (25.4 mm) of the boat bottom.

2. Center outboard on the transom.

a

0 — 1 in. (0 — 25.4mm)

3. Secure outboard to the transom temporarily using C-clamps.

a — Anti-Ventilation Plate

7. Fasten outboard with provided mounting hardware shown. Apply RTV 587 Silicon Sealer to shanks of bolts (not threads).

116

c

4. Mark location for four mounting holes.

NOTE: Normally the 4 upper mounting holes marked are to be drilled. This allows the outboard to be raised without re-drilling. Use other holes if necessary to avoid obstructions.

a

a

b 116

RTV 587 Silicone Sealer

a — 1/2 in. (12.7 mm) Diameter Bolt (4) b — Flat Washer (4) c — Locknut (4)

a

WARNING a

a — Upper Mounting Holes 1D-2 — IMPORTANT INFORMATION

a

Before operation, the outboard must be correctly installed with four mounting bolts shown. Failure to correctly fasten outboard could result in outboard ejecting off boat transom causing serious injury, death, or property damage. 90-852572R02 NOVEMBER 2002

NOTE: Mercury/Quicksilver Accessory Outboard Mounting Kit (P/N 812432A5) allows for quick removal and installation of outboard. Refer to installation instructions supplied with the mounting kit before drilling any holes. Tighten retainer screws into lower mounting holes when using mounting kit.

40-50 HP – Thumb Screw Models

a

a — Thumb Screw

a

WARNING Outboard must be fastened to boat transom one of two ways: 1) permanently fastened to transom with thumb screws and mounting bolts (provided), or 2) secured to the transom using the optional outboard mounting kit (P/N 812432A5). Should the outboard strike an underwater object or be steered into a sharp turn, failure to fasten outboard correctly to the boat transom with mounting bolts or optional mounting kit could result in outboard ejecting suddenly off boat transom causing serious injury, death, boat damage, or loss of outboard. 1. Center outboard on the transom.

b

a — Accessory Outboard Mounting KIt b — Retaining Screws

3. Type 1 Bracket – Drill two 1/2 in. (12.7 mm) holes through a lower set of mounting holes. 4. Type 2 Bracket – Drill two 3/8 in. (9.5 mm) holes through the lower mounting holes. 5. Fasten outboard with provided mounting hardware shown. Apply RTV 587 Silicon Sealer to shanks of bolts (not threads). Type 2 Bracket

Type 1 Bracket

f

f d

116

b

d

c

2. Position outboard so the anti-ventilation plate is within 1 in. (25.4 mm) of the boat bottom.

a

0 — 1 in. (0 — 25.4 mm)

a — Anti-Ventilation Plate 90-852572R02 NOVEMBER 2002

a 116

a b c d e

c

—

RTV 587 Silicone Sealer

116

1/2 in.(12.7 mm) Diameter Bolt (2) 3/8 in. (9.5 mm) Diameter Bolt (2) Flat Washer (2) Locknut (2) Thumb Screws, Tighten Securely

WARNING DO NOT, under any circumstances, allow the cupped washers on the ends of the thumb screws to be closer than 1 in. (25.4 mm) from top of the boat transom, not shims. IMPORTANT INFORMATION — 1D-3

Installing Outboard 55-60 HP

9. Drill four mounting holes using a 17/32 in. (13.5 mm) drill bit.

55-60 HP — Non-Thumb Screw Models a

a — Non Thumb Screw

10. Position outboard so the anti-ventilation plate is within 1 in. (25.4 mm) of the boat bottom.

6. Center outboard on the transom.

a

0 — 1 in. (0 — 25.4 mm) 7. Secure outboard to the transom temporarily using C-clamps.

a — Anti-Ventilation Plate

11. Fasten outboard with provided mounting hardware shown. Apply RTV 587 Silicon Sealer to shank of bolts (not threads).

8. Mark location for four mounting holes.

NOTE: Normally the 4 upper mounting holes are to be drilled. This allows the outboard to be raised without re-drilling. Use other holes if necessary to avoid obstructions.

a a

c

116

b 116

a RTV 587 Silicone Sealer

a — 1/2 in. Diameter Bolts (4) b — Flat Washer (4) c — Locknut (4)

WARNING a

a — Upper Mounting Holes 1D-4 — IMPORTANT INFORMATION

a

Before operation, the outboard must be correctly installed with four mounting bolts shown. Failure to correctly fasten outboard could result in outboard ejecting off boat transom causing serious injury, death, or property damage. 90-852572R02 NOVEMBER 2002

NOTE: The Outboard Mounting Kit (P/N 812432A4) allows for quick removal and installation of outboard. Refer to installation instructions supplied with the mounting kit before drilling any holes.

55-60 HP – Thumb Screw Models

a

a — Thumb Screw

WARNING

a

Outboard must be fastened to boat transom one of two ways: 1) permanently fastened to transom with thumb screws, and mounting bolts (provided), or 2) secured to the transom using the optional outboard mounting kit (P/N 812432A4). Should the outboard strike an underwater object or be steered into a sharp turn, failure to fasten outboard correctly to the boat transom with mounting bolts or optional mounting kit could result in outboard ejecting suddenly off boat transom causing serious injury, death, boat damage, or loss of outboard.

a — Accessory Outboard Mounting Kit

3. Drill four 1/2 in. (12.7 mm) mounting holes. 4. Fasten outboard with provided mounting hardware shown. Apply RTV 587 Silicon Sealer to shank of bolt (not thread).

e

1. Center outboard on the transom.

116

c b a 116

2. Position outboard so the anti-ventilation plate is within 1 in. (25.4 mm) of the boat bottom.

a b c d

—

RTV 587 Silicone Sealer (92-91601-1)

1/2 in.(12.7 mm) Diameter Bolt (4) Flat Washer (4) Locknut (4) Thumb Screws, Tighten Securely

WARNING a

DO NOT, under any circumstances, allow the cupped washers on the ends of the thumb screws to be closer than 1 inch (25.4 mm) from top of the boat transom, not shims.

0 — 1 in. (0 — 25.4 mm)

a — Anti-Ventilation Plate

90-852572R02 NOVEMBER 2002

IMPORTANT INFORMATION — 1D-5

Wiring Harness

Battery Cable Connections

IMPORTANT: Warning Horn Requirement – The remote control or key switch assembly must be wired with a warning horn. This warning horn is used with the engine warning system.

SINGLE OUTBOARD

a

1. Route wiring harness into bottom cowl.

(+) 40-50 HP

b

(–) a

c

a — Red Sleeve (Positive) b — Black Sleeve (Negative) c — Starting Battery

60 HP DUAL OUTBOARD

a

1. Connect a common ground cable (wire size same as main battery cable) between negative (–) terminals on starting batteries.

a — Route wiring harness into bottom cowl

2. Connect wiring. Place harness into the holder.

(–)

40-50-60 HP

a (–) a — Ground Cable (Same Wire Size As Main Battery Cable – Connect Between Negative (–) Terminals

BLU/WHT GRN/WHT TAN BRN/WHT

BLU/WHT GRN/WHT

a

a — Power Trim Connections 1D-6 — IMPORTANT INFORMATION

90-852572R02 NOVEMBER 2002

Shift and Throttle Cable 40 and 50 Hp Models

3. Push-in on the cable end until resistance is felt. Adjust the cable barrel to attain the measured distance taken in Step 2.

Install cables into the remote control following the instructions provided with the remote control.

4. Place cable barrel into the bottom hole in the barrel holder. Fasten cable to pin with retainer.

NOTE: Install the shift cable to the engine first. The shift cable is the first cable to move when the remote control handle is moved out of neutral.

a

40-50 Hp – Shift Cable Installation 1. Position remote control and outboard into neutral.

b

N

2. Measure distance between mounting pin and middle of the barrel holder.

a c

d

a — Move Cable Barrel to Attain the Measured Distance Taken in Step 2 b — Cable Barrel c — Barrel Holder, Place Barrel into Bottom Hole d — Retainer

5. Check shift cable adjustments as follows:

c b a — Distance Between Pin and Middle of Barrel Holder b — Mounting Pin c — Barrel Holder

a. Shift remote control into forward. The propeller shaft should be locked in gear. If not, adjust the barrel closer to the cable end. b. Shift remote control into neutral. The propeller shaft should turn freely without drag. If not, adjust the barrel away from the cable end. Repeat steps a and b. c. Shift remote control into reverse while turning propeller. The propeller shaft should be locked in gear. If not, adjust the barrel away from the cable end . Repeat steps a through c. d. Shift remote control back to neutral. The propeller shaft should turn freely without drag. If not, adjust the barrel closer to the cable end. Repeat steps a through d.

90-852572R02 NOVEMBER 2002

IMPORTANT INFORMATION — 1D-7

40-50 Hp – Throttle Cable Installation

4. Check throttle cable adjustment as follows: a. Shift outboard into gear a few times to activate the throttle linkage. Make sure to rotate the propeller shaft while shifting into reverse.

1. Position remote control into neutral.

N

F

2. Install cable to the throttle lever. Tighten locknut, then back-off the locknut 1/4 turn.

N

R

b. Return remote control to neutral. Place a thin piece of paper between idle adjustment screw and idle stop. Adjustment is correct when the paper can be removed without tearing, but has some drag on it. Readjust cable barrel if necessary.

a b c

b

a — Throttle Cable b — Nylon Washer c — Locknut, Tighten Locknut, Then Back Off the Locknut 1/4 Turn

3. Adjust the cable barrel so that the installed throttle cable will hold the idle adjustment screw against the stop.

a

a — Idle Adjustment Screw b — Idle Stop

5. Lock the barrel holder in place with the cable latch.

a

c

a

b

a — Cable Latch

a — Cable Barrel, Adjust to Hold Idle Adjustment Screw Against Stop b — Idle Adjustment Screw c — Barrel Holder, Place Barrel Into Top Hole

1D-8 — IMPORTANT INFORMATION

90-852572R02 NOVEMBER 2002

Shift and Throttle Cable 60 HP Models

3. Push-in on the cable end until resistance is felt. Adjust the cable barrel to attain the measured distance taken in Step 2.

Install cables into the remote control following the instructions provided with the remote control.

4. Place cable barrel into the bottom hole in the barrel holder. Fasten cable to pin with locknut.

NOTE: Install the shift cable to the engine first. The shift cable is the first cable to move when the remote control handle is moved out of neutral.

a

60 HP – Shift Cable Installation

b

1. Position remote control and outboard into neutral.

N

d 2. Measure distance between mounting pin and middle of the barrel holder.

e c

a c

b

a — Move Cable Barrel to Attain the Measured Distance Taken in Step 2 b — Cable Barrel c — Barrel Holder, Place Barrel Into Bottom Hole d — Nylon Washer e — Locknut, Tighten Locknut, Then Back-Off the Locknut 1/4 Turn

5. Check shift cable adjustments as follows:

a. Shift remote control into forward. The propeller shaft should be locked in gear. If not, adjust the barrel closer to the cable end. a — Distance Between Pin and Middle of Barrel Holder b — Mounting Pin c — Barrel Holder

b. Shift remote control into neutral. The propeller shaft should turn freely without drag. If not, adjust the barrel away from the cable end. Repeat steps a and b. c. Shift remote control into reverse while turning propeller. The propeller shaft should be locked in gear. If not, adjust the barrel away from the cable end . Repeat steps a through c. d. Shift remote control back to neutral. The propeller shaft should turn freely without drag. If not, adjust the barrel closer to the cable end. Repeat steps a through d.

90-852572R02 NOVEMBER 2002

IMPORTANT INFORMATION — 1D-9

4. Check throttle cable adjustment as follows:

60 HP – Throttle Cable Installation

a. Shift outboard into gear a few times to activate the throttle linkage. Make sure to rotate the propeller shaft while shifting into reverse.

1. Position remote control into neutral.

N

F

2. Install cable to the throttle lever. Tighten locknut, then back-off the locknut 1/4 turn.

N

R

b. Return remote control to neutral. Place a thin piece of paper between idle adjustment screw and idle stop. Adjustment is correct when the paper can be removed without tearing, but has some drag on it. Readjust cable barrel if necessary.

a b c

b

a — Throttle Cable b — Nylon Washer c — Locknut, Tighten Locknut, Then Back-Off the Locknut 1/4 Turn

3. Adjust the cable barrel so that the installed throttle cable will hold the idle adjustment screw against the stop.

a

a — Idle Adjustment Screw b — Idle Stop

5. Lock the barrel holder in place with the cable latch.

b

a

a a — Cable Latch

c a — Cable Barrel – Adjust To Hold Idle Adjustment Screw Against Stop b — Idle Adjustment Screw c — Barrel Holder – Place Barrel Into Top Hole

1D-10 — IMPORTANT INFORMATION

90-852572R02 NOVEMBER 2002

Trim Tab Adjustment The trim tab can be adjusted within limits to help to compensate for steering torque. Adjust trim tab as follows: 1. If boat tends to pull to the right, move the rear edge of the trim tab to the right. 2. If boat tends to pull to the left, move the rear edge of the trim tab to the left.

a

a — Trim Tab

NOTE: Trim tab adjustment will have little effect reducing steering torque if the the anti-ventilation plate is raised 2 inches (50.8 mm) or more above the boat bottom.

90-852572R02 NOVEMBER 2002

IMPORTANT INFORMATION — 1D-11

1D-12 — IMPORTANT INFORMATION

90-852572R02 NOVEMBER 2002

ELECTRICAL

2 A

55042

IGNITION

Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel And Stator (Electric) . . . . . . . . . . . . Flywheel And Stator (Manual) . . . . . . . . . . . . Electrical Components 40/50 . . . . . . . . . . . . Electrical Components 55/60 . . . . . . . . . . . . Theory of Operation . . . . . . . . . . . . . . . . . . . . Capacitor Charging #1 CDM . . . . . . . . . . Capacitor Charging #2 & #3 CDM . . . . . . #1 Cylinder Trigger Circuit . . . . . . . . . . . . Ignition Coil Circuit . . . . . . . . . . . . . . . . . . . Stop Circuit . . . . . . . . . . . . . . . . . . . . . . . . . Rev Limiter Circuit . . . . . . . . . . . . . . . . . . . Ignition Component Description . . . . . . . . . . Capacitor Discharge Module (CDM) . . . . Trigger Coil . . . . . . . . . . . . . . . . . . . . . . . . . Stator Assembly . . . . . . . . . . . . . . . . . . . . . Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . CDM (P/N 827509A) Trouble Shooting . . . . Chart 1- CDM Trouble Shooting Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . CDM Stop Diode Trouble Shooting . . . . . Chart 2-CDM Trouble Shooting Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . Chart 3-CDM Trouble Shooting Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . CDM Test with DMT 2000 Multi-meter 91-854009A01 . . . . . . . . . . . . . . . . . . . . . . CDM Test with Volt/Ohm/DVA Meter 91-99750A1 . . . . . . . . . . . . . . . . . . . . . . . . Ignition Test Procedures . . . . . . . . . . . . . . . . . Direct Voltage Adaptor (DVA) Test . . . . . Resistance Tests . . . . . . . . . . . . . . . . . . . . Flywheel Removal and Installation . . . . . . . . Stator Removal and Installation . . . . . . . . . . Trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2A-0 — ELECTRICAL

Page 2A-1 2A-2 2A-3 2A-4 2A-5 2A-6 2A-8 2A-10 2A-10 2A-11 2A-12 2A-13 2A-14 2A-15 2A-16 2A-16 2A-16 2A-16 2A-16 2A-17 2A-17 2A-18 2A-19 2A-21 2A-22 2A-23 2A-24 2A-24 2A-25 2A-26 2A-27 2A-27 2A-28

90-852572R02 NOVEMBER 2002

Specifications Type Spark Plug Type IGNITION SYSTEM Spark Plug Gap Firing Order

TIMING

Idle Maximum Timing @ Cranking Speed -Model 40/50/60 -Model 55/60 Seapro-Marathon @ 5000 RPM – Model 40/50/60 – Model 55/60 Seapro-Marathon

Capacitor Discharge NGK BP8H-N-10 *NGK BPZ8H-N-10 NGK BUZ8H NGK BP8HS-10 0.040 in. (1.0mm) 1-2-3 T.D.C. ± 2° 24° B.T.D.C. 18° B.T.D.C. 22° B.T.D.C. 16° B.T.D.C.

*Suppressor (resistor) spark plug

90-852572R02 NOVEMBER 2002

ELECTRICAL — 2A-1

Special Tools 1. Flywheel Holder 91-52344 6. Spark Gap Tester 91-63998A1

2. Flywheel Puller 91-849154T1

7. TPI/CDM Test Harness 84-825207A2 3. 91-99750A1 Multi Meter/DVA Tester

4. DMT 2000 Digital Tachometer Multi-meter91-854009A01

8. Spark Gap Tester 91-850439

9. DVA Adaptor 91-89045

5. DVA Adaptor 91-89045-1

91-89045

2A-2 — ELECTRICAL

90-852572R02 NOVEMBER 2002

Notes:

90-852572R02 NOVEMBER 2002

ELECTRICAL — 2A-3

Flywheel And Stator (Electric) 1 11

2 3

4

6 51

5 7

51

Loctite 222 Thread Locker

95

2-4-C with Teflon

REF. REF NO. QTY. 1 1 2 1 3 1 4 1 5 1 6 4 7 1 8 1 9 1 10 2 1 11

10

8 9

95

10

TORQUE DESCRIPTION FLYWHEEL COVER NUT WASHER FLYWHEEL STATOR SCREW (M5 x 30) TRIGGER SWIVEL BALL SWIVEL BASE CABLE TIE DECAL-EPA INFORMATION

2A-4 — ELECTRICAL

lb. in. lb. ft. 100

60

N·m 135.6

6.8

90-852572R02 NOVEMBER 2002

Flywheel And Stator (Manual) 2 3

1

51

5

4

6 9 10 7 8 51

Loctite 222 Thread Locker

95

2-4-C with Teflon

REF. REF NO. QTY. 1 1 2 1 3 1 4 1 5 4 6 1 7 1 8 1 9 2 10 2

95

9

TORQUE DESCRIPTION FLYWHEEL NUT WASHER STATOR SCREW (M5 x 30) TRIGGER SWIVEL BALL SWIVEL BASE CABLE TIE PLUG

90-852572R02 NOVEMBER 2002

lb. in. lb. ft. 100

60

N·m 135.6

6.8

ELECTRICAL — 2A-5

Electrical Components 40/50

41 21

43

20 4

25

37

3

1

39

2 23 25

42

26

38 36 40

25

19 24

5

22

18 27

7 28 25

18 17 16 8

6 25

15 25

13

35

12

25

10

14 13 12

32 31 33

9 22 34

23

11 7

30

29

25

Liquid Neoprene

2A-6 — ELECTRICAL

90-852572R02 NOVEMBER 2002

Electrical Components 40/50 REF. REF NO. QTY. 1 1 2 1 3 1 4 1 1 5 1 6 1 7 3 8 1 9 2 10 2 11 2 12 2 13 2 14 1 15 1 16 2 17 1 18 2 19 1 20 1 21 1 22 1 23 AR 24 2 25 1 26 1 27 1 28 2 29 1 30 1 31 3 32 3 33 3 34 3 35 1 2 36 1 37 3 38 3 3 3 39 3 40 6 41 1 42 1 1 43 1

TORQUE DESCRIPTION PLATE–Electrical SCREW (M5 x 12) WASHER STA–STRAP REV LIMITER (MANUAL) REV LIMITER CLAMP SCREW (M5 x 12) SOLENOID ASSEMBLY BUSHING GROMMET SCREW (M6 x 25) ELECTRIC NUT (1/4-20) LOCKWASHER CABLE CABLE NUT VOLTAGE REGULATOR SCREW (M6 x 35) J CLAMP BOOT BATTERY CABLE (NEGATIVE) WASHER (QTY. OF 3 ON ELECTRIC) STA–STRAP SCREW (M6 x 25) CABLE SCREW (M8 x 20)(MANUAL) SCREW (M6 x 10)(MANUAL) J CLAMP (QTY. OF 3 ON ELECTRIC) HARNESS ASSEMBLY–Engine (ELECTRIC) FUSE GROMMET BUSHING WASHER SCREW (M6 x 25) HARNESS-Ignition CDM ASSEMBLY (5 IN. LEADS) CDM ASSEMBLY (8 IN. LEADS) HI-TENSION CABLE BOOT SPARK PLUG (NGK# BP8H-N-10) SPARK PLUG (NGK#BPZ–8H–N–10) SPARK PLUG (NGK#BUZ8H) SCREW (M6 x 14) HARNESS-Power (MANUAL) HARNESS HARNESS ASSEMBLY. -Adaptor (MANUAL) HARNESS ASSEMBLY. -Adaptor (ELECTRIC)

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

N·m

40

4.5

40

4.5

60 30

6.8 3.4

20

2.3

60

6.8

40

4.5

30 60

3.4 6.8

100

11.3

20 20 20 60

27.1 27.1 27.1 6.8

ELECTRICAL — 2A-7

Electrical Components 55/60

21 42 20 55 HP ONLY

4

25

6

38

3

1

40

2

43 23

25

39

26 37 41

25

19 24

5

22 18 27

7 28 25

18 17 16 8

6

15

25 25

36

13 12

25

10

14 13 12

33

9 32 34

22 35

23

11 7

30

29 6

Dielectric Grease (92-823506—1)

25

Liquid Neoprene (92-25711—2)

2A-8 — ELECTRICAL

31

90-852572R02 NOVEMBER 2002

Electrical Components 55/60 REF. REF NO. QTY. 1 1 2 1 3 1 4 1 1 5 1 6 1 7 3 8 1 9 2 10 2 11 2 12 2 13 2 14 1 15 1 16 2 17 1 18 2 19 1 20 1 21 1 22 2 23 AR 24 2 25 1 26 1 27 1 28 3 29 1 30 1 31 1 32 3 33 3 34 3 35 3 36 1 37 3 38 3 39 3 3 3 40 3 3 41 6 42 1 43 1

TORQUE DESCRIPTION PLATE–Electrical SCREW (M5 x 12) WASHER STA–STRAP REV LIMITER (MANUAL) REV LIMITER CLAMP SCREW (M5 x 12) SOLENOID ASSEMBLY BUSHING GROMMET SCREW (M6 x 25) NUT (1/4-20) ELECTRIC LOCKWASHER CABLE CABLE NUT VOLTAGE REGULATOR SCREW (M6 x 35) J CLAMP BOOT BATTERY CABLE (NEGATIVE) WASHER STA–STRAP SCREW (M6 x 25) CABLE SCREW (M8 x 20)(MANUAL) SCREW (M6 x 10)(MANUAL) J CLAMP (Qty. of 2 required on Manual) HARNESS ASSEMBLY–Engine FUSE ELECTRIC PLUG GROMMET BUSHING WASHER SCREW (M6 x 25) HARNESS-Ignition CDM ASSEMBLY HI-TENSION CABLE BOOT SPARK PLUG (NGK# BP8H-N-10) SPARK PLUG (NGK#BPZ–8H–N–10) SPARK PLUG (NGK#BUZ8H) SPARK PLUG (NGK#BP8HS-10) SCREW (M6 x 14) HARNESS-Power MANUAL HARNESS

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

N·m

40

4.5

40

4.5

60 30

6.8 3.4

20

2.3

60

6.8

40

4.5

30 60

3.4 6.8

100

11.3

20 20 20 20 60

27.1 27.1 27.1 27.1 6.8

ELECTRICAL — 2A-9

Theory of Operation

Capacitor Charging #1 CDM

This outboard ignition system is alternator driven (distributor-less) capacitor discharge system. Major components of the ignition system are the flywheel, stator, trigger, capacitor discharge modules (CDM’s) and spark plugs. Each capacitor discharge module functions as a combination switchbox and secondary ignition coil.

The STATOR assembly is mounted to the block below the flywheel and has 3 CAPACITOR CHARGING COILS wound in series. The FLYWHEEL is fitted with 6 permanent magnets inside the outer rim. The flywheel rotates the permanent magnets past the capacitor charging coils causing the coils to produce AC voltage (260–320 volts). The AC voltage is then conducted to the CAPACITOR DISCHARGE MODULES (CDM), where it is rectified (DC) and stored in a capacitor. The stator voltage return path is through the ground wire of the other CDM and back through that CDM’s charging coil wire to the capacitor charging coils.

b

a





 



3

+  

_

1

+ +

BLK/YEL

_



BLK

 



j

WHT/GRN PPL

2



d



_

c



e

WHT/GRN GRN/WHT

YEL YEL BLK

WHT BRN

BLK/YEL

BLK

     

BRN

i

    

BLK/YEL PPL BLK

COILSCR-

BRN

CAPACITOR-

f

g

h

DIODEa b c d e

—

Battery Charging Coils Trigger Coils Capacitor Charge Coils CDM #1 CDM #2

2A-10 — ELECTRICAL

f g h i j

—

CDM #3 Rev. Limiter (Not Used On All Models) To Ignition Switch Stop Switch To Voltage Regulator 90-852572R02 NOVEMBER 2002

Capacitor Charging #2 & #3 CDM NOTE: #1 CDM stator voltage return path is through either CDM #2 or #3. The return path for CDM #2 and #3 is through CDM #1, if #1 stator wire is disconnected the engine will die (the stator circuit is incomplete and the capacitors cannot be charged).

The flywheel rotates the permanent magnets past the capacitor charging coils causing the coils to produce AC voltage (260–320 volts). The opposite voltage pulse is then conducted to the CAPACITOR DISCHARGE MODULES (CDM), where it is rectified (DC) and stored in a capacitor. The stator voltage return path is through the ground wire of the other CDM and back through that CDM’s charging coil wire to the capacitor charging coils.

b

a





 



3

+  

_

1

+ +

BLK/YEL

_



BLK

 



j

WHT/GRN PPL

2



d



_

c



e

WHT/GRN GRN/WHT

YEL YEL BLK

WHT BRN

BLK/YEL

BLK

     

BRN

i

    

BLK/YEL PPL BLK

COILSCR-

BRN

CAPACITOR-

f

g

h

DIODEa b c d e

—

Battery Charging Coils Trigger Coils Capacitor Charge Coils CDM #1 CDM #2

90-852572R02 NOVEMBER 2002

f g h i j

—

CDM #3 Rev. Limiter (Not Used On All Models) To Ignition Switch Stop Switch To Voltage Regulator

ELECTRICAL — 2A-11

coils to produce a voltage pulse which is sent to the respective capacitor discharge module (CDM). A positive voltage pulse (N–S) will activate the electronic switch (SCR) inside the capacitor discharge module (CDM). The switch discharges the capacitor voltage through the coil primary windings. The return voltage pulse exits the CDM through the ground wire and returns through the trigger ground.

#1 Cylinder Trigger Circuit The TRIGGER assembly (also mounted under the flywheel) has one coil for each cylinder. These coils are mounted adjacent to the flywheel center hub. The center hub of the flywheel contains a permanent magnet with two north–south transitions. As the flywheel rotates, the magnet north–south transitions pass the trigger coils. This causes the trigger

b

a





 



3

+  

_

1

+ +

BLK/YEL

_



BLK

 



j

WHT/GRN PPL

2



d



_

c



e

WHT/GRN GRN/WHT

YEL YEL BLK

WHT BRN

BLK/YEL

BLK

     

BRN

i

    

BLK/YEL PPL BLK

COILSCR-

BRN

CAPACITOR-

f

g

h

DIODEa b c d e

—

Battery Charging Coils Trigger Coils Capacitor Charge Coils CDM #1 CDM #2

2A-12 — ELECTRICAL

f g h i j

—

CDM #3 Rev. Limiter (Not Used On All Models) To Ignition Switch Stop Switch To Voltage Regulator

90-852572R02 NOVEMBER 2002

Ignition Coil Circuit As the capacitor voltage flows through the primary windings of the ignition coil, a voltage is induced into the ignition coil secondary windings. This secondary voltage rises to the level required to jump the spark plug gap and return to ground. This secondary voltage can, if necessary, reach approximately 40,000 volts. To complete the secondary voltage path, the released voltage enters the ground circuit of CDM module.

b

a





 



3

+  

_

1

+ +

BLK/YEL

_



BLK

 



j

WHT/GRN PPL

2



d



_

c



e

WHT/GRN GRN/WHT

YEL YEL BLK

WHT BRN

BLK/YEL

BLK

     

BRN

i

    

BLK/YEL PPL BLK

COILSCR-

BRN

CAPACITOR-

f

g

h

DIODEa b c d e

—

Battery Charging Coils Trigger Coils Capacitor Charge Coils CDM #1 CDM #2

90-852572R02 NOVEMBER 2002

f g h i j

—

CDM #3 Rev. Limiter (Not Used On All Models) To Ignition Switch Stop Switch To Voltage Regulator

ELECTRICAL — 2A-13

Stop Circuit To stop the engine, the stop switch is closed allowing the capacitor charge current from the stator to drain directly to ground.

NOTE: The CDM contains a zener diode (not shown for clarity). This diode prevents overcharging of the capacitor (and possible failure) if the SCR does not receive a trigger pulse.

b

a





 



3

+  

_

1

+ +

BLK/YEL

_



BLK

 



j

WHT/GRN PPL

2



d



_

c



e

WHT/GRN GRN/WHT

YEL YEL BLK

WHT BRN

BLK BLK/YEL

BRN

i

   

BLK/YEL PPL BLK

COILSCR-

BRN

CAPACITOR-

f

g

h

DIODEa b c d e

—

Battery Charging Coils Trigger Coils Capacitor Charge Coils CDM #1 CDM #2

2A-14 — ELECTRICAL

f g h i j

—

CDM #3 Rev. Limiter (Not Used On All Models) To Ignition Switch Stop Switch To Voltage Regulator

90-852572R02 NOVEMBER 2002

Rev Limiter Circuit The rev limiter is activated through the purple wire when the key switch is rotated to the “on” position. The rev limiter uses a trigger signal (brown wire) to determine engine speed or rpm. If the engine speed exceeds the specified rpm, the rev limiter will ground out the CDM capacitor charge. The capacitor voltage flows through the black/yellow wires into the rev limiter and to engine ground through the black wire.

b

a





 



3

+  

_

1

+ +

BLK/YEL

_



BLK

 



j

WHT/GRN PPL

2



d



_

c



e

WHT/GRN GRN/WHT

YEL YEL BLK

WHT BRN

i BRN

   

BLK

   BLK/YEL



  

BLK/YEL PPL BLK

COILSCR-

BRN

CAPACITOR-

f

g

h

DIODEa b c d e

—

Battery Charging Coils Trigger Coils Capacitor Charge Coils CDM #1 CDM #2

90-852572R02 NOVEMBER 2002

f g h i j

—

CDM #3 Rev. Limiter (Not Used On All Models) To Ignition Switch Stop Switch To Voltage Regulator

ELECTRICAL — 2A-15

Ignition Component Description Capacitor Discharge Module (CDM)

Stator Assembly Located under the flywheel in the stator assembly are 12 coils (6 for manual stator), 3 ignition charge coils and 9 auxiliary (3 for manual) power coils wound in series that provide voltage to the CDM’s and battery/ auxiliary circuits respectively.

Each module contains an ignition coil and amplifier circuitry which produces approximately 45,000 volts at the spark plugs.

Flywheel Trigger Coil Located under flywheel. Is charged by single magnet on flywheel hub. Trigger pulses are sent to CDM.

Contains 6 magnets (12 pole) around circumference. Has one magnet on inner hub for trigger. Outer magnets are for battery charge coils and ignition charge coils.

NOTE: Electric start model flywheel shown.

2A-16 — ELECTRICAL

90-852572R02 NOVEMBER 2002

CDM (P/N 827509A_) Troubleshooting Chart 1- CDM Trouble Shooting Flowchart Step

Action

Value

Yes

No

Tools High Tension lead pin P/N 84-813706A56

1

Verify High Tension Leads, Spark Plug and Spark Boots are in good condition. Inspect wires for chafing. Visual Inspection

–

Step 2

Replace Failed Component Step 2

2

Verify 4 Pin Connector Integrity

–

Step 3

Repair/Replace Connector Components Step 3

Correct DMT 2000 DigiGround Path tal Tachometer/ Multi-meter P/N Step 4 91-854009A1 & DVA Adaptor 91-89045-1 Test Harness P/N 84-825207A2

Visual Inspection

–

3

Verify Ground from CDM connector to block

0.2 Ohms and below *

Step 4

4

Test all CDMs at Cranking with Spark Gap Tester

7/16 in. (11.11 mm) gap

If at least Continue Spark Gap Tesone CDM with Chart #2 ter has spark, P/N 91-850439 continue with Chart #3

Spark on All CDMs? Will spark jump a 7/16 in. (11.11 mm) gap?

NOTE: * To obtain accurate reading, short test meter leads together and subtract value from reading or adust meter to zero. CDM (P/N 827509A_)

A B C D

a b c d

—

Ground Black/Yellow Trigger Connection Stator Connection

90-852572R02 NOVEMBER 2002

ELECTRICAL — 2A-17

CDM Stop Diode Troubleshooting 2 Cyl.: CDM #1 gets its charging ground path through CDM #2. CDM #2 gets its charging ground path through CDM #1. A shorted Stop Diode in either CDM would prevent the opposite one from sparking.

1

2

3 Cyl.: CDM #1 gets its charging ground path through CDM #2 or #3. CDM #2 and #3 get their charging ground path through CDM #1. A shorted Stop Diode in CDM #1 would prevent CDMs #2 and #3 from sparking. A shorted Stop Diode in CDM #2 or #3 would prevent CDM #1 from sparking.

1

2

3

4 Cyl.: CDM #1 and #2 get their charging ground path through CDM #3 or #4. CDM #3 and #4 get their charging ground path through CDM #1 or #2. A shorted Stop Diode in CDM #1 or #2 would prevent CDMs #3 and #4 from sparking. A shorted Stop Diode in CDM #3 or #4 would prevent CDM #1 and #2 from sparking.

1

2A-18 — ELECTRICAL

2

3

4

90-852572R02 NOVEMBER 2002

Chart 2-CDM Trouble Shooting Flowchart (NO SPARK ON ANY CDM) Step

Action

Value

Yes

No

Tools

1

With the key switch ON: NO continuity Verify continuity between BLK/YEL harness wire and ground. This Test Checks: Lanyard Switch Key Switch Rev Limiter (external) Chafed BLK/YEL wire CDM Stop Circuit

Step 2

Repair or Replace Component Run Engine Verify Repair Step 7

DMT 2000 Digital Tachometer/ Multi-meter P/N 91-854009A1 & DVA Adaptor 91-89045-1

2

Un-plug all CDMs and verify continuity between disconnected BLK/ YEL harness wire and ground. This Test Checks: CDM Harness

NO continuity

Step 3

Repair or Replace Component Run Engine Verify Repair Step 7

DMT 2000 Digital Tachometer/ Multi-meter P/N 91-854009A1 & DVA Adaptor P/N 91-89045-1

3

Connect CDM one at a time This Test Checks: Individual CDM Stop Circuits

Resistance will rise with each CDM connected, full continuity indicates shorted CDM stop circuit.*

Step 4

Repair or Replace Component Run Engine Verify Repair Step 7

DMT 2000 Digital Tachometer/ Multi-meter P/N 91-854009A1 & DVA Adaptor P/N 91-89045-1 TPI/CDM Test Harness 84-825207A2

4

Check Stator Resistance between GRN/WHT and WHT/GRN Open circuit voltage at cranking should be no less than 100 Volts on the DVA

660-710 Ohms 2, 3, 4 Cyl. Models

Step 5

Replace Stator Run Engine Verify Repair Step 7

DMT 2000 Digital Tachometer/ Multi-meter P/N 91-854009A1 & DVA Adaptor 91-89045-1

5

Check Trigger/Crank Shaft Position Sensor Output:

1 Volt and above — Step 6 CDM disconnected. 0.2 — 5 Volts- CDM connected.

2, 3, & 4 Cyl Replace Trigger Run Engine Verify Repair Step 7

DMT 2000 Digital Tachometer/ Multi-meter P/N 91-854009A1 & DVA Adaptor 91-89045-1 TPI/CDM Test Harness 84-825207A2

Cranking with CDM disconnected. Cranking with CDM connected.

NOTE: *Diode Readings: Due to the differences in test meters, results other than specified may be obtained. In such a case, reverse meter leads and re-test. If test results then read as specified CDM is O.K. The diode measurements above will be opposite if using a Fluke equivalent multimeter.

90-852572R02 NOVEMBER 2002

ELECTRICAL — 2A-19

CHART #2 (NO SPARK ON ANY CDM) (CONTINUED) 6

Test all CDMs at Cranking with Spark Gap Tester

7/16 in. (11.11 mm) gap

Step 7

Verify All Preceding Steps

Spark Gap Tester P/N 91-850439

Stator: 200 Volts and above

Run Engine Verify Repair

Refer to *Note DMT 2000 DigiBelow tal Tachometer/ Multi-meter P/N 91-854009A1 & DVA Adaptor 91-89045-1 TPI/CDM Test Harness 84-825207A2

Spark on All CDMs? Will spark jump a 7/16 in. (11.11 mm) gap?

7

If mis-firing is in a repeatable range: Perform DVA readings on stator and trigger at all running speeds.*

Trigger: 2 Volts and above

END

NOTE: * Stator tests will only isolate problem down to a charging pair. Further testing is necessary to determine faulty CDM. Disconnecting one CDM of the charging pair is recommended.

2A-20 — ELECTRICAL

90-852572R02 NOVEMBER 2002

Chart 3-CDM Troubleshooting Flowchart (AT LEAST ONE CDM HAS SPARK) Step

Action

Value

Yes

No

Tools

Replace any CDMs that do not pass specifications even if they fire Step 2

DMT 2000 Digital Tachometer/ Multi-meter P/N 91-854009A1 & DVA Adaptor 91-89045-1

1

Resistance Check ALL CDMs

Refer to chart

Step 3

2

Test all CDMs at Cranking with Spark Gap Tester

7/16 in. (11.11 mm) gap

Run Engine Step 3 Verify Repair Step5

Spark Gap Tester P/N 91-850439

1 Volt and above — CDM disconnected. 0.2 — 5 Volts CDM connected.

Step 4

DMT 2000 Digital Tachometer/ Multi-meter P/N 91-854009A1 & DVA Adaptor 91-89045-1 TPI/CDM Test Harness 84-825207A2

7/16 in. (11.11 mm) gap

Run Engine Replace any Spark Gap TesVerify Repair non-firing ter CDMs P/N 91-850439 Step5 Step 5

Stator: 200 Volts and above

Run Engine Refer to DMT 2000 DigiVerify Repair *Note Below. tal Tachometer/ Multi-meter P/N END 91-854009A1 & DVA Adaptor 91-89045-1 TPI/CDM Test Harness 84-825207A2

Spark on All CDMs Will spark jump a 7/16 in. (11.11 mm) gap?

3

Check Trigger Output: Cranking with CDM disconnected. Cranking with CDM connected.

4

Test all CDMs at Cranking with Spark Gap Tester Spark on All CDMs? Will spark jump a 7/16 in. (11.11 mm) gap?

5

If mis-firing is in a repeatable range: Perform DVA readings on stator and trigger at all running speeds.*

Trigger: 2 Volts and above

2, 3, & 4 Cyl — Replace Trigger Run Engine Verify Repair Step 5

* Note: Stator tests will only isolate problem down to a charging pair. Further testing is necessary to determine faulty CDM. Disconnecting one CDM of the charging pair is recommended.

90-852572R02 NOVEMBER 2002

ELECTRICAL — 2A-21

CDM Test with DMT 2000 Multi-meter 91-854009A1 IMPORTANT Spark plug wires are screwed into CDM.

A B C D

a — Ground b — Black/Yellow

c — Trigger Connection d — Stator Connection

A resistance check is required and can be performed on the CDM as follows:

NOTE: This test can be performed using the test harness (P/N 84-825207A2). DO NOT connect the test harness plug to the stator/trigger engine wire harness. Set meter to for diode check. CAPACITOR DISCHARGE MODULE Circuit Test

Connect Negative (–) Meter Lead To:

Connect Positive (+) Meter Lead To:

Diode Check

 Setting (Auto Range)

Stop Diode Forward Bias

Green (D)/ or Green test harness lead

Black/Yellow (B)/ or Black/Yellow test harness lead

OUCH or O.L.

OUCH or O.L.

Stop Diode Reverse Bias

Black/Yellow (B)/ or Black/Yellow test harness lead

Green (D)/ or Green test harness lead

0.45-0.8 V

1.0-4.0 mΩ

Return Ground Path Diode, Reverse Bias

Green (D)/ or Green test harness lead

Ground Pin (A) or Black test harness lead

0.45-0.8 V

1-30 mΩ, then slowly increases to OUCH or O.L.

Return Ground Path Diode, Forward Bias

Ground Pin (A)/ or Black test harness lead

Green (D)/ or Green test harness lead

OUCH or O.L.

1.0-4.0 mΩ

CDM Trigger Input Resistance

Ground Pin (A)/ or Black test harness lead

White (C)/ or White test harness lead

0.45-1.5 V (Not a perferred test)

1000 — 1300 Ohms

Coil Secondary Impedance

Ground Pin (A) or Black test harness lead

Spark Plug Terminal (At Spark Plug Boot)

0.45-1.5 V (Not a perferred test)

900 — 1200 Ohms

*Diode Readings: Due to the differences in test meters, results other than specified may be obtained. In such a case, reverse meter leads and re-test. If test results then read as specified CDM is O.K. The diode measurements above will be opposite if using a Fluke equivalent multimeter.

NOTE: If CDM checks good, a secondary test can be performed to ensure that CDM is good when running hot. Heat CDM with hot air gun to approximately 85
C (185
F). Repeat Resistance test above and Test 4 on Chart 1 while hot.

2A-22 — ELECTRICAL

90-852572R02 NOVEMBER 2002

CDM Test with Volt/Ohm/DVA Meter 91-99750A1 IMPORTANT Spark plug wires are screwed into CDM.

A B C D

a — Ground b — Black/Yellow

c — Trigger Connection d — Stator Connection

A resistance check is required and can be performed on the CDM as follows:

NOTE: This test can be performed using the test harness (P/N 84-825207A2). DO NOT connect the test harness plug to the stator/trigger engine wire harness. CAPACITOR DISCHARGE MODULE Circuit Test

Connect Negative (–) Meter Lead To:

Connect Positive (+) Meter Lead To:

Ohms Scale

Results:

Stop Diode Forward Bias

Green (D)/ or Green test harness lead

Black/Yellow (B)/ or Black/Yellow test harness lead

R x 100 Diode Reading*

Continuity

Stop Diode Reverse Bias

Black/Yellow (B)/ or Black/Yellow test harness lead

Green (D)/ or Green test harness lead

R x 100 Diode Reading*

No Continuity

Return Ground Path Diode, Reverse Bias

Green (D)/ or Green test harness lead

Ground Pin (A) or Black test harness lead

R x 100 Diode Reading*

No Continuity

Return Ground Path Diode, Forward Bias

Ground Pin (A)/ or Black test harness lead

Green (D)/ or Green test harness lead

R x 100 Diode Reading*

Continuity

CDM Trigger Input Resistance

Ground Pin (A)/ or Black test harness lead

White (C)/ or White test harness lead

R x 100

1000 — 1250 Ohms

Coil Secondary Impedance

Ground Pin (A) or Black test harness lead

Spark Plug Terminal (At Spark Plug Boot)

R x 100

900 — 1200 Ohms

*Diode Readings: Due to the differences in test meters, results other than specified may be obtained. In such a case, reverse meter leads and re-test. If test results then read as specified CDM is O.K. The diode measurements above will be opposite if using a Fluke equivalent multimeter.

NOTE: If CDM checks good, a secondary test can be performed to ensure that CDM is good when running hot. Heat CDM with hot air gun to approximately 85
C (185
F). Repeat Resistance test above and Test 4 on Chart 1 while hot.

90-852572R02 NOVEMBER 2002

ELECTRICAL — 2A-23

Ignition Test Procedures Direct Voltage Adaptor (DVA) Test CAUTION DVA checks can be made while cranking engine with starter motor. To prevent engine from starting while being cranked, all spark plugs must be removed.

CAUTION

Stator Output Test

400 DVA Scale

Positive Meter Negative Lead (+) Meter Lead (–)

DVA Reading

Connect to Green Test Harness Lead

100 — 320

Connect to Black Test Harness Lead

c. If only one CDM stator reading is below specifications, replace that CDM. If all CDM stator voltage readings are low, go to “Testing Stator Resistance”.

INSURE that the Positive (+) meter lead is connected to the DVA receptacle on the meter.

•

DO NOT CHANGE meter selector switch position while engine is running and/or being “cranked”.

NOTE: Each CDM is grounded through the engine wiring harness via the connector plug. It is not necessary to have the CDM mounted on the ignition plate for testing.

BLK

•

GRN

To protect against meter and/or component damage, observe the following precautions:

1. Remove all spark plugs. 2. Insert spark gap tool (P/N 91-63998A1) into each spark plug boot and attach alligator clips to a good engine ground. 3. Disconnect remote fuel line from engine. 4. Make sure all CDMs are plugged in. 5. Test Stator and Trigger voltage to CDM: a. Install test harness (84-825207A2) between ignition harness and CDM.

a

b

c

d. Test each CDM. Trigger Output Test

2 DVA Scale

Positive Meter Negative Lead (+) Meter Lead (–)

DVA Reading

White Test Harness Lead

0.2 — 2.0

Black Test Harness Lead

If reading is below specifications, replace trigger. If reading is above specifications, check CDM.

a — Stator/Trigger Harness b — Test Harness (84-825207A2) c — Capacitor Discharge Module

b. Test each CDM.

2A-24 — ELECTRICAL

90-852572R02 NOVEMBER 2002

NOTE: If voltage remains low after installing a new trigger, replaced CDM.

Resistance Tests TRIGGER A resistance test is not used on the trigger. Test trigger as outlined under “Testing Voltage Output to CDM” “Trigger Output Test”. STATOR 1. Disconnect stator leads.

BLK

WHT

NOTE: Resistance varies greatly with temperature. Measurements should be taken with an ambient temperature range of 65° to 85° F. Stator Resistance Test Positive Meter Negative Lead (+) Meter Lead (–)

ENGINE RUNNING AT IDLE It is not necessary to perform this test if the voltage output was tested in the previous step. Stator Output Test

400 DVA Scale

Positive Meter Negative Lead (+) Meter Lead (–)

DVA Reading

Connect to Green Test Harness Lead

Connect to Black Test Harness Lead

200 — 350

If stator output is low, go to “Testing Stator Resistance”. Trigger Output Test

20 DVA Scale

Positive Meter Negative Lead (+) Meter Lead (–)

DVA Reading

White Test Harness Lead

2 — 8 Volts

Black Test Harness Lead

Connect to White/Green stator lead

Connect to Green/White stator lead

R x 1 Ohms S l or Scale Auto Range DMT 2000 660-710 385-405 2.5 L 990-1210 3.0 L

Connect to White/Green stator lead

Connect to engine ground

No continuity

Connect to Green/White stator lead

Connect to engine ground

No continuity

IMPORTANT If all CDM stator output voltage is low and stator resistance tests are within specifications, then each CDM (one at a time) must be replaced with a CDM known to be good until stator output voltage returns to proper levels. This process of elimination will reveal a defective CDM.

If reading is below specifications, replace trigger. If reading is above specifications, check CDM.

NOTE: If voltage remains low after installing a new trigger, replace CDM.

RX1 90-852572R02 NOVEMBER 2002

ELECTRICAL — 2A-25

6. Remove flywheel. Remove flywheel key.

Flywheel Removal and Installation

7. Carefully inspect flywheel for cracks or damage. 8. Inspect crankshaft and flywheel tapers for worn or damaged key ways.

REMOVAL

9. Check for loose or damaged flywheel magnets (outer rim and center hub). Replace flywheel if necessary.

1. Remove flywheel cover from engine.

WARNING Engine could possibly start when turning flywheel during removal and installation; therefore, disconnect (and isolate) spark plug leads from spark plugs to prevent engine from starting.

INSTALLATION 1. Install flywheel key in crankshaft slot with outer edge of key parallel to center line of crankshaft.

2. Disconnect spark plug leads from spark plugs. 3. While holding flywheel with flywheel holder (91-52344), remove flywheel nut and washer.

a

a — Flywheel Key

2. Align slot in flywheel center bore with flywheel key and install flywheel onto crankshaft.

a

55332

a — Flywheel Holder

3. Install washer and nut. 4. Hold flywheel with Flywheel Holder (91-52344); torque nut to 125 lb. ft. (169.5 N·m).

4. Install a crankshaft Protector Cap (91-24161) on end of crankshaft, then install Flywheel Puller (91-849154T1) into flywheel. 5. Hold flywheel tool with wrench while tightening bolt down on protector cap. Tighten bolt until flywheel comes free.

a a

55332

a — Flywheel Holder

55333 a — Flywheel Puller

NOTE: Neither heat nor hammer should be used on flywheel to aid in removal as damage to flywheel or electrical components under flywheel may result.

2A-26 — ELECTRICAL

90-852572R02 NOVEMBER 2002

INSTALLATION

Stator Removal and Installation

1. Set stator on bearing cage. Secure with screws. Screws threads should be lightly coated with loctite 222 and torqued to 60 lb. in. (6.8 N·m).

REMOVAL 1. Remove flywheel. See “Removing Flywheel” In This Section. 2. Remove yellow stator leads from rectifier/regulator leads. 3. Disconnect all stator leads from CDM wire harness.

NOTE: Removal of ignition plate may be necessary to gain access to stator leads.

a a

4. Remove screws and lift stator off bearing cage.

55330 a — Screws

2. Connect yellow stator leads to yellow voltage regulator leads (electric models). 3. Connect all stator leads to corresponding CDM wire harness.

a a

4. Install flywheel. See “Installing Flywheel” in this section.

55330 a — Screws

Trigger REMOVAL 1. Remove flywheel. See “Removing Flywheel” in this section. 2. Remove stator. See “Removing Stator” in this section. 3. Disconnect trigger leads from CDM wire harness.

90-852572R02 NOVEMBER 2002

ELECTRICAL — 2A-27

4. Disconnect link arm and remove trigger.

CDM REMOVAL

WARNING

a

Always disconnect battery and disconnect spark plug leads from spark plugs before working on motor.

b

1. Disconnect CDM wire harness plug. 19459

2. Remove screws securing CDM to ignition plate. INSTALLATION

a — Link Arm b — Trigger

1. Position CDM on ignition plate. Install screws, torque to 60 lb. in. (6.8 N·m).

5. Lift trigger off bearing cage.

2. Connect CDM wire harness plug to CDM. 55042

INSTALLATION 1. Install trigger and connect link arm.

b

a

a

b

19459

a — Wire Harness Plug b — Screws

a — Link Arm b — Trigger

2. Place trigger on bearing cage. 3. Route lead wires under ignition plate and down to the CDM wire harness. 4. Connect corresponding trigger leads to CDM wire harness. 5. Install stator. See “Installing Stator” in this section. 6. Install flywheel. See “Installing Flywheel” in this section. 7. Check engine timing. See “Engine Timing” in Section 2C.

2A-28 — ELECTRICAL

90-852572R02 NOVEMBER 2002

ELECTRICAL

2 B

CHARGING AND STARTING SYSTEM

Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions . . . . . . . . . . . . . . . . . . . . . . . . . Operating Engine Without Battery . . . . . . . . Specific Gravity Readings . . . . . . . . . . . . . . . Specific Gravity Cell Comparison Test . . Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . Charging A Discharged Battery . . . . . . . . . . Winter Storage of Batteries . . . . . . . . . . . . . . Battery Charging System Troubleshooting . Description . . . . . . . . . . . . . . . . . . . . . . . . . Starting System . . . . . . . . . . . . . . . . . . . . . . . . Starting System Components . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting the Starting Circuit . . . . Starting Circuit Wiring Diagram . . . . . . . . . . . Starting Circuit Troubleshooting Flow Chart Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . . . . Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brush Replacement . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . .

2B-0 — ELECTRICAL

Page 2B-1 2B-1 2B-2 2B-4 2B-4 2B-4 2B-4 2B-5 2B-5 2B-5 2B-6 2B-6 2B-6 2B-11 2B-11 2B-11 2B-11 2B-12 2B-13 2B-15 2B-15 2B-15 2B-16 2B-16 2B-18 2B-19 2B-20

90-852572R02 NOVEMBER 2002

Specifications STARTING SYSTEM

CHARGING SYSTEM

Manual Start Electric Start Starter Draw (Under Load) Recommended Battery Rating Minimum Reserve Capacity Cold Cranking Amperage (CCA) Alternator Output Electric Models Manual Models

Recoil Starter 125 Amperes 100 Minutes 350 Amperes 18 Amperes @ 2000 RPM 9 Amperes @ 3000 RPM

Special Tools 1. Volt/Ohm Meter 91-99750A1.

90-852572R02 NOVEMBER 2002

ELECTRICAL — 2B-1

Starter Motor

3

2

4 5

10 14 8 9 7

6 1

16

15 12 11 8

14

13

25

25

2B-2 — ELECTRICAL

Liquid Neoprene

90-852572R02 NOVEMBER 2002

Starter Motor REF. REF NO. QTY. 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 10 2 11 1 12 1 13 1 14 3 15 1 16 1

TORQUE DESCRIPTION STARTER MOTOR THRU-BOLT DRIVE KIT DRIVE ASSEMBLY DRIVE CAP ARMATURE COMMUTATOR CAP BRUSH & SPRING KIT BRUSH HOLDER SCREW LOCKWASHER NUT (1/4-20) BATTERY CABLE (5/16) (POSITIVE) SCREW (M8 x 45) DECAL–Warning BRACKET-Oil Tank

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

N·m

70

7.9

60

6.8 16.5

22.3

ELECTRICAL — 2B-3

Battery

Specific Gravity Readings

Precautions

Use a hydrometer to measure specific gravity of electrolyte in each cell.

CAUTION If battery acid comes into contact with skin or eyes, wash skin immediately with a mild soap. Flush eyes with water immediately and see a doctor.

a

When charging batteries, an explosive gas mixture forms in each cell. A portion of this gas escapes through holes in vent plugs and may form an explosive atmosphere around battery if ventilation is poor. This explosive gas may remain in or around battery for several hours after it has been charged. Sparks or flames can ignite this gas and cause an internal explosion which may shatter the battery. The following precautions should be observed to prevent an explosion. 1. DO NOT smoke near batteries being charged or which have been charged very recently. 2. DO NOT break live circuits at terminals of batteries because a spark usually occurs at the point where a live circuit is broken. Always be careful when connecting or disconnecting cable clamps on chargers. Poor connections are a common cause of electrical arcs which cause explosions. 3. DO NOT reverse polarity of battery cables on battery terminals.

22532

a — Hydrometer

Hydrometer measures percentage of sulfuric acid in battery electrolyte in terms of specific gravity. As a battery drops from a charged to a discharged condition, acid leaves the solution and chemically combines with the plates, causing a decrease in specific gravity of electrolyte. An indication of concentration of electrolyte is obtained with a hydrometer. When using a hydrometer, observe the following points:

Operating Engine Without Battery If desired (or in an emergency), engines equipped with an alternator can be started and operated without a battery (either disconnected or removed) if “Warning”, below, is followed.

WARNING Before operating engine with battery leads disconnected from battery, disconnect stator leads (yellow) from voltage regulator. Insulate (electrical tape) stator lead terminals.

2B-4 — ELECTRICAL

1. Hydrometer must be clean (inside and out) to insure an accurate reading. 2. Never take hydrometer readings immediately after water has been added. Water must be thoroughly mixed with electrolyte by charging for at least 15 minutes at a rate high enough to cause vigorous gassing. 3. If hydrometer has built-in thermometer, draw liquid in several times to ensure correct temperature before taking reading. 4. Hold hydrometer vertically and draw in just enough liquid from battery cell so that float is freefloating. Hold hydrometer at eye level so that float is vertical and free of outer tube, then take reading at surface of liquid. Disregard curvature where liquid rises against float stem due to capillary action.

90-852572R02 NOVEMBER 2002

5. Avoid dropping electrolyte on boat or clothing, as it is extremely corrosive. Wash off immediately with baking soda solution.

Charging A Discharged Battery

Specific gravity of electrolyte varies not only with percentage of acid in liquid, but also with temperature. As temperature drops, electrolyte contracts, so that specific gravity increases. Unless these variations in specific gravity are taken into account, specific gravity obtained by hydrometer may not give a true indication of concentration of acid in electrolyte.

The following basic rules apply to any battery charging situation:

A fully charged battery will have a specific gravity reading of approximately 1.270 at an electrolyte temperature of 80° F (27° C). If electrolyte temperature is above or below 80° F, additions or subtractions must be made in order to obtain a hydrometer reading corrected to 80° F standard. For every 10° F (3.3° C) above 80° F, add 4 specific gravity points (.004) to hydrometer reading. Example: A hydrometer reading of 1.260 at 110° F (43° C) would be 1.272 corrected to 80° F, indicating a fully charged battery. For every 10° below 80° F, subtract 4 points (.004) from the reading. Example: A hydrometer reading of 1.272 at 0° F (-18° C) would be 1.240 corrected to 80° F, indicating a partially charged battery.

1. Any battery may be charged at any rate, (in amperes) as long as spilling of electrolyte (from violent gassing) does not occur, and as long as electrolyte temperature does not exceed 125° F (52° C). If spewing of electrolyte occurs, or if electrolyte temperature exceeds 125° F, charging rate (in amperes) must be reduced or temporarily halted to avoid damage to the battery. 2. Battery is fully charged when, over a 2-hour period at a low charging rate (in amperes), all cells are gassing freely (not spewing liquid electrolyte), and no change in specific gravity occurs. Full charge specific gravity is 1.260-1.275, corrected for electrolyte temperature with electrolyte level at 3/16” (4.8 mm) over plate. For most satisfactory charging, lower charging rates in amperes are recommended.

Specific Gravity Cell Comparison Test

3. If, after prolonged charging, specific gravity of at least 1.230 on all cells cannot be reached, battery is not in optimum condition and will not provide optimum performance; however, it may continue to provide additional service, if it has performed satisfactorily in the past.

This test may be used when an instrumental tester is not available. To perform this test, measure specific gravity of each cell, regardless of state of charge, and interpret results as follows: If specific gravity readings show a difference between highest and lowest cell of .050 (50 points) or more, battery is defective and should be replaced.

4. To check battery voltage while cranking engine with electric starter motor, place red (+) lead of tester on positive (+) battery terminal and black (-) lead of tester on negative (-) battery terminal. If the voltage drops below 9-1/2 volts while cranking, the battery is weak and should be recharged or replaced.

Electrolyte Level Check electrolyte level in battery regularly. A battery in use in hot weather should be checked more frequently because of more rapid loss of water. If electrolyte level is found to be low, then distilled water should be added to each cell until liquid level rises approximately 3/16” (4.8mm) over plate. DO NOT OVERFILL, because this will cause loss of electrolyte and result in poor performance, short life and excessive corrosion.

CAUTION During service, only distilled water should be added to the battery, not electrolyte.

90-852572R02 NOVEMBER 2002

ELECTRICAL — 2B-5

Winter Storage of Batteries Battery companies are not responsible for battery damage, either in winter storage or in dealer stock, if the following instructions are not observed: 1. Remove battery from its installation as soon as possible and remove all grease, sulfate and dirt from top surface by running water over top of battery. Be sure, however, that vent caps are tight beforehand, and blow off all excess water thoroughly with compressed air. Check water level, making sure that plates are covered. 2. When adding distilled water to battery, be extremely careful not to fill more than 3/16” (4.8mm) over plate inside battery. Battery solution or electrolyte expands from heat caused by charging. Overfilling battery will cause electrolyte to overflow (if filled beyond 3/16” (4.8 mm) over plate).

Battery Charging System Troubleshooting Description The battery charging system components are the stator, voltage regulator/rectifier and the battery. Alternating current is generated in the stator alternator coils and flows to the regulator/rectifier. The rectifier changes the alternating current to direct current for charging the battery and the regulator senses battery voltage and allows the correct amount of direct current to charge the battery. The charging system may be damaged by: a. Reversed battery cables. b. Running the engine with battery cables disconnected and stator leads connected to regulator/rectifier.

3. Grease terminal bolts well with 2-4-C with Teflon, and store battery in COOL-DRY place. Remove battery from storage every 30-45 days, check water level (add water if necessary), and put on charge for 5 or 6 hours at 6 amperes. DO NOT FAST CHARGE.

c. Open circuit, such as a broken wire or loose connection.

4. If specific gravity drops below 1.240, check battery for reason, and then recharge. When gravity reaches 1.260, discontinue charging. To check specific gravity, use a hydrometer, which can be purchased locally.

a

5. Repeat preceding charging procedure every 30-45 days, as long as battery is in storage. When ready to place battery back in service, remove excess grease from terminals (a small amount is desirable on terminals at all times), recharge again as necessary and re-install battery.

b

d

WARNING Hydrogen and oxygen gases are produced during normal battery operation or charging. Sparks or flame can cause this mixture to ignite and explode if they are brought near the battery. Sulfuric acid in battery can cause serious burns, if spilled on skin or in eyes. Flush or wash away immediately with clear water.

c a b c d

—

Stator Voltage Regulator/Rectifier Start Solenoid 12V Battery

A fault in the battery charging system usually will cause the battery to become undercharged. Check battery electrolyte level, and charge battery. See “Electrolyte Level”, and “Charging a Discharged Battery”. If battery will not accept a satisfactory charge, replace battery. If battery accepts a satisfactory charge, determine the cause of the charging system problem as follows.

2B-6 — ELECTRICAL

90-852572R02 NOVEMBER 2002

1. Check for correct battery polarity [red cable to positive (+) battery terminal]. If polarity was incorrect, check for damaged rectifier. See “rectifier test”, later in this section. 2. Check for loose or corroded battery connections. 3. Visually inspect wiring between stator and battery for cuts, chafing, and disconnected, loose or corroded connection. 4. Excessive electrical load (from too many accessories) will cause battery to run down. If visual inspection determines that battery connections and wiring are OK, perform the following stator and alternator systems tests.

STATOR OHMS TEST (ALTERNATOR COILS ONLY)

NOTE: Stator can be tested without removing from engine. 1. Disconnect both yellow (stator leads) from voltage regulator/rectifier, or terminal block. 2. Use an ohmmeter and perform the following test. IMPORTANT: If stator is mounted on engine, black stator lead (if provided) must be grounded to powerhead when testing. 3. Replace stator if readings are outside ranges

shown.

NOTE: Resistance varies greatly with temperature. Measurements should be taken with an ambient temperature range of 65° to 85° F. 9 Ampere Manual Stator Test Leads

Resistance (Ohms)

Scale Reading

Between Yellow Stator Leads

0.16 — 0.19*

Rx1

Between Either Yellow Stator Lead and Engine Ground

No Continuity

R x 1000

* DC Resistance of these windings generally is less than 1.5 Ohms. If a reading resembling a short is obtained, this would be acceptable.

18 Ampere Stator Test Leads

Resistance (Ohms)

Scale Reading

Between Yellow Stator Leads

0.16 — 0.19*

Rx1

Between Either Yellow Stator Lead and Engine Ground

No Continuity

R x 1000

* DC Resistance of these windings generally is less than 1.5 Ohms. If a reading resembling a short is obtained, this would be acceptable.

90-852572R02 NOVEMBER 2002

ELECTRICAL — 2B-7

ALTERNATOR SYSTEMS TEST

6. Remove RED sense lead wire from starter sole-

9 Ampere Manual Stator IMPORTANT: Rectifier (optional accessory) must be functioning properly for accurate test results to be obtained.

noid terminal and connect to the positive (+) terminal of a 9 volt transistor battery. Ground the negative (–) terminal of the 9 volt battery to the engine.

1. Remove RED lead from (+) terminal of rectifier. 2. Connect RED (+) ammeter lead to rectifier (+) ter-

a

minal and BLACK (–) ammeter lead to RED rectifier lead. 3. With engine running at the indicated RPM, the

ammeter should indicate the following approximate amperes:

9 Ampere Manual Stator

RPM

AMPERES

Idle

0

1000

0.6

2000

8.0

3000

9.0

4. If proper ampere readings are not obtained, re-

place stator.

18 Ampere Stator 1. Check battery voltage at battery with engine running. 2. If battery voltage is above 14.5 volts, replace voltage regulator/rectifier. Check condition of battery as overcharging may damage battery. 3. If battery voltage is below 14.5 volts, charge battery; refer to “Charging a Discharged Battery”, preceding. If battery can not be satisfactorily charged, replace battery. 4. If battery accepts a satisfactory charge, check battery voltage while cranking engine; refer to “Charging a Discharged Battery”, preceding. If cranking voltage is not acceptable, replace battery.

a — Red Sense Lead (Female Connector)

7. Connect RED (+) ammeter lead to larger diame-

ter RED harness wire, and BLACK (–) ammeter lead to POSITIVE terminal on starter solenoid. 8. Secure starter wires away from flywheel.

9. With engine running at the indicated RPM’s, the ammeter should indicate the following approximate amperes:

18 Ampere Stator

RPM

AMPERES

Idle

2.8

1000

9.3

2000

18

10. A reading of 18 amperes at 2000 RPM indicates

the charging system is functioning properly. The battery is being discharged because of the excessive amperage draw on the system (the draw is greater than the amperage output of the engine charging system). 11. If ammeter reads less than required amperes @

3000 RPM, test the stator; refer to “Stator Ohm Test (Alternator Coils Only)”. If stator tests OK, replace voltage regulator.

5. If cranking voltage is acceptable, disconnect

larger diameter RED harness wire from starter solenoid terminal.

2B-8 — ELECTRICAL

90-852572R02 NOVEMBER 2002

RECTIFIER TEST (OPTIONAL ACCESSORY FOR 9 AMP STATOR)

d

a

c

WARNING Disconnect battery leads from battery before testing rectifier.

b

NOTE: Rectifier can be tested without removing from

f

engine. 1. Disconnect all wires from terminals on rectifier. 2. Use an ohmmeter (R x 1000 scale) and perform

e

the following test. Refer to drawing for rectifier terminal identification.

07300

a b c d e f

—

Terminal Terminal Terminal Stator Terminals Positive Terminal Ground

Connect red meter lead to ground, black lead alternately to terminals “a” and “c”.

Continuity Indicated. Connect black meter lead to ground, red lead alternately to terminals “a” and “c”.

No Continuity Indicated. Connect black meter lead to terminal “b”, red lead alternately to terminals “a” and “c”.

No Continuity Indicated. Connect black meter lead to ground, red lead alternately to terminals “a” and “c”.

Continuity Indicated. Replace Rectifier.

No Continuity Indicated. Replace Rectifier.

Continuity Indicated. Connect red meter lead to terminal “b”, black lead alternately to terminals “a” and “c”.

No Continuity Indicated. Replace Rectifier.

Continuity Indicated. Replace Rectifier.

No Continuity Indicated. Rectifier tests O.K.

90-852572R02 NOVEMBER 2002

Continuity Indicated. Connect black meter lead to terminal “b”, red lead alternately to terminals “a” and “c”.

Continuity Indicated. Replace Rectifier.

No Continuity Indicated Connect red meter lead to terminal “b”, black lead alternately to terminals “a” and “c”.

No Continuity Indicated. Replace Rectifier.

Continuity Indicated. Rectifier Tests O.K.

ELECTRICAL — 2B-9

VOLTAGE REGULATOR/RECTIFIER TEST

SCR TEST:

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.

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): 15,000 —  OHMS (15k — ) TACHOMETER CIRCUIT TEST: 1. Set Ohm meter to R X 1k scale.

DIODE TEST: 1. Set Ohm meter to R X 10 scale. 2. Connect Red (+) meter lead to RED regulator lead.

2. Connect Red (+) meter lead to GREY regulator lead. 3. Connect Black (–) meter lead to regulator case. TEST RESULTS: 10,000 — 50,000 OHMS (10k — 50k)

3. Connect Black (–) meter lead to 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 (+) meter lead to the other YELLOW regulator lead for 2ND test reading. TEST RESULTS (1ST READING): 40,000 to  OHMS TEST RESULTS (2ND READING):  OHMS (No needle movement)

2B-10 — ELECTRICAL

90-852572R02 NOVEMBER 2002

Starting System

Troubleshooting the Starting Circuit

Starting System Components

Before beginning the starting circuit troubleshooting flow chart, following, check first for the following conditions:

The starting system consists of the following components. 1. Battery 2. Starter Solenoid 3. Neutral Start Switch

1. Make sure that battery is fully charged. 2. Check that control lever is in “NEUTRAL” position. 3. Check bullet connectors for corrosion and loose connections. 4. Check cables and wiring for frayed and worn insulation.

4. Starter Motor 5. Ignition Switch

5. Check in-line fuse in RED wire; see diagram.

Description The function of the starting system is to crank the engine. The battery supplies electrical energy to crank the starter motor. When the ignition switch is turned to “START” position, the starter solenoid is activated and completes the starting circuit between the battery and starter. The neutral start switch opens the start circuit when the shift control lever is not in neutral. This prevents accidental starting when engine is in gear.

CAUTION The starter motor may be damaged if operated continuously. DO NOT operate continuously for more than 30 seconds. Allow a 2 minute cooling period between starting attempts.

90-852572R02 NOVEMBER 2002

ELECTRICAL — 2B-11

Starting Circuit Wiring Diagram

b a

c

f

e

d

a b c d e f

—

Key Switch Neutral Start Switch Starter Solenoid Battery 20 Amp Fuse

2B-12 — ELECTRICAL

90-852572R02 NOVEMBER 2002

Starting Circuit Troubleshooting Flow Chart Starter Motor Does Not Turn

SAFETY WARNING: Disconnect BLACK (starter motor) cable from starter solenoid test point 1 BEFORE making tests 1-through-7 to prevent unexpected engine cranking.

TEST 1 Use an ohmmeter (R x 1 scale) and connect meter leads between NEGATIVE (-) battery post and common powerhead ground.

No continuity indicated; there is an open circuit in the BLACK NEGATIVE (-) battery cable between the NEGATIVE (-) battery post and the powerhead. • Check cable for loose or corroded connections. • Check cable for open circuit.

Continuity Indicated Proceed to TEST 2

* Battery Voltage

TEST 2 No voltage reading; proceed to TEST 3.

a. Disconnect BLACK ground wires from Test Point 2. b. Connect voltmeter between common engine ground and Test Point 2. c. Turn ignition key to “Start” position.

12 Volt Reading*

TEST 3 a. Reconnect BLACK ground wires. b. Connect voltmeter between common engine ground and Test Point 3. c. Turn ignition key to “Start” position.

Check BLACK ground wire for poor connection or open circuit. Reconnect ground wire to starter solenoid; proceed to TEST 7.

12 Volt Reading

No voltage reading; proceed to TEST 4.

Defective starter solenoid.

TEST 4 No voltage reading; proceed to TEST 5.

a. Connect voltmeter between common engine ground and Test Point 4. b. Turn ignition key to “Start” position.

12 Volt Reading* Neutral start switch is open, or YELLOW/RED wire is open between Test Points 4 and 3.

TEST 5 No voltage reading; proceed to TEST 6.

12 Volt Reading*

Connect voltmeter between common engine ground and Test Point 5.

Defective ignition switch.

TEST 6 Connect voltmeter between common engine ground and Test Point 6.

No voltage reading; check RED wire between battery (+) positive terminal and Test Point 6.

90-852572R02 NOVEMBER 2002

12 Volt Reading* Check fuse in RED wire between test points 5 and 6. Check for open RED wire between test points 5 and 6.

ELECTRICAL — 2B-13

TEST 7 a. Connect voltmeter between common engine ground and Test Point 1. b. Turn ignition key to “Start” position.

12 Volt Reading*

No voltage reading; Defective starter solenoid.

Should hear solenoid click; proceed to TEST 8.

TEST 8 a. Reconnect BLACK (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.

No voltage reading; check BLACK cable for poor connection or open circuit.

2B-14 — ELECTRICAL

12 Volt Reading* Check BLACK ground cable at starter for loose or corroded connection, or open circuit. If cable is O.K., check starter motor.

90-852572R02 NOVEMBER 2002

a

Starter Motor

c

Removal WARNING Always disconnect the battery and remove spark plug leads from spark plugs before working on motor. 1. Disconnect battery leads from battery. 2. Disconnect BLACK cable (with YELLOW sleeve). 3. Remove 3 bolts. 4. Remove starter.

c

a

b

a — Thru-Bolts b — Commutator End Cap c — Brush/Springs

2. Pull armature from starter frame. 3. Remove locknut.

b b b

a

a

b 55329

a — Black Cable (with YELLOW sleeve) b — Bolts (3)

Disassembly

a — Armature b — Locknut

1. Remove 2 thru-bolts and commutator end cap, taking care not to lose brush springs.

90-852572R02 NOVEMBER 2002

ELECTRICAL — 2B-15

4. Remove components from armature.

b. Clean the commutator slots after undercut-

ting.

d c.

e

f

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 are repairable. The

a

a b c d e f

—

b

c

most likely place for an open circuit is at the commutator bars. Long cranking 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.

Spacer Spring Drive Assembly Drive End Cap Armature Shaft Washer

11. Clean out the copper or brush dust from slots be-

tween the commutator bars. 12. Check the armature for shorts and ground. See “Testing”, following.

Cleaning and Inspection

Testing

1. Clean all motor parts. 2. Check pinion teeth for chips, cracks or excessive

wear. 3. Replace the drive clutch spring and/or collar, if

tension is not adequate, or if wear is excessive. 4. Check that the brush holder is not damaged or is

not holding the brushes against the commutator.

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.

5. Replace brushes that are pitted or worn to less

than 1/4 in. (6.4mm) in length. Refer to “Brush Replacement”, following. 6. Replace a damaged or excessively worn bushing

in the end cap. 7. Check the armature conductor (commutator bar

junction) for a firm connection. A poor connection usually results in a burned commutator bar. 8. Re-surface and undercut a rough commutator, as

follows:

CAUTION Do not turn down the commutator excessively. a. Re-surface the commutator and undercut the

insulation between the commutator bars 1/3 in. (8.5 mm) to the full width of the insulation, make sure that the undercut is flat.

2B-16 — ELECTRICAL

90-852572R02 NOVEMBER 2002

ARMATURE TEST FOR GROUND

TESTING NEGATIVE BRUSHES FOR GROUND

1. Set ohmmeter to (R x 1 scale). Place one lead of

Set ohmmeter to (R x 1 scale). Place one lead of ohmmeter on the negative brush and the other lead on the end cap (bare metal). If the meter indicates no continuity, replace the negative brush. Repeat this procedure on the other negative brush.

ohmmeter on armature core (or shaft) and other lead on commutator, as shown. 2. If

meter indicates continuity, armature is grounded and must be replaced.

a

b

11675

CHECKING POSITIVE BRUSHES AND TERMINALS 1. Connect ohmmeter (R x 1 scale) leads between

positive brushes. 2. Ohmmeter must indicate full continuity (zero re-

a — Negative (-) Brushes b — End Cap

sistance). If resistance is indicated, check lead to positive terminal solder connection. If connection cannot be repaired, brushes must be replaced. Refer to “BRUSH REPLACEMENT”.

a

11673 a — Positive Brushes

90-852572R02 NOVEMBER 2002

ELECTRICAL — 2B-17

STARTER SOLENOID TEST

Brush Replacement

Test starter solenoid as follows:

IMPORTANT: Replace brushes that are pitted or worn to less than 1/4 in. (6.4 mm) in length.

1. Disconnect all leads from solenoid terminals. 2. Use an ohmmeter, set to (R x 1 scale) and con-

nect between solenoid terminals 3 and 4. 3. Connect a 12-volt supply between solenoid ter-

minals 1 and 2. Solenoid should click and meter should read zero ohms.

c

4. If meter does not read zero ohms (full continuity),

replace solenoid.

d e

b

a

f g 11660



a b c d e f g

—

Positive (+) Terminal Long Brush Lead Push Lead Into Slot Insulating Washer Flat Washer Lock Washer Nut

a c

a

b

b 

 14354

d

a — Ohmmeter Leads b — 12-Volt Supply

d b

a 11656

a b c d

2B-18 — ELECTRICAL

—

Positive (+) Brushes Negative (–) Brushes Brush Holder Bolts (Fasten Negative Brushes and Holder)

90-852572R02 NOVEMBER 2002

Brush Retainer Tool Layout (Full Size)

Reassembly 1. Lubricate helix threads and drive end cap bushing with SAE 10W oil. 2. Install components onto armature shaft.

d c

a

b

e

g f

11658 a b c d e f g

—

Washer Helix Threads Armature Shaft Drive End Cap Drive Assembly Spring Spacer

3. Install locknut.

a

Brush Retainer Tool Side View (Full Size)

18-Gauge Sheet Metal

51711

METRIC SCALE 3” = 76.2mm 2” = 50.8mm 1-3/4” = 44.5mm 1-11/16”= 42.9mm 3/4” = 19.1mm 1/2” = 12.7mm

4. Construct a brush retainer tool as shown. 90-852572R02 NOVEMBER 2002

ELECTRICAL — 2B-19

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.

Installation 1. Secure starter to block with 3 bolts. Torque bolts to 16.6 lb. ft. (22.5 N·m). Secure NEGATIVE battery lead to block with bottom bolt. 2. Connect battery lead (BLACK with YELLOW sleeve) to starter. Torque attaching nut to 60 lb.

a

in.(6.8 N·m).

b

b b

11661 a — Brush Retainer Tool b — Bushing

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. (25.4 mm). Align marks as shown. 8. Install commutator end cap onto starter frame; align marks as shown, and remove brush retainer tool.

a

b 55329

a — Black Cable (with YELLOW sleeve) b — Bolts (3)

9. Install thru-bolts and torque to 70 lb. in. (7.9 N·m).

c

c

a

b

52659 a — Alignment Marks b — End Cap Alignment Marks c — Bolts

2B-20 — ELECTRICAL

90-852572R02 NOVEMBER 2002

ELECTRICAL

2 C

TIMING/SYNCHRONIZING/ADJUSTING

Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Idle Timing Adjustment . . . . . . . . . . . . . . . . Maximum Timing Adjustment . . . . . . . . . . . Carburetor Synchronization . . . . . . . . . . . . . . Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2C-0 — ELECTRICAL

Page 2C-1 2C-1 2C-2 2C-2 2C-2 2C-3 2C-4 2C-4

90-852572R02 NOVEMBER 2002

Specifications

TIMING

Idle Maximum Timing @ Cranking Speed -Model 40/50/60 -Model 55 @ 5000 RPM – Model 50/60 – Model 55/60 Idle RPM Wide Open Throttle (W.O.T.) RPM Spark Plug Type

Spark Plug Gap Firing Order

T.D.C. to 2° B.T.D.C. 24° B.T.D.C. 18° B.T.D.C. 22° B.T.D.C. 16° B.T.D.C. 675 ± 25 5000-5500 NGK BP8H-N-10 *NGK BPZ8H-N-10 NGK BUZ8H NGK BP8HS-10 0.040 in. (1.0mm) 1-2-3

*Suppressor (resistor) spark plug

Special Tools 1. Service Tachometer P/N 91-854009A1

3. Spark Gap Tool P/N 91-63998A1

*May be obtained locally.

2. Timing Light P/N *91-99379

*May be obtained locally.

90-852572R02 NOVEMBER 2002

ELECTRICAL — 2C-1

Maximum Timing Adjustment

Timing CAUTION Engine may be timed while cranking engine with starter motor. To prevent engine from starting when being cranked, all spark plugs must be removed.

1. Hold control arm so that maximum spark advance screw is against stop. Crank engine with starter motor and adjust maximum spark advance screw to align the specified BTDC timing mark on flywheel with timing pointer. Tighten locknut.

1. Insert Spark Gap Tool (91-63998A1) into each spark plug boot and attach alligator clips to good engine ground.

b

2. Disconnect remote fuel line from engine. 3. Connect remote control electric harness to engine wiring harness. 4. Remove throttle cable barrel from barrel retainer.

c a

Idle Timing Adjustment 5. Connect timing light to No. 1 (TOP) spark plug lead.

WARNING While cranking engine, keep clear of propeller as it may rotate. 51045

6. Shift engine to neutral. IMPORTANT: To time engine at cranking speed, a fully charged battery must be used. 7. Hold throttle arm at idle position as shown below, crank engine with starter motor and adjust idle timing screw to align T.D.C. timing mark of flywheel with timing pointer. Tighten locknut.

NOTE: Timing will be T.D.C. to 2° B.T.D.C. after adjusting idle RPM.

a — Control Arm b — Spark Advance Screw c — Locknut

NOTE: All timing adjustments made to engine under cranking speed conditions should be verified with engine running and adjustments made if necessary. This is due to advance characteristics of individual ignition systems.

55039

a b

TDC 10

0

10

a — Idle Timing Screw b — Locknut

2C-2 — ELECTRICAL

90-852572R02 NOVEMBER 2002

Carburetor Synchronization 1. Remove attenuator cover (see section 3B,“Carburetor Removal”).

7. Place roller of cam follower against throttle cam and adjust idle stop screw to align recessed mark of throttle cam with center of cam follower roller. Tighten locknut.

2. Loosen screw of cam follower.

55039

3. Loosen two (2) synchronizing screws located on throttle levers of top and bottom carburetors.

c

4. Look into throats of carburetors and verify all throttle shutters are completely closed. Tighten synchronizing screws.

b

d

55039

f a

b e

a a b c d e f

—

Throttle Arm Idle Stop Screw Throttle Cam Raised Mark Locknut Cam Roller

b a — Screw-Cam Follower b — Screws-Synchronizing

5. Recheck throttle shutters and make any necessary adjustments.

8. Hold throttle arm at idle position. Adjust cam follower so that a clearance of .005-.040 in.(0.13 mm-1.02 mm) exists between roller of cam follower and throttle cam. Tighten screw securing cam follower.

6. Hold throttle arm so that idle stop screw is against stop.

d

c

.005-.040 in.

b a 55039

a b c d

90-852572R02 NOVEMBER 2002

—

Cam Follower Screw Roller Throttle Cam

ELECTRICAL — 2C-3

9. Hold throttle arm against full throttle stop screw. Adjust full throttle stop screw to allow throttle shutters to open fully while providing approximately .015 in. (.38 mm) free-play in throttle linkage to prevent carburetor throttle shutters from acting as throttle stops at wide open throttle. Tighten locknut on stop screw.

Adjustments Idle 1. With engine in water, connect electrical harness (if equipped) and fuel line to engine. Start engine and allow to warm up. 2. Properly adjust carburetor low speed mixture screws. Initial setting is 1-1/4 turns off seat. 3. Hold throttle arm at idle position (throttle cable barrel removed from barrel retainer). Adjust idle timing screw to attain an engine idle RPM of 650-700 RPM in “FORWARD” gear. Tighten locknut and turn off engine.

a

55039

b

a c 51045

b

a — Throttle Arm b — Stop Screw c — Locknut (Hidden)

10. Reinstall attenuator cover.

a — Idle Timing Screw b — Locknut

2C-4 — ELECTRICAL

90-852572R02 NOVEMBER 2002

ELECTRICAL

2 D

WIRING DIAGRAMS

Table of Contents 40/55 MH Wiring Diagram . . . . . . . . . . . . . . . 40/50/60 EO Wiring Diagram . . . . . . . . . . . . 40/50 EHPTO Wiring Diagram . . . . . . . . . . . 40/50/60 EPTO Wiring Diagram . . . . . . . . . . 60 EHPTO Wiring Diagram . . . . . . . . . . . . . . COMMANDER 2000 Side Mount Remote Control Wiring Diagrams . . . . . . . . . . . . . . . . Key/Choke Switch Continuity Test . . . . . . Power Trim/Tilt Electric Start with Warning Horn . . . . . . . . . . . . . . . . . . . . . . . . . . Power Tilt Electric Start with Warning Horn . . . . . . . . . . . . . . . . . . . . . . . . . . Electric Start with Warning Horn . . . . . . . . . .

2D-0 — ELECTRICAL

Page 2D-1 2D-2 2D-3 2D-4 2D-5 2D-6 2D-6 2D-7 2D-8 2D-9

90-852572R02 NOVEMBER 2002

40/55 MH Wiring Diagram b a

j

c i d h e

f

g

a b c d e

—

Trigger Stator Temperature Switch Warning Horn Push-Button Stop Switch

90-852572R02 NOVEMBER 2002

f g h i j

—

Lanyard Stop Switch Rev. Limiter CDM #3 CDM #2 CDM #1

ELECTRICAL — 2D-1

40/50/60 EO Wiring Diagram b a

c

d e

o f n

g

m

h

l i

j

k

a b c d e f g h

—

Trigger Stator Remote Control 20 Amp Fuse Starter Fuel Enrichment Solenoid Oil Level Switch Head Temp. Switch

2D-2 — ELECTRICAL

i j k l mno-

12 V Battery Start Solenoid Voltage Regulator Rev. Limiter CDM #3 CDM #2 CDM #1

90-852572R02 NOVEMBER 2002

40/50 EHPTO Wiring Diagram

e

d f c

l j b

k

g i

h a

n

m x

o w p v

q

u r

s

t a b c d e f g h i j k l

—

Trigger Stator Key Switch Warning Horn Push Button Stop Switch Lanyard Switch Remote Control 20 Amp Fuse Cowl Mounted Trim Switch Trim-Down Relay Trim-Up Relay Starter

90-852572R02 NOVEMBER 2002

mnopqr s t uv wx —

Fuel Enrichment Solenoid Trim Pump Oil Level Switch Head Temperature Switch 12 Volt Battery Neutral Start Switch Start Solenoid Voltage Regulator Rev. Limiter CDM 3 CDM 2 CDM 1

ELECTRICAL — 2D-3

40/50/60 EPTO Wiring Diagram

h

b f

g

a c

d

e

s i r

j k

q

l

p m o

n

a b c d e f g h i j

—

Trigger Stator Remote Control 20 Amp Fuse Cowl Mounted Trim Switch Trim-Down Relay Switch Trim-Up Relay Switch Starter Trim Pump Fuel Enrichment Solenoid

2D-4 — ELECTRICAL

k l mnopqr s —

Oil Level Switch Head Temp. Switch 12V Battery Start Solenoid Voltage Regulator Rev. Limiter CDM #3 CDM #2 CDM #1

90-852572R02 NOVEMBER 2002

60 EHPTO Wiring Diagram c d

a x i

b

e f h

g

w k

j

y

l v

m

u

n o

t

p

s

q

r

abc def ghi j k l m-

Key Switch Warning Horn Neutral Start Switch Tiller Handle Trim Switch Push-Button Stop Switch Lanyard Stop Switch Starter Trim-Up Relay Trim-Down Relay Cowl Mounted Trim Switch 20 Amp Fuse Trim Pump Fuel Enrichment Solenoid

90-852572R02 NOVEMBER 2002

nopqr s t uv wx y —

Oil Level Switch Head Temp. Switch 12V Battery Start Solenoid Voltage Regulator Rev. Limiter CDM #3 CDM #2 CDM #1 Trigger Stator Remote Control

ELECTRICAL — 2D-5

COMMANDER 2000 Side Mount Remote Control Wiring Diagrams Key/Choke Switch Continuity Test

“OFF” “RUN” “START” PUSH (CHOKE)*

BLK/YEL — BLK RED — PUR RED — PUR — YEL/RED RED — YEL/BLK

*Key switch must be positioned to “RUN” or “START” and key pushed in to actuate choke, for this continuity test.

2D-6 — ELECTRICAL

90-852572R02 NOVEMBER 2002

Power Trim/Tilt Electric Start with Warning Horn g

e

d

a

f b

BLK BLU BRN GRY GRN PUR RED TAN WHT YEL

• • • • • • • • • •

BLACK BLUE BROWN GRAY GREEN PURPLE RED TAN WHITE YELLOW

c

23891

a — Ignition/Choke Switch b — Emergency Stop Switch c — Neutral Start Switch d — Tachometer/Accessories Harness Connector e — Wiring Harness Connector f — Warning Horn g — Trim/Tilt Switch

90-852572R02 NOVEMBER 2002

ELECTRICAL — 2D-7

Electric Start with Warning Horn

e

d

f

a b

BLK BLU BRN GRY GRN PUR RED TAN WHT YEL LIT

• • • • • • • • • • •

BLACK BLUE BROWN GREY GREEN PURPLE RED TAN WHITE YELLOW LIGHT

c

a — Ignition/Choke Switch b — Emergency Stop Switch c — Neutral Start Switch d — Tachometer/Accessories Harness Connector e — Wiring Harness Connector f — Warning Horn

2D-8 — ELECTRICAL

90-852572R02 NOVEMBER 2002

Power Tilt Electric Start with Warning Horn • • • • • • • • • • •

BLACK BLUE BROWN GREY GREEN PURPLE RED TAN WHITE YELLOW LIGHT

c

k

b

e

a

d

j

f

i

g

h

BLK BLU BRN GRY GRN PUR RED TAN WHT YEL LIT

l

24072

a — Ignition/Choke Switch b — Emergency Stop Switch c — Neutral Start Switch d — Tachometer/Accessories Harness e — Wiring Harness Connector f — Warning Horn

90-852572R02 NOVEMBER 2002

g — Trim/Tilt Switch h — Wire Retainer i – Control Handle j — Trim Harness Bushing k — Trim Harness Connector l — Lead to Trim Indicator Gauge

ELECTRICAL — 2D-9

2D-10 — ELECTRICAL

90-852572R02 NOVEMBER 2002

FUEL SYSTEM

3 A

FUEL PUMP Table of Contents Table of Contents . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Pump (Electric) 40/50/55/60 . . . . . . . . . Fuel Pump (Electric) 40/50/55/60 . . . . . . . . . Fuel Pump (Manual) 40/50 . . . . . . . . . . . . . . Fuel Pump (Manual) 40/50 . . . . . . . . . . . . . . Fuel Pump (Manual) 55/60 . . . . . . . . . . . . . . Fuel Pump (Manual) 55/60 . . . . . . . . . . . . . . Theory of Operation . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Pump Removal . . . . . . . . . . . . . . . . . . . . Fuel Pump Disassembly . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . Check Valve Reassembly . . . . . . . . . . . . . Fuel Pump Reassembly . . . . . . . . . . . . . . Fuel Pump Assembly . . . . . . . . . . . . . . . . . . .

3A-0 — FUEL SYSTEM

Page 3A-0 3A-1 3A-2 3A-3 3A-4 3A-5 3A-6 3A-7 3A-8 3A-8 3A-9 3A-10 3A-10 3A-10 3A-11 3A-11 3A-12 3A-13

90-852572R02 NOVEMBER 2002

Specifications

FUEL SYSTEM

Fuel Electric Start Models Manual Start Models Recommended Gasoline Recommended Oil Gasoline/Oil Ratio Fuel Pressure @ Idle @ W.O.T.

90-852572R02 NOVEMBER 2002

Straight Gasoline Pre-mixed Gasoline and Oil Unleaded-87 Octane Minimum TC-WII or TC-W3 Two Cycle Outboard Oil 50:1 (Including Break-In) 3.5 PSI (24 kPa) 6.0 PSI (41 kPa)

FUEL SYSTEM — 3A-1

Fuel Pump (Electric) 40/50/55/60 E 34 33

21

32

21 38

39

31

A

37

35

21

36

C

20

D

21 19 21 18 7 6

21 1 4

5

11

2 5 12

2

3

4

14

9

17

21 10

23 13

21

15

8

9

B

24

16 21 22 29

21 27

28

30

15 21

26 25 21

F 9

Loctite 567 PST Pipe Sealant

A= To top carburetor B= to crankcase D= TO INTAKE MANIFOLD FITTING F = to oil pump outlet

3A-2 — FUEL SYSTEM

c= to oil pump fitting E= TO FITTING

90-852572R02 NOVEMBER 2002

Fuel Pump (Electric) 40/50/55/60 REF. REF NO. QTY. – 1 1 1 2 2 3 1 4 2 5 2 6 1 7 1 8 1 9 1 10 1 11 1 12 1 13 1 14 1 15 2 2 16 2 17 1 18 1 19 1 20 1 21 AR 22 1 23 1 24 1 25 1 22 1 23 1 24 1 25 1 26 1 27 1 28 1 29 1 30 1 1 31 1 32 1 33 1 1 34 1 1 35 1 1 36 1 37 1 38 1 39 1

TORQUE DESCRIPTION FUEL PUMP ASSEMBLY FUEL PUMP DIAPHRAGM KIT DIAPHRAGM RUBBER CHECK VALVE RETAINER SPRING CAP SPRING CAP DIAPHRAGM GASKET GASKET–boost GASKET–pulse PLATE FITTING SCREW–fuel pump (M5 x 40) SCREW– pump to crankcase (M6 x 50) BASE HOSE FUEL FILTER FUEL LINE STA-STRAP HOSE (1-1/2 IN.) HOSE (1-1/2 IN.) 40 WYE CONNECTOR HOSE (2 IN.) HOSE (1-1/4 IN.) HOSE (1-1/4 IN.) 50 TEE CONNECTOR HOSE (1-1/2 IN.) HOSE (22 IN.) CHECK VALVE FUEL CONNECTOR SCREW (M6 x 35) HOSE (4-1/4 IN.) CLAMP (NO STAMPING) CLAMP (STAMPED ’3’) SOLENOID VALVE (USE WITH NO STAMPING CLAMP SOLENOID VALVE (USE WITH STAMPED ’3’ CLAMP HOSE (9-1/2 IN.) (MANUAL BUTTON MOUNTED DOWN) HOSE (8 IN.) (MANUAL BUTTON MOUNTED UP) HOSE (3-1/4 IN.) (MANUAL BUTTON MOUNTED DOWN) HOSE (4 IN.) (MANUAL BUTTON MOUNTED UP) HOSE (16 IN.) (MANUAL BUTTON MOUNTED DOWN) HOSE (14 IN.) (MANUAL BUTTON MOUNTED UP) TEE FITTING HOSE (2 IN.) SCREW (M6 x 16)

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

N·m

55 55

6.2 6.2

80

9.0

100

11

FUEL SYSTEM — 3A-3

Fuel Pump (Manual) 40/50 A

25 26

20

C

D

19

25

22 19 23

30

19

7 6

1 4

24 5 11

29

2

5 12

3

2 4

14

9 17 10

E

19

8

13

15

9

B

16

19

28 18

27

15

21 19

19

9

Loctite 567 PST Pipe Sealant

A= TO CARBURETOR D= TO MANIFOLD TOP

3A-4 — FUEL SYSTEM

B= TO CRANKCASE C = TO TOP CARB E= TO MANIFOLD BOTTOM

90-852572R02 NOVEMBER 2002

Fuel Pump (Manual) 40/50 REF. REF NO. QTY. – 1 1 1 2 2 3 1 4 2 5 2 6 1 7 1 8 1 9 1 10 1 11 1 12 1 13 1 14 1 15 2 2 16 2 17 1 18 1 19 AR 20 1 21 1 22 1 23 1 24 1 25 2 26 1 27 1 28 1 29 1 30

1

TORQUE DESCRIPTION FUEL PUMP ASSEMBLY FUEL PUMP CHECK VALVE DIAPHRAGM KIT RUBBER CHECK VALVE RETAINER SPRING CAP SPRING CAP DIAPHRAGM GASKET GASKET–boost GASKET–pulse PLATE FITTING SCREW–fuel pump (M5 x 40) SCREW–pump to crankcase (M6 x 50) BASE

lb. in. lb. ft.

N·m

55 55

6.2 6.2

80

9.0

HOSE (22 IN.) STA-STRAP HOSE HOSE (4-1/4 IN.) FUEL FILTER HOSE TEE FITTING HOSE (9-1/2 IN.) PRIMER BULB FUEL CONNECTOR SCREW (M6 x 35) HOSE (5-1/2 IN.) HOSE (1-1/2 IN.)

90-852572R02 NOVEMBER 2002

FUEL SYSTEM — 3A-5

Fuel Pump (Manual) 55/60 27

30

D

C A

27

21

29

20

7 6

1 4

26 5 11

28

2

5 12

3

2 4

14

9 17 10

E

20 9

13 19

B

8

15

16

20 20 15

22 20

32 20 31

25

18 20

9

24

Loctite 567 PST Pipe Sealant

23

A= TO CARBURETOR, B= TO CRANKCASE , C = TO TOP FLOAT BOWL, D = TO TOP INTAKE MANIFOLD, E = TO LOWER INTAKE MANIFOLD, 3A-6 — FUEL SYSTEM

90-852572R02 NOVEMBER 2002

Fuel Pump (Manual) 55/60 REF. REF NO. QTY. – 1 1 1 2 2 3 1 4 2 5 2 6 1 7 1 8 1 9 1 10 1 11 1 12 1 13 1 14 1 15 2 2 16 2 17 1 18 1 19 1 20 AR 21 1 22 1 23 1 24 1 25 1 26 1 27 2 28 1 29 1 30 1 31 1 32 1

TORQUE DESCRIPTION FUEL PUMP ASSEMBLY FUEL PUMP ASSEMBLY DIAPHRAGM KIT DIAPHRAGM RUBBER CHECK VALVE RETAINER SPRING CAP SPRING CAP DIAPHRAGM GASKET GASKET–boost GASKET–pulse PLATE FITTING SCREW–fuel pump SCREW–fuel pump to crankcase BASE HOSE (10 IN.) HOSE (14-1/4 IN.) STA-STRAP HOSE HOSE (4-1/4 IN.) FUEL FILTER BRACKET NUT TEE FITTING HOSE (9-1/2 IN.) HOSE (5-1/2 IN.) HOSE (1-1/2 IN.) PRIMER BULB FUEL CONNECTOR SCREW

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

55 55

N·m

6.2 6.2

Drive Tight

80

9.0

FUEL SYSTEM — 3A-7

Theory of Operation The fuel pump is a crankcase-pressure-operated, diaphragm-type pump. Crankcase pulsating pressure is transferred by way of a passage (hole) from the crankcase to the fuel pump. When the piston travels upward, a vacuum is created in the crankcase. This vacuum pulls in the fuel pump diaphragm, the inlet check valve (in fuel pump) is opened, and fuel is drawn into fuel pump. Downward motion of the piston forces out the fuel pump diaphragm, closes the inlet check valve (to keep fuel from returning to fuel tank) and opens the outlet check valve, forcing fuel to the carburetors.

Troubleshooting WARNING FIRE AND EXPLOSION HAZARD. Observe fire prevention rules, particularly NO SMOKING. Before servicing any part of the fuel system, disconnect electrical system at the battery. Drain the fuel system completely. Use an approved container to collect and store fuel. Wipe up any spillage immediately. Materials used to contain spillage must be disposed of in an approved receptacle. Any fuel system service must be performed in a well ventilated area.

Checking For Restricted Fuel Flow Caused By Anti-Siphon Valves While anti-siphon valves are helpful from a safety stand-point, they clog, they may be too small, or they may have too heavy a spring. The pressure drop that occurs with these valves can create operational problems and/or powerhead damage by restricting flow of fuel. Some symptoms of restricted (lean) fuel flow, are:
Loss of fuel pump pressure
Loss of power
High speed surging
Preignition/detonation (piston dome erosion)
Outboard hesitates upon acceleration
Outboard runs rough
Outboard quits and cannot be restarted
Outboard will not start
Vapor lock Any type of anti-siphon device must be located between the outboard fuel inlet and fuel tank outlet. A method of checking [if such a device (or bad fuel) is a problem source] is to operate the outboard with a separate fuel supply which is known to be good. If it is found that the anti-siphon valve is the cause of the problem, either 1) replace the anti-siphon valve, or 2) replace it with a solenoid-operated fuel shutoff valve.

FUEL LEAKAGE FROM ANY PART OF THE FUEL SYSTEM CAN BE A FIRE AND EXPLOSION HAZARD WHICH CAN CAUSE SERIOUS BODILY INJURY OR DEATH. Careful periodic inspection of the entire fuel system is mandatory, particularly after engine storage. All fuel components, including fuel tanks, weather plastic, metal, fiberglass, fuel lines, primer bulbs, and fittings, must be inspected for corrosion. Any sign of leakage or deterioration necessitates replacement before further engine operation.

3A-8 — FUEL SYSTEM

90-852572R02 NOVEMBER 2002

Testing

PROBLEM: LACK OF FUEL PUMP PRESSURE

Install clear fuel hose(s) between fuel pump and carburetor(s). Run engine, and inspect hose(s) for air bubbles. If air bubbles are found, see “Air Bubbles in Fuel Line” . If air bubbles are not found, see “Lack of Fuel Pump Pressure”.

Possible Cause

Corrective Action

Anti-siphon valve.

Refer to “Checking for Restricted Fuel Flow Caused by Anti-siphon Valves” preceding.

Air in fuel line.

“Air Bubbles in Fuel Line,” preceding.

PROBLEM: AIR BUBBLES IN FUEL LINE Possible Cause

Corrective Action

Low fuel in tank.

Fill tank.

Dirty or clogged fuel fil- Clean or replace filter. ter.

Loose fuel line connec- Inspect and tighten contion. nections.

Dirty or clogged fuel Clean or replace pickup. pickup in fuel tank.

Fuel pump fitting loose.

Worn out fuel pump dia- Rebuild pump. phragm.

Tighten fitting.

A hole or cut in fuel line. Inspect condition of fuel lines and replace any found bad. Fuel pump screws loose.

anchor Inspect and tighten all screws.

Fuel pump gaskets worn Rebuild fuel pump. out.

Defective check valves Rebuild pump. in fuel pump. Broken check valve re- Rebuild pump. tainer. Pulse hole plugged.

Remove pump clean out hole.

and

Hole in pulse hose.

Replace pulse hose.

Loose pulse hose.

Tighten connection.

Boost diaphragm gasket Check seal between distorted or out of place. mating surfaces where “rib” divides pulse chamber. Gasket must align with rib. Align or replace gasket as necessary.

90-852572R02 NOVEMBER 2002

FUEL SYSTEM — 3A-9

Fuel Pump Removal

Fuel Pump Disassembly

1. Remove oil tank from outboard (if equipped) . Refer to Section 3C “Oil Injection System.”

1. Remove bolts and chamber plate.

a

b

2. Remove fuel “inlet” hose, “outlet” hose, and pulse hose. 3. Remove two bolts securing fuel pump to powerhead.

e

d

b

c a

a e

—

a — Bolt (2) b — Chamber Plate

e

2. Disassemble fuel pump as shown in “Fuel Pump Exploded View.”

d

Cleaning and Inspection 1. Clean fuel pump housing, chamber plate and pump base. Dry with compressed air.

51267

a b c d e

51267

2. Look at spring for signs of bad coils or other damage.

Inlet Fuel Hose Outlet Fuel Hose Pulse Hose — From Crankcase Bolt (2) Sta-strap

3. Check pump body, chamber plate and pump base for cracks or rough gasket surfaces.

4. Remove gasket from backside and replace gasket as necessary — check gasket in port area.

4. Check hoses for looseness or signs of leakage. 5. Look at check valve discs for cracks, tears, or other damage. 6. Repair of fuel pump is limited to the replacement of those bad parts found during inspection.

b a

51267

a — Gasket b — Port Area

3A-10 — FUEL SYSTEM

90-852572R02 NOVEMBER 2002

3. With retainer installed in pump body, break retainer rod from retainer by bending sideways.

Reassembly Check Valve Reassembly 1. Insert retainer through check valve.

d

b

b a

c a

a

23601 a — Retainer Rod b — Retainer Cap

Design I a b c d

—

4. Reinstall rod into retainer cap and, use a small hammer or hammer and punch to tap rod down into retainer until flush with top of retainer.

Design II

Retainer Plastic Check Valve Plastic Disc Rubber Check Valve

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

a b

a b 23610 50161 a — Retainer b — Plastic Check Valve

90-852572R02 NOVEMBER 2002

a — Rod b — Retainer Cap

FUEL SYSTEM — 3A-11

Fuel Pump Reassembly IMPORTANT: ALWAYS REPLACE GASKETS. After reassembling check valve in fuel pump body, using the following procedure will help insure proper reassembly: 1. Insert two 3 in. (76mm) minimum length 1/4 in. screws (not the fuel pump screws) OR 1/4 in. dowels, through the opposite large holes (6mm screw holes) in the Chamber Plate (l), as locating dowels, and turn plate upside down so that the inner side is facing up. 2. Insert Coil Spring (k) and Cap (j) in place. 3. Place Boost Chamber DIAPHRAGM (i) over dowels (screws) and lower onto Chamber Plate — BE SURE that gasket directional alignment is correct and that “V-tabs” are aligned.

5. Place Fuel Pump Body (a) over dowels, and lower to assembly. 6. Insert Coil Spring (f) and Cap (g) in pump body. 7. Place Fuel Pump GASKET (m) over dowels, and lower to assembly. 8. Place Pulse Chamber DIAPHRAGM (i) over dowels, and lower to assembly. 9. Place Fuel Pump Base (n) over dowels, and lower to assembly. 10. Grasp assembly firmly and clamp together with hands—turn over, and insert the 5mm Fuel Pump SCREWS (r) (hex-head). Tighten screws to 55 lbin. (6.2 Nm). After tightening, remove dowels (1/4 in. screws) used for locators. 11. Check that the directional alignment of all parts is correct and that the “V-Tabs” are aligned.

4. Place Boost GASKET (h) over dowels, and lower to assembly.

3A-12 — FUEL SYSTEM

90-852572R02 NOVEMBER 2002

Fuel Pump Assembly q

e d c

DESIGN I g f

a

DESIGN II b

h

d

c

i

b

j k l r

p

o n i m 51549

a b c d e f g h i

—

Fuel Pump Body Plastic Check Valve (2) Design II Check Valve Retainer (2) Plastic Disc (2) Design I Rubber Check Valve (2) Design I Boost Spring Cap Gasket – Boost Diaphragm (2)

90-852572R02 NOVEMBER 2002

j k l mnopqr —

Cap Spring Chamber Plate Gasket — Pulse Fuel Pump Base Base Gasket Alignment Tabs Opposite Side View Screw (2) (M5 x 40)

FUEL SYSTEM — 3A-13

3A-14 — FUEL SYSTEM

90-852572R02 NOVEMBER 2002

FUEL SYSTEM

3 B

CARBURETOR

Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . WME Carburetor Chart . . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . Carburetor 40/50 . . . . . . . . . . . . . . . . . . . . . . . Carburetor 55/60 . . . . . . . . . . . . . . . . . . . . . . . Attenuator Plate 40/50 . . . . . . . . . . . . . . . . . . Attenuator Plate 55/60 . . . . . . . . . . . . . . . . . . Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . Idle Mixture Screw Adjustment . . . . . . . . Idle Speed Adjustment . . . . . . . . . . . . . . . Float Adjustment . . . . . . . . . . . . . . . . . . . . Main (High Speed) Jet Adjustment . . . . . Jet Orifice Size Chart . . . . . . . . . . . . . . . . High Altitude Jet Chart . . . . . . . . . . . . . . . Fuel System Troubleshooting . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . Problem: Engine Floods . . . . . . . . . . . . . . Problem: Engine Runs Too Rich . . . . . . . Problem: Fuel Blow Back Out Of Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . Problem: Rough Idle . . . . . . . . . . . . . . . . . Problem: Engine Turns Over But Will Not Start Or Starts Hard When Cold . . . . Problem: Unable to Reduce Engine RPM to Slow Idle . . . . . . . . . . . . . . . . . . . . Problem: Engine Runs Too Lean . . . . . . . Problems: Engine Idles Rough And Stalls Engine Runs Uneven Or Surges Engine Will Not Accelerate . . . . . . . . . . . . Removal/Installation . . . . . . . . . . . . . . . . . . . . 40/50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . Enrichment System . . . . . . . . . . . . . . . . . . . . . Electric Enrichener Valve . . . . . . . . . . . . . Manual Primer Button . . . . . . . . . . . . . . . .

3B-0 — FUEL SYSTEM

Page 3B-1 3B-1 3B-1 3B-2 3B-4 3B-6 3B-8 3B-10 3B-10 3B-10 3B-10 3B-11 3B-11 3B-12 3B-13 3B-13 3B-13 3B-13 3B-13 3B-13 3B-14 3B-14 3B-15

3B-15 3B-16 3B-16 3B-16 3B-17 3B-18 3B-18 3B-20

90-852572R02 NOVEMBER 2002

Specifications 675 ± 25 5000-5500 9/16 in. (14.29 mm)

Idle RPM (In Forward Gear) Wide Open Throttle (W.O.T.) RPM Float Height CARBURETOR

WME Carburetor Chart NOTE: Carburetor Number Stamped on Side of Carburetor Body.

Model

Year

Carburetor Number

Main Fuel Jet

Preset Idle Screw Turns Open

40 Electric

1998

53-1,-2,-3

0.044 in.

1-1/4

40 Manual

1997-1/2/98

69-1,-2,-3

0.044 in.

1-1/4

50 Manual/Electric

1998

68-1,-2,-3

0.052 in.

1-1/4

55/60 Manual

1998

57-1,-2,-3

0.058 in.

1-1/4

60 Electric

1998

58-1,-2,-3

0.060 in.

1-1/8

Special Tools 1.

Carburetor Scale (P/N 91-36392)

73656

90-852572R02 NOVEMBER 2002

FUEL SYSTEM — 3B-1

Carburetor 40/50

2 5 3

11 10 7 9

7

4

8

5

6

15

12

16 1 13 17 18

19 20

14

21

22

25 26 27 23 24

7

Loctite 271 Thread Locker

3B-2 — FUEL SYSTEM

90-852572R02 NOVEMBER 2002

Carburetor 40/50 REF. REF NO. QTY. 1 1 1 1 2 1 3 1 4 1 2 2 3 1 5 2 6 3 7 3 8 3 9 3 10 3 11 6 12 3 13 1 14 1 15 6 16 3 17 3 18 3 19 3 20 3 21 3 22 3 23 12 3 1 24 2 25 3 26 3 3 27 3

TORQUE DESCRIPTION CARBURETOR (ELECTRIC 40 — WME-53) CARBURETOR (MANUAL 40 — WME-69) CARBURETOR (50 — WME-68) THROTTLE SHAFT (UPPER) THROTTLE SHAFT (CENTER) WME-53/68 THROTTLE SHAFT (BOTTOM) THROTTLE SHAFT (UPPER/BOTTOM) WME-69 THROTTLE SHAFT (CENTER) SCREW–throttle adjustment (UPPER/BOTTOM) SPRING–throttle return IDLE NEEDLE SPRING–idle needle GASKET–cover plate COVER PLATE SCREW–cover plate GASKET–flange THROTTLE LEVER Bottom — WME-53/68 SCREW–oil pump lever SCREW–throttle valve THROTTLE VALVE RETAINING RING FLOAT SHAFT GASKET–nozzle well GASKET–fuel bowl INLET NEEDLE VALVE FLOAT SCREW–fuel bowl FUEL BOWL (WME-53/68) FUEL BOWL (UPPER) WME-69 FUEL BOWL (CENTER/BOTTOM) PLUG KIT SEAL–bowl drain MAIN FUEL JET (.044 — WME-53/WME-69) MAIN JET (.052 — WME-68)

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

N·m

18

2.0

6

0.7

18

2.0

14 14

1.6 1.6

FUEL SYSTEM — 3B-3

Carburetor 55/60

3 5

2

11 10 7 9

7

8

4 6

15

12

16

13

1 17 18

19 20

14

21

22

25 26 27 23 24

7

Loctite 271 Thread Locker

3B-4 — FUEL SYSTEM

90-852572R02 NOVEMBER 2002

Carburetor 55/60 REF. REF NO. QTY. 1 1 1 2 1 3 1 1 4 2 2 3 1 5 2 6 3 7 3 8 3 9 3 10 3 11 6 12 3 13 1 14 1 15 6 16 3 17 3 18 3 19 3 20 3 21 3 22 3 23 12 1 2 24 3 25 26 27

3 3 3 3

TORQUE DESCRIPTION CARBURETOR (60 ELECTRIC — WME-58) CARBURETOR (55/60 MANUAL — WME-57) THROTTLE SHAFT (UPPER) THROTTLE SHAFT (CENTER) WME-58 THROTTLE SHAFT (BOTTOM) THROTTLE SHAFT (UPPER/BOTTOM) THROTTLE SHAFT (CENTER) WME-57 SCREW–throttle adjustment (UPPER/BOTTOM) SPRING–throttle return IDLE NEEDLE SPRING–idle needle GASKET–cover plate COVER PLATE SCREW–cover plate GASKET–flange THROTTLE LEVER WME-58 — Bottom SCREW–oil pump lever SCREW–throttle valve THROTTLE VALVE RETAINING RING FLOAT SHAFT GASKET–nozzle well GASKET–fuel bowl INLET NEEDLE VALVE FLOAT SCREW–fuel bowl FUEL BOWL (UPPER) WME-57 FUEL BOWL (CENTER/BOTTOM) FUEL BOWL (WME-58) PLUG KIT SEAL–bowl drain MAIN FUEL JET (.058 — WME-57) MAIN JET (.060 — WME-58)

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

N·m

18

2.0

6

0.7

18

2.0

25

2.8

14 14

1.6 1.6

FUEL SYSTEM — 3B-5

Attenuator Plate 40/50 A

B 19

17

17 13

19

16

10

9

17 15 17

17 12

9

10

14

11

12 11

17 18 13 17

13 17

7

1 8 20

6

3 2 21

4 5

A = MANUAL 3B-6 — FUEL SYSTEM

22

B = ELECTRIC 90-852572R02 NOVEMBER 2002

Attenuator Plate 40/50 REF. REF NO. QTY. 1 1 2 1 3 1 4 1 5 1 6 3 7 1 8 6 9 1 10 1 11 1 12 1 2 13 1 14 15 16 17 18 19 20 21 22

1 1 1 AR 3 1 1 1 1

TORQUE DESCRIPTION SOUND ATTENUATOR SCREW (M6 x 16) WASHER CAP PLUG BRACKET SEAL BRACKET SCREW (M8 x 100) ARM ROLLER SCREW (M5 x 6) WASHER

lb. in. lb. ft.

N·m

Drive Tight

100

11

Drive Tight

TUBING (4-1/4 IN.)(MANUAL) TUBING (4-1/4 IN.) TUBING (3 IN.) FITTING–Tee

ELECTRIC

TUBING (1 IN.) STA-STRAP GASKET THROTTLE LINK DECAL–Warning (MANUAL) DECAL–Caution DECAL-Caution in gear idle (ELECTRIC)

90-852572R02 NOVEMBER 2002

FUEL SYSTEM — 3B-7

Attenuator Plate 55/60 A

B 18

20

18 17

14 10

11

C

18 16 18

18

20

15

13 12

10

11

18

19 14 18

13 12

14 18

5 4

8 1

6

9 3

7 21 A= MANUAL HOSE ROUTING 3B-8 — FUEL SYSTEM

B = ELECTRIC HOSE ROUTING

2 C = TO ENRICHENER VALVE 90-852572R02 NOVEMBER 2002

Attenuator Plate 55/60 REF. REF NO. QTY. 1 1 2 4 3 1 4 3 5 2 6 6 7 1 8 1 9 1 10 1 11 1 12 1 13 1 2 14 1 15 1 16 1 17 1 18 AR 19 3 20 1 1 21

TORQUE DESCRIPTION SOUND ATTENUATOR SCREW CAP PLUG SEAL SOUND ATTENUATOR PLATE SCREW (M8 x 100) DECAL-Warning (MANUAL) DECAL-Caution DECAL-Full Throttle Timing (ELECTRIC) ARM ROLLER SCREW (M5 x 6) WASHER TUBING (4-1/4 IN.)(MANUAL) TUBING (4-1/4 IN.) TUBING (3 IN.) ELECTRIC FITTING-Tee TUBING (1 IN.) STA-STRAP GASKET THROTTLE LINK DECAL-Caution In Gear Idle

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

N·m

Drive Tight

100

11

Drive Tight

FUEL SYSTEM — 3B-9

Idle Speed Adjustment

Adjustments Idle Mixture Screw Adjustment INITIAL STARTING ADJUSTMENT Turn idle mixture screw in (clockwise) until it seats LIGHTLY—then back-off (each carburetor) the correct number of turns (See Specifications).

1. Adjust engine idle RPM as outlined in Section 2C “Timing/Synchronizing/Adjusting.”

Float Adjustment 1. Remove carburetor as outlined in “Carburetor Removal” in this section. 2. Remove fuel bowl and gasket and check float level using a carburetor scale (gasket removed).

RUNNING QUALITY ADJUSTMENT 2. Position outboard at level trim. With gear case submerged, start outboard and allow to warm up. Throttle outboard back to idle for about one minute. 3. Shift outboard into forward gear. Turn low speed mixture “in” (clockwise) until outboard starts to bog down and misfire. Turn mixture screw out 1/4 turn or more. 52372

9/16 in. (14.29 mm)

a 3. Attach Spring Clip on Inlet Needle to metal float tab and place needle into its seat.

b a

b

c 55883 a — Metal Float Tab b — Spring Clip

4. If necessary, adjust float level by bending metal

tab (on float) to which inlet needle is clipped. a — Top Idle Mixture Screw b — Middle Idle Mixture Screw c — Bottom Idle Mixture Screw

4. Check for too lean mixture on acceleration. 5. DO NOT adjust leaner than necessary to attain reasonable smooth idling. When in doubt, stay on the slightly rich side of the adjustment.

a

a — Bend Tab Here for Float Level Adjustment

3B-10 — FUEL SYSTEM

90-852572R02 NOVEMBER 2002

Main (High Speed) Jet Adjustment The carburetor has a fixed high speed jet. Extreme changes in weather (temperature and humidity) and/ or elevation may result in a too lean or rich fuel mixture at wide-open-throttle, which may require a change in the high speed jet. A smaller size main jet will lean the fuel mixture, and a larger size jet will enrich the fuel mixture.

c

a a — High Speed Jet b — Bowl Drain Plug c — Idle Mixture Screw

90-852572R02 NOVEMBER 2002

b

Jet Orifice Size Chart NOTE: 10-32 Thread Size Jet Orifice Size-inches

Part Number

0.034

19266034

0.036

19266036

0.038

19266038

0.040

19266040

0.042

1399-5315

0.044

1395-7394

0.046

1399-5317

0.048

1395-6246

0.050

1395-6028

0.052

1395-6359

0.054

1399-5225

0.056

1399-5213

0.058

1395-7831

0.060

1395-6487

0.062

1399-4217

0.064

1399-4216

0.066

1399-4215

0.068

1395-6029

0.070

1395-6030

0.072

1395-6207

0.074

1399-3794

0.076

1399-3796

0.078

1395-6680

0.080

1395-6201

0.082

1399-3518

0.084

1399-3517

0.086

1395-5815

0.088

1395-6202

0.090

1395-6247

0.092

1395-5733

0.094

1395-8423

0.096

1399-6249

0.098

1395-7335

FUEL SYSTEM — 3B-11

High Altitude Jet Chart Factory installed main fuel jets are normally adequate for proper performance up to approximately 5000 feet (1524 m) above sea level. Between 2000 feet (609.6 m) and 5000 feet (1524 m) the reduction of the main fuel jet(s) may result in improved performance and fuel economy. Above 5000 feet, however, it is recommended that main jet size be reduced as shown per 1000 feet (304.8 m) in the following chart. RETURN TO LOWER ELEVATION. Carburetor jet changes must be reversed to avoid a lean fuel condition when used at low elevation. 1000 304.8

2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 609.6 914.4 1219.2 1524 1828.8 2133.6 2438.4 2743.2 3048 3352.8 3657.6

0.034

0.034

0.034 0.032

0.032

0.032

0.032

0.032

0.032

0.030

0.030

0.030

0.030

0.036

0.036

0.036 0.034

0.034

0.034

0.034

0.034

0.032

0.032

0.032

0.032

0.032

0.038

0.038

0.038 0.036

0.036

0.036

0.036

0.036

0.034

0.034

0.034

0.034

0.034

0.040

0.040

0.040 0.038

0.038

0.038

0.038

0.038

0.036

0.036

0.036

0.036

0.034

0.042

0.042

0.042 0.040

0.040

0.040

0.040

0.038

0.038

0.038

0.038

0.038

0.036

0.044

0.044

0.044 0.042

0.042

0.042

0.042

0.040

0.040

0.040

0.040

0.038

0.038

0.046

0.046

0.046 0.044

0.044

0.044

0.044

0.042

0.042

0.042

0.042

0.040

0.040

0.048

0.048

0.048 0.046

0.046

0.046

0.046

0.044

0.044

0.044

0.042

0.042

0.042

0.050

0.050

0.050 0.048

0.048

0.048

0.046

0.046

0.046

0.046

0.044

0.044

0.044

0.052

0.052

0.050 0.050

0.050

0.050

0.048

0.048

0.048

0.048

0.046

0.046

0.046

0.054

0.054

0.052 0.052

0.052

0.052

0.050

0.050

0.050

0.048

0.048

0.048

0.048

0.056

0.056

0.054 0.054

0.054

0.054

0.052

0.052

0.052

0.050

0.050

0.050

0.048

0.058

0.058

0.056 0.056

0.056

0.056

0.054

0.054

0.054

0.052

0.052

0.052

0.050

0.060

0.060

0.058 0.058

0.058

0.056

0.056

0.056

0.054

0.054

0.054

0.052

0.052

0.062

0.062

0.060 0.060

0.060

0.058

0.058

0.058

0.056

0.056

0.056

0.054

0.054

0.064

0.064

0.062 0.062

0.062

0.060

0.060

0.060

0.058

0.058

0.058

0.056

0.056

0.066

0.066

0.064 0.064

0.064

0.062

0.062

0.062

0.060

0.060

0.060

0.058

0.058

0.068

0.068

0.066 0.066

0.066

0.064

0.064

0.064

0.062

0.062

0.060

0.060

0.060

0.070

0.070

0.068 0.068

0.068

0.066

0.066

0.064

0.064

0.064

0.062

0.062

0.062

0.072

0.072

0.070 0.070

0.070

0.068

0.068

0.066

0.066

0.066

0.064

0.064

0.062

0.074

0.074

0.072 0.072

0.070

0.070

0.070

0.068

0.068

0.068

0.066

0.066

0.064

0.076

0.076

0.074 0.074

0.072

0.072

0.072

0.070

0.070

0.068

0.068

0.068

0.066

0.078

0.078

0.076 0.076

0.074

0.074

0.074

0.072

0.072

0.070

0.070

0.068

0.068

0.080

0.080

0.078 0.078

0.076

0.076

0.076

0.074

0.074

0.072

0.072

0.070

0.070

0.082

0.082

0.080 0.080

0.078

0.078

0.076

0.076

0.076

0.074

0.074

0.072

0.072

0.084

0.084

0.082 0.082

0.080

0.080

0.078

0.078

0.076

0.076

0.076

0.074

0.074

0.086

0.086

0.084 0.084

0.082

0.082

0.080

0.080

0.078

0.078

0.076

0.076

0.074

0.088

0.088

0.086 0.086

0.084

0.084

0.082

0.082

0.080

0.080

0.078

0.078

0.076

0.090

0.090

0.088 0.088

0.086

0.086

0.084

0.084

0.082

0.082

0.080

0.080

0.078

0.092

0.092

0.090 0.090

0.088

0.088

0.086

0.086

0.084

0.084

0.082

0.082

0.080

0.094

0.094

0.092 0.092

0.090

0.090

0.088

0.088

0.086

0.086

0.084

0.084

0.082

0.096

0.096

0.094 0.094

0.092

0.092

0.090

0.090

0.088

0.086

0.086

0.084

0.084

0.098

0.098

0.096 0.096

0.094

0.092

0.092

0.090

0.090

0.088

0.088

0.086

0.086

Feet Meter Jet Size

3B-12 — FUEL SYSTEM

90-852572R02 NOVEMBER 2002

Fuel System Troubleshooting General Information Problems that are thought to be caused by the fuel system may, in reality, be something completely different. Items, that are shown below, could give the impression that there is a problem in the fuel system. 1. Propeller 2. Spark Plugs 3. Ignition Timing 4. Ignition Spark Voltage 5. Cylinder Compression 6. Reed Valves Typical symptoms and solutions in troubleshooting a fuel system are shown below.

Problem: Engine Floods Possible Cause

Corrective Action

Dirt or debris are preventing inlet needle from seating

Flush out inlet seat and clean inlet needle

Worn inlet needle

Replace

Punctured float

Replace

Incorrect float setting

Reset float

Problem: Engine Runs Too Rich Possible Cause

Corrective Action

Fuel level too high

Reset float to correct level

Carburetor floods

See preceding “Engine Floods”

Idle nozzle air holes plugged

Blow out with compressed air

Restricted air flow

Inspect cowl air inlet and carburetor for obstructions

Main fuel jet loose

Re-tighten jet

Problem: Fuel Blow Back Out Of Carburetor Possible Cause Chipped or broken reeds on reed block

Corrective Action Replace reeds

Problem: Rough Idle Possible Cause Excessive pre-load on reeds

90-852572R02 NOVEMBER 2002

Corrective Action Replace reeds

FUEL SYSTEM — 3B-13

Problem: Engine Turns Over But Will Not Start Or Starts Hard When Cold Possible Cause

Corrective Action

Improper starting procedure used.

Review starting procedure as outlined in “Operation and Maintenance Manual”.

Fuel tank empty or too low. Improperly mixed fuel. Contaminants (water, dirt, etc.) in fuel.

Check fuel in tank and replace or add whichever is necessary.

Fuel tank air vent closed or restricted.

Check air vent on fuel tank. Air vent must be open all the way and free from any contaminants.

Pinched, cut, restricted fuel line or loose fuel line connection.

Inspect all fuel lines and replace as needed. Tighten fuel line connections.

Dirty or restricted fuel filter.

Inspect and replace or clean all fuel filters.

Choke solenoid or enrichment valve not operating.

Inspect solenoid or valve and wiring. Replace as required.

Needle and seat in carburetor that is either stuck open (flooding) or closed (no fuel).

Refer to carburetor disassembly in this section.

Improper carburetor jet, restricted jet or idle mixture screw out of adjustment.

Refer to carburetor adjustments in this section.

Improper float level.

Refer to carburetor adjustments in this section.

Low fuel pump pressure.

Refer to Section 3A “Fuel Pump”.

Defective anti-siphon valve.

Refer to Section 3A “Fuel Pump”.

Needle and seat in carburetor that is either stuck open or closed.

Refer to carburetor adjustments in this section.

Improper float level.

Refer to carburetor adjustments in this section.

Carburetor loose on intake manifold.

Check tightness of carburetor nuts.

Reed block loose or gasket defective.

Using a pressure oil can, apply 2-cycle oil around reed block housing/crankcase housing matching surfaces and carburetor base. If engine RPM changes, tighten bolts/nuts or replace gaskets as required.

Improperly routed or restricted bleed hose(s).

Refer to bleed hose routing in Section 4A “Powerhead”.

Damaged fuel pump diaphragm.

Refer to Section 3A “Fuel Pump”.

Carburetor mixing chamber cover leaking air.

Tighten screws or replace gasket.

Off idle holes plugged.

Blow with compressed air.

Main nozzle or idle nozzle air bleed holes plugged.

Blow with compressed air.

Damaged reeds.

Refer to Section 4A “Powerhead” for reed inspection.

Fuel pick-up outlet tube in fuel tank cracked.

Replace.

Problem: Unable to Reduce Engine RPM to Slow Idle Possible Cause Chipped or broken reeds on reed block.

3B-14 — FUEL SYSTEM

Corrective Action Replace reeds.

90-852572R02 NOVEMBER 2002

Problem: Engine Runs Too Lean Possible Cause

Corrective Action

Carburetor is loose. Air leaks past mixing chamber cover.

Tighten bolts securely. Tighten cover or replace gasket.

Fuel level is too low.

Reset float level.

Clogged high speed jet.

Inspect jet for varnish or debris and clean.

Restricted fuel flow to carburetor.

Check fuel lines and filter(s) for restricted flow.

Incorrect high speed jet.

Refer to main jet chart and replace with proper jet.

Idle mixture set too lean.

Adjust to run richer (turn idle mix screw counterclockwise).

Air leakage into fuel system.

Inspect fuel line connections, hose clamps, fuel pump and fuel outlet tube (located in fuel tank) for loose fittings.

Anti-siphon valve restricting fuel flow.

Refer to Section 3A for checking for restriction of fuel flow caused by anti-siphon valve.

Problems: -Engine Idles Rough And Stalls -Engine Runs Uneven Or Surges -Engine Will Not Accelerate Possible Cause

Corrective Action

Fuel tank air vent closed or restricted.

Air vent must be open all the way and free from restrictions.

A pinched, cut or restricted fuel line; also loose fuel line connection.

Check all fuel lines and replace as needed. Check and tighten all fuel line connections.

A dirty or restricted fuel filter.

Check, replace, or clean all fuel filters.

Restricted filter in fuel tank.

Clean by rinsing in clean lead-free gasoline or kerosene.

Improperly mixed fuel; contaminants (water, dirt, etc,) in fuel.

Check fuel and replace, if necessary.

An inlet needle (in carburetor) that is either stuck open or closed. (A needle, that is stuck open, will cause a flooding condition. A needle, that is stuck closed, will prevent fuel from entering carburetor.)

Remove and replace with new inlet needle.

Incorrect idle mixture adjustment.

Re-adjust.

Carburetor is loose.

Tighten bolts securely.

Chamber cover leaking air.

Tighten or replace gasket.

Off idle holes plugged.

Blow out with compressed air.

Main nozzle or idle nozzle air bleed holes plugged.

Blow out with compressed air.

Improper main jet or restricted jet.

Clean or replace with proper jet (refer to “Main Jet Chart”).

Damaged reed(s).

Inspect reeds as outlined in Section 4A.

A crack in the fuel pick-up outlet tube (located in fuel Replace. tank).

90-852572R02 NOVEMBER 2002

FUEL SYSTEM — 3B-15

55/60

Removal/Installation

Attenuator cover and screw.

40/50 Attenuator cover and screw.

b

55041

55148

a

a

a b

a — Screws (4) b — Attenuator Cover

a — Screw b — Attenuator Cover

Carburetor mounting bolts.

Carburetor mounting bolts. 55172

50527

a

a a

a — Carburetor Bolts (6)

3B-16 — FUEL SYSTEM

a a

a — Carburetor Bolts (6)

90-852572R02 NOVEMBER 2002

5. Inspect inlet needle valve. Replace if end is worn or grooved.

Inspection CAUTION Do not use steel wire for cleaning the jets as this may enlarge the jet diameters and seriously affect performance. Use a petroleum based solvent for cleaning and blow out all passages with compressed air.

28375

1. Inspect carburetor body. Replace if cracked or damaged.

2. Inspect float. Replace if cracked or damaged.

55883

3. Inspect idle mixture screw. Replace if bent or damaged.

53673

4. Inspect main jet. Clean if contaminated. 53672

90-852572R02 NOVEMBER 2002

FUEL SYSTEM — 3B-17

Enrichment System Electric Enrichener Valve The enrichener system provides the engine with an extra fuel charge for ease of cold engine starting. The system consists of an electrically operated enrichener valve which is connected by a hose to the intake manifold. Fuel is pressure fed to the valve from the float bowl of the top carburetor via a hose. When the ignition key is turned to the “on” position and pushed in (and held in) current is sent to the valve causing it to open, which allows fuel to pass thru. The fuel passes thru a hose and is supplied to the engine via fitting located in the intake manifold of the middle carburetor. When the key (or choke button) is released, the valve will return to the closed position. The valve can be operated manually by pressing and holding the button located at the bottom of the valve. ENRICHENER VALVE FUEL FLOW DIAGRAM

b

c

a

a — Carburetor b — Enrichment Valve c — Intake Manifold

3B-18 — FUEL SYSTEM

90-852572R02 NOVEMBER 2002

ENRICHENER VALVE TEST IMPORTANT: Use of enrichener if engine is warm could result in engine flooding

Push Key (Or Choke Button) In, Valve Should Click.

Click

No Click Check for battery voltage to yellow/black wire at terminal block on engine when key (or choke button) is pushed in.

Squeeze primer bulb until bulb is firm. Remove lower hose from fitting on enrichener valve. Place a container under valve, then push key (or choke button). Check for fuel flow from fitting.

Battery Voltage Indicated Check for loose or corroded connection between yellow/black wire and black wire (under same screw at terminal block). Check that other black wire at terminal block is properly grounded. Repair connections(s) as necessary, then push key (or choke button) in. If enrichener valve DOES NOT click, replace valve.

No Voltage Indicated Check for open in circuit, yellow/black wire between key switch (or choke button) and terminal block.

Fuel Flow from Fitting Valve is O.K. Check hoses and fittings from valve to carburetors for leaks or obstructions.

No Fuel Flow from Fitting Remove upper hose from fitting on enrichener valve. If fuel flows from hose, replace valve. If not, check hose and carburetor fittings for leaks or obstructions.

90-852572R02 NOVEMBER 2002

FUEL SYSTEM — 3B-19

Manual Primer Button

CAUTION

The manual starting primer bulb is designed to provide a rich fuel mixture to the engine during cold start conditions. When the primer bulb is pressed in, fuel is forced from the primer bulb into the intake manifold via hose and fitting on the side of the manifold. When the primer bulb is released, a suction is created in the bulb and fuel is drawn into the bulb through a hose from the carburetor float bowl.

All safety precautions should be adhered to when testing the primer bulb system. Fuel should be directed into suitable container and all flammable materials extinguished and sources of spark turned off. PRIMER BUTTON TEST Removing the primer hose from the intake manifold and pressing the primer bulb will determine if the primer is working properly as fuel should be expelled from the hose whenever the primer bulb is pressed.

PRIMER BUTTON FUEL FLOW DIAGRAM

b

d

a

c

f

e

a b c d e f

—

Primer Cover Primer Check Valve Primer Button Starter Handle Rest Carburetor (3) Intake Manifold

3B-20 — FUEL SYSTEM

90-852572R02 NOVEMBER 2002

FUEL SYSTEM

3 C

OIL INJECTION

Table of Contents Page Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-1 Oil Injection Components 40/50 . . . . . . . . . . . . 3C-2 Oil Injection Components 60 . . . . . . . . . . . . . . . 3C-4 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . 3C-6 Oil Flow Diagram . . . . . . . . . . . . . . . . . . . . . . 3C-6 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-7 Carburetor/Oil Pump Synchronization . . . . 3C-7 Bleeding Air From Oil Injection System . . . 3C-7 Bleeding Air From Oil Pump Inlet Hose . . . . . . . . . . . . . . . . . 3C-7 Bleeding Air From Oil Pump Outlet Hose . . . . . . . . . . . . . . . 3C-7 Check Operation of the Oil Injection System (Engine Running) . . . . . . . . . . . . . . . 3C-8 Oil Pump Volume (Flow) Test . . . . . . . . . 3C-8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-8 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . 3C-9 Installing Drive Gear (For Oil Injection Pump) Onto Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . 3C-10 Engine Mounted Oil Reservoir . . . . . . . . . . . . 3C-10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-11

3C-0 — FUEL SYSTEM

90-852572R02 NOVEMBER 2002

Specifications Recommended Oil

OIL INJECTION

Oil Tank Capacity/Approximate Time Reserve Capacity/Approximate. Time Oil Output With Engine RPM of 1500 and Oil Pump @ W.O.T.* Model 40 Model 50/60

TC-W II or TC-W3 2 Cycle Outboard Oil 3.0 qts. (2.8 L) / 7.0 hours 14.5 fl. oz. (0.43 L) / 0.5 hour

15.0 ± 3.0 cc of oil in 10 minutes 22.0 ± 3.0 cc of oil in 10 minutes

*See Checking Oil Pump Volume Flow in this section for proper procedures for checking volume flow.

90-852572R02 NOVEMBER 2002

FUEL SYSTEM — 3C-1

Oil Injection Components 40/50 4

4

22

25

18

23

24 26 20 21 5

6 7

27

3 8 9 1 2

19

4

10

17

13 11

15 14

12 16

4

Needle Bearing Assembly Lubricant

3C-2 — FUEL SYSTEM

90-852572R02 NOVEMBER 2002

Oil Injection Components 40/50 REF. REF NO. QTY. 1 2 2 2 3 2 4 1 5 1 6 1 7 1 8 1 9 1 10 1 11 2 12 1 13 1 14 1 15 1 16 1 17 1 18 19 20 21 22 23 24 25 26 27

1 1 1 1 2 1 1 1 1 1

TORQUE DESCRIPTION BUSHING–Flanged GROMMET SCREW (M6 x 25) OIL TANK ASSEMBLY CAP ASSEMBLY TETHER NUT–Push VENT ASSEMBLY VALVE SEAL STA–STRAP GROMMET SWITCH SCREW (.164-18 x .375) WASHER SPACER TUBING (12 IN.) OIL INJECTION PUMP (40) OIL INJECTION PUMP (50) O RING O RING SCREW (M5 x 20) DRIVEN GEAR BEARING ASSEMBLY BUSHING (FLANGED) BUSHING LINK

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

60

N·m

6.8

Drive Tight

60

6.8

FUEL SYSTEM — 3C-3

Oil Injection Components 55/60 4 4

20

17 21

18

19

16

2

15 3 4

14

23 6 9

5

7

1 8

11 22

10 13 12

4

Needle Bearing Assembly Lubricant

3C-4 — FUEL SYSTEM

90-852572R02 NOVEMBER 2002

Oil Injection Components 55/60 REF. REF NO. QTY. 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 10 1 11 1 12 1 13 1 14 1 15 1 16 1 17 2 18 1 19 1 20 1 21 1 22 1 23 1

TORQUE DESCRIPTION OIL TANK CAP ASSEMBLY TETHER PUSH NUT SEAL VENT VALVE GROMMET BOOT BOOT SWITCH SCREW (.164-18 X .375) WASHER OIL INJECTION PUMP O-RING O-RING SCREW DRIVEN GEAR BEARING ASSEMBLY BUSHING (FLANGED) BUSHING HOSE (6 IN.) LINK

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

N·m

Drive Tight

60

6.8

FUEL SYSTEM — 3C-5

The major components of the oil injection system are an oil tank, oil pump, and low oil warning system.

A link rod is connected between the throttle linkage and oil pump lever. When the throttle position is changed, the link rod rotates the oil pump valve, which changes the fuel/oil ratio.

The oil tank is attached to the powerhead and holds oil for delivery to the oil pump. Oil is gravity fed to the oil pump via a hose. The oil pump injects oil into the fuel line prior to the fuel pump and is driven by the crankshaft.

The oil tank is equipped with a low oil sensor and a magnetic float. When oil level in oil tank drops to approximately 14.5 fl. oz. (435 mL), the magnetized float will complete the circuit between the low oil sensor leads, causing the warning horn to sound.

Theory of Operation

Oil Flow Diagram b a e c d

f g h i

j

a b c d e f

—

Oil Reservoir Fill Cap Oil Level Sight Gauge Carburetor Fuel Filter Fuel Pump

3C-6 — FUEL SYSTEM

g h i j

—

2 PSI Check Valve Oil Pump Relief Fitting Oil Pump Inlet Fuel Connector

90-852572R02 NOVEMBER 2002

BLEEDING AIR FROM OIL PUMP OUTLET HOSE

Adjustments

1. Purge air from outlet hose by running engine (on 50:1 gasoline/oil mixture in fuel tank) at idle speed until no air bubbles are present in outlet hose.

Carburetor/Oil Pump Synchronization

c

1. Set carburetor linkage at idle position. Adjust length of link rod so stamped mark of oil pump body aligns with stamped mark of oil pump lever.

c

a

b

d

b 52047

a — Bleed Screw b — Inlet Hose c — Outlet Hose

a a b c d

—

Link Rod Oil Pump Body Stamped Mark Oil Pump Lever Stamped Mark Bleed Screw

Bleeding Air From Oil Injection System CAUTION If air exists in either oil pump hose (inlet or outlet), the air MUST BE bled from hose(s) or engine damage may occur.

BLEEDING AIR FROM OIL PUMP INLET HOSE With engine not running, place a shop towel below oil pump. Loosen bleed screw three to four turns and allow air bubbles to exit inlet hose. Torque bleed screw to 25 lb. in. (2.8 N·m). This procedure also allows oil pump to fill with oil.

90-852572R02 NOVEMBER 2002

FUEL SYSTEM — 3C-7

Check Operation of the Oil Injection System (Engine Running)

Troubleshooting

OIL PUMP VOLUME (FLOW) TEST

2. Inspect the oil pump inlet hose for air bubbles. If air exists, place a shop towel below the oil pump and loosen bleed screw four turns. Allow oil to flow out of the bleed hole until air is removed from the hose.

WARNING The input fuel line TEE fitting from which the oil line was removed MUST BE CAPPED OFF to prevent fuel leakage while the engine is running.

NOTE: The following specifications are determined with the outboard running off a remote fuel supply with pre-mix fuel. The oil pump output hose (clear) must be disconnected from the input fuel line TEE fitting and directed into a graduated container. The input fuel line TEE fitting from which the oil line was removed MUST BE CAPPED OFF to prevent fuel leakage while the engine is running.

1. Fill tank with recommended oil.

3. Inspect the oil pump outlet oil hose for air bubbles. If air exists, disconnect link rod from oil pump. Start engine and run at 1000 to 1500 RPM. Rotate (and hold) the pump arm full counterclockwise until the air is purged out of the hose.

b

c a a c

b

e 52047

a — Bleed Screw b — Inlet Hose c — Outlet Hose

a b c d e

—

d

Inlet Hose Outlet Hose Bleed Screw Link Rod Pump Arm

40/50 H.P. Flow Specifications: @ 1500 RPM with oil pump link arm DISCONNECTED and pump arm rotated FULL COUNTERCLOCKWISE and HELD AGAINST PUMP CASTING 15.0cc ± 3.0 cc of oil in 10 minutes. 60 H.P. Model Flow Specifications: @ 1500 RPM with oil pump link arm DISCONNECTED and pump arm rotated FULL COUNTERCLOCKWISE and HELD AGAINST PUMP CASTING 22.0cc ± 3.0 cc of oil in 10 minutes.

3C-8 — FUEL SYSTEM

1. Check oil level in oil tank. If oil level is approximately 14.5 fl. oz. (435 ml) or less, the problem is low oil level. Add oil to oil tank.

NOTE: There is a safety reserve of oil left in the oil tank after the low oil warning is sounded that allows enough oil for approximately 0.5 hours of full throttle operation. 2. If there is more than approximately 14.5 fl. oz. (435 ml) of oil remaining in tank, then the problem may be a faulty low oil warning sensor. Refer to troubleshooting chart following.

90-852572R02 NOVEMBER 2002

Troubleshooting Chart

Problem: Warning Horn Stays On When Ignition Key is Turned to “ON” Position (Engine Cold).

Possible Cause Faulty Engine overheat sensor.

Corrective Action If warning horn sounds a continuous “beep”, the engine overheat sensor may be faulty. Disconnect tan/blue overheat sensor lead at bullet connection. Turn ignition key to “ON” position. If horn stops sounding, the engine overheat sensor is faulty.

Problem: Warning Horn Sounds (Continuous Beep) When Engine is Running and Oil Tank is Full. Possible Cause Defective low oil sensor (located in bottom of oil tank).

90-852572R02 NOVEMBER 2002

Corrective Action Disconnect both low oil sensor leads (blue) at bullet connections. Connect an ohmmeter between sensor leads. There should be no continuity through sensor. If continuity exists, sensor is faulty.

FUEL SYSTEM — 3C-9

Installing Drive Gear (For Oil Injection Pump) Onto Crankshaft 1. Refer to Section 4A (Powerhead) for proper disassembly of components. 2. Inspect gear teeth for damage. Replace gear if any of these problems exist: *Excessive Wear *Cracks in hub or rear (DO NOT mistake plastic flow lines for cracks) *Distorted Teeth

Engine Mounted Oil Reservoir Removal 1. Disconnect battery cables. 2. Remove bolts securing oil tank. 40/50 HP MODEL a. Remove bolts (2).

b

a

a a — Bolts (2)

a 51084

60 HP MODEL b. Remove starter/oil bracket.

a — Oil Drive Gear b — Key

b

a

3. Refer to section 4A (Powerhead) for proper re-assembly of components.

51080

a — Starter Bracket b — Bolt

3C-10 — FUEL SYSTEM

90-852572R02 NOVEMBER 2002

3. Disconnect oil hose and low oil sensor wires (BLUE) at bullet connectors. Remove oil reservoir.

Installation 1. Install oil level sensor and secure in place.

NOTE: 40/50 H.P. version shown.

b a

51204

55320

a — Oil Level Sensor b — Screw (Tighten Securely)

b 2. Connect sensor oil level wires (Light Blue/Black) at bullet connectors. Re-connect oil hose and secure in place with sta-strap. Install reservoir to outboard.

a a — Oil Tank Wires (Light Blue/Black) b — Oil Hose

NOTE: 40/50 H.P. version shown.

4. Remove oil level sensor from oil reservoir.

CAUTION Oil level sensor is FRAGILE. Handle with care.

55320

a b

b a 51204

a — Screw b — Oil Level Sensor

90-852572R02 NOVEMBER 2002

a — Oil Level Sensor Wires b — Oil Hose

FUEL SYSTEM — 3C-11

3. Install starter/oil tank bracket.

60 HP MODEL b. Install starter/oil bracket. Torque to 16.5 lb. ft. (22.3 N·m).

40/50 HP MODEL a. Install bolts (2). Torque to 60 lb. in. (6.8 N·m).

a

b

a

a

51080

a — Starter Bracket b — Bolt Torque to 16.5 lb. ft. (22.3 N·m) a — Bolts (2) Torque to 60 lb. in. (6.8 N·m)

4. Re-connect battery cables.

3C-12 — FUEL SYSTEM

90-852572R02 NOVEMBER 2002

FUEL SYSTEM

3 D Emission Control 967 Information cc This engine conforms to 1998 Model Year U.S. EPA regulations for marine SI engines. Refer to Owners Manual for required maintenance.

Exhaust Emission Control Systems: Fuel/Oil Engine Lubricants: TC-Wll or Ratio: Not TC-W3 2 Cycle Outboard Oil Adjustable ECM Controlled Family: xxxxxxx.xxxx

1998 PART # 37–XXXXX XX

This engine is certified to operate on regular 87 octane unleaded fuel (R+M)/2 Idle Speed (in gear): XXX RPM Timing: Spark Plug: NGK BP8H-N-10

Gap: 0.040 in.

FEL: 32.20 GM/KW-HR

40-60 2-Stroke JAN

FEB

MAR

APR

EMISSIONS

MAY

JUNE

JULY

AUG

SEP

OCT

NOV

DEC

Table of Contents Exhaust Emissions Standards . . . . . . . . . . . What Are Emissions? . . . . . . . . . . . . . . . . Hydrocarbons – HC . . . . . . . . . . . . . . . . . . Carbon Monoxide – CO . . . . . . . . . . . . . . Oxides of Nitrogen — NOx . . . . . . . . . . . . . Controlling Emissions . . . . . . . . . . . . . . . . Stoichiometric (14.7:1) Air/Fuel Ratio . . . Outboard Hydrocarbon Emissions Reductions . . . . . . . . . . . . . . . . . . Stratified Vs Homogenized Charge . . . . . . . Homogenized Charge . . . . . . . . . . . . . . . . Stratified Charge . . . . . . . . . . . . . . . . . . . . Emissions Information . . . . . . . . . . . . . . . . . . Manufacturer’s Responsibility . . . . . . . . . Dealer Responsibility . . . . . . . . . . . . . . . . . Owner Responsibility . . . . . . . . . . . . . . . . . EPA Emission Regulations . . . . . . . . . . . . Certification Label . . . . . . . . . . . . . . . . . . . EPA Information Decal Location . . . . . . .

FUEL SYSTEM — 3D-0

Page 3D-1 3D-1 3D-1 3D-1 3D-1 3D-1 3D-1 3D-2 3D-3 3D-3 3D-3 3D-4 3D-4 3D-4 3D-4 3D-4 3D-5 3D-6

90-852572R02 NOVEMBER 2002

Exhaust Emissions Standards Through the Environmental Protection Agency (EPA), the federal government has established exhaust emissions standards for all new marine engines sold in the U.S..

What Are Emissions? Emissions are what comes out of the exhaust system in the exhaust gas when the engine is running. They are formed as a result of the process of combustion or incomplete combustion. To understand exhaust gas emissions, remember that both air and fuel are made of several elements. Air contains oxygen and nitrogen among other elements; gasoline contains mainly hydrogen and carbon. These four elements combine chemically during combustion. If combustion were complete, the mixture of air and gasoline would result in these emissions: water, carbon dioxide and nitrogen, which are not harmful to the environment. However combustion is not usually complete. Also, potentially harmful gases can be formed during and after combustion. All marine engines must reduce the emission of certain pollutants, or potentially harmful gases, in the exhaust to conform with levels legislated by the EPA. Emissions standards become more stringent each year. Standards are set primarily with regard to three emissions: hydrocarbons (HC), carbon monoxide (CO) and oxides of nitrogen (NOx).

Hydrocarbons – HC Gasoline is a hydrocarbon fuel. The two elements of hydrogen and carbon are burned during combustion in combination with oxygen. But they are not totally consumed. Some pass through the combustion chamber and exit the exhaust system as unburned gases known as hydrocarbons.

Carbon Monoxide – CO Carbon is one of the elements that make up the fuel burned in the engine along with oxygen during the combustion process. If the carbon in the gasoline could combine with enough oxygen (one carbon atom with two oxygen atoms), it would come out of the engine in the form of carbon dioxide (CO2).

90-852572R02 NOVEMBER 2002

CO2 is a harmless gas. Carbon often combines with insufficient oxygen (one carbon atom with one oxygen atom). This forms carbon monoxide, CO. Carbon monoxide is the product of incomplete combustion and is a dangerous, potentially lethal gas.

Oxides of Nitrogen — NOx NOx is a slightly different byproduct of combustion. Nitrogen is one of the elements that makes up the air going into the engine. Under extremely high temperatures, it combines with oxygen to form oxides of nitrogen (NOx). This happens in the engine’s combustion chambers when temperatures are too high. NOx itself is not harmful, but when exposed to sunlight it combines with unburned hydrocarbons to create the visible air pollutant known as smog. Smog is a serious problem in California as well as many other heavily populated areas of the United States.

Controlling Emissions There are two principle methods of reducing emissions from a two-stroke-cycle marine engine. The first method is to control the air/fuel ratio that goes into the combustion chamber. The second is to control the time when this air/fuel mixture enters the combustion chamber. Timing is important, to prevent any unburned mixture from escaping out of the exhaust port.

Stoichiometric (14.7:1) Air/Fuel Ratio In the search to control pollutants and reduce exhaust emissions, engineers have discovered that they can be reduced effectively if a gasoline engine operates at an air/fuel ratio of 14.7:1. The technical term for this ideal ratio is stoichiometric. An air/fuel ratio of 14.7:1 provides the best control of all three elements in the exhaust under almost all conditions. The HC and CO content of the exhaust gas is influenced significantly by the air/fuel ratio. At an air/ fuel ratio leaner than 14.7:1, HC and CO levels are low, but with a ratio richer than 14.7:1, they rise rapidly. It would seem that controlling HC and CO by themselves might not be such a difficult task; the air/fuel ratio only needs to be kept leaner than 14.7:1. However, there is also NOx to consider.

FUEL SYSTEM — 3D-1

As the air/fuel ratio becomes leaner, combustion temperatures increase. Higher combustion temperatures raise the NOx content of the exhaust. But, enrichening the air/fuel ratio to decrease combustion temperatures to reduce NOx also increases HC and CO, as well as lowering fuel economy. So the solution to controlling NOx — as well as HC and CO — is to keep the air/fuel ratio as close to 14.7:1 as possible.

Outboard Hydrocarbon Emissions Reductions 8 1/3%
PER YEAR OVER 9 MODEL YEARS 120

100

80

60

40

20

0

96

97

FUEL SYSTEM — 3D-2

98

99

2000

01

02

03

04

05

06

07

08

90-852572R02 NOVEMBER 2002

Stratified vs Homogenized Charge DFI engines use a stratified charge inside the combustion chamber to aid in reducing emissions. All other models use a homogenized charge. The difference between the two is:

Homogenized Charge

Stratified Charge

A homogenized charge has the fuel/air particles mixed evenly throughout the cylinder. This mixing occurs inside the carburetor venturi, reed blocks and crankcase. Additional mixing occurs as the fuel is forced through the transfer system into the cylinder.

A stratified charged engine pulls only 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. Surrounding 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.

The homogenized charge is easy to ignite when the air/fuel ratio is approximately 14.7:1.

A stratified charge is hard to ignite, the fuel/air bubble is not evenly mixed at 14.7:1 and not easily ignited.

90-852572R02 NOVEMBER 2002

FUEL SYSTEM — 3D-3

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 certification decal/emissions control information label, showing emission levels and engine specifications 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 decal, attention must be given to any adjustments that are made that effect 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 adjustments.

EPA Emission Regulations All new 1998 and later outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors. This certification is contingent on certain adjustments being set to factory standards. For this reason, the factory procedure for servicing the product must be strictly followed and, whenever practicable, returned to the original intent of the design. The responsibilities listed above are general and in no way a complete listing of the rules and regulations pertaining to the EPA laws on exhaust emissions for marine products. For more detailed information on this subject, you may contact the following locations: VIA U.S. POSTAL SERVICE: Office of Mobile Sources Engine Programs and Compliance Division Engine Compliance Programs Group (6403J) 401 M St. NW Washington, DC 20460 VIA EXPRESS or COURIER MAIL: Office of Mobile Sources Engine Programs and Compliance Division Engine Compliance Programs Group (6403J) 501 3rd St. NW Washington, DC 20001 EPA INTERNET WEB SITE: http:/www.epa.gov/omswww

Owner Responsibility The owner/operator is required to have engine maintenance performed to maintain emission levels within prescribed certification standards. The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications. Single engine exceptions may be allowed with permission from the EPA for racing and testing.

FUEL SYSTEM — 3D-4

90-852572R02 NOVEMBER 2002

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 certification label and is not representative of any one model.

h a

Emission Control 967 Information cc This engine conforms to 1998 Model Year U.S. EPA regulations for marine SI engines. Refer to Owners Manual for required maintenance.

n m

Exhaust Emission Control Systems: Fuel/Oil Engine Lubricants: TC-Wll or Ratio: Not TC-W3 2 Cycle Outboard Oil Adjustable ECM Controlled Family: WM9XM.323220

1998

This engine is certified to operate on regular 87 octane unleaded fuel (R+M)/2

d

Timing: Spark Plug: NGK BP8H-N-10

Gap: 0.040 in.

FEL: 32.20 GM/KW-HR

40-60 2-Stroke FEB

MAR

k

a b c d e f g h i j

—

APR

MAY

JUNE

j

Spark Ignition (SI) Model Year of Engine and Production Decal Part Number Type and Octane of fuel (Recommended Fuel) Timing Specifications When Adjustable Spark Plug Gap Recommended Spark Plug For Best Engine Performance Engine Horsepower Rating Engine Displacement Valve Clearance (Four Stoke Engines Only) Recommended Oil/Fuel Ratio For Best Engine Performance and Minimal Emissions k — Month of Production (Boxing Month Will Be Punched) l — FEL: Represents (Mercury Marine) Statement of the Maximum Emissions Output For the Engine Family

90-852572R02 NOVEMBER 2002

c

Idle Speed (in gear): XXX RPM

l JAN

b

JULY

AUG

SEP

OCT

NOV

e f g

DEC

i m — Family Example:

W M9X M 03.0 2 2 0

Model Year Regulation Application Unspecified W=1998 M=Marine 1=PWC X=1999 2=OB Manufacturer Displacement Technology type Mercury Marine Liter 1=Existing Cubic Inch 2=New n — Engine Lubricants Recommended by the Manufacturer

FUEL SYSTEM — 3D-5

EPA Information Decal Location Model

Service Part No.

Location on Engine

2003 Merc/Mar 965cc, 2-Stroke (40-60 H.P.)

37-804665A03

Top Cowl Inlet Duct

2002 Merc/Mar 965cc, 2-Stroke (40-60 H.P.)

37-804665A02

Top Cowl Inlet Duct

2001 Merc/Mar 965cc, 2-Stroke (40-60 H.P.)

37-804665A01

Top Cowl Inlet Duct

2000 Merc/Mar 965cc, 2-Stroke (40-60 H.P.)

37-804665A00

Top Cowl Inlet Duct

1999 Merc/Mar 965cc, 2-Stroke (40-60 H.P.)

37-856985A7

Top Cowl Inlet Duct

1998 Merc/Mar 965cc, 2-Stroke (40-60 H.P.)

37-855577 8

Top Cowl Inlet Duct

FUEL SYSTEM — 3D-6

90-852572R02 NOVEMBER 2002

POWERHEAD

4

Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Block And Crankcase 40/50 . . . . . Cylinder Block And Crankcase 40/50 . . . . . Cylinder Block And Crankcase 55/60 . . . . . Cylinder Block And Crankcase 55/60 . . . . . Induction Manifold And Reed Block 40/50 . Induction Manifold And Reed Block 55/60 . Induction Manifold And Reed Block 55/60 . Crankshaft, Pistons And Connection Rods . Crankshaft, Pistons And Connecting Rods . Torque Sequence . . . . . . . . . . . . . . . . . . . . . . Crankcase Cover . . . . . . . . . . . . . . . . . . . . Lower End Cap . . . . . . . . . . . . . . . . . . . . . . Intake/Reed Block Manifold Bolts . . . . . . Water Circulation . . . . . . . . . . . . . . . . . . . . . . . Thermostat Test . . . . . . . . . . . . . . . . . . . . . Temperature Switch Test 1905F (885C) . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . Powerhead Removal . . . . . . . . . . . . . . . . . . . Powerhead Disassembly . . . . . . . . . . . . . . . . Removing Engine Components . . . . . . . . Crankshaft Disassembly . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . . . . . . . Cylinder Block and Crankcase Cover . . . Check Valves . . . . . . . . . . . . . . . . . . . . . . . Piston and Piston Rings . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Rods . . . . . . . . . . . . . . . . . . . . Reed Blocks . . . . . . . . . . . . . . . . . . . . . . . . Reassembly and Installation . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . Assembling Rod to Piston . . . . . . . . . . . . Piston Ring Installation . . . . . . . . . . . . . . . Crankshaft Installation . . . . . . . . . . . . . . . . Installing Rods to Crankshaft . . . . . . . . . . Connecting Rod Cap Alignment . . . . . . . Crankcase Cover to Block . . . . . . . . . . . . Lower End Cap . . . . . . . . . . . . . . . . . . . . . . Intake/Reed Block Manifold Installation . Thermostat Cover Installation . . . . . . . . . Install Remaining Engine Components . Powerhead Installation . . . . . . . . . . . . . . . . . . Test Run Procedure . . . . . . . . . . . . . . . . . . . . Important Information . . . . . . . . . . . . . . . . . . .

4-0 — POWERHEAD

Page 4-1 4-2 4-4 4-5 4-6 4-7 4-8 4-10 4-11 4-12 4-13 4-14 4-14 4-14 4-14 4-15 4-16 4-16 4-17 4-17 4-19 4-19 4-21 4-24 4-24 4-25 4-25 4-27 4-27 4-28 4-29 4-29 4-30 4-32 4-33 4-35 4-35 4-36 4-36 4-37 4-38 4-39 4-39 4-42 4-42

90-852572R02 NOVEMBER 2002

Specifications CYLINDER BLOCK STROKE

Type Displacement

3 Cylinder-2 Cycle-Loop Charged 59 cu. in. (967 cc)

Length

2.796 in. (71.018 mm)

CYLINDER BORE

Diameter Taper/Out of Round Maximum Bore Type

2.993 in. (76.022 mm) 0.003 in. (0.076 mm) Cast Iron

PISTON

Type Standard Diameter 0.015 in. (0.381 mm) Oversize

Aluminum 2.988 in. (75.895 mm) 3.003 in. (76.276 mm)

REEDS

Reed Stand Open (Max.) Reed Stop (Max.) 40 50/55/60 Reed Thickness

TEMPERATURE SWITCH

90-852572R02 NOVEMBER 2002

Temperature Normal 190°F ± 8° (88°C ± 4°C) 170°F ± 8° (77°C ± 4°C)

0.020 in. (0.50 mm) 0.090 in. (2.286 mm) Not Adjustable 0.010 in. (0.254 mm) Open — No Continuity Closed — Full Continuity Open — No Continuity

POWERHEAD — 4-1

6. Piston Ring Expander 91-24697

Special Tools 1. Lifting Eye 91-90455

2. Flywheel Holder 91-52344

7. Lock-ring Removal Tool 91-52952T1

8. Piston Pin Tool 91-74607A3 73790

3. Flywheel Puller 91-73687A2

9. Driver Head 91-55919

4. Powerhead Stand 91-25821T1 (55/60) 10. Universal Puller Plate 91-37241

5. Powerhead Stand 91-827001A1 (40/50)

4-2 — POWERHEAD

90-852572R02 NOVEMBER 2002

11. Snap Ring Pliers 91-24283

12. Piston Lock Ring Installer 91-77109A3

13. Torque Wrench (0-200 lb. ft.) Obtain Locally

14. Torque Wrench (0-150 lb. in.) 91-66274

15. Compression Tester 91-29287

54965

90-852572R02 NOVEMBER 2002

POWERHEAD — 4-3

Cylinder Block And Crankcase 40/50 33

23

24 9

36

20

17

35 34

26

27

14

28

15

25

31

1

32 30 21

33

29 9

22 9

19

9

18

6

13

17

8

19

7

5 11 9

16

18

12

9

12

10 41

2

39 40

37

4

3 4

9

1

38

13 2 14

3 4

12

A

11

5

6 10

4

Needle Bearing Assembly Lubricant

9

Loctite 567 PST Pipe Sealant

12

Loctite Master Gasket

33

Loctite 680 Retaining Compound

8

9 7

A = Torque Sequence 4-4 — POWERHEAD

90-852572R02 NOVEMBER 2002

Cylinder Block And Crankcase 40/50 REF. REF NO. QTY. 1 1 2 8 3 6 4 1 5 1 6 1 7 2 8 2 9 1 10 1 11 1 12 1 13 3 14 1 15 2 16 1 17 2 18 2 19 2 1 20 1 21 1 22 1 23 1 24 4 25 1 26 1 27 1 28 1 29 1 30 1 31 1 32 1 33 1 34 2 35 2 36 2 37 1 38 1 39 1 40 2 41 2

TORQUE DESCRIPTION CYLINDER BLOCK SCREW (M8 x 80) SCREW (M8 x 30) CHECK VALVE HOSE (15 IN.) CHECK VALVE (PRESS-IN) CARRIER ASSEMBLY CHECK VALVE ADJUSTING SCREW JAM NUT CAP DOWEL PIN (LOCATING) DOWEL PIN (BEARING RACE) GASKET STUD PIPE PLUG (3/8-18) PIPE PLUG ELBOW CHECK VALVE COVER (S/N- 0G662183 & UP) COVER (S/N-OG662182 & BELOW) LIFTING EYE MANUAL SCREW (M8 x 25) SERIAL NUMBER PLUG SCREW (M8 x 25) CARRIER THERMOSTAT (110 Degrees) SEAL (S/N- 0G662183 & UP) O RING (S/N-0G662182 & BELOW) TEMPERATURE SENDER RETAINER SCREW WASHER ELBOW WASHER WASHER WING NUT ELECTRIC FITTING COVER O-RING MANUAL SCREW (M5 x 20) HOSE (5-1/2 IN.)

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

N·m

18.4 18.4

24.9 24.9

18.4

24.9

18.4

24.9

Drive Tight

Hand Tight

60

6.8

POWERHEAD — 4-5

Cylinder Block And Crankcase 55/60 26

22 29

14

28 45 27

12

4

Needle Bearing Assembly Lubricant

9

Loctite 567 PST Pipe Sealant

12

Loctite Master Gasket

33

Loctite 680 Retaining Compound

A = Torque Sequence

4-6 — POWERHEAD

90-852572R02 NOVEMBER 2002

Cylinder Block And Crankcase 55/60 REF. REF NO. QTY. 1 1 2 8 3 6 4 1 5 1 6 1 7 2 8 2 9 1 10 1 11 1 12 1 13 3 14 1 15 2 16 1 17 1 18 1 19 1 20 2 21 2 1 22 1 23 1 24 1 25 1 26 4 27 1

TORQUE DESCRIPTION CYLINDER BLOCK SCREW (M8 x 80) SCREW (M8 x 30) CHECK VALVE HOSE (15 IN.) CHECK VALVE (PRESS-IN) CARRIER ASSEMBLY CHECK VALVE ADJUSTING SCREW (M6 x 55) JAM NUT CAP DOWEL PIN (LOCATING) DOWEL PIN (BEARING RACE) GASKET STUD PIPE PLUG (3/8-18) PIPE PLUG (ELECTRIC) PIPE PLUG (MANUAL) PIPE PLUG ELBOW CHECK VALVE COVER (S/N- 0G662183 & ABOVE) COVER (S/N-0G662182 & BELOW) LIFTING EYE (MANUAL) SCREW (M8 x 25) (MANUAL) DECAL — SERIALIZATION SCREW (M8 x 25) CARIER (ELECTRIC)

28 29

1 1

THERMOSTAT (110 °F) (ELECTRIC) O-RING (S/N 0G662182 & BELOW)

30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

1 1 1 1 2 2 2 1 1 1 1 1 2 2 1 1

TEMPERATURE SENDER RETAINER SCREW WASHER WASHER (ELECTRIC) WASHER (ELECTRIC) WING NUT (ELECTRIC) ELBOW (ELECTRIC) ELBOW (MANUAL) FITTING (ELECTRIC) COVER (MANUAL) O-RING (MANUAL) SCREW (M5 x 20) (MANUAL) HOSE (5-1/2 IN.) DECAL-Caution-Start (ELECTRIC-NON-HANDLE) SEAL (S/N 0G662183 & ABOVE)

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

N·m

18.4 18.4

24.9 24.9

18.4

24.9

18.4

24.9

Drive Tight

Hand Tight

60

6.8

POWERHEAD — 4-7

Induction Manifold And Reed Block 40/50

14

15

27 28 25

20 26 24 23

13

22 21

A 33

19 11 10 9 7 8

1

5 4 3 2

12

B

6 14

14 19

17 18 16 16

14

2 Cycle Premium Outboard Oil

19

Perfect Seal

33

Loctite 680 Retaining Compound

A= ELECTRIC 4-8 — POWERHEAD

20 13

B = MANUAL 90-852572R02 NOVEMBER 2002

Induction Manifold And Reed Block 40/50 REF. REF NO. QTY. 1 1 2 1 3 1 4 1 5 1 6 3 7 1 8 2 2 9 10 2 11 2 12 4 13 1 1 14 1 15 1 16 3 17 1 18 1 19 1 20 10 21 1 22 1 23 6 24 3 25 3 26 3 27 3 28 3

TORQUE DESCRIPTION

lb. in. lb. ft.

GASKET LOWER END CAP ASSEMBLY OIL SEAL OIL SEAL O-RING SCREW (M8 x 20) BRACKET ASSEMBLY STUD WASHER WASHER ELECTRIC WING NUT SCREW (M8 x 35) WASHER (Bottom Left Only) INDUCTION MANIFOLD (ELECTRIC) INDUCTION MANIFOLD (MANUAL) ELBOW (ELECTRIC) ELBOW (MANUAL) CAP STA STRAP GASKET SCREW (M8 x 30) REED BLOCK ASSEMBLY GASKET DOWEL PIN REED SET TAB WASHER RETAINER (50) REED STOP (40) SCREW (M6 x 16)

90-852572R02 NOVEMBER 2002

18.4

N·m

24.9

Hand Tight 18.4 24.9

18.4

60

24.9

6.8

POWERHEAD — 4-9

Induction Manifold And Reed Block 55/60

26 25

27 13 32 31 28 29 14 30

24

22 23 21 20

17

33

19

33

18 16 1

A

11 10 9 7 8

5 4 3 2

B 12

6 14

13

19

15 14

2 Cycle Premium Outboard Oil

19

Perfect Seal

33

Loctite 680 Retaining Compound

A= ELECTRIC 4-10 — POWERHEAD

17

B = MANUAL 90-852572R02 NOVEMBER 2002

Induction Manifold And Reed Block 55/60 REF. REF NO. QTY. 1 1 2 1 3 1 4 1 5 1 6 3 7 1 8 2 2 9 10 2 11 2 12 4 1 13 1 14 1 15 2 16 1 17 10 18 1 19 1 20 6 21 3 22 3 23 3 24 3 25 1 26 2 27 2 28 1 29 1 30 1 31 1 32 1

TORQUE DESCRIPTION

lb. in. lb. ft.

GASKET LOWER END CAP ASSEMBLY OIL SEAL OIL SEAL O-RING SCREW (M8 x 20) BRACKET ASSEMBLY STUD WASHER WASHER ELECTRIC WING NUT SCREW (M8 x 35) INDUCTION MANIFOLD (ELECTRIC) INDUCTION MANIFOLD (MANUAL) ELBOW (ELECTRIC) ELBOW (MANUAL) GASKET SCREW (M8 x 30) REED BLOCK ASSEMBLY GASKET DOWEL PIN REED SET TAB WASHER RETAINER SCREW (M6 x 16) SHIFT RAIL TAB WASHER SCREW (M8 x 25) SLIDE NYLINER NUT WASHER NUT

90-852572R02 NOVEMBER 2002

18.4

N·m

24.9

Hand Tight 18.4 24.9

18.4

24.9

60

6.8

165

18.6

Drive Tight Drive Tight

POWERHEAD — 4-11

Crankshaft, Pistons And Connection Rods

14 14

12 7

16 17

14 13

14

6

15

95

5 11

14

14

12

19

19

15

14

18 8 1 8

2

95

9

3 14

4

10

14

2 Cycle Premium Outboard Oil

95

2-4-C with Teflon

4-12 — POWERHEAD

90-852572R02 NOVEMBER 2002

Crankshaft, Pistons And Connecting Rods REF. REF NO. QTY. 1 1 2 1 3 1 4 1 5 2 6 1 7 1 8 2 9 56 10 2 11 3 12 6 13 3 14 3 15 3 16 6 17 87 18 6

TORQUE DESCRIPTION CRANKSHAFT ASSEMBLY DRIVER GEAR BALL BEARING RETAINING RING KEY ROLLER BEARING (TOP) OIL SEAL RACE ROLLER RING–Seal PISTON ASSEMBLY LOCK RING PISTON RING PISTON RING (CHROME FACE) CONNECTING ROD ASSEMBLY WASHER NEEDLE BEARING SCREW (1/4-28) 1ST TORQUE 2ND TORQUE

19

6

lb. in. lb. ft.

N·m

15 120 + 1/4 Turn

1.7 13.7 + 1/4 Turn

ROLLER BEARING

90-852572R02 NOVEMBER 2002

POWERHEAD — 4-13

Intake/Reed Block Manifold Bolts

Torque Sequence Crankcase Cover















































PE-51085



Torque bolts in sequence to 18.4 lb-ft (24.9 Nm).

PE-51085

Torque bolts in sequence to 18.4 lb-ft (24.9 Nm).

Lower End Cap







 PE-51086

Torque bolts in sequence to 18.4 lb-ft (24.9 Nm).

4-14 — POWERHEAD

90-852572R02 NOVEMBER 2002

Water Circulation

55334

90-852572R02 NOVEMBER 2002

POWERHEAD — 4-15

Thermostat Test Wash thermostat with clean water. Using a thermostat tester, similar to the one shown, test thermostat as follows:

Temperature Switch Test 190°F (88°C) The 190°F (88°C) temperature switch is located in outer side of cylinder head as shown.

• Open thermostat valve, then insert a thread between valve and thermostat body. Allow valve to close against thread. • Suspend thermostat (from thread) and thermometer inside tester so that neither touches the container. Bottom of thermometer must be even with bottom of thermostat to obtain correct thermostat opening.

a

• Fill thermostat tester with water to cover thermostat. • Plug tester into electrical outlet. • Observe temperature at which thermostat begins to open. Thermostat will drop off thread when it starts to open. Thermostat must begin to open when temperature reaches 5° F (3° C) above designated stamping on bottom of thermostat. • Continue to heat water until thermostat is completely open. • Unplug tester unit. • Replace thermostat, if it fails to open at the specified temperature, or if it does not fully open.

56671 a — Temperature Switch

During normal engine operating temperature, the switch electrical circuit is open. The switch will close when the temperature reaches 190°F ± 8°F (88°C ± 4°C). Reset of the switch to open circuit occurs at 170°F ± 8°F (77°C ± 4°C). To test, place switch end into water with thermometer and heat to 190°F ± 8°F (88°C ± 4°C). Take out and perform ohms test. Compare to specifications. If switch does not fall within specifications, replace switch.

PE-51087

4-16 — POWERHEAD

90-852572R02 NOVEMBER 2002

General Information

7. Disconnect blue oil warning module wires.

Powerhead “Disassembly” and “Reassembly” instructions are printed in a sequence that should be followed to assure best results when removing or replacing powerhead components. If complete disassembly is not necessary, start reassembly at point disassembly was stopped. Refer to “Table of Contents” preceding.

8. Remove BLACK ground lead between powerhead and engine tray.

If major powerhead repairs are to be performed, remove powerhead from drive shaft housing as an assembly. Remove external engine components referring to appropriate section of service manual.

9. Remove tell-tale hose from powerhead. 10. Remove anti-start in gear cable on manual start models and disconnect neutral switch bullet connectors on all models. 11. Remove primer hoses from carb and manifold on manual start models and remove recoil starter. 12. Remove bolt, nut and flat washer securing upper drive shaft housing cover and remove cover.

Powerhead Removal 1. Disconnect battery leads from battery (if applicable). 2. Remove spark plug leads from spark plugs. 3. Disconnect remote control harness from engine (if applicable) — or lanyard and stop button/horn wiring on manual models. 4. Disconnect trim switch and trim relay wires. 5. Disconnect fuel connector from engine. Fuel line must also be removed at either engine tray or fuel filter. 6. Remove throttle and shift cables.

b a a — Nut b — Drive Shaft Housing Cover

90-852572R02 NOVEMBER 2002

POWERHEAD — 4-17

13. Thread lifting eye at least 5 turns into flywheel.

WARNING DO NOT leave powerhead suspended from hoist. Powerhead should be installed on a suitable stand or lowered to floor upon removal from drive shaft housing to avoid personal injury or damage to product.

a

15. Using suitable hoist, remove powerhead from drive shaft housing. 55320

a — Lifting Eye (91-90455)

14. Remove 6 bolts securing powerhead to drive shaft housing.

a

a

55319 a — Bolts (6)

4-18 — POWERHEAD

90-852572R02 NOVEMBER 2002

THERMOSTAT ASSEMBLY

Powerhead Disassembly Removing Engine Components NOTE: Refer to appropriate sections in service manual for removal of individual fuel and electrical sub-assemblies from powerhead. Component/Assembly

Section

CDM

2A

Flywheel

2A

Stator Assembly

2A

Trigger Assembly

2A

Starter Motor

2B

Starter Solenoid

2B

b

c

d e

Voltage Regulator/Rectifier

2B

a

Fuel Pump

3A

S/N 0G662182 & Below

Carburetor and Linkage

3B

Air Silencer

3B

Fuel Enrichment Valve

3B

Oil Pump

3C

a b c d e f

Shift Cable Latch Assembly

7A

Control Cable Anchor Bracket

7A

—

f

Bolts Thermostat Cover — 827251-C Thermostat Cover Gasket Thermostat O-ring Carrier

NOTE: All ignition and electrical components can be removed and installed as an assembly. 1. Place powerhead in repair stand or on bench.

b

c f

e a

d

S/N 0G662183 & Up a b c d e f

a

—

Bolts Thermostat Cover — 827251C-1 Thermostat Cover Gasket Thermostat Seal Carrier

55322 a — Powerhead Stand (91-8250011A1) (40/50) Shown. Powerhead Stand (91-25821A1) (55/60)

90-852572R02 NOVEMBER 2002

POWERHEAD — 4-19

2. Remove intake manifold and reed block manifold.

3. Remove check valves and holders.

a

a

55323 55322

a — Check Valve/Holders

a — Bolts (14)

4. Place engine on work bench and remove end cap bolts.

55324

a a — Bolts

4-20 — POWERHEAD

90-852572R02 NOVEMBER 2002

5. Remove crankcase cover bolts.

a

Crankshaft Disassembly 55323

1. Remove roller bearing assemblies from crankshaft.

b

c c

b a — Bolts (14) b — Lower End Cap

6. Remove crankcase cover from cylinder block.

a

7. Remove end cap.

a PE-51085

a — Roller Bearing Race b — Roller Bearing c — Retaining Ring

2. Remove 2 bolts from each rod cap. Keep components with respective connecting rod. 55325

IMPORTANT: Always use new rod bolts.

a Crankcase Cover Removed

8. Remove crankshaft assembly.

PE-51080

a — Bolts, use 1/4 – 12 point socket

Crankshaft Assembly Removed

90-852572R02 NOVEMBER 2002

POWERHEAD — 4-21

3. Remove connecting rod/piston assembly from crankshaft; re-attach caps to respective rod as each is removed. CAPS MUST BE INSTALLED IN SAME DIRECTION ON SAME ROD, or mating surface will not seat properly.

6. Remove piston rings. Always install new piston rings.

a

4. Remove main bearing sealing rings.

b

PE-51081

a — Piston Ring Expander (91-24697) b — Piston Rings

NOTE: Cylinders must be honed for rings to seat properly.

PE-51083

5. Scribe (with awl) identification number (cylinder 1, 2, and 3) on inside of piston and connecting rod in order to reassemble piston to same connecting rod.

CAUTION Safety glasses should be worn when removing or installing locking rings. 7. Remove piston pin lock rings using awl. Always install new lock rings.

1 PE-51081

4-22 — POWERHEAD

PE-51083

90-852572R02 NOVEMBER 2002

8. Remove piston pin.

11. Press crankshaft bearing as shown.

b

a

PE-51086

a — Piston Pin b — Piston Pin Tool (91-74607A3)

9. Remove piston pin needle bearings (29 per piston pin) and locating washers (2 per piston) as shown.

PE-51081

12. Remove oil drive gear if necessary.

a

PE-51088

a — Locating Washers

CAUTION Bearing removal will cause bearing damage and will require replacement.

b

10. Inspect crankshaft bearing. Remove bearing and retaining ring only if necessary.

a b a PE-51084

a — Oil Drive Gear b — Key PE-51084

a — Bearing b — Retaining Ring

90-852572R02 NOVEMBER 2002

POWERHEAD — 4-23

Cleaning and Inspection Cylinder Block and Crankcase Cover IMPORTANT: Crankcase cover and cylinder block are matched, line-bored assembly should not be mismatched by using a different crankcase cover or cylinder block.

CAUTION If crankcase cover and cylinder block is to be submerged in a very strong cleaning solution, it will be necessary to remove the crankcase cover/ cylinder block bleed system from cover/cylinder block to prevent damage to hoses and check valves. CYLINDER BORE SIZE PISTON SIZE

CYL. BLOCK FINISH HONE

Standard Diameter

2.993 in. 76.022 mm

.015 Oversize

3.008 in. 76.403 mm

• Inspect cylinder bores for scoring (a transfer of aluminum from piston to cylinder wall). Cylinder wall scoring usually can be “cleaned up” by honing or re-boring.

CAUTION When re-boring cylinder block, remove hone frequently and check condition of cylinder walls. DO NOT hone any more than absolutely necessary, as hone can remove cylinder wall material rapidly. • Inspect cylinder block and crankcase cover for cracks or fractures. • Check gasket surfaces for nicks, deep grooves, cracks and distortions that could cause compression leakages. • Check that all water passages in cylinder block are not obstructed. Check locating pins in cylinder block that they are tight. • Check crankcase cover fuel/bleed passages that they are not obstructed. Verify that check valves (2) in crankcase cover and block are not damaged. • Thoroughly clean cylinder block and crankcase cover. Verify that all sealant and old gaskets are removed from matching surfaces. Clean all carbon deposits from exhaust ports.

HONING PROCEDURE Follow hone manufacture’s recommendations for use of hone cleaning and lubrication during honing. IMPORTANT: After honing, bores should be thoroughly cleaned with hot water and detergent. Scrub well with stiff bristle brush and rinse with hot water. If any abrasive material is allowed to remain in the cylinder bore, it will cause a rapid wear of new piston rings and cylinder bore. After cleaning, bores should be swabbed several times with 2 cycle engine oil and a clean cloth. Wipe excess oil with clean, dry cloth. Cylinders should not be cleaned with kerosene or gasoline. Clean remainder of cylinder block. • Hone all cylinder walls just enough to de-glaze.

• Inspect spark plug holes for stripped or damaged threads.

4-24 — POWERHEAD

90-852572R02 NOVEMBER 2002

• Measure cylinder bore inside diameter (with an inside micrometer) of each cylinder, as shown below. Check for tapered, out-of-round (“eggshaped”) and oversize bore.

TOP

TO CHECK: Inspect check valves by looking through hole. If light can be seen the nylon ball is bad (probably melted); replace valve. If you see no light, insert fine wire into check valve hole to see if there is slight movement of nylon ball. If ball moves, valve is O.K.. Replace valve if ball does not move. Install check valve into check valve holder as shown. Air

a CENTER

b

BOTTOM

Air

• If a cylinder bore is tapered, out-of-round or worn more than .003 in. (0.08 mm) from standard “Cylinder Block Finish Hone” diameter (refer to chart), it will be necessary to re-bore that cylinder(s) to designated oversize bore and install oversize piston(s) and piston rings during reassembly.

NOTE: The weight of an oversize piston is approximately the same as a standard size piston; therefore, it is not necessary to re-bore all cylinders in a block just because one cylinder requires re-boring. IMPORTANT: Ports must be de-burred after honing. • After honing and thoroughly cleaning cylinder bores, apply 2 cycle outboard oil to cylinder walls to prevent rusting.

Check Valves NOTE: Check valves can be replaced by removing intake manifold when powerhead is attached to driveshaft housing. The check valves are a 3/16 in. (4.76 mm) diameter brass casing containing a nylon ball-valve. These can be damaged by hot combustion blow-by into crankcase (ie.: backfire, or a hole in top of piston, etc.).

90-852572R02 NOVEMBER 2002

PE-51080

a — Check Valve b — Holder

Piston and Piston Rings IMPORTANT: If engine was submerged while engine was running, piston pin and connecting rod may be bent. If piston pin is bent, piston must be replaced. Piston pins are not sold separately because of matched fit into piston. If piston pin is bent, connecting rod must be checked for straightness (refer to “Connecting Rods” for checking straightness). • Inspect piston for scoring and excessive piston skirt wear. • Check tightness of piston ring locating pins. Locating pins must be tight. • Thoroughly clean pistons. Carefully remove carbon deposits, with a soft wire brush or carbon remover solution. DO NOT burr or round off machined edges. • Inspect piston grooves for wear and carbon accumulation. If necessary, scrape carbon from piston ring grooves being careful not to scratch sides of grooves. Refer to procedure for cleaning piston ring grooves.

POWERHEAD — 4-25

CLEANING PISTON RING GROOVES

MEASURING PISTON SKIRT

IMPORTANT: The piston rings are half – keystone rings – (tapered on the top side) – follow cleaning and inspection carefully! Chromed ring is installed on top.

Measure piston skirt at right angle (90°) to piston pin centerline, 0.50 in. (12.7 mm) up from bottom edge of skirt.

.50 in. (12.7 mm) Enlarged View of Piston Ring Grooves

CAUTION Care must be taken not to scratch the side surfaces of ring groove. Scratching the side surfaces of the ring groove will cause damage to the ring groove.

PISTON SIZE

PISTON SKIRT DIAMETER

CYL. BORE FINISH HONE

Standard Piston

2.988 in. (75.895 mm)

2.993 in. (76.022 mm)

.015 Oversize

3.003 in. (76.276 mm)

3.008 in. (76.403 mm)

• Use a bristle brush and carbon remover solution to remove carbon from side surfaces. • A tool can be made for cleaning the inner diameter of the tapered ring grooves. The tool can be made from a broken tapered piston ring with the side taper removed to enable inside edge of the ring to reach the inside diameter of the groove. Carefully scrape the carbon from inner diameter of ring grooves. Care must be taken not to damage the grooves by scratching the surfaces of the grooves.

4-26 — POWERHEAD

90-852572R02 NOVEMBER 2002

Connecting Rods

Crankshaft • Inspect crankshaft to drive shaft splines for wear. (Replace crankshaft, if necessary.) • Check crankshaft for straightness. (Replace as necessary.) • Inspect crankshaft oil seal surfaces. Sealing surfaces must not be grooved, pitted or scratched. (Replace as necessary.) • Check all crankshaft bearing surfaces for rust, water marks, chatter marks, uneven wear and/or overheating. (Refer to “Connecting Rods”.) • If necessary, clean crankshaft surfaces with crocus cloth as shown.

If necessary, clean connecting rod surfaces as follows: • Attach end caps to connecting rods. Following these directions, tighten rod cap attaching bolts to specifications. Recheck alignment.

CAUTION Crocus cloth MUST BE USED to clean bearing surface at crankshaft end of connecting rod. DO NOT use any other type of abrasive cloth. • Clean crankshaft end of connecting rod by using crocus cloth placed in a slotted 3/8 in. (9.5 mm) diameter shaft, as shown. Insert shaft in a drill press and operate press at full speed while keeping connecting rod at a 90° angle to slotted shaft. IMPORTANT: Clean connecting rod just enough to clean bearing surfaces. DO NOT continue to clean after marks are removed from bearing surfaces. • Clean piston pin end of connecting rod, using same method as above. Use 320 grit carborundum cloth instead of crocus cloth. • Thoroughly wash connecting rods to remove abrasive grit. Recheck bearing surfaces of connecting rods. Replace any connecting rod that cannot be properly polished. Lubricate bearing surfaces of connecting rods which will be reused with 2 cycle Premium Outboard Oil to prevent rust.

PE-51089

• Thoroughly clean (with solvent) and dry crankshaft and crankshaft ball bearings. Recheck surfaces of crankshaft. Replace crankshaft if surfaces cannot be properly “cleaned up”. If crankshaft will be reused, lubricate surfaces of crankshaft with light oil to prevent rust. DO NOT lubricate crankshaft ball bearings at this time.

PE-51083

WARNING DO NOT spin-dry crankshaft ball bearing with compressed air.

90-852572R02 NOVEMBER 2002

POWERHEAD — 4-27

Reed Blocks NOTE: Do not disassemble reed block unless necessary.

IMPORTANT: Do not reverse the reed petals for additional use – replace reed when necessary.

50/55/60

Reed should lie flat. There should be no pre-load (pressure between reed and reed-block), although a slight pre-load is tolerable.

e d

The maximum allowable opening between reed and reed-block is .020 in. (0.5mm). This must be checked with a flat blade feeler gauge, as shown. 40 HP Shown

a c a b

PE-51089

a b c d e

—

Reed Block Reed (3 Sets) Retaining Washer Tab Washer Bolt (With Loctite 271)

55350 a — 0.020 in. (0.50 mm) Maximum

40

d

55349

c a b

a b c d e

—

e

Reed Block Reed (3 Sets) Tab Washer Bolt (With Loctite 271) Reed Stop

4-28 — POWERHEAD

90-852572R02 NOVEMBER 2002

If the opening exceeds .020 in. (0.5 mm), or if the reed is chipped, cracked or otherwise damaged, replace.

Reassembly and Installation General Information Before proceeding with powerhead reassembly, be sure that all parts to be reused have been carefully cleaned and thoroughly inspected, as outlined in “Cleaning and Inspection”. Parts which have not been properly cleaned (or which are questionable), can severely damage an otherwise perfectly good powerhead within a few minutes of operation. All new powerhead gaskets must be installed during assembly. During reassembly, lubricate parts with 2-Cycle Premium Outboard Oil whenever 2-cycle oil is specified, and Mercury/Quicksilver 2-4-C with Teflon whenever grease is specified. A torque wrench is essential for correct reassembly of powerhead. Do not attempt to reassemble powerhead without using a torque wrench.

.020

PE-51089

CAUTION Replace locking tab-Washer. DO NOT REUSE. If reed block was disassembled, reassemble by locating reeds on pins with retaining washer. Use new tab-washer. Insert bolt, and torque to 60 lb. in. (6.8 N·m); then, if necessary, continue the torque to align flat on hex-head to locking tab. DO NOT exceed 100 lb. in. (11.3 N·m) of torque. Bend up lock tab to secure bolt position. Specified reed stop opening is 0.090 in. (2.286 mm). If reed stop opening is not correct, carefully bend reed stop to achieve specified opening. 40 HP

a

55350 a — 0.090 in. (2.286 mm)

90-852572R02 NOVEMBER 2002

POWERHEAD — 4-29

2. Install needle bearings.

CAUTION

b

Any GREASE used for bearings INSIDE the powerhead MUST BE gasoline soluble. Use only Needle Bearing Assembly Lubricant. DO NOT use 2-4-C with Teflon, or other lubricants inside the powerhead, or damage may occur.

a

Assembling Rod to Piston CAUTION

PE-51081

Never intermix new needle bearings with used needle bearings. It is required to replace needle bearings as a set. Never intermix needle bearings from one connecting rod with those of another connecting rod 1. Place clean needle bearings on a clean sheet of paper and lubricate with Needle Bearing Assembly Lubricant.

a — Needle Bearings (29) b — Sleeve [from Piston Pin Tool (91-74607A3)]

3. Place locating rings on connecting rod, carefully place piston over end of rod. Refer to scribed identification number for matching rod to piston and direction of assembly (which side of rod is “UP”).

Service Tip

b

1

1

a PE-51083

a — Scribed Identification Number b — Thrust Washer

PE-51228

If the tip of an awl can be inserted between needle bearings, one or more needles are missing and must be replaced.

4-30 — POWERHEAD

90-852572R02 NOVEMBER 2002

4. Push sleeve from piston using piston pin tool.

a

b

6. Install new piston pin lock rings (each side of piston) using Lockring Tool (p/n 91-77109A3). 7. Make sure lockrings are properly seated in piston grooves.

CAUTION Do not re-use piston pin lockrings. Use only new lockrings and make sure they are properly seated in piston grooves.

b

PE-51080

a

a — Sleeve b — Piston Pin Tool (91-74607A3)

5. Place piston pin over tool, and tap into position (driving tool out other side). PE-51086

a

a — Lockring Installation Tool (91-77109A3) b — Lockring (2)

b

PE-51086

a — Piston Pin b — Piston Pin Tool (91-74607A3)

WARNING Eye protection must be worn while installing piston pin lock-rings.

PE-51086

NOTE: Shaft of previous Lockring Installation Tool 91-77109A3 must be modified (shortened) to 1.050 in. (26.7 mm). 1.050 in. (26.7 mm)

90-852572R02 NOVEMBER 2002

POWERHEAD — 4-31

Piston Ring Installation IMPORTANT: Piston ring side with mark must be facing up.

Piston Ring

1. Install piston ring in appropriate groove on piston using Piston Ring Expander Tool. Spread rings just enough to slip over piston. Top Groove – Chromed Ring Bottom Groove – Steel Ring 2. Check piston rings to be sure they fit freely in groove. Lubricate rings and cylinder wall with 2-cycle oil.

Piston rings are tapered on the top side, and flat (rectangular) on the bottom side (half-keystone rings). Note that top ring is chromed and bottom ring is steel.

a

b Enlarged View of Piston Ring Grooves PE-51081

a — Piston Ring Expander (91-24697) b — Piston Rings

3. Align piston ring end gaps with ring locating pins as shown. Check locating pins making sure they are tight.

CAUTION

a

Care must be taken not to scratch the side surfaces of ring groove. Scratching this area will damage the ring groove.

a b PE-51228

b

a

PE-51082

a — Locating Pin b — Piston Rings 4-32 — POWERHEAD

90-852572R02 NOVEMBER 2002

4. Remove connecting rod cap from connecting rod being installed. 5. Install each piston with “UP” identification facing flywheel end. Pistons MUST be installed in this direction. UP

Crankshaft Installation 1. If lower bearing and gear were removed from crankshaft, slide gear in place (note keyway and key in gear to crankshaft assembly). Install gear to crankshaft using an arbor press and suitable mandrel. 2. Install main bearing retaining ring after pressing main bearing tight against oil gear.

b a c

CAUTION Pistons must be installed very carefully into cylinders. Piston rings can not be inspected through exhaust ports. 6. Bottom end of cylinder bore has taper which permits the insertion of the piston into block without using a piston ring compressor. Place piston carefully into cylinder. PE-51084

a — Lower Bearing b — Gear c — Retaining Ring

CAUTION Safety glasses should be worn when removing or installing ring seals. 3. Install ring seals (2) to crankshaft.

b

PE-51087

a PE-51083

a — Ring Seal b — Slot On Crankshaft 90-852572R02 NOVEMBER 2002

POWERHEAD — 4-33

6. Position cylinder block and piston rods as shown. Insert locating pins.

CAUTION Any grease used for bearings INSIDE the powerhead MUST BE gasoline soluble. Use only Needle Bearing Assembly Lubricant. DO NOT use 2-4-C with Teflon, or other lubricants inside powerhead, or damage to engine may occur.

a

a

a

4. Grease crankshaft journal with Needle Bearing Assembly Lubricant to hold bearing in place. Position needle bearings on journal. There are 28 bearings per each center main.

PE-51088

Flywheel End

Lower End

a — Locating Pins

7. Place crankshaft into cylinder block; align and seat top and center main bearings so that locating pins on block align with larger holes in each bearing race.

a b

PE-51081

a — Crankshaft Journal b — Bearings (28)

IMPORTANT: Snap ring groove faces up towards flywheel. 5. Attach main bearing races with holes towards lower gear end of crankshaft. Secure each main bearing race with retaining ring. Lubricate top main bearing with 2-cycle engine oil and install to crankshaft as shown.

c

b

a

b PE-51080

PE-5108

a — Main Bearing Race b — Retaining Ring (Groove Faces Flywheel) c — Top Main Bearing (One Piece)

4-34 — POWERHEAD

90-852572R02 NOVEMBER 2002

Installing Rods to Crankshaft

Connecting Rod Cap Alignment

1. Oil rod and bearing cage with 2-cycle oil.

1. Check each connecting rod for correct alignment by carefully running fingernails up and down edge of rod cap. If not aligned, a ridge can be seen or felt at the separating line. Correct any misalignment.

2. Pull rod into place and install bearing cages as shown.

a

b

PE-51080

NOTE: Clean rod bolt/rod cap bolt holes of oil and debris before reassembly. IMPORTANT: Always use new rod bolts. The rod cap and rod must be aligned and held together when threading oiled bolt. Check that mating surfaces are tight together after bolt enters threads in piston rod.

f

d

c

e

g

3. Place rod cap over bearing cages. While holding cap to rod, insert slightly oiled bolts and lightly tighten while observing cap to rod alignment. PE-51224

a b c d e f g

PE-51089

90-852572R02 NOVEMBER 2002

—

Front View Correct Front View Incorrect Side View Correct Side View Incorrect Space Side View Incorrect Ridge

2. When connecting rods are attached, and bolts drawn down finger tight, torque rod-cap bolts to 15 lb. in. (1.7 Nm). Recheck alignment. Re-torque to 120 lb-in. (13.6 Nm) + 1/4 Turn. Recheck top and center main alignment with dowel pins.

POWERHEAD — 4-35

Crankcase Cover to Block

Lower End Cap

1. Install upper seal to crankshaft.

1. Clean thoroughly, including seal and O-ring seats; remove Perfect Seal residue and clean cap-to-head mating surface. 40/50 models — Lip of smaller seal faces away from powerhead. Lip of larger seal faces toward powerhead.

a

a

14

c b 14

PE-51088

2 Cycle Premium Outboard Oil

PE-51243

a — Lip of Larger Seal b — Lip of Smaller Seal c — End Cap/Perfect Seal

a — Oil Seal (Lubricate Inside with 2-cycle oil)

2. Apply LOCTITE MASTER GASKET SEALANT to clean block surface. Instructions in kit must be followed exactly.

55/60 models — Lip of smaller seal faces away from powerhead. Lip of larger seal faces away powerhead.

IMPORTANT: Extend sealer to edge on each center main journal to prevent blow-by between cylinders.

2. Install end cap assembly (lubricate seals with 2-cycle engine oil) to block. Apply Perfect Seal to flange of end cap.

14

a

c b PE-51088 PE-51087

Sealant “Bead Pattern” Indicated by Bold Line Above

14

2 Cycle Premium Outboard Oil

a — Lip of Larger Seal b — Lip of Smaller Seal c — End Cap/Perfect Seal

3. Using suitable mandrel, press oil seals into cap until fully seated. 4. Install end cap assembly (lubricate seals with 2-cycle engine oil) to block. Apply Perfect Seal to flange of end cap. 4-36 — POWERHEAD

90-852572R02 NOVEMBER 2002

5. Place crankcase cover onto block.

Intake/Reed Block Manifold Installation 1. Place engine on repair stand or on bench.

NOTE: Powerhead repair stand p/n 91-25821T1 can be used.

b a

PE-51084

a — Crankcase Cover b — End Cap

6. Insert clean bolts (note 2 sizes) and finger tighten. 7. Torque bolts to 18 lb. ft. (24 N·m) following sequence shown below. 











55323

2. Install check valve/holders.









 

PE-51085



PE-51080

a   PE-51086

NOTE: Inspect all hoses on reinstallation. Replace if necessary. a — Check Valve/Holders 90-852572R02 NOVEMBER 2002

POWERHEAD — 4-37

3. Install reed block manifold and intake manifold with gasket to cylinder block.

Thermostat Cover Installation 1. Thermostat cover 827251C-1. Torque bolts to 18 lb. ft. (24 N·m).

a

c

b

f

e PE-51225

a — Can Only Be Installed One way

4. Install bolts and torque to 18 lb. ft. (24 N·m) in sequence shown below. 

 

 

a b c d e f

—

Bolts Thermostat Cover — 827251C-1 Thermostat Cover Gasket Thermostat Seal Carrier

2. Thermostat cover 827251-C. Torque bolts to 18 lb. ft. (24 N·m).









b 

d

a

c





a

PE-51085

a b c d e f

4-38 — POWERHEAD

—

d e

f

Bolts Thermostat Cover — 827251-C Thermostat Cover Gasket Thermostat O-ring Carrier

90-852572R02 NOVEMBER 2002

Install Remaining Engine Components

Powerhead Installation CAUTION

Component/Assembly

Section

CDM

2A

Flywheel

2A

Stator Assembly

2A

Trigger Assembly

2A

Starter Motor

2B

Starter Solenoid

2B

Voltage Regulator/Rectifier

2B

Fuel Pump

3A

Carburetor and Linkage

3B

Air Silencer

3B

Fuel Enrichment Valve

3B

Oil Pump

3C

Shift Cable Latch Assembly

7A

Control Cable Anchor Bracket

7A

There are two different gasket styles. Newer style replaces old. Note tab on outer edge and also different configuration as shown on new style. Replace with same style or new style gasket. Engine damage could result with 50/55/60 gasket installed on 40/50/55/60 models.

40/50/55/60

40/50/55/60 Models P/N 27-828553

NOTE: All ignition and electrical components can be removed and installed as an assembly.

50/55/60 Models P/N 27-812865 DO NOT INSTALL ON 40/50/55/60 MODELS

90-852572R02 NOVEMBER 2002

POWERHEAD — 4-39

1. Install lifting eye (P/N 91-90455T) into flywheel a minimum of 5 turns. Install powerhead to driveshaft housing. Slide shift slide on rail while lowering powerhead on splines of drive shaft.

3. Install cover. Torque bolts to 80 lb. in. (9 N·m).

55320

b a a — Bolts — Torque to 80 lb. in. (9 N⋅m) b — Cover

2. Install Powerhead bolts. Torque to 28 lb.ft. (38 N·m).

4. Reattach ground wire to powerhead. Connect wires from trim relay switch. Connect tell tale hose.

a

a

a 55014 a — Ground Lead

55319 a — Bolts

4-40 — POWERHEAD

90-852572R02 NOVEMBER 2002

5. Install oil tank. 6. Reconnect wires and oil hose. Secure in place with sta-strap.

7. Install control cables. Refer to Cable Adjustment in Section 7A. 8. Reconnect trim switch. See Section 2D Wiring Diagrams. 9. Connect control/trim harness and fuel line.

c

b

a

a — Oil Tank Wires b — Power Trim Wires c — Oil Hose (Connect to Tank)

PE-51082

10. Install battery cables.

b

a

(–)

(+)

PE-51084

a — Red Sleeve (Positive) b — Black Sleeve (Negative)

90-852572R02 NOVEMBER 2002

POWERHEAD — 4-41

Test Run Procedure CAUTION When engine is started, IMMEDIATELY check that water pump is operating. Operation of water pump is indicated by water discharging from “tell tale”. 1. While test running outboard, check powerhead assembly for leaks and/or unusual noises. Make any repairs before placing outboard in service.

Important Information Proper break-in assures that all moving parts “wearin” evenly to ensure a longer engine life and optimum performance. Operate your new outboard motor at varied throttle settings – not to exceed 1/2 throttle (2500-3500 RPM) during the first hour or the first five gallons of break-in fuel. Refer to “Fuel Mixture and Gasoline/Oil Recommendations” – “Break-In Fuel Mixture” located in your operation and Maintenance Manual. During the second hour operation, or the second 5 gallons (20 Liters) of break-in fuel, operate the Outboard at varied throttle settings not to exceed 4500 RPM. DO NOT OPERATE YOUR NEW OUTBOARD MOTOR AT FULL THROTTLE UNTIL THE SECOND HOUR OF BREAK-IN IS COMPLETED.This includes full throttle acceleration, pulling water skiers, or wide open throttle running. After the first two hours of running, approximately 10 gallons (40 Liters) of fuel, full throttle operation may be attained, but not sustained, for the remaining break-in fuel (approximately 5 gallons). For the next five hours of operation, full throttle operation may, again, be attained, but it is strongly not recommended for sustained use. (Not more than 5 minutes of continuous wide open throttle.)

CAUTION SEVERE DAMAGE to your engine can result by not complying with the preceding break-in procedures.

4-42 — POWERHEAD

90-852572R02 NOVEMBER 2002

MID-SECTION

5 A

40/50 CLAMP/SWIVEL BRACKETS AND DRIVE SHAFT HOUSING

Table of Contents Page Clamp Bracket . . . . . . . . . . . . . . . . . . . . . . . . . 5A-2 Swivel Tube Components . . . . . . . . . . . . . . . 5A-4 Swivel Bracket Components . . . . . . . . . . . . . 5A-6 Drive Shaft Housing/Exhaust Plate Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-8 Drive Shaft Housing Disassembly/Reassembly . . . . . . . . . . . . . . . 5A-10

5A-0 — MID-SECTION

90-852572R02 NOVEMBER 2002

Notes:

90-852572R02 NOVEMBER 2002

MID-SECTION — 5A-1

Clamp Bracket

7

Loctite 271 Thread Locker

95

2-4-C with Teflon

5A-2 — MID-SECTION

90-852572R02 NOVEMBER 2002

Clamp Bracket REF. REF NO. QTY. 1 1 1 1 2 1 3 2 4 2 5 2 6 2 7 2 8 1 9 1 10 1 11 1 12 1 13 1 14 1 15 1 16 1 17 2 18 2 19 4 20 4 21 4 22 1 23 1 24 1 25 1 26 1 27 1 28 1 29 1 30 1 31 1 32 1 33 1 34 2 35 2 36 2 37 2 38 2 39 2 40 2 41 1 42 1

TORQUE DESCRIPTION CLAMP BRACKET (BLACK)

N·m

PORT

CLAMP BRACKET (GRAY) CLAMP BRACKET (BLACK) STARBOARD CLAMP BRACKET (GRAY) THUMB SCREW ASSEMBLY (MANUAL) HANDLE (MANUAL) RIVET (MANUAL) WASHER (MANUAL) SCREW (Hex shoulder) (MANUAL) CAP–Tilt Stop Pin (O.D. of Ref. #11 is 0.75 in. & Ref. #10 is not flanged) ROLL PIN (O.D. of Ref. #11 is 0.75 in. & Ref. #10 is not flanged) BUSHING (O.D. of Ref. #11 is 0.75 in. & Ref. #10 is not flanged) PIN-TILT-STOP (O.D. of Ref. #11 is 0.75 in. & Ref. #10 is not flanged) CAP-TILT-STOP (O.D. of Ref. #15 is 0.56 in. & Ref. #14 is flanged) ROLL PIN (O.D. of Ref. #15 is 0.56 in. & Ref. #14 is flanged) BUSHING (O.D. of Ref. #15 is 0.56 in. & Ref. #14 is flanged) PIN-TILT STOP (O.D. of Ref. #15 is 0.56 in. & Ref. #14 is flanged) ANODE WASHER SCREW (M6 x 25) NUT (.500-20) WASHER SCREW (.500-20 x 4 IN.) DECAL-Tilt Lock DECAL-Warning TRIM, HYDRAULIC ASSIST (GAS ASSIST TRIM) CABLE (GAS ASSIST TRIM) TILT LEVER (GAS ASSIST TRIM) TILT KNOB GAS ASSIST TRIM LEVER ARM (GAS ASSIST TRIM) WAVE WASHER (GAS ASSIST TRIM) ROLL PIN (1/8 x 3/4 IN.) (GAS ASSIST TRIM) LINK (GAS ASSIST TRIM) NUT (GAS ASSIST TRIM) ANCHOR PIN (14MM) (GAS ASSIST/POWER TRIM) BUSHING (GAS ASSIST/POWER TRIM) BUSHING (GAS ASSIST/POWER TRIM) WASHER (GAS ASSIST/POWER TRIM) NUT (GAS ASSIST/POWER TRIM) SCREW (M10 x 40) (GAS ASSIST/POWER TRIM) WASHER (GAS ASSIST/POWER TRIM) NUT (GAS ASSIST/POWER TRIM) TILT LOCK PIN (NON POWER TRIM) SPRING (NON POWER TRIM)

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

60

6.8

60

6.8 Drive Tight

MID-SECTION — 5A-3

Swivel Tube Components

14

1 2 95

3

5

4

95

6 7 8 94

9 10

11

13

94

Anti-Corrosion Grease

95

2-4-C with Teflon

5A-4 — MID-SECTION

12

90-852572R02 NOVEMBER 2002

Swivel Tube Components REF. REF NO. QTY. 1 1 1 2 1 3 1 4 2 5 1 6 1 7 1 8 1 9 1 10 1 11 1 12 1 13 2 14 1

TORQUE DESCRIPTION

lb. in. lb. ft.

N·m

SWIVEL TUBE HEAD (BLACK) SWIVEL TUBE HEAD (GRAY) BRACKET TAB WASHER NON HANDLE SCREW (M10 x 45 Hex head cap) NUT (.375-24) LEVER–Co–pilot WASHER ROD (THREADED) BRAKE PLATE DISC–Brake PLATE–Swivel Head DISC–Brake SCREW (HEX SHOULDER) BUMPER

90-852572R02 NOVEMBER 2002

32

70

43.4

7.9

MID-SECTION — 5A-5

Swivel Bracket Components 1 95

95

4

95

22

5

3

21

A

8

B

2 7

6 12

20

95

95

9 25 16

26

15 24

B

14 22 27 95

23 13

19 18

10

17 11

C 95

95

2-4-C with Teflon

A – Tighten nut until it seats and then back off 1/4 turn. B – Tighten nut to 32 lb. ft. (43.4 N·m) and then back off 1/4 turn, C – To screw on bottom yoke. 5A-6 — MID-SECTION

90-852572R02 NOVEMBER 2002

Swivel Bracket Components REF. REF NO. QTY. 1 1 2 1 3 1 4 2 5 2 6 1 1 7 1 8 1 9 3 10 1 11 1 12 1 13 1 14 1 1 15 1 16 1 17 1 18 1 19 1 20 1 21 1 22 2 23 1 24 1 25 2 26 1 27 1

TORQUE DESCRIPTION LINK ROD SCREW (1-1/2 IN.) WASHER NON HANDLE VERSIONS WASHER NUT (.375-24) PUCK–Co-pilot SWIVEL BRACKET ASSEMBLY (BLACK) SWIVEL BRACKET ASSEMBLY (GRAY) BUSHING (UPPER) GREASE FITTING (Qty. of 4 on Handle Version) Drive Tight BUSHING (LOWER) SEAL DECAL CABLE ASSEMBLY WASHER SCREW (M8 x 10) (HANDLE VERSIONS) SCREW (M8 x 1.25 x 25)(NON-HANDLE VERSIONS) SEAL-Co-Pilot SEAL KIT NON-HANDLE VERSIONS O RING SPACER WASHER TILT TUBE NUT (.875-14) DECAL–Co-pilot PIN (TRILOBE) BUSHING PIVOT PIN (UPPER) SCREW (10-16 x 3/8 IN.)

90-852572R02 NOVEMBER 2002

lb. in. lb. ft. 20

N·m 27.1

See “A”

17

23

See “B”

Drive Tight

MID-SECTION — 5A-7

Drive Shaft Housing/Exhaust Plate Components 21 20

22

18

16

27 25 24

15 19 17

23

26 95

26

14 13 28

30 141

12

26

29 10

11

Cyanacrylate Adhesive

95

2-4-C with Teflon

33

Loctite 680 Retaining Compound

9

31 8

26

32 95

35

6

33 40 46

7

34 46

44

45

39

39 33

42 37 38 40 41

5

36

43

4 42 47

95

A

1

3 95

2

A = TO PORT SIDE OF SWIVEL BRACKET 5A-8 — MID-SECTION

90-852572R02 NOVEMBER 2002

Drive Shaft Housing/Exhaust Plate Components REF. REF NO. QTY. 1 2 2 1 3 1 4 1 1 5 1 6 1 7 4 8 1 1 9 1 10 4 11 1 12 1 13 1 14 1 15 1 16 1 17 1 18 1 19 2 20 1 21 4 22 1 23 2 24 2 25 2 1 26 1 27 1 28 1 29 1 30 1 31 1 32 1 33 1 34 6 1 1 35 1 1 36 1 37 1 38 1 39 2 2 40 2 41 4 2 42 2 43 3 44 3 45 3 46 2 47 2

TORQUE DESCRIPTION SCREW (M8 x 55) GROMMET–Water Tube CLAMP–Water Tube SEAL–Water Tube WATER TUBE (SHORT) WATER TUBE (LONG) EXHAUST TUBE SCREW (M8 x 45) GASKET–Drive Shaft Housing ADAPTOR PLATE (BLACK) ADAPTOR PLATE (GRAY) DOWEL PIN SCREW (M10 x .75) SEAL–Bottom Cowl COUPLER GROMMET–Shift Shaft SHIFT SHAFT (UPPER) WASHER PIN–Shift Link COTTER PIN SCREW (M12 x 1.75 x 162) MOUNT SCREW (M8 x 45) CABLE ASSEMBLY WASHER WASHER NUT (M12 x 1.75) TRIM COVER (BLACK) TRIM COVER (GRAY) BUMPER SCREW (M5 x .8 x 60) WASHER NUT (M5 x .8) BUMPER–Trim Cover SEAL–Exhaust Tube SEAL–Idle Relief SCREW (M10 x 110) DRIVESHAFT HOUSING (BLACK) (LONG) DRIVESHAFT HOUSING (GRAY) DRIVESHAFT HOUSING (BLACK) (SHORT) DRIVESHAFT HOUSING (GRAY) STUD (M10 x 1.5 x 50) WASHER NUT (M10) MOUNT (LOWER) COVER–Mount (BLACK) COVER–Mount (GRAY) SCREW (M8 x 1.25 x 35) BOTTOM YOKE (BLACK) BOTTOM YOKE (GRAY) SCREW (M8 x 40) WASHER NUT (M8 x 1.25) SCREW (M12 x 125) NUT (M12 x 1.75)

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

N·m

80

9.0

16.5

22.4

16.5

22.4

18.3

24.0

50

67.8

Drive Tight

29

39.3

18.3

24.9

18.3

24.9

100

11 50

67.8

MID-SECTION — 5A-9

Drive Shaft Housing Disassembly/Reassembly Servicing components such as steering arm, drive shaft housing, exhaust assembly and swivel bracket will usually require powerhead and/or gear housing removal.

WARNING Failure to support outboard as shown could result in personal injury and/or damage to outboard or boat.

a

Refer to Section 4 for powerhead removal and Section 6A for gear housing removal. The transom bracket, lower mount bracket, tilt tube and lower engine mounts can be serviced without powerhead/gear housing removal. However, OUTBOARD MUST BE SUPPORTED BEFORE SERVICING COMPONENTS.

b c

51078 a — Hoist b — Rope c — Lifting Eye (91-90455)

IMPORTANT: All gaskets should be replaced when removing powerhead and/or disassembling drive shaft housing. Corresponding gasket mating surfaces should be cleaned of any gasket material before installing new gaskets.

5A-10 — MID-SECTION

90-852572R02 NOVEMBER 2002

MID-SECTION

5 B

55/60 CLAMP/SWIVEL BRACKETS AND DRIVE SHAFT HOUSING

Table of Contents Page Clamp Bracket Components (Manual) . . . . 5B-2 Transom Bracket Components (Electric) . . 5B-4 Swivel Bracket Components . . . . . . . . . . . . . 5B-6 Drive Shaft Housing . . . . . . . . . . . . . . . . . . . . 5B-8 Drive Shaft Housing Disassembly/Reassembly . . . . . . . . . . . . . . . 5B-10

5B-0 — MID-SECTION

90-852572R02 NOVEMBER 2002

Notes:

90-852572R02 NOVEMBER 2002

MID-SECTION — 5B-1

Clamp Bracket Components (Manual)

32 36

7

95

9

8

10 39

38

22

31

37 35 34 33

2

4 3 5

95

6

11 16

95

17

25

21

23 24

22 12 1 18 20

15 14

28 19

29

27 30

95

23

13

26

2-4-C with Teflon

5B-2 — MID-SECTION

90-852572R02 NOVEMBER 2002

Clamp Bracket Components (Manual) REF. REF NO. QTY. 1 1 1 2 1 3 1 1 4 1 1 5 1 6 1 7 1 8 1 1 9 1 10 1 11 2 1 12 1 13 1 14 2 15 2 5 16 1 17 4 18 2 19 1 20 1 21 1 22 2 23 2 24 2 25 2 26 1 27 1 28 4 29 4 30 4 31 1 32 1 33 1 34 1 35 1 36 1 37 1 38 1 39 1

TORQUE DESCRIPTION CLAMP BRACKET (BLACK) CLAMP BRACKET (GRAY) GREASE FITTING GROOVE PIN CLAMP BRACKET (BLACK) CLAMP BRACKET (GRAY) TILT LOCK LEVER (BLACK) TILT LOCK LEVER (GRAY) SPRING NYLINER SPRING KNOB (BLACK) KNOB (GRAY) GROOVE PIN WASHER ANCHOR BRACKET (BLACK) ANCHOR BRACKET (GRAY) ANODE ASSEMBLY SCREW WASHER SCREW (30 MM) SCREW (35 MM) LOCKWASHER NUT TILT PIN ASSEMBLY SPRING TILT TUBE NUT THUMB SCREW ASSEMBLY WASHER SCREW HANDLE RIVET SCREW WASHER NUT LINK TILT LEVER BUSHING WASHER WAVE WASHER TILT KNOB SCREW (.375-16 x .62) DECAL, Tilt Lock DECAL, Warning

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

N·m

PORT

STARBOARD

60

6.8

22

29.8

60

6.8

Drive Tight Drive Tight

18.3

24.9

MID-SECTION — 5B-3

Transom Bracket Components (Electric)

34 38

7

95

39

9

8

10

23

33

37 36 35

19

11

4

2 3 5

27 29

28 17

95

6

16

95

22 23

12 18 21

25

13 15

30 24

26 20

1

14 31 32

95

2-4-C with Teflon

5B-4 — MID-SECTION

90-852572R02 NOVEMBER 2002

Transom Bracket Components (Electric) REF. REF NO. QTY. 1 1 1 2 1 3 1 1 4 1 1 5 1 6 1 7 1 8 1 1 9 1 10 1 11 2 1 12 1 13 1 14 2 15 2 5 16 1 17 4 18 2 19 1 20 1 21 1 22 1

TORQUE DESCRIPTION TRANSOM BRACKET (BLACK) TRANSOM BRACKET (GRAY) PORT GREASE FITTING GROOVE PIN TRANSOM BRACKET (BLACK) TRANSOM BRACKET (GRAY) STARBOARD TILT LOCK LEVER (BLACK) TILT LOCK LEVER (GRAY) SPRING NYLINER SPRING KNOB (BLACK) KNOB (GRAY) GROOVE PIN WASHER ANCHOR BRACKET (BLACK) ANCHOR BRACKET (GRAY) ANODE ASSEMBLY SCREW (M6 x 25) WASHER SCREW (30 MM) SCREW (35 MM) LOCKWASHER NUT DECAL, Tilt Lock TILT PIN ASSEMBLY NON POWER TRIM SPRING TILT TUBE

23

2

NUT

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

1 1 1 1 1 1 4 4 4 1 1 1 1 1 1 1

SEAL KIT O RING SPACER CLIP C-WASHER POWER TRIM SCREW SCREW WASHER NUT LINK TILT LEVER BUSHING NON POWER TRIM WASHER WAVE WASHER TILT KNOB SCREW (.375-16 x .62)

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

N·m

60

6.8

Tighten nut to 32 lb. ft. and then back off 1/4 turn

Drive Tight Drive Tight Drive Tight

18.3

24.9

MID-SECTION — 5B-5

Swivel Bracket Components

10

9 17

12 13 11

18

16

19

95

14 15 95

20

95

3

21

4

2

24

95

1 5

23 2

95

3 6 7 22

8

95

2-4-C with Teflon

5B-6 — MID-SECTION

90-852572R02 NOVEMBER 2002

Swivel Bracket Components REF. REF NO. QTY. 1 1 1 1 1 2 2 3 2 4 2 5 3 6 1 1 7 1 8 1 1 1 9 1 1 10 1 11 1 12 1 13 2 1 14 1 15 1 16 1 17 1 18 2

TORQUE SWIVEL BRACKET (BLACK) SWIVEL BRACKET (GRAY) SWIVEL BRACKET (BLACK) SWIVEL BRACKET (GRAY) BEARING OIL SEAL BEARING GREASE FITTING WASHER BOTTOM YOKE (BLACK) BOTTOM YOKE (GRAY) RETAINING RING SWIVEL PIN (BLACK) SWIVEL PIN (GRAY) SWIVEL PIN (BLACK) SWIVEL PIN (GRAY) PIN–Co–Pilot BRACKET STRAP SCREW (M10 x 30) LINK ROD (STARBOARD) LINK ROD (PORT) SCREW (1-1/2 IN.) WASHER NUT WASHER

19

1

NUT

20 21 22 23 24

1 1 1 1 1

WASHER ROLL PIN (HANDLE) CABLE SCREW (1/4-20x .50) DECAL (Serial Over laminate)

90-852572R02 NOVEMBER 2002

DESCRIPTION SHORT

lb. in. lb. ft.

N·m

LONG

38

4.3

SHORT

LONG

18.3

24.9

20

27.1

20

27.1

50/60

Tighten nut until it seats and then back off 1/4 turn

Drive Tight

MID-SECTION — 5B-7

Drive Shaft Housing

3 20 15

1

17

21

12 13

19 18 14

33

2

9 6

7 11

8 4 5

14 10

16

23 22 7 8

33

33

Loctite 680 Retaining Compound

5B-8 — MID-SECTION

90-852572R02 NOVEMBER 2002

Drive Shaft Housing REF. REF NO. QTY. 1 1 1 1 1 1 2 1 3 6 4 4 5 5 4 6 4 7 1 8 1 6 4 7 5 8 5 9 1 10 1 11 1 12 2 13 2 14 4 15 1 16 2 17 4 18 2 19 4 20 2 21 4 1 22 1 23 1

TORQUE DESCRIPTION DRIVE SHAFT HOUSING (SHORT) DRIVE SHAFT HOUSING (LONG) DRIVE SHAFT HOUSING (JET 45) STUD (M10 x 60) (SHORT/LONG) STUD (M10 x 100) (60 BIG FOOT — LONG) STUD (M10 x 166) (60 BIG FOOT — LL) SCREW (M10 x 110) STUD (M10 x 124) (60 BIGFOOT — LL — FRONT) STUD (M10 x 120) (55 LL — FRONT) SCREW (SHORT/LONG)(NON JET MODELS) WASHER WASHER NON BIGFOOT MODELS NUT WASHER WASHER BIGFOOT MODELS NUT SPEEDOMETER PICK-UP ASSEMBLY CONNECTOR (STRAIGHT) FITTING BOLT (M12 x 154) LOWER MOUNT WASHER GROUND WIRE NUT SCREW (M8 x 25) CLAMP NUT COVER SCREW SPACER SPACER (LL) COUPLING

MODEL VERSION LENGTH DESIGNATION: SHORT = 15 IN. LONG = 20 IN.

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

N·m

30

40

40

54.2

40

54.2

40

54.2

18.3

24.9

50 18.3

67.8 24.9

Drive Tight

LL = 22-1/2 IN.

MID-SECTION — 5B-9

Drive Shaft Housing Disassembly/Reassembly Servicing components such as steering arm, drive shaft housing, exhaust assembly and swivel bracket will usually require powerhead and/or gear housing removal.

WARNING Failure to support outboard as shown could result in personal injury and/or damage to outboard or boat.

a

Refer to Section 4 for powerhead removal and Section 6B for gear housing removal. The transom bracket, lower mount bracket, tilt tube and lower engine mounts can be serviced without powerhead/gear housing removal. However, OUTBOARD MUST BE SUPPORTED BEFORE SERVICING COMPONENTS.

b c

51078 a — Hoist b — Rope c — Lifting Eye (91-90455T)

IMPORTANT: All gaskets should be replaced when removing powerhead and/or disassembling drive shaft housing. Corresponding gasket mating surfaces should be cleaned of any gasket material before installing new gaskets.

5B-10 — MID-SECTION

90-852572R02 NOVEMBER 2002

MID SECTION

5 C

40/50 POWER TRIM

Table of Contents Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . Power Trim Components . . . . . . . . . . . . . . . . Theory Of Operation . . . . . . . . . . . . . . . . . . . . Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . Trimming Characteristics . . . . . . . . . . . . . Trailering Outboard . . . . . . . . . . . . . . . . . . Tilting Outboard Up and Down Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . Trim “In” Angle Adjustment . . . . . . . . . . . . Power Trim Flow Diagrams . . . . . . . . . . . Trim Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tilt Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum Tilt . . . . . . . . . . . . . . . . . . . . . . . . Down Mode . . . . . . . . . . . . . . . . . . . . . . . . . Shock Function Up . . . . . . . . . . . . . . . . . . Shock Function Return . . . . . . . . . . . . . . . Manual Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . Preliminary Checks . . . . . . . . . . . . . . . . . . Hydraulic System Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting the Power Trim Electrical System . . . . . . . . . . . . . . . . . . . . Troubleshooting the Power Trim Electrical System . . . . . . . . . . . . . . . . . . . .

5C-0 — MID-SECTION

Page 5C-1 5C-2 5C-4 5C-4 5C-4 5C-5 5C-5 5C-5 5C-6 5C-7 5C-9 5C-11 5C-13 5C-15 5C-17 5C-19 5C-20 5C-20 5C-21 5C-22 5C-23

Power Trim System Removal . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . Shock Rod Removal . . . . . . . . . . . . . . . . . Shock Rod Disassembly . . . . . . . . . . . . . . . . Memory Piston Removal . . . . . . . . . . . . . . Trim Motor Removal . . . . . . . . . . . . . . . . . Oil Pump Removal . . . . . . . . . . . . . . . . . . . Tilt Relief Valve Removal . . . . . . . . . . . . . Suction Seat Removal . . . . . . . . . . . . . . . . Pilot Check Valve Assembly Removal . . Cleaning/Inspection/Repair . . . . . . . . . . . . . . Trim Motor Electrical Tests . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . O-Ring and Seal Placement . . . . . . . . . . . Power Trim Reassembly . . . . . . . . . . . . . . . . Tilt Relief Valve Reassembly . . . . . . . . . . Suction Seat Reassembly . . . . . . . . . . . . Pilot Check Valve Reassembly . . . . . . . . Oil Pump Reassembly . . . . . . . . . . . . . . . . Trim Motor Reassembly . . . . . . . . . . . . . . Shock Rod Reassembly . . . . . . . . . . . . . . Shock Rod Installation . . . . . . . . . . . . . . . Manual Release Valve Installation . . . . . Bleeding Power Trim Unit . . . . . . . . . . . . . Power Trim System Installation . . . . . . . . . .

Page 5C-27 5C-28 5C-28 5C-29 5C-31 5C-32 5C-33 5C-33 5C-34 5C-34 5C-35 5C-35 5C-36 5C-36 5C-38 5C-38 5C-38 5C-39 5C-39 5C-40 5C-40 5C-42 5C-42 5C-42 5C-43

5C-24 5C-25 5C-26

90-852572R02 NOVEMBER 2002

Special Tools 1. Spanner Wrench P/N 91-74951

2. Lock-Ring Pliers P/N 91-822778A3

3. Expanding Rod P/N CG 41-11*

4. Collet P/N CG 41-12*

5. Heat Lamp P/N 91-63209

* = Snap-On 90-852572R02 NOVEMBER 2002

MID-SECTION — 5C-1

Power Trim Components 27 28 29

B

11

A

12

13

25

14

20

2

G

15 110

16

110

8 17

22

C 6

21

26 23

110

24

1

10

25

9

D

7 3

4

19 3

E 5

D

18 25

F

5C-2 — MID-SECTION

114

Liquid Neoprene Power Trim and Steering Fluid

90-852572R02 NOVEMBER 2002

Power Trim REF. REF NO. QTY. 1 1 – 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 10 1 11 1 12 4 13 4 14 1 15 1 16 1 17 1 18 1 19 1 20 1 21 1 22 2 23 2 24 2 25 2 26 2 27 1 28 1 29 2

TORQUE DESCRIPTION POWER TRIM ASSEMBLY O-RING KIT SHOCK ROD ASSY. PILOT CHECK ASSEMBLY TILT RELIEF VALVE ASSEMBLY SUCTION SEAT ASSEMBLY PUMP ASSEMBLY BALL/SPRING SCREW FILTER O-RING MOTOR ASSEMBLY SCREW WASHER CABLE O-RING COUPLER MEMORY PISTON MANUAL RELEASE VALVE ASSEMBLY RESERVOIR PLUG BRACKET HARNESS-Trim SCREW (M6 x 25) RELAY BRACKET GROMMET BUSHING SCREW (10-16 x 1/2 IN.) C WASHER CLIP

lb. in. lb. ft.

45

N·m

120 120 120

61 13.6 13.6 13.6

70

7.9

80

9.0

Drive Tight Drive Tight

A — Torque cylinder cap to 45 lb. ft. (61 N⋅m) B — Torque screw to 80 lb. in. (9.0 N⋅m) C — Torque screw to 70 lb. in. (7.9 N⋅m) D — Torque pilot check plug to 120 lb. in. (13.6 N⋅m) E — Torque tilt relief plug to 120 lb. in. (13.6 N⋅m) F — Torque suction seat plug to 120 lb. in. (13.6 N⋅m) G — Torque shock piston to 45 lb. ft. (61 N⋅m)

90-852572R02 NOVEMBER 2002

MID-SECTION — 5C-3

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.

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 transmission 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.

When trimming your outboard from a mid-trim position (trim tab in neutral, straight fore-and-aft, position), you can expect the following results:

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.

TRIMMING OUTBOARD “UP” (“OUT”)

TRIMMING OUTBOARD “DOWN” (“IN”)

WARNING

WARNING

Excessive trim “out” may reduce the stability of some high speed hulls. To correct instability at high speed, reduce the power gradually and trim the motor “In” slightly before resuming high speed operation. (Rapid reduction in power will cause a sudden change of steering torque and may cause additional momentary boat instability.

Excessive speed at minimum trim “In” may cause undesirable and/or unsafe steering conditions. Each boat should be tested for handling characteristics after any adjustment is made to the tilt angle (tilt pin relocation). •

Will help planing off, particularly with a heavy load.

•

Will lift bow of boat, general increasing top speed.

•

Usually improves ride in choppy water.

•

Transfers steering torque harder to left on installations below 23 in. transom height.

•

In excess, can cause boat to veer to the left or right (bow steer).

•

Increases clearance over submerged objects.

•

•

In excess, can cause porpoising and/or ventilation.

Transfers steering torque harder to right (or less to the left).

•

•

In excess, can cause insufficient water supply to water pump resulting in serious water pump and/ or powerhead overheating damage.

Improves planing speed acceleration (by moving tilt pin one hole closer to transom).

5C-4 — MID-SECTION

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 passageways into the “down” side of the trim cylinder. The trim rod will move the engine downward to the desired angle. 90-852572R02 NOVEMBER 2002

Trailering Outboard

Trim “In” Angle Adjustment

WARNING

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 position for trailering.

Tilting Outboard Up and Down Manually WARNING Before loosening the manual release valve, make sure all persons are clear of engine 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).

Operating some boats with engine trimmed to the full “in” trim angle at planing speed will cause undesirable and/or unsafe steering conditions. Each boat must be water tested for handling characteristics after engine installation and after any trim adjustments. IMPORTANT: Some boat/motor combinations that are trimmed to the full “in” trim angle, will not experience any undesirable and/or unsafe steering conditions during planing speed. However, some boats with engine trimmed to the full “in” trim angle at planing speed will cause undesirable and/or unsafe steering conditions. If these steering conditions are experienced, adjust the left and right tilt stop pins to prevent unsafe handling characteristics. Water test the boat. If undesirable and/or unsafe steering conditions are experienced (boat runs with nose down), adjust the left and right tilt stop pins in proper hole to prevent unsafe handling characteristics.

a

b

a a — Manual Release Valve

b — Left Tilt Stop Pin c — Right Tilt Stop Pin

IMPORTANT: In order to remove the right tilt stop pin it may be necessary to remove the upper pivot pin and pivot the tilt/trim assembly out of theclamp brackets. See “Power Trim System Removal” to remove the upper pivot pin.

90-852572R02 NOVEMBER 2002

MID-SECTION — 5C-5

POWER TRIM FLOW DIAGRAMS TRIM UP Reservoir and Feed Oil Oil Under Pressure Return Oil

b

a

u

t

s

n

o

w q r

w

c

v

d

p

e

Á Á Á Á Á

m l

Up Pressure 2530 PSI (minimum)

h k i

j

abc def ghi j k l m-

Electric Motor Trim Ram Impact Relief Valve Shock Piston Memory Piston Manifold Suction Seat Down Pressure Operated Valve Tilt Relief Actuator Manual Release Valve Tilt Relief Valve Up Pressure Operated Valve Down Circuit Feed Valve

5C-6 — MID-SECTION

g

f

nopqr s t uv w-

Oil Pump Up Circuit Feed Valve Check Ball Shuttle Valve Down Pressure Regulating Valve Check Ball Reservoir Oil Oil Reservoir Oil Fill Cap Shock Return Valve Filter

90-852572R02 NOVEMBER 2002

TRIM UP When the trim switch is activated in the up position, the electric motor (a) begins to rotate the pump gears, the oil pump (n) draws a small amount of oil through the filter, up circuit pick–up and past the feed valve check ball (o). The oil pump gear (n) rotation forces oil into the passages for the up circuit. Oil, under pressure, will slide the shuttle valve (p) against the down circuit pressure operated valve (h). The shuttle valve will mechanically open the down pressure 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 (t) by the ball inside the down circuit feed valve (m). The pressure of the oil will force the up circuit pressure operated valve (l) to open, allowing the oil to enter the passages inside the manifold (f) leading to the trim cylinder up cavity. Oil is blocked from all other passages by the closed manual relief valve (j) and closed tilt relief valve (k). Oil under pressure will enter the trim cylinder below the memory piston (e). With an increasing amount of oil entering the cylinder, the memory piston contacts the shock piston (d) and forces the trim ram (b) 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 cylinder and enters the manifold passages. Inside the manifold the oil seats the ball (r) inside the suction seat (g), closing the passage into the reservoir. The oil is drawn back into the pump (n) through the open pressure operated valve (h) and enters the pump as supply for the up circuit.

90-852572R02 NOVEMBER 2002

MID-SECTION — 5C-7

TILT UP Reservoir and Feed Oil Oil Under Pressure Return Oil

b

a

t

u n

p

l

d

w q r

Á ÁÁ Á ÁÁ Á

Tilt Relief Pressure 500–600 PSI

h

k i

j

abc def ghi j k l m-

c

v

e

o

w

m

s

Electric Motor Trim Ram Impact Relief Valve Shock Piston Memory Piston Manifold Suction Seat Down Pressure Operated Valve Tilt Relief Actuator Manual Release Valve Tilt Relief Valve Up Pressure Operated Valve Down Circuit Feed Valve

5C-8 — MID-SECTION

g

f

nopqr s t uv w-

Oil Pump Up Circuit Feed Valve Shuttle Valve Down Pressure Regulating Valve Check Ball Reservoir Oil Oil Reservoir Oil Fill Cap Shock Return Valve Filter

90-852572R02 NOVEMBER 2002

TILT UP In the up mode, as the trim ram (b) extends from the cylinder, the memory piston (e) clears or uncovers the pressure relief passage. Oil from the up cavity will enter this passage and open the tilt pressure relief valve (k). 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 engine rpm’s fall, or if engine is not in forward gear, the oil pressure is available to extend the trim ram (b) up into the tilt range.

90-852572R02 NOVEMBER 2002

MID-SECTION — 5C-9

MAXIMUM TILT Reservoir and Feed Oil Oil Under Pressure

b

Return Oil

a cd

v

e

t

u

n

Tilt Relief Pressure 500–600 PSI

s

o

w q r

w p m l

Á ÁÁ Á ÁÁ Á h

k i

j

abc def ghi j k l m-

Electric Motor Trim Ram Impact Relief Valve Shock Piston Memory Piston Manifold Suction Seat Down Pressure Operated Valve Tilt Relief Actuator Manual Release Valve Tilt Relief Valve Up Pressure Operated Valve Down Circuit Feed Valve

5C-10 — MID-SECTION

g

f

nopqr s t uv w-

Oil Pump Up Circuit Feed Valve Shuttle Valve Down Pressure Regulating Valve Check Ball Reservoir Oil Oil Reservoir Oil Fill Cap Shock Return Valve Filter

90-852572R02 NOVEMBER 2002

MAXIMUM TILT With the cylinder at maximum travel, and due to no ram movement, the pressure inside of the trim cylinder will increase to the pressure required to move the tilt relief actuator (i). The tilt relief actuator’s ”pin” opens the tilt relief valve (k). Up pressure flows into the trim relief passage, and return back into the reservoir (t).

90-852572R02 NOVEMBER 2002

MID-SECTION — 5C-11

TRIM DOWN Reservoir and Feed Oil Oil Under Pressure

b

Return Oil

a

Down Relief 500–800 PSI

t

u n

s o o

w

v

q r

w

p

cd e

m

Á Á ÁÁ Á ÁÁ

m l l

k

h

k i

j

abc def ghi j k l m-

Electric Motor Trim Ram Impact Relief Valve Shock Piston Memory Piston Manifold Suction Seat Down Pressure Operated Valve Tilt Relief Actuator Manual Release Valve Tilt Relief Valve Up Pressure Operated Valve Down Circuit Feed Valve

5C-12 — MID-SECTION

g

f

nopqr s t uv w-

Oil Pump Up Circuit Feed Valve Shuttle Valve Down Pressure Regulating Valve Check Ball Reservoir Oil Oil Reservoir Oil Fill Cap Shock Return Valve Filter

90-852572R02 NOVEMBER 2002

DOWN MODE When the trim switch is activated in the down position, the electric motor (a) will rotate the pump (n) in the opposite direction. With the pump gears rotating backwards, the flow of oil is reversed. Oil is drawn through the filter, past the feed check valve (m), into the down circuit oil pick–up, and finally into the oil pump. The pump feeds pressurized oil into the down passages, oil will slide the shuttle valve (p) into the up circuit pressure operated valve (l). The shuttle valve will mechanically open the pressure operated valve and allow oil, from the up cavity of the manifold (f), 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 reservoir by the shuttle valve (p) inside the up circuit feed valve. Oil, under pressure, opens the pressure operated valve (h) and enters the down passages inside of the manifold (f). The manifold passage connects into the trim cylinder passage leading to the top of the cylinder. The cavity, inside the cylinder, above the shock piston (d) is the down cavity. As the down cavity fills with oil, the trim ram (b) 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 up pressure operated valve (l). When the trim ram reaches full travel, the oil pressure inside the down circuit will rise until the down pressure regulation valve (q) opens, bypassing oil back into the reservoir(t). When the trim button is released, and the oil pump stops supplying pressure, both of the pressure operated valves (h & l) will close and; if open, the down pressure regulating valve (q) will close. The closed valves will lock the fluid on either side of the shock piston (d), holding the outboard motor in position.

90-852572R02 NOVEMBER 2002

MID-SECTION — 5C-13

SHOCK FUNCTION UP Reservoir and Feed Oil Oil Under Pressure

b

Return Oil

a

t

u

s v

n o w

q r

w

cd 1550–1850 PSI

p

e

Á Á Á Á Á

m l

h k i

j

abc def ghi j k l m-

Electric Motor Trim Ram Impact Relief Valve Shock Piston Memory Piston Manifold Suction Seat Down Pressure Operated Valve Tilt Relief Actuator Manual Release Valve Tilt Relief Valve Up Pressure Operated Valve Down Circuit Feed Valve

5C-14 — MID-SECTION

g

f

nopqr s t uv w-

Oil Pump Up Circuit Feed Valve Shuttle Valve Down Pressure Regulating Valve Check Ball Reservoir Oil Oil Reservoir Oil Fill Cap Shock Return Valve Filter

90-852572R02 NOVEMBER 2002

SHOCK FUNCTION UP Oil inside the down cavity is locked in a static position by the down pressure operated valve (h), the manual release valve (j) and the tilt relief valve (k). If the outboard strikes an underwater object while in forward gear the trim ram (b) will try to rapidly extend from the cylinder, the pressure increases inside the trim cylinder down cavity and connecting passages. The rise in pressure will seat the check ball (r) inside the suction seat (g), preventing fluid from returning into the reservoir. When the pressure increases to the level required, the impact relief valve (c), located inside the shock piston (d), will open and allow the fluid to pass through the shock piston. As the fluid passes through the piston, the trim ram (b) will extend from the trim cylinder. The memory piston (e) 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 trim ram piston is trapped between the memory piston (e) and shock piston (d).

90-852572R02 NOVEMBER 2002

MID-SECTION — 5C-15

SHOCK FUNCTION RETURN Reservoir and Feed Oil

b

Oil Under Pressure Return Oil

a

t

u

s v

n w

o

cd

w q r

p

Á Á ÁÁ Á Á ÁÁ ÁÁ

e

m l

h

k i

j

abc def ghi j k l m-

Electric Motor Trim Ram Impact Relief Valve Shock Piston Memory Piston Manifold Suction Seat Down Pressure Operated Valve Tilt Relief Actuator Manual Release Valve Tilt Relief Valve Up Pressure Operated Valve Down Circuit Feed Valve

5C-16 — MID-SECTION

g

f

nopqr s t uv w-

Oil Pump Up Circuit Feed Valve Shuttle Valve Down Pressure Regulating Valve Check Ball Reservoir Oil Oil Reservoir Oil Fill Cap Shock Return Valve Filter

90-852572R02 NOVEMBER 2002

SHOCK FUNCTION RETURN After the engine clears the under water object, the weight of the engine will increase the oil pressure between the memory piston (e) and shock piston (d) to the level required to open the shock return valve (v), inside the shock piston, allowing the oil to bleed back through the shock piston into the down cavity. If required, additional oil will enter the down cavity through the suction seat (g). This will return the engine back against the memory piston (e) into the original running position.

90-852572R02 NOVEMBER 2002

MID-SECTION — 5C-17

MANUAL TILT Reservoir and Feed Oil Return Oil

b

a

t

u

s

n o w

q r w

v

p

Á Á Á Á Á

cd e

m

l

h

k i

j

abc def ghi j k l m-

Electric Motor Trim Ram Impact Relief Valve Shock Piston Memory Piston Manifold Suction Seat Down Pressure Operated Valve Tilt Relief Actuator Manual Release Valve Tilt Relief Valve Up Pressure Operated Valve Down Circuit Feed Valve

5C-18 — MID-SECTION

g

f

nopqr s t uv w-

Oil Pump Up Circuit Feed Valve Shuttle Valve Down Pressure Regulating Valve Check Ball Reservoir Oil Oil Reservoir Oil Fill Cap Shock Return Valve Filter

90-852572R02 NOVEMBER 2002

MANUAL TILT To manually tilt the outboard engine, the owner will need to back out the manual release valve (j). With the valve backed out, the internal passages inside the manifold are connected together. These passages connect both the cylinder down and up cavities together, along with the reservoir (t), allowing the engine to be raised or lowered. Trim ram (b) movement will continue until the manual release valve is closed, locking the fluid inside of the cylinder and manifold.

90-852572R02 NOVEMBER 2002

MID-SECTION — 5C-19

Troubleshooting

Follow preliminary checks before proceeding to troubleshooting flow diagrams (following).

Support outboard with tilt lock pin when servicing power trim system. IMPORTANT: After debris or failed components have been found (during troubleshooting 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.

Preliminary Checks

IMPORTANT: Power trim system is pressurized. Outboard must be in the full “UP” position (trim rod fully extended) prior to fill/drain plug, or manual release valve removal.

2. Check trim pump fluid level with outboard in full “UP” position and fill if necessary. Refer to “Bleeding Power Trim Unit”.

Refer to instructions following if disassembly is required when servicing.

5C-20 — MID-SECTION

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.

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 defective components in trim assembly. Clean or replace components as required.

90-852572R02 NOVEMBER 2002

Hydraulic System Troubleshooting Flow Chart OUTBOARD WILL NOT HOLD TILTED POSITION DURING REVERSE AND/OR TRAILS OUT DURING HIGH SPEED DECELERATION.

Manual release valve and O-ring damaged.

Manual release valve and O-rings appear to be O.K. — Clean and reinstall manual release valve.

Inspect manual release valve.

Trim will not hold reverse thrust.

Replace manual release valve and O-rings.

Trim system holds reverse thrust. Testing complete.

Trim system holds reverse thrust. Testing complete.

Remove and inspect piston rod assembly for debris and/or shock ball hang up.

Debris and/or shock ball hang up identified.

Trim will not hold reverse thrust.

Replace piston rod assembly.

Trim system holds reverse thrust. Testing complete.

Remove PO check valve assembly, inspect Orings and seals for damage.

Trim system holds reverse thrust. Testing complete.

Debris and/or damage identified.

PO check valve appears O.K. — Clean and reinstall PO check valve assembly.

Replace PO check valve assembly.

Trim system holds reverse thrust. Testing complete.

Shock piston appears O.K. — Clean and reinstall piston rod assembly.

Trim system holds reverse thrust. Testing complete. Trim will not hold reverse thrust.

continued on next page 90-852572R02 NOVEMBER 2002

MID-SECTION — 5C-21

Hydraulic System Troubleshooting Flow Chart continued

Remove suction seat assembly and inspect for debris and/or damage. Suction seat assembly appears O.K. — Clean and reinstall suction seat assembly.

Debris and/or damage identified.

Replace suction seat assembly.

Trim system holds reverse thrust. Testing complete.

5C-22 — MID-SECTION

Trim will not hold reverse thrust.

Trim system holds reverse thrust. Testing complete.

Replace trim system.

90-852572R02 NOVEMBER 2002

Hydraulic System Troubleshooting Flow Chart TRIM SYSTEM LEAKS DOWN WITH MANUAL RELEASE VALVE CLOSED.

Manual release valve and O-ring damaged.

Inspect manual release valve.

Trim system down.

Replace manual release valve and O-rings.

leaks Trim system does not leak down. Testing complete.

Remove tilt relief valving and inspect O-rings and seals for debris and/or damage.

Trim system does not leak down. Testing complete.

Tilt relief valving and O-rings appear to be O.K. — Clean and reinstall tilt relief valving.

Debris and/or damage identified.

Replace tilt relief valving.

Trim system does not leak down. Testing complete.

Trim system down.

Replace PO check valve assembly.

90-852572R02 NOVEMBER 2002

leaks

Trim system does not leak down. Testing complete.

Remove PO check valve assembly, inspect Orings and seals for damage.

Debris and/or damage identified.

Trim system does not leak down. Testing complete.

Manual release valve and Orings appear to be O.K. — Clean and reinstall manual release valve.

Trim system down.

PO check valve appears O.K. — Clean and reinstall PO check valve assembly.

leaks

Trim system does not leak down. Testing complete.

continued on next page

MID-SECTION — 5C-23

Hydraulic System Troubleshooting Flow Chart continued

Inspect memory piston O-ring and cylinder bore. Cylinder bore appears smooth with no debris.

Replace memory piston and shock piston O-rings.

Trim system does not leak down. Testing complete.

5C-24 — MID-SECTION

Cylinder bore appears rough and/or debris found in cylinder.

Trim leaks down.

Replace trim system.

90-852572R02 NOVEMBER 2002

Troubleshooting the Power Trim Electrical System Trim Switch (Remote Control Mounted)

Trim Switch (Panel Mounted)

UP DN

UP DN

BLU/WHT

Fuse Holder

GRN/WHT BLU/WHT or PUR GRN/WHT or GRN RED

Remote Control RED

Fuse Holder

+

B

–

2

RED/PUR

A

RED/PUR RED

Battery Starter Bolt GRN/WHT

Solenoid

BLU/WHT

3

Down Relay LT. GRN/WHT

GRN/WHT GRN 14 BLK RED BLK

LT. GRN/WHT

LT. BLU/WHT

LT.BLU/WHT BLUE 14 BLK RED BLK

Up Relay

LT. BLU/WHT

4

1 UP DN

Cowl Switch

Trim Pump Motor

90-852572R02 NOVEMBER 2002

MID-SECTION — 5C-25

Troubleshooting the Power Trim Electrical System Refer to wiring diagram on preceding page for location of wire connections. Problem

Possible Cause

Remedy

Trim Switch “UP” is inopera1. Open wire between Wire Connection (1) tive, but the Cowl Switch “UP” and Trim Switch. does operate. 2. Faulty Trim Switch.

1. Check for an open connection or cut wire. 2. Replace.

Cowl Switch “UP” is inoperative, but the Trim Switch “UP” does operate.

1. Check for an open connection or cut wire. 2. Replace.

1. Open wire between Wire Connection (2) and Solenoid. 2. Faulty Cowl Switch.

Trim Switch “UP” and Cowl 1. Open wire between Wire Connection (1) Switch “UP” are both inopera- and the “Up” Relay tive. 2. Open BLK wire between ground and “UP” Relay. 3. Open RED wire between Solenoid and “Up” Relay 4. Faulty Up Relay .

1. Check for an open connection.

Trim Switch “DOWN” is inoperative, but the Cowl Switch “DOWN” does operate.

1. Open wire between Wire Connection (3) and Trim Switch. 2. Faulty Trim Switch.

1. Check for an open connection or cut wire. 2. Replace.

Cowl Switch “DOWN” is inoperative, but the Trim Switch “DOWN” does operate.

1. Open wire between Wire Connection (2) and Solenoid. 2. Faulty Cowl Switch.

1. Check for an open connection or cut wire. 2. Replace.

Trim Switch “DOWN” and Cowl Switch “DOWN” are both inoperative.

1. Open wire between Wire Connection (3) and the “Up” Relay. 2. Open BLK wire between ground and “Down” Relay. 3. Open RED wire between Solenoid and “Down” Relay. 4. Faulty “Down” Relay.

1. Check for an open connection.

Trim Switch “UP” and “DOWN” are both inoperative, but the Cowl Switch does operate.

1. 20 AMP Fuse blown. 2. Faulty trim switch. 3. Wire is open between fuse holder and solenoid. 4. Wire is open between fuse holder and trim switch.

1. Replace fuse. Locate the cause of the blown fuse. Check electrical wiring for a shorted circuit. 2. Replace. 3. Check for an open connection or cut wire. 4. Check for a loose or corroded connection.

Trim Switch and Cowl Switch are both inoperative.

1. One of the Trim Pump Motor wires is open between the motor and the Relays. 2. Faulty trim pump motor.

1. Check wire connections (4) for loose or corroded condition. 2. If voltage is present at connections (4) when the appropriate trim button is pressed, than motor is faulty. Replace motor.

Trim system operates (motor runs) without pressing the switches.

1. The Trim or Cowl switch is shorted.

1. Replace.

5C-26 — MID-SECTION

2. Check for an open connection. 3. Check for an open connection. 4. Replace.

2. Check for an open connection. 3. Check for an open connection. 4. Replace.

90-852572R02 NOVEMBER 2002

Power Trim System Removal

3. Remove the trilobe pin

1. Tilt outboard to the full up position and support with tilt lock pin.

4. Drive out the upper pivot pin.

a b

a — Tilt Lock Pin

a

2. Disconnect the power trim wire harness and remove clamps.

a — Trilobe Pin b — Upper Pivot Pin

5. Remove the sacrificial anode.

a a — Power Trim Wire Harness Clamps

a a — Sacrificial Anode

90-852572R02 NOVEMBER 2002

MID-SECTION — 5C-27

6. Remove nuts and washers securing the lower pivot pin. Remove lower pivot pin. Retain the pivot pin bushings from the clamp brackets and trim unit. 7. Remove the trim unit.

Disassembly Shock Rod Removal IMPORTANT: Power trim system is pressurized. Outboard must be in the full “UP” position (trim rod fully extended) prior to fill/drain plug, or manual release valve removal. 1. Remove reservoir cap. 2. Remove manual release valve assembly.

a b a — Reservoir Cap b — Manual Release Valve

3. Drain power trim fluid as shown.

5C-28 — MID-SECTION

90-852572R02 NOVEMBER 2002

4. Secure power trim assembly in a soft jaw vise.

Shock Rod Disassembly

5. Unscrew end cap assembly from cylinder using spanner wrench 91-74951.

NOTE: The only serviceable items on the shock rod assembly are the o-rings and wiper ring. If shock rod requires any other repair, replace shock rod assembly.

d c 6. Remove shock rod assembly from cylinder.

c b

a c c a b c d

—

End Cap Shock Piston O-ring Wiper Ring

1. Place shock rod assembly on clean work surface. 2. Remove bolt from end of shock rod.

a

a — Bolt

90-852572R02 NOVEMBER 2002

MID-SECTION — 5C-29

3. Remove check ball components from shock rod piston.

CAUTION When removing shock piston, spanner wrench must have 1/4 in. x 5/16 in. long pegs to avoid damage to shock piston.

4. Remove o-ring from shock rod 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].

c b

7. Allow shock rod piston to cool. Remove from shock rod.

a

d 51147

a b c d

—

Spring (5) Seat (5) Ball (5) O-ring

51146

a

b

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.

5C-30 — MID-SECTION

90-852572R02 NOVEMBER 2002

10. Remove inner o-ring from shock rod piston.

Memory Piston Removal 15. Remove memory piston from cylinder using one of two methods: a. Using lock ring pliers (P/N 91-822778A3) or suitable tool.

b a 51199

a — Shock Piston b — O-ring

11. Remove cylinder end cap assembly from shock rod.

b. Blowing compressed air into manual release valve hole using air nozzle.

12. Inspect shock. If wiper (located in cap) has failed to keep rod clean, replace wiper.

WARNING

13. Place end cap on clean work surface. 14. Remove rod wiper, inner o-ring, and outer o-ring.

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.

a

a c b b

51145

a — Rod Wiper b — Inner O-ring c — Outer O-ring

d

c

a b c d

90-852572R02 NOVEMBER 2002

—

Adaptor Air Hose Memory Piston Exit Shop Rag

MID-SECTION — 5C-31

16. Remove o-ring from memory piston.

Trim Motor Removal 1. Secure power trim assembly in soft jawed vise. 2. Remove screws securing trim motor to manifold. 3. Remove motor assembly.

a a b a — O-ring

a — Trim Motor b — Screw (4)

5C-32 — MID-SECTION

90-852572R02 NOVEMBER 2002

Oil Pump Removal

Tilt Relief Valve Removal

1. Remove oil filter and pump from manifold.

NOTE: The following procedures requires the use of a Snap-On blind hole removal tool #CG 41-11 with 5/16” attachment #41-12. Or a removal tool can be fabricated with the material and specifications listed below.

IMPORTANT: DO NOT disassemble the oil pump. The pump is not serviceable.

a

3 1/4” 1/4”

b

e 4 1/2”

d c f

a

a — Removal Tool made from .060 Stainless Steel Rod

a b c d e f

—

Screw (2) Oil Pump Spring Filter O-Ring Down Relief Ball

90-852572R02 NOVEMBER 2002

MID-SECTION — 5C-33

1. Unscrew plug from manifold and remove spring and poppet assembly.

NOTE: Do not lose shim that may be lodged in the plug. 2. Use the removal tool and pull out the pilot valve.

Suction Seat Removal 1. Unscrew plug from manifold and remove ball. 2. Use a pin punch and knock the filter and suction seat out from the inside of the manifold cavity.

CAUTION DO NOT use any tool on the suction seat as any damage to the surface will not allow the ball to seat.

a

a b c

b

b

d

b b

c d e a b c d e f g h

—

f

g

h

Tilt Relief Valve Assembly O-Rings Actuator Pin Pilot Valve Poppet Assembly Spring Shim Plug

a b c d

—

Filter Suction Seat Ball Plug

Pilot Check Valve Assembly Removal 1. Unscrew both plugs. 2. Remove both springs and poppets.

IMPORTANT: Inspect poppet assembly for debris in the area shown. If debris is found on poppet, replace poppet.

a b

a — Debris Under Valve Tip b — Rubber Seat

5C-34 — MID-SECTION

90-852572R02 NOVEMBER 2002

3. Use the (.060 wire) removal tool (see previous page) and push out the spool and one seat.

Cleaning/Inspection/Repair

4. From opposite side, use a punch and push out the remaining seat.

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 25-827668A1. Lubricate all O-rings with power trim 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 assembly.

a

a b c d e

—

b

c

d

e

d

b

c

a

Plug (2) Spring (2) Poppet Assembly (2) Seat (2) Spool (1)

IMPORTANT: Inspect poppet assemblies for debris in the area shown. If debris is found on poppets, replace poppets.

a b

a — Debris Under Valve Tip b — Rubber Seat

90-852572R02 NOVEMBER 2002

MID-SECTION — 5C-35

Reassembly O-Ring and Seal Placement O-Rings and Seals are part of O-Ring Kit 25-827668A1

q

r

p

o l n m

k

i w h j

v

a

b c

w d

h i

w

g u e

t

s

f

5C-36 — MID-SECTION

90-852572R02 NOVEMBER 2002

O-Ring and Seal Placement O-Ring

Description

O-Ring I.D.

O-Ring O.D.

O-Ring Width

a

Actuator Pin

0.07 in. (1.78 mm)

0.21 in. (5.33 mm)

0.07 in. (1.78 mm)

b

Tilt Relief Cartridge

0.239 in. (6.07 mm)

0.379 in. (9.63 mm)

0.07 in. (1.78 mm)

c

Tilt Relief Cartridge

0.301 in. (7.65 mm)

0.441 in. (11.20 mm)

0.07 in. (1.78 mm)

d

Tilt Relief Plug

0.359 in. (9.12 mm)

0.565 in. (14.35 mm)

0.139 in. (3.53 mm)

e

Suction Seat

0.301 in. (7.65 mm)

0.441 in. (11.20 mm)

0.07 in. (1.78 mm)

f

Suction Seat Plug

0.487 in. (12.37 mm)

0.693 in. (17.60 mm)

0.103 in. (2.62 mm)

g

Spool

0.239 in. (6.07 mm)

0.379 in. (9.63 mm)

0.07 in. (1.78 mm)

h

P. O. Check Seat

0.364 in. (9.25 mm)

0.504 in. (12.80 mm)

0.07 in. (1.78 mm)

i

P. O. Check Plug

0.489 in. (12.42 mm)

0.629 in. (15.98 mm)

0.07 in. (1.78 mm)

j

Pump Ports

0.145 in. (3.68 mm)

0.285 in. (7.24mm)

0.07 in. (1.78 mm)

k

Pump Filter

l

Reservoir/Motor

2.614 in. (66.40 mm)

2.754 in. (70.0 mm)

0.07 in. (1.78 mm)

m

Memory Piston

1.037 in. (26.34 mm)

1.457 in. (37.0 mm)

0.21 in. (5.33 mm)

n

Piston Bolt

0.364 in. (9.25 mm)

0.504 in. (12.80 mm)

0.07 in. (1.78 mm)

o

Shock Piston

1.171 in. (29.74 mm)

1.449 in. (36.80 mm)

0.139 in. (3.53 mm)

p

Cylinder Cap

1.364 in. (34.65 mm)

1.50 in. (38.10 mm)

0.07 in. (1.78 mm)

q

Wiper Ring

r

Cylinder Cap — Inner

0.546 in. (13.87 mm)

0.752 in. (19.10 mm)

0.139 in. (3.53 mm)

s

Manual Release Valve

0.239 in. (6.07 mm)

0.379 in. (9.63 mm)

0.07 in. (1.78 mm)

t

Manual Release Valve

0.176 in. (4.47 mm)

0.316 in. (8.03 mm)

0.07 in. (1.78 mm)

u

Manual Release Valve

0.114 in. (2.90 mm)

0.254 in. (6.45 mm)

0.07 in. (1.78 mm)

v

Reservoir Plug

0.426 in. (10.82 mm)

0.566 in. (14.38 mm)

0.07 in. (1.78 mm)

w

Check Valve

O-ring, Pump Filter — Square Cut

Cutaway Veiw Of O-Ring Width

O.D.

90-852572R02 NOVEMBER 2002

I.D.

MID-SECTION — 5C-37

Power Trim Reassembly

Suction Seat Reassembly

IMPORTANT: Lubricate all O-rings with Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid.

1. Lubricate O-rings with power trim fluid.

Tilt Relief Valve Reassembly

3. Install ball and plug. Torque plug to 120 lb. in. (13.5 N·m).

2. Install filter and suction seat using a 9/32” or 7 mm socket on OUTSIDE diameter of suction seat.

1. Lubricate O-rings with power trim fluid. 2. Place actuator pin into pilot valve. 3. Install and seat the pilot valve into manifold. Seat the pilot valve using a 9/32″ or 7 mm socket on OUTSIDE diameter of the pilot valve.

a

IMPORTANT: The pilot valve must be seated using a suitable mandrel on the OUTSIDE diameter.

b

4. Install poppet, spring, shim (if used) and plug. Torque plug to 120 lb. in. (13.5 N·m).

c d

a b c d

a b

b

—

Filter Suction Seat Ball Plug — Torque to 120 lb. in (13.5 N⋅m)

b b

c

c d e a b c d e f g h

—

f

g

h

Tilt Relief Valve Assembly O-Rings Actuator Pin Pilot Valve Poppet Assembly Spring Shim Plug — Torque to 120 lb. in (13.5 N⋅m)

5C-38 — MID-SECTION

90-852572R02 NOVEMBER 2002

Pilot Check Valve Reassembly

Oil Pump Reassembly

1. Lubricate o-rings with power trim fluid.

1. Install the down relief ball and spring into manifold.

2. Install one of the seats into manifold. Push the seat into place using a 9/32” or 7 mm socket on the OUTSIDE diameter of the seat.

2. Check to see that O-Rings are placed on bottom of pump.

3. Install corresponding poppet, spring and plug.

3. Place O-Ring (square cut) on filter.

4. From the opposite side of the manifold, install spool and the other seat. Push the seat into place using a 9/32” or 7 mm socket on OUTSIDE diameter of seat.

4. Place filter over the oil pump. 5. Install oil pump with two (2) screws. Torque screws to 70 lb. in. (7.9 N·m).

5. Install remaining poppet, spring and plug. Torque plugs to 120 lb. in. (13.5 N·m).

a

g

b

a c

b c

d

d

e f

e d c b a a b c d e

—

Plug (2) — Torque to 120 lb. in (13.5 N⋅m) Spring (2) Poppet (2) Seat (2) Spool a b c d e f g

90-852572R02 NOVEMBER 2002

—

Screws (2) — Torque to 70 lb. in (7.9 N⋅m) Oil Pump O-ring Filter Spring Down Relief Ball Pump O-Ring (2)

MID-SECTION — 5C-39

Trim Motor Reassembly

Shock Rod Reassembly

1. Align coupler between oil pump and motor.

1. Install lubricated o-rings to end cap.

2. Install trim motor and secure with four (4) screws. Torque screws to 80 lb. in. (9.0 N·m).

2. Install rod wiper.

a c

f

b

c e

51145

a — Rod Wiper b — Inner O-ring c — Outer O-ring

d 3. Install lubricated o-rings to shock piston.

b

a

c

b a

51199

a — Shock Piston b — O-ring c — O-ring

a b c d e f

—

Coupler O-ring Trim Pump Motor Ground Strap Lock Washer (1) Screws (4) — Torque to 80 lb. in (9.0 N⋅m)

5C-40 — MID-SECTION

90-852572R02 NOVEMBER 2002

4. Clamp shock rod in soft jawed vise.

9. Remove shock rod assembly from vise.

5. Position cylinder end cap onto rod as shown.

10. Install ball, seat, and spring (five sets) to shock rod piston.

c b a

51147 51146

CAUTION When installing shock rod piston, spanner wrench must have 1/4 in. x 5/16 in. (6.4mm x8mm) long pegs to avoid damage to shock rod piston. 6. Apply Loctite 271 Thread Locker to threads on shock rod.

a — Spring (5) b — Seat (5) c — Ball (5)

11. Secure components with shock piston bolt. Torque bolt to 45 lb.in. (61 Nm).

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 N⋅m).

b

a

a

a — Bolt — Torque to 45 lb. in (61 N⋅m)

51146

a — Shock Rod Piston — Torque to 90 lb. ft (122 N⋅m) b — Spanner Wrench

90-852572R02 NOVEMBER 2002

MID-SECTION — 5C-41

Shock Rod Installation

Manual Release Valve Installation

1. Place trim cylinder in soft jawed vice.

1. Install “E” clip (if removed) and lubricate o-rings with power trim fluid.

2. Install lubricated o-ring to memory piston and place into cylinder. Push memory piston all the way to bottom.

2. Insert manual release valve into manifold and tighten securely.

a b

a — Memory Piston b — O-ring

3. Fill cylinder three inches (76.2mm) from top of cylinder using Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. 4. Install shock rod into cylinder until power trim fluid flows through oil blow off ball passage. Fill remaining cylinder to just below the cylinder threads.

Bleeding Power Trim Unit 1. Secure power trim unit in soft jawed vise. 2. Remove reservoir plug. Add power trim fluid until its even with the bottom of the fill hole. Reinstall plug. 3. Close the manual release valve. (Turn full clockwise).

a a

a — 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 [3/16 in. x 5/16 in. (4.8mm x 8mm) long pegs]. If a torquing type spanner tool is used to tighten end cap, then torque to 45 lb. ft. (61.0 N·m).

a — Reservoir Plug

4. Using a 12 volt power supply connect the positive lead to (blue) trim motor wire and negative lead to (green) trim motor wire and drive shock rod to the up position. 5. Using a 12 volt power supply, connect the positive lead to the (green) trim motor wire, and the negative lead to the (blue) trim motor wire and drive the shock rod to the down position. 6. Recheck fluid level with rod fully extended, add fluid if required and repeat cycle until fluid level stays even with the bottom of the fill hole.

5C-42 — MID-SECTION

90-852572R02 NOVEMBER 2002

4. Install sacrificial anode to clamp brackets. Fasten ground strap between anode and clamp bracket.

Power Trim System Installation 1. Lubricate lower pivot pin, mounting holes and bushings with 2-4-C with Teflon. 2. Install lower pivot pin bushings into the clamp brackets and trim unit.

a b a — Ground Wire b — Sacrificial Anode

a

5. Lubricate the upper pivot pin and mounting holes with 2-4-C with Teflon. 6. Fasten shock rod with the upper pivot pin.

b 95

95

NOTE: Pivot pin should be installed with grooved end inserted first.

2-4-C with Teflon

a — Bushing (2) Install into each Clamp Bracket b — Bushing (2) Install into each side of Trim Unit

3. Install lower pivot pin. Secure with flat washers and nuts. Torque nuts to 18 lb. ft. (24.4 N·m).

95

95

2-4-C with Teflon

a b a — Nuts — Torque to 18 lb. ft. (24.4 N⋅m) b — Washers (Not Shown)

90-852572R02 NOVEMBER 2002

MID-SECTION — 5C-43

7. Secure upper pivot pin with trilobe pin. Press trilobe pin in until its fully seated.

11. Secure wire harness with clamps as shown.

a

a — Trilobe Pin

8. Re-connect trim wire harness leads (see wiring diagram, Section 2D for proper connections). 9. Recheck fluid level (tilt/trim rod fully extended). 10. Route wire harness through clamp bracket and cowling.

a

a — Wire Harness

5C-44 — MID-SECTION

90-852572R02 NOVEMBER 2002

MID-SECTION

5 D 55331

55/60 POWER TRIM

Table of Contents Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . Power Trim Components . . . . . . . . . . . . . . . . Theory Of Operation . . . . . . . . . . . . . . . . . . . . Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . Trimming Characteristics . . . . . . . . . . . . . Trailering Outboard . . . . . . . . . . . . . . . . . . Tilting Outboard Up and Down Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Trim Flow Diagrams . . . . . . . . . . . . . . Trim Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tilt Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum Tilt . . . . . . . . . . . . . . . . . . . . . . . . Down Mode . . . . . . . . . . . . . . . . . . . . . . . . . Shock Function Up . . . . . . . . . . . . . . . . . . Shock Function Return . . . . . . . . . . . . . . . Manual Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . Preliminary Checks . . . . . . . . . . . . . . . . . . Hydraulic System Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting the Power Trim Electrical System . . . . . . . . . . . . . . . . . . . . Troubleshooting the Power Trim Electrical System . . . . . . . . . . . . . . . . . . . .

5D-0 — MID-SECTION

Page 5D-1 5D-2 5D-4 5D-4 5D-4 5D-5 5D-5 5D-6 5D-7 5D-9 5D-11 5D-13 5D-15 5D-17 5D-19 5D-20 5D-20 5D-21 5D-22 5D-23

Power Trim System Removal . . . . . . . . . . . . Power Trim Disassembly . . . . . . . . . . . . . . . . Trim Motor Removal . . . . . . . . . . . . . . . . . Pump and Components Removal . . . . . . Manifold Removal . . . . . . . . . . . . . . . . . . . Shock Rod Removal . . . . . . . . . . . . . . . . . Shock Rod Disassembly . . . . . . . . . . . . . . . . Memory Piston Removal . . . . . . . . . . . . . . Cleaning/Inspection/Repair . . . . . . . . . . . . . . Trim Motor Electrical Tests . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . O-Ring and Seal Placement . . . . . . . . . . . O-Ring Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . O-Ring Description and Sizes . . . . . . . . . . . . Power Trim Reassembly . . . . . . . . . . . . . . . . Shock Rod Reassembly . . . . . . . . . . . . . . Shock Rod Installation . . . . . . . . . . . . . . . Trim Limit Assembly Installation . . . . . . . Manual Release Valve Installation . . . . . Manifold Installation . . . . . . . . . . . . . . . . . . Oil Pump Installation . . . . . . . . . . . . . . . . . Pressure Operated Assembly Installation Reservoir/Motor Installation . . . . . . . . . . . Bleeding Power Trim Unit . . . . . . . . . . . . . Installation of Power Trim System . . . . . . . .

Page 5D-27 5D-28 5D-29 5D-29 5D-30 5D-30 5D-31 5D-33 5D-34 5D-34 5D-35 5D-35 5D-36 5D-37 5D-38 5D-38 5D-39 5D-40 5D-40 5D-40 5D-41 5D-42 5D-42 5D-43 5D-43

5D-24 5D-25 5D-26

90-852572R02 NOVEMBER 2002

Special Tools 1. Spanner Wrench P/N 91-74951

2. Lock-Ring Pliers P/N 91-822778A3

3. Expanding Rod P/N CG 41-11*

4. Collet P/N CG 41-14*

5. Heat Lamp P/N 91-63209

* = Snap-On

90-852572R02 NOVEMBER 2002

MID-SECTION — 5D-1

Power Trim Components A

17

19

20 22

3

26

1

21 23

95

F

25

24

4

B

2 4 12

16 8

9

D

7

5 13

E C 6 11

6 11 6 11

17

15 11

7

11

6 11 11

95

15

18

14

6

D

7

Loctite 271 Thread Locker

95

2-4-C with Teflon

10 11

NOTE: Lubricate all O-rings using Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. NOTE: It is recommended that all O-rings be replaced when servicing tilt system. 5D-2 — MID-SECTION

90-852572R02 NOVEMBER 2002

Power Trim Components REF. REF NO. QTY. – 1 1 1 2 1 3 1 4 2 5 1 6 1 7 1 8 1 9 1 10 1 11 1 12 1 13 1 14 1 15 1 16 1 – 1 17 2 18 1 19 1 20 1 21 1 22 2 23 2 24 2 25 2 26 2

TORQUE DESCRIPTION POWER TRIM PUMP SHOCK ROD KIT MEMORY PISTON ASSEMBLY O-RING REBUILD KIT O-RING CYLINDER ASSEMBLY TRIM LIMIT VALVE KIT PUMP ASSEMBLY MOTOR KIT RESERVOIR PLUG MANUAL RELEASE ASSEMBLY MANIFOLD KIT SCREW KIT (MOTOR) DRIVE SHAFT FILTER KIT P.O. CHECK ASSEMBLY KIT CABLE O RING KIT (COMPLETE TRIM) GROOVE PIN ANCHOR PIN PIN BRACKET HARNESS-Trim SCREW (M6 x 25) RELAY BRACKET GROMMET BUSHING

lb. in. lb. ft. 45

N·m 61

Drive Tight Drive Tight 80

9.0

120

13.5

A – Torque cylinder cap to 45 lb. ft. (61 N·m) B – Torque screws to 80 lb. in. (9.0 N·m) C – Torque screws to 70 lb. in. (7.9 N·m) D – Torque plugs to 120 lb. in. (13.5 N·m) E – Torque screws to 100 lb. in. (11 N·m) F – Torque shock piston to 90 lb. ft. (122 N·m)

90-852572R02 NOVEMBER 2002

MID-SECTION — 5D-3

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.

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 transmission 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.

When trimming your outboard from a mid-trim position (trim tab in neutral, straight fore-and-aft, position), you can expect the following results:

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.

TRIMMING OUTBOARD “UP” (“OUT”)

TRIMMING OUTBOARD “DOWN” (“IN”)

WARNING

WARNING

Excessive trim “out” may reduce the stability of some high speed hulls. To correct instability at high speed, reduce the power gradually and trim the motor “In” slightly before resuming high speed operation. (Rapid reduction in power will cause a sudden change of steering torque and may cause additional momentary boat instability.)

Excessive speed at minimum trim “In” may cause undesirable and/or unsafe steering conditions. Each boat should be tested for handling characteristics after any adjustment is made to the tilt angle (tilt 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).

•

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.

5D-4 — MID-SECTION

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 passageways into the “down” side of the trim cylinder. The trim rod will move the engine downward to the desired angle. 90-852572R02 NOVEMBER 2002

Trailering Outboard WARNING

Tilting Outboard Up and Down Manually 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.

Before loosening the manual release valve, make sure all persons are clear of engine, as engine will drop to full “down” position when valve is loosened.

While operating “up” circuit, the cylinder rod will continue to tilt the outboard to a full up position for trailering.

With power trim installed, the outboard can be raised or lowered manually by opening the manual release valve 3 to 4 turns (counterclockwise).

a

55170 a — Manual Release Valve

90-852572R02 NOVEMBER 2002

MID-SECTION — 5D-5

Power Trim Flow Diagrams Trim Up Circuit

b

a

c

w

d i

 v

u t

j

l k

e h m n

g f

Í Í

Reservoir Oil

g

Filtered Feed Oil

Í Í

Return Oil

o p

Oil Under Pressure

s  r

a b c d e f g h i j k l

—

Piston Rod End Cap Electric Motor Reservoir Oil Down Pressure Regulating Valve Down Pressure Operated Valve Filter (2 shown for clarity) Shock Return Valve Up Circuit Suction Port Oil Pump Down Circuit Suction Port Oil Fill Cap

5D-6 — MID-SECTION

q mnopqr s t uv w-

Shuttle Valve Up Pressure Operated Valve Manifold Reverse Suction Valve Manual Release Valve Manifold Tilt Relief Valve Tilt Relief Piston Memory Piston Shock Piston Impact Relief Valve Cylinder

90-852572R02 NOVEMBER 2002

Trim Up When the trim switch is activated in the up position, the electric motor (c) begins to rotate the 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 passages 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 pressure 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 operated 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 cylinder and enters the manifold passages. The oil is drawn back into the pump (j) through the open down pressure operated valve (f) and enters the pump as supply for the up circuit. 1 — Up Pressure: 1625 psi (11,000 kPa) Maximum 2 — Tilt Relief Pressure: 250-400 psi (1725-2750 kPa) 3 — Impact Relief Pressure: 880-1100 psi (6070-7585 kPa)

90-852572R02 NOVEMBER 2002

MID-SECTION — 5D-7

Tilt Circuit

b

a

c

w



uv

d

h

i

t

l

j k

e g

f

Reservoir Oil

m n

Í Í

g

Í Í s

Filtered Feed Oil Return Oil Oil Under Pressure

o p

r  q

a b c d e f g h i j k l

—

Piston Rod End Cap Electric Motor Reservoir Oil Down Pressure Regulating Valve Down Pressure Operated Valve Filter (2 shown for clarity) Shock Return Valve Up Circuit Suction Port Oil Pump Down Circuit Suction Port Oil Fill Cap

5D-8 — MID-SECTION

mnopqr s t uv w-

Shuttle Valve Up Pressure Operated Valve Manifold Reverse Suction Valve Manual Release Valve Manifold Tilt Relief Valve Tilt Relief Piston Memory Piston Shock Piston Impact Relief Valve Cylinder

90-852572R02 NOVEMBER 2002

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 engine rpm’s fall or if engine is not in forward gear, the oil pressure is available to extend the piston rod (a) up into the tilt range. 1 — Up Pressure: 1625 psi (11,000 kPa) Maximum 2 — Tilt Relief Pressure: 250-400 psi (1725-2750 kPa) 3 — Impact Relief Pressure: 880-1100 psi (6070-7585 kPa)

90-852572R02 NOVEMBER 2002

MID-SECTION — 5D-9

Maximum Tilt

 v

a

b h

u c

t w

d i

j

l

k

e g

f

Í Í

—

Piston Rod End Cap Electric Motor Reservoir Oil Down Pressure Regulating Valve Down Pressure Operated Valve Filter (2 shown for clarity) Shock Return Valve Up Circuit Suction Port Oil Pump Down Circuit Suction Port Oil Fill Cap

5D-10 — MID-SECTION

g

Í Í

s a b c d e f g h i j k l

Reservoir Oil

m n

r  mnopqr s t uv w-

Filtered Feed Oil Return Oil Oil Under Pressure

o p

q Shuttle Valve Up Pressure Operated Valve Manifold Reverse Suction Valve Manual Release Valve Manifold Tilt Relief Valve Tilt Relief Piston Memory Piston Shock Piston Impact Relief Valve Cylinder

90-852572R02 NOVEMBER 2002

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. 1 — Up Pressure: 1625 psi (11,000 kPa) Maximum 2 — Tilt Relief Pressure: 250-400 psi (1725-2750 kPa) 3 — Impact Relief Pressure: 880-1100 psi (6070-7585 kPa)

90-852572R02 NOVEMBER 2002

MID-SECTION — 5D-11

Down Circuit

DOWN CIRCUIT b

a

c

w

d 

t

j

k

l

e

v u

i

h

f g

m n

Í Í

Reservoir Oil

Í Í

g

Filtered Feed Oil Return Oil

o p

Oil Under Pressure

s a b c d e f g h i j k l

—

Piston Rod End Cap Electric Motor Reservoir Oil Down Pressure Regulating Valve Down Pressure Operated Valve Filter (2 shown for clarity) Shock Return Valve Up Circuit Suction Port Oil Pump Down Circuit Suction Port Oil Fill Cap

5D-12 — MID-SECTION

r  mnopqr s t uv w-

q Shuttle Valve Up Pressure Operated Valve Manifold Reverse Suction Valve Manual Release Valve Manifold Tilt Relief Valve Tilt Relief Piston Memory Piston Shock Piston Impact Relief Valve Cylinder

90-852572R02 NOVEMBER 2002

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 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 cavity 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 reservoir by the ball (i) inside the up circuit suction port. Oil, under pressure, opens the down 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 cylinder. 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 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 regulating 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. 1 — Up Pressure: 1625 psi (11,000 kPa) Maximum 2 — Tilt Relief Pressure: 250-400 psi (1725-2750 kPa) 3 — Impact Relief Pressure: 880-1100 psi (6070-7585 kPa)

90-852572R02 NOVEMBER 2002

MID-SECTION — 5D-13

Shock Function Up

b

a

c

w

 v

u

h d

i

j

k

l

t e f

m

g

Í Í

Piston Rod End Cap Electric Motor Reservoir Oil Down Pressure Regulating Valve Down Pressure Operated Valve Filter (2 shown for clarity) Shock Return Valve Up Circuit Suction Port Oil Pump Down Circuit Suction Port Oil Fill Cap

5D-14 — MID-SECTION

Oil Under Pressure

o p

r

—

Return Oil

g

Í Í s

a b c d e f g h i j k l

Reservoir Oil

n

mnopqr s t uv w-

q

Shuttle Valve Up Pressure Operated Valve Manifold Reverse Suction Valve Manual Release Valve Manifold Tilt Relief Valve Tilt Relief Piston Memory Piston Shock Piston Impact Relief Valve Cylinder

90-852572R02 NOVEMBER 2002

Shock Function Up Oil inside the down cavity is locked in a static position by the down 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), 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 the shock piston. 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 piston is trapped between the memory piston (t) and shock piston (u). 1 — Tilt Relief Pressure: 250-400 psi (1725-2750 kPa) 2 — Impact Relief Pressure: 880-1100 psi (6070-7585 kPa)

90-852572R02 NOVEMBER 2002

MID-SECTION — 5D-15

Shock Function Return

b

a

c w

 v

h u d

t

i

j

k

l

e f g

Í Í

—

Piston Rod End Cap Electric Motor Reservoir Oil Down Pressure Regulating Valve Down Pressure Operated Valve Filter (2 shown for clarity) Shock Return Valve Up Circuit Suction Port Oil Pump Down Circuit Suction Port Oil Fill Cap

5D-16 — MID-SECTION

r

Return Oil

g

Í Í

s a b c d e f g h i j k l

Reservoir Oil

m n

Oil Under Pressure

o p

q mnopqr s t uv w-

Shuttle Valve Up Pressure Operated Valve Manifold Reverse Suction Valve Manual Release Valve Manifold Tilt Relief Valve Tilt Relief Piston Memory Piston Shock Piston Impact Relief Valve Cylinder

90-852572R02 NOVEMBER 2002

Shock Function Return After the engine clears the under water object, the weight of the engine will increase the oil pressure between the memory piston (t) and shock piston (u) to the level required to open the shock return valve (h), inside the shock piston, allowing the oil to bleed back through the shock piston into the down cavity. If required, additional oil will enter the down cavity through the manifold reverse suction valve (o). This will return the engine back against the memory piston (t) and into the original running position. 1 — Tilt Relief Pressure: 250-400 psi (1725-2750 kPa) 2 — Impact Relief Pressure: 880-1100 psi (6070-7585 kPa)

90-852572R02 NOVEMBER 2002

MID-SECTION — 5D-17

Manual Release

b

a

   


  

c

w

v u

h

d

i

j

k

l

t e g

f

Reservoir Oil

m n

ÍÍ ÍÍ s

Return Oil

g

Í Í

Filtered Oil

o p

r q

a b c d e f g h i j k l

—

Piston Rod End Cap Electric Motor Reservoir Oil Down Pressure Regulating Valve Down Pressure Operated Valve Filter (2 shown for clarity) Shock Return Valve Up Circuit Suction Port Oil Pump Down Circuit Suction Port Oil Fill Cap

5D-18 — MID-SECTION

mnopqr s t uv w-

Shuttle Valve Up Pressure Operated Valve Manifold Reverse Suction Valve Manual Release Valve Manifold Tilt Relief Valve Tilt Relief Piston Memory Piston Shock Piston Impact Relief Valve Cylinder

90-852572R02 NOVEMBER 2002

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 together, 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. 1 — Up Pressure: 1625 psi (11,000 kPa) Maximum 2 — Tilt Relief Pressure: 250-400 psi (1725-2750 kPa) 3 — Impact Relief Pressure: 880-1100 psi (6070-7585 kPa)

90-852572R02 NOVEMBER 2002

MID-SECTION — 5D-19

Troubleshooting Support outboard with tilt lock pin when servicing power trim system. IMPORTANT: After debris or failed components have been found (during troubleshooting 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” position (trim rod fully extended) prior to fill/drain plug, or manual release valve removal. 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 defective components in trim assembly. Clean or replace components as required.

5D-20 — MID-SECTION

90-852572R02 NOVEMBER 2002

Hydraulic System Troubleshooting Flow Chart OUTBOARD WILL NOT HOLD TILTED POSITION DURING REVERSE AND/OR TRAILS OUT DURING HIGH SPEED DECELERATION.

Manual release valve and O-ring damaged.

Manual release valve and O-rings appear to be O.K. Clean and reinstall manual release valve.

Inspect manual release valve.

Trim will not hold reverse thrust.

Replace manual release valve and O-rings.

Trim system holds reverse thrust. Testing complete.

Trim system holds reverse thrust. Testing complete.

Remove and inspect piston rod assembly for debris and/or shock ball hang up.

Debris and/or shock ball hang up identified.

Trim will not hold reverse thrust.

Replace piston rod assembly.

Shock piston appears O.K. — Clean and reinstall piston rod assembly.

Trim system holds reverse thrust. Testing complete.

Remove PO check valve assembly, inspect O-rings and seals for damage. Trim system holds reverse thrust. Testing complete. Debris and/or damage identified.

PO check valve appears O.K. — Clean and reinstall PO check valve assembly.

Replace PO check valve assembly.

Trim system holds reverse thrust. Testing complete.

Trim system holds reverse thrust. Testing complete. Trim will not hold reverse thrust.

continued on next page 90-852572R02 NOVEMBER 2002

MID-SECTION — 5D-21

Hydraulic System Troubleshooting Flow Chart (continued) continued

Remove suction seat assembly and inspect for debris and/or damage. Suction seat assembly appears O.K. — Clean and reinstall suction seat assembly.

Debris and/or damage identified.

Replace suction seat assembly.

Trim system holds reverse thrust. Testing complete.

5D-22 — MID-SECTION

Trim will not hold reverse thrust.

Trim system holds reverse thrust. Testing complete.

Replace trim system.

90-852572R02 NOVEMBER 2002

Hydraulic System Troubleshooting Flow Chart TRIM SYSTEM LEAKS DOWN WITH MANUAL RELEASE VALVE CLOSED.

Manual release valve and O-ring damaged.

Inspect manual release valve.

Trim system down.

Replace manual release valve and O-rings.

leaks Trim system does not leak down. Testing complete.

Remove tilt relief valving and inspect O-rings and seals for debris and/or damage.

Trim system does not leak down. Testing complete.

Tilt relief valving and O-rings appear to be O.K. — Clean and reinstall tilt relief valving.

Debris and/or damage identified.

Replace tilt relief valving.

Trim system does not leak down. Testing complete.

Trim system down.

Replace PO check valve assembly.

90-852572R02 NOVEMBER 2002

leaks

Trim system does not leak down. Testing complete.

Remove PO check valve assembly, inspect Orings and seals for damage.

Debris and/or damage identified.

Trim system does not leak down. Testing complete.

Manual release valve and Orings appear to be O.K. — Clean and reinstall manual release valve.

PO check valve appears O.K. — Clean and reinstall PO check valve assembly.

Trim system leaks down.

Trim system does not leak down. Testing complete.

continued on next page

MID-SECTION — 5D-23

Hydraulic System Troubleshooting Flow Chart (continued) continued

Inspect memory piston O-ring and cylinder bore. Cylinder bore appears rough and/or debris found in cylinder.

Cylinder bore appears smooth with no debris.

Replace memory piston and shock piston O-rings.

Trim system does not leak down. Testing complete.

5D-24 — MID-SECTION

Trim leaks down.

Replace trim system.

90-852572R02 NOVEMBER 2002

Troubleshooting the Power Trim Electrical System Trim Switch (Remote Control Mounted)

Trim Switch (Panel Mounted)

UP DN

UP DN

BLU/WHT

Fuse Holder

GRN/WHT BLU/WHT or PUR GRN/WHT or GRN RED

Remote Control RED

Fuse Holder

+

B

–

2

RED/PUR

A

RED/PUR RED

Battery Starter Bolt GRN/WHT

Solenoid

BLU/WHT

3

Down Relay LT. GRN/WHT

GRN/WHT GRN 14 BLK RED BLK

LT. GRN/WHT

LT. BLU/WHT

LT.BLU/WHT BLUE 14 BLK RED BLK

Up Relay

LT. BLU/WHT

4

1 UP DN

Cowl Switch

Trim Pump Motor

90-852572R02 NOVEMBER 2002

MID-SECTION — 5D-25

Troubleshooting the Power Trim Electrical System Refer to wiring diagram on preceding page for location of wire connections. Problem

Possible Cause

Remedy

Trim Switch “UP” is inopera1. Open wire between Wire Connection (1) tive, but the Cowl Switch “UP” and Trim Switch. does operate. 2. Faulty Trim Switch.

1. Check for an open connection or cut wire. 2. Replace.

Cowl Switch “UP” is inoperative, but the Trim Switch “UP” does operate.

1. Check for an open connection or cut wire. 2. Replace.

1. Open wire between Wire Connection (2) and Solenoid. 2. Faulty Cowl Switch.

Trim Switch “UP” and Cowl 1. Open wire between Wire Connection (1) Switch “UP” are both inopera- and the “Up” Relay. tive. 2. Open BLK wire between ground and “UP” Relay. 3. Open RED wire between Solenoid and “UP” Relay. 4. Faulty “UP” Relay .

1. Check for an open connection.

Trim Switch “DOWN” is inoperative, but the Cowl Switch “DOWN” does operate.

1. Open wire between Wire Connection (3) and Trim Switch. 2. Faulty Trim Switch.

1. Check for an open connection or cut wire. 2. Replace.

Cowl Switch “DOWN” is inoperative, but the Trim Switch “DOWN” does operate.

1. Open wire between Wire Connection (2) and Solenoid. 2. Faulty Cowl Switch.

1. Check for a open connection or cut wire. 2. Replace

Trim Switch “DOWN” and Cowl Switch “DOWN” are both inoperative.

1. Open wire between Wire Connection (3) and the “UP” Relay. 2. Open BLK wire between ground and “DOWN” Relay. 3. Open RED wire between Solenoid and “DOWN” Relay. 4. Faulty “DOWN” Relay

1. Check for an open connection.

2. Check for an open connection. 3. Check for an open connection. 4. Replace.

2. Check for an open connection. 3. Check for an open connection. 4. Replace.

Trim Switch “UP” and 1. 20 AMP Fuse blown. “DOWN” are both inoperative, but the Cowl Switch does operate. 2. Faulty trim switch. 3. Wire is open between fuse holder and solenoid. 4. Wire is open between fuse holder and trim switch.

1. Replace fuse. Locate the cause of the blown fuse. Check electrical wiring for a shorted circuit. 2. Replace. 3. Check for a open connection or cut wire. 4. Check for a loose or corroded connection.

Trim Switch and Cowl Switch are both inoperative.

1. One of the Trim Pump Motor wires is open between the motor and the Relays. 2. Faulty trim pump motor.

1. Check wire connections (4) for loose or corroded condition. 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 runs) without pressing the switches.

1. The Trim or Cowl switch is shorted.

1. Replace.

5D-26 — MID-SECTION

90-852572R02 NOVEMBER 2002

Power Trim System Removal

3. Remove the trilobe pin.

1. Tilt outboard to the full up position and support with tilt lock pin.

4. Drive out the upper pivot pin.

a b a

55464

a — Trilobe Pin b — Upper Pivot Pin

a — Tilt Lock Pin

5. Remove the sacrificial anode. 2. Disconnect the power trim wire harness and remove clamp.

a b

a

55331

a — Sacrificial Anode

55264 a — Power Trim Wire Harness Clamp b — Harness

90-852572R02 NOVEMBER 2002

MID-SECTION — 5D-27

6. Use suitable punch to remove (Drive Up) lower pin. Retain dowel pin.

Power Trim Disassembly IMPORTANT: Power trim system is pressurized. Trim rod must be in the full “UP” position (fully extended prior to fill/drain plug, or manual release valve removal. 1. Remove reservoir cap. 2. Remove manual release valve assembly to drain oil.

a 51144

a — Dowel Pin

a 7. Use suitable punch to drive out lower pivot pin.

b 55263 a — Reservoir Cap b — Manual Release Valve

a

51144

a — Lower Pivot Pin

5D-28 — MID-SECTION

90-852572R02 NOVEMBER 2002

Trim Motor Removal

Pump and Components Removal

1. Secure power trim assembly in a soft jaw vise.

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 remove spool .

2. Remove four (4) screws to remove motor/reservoir. Remove reservoir seal and coupler.

a

b

b d c d a

e

a b c d e

—

Screw (4) Reservoir Reservoir Seal Coupler Manifold Assembly

a b c d e

—

b

c

d

a

c

e

Plug (2) Spring (2) Check Valve/Poppet (2) Seat (2) Spool

IMPORTANT: Inspect poppet assembly for debris in the area shown. If debris is found on poppet replace poppet.

a b

a — Debris Under Valve Tip b — Rubber Seat

90-852572R02 NOVEMBER 2002

MID-SECTION — 5D-29

2. Remove three (3) screws to remove pump. Remove filter and filter seal under pump. Remove suction seat assembly.

2. Remove tilt relief components.

a

a b

b c

c d

d a b c d

a b c d

—

—

51008

Spring Poppet Spool Housing Trim Limit Spool

Shock Rod Removal

Screws (3) Filter Seal Filter Suction Seat Assembly

1. Unscrew end cap assembly from cylinder using spanner wrench [1/4 in. x 5/16 in. (6.4mm x 8mm) long pegs].

Manifold Removal 1. Remove two (2) screws to remove manifold from cylinder.

2. Remove shock rod assembly from cylinder.

a 51146

a — Screw (2)

5D-30 — MID-SECTION

90-852572R02 NOVEMBER 2002

3. Remove check ball components from shock rod piston.

Shock Rod Disassembly NOTE: The only serviceable items on the shock rod assembly are the O-rings and wiper ring. If shock rod requires any other repair, replace shock rod assembly.

4. Remove O-ring from shock rod piston.

c c

b

b a

b a

d

a — End Cap b — O-ring (2) c — Wiper Ring

51147

1. Place shock rod assembly on clean work surface. 2. Remove three (3) screws and remove plate from shock rod piston.

a b c d

—

Spring (5) Seat (5) Ball (5) O-ring

a

b c 51143

a — Screw (3) b — Plate c — Shock Rod Piston

90-852572R02 NOVEMBER 2002

MID-SECTION — 5D-31

10. Remove inner O-ring from shock rod piston.

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.

b a 51199

a — Shock Piston b — O-ring

11. Remove cylinder end cap assembly from shock rod. 12. Inspect shock. If wiper (located in cap) has failed to keep rod clean, replace wiper. 13. Place end cap on clean work surface.

51146

a

14. Remove rod wiper, inner O-ring, and outer Oring.

b

a c b

51145

51146

a — Rod Wiper b — Inner O-ring c — Outer O-ring

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. 5D-32 — MID-SECTION

90-852572R02 NOVEMBER 2002

2. Remove O-ring from memory piston.

Memory Piston Removal

a

1. Remove memory piston from cylinder using one of two methods:

b

a. Using lock ring pliers (P/N 91-822778A3) or suitable tool.

51144

a — O-Ring b — Memory Piston

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.

a

b

c 55466 a — Adaptor/Air Hose b — Memory Piston Exit c — Shop Rag 90-852572R02 NOVEMBER 2002

MID-SECTION — 5D-33

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 25-8809880A1. Lubricate all O-rings with Power Trim and Steering Fluid. 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 assembly.

5D-34 — MID-SECTION

90-852572R02 NOVEMBER 2002

Reassembly O-Ring and Seal Placement O-Rings and Seals are part of O-Ring Kit 25-809880A1

1 2

3

5

4

22

6 7

8 20 10

19

9

11

21

13 12

14

18 9 10 9 8

90-852572R02 NOVEMBER 2002

15 16

17

MID-SECTION — 5D-35

O-ring Sizes 2

1

9

3 7

4, 22

13

5

12, 17, 18

14

15, 20 6 16

19

8

Cutaway View of O-Ring Width

21

10

11 O.D.

I.D.

O-RINGS SHOWN ARE ACTUAL SIZE 5D-36 — MID-SECTION

90-852572R02 NOVEMBER 2002

O-ring Description and Sizes O-Ring

Description

O-Ring I.D.

O-Ring O.D.

O-Ring Width

1

Wiper Ring (412585)

2

Cyl. Cap, Inner12586)

0.671 in. (17.04 mm)

0.949 in. (24.10 mm)

0.139 in. (3.53 mm)

3

Cyl. Cap8134)

1.864 in. (47.34 mm)

2.004 in. (50.90 mm)

0.07 in. (1.78 mm)

4

Shock Piston2579)

1.6 in. (40.64 mm)

2.02 in. (53.086 mm)

0.21 in. (5.334 mm)

5

Piston Bolt05797)

0.676 in. (17.17 mm)

.816 in. (20.726 mm)

0.07 in. (1.78 mm)

6

Reservoir Plug01271)

0.549 in. (13.94 mm)

0.755 in. (19.17 mm)

0.103 in. (2.616 mm)

7

Motor Seal12599) 0.489 in. (12.42 mm)

0.629 in. (15.97 mm)

0.07 in. (1.78 mm)

8 (2)

P.O. Check Plug06484)

9 (3)

Poppet Assy.74585)

10 (2)

P.O. Check Seat07328)

0.364 in. (9.25 mm)

0.504 in. (12.80 mm)

0.07 in. (1.78 mm)

11 (2)

Pump Port

0.145 in. (3.683 mm)

0.285 in. (7.239 mm)

0.07 in. (1.78 mm)

12

Suction Seat

0.239 in. (6.07 mm)

0.379 in. (9.626 mm)

0.07 in. (1.78 mm)

13

Filter Seal12607)

14

Filter12590)

15

Manual Release406483)

0.114 in. (2.90 mm)

0.254 in. (6.451 mm)

0.07 in. (1.78 mm)

16

Manual Release06226)

0.176 in. (4.47 mm)

0.316 in. (8.026 mm)

0.07 in. (1.78 mm)

17

Manual Release09051)

0.239 in. (6.07 mm)

0.379 in. (9.626 mm)

0.07 in. (1.78 mm)

18

Spool09051)

0.239 in. (6.07 mm)

0.379 in. (9.626 mm)

0.07 in. (1.78 mm)

Spool Housing09005)

0.301 in. (7.645 mm)

0.441 in. (11.20 mm)

0.07 in. (1.78 mm)

Trim Limit Spool06483)

0.114 in. (2.895 mm)

0.254 in. (6.451 mm)

0.07 in. (1.78 mm)

Manifold405387)

0.208 in. (5.283 mm)

0.348 in. (8.839 mm)

0.07 in. (1.78 mm)

Memory Piston412579)

1.6 in. (40.64 mm)

2.02 in. (53.086 mm)

0.21 in. (5.334 mm)

19 (3) 20 21 (2) 22

90-852572R02 NOVEMBER 2002

MID-SECTION — 5D-37

Power Trim Reassembly

4. Clamp shock rod in soft jawed vise.

IMPORTANT: Lubricate all O-rings with Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid.

5. Position cylinder end cap onto rod as shown.

Shock Rod Reassembly 1. Install lubricated O-rings to end cap. 2. Install rod wiper.

51146

a c

CAUTION

b

When installing shock rod piston, spanner wrench must have 1/4 in. x 5/16 in. (6.4mm x8mm) long pegs to avoid damage to shock rod piston. 51145

a — Rod Wiper b — Inner O-ring c — Outer O-ring

6. Apply Loctite 271 Thread Locker 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 N⋅m).

3. Install lubricated O-rings to shock piston.

b

a

c

b a

51199

a — Shock Piston b — O-ring c — O-ring 51146

a — Shock Rod Piston — Torque to 90 lb. ft. (122 N⋅m) b — Spanner Wrench

5D-38 — MID-SECTION

90-852572R02 NOVEMBER 2002

9. Remove shock rod assembly from vise.

Shock Rod Installation

10. Install ball, seat, and spring (five sets) to shock rod piston.

1. Place trim cylinder in soft jawed vice.

11. Secure components with plate. Torque screws to 35 lb. in. (4.0 Nm).

2. Install lubricated O-ring to memory piston and place into cylinder. Push memory piston all the way to bottom.

a b

e d

a — Memory Piston b — O-ring

c a

b

a b c d e

—

Screw (3) Torque to 35 lb. in. (4.0 N⋅m) Plate Spring (5) Seat (5) Ball (5)

51147

3. Fill cylinder three inches (76.2mm) from top of cylinder using Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. 4. Install shock rod into cylinder until power trim fluid flows through oil blow off ball passage. Fill remaining cylinder to just below the cylinder threads.

a

a — 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 N·m).

90-852572R02 NOVEMBER 2002

MID-SECTION — 5D-39

Trim Limit Assembly Installation

Manifold Installation

1. Lubricate all O-rings. Install spring, poppet, spool housing and trim limit spool into manifold.

1. Install dowel pin and two (2) lubricated O-rings into trim cylinder.

NOTE: There are two different size springs used in this manifold. The heavy spring is used on 75 to 125 HP engines. The light spring is used on 40 to 60 HP engines.

a or

a b

b c

d a b c d

—

a — O-Ring (2) b — Dowel Pin

2. Align the trim cylinder and pump/reservoir assembly together.

51008

Spring Poppet Spool Housing Trim Limit Spool

a

Manual Release Valve Installation 1. Install “E” clip (if removed) and lubricate O-rings to manual release valve. 2. Install manual release valve assembly into manifold.

a

b a — Trim Cylinder Assembly b — Reservoir/Manifold Assembly

c

b a — Manifold b — Manual Release Valve c — E Clip

5D-40 — MID-SECTION

90-852572R02 NOVEMBER 2002

3. Install the two (2) long screws and torque to 100 lb. in. (11 N⋅m).

Oil Pump Installation 1. Install spring, ball, lubricated O-ring and plastic seat to manifold. 2. Check to see that O-rings are placed on bottom of pump. 3. Install filter and filter seal under pump. Install pump onto manifold. Torque screws to 70 lb. in. (7.7 N⋅m).

a

a 51146

a — Screw (2) Torque to 100 lb. in. (11 N⋅m)

b

a — Screw (3) Torque to 70 lb. in. (7.7 N⋅m) b — Suction Seat Assembly

90-852572R02 NOVEMBER 2002

MID-SECTION — 5D-41

Pressure Operated Assembly Installation

Reservoir/Motor Installation

IMPORTANT: Inspect poppet assembly for debris in the area shown. If debris is found on poppet, replace poppet.

3. 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 N⋅m).

a

a b

b

c a — Debris Under Valve Tip b — Rubber Seat

d

1. Lubricate O-rings. 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 N⋅m).

f e

a d

a a b c d e

—

b

c

d

c

b

a b c d e f

—

Screw (4) Torque to 80 lb. in. (9 N⋅m) Reservoir Reservoir Seal Coupler Manifold Assembly Ground Strap

e 4. Fill reservoir to bottom of fill hole using Power Trim Fluid. If not available, use automotive (ATF) automatic transmission fluid.

Plug (2) Torque to 120 lb. in. (13.5 N⋅m) Spring (2) Check Valve/Poppet (2) Seat (2) Spool

5D-42 — MID-SECTION

90-852572R02 NOVEMBER 2002

Bleeding Power Trim Unit 1. Secure power trim unit in soft jawed vise.

Installation of Power Trim System

2. Add power trim fluid until it’s even with the bottom of the fill hole. Reinstall plug.

1. Lubricate lower pivot pin, mounting holes with 2-4-C with Teflon.

3. Close the manual release valve. (Turn full clockwise).

2. Start lower pivot pin into pivot pin bore and position lower dowel pin (retained) in its respective hole.

b a

b a

95

55263 51148

a — Reservoir Plug/Fill Hole b — Manual Release Valve

4. Using a 12 volt power supply, connect the positive lead to (blue) trim motor wire and negative lead to (green) trim motor wire and drive shock rod to the up position. Repeat three times.

95

2-4-C with Teflon

a — Lower Pivot Pin b — Lower Dowel Pin

3. Position trim cylinder assembly (bottom first) between clamp brackets.

5. Connect the positive lead to the (green) trim motor wire, and the negative lead to the (blue) trim motor wire and drive the shock rod to the down position. 6. Recheck fluid level, add fluid if required and repeat cycle until fluid level stays even with the bottom of the fill hole.

a

55467 a — Trim Cylinder Assembly

90-852572R02 NOVEMBER 2002

MID-SECTION — 5D-43

4. Apply 2-4-C with Teflon to lower pivot pin. Using a suitable punch, drive lower pivot pin into clamp bracket and trim cylinder assembly until pivot pin is flush with outside surface.

6. Apply 2-4-C with Teflon to surface of upper pivot pin, pivot pin bore and trim ram bore.

a c

b

95

a

95 51148 51147

95

2-4-C with Teflon

95

2-4-C with Teflon

a — Pivot Pin b — Pivot Pin Bore c — Trim Ram Bore

a — Lower Pivot Pin

5. Using a suitable punch, drive lower dowel pin into its hole until seated.

7. Using a suitable mallet, drive upper pivot pin into swivel bracket and through trim ram until pivot pin is flush with swivel bracket.

b

a

a c

51148

a — Lower Dowel Pin

5D-44 — MID-SECTION

51148

a — Pivot Pin b — Swivel Bracket c — Trim Ram

90-852572R02 NOVEMBER 2002

8. Drive trilobe pin (a) into its hole until seated.

10. Route trim harness through clamp bracket and cowling.

a

a

55464 a — Trilobe Pin

55264

9. Install sacrificial aluminum anode to reservoir bracket placing ground strap between bracket and anode, as shown.

a — Trim Harness

11. Secure trim harness with clamp, as shown.

a

b

a c

55465

a — Sacrificial Anode b — Ground Strap c — Bracket a — Clamp

90-852572R02 NOVEMBER 2002

MID-SECTION — 5D-45

5D-46 — MID-SECTION

90-852572R02 NOVEMBER 2002

MID-SECTION

5 E

40/50 MANUAL TILT ASSIST

Table of Contents Clamp Bracket . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Assist Adjustments . . . . . . . . . . . . Manual Trim System Removal . . . . . . . . . . . Manual Trim System Installation . . . . . . . . . .

5E-0 — MID-SECTION

Page 5E-2 5E-4 5E-4 5E-5

90-852572R02 NOVEMBER 2002

Notes:

90-852572R02 NOVEMBER 2002

MID-SECTION — 5E-1

Clamp Bracket

7

Loctite 271 — Thread Locker

95

2-4-C with Teflon

5E-2 — MID-SECTION

90-852572R02 NOVEMBER 2002

Clamp Bracket REF. REF NO. QTY. 1 1 1 1 2 1 3 2 4 2 5 2 6 2 7 2 8 1 9 1 10 1 11 1 12 1 13 1 14 1 15 1 16 1 17 2 18 2 19 4 20 4 21 4 22 1 23 1 24 1 25 1 26 1 27 1 28 1 29 1 30 1 31 1 32 1 33 1 34 2 35 2 36 2 37 2 38 2 39 2 40 2 41 1 42 1

TORQUE DESCRIPTION CLAMP BRACKET (BLACK)

N·m

PORT

CLAMP BRACKET (GRAY) CLAMP BRACKET (BLACK) STARBOARD CLAMP BRACKET (GRAY) THUMB SCREW ASSEMBLY (MANUAL) HANDLE (MANUAL) RIVET (MANUAL) WASHER (MANUAL) SCREW (Hex shoulder) (MANUAL) CAP–Tilt Stop Pin (O.D. of Ref. #11 is 0.75 in. & Ref. #10 is not flanged) ROLL PIN (O.D. of Ref. #11 is 0.75 in. & Ref. #10 is not flanged) BUSHING (O.D. of Ref. #11 is 0.75 in. & Ref. #10 is not flanged) PIN-TILT-STOP (O.D. of Ref. #11 is 0.75 in. & Ref. #10 is not flanged) CAP-TILT-STOP (O.D. of Ref. #15 is 0.56 in. & Ref. #14 is flanged) ROLL PIN (O.D. of Ref. #15 is 0.56 in. & Ref. #14 is flanged) BUSHING (O.D. of Ref. #15 is 0.56 in. & Ref. #14 is flanged) PIN-TILT STOP (O.D. of Ref. #15 is 0.56 in. & Ref. #14 is flanged) ANODE WASHER SCREW (M6 x 25) NUT (.500-20) WASHER SCREW (.500-20 x 4 IN.) DECAL-Tilt Lock DECAL-Warning TRIM, HYDRAULIC ASSIST (GAS ASSIST TRIM) CABLE (GAS ASSIST TRIM) TILT LEVER (GAS ASSIST TRIM) TILT KNOB GAS ASSIST TRIM LEVER ARM (GAS ASSIST TRIM) WAVE WASHER (GAS ASSIST TRIM) ROLL PIN (1/8 x 3/4 IN.) (GAS ASSIST TRIM) LINK (GAS ASSIST TRIM) NUT (GAS ASSIST TRIM) ANCHOR PIN (14MM) (GAS ASSIST/POWER TRIM) BUSHING (GAS ASSIST/POWER TRIM) BUSHING (GAS ASSIST/POWER TRIM) WASHER (GAS ASSIST/POWER TRIM) NUT (GAS ASSIST/POWER TRIM) SCREW (M10 x 40) (GAS ASSIST/POWER TRIM) WASHER (GAS ASSIST/POWER TRIM) NUT (GAS ASSIST/POWER TRIM) TILT LOCK PIN (NON POWER TRIM) SPRING (NON POWER TRIM)

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

60

6.8

60

6.8 Drive Tight

MID-SECTION — 5E-3

Hydraulic Assist Adjustments

Manual Trim System Removal 1. Tilt outboard to the full up position and support with tilt stop pin.

WARNING This hydraulic assist system’s contents are under pressure. Do not puncture, disassemble or apply heat or flame. IMPORTANT: If debris or leaking is found, unit must be replaced. This hydraulic assist system is NOT SERVICEABLE. Replace if necessary.

a

1. Check manual release cam adjustment. Cam must open and close freely. Adjust cam link rod as necessary.

b a

a — Tilt Stop Pin

2. Remove the trilobe pin. 3. Drive out the upper pivot pin.

b

a — Link Rod b — Manual Release Lever

a

2. Check for external leaks in the manual tilt system. Replace unit if leak is found.

a — Trilobe Pin b — Upper Pivot Pin

5E-4 — MID-SECTION

90-852572R02 NOVEMBER 2002

4. Disconnect link rod from cam lever. 5. Remove tilt lock pin. Remove nuts and washers securing the lower pivot pin. Remove anode bolt to remove ground strap. Remove lower anchor pin. Retain the anchor pin bushings from the clamp brackets and trim unit. 6. Remove trim unit.

Manual Trim System Installation 1. Apply 2-4-C with Teflon to surface of lower anchor pin and anchor pin hole. Place trim into proper position. Install anchor pin and bushings into anchor pin hole and clamp brackets. Install nuts and washers to anchor pin and tighten securely. Install ground strap and anode bolt. 2. Install tilt lock pin.

b

a c

a

d f

95

e a b c d e f

—

Tilt Lock Pin Link Rod Cam Lever Nut (2) Anode Bolt/Ground Strap Pivot Pin

90-852572R02 NOVEMBER 2002

b d c 95

a b c d

—

2-4-C with Teflon

Tilt Lock Pin Nut (2) Anode Bolt/Ground Strap Pivot Pin

MID-SECTION — 5E-5

3. Apply 2-4-C with Teflon to surface of upper pivot pin, pivot hole and shock rod hole. 4. Position trim into position and drive pivot pin into swivel bracket and through shock rod until pivot pin is flush with swivel bracket. Drive trilobe pin into its hole until seated.

6. Check manual release cam adjustment. Cam must open and close freely. Adjust cam link rod as necessary.

b a

b

95

a 95

a — Link Rod b — Manual Release Lever

2-4-C with Teflon

a — Trilobe Pin b — Upper Pivot Pin

5. Connect link rod onto cam lever.

a

b

a — Link Rod b — Cam Lever

5E-6 — MID-SECTION

90-852572R02 NOVEMBER 2002

MID-SECTION

5 F

55/60 MANUAL TILT SYSTEM

Table of Contents Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Tilt Components . . . . . . . . . . . . . . . . Manual Tilt Components . . . . . . . . . . . . . . . . Tilt Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tilt Down . . . . . . . . . . . . . . . . . . . . . . . . . . . Slow Tilt Down Under High Thrust . . . . . Under Water Strike With Valves Open . . Shock Function With Valves Closed . . . . Shock Function Return . . . . . . . . . . . . . . . Hydraulic System Troubleshooting . . . . . . . . Manual Tilt System Removal . . . . . . . . . . . . . Manual Tilt System Disassembly . . . . . . . . . Accumulator Removal . . . . . . . . . . . . . . . . Shock Rod Removal . . . . . . . . . . . . . . . . . Shock Rod Disassembly . . . . . . . . . . . . . . . . Valve Block Removal . . . . . . . . . . . . . . . . . Memory Piston Removal . . . . . . . . . . . . . . Valve Block Disassembly . . . . . . . . . . . . . . . . Reassembly — O-Ring and Seal Placement Actual O-Ring Sizes . . . . . . . . . . . . . . . . . . . . O-ring Description and Sizes . . . . . . . . . . . . . Manual Tilt System Cleaning and Inspection Manual Tilt System Reassembly . . . . . . . . . Valve Block Installation . . . . . . . . . . . . . . . Shock Rod Reassembly . . . . . . . . . . . . . . Shock Rod Installation and Fluid Filling Procedure . . . . . . . . . . . . . . . . . . . . Filling Procedure Option Two Instructions for Making Retaining Tool . . . . . . . . . . . . . Bleeding Manual Tilt System . . . . . . . . . . . . . Manual Tilt System Installation . . . . . . . . . . . Manual Release Valve Adjustment . . . . .

5F-0 — MID-SECTION

Page 5F-1 5F-2 5F-3 5F-5 5F-7 5F-9 5F-11 5F-13 5F-15 5F-16 5F-17 5F-18 5F-18 5F-19 5F-20 5F-22 5F-22 5F-23 5F-24 5F-25 5F-26 5F-27 5F-27 5F-28 5F-29 5F-30 5F-32 5F-33 5F-35 5F-36

90-852572R02 NOVEMBER 2002

Special Tools 1. Spanner Wrench P/N 91-74951

2. Lock-Ring Pliers P/N 91-822778A3

3. Heat Lamp P/N 91-63209

90-852572R02 NOVEMBER 2002

MID-SECTION — 5F-1

Manual Tilt Components

A

95

F

B

E

D

7

95

C 7

Loctite 271 Thread Locker

95

2-4-C with Teflon

NOTE: Lubricate all O-rings using Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. NOTE: It is recommended that all O-rings be replaced when servicing tilt system. 5F-2 — MID-SECTION

90-852572R02 NOVEMBER 2002

Manual Tilt Components REF. REF NO. QTY. 1 1 1 2 1 3 1 4 2 5 1 6 1 7 1 8 1 9 1 10 1 11 1 12 1 – 1 13 2 14 2

TORQUE DESCRIPTION

lb. in. lb. ft.

SHOCK ROD ASSEMBLY SHOCK ROD ASSEMBLY (BEACHING) MEMORY PISTON ASSEMBLY O RING REBUILD KIT-Cylinder O RING CYLINDER ASSEMBLY SCREW AND SEAL KIT ACCUMULATOR ASSEMBLY VALVE BODY ASSEMBLY CAM KIT VELOCITY VALVE KIT CHECK SYSTEM REPAIR KIT CABLE O RING KIT PIN GROOVE PIN

75 75

N·m

45

61

35

47

8.5 8.5

A – Torque cylinder cap to 45 lb. ft. (61 N·m) B – Torque Accumulator to 35 lb. ft. (47 N·m) C – Torque Velocity Valve to 75 lb. in. (8.5 N·m) D – Torque Transfer Valve Plug to 75 lb. in. (8.5 N·m) E – Torque Screw to 100 lb. in. (11 N·m) F – Torque Shock Piston to 90 lb. ft. (122 N·m)

90-852572R02 NOVEMBER 2002

MID-SECTION — 5F-3

Manual Trim Flow Diagrams Up Circuit b a

c

d

p e o

f n k

m

l

a b c d e f g h

—

Shock Rod End Cap Accumulator Accumulator Piston Accumulator Check Valve Camshaft Lever Manifold Down Fast Transfer Valve

5F-4 — MID-SECTION

j

i j k l mnop-

i

h

g

Down Slow Transfer Valve Up Fast Transfer Valve Surge Valve Cylinder Memory Piston Shock Piston Shock Return Valve Impact Relief Valve

90-852572R02 NOVEMBER 2002

Tilt Up With the engine in the down position, the accumulator piston (d) will be at the top of the accumulator (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 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 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.

90-852572R02 NOVEMBER 2002

MID-SECTION — 5F-5

Down Circuit

b a

c

d

p e o

f n k m

l

a b c d e f g h

—

Shock Rod End Cap Accumulator Accumulator Piston Accumulator Check Valve Camshaft Lever Manifold Down Fast Transfer Valve

5F-6 — MID-SECTION

j

i j k l mnop-

i

h

g

Down Slow Transfer Valve Up Fast Transfer Valve Surge Valve Cylinder Memory Piston Shock Piston Shock Return Valve Impact Relief Valve 90-852572R02 NOVEMBER 2002

Tilt Down With the engine tilted up, the piston inside the accumulator piston (d) will be at the bottom of the accumulator (c) and the gas pressure is low. To lower the engine, the camshaft lever (f) is rotated 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 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 fast transfer valve (h) and down slow transfer valve (i). Fluid will flow past the up 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 compress 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.

90-852572R02 NOVEMBER 2002

MID-SECTION — 5F-7

Slow Tilt Down Under High Thrust

b a

c

d

p

f

e o

n k m j

i

h

g

l

a b c d e f g h

—

Shock Rod End Cap Accumulator Accumulator Piston Accumulator Check Valve Camshaft Lever Manifold Down Fast Transfer Valve

5F-8 — MID-SECTION

i j k l mnop-

Down Slow Transfer Valve Up Fast Transfer Valve Surge Valve Cylinder Memory Piston Shock Piston Shock Return Valve Impact Relief Valve 90-852572R02 NOVEMBER 2002

Slow Tilt Down Under High Thrust To tilt the engine down under high thrust conditions [where the propeller thrust forces the shock rod down, creating higher pressure below the memory piston (m)], the camshaft lever (f) is rotated slightly downward. The internal shaft connected to the lever will open the down slow transfer valve (i) allowing oil under pressure into the cavity around the shaft. The higher oil pressure will open the up fast transfer valve (j) allowing oil from the bottom of the cylinder to flow above the shock piston (n) while lowering the engine. Additional oil will flow into the accumulator (c) as the internal pressure forces the accumulator check valve (e) to open. Oil flowing into the accumulator moves the accumulator piston (d) and compresses the gas.

90-852572R02 NOVEMBER 2002

MID-SECTION — 5F-9

Under Water Strike (Valves Open)

b a

c

d p o

e

f n k

m

j

i

h

l

a b c d e f g h

—

Shock Rod End Cap Accumulator Accumulator Piston Accumulator Check Valve Camshaft Lever Manifold Down Fast Transfer Valve

5F-10 — MID-SECTION

i j k l mnop-

g

Down Slow Transfer Valve Up Fast Transfer Valve Surge Valve Cylinder Memory Piston Shock Piston Shock Return Valve Impact Relief Valve 90-852572R02 NOVEMBER 2002

Under Water Strike (Valves Open) Should the drive unit strike a submerged object while in forward motion, the shock rod (a) will extend from the tilt cylinder (l). Fluid will attempt to exit the cylinder through the interconnecting passage. The rapid fluid flow will increase the pressure below the surge valve (k), causing the valve to move, closing the oil return passage back into the accumulator (c). Oil inside the up cavity is locked in a static position by the closed up fast transfer valve (j), the closed down slow transfer valve (i) and down fast transfer valve (h). As the shock rod extends outward, the pressure inside the up cavity will reach sufficient pressure to open the shock valve (p) which opens at 880–1110 PSI. Oil will flow into the cavity created as the shock rod & shock piston (a & n) moves away from the memory piston (m).

90-852572R02 NOVEMBER 2002

MID-SECTION — 5F-11

Shock Function (Valve Closed)

b a

c Accumulator Gas Pressure 400 PSI

d

p o e

n f k

m

j

i

h

g

l

a b c d e f g h

—

Shock Rod End Cap Accumulator Accumulator Piston Accumulator Check Valve Camshaft Lever Manifold Down Fast Transfer Valve

5F-12 — MID-SECTION

i j k l mnop-

Down Slow Transfer Valve Up Fast Transfer Valve Surge Valve Cylinder Memory Piston Shock Piston Shock Return Valve Impact Relief Valve 90-852572R02 NOVEMBER 2002

Shock Function with Valve Closed Should the drive unit strike a submerged object while in forward motion, the shock rod (a) will extend from the cylinder (l). Oil inside the up cavity is locked in a static position by the closed up fast transfer valve (j), the closed down slow transfer valve (i) and closed down fast transfer valve (h). Fluid will attempt to exit the cylinder through the interconnecting passage back into the accumulator (c). The closed up fast transfer valve (j) will prevent the fluid return. As the shock rod extends outward, the pressure inside the up cavity will reach sufficient pressure to open the shock valve (p) which opens at 880–1110 PSI. Oil will flow into the cavity created as the shock rod & shock piston (n) moves away from the memory piston (m).

90-852572R02 NOVEMBER 2002

MID-SECTION — 5F-13

Shock Function Return

b a

c

d

p o e

n f k m j

i

h

g

l

a b c d e f g h

—

Shock Rod End Cap Accumulator Accumulator Piston Accumulator Check Valve Camshaft Lever Manifold Down Fast Transfer Valve

5F-14 — MID-SECTION

i j k l mnop-

Down Slow Transfer Valve Up Fast Transfer Valve Surge Valve Cylinder Memory Piston Shock Piston Shock Return Valve Impact Relief Valve 90-852572R02 NOVEMBER 2002

Shock Function Return After the drive clears the object, the shock return valve (o) will allow the oil to flow from between the shock piston (n) and memory piston (m) onto the down cavity as the drive returns to its original running position.

90-852572R02 NOVEMBER 2002

MID-SECTION — 5F-15

Hydraulic System Troubleshooting Refer to disassembly/reassembly instructions (following) if disassembly is required when servicing. IMPORTANT: After debris or failed components have been found (during troubleshooting procedure), it is recommended that unit be disassembled completely and all O-rings be replaced. Check ball components and castings must be cleaned using engine cleaner and compressed air or replaced prior to reassembly.

3. Check for discharged accumulator. 35 to 50 lb. ft. (47-68 N·m) of pulling force must be attained when tilting outboard from full “down” to full “up” position. If more than 50 lb. ft. (68 N·m) of force is required, replace accumulator.

a

Support outboard with tilt lock lever when servicing manual tilt system. 1. Check manual release cam adjustment. Cam must open and close freely. Adjust cam link rod as necessary.

b

b

a 50431

c a — Weight Scale b — Valve Lever (open position)

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.

5F-16 — MID-SECTION

90-852572R02 NOVEMBER 2002

Manual Tilt System Removal CAUTION

3. Position piece of wood under transom bracket instead of tilt lock for access of removing pin. Use suitable punch to remove (DRIVE DOWN) upper dowel pin. Retain dowel pin.

Remove cowling and remove all spark plug leads from spark plugs to prevent accidental starting while servicing outboard.

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 engine or causing personal injury. To avoid such injury support outboard in the up position using tilt lock lever.

b

a 51144

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. 1. Support outboard in the up position using tilt lock lever.

a — Upper Dowel Pin b — Wood

4. Position tilt lock and remove piece of wood. Use suitable punch to drive out upper pivot pin.

a

2. Remove link rod.

a

b

b

51144

a — Upper Pivot Pin b — Tilt Lock

5. Use punch to remove (DRIVE UP) lower dowel pin. Retain dowel pin.

51143

a — Link Rod b — Accumulator

a 51144

a — Lower Dowel Pin 90-852572R02 NOVEMBER 2002

MID-SECTION — 5F-17

6. Use suitable punch to drive out lower pivot pin.

Manual Tilt System Disassembly NOTE: Accumulator contains a high pressure nitrogen charge and is NOT SERVICEABLE. Replace if necessary.

WARNING 51144

a

This tilt system is pressurized. Remove accumulator only when shock rod is in full up position.

a — Lower Pivot Pin

Accumulator Removal 7. Tilt shock absorber assembly (TOP FIRST) out from clamp bracket and remove assembly.

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 surge valve enough to drip, wait until dripping stops.

a



5. When fluid stops dripping, loosen and remove accumulator.

51144

a — Manual Tilt System

a b

c a — Accumulator b — Cam Lever c — Velocity Plug

5F-18 — MID-SECTION

51143

90-852572R02 NOVEMBER 2002

6. If plunger can be compressed into accumulator by hand, accumulator is defective. Replace accumulator.

Shock Rod Removal 1. Unscrew cylinder end cap assembly using spanner wrench [1/4 in. x 5/16 in. long pegs].

a

51145

2. Remove shock rod assembly from cylinder.

51143

a — Plunger

7. Once accumulator is removed, remove O-ring, conical spring, steel ball and plunger.

a b c d

51145

a b c d

—

Conical Spring Steel Ball Plunger O-ring

90-852572R02 NOVEMBER 2002

MID-SECTION — 5F-19

3. Remove check ball components from shock rod piston.

Shock Rod Disassembly NOTE: The only serviceable items on the shock rod assembly are the O-rings and wiper ring. If shock rod requires any other repair, replace shock rod assembly.

4. Remove O-ring.

c b

b

c

a

b a

d

a — End Cap b — O-ring (2) c — Wiper Ring

51147

1. Place shock rod assembly on clean work surface. 2. Remove three (3) screws and remove plate from shock rod piston.

a b c d

—

Spring (5) Seat (5) Ball (5) O-ring

a

b c 51143

a — Screw (3) b — Plate c — Shock Rod Piston

5F-20 — MID-SECTION

90-852572R02 NOVEMBER 2002

9. Clean shock and components with compressed air.

CAUTION When removing shock piston, spanner wrench must have 1/4 in. x 5/16 in. long pegs to avoid damage to shock piston.

10. Remove inner O-ring.

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 51199

a — Shock Piston b — O-ring

11. Remove cylinder end cap assembly from shock rod. 12. Inspect shock. If wiper (located in cap) has failed to keep rod clean, replace wiper. 13. Place end cap on clean work surface. 14. Remove rod wiper, inner O-ring, and outer Oring. 51146

a

b

51147

51146

a a — Spanner Wrench b — Shock Rod Piston

c b

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.

90-852572R02 NOVEMBER 2002

51145

a — Rod Wiper b — Inner O-ring c — Outer O-ring

MID-SECTION — 5F-21

Valve Block Removal

Memory Piston Removal

1. Remove two screws from the shock rod cylinder to separate the valve block.

1. Remove memory piston from cylinder using one of two methods: a. Using lock ring pliers.

b a

c 51146

a — Screw b — Valve Block c — Shock Rod Cylinder

51144

b. Blowing compressed air into center O-ring hole.

2. Remove O-rings and dowel pins.

WARNING b

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.

a

a 51148

a — O-ring (2) b — Dowel Pin (2)

b

c 55466

a — Adaptor/Air Hose b — Memory Piston Exit c — Shop Rag

5F-22 — MID-SECTION

90-852572R02 NOVEMBER 2002

2. Remove O-ring from memory piston.

3. Remove surge valve assembly.

a b

a b c d 51144

a — O-Ring b — Memory Piston

a b c d

Valve Block Disassembly

—

Spool Spring O-ring Screw Plug

1. Remove check retainer plug and components. 2. Remove hydraulic oil transfer valve plugs and components.

4. Remove screw and remove cam assembly.

e d c b a

a b c d e

—

Spacer Retainer Clip Retainer Clip Screw Shaft Seal Cam

a b 51142

a — Transfer Valve Plug Assembly (2) b — Check Retainer Plug or Screw Assembly

90-852572R02 NOVEMBER 2002

MID-SECTION — 5F-23

Reassembly — O-Ring and Seal Placement 1

2 3

5 4

14

7 9 6

11 12

10 8

13 NOTE: Lubricate all O-rings using Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. NOTE: It is recommended that all O-rings be replaced when servicing tilt system. 5F-24 — MID-SECTION

90-852572R02 NOVEMBER 2002

Actual O-Ring Sizes 1 2

9

3

4, 14

5

10

6 (2)

11 & 13

Cutaway View of O-Ring 12

7

Width

8 (2) O.D.

I.D.

O-RINGS SHOWN ARE ACTUAL SIZE 90-852572R02 NOVEMBER 2002

MID-SECTION — 5F-25

O-ring Description and Sizes O-Ring

Description

O-Ring I.D.

O-Ring O.D.

O-Ring Width

1

Wiper Ring (412585)

2

Cyl. Cap, Inner (412586)

0.671 in. (17.04 mm)

0.949 in. (24.10 mm)

0.139 in. (3.53 mm)

3

Cyl. Cap (408134)

1.864 in. (47.34 mm)

2.004 in. (50.90 mm)

0.07 in. (1.78 mm)

4

Shock Piston (412782)

1.6 in. (40.64 mm)

2.02 in. (53.086 mm)

0.21 in. (5.334 mm)

5

Piston Bolt (405797)

0.676 in. (17.17 mm)

.816 in. (20.726 mm)

0.07 in. (1.78 mm)

Manifold Split Line405387 0.208 in. (5.283 mm)

0.348 in. (8.839 mm)

0.07 in. (1.78 mm)

Slow Valve (401627)

0.114 in. (2.90 mm)

0.254 in. (6.451 mm)

0.07 in. (1.78 mm)

Plug (404463)

0.489 in. (12.42 mm)

0.629 in. (15.97 mm)

0.07 in. (1.78 mm)

9

Accumulator (412175)

2.114 in. (53.69 mm)

2.254 in. (57.25 mm)

0.07 in. (1.78 mm)

10

Lip Seal (412574)

11

Cam Shaft (402664)

0.301 in. (7.645 mm)

0.441 in. (11.20 mm)

0.07 in. (1.78 mm)

12

Back Up Ring (412592)

13

Surge Valve (402664)

0.301 in. (7.645 mm)

0.441 in. (11.20 mm)

0.07 in. (1.78 mm)

14

Memory Piston

1.6 in. (40.64 mm)

2.02 in. (53.086 mm)

0.21 in. (5.334 mm)

6 (2) 7 8 (2)

5F-26 — MID-SECTION

90-852572R02 NOVEMBER 2002

Manual Tilt System Cleaning and Inspection

VALVE BODY CHECK REASSEMBLY 1. Install lubricated O-ring, plunger, steel ball and conical spring to valve block.

1. It is recommended that all O-rings exposed during disassembly be replaced.

a

2. Clean components, filter, and check valve seats using engine cleaner and compressed air. Do not use cloth rags.

b

3. Inspect all machined surfaces for burrs or scoring to assure O-ring longevity.

d

c

4. Inspect shock rod. If scraper (located in cap) has failed to keep rod clean, replace scraper. 51145

Manual Tilt System Reassembly IMPORTANT: Components must be dirt and lint free. Slightest amount of debris in tilt system could cause system to malfunction.

a b c d

—

Conical Spring Steel Ball Plunger O-ring

Apply Power Trim and Steering Fluid to all O-rings during reassembly. If not available, use automotive (ATF) automatic transmission fluid.

VELOCITY VALVE REASSEMBLY

CAM SHAFT REASSEMBLY

2. Torque screw plug to 75 lb. in. (8.5 N⋅m).

1. Install spool, spring, lubricated O-ring and screw plug (surge valve assembly) into valve block.

IMPORTANT: Cam shaft O-ring must be lubricated using 2-4-C with Teflon. 1. Install lubricated O-ring and back up seal to cam. 2. Install shaft seal in valve block with lips facing out. 3. Install cam shaft assembly in valve block.

a

4. Secure cam shaft in place using insulator, retainer plate, and screw. Tighten screw securely.

b

g e f

d

c d

c b a

95

95

a b c d e f g

—

a b c d

—

Spool Spring O-ring Screw Plug — Torque to 75 lb. in. (8.5 N⋅m)

2-4-C with Teflon

Spacer Retainer Clip Retainer Clip Screw Shaft Seal O-ring Back up Seal Cam

90-852572R02 NOVEMBER 2002

MID-SECTION — 5F-27

CHECK RETAINER REASSEMBLY

Valve Block Installation

1. Install plunger, spring (large), ball, spring (small), and plug into valve block.

1. Install lubricated O-rings and dowel pins.

b 1

a

51148

a b c d e a b c d e

—

a — O-ring (2) b — Dowel Pin (2)

51142

Plunger Spring (Large) Ball Spring (Small) Plug

2. Install valve block to shock rod cylinder. Insert screws to shock rod cylinder and torque to 100 lb. in. (11 N·m).

a b

VALVE PLUG REASSEMBLY 1. Install plunger, steel ball, spring, lubricated Oring and screw plug. Torque screw plugs to 75 lb. in. (8.5 N⋅m).

c 51146

a — Valve Block b — Screw (2) Torque to 100 lb. in. (11 N⋅m) c — Shock Rod Cylinder

a b c d e a b c d e

—

51142

Plunger (2) Steel Ball (2) Spring (2) O-ring (2) Screw Plug (2) Torque to 75 lb. in. (8.5 N⋅m)

5F-28 — MID-SECTION

90-852572R02 NOVEMBER 2002

Shock Rod Reassembly

4. Clamp shock rod in soft jawed vise.

1. Install lubricated O-rings to end cap.

5. Position cylinder end cap onto rod, as shown.

2. Install rod wiper.

a c b 51146

51145

a — Rod Wiper b — Inner O-ring c — Outer O-ring

CAUTION When installing shock rod piston, spanner

3. Install lubricated O-rings to shock piston.

wrench must have 1/4 in. x 5/16 in. (6.4mm x8mm) long pegs to avoid damage to shock rod piston. 6. Apply Loctite 271 Thread Locker 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 N⋅m).

b c a

a

b

51199

a — Shock Piston b — O-ring c — O-ring

7

51146 7

Loctite 271 Thread Locker

a — Spanner Wrench b — Shock Rod Piston — Torque to 90 lb. ft. (122 N⋅m)

90-852572R02 NOVEMBER 2002

MID-SECTION — 5F-29

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 N⋅m). 11. Remove shock rod assembly from vise.

Shock Rod Installation and Fluid Filling Procedure NOTE: There are two ways for the filling procedure. The first is the easiest and less time consuming. Filling Procedure Option One 1. Place trim cylinder in soft jawed vice. 2. With manifold cam lever closed (Up Position), fill cylinder and manifold to top with Power Trim and Steering Fluid, or (ATF) automatic transmission fluid. Let bubbles disperse.

d

e

3. Install lubricated O-ring to memory piston. 4. Using lock ring pliers (P/N 91-822778A3). Set memory piston in top of cylinder then open cam lever (Down Position) and push memory piston down just below cylinder treads. Close cam lever (Up Position).

c a

b a b c d e

—

51147

Screw (3) Torque to 35 lb. in. (3.9 N⋅m) Plate Spring (5) Seat (5) Ball (5)

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″ below cylinder threads. Close cam lever (Up Position).

5F-30 — MID-SECTION

90-852572R02 NOVEMBER 2002

6. Fill top of shock rod assembly with fluid to top of cylinder. Open cam lever (Down Position) 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 N⋅m). 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 N⋅m).

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.

90-852572R02 NOVEMBER 2002

MID-SECTION — 5F-31

Filling Procedure Option Two Instructions for Making Retaining Tool

3/16 in x 3 in. (5 x 7.5 cm) Steel Plate 3/8 in. x 13 in. (10mm x 33cm) Threaded Rod 4in. x 1/4 in. min. (10cm x 6.4mm) minimum Channel Iron

10 in. (25 cm) 8 in. (20 cm)

1 in. (25mm)

3 in. (76mm) 2 holes, 7/16 in. dia. (11 mm) 1 1/4 in. dia. (30m)

5 in. (125mm)

20 in. (508mm)

2 in. (50mm)

4 in. (100 mm)

6 in. (152mm)

5F-32 — MID-SECTION

8 in. (203mm)

3/8 in. dia. 2 holes

90-852572R02 NOVEMBER 2002

Bleeding Manual Tilt System IMPORTANT: While bleeding tilt system, time must be allowed between each stroke to allow air bubbles to dissipate.

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.

1. With shock rod in the full up position and manifold cam lever open (facing down), secure tilt system to retaining tool and container. (A No. 10 can or 3 lb. coffee can could be used). 2. Fill container to near full level using Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. IMPORTANT: Fluid level must remain above accumulator opening during bleeding process.

a 50432

e b

4. During up stroke, pull up on rod slowly 3 in. (76mm) from base.

c a

5. Wait until all air bubbles to exit accumulator base.

d 50447

a b c d e

—

Retaining Tool Tilt System Container Cam Lever Accumulator Opening

50433

6. Slowly cycle unit 5-8 times (round trip per cycle) using short strokes 3 in. (76mm) from base allowing bubbles to disappear during each stroke.

90-852572R02 NOVEMBER 2002

MID-SECTION — 5F-33

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.

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 N·m).

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.

50433

50432

10. Tighten accumulator snugly at this time.

50432

5F-34 — MID-SECTION

90-852572R02 NOVEMBER 2002

4. Using a suitable punch, drive lower pivot pin into clamp bracket and trim cylinder assembly until pivot pin is flush with outside surface.

Manual Tilt System Installation 1. Apply 2-4-C with Teflon to lower pivot pin hole and pivot pin surface. 2. Start lower pivot pin into pivot pin hole and position lower dowel pin (retained) in its hole.

b

a 51147

a — Lower Pivot Pin

a 95 51148 95

5. Using a punch, drive lower dowel pin in until seated.

2-4-C with Teflon (92-802859A1)

a — Lower Pivot Pin b — Lower Dowel Pin

3. Reinstall manual tilt system, bottom first. Reconnect release valve link rod. 

a a 51148

a — Lower Dowel Pin

51144

a — Manual Tilt System

90-852572R02 NOVEMBER 2002

MID-SECTION — 5F-35

6. Apply 2-4-C with Teflon to surface of upper pivot pin, pivot pin hole and shock rod hole.

a

b

8. Drive upper dowel pin (a) into its hole until seated.

c

a 51147 95 51148 95

a — Dowel Pin

2-4-C with Teflon

9. Check manual release cam adjustment. Cam must open and close freely. Adjust link rod as necessary.

a — Pivot Pin b — Pivot Pin Bore c — Shock Rod Bore

7. Using a mallet, drive upper pivot pin into swivel bracket and through shock rod until pivot pin is flush with swivel bracket.

Manual Release Valve Adjustment 1. With outboard in full up position, place tilt lock lever forward. 2. Lift cam lever (with link rod) to full up position.

a

b c

c a

51148

a — Pivot Pin b — Swivel Bracket c — Shock Rod

b

51143

a — Tilt Lock Lever b — Cam Lever c — Link Rod

3. Link rod end must snap onto ball of tilt lock lever without moving tilt lock lever or cam lever. 5F-36 — MID-SECTION

90-852572R02 NOVEMBER 2002

LOWER UNIT

6 A 40/50 LOWER UNIT

Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Housing (Drive Shaft)(40/50) . . . . . . . Gear Housing (Propeller Shaft)(40/50) . . . . General Service Recommendations . . . . . . Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Draining and Inspecting Gear Lubricant . . . Propeller Removal . . . . . . . . . . . . . . . . . . . . . . Gear Housing Removal . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Pump . . . . . . . . . . . . . . . . . . . . . . . . Water Pump Seals . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upper Drive Shaft Bearing . . . . . . . . . . . . Pinion Gear Bearing . . . . . . . . . . . . . . . . . Pinion Gear . . . . . . . . . . . . . . . . . . . . . . . . . Forward Gear . . . . . . . . . . . . . . . . . . . . . . . Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . Propeller Shaft Disassembly . . . . . . . . . . Propeller Shaft and Carrier Inspection . . . . Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cam Follower . . . . . . . . . . . . . . . . . . . . . . . Reverse Gear . . . . . . . . . . . . . . . . . . . . . . . Reverse Gear Bearing . . . . . . . . . . . . . . . Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . Gear Housing Reassembly . . . . . . . . . . . . . . Shift Shaft Assembly . . . . . . . . . . . . . . . . . Pinion Bearing Race . . . . . . . . . . . . . . . . . Forward Gear . . . . . . . . . . . . . . . . . . . . . . . Pinion Gear/Drive Shaft Assembly . . . . . Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . Water Pump . . . . . . . . . . . . . . . . . . . . . . . . Gear Housing Pressure Test . . . . . . . . . . . . . Gear Housing Installation . . . . . . . . . . . . . . . . Filling Gear Housing with Lubricant . . . . Installing Gear Housing to Drive Shaft Housing . . . . . . . . . . . . . . . . . . . . . . . Trim Tab Adjustment and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . Propeller Installation . . . . . . . . . . . . . . . . . . . .

6A-0 — LOWER UNIT

Page 6A-1 6A-2 6A-4 6A-6 6A-8 6A-8 6A-8 6A-9 6A-9 6A-10 6A-11 6A-11 6A-14 6A-15 6A-15 6A-15 6A-15 6A-16 6A-17 6A-18 6A-18 6A-18 6A-18 6A-19 6A-19 6A-20 6A-21 6A-22 6A-22 6A-23 6A-23 6A-24 6A-25 6A-26 6A-27 6A-27 6A-27 6A-28 6A-29 6A-30

90-852572R02 NOVEMBER 2002

Specifications

GEAR HOUSING

Gear Ratio Gearcase Capacity Lubricant Type Forward Gear Number of Teeth Pinion Gear Number of Teeth Pinion Height Forward Gear Backlash Reverse Gear Backlash Water Pressure With Thermostat @ Idle @ W.O.T. W/O Thermostat @ Idle @ W.O.T. Pressure Test

1.83:1 14.9 fl. oz. (440 mL) Premium Gear Lubricant 22 Spiral/Bevel 12 Spiral/Bevel No Adjustment No Adjustment No Adjustment 0.5-1.5 PSI (3-10 kPa) @ 750 RPM 5-7 PSI (34-48 kPa) @ 5000 RPM 0-1 PSI (0-6 kPa) @ 750 RPM 5-7 PSI (34-48 kPa) @ 5000 RPM 10-12 PSI (68-83 kPa) for 5 Minutes

NOTE: Before filling gear case, apply 10-12 PSI of air pressure at the vent hole. Pressure should not drop for 5 minutes while alternately applying a 2-3 pound force to the top of the shift shaft in the fore and aft direction.

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6A-1

5. Mandrel 91-36571

Special Tools 1. Bearing 31-85560 54978

6. Universal Puller Plate 91-37241 2. Driver 91-13779

3. Bearing Puller & Installation Tool 91-31229A7 a. Nut 11-24156

b. Washer (2) 12-34961

7. Driver Head 91-37312T

c. Plate 91-29310

d. Shaft 91-31229 8. Driver 91-817011T

51043

4. Bearing Puller Tool 91-27780 9. Driver Rod 91-37323

6A-2 — LOWER UNIT

90-852572R02 NOVEMBER 2002

10. Drive Shaft Holding Tool 91-825196

16. Driver 91-826872

11. Mandrel 91-825197T

17. Leakage Tester FT8950

12. Driver 91-817007T

51043

13. Mandrel 91-825198

14. Pilot 91-825199

15. Spring Hook 91-825200A1

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6A-3

Gear Housing (Drive Shaft)(40/50)

95

7

23 24 22 28 29 25

95

14 26

140

12

30

82

7

13 95

31

95

15 21

32

95

27

33 34 36

2

16 17

95

35

18

37

3 38

20

39

19

1

11 4

10

5

82

9 8 7

Loctite 271 Thread Locker

82

Premium Gear Lubricant

95

2-4-C with Teflon Loctite 405

140

6A-4 — LOWER UNIT

7

7 6

90-852572R02 NOVEMBER 2002

Gear Housing (Drive Shaft)(40/50) REF. REF NO. QTY. – 1 – 1 – 1 – 1 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 10 1 11 1 12 4 13 1 14 1 15 1 16 1 17 1 18 1 19 1 20 1 21 1 22 1 23 1 24 1 25 1 26 1 1 27 1 28 1 29 1 30 1 31 1 32 1 33 1 34 1 1 35 1 36 1 37 1 38 1 39 1

TORQUE DESCRIPTION GEAR HOUSING (BLACK) SHORT GEAR HOUSING (GRAY) GEAR HOUSING (BLACK) LONG GEAR HOUSING (GRAY) GEAR HOUSING (BASIC-BLACK) GEAR HOUSING (BASIC-GRAY) SEAL/PLATE KIT PLATE SCREW (.375-16 x .25) WASHER–Sealing DRAIN SCREW (MAGNETIC) WASHER–Sealing NUT PINION GEAR (12 TEETH) BEARING ASSEMBLY–Roller CUP SCREW (M6 x 16) WATER PUMP ASSEMBLY SEAL–Water Tube WASHER KEY WASHER GASKET GASKET (LOWER) FACE PLATE IMPELLER WATER PUMP BASE ASSEMBLY SEAL–Oil SEAL–Oil O RING BALL BEARING DRIVESHAFT (SHORT) DRIVESHAFT (LONG) NUT (INCLUDED WITH REF #35) CABLE TIE BOOT–Shift Shaft RETAINER–Shift Shaft O RING O RING WASHER SHIFT SHAFT (SHORT) SHIFT SHAFT (LONG) WASHER ROLL PIN CAM–Shift PIN

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

N·m

55

6.2

55

6.2 50

60

67.8

6.8

LOWER UNIT — 6A-5

Gear Housing (Propeller Shaft)(40/50)

43

45

42 47

44

46 56

41

68 55

40

54 1 40

53 52

70 71

95

48

51 50

69 64

66

82

49

65 67

73 60 72

7

63

61 62

7

59 58

82

95

57 82

95

94 7

Loctite 271 Thread Locker

82

Premium Gear Lubricant

94

Anti-Corrosion Grease

95

2-4-C with Teflon

6A-6 — LOWER UNIT

90-852572R02 NOVEMBER 2002

Gear Housing (Propeller Shaft)(40/50) REF. REF NO. QTY. – 1 – 1 – 1 – 1 1 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73

1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 1 1 1 1 4 4

TORQUE GEAR HOUSING (BLACK) GEAR HOUSING (GRAY) GEAR HOUSING (BLACK) GEAR HOUSING (GRAY)

DESCRIPTION SHORT

lb. in. lb. ft.

N·m

LONG

GEAR HOUSING (BASIC-BLACK) GEAR HOUSING (BASIC-GRAY) DOWEL PIN GASKET Water Tube TUBE PLUG–RUBBER SCREEN–Water Inlet TRIM TAB SCREW (M8 x 20) WASHER FORWARD GEAR ASSEMBLY (22 TEETH) ROLLER BEARING ASSEMBLY CUP ROLLER BEARING FOLLOWER–Cam SPRING PIN–Cross CLUTCH SPRING PROPELLER SHAFT REVERSE GEAR (22 TEETH) BALL BEARING BEARING CARRIER O RING NEEDLE BEARING OIL SEAL OIL SEAL WASHER WASHER (USE WITH THREADED INSERT) SCREW (M8 x 25 – Cap Screw) SCREW (M8 x 30) (Use With Threaded Insert) THREADED INSERT DECAL 1.83:1 (12 x 22) THRUST HUB PROP NUT TAB WASHER SCREW WASHER

90-852572R02 NOVEMBER 2002

23.3

31.6

16.5 18.8

22.4 25.4

55

74.6

40

54.2

LOWER UNIT — 6A-7

General Service Recommendations There may be more than one way to “disassemble” or “reassemble” a particular part(s), therefore, it is recommended that the entire procedure be read prior to repair. IMPORTANT: Read the following before attempting any repairs. In many cases, disassembly of a sub-assembly may not be necessary until cleaning and inspection reveals that disassembly is required for replacement of one or more components. Service procedure order in this section is a normal disassembly-reassembly sequence. Threaded parts are right hand (RH), unless otherwise indicated.

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, uneven 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 appearance. 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 with Teflon on all O-rings and on I.D. of oil seals. Apply 2-4-C with Teflon to external surfaces of bearing carrier.

When holding, pressing or driving is required, use soft metal vise jaw protectors or wood for protection of parts. Use a suitable mandrel (one that will contact only the bearing race) when pressing or driving bearings. Whenever compressed air is used to dry a part, verify that no water is present in air line.

Bearings All bearings must be cleaned and inspected. Clean bearings with solvent and dry with compressed air. Air should be directed at the bearing so that it passes through the bearing. DO NOT spin bearing with compressed air, as this may cause bearing to score from lack of lubrication. After cleaning, lubricate bearings with Premium Gear Lubricant. DO NOT lubricate tapered bearing cups until after inspection. Inspect all bearings for roughness, catches and bearing race side wear. Work inner bearing race in-andout, while holding outer race, to check for side wear. When inspecting tapered bearings, determine condition of rollers and inner bearing race by inspecting bearing cup for pitting, scoring, grooves, uneven wear, imbedded particles and/or 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.

6A-8 — LOWER UNIT

90-852572R02 NOVEMBER 2002

Draining and Inspecting Gear Lubricant

Propeller Removal WARNING

WARNING If gear housing is installed on outboard, disconnect (and isolate) spark plug leads from spark plugs before working near the propeller. 1. With gear housing in normal running position, place a clean pan under housing and remove vent plug and fill/drain plug (with gaskets).

If gear housing is not removed from outboard, before attempting to remove or install the propeller, remove (and isolate) spark plug leads from spark plugs to prevent outboard from starting. 1. Bend tabs of tab washer away from nut.

a

a

b b 51119

a — Vent Plug/Washer b — Fill/Drain Plug/Washer

2. Inspect gear lubricant for metal particles (lubricant will have a “metal flake” appearance). Presence of fine metal particles (resembling powder) on the drain plug magnet indicates normal wear. Metal chips on the magnet indicate the need for gear housing disassembly and component inspection.

a — Tab Washer b — Nut

2. Use a block of wood to prevent propeller from rotating. Remove nut and pull components from shaft.

a

3. Note color of gear lubricant. White or cream color indicates presence of water. Gear lubricant drained from a gear case assembled with Special Lubricant 101 or a gear case recently in operation will have a yellowish color due to lubricant agitation/aeration. This is normal and should not be confused with the presence of water. 4. Presence of water indicates the need for disassembly and inspection of oil seals, O-rings, gaskets and components for damage.

50552 a — Block of Wood

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6A-9

4. Make a scribe line showing alignment of trim tab to gear case and remove trim tab bolt and washer.

Gear Housing Removal WARNING

b

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.

a

2. Shift into NEUTRAL. 3. Loosen jam nut. Unscrew attaching nut to separate shift shaft. 30/40, 40/50, FORCE 40/50

52835 a — Bolt and Washer b — Scribe Line

b a

5. Remove nut and washer in trim tab cavity.

52832 a — Jam Nut b — Attaching Nut

a 25 (4 STROKE), 45/50 (4 STROKE)

a

52835 a — Nut and Washer

b

a — Retainer b — Lower Clip

6A-10 — LOWER UNIT

90-852572R02 NOVEMBER 2002

6. Remove 4 bolts securing gear case to drive shaft housing.

2. Remove cover, washer (above impeller), impeller, key and washer (below impeller). 3. Remove cover gasket, base plate and base gasket.

a

a

b c

52836 a — Bolt (4)

d

Disassembly

e

Water Pump NOTE: If water tube seal remained in drive shaft housing, remove seal from housing and reinstall on water pump cover. Secure seal to cover with Loctite 405.

f

1. Remove 4 bolts securing pump cover.

g

a b h 52692

52830 a — Seal b — Bolt (4)

NOTE: Replace cover if thickness of steel at discharge slots is 0.060 in. (1.524mm) or less, or if grooves (other than impeller sealing groove) in cover roof are more than 0.030 in. (0.762mm) deep.

90-852572R02 NOVEMBER 2002

a b c d e f g h

—

Cover Washer (above impeller) Impeller Key Washer (below impeller) Cover Gasket Face Plate Base Gasket

NOTE: Replace impeller if: – Impeller blades are cracked, torn or worn. – Impeller is glazed or melted – Rubber portion of impeller is not bonded to impeller hub.

LOWER UNIT — 6A-11

4. Remove and/or replace exhaust deflector plate if damaged.

NOTE: When removing propeller shaft assembly, cam follower may dislodge. Retrieve follower from gear housing. 7. Remove propeller shaft assembly.

a

52832 a — Deflector Plate

a 52864

5. Remove bearing carrier attaching bolts and locking tab washers or flat washers. Discard tab washers.

b

a — Propeller Shaft

Model

Drive Shaft Holding Tool

25, 45/50 (4-Stroke)

91-83180M

Force 40/50

91-825196

30/40, 40/50

91-825196

8. Remove pinion nut and discard.

a

51043

a

a — Bolts and Tab Washers or Flat Washers b — Tab Washers Style 2

b 6. Using Puller (91-27780), remove carrier assembly from gear case. 52864

a a — Drive Shaft Holding Tool b — Pinion Gear

9. Remove drive shaft assembly and pinion gear.

52829 a — Puller (91-27780)

6A-12 — LOWER UNIT

90-852572R02 NOVEMBER 2002

10. Remove forward gear.

12. Insert pinion bearing race puller (91-825200A1) through gear case and position inside of pinion bearing race. Insert driver (91-13779) into puller through drive shaft cavity and drive out race.

b

a

a 52870 a — Forward Gear 52844

11. Remove shift shaft assembly

a — Puller (91-825200A1) b — Driver (91-13779)

13. Remove forward bearing race with puller (91-27780).

a

b

a

52841 a — Shift Shaft Assembly

53838 a — Race b — Puller (91-27780)

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6A-13

Water Pump Seals NOTE: All gaskets, seals and O-rings should be replaced as a normal repair procedure during gear case disassembly.

3. With lip of ribbed neoprene O.D. seal facing towards small shoulder of Mandrel (91-825197), press seal into carrier until mandrel bottoms on carrier.

NOTE: DO NOT use a screwdriver to remove seals from carrier, as carrier may be damaged. 1. Using a suitable mandrel, press both seals from carrier.

a

a

b

7

b

c

d 52692 a b c d

—

Neoprene Ribbed Seal Metal Cased Seal Carrier O-ring

NOTE: Apply a light coat of 2-4-C with Teflon to the lips of both seals after installation in carrier.

Loctite 271 Thread Locker

7

52853 a — Seal (Ribbed Neoprene) Lip Facing Up b — Mandrel (91-825197)

2. Apply Loctite 271 to the O.D. of the metal cased seal. With seal lip facing away from the large shoulder of mandrel (91-825197), press seal into carrier until mandrel bottoms on carrier.

4. Apply a light coat of 2-4-C with Teflon to the new O-ring and install on carrier.

95

a

52825

a 95

2-4-C with Teflon

a — O-ring

b

52850 a — Seal (Metal Cased) Lip Facing Down b — Mandrel (91-825197) 6A-14 — LOWER UNIT

90-852572R02 NOVEMBER 2002

Pinion Gear Bearing

Inspection

1. Inspect bearing for rust, roughness or discoloration from lack of lubricant.

Upper Drive Shaft Bearing 1. Inspect bearing for rust, roughness or discoloration from lack of lubricant. 2. DO NOT remove bearing from drive shaft unless bearing must be replaced, as removal process will damage bearing.

2. If bearing is damaged, bearing and race must be replaced as an assembly. 3. If race appears to have spun in drive shaft bore, gear case housing must be replaced.

a

3. If bearing must be replaced, position drive shaft assembly in vise (jaws of vise supporting only bearing) and while holding drive shaft, strike top of drive shaft with lead hammer and drive bearing off.

b 52823 a — Bearing b — Race

Pinion Gear a

1. Inspect pinion gear teeth for rust, chipping, excessive wear (teeth are sharp edged) or broken. 2. If pinion gear teeth are damaged, also inspect forward and reverse gear teeth for damage. 3. Replace gears as required.

a — Bearing

4.

To install new bearing, thread old pinion nut 3/4 way onto drive shaft. Position Universal Puller Plate (91-37241) under bearing and press on pinion nut while holding drive shaft until bearing seats against shoulder.

52839

a

b c

52387 a — Old Pinion Nut (Nut Should be Above Drive Shaft) b — Bearing c — Universal Puller Plate (91-37241) 90-852572R02 NOVEMBER 2002

LOWER UNIT — 6A-15

Forward Gear 1. Inspect forward gear teeth for rust, chipping, excessive wear (teeth are sharped edged), or broken teeth.

4. Use a suitable mandrel to press needle bearing out of forward gear.

2. Inspect forward gear clutch jaws for wear. Rounded jaws indicate the following:

a

b

a. Improper shift cable adjustment. b. Engine idle speed too high. c. Shifting too slowly.

52873 a — Mandrel (14 mm Socket) b — Bearing

5. Use Driver 91-826872 to press new needle bearing into forward gear. Press on numbered side of bearing. 52874

a 3. Inspect propeller shaft forward gear bearing surface to determine condition of forward gear needle bearing. If bearing surface is discolored (from lack of lubricant), pitted or worn, propeller shaft and bearing should be replaced.

b

82

52847 82

52874

b

a

Premium Gear Lubricant

a — Driver (91-826872) b — Bearing

52846 a — Bearing Surface b — Bearing

6A-16 — LOWER UNIT

90-852572R02 NOVEMBER 2002

6. Inspect forward gear tapered bearing and race for rust, roughness or excessive wear (looseness). 7. If bearing is in serviceable condition, DO NOT remove bearing from gear, as removal process will damage bearing.

Shift Shaft 1. Inspect shift cam for wear or galling. Replace cam if necessary. 2. If cam is worn, inspect cam follower in end of propeller shaft for wear.

8. If bearing must be replaced, remove bearing from gear using Universal Puller Plate (91-37241) and suitable mandrel. 9. Replace bearing and race as a set. Use suitable mandrel to press bearing onto gear. PRESS ONLY ON INNER RACE when installing bearing.

b

b a 52845

a

a — Cam Follower b — Shift Cam

3. Inspect shift shaft boot for deterioration. 4. Inspect shift shaft carrier O-ring for cuts or abrasions. It is a good service procedure to replace all O-rings, seals and gaskets regardless of appearance. 51119

a

REMOVAL a — Universal Puller Plate (91-37241) b — Mandrel (15/16 in. socket)

b

a

52828 a — Boot b — O-ring

INSTALLATION a — Mandrel (1-1/8 in. socket)

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6A-17

Propeller Shaft Disassembly 1. Remove propeller shaft from carrier and disassemble shaft.

a

d b

Clutch

c

1. Inspect clutch jaws for chips or rounding off.

e a b c d e f

—

Propeller Shaft and Carrier Inspection

f

2. If wear is present, inspect corresponding forward or reverse gear matching jaws for similar wear. Replace appropriate components as required.

Prop Shaft Retaining Spring Clutch Dog Cross Pin Cam Follower Spring Cam Follower

2. Remove reverse gear and bearing from carrier with Puller (91-27780). 52824

a

Cam Follower 1. Inspect cam follower for wear or galling. 2. If wear is present, inspect corresponding shift cam for wear. Replace if worn.

b

52840 a — Reverse Gear and Bearing b — Puller (91-27780)

6A-18 — LOWER UNIT

52822

90-852572R02 NOVEMBER 2002

Reverse Gear 1. Inspect reverse gear teeth for rust, chipping excessive wear (teeth are sharped edged) or broken teeth.

4. Install new bearing using a suitable mandrel. PRESS ONLY ON INNER RACE when installing bearing.

2. Inspect reverse gear clutch jaws for wear. Rounded jaws indicate the following: a. Improper shift cable adjustment. b. Engine idle speed too high.

d

c. Shifting too slowly.

51289

a b

c 51269

REMOVAL a b c d

—

Bearing Reverse Gear Universal Puller Plate (91-37241) Driver (91-37312)

52875

Reverse Gear Bearing

a

1. Inspect bearing for rust, roughness or excessive wear (looseness). 2. If bearing is in serviceable condition, DO NOT remove bearing from gear as removal will damage bearing.

b 82

3. If bearing must be replaced, remove bearing from gear using Universal Puller Plate (91-37241) and Driver (91-37312). INSTALLATION

52867

a — Mandrel (1-1/4 in. socket) b — Bearing 82

90-852572R02 NOVEMBER 2002

Premium Gear Lubricant

LOWER UNIT — 6A-19

Bearing Carrier

4. Apply a light coat of Special Lubricant 101 to O.D. of bearing.

NEEDLE BEARING

5. Install bearing using Mandrel 91-817011.

1. The condition of the carrier needle bearing can be determined by inspecting its running surface on the propeller shaft.

6. Press bearing into carrier until mandrel bottoms on carrier.

2. If the shaft is discolored (from lack of oil) or pitted, replace bearing and shaft.

b

3. Bearing can be removed by using Driver Rod (91-37323) and Driver (91-37312). Removing bearing will also remove both propeller shaft seals.

a

34

a

52861

b

34

Special Lubricant 101

a — Bearing b — Mandrel (91-817011)

c 7. Apply Loctite 271 to O.D. of small diameter seal. 8. With seal lip facing away from large shoulder of Mandrel 91-817007, press seal into carrier until mandrel bottoms on carrier.

d b 51264 a b c d

—

Driver Rod (91-37323) Driver (91-37312) Needle Bearing Seals

a 7

52862 7

Loctite 271 Thread Locker

a — Seal b — Mandrel (91-817007)

6A-20 — LOWER UNIT

90-852572R02 NOVEMBER 2002

9. Apply Loctite 271 to O.D. of large diameter seal. 10. With seal lip FACING TOWARDS SMALL SHOULDER of Mandrel 91-817007, press seal into carrier until mandrel bottoms on carrier.

11. Bearing carrier O-ring should be inspected for cuts and abrasions.

NOTE: It is a good repair procedure to replace all Orings and seals regardless of appearance. 12. Apply 2-4-C with Teflon to O-ring and install on carrier.

b

13. Using suitable mandrel, press reverse gear assembly into carrier.

a

b c a

95

7

52863 7

Loctite 271 Thread Locker

a — Seal b — Mandrel (91-817007)

52827 95

Installation Note: If service tools are not available, the following reference dimensions apply for installing bearing and seals to proper depths.

2-4-C with Teflon

a — O-ring b — Mandrel (3/4 in. Socket) c — Reverse Gear Assembly

.82 in. (20mm)

Gear Housing Reassembly

a

51275

a — Bearing

.44 in. (11mm) .04 in. (1mm)

b a 51275

IMPORTANT: The 30/40 gear case assembly does not have have any shims for the gear assemblies. Backlash cannot be adjusted. The mechanic must verify that all bearing races are firmly seated in the gear case during reassembly and that all gear case components are in serviceable condition. Prior to installing the seal carrier and water pump assembly on the drive shaft, the FORWARD gear should be held stationary (with a screw driver or similar tool). While pulling up on the drive shaft, lightly turn the shaft back and forth. A light “clicking” sound should be heard indicating the presence of backlash between FORWARD and PINION gears. If this backlash is not present, the pinion gear race and/or forward gear race are not fully seated. Races should be removed and inspected for debris. Reinstall races and check backlash. If backlash is still not present, replace gear housing.

a — Oil Seal (Install with Lip Down) b — Oil Seal (Install with Lip Up) 90-852572R02 NOVEMBER 2002

LOWER UNIT — 6A-21

Shift Shaft Assembly

Pinion Bearing Race

1. Apply 2-4-C with Teflon to new O-rings and install O-rings on shift shaft and carrier.

1. Apply Premium Gear Lubricant to O.D. of race.

2. Install carrier on shift shaft. IMPORTANT: When installing shift shaft assembly into gear housing, DO NOT BOTTOM OUT SHAFT IN HOUSING. Pull up on shift shaft until shift boot is not deformed. If shaft is bottomed out, cross pin in clutch dog will be bent by cam follower when tightening carrier bolts.

2. Position race in gear housing (NUMBERS UP TAPERED SIDE FACING DOWN). 3. Draw race up into housing until seated.

a

f

b

d

c

3. Install shift shaft/carrier assembly into gear housing. 4. Secure boot to carrier with sta-strap.

e

5. Position shift shaft so ramp faces towards propeller shaft.

d

c a

b

g

95

82

52842

e 82

52841 95

a b c d e

—

2-4-C with Teflon

O-rings Carrier Boot Sta-strap Ramp

6A-22 — LOWER UNIT

a b c d e f g

—

Premium Gear Lubricant

Threaded Rod (91-31229) Washer (2) (12-34961) Bearing (31-85560) Plate (91-29310) Pilot (91-825199) Nut (11-24156) Mandrel (91-825198)

90-852572R02 NOVEMBER 2002

Forward Gear

Pinion Gear/Drive Shaft Assembly

1. Apply Premium Gear Lubricant to O.D. of race. Install forward gear bearing race into housing using Mandrel 91-36571 and propeller shaft. Use a lead hammer on prop shaft to prevent damage to threads. Bearing carrier should be installed to keep prop shaft centered while seating race.

1. Clean pinion nut and pinion nut threads of drive shaft with Loctite Primer N. 2. Position pinion bearing into race while installing drive shaft and pinion gear into housing. 3. Apply Loctite 271 to pinion nut threads. 4. Install new pinion nut, with rounded corners FACING pinion gear, onto drive shaft.

b

Model

Drive Shaft Holding Tool

25, 45/50 (4-Stroke)

91-83180M

Force 40/50

91-825196

30/40, 40/50

91-825196

82

a 82

52843

Premium Gear Lubricant

5. Using Drive Shaft Holding Tool to hold drive shaft, torque pinion nut to 50 lb. ft. (67.8 N·m).

a — Race b — Mandrel (91-36571)

NOTE: Remove drain plug/magnet assembly from gear case (if installed) to prevent possible breakage of magnet if struck by forward gear.

51043

c

1. Install forward gear and bearing assembly into forward gear race.

d

b 7

a

52864 7

a

a b c d

—

Loctite 271 Thread Locker

Pinion Nut [Torque to 50 lb. ft. (67.8 N·m)] Pinion Gear Pinion Bearing Drive Shaft Holding Tool

52870 a — Forward Gear Assembly

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6A-23

6. Install cam follower.

Propeller Shaft 1. Slide clutch (short shoulder faces forward gear) over propeller shaft aligning cross pin hole with slot in propeller shaft. 2. Insert cam follower spring into propeller shaft. 3. Using a 3/16 in. allen wrench or similar device, compress the follower spring enough to insert the cross pin partially through clutch. 4. Remove wrench and press cross pin through clutch and propeller shaft until flush.

c

a

a 95

52826 95

2-4-C with Teflon

a — Cam Follower

b 52851 a — Short Shoulder b — Allen Wrench c — Cross Pin

7. Install propeller shaft assembly into gear case.

5. Reinstall retaining spring. position spring so as spring coils lay flat in clutch groove.

a

a 52864

52854 a — Spring

a — Propeller Shaft Assembly

NOTE: Applying 2-4-C with Teflon to cam follower will aid in retention of follower in propeller shaft during installation of propeller shaft assembly into gear case.

6A-24 — LOWER UNIT

90-852572R02 NOVEMBER 2002

4. Torque bolts to 225 lb. in./18.8 lb ft. (25.4 N⋅m)

Bearing Carrier 1. Install carrier into gear case. 2. Discard the original tab washers or the thin 0.063 in. (1.60 mm) flat washers and the 25 mm long bolts on models listed. Install thicker flat washers and longer bolts.

7

a

25 (2 Cylinder — 4 Stroke) USA 0G621670 and below 45/50 (4 Cylinder — 4 Stroke) Non Big Foot USA 0G621709 and below 30/40 (2 Cylinder — 2 Stroke) USA 0G650736 and below Belgium . . . . . NA 40/50 (3 Cylinder — 2 Stroke) USA 0G650699 and below Belgium . . . . . NA

a

Force 40/50 (2 Cylinder — 2 Stroke) USA 0E323508 and below

a

b

c

51117

7 7

Loctite 271 Thread Locker

a — Torque Bolts to 225 lb. in./18.8 lb. ft. (25.4 N⋅m)

a — Bolt 25 mm Long — Discard b — Tab Washer — Discard c — Thin Flat Washer 0.063 in. (1.60 mm) thick — Discard

3. Install thicker flat washers and longer bolts.

a

b

a — Bolt (10-855940-30) 1.18 in. (30 mm) Long b — Washer (12-855941) 0.090 in. (2.29 mm) Thick

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6A-25

4. Install impeller and nylon washer.

Water Pump 1. Install water pump seal carrier.

b

2. Install exhaust deflector plate, if removed.

b

a

a

52832 a — Seal Carrier b — Exhaust Deflector

3. Install base gasket, face plate, pump cover gasket (NEOPRENE STRIP FACES UP), nylon washer and impeller key.

d c

52869 a — Impeller b — Nylon Washer

NOTE: Apply a light coat of 2-4-C with Teflon to inside of pump cover to ease installation of cover over impeller. 5. Install pump cover. Rotate drive shaft CLOCKWISE while pressing cover down over impeller.

f

6. Apply Loctite 271 to retaining bolts and torque bolts to 60 lb. in. (6.8 N·m).

e b

b 7

a 52868 a b c d e f

—

Base Gasket Base Plate Cover Gasket Neoprene Strip Nylon Washer Key

IMPORTANT: If impeller being installed has been previously used and vanes have taken a “set,” DO NOT INSTALL THE IMPELLER WITH THE VANES REVERSED FROM THEIR PREVIOUS “SET” AS VANE BREAKAGE WILL OCCUR SHORTLY AFTER UNIT IS RETURNED TO SERVICE. 6A-26 — LOWER UNIT

a 7

Loctite 271 Thread Locker 52830

a — Cover b — Bolts [Torque to 60 lb. in. (6.8 N·m)]

90-852572R02 NOVEMBER 2002

Gear Housing Pressure Test

Gear Housing Installation

1. Remove vent plug and install pressure test gauge. Tighten securely.

Filling Gear Housing with Lubricant NOTE: Gear housing lubricant capacity is approximately 14.9 fl. oz. (440 ml).

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 Premium Gear Lubricant. 1. Remove any gasket material from “Fill” and “Vent” plugs and gear housing. Install new gaskets on “Fill” and “Vent” plugs. IMPORTANT: Never add lubricant without removing “Vent” plug. Gear housing cannot be filled because of trapped air. Fill gear housing when driveshaft is in a vertical position. 2. Pressurize housing to 10-12 PSI (69-83 kPa) and observe gauge for 5 minutes. 3. Rotate drive shaft, prop shaft and move shift rod while housing is pressurized to check for leaks.

2. Remove “Fill” plug and gasket. 3. Insert lubricant tube in “Fill” hole, then remove “Vent” plug and gasket. 4. Fill until excess lubricant flows out of “Vent” hole. 5. Replace this “Vent” plug and gasket. 6. Install “Fill” plug and gasket.

a

4. If pressure drop is noted immerse housing in water. 5. Re-pressurize to 10-12 PSI (69-83 kPa) and check for air bubbles. 6. Replace leaking seals as necessary. Retest housing.

a — “Vent” Plug

NOTE: It should hold 10-12 PSI (69-83 kPa) for 5 minutes. 7. Remove tester from housing and install vent plug.

90-852572R02 NOVEMBER 2002

7. Torque “Fill” and “Vent” screws to 55 lb. in. (6.2 N·m).

LOWER UNIT — 6A-27

Installing Gear Housing to Drive Shaft Housing WARNING Disconnect (and isolate) spark plug leads before installing gear housing onto drive shaft housing.

6. Reconnect shift shaft with coupler nut and jam nut. Tighten jam nut against coupler nut.

NOTE: After reconnecting shift shaft, bottom of jam nut should be approximately flush with top of spray plate. 30/40, 40/50, FORCE 40/50

1. Position shift lever in NEUTRAL gear position. 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. IMPORTANT: Liberally apply 2-4-C with Teflon to drive shaft splines. 4. Position drive shaft into drive shaft housing. Move gear housing upwards in drive shaft housing while aligning both shift shafts, water tube seal and drive shaft splines.

a

c

NOTE: If the drive shaft splines will not align with the crankshaft splines, rotate flywheel slightly while pushing gear housing into drive shaft housing.

b

5. Install 4 bolts and washers, (two each side). Torque bolts to 40 lb. ft. (54.2 N·m).

52834 a — Coupler Nut b — Jam Nut c — Spray Plate

a

7. Connect shift shaft by sliding retainer to the right and snapping into upper “locked” position. 25 (4 STROKE), 45/50 (4 STROKE)

a

b

52836 a — Bolt and Washers (2 each side) [Torque Bolt to 40 lb. ft. (54.2 N·m)]

53859

a — Retainer b — Lower Clip

6A-28 — LOWER UNIT

90-852572R02 NOVEMBER 2002

8. Install locknut and washer. Torque nut to 40 lb. ft. (54.2 N·m).

a

Trim Tab Adjustment and Replacement IMPORTANT: The trim tab is made of a special alloy to aid in protecting the drive shaft housing and gear housing from galvanic corrosion (corrosion and pitting of metal surfaces). Do not paint or place protective coating on the trim tab, or trim tab corrosion protection function will be lost. Replace trim tab if 50% (or more) corroded. Mark location of old trim tab on anti-ventilation plate before removal; install new trim tab in same location. 1. Check trim tab position as follows: a. Operate boat at the speed at which it would

normally be operated. b. If the boat pulls to the right (starboard), the

52833 a — Locknut and Washer [Torque Nut to 40 lb. ft. (54.2 N·m)]

trailing edge of trim tab must be moved to the right. If the boat pulls to the left (port), the trailing edge of trim tab must be moved to the left. 2. If necessary, adjust trim tab as follows: a. Shift engine control into NEUTRAL and turn

9. Check shift operation. a. In NEUTRAL, propeller shaft should turn freely in either direction. b. In FORWARD, propeller shaft SHOULD NOT TURN COUNTERCLOCKWISE. c. In REVERSE, propeller shaft SHOULD NOT TURN IN EITHER DIRECTION. IMPORTANT: If shift operation is not as described, remove the gear housing and correct the shift operation.

ignition key to “OFF” position.

NOTE: Loosen trim tab bolt sufficiently to allow trim tab to disengage from locking ridges in gear case before attempting to move tab. DO NOT strike trim tab with a hard object to make adjustments. b. If boat pulls to the left, adjust trailing edge of

trim tab to the left. If boat pulls to the right, adjust trailing edge of trim tab to the right.

a

b c

52835 a — Trim Tab b — Anti-Ventilation Plate c — Retaining Bolt and Washer; Torque Bolt to 15.8 lb. ft. (21.4 N·m)

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6A-29

Propeller Installation

CAUTION

WARNING Disconnect and isolate spark plug leads when working near the propeller to prevent the outboard from starting. 1. Apply one of the following products on propeller shaft splines. a. Anti-Corrosion Grease

Do not misinterpret propeller shaft movement for propeller movement. Propeller and propeller shaft may move fore-and-aft. However, the propeller itself should not move fore-and-aft on the propeller shaft. 4. Re-check propeller nut for tightness after first use. Check for tightness periodically, especially if a stainless propeller is used.

b. 2-4-C with Teflon 2. Install components. a. Flo-Torque I Drive Hub Propellers – Install forward thrust hub, propeller, propeller nut retainer and propeller nut onto the shaft.

d

c

b 94

a b c d

—

94

a

Anti-Corrosion Grease

Forward Thrust Hub Propeller Propeller Nut Retainer Propeller Nut — Torque to 55 lb. ft. (74.6 N⋅m)

b. Flo-Torque II Drive Hub Propellers – Install forward thrust hub, propeller, replaceable drive sleeve, rear thrust hub retainer and propeller nut onto the shaft.

f e

d

c 94

a b c d e f

—

b

a

94

Anti-Corrosion Grease

Forward Thrust Hub Propeller Drive Sleeve Rear Thrust Hub Retainer Propeller Nut — Torque to 55 lb. ft. (74.6 N⋅m)

3. Re-check propeller nut for tightness after first use. Check for tightness periodically, especially if a stainless propeller is used. 6A-30 — LOWER UNIT

90-852572R02 NOVEMBER 2002

LOWER UNIT

6 B 55/60 LOWER UNIT

Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Housing (Drive Shaft) (55/60) . . . . . . . Gear Housing (Propeller Shaft)(55/60) . . . . General Service Recommendations . . . . . . Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Draining and Inspecting Gear Lubricant . . . Propeller Removal . . . . . . . . . . . . . . . . . . . Gear Housing Removal . . . . . . . . . . . . . . . Gear Housing Disassembly . . . . . . . . . . . Water Pump . . . . . . . . . . . . . . . . . . . . . . . . Bearing Carrier and Propeller Shaft . . . . Propeller Shaft Disassembly . . . . . . . . . . . . . Pinion Gear, Driveshaft and Forward Gear . Upper Driveshaft Bearing . . . . . . . . . . . . . . . . Lower Driveshaft Bearing . . . . . . . . . . . . . Forward Gear Bearing Race . . . . . . . . . . Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Housing Reassembly . . . . . . . . . . . . . . Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . Forward Gear Bearing Race . . . . . . . . . . Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . Reverse Gear . . . . . . . . . . . . . . . . . . . . . . . Forward Gear . . . . . . . . . . . . . . . . . . . . . . . Lower Driveshaft Bearing Installation . . . Upper Driveshaft Bearing Installation . . . Forward Gear, Pinion Gear, Upper Driveshaft Bearing Race, Retainer and Driveshaft Installation . . . . . . . . . . . . Pinion Gear Location and Forward Gear Backlash . . . . . . . . . . . . . . . . . . . . . . Determining Forward Gear Backlash . . . Bearing Carrier and Propeller Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . Water Pump Re-assembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Housing Pressure Test . . . . . . . . . . . . . Gear Housing Installation . . . . . . . . . . . . . . . . Filling Gear Housing with Lubricant . . . . Gear Housing Installation . . . . . . . . . . . . . Propeller Installation . . . . . . . . . . . . . . . . . Trim Tab Adjustment and Replacement .

6B-0 — LOWER UNIT

Page 6B-1 6B-2 6B-6 6B-8 6B-10 6B-10 6B-10 6B-11 6B-11 6B-12 6B-12 6B-12 6B-14 6B-15 6B-16 6B-17 6B-17 6B-17 6B-18 6B-19 6B-19 6B-20 6B-20 6B-21 6B-22 6B-22 6B-23 6B-24

6B-24 6B-25 6B-26 6B-27 6B-28 6B-29 6B-31 6B-32 6B-32 6B-33 6B-34 6B-34

90-852572R02 NOVEMBER 2002

Specifications Gear Ratio Gearcase Capacity Lubricant Type Forward Gear Number of Teeth Pinion Gear Number of Teeth GEAR HOUSING

Pinion Height Forward Gear Backlash Water Pressure @ Idle @ W.O.T. Pressure Test

90-852572R02 NOVEMBER 2002

1.64:1 11.5 fl. oz. (340mL) Premium Gear Lubricant 23 14 0.025 in. (0.64 mm) Pinion Gear Locating Tool (91-817008A2) 0.013–0.019 in. (0.33–0.48 mm) Backlash Indicator Tool (91-19660—1) Mark #3 1–3 PSI (7-21 kPa) 7–12 PSI (48-83 kPa) 10-12 PSI (69-83 kPa) for 5 Minutes

LOWER UNIT — 6B-1

2. Backlash Indicator Tool 91-19660—1.

Special Tools 1. Bearing Preload Tool 91-14311A-2.

b

a c

19660-1

51043

c 3. Puller 91-27780.

d e

l

f g 4. Universal Puller Plate 91-37241.

h i

j

k

51270

Ref.

Description

Qty.

a

Bushing — 3/4 in. (19 mm) I.D.

1

b

Bushing — 7/8 in. (22 mm) I.D.

1

c

Set Screw

2

d

Nut

1

e

Bolt

1

f

Spring

1

g

Washer

1

h

Bearing

1

i

Adaptor

1

j

Plate

1

k

Nut

1

l

Stud

1

5. Driver Head 91-37312T.

6. Driver Rod 91-37323.

74184

NOTE: Bearing Preload Tool 91-14311A-1 may be updated to a 91-14311A-2 tool, by ordering Update Kit 91-817057A-1. 6B-2 — LOWER UNIT

90-852572R02 NOVEMBER 2002

7. Bearing Retaining Tool 91-43506T.

11. Forward Gear Bearing Installer 91-817005.

51043

12. Water Pump Base Seal Installer 91-817006.

73600

51043

8. Puller Jaws 91-46086A1 and Puller Bolt 91-85716. 13. Bearing Carrier Seal Installer 91-817007T.

73599

9. Dial Indicator 91-58222A1. 51043

14. Pinion Gear Location Tool 91-817008A2.

73429

10. Dial Indicator Adaptor Kit 91-83155.

51043

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6B-3

15. Forward Gear Bearing Race Driver Cup 91-817009T.

18. Lower Driveshaft Bearing Driver Assembly 91-817058A1.

51043

16. Needle Bearing Installer 91-817011T.

51043 51043

17. Backlash Indicator Tool 91-817057A1. 19. Driveshaft Holding Tool 91-817070.

d c 51043

a b

51043

51270

Ref.

Description

Qty.

a

Plate

1

b

Nut

1

c

Stud

1

d

Sleeve

1

91-817057A-1 Update Kit (Converts 91-14311A-1 Bearing Preload Kit Tool to a 91-14311A-2)

6B-4 — LOWER UNIT

90-852572R02 NOVEMBER 2002

Notes:

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6B-5

Gear Housing (Drive Shaft) (55/60) 7

32

34

140

29

22 28

95

21 20 19

27 31 34

95

33 Loctite 271 Thread Locker

7

Loctite 405

140

30 7

82

Premium Gear Lubricant

95

2-4-C with Teflon

23 18

95

24 26

87

25

10

95

95

6

7

8 7

87

9 5

1 35

17 15 16 14

3

95

4 13

11 12 3 4 7

4 2

6B-6 — LOWER UNIT

90-852572R02 NOVEMBER 2002

Gear Housing (Drive Shaft)(55/60) REF. REF NO. QTY. – 1 – 1 – 1 – 1 – 1 – 1 1 1 1 2 1 3 2 4 3 5 1 6 1 7 1 8 1 9 1 10 1 11 1 12 1 1 13 1 14 1 15 1 16 1 17 1 1 1 18 1 1 19 AR 20 1 21 1 22 1 23 1 24 1 25 1 26 1 27 1 28 1 29 1 1 30 1 31 32 33 34 35

1 1 1 6 1

TORQUE DESCRIPTION GEAR HOUSING (BLACK) SHORT GEAR HOUSING (GRAY) GEAR HOUSING (BLACK) LONG GEAR HOUSING (GRAY) GEAR HOUSING (BLACK) X-LONG GEAR HOUSING (GRAY) GEAR HOUSING (BLACK) GEAR HOUSING (GRAY) DRAIN SCREW SCREW WASHER-sealing DOWEL PIN DOWEL PIN PIPE PLUG ROLLER BEARING SEAL KIT FILLER PLATE PINION GEAR (14 TEETH) NUT SHIFT SHAFT ASSEMBLY (SHORT/LONG) SHIFT SHAFT (X-LONG) RETAINING RING BUSHING ASSEMBLY O-RING OIL SEAL DRIVE SHAFT (SHORT) DRIVE SHAFT (LONG) 60 ELECTRIC DRIVE SHAFT (X-LONG) DRIVE SHAFT (55 MANUAL) SHIM SET TAPERED ROLLER BEARING CUP NUT WATER PUMP BASE O-RING OIL SEAL OIL SEAL IMPELLER KEY WATER PUMP GASKET (LOWER) GASKET (EXPORT — HIGH SULFUR LEADED FUELS/ WARM WATER) GASKET (UPPER) SEAL (SHORT/LONG) FACE PLATE SCREW SHIFT CAM

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

58 58

60

N·m

6.5 6.5

50

67.8

75

101.7

5

6.8

LOWER UNIT — 6B-7

Gear Housing (Propeller Shaft)(55/60)

58 60 59 1 95

45

63 64 61

44

46

42 41

7

39 55

40 37

56

38 36

57 62 95

54

53

52 50 95

51 49 48 94

95

7 94 95

47 43

Loctite 271 Thread Locker Anti-Corrosion Grease 2-4-C with Teflon

6B-8 — LOWER UNIT

90-852572R02 NOVEMBER 2002

Gear Housing (Propeller Shaft)(55/60) REF. REF NO. QTY. – 1 – 1 – 1 – 1 – 1 – 1 1 1 1 36 AR 37 1 38 1 39 1 40 1 41 1 42 1 43 1 44 1 45 1 46 1 47 1 48 1 49 1 50 1 51 1 52 1 53 1 54 1 2 55 2 56 57 58 59 60 61 62 63 64

2 2 2 1 1 1 1 1 1 1

TORQUE DESCRIPTION GEAR HOUSING (BLACK) SHORT GEAR HOUSING (GRAY) GEAR HOUSING (BLACK) LONG GEAR HOUSING (GRAY) GEAR HOUSING (BLACK) X-LONG GEAR HOUSING (GRAY) GEAR HOUSING (BLACK) GEAR HOUSING (GRAY) SHIM SET TAPERED ROLLER BEARING CUP FORWARD GEAR (23 TEETH) ROLLER BEARING CAM FOLLOWER SLIDE SPRING CLUTCH CROSS PIN SPRING PROPELLER SHAFT REVERSE GEAR (23 TEETH) BALL BEARING BEARING CARRIER ASSEMBLY O-RING ROLLER BEARING OIL SEAL OIL SEAL SCREW (M8 x 25) SCREW (M8 x 25) (Use with Threaded Insert) WASHER WASHER (Use with Threaded Insert) THREADED INSERT TRIM TAB SCREW WASHER PROPELLER KIT (55 BEACHING) THRUST HUB PROPELLER NUT TAB WASHER

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

N·m

16.5

22.4

18.8

25.4

40

54.2

55

74.6

LOWER UNIT — 6B-9

General Service Recommendations There may be more than one way to “disassemble” or “reassemble” a particular part(s), therefore, it is recommended that the entire procedure be read prior to repair. IMPORTANT: Read the following before attempting any repairs. In many cases, disassembly of a sub-assembly may not be necessary until cleaning and inspection reveals that disassembly is required for replacement of one or more components. Service procedure order in this section is a normal disassembly-reassembly sequence. Threaded parts are right hand (RH), unless otherwise indicated.

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, uneven 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 appearance. To prevent leakage around seals, apply Loctite 271 Thread Locker 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 with Teflon on all O-rings and on I.D. of oil seals. Apply 2-4-C with Teflon to external surfaces of bearing carrier.

When holding, pressing or driving is required, use soft metal vise jaw protectors or wood for protection of parts. Use a suitable mandrel (one that will contact only the bearing race) when pressing or driving bearings. Whenever compressed air is used to dry a part, verify that no water is present in air line.

Bearings All bearings must be cleaned and inspected. Clean bearings with solvent and dry with compressed air. Air should be directed at the bearing so that it passes through the bearing. DO NOT spin bearing with compressed air, as this may cause bearing to score from lack of lubrication. After cleaning, lubricate bearings with Premium Gear Lubricant. DO NOT lubricate tapered bearing cups until after inspection. Inspect all bearings for roughness, catches and bearing race side wear. Work inner bearing race in-andout, while holding outer race, to check for side wear. When inspecting tapered bearings, determine condition of rollers and inner bearing race by inspecting bearing cup for pitting, scoring, grooves, uneven wear, imbedded particles and/or 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.

6B-10 — LOWER UNIT

90-852572R02 NOVEMBER 2002

Draining and Inspecting Gear Lubricant

Propeller Removal WARNING

WARNING If gear housing is installed on outboard, disconnect (and isolate) spark plug leads from spark plugs before working near the propeller. 1. With gear housing in normal running position, place a clean pan under housing and remove two vent plugs and one fill/drain plug (with gaskets).

If gear housing is not removed from outboard, before attempting to remove or install the propeller, remove (and isolate) spark plug leads from spark plugs to prevent outboard from starting. 1. Bend tabs of tab washer away from nut.

a a b

51119

a — Tab Washer b — Nut

b 50558

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) on the drain plug magnet indicates normal wear. Metal chips on the magnet indicate the need for gear housing disassembly and component inspection.

2. Use a block of wood to prevent propeller from rotating. Remove nut and pull components from shaft.

a

3. Note color of gear lubricant. White or cream color indicates presence of water. Gear lubricant drained from a gearcase recently in operation will have a yellowish color due to lubricant agitation/ aeration. This is normal and should not be confused with the presence of water. 4. Presence of water indicates the need for disassembly and inspection of oil seals, o-rings, gaskets and components for damage. 50552

a — Block of Wood

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6B-11

Gear Housing Removal

Gear Housing Disassembly Water Pump

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 into forward gear. 3. Tilt engine to full “Up ” position. 4. Remove four bolts and washers, two from each side. 5. Remove trim tab. 6. Remove locknut and washer in trim tab recess. 7. Remove gear housing.

1. If water tube seal stayed on water tube (inside of driveshaft housing) when gear housing was removed, then pull seal from water tube. Replace water tube seal if damaged. 2. Remove 6 screws, washers and isolators (Design 1). Remove cover.

NOTE: Isolators from forward 2 screws are different from the other isolators. Retain these for proper reassembly (Design 1, S/N USA-0G290584, BEL-9885944 and below). IMPORTANT: The circular groove formed by the impeller sealing bead should be disregarded when inspecting cover and plate as the depth of the groove will not affect water pump output. 3. Replace cover if thickness of steel at the discharge slots is .060 in. (1.524mm) or less, or if groove(s) (other than impeller sealing groove) in cover roof are more than .030 in. (.762mm) deep.

c

a

e

b

c

b

a

c

b

b

c d

50555

a — Bolts and Washers (4) b — Trim Tab c — Locknut and Washer

6B-12 — LOWER UNIT

a b c d e

—

d

51206

Water Tube Seal Bolts (6) Washers (6) Isolators (6) Cover

90-852572R02 NOVEMBER 2002

4. Lift impeller, drive key, and gasket. Replace impeller if: – Impeller blades are cracked, torn, or worn.

New Style Base 8. Remove water pump base by lifting gently as shown. Inspect carefully for cracks.

– Impeller is glazed or melted (caused by insufficient water supply).

a

– Rubber portion of impeller is not bonded to impeller hub.

a

c b 55874 51207

a — Water Pump Base a — Impeller b — Drive Key c — Gasket

9. Remove (and discard) seals, if damaged.

5. Remove plate and gasket.

a

6. Replace plate if groove(s) (other than impeller sealing groove) in plate are more than .030 in. (.762mm) deep.

a

b 51205 51206

a — Plate b — Gasket

a — Seals

10. Remove seal and plate if damaged or worn.

Old Style Base 7. Remove water pump base by lifting gently as shown. Inspect carefully for cracks.

a a

b

51206

a — Water Pump Base 90-852572R02 NOVEMBER 2002

51268

a — Seal b — Plate LOWER UNIT — 6B-13

Bearing Carrier and Propeller Shaft 1. Drain lubricant; refer to “Draining and Inspecting Gear Lubricant”. 2. Remove bolts.

4. 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. 5. If reverse gear bearing is rusted or does not roll freely, replace bearing. Remove bearing and reverse gear using bearing puller (91-27780).

a

a

a 51117

a — Bolts (2)

3. With propeller shaft horizontal, pull carrier to break seal with gear housing. Remove bearing carrier/propeller shaft components. Do not leave cam follower in end of propeller shaft. Remove propeller shaft from bearing carrier using bearing puller.

b d

c

e a b c d e

—

51205

a — Bearing Puller (91-27780)

a

19180

Bearing Carrier Puller Jaws (91-46086A1) Puller Bolt (91-85716) Thrust Hub Propeller Shaft

6B-14 — LOWER UNIT

90-852572R02 NOVEMBER 2002

6. Remove ball bearing from reverse gear using Universal Puller Plate and mandrel.

8. Remove seals (if not removed with bearing) and O-ring.

a d 51263

a — O-ring 51289

Propeller Shaft Disassembly 1. Remove spring. Push out cross pin.

a b a b c d

—

c 51269

Ball Bearing Reverse Gear Universal Puller Plate (91-37241) Driver Head (91-37312)

a

51265

7. If bearing is rusted or does not roll freely, replace bearing. Remove bearing and oil seals. Discard oil seals.

d b a

c

b

c

e 51268

a b c d e

d

—

Spring Cam Follower Apply Pressure as Shown Punch Cross Pin

51264

a b c d

—

Driver Rod (91-37323) Driver Head (91-37312) Propeller Shaft Needle Bearing Oil Seals (2)

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6B-15

2. Replace cam follower if worn or pitted on either end.

Pinion Gear, Driveshaft and Forward Gear

3. Replace sliding clutch if jaws are rounded or chipped. Rounded jaws indicate the following:

1. Hold driveshaft using Driveshaft Holding Tool (91-817070); remove (and discard) pinion nut.

a. Improper shift cable adjustment. b. Engine idle speed too high while shifting.

2. Remove driveshaft, pinion gear, and forward gear.

c. Shifting too slowly.

3. Replace pinion gear if chipped or worn.

a

e

e

4. Replace bearing if rusted or damaged; or does not roll freely. To remove, refer to “Lower Driveshaft Bearing”, following.

c

5. Replace forward gear if gear teeth are chipped or worn.

a d a b c d e

—

b

51265

Cam Follower Guide Block Spring Sliding Clutch Jaws

51043

c

4. Check bearing surfaces of propeller shaft. If shaft is worn/pitted, replace shaft and corresponding bearing.

d

5. Replace propeller shaft if:

f

a. Splines are twisted or worn. b. Oil seal surface is grooved in excess of 0.005 in. (0.12mm). c. Shaft has a noticeable “wobble” or is bent more than 0.006 in. (.152 mm). Check with a dial indicator and V-blocks.

b

b

c

e

b

51263

a b c d e f

—

Driveshaft Holding Tool (91-817070) Pinion Nut Driveshaft Pinion Gear Bearing Forward Gear

6. Replace bearing if rusted or does not roll freely after cleaning in solvent. Remove as shown.

a

51139

a — V-Blocks b — Bearing Surfaces c — Check with Dial Indicator Here

19203

6B-16 — LOWER UNIT

90-852572R02 NOVEMBER 2002

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 (91-37241) and Mandrel. To remove race, refer to “Forward Gear Bearing Race”, following.

Lower Driveshaft Bearing 1. Remove lower driveshaft bearing using tool (91-817058A1) with bushing installed.

c a

b

b

c

51119

a — Bearing/Race b — Puller Plate (91-37241) c — Mandrel

a

Upper Driveshaft Bearing 1. Replace bearing and race if either bearing or race are rusted or damaged; or if bearing does not roll freely after cleaning in solvent.

51260

a — Bearing b — Removal Tool (91-817058A1) c — Bushing

a

Forward Gear Bearing Race IMPORTANT: Retain shim(s) for re-assembly. 1. Remove race and shim(s) using bearing puller (91-27780).

b c 51271

a — Bearing

90-852572R02 NOVEMBER 2002

a

51265

a — Race b — Shim(s) c — Bearing Puller (91-27780) LOWER UNIT — 6B-17

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.

Shift Shaft 1. Remove shift shaft coupler and spacer.

a

d b

a

c

b

51271

a — Coupler b — Spacer

51264

2. Remove shift shaft bushing and shift shaft. Protect shift shaft to prevent spline damage.

a b c d

—

Shift Shaft Bushing “E” Clip Shift Shaft O-ring

5. Remove (and discard) seal if damaged.

b a

a

51205

a — Shift Shaft Bushing b — Shift Shaft 51265

3. Remove shift shaft cam, replace if worn.

a — Seal

a

51117

a — Shift Shaft Cam

6B-18 — LOWER UNIT

90-852572R02 NOVEMBER 2002

5. Install shift cam (numbers toward top of gear housing); align hole in shift cam with hole.

Gear Housing Reassembly Shift Shaft

b

1. Apply Perfect Seal on O.D. of new seal. Install with seal lip up, as shown. 2. Press seal into shift shaft bushing until seal bottoms. Use a suitable tool.

a

3. Apply Needle Bearing Assembly Lubricant on Oring and I.D. of seal.

c

4

a 19 51117

a — Shift Cam b — Hole

b

51270 4

Needle Bearing Assembly Lubricant

19

Perfect Seal

a — Seal — Lips Facing Up b — Shift Shaft Bushing c — Tool

6. Install shift shaft assembly; insert splines into shift cam.

a

4. Assemble components.

d b

c

a

51264

a b c d

—

Shift Shaft “E” Clip Bushing O-ring

90-852572R02 NOVEMBER 2002

51268

a — Shift Shaft Assembly

LOWER UNIT — 6B-19

Propeller Shaft

Forward Gear Bearing Race

1. Install components.

1. Place shim(s), retained from disassembly, into housing. If shim(s) were lost or damaged, or a new gearcase is being assembled, start with a .010 in. (.254mm) shim.

d

c

a

2. Drive bearing race into housing. Use a lead hammer to avoid damage to propshaft. 95

95

b

2-4-C with Teflon

51265

a — Spring b — Clutch (Align Hole with Slot in Prop Shaft, Long End of Clutch with 3 Teeth Towards Prop Shaft Shoulder) c — Guide Block d — Cam Follower (Hold in Place with 2-4-C with Teflon

d

a c

4

2. Install cross pin.

b

51043

c

51265 4

a b c d

—

Needle Bearing Assembly Lubricant

Shim(s) Driver Cup (91-817009) Propeller Shaft Assembled Bearing Carrier

b a

51268

a — Cross Pin b — Cam Follower c — Apply Pressure in This Direction

3. Install spring.

NOTE: Spring windings must lay flat with no overlapping in clutch groove after installation.

a

51265

a — Spring

6B-20 — LOWER UNIT

90-852572R02 NOVEMBER 2002

Bearing Carrier 1. Lubricate O.D. of needle bearing with Needle Bearing Assembly Lubricant.

4. Install large diameter seal on installer tool. Seal lip faces towards shoulder on installer tool. Press in until Installer tool bottoms.

2. Install needle bearing. Installation Note: Push against numbered end of bearing.

b b

a a 51043

51043

7 4

51263 7

Loctite 271 Thread Locker

a — Large Diameter Seal b — Installer Tool (91-817007)

51269 4

Needle Bearing Assembly Lubricant

Installation Note: If service tools are not available, the following reference dimensions apply for installing bearing and seals to proper depths.

a — Needle Bearing b — Installer (91-817011)

.82 in. (20mm)

3. Install small diameter oil seal. Seal lip faces away from shoulder on Installer Tool. Press seal in until Installer Tool bottoms.

b a 51275

a

a — Bearing

.44 in. (11mm) .04 in. (1mm)

7 51043

b a 51206 7

Loctite 271 Thread Locker

a — Small Diameter Seal b — Installer Tool (91-817007)

90-852572R02 NOVEMBER 2002

51275

a — Oil Seal (Install with Lip Down) b — Oil Seal (Install with Lip Up)

LOWER UNIT — 6B-21

5. Lubricate O-ring with 2-4-C with Teflon. Install O-ring.

2. Install reverse gear and bearing assembly. Lubricate O.D. of bearing with Needle Bearing Assembly. Lubricant before installation.

b

a 95

95

2-4-C with Teflon

a

51263

c

a — O-ring 4

Reverse Gear 1. Lubricate I.D. of bearing with Needle Bearing Assembly Lubricant. Use Installer Tool and press onto gear until bearing bottoms. 51264 4

Needle Bearing Assembly Lubricant

a — Reverse Gear and Bearing Assembly b — Installer Tool (91-817007) c — Bearing Carrier

b a

Forward Gear 1. Press new propshaft bearing into gear. Lubricate O.D. of bearing with Needle Bearing Assembly Lubricant before installation. Press until Installer Tool bottoms. Installation Note: Push against numbered end of bearing.

4

51205 4

51043

Needle Bearing Assembly Lubricant

a — Bearing b — Installer Tool (91-817007)

a

4

4

Needle Bearing Assembly Lubricant

51291

a — Installer Tool (91-817005)

6B-22 — LOWER UNIT

90-852572R02 NOVEMBER 2002

2. Press tapered roller bearing onto gear. Lubricate I.D. of bearing with Needle Bearing Assembly Lubricant before installation. Use Installer Tool. Press until bearing bottoms on gear.

Lower Driveshaft Bearing Installation 1. Lubricate O.D. of bearing race with Needle Bearing Assembly Lubricant. 2. Install bearing into housing. Press until Installer Tool bottoms. Installation Note: Push against numbered end of bearing.

b a

4

7.05 in. 7.07 in.

(

)

179.0mm 179.5mm

b

4

a 51272 4

Needle Bearing Assembly Lubricant

c

a — Bearing (Lubricate I.D. Before Assembly) b — Installer Tool (91-817007)

51260 4

Needle Bearing Assembly Lubricant

a — Needle Bearing (Lubricate O.D. Before Assembly) b — Bearing Installer Tool (91-817058A1) c — Reference (Bearing Depth)

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6B-23

Upper Driveshaft Bearing Installation 1. Press upper driveshaft bearing onto driveshaft. Lubricate I.D. of bearing with Needle Bearing Assembly Lubricant before pressing in place.

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.

d c 51285

e g

51043

4

a

b g

a

f 51263

51268 4

Needle Bearing Assembly Lubricant

a — Forward Gear/Bearing: Apply Gear Lube to Bearing Rollers Before Installation b — Pinion Gear c — Upper Driveshaft Bearing Race and Shim(s) d — Upper Driveshaft Bearing Retainer [Torque to 75 lb. ft. (101.7 N·m)] Use Tool (91-43506) e — Driveshaft f — Driveshaft Holding Tool (91-817070) g — Pinion Nut (New) (See Note at “Pinion Gear Depth”, Following.) Recess in Nut is Installed Toward Pinion Gear (See Inset).

a — Upper Driveshaft Bearing (Lubricate I.D. Before Assembly)

6B-24 — LOWER UNIT

90-852572R02 NOVEMBER 2002

3. Measure distance.

Pinion Gear Location and Forward Gear Backlash

4. Increase distance by 1 in. (25.4mm). 5. Rotate driveshaft 10 revolutions. This properly seats upper driveshaft tapered roller bearing.

DETERMINING PINION GEAR LOCATION

NOTE: Read entire procedure before attempting any change in shim thickness.

c

IMPORTANT: Forward gear assembly must be installed in gear housing when checking pinion gear depth to obtain accurate shim measurements.

a

1. Clean the gear housing bearing carrier shoulder and diameter. 2. Position gear housing upright (driveshaft vertical). Install Bearing Preload Tool in sequence shown.

b

h 3/4 in. (19mm) I.D.

i

19884

i

a — Distance, 1 in. (25.4 mm) b — Bolt c — Nut

g f 6. Insert Pinion Location Tool. Position access hole as shown. Insert feeler gauge between gauging surface and pinion gear.

e

a

b

c

d

d c b

a 51270

a b c d e f g h i

—

Plate Adaptor: Bearing surfaces clean and free of nicks Thrust Bearing: Oiled and able to move freely Thrust Washer: Clean and free of nicks and bends Spring Nut: Threaded all the way onto bolt Bolt: Held snug against spring Sleeve: Holes in sleeve must align with set screws Set Screw (2): Tighten against drive shaft, bolt should not slide on driveshaft

90-852572R02 NOVEMBER 2002

51265

a b c d

—

Pinion Location Tool (91-817008A2) Access Hole Gauging Surface Pinion Gear

LOWER UNIT — 6B-25

7. The correct clearance between the gauging surface and the pinion gear is .025 in. (0.64mm). 8. To obtain .025 in. (0.64mm), add or subtract shims below the upper bearing race to lower or raise the pinion gear. 9. After final adjustment to pinion height, and forward gear backlash has been established, apply Loctite 271 Thread Locker to threads and torque new pinion nut to 50 lb. ft. (67 N·m).

c

Determining Forward Gear Backlash NOTE: Read entire procedure before attempting any change in shim thickness. 1. Obtain correct pinion gear location; refer to “Determining Pinion Gear Location”, preceding. 2. Install Bearing Preload Tool on driveshaft; refer to “Determining Pinion Gear Location”, preceding. 3. Install components. 4. Torque to 45 lb. in. (5 N·m)

a

51285

d b

a

b

7

c

c

51119

a b c d 7

Loctite 271 Thread Locker

a — Bearing Race b — Shim(s) c — Pinion Nut (Recessed Side Toward Pinion)

51263

—

Propeller Shaft* Bearing Carrier* (Assembled) Puller Jaws (91-46086A1) Puller Bolt (91-58716) Torque to 45 lb. in. (5.1 N·m).

*Refer to “Bearing Carrier and Propeller Shaft Installation”, following.

5. Rotate driveshaft 10 revolutions to properly seat forward gear tapered roller bearing. 6. Re-torque puller bolt to 45 lb. in. (5.1 N·m).

6B-26 — LOWER UNIT

90-852572R02 NOVEMBER 2002

7. Install components.

e

d

Bearing Carrier and Propeller Shaft Installation

f

1. Insert propeller shaft assembly into bearing carrier. 2. Lubricate O-ring and areas shown with 2-4-C with Teflon. 3. Install bearing carrier and propeller shaft assembly into gear housing. Use care not to displace cam follower.

a

c b

c 51275

a b c d e f

—

Threaded Rod Washers Nuts Dial Indicator Adaptor Kit (91-83155) Dial Indicator (91-58222A1) Backlash Indicator Tool (91-19660—1)

95

95

a

b

51271

2-4-C with Teflon

a — O-ring b — Cam Follower

8. Position Dial Indicator on line “3” on Backlash Indicator Tool. 9. Turn driveshaft back-and-forth (check for no rotation at the propeller shaft). 10. Dial Indicator registers amount of backlash, which must be between .013 in. (.33mm) and .019 in. (.48mm). 11. If backlash is less than the minimum reading, remove shim(s)* from in front of the forward gear bearing race. 12. If backlash is more than the maximum reading, add shim(s) in front of the forward gear bearing race. * By adding or subtracting .001 in. (0.025mm) shim, the backlash will change 0.0125 in. (0.032mm).

NOTE: When final measurement has been made, apply Loctite 271 Thread Locker to threads of pinion nut. Torque to 50 lb. ft. (67.8 N·m).

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6B-27

4. Torque bolts to 225 lb. in./18.8 lb ft. (25.4 N⋅m)

Bearing Carrier 1. Install carrier into gear case.

7

2. Discard the thin 0.063 in. (1.60 mm) flat washers and the 25 mm long bolts on models listed. Install thicker flat washers and longer bolts.

a

55/60 (3 Cylinder — 2 Stroke) Non Big Foot USA 0G662097 and below Belgium NA

a

b

a

a — Bolt 25 mm Long — Discard b — Thin Flat Washer 0.063 in. (1.60 mm) thick — Discard

51117 7

3. Install thicker flat washers and longer bolts.

a

b

7

Loctite 271 Thread Locker

a — Torque Bolts to 225 lb. in./18.8 lb. in (25.4 N⋅m)

a — Bolt (10-855940-30) 1.18 in. (30 mm) Long b — Washer (12-855941) 0.090 in. (2.29 mm)

6B-28 — LOWER UNIT

90-852572R02 NOVEMBER 2002

NOTE: If installation tool is not available, press seals in as shown to depths indicated.

Water Pump Re-assembly and Installation

0.04 in. (1.02 mm)

1. Place seal on longer shoulder side of tool.

a

2. Press into water pump base until tool bottoms.

b c

b

82

55878 a — Seal (Install with spring visible when installed.) b — Seal (Install with spring visible when installed.) c — Seal Bottom

a

5. Install O-ring. Lubricate O-ring and gear housing bore with Special Lubricant 101. 55876

6. Install water pump base into gear case.

Premium Gear Lubricant

82

a — Seal (Install with spring visible when installed.) b — Seal Installation Tool (91-817006)

3. Place seal on shorter side of tool.

b

4. Press into water pump base until tool bottoms.

a 95

c

c

82

b a 55879 95

55877 82

2-4-C with Teflon

a — O-ring b — Water Pump Base c — Gear Case

Premium Gear Lubricant

a — Seal b — Shorter Side of Tool c — Seal Installation Tool (91-817006)

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6B-29

7. If removed previously, re-install seal and plate.

10. Lubricate I.D. of cover with Needle Bearing Assembly Lubricant. Install gasket with bead toward cover.

b

a

4

b 51290 4

a

Needle Bearing Assembly Lubricant

a — Gasket b — Bead Toward Cover

51268

11. Rotate driveshaft clockwise and push cover down. Secure cover.

a — Seal b — Plate

a c

d

8. Install gasket and face plate.

b

d c

a

d c b

b

b

c 51275

51293

a — Gasket b — Face Plate

IMPORTANT: If the old impeller is re-used, install in the original (clockwise) direction of rotation.

a — Cover b — Isolators, (Design 1) Note: 2 isolators for forward screws are different from remaining 4 isolators c — Washers (6) d — Bolts (6); Apply Loctite on threads and torque to 60 lb. in. (6.8 N·m).

NOTE: Torque cover screws as shown.

9. Install drive key and impeller. 1

b

3 5

6

a

4

2

51271 51292

a — Drive Key b — Impeller 6B-30 — LOWER UNIT

90-852572R02 NOVEMBER 2002

12. If water tube seal stayed on water tube (inside of driveshaft), pull seal from water tube.

3. Rotate driveshaft, prop shaft and move shift rod while housing is pressurized to check for leaks.

13. Lubricate I.D. of water tube seal with 2-4-C with Teflon and install.

a

51206

a — Water Tube Seal

Gear Housing Pressure Test 1. Remove vent plug and install pressure test gauge. Tighten securely.

4. If pressure drop is noted, immerse housing in water. 5. Re-pressurize to 10-12 PSI (69-83 kPa) and check for air bubbles. 6. Replace leaking seals as necessary. Retest housing.

NOTE: It should hold 10-12 PSI (69-83 kPa) for 5 minutes. 7. Remove tester from housing and install vent plug.

2. Pressurize housing to 10-12 PSI (69-83 kPa) and observe gauge for 5 minutes.

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6B-31

Gear Housing Installation

7. Install Fill plug and gasket.

Filling Gear Housing with Lubricant NOTE: Gear housing lubricant capacity is approximately 11.5 fl. oz. (340 ml).

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 Premium Gear Lubricant.

b

c

1. Remove any gasket material from Fill and Vent plugs and gear housing. Install new gaskets on Fill and Vent plugs. IMPORTANT: Never add lubricant without removing “Vent” plugs. Gear housing cannot be filled because of trapped air. Fill gear housing when driveshaft is in a vertical position.

a

2. Remove Fill plug and gasket.

50558

3. Insert lubricant tube in Fill hole, then remove Vent plugs and gaskets.

8. Torque Fill and Vent plugs to 58 lb. in. (6.5 Nm)

4. Fill until excess lubricant flows out of left “Vent” hole.

a — Fill Plug b — Vent Plug c — Vent Plug

5. Replace left Vent plug and gasket and continue to fill until lubricant flows from right Vent hole. 6. Replace right Vent plug and gasket.

6B-32 — LOWER UNIT

90-852572R02 NOVEMBER 2002

Gear Housing Installation

CAUTION

WARNING Disconnect (and isolate) spark plug leads before installing gear housing onto driveshaft housing. 1. Position shift block in forward gear position.

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 2-4-C with 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 housing while aligning shift shaft coupler, water tube seal and driveshaft splines.

a 51190

a — Shift Block

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.

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 Thread Locker on threads of bolts prior to installation. 9. Install locknut and washer. 10. Torque bolts and locknut to 40 lb. ft. (54 N·m).

95

a

74

c b 7

a

b 51206

74

Loctite 405

95

2-4-C with Teflon

a — Water Tube Seal b — Spacer c — Shift Shaft Coupler

90-852572R02 NOVEMBER 2002

50551 7

Loctite 271 Thread Locker

a — Bolts and Washers b — Locknut and Washer

LOWER UNIT — 6B-33

11. Check shift operation. a. Gear housing should not engage when propeller shaft is turned clockwise when in forward gear. b. Propeller shaft will rotate freely in either direction when gearcase is in neutral. c. Propeller shaft will not rotate in either direction when gearcase is in reverse. IMPORTANT: If shift operation is not as described, remove the gear housing and correct the shift operation.

Do not misinterpret propeller shaft movement for propeller movement, propeller and propeller shaft however may move fore-and-aft. However, the propeller itself should not move fore-and-aft on the propeller shaft. 3. Re-check propeller nut for tightness after first use. Check for tightness periodically, especially if a stainless propeller is used. 4. Install and adjust trim tab as follows.

Trim Tab Adjustment and Replacement

Propeller Installation WARNING Disconnect and isolate spark plug leads when working near the propeller to prevent the outboard from starting. 1. Apply one of the following products on propeller shaft splines. – Anti-Corrosion Grease – 2-4-C with Teflon 2. Install components.

c

CAUTION

IMPORTANT: The trim tab is made of a special alloy to aid in protecting the drive shaft housing and gear housing from galvanic corrosion (corrosion and pitting of metal surfaces). Do not paint or place protective coating on the trim tab, or trim tab corrosion protection function will be lost. 1. Replace trim tab if 50% (or more) corroded. Mark location of old trim tab on anti-ventilation plate before removal; install new trim tab in same location. 2. The trim tab will offset (balance) some of the “steering load” that is caused by “propeller torque” at higher speeds. If at higher speeds the boat turns more easily to the left, loosen bolt, move the trim tab (trailing edge) to the left (when viewed from behind); re-tighten bolt. Turn trim tab (trailing edge) to the right if the boat turns more easily to the right.

a

a

c

b d 94

94

b

Anti-Corrosion Grease

50551 50553

a b c d

—

Thrust Hub; Flat Surface Towards Propeller Propeller Tab Washer; Bend Tabs Down Against Nut Flats Locknut; Torque to 55 lb. ft. (75 N·m)

6B-34 — LOWER UNIT

a — Trim Tab b — Anti-Ventilation Plate c — Retaining Bolt and Washer; Torque Bolt to 22 lbs. ft. (29.8 N·m) 90-852572R02 NOVEMBER 2002

LOWER UNIT

791-H

BIGFOOT GEAR HOUSING 4-1/4 IN. (108 MM) DIAMETER GEAR CASE

6 C

Table of Contents Page Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-2 Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-5 Gear Housing (Drive Shaft)(60 Bigfoot) . . . 6C-6 Gear Housing (Drive Shaft)(60 Bigfoot) . . . 6C-7 Gear Housing (Prop Shaft)(60 Bigfoot) . . . . 6C-8 Gear Housing (Prop Shaft)(60 Bigfoot) . . . . 6C-9 Gear Case Identification . . . . . . . . . . . . . . . . . 6C-10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-10 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-10 Draining and Inspecting Gear Housing Lubricant . . . . . . . . . . . . . . 6C-10 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . 6C-11 Bearing Carrier and Propeller Shaft . . . . 6C-13 Pinion Gear, Drive Shaft, and Forward Gear . . . . . . . . . . . . . . . . . . . 6C-15 Upper Drive Shaft Bearing . . . . . . . . . . . . 6C-17 Oil Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-17 Lower Drive Shaft Bearing Race . . . . . . . 6C-18 Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-18 Forward Gear Bearing Race . . . . . . . . . . 6C-19 Trim Tab Adjustment and Replacement . 6C-19 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-20 Forward Gear Bearing Race . . . . . . . . . . 6C-20 Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-20 Bearing Carrier Reassembly . . . . . . . . . . 6C-21 Forward Gear Reassembly . . . . . . . . . . . 6C-23 Propeller Shaft Reassembly . . . . . . . . . . . 6C-24 Drive Shaft Wear Sleeve Installation . . . 6C-25 Lower Drive Shaft Bearing Race Installation . . . . . . . . . . . . . . . . . . . . 6C-26 Oil Sleeve Installation . . . . . . . . . . . . . . . . 6C-26 Upper Drive Shaft Bearing Installation . . 6C-26 Forward Gear, Lower Drive Shaft Bearing, Pinion Gear, and Drive Shaft Installation . . . . . . . . . . . 6C-27 Pinion Gear Depth and Forward Gear Backlash . . . . . . . . . . 6C-28 Determining Forward Gear Backlash . . . 6C-30 Bearing Carrier and Propeller Shaft Installation . . . . . . . . 6C-32 Water Pump Reassembly and Installation . . . . . . . . . . . . . . . . . . . . . 6C-33 Gear Housing Pressure Test . . . . . . . . . . 6C-35 Filling Gear Housing With Lubricant . . . . . . 6C-35 Gearcase Installation . . . . . . . . . . . . . . . . . . . 6C-36 Trim Tab Adjustment . . . . . . . . . . . . . . . . . 6C-38

6C-0 — LOWER UNIT

90-852572R02 NOVEMBER 2002

Specifications Gear Ratio Gearcase Capacity Lubricant Type

GEAR HOUSING S/N USA-0T622484/ BEL-0P222544 AND BELOW (2.31:1)

Forward Gear Number of Teeth Pinion Gear Number of Teeth Pinion Height

Forward Gear Backlash Water Pressure @ 750 rpm (Idle) @ 6000 rpm (W.O.T.) Pressure Test

Gear Ratio Gearcase Capacity Lubricant Type

1998 AND NEWER GEAR HOUSING S/N USA-0T622485/ BEL-0P222545 AND UP (2.33:1)

Forward Gear Number of Teeth Pinion Gear Number of Teeth Pinion Height

Forward Gear Backlash Water Pressure @ 750 rpm (Idle) @ 6000 rpm (W.O.T.) Pressure Test

90-852572R02 NOVEMBER 2002

2.31:1 22.5 fl. oz. (655 mL) Premium Gear Lubricant 30 Spiral/Bevel 13 Spiral/Bevel 0.025 in. (0.64 mm) Pinion Gear Locating Tool (91-12349A2) Flat #8 Disc #3 0.012-0.019 in. (0.30-0.48 mm) Backlash Indicator Tool (91-78473) Mark #4 2.0-4.0 PSI (14-28 kPa) 10.0-15.0 PSI (69-103 kPa) 10.0-12.0 PSI (69-83 kPa) for 5 Minutes

2.33:1 22.5 fl. oz. (655 mL) Premium Gear Lubricant 28 Spiral/Bevel 12 Spiral/Bevel 0.025 in. (0.64 mm) Pinion Gear Locating Tool (91-12349A2) Flat #8 Disc #3 0.012-0.019 in. (0.30-0.48 mm) Backlash Indicator Tool (91-78473) Mark #4 2.0-4.0 PSI (14-28 kPa) 10.0-15.0 PSI (69-103 kPa) 10.0-12.0 PSI (69-83 kPa) for 5 Minutes

LOWER UNIT — 6C-1

6. Bearing Race Tool (91-14308T02)

Special Tools 1. Pinion Gear Locating Tool (91-12349A2)

b

a

a — P/N 91-889622A01, Stamped 91-889622 b — P/N 91-13778T1, No Stamp Mark

7. Bearing Cup Driver (91-14309T02)

a

55079

2. Bearing Installation Tool (91-13945)

b a — P/N 91-889623, Stamped 91-889623 b — P/N 91-13780, Stamped 91-13780

NOTE: Treaded Rod (91-31229) and Nut (11-24156) are from Bearing Removal and Installation Kit 91-31229A7 Lower Drive Shaft Bearing Race Tool Application 3. Oil Seal Driver (91-13949)

Gear Ratio

Pinion Gear Teeth

Bearing Race Tool

Bearing Cup Driver

2.31:1

13

91-13778T1 (No Stamp)

91-13780 (Stamped 91-13780)

2.33:1

12

91-889622A01 (Stamped 91-889622)

91-889623 (Stamped 91-889623)

4. Bearing Race Tool (91-14308T1)

NOTE: Bearing Race Tool 91-889622A1 should be combined with Bearing Race Tool 91-14308T1 to create 91-18308T02 which will supersede and replace the 91-14308T1. NOTE: Bearing Cup Driver 91-889623 should be combined with Bearing Cup Driver 91-14309T1 to create 91-18309T2 which will supersede and replace the 91-14309T1.

5. Bearing Cup Driver (91-14309T1)

a a — P/N 91-13780, Stamped 91-13780

NOTE: Treaded Rod (91-31229) and Nut (11-24156) are from Bearing Removal and Installation Kit 91-31229A7

6C-2 — LOWER UNIT

90-852572R02 NOVEMBER 2002

8. Wear Sleeve Installation Tool (91-14310T1)

9. Bearing Preload Tool (91-14311A2)

13. Oil Seal Driver (91-31108T)

14. Treaded Rod (91-31229) and Nut (91-24156)*

15. Slide Hammer (91-34569A1)

16. Mandrel (91-36569T)*

10. Mandrel (91-15755T)*

73815

11. Backlash Indicator Tool (91-19660—1) (4 cyl.)

17. Universal Puller Plate (91-37241)

19660-1

12. Mandrel (91-31106T)

73652

18. Driver Rod (91-37323T)*

74184

* From Bearing Removal and Installation Kit (91-31229A7)

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6C-3

19. Mandrel (91-37350T)

24. Puller Bolt (91-85716)

25. Dial Indicator Adaptor Kit (91-83155) 20. Puller Jaws (91-46086A1)

21. Driver Shaft Holding Tool (91-56775)

22. Dial Indicator (91-58222A1)

23. Backlash Indicator Tool (91-78473) (3 cyl.)

26. Bearing Puller Assembly (91-83165T)

27. Bearing Installation Tool (91-855875)

56783

* From Bearing Removal and Installation Kit (91-31229A7)

6C-4 — LOWER UNIT

90-852572R02 NOVEMBER 2002

Notes:

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6C-5

Gear Housing (Drive Shaft)(60 Bigfoot)

82

7

Loctite 271 Thread Locker

82

Premium Gear Lubricant

95

2-4-C with Teflon

6C-6 — LOWER UNIT

90-852572R02 NOVEMBER 2002

Gear Housing (Drive Shaft)(60 Bigfoot) REF. REF DESCRIPTION NO. QTY. 1 1 GEAR HOUSING 2 1 DOWEL PIN (FRONT) 3 1 OILER TUBE 4 2 DRAIN SCREW 5 3 WASHER–Sealing 6 1 DOWEL PIN (REAR) 7 1 TRIM TAB (USE W/GH W/O ANODES) 8 1 SCREW (7/16-14 x 1-1/4) 9 1 WASHER 10 1 CARRIER 11 1 NEEDLE BEARINGS 12 2 ANODE 13 1 NUT 14 1 SCREW 15 1 PINION GEAR (Part of 43-850033A2) (13 TEETH) 1 PINION GEAR (Part of 43-882813A3) (12 TEETH) 16 1 NUT 17 1 SHIFT CAM 18 1 TAPERED ROLLER BEARING 19 1 SHIM ASSEMBLY 1 DRIVE SHAFT ASSEMBLY (LONG) 20 1 DRIVE SHAFT ASSEMBLY (LL) 21 1 WEAR SLEEVE ASSEMBLY 22 1 SEAL RING 23 1 COVER ASSEMBLY 24 1 GASKET 25 1 GASKET 26 1 OIL SEAL (LOWER) 27 1 OIL SEAL (UPPER) 28 1 GASKET 29 1 WATER PUMP ASSEMBLY 30 1 FACE PLATE 31 4 SCREW (M6 x 30) 32 1 SEAL 33 1 KEY 34 1 IMPELLER 35 6 SCREW (M6 x 25) 1 SHIFT SHAFT ASSEMBLY (LONG) 36 1 SHIFT SHAFT ASSEMBLY (LL) 37 1 E-RING 38 1 BUSHING ASSEMBLY 39 1 O-RING 40 1 OIL SEAL 41 2 SCREW (M6 x 25) 42 1 FACE SEAL MODEL VERSION LENGTH DESIGNATION LONG = 20 IN.

90-852572R02 NOVEMBER 2002

TORQUE lb. in. lb. ft.

60

N·m

7

22

60

30

7

70

95

60

7

60

7

35

4

LL = 22-1/2 IN.

LOWER UNIT — 6C-7

Gear Housing (Prop Shaft)(60 Bigfoot) 95

69

1

50

45 48

46

49 47

43 44

67 68

68

57

95 95

55 71

54

72

53 52 7

51

65 66

64 95

70 60 59

58

95 95

56 61

62 63

7

Loctite 271 Thread Locker

95

2-4-C with Teflon

6C-8 — LOWER UNIT

90-852572R02 NOVEMBER 2002

Gear Housing (Prop Shaft)(60 Bigfoot) REF. REF NO. QTY. – 1 – 1 – 1 – 1 1 1 1 43 1 44 1 45 1 1 46 1 47 1 48 3 49 1 50 1 51 1 52 1 53 1 54 1 55 1 1 56 1 57 1 58 1 59 1 60 1 61 1 62 1 63 1 64 2 65 2 66 2 67 1 68 2 69 1 70 1 71 1 72 1

TORQUE DESCRIPTION GEAR HOUSING (LONG) BLACK GEAR HOUSING (LL) GEAR HOUSING (LONG) GRAY GEAR HOUSING (LL) GEAR HOUSING ASSEMBLY (BLACK) GEAR HOUSING ASSEMBLY (GRAY) TAPERED ROLLER BEARING ASSEMBLY CUP FORWARD GEAR (Also part of 43-850033A2) (30 TEETH) FORWARD GEAR (Also part of 43-882813A3) (28 TEETH) ROLLER BEARING CAM FOLLOWER ASSEMBLY BALL SLIDE SPRING CLUTCH CROSS PIN SPRING PROPELLER SHAFT REVERSE GEAR (30 TEETH) (Use with 30 tooth forward gear) REVERSE GEAR (28 TEETH) (Use with 28 tooth forward gear) BEARING CARRIER ASSEMBLY O-RING ROLLER BEARING OIL SEAL (INNER) OIL SEAL (OUTER) ROLLER BEARING THRUST WASHER THRUST BEARING STUD WASHER NUT SHIM ASSEMBLY THREAD INSERT DECAL THRUST HUB ASSEMBLY PROPELLER NUT ASSEMBLY TAB WASHER

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

N·m

100

135

25

33.9

LOWER UNIT — 6C-9

Gear Case Identification

Removal

CAUTION

WARNING

Identify gear case design to ensure correct components are being installed. Design I — 3 Jaw Reverse Clutch (a) gear case identified with straight machined edge for trim tab screw mounting surface. Design II — 6 Jaw Reverse Clutch (b) gear case identified with angled machined edge for trim tab screw mounting surface.

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 fasteners.

a

b

5. Remove locknut and washer. 6. Remove gear housing.

a

b

53992

1987 – 1997 1998 and Newer 3 Jaw Reverse Clutch 6 Jaw Reverse Clutch a — Design I — 3 Jaw Reverse Clutch Gear Case Identifier b — Design II — 6 Jaw Reverse Clutch Gear Case Identifier

a — Fasteners (2 each side) b — Locknut and Washer

Disassembly Draining and Inspecting Gear Housing Lubricant WARNING If gear housing is installed on engine, to avoid accidental starting, disconnect (and isolate) spark plug leads from spark plugs before working near the propeller. 1. With gear housing in normal running position, place a clean pan under housing and remove the two vent screws and one fill/drain screw (with gaskets).

6C-10 — LOWER UNIT

90-852572R02 NOVEMBER 2002

Water Pump 1. If water tube seal stayed on water tube (inside of drive shaft housing) when gear housing was removed, pull water tube seal from water tube.

c

a

2. Replace water tube seal, if damaged. 3. Remove 4 bolts, washers, and isolators. 4. Remove cover.

a c

b

b 53922 a — Oil Level Screw b — Fill/Drain Screw c — Vent Screw

2. Inspect gear lubricant for metal particles (lubricant will have a metal flake appearance). Presence of fine metal particles (resembling powder) on the drain plug bar magnet indicates normal wear. The presence of metal chips on the drain plug bar magnet indicates the need for gear housing disassembly and component inspection. 3. Note color of gear lubricant. White or cream color MAY indicate presence of water in lubricant. Gear lubricant which has been drained from a gear case recently in operation will have a yellowish color due to lubricant agitation/aeration. Gear lube which is mixed with assembly lubricant (Special Lube 101 or 2-4-C with 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 (68 – 82 kPa) of pressure for 5 minutes without leaking down. Pouring a portion of the gear lubricant into a glass jar and allowing the lubricant to settle will allow any water in the lube to separate and settle to the bottom of the jar. 4. Presence of water in gear lubricant indicates the need for disassembly and inspection of oil seals, seal surfaces, O-rings, water pump gaskets as well as gear housing components for damage. If gearcase is rebuilt, gearcase should be pressure checked before filling with lubricant.

b

19212 a — Water Tube Seal b — Bolts (4 each) c — Cover

IMPORTANT: The circular groove formed by the impeller sealing bead should be disregarded when inspecting cover (Step 5) and plate (Step 9), as the depth of the groove will not affect water pump output. 5. Replace cover if thickness of steel at the discharge slots is 0.060 in. (1.52mm) or less, or if groove(s) (other than impeller sealing bead groove) in cover roof are more than 0.030 in. (0.76mm) deep. 6. Lift impeller, drive key, and gasket from drive shaft.

a

c

b

19220 a — Impeller b — Drive Key c — Gasket 90-852572R02 NOVEMBER 2002

LOWER UNIT — 6C-11

7. Inspect impeller. Replace impeller if any of the following conditions exist: •

Impeller blade(s) are cracked, torn, or worn.

•

Impeller is glazed or melted (caused by operation without sufficient water supply).

•

Rubber portion of impeller is not bonded to impeller hub.

11. Remove water pump base.

a

8. Remove plate and gasket. 9. Replace plate if groove(s) (other than impeller sealing bead groove) in plate are more than 0.030 in. (0.76mm) deep.

19226 a — Water Pump Base

c a

12. Remove (and discard) seals.

a b

19219 a — Plate b — Gasket c — Impeller Sealing Groove

19195 a — Seals

10. Remove bolts and washers.

13. Remove gasket.

a

a

19218

19217 a — Bolts and Washers (6 each)

6C-12 — LOWER UNIT

a — Gasket

90-852572R02 NOVEMBER 2002

Bearing Carrier and Propeller Shaft 1. Remove fasteners.

4. Lift reverse gear, thrust bearing and thrust washer from bearing carrier. 5. Replace reverse gear if gear teeth or clutch teeth on reverse gear are chipped or worn. If reverse gear must be replaced, pinion gear and sliding clutch should be inspected for damage.

a

6. Replace thrust bearing and thrust washer if rusted or damaged.

a b

c

a a — Fasteners

2. With propeller shaft horizontal, pull carrier to break seal with gear housing. Remove bearing carrier/propeller shaft components as an assembly, taking care not to lose cam follower or 3 metal balls in end of propeller shaft. 3. Remove propeller shaft from bearing carrier.

e c

a — Reverse Gear b — Thrust Bearing c — Thrust Washer

b a

7. If bearing is rusted or does not roll freely, replace bearing. Remove bearing using Slide Hammer (91-34569A1).

a

d a b c d e

—

51116

Bearing Carrier Puller Jaws (91-46086A1) Puller Bolt (91-85716) Thrust Hub Propeller Shaft

19205 a — Bearing

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6C-13

8. If bearing is rusted or does not roll freely, replace bearing. Remove bearing and oil seals using Mandrel* (91-36569T) and Driver Rod* (91-37323). Discard oil seals.

10. Remove spring.

* From Bearing Removal and Installation Kit (91-31229A7)

a

c

a 51876 a — Spring

11. Apply constant pressure to cam follower to prevent cam follower assembly from ejecting from propeller shaft while pushing cross pin out of clutch dog.

b

51264

a — Bearing b — Mandrel (91-36569T) c — Driver Rod (91-37323)

b

9. Remove (if not removed with bearing in Step propeller shaft seals and bearing carrier O-ring.

a a

51800

a — Cross Pin b — Cam Follower 51263 a — O-ring

6C-14 — LOWER UNIT

12. Remove components from propeller shaft.

90-852572R02 NOVEMBER 2002

13. Replace cam follower if worn or pitted. 14. Replace sliding clutch if jaws are rounded or chipped. Rounded jaws indicate one or more of the following:

Pinion Gear, Drive Shaft, and Forward Gear Model

Drive Shaft Holding Tool

a. Improper shift cable adjustment.

50 Bigfoot (4-Stroke)

91-56775T

b. Engine idle speed too high while shifting.

60 Bigfoot

91-817070

c. Shifting from neutral to reverse (or forward) too slowly.

75/90/100/115/125

91-56775T

a

b c

e

d

1. Hold drive shaft using Drive Shaft Holding Tool (91-56775T); remove (and discard) pinion nut. 2. Remove drive shaft, pinion gear, bearing and forward gear. 3. Replace pinion gear if it is chipped or worn.

f a b c d e f

—

f

51265

Cam Follower 3 Metal Balls Guide Block Spring Sliding Clutch Jaws

4. Replace bearing and race if either are rusted or damaged; or if bearing does not roll freely. To remove race, refer to Lower Drive Shaft Bearing Race, following. 5. Replace forward gear if gear teeth or clutch teeth are chipped or worn.

a c

15. Check bearing surfaces of propeller shaft for pitting or wear. If shaft is worn or pitted, replace shaft and corresponding bearing. 16. Replace propeller shaft if any of the following exist: a. Splines are twisted or worn. b. Oil seal surface is grooved. c. Shaft has a noticeable wobble or is bent more than 0.009 in. (0.23mm). Prop shaft trueness should be measured with a dial indicator with prop shaft on V-blocks.

c

b

e

b d

b f

a

19175 51877

a — V-Blocks b — Bearing Surfaces c — Measure with Dial Indicator at This Point

90-852572R02 NOVEMBER 2002

a b c d e f

—

Drive Shaft Holding Tool (91-56775T) Pinion Nut Drive Shaft Pinion Gear Bearing Forward Gear

LOWER UNIT — 6C-15

6. Replace bearing if it is rusted or does not roll freely.

9. Replace drive shaft if splines are worn or twisted.

7. Use a suitable tool (screwdriver or awl) to remove retaining ring. Use a punch and hammer to remove bearing.

10. If bearing surface is damaged, replace drive shaft and corresponding bearing.

a

IMPORTANT: Do not tighten vise against drive shaft. 11. If wear sleeve is deeply grooved; allowing water to enter gear case, remove (and discard) sleeve using Universal Puller Plate (91-37241) and mallet.

e a a — Retaining Ring

a

19203 a — Bearing

d

8. Replace forward gear bearing and race if either are rusted or damaged; or if bearing does not roll freely. Remove bearing from gear using Universal Puller Plate (91-37241) and mandrel. To remove race, refer to Forward Gear Bearing Race, following.

c

b a 19710

c

a

a b c d e

—

Splines Bearing Surface Wear Sleeve Universal Puller Plate (91-37241) Mallet

12. Remove (and discard) rubber ring.

a b 51119 19152 a — Forward Gear Bearing b — Universal Puller Plate (91-37241) c — Mandrel

6C-16 — LOWER UNIT

a — Rubber Ring

90-852572R02 NOVEMBER 2002

Upper Drive Shaft Bearing

Oil Sleeve

1. Replace upper drive shaft bearing and sleeve if either are rust stained, or if bearing will not roll freely. Remove bearing and then sleeve using Puller Assembly (91-83165T) with suitable jaws.

1. Remove oil sleeve (if necessary) using Puller Assembly (91-83165T) with suitable jaws.

b

OR a

c

a

19222

b

19177

a — Upper Drive Shaft Bearing b — Sleeve c — Puller Assembly (91-83165T)

IMPORTANT: Upper drive shaft bearing/sleeve must be removed prior to oil sleeve removal. Refer to Upper Drive Shaft Bearing, preceding.

a — Oil Sleeve b — Puller Assembly (91-83165T)

IMPORTANT: Upper drive shaft bearing/sleeve and oil sleeve do not have to be removed for lower drive shaft bearing race removal.

IMPORTANT: Upper drive shaft bearing/sleeve do not have to be removed for lower drive shaft bearing race removal.

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6C-17

Lower Drive Shaft Bearing Race

Shift Shaft

IMPORTANT: Upper drive shaft bearing/sleeve do not have to be removed for lower drive shaft bearing race removal.

1. Remove shift shaft coupler and nylon spacer.

b

a

IMPORTANT: Retain shim(s) for reassembly. 1. Remove race and shim(s) using bearing race tool.

NOTE: See Bearing Race Tool application chart in the Special Tools list in this section for correct tool.

c

53925 a — Shift Shaft Coupler b — Spacer

2. Remove bolts.

a

b 53926 a — Bolts

NOTE: Gearcase should be in FORWARD for easiest removal of shift shaft.

a

3. Remove shift shaft bushing and shift shaft. 19171

a

b

a — Race b — Shim(s) c — Bearing Race Tool (91-14308T1 or 91-14308T02)

53927 a — Bushing b — Shift Shaft

6C-18 — LOWER UNIT

90-852572R02 NOVEMBER 2002

4. Remove shift cam from housing.

Forward Gear Bearing Race

5. Replace shift cam if worn.

IMPORTANT: Retain shim(s) for reassembly. If shims are damaged, replace with new shims of equal thickness. 1. Remove race and shim(s) using Slide Hammer (91-34569A1).

a

a b 51117 a — Shift Cam

NOTE: If shift shaft splines are rough, shift shaft seal lips will be cut during removal/installation. 6. Remove shift shaft bushing and clip from shift shaft. 7. Replace shift shaft if splines are worn or shaft is twisted. 8. Remove (and discard) O-ring.

a d

c

e b

d

c

27653

a — Race b — Shim(s) c — Slide Hammer (91-34569A1)

Trim Tab Adjustment and Replacement IMPORTANT: The trim tab is now painted and does NOT aid in protecting the drive shaft housing and gear housing from galvanic corrosion (corrosion and pitting of metal surfaces). Side anodes now provide protection. Do not paint or place protective coating on the side anodes, or corrosion protection function will be lost. 1. Replace trim tab if damaged. Mark location of old trim tab on anti-ventilation plate before removal; install new trim tab in same location.

53928 a b c d e

—

Bushing Clip Shift Shaft Splines O-ring

9. Remove (and discard) seal.

c

b

a 53929 a — Seal 90-852572R02 NOVEMBER 2002

2. The trim tab provides a means to offset (balance) some of the steering load that is caused by propeller torque at higher operating speeds. If at higher speeds the boat turns more easily to the left, loosen bolt, move the trim tab (trailing edge) to the left (when viewed from behind); retighten bolt. Turn trim tab (trailing edge) to the right if the boat turns more easily to the right.

a

53931

a — Trim Tab b — Anti-Ventilation Plate c — Retaining Bolt and Washer; Torque Bolt to 22 lbs. ft. (29.8 N
m) LOWER UNIT — 6C-19

5. Assemble components as shown.

Reassembly

a

b

Forward Gear 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. (0.254mm) shim(s). 2. Assemble components as shown; drive race into housing by striking propeller shaft end with lead hammer.

e

d

c

53928

a — Shift Shaft b — E-Clip c — Shift Shaft Bushing

6. Install shift cam (numbers toward top of gear housing); align hole in shift cam with hole.

c

60 Bigfoot 75/90/100/115/125

a

95

b 95

a b c d e

—

2-4-C With Teflon

b

19179

Shim(s) Race, Apply 2-4-C with Teflon Lubricant on O.D. Mandrel (91-31106T) Disassembled Propeller Shaft Assembled Bearing Carrier

a

51117 a — Shift Cam (marked with UP and part number) b — Gear Housing Hole

60 Bigfoot 75/90/100/115/125

Shift Shaft 1. Apply Loctite 271 Thread Locker on O.D. of new seal. 2. Press seal into shift shaft bushing until seal is seated against shoulder.

b

850307

3. Install new O-ring. 4. Apply 2-4-C with Teflon on O-ring and I.D. of seal.

c

a

a 7

b

d 7

a b c d

—

56791

53930

Loctite 271 Thread Locker

Seal (Lip faces UP) Bushing Surface O-ring

6C-20 — LOWER UNIT

a — Shift Cam (marked with part number only) b — Gear Housing Hole

90-852572R02 NOVEMBER 2002

50 Bigfoot (4-Stroke)

8. Apply Loctite 271 Thread Locker on bottom half of threads of bolts; install bolts and torque to 35 lb. in. (4.0 N·m).

b

a

7

a 850307

Loctite 271 Thread Locker

7

53926

a — Bolts [Torque to 35 lb. in. (4.0 N·m)] 51117

Bearing Carrier Reassembly

a — Shift Cam (Numbers Down) b — Hole

7. Install shift shaft assembly; insert splines into shift cam.

1. Lubricate O.D. of bearing and bearing carrier bore with 2-4-C with Teflon. 2. Protect lip on forward side of bearing carrier, using Bearing Installation Tool (91-13945). 3. Press propeller shaft needle bearing (number side toward mandrel) into carrier, until bearing bottoms out.

a

c 95

b

b

53932 a — Shift Shaft Assembly b — Splines

a

95

2-4-C With Teflon

21042

a — Bearing Installation Tool (91-13945) b — Mandrel (91-15755T) c — Suitable Driver Rod 90-852572R02 NOVEMBER 2002

LOWER UNIT — 6C-21

4. Place smaller diameter seal on longer shoulder of Oil Seal Driver (91-31108T) with seal lip away from shoulder. 5. Protect lip on front side of bearing carrier using Bearing Installation Tool (91-13945). Apply Loctite 271 Thread Locker on O.D. of seal. Press seal into carrier until tool bottoms.

8. Install O-ring. 9. Lubricate O-ring with 2-4-C with Teflon. Lubricate seal lips with 2-4-C with Teflon. Lubricate outside diameter of bearing and bearing carrier bore with a light coating of 2-4-C with Teflon. 10. Press bearing into carrier until tool bottoms.

b

a

b

95 7

a c

c

7

Loctite 271 Thread Locker

21040 19163

a — Seal b — Oil Seal Driver (91-31108T) c — Bearing Installation Tool (91-13945)

95

6. Place larger diameter seal on shorter shoulder of Oil Seal Driver (91-31108T) with seal lip toward shoulder. 7. Protect lip on front side of bearing carrier using Bearing Installation Tool (91-13945). Apply Loctite 271 Thread Locker on O.D. of new seal. Press seal into carrier until tool bottoms.

2-4-C With Teflon

a — O-ring b — Bearing, Numbered Side Toward Tool c — Bearing Installation Tool (91-13945)

11. Install thrust washer. Coat thrust washer with Premium Gear Lubricant.

a 82

b

a 7

a c

19167 7

Loctite 271 Thread Locker

a — Seal b — Oil Seal Driver (91-31108T) c — Bearing Installation Tool (91-13945) 6C-22 — LOWER UNIT

82

Premium Gear Lubricant

21041 a — Thrust Washer

90-852572R02 NOVEMBER 2002

12. Install thrust bearing. Coat thrust bearing with Premium Gear Lubricant.

a

82

Forward Gear Reassembly 1. Press tapered bearing onto gear (press only on inner race of bearing). 82

a b

82

Premium Gear Lubricant 51869

19168

Premium Gear Lubricant

82

a — Thrust Bearing

13. Apply gear lubricant to bearing surface of reverse gear and install reverse gear.

b 82

a

a — Mandrel (91-37350T) b — Bearing; Lubricate I.D. with gear lubricant

2. Inspect reverse gear end of clutch to determine the number of jaws. Refer to chart, following, for tool end selection. Model

Installation Tool

End Stamped

Bearing Position

3 Jaw Reverse Clutch

91-856875A1

3

0.155 in. (3.94mm) below surface

6 Jaw Reverse Clutch

91-856875A1

6

Flush with surface

3 Jaw Reverse Clutch

a

c 19202 82

Premium Gear Lubricant

b

56783

a — Stamped 3 b — Numbered end of Needle Bearing c — 3 Jaw Reverse Clutch

a — Reverse Gear b — Bearing Surface 90-852572R02 NOVEMBER 2002

LOWER UNIT — 6C-23

6 Jaw Reverse Clutch

Propeller Shaft Reassembly a

1. Install components into propeller shaft in sequence shown.

d

c b

a

19154

c

b 56784

a — Stamped 6 b — Numbered end of Needle Bearing c — 6 Jaw Reverse Clutch

3. Apply gear lubricant to I.D. of forward gear. Press bearing into forward gear until tool contacts gear.

a b c d

—

Spring Guide Block 3 Metal Balls* Cam Follower*

* Hold in Place With 2-4-C with Teflon

2. Install cross pin.

b a a 82

51800 a — Apply Pressure in This Direction b — Cross Pin

3. Install spring. DO NOT overlap springs.

b

56785 82

Premium Gear Lubricant

a a — Forward Gear Bearing Installer (91-856875A1) b — Needle Bearing, Numbered Side Toward Installer Tool

51876 a — Spring

6C-24 — LOWER UNIT

90-852572R02 NOVEMBER 2002

Drive Shaft Wear Sleeve Installation 1. Install new rubber ring.

4. Press sleeve onto drive shaft using Wear Sleeve Installation Tool (91-14310T1); continue pressing until surface contacts surface.

2. Apply a light coat of Loctite 271 Thread Locker on outside diameter of rubber ring.

b

a

7 7

Loctite 271 Thread Locker

19152

a — Ring

d 3. Insert sleeve into holder*. * Component of Wear Sleeve Installation Tool (91-14310T1).

a

c a

a b

19166

b

a b c d

—

Drive Shaft Wear Sleeve Installation Tool Surface Surface

5. Remove excess Loctite from assembled shaft.

19169 a — Sleeve b — Holder

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6C-25

Lower Drive Shaft Bearing Race Installation

Oil Sleeve Installation 1. Install oil sleeve with tab positioned as shown.

IMPORTANT: Lower drive shaft bearing cup can be installed with or without upper drive shaft bearing/sleeve and oil sleeve installed.

b

1. Lubricate O.D. of bearing race with 2-4-C with Teflon.

a

2. Install shim(s) and bearing race into housing.

NOTE: Verify shim(s) are not cocked when drawing up race. 91-14309T1 91-14309T02

f

d

e

e 53934

c

f

a — Oil Sleeve b — Tab

d

Upper Drive Shaft Bearing Installation 1. Lubricate I.D. of bearing holder and O.D. of bearing with 2-4-C with Teflon. 2. Press bearing into sleeve.

a b c 95

2-4-C with Teflon

95

53933

d 95

a — Shim(s); Retained From Disassembly. If Shim(s) Were Lost or a New Gear Housing is Being Assembled, Start With 0.025 in. (0.635mm) Shim(s) b — Bearing Race c — Mandrel* (91-13780 or 91-143009T02) d — Mandrel* (91-13781) e — Threaded Rod** (91-31229) f — Nut** (11-24156)

c a b

* From Bearing Installation Tool (91-14309T01 or 91-14309T02) ** From Bearing Removal and Installation Kit (91-31229A7)

NOTE: See Bearing Race Tool application chart in the Special Tools list in this section for correct tool.

6C-26 — LOWER UNIT

95

a b c d

—

2-4-C With Teflon

19164

Bearing Sleeve Tapered End Bearing; Numbered Side Toward Mandrel Mandrel (91-13781); From Bearing Installation Tool (91-14309T1)

90-852572R02 NOVEMBER 2002

IMPORTANT: Oil sleeve must be installed prior to upper drive bearing installation. IMPORTANT: Upper drive shaft bearing/sleeve can be installed with or without lower drive shaft bearing cup installed. 3. Install bearing/sleeve into housing.

f e c

e

d

f c a

b

Forward Gear, Lower Drive Shaft Bearing, Pinion Gear, and Drive Shaft Installation Model

Drive Shaft Holding Tool

40/50 Bigfoot (4-Stroke)

91-56775T

50/60 Bigfoot (4 Stroke)

91-817070

75/90/115EFI (4 Stroke)

91-804776A1

60 Bigfoot/ 75/90/100/115/125 (2 Stroke)

91-56775T

1. Install components in sequence shown.

e

d

d d 53935 a b c d e f

—

Bearing/Sleeve Tapered End Mandrel* (91-13781) Mandrel* (91-13780 or 91-889623) Threaded Rod** (91-31229) Nut** (11-24156)

b

* From Bearing Installation Tool (91-14309T1 or 91-14309T02) ** From Bearing Removal and Installation Kit (91-31229A7)

c

NOTE: See Bearing Race Tool application chart in the Special Tools list in this section for correct tool.

f 7

a 19175

7

Loctite 271 Thread Locker

a — Forward Gear/Bearing: Work gear lube into bearing rollers. b — Lower Drive Shaft Tapered Roller Bearing: Work gear lube into bearing rollers. c — Pinion Gear d — Drive Shaft e — Drive Shaft Holding Tool f — Pinion Nut (New): Apply Loctite 271 Thread Locker to threads during final assembly (after pinion gear depth and forward gear backlash have been set), torque to 70 lb. ft. (95 N·m)

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6C-27

Pinion Gear Depth and Forward Gear Backlash

3. Measure distance between top of nut and bottom of bolt head. 4. Increase distance by 1 in. (25.4mm).

DETERMINING PINION GEAR DEPTH

NOTE: Read entire procedure before attempting any change in shim thickness.

5. Rotate drive shaft 5 to 10 revolutions. This should properly seat upper drive shaft tapered roller bearing.

IMPORTANT: Forward gear assembly must be installed in gear housing when checking pinion gear depth or an inaccurate measurement will be obtained.

a c

1. Clean the gear housing bearing carrier shoulder and diameter. 2. With gear housing positioned up right (drive shaft vertical), install Bearing Preload Tool (91-14311A2) over drive shaft in sequence shown.

b

g h

h c

e f

19884

b a

a — 1 in. (25.4mm) b — Nut c — Bolt Head

d

a b c d e f g h

—

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

6C-28 — LOWER UNIT

90-852572R02 NOVEMBER 2002

6. Assemble Pinion Gear Locating Tool (91-12349A2) as shown; do not tighten collar retaining bolt at this time.

b

d

c

MODEL

GEAR RATIO (PINION GEAR TEETH/ REVERSE GEAR TEETH)

USE FLAT NO.

50 Bigfoot (4-stroke)

13/30

8

60 Bigfoot/60 Seapro/60 Marathon

12/28 13/30

8

75-thru-90 (3 Cylinder)

12/28 13/30

8

100/115/125 (4 Cylinder)

14/29

2

e

c

a

9. Insert tool into forward gear assembly; position proper numbered flat (from chart) of gauging block – under pinion gear.

10. Install the number 3 locating disc against bearing carrier shoulder in gear housing.

f

11. Position access hole as shown. a — Arbor b — Gauging Block; Install With Numbers Away From Split Collar c — Bolt; Gauging Block Retaining d — Split Collar e — Bolt; Collar Retaining f — Snap Ring

b

7. Insert tool into forward gear assembly; position gauging block under pinion gear as shown.

a

a

24643 a — Locating Disc b — Access Hole 22067 a — Gauging Block

8. Remove tool, taking care not to change gauging block position, and tighten collar retaining bolt.

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6C-29

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. (0.64mm). 14. If clearance is correct, leave Bearing Preload Tool on drive shaft and proceed to Determining Forward Gear Backlash, following. 15. If clearance is incorrect, add (or subtract) shims from above bearing race to lower (or raise) pinion gear. When reinstalling pinion nut, apply Loctite 271 Thread Locker on threads of nut.

Determining Forward Gear Backlash NOTE: Read entire procedure before attempting any change in shim thickness. 1. Obtain correct pinion gear depth; refer to Determining Pinion Gear Depth, preceding. 2. Install Bearing Preload Tool (91-14311A2) on drive shaft; refer to Determining Pinion Gear Depth, preceding. 3. Install components as shown.

c a d d 7

a b c d

—

b

b

24643 7

a

c

Loctite 271 Thread Locker

Feeler Gauge Gauging Block Pinion Gear Bearing Race

a b c d

—

53936

Propeller Shaft* Bearing Carrier* (Assembled) Puller Jaws (91-46086A1) Puller Bolt (91-85716); Torque to 45 lbs. in. (5.1 N·m)

* Refer to Bearing Carrier and Propeller Shaft Installation, following.

4. Rotate drive shaft 5 to 10 revolutions. This should properly seat forward gear tapered roller bearing.

6C-30 — LOWER UNIT

90-852572R02 NOVEMBER 2002

5. Install components as shown.

e

7. Lightly turn drive shaft back and forth (no movement should be noticed at propeller shaft).

f

d

8. Dial Indicator registers amount of backlash, which must be between specification shown in chart.

c

a

MODEL

DIAL INDICATOR MINIMUM

READING MAXIMUM

50 Bigfoot (4-Stroke)

0.012 in. (0.30mm)

0.019 in. (.48mm)

60 Bigfoot

0.012 in. (0.30mm)

0.019 in. (.48mm)

75-thru-90 (3 Cylinder)

0.012 in. (0.30mm)

0.019 in. (.48mm)

100/115/125 (4 Cylinder)

0.015 in. (0.38mm)

0.022 in. (0.55mm)

9. If backlash is less than the minimum specification, remove shim(s) from in front of forward gear bearing race to obtain correct backlash. When reinstalling pinion nut, apply Loctite 271 Thread Locker on threads of nut.

c b a b c d e f

—

51117

Threaded Rod (Obtain Locally) Washers Nuts Dial Indicator Adaptor Kit (91-83155) Dial Indicator (91-58222A1) Backlash Indicator Tool

10. If backlash is more than the maximum specification, add shims in front of forward gear bearing race to obtain correct backlash. When reinstalling pinion nut, apply Loctite 271 Thread Locker on threads of nut.

NOTE: By adding or subtracting 0.001 in. (0.03mm) shim, the backlash will change approximately 0.001 in. (.03mm).

6. Position Dial Indicator on appropriate line (from chart) marked on Backlash Indicator Tool. MODEL

ALIGN POINTER OF DIAL INDICATOR WITH MARK

50 Bigfoot (4-stroke) Backlash Indicator Tool (91-78473)

4

60 Seapro/60 Marathon/60 Bigfoot Backlash Indicator Tool (91-78473)

4

75-thru-90 (3 Cylinder) Backlash Indicator Tool (91-78473)

4

100/115/125 (4 Cylinder) Backlash Indicator Tool (91-19660—1)

1

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6C-31

Bearing Carrier and Propeller Shaft Installation

4. Install bearing carrier and propeller shaft into housing with the word TOP located on flange toward top of housing.

1. Insert propeller shaft assembly into bearing carrier. 2. Before installing bearing carrier assembly into gear housing, obtain locally a 6 in. (152.4mm) long by 1-1/4 in. – 1-1/2 in. (31.7mm – 38.1mm) diameter piece of PVC pipe. Install the PVC pipe over the prop shaft and secure the pipe against the bearing carrier assembly with the propeller nut and tab washer. This will allow the reverse gear to apply pressure to the reverse gear thrust bearing to prevent the thrust bearing from being inadvertently dislodged as the bearing carrier assembly is installed in the gear housing.

a

b

c

a

b c

d

95

95

21044 95

2-4-C With Teflon

a — Apply 2-4-C with Teflon b — O-ring c — TOP

e a b c d e

—

21043

Bearing Carrier Assembly PVC Pipe Tab Washer Prop Shaft Propeller Nut

3. Lubricate O-ring and mating surfaces with 2-4-C with Teflon.

5. Install components as shown.

NOTE: Use thick 0.090 in. (2.29mm) washers (12-855941) under fasteners if not previously installed. Washer Thickness

Fastener Torque

0.090 in. (2.29mm)

22 lb. ft. (29.8 N·m)

0.060 in. (1.53mm)

25 lb. ft. (33.9 N·m)

b a

a — Washers b — Fasteners; (If using Bolts – Apply Loctite 271 Thread Locker on Threads)

6C-32 — LOWER UNIT

90-852572R02 NOVEMBER 2002

3. Place seal on shorter shoulder side of Oil Seal Driver (91-13949) with seal lip toward shoulder.

Water Pump Reassembly and Installation 1. Place seal on longer shoulder side of Oil Seal Driver (91-13949) with seal lip away from shoulder. 2. Apply Loctite 271 Thread Locker on O.D. of seal; press seal into water pump base until tool bottoms. Lubricate seal lip with 2-4-C with Teflon. 95

a

4. Apply Loctite 271 Thread Locker on O.D. of seal; press seal into water pump base until tool bottoms. 5. Lubricate lip of each seal with 2-4-C with Teflon. 95

a

7

7

b b c c c c

51553 7

Loctite 271 Thread Locker

95

2-4-C With Teflon

51553 7

Loctite 271 Thread Locker

95

2-4-C With Teflon

a — Seal – Teflon Coated Lip (Flat Brownish Color – Lip faces toward Power Head) b — Spring Faces Toward Power Head c — Oil Seal Driver (91-13949)

a — Seal (Gloss Black Color – Lip faces toward Gear Case) b — Spring Faces Toward Gear Case c — Oil Seal Driver (91-13949)

6. Install gasket.

a

19218 a — Gasket

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6C-33

7. Install components as shown.

9. Install gasket, drive key and impeller.

c

7

a

b

b a

19220

7

19217

Loctite 271 Thread Locker

a — Water Pump Base b — Bolts and Washers; Apply Loctite 271 Thread Locker on bottom 1/2 of Threads and Torque to 60 lb. in. (6.8 N·m)

8. Install gasket and plate.

a — Gasket b — Drive Key c — Impeller

10. Lubricate I.D. of cover with 2-4-C with Teflon. 11. Rotate drive shaft clockwise and push cover down over impeller. 12. Install cover.

b

13. 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. 14. Lubricate I.D. of water tube seal with 2-4-C with Teflon and install as shown.

a

95

19219 a — Gasket b — Plate

b 7 95

a

c

IMPORTANT: If the old impeller will be re-used, impeller must be installed in original (clockwise) direction of rotation.

19212 7

Loctite 271 Thread Locker

95

2-4-C With Teflon

a — Cover b — Seal c — Bolts (4); Apply Loctite 271 Thread Locker on Threads and Torque to 60 lb. in. (6.8 N·m).

NOTE: It is recommended that the gearcase be pressure tested for leaks after reassembly and BEFORE gear lube is added. Gearcase should hold 10 to 12 psi (68-82kPa) for 5 minutes. 52869

6C-34 — LOWER UNIT

90-852572R02 NOVEMBER 2002

Gear Housing Pressure Test 1. Remove vent plug and install pressure test gauge.

Filling Gear Housing With Lubricant NOTE: Gear housing lubricant capacity is 22.5 fl. oz. (665.2ml).

WARNING If gear housing is installed on engine, to avoid accidental starting, disconnect (and isolate) spark plug leads from spark plugs before working near the propeller.

CAUTION Do not use automotive grease in the gear housing. Use only Premium Gear Lube . 1. Remove any gasket material from Fill and Vent screws and gear housing. 2. Install new gaskets on Fill and Vent screws. 2. Pressurized housing to 10 to 12 psi (69-82 kPa) and observe gauge for 5 minutes. 3. Rotate drive shaft, prop shaft and move shift shaft while housing is pressurized to check for leaks.

IMPORTANT: Never apply lubricant to gear housing without first removing Vent screws or gear housing cannot be filled because of trapped air. Fill gear housing only when housing is in a vertical position. 3. Insert lubricant tube into Fill hole. 4. Fill gear housing with lubricant until excess starts to flow out of one (first) Vent screw hole.

4. If pressure drop is noted, immerse housing in water. 5. Re-pressurize to 10 to 12 psi (69-82 kPa) and check for air bubbles. 6. Replace leaking seals as necessary. Retest housing.

NOTE: Gearcase should hold 10 to 12 psi (69-82 kPa) for 5 minutes. 7. Remove tester from housing and install vent plug. Torque vent screw to 60 lb. in. (6.8 N·m).

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6C-35

5. Replace this lubricant Vent screw and gasket only and continue filling until excess starts to flow out of second lubricant Vent screw hole.

a

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 accidental engine starting and possible injury.

c

1. Position outboard shift linkage into forward gear position.

b

53922

a — Vent Screw (Torque to 60 lb. in. (6.8 N·m) b — Fill/Drain Screw (Torque to 60 lb. in. (6.8 N·m) c — Oil Level Vent Screw (Torque to 60 lb. in. (6.8 N·m)

6. Replace second lubricant Vent screw and gasket.

a Models 40/45/50 Bigfoot (4-Stroke) Remote Control Model Shown a — Shift Lever

IMPORTANT: Do not lose more than one fluid ounce (30cc) of gear lubricant while reinstalling FILL screw. 7. Remove lubricant tube from Fill hole; install Fill screw and gasket. Torque Fill screw to 60 lb. in. (6.8 N·m).

a Models 60 Bigfoot a — Shift Block

a

b

19879

Models 75/90/100/115/125 a — Shift Block; Front of Block MUST Extend 1/8 in. (3.2mm) Past Front of Rail. b — Rail

6C-36 — LOWER UNIT

90-852572R02 NOVEMBER 2002

2. Tilt engine to full UP position and engage tilt lock lever.

8. Install components as shown in appropriate photo.

3. Shift gear housing into neutral position. Propeller shaft will rotate freely in either direction.

POWER TRIM MODELS

4. Install water tube seal; lube I.D. of seal with 2-4-C with Teflon.

c

5. Apply a bead of RTV Sealer as shown.

b

95

a

116

a b

53968 53938 116 95

RTV Silicone Sealer 2-4-C With Teflon

a — Water Tube Seal b — RTV Sealer

a — Nylon Spacer b — Shift Shaft Coupler; Used on Models Equipped with Power Trim c — Bushing 40/45/50 Bigfoot (4-Stroke) Only

NON-POWER TRIM MODELS

a

b

CAUTION Do not use lubricant on top of drive shaft. Excess lubricant, that is trapped in clearance space, will not allow drive shaft to fully engage with crankshaft. Subsequently, tightening the gear housing fasteners (while lubricant is on top of drive shaft) will load the drive shaft/crankshaft and damage either or both the power head and gear housing. Top of drive shaft is to be wiped free of lubricant.

c

6. Apply a light coat of 2-4-C with Teflon onto drive shaft splines. 7. Apply a light coat of 2-4-C with Teflon on gear case shift shaft splines and upper shift shaft splines. Do not use lubricant on ends of shift shafts. 53925

a — Nylon Spacer b — Shift Shaft Coupler; Used on Models NOT Equipped with Power Trim c — Flat; MUST BE Positioned Toward Front of Gear Housing

9. Shift gear housing into forward gear position. In forward gear the gear housing will ratchet when propeller shaft is turned clockwise and resistance will be felt when propeller shaft is rotated counterclockwise. 90-852572R02 NOVEMBER 2002

LOWER UNIT — 6C-37

10. Apply Loctite Grade 271 Thread Locker on threads of gear housing retaining bolts.

NOTE: If, while performing Step 11, the drive shaft splines will not align with the crankshaft splines, place a propeller onto propeller shaft and turn it counterclockwise as the gear housing is being pushed toward drive shaft housing. NOTE: During installation of gear housing, it may be necessary to move the shift block (located under cowl) slightly to align upper shift shaft splines with shift shaft coupler splines. 11. Position gear housing so that the drive shaft is protruding into drive shaft housing. 12. Move gear housing up toward drive shaft housing, while aligning upper shift shaft splines with shift shaft coupler splines, water tube with water tube seal, and crank shaft splines with drive shaft splines. 13. Install 4 bolts and washers (two each side). 14. Install locknut and washer. 15. Torque bolts and locknut (or nuts only if applicable) to 40 lbs. ft. (54.0 N·m).

IMPORTANT: If shift operation is not as described, preceding, the gear housing must be removed and the cause corrected.

Trim Tab Adjustment 1. Check trim tab position as follows: a. Operate boat at the speed at which it normally would be operated. b. If the boat pulls to the right (STARBOARD), the trailing edge of trim tab must be moved to the right. If the boat pulls to the left (PORT), the trailing edge of trim tab must be moved to the left. 2. If necessary, adjust trim tab as follows: a. Shift engine control into NEUTRAL and turn ignition key to OFF position.

NOTE: Loosen trim tab bolt sufficiently to allow trim tab to disengage from locking ridges in gear case before attempting to move tab. DO NOT strike trim tab with a hard object to make adjustments. b. If boat pulls to the left, adjust trailing edge of trim tab to the left. If boat pulls to the right, adjust trailing edge of trim tab to the right. 3. Tighten trim tab retaining bolt and washer to 22 lb. ft. (30.0 N·m).

b

a

53922

a — Bolts and Washers (4) b — Locknut and Washer

16. Check shift operation as follows: a. Place shift lever in forward gear. Gear housing should ratchet when propeller shaft is turned clockwise and resistance should be felt when propeller shaft is turned counterclockwise. b. Place shift lever in neutral. Propeller shaft should rotate freely in either direction. c. While rotating propeller shaft, place shift lever in reverse gear. Resistance should be felt when propeller shaft is rotated in either direction. 6C-38 — LOWER UNIT

90-852572R02 NOVEMBER 2002

LOWER UNIT

6 D JET DRIVE

Table of Contents Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Jet 30 Pump Assembly . . . . . . . . . . . . . . . . . . Jet 30 Pump Assembly . . . . . . . . . . . . . . . . . . Jet 30 Water Pump Components . . . . . . . . . Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Jet 40/45 Pump Assembly . . . . . . . . . . . . . . . Jet 40/45 Water Pump Components . . . . . . Selecting A Boat That Is Best Suited For Jet Power . . . . . . . . . . . . . . . . . . . . . . . . . Engine Horsepower Selection . . . . . . . . . . . . Transom Height of the Boat . . . . . . . . . . . . . . Locate Center Line of the Outboard . . . . . . . Outboard Mounting Height . . . . . . . . . . . . . . . Setting Outboard Mounting Height on Boats with Flat Bottom Hulls . . . . . . . Water Testing . . . . . . . . . . . . . . . . . . . . . . . . . . Checking for Cavitation . . . . . . . . . . . . . . . Shift Cable Installation . . . . . . . . . . . . . . . . . . Lubricating The Drive Shaft Bearing . . . . . . Impeller Removal and Installation . . . . . . . . Steering Pull Adjustment . . . . . . . . . . . . . . . . Impeller Clearance Adjustment . . . . . . . . . . . Worn (Dull) Impeller . . . . . . . . . . . . . . . . . . . . Flushing The Cooling System . . . . . . . . . . . . Liner Replacement . . . . . . . . . . . . . . . . . . . . . Jet Drive Removal . . . . . . . . . . . . . . . . . . . . . . Water Pump Removal and Installation . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembling Water Pump to Jet Drive . . Bearing Carrier Removal . . . . . . . . . . . . . . . . Bearing Carrier Disassembly . . . . . . . . . . . . . Bearing Carrier Reassembly . . . . . . . . . . . . . Installing Lower Seals . . . . . . . . . . . . . . . . Installing Upper Seals . . . . . . . . . . . . . . . . Installing Drive Shaft Ball Bearing . . . . . . Installing Drive Shaft . . . . . . . . . . . . . . . . . Installing Jet Drive to Drive Shaft Housing . . . . . . . . . . . . . . . . .

6D-0 — LOWER UNIT

Page 6D-1 6D-2 6D-3 6D-4 6D-5 6D-6 6D-8 6D-9 6D-9 6D-10 6D-10 6D-10 6D-11 6D-11 6D-11 6D-12 6D-13 6D-13 6D-15 6D-15 6D-15 6D-16 6D-16 6D-16 6D-18 6D-18 6D-18 6D-19 6D-19 6D-19 6D-19 6D-20 6D-20 6D-20 6D-22

90-852572R02 NOVEMBER 2002

Notes:

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6D-1

Jet 30 Pump Assembly

7

Loctite 271 Thread Locker

95

2-4-C with Teflon

6D-2 — LOWER UNIT

90-852572R02 NOVEMBER 2002

Jet 30 Pump Assembly REF. REF NO. QTY. – 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 10 1 11 1 12 1 13 1 14 1 15 8 16 1 17 6 18 4 19 4 20 2 21 1 22 1 23 1 24 2 2 25 2 26 4 27 1 28 1 29 1 30 7 31 4 32 2

TORQUE DESCRIPTION JET PUMP ASSEMBLY (BLACK) HOUSING-Pump HOSE-lube SHIFT LINKAGE KIT CAM REVERSE GATE WITH BUMPER IMPELLER (STAINLESS STEEL) HOUSING-Intake LINER DRIVESHAFT THRUSTWASHER BALL BEARING SLEEVE NUT KEY SHIM TAB WASHER SCREW (1/4-20 X 3/4) SCREW (1/4-20 x .875) WASHER SCREW (1/4-20 x .625) SCREW (.312-18 x 1.25) BRACKET NUT PIN-Dowel SCREW (.312-18 x 2-1/2 IN.) SCREW (.312-18 x 2-3/4 IN.) WASHER SCREW (.375-16 x 1-1/4 IN.) ADAPTOR SCREW (M10 x 30) WASHER SCREW (M10 X 35) DOWEL PIN

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

N·m

Drive Tight

70 70

8.0 8.0

70 155

8.0 17.6

155

17.6

155 155

17.6 17.6 18.4

24.9

25

34

25

34

LOWER UNIT — 6D-3

Jet 30 Water Pump Components 10

3 74

1 7

2 95

4 9 5 6 7

8

7

Loctite 271 Thread Locker

74

Loctite 405

95

2-4-C with Teflon

REF. REF NO. QTY. 1 4 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 10 1 11 1

11

TORQUE DESCRIPTION SCREW (M6 x 16) WATER PUMP ASSEMBLY SEAL–Water Tube WASHER KEY WASHER GASKET FACE PLATE IMPELLER WATER TUBE EXTENSION GASKET

6D-4 — LOWER UNIT

lb. in. lb. ft. 60

N·m 6.8

90-852572R02 NOVEMBER 2002

Notes:

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6D-5

Jet 40/45 Pump Assembly

7

Loctite 271 Thread Locker

95

2-4-C with Teflon

6D-6 — LOWER UNIT

90-852572R02 NOVEMBER 2002

Jet 40/45 Pump Assembly REF. REF NO. QTY. – 1 1 1 2 1 3 1 4 1 5 1 6 6 7 6 8 4 9 1 10 1 11 1 12 1 13 1 14 1 15 1 16 1 17 6 18 1 19 8 20 1 21 2 22 1 23 1 24 1 25 2 26 2 27 1 28 1 29 1 30 1

TORQUE DESCRIPTION JET PUMP ASSEMBLY (BLACK) HOUSING-Pump SHIFT LINKAGE KIT CAM REVERSE GATE WITH BUMPER HOSE-Lube STUD (.312-18 X 1.81 NUT SCREW (.312-18 X 1.0) IMPELLER HOUSING-Intake LINER DRIVESHAFT THRUSTWASHER BALL BEARING SLEEVE NUT WASHER KEY SHIM TAB WASHER SCREW (1/4-20 X .625) SCREW (.312-18 x 1.25) BRACKET NUT PIN-Dowel SCREW (M10 x 60) SCREW (M10 x 90) SCREW (M10 x 70) SCREW ((.375-16 X 2-3/4) WASHER

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

155 155 155

N·m

17.5 17.5 17.5

Drive Tight

70 70

8.0 8.0

155

17.5 25 25 25 22

34 34 34 35

LOWER UNIT — 6D-7

Jet 40/45 Water Pump Components

5

7

3 2 1 95

4 7 6

95

REF. REF NO. QTY. 1 1 2 1 3 1 4 1 5 1 6 1 7 6

2-4-C with Teflon TORQUE DESCRIPTION IMPELLER KEY WATER PUMP GASKET (UPPER) SEAL FACE PLATE SCREW

6D-8 — LOWER UNIT

lb. in. lb. ft.

60

N·m

6.7

90-852572R02 NOVEMBER 2002

Selecting A Boat That Is Best Suited For Jet Power

Engine Horsepower Selection

To obtain the best performance from the jet drive, the boat should have the following features:

A boat operating at slow speed requires considerably more depth than one which is planing on the surface of the water. It is important, therefore, to use sufficient horsepower and not to overload your boat beyond its ability to plane. See the following table.

1. The boat should be as light as possible. 2. The boat should have hull and transom that is designed for use with a jet drive. 3. The boat should be at least 13 feet in length.

Engine Horsepower Selection The following table is based on experience obtained with sledtype boats using outboard jets. The gross weights shown includes the outboard, boat, people, and all the gear carried. For a given horsepower loading beyond these weights will give less than good performance.

220 200 180 160 140 HP

120 100 80 60 40 20 0 500

6

8 1000 12

14

16

18 2000 22

24

26 28 3000 32

34 36

Gross Weight — Lbs.

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6D-9

Transom Height of the Boat Outboards with jet drives will be mounted approximately 7 inches higher on the transom than propeller driven outboards. This requires outboards that have a 15 in. shaft length to be installed on boats having a 22 in. transom height and outboards that have a 20 in. shaft length to be installed on boats having a 27 in. transom height.

SETTING OUTBOARD MOUNTING HEIGHT ON BOATS WITH “V” BOTTOM HULLS 1. Measure the width of the leading edge on the water intake housing. Make a horizontal line on the transom up from the “V” bottom the same length as the width of the water intake housing.

If the boat transom is of insufficient height, and the outboard cannot be installed to the recommended height, contact the boat manufacturer for recommended procedure to build up the boat transom.

a

b

Locate Center Line of the Outboard Locate (and mark with pencil) the vertical centerline of boat transom.

a — Horizontal Line b — Water Intake Housing

2. Place (center) the outboard on the boat transom so that the transom brackets are resting on top of the transom. Temporally fasten the outboard to the transom using two C-clamps. 3. Position the outboard in a vertical position.

A

B

a C

4. Line-up a straight edge along the bottom of the boat with the horizontal line made in Step 1 and measure the distance between the horizontal line and top front edge of the water intake housing.

D

a — Centerline of Transom

Outboard Mounting Height The initial outboard mounting height setting will work good for most applications, however, because of different boat/hulls designs, the setting should be rechecked by test-running the boat. Refer to “Water Testing”. • Installing the outboard too high on the transom will

allow the water intake to suck in air and cause cavitation. (cavitation will cause the engine to overspeed in spurts and reduce thrust). This condition should be avoided by proper height setting.

a b a — Straight Edge b — Water Intake Housing

5. Raise the outboard up on the transom the distance measured in Step 4. Use a straight edge and recheck the mounting height. The top edge of the water intake housing should be lined up with the horizontal line made in Step 1.

• Installing the outboard too low on the transom will

allow excessive drag.

6. Fasten outboard to the transom at this height. 6D-10 — LOWER UNIT

90-852572R02 NOVEMBER 2002

Setting Outboard Mounting Height on Boats with Flat Bottom Hulls 1. Place (center) the outboard on the boat transom so that the transom brackets are resting on top of the transom. Temporarily fasten the outboard to the transom using two C-clamps. 2. Position the outboard in a vertical position. 3. Place a straight edge along the bottom of the boat as shown and measure the distance between the bottom of the boat and top front edge of the water intake housing.

When operating the boat, the outboard drive shaft should be vertical when planing or tilted toward the boat in order to provide a scooping angle on the water intake. Tilting the outboard out beyond a vertical position reduces the scoop angle and can cause impeller slippage and cavitation. If the angle of the boat transom does not allow the drive shaft to be positioned vertical a Wedge kit should be installed behind the transom brackets to increase the tilt-in angle.

NOTE: Slight cavitation in sharp turns and rough water is acceptable but excessive cavitation is harmful to the outboard and should be avoided. Test run the boat. If cavitation occurs (air enters the pump causing loss of thrust, engine over-speeds erratically). the first thing to try is lowering the outboard height 1/4 in. This can be accomplished by elongating the drilled mounting holes in the boat transom by 1/4 in. If cavitation still exists after lowering the outboard 1/4 in., it maybe helpful to seek advice from the boat manufacturer.

a b a — Straight Edge b — Top Edge of Water Intake Housing

4. Raise the outboard up on the transom the distance measured in Step 3. Use a straight edge and recheck the mounting height. The top edge of the water intake housing should be in line with the bottom of the boat as shown.

A number of other options are available to further reduce cavitation. 1. Water intake fin kit – Available from the Specialty Mfg. Co. for jet models 30 through 140. The purpose of these fins is to ram more water into the intake and shield the forward sides of the intake from the entrance of air. This kit will help reduce cavitation when running with the wind in a chop.

a a — Intake Fin Kit

5. Fasten outboard to the transom at this height.

Water Testing

Water Intake Fin Kit Part No.1186 for jet models 45 through 140 and Part No. 1185 for jet model 30 is available from. Specialty Mfg. Co. 2035 Edison Ave. San Leandro, CA 94577

Checking for Cavitation Making the initial outboard height setting should be close to the optimum setting for the outboard. However because of the hull design of some boats, obstructions or imperfections in the hull ahead of the water intake may require this setting to change in order to prevent cavitation at running speeds.

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6D-11

Checking for Cavitation (Continued) 2. Rough Water Plate – Using this type of plate may be helpful in reducing cavitation when running in windy rough water conditions where air is sucked-in the water intake when jumping waves. Install a 1/32 in. metal plate that extends from the hull bottom to the top of the water intake housing. This plate tends to reduce air intake, as well as, reduce spray.

4. Attach the brass barrel to the bracket with bolt and locknut. Tighten the bolt until it seats against the barrel, then back off the bolt 1/4 turn. Hold bolt from turning, and tighten locknut on bolt. The barrel must be free to pivot.

c b a

a d a b c d

—

Shift Cable Shift Cam Barrel Roller

a — Rough Water Plate

Shift Cable Installation WARNING The shift cable must be adjusted to lock the reverse gate against unexpected engagement (caused by water pressure hitting the gate) while operating the boat in forward. Activation of the reverse gate will cause sudden unexpected stopping of the boat. Sudden stopping may cause occupants to be thrown within the boat or even out of the boat. This action may result in serious injury or death.

5. Recheck the shift cable adjustment in forward shift position. The correct shift adjustment will position the cam far enough on the roller in order to lock the reverse gate into forward position. You should not be able to forcibly push up the reverse gate toward neutral. Pull on the reverse gate by hand to verify this. IMPORTANT: The forward locking of the reverse gate must be met. If not, readjust the shift cable.

1. Attach shift cable to the shift cam with flat washer and locknut as shown. Tighten locknut against the flat washer, then back-off the locknut 1/4 turn. 2. Place remote control handle into full forward position. 3. Adjust the brass barrel on the shift cable so that roller is at the full end of travel (bottom) in the shift cam when the remote control is in full forward.

6D-12 — LOWER UNIT

90-852572R02 NOVEMBER 2002

Lubricating The Drive Shaft Bearing Recommended Lubrication — Use 2-4-C with Teflon. IMPORTANT: It is important that you do not use a general-all-purpose grease for this bearing. The lubricant we recommend is a water resistant grease of the proper consistency for this application. If you use a substitute grease, be sure that it is water resistant and of the same consistency.

Impeller Removal and Installation REMOVAL 1. Shift outboard to NEUTRAL (N) position. 2. Remove spark plug leads to prevent engine from starting. 3. Remove the water intake housing that is fastened with six bolts or nuts (used with studs).

Frequency of Lubrication — We recommend lubricating the drive shaft bearing after each day’s use and after every 10 hours of operation. After every 30 hours of operation, pump in extra grease to purge out any moisture.

a

b

c

a — Vent Hose b — Grease Gun c — Grease Exiting Vent Hose

4. Straighten the bent tabs on the impeller nut retainer and remove the impeller nut. 5. Pull impeller straight off the shaft. If the impeller is tight, use a hammer and block of wood to rotate the impeller (clockwise) on the shaft until the keyway is directly above the flat on the shaft. This will free the jammed key and allow removal.

Lubricating Procedure — Pull vent hose off the grease fitting. Pump in grease through the grease fitting (using the grease gun provided) until excess grease starts to exit the vent hose. Reconnect the vent hose (a) onto the grease fitting after greasing. After 30 hours of operation, pump in extra grease to purge out any moisture. Visually inspecting the purged grease at this time will give you an indication of conditions inside the bearing housing. A gradual increase in moisture content, indicates seal wear. If the grease begins to turn dark, dirty gray, the drive shaft bearing and seals should be inspected and replaced if necessary. Some discoloration of the grease is normal during the break-in period on a new set of seals.

90-852572R02 NOVEMBER 2002

b

a

a — Tab b — Nut

LOWER UNIT — 6D-13

INSTALLATION 1. Grease the drive shaft, shear key, and impeller bore. Place the plastic sleeve inside the impeller and install impeller, shear key, shims nut retainer, and impeller nut. Turn the nut tight on the shaft to remove any play between the impeller and shaft. If the tabs on the retainer do not line up with the flats on the nut, remove the nut and turn the retainer over and re-tighten the nut again.

3. After setting the impeller height, tighten the impeller nut snug with a wrench. Secure impeller nut by bending tabs against the flats on the impeller nut.

a

a a — Tabs

b c d e f a b c d e f

—

Plastic Sleeve Impeller Shear Key Shims Nut Retainer Impeller Nut

4. Reinstall the water intake housing with six bolts or nuts (used with studs). Check clearance around the impeller to make sure the water intake housing is centered and not rubbing against the liner. Torque mounting bolts to 100 lb. in. (11.2 N·m).

NOTE: If the outboard is used in salt water, apply Anti-Corrosion Grease around the entire mounting flange on the water intake housing and also to the threads on the six mounting bolts/nuts.

2. Temporarily reinstall the water intake housing in order to check for impeller clearance. The clearance between the impeller and liner should be 0.030 in. (0.8 mm). Shim washers can be transferred to either side of the impeller to raise or lower the impeller to the correct clearance setting. The water intake housing can be shifted side ways a small amount in order to center the liner.

.03 in. (.8mm)

6D-14 — LOWER UNIT

90-852572R02 NOVEMBER 2002

Steering Pull Adjustment

Worn (Dull) Impeller

The steering on some boats will have the tendency to pull towards starboard. This pulling condition can be corrected by using a pliers and bending the ends of the exhaust fins 1/16 in. (1.5mm) toward the starboard side of the outboard.

Do Not sharpen or alter the top side lifting angle

leading edge

Enlarged View

a Sharpen to a 1/32 in. (.8mm) radius by removing material from bottom side only

a — Exhaust Fins

Impeller Clearance Adjustment 1. The impeller should be adjusted so there is approximately 0.03 in. (0.8mm) clearance between the impeller edge and liner. Operating the jet drive in waters that contain sand and gravel can cause wear to the impeller blades, and the clearance will start to exceed 0.03 in. (0.8mm). As the blades wear, shims located in the stack outside of the impeller can be transferred behind the impeller. This will move the impeller further down into the tapered liner to reduce the clearance.

The intake of gravel through the pump can round off and wear the leading edges on the impeller. Some conditions you may experience from a worn impeller are (1) a noticeable performance loss, especially on acceleration, (2) difficulty getting the boat on plane, or (3) an increase in engine RPM at wide open throttle. Check the impeller blades occasionally for damage. Use a flat file to resharpen the leading edges as shown.

2. Check the impeller clearance by sliding a feeler gauge through the intake grate and measure the clearance between the impeller edge and liner. If adjustment is required, refer to “Impeller Removal and Installation”.

a

.03 in. (.8mm) a — Shims 90-852572R02 NOVEMBER 2002

LOWER UNIT — 6D-15

Flushing The Cooling System

2. Remove the liner. If the liner is tight, tap on the inner edge of the liner with a long drift punch through the intake grate.

Use Quicksilver accessory hose coupling Part Number 24789A1.

NOTE: Apply grease to the liner mounting bolt threads before assembly.

1. Remove plug and gasket and thread-in hose coupling.

3. Position the liner into the water intake housing. Line up one of the liner bolts and lightly thread it in. It may be necessary to tap or press the liner into the water intake housing to locate the liner for installation of the remaining bolts. Torque bolts to 100 lbs. in. (11.2 N·m)

2. Attach a water hose to the hose coupling. Turn on the water gently, start the engine, and run it at idle speed only. 3. Check for a steady stream of water flowing out of the water pump indicator hole. Continue flushing the outboard for 3 to 5 minutes; adjust water pressure if needed. 4. Stop the engine, turn off the water, and remove the hose coupling. Reinstall the plug and gasket.

4. Grind off the ends of any bolts that may extend beyond the inner liner surface.

Jet Drive Removal 1. Shift outboard to NEUTRAL (N) position and disconnect the shift linkage. 2. Remove spark plug leads to prevent engine from starting. 3. Remove the water intake housing that is fastened with six screws or nuts (used with studs).

a

b a — Plug and Gasket b — Hose Coupling

Liner Replacement

1. Mark the liner mounting bolts for reassembly into the same holes. Remove the bolts. 6D-16 — LOWER UNIT

90-852572R02 NOVEMBER 2002

4. Straighten the bent tabs on the impeller nut retainer and remove the impeller nut. 5. Pull impeller straight off the shaft. If the impeller is tight, use a hammer and block of wood to rotate the impeller (clockwise) on the shaft until the keyway is directly above the flat on the shaft. This will free the jammed key and allow removal.

b

a

a — Tabs b — Nut

6. Remove 5 bolts securing jet drive to drive shaft housing and remove pump.

a a

54165

b

a — Bolts (4) b — Bolt (1)

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6D-17

b. Impeller is glazed or melted (caused by insufficient water supply.)

Water Pump Removal and Installation

c. Rubber portion of impeller is not bonded to impeller hub.

Removal

1. Install face plate, gasket(s) and impeller key.

1. Remove water pump assembly as shown according to model size.

IMPORTANT: If impeller being installed has been previously used and vanes have taken a “set,” DO NOT INSTALL THE IMPELLER WITH THE VANES REVERSED FROM THEIR PREVIOUS “SET” AS VANE BREAKAGE WILL OCCUR SHORTLY AFTER UNIT IS RETURNED TO SERVICE.

Reassembling Water Pump to Jet Drive NOTE: Replace water pump cover if thickness of steel at discharge slots is 0.060 in. (1.524mm) or less, or if groove(s) (other than impeller sealing groove) in cover roof are more than 0.030 in. (0.762mm) deep.

2. Install impeller.

NOTE: Replace impeller if:

3. Install pump cover. Rotate drive shaft CLOCKWISE while pressing cover down over impeller.

a. Impeller blades are cracked, torn or worn.

30 Hp

NOTE: Apply a light coat of 2-4-C with Teflon to inside of pump cover to ease installation of cover over impeller.

4. Apply Loctite 271 to retaining screws (4) and torque to 60 lb. in. (6.8 N·m).

j

40/45 Hp

c

c 74

95

a

b

7

b 95

g

e

a

d i

d

e f

f g h

k a b c d e f g h i j k

—

Screw Water Pump Cover Assembly Seal Washer Key Washer Gasket Face Plate Impeller Water Tube Extension Gasket

6D-18 — LOWER UNIT

54258 a b c d e f g

—

Impeller Key Water Pump Cover Assembly Gasket Seal Face Plate Screw 7

Loctite 271 Thread Locker

74

Loctite 405

95

2-4-C with Teflon 90-852572R02 NOVEMBER 2002

Bearing Carrier Removal

Bearing Carrier Reassembly

1. Remove 4 bolts securing bearing carrier to jet drive.

Installing Lower Seals

a

Install seals into bearing carrier as follows: 1. Install O-ring seals into the top seats of the three passage holes. 2. Install spiral retaining ring into the inner ring groove. 3. Spread a film of grease around the inside bore of the seal surface before pressing in the seals.

a

54165

a — Bolts

Bearing Carrier Disassembly 1. Remove the large beveled snap ring from the bearing carrier. 2. Heat the bearing carrier with a torch only until you can barely touch it.

4. Press in the garter spring seal against the inner retaining ring as shown. Fill the garter spring cavity in the seal with grease. 5. Install spiral retaining ring into the outer ring groove. Align the notched ends of the retaining ring to straddle the small vent hole drilled in the ring groove. 6. Press in the outer seal against the retaining ring as shown. 7. Grease all the seal lips.

a

3. Hold the drive shaft vertical and bump the impeller end of the drive shaft against a wooden block causing the bearing carrier to slide down off the bearing. 4. Remove snap ring, press the ball bearing off the drive shaft. Leave the bearing thrust ring (located in the drive shaft groove) unless damaged. 5. Remove the seals and spiral retaining rings from the bearing carrier and the upper seal housing. 6. Clean all parts thoroughly and remove any burrs.

a

d

a

e

b c

d

c b a b c d e f

—

Snap Ring Bearing Carrier Ball Bearing Upper Seal Housing Snap Ring Thrust Ring

90-852572R02 NOVEMBER 2002

f

a b c d e f

—

e

f

O-rings Retaining Ring Spring Seal Retaining Ring Outer Seal The Notched ends of the Retaining Ring Must Straddle this Vent Hole

LOWER UNIT — 6D-19

Installing Upper Seals

Installing Drive Shaft Ball Bearing

1. Install spiral retaining ring into the inner ring groove of the upper seal housing.

1. If removed, install the bearing thrust ring into the groove on the drive shaft.

2. Spread a film of grease around the inside bore of the seal surface before pressing in the seals.

2. Install collar onto the drive shaft. Press the new ball bearing onto the drive shaft, pressing against the inner race only. Press collar over the thrust ring, locking it in its groove. Install snap ring into drive shaft groove below the bearing.

3. Press in the garter spring seal against the inner retaining ring as shown. Fill the garter spring cavity in the seal with grease.

a

4. Install spiral retaining ring into the outer ring groove. Align the notched ends of the retaining ring to straddle the small vent hole drilled in the ring groove.

b c b

a

5. Press in the outer seal against the retaining ring as shown.

d

6. Grease all the seal lips. 7. Grease the two O-ring seals and install them into the outer ring grooves.

c a b c d

—

d

Bearing Thrust Ring Collar Ball Bearing Snap Ring

Installing Drive Shaft 1. Lubricate the seals and inside bore of the bearing carrier. 2. Place the drive shaft (impeller end facing up) into a vise.

e

3. Heat the bearing carrier until it feels warm to the touch.

c

d

a

a b c d e f

—

4. Place the bearing carrier onto the drive shaft. Square up the inner bore with the ball bearing and push the bearing carrier down until it bottoms-out against the bearing. It may be necessary to lightly tap bearing carrier onto the bearing using a rubber hammer.

NOTE: Only a light pressing force is needed to press on the bearing carrier. It may be necessary to lightly tap the bearing carrier onto the bearing using a rubber hammer.

b f

Retaining Ring Spring Seal Retaining Ring Outer Seal O-rings The Notched ends of the Retaining Ring Must Straddle this Vent Hole

a

b

a — Bearing Carrier b — Drive Shaft 6D-20 — LOWER UNIT

90-852572R02 NOVEMBER 2002

5. Grease the upper seals and inside bore of the bearing carrier to ease entry of the seal housing.

Bearing Carrier Installation 1. Install the bearing carrier into the jet drive. Secure carrier in drive with 4 bolts. Torque bolts to 70 lb. in. (7.9 N·m).

6. Install the thrust washer against the ball bearing. 7. Install spacer, and the upper seal housing being careful not to damage the O-ring seals as they pass the snap ring groove. Only finger pressure should be necessary to push in the housing.

2. Fill carrier with grease, using the grease gun supplied with the jet drive. If using a hand lever gun, pump very slowly so as to not build up internal grease pressure and damage the seals or housing.

8. Install the beveled snap ring, beveled side facing up into the ring groove. Make sure the snap ring is fully seated into groove.

a

b

c

d

a b c d e

—

Snap Ring Upper Seal Housing Spacer Thrust Washer Bolts [Torque to 70 lb. in. (7.9 N·m)]

e

e

90-852572R02 NOVEMBER 2002

LOWER UNIT — 6D-21

Installing Jet Drive to Drive Shaft Housing 1. Apply a light coat of 2-4-C with Teflon to the drive shaft splines. DO NOT APPLY GREASE TO THE TOP OF THE DRIVE SHAFT AS THE GREASE WILL PREVENT THE DRIVE SHAFT FROM FULLY ENGAGING THE CRANKSHAFT AND DAMAGE TO THE POWERHEAD AND/OR GEAR CASE WILL RESULT.

5. Grease the drive shaft, shear key, and impeller bore. Place the plastic sleeve inside the impeller and install impeller, shear key, shims nut retainer, and impeller nut. Turn the nut tight on the shaft to remove any play between the impeller and shaft. If the tabs on the retainer do not line up with the flats on the nut, remove the nut and turn the retainer over and re-tighten the nut again.

2. Carefully slide jet drive into drive shaft housing while aligning drive shaft splines with crankshaft and the water tube with the water pump cover seal.

a

3. Secure jet drive to drive shaft housing with 4 bolts. Torque bolts to 25 lb. ft. (34.0 N·m)].

b c d e f

a a

a b c d e f

54165 a — Bolts [Torque to 25 lb. ft. (33.9 N·m)]

4. Secure aft end of jet drive to drive shaft housing with bolt and washer. Torque bolt to 22.5 lb. ft. (30 .5 N·m).

—

Plastic Sleeve Impeller Shear Key Shims Nut Retainer Impeller Nut

6. Temporarily reinstall the water intake housing in order to check for impeller clearance. The clearance between the impeller and liner should be 0.030 in. (0.8 mm). Shim washers can be transferred to either side of the impeller to raise or lower the impeller to the correct clearance setting. The water intake housing can be shifted side ways a small amount in order to center the liner.

a

.03 in. (.8mm) a — Bolt and Washer [Torque to 22.5 N·m)]

6D-22 — LOWER UNIT

90-852572R02 NOVEMBER 2002

7. After setting the impeller height, tighten the impeller nut snug with a wrench. Secure impeller nut by bending tabs against the flats on the impeller nut.

NOTE: If the outboard is used in salt water, apply Anti-Corrosion Grease around the entire mounting flange on the water intake housing and also to the threads on the six mounting bolts.

a a — Tabs

8. Reinstall the water intake housing with six bolts or nuts (used with studs). Check clearance around the impeller to make sure the water intake housing is centered and not rubbing against the liner. Torque mounting bolts to 100 lbs. in. (11.5 N·m).

90-852572R02 NOVEMBER 2002

9. Refer to “SHIFT CABLE INSTALLATION” page 12 and reinstall shift cable to jet drive.

LOWER UNIT — 6D-23

6D-24 — LOWER UNIT

90-852572R02 NOVEMBER 2002

ATTACHMENTS/CONTROL LINKAGE

7 A THROTTLE/SHIFT LINKAGE

Table of Contents Throttle Lever And Linkage 40/50 . . . . . . . . Throttle Lever And Linkage 55/60 . . . . . . . .

7A-0 — ATTACHMENTS/CONTROL LINKAGE

Page 7A-2 7A-4

90-852572R02 NOVEMBER 2002

Notes:

90-852572R02 NOVEMBER 2002

ATTACHMENTS/CONTROL LINKAGE — 7A-1

Throttle Lever And Linkage 40/50 21 20 22

2

16

18

12 3

95

10

11 9

19

8

17 95

95

13

5 1

14

6

7 4

15 95

95

29 28 29

33

28

25

27

33

25

23 27

24 30

26 23

95

33

Loctite 680 Retaining Compound

95

2-4-C with Teflon

A = ELECTRIC 7A-2 — ATTACHMENTS/CONTROL LINKAGE

95

32 31

A

13

B

B = HANDLE VERSIONS 90-852572R02 NOVEMBER 2002

Throttle Lever And Linkage 40/50 REF. REF NO. QTY. 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 10 1 11 1 12 1

TORQUE DESCRIPTION THROTTLE LEVER ADJUSTING SCREW JAM NUT PIN WASHER NUT ADJUSTING SCREW (M6 x 55) JAM NUT CAP BUSHING INSERT SCREW (M10 x 45)

13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

SWIVEL BUSHING SPRING WASHER SPARK ADVANCE LEVER SPARK ADVANCE ROD SWIVEL BASE ADJUSTING SCREW (M6 x 55) JAM NUT CAP SWIVEL BALL STUD SPRING (ELECTRIC) THROTTLE CAM SWIVEL BUSHING THROTTLE ROD WASHER NUT

30 31 32

1 1 1

WASHER (ELECTRIC) BRACKET-Throttle cable HANDLE VERSIONS SCREW (M6 x 16)

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

N·m

Drive Tight

Drive Tight but Joint must move freely

Drive Tight but joint must move freely

80

9.0

ATTACHMENTS/CONTROL LINKAGE — 7A-3

Throttle Lever And Linkage 55/60 21 20

2 3

16

18 22

95

12 11

9

10

8

19 17

95

95

13

5

16

1

6

7

14

4

15

95

28 27 25 33

26 24 29

33 95

13 23

95

Loctite 680 Retaining Compound 2-4-C with Teflon

7A-4 — ATTACHMENTS/CONTROL LINKAGE

90-852572R02 NOVEMBER 2002

Throttle Lever And Linkage 55/60 REF. REF NO. QTY. 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 10 1 11 1 12 1

TORQUE DESCRIPTION THROTTLE LEVER ADJUSTING SCREW (M5 x 35) JAM NUT PIN WASHER NUT ADJUSTING SCREW (M6 x 55) JAM NUT CAP BUSHING INSERT SCREW (M10 x 45)

13 14 15 – 16 17 18 19 20 21 22 23 24 25 26 27 28

2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

SWIVEL BUSHING SPRING WASHER SPARK ADVANCE LEVER ASSEMBLY SPARK ADVANCE LEVER SPARK ADVANCE ROD SWIVEL BASE ADJUSTING SCREW (M6 x 55) JAM NUT CAP SWIVEL BALL STUD SPRING THROTTLE CAM THROTTLE ROD WASHER NUT

29

1

WASHER

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

N·m

Drive Tight

Drive Tight but Joint must move freely

Drive Tight but joint must move freely

ATTACHMENTS/CONTROL LINKAGE — 7A-5

7A-6 — ATTACHMENTS/CONTROL LINKAGE

90-852572R02 NOVEMBER 2002

ATTACHMENTS/CONTROL LINKAGE

7 B TILLER HANDLE

Table of Contents Tiller Handle 40/50 . . . . . . . . . . . . . . . . . . . . . Tiller Handle 40/50 . . . . . . . . . . . . . . . . . . . . . Steering Handle Kit 55/60 . . . . . . . . . . . . . . . Steering Handle Kit 55/60 . . . . . . . . . . . . . . . Steering Handle Kit 55/60 . . . . . . . . . . . . . . . Tiller Arm/Shift Lever Removal . . . . . . . . . . . Tiller Handle Disassembly . . . . . . . . . . . . . . . Tiller Arm Reassembly . . . . . . . . . . . . . . . . . . Tiller Arm/Shift Lever Installation . . . . . . . . . Shift Link Rod Installation and Adjustment to Engine . . . . . . . . . . . . . . . . Throttle Cable Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . Co-Pilot Installation . . . . . . . . . . . . . . . . . . . . . Tiller Handle Installation . . . . . . . . . . . . . . . . . Wiring Harness Connection . . . . . . . . . . . . . .

7B-0 — ATTACHMENTS/CONTROL LINKAGE

Page 7B-2 7B-3 7B-4 7B-6 7B-8 7B-10 7B-12 7B-14 7B-17 7B-18 7B-19 7B-20 7B-21 7B-22

90-852572R02 NOVEMBER 2002

Notes:

90-852572R02 NOVEMBER 2002

ATTACHMENTS/CONTROL LINKAGE — 7B-1

Tiller Handle 40/50 1 2

5

3 4

8

6 95

9

7 95

10

95 95

26

95

11

27 30 29 32

28

12 13 14 15

33 24

17

16

31 25

23

18

19

20

22

21

95

2-4-C with Teflon

7B-2 — ATTACHMENTS/CONTROL LINKAGE

90-852572R02 NOVEMBER 2002

Tiller Handle 40/50 REF. REF NO. QTY. 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 2 9 1 10 1 1 11 1 12 1 13 1 14 1 15 1 16 1 17 1 18 1 19 1 20 1 21 1 22 1 23 2 24 1 25 1 26 1 27 1 28 1 29 1 30 1 31 1 32 1 33 1

TORQUE DESCRIPTION COVER KIT PULLEY CASE SCREW (10-16 x 1/2 IN. Self Tap) CABLE–Throttle CABLE–Throttle SLEEVE–Insulation SCREW (M8 x 1.25 Hex flange head) COVER–Side BUSHING ARM–Steering Handle (BLACK) ARM–Steering Handle (GRAY) RETAINER SCREW (M5 x 16 Hex Washer Head) SCREW (M6 x 1 x 25 Hex Head Cap) LOCK–Throttle SPRING KNOBS–Throttle TILLER TUBE DECAL (TURTLE/RABBIT) HANDLE–Throttle GRIP–Throttle Handle SWITCH–Stop SCREW (M10 x 110 Hex Head Cap) TAB WASHER CLIP–Cable Retainer SPACER BRACKET–Tiller WAVE WASHER BUSHING WASHER STOP SWITCH RETAINER LANYARD STOP SWITCH

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

20

N·m

2.3

16.5

35

22.4

4.0

35

47.5

ATTACHMENTS/CONTROL LINKAGE — 7B-3

Steering Handle Kit 55/60 95

22

26

27

28 30

23

29

2

25

21 25 18

3

19

7

2

24

20

16

1 13 11

36 14 32 35

33

34 4 95

12

6

17

9 31

5

8 10

15

9

7

95

2-4-C with Teflon (92-802859A1)

7B-4 — ATTACHMENTS/CONTROL LINKAGE

90-852572R02 NOVEMBER 2002

Steering Handle Kit 55/60 REF. REF NO. QTY. 1 1 1 2 2 3 1 4 1 5 1 6 1 6 7 1 8 1 9 2 10 1 11 1 12 1 13 1 14 1 15 1 16 1 17 1 – 1 18 1 19 1 20 1 21 1 22 1 23 1 24 1 25 2 26 1 27 1 28 1 29 1 30 1 31 1 32 1 33 1 34 1 35 2 36 1

TORQUE DESCRIPTION STEERING ARM (BLACK) STEERING ARM (GRAY) BUSHING GREASE FITTING HOUSING PLATE GASKET SCREW (10-16 x 1/2 IN.) SCREW (10-16 x 3/5 IN.) CLAMP SCREW (M5 x 40) WING NUT THROTTLE HANDLE/STOP SWITCH KIT STOP SWITCH DECAL-Throttle SCREW (10-16 x 3/8 IN.) GRIP J-CLAMP J-CLAMP THROTTLE CABLE KIT CONDUIT GUIDE TUBE BARREL SET SCREW (10-32) CABLE GUIDE ANCHOR SET SCREW (8-32) SCREW (M10 x 105) CAP WASHER WASHER SPACER THROTTLE TUBE ROLL PIN DRIVE WHEEL INSULATOR CABLE TIE NUT

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

N·m

Drive Tight

Drive Tight Drive Tight 40

4.5

Drive Tight

Drive Tight

Drive Tight 40 54.2

40

54.2

ATTACHMENTS/CONTROL LINKAGE — 7B-5

Steering Handle Kit 55/60 30 29

37 36

31

45

7

21 28

33 32

34

24

33

3

47

51

2 1

52 35

26 46

95

25

4 5

53

9

27 23

54

48

22

13 8

49

6

14 16

7

10

15 50

11

12

17

38 34

20 19 42 42 44

43

39

33

41 40 42 7 34

Loctite 271 Thread Locker

18

Special Lubricant 101

95

2-4-C with Teflon

33

Loctite 680 Retaining Compound

7B-6 — ATTACHMENTS/CONTROL LINKAGE

90-852572R02 NOVEMBER 2002

Steering Handle Kit 55/60 REF. REF NO. QTY. 1 1 1 2 1 3 2 4 2 5 2 6 1 7 1 8 1 9 1 10 1 11 4 12 1 13 1 14 1 15 1 16 1 17 1 18 1 19 1 20 1 1 21 1 22 1 23 1 24 1 25 1 26 1

TORQUE DESCRIPTION BRACKET (BLACK) BRACKET (GRAY) DECAL-Shift STUD (M10 x 58) TAB WASHER NUT STOP HARNESS CABLE MANUAL PLUG GROMMET COVER SCREW (10-16 x 1/2 IN.) HORN PLUG (MANUAL) STOP SWITCH POWER TRIM LANYARD RETAINER CABLE STUD (M10 x 2.12) NUT WASHER SHIFT LEVER (BLACK) SHIFT LEVER (GRAY) SCREW (M8 x 45) TAB WASHER BUSHING WASHER (PLASTIC) WASHER (BELLEVILLE)

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

35

N·m

47.5

Drive Tight

75

8.5

70

7.9

ATTACHMENTS/CONTROL LINKAGE — 7B-7

Steering Handle Kit 55/60 30 29

37 36

31

45

7

21 28

33 32

34

24

33

3

47

51

2 1

52 35

26 46

95

25

4 5

53

9

27 23

54

48

22

13 8

49

6

14 16

7

10

15 50

11

12

17

38

34

20 19 42 42 44

43

39

33

41 40 42 7

Loctite 271 Thread Locker

18 34

Special Lubricant 101

95

2-4-C with Teflon

33

Loctite 680 Retaining Compound

7B-8 — ATTACHMENTS/CONTROL LINKAGE

90-852572R02 NOVEMBER 2002

Steering Handle Kit 55/60 REF. REF NO. QTY. 27 1 28 1 29 1 30 1 31 1 32 1 33 1 34 1 35 1 36 1 37 1 38 1 39 1 40 1 41 1 42 3 43 1 44 1 45 1 46 1 47 1 48 1 49 1 50 51 52 53 54

2 1 2 1 1

TORQUE DESCRIPTION WASHER SHIFT ROD NUT ROD END BUSHING WASHER COTTER PIN DETENT ASSEMBLY SPRING STUD KNOB CO-PILOT LEVER BRAKE CO-PILOT DRIVER WASHER BRAKE DISC ARM (TOP) ARM (BOTTOM) HARNESS ASSEMBLY KEY SWITCH (See below for Keys) NUT DECAL-Trim TRIM SWITCH POWER TRIM NUT SWITCH ASSEMBLY SCREW CLAMP SCREW

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

N·m

Drive Tight Drive Tight

ATTACHMENTS/CONTROL LINKAGE — 7B-9

4. Release latch and remove throttle cable with grommet from bottom cowl.

Tiller Arm/Shift Lever Removal 1. Remove battery cables from battery.

b

a 51093

a — Rubber Grommet b — Throttle Cable 51084

5. Remove cotter key from shift rod. 2. Remove outboard cowling. 3. Remove nut securing throttle cable to engine. 55342

c a

b

55347

a — Tiller Handle b — Shift Rod c — Lower Cowl

6. Remove cover.

a a b c d

—

b

c

d

Throttle Cable Throttle Lever Washer Locknut

b

a

55340

a — Cover b — Screw (4)

7B-10 — ATTACHMENTS/CONTROL LINKAGE

90-852572R02 NOVEMBER 2002

7. Disconnect stop switch wire at bullet connector and screw securing ground wire.

a

9. Remove bolt and nut from tiller handle bracket.

b

55339

a

55336

a — Bolt b — Nut (Hidden)

a — Stop Switch Wire (Bullet Connector)

8. Remove plug from tiller handle bracket

10. Remove tiller handle, two (2) nylon bushings, stainless steel spacer and two (2) flat washers from bracket.

d

c

e

a b 55338 a — Plug

a a b c d e

90-852572R02 NOVEMBER 2002

—

51606

Tiller Handle Nylon bushing (2) Stainless Steel Spacer Washer (2) Bolt

ATTACHMENTS/CONTROL LINKAGE — 7B-11

11. Bend tab washer away form bolt securing shift lever and remove bolt and lever from bracket.

3. Cut sta-strap securing stop switch harness and remove screw from harness J-clip.

d c

a

b

a

b

51603 51606

a b c d

—

Tab Washer Bolt Shift Lever Bracket

a — Sta-Strap b — Screw

4. Remove stop switch and twist grip from tiller handle.

Tiller Handle Disassembly 1. Using a flat tip screwdriver, carefully pry/push rubber grip off tiller handle.

b

a

51603

b

a

51603

a — Grip b — Tiller Handle

a — Stop Switch b — Twist Grip

5. Remove throttle cable anchor screws and remove cable guide.

2. Remove screw from twist grip.

b a

51603

a

a — Screw 51602

a a — Anchor Screws b — Throttle Cable Guide 7B-12 — ATTACHMENTS/CONTROL LINKAGE

90-852572R02 NOVEMBER 2002

6. Remove allen screw from brass barrel and remove barrel.

9. Remove cover plate and gasket from tiller handle. 10. Remove bolt from throttle friction assembly.

c

a e

a

d

b

51602

b a — Allen Screw b — Brass Barrel

c 51604

7. Unscrew (counterclockwise) stainless steel conduit from tiller handle.

a b c d e

—

Cover Plate Gasket (below plate) Screw (4) Throttle Friction Assembly Bolt

11. Remove throttle arm, gear assembly and friction device from tiller handle. Slide gear cover and friction device off of the throttle arm.

d

c

a

a 51603

b a — Conduit

a b c d

8. Pull throttle cable from tiller handle.

—

51604

Throttle Arm Gear Assembly Friction Device Gear Cover

12. Drive out drift pin and remove throttle gear from throttle arm.

b

a

a

51604

51602

a — Throttle Cable 90-852572R02 NOVEMBER 2002

a — Gear b — Drift Pin ATTACHMENTS/CONTROL LINKAGE — 7B-13

6. Install gasket and cover plate over gear assembly. DO NOT OVERTIGHTEN attaching screws.

Tiller Arm Reassembly 1. Reinstall throttle gear on throttle arm and secure gear to arm with new drift pin.

c a

b

b

c

a 51602

a — Gear b — Drift Pin

51604

a — Cover Plate b — Gasket (Below Cover) c — Screw (4)

2. Apply a light coat of Special Lubricant 101 to gear teeth and inside of gear cover. 3. Slide cover and friction device onto throttle arm.

d

34

c

a

7. Rotate throttle arm so that twist grip attaching screw hole faces DOWN and gear drift pin faces UP. 8. Insert throttle cable (CURVED END FACING UP) into tiller handle gear assembly while rotating tiller arm counterclockwise.

a

b 34

a b c d

—

51604

Special Lubricant 101

Throttle Arm Gear Throttle Friction Device Cover

4. Install throttle arm assembly into tiller arm. 5. Torque friction device attaching bolt to 40 lb. in. (4.5 N·m)

a

51604

a — Gear Drift Pin (FACES UP)

51604

a — Bolt [Torque to 40 lb. in. (4.5 N.m)]

7B-14 — ATTACHMENTS/CONTROL LINKAGE

90-852572R02 NOVEMBER 2002

9. Retract throttle cable into gear assembly until approximately 17 in. (43 cm) extends from the tiller arm.

11. Slide brass barrel over throttle cable tube. Secure barrel to tube with allen screw approximately 3.5 in. (89 mm) from stainless conduit. DO NOT OVERTIGHTEN screw, as tubing may be crushed, binding throttle cable. Position barrel to face towards tiller handle.

a d b c 51604

a — Cable [Extends 17 in. (43 cm)]

10. Slide stainless steel conduit over throttle cable and thread into tiller arm until lightly seated. Rotate conduit counterclockwise one full turn from a lightly seated position.

a 51607

a b c d

—

Brass Barrel Tube Allen Screw Tiller Handle

12. Install throttle cable guide onto throttle cable. Secure guide to cable with anchor and two screws. Guide hole should face up.

a b a

c 51604

a — Stainless Steel Conduit

90-852572R02 NOVEMBER 2002

51602

a — Cable Guide b — Screws (2) c — Hole (Faces Up)

ATTACHMENTS/CONTROL LINKAGE — 7B-15

13. Position throttle arm slot to face stop harness exit hole in tiller handle. Route stop switch harness through twist grip, into throttle arm, and out through side of tiller handle.

15. Sta-strap harness to throttle arm.

CAUTION Allow enough slack in harness (rotate throttle grip in both directions) before securing harness to handle assembly with J-clip. 16. Attach harness to tiller arm with J-clip allowing enough slack in harness for full throttle rotation. 17. Attach sta-strap to end of harness sleeve.

a b

d

e

c a

51602

a b c d e

—

Slot Exit Hole Harness Twist Grip Stop Switch

b 14. Secure twist grip to throttle arm with attaching screw. 51603

a

a — Sta-strap b — J-clip

18. Install rubber twist grip by aligning ridges on plastic twist grip with grooves inside of rubber grip. 51603

a — Screw

NOTE: Applying a soapy water solution to rubber grip will ease installation.

b

a

51603

a — Ridges b — Grooves (Under Handle)

7B-16 — ATTACHMENTS/CONTROL LINKAGE

90-852572R02 NOVEMBER 2002

3. Reinstall plug.

Tiller Arm/Shift Lever Installation 1. Install shift lever with detent assembly to bracket.

g

f a

d c d a a b c d e f g

—

e 55338

b

a — Plug

55337

Bolt Tab Washer Washer Wave Washer (2) Shift Lever Bushing Detent Assembly

4. Connect stop switch wire at bullet connector and secure ground wire to handle with screw.

2. Install tiller handle with bushings to bracket. Secure in place with washers and bolt with nut. Tighten bolt, allowing tiller handle movement. Torque nut to 40 lb. ft. (54 N·m).

c

a

d

55339

e

a — Stop Switch Wire (Bullet Connector)

b

a a b c d e

—

51606

Tiller Handle Bushings (2) Stainless Steel Bushing Washers (2) Bolt

90-852572R02 NOVEMBER 2002

ATTACHMENTS/CONTROL LINKAGE — 7B-17

5. Install Cover.

Shift Link Rod Installation and Adjustment to Engine 1. Position shift handle to neutral. 2. Manually shift outboard (shift actuator lever) to neutral. Propeller turns freely in both directions. 3. Adjust shift link rod end to slip over shift actuator bolt with slight preload toward reverse. Install washer and locknut. 55342

b

a 55340

a — Cover b — Screw (4)

6. Install cotter key and components to shift rod.

a

c

b a

55347

a — Tiller Handle b — Shift Rod c — Lower Cowl

a b c d

—

b

c

d

Shift Cable End Actuator Stud Washer Locknut (Tighten until snug, then back off 1/4 turn)

4. Check shift link rod adjustment as follows:

7. Install throttle cable with grommet.

a. Place shift lever in “F” (forward) position. Propeller should rotate in a CLOCKWISE direction. If propeller does not rotate CLOCKWISE, length of link rod must be reduced and step “a” repeated.

b

b. Place shift lever in “N” (neutral) position. Propeller should rotate freely without drag. If not, length of link rod must be increased and steps “a” and “b” must be repeated. c. While rotating propeller, place shift lever in “R” (reverse) position. If propeller can rotate in either direction, length of link rod must be increased and steps “a” through “c” repeated.

a 51093

a — Rubber Grommet b — Throttle Cable

8. Proceed to “Shift Link Rod Installation and Adjustment to Engine” and “Throttle Cable Installation and Adjustment.” 7B-18 — ATTACHMENTS/CONTROL LINKAGE

d. Place engine shift lever in “N” (neutral) position. Propeller should turn freely in both directions. If not, length of link rod must be decreased and steps “a” through “d” must be repeated.

90-852572R02 NOVEMBER 2002

Throttle Cable Installation and Adjustment 1. Rotate throttle twist grip fully clockwise to stop “IDLE” position. 2. Back out set screw from throttle cable barrel until two or three threads are exposed.

4. Holding throttle lever against idle stop, adjust throttle cable to slip into upper hole of barrel receptacle with a very light preload of throttle lever against idle stop. Apply small amount of Loctite Grade “A” to threads of set screw. Tighten until snug, then an additional 1/8 turn. 55342

a

b

51077

a — Set Screw b — Throttle Cable Barrel

3. Place end of throttle cable guide over peg of throttle lever and secure with locknut and washer.

c

a

b

55342 a — Throttle Lever b — Idle Stop c — Barrel Receptacle

5. Secure barrel in place with barrel retainer.

b

a a b c d

—

c

d

Throttle Cable End Throttle Lever Washer Locknut (Tighten until snug, then back off 1/4 turn)

CAUTION DO NOT exceed 1/4 turn on set screw after it has bottomed-out.

a

51091

a — Barrel Retainer

6. Check preload on throttle cable by placing a thin piece of paper between idle stop screw and idle stop. Preload is correct when paper can be removed without tearing and still have drag on it. Readjust cable barrel if necessary. 7. Install Cowl.

90-852572R02 NOVEMBER 2002

ATTACHMENTS/CONTROL LINKAGE — 7B-19

3. Install brake disk and brake.

Co-Pilot Installation NOTE: To install Co-Pilot kit, tiller handle must be removed and battery cables disconnected.

c b

1. Install brake disk on swivel bracket. Position “bottom up” lever, brake disk and “top up” lever onto swivel bracket. Note location of pin (on steering arm) in relation to top and bottom levers as shown.

e c

a

b

d

a — Brake Disk (3) b — Brake c — Pin (Holds brake in place)

4. Lubricate driver surface with Special Lubricant 101. Install driver into handle and adjust until driver (flat) is flush with handle.

a b a b c d e

—

51094

51094

51093

b

Swivel Bracket Brake Disk Bottom Up Lever Top Up Lever Pin, Steering Arm

34

a 2. Double nut co-pilot stud and apply Loctite No. 35 to swivel bracket end of stud. Install until flush with bottom of swivel bracket. Stake stud in place as shown. Drive dowel pin from bottom of swivel bracket until flush with bottom of bracket. Remove nuts. 17

34

55343

Special Lubricant 101

a — Handle b — Driver (Flush to slightly recessed)

5. Install components to stud. Align hex of driver with hex in brake.

b 55344

b c

a c 28063

c 33

Loctite 680 Retaining Compound

a — Stud b — Stake Marks c — Dowel Pin (Driven through Bottom of Swivel Bracket)

7B-20 — ATTACHMENTS/CONTROL LINKAGE

a

5109

a — Handle b — Driver c — Plastic Washer

90-852572R02 NOVEMBER 2002

6. Holding components in place (lever facing forward), install lock nut and torque to 75 lb. in. (8 N·m).

2. Install tiller handle to studs with shift rod positioned through cowl opening as shown.

55345

a

c a

b

55347

a — Tiller Handle b — Shift Rod c — Cowl a — Locknut [75 lb. in. (8 N·m)]

3. Secure tiller handle assembly in place.

Tiller Handle Installation 1. Apply Loctite 680 Retaining Compound to threads (steering arm end) of tiller handle studs. Install with stud installer. Tighten securely.

c

b

a b

b 55348

33 33

a

Loctite 680 Retaining Compound

55346

a — Tiller Handle Assembly b — Tab Washer (bend tabs against flats of locknuts) c — Locknuts [Torque to 26 lb. ft. (35 N·m)]

a — Studs b — Steering Arm

90-852572R02 NOVEMBER 2002

ATTACHMENTS/CONTROL LINKAGE — 7B-21

4. Install rubber grommet to throttle cable and install into bottom cowl. NOTE: A light lubricant on grommet will aid in installation over shift rod.

a — Wiring Harness b — Rubber Grommet

3. Connect handle wiring harness at engine harness connector. 4. Reconnect battery cables.

b

b a (–)

a c (+) 51093

a — Rubber Grommet b — Throttle Cable c — Shift Rod 51084

5. Adjust shift link rod and throttle cable “Shift Link Rod Installation and Adjustment” and “Throttle Cable Installation and Adjustment” as required.

Wiring Harness Connection

a — Red Sleeve (Positive) b — Black Sleeve (Negative)

5. Adjust co-pilot tension by moving handle to port (loosen) or starboard (tighten). Locknut on co-pilot stud may have to be adjusted to attain desired tension on tiller arm.

1. Remove battery cables from battery. 2. Route wiring harness through rubber grommet. Note, light oil on rubber grommet will aid in wiring harness installation. 55335

b

MORE

LESS

55348

a

7B-22 — ATTACHMENTS/CONTROL LINKAGE

90-852572R02 NOVEMBER 2002

MANUAL STARTER

8

Table of Contents Page Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Starter Assembly (Manual) 40/50 . . . . . . . . . . 8-2 Starter Assembly (Manual) 55/60 . . . . . . . . . . 8-4 Rewind Starter Disassembly . . . . . . . . . . . . . . 8-6 Cleaning and Inspection . . . . . . . . . . . . . . . . . . 8-7 Rewind Starter Reassembly . . . . . . . . . . . . . . 8-7 Adjusting Rewind Spring Tension . . . . . . . . . . 8-8 Starter Interlock Cable Adjustment . . . . . . . . 8-10

8-0 — MANUAL STARTER

90-852572R02 NOVEMBER 2002

Specifications MANUAL STARTER ROPE

90-852572R02 NOVEMBER 2002

Length

66 in. (1676 mm)

MANUAL STARTER — 8-1

Starter Assembly (Manual) 40/50 5

18

6 3

36 13

37 11 34 35 10 9

4 15 14 16

1 2

8 17 7 8

12 9

19

24

20 25 21

95 95

22

23

26

27 28 29 95

95

31

30

32 33

2-4-C with Teflon

8-2 — MANUAL STARTER

90-852572R02 NOVEMBER 2002

Starter Assembly (Manual) 40/50 REF. REF NO. QTY. 1 1 2 1 – 1 3 1 4 1 5 2 6 2 7 4 8 8 9 8 10 4 11 1 12 1 13 1 14 1 15 1 16 1 17 1 – 1 18 1 19 1 20 1 21 1 22 1 23 3 24 1 25 1 26 1 27 2 28 2 29 2 30 1 31 1 32 1 33 1 34 1 35 1 36 1 37 1

TORQUE DESCRIPTION HANDLE RETAINER REST–Starter Handle REST SEAL SCREW (M6 x 30) SPACER BUSHING GROMMET WASHER NUT TIMING DECAL INTERLOCK CABLE SCREW (10 -16 x .625) WASHER COTTER PIN SCREW COTTER PIN RECOIL STARTER STARTER HOUSING SPRING INTERLOCK LEVER CAM RETAINER SCREW WASHER — SPRING SPRING STARTER SHEAVE SPRING CAM RETAINING RING STARTER ROPE SPRING CAM SCREW BUSHING RETAINING RING DECAL-Caution in gear idle DECAL-EPA Information

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

N·m

55

6.2

75

8.5

Drive Tight

Drive Tight

Drive Tight

135

15.3

MANUAL STARTER — 8-3

Starter Assembly (Manual) 55/60 5 26

18

6 3

13

36

4

1 2

34 35

15 14

10 9

16

8 7

17 11

12

8

9

19

24

20 25

95

21 95

22

23

26

Cyanacrylate Adhesive

95

2-4-C with Teflon

26

27 28 29

31

30

32 33

95

8-4 — MANUAL STARTER

90-852572R02 NOVEMBER 2002

Starter Assembly (Manual) 55/60 REF. REF NO. QTY. 1 1 2 1 3 1 4 1 5 2 6 2 7 4 8 8 9 8 10 4 11 1 12 1 13 1 14 1 15 1 16 1 17 1 – 1 18 1 19 1 20 1 21 1 22 1 23 3 24 1 25 1 26 1 27 2 28 2 29 2 30 1 31 1 32 1 33 1 34 1 35 1 36 1

TORQUE DESCRIPTION HANDLE ASSEMBLY RETAINER REST SEAL SCREW (M6 x 75) SPACER BUSHING GROMMET WASHER NUT INTERLOCK CABLE SCREW WASHER COTTER PIN SCREW COTTER PIN WASHER RECOIL STARTER STARTER HOUSING SPRING INTERLOCK LEVER CAM RETAINER SCREW WASHER — SPRING SPRING STARTER SHEAVE SPRING CAM RETAINING RING STARTER ROPE SPRING CAM SCREW BUSHING RETAINING RING DECAL-Full throttle timing

90-852572R02 NOVEMBER 2002

lb. in. lb. ft.

N·m

55

6.2

75

8.5 Drive Tight

Drive Tight

135

15.3

MANUAL STARTER — 8-5

Rewind Starter Disassembly

6. Remove cam retainer.

b

a

WARNING When disassembling and reassembling rewind starter, SAFETY GLASSES must be worn in case rewind spring uncoils out of the housing. 1. Remove retaining clip and attaching screw which secures shift interlock cable to starter housing. 2. Remove bolts (4) securing rewind starter to engine.

b

c

a c 28374

a — Screws (3) b — Cam Retainer

c

7. Remove cam lever, cam lever spring, and interlock lever.

c

a b 51606

c

a — Retaining Clip b — Screw c — Bolts (4)

3. Slowly pull the starter rope out from the handle rest approximately 2 feet (60 cm) and tie an overhand knot between the rewind housing and the handle rest. 4. Remove retainer from rope handle and untie the rope handle knot. 5. Remove the rewind starter.

a 28375

a — Cam Lever b — Cam Lever Spring c — Interlock Lever

b

a — Overhand Knot b — Retainer 8-6 — MANUAL STARTER

90-852572R02 NOVEMBER 2002

8. Remove starter sheave.

Cleaning and Inspection a

1. Clean components in solvent and dry with compressed air. 2. Inspect rewind spring for kinks, burrs, corrosion of breakage. 3. Inspect starter sheave, rope guide and starter housing for nicks, grooves, cracks, wear or distortion, especially area of rope travel. 4. Inspect bushing, starter drive pawl and spring for wear or damage. 5. Inspect starter rope for wear.

b

6. Replace components as necessary.

51605

a — Starter Sheave b — Screw

Rewind Starter Reassembly

9. Spring is replaced as a spring/cover assembly.

a

WARNING When reassembling rewind starter, SAFETY GLASSES must be worn in case rewind spring uncoils out of the housing. 1. Install spring/cover assembly into sheave.

a

51607

a — Spring/Cover Assembly

51607

a — Spring/Cover Assembly

90-852572R02 NOVEMBER 2002

MANUAL STARTER — 8-7

2. Install starter sheave to housing and secure in place with screw. Torque to 135 lb. in. (15.3 N·m).

4. Reinstall cam retainer and secure with screws (3).

a

a b

28374

b

51605

a — Screws (3) b — Cam Retainer

a — Starter Sheave b — Screw

3. Install interlock lever, position cam spring into recess of starter housing and reinstall cam lever.

a b

Adjusting Rewind Spring Tension 1. Rotate sheave, without rope installed, counterclockwise until it stops (coil is bound). Then back off one full turn, plus what is needed to align rope end with hole in starter sheave with hole in housing.

a

c

51605 28375

a — Sheave

a — Cam Lever b — Cam Lever Spring c — Interlock Lever

8-8 — MANUAL STARTER

90-852572R02 NOVEMBER 2002

2. Route starter rope through rope guide in housing. Tie an overhand knot in rope approximately 12 in. (305 mm) from end of rope.

5. Secure rewind starter to engine bolts (4), torque to 90 lb. in. (10 N·m). Secure interlock lock cable with retaining clip and screw.

a

b c

c

a

c

c

b d 51606

a — Sheave b — Tie Off Starter Rope 12 in. (305 mm) from End with Overhand Knot

a b c d

—

Retaining Clip Screw Bolts (4) Torque to 90 lb. in. (10 N·m) Bracket

NOTE: Check operation of rewind and rewind tension before outboard installation. 3. Place rewind starter on engine. 4. Pull starter rope through bracket, handle, and starter rope retainer. Secure starter rope to starter rope retainer with knot.

a b c d

a b c d

—

Starter Rope Bracket Handle Starter Rope Retainer

90-852572R02 NOVEMBER 2002

MANUAL STARTER — 8-9

Starter Interlock Cable Adjustment IMPORTANT: Lubricate core wire of interlock cable with light oil prior to making adjustments. 1. While rotating the propeller shaft, place the gear shift lever into REVERSE. 2. Return the gear shift lever to NEUTRAL without going past neutral detent. 3. Place end of interlock cable over pin of cam lever and secure with retaining pin. 4. Secure interlock cable to starter housing using adjusting screw. Do not tighten screw at this time. 5. Adjust interlock cable to align raised mark of cam lever with pointer of rewind housing.

c

a d

b e

28376

a b c d e

—

Interlock Cable Retaining Pin Adjustment Screw Raised Mark of Cam Lever Pointer of Rewind Housing

6. Tighten cable adjustment screw and check adjustment after 4 or 5 shift cycles.

8-10 — MANUAL STARTER

90-852572R02 NOVEMBER 2002