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Troubleshooting

1. Index QUEE 90 12934 2 1097 TROUBLESHOOTING 1C 31 Drive Unit Will Not Stay In Full OUT UP Position For Extended Periods 1 External leakage 1 Check for cause and correct Add oil to pump 1 and bleed trim system E 2 Test as explained following Replace valve body and gear assembly Also check trim cylinders 7 internally for internal leakage Drive Unit Will Not Stay In Trimmed OUT UP Position When Underway 1 Airin trim system 1 Check for cause of entry Fill and bleed system 2 External leakage 2 Check for cause and correct Add oil to pump and bleed trim system Pump OUT UP circuit leaking internally 3 4 3 Test as explained following Replace valve body 5 and gear assembly Drive Unit Trails OUT UP on Deceleration or When Shifting into Reverse Unit Thumps When Shifting 1 Air in trim system 1 Determine cause for air entry and correct Add oil to pump and bleed trim system 2 Trim cylinder s 7 leaking internally 2 Test as explained following Replace or rebuild cylinder s 7 aS necessary 3 Trim pump IN DOWN circuit 3 6 9 leaking Test as explained following internally Oil Foams Out of Pump Vent Screw 1 Contaminated oil 1 Flush system with clean oil refill pump and bleed trim system 2 Oil level low 2 Check for cause of low oil level and correct Add oil to pump 1 and bleed system Index QUEE 1C 32 TROUBLESHOOTING 90 12934 2 1097
2. 5 Armature faulty 5 Test and replace if bad 6 Field and frame faulty 6 Test and replace if bad 7 Pump gears frozen 7 Replace pump adaptor 8 Disconnect blue white lead 2 from solenoid 8 Trim harness shorted between UP and DOWN terminal If pump motor will now run in the Circuit DOWN direction a short in the harness is indicated Index QUEE 1 18 TROUBLESHOOTING 90 12934 2 1097 Pump Motor Will Not Run Up Or Down In Either Manual Or Auto Mode Solenoids Do Not Click 1 Pump negative battery cable loose corroded or 1 Check cable 13 for a loose or corroded damaged connection or damage 2 wiring harness is loose B comedor 3 Connect a jumper wire between terminals 1 and 7 If pump now operates circuit breaker is faulty and field and frame assembly must be replaced 3 Faulty thermal circuit breaker in pump motor With ignition switch in Run position and mode switch in Manual mode check for voltage at terminal 8 while trimming UP and terminal 12 while trimming DOWN If no voltage is indicated refer to items 5 and 6 immediately following 4 Opencircuit in mode switch wiring harness Check for voltage at terminal 25 with ignition switch in Run position If no voltage is indicated check power lead for a poor connection 5 No power to mode switch Check for voltage at terminal 24 with mode switch in Auto
3. Prestolite Trim System Diagram gt LEES TROUBLESHOOTING 1C 33 N SM EN Oo N Y Oo Corrosion Protection Corrosion Of Underwater Parts Without Mercathode Or Current Protection Cause Remedy 1 Sacrificial anode s consumed 1 Replace anode s when 50 consumed 2 Add Mercathode impressed current protection 2 Stainless steel propeller installed or additional sacrificial anodes 3 Remove anode s clean contact surface 3 Sacrificial anode s not grounded to drive reinstall check continuity 4 Loss of continuity between underwater parts amp 4 Provide good ground connections ground 5 Shore power causing overload of anode s 5 Disconnect shore power or install Quicksilver or Mercathode isolator 6 Prime and repaint and or install additional 6 Paint on drive heavily abraded exposed metal anode s 7 Sacrificial anode s painted 7 Remove paint or replace anode s 8 Leave drive down install additional anode below water line or transom mount a 8 Drive tilted so far that anode s are out of the water Mercathode 9 Provide good ground to drive All parts must be 9 Only power trim cylinders corroded grounded 10 Corrosion in area of exhaust outlets exhaust 10 Remove deposits with marine or auto wax deposits can cause corrosion 11 Corrosion occurring after unit removed from 11 Wash exterior and flush int
4. 80 mm with 15 20 Ib 6 8 9 kg load applied to the cable end guide Models with Shift Assist This measurement can be taken by installing the remote control shift cable and using the shift assist assembly provided to place the proper load on the shift cable drive unit shift cable should not be installed Models without Shift Assist This measurement can be taken by lightly pushing and pulling on the re mote control shift cable end guide to place the prop er load 15 20 Ib 6 8 9 kg on the shift cable 1 Place remote control into gear as follows Right Hand Rotation Drive Unit forward gear wide open throttle position Left Hand Rotation Drive Unit reverse gear wide open throttle position Place a mark on threaded tube against edge of cable end guide 90 12934 2 1097 2 Place remote control into the opposite gear from that established in step 1 Measure the distance between the edge of the shift cable end guide and the mark in step 1 Total shift cable output must not be less than 2 7 8 in 73 mm or more than 3 1 8 80 mm If out put is incorrect remote con trol and or shift cable must be replaced With Shift Assist Assembly a Shift Assist Assembly b Remote Control Shift Cable Retracted c Edge of Cable End Guide Mark d Remote Control Shift Cable Extended e Measurement Taken from Mark to Edge of Cable End Guide 2 7 8 in 73 mm to 3 1 8 in 80 mm Index 90
5. 25 Power Trim System Troubleshooting Hydraulic System on Oildyne Trim Pump 16 26 Drive Unit Cannot Be Trimmed Out Up 16 26 Drive Unit Cannot Be Lowered From UD 9 tw Cte 1C 27 Drive Unit Will Not Stay In Full Up Position For Extended Periods 1C 28 Drive Will Not Stay In The Trimmed Out Up Position When Underway 1C 28 Drive Unit Trails Out Up On Deceleration Or When Shifting Into Reverse 1C 28 Oil Foams Out Of Pump Fill Vent Screw 1C 29 The Trim Pump Motor Runs But Does Not Pump Oil 1C 29 Power Trim Hydraulic Schematic 1C 30 Power Trim System Troubleshooting Hydraulic System on Prestolite Trim Pump 1C 31 Drive Unit Cannot Be Trimmed Out Up 16 31 Drive Unit Cannot Be Lowered From OUT UP Position 1C 31 Drive Unit Will Not Stay In Full Out Up Position For Extended Periods 1C 32 Drive Unit Will Not Stay In Trimmed Out Up Position When Underway 1C 32 Drive Unit Trails OUT UP on Deceleration or When Shifting into Reverse 1C 32 Oil Foams Out of Pump Vent Screw 1 32 Prestolite Trim System Diagram 1C 33 Corrosion Protection 1C 34 Corrosion Of Underwater Parts Without Merca thode Or Current Protection 1C 34 Corrosion On Underwater Parts With Merca thode Or Current Protection 1C 34 Co
6. Unattended 1 Faulty trim or trailer switch 1 Replace switch 2 a trim pump harness or trim control 2 Repair or replace as required Index QUEE 1 14 TROUBLESHOOTING 90 12934 2 1097 Power Trim BLK BLU BRN GRY GRN ORN PUR RED TAN WHT YEL LIT DRK GROUND BOLT FLOOR MOUNT U A I H lH H H H gg H H H H HH I 1110 AMP GRN WHT SOLENOID 22252 Wiring Diagram With 3 Button Trim Control Index QU TEL 90 12934 2 1097 TROUBLESHOOTING 1C 15 H id O3H SOLENOID X y 99 X eo em i 2 2 s T 7 j sh 2 v ED SOLENOID v LUN as o 26351 Power Trim Electrical System Wiring Diagram with 3 Button Trim Control Index QU TEL 1 16 TROUBLESHOOTING 90 12934 2 1097 27690 18 ZL TOYLNOD Wit H3MOd 3A331S Index 90 12934 2 1097 TROUBLESHOOTING 1C 17 Auto Trim Electrical System NOTE Refer to wiring diagram following for assistance in electrical system troubleshooting Pump Motor Will Not Run Up Or Down In Either Manual Or Auto Mode Solenoids Click 1 Pump positive battery cable connection loose or 1 Check cable 14 corroded 2 110 amp fuse blown or loose or corroded M SA Sas EON 2 Check for voltage at terminal 5 3 motor brushes stuck corroded or worn 3 enone 4 Armature commutator dirty 4 Clean or replace
7. and correct Add oil to pump and bleed trim system 3 Manual release valve 2 not completely closed 3 Close valve 2 completely 5 oses 5 6 reversed on one cylinder only 5 Connect hoses 5 6 correctly 6 Trim cylinder s 7 binding 6 Check for cause of binding bent piston rod 8 etc Repair or replace as necessary 7 Gimbal housing to trim pump hydraulic hoses 4 9 pinched 7 Replace hose 4 9 Drive Unit Cannot Be Lowered From OUT UP Position or Lowers with Jerky Movements 1 Air in trim system 1 Check for cause of entry Fill and bleed trim system 2 Insufficient pump IN DOWN pressure or shuttle 2 Test as explained following Replace valve body valve 3 stuck and gear assembly 3 Trim cylinder s 7 leaking internally 3 Test as explained following Rebuild or replace cylinder 7 as necessary 4 Trim cylinder s 7 binding 4 Check for cause of binding bent piston rod 8 etc Repair or replace as necessary 4 Insufficient pump pressure or pump shuttle valve 4 Test as explained following Replace valve body 3 stuck and gear assembly H 5 Gimbal housing to trim pump hydraulic hose 4 9 pinched 5 Replace hoses 4 9 5 6 6 Hoses 5 6 reversed on one trim cylinder only 6 Reconnect hoses correctly Me 7 Check for cause of binding bent gimbal ring c drive shaft housing etc replace
8. mount height or loose or soft Improperly installed or failed rear engine mounts This will affect engine alignment but usually is not detectable with engine alignment tool Boat transom too thin Thickness 2 in 51 mm minimum 2 1 4 in 57 mm maximum Boat transom thickness uneven This could affect engine to transom assembly alignment It is usually not detectable with alignment tool Variation 1 8 in 3 mm maximum Bell housing contacting gimbal ring This would cause knocking in the fully trimmed IN position only Index 90 12934 2 1097 mounts Make sure there is clearance between flywheel housing and fiber washer If no clearance exists mounts have probably sagged Install mounts correctly or replace as necessary Add thickness to transom Repair boat as necessary Check for soft or split trim cylinder bushings and loose or worn hinge pin bushings TROUBLESHOOTING 1C 5 Drive Shaft Housing Noise continued 20 Measure the distance between the engine 20 Stringer height uneven or transom assembly flywheel housing and the inner transom plate on installed crooked on boat transom This will affect engine alignment but is usually not detectable with alignment tool Weak boat transom or boat bottom that flexes under power and causes engine misalignment this condition will usually cause engine coupler failure Rear engine mount attaching hardware improperly installe
9. relief valve o Hoses reversed on one oylinder only 5 Connect hoses 7 and 8 correctly 6 Check for cause of binding bent piston rod 6 cylinder s binding scored cylinder etc Repair or replace as 4 Insufficient pump pressure or pump shuttle valve Stuck necessary 7 Qimbal housing to trim pump hydraulic hose gt iBasBcshoso 57 pinched 8 Up pressure relief valve has dirt particles under 8 Replace with a new valve kit check ball 9 Relief balls stuck in the up side of the pump 9 Replace the pump assembly in the adapter assembly 10 Dirt or foreign material under the up pressure 10 Replace the up pressure relief valve assembly relief valve 11 Check the condition of the oil it may be 11 Remove the reservoir and clean out the contaminated and thick like honey contaminated oil 12 A possible tight adaptor pump gear or water 12 Replace the pump assembly in the adaptor or oil in the motor replace the electric motor assembly Index 1 26 TROUBLESHOOTING 90 12934 2 1097 Drive Unit Cannot Lowered From Up Position Or Lowers With Jerky Movements Cause Remedy 1 Check for cause of entry Fill and bleed trim 1 Airin trim system System 2 Low oil level 2 Add oil 3 Damaged O rings on manual release valve if equipped 3 Replace valve 4 Test as explained in Testing Power Trim Pump Sec 5A If shuttle 1 is stuck replace 4 Ins
10. 12934 2 1097 50499 Without Shift Assist Assembly a Shift Cable End Guide b Remote Control Shift Cable Lightly Pull on End Guide c Place a Mark on Tube Against Edge of Cable End Guide d Remote Control Shift Cable Lightly Push In on End Guide e Measurement Taken from Mark to Edge of Cable End Guide 2 7 8 in 73 mm to 3 1 8 in 80 mm TROUBLESHOOTING 1C 43 Checking Cutout Switch Timing 1 Disconnect cutout switch white green wire from terminal block 2 Connect ohmmeter positive lead to cutout switch white green wire and ohmmeter negative lead to cutout switch black wire at terminal block 3 Set ohmmeter on Rx1 scale Wi 9 50497 Terminal Block Cutout Switch WHITE GREEN Wire C Cutout Switch BLACK Wire NOTE Refer to the end of this section for the pattern and dimensions needed to fabricate a similar tool 4 Slowly move cutout switch roller off of its seat Circuit should close full continuity reading when roller is moved 1 8 in 3 mm Use the 1 8 in rod on the end of special tool to gauge this movement 50497 Special Tool b 1 8 in 8 mm Index 1 44 TROUBLESHOOTING If switch closes too early less than 1 8 in 3 mm Roller must be bent away from its seat If switch closes too late more than 1 8 in 3 mm Roller must be bent toward its seat If necessary use special tool to bend lever as shown a
11. Full Up Position For Extended Periods 1 External leakage 1 Check for cause and correct Add oil to pump and bleed trim system 2 Damaged o ring on manual release valve if so 2 Replace valve and or close completely equipped or valve not closed completely 3 Test Replace adaptor 2 or attempt to repair by replacing the following e Thermal relief valve 4 e Pilot check valve or seals 9 3 Pump OUT UP circuit leaking internally 4 Trim cylinder s leaking internally and pump DOWN circuit leaking internally both must be faulty to cause this problem 4 Rebuild cylinders 5 Repair or replace adaptor 2 as required 5 Either Foreign Material under the poppet valve seat or a bad rubber seat on the face of the 5 Install an Overhaul Kit poppet valve Drive Will Not Stay In The Trimmed Out Up Position When Underway NOTE Use the following in conjunction with items mentioned under Drive Unit Will Not Stay In Full Up Position For Extended Periods 1 Air in trim system Check for cause of entry Fill and bleed system 1 2 Leaky shuttle poppet valve 1 2 Install repair kit for shuttle valve 1 Drive Unit Trails Out Up On Deceleration Or When Shifting Into Reverse Unit Thumps When Shifting 1 Test Rebuild or replace 1 cylinders s leaking internally cylinders as necessary 2 Test Replace adaptor or attempt to repair by replacing the foll
12. GENERAL INFORMATION TROUBLESHOOTING Index Table of Contents Page Troubleshooting 1C 1 Sterndrive Unit Troubleshooting 1C 1 Sterndrive Unit Will Not Slide Into Bell Housing 1C 1 Drive Unit Does Not Shift Into Gear Remote Control Shift Handle Moves 1C 1 Drive Unit Does Not Shift Into Gear Remote Control Shift Handle Does Not Move 1C 2 Drive Unit Shifts Hard 1 2 Drive Unit In Gear Will Not Shift Out Of Cal eT 1 3 Drive Unit Jumps Out Of Gear 1C 3 Gear Housing Noise 1C 3 Drive Shaft Housing Noise 1C 4 Performance Troubleshooting 1C 7 Low Full Throttle Engine RPM 1C 7 High Full Throttle Engine RPM 1C 7 Propeller Ventilating Cavitating 1C 7 Poor Boat Performance And Or Poor Maneuverability Bow Too Low 1C 8 Poor Boat Performance And Or Poor Maneuverability Bow Too High 1C 8 oteering System Troubleshooting 1C 9 Hard Steering Ride Guide Steering System n nn 16 9 Hard Steering Power Steering System 16 9 Power Steering System External Fluid Leaks 1 10 Power Electrical System 1C 11 Power Trim Pump Motor Will Not Run In The Out Up Or In Down Direction 1C 11 Power Trim Motor Runs In The Out Up Direction Not I
13. Lever b Roller C Special Tool 5 Once cutout switch is timed properly reconnect wires atterminal block and coat terminals with lig uid neoprene 50499 a BLACK Wires b WHITE GREEN Wires 6 Shift remote Control into gear as follows Right Hand Rotation Drive Unit reverse gear wide open throttle position Left Hand Rotation Drive Unit forward gear wide open throttle position 90 12934 2 1097 While shifting rotate propeller shaft clockwise Clutch should engage and cause propeller shaft to lock If clutch does not engage loosen adjustable stud on shift lever and move it upward in slot until clutch engages with gear Retighten stud Shift re mote control several times and ensure that shift cut out switch roller is still centered a Adjustable Stud b Shift Cutout Switch Roller Index 90 12934 2 1097 Checking Operation 1 Reconnect throttle cable s removed earlier 2 Place boat in water and start engine Check the following a Shift into forward and reverse gear making sure that clutch engages before engine be gins to accelerate b Accelerate engine in forward and reverse gear to ensure engine does not shut down c Check that shift cutout switch roller is cen tered in notch of shift cutout lever with drive unit in forward and reverse gear d Shifting from in gear position to neutral en sure drive unit is in neutral before remote con trol shift lever comes to neutr
14. Manual Mode Functions Properly 1 Open in control module battery cables or wiring 4 Check cables 16 and 18 and lead 20 harness 2 Check for voltage at terminal 24 and 25 with 2 Faulty mode switch switch in Auto mode If voltage exists at terminal 25 but not 24 switch is faulty 3 Faulty control module 3 Replace Index QUEE 90 12934 2 1097 TROUBLESHOOTING 1C 21 Pump Motor Will Run Down But Not Up In Auto Mode Manual Mode Functions Properly 1 Open circuit in control module sense lead 1 Check lead 17 in Figure 12 for loose or corroded connections or damage 2 Faulty control module 2 Replace Pump Motor Will Run Up But Not Down In Auto Mode Manual Mode Functions Properly 1 Check for voltage at terminal 21 and 22 while turning ignition switch to Run position in auto mode If voltage exists at 21 but not at 22 switch is faulty TCR 2 Check lead 19 for a loose or corroded 2 Open circuit in wiring connection or damage 3 Faulty control module 3 Replace Trim System Completely Inoperative In Manual Mode Auto Mode Functions Properly 1 Faulty mode switch 1 Check for voltage at terminal 26 with mode 1 Faulty mode switch switch in Manual mode If no voltage is indicated replace switch T 2 Check leads 27 and 33 for loose or corroded 2 Open circuit wiring h
15. al detent posi tion TROUBLESHOOTING 1 45 926089 pec ul I g 33116 L Ul OL L AA3IA dO L __ NMOHS SV QN38 J AQIS 331 9 L u 9L L _ b ut g L d d TOOL LNANLSNFaV HOLIMS LNOLND Qquvogaqavo tiddVd NOOLS OL 31 31 95 2 Q O I gt lt 58 Eg cO ki 90 12934 2 1097
16. arness connections or damage Index QUEE 1 22 TROUBLESHOOTING 90 12934 2 1097 In Down Switch Inoperative Manual Trim Control Out Up Switch and Trailer Switch Function Auto Mode Functions Properly Check for voltage at terminal 38 while trimming 1 Faulty IN DOWN switch in manual trim control IN DOWN in Manual mode If no voltage is indicated switch is faulty Check for voltage at terminal 23 while trimming IN DOWN If no voltage is present check leads 28 and 34 for a loose or corroded connection or damage Check for voltage at terminal 22 while trimming ae Pauly mode eile IN DOWN If no voltage exists switch is faulty Trim Out Up Switch And Trailer Switch Inoperative In Manual Trim Control Trim In Down Switch Operates Auto Mode Functions Properly Trim control 20 amp fuse if so equipped 43 Determine cause for blown fuse and correct blown before replacing fuse 2 Open in power supply lead to trim and trailer 2 Check voltage at terminal 44 If no voltage is switch indicated check lead 45 for a poor connection or damage 2 Open circuit in wiring harness Faulty trim OUT UP switch applies only to trim 3 Check for voltage at terminal 40 while controls where it is necessary to actuate trim actuating trim OUT UP switch Replace UP switch in order for trailer switch to function switch if no voltage is indicated Trim Out Up S
17. d battery Check the grounding wire between the drive and the controller 90 12934 2 1097 Corrosion Troubleshooting Procedures 1 Unplug shore power if equipped 2 Measure hull potential with silver silver chloride reference electrode and digital volt ohm meter Drive is corroding see DRIVE Below 850 millivolts CORRODING p 1C 35 Between 850 1100 millivolts Drive is protected Drive is overprotected see Above 1100 millivolts DRIVE OVERPROTECTED p 1C 37 READINGS oji Drive is corroding see DRIVE Below 750 millivolts CORRODING p 1C 35 Between 750 1050 millivolts Drive is protected Drive is overprotected see Above 1050 millivolts DRIVE OVERPROTECTED 1C 37 CORROSION SYMPTOMS e Paint blistering usually on sharp edges e Loosely adhering white corrosion products on exposed aluminum surfaces do not confuse these with tenaciously clinging calcium carbonate deposits e Aluminum pitting Index QUEE 90 12934 2 1097 TROUBLESHOOTING 1C 37 Shift System Troubleshooting NOTE Some models may be equipped with a shift assist assembly The only difference with these mod els is that the remote control shift cable attaching hardware is slightly longer Shift cable adjustment is the same as all other versions Checking for Excessive Play Checking the drive unit for excessive play in shift sys tem can be done with the boat in the water or on land Refer to appropriate proc
18. d connection 1e Gheesconnections and o In wing diagram Clean and or tighten as necessary 2 Check for battery voltage at terminal 3 while trimming OUT UP If no voltage is indicated replace solenoid 3 Solenoid faulty 3 Replace solenoid Index 90 12934 2 1097 TROUBLESHOOTING 1C 13 2 Open OUT UP circuit trim control or pump wiring harness 2 Open OUT UP circuit in trim control or pump wiring harness Control Out Up Switch Inoperative Trailer Switch Operates 1 Trim limit switch lead bullet connectors loose 1 Clean and or tighten connections 14 15 16 corroded and 17 in wiring diagram aS necessary Disconnect trim limit switch leads from trim harness Connect a continuity meter between leads 16 and 17 Continuity should be 2 Trim limit switch or leads faulty indicated with drive unit in full IN DOWN position If not check for damaged leads or poor connections If this is not the cause replace limit switch Check for a loose or corroded OUT UP circuit connection damaged OUT UP circuit lead or faulty OUT UP trim switch Repair or replace as necessary 3 Open in trim control OUT UP circuit Trim Control Trailer Switch Inoperative Trim Out Up Switch Functions Check for a faulty trailer switch loose or corroded Open trim control trailer circuit connections or damaged trailer circuit lead Trim System Functions While
19. d or missing Engine mounting holes drilled off center in inner transom plate engine supports or engine flywheel housing Misalignment between bell housing gimbal housing and engine coupler Index 16 6 TROUBLESHOOTING both sides If distances are uneven the problem may be due to uneven stringer height or a cocked transom assembly Adjust the stringer height or relocate the transom cutout as required This condition can sometimes be detected by having someone apply force to the top of the drive unit while watching the inner transom plate If movement can be observed the transom is weak and must be repaired Reinstall hardware correctly Make sure the holes are equally spaced fore and aft and are equal distance from the centerline Contact your regional service center and arrange to have a technical service representative check the unit using a special gauge 90 12934 2 1097 Performance Troubleshooting Low Full Throttle Engine RPM 4 Dirty or damaged boat bottom 4 Clean and or resurface boat bottom 5 Drive installation too low on transom Contact boat manufacturer for installation specifications 6 Permanent hook in boat bottom 6 Check for a hook in the boat bottom by placing a straight edge at least 6ft 2m long under the NOTE Some boats are built with a slight hook for bottom edge of the transom If a hook is correct boat performance found contact
20. de lead brown and the R terminal on the controller Mercathode system not functioning Index 1 36 TROUBLESHOOTING p Disconnect reference electrode lead brown from terminal on controller Connect the lead to the positive terminal of a digital multimeter set on 0 2000 millivolt scale Connect the negative meter lead to the negative battery terminal Note the meter reading then repeat the test with a test silver silver chloride reference electrode held behind the drive The same reading should be obtained in both cases If not replace the reference electrode Check controller output If the hull potential indicates overprotection remove the reference electrode lead from the controller if the controller is off no impressed current called for the voltage between the negative black and the anode should be less than 1 volt If your digital voltmeter can measure amperage with the reference electrode disconnected the amperage between the negative on the controller and the anode terminal should be less than 1 milliamp Replace the controller Disconnect electrical components one at a time and observe the multimeter reading until you eliminate the high reading see Troubleshooting Procedures Correct the source of the stray current Clean and or tighten the connection Repair wiring as needed Check the fuse in the hot lead Check battery Check for loose connections at controller an
21. dify transom cutout opening in turns 2 Determine cause for interference loose engine mounts transom too thin etc da correct as necessary 3 Propeller with untrue or out of balance blades 3 Repair or replace as required 4 Abnormal sterndrive operation Instruct operator on proper operating technique 2 Engine flywheel housing contacting inner transom plate or exhaust pipe 5 Make sure that proper thickness retaining rings U joint cross and bearing assembly retaining rings improperly installed are used and that rings are fully seated in u joint bearing cap grooves Excessive side to side play in u joint cross and 6 Replace cross and bearing assembly bearing assemblies Make sure proper cross and bearing assemblies are used If interference is noted replace center Socket U joint bearing caps contacting center socket or drive shaft housing bearing retainer 8 Disassemble cross and bearing assemblies and inspect DO NOT RELY ON FEEL Replace assemblies if they show signs of scoring galling roughness lack of lubricant etc U joint cross and bearings rough O rings missing or flattened out on u joint shaft causing shaft to rattle against ID of gimbal 9 Install new o rings bearing 10 Remove u joint coupling end yoke and insert into gimbal bearing and engine coupling Rotate shaft back and forth If play is excessive replace u joint coupling end yoke and or engine coupler as necessar
22. ds are corroded or not 7 Clean and lubricate lubricated 8 Shift cutout switch improperly adjusted or 8 Adjust or replace switch Inoperative 10 dh shaft bushing in bell housing or gear ousing corroded 11 Shift crank and or clutch actuating spool worn 12 Damaged shift shaft bushing 13 Bent upper intermediate or lower shift shaft s Index QU TEL 1C 2 TROUBLESHOOTING 90 12934 2 1097 Drive Unit In Gear Will Not Shift Out Of Gear 1 Shift cable broken 1 Replace cable and adjust 2 Cable end not connected in drive unit 2 Remove and reinstall drive unit 3 Remote control damaged 3 Repair or replace remote control 4 Internal shift mechanism damage 4 Repair or replace as necessary Drive Unit Jumps Out Of Gear 1 Shift cables improperly adjusted 1 Adjust shift cables Gear Housing Noise 1 Metal particles in drive unit lubricant 1 Disassemble clean and inspect and replace necessary components 2 Propeller incorrectly installed 2 Inspect mounting hardware Install propeller correctly 3 Propeller shaft bent 3 Inspect and replace if necessary 4 Incorrect gear shimming 4 wes gear housing backlash and pinion gear Worn or damaged gears and or bearings caused E Disassemble inspect feplace by impact overheating or improper shimming i Index QU TEL 90 12934 2 1097 TROUBLESHOOTING 1C 3 Drive Shaft Housing Noise Steering lever contacting transom cutout Mo
23. edure following Boat Out of Water Engine Off 1 Disconnect remote control shift cable a Shift Assist Assembly b Remote Control Shift Cable IMPORTANT If boat is equipped with A REMOTE CONTROL THAT HAS SEPARATE SHIFT AND THROTTLE LEVERS this shift assist assembly should NOT be used The use of the shift assist assembly with this type of remote control can cause the shift lever to move out of gear unex pectedly 71339 a Shift Lever b Throttle Lever Index 1C 38 TROUBLESHOOTING Later Models With Plastic Shift Lever a Remote Control Shift Cable b Plastic Shift Lever c Clevis Pin and Cotter Pin d Locknut and Washer Earlier Models With Metal Shift Lever a Remote Control Shaft Cable b Metal Shift Lever c Locknuts and Washers 90 12934 2 1097 IMPORTANT When pushing or pulling on drive unit shift cable in the following steps apply enough pressure so that shift cutout switch roll er starts to move off center of notch then ease up slightly Use a fine tip marking device to mark threaded tube to obtain an accurate measure ment a Shift Cutout Switch Roller 2 Check for excessive play in drive unit shift system as follows a Place drive unit into gear by pushing in on drive unit shift cable while simultaneously ro tating propeller shaft counterclockwise until shaft stops to ensure full clutch engagement b Place a mark on shift cable threaded tube again
24. ength cable long loops and long bends 3 Steering cable corroded or not lubricated 3 Lubricate or replace the cable 4 Ride Guide rack or rotary head not lubricated 4 Disassemble and lubricate Hard Steering Engine Running Power Steering System 1 Low power steering pump fluid level 1 Check fluid level 2 Loose power steering pump drive belt 2 Adjust belt tension 3 Airin system 3 Locate source of air in lines or fittings Correct and air bleed system 4 Fluid leak 4 Locate and correct source of leak 5 fthe above 4 steps do not solve the problem 5 Test power steering system test the power steering system Index QU TEL 90 12934 2 1097 TROUBLESHOOTING 1C 9 Power Steering System External Fluid Leaks 1 Pump reservoir leaking at fill cap reservoir too 1 full Remove fluid to bring to proper level 2 Locate source of air or water and correct Air may enter because of low reservoir fluid level or internal pump leak Test pump 3 Loose hose connections 3 Tighten hose connections 2 Pumpreservoir leaking at fill cap air or water in fluid Index QUEE 1 10 TROUBLESHOOTING 90 12934 2 1097 Power Electrical System Power Trim Pump Motor Will Not Run In The Out Up Or In Down Direction Solenoids Do Not Click IMPORTANT Refer to wiring diagram at end of this section for assistance in electrical system trouble shooting 1 Thermal circuit breaker in pump motor br
25. erior with fresh water saltwater Corrosion On Underwater Parts With Mercathode Or Current Protection Drive Corroding 1 Poor connection between reference electrode brown lead or anode orange lead and 1 Clean and or tighten connection Repair wiring Mercathode controller Index QUEE 1 34 TROUBLESHOOTING 90 12934 2 1097 Corrosion On Underwater Parts With Mercathode Or Impressed Current Protection Drive Corroding Continued 2 Disconnect reference electrode lead brown from the controller R terminal Connect the lead to positive terminal of a digital multi meter set on 0 2000 millivolt scale Connect negative meter lead to negative battery terminal Note meter reading then repeat the test with a test silver silver chloride reference electrode held behind the drive The same reading should be obtained in both cases If not replace the reference electrode 2 Faulty Mercathode reference electrode 3 With anode and reference electrode leads connected to controller connect a jumper wire between and terminals on controller Connect positive lead of volt meter set on 0 20 scale to A terminal on controller 3 Faulty Mercathode controller Connect the negative meter lead to the negative controller terminal Reading should be as follows e Freshwater Areas 11 5 volts minimum e Seawater Areas 3 55 volts minimum If the reading is low replace the cont
26. g or pulling on drive 5 unit shift cable in the following steps apply just e enough pressure so that shift cutout switch roll er just starts to move off center of notch then ease up slightly Use a fine tip marking device to r wh 154 6 S T N v mark threaded tube to obtain an accurate mea RE x TARN surement EXTA IT T ia ka d Throttle Cable End Guide b Carburetor Throttle Lever 3 Disconnect remote control shift cable a Shift Cutout Switch Roller Later Models With Plastic Shift Lever Remote Control Shift Cable Plastic Shift Lever Clevis Pin and Cotter Pin Locknut and Washer O OO 9 Index QU FEL 1 40 TROUBLESHOOTING 90 12934 2 1097 4 Check for excessive play in drive unit shift system as follows a Pushin on drive unit shift cable b Place a mark on shift cable threaded tube against cable end guide f WA LEMA A 1 w 50499 a Drive Unit Shaft Cable b Threaded Tube c Lightly pull on drive unit shift cable end guide and place another mark on threaded tube d Measure distance between both marks Distance should be 9 16 in 14 mm or less 50497 9 16 in 14 mm Or Less If play is 9 16 in 14 mm or less No further attention to drive unit is needed Proceed with adjustments If play is more than 9 16 in 14 mm Drive unit must be removed to further isolate e
27. in gimbal housing 4 Damaged u joint shaft splines and or engine 4 Inspect and replace if necessary coupler splines 5 Lower shift shaft not in forward gear position 5 Properly align shift shafts Bell Housing shift shaft not lined up 6 Bell housing shift shaft coupler not aligned 6 Place coupler in forward gear position Drive Unit Does Not Shift Into Gear Remote Control Shift Handle Moves Index QU TEL 90 12934 2 1097 TROUBLESHOOTING 1C 1 Drive Unit Does Not Shift Into Gear Remote Control Shift Handle Does Not Move 1 Control box not properly assembled 2 Broken or damaged linkage in control box 3 Controls improperly adjusted cable end guide 3 Adjust shift cables hitting brass barrel 4 Shift shaft or shift shaft lever jammed 4 Install shift crank properly 5 Shift cable not installed deep enough into bell 5 Install cable further into bell housing housing Drive Unit Shifts Hard 1 Shift cables improperly adjusted 1 Adjust shift cables 2 Damaged remote control or drive unit shift cable 2 Replace cable s and adjust 3 Shift cable too short sharp bends or too long 3 Select and install proper length cable loops and long bends 4 Corroded shift cables 4 Replace adjust and check for water leakage 5 Internal wear in remote control box 5 Repair as needed 6 Shift cable attaching nuts too tight end cannot 2 Properly install nuts pivot 7 Shift cable pivot en
28. mode and terminal 26 with switch in the Manual mode Replace switch if no voltage is indicated 6 Faulty mode switch Pump Motor Will Run Up But Not Down In Both Manual And Auto Modes Down Solenoid Does Not Click 1 Loose or Dirty solenoid connections 1 Check connections 4 7 and 12 2 Check for voltage at terminal 12 while trimming DOWN in Manual mode If no voltage is indicated repeat test at terminal 22 and 23 If voltage exists at terminal 23 but not at 22 switch is faulty If voltage is present at terminal 22 check leads 3 and 48 and connector 47 for an open condition 3 Faulty DOWN solenoid 3 Replace Index QU TEL 90 12934 2 1097 TROUBLESHOOTING 1C 19 2 Faulty mode switch or open in DOWN circuit Pump Motor Will Run Up But Not Down In Both Manual And Auto Modes Down Solenoid Clicks 1 Loose or dirty solenoid connections 1 Check connections 10 and 11 2 Check for voltage at terminal 11 while trimming 2 Faulty solenoid DOWN in Manual mode If no voltage is indicated replace solenoid 3 Faulty DOWN field winding 3 Replace field and frame Pump Motor Runs Down But Not Up In Both The Manual And Auto Modes Up Solenoid Clicks 1 Loose or dirty solenoid connections 1 Check connections 5 and 6 2 Check for voltage at terminal 6 while trimming UP If no
29. n The In Down Direction 1C 12 Power Trim Pump Motor Runs In Down But Not In The Out Up Direction 1C 13 Trim Control Out Up Switch Inoperative 1C 14 Trim Control Trailer Switch Inoperative 1C 14 Trim System Functions While Unattended 1C 14 Auto Trim Electrical System 1C 18 Pump Motor Will Not Run Up Or Down In Either Manual Or Auto Mode 1C 18 Pump Motor Will Run Up But Not Down In Both Manual And Auto Modes 1C 19 Pump Motor Runs Down But Not Up In Both The Manual And Auto Modes 1C 20 Pump Motor Will Not Stop Running Down In Auto Mode 1C 21 Pump Motor Will Not Run Up Or Down In Auto Mode 1C 21 Pump Motor Will Run Down But Not Up In Auto Mode 1C 22 Pump Motor Will Run Up But Not Down In Auto Mode 1 22 Index Page Trim System Completely Inoperative In Manual Mode 1C 22 Trim In Down Switch Inoperative In Manual Trim Control 1 23 Out Up Switch And Trailer Switch Inoperative In Manual Trim Control 16 23 Trim Out Up Switch Inoperative In Manual Trim Control 1C 23 Boat Is On Plane Well Before Drive Unit Begins To Trim Out 1C 24 Boat Is Not On Plane Before Drive Unit Begins To Plane Out 1C 24 Auto Trim II System Wiring Diagram 1C
30. oken 1 Replace commutator end plate assembly 2 Determine cause for blown fuse and correct before replacing fuse NOTE If fuse blows while trimming Out Up or raising drive unit problem may be due to grounded trim limit 2 20 amp fuse blown switch leads To check for grounded condition discon nect trim limit switch leads at bullet connector 14 15 16 and 17 in wiring diagram If drive unit can now be raised using Trailer switch trim limit switch or leads are grounded 3 Power trim pump battery cables or wiring 3 Clean and or tighten connections 1 2 4 harness connections corroded or lose 10 11 12 and 18 as necessary n ML 4 Clean and secure connection 13 as necessary Check for voltage at terminal 4 If no voltage is 5 110 amp fuse blown indicated determine cause for blown fuse and NOTE Does not apply to an intermittent problem correct then replace fuse Trimming OUT UP and IN DOWN simultaneously will blow fuse Check for battery voltage at terminal 8 while trimming OUT UP and at terminal 6 while trimming IN DOWN If no voltage is indicated check trim control for a loose or corroded connection or a damaged power supply lead in harness 6 Open circuit in trim control wiring harness Index QU TEL 90 12934 2 1097 TROUBLESHOOTING 1C 11 Power Pump Motor Will Not Run In The Out Up Or In Down Direction Bo
31. owing e Pilot check valves or seals 9 e Install trim pump rebuild kit 2 Trim pump IN DOWN circuit leaking internally Index QUEE 1 28 TROUBLESHOOTING 90 12934 2 1097 Oil Foams Out Of Pump Fill Vent Screw j oniaminaied 1 Flush system with clean oil refill pump and bleed trim system 2 Check for cause of low level and correct DN Add oil to pump and bleed system The Trim Pump Motor Runs But Does Not Pump Oil 1 Broken coupler between the pump and the 1 Replace the coupler motor Index QU TEL 90 12934 2 1097 TROUBLESHOOTING 1C 29 Power Hydraulic Schematic 1 Shuttle 2 Pump Adaptor 3 Out Up Pressure Helief Valve 4 Thermal Relief Valve 5 Trim Cylinder 6 IN DOWN Pressure Relief Valve 7 Out Up Hose 8 IN DOWN Hose 9 Pilot Check Valves 10 Gimbal Ring to Trim Cylinder IN DOWN Hose 11 Gimbal Ring to Trim Cylinder OUT UP Hose ate hatha M 4 x e Index 1C 30 TROUBLESHOOTING um 73552 403 T 90 12934 2 1097 Power System Troubleshooting Hydraulic System Prestolite Trim Pump Drive Unit Cannot Be Trimmed OUT UP Or Trims Slowly Or with Jerky Movements Numbers refer to callouts on the Oildyne Trim System Diagram P 1C 21 Cause Remedy 1 Power trim pump oil level low 1 1 Fd cause of low oil level and correct 2 Air in trim system 2 Check for cause of entry
32. rcuit wiring harness connection damaged IN DOWN circuit lead or a faulty IN DOWN trim switch Repair or replace as required 3 Solenoid faulty 3 Replace solenoid Index QUEE 1C 12 TROUBLESHOOTING 90 12934 2 1097 Power Motor Runs In The In Down Direction But Not In The Out Up Direction Both Trim And Trailer Switches Inoperative Out Up Solenoid Does Not Click 1 Loose or dirty solenoid connections 1 Check connections 8 and 9 Clean and or tighten as necessary 2 Check for battery voltage at terminal 8 while trimming OUT UP If no voltage is indicated check for a loose or corroded OUT UP circuit connection blown fuse if trim control is so equipped damaged OUT UP circuit lead or a faulty OUT UP trim switch Repair or replace as necessary 3 Solenoid faulty 3 Replace solenoid Power Trim Pump Motor Runs In The Out Up But Not In The In Down Direction In Down Solenoid Clicks Check connections 4 and 5 in wiring SU clone diagram and clean and or tighten as required 2 Check for battery voltage at terminal 5 while 2 Faulty solenoid trimming IN DOWN If no voltage is indicated replace solenoid 3 Faulty IN DOWN field winding 3 Replace field and frame assembly Power Trim Pump Motor Runs In The In Down Direction But Not In The Out Up Direction Both Trim And Trailer Switches Inoperative Out Up Solenoid Clicks 1 Loose or dirty solenoi
33. rim angle 2 Redistribute boat load to bow If stern overweight 2 Boat is stern heavy is caused by permanently installed fuel tank s etc contact the boat manufacturer 3 Propeller pitch too high 3 Water test the boat using a lower pitch propeller 4 Check for a rocker in the boat bottom by lacing a straight edge at least 6 ft 2m long NOTE Some boats are built with a slight rocker qnn winan ae of the p UA 9 for correct boat performance rocker is found contact the boat manufacturer 5 Dirty boat bottom 5 Clean boat bottom 4 Permanent rocker in boat bottom Index QUEE 1 8 TROUBLESHOOTING 90 12934 2 1097 Steering System 2 Remove clevis pin which secures piston rod end clevis to stern drive steering lever Troubleshooting 3 Turn steering wheel thru entire steering range If If Power Package is equipped with Power Steering steering difficulty is encountered problem is lo first determine if problem is caused by the Power cated in Ride Guide steering system or Ride Guide portion the steer If steering wheel turns with ease problem is located in Power Steering system Proceed as follows 1 Remove clevis pin which attaches steering cable to Power Steering unit piston rod end clevis Hard Steering Ride Guide Steering System 1 Damaged steering cable 1 Replace cable 2 Steering cable too short sharp bends or too 2 Select and install proper l
34. roller 4 Too much cathode such as stainless steel Mercathode system overpowered by large quantity of stainless steel below the water line 5 Loss of continuity between drive components 5 Ensure continuity check continuity wires and and ground washers 6 Sacrificial anodes consumed painted or 6 Replace anodes Inoperative 7 Mercathode reference electrode or anode 7 Remove paint or replace anode or Mercathode painted reference electrode 8 Connect positive lead of volt meter set on 0 20 volt scale to positive terminal on the controller and negative volt meter lead to negative terminal Meter should indicate battery voltage Check for blown fuse if so equipped on a standard Mercathode system Clean the connection or repair wiring as required 8 No power to Mercathode controller Check the fuse in the hot lead Check battery 9 Mercathode system not functioning Check for loose connections at controller and battery Check the grounding wire between the drive and the controller Index QU TE 90 12934 2 1097 TROUBLESHOOTING 1C 35 Corrosion On Underwater Parts With Mercathode Or Impressed Current Protection Drive Overprotected 1 Faulty Mercathode reference electrode Faulty Mercathode controller Stray current corrosion electrical current leaves a metal conductor and creates a path through the water Poor connection between the Mercathode reference electro
35. rrosion Troubleshooting Procedures 1C 37 Shift System Troubleshooting 1C 38 Checking for Excessive Play 1C 38 Isolating Excessive Play 1C 41 Checking Remote Control Shift Cable icu cp xl qo dud oaa Oe wie sir qd 1C 42 Checking Cutout Switch Timing 1C 44 Checking Operation 1C 45 90 12934 2 1097 Troubleshooting Effective troubleshooting is best enhanced by e Personal product knowledge and experience of This section is a guide for performance and product troubleshooting Referrals to specific sections of this manual are made where special tests or repair proce e Allowing adequate time for testing and analysis dures are to be performed e Utilizing these charts as a guide a starting Because of the relationship between Power Package point components engine and sterndrive it will be neces sary some cases to simultaneously refer to the appropriate Engine Service Manual for further trouble shooting information Sterndrive Unit Troubleshooting Sterndrive Unit Will Not Slide Into Bell Housing 1 U joint shaft splines not aligned with engine 1 Rotate propeller COUNTERCLOCKWISE coupler splines to align splines 2 Engine not aligned 2 Check engine alignment 3 Check engine alignment to determine if gimbal 3 Gimbal bearing not properly installed bearing is cocked or improperly installed
36. st edge of end guide w SS IN Qo a a 62 0 50499 22266 Drive Unit Shift Cable b Propeller Shaft c Threaded Tube Index 90 12934 2 1097 While maintaining pressure on propeller shaft in a counterclockwise direction to keep clutch locked with gear lightly pull out on shift cable end guide and place another mark on threaded tube d Measure distance between both marks Dis tance should be 9 16 in 14 mm or less a 9 16 in 14 mm or Less b Propeller Shaft If play is 9 16 in 14 mm or less No further attention to drive unit is needed Proceed with adjustments If play is more than 9 16 in 14 mm Drive unit must be removed to further isolate excessive play TROUBLESHOOTING 1 39 Boat In Water Engine Running e Atleast two people will be needed for the fol lowing procedure one person to check the adjustment and one person to stay at the con trol station of the boat e Ensure boat is secured to dock and precau tions have been taken to avoid damage to boat prior to placing drive unit into gear 1 Start engine and let it warm up Refer to operating procedures in Operation and Maintenance Earlier Models With Metal Shift Lever Manual a Remote Control Shaft Cable b Metal Shift Lever 2 Disconnect throttle cable s from carburetor s and Washers 8 7 q IMPORTANT When pushin
37. tch Index QUEE 1 24 TROUBLESHOOTING 90 12934 2 1097 Auto Il System Wiring Diagram BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN ORN ORANGE PNK PINK PUR PURPLE RED RED TAN TAN WHT WHITE YEL YELLOW LIT LIGHT DRK DARK GROUND BOLT FLOOR MOUNT MANUAL TRIM CONTROL AUTO TRIM MODE SWITCH Q5 ADJACENT GAUGE OR IGN TERMINAL OR IGNITION SWITCH BLU WHT CONTROL MODULE BLU WHT 22178 Index QUEE 90 12934 2 1097 TROUBLESHOOTING 1C 25 Power System Troubleshooting Hydraulic System on Oildyne Trim Pump NOTE The callouts eg 5 in the Hydraulic System troubleshooting section refer to the hydraulic schematic on page 1C 37 Drive Unit Cannot Be Trimmed Out Up Trims Slowly Or Trims With Jerky Movements Power Trim pump oil level low 1 Check for cause of low oil level and correct Add oil and bleed trim system 2 Air in trim system 2 Check for cause of entry and correct Add oil to pump and bleed air from system 3 O rings damaged on Manual Release Valve 3 Replace valve and or close completely if equipped or valve not completely closed 4 Test as explained in Testing Power Pump Sec 5A If shuttle 1 is stuck replace pump adaptor Sec 5A If pressure is low replace adaptor or attempt to repair by replacing the following components e OUT UP pressure relief valve e Thermal
38. th Solenoids Click 1 Check for battery voltage at terminal 5 in wiring diagram while trimming IN DOWN and at terminal 3 while trimming OUT UP If no voltage is indicated check connections 2 3 4 and 5 and or replace solenoids 2 eiie motor brushes stuck corroded or worn 2 Clean or replace as required 3 Armature commutator dirty 3 Clean or replace armature as required 1 Faulty solenoids or loose or corroded connections 6 Pump gears froze 6 Replace pump valve body and gear assembly 4 Test for shortened open or grounded condition 4 Armature faulty and replace if bad p 9 5 Check for open or grounded condition Replace 9 Field and frame faulty field and frame assembly if bad 7 Disconnect blue white lead from solenoid 7 Power trim pump harness or trim control terminal 8 If pump motor will now run in the harness shortened IN DOWN direction a short in harness exists Repair or replace harness as necessary Power Trim Motor Runs In The Out Up Direction But Not In The In Down Direction In Down Solenoid Does Not Click 1 Check connections 6 7 8 and 9 in 1 Loose or dirty solenoid connections wiring diagram and clean and or tighten as required 2 Check for battery voltage at terminal 6 while trimming IN DOWN If no voltage is indicated 2 Open IN DOWN circuit in trim control or pump check for a loose or corroded IN DOWN ci
39. the boat manufacturer High Full Throttle Engine RPM 1 Improper propeller pitch 1 Water test boat using a higher pitch propeller 2 Propeller hub slipping 2 Replace hub or replace propeller 3 Drive installation too high on transom 3 Contact boat manufacturer for installation specifications 4 Engine coupler hub slipping 4 Replace hub Propeller Ventilating Cavitating Index QU TEL 90 12934 2 1097 TROUBLESHOOTING 1C 7 Poor Boat Performance And Or Poor Maneuverability Bow Too Low 1 Improper drive unit trim angle 1 Properly adjust drive unit trim angle 2 Boat is bow heavy 2 HRedistribute boat load to stern If bow over weigh is caused by permanently installed fuel tank s etc contact the boat manufacturer 3 Boatis underpowered 3 Check horsepower to weight ratio Contact the boat manufacturer 4 Permanent hook in boat bottom 4 Check for a hook in the boat bottom by placing NOTE Some boats are built with a slight hook for e at 6ft 2m T correct boat performance the bottom eage the transom hook IS found contact the boat manufacturer 5 Power hook or weak boat bottom 5 Water test boat Boat will perform normally until hook develops at high speed then loss of RPM and speed will occur Contact boat manufacturer Poor Boat Performance And Or Poor Maneuverability Bow Too High 1 Improper drive unit trim angle 1 Properly adjust drive unit t
40. ufficient IN DOWN pressure or shuttle 1 pump adaptor Sec 5A If pressure 1 low valve stuck replace adaptor or attempt to repair by replacing the following item e IN DOWN pressure relief valve 6 5 Trim cylinder s block leaking internally 5 Test Rebuild or replace cylinder as necessary 6 Check for cause of binding Repair or replace 6 cylinder s S binding as necessary 7 Gimbal housing to trim pump hydraulic hose 8 or 7 pinched 7 Replace hose 8 or 7 8 Hoses 10 and 11 reversed on one trim 8 Reconnect hoses 10 and 11 correctly cylinder only 9 Drive unit binding in gimbal ring 9 Check for cause of binding and replace 10 Down Pressure relief valve 6 has dirt particles under check ball 10 Replace with a new valve kit 11 Foreign material under down pressure relief valve 11 Replace the down pressure relief valve assembly 12 Dirt or foreign material under the down pressure relief valve 12 Replace the down pressure relief valve assembly 13 Check the condition of the oil it may be 13 Remove the reservoir and clean out the contaminated and thick like honey contaminated oil 14 A possible tight adaptor pump gear or water or oil in the motor 14 Replace the pump assembly in the adaptor or replace the electric motor assembly 90 12934 2 1097 TROUBLESHOOTING 1C 27 Drive Unit Will Not Stay In
41. voltage is indicated replace solenoid 3 Faulty UP field winding 3 Replace field and frame Pump Motor Runs Down But Not Up In Both the Manual and Auto Mode Up Solenoid Does Not Click 1 Faulty solenoid 1 Replace solenoid 2 Faulty solenoid Index QUEE 1C 20 TROUBLESHOOTING 90 12934 2 1097 Pump Motor Will Not Stop Running Down In Auto Mode Out Up Switch And Trailer Switch Inoperative In Manual Mode NOTE An internal timer in the control module stops the pump motor 50 seconds after this condition occurs 1 Loose or dirty solenoid connection 1 Check connections 7 and 8 2 Check for voltage at terminal 8 while trimming UP in Manual mode If voltage exists an 2 Faulty solenoid open condition in solenoid is indicated and solenoid must be replaced If no voltage is indicated refer to steps 3 through 6 following 3 Loose or corroded trim limit switch lead 3 Check connections 32 and 36 connections 4 Disconnect trim limit switch leads 32 and 36 and connect a continuity meter between leads 4 Faulty trim limit switch Continuity should exist with drive unit in DOWN position If not readjust or replace switch as necessary 5 Check leads 30 35 46 and 2 for loose P OPen ruri s corroded connections or physical damage 6 Faulty control module 6 Replace Pump Motor Will Not Run Up Or Down In Auto Mode
42. witch Inoperative In Manual Trim Control Trailer Switch Operates Properly Auto Mode Functions Correctly 1 Faulty trim OUT UP switch applies only to 1 While actuating switch check for voltage at trim controls where it is not necessary to actuate output terminal Replace switch if voltage is trim UP switch in order for trailer switch to not indicated function not shown 2 Open circuit in wiring harness 2 Check leads 31 and 37 for loose or corroded connections or damage 3 Faulty control module 3 Replace Index 90 12934 2 1097 TROUBLESHOOTING 1C 23 Trailer Switch Inoperative In Manual Control Out Up Switch Functions Check for voltage at terminal 41 and 42 while actuating trailer switch If voltage exists at terminal 42 but not at terminal 41 a faulty switch is indicated If no voltage exists at terminal 42 check power supply lead for an open 2 Open in wirin 2 Check lead 39 for a loose or corroded e d connection or damage Boat Is On Plane Well Before Drive Unit Begins To Trim Out 1 Control module adjustment incorrect 1 Refer to SECTION 5 for adjustment procedure 2 Faulty control module 2 control module Boat Is Not On Plane Before Drive Unit Begins To Plane Out 1 Control module adjustment incorrect 1 Refer to SECTION 5 for adjustment 2 Faulty control module 2 control module 1 Faulty trailer swi
43. xcessive play Index 90 12934 2 1097 Isolating Excessive Play NOTE Refer to the end of this section for templates and patterns needed to fabricate similar tools 1 To determine shift shaft rotational end play use a tool such as the one shown to measure degrees of play in shift shaft with clutch locked and held in gear a Install tool as shown a Pointer Installed on Shift Shaft b Scale 1 Increments c Nut TROUBLESHOOTING 1C 41 b Rotate shift shaft coupler clockwise while si multaneously turning propeller shaft counter clockwise until clutch locks into gear Make note of pointer location on scale 50498 Shift Shaft Coupler b Pointer c Scale While maintaining pressure propeller shaft to keep clutch locked with gear lightly turn shift shaft coupler counterclockwise Make note of pointer location y J 50498 Shift Shaft Coupler b Pointer c Scale Index 1C 42 TROUBLESHOOTING d Determine total degrees of movement If 12 or less Problem is with the drive unit shift cable upper shift shaft assembly and lever assem bly If more than 12 Problem is with gear case shift spool assembly Whichever the case refer to appropriate section for repair of applicable components Checking Remote Control Shift Cable Output IMPORTANT Remote control must provide a shift cable travel at the shift plate end of 2 7 8 in 73 mm to 3 1 8 in
44. y Worn u joint shaft splines and or engine coupler splines 11 Adjust alignment making sure that alignment tool moves in and out of coupler freely After proper alignment has been obtained check for a cocked coupler by rotating engine coupler 1 2 turn and rechecking alignment If proper alignment is no longer observed coupler is crooked and must be replaced Engine alignment incorrect or engine coupler crooked Index 1 4 TROUBLESHOOTING 90 12934 2 1097 Drive Shaft Housing Noise continued 12 Replace gimbal bearing IMPORTANT Gimbal bearing and carrier MUST BE replaced as an assembly as they are a matched set Failure to do this may result in a loose bearing fit in carrier 12 Gimbal bearing rough 13 Reinstall bearing using a new tolerance ring if carrier is loose in gimbal housing If bearing is loose in carrier bearing assembly must be replaced Loose gimbal bearing Gimbal bearing not fully seated in gimbal housing Yoke moves back and forth when turning and may hammer against bearing if not fully seated 14 Drive bearing assembly into place IMPORTANT Gimbal bearing must be pressed in past lead in chamfer in bearing bore Excessive clearance between gimbal ring and gimbal housing This could cause misalignment between bell housing and gimbal housing and also may allow gimbal ring to vibrate up and down in turns 15 Check and adjust clearance Check for uneven

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