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1. 26 1 14 mi uvRbex owR 721711 1731711 pui uvRek pE sme _____ ___ _ _ SCREW M6 x 35 3 NON SEAPRO MARATHON 110 12 4 USA OG BEL amp UP iN 26 SCREW M6 x 20 NON SEAPRO MARATHON 3 SCREW 6 x 35 em TT USA 0G BEL amp BELOW WASHER 62x 255x 03 COMMERCIAL pL NUT M6 Nylon Insert ENGINES 110 12 4 79171 30 1 31 1 DECAL Caution Startin Gear REMOTE CONTROL f 732 i bECAL emegengstmrprcedues 90 826883R2 JUNE 1998 Page 8 3 MANUAL STARTER Rewind Starter Assembly Removal DO NOT turn or cock fuel filter assembly when removing Remove fuel filter by pulling straight down Turning or cocking fuel filter may break fuel line connec tion on filter 1 Pry fuel filter from starter rope guide DO NOT turn or cock filter pull straight down b Guide 2 Unsnap interlock link rod from lower lock lever a Link Rod b Lock Lever Page 8 4 90 826883R2 JUNE 1998 MANUAL STARTER 3 Remove 3 bolts and lift rewind starter from engine a Bolts b Rewind Starter Installation 1 Secure rewind starter to engine with 3 bolts Apply Loctite 242 to threads of 3 mount ing bolts Torque bolts to 110 Ib in 12 4 N m Loctite 242 92 809821 Bolts Torque to 110 Ib in 12 4 N m b Rewind Starter 90 826883
2. CAWFOUOWER E mE mE mE E mE mE mE M 5 5 5 2 3 Im Im OIL SEAL OUTER BOLT M10 x 35 THRUSTRUBASSENS mE mE UJ Im Ul NO gt N UU NO NO Un NO PROPELLER 1 PROP NUT 16 7 22 6 Slow E GEN LAEN KEEN EMEN ERE N 0 1 90 826883R2 JUNE 1998 Page 6A 9 GEAR HOUSING General Service Recommendations BEARINGS SEALS Page 6A 10 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 thatdisassembly is required for replacementof 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 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 All bearings must be cleaned and inspected Clean bearings with sol
3. a Grommet b Cables 53149 Page 2B 30 90 826883R2 JUNE 1998 Plug Harness Battery Charging Kit Installation BATTERY CHARGING AND STARTING SYSTEMS 1 Install plug harness through fuel fitting opening in bottom cowl 2 Route harness along PORT side of engine to rectifier al SEY hd P 2 gt a QN Sy 55515 2 53063 Harness 3 Refer to Section 2D for wiring connections Emergency Stop Switch Lanyard Type Installation 1 Route emergency stop switch wiring through opening in STARBOARD bottom cowl 53054 a Stop Switch 2 Secure stop switch into opening in bottom cowl using Clip a Clip 3 Refer to Section 2D for wiring connections 90 826883R2 JUNE 1998 Page 2B 31 TIMING SYNCHRONIZING ADJUSTING ELECTRICAL Section 2C Timing Synchronizing Adjusting Table of Contents Specifications 2 1 20 Jet 20 25 Models Non Marathon SeaPro 2C 10 Special ToolS 9 2C 2 Timing Synchronizing Adjusting Remote Control Timing Synchronizing m PP 2C 10 Adjusting Tiller Handle amp Side Shift Models 2C 3 Shift and Throttle Cable Installation to the Side Shift Models Adjusting Tiller Handle Outboard 2C 13 Cables m 2C 4 Shift Cable Installation 2C 14 Tiller Shift Models Adjusting Link Rod
4. 57083 a Transfer Covers Page 4 14 90 826883R2 JUNE 1998 POWERHEAD 9 Remove 4 bolts and 2 transfer covers Port Side 57085 Transfer Covers 10 Remove 6 bolts which secure crankcase cover to cylinder block n 57090 a Bolts 6 90 826883R2 JUNE 1998 Page 4 15 POWERHEAD 11 Use soft mallet to break seal between crankcase cover and cylinder block 57086 57087 4 16 90 826883R2 JUNE 1998 POWERHEAD Crankshaft 1 Remove cylinder block from crankshaft assembly aid 57088 2 Slide upper and lower roller bearings and seals off of crankshaft Discard seals 57089 a Crankshaft Seal Upper b Bearing c Crankshaft Seal Lower 90 826883R2 JUNE 1998 Page 4 17 POWERHEAD CENTER MAIN BEARING REMOVAL 1 Remove retaining ring from groove of center main bearing race 57092 a Retaining Ring 2 Remove center main bearing races and center main bearing halves Remove main bearing thrust washers 57093 Bearing Halves b Thrust Washers Page 4 18 90 826883R2 JUNE 1998 POWERHEAD PISTON AND ROD DISASSEMBLY Eye protection MUST BE worn while removing piston lockrings IMPORTANT Identify upper 1 and lower 2 pistons and connecting rods Store piston pin piston pin needle bearings locating washers connecting rod bearings rod caps and bolts together with corresponding pis
5. Wed 8 95 522444444444 Dive Ta CWASHER dipserew CT 2 SWITCH BOX 20 S USA 0G590000 amp UP SWITCH BOX J ET 20 S USA 0G589999 amp BELOW oo po SWITCH BOX 20 25 USA S N 0G437999 amp BELOW BEL S N 9926999 amp BELOW SWITCH BOX 20 25 USA S N 0G 438000 thru 0G 589999 BEL S N 9927000 thru 9973099 SWITCH BOX 20 25 USA S N 0G 590000 amp UP BEL S N 9973100 amp UP SCREW M5 x 20 P Drive Tigi ERMINAL BLOCK CREW terminal block 10 16x5 8 IN COMMERCIAL CREW terminal block 10 16x3 8 IN CREW M5x 8x30 hex head TA STRAP SPARK PLUG ZBP8H N 10 S S STATOR ASSEMBLY auxiliary S S gt R SPARK PLUG NGK BPZ8H N 10 CAN BELG 2 IGNITION COLASSEMBLY 2 CABLE ASSEMBLY Black gt NINININI N ININ el H ej 3 NO e N N e e N e e Nn el E Nol ol Nol N 90 826883 R2 JUNE 1998 Page 2A 5 IGNITION Ignition Description Page 2A 6 The ignition system Is an alternator driven capacitor discharge system Major compo nents of the ignition system are the flywheel stator trigger coil switch box 2 ignition coils and 2 spark plugs The flywheel has permanent magnets mounted in both the outer rim and the center hub The BLAC
6. 6A 15 SMM SINUS 6A 28 WaterPump 6A 16 Forward Gear Installation 6A 29 SHM SNA P 6A 18 Pinion and Driveshaft 6A 31 Drive Shaft and Pinion Gear 6A 18 Propeller 6A 31 Upper Drive Shaft and Bearing Seals 19 Bearing 6A 33 Lower Drive Shaft Bearing Cup 6A 20 Bearing Carrier P ropeller Shaft Installation 6A 34 Forward Gear Race 6A 20 Water PUMP 6A 35 Cleaning and Inspection 6A 21 Gear Housing Installation 6A 36 Gear Housing Bearing Carrier Castings 6A 21 Trim Tab Adjustment and Replacement 6A 41 cr 6A 21 Filling Gear Housing with Lubricant 6A 42 Needle 0 6A 21 Specifications Gear Ratio 2 42 1 Gearcase Capacity 7 8 fl oz 230 mL Lubricant Type Quicksilver Gear Lube P remium Blend Forward Gear Number of Teeth 29 Spiral B evel GEAR HOUSING Pinion Gear BIGFOOT 2 42 1 Number of Teeth 12 Spiral Bevel Pinion Height No Adjustment Forward Gear Backlash No Adjustment Water Pressure With Thermostat 9 950 rpm Idle 1 4 psi 7 28 kPa 5000 rpm WOT 6 9 psi 41 62 kPa 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
7. 4 52 Page 4 1 POWERHEAD Specifications HORSEPOWER Model 20 et 20 14 9 KW Model 20 20 14 9 Model 25 25 18 7 CYLINDER Type Two Two Cylinder Two Cycle TWO a BLOCK Displacement 24 4 cu in 400 cc STROKE Length 2 362 60mm 60 mm CYLINDER Diameter Diameter Standard 2 562 In 2 562in 65 0 mm 01 mm BORE Taper Out of Round Maximum 0 003 in 0 08 mm Bore Type S N 0G202749 and Below Chrome S N 0G202750 and Above 5 CRANK SHAFT Top Main Bearing J ournal 1 251 in 31 77 mm Center Main Bearing J ournal 1 000 in 25 40 mm Bottom Main Bearing J ournal 1 125 in 28 58 mm Connecting Rod J ournal 0 883 in 22 43 mm End Play 0 004 0 019 0 10 0 64 mm CONNECTING Piston Pin End L D 1 0 0 897 in 22 78 0 897 22 78 ROD Crankpin End I D 1 196 in 30 38 mm PISTON Piston Type Type O D at Skirt Standard 2 5583 2 5593 64 98 65 00 Ring End Gap 0 011 0 025 28 mm 64 mm PISTON DIA 2 5583 in 0005 in 64 98 mm 0127 mm Using a micrometer measure dimension A atlocation shown Dimension A should be 2 5583 in 0005 for Dimension a STANDARD size piston new Di 5 mension A will be 0 001 0 0015 less if coating is worn off piston used Models S N 0G202749 and Below NOTE The cylinder bores are chrome and cannot be be rebored o
8. 90 826883R2 JUNE 1998 Page 6B 9 JET DRIVE n Selecting A Boat That Is Best Suited For J et Power To obtain the best performance from the jet drive the boatshould have the following fea tures 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 atleast 13 feet in length Engine Horsepower Selection A boatoperating atslow speed requires considerably more depth than one which is plan ing 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 The following table is based on experience obtained with sled type 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 x LLL LL LLL 12 deb b pe 180 HP L 60 EET TT TTT 500 6 8 100012 14 16 18 2000 22 24 26 28 3000 32 34 36 Gross Weight Lbs Page 6B 10 90 826883R2 JUNE 1998 JET DRIVE 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 22 in transom height and outboards t
9. RPM 30 5800 R P M 25 20 1 6200 RPM 15 B T D C 1C 5 750 x50 Approx 3 5 B T D C 0 1000 2000 3000 4000 5000 6000 7000 Engine Speed RPM 90 826883 R2 JUNE 1998 Page 2A 11 IGNITION Ignition Test Procedures Direct Voltage Adapter DVA Page 2A 12 DANGER HIGH VOLTAGE SHOCK HAZARD Do nottouch ignition components and or metal test probes while engine is running and or being cranked STAY CLEAR OF SPARK PLUG LEADS To assure personal safety each individual spark plug lead should be grounded to engine When testing or servicing the ignition system high voltage is present DO TOUCH OR DISCONNECT any ignition parts while engine is running while key switch is on or while battery cables are connected i Failure to comply with the following items may result in damage to the ignition system 2 DO NOT reverse battery cable connections The battery negative cable is ground DO NOT spark battery terminals with battery cable connections to check po larity DO NOT disconnect battery cables while engine is running DO NOT crank engine with CDI or Ignition Coils not grounded 400 VDC test position or higher MUST BE used for all tests INSURE the Positive lead terminal of DVA is connected to the Positive re ceptacle of meter DO NOT CHANGE meter selector switch position while engine Is running and or being cranked ALL COMPONENTS
10. Service Manual Outline Specifications B Maintenance C General Information D Outboard Installation Powerhead oe id Section Section 5 Mid Section Section 6 Lower Unit Lower Unit Section 7 Attachments Control Linkage A Throttle Shift Linkage C Side Shift Section 8 Manual Starter Manual Starter 90 826883R2 JUNE 1998 Page iii Notice Throughout this publication Dangers Warnings and Cautions accompanied by the In ternational HAZARD Symbol A are used to alert the mechanic to special instructions con cerning a particular service or operation that may be hazardous if performed incorrectly or carelessly OBSERVE THEM CAREFULLY 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 A DANGER DANGER Immediate hazards which WILL result in severe personal injury or death WARNING Hazards or unsafe practices which COULD result in severe personal in jury or death 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
11. ohmmeter and perform the following tests RUN OFF NO CONTINUITY CONTINUITY 1 Ohm or Less 23421 3 If meter readings are other than specified replace emergency stop switch Push Button Stop Switch IMPORTANT Refer to Section 2D Wiring Diagrams for wiring connections 1 Disconnect push button stop switch leads from engine wiring 2 Use an ohmmeter and perform the following tests CONTINUITY Ohm or Less 42441 3 If meter readings are other than specified replace push button stop switch 90 826883R2 JUNE 1998 Page 2B 15 BATTERY CHARGING AND STARTING SYSTEMS Starter Motor Disassembly 1 Remove 2 thru bolts from starter a Bolts 2 Lightly tap on end of shaft and lower end cap with rubber mallet Do not loose brush Springs lt 53235 Lower End b Washers Bolts 3 Tapon drive end cap to loosen Remove end cap and armature from starter housing 4 f removal of parts that are installed on armature is necessary hold armature with Strap Wrench 91 24937A1 and remove locknut and discard from end of shaft i HELL th Kt 53081 Strap Wrench 91 24937A1 b Locknut discard Page 2B 16 90 826883R2 JUNE 1998 BATTERY CHARGING AND STARTING SYSTEMS 5 Remove parts from shaft 53228 Locknut Spacer Spring Drive Assembly e Drive End Cap f Armature Shaft g Helix Threads
12. 1 7 Battery Storage 1B 13 Specifications Gear Case Lubricant Capacity Gear Case EBT oz 260 070 Special Tools 1 Flushing Attachment 44357A2 90 826883R2 JUNE 1998 Page 1B 1 MAINTENANCE Quicksilver Lubricant Sealant 1 Quicksilver Anti Corrosion Grease P N 92 78376A6 QUICK SILV R ANTI CORROSION Page 1B 2 90 826883R2 JUNE 1998 MAINTENANCE Inspection and Maintenance Schedule Before Each Use 1 Check that lanyard stop switch stops the engine Visually inspect the fuel system for deterioration or leaks Check outboard for tightness on transom Check steering system for binding or loose components Visually check steering link rod fasteners for proper tightness D WN Check propeller blades for damage After Each Use 1 Flush out the outboard cooling system if operating in salt or polluted water 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 Every 100 Hours of Use or Once Yearly Whichever Occurs First 1 Lubricate all lubrication points Lubricate more frequently when used in salt water Inspect and clean spark plugs Check fuel line filter for contaminants Check carburetor adjustments if required Check corrosion control anodes Check more frequently when used salt water Drain and replace gear case lubricant Lubricate splines on the drive shaft
13. RED to either GRAY or YELLOW BLACK to GROUND NO CONTINUITY x 1000 90 826883R2 JUNE 1998 Page 2B 9 BATTERY CHARGING AND STARTING SYSTEMS Rectifier Test Disconnect battery leads from battery before testing rectifier NOTE Rectifier can be tested without removing from engine 07300 Rectifier Test continued Connect RED meter lead to ground BLACK lead alternately to terminals a and Continuity Indicated No Continuity Indicated Connect BLACK meter lead to ground RED Connect BLACK meter lead to ground RED lead alternately to terminals a and lead alternately to terminals a and No Continuity Indicated Continuity Indicated Connect BLACK meter lead to terminal b Replace Rectifier RED lead alternately to terminals a and No Continuity Indicated Continuity Indicated Replace Rectifier Connect BLACK meter lead to terminal b RED lead alternately to terminals a and c Continuity Indicated No Continuity Indicated Connect RED meter lead to termi Replace Rectifier nal b BLACK lead alternately to Continuity Indicated No Continuity Indicated Replace Rectifier Connect RED meter lead to termi nal b BLACK lead alternately to terminals a and c terminals a and c No Continuity Indicated Continuity Indicated No Continuity Indicated Continuity Indicated Rectifier tests O K Replace Rectifier
14. 1D 11 Installing Ride Guide Steering Cable to Placing Tilt Pin in Lower Holes 1D 11 the 1 4 Placing Tilt Pin in Upper Holes 1D 12 Steering Cable 5 10 4 Trim Tab Adjustment 1D 12 Steering Link Rod Installation 1D 5 Notice to Installer and Owner This manualas wellas safety labels posted on the outboard use the following safety alerts to draw your attention to special safety instructions that should be followed A DANGER DANGER Immediate hazards which WILL result in severe personal injury or death WARNING Hazards or unsafe practices which COULD result in severe personal injury or death CAUTION Hazards or unsafe practices which could result in minor injury or product or property damage Boat Horsepower Capacity U S COAST GUARD CAPACITY MAXIMUM HORSEPOWER MAXIMUM PERSON CAPACITY POUNDS XXX MAXIMUM WEIGHT CAPACITY XXX Do not overpower or overload your boat Most boats will carry a required capacity plate indicating the maximum acceptable power and load as determined by the manufacturer following certain federal guidelines If in doubt contact your dealer or the boat manufac turer 90 826883R2 JUNE 1998 10 1 OUTBOARD MOTOR INSTALLATION Using an outboard that exceeds the maximum horsepower limit of a boat can 1 cause loss of bo
15. Page 7 2 90 826883R2 JUNE 1998 E THROTTLE SHIFT LINKAGE Throttle and Shift Linkage Tiller Handle Shift TORQUE DESCRIPTION in Ib ft 5 5 5 3 1 SWITCH interlock SCREW MOxbgShexhdcap 10 NO LINK spark adjustment S N SOCKET USA 0G437999 amp BELOW NUT BEL 9926999 amp BELOW OTTLE CAM ASSEMBLY S USA 0G 286099 amp BELOW 1 PRIMARY LEVER BEL 9881099 amp BELOW 1 WASHER 62x 255x 03 Use w Ref 20 1 THROTTLE CAM ASSEMBLY S N LEVER gear shift USA 0G286100 thru 06437999 PRIMARY LEVER BEL 9881100 thru 9926999 I lt gt s 20 e e e N e e e e e e e el elel e lt Q D 4 ct WASHER Use w Ref 20 WASHER WAVE WASHER THROTTLE CAM S N SPRING USA 0G 438000 amp UP SPARK ARM BEL 9927000 amp UP TIMING LINK SECONDARY GEAR PRIMARY GEAR CREW CREW CREW 62x 03 90 826883R2 JUNE 1998 Page 7 3 A gt gt gt UJ GJ GJ GJ GJ GJ GJ GJ GJ GJ NO NO NO e e e e e hej e eje lt j Ol 1 Gol LJ N2 e LO 00 OY CO OY GI GW NI OY wI m m m NJ NJ NJ C A A m Kj U W Oo
16. 11 3 Page 2B 22 90 826883R2 JUNE 1998 BATTERY CHARGING AND STARTING SYSTEMS Neutral Start Switch Electric Start Tiller Handle Shift Models 1 Mount neutral start switch onto control platform with 2 bolts and plate 2 Torque mounting bolts to 5 Ib in 0 6 53077 a Neutral Start S witch b Plate c Bolts Torque to 5 Ib in 0 6 N m 3 Route switch harness over block Secure harness to stator harness with sta strap 4 Route harness behind rectifier Attach BLACK lead to solenoid mount bolt Attach Black lead with YELLOW sleeve to terminal 1 of starter solenoid Switch Harness b BLACK Lead c BLACK Lead with YELLOW Sleeve d Terminal 1 e Sta strap 90 826883R2 JUNE 1998 Page 2B 23 BATTERY CHARGING AND STARTING SYSTEMS Tiller Handle Start Button 1 The tiller handle start button assembly is secured to the tiller handle by 2 semi loops which snap fit onto the tiller throttle shaft To remove the button assembly pry the as sembly away from the tiller handle with a flat tio screw driver 2 The starter button harness is routed into the lower cowl through the fuel connector access hole 53216 a Start Button Assembly b Semi Loops c Harness d Fuel Connector 3 The starter button harness is routed down the PORT side of lower engine to cowl 4 RED harness lead 15 connected to the POSITIVE terminal of the rectifier Torque attaching nut to 25 Ib in
17. 2 8 24445 2 9 90 826883 R2 JUNE 1998 Ignition Switch 2A 9 Electronic Spark Advance 2A 11 Ignition Test Procedures 2A 12 Direct Voltage Adapter DVA 2A 12 Ignition Troubleshooting 2A 13 Ignition Diagnostic Procedures 2A 13 Ignition Troubleshooting 2A 15 Electronic Spark Advance 2A 15 Tool Multimeter DVA Tester 91 99750A1 2A 15 Ignition Troubleshooting 2A 16 Mechanical Spark Advance 2A 16 Ignition Troubleshooting RED Stator 2 17 2 1 IGNITION Specifications Type Capacitor Discharge Ignition Spark Plug Type NGK NGK BP8H N 10 Spark Plug Gap 0 040 in 1 0 mm Spark Plug Hex 18 mm Firing Order 1 2 20 J et 19941 THRU 1998 20 25 19941 THRU 1996 Electronic Spark Advance Idle 750 50 RPM In Forward Gear 4o 20B T D C Not Adjustable Fast Idle Speed 1400 RPM 250 RPM Maximum BTDC Running 25 1 9 5500 RPM Setup Timing 28 B T D C 3000 200 R P M Set up timing of 28 B T D C will be retarded to 25 B T D C 5500 R P M Stator High Speed Winding 100 180 W RED BLK Stator Low Speed Winding 2900 3500 W BLUE BLACK Diode Test 2800 3400 W RED BLUE Ignition Coil Resistance Primary 0 W Secondary w o Boots 850 1200 W
18. 2 Remove four 4 screws securing water pump to gear housing as shown in illustration a C entrifugal Slinger b Water Pump Mounting Screws 3 Remove cover nylon washers above and below impeller impeller and drive key from drive shaft 4 tis recommended that impeller be replaced whenever gear case is being serviced NOTE If impeller is not going to be replaced DO NOT install impeller in reverse rotation to its original state as vanes have taken a set Vanes will crack and break shortly after out board is returned to service Page 6A 16 90 826883R2 JUNE 1998 GEAR HOUSING 5 Remove face plate and base gasket 6 Remove shift shaft from housing a LE a lt b p 9 FEAS k K Si 1 lt lt Tm lt LK ES A Q N a TLLA L 7 TIT SSN 2 222 VEI 7A 2 56809 b Nylon Washer c Impeller d Nylon Washer e Key f S hift S haft g F ace Plate h Base Gasket NOTE Replace impeller if gt Impeller blades are cracked torn or worn gt Impeller is glazed or melted gt Rubber portion of impeller is not bonded to impeller hub 90 826883R2 JUNE 1998 Page 6A 17 GEAR HOUSING Shift Shaft ES 1 Pull shift shaft assembly from gear housing 2 Remove and replace outer O ring from shift shaft retainer a S hift S haft b Boot c Retainer d O r
19. 3 Pull out and remove horizontal shift shaft 57046 a Horizontal Shift Shaft Installation 1 Install horizontal shift shaft shift lever assembly into opening in STARBOARD side of crankcase cover 57046 a Horizontal Shift Shaft b Shift Lever 90 826883R2 JUNE 1998 Page 7A 15 THROTTLE SHIFT LINKAGE 2 Secure end of shift shaft to yoke of horizontal shift shaft with lever 57047 a Lever 3 Reinstall access cover and secure with nutand bolt Torque 50 Ib in 5 6 N m 57035 a Access Cover b Nut Torque to 50 Ib in 5 6 N m 4 Referto Control Platform Throttle Cam Control Lever previous and reinstall plat form shift link and throttle cam Page 7 16 90 826883R2 JUNE 1998 TILLER HANDLE CONTROLS Section 7B Tiller Handle Table of Contents Tiller Handle Assembly 7B 2 Removal 7B 5 Control Cables 7B 4 Installation 78 7 7B 4 Contuol Cabl6S 2 4525 7B 10 Tiller Handle Removal Disassembly 7B 5 Installation 7B 10 90 826883R2 JUNE 1998 Page 7B 1 TILLER HANDLE Tiller Handle Assembly Loctite 271 92 809820 2 4 C With Teflon 92 825407A12 Page B 2 90 826883R2 JUNE 1998 E TILLER HANDLE Tiller Handle Assembly TORQUE QTY DESCRIPTION Ib in Ib ft
20. 90 826883R2 JUNE 1998 Page 3B 7 POWERHEAD POWERHEAD Section 4 Powerhead Table of Contents Specifications 4 2 Special Tools 4 3 Cylinder Block and Covers 4 5 Crankshaft Pistons and Flywheel 4 7 Torque 4 9 Powerhead 4 10 Powerhead Disassembly 4 12 Cylinder 4 12 ecu mM ae bred ne hee 4 17 Powerhead Cleaning and Inspection 4 22 Cylinder Block and Crankcase Cover 4 22 Exhaust Manifold and Exhaust Cover 4 23 Cylinder Bore 4 23 lt 5 4 26 90 826883R2 JUNE 1998 5 Connecting Rod ITI Reed Block Bleed System Thermostat Powerhead Reassembly General Cylinder Powerhead Installation Set Up and Test Run Procedures 4 52 Break In Procedure
21. Electric start models Inspect battery eee du Remote control models Check control cable adjustments 10 Remove engine deposits with Quicksilver Power Tune Engine Cleaner 11 Check tightness of bolts nuts and other fasteners 12 Clean fuel tank pick up filter Every 300 Hours of Use or Three Years 1 Replace water pump impeller more often if overheating occurs or reduced water pressure is noted These items should be serviced by an authorized dealer 90 826883R2 JUNE 1998 Page 1 3 MAINTENANCE 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 a Quicksilver accessory or equivalent flushing attachment To avoid possible injury when flushing remove the propeller Refer to Propeller Replacement 1 Remove propeller referto Propeller Replacement Install the flushing attachmentso the rubber cups fit tightly over the cooling water intake holes Never start or run your outboard even momentarily without water circulating through the cooling water intake in the gear case to prevent damage to the water pump running dry or overheating of the engine 2 Attach a water hose to the flushing attachment Turn on the water and adjust the flow 50 water Is leaking around the rubber cups to ensure the engine
22. GASKET THERMOSTAT PLUG serial number STRAP SCREW M5x 8x16 GASKET exhaust manifold EXHAUST MANIFOLD GASKET exhaust manifold cover SCREW M6 x 1 x 40 eA m ST LO OTR 3 O eM ST LO CO CO OO eA LON WO LO C Stisr st st st 90 826883R2 JUNE 1998 Page 4 6 POWERHEAD Crankshaft Pistons and Flywheel AVERTISSEMENT ASSURER QUE LE LEVIE Loctite 271 92 809820 2 Cycle Outboard Oil 92 13249A24 2 4 C With Teflon 92 825407A12 A ELECTRIC START MODELS ONLY 90 826883R2 JUNE 1998 Page 4 7 E Crankshaft Pistons and Flywheel POWERHEAD TORQUE DESCRIPTION in Ib ft DECAL warning NOT A SERVICE PART F RING GEAR flywheel ELECTRIC S CREW M5x 8x13 OLLER BEARING upper 5 5 5 3 57 5 Im Im PISTON AND PIN ASSEMBLY LOCK RING piston pin USA S N 0G202749 amp BELOW PISTON RING BEL 09855586 amp BELOW PISTON RING Partof Ref 24 PISTON AND PIN ASSEMBLY STD PISTON AND PIN ASSEMBLY 030 O S LOCK RING piston pin USA S N 0G202750 amp UP PISTON RING ASSEMBLY STD BEL 09855587 amp UP N e N NIN 2 PISTON RING ASSEMBLY 030 0 5 PISTON RING
23. UJ THROTTLE SHIFT LINKAGE Control Cables Tiller Handle Shift Removal Installation Refer to Section 7B for removal and installation instructions Control Platform Removal Disassembly 1 Disconnect control cables from anchor bracket and pulley as outlined in Section 7B 2 Disconnect throttle link rod from ball joint of primary throttle lever SS Cables b Bracket Pulley d Link Rod e Throttle Lever Page 7 4 90 826883R2 JUNE 1998 THROTTLE SHIFT LINKAGE 3 Disconnect shift link rod from ball joint of gear shift lever a Shift Link Rod b Gear Shift Lever c Shift Lever 4 Remove 3 bolts and control platform 57034 a Bolts b Control Platform 90 826883R2 JUNE 1998 Page 7 5 THROTTLE SHIFT LINKAGE 5 Remove nuts and flat washers a b Nuts Flat Washers 6 Disassemble control platform 7 6 Se 0 Bolts 2 Torque to 120 Ib in 13 6 N m Flatwashers 2 Primary Gear Bushing Long Mount Bolts Torque to 120 Ib in 13 6 N m Control Platform Bushing Short Detent Spring Detent Ball Secondary Gear 57040 53174 90 826883R2 JUNE 1998 THROTTLE SHIFT LINKAGE Reassembly Installation 1 Install short bushing and long bushing on control platform 2 Install detent spring and detent ball into recess of control platform 3 Lubricate bushings and area
24. a Reverse Hook Guide b J am Nut c Coupler 20 25 2 Stroke 4 Unlatch and remove retainer to free shift shaft for removal of gearcase a R etainer Page 6A 12 90 826883R2 JUNE 1998 GEAR HOUSING NOTE A flat washer is located on the shift shaft near the top of the shaft This washer may Slide off shift shaft when gear case is removed Do lose washer as washer is necessary for reassembly a Flat Washer 5 Remove four screws and remove gear housing 56804 a Screws 4 NOTE If water tube should pull out of driveshaft housing remove tube from water pump and insert tube back into driveshaft housing to aid in reassembly 90 826883R2 JUNE 1998 Page 6A 13 GEAR HOUSING Disassembly IMPORTANT It is recommended that during complete disassembly of gear housing all O rings and oil seals be replaced regardless of their appearance Bearing Carrier 1 Remove 3 screws which secure the O ring retainer plate and O ring to the bearing carrier Remove the O ring retainer plate and O ring from gear housing 2 Remove bearing carrier using Special Tool 91 93843 1 LEFT HAND THREAD 122 p lt 722277777 a 222 BZN 2277 72502772 221 Y WV a Screws 3 b O Ring Retainer Plate c O Ring d Bearing Carrier 3 While holding onto propeller shaft and bearing carrier pull propeller s
25. 1 SERHOUNGASEMBY 7 1 2 6 55824 37525 e s OTi 1 s i E 28 5 88 ui gt a seRENSmbwd uai ROLLER BEARING ASSEMBLY asi 1 f e p f S 19 11 ere f apr m ui owe 75 1 T Gr i sk 88 sofa NUT Gs 1i smmsmeTUPE 40 i wwsmm ft sRNG apr Rum LE _ NO CO 20 5 m I A TU CD D gt GEARHOUSING B Gear Housing Propeller Shaft 45 TUS H 7 Loctite 271 92 809819 Super Duty Gear Lubricant 92 850737A1 567 2 Anti Corrosion Grease 92 850735 1 2 4 C w Teflon 92 850736A1 Page 6A 8 90 826883R2 JUNE 1998 GEAR HOUSING Gear Housing Propeller Shaft TORQUE DESCRIPTION in GEAR HOUSING ASSEMBLY mE TRMTB TAPEREDROLLERBERRNG
26. 12 Route upper and lower bleed hoses to their respective fittings as shown 13 Install starboard transfer port covers with new seals Torque attaching bolts to 40 Ib in 9 0 N m E 11 Aa gt 57078 Upper Bleed Hose b Lower Bleed Hose c Transfer Port Covers 14 Install transfer port covers with new seals Torque attaching bolts to 40 Ib in 4 5 N m LLL 2 085 a Transfer Port Covers b Bolts Torque to 40 Ib in 4 5 N m 90 826883R2 JUNE 1998 Page 4 49 POWERHEAD 15 Install exhaust manifold and exhaust cover with new gaskets Torque bolts to 140 Ib in 15 8 N m in torque sequence shown 57084 a Exhaust Manifold b Exhaust Cover 16 Install cylinder block cover with thermostat and new gaskets Torque bolts to 140 Ib in 15 8 N m in torque sequence shown NOTE If tell tale elbow fitting is removed replaced atthermostat cover apply Loctite PST Pipe Sealant to threads of elbow fitting prior to installation Loctite PST Pipe Sealant 92 809822 Cylinder Block Cover b Thermostat Under Cover c Gasket d Elbow e Bolts Torque to 140 Ib in 15 8 N m 57081 Page 4 50 90 826883R2 JUNE 1998 POWERHEAD Powerhead Installation 1 Verify powerhead base surface and driveshafthousing mating surfaces are free of old gasket material 2 Install powerhead with new gasket onto driveshaft housing NOTE It may be necessar
27. 17 Apply a light coatof oil on forward geartapered bearing then position forward gear as sembly in gear housing 90 826883R2 JUNE 1998 GEAR HOUSING Pinion and Driveshaft 1 Place lower drive shaft tapered roller bearing into bearing cup 2 Place pinion gear into gear housing with teeth of pinion meshed with teeth of forward gear 3 Insert driveshaft into gear housing while holding pinion in place with other hand Rotate driveshaft back and forth to align splines on driveshaft with splines in pinion gear 4 Secure pinion gear to driveshaft Apply Loctite 271 to pinion nut or bolt Refer to table for Fastener Type and Torque Mode Fastener Type 9 9 15 Bigfoot 4 Stroke 15 Ib ft 20 3 Nm 20 25 2 Stroke Pinion Bolt 13 3 lb ft 18 0 Nm L Fi gt bY Ss H 7 gt Loctite 271 92 809819 56913 a Tapered Roller Bearing b P inion Gear c Fastener Propeller Shaft 1 Position sliding clutch over propeller shaft spline with cross pin holes aligned with slots in propeller shaft a S hort End b Cross Pin Hole c Slot 2 Applya small amountoflightoil onto sliding clutch spring and insertspring into propeller shaft 90 826883R2 JUNE 1998 Page 6A 31 E GEAR HOUSING 3 Insert flat end of cam follower into propeller shaft a S pring b Flat End of Cam Follower 4 Place cam follower against a solid object and push against cam follower to compress Spring
28. 20 J et 1999 and Newer 20 25 1997 98 Models Mechanical Spark Advance Idle 750 50 RPM In Forward 60 0B T D C Gear Fast Idle Speed 1500 RPM 200 RPM Maximum BTDC Running 25 1 9 5500 RPM Stator High Speed Winding 120 180 W BLK WHT GRD Stator Low Speed Winding 3200 3800 W BLK YEL GRD Diode Test 3100 3700 W BLK YEL BLK WHT Ignition Coil Resistance Primary 0 02 0 04 W Secondary w o Boots 8000 11000 W Trigger 6500 8500 W IGNITION SYSTEM Readings taken 9 68 F 209 Page 2A 2 90 826883R2 JUNE 1998 IGNITION Special Tools 1 DMT 2000 Digital Tachometer Multi meter P N 91 854009A1 2 3 Flywheel Puller P N 91 83164 4 Flywheel Holder 91 52344 5 Spark Gap Board 91 850439 55117 90 826883 R2 JUNE 1998 Page 2A 3 IGNITION Ignition Electrical Components Dielectric Grease 92 823506 1 Loctite 271 92 809820 B 25 D Liquid Neoprene 92 25711 2 A ALTERNATOR VERSION ONLY Page 2A 4 90 826883R2 JUNE 1998 IGNITION Ignition Electrical Components E TORQUE 1 COVER ignition coil 2 1 SCREW ignition cover M5x 8x55 80 90 STATOR ASSEMBLY 20 25 USA S N 0G 437999 amp BELOW BEL S N 9926999 amp BELOW STATOR ASSEMBLY 20 25 USA S N 0G 438000 amp UP BEL S N 9927000 amp UP STATOR ASSEMBLY J ET 20 oo po Waxes 8 95
29. 2C 5 Throttle Cable Installation 2C 15 Starting Procedure 2C 6 Starting Procedure 2C 16 Timing Checking and Adjustment 2C 6 Adjusting Idle Speed 2C 17 Adjusting Idle Speed 2C 8 Specifications TIMING 20 Jet 19941 THRU 1998 SPECIFI 20 25 19941 THRU 1996 CATIONS Electronic Spark Advance Idle 750 50 RPM In Forward Gear 4 2 B T D C Not Adjustable Fast Idle Speed 1400 RPM 250 RPM Maximum BTDC Running 25 1 5500 RPM Setup Timing 28 B T D C 3000 200 R P M Set up timing of 28 B T D C will be retarded to 25 B T D C 5500 R P M 20 Jet 1999 AND NEWER 20 25 1997 AND NEWER Mechanical Spark Advance Idle 750 50 RPM In Forward Gear 6 1 B T D C Fast Idle Speed 1500 RPM 200 RPM Maximum BTDC Running 25 1 5500 RPM 90 826883R2 JUNE 1998 Page 2C 1 E TIMING SYNCHRONIZING ADJUSTING Special Tools 1 DMT 2000 Service Tachometer 91 854009A1 be obtained locally Page 2C 2 90 826883R2 JUNE 1998 TIMING SYNCHRONIZING ADJUSTING Timing Synchronizing Adjusting Tiller Handle amp Side Shift Models NOTE Timing Synchronizing adjustments are the same for tiller and side shift models unless otherwise specified 1 Check all electrical connections to ensure they are tight and secure including battery connections on electric start models
30. For models not equipped with an idle speed screw the carburetor has been calibrated at the factory to maintain an idle speed of 650 75 RPM in Forward gear Page 3A 14 90 826883R2 JUNE 1998 CARBURETOR FUEL PUMP 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 in the list on the right could give the impres sion that there is a problem in the fuel system Propeller Spark Plugs Ignition Timing Ignition Spark Voltage Cylinder Compression gt Xm de Sy Reed Valves Typical symptoms and solutions in troubleshooting a fuel system are shown below Problem Engine Turns Over but Will Not Start or Starts Hard When Cold Problem Engine Idles Rough and Stalls Problem Engine Runs Uneven or Surges Problem Engine Will Not Accelerate Possible Cause Corrective Action Improper starting procedure used Review starting procedure as outlined in Opera tion and Maintenance Manual Fuel tank empty or too low Improperly mixed fuel Check fuel in tank and replace or add whichever is Contaminants water dirt etc in fuel 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 Inspect all fuel lines and replace as needed Tight connection
31. Fuel System Cylinder Compression etc b Check all engine ground leads for loose or corroded connections c Disconnectand reconnectignition harness connectors to verify proper continuity PROBLEM CORRECTION 1 No Spark or Weak Spark on Both Cylinders No Spark Trigger Stator Ignition Switch Box or Bad Ground Connection from S witch Box to Block Weak Spark Stator 2 No Spark or Weak Spark on 1 Cylinder Ignition S witch Box or Coil 3 Timing Fluctuates Note It is normal for timing Shorted Trigger Wire or Ignition Switch Box to fluctuate 2 3 Idle If engine RPM exceeds 5800 switch box will retard timing from 25eBTDC to 15 f engine RPM drops below 600 idle stabilizer in switch box will advance timing to as high as L1OoBTDC crank ing speed of 300 RPM 4 Timing will not Advance Note If timing will not Defective Switch Box advance on only 1 cylinder check wir for shorted trigger wire 5 Engine Misfires High RPM Defective Coil Defective S witch Box 90 826883 R2 JUNE 1998 Page 2A 13 IGNITION 6 Engine Hard to Start when Cold Defective Trigger Assembly Defective Ignition Switch Box 7 Engine Misfires Low RPM butRuns Smooth Defective Harness or loose connections High RPM Defective Switch Box Defective Stator 8 Engine Starts Hard when Hot Defective Switch Box or Trigger 9 Engine Occasionally Misfires Replace Standard Spark Plug with Inductor Plug Bad Ground Connection from Switch
32. Part of Ref 24 LJ OJ GJ GJ NII NOI NI N N NI NI NI NI NI N e e e es BA d1 e wI NI ejl gt UJ A m Page 4 8 90 826883R2 JUNE 1998 POWERHEAD Torque Sequence 1 Exhaust Cover 140 lb in 15 8 N m 2 Crankcase Cover 30 0 Ib ft 41 1 N m ow A 3 Cylinder Block Cover 140 Ib in 15 8 N m Page 4 9 90 826883R2 JUNE 1998 POWERHEAD Powerhead Removal 1 Remove the following components assemblies referring to the listed service manual sections ComponentiAssembly Section Rewind Starter Flywheel and Ignition Electrical Components 2 Throttle S hift Mechanism 2 Disconnect tell tale hose from bottom cowl CA 57073 Tell tale Hose 3 Remove 4 bolts 57076 a Bolts 2 each side Page 4 10 90 826883R2 JUNE 1998 POWERHEAD 4 Remove 6 bolts securing powerhead 57077 a Bolts 3 each side 5 Rock powerhead to break gasket and lift powerhead from drive shaft housing 6 Place powerhead on bench or powerhead stand 91 25821A1 mounted in vise LJ A 1 a f N N 53203 a Powerhead Stand 91 25821A1 90 826883R2 JUNE 1998 Page 4 11 POWERHEAD Powerhead Disassembly Cylinder Block 1 Remove
33. Sparks or flames can ignite this gas and cause an internal ex plosion 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 re cently 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 dis connecting cable clamps on chargers Poorconnections are common cause of elec trical arcs which cause explosions 3 DO NOT reverse polarity of battery cables on battery terminals 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 Recommended Battery 12 volt battery with a Marine Cranking Amperage rating minimum of 465 amperes or ora Cold Cranking Amperage of 400 Operating Engine Without Battery If desired in an emergency engines equipped with an alternator can be started and operated withouta battery either disconnected or removed if WARNING below is fol lowed Before operating engine with battery leads disconnected from battery discon nect stator leads Yellow from rectifier Insulate tape stator lead ring terminals Specific Gravity Readings Use a hydrometer to measure specific gravity of electrolyte each cell a Hydrometer Page 2B
34. Wl 1 90 826883R2 JUNE 1998 Page 7B 3 TILLER HANDLE Control Cables Removal 1 Place tiller handle twist grip in NEUTRAL position 2 Remove throttle link rod from throttle cam and primary throttle lever KOZAN ODA 56 ZN UIN 99797 Sl ir e 57031 Link Rod b Throttle Cam c Primary Throttle Lever 3 Loosen jam nuts which secure control cables to anchor bracket 4 Unwrap and remove control cables from pulley of primary gear NOTE If not replacing control cables mark top cable with a piece of tape to aid in reas sembly 57032 Jam Nuts b Gear Page B 4 90 826883R2 JUNE 1998 TILLER HANDLE 5 Remove nut securing access cover and remove cover 57035 a Nut b Access Cover 6 Disconnect stop button wires BLACK YELLOW and BLACK 57036 a BLACK YELLOW b BLACK 90 826883R2 JUNE 1998 Page 7B 5 TILLER HANDLE Tiller Handle Removal Disassembly Removal 1 Remove 2 bolts securing tiller handle to anchor bracket and remove tiller handle as sembly ANO 57037 a Bolts 2 Remove bushing flatwashers 2 wave washer and tiller handle washer Remove re tainer and bolt 53248 Bushing Flat Washer 2 Wave Washer Tiller Handle Washer Retainer Bolt D Page 7B 6 90 826883R2 JUNE 1998 TILLER HANDLE 3 Slide tiller tube out of pulley case 53256 a
35. b Locating Washers 6 Remove and discard coupling seal using Snap On Expanding Rod CG 40 4 Snap On Collet CG 40 A6 Slide Hammer 91 34569A1 P urchase from Snap On Tools Corporation 2801 80th Street Kenosha WI 53141 1410 Tati CG 40 4 CG 40 A6 53045 57102 a Coupling Seal b Collet CG 40 15 c Expanding Rod CG 40 4 d Slide Hammer 91 34569A1 90 826883R2 JUNE 1998 Page 4 21 POWERHEAD c Powerhead Cleaning and Inspection Cylinder Block and Crankcase Cover IMPORTANT Crankcase cover and cylinder block are a matched line bored as sembly and must be replaced as a set Page 4 22 1 Thoroughly clean cylinder block and crankcase cover with Quicksilver Power Tune Engine Cleaner 91 92 15104A12 Verify that all sealant and old gaskets are re moved from mating surfaces Remove all carbon deposits from exhaust ports de compression ports and cylinder dome Inspect cylinder block and crankcase cover for cracks or fractures Check gasket surfaces for nicks deep grooves cracks and distortion Inspectall water and fuel passages in cylinder block and crankcase cover for obstruc tions Verify that all fittings and plugs are tight If the center main bearing alignment pin is loose cylinder block and crankcase cover must be replaced a Alignment Pin 90 826883R2 JUNE 1998 POWERHEAD 57103 a Decompression Ports Exhaust Manifold and Exhaust Cover 1 Remove all carbon de
36. en 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 Refer to carburetor disassembly in this section open flooding or closed no fuel Improper carburetor jet restricted jet or idle mix Refer to carburetor adjustments in this section ture screw out of adjustment Improper float level Refer to carburetor adjustments in this section Low fuel pump pressure Disassemble and inspect fuel pump components Defective anti siphon valve Inspect valve and or test engine without valve in fuel system 90 826883R2 JUNE 1998 Page 3A 15 CARBURETOR FUEL PUMP Possible Cause Corrective Action Improperly mixed fuel Contaminants water dirt Check fuel in tank and replace if necessary etc in fuel Fuel tank air vent closed or restricted Check air vent on tank Vent must be open all the way and free from any contaminants Inspect all fuel lines and replace as needed In spect and tighten all fuel line connections Inspect and replace or clean all fuel filters A pinched cut or restricted fuel line Also loose fuel line connection Dirty or restricted fuel filter Low fuel pump pressure Disassemble and inspect fuel pump components Inspect valve and or test engine without valve in fuel system Refer
37. free movement SYMPTOMS OF A DEFECTIVE PRIMER SYSTEM 1 Outboard is hard to start a Diaphragm is cut b Primer check ball is stuck in the closed position c Primer passage is plugged with debris or varnish 2 Outboard smokes excessively at idle a Primer check ball is not seated due to debris varnish or damaged check ball spring Seal Screw 4 Torque to 14 Ib in 1 6 N m Cover Diaphragm Gasket Spring Primer Bowl Check Ball Spring Gasket Plug A JO 90 826883R2 JUNE 1998 Page 3A 23 E CARBURETOR FUEL PUMP Servicing Sight Bowl Fuel Filter Exercise extreme caution when cleaning fuel filter elements Gasoline is extreme ly flammable and highly explosive under certain conditions Always stop the en gine and DO NOT smoke or allow open flames in the area while cleaning fuel filter elements DO turn or cock fuel filter assembly when removing or installing PULL STRAIGHT DOWN when removing assembly PUSH STRAIGHT UP when instal ling assembly Turning or cocking fuel filter may break fuel line connection on fil ter The sight bowl fuel filter removes dirt and water from the fuel Check the sight bowl frequently and clean the filter as required 1 Verify that the sight bowl rubber sealing ring is properly positioned in the bowl 2 Reinstall element in filter cover 3 Thread sight bowl onto filter cover 4 Tighten bowl securely by ha
38. o Jef 17 NUT 7 8 14 120 10 0 13 6 SCREW M6x1x40 12 0 15 8 ANDLE carrying PACER ASHER tilt tube NY LON LT TUBE ASHER tilt tube NYLON ECAL co pilot LT PIN ASSEMBLY SPRING CREW M6x1x40 UT 7 8 14 LIP safety OLT clamp bracket to transom WASHER clamp bracket bolt NUT clamp bracket bolt UT 1 4 28 CREW 1 4 28 1 IN LEVER tilt stop starboard side UT 1 4 28 PRING tilt stop lever screw CREW 1 4 28x1 3 4 IN SCREW 1 4 28x1 3 4 IN WAVE WASHER tilt stop strap screw NUT 1 4 28 STRAP tilt stop port side CREW 1 4 28x1 IN Oo Oo Oo NO gt A LJ NI NINI NI NI NI NMI NINI ej ej ej Re I J J BI mp J Ui BS w NJ Ui By wi NI GO WO NNI 3 GW NI WH Ni e O N O U Cn UJ UJ UJ UJ UJ UJ UJ C co on 90 826883R2 JUNE 1998 Page 5 3 CLAMP AND SWIVEL BRACKET Swivel Bracket Assembly Loctite 271 92 809820 Anti Corrosion Grease 92 78376A6 2 4 C With Teflon 92 825407A12 A REMOTE CONTROL MODELS ONLY B TILLER HANDLE MODELS ONLY Page 5 4 90 826883R2 JUNE 1998 E CLAMP AND SWIVEL BRACKET S wivel Bracket Assembly TORQUE DESCRIPTION lt 3 OD reverse hook N HANDLE WASHER BRAKE PLATE BRAKE DISC WIVEL HEAD PLATE Included W Ref 36 RAKE DISC CREW
39. 0 084 0 080 0 080 0 076 0 074 0 08 0 086 0 08 0 078 0 074 0 08 0 088 0 08 0 080 0 076 0 09 0 090 0 08 0 082 0 078 0 09 0 09 0 08 0 084 0 080 0 09 0 094 0 092 0 092 0 090 0 090 0 086 0 082 0 09 0 096 0 094 0 094 0 092 0 092 0 086 0 084 0 09 0 098 0 096 0 096 0 094 0 092 0 088 0 086 Feet A A Cy A OT 90 826883R2 JUNE 1998 Page 7 E CARBURETOR FUEL PUMP Carburetor Float Adjustment AS 10 ap ence 1 in 25 4 gt ip 17111 a Carburetor Scale 91 36392 b Measured from bottom of float Rs omen 52646 Float b Float Hinge Float Pin d Bend Float Arm Here to Adjust Float Level e Needle Page 3A 8 90 826883R2 JUNE 1998 CARBURETOR FUEL PUMP Carburetor Adjustments 1 Place outboard in water 2 Checktiller handle cable adjustment for full throttle movement in both Forward and Reverse gears Adjust jam nuts for proper travel and to eliminate any slack tan 57049 Jam Nuts INITIAL CARBURETOR ADJUSTMENTS Idle Speed Screw Models So Equipped 1 Shift outboard to Neutral and place throttle twist grip to Slow 2 Push primer fast idle knob completely in and rotate knob fully counterclockwise 9 037 90 826883R2 JUNE 1998 Page 3A 9 CARBURETOR FUEL PUMP 3 Back idle speed screw off of cam follower
40. 2 8 N m 5 The YELLOW RED harness lead attaches to the Z2 terminal of the starter terminal Torque attaching nut to 15 Ib in 1 7 53215 RED Lead Torque nut to 25 Ib in 2 8 N m b YELLOW RED Lead Torque nut 15 Ib in 1 7 N m Page 2B 24 90 826883R2 JUNE 1998 BATTERY CHARGING AND STARTING SYSTEMS Choke Solenoid Installation IMPORTANT New gasket MUST be positioned as shown when being installed 1 Install new gasket with solenoid plate assembly 2 Secure assembly with 2 screws Torque screws to 18 Ib in 2 0 53209 a Gasket b Solenoid Plate Screws Torque to 18 Ib in 2 0 90 826883R2 JUNE 1998 Page 2B 25 BATTERY CHARGING AND STARTING SYSTEMS Battery Cables Engine Wiring Harness Remote Electric Start Models 1 Slide battery cables through sleeve 53066 a Battery Cables b Sleeve 2 Thread battery cable sleeve through wire retainer of engine wiring harness Verify 1 25 4mm of sleeve remains to the outside of wire retainer in 25 4mm 53065 a Sleeve b Retainer Harness Page 2B 26 90 826883R2 JUNE 1998 BATTERY CHARGING AND STARTING SYSTEMS 3 Remove carburetor as outlined in Section 3 4 Thread engine wiring harness first and then battery cable sleeve through opening in bottom cowl QB YC i SEN 53210 Harness b Battery Cable Sleeve Opening 5 Route engine wiring harness and bat
41. 20 WASHER THROTTLE CAM WASHER SPARK ADJ UST LINK SOCKET NUT ANCHOR BRACKET cable THROTTLE CAM 20 25 WASHER SPARK ADJUST LINK S N SOCKET USA 0G 437999 amp BELOW NUT BEL 9926999 amp BELOW ANCHOR BRACKET cable ANCHOR BRACKET cable WASHER WAVE WASHER THROTTLE CAM 20 25 S N SPRING USA 0G438000 amp UP SPARK ARM BEL 9927000 amp UP TIMING LINK SCREW M6x1x 25 120 BUSHING 3 SCREW M5x1x16 A NO m NM n FR el el n mej e efl el zl n uh ess OW U1 WI wj JU P w el I NO 90 826883R2 JUNE 1998 Page C 3 SIDE SHIFT Throttle Cables Side Shift Models Removal Installation Refer to Section 7B for removal and installation instructions Throttle Cam Control Lever Removal 1 Refer to Section 7B for removal of throttle cables 2 Remove bolt and flat washer securing cam lever to powerhead A Y 2 ya VEU GY Throttle Cam b Control Lever c Flat Washer Bolt Page 7 4 90 826883R2 JUNE 1998 SIDE SHIFT Throttle Cam Control Lever Reassembly 1 Position spring assembly over hub of throttle cam 57042 a Inner Spring Ends b Hub c Tab 2 Lubricate bushing with 2 4 C w Teflon and install bushing and wave washer 57042 2 4 C With Teflon 92 82540
42. 3 bolts and remove intake manifold reed block 57079 a Bolts b Intake Manifold Reed Block IMPORTANT Reed block can be inspected without disassembling If inspection of reed block indicates that replacement of a partis necessary entire reed block as sembly must be replaced as individual parts are not sold separately 2 Inspect seal for cuts or abraisions If seal is damaged entire reed block assembly must be replaced 3 Inspect reeds for cracks or chips a Seal b Reeds c Reed Valve Opening Maximum Opening 0 007 in 0 178mm Page 4 12 90 826883R2 JUNE 1998 POWERHEAD 4 Remove 2 bolts and remove thermostat cover 57081 a Bolts 2 b Cover 5 Remove thermostat if equipped 6 Remove 5 bolts and remove cylinder block cover 57082 a Bolts b Cover c Thermostat if equipped 90 826883R2 JUNE 1998 Page 4 13 7 Remove 9 bolts and separate exhaust cover and exhaust manifold from cylinder block ON oc ez tels POWERHEAD A s 57084 a Bolts 9 b Exhaust Cover c Exhaust Manifold NOTE If engine is suspected of having been overheated or spark plugs are grayish col ored a sign of possible water intrusion inspectexhaust manifold for warpage or for prop er placementand integrity of gaskets which will allow water to enter cylinders through ex haust ports 8 Remove 10 bolts and 4 transfer covers Starboard Side Le 1
43. 34961 f Hex Nut 0 625x18 2 11 24156 Install new driveshaft oil seals into driveshaft bore of gear housing as follows gt Apply Loctite 271 to outer diameter of driveshaft oil seals gt With lip of seal facing down press the first oil seal into driveshaft bore until seal is just below the top of driveshaft bore gt With lip of seal facing up and using Installation tool 91 858775 press the second oil seal into driveshaft bore until seal is 3 16 4 7 mm below top of driveshaft bore gt Wipe off excess Loctite 3 16 lt 4 7 mm H 7 gt Loctite 90 826883R2 JUNE 1998 NM 2 809819 271 9 a Upper Driveshaft Bearing b Mandrel c Seals 2 d Oil Seal with Lip of Seal Facing Up e Oil Seal with Lip of Seal Facing Down f Installation Tool 91 858775 Page 6A 27 GEAR HOUSING Shift Shaft 1 Install shift shaft assembly into gear housing assembly a S hift S haft Assembly b Boot c Retainer d O ring outer e O ring inner f Washer g Spring h Washer I R oll Pin j Driver P in k S hift Cam Page 6A 28 90 826883R2 JUNE 1998 Forward Gear In 1 2 90 826883R2 JUNE 1998 GEAR HOUSING stallation Install forward gear bearing race into gear housing Apply light coat of Super Duty GearLubricantto forward gear bearing race bore in pro peller shaft cavity Position tapered bearing race squarely over bearing bore in front portion of propeller shaft cavity Place ma
44. 4 Turn idle speed screw inward clockwise until it just touches cam follower then inward an additional 1 2 turn to slightly open throttle plate em RE _ e 57070 Idle Speed Screw b Cam Follower Page 3A 10 90 826883R2 JUNE 1998 LOW SPEED MIXTURE SCREW CARBURETOR FUEL PUMP 1 Remove access plug from carburetor air intake cover models so equipped Ws Y V 7 Access Plug b Intake Cover 2 Turn low speed mixture screw slowly inward clockwise until it seats lightly then back screw out counterclockwise 1 1 2 to 1 3 8 turns turning mixture screw in tight will damage needle and seat K 57072 3 Do not install access plug at this time 9 071 a Low Speed Mixture Screw 90 826883R2 JUNE 1998 Page 3A 11 CARBURETOR FUEL PUMP IDLE WIRE ADJUSTMENT 1 Push primer fast idle knob completely in and rotate fully counterclockwise 2 Shift engine to Neutral ry _ _ lt 57037 3 Adjust screw a to remove all clearance between idle wire and trigger 57070 Screw b Idle Wire 4 Check fast idle speed by turning primer knob to full clockwise position Fast idle soeed should be 1500 2000 RPM Page 3A 12 90 826883R2 JUNE 1998 CARBURETOR FUEL PUMP IDLE ADJUSTMENT Low speed Mixture Adjustment 1 Start engine and allow to warm up run fo
45. 4 90 826883R2 JUNE 1998 BATTERY CHARGING AND STARTING SYSTEMS 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 solu tion and chemically combines with the plates causing a decrease in specific gravity of electrolyte An indication of concentration of electrolyte is obtained with a hydrometer When using a hydrometer observe the following points 1 Hydrometer must be clean inside and out to insure an accurate reading 2 Never take hydrometer readings immediately after water has been added Water must be thoroughly mixed with electrolyte by charging for atleast 15 minutes ata rate high enough to cause vigorous gassing 3 Ifhydrometer 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 cellso thatfloat is free floating 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 5 Avoid dropping electrolyte on boat or clothing as it is extremely corrosive Wash off immediately with baking soda solution Specific gravity of electrolyte varies notonly with percentage of acid in liquid but also with temperature As temperature drops electrolyt
46. 5 CLAMP AND SWIVEL BRACKET Drive Shaft Housing Assembly Loctite 271 92 809820 A SERVICE ONLY Page 5 6 90 826883R2 JUNE 1998 2 CLAMP AND SWIVEL BRACKET Drive Shaft Housing Assembly TORQUE DESCRIPTION Ib in Ib ft N m SERLadprphe ADAPTOR PLATE ASSEMBLY GASKET adaporpte mE mE mE HEN NE EE NEN NEN NE HOUSING ASSEMBLY water tube EN m m 7 Screw WATER TUBE SHORT SHAFT a WATER TUBE LONG SHAFT HOUSING ASSEMBLY SHORT SHAFT BLACK BEEN HOUSING ASSEMBLY LONG SHAFT L1 HOUSING ASSEMBLY SHORT SHAFT GRAY HOUSING ASSEMBLY LONG SHAFT __ EN 1 HOUSING ASSEMBLY LONG TRACKER GRAPHITE GRAY GASKET drive shaft housing GASKET idle relief cover COVER idle relief 1 lt Q gt SCREW cover 1 4 20x1 1 4 IN ive SCREW drive shaft housing to block M8 x 70 1 27 1 WASHER drive shaft housing screw SCREW M6x1x20 TRIM COVER BLACK TRIM COVER GRAY 1 TRIM COVER TRACKER GRAPHITE GRAY UO ve 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 Refer to SECTION 4 for powerhead removal and SECTION 6 for gear housing removal The transom bracket
47. 5 Insert a punch thru the cross pin holes in sliding clutch between cam follower and spring 6 Apply a light coat of oil on cross pin and install cross pin into sliding clutch by pushing punch out of clutch with cross pin as shown Release pressure on cam follower and remove follower from propeller shaft 2 4 w Teflon 92 850736A1 a Punch b Cross Pin c Cam Follower 7 Install cross pin retainer spring a Cross Pin Retainer Spring 8 Place adab of 2 4 C w Teflon into end of propeller shaft and install cam follower flatend first Page 6A 32 90 826883R2 JUNE 1998 GEAR HOUSING Bearing Carrier 1 Apply a small amount of oil into bearing bore in bearing carrier 2 Position bearing carrier on a press with the threaded side down 3 Place propeller shaft bearing into aft end of bearing carrier with lettered end of bearing up 4 Use installation tool 91 858777 to press bearing into bearing carrier until the installa tion tool bottoms out or using a suitable mandrel press bearing to depth of 1 9 64 in 28 9 mm from end of bearing carrier housing 1 9 64 in IRN 28 9 91 858777 a Suitable Mandrel b P ropeller Shaft Bearing c Lettered end of Bearing 5 Apply Loctite Type 271 to outer diameter of inner propeller shaft seal Use installation tool 91 858776 to press inner seal into bearing carrier lip of seal is facing inward to a depth of
48. 7 8 in 22 2 mm from end of bearing carrier housing 6 Apply 2 4 C w Teflon between seals 7 Apply Loctite Type 271 to outside diameter of the outer propeller shaft seal Rotate installation tool and press outer seal into bearing carrier lip of seal 15 facing outward to a depth of 13 32 in 10 3 mm from end of bearing carrier housing H 7 Loctite 271 92 809819 2 4 C w Teflon 92 850736A1 7 8 13 32 in 22 2 el 10 3 mm 91 858776 a Inner P ropeller S haft S eal b Outer Propeller Shaft S eal 90 826883R2 JUNE 1998 Page 6A 33 GEAR HOUSING Bearing Carrier Propeller Shaft Installation 1 Apply a small amount of 2 4 C w Teflon between lips of propeller shaft oil seals Apply 2 4 C w Teflon to threads O ring groove and pilot diameter 2 Slide reverse gear into bearing carrier assembly Slide bearing carrier assembly over propeller shaftand thread itinto propeller shaft cavity as far as possible by hand LEFT HAND THREAD 3 Torque bearing carrier using Special Tool 91 93843 1 Torque to 80 Ib ft 108 5 Nm 1 gt 2222 m SV S IS 222 a Reverse Gear b Bearing Carrier Assembly 2772 24 4 Install O ring and O ring retainer plate on bearing carrier 5 Secure O ring retainer plate to bearing
49. Box to Block Page 2A 14 90 826883R2 JUNE 1998 IGNITION Ignition Troubleshooting Electronic Spark Advance DANGER HIGH VOLTAGE SHOCK HAZARD Do not touch ignition components and or metal test probes while engine 15 running and or being cranked STAY CLEAR SPARK PLUG LEADS To assure personal safety each individual spark plug lead should be grounded to engine When testing or servicing the ignition system high voltage is present DO NOT TOUCH OR DISCONNECT any ignition parts while engine is running while key switch 15 on Tool Multimeter DVA Tester 91 99750A1 Selector Voltage Voltage Component Sw DVA Lead Lead Reading Reading Test Posi tion Red Black 300 3000 3000 4000 RPM RPM Coil Coil Coil Sw Box Black Yellow _ Test 2 Stop Circuit 400 DVA Ground 220 320 300 350 Stator x Blue Sw 2 _ Test 3 Low Speed 400 DVA Bee Ground 220 320 300 350 Stator Red Sw 2 _ Test 4 High Speed 400 DVA Box Terminal Ground 30 220 200 280 f using a meter that requires a DVA adapter place selector switch to the 400 VDC posi tion 1 Readings may vary at cranking speed or at idle 2 Back probe the electrical connector in order to make connection Multimeter Ohm Checks Tested Part Multimeter Connected To Meter Scale Meter Reading Wires RED RED Rx1W 100 180 BLACK BLACK RED BLUE Test5 S tator x 100 29 35 BLACK BLACK
50. Electric Models Equipped with Remote Control Electronic Advance Model 20 25 19941 THRU 1997 BLACK BROWN GRAY Q JJ GREEN RED RED WHT WHITE YEL YELLOW Stator Trigger Ignition Coil Top Cylinder Ignition Coil Bottom Cylinder Rectifier Switch Box Charging Coils Starter Motor Starter Solenoid Fuse Holder 20 Ampere Fuse Remote Control Harness 12 VDC Battery m Neutral Start Switch 20 4 90 826883R2 JUNE 1998 WIRING DIAGRAMS Manual Start Models Mechanical Advance Model 20 25 1998 N YEL X RN WHT N BRN YEL BLK WHT BLK YEL _ p GRN YEL BLK BLACK BRN BROWN GRY GRAY GRN GREEN RED RED WHT WHITE YEL YELLOW Stator Trigger Switch Box Ignition Coil Top Cylinder Ignition Coil Bottom Cylinder Stop Switch Emergency Stop Switch 90 826883R2 JUNE 1998 Page 2D 5 WIRING DIAGRAMS Electric Start Models with Tiller Handle Start Button Mechanical Advance Model 20 25 1998 Q BRN WHT BRN YEL HT BLKWHT CD5 GRN YEL Black BRN Brown GRY Gray GRN Green RED Red WHT White YEL Yellow Charging Coils Stator Ignition Coil Top Cylinder Ignition Coil Bottom Cylinder Rectifier Switch Box Trigger Starter Motor Starter Solenoid Emergency Stop Switch
51. Hex Firing Order 20 Jet 19941 gt THRU 1998 20 25 19941 THRU 1996 Electronic Spark Advance Idle 750 50 RPM In Forward Gear Fast Idle Speed Maximum BTDC Running Setup Timing Stator High Speed Winding Stator Low Speed Winding Diode Test Ignition Coil Resistance Primary Secondary w o Boots 20 Jet 1999 and Newer 20 25 1997 98 Models Mechanical Spark Advance Idle 750 50 RPM In Forward Gear Fast Idle Speed Maximum BTDC Running Stator High Speed Winding Stator Low Speed Winding Diode Test Ignition Coil Resistance Primary Secondary w o Boots Trigger Capacitor Discharge Ignition NGK BP8H N 10 0 040 in 1 0 mm 18 mm 1 2 4 2 B T D C Not Adjustable 1400 RPM 250 RPM 25 1 5500 RPM 28 B T D C 3000 200 R P M Set up timing of 28 B T D C will be retarded to 25 B T D C 5500 R P M 100 180 RED 2900 3500 BLUE BLACK 2800 3400 RED BLUE 00 850 1200 Q 6 1 B T D C 1500 RPM 200 RPM 25 1 5500 RPM 120 180 BLK WHT GRD 3200 3800 BLK YEL GRD 3100 3700 Q BLK YEL BLK WHT 0 02 0 04 8000 11000 6500 8500 0 030 in 0 8 mm JET DRIVE Impeller Liner Clearance Use BPZ8H N 10 Where Radio Frequency Interference RFI Suppression is Required Page 1A 4 90 826883R2 JUNE 1998 Master Specifications CARBURETOR SPECIFI CATIONS TIMING SPECIFI CATIONS I
52. INSERT SEAL water tube RING driveshaft rubber 24 SCREW M6 x 16 5 8 7 9 4 SCREW M5 x 16 12 4 BUSHING Use with M5 X 16 REF 11 90 826883R2 JUNE 1998 Page 6B 5 c J ET DRIVE n J et Pump Assembly S N 0G 157846 amp Up gt Y Loctite 271 92 809820 2 4 C With Teflon 92 825407A12 Page 6B 6 90 826883R2 JUNE 1998 JET DRIVE J et Pump Assembly S N 0G157846 amp Up TORQUE QTY DESCRIPTION Ib in Ib ft N m ET PUMP ASSEMBLY HOUSING pump HOSE lube 5 KEY impeller 7 SSCS NI NI I 2 co UJ N UJ ul wo gt Ul ol gt N N Un 90 826883R2 JUNE 1998 Page 6B 7 c J ET DRIVE n J et Linkage S N 0G 157846 amp Up 13 715 S __g B 3 6 Loctite 271 92 809820 Page 6B 8 90 826883R2 JUNE 1998 JET DRIVE J et Linkage S N 06157846 amp Up TORQUE QTY DESCRIPTION Ib in Ib ft 1 1 NUT LOCKWASHER SHIFT HANDLE Use without Ref 4 SHIFT HANDLE Use with Ref 4 SPACER sleeve ROD END SPRING WASHER COTTER PIN NUT 70 5 8 7 9 SHIFT LEVER SCREW 10 32 x 3 4 SCREW 10 32 x 2 1 2 30 2 5 3 4 SHIFT ROD ROD END TILT LATCH ROD el e RP NNN FP
53. MOTOR INSTALLATION 2 Position the remote wiring harness and battery cables thru the bottom cowl rubber grommet as shown Plug the remote wiring harness into the engine wiring harness connector 4 Secure the connection together using retainer L1 Rubber Grommet b Remote Wiring Harness c Engine Harness Connector d Retainer 5 Fasten the remote wiring harness and battery cables into the bottom cowl rubber grommet with retainer uu ere a Retainer 90 826883R2 JUNE 1998 Page 1D 9 2 OUTBOARD MOTOR INSTALLATION Battery Cable Connections SINGLE OUTBOARD RED Sleeve POSITIVE b BLACK Sleeve NEGATIVE Starting Battery DUAL OUTBOARD 1 Connecta common ground cable wire size same as engine battery cables between negative terminals on starting batteries a Ground Cable Same Wire Size As Engine Battery Cable Connect Between Negative Terminals Propeller Installation If the propeller shaft is rotated while the engine is in gear there is the possibility thatthe engine will crank over and start To preventthis type of accidental engine starting and possible serious injury caused from being struck by a rotating pro peller always shift outboard to neutral position and remove spark plug leads when you are servicing the propeller Page 1D 10 90 826883R2 JUNE 1998 OUTBOARD MOTOR INSTALLATION Flo Torg Drive Hub Propellers a
54. RED RED 100 W 28 34 BLACK BLUE RED BROWN WHITE Test 6 Trigger R x 100 W 6 5 8 5 BLACK BROWN YEL LOW 90 826883 R2 JUNE 1998 Page 2A 15 IGNITION Terminal Ignition Coils Terminal wire discon Spark Plug Tower nected Terminal NOTE Copper is an excellent conductor however resistance may notably vary between low and high temperature Therefore reasonable differences can be accepted between resistance readings and specifications The above readings are for a cold room temperature engine Resistance will increase if the engine is warm Ignition Troubleshooting Mechanical Spark Advance TOOL MULTIMETER DVA TESTER 91 99750 Multimeter Resistance 2 GROUND BLACK WHITE BLACK YELLOW wires discon GROUND R x 100 32 38 nected from switch BLACK YELLOW boxes BLACK WHITE R x 100 31 37 Trigger BROWN Y ELLOW and BROWN Y ELLOW BROWN wires dis R x 100 6 5 8 5 connected from BROWN switch boxes RED Terminal all wires dis connected RED Spark Plug Tower Tested Part Multimeter Connected To Selector Reading At Reading At Wires Position 300 1000 RPM 1000 4000 RPM Terminal Switch Box Primary Coil 400 VDC 125 260 200 360 Terminal 5 witch Box GROUND Stop Circuit Stator Low 400 VDC 150 300 250 360 Speed BLACK YELLOW GROUND gon 400 VDC 10 75 50 300 BLACK WHITE Page 2A 16 90 826883R2 JUNE 1998 IGNITION Ignition Troublesh
55. Replace Rectifier Rectifier Tests O K Page 2B 10 90 826883R2 JUNE 1998 BATTERY CHARGING AND STARTING SYSTEMS Starting System STARTER MOTOR AMPERES DRAW PART NO AMP DRAW AMP DRAW 1 sames Starter Motor Teeth STARTING SYSTEM COMPONENTS Description The starting system consists of the following components 1 Battery 2 Starter Solenoid 3 Neutral Start Switch 4 Starter Motor 5 Ignition Switch 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 15 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 notin neutral This prevents accidental starting when engine 15 in gear The starter motor be damaged if operated continuously DO NOT operate continuously for more than 30 seconds Allow a 2 minute cooling period between starting attempts Troubleshooting the Starting Circuit Before beginning the starting circuit troubleshooting flow chart following check first for the following conditions 1 Make sure that battery 15 fully charged 2 Check that control lever is in NEUTRAL position 3 Check terminals for corrosion and loose connections 4 Check cables and wiring for frayed and worn insulati
56. Shift outboard to Neutral on side shift model place throttle twist grip to Slow Push choke primer all the way In On models equipped with a primer turn knob to full Counterclockwise position 4 Checkthe tiller handle cables for proper adjustment If necessary adjust cables and remove any slack 5 With the outboard placed in Neutral back the idle speed screw off the cam follower 28192 a Idle Speed Screw b Cam Follower c Side Shift Model Shown 90 826883R2 JUNE 1998 Page 2C 3 TIMING SYNCHRONIZING ADJUSTING 6 Turn idle speed screw In until the cam follower just makes contact with throttle cam then turn In one additional turn to slightly open throttle plate 4 AM p 2 gt 5 5 a Cam Follower b Idle Speed Screw c Throttle Cam d Side Shift Model Shown NOTE The throttle return spring on cam follower plate should just contact the fuel pump housing at wide open throttle position Do not allow the throttle spring to act as a throttle stop 7 Place throttle twist grip to Full Throttle position Verify that the throttle plate can achieve wide open throttle If adjustment is necessary adjust tiller cables or throttle link rod as shown Side Shift Models Adjusting Tiller Handle Cables a Cam Follower Plate b Fuel Pump Housing c Throttle Cables Page 2C 4 90 826883R2 JUNE 1998 TIMING SYNCHRONIZING ADJUSTING Tiller Shift Models Adjusting Lin
57. WMC 45 JET 20 THROTTLE SHAFT 20 25HP WMC52 52A 53 53A FUEL BOWL FLOAT VALVE inlet needle JET main fuel 044 20HP JET main fuel 076 25HP JET 20 PLUG jet retainer COVER diaphragm SCREW diaphragm cover BODY fuel pump SCREW fuel pump cover COVER fuel pump COVER fuel pump JET 20 PLUG GASKET DIAPHRAGM KIT REPAIR PARTS KIT PLATE cover MANUAL ELECTRIC CHOKE ELECTRIC SCREW cover plate GASKET carburetor DIAPHRAGM GASKET GASKET FLOAT PIN FLOAT LEVER PRIMER INJECTOR SERVICE KIT See illustration for contents CREW CO pe 9 Uo 2 ur MOIN DOT NINININI NI NI 90 826883R2 JUNE 1998 Page 3A 3 CARBURETOR FUEL PUMP Carburetor Seapro Marathon 15 25 amp Super 15 Page 3A 4 90 826883R2 JUNE 1998 CARBURETOR FUEL PUMP Carburetor Seapro Marathon 15 25 amp Super 15 TORQUE 5 5 5 2 3 ha oo DESCRIPTION CARBURETOR WMC 54 CARBURETOR WMC 46A CARBURETOR WMC 56 THROTTLE VALVE WMC 46 46A 54 54A THROTTLE VALVE WMC 56 56A THROTTLE SHAFT FUEL BOWL FLOAT VALVE inlet needle JET main fuel 076 WMC 46 JET main fuel 080 WMC 46A 54 544 JET main fuel 046 WMC 56 56A PLUG jet retainer CHOKE SHAFT CHOKE LEVER BODY fuel pump SCREW fuel pump cover COVER pump WMC 54 54A 56 56A COVER fuel p
58. above sea level Between 2000 feet 609 6m and 5000 feet 1524m the reduction of the main fuel jet s may result in improved performance and fuel economy Above 5000 feet however itis recommended that main jet size be reduced as shown per 1000 feet 304 8m in the following chart RETURN TO LOWER ELEVA TION Carburetor jet changes must be reversed to avoid a lean fuel condition when used at low elevation Meter 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 1100033 12000 304 8 609 6 914 4 1219 2 1524 1828 8 2133 6 2438 4 2743 2 3048 52 8 3657 6 Jet Size Jet Size _ ___ 0084 0032 0092 0 032 0032 0032 0032 0530 0030 0080 0299 0038 0 036 0 086 0 034 oos 0 034 oos 0082 0032 0032 0082 0092 0 042 0 042 0 040 0 038 0 036 0 04 0 04 0 042 0 042 0 040 0 038 0 04 0 04 0 04 0 042 0 040 0 04 0 04 0 04 0 044 0 042 0 050 0 050 0 04 0 046 0 044 0 052 0 052 0 050 0 050 0 048 0 046 0 054 0 052 0 052 0 048 0 048 0 062 0 062 0 06 0 056 0 054 0 064 0 064 0 06 0 058 0 056 0 06 0 06 0 064 0 064 0 064 0 062 0 060 0 058 0 06 0 068 0 066 0 066 0 06 0 064 0 062 0 060 0 07 0 070 0 068 0 068 0 068 0 066 0 064 0 062 0 07 0 07 0 07 0 066 0 062 0 07 0 07 0 07 0 068 0 064 0 07 0 07 0 07 0 068 0 066 0 07 0 07 0 07 0 070 0 068 0 08 0 080 0 078 0 078 0 076 0 076 0 072 0 070 0 08 0 082 0 080 0 080 0 078 0 078 0 074 0 072 0 08
59. b Push Start Switch No voltage reading Defective 12 Volt Reading 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 Push Start Switch No voltage reading check BLACK cable 12 Volt Reading for poor connection or open circuit Check BLACK ground cable at starter for loose or corroded connection or open cir cuit If cable is O K check starter motor 90 826883R2 JUNE 1998 Page 2B 13 BATTERY CHARGING AND STARTING SYSTEMS Commander 2000 Key Switch Test 1 Disconnect remote control wiring harness and instrument panel connector 2 Setohmmeter on R x 1 scale for the following tests BLACK PUR PURPLE RED RED YEL YELLOW CONTINUITY SHOULD BE INDICATED AT THE FOLLOWING POINTS RED YEL RED PUR KEY POSITION BLK YEL NOTE Key switch mustbe positioned to RUN or START and key pushed in to actuate choke for this test 3 If meterreadings are other than specified in the preceding tests verify that switch and not wiring is faulty If wiring checks ok replace switch Page 2B 14 90 826883R2 JUNE 1998 BATTERY CHARGING AND STARTING SYSTEMS Emergency Stop Switch Lanyard Type IMPORTANT Refer to Section 2D Wiring Diagrams for wiring connections 1 Disconnect emergency stop switch leads from engine wiring 2 Use
60. blade still vibrates replace armature 01440 a Hack Saw Blade b Armature Core Commutator TESTING ARMATURE FOR GROUND 1 Use an ohmmeter R x 100 to check for no continuity between commutator and ar mature core or commutator and shaft 2 If continuity exists armature is grounded and must be replaced a Commutator b Armature Core c Shaft Page 2B 18 90 826883R2 JUNE 1998 5 BATTERY CHARGING AND STARTING SYSTEMS Starter Motor Reassembly 1 90 826883R2 JUNE 1998 Reinstall brush assembly 9 9 53075 a Brush b End Cap c Fiber Washer d Metal Washer e Nut Apply a drop of SAE 10W oilto to helix threads on armature shaft DO NOT over lubri cate a Helix Threads Apply a drop of SAE 10W oilto bushings in drive end cap and lower end cap DO NOT over lubricate Reinstall components on armature shaft Use a new locknut and tighten securely 53228 a Locknut b Spacer Spring d Drive Assembly e Drive End Cap f Armature Shaft Helix Threads Washer gt Page 2B 19 BATTERY CHARGING AND STARTING SYSTEMS 5 Position armature into starter frame so that commutator end of armature is at end of Starter frame where permanent magnets are recessed 1 5 16 33 3mm Align marks as shown 53082 a Alignment Marks b Bottom Edge of Permanent Magnets 6 Install springs and brushes into brush holders Spread brushes and hold in plac
61. 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 fac tory procedure for servicing the product must be strictly followed and whenever practica ble returned to the original intent of the design The responsibilities listed above are general and in 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 6403 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 6403 501 3rd St NW Washington DC 20001 EPA INTERNET WEB SITE http www epa gov omswww CERTIFICATION LABEL The certification label must be placed on each engine at the time of manufacture and must be replaced in the same location if damaged or removed Shown below is a typical certifi cation label and is not representative of any one model Label shown below is not to scale shown at twice the normal size 90 828883R2 JUNE
62. carrier with 3 screws NOTE Orientate O ring to prevent pinching it 6 Torque screws to 65 lb in 7 2 Nm E wd IK E NS p b a O Ring b O Ring Retainer P late d CLI o c Screws 3 Torque to 65 7 2 Nm d Bearing Carrier Page 6A 34 90 826883R2 JUNE 1998 GEAR HOUSING Water Pump 1 Slide a new face plate gasket and face plate over driveshaft and position them on gear housing 2 Install nylon washer over driveshaft and set it flat against face plate Place impeller drive key on flat of driveshaft Slide new impeller over driveshaft Align impeller keyway with drive key then push im peller over drive key and against face plate If reusing impeller not recommended note orientation of vane set Install nylon washer and set it flat against impeller Install new O ring in water pump cover Install cover assembly over driveshaft and down against impeller e a Nylon Washer b Face Plate c Drive Key 7 While pushing down on water pump cover assembly rotate driveshaft clockwise to install impeller cover and seat cover against face plate 8 Align mounting holes in gasket face plate and water pump cover with mounting holes in gear housing Install four 4 screws applying Loctite 271 and torque to 60 Ib in 6 8 Nm
63. connect fuel line to engine squeeze bulb until firm and check for carburetor flooding 4 Turn the ignition key switch on the remote control box to on position and depress the ignition key This will activate the choke solenoid on the carburetor to enrich the fuel circuit 90 826883R2 JUNE 1998 Page 2C 17 WIRING DIAGRAMS ELECTRICAL Section 2D Wiring Diagrams Table of Contents Manual Start Models Electronic Advance Model 20 25 19941 2 THRU 1997 Model 20 Jet 19941 2 THRU 1998 2D 2 Electric Start Models with Tiller Handle Start Button Electronic Advance Model 20 25 19941 2 THRU 1997 2D 3 Electric Models Equipped with Remote Control Electronic Advance Model 20 25 19941 2 THRU 1997 2D 4 Manual Start Models Mechanical Advance Model 20 25 1998 2D 5 Electric Start Models with Tiller Handle Start Button Mechanical Advance Model 20 25 1998 2D 6 Electric Models Equipped with Remote Control Mechanical Advance Model 20 25 1998 2D 7 90 826883R2 JUNE 1998 Manual Start Ignition Wiring Diagram RED Stator Model 20 Jet 20 25 1999 and NEWER Manual Start Wiring Diagram RED Stator Model 20 25 1999 NEWER Work Model 20 9 Electric Start Models with Tiller Handle Start Button RED Stator Model 20 25 1999 and NEWER 20 10 Electric Models Equi
64. 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 approxi mately 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 During service only distilled water should be added to the battery not electro lyte 90 826883R2 JUNE 1998 Page 2B 5 BATTERY CHARGING AND STARTING SYSTEMS Charging A Discharged Battery The following basic rules apply to any battery charging situation 1 Any battery be charged at any rate amperes as long as Spilling of electrolyte from violentgassing does notoccur and as long as electrolyte temperature does not exceed 125 52 C If spewing of electrolyte occurs or if electrolyte temperature exceeds 125oF charging rate in amperes must be reduced or temporarily halted to avoid damage to the battery Battery is fully charged when 2 hour period ata low charging rate in amperes all cells are gassing freely not spewing liquid electrolyte and no change in specific gravity occurs Full charge specific gravity is 1 260 1 275 corrected for electrolyte temperature with electrolyte level at 3 16 4 8mm over plate For most satisfactory charging lower charging rates in amperes are recommended If after prolonged charging specific gravity of at least 1 230 on all cells cannot be r
65. of combustion or incomplete com bustion To understand exhaust gas emissions remember that both air and fuel are made of several elements Air contains oxygen and nitrogen among other elements gasolene 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 environ ment But 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 emis sions hydrocarbons HC carbon monoxide 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 oxy gen during the combustion process If the carbon in the gasoline could combine with enough oxygen one carbon atom with two oxyge
66. proper propeller to allow it to operate at or near the top end of the recommended maximum RPM range at wide open throttle with a normal boat load Not only does this allow the engine to develop full power but equally important is the fact that the engine also will be operating in RPM range that discourages damaging deto nation This of course enhances overall reliability and durability of the engine Boat WEIGHT DISTRIBUTION 1 Proper positioning of the weight inside the boat persons and gear has a significant 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 porpoise 3 Can make the bow bounce excessively in choppy water 4 Will increase the danger of the following wave splashing into the boat when coming off plane b Shifting weight to the front bow 1 Improves ease of planing off 2 Generally improves rough water ride 3 If excessive can make the boat veer left and right bow steer BOTTOM For maximum speed a boat bottom should be nearly a flat plane where it contacts the water and particularly straight and smooth in fore and aft direction 1 Hook Exists when bottom is concave in fore and aft direction when viewed from the side When boatis planing hook causes more lift on bottom neartransom and allows bow to drop thus greatly increasing wetted surface and reducing boat speed Ho
67. rest ing on top of the transom Temporarily fasten the outboard to the transom using two C clamps 3 Position the outboard in a vertical position 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 a Straight Edge b Top Front Edge of Water Intake Housing 5 Raise The outboard up on the transom the distance measured in Step 4 Use a straightedge and recheck the mounting height The top edge of the water intake hous ing should be lined up with the horizontal line made in Step 1 6 Fasten outboard to the transom at this height Page 6B 12 90 826883R2 JUNE 1998 JET DRIVE SETTING OUTBOARD MOUNTING HEIGHT ON BOATS WITH FLAT BOTTOM HULLS 1 Place center the outboard on the boattransom so thatthe transom brackets are rest ing 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 Placeastraightedge along the bottom ofthe boatas shown and measure the distance between the bottom of the boat and top front edge of the water intake housing Straight Edge b Top Front 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 wit
68. servicing the products described herein It is assumed that these personnel are familiar with the servicing procedures of these prod ucts 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 in cludes the use of mechanics common hand tools and the special Mercury Marine or recom mended tools from other suppliers We could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of the possible hazards and or results of each method We have not undertaken any such wide evaluation Therefore anyone who uses a service procedure and or tool which is not recommended by the manufacturer first must completely satisfy himself that neither his nor the products safety will be endangered by the service procedure selected All information illustrations and specifications contained in this manual are based on the latest product information available at the time of publication As required revisions to this manual will be sent to all dealers contracted by us to sell and or service these products It should be kept in mind while working on the product that the electrical system and ignition system 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 mech
69. the shift shaft in the fore and aft direction 90 826883R2 JUNE 1998 Page 6A 1 GEAR HOUSING Quicksilver Lubricants and Service Aids 92 809819 Loctite 271 92 850736 1 2 4 w Teflon 92 809824 Loctite Primer 7649 92 850737 1 Super Duty Gear Lubricant Special Tools 1 Universal Puller Plate 91 37241 3 Bearing Puller amp Installation Tool 91 31229A7 a Nut11 24156 Washer 2 12 34961 c Plate 91 29310 d Threaded Rod 91 31229 DDD ny Page 6A 2 90 826883R2 JUNE 1998 GEAR HOUSING e Mandrel 91 36571 4 Bearing Puller Tool 91 27780 5 Slide Hammer 91 34569A1 91 93843 1 7 Bearing Cup Puller 91 44385 91 44386 56812 8 Bushing Removal Tool 91 824787 90 826883R2 JUNE 1998 Page 6A 3 GEAR HOUSING 9 Driveshaft Seal Installation Tool 91 858775 10 Bearing Carrier Prop Shaft Seal Installation Tool 91 858776 11 Bearing Carrier Prop Shaft Bearing Installation Tool 91 858777 Page 6A 4 90 826883R2 JUNE 1998 GEAR HOUSING Notes 90 826883R2 JUNE 1998 Page 6A 5 E GEAR HOUSING Gear Housing Drive Shaft p Ul XU 17 moz f H 7 Loctite 271 92 809819 ll 1g S uper Duty Gear Lubricant 92 850737A1 d Loctite Primer 7649 92 809824 2 4 C w Teflon 92 850736A1 Page 6A 6 90 826883R2 JUNE 1998 m gt JJ L e TORQUE
70. to 35 ft 47 5 N m a Cable End b Attaching Nut Torque to 35 Ib ft 47 5 N m Steering Cable Seal 3 Place a mark on tilt tube 5 8 in 15 9mm from port end of tube Slide plastic spacer o ring and cap over steering cable end to tilt tube on engine 1 4 in MP Mark b Spacer O ring Page 1D 4 90 826883R2 JUNE 1998 OUTBOARD MOTOR INSTALLATION 4 Thread cap up to the 1 4 in 6 4mm mark Cap Steering Link Rod Installation IMPORTANT The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt a Part Number 10 14000 and self locking nuts b amp c Part Number 11 34863 These locknuts must never be replaced with common nuts non locking as they will work loose and vibrate off freeing the link rod to disengage 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 1 Assemble steering link rod to steering cable with two flat washers d and nylon insert locknut b Part Number 11 34863 Tighten locknut b until itseats then back nut off 1 4 turn 2 Assemble steering link rod to engine with special washer head bolt PartNumber 10 14000 and nylon insert locknut c PartNumber 11 34863 Firsttorque bolt a to
71. to carburetor adjustments in this section Defective anti siphon valve Needle and seat in carburetor that is either stuck open or closed Improper carburetor jet restricted jet or idle mix ture screw out of adjustment Improper float level Refer to carburetor adjustments in this section 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 Powerhead sec tion Damaged fuel pump diaphragm Disassemble and inspect fuel pump components 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 4 for reed inspection Fuel pick up outlet tube in fuel tank cracked Replace Wrong spark plug or improper spark plug gap Install correct plug or readjust gap Improper spark timing Reset timing to correct specifications Page 3A 16 90 826883R2 JUNE 1998 CARBURETOR FUEL PUMP Problem Engine Floods Possible Cause Corrective Action Dirt or debris are preventi
72. use an oil can Apply oil generously and fre quently on both stones and work area When honing cylinder block remove hone frequently and check condition of cyl inder walls DO NOT hone any more than absolutely necessary as hone can re move cylinder wall material rapidly c Startstroking atsmallest diameter Maintain firm stone pressure against cylinder wall to assure fast stock removal and accurate results d Localize stroking in the smallest diameter until drill soeed is constant throughout length of bore Expand stones as necessary to compensate for stock removal and stone wear Stroke ata rate of 30 complete cycles per minute to produce best cross hatch pattern Use honing oil generously Thoroughly clean cylinder bores with hot water and detergent Scrub well with a Stiff bristle brush and rinse thoroughly with hot water A good cleaning Is essential If any of the abrasive material is allowed to remain in the cylinder bore it will cause rapid wear of new piston rings and cylinder bore in addition to bearings After cleaning bores should be swabbed several times with engine oil and a clean cloth then wiped with a clean dry cloth Cylinders should not be cleaned with kerosene orgasoline Clean remainder of cylinder block to remove excess materi al spread during honing operation Hone all cylinder walls just enough to de glaze walls 4 Measure cylinder bore diameter with snap gauge micrometer at top middle a
73. 0 003 in 0 076 mm is allowable If out of round is more than 0 003 in 0 076 mm cylinder block and crankcase cover must be replaced MEASURING CYLINDER BORE 1 Measure ring traveled area of cylinder bore at3 depths 6 places by positioning mea Suring instrument in line with and at right angle 90 to piston pin centerline 2 bore is tapered egg shaped or out of round by more than 0 003 in 0 076 mm replace cylinder block TOP CENTER BOTTOM Page 4 24 90 826883R2 JUNE 1998 POWERHEAD STANDARD CYLINDER BORE DIAMETER 20 25 20 J ET BORE TYPE STANDARD BORE DIAMETER ALL MODELS S N 06202749 The cylinder bores are chrome 2 562 in 65 01 mm AND BELOW and cannot be rebored or effi ciently honed Check each cylin der bore for an out of round egged shaped cylinder A maxi mum of 0 003 in 0 076 mm Is allowable ALL MODELS S N 0G202750 The cylinder block is Mercosil 2 562 in 65 01 mm AND ABOVE and the cylinders can be rebored to 0 030 in 0 762 mm over sized Check each cylinder bore for an out of round egged shaped cylinder A maximum of 0 003 in 0 076 mm 15 allow able HONING PROCEDURE a When cylinders are to be honed follow the hone manufacturer s recommenda tions for use of the hone and cleaning and lubrication during honing b Forbestresults a continuous flow of honing oil should be pumped into the work area If pumping oil is not practical
74. 1998 EMISSIONS WE UR Emission C ntrol 400 1999 Information CC PART 37 856984 5 This engine conforms to 1999 Mod Year Idle Speed in gear 750 RPM U S EPA regulations for Slengines Eier Owner Sm Timing Idle 6 WOT 25 BTDC e for required maintenance Family WM9XM 0024210 Standard Spark Plug NGK BP8H N 10 040 FEL 199 92 GM KW HR Valve Clearance Cold mm g j Intake N A Exhaust N A 20 25 HP 1 JAN FEB APR MAY JUNE JULY AUG SEP NOV DEC a Spark Ignition SI b Cubic Centimeter c Model year of engine and production decal part number d Idle Speed In Gear e Timing specifications when adjustable f Recommended spark plug for best engine performance g Valve Clearance Four Stroke engines only h Engine Horsepower rating Month of production Boxing month will punched j FEL Represents Mercury Marine statement of the maximum emissions out put for the engine family k Family example AM TAN d NV W 1998 M Marine 1 PWC X 1999 2 Manufacturer Displacement Technology type Mercury Marine Liter 1 Existing Cubic Inch 2 New Decal Location Production Part No Service Part No Location on Engine 1998 12 24 ci 3 855211 3 855577 5 Inside Top Cowl 20 25 1999 Merc Mar 12 24 ci 3 856984 5 3 856985 5 Inside Top Cowl 20 25
75. 20 Ib ft 27 1 then torque locknut c to 20 Ib ft 27 1 N m C RS 54 0 Bolt 10 14000 Lock Nut 11 34863 Lock Nut 11 34863 Washers 2 each 90 826883R2 JUNE 1998 Page 1D 5 OUTBOARD MOTOR INSTALLATION After installation is complete and before operating outboard check that boat will turn right when steering wheel is turned right and that boat will turn left when steering wheel is turned left Check steering thru full range left and right and at all tilt angles to assure interference free movement Remote Control Installation Refer to Quicksilver Accessory Guide for appropriate electric or manual remote control Use instructions provided with control for proper installation Shift and Throttie Cable Installation to the Outboard Install the shiftcable and throttle cable into the remote control and mountthe remote con trol following instructions which are provided with the remote control NOTE Install the shift cable before the throttle cable The shift cable 15 the first cable to move when the remote control handle is moved into gear Shift Cable Installation 1 Move the remote control handle into full reverse position 2 Place the engine shift lever a into reverse position toward rear while rotating pro peller The propeller shaft will not rotate in either direction when in reverse position 3 Open up the cable retainer cover b and remove the ba
76. 35 mm it maybe helpful to seek advice from the boat manufacturer A number of other options are available to further reduce cavitation 1 Water intake fin kit a Available from the S pecialty Mfg Co for jet models 30 thru 140 The purpose of these fins is to ram more water into the intake and shield the for ward sides of the intake from the entrance of air This kit will help reduce cavitation when running with the wind in a chop a Intake Fin Kit Water Intake Fin KitP artNo 1186 for jet models 45 thru 140 and PartNo 1185 forjetmod el 30 is available from Specialty Mfg Co 2035 Edison Ave San Leandro CA 94577 2 Rough Water Plate b 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 0 794 mm 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 a Rough Water Plate 90 826883R2 JUNE 1998 JET DRIVE Shift Link Rod Adjustment The shift link rod 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 acti
77. 37241 c Mandrel 5 8 in Socket 5 If inspection determines that replacement of forward gear bushing is required remove bushing from forward gear using one of two ways 6 Using a Punch Secure forward gear in a vise Be Sure to use a Soft jaw vise and do not clamp onto tapered bearing Use a punch and hammer remove bushing from the clutch jaw teeth side of gear 7 Using a Press Press bushing from gear using Bushing Removal Tool 91 824787 E 91 824787 CN a F orward Gear d Punch b Vise Protector e Bushing Removal Tool 91 824787 c Bushing Page 6A 24 90 826883R2 JUNE 1998 GEAR HOUSING Pinion Gear 1 Inspect pinion gear teeth for breakage rust chipping or excessive wear 2 Ifpinion gear teeth are damaged inspect FORWARD and REVERSE gear for damage 3 Replace gears as required a P inion Gear Driveshaft IMPORTANT If upper drive shaft bushing or lower drive shaft needle bearing race ap pear to be spinning in their respective bores the gear housing should be replaced 1 Replace drive shaft if the following exist gt Splines are twisted or worn gt Oil seal surface is grooved gt Bearing Bushing journal surfaces are pitted or worn Replace corresponding bearing as well a Bearing Bushing Surface b Bearing Bushing Surface c Seal Surface 90 826883R2 JUNE 1998 Page 6A 25 GEAR HOUSING Bearing Carrier 1 Ifinspection of bearing area on propeller shaft determines that replac
78. 4 Operating Engine Without Battery 2B 4 Specific Gravity 5 2B 4 Electrolyte 2B 5 Charging A Discharged Battery 2B 6 Winter Storage of Batteries 2B 6 Voltage Regulator Test 2B 7 Lamps Burn Out When Engine RPM 15 Increased 2 7 Lamps Burn Dim at Wide Open Throttle 2B 7 Battery Charging System 2B 7 Description ea e acea 2B 7 Alternator Amperes Output 2B 8 Battery Charging System Troubleshooting 2B 9 Alternator Test 2B 9 Rectifier 2B 10 Starting System 2B 11 Starter Motor Amperes Draw 2B 11 Starting System Components 2B 11 DESCIDUON iieiea 2B 11 Troubleshooting the Starting Circuit 2B 11 Specifications Commander 2000 Key Switch Test Emergency Stop Switch Lanyard Type 2B 15 Push Button Stop Switch 2B 15 Starter Motor 2B 16 Disassembly 2 16 Cleaning and Inspection 2B 17 Testing Motor 2B 18 Starter Motor Reassembly 2B 19 Starter Solenoid 2B 21 Flywhe
79. 7A12 a Bushing b Wave Washer 90 826883R2 JUNE 1998 Page 7 5 SIDE SHIFT 3 Install control lever onto throttle cam assembly so thattab of control leveris positioned between ends of inner spring 57043 Control Lever b Tab c Ends of Inner Spring Installation 1 Secure throttle cam control lever assembly onto mounting boss of crankcase cover with bolt Torque bolt to 120 Ib in 13 6 N m 2 Connecttiming link between ball joints of control lever and trigger assembly 57065 a Throttle Cam b Control Lever c Flat Washer d Bolt Torque bolt to 120 Ib in 13 6 N m e Timing Link Page 7C 6 90 826883R2 JUNE 1998 3 90 826883R2 JUNE 1998 SIDE SHIFT Connect throttle cables to throttle cam and throttle cable anchor bracket as outlined in Throttle Cable Installation preceding Nd 57063 a Throttle Cables b Throttle Cam c Bracket Page 7C 7 SIDE SHIFT Neutral Interlock Control Lever Reassembly Installation 1 Lubricate bushing with 2 4 C w Teflon and install bushing 2 4 C With Teflon 92 825407A12 a Bushing 2 Secure interlock lever components with bolt onto mounting boss of crankcase cover M mm 57045 57064 Interlock Lever Flat Washer Bolt Torque to 120 Ib in 13 6 N m Neutral Interlock Wire 7 8 90 826883R2 JUNE 1998 SIDE SHIFT Horizontal Shift Shaft Reassem
80. 883R2 JUNE 1998 E BATTERY CHARGING AND STARTING SYSTEMS Electric Start Components TORQUE QTY DESCRIPTION in Ib ft 5 5 3 Drive Tigri wrmo39ms 15 i wrmoxses 15 CABLE ASSEMBLY RU i STARTER SOLENOID ASSEMBLY 1 i 1 SCREW 14 1 wrwexses 3 WsUaRGwewd 1 RETANER amesscomeda 140 1 WIRING HARNESS ASSEMBLY engme 3 me i STARTER MOTORASSEMBLY Tre RTC 20 189 248 _________ f o HOUSING switch I UJ UJ Co A A BATTERY WIRE ASSEMBLY black BATTERY WIRE ASSEMBLY red LJ wI 00 NOI NI NI NI NI NI NINI N ej IBI m Im J Oil BS Gol NI e O O NI OFF By GU NI OI WO By GW 90 826883R2 JUNE 1998 Page 2B 3 BATTERY CHARGING AND STARTING SYSTEMS Battery Precautions When charging batteries an explosive gas mixture forms in each cell A portion of this gas escapes thru holes in vent plugs and may form an explosive atmosphere around battery if ventilation is poor This explosive gas may remain in or around battery for several hours after ithas been charged
81. 9 Slide centrifugal slinger down drive shaft _ H 7 Loctite 271 92 809819 a Centrifugal Slinger b S crews 4 Torque to 60 6 8 Nm 90 826883R2 JUNE 1998 Page 6A 35 E GEAR HOUSING Gear Housing Installation 9 9 15 Bigfoot 4 Stroke To prevent accidental engine starting remove and isolate spark plug leads from spark plugs before installing gear housing IMPORTANT If water tube has been removed follow installation procedure in Sec tion 5 Water tube location is critical for proper alignment to water pump 1 Tilt outboard to full UP position 2 Place shift handle tiller models or shift lever remote control models into neutral 3 Place gear housing into neutral by pushing down on the lower shift shaft from forward gear to neutral detent Propeller will rotate freely in either direction 4 Coat splines of drive shaft with 2 4 C w Teflon 5 Guide gear housing onto drive shaft housing to aligning the following gt Keep mating surfaces of gear housing drive shaft housing parallel NOTE It may be necessary to rotate the flywheel to aid engagement of drive shaft splines to crankshaft splines gt Insert drive shaft into the opening in the upper part of the drive shaft housing to align with crankshaft splines gt Guide lower shift shaft thru rubber seal opening in lower drive shaft housing and up thru loop of reverse lock link rod gt Position water tube g
82. A A certifi cation 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 90 826883R2 JUNE 1998 Page 3B 5 EMISSIONS Dealer Responsibility When performing service on all 1998 and later outboards that carry a certification atten tion must be given to any adjustments that are made that affect emission levels Adjustments must be kept within published factory specifications Replacement or repair of any emission related component must be executed in a manner that maintains emission levels within the prescribed certification standards Dealers are not to modify the engine in any manner that would alter the horsepower or allow emission levels to exceed their predetermined factory specifications Exceptions include manufacturers prescribed changes such as that for altitude adjust ments Owner Responsibility The owner operator is required to have engine maintenance performed to maintain emis sion levels within prescribed certification standards The owner operator is not to modify the engine in any manner that would alter the horse power or allow emissions levels to exceed their predetermined factory specifications Single engine exceptions may be allowed with permission from the EPA for racing and testing EPA Emission Regulations Page 3B 6 All new 1998 and later outboards manufactured
83. A fault in the battery charging system usually will cause the battery to become under charged 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 ofthe charging system prob lem as follows 1 Check for correct battery polarity RED cable to POSITIVE battery terminal If po larity was incorrect check for damaged rectifier See RECTIFIER TEST Check for loose or corroded battery connections 3 Visually inspect wiring between stator and battery for cuts chafing and disconnected loose or corroded connection 4 Excessive electrical load from too many accessories will cause battery to run down If visual inspection determines that battery connections and wiring are OK perform the following stator and rectifier tests Alternator Test NOTE Alternator can be tested without removing from engine DC resistance of these windings generally is less than 1 ohm A reading that resembles a short is acceptable 1 Disconnect GRAY and YELLOW alternator leads from terminals on either rectifier voltage regulator or isolator block 2 Use an ohmmeter and perform tests as shown in following chart 3 If meter readings are other than specified replace alternator assembly Test Leads Resistance RED to YELLOW 0 65 Rx1 BLACK to GRAY
84. D STARTING SYSTEMS Battery Voltage TEST 2 a Connect voltmeter between common engine ground and Test Point 2 No voltage reading b Push start switch proceed to TEST 3 TEST 3 a Connect voltmeter between common engine ground and Test Point 3 b Push Start Switch No voltage reading 12 Volt Reading proceed to TEST 4 Defective starter solenoid TEST 4 a Connect voltmeter between common engine ground and Test Point 4 No voltage reading b Push Start Switch proceed to TEST 5 TEST 5 Connect voltmeter between common 12 Volt Reading No voltage reading engine ground and Test Point 5 Defective ignition switch proceed to TEST 6 TEST 6 Connect voltmeter between common engine ground and Test Point 6 12 Volt Reading Check BLACK ground wire for poor connec tion or open circuit Reconnect ground wire to Starter solenoid proceed to TEST 7 Electric Start Tiller Handle Model Neutral start switch on lower engine cowl is open or BLACK or WHITE switch leads are disconnected or damaged Proceed to TEST 7 12 Volt Reading Neutral start switch is open or YELLOW RED wire is open between Test Points 4 and 3 No voltage reading check RED wire be an 12 Volt Reading 0 positive terminal and Test Check fuse in RED wire between test points 5 and 6 Check for open RED wire between test points 5 and 6 TEST 7 a Connect voltmeter between common engine ground and Test Point 1
85. E 1998 POWERHEAD NOTE Bearing race halves retainer ring groove faces toward flywheel end of crankshaft 4 Reinstall bearing race halves Secure halves with retainer ring NOTE Install retainer ring so that ring bridges both fracture lines of bearing race 57109 a Race Halves b Retainer Ring 90 826883R2 JUNE 1998 Page 4 37 POWERHEAD 5 Check center main thrust washers for wear as follows a Push thrust washers and center main bearing toward either end of crankshaft b Usea feeler gauge and check clearance between crankshaftand thrust washers c If clearance between crankshaft and thrust washers is greater than 0 030 in 0 762 mm replace thrust washers 57110 a Thrust Washers b Feeler Gauge NOTE It is recommended that the piston pin and piston be installed on the connecting rod prior to installing the connecting rod on the crankshaft to avoid possible bending of the rod during piston pin installation IMPORTANT When replacing needle bearings replace all needles as a set Do not use old and new needles together 6 Install piston onto connecting rod as follows a Lubricate sleeve of Piston Pin Tool 91 76160A2 with 2 4 C w Teflon Marine Lu bricant 92 825407A12 b Hold lower locating washer and sleeve onto piston pin bore of connecting rod and install needle bearing set of 27 2 4 C With Teflon 92 825407A12 a Sleeve b Locating Washer c Needle Bearings 27 Page 4 38 90 826883
86. E 1998 Page 3A 21 CARBURETOR FUEL PUMP Fuel Pump Removal and Disassembly IMPORTANT Fuel pump check valve diaphragm and gasket should NOT be re used once the fuel pump is disassembled 1 Remove 5 screws securing fuel pump assembly to carburetor 2 Separate fuel pump components Cleaning and Inspection 1 Clean and dry all parts thoroughly Inspect pump body and base on carburetor for nicks cracks or rough gasket surface Inspect pump check valve diaphragm Diaphragm MUST BE flat and free from holes and imperfections 4 Pump body surface below check valves MUST BE flat so that check valve will seat Reassembly and Installation 1 Inspect all parts for serviceability 2 Reassemble fuel pump Secure fuel pump assembly to carburetor with 5 screws Torque screws to 18 Ib in 3 2 N m Gasket Pump Body Spring Cap Gasket Diaphragm Pump Cover Lock Washer 5 Screw 5 Torque screws to 18 Ib 3 2 N m Idle Timing Screw Nut A JO Page 3A 22 90 826883R2 JUNE 1998 CARBURETOR FUEL PUMP Primer System The primer system provides extra fuel to the outboard whenever the primer knob is pulled out The primer system components should be inspected carefully for serviceability The diaphragm and gaskets should be inspected for cuts or abrasions Replace accordingly The primer check ball and springs should be inspected for debris or varnish which restrict
87. Forward Thrust Hub b Propeller Rear Thrust Hub d Propeller Nut Tighten Flo Torq Drive Hub Propellers a Forward Thrust Hub b Replaceable Drive Sleeve c Propeller d Rear Thrust Hub Propeller Nut Tighten Tilt Pin Adjustment Placing Tilt Pin in Lower Holes Lower the bow Result in quicker planing off especially with a heavy load or a stern heavy boat Generally improve the ride in choppy water Increase steering torque or pull to the right with the normal right hand rotation propel ler e W N 5 Inexcess lowerthe bow of some boats to pointat which they begin to plow with their bow in the water while on plane This can result in an unexpected turn in either direc tion called bow steering or over steering if any turn is attempted or if a significant wave is encountered 90 826883R2 JUNE 1998 Page 1D 11 OUTBOARD MOTOR INSTALLATION Lift the bow out of the water Generally increase top speed Increase clearance over submerged objects or a shallow bottom W N Increase steering torque or pull to the left ata normal installation height with the nor mal right hand rotation propeller 5 In excess cause boat porpoising bouncing or propeller ventilation Trim Tab Adjustment Propeller steering torque may cause boatto pull in one direction This steering torque re sults from outboard not being adjusted so the propeller shaft is parallel to the water s
88. K stator assembly is mounted below the flywheel and has a low speed LS and high speed HS capacitor charging coil Low speed coil provides primary voltage to the switch box from idle to approximately 2500 RPM The high speed coil provides primary voltage from 2000 RPM to the maximum RPM the outboard is capable of achieving The RED stator assembly is mounted below the flywheel and has only one capacitor charging coil As the flywheel rotates the magnets mounted in the flywheel outer rim pass the charging coils creating voltage This voltage charges the capacitor located in the switch box As the flywheel continues to rotate the magnets in the center hub pass the trigger coil creating AC voltage This voltage turns on one ofthe two electronic switches S CR in the switch box A positive voltage pulse turns on the SCR switch associated with cylinder 1 a negative voltage pulse turns on the SCR switch associated with cylinder 2 The SCR switch discharges the stored capacitor voltage into the primary side of the re spective ignition coil The ignition coil multiplies this voltage to a value high enough to jump the spark plug gap 32000 volts for standard coils 40000 volts for high energy coils This sequence occurs once per engine revolution for each cylinder S park timing on electronically advanced models is controlled internally by the switch box with a fixed trigger S park timing on mechanically advanced models is changed advance
89. Let dry flash off for five minutes and apply another even coat of one half to one mil film thickness This urethane paint will dry to the touch matter of hours but will remain sensi tive to scratches and abrasions for a few days 9 The type of spray gun used will determine the proper reduction ratio of the paint IMPORTANT Do not paint sacrificial zinc trim tab or zinc anode 10 Cut out a cardboard plug for trim tab pocket to keep paint off of mating surface to maintain good continuity circuitry between trim tab and gear housing Decal Application Decal Removal 1 Mark decal location before removal to assure proper alignment of new decal 2 Carefully soften decal and decal adhesive with a heat gun or heat blower while remov ing old decal 3 Clean decal contact area with a 1 1 mixture of isopropyl alcohol and water 4 Thoroughly dry decal contact area and check for a completely cleaned surface Instructions for Wet Application NOTE The following decal installation instructions are provided for a Wet installation All decals should be applied wet TOOLS REQUIRED 1 Plastic Squeegee 2 Stick Pin 3 Dish Washing Liquid Detergent without ammonia Joy and Drift are known to be compatible for this process Automotive Body Filler Squeegee Do not use a soap that contains petroleum based solvents SERVICE TIP Placement of decals using the Wet application will allow time to p
90. M6x1x14 Included W Ref 36 D N UJ NIN N CJ UJ UU mL on I WO DIN N WO O O SWIVEL BRACKET GREASE FITTING GREASE FITTING GREASE FITTING BUSHING KIT O RING BUSHING BUSHING WASHER OOK ASSEMBLY reverse lock SPRING REMOTE CONTROL MODELS SPRING ALL OTHER MODELS SPRING RING retaining E UO UJ W GO WN AJ U 4 20 c 4 ROLL BRACKET EVER control ING retaining OVER lower mount SCREW M8x100 SCREW M8x60 WASHER UMPER front MOUNT lower SWIVEL HEAD S CREW upper mount M8x1 25x133 MOUNT upper WASHER rubber upper mount screw WASHER upper mount screw NUT upper mount screw SCREW 375 24x1 25 STEERING LINK ASSEMBLY WASHER RACKET ride guide BLACK SCREW M10x1 5x25 LOCKWASHER ASHER Ul I lt gt gt gt 4 OJ GY GU GJ GJ GJ NO N2 NA I PH IH A3 S TNT Un BS ES C N MI GO NOIR WH 00 MI 3 OT B GI NOIR WO 00 o Mm ROP te RO ROT EE RO TR ES TR JR RR INR Re Re ES Z N CJ CJ UU m oO NO Ol NO NIN NO 5 Jil u A N A Ae m gt 45 gt A gt I I m O WO I I 90 826883R2 JUNE 1998 Page 5
91. MUST BE GROUNDED during tests Running or cranking engine with CDI or Ignition Coils ungrounded may damage components f using a meter with a built in DVA the DVA 400 or DVA 500 VDC test position should be used NOTE Test leads are not supplied with the Direct Voltage Adapter Use test leads Supplied with multi meter Test procedures and specifications are provided for checking primary ignition voltage while the engine 15 running and or being cranked with all harnesses connected 90 826883R2 JUNE 1998 IGNITION Ignition Troubleshooting DANGER HIGH VOLTAGE SHOCK HAZARD Do nottouch ignition components and or metal test probes while engine is running and or being cranked STAY CLEAR OF SPARK PLUG LEADS To assure personal safety each individual spark plug lead should be grounded to engine When testing or servicing the ignition system high voltage is present DO NOT TOUCH OR DISCONNECT any ignition parts while engine is running Ignition Diagnostic Procedures TROUBLESHOOTING TIP With engine running use inductive timing lightto check spark advance of each cylinder as throttle is opened and closed If timing advances and retards Smoothly on each cylinder ignition system is MOST LIKELY functioning properly IMPORTANT If outboard appears to have an ignition system failure it is recom mended that before beginning in depth troubleshooting a Ensure that the engine 15 mechanically sound condition
92. N GRY GRAY GRN GREEN RED RED WHT WHITE YEL YELLOW Stator Trigger Switch Box Ignition Coil Bottom Cylinder Ignition Coil Top Cylinder Stop Switch Emergency Stop Switch Terminal Strip Charging Coils Ja ro 90 826883R2 JUNE 1998 Page 2D 9 WIRING DIAGRAMS Electric Start Models with Tiller Handle Start Button RED Stator Model 20 25 1999 and NEWER BRN YEL _ gt _ BRN YE lt gt BRN WH GRN WHT 7 1 GRN WH WHT GRN gt C WHT GR BLKYEL Q gt BLKYEL tC C X _BLK YEL BLK im gt BL BLK BLACK BRN BROWN GRY GRAY GRN GREEN RED RED WHT WHITE YEL YELLOW Stator Trigger Switch Box Ignition Coil Bottom Cylinder Ignition Coil Top Cylinder Emergency Stop Switch Push Button Stop Switch Rectifier Charging Coils Neutral Start Switch Push Button Start Switch Start Solenoid 12 VDC Battery Starter Motor aS oo r Page 2D 10 90 826883R2 JUNE 1998 WIRING DIAGRAMS Electric Models Equipped with Remote Control RED Stator Model 20 25 1999 and NEWER Stator Trigger Switch Box Ignition Coil Bottom Cylinder Ignition Coil Top Cylinder Choke Solenoid Remote Control Harness Fuse Holder 20 Ampere Fuse Rectifier Charging Coils Starter Solenoid 12 VDC Battery Starter Motor qq 00
93. N m EXE X TILLER HANDLE BLACK TILLER HANDLE TILLER HANDLE GRAY SHIFT TILLER HANDLE BLACK SIDE SHIFT m AJ gt m gt COVER KIT TILLER HANDLE SHIFT COVER KIT SIDE SHIFT PULLEY CASE SCREW 10 16x1 2 IN ive Ti THROTTLE CABLE TILLER HANDLE SHIFT THROTTLE CABLE SIDE SHIFT THROTTLE CABLE TILLER HANDLE SHIFT THROTTLE CABLE SIDE SHIFT NENNEN SLEEVE throttle cable EN 80 lt D Q gt ARM steering handle BLACK ARM steering handle GRAY SCREW M5x1x16 SCREW M6x1x20 DECAL TILLER HANDLE SHIFT DECAL SIDE SHIFT THROTTLE HANDLE TILLER HANDLE SHIFT ___ ___ 1 ___ __ __ NENNEN __ __ THROTTLE HANDLE SIDE SHIFT __ __ ___ NEM NEN NER NEM gt AJ D D Q GRIP throttle handle STOP SWITCH RETAINER PLATE tiller handle Use with 6MM screw REF 9 PLATE tiller handle Use with 5MM screw REF 9 USHING SCREW M10x1 5x80 390 32 5 44 1 BRACKET BLACK BRACKET GRAY USHING __ __ NENNEN 1 __ __ EE NNI NEM EN N UJ vW AVE WASHER ASHER ASHER n Trl rl FH mnm sj 5 TFT ET Wl co e oO Qo 5
94. ND OF CONNECTING ROD 320 grit Carborundum cloth MUST BE USED to clean bearing surface at PISTON PIN END OF CONNECTING ROD VERIFY CAP TO ROD ALIGNMENT BEFORE TORQUING ROD BOLTS DO NOT continue to clean connecting rod bearing surfaces after marks have been removed NOTE Wash rod to remove abrasive gritand apply light oil to bearing surfaces to prevent rust n ara ea ay 100 Ib in 11 3 N m a To Drill Motor b Use 320 Carborundum Crocus Cloth Page 4 30 90 826883R2 JUNE 1998 POWERHEAD Pistons IMPORTANT If engine was submerged while engine was running piston and or connecting rod be bent If piston pin is bent piston must be replaced If piston pin is bent connecting rod must be checked for straightness 1 Inspect pistons for scoring and excessive piston skirt wear 2 Check tightness of piston ring locating pins Locating pins must be tight 57105 a Locating Pins 3 Thoroughly clean pistons Carefully remove carbon deposits from pistons with a soft wire brush or carbon remove solution Do not burr or round off machined edges Inspect piston ring grooves for wear and carbon accumulation If necessary scrape car bon from piston ring grooves being careful not to scratch sides of grooves Refer to procedure following for cleaning piston ring grooves CLEANING PISTON RING GROOVES Keystone tapered ring grooves Care mustbe taken notto scratc
95. ORTANT Advise the owner that the break in procedure must be followed ACTLY when returning an overhauled engine to service 1 Mix gasoline and oil at the normal 50 1 ratio 2 Operate engine at varied throttle settings for the first hour 1 hour AVOID both wide open throttle operation and prolonged idle in cold water areas during this period 3 After the first hour of operation the engine is may be run atany speed DO NOT EX CEED the full throttle RPM range listed in Specifications preceding Page 4 52 90 826883R2 JUNE 1998 CLAMP AND SWIVEL BRACKET MIDSECTION Section 5 CLAMP and SWIVEL BRACKET Table of Contents Clamp Bracket Assembly 5A 2 Swivel Bracket Assembly 5A 4 Drive Shaft Housing Assembly 5A 6 Drive Shaft Housing Disassembly Reassembly 5A 7 90 826883R2 JUNE 1998 Page 5 1 E CLAMP AND SWIVEL BRACKET Clamp Bracket Assembly 2 4 C With Teflon 92 825407A12 Page 5 2 90 826883R2 JUNE 1998 CLAMP AND SWIVEL BRACKET Clamp Bracket Assembly E TORQUE 1 CLAMP BRACKET STBD BLACK 2 11 7 CLAMP BRACKET STBD GRAY po CLAMP BRACKET STBD TRACKER GRAPHITE GRAY p CLAMP BRACKET PORT BLACK p CLAMP BRACKET PORT GRAY p CLAMP BRACKET PORT TRACKER GRAPHITE GRAY p THUMBSCREWASSEMBIY RIVE
96. R2 JUNE 1998 POWERHEAD NOTE If the tip of an awl can be inserted between the needle bearings one or more needles are missing and must be replaced 57111 c Install upper locating washer 57113 a Locating Washer d Slide piston onto connecting rod centering piston pin bore over sleeve Slide piston tool up thru piston pin bore and remove sleeve 57114 a Sleeve b Piston Pin Tool 91 76160A2 90 826883R2 JUNE 1998 Page 4 39 POWERHEAD f Apply light oil to piston pin and place piston pin onto tool 2 Cycle Outboard Oil 92 826666A24 57115 Piston Pin b Piston Pin Tool 91 76160A2 g Support bottom of piston and hold piston pin tool up against piston pin h Drive piston pin into piston pin bore with a soft face mallet until pin is flush with piston 57100 a Piston Pin Tool 91 76160A2 b Piston Pin Page 4 40 90 826883R2 JUNE 1998 POWERHEAD i Move piston pin tool to top of piston pin bore and center piston pin in piston 57116 a Piston Pin Tool 91 76160A2 7 Install new lockrings into grooves in both ends of piston pin bore 37117 a Lockring 90 826883R2 JUNE 1998 Page 4 41 POWERHEAD 8 Install connecting rods onto crankshaft as follows a Apply 2 4 C w Teflon Marine Lubricant to connecting rod big end bearings IMPORTANT Replace roller bearing halves as a set DO NOT use old and new halves together 0 Place both halves of connecting rod b
97. R2 JUNE 1998 Page 8 5 MANUAL STARTER 2 Snap interlock link rod into lower lock lever Link Rod b Lock Lever Push filter straight up when installing Turning or cocking filter may break fuel line connection on filter 3 Push ball of fuel filter into socket of rope guide DO NOT turn or cock fuel filter Sr Filter b Guide Page 8 6 90 826883R2 JUNE 1998 MANUAL STARTER Starter Rope Replacement 1 Remove rewind starter from engine as outlined previously NOTE If starter is broken remove all remaining rope from sheave 2 Disengage starter interlock from starter sheave 3 Pull starter rope handle out from rewind starter about 1 ft 30 5cm and tie a knotat this point to prevent rope from being pulled back into rewind starter NOTE 1999 Model and newer have a redesigned rope guide support which must be re moved before replacing starter rope 57051 Interlock b Rope Guide Support 1999 Model and Newer 4 Remove rope retainer from starter handle and rope a Starter Handle b Retainer 90 826883R2 JUNE 1998 Page 8 7 MANUAL STARTER 5 Install starter handle new rope cut to a length of 66 in 1676 mm Tie a knot into end of rope Place knot into recess of rope retainer Install rope retainer into starter handle 53233 a Handle b Knot c Retainer 8 8 90 826883R2 JUNE 1998 MANUAL STARTER 7 While holding sheav
98. Stop Switch Start Switch 12 VDC Battery Neutral Start Switch e 20 6 90 826883R2 JUNE 1998 WIRING DIAGRAMS Electric Models Equipped with Remote Control Mechanical Advance Model 20 25 1998 gt GRN YEL BRN WHT AN WHT Tre BLK BLACK BRN BROWN GRY GRAY GRN GREEN RED RED WHT WHITE YEL YELLOW Charging Coils Stator Ignition Coil Top Cylinder Ignition Coil Bottom Cylinder Rectifier Switch Box Trigger Starter Motor Starter Solenoid Fuse Holder 20 Ampere Fuse Remote Control Wiring Harness 12 VDC Battery m Choke Solenoid AX 20 0200o0nm 90 826883R2 JUNE 1998 Page 2D 7 WIRING DIAGRAMS Manual Start Ignition Wiring Diagram RED Stator Model 20 Jet 20 25 1999 and NEWER GRN YEL O m BLK YEL BLKYEL 1 gt K G gt BLK 400 BLK BLACK BRN BROWN GRY GRAY GRN GREEN RED RED WHT WHITE YEL YELLOW Stator Trigger Switch Box Ignition Coil Bottom Cylinder Ignition Coil Top Cylinder Emergency Stop Switch Stop Switch 20 8 90 826883R2 JUNE 1998 WIRING DIAGRAMS Manual Start Wiring Diagram RED Stator Model 20 25 1999 and NEWER Work Model BRN WHT 4 BRN WH BLK YEL ____ _ BLK YEL BLK YEL KK BLK BLACK BRN BROW
99. Tiller Tube b Pulley Case 4 Remove pulley case assembly from tiller handle and remove cover bolt a Pulley Case Assembly b Cover Bolt 5 Remove cover and lift pulley assembly from case Replace cables as required 53257 a Cover b Pulley Assembly 90 826883R2 JUNE 1998 Page 7B 7 TILLER HANDLE Installation 1 Wrap cables around pulley Top cable wraps and locks in top groove Bottom cable wraps and locks in bottom groove 2 Place pulley and cable assembly into pulley case a Pulley b Top Cable c Bottom Cable 3 Install pulley cover and secure cover with bolt a Cover b Bolt Drive Tight 4 Install pulley assembly into tiller handle and slide tiller tube into pulley 53256 a Pulley Assembly b Tiller Tube Page B 8 90 826883R2 JUNE 1998 TILLER HANDLE 5 Secure tiller tube in handle with retainer and bolt Torque bolt to 50 Ib in 5 6 N m 6 Install tiller washer tab aligns with slot in handle plain washer wave washer plain washer and flanged bushing over cable harness assembly 53248 a Retainer b Bolt Torque to 50 Ib in 5 6 N m c Tiller Washer d Tab e Slot f Plain Washer g Wave Washer h Flanged Bushing 7 Slide tiller handle assembly into anchor bracket 8 Route stop button harness through fuel connector opening in bottom cowl 9 Route control cables through opening in bottom cowl 10 Align tabs of inner and outer flanged bushings wit
100. V P UN YEL BLK 16 PUR 12 2 YEL RED 7 RED 8 23890 Ignition Choke Switch b Emergency Stop Switch c Neutral Start Switch d Tachometer Accessories Harness Connector e Wiring Harness Connector Page 2D 15 90 826883R2 JUNE 1998 WIRING DIAGRAMS Commander 3000 Panel Mount Control A TTA YEL RE UNM ges gt BRN BROWN GRY GRAY GRN GREEN RED RED WHT WHITE YEL YELLOW a Neutral Interlock Switch b Emergency Stop Switch Page 2D 16 90 826883R2 JUNE 1998 CARBURETOR FUEL PUMP FUEL SYSTEM Section 3A Carburetor Fuel Pump Table of Contents Specifications 1 Carburetor Removal Special Tools 1 Carburetor Installation Carburetor 20 25 JET 20 SA2 3PUSDHPUNIB verbesfrbesrrIRErPECe5TPAXG I ANE Carburetor Seapro Marathon 15 25 amp Super 15 3A 4 Removal and Disassembly Carburetor Adjustments 3A 6 Cleaning and Inspection Low Speed Mixture Screw 3A 6 Reassembly and Installation Main SA 6 J Primer System High Altitude Jet Chart 7 Symptoms of a defective primer syst
101. White Ground Lead Stator Connector Stator Lead RED High Speed Stator Ground Lead BLACK Stator Lead Blue Low Speed Engine Stop Lead BLACK YELLOW Trigger Lead BROWN WHITE Trigger Lead BROWN Y ELLOW SO 0 90 826883 R2 JUNE 1998 Page 2A 9 IGNITION MECHANICAL SPARK ADVANCE BLACK STATOR The ignition switch box receives an currentfrom the low and high speed stator assem bly This currentis rectified and changed to a DC current where it will be stored in the inter nal capacitor A voltage pulse from the trigger assembly in firing order turns on respec tive SCR switch which discharges the capacitor stored voltage and sends itto the ignition coil a 1 Coil Primary Lead Green Yellow b 2 Coil Primary Lead Green White c Ground Lead d Engine Stop Lead BLACK YELLOW e Trigger Lead BROWN YELLOW f Stator Lead BLACK WHITE High Speed g Trigger Lead BROWN WHITE h Stator Lead BLACK Y ELLOW Low Speed MECHANICAL AND ELECTRONIC SPARK ADVANCE RED STATOR The mechanical and electronic spark advance mechanism circuitry operate the same with the RED stator as they do with the BLACK stator The only difference is thatthe RED stator has only 1 charging coil whereas the BLACK stator has 2 charging coils 1 high speed coil and 1 low speed coil Page 2A 10 90 826883R2 JUNE 1998 IGNITION Electronic Spark Advance Set Up Timing 3000 200
102. age 8 11 MANUAL STARTER Cleaning and Inspection 1 Clean rewind spring assembly with solvent and dry with compressed air 2 Inspectrewind spring withoutremoving spring from retainer for kinks burrs or break age Replace assembly if necessary 3 Inspect cam tension spring for damage Replace as necessary 4 Inspectstarter sheave and housing for nicks grooves cracks and distortion especial ly in area of rope travel Replace assembly if necessary 5 Inspect starter rope for wear and replace if necessary Reassembly 1 Apply 2 4 C w Teflon 92 825407A12 to rewind spring and cam tension spring 2 Install rewind spring assembly into recoil housing positioning end of spring notch 57059 2 4 C With Teflon 92 825407A12 a Rewind Spring b Notch c Cam Tension Spring Page 8 12 90 826883R2 JUNE 1998 MANUAL STARTER 3 Install starter sheave into housing aligning notches in sheave with appropriate loca tions on recoil spring 57060 a Sheave b Alignment Notches 4 Secure cam to housing with bolt Torque bolt to 70 Ib in 7 9 Sy Se SK A SA 57055 2 4 C With Teflon 92 825407A12 a b Bolt NOTE If after tightening cam retaining bolt sheave does not move freely sheave is not aligned properly with recoil spring retainer Remove cam retainer bolt and check align ment of sheave with spring retainer 5 Apply 2 4 C w Teflon to edg
103. al passengers equipment pulling ski ers etc Page 1C 6 90 826883R2 JUNE 1998 GENERAL INFORMATION Propeller Removal Installation 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 pro peller always shift outboard to neutral position and remove spark plug leads when you are servicing the propeller 1 Shift outboard to neutral position 2 Remove the spark plug leads to prevent engine from starting lt D 3 Place a block of wood between gear case and propeller to hold propeller and remove propeller nut 4 Pull propeller straight off shaft If propeller is seized to the shaft and cannot be re moved have the propeller removed by an authorized dealer 90 826883R2 JUNE 1998 Page 1C 7 GENERAL INFORMATION 5 Coat the propeller shaft with Quicksilver Anti Corrosion Grease or 2 4 C Marine Lu bricant with Teflon IMPORTANT To prevent the propeller hub from corroding and seizing to the pro peller shaft especially in salt water always apply a coat of the recommended lubri cant to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed 6 Flo Torque Drive Hub Propellers Install forward thrust hub propeller rear thrust hub a
104. alt water apply Quicksilver Anti Corrosion Grease around the entire mounting flange on the water intake housing and also to the threads on the six mounting bolts 90 826883R2 JUNE 1998 Page 6B 19 c J ET DRIVE n Steering Pull Adjustment 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 5 mm toward the starboard side of the outboard a ExhaustFins Impeller Clearance Adjustment 1 The impeller should be adjusted so there is approximately 0 030 in 0 8 mm clear ance between the impeller edge and liner Operating the jet drive in waters that con tain sand and gravel can cause wear to the impeller blades and the clearance will startto exceed 0 030 in 0 8 mm As the blades wear shims a located in the stack outside of the impeller can be transferred behind the impeller This will move the im peller further down into the tapered liner to reduce the clearance 2 Checkthe impeller clearance by sliding a feeler gauge through the intake grate and measure the clearance between the impeller edge and liner If adjustmentis required refer to Impeller Removal and Installation a Shims Page 6B 20 90 826883R2 JUNE 1998 Worn Dull Impeller JET DRIVE The intake of gravel through the pump can round off and wear the leading edges on the impeller Some conditions you
105. anic the battery cables should be disconnected at the battery Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive internal damage when the engine is started 90 826883R2 JUNE 1998 Page 5 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 met ric 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 Mis matched 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 when ever possible Where the fasteners are not satisfactory for re use care should be taken to select a replacement that matches the original Cleanliness and Care of Outboard Motor 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 manu al it should be understood that proper cleaning and protection of machined surfaces and friction areas is a part of the repair procedure This is con
106. at control 2 place too much weight at the transom altering the designed flotation characteristics of the boat or 3 cause the boat to break apart particularly around the transom area Overpowering a boat can result in serious injury death or boat damage Outboard Remote Control The remote control connected to your outboard mustbe equipped with a start in gear pro tection device This prevents the engine from starting when the outboard is in gear Avoid serious injury or death from a sudden unexpected acceleration when start ing your engine The design of this outboard requires that the remote control used with it must have a built in start in gear protection device Selecting Accessories For The Outboard Genuine Mercury Marine Quicksilver Accessories have been specifically designed and tested for your outboard Mercury Marine Quicksilver accessories are available from Mercury Marine dealers Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system Acquire and read the instal lation operation and maintenance manuals for all your selected accessories Selecting Steering Cables and Remote Control Cables Install steering mountand steering wheel in accordance with installation instructions that accompany each IMPORTANT Steering cable must be correct length Sharp bends on too short of a cable result in kinks too long of a cable requir
107. bent con necting rod and or bent crankshaft exists If this is the case the powerhead must be dis assembled Salt Water Submersion Special Instructions Due to the corrosive effect of salt water on internal engine components complete disas sembly is necessary before any attempt is made to start the engine Fresh Water Submersion Special Instructions Recover engine as quickly as possible Remove cowling Flush exterior of outboard with fresh water to remove mud weeds etc DO NOT at tempt 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 fly wheel 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 com
108. bly Installation 1 Install horizontal shift shaft shift lever assembly into opening in STARBOARD side of crankcase cover 57046 a Horizontal Shift Shaft b Shift Lever 2 Secure horizontal shift shaft to shift rod with lever 57047 a Lever b Horizontal Shift Shaft c ShiftRod 90 826883R2 JUNE 1998 Page 7 9 SIDE SHIFT 3 Install rubber grommet into opening in starboard side of bottom cowl 4 Secure shift handle onto end of horizontal shift shaft with screw and flat washer Torque screw to 50 Ib in 5 6 N m T 57061 a Grommet b Shift Handle c Screw d Washer Page C 10 90 826883R2 JUNE 1998 MANUAL STARTER OUTBOARD MOTOR INSTALLATION ATTACHMENTS Section 8 Manual Starter Table of Contents Specifications 8 1 Starter Rope 8 7 Starter Assembly Manual 8 2 8 11 Rewind Starter Assembly 8 4 Cleaning and Inspection 8 12 Removal MP 8 4 8 12 Installation 8 5 Specifications STARTING Manual Start Recoil SYSTEM Rope Length 66 in 1676 mm 90 826883R2 JUNE 1998 Page 8 1 MANUAL STARTER Starter Assembly Manual This engine has passed a factory ToS meee 31 EMERGENCY STARTING PROCEDURE Refer Operat
109. bolt to 120 Ib in 13 6 N m 2 Connecttiming link between ball joints of control lever and trigger assembly 57041 Throttle Cam b Control Lever c Flat Washer d Bolt Torque bolt to 120 Ib in 13 6 N m e Timing Link 3 Adjustthrottle link rod to a length of 5 1 4 in 13 3cm as measured between ball joint center lines 4 Connect throttle link rod between ball joints of throttle cam and primary throttle lever AW y lt lt 1 ee 57031 Throttle Link Rod Adjust to a length of 5 1 4 in 13 3cm b Throttle Cam c Primary Gear Page A 12 90 826883R2 JUNE 1998 THROTTLE SHIFT LINKAGE Neutral Interlock Control Lever Reassembly Installation 1 Lubricate bushing with 2 4 C w Teflon and install bushing 2 4 C With Teflon 92 825407A12 a Bushing 2 Secure interlock lever components with bolt onto mounting boss of crankcase cover 57045 57044 Interlock lever Flat washer Bolt Torque to 120 Ib in 13 6 N m Neutral Interlock Wire aan 90 826883R2 JUNE 1998 Page 7A 13 THROTTLE SHIFT LINKAGE Horizontal Shift Shaft Removal 1 Remove nut securing access cover to port side of bottom cowl Remove cover fW k 5 45377 coe 2 Liftup and remove lever securing horizontal shift shaft 57035 gt Wy 2 56915 Lever 7 14 90 826883R2 JUNE 1998 THROTTLE SHIFT LINKAGE
110. 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 Quicksilver Accessory Guide for a complete list of available propellers 1 Select a propeller that will allow the engine to operate at or near the top of the recom mended full throttle RPM range listed in Specifications preceding with a normal load Maximum engine speed RPM for propeller selection exists when boat speed is 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 f full throttle operation is below the recommended range the propeller MUST BE changed to one with a lower pitch to prevent loss of performance and possible engine damage 3 After initial propeller installation the following common conditions may require that the propeller be changed to a lower pitch a Warmer weather and great humidity will cause an RPM loss b Operating in a higher elevation causes an RPM loss Operating with a damaged propeller or a dirty boat bottom or gear housing will cause an RPM loss d Operation with an increased load addition
111. ce the drive shaft b impeller end facing up into a vise Heat the bearing carrier a until it feels warm to the touch Place the bearing carrier a onto the drive shaft Square up the inner bore with the ball bearing s and push the bearing carrier down until it bottoms outagainst bear ing Itmay be necessary to lightly tap bearing carrier onto the bearing s using a rub ber hammer NOTE Only a light pressing force is needed to press on the bearing carrier Itmay be nec essary to lightly tap the bearing carrier onto the bearing s using a rubber hammer W N CL a Bearing Carrier b Drive Shaft 90 826883R2 JUNE 1998 Page 6B 27 JET DRIVE Installing Upper Seal Housing Single Bearing System 1 2 3 Install the upper seal housing b being careful notto damage the O ring seals as they Page 6B 28 Grease the upper O ring seals and inside bore of the bearing carrier to ease entry of the seal housing Large Diameter Bearing Type Only Install thrust washer d GRAY teflon coating Side of thrust washer FACES ball bearing on top of bearing Install spacer on top of the thrust washer pass the snap ring groove Only finger pressure should be necessary to push in the housing Install the beveled snap ring a beveled side facing up into the ring groove Make sure the snap ring is fully seated into groove Install
112. ch up any paint nicks 3 Spray Quicksilver Corrosion Guard on external metal surfaces except corrosion con trol anodes Protecting Internal Engine Components NOTE Before performing Steps 1 and 2 make sure the fuel system has been prepared for storage 1 Place the outboard in water or connect flushing attachment circulating cooling wa ter Start the engine and let it run in neutral to warm up 2 With engine running at fast idle stop the fuel flow by disconnecting the remote fuel line When engine begins to stall quickly spray Quicksilver Storage S eal into carbure tor until engine stops from lack of fuel 3 Remove the spark plugs and inject a five second spray of Quicksilver Storage Seal around the inside of each cylinder Page 1B 12 90 826883R2 JUNE 1998 MAINTENANCE 4 Rotate the flywheel manually several times to distribute the storage seal in the cylin ders Reinstall spark plugs Gear Case Drain and refill the gear case lubricant refer to maintenance procedure Positioning Outboard for Storage Store outboard an upright position to allow water to drain out of outboard 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 f
113. cient to refinish several gear housings Procedure 1 Wash gear housing with a muriatic acid base cleaner to remove any type of marine growth and rinse with water if necessary 2 Wash gear housing with soap and water then rinse Sand blistered area with 3M 180 grit sandpaper or P180 Gold Film Disc to remove paint blisters only Feather edge all broken paint edges 4 Clean gear housing thoroughly with DX 330 wax and grease remover 5 Spotrepair surfaces where bare metal is exposed with DX 503 alodine treatment IMPORTANT Do not use any type of aerosol spray paints as the paint will not prop erly adhere to the surface nor will the coating be sufficiently thick to resist future paint blistering 6 Mix epoxy chromate primer DP 40 with equal part catalyst DP 401 per manufac turers instructions allowing proper induction period for permeation of the epoxy prim er and catalyst 7 Allow a minimum of one hour drying time and no more than one week before top coat ing assemblies 8 Use Ditzler Urethane DU9000 for Mercury Black DU34334 for Mariner Grey and DU35466 for Force Charcoal and DU33414M for Sea Ray White Catalyze all three colors with Ditzler 005 catalyst mixed 1 1 ratio Reduce with solvents per Ditzler label 90 826883R2 JUNE 1998 GENERAL INFORMATION sure to comply with instructions on the label for ventilation and respirators Using a spray gun apply one half to one mil even film thickness
114. cure cover with nut and bolt Torque nut 50 Ib in 5 6 N m 57035 a Access Cover b Nut Torque to 50 Ib 5 6 N m 90 826883R2 JUNE 1998 Page 7B 11 SIDE SHIFT CONTROLS Section 7C Side Shift Table of Contents Throttle And Shift Linkage Side Shift 7C 2 Installation 7C 6 Throttle Cables Side Shift Models 7C 4 Neutral Interlock Control Lever 7 8 Removal Installation 7C 4 Reassembly Installation 7C 8 Throttle Cam Control Lever 7C 4 Horizontal 5171 5 7C 9 Removal 7C 4 Reassembly Installation 7C 9 Throttle Cam Control Lever 7C 5 Reassembly 7 5 90 826883R2 JUNE 1998 Page 7 1 SIDE SHIFT Throttle And Shift Linkage Side Shift 2 4 C With Teflon 92 825407A12 Page C 2 90 826883R2 JUNE 1998 SIDE SHIFT Throttle and Shift Linkage Side Shift TORQUE QTY DESCRIPTION b in Ib ft LINK interlock LEVER 20 25 J ET 20 S N G157846 amp UP LEVER JET 20 S N G157845 amp BELOW SCREW M6x1x25 WASHER BUSHING LEVER backplate S PRING detent NOT USED ONJET 20 SPRING PLATE S N G157845 amp BELOW SCREW M5x0 8x16 LEVER horizontal shift shaft PORT SHIFT SHAFT HORIZONTAL SHIFT HANDLE SCREW M5 x
115. d Page 1A 2 90 826883R2 JUNE 1998 SPECIFICATIONS Master Specifications Forward Neutral Reverse Full Shift Gear Ratio 2 25 1 Gearcase Capacity 8 8 fl oz 260 ml Lubricant Type Quicksilver Gear Lube Premium Blend Forward Gear No of Teeth Type Pinion Gear No of Teeth Type 27 Pinion 12 Foreword Gear Backlash Not Adjustable Reverse Gear Backlash Not Adjustable Water Pressure RPM Not Adjustable Water Pressure With 120 Thermostat 2 7 PSI 2000 RPM 0 6 PSI SPORADIC 2000 RPM MID Transom Height Short Shaft 15 in 88 cm SECTION Long Shaft 20 in 51 cm FUEL Fuel Pump Type Integral SYSTEM Recommended Gasoline Automotive Unleaded with a Minimum Pump Posted Octane Rating of 87 Fuel Tank Capacity 6 6 U S Gallons Operating Fuel Oil Ratio 50 1 OIL Recommended Oil Pre Mix 50 1 TC W or TC W III 2 Cycle Outboard Oil STARTING Manual Start Recoil SYSTEM Rope Length 66 in 1676 mm Electric Start 12 Volt Ampere Draw cranking 55 amperes CHARGING Alternator Output SYSTEM BLACK Stator 2 Magnet Flywheel 4 Amp 48 Watt 8 Pole 4 Pulses 6000 RPM RED Stator 4 Magnet Flywheel 6 amp 72 Watt 10 Pole 5 Pulses 6000 RPM BATTERY Battery Rating 465 Marine Cranking Amps MCA or 350 Cold Cranking Amps CCA 90 826883R2 JUNE 1998 Page 1A 3 SPECIFICATIONS IGNITION SYSTEM Readings taken 68 F 20 C Type Spark Plug Type NGK Spark Plug Gap Spark Plug
116. d one center hub magnet The outer magnets are needed for battery charge coil and ignition charge coils The inner hub magnet is for trigger coll NOTE Commercial and service flywheels will have 2 additional spacers and a retaining ring used only with the RED stator Page 2A 8 90 826883R2 JUNE 1998 IGNITION Ignition Coil The primary side of the ignition coil receives voltage discharged from a capacitor in the ignition switch box The voltage is multiplied by the coil until itcan jump the spark plug gap Ignition coil maximum output approximately 35000 volts 52642 Positive Primary Terminal b Negative Terminal Ignition Switch Box ELECTRONIC SPARK ADVANCE BLACK STATOR The ignition switch box receives an AC currentfrom the low and high speed stator assem bly This currentis rectified and changed to a DC current where it will be stored in the inter nal capacitor A voltage pulse from the trigger assembly in firing order turns on a respec tive SCR switch which discharges the capacitor stored voltage and sends itto the ignition Coil The switch box contains an electrical circuit that controls the ignition spark timing The switch box senses the engine R P M by counting trigger pulses and adjusts the engine timing accordingly No idle timing adjustment is required Refer to the Timing S ynchronizing Adjusting sec tion of this manual 41 Coil Primary Lead Green Yellow 42 Coil Primary Lead Green
117. d retarded by rotat ing the trigger coil which changes the trigger coil position in relation to the magnets in the center hub of the flywheel The stop switch or ignition switch shorts the output of the stator to ground to stop the engine on all models 90 826883R2 JUNE 1998 IGNITION Electronic Spark Advance 20 25 OUTBOARDS SERIAL NUMBER USA 06044027 THRU 06437999 BELGIUM 09807909 THRU 09926999 20 OUTBOARDS USA 06044027 THRU 06760299 BELGIUM 09807909 THRU 09016999 The spark timing is controlled by an electronic circuit within the engine switch box The trigger assembly is positioned for maximum advance Refer to Set Up Timing Adjust mentP rocedure The electronic timing feature of the switch box retards the timing on start up and atidle RPM As the engine RPM increases the timing will advance Maximum tim ing will occur at approximately 2500 RPM Mechanical Spark Advance 20 25 OUTBOARDS SERIAL NUMBER USA 0G438000 AND ABOVE BELGIUM 09927000 AND ABOVE 20 ET OUTBOARDS SERIAL NUMBER USA 0G 760300 AND ABOVE BELGIUM 09017000 AND ABOVE The spark timing is changed advanced retarded by rotating the trigger coil which changes the trigger coil position in relation to the magnets in the center hub of the fly wheel The stop switch or ignition switch shorts the output of the stator to ground to stop the engine RPM Limiter The 20 ET RED stator ignition module contains a RP M limiter circuit which interrupts
118. damage If any of these conditions is found the fuel line or primer bulb must be replaced Engine Fuel Filter Inspect sight bowl for water accumulation and inspect the filter element for sediment Clean filter as follows REMOVAL 1 Hold onto the cover to prevent it from turning 2 Turn off the sight bowl 3 Pull out the filter element and wash it with cleaning solvent 90 826883R2 JUNE 1998 Page 1B 5 MAINTENANCE INSTALLATION 1 Push the filter element with open end toward cover into cover 2 Place the O ring seal into the sight bowl and screw the sight bowl hand tight into the cover 3 Visually inspect for fuel leakage around the sight bowl by squeezing the primer bulb until firm forcing fuel into the sight bowl Corrosion Control Anode Your outboard has a corrosion control anode installed to the gear case An anode helps protectthe outboard against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard metals The 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 com pletely eroded Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode a Anode Page 1B 6 90 826883R2 JUNE 1998 MAINTENANCE Spark Plug Inspection Inspect spark plugs at the recommended intervals 1 Remove the spark plug lead
119. dle RPM In Forward Gear Wide Open Throttle WOT RPM 20 25 Idle Mixture Screw Adjustment Preset Turns Out 20 20 Jet 25 25 Seapro 25 Marathon Float Level Main Jet Size 19941 5 thru 1996 20 WMC 44 25 20 Jet WMC 45 25 Seapro Marathon WMC 46 25 Seapro Marathon WMC 46A 1997 and Newer 20 Jet WMC 45 20 WMC 52 25 WMC 53 25 Seapro Marathon WMC 54 20 Jet 19941 THRU 1998 20 25 19941 THRU 1996 Electronic Spark Advance Idle 750 50 RPM In Forward Gear Fast Idle Speed Maximum BTDC Running Setup Timing 20 25 1997 AND NEWER 20 Jet 1999 AND NEWER Mechanical Spark Advance Idle 750 50 RPM In Forward Gear Fast Idle Speed Maximum BTDC Running 90 826883R2 JUNE 1998 SPECIFICATIONS 750 50 4500 5500 9000 6000 1 1 4 Turn 1 1 2 1 2 Turn 1 1 4 1 4 Turn 1 0 in 25 4 mm 0 044 0 076 in 0 076 in 0 080 in 0 076 in 0 044 0 076 in 0 080 in 4 2 B T D C Not Adjustable 1400 RPM 250 RPM 25 1 5500 RPM 28 B T D C 3000 200 R P M Set up timing of 28 B T D C will be retarded to 25 B T D C 5500 R P M 6 1 B T D C 1500 RPM 200 RPM 25 1 095500 RPM Page 1A 5 MAINTENANCE IMPORTANT INFORMATION Section 1B Maintenance Table of Contents Table of Contents 18 1 Battery Inspection 1B 7 Specifications 1B 1 Fuse R
120. e 90 826883R2 JUNE 1998 Page 1B 11 MAINTENANCE 5 Remove lubricant tube and reinstall cleaned fill drain plug and sealing washer Storage Preparations Fuel System IMPORTANT Gasoline containing alcohol ethanol or methanol can cause a for mation of acid during storage and can damage the fuel system If the gasoline be ing used contains alcohol It is advisable to drain as much of the remaining gaso line as possible from the fuel tank remote fuel line and engine fuel system F illthe fuel system tank hoses fuel pumps and fuel injection systems with treated sta bilized fuel to help prevent formation of varnish and gum Proceed with following instruc tions 1 Portable Fuel Tank Pourthe required amountof Quicksilver Gasoline Stabilizer fol low instructions on container into fuel tank Tip fuel tank back and forth to mix stabiliz er with the fuel 2 Permanently Installed Fuel Tank Pour the required amount of Quicksilver Gasoline Stabilizer follow instructions on container into a separate container and mix with ap proximately one quart one liter of gasoline Pour this mixture into fuel tank 3 Place the outboard in water or connect flushing attachment for circulating cooling wa ter Run the engine for ten minutes to allow treated fuel to fill the fuel system Protecting External Engine Components 1 Lubricate all outboard components listed in the Inspection and Maintenance Sched ule 2 Tou
121. e 2C 15 TIMING SYNCHRONIZING ADJUSTING 6 Place the rubber seal side with holes towards front onto the control cables and install control cables barrel holder and rubber seal into the cable holder as shown 7 Lock the barrel holder in place with the cable retainer latch a Rubber Seal b Retainer Latch Starting Procedure ELECTRIC START REMOTE CONTROL MODELS Page 2C 16 NOTE Starting a cold engine will usually require the use of the choke enrichener to start the engine The choke enrichener is operated by pushing in on the ignition key while start ing the engine It may also be helpful to prime the engine 1 to 3 times using the manual primer knob on the outboard IMPORTANT DO NOT lift fast idle lever up when starting a cold engine Leave the lever in the down position until the engine starts 1 Turn ignition key to the START position If the engine is cold push In on key to enrich the engine If the engine fails to start in ten seconds return key to ON position wait 30 seconds and try again 2 If engine begins to stall re activate the choke enrichener until engine is running smoothly NOTE Starting Flooded Engine Lift the fast idle lever to full up Without using the choke enrichener continue to crank the engine for starting 3 Afterthe engine has started slowly lift up the fast idle lever to increase idle speed until engine is warmed up Return fast idle lever to full down po
122. e Installation To The Outboard Install the shift cable and throttle cable into the remote control and mount the remote con trol following instructions which are provided with the remote control NOTE Install the shift cable before the throttle cable The shift cable is the first cable to move when the remote control handle is moved into gear 90 826883R2 JUNE 1998 Page 2C 13 TIMING SYNCHRONIZING ADJUSTING Shift Cable Installation Move the remote control handle into full reverse position Page 2C 14 2 Place the engine shift lever into reverse position toward rear while rotating propeller The propeller shaft will not rotate in either direction when in reverse position Open up the cable retainer cover and remove the barrel holder and front rubber grom met Install the shift cable onto the shift lever pin lock in place with retainer latch Adjust the shift cable barrel so it will fit into the bottom hole of the barrel holder f and that the barrel holder will slide freely into the retaining pocket without pre loading the shift cable a Shift Lever b Cable Retainer Cover c Shift Cable d Shift Lever Pin e Retainer Latch 6 Check shift cable adjustments as follows With remote control shifted into forward the propeller shaft should lock solidly in gear If it does not adjust the cable barrel closer to the engine shift lever Shift remote control into neutral The propeller shaft should turn freel
123. e contracts so that specific gravity in creases 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 electro lyte A fully charged battery will have a specific gravity reading of approximately 1 270 atan electrolyte temperature of 8004 27 If electrolyte temperature is above or below 80 F additions or subtractions must be made in order to obtain a hydrometer reading cor rected to 80 standard Forevery 10oF 3 above 80 add 4 specific gravity points 004 to hydrometer reading Example A hydrometer reading of 1 260 at 110oF 43 C would be 1 272 corrected to 80F indicating a fully charged battery Forevery 10cbelow 80oF subtract 4 points 004 from the reading Example hydrome terreading of 1 272 atOof 18 would be 1 240 corrected to 80 indicating a partially charged battery SPECIFIC GRAVITY CELL COMPARISON TEST This test may be used when an instrumental tester is not available To perform this test measure specific gravity of each cell regardless of state of charge and interpret results as follows If specific gravity readings show a difference between highestand lowest cell of 050 50 points or more battery is defective and should be replaced Electrolyte Level Check electrolyte level in battery regularly A battery in use in hot weather should be checked more frequently because of
124. e fuse with a fuse of the same rating Replace with a new SFE 20 AMP fuse Lubrication Points Lubricate Points 1 thru 6 with Quicksilver 2 4 C Marine Lubricant with Teflon or Special Lubricant 101 1 Steering Friction Adjustment Shaft Tiller Handle Models Lubricate fitting 2 Swivel Bracket Lubricate fitting Page 1B 8 90 826883R2 JUNE 1998 MAINTENANCE 4 Tilt Tube Lubricate fittings wir U gt NAD O 5 The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant Adding lubricant to steering cable when fully extended could cause steering cable to become hydraulically locked An hydraulically locked steering cable will cause loss of steering control possibly resulting in se rious injury or death 6 Steering Cable Grease F itting If Equipped Rotate steering wheel to fully retractthe steering cable end a into the outboard tilt tube Lubricate through fitting b Lubricate points 7 With Light Weight Oil 7 Steering Link Rod Pivot Points Lubricate points 90 826883R2 JUNE 1998 Page 1B 9 MAINTENANCE Lubricate Point 8 with Quicksilver Anti Corrosion Grease 2 4 C Marine Lubri cant with Teflon 8 Propeller Shaft Refer to Propeller Replacement for removal and installation of the propeller Coat the entire propeller shaft with lubricant to prevent the propeller hub from corrodin
125. e in this position lift knotfrom recess and pull all remaining rope from sheave 57053 a Sheave b Knot c Recess 8 Turn sheave COUNTERCLOCKWISE until stop indicating spring is wound tight 9 Slowly turn sheave CLOCKWISE with spring tension until knotrecess is aligned with rope hole in starter housing 57054 a Sheave b Knot Recess c Rope Hole 90 826883R2 JUNE 1998 Page 8 9 MANUAL STARTER 10 Push end of new rope through rope holes in starter housing and starter sheave Pull end of rope out of knot recess 57056 a Rope b Holes c KnotRecess 11 Tie a knot into end of rope and pull knot back into knot recess 57057 a Knot b KnotRecess 12 Allow starter rope to be slowly rewound onto starter sheave 13 Reinstall rope guide support if applicable Page 8 10 90 826883R2 JUNE 1998 MANUAL STARTER Disassembly When disassembling rewind starter SAFETY GLASSES MUST BE WORN incase spring should uncoil out of housing 1 Remove starter rope as outlined previously 2 With rope removed allow sheave to slowly unwind to release spring tension 3 Remove bolt securing cam and sheave to housing 57055 a Bolt b Sheave 4 Gently lift starter sheave from housing 5 Rewind spring assembly be replaced as required DO NOT remove spring from retainer Spring and retainer are replaced as an assembly 57058 a Sheave b Rewind Spring 90 826883R2 JUNE 1998 P
126. e of cam that contacts both pawls 6 Install starter rope as outlined previously 7 Install rewind starter as outlined previously 90 826883R2 JUNE 1998 Page 8 13
127. e swivel bracket Serial Number Model Year Model Description Year Manufactured Certified Europe Insignia 90 826883R2 JUNE 1998 OGXXXXXX Page 1C 1 GENERAL INFORMATION Conditions Affecting Performance Weather Page 1C 2 Rated HP Horsepower Loss Due to Atmosphere Conditions Summer HP Secondary Loss Due to Propeller Becom ing Too Large for Summer Horsepower HORSEPOWER ENGINE RPM Rated RPM It is a known fact that weather conditions exert a profound effect on power output of inter nal 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 con ditions Corporations internationally have settled on adoption of 1 5 0 International Standards Organization engine test standards as set forth in 1 5 3046 standardizing the compu tation of horsepower from data obtained on the dynamometer correcting all values to the power that the engine will produce at sea level at 30 relative humidity at 77 F 25 C temperature and a barometric pressure of 29 61 inches of mercury Summer Conditions of high temperature low barometric pressure and high humidity all combine to reduce the engine power This in turn is reflected in decreased boat speeds as much as 2 or 3 miles per hour 3 or 5 Km per hour in some cases Refer to previous chart Nothing w
128. e unnecessary bends and or loops Both conditions place extra stress on the cable Refer to Quicksilver Accessories Guide to determine correct length of steering cable Page 1D 2 90 826883R2 JUNE 1998 Installing Outboard OUTBOARD MOTOR INSTALLATION 1 Measure the transom height of your boat The boat bottom should be aligned or be within 1 in 25mm above the anti ventilation plate a of the outboard 0 lin 0 25mm a Anti Ventilation P late 2 Place outboard on center line of transom 4 To prevent loss of outboard overboard fasten outboard by drilling two 5 16 in 7 9 mm holes through the transom using transom clamp holes as a template Fasten with two bolts flat washers and locknuts Use a marine waterproofing sealer in holes and around bolts to make the installation water tight a Bolts 2 b FlatWashers 2 C Locknuts 2 90 826883R2 JUNE 1998 Page 1D 3 OUTBOARD MOTOR INSTALLATION Steering Cable and Steering Link Rod Installation Installing Ride Guide Steering Cable to the Outboard IMPORTANT Before installing steering cable into tilt tube lubricate entire cable end with Quicksilver 2 4 C w Teflon Marine Lubricant 92 825407A 12 1 Lubricate the entire cable end e p m a Quicksilver 2 4 C Marine Lubricant with Teflon 2 Insertsteering cable end thru outboard tilt tube and secure steering cable to tilt tube with steering cable attaching nut as shown Torque nut
129. e with a strip of spring steel 7 Push in on drive end of shaft so that commutator will extend out of starter frame a Brushes b Spring Steel Commutator Page 2B 20 90 826883R2 JUNE 1998 BATTERY CHARGING AND STARTING SYSTEMS 8 Install lower end cap onto starter frame 53083 a Alignment Mark Must Align with Slot b Slot c Lower End Cap Starter Solenoid Test Test starter solenoid as follows 1 Disconnect all leads from solenoid terminals 2 Useanohmmeter x 1 scale and connect between solenoid terminals 3 and 4 3 Connecta 12 volt supply between solenoid terminals 1 and 2 Solenoid should click and meter should read zero ohms 4 f meter does not read zero ohms full continuity replace solenoid ange a Ohmmeter Leads b 12 Volt Supply 90 826883R2 JUNE 1998 Page 2B 21 BATTERY CHARGING AND STARTING SYSTEMS Flywheel Ring Gear Installation IMPORTANT Before installing ring gear on flywheel inspect gear and flywheel for paint runs which will prevent ring gear from laying flat against flywheel 1 Inspect and remove any paint runs on ring gear and or mounting surface on fly wheel 2 Place gear on flywheel with countersink side of mounting holes toward the outside 3 Apply Loctite 271 to threads of 4 gear mounting screws and secure gear to flywheel Torque screws to 100 Ib in 11 3 N m 5 Ring Gear Flywheel Screws Torque to 100 Ib in
130. eached battery is not in optimum condition and will not provide optimum perform ance however it may continue to provide additional service if ithas performed satis factorily in the past 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 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 Page 2B 6 Remove battery from its installation as soon as possible and remove all grease sul fate and dirt from top surface by running water over top of battery Be sure however thatventcaps are tight beforehand and blow off all excess water thoroughly with com pressed air Check water level making sure that plates are covered 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 be yond 3 16 over plate Grease terminal bolts well with Quicksilver 2 4 C Marine Lubricant and store battery in COOL DRY place Remove battery from storage every 30 45 da
131. ection 6B 10 Transom Height of the Boat 6B 11 Locate Centerline of the Outboard 6 11 Outboard Mounting Height 6B 11 Water Testing 68 13 Checking for Cavitation 68 13 Shift Link Rod Adjustment 6B 15 Checking Shift Link Rod Adjustment 6B 15 Adjusting Shift Link Rod 6B 15 Lubricating the Drive Shaft Bearing 6B 16 Impeller Removal and Installation oB 17 Steering Pull Adjustment 6B 20 Impeller Clearance Adjustment 6B 20 Specifications J ET DRIVE Impeller Liner Clearance 90 826883R2 JUNE 1998 J ET DRIVE Worn Dull 6B 21 Liner Replacement 6B 22 J et Drive Removal and Installation 6B 23 6B 23 installation bx rea 6B 23 Water Pump Removal and Installation 6B 24 Removal 6 24 6B 24 Bearing Carrier Removal and Installation 6B 25 REMOVAL T 6B 25 installation x trc o o OR ECC EROGO 6B 25 Installing Drive Shaft Bearing 6B 25 Single Bearing System Small Diameter Bearing 6B 25 Single Bearing System Large Diameter Bearing Installing Drive Shaft Installing Upper Seal Hous
132. el Ring 2B 22 Installation 2 22 Neutral Start Switch Electric Start Tiller Handle 51 28 23 Tiller Handle Start Button 2B 24 Choke Solenoid 2B 25 Installation 2B 25 Battery Cables Engine Wiring Harness Remote Electric Start Models 2B 26 Battery Cables Tiller Handle Push Button Electric StartModels 2B 29 Installation 2B 29 Plug Harness Battery Charging Kit 2B 31 Installation 2B 31 Emergency Stop Switch Lanyard Type 2B 31 IriStallaliOlt ersi dx tricis oe ae o ERO CR Rn 2B 31 BATTERY Battery Rating 465 Marine Cranking Amps MCA or 350 Cold Cranking Amps CCA CHARGING SYSTEM Alternator Output RED Stator 4 Magnet Flywheel 10 Pole 5 Pulse STARTING SYSTEM Manual Start Electric Start Ampere Draw Under Load No Load 90 826883R2 JUNE 1998 BLACK Stator 2 Magnet Flywheel 8 Pole 4 Pulse 4 Amp 48 Watt 9 6000 RPM 6 amp 72 Watt 9 6000 RPM Recoil 12 Volt 55 amperes 15 Amperes Page 2B 1 BATTERY CHARGING AND STARTING SYSTEMS Electric Start Components 2 Cycle Outboard Oil 92 13249A24 25 D Liquid Neoprene 92 25711 2 A LOCAL ELECTRIC ONLY B SERVICE ONLY Page 2B 2 90 826
133. em 3A 23 Carburetor Float Adjustment 3A 8 Servicing Sight Bowl Fuel Filter 3A 24 Carburetor Adjustments 3A 9 Fuel System Troubleshooting 15 General Information 3A 15 Specifications CARBURETOR Idle RPM In Forward Gear 750 50 SPECIFI Wide Open Throttle WOT RPM CATIONS 20 4500 5500 25 5000 6000 Idle Mixture Screw Adjustment Preset Turns Out 20 1 1 4 Turn 20 Jet 1 1 2 1 2 Turn 25 25 Seapro 25 Marathon 1 1 4 1 4 Turn Float Level 1 0 in 25 4 mm Main Jet Size 19941 5 thru 1996 20 WMC 44 25 20 Jet WMC 45 25 Seapro Marathon WMC 46 25 Seapro Marathon WMC 46A 1997 and Newer 20 Jet WMC 45 20 WMC 52 25 WMC 53 25 Seapro Marathon WMC 54 0 044 0 076 in 0 076 in 0 080 in 0 076 in 0 044 0 076 in 0 080 in Special Tools 1 Carburetor Scale 90 826883R2 JUNE 1998 Page 3A 1 CARBURETOR FUEL PUMP Carburetor 20 25 JET 20 CONTENTS OF PRIMER INJECTOR KIT PART NO 1395 9844A1 REFERENCE NO 26 Page 3A 2 90 826883R2 JUNE 1998 CARBURETOR FUEL PUMP Carburetor 20 25 JET 20 TORQUE QTY DESCRIPTION Ib in Ib ft N m CARBURETOR WMC 52 20HP CARBURETOR WMC 53 25HP CARBURETOR WMC 44 20HP CARBURETOR WMC 45 25HP JET 20 THROTTLE VALVE 20HP THROTTLE VALVE 25HP JET 20 THROTTLE SHAFT 20 WMC 44 THROTTLE SHAFT 25
134. ement of bearing inside of bearing carrier is required remove bearing from bearing carrier 2 Secure bearing carrierina vise DO NOT clamp onto threaded portion of bearing carrier 3 Remove bearing from bearing carrier with a punch or suitable mandrel socket and ham D 4 a Bearing b Punch Reassembly Drive Shaft Bearing and Seals 1 Install upper driveshaft bearing into driveshaft bore of gear housing sleeve Apply a light coat of 2 4 C w Teflon to upper driveshaft bearing retainer bore as follows gt Place upper driveshaft bearing over bearing retainer bearing bore with lettered side of bearing face up gt Using a suitable mandrel press bearing into gear housing sleeve until the bear ing is just below the oil hole to a depth of 1 00 in 25 4 mm as shown 1 00 in 25 4 mm a Upper Driveshaft Bearing b Mandrel c Oil Hole Page 6A 26 90 826883R2 JUNE 1998 2 a Bearing Cup b Bearing Cup Puller 91 44385 c Flat Washers 2 12 3 7 UL ALFA LL TTL LII GEAR HOUSING Install lower driveshaft bearing cup into driveshaft bore of gear housing as follows gt Assemble bearing cup as shown gt Draw bearing cup up to shoulder of gearcase housing using cup puller 91 44385 as shown 91 44385 91 29310 12 34961 11 24156 91 44385 d Threaded Rod 0 625x18 16 in long 91 31229 e P late 91 29310
135. eplacement Electric Start Remote Gear Case Lubricant Capacity 18 1 Control 145 1B 8 5 1 1 Lubrication 1B 8 Quicksilver Lubricant Sealant 1B 2 GearCase Lubrication 1B 10 Inspection and Maintenance Schedule 1B 3 Gear Case Lubricant Capacity 1B 10 Before Each USC 1B 3 Draining Gear CaSe 1B 10 After Each Use 1B 3 Draining Gear 5 1B 11 Every 100 Hours of Use or Once Yearly Checking Lubricant Level and Refilling Whichever Occurs 1B 3 1 40 en nes 1B 11 Every 300 Hours of Use or Three Years 1B 3 Storage Preparations 1B 12 Flushing The Cooling System 1B 4 Fuel System 1B 12 Fuel System 1 5 Protecting External Engine Components 1 12 Fuel Line 1B 5 Protecting Internal Engine Components 1B 12 Engine 1B 5 1 13 Corrosion Control Anode 1B 6 Positioning Outboard for Storage 1B 13 Spark Plug Inspection
136. faces of reed block that could cause leakage 3 Check for chipped or broken reeds 4 nspectreed block seal forswelling orlooseness Replace reed block assembly if nec essary 5 Ifreeds have been removed retorque screws to 25 Ib in 2 8 N m Check reeds as Outlined in Reed Opening and Reed Stop Opening following Page 4 32 90 826883R2 JUNE 1998 REED OPENING POWERHEAD 1 Check reeds for preload and stand open conditions Stand open should not exceed 0 007 in 0 178 mm Replace reed block assembly if necessary NX 2 I a Reed b Reed Stop c Lock Washer d Screw e Reed Block f Seal Vulcanized to Reed Block NOTE Reed Stop Opening is not adjustable Bleed System 1 2 Inspect bleed hoses for deterioration Replace hoses as required Inspect bleed valves in lower crankcase cover for proper function Valve should flow fuel only one way from bottom of crankcase cover to intake transfer port cover side of each cylinder If check ball in valve is stuck open or closed replace check valve 90 826883R2 JUNE 1998 1 90eFitting 2 2 Bleed Check Valves 2 3 Starboard Bleed Line To Bottom 90oF itting 4 Port Bleed Line To Top 90oF itting 5 Bleed hoses must be routed thru slot Page 4 33 POWERHEAD Thermostat Wash thermostat with clean water Using a thermostat tester similar to the one shown test thermostat as follows gt Open thermostat valve then inser
137. for rust fracturing wear galling or overheating blued Always replace bearings as a set if replacement is necessary 3 Apply light oil to bearings after inspection to prevent rust NOTE Use 2 4 with Teflon to hold bearings in place while reassembling roller bearings to crankshaft 2 Cycle Outboard Oil 92 826666424 90 826883R2 JUNE 1998 Page 4 27 POWERHEAD Connecting Rod 1 Check connecting rods for alignment by placing rods on a surface plate If light can be seen under any portion of machined surfaces if rod has a slight wobble on plate or if a 0 002 0 051 mm feeler gauge can be inserted between any machined sur face and surface plate rod 15 bent and must be discarded 57126 a Feeler Gauge b Surface Plate c Even Downward Pressure 2 Overheating Overheating is visible as a bluish bearing surface color that is caused by inadequate lubrication or excessive RPM 3 Rust Rust formation on bearing surfaces causes uneven pitting of surface s Page 4 28 90 826883R2 JUNE 1998 POWERHEAD 4 Water Marks When bearing surfaces are subjected to water contamination a bear ing surface etching occurs This etching resembles the size of the bearing 51853 5 Spalling 5 palling is the loss of bearing surface and itresembles flaking or chipping S palling will be most evident on the thrust portion of the connecting rod in line with the beam General bearing surface deteriorati
138. g to the shaft Gear Case Lubrication Gear Case Lubricant Capacity Draining Gear Case When adding or changing gear case lubricant visually check for the presence of water in the lubricant If water is present itmay have settled to the bottom and will drain out prior to the lubricant or itmay be mixed with the lubricant giving ita milky colored appearance If water is noticed have the gear case checked by your dealer Water in the lubricant may resultin premature bearing failure or in freezing temperatures willturn to ice and damage the gear case Whenever you remove the fill drain plug examine the magnetic end for metal particles small amount of metal filings or fine metal particles indicates normal gear wear An ex cessive amount of metal filings or larger particles chips may indicate abnormal gear wear and should be checked by an authorized dealer Page 1B 10 90 826883R2 JUNE 1998 MAINTENANCE Draining Gear Case 1 Place outboard in a vertical operating position 2 Place drain pan below outboard 3 Remove fill drain plug a and vent plug b and drain lubricant Checking Lubricant Level and Refilling Gear Case 1 Place outboard in a vertical operating position 2 Remove vent plug from vent hole a 3 Place lubricant tube into the fill hole b and add lubricant until it appears at the vent hole a 4 Stop adding lubricant Install the vent plug and sealing washer before removing the lubricant tub
139. gs with compressed air Clean bearing in solvent and dry with compressed air Bearing should be free of rust stains Attempt to work inner bearing race in and out There should not be excessive play Lubricate ball bearing with Quicksilver Gear Lube Rotate inner bearing race Bearing should have smooth action If ball bearing sounds orfeels rough orhas catches remove and discard bearing Refer to Bearing Carrier following W N HR Needle Bearing 1 Clean needle bearings in solvent and dry with compressed air 2 Replace bearing if needles are rusted fractured worn galled badly discolored or if area of shaft that bearing contacts is worn or pitted Refer to Drive Shaft following 56431 90 826883R2 JUNE 1998 Page 6A 21 GEAR HOUSING Cam Follower 1 Inspect cam follower for wear or galling If wear 15 present inspect corresponding shift cam for wear Replace if worn 52822 Clutch 1 Replace clutch if jaws are rounded or chipped Rounded jaws may be caused by the fol lowing gt Improper shift cable adjustment or linkage gt Engine idle speed too high while shifting gt Shifting too slowly from NEUTRAL into FORWARD or REVERSE VATA Va 52990 Propeller shaft 1 Check propeller shaft for straightness 2 Inspectbushing bearing surfaces of propeller shaftfor pitting or wear Replace shaftand corresponding bushing bearing if wear or pitting 15 observed 3 Replace propel
140. h Washer Cleaning and Inspection 1 Ifbrushes are pitted chipped or worn to less than 3 16 in 4 8mm replace brushes IMPORTANT DO NOT clean the starter drive assembly or armature shaft while starter motor is installed on outboard The cleaning solution will drain dirtinto mo tor housing 2 Ifthe motor drive assembly does not fully engage with flywheel the drive assembly may be binding on the helix threads on the armature shaft due to dirt or wear Locate cause of binding and correct before reassembling aan Clean drive components with cleaning solution and inspect parts for wear 4 Clean commutator with No 00 sandpaper Remove any oil from commutator If com mutator surface is pitted rough or worn unevenly resurface on a lathe 5 Resurface commutator on a lathe as follows a Usealathe to turn down the commutator surface DO NOT turn down the commu tator surface excessively b Clean copper particles from slots between commutator bars c Sand commutator lightly with No 00 sand paper to remove burrs Thoroughly clean the armature after resurfacing and sanding 90 826883R2 JUNE 1998 Page 2B 17 BATTERY CHARGING AND STARTING SYSTEMS Testing Motor Armature TESTING ARMATURE FOR SHORTS 1 Place armature in a growler and switch growler on 2 Hold hack saw blade over armature core while rotating armature 3 Ifsaw blade vibrates armature is shorted Retestafter cleaning between commutator bars If saw
141. h slots in anchor bracket 2 53169 Stop Button Harness b Control Cables Tabs 90 826883R2 JUNE 1998 Page 7B 9 cM 11 Pull on cable ends to remove slack and secure tiller handle to anchor bracket with plate and 2 bolts Torque bolts to 80 Ib in 9 0 N m TILLER HANDLE 57037 a Plate b Bolts Torque to 80 Ib in 9 0 N m Control Cables Installation 1 Rotate tiller handle twist grip to REVERSE gear position 2 Route extended cable over top of primary gear pulley and secure cable into inner groove of pulley Place cable jacket into top notch of cable anchor bracket 57048 a Extended Cable b Inner Groove c Cable acket Notch Page B 10 90 826883R2 JUNE 1998 TILLER HANDLE 3 Rotate tiller handle to FORWARD gear position 4 Route remaining cable below primary gear pulley and secure cable into outer groove of pulley Place cable jacket into lower notch of cable anchor bracket 5 Rotate tiller handle twist grip to NEUTRAL 6 Rotate tiller handle twist grip to SLOW position 7 Adjustjam nuts to remove slack from throttle cables while allowing full travel of throttle linkage carburetor throttle shutter M D HTN hyp Lo OSA Sale 2 NP a oan a oy KE 7 4 L a P c 57049 a Cable b Outer Groove c Cable J acket d Lower Notch e Nuts 8 Reinstall access cover Se
142. h the bottom of the boat as shown 5 Fasten outboard to the transom at this height Water Testing 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 imperfec tions in the hull ahead of the water intake may require this setting to change in order to prevent cavitation at running speeds When operating the boat the outboard drive shaftshould be vertical when planing ortilted toward the boat in order to provide a scooping angle on the water intake Tilting the out board outbeyond a vertical position reduces the scoop angle and can cause impeller slip page and cavitation If the angle of the boat transom does not allow the drive shaft to be positioned vertically a Wedge kit should be installed behind the transom brackets to in crease the tilt in angle NOTE Slight cavitation in sharp turns and rough water is acceptable but excessive ca vitation is harmful to the outboard and should be avoided 90 826883R2 JUNE 1998 Page 6B 13 JET DRIVE Page 6B 14 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 boattransom by 1 4 In If cavitation still exists after lowering the outboard 1 4 in 6
143. h the side surfaces of the ring groove Scratching the side surface of the ring groove will damage the ring groove 1 Useabristle brush and carbon remover solution to remove carbon from side surfaces 2 Atool can be made for cleaning the inner diameter of the tapered ring grooves For the top ring groove a tool can be made from a broken tapered piston ring with the side taper removed to enable the inside edge ofthe ring to reach the inner diameter of the groove bottom ring groove tool can be made from a broken rectangular ring Carefully scrape carbon from inner diameter of ring grooves Care mustbe taken not to damage the grooves by scratching the side surfaces of the grooves Piston with 1 half keystone half tapered and 1 rectangular ring 90 826883R2 JUNE 1998 Page 4 31 POWERHEAD MEASURING PISTON 1 Measure piston skirt at right angle 90 to piston pin centerline PISTON CLEARANCE MINIMUM BORE MEASUREMENT MAXIMUM PISTON MEASUREMENT PISTON CLEARANCE PISTON CLEARANCE 0 003 in 0 004 in 0 076 mm 0 101 mm Reed Block IMPORTANT DO NOT remove reeds from reed block except for inspection pur poses only DO NOT turn used reeds over for reuse If a reed block component is damaged the entire reed block assembly must be replaced Individual compo nents are not sold separately 1 Thoroughly clean reeds and reed block 2 Check for wear indentations cracks or grooves On Sealing sur
144. haft from propeller shaft cavity as shown NOTE Cam follower is free to slide out of propeller shaft 4 Remove reverse gear and bearing carrier from propeller shaft 5 Separate reverse gear from bearing carrier tA AIL SIN a Cam Follower b P ropeller Shaft Assembly c Reverse Gear d Bearing Carrier Page 6A 14 90 826883R2 JUNE 1998 GEAR HOUSING NOTE When using a screwdriver to remove carrier seals be careful not to scar carrier seal Surface If carrier seal surface 15 damaged replace carrier 6 Secure bearing carrier in a vise Using a screwdriver pry out both seals from bearing Carrier a Oil Seals Propeller Shaft 1 Inserta thin blade screwdriver or awl under first coil from front of cross pin retainer Spring 2 Rotate propeller shaft to unwind spring from sliding clutch a Awl b Cross Pin Retaining Ring 3 Insert flat end of cam follower into front end of propeller shaft 4 Position cam follower against a solid surface 90 826883R2 JUNE 1998 Page 6A 15 GEAR HOUSING 5 Push against cam follower Use a punch or awl to push cross pin out of sliding clutch 6 Release pressure against cam follower LIE lt N a Cam Follower b Cross Pin 7 Remove cam follower spring and sliding clutch from propeller shaft 6 2 Cie a Cam Follower b S pring c Clutch Water Pump 1 Slide centrifugal slinger off drive shaft
145. hat have a 20 in Shaft length to be installed on boats having a 27 in transom height 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 Locate Centerline Of The Outboard Locate and mark with pencil the vertical centerline a of boat transom a Centerline of Transom Outboard Mounting Height The initial outboard mounting height setting will work good for mostapplications however because of different boat hulls designs the setting should be rechecked by test running the boat Refer to Water Testing gt 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 spurts and reduce thrust This condition should be avoided by proper height setting gt Installing the outboard too low on the transom will allow excessive drag 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 a onthe transom up from V bottom the same length as the width of the water intake housing b a Horizontal Line b Width of Water Intake Housing 90 826883R2 JUNE 1998 Page 6B 11 c J ET DRIVE n 2 Place center the outboard on the boattransom so thatthe transom brackets are
146. he 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 e Over advanced ignition timing e Use of low octane gasoline e Propeller pitch too high engine RPM below recommended maximum range e Lean fuel mixture at or near wide open throttle Spark plugs heat range too hot incorrect reach cross firing e nadequate engine cooling deteriorated cooling system Combustion chamber piston deposits result in higher compression ratio Detonation usually can be prevented if 1 The engine is correctly set up 2 Diligent maintenance is applied to combat the detonation causes 527 ELE DU 2 uos Ou E a r Ss QI 51115 Damaged Piston Resulting from Detonation Page 1C 4 90 826883R2 JUNE 1998 GENERAL INFORMATION Following Complete Submersion 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
147. ig end roller bearing onto crank pin 2 4 C With Teflon 92 825407A12 a Roller Bearing The word UP cast on the outside of piston must be toward flywheel end of crankshaft when installing piston rod assembly onto crankshaft Failure to orient piston rod assembly correctly on crankshaft will result piston rings catching in ports causing powerhead damage If UP is not present on top of piston raised rib on wrist pin boss must face up towards flywheel end of crankshaft 57096 57095 4 42 90 826883R2 JUNE 1998 E POWERHEAD IMPORTANT Clean connecting rod bolts with solventand dry with compressed air Inspect threads for damage If threads are not damaged bolts may be reused Ap ply light oil to threads prior to installation C Observe connecting rod cap fracture line for correct alignment Secure connect ing rod with v notch of rod toward flywheel end of crankshaft onto crankshaft with rod cap and bolts Torque bolts to 150 Ib in 16 9 N m 2 Cycle Outboard Oil 92 826666A24 EUG a Fracture Line b Connecting Rod c V Notch Toward Flywheel d Rod Cap e Bolts Torque to 150 Ib in 16 9 N m 90 826883R2 JUNE 1998 Page 4 43 POWERHEAD d Correct piston installation N N 25 5 lt _ 57120 a Intake Side b Exhaust Side 9 Install new piston rings using Piston Ring Expander 91 24697 InstallRECTANGU LAR ring firstin bottom ring groove Ins
148. 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 6 Repeat steps 2 4 as required to reduce steering torque a Trim Tab b R etaining Bolt 90 826883R2 JUNE 1998 Page 6A 41 GEAR HOUSING Filling Gear Housing with Lubricant 1 Place outboard in a vertical operating position 2 Remove vent plug from vent hole 3 Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole a Vent Hole b Lubricant Tube 4 Install the vent plug and sealing washer before removing the lubricant tube 5 Remove lubricant tube and reinstall cleaned fill drain plug and sealing washer a Vent Plug b F ill Plug 6 Apply a liberal coat of 2 4 C w Teflon 92 825407A12 to propeller shaft splines 2 4 C w Teflon 92 850736A 1 7 Install thrust hub cap on thrust hub Page 6A 42 90 826883R2 JUNE 1998 LOWER UNIT Section 6B et Drive Table of Contents J et Pump Assembly S N 0G157845 amp Below 6B 2 J et Linkage S N 0G157845 amp Below 6B 4 etWater Pump Components 6B 5 J et Pump Assembly S N 06157846 amp Up 6B 6 J et Linkage S N 06157846 amp Up 6B 8 Selecting a Boat that 5 Best Suited for et Power 6B 10 Engine Horsepower Sel
149. ill hesitate or stall on accel eration Readjust mixture if necessary Install access plug a Idle Mixture Screw Behind Access Plug b Access Plug 6 Readjust idle speed screw in Forward gear to specification 90 826883R2 JUNE 1998 Page 2C 9 TIMING SYNCHRONIZING ADJUSTING 20 Jet 20 25 Models Non Marathon SeaPro 1 With the engine in Neutral and the primer enrichener pushed to the Full In and Full Clockwise position adjust the fast idle soeed screw per specification i 52789 a Fast Idle Screw b Primer Enrichener 2 Check the primer enrichener circuit by pulling the primer enrichener knob to the full out position The engine speed should drop a minimum of 300 R P M and remain run ning for approximately five 5 seconds before stalling Timing Synchronizing Adjusting Remote Control Models 1 Check all electrical connections to ensure they are tight and secure including battery connections on electric start models 2 Push primer enrichener to Full In position and turn the primer knob to Full Counter clockwise position Page 2C 10 90 826883R2 JUNE 1998 TIMING SYNCHRONIZING ADJUSTING 3 Manually pull throttle lever to Full position until the stop tab on the throttle arm contacts the stop tab on the shift platform 7 em ZIEL OT cos est 50 52798 a Stop Tab b Shift Platf
150. ill 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 combus tion 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 wa ter vapor or humidity content Accompanying this weather inspired loss of power is a second but more subile loss At rigging time in early spring the engine was equipped with a propeller that allowed the en gine to turn within its recommended RPM range at full throttle With the coming of the sum mer weather and the consequent drop in available horsepower this propeller will in ef fect become too large Consequently the engine operates at less than its recommended RPM 90 826883R2 JUNE 1998 GENERAL INFORMATION 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 itis essential that the engine have the
151. iner 26 Check shift operation as follows gt Place shift lever in FORWARD Gear housing should ratchet when propeller shaft is turned clockwise and resistance should be felt when propeller is turned coun terclockwise gt Place shift lever in NEUTRAL Resistance should NOT be felt when propeller shaft is rotated in either direction gt Place shift lever in REVERSE Resistance should be felt when propeller shaft is rotated in either direction gt If shift operation is not as described recheck the coupler installation procedure Page 6A 40 90 826883R2 JUNE 1998 GEAR HOUSING Trim Tab Adjustment and Replacement IMPORTANT The trim tab 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 corro sion protection function will be lost Replace trim tab if 50 or more corroded Mark location of old trim tab on anti ventilation place before removal install new trim tab in same location 1 Check trim tab position 2 Operate boat at the speed at which it would normally be operated 3 Ifthe 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 4 f necessary adjust trim tab 5 Shift engine control into NEUTRAL and turn
152. ing Single Bearing System 0 030 in 0 8 mm Page 6B 1 c J ET DRIVE n J et Pump Assembly S N 0G 157845 amp Below Loctite 271 92 809820 2 4 C With Teflon 92 825407A12 Page 6B 2 90 826883R2 JUNE 1998 JET DRIVE J et Pump Assembly S N 0G157845 amp Below TORQUE QTY DESCRIPTION Ib in Ib ft N m JET PUMP ASSEMBLY BLACK J GR URMESRRET SASEgug 71 32 160 150 mE mE j KEY impeller 1 7 SHMM impeler 910 j 96 80 108 34 TAB WASHER SCREW 250 20 x 3 4 SCREW 10 24 x 5 8 90 826883R2 JUNE 1998 Page 6B 3 JET DRIVE J et Linkage S N 06157845 amp Below 1 0798 TORQUE DESCRIPTION Ib NUT 1 4 28 NUT LEVER ASSEMBLY 1 1 SCREW 1 4 20 x 1 1 4 1 LEVER MOUNT 74 in Ib ft lt 3 6B 4 90 826883R2 JUNE 1998 JET DRIVE J et Water Pump Components Loctite 271 92 809820 2 4 C With Teflon 92 825407A12 TORQUE QTY DESCRIPTION Ib in 1 1 FACE PLATE WASHER impeller KEY Impeller Drive 4 1 IMPELLER WASHER impeller RING water pump KG WATER PUMP ASSEMBLY 8 1
153. ing outer e O ring inner f Washer Drive Shaft and Pinion Gear r es oe D g S pring h Washer I R oll Pin j Driver P in k S hift Cam 1 Clamp driveshaft in a soft jaw vise and remove pinion nut or bolt that secures pinion to driveshaft Pull driveshaft out of gear housing Remove pinion and tapered roller bear ing NOTE 9 9 15 Bigfoot 4 Stroke uses nutto secure pinion gear 20 25 2 Stroke uses bolt to secure pinion gear a P inion Nut Bolt b P inion c Tapered Roller Bearing Page 6A 18 ZE LZZ 4747 AN 2222 4 AA ZZ A N o d 90 826883R2 JUNE 1998 GEAR HOUSING Upper Drive Shaft and Bearing Seals 1 Using Water Pump Cartridge Puller 91 27780 as shown remove the driveshaft oil seals from gear housing 91 27780 ad 2224 x a Oil Seals b Water Pump Cartridge Puller 2 Using suitable mandrel drive upper drive shaft bearing through gearcase sleeve to the bottom of gearcase 3 Do not remove gearcase sleeve not shown a Upper Driveshaft Bearing b Mandrel 90 826883R2 JUNE 1998 Page 6A 19 GEAR HOUSING Lower Drive Shaft Bearing Cup 1 Fasten bearing cup puller on a threaded rod as shown 2 Tighten hex nutand draw the bearing cup puller up into bearing cup until on tool snaps over the top side of bearing cage Rem
154. ion tor detailed starilug instructions sad Connect nel Beg 906 open tank vonl on e primer pati fem e SIFT INTO NEUTRAL Emergency mest be Ia run start position Engage spore repo in notch in aad wind 1 2 Hanes engine pull oul E onplag be net out choke kaob Poll rege 20 19 2 5 Cyanacrylate Adhesive purchase locally 2 4 C With Teflon 92 825407A12 A 30 b in 3 5 110b in 12 5 N m Page 8 2 90 826883R2 JUNE 1998 E MANUAL STARTER Starter Assembly Manual TORQUE RECOIL STARTER ASSEMBLY USA 0G BEL amp BELOW RECOIL STARTER ASSEMBLY USA 0G BEL amp UP ae HOUSING starter USA 0G BEL amp BELOW HOUSING starter USA 0G BEL amp UP SCREW 1 4 20 135 110 153 3 1 pai mem 75111 E 79121 _____ f umi smWweam uui 77 55 ui mRmNR SCREW support to starter housing M5x35MM oo po 4 E
155. k Rod 92912 a Contact Point spring to just contact fuel pump housing b Throttle Return Spring c Throttle Link Rod 8 Remove access plug from carburetor air intake cover 9 Turn idle mixture screw in clockwise until LIGHTLY seated then back out to an initial setting See Specifications Chart a Access Plug b Idle Mixture Screw Behind Access Plug Keep clear of propeller while cranking and running the outboard motor 10 With the outboard in water connect fuel line to engine squeeze bulb until firm and check for carburetor flooding 11 Check choke operation making sure choke shutter opens and closes all the way IMPORTANT Local Electric Start Models Only Check the neutral start micro switch for proper operation Try to start the engine in the Forward Neutral and Reverse gear with the electric start button The engine must start Neutral Only 90 826883R2 JUNE 1998 Page 2C 5 TIMING SYNCHRONIZING ADJUSTING Starting Procedure 15XD 25 SEAPRO MARATHON MODELS ONLY NOTE Outboards equipped with a thermostat will have a Sporadic tell tail water dis charge Pull choke to full OUT position and start the engine Immediately after the engine starts push the choke knob to Full In position Check for water at the tell tale and at the idle relief holes Tell tale pressure to be per General Specifications 20 JET 20 25 MODELS NOTE Outboards equipped with a thermosta
156. l Remove link wire from fast idle lever Disconnect fuel line from carburetor Remove carburetor mounting nuts Lift carburetor from engine e EE 2 SCA a LN E OF VR 57068 Arm b Primer Knob c Bezel d Slide Block e Link Wire 90 826883R2 JUNE 1998 CARBURETOR FUEL PUMP Carburetor Installation 1 Install carburetor with new gasket onto mounting studs Start attaching nuts but do not tighten 5 067 a Gasket b Nuts 2 Install primer assembly onto carburetor Position alignment hole on assembly over post on bottom of carburetor 5 066 a Alignment Hole b Post 90 826883R2 JUNE 1998 Page 3A 19 CARBURETOR FUEL PUMP 3 Install air cover onto carburetor and secure with 2 screws 4 Tighten carburetor attaching nuts 57075 a Screws b Nuts 5 Secure fuel line to carb with sta strap 6 Reconnect link wire to fast idle lever 57070 a Fuel Line b Sta strap c Link Wire Page 3A 20 90 826883R2 JUNE 1998 CARBURETOR FUEL PUMP 7 Push down on primer arm and insert primer knob bezel and slide block into primer assembly 5 068 a Primer Arm b Primer Knob c Bezel d Slide Block 8 Tighten screw to secure slide block in place 9 Align notch in back side of bezel with tab on bottom cowl and secure bezel in place with retaining clip 5 069 a Screw b Retaining Clip 90 826883R2 JUN
157. l and Installation Removal 1 Remove water pump assembly and water pump base 2 Remove 2 screws securing bearing carrier to jet drive Remove bearing carrier Installation Reinstall bearing carrier as shown a Screws 2 Apply Loctite 271 to Threads Torque to 30 Ib in 3 4 N m Installing Drive Shaft Bearing Single Bearing System Small Diameter Bearing 1 If removed install the bearing thrust ring a into the groove on the drive shaft 2 Install collar b onto the drive shaft Install thrust washer c gray Teflon coating side facing the ball bearing Press the new ball bearing d onto the drive shaft pressing against the inner race only Press collar b over the thrust ring a locking it in its groove Install snap ring e into drive shaft groove below the bearing 90 826883R2 JUNE 1998 Page 6B 25 c J ET DRIVE n Single Bearing System Large Diameter Bearing 1 If removed install the bearing thrust ring into the groove on the drive shaft 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 a locking it in its groove Install snap ring into drive shaft groove below the bearing a Bearing Thrust Ring b Collar Ball Bearing d Snap Ring Page 6B 26 90 826883R2 JUNE 1998 JET DRIVE Installing Drive Shaft Lubricate the seals and inside bore of the bearing carrier a Pla
158. ler shaft if any of the following exist gt Splines are twisted or worn gt Oil seal surface is grooved gt Shafthas a noticeable wobble or is bent more than 0 006 in 0 15 mm 56807 a Bushing Bearing Surfaces b Oil Seal Surface c Measure Here for Wobble When measuring shaft for wobble use v blocks and support at bushing surface Page 6A 22 90 826883R2 JUNE 1998 GEAR HOUSING Shift Shaft 1 Inspect shift shaft retainer for cracks and replace if necessary 2 Inspect shift cam face for wear Replace if worn 53034 09 0 0009 a Shift Cam b S hift Shaft Retainer Reverse And Forward Gear 1 Inspect gear teeth for pitting uneven wear scoring etc Replace gear if any damage is found 2 Inspect gear clutch jaws Replace gear if jaws are rounded or chipped a Gear Teeth b Clutch Teeth 90 826883R2 JUNE 1998 Page 6A 23 GEAR HOUSING 3 Inspect FORWARD gear tapered bearing and race for rust roughness pitting spalling or excessive wear looseness NOTE DO NOT remove tapered bearing from FORWARD gear unless replacementis nec essary as removal process will damage bearing 4 f bearing must be replaced remove bearing from gear using Universal Puller Plate 91 37241 and a suitable mandrel 5 8 in socket IMPORTANT If FORWARD gear tapered bearing or race requires replacement re place bearing and race as a set 91 37241 a Bearing b Universal Puller Plate 91
159. ll vent hose off the grease fitting Pump in grease through the grease fitting until excess grease starts to exit the vent hose a Vent Hose b Grease Exiting Vent Hose Reconnect the vent hose onto the grease fitting after greasing After 30 hours of operation pump in extra grease to purge out any moisture Visually in specting the purged grease atthis 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 in spected and replaced if necessary Some discoloration of the grease is normal during the break in period on a new set of seals Page 6B 16 90 826883R2 JUNE 1998 JET DRIVE 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 screws 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 Tab b Nut 90 826883R2 JUNE 1998 Page 6B 17 J DRIVE INSTALLATION Page 6B 18 1 Grease the drive shaft shear ke
160. lower mount bracket tilttube and lower engine mounts can be serv iced without powerhead gear housing removal However OUTBOARD MUST BE SUP PORTED BEFORE SERVICING COMPONENTS IMPORTANT All gaskets should be replaced when removing powerhead and or disassembling drive shafthousing Corresponding gasket mating surfaces should be cleaned of any gasket material before installing new gaskets 90 826883R2 JUNE 1998 Page 5 7 GEAR HOUSING LOWER UNIT Section 6A Gear Housing Table of Contents Specifications 6A 1 Cam Follower 6A 22 Quicksilver Lubricants and Service Aids 6A 2 Io HORE RUE CAES Xr ES 6A 22 Special Tools 6A 2 Propeller shaft 6A 22 Gear Housing Drive Shaft 6A 6 SAR wan HER ERES eR 6A 23 Gear Housing Propeller Shaft 6A 8 Reverse And Forward Gear 6A 23 General Service Recommendations 6A 10 PINION Gear o uses mi 25 Draining and Inspecting Gear Lubricant 6A 11 Driveshaft 6A 25 Gear Housing Removal 6A 12 Bearing 6A 26 Disassembly 6A 14 Reassembly 6A 26 Bearing 6A 14 Drive Shaft Bearing and Seals 6A 26 Propeller
161. m CYLINDER Diameter Standard 2 562 in 65 01 mm BORE Taper Out of Round Maximum 0 003 in 0 08 mm Bore Type S N 0G202749 and Below Chrome S N 0G202750 and Above Mercosil CRANK SHAFT Top Main Bearing Journal 1 251 in Center Main Bearing Journal 1 000 in Bottom Main Bearing Journal 1 125 in Connecting Rod Journal 0 883 in End Play 0 004 0 019 0 10 0 64 mm CONNECTING Piston Pin End I D 0 897 in 0 897 22 78mm mm ROD Crankpin End 1 0 1 196 in 30 38 mm PISTON Piston Type Aluminum O D at Skirt Standard 2 5583 2 5593 64 98 65 00 Ring End Gap 0 011 0 025 28 mm 64 mm PISTON DIA 2 5583 0005 64 98 mm 0127 mm Using micrometer measure dimension A at location shown Dimension A should be 2 5583 in 0005 for Dimension A a STANDARD size piston new Di mension will be 0 001 0 0015 to Pis on Pin n less if coating is worn off piston used Models S N 0G202749 and Below NOTE The cylinder bores are chrome and cannot be be rebored or efficiently honed Check each cylinder bore for an out of round egg shaped cylinder A maximum of 0 003 in 0076mm is allowable Models S N 0G202750 and Above NOTE The cylinder block is Mercosil and the cylinders can be rebored to 0 030 in over sized Check each cylinder bore for an out of round egg shaped cylinder A maximum of 0 003 in 0 076mm is allowe
162. may experience from a worn impeller are 1 a noticeable performance loss especially on acceleration 2 difficultly getting the boat on plane or 3 an increase in engine RPM at wide open throttle Check the impeller blades occasion ally for damage Use a flat file to resharpen the leading edges as shown Do not sharpen or alter the top side lifting angle b Leading Edge c Sharpen to 1 32 in 0 8mm radius by removing material from bottom side only d Enlarged View 90 826883R2 JUNE 1998 Page 6B 21 c J ET DRIVE n Liner Replacement 1 Mark the liner mounting bolts for reassembly into the same holes Remove the bolts 2 Remove the liner If the liner is tight tap on the inner edge ofthe liner with a long drift punch through the intake grate NOTE Apply grease to the liner mounting bolt threads before assembly 3 Position the liner into the water intake housing Line up one ofthe liner bolts and lightly thread itin 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 Ibs in 11 3 N m 4 Grind off the ends of any bolts that may extend beyond the inner liner surface Page 6B 22 90 826883R2 JUNE 1998 JET DRIVE J et Drive Removal and Installation Removal 1 Remove water intake and impeller R eferto Impeller Removaland Installation preced ing 2 Disconnect the shift linkage Remove 5 bolts show
163. mbustion chamber to aid in reducing emissions All other models use a homogenized charge The difference between the two IS Homogenized 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 The homogenized charge is easy to ignite as the air fuel ratio is approximately 14 7 1 A ye Page 3B 4 90 828883R2 JUNE 1998 EMISSIONS Stratified Charge A stratified charge engine only pulls air through the transfer system The fuel required for combustion is forced into the cylinder through an injector placed in the top of the cylinder head The injector sprays a fuel air mixture in the form of a bubble into the cylinder Sur rounding this bubble is air supplied by the transfer system As the bubble is ignited and burns the surrounding air provides almost complete combustion before the exhaust port opens A stratified charge is hard to ignite the fuel air bubble is not evenly mixed at 14 7 1 and not easily ignited Emissions Information Manufacturer s Responsibility Beginning with 1998 model year engines manufacturers of all marine propulsion engines must determine the exhaust emission levels for each engine horsepower family and certi fy these engines with the United States Environmental Protection Agency EP
164. n securing jet drive to drive shaft housing and remove jet drive Installation 1 Install jet drive with bolts shown 7 D Loctite 271 92 809820 Bolts 4 Apply Loctite 271 to Threads and Torque to 25 Ib ft 34 0 N m b Bolt 1 Apply Loctite 271 to Threads and Torque to 23 0 Ib ft 31 0 N m 90 826883R2 JUNE 1998 Page 6B 23 JET DRIVE Water Pump Removal and Installation Removal Installation 1 Remove water pump assembly as shown IMPORTANT If impeller being installed has been previously used and vanes have taken a set do notinstall the impeller with the vanes reversed from their previous set as vane breakage will occur shortly after unit is returned to service NOTE Apply a light coat of 2 4 C w Teflon to inside of pump cover to ease installation of cover over impeller 1 Reassemble water pump assembly as shown Rotate drive shaft CLOCKWISE while pressing water pump body down over impeller d a b BD h AS E Le E 2 4 C With Teflon 92 825407A12 Page 6B 24 a Boltand flat washer 4 Apply Loctite 271 to threads b Bushing 4 Used on earlier type water pumps c Rubber Ring d Seal Water Tube e Pump Assembly f O Ring g Washer h Impeller Key j Washer k Face Plate Screw 4 Apply Loctite 271 Torque to 35 Ib in 4 0 N m m Base 90 826883R2 JUNE 1998 JET DRIVE Bearing Carrier Remova
165. n atoms it would come out of the en gine in the form of carbon dioxide is a harmless gas But carbon often com bines with insufficient oxygen one carbon atom with one oxygen atom This forms car bon monoxide CO Carbon monoxide is the product of incomplete combustion and is a dangerous potentially lethal gas 90 826883R2 JUNE 1998 Page 3B 1 EMISSIONS a 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 cham ber 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 engi
166. nd 1 Fuel Line 2 Sta strap 4 3 Cover 4 Filter 5 Rubber Sealing Wash er 6 Sight Bowl 7 Fuel Line Connector Page 3A 24 90 826883R2 JUNE 1998 EMISSIONS FUEL SYSTEM Section 3B Emissions Table of Contents Table of Contents 3C 1 Stratified Charge Exhaust Emissions Standards 3C 1 Emissions Information What Are Emissions 3C 1 Manufacturer s Responsibility Hydrocarbons 3C 1 Dealer Responsibility Carbon Monoxide 3C 1 Owner Responsibility Oxides of Nitrogen 3C 1 EPA Emission Regulations Controlling Emissions 3C 2 Decal Location Stoichiometric 14 7 1 Air Fuel Ratio 3C 2 Outboard Hydrocarbon Emissions Reductions 3C 3 Stratified VS Homogenized Charge 3C 4 Homogenized 3C 4 Exhaust Emissions Standards Through the Environmental Protection Agency EPA the federal government has estab lished 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
167. nd bottom of each cylinder Check for tapered out of round egg shaped and oversize bore IMPORTANT Ports must be deburred after honing 90 826883R2 JUNE 1998 Page 4 25 POWERHEAD Crankshaft 1 Inspect crankshaft to drive shaft splines for wear 2 Check crankshaft for straightness runout 0 003 0 076 mm 3 Inspect crankshaft oil seal surfaces Sealing surfaces must not be grooved pitted or scratched If top crankshaft sealing surface is severely worn replace crankshaft If bottom crankshaft sealing surface Is worn replace crankshaft coupling seal 4 Check all crankshaft bearing surfaces for rust water marks chatter marks uneven wear and or overheating blued 5 If necessary clean up crankshaft bearing surfaces with crocus cloth 57104 a Crocus Cloth 6 Thoroughly clean crankshaft with solvent and dry with compressed air 7 Rechecksurfaces of crankshaftand replace crankshaftif surfaces can notbe properly cleaned up 8 If crankshaft will be reused apply light oil to prevent rust Page 4 26 90 826883R2 JUNE 1998 POWERHEAD Seals It is recommended that all seals be replaced as a standard rebuilding procedure NOTE Both top and bottom crankshaft seals face down when installed on crankshaft cy 53200 a Top Crankshaft Seal b Bottom Crankshaft Seal Bearings ROLLER BEARINGS 1 Clean roller bearing with solvent and dry with compressed air 2 Inspectroller bearing
168. nd propeller nut onto the shaft a Forward Thrust Hub b Propeller c Rear Thrust Hub d Propeller Nut 7 Flo Torque 1 Drive Hub Propellers Install forward thrust hub replaceable drive sleeve propeller rear thrust hub and propeller nut onto the shaft Forward Thrust Hub Replaceable Drive Sleeve Propeller Rear Thrust Hub Propeller Nut 1 8 90 826883R2 JUNE 1998 GENERAL INFORMATION 8 Place a block of wood between gear case and propeller and tighten propeller nut Compression Check Remove spark plugs Install compression gauge in spark plug hole Hold throttle plate at W O T Crank the engine over until the compression reading peaks on the gauge Record the reading iw ce 5 Check and record compression of each cylinder The highest and lowest reading recorded should not differ by more than 15 see example chart below A reading below 120 psi might indicate a total engine wear problem Example of compression test differences Maximum psi Minimum psi 6 Compression check is important because an engine with low or uneven compression cannot be tuned successfully to give peak performance It is essential therefore that improper compression be corrected before proceeding with an engine tuneup 7 Cylinder scoring If powerhead shows any indication of overheating such as discol ored or scorched paint visually inspect cylinders for scoring or o
169. ndrel 91 36571 from Bearing Installation Kit 91 31229A7 over tapered bearing race Place propeller shaft into hole in center of mandrel Install bearing carrier assembly over propeller shaft and thread it in 4 or 5 turns Thread a suitable nut onto propeller shaft to protect propeller shaft threads DO NOT use propeller nut Use a malletto drive propeller shaft against mandrel until tapered bearing race is firmly seated in bearing race bore D IUDAS 91 36571 Super Duty Gear Lubricant 92 850737A1 a Forward Gear Bearing Race b Mandrel 91 36571 c Propeller S haft d Bearing Carrier Page 6A 29 GEAR HOUSING Page 6A 30 10 11 12 13 14 15 16 Remove nutfrom propeller shaft then remove bearing carrier propeller shaft and man drel from propeller shaft cavity Apply a light coat of oil on tapered bearing race Place forward gear on a press with gear teeth down Apply a light coat of oil to I D of forward gear tapered bearing Position forward gear tapered bearing over gear Press on inner race of bearing until bearing is firmly seated against forward gear Apply a light coat of Gear Lube to bore in center of forward gear Using a suitable mandrel press forward gear bushing into forward gear until bushing is flush with the back of gear 474 2 4 C w Teflon 92 850736A1 a Press b Mandrel c Bearing d Forward Gear e Bushing
170. neers have discov ered 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 As the air fuel ratio becomes leaner combustion temperatures increase Higher combus tion temperatures raise the NOx content of the exhaust But enrichening the air fuel ratio to decrease combustion temperatures and 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 Page 3B 2 90 828883R2 JUNE 1998 EMISSIONS OUTBOARD HYDROCARBON EMISSIONS REDUCTIONS 8 1 3 PER YEAR OVER 9 MODEL YEARS 120 100 80 60 40 20 96 97 98 99 2000 01 02 03 04 05 06 07 08 90 826883R2 JUNE 1998 Page 3B 3 EMISSIONS a STRATIFIED VS HOMOGENIZED CHARGE DFI engines use a stratified charge inside the co
171. ng inlet needle from Flush out inlet seat and clean inlet needle seating Incorrect float setting Reset float Problem Engine Runs Too Rich Restricted air flow Inspect cowl air inlet and carburetor for obstruc tions Main fuel jet loose Retighten jet Problem Fuel Blowback Out of Carburetor Problem Unable to Reduce Engine RPM to Slow Idle Possible Cause Corrective Action Chipped or broken reeds on reed block Replace reeds Problem Rough Idle Possible Cause Corrective Action Excessive preload on reeds Replace reeds Problem Engine Runs Too Lean Possible Cause Corrective Action Carburetor is loose Air leaks past mixing chamber Tighten bolts securely Tighten cover or replace cover gasket Idle mixture set too lean Adjust to run richer turn idle mix screw counter clockwise Air leakage into fuel system Inspect fuel line connections hose clamps fuel and fuel outlet tube located in fuel tank for loose fittings Anti siphon valve restricting fuel flow Inspect valve and or test engine without valve in fuel system 90 826883R2 JUNE 1998 Page 3A 17 CARBURETOR FUEL PUMP Carburetor Removal Page 3A 18 C E NOTE Air intake cover has been removed for visual clarity 1 Loosen primer cam retaining screw 2 Remove retaining clip 57069 a Screw b Retaining Clip Push down on primer arm and pull primer knob bezel and slide block out of bottom cow
172. ngth of 5 1 4 in 13 3 cm as measured between ball joint centerlines 14 Connect throttle link rod between ball joints of primary gear and throttle cam aan S Oem KR Q7 DA 0 Mm C n SSS Throttle Link Rod Adjust to length of 5 1 4 in 13 3 cm Primary Gear Throttle Cam Pulley Anchor Bracket Control Cables 90 826883R2 JUNE 1998 Page 7 9 THROTTLE SHIFT LINKAGE Throttle Cam Control Lever Removal 1 Refer to Section 7B for removal of throttle cables 2 Remove bolt and flat washer securing cam lever to powerhead 55 MEN 952 57041 a Bolt b Washer Cam Lever Throttle Cam Control Lever Reassembly 1 Position spring over hub of throttle cam Spring ends must straddle tab 57042 a Hub b Spring Ends 7 10 90 826883R2 JUNE 1998 THROTTLE SHIFT LINKAGE 2 Lubricate bushing with 2 4 C w Teflon and install bushing and wave washer 2 4 C With Teflon 92 825407A12 a Bushing b Wave Washer 3 Install control leveronto throttle cam assembly so thattab of control leveris positioned between ends of spring 57043 a Control Lever b Tab c Ends of Spring 90 826883R2 JUNE 1998 Page 7A 11 THROTTLE SHIFT LINKAGE Installation 1 Secure throttle cam control lever assembly onto mounting boss of crankcase cover with bolt Torque
173. of 90 826883R2 JUNE 1998 GRN WHT4 71 1 GRN WH WHT GRN gt _ WHT GRN BRN YEL gt a e BL BLK BLACK BRN BROWN GRY GRAY GRN GREEN RED RED WHT WHITE YEL YELLOW Page 2D 11 WIRING DIAGRAMS Optional Electrical Accessories Wiring Diagrams Manual Start Model with Lighting Coil and Unregulated AC Voltage Terminal Block Manual Start Model with Battery Charging Kit Rectifier Manual Start Model with Voltage Regulator Voltage Regulator 0 20 12 90 826883R2 JUNE 1998 WIRING DIAGRAMS Commander Remote Control Electric Start BLACK BROWN GRAY GREEN RED WHITE YELLOW Ignition Choke Switch Emergency Stop Switch Neutral Start Switch Tachometer Accessories Harness Connector Remote Control Harness Connector oO o 90 826883R2 JUNE 1998 Page 2D 13 WIRING DIAGRAMS Commander 2000 Remote Control Manual BLK BLACK BRN BROWN GRY GRAY GRN GREEN RED RED WHT WHITE YEL YELLOW RUN OFF Switch b Emergency Stop Switch Stop Switch Harness Page 2D 14 23893 90 826883R2 JUNE 1998 WIRING DIAGRAMS Commander 2000 Remote Control Electric Start BLK BLACK BRN BROWN GRY GRAY GRN GREEN RED RED WHT WHITE YEL YELLOW go gt J lt L a N Pd 77 BLK 4 TAN BLU 3
174. of platform traveled by gears with 2 4 C w Teflon 57038 2 4 C With Teflon 92 825407A12 a Short Bushing b Long Bushing c Platform 4 nstall secondary gear over short bushing and detent ball and spring as shown 5 Secure secondary gear with bolt and flat washer Torque 120 Ib in 13 6 N m 6 Lubricate gear teeth with 2 4 C w Teflon 57039 2 4 C With Teflon 92 825407A12 a Secondary Gear b Boltand Flat Washer Torque to 120 Ib in 13 6 N m 90 826883R2 JUNE 1998 Page 7A 7 THROTTLE SHIFT LINKAGE 7 Install primary gear over long bushing as shown 8 Secure primary gear with bolt and flat washer Torque bolt to 120 Ib in 13 6 N m 9 Lubricate gear teeth with 2 4 C w Teflon 57040 2 4 C With Teflon 92 825407A12 a Primary Gear b Boltand Flat Washer Torque to 120 Ib in 13 6 N m 10 Secure assembled control platform onto cylinder block using 3 bolts Torque bolts to 120 Ib in 13 6 N m 57034 a Platform b Bolts Torque to 120 Ib in 13 6 N m Page 7 8 90 826883R2 JUNE 1998 THROTTLE SHIFT LINKAGE 11 Adjust shift link rod to a length of 5 1 2 in 13 9 cm as measured between ball joint centerlines 12 Connect shift link rod between joints of secondary lever and shift shaft lever an 57033 Shift Link Rod Adjust to length of 5 1 2 13 9 cm b Shift Shaft Lever c Secondary Lever 13 Adjust throttle link rod to a le
175. of reverse lock link rod and shift shaft coupling jam 16 If no free play exists turn coupling up shiftshafta maximum of 1 1 2 turns and re tighten jam nut against coupling Page 6A 38 90 826883R2 JUNE 1998 GEAR HOUSING 20 25 2 Stroke 17 While turning drive shaft in a clockwise direction pull up lightly on shift shaft until gear housing is in forward gear propeller shaft turns clockwise 18 Install flat washer retained onto shift shaft 51187 a Washer IMPORTANT Verify water tube inside drive shafthousing is connected to the water tube seal in the adaptor plate 19 Position twist grip on tiller handle so that outboard is in forward gear NOTE Itis notnecessary to grease the drive shaftsplines prior to installation of gear hous ing assembly Splines receive internal engine lubrication during normal engine operation 20 Position gear housing so that drive shaftand shift shaft extend up into drive shafthous ing 21 Move gear housing up toward drive shafthousing while keeping machined surfaces par allel 22 Guide shift shaft thru loop in the reverse lock rod 23 Guide water tube into rubber seal in water pump cover 24 Guide drive shaft into crankshaft NOTE It may be necessary to rotate the flywheel to aid engagement of drive shaft splines to crank shaft splines 90 826883R2 JUNE 1998 Page 6A 39 E GEAR HOUSING 25 Secure shift rod to horizontal shift shaft with retainer a R eta
176. ok frequently is caused by supporting boat too far ahead of transom while hauling on a trailer or during storage 2 Rocker The reverse of hook and much less common Rocker exists if bottom is con vex in fore and aft direction when viewed from the side and boat has strong tendency to porpoise 3 Surface Roughness Moss barnacles etc on boat or corrosion of outboard s gear housing increase skin friction and cause speed loss Clean surfaces when necessary WATER ABSORPTION lt is imperative that all through hull fasteners be coated with a quality marine sealer at time of installation Water intrusion into the transom core and or inner hull will result in addition al boat weight reduced boat performance hull decay and eventual structural failure 90 826883R2 JUNE 1998 Page 1C 3 GENERAL INFORMATION CAVITATION 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 ero sion of the propeller blade surface If allowed to continue eventual blade failure break age will occur 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 t
177. on 5 Check in line fuse in RED wire see diagram SEC 2D The following STARTING CIRCUIT TROUBLESHOOTING FLOW CHART is designed as an aid to troubleshooting the starting circuit This flow chart will accurately locate any existing malfunction Location of TEST POINTS called outin the chart are numbered in diagram below IMPORTANT Remote Control Electric Start Models have a 20 Ampere fuse located under the cowl next to the starter solenoid This fuse protects the remote control harness If this fuse is open the starter will be inoperative The cause of the blown fuse a short should be found and corrected 90 826883R2 JUNE 1998 Page 2B 11 BATTERY CHARGING AND STARTING SYSTEMS YELLOW SLEEVE A S 7 To Rectifier 53056 Starting Circuit Troubleshooting Flow Chart Starter Motor Does Not Turn SAFETY WARNING Disconnect BLACK w YELLOW sleeve cable from starter solenoid test point 1 BEFORE making tests to prevent unexpected engine cranking TEST 1 Use ohmmeter x 1 scale and connect meter leads between NEGATIVE battery postand common pow erhead ground No Continuity Indicated There is anopencircuitin the BLACK NEGATIVE bat Continuity Indicated tery cable between the NEGATIVE battery post and Proceed to TEST 2 on next page the powerhead gt Check cable for loose or corroded connections gt Check cable for open Page 2B 12 90 826883R2 JUNE 1998 BATTERY CHARGING AN
178. on could be caused by or accelerated by improper lubrication Cla a Spalling 6 Chatter Marks Chatter marks are the result of a combination of low speed low load cold water temperature operation aggravated by inadequate lubrication and or im proper fuel Under these conditions the crankshaft journal is hammered by the con necting rod As ignition occurs in the cylinder the piston pushes the connecting rod with tremendous force and this force is transferred to the connecting rod journal Since there is little or no load on the crankshaft itbounces away from the connecting rod The crankshaft then remains immobile for a split second until the piston travel causes the connecting rod to catch upto the waiting crankshaftjournal then hammers it The repetition of this action causes a rough bearing surface s which resembles a tiny washboard In some instances the connecting rod crank pin bore becomes highly polished During operation the engine will emit a whirr and or chirp sound when it is accelerated rapidly from idle speed to approximately 1500 RPM then quickly re turned to idle If the preceding conditions are found replace both the crankshaft and connecting rod s Y 51853 a Chatter Marks Between Arrows 90 826883R2 JUNE 1998 Page 4 29 POWERHEAD 7 Uneven Wear Uneven wear could be caused by a bent connecting rod a Uneven Wear Crocus cloth MUST BE USED to clean bearing surface at CRANKSHAFT E
179. on may result in serious injury or death Checking Shift Link Rod Adjustment Check the shift link rod a adjustment in forward shift position The correct adjustment will position the shift cam b far enough on the roller c in order to lock the the reverse gate d 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 Adjusting Shift Link Rod 1 Place the shift handle into full forward shift position 2 Adjust length of the shift link rod a so that roller is atthe full end of travel bot tom in the shift cam when the shift handle 15 in full forward a Shift Link Rod b ShiftCam c Roller d Reverse Gate 90 826883R2 JUNE 1998 Page 6B 15 c J ET DRIVE n Lubricating the Drive Shaft Bearing Recommended Lubrication Use Quicksilver 2 4 C w Teflon or Lubriplate 630 AA Grease 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 Frequency of lubrication We recommend lubricating the drive shaftbearing 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 Lubricating Procedure Pu
180. on the aluminum depositfor 1 to 2 minutes then wash cyl inder thoroughly with hot water and detergent d Steps b and c may require repeating several times before all aluminum depos its are gone e Aftercleaning aluminum deposits from cylinder bores apply lightoil to each cylin der bore with a clean cloth 90 826883R2 JUNE 1998 Page 4 23 POWERHEAD 4 Check each cylinder bore for an out of round egged shaped cylinder A maximum of 0 003 in 0 076mm is allowable If out of round is more than 0 003 in 0 076 mm cylinder block and crankcase cover must be replaced MERCOSIL BORE ALL MODELS S N 0G202750 AND ABOVE 1 Inspect cylinder bores for scoring scuffing or a transfer of aluminum from piston to cylinder wall Scoring or scuffing if NOT TOO SEVERE can normally be removed by honing If a transfer of aluminum has occurred a diluted muriatic acid such as TIDY BOWL CLEANER should be applied to the areas of the cylinder bore where transfer of aluminum has occurred After the acidic solution has removed the transferred alu minum thoroughly wash the cylinder bore s with hot water and detergent to remove any remaining acid Cylinder walls may now be honed to remove any glaze and to aid in the seating of new piston rings 2 Thecylinder block is Mercosil and if necessary be rebored to 0 030 in 0 762 mm oversized 3 Check each cylinder bore for an out of round egged shaped cylinder A maximum of
181. one cylinder when RPM exceeds 6200 100 RPM Ignition Component Description Trigger Coil A single wound coil located under the flywheel The trigger is charged by the center hub flywheel magnet and sends a pulse voltage to an SCR switch located in the ignition Switch box 52642 a Trigger Coil ELECTRONIC SPARK ADVANCE The trigger is mounted in a fixed timing position 90 826883 R2 JUNE 1998 Page 2 7 IGNITION MECHANICAL SPARK ADVANCE S park timing is changed advanced retarded by rotating the trigger which changes the trigger coil position in relation to the magnets the center hub of the flywheel Stator The ignition stator located under the flywheel contains two stator windings One low Speed winding and one high speed winding As the outer flywheel magnets pass the stator windings a current is produced that charges a capacitor in the ignition switch box Electronic Spark Advance Stator 52642 a Low Speed Winding b High Speed Winding Flywheel Center Hub Magnet b Outer Magnet c BLACK Stator Flywheel 2 Magnets d RED Stator Flywheel 4 Magnets e Spacers The flywheel assembly BLACK stator contains two outer magnets 8 Pole 4 Pulse and one center hub magnet The outer magnets are needed for battery charge coil and ignition charge coils The inner hub magnet is for trigger coil The flywheel assembly RED stator contains four outer magnets 10 Pole 5 Pulse an
182. ooting RED Stator TOOL MULTIMETER DVA TESTER 91 99750 Multimeter Resistance Stator GREEN WHITE and GREEN WHITE WHITE GREEN 370 445 wires disconnected from switch boxes WHITE GREEN Trigger BROWN BROWN YELLOW YELLOW and BROWN WHITE wires disconnected from switch boxes BROWN WHITE RED Terminal Rxl 0 02 0 04 Ignition Coils BLACK Terminal all wires dis RED Spark Plug Tower connected R x 1000 3 11 BLACK Terminal Tested Part Multimeter C ted T Selector Reading At Reading At Position 300 1000 RPM 1000 4000 RPM Terminal Switch Box Primary Coil 400 VDC 125 320 200 320 Terminal BLACK YELLOW Switch Box Stop Circuit 400 VDC 150 330 250 330 GROUND GREEN WHITE 400 VDC 150 330 250 330 GROUND Stator Voltage WHITE GREEN 400 VDC 150 330 250 330 GROUND NOTE Copper is an excellent conductor but resistance may notably vary between low and high temperature Therefore reasonable differences can be accepted between re sistance readings and specifications 90 826883 R2 JUNE 1998 Page 2A 17 BATTERY CHARGING AND STARTING SYSTEMS ELECTRICAL Section 2B Battery Charging and Starting Systems Table of Contents Specifications 2B 1 Electric Start Components 2B 2 CPP m 2B 4 5 och arr acea Pekan on dpa 2B 4 Recommended Battery 2B
183. or spring tension thru transfer and exhaust ports by pressing with a screwdriver If no spring tension exists ring fails to return to position itis likely that the piston ring was broken during assembly replace broken piston ring s Use caution not to burr piston rings while inspecting 57124 Page 4 46 90 826883R2 JUNE 1998 POWERHEAD 7 Clean crankcase sealing surfaces according to Loctite Master Gasket instructions Apply a continuous bead of Loctite sealantalong the inside of the mounting bolt holes of crankcase cover 57123 a Sealant 8 Place crankcase cover onto cylinder block and secure with 6 bolts Torque bolts to 30 0 Ib ft 40 7 N m in numbered torque sequence 53192 a Bolts Torque to 16 7 Ib ft 22 7 N m 90 826883R2 JUNE 1998 Page 4 47 POWERHEAD 9 Rotate crankshaft several times to assure free operation 10 If disassembled assemble reed block as follows a Torque reed stop screws to 25 Ib in 2 8 N m b Lubricate seal with 2 4 C w Teflon and install reed block onto cylinder block 2 4 C With Teflon 92 825407A12 57080 a Screws Torque to 25 Ib in 2 8 b Seal c Reed Valve Opening Maximum Opening 0 007 in 0 178 mm 11 Secure carburetor adaptor plate with new gasketto cylinder block with 3 bolts Torque bolts to 80 Ib in 9 0 N m 57079 Adaptor Plate b Bolts Torque to 80 Ib in 9 0 N m Page 4 48 90 826883R2 JUNE 1998 POWERHEAD
184. orm Stop Tab c Throttle Lever 4 Back the idle speed screw off of cam follower SS 52800 a Idle Speed Screw b Cam Follower 90 826883R2 JUNE 1998 Page 2C 11 TIMING SYNCHRONIZING ADJUSTING 5 Turn idle speed screw In until the cam follower just makes contact with throttle cam then turn In one additional turn to slightly open throttle plate Y TE QA gt lt 91 5 A Ip SG eee 225 TAM Y 7 t e rP a Idle Speed Screw b Cam Follower c Throttle Cam NOTE The throttle return spring on cam follower plate should just contact the fuel pump housing at wide open throttle position If not adjust the throttle link rod Do not allow the throttle spring to act as a throttle stop 52912 a Contact Point spring to just contact fuel pump housing b Throttle Return Spring Page 2C 12 90 826883R2 JUNE 1998 TIMING SYNCHRONIZING ADJUSTING 6 Manually push throttle lever forward until it contacts the throttle stop on shift platform Verify that the throttle plate can achieve wide open throttle and that no preload exists on the throttle return spring behind the cam follower plate Adjust throttle link rod if necessary 52799 Throttle Stop b Throttle Lever c Return Spring do not allow to act as a throttle stop d Throttle Link Rod Shift and Throttle Cabl
185. osition decal Read entire installation instructions on this technique before pro ceeding TEMPERATURE IMPORTANT Installation of vinyl decals should not be attempted while in direct sunlight Air and surface temperature should be between 60 F 15 C and 100 F 38 C for best application SURFACE PREPARATION IMPORTANT Do not use a soap or any petroleum based solvents to clean applica tion surface Clean entire application surface with mild dish washing liquid and water Rinse surface thoroughly with clean water 90 826883R2 JUNE 1998 Page 1 11 GENERAL INFORMATION DECAL APPLICATION 1 Mix 1 5 ounce 16 ml of dish washing liquid in one gallon 41 of cool water to use as wetting solution NOTE Leave protective masking if present on the face of decal until final steps of decal installation This will ensure that the vinyl decal keeps it s shape during installation 2 Place the decal face down on a clean work surface and remove the paper backing from adhesive side of decal 3 Using a spray bottle flood the entire adhesive side of the decal with the pre mixed wetting solution Flood area where the decal will be positioned with wetting solution Position pre wetted decal on wetted surface and slide into position 6 Starting at the center of the decal lightly squeegee out the air bubbles and wetting solution with overlapping strokes to the outer edge of the decal Continue going over the decal surface until all
186. ove threaded rod assembly 3 Insert tapered end of rod 91 44385 into bearing cup puller and tap bearing cup out of driveshaft bore OR ALO 2 27 2 4 e 4 4 4 4 p i L 4 224 22 4 21 bs NS 2277 77 di NN 1 DS BEN AM Cup b Bearing Cup Puller 91 44385 c Flat Washers 2 12 34961 d Hex Nut 0 625x18 11 24156 e Threaded Rod 0 625x18 16 Long 91 31229 f Plate 91 29310 g Hex Nut 0 625x18 11 24156 h Tapered Rod 91 44385 Forward Gear Race 1 Slide hammer to remove forward gear tapered bearing race as shown See aN 1 q me 91 34569 1 a Slide Hammer b Tapered Bearing Race Page 6A 20 90 826883R2 JUNE 1998 GEAR HOUSING Cleaning and Inspection Gear Housing Bearing Carrier Castings 1 Thoroughly clean gear housing bearing carrier castings Be sure all old gasket material is removed from mating surfaces and thatcarbon deposits have been removed from ex haust passages 2 Inspect castings for cracks or fractures 3 Checksealing surfaces for nicks deep grooves and distortion which could cause leaks 4 Check water passages for obstructions Ball Bearings NOT spin dry ball bearin
187. ply 2 4 w Teflon on all O rings and on I D of oil seals Apply 2 4 C w Teflon to bearing carrier threads and pilot diameters 90 826883R2 JUNE 1998 GEAR HOUSING Draining and Inspecting Gear Lubricant 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 a Vent Plug Washer b Drain Plug Washer 2 Inspectgearlubricantfor metal particles lubricantwillhave a flake appearance Presence of fine metal particles resembling powder on the drain plug magnetindicates normal wear Metal chips on the magnet indicate the need for gear housing disassembly and component inspection 3 Note color of gear lubricant White or cream color indicates presence of water 4 Presence of water indicates the need for disassembly and inspection of oil seals O rings gaskets and components for damage Pressure check prior to disassembly to determine leak area 90 826883R2 JUNE 1998 Page 6A 11 E GEAR HOUSING Gear Housing Removal spark plugs BEFORE removing gear housing 1 Tilt outboard to full UP position 9 9 15 Bigfoot 4 Stroke 2 Remove reverse hook guide assembly from lower shift shaft 3 Loosen nutand disconnect coupler Remove jam allow removal of gearcase
188. posits and gasket material from exhaust manifold and cover 2 Inspect for grooves cracks or distortion that could cause leakage Replace parts as required Cylinder Bore CHROME BORE ALL MODELS S N 0G202749 AND BELOW Cylinder bores which are chrome cannot be bored or efficiently honed Honing a chrome cylinder bore is notnecessary noris itrecommended Do not mistake cylinder bore poros ity pitting for cylinder damage Porosity in a chrome lined cylinder is normal and is not detrimental to engine operation or performance 1 If chrome surface is flaking or if a groove or any other mark penetrates the chrome Surfacing to the aluminum portion of the cylinder wall the cylinder block must be re placed 2 Todetermine if a groove or mark on the cylinder wall penetrates the chrome surfacing to the aluminum cylinder wall apply a small amount of diluted muriatic acid TIDY BOWL CLEANER to the groove or mark If the groove or mark begins to fizz the aluminum wall is exposed and the cylinder block and crankcase cover must be re placed 3 Ifa piston is scored and transferred aluminum to the cylinder walls remove the alumi num from the wall as follows a Remove allloose aluminum deposits from cylinder walls with a stiff bristle brush b Applyasmallamountofdiluted muriatic acid TIDY BOWL CLEANER onto alumi num deposits A fizzing action will appear indicating that aluminum is being dis solved C Leave the acid solution
189. pped with Remote Control RED Stator Model 20 25 1999 and NEWER 2D 11 Optional Electrical Accessories Wiring Diagrams 2D 12 Commander Remote Control Electric Start 20 13 Commander 2000 Remote Control Manual 20 14 Commander 2000 Remote Control Electric Start 2D 15 Commander 3000 Panel Mount Control 2D 16 Page 2D 1 WIRING DIAGRAMS Manual Start Models Electronic Advance Model 20 25 1994 5 THRU 1997 Model 20 Jet 19941 THRU 1998 BRN WHT BLK BLACK BRN BROWN GRY GRAY GRN GREEN RED RED WHT WHITE YEL YELLOW Charging Coils Stator Ignition Coil Top Cylinder Ignition Coil Bottom Cylinder Emergency Stop Switch Stop Switch Switch Box Trigger Terminal Block o oooontov Page 2D 2 90 826883R2 JUNE 1998 WIRING DIAGRAMS Electric Start Models with Tiller Handle Start Button Electronic Advance Model 20 25 1994 5 THRU 1997 ec BRN WHT BRN YE BLK BLACK BRN BROWN GRY GRAY GRN GREEN RED RED WHT WHITE YEL YELLOW Stator Trigger Ignition Coil Top Cylinder Ignition Coil Bottom Cylinder Emergency Stop Switch Stop Switch Rectifier Switch Box Charging Coils Starter Motor Starter Solenoid Start Button 12 VDC Battery Neutral Start Switch n mere cob o S 90 826883R2 JUNE 1998 Page 2D 3 WIRING DIAGRAMS
190. pressed 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 dam age may occur If unable to start engine in this period disassemble engine and clean all parts Apply oil as soon as possible 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 Quicksilver Propellers and Boat Performance Information Part No 90 86144 90 826883R2 JUNE 1998 Page 1C 5 GENERAL INFORMATION 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
191. proximately 3000 RPM and note lamp brightness If lamps are considerably brighter than with leads connected to regulator the regulator is defective If lamps are NOT considerably brighter check the alternator refer to Alternator Test following Battery Charging System Description The battery charging system components are the alternator rectifierand battery Alternat ing current generated in alternator coils flows to the rectifier which changes AC current to direct current DC for charging the battery a Alternator b Rectifier Battery The charging system may be damaged by a Reversed battery cables b Running the engine with battery cables disconnected and alternator leads con nected to rectifier circuit such as a broken wire or loose connection 90 826883R2 JUNE 1998 Page 2B 7 BATTERY CHARGING AND STARTING SYSTEMS Alternator Amperes Output Amperage output can be measured by installing a 10 ampere minimum amp meter in series between the rectifier and the battery or by clamping an inductive type amp meter 10 amp minimum over the RED output lead from the rectifier to the battery BLACK Stator 2 Magnet Flywheel 0 RED Stator 4 Magnet Flywheel 4000 1 i3 8 5000 6 1 6 3 5206 NN 2 8 90 826883R2 JUNE 1998 BATTERY CHARGING AND STARTING SYSTEMS Battery Charging System Troubleshooting
192. r efficiently honed Check each cylinder bore for an out of round egg shaped cylinder A maximum of 0 003 in 0076mm is allowable Models S N 0G202750 and Above NOTE The cylinder block is Mercosil and the cylinders can be rebored to 0 030 in over sized Check each cylinder bore for an out of round egg shaped cylinder A maximum of 0 003 in 0 076mm 15 allowed Page 4 2 90 826883R2 JUNE 1998 POWERHEAD Special Tools 1 Powerhead Stand 91 25821A1 90 826883R2 JUNE 1998 Page 4 3 POWERHEAD Page 4 4 6 Flywheel Puller 91 83164M Bolts 10mm 3 91 83191 7 Compression Tester 91 29287 90 826883R2 JUNE 1998 Cylinder Block and Covers Loctite 271 92 809820 Loctite PST Pipe Sealant 92 809822 HB 12 D Loctite Master Gasket 92 12564 2 2 4 C With Teflon 92 825407A12 SIDE SHIFT AND TILLER SHIFT ONLY 90 826883R2 JUNE 1998 Page 4 5 c Cylinder Block and Covers POWERHEAD Lu 5 gt de A coc C cc LL e STUD M6x1x50 Commercial DOWEL PIN mo zm oz ETE o gt lt gt lt gt lt x n gt lt To lt tO E lt m zo cac lee Ole u w u u LUI n uon riu ce for gt lt gt PIPE PLUG BRASS SCREW 30 MM FITTING HOSE tell tale 8 IN ELBOW SCREW M6x1x40
193. r several minutes Throttle engine back to idle for about one minute to allow RPM to stabilize 2 Push primer fast idle knob completely in and rotate knob fully counterclockwise 5 037 3 With engine running at idling speed while in Forward gear turn low speed mixture screw counterclockwise until engine starts to load up or fire unevenly from over rich mixture 4 Slowly turn low speed mixture screw clockwise until cylinders fire evenly and engine picks up speed 9 071 a Low Speed Mixture Screw 5 Continue turning mixture screw clockwise until too lean a mixture is obtained and en gine slows down and misfires Set low speed mixture screw halfway between rich and lean 7 DO NOT adjust leaner than necessary to attain reasonably smooth idling When in doubt set mixture slightly richer rather than too lean Check for freedom from 4 cycling between idle and 2000 RPM in Forward gear Install access plug into opening in carburetor air intake cover 90 826883R2 JUNE 1998 Page 3A 13 CARBURETOR FUEL PUMP IDLE SPEED ADJUSTMENT MODELS EQUIPPED WITH IDLE SCREW 1 With engine running at idle in Forward gear make sure primer fast idle knob is pushed completely in and rotate fully counterclockwise to stop 2 Adjust idle speed screw a to obtain recommended idle speed see specifications 57070 Idle Speed Screw IDLE SPEED ADJUSTMENT MODELS EQUIPPED WITH AN IDLE SPEED SCREW
194. rd in Forward gear and check set up timing If not within specifications adjustment will be required a Timing Mark b Side Shift Model Shown To prevent personal injury from spinning flywheel Do Not attempt to adjust the trigger link rod Maximum Timing Adjustment with engine running ADJUSTING SET UP TIMING With the engine OFF snap the trigger link rod socket off ball stud and e Extend rod length to Advance timing e Shorten rod length to Retard timing onap link rod onto ball stud re start the engine and check set up timing specification 28192 a Trigger Link Rod Set up Timing Adjustment b Side Shift Model Shown 90 826883R2 JUNE 1998 Page 2C 7 TIMING SYNCHRONIZING ADJUSTING MECHANICAL SPARK ADVANCE MODELS 20 JET 20 25 1997 AND NEWER 1 Using approved test procedure place the outboard in Forward gear and check the maximum and idle timing If not within specifications adjustment will be required MAX IDLE 0 30 20 10 0 ma nu AR 10 a Timing Mark b Maximum Timing Jam Nut c Maximum Timing Screw d Idle Timing Jam Nut e Idle Timing Screw ADJUSTING MAXIMUM TIMING 1 Loosen maximum timing jam nut and turn maximum timing adjustment screw in out to obtain specified timing NOTE Turning screw out will advance timing Turning screw will retard timing ADJUSTING IDLE TIMING 1 Loosen idle timing jam nut and turn idle timing adju
195. receives an adequate Supply of cooling water 3 Start the engine and run it at idle speed in neutral shift position Page 1B 4 90 826883R2 JUNE 1998 MAINTENANCE 4 Adjust water flow if necessary 50 excess water continues leaking out from around the rubber cups to ensure the engine 15 receiving an adequate supply of cooling water 5 Check fora steady stream of water flowing out of the water pump indicator hole Con tinue flushing the outboard for 3 to 5 minutes carefully monitoring water supply at all times 6 Stop the engine turn off the water and remove the flushing attachment Reinstall the propeller Fuel System Avoid serious injury or death from gasoline fire or explosion Carefully follow all fuel system service instructions Always stop the engine and DO NOT smoke or allow open flames or sparks in the area while servicing any part of the fuel sys tem Before servicing any partof the fuel system stop engine and disconnectthe battery Drain the fuel system completely Use an approved container to collect and store fuel Wipe up any spillage immediately Material used to contain spillage must be disposed of in an ap proved receptacle Any fuel system service must be performed in a well ventilated area Inspect any completed service work for sign of fuel leakage Fuel Line Inspection Visually inspectthe fuel line and primer bulb for cracks swelling leaks hardness or other Signs of deterioration or
196. rom 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 90 826883R2 JUNE 1998 Page 1B 13 GENERAL INFORMATION IMPORTANT INFORMATION Section 1C General Information Table of Contents Table of Contents 1C 1 Serial Number Location 1C 1 Conditions Affecting Performance 1C 2 WeallieE 22cm dieser REX 1C 2 1 3 es a 1C 4 Following Complete Submersion 16 5 Submerged While Running Special Instructions 1C 5 Salt Water Submersion Special Instructions 1C 5 Serial Number Location Fresh Water Submersion Special Instructions 1C 5 Propeller Selection 1 6 Propeller Removal Installation 1C 7 Compression Check 16 9 Painting Procedures 1 10 Cleaning amp Painting Aluminum Propellers amp Gear HOUSINGS 1 10 Decal Application 16 11 Decal Removal 1C 11 Instructions for Wet Application 1C 11 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 th
197. rrel holder and front rubber grommet 4 Install the shift cable c onto the shift lever pin d lock in place with retainer latch 5 Adjustthe shift cable barrel so it will fit into the bottom hole of the barrel holder f and thatthe barrel holder will slide freely into the retaining pocket without pre loading the shift cable 2 D N 5 59 TICK QA 5 WO WAU Ja 9 E f 5 3 Shift Lever Cable Retainer Cover Shift Cable Shift Lever Pin Retainer Latch Barrel Holder 6 Check shift cable adjustments as follows gt D 10 6 90 826883R2 JUNE 1998 OUTBOARD MOTOR INSTALLATION With remote control shifted into forward the propeller shaft should lock solidly in gear If does not adjust the cable barrel closer to the engine shift lever Shift remote control into neutral The propeller shaft should turn freely without drag If not adjust the barrel away from the engine shift lever Repeatsteps a and b Shift remote control into reverse while turning the propeller shaft The propeller shaftshould lock solidly in gear If not adjustthe barrel away from the engine shift lever Repeat steps a thru c Return remote control handle to neutral The propeller shaft should turn freely without drag If not adjust the barrel closer to the engine shift lever Repeatsteps a thru d Throttle Cable In
198. s by twisting the rubber boots slightly and pull off 2 Remove the spark plugs to inspect and clean Replace spark plug if electrode is worn or the Insulator is rough cracked broken blistered or fouled 3 Setthe spark plug gap See Specification Chart in General Information Section 408 4 Before reinstalling spark plugs clean away dirt on the spark plug seats Install plugs finger tight and tighten 1 4 turn or torque to 20 Ib ft 27 1 Nem Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting ca pability IMPORTANT Read the safety and maintenance instructions which accompany your battery 1 Turn off the engine before servicing the battery 2 Add water as necessary to keep the battery full 3 Make sure the battery is secure against movement 4 Battery cable terminals should be clean tight and correctly installed P ositive to posi tive and negative to negative 5 Make sure the battery is equipped with a nonconductive shield to prevent accidental shorting of battery terminals 90 826883R2 JUNE 1998 Page 1 7 MAINTENANCE Fuse Replacement Electric Start Remote Control Models The electric starting circuit is protected from overload by SFE 20 AMP fuse If the fuse 15 blown the electric starter motor will not operate Try to locate and correct the cause of the overload If the cause is not found the fuse may blow again Replace th
199. s specified and Quicksilver 2 4 C w Teflon Marine Lubricant whenever grease Is specified Any GREASE used for bearings INSIDE the powerhead MUST BE gasoline solu ble Use only Quicksilver 2 4 C w Teflon Marine Lubricant or Quicksilver Needle Bearing Assembly Lubricant The use of any other grease may result in power head damage A torque wrench is essential for correctreassembly of powerhead Do notattemptto reas semble powerhead without using a torque wrench NOTE Three designs of crankshaft seals have been used Design 3 is the current ap plica tion 57097 a Design 1 O ring fits in groove on driveshaft b Design 2 O ring fits inside of carrier c Design 3 3 lip seal permanently installed inside of carrier 90 826883R2 JUNE 1998 Page 4 35 POWERHEAD 1 If removed reinstall new crankshaft carrier as follows a Apply a thin coat of Loctite 271 to carrier surface on crankshaft b Square the carrier with crankshaft and using a 7 8 in deep well socket and ham mer carefully seat carrier onto crankshaft Loctite 271 92 809820 a Carrier b 7 8 in deep well socket 2 Apply 2 4 w Teflon to crankshaft roller bearings and thrust washers to hold compo nents in place on crankshaft while reassembling 3 Install roller bearings and thrust washers onto crankshaft 2 4 C With Teflon 92 825407A12 a Race Halves with Roller Bearings b Thrust Washers Page 4 36 90 826883R2 JUN
200. sidered standard shop practice even if not specifically stated 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 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 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 de scribed in this manual Page Numbering Two number groups appear at the bottom of each page The example below is self explana tory EXAMPLE 90 826883 R2 JUNE 1998 6A 7 Revision No 2 Month of Printing Section Number Year of Printing Part of Section Letter Page ii Page Number 90 826883R2 JUNE 1998 SPECIFICATIONS IMPORTANT INFORMATION Section 1A Specifications Table of Contents Master Specifications 1A 2 90 826883R2 JUNE 1998 Page 1A 1 SPECIFICATIONS Master Specifications Model 15XD 20 Jet 20 25 HORSEPOWER Model 20 Jet 20 14 9 KW Model 20 20 14 9 Model 25 25 18 7 OUTBOARD 15 in 88 cm 114 lbs 52 kg WEIGHT 20 in 51 cm 117 lbs 53 kg 20 Jet 124 lbs 56 kg CYLINDER Type Two Cylinder Two Cycle BLOCK Displacement 24 4 cu in 400 cc STROKE Length 2 362 in 60 m
201. sition NOTE Outboards equipped with a thermostat will have a Sporadic tell tail water dis charge 4 Immediately after the engine starts check for water at the tell tail and at idle relief holes Tell tail pressure should be per specification 90 826883R2 JUNE 1998 TIMING SYNCHRONIZING ADJUSTING MANUAL START REMOTE CONTROL MODELS 1 Turn primer enrichener knob fully Clockwise and Pull to Full Out position two 2 times waiting approximately five 5 seconds between pulls leaving the knob out after second pull NOTE Outboards equipped with a thermostat will have a Sporadic tell tail water dis charge 2 Startthe outboard After the outboard starts push the primer knob to the Full In posi tion and immediately check for water at the tell tail and idle relief holes After allowing the engine to warm up turn the primer knob to Full Counterclockwise position Tell tail pressure should be per General Specification Adjusting Idle Speed 1 Remove access plug from carburetor air intake cover 2 Turn idle mixture screw in clockwise until LIGHTLY seated then back out to an initial setting See Specifications Chart J SAS a EST FS a Qu S P UN d 5 QU Ge en Lt 52804 a Access Plug b Idle Mixture Screw Behind Access Plug Keep clear of propeller while cranking and running the outboard motor 3 With outboard in the water
202. stallation NOTE Attach Shift cable to engine prior to attaching throttle cable 1 2 3 90 826883R2 JUNE 1998 Position the remote control handle forward to wide open throttle position Install the throttle cable a onto the throttle pin b lock in place with retainer latch c Move throttle lever g until tab e contacts throttle stop f Adjust the barrel on the throttle cable so that the barrel will fit into the barrel holder d S lip the barrel into the barrel holder and place the barrel holder into the retaining pock et Check the throttle cable adjustment as follows Move the remote control handle back to neutral a few times and then return the handle back to forward wide open position b Recheck to make sure tab is contacting throttle stop f Throttle Cable Throttle P in Retainer Latch Barrel Holder Tab Throttle Stop Throttle Lever 0 10 7 OUTBOARD MOTOR INSTALLATION 6 Place the rubber seal side with holes towards front onto the control cables and install control cables barrel holder and rubber seal into the cable holder as shown 7 Lock the barrel holder in place with the cable retainer latch a Rubber Seal b Cable Retainer Latch Remote Wiring Harness Connection to Engine 1 Remove wire retainer from the bottom cowl a Wire Retainer Page 1D 8 90 826883R2 JUNE 1998 OUTBOARD
203. stment screw in out to obtain speci fied timing NOTE Turning screw in will advance timing Turning screw out will retard timing NOTE Outboards equipped with a thermostat will have a Sporadic tell tail water dis charge Adjusting Idle Speed 1 Start the outboard After the outboard starts push the primer knob to the Full In posi tion and immediately check for water at the tell tail and idle relief holes After allowing the engine to warm up turn the primer knob to Full Counterclockwise position Tell tail pressure should be per General Specification 2 Run engine at 3500 R P M and check stop button function and lanyard stop switch function Page 2C 8 90 826883R2 JUNE 1998 TIMING SYNCHRONIZING ADJUSTING 3 Adjust idle soeed screw in Forward gear to specification 28194 Side Shift Model Shown a Idle Speed Screw b Side Shift Model Shown NOTE When setting idle mixture DO NOT adjust leaner than necessary to attain reason ably smooth idling When in doubt set to the slightly rich side of highest RH P M 4 Adjustcarburetor for best performance after clearing the engine With engine running at idle speed in Forward gear turn mixture screw In clockwise until engine starts to loose R P M fire unevenly and or misfires Back out 1 4 turn or more See General opecifications for minimum and maximum adjustment 5 Check for too lean of mixture on acceleration Engine w
204. t a thread between valve and thermostat body Allow valve to close against thread gt Suspend thermostat from thread and thermometer inside tester so that neither touches the container Bottom of thermometer must be even with bottom of ther mostat to obtain correct thermostat opening gt Fill thermostat tester with water to cover thermostat Plug tester into electrical outlet M gt 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 5oF 300C above designated stamping on bottom of thermostat gt Continue to heat water until thermostat is completely open M Unplug tester unit gt Replace thermostat if it fails to open at the specified temperature or if it does not fully open 51087 Page 4 34 90 826883R2 JUNE 1998 POWERHEAD Powerhead Reassembly General Information Crankshaft 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 Inspec tion Parts which have not been properly cleaned or which are questionable verely damage an otherwise perfectly good powerhead within a few minutes of operation All new powerhead gaskets must be installed during assembly During reassembly lubricate parts with Quicksilver 2 Cycle Outboard Oil whenever 2 cycle oil i
205. t will have a Sporadic tell tail water dis charge Turn primer enrichener knob fully clockwise and pull to the Full Out position two 2 times waiting approximately five 5 seconds between pulls leaving the knob out after the second pull Start the engine Immediately after the engine starts push the primer knob to Full In position and check for water at the tell tail and idle relief holes Allow the engine to warm up then turn the primer knob to the Full Counterclockwise position Tell tale pressure to be per General Specifications prevent personal injury or possible death from loss of balance or stability while servicing the motor DO NOT attempt to check or adjust timing while boat is in motion Failure to follow one of the recommended Servicing procedures may result in the person falling overboard or causing personal injury from fall in boat Timing Checking and Adjustment IMPORTANT When checking the set up timing with the engine running one of the following test procedures must be followed Check maximum timing per the set up specification while running the outboard e IN TEST TANK e IN TEST TANK ON DYNAMOMETER e WHILE STILL SECURED ON BOAT TRAILER Backed in the Water Page 2C 6 90 826883R2 JUNE 1998 TIMING SYNCHRONIZING ADJUSTING ELECTRONIC SPARK ADVANCE MODELS 20 25 19941 gt THRU 1996 AND 20 JET 1994 THRU 1998 1 Using approved test procedure place the outboa
206. tall HALF KEYSTONE ring in top ring groove Align piston rings with each respective ring groove locating pin 72 57121 Piston Ring Expander 91 24697 b Rectangular Ring c Half Keystone Ring d Locating Pin Page 4 44 90 826883R2 JUNE 1998 POWERHEAD 10 Apply outboard oil to upper and lower roller bearings and install bearings on crank shaft Numbered side of bearing should face UP or OUT on bearings 11 Install new upper and lower crankshaft seals Both seal lips face down Apply 2 4 C w Teflon to seal lips 2 Cycle Outboard Oil 92 826666A24 2 4 C With Teflon 92 825407A12 a Upper Crankshaft S eal b Upper Crankshaft Bearing Numbers letters face up out c Lower Crankshaft Bearing Numbers letters face down out Lower Crankshaft Seal 57089 90 826883R2 JUNE 1998 Page 4 45 POWERHEAD Cylinder Block Piston rings must be properly positioned with locating pin between piston ring end gaps Improperly positioned piston rings will break during installation 1 Lubricate piston rings piston and cylinder wall with light oil 2 Keeping crankshaft horizontal guide pistons into cylinder bores 3 Align hole in center main bearing race with pin of cylinder block 57122 a Hole b Pin Hidden c Align Pin In Slot 4 Position alignmentboss of upper crankshaft roller bearing into notch in cylinder block 5 Gently push seals inward to seat 6 Checkeach piston ring f
207. tery cable sleeve under carburetor location around to PORT side of cylinder block 90 826883R2 JUNE 1998 Page 2B 27 BATTERY CHARGING AND STARTING SYSTEMS 6 Push wire retainer into opening of bottom cowl and secure with clip 53068 a Clip 7 Secure harness and battery cable sleeve with sta strap just inside bottom cowl 8 Reinstall carburetor as outlined in Sec 3A a Sta strap 9 Secure fuse holder in J clip A C ae Ete ORS al wot lt lt a Fuse Holder b J clip uj Page 2B 28 90 826883R2 JUNE 1998 BATTERY CHARGING AND STARTING SYSTEMS 10 Plug remote control harness connector into engine wiring harness connector and se cure with harness connector retainer 53064 a Remote Control Harness b Engine Harness Retainer Battery Cables Tiller Handle Push Button Electric Start Models Installation 1 Fasten harness clamp to bottom cowl with nut washer and bolt w 53069 a Clamp b Nut c Washer d Bolt 90 826883R2 JUNE 1998 Page 2B 29 BATTERY CHARGING AND STARTING SYSTEMS 2 Slide battery cables through sleeve 3 Slide harness clamp over battery cable sleeve and position cables into bottom cowl 4 Position harness clamp onto clamp bracket in bottom cowl Tighten clamp securely 53067 a Clamp b Bracket 5 Slide battery cable grommet over battery cables and install grommet into opening in starboard bottom cowl
208. the bearing carrier into the jet drive and fill with grease using a grease If using a hand lever gun pump very slowly so as to not build up internal grease pres sure and damage the seals or housing S mall Diameter Bearing Type Large Diameter Bearing Type 90 826883R2 JUNE 1998 THROTTLE SHIFT LINKAGE CONTROLS Section 7A Throttle Shift Linkage Table of Contents Throttle and Shift Linkage Tiller Handle Shift 7A 2 Control Cables Tiller Handle Shift 7 4 Removal Installation 4 Control Platform 4 4 Reassembly Installation 7 Throttle Cam Control Lever 7A 10 MR 7A 10 90 826883R2 JUNE 1998 Throttle Cam Control Lever 7A 10 Reassembly 7A 10 INSTANGUON wade aera bss bees dade ded ee 12 Neutral Interlock Control Lever 13 Reassembly Installation 13 Horizontal 517 5 14 Removal 7A 14 instalator 522255244 ae endo koa cs 7 15 Page A 1 THROTTLE SHIFT LINKAGE Throttle and Shift Linkage Tiller Handle Shift 2 4 C With Teflon 92 825407A12 A LOCAL ELECTRIC ONLY
209. ther damage as out lined in Section 4 Powerhead 90 826883R2 JUNE 1998 Page 1C 9 GENERAL INFORMATION Painting Procedures Cleaning amp Painting Aluminum Propellers amp Gear Housings PROPELLERS Avoid serious injury from flying debris Avoid serious injury from airborne par ticles Use eye and breathing protection with proper ventilation 1 Sand the entire area to be painted with 3M 120 Regalite Polycut or coarse Scotch Brite disc or belts Feather edges of all broken paint edges Try not to sand through the primer Clean the surface to be painted using PPG Industries DX330 Wax and Grease Re mover or equivalent Xylene or M E K If bare metal has been exposed use Quicksilver s Light Gray Primer 5 Allow aminimum of 1 hour dry time and no more than 1 week before applying the finish coat 6 Apply the finish coat using Quicksilver s EDP Propeller Black GEAR HOUSINGS Page 1C 10 The following procedures should be used in refinishing gear housings This procedure will provide the most durable paint system available in the field The materials recommended are of high quality and approximate marine requirements The following procedure will provide a repaint job that compares with a properly applied factory paint finish It is recom mended that the listed materials be purchased from a local Ditzler Automotive Finish Sup ply Outlet The minimum package quantity of each material shown following is suffi
210. ton and connecting rod for reassembly 1 Using Piston Ring Expander 91 24697 remove and discard piston rings 57094 a Ring Expander 91 24697 2 Remove and discard piston pin lockrings 2 7 W gt C2 57098 Lockrings discard IMPORTANT Itis recommended thatthe piston and rod assembly be removed from the crankshaft before removing the piston pin to prevent possible bending of the connecting rod IMPORTANT Itis recommended that new needle bearings be installed in connect ing rod to assure lasting repair If needle bearings must be reused they should be reassembled on the same crankpin throw and on the same connecting rod 90 826883R2 JUNE 1998 Page 4 19 POWERHEAD IMPORTANT Keep the same connecting rod cap cage and roller bearings if re used together and install them in their original location on the crankshaft 3 Remove and discard rod bolts and remove piston and rod assembly from crank shaft 57099 a Rod Bolts discard 4 While supporting piston use Piston Pin Tool 91 76160A2 and soft faced mallet to drive piston pin from piston 57100 a Piston Pin Tool 91 76160A2 b Piston Pin Page 4 20 90 826883R2 JUNE 1998 POWERHEAD IMPORTANT Piston pin needle bearings and locating washers will fall out when piston is removed from connecting rod 5 Slide piston pin tool from piston and remove piston needle bearings and locating washers a Needle Bearings
211. uide onto water tube a Reverse Lock Link Rod b Lower Shift Shaft am Nut Page 6A 36 90 826883R2 JUNE 1998 GEAR HOUSING 6 Secure gear housing to drive shaft house with four 4 screws Torque screws to 40 lb ft 54 2 Nm a Screws 4 Torque to 40 lb ft 54 2 Nm 7 Thread retained jam nut onto lower shift to expose five 5 threads above the nut 8 Reconnect shift shaft coupling and tighten jam nut against coupler 9 Shift to forward gear 10 Assemble reverse hook guide around lower shift shaft and tighten bolt nut to allow ad justment a J am Nut b Coupling c Reverse Hook Guide d Lower Shift S haft 90 826883R2 JUNE 1998 Page 6A 37 GEAR HOUSING 11 Lift and hold reverse lock hook in the full up position 12 Slide reverse hook guide up shiftshaftto make contact with loop of reverse lock link rod DO NOT bend link rod Tighten guide bolt nut to a torque of 50 5 7 a Reverse Hook Guide b Bolt Nut Torque to 50 5 7 Nm c Reverse Lock Hook Link Rod d Reverse Lock Hook 13 Lower outboard to the normal operating position 14 Check reverse lock operation as follows gt Forward Gear Reverse lock fully released Outboard will tilt up gt Neutral Reverse lock engaged Outboard will not tilt up gt Reverse Gear Reverse lock fully engaged Outboard will not tilt up 15 Shiftoutboard into reverse and verify thatfree play exists between lowerloop
212. ump WMC 46 46A CHOKE VALVE GASKET DIAPHRAGM KIT REPAIR PARTS KIT PLATE cover SCHEW bowl drain SCHEW cover plate GASKET carburetor DIAPHRAGM GASKET GASKET FLOAT PIN FLOAT LEVER CHOKE LINK CREW CO NO DO NI DOT DOT DOP DOPE DOP N gt ot Zo gt 90 826883R2 JUNE 1998 Page 3A 5 E CARBURETOR FUEL PUMP Carburetor Adjustments Carburetor Number Stamped at Top of Carburetor Mounting Flange Carburetor Number Model Main Jet Bowl Back Float Pre Set Idle H P Size Vent Jet Drag Jet Setting Mixture Screw Open WMC 43 25 080 None None 1 0 in 1 1 2 Turns Commercial 25 4 mm WMC 44 20 044 None None 1 0 in 1 1 2 Turns 25 4 mm WMC 52 20 044 None None 1 0 in 1 1 2 Turns 25 4 mm WMC 53 25 076 None None 1 0 in 1 1 2 Turns WMC 53A 25 4 mm WMC 54 25 080 1 0 in 1 1 2 Turns Commercial 25 4 mm Low Speed Mixture Screw Main Jet a Main Jet High Altitude High Speed Jetting Altitude Main Jet 25 SeaPro Marathon 0 5000 ft 044 076 in 080 in 0 1524m 5000 7500 ft 042 in 074 in 078 in 1524 2286m 7500 10000 040 in 072 in 076 in 2286 3048m Standard Main Jet Page 3A 6 90 826883R2 JUNE 1998 CARBURETOR FUEL PUMP High Altitude Jet Chart Factory installed main fuel jets are normally adequate for proper performance up to approximately 5000 feet 1524m
213. ur face Thetrim tab can help compensate forthis steering torque and can be adjusted within limits to reduce any unequal steering effort NOTE Trim tab adjustment will have little effect reducing steering torque if the outboard is installed with the anti ventilation plate approximately 2 inches 50mm or more above the boat bottom O perate boatatnormal cruising speed with the outboard setatthe desired transom angle adjustment Turn boat left and right and note the direction the boat turns more easily If adjustment is necessary loosen trim tab bolt and make small adjustments ata time If the boatturns more easily to the left move the trailing edge of trim tab to the left If the boatturns more easily to the right move the trailing edge of trim tab to the right R etighten bolt and retest Page 1D 12 90 826883R2 JUNE 1998 IGNITION ELECTRICAL Section 2A Ignition Table of Contents Specifications 2A 2 Special Tools 2A 3 Ignition Electrical Components 2A 4 Ignition Description 2A 6 Electronic Spark Advance 2 7 Mechanical Spark Advance 2 7 15XD RPM 2 7 Ignition Component Description 2 7 vain tenga d mae Venen qid 2 7 E E A 2A 8 Flywheel
214. vent and dry with com pressed air Air should be directed at the bearing so that it passes through the bearing DO NOT spin bearing with compressed air as this may cause bearing to score from lack of lu brication After cleaning lubricate bearings with Quicksilver Gear Lubricant DO NOT lubri cate tapered bearing cups until after inspection Inspectall bearings for roughness catches and bearing race side wear Work inner bearing race in and out while holding outer race to check for side wear When inspecting tapered bearings determine condition of rollers and inner bearing race by inspecting bearing cup for pitting scoring grooves uneven wear imbedded particles and or discoloration from over heating Always replace tapered bearing and race as a set Inspect gear housing for bearing races that have spun in their respective bores If race s have spun gear housing must be replaced Roller bearing condition is determined by inspecting the surface of the shaft that the roller bearing supports Check shaftsurface for pitting scoring grooving imbedded particles un even wear and or discoloration from overheating The shaft and bearing must be replaced if such a condition exists As anormal 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 Ap
215. wrinkles are gone and adhesive bonds to the cowl surface 7 Wipe decal surface with soft paper towel or cloth 8 Wait 10 15 minutes otarting at one corner carefully and slowly pull the masking off the decal surface at a 180 angle NOTE To remove any remaining bubbles pierce the decal at one end of the bubble with stick pin and press out the entrapped air or wetting solution with your thumb moving to ward the puncture Page 1C 12 90 826883R2 JUNE 1998 OUTBOARD MOTOR INSTALLATION IMPORTANT INFORMATION Section 1D Outboard Motor Installation Table of Contents Table of Contents 1D 1 Remote Control Installation 1D 6 Notice to Installer and 1D 1 Shift and Throttle Cable Installation to Boat Horsepower Capacity 1D 1 the Outboard iac od a Y Ra CER 1D 6 Outboard Remote 1D 1 Shift Cable Installation 1D 6 Selecting Accessories For The Outboard 1D 2 Throttle Cable Installation 1D 7 Selecting Steering Cables and Remote Control Remote Wiring Harness Connection to Engine 1D 8 Wc 1D 2 Battery Cable Connections 1D 10 Installing Outboard 1D 3 Propeller Installation 1D 11 Steering Cable and Steering Link Rod Installation 10 4 TiltPin
216. y and impeller bore Place the plastic sleeve a in side the impeller b and install impeller shear key c shims d retainer e and impeller nut f Turn the nuttighton the shaftto 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 a Plastic Sleeve b Impeller c Shear Key d Shims e Nut Retainer f Impeller Nut 2 Temporarily reinstall the water intake housing in orderto 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 impellerto raise orlowerthe impeller to the correct clearance setting The water intake housing can be shifted side ways a small amount in order to center the liner ere FF E duke 8 64 NM gt 7 2 o tmn ar um amp 03 in 8mm 90 826883R2 JUNE 1998 JET DRIVE 3 After setting the impeller height tighten the impeller nut snug with a wrench Secure impeller nut by bending tabs a against the flats on the impeller nut Tabs 4 Reinstall the water intake housing with six bolts 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 Ib in 11 3 N m NOTE If the outboard is used in s
217. y to rotate propeller shaft slightly to align crankshaft splines with driveshaft splines 3 Secure powerhead to driveshaft with 6 bolts Torque bolts to 20 Ib ft 27 1 N m 57077 Bolts Torque to 20 Ib ft 27 1 4 Reinstall trim cover Torque bolts to 85 Ib in 9 6 N N m 57076 Bolts Torque to 85 Ib in 9 6 N m 90 826883R2 JUNE 1998 Page 4 51 POWERHEAD 5 Install tell tale hose and attach hose to fitting on bottom cowl CN 57073 a Tell Tale Hose 6 Install the following components assemblies referring to the listed service manual sections ComponentiAssembly Section Throttle S hift Mechanism TAIB C Electrical Ignition Components and Flywheel 2 Rewind Starter D Set Up and Test Run Procedures When engine is started IMMEDIATELY check for fuel leaks and water leaks Check for water pump operation by water being discharged from tell tale 1 Following powerhead repairs refer to Section 2C Timing S ynchronizing Adjusting and perform set up procedures 2 While test running engine check powerhead assembly for leaks and or unusual noises Make any repairs BEFORE returning engine to service Break In Procedure To avoid possible engine damage break in procedure MUST BE completed FORE operating engine continuously at full throttle Failure to break in engine in properly will result in engine failure or shortened powerhead life IMP
218. y without drag If not adjust the barrel away from the engine shift lever Repeat steps a and b Shift remote control into reverse while turning the propeller shaft The propeller shaft should lock solidly in gear If not adjust the barrel away from the engine shift lever Repeat steps a thru c Return remote control handle to neutral The propeller shaft should turn freely without drag If not adjust the barrel closer to the engine shift lever Repeat steps a thru d 90 826883R2 JUNE 1998 TIMING SYNCHRONIZING ADJUSTING Throttle Cable Installation NOTE Attach Shift cable to engine prior to attaching throttle cable 1 2 3 90 826883R2 JUNE 1998 Position the remote control handle forward to wide open throttle position Install the throttle cable onto the throttle pin lock in place with retainer latch Move throttle lever until tab contacts throttle stop Adjust the barrel on the throttle cable so that the barrel will fit into the barrel holder Slip the barrel into the barrel holder and place the barrel holder into the retaining pock et Check the throttle cable adjustment as follows a Move the remote control handle back to neutral a few times and then return the handle back to forward wide open position b Recheck to make sure tab is contacting throttle stop N a Throttle Cable b Throttle Pin c Retainer Latch d Barrel Holder e Tab f Throttle Stop g Throttle Lever Pag
219. ys check water level add water if necessary and put on charge for 5 or 6 hours at 6 amperes DO NOT FAST CHARGE 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 Repeat preceding charging procedure every 30 45 days as long as battery is in stor age When ready to place battery back in service remove excess grease from termi nals a small amountis desirable on terminals atall times recharge again as neces sary and re install battery 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 90 826883R2 JUNE 1998 BATTERY CHARGING AND STARTING SYSTEMS Voltage Regulator Test Lamps Burn Out When Engine RPM is Increased The voltage regulator is defective Replace regulator Lamps Burn Dim at Wide Open Throttle 1 Run engine at mid range approximately 3000 RPM with 3 number 94 lamps con nected to voltage regulator output leads Note lamp brightness 2 Disconnect the leads at one terminal of regulator Connect the leads together using a screw and nut Isolate tape connection 3 Run engine at mid range ap

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